Greenheck ERCH User Manual

Document 476054

Energy Recovery Ventilator

with Heating and Cooling

Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage!

Model ERCH

General Safety Information

Only qualiﬁed personnel should install this system. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards, including environmental. Other considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.

1. Follow all local electrical and safety codes, as well as

the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electrical Code (CE) in Canada.

2. All moving parts must be free to rotate without striking or rubbing any stationary objects.

3. Unit must be securely and adequately grounded.

4. Do not spin fan wheel faster than maximum cataloged fan RPM. Adjustments to fan speed signiﬁcantly affect motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.

5. Verify that the power source is compatible with the equipment.

6. Never open access doors to the unit while it is running.

DANGER

• Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch or breaker to prevent accidental power up.

• If this unit is equipped with optional gas accessories, turn off gas supply whenever power is disconnected.

CAUTION

This unit may be equipped with a compressed refrigerant system. If a leak in the system should occur, immediately evacuate and ventilate the area. An EPA Certified Technician must be engaged to make repairs or corrections. Refrigerant leaks may also cause bodily harm.

CAUTION

When servicing the unit, the internal components may be hot enough to cause pain or injury. Allow time for cooling before servicing.

WARNING

The roof lining contains high voltage wiring. To prevent electrocution, do not puncture the interior or exterior panels of the roof.

Model ERCH Energy Recovery Ventilator 1

Table of Contents

General Safety Information ...................1

Receiving, Handling and Storage ..............3

Product Overview ...........................4

Optional Subassemblies ....................4-5

Installation

Unit Dimensions and Weights ..................6

Curb Outside Dimensions, Recommended

Roof Openings and Curb Weights .............7

Service Clearances and Access Locations .....8-12

Handling ..................................13

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Roof Curb Mounting ........................14

Optional Piping Vestibule .....................14

Rail Mounting/Layout ........................15

Duct Connections ..........................15

Electrical Installation

Procedure .................................16

Field-Provided Disconnect ....................17

Discharge Air Temperature Sensor .............17

Typical Control Center Components ............17

Optional Accessory Wiring Schematics ..........18

Piping Installation

Optional Gas Piping .........................19

Gas Connections ...........................19

Optional Coil Piping .........................19

Water ..................................19

Direct Expansion .........................19

Condensate Drain Trap ....................20

Heat Pump Piping Sizes & Connections .......20

Evaporative Cooler ........................21

Water Supply Locations ..................22

Unit Overview

Basic Unit .................................23

Optional Component Overview

Economizer ...............................23

Frost Control ..............................24

Variable Frequency Drive .....................24

CO2 Sensor ...............................24

Phase Monitor .............................24

Rotation Sensor ............................24

Dirty Filter Sensor ..........................24

Microprocessor Control ......................25

Unoccupied Recirculation Damper .............25

Service Outlet ..............................25

Vapor Tight Lights ..........................25

Hot Gas Bypass Valve .......................25

Hot Gas Reheat Valve .......................25

Digital Scroll Compressor ....................25

Outdoor Airflow Monitor .....................26

Smoke Detector ............................26

Cooling System Overview

Packaged DX ..............................27

Water-Source Heat Pump (HP) ................27

Start-Up

Warnings .................................29

Special Tools Required ......................29

Start-Up Procedure .........................29

Voltage Imbalance ..........................29

Pre-Start-Up Checklist .......................30

Start-Up Checklist .......................30-31

Optional Accessories Checklist ................32

Start-Up Components

Energy Wheel ..............................33

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-34

Vibration ..................................34

Hot Gas Bypass Valve .......................34

Optional Start-Up Components

Dirty Filter Switch ...........................35

Economizer ............................35-36

Frost Control ..............................36

Outdoor Airflow Monitor .....................37

Evaporative Cooler ..........................38

Variable Frequency Drives ................39-40

Routine Maintenance

Maintenance Frequency ......................41

Units with Packaged DX .....................41

Units with Heat Pump .......................41

Maintenance Procedures

Lubrication ..............................42

Dampers ................................42

Gas Furnace .............................42

Fan Belts ...............................42

Fan Motors ..............................42

Fan Wheel & Fasteners ....................42

Bearings ................................42

Internal Filter ............................43

External Filter ............................43

Coils ...................................43

Door Seals ..............................43

Energy Wheel ............................44

Evaporative Cooling .......................45

Troubleshooting

Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Refrigeration Circuit ......................47-50

Energy Wheel ..............................50

Evaporative Cooling ......................51-52

Controller Alarms ...........................53

Rotation Sensor ............................53

Digital Scroll ...............................53

Unit Protection Module

......................54

Economizer ...............................54

Reference

Technical Assistance Information ..............54

Additional Installation, Operation and

Maintenance Manuals .....................54

Maintenance Log ...........................55

Our Commitment ....................Backcover

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Receiving

Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notiﬁcation on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be ﬁlled out by the carrier upon arrival and reported to the Trafﬁc Department. If damaged upon arrival, ﬁle claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of manufacturer.

Unpacking

Verify that all required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Conﬁrmation of shipment(s) must be limited to only items on the bill of lading.

Handling

Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce ability of unit to resist corrosion.

Storage

Units are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the unit and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.

INDOOR — The ideal environment for the storage of

units and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Temperatures should be evenly maintained between 30°F (-1°C) and 110°F (43°C) (wide temperature swings may cause condensation and “sweating” of metal parts). All accessories must be stored indoors in a clean, dry atmosphere.

Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To avoid “sweating” of metal parts allow cold parts to reach room temperature. To dry parts and packages use a portable electric heater to get rid of any moisture build up. Leave coverings loose to permit air circulation and to allow for periodic inspection.

The unit should be stored at least 3½ in. (89 mm) off the ﬂoor on wooden blocks covered with moisture proof paper or polyethylene sheathing. Aisles between parts and along all walls should be provided to permit air circulation and space for inspection.

OUTDOOR — Units designed for outdoor applications

may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed.

The fan should be placed on a level surface to prevent water from leaking into the unit. The unit should be elevated on an adequate number of wooden blocks so that it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight, and space for periodic inspection. To minimize water accumulation, place all unit parts on blocking supports so that rain water will run off.

Do not cover parts with plastic ﬁlm or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.

Inspection and Maintenance during Storage

While in storage, inspect fans once per month. Keep a record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the fan wheel by hand ten to ﬁfteen revolutions to distribute lubricant on motor. Every three months, the fan motor should be energized. If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or ﬁne emery paper and oil. Do not destroy the continuity of the surfaces. Wipe thoroughly clean with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD40

® or the equivalent.

REMOVING FROM STORAGE — As units are removed

from storage to be installed in their ﬁnal location, they should be protected and maintained in a similar fashion, until the equipment goes into operation.

Prior to installing the unit and system components, inspect the unit assembly to make sure it is in working order.

1. Check all fasteners, set screws on the fan, wheel, bearings, drive, motor base, and accessories for tightness.

2. Rotate the fan wheel(s) by hand and assure no parts are rubbing.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®3

Product Overview

The model ERCH combines the beneﬁts of energy recovery and many combinations of supplemental heating and cooling. Heating sources include indirect gas, electric, hot water, and water-source heat pump. Cooling sources include, packaged direct expansion, split direct expansion, chilled water, and water-source heat pump. Indirect evaporative and indirect/direct evaporative cooling is also available in this platform. This product is speciﬁcally designed to process 100% outdoor air to desired supply conditions. Four housing sizes provide air ﬂow capacities from 1,000 CFM to 10,000 CFM with external static pressures up to 1.75 in. wg.

Tons

Model

ERCH-20 4, 5, 6, single stage 4, 5, 6, 7 single stage

ERCH-45 8, 10, 12.5, 15 8, 10, 11, 12.5, 14

ERCH-55 15, 17.5, 20 15, 16, 19

ERCH-90 20, 25, 30 20, 22, 24, 27, 30

Water-Source

Heat Pump

Packaged Direct

Expansion

Optional Subassemblies

Dampers

There are four locations where dampers can be installed. Low leakage or insulated low leakage motorized dampers can be added in the outdoor airstream and/or return airstream. An unoccupied recirculating air damper is also available. A backdraft damper is standard in the exhaust hood.

Filters

There is the option of either two-inch thick MERV 8 or MERV 8 and 13 pre-ﬁlters in the outdoor airstream and MERV 8 ﬁlters in the exhaust airstream. There are also permanent washable aluminum mesh ﬁlters in the optional weatherhood.

Backdraft

Permanent

Aluminum

Mesh Filters

Motorized Outdoor

Exhaust Damper

Exhaust

Weatherhood

Ooutdoor Air

Weatherhood

Air Damper

Two-inch thick MERV 8 or MERV

8 and 13 pleated ﬁlters

Two-inch thick MERV 8

pleated ﬁlters

Wheel Cassette

Filters

Motorized Return Air

Damper

Electrical Box

Return Air

Filters

Coil Section

Motorized Recirculating Air Damper

Intake

Hot Water / Chilled Water Coils

Water coils can be used for a single purpose such as heating or cooling, or their function can be alternated between heating and cooling by changing the temperature of the water ﬂowing through the coil. Depending on the application, it may be necessary to use a glycol mixture to prevent the liquid from freezing. The water coils are engineered to operate at pressures up to 250 PSIG and temperatures up to 300°F, but ancillary equipment such as valves and pumps will often dictate lower operating temperatures. All water coils are pressure tested at the factory with 450 PSIG of dry nitrogen.

Steam Coils

Steam coils are used for heating applications and are built to operate at pressures of up to 125 PSIG with a maximum temperature of 353°F. They are pressure tested with 600 PSIG of dry nitrogen. The most frequent use of steam coils is for retroﬁtting or modifying existing steam heat systems.

Evaporative Cooler

Evaporative cooling modules include Munters® CELdek® media (GLASdek® optional) and a stainless steel frame. Evaporative cooling media is 12 inches in depth and capable of 90% cooling effectiveness. A cooling module in the exhaust airstream for indirect evaporative cooling is standard. For combination indirect and direct evaporative cooling, an evaporative section may also be added to the outdoor air stream. Optional features include an automatic drain and ﬁll with freeze protection.

Packaged Direct Expansion (PDX)

The DX system comes fully charged from the factory with refrigerant and is ready for installation upon arrival. The smaller tonnage units (4-7 tons) contain a single compressor, allowing for one stage of cooling. Larger units (8-30 tons) come standard with two compressors This allows for staging of compressors to meet a wider range of outdoor air loads with reducing the amount of cycles per compressor.

Integral Components

All units are provided with an expansion valve, hermetic scroll compressor(s), liquid line ﬁlter drier, high pressure manual reset cutout, low pressure auto-reset cutout, time delays for compressor protection, service/charging

Indirect Gas Heater

valves, moisture indicating sight glass, and optional hot gas bypass. The compressors also come standard with a crankcase heater for additional protection.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Split DX

The unit is equipped with an evaporator coil that will be connected to a separate condensing unit (provided by others). Depending on controlling options, the condensing unit will be controlled by others or an integral unit microprocessor controller. Piping components such as thermostatic expansion valve, ﬁlter drier, sight glass, etc., shall be ﬁeld-provided.

Heat Pump Module

Units with an optional, integral heat pump module contains hermetic scroll-type compressor(s), a coaxial refrigerant-to-water heat exchanger(s), refrigerant ﬂow reversing valve(s), expansion valve(s), liquid line ﬁlter drier, high pressure manual reset cutout, crankcase heater(s) and various sensors, service ports and safety devices. The heat pump is intended to be connected to an external water source such as a water cooling tower, boiler, or a geothermal source. The module is piped to the airside coil located in the supply airstream and optionally to a reheat coil that will control humidity. The location of components in the module will vary.

Control circuitry and the Unit Protection Module (UPM) for the heat pump will be provided by the factory. The UPM is a printed circuit board and has LED fault indicator lights to indicate various alarm conditions and also power status. A unitspeciﬁc schematic for electrical circuits is located in the control center and another unit-speciﬁc schematic for heat pump circuitry and UPM are located in the heat pump module.

Unit Protection Module

(UPM)

Electric Post-Heaters

The optional post-heater is used as a heat source for the building and is integrated into the supply airstream.

A temperature sensor (with a ﬁeld-adjustable set point) is mounted in the supply airstream after the post-heater to turn the post-heater on. A SCR heater allows for an inﬁnite amount of modulating control of the heat to provide an accurate discharge temperature during the call for heat.

As standard, the post-heater control panel is not single point wired to the unit control center. Separate power must be supplied to the post-heater disconnect (located in unit control center). Electric heaters are available in 208, 230, 460, or 575 VAC (refer to heater nameplate for voltage).

Indirect Gas Furnace

An optional indirect gas furnace may be installed and provides supplementary heat to the building. Refer to the PVF/PVG Indirect Gas-Fired Heat manuals provided with the unit. A unit-speciﬁc wiring diagram is located inside the furnace housing access door.

Outdoor Air Weatherhood

Outdoor air weatherhood will be factory-mounted.

Exhaust Air Weatherhood

The exhaust weatherhood is shipped separately as a kit with its own instructions. Backdraft dampers are always included as an integral part of the exhaust hood assemblies.

High Efficiency

Scroll Type

Compressors

Coaxial

Refrigerant-

to-Water Heat

Exchangers

Refrigerant

Reversing

Valves

Water Intake

and Discharge

Connections

Heat Pump Module

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®5

Installation

Unit Dimensions and Weights

Model

ERCH-20

ERCH-45

ERCH-55

ERCH-90

Overall Exterior Dimensions

Configuration Length Width Height

Heating Only 76.2

Exhaust

Hood

Outdoor Air

Hood

Approximate

Weight

(lbs)

1550

Cooling Coil* 96.2 1825

PDX

WSHP 2375

108.2

54.3 54.2 20.8 17.7

2350

Evap Cooling 1800

Heating Only 84.3

2325

Cooling Coil* 104.3 2725

PDX

WSHP 3775

119.3

64.4 70.2 20.7 21.7

3675

Evap Cooling 2900

Heating Only 97.5

3000

Cooling Coil* 116.5 3475

PDX

WSHP 4725

133.5

75.2 71 23.6 21.7

4125

Evap Cooling 3325

Heating Only 109.5

4300

Cooling Coil* 129.5 5050

PDX

WSHP 6450

151.5

94.5 89 25.5 26.7

6325

Evap Cooling 5400

*With or without heat.

PDX = Packaged Direct Expansion

WSHP = Water-Source Heat Pump

All dimensions are in inches. Unit weights assume rooftop configuration with weatherhood, filters, outdoor air damper and heating or cooling options (where applicable) including but not limited to: a six row dx coil, integral condensing section and an indirect gas-fired furnace. The approximate weight (lbs) is assuming all possible accessories are added per housing and may vary by 10% depending on unit.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Installation

Curb Outside Dimensions, Recommended Roof Openings and Curb Weights

Model Configuration

Heating Only 71.8 49.9

Cooling Coil* 91.8 49.9

ERCH-20

PDX

WSHP

Evap Cooling

Heating Only 79.9 60

Cooling Coil* 99.9 60

ERCH-45

PDX

WSHP

Evap Cooling

Heating Only 93.1 70.8

Cooling Coil* 112.1 70.8

ERCH-55

PDX

WSHP

Evap Cooling

Heating Only 105.1 90.1

Cooling Coil* 112.1 70.8

ERCH-90

PDX

WSHP

Evap Cooling

Outside

Curb

Dimensions

Length Width A B C D

103.8 49.9 40.7 166

114.9 60 44.5 195

129.1 70.8 58.6 228

147.1 90.1 61.4 291

Recommended

Roof

Openings

28.6

45.2 30

29.5

55.3 35.1

40.6

66 41.8

41.4

85.4 51.1

Optional

Piping

Vestibule

12 inch

Curb

Weight

16.6 134 157 +6.9 +8.3

147 179 +7.7 +9.5

NA NA NA

16.6 157 180 +8.0 +9.4

170 202 +8.8 +10.6

NA NA NA

16.6 184 207 +9.3 +10.7

196 228 +10.1 +11.9

NA NA NA

16.6 231 254 +11.2 +12.6

196 228 +12 +13.8

NA NA NA

12 inch

Curb

Weight

with Piping

Vestibule

199

228

260

323

Curb

weight

only

Adder per inch

+8.3

+9.5

+10.9

+13.1

Curb Weight

with Piping

Vestibule

+10.1

+11.4

+12.7

+14.9

*With or without heating.

PDX = Packaged Direct Expansion

WSHP = Water-Source Heat Pump

All dimensions are in inches. All weights are in pounds. Various curb heights are available, use the adder per inch column to determine the weights above 12 inches.

RETURN AIR INTAKE

SUPPLY AIR DISCHARGE

OPTIONAL

PIPING VESTIBULE

C D

26.1 inches

1-inch Foam Insulation

Curb Duct

Adaptor

1.9 inches

1/2 inch

Curb

Unit Base

1.63

inches

1 inch

Curb

Height

Curb Cap Details for Factory-Supplied Roof Curbs

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®7

Service Clearances / Access Panel - Heating Only

Units require minimum clearances for access on all sides for routine maintenance. Filter replacement, drain pan inspection and cleaning, energy wheel cassette inspection, fan bearing lubrication and belt adjustment are examples of routine maintenance that must be performed. Blower and motor assemblies, energy recovery wheel cassette, coil and ﬁlter sections are always provided with a service door or panel for proper component access.

*Cassette removal only available on housing sizes 20 and 45.

ACCESS DOOR

OUTDOOR

WEATHERHOOD

EXHAUST AIR

WEATHERHOOD

OUTDOOR AIR FILTERS

*CASSETTE REMOVAL

WHEEL CASSETTE

ACCESS DOOR

EXHAUST FILTERS

HEATING COIL

ACCESS DOOR

ELECTRICAL BOX

Model A (in.) B (in.)

ERCH-20 48 36 ERCH-45 64 42 ERCH-55 42 42 ERCH-90 42 48

52 inches

CLEARANCE WITH IG HEATER

0 inches

CLEARANCE WITHOUT IG HEATER

INDIRECT GAS FURNACE

36 inches

ACCESS DOOR

PIPING VESTIBULE

(OPTIONAL)

ACCESS DOOR

Drawing shows both heating coil and indirect gas furnace options. Electric heat is also available. Only one can be selected.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Service Clearances / Access Panel - Cooling Coil (with or without heating)

*Cassette removal only available on housing sizes 20 and 45.

ACCESS DOOR

OUTDOOR

WEATHERHOOD

EXHAUST AIR

WEATHERHOOD

OUTDOOR AIR FILTERS

*CASSETTE REMOVAL

WHEEL CASSETTE

ACCESS DOOR

EXHAUST FILTERS

COOLING COIL

ACCESS PANEL

HEATING COIL

ACCESS DOOR

ELECTRICAL BOX

Model A (in.) B (in.) ERCH-20 48 36 ERCH-45 64 42 ERCH-55 42 42 ERCH-90 42 48

52 inches

CLEARANCE WITH IG HEATER

0 inches

CLEARANCE WITHOUT IG HEATER

INDIRECT GAS FURNACE

ACCESS DOOR

48 inches

CLEARANCE WITH VESTIBULE

36 inches

CLEARANCE WITHOUT VESTIBULE

ACCESS DOOR

PIPING VESTIBULE

(OPTIONAL)

Drawing shows both heating coil and indirect gas furnace options. Only one can be selected.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®9

Service Clearances / Access Panel - Integral Air-Cooled Packaged DX

*Cassette removal only available on housing sizes 20 and 45.

EXHAUST AIR

WEATHERHOOD

ACCESS DOOR

OUTDOOR

WEATHERHOOD

OUTDOOR AIR FILTERS

*CASSETTE REMOVAL

WHEEL CASSETTE

ACCESS DOOR

ACCESS DOORS

ELECTRICAL BOX

EXHAUST FILTERS

COOLING COIL

ACCESS PANEL

HEATING COIL

HGRH COIL

ACCESS DOOR

ACCESS PANEL

COMPRESSORS

ACCESS PANEL

Model A (in.) B (in.) ERCH-20 48 36 ERCH-45 64 42 ERCH-55 42 42 ERCH-90 42 48

42 inches

MINIMUM

CONDENSING SECTION

36 inches

CLEARANCE WITHOUT VESTIBULE

PIPING VESTIBULE

(OPTIONAL)

48 inches

CLEARANCE

WITH VESTIBULE

Drawing shows both heating coil and indirect gas furnace options. Electric heat is also available. Only one can be selected. Optional hot gas reheat coil also shown, available with split or packaged DX.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Service Clearances / Access Panel - Water-Source Heat Pump

*Cassette removal only available on housing sizes 20 and 45.

ACCESS DOOR

OUTDOOR

WEATHERHOOD

EXHAUST AIR

WEATHERHOOD

OUTDOOR AIR FILTERS

*CASSETTE REMOVAL

WHEEL CASSETTE

ACCESS DOORS

ELECTRICAL BOX

EXHAUST FILTERS

HEATING AND

COOLING COIL

ACCESS PANEL

Model A (in.) B (in.) ERCH-20 48 36 ERCH-45 64 42 ERCH-55 42 42 ERCH-90 42 48

ACCESS PANEL

ACCESS DOOR

HEAT PUMP

42 inches

HGRH COIL

ACCESS DOOR

Drawing shows optional hot gas reheat coil.

ACCESS DOOR

36 inches

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®11

Service Clearances / Access Panel - Evaporative Cooling

*Cassette removal only available on housing sizes 20 and 45.

ACCESS DOOR

OUTDOOR

WEATHERHOOD

EXHAUST AIR

WEATHERHOOD

OUTDOOR AIR FILTERS

*CASSETTE REMOVAL

WHEEL CASSETTE

ACCESS DOORS

INDIRECT

EVAP

DIRECT

EVAP

Model A (in.) B (in.) ERCH-20 48 36 ERCH-45 64 42

ACCESS DOOR

ELECTRICAL BOX

EXHAUST FILTERS

ERCH-55 42 42 ERCH-90 42 48

52 inches

CLEARANCE WITH IG HEATER

0 inches

CLEARANCE WITHOUT IG HEATER

INDIRECT GAS FURNACE

ACCESS DOOR

36 inches

Drawing shows optional indirect gas furnace. Electric heat is also available. Only one can be selected.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Handling

While this unit was constructed with quality and dependability in mind, damage still may occur during handling of the unit for installation. Exercise extreme caution to prevent any damage from occurring to the refrigerant system. This unit could contain a system pressurized with refrigerant that, if damaged, could leak into the atmosphere or cause bodily harm due to the extreme cold nature of expanding refrigerant. Use protective equipment such as gloves and safety glasses to minimize or prevent injury in case of a system leak during installation.

The system design and installation should follow accepted industry practice, such as described in the ASHRAE Handbook. Adequate space should be left around the unit for piping coils and drains, ﬁlter replacement, and maintenance. Sufﬁcient space should be provided on the side of the unit for routine service and component removal should that become necessary.

Lifting

WARNING

All factory-provided lifting lugs must be used when lifting the units. Failure to comply with this safety precaution could result in property damage, serious injury, or death.

1. Before lifting, be sure that all shipping material has

been removed from unit.

2. To assist in determining rigging requirements,

weights are provided in the Installation, Unit Dimensions and Weights section of this manual.

3. Unit must be lifted by all lifting lugs provided on

base structure.

4. Rigger to use suitable mating hardware to attach to

unit lifting lugs.

5. Spreader bar(s) must span the unit to prevent

damage to the cabinet by the lift cables.

6. Always test-lift the unit to check for proper balance

and rigging before hoisting to desired location.

7. Never lift units by weatherhoods.

8. Never lift units in windy conditions.

9. Preparation of curb and roof openings should be

completed prior to lifting unit to the roof.

10. Check to be sure that gasketing (supplied by

others) has been applied to the curb prior to lifting the unit and setting on curb.

11. Do not use fork lifts for handling unit.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®13

Roof Curb Mounting

Rooftop units require curbs to be mounted ﬁrst. The duct connections must be located so they will be clear of structural members of the building.

Position the unit roof opening such that the supply discharge and exhaust inlet of the unit will line up with the corresponding ductwork. Be sure to allow for the recommended service clearances when positioning opening.

Do not face the outdoor air intake of the unit into prevailing wind and keep the intake away from any other exhaust fans. Likewise, position the exhaust discharge opening away from outdoor air intakes of any other equipment.

1. Factory-Supplied Roof Curbs: Roof curbs are Model GKD, which are shipped in a knockdown kit (includes duct adapter) and require ﬁeld assembly (by others). Assembly instructions are included with the curb.

2. Install Curb: Locate curb over roof opening and fasten in place. Reference Installation, Curb Outside Dimensions, Recommended Roof Openings and Weights in this manual. Check that the diagonal dimensions are within ±1/8 inch of each other and adjust as necessary. For proper coil drainage and unit operation, it is important that the installation be level. Shim as required to level.

3. Install Ductwork: Installation of all ducts should be done in accordance with SMACNA and AMCA guidelines. Duct adapter provided to support ducts prior to setting the unit.

4. Set the Unit: Lift unit to a point directly above the curb and duct openings. Guide unit while lowering to align with duct openings. Roof curbs ﬁt inside the unit base. Make sure the unit is properly seated on the curb and is level. Gasketing (by others) needs to be installed to curb creating a seal between the ductwork and the base of the unit.

5. Install Vestibule: If unit was ordered with a vestibule and it has not yet been attached to the unit, caulk and attach the vestibule at this time.

Optional Piping Vestibule

Insulated enclosure that is mounted externally to the unit in order to protect the water supply and return piping. Not available in models with water-source heat pump or evaporative cooling.

Supply Blower Access Door

Drain Pan Connection

Exhaust Blower Access Door

Outdoor Air Weatherhood

Cassette/Filter Access Door

Cooling Coil (with or without heating) or PDX

Exhaust Blower Access Door

Outdoor Air Weatherhood

Cassette/Filter Access Door

Heating Only

Piping Vestibule

Supply Blower Access Door

Piping Vestibule

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

POOR

Rail Mounting / Layout

1. Rails designed to handle the weight of the unit should be positioned as shown on the diagram (rails by others).

2. Make sure that rail positioning does not interfere with the supply air discharge opening or the exhaust air intake opening on the unit. Avoid area dimensioned “B” below.

3. Rails should run the width of the unit and extend beyond the unit a minimum of 12 inches on each side.

ERCH-20 Recommended Duct Size

Intake Duct Size Discharge 9-9 Blower 10-6 Blower

OIE 22 x 26 SDE 16 x 16 16 x 16

OIT 24 x 20 SDS 16 x 16 16 x 16

RIE 16 x 32 SDT 16 x 16 16 x 16

RIS 18 x 30 SDT/IG 28 x 24 28 x 24

RIB 16 x 32 SDB 12 x 14 12 x 14

RIT 16 x 32 EDE 16 x 16 16 x 16

EDT 16 x 16 16 x 16

EDS 16 x 16 16 x 16

4. Set unit on rails.

ERCH-45 Recommended Duct Size

Intake Duct Size Discharge

12-8 Blower

12-12 Blower

9-9 Blower

OIE 28 x 36 SDE 20 x 20 16 x 16

OIT 34 x 24 SDS 20 x 20 16 x 16

RIE 24 x 40 SDT 20 x 20 16 x 16

RIS 26 x 32 SDT/IG 28 x 28 28 x 28

RIB 20 x 48 SDB 16 x 18 16 x 18

RIT 28 x 30 EDE 20 x 20 16 x 16

Rail Mounting

Unit Size A B

EDT 20 x 20 16 x 16

EDS 20 x 20 16 x 16

ERCH-20 5.0 41.0

ERCH-45 7.0 41.9

ERCH-55 5.5 53.0

ERCH-90 6.0 59.0

All dimensions are in inches.

ERCH-55 Recommended Duct Size

Intake Duct Size Discharge 12-12 Blower 15-15 Blower

OIE 32 x 52 SDE 20 x 20 28 x 28

OIT 40 x 28 SDS 20 x 20 28 x 28

RIE 30 x 40 SDT 20 x 20 28 x 28

Ductwork Connections

Examples of poor and good fan-to-duct connections are shown. Airﬂow out of the fan should be directed straight or curve the same direction as the

RIS 30 x 38 SDT/IG 38 x 30 38 x 30

RIB 20 x 54 SDB 16 x 18 18 x 20

RIT 30 x 40 EDE 20 x 20 28 x 28

EDT 20 x 20 28 x 28

EDS 20 x 20 28 x 28

fan wheel rotates. Poor duct installation will result in low airﬂow and other system effects.

Length of Straight Duct

GOOD

Inlet/Outlet Descriptions

Code Description Code Description

OIE Outdoor Air Intake End SDT Supply Discharge Top

OIT Outdoor Air Intake Top SDT/IG Supply Discharge Top w/IG

RIE Return Air Intake End SDS Supply Discharge Side

RIS Return Air Intake Side SDB Supply Discharge Bottom

RIB Return Air Intake Bottom EDE Exhaust Discharge End

ERCH-90 Recommended Duct Size

Intake Duct Size Discharge 15-15 Blower 18-18 Blower

OIE 34 x 64 SDE 28 x 28 32 x 32

OIT 34 x 50 SDS 28 x 28 32 x 32

RIE 32 x 60 SDT 28 x 28 32 x 32

RIS 40 x 40 SDT/IG 34 x 34 34 x 33

RIB 22 x 74 SDB 18 x 20 20 x 24

RIT 40 x 40 EDE 28 x 28 32 x 32

EDT 28 x 28 32 x 32

EDS 28 x 28 32 x 32

All dimensions shown in inches.

• Recommended duct sizes are based on velocities across the cfm range of each model at approximately 800 feet per minute (FPM) at minimum airflow and up to 1600 fpm at maximum airflow.

• Recommended duct sizes are only intended to be a guide and may not satisfy the requirements of the project. Refer to plans for appropriate job specific duct size and/or velocity limitations.

RIT Return Air Intake Top EDT Exhaust Discharge Top

SDE Supply Discharge End EDS Exhaust Out Side

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®15

Electrical Installation

WARNING

The roof lining contains high voltage wiring. To prevent electrocution, do not puncture the interior or exterior panels of the roof.

WARNING

To prevent injury or death due to electrocution or contact with moving parts, lock disconnect switch open. For units with a gas furnace, if you turn off the power supply, turn off the gas.

IMPORTANT

Before connecting power to the unit, read and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached on the inside of the control center door(s).

IMPORTANT

All wiring should be done in accordance with the latest edition of the National Electrical Code ANSI/NFPA70 and any local codes that may apply. In Canada, wiring should be done in accordance with the Canadian Electrical Code.

IMPORTANT

The equipment must be properly grounded and bonded. Any wiring running through the unit in the airstream must be protected by metal conduit, metal clad cable or raceways.

CAUTION

If replacement wire is required, it must have a temperature rating of at least 105°C, except for an energy cut-off or sensor lead wire which must be rated to 150°C.

DANGER

High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician.

CAUTION

Any wiring deviations may result in personal injury or property damage. Manufacturer is not responsible for any damage to, or failure of the unit caused by incorrect final wiring.

WARNING

If unit is equipped with a microprocessor, terminals Y1, Y2 and W1 cannot be wired to a thermostat. Wiring to these terminals will bypass unit’s internal safeties.

1. Determine the Size of the Main Power Lines The unit’s nameplate states the voltage and the unit’s MCA. The main power lines to the unit should be sized accordingly. The nameplate is located on the outside of the unit on the control panel side.

2. Determine the Size of Electric Heater Wiring

An optional electric heater may require a separate power supply. The power connection should be made to the factory-provided electric heater disconnect and must be compatible with the ratings on the nameplate, supply power voltage, phase and amperage. Consult ANSI/NFPA 70 and CSA C22.1 for proper conductor sizing.

3. Provide the Opening(s) for the Electrical Connections

Electrical openings vary by unit size and arrangement and are ﬁeld-supplied.

4. Connect the Power Supplies Connect the main power lines and electric heater power lines to the disconnect switches or terminal blocks and main grounding lug(s). Torque ﬁeld connections to manufacturer’s recommendations.

5. Wire the Optional Convenience Outlet The convenience outlet requires a separate 115V power supply circuit. The circuit must include short circuit protection which may need to be supplied by others.

6. Connect Field-Wired Low Voltage Components Most factory-supplied electrical components are prewired. To determine what electrical accessories require additional ﬁeld-wiring, refer to the unitspeciﬁc wiring diagram located on the inside of the control center access door.

If unit is equipped with a microprocessor, terminals Y1, Y2 and W1 cannot be wired to a thermostat. Wiring to these terminals will bypass unit’s internal safeties.

Control wires should not be run inside the same conduit as that carrying the supply power. Make sure that ﬁeld-supplied conduit does not interfere with access panel operation. All low voltage wiring should be run in conduit wherever it may be exposed to the weather.

The low voltage control circuit is 24 VAC and control wiring should not exceed 0.75 ohms. If wire resistance exceeds 0.75 ohms, an isolation relay should be added to the unit control center and wired in place of the remote switch (typically between terminal blocks R and G on the terminal strip. The relay must be rated for at least 5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to “chatter” or not pull in which can cause contactor failures and/or motor failures.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Field-Provided Disconnect

If ﬁeld-installing an additional disconnect switch, it is recommended that there is at least four feet of service room between the switch and system access panels. When providing or replacing fuses in a fusible disconnect, use dual element time delay fuses and size according to the rating plate.

Typical Control Center Components with Microprocessor Control

Discharge Air Temperature Sensor

Without Indirect Gas Furnace

For units without an indirect gas furnace, the discharge air temperature sensor is factory-mounted in the blower discharge section of the unit behind the blower cut off plate.

WARNING

Discharge air temperature sensor is to be fieldinstalled prior to unit start-up on units with an indirect gas furnace.

With Indirect Gas Furnace

For units with an indirect gas furnace, the discharge air temperature sensor is to be ﬁeld-installed prior to unit start up at least three duct diameters downstream of the heat exchanger or where good mixed average temperature occurs in the ductwork. The discharge air sensor is shipped loose and can be found in the unit’s control center. See the unit-speciﬁc wiring diagram for connection locations.

10 10

16 16

7 7

Individual components and locations will vary.

1. Main disconnect (non-fusible, lockable)

2. Motor starter - outdoor air fan

3. Motor starter - exhaust air fan

4. Motor contactor - energy wheel

5. 24 VAC control transformer

6. 24 VAC terminal strip

7. Fuses for blower motors

8. Grounding lug

9. Distribution block

10. Compressor fuse blocks

Optional Components

11. Microprocessor controller

12. Dirty ﬁlter pressure switches

13. GreenTrol®

14. Frost control pressure switch

15. Energy recovery wheel VFD

16. Compressor contactors

17. Condenser fan contactors

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®17

Optional Accessory Wiring Schematics

Remote Panel

The remote panel is available with a number of different alarm lights and switches to control the unit. The remote panel ships loose and requires mounting and wiring in the ﬁeld. The remote panel is available with the following options:

• Unit on/off switch

• Unit on/off light

• 7-day time clock

• Hand/off/auto switch

• Dirty ﬁlter light

• Economizer light

• Frost control light

• Wheel rotation sensor light

Unit Interfacing Terminals

Heating/Cooling Switches and Night Setback Switch/ Timer

TERMINAL BLOCKS IN

UNIT CONTROL CENTER

UNIT ON/OFF

COOL STAGE 1 / ECONOMIZER

COOL STAGE 2

HEAT

7-Day Timer

TERMINAL BLOCKS IN

UNIT CONTROL CENTER

BLACK BLUE

RED

(CAPPED)

TIMER

On/Off/Auto Switch & Indictor Light Wiring

TERMINAL BLOCKS IN

UNIT CONTROL CENTER

UNIT ON/OFF

FROST CONTROL

ECONOMIZER

WHEEL ROTATION

OFF

AUTO

* -- BMS, TIMECLOCK,

TSTAT, RTU, ETC.

UNOCCUPIED RECIRCULATION

Dirty Filter Indicator

(Powered by others)

SUPPLY DIRTY FILTER SWITCH

EXHAUST DIRTY FILTER SWITCH

HOT COMMON

DIRTY FILTER

SUPPLY DIRTY FILTER SWITCH

EXHAUST DIRTY FILTER SWITCH

ON/OFF/AUTO SWITCH ALLOWS THREE MODES OF OPERATION "ON" - UNIT IS TURNED ON MANUALLY "OFF" - UNIT IS TURNED OFF MANUALLY "AUTO" - UNIT IS CONTROLLED VIA SCHEDULER OF BMS, TIMECLOCK, TSAT, ETC.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

DIRTY FILTER

Piping Installation

Optional Gas Piping

Units with indirect gas-ﬁred furnaces require ﬁeldsupplied and installed gas supply piping. The unit gas connection is pressure is 14 in. wg.

From Gas Supply

Gas Connections

If this unit is equipped with an indirect gas-ﬁred furnace, connection to an appropriate gas supply line will be required. For complete information on installation procedures for the optional gas furnace, refer the PVF/PVG Indirect Gas-Fired Heat Module Installation, Operation, and Maintenance Manual.

Optional Coil Piping

Factory-installed cooling and heating components are mounted in the coil section of the unit. The coil section is downstream of the energy wheel on the supply air side of the unit. Note the coil connection locations on the picture. Coil connections are located external to the unit as shown.

Note: DX coil liquid connection is internal to units.

Water Coils

⁄4 inch NPT. The maximum allowable gas

Ground

Joint

Gas Cock

Bleeder Valve or 1/8 in Plugged Tap

Typical Gas Supply Piping Connection

Water coil

connections

Union

connection

8 in. Trap

DX coil

liquid

access

door

Gas to

Controls

2. Connect the water supply to the bottom connection on the air leaving side and the water return to the top connection on the air entering side. Connecting the supply and/or return in any other manner will result in very poor performance. Be sure to replace factory-installed grommets around coil connections if removed for piping. Failure to replace grommets will result in water leakage into the unit and altered performance.

3. Water coils are not normally recommended for use with entering air temperatures below 40°F. No control system can be depended on to be 100% safe against freeze-up with water coils. Glycol solutions or brines are the only safe media for operation of water coils with low entering air conditions. If glycol or brine solutions are not used, coils must be drained when freezing conditions are expected. If required,

vent and drain connections must be fieldpiped, external to the unit.

4. Pipe sizes for the system must be selected on the basis of the head (pressure) available from the circulation pump. The velocity should not exceed 6 feet per second and the friction loss should be approximately 3 feet of water column per 100 feet of pipe.

5. For chilled water coils, the condensate drain pipe should be sized adequately to ensure the condensate drains properly. Refer to Drain Trap section.

Direct Expansion (DX) Coils (Split DX)

1. Piping should be in accordance with accepted industry standards. Pipework should be supported independently of the coils. Undue stress should not be applied at the connection to coil headers.

2. The condensate drain pipe should be sized adequately to ensure the condensate drains properly. Refer to Condensate Drain Trap section.

3. When connecting suction and liquid connections make sure the coil is free from all foreign material. Make sure all joints are tight and free of leakage. Be sure to replace factory-installed grommets around coil connections if removed for piping.

4. Manufacturer does not supply compressor or condensing units with standard models. For further instruction on DX coil installation and operation contact your compressor and/or condenser manufacturer.

1. Piping should be in accordance with accepted industry standards. Pipework should be supported independently of the coils. When installing couplings, do not apply undue stress to the connection extending through the unit. Use a backup pipe wrench to avoid breaking the weld between coil connection and header.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®19

Condensate Drain Trap

This unit is equipped with a stainless steel condensate pan with a 1-inch MPT stainless steel drain connection. It is important that the drain connection be ﬁtted with a P trap to ensure proper drainage of condensate while maintaining internal static pressures.

A P trap assembly (kit) is supplied with each unit and is to be assembled and installed as local conditions require and according to the assembly instructions provided with the P trap. If local and area codes permit, the condensate may be drained back onto the roof, but a drip pad should be provided beneath the outlet. If local and area codes require a permanent drain line, it should be fabricated and installed in accordance with Best Practices and all codes.

In some climates, it will be necessary to provide freeze protection for the P trap and drain line. The P trap should be kept ﬁlled with water or glycol solution at all times and it should be protected from freezing to protect the P trap from damage. If severe weather conditions occur, it may be necessary to fabricate a P trap and drain line of metal and install a heat tape to prevent freezing.

Heat Pump Piping Sizes and Connections

Pipe Size

(in. FPT)

1.25

1.5

Model Tonnage

ERCH-20 4 2

ERCH-45 8 2

ERCH-20 5 2

ERCH-45 10 2

ERCH-20 6 2

ERCH-45

ERCH-55 15 2

ERCH-55

ERCH-90

12.5 2

15 2

17.5 2

20 2

25 2

30 2

Number of

Connections

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Optional Evaporative Cooler

CAUTION

All solenoids valves and traps must be installed below the roof to protect the supply water line from freezing. If they cannot be installed below the roof, an alternative method must be used to protect the lines from freezing.

IMPORTANT

The supply line should be of adequate size and pressure to resupply the amount of water lost due to bleed-off and evaporation. The drain line should be the same size or larger than the supply line.

CAUTION

Provisions must be taken to prevent damage to the evaporative cooling section during freezing conditions. The sump, drain lines and supply lines must be drained prior to freezing conditions or an alternate method must be used to protect the lines and media.

Recirculating Pump

This option includes a pump that recirculates water over the evaporative media. The pump is activated by a call for cooling. A ﬁeld-adjustable bleed-off valve keeps mineral concentrations low.

Supply

Line

Supply Line Valve

(Normally Closed)

Drain Line Valve

(Normally Open)

Drain Line

Trap

Recirculating Evaporative Piping

1. Install the Water Supply Line. Supply line opening

requirements vary by unit size and arrangement and are ﬁeld-supplied. Connect the water supply line to the ﬂoat valve through the supply line opening in the evaporative cooling unit. Install a manual shutoff valve in the supply line as shown above.

2. Install the Drain Line. Connect an unobstructed drain line to the drain and overﬂow connections on the evaporative cooler. A manual shut off valve (by others) is required for the evaporative cooler drain line. A trap should be used to prevent

Drain Trap

sewer gas from being drawn into the unit.

Overflow

6 in. min.

3. Check/Adjust Water Level. Check the water level in the sump tank. The water level should be above the pump intake and below the overﬂow. Adjust the ﬂoat as needed to achieve the proper water level.

Auto Drain and Flush

This option includes a recirculating pump and ﬁeldadjustable timer that will periodically ﬂush the sump to keep mineral concentrations low.

Sump Overflow

Sump Drain

VALVE C

Sump Drain Solenoid

(Normally Open)

Supply Line Drain Solenoid

VALVE B

(Normally Open)

Auto Drain & Flush Evaporative Piping

Trap

Drain Line

CAUTION

The supply solenoid (Valve A) is NOT the same as the drain solenoids (Valve B and Valve C). Make sure to use the proper solenoid for each location. Check your local code requirements for proper installation of this type of system.

1. Install the Water Supply Line. Supply line opening requirements vary by unit size and arrangement and are ﬁeld-supplied. Connect the water supply line to the ﬂoat valve through the supply line opening in the evaporative cooling unit. Install the 1/2-inch normally closed solenoid (Valve A) in the supply line. Install the 1/4-inch normally open solenoid (Valve B) between the supply line and the drain line.

2. Install the Drain Line. Connect an unobstructed drain line to the sump drain overﬂow connection. Install the 3/4-inch normally open solenoid (ValveC) between the sump drain connection and the drain line. A trap should be used to prevent

Drain Trap

sewer gas from being drawn into the unit.

Supply

Line

VALVE A

Supply Solenoid

(Normally Closed)

6 in. min.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®21

Auto Drain & Flush Valves

(when provided by Manufacturer)

Assembly

No.

852178

Mfg

Part No.

ASCO

Part No.

Solenoid

Type

De-Energized

Position

461262 8210G2 Supply Closed

Supply

461263 8262G262

Line

Open

Drain

461264 8210G35

Sump

Drain

Open

Diameter Qty.

1/2-inch

(12.7 mm)

1/4-inch

(6.35 mm)

3/4-inch

(19.05 mm)

Part numbers subject to change.

Water Supply Connection Locations for Evaporative Cooler

Model

Water Supply Connection Locations

ABCD

ERCH-20 37.5 4.5 4.5 46

ERCH-45 45.25 4.5 4.5 51.5

ERCH-55 56 4.5 4.5 57

ERCH-90 59 4.5 4.5 68

Dimensions from outside of unit (in inches)

EXHAUST FILTERS

OUTDOOR AIR

WHEEL CASSETTE

DIRECT

EVAP

INTAKE

Ø0.875 Run 1/4 in. line up through 7/8 in. hole here and

bring around end of sump to supply connection.

1/4 in. water supply connection

ELECTRICAL BOX

INDIRECT

EVAP

RETURN AIR

INTAKE

OUTDOOR AIR FILTERS

1/4 in. water supply connection

Run 1/4 in. line up through 7/8 in. hole here

Ø0.875

and bring around end of sump to supply connection.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Unit Overview

Optional Component Overview

Basic Unit

The unit is pre-wired such that when a call for outside air is made (via ﬁeld-supplied 24 VAC control signal wired to unit control center), the supply fan, exhaust fan, and energy wheel are energized and optional motorized dampers open.

The unit can be supplied with or without heating and cooling coils. For units with coils, controls can be supplied by manufacturer or by the controls contractor. If supplied by the controls contractor, they would provide, mount, and wire any temperature controllers and temperature or relative humidity sensors required for the unit to discharge air at the desired conditions. However, temperature, pressure, and current sensors can be provided by manufacturer for purposes of monitoring via the BMS.

Summer Operation

Outdoor air is preconditioned (temperature and moisture levels are decreased) by the transfer of energy from the cooler, drier exhaust air via the energy recovery wheel. Units supplied with cooling coils can further cool the air coming off the wheel and strip out moisture to levels at or below room design. A heating coil downstream of the cooling coil can reheat the air to a more comfortable discharge temperature to the space.

Return Air

75°F

50% RH

Exhaust Air

Supply Air

Outdoor Air

95°F

117 grains/lb.

79°F

75 grains/lb.

Winter Operation

Outdoor air is preconditioned (temperature and moisture levels are increased) by the transfer of energy from the warmer, more humid exhaust air via the energy recovery wheel. Units supplied with heating coils can further heat the air coming off the wheel to levels at or above room design.

Economizer

The energy wheel operation can be altered to take advantage of economizer operation (free cooling). Two modes are available:

1. Stopping the wheel

2. Modulating the wheel

Stopping the wheel: A ﬁeld-supplied call for cool (Y1) is required. De-energizing the wheel is accomplished in one of three ways:

1. The outdoor air temperature is less than the

outdoor dry bulb set point (DRYBLB SET)

2. The outdoor air temperature is less than the return

air temperature

3. The outdoor air enthalpy is within the preset

enthalpy curve

A low temperature lock out (LOW T LOCK) is also set to deactivate mechanical cooling when it exceeds the outdoor air temperature (factory default 32°F). Effectively, the two sensors create a deadband where the energy recovery wheel will not operate and free cooling from outside can be brought into the building unconditioned.

Modulating the wheel (factory): A variable frequency drive is fully programmed at the factory. A “call for cool” must be ﬁeld-wired to the unit (Terminals provided in unit. Refer to wiring diagram in unit control center.) to allow for initiation of economizer mode. The unit recognizes economizer conditions based one of the previously mention sensors and set points. The unit will then modulate the wheel speed to maintain the mixed air temperature set point (MAT SET).

Modulating the wheel (by others): A variable frequency drive is fully programmed at the factory. A ﬁeld-supplied 0-10 VDC signal will be required for operation of the energy wheel. The ﬁeld will be required to have full control of the energy wheel speed at all times. If no 0-10 VDC signal is provided, the energy wheel will run at the factory default of 3 Hz and no energy transfer will be captured.

Exhaust Air

Outdoor Air

10°F

5 grains/lb.

Return Air

72°F

40% RH

Supply Air

60°F

39 grains/lb.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®23

Frost Control

Extremely cold outdoor air temperatures can cause moisture condensation and frosting on the energy recovery wheel. Frost control is an optional feature that will prevent/control wheel frosting. Three options are available:

1. Timed exhaust frost control

2. Electric preheat frost control

3. Modulating wheel frost control

All of these options are provided with a thermodisc mounted in the outdoor air intake compartment and a pressure sensor to monitor pressure drop across the energy wheel.

An outdoor air temperature of below 5°F and an increase in pressure drop would indicate that frost is occurring. Both the pressure sensor and the outdoor air thermodisc must trigger in order to initiate frost control. The two sensors together ensure that frost control is only initiated during a real frost condition.

Timed exhaust frost control includes a timer in addition to the thermodisc and wheel pressure sensor. When timed exhaust frost control is initiated, the timer will turn the supply blower off. Time exhaust using default timer setting will shut down the supply fan for 5 minutes every 30 minutes to allow exhaust to defrost energy wheel. Use the test procedure in the Optional Start-Up Accessories section for troubleshooting.

Electric preheat frost control includes an electric heater (at outdoor air intake) in addition to the thermodisc and pressure sensor on wheel. When electric preheat frost control is initiated, the electric preheater will turn on and warm the air entering the energy wheel to avoid frosting. Use the test procedure in the Optional Start-Up Accessories section for troubleshooting.

Modulating wheel frost control includes a variable frequency drive (VFD) in addition to the thermodisc and pressure sensor. When modulating wheel frost control is initiated, the VFD will reduce the speed of the wheel. Reducing the speed of the energy wheel reduces its effectiveness, which keeps the exhaust air condition from reaching saturation, thus, eliminating condensation and frosting. If the outdoor air temperature is greater than the frost threshold temperature OR the pressure differential is less than the set point, the wheel will run at full speed. If the outdoor air temperature is less than 5°F AND the pressure differential is greater than the set point, the wheel will run at reduced speed until the pressure differential falls below the set point. The VFD will be fully programmed at the factory.

Variable Frequency Drives (VFD)

Variable frequency drives are used to control the speed of the fan as either multi-speed or modulating control. Multi-speed VFDs reference a contact which can be made by a switch or a sensor with a satisﬁed set point. Modulating control references a 2-10 VDC signal to the VFD which will vary the fan speed from a minimum 50% to full 100% rpm. An optional CO

sensor is available to

provide both a set point contact or a modulating 2-10 VDC signal.

CO2 Sensor

This accessory is often used in Demand Control Ventilation (DCV) applications. The factory-provided sensors can either be set to reference a set point for multi-speed operation, or output a 2-10 VDC signal to modulate the fan speed. These can either be shipped loose to mount in the ductwork, or can be factory-mounted in the return air intake. Follow instructions supplied with sensor for installation and wiring details.

Phase Monitor

The unit control circuitry includes a phase monitor that constantly checks for phase reversal or loss of phase. When a fault is detected, it cuts off the 24 VAC that goes to the low voltage terminal strip, thereby shutting down the unit.

Rotation Sensor

The rotation sensor monitors energy wheel rotation. If the wheel should stop rotating, the sensor will close a set of contacts in the unit control center. Field-wiring of a light (or other alarm) between terminals R and 12 in the unit control center will notify maintenance personnel when a failure has occurred.

Dirty Filter Sensor

Dirty ﬁlter sensors monitor pressure drop across the outdoor air ﬁlters, exhaust air ﬁlters, or both. If the pressure drop across the ﬁlters exceeds the set point, the sensor will close a set of contacts in the unit control center. Field-wiring of a light (or other alarm) to these contacts will notify maintenance personnel when ﬁlters need to be replaced. The switch has not been set at the factory due to external system losses that will affect the switch. This switch will need minor ﬁeld adjustments after the unit has been installed with all ductwork complete. The dirty ﬁlter switch is mounted in the exhaust inlet compartment next to the unit control center or in unit control center.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Microprocessor Control

The microprocessor controller is speciﬁcally designed and programmed to optimize the performance of the unit with supplemental heating and cooling. This option ensures that the outdoor air is conditioned to the desired discharge conditions. The controller and accompanying sensors are factory-mounted, wired and programmed. Default settings are pre-programmed, but are easily ﬁeldadjustable.

The microprocessor controller can be interfaced with a Building Management System through LonWorks®, BACnet®, or ModBus.

Please refer to the Installation, Operation and Maintenance manual for detailed information.

Unoccupied Recirculation Damper

The unoccupied recirculation option provides a recirculation damper from the return air intake to the supply airstream to reduce heating and cooling loads when less ventilation is required. During the unoccupied mode, the exhaust fan will remain off and the supply air fan will operate with mode of tempering to maintain unoccupied temperature set point.

Service Outlet

120 VAC GFCI service outlet ships loose for ﬁeld installation. Requires separate power source so power is available when unit main disconnect is turned off for servicing.

Vapor Tight Lights

Vapor tight lights provide light to each of the compartments in the energy recovery unit. The lights are wired to a junction box mounted on the outside of the unit. The switch to turn the lights on is located in the unit control center. The switch requires a separate power source to allow for power to the lights when the unit main disconnect is off for servicing.

Hot Gas Bypass Valve (standard scroll)

On units equipped with hot gas bypass, hot gas from the compressor is injected into the liquid line of the evaporator coil after the thermostatic expansion valve. This process starts to occur when suction gas temperatures drop below 28°F, which is 32°-34°F coil surface temperature. Hot gas helps the evaporator coil from freezing up and the compressor from cycling. The valve needs to be adjusted to exact speciﬁcations once unit is installed in the ﬁeld.

Hot Gas Reheat Valve

Units equipped with a reheat coil use a three-way valve with actuator to control the supply air discharge temperature of the unit during dehumidiﬁcation mode. The unit controller provides a 0-10VDC signal to control the amount of reheat to meet the supply temperature set point.

Digital Scroll Compressor - PDX Only

Refrigeration Modulation

Digital scroll compressors modulate the refrigeration system, increasing performance. A conventional ﬁxed scroll compressor runs at full load and then shuts down when user set points are reached. The digital scroll compressor modulates its cooling capacity (10-100%) by means of cycling through rapid load/no-load cycles without shutting down the compressor motor (digital control). Because it can operate at less than full load, evaporator coil temperatures are much more constant as hysteresis is improved and humidity control is enhanced.

Electronic Control

The use of a digital scroll compressor also requires a controller. This controller may be found in the compressor compartment of the unit. The controller works in conjunction with a microprocessor controller and requires an analog input. The controller is pre-programmed and wired and does not require any further servicing by the owner. Detailed information on the electronic control circuitry will be found on the unit-speciﬁc wiring diagram in the control center. The controller constantly monitors and controls the operation of the digital scroll compressor. LED indicator lights verify the presence of power, operation of the unloader solenoid and also indicate various alarm conditions.

Two Compressor Operation Concept

Whenever two compressors are used in a unit, the digital scroll compressor is part of refrigerant circuit “A”. A conventional ﬁxed scroll compressor is used for circuit “B”. The controller requires a 1 VDC signal to verify control connection at all times. The minimum input signal that will cause the compressor to run is 1.9 volts and the maximum is 5 volts (100% cooling). Whenever there is a call for cooling, circuit A will be activated ﬁrst. Circuit A will provide all necessary cooling until the call for cooling exceeds 50%. When the call for cooling reaches 50%, the digital scroll will shut down and the ﬁxed scroll compressor will begin running. Once the call for cooling exceeds 70%, then the digital scroll will begin running again, in conjunction with the ﬁxed scroll compressor.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®25

Outdoor Airﬂow Monitor

A factory-wired, mounted and powered airﬂow monitoring system is provided. The airﬂow control system offers the following functionality:

• Display of outdoor airﬂow rate in actual cubic feet per minute (CFM) or actual liters per second (LPS) on a 16 character LCD display.

• Two conﬁgurable analog outputs for transmitting outdoor airﬂow rate, outdoor air temperature, or a proportional-integral-derivative (PID) control signal based on an outdoor airﬂow set point.

• A conﬁgurable digital output that operates based on an airﬂow set point or range.

Operation

Outdoor airﬂow monitoring is accomplished using two thermal dispersion sensors that accurately measure airﬂow velocity down to zero feet per minute (fpm). The airﬂow controller takes the average measurement for two sensor conﬁgurations, and determines the outdoor airﬂow rate based on the effective intake area. Field calibration of the outdoor airﬂow monitoring device determines the effective intake area of the unit.

Refer to GreenTrol® Automation Inc. GF-2200A technical data sheet for further detail.

Smoke Detector

The Hochiki America DH-98 duct smoke detector provides early detection of smoke and products of combustion present in air moving through HVAC duct systems. The DH-98-P is designed to prevent the recirculation of smoke in areas by the air handling systems, fans, and blowers. Complete systems may be shut down in the event of smoke detection. The Hochiki America DH-98-P operate on 115 VAC, 24 VAC and 24 VDC.

The DH-98-P is designed and built to meet all local requirements, as well as the NFPA regulations regarding duct smoke detectors. Output terminals are provided for remote accessories such as a horn, strobe, remote status indicators and reset key switches or push buttons.

Refer to Hochiki America DH-98-P installation instructions for further detail.

IMPORTANT

For the outdoor airflow monitoring device to perform as intended, field calibration is required. Calibration of the airflow monitoring device requires an independent measurement of airflow and should be performed when the system undergoes test and balance.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Cooling System Overview

Packaged DX Cooling with Digital Scroll Compressor

Supply Airﬂow

1. Compressor

2. High Limit Pressure Switch

The switch opens when refrigerant pressure increases above the set point in the liquid line and it then requires a manual reset.

3. Hot Gas Reheat Valve (optional)

Units equipped with a reheat coil use a threeway valve with actuator to control the supply air discharge temperature of the unit during dehumidiﬁcation mode. The unit controller provides a 0-10 VDC signal to control the amount of reheat to meet the supply temperature set point.

4. Hot Gas Reheat Coil

5. Hot Gas Reheat Check Valve

6. Condenser Fans

7. Condensing Coil

8. Liquid Receiver (optional)

Condenser Airﬂow

9. Sight Glass

10. Liquid Line Filter Drier

11. Thermostatic Expansion Valve (TXV)

12. Evaporative Coil

13. Low Limit Pressure Switch

124

Each unit is equipped with a TXV on each refrigerant circuit. The valve controls the ﬂow of liquid refrigerant entering the evaporator coil by maintaining a constant, factory-set superheat of 10°F. The valve is adjustable and is located on the side of the evaporator coil and can be accessed through the inner coil access panel.

The switch is installed in the suction line and disables the DX system when the suction pressure drops below the set point. The switch will autoreset when the pressure rises above the auto-reset set point.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®27

Water-Source Heat Pump with Standard Scroll Compressor

Water InWater Out

Supply

Airﬂow

1. Compressor

2. High Limit Pressure Switch

3. Hot Gas Reheat Valve (optional)

4. Hot Gas Reheat Coil

5. Hot Gas Reheat Check Valve

6. Liquid Receiver (optional)

7. Liquid Line Filter Drier

8. Thermostatic Expansion Valve (TXV)

9. Low Limit Pressure Switch

10. Hot Gas Bypass Valve (optional)

On units equipped with hot gas bypass, hot gas from the compressor is injected into the refrigerant line of the evaporator coil after the TXV.

11. Airside Coil

Each unit uses a single refrigerant coil known as an airside coil. If two compressors are used in the unit, then the airside coil will be a split conﬁguration so that each compressor has a dedicated portion of the airside coil. Depending on whether the unit is in cooling or heating mode, the airside coil will function as either a condensing coil or an evaporator coil.

12. Coaxial Refrigerant-to-Water Heat Exchanger

The unit uses one coaxial heat exchanger per compressor, essentially a tube inside a tube. Water ﬂows through the inner copper tube and compressed refrigerant is forced through the spaces between the inner and outer tubes. Depending on whether the unit is functioning in a cooling or a heating capacity, heat is rejected from one tube to the other.

13. Reversing Valves Each compressor is equipped with a reversing valve to reverse the direction of refrigerant ﬂow. Changing refrigerant ﬂow allows the unit to operate.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Start-Up Unit

SPECIAL TOOLS REQUIRED

DANGER

Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit to OFF at disconnect switch(es). Unit may have multiple power supplies.

CAUTION

Use caution when removing access panels or other unit components, especially while standing on a ladder or other potentially unsteady base. Access panels and unit components can be heavy and serious injury may occur.

CAUTION

Do not operate without the filters and birdscreen installed. They prevent the entry of foreign objects such as leaves, birds, etc.

CAUTION

Do not run unit during construction phase. Damage to internal components may result and void warranty.

WARNING

• Unit was factory tested. All blowers, fans, and compressors are set-up to run correctly when supplied power. If any one fan is running backwards or the compressor is making loud noises, immediately turn off the power. Switch two leads on the incoming power to the disconnect. This will ensure proper operation of the unit. Failure to comply may damage the compressors and void the warranty.

• Do not jumper any safety devices when operating the unit. This may damage components within or cause serious injury or death.

• Do not operate compressor when the outdoor temperature is below 40°F.

• Do not short-cycle the compressor. Allow 5 minutes between “on” cycles to prevent compressor damage.

• Prior to starting up the unit, power must be energized for 24 hours without a call for cooling to allow the compressor crankcase heaters time to boil off any liquid refrigerant present in the compressor.

• DX system is charged with refrigerant. Start-up must be performed by EPA Certified Technician.

• Voltage Meter (with wire probes)

• Amperage Meter

• Pressure Gauges – (refrigerant)

• Tachometer

• Thermometer

• U-tube manometer or equivalent

Start-Up Procedure

The unit will be in operational mode during start-up. Use necessary precautions to avoid injury. All data must be collected while the unit is running. In order to measure volts and amps, the control center door needs to be open and the unit energized.

• Make sure Pre-Start-Up checklist is complete.

• Jumper R to G to enable unit. Jumper R to Y1 and R to Y2 to enable cooling and R to W1 to enable heat for units without microprocessor.

• Turn the disconnect on. After 3 minutes, compressors will come on. Make sure all fans and compressors are rotating the correct direction.

• Allow the unit to run until the refrigerant system stabilizes. Approximately 10-15 minutes.

Voltage Imbalance

In a three-phase system, excessive voltage imbalance between phases will cause motors to overheat and eventually fail. Maximum allowable imbalance is 2%. To determine voltage imbalance, use recorded voltage measurements in this formula.

Key: V1, V2, V3 = line voltages as measured VA (average) = (V1 + V2 + V3) / 3 VD = Line voltage (V1, V2 or V3) that deviates farthest from average (VA)

Formula: % Voltage Imbalance = [100 x (VA-VD)] /VA

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®29

Pre Start-Up

Every installation requires a comprehensive start-up to ensure proper operation of the unit. As part of that process, the following checklist must be completed and information recorded. Starting up the unit in accordance with this checklist will not only ensure proper operation, but will also provide valuable information to personnel performing future maintenance. Should an issue arise which requires factory assistance, this completed document will allow unit experts to provide quicker resolve. Qualiﬁed personnel should perform start-up to ensure safe and proper practices are followed.

Unit Model No. __________________________________

Unit Serial No. ____________________________________

Heat Pump Model No. ____________________________

Energy Wheel Serial Number _______________________

Compressor 1 Model No. _________________________

Compressor 2 Model No. _________________________

Start-Up Date ____________________________________

Start-Up Personnel Name _________________________

Start-Up Company ________________________________

Phone Number ___________________________________

Pre Start-Up Checklist

Disconnect and lock-out all power switches.

 Remove any foreign objects that are located in the

energy recovery unit.

 Check all fasteners, set-screws, and locking collars

on the fans, bearings, drives, motor bases and accessories for tightness.

 Check fan rotation.

Start-Up Checklist

 Rotate the fan wheels and energy recovery wheels

by hand and ensure no parts are rubbing.

 Check the fan belt drives for proper alignment and

tension.

 Filters can load up with dirt during building

construction. Replace any dirty pleated ﬁlters and clean the aluminum mesh ﬁlters in the intake hood.

 Verify that non-motorized dampers open and close

properly.

 Check the tightness of all electrical wiring

connections.

 Verify control wire gauge.

 Verify diameter seal settings on the energy recovery

wheel.

 Verify proper drain trap installation.

 Check condensing fans for any damage or

misalignment. Spin the blades and make sure they don’t contact any parts and are free-turning without any resistance.

 Look over the piping system. Inspect for oil at all

tubing connections. Oil typically highlights a leak in the system.

 Inspect all coils within the unit. Fins may get

damaged in transit or during construction. Carefully straighten ﬁns with a ﬁn comb.

 If there is an indirect gas-ﬁred furnace in this unit,

refer to the manual provided with this unit for PreStart-Up information.

 This unit contains a crankcase heater for each

compressor which needs power supplied to it 24hours prior to start-up. If start-up is scheduled in 24 hours, unlock the disconnect power and energize unit.

Line Voltage. Check at unit disconnect.

L1-L2 Volts L2-L3 Volts L1-L3 Volts

Motor Amp Draw

Supply Motor Amps L1 Amps L2 Amps L3 Amps

Exhaust Motor Amps L1 Amps L2 Amps L3 Amps

Fan RPM

Supply Fan RPM Supply Fan Yes / No

Measured Airflow CFM

Exhaust Fan RPM Exhaust Fan Yes / No

Measured Airflow CFM

Correct fan rotation direction?

Energy Wheel Motor

L1 Amps L2 Amps L3 Amps

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Heating System / Electric Heat

Pre-Heater L1-L2 Volts L2-L3 Volts L1-L3 Volts

L1 Amps L2 Amps L3 Amps

Temp. Rise

Post-Heater L1-L2 Volts L2-L3 Volts L1-L3 Volts

L1 Amps L2 Amps L3 Amps

Temp. Rise

Cooling System

Outdoor Air Temperature Deg F Outdoor Air Relative Humidity % RH

Return Air Temperature Deg F Return Air Relative Humidity % RH

Condensing Fan 1 Condensing Fan 2 Condensing Fan 3

L1 ____________ Amps L1 ____________ Amps L1 ____________ Amps

L2 ____________ Amps L2 ____________ Amps L2 ____________ Amps

L3 ____________ Amps L3 ____________ Amps L3 ____________ Amps

A. Discharge Pressure

B. Discharge Pressure Converted to

Temperature

C. Liquid Line Temperature

D. Subcooling (B-C)

Should be between 12º and 17ºF

E. Suction Line Pressure

F. Suction Line Temperature

G. Suction Pressure Converted to

Temperature

H. Superheat (F-G)

Should be between 8º and 12ºF

Water In

Water Out

Hot Gas Bypass Operational

(Not present on digital scroll compressors)

Suction Pressure Set Point

Compressor Sight Glass

Compressor 1

Hot gas reheat valve

closed

Compressor 1

Hot gas reheat valve

open

Compressor 2

L1 ____________ Amps L1 ____________ Amps L1 ____________ Amps

L2 ____________ Amps L2 ____________ Amps L2 ____________ Amps

L3 ____________ Amps L3 ____________ Amps L3 ____________ Amps

Crankcase heater _________ Amps

Cooling HP Heating Cooling Cooling HP Heating

Yes / No Yes / No Yes / No Yes / No Yes / No

Oil Level

Oil Foaming Yes / No Yes / No Yes / No Yes / No Yes / No

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®31

Optional Accessories Checklist

Refer to the respective sections in this Installation, Operation and Maintenance Manual for detailed information. Refer to wiring diagram in unit control center to determine what electrical accessories were provided.

Frost Control Application / Operation Section: Setting Factory Default

Yes No Frost Control set point 5°F

Differential 2°F

Timer Refer to IOM

Yes No Frost Control Modulating Refer to IOM

Economizer Application / Operation Section:

Yes No Economizer (temperature)

Set point 65°F

Offset 20°F

Differential 2°F

Yes No Economizer (enthalpy)

Set point B

Yes No Economizer (modulating) Refer to IOM

Optional Accessories Section: Operational

Yes No Wheel Rotation Sensor

(

⁄8 in. from wheel)

Yes No OA Dirty Filter Sensor Yes No N/A

Yes No EA Dirty Filter Sensor Yes No N/A

Yes No CO2 Sensor Yes No N/A

Yes No Service Outlet Yes No N/A

Yes No Vapor Tight Lights Yes No N/A

Yes No Remote Control Panel Yes No N/A

Yes No N/A

Variable Frequency Drives Section: Operational

Yes No Blower VFDs Yes No N/A

Yes No Wheel VFD Yes No N/A

Damper Section: Operational

Yes No Outdoor Air Damper Yes No N/A

Yes No Exhaust Air Damper Yes No N/A

Yes No Night Setback Damper Yes No N/A

Indirect Gas Furnace:

Yes No Refer to PVF/PVG Installation, Operation and Maintenance for start-up information.

Outdoor Air Monitoring:

Yes No Field calibrated.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Start-Up Components

tRet

aain

Scr

ews

Energy Wheel

The energy wheel is installed in the unit’s airstream with one half of the wheel in the intake airstream and one half in the return airstream. Air leakage between the two airstreams has to be kept to a minimum and the wheel has air seals that must be adjusted for that purpose. The seals must be adjusted at time of start-up.

Drive Belt

Inspect the drive belt. Make sure the belt rides smoothly in the pulley and around the outside of the wheel. Note the directional arrow and data information shown in the image.

Bearing Support

Push the wheel cassette back into the unit and plug in the power connector. Turn the main power supply back on and then observe the operation of the wheel by opening the wheel access door slightly. Remove ﬁlters if necessary to observe the wheel.

Fans

The unit contains a forward-curved supply fan and a forward curved exhaust fan. These forward-curved fans should be checked for free rotation. If any binding occurs, check for concealed damage and foreign objects in the fan housing. Be sure to check the belt drives per the start-up recommendations in the following section.

Centering of the fan wheel can be accomplished by loosening the wheel hub set screw and moving the wheel to the desired position.

Adjustable

Air Seals

Label showing

cassette serial number

and date code

Drive Belt

Drive Pulley

Adjust the Air Seals

The ﬁrst step in wheel seal adjustment is to make sure the unit power supply is locked out. Disconnect the wiring to the wheel module and pull the wheel cassette out of the cabinet on its tracks. Large cassettes are not removable. Then slowly rotate the wheel by hand to make sure there is no binding or misalignment. The wheel should rotate smoothly and should not bind.

There is a perimeter seal located around the outside of the wheel and a diameter seal across the face of the wheel on both sides. Check to make sure that all air seals are secure and in good condition.

Adjust the air seals by loosening all the air seal retaining screws on the bearing support (see image for reference). Using a piece of paper as a feeler gauge, adjust the seals so they almost touch

Bearing Support Bar

Showing air seal assembly

the face of the wheel while tugging slightly on the paper. When the wheel is rotated, there should be a slight tug on the paper. Tighten the screws, repeat the steps on the other set of seals.

CAUTION

When operating conditions of the fan are to be changed (speed, pressure, temperature, etc.), consult manufacturer to determine if the unit can operate safely at the new conditions.

Fan Performance Modiﬁcations

Due to job speciﬁcation revisions, it may be necessary to adjust or change the sheave or pulley to obtain the desired airﬂow at the time of installation. The start-up technician must check blower amperage to ensure that the amperage listed on the motor nameplate is not exceeded. Amperage to be tested with access doors closed and ductwork installed.

Fan Belt Drives

The fan belt drive components, when supplied by manufacturer, have been carefully selected for the unit’s speciﬁc operating condition. Utilizing different components than those supplied could result in unsafe operating conditions which may cause personal injury or failure of the following components:

• Fan Shaft • Bearings • Motor

• Fan Wheel • Belt

Tighten all fasteners and set screws securely and realign drive pulleys after adjustment. Check pulleys and belts for proper alignment to avoid unnecessary belt wear, noise, vibration and power loss. Motor and drive shafts must be parallel and pulleys in line (see diagrams in Belt Drive Installation section).

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®33

Belt Drive Installation

1. Remove the protective coating from the end of the fan shaft and assure that it is free of nicks and burrs.

2. Check fan and motor shafts for parallel and angular alignment.

3. Slide sheaves on shafts. Do not drive sheaves on as this may result in bearing damage.

4. Align fan and motor sheaves with a straightedge to centerline.

5. Place belts over sheaves. Do not pry or force belts, as this could result in damage to the cords in the belts.

6. With the fan off, adjust the belt tension by moving the motor base. (See belt tensioning procedures in the Routine Maintenance section of this manual). When in operation, the tight side of the belts should be in a straight line from sheave to sheave with a slight bow on the slack side.

WRONG WRONG

WRONG CORRECT

Proper alignment of motor and drive shaft.

0.25 in.

1.5 in.

centerline

straightedge

2 in.

Pulley

alignment

example

Direction of Fan Wheel Rotation

Blower access is labeled on unit. Check for proper wheel rotation by momentarily energizing the fan. Rotation is determined by viewing the wheel from the

Airﬂow

drive side and should match the rotation decal afﬁxed to the fan housing.

If the wheel is rotating the wrong

way, direction can be reversed by interchanging any two of the three electrical leads.

Check for unusual noise, vibration, or overheating of bearings. Refer to the Troubleshooting section of this manual if a problem develops.

Forward Curved

Fan RPM

Supply fan and exhaust fan will have an adjustable motor pulley (on 15 HP and below) preset at the factory to the customer-speciﬁed RPM. Fan speed can be increased or decreased by adjusting the pitch diameter of the motor pulley. Multi-groove variable pitch pulleys must be adjusted an equal number of turns open or closed. Any increase in fan speed represents a substantial increase in load on the motor. Always check the motor amperage reading and compare it to the

amperage rating shown on the motor nameplate when changing fan RPM. All access doors must be installed except the control center door.

WARNING

Do not operate units with access doors open or without proper ductwork in place as the fan motors will overload.

Maximum RPM for

Forward-Curved Blowers

Class I

Max RPM

Class II

Max RPM

Model

ERCH-20

ERCH-45

ERCH-55

ERCH-90

Blower Diameter

x Width

(inches)

10 x 6 1700 --

9 x 9 1750 2800

12 x 8 1400 2000

12 x 12 1500 2000

15 x 15 1250 1725

18 x 18 1000 1450

Vibration

Excessive vibration may be experienced during initial start-up and can cause a multitude of problems, including structural and/or component failure.

Many of these conditions can be discovered by careful observation. Refer to the Troubleshooting section of

Vibration Causes

Off axis or loose components Drive component unbalance Poor inlet / outlet conditions Foundation stiffness

this manual for corrective actions. If observation cannot locate the source of vibration, a qualiﬁed technician using vibration

analysis equipment should be consulted. If the problem is wheel unbalance, in-place balancing can be done.

Generally, fan vibration and noise is transmitted to other parts of the building by the ductwork. To eliminate this undesirable effect, the use of heavy canvas connectors is recommended.

Hot Gas Bypass Valve (standard scroll)

To adjust, connect a pressure gauge to the suction line and block the entering air to the evaporator coil. The valve should begin to open when the suction pressure drops to approximately 115 PSIG for R-410A (the valve will feel warm to the touch). Adjustments are made by ﬁrst removing the cap on the bottom of the valve and then turning the adjusting stem clockwise to increase the setting pressure (counterclockwise to decrease). Allow several minutes between adjustments for the system to stabilize. When adjustment is complete, replace the cap on the valve.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Optional Start-Up Components

Dirty Filter Switch

To adjust the switch, the unit must be running with all of the access doors in place, except for the compartment where the switch is located (exhaust intake compartment). The adjusting screw is located on the top of the switch.

Setscrew (on front of switch) must be manually adjusted after the system is in operation.

Negative pressure connection is toward the ‘front or top’ of the switch. (Senses pressure on

the blower side of filters)

Positive pressure connection is toward the ‘back or bottom’ of the switch. (Senses pressure at air inlet side of filters)

1. Open the ﬁlter compartment and place a sheet of plastic or cardboard over 50% of the ﬁlter media.

2. Replace the ﬁlter compartment door.

3. Check to see if there is power at the alert signal leads (refer to electrical diagram).

4. Whether there is power or not, turn the adjustment screw on the dirty ﬁlter gauge (clockwise if you did not have power, counterclockwise if you did have power) until the power comes on or just before the power goes off.

5. Open the ﬁlter compartment and remove the obstructing material.

6. Replace the door and check to make sure that you do not have power at the alert signal leads. The unit is now ready for operation.

Economizer

Relevant Set Points

1. MAT SET The mixed air temperature set point after the energy wheel. The control will modulate the energy wheel to maintain temperature as best as it can (Set point menu, default 53°F)

2. LOW T LOCK The set point for the low temperature mechanical cooling lockout. (Set point menu, default 32°F)

3. DRYBLB SET The outdoor air set point to call for economizer. (Set point menu, default 63°F)

4. MIN POS The minimum signal voltage sent to the energy wheel. This must be set to 2 VDC. (Set point menu, default 2.8 VDC)

5. AUX1 O The controllers operating sequence structure. (Set point menu, default ‘None’)

6. ERV OAT SP The set point for low temperature economizer lockout. This is the low temperature set point when AUX1 O is set to ERV. (Set point menu, default 32°F)

7. STG3 DLY Time delay after second cooling stage is enabled (Advanced setup menu, default 2 hrs.)

Using the Keypad with Settings and Parameters

To use the keypad when working with Set Points, System and Advanced Settings, Checkout Tests, and Alarms:

1. Navigate to the desired menu.

2. Press currently displayed menu.

3. Use the and buttons to scroll to the desired parameter.

4. Press displayed item.

5. Press the displayed parameter value.a

6. Press the button to increase (change) the displayed parameter value.

7. Press store it in non-volatile RAM.

8. CHANGE STORED displays.

9. Press parameter.

10. Press (escape) to return to the current menu parameter.

When values are displayed, pressing and holding the

or button causes the display to automatically

increment.

The table shows which set points are relevant to the given sequences. Refer to the wiring diagram for the units’ sequence.

DRYBLB SET X X

MAT SET X X X X X X

LOW T LOCK X X X X X X

ERV OAT SP X X X

MIN POS X X X

AUX1 OUT ERV ERV ERV

STG3 DLY X X X X X X

(enter) to display the ﬁrst item in the

(enter) to display the value of the currently

button to increase (change) the

(enter) to accept the displayed value and

(enter) to return the current menu

MODULATE WHEEL STOP WHEEL

Temp

Enthalpy

OA/RA

Temp

Differential

Temp

Enthalpy

OA/RA

Temp

Differential

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®35

Stop Wheel

1. Navigate to the Checkout menu and press (enter).

2. The energy wheel and cooling should stop.

3. Navigate to Connect ERV and press

(enter) twice

to run the test.

4. Voltage between AUX1-O and C should be 24 VAC. The energy wheel should activate.

Modulate Wheel

1. Navigate to the Checkout menu and press (Enter).

2. The cooling should turn off and the wheel should be rotating at full speed.

3. Navigate to Damper Open and press to run the test.

4. Voltage between terminals ACT 2-10 and ACT COM should be 10 VDC. This will slow the wheel down to minimum speed.

5. Press

(escape), navigate to Damper Close and

press (enter) twice to run the test.

6. Voltage between terminal ACT 2-10 and ACT COM should be 2 VDC. This will speed the wheel up to maximum speed.

(enter) twice

Frost Control

Timed Exhaust

1. Remove power from unit.

2. Jumper the frost indicating wheel pressure switch in the unit control center.

3. Jumper the temperature indicating thermodisc in the unit control center. Thermodisc has a pre-set temperature of 5°F.

4. Set the frost control timer scale for T1 and T2 to 1m. Set the timer settings for T1 and T2 to 10.

5. Add power to the unit. Blower should cycle on for one minute, then turn off for one minute.

6. Remove power from unit and remove jumpers that were placed. Reset timer settings.

• T1 timer

setting set to 5 and timer scale set to 10m for 5 minutes of wheel off time.

• T2 timer

setting set to 5 and timer scale set to 1h for 30 minutes of wheel on time.

Timer Scale

Timer

Settings

Timer Scale

Settings

Electric Preheat

1. Remove power from unit.

2. Jumper the frost indicating wheel pressure switch in the preheat control center.

3. Jumper the temperature indicating thermodisc in the preheat control center. Thermodisc has a pre-set temperature of 5° F.

4. Apply power to unit. Preheater should turn on.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Outdoor Airﬂow Monitor

For additional information on how to navigate through the airﬂow controller menus, refer to technical manuals GF-2200A from GreenTrol® Automation Inc. at www. greentrol.com.

Field calibration procedure:

1. Turn off power to the unit using the power disconnect(s).

2. Remove the cover from the GreenTrol airﬂow monitoring controller.

3. Install a jumper wire between terminals R and G on the unit’s terminal board if one isn’t present.

4. When safe, turn the power back on to the unit using the power disconnect(s).

If no microprocessor controller, skip to step 8. Steps 5-7 are for microprocessor only.

5. Look at the unit’s microprocessor controller screen and view the status of the unit. If the displayed status is “System Off” continue with step 6, otherwise go to step 7.

6. Adjust the unit on/off priorities on the unit’s microprocessor controller so that the unit will run for calibration.

a. Push the “Prg” button on the microprocessor

controller.

b. Use the up and down arrows to get to the “On/

Off Unit” menu.

c. Push the enter button to view the current unit

on/off priorities.

d. Push the down arrow to display the Unit ON/

OFF Control screen.

e. Record the settings below so they can be

changed back when calibration is complete.

By digit input: ___________

By BMS: ___________

By Scheduler: ___________

f. Use the enter button to navigate between the

different settings on the page, use the up and down arrows to change the values so that “By digit input” is the only setting with “Yes”.

7. Enter the service override menu to control the damper position.

a. At the Home Screen push the “Prg” button. (If

you’re not at the home screen push the escape button until you get there).

b. Use the up and down arrows to get to the

“Service” menu, then push the enter button.

c. If you’re asked for a password, enter “1000”

for the password and push enter.

d. Use the up and down arrows to get to the

“Overrides” screen, then push enter.

e. Use the arrow buttons to get the supply

override.

8. Measure the supply airﬂow rate of the unit using an approved test and balance method.

9. Without making any changes to the system, calibrate the airﬂow monitoring controller so it reads the airﬂow measured in step 8 by using the Field Calibration Wizard.

a. The ﬁeld calibration lasts for two minutes. Any

signiﬁcant changes in airﬂow will affect the accuracy of the reading.

b. To enter the Field Calibration Wizard, hold the

Down and Enter buttons simultaneously on the airﬂow controller, then release the buttons.

c. Push the enter to enter to go Wizard 1

d. Push the enter button twice and change Wiz1

Enable to YES.

e. When asked for the number of calibration

points (Cal Points), set the value to 1.

f. Push the enter button when the display says

“Set Flow 1”.

g. After completing the steps above, set the

FLOW1 value to the airﬂow measured in step 8, then push the enter button to begin calibration.

10. After the calibration is completed, measure the supply airﬂow rate again and compare with the value on the airﬂow controller’s display

a. If the values are within 5% of each other the

device has been successfully calibrated.

b. If the values are not within 5% of each other

repeat the ﬁeld calibration process.

11. If you had to change the On/Off priorities on the microprocessor unit controller, change them back to the values that were written down in part 6.

12. Turn off power to the unit using the power disconnect(s) and wait one minute for the variable frequency drive(s) to lose backup power.

13. Replace the cover to the GreenTrol airﬂow monitoring station.

14. If you added a jumper between terminals R and G in step 3 remove it at this time. If a jumper was already in place, leave it in place.

15. When safe, turn the power back on to the unit using the power disconnect(s).

a. Recycling of the power resets the manual

override values that were set during the calibration.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®37

Evaporative Cooler

1. Check the Installation. The media may have been removed during installation, so its orientation should be double checked. The media should be installed with the steeper ﬂute

Entering Air

angle sloping down towards the entering air side.

Media Orientation

Verify that the stainless steel caps and distribution headers are in place. The headers should be located over the media towards the entering air side. The caps should be placed over the headers.

2. Check the Pump Filter. Check that the pump ﬁlter is around the pump inlet.

3. Fill the Sump and Adjust the Float. Turn on the water supply and allow the sump tank to ﬁll. Adjust the ﬂoat valve to shut-off the water supply when the sump is ﬁlled to within one inch of the bottom of the overﬂow.

4. Break-In the Media. Open the bleed-off valve completely and saturate the media with the blower(s) off for no less than 20minutes.

5. Check the Flow Rate. The pumps should provide enough water to saturate the media in 45 to 60 seconds. Consult the factory if adequate ﬂow is not achieved.

6. Adjust the Water Bleed-Off Rate. The water bleedoff rate is dependent on the water’s mineral content. The bleed-off should be adjusted based on the media’s mineral deposits after two weeks of service.

45º

Leaving Air

15º

Set the Timer Scale and Settings dials:

• t timer setting set to 10 and timer scale set to 1d for 1 day of operation

• T2 timer setting set to 10 and the timer scale set to 10m for 10 minutes of drain time

Timer Scale

Timer

Settings

Timer Scale

Auto Drain and Flush Timer

Settings

8. Put the Unit into Service. Remove the jumper, and energize the blower(s). Verify proper operation.

IMPORTANT

Check the media for minerals after two weeks of service and adjust the bleed-off rate accordingly.

Overflow

Bleed-Off

Valve

Pump

Filter

Supply

Connection

Float Valve

Threaded Float

Adjustment

NOTE

A jumper will need to be installed in the control center to power the evaporative pumps with the blower(s) off. Reference the unit’s ladder diagram to determine proper terminals.

7. Set the Optional Auto Drain and Flush. This system will automatically drain the sump tank and ﬁll it with fresh water at the ﬁeld-adjustable intervals, typically once every 24 hours. This ﬂushes mineral build-up and debris from the tank to promote low maintenance and increase media pad life.

In addition, the system will protect the evaporative

cooler from freezing by draining the sump tank and supply line when the outside temperatures fall below the set point of the outside air sensor. This is set to 45° F and is not adjustable. The auto drain and ﬁll outdoor air sensor should be installed in an area that is shaded from direct sunlight so the outside air sensor probe will detect an accurate air temperature.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Evaporative Cooler Set-Up

Variable Frequency Drives

Optional factory-installed, wired, and programmed variable frequency drives (VFDs) may have been provided for modulating or multi-speed control of the blowers and energy recovery wheel for economizer and frost control modes. One VFD, either Yaskawa model V1000 or J1000, is provided for each blower (supply air and exhaust) and one Yaskawa model J1000 is provided for the energy recovery wheel.

Refer to the tables in this section for factory settings and ﬁeld wiring requirements. Refer to the unit control center for unit speciﬁc wiring diagram. When making adjustments outside of the factory set points, refer to Yaskawa VFD instruction manual, which can be found online at www.drives.com. For technical support, contact Yaskawa direct at 1-800-927-5292.

IGS-S+R-R+

MPACAMAC+VA2A1PCP2P1

MA MB MCRPH1SCHCS7S6S5S4S3S2S1

J1000

V1000

A1 AC

SEE VFD INSTALLATION MANUAL FOR MORE DETAIL

FOR CONTINUOUS 60Hz OPERATION JUMPER TERMINALS A1 AND +V.

USER TO PROVIDE CONTACTS AND ISOLATION AS REQUIRED

SEE VFD INSTALLATION MANUAL FOR MORE DETAIL

TO CHANGE THE FACTORY SET Hz CHANGE THE FOLLOWING PARAMETERS. PARAMETER A1-01 CHANGE TO 2 PARAMETER d1-01 FOR NEW 60Hz SETTING PARAMETER d1-02 FOR NEW 40Hz SETTING PARAMETER d1-03 FOR NEW 30Hz SETTING PARAMETER A1-01 CHANGE TO 0

0-10 VDC CONTROL SIGNAL (BY OTHERS) WIRED TO A1 (+) AND AC (COMMON) 0 VDC=30 Hz 10 VDC=60 Hz

FOR ONE 0-10 SIGNAL, WIRE TO DRIVES IN PARALLEL

OPTION 2 - MULTI SPEED CONTROL

S5S4 SC

NEITHER S4 OR S5 CONTACT CLOSED DRIVE SPEED = 60 Hz.

S4 TO SC CONTACT CLOSED (BY OTHERS) DRIVE SPEED = 40 Hz.

S5 TO SC CONTACT CLOSED (BY OTHERS) DRIVE SPEED = 30 Hz.

MA MB MCACAMAC+VA1SCS5S4S3S2S1

Factory Set Points

Variable frequency drives (VFDs) for the blowers are factory setup to operate in one of the three following modes:

• Modulating: 0-10 VDC signal wired in the ﬁeld by others varies the speed of the blower between 30 and 60Hz

• Multi-speed: Digital contact closures by others command the VFD to run at multiple speed settings:

- Open - Drive runs at 60Hz

- SC to S4 - Drive runs at 40Hz

- SC to S5 - Drive runs at 30Hz

• CO

Sensor:

Set Point Control: A carbon dioxide sensor is

provided from the factory for ﬁeld-mounting OR unit mounting in the space(s) being served by the energy recovery unit. The CO2 sensors are wired to the unit VFD’s with two preset speeds of 700 PPM or less CO

= 50% fan speed and 800 PPM

or greater CO2 = 100% fan speed.

Proportional Control: A carbon dioxide sensor is

provided from the factory for ﬁeld-mounting OR unit mounting in the space(s) being served by the energy recovery unit. The CO

sensors are wired

to the unit VFD’s with default factory settings of 500 PPM or less CO

= 50% fan speed and

1000 PPM or greater CO2 = 100% fan speed. Modulation of VFD occurs proportional to CO2 between 500 and 1000 PPM.

The terminal locations for Modulating and Multi-speed are shown on the previous page. Most of the set points in the VFDs are Yaskawa factory defaults. However, a few set points are changed at Greenheck and are shown in the tables. These settings are based on the VFD mode selected.

Change Set Points

To gain access to change set points on the V1000 and J1000 drives, parameter A1-01 needs to be set at “2”. To prevent access or tampering with drive settings on either drive, change parameter A1-01 to “0”.

• Drive Operation

- SC to S1 contact for On/Off

- A1 (0-10 VDC) referenced to AC

Can use +15 VDC from +V

Resetting the V1000 drive to factory defaults

To reset the V1000 drive back to Greenheck factory defaults go to parameter A1-01 and set it to “2”. Then go to A1-03 and change it to “1110” and press enter. The drive is now reset back to the settings programmed at Greenheck. This option is not available on the J1000.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®39

Modulating Control for Fan Speed

(0-10 VDC)

Parameter

Setting

V1000 J1000

A1-01 Access Level 2 2

B1-17 VFD Start-Up Setting 1 1

C6-02 Carrier Frequency 1 1

D2-02 Ref Lower Limit 50% 50%

E2-01 Motor Rated FLA

Motor

FLA

Motor

FLA

H2-01 Terminal MA, MC Function 5 5

H3-04 Terminal A1 Bias 50% 50%

L4-01 H2-01 Frequency Detection 15 15

L5-01 Auto Restart Attempt 5 5

A1-01 Access Level 0 0

CO2 Proportional Control

Parameter

Setting

V1000 J1000

B1-17 VFD Start-Up Setting 1 1

C6-02 Carrier Frequency 1 1

D2-02 Ref Lower Limit 50% 50%

E2-01 Motor Rated FLA FLA FLA

H3-03

H3-04

Analog Frequency Reference

(Gain)

Analog Frequency Reference

(Bias)

150% 150%

25% 25%

L2-01 Ride Thru Power Loss 2 2

L4-05 Frequency Ref Loss 0 NA

L5-01 Auto Restart Attempt 5 5

A1-01 Access Level 0 0

CO2 Sensor Control for Fan Speed

(1/2 speed when CO2 drops below 700 PPM) (Full speed when CO2 rises above 800 PPM)

Multi-Speed Control for Fan Speed

(1/3 or 1/2 speed reduction)

Parameter

Setting

V1000 J1000

A1-01 Access Level 2 2

B1-01 Reference Source (Frequency) 0 0

B1-17 VFD Start-Up Setting 1 1

C6-02 Carrier Frequency 1 1

D1-01 Frequency Reference 1 60 Hz 60 Hz

D1-02 Frequency Reference 2 40 Hz 40 Hz

D1-03 Frequency Reference 3 30 Hz 30 Hz

D1-04 Frequency Reference 4 60 Hz 60 Hz

D2-02 Ref Lower Limit 50% 50%

E2-01 Motor Rated FLA

H1-04

H1-05

H1-06

Multi-Function Input Sel 4

(Terminal S4)

Multi-Function Input Sel 5

(Terminal S5)

Multi-Function Input Sel 6

(Terminal S6)

Motor

FLA

5NA

Motor

FLA

H2-01 Terminal MA, MC Function 5 5

H3-10 A2 Not Used F NA

L4-01 H2-01 Frequency Detection 15 15

L5-01 Auto Restart Attempt 5 5

A1-01 Access Level 0 0

Variable Frequency Drives for

Energy Recovery Wheel

Parameter Setting – J1000

A1-01 Access Level 2

B1-17 VFD Auto Start 1

C1-04 Decel Time 600

*C4-01 Torque Gain 0.6

C6-02 Carrier Frequency 2

D2-01 Ref Upper Limit 40 or 50*

D2-02 Ref Lower Limit 5%

E2-01 Motor Rated FLA Motor FLA

E2-03 Motor No-Load Current

H1-02

H2-01

H1-04

Multi-Function Input

(Terminal S2)

Multi-Function Output

(MA, MB, MC)

Multi-Function Input Sel 4

(Terminal S4)

Economizer Signal Source

(0-10 VDC)

H3-03

H3-04

Analog Frequency Reference

(Gain)

Analog Frequency Reference

(Bias)

Must be less

than FLA

Setting

Honeywell

Module

40 or

50**

Controller

L1-01 Elect Thermal Overload 2

L2-01 Ride Thru Power Loss 2

L4-01 Frequency Detection Level 15

L5-01 Auto Restart Attempt 5

A1-01 Access Level 0

* 208/230 volt only **36 through 52 inch wheels are 40 (24 Hz) 58 or 74 inch wheel is 50 (30 Hz)

Carel

40 or

50*

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Routine Maintenance

DANGER

Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to the unit to OFF at disconnect switch(es). Unit may have multiple power supplies.

CAUTION

This unit requires minimal maintenance to operate properly. Maintenance requirements for this model vary for each installation and depend greatly on how much the system is used and the cleanliness of the air. Proper maintenance will both increase the life of the system and maintain its efﬁciency. Maintenance must be performed by experienced technicians and in the case of refrigeration systems, must be done by an EPA certiﬁed technician.

Maintenance frequency is based on a presumed nominal use of the system. If the system is being run constantly, the frequency should be adjusted accordingly. If there is seasonal debris in the air which can be drawn into the ﬁlters and the coils, they should be checked more frequently. If the system is being used for only a few hours per day, the frequency may be reduced. Use the maintenance log at the end of this manual to record each maintenance session and observations and then establish a maintenance schedule that is appropriate for the installation. The following is provided as a guideline:

Maintenance Frequency

Monthly

1. External Filter Clean metal mesh ﬁlters

2. Internal Filters Replace MERV 8 ﬁlters monthly.

Adjust replacement schedule for MERV 13 or other ﬁlters as inspection requires.

Semiannually

1. Check motor and motor bearings Check for excessive heat, vibration or noise.

Lubricate bearings in accordance with the motor manufacturer’s recommendations.

2. Condensate Drain (if applicable) Inspect and clean – reﬁll with water

3. Condenser Coils Inspect for cleanliness – clean as required

Annually

It is recommended that the annual inspection and maintenance occur at the start of the cooling season. After completing the checklist, follow the unit startup checklist provided in the manual to ensure the refrigeration system operates in the intended matter.

1. Lubrication Apply lubricant where required

2. Dampers Check for unobstructed operation

3. Blower Wheel and Fasteners Check for cleanliness

Check all fasteners for tightness Check for fatigue, corrosion, wear

4. Door Seal Check if intact and pliable

5. Wiring Connections Check all connections for tightness

6. Cabinet Check entire cabinet, inside and out, for dirt

buildup or corrosion. Remove accumulated dirt, remove any surface corrosion and coat the area with appropriate ﬁnish.

Units with Packaged DX

Semiannually

1. Evaporator Coil Maintenance Check for cleanliness - clean if required

2. Condenser Coil Maintenance Check for cleanliness - clean if required

3. Condensate Drain Inspect and clean - reﬁll with water

4. Condensing Fan Blades and Motors Check for cleanliness Check all fasteners for tightness Check for fatigue, corrosion and wear

Units with Heat Pump

An annual inspection of the heat pump system by a licensed refrigeration mechanic is recommended.

1. Inspect entire heat pump for cleanliness.

2. Record performance data for volts, amps and water temperature differences (both heating and cooling).

3. Compare annual data to recorded start-up data.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®41

Maintenance Procedures

WARNING

REFER TO GENERAL SAFETY INFORMATION

Do not operate this unit without the filters and birdscreen installed. They prevent the entry of foreign objects such as leaves, birds, etc. Do not remove access panels or other unit components while standing on a ladder or other unsteady base. Access panels and unit components are heavy and serious injury may occur.

Lubrication

Check all moving components for proper lubrication. Apply lubricant where required. Any components showing excessive wear should be replaced to maintain the integrity of the unit and ensure proper operation.

Dampers

Check all dampers to ensure they open and close properly and without binding. Backdraft dampers can be checked by hand to determine if blades open and close freely. Apply power to motorized dampers to ensure the actuator opens and closes the damper as designed.

Gas Furnace

Maintain furnace in accordance with instructions in the Indirect Gas-Fired Heat IOM shipped with this unit.

Fan Belts

Belts must be checked on a regular basis for wear, tension, alignment, and dirt accumulation. Premature or frequent belt failures can be caused by improper belt tension (either too loose or too tight) or misaligned sheaves. Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result in failure of the fan and/or motor bearings. Conversely, loose belts will cause squealing on start-up, excessive belt flutter, slippage, and overheated sheaves. Both loose and tight belts can cause fan vibration.

When replacing belts on multiple groove drives, all belts should be changed to provide uniform drive loading. Do not pry belts on or off the sheave. Loosen belt tension until belts can be removed by simply lifting the belts off the sheaves. After replacing belts, insure that slack in each belt is on the same side of the drive. Belt dressing should never be used.

Do not install new belts on worn sheaves. If the sheaves have grooves worn in them, they must be replaced before new belts are installed.

The proper belt setting is the lowest tension at which the belts will not slip under peak load operation. For initial tensioning, set the belt deﬂection at 1/64-inch for each inch of belt span (measured half-way between sheave centers). For example, if the belt span is 64 inches,

Deflection =

Belt Span

the belt deﬂection should be one inch (using moderate thumb pressure at mid-point of the drive). Check belt tension two times during the ﬁrst 24 hours of operation and periodically thereafter.

Fan Motors

Motor maintenance is generally limited to cleaning and lubrication. Cleaning should be limited to exterior surfaces only. Removing dust and grease buildup on the motor housing assists proper cooling. Never washdown the motor with high pressure spray. Greasing of motors is only intended when ﬁttings are provided. Fan motors typically have two grease ﬁttings. Each motor manufacturer has different lubrication schedules for different models. Go to the motor manufacturer’s website and download their maintenance requirements. Do not over-lubricate motors or use an incompatible grease. Many fractional motors are permanently lubricated for life and require no further lubrication.

Fan Wheel and Fasteners

Wheels require very little attention when moving clean air. Occasionally oil and dust may accumulate on the wheel causing imbalance. When this occurs, the wheel and housing should be cleaned to assure smooth and safe operation. Inspect fan impeller and housing for fatigue, corrosion, or wear.

Routinely check all fasteners, set screws and locking collars on the fan, bearings, drive, motor base and accessories for tightness. A proper maintenance program will help preserve the performance and reliability designed into the fan.

Bearings

Most bearings are permanently lubricated and require no further lubrication under normal use. Normal use being considered -20° to 120°F and in a relatively clean environment. Some bearings are relubricatable and will need to be regreased depending on fan use. Check your bearings for grease zerk ﬁttings to ﬁnd out what type of bearing you have. If your fan is not being operated under normal use, bearings should be checked monthly for lubrication.

Shaft bearings are the most critical moving part of a fan. Therefore, special attention should be given to keeping the bearings clean and well lubricated. Proper lubrication provides for reduction in friction and wear, transmission and dissipation of heat, extended bearing life and prevention of rust.

In order for a lubricant to fulﬁll these tasks, the proper grease applied at regular intervals is required.

If unusual conditions exist—temperatures below 32°F or above 200°F, moisture or contaminants—more frequent lubrication is required.

With the unit running, add grease very slowly with a manual grease gun until a slight bead of grease forms at the seal.

Be careful not to unseat the seal by over lubricating or using excessive pressure. A guide to the amount

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

of grease to be used is to ﬁll 30% to 60% of available space in the bearing and housing.

A high quality lithium based grease conforming to NLGI Grade 2 consistency should be used.

Internal Filter

The unit will typically be provided with 2-inch thick pleated paper ﬁlters in the airstream. These ﬁlters should be checked according to a routine maintenance schedule and replaced as necessary to ensure proper airﬂow through the unit. Replacement ﬁlters shall be of same performance and quality as factory-installed ﬁlters.

Filters upstream of the coil should be checked regularly. If the ﬁlters are dirty, they should be cleaned or replaced. It is important the ﬁlters stay clean to maintain desired airﬂow.

Internal Filter Size and Quantities

Model

ERCH-20 20 x 20 2 2

ERCH-45 20 x 25 3 3

ERCH-55 16 x 20 6 6

ERCH-90 20 x 20 8 8

Filter Size

(inches)

Quantity

Supply

Quantity Exhaust

External Filter

Aluminum mesh, 2-inch thick ﬁlters are located in the supply weatherhood (if the weatherhood option was purchased). These ﬁlters should be checked and cleaned on a regular basis for best efﬁciency. The frequency of cleaning depends upon the cleanliness of the incoming air. These ﬁlters should be cleaned by rinsing with a mild detergent in warm water prior to start-up.

External Filter Size and Quantities

Model

ERCH-20 16 x 20 2

ERCH-45 16 x 20 4

ERCH-55 16 x 20 6

ERCH-90 16 x 20 8

Filter Size

(inches)

Quantity

Filter

External Filter

Access

Coils

Coils must be cleaned to maintain maximum performance. Check coils once per year under normal operating conditions and if dirty, brush or vacuum clean. Soiled ﬁns reduce the capacity of the coil, demand more energy from the fan and create an environment for odor and bacteria to grow and spread through the conditioned zone.

For coils with fragile ﬁns or high ﬁn density, foaming chemical sprays and washes are available. Care must be taken not to damage the coils, including the ﬁns, while cleaning. Caution: Fin edges are sharp!

WARNING

Biological hazard. May cause disease. Cleaning should be performed by qualiﬁed personnel only.

Drain pans in any air conditioning unit will have some moisture in them, therefore, algae and other organisms will grow due to airborne spores and bacteria. Periodic cleaning is necessary to prevent this buildup from plugging the drain and causing the drain pan to overﬂow. Inspect twice a year to avoid the possibility of overﬂow. Also, drain pans should be kept clean to prevent the spread of disease.

Winterizing Coils

Coil freeze-up can be caused by such things as air stratiﬁcation and failure of outdoor air dampers and/ or preheat coils. Routine draining of water cooling coils for winter shutdown cannot be depended upon as insurance against freeze-up. Severe coil damage may result. It is recommended that all coils be drained as thoroughly as possible and then treated in the following manner.

WARNING

Carefully read instructions for mixing antifreeze solution used. Some products will have a higher freezing point in their natural state than when mixed with water.

Fill each coil independently with an antifreeze solution using a small circulating pump and again thoroughly drain. Check freezing point of antifreeze before proceeding to next coil. Due to a small amount of water always remaining in each coil, there will be diluting effect. The small amount of antifreeze solution remaining in the coil must always be concentrated enough to prevent freeze-up.

Door Seals

An EPDM foam rubber bulb seal backed with a high strength acrylic adhesive is installed on the door frame of the unit. This creates and air tight seal between the rubber seal and the door. Inspect at least annually to ensure that the seal is damage free and still intact.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®43

Energy Wheel Maintenance

WARNING

Whenever performing maintenance or inspections, always disconnect the power source.

Inspection

The wheel should be inspected semiannually in accordance with the maintenance schedule. Maintenance of the wheel consists mainly of inspecting the wheel for cleanliness and then checking the drive motor, belt, and pulley for wear. If the wheel layers appear dirty, the wheel should be disassembled and cleaned.

The wheel rotates through the two airstreams which are moving in opposite directions, the wheel is self-cleaning, up to a point. If the wheel media becomes blocked by dirt or dust, or if the media collects

Energy Wheel

Cassette

a layer of smoke residue or an oily ﬁlm, the energy transfer efﬁciency drops.

The main factor in the frequency of cleaning is the cleanliness of the air. If air ﬁlters are not changed frequently, the wheel will collect contaminants and will then have to be cleaned.

Wheel Disassembly

Wheels are part of a cassette that may be pulled from the unit for easy access. There may be a small damper assembly or other component that blocks removal of the cassette. Before sliding out the cassette or any other component, disconnect any power supply cord and secure it so it cannot jam or otherwise get damaged.

Each wheel has removable segments that hold the coated layers of media and each segment is held in place with two retaining clips located on the outer rim of the wheel. When removing more than one segment, remove them in sequence from opposite sides of the wheel (180 degrees apart) to reduce the imbalance. Secure the wheel against rotation. Carefully release the two retaining clips and swing them fully open. The segment can now be removed by pushing the face of the segment close to the outer rim of the wheel. Wheel segments are built to close tolerances and the segment may have to be jiggled to remove it. Do not use a hammer or otherwise force the segment because these are high value items and are not built to withstand abuse.

Whenever retaining clips are opened, they should be closed as soon as possible. If the wheel should rotate when a clip is open, the clip will jam against the bearing support bar and could cause damage.

Segment Retaining Clip

Cleaning

Maintenance or cleaning of the wheel segments should be done with the segments removed from the wheel cassette to avoid splashing liquids or cleaning agents inside the cabinet. If the energy wheel appears excessively dirty, it should be cleaned to ensure maximum operating efﬁciency. Only excessive buildup of foreign materials needs to be removed.

DISCOLORATION AND STAINING OF ENERGY RECOVERY WHEEL DOES NOT AFFECT ITS PERFORMANCE.

Thoroughly spray the wheel matrix with a household cleaner such as Fantastik™ or the equivalent. Gently rinse with warm water and use a soft brush to remove any heavy accumulations. A detergent/water solution can also be used. Avoid aggressive organic solvents, such as acetone. Wheel segments can be soaked in the above solution overnight for removal of stubborn dirt or accumulations.

After cleaning is complete, shake excess water from the wheel or segments. Dry the wheel or segments before putting them back into the cassette.

Reassembly

When reinstalling the segments, be sure to install them with the correct face toward the motor side of the cassette. Note that one face of each segment is smooth and the other face has a reinforcing channel or support cut into the surface.

Wheel Segment

(Pulley Side)

Wheel Segment

(Motor Side)

Wheel Belt

Inspect belts each time ﬁlters are replaced. Belts that look chewed up or are leaving belt dust near the motor pulley may indicate a problem with the wheel. Be sure to inspect wheel for smooth and unrestricted rotation. If a belt requires replacement, contact the local manufacturer representative. Instructions for replacement will ship with the new belt.

Wheel Bearing

In the unlikely event that a wheel bearing fails, the bearing is behind a removable plate on the wheel support beam (slide cassette halfway out of cabinet to access). Contact the local manufacturer representative for detailed instructions on how to replace the bearing.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Evaporative Cooling Maintenance

Regularly scheduled maintenance is the key to peak performance, minimized cost, and extended life of the evaporative cooler. The following is a checklist of items that need to be looked at on a regular basis.

1. The media should be checked for mineral and foreign material deposits that have built up. If these items are left on the media, the life and performance of the unit will be greatly reduced. Also, there are risks of water carryover when this type of condition exists. When signs of mineral build-up are noticed, you should increase the bleed off rate. If this does not solve the problem, chemicals may need to be added to the water. The evaporative pads tend to be selfcleaning. Depending on water quality and system maintenance, the useful life of the pads should be 3 to 5 years.

2. The media should be periodically brushed lightly with a soft bristle brush in an up and down motion (never brush side-to-side) while ﬂushing with water. This will also aid in reducing the amount of foreign material build-up.

3. The water should be shut off and all the lines drained when the temperature drops below 50°F.

4. When the evaporative cooler is going to be used for the ﬁrst time each season, it is recommended that the media be ﬂushed with clean water for a period of 2 minutes.

5. At the beginning of each cooling season, the upright recirculating pump should have the shaft oiled and spun to eliminate the potential of seizing and pump burn out.

6. If the cooling media was removed from the unit, check to make sure that is not installed backwards. If the media is installed backwards, there will be large amounts of water carry over downstream of the evaporative cooler. Continuous operation in this manner may cause serious damage and void the warranty.

7. At the end of each cooling season the evaporative cooler should be thoroughly cleaned. A dispersant and biocide (consult water treatment consultant for suitable materials and dosage levels) should be recirculated for 12 to 24 hours prior to performing the following steps:

a. Disconnect power to unit. b. Shut off all water to the unit. c. Open evaporative cooling section door. d. Flush distribution headers and media for

20 minutes.

e. Turn off pumps and drain all water distribution

piping, headers, etc. f. Dry media completely by running blowers. g. Brush media as described in Step 2 and

repeat steps 7d and 7e.

h. Clean all remaining components (i.e. sump,

pump, etc.) of any mineral deposits or foreign

materials. i. Replace all worn or non-functioning parts. j. Reassemble the cooling unit. k. Close cooling section door. l. Turn the main disconnect ‘ON’, leaving the

cooling switch in the ‘OFF’ position.

8. If the evaporative cooler will be turned off during the cooling season for an extended period of time, it is recommended that the media be dried out. This can be accomplished by allowing the blowers to continue to run for one to two hours. Doing so, will prevent organic build-up on the media and subsequent odors getting into the space.

9. Media should be permitted to dry once per week by allowing the blowers to run for one to two hours.

IMPORTANT

Replacement media should be from the same manufacturer and be the same size as the original media provided with the unit.

10. A ﬂush cycle should be performed weekly for one hour with the fans off.

To remove media, disconnect water line to evap header as shown below. Then slide media section out of unit. Sump will remain in unit. If media is wet, turn off water supply, then turn on unit and allow air to ﬂow thru media for 10 -20 minutes. This will dry the media out and make it lighter and easier to handle.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®45

Troubleshooting – Unit

Symptom Possible Cause Corrective Action

Blown fuse or open circuit breaker. Replace fuse or reset circuit breaker and check amps.

Blower fails to operate

Motor starters “chatter” or do not pull in

Motor over amps

Defective motor or capacitor. Replace.

Motor overloaded. Reset VFD and check amps.

Electrical.

Control power (24 VAC) wiring run is too long. (Resistance should not exceed 0.75 ohms).

Check for On/Off switches. Check for correct supply voltage. Check Control wiring.

Shorten wiring run to mechanical room or install a relay to turn unit on/off. Consult factory for relay information. Increase wire gauge size so that resistance is 0.75 ohms or less.

Incoming supply power is less than anticipated. Voltage supplied to starter coil must be within +10% / -15% of nominal

Need to increase supply power or use a special control transformer which is sized for the actual supply power.

voltage stated on the coil.

Static pressures are higher than design. Check for dirty filters. Improve ductwork.

Motor voltage incorrect.

Motor horsepower too low.

Check motor wiring. Check motor nameplate versus supplied voltage.

See specifications and catalog for fan curves to determine if horsepower is sufficient.

Shorted windings in motor. Replace motor.

Unit damper not fully open. Adjust damper linkage or replace damper motor.

System static pressure too high.

Blower speed too low.

Improve ductwork to eliminate losses using good duct practices.

Check maximum motor RPM and compare with catalog data. Verify that external control wiring is in place if required.

Low airflow (cfm)

Fan wheels are operating backwards.

Dirty filter.

For 3-phase, see Direction of Fan Wheel Rotation Direction in Start-Up Components section.

Replace filters or follow cleaning procedures in Routine Maintenance section of this manual.

Leaks in ductwork. Repair.

High airflow (cfm)

Excessive noise or vibration

Elbows or other obstructions may be obstructing fan outlet.

Blower fan speed too high.

Filter(s) not in place. Install filters.

Insufficient static pressure (Ps). (airflow resistance)

Fan wheel rubbing on inlet.

Bearings.

Loose wheel on shaft. Tighten wheel hub.

Motor base or blower loose. Tighten mounting bolts.

Correct or improve ductwork.

Check for correct maximum fan RPM. Decrease maximum fan speed if necessary in the VFD.

Induce Ps into system ductwork. Make sure grilles and access doors are installed. Decrease fan speed if necessary.

Adjust wheel and/or inlet cone. Tighten wheel hub or bearing collars on shaft.

Replace defective bearing(s). Lubricate bearings. Tighten collars and fasteners.

Make sure ductwork is supported properly. Make sure ductwork

Noise being transmitted by duct.

metal thickness is sized for proper stiffness. Check duct size at discharge to ensure that air velocities are not too high.

Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service information.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Troubleshooting – Refrigeration Circuit

TROUBLESHOOTING NOTE

IMPORTANT

Do not release refrigerant to the atmosphere! If Before any components are changed on the refrigeration system, the cause of the failure must be identified. Further problems will exist unless the true cause or problem is identified and corrected.

required service procedures include the adding or

removing of refrigerant, the service technician must

comply with all federal, state and local laws. The

procedures discussed in this manual should only be

performed by a qualified EPA Certified Technician.

NOTE: Unit is equipped with a phase loss/phase reversal control. If system does not start, check phase of electrical supply.

The ﬁrst step in troubleshooting a refrigeration circuit is to examine the microprocessor and digital scroll compressor controller (if present) and see if there is a fault code. The next step is to check airﬂow conditions (e.g. improper ductwork, atypical wet bulb / dry bulb, etc.). After these steps have been eliminated, proceed with troubleshooting by following this guide.

Symptom Possible Cause Corrective Action

Open disconnect switch or circuit breaker. Close switch and/or breaker.

Compressor contactor not closing.

Blown fuse or tripped breaker.

Low line voltage.

Check voltage to contactor coil, transformer, slave relay, system. Replace parts as necessary.

Check for reason and repair. Replace fuse after correcting problem.

Check line voltage. If more than 10% from compressor marking, correcting is necessary.

Compressor will not run or does not start

Compressor starts but cuts out on low pressure

Low pressure switch activates at 50 PSIG

Motor thermal protector automatically resets. Allow time (two

Compressor motor protector open.

Compressor defective.

High pressure switch open or defective.

Low pressure switch open or defective.

Open room thermostat or control. (No cooling required).

Loose wiring. Check all wire terminals and tighten as necessary.

Low or loss of refrigerant charge. Check refrigerant pressures and temperatures (subcooling).

Airflow restricted.

Restriction in refrigerant line.

Defective low pressure switch. Replace.

hours) for compressor to cool down so protector will reset. Restart and check for reason overheat occurred.

Check motor for open circuit, short circuit, grounded windings, or burn out. Compressor may be seized; check refrigerant. If necessary, replace compressor.

If manual reset (high pressure), reset switch. (Switch opens at 600 psi and will not reset above 420 psi for R-410A). Replace if defective.

Switch will open at 50 psi and auto-close at 90 psi. Replace if defective.

Check room temperature. If temperature is proper, wait for thermostat to close.

Check for dirty evaporator coil, dirty filters, dampers closed, iced evaporator coil, improper belt, check motor amps, check duct design.

Check refrigerant pressures, look for frosted tubing and components indicating a restriction. Check pressure drop across the filter drier.

Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service information.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®47

Troubleshooting – Refrigeration Circuit

Symptom Possible Cause Corrective Action

Refrigerant overcharge. Check pressures, charge by subcooling.

Compressor starts but cuts out on high pressure switch

High pressure activates at 600 PSIG

Compressor cuts out on thermal overload

Condenser fan motor defective. Check fan motor.

Condenser coil inlet obstructed or dirty. Check coil and clearances. Clean coil if necessary.

Air or non-condensables in system.

Check high side equalized pressures, check thermal expansion valves.

Defective high pressure switch. Replace.

Restriction in discharge or liquid line.

Check refrigerant line pressures, check thermal expansion valves, replace any defective component.

Condensing fan relay not pulling in. Replace.

Low voltage. Check voltage.

Sustained high discharge pressure.

High suction and discharge pressures.

Defective compressor overload.

Check running amperage and conditions described under “low suction pressure” symptoms.

Check thermal expansion valve setting, check for air in system. Check air conditions and cfm.

If compressor is hot, allow compressor to cool for two hours. Recheck for open circuit.

Improper refrigerant charge. Check subcooling.

Improperly wired. Review wiring schematics.

Loose wiring. Check all connections.

Defective start relay. Replace relay.

Motor windings damaged. Verify amp draw.

Improperly wired. Review wiring schematics.

Low line voltage. Check voltage.

Compressor

Loose wiring. Check all connections.

hums, but will not start

Defective start relay. Replace relay.

Motor winding damaged. Verify amp draws. Replace compressor if necessary.

Internal compressor mechanical damage. Replace.

Refrigerant overcharge. Check pressures and subcooling.

Check thermal expansion valve setting. Check for refrigerant overcharge.

Dampen tubing vibration by taping or clamping. Carefully bend tubing away from contact where possible.

Compressor

Liquid floodback.

Tubing rattle.

noisy or vibrating

Scroll compressor rotating in reverse. (3-phase)

Check high and low side pressures during operation to confirm. Rewire for opposite rotation.

Damaged compressor. Replace the compressor.

Improper mounting on unit base.

Check that compressor is properly isolated and mounting bolts are tight.

Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service information.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Troubleshooting – Refrigeration Circuit

Symptom Possible Cause Corrective Action

High suction pressure

High discharge pressure

Excessive load on evaporator coil.

Compressor is unloaded. (digital scroll)

Expansion valve sensing bulb not secured to suction line.

Thermostatic expansion valve. Overfeeding.

Room load too large. Reduce the load or add more equipment.

Overcharged. Check pressures and subcooling.

Thermal expansion valve setting.

Air inlet to condenser dirty or obstructed.

Condenser fan motor defective. Check condenser fan motor.

Too much refrigerant. Check subcooling. Remove excess refrigerant.

Non-condensable in system. Remove non-condensable from system.

Check for high entering wet bulb temperature, check for excessive air flow.

Check digital scroll controller signal and solenoid valve.

Check the thermal expansion valve, ensure bulb is insulated. Check superheat. If superheat is high, then valve is choking refrigerant flow.

• Check bulb for contact.

• Adjust valve for superheat ~10°F.

• Replace valve power head or valve.

Check bulb location and clamping. Adjust superheat. Replace expansion valve power head.

Check thermal expansion setting and calibrate superheat/subcooling.

Check for proper clearances and possible air recirculating. Clean coil.

Low suction pressure

Dirty condenser coil. Clean condenser coil.

Condenser fan not running or running backwards.

High load conditions. Add more equipment or reduce load.

Refrigerant undercharge/loss of refrigerant charge.

Blower running backward.

Low entering air temperature. (Low load conditions).

Refrigerant leak. Check system for leaks. Repair leaks and add refrigerant.

Evaporator dirty or iced-up, or airflow restricted.

Plugged liquid line filter-drier. Replace filter-drier, check psi across filter.

Improper hot gas bypass setting. Check setting and correct as required.

Expansion valve defective, superheat too high or valve too small.

Moisture in system, check sight glass. Reclaim refrigerant, check for leaks, recharge.

Insufficient refrigerant charge.

Check electrical circuit and fuse. Check fan cycling controls.

Check pressures and subcooling.

Confirm blower rotation. If reversed, interchange any two wires from 3-phase disconnect.

Check entering air wet bulb conditions.

Clean the coil. Check fan operation. Check airflow.

Adjust valve for proper superheat or replace the expansion valve if too small or defective.

Check subcooling, check for leak. Repair leak and add refrigerant.

Low discharge pressure

Defective or improperly adjusted expansion valve.

Low suction pressure. See “low suction pressure”.

Faulty condenser temperature controls. (Condensing fan cycle switch).

Check superheating and adjust thermal expansion valve.

Check condenser controls and reset to obtain desired condensing temperature.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®49

Troubleshooting – Refrigeration Circuit

Symptom Possible Cause Corrective Action

Thermostat location or controls malfunction. Check thermostat, check heat anticipator setting.

Improper refrigerant charge. Check subcooling, verify superheat.

Defective low pressure control. Check high or low pressure switch.

Compressor short cycles

Poor air distribution. Check ductwork for recirculating.

High discharge pressure. See “high discharge pressure”.

Low airflow at evaporator(s). Check blower operation and airstream restrictions.

Incorrect unit selection (oversized). Contact factory.

Refrigerant leak. Check system for leaks. Repair leaks and add refrigerant.

Compressor loses oil

Not enough cooling or lack of cooling

Liquid line is frosted or wet

Suction line is frosting

Frost on evaporator coil

Short cycling. Check low pressure control settings.

Refrigerant flood back.

Reheat flush cycle inadequate. Contact factory.

Refrigeration undercharged. Check subcooling. Adjust charge, if necessary.

Dirty filter or evaporator coil. Check filter, coil and airflow.

Dirty or clogged condenser coil. Check coil and airflow.

Air or other non-condensables in system.

Restriction in suction and liquid line. Check for restrictions in refrigerant circuit.

Control contacts stuck. Check wiring.

Excessive load. Add more equipment or reduce room load.

Restriction in liquid line. Clear restriction upstream of point of frosting.

Insufficient evaporator airflow.

Malfunctioning or defective expansion valve. Check bulb of thermal expansion valve.

Hot gas bypass valve not functioning properly.

Manual hot gas bypass valve closed. Open valve.

Low load or airflow. Increase airflow, check filters.

Check thermal expansion valve setting. Check for refrigerant overcharge. Check crankcase heater operation.

Check equalized high side pressure with equivalent outdoor temperature.

Check airflow, check filters, check VFD control signal for proper operation.

Check valve. If defective, replace.

Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service information.

Troubleshooting - Energy Wheel

Symptom Possible Cause Corrective Action

Air seals are too tight.

Energy wheel does NOT turn

Energy wheel runs intermittently

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Broken belt. Replace.

No power to wheel motor.

Wheel motor overloads are tripping due to rubbing between wheel and air seals.

See Air Seals in the Start-Up Components, Energy Wheel section.

Make sure wheel drive is plugged in. Verify power is available.

Recheck air seals, make sure they are not too tight. See Adjust the Air Seals in the Start-Up Components, Energy Wheel section.

Troubleshooting – Evaporative Cooling

Symptom Possible Cause Corrective Action

Insufficient water volume or recirculation pump not operating

Irregular water distribution on cooling media

Scale and mineral deposit formation on face of media

Water level in sump pan too low.

Pump filter clogged.

Pump not getting power.

Check water level in sump pan. Water level should be maintained at greater than one inch.

Check the pump filter at the inlet. Clean the filter if clogged or dirty.

If pump is not operating, check wiring for loose connections and proper voltage.

Remove media from unit and remove media cover

Clogged header.

to visually inspect header assembly. Clear holes with drill if necessary.

Water flow adjustment device improperly set. Check water flow adjustment clamp for proper setting.

Clogged header.

Water distribution header, orifices or media partially blocked or plugged.

Water flow adjustment device improperly set. Check water flow adjustment clamp for proper setting.

Water mineral concentration too high. Increase bleed rate.

Increase water flow rate. Media is self-cleaning with flow rate of 1-1/2 to 2 gpm per square foot of media

Water flow rate too low.

top area. Generally this flow rate prevents dissolved solvents from collecting on the media. To prevent further trouble, flush and clean the system more frequently.

Header partially clogged.

Check water flow across the face of the media. Irregular water distribution must be corrected (see above).

Water Carryover

Inadequate cooling

Excessive water discharge into drain

If this condition persists, chemicals may need to be

Poor quality supply water.

added. Water pH should be maintained between 6 and 8.

Header partially clogged. Irregular water distribution on face of media (see above).

Unit moving too much air volume.

Non-uniform airflow across entering media face.

Average face velocity exceeds 550 fpm. Decrease fan rpm and airflow.

Localized face velocities exceeding 550 fpm. Air filters or media face area is partially blocked. Clean or replace air filters and media.

Sump overflow drain not operating. Check the overflow for blockage.

Header partially clogged.

Unit moving too much air volume.

Poor weather conditions for application.

Water flow rate too low.

Bleeder valve improperly adjusted.

Water level in sump pan too low.

Irregular water distribution over face of media (see above).

Average face velocity exceeds 550 fpm. Decrease fan rpm and airflow.

Check outside wet-bulb temperature. High wet-bulb temperatures can decrease performance.

Check water flow rate over media. Flow rate should be 1-1/2 to 2 gpm per square foot of media top area.

Check the water bleed off rate and make sure that it is not excessive.

Check water level in sump pan. The level should be at one inch.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®51

Troubleshooting – Evaporative Cooling

Pad installed backwards. To get the performance from

the cooling pads, they must be installed properly. The

pads are manufactured with 15/45 degree flute angles.

The pads must always be installed with the steeper flute

angle sloping down toward the entering air side.

Poor performance after cooling pad replacement

Incorrect pad installation.

Entering Air

Leaving Air

Always have a completed Pre-Start-Up Checklist and Start-Up Checklist prior to requesting parts or service information.

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Troubleshooting - Controller Alarms

Troubleshooting - Rotation Sensor

The ﬁrst step in troubleshooting the unit is to check the on-board alarm indicators. Several of the electronic controls in the unit monitor the system for faults and will go into alarm, shutting down the unit or a single function within the unit.

Microprocessor Controller

Check the screen on the microprocessor for an alarm condition. If it is in alarm condition, a message will show on the screen.

The microprocessor controller is located in the main control center. If it is in alarm condition, the alarm button will blink red. Press the alarm button to see the speciﬁc condition or to reset the microprocessor. Refer to the Installation Operations and Maintenance manual for detailed information on fault codes and see the unitspeciﬁc wiring diagram.

Phase Monitor

The phase monitor has two LED indicator lights, one red and one green. Green indicates proper operational status, red indicates the unit has detected a fault and is in alarm condition.

Variable Frequency Drive (VFD)

VFDs have a display screen that will show an alarm condition. If a fault such as a voltage spike occurs, the VFD will go into alarm and will not reset until a hard restart is performed. See the unitspeciﬁc manufacturer’s manual supplied with the unit. VFDs are located in the main control center.

FX05 Furnace Controller

Present only if an indirect gas-ﬁred furnace option is present.

The FX05 furnace controller will display an alarm condition if present. The controller will be found in the furnace control center. See the furnace Installation, Operation and Maintenance manual and the controller manufacturer’s unit-speciﬁc manual for further information.

When the unit is ﬁrst turned on, the LED on the back of the sensor should turn on and stay on with the wheel running.

1. When the wheel is spinning, the contact in the rotation sensor is closed and the small LED light on the sensor in ON.

2. When the wheel is stopped there is a 10-20 second delay before the sensor will indicate no rotation. When the sensor indicates no rotation, it opens the internal contact and the LED light of OFF.

3. If the LED comes on and then shuts off after 5 seconds or less, the sensor is NOT properly set. Contact manufacturer for adjustment

procedure.

4. If the LED comes on and then shuts off after 10-20 seconds, the sensor is properly set although it is either to close to the wheel or not close enough. It should be 4 mm from the wheel. Verify that the sensor depth was set using the appropriate gauge.

When the wheel is unplugged and the unit is still powered on:

1. The LED should stay on for 10-20 seconds and then turn off.

Troubleshooting - Digital Scroll Compressor Controller (PDX Only)

The Fault Code chart is printed on the back of the controller. Note that if the controller generates either a Code 2 or a Code 4 Lockout, a manual reset must be performed. Manual Reset is accomplished by shutting off main power to the unit and then turning it back on.

Digital Compressor Controller Fault Codes

Alert

Code

Code 2* High discharge

Code 3 Compressor

Code 4* Locked rotor Blinks 4 times Lockout

Code 5 Demand signal

Code 6 Discharge

Code 7 Future N/A N/A

Code 8 Welded

Code 9 Low voltage Blinks 9 times Trip

* Protective faults that require manual reset

System

Condition

temp trip

protector trip

loss

thermistor fault

contactor

Diagnostic Alert Light

Blinks 2 times Lockout

Blinks 3 times Lockout

Blinks 5 times Lockout

Blinks 6 times Reduce

Blinks 8 times Unload

Action

capacity

compressor

General Description - NOT model specificModel ERCH Energy Recovery Ventilator®53

Troubleshooting - Unit Protection Module (Heat Pump Only)

Troubleshooting - Economizer Alarms

Each unit includes one Unit Protection Module (UPM) printed circuit board with two LED indictor lights. The UPM board will come from the factory with default settings.

Intelligent Reset

If a fault condition is initiated, the ﬁve minute delay on break

Default Settings

Freeze NO

Temp 35°F

Lockout 2

Reset T

Alarm CONT

Test NO

Hot/Dry Alarm HOT

time period and the random start timer is initiated and the unit will restart after these delays expire. During this period the fault LED will indicate the cause of the fault. If the fault condition occurs 2 or 4 times (depending on 2 or 4 setting for Lockout dip switch) before 60 minutes, the unit will go into a hard lockout and requires a manual lockout reset. A single condensate overﬂow fault will cause the unit to go into a hard lockout immediately, and will require a manual lockout reset.

Lockout Reset

A hard lockout can be reset by turning the unit thermostat off and then back on when the “RESET” dip switch is set to “Y” or by shutting off unit power at the circuit breaker when the “RESET” dip switch is set to “R”.

LED

Color

Green Power LED indicates 18-30 VAC present at the board

Dual or Single

Compressor

Dual

Compressor

Red

Single

Compressor

LED Fault Indication

# of

Status

blinks

High pressure lockout

Compressor 1

Low pressure lockout

Compressor 1

High pressure lockout

Compressor 2

Low pressure lockout

Compressor 2

Freeze sensor lockout

(optional item)

Condensate overflow in coil

drain pan (optional item)

Brownout AC voltage to R

and C terminal below 18 VAC

1 High pressure lockout

2 Low pressure lockout

Freeze sensor lockout

(optional item)

Condensate overflow in coil

drain pan (optional item)

Brownout AC voltage to R

and C terminals below 18 VAC

Addressing Alarms

Alarms will signify a faulty sensor. When this occurs, verify all connections to the sensor and controller are secure. Press enter twice to clear the alarm. If the issue persists, consult the factory.

Clearing Alarms

Once the alarm has been identiﬁed and the cause has been removed (e.g. replaced faulty sensor), the alarm can be cleared from the display.

To clear an alarm, perform the following:

1. Navigate to the desired alarm.

2. Press the

(enter).

3. ERASE? displays.

4. Press

(enter).

5. ALARM ERASED displays.

6. Press

(escape) to complete the action and return

to the previous menu.

NOTE

If an alarm still exists after you clear it, it redisplays within 5 seconds.

Reference

Technical Support

For technical support contact the Tempered Air Products group from Monday - Friday, 8AM-5PM CST at 1-877-202-6123.

Refer to the following Installation, Operation and Maintenance Manuals for additional details. All are available at www.greenheck.com

• DDC Controller for Energy Recovery

• ERCH Curbs

• PVF/PVG Indirect Gas-Fired Heat Modules

General Description - NOT model specificModel ERCH Energy Recovery Ventilator

Maintenance Log

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

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Date ___________________Time _____________ AM/PM

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Date ___________________Time _____________ AM/PM

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Notes: ___________________________________________

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Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

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Date ___________________Time _____________ AM/PM

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Date ___________________Time _____________ AM/PM

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Date ___________________Time _____________ AM/PM

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Date ___________________Time _____________ AM/PM

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Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

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General Description - NOT model specificModel ERCH Energy Recovery Ventilator®55

Our Commitment

As a result of our commitment to continuous improvement, Greenheck reserves the right to change speciﬁcations without notice.

Speciﬁc Greenheck product warranties are located on greenheck.com within the product area tabs and in the Library under Warranties.

Greenheck catalog Energy Recovery Ventilator Model ERCH, provides additional information describing the equipment, fan performance, available accessories, and speciﬁcation data.

Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com

AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, provides additional safety information. This publication can be obtained from AMCA International, Inc. at: www.amca.org.

Greenheck ERCH User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual