Greenheck ERV-10 Installation Manual
Document 476412
Energy Recovery Ventilators
®
Installation, Operation and Maintenance Manual
Please read and save these instructions. 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! Retain instructions for future reference.
Models:
ERV-10
ERV-20
ERV-45
ERV-55
ERV-90
ERV-120
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.
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.
DANGER
Always disconnect power before working on or near
this equipment. Lock and tag the disconnect switch
or breaker to prevent accidental power up.
CAUTION
When servicing the unit, the internal components
may be hot enough to cause pain or injury. Allow
time for cooling before servicing.
CAUTION
Precaution should be taken in explosive
atmospheres.
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 (CEC) 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 effects 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. Do not allow the power cable to kink or come in
contact with oil, grease, hot surfaces or chemicals.
Replace cord immediately if damaged.
6. Verify that the power source is compatible with the
equipment.
7. Never open access doors to the unit while it is
running.
®
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1
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 the Traffic
Department. If damaged upon arrival, file claim
with carrier. Any physical damage to the unit after
acceptance is not the responsibility of Greenheck Fan
Corporation.
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.
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
clean thoroughly with Tectyl
the equivalent. For hard to reach internal surfaces or
for occasional use, consider using Tectyl® 511M Rust
Preventive or WD-40® or the equivalent.
®
506 (Ashland Inc.) or
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 each piece in such a manner as to keep from
scratching or chipping the coating. Damaged finish
may reduce ability of the 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.
Inspection and Maintenance during
Storage
While in storage, inspect units 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 all moving components by hand
ten to fifteen revolutions to distribute lubricant on
motor and bearings. If paint deterioration begins,
consideration should be given to touch-up or
repainting. Units with special coatings may require
special techniques for touch-up or repair.
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Table of Contents
Product Overview
Product Overview . . . . . . . . . . . . . 3
Supplemental Installation, Operation and
Maintenance Manuals . . . . . . . . . . . 3
Optional Subassemblies . . . . . . . . . . 3
Installation
Dimensional Data . . . . . . . . . . . . 4-5
Recommended Roof Openings & Weights . . . 6
Service Clearances . . . . . . . . . . . . 7
Access Panel Locations . . . . . . . . . 8-9
Handling . . . . . . . . . . . . . . . . . 9
Lifting . . . . . . . . . . . . . . . . . . 9
Roof Curb Mounting . . . . . . . . . . . . 10
Curb Outside Dimensions and Weights . . . . 10
Ductwork Connections . . . . . . . . . . . 10
Rail Mounting / Layout . . . . . . . . . . . 11
Outdoor Air Weatherhood . . . . . . . . . . 11
Exhaust Weatherhood . . . . . . . . . . . 11
Dampers. . . . . . . . . . . . . . . . . 11
Electrical Information
General Electrical Information . . . . . . . . 12
Control Center Components . . . . . . . . . 13
Optional Accessory Wiring Schematics . . . . 14
Unit Overview . . . . . . . . . . . . . . . 15
Optional Component Overview
Economizer . . . . . . . . . . . . . . . 15
Frost Control . . . . . . . . . . . . . . . 16
Variable Frequency Drive . . . . . . . . . . 16
CO
Sensor . . . . . . . . . . . . . . . 16
2
Rotation Sensor . . . . . . . . . . . . . . 16
Dirty Filter Switch . . . . . . . . . . . . . 16
Service Outlet . . . . . . . . . . . . . . 16
Start-Up
General . . . . . . . . . . . . . . . . . 17
Pre Start-Up Checklist . . . . . . . . . . . 17
Special Tools Required . . . . . . . . . . . 17
Start-Up Checklist. . . . . . . . . . . . . 17
Optional Accessories Checklists . . . . . . . 18
Start-Up Components
Fans . . . . . . . . . . . . . . . . . . 19
Vibration . . . . . . . . . . . . . . . . . 20
Energy Recovery Wheel . . . . . . . . . . 20
Drive Belt . . . . . . . . . . . . . . . . 20
Air Seals . . . . . . . . . . . . . . . . . 20
Optional Start-Up Components
Dirty Filter Switch . . . . . . . . . . . . . 20
Economizer . . . . . . . . . . . . . . . 21
Frost Control . . . . . . . . . . . . . . . 22
Variable Frequency Drives . . . . . . . .22-24
Routine Maintenance. . . . . . . . . . 25-28
Troubleshooting
Economizer Alarms . . . . . . . . . . . . 28
Airflow. . . . . . . . . . . . . . . . . . 29
Unit . . . . . . . . . . . . . . . . . 30-31
Maintenance Log . . . . . . . . . Backcover
Our Commitment . . . . . . . . . Backcover
The ERV brings in fresh, outdoor air and removes
stale, exhaust air. Prior to discharging the exhaust
air, the energy recovery wheel transfers energy from
the exhaust air to the outdoor air at an efficiency
of 70-80%. Simply put, this unit preconditions the
outdoor air to save money on heating and cooling
costs.
Supplemental IOMs
Refer to the following Installation, Operation and
Maintenance (IOM) Manuals for additional details:
• ERV-90 and ERV-120 Curbs
• ERV Exhaust Weatherhood
Optional Subassemblies
Electric Heater Application/Operation
Factory installed electric heaters can be provided for
preheat frost control. An electric preheater warms
the outdoor air prior to the energy recovery wheel
to prevent frosting on the wheel. Electric heaters
are available in 208, 230, or 460 VAC (refer to heater
nameplate for voltage).
Preheaters: Preheaters are standard as single-stage
on/off control. Preheaters are single point wired at
the factory. A thermodisc temperature sensor (with
a 5°F set point) is mounted in the outdoor airstream
after the preheater to turn the preheater on. See Frost
Control Application/Operation for typical set points. If
the temperature falls below
the set point and the wheel
pressure drop sensor is
triggered, the preheater will
turn on.
Access to the preheater
control panel is through the
outdoor air filter door.
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Installation
g
a
Dimensional Data
ERV-10, 20, 45 and 55
Unit Size
ERV-10 46 34 27 10 16 6
ERV-20 62 51 34 18 18 8
ERV-45 67 67 44 24 24 10
Exterior Dimensions Unit Opening Dimensions
ABCFGKLQP
3
⁄4 71016
3
⁄8 111⁄2 19 18
3
⁄4 131⁄2 26 26
ERV-55 75 70 67 22 27 16 18
All dimensions are in inches.
Outdoor Air Discharge
LxK
Exhaust Air Intake
FxG
Outdoor Air Intake
Q x P
C
3
⁄4 28 48
Outdoor Air Discharge
LxK
B
C
A
A
Exhaust Air Discharge
Outdoor Air Discharge
LxK
B
C
FxG
B
Exhaust Air Intake
FxG
Exhaust Air Discharge
Arrangement A Arrangement B
Outdoor Air Discharge
LxK
Exhaust Air Discharge
A
C
Outdoor Air IntakeExhaust Air Intake
Exhaust Air Intake
B
FxG
Outdoor Air Int
A
Outdoor Air Intake
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Arrangement C Arrangement D
Installation
Dimensional Data
ERV-90 and 120
Unit Size
ABCDEFGK LQP
ERV-90L 124 84 64 16 19 48 25 16 18
Exterior Dimensions Unit Opening Dimensions
5
⁄8 60 25
ERV-90H 124 84 64 16 19 48 25 19 22 60 25
ERV-120H 146 97 77 17
1
⁄2 263⁄4 60 28 23 25 70 30
All dimensions are in inches.
Outdoor Air Discharge
L x K
E
A
Exhaust
Hood
Outdoor Air Inlet
Q x P
C
Exhaust Air Discharge
L x K
Outdoor Air Discharge
L x K
Exhaust Air Inlet
F x G
C
B
A
Intake
Hood
Exhaust Air Inlet
H x J
D
B
C
Intake
Hood
Arrangement A Arrangement B
Exhaust Air Inlet
H x J
D
B
Outdoor Air Discharge
L x K
E
A
Exhaust
Hood
C
Intake
Hood
D
B
Arrangement C Arrangement D
Outdoor Air Discharge
L x K
Exhaust Air Inlet
E
A
Exhaust
Hood
F x G
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Recommended Roof Openings & Weights
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 (see Service Clearances).
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.
When cutting only duct openings, cut opening 1 inch
(25 mm) larger than duct size to allow clearance for
installation. Area enclosed by roof curb must comply
with clearance to combustible materials. If the roof is
constructed of combustible materials, area within the
roof curb must be ventilated, left open, or covered
with non-combustible material which has an “R”
value of at least 5. If area within curb is open, higher
radiated sound levels may result.
Where the supply or warm air duct passes thru a
combustible roof, a clearance of one inch must be
maintained between the outside edges of the duct
and combustible material in accordance with NFPA
Standard 90A.
EXHAUST
INLET
ERV-90 and 120
V
EXHAUST
INTAKE
SUPPLY
DISCHARGE
0.50
U
V
SUPPLY
DISCHARGE
U
0.50
ERV-10, 20, 45 and 55
Unit Size U V
Approx.
Weight (lbs.)
ERV-10 26.5 20 340
ERV-20 43 26 860
ERV-45 58 35 1290
ERV-55 60 30 1470
ERV-90 62 36 3230
ERV-120 77 38 3700
All dimensions are in inches. *Weight assumes outdoor unit
with filters, weatherhoods and outdoor air intake damper.
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Service Clearances
ERV-10, 20, 45 and 55 units require minimum clearances to perform routine maintenance, such as filter
replacement, energy wheel cassette inspection, and fan belt adjustment. Blower and motor assemblies,
energy recovery wheel cassette and filter sections are always provided with a service door or panel for proper
component access. Clearances for component removal may be greater than the service clearances, refer to
drawings below for these dimensions.
ERV-10, ERV-20, ERV-45, ERV-55 ERV-90, ERV-120
Access Panels
T
Exhaust
Side
Outdoor
Air Side
R
Cassette slides out*
S
*ERV-10, 20, and 45 only.
Arrangement A
Recommended Service Clearances
Unit Size R S T X
ERV-10 32 30 42
ERV-20
ERV-45
ERV-55
(30 for maintenance)
(39 for maintenance)
(32 for maintenance)
44
60
65
ERV-90 42
ERV-120 42
All dimensions are in inches.
30 42
40 42
40 42
Access Panels
X
Access PanelAccess Panel
Cassette
X
Access PanelAccess Panel
X
Cassette
Access Panel
X
Access Panel
X
Arrangement A
X
Cassette
Access PanelAccess Panel
X
Cassette
Supply
Weatherhood
Arrangement B, C or D
Energy Recovery Ventilator
Access Panel
Exhaust
Weatherhood
X
7
Access Panel Locations
g
ERV-10, ERV-20, ERV-45, ERV-55 ERV-90
Outdoor Air
Discharge
Exhaust Air
Inlet
3
1
2
Interior
3
Outdoor Air
Discharge
5
2
6
Exhaust Air
Inlet
3
4
Arrangement A
1
3
Exhaust Air
Dischar
e
Arrangement B, C or D
Exhaust Air
Discharge
4
Outdoor Ai
2
Intake
Outdoor Air
Intake
Outdoor Air Inlet
Exhaust Air Discharge
Rooftop
3
4
1
Arrangement A
5
2
6
4
Intake Hood
1
Exhaust Hood
Arrangement B, C or D
3
1
Outdoor air blower and motor
Energy wheel cassette
Energy wheel cassette
Internal filters
2
Outdoor air intake damper
Frost control
Outdoor air sensors
Main disconnect
3
Electrical control center
Internal filters
4
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Exhaust air blower and motor
1
2
Exhaust blower and motor
Electric control center
Main Disconnect
Energy wheel cassette
3
Internal filters
Frost control
Outdoor air sensors
4
5
6
Preheater controls
Outdoor air intake damper
Supply blower and motor
Exhaust air intake damper
Access Panel Locations continued
ERV-120
Outdoor Air
Discharge
2
3
Exhaust Air
Intake
3
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.
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 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.
Outdoor Air Intake
Exhaust Air Discharge
3
4
1
Arrangement A
2
4
Outdoor
Weatherhood
Arrangement B, C or D
Exhaust Hood
Lifting
WARNING
All factory provided lifting lugs must be used when
lifting the unit. 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 shown below.
3. Unit must be lifted by all lifting lugs provided on
3
1
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.
1
2
3
4
Exhaust blower and motor
Electric control center
Main disconnect
Supply blower and motor
Exhaust air intake damper
Energy wheel cassette
Internal filters
Frost control
Outdoor air sensor
Preheater controls
Outdoor air intake damper
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.
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Roof Curb Mounting
R
o
t
a
t
i
o
n
POOR
Roof curb details including duct location dimensions,
are available on ERV-90 & 120 Roof Curb Assembly
Instructions.
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.
1. Factory Supplied Roof Curbs: Roof curbs are
Model GPI or GPNS for the ERV-10, 20, 45, 55.
The GPI or GPNS ships assembled and includes a
duct adapter.
Roof curbs are Model GKD for the ERV-90 and
120. The GKD ships in a knockdown kit (includes
duct adapter) and requires field assembly (by
others). Assembly instructions are included with
the GKD curbs.
2. Install Curb: Locate curb over roof opening and
fasten in place. (Refer to Recommended Roof
Openings). Check that the diagonal dimensions
are within ±1/8 inch of each other and adjust
as necessary. For proper 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.
Curb Outside Dimensions and Weights
Side of Unit
B
C
D
Roof Curb
E
Base
A
1-inch Insulation
Curb Cap Details for Factory Supplied Roof Curbs
Unit Size A
BCDE
ERV-10 1.75 2.00 1.00 1.125 0.750
ERV-20 1.75 2.00 1.00 1.200 0.875
ERV-45 1.75 2.00 1.00 0.813 0.875
ERV-55 1.75 2.00 1.00 0.813 0.750
ERV-90 1.813 4.00 1.75 1.000 0.750
ERV-120 1.938 4.125 1.938 1.125 0.625
All dimensions are in inches.
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
fan wheel rotates. Poor
duct installation will
result in low airflow and
other system effects.
n
o
i
t
a
t
o
R
Length of Straight Duct
W
L
ERV-90 and 120
Unit Size L W Curb Weight (lbs.)
ERV-10 42.5 30.5 60
ERV-20 58.5 47.5 115
ERV-45 63.5 63.5 160
ERV-55 71.8 66 185
ERV-90 120.5 80.5 520
ERV-120 142.25 93 700
All dimensions are in inches. Weights are for 12-inch high
GPI type curbs.
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GOOD
Recommended Discharge Duct Size and Length
Model Blower Size Duct Size Straight Duct Length
ERV-10 10 9 x 9 36
ERV-20 10 14 x 14 36
ERV-45 12 20 x 20 36
ERV-55 15 28 x 28 60
ERV-90L 15 28 x 28 60
ERV-90H 18 32 x 32 60
ERV-120 20 34 x 34 72
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.
• Straight duct lengths were calculated based on 100% effective
duct length requirements as prescribed in AMCA Publication
201. Calculated values have been rounded up to nearest foot.
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