Greenheck ERV-251, ERV-361, ERV-581, ERV-521, ERV-522 Installation, Operation And Maintenance Manual

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Page 1

GREENHECK

P.O. BOX 410 SCHOFIELD, WISCONSIN 54476-0410

PH. 715-359-6171

ENERGY RECOVERY VENTILATORS

Models ERV-251, 361, 521, 581, 522 & 582

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

**WARNING**

DISCONNECT ALL ELECTRICAL POWER TO THE ERV PRIOR TO INSPECTION OR SERVICING BY

SECURING THE MAIN DISCONNECT SWITCH TO THE "OFF" POSITION. FAILURE TO COMPLY WITH THIS

SAFETY PRECAUTION COULD RESULT IN SERIOUS INJURY OR DEATH.

**IMPORTANT**

ALL FACTORY PROVIDED LIFTING LUGS MUST BE USED WHEN LIFTING ANY ERV.

FAILURE TO COMPLY WITH THIS SAFETY PRECAUTION COULD RESULT IN PROPERTY

DAMAGE, SERIOUS INJURY OR DEATH.

PART #455924

READ AND SAVE THESE INSTRUCTIONS

Page 2

GENERAL

Greenheck Energy Recovery Ventilators, model ERV, are thoroughly inspected and test run at the factory. However, damage may occur during shipping and handling. Consequently, it is important to inspect the unit for visible and concealed damage before beginning installation. Report any damage to the shipper immediately. In addition, assure all accessory items are present. Some accessory items are stored inside the unit during shipping. Care must be taken during installation to prevent damage to units.

INSTALLATION

The system design and installation should follow accepted industry practice, such as described in the ASHRAE Handbook.

Minimum service clearance should be provided on the side of the unit for routine service and component removal should it become necessary.

Before beginning installation see pages 8 through 11 for dimensional data and details on appropriate service clearances.

Installation...............................................2

Lifting...................................................3

Mounting..............................................4

Duct Connection.................................6

Weatherhoods.....................................6

Electrical...........................................6-7

Dimensional Data

- 251, 361, 521, 581

......8

Service Clearances

- 251, 361, 521, 581

.....9

Dimensional Data

- 522, 582

.................10

Service Clearances

- 522, 582

...............11

System Startup .....................................12

Energy Wheel....................................12

Fan RPM............................................13

Fan Wheel .........................................13

Motors...............................................13

Setting for Options............................13

Routine Maintenance ..............................14

Belts ......................................................14

Fasteners and set screws....................14

Filters ....................................................15

Energy Recovery Wheel Maintenance ..16

Accessing the Energy Wheel ...............16

Removing Energy Wheel......................17

Cleaning Energy Wheel ........................17

Maintenance Documentation ............18-19

Troubleshooting.......................................20

Warranty ..................................................20

TABLE OF CONTENTS

Page 3

LIFTING

Greenheck model ERVs must be lifted as it ships from the factory. All units are equipped with lifting lugs. THE USE OF ALL LIFTING LUGS IS MANDATORY WHEN LIFTING. Lifting of the ERV should only be done with the access doors/panels closed and in place to avoid damage to the unit.

Use spreader bars to prevent damage to the unit cabinetry. Spreader bars must be positioned to prevent the cables from rubbing against the unit frame or panels. Before hoisting into position, test lift the unit to verify stability and balance. Avoid twisting or uneven lifting of the unit. Never lift an ERV by weatherhoods.

FIGURE 2

ERV-522 and 582

FIGURE 1

SLAB MOUNTING

Arrangement D (Horizontal Discharge)

Slab Construction

• The recommended slab size is 12 inches wider and longer than the total unit size.

• The material should be concrete with a thickness of at least 4 inches and proper reinforcement wire.

• The slab should be set and leveled on a sufficient bed of gravel for proper drainage.

1. Slab Co

Recomme total unit s Recomme

ERV-251, 361, 521 and 581

Lift Lugs

Spreader Bar

Lift Lugs

Page 4

INSTALLATION (continued)

SURFACE RAIL MOUNTING

Arrangement A or D

For proper support, rails should be located 6 to 12 inches in from the outer edges of the unit and should extend at least 6” beyond the sides of the unit. Rails are by others.

Front

Back

Refer to pages 8 through 11 for unit dimensions

and appropriate service clearances.

CURB MOUNTING

Arrangement B, C and D

Recommended Roof Opening ERV-251, 361, 521 and 581

ERV-522 and 582

Roof curbs are Model GKD, which are shipped in a knockdown kit and require field assembly (by others). Assembly instructions are included with the curb.

2. Cut Roof Opening and Locate Curb

Locate the unit over the roof opening, so the unit openings and corresponding ducts line up. See the drawing below.

Be sure to allow for the recommended service clearances. Keep the inlet of the ERV away from any other exhaust fans. See page 6 for Recommended Duct Sizes.

EXHAUST

INLET

SUPPLY

OUTLET

Recommended Roof Opening ERV-522 and 582

Model U V

ERV-251 26.5 20 ERV-361 43 26 ERV-521 58 35 ERV-581 60 30

Model U V

ERV-522 65 37 ERV-582 77 38

ERV-251, 361, 521 and 581

1. Factory Supplied Roof Curbs

Roof curbs are either Model GPNS or GPI, which are factory fabricated and assembled.

EXHAUST

INLET

SUPPLY

OUTLET

All dimensions shown are in inches.

Page 5

Model L W

ERV-251 30.5 42.5 ERV-361 58.5 47.5 ERV-521 63.5 63.5 ERV-581 71.8 66 ERV-522 120.5 80.5 ERV-582 142.25 93

Roof curb details, including duct

location dimensions, are available on

ERV roof curb submittals.

FIGURE 3

FIGURE 4

3. Install Curb

Locate curb over roof opening with dimensions shown on page 4 and fasten in place.

Check that the diagonal dimensions are within ±1/8” of each other and adjust as necessary. Shim as required to level.

Lower unit onto curb by following the LIFTING instructions on page 3 of this manual. Note, roof curbs fit inside the ERV unit base.

4. Install Duct Work

Installation of all ducts should be done in accordance with SMACNA and AMCA guidelines.

The chart on page 6 shows the duct sizes and straight lengths recommended for optimal performance (AMCA 201-90). Using duct sizes less than the recommended lengths will affect fan performance. Good duct installation practices should be followed for the remaining ductwork.

ERV-251, 361, 521 and 581

The duct adapter should be used only for properly locating ducts on these units. The factory duct adapter must not be used for structural support of the ducts.

ERV-522 and 582

This duct adapter can be used to locate and support the duct work.

Curb Outside Dimensions

ERV-522 and 582

ERV-251, 361, 521 and 581

All dimensions shown are in inches.

Page 6

Main Disconnect

Off

Exhaust Hood

Control Center

Exhaust Hood

Supply Hood

Main Disconnect

Off

Control Center

Main Disconnect

Off

ERV-251 & 581

ERV-361 & 521

ERV-522 & 582

FIGURE 3

WEATHERHOODS (Arrangement B, C and D)

The outdoor air intake weatherhood is shipped factory assembled and mounted to the ERV. The exhaust discharge weatherhood is fastened to the skid and shipped with the ERV unit.

DUCT WORK CONNECTIONS

Examples of good and poor fan-to-duct connections are shown in Figure 3. Air flow 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, increased noise levels and other system effects.

INSTALLATION (continued)

Recommended Discharge

Duct Size and Length

ERV

Duct

Straight

Model

Blower

Size

Duct

Size Length

251 10 9 x 9 40 361 10 14 x 14 40 521 12 20 x 20 48 581 15 28 x 28 60

522S 15 28 x 28 60 522H 18 32 x 32 72

582 20 34 x 34 80

ELECTRICAL CONNECTIONS

CAUTION !

If any of the original wire must be replaced,

the replacement wire must have a temperature

rating of at least 105°C, except for energy cut-off

or sensor lead wire which must be 150°C.

DANGER !

High voltage electrical input is required for this

equipment. This work should be performed by a

qualified electrician.

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

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

FIGURE 4

All dimensions shown are in inches.

Length of Straight Duct

GOOD

POOR

Page 7

Sequence for wiring ERV unit:

1.The unit’s nameplate states the voltage and total amperage required. The wire supplying power to the unit should be sized for the label’s voltage and amperage.

2.The main power line should be connected to the disconnect switch. Make sure that the disconnect lugs are securely tightened. A door interlocking safety disconnect is provided as a standard feature with model ERV, (see Figure 4, page 6).

Power may be routed to the control center through the curb or the knock-outs on the side of the ERV. The locations for the knockouts and control center are provided on the ERV submittal. If power will be routed through the curb and unit base panels, then run the power supply up through the base panel near the exhaust intake opening of the ERV.

3.Connect control wiring to the terminal strip located in the electrical control center. All ERV units include, as standard, a transformer to achieve the 24 VAC control voltage.

4.Refer to the wiring diagram located in the control center or included with this manual for controlling the ERV.

CAUTION

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

INSTALLATION (continued)

1. Main Disconnect

2. Motor Starter -Exhaust Air Fan

3. Motor Starter-Outdoor Air Fan

4. Motor Contactor-Energy Wheel

5. Control Power Transformer (460 to 24 VAC)

6. Energy Wheel Motor Transformer (460 to 230 VAC)

7. 24 VAC Terminal strip

8. Internal fuses for the control circuit and wheel drive transformer

ELECTRICAL CONNECTIONS

TYPICAL CONTROL CENTER COMPONENTS

Page 8

Exterior Dimensions Duct Dimensions * Approximate

Model

ABCD E FG K L Q P

Weight (lbs)

ERV-251 46 34 27 16 8 10 16 63/4

7 10 16 250

ERV-361 62 51 34 15 15 18 18 8

/8 111/2 19 18 750 ERV-521 67 67 44 18 15 24 24 103/4 131/2 26 26 1200 ERV-581 75 70 67 16 22 22 27 16 183/4 28 48 1450

MODELS ERV-251, ERV-361, ERV-521 AND ERV-581

Arrangement A

Outdoor Air Inlet

Q x P

Exhaust Air Discharge

LxK

Outdoor Air Discharge

LxK

Exhaust Air Inlet

FxG

Arrangement B

Exhaust Air Inlet

FxG

Outdoor Air Discharge

LxK

Intake Hood

Exhaust Hood

Arrangement C

Exhaust Hood

Intake Hood

Exhaust Air Inlet

FxG

Outdoor Air Discharge

LxK

Exhaust Air Inlet

FxG

Outdoor Air Discharge

LxK

Intake Hood

Arrangement D

Exhaust Hood

All dimensions shown are in inches.

DIMENSIONAL DATA

* Weight dependent on components and accessories.

Page 9

Supply Hood

Exhaust Hood

Cassette Slides out

Access Panels

Access Panel

Exhaust

Side

Supply

Side

SERVICE CLEARANCES FOR ERV-251, 361, 521 AND 581

ACCESS PANEL LOCATIONS

ERV 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 are shown below.

Outdoor Air

Inlet

Exhaust Air

Discharge

Exhaust Air

Inlet

Outdoor Air

Discharge

Model R S T

251 32 30 30 361 44 30 30 521 60 40 40 581 65 40 40

ERV-251, 361, 521 and 581 Recommend Clearances

All dimensions shown are in inches.

Exhaust

Hood

Intake

Hood

Access panel for:

•Outdoor air blower and motor

•Energy wheel cassette

Access panel for:

•Energy wheel cassette

•Internal Filters

•Outdoor air inlet damper

•Frost control

•Outdoor air sensors

Access panel for:

•Main disconnect

•Electrical control center

•Internal filters

Access panel for:

•Exhaust air blower and motor

Arrangement A

Arrangement B, C or D

Access Panels

Exhaust

Side

Supply

Side

Cassette Slides out

Access Panels

Page 10

DIMENSIONAL DATA

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust Air Discharge

L x K

Outdoor Air Inlet

Q x P

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust

Hood

Intake

Hood

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust

Hood

Intake

Hood

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust

Hood

Intake

Hood

Arrangement A

Arrangement B

Arrangement D

Arrangement C

* Weight dependent on components and accessories.

All dimensions shown are in inches.

ABCDEFGHJKLQP

ERV-522S 124 84 64 16 19 26 36 48 25 16 18 5/

8 60 25 3000

ERV-522H 124 84 64 16 19 26 36 48 25 19 22 60 25 3000

MODEL ERV-522 AND ERV-582

Model

Exterior Dimensions Duct Dimensions

* Approximate

Weight

ERV-582H

146

3600

Page 11

Model X

ERV-522 38 ERV-582 56

Cassette

Supply Weather Hood

Exhaust Weather Hood

Access Panel

Access PanelAccess Panel

Access Panel

SERVICE CLEARANCES FOR ERV-522 AND 582

ACCESS PANEL LOCATIONS

Clearances for component removal are shown below.

Interior

Rooftop

Exhaust Air

Inlet

Outdoor Air Inlet

Exhaust Air Discharge

Exhaust Hood

Intake Hood

Outdoor Air

Discharge

asse

tte

asse

tte

Access PanelAccess Panel

Access Panel

All dimensions shown are in inches.

Access panel for:

•Electrical Control Center

•Main disconnect

•Supply blower and motor

•Exhaust inlet damper

Access panel for:

•Energy wheel cassette

•Internal filters

•Frost control

•Outdoor air sensor

Access panel for:

•Preheater controls

•Supply inlet damper

Access panel for:

•Exhaust blower and motor

Arrangement A Arrangement B, C or D

Page 12

For proper unit function and safety, follow everything in this startup procedure in the order presented. This is to be done after the electrical connections are complete.

Special Tools Required • Volt meter

• Incline manometer or equivalent

• Tachometer

• Amperage meter

1. General

Check all fasteners and set screws for tightness. This is especially important for bearings and fan wheels. Also, if dampers are not motorized, check that they open and close without binding.

SYSTEM STARTUP

**WARNING**

DO NOT OPERATE ENERGY RECOVERY VENTILATOR WITHOUT THE FILTERS AND BIRDSCREENS INSTALLED.

THEY PREVENT THE ENTRY OF FOREIGN OBJECTS SUCH AS LEAVES, BIRDS, ETC.

DO NOT REMOVE ACCESS PANELS OR OTHER COMPONENTS WHILE STANDING ON A LADDER OR OTHER

UNSTEADY BASE. ACCESS PANELS AND COMPONENTS ARE HEAVY AND SERIOUS INJURY MAY OCCUR.

2. Check Voltage

Before starting the unit compare the supplied voltage with the unit’s nameplate voltage and the motor voltage.

3. Energy Recovery Wheel

First, follow the instructions on page 16 for pulling the energy recovery cassette halfway out of the unit.

DRIVE BELT

Turn the energy recovery wheel by hand to verify free operation. Inspect the belt, which drives the energy wheel rotation. Make sure the belt rides smoothly through the pulley and over the wheel rim.

AIR SEALS

Turn the energy recovery wheel by hand to verify free operation. Check that the air seals, located around the outside of the wheel and across the center (both sides of wheel), are secure and in good condition.

Air seals which are too tight will prevent proper rotation of the energy recovery wheel. Recheck the air seals for tightness. Air seal clearance may be checked by placing a sheet of paper, like a feeler gauge, against the wheel face. To adjust the air seals, loosen all eight seal retaining screws. These screws are located on the bearing support that spans the length of the cassette through the wheel center. Tighten the screws so the air seals tug slightly on the sheet of paper as the wheel is turned.

Replace cassette into unit, plug in wheel drive, replace access door and apply power. Observe that the wheel rotates freely. If wheel does not rotate or is binding, remove the cassette (instruction on page 16).

FIGURE 5

Drive Belt

Drive Pulley

Adjustable

Air Seals

Label showing

cassette serial no.

and date code

Page 13

7. Settings for Optional Components

Frost Control

Preheater: If outdoor air temperature is below set point then the preheater heats incoming outdoor air above

the Frost Threshold temperature. Typical settings are shown at the right.

Timed Exhaust: De-energizes the outdoor air blower for a specified period, if the outdoor temperature is below the set point. The outdoor air blower returns to normal operation for a specified period. This cycle ends when the outside temperature rises above the set point.

Typical settings are: Temp. Sensor : 0°F, Timer (Blower Off): 5 minutes and Timer (Blower On) 45 minutes.

Outdoor/Economizer Sensors

All economizer sensors must be by-passed for proper winter or heating season operation. The by-pass can be accomplished utilizing the Auto-override option or by wiring a summer/winter switch as shown on the ERV wiring or ladder diagram.

Temperature Sensor: De-energizes the energy wheel drive motor when the outdoor temperature is below the set point. The wheel motor re-energizes when the outdoor air temperature is above the set point.

Typical settings are: 65°F

Enthalpy Sensor: De-energizes the energy wheel drive motor when the outdoor enthalpy drops below the set point. The wheel motor re-energizes when the outdoor air enthalpy is above the set point.

Four settings available on controller.

4. Check Blower Rotation

First, hand rotate the blower to ensure that the wheel is not rubbing against the scroll. If the blower is rotating in the wrong direction, the unit will move some air but not perform properly.

To check the rotation, open the blower access panels, which are labeled either supply or exhaust, and run the blower momentarily to determine the rotation.

To reverse the rotation, turn the power off and use the following procedure:

• For single phase units, rewire the motor per the instructions on the motor.

• For three phase units, interchange any two power leads. This can be done at the motor starter.

5. Air Volume Check and Measurement

Along with the building balance, the units air volume (cfm) should be measured and compared with its rated air volume. This unit is flexible (fixed drives for 15 hp units) for varying air volume, but the actual air volume should be known for making final adjustments. Note: Model ERV-251 is direct drive, balancing damper or speed control needed for air flow balancing.

The most accurate way to measure the air volume is by using the pitot traverse method in the ductwork away from the blower. Other methods can be used but should be proven and accurate.

To adjust the air volume, change the fan rpm or the system losses. See Trouble Shooting section on page 20.

6. Measure Motor Voltage, Amperage and Fan RPM

All access doors must be installed except the control center door (Exception: ERV-522 control center door must be installed). Measure and record the input voltage and motor amperage(s).

To measure the fan rpm, the blower door will need to be removed. Minimize measurement time because the motor may overamp with the door removed. Do not operate units with access doors/panels open as the

motors will overload.

With blower door closed compare measured amps to the motor nameplate full load amps and correct if overamping.

FROST THRESHOLD TEMPERATURE

Indoor RH at Frost Threshold

70° F Temperature

20% -10°F 30% -5°F 40% 0°F

Airflow

Page 14

ROUTINE MAINTENANCE

CAUTION: See **WARNING** on Page 1

After the ERV has been put into operation, an annual inspection and maintenance program should be set-up to preserve reliability and performance. Include the following items in this program,

• BELTS • REMOVAL OF DUST/DIRT

• FASTENERS • FILTER MAINTENANCE

• SET SCREWS • ENERGY WHEEL CASSETTE

BELTS

Premature belt failures are frequently caused by improper belt tension (either too tight or too loose) or misaligned pulleys. The proper tension for operating a V-belt is the lowest tension at which the belts will not slip at peak load conditions. For initial tensioning, the proper belt deflection half way between pulley centers is

inch

per foot of belt

span. The belt deflection should be

inch using moderate thumb

pressure at midpoint of the drive (See Figure 6). Check belt tension two weeks after start-up and periodically thereafter.

To adjust belt tension, simply loosen four fasteners (two on each side of the motor plate) and slide the motor plate away from the fan shaft until proper belt tension is attained. On some ERVs, fasteners attaching the motor to the motor plate must be loosened in order to adjust the belt.

It is very important that the drive pulleys remain in proper alignment after adjustments are made. Misalignment of pulleys will result in premature belt wear, noise, vibration and power loss.(See Figure 7). Maintain belts and motors through the provided access panels.

FASTENERS AND SET SCREWS

Any fan vibration has a tendency to loosen mechanical fasteners. A periodic inspection should include checking all fasteners and set screws for tightness. Particular attention should be paid to set screws attaching the fan wheel to the shaft and the shaft to the bearings. Loose bearing set screws will lead to premature failure of the fan shaft.

REMOVAL OF DUST AND DIRT

Dirt clogs cooling openings on the motor housing, contaminates bearing lubricant and collects on fan wheel blades causing severe imbalance if left unchecked. The exterior surface of the motor, inlet area and entire fan wheel should be thoroughly cleaned periodically. Use caution and do not allow water or solvents to enter the motor or bearings. Under no circumstances should motors or bearings be sprayed with steam or water. Maintenance to these components is achieved through the provided access panels.

FIGURE 6

FIGURE 7

Deflection =

Belt Span

WRONG WRONG

WRONG CORRECT

Page 15

Model Filter Size Quantity

ERV-251 16 x 25 1 ERV-361 16 x 20 2 ERV-521 16 x 25 3 ERV-581 16 x 20 6 ERV-522 16 x 25 7 ERV-582 20 x 25 6

EXTERNAL FILTER MAINTENANCE

Aluminum mesh 2 inch filters are located in the supply weatherhood on outdoor units. 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.

To remove these filters, pull the side access panel off and simply slide the filters out of the weatherhood.

Clean filters by rinsing with a mild detergent in warm water. After the filters are dry, an adhesive spray available at most filter distributors may be applied to increase filter efficiency.

Internal

INTERNAL FILTER MAINTENANCE

Opening the access panels labeled "Filter Access" provides access to the 2 inch deep, pleated 30% efficient filters. These filters should be checked regularly and cleaned or replaced as needed.

Page 16

CAUTION: See **WARNING** on Page 1

Annual inspection of the energy recovery wheel is recommended. ERV units ventilating smoking lounges and other non-clean air spaces should have energy recovery wheel inspections more often based upon need.

FIGURE 8

MAINTENANCE OF THE ENERGY RECOVERY WHEEL

FIGURE 10

ACCESSING ENERGY RECOVERY WHEEL IN MODELS ERV-251, 361, 521 and 581

Disconnect power to the ERV. Remove access panel(s) labeled “Energy Wheel Cassette Access”.

UNPLUG the wheel drive motor. The center channel must be removed to access the energy wheel cassette. Use a 5/16 inch open or close wrench to remove the (3) fasteners that hold the center channel in place.

Pull the cassette halfway out as shown in Figure 8.

When service is complete, reattach the center channel before putting access panels back in place.

ACCESSING ENERGY RECOVERY WHEELS IN MODEL ERV-522 AND 582

Disconnect power to the ERV. Remove access panels labeled “Energy Wheel Cassette Access”, which reveals the energy wheel cassette. There are additional panels that must be removed in order to slide out the cassettes. Figure 9 shows the energy wheel and panel.

UNPLUG the wheel drive motor and pull the cassette halfway out as shown in Figure 10.

This panel must be

removed before energy

wheel can slide out.

NOTE: ERV model’s 522 and

582 each have two energy wheels with access panels for both wheels. Wheels slide out

at opposite corners.

FIGURE 9

Page 17

ERV-251

First, remove the drive belts and the collars on both bearings. On the pulley side of the cassette remove the (4) fasteners that hold the bearing support channel in place. Once the bearing support is removed the wheel can be pulled from the cassette. To replace the wheel reverse this procedure.

ERV-361, 521, 581, 522 & 582

(stainless steel rim)

Steel retainers are located on the inside of the wheel rim (see Figure 11). Push the retainer towards the center of the wheel, then lift up and away to release segments.

NOTE: PLACE RETAINERS BACK IN THE ORIGINAL

POSITION BEFORE ROTATING THE ENERGY RECOVERY WHEEL. OTHERWISE DAMAGE TO THE RETAINER WILL OCCUR.

REMOVING THE ENERGY RECOVERY WHEEL OR SEGMENTS

FIGURE 11

RECOMMENDED CLEANING PROCEDURE FOR ENERGY RECOVERY WHEELS

First, remove the energy recovery wheel segments by following the instructions on this page. (For one-piece wheels smaller than 30 inches in diameter, remove the wheel from the cassette.)

Wash the segments or small wheels with a non-acid based (evaporator) coil cleaner or alkaline detergent solution. Non-acid based coil cleaner such as KMP Acti-Clean AK-1 concentrate in a 5% solution has been demonstrated to provide excellent results. Do not use acid based cleaners, aromatic solvents, temperatures in excess of 140°F or steam; damage to the wheel may result. Soak in the cleaning solution until grease and/or tar deposits are loosened. Internal heat exchange surfaces may be examined by separating the polymer strips by hand. (Note: some staining of the desiccant may remain and is not harmful to performance.)

After soaking, rinse the dirty solution from the wheel until the water runs clear. Allow excess water to drain prior to replacing segments in the wheel or reinstalling the wheel in the cassette. A small amount of water remaining in the wheel will be dried out by the airflow.

FREQUENCY OF ENERGY WHEEL CLEANING

A regular cleaning cycle must be established for the energy recovery wheel in order to maintain optimum sensible and latent energy transfer. In reasonably clean environments such as schools, offices or retail stores, the energy recovery wheel should be inspected annually and cleaned as needed.

For applications experiencing unusually high levels of tobacco smoke, such as lounges, nightclubs, bars and restaurants, washing of the energy recovery wheel every six months may be necessary to maintain latent energy (water vapor) transfer efficiency.

Failure to follow a regular cleaning cycle for the energy recovery wheel can result in significant energy transfer performance losses.

Bracket Segment Retainer

CatchSegment Retainer

Lift Away From Segment

Inside of Wheel Rim

Spoke

Push Toward Center

Center of W

heel

Page 18

ENERGY RECOVERY WHEEL DRIVE BELT

Drive belt(s) should be inspected annually. Normal operation eventually causes stretching or wear on the belt(s). Once this occurs the belt(s) should be replaced.

Replacement or spare energy wheel drive belt kits are available and ship with their own instructions. The serial number and date code of the energy wheel cassette are required to obtain the proper replacement belt kit from the factory.

MAINTENANCE OF THE ENERGY RECOVERY WHEEL (continued)

Name Plate Information

Model: _______________________________ Volts: ___________Hertz: _______ Phase: ___

Wheel Serial Number:____________________ Manufacture Date Code: _____________

ENERGY RECOVERY WHEEL MAINTENANCE DOCUMENTATION

Field Start-Up Documentation

Energy Wheel

Rotates Freely

❏

Yes

❏

No, check items below.

Air Seal Tightness

❏

Acceptable

❏

Adjusted as on page 12

Belts runs smoothly❏Yes

❏

Adjusted

Maintenance

Date Time Notes:

Note: The energy wheel serial number and date

code are located on a label above the drive pulley on the energy wheel cassette.

Page 19

Job Information

Job Name: ________________________________________ Address:__________________________________________ City: ________________ State: ________ Zip: __________ Phone: __________________ Fax: ____________________ Contact Person: ___________________________________

Service Organization: ______________________________ Address:__________________________________________ City: ________________ State: ________ Zip: __________ Phone: __________________ Fax: ____________________ Work Done By:____________________________________

Name Plate Information

Model: ___________________________________________ Volts: ___________ Hertz: __________ Phase: _________ Min. Circuit Amps: _____________ Mark: _____________ Supply Hp: _____________ Exhaust Hp: ______________ Unit Serial Number:______________________________

Supply Motor Voltage: Supply Motor Amperage: Supply Fan rpm: Exhaust Motor Voltage: Exhaust Motor Amperage: Exhaust Fan rpm:

Maintenance

Date Time Notes:

Field Start-Up Documentation

Actual Voltage: Hertz: Phase: Actual Amperage:

Supply Blower

Rotation ❏ Correct

Air Volume Design

cfm

Actual

cfm

Exhaust Blower

Rotation ❏ Correct

Air Volume Design cfm

Actual cfm

UNIT MAINTENANCE DOCUMENTATION

Page 20

TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Electrical Check fuses/circuit breakers, replace if needed. Check for On/Off

switches. Check for correct supply voltage.

Unit is NOT

Drive Check for broken or loose belts. Tighten loose pulleys.

Operating

Motor Check that the motor hp is correct and not tripping overloads. Fan Wheel Rubbing on Inlet Adjust wheel and/or inlet cone. Tighten wheel hub or bearing

collars on shaft.

Excessive

Bearings Replace defective bearing(s). Lubricate bearings. Tighten collars

Noise

and fasteners.

Belts Tighten sheaves on motor/fan shaft. Adjust belt tension. Align

sheaves properly (see page 14). Replace worn belts or sheaves. Wheel Out of Balance Replace or rebalance. Blower Fan Speed too Low Check for correct drives and rpm’s with catalog data.

Fan wheels are operating For 3 phase see Fan Wheel Rotation on page 13. backwards. Check blower rotation.

Low

Airflow (cfm)

Dirty filters or energy wheel Follow cleaning procedures on page 17. High Static Pressure Incorrect fan-to-duct connections. Make sure dampers open

appropriately. Increase fan speed. Blower Fan Speed too High Check for correct fan rpm.

High

Airflow (cfm) Low Static Pressure Make sure grilles, filters, and access doors are installed. Decrease

fan speed. Blower fan motor overloads are Decrease fan speed.

One or Both Blowers tripping

Turn Off

Exhaust Only or On/Off frost Adjust frost temperature sensor set point as needed.

control sensors are tripping

Air seals too tight See Energy Recovery Wheel on page 12.

Energy Wheel

"Economizer" temperature Adjust temperature or enthalpy set points as needed.

Does NOT Turn

sensors are operating No power to wheel motor Make sure wheel drive is plugged in. Verify power is available. Wheel Drive Belt Check for loose or broken belts. Replace belts (consult factory).

Energy Wheel Runs

Wheel motor overloads are Recheck air seals, make sure they are not to tight. See Energy

Intermittently

tripping, due to rubbing Recovery Wheel on page 12. between wheel and air seals

* Always provide the unit model and serial number when requesting parts or service information. * Always check motor amps and compare to nameplate rating.

Warranty

Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the purchase date. The energy recovery wheel is warranted to be free from defects in material and workmanship for a period of five years from the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory, transportation prepaid.

Motors are warranted by the motor manufacturer for a period of one year. Should motors furnished by Greenheck prove defective during this period, they should be returned to the nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.

Due to continuing product development, Greenheck has the right to change specifications without notice

IOM ERV - FS

Rev 4 September 2000