Greenheck ERVe User Manual

Document 473007

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.

Model ERVe

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 Electric 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.

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 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® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40

or the equivalent.

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.

Energy Recovery Ventilator

Table of Contents

Product Overview

Product Overview . . . . . . . . . . . . . 3

Supplemental Installation, Operation and

Maintenance Manuals . . . . . . . . . . . 3

Optional Subassemblies . . . . . . . . . . 3

Installation

Dimensional Data . . . . . . . . . . . . . 4

Recommended Roof Openings & Weights . . . 5

Service Clearances . . . . . . . . . . . . 5

Access Panel Description and Location . . . . 5

Handling . . . . . . . . . . . . . . . . . 6

Lifting . . . . . . . . . . . . . . . . . . 6

Roof Curb Mounting . . . . . . . . . . . . 6

Curb Outside Dimensions and Weights . . . .6-7

Ductwork Connections . . . . . . . . . . . 7

Rail Mounting / Layout . . . . . . . . . . . 7

Outdoor Air Weatherhood . . . . . . . . . . 8

Exhaust Weatherhood . . . . . . . . . . . 8

Dampers. . . . . . . . . . . . . . . . . 8

Exhaust Air Damper Installation . . . . . . . 8

Electrical Information

General Electrical Information . . . . . . . 8-9

Control Center Components . . . . . . . . . 9

Optional Accessory Wiring Schematics . . . . 10

Unit Overview . . . . . . . . . . . . . . . 11

Optional Component Overview

Economizer . . . . . . . . . . . . . . . 11

Frost Control . . . . . . . . . . . . . . . 12

Variable Frequency Drive . . . . . . . . . . 12

Sensor . . . . . . . . . . . . . . . 12

Rotation Sensor . . . . . . . . . . . . . . 12

Dirty Filter Switch . . . . . . . . . . . . . 12

Service Outlet . . . . . . . . . . . . . . 12

Start-Up

General . . . . . . . . . . . . . . . . . 13

Pre Start-Up Checklist . . . . . . . . . . . 13

Special Tools Required . . . . . . . . . . . 13

Start-Up Checklist. . . . . . . . . . . . . 13

Optional Accessories Checklist . . . . . . . 14

Start-Up Components

Fans . . . . . . . . . . . . . . . . . . 15

Vibration . . . . . . . . . . . . . . . . . 16

Energy Recovery Wheel . . . . . . . . . . 16

Drive Belt . . . . . . . . . . . . . . . . 16

Air Seals . . . . . . . . . . . . . . . . . 16

Optional Start-Up Components

Dirty Filter Switch . . . . . . . . . . . . . 16

Economizer . . . . . . . . . . . . . . . 17

Frost Control . . . . . . . . . . . . . . . 18

Variable Frequency Drives . . . . . . . .18-20

Routine Maintenance. . . . . . . . . . .21-23

Troubleshooting

Economizer Alarms . . . . . . . . . . . . 24

Airﬂow. . . . . . . . . . . . . . . . . . 25

Unit . . . . . . . . . . . . . . . . . 25-27

Maintenance Log . . . . . . . . . Backcover

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

The ERVe 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 effectiveness of 70-80%. Simply put, this unit preconditions the outdoor air to save money on heating and cooling costs.

Enthalpy Wheel

Supply Air to Building

Supply Blower

Return Air from Building

Filters

Exhaust Air

Outdoor Air Weatherhood

Outdoor Air

Exhaust Blower

Exhaust Weatherhood

Supplemental IOMs

Refer to the following Installation, Operation and Maintenance (IOM) Manuals for additional details:

• 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.

Energy Recovery Ventilator

Installation

Dimensional Data

D A

Exhaust Air

Weatherhood

Electrical Box

RA Intake

SA Discharge

EA Discharge

OA Intake

RA Intake

SA Discharge

OA Intake

2-inch Filters

Energy Wheel

Outdoor Air

Weatherhood

2-inch Filters

Unit Dimensions

Unit Size A

ERVe-20 67.0 50.8 46.3 17.8 20.8

ERVe-35 69.2 60.8 54.4 21.8 17.8

ERVe-45 72.2 67.1 60.2 21.8 19.2

ERVe-55 84.1 75.3 71.4 21.8 23.9

All dimensions are in inches. Door handles, hinges and other protrusions are not included in the dimensions above. Dimensions are rounded up to the nearest .1 inch.

BCDE

Duct Dimensions

Unit Size A

ERVe-20 11.8

ERVe-35 13.1

ERVe-45 15.8

ERVe-55 18.6

BCD

18.0 12.2 10.7 15.8 18.0 10.8 25.8

20.5 13.7 11.9 21.5 20.5 15.8 27.8

22.5 16.1 14.0 24.5 22.5 18.8 29.1

26.0 19.2 16.4 28.0 26.0 23.8 34.8

FGH

All dimensions are in inches.

Intake and Discharge Options

Unit Size Bottom

Top Side End

ERVe-20 X

ERVe-35 X X

ERVe-45 X X

ERVe-55 X

OA - Outdoor Air SA - Supply Air (to the space) RA - Return Air (from the space) EA - Exhaust Air

Energy Recovery Ventilator

Recommended Roof Opening & Weights

CLEARANCE

Service Clearances

1.63

Approx.

Weight (lbs.)

EXHAUST

INLET

SUPPLY OUTLET

Unit Size A B

ERVe-20 22 37 825

ERVe-35 25 44.5 1100

ERVe-45 27 51.5 1275

ERVe-55 27 60 1550

All dimensions are in inches. These weights include sheet metal weights added together with the largest motors, blowers and accessories for the units.

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.

ERVe 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.

Recommended Service Clearances

Unit Size A B C D

ERVe-20 24 24 42 35

ERVe-35 32 24 48 43

ERVe-45 32 24 54 43

ERVe-55 32 24 60 44

All dimensions are in inches.

Access Panel Description and Location

Outdoor air filters Frost control

Outdoor air sensors Preheater and controls Outdoor air intake damper

Supply blower and motor

Electric control center Main disconnect

Energy wheel cassette

Exhaust air filters Exhaust air intake damper

Exhaust blower and motor Outdoor air intake damper actuator

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.

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 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 corner lifting points provided on base structure.

4. Rigger to use suitable mating hardware to attach to unit corner lifting points.

5. Spreader bar(s) must span the unit to prevent damage to the cabinet by the lift cables.

Roof Curb Mounting

Roof curb details including duct location dimensions, are available on Roof Curb Assembly Instructions, Part Number 472119.

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 GKD. 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. Install Insulation: One-inch deep insulation pans were provided with the curb assembly. Install insulation prior to setting the unit. Insulation is not included from the factory.

5. 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

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.

Energy Recovery Ventilator

Unit Size L W LF WF

ERVe-20 61.125 40.375 64.875 44.125 93

ERVe-35 63.375 48.5 67.125 52.25 106

ERVe-45 67.375 55.5 71.125 59.25 120

ERVe-55 78.25 65.5 82 69.188 148

All dimensions are in inches. Weights are for 14-inch high GKD type curbs.

Curb Weight

(lbs.)

Curb Outside Dimensions - continued

POOR

Unit Side

1.895

4.844

Roof Curb

1.549

0.775

Unit Base

Insulation Pan

(Insulation not included)

Curb Cap Details for Factory Supplied Roof Curbs

Ductwork Connections

Examples of poor and good fan-to-duct connections are shown below. 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.

Rail Mounting / Layout

1. Rails designed to handle the weight of the ERVe 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 ERVe unit. Avoid area dimensioned “B” below.

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

4. Set unit on rails.

Isometric view of

ERVe on rails

Length of Straight Duct

GOOD

Recommended Discharge Duct Size and Length

Model Blower Size Duct Size Straight Duct Length

ERVe-20 9 14 x 14 36

ERVe-35 10 20 x 20 36

ERVe-45 12 20 x 20 36

ERVe-55 15 28 x 28 60

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.

Side view of

ERVe on rails

Unit Size A

ERVe-20 5.75 18

ERVe-35 5.75 20.5

ERVe-45 6 22.5

ERVe-55 6 26

All dimensions are in inches.

Energy Recovery Ventilator

Outdoor Air Weatherhood

Outdoor air weatherhood will be factory mounted.

Exhaust Weatherhood

The exhaust weatherhood is shipped separately as a kit with its own instructions.

Dampers

Backdraft dampers are always included as an integral part of the exhaust hood assemblies. Motorized outdoor air and exhaust air dampers are optional. Outdoor air dampers are factory mounted and wired at the intake. Exhaust air dampers, depending on the unit configuration, may require final installation. If your unit is configured as return air intake on the end of the unit, the exhaust air damper is factory installed and wired. If your unit is configured with the return air intake location on the bottom, final installation is required per the instructions provided.

Exhaust Air Damper Installation

(Bottom return air intake conﬁguration only)

1. Open the exhaust air filter and wheel access door.

2. Remove exhaust air filters and possibly the energy wheel for more working area inside the unit.

3. Remove the two screws holding the damper in place as shown (save screws for step 7).

4. Bend the brackets holding the damper out and away from the damper as shown in the Part Removal drawing. Use caution while executing this step, as the damper is heavy. Guide it into place gently and avoid dropping it, as damage may occur.

5. Once the damper is positioned as shown in the Part Removal drawing, remove the four (4) screws holding the shipping brackets in place.

6. Remove the shipping brackets and discard.

7. Insert screws removed in step 3 through the damper flange in the same location they were removed from.

Shipping Location

Step 4

Step 5

Step 4

Part Removal

Final Installation

Electrical Information

The unit must be electrically grounded in accordance with the current National Electrical Code, ANSI/NFPA

70. In Canada, use current CSA Standard C22.1, Canadian Electrical Code, Part 1. In addition, the installer should be aware of any local ordinances or electrical company requirements that might apply. System power wiring must be properly fused and conform to the local and national electrical codes. System power wiring is to the unit main disconnect (door interlocking disconnect switch standard on most units) or distribution block and must be compatible with the ratings on the nameplate: supply power voltage, phase, and amperage (Minimum Circuit Amps - MCA, Maximum Overcurrent Protection

- MOP). All wiring beyond this point has been done by the manufacturer and cannot be modified without affecting the unit’s agency / safety certification.

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.

If power supply is desired through bottom of unit, run the wiring through the curb, cut a hole in the cabinet bottom, and wire to the disconnect switch. Seal penetration in cabinet bottom to prevent leakage.

The electric supply to the unit must meet stringent requirements for the system to operate properly. Voltage supply and voltage imbalance between phases should be within the following tolerances. If the power is not within these voltage tolerances, contact the power company prior to operating the system.

Voltage Supply: See voltage use range on the rating plate. Measure and record each supply leg voltage at all line disconnect switches. Readings must fall within the allowable range on the rating plate.

Voltage Imbalance: In a 3-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

Energy Recovery Ventilator

CAUTION

If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105ºC.

CAUTION

High voltage wiring is run in the top roof panel(s) of this unit. Do not install sensors or other devices through the top panel(s).

Typical Control Center Components

1. Main Disconnect (non-fusible, lockable)

2. Motor Starter – Exhaust Air Fan

3. Motor Starter – Outdoor Air Fan

4. Motor Contactor – Energy Wheel

5. 24 VAC Control Transformer

6. 24 VAC Terminal strip

7. Fuses for blower motors

WARNING

To prevent injury or death due to electrocution or contact with moving parts, lock disconnect switch open.

Most factory supplied electrical components are prewired. To determine what electrical accessories require additional field wiring, refer to the unit specific wiring diagram located on the inside of the unit control center access door. The low voltage control circuit is 24 VAC and control wiring should not exceed

0.75ohms.

Refer to Field Control Wiring Length/Gauge table for wire length maximums for a given wire gauge.

Field Control Wiring Length/Gauge

Total

Wire Length

125 ft. 18 200 ft. 16 300 ft. 14 450 ft. 12

Minimum

Wire Gauge

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.

If wire resistance exceeds 0.75 ohms, an industrialstyle, plug-in 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 (refer to Typical Control Center Components). 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.

2 3 4

Exploded Detail

of Terminal Strip

Energy Recovery Ventilator

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