Greenheck Fan 473501 User Manual
Part #473501
®
ERCH-HP Energy Recovery Ventilator
with Heat Pump
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 ERCH-HP
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 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 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 is 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.
Model ERCH-HP Energy Recovery Unit
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 filed
with the Traffic Department. If damaged upon arrival, file
claim with carrier. Any physical damage to the unit after
acceptance is not the responsibility of the 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. Number
and location of lifting 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.
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.
Model ERCH-HP Energy Recovery Unit
2
Table of Contents
General Safety Information ....................1
Receiving, Handling and Storage ...............2
Product Overview ............................4
Models and Capacities ........................4
Subassemblies
Coils ......................................5
Dampers ..................................5
Energy Wheel ..............................5
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Heat Pump Module ..........................6
Optional Electric Heaters ......................6
Optional Indirect Gas Furnace ..................6
Installation
Dimensional Data ............................7
Unit Weights and Recommended Roof Opening ...7
Service Clearances ..........................8
Handling, Lifting and Lifting Lugs ...............9
Roof Curb Mounting, Dimensions, Weights ......10
Ductwork Connections ......................11
Rail Mounting / Layout .......................11
Exhaust Weatherhood .......................11
Start-Up Unit ...............................12
Pre-Start-Up Checklist .......................13
Start-Up Procedure .........................13
Voltage Imbalance ..........................13
Unit Start-Up Checklist ......................14
Electrical Information
General Electrical Information .................15
Discharge Air Temp Sensor ...................16
Plumbing/Piping Overview
Condensate Drain Trap ......................16
Optional Remote Control Panel and
Wiring Schematics .........................17
Typical Control Center Components ............18
Electrical Controls
Optional Frost Control .......................19
Optional Economizer ........................20
Phase Monitor .............................20
Variable Frequency Drive .....................20
Optional Rotation Sensor .....................21
Dirty Filter Sensor ..........................21
Energy Wheel
Start-Up ..................................22
Sequence of Operation ......................22
Maintenance ...............................23
Troubleshooting ............................24
Heat Pump Overview
Heat Pump Components .....................24
Heat Pump Controls ........................25
Refrigeration Schematic ......................26
Typical Operating Conditions ..................26
Unit Protection Module Fault Indicators .........27
Troubleshooting
Controller Alarms ...........................28
Airflow ...................................29
Unit ......................................30
Refrigeration Circuit ......................31-35
Maintenance
Monthly, Semianually, Annually ................36
Heat Pump ................................36
Maintenance Procedures
Lubrication ................................36
Dampers ..................................36
Fan Belts ..............................36-37
Fan Motors ................................37
Fan Wheel and Fasteners ....................37
Fan Bearings ..............................37
Internal Filter Maintenance ...................38
External Filter Maintenance ...................38
Coil Maintenance ...........................38
Maintenance Log ............................39
Warranty ............................Backcover
Model ERCH-HP Energy Recovery Unit
3
Product Overview
Models and Capacities
This unit brings in fresh, outdoor air and removes
stale exhaust air from the building. The intake and
exhaust airstreams move through the unit in opposite
directions in separate passages, and each airstream
passes through an energy wheel. In cooling mode, the
energy wheel removes both heat and moisture from
the incoming airstream and rejects it into the exhaust
airstream. In heating mode, the energy wheel removes
heat and humidity from the exhaust air and rejects
it into the intake air, thus reclaiming energy already
expended to heat the building air.
In addition to the energy wheel, this unit incorporates
a packaged water source heat pump The heat pump
system comes from the factory fully-charged with
refrigerant and is ready for connection to a water source
upon arrival.
For purposes of providing temporary emergency heat,
an optional secondary heating source such as indirect
gas furnace or electric heaters may also be installed.
The smaller tonnage units (4-6 tons) contain a single
compressor, allowing for one stage of cooling. Larger
units (8-30 tons) come standard with two compressors
and a split airside coil. This allows for staging of
compressors to meet a wider range of outdoor air loads
while reducing the amount of cycles per compressor.
Simply put, this unit preconditions the outdoor air to
save money on heating and cooling costs and then
provides supplemental heating and cooling by means
of a highly efficient heat pump.
This unit is manufactured in four different platform sizes;
20, 45, 55 and 90. Each platform has multiple options
for heating and cooling capacities.
All 4, 5 and 6 ton capacity units have a single scroll
type compressor and all other units have two scroll type
compressors and use a split airside heat pump coil.
Heat Pump Capacity
Unit Size Tons
ERCH-HP 20 4, 5, 6
ERCH-HP 45 8, 10, 12.5, 15
ERCH-HP 55 15, 17.5, 20
ERCH-HP 90 20, 25, 30
Heat Pump
Airside Heating
and Cooling Coil
Outdoor
Air Intake
Filters
Energy Wheel
Cassette
Reheat
Coil
Heat Pump
Compressor(s)
Supply Air
Motor & Blower
Heat Pump Module
(component locations
will vary)
Coaxial
Refrigerant-to-Water
Heat Exchanger
Model ERCH-HP Energy Recovery Unit
4
Subassemblies
Coils
The airside coil is connected to the heat pump
compressor(s) and is the primary vehicle for heating
and cooling of the building. A reheat coil is optionally
available and is installed in the supply airstream
adjacent to the airside coil. The reheat coil is also
connected to the heat pump but is used only when the
unit is in cooling mode.
Heat Pump
Airside Coil
Optional Heat Pump
Reheat Coil
Dampers
There are four locations where dampers are optionally
installed.
Energy Wheel
The energy wheel rotates through both the outdoor air
and the exhaust airstreams, removing both sensible
(heat) energy and latent moisture from one airstream
and transferring it to the other airstream. The energy
wheel itself is comprised of segments which can be
removed for servicing.
Bearing Support
Adjustable
Air Seals
Label showing
cassette serial number
and date code
Drive Belt
Drive Pulley
Filters
There are three locations in the unit where filters will be
found.
Gravity Type
Exhaust Damper
Exhaust
Hood
Ooutdoor Air
Motorized Outdoor
Air Intake Damper
Hood
Filters
Wheel Cassette
Motorized Exhaust
Air Damper
Electrical Box
Exhaust Air
Filters
Coil Section
Intake
Motorized Recirculating Air
Damper
Indirect Gas Heater
Exhaust
Hood
Hood
Ooutdoor Air
Filters
Permanent Metal Filters
Two-inch thick MERV 8
pleated filters
Filters
Wheel Cassette
Coil Section
Two-inch thick MERV 8 or
MERV 13 pleated filters
Electrical Box
Exhaust Air
Intake
Indirect Gas Heater
Model ERCH-HP Energy Recovery Unit
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Heat Pump Module
Every unit has an integral heat pump module that
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 which allows the unit to run at less than full
capacity and results in fewer compressor cycles. The
heat pump is intended to be connected to an external
water source such as a water cooling tower or boiler, a
geothermal source or even a ground loop. The module
is piped to the airside coil located in the intake 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 module are located in the heat pump
module. 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 is located in the heat pump module.
Unit Protection Module
(UPM)
Optional Electric Heaters
There are two optional electric heaters available. One is
a preheater and is used to prevent frost buildup on the
energy wheel. It is located directly in front of the intake
air filter assembly. The second optional heater is used
as a supplementary emergency heat source for the
building and is integrated into the supply airstream.
Optional Electric
Preheater Location
Supply Air Motor and
Blower Assembly
Optional Electric
Heater Location
Optional Indirect Gas Furnace
An optional indirect gas furnace may be installed and
provides supplementary emergency heat to the building.
A complete Installation, Operation and Maintenance
Manual for the furnace is provided with the unit. A unitspecific wiring diagram is located inside the furnace
housing access door.
High Efficiency
Scroll Type
Compressors
Coaxial
Refrigerant-
to-Water Heat
Exchangers
Refrigerant
Reversing
Valves
Indirect Gas Furnace
Water Intake
and Discharge
Connections
Heat Pump Module
Model ERCH-HP Energy Recovery Unit
6
Installation
Dimensional Data
Overall Exterior Dimensions
Model
(including Lifting Lugs)
ERCH-HP 20 59.5 75 116
ERCH-HP 45 69.5 86 122
ERCH-HP 55 79.5 101 134
ERCH-HP 90 99.5 123 147
All dimensions shown are in inches.
Unit Weights and Recommended Roof Opening
Exhaust
Intake
Width
V
Overall Width
(with Exhaust Hood)
Overall Length
(with Outdoor Air Hood)
U
Supply
Discharge
1/2 inch
Unit Size U V
1/2 inch 1/2 inch
Approximate
Weight (pounds)
ERCH-HP 20 46 37 2150
ERCH-HP 45 54 39 3500
ERCH-HP 55 65 47 4450
ERCH-HP 90 85 49 5300
All dimensions are in inches. Unit weights assume rooftop
configuration with weatherhoods, filters, outdoor air damper,
six row DX coil, integral condensing section and an indirect
gas-fired furnace.
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.
Model ERCH-HP Energy Recovery Unit
7
Service Clearances
Minimum clearances are required 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 wheel cassette, coil 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 for these dimensions.
ERCH-HP 20
ERCH-HP 45
36 IN
WHEEL CASSETTE
ACCESS PANEL
FILTERS
ACCESS PANEL
ELECTRICAL BOX
EXHAUST AIR
INTAKE
ACCESS PANEL
ACCESS PANEL
36 IN
MINIMUM
52 IN
CLEARANCE
WITH IG HEATER
36 IN
ACCESS PANEL
EXHAUST
HOOD
ERCH-HP 55
ERCH-HP 90
HOOD
OUTDOOR AIR
FILTERS
*48 IN **64 IN
ACCESS PANEL
COIL SECTION
ACCESS PANEL
ACCESS PANEL
IG HEATER
Clearances for service and component removal on ERCH-HP 20 and ERCH-HP 45
* Clearance for energy wheel removal on ERCH-HP 20
** Clearance for energy wheel removal on ERCH-HP 45
42 IN
42 IN
ACCESS PANEL
HOOD
OUTDOOR AIR
EXHAUST
HOOD
FILTERS
ACCESS PANEL
WHEEL CASSETTE
FILTERS
COIL SECTION
ACCESS PANEL
ELECTRICAL BOX
EXHAUST AIR
INTAKE
ACCESS PANEL
ACCESS PANEL
IG HEATER
36 IN
MINIMUM
52 IN
CLEARANCE
WITH IG HEATER
Clearances for service and component removal on ERCH-HP 55 and ERCH-HP 90
Model ERCH-HP Energy Recovery Unit
8
ACCESS PANEL
ACCESS PANEL
42 IN
ACCESS PANEL
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 contains 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
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
Weights and Recommended Roof Opening 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.
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. Unit weights assume rooftop
configuration with weatherhoods, filters, outdoor air
damper, six row DX coil, integral condensing section
and an indirect gas fired furnace.
Lifting Lugs
NOTE
On some models, one lifting lug may be positioned
directly in front of the condensate drain connection.
Any lifting lug that is located as shown should be
removed in order to permit installation of the P trap
drain kit.
Model ERCH-HP Energy Recovery Unit
9
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.
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.
Install Curb: Locate curb over roof opening and
fasten in place. Reference Installation, Unit Weights
and Recommended Roof Openings 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.
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.
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.
Set the Unit
Curb Outside Dimensions and Weights
SIDE OF UNIT
A
B
C
D
E
ROOF CURB
Curb Cap Details for Factory-Supplied Roof Curbs
Curb Cap Dimensions
Unit Size A B C D E
ERCH-HP 20 2.00 2.00 1.00 0.88 0.75
ERCH-HP 45 2.00 4.25 2.00 1.31 0.50
ERCH-HP 55 2.00 4.25 2.00 1.31 0.50
ERCH-HP 90 2.00 4.25 2.00 1.31 0.50
All dimensions are in inches.
BASE
1 INCH INSULATION
Curb Outside Dimensions and Curb Weights (lbs)
Unit Size L W Weight
ERCH-HP 20 104.88 51.00 310
ERCH-HP 45 115.75 60.63 400
ERCH-HP 55 129.88 71.50 510
ERCH-HP 90 148.13 90.75 720
All dimensions are in inches. Weights are for 12 inch high
curbs. Roof curb details, including duct locations dimensions
are available on the roof curb assembly instructions.
Model ERCH-HP Energy Recovery Unit
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Tu rning
Vanes
Ductwork Connections
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Tu rning
Vanes
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.
n
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Recommended Discharge Duct Size and Length
Unit Size
Blower
ERCH-HP 20 9 14 x 14 36
ERCH-HP 45 10 20 x 20 36
ERCH-HP 55 12 20 x 20 36
ERCH-HP 90 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.
Size
Length of Straight Duct
GOOD
Duct Size
Straight Duct
Length
Rail Mounting / Layout
• Rails designed to handle the weight of the unit
should be positioned as shown on the diagram
(rails by others).
• 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.
• Rails should run the width of the unit and extend
beyond the unit a minimum of 12 inches on each
side.
• Set unit on rails.
Outdoor Air
Intake Hood
Supply/Exhaust
Opening
B A
Side view of unit on rails
Rail Mounting
Unit Size A B
ERCH-HP 20 5.0 41.0
ERCH-HP 45 7.0 41.9
ERCH-HP 55 5.5 53.0
ERCH-HP 90 6.0 59.0
All dimensions are in inches.
Isometric view of unit
Exhaust Weatherhood
The exhaust weatherhood is shipped separately as a kit
with its own instructions.
Model ERCH-HP Energy Recovery Unit
11
Start-Up Unit
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 birdscreens
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 40ºF.
• 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.
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 Date Code _________________________
Compressor 1 Model No. _________________________
Compressor 2 Model No. _________________________
Start-Up Date ___________________________________
Start-Up Personnel Name ________________________
Start-Up Company _______________________________
Phone Number ___________________________________
Model ERCH-HP Energy Recovery Unit
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