Greenheck Fan ERVe User Manual

Part #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.

Model ERVe 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 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.

Model ERVe Energy Recovery Unit

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Table of Contents

Basic Operation

Basic Operation . . . . . . . . . . . . . . 3

Installation

Supplemental Installation, Operation and

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

Installation Concerns. . . . . . . . . . . . 3

Lifting with a Crane / Forklift. . . . . . . . . 4

Roof Curb and Rail Mounting

Recommended Roof Opening . . . . . . . . 4

Roof Curb Mounting . . . . . . . . . . . . 5

Curb Dimensions and Weights . . . . . . . . 5

Ductwork Connections . . . . . . . . . . . 5

Rail Mounting / Layout . . . . . . . . . . . 6

Service Clearances . . . . . . . . . . . . 6

Access Panel Description and Location . . . 6

Dimensional Data . . . . . . . . . . . . . 7

Electrical Information

General Electrical Information . . . . . . . . 8

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

Electric Heater Application/Operation . . . . . 9

Unit Accessories. . . . . . . . . . . . . . 10

Exhaust Air Damper Installation . . . . . . . 10

Optional Accessories

Frost Control Application/Operation . . . . . 11

Economizer Application/Operation . . . . . . 12

Variable Frequency Drives and Wiring . . . . 13 -14

Typical Wiring Diagram . . . . . . . . . . . 15

Sensors and Lights . . . . . . . . . . . . 16

Remote Control Panel and Wiring . . . . . . 17

Sensors Mounted by Factory . . . . . . . . 18

Sequence of Operation
Start-Up

Unit . . . . . . . . . . . . . . . . . . . 19

Optional Accessories . . . . . . . . . . . 20

Fan . . . . . . . . . . . . . . . . . .21-22

Energy Recovery Wheel . . . . . . . . . . 22

Routine Maintenance Checklist

General . . . . . . . . . . . . . . . . . 23

Fan Belts. . . . . . . . . . . . . . . . . 23

Fan Motors . . . . . . . . . . . . . . . . 23

Fan Wheel and Fasteners . . . . . . . . . . 24

Fan Bearings . . . . . . . . . . . . . . . 24

Filters . . . . . . . . . . . . . . . . . . 24

Door Seal Maintenance . . . . . . . . . . . 24

Energy Recovery Wheel Maintenance

Accessing Energy Recovery Wheel . . . . . 25

Removing Energy Recovery Wheel Segments 25

Cleaning Wheel or Segments . . . . . . . 25

Wheel Belt . . . . . . . . . . . . . . . 25

Wheel Bearing . . . . . . . . . . . . . 25

Parts List . . . . . . . . . . . . . . . . . 26

Sequence of Operation . . . . . . . . . . . 26

Troubleshooting – Airflow. . . . . . . . . . 27

Troubleshooting – Unit . . . . . . . . . 28-29

Maintenance Log . . . . . . . . . . . 30-31

Warranty . . . . . . . . . . . . . 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

Filters

Exhaust Air

Outdoor Air Weatherhood

Outdoor Air

Exhaust Blower

Exhaust Weatherhood

Supplemental Installation,
Operation and Maintenance
Manuals

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

Part #462844 — Exhaust Weatherhood

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
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.

See Service Clearances and Access Panel Description
sections for more details.

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.

Model ERVe Energy Recovery Unit

3

Lifting with a Crane

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 and Rail Mounting

Recommended Roof Opening

A

EXHAUST

INLET

SUPPLY
OUTLET

Unit Size A B

ERVe-20 22 37

ERVe-35 25 44.5

ERVe-45 27 51.5

ERVe-55 27 60

All dimensions are in inches.

1.63

1.63

B

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.

Unit Weights (lbs.)

Unit Size Approx. Weight

ERVe-20 825

ERVe-35 1100

ERVe-45 1275

ERVe-55 1550

The weights shown are a worst case scenario based
on the sheet metal and component weights for the
unit. These weights include sheet metal weights
added together with the largest motors, blowers and
accessories for the units.

Lifting with a Forklift

Unit base rail includes fork-able lifting locations. Use
weights shown to determine forklift size requirements.

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
(25mm) 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.

Model ERVe Energy Recovery Unit

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Roof Curb Mounting

LENGTH WIDTH L INCLUDING FLANGE W INCLUDING FLANGE WEIGHT
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

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Tu rning

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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

Curb Outside Dimensions - continued

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.

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Length of Straight Duct

W

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.

GOOD

Recommended Discharge Duct Size and Length

Model Blower Size Duct Size Straight Duct Length

L

W

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

L

WF

LF

Curb Weight

(lbs.)

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.

Model ERVe Energy Recovery Unit

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Rail Mounting / Layout

D

C

B

A

D

CLEARANCE

CLEARANCE

 • RailsdesignedtohandletheweightoftheERVe

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 ERVe unit.
Avoid area dimensioned “B” below.

 • Railsshouldextendbeyondtheunitaminimum

of 12 inches on each side.

 • Setunitonrails.

Isometric view of

ERVe on rails

Service Clearances

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

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.

B

3

4

5

1

AB

2

Outdoor air filters
Frost control

1

Outdoor air sensors
Preheater and controls
Outdoor air intake damper

2

3

Supply blower and motor

Electric control center
Main disconnect

Energy wheel cassette

4

Exhaust air filters
Exhaust air intake damper

5

Exhaust blower and motor
Outdoor air intake damper actuator

Model ERVe Energy Recovery Unit

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Dimensional Data

Electrical Box

2-inch Filters

2-inch Filters

Energy Wheel

E

Outdoor Air

Weatherhood

Exhaust Air

Weatherhood

D

CLEARANCE

CLEARANCE

CLEARANCE

C

B

A

D

CLEARANCE

CLEARANCE

D A

Exhaust Air

Weatherhood

Outdoor Air

Weatherhood

2-inch Filters

2-inch Filters

Energy Wheel

Electrical Box

E

C

B

EA Discharge

RA Intake

OA Intake

OA Intake

Duct Dimensions

Unit Size A

ERVe-20 11.8

ERVe-35 13.1

ERVe-45 15.8

ERVe-55 18.6

B C D

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

All dimensions are in inches.

G

RA Intake

H

SA Discharge

D

C

SA Discharge

E

F

A

E

B

F G H

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.

B C D E

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

Model ERVe Energy Recovery Unit

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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

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).

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.

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.

Model ERVe Energy Recovery Unit

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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

5

1

6

7

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.

2 3 4

Exploded Detail

of Terminal Strip

Access to Control Center Components

is gained through the access panel indicated.

Model ERVe Energy Recovery Unit

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Unit Accessories

Shipping Image

Shipping Image

Part Removal

Step 4

Step 5

Step 4

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
Instructions

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.

(bottom return air intake

Shipping Location

Step 4

Step 5

Step 4

Part Removal

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.

Model ERVe Energy Recovery Unit

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Final Installation