Greenheck Fan Energy Recovery Ventilator ERVe User's Manual
Contents
1. Provided with Unit Frost Control Application Operation section Setting Factory Default Yes No Frost Control set point 5 F Differential 2 F Timer Refer to IOM Yes No Frost Control Modulating Refer to IOM Economizer Application Operation section Yes No Economizer temperature Set point 65 F Offset 20 F Differential 2 F Yes No Economizer enthalpy Set point D Yes No Economizer modulating Refer to IOM Optional Accessories section Operational Yes No Wheel Rotation Sensor Yes No N A Yes No OA Dirty Filter Sensor Yes No N A Yes No EA Dirty Filter Sensor Yes No N A Yes No CO Sensor Yes No N A Yes No Service Outlet Yes No N A Yes No Vapor Tight Lights Yes No N A Yes No Remote Control Panel Yes No N A Variable Frequency Drives section Operational Yes No Blower VFDs Yes No N A Yes No Wheel VFD Yes No N A Damper section Operational Yes No Outdoor Air Damper Yes No N A Yes No Exhaust Air Damper Yes No N A EJ Model ERVe Energy Recovery Unit Unit Start Up Refer to Parts List section for component locations Fans The ERVe models contain two forward curved supply amp exhaust fans These forward curved fans should be checked for free rotation If any binding occurs check for concealed damage and foreign objects in the fan housing Be sure to check the belt drives per the start up r2. Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes EJ Model ERVe Energy Recovery Unit Maintenance Log Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes H Model ERVe Energy Recovery Unit EH Warranty Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the shipment date The energy recovery wheel is warranted to be free from defects in material and workmanship for a period of five years from the shipment 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 Gree
3. Check for broken or loose belts Tighten loose Drive pulleys Shorten wiring run to mechanical room or install a relay which will turn unit on off Consult Factory for relay information Control power 24 VAC wiring run is too long Motor starters resistance should not exceed 0 75 ohms chatter or do not pull in Incoming supply power is less than anticipated Need to increase supply power or use a special Voltage supplied to starter coil must be within control transformer which is sized for the actual 10 15 of nominal voltage stated on the coil supply power CFM too high Check cfm and adjust drives if needed Static pressures are higher or lower than If higher ductwork should be improved design If lower fan rom should be lower Blower rotation is incorrect Check rotation and reverse if necessary Motor over amps Check motor nameplate versus supplied Motor voltage incorrect voltage See specifications and catalog for fan curves to Motor horsepower too low yer od determine if horsepower is sufficient Shorted windings in motor Replace motor Unit damper not fully open Adjust damper linkage or replace damper motor Improve ductwork to eliminate losses using System static pressure too high good duct practices Check for correct drives and rpm with catalog Blower speed too low data For 3 phase see Direction of Fan Wheel Fan wheels are operating backwards Rotation under Unit Start Up sectio
4. is gained through the access panel indicated 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 Model ERVe Energy Recovery Unit EJ Unit Accessories 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 SS 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 co
5. Field wiring of a light or other alarm between terminals R amp 12 in the unit control center will notify maintenance personnel when a failure has occurred Refer to Remote Panel Wiring Schematics section for wiring details Dirty Filter Sensor Dirty filter sensors monitor pressure drop across the outdoor air filters exhaust air filters or both If the pressure drop across the filters exceeds the set point the sensor will close a set of contacts in the unit control center Field wiring of a light or other alarm to these contacts will notify maintenance personnel when filters need to be replaced The switch has not been set at the factory due to external system losses that will affect the switch This switch will need minor field adjustments after the unit has been installed with all ductwork complete The dirty filter switch is mounted in the unit control center To adjust the switch the unit must be running with all of the access doors in place The adjusting screw is located on the top of the switch Open the filter compartment and place a sheet of plastic or cardboard over 50 of the filter media Replace the filter compartment door Check to see if there is power at the alert signal leads Refer to electrical diagram Whether there is power or not turn the adjustment screw on the dirty filter gauge clockwise if you did not have power counterclockwise if you did have power until the power comes on or just before the po
6. General Electrical Information 8 Control Center Components 9 Electric Heater een ATARA 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 EE Remote Control Panel and Wiring isi de a eh ov WE Sensors Mounted by Factory 18 Sequence of Operation Start Up Unit so o o ouo wow Td Optional Accessories Tur 20 Fan TP 21 22 Energy Recovery Wheel ae tee tet es as Se ee eA Routine Maintenance Checklist General 23 Fan Belts 298 Fan Motors OPERE Fan Wheel and Fasteners bom amp of SO oe we 94 Fan Bearings 24 Filters ze oom cwm amp 24 Door Seal Maintenance za 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 zem m codem a i20 Sequence of Operation TX EET IE Troubleshooting Airflow 27 Troubleshooting Unit 28 29 Maintenance Log 30 31 Warranty Backcover H Basic Operation The ERVe brings in fresh outdoor air and removes stale exhaust air Prior to d
7. RE GREENHECK Building Value in Air 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 Listed 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 eZ V agio When servicing the unit the internal components may be hot enough to cause pain or injury Allow time for cooling before servicing e7 V aglen Precaution should be taken in explosive atmospheres IN Model ERVe Energy Recovery Unit Follow all local e
8. adjustable motor pulley on 15 HP and below preset at the factory to the customer specified RPM Fan speed can be increased or decreased by adjusting the pitch diameter of the motor pulley Multigroove variable pitch pulleys must be adjusted an equal number of turns open or closed Any increase in fan speed represents a substantial increase in load on the motor Always check the motor amperage reading and compare it to the amperage rating shown on the motor nameplate when changing fan RPM All access doors must be installed except the control center door Do not operate units with access doors open or without proper ductwork in place as the fan motors will overload Model ERVe Energy Recovery Unit Bl Vibration Excessive vibration may be experienced during initial start up Left unchecked excessive vibration can cause a multitude of problems including structural and or component failure The most common sources of vibration are listed Many of these conditions can be discovered by careful observation Refer to the Troubleshooting section of this manual for corrective actions If observation cannot locate the source of vibration a qualified technician using vibration analysis equipment should be consulted If the problem is wheel unbalance in place balancing can be done Wheel Unbalance Drive Pulley Misalignment Incorrect Belt Tension Bearing Misalignment Mechanical Looseness Faulty Belts Drive Component Unbalance Po
9. e Rails designed to handle the weight of the ERVe should be positioned as shown on the diagram rails by others e 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 e Rails should extend beyond the unit a minimum of 12 inches on each side e Set unit on rails Isometric view of ERVe on rails L J Edge a e Side view of ERVe on rails Unit Size A B 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 l6 Model ERVe Energy Recovery Unit 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 Pd dis or panel for proper component access al D ae DN Recommended Service Clearances Unit Size A B Cc 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 El
10. motor shafts for parallel and angular alignment 3 Slide sheaves on shafts Do not drive sheaves on as this may result in bearing damage 4 Align fan and motor sheaves with a straight edge or string and tighten 5 Place belts over sheaves Do not pry or force belts as this could result in damage to the cords in the belts 6 With the fan off adjust the belt tension by moving the motor base See belt tensioning procedures in the Routine Maintenance section of this manual When in operation the tight side of the belts should be in a straight line from sheave to sheave with a slight bow on the slack side ul WRONG WRONG WRONG CORRECT Direction of Fan Wheel Rotation Blower access is labeled on unit Check for proper wheel rotation by momentarily energizing the fan Rotation is determined by viewing the wheel from the drive side and should match the rotation decal affixed to the fan housing see Rotation Direction figures If the wheel is rotating the wrong way direction can be reversed by interchanging any two of the three electrical leads Check for unusual noise vibration or overheating of bearings Refer to the Troubleshooting section of this manual if a problem develops Rotation gt Airflow Forward Curved Fan RPM Supply fan and exhaust fan will have an
11. 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 6 Always test lift the unit to check for proper balance and rigging before hoisting to desired location Never lift units by weatherhoods Never lift units in windy conditions 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 O ON Unit Weights Ibs 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 au Model ERVe Energy Recovery Unit Roof Curb and Rail Mounting Recommended Roof Opening A 71 63 1 63 EXHAUST INLET SUPPLY OUTLET Uni
12. 8 All dimensions are in inches Weights are for 14 inch high GKD type curbs 8 Curb Outside Dimensions continued Unit Side 95 Unit Base Insulation Pan 4 844 Insulation not included Pd Roof Curb La d 0 775 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 sion a Recommended Discharge Duct Size and Length Model Blower Size Duct Size Straight Duct Length ERVe 20 9 14x14 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 e 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 EJ Rail Mounting Layout
13. LT on readout rating to setting in VFD Adjust accordingly Recheck air seals make sure they are not too tight See Energy Recovery Wheel under Unit Start Up Section Adjust wheel and or inlet cone Tighten wheel Fan wheel rubbing on inlet hub or bearing collars on shaft Beari Replace defective bearing s Lubricate earings bearings Tighten collars and fasteners Wheel out of balance Replace or rebalance Loose wheel on shaft Tighten wheel setscrew Loose motor or blower sheave Tighten sheave setscrew Belts too loose Adjust belt tension after 24 hours of operation poca Belts too tight Loosen to maintain a 3 8 inch deflection per Or serene gat foot of span between sheaves Motor base or blower loose Tighten mounting bolts Buildup of material on wheel Clean wheel and housing Make sure ductwork is supported properly Make sure ductwork metal thickness is sized for proper stiffness Check duct size at discharge to ensure that air velocities are not too high Energy wheel runs Wheel motor overloads are tripping due to intermittently rubbing between wheel and air seals Noise being transmitted by duct Always have a completed Pre Start Up Checklist unit Start Up Checklist and Optional Accessories Checklist prior to requesting parts or service information H Model ERVe Energy Recovery Unit E Maintenance Log
14. NTROL ECONOMIZER CONTROL LEGEND CC COMPRESSOR CONTACTOR CF CONDENSING FAN CONTACTOR CH COMPRESSOR SUMP HEATER D DAMPER DB POWER DISTRIBUTION BLOCK DL DAMPER LIMIT SWITCH DS DISCONNECT SWITCH EC ECONOMIZER CONTROLLER FCS CONDENSOR FAN CYCLE SWITCH FU FUSES FUS CONTROL TRANSFORMER FUSES NOT ON CLASS II FZ1 FREEZE PROTECTION HPS HIGH PRESSURE SWITCH MANUAL RESET LPS LOW PRESSURE SWITCH PS1 WHEEL FROST PRESSURE SWITCH PS2 SUPPLY DIRTY FILTER PRESSURE SWITCH PS3 EXHAUST DIRTY FILTER PRESSURE SWITCH ENERGY WHEEL RELAY CONTACTOR R2 OCCUPIED UNOCCUPIED RELAY EXHAUST BLOWER VFD RELAY SUPPLY BLOWER VFD RELAY R5 MODULATING WHEEL FROST CONTROL RELAY R6 ECONOMIZER RELAY R7 COMPRESSOR INTERLOCK RELAY R8 EVAP RELAY INDIRECT R9 EVAP RELAY DIRECT R10 UNIT RELAY OS1 FAN SWITCH S2 ROTATION SENSOR REED SWITCH 53 ROTATION SENSOR REED SWITCH 54 CALL FOR HEAT SWITCH S5 BYPASS SWITCH OS6 CALL FOR COOL SWITCH FIRST STAGE 57 CALL FOR COOL SWITCH SECOND STAGE ST MOTOR STARTER T1 FROST CONTROL TIMER TYPICAL SETTINGS t1 OFF 5 MIN t2 ON 30 MIN T2 ROTATION SENSOR TIMER T3 ROTATION SENSOR TIMER T4 ECONOMIZER WHEEL JOG TIMER TYPICAL SETTINGS t1 OFF 3 HRS t2 ON 10 SEC T5 EVAP DELAY OFF TIMER T6 COMPRESSOR MINIMUM OFF TIMER TYP 3 MIN T7 COMPRESSOR MINIMUM OFF TIMER TYP 3 MIN TR TRANSFORMER TS1 FROST CONTROL THERMOSTAT JUMPER HEAT CLOSES ON TEMP DECREASE TYPICAL SETTING 5 F TS2 ECONOMIZER LO
15. OAAW OA After Wheel RAI RA Exhaust Inlet Temp OAD Supply Discharge Temp EAW Exhaust After Wheel Temp Pressure Sensors analog or digital Drawing Labels Terminal Strip Labels OAF P OA Supply Filter Pressure OAW P Outdoor Air Wheel Pressure RAF P RA Exhaust Filter Pressure EW P Exhaust Wheel Pressure Amp Current Sensors analog or digital Drawing Labels OAF A Terminal Strip Labels Supply Fan Amps EF A Exhaust Fan Amps 18 Model ERVe Energy Recovery Unit Start Up 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 WARNING 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 Do not operate energy recovery ventilator without the filters and birdscreens installed They prevent the entry of foreign objects such as leaves birds etc e7 V agile Do not run unit during construction phase Damage to internal components may result and void warranty General Start Up Information 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 inform
16. Off 2 2 2 BG Frost Control y Economizer yx 7 e 9 B Rotation Sensor Y o PS2 AE No Supply Dirty Filter Exhaust Dirty Filter ri Dirty Filter Indicator power by others No Supply Dirty Filter Y Exhaust Dirty Filter Hot L1 Refer to Pressure Switch for voltage and load ratings Model ERVe Energy Recovery Unit Sensors Mounted by Factory Factory mounted temperature pressure and current sensors are available in the locations indicated on the unit diagram below A list of available sensors is shown below The specific sensors provided on a given unit are labeled in the unit control center on the terminal strip Sensors are wired to the terminal strip to make it easy for the controls contractor to connect the Building Management System for monitoring purposes idl RAF P EF A EAW RAI MEE AC 0 FILTER INSIDE EXHAUST l BLOWER W Lu a OAF P T OAI m OAAW OAF A OA d OUSTIDE FILTER OA gt INSIDE BLOWER OAD OAW P Temperature Sensors 1K Ohm RTD Drawing Labels Terminal Strip Labels OAI OA Supply Inlet Temp
17. W LIMIT THERMOSTAT JUMPER HEAT OPENS ON TEMP DECREASE TYP SETTING 20 OFFSET OR 50 F TS3 ECONOMIZER UPPER LIMIT THERMOSTAT JUMPER HEAT CLOSES ON TEMP DECREASE TYP SETTING 65 F 2 DIFF TS4 ROOM OVERRIDE SENSOR TSS INLET AIR POST HEATER LOCKOUT THERMOSTAT AFTER WHEEL CLOSES ON TEMP DECREASE TYPICAL SETTING 65 F TS6 INLET AIR COMPRESSOR LOCKOUT THERMOSTAT JUMPER HEAT OPENS ON TEMP DECREASE TYPICAL SETTING 60 F 2 DIFF FACTORY SUPPLIED AND WIRED o FIELD WIRED FIELD CONTROL WIRING RESISTANCE SHOULD NOT EXCEED 0 75 OHM IF RESISTANCE EXCEEDS 0 75 OHM THEN CONSULT FACTORY USE 14 GAUGE MINIMUM WIRE THICKNESS FOR CONTROL WIRING REPLACEMENT FUSES MUST HAVE A MINIMUM I R RATING OF 5 KA CAUTION UNIT SHALL BE GROUND IN ACCORDANCE WITH N E C POWER MUST BE OFF WHILE SERVICING USER INTERFACE CONNECTIONS USER TO VERIFY THAT TR1 CAN HANDLE THE VA LOAD OF INDICATOR DEVICES DIRTY FILTER INDICATOR SHOWN AS 24V POWER FROM UNIT Ps2 NC c NO SUPPLY DIRTY R orp dc FILTER SWITCH s ga Nes um emis nl Ps3 NC NO EXHAUST DIRTY R opm fc FILTER SWITCH S dc Ne eeu cil FROST CONTROL INDICATOR amp gt nira ROTATION INDICATOR ne Ade Model ERVe Energy Recovery Unit EH Rotation Sensor The rotation sensor monitors energy recovery wheel rotation If the wheel should stop rotating the sensor will close a set of contacts in the unit control center
18. age 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 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 105 C I8 Model ERVe Energy Recovery Unit e7 V aglen 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
19. allow for power to the lights when the unit main disconnect is off for servicing Remote Control Panel and Wiring Schematics The remote panel is a series of junction boxes ganged together and includes a stainless steel faceplate The remote panel is available with a number of different alarm lights and switches to control the unit The remote panel ships loose and requires mounting and wiring in the field The remote panel is available with the following options Unit on off switch Unit on off light 7 day time clock Hand off auto switch Time delay override Economizer light Frost control light Exhaust air dirty filter light Outdoor air dirty filter light Wheel rotation sensor light Refer to Electrical Connections section for Field Control Wiring recommendations 7 Day Timer or On Off Switch 7 Day Timer Terminal Block in Unit Control Center x 1 Unit On Off For 7 Day Timer use blue and black wires Red wires should be capped off Hand Off Auto Switch a Terminal Block in unit Control Center o On L o o Off Auto eoe Qo BMS Hand Off Auto Switch allows the unit to Off off On Manual Operation Auto Unit is controlled by BMS RTU etc NOTE RTU controllers are by others 8 Indicator Lights powered by the ER Unit o p g 2 Unit On
20. ally 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 volt
21. ams These filters should be checked per a routine maintenance schedule and replaced as necessary to ensure proper airflow through the unit See table for pleated filter size and quantity for each unit Replacement filters shall be of same performance and quality as factory installed filters Filter type must be pleated design with integral metal grid Two acceptable filter replacements are Aerostar Series 400 or Farr 30 30 EZ Model ERVe Energy Recovery Unit Filter Size and Quantities poneo Supply Exhaust Supply Exhaust emea 20x20 20x20 2 2 Femess 16x20 xz 6 6 All dimensions in inches Outdoor Air Filters Access to the outdoor air filters is through the door labeled as Filter Access on the outdoor air side of the unit Exhaust Air Filters Access to the exhaust air filters is through the door labeled as Filter Access on the exhaust air side of the unit Refer to Access Door Descriptions section for additional information on filter locations Door Seal Maintenance Slip on type seal is installed on the door Inspect at least annually to ensure that seal is still pliable and intact Energy Recovery Wheel Maintenance Annual inspection of the energy recovery wheel is recommended Units ventilating smoking lounges and other non clean air spaces should have energy recovery wheel inspections more often based upon need Inspections for smoke ventilation applications are recommended bi
22. ation 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 Number e g ERVe 20 Unit Serial Number e g 10111000 Energy Wheel Date Code e g 0450 Start Up Date Start Up Personnel Name Start Up Company Phone Number Pre Start Up Checklist check as items are completed L1 Disconnect and lock out all power switches L1 Remove any foreign objects that are located in the energy recovery unit L1 Check all fasteners set screws and locking collars on the fans bearings drives motor bases and accessories for tightness 8 L1 Rotate the fan wheels and energy recovery wheels by hand and ensure no parts are rubbing If rubbing occurs refer to Start Up section for more information O Check the fan belt drives for proper alignment and tension refer to Start Up section for more information L1 Filters can load up with dirt during building construction Replace any dirty pleated filters and clean the aluminum mesh filters in the intake hood refer to Routine Maintenance section L1 Verify that non motorized dampers
23. d dust may accumulate on the wheel causing imbalance When this occurs the wheel and housing should be cleaned to assure smooth and safe operation Inspect fan impeller and housing for fatigue corrosion or wear Routinely check all fasteners set screws and locking collars on the fan bearings drive motor base and accessories for tightness A proper maintenance program will help preserve the performance and reliability designed into the fan Bearings Most bearings are permanently lubricated and require no further lubrication under normal use Normal use being considered 20 F to 120 F and in a relatively clean environment Some bearings are re lubricatable and will need to be regreased depending on fan use Check your bearings for grease zerk fittings to find out what type of bearing you have If your fan is not being operated under normal use bearings should be checked monthly for lubrication External Filter Maintenance Aluminum mesh 2 inch deep filters are located in the supply weatherhood if the weatherhood option was purchased 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 These filters should be cleaned prior to start up Clean filters by rinsing with a mild detergent in warm water Internal Filter Maintenance The ERVe units are always provided with 2 inch pleated filters in the outdoor air and exhaust airstre
24. d frosting on the energy recovery wheel Frost control is an optional feature that will prevent control wheel frosting Three options are available 1 Timed Exhaust frost control 2 Electric preheat frost control 3 Modulating wheel frost control All of these options are provided with a thermostat with probe mounted in the outdoor air intake compartment and a pressure sensor to monitor pressure drop across the wheel Frost Threshold Temperatures Indoor RH 70 F Frost Threshold Temp 20 10 F 30 5 F 40 0 F The typical temperature setting corresponds to the indoor air relative humidity as shown in the Frost Threshold Temperatures Table and represents when frost can occur An increase in pressure drop would indicate that frost is occurring Both the pressure sensor AND the outdoor air temperature sensor must trigger in order to initiate frost control The two sensors together ensure that frost control is only initiated during a real frost condition Field wiring of a light or other alarm between 6 amp C in the control center will notify personnel when unit is in frost control mode refer to Remote Panel Wiring schematics section for wiring details The following explains the three options in more detail Timed exhaust frost control includes a timer in addition to the thermostat and wheel pressure sensor When timed exhaust frost control is initiated the timer will turn the supply blower o
25. e 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 Replace cassette into unit plug in wheel drive replace access door and apply power Observe by opening door slightly remove filters if necessary to view wheel the wheel should rotate freely at about 20 40 RPM Routine Maintenance 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 e7 0a ate Use caution when removing access panels or other unit components especially while standing ona ladder or other potentially unsteady base Access panels and unit components can be heavy and serious injury may occur Once the unit has been put into operation a routine maintenance program should be set up to preserve reliability and performance Items to be included in this program are Lubrication Apply lubrication where required Dampers Check for unobstructed operation Fan Belts Check for wear tension alignment Motors Check for cleanliness Blower Wheel amp Fasteners Check for cleanliness Check all fasteners for tightness Check for fatigue corrosion wear Bearings Check for cleanliness Check set screws for tightness Lubricate as required External Filter Check for cleanliness clean if r
26. e 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 2 Model ERVe Energy Recovery Unit 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 cominuitg or 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 Table of Contents 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
27. eave Loosen belt tension until belts can be removed by simply lifting the belts off the sheaves After replacing belts ensure that slack in each belt is on the same side of the drive Belt dressing should never be used Do not install new belts on worn sheaves If the sheaves have grooves worn in them they must be replaced before new belts are installed The proper belt setting is the lowest tension at which the belts will not slip under peak load operation For initial tensioning set the belt deflection at 1 64 inch for each inch of belt span measured half way between sheave centers For example if the belt span is 64 inches the belt deflection should be one inch using moderate thumb pressure at mid point of the drive Check belt tension two times during the first 24 hours of operation and periodically thereafter Belt Span Fan Motors Motor maintenance is generally limited to cleaning and lubrication Cleaning should be limited to exterior surfaces only Removing dust and grease buildup on the motor housing assists proper motor cooling Never wash down motor with high pressure spray Greasing of motors is only intended when fittings are provided Many fractional motors are permanently lubricated for life and require no further lubrication Deflection Belt Span 64 Model ERVe Energy Recovery Unit ES Fan Wheel amp Fasteners Wheels require very little attention when moving clean air Occasionally oil an
28. ecommendations in the following section Forward Curved Exhaust Fan CAUTION When operating conditions of the fan are to be changed speed pressure temperature etc consult Greenheck to determine if the unit can operate safely at the new conditions Fan Performance Modifications Due to job specification revisions it may be necessary to adjust or change the sheave or pulley to obtain the desired airflow at the time of installation Start up technician must check blower amperage to ensure that the amperage listed on the motor nameplate is not exceeded Amperage to be tested with access doors closed and ductwork installed Fan Belt Drives The fan belt drive components when supplied by Greenheck have been carefully selected for the unit s specific operating condition Utilizing different components than those supplied could result in unsafe operating conditions which may cause personal injury or failure of the following components Fan Shaft Bearings Motor Fan Wheel Belt Tighten all fasteners and set screws securely and realign drive pulleys after adjustment Check pulleys and belts for proper alignment to avoid unnecessary belt wear noise vibration and power loss Motor and drive shafts must be parallel and pulleys in line see diagrams in this section Belt Drive Installation 1 Remove the protective coating from the end of the fan shaft and assure that it is free of nicks and burrs 2 Check fan and
29. ectric control center Main disconnect Energy wheel cassette Exhaust air filters Exhaust air intake damper Exhaust blower and motor Outdoor air intake damper actuator Dimensional Data Exhaust Air Weatherhood Electrical Box 2 inch Filters Energy Wheel Outdoor Air Weatherhood 2 inch Filters T d OA Intake ino gt OA Intake Duct Dimensions Unit Size A B Cc D E F G H ERVe 20 11 8 18 0 12 2 10 7 15 8 18 0 10 8 25 8 ERVe 35 13 1 20 5 13 7 11 9 21 5 20 5 15 8 27 8 ERVe 45 15 8 22 5 16 1 14 0 24 5 22 5 18 8 29 1 ERVe 55 18 6 26 0 19 2 16 4 28 0 26 0 23 8 34 8 All dimensions are in inches Unit Dimensions Intake and Discharge Options Unit Size A B Cc D Unit Size Bottom Top Side End ERVe 20 67 0 50 8 46 3 17 8 ERVe 20 X ERVe 35 69 2 60 8 54 4 21 8 ERVe 35 X X ERVe 45 72 2 67 1 60 2 21 8 ERVe 45 X X ERVe 55 84 1 75 8 71 4 21 8 ERVe 55 X 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 OA Outdoor Air SA Supply Air to the space RA Return Air from the space EA Exhaust Air Model ERVe Energy Recovery Unit Electrical Information The unit must be electric
30. equired Internal Filter Check for cleanliness replace if required Door Seal Check if intact and pliable Energy Recovery Wheel Check for cleanliness clean if required Check belt for wear Check pulley bearings and motor Maintenance Procedures Lubrication Check all moving components for proper lubrication Apply lubrication where required Any components showing excessive wear should be replaced to maintain the integrity of the unit and ensure proper operation 8 Dampers Check all dampers to ensure they open and close properly and without binding Backdraft dampers can be checked by hand to determine if blades open and close freely Apply power to motorized dampers to ensure the actuator opens and closes the damper as designed Fan Belts Belts must be checked on a regular basis for wear tension alignment and dirt accumulation Premature or frequent belt failures can be caused by improper belt tension either too loose or too tight or misaligned sheaves Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result in failure of the fan and or motor bearings Conversely loose belts will cause squealing on start up excessive belt flutter slippage and overheated sheaves Both loose and tight belts can cause fan vibration When replacing belts on multiple groove drives all belts should be changed to provide uniform drive loading Do not pry belts on or off the sh
31. et back to the settings programmed at Greenheck This option is not available on the J1000 MODULATING CONTROL FOR FAN SPEED 0 10 VDC Setting aoe V1000 J1000 A1 01 Access Level 2 2 b1 17 VFD Start Up Setting 1 1 C1 01 Acceleration Time 30 sec 30 sec C1 02 Deceleration Time 30 sec 30 sec C6 02 Carrier Frequency 1 1 d2 02 Ref Lower Limit 50 50 E2 01 Motor Rated FLA p rad H3 04 Terminal A1 Bias 50 50 A1 01 Access Level 0 0 MULTI SPEED CONTROL FOR FAN SPEED 1 3 OR 1 2 SPEED REDUCTION CO SENSOR CONTROL FOR FAN SPEED 1 2 SPEED WHEN C05 DROPS BELOW 700 PPM FULL SPEED WHEN CO RISES ABOVE 800 PPM Setting Parameter V1000 J1000 A1 01 Access Level 2 2 b1 01 Reference Source Frequency 0 0 b1 17 VFD Start Up Setting 1 1 C1 01 Acceleration Time 30 sec 30 sec C1 02 Deceleration Time 30 sec 30 sec C6 02 Carrier Frequency 1 1 d1 01 Frequency Reference 1 60 Hz 30 Hz d1 02 Frequency Reference 2 30 Hz 60 Hz d2 02 Ref Lower Limit 50 50 E2 01 Motor Rated FLA pra ia H3 10 A2 Not Used F NA A1 01 Access Level 0 0 Variable Frequency Drives for Energy Recovery Wheel Optional factory installed VFD for the energy recovery wheel is programmed at the factory per the settings shown below for economizer and frost control modes The VFD provided is a Yaskawa model J1000 Refer to
32. hake the excess water from the wheel or segments Dry wheel or segments before placing them back into the cassette Place wheel or segments back into cassette by reversing removal procedures CAUTION Do not clean energy recovery wheel segments with water in excess of 140 F 60 C Do not dry energy recovery wheel segments in air in excess of 140 F 60 C The use of a pressure washer to clean segments is not recommended Damage could result Energy Recovery Wheel Belt Inspect belts each time filters are replaced Belts that look chewed up or are leaving belt dust near the motor pulley may indicate a problem with the wheel Be sure to inspect wheel for smooth and unrestricted rotation If a belt requires replacement contact the local Greenheck representative Instructions for replacement will ship with the new belt Wheel Belt amp Pulley Energy Recovery Wheel Bearing In the unlikely event that a wheel bearing fails the bearing is behind a removable plate on the wheel support beam Contact the local Greenheck representative for detailed instructions on how to replace the bearing Wheel Bearing Model ERVe Energy Recovery Unit 25 Parts List 1 Supply blower e Forward curved fan e Adjustable motor mount for belt tensioning e Adjustable sheaves for speed control Not depicted on this image 2 Vibrations isolators quantity 4 per blower e Neoprene 3 Energy recovery wheel ca
33. hould stop rotating e Turn both sensors as high as they will go The wheel should start rotating e Set the Temperature sensor at desired point for economizer operation to begin Set the Override sensor at desired point for economizer operation to end factory default is 65 F and 50 F respectively Enthalpy Sensor with Override e Turn unit power off Disconnect C7400 Solid State Enthalpy Sensor from terminal So on the enthalpy controller Also disconnect the 620 ohm resistor from a f terminal Sr on the Enthalpy enthalpy controller Sensor with Turn unit power on The Override LED on the enthalpy controller should light and the energy recovery wheel should not rotate z Turn unit power off Reconnect 620 ohm resistor to terminal Sr on the enthalpy controller Turn unit power on The LED on the enthalpy controller Enthalpy Controller IH Model ERVe Energy Recovery Unit should not light and the energy recovery wheel should energize and rotate If these steps provide the results described the enthalpy economizer is working properly e Turn unit power off Reconnect C7400 Solid State Enthalpy Sensor to terminal SO Modulating the Wheel In applications in which an internal heat gain is present in the space the rotational speed of the energy wheel may be modulated via variable frequency drive to avoid overheating the space during the winter The speed of the energy wheel will be controlled in resp
34. ischarging the exhaust air the energy recovery wheel transfers energy from the exhaust air to the outdoor air at an effectiveness of 70 8096 Simply put this unit preconditions the outdoor air to save money on heating and cooling costs Enthalpy Wheel Supply Air to Building Filters __ Outdoor Air Weatherhood Supply Outdoor Air Blower Return Air from Building Filters Exhaust Slower Exhaust Weatherhood Exhaust Air 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 EJ 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
35. l ERVe Energy Recovery Unit BR Typical Wiring Diagram Following is an example of a typical wiring diagram located in the unit control center This wiring diagram includes a legend highlighting which accessories were provided with the unit Factory wiring and field wiring are also indicated This particular example includes 1 variable frequency drives on the blowers requiring a modulating input 2 modulating energy recovery wheel with factory controls for economizer 3 energy recovery wheel rotation sensor 4 outdoor air and exhaust air dirty filter switches 5 motorized outdoor air and exhaust air intake dampers and 6 timed exhaust frost control Many other factory installed and wired accessories are available DS 5 MAIN POWER TOUNIT 9 B g croup d d 3 24 SECONDARY EXHAUST FAN MOTOR SUPPLY FAN MOTOR FC MA MC SEE BELOW FOR TERMINAL CONNECTIONS MULTI VOLTAGE PRIMARY or EXHAUST DAMPER VFD EOL EXHAUST FAN MB MC 2 7 22 sun DAMPER VFD S OL SUPPLY FAN ENERGY WHEEL ROTATION SENSOR OA SENSOR 24 VAC THERMOSTAT S TS1 O SENSOR THERMOSTAT CONTROLLER S t NO C S6 e 4 4y R o M 1 FE Pen m TO FRAND FC 620 OHM RESISTOR OR SR L ON VFD W RETURN AIR SENSOR SR 2 Cr OUTDOOR AIR so SENSOR S04 5 MIXED AIR T 2 SENSOR n 3 4 FROST CO
36. lectrical 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 All moving parts must be free to rotate without striking or rubbing any stationary objects Unit must be securely and adequately grounded 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 Do not allow the power cable to kink or come in contact with oil grease hot surfaces or chemicals Replace cord immediately if damaged Verify that the power source is compatible with the equipment Never open access doors to the unit while it is running 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 up
37. lowing test procedure for troubleshooting Testing e Jumper out the thermodisc temperature sensor and the wheel pressure sensor The heater should turn on e If it doesn t either put the outdoor air side doors on or temporarily jumper the airflow pressure switch in the preheater control center to avoid nuisance tripping of the pressure switch Also check the airflow switch pressure tap located at the supply discharge blower to ensure the tubing is connected and the tap is not blocked Remember to remove the jumpers Modulating wheel frost control includes a variable frequency drive in addition to the thermostat and pressure sensor When modulating wheel frost control is initiated the variable frequency drive will reduce the speed of the wheel Reducing the speed of the energy wheel reduces its effectiveness which keeps the exhaust air condition from reaching saturation thus eliminating condensation and frosting If the outdoor air temperature is greater than the frost threshold temperature OR the pressure differential is less than the set point the wheel will run at full speed If the outdoor air temperature is less than the frost threshold temperature AND the pressure differential is greater than the set point the wheel will run at reduced speed until the pressure differential falls below the set point The temperature and pressure differential set points are set at the factory but are field adjustable refer to VFD section fo
38. monthly to quarterly until a regular schedule can be established Accessing the Energy Recovery Wheel Disconnect power to the ERVe Open door labeled Energy Wheel Cassette Access Unplug the wheel drive motor Pull the wheel cassette halfway out Removing the Energy Recovery Wheel Segments stainless steel rim Steel retainers are located on the inside of the wheel rim Push the retainer towards the center of the wheel then lift up and away to release segments Bracket Segment Retainer Catch Segment Retainer inside of wheel rim Push toward center Important Place retainers back in the original position before rotating the energy recovery wheel otherwise damage to retainer will occur Wheel segment removed Cleaning the Energy Recovery Wheel If the wheel appears excessively dirty it should be cleaned to ensure maximum operating efficiency Only excessive buildup of foreign material needs to be removed Discoloration and staining of energy recovery wheel does not affect its performance Thoroughly spray wheel matrix with household cleaner such as Fantastik or equivalent Gently rinse with warm water and using a soft brush remove any heavier accumulation A detergent water solution can also be used Avoid aggressive organic solvents such as acetone The energy recovery wheel segments can be soaked in the above solution overnight for stubborn dirt or accumulation After cleaning is complete s
39. n Low airflow cfm H p Dirty filter or energy wheel Follow cleaning procedures in Routine Maintenance section Elbows or other obstructions may be Correct or improve ductwork obstructing fan outlet Belt slippage Adjust belt tension Blower fan speed too high Check for correct fan rpm Decrease fan speed if necessary High airflow cfm Filter s not in place Install filters Induce Ps into system ductwork Make sure grilles and access doors are installed Decrease fan speed if necessary Insufficient static pressure Ps airflow resistance Always have a completed Pre Start Up Checklist unit Start Up Checklist and Optional Accessories Checklist prior to requesting parts or service information 28 Model ERVe Energy Recovery Unit BR Troubleshooting Unit Symptom Possible Cause Corrective Action One or both blowers turn off intermittently and Exhaust Only frost control sensors are tripping back on after about 2 minutes Adjust frost temperature sensor set point as needed Air seals are too tight See Energy Recovery Wheel under Unit Start Up section i a Adjust temperature or enthalpy set points as Economizer sensors are operating needed Energy wheel does No power to wheel motor Make sure wheel drive is plugged in Verify NOT turn power is available Wheel drive belt Check for loose or broken belts Replace belts consult factory Refer to VFD section Compare motor amp VFD overload O
40. n and off to allow the warm exhaust air to defrost the energy recovery wheel Default factory settings are 5 minutes off and 30 minutes on Use the following test procedure for troubleshooting Testing refer to Timer Faceplate drawing below e Jumper the wheel pressure switch in the unit control center Set the Timer Scale for T1 and T2 to 1 minute Set 1 the Timer Settings for emer T1 and T2 to 1 0 Set the dip switch to the down position normal position zi e Turn the temperature sensor up as high as possible The supply blower should cycle on for one minute then turn off for one minute e After testing set the Timer Scale as follows T1 2 10 minutes T2 1 hour e Set the Timer Settings as follows T1 0 5 T2 0 5 The timer is now set for 5 minutes off and 30 minutes on Remember to remove the jumper Electric preheat frost control includes an electric heater at outdoor air intake an airflow pressure switch and thermodisc temperature sensor located at the preheater in addition to a pressure sensor across the energy wheel Refer to Electric Heater Application Operation for electric preheater location When electric preheat frost control is initiated the electric preheater will turn on and warm the air entering the energy wheel to avoid frosting The thermodisc temperature sensor installed has a 5 F nonadjustable set point For custom temperature set point thermodiscs please contact the factory Use the fol
41. nfiguration 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 10 Model ERVe Energy Recovery Unit Exhaust Air Damper Installation Instructions 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 Shipping Location 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 Step 4 Step 5 Step 4 Tae OlQ 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 Final Installation Optional Accessories Frost Control Application Operation Extremely cold outdoor air temperatures can cause moisture condensation an
42. nheck 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 As a result of our commitment to continuous improvement Greenheck reserves the right to change specifications without notice Greenheck Catalog Energy Recovery Ventilator Model ERVe AMCA Publication 410 96 Safety Practices for Users and provides additional information describing the equipment Installers of Industrial and Commercial Fans provides fan performance available accessories and specification additional safety information This publication can be data obtained from AMCA International Inc at www amca org B GREENHECK Building Value in Air Phone 715 359 6171 Fax 715 355 2399 E mail gfcinfo greenheck com Web site www greenheck com EH 473007 Model ERVe IOM Rev 2 April 2012 Copyright 2012 O Greenheck Fan Corp
43. ns 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 UnitSize L w LF WF Mac rua 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 69188 14
44. on 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 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 moistur
45. oning Economizer Operation Refer to Economizer Application Operation section Winter Operation Outdoor air is preconditioned temperature and moisture levels are increased by the transfer of energy from the warmer more humid exhaust air via the energy recovery wheel The preconditioned air is typically mixed with return air going back to the air handler for final conditioning Frost Control Operation Refer to Frost Control Application Operation section Other Accessories Rotation Sensor Refer to Optional Accessories section Dirty Filter Sensor Refer to Optional Accessories section CO Sensor Refer to Optional Accessories section VFD on Blowers VFDs on blowers are often used as part of a demand control ventilation system This type of system takes advantage of varying occupancy through the use of CO sensors to monitor space CO levels If CO levels are low in the space the VFD will operate the blowers at minimum airflow required by code As the space occupancy increases and CO levels increase the VFD will increase the amount of fresh outdoor air being brought in to offset the CO levels in the space exhaust airflow is increased proportionally as outdoor airflow increases As CO levels come back down the airflow will decrease back to minimum requirements Troubleshooting Airflow Test and Balance Report The Test and Balance Report TAB is utilized to determine whether the appropriate amount of
46. onse to the discharge temperature set point Sequence of Operation The variable frequency drive is fully programmed at the factory refer to VFD section for more information A call for cool must be field wired to the unit terminals provided in unit refer to wiring diagram in unit control center to allow for initiation of economizer mode When the space calls for cooling factory supplied controls will drive the following wheel operations Da2T Wheel runs at full speed AO TRA maximum energy recovery Tao lt q Wheel is stopped no energy recove Tao gt Tsa gy ry Tao lt g PA Wheel will modulate to maintain discharge temperature Tao lt Tsa 9 P Where Toa is the outdoor air temperature set point Tra is the return air temperature set point and Tsa is the supply air discharge thermostat set point Variable Frequency Drives for Energy Recovery Blowers Optional factory installed wired and programmed variable frequency drives VFDs may have been provided for modulating or multispeed control of the blowers One VFD is provided for each blower supply air and exhaust The VFD s provided are either Yaskawa model V1000 or J1000 Refer to the tables in this section for factory settings and field wiring requirements Refer to the unit control center for unit specific wiring diagram an example wiring diagram has been provided in this manual for reference When making adjustments outside of the fac
47. open and close properly O Check the tightness of all factory wiring connections O Verify control wire gauge refer to the Electrical Connections section O Verify diameter seal settings on the energy recovery wheel refer to Start Up section for more information O Install exhaust inlet motorized damper see Unit Accessories section SPECIAL TOOLS REQUIRED Voltage Meter with wire probes Amperage Meter Thermometer Tachometer Incline manometer or equivalent Start Up Checklist The unit will be in operational mode during start up Use necessary precautions to avoid injury All data must be collected while the unit is running In order to measure volts amp amps the control center door must be open and the unit energized using a crescent wrench to turn the disconnect handle Check line voltage at unit disconnect L1 L2 volts L2 L3 volts L1 L3 volts Motor Amp Draw e Supply Fan L1 amps L2 amps L3 amps e Exhaust Fan L1 amps L2 amps L3 amps e Energy Wheel L1 amps L2 amps L3 amps Fan RPM Supply Fan Exhaust Fan Correct fan rotation direction Supply Fan Yes No Exhaust Fan Yes No Model ERVe Energy Recovery Unit EE Optional Accessories Checklist Refer to the respective sections in this Installation Operation and Maintenance Manual for detailed information Refer to wiring diagram in unit control center to determine what electrical accessories were provided
48. or Inlet Outlet Conditions Foundation Stiffness Generally fan vibration and noise is transmitted to other parts of the building by the ductwork To eliminate this undesirable effect the use of heavy canvas connectors is recommended Energy Recovery Wheel The ERVe models contain a total energy recovery wheel The wheels are inspected for proper mechanical operation at the factory However during shipping and handling shifting can occur that may affect wheel operation The wheel is accessible through the access door marked Energy Wheel Cassette Access Turn the energy recovery wheels by hand to verify free operation The wheel should rotate smoothly and should not wobble Inside layout of ERVe Bearing Adjustable Support Air Seals Label showing cassette serial and date code Drive Belt Drive Pulley A Model ERVe Energy Recovery Unit Drive Belt Inspect the drive belt Make sure the belt rides smoothly through the pulley and over the wheel rim Air Seals 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 seal clearance is determined by placing a sheet of paper to act as a feeler gauge against the wheel face To access seals follow the instructions in the Energy Recovery Wheel Maintenance section To adjust the air seals loosen all eight seal retaining screws These screws are located on th
49. outdoor air and exhaust air is being supplied and removed from a building respectively There are no set rules on what information must be included in a TAB report As such if a TAB report indicates that the airflow on a unit is low prior to contacting the factory please determine the following information Unit 1 Unit 2 Unit 3 Unit 4 Model Number Serial Number Nameplate Information Voltage Hertz Phase Outdoor Air Fan Amps Exhaust Fan Amps Outdoor Air Fan Horsepower Exhaust Fan Horsepower Design Airflow Outdoor Air Exhaust Measured Airflow Outdoor Air Exhaust Measured Data Blower Rotation Outdoor Air Fan RPM Exhaust Fan RPM Outdoor Air Fan Amp Draw Exhaust Fan Amp Draw Pressure Drop Across Energy Recovery Wheel Outdoor Air Side Exhaust Side Airflow problems can often be tied back to improper ductwork installation Be sure to install ductwork in accordance with SMACNA and AMCA guidelines B Model ERVe Energy Recovery Unit Troubleshooting Unit Symptom Possible Cause Corrective Action Aem Replace fuse or reset circuit breaker and check Blown fuse or open circuit breaker amps Blower fails to Motor starter overloaded Reset starter and check amps operate Check for On Off switches Check for correct Electrical supply voltage
50. quency Drives VFDs for the blowers are factory setup to operate in one of the three following modes Modulating 0 10 VDC signal wired in the field by others varies the speed of the blower between 30 and 60Hz Multispeed Digital contact closures by others command the VFD to run at multiple speed settings e SC to S4 Drive runs at 40Hz e SC to S5 Drive runs at 30Hz CO Sensor A digital contact closure from an optional factory provided CO sensor sends the VFD to high or low speed depending on CO ppm levels at the sensor The terminal locations for Modulating option 1 and Multi speed option 2 are shown on the left Most of the set points in the VFDs are Yaskawa factory defaults However a few set points are changed at Greenheck and are shown in the tables on the next page These settings are based on the VFD mode selected To gain access to change set points on the V1000 and 41000 drives parameter A1 01 needs to be set at 2 To prevent access or tampering with drive settings on either drive change parameter A1 01 to 0 Drive Operation SC to S1 contact for On Off A1 0 10 VDC referenced to AC Can use 15 VDC from V Model ERVe Energy Recovery Unit EE Factory Set Points continued Resetting the V1000 drive to factory defaults To reset the V1000 drive back to Greenheck factory defaults go to parameter A1 01 and set it to 2 Then go to A1 03 and change it to 1110 and press enter The drive is now res
51. r more information The variable frequency drive will be fully programmed at the factory Model ERVe Energy Recovery Unit EH Economizer Application Operation The energy recovery wheel operation can be altered to take advantage of economizer operation free cooling Two modes are available 1 De energizing the wheel 2 Modulating the wheel A field supplied call for cool Y1 is required De energizing the wheel is accomplished with a signal from a Temperature or Enthalpy sensor mounted in the air intake compartment This primary sensor will de energize the energy wheel when the outdoor air temperature factory default is 65 F or enthalpy factory default is the D setting is below the field adjustable set point An Override temperature sensor is also furnished in the outdoor air intake compartment to deactivate economizer mode The Override with field adjustable set point is set at some temperature lower than the primary sensor factory default is 50 F Effectively the two sensors create a deadband where the energy recovery wheel will not operate and free cooling from outside can be brought into the building unconditioned Testing Temperature Sensor with Override e Turn both Temperature and Override thermostats down as low as they go The wheel should be rotating e Turn the Temperature sensor Temperature up as high as it goes and keep Sensor with the Override sensor as low as it Override will go The wheel s
52. ssette 4 Removable energy recovery wheel segments 5 Standard supply weatherhood with 2 inch aluminum mesh filter 6 Standard exhaust weatherhood with birdscreen Not depicted on this image 7 Standard supply and exhaust air filter racks for 2 inch pleated 30 efficient filters 8 Electrical control box standard features e Single point power e Disconnect interlocked with access door e Motor starters for the supply blower exhaust blower and energy wheel motors 24 VAC control circuit with terminal strip 9 Exhaust blower e Forward curved fan e Adjustable motor mount for belt tensioning Adjustable sheaves for speed control Not depicted on this image Eg Model ERVe Energy Recovery Unit Sequence of Operation Basic Unit The ERVe units are prewired such that when a call for outside air is made via field supplied 24 VAC control signal wired to unit control center the supply fan exhaust fan and energy wheel are energized and optional motorized dampers open The ERVe is normally slaved 24 volt to the roof top air handler When the roof top air handler starts the auxiliary contactor in the air handler closes to start the ERVe Summer Operation Outdoor air is preconditioned temperature and moisture levels are decreased by the transfer of energy from the cooler drier exhaust air via the energy recovery wheel The preconditioned air is typically mixed with return air going back to the air handler for final conditi
53. t 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 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 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 connectio
54. the VFD instruction manual that ships with the unit when making adjustments P 1 Setting rameter ina ara viooo J1000 Parameter Setting J1000 A1 01 Access Level 2 2 Al vor b1 01 Reference Source Frequency 0 0 Ce Cani E 2 2ta 2 b1 17 VFD Start Up Setting 1 1 Som EU ae eee C1 01 Acceleration Time 30 sec 30 sec ane a em a E C1 02 Deceleration Time 30 sec 30 sec RU 2 E2 01 Motor Rated FLA Motor FLA C6 02 Carrier Frequency 1 1 Must beless d1 01 Frequency Reference 1 60 Hz 60 Hz E2 03 Motor No Load Current than FLA d1 02 Frequency Reference 2 40 Hz 40 Hz H1 02 Multi Function Input 6 d1 03 Frequency Reference 3 30 Hz 30 Hz 7 Terminal S2 d1 04 Frequency Reference 4 60 Hz 60 Hz H2 01 Multi Function Output 5 d2 02 Ref Lower Limit 50 50 MA MB MC ttin E2 01 Motor Rated FLA ers prs Economizer Signal Source Hone l ug 0 10 VDC H Multi Function Input Sel 4 Module Controller H1 04 3 3 Terminal S4 Analog Frequency Reference H3 03 0 100 Multi Function Input Sel 5 Gain H1 05 4 4 Terminal S5 H3 04 Analog Frequency Reference 99 0 H1 06 Multi Function Input Sel 6 5 NA Bias Terminal S6 L1 01 Elect Thermal Overload 2 H3 10 A2 Not Used F NA L4 01 Frequency Detection Level 15 A1 01 Access Level 0 0 A1 01 Access Level 0 30 through 64 inch wheels are 40 24 Hz 74 inch wheel is 5096 30 Hz 14 Mode
55. tory set points refer to Yaskawa VFD instruction manual which can be found online at www drives com For technical support contact Yaskawa direct at 1 800 927 5292 nnn FBDOD o Foon lt gt ace n LLL O V1000 OPTION 1 0 10 VDC CONTROL USER TO PROVIDE ISOLATION AS REQUIRED 0 10 VDC CONTROL SIGNAL BY OTHERS WIRED TO A1 AND AC COMMON 0 VDC 30 Hz 10 VDC 60 Hz FOR ONE 0 10 SIGNAL WIRE TO DRIVES IN PARALLEL SEE VFD INSTALLATION MANUAL FOR MORE DETAIL FOR CONTINUOUS 60Hz OPERATION JUMPER TERMINALS A1 AND V OPTION 2 MULTI SPEED CONTROL USER TO PROVIDE CONTACTS AND ISOLATION AS REQUIRED NEITHER S4 OR S5 CONTACT CLOSED DRIVE SPEED 60 Hz S4 s5 SC LIII S4 TO SC CONTACT CLOSED BY OTHERS zi c p n DRIVE SPEED 40 Hz TT I S5 TO SC CONTACT CLOSED BY OTHERS Lt DRIVE SPEED 30 Hz SEE VFD INSTALLATION MANUAL FOR MORE DETAIL TO CHANGE THE FACTORY SET Hz CHANGE THE FOLLOWING PARAMETERS PARAMETER A1 01 CHANGE TO 2 PARAMETER d1 01 FOR NEW 60Hz SETTING PARAMETER d1 02 FOR NEW 40Hz SETTING PARAMETER d1 03 FOR NEW 30Hz SETTING PARAMETER A1 01 CHANGE TO 0 O nnn 6008 om Eo at 1 S2 S3 S4 S5 SC A1 V AC AM AC MA MB MC Q J1000 Factory Set Points Variable Fre
56. wer goes off Open the filter compartment and remove the obstructing material Replace the door and check to make sure that you do not have power at the alert signal leads The unit is now ready for operation Setscrew on front of switch must be manually adjusted after the system is in operation er Negative pressure connection is toward the front or top of the switch senses blower side of filters Positive pressure connection is toward the back or bottom of the switch senses air inlet side of filters II Model ERVe Energy Recovery Unit CO Sensor This accessory is often used to provide a modulating control signal to a variable frequency drive to raise and lower airflow in relationship to the CO levels in the space This strategy is often referred to as Demand Control Ventilation and provides further energy savings to the system Follow instructions supplied with sensor for installation and wiring details Service Outlet 120 VAC GFCI service outlet ships loose for field installation Requires separate power source so power is available when unit main disconnect is turned off for servicing Vapor Tight Lights Vapor tight lights provide light to each of the compartments in the energy recovery unit The lights are wired to a junction box mounted on the outside of the unit The switch to turn the lights on is located in the unit control center The switch requires a separate power source to
57. 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 Minimum Wire Length Wire Gauge 125 ft 18 200 ft 16 300 ft 14 450 ft 12 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 industrial style 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 Typical Control Center Components 1 NOaPron Main Disconnect non fusible lockable Motor Starter Exhaust Air Fan Motor Starter Outdoor Air Fan Motor Contactor Energy Wheel 24 VAC Control Transformer 24 VAC Terminal strip Fuses for blower motors Exploded Detail of Terminal Strip Access to Control Center Components
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