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Greenheck Fan 455924 ERV-581 User's Manual

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Contents

1. EW P RAF P EF A EAW RAI aert A Q Q ERER p EXHAUST BLOWER OAF P OAI OAAW OAF A ENERGY WHEEL SUPPLY BLOWER OA 2 Bee l Q J I gt me OAD OAW P Temperature Sensors 1K Ohm RTD Drawing Labels Terminal Strip Labels OAI OA Supply Inlet Temp 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 Terminal Strip Labels OAF A Supply Fan Amps EF A Exhaust Fan Amps H Model ERV Energy Recovery Unit BI 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 b
2. 125 0 750 ERV 361 1 75 2 00 1 00 1 200 0 875 ERV 521 1 75 2 00 1 00 0 813 0 875 ERV 581 1 75 2 00 1 00 0 813 0 750 ERV 522 1 813 4 00 1 75 1 000 0 750 ERV 582 1 938 4 125 1 938 1 125 0 625 All dimensions are in inches Ductwork Connections Examples of poor and good fan to duct connections are shown 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 Recommended Discharge Duct Size and Length Model Blower Size Duct Size Straight Duct Length ERV 251 10 9x9 36 ERV 361 10 14x14 36 ERV 521 12 20 x 20 36 ERV 581 15 28 x 28 60 ERV 522S 15 28 x 28 60 ERV 522H 18 32 x 32 60 ERV 582 20 34 x 34 72 Unit Size L w Curb Weight Ibs ERV 251 42 5 30 5 60 ERV 361 58 5 47 5 115 ERV 521 63 5 63 5 160 ERV 581 71 8 66 185 ERV 522 120 5 80 5 520 ERV 582 142 25 93 700 All dimensions are in inches Weights are for 12 inch high GPI type curbs H 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 si
3. 26 unit will line up with ERV 521 58 35 the corresponding ERV 581 60 30 ductwork Be sure ERV 522 62 36 to allow for the recommended service ERV 582 ay 38 clearances when All dimensions are in inches 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 IH Roof Curb Mounting Roof curb details including duct location dimensions are available on ERV 522 amp 582 Roof Curb Assembly Instructions Part 460988 Rooftop units require curbs to be mounted first The duct connections must be located so they will be clear of structural members of the
4. RE GREENHECK Building Value in Air Part 455924 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 Models ERV 251 ERV 361 ERV 521 ERV 581 ERV 522 ERV 582 Liste 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 Model ERV Energy Reco
5. access panel indicated ERV 522 ERV 582 i Exhaust Hood Hood 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 2 stage step control Step control heaters are designed with multiple stages made up of equal increments of heating capability For example a 10 kW heater with two stages will be composed of two 5 kW stages Preheaters are single point wired at the factory A temperature sensor with field adjustable 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 first stage of the preheater will turn on If the first stage does not satisfy the set point the second stage will also turn on Electric Preheater The preheater is single point wired to the unit control center Access to the preheater control panel is through the outdoor air filter door Unit Accessories Outdoor Air Weatherhood Outdoor air weatherhood will be 2R factory mounted Kn Exhaust Weatherhood The exhaust wea
6. accordance with SMACNA and AMCA guidelines E Model ERV Energy Recovery Unit A Troubleshooting Unit Symptom Possible Cause Corrective Action Blower fails to operate Motor starters chatter or do not pull in Motor over amps Low airflow cfm High airflow cfm s Replace fuse or reset circuit breaker and check Blown fuse or open circuit breaker amps Motor starter overloaded Reset starter and check amps Check for On Off switches Check for correct Electrical supply voltage 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 resistance should not exceed 0 75 ohms 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 rpm should be lower Blower rotation is incorrect Check rotation and reverse if necessary Motor voltage incorrect Check motor nameplate versus supplied voltage Miotorhorsesower tas low See specifications and catalog for fan curves
7. 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 Model ERV Energy Recovery Unit EJ Troubleshooting Airflow Test and Balance Report The Test and Balance Report TAB is utilized to determine whether the appropriate amount of 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 Air Side Airflow problems can often be tied back to improper ductwork installation Be sure to install ductwork in
8. and the collars in both bearings On the pulley side of the cassette remove the four 4 fasteners that hold the bearing support channel in place Once the bearing support is removed the wheel can be pulled from the cassette To replace the wheel reverse this procedure Removing the Energy Recovery Wheel Segments ERV 361 521 581 522 and 582 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 Lift away from segment Catch Segment Retainer m 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 ove
9. building 1 Factory Supplied Roof Curbs Roof curbs are Model GPI or GPNS for the ERV 251 361 521 581 The GPI or GPNS ships assembled and includes a duct adapter Roof curbs are Model GKD for the ERV 522 and 582 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 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 L ERV 522 and 582 ERV 251 361 521 and 581 Curb Outside Dimensions continued P di Base Side of Unit A 1 inch Insulation m l SC 1 Roof Curb Curb Cap Details for Factory Supplied Roof Curbs Unit Size A B C D E ERV 251 1 75 2 00 1 00 1
10. 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 allow for power to the lights when the unit main disconnect is off for servicing Model ERV Energy Recovery Unit EE Remote Control Panel and Wiring Schematics 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 e 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 Un
11. 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 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 ERV Energy Recovery Unit 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
12. remove the jumper Electric preheat frost control includes an electric heater at outdoor air intake and an airflow pressure switch located at the preheater in addition to the thermostat and pressure sensor on 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 Use the following test procedure for troubleshooting Testing Turn the thermostat as high as it will go and jumper 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 t
13. 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 IH Factory Set Points continued CO SENSOR CONTROL FOR FAN SPEED Resetting the drive to factory defaults 1 2 SPEED WHEN C05 DROPS BELOW 700 PPM To reset the drive back to Greenheck factory defaults go to parameter A1 01 and set it to 2 Then go to Parameter Setting A1 03 and change it to 1110 and press enter The Po 1000 J1000 drive is now reset back to the settings programmed at A1 01 Access Level 2 2 Greenheck b1 01 Reference Source Frequency 0 0 b1 17 VFD Start Up Setting 1 1 MODULATING CONTROL FOR FAN SPEED C1 01 Acceleration Time 30 sec 30 sec 0 10 VDC C1 02 Deceleration Time 30 sec 30 sec Setting C6 02 Carrier Frequency 1 1 Parameter V1000 J1000 d1 01 Frequency Reference 1 60 Hz 30 Hz A1 01 Access Level 2 2 di 02 Frequency Reference 2 30 Hz 60 Hz b1 17 VFD Start Up Setting 1 1 d2 02 Ref Lower Limit 50 50 C1 01 Acceleration Time 30 sec 30 sec E2 01 Motor Rated FLA ane rs C1 02 Deceleration Time 30 sec 30 sec C6 02 Carrier Frequency 1 1 ne A2 Not Used E NA d2 02 Ref Lower Limit 5096 50 BM BUE 2 E2 01 Motor R
14. 22 shown with intake weatherhood exhaust weatherhood outdoor air filters and exhaust air filters 1 Supply blower e Forward curved fan e Adjustable motor mount for belt tensioning e Adjustable sheaves for speed control 2 Vibrations isolators quantity 4 per blower e Neoprene 3 Energy recovery wheel cassette e one wheel on models ERV 251 361 521 amp 581 e two wheels on models ERV 522 A 582 4 Removable energy recovery wheel segments 5 Optional supply weatherhood with 2 inch aluminum mesh filter EJ Model ERV Energy Recovery Unit Optional exhaust weatherhood with birdscreen Optional supply and exhaust air filter racks for 2 inch pleated 30 efficient filters Electrical control box standard features Single point power e Disconnect interlocked with access door e Motor starters for the supply blower exhaust blower and energy wheel motors e 24 VAC control circuit with terminal strip Exhaust blower Forward curved fan Adjustable motor mount for belt tensioning Adjustable sheaves for speed control Sequence of Operation Basic Unit The ERV 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 ERV is normally slaved 24 volt to the roof top air handler When the roof top air handler starts the auxiliary conta
15. EE VFD INSTALLATION MANUAL FOR MORE DETAIL TO CHANGE THE FACTORY SET Hz CHANGE THE FOLLOWING PARAMETERS PARAMETER n01 CHANGE TO 1 PARAMETER n21 FOR NEW 60Hz SETTING PARAMETER n22 FOR NEW 40Hz SETTING PARAMETER n23 FOR NEW 30Hz SETTING PARAMETER n01 CHANGE TO 0 16 Model ERV Energy Recovery Unit Sils2 s3 s4 ss sc A1 v ACIAMIAC MA MB MC J1000 Factory Set Points Variable Frequency 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 Multi speed 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 J1000 drives parameter A1 01 needs to be set at 2 To prevent access or tampering
16. F 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 LOW 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 oro O FILTER SWITCH N gi ae a
17. Input Sel 6 Analog Frequency Reference H1 06 Ge Ue 5 NA H3 04 9 Bias 99 0 H3 10 A2 Not Used F NA L1 01 Elect Thermal Overload 2 A1 01 Access Level 0 0 L4 01 Frequency Detection Level 20 A1 01 Access Level 0 36 inch wheel is 66 40 Hz All other wheels are 100 60 Hz B Model ERV Energy Recovery Unit 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 Di 3 MAIN POWER m TOUNIT dim PS croup Y o 24 SECONDARY L H S1 SC FR FC B HA 3 EXHAUST FAN U R MOTOR 13 0 10 VDC rf SC FR a 4 SUPPLYFAN MOTOR FC MA MC SEE BELOW FOR TERMINAL CONNECTIONS MULTI VOLTAGE PRIMARY EXHAUST DAMPER VFD E O L MB MC 2 7 u DAMPER VFD S O L EXHAUST FAN SUPPLY FAN ENERGY WHEEL ROTATION SENSOR
18. L2 amps L3 amps 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 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 Provided with Unit Frost Control Application Operation section Setting Factory Detault 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 Exh
19. OA SENSOR 24 VAC THERMOSTAT S TS1 O SENSOR COM THERMOSTAT CONTROLLER S NO C S6 4 ml mo m 1 8 sag m TO FRAND FC 620 OHM RESISTOR OR SR L ON VFD W RETURN AIR SENSOR SR S CD OUTDOOR AIR so SENSOR SO 5 MIXED AIR T 2 SENSOR n 3 4 EE Model ERV Energy Recovery Unit FROST CONTROL 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 RI ENERGY WHEEL RELAY CONTACTOR R2 OCCUPIED UNOCCUPIED RELAY R3 EXHAUST BLOWER VFD RELAY R4 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 9S1 FAN SWITCH S2 ROTATION SENSOR REED SWITCH S3 ROTATION SENSOR REED SWITCH S4 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 OF
20. PS3 NC c NO EXHAUST DIRTY O opm IH sc FILTER SWITCH N I 4c x em FROST CONTROL INDICATOR ae gt le nk dc ROTATION INDICATOR 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 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 exhaust inlet compartment next to the unit control center or in unit control center To adjust the switch the unit must be running with all of the access doors in place except for the compartment where the switch is located exhaus
21. amper Energy wheel cassette Internal filters Frost control Outdoor air sensor 3 Preheater controls Outdoor air intake damper Model ERV Energy Recovery Unit EE Dimensional Data ERV 251 361 521 and 581 2 Exterior Dimensions nm Unit Opening Dimensions Unit Size Unit Size A B C D E F G K L Q P ERV 251 46 34 27 12 8 ERV 251 10 16 6 7 10 16 ERV 361 62 51 34 18 15 ERV 361 18 18 8 11 19 18 ERV 521 67 67 44 16 15 ERV 521 24 24 10 13 26 26 ERV 581 75 70 67 16 22 ERV 581 22 27 16 18 28 48 All dimensions are in inches All dimensions are in inches Outdoor Air Discharge Outdoor Air Discharge LxK LxK Exhaust Air Inlet FxG Outdoor Air Inlet 7l Lh 4 D A C a Exhaust Air Inlet FxG i Exhaust Air Discharge Exhaust Hood Intake Hood LxK Arrangement A Arrangement B Outdoor Air Discharge Pus S Outdoor Air Discharge LxK Exhaust Air Inlet FxG Exhaust Air Inlet FxG Intake Hood b Arrangement C Arrangement D Intake Hood Exhaust Hood Exhaust Hood IH Model ERV Energy Recovery Unit ERV 522 and 582 ne Exterior Dimensions Su Unit Opening Dimensions Unit Size Unit Size A B C D E F G K L Q P ERV 522S 124 84 64 16 19 ERV 522S 48 25 16 18 60 25 ERV 522H 124 84 64 16 19 ERV 522H 48 25 19 22 60 25 ERV 582H 146 97 77 17 26 ERV 582H 60 28 23 25 70 30 All dime
22. 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 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 inspectio
23. ated FLA GEN Variable Frequency Drives for Energy H3 04 Terminal A1 Bias 50 50 Recovery Wheel A1 01 Access Level 0 0 Optional factory installed VFD for the energy recovery wheel is programmed at the factory per the settings O shown below for economizer and frost control modes MULTI SPEED CONTROL FOR FAN SPEED The VFD provided is a Yaskawa model J1000 Refer 1 3 OR 1 2 SPEED REDUCTION to the VFD instruction manual that ships with the unit Setting when making adjustments Parameter KE Parameter Setting J1000 ln DEED Level JA p 2 A1 01 Access Level 2 b1 01 Reference Source Frequency 0 0 b1 17 VFD Auto Start 1 Bist MPH StartUp Setting C6 02 Carrier Frequency 2 C1 01 Acceleration Time 30 sec 30 sec d2 01 Ref Upper Limit 100 or 66 C1 02 Deceleration Time 30 sec 30 sec d2 02 Ref Lower Limit 5 ER Carer E xu E2 01 Motor Rated FLA Motor FLA requency Reference z z di 02 Frequency Reference 2 40 Hz 40 Hz E2 03 Motor No Load Current EES E PS d1 03 Frequency Reference 3 30 Hz 30 Hz H1 02 Multi Function Input 6 d1 04 Frequency Reference 4 60 Hz 60 Hz Terminal S2 d2 02 Ref Lower Limit 50 50 H2 01 Multi Function Output 5 Motor Motor MA MB MC E2 01 Motor Rated FLA FLA FLA E si is Setting Multi Function Input Sel 4 E une Qa EE Honeywell Carel H1 04 Terminal S4 3 S 0 10 VDG Module Controller Multi Function Input Sel 5 Analog Frequency Reference guai Terminal 5 1 Heras Gain bs Multi Function
24. aust Air Damper Yes No N A Model ERV Energy Recovery Unit ES Unit Start Up Refer to Parts List section for component locations Fans The ERV models contain two forward curved supply amp e exhaust fans These forward curved fans should be checked for free rotation If any binding j occurs check for concealed damage and foreign objects in the fan housing Be sure to Forward Curved check the belt drives per the Exhaust Fan start up recommendations in the following section 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 e Fan Shaft e Bearings e Motor e Fan Wheel Belt Tight
25. band 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 should stop rotating 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 cam y E 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 e 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 H should not light and the energy recovery wheel should energize and rotate If these steps provide the results described th
26. ctor in the air handler closes to start the ERV 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 conditioning 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 Variable Frequency Drive 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
27. d by all lifting lugs provided on base structure 4 Rigger to use suitable mating hardware to attach to unit lifting lugs 5 Spreader bar s must span the unit to prevent damage to the cabinet by the lift cables 6 Always test lift the unit to check for proper balance and rigging before hoisting to desired location 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 has been applied to the curb prior to lifting the unit and setting on curb 11 Do not use fork lifts for handling unit Oo ON Unit Weights Unit Size Approx Weight Ibs ERV 251 340 ERV 361 860 ERV 521 1290 ERV 581 1470 ERV 522 3230 ERV 582 3700 Weight assumes outdoor unit with filters weatherhoods and outdoor air intake damper au Model ERV Energy Recovery Unit Recommended Roof Opening PO 11 EXHAUST INTAKE d x os SUPPLY DISCHARGE PAS D s El 1 i 0 50 0 50 H ERV 251 361 521 and 581 U EXHAUST INLET ER v af 250 ag ERV 522 and 582 Position the unit roof opening such that the Unit Size V supply discharge and ERV 251 26 5 20 exhaust inlet of the ERV 361 43
28. e 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 response 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 rt Wheel runs at full speed AO RA maximum energy recovery Tao lt Mu 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 Model ERV Energy Recovery Unit EH Variable Frequency Drives for Energy Recovery Blowers Optional factory installed wired and programmed variable frequency drives VFDs may have b
29. e 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 CAUTION 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 information recorded Starting up the unit in accordance with this checklist will not only ensure proper operation but will also provide valuable information to personnel performing future maintenance Should an issue arise which requires factory assistance this completed document will allow unit experts to provide quicker resolve Qualified personnel should perform start up to ensure safe and proper practices are followed Unit Model Number e g ERV 361 Unit Serial Number e g 04099999 or 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 O Disconnect and lock out all power switches O Remove any foreign objects that are located in the energy recovery unit O Check all fasteners set screws and locking collars on the fans bearings drives motor bases and accessories for t
30. e operation The wheel should rotate TENET Label rive Be showing smoothly and cassetta should not serial wobble and date Drive Pulley EN code H 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 enter the unit for the ERV 581 and 582 or pull out the cassette for the ERV 251 361 521 and 522 following 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 the bearing support that spans the length of the cassette through the wheel center Tighten the screws so the air seals tug slightly on the sheet of paper 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 50 60 RPM Model ERV Energy Recovery Unit E 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 multipl
31. e power supplies CAUTION Use caution when removing access panels or other unit components especially while standing on a ladder or other potentially unsteady base Access panels and unit components can be heavy and serious injury may occur 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 required 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 Eg Model ERV Energy Recovery Unit Dampers Check all dampers to ensure they open and close properly and without bi
32. een provided for modulating or multi speed 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 factory 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 P1 P2 PC A1 A2 f 1 S2 S3 S4 S5 S6 S7 HC SC H1 RP MA MB MC fo 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 LLL S4 TO SC CONTACT CLOSED BY OTHERS tt DRIVE SPEED 40 Hz T T I S5 TO SC CONTACT CLOSED BY OTHERS I 2b n DRIVE SPEED 30 Hz S
33. egral metal grid Two acceptable filter replacements are Aerostar Series 400 or Farr 30 30 Filter Size and Quantities aud Loue Sere net ERV 251 16 x 25 1 1 ERV 361 16 x 20 2 2 ERV 521 16 x 25 3 3 ERV 581 16 x 20 6 6 ERV 522 16 x 25 7 7 ERV 582 20 x 25 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 ERV 251 361 521 and 581 Closed cell foam tape is installed on the perimeter of the door Inspect at least annually to ensure that the seal is still intact ERV 522 amp 582 Slip on type vinyl seal is installed on the perimeter of the door openings 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 bimonthly to quarterly until a regular schedule can be established Accessing the Ene
34. en 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 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 EZ Model ERV Energy Recovery Unit 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 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 viewi
35. exhaust air the energy recovery wheel transfers energy from the exhaust air to the outdoor air at an efficiency of 70 80 Simply put this unit preconditions the outdoor air to save money on heating and cooling costs Exhaust air from building Energy Recovery Exhaust air Wheel discharged outside Outdoor air Preconditioned air sent to space Supplemental Installation Operation and Maintenance Manuals Refer to the following Installation Operation and Maintenance Manuals for additional details Part 460988 ERV 522 and ERV 582 Curbs Part 462844 ERV 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 ERV Energy Recovery Unit E Lifting 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 lifte
36. hreshold 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 for more information The variable frequency drive will be fully programmed at the factory 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 dead
37. ightness Model ERV Energy Recovery Unit 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 open and close properly L 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 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
38. it On Off For 7 Day Timer use blue and black wires Red wires should be capped off Hand Off Auto Switch Terminal Block in unit On Control Center L o o Off Auto 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 EJ Model ERV Energy Recovery Unit Indicator Lights powered by the ER Unit o 32 RS E Unit On Off t 2 Be Frost Control Yx He Economizer mA B Rotation Sensor n o PS2 o c No Supply Dirty Filter PS3 Nc c No Exhaust Dirty Filter Dirty Filter Indicator power by others No Supply Dirty Filter Yr Exhaust Dirty Filter Hot L1 Refer to Pressure Switch for voltage and load ratings 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
39. latively 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 To access these filters remove bottom bolt in the access door on the side of the weatherhood Slide the access door up and then pull bottom out to remove door Then slide the filters out see picture at right Clean filters by rinsing with a mild detergent in warm water Outdoor air intake hood mesh filter access Internal Filter Maintenance The ERV units will typically be provided with 2 inch pleated filters in the outdoor air and exhaust airstreams 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 int
40. 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 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 Boro um ct S OK 9 d e D m 2 d Exploded Detail of Terminal Strip ERV 251 361 521 581 Access to Control Center Components is gained through the
41. m routine maintenance such as filter replacement energy wheel cassette inspection and fan belt adjustment Blower and motor assemblies energy recovery wheel cassette and filter sections are always provided with a service door or panel for proper component access Clearances for component removal may be greater than the service clearances refer to drawings below for these dimensions ERV 251 ERV 361 ERV 521 ERV 581 ERV 522 ERV 582 sjoueg sseoov Exhaust Side Outdoor Air Side 1 si Cassette slides out ee ERA Access Panels Jeueg ss o5y XN EN S Es Access Panel ERV 251 361 and 521 only Arrangement A Jeueg sseooy Exhaust Hood Exhaust Side Outdoor Air Side R Cassette slides out Joueg sseoov M NS Access Panel Access Panels f Intake Hood x Access Panel LN Vy ERV 251 361 and 521 only yy Arrangement B C or D Wf f X zc Gy Recommended Service Clearances i Unit Size R s T x E ERV 251 32 30 30 E 44 oe ERY 961 30 for maintenance 2m 3p RER 60 ERES 39 for maintenance n 40 Ka 65 ERV 581 32 for maintenance 40 a0 Arrangement B C or D ERV 522 38 ERV 582 42 All dimensions are in inches Model ERV Energy Recovery Unit Electrical Infor
42. mation 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
43. n 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 2 Model ERV 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 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 Table of Contents Basic Operation 3 Installation Supplemental Installation Operation and Maintenance Manuals 3 Installation Concerns 3 Lifting 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 7 Electrical Information General Electrical Information 8 Control Cen
44. nding 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 sheave Loosen belt tension until belts can be removed by simply lifting the belts off the sheaves After replacing belts insure 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 wa
45. ng 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 Forward Curved Fan RPM Supply fan and exhaust fan will have an 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 Multi groove 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 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 observati
46. nsions are in inches Outdoor Air Discharge LxK Exhaust Air Inlet Outdoor Air Inlet QxP Arrangement A Exhaust Air Inlet Cutdcor Ar Discharge HxJ Exhaust Hood Arrangement C All dimensions are in inches Exhaust Air Inlet Outdoor Air Discharge HxJ LxK Exhaust Hood Arrangement B Outdoor Air Discharge LxK Exhaust Air Inlet FxG Exhaust Hood Arrangement D Model ERV Energy Recovery Unit EE Optional Accessories Frost Control Application Operation Extremely cold outdoor air temperatures can cause moisture condensation and 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 sen
47. o 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 ERV 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 E mail gfcinfo greenheck com e Website www greenheck com EJ 455924 Model ERV IOM Rev 6 February 2009 Copyright 2009 O Greenheck Fan Corp
48. on 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 Poor 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 ERV 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 For the ERV 251 361 521 and 522 the wheel cassette s slide out Due to the size and weight of the ERV 581 and 582 wheels they remain stationary and all maintenance is performed in place There is room inside the unit to perform energy recovery wheel servicing Inside layout of ERV 361 Inside layout of ERV 522 Turn the ener eee Bearing haste b Adjustable Support wheels by Air Seals hand to verify fre
49. rgy Recovery Wheel in Models ERV 251 361 521 and 581 Disconnect power to the ERV Remove access panel s labeled Energy Wheel Cassette Access Unplug the wheel drive motor The center channel must be removed to access the energy wheel cassette Use a 5 16 inch open or closed wrench to remove the three 3 fasteners that hold the center channel in place Access to wheel through outdoor air filter door Pull the cassette halfway out as shown Except on ERV 581 wheel is stationary When service is complete reattach the center channel before putting access panels back in place Model ERV Energy Recovery Unit Accessing the Energy Recovery Wheel in Models ERV 522 and 582 Disconnect power to the ERV Remove access panel s labeled Energy Wheel Cassette Access which reveals the energy wheel cassette There are additional panels that must be removed in order to slide out the cassettes See pictures providing additional visual information Unplug the wheel drive motor and pull the cassette halfway out as shown NOTE ERV 522 has two energy wheels with access panels for both wheels Wheels slide out on opposite corners Energy recovery wheels for ERV 582 are hard wired and not designed to slide out This panel must be removed before the energy wheel can slide out ERV 522 only 28 Model ERV Energy Recovery Unit Removing the Energy Recovery Wheel in ERV 251 First remove the drive belts
50. rnight for stubborn dirt or accumulation After cleaning is complete shake 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 Wheel Belt amp Pulley representative Instructions for replacement will ship with the new belt 2 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 which is accessible through the outdoor air filter door and exhaust filter door on the ERV 522 and 582 Contact the local Greenheck representative for detailed Wheel Bearing instructions on how to replace the bearing H Model ERV Energy Recovery Unit E Parts List Inside layout of ERV 361 Inside layout of ERV 5
51. sor must trigger in order to initiate frost control The two sensors together insure 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 on 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 de the Timer Settings for mer T1 and T2 to 1 0 Set the dip switch to the down position normal position mi 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 14 Model ERV Energy Recovery Unit e After testing set the Timer Scale as follows T1 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
52. t intake compartment Model ERV units require the opening around the control center to be covered with cardboard plywood etc to set up the dirty filter switch 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 power 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 dent be manually adjusted after the system is in operation Negative pressure connection is toward the front or top of the switch senses blower side of filters f Positive pressure connection is toward the back or bottom of the switch senses air inlet side of filters 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
53. ter Components 9 Electric Heater Application Operation 9 Unit Accessories I 9 Access Panel Description and Location 10 11 Dimensional Data 12 13 Optional Accessories Frost Control Application Operation 14 Economizer Application Operation 15 Variable Frequency Drives and Wiring 16 17 Typical Wiring Diagram 18 Sensors and Lights some dm ow 19 Remote Control Panel and Wiring a ee dos 120 Sensors Mounted by Factory 21 Sequence of Operation Start Up Unit PE Optional AGcassorles sod Ala A p a E s w28 Fan DEENEN Energy Recovery Wheel EE Routine Maintenance Checklist General S Fan Belts 26 Fan Motors ic de W Om Ch wok ww Fan Wheel and Fasteners Zw dehinc a 4f Fan Bearings 27 Filters LEE Door Seal Maintenance de zi ne ie mof Energy Recovery Wheel Maintenance Accessing Energy Recovery Wheel 27 28 Removing Wheel Segments 28 Cleaning Wheel Segments 29 Wheel Belt S Wheel Bearing 29 Parts List fae ioe tee wa ce ce AE 0 Sequence of Operation dam x oce wow o cm cl Troubleshooting Airflow 32 Troubleshooting Unit 33 34 Maintenance Log 35 Warranty Backcover H Basic Operation The ERV brings in fresh outdoor air and removes stale exhaust air Prior to discharging the
54. therhood is shipped separately as a kit with its own Dp 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 and are factory mounted and wired at the intake Model ERV Energy Recovery Unit EJ Access Panel Description and Location ERV 251 ERV 361 ERV 521 ERV 581 Outdoor Air Exhaust Air Inlet Outdoor Air Inlet Exhaust Air Discharge Arrangement A Exhaust Hood Arrangement B C or D Energy wheel cassette Internal filters Outdoor air intake damper Frost control Outdoor air sensors Main disconnect Electrical control center Internal filters Exhaust air blower and motor 10 Model ERV Energy Recovery Unit ERV 522 Outdoor Air Discharge Interior Exhaust Air Inlet Outdoor Air Inlet Exhaust Air Discharge Exhaust Hood Intake Hood Arrangement B C or D Exhaust blower and motor Electric control center Main Disconnect Energy wheel cassette Internal filters Frost control Outdoor air sensors 3 Preheater controls Outdoor air intake damper I Supply blower and motor Exhaust air intake damper ERV 582 Outdoor Air Discharge Exhaust Air Inlet Outdoor Air Inlet Exhaust Air Discharge Arrangement A Exhaust Hood Electric control center Main disconnect Supply blower and motor Exhaust air intake d
55. tight See Energy Recovery Wheel under Unit Start Up section 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 OE or 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 a a Belts too tight Loosen to maintain a 3 8 inch deflection per Or vioraton 9s 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
56. to P 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 Fan whale am operatingibackwards For 3 phase see Direction of Fan Wheel P g Rotation under Unit Start Up section 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 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 H Model ERV Energy Recovery Unit EE 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
57. 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 EI Model ERV Energy Recovery Unit BR 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 ERV Energy Recovery Unit EJ 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 purchase date Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory transportation prepaid Motors are warranted by the motor manufacturer for a period of one year Should motors furnished by Greenheck prove defective during this period they should be returned t
58. very Unit 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 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
59. y 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 Fan Wheel amp Fasteners Wheels require very little attention when moving clean air Occasionally oil and 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 re
60. ze 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 ERV Energy Recovery Unit EJ Rail Mounting Layout e Rails designed to handle the weight of the ERV 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 ERV 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 ERV 251 ERV 361 ERV 521 ERV 581 S i ER Isometric view ERV on rails i OUTDOOR AIR WH INTAKE HOOD OUTDOOR AIR SIDE SUPPLY EXHAUST OPENING ERV on rails a Unit Size A B ERV 251 4 50 16 ERV 361 4 75 18 ERV 521 5 75 24 ERV 581 4 875 22 All dimensions are in inches 6 Model ERV Energy Recovery Unit ERV 522 ERV 582 Isometric view of ERV on rails OUTDOOR AIR INTAKE HOOD OUTDOOR AIR INTAKE END SUPPLY EXHAUST OPENING Side view of 1 ERV on rails E A B Unit Size A B ERV 522 4 625 32 ERV 582 4 875 33 25 All dimensions are in inches Service Clearances ERV 251 361 521 and 581 units require minimum clearances to perfor

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