Greenheck Fan Ventilation Hood ERV 251 User Manual

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

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.

1. Follow all local electrical and safety codes, as well

as the National Electrical Code (NEC), the National

Fire Protection Agency (NFPA), where applicable.

Follow the Canadian Electric Code (CEC) in

Canada.

2. All moving parts must be free to rotate without

striking or rubbing any stationary objects.

3. Unit must be securely and adequately grounded.

4. Do not spin fan wheel faster than maximum

cataloged fan RPM. Adjustments to fan speed

significantly effects motor load. If the fan RPM is

changed, the motor current should be checked to

make sure it is not exceeding the motor nameplate

amps.

DANGER

Always disconnect power before working on or near

this equipment. Lock and tag the disconnect switch

or breaker to prevent accidental power up.

5. Do not allow the power cable to kink or come in

contact with oil, grease, hot surfaces or chemicals.

Replace cord immediately if damaged.

CAUTION

When servicing the unit, the internal components

may be hot enough to cause pain or injury. Allow

time for cooling before servicing.

6. Verify that the power source is compatible with the

equipment.

7. Never open access doors to the unit while it is

running.

CAUTION

Precaution should be taken in explosive

atmospheres.

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Table of Contents

Basic Operation

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

Installation

Supplemental Installation, Operation and

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

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

Lifting . . . . . . . . . . . . . . . . . . 4

Roof Curb and Rail Mounting

The ERV brings in fresh, outdoor air and removes

stale, exhaust air. Prior to discharging the exhaust

air, the energy recovery wheel transfers energy from

the exhaust air to the outdoor air at an efficiency

of 70-80%. Simply put, this unit preconditions the

outdoor air to save money on heating and cooling

costs.

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

Exhaust air

from building

Energy Recovery

Wheel

Exhaust air

discharged

outside

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

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

Electric Heater Application/Operation . . . . . 9

Unit Accessories. . . . . . . . . . . . . . 9

Access Panel Description and Location . .10-11

Dimensional Data . . . . . . . . . . . . 12-13

Optional Accessories

Outdoor

air

Frost Control Application/Operation . . . . . 14

Economizer Application/Operation . . . . . . 15

Variable Frequency Drives and Wiring . . . .16-17

Typical Wiring Diagram . . . . . . . . . . . 18

Sensors and Lights . . . . . . . . . . . . 19

Remote Control Panel and Wiring . . . . . . 20

Sensors Mounted by Factory . . . . . . . . 21

Sequence of Operation

Preconditioned air

sent to space

Supplemental Installation,

Operation and Maintenance

Manuals

Refer to the following Installation, Operation and

Maintenance Manuals for additional details:

Start-Up

Unit . . . . . . . . . . . . . . . . . . . 22

Optional Accessories . . . . . . . . . . . 23

Fan . . . . . . . . . . . . . . . . . . . 24

Energy Recovery Wheel . . . . . . . . . . 25

Routine Maintenance Checklist

General . . . . . . . . . . . . . . . . . 26

Fan Belts. . . . . . . . . . . . . . . . . 26

Fan Motors . . . . . . . . . . . . . . . . 26

Fan Wheel and Fasteners . . . . . . . . . . 27

Fan Bearings . . . . . . . . . . . . . . . 27

Filters . . . . . . . . . . . . . . . . . . 27

Door Seal Maintenance. . . . . . . . . . . 27

Energy Recovery Wheel Maintenance

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.

Accessing Energy Recovery Wheel . . . .27-28

Removing Wheel Segments . . . . . . . . 28

Cleaning Wheel Segments . . . . . . . . 29

Wheel Belt . . . . . . . . . . . . . . . 29

Wheel Bearing . . . . . . . . . . . . . 29

Parts List . . . . . . . . . . . . . . . . . 30

Sequence of Operation . . . . . . . . . . . 31

Troubleshooting – Airflow. . . . . . . . . . 32

Troubleshooting – Unit . . . . . . . . . 33-34

Maintenance Log . . . . . . . . . . . . . 35

Warranty . . . . . . . . . . . . . Backcover

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.

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Lifting

Recommended Roof Opening

1. Before lifting, be sure that all shipping material

has been removed from unit.

2. To assist in determining rigging requirements,

weights are shown below.

3. Unit must be lifted by all lifting lugs provided on

base structure.

EXHAUST

INTAKE

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.

SUPPLY

DISCHARGE

0.50

ERV-251, 361, 521 and 581

EXHAUST

INLET

6. Always test-lift the unit to check for proper

balance and rigging before hoisting to desired

location.

ERV-522 and 582

7. Never lift units by weatherhoods.

8. Never lift units in windy conditions.

9. Preparation of curb and roof openings should be

completed prior to lifting unit to the roof.

10. Check to be sure that gasketing has been applied

to the curb prior to lifting the unit and setting on

curb.

Position the unit roof

Unit Size

opening such that the

ERV-251

ERV-361

ERV-521

ERV-581

ERV-522

ERV-582

26.5

supply discharge and

exhaust inlet of the

unit will line up with

the corresponding

ductwork. Be sure

to allow for the

11. Do not use fork lifts for handling unit.

recommended service

clearances when

All dimensions are in inches.

Unit Weights

positioning opening

Unit Size

ERV-251

ERV-361

ERV-521

ERV-581

ERV-522

ERV-582

Approx. Weight (lbs)*

(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.

340

860

1290

1470

3230

3700

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.

*Weight assumes outdoor unit with

filters, weatherhoods and outdoor

air intake damper.

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.

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Roof Curb Mounting

Curb Outside Dimensions - continued

Roof curb details including duct location dimensions,

are available on ERV-522 & 582 Roof Curb Assembly

Instructions, Part #460988.

Base

Side of Unit

Rooftop units require curbs to be mounted first. The

duct connections must be located so they will be

clear of structural members of the building.

1-inch Insulation

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 Curb

Curb Cap Details for Factory Supplied Roof Curbs

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.

Unit Size

ERV-251

ERV-361

ERV-521

ERV-581

ERV-522

ERV-582

1.75

1.813

1.938

2.00

4.00

4.125

1.00

1.75

1.938

1.125

1.200

0.813

1.000

1.125

0.750

0.875

0.750

0.625

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.

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.

POOR

Curb Outside Dimensions and Weights

Length of Straight Duct

GOOD

Recommended Discharge Duct Size and Length

Model

ERV-251

ERV-361

ERV-521

ERV-581

ERV-522S

ERV-522H

ERV-582

Blower Size Duct Size Straight Duct Length

9 x 9

14 x 14

20 x 20

28 x 28

32 x 32

34 x 34

ERV-251, 361, 521 and 581

ERV-522 and 582

Unit Size

ERV-251

ERV-361

ERV-521

ERV-581

ERV-522

ERV-582

Curb Weight (lbs.)

All dimensions shown in inches.

•

Recommended duct sizes are based on velocities across the

cfm range of each model at approximately 800 feet per minute

(FPM) at minimum airflow and up to 1600 fpm at maximum

airflow. Recommended duct sizes are only intended to be a

guide and may not satisfy the requirements of the project.

Refer to plans for appropriate job specific duct size and/or

velocity limitations.

42.5

30.5

47.5

63.5

58.5

115

160

185

520

700

63.5

71.8

120.5

142.25

80.5

•

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.

All dimensions are in inches. Weights are for 12-inch high

GPI type curbs.

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Rail Mounting / Layout

• Rails designed to handle the weight of the ERV should be positioned as shown on the diagram (rails by

others).

• Make sure that rail positioning does not interfere with the supply air discharge opening or the exhaust air

intake opening on the ERV unit. Avoid area dimensioned “B” below.

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

• Set unit on rails.

ERV-251

ERV-361

ERV-521

ERV-581

ERV-522

ERV-582

OUTDOOR

INT

AKE END

Isometric view of

ERV on rails

Isometric view of

ERV on rails

OUTDOOR

AIR

OUTDOOR AIR INTAKE HOOD

INTAKE

HOOD

OUTDOOR AIR SIDE

SUPPLY/EXHAUST

OPENING

OUTDOOR AIR INTAKE END

SUPPLY/EXHAUST

OPENING

Side view of

ERV on rails

Side view of

ERV on rails

Unit Size

ERV-251

ERV-361

ERV-521

ERV-581

Unit Size

ERV-522

ERV-582

4.50

4.75

5.75

4.875

4.625

4.875

33.25

All dimensions are in inches.

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Service Clearances

ERV-251, 361, 521 and 581 units require minimum clearances to perform routine maintenance, such as filter

replacement, energy wheel cassette inspection, and fan belt adjustment. Blower and motor assemblies,

energy recovery wheel cassette and filter sections are always provided with a service door or panel for proper

component access. 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

Exhaust

Side

Outdoor

Air Side

Cassette slides out*

*ERV-251, 361, and 521 only.

Arrangement A

Exhaust

Side

Outdoor

Air Side

Cassette slides out*

Arrangement A

Exhaust

Hood

Intake Hood

Access Panel

*ERV-251, 361, and 521 only.

Arrangement B, C or D

Recommended Service Clearances

Unit Size

ERV-251

Exhaust

Weatherhood

ERV-361

ERV-521

ERV-581

(30 for maintenance)

Supply

Weatherhood

(39 for maintenance)

(32 for maintenance)

Arrangement B, C or D

ERV-522

ERV-582

All dimensions are in inches.

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Electrical Information

WARNING

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.

To prevent injury or death due to electrocution or

contact with moving parts, lock disconnect switch

open.

Most factory supplied electrical components are

prewired. To determine what electrical accessories

require additional field wiring, refer to the unit specific

wiring diagram located on the inside of the unit

control center access door. The low voltage control

circuit is 24 VAC and control wiring should not exceed

0.75 ohms.

Refer to Field Control Wiring Length/Gauge table for

wire length maximums for a given wire gauge.

Field Control Wiring Length/Gauge

Total

Wire Length

Minimum

Wire Gauge

125 ft.

200 ft.

300 ft.

450 ft.

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.

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 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.

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.

The electric supply to the unit must meet stringent

requirements for the system to operate properly.

Voltage supply and voltage imbalance between

phases should be within the following tolerances.

If the power is not within these voltage tolerances,

contact the power company prior to operating the

system.

Voltage Supply: See voltage use range on the rating

plate. Measure and record each supply leg voltage at

all line disconnect switches. Readings must fall within

the allowable range on the rating plate.

Voltage Imbalance: In a 3-phase system, excessive

voltage imbalance between phases will cause motors

to overheat and eventually fail. Maximum allowable

imbalance is 2%. To determine voltage imbalance,

use recorded voltage measurements in this formula.

Key:

V1, V2, V3 = line voltages as measured

VA (average) = (V1 + V2 + V3) / 3

VD = Line voltage (V1, V2 or V3) that

deviates farthest from average (VA)

Formula: % Voltage Imbalance = [100 x (VA-VD)] / VA

CAUTION

If any of the original wire as supplied with the

appliance must be replaced, it must be replaced

with wiring material having a temperature rating of

at least 105ºC.

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Typical Control Center Components

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).

1. Main Disconnect (non-fusible, lockable)

2. Motor Starter – Exhaust Air Fan

3. Motor Starter – Outdoor Air Fan

4. Motor Contactor – Energy Wheel

5. 24 VAC Control Transformer

6. 24 VAC Terminal strip

7. Fuses for blower motors

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.

Exploded Detail

of Terminal Strip

ERV-251, 361, 521, 581

Intake

Hood

Unit Accessories

Exhaust

Hood

Outdoor Air Weatherhood

Outdoor air weatherhood will be

factory mounted.

Access to Control Center Components

is gained through the access panel indicated.

Exhaust Weatherhood

The exhaust weatherhood is shipped

separately as a kit with its own

instructions.

ERV-522

ERV-582

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.

Exhaust Hood

Intake

Hood

Intake

Hood

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Access Panel Description and Location

ERV-251, ERV-361, ERV-521, ERV-581

ERV-522

Outdoor Air

Discharge

Outdoor Air

Discharge

Interior

Exhaust Air

Inlet

Exhaust Air

Inlet

Outdoor Air

Inlet

Outdoor Air Inlet

Exhaust Air Discharge

Exhaust Air

Discharge

Arrangement A

Rooftop

Intake

Hood

Exhaust Hood

Exhaust

Hood

Intake Hood

Arrangement B, C or D

Outdoor air blower and motor

Energy wheel cassette

Internal filters

Exhaust blower and motor

Electric control center

Main Disconnect

Energy wheel cassette

Internal filters

Outdoor air intake damper

Frost control

Outdoor air sensors

Main disconnect

Outdoor air sensors

Preheater controls

Outdoor air intake damper

Electrical control center

Internal filters

Supply blower and motor

Exhaust air intake damper

Exhaust air blower and motor

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ERV-582

Outdoor Air

Discharge

Exhaust Air

Inlet

Outdoor Air Inlet

Exhaust Air Discharge

Arrangement A

Exhaust Hood

Intake

Hood

Arrangement B, C or D

Exhaust blower and motor

Electric control center

Main disconnect

Supply blower and motor

Exhaust air intake damper

Energy wheel cassette

Internal filters

Frost control

Outdoor air sensor

Preheater controls

Outdoor air intake damper

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Dimensional Data

ERV-251, 361, 521 and 581

Exterior Dimensions

Unit Opening Dimensions

Unit Size

6³⁄4

8³⁄8

10³⁄4

ERV-251

ERV-361

ERV-521

ERV-581

ERV-251

ERV-361

ERV-521

ERV-581

11¹⁄2

13¹⁄2

18³⁄4

All dimensions are in inches.

Outdoor Air Discharge

L x K

Outdoor Air Discharge

L x K

Exhaust Air Inlet

F x G

Outdoor Air Inlet

Q x P

Exhaust Air Inlet

F x G

Exhaust Air Discharge

L x K

Intake Hood

Exhaust Hood

Arrangement A

Arrangement B

Outdoor Air Discharge

L x K

Outdoor Air Discharge

L x K

Exhaust Air Inlet

F x G

Exhaust Air Inlet

F x G

Intake Hood

Exhaust Hood

Arrangement C

Arrangement D

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ERV-522 and 582

Exterior Dimensions

Unit Opening Dimensions

Unit Size

18⁵⁄8

ERV-522S

ERV-522H

ERV-582H

124

146

ERV-522S

ERV-522H

ERV-582H

26³⁄4

17¹⁄2

All dimensions are in inches.

Outdoor Air Discharge

L x K

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust Air Inlet

F x G

Outdoor Air Inlet

Q x P

Intake

Hood

Exhaust Air Discharge

L x K

Exhaust

Hood

Arrangement A

Arrangement B

Outdoor Air Discharge

L x K

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust Air Inlet

F x G

Intake

Hood

Intake

Hood

Exhaust

Hood

Exhaust

Hood

Arrangement C

Arrangement D

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•

After testing, set the Timer Scale as follows:

Optional Accessories

T1 = 10 minutes, T2 = 1 hour

Frost Control Application/Operation

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.

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:

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.

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

Testing:

Indoor RH @ 70°F

Frost Threshold Temp

•

Turn the thermostat as high as it will go and

jumper the wheel pressure sensor. The heater

should turn on.

20%

30%

40%

-10º F

-5º F

0º F

•

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.

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 insure that frost control is

only initiated during a real frost condition. Field

wiring of a light (or other alarm) between 6 & 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.

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 for more

information). The variable frequency drive will be fully

programmed at the factory.

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)

•

Jumper the wheel

pressure switch in the

unit control center. Set

the Timer Scale for T1

and T2 to 1 minute. Set

the Timer Settings for

T1 and T2 to 1.0. Set the

dip switch to the down

position. (normal position)

0.8 0.6

1.0 0.4

0.2

Dip

Switch

1 MIN T2

Timer

Scale

1 MIN T1

0.8 0.6

1.0 0.4

0.2

•

Turn the temperature

sensor up as high as

possible. The supply blower should cycle on for

one minute, then turn off for one minute.

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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.

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

•

Turn unit power off. Reconnect C7400 Solid State

Enthalpy Sensor to terminal So.

A field supplied call for cool (Y1) is required.

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.

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 65ºF) 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 50ºF). 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.

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:

Testing

Wheel runs at full speed.

T_AO> T_RA

Temperature Sensor with Override

(maximum energy recovery)

•

Turn both Temperature and

Override thermostats down as

low as they go. The wheel should

be rotating.

T_AO< T_RA

Wheel is stopped.

and

(no energy recovery)

T_AO> T_SA

T_AO< T_RA

Wheel will modulate to maintain

•

Turn the Temperature sensor

up as high as it goes, and keep

the Override sensor as low as it

will go. The wheel should stop

rotating.

Temperature

Sensor with

Override

and

discharge temperature.

T_AO< T_SA

Where (T ) is the outdoor air temperature set point,

(T ) is the return air temperature set point, and (T

)

•

Turn both sensors as high as they will go. The

wheel should start rotating.

is the supply air discharge thermostat set point.

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 65ºF and 50ºF,

respectively).

Enthalpy Sensor with Override

•

Turn unit power off. Disconnect

C7400 Solid State Enthalpy Sensor

from terminal So on the enthalpy

controller. Also, disconnect the

620 ohm resistor from

terminal Sr on the

enthalpy controller.

Turn unit power on. The

LED on the enthalpy

Enthalpy

Sensor with

Override

controller should light and the energy

recovery wheel should not rotate.

• 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

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Variable Frequency Drives for Energy Recovery Blowers

Optional factory installed, wired, and programmed variable frequency drives (VFDs) may have been 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.

R+ R- S+ S- IG

P1 P2 PC A1 A2 +V AC AM AC MP

S1 S2 S3 S4 S5 S6 S7 HC SC H1 RP MA MB MC

S1 S2 S3 S4 S5 SC A1 +V AC AM AC

MA MB MC

J1000

V1000

Factory Set Points

Variable Frequency Drives (VFDs) for the blowers are

factory setup to operate in one of the three following

modes:

OPTION 1 - 0-10 VDC CONTROL

USER TO PROVIDE ISOLATION AS REQUIRED

Modulating: 0-10 VDC signal wired in the field by

others varies the speed of the blower between 30

and 60Hz

0-10 VDC CONTROL SIGNAL (BY OTHERS)

WIRED TO A1 (+) AND AC (COMMON)

0 VDC=30 Hz

A1 AC

10 VDC=60 Hz

Multi-speed: Digital contact closures by others

command the VFD to run at multiple speed settings:

• SC to S4 - Drive runs at 40Hz

FOR ONE 0-10 SIGNAL, WIRE TO DRIVES IN PARALLEL

SEE VFD INSTALLATION MANUAL FOR MORE DETAIL

• SC to S5 - Drive runs at 30Hz

FOR CONTINUOUS 60Hz OPERATION JUMPER TERMINALS A1 AND +V.

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

OPTION 2 - MULTI SPEED CONTROL

levels at the sensor.

USER TO PROVIDE CONTACTS AND ISOLATION

AS REQUIRED

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 with drive settings on

either drive, change parameter A1-01 to “0”.

NEITHER S4 OR S5 CONTACT CLOSED

S4 S5 SC

DRIVE SPEED = 60 Hz.

S4 TO SC CONTACT CLOSED (BY OTHERS)

DRIVE SPEED = 40 Hz.

S5 TO SC CONTACT CLOSED (BY OTHERS)

DRIVE SPEED = 30 Hz.

SEE 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

Drive Operation

SC to S1 contact for On/Off

A1 (0-10 VDC) referenced to AC. Can use +15 VDC

from +V

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Factory Set Points - continued

CO SENSOR CONTROL FOR FAN SPEED

Resetting the drive to factory defaults

To reset the 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 reset back to the settings programmed at

Greenheck.

(1/2 SPEED WHEN C0 DROPS bELOW 700 PPM)

Setting

Parameter

V1000

J1000

A1-01

Access Level

b1-01 Reference Source (Frequency)

b1-17

C1-01

C1-02

C6-02

d1-01

d1-02

d2-02

VFD Start-Up Setting

Acceleration Time

Deceleration Time

Carrier Frequency

MODULATING CONTROL FOR FAN SPEED

(0-10 VDC)

30 sec. 30 sec.

Setting

Parameter

Frequency Reference 1

Frequency Reference 2

Ref Lower Limit

60 Hz

30 Hz

50%

30 Hz

60 Hz

50%

V1000

J1000

A1-01

b1-17

C1-01

C1-02

C6-02

d2-02

Access Level

VFD Start-Up Setting

Acceleration Time

Deceleration Time

Carrier Frequency

Ref Lower Limit

Motor

FLA

Motor

FLA

30 sec. 30 sec.

E2-01

Motor Rated FLA

H3-10

A1-01

A2 Not Used

Access Level

50%

Motor

FLA

50%

Motor

FLA

E2-01

Motor Rated FLA

Variable Frequency Drives for Energy

Recovery Wheel

H3-04

A1-01

Terminal A1 Bias

Access Level

50%

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 the VFD instruction manual that ships with the unit

when making adjustments.

MULTI-SPEED CONTROL FOR FAN SPEED

(1/3 OR 1/2 SPEED REDUCTION)

Setting

Parameter

V1000

J1000

Parameter

Access Level

Setting – J1000

A1-01

Access Level

A1-01

b1-17

C6-02

d2-01

d2-02

E2-01

b1-01 Reference Source (Frequency)

VFD Auto Start

Carrier Frequency

Ref Upper Limit

Ref Lower Limit

Motor Rated FLA

b1-17

C1-01

C1-02

C6-02

d1-01

d1-02

d1-03

d1-04

d2-02

VFD Start-Up Setting

Acceleration Time

100% or 66%*

30 sec. 30 sec.

Deceleration Time

Carrier Frequency

Motor FLA

Must be less than

FLA

Frequency Reference 1

Frequency Reference 2

Frequency Reference 3

Frequency Reference 4

Ref Lower Limit

60 Hz

40 Hz

30 Hz

60 Hz

50%

60 Hz

40 Hz

30 Hz

60 Hz

50%

E2-03

H1-02

H2-01

Motor No-Load Current

Multi-Function Input

(Terminal S2)

Multi-Function Output

(MA, MB, MC)

Motor

FLA

Motor

FLA

E2-01

H1-04

H1-05

H1-06

Motor Rated FLA

Setting

Economizer Signal Source

(0-10 VDC)

Honeywell

Carel

Multi-Function Input Sel 4

(Terminal S4)

Module Controller

Analog Frequency Reference

Multi-Function Input Sel 5

(Terminal S5)

H3-03

100

(Gain)

Analog Frequency Reference

Multi-Function Input Sel 6

(Terminal S6)

H3-04

(Bias)

L1-01

L4-01

A1-01

Elect Thermal Overload

Frequency Detection Level

Access Level

H3-10

A1-01

A2 Not Used

Access Level

*36 inch wheel is 66% (40 Hz). All other wheels are 100% (60 Hz).

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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.

DS1

VFD-E

MAIN POWER

TO UNIT

LEGEND

S1 SC FR FC

CC COMPRESSOR CONTACTOR

CF CONDENSING FAN CONTACTOR

CH COMPRESSOR SUMP HEATER

EXHAUST FAN

MOTOR

GROUND

0-10 VDC

DAMPER

VFD-S

DB POWER DISTRIBUTION BLOCK

DL DAMPER LIMIT SWITCH

DS DISCONNECT SWITCH

EC ECONOMIZER CONTROLLER

FCS CONDENSOR FAN CYCLE SWITCH

FU FUSES

S1 SC FR FC

SUPPLY FAN

MOTOR

0-10 VDC

FU5 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

R1 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

VFD-W

ENERGY WHEEL

FR FC MA MC

SEE BELOW FOR

TERMINAL CONNECTIONS

FU5

TR1

R7 COMPRESSOR INTERLOCK RELAY

R8 EVAP RELAY (INDIRECT)

R9 EVAP RELAY (DIRECT)

R10 UNIT RELAY

S1 FAN SWITCH

S2 ROTATION SENSOR REED SWITCH

S3 ROTATION SENSOR REED SWITCH

S4 CALL FOR HEAT SWITCH

MULTI-VOLTAGE PRIMARY

24 SECONDARY

S5 BYPASS SWITCH

S6 CALL FOR COOL SWITCH (FIRST STAGE)

S7 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

EXHAUST DAMPER

T3 ROTATION SENSOR TIMER

T4 ECONOMIZER WHEEL JOG TIMER

TYPICAL SETTINGS t1(OFF) = 3 HRS., t2(ON) = 10 SEC.

T5 EVAP DELAY OFF TIMER

VFD-E O.L.

MB MC

EXHAUST FAN

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.

SUPPLY DAMPER

TS2 ECONOMIZER LOW LIMIT THERMOSTAT (JUMPER - HEAT )

VFD-S O.L.

OPENS ON TEMP. DECREASE TYP. SETTING 20 OFFSET OR 50 F.

SUPPLY FAN

TS3 ECONOMIZER UPPER LIMIT THERMOSTAT (JUMPER - HEAT)

CLOSES ON TEMP. DECREASE TYP. SETTING 65 F./2 DIFF.

TS4 ROOM OVERRIDE SENSOR

TS5 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.

ENERGY WHEEL

ROTATION SENSOR

TO MA AND MC

ON VFD-W

FACTORY SUPPLIED AND WIRED

FIELD WIRED

OA-SENSOR

SENSOR

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.

24 VAC

THERMOSTAT(S) TS1,

COM

THERMOSTAT CONTROLLER(S)

FROST CONTROL

PS1

TS1

REPLACEMENT FUSES: MUST HAVE A MINIMUM I.R. RATING OF 5 KA

COM

CAUTION:

UNIT SHALL BE GROUND IN ACCORDANCE WITH N.E.C.

POWER MUST BE OFF WHILE SERVICING.

ECONOMIZER CONTROL

TR1

TO FR AND FC

ON VFD-W

2-10V

USER INTERFACE CONNECTIONS:

SR+

SO+

620 OHM RESISTOR OR

RETURN AIR SENSOR

USER TO VERIFY THAT TR1 CAN HANDLE THE VA LOAD OF INDICATOR DEVICES.

DIRTY FILTER INDICATOR SHOWN AS 24V POWER FROM UNIT.

PS2

OUTDOOR AIR

SENSOR

MIXED AIR

SENSOR

SUPPLY DIRTY

FILTER SWITCH

PS3

EXHAUST DIRTY

FILTER SWITCH

FROST CONTROL INDICATOR

ROTATION INDICATOR

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Rotation Sensor

CO 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 & 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).

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

Dirty Filter Sensor

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.

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.

Vapor Tight Lights

Vapor tight lights provide light to each of the

compartments in the energy

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.

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.

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 (exhaust

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

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)

Positive pressure connection is toward the ‘back or

bottom’ of the switch. (senses air inlet side of filters)

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Indicator Lights powered by the ER Unit

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

Unit On/Off

The remote panel is available with the following

options:

Frost Control

Economizer

• Unit on/off switch

Rotation Sensor

• Unit on/off light

• 7-day time clock

PS2

• Hand/off/auto switch

• Time delay override

• Economizer light

Supply Dirty Filter

Exhaust Dirty Filter

• Frost control light

PS3

• Exhaust air dirty ﬁlter light

• Outdoor air dirty ﬁlter light

• Wheel rotation sensor light

Refer to Electrical Connections section for Field Control

Wiring recommendations.

Dirty Filter Indicator (power by others)

7-Day Timer or On/Off Switch

PS2

Supply Dirty Filter

Exhaust Dirty Filter

7-Day Timer

Terminal Block

in Unit

Control Center

S1 - Unit On/Off

PS3

Hot

For 7-Day Timer, use blue and black wires.

Red wires should be capped off.

Refer to Pressure Switch for voltage and load ratings.

Hand/Off/Auto Switch

Terminal Block

in unit

Control Center

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.

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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.

EW-P

RAF-P

EF-A

EAW

RAI

FILTER

OUTSIDE

FROM

INSIDE

EXHAUST

BLOWER

OAF-P

OAI

OAAW

OAF-A

FILTER

FROM

OUSTIDE

INSIDE

SUPPLY

BLOWER

OAD

OAW-P

Temperature Sensors - 1K Ohm RTD

Drawing Labels Terminal Strip Labels

OAI

OA/Supply Inlet Temp

OA After Wheel

OAAW

RAI

RA/Exhaust Inlet Temp

Supply Discharge Temp

Exhaust After Wheel Temp

OAD

EAW

Pressure Sensors (analog or digital)

Drawing Labels Terminal Strip Labels

OAF-P

OAW-P

RAF-P

EW-P

OA/Supply Filter Pressure

Outdoor Air Wheel Pressure

RA/Exhaust Filter Pressure

Exhaust Wheel Pressure

Amp - Current Sensors (analog or digital)

Drawing Labels Terminal Strip Labels

OAF-A

EF-A

Supply Fan Amps

Exhaust Fan Amps

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o 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.

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.

o Check the fan belt drives for proper alignment

and tension (refer to Start-Up section for more

information).

o 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).

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.

o Verify that non-motorized dampers open and close

properly.

o Check the tightness of all factory wiring

connections.

Do not operate energy recovery ventilator without

the filters and birdscreens installed. They prevent

the entry of foreign objects such as leaves, birds,

etc.

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).

CAUTION

Do not run unit during construction phase. Damage

to internal components may result and void

warranty.

SPECIAL TOOLS REQUIRED

• Voltage Meter (with wire probes)

• Amperage Meter

• Thermometer

• Tachometer

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.

• 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 & 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

Unit Model Number _______________________________

(e.g. ERV-361)

Motor Amp Draw

Unit Serial Number _______________________________

(e.g. 04C99999 or 10111000)

• Supply Fan

• Exhaust Fan

_______ L1 amps

_______ L2 amps

_______ L3 amps

______ L1 amps

______ L2 amps

______ L3 amps

Energy Wheel Date Code __________________________

(e.g. 0450)

Start-Up Date

_______________________________

Start-Up Personnel Name__________________________

Start-Up Company _______________________________

• Energy Wheel

_______ L1 amps

_______ L2 amps

_______ L3 amps

Phone Number

_______________________________

Pre Start-Up Checklist – check as items are

Fan RPM

completed.

_______ Supply Fan ______ Exhaust Fan

o Disconnect and lock-out all power switches

Correct fan rotation direction

o Remove any foreign objects that are located in the

Supply Fan

Exhaust Fan

Yes / No

energy recovery unit.

o Check all fasteners, set-screws, and locking collars

on the fans, bearings, drives, motor bases and

accessories for tightness.

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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 Default

Yes

Frost Control set point

Differential

5ºF

2ºF

Timer

Refer to IOM

Yes

Frost Control Modulating

Economizer Application / Operation section:

Yes

Economizer (temperature)

Set point

65ºF

20ºF

2ºF

Offset

Differential

Yes

Economizer (enthalpy)

Set point

Economizer (modulating)

Refer to IOM

Optional Accessories section:

Operational

Yes

Wheel Rotation Sensor

OA Dirty Filter Sensor

EA Dirty Filter Sensor

Yes

N/A

CO Sensor

Service Outlet

Vapor Tight Lights

Remote Control Panel

Variable Frequency Drives section:

Operational

Yes

Blower VFDs

Wheel VFD

Yes

N/A

Damper section:

Operational

Yes

Outdoor Air Damper

Exhaust Air Damper

Yes

N/A

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5. Place belts over sheaves. Do not pry or force

belts, as this could result in damage to the cords

in the belts.

Unit Start-Up

Refer to Parts List section for component locations.

Fans

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.

The ERV models contain two

forward curved (supply &

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 recommendations in

the following section.

Forward Curved

Exhaust Fan

WRONG

CORRECT

CAUTION

Direction of Fan Wheel Rotation

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.

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.

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.

Airﬂow

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:

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.

• Fan Shaft

• Fan Wheel

• Bearings

• Belt

• Motor

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 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.

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Vibration

Drive Belt

Inspect the drive belt. Make sure the belt rides

smoothly through the pulley and over the wheel rim.

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.

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.

Many of these conditions can be discovered by

careful observation.

Wheel Unbalance

Refer to the

Troubleshooting

Drive Pulley Misalignment

Incorrect Belt Tension

Bearing Misalignment

Mechanical Looseness

Faulty Belts

Drive Component Unbalance

Poor Inlet/Outlet Conditions

Foundation Stiffness

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.

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.

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

Inside layout of ERV-361

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

Inside layout of ERV-522

in place. There is room inside the unit to perform

energy recovery wheel servicing.

Turn the

energy

recovery

Bearing

Support

Adjustable

Air Seals

wheels by

hand to verify

free operation.

The wheel

should rotate

smoothly and

should not

wobble.

Label

showing

cassette

serial #

and date

code

Drive Belt

Drive Pulley

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Dampers

Routine Maintenance

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.

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.

Fan Belts

CAUTION

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.

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:

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.

Lubrication

Apply lubrication where required

Dampers

Check for unobstructed operation

Fan Belts

Check for wear, tension, alignment

Motors

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.

Check for cleanliness

Blower Wheel & Fasteners

Check for cleanliness

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

Check all fasteners for tightness

Check for fatigue, corrosion, wear

Bearings

Check for cleanliness

Check set screws for tightness

Lubricate as required

be one inch (using

moderate thumb

Belt Span

Deflection =

External Filter

pressure at mid-point

of the drive). Check

belt tension two times

during the first 24 hours

of operation and

Check for cleanliness - clean if required

Internal Filter

Check for cleanliness - replace if required

Door Seal

Belt Span

periodically thereafter.

Check if intact and pliable

Fan Motors

Energy Recovery Wheel

Check for cleanliness - clean if required

Check belt for wear

Check pulley, bearings, and motor

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

Maintenance Procedures:

Lubrication

with high pressure spray.

Greasing of motors is

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.

only intended when

fittings are provided.

Many fractional motors

are permanently

lubricated for life and

require no further

lubrication.

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Fan Wheel & Fasteners

Filter Size and Quantities

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.

Internal

Quantity Quantity

Supply Exhaust

Unit Size

Filter Size

ERV-251

ERV-361

ERV-521

ERV-581

ERV-522

ERV-582

16 x 25

16 x 20

16 x 25

16 x 20

16 x 25

20 x 25

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.

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.

Bearings

Most bearings are permanently lubricated and require

no further lubrication under normal use. Normal use

being considered -20ºF to 120ºF 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.

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.

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.

ERV-522 & 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

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).

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.

Clean filters by rinsing with

a mild detergent in warm

water.

Outdoor air intake hood

Accessing the Energy Recovery Wheel in

Models ERV-251, 361, 521 and 581

mesh filter access

Disconnect power to the ERV. Remove access

panel(s) labeled “Energy Wheel Cassette Access”.

Internal Filter Maintenance

The ERV units will typically be provided with 2-inch,

pleated filters in the outdoor air and exhaust

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)

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 integral metal

grid. Two acceptable filter replacements are Aerostar

fasteners that hold the

center channel in place.

Access to wheel through

outdoor air filter door

Series 400 or Farr 30/30 .

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.

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Accessing the Energy Recovery Wheel in

Models ERV-522 and 582

Removing the Energy Recovery Wheel in

ERV-251

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).

First, remove the drive belts 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.

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.

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.

This panel must

be removed before

the energy wheel

can slide out.

Bracket Segment

Retainer

Lift away from

segment

Catch Segment

Retainer

Inside of wheel rim

Spoke

(ERV-522 only)

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

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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, 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 140ºF (60ºC).

Do not dry energy recovery wheel segments in air in

excess of 140ºF (60ºC).

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

Wheel Belt & Pulley

the local Greenheck

representative. Instructions

for replacement will ship with the new belt.

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

instructions on how to

replace the bearing.

Wheel Bearing

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Parts List

Inside layout of ERV-361

Inside layout of ERV-522

(shown with intake weatherhood, exhaust weatherhood, outdoor air filters, and exhaust air filters)

1. Supply blower

• Forward curved fan

6. Optional exhaust weatherhood with birdscreen

• Adjustable motor mount for belt tensioning

• Adjustable sheaves for speed control

7. Optional supply and exhaust air filter racks for

2 inch pleated, 30% efficient filters

2. Vibrations isolators (quantity 4 per blower)

8. Electrical control box (standard features)

• Single point power

• Neoprene

• Disconnect interlocked with access door

3. Energy recovery wheel cassette

• Motor starters for the supply blower, exhaust

blower and energy wheel motors

• 24 VAC control circuit with terminal strip

• one wheel on models ERV-251, 361, 521 & 581

• two wheels on models ERV-522 & 582

4. Removable energy recovery wheel segments

9. Exhaust blower

• Forward curved fan

• Adjustable motor mount for belt tensioning

• Adjustable sheaves for speed control

5. Optional supply weatherhood with 2 inch

aluminum mesh filter

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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

contactor 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

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.

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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

accordance with SMACNA and AMCA guidelines.

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Troubleshooting – Unit

Symptom

Possible Cause

Corrective Action

Replace fuse or reset circuit breaker and check

amps.

Blown fuse or open circuit breaker.

Defective motor or capacitor.

Motor starter overloaded.

Replace.

Blower fails to

Reset starter and check amps.

operate

Check for On/Off switches. Check for correct

supply voltage.

Electrical.

Drive.

Check for broken or loose belts. Tighten loose

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).

Motor starters

“chatter” or

do not pull in

Incoming supply power is less than anticipated.

Voltage supplied to starter coil must be within

Need to increase supply power or use a special

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

design.

If higher, ductwork should be improved.

If lower, fan rpm should be lower.

Blower rotation is incorrect.

Motor voltage incorrect.

Check rotation and reverse if necessary.

Motor over amps

Check motor nameplate versus supplied

voltage.

See specifications and catalog for fan curves to

determine if horsepower is sufficient.

Motor horsepower too low.

Shorted windings in motor.

Unit damper not fully open.

Replace motor.

Adjust damper linkage or replace damper motor.

Improve ductwork to eliminate losses using

good duct practices.

System static pressure too high.

Blower speed too low.

Check for correct drives and rpm with catalog

data.

For 3-phase, see Direction of Fan Wheel

Rotation under Unit Start-Up section.

Fan wheels are operating backwards.

Low airflow (cfm)

Follow cleaning procedures in Routine

Maintenance section.

Dirty filter or energy wheel.

Leaks in ductwork.

Repair.

Elbows or other obstructions may be

obstructing fan outlet.

Correct or improve ductwork.

Adjust belt tension.

Belt slippage.

Check for correct fan rpm. Decrease fan speed

if necessary.

Blower fan speed too high.

Filter(s) not in place.

Install filters.

High airflow (cfm)

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.

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Troubleshooting – Unit

Symptom

Possible Cause

Corrective Action

One or both

blowers turn off

intermittently and

back on after

Adjust frost temperature sensor set point as

needed.

Exhaust Only frost control sensors are tripping.

about 2 minutes

See Energy Recovery Wheel under Unit Start-Up

section.

Air seals are too tight.

Adjust temperature or enthalpy set points as

needed.

“Economizer” sensors are operating.

No power to wheel motor.

Wheel drive belt.

Energy wheel does

NOT turn

Make sure wheel drive is plugged in. Verify

power is available.

Check for loose or broken belts. Replace belts

(consult factory).

Refer to VFD section. Compare motor amp

rating to setting in VFD. Adjust accordingly.

VFD overload. (OL1 on readout)

Recheck air seals, make sure they are not too

tight. See Energy Recovery Wheel under Unit

Start-Up Section.

Energy wheel runs

intermittently

Wheel motor overloads are tripping, due to

rubbing between wheel and air seals.

Adjust wheel and/or inlet cone. Tighten wheel

hub or bearing collars on shaft.

Fan wheel rubbing on inlet.

Bearings.

Replace defective bearing(s). Lubricate

bearings. Tighten collars and fasteners.

Wheel out of balance.

Loose wheel on shaft.

Loose motor or blower sheave.

Belts too loose.

Replace or rebalance.

Tighten wheel setscrew.

Tighten sheave setscrew.

Adjust belt tension after 24 hours of operation.

Excessive noise

or vibration

Loosen to maintain a 3/8 inch deflection per

foot of span between sheaves.

Belts too tight.

Worn belt.

Replace.

Motor base or blower loose.

Buildup of material on wheel.

Bearing and drive misaligned.

Tighten mounting bolts.

Clean wheel and housing.

Realign.

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.

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.

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Maintenance Log

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

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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 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 ERV,

provides additional information describing the equipment,

fan performance, available accessories, and speciﬁcation

data.

AMCA Publication 410-96, Safety Practices for Users and

Installers of Industrial and Commercial Fans, provides

additional safety information. This publication can be

obtained from AMCA International, Inc. at: www.amca.org.

Phone: (715) 359-6171 • Fax: (715) 355-2399 • E-mail: [email protected] • Website: www.greenheck.com

455924 • Model ERV IOM, Rev. 6, February 2009

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