Greenheck ERV-251 User manual

GREENHECK

P.O. BOX 410 SCHOFIELD, WISCONSIN 54476-0410

PH. 715-359-6171

ENERGY RECOVERY VENTILATORS

Models ERV-251, 361, 521, 581, 522 & 582

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

**WARNING**

DISCONNECT ALL ELECTRICAL POWER TO THE ERV PRIOR TO INSPECTION OR SERVICING BY

SECURING THE MAIN DISCONNECT SWITCH TO THE "OFF" POSITION. FAILURE TO COMPLY WITH THIS

SAFETY PRECAUTION COULD RESULT IN SERIOUS INJURY OR DEATH.

**IMPORTANT**

ALL FACTORY PROVIDED LIFTING LUGS MUST BE USED WHEN LIFTING ANY ERV.

FAILURE TO COMPLY WITH THIS SAFETY PRECAUTION COULD RESULT IN PROPERTY

DAMAGE, SERIOUS INJURY OR DEATH.

PART #455924

READ AND SAVE THESE INSTRUCTIONS

GENERAL

Greenheck Energy Recovery Ventilators, model ERV, are thoroughly inspected and test run at the factory.

However, damage may occur during shipping and handling. Consequently, it is important to inspect the unit for

visible and concealed damage before beginning installation. Report any damage to the shipper immediately. In

addition, assure all accessory items are present. Some accessory items are stored inside the unit during shipping.

Care must be taken during installation to prevent damage to units.

INSTALLATION

The system design and installation should

follow accepted industry practice, such as

described in the ASHRAE Handbook.

Minimum service clearance should be provided

on the side of the unit for routine service and

component removal should it become

necessary.

Before beginning installation see pages 8

through 11 for dimensional data and details on

appropriate service clearances.

Installation...............................................2

Lifting...................................................3

Mounting..............................................4

Duct Connection.................................6

Weatherhoods.....................................6

Electrical...........................................6-7

Dimensional Data- 251, 361, 521, 581 ......8

Service Clearances- 251, 361, 521, 581.....9

Dimensional Data- 522, 582 .................10

Service Clearances- 522, 582...............11

System Startup .....................................12

Energy Wheel....................................12

Fan RPM............................................13

Fan Wheel .........................................13

Motors...............................................13

Setting for Options............................13

Routine Maintenance ..............................14

Belts ......................................................14

Fasteners and set screws....................14

Filters ....................................................15

Energy Recovery Wheel Maintenance ..16

Accessing the Energy Wheel ...............16

Removing Energy Wheel......................17

Cleaning Energy Wheel ........................17

Maintenance Documentation ............18-19

Troubleshooting.......................................20

Warranty ..................................................20

TABLE OF CONTENTS

LIFTING

Greenheck model ERVs must be lifted as it ships from the factory. All units are equipped with lifting lugs.

THE USE OF ALL LIFTING LUGS IS MANDATORY WHEN LIFTING. Lifting of the ERV should only be

done with the access doors/panels closed and in place to avoid damage to the unit.

Use spreader bars to prevent damage to the unit cabinetry. Spreader bars must be positioned to prevent

the cables from rubbing against the unit frame or panels. Before hoisting into position, test lift the unit to

verify stability and balance. Avoid twisting or uneven lifting of the unit. Never lift an ERV by

weatherhoods.

FIGURE 2

ERV-522 and 582

FIGURE 1

SLAB MOUNTING

Arrangement D (Horizontal Discharge)

Slab Construction

• The recommended slab size is 12 inches

wider and longer than the total unit size.

• The material should be concrete with a

thickness of at least 4 inches and proper

reinforcement wire.

• The slab should be set and leveled on a

sufficient bed of gravel for proper drainage.

1. Slab Co

Recomme

total unit s

Recomme

ERV-251, 361, 521 and 581

Lift Lugs

Spreader Bar

Lift Lugs

INSTALLATION (continued)

SURFACE RAIL MOUNTING

Arrangement A or D

For proper support, rails should be located 6 to 12 inches in

from the outer edges of the unit and should extend at least

6” beyond the sides of the unit. Rails are by others.

Front

Back

Refer to pages 8 through 11 for unit dimensions

and appropriate service clearances.

CURB MOUNTING

Arrangement B, C and D

Recommended Roof Opening

ERV-251, 361, 521 and 581

ERV-522 and 582

Roof curbs are Model GKD, which are shipped in a

knockdown kit and require field assembly (by others).

Assembly instructions are included with the curb.

2. Cut Roof Opening and Locate Curb

Locate the unit over the roof opening, so the unit

openings and corresponding ducts line up. See the

drawing below.

Be sure to allow for the recommended service clearances.

Keep the inlet of the ERV away from any other exhaust

fans. See page 6 for Recommended Duct Sizes.

EXHAUST

INLET

SUPPLY

OUTLET

Recommended Roof Opening

ERV-522 and 582

Model U V

ERV-251 26.5 20

ERV-361 43 26

ERV-521 58 35

ERV-581 60 30

Model U V

ERV-522 65 37

ERV-582 77 38

ERV-251, 361, 521 and 581

1. Factory Supplied Roof Curbs

Roof curbs are either Model GPNS or GPI, which are

factory fabricated and assembled.

EXHAUST

INLET

SUPPLY

OUTLET

All dimensions shown are in inches.

Model L W

ERV-251 30.5 42.5

ERV-361 58.5 47.5

ERV-521 63.5 63.5

ERV-581 71.8 66

ERV-522 120.5 80.5

ERV-582 142.25 93

Roof curb details, including duct

location dimensions, are available on

ERV roof curb submittals.

FIGURE 3 FIGURE 4

3. Install Curb

Locate curb over roof opening with dimensions

shown on page 4 and fasten in place.

Check that the diagonal dimensions are within

±1/8” of each other and adjust as necessary.

Shim as required to level.

Lower unit onto curb by following the LIFTING

instructions on page 3 of this manual. Note, roof

curbs fit inside the ERV unit base.

4. Install Duct Work

Installation of all ducts should be done in

accordance with SMACNA and AMCA guidelines.

The chart on page 6 shows the duct sizes and

straight lengths recommended for optimal

performance (AMCA 201-90). Using duct sizes

less than the recommended lengths will affect fan

performance. Good duct installation practices

should be followed for the remaining ductwork.

ERV-251, 361, 521 and 581

The duct adapter should be used only for properly

locating ducts on these units. The factory duct

adapter must not be used for structural support of

the ducts.

ERV-522 and 582

This duct adapter can be used to locate and

support the duct work.

Curb Outside Dimensions

ERV-522 and 582

ERV-251, 361, 521 and 581

All dimensions shown are in inches.

Main

Disconnect

OnOff Exhaust

Hood

Control Center

Exhaust Hood Supply Hood

Main

Disconnect

OnOff

Control Center

Main

Disconnect

OnOff

ERV-251 & 581

ERV-361 & 521 ERV-522 & 582

Length of Straight Duct

GOOD

POOR

FIGURE 3

WEATHERHOODS (Arrangement B, C and D)

The outdoor air intake weatherhood is shipped factory assembled and mounted to the ERV. The exhaust

discharge weatherhood is fastened to the skid and shipped with the ERV unit.

DUCT WORK CONNECTIONS

Examples of good and poor fan-to-duct

connections are shown in Figure 3. Air flow

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, increased noise levels and other

system effects.

INSTALLATION (continued)

Recommended Discharge

Duct Size and Length

ERV ERV Duct Straight

Model Blower Size Duct

Size Length

251 10 9 x 9 40

361 10 14 x 14 40

521 12 20 x 20 48

581 15 28 x 28 60

522S 15 28 x 28 60

522H 18 32 x 32 72

582 20 34 x 34 80

ELECTRICAL CONNECTIONS CAUTION !

If any of the original wire must be replaced,

the replacement wire must have a temperature

rating of at least 105°C, except for energy cut-off

or sensor lead wire which must be 150°C.

DANGER !

High voltage electrical input is required for this

equipment. This work should be performed by a

qualified electrician.

Before connecting power to the unit, read and

understand the following instructions and

wiring diagrams. Complete wiring diagrams are

attached inside the door(s) of the unit.

All wiring should be done in accordance with

the National Electrical Code ANSI/NFPA 70-

latest edition and any local codes that may

apply. In Canada, wiring should be done in

accordance with the Canadian Electrical Code.

The equipment must be properly grounded.

FIGURE 4

All dimensions shown are in inches.

Sequence for wiring ERV unit:

1.The unit’s nameplate states the voltage and total amperage required. The wire

supplying power to the unit should be sized for the label’s voltage and amperage.

2.The main power line should be connected to the disconnect switch. Make sure that the

disconnect lugs are securely tightened. A door interlocking safety disconnect is provided

as a standard feature with model ERV, (see Figure 4, page 6).

Power may be routed to the control center through the curb or the knock-outs on the side

of the ERV. The locations for the knockouts and control center are provided on the ERV

submittal. If power will be routed through the curb and unit base panels, then run the

power supply up through the base panel near the exhaust intake opening of the ERV.

3.Connect control wiring to the terminal strip located in the electrical control center. All

ERV units include, as standard, a transformer to achieve the 24 VAC control voltage.

4.Refer to the wiring diagram located in the control center or included with this manual for

controlling the ERV.

CAUTION

Any wiring deviations may result in personal injury or property damage. Greenheck is not

responsible for any damage to, or failure of the ERV unit caused by incorrect field wiring.

INSTALLATION (continued)

1. Main Disconnect

2. Motor Starter -Exhaust Air Fan

3. Motor Starter-Outdoor Air Fan

4. Motor Contactor-Energy Wheel

5. Control Power Transformer

(460 to 24 VAC)

6. Energy Wheel Motor Transformer

(460 to 230 VAC)

7. 24 VAC Terminal strip

8. Internal fuses for the control

circuit and wheel drive transformer

ELECTRICAL CONNECTIONS

TYPICAL CONTROL CENTER COMPONENTS

Exterior Dimensions Duct Dimensions * Approximate

Model ABCD E FG K L Q P Weight (lbs)

ERV-251 46 34 27 16 8 10 16 63/47 10 16 250

ERV-361 62 51 34 15 15 18 18 83/8111/219 18 750

ERV-521 67 67 44 18 15 24 24 103/4131/226 26 1200

ERV-581 75 70 67 16 22 22 27 16 183/428 48 1450

MODELS ERV-251, ERV-361, ERV-521 AND ERV-581

Arrangement A

Outdoor Air Inlet

Q x P

Exhaust Air Discharge

LxK

Outdoor Air Discharge

LxK

Exhaust Air Inlet

FxG

Arrangement B

Exhaust Air Inlet

FxG

Outdoor Air Discharge

LxK

Intake Hood

Exhaust Hood

Arrangement C

Exhaust Hood Intake Hood

Exhaust Air Inlet

FxG

Outdoor Air Discharge

LxK

Exhaust Air Inlet

FxG

Outdoor Air Discharge

LxK

Intake Hood

Arrangement D

Exhaust Hood

All dimensions shown are in inches.

DIMENSIONAL DATA

* Weight dependent on components and accessories.

Supply Hood

Exhaust

Hood

Cassette Slides out

Access Panels

Access Panel

Exhaust

Side Supply

Side

SERVICE CLEARANCES FOR ERV-251, 361, 521 AND 581

ACCESS PANEL LOCATIONS

ERV 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 are shown below.

Outdoor Air

Inlet

Exhaust Air

Discharge

Exhaust Air

Inlet

Outdoor Air

Discharge

Cassette Slides out

Access Panels

Exhaust

Side Supply

Side

Model R S T

251 32 30 30

361 44 30 30

521 60 40 40

581 65 40 40

ERV-251, 361, 521 and 581 Recommend Clearances

All dimensions shown are in inches.

Exhaust

Hood

Intake

Hood

Access panel for:

•Outdoor air blower and motor

•Energy wheel cassette

Access panel for:

•Energy wheel cassette

•Internal Filters

•Outdoor air inlet damper

•Frost control

•Outdoor air sensors

Access panel for:

•Main disconnect

•Electrical control center

•Internal filters

Access panel for:

•Exhaust air blower and motor

Arrangement A

Arrangement B, C or D

DIMENSIONAL DATA

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust Air Discharge

L x K

Outdoor Air Inlet

Q x P

BDA

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust

Hood

Intake

Hood

BDA

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust

Hood

Intake

Hood

BDA

Outdoor Air Discharge

L x K

Exhaust Air Inlet

H x J

Exhaust

Hood

Intake

Hood

Arrangement A Arrangement B

Arrangement D

Arrangement C

* Weight dependent on components and accessories.

All dimensions shown are in inches.

ABCDEFGH JKLQP

ERV-522S 124 84 64 16 19 26 36 48 25 16 18 5/860 25 3000

ERV-522H 124 84 64 16 19 26 36 48 25 19 22 60 25 3000

MODEL ERV-522 AND ERV-582

Model Exterior Dimensions Duct Dimensions * Approximate

Weight

ERV-582H 146 97 77 26 3/431 38 60 28 25 25 70 30 3600

17 1/2

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