Greenheck Fan Energy Recovery Unit With Heating Erh 20 Users Manual IOM 01 02

Energy Recovery Unit With Heating ERH-20 ERHIOM

ERH-90 to the manual f83dcc75-748e-4697-9c9d-e06abecc9335

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**WARNING**

DISCONNECT AND SECURE TO THE "OFF"

POSITION ALL ELECTRICAL POWER TO THE

UNITS PRIOR TO INSPECTION OR SERVICING.

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 THE UNITS. FAILURE

TO COMPLY WITH THIS SAFETY PRECAUTION

COULD RESULT IN PROPERTY DAMAGE,

SERIOUS INJURY OR DEATH.

PART #459657

READ AND SAVE THESE INSTRUCTIONS

®

ENERGY RECOVERY UNIT

with HEATING

Models: ERH-20, 45, 55, & 90

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Heating Section

Energy Recovery Wheel

INSTALLATION SUPPLEMENT

Refer to the following Greenheck installation

supplement for ERH units supplied with Indirect

Gas (IG) heating:

Model PVF, Indirect Gas Fired Furnaces for

Energy Recovery Units, Part #461006

GENERAL

Greenheck Energy Recovery units with

Tempering are thoroughly inspected and test

run at the factory. However, damage may

occur during handling and shipping.

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.

TABLE OF CONTENTS

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

Installation . . . . . . . . . . . . . . . . . . . . . . . 3

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

Recommended Roof Openings . . . . . . .3

Unit Weights . . . . . . . . . . . . . . . . . . . . .3

Roof Curb Mounting . . . . . . . . . . . . . . .4

Duct Work Connections . . . . . . . . . . . . 4

Weatherhoods . . . . . . . . . . . . . . . . . . . 4

Electrical . . . . . . . . . . . . . . . . . . . . . . . .5

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

Water Coil Location and Connection . . 7

Water Coil Recommendations . . . . . . . 7

Electric Heater Application/Operation .8

Frost Control Application/Operation . .9

Dirty Filter Switch Operation . . . . . . . .9

Economizer Application/Operation . . .10

Start Up Checks . . . . . . . . . . . . . . . . . . 11

Fan wheel . . . . . . . . . . . . . . . . . . . . . . 11

Fan RPM . . . . . . . . . . . . . . . . . . . . . . . 12

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

Coils . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Routine Maintenance . . . . . . . . . . . 13-14

Belts . . . . . . . . . . . . . . . . . . . . . . . . . .13

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

Blower Wheel and Fasteners . . . . . . . .13

Vibration . . . . . . . . . . . . . . . . . . . . . . .14

Filters . . . . . . . . . . . . . . . . . . . . . . . . . 14

Coil Maintenance . . . . . . . . . . . . . . . . .15

Energy Recovery Wheel Maintenance .16

Accessing Energy Recovery Wheel . . .16

Removing Wheel Segments . . . . . . . .17

Cleaning Wheel Segments . . . . . . . . .17

Parts List . . . . . . . . . . . . . . . . . . . . . . . .18

Unit Trouble Shooting . . . . . . . . . . .19-20

STORAGE

When a unit is not going to be in service for an extended amount of time, certain procedures should be

followed to keep the fans in proper operating condition.

• Rotate fan wheel monthly and purge grease from bearings once every three months

• Cover unit with tarp to protect from dirt and moisture (Note: do not use a black tarp as this will promote

condensation)

• Energize fan motor once every three months

• Store belts flat to keep them from warping and stretching

• Store unit in location which does not have vibration

• After storage period, purge grease from fan bearings before putting fan into service

If storage of unit is in a humid, dusty or corrosive atmosphere, rotate the fan and purge the bearings once a

month. Improper storage which results in damage to the unit or components will void the warranty.

2

3

INSTALLATION

The system design and installation should follow accepted industry

practice, such as described in the ASHRAE Handbook.

Adequate space should be left around the unit for piping coils and

drains, 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 page 6 for more detail on appropriate clearances.

LIFTING

Units 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 should only be done with all

access doors closed to avoid damaging the unit. To prevent damage

to the unit cabinetry, use spreader bars. Spreader bars must be in

position to stop cables from rubbing the frame or panels. Before

hoisting into position, test lift to insure stability and balance. Avoid

twisting or uneven lifting of the unit. Never lift units by weatherhoods.

The ERH 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. This

particular unit also has

a heater option

available after the

recovery wheel to

further increase the

fresh air temperature if

desired.

Lift using lifting

lugs and

spreader bar

FIGURE 1

Unit Size Approx. Weight (lbs)

ERH-20 1000

ERH-45 1800

ERH-55 2500

ERH-90 4500

UNIT WEIGHTS (dry weights)

RECOMMENDED ROOF OPENING

BASIC OPERATION

EXHAUST

INLET

SUPPLY

OUTLET

V

U

Model U V

ERH-20 46 37

ERH-45 54 39

ERH-55 65 47

ERH-90 85 49

Dimensions shown are in inches.

FIGURE 2

TABLE 2

TABLE 1

Outdoor Air

Exhaust Air

discharged outside

Exhaust Air

from building

Preconditioned Air sent

to conditioning system

Optional

Heater

Energy

Recovery

Wheel

4

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Length of Straight Duct

GOOD

R

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POOR

FIGURE 4

DUCT WORK CONNECTIONS

Examples of good and poor fan-to-duct connections are shown below (See FIGURE 4). 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.

1. Factory Supplied Roof Curbs

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

Layout the unit roof opening such that the supply

discharge & exhaust inlet of the unit will line up

with the corresponding ductwork (refer to

Recommended Roof Openings on page 3). Be

sure to allow for the recommended service

clearances. Keep the supply inlet of the unit away

from any other exhaust fans.

3. Install Curb

Locate curb over roof opening and fasten in place.

Check that the diagonal dimensions are within

±1/8 inch 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 unit base.

4. Install Duct Work

Installation of all

ducts should be

done in accordance

with SMACNA and

AMCA guidelines.

Model L W

ERH-20 73 51

ERH-45 80.75 60.63

ERH-55 94 71.5

ERH-90 106.25 90.75

ROOF CURB MOUNTING

L

W

Curb Outside Dimensions

Dimensions shown are in inches.

FIGURE 3

Roof curb details, including duct

location dimensions, are available

on ERH roof curb submittals.

Recommended Discharge

Duct Size and Length

ERH ERH Duct Straight

Model Blower Size Duct

Size Length

20 10 14 x 14 40

45 12 20 x 20 48

55 15 28 x 28 60

90 18 32 x 32 72

Dimensions shown are in inches.

TABLE 3

TABLE 4

5

Main

Disconnect

On

Off

Exhaust

Hood

Control Center

Intake

Hood

INSTALLATION (continued)

WEATHERHOODS

Supply weatherhood will be factory mounted. The exhaust weatherhood is shipped separately as a kit with its

own instructions.

EXHAUST DAMPERS

Backdraft dampers for exhaust discharge are mounted in the unit. Motorized dampers are shipped loose (inside

ERH) and must be field installed.

ELECTRICAL CONNECTIONS

The electrical supply must be compatible with that shown on the nameplate: voltage, phase, and amperage

capacity. The electrical supply line must be properly fused and conform to local and national electrical codes.

All internal electrical components are pre-wired at the factory. Field electrical connections only need to be made

inside the unit to the main disconnect (See FIGURE 5, Item #1) and the 24 volt control circuit (See FIGURE 5,

Item #7). A door interlocking safety disconnect is provided as standard feature.

Note: Standard factory installed electric post heaters have their own disconnect separate from the unit

disconnect. Thus, electric post heaters require a separate power connection.

IMPORTANT: Use minimum 14 ga. wire for 24 volt control power.

Control wire resistance should not exceed 0.75 ohms (approximately 285 feet total length for

14 ga. wire; 455 feet total length for 12 ga. wire). 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 (between terminal blocks 2 and 3 on the control strip — See FIGURE 5,

Item #7). 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.

1

23

4

6

5

7

8

1. Main Disconnect

2. Motor Starter — Exhaust/Scavenger

Air Fan

3. Motor Starter — Outdoor Air Fan

4. Motor Contactor — Energy Wheel

5. Control Power Transformer

(24 VAC Secondary)

6. Energy Wheel Motor Transformer

(230 VAC Secondary)

(for ERH-20 & ERH-45 units with

primary voltage greater than 230 Vac)

7. 24 VAC Terminal strip

8. Fuses for the control circuit, wheel

drive transformer, and blower

motors.

TYPICAL CONTROL CENTER COMPONENTS

FIGURE 5

Wheel Cassette

2 in. filters

2 in. filters

Exhaust Air

Intake

Electrical Box

Access Panel

Access Panel

Access Panel

Access Panel

Access Panel

Cassette

Slides Out

52 in.

Clearance with

IG Heater

0 in.

Clearance without

IG Heater

Exhaust

Hood

Outdoor Air Hood

IG Heater

*48 in. **64 in.

36 in.

36 in.

TOP VIEW

SERVICE CLEARANCES / ACCESS PANEL LOCATIONS for Model ERH

ERH-20, 45, 55, and 90 units require minimum clearances for access on all sides for routine maintenance. Filter

replacement, drain pan inspection and cleaning, energy wheel cassette inspection, fan bearing lubrication and

belt adjustment, are examples of routine maintenance that must be performed. Blower and motor assemblies,

energy recovery wheel cassette, coil 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 FIGURES 6 and 7 below for these dimensions.

FIGURE 6

Wheel Cassette

2 in. filters

2 in. filters

Exhaust Air

Intake

Electrical Box

Access Panel

Access Panel

Access Panel

Access Panel

Access Panel

52 in.

Clearance with

IG Heater

0 in.

Clearance without

IG Heater

Exhaust

Hood

Outdoor Air Hood

IG Heater

42 in.

42 in.

42 in.

TOP VIEW

FIGURE 7

6

Clearances for service and component removal on ERH-20 and ERH-45

*Clearance for energy wheel removal on ERH-20.

**Clearance for energy wheel removal on ERH-45.

Clearances for service on ERH-55 and ERH-90

1. Piping should be in accordance with accepted

industry standards. Pipework should be supported

independently of the coils. Water connections are

male NPT iron pipe. When installing couplings, do

not apply undue stress to the connection

extending through the unit. Use a backup pipe

wrench to avoid breaking the weld between coil

connection and header.

2. Connect the WATER SUPPLY TO THE BOTTOM

CONNECTION on the air leaving side and the

WATER RETURN TO THE TOP CONNECTION on

the air entering side. To insure proper venting, an

external air vent in the piping is recommended.

Connecting the supply and/or return in any other

manner will result in very poor performance. Be

sure to replace factory installed grommets around

coil connections if removed for piping. Failure to

replace grommets will result in water leakage into

the unit and altered performance.

3. The air vent at the uppermost point should be

temporarily opened during system start-up to

release all of the air from the coil. To maintain heat

transfer capacity, periodically vent any air in coil.

4. Water coils are not normally recommended for use

with entering air temperatures below 40oF;

however, the energy recovery wheel maintains a

pre-coil temperature higher than 40oF. No control

system can be depended on to be 100% safe

against freeze-up with water coils. Glycol

solutions or brines are the only safe media for

operation of water coils with low entering air

conditions.

CONTINUOUS WATER CIRCULATION THROUGH

THE COIL AT ALL TIMES IS HIGHLY

RECOMMENDED.

5. Pipe sizes for the system must be selected on the

basis of the head (pressure) available from the

circulation pump. The velocity should not exceed

6 feet per second and the friction loss should be

approximately 3 feet of water column per 100 feet

of pipe.

WATER COIL APPLICATION

RECOMMENDATIONS

Factory installed heating components are mounted

down stream of the energy wheel on the supply air side

of the unit.

See FIGURE 8 & 9 for coil connection location. Coil

connections are located external to the unit as shown.

Coil connections that are not external have been ordered

from the factory with interior or exhaust air stream coil

connections.

7

WATER COIL LOCATION AND CONNECTION

A hot water coil can be factory installed in the coil section of the ERH. The coil section is downstream of the

energy wheel on the supply air side of the unit. Coil connections are external to the unit as shown below. Coil

connections not external have been ordered from the factory with internal or exhaust air stream connections.

A

C

B

D

Model A B C D

ERH-20 15 33 3⁄441 1⁄411⁄2NPT

ERH-45L 17 1⁄239 1⁄446 3⁄411⁄2NPT

ERH-45H 17 1⁄248 1⁄446 3⁄42 NPT

ERH-55 17 1⁄254 1⁄450 1⁄22 NPT

ERH-90 17 1⁄2See Note 5 62 1⁄411⁄2NPT

TABLE 5

FIGURE 9 FIGURE 10

Note 1: Dimensions shown are for 1-row coil.

Note 2: All dimensions are in inches (measured

to center of coil connections).

Note 3: NPT - National Pipe Thread.

Note 4: ‘A’ dimension assumes a 12 in. curb.

Note 5: The ERH-90 uses a dual coil (stacked

on top of each other). Refer to FIGURE

10 for the ‘B’ dimension.

30

3⁄4

30

3⁄4

6

3⁄4

Top

Coil

Bottom

Coil

ERH-90 Coil

Connections

FIGURE 8

DX coil liquid

connection

access door

Water coil

connections

8

ELECTRIC HEATER APPLICATION/OPERATION

Factory installed electric heaters can be provided for preheat and/or post-heat (see FIGURE 11). An electric

preheater warms the outdoor air prior to the energy recovery wheel to prevent frosting on the wheel. An electric

post-heater warms the air leaving the energy recovery wheel to a user specified discharge temperature. Electric

heaters are available in 208, 230, or 460 Vac (refer to heater nameplate for voltage).

Preheaters: Preheaters are standard as 2-stage, step control. Step control heaters are designed with

multiple stages made up of equal increments of heating capability. For example, a 10 kW

heater with two stages will be composed of two 5-kW stages. Preheaters are single point

wired at the factory. A temperature sensor (with field adjustable set point) is mounted in the

outdoor airstream after the preheater to turn the preheater on. See FROST CONTROL

APPLICATION/OPERATION for typical set points. If the outdoor air temperature falls below the

set point, 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.

Post-heaters: Post-heaters are standard as 4-stage, step control. Post-heaters are not single point wired

(see ELECTRICAL CONNECTIONS, page 5). The functionality of a 4-stage heater is the same

as the 2-stage preheater above, except it has an additional two stages of heat control.

Post-heaters supplied with Greenheck temperature control package are 3-stage with binary

control that provides 7 steps of heating. For example, a 35 kW heater with three stages will be

composed of 5, 10, and 20 kW stages. The stages essentially ‘mix and match’ to provide heat

output from 5 kW to 35 kW, in 5 kW increments.

FIGURE 11

Electric Post-Heater

The post-heater is not single

point wired to the ERH control

center (requires separate

power). The post-heater and the

ERH each have their own

disconnect located in the UNIT

control center.

If required, access to the post-

heater control panel is through

the exhaust filter door.

Electric Preheater

The preheater is single point wired to the ERH control

center (does not require separate power). Access to the

preheater control panel is through the supply filter door.

FROST CONTROL APPLICATION/OPERATION

DIRTY FILTER SWITCH SETUP

When outdoor air temperatures are extremely cold, moisture condensation and frosting on the energy recovery

wheel is possible. Frost control is an optional feature that will prevent wheel frosting. Two options are available:

1) Timed Exhaust frost control and

2) Preheat frost control

Timed exhaust frost control includes a thermostat (with

probe) mounted in the supply air inlet compartment (see

FIGURE 13, page 10) and a timer (Figure 12) mounted in the

ERH control center. The thermostat will turn on the timed

exhaust frost control feature at a predetermined field

adjustable outdoor air temperature (referred to as the Frost

Threshold temperature). The typical temperature setting

corresponds to the indoor air relative humidity as shown in TABLE 6.

Testing (refer to FIGURE 12)

•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.

•Turn the temperature sensor up as high as possible.

The supply blower should cycle on for one minute,

then turn off for one minute.

•After testing, set the Timer Scale as follows: T1 = 10

minutes, T2 = 1 hour

•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.

Preheat frost control (see FIGURE 11, page 8) includes a

thermostat (with probe) and an electric heater located in the

supply air inlet compartment and an air pressure switch in the

supply air outlet compartment. The thermostat should be set

according to the Frost Threshold temperatures shown in TABLE 6.

When the outdoor air temperature reaches the thermostat setting,

the electric preheater will turn on and warm the air entering the energy

wheel.

Testing

•Turn the thermostat as high as it will go. The heater should turn on.

•If it doesn’t, either put the supply side doors on or temporarily jumper the

air pressure switch to avoid nuisance tripping of the pressure switch.

Remember to remove the jumper.

9

A1 B1 15

16 18 A2

0.20

0.41.0

0.60.8

0.20

0.41.0

0.60.8

T1

T2 T21 MIN

T11 MIN

Timer

Scale

Dip

Switch

Indoor RH @ 70°F Frost Threshold Temp

20% -10°F

30% -5°F

40% 0°F

TABLE 6

FIGURE 12

This unit may be equipped with a dirty filter switch that functions on differential air pressures to close a relay

when the unit filters are clogged and need cleaning. This 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 electrical control center.

To adjust the switch the unit must be running with all of the access doors in place, except for the compartment

where the switch is located (exhaust inlet compartment). Remove the switch cover plate. 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). If there is no power, turn the adjustment screw on the dirty filter gage

clockwise until you have power. 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.

The energy recovery wheel may be de-energized for the purpose of providing economizer (free cooling)

operation. This can be achieved with a signal from a Temperature or Enthalpy sensor mounted in the supply air

inlet compartment (see FIGURE 13). This Primary sensor will de-energize the energy wheel when the outdoor air

temperature (factory default is 65°F) or enthalpy (factory default is the ‘D’ setting) is below the field adjustable

set point. An additional Override temperature sensor is also furnished in the supply air inlet compartment to

deactivate economizer mode (see FIGURE 13). The Override (with field adjustable set point) is set at some

temperature lower than the Primary sensor (factory default is 50°F). Effectively, the two sensors create a

deadband where the energy recovery wheel will not operate and free cooling from outside can be brought into

the building unconditioned.

Testing (terminals referenced below are in the unit control center — see FIGURE 5, Item #7)

Temperature sensor with Override

•Turn both Temperature and Override

thermostats down as low as they go.

The wheel should be rotating.

•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.

•Turn both sensors as high as they will

go. The wheel should start rotating.

•Set the Temperature sensor to the

desired temperature for economizer

operation to begin. Set the Override

sensor to the desired temperature for

economizer operation to end (factory

default is 65°F and 50°F, respectively).

Enthalpy sensor with Override

•A factory-installed 620 ohm resistor is

connected across terminals SR and +.

The Override sensor should be turned

down below current temperature in unit. Turn the unit on; LED on the sensor should be off. Check

continuity across terminals 2 and 3, there should not be continuity. There should be continuity

between terminals 1 and 2.

•Disconnect the 620 ohm resistor from terminals SR and +. LED should turn on. There should be

continuity between terminals 2 and 3. There should not be continuity between terminals 1 and 2.

•Turn the Override sensor above current temperature in unit. There should be continuity between

terminals 3 and 6. Set the Override sensor to the desired temperature for economizer operation to end

(factory default is 50°F).

•Reconnect the factory-installed jumper.

10

ECONOMIZER APPLICATION/OPERATION

Enthalpy Sensor

(Primary Sensor)

Timed Exhaust

Frost Control

Override

Probes

FIGURE 13

11

GENERAL

Check all fasteners and set screws for tightness. This is especially important

for bearings and fan wheels. Also, if dampers are not motorized, check that

they open and close without binding.

FAN WHEEL ROTATION

Hand rotate the blower to ensure that the wheel is not rubbing against the

scroll. If the blower is rotating in the wrong direction, the unit will move some

air but not perform properly.

To check the rotation, open the blower access panels, which are labeled either

supply or exhaust, and run the blower momentarily to determine the rotation.

Rotation should be in the same direction as airflow at the outlet (See FIGURES

14 & 15). Check for unusual noise, vibration or overheating of bearings. Refer to

the “Trouble Shooting” section of this manual if a problem develops.

To reverse the rotation, turn the power off and use the following procedure:

•For single phase units, rewire the motor per the instructions on the

motor.

•For three phase units, interchange any two power leads. (this can be

done at the motor starter).

START UP CHECKS

**WARNING**

DO NOT OPERATE ENERGY RECOVERY VENTILATOR WITHOUT THE FILTERS AND BIRDSCREENS INSTALLED.

THEY PREVENT THE ENTRY OF FOREIGN OBJECTS SUCH AS LEAVES, BIRDS, ETC.

DO NOT REMOVE ACCESS PANELS OR OTHER UNIT COMPONENTS WHILE STANDING ON A LADDER OR OTHER

UNSTEADY BASE. ACCESS PANELS AND UNIT COMPONENTS ARE HEAVY AND SERIOUS INJURY MAY OCCUR.

CAUTION: See **WARNING** on page 1 and above

For proper unit function and safety, follow everything in this start-up procedure in the order presented. This to

be done after the electrical and gas connections are complete.

Pre-Start Check List

1. Disconnect and lock-out all power switches to fan.

2. Check all fasteners, set screws and locking collars on the fan, bearings, drive, motor base and

accessories for tightness.

3. Rotate the fan wheel by hand and assure no parts are rubbing.

4. Check the V-belt drive for proper alignment and tension.

Special Tools Required • Voltage meter

• Incline manometer or equivalent

• Tachometer

• Thermometer

• Amperage meter

R

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Airflow

FIGURE 14

FIGURE 15

R

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ENERGY RECOVERY WHEEL

CAUTION: See **WARNING** on page 1 and 11

For the ERH-20 and ERH-45, open the access door marked

"Energy Wheel Cassette Access". UNPLUG the wheel drive

motor and remove the metal spacer. Then pull the cassette

out halfway as seen in FIGURE 17.

Note: For the ERH-55 and ERH-90, the energy recovery

wheel does not slide out due to its size and weight. There is

ample room inside the unit to perform energy recovery wheel

servicing.

Turn the energy recovery wheel by hand to verify free

operation. 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. Replace cassette

into unit, plug in wheel drive, replace access door and apply

power. Observe that the standard and high flow wheel

rotates freely at about 60 RPM.

If wheel does not rotate or rotates too slowly, remove the

cassette (following the instruction on page 16). Air seals, which are too tight, will prevent proper rotation of the

energy recovery wheel. Recheck the air seals for tightness. Air seal clearance may be checked by placing a

sheet of paper, to act as a feeler gauge, against the wheel face. 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.

COILS

Leak test thermal system to insure tight connections.

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 FIGURE 16).

FAN RPM

The adjustable motor pulley is 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. Access these components through the labeled access

panels.

All access doors must be installed except the control center door.

To measure the fan rpm, the blower door will need to be removed.

Minimize measurement time because the motor may overamp with

the door removed. Do not operate units with access doors/panels

open or without proper ductwork in place as the motors will

overload.

FIGURE 17

FIGURE 16

WRONG WRONG

WRONG CORRECT

13

ROUTINE MAINTENANCE

CAUTION: See **WARNING** on Page 1 and 11

Once the unit has been put into operation, a periodic maintenance program should be set up to preserve the

reliability and performance. Items to be included in this program are:

• BELTS

• MOTORS

• WHEEL AND FASTENERS

• VIBRATION

• FILTER MAINTENANCE

• COIL MAINTENANCE

• ENERGY WHEEL CASSETTE

FAN BELTS

Belts tend to stretch after a period of time. They should be

periodically checked for tension and wear. When replacing

belts, use the same type as supplied with the unit.

Replacement of belts should be accomplished by loosening

the motor slide plate so the belts may be removed by hand.

Do not force belts on or off as this may cause breakage of

cords and lead to premature belt failure.

Belt tension should be adjusted to allow 1/64 in. of belt

deflection per 1 in. of belt span. For example, a 16 in. belt

span should have 16/64 in. or 1/4 in. of deflection with

moderate thumb pressure at mid-point between the pulleys

(FIGURE 18).

Deflection = Belt Span

64

Belt Span

FIGURE 18

MOTORS

Motor maintenance is generally limited to cleaning and lubrication (where applicable). Cleaning should be

limited to exterior surfaces only. Removing dust and grease build-up on the motor housing assures proper

motor cooling. Use caution and do not allow water or solvents to enter the motor or bearings. Under no

circumstances should motors or bearings be sprayed with steam, water or solvents.

Greasing of motors is intended only when fittings are provided. Many fractional horsepower motors are

permanently lubricated for life and require no further lubrication. Motors supplied with grease fittings should

be greased in accordance with the manufacturer’s recommendations.

WHEEL AND FASTENERS

Wheels require very little attention when moving clean air. Occasionally oil and dust may accumulate on the

wheel causing imbalance. When this occurs the wheel and housing should be cleaned to assure smooth and

safe operation. Inspect fan impeller and housing for fatigue, corrosion or wear.

Routinely check all fasteners, set screws and locking collars on the fan, bearings, drive, motor base and

accessories for tightness. A proper maintenance program will help preserve the performance and reliability

designed into the fan.

14

EXTERNAL FILTER MAINTENANCE

Aluminum mesh 2 in. 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.

To remove these filters, remove bottom bolt in the

access door on the side of the weatherhood. Slide

the access door up and then pull out. Then, slide

the filters out (see FIGURE 19).

Clean filters by rinsing with a mild detergent in

warm water. After the filters are dry, an adhesive

spray available at most filter distributors may be

applied to increase filter efficiency.

INTERNAL FILTER MAINTENANCE

Opening the access doors labeled as “Filter

Access” provides access to the pleated 30%

filters (if the filter option was purchased). These

filters should be checked regularly, cleaned or

replaced as needed. See TABLE 7 for pleated filter

size and quantity for each unit.

FIGURE 19

Internal

Model Filter Size Quantity

ERH-20 20 x 20 2

ERH-45 20 x 25 3

ERH-55 16 x 25 6

ERH-90 20 x 20 8

VIBRATION

Excessive vibration maybe 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 below.

Many of these conditions can be discovered by careful observation.

Refer to the troubleshooting section of this manual for corrective actions.

If observation cannot locate the source of vibration, a qualified

technician using vibration analysis equipment should be consulted. If the

problem is wheel unbalance, in-place balancing can be done providing

there is access to the fan wheel.

Generally, fan vibration and noise are transmitted to other parts of the

building by the ductwork. To eliminate this undesirable effect, the use of

heavy canvas connectors is recommended.

1. Wheel Unbalance

2. Drive Pulley Misalignment

3. Incorrect Belt Tension

4. Bearing Misalignment

5. Mechanical Looseness

6. Faulty Belts

7. Drive Component Unbalance

8. Poor Inlet/Outlet Conditions

9. Foundation Stiffness

TABLE 7

15

WATER COIL MAINTENANCE

CAUTION: See **WARNING** on Page 1 and 11

FILTERS

Filters upstream of the coil should be checked regularly. If the filters are dirty, they should be cleaned or

replaced. It is important that the coils stay clean to maintain desired airflow. See page 14 for more information

on filter maintenance.

COIL MAINTENANCE

1. Coils must be clean to obtain maximum performance. Check once a year under normal operating

conditions and, if dirty, brush or vacuum clean. Soiled fins reduce the capacity of the coil, demand more

energy from the fan, and create an environment for odor and bacteria to grow and spread through the

conditioned zone. High pressure water (700 Psi or less) may be used to clean coils with fin thickness over

0.0095 inches thick. TEST THE SPRAY PRESSURE over a small corner of the coil to determine if the fins

will withstand the spray pressure.

For coils with fragile fins or high fin density, foaming chemical sprays and washes are available. Many coil

cleaners contain harsh chemicals, so they must be used with caution by qualified personnel only. Care

must be taken not to damage the coils, including fins, while cleaning.

CAUTION: Fin edges are sharp.

**WARNING**

BIOLOGICAL HAZARD. MAY CAUSE DISEASE. CLEANING SHOULD BE PERFORMED BY QUALIFIED PERSONNEL.

FIGURE 20

For the ERH-20 and ERH-45, open the access door marked "Energy Wheel Cassette Access" (FIGURE 20).

UNPLUG the wheel drive motor and remove the metal spacer. Then pull the cassette out halfway (FIGURE 21).

The energy recovery wheel cassettes for model ERH-55 and ERH-90 do not slide out due to their size and

weight. Service to these energy wheel cassettes can be done through the Filter and Electrical Control Box

access doors, or by entering the unit through the Exhaust Blower access door.

**WARNING: Disconnect power to the unit before performing any type of service.**

ACCESSING ENERGY RECOVERY WHEEL

FIGURE 21

ROUTINE ENERGY RECOVERY WHEEL MAINTENANCE

CAUTION: See **WARNING** on Page 1 and 11

MAINTENANCE OF THE ENERGY RECOVERY WHEEL

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.

16

CLEANING ENERGY RECOVERY WHEEL SEGMENTS

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 Fantastic™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.

** DO NOT CLEAN ENERGY RECOVERY WHEEL SEGMENTS WITH WATER IN EXCESS OF 140°F

** DO NOT DRY ENERGY RECOVERY WHEEL SEGMENTS IN AIR IN EXCESS OF 140°F.

IMPORTANT! PLACE RETAINERS BACK IN THE ORIGINAL

POSITION BEFORE ROTATING THE ENERGY

RECOVERY WHEEL. OTHERWISE DAMAGE TO

RETAINER WILL OCCUR.

Bracket Segment Retainer

Lift Away

From Segment

Catch-

Segment Retainer

Push Toward Center

Center of Wheel

Spoke

Inside of Wheel Rim

FIGURE 22

Model ERH-20, 45, 55, & 90

Steel retainers are located on the

inside of the wheel rim (FIGURE 22).

Push the retainer toward center of

wheel, then lift up and away to

release segments (FIGURE 23).

REMOVING THE ENERGY RECOVERY WHEEL SEGMENTS

FIGURE 23

17

PARTS LIST

1

2

3

4

8

5

6

7

7

9

Model ERH

(shown with indirect gas heater)

10

18

1. Supply blower

-Forward curved fan

-Adjustable motor mount for belt tensioning

-Adjustable sheaves for speed control

2. Vibrations isolators (quantity 4 per blower)

- Neoprene

3. Energy recovery wheel cassette

4. Removable energy recovery wheel segments

5. Optional supply weatherhood with 2 in. aluminum

mesh filter

6. Optional exhaust weatherhood with birdscreen

7. Optional supply and exhaust air filter racks with 2

in. pleated, 30% efficient filters

8. Electrical control box (standard features)

-Single point power

-Disconnect interlocked with access door

-Motor starters for the supply blower, exhaust

blower and energy wheel motors.

-24 Vac, control circuit with terminal strip

9. Supply air tempering options

-Electric heat

-Hot water heat

-Indirect gas heat

10. Exhaust blower

-Forward curved fan

-Adjustable motor mount for belt tensioning

-Adjustable sheaves for speed control

* Always provide the unit model and serial number when requesting parts or service information. * Always check motor amps and compare to nameplate rating.

19

Control power (24 Vac) wiring

run is too long (resistance

should not exceed 0.75 ohms).

Shorten wiring run to mechanical room or install a relay

which will turn unit on/off (C/F for relay information).

Incoming supply power is

less than anticipated. Voltage

supplied to starter coil must

be within +10% / -15% of

nominal voltage stated on

the coil.

Need to increase supply power or use a special control

transformer which is sized for the actual supply power.

Motor Starters

“Chatter” or Do

Not Pull In

Blown fuse or open circuit

breaker.

Replace fuse or reset circuit breaker and check amps.

Possible CauseSymptom Corrective Action

Defective motor or capacitor. Replace

Motor starter overloaded. Reset starter and check amps.

Electrical. Check for On/Off switches. Check for correct supply voltage.

Drive. Check for broken or loose belts. Tighten loose pulleys.

Blower Fails to

Operate

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. Check rotation and reverse if necessary.

Motor voltage incorrect. Check motor nameplate versus supplied voltage.

Motor horsepower too low. See specifications and catalog for fan curves to determine if

horsepower is sufficient.

Motor Over Amps

Shorted windings in motor. Replace motor.

Unit damper not fully open. Adjust damper linkage or replace damper motor.

System static pressure too high Improve ductwork to eliminate losses using good duct

practices.

Blower speed too low. Check for correct drives and rpm with catalog data.

Fan wheels are operating

backwards.

For 3-phase see Fan Wheel Rotation on page 11.

Dirty filter or energy wheel. Follow cleaning procedures on pages 14 and 17.

Leaks in ductwork. Repair.

Elbows or other obstructions

may be obstructing fan outlet.

Correct or improve ductwork.

Belt slippage. Adjust belt tension.

Blower fan speed too high. Check for correct fan rpm. Decrease fan speed if necessary.

Filter(s) not in place. Install filters.

Insufficient static pressure (Ps)

(airflow resistance).

Induce Ps into system ductwork. Make sure grilles and

access doors are installed. Decrease fan speed if necessary.

Low Airflow (cfm)

High Airflow (cfm)

Trouble Shooting

IOM ERH FS

Rev. 1 January 2002

Warranty

Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from

the purchase 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.

GREENHECK

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

PH. 715-359-6171

www.greenheck.com

®

Due to continuing product development Greenheck has the right to change specifications without notice

* Always provide the unit model and serial number when requesting parts or service information. * Always check motor amps and compare to nameplate rating.

Energy Wheel

Does NOT Turn

Blower fan motor overloads are

tripping and auto-resetting.

Decrease fan speed.

Possible CauseSymptom Corrective Action

Exhaust Only frost control

sensors are tripping.

Adjust frost temperature sensor set point as needed.

Air seals are too tight. See Energy Recovery Wheel on page 12

“Economizer” sensors are

operating.

Adjust temperature or enthalpy set points as needed.

No power to wheel motor. Make sure wheel drive is plugged in. Verify power is

available.

Wheel drive belt Check for loose or broken belts. Replace belts (consult

factory).

One or Both

Blowers Turn Off

Intermittently and

Back on After

About 2 Minutes

Wheel motor overloads are

tripping, due to rubbing

between wheel and air seals.

Recheck air seals, make sure they are not too tight. See

Energy Recovery Wheel on page 12.

Fan wheel rubbing on inlet Adjust wheel and/or inlet cone. Tighten wheel hub or bearing

collars on shaft.

Bearings. Replace defective bearings (s). Lubricate bearings. Tighten

collars and fasteners.

Wheel out of balance. Replace or rebalance.

Loose wheel on shaft. Tighten wheel setscrew.

Energy Wheel

Runs Intermittently

Loose motor or blower sheave. Tighten sheave setscrew.

Belts too loose. Adjust belt tension after 24 hours of operation.

Belts too tight. Loosen to maintain a 3/8 inch deflection per foot of span

between sheaves.

Worn belt. Replace.

Motor base or blower loose. Tighten mounting bolts.

Build up of material on wheel. Clean wheel and housing.

Bearing and drive misaligned. Realign.

Noise being transmitted by

duct.

Make sure duct work is supported properly. Make sure duct

work metal thickness is sized for proper stiffness. Check duct

size at discharge to ensure that air velocities are not too high.

Excessive Noise or

Vibration

Trouble Shooting

Copyright © 2002 Greenheck Fan Corp.