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Installation, Operation and Maintenance Manual
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the
product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could
result in personal injury and/or property damage! Retain instructions for future reference.
Model ERCH-HP
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,
including environmental. 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 affect 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.
5. Verify that the power source is compatible with the
equipment.
6. Never open access doors to the unit while it is
running.
ERCH-HP Energy Recovery Ventilator
• Always disconnect power before working on or near
this equipment. Lock and tag the disconnect switch
or breaker to prevent accidental power up.
• If this unit is equipped with optional gas
accessories, turn off gas supply whenever power is
disconnected.
This unit is equipped with a compressed refrigerant
system. If a leak in the system should occur,
immediately evacuate and ventilate the area. An EPA
Certified Technician must be engaged to make repairs
or corrections. Refrigerant leaks may also cause
bodily harm.
When servicing the unit, the internal components may
be hot enough to cause pain or injury. Allow time for
cooling before servicing.
Model ERCH-HP Energy Recovery Unit
Part #473501
with Heat Pump
DANGER
CAUTION
CAUTION
1
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Table of Contents
Summary of Contents for Greenheck ERCH-HP
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Page 1: General Safety Information
Part #473501 ERCH-HP Energy Recovery Ventilator ® with Heat Pump 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. -
Page 2: Receiving, Handling And Storage
Receiving Storage Upon receiving the product, check to make sure all Units are protected against damage during shipment. If items are accounted for by referencing the bill of lading the unit cannot be installed and operated immediately, to ensure all items were received. Inspect each crate for precautions need to be taken to prevent deterioration of shipping damage before accepting delivery. -
Page 3: Table Of Contents
Table of Contents General Safety Information ....1 Energy Wheel Receiving, Handling and Storage ....2 Start-Up . -
Page 4: Product Overview
Product Overview Models and Capacities This unit brings in fresh, outdoor air and removes This unit is manufactured in four different platform sizes; stale exhaust air from the building. The intake and 20, 45, 55 and 90. Each platform has multiple options exhaust airstreams move through the unit in opposite for heating and cooling capacities. -
Page 5: Subassemblies
Subassemblies Coils Energy Wheel The airside coil is connected to the heat pump The energy wheel rotates through both the outdoor air compressor(s) and is the primary vehicle for heating and the exhaust airstreams, removing both sensible and cooling of the building. A reheat coil is optionally (heat) energy and latent moisture from one airstream available and is installed in the supply airstream and transferring it to the other airstream. -
Page 6: Heat Pump Module
Heat Pump Module Optional Electric Heaters Every unit has an integral heat pump module that There are two optional electric heaters available. One is contains hermetic scroll-type compressor(s), a coaxial a preheater and is used to prevent frost buildup on the refrigerant-to-water heat exchanger(s), refrigerant flow energy wheel. -
Page 7: Installation
Installation Dimensional Data Overall Exterior Dimensions Model Width Overall Width Overall Length (including Lifting Lugs) (with Exhaust Hood) (with Outdoor Air Hood) ERCH-HP 20 59.5 ERCH-HP 45 69.5 ERCH-HP 55 79.5 ERCH-HP 90 99.5 All dimensions shown are in inches. Unit Weights and Recommended Roof Opening Exhaust Intake... -
Page 8: Service Clearances
Service Clearances Minimum clearances are required 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 wheel cassette, coil and filter sections are always provided with a service door or panel for proper component access. -
Page 9: Handling, Lifting And Lifting Lugs
Handling While this unit was constructed with quality and WARNING dependability in mind, damage still may occur during All factory provided lifting lugs must be used when handling of the unit for installation. Exercise extreme lifting the units. Failure to comply with this safety caution to prevent any damage from occurring to precaution could result in property damage, serious the refrigerant system. -
Page 10: Roof Curb Mounting, Dimensions, Weights
Roof Curb Mounting Curb Outside Dimensions and Weights Rooftop units require curbs to be mounted first. The duct connections must be located so they will be clear SIDE OF UNIT of structural members of the building. BASE Factory Supplied Roof Curbs: Roof curbs are Model GKD, which are shipped in a knockdown kit (includes duct adapter) and require field assembly (by others). -
Page 11: Ductwork Connections
POOR GOOD POOR GOOD Ductwork Connections Rail Mounting / Layout Examples of poor and good fan-to-duct connections • Rails designed to handle the weight of the unit are shown below. Airflow out of the fan should be positioned as shown on the diagram should be directed straight or curve (rails by others). -
Page 12: Start-Up Unit
Start-Up Unit Every installation requires a comprehensive start-up DANGER to ensure proper operation of the unit. As part of that Electric shock hazard. Can cause injury or death. process, the following checklist must be completed and Before attempting to perform any service or information recorded. -
Page 13: Pre-Start-Up Checklist
Pre-Start-Up Checklist SPECIAL TOOLS REQUIRED o Disconnect and lock-out all power switches. • Voltage Meter (with wire probes) o Remove any foreign objects that are located in the • Amperage Meter energy recovery unit. • Pressure Gauges – (refrigerant) o Check all fasteners, set-screws, and locking collars •... -
Page 14: Unit Start-Up Checklist
Unit Start-Up Checklist Line Voltage. Check at unit disconnect. L1-L2 Volts L2-L3 Volts L1-L3 Volts Motor Amp Draw Supply Motor Amps Amps Amps Amps Exhaust Motor Amps Amps Amps Amps Fan RPM Supply Fan RPM Exhaust Fan RPM Correct fan rotation direction? Supply Fan Yes / No Exhaust Fan... -
Page 15: Electrical Information
EXH HP SUP HP Electrical Information Determine the Size of the Main Power Lines Unit’s Total MCA WARNING The unit’s nameplate states the voltage and the unit’s MCA. The main power lines to the unit should be sized The roof lining contains high voltage wiring. To prevent accordingly. -
Page 16: Discharge Air Temp Sensor
Plumbing / Piping Overview Most factory-supplied electrical components are prewired. To determine what electrical accessories Condensate Drain Trap require additional field-wiring, refer to the unit-specific wiring diagram located on the inside of the control This unit is equipped with a stainless steel condensate center access door. -
Page 17: Optional Remote Control Panel And Wiring Schematics
Optional Remote Control Panel Indicator Lights powered by the ER Unit and Wiring Schematics The remote panel is a series of junction boxes ganged together and includes a stainless steel faceplate. The Unit On/Off remote panel is available with a number of different alarm lights and switches to control the unit. -
Page 18: Typical Control Center Components
Typical Control Center Components - individual components and locations will vary Optional Control Center Components 1. Main disconnect (non-fusible, lockable) 2. Motor starter - exhaust air fan 12. DDC controller 3. Motor starter - outdoor air fan 13. Dirty filter pressure switches 4. -
Page 19: Electrical Controls
Electrical Controls • Turn the temperature sensor up as high as Optional Frost Control possible. The supply blower should cycle on for Extremely cold outdoor air temperatures can cause one minute, then turn off for one minute. moisture condensation and frosting on the enthalpy •... -
Page 20: Optional Economizer
Optional Economizer The energy wheel operation can be altered to take Modulating the wheel: In applications in which an internal heat gain is present in the space, the rotational advantage of economizer operation (free cooling). Two modes are available: speed of the energy wheel may be modulated (via 1. -
Page 21: Optional Rotation Sensor
Optional Rotation Sensor The rotation sensor monitors energy 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 and 12 in the unit control center will notify maintenance personnel when a failure has occurred. -
Page 22: Energy Wheel
Energy Wheel Start-Up If selected, the energy wheel is installed in the unit’s should be a slight tug on the paper. Tighten the screws, airstream with one half of the wheel in the intake repeat the steps on the other set of seals. airstream and one half in the exhaust airstream. -
Page 23: Maintenance
Energy Wheel Maintenance Cleaning WARNING Maintenance or cleaning of the wheel segments Whenever performing maintenance or inspections, should be done with the segments removed from always disconnect the power source. the wheel cassette to avoid splashing liquids or cleaning agents inside the cabinet. If the energy wheel Inspection appears excessively dirty, it should be cleaned to The wheel should be inspected semiannually... -
Page 24: Troubleshooting
Energy Wheel Troubleshooting Symptom Possible Cause Corrective Action See air seals under Start-Up, Energy Wheel Air seals are too tight. section. Energy wheel Broken belt. Replace. does NOT turn Make sure wheel drive is plugged in. Verify No power to wheel motor. power is available. -
Page 25: Heat Pump Controls
Heat Pump Controls Freeze Sensor Each unit is factory provided with a Unit Protection This is optional and can be set to ignore or monitor a Module (UPM) that controls compressor operation and freeze sensor. There are two configurable freeze points, monitors the safety controls that protect the unit. -
Page 26: Refrigeration Schematic
Refrigeration System Schematic Typical Operating Conditions Location Refrigerant State Temperature Pressure Superheat/Subcool Before water-to-refrigerant Hot Vapor 150°F 330 PSIG 50°F Superheat heat exchanger Cooling After water-to-refrigerant Warm Liquid 85°F 330 PSIG 15°F Subcool Mode / heat exchanger Refrigerant After Thermostatic Saturated Liquid- Properties -45°F... -
Page 27: Unit Protection Module Fault Indicators
Unit Protection Module (UPM) Fault Indications Each unit includes one Unit Protection Module (UPM) Lockout Reset printed circuit board and each UPM has two LED A hard lockout can be reset by turning the unit indictor lights. thermostat off and then back on when the “RESET” dip switch is set to “Y”... -
Page 28: Controller Alarms
Troubleshooting - Controller Alarms The first step in troubleshooting the unit is to check the on-board alarm indicators. Several of the electronic controls in the unit monitor the system for faults and will go into alarm, shutting down the unit or a single function within the unit. -
Page 29: Airflow
Troubleshooting – Airflow 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... -
Page 30: Unit
Troubleshooting – Unit Symptom Possible Cause Corrective Action CFM too high. Check cfm and adjust drives if needed. If higher, ductwork should be improved. Static pressures are higher or lower than design. If lower, fan rpm should be lower. Blower rotation is incorrect. Check rotation and reverse if necessary. -
Page 31: Refrigeration Circuit
Troubleshooting – Refrigeration Circuit TROUBLESHOOTING NOTE IMPORTANT Do not release refrigerant to the atmosphere! If Before any components are changed on the required service procedures include the adding or refrigeration system, the cause of the failure must be removing of refrigerant, the service technician must identified. - Page 32 Troubleshooting – Refrigeration Circuit Symptom Possible Cause Corrective Action Refrigerant overcharge. Check pressures, charge by subcooling. Condenser fan motor defective. Check fan motor. Compressor starts Condenser coil inlet obstructed or dirty. Check coil and inlet clearances. but cuts out on high pressure switch Check high side equalized pressure reading with Air or non-condensables in system.
- Page 33 Troubleshooting – Refrigeration Circuit Symptom Possible Cause Corrective Action Refrigerant overcharge. Check pressures and subcooling. Check thermal expansion valve setting. Check for Liquid floodback. refrigerant overcharge. Dampen tubing vibration by taping or clamping. Tubing rattle. Carefully bend tubing away from contact where Compressor noisy possible.
- Page 34 Troubleshooting – Refrigeration Circuit Symptom Possible Cause Corrective Action Refrigerant undercharge. Check pressures and subcooling. Interchange any two wires from 3 phase Blower running backward. disconnect. Loose blower, pulley or belts. Check drive pulley alignment, belt tension. Low entering air temperature (low load condition). Check entering air wet bulb conditions. Check system for leaks.
- Page 35 Troubleshooting – Refrigeration Circuit Symptom Possible Cause Corrective Action Thoroughly defrost evaporator. After defrost, Low oil level (trapped oil in evaporator or suction observe level, add oil. Check for leaks. Check lines line). for proper slope and traps. Adjust expansion valve for higher superheat. Check Excessive liquid refrigerant in the crankcase.
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Page 36: Monthly, Semianually, Annually
Routine Maintenance 3. Motors Check for cleanliness 4. Fan Belts DANGER Check for wear, tension, alignment Electric shock hazard. Can cause injury or death. 5. Blower Wheel & Fasteners Before attempting to perform any service or Check for cleanliness maintenance, turn the electrical power to unit to OFF Check all fasteners for tightness at disconnect switch(es). -
Page 37: Fan Motors
Fan Bearings When replacing belts on multiple groove drives, all belts should be changed to provide uniform drive loading. Do Most bearings are permanently lubricated and require not pry belts on or off the sheave. Loosen belt tension no further lubrication under normal use. Normal use until belts can be removed by simply lifting the belts off being considered -20ºF to 120ºF and in a relatively clean the sheaves. -
Page 38: Internal Filter Maintenance
Internal Filter Maintenance Coil Maintenance The unit will typically be provided with 2-inch, pleated Coils must be cleaned to obtain maximum performance. filters in the supply airstream. These filters should Check once a year under normal operating conditions be checked per a routine maintenance schedule and if dirty, brush or vacuum clean. -
Page 39: Maintenance Log
Maintenance Log Date ___________________Time _____________ AM/PM Date ___________________Time _____________ AM/PM Notes: ___________________________________________ Notes: ___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date ___________________Time _____________ AM/PM Date ___________________Time _____________ AM/PM Notes: ___________________________________________ Notes: ___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date ___________________Time _____________ AM/PM... -
Page 40: Warranty
AMCA International, Inc. at: www.amca.org. performance, available accessories, and specification data. ® Phone: (715) 359-6171 • Fax: (715) 355-2399 • E-mail: gfcinfo@greenheck.com • Web site: www.greenheck.com 473501 • Model ERCH-HP IOM, Rev. 2, March 2012 Copyright 2012 © Greenheck Fan Corp.