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
2
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
3
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
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
Front
Back
Back
4
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
V
U
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.
U
V
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
5
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
L
W
WL
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
R
o
t
a
t
i
o
n
Length of Straight Duct
GOOD
R
o
t
a
t
i
o
n
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)
6
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.

1
23
4
6
5
7
8
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.
7
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
AB
C
Outdoor Air Inlet
Q x P
Exhaust Air Discharge
LxK
Outdoor Air Discharge
LxK
Exhaust Air Inlet
FxG
C
BA
D
E
Arrangement B
Exhaust Air Inlet
FxG
Outdoor Air Discharge
LxK
Intake Hood
Exhaust Hood
C
BA
D
E
Arrangement C
Exhaust Hood Intake Hood
Exhaust Air Inlet
FxG
Outdoor Air Discharge
LxK
Exhaust Air Inlet
FxG
Outdoor Air Discharge
LxK
Intake Hood
C
BA
D
E
Arrangement D
Exhaust Hood
All dimensions shown are in inches.
DIMENSIONAL DATA
8
* Weight dependent on components and accessories.

Supply Hood
Exhaust
Hood
Cassette Slides out
Access Panels
Access Panel
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
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.
9
1
1
4
3
4
2
2
3
Exhaust
Hood
Intake
Hood
4
1
2
3
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 A
Arrangement B, C or D
Arrangement B, C or D
T
T
T
R
R
S

DIMENSIONAL DATA
10
Outdoor Air Discharge
L x K
Exhaust Air Inlet
H x J
Exhaust Air Discharge
L x K
Outdoor Air Inlet
Q x P
C
BA
C
BDA
E
Outdoor Air Discharge
L x K
Exhaust Air Inlet
H x J
Exhaust
Hood
Intake
Hood
C
BDA
E
Outdoor Air Discharge
L x K
Exhaust Air Inlet
H x J
Exhaust
Hood
Intake
Hood
C
BDA
E
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