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Greenheck Fan 473501 User's Manual

1. Your UPM board will come Default Settings from the factory with the following default settings Freeze NO Temp 35 Lockout 2 Reset T Alarm CONT Test NO Hot Dry Alarm HOT Model ERCH HP Energy Recovery Unit 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 DDC Controller Check the screen on the DDC for an alarm condition If the DDC is in an alarm condition a message will show on the DDC screen The DDC is located in the main control center If the DDC is in alarm condition the alarm button will blink red Press the alarm button to see the specific condition or to reset the DDC Refer to the DDC Installation Operations and Maintenance manual for detailed information on fault codes and see the unit specific wiring diagram Phase Monitor The phase monitor has two LED indicator lights one red and one green Green indicates proper operational status red indicates the unit has detected a fault and is in alarm condition Variable Frequency Drive VFD Variable frequency drives have a display screen that will show an alarm condition If a fault such as a voltage spike occurs the VFD will go into alarm and will not reset until a hard restart is
2. 19 Optional Economizer 20 Phase Monitor 20 Variable Frequency 20 Optional Rotation 21 Dirty Filter Sensor 21 H Energy Wheel SAMO sate eee See toe Ea das 22 Sequence of Operation 22 Maintenance 23 Troubleshooting 5 Are ERR ER ERAS 24 Heat Pump Overview Heat Pump 24 Heat Pump Controls 25 Refrigeration 26 Typical Operating Conditions 26 Unit Protection Module Fault Indicators 27 Troubleshooting Controller 28 AirflOW acere en ea RUE a CR oe n 29 un rin xem 30 Refrigeration Circuit 31 35 Maintenance Monthly Semianually 36 Heat Pumps e EXER ERR RE 36 Maintenance Procedures lubrication sx RR a ERAS 36 Dampers ics xc uo essor d 36 Fan Belts nie REG REA 36 37 ran Motors osse ke RR vee dere ede ERG 37 Fan Wheel and Fasteners 37 Fan Bearings sss ER eee eee vbw ee 37 Internal Filter Maintenance 38 E
3. 4 Models and 4 Subassemblies CONSE a xxm ERRASSE NE 5 Dampers sa ees PERSE E peas mea ba irs 5 Energy Wheel i m m PEE n 5 dll cct PPP 5 Heat Pump 6 Optional Electric lt 6 Optional Indirect Gas Furnace 6 Installation Dimensional Data 7 Unit Weights and Recommended Roof Opening 7 Service Clearances 8 Handling Lifting and Lifting Lugs 9 Roof Curb Mounting Dimensions Weights 10 Ductwork Connections 11 Rail Mounting 11 Exhaust 11 Start Up Unit 12 Pre Start Up Checklist 13 Start Up Procedure 13 Voltage Imbalance 13 Unit Start Up 14 Electrical Information General Electrical Information 15 Discharge Air Temp 16 Plumbing Piping Overview Condensate Drain Trap 16 Optional Remote Control Panel and Wiring 17 Typical Control Center Components 18 Electrical Controls Optional Frost
4. Electrical Nameplate Determine the Size of Electric Heater Wiring An optional electric heater may require a separate power supply The power connection should be made to the factory provided electric heater disconnect and must be compatible with the ratings on the nameplate supply power voltage phase and amperage Consult ANSI NFPA 70 and CSA C22 1 for proper conductor sizing Provide the Opening s for the Electrical Connections Electrical openings vary by unit size and arrangement and are field supplied Connect the Power Supplies Connect the main power lines and electric heater power lines to the disconnect switches or terminal blocks and main grounding lug s Torque field connections to manufacturer s recommendations Wire the Optional Convenience Outlet The convenience outlet requires a separate 115V power supply circuit The circuit must include short circuit protection which may need to be supplied by others Connect Field Wired Low Voltage Components Reference the Ladder Diagram on the inside of the control center door for correct wiring of the following accessories Remote Panel e Room Temperature Sensor Room Dehumidistat Discharge Temperature Sensor Model ERCH HP Energy Recovery Unit ET 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 insi
5. EXHAUST AIR INTAKE OUTDOOR AIR HOOD FILTERS WHEEL CASSETTE 36 IN MINIMUM 52 1N COIL SECTION 1 HEATER ACCESS PANEL ACCESS PANEL 42 IN ACCESS PANEL CLEARANCE WITH IG HEATER Clearances for service and component removal on ERCH HP 55 and ERCH HP 90 Handling While this unit was constructed with quality and dependability in mind damage still may occur during handling of the unit for installation Exercise extreme caution to prevent any damage from occurring to the refrigerant system This unit contains a system pressurized with refrigerant that if damaged could leak into the atmosphere or cause bodily harm due to the extreme cold nature of expanding refrigerant Use protective equipment such as gloves and safety glasses to minimize or prevent injury in case of a system leak during 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 Lifting 1 Before lifting be sure that all
6. GREENHECK Building Value in Air 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 Model ERCH HP I pod L US Listed Intertek 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 gr
7. H Model ERCH HP Energy Recovery Unit 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 shipment 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 with Integral AMCA Publication 410 96 Safety Practices for Users and Water Source Heat Pump Model ERCH HP provides Installers of Industrial and Commercial Fans provides additional information describing the equipment fan additional safety information This publication can be obtained performance available accessories and specification data from AMCA International Inc at www amca org GREENHECK Building Value in Air Phone 715 359 6171 e Fax 715 355 2399 E mail gfcinfo greenheck com e We
8. Indirect Gas Heater n Dec LM Ooutdoor Air Hood Two inch thick MERV 8 or MERV 13 pleated filters gt Permanent Metal Filters Model ERCH HP Energy Recovery Unit EJ Heat Pump Module Every unit has an integral heat pump module that contains hermetic scroll type compressor s a coaxial refrigerant to water heat exchanger s refrigerant flow reversing valve s expansion valve s liquid line filter drier high pressure manual reset cutout crankcase heater s and various sensors service ports and safety devices which allows the unit to run at less than full capacity and results in fewer compressor cycles The heat pump is intended to be connected to an external water source such as a water cooling tower or boiler a geothermal source or even a ground loop The module is piped to the airside coil located in the intake airstream and optionally to a reheat coil that will control humidity The location of components in the module will vary Control circuitry and the Unit Protection Module UPM for the heat pump module are located in the heat pump module The UPM is a z printed circuit board and has LED fault indicator lights to indicate various alarm conditions and also power status A unit specific schematic for electrical circuits is located in the control center and another unit specific schematic for heat pump circuitry is located in the
9. 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 Fan Belts 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 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 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 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 d
10. from terminal Sr on the enthalpy m controller Turn unit power on The m LED on the enthalpy controller should light and the energy recovery wheel should not rotate e 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 should not light and the energy recovery wheel should energize and rotate If the steps above provide the results described the enthalpy economizer is working properly Enthalpy Controller e Turn unit power off Reconnect C7400 solid state enthalpy sensor to terminal So EJ Model ERCH HP Energy Recovery Unit 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 Sequence of operation The variable frequency drive is fully programmed at the factory 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 Where Toa is the outdoor air temperature set point Tha is the return air temperature set point and
11. Check bottom plate or leaking compressor Compressor short cycling Check low pressure control setting Refrigerant leak Check system for leaks Repair leaks and add refrigerant Short cycling Check low pressure control settings Air or other non condensables in system erase side pressure with equivalent Running cycle is outdoor temperature Defective compressor See High suction pressure operates continuously Restriction in suction and liquid line Check for restrictions in refrigerant circuit Control contacts stuck Check wiring Too low of a system thermostat setting or Adjust or replace thermostat defective thermostat Liquid line 1922598 3 undercharge Adjust the 5 5 by subcooling is too hot High discharge pressure discharge pressure See See High discharge pressure discharge pressure lite Restriction in liquid line Clear restriction upstream of point of frosting frosted or wet Check airflow check filters check drive for loose parts or belts Suction line Always have a completed Pre Start Up Checklist and Unit Start Up Checklist prior to requesting parts or service information Low oil level trapped oil in evaporator or suction line Insufficient evaporator airflow H Model ERCH HP Energy Recovery Unit Routine Maintenance DANGER Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the
12. Tsa is the supply air discharge thermostat set point Wheel runs at full speed gt maximum energy recovery Tao lt TRA Wheel is stopped Tace no energy recovery Tao lt Wheel will modulate to maintain discharge temperature Tao lt TsA Phase Monitor The unit control circuitry includes a Pune monitor that constantly checks for phase reversal loss of phase or a power brownout It requires 24 VAC to operate and when it detects a fault it cuts off the 24 VAC that goes to the low voltage terminal strip thereby shutting off all motors Variable Frequency Drive VFD If a VFD was provided and installed at the factory it has been preset to control the speed of the blower motor for optimum performance The motor speed needs to be verified during test and balance of the unit Typical Phase Monitor Typical Variable Frequency Drive VFD Refer to unit specific documentation 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 Dirty Filter Sensor Dirty filter sensors monitor pressure drop across the outdoor air filters exhaust air filters or both If the pressure drop across the filte
13. and Recommended Roof Opening eU eer SR dl l i Exhaust Intake l U l Supply Discharge 1 l EA 2 Y 1 2 inch 1 2 inch 4 1 2 inch Unit Size U V E ERCH HP20 46 37 2150 45 54 39 3500 ERCH HP 55 65 47 4450 ERCH HP90 85 49 5300 All dimensions are in inches Unit weights assume rooftop configuration with weatherhoods filters outdoor air damper six row DX coil integral condensing section and an indirect gas fired furnace Position the unit roof opening such that the supply discharge and exhaust inlet of the unit will line up with the corresponding ductwork Be sure to allow for the recommended service clearances when positioning opening 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 8 Model ERCH HP Energy Recovery Unit 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 perf
14. at Green the board Dual or Single ol Status blinks Compressor 1 High pressure lockout Compressor 1 2 Low pressure lockout Compressor 1 3 High pressure lockout Compressor 2 4 Low pressure lockout Dual Compressor 2 Compressor 5 Freeze sensor lockout optional item Condensate overflow Red 6 in coil drain pan optional item Brownout AC voltage 7 to R and C terminal below 18 VAC 1 High pressure lockout 2 Low pressure lockout 3 Freeze sensor lockout optional item Single Condensate overflow Compressor drain pan optional item Brownout AC voltage 5 to R and C terminals below 18 VAC Intelligent Reset If a fault condition is initiated the five minute delay on break time period and the random start timer is initiated and the unit will restart after these delays expire During this period the fault LED will indicate the cause of the fault If the fault condition occurs 2 or 4 times depending on 2 or 4 setting for Lockout dip Switch before 60 minutes the unit will go into a hard lockout and requires a manual lockout reset A single condensate overflow fault will cause the unit to go into a hard lockout immediately and will require a manual lockout reset Lockout Reset A hard lockout can be reset by turning the unit thermostat off and then back on when the RESET dip switch is set to Y or by shutting off unit power at the circuit breaker when the RESET dip switch is set to SEC
15. disassembled and cleaned The wheel rotates through the two airstreams which are moving in opposite directions the wheel is self cleaning up to a point If the wheel media becomes blocked by dirt or dust or if the media collects a layer of smoke residue or an oily film the energy transfer efficiency drops The main factor in the frequency of cleaning is the cleanliness of the air If air filters are not changed frequently the wheel will collect contaminants and will then have to be cleaned Wheel Disassembly Wheels are part of a cassette that may be pulled from the unit for easy access There may be a small damper assembly or other component that blocks removal of the cassette Before sliding out the cassette or any other component disconnect any power supply cord and secure it so it cannot jam or otherwise get damaged Energy Wheel Cassette Each wheel has removable segments that hold the coated layers of media and each segment is held in place with two retaining clips located on the outer rim of the wheel When removing more than one segment remove them in sequence from opposite sides of the wheel 180 degrees apart to reduce the imbalance Secure the wheel against rotation Carefully release the two retaining clips and swing them fully open The segment can now be removed by pushing the face of the segment close to the outer rim of the wheel Wheel segments are built to close tolerances and the segment may have to b
16. performed See the unit specific manufacturer s manual supplied with the unit VFDs are located in the main control center FX05 Furnace Controller Present only if an indirect gas fired furnace option is present The FX05 furnace controller will display an alarm condition if present The controller will be found in the furnace control cneter See the furnace installation operation and maintenance manual and the controller manufacturer s unit specific manul for further information 28 Model ERCH HP Energy Recovery Unit 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 Unit 43 Unit 4 Model Number Serial Number Nameplate Information Voltage Hertz Phase Outdoor Air Fan Amps Outdoor Air Fan Horsepower Design Airflow Outdoor Air Measured Airflow Outdoor Air Measured Data Blower Rotation Outdoor Air Fan RPM Outdoor Air Fan Amp Draw Airflow problems can often be tied back to improper ductwork installation Be sure to install
17. 2 Amps L3 Amps Compressors Compressor 1 L1 Amps L2 Amps L3 Amps Crankcase Heater 1 11 Amps Compressor 2 Li L2 L3 Amps Crankcase Heater 1 1 Amps Condensing Fans Condensing Fan 1 L1 L2 L3 Amps Condensing Fan 2 L1 L2 Amps L3 Condensing Fan 3 L1 L2 Amps L3 Outdoor Air Temperature F Return Air Temperature LL Deg F Outdoor Air Relative Humidity LL 96 RH Return Air Relative Humidity LL 96 RH Superheat sd DegF Should be between 8 and 12 F Subcooling DegF Should be between 12 and 17 F Discharge Pressure PSIG Should be between 200 and 280 PSIG for R22 or 300 and 500 PSIG for R410a Suction Line Pressure 2 PSIG Should be between 60 and 80 PSIG for R22 or 100 and 135 PSIG for R410a Liquid Line Temp Suction Line Temp LL Deg F Moisture Indicating Sight Glass Liquid Visible Yes No Color of Center Dot Green Yellow Hot Gas Bypass Operational Yes No 14 Model ERCH HP Energy Recovery Unit H Electrical Information WARNING The roof lining contains high voltage wiring To prevent electrocution do not puncture the interior or exterior panels of the roof WARNING To prevent injury or death due to electrocution or contact with moving parts lock disconnect switch open For units with a gas furnace if you turn off the power supply turn off the gas IMPORTANT Befor
18. EFER TO GENERAL SAFETY INFORMATION Do not operate make up air 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 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 by rinsing with a mild detergent in warm water prior to start up 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 Model ERCH HP Energy Recovery Unit Coil Maintenance Coils must be cleaned 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 SPRA
19. Use the following test procedure for troubleshooting Testing refer to Timer diagram e Jumper the wheel pressure switch in the unit control center Set the Timer Scale for T1 and T2 to 1 minute Set the T2 Timer Settings for T1 and T2 to 1 0 Set the dip switch to the down position normal position Dip Switch T1 Turn the temperature sensor up as high as possible The supply blower should cycle on for one minute then turn off for one minute e After testing set the Timer Scale as follows T1 10 minutes T2 1 hour e 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 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 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 Testing f no DDC controller is present jumper thermodisc and jumper the wheel pressure sensor The heater should turn on e fit doesn t either put the outdoor airside 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 press
20. Y 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 the fins while cleaning Caution Fin edges are sharp WARNING Biological hazard May cause disease Cleaning should be performed by qualified personnel Drain pans in any air conditioning unit will have some moisture in them therefore algae and other organisms will grow due to airborne spores and bacteria Periodic cleaning is necessary to prevent this buildup from plugging the drain and causing the drain pan to overflow Inspect twice a year to avoid the possibility of overflow Also drain pans should be kept clean to prevent the spread of disease Cleaning should be performed by qualified personnel Maintenance Log Date Time Date Time AM PM Notes Notes Date Time Date Time AM PM Notes Notes Date Time Date Time AM PM Notes Notes Date Time Date Time AM PM Notes Notes Date Time Date Time AM PM Notes Notes Date Time Date Time AM PM Notes Notes
21. after correcting problem Check line voltage If more than 10 from Low line voltage compressor marking correcting is necessary Motor thermal protector automatically resets Allow time 2 hrs for compressor to cool down so protector will reset Restart and check for reason overheat occurred Compressor motor protector open Compressor will not run or Check motor for open circuit short circuit does not grounded windings or burn out try to start Compressor defective Compressor may be seized check refrigerant If necessary replace compressor If manual reset high pressure reset switch Switch opens at 600 psi and will not reset above High or low pressure switch open or defective 420 psi for R 410A If auto reset low pressure does not reset and everything else is OK replace switch Open room thermostat or control Check room temperature If temperature is proper no cooling required wait for thermostat to close Check all wire terminals and tighten as necessary Low refrigerant charge Check refrigerant pressures Compressor starts Check for dirty evaporator coil dirty filters but cuts out on low Airflow restricted dampers closed iced evaporator coil improper pressure belt check motor amps check duct design Check refrigerant pressure check and adjust Low pressure Restriction in refrigerant line thermal expansion valve If not functioning properly switch activates check for pressure drop ac
22. ain Trap This unit is equipped with a stainless steel condensate pan with a stainless steel connection It is important that the drain connection be fitted with a P trap to ensure proper drainage of condensate while maintaining internal static pressures A P trap assembly kit is supplied with each unit and is to be assembled and installed as local conditions require and according to the assembly instructions provided with the P trap If local condensate be drained back onto the roof but a drip pad should be provided beneath the outlet If local and area codes require a permanent drain line it should be fabricated and installed in and all codes In some climates it will be necessary to provide freeze protection for the P trap and drain line The P trap should be kept filled with water or glycol solution at all times and it should be protected from freezing to protect the P trap from damage If severe weather conditions occur it may be necessary to fabricate a P trap and drain line of metal and install a and area codes permit the B accordance with Best Practices heat tape to prevent freezing Optional Remote Control Panel Indicator Lights powered by the ER Unit and Wiring Schematics The remote panel is a series of junction boxes ganged D together and includes a stainless steel faceplate The UON remote panel is available with a number of differen
23. ant State Temperature Pressure Superheat Subcool Before water to refrigerant Hat Vapor 150 F 330 PSIG 50 F Superheat heat exchanger Cooling to refri EN Warm Liquid 85 F 330 PSIG 15 F Subcool After Th tati Saturated Liquid Properties er Thermostatic aturated Liquid 45 F 144 PSIG Expansion Valve Vapor mix After Airside Coil Cold Vapor 55 F 145 PSIG 10 F Superheat Water entering the coaxial heat exchanger is warmed by the heat it absorbs from the refrigerant and leaves about 10 F warmer Location Refrigerant State Temperature Pressure Superheat Subcool Before Airside Coil Hot Vapor 130 F 250 PSIG 50 F Superheat Heating After Airside Coil Warm Liquid 65 F 250 PSIG 15 F Subcool Mode After Thermostatic Saturated Liquid o Refrigerant Expansion Valve Vapor mix Properties After water to refrigerant Cold Vapor 45 F 120 PSIG 10 F Superheat heat exchanger Water entering the coaxial heat exchanger is cooled because of the heat being absorbed by the refrigerant and leaves about 6 F warmer E Model ERCH HP Energy Recovery Unit Unit Protection Module UPM Fault Indications Each unit includes one Unit Protection Module UPM printed circuit board and each UPM has two LED indictor lights ed LED Fault Indication Power LED indicates 18 30 VAC present
24. b site www greenheck com 473501 Model ERCH HP IOM Rev 2 March 2012 Copyright 2012 Greenheck Fan Corp
25. cklist and Unit Start Up Checklist prior to requesting parts or service information Sustained high discharge pressure Model ERCH HP Energy Recovery Unit H Troubleshooting Refrigeration Circuit Symptom Possible Cause Corrective Action Refrigerant overcharge Check pressures and subcooling Liquid floodback Check thermal expansion valve setting Check for refrigerant overcharge Compressor noisy or vibrating High suction pressure High discharge pressure Tubing rattle Dampen tubing vibration by taping or clamping Carefully bend tubing away from contact where possible Scroll compressor rotating in reverse 3 phase Rewire for opposite rotation Worn or damaged compressor Replace the compressor Improper mounting on unit base Check that compressor is properly isolated Check for high entering wet bulb temperature Excessive load on evaporator coil Check for excessive air Compressor is unloaded Expansion valve not secured to suction line Thermostatic expansion valve pressure limit feature incorrect or inoperative Overfeeding Check head pressure check thermal expansion valve if not functioning properly check pressure drop across filter drier Check the thermal expansion valve ensure bulb is insulated Check superheat If superheat is high then valve is out of control and pegged wide open Check bulb for contact Adjust valve for superheat Replace valve powe
26. de of the control center access door The low voltage control circuit is 24 VAC and control wiring should not exceed 0 75 ohms 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 All low voltage wiring should be run in conduit wherever it may be exposed to the weather If wire resistance exceeds 0 75 ohms an insulator 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 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 Discharge Air Temperature Sensor WARNING Discharge air temperature sensor is to be field installed prior to unit start up The sensor is to be installed at least three duct diameters downstream of the heat exchangers or where good mixed average temperature occurs All other sensor and low voltage devices are connected to the low voltage terminal strip in the control center This discharge air sensor is shipped loose and can be found in the unit s control center See the unit specific wiring diagram for connection locations 16 Model ERCH HP Energy Recovery Unit Plumbing Piping Overview Condensate Dr
27. ductwork in accordance with SMACNA and AMCA guidelines Troubleshooting Unit Symptom Possible Cause operate Check for On Off switches Check for correct supply voltage Check for broken or loose belts Tighten loose Drive pulleys Shorten wiring run to mechanical room or install a Control power 24 wiring run is too long relay which will turn unit on off Consult Factory for resistance should not exceed 0 75 ohms relay information Increase wire gauge size so that Motor starters resistance is 075 ohms or less chatter or do not pull in Incoming supply power is less than anticipated Voltage supplied to starter coil must be within 10 1596 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 Always have a completed Pre Start Up Checklist and Unit Start Up Checklist prior to requesting parts or service information Model ERCH HP Energy Recovery Unit EJ Troubleshooting Unit Symptom Possible Cause Corrective Action Motor over amps Low airflow cfm High airflow cfm Excessive noise or vibration CFM too high Check cfm and adjust drives if needed Static pressures are higher or lower than design I higher ductwork should be improved If lower fan rom should be lower Blower rotation is incorrect Check rotation and reverse if necessary Motor voltage incorrect Check
28. e connecting power to the unit read and understand the following instructions and wiring diagrams Complete wiring diagrams are attached on the inside of the control center door s IMPORTANT All wiring should be done in accordance with the latest edition of the National Electric Code ANSI NFPA 70 and any local codes that may apply In Canada wiring should be done in accordance with the Canadian Electrical Code IMPORTANT The equipment must be properly grounded Any wiring running through the unit in the airstream must be protected by metal conduit metal clad cable or raceways CAUTION If replacement wire is required it must have a temperature rating of at least 105 C except for an energy cut off or sensor lead wire which must be rated to 150 C DANGER High voltage electrical input is needed for this equipment This work should be performed by a qualified electrician CAUTION Any wiring deviations may result in personal injury or property damage Manufacturer is not responsible for any damage to or failure of the unit caused by incorrect final wiring Determine the Size of the Main Power Lines The unit s nameplate states the voltage and the unit s MCA The main power lines to the unit should be sized accordingly The nameplate is located on the outside of the unit on the control panel side Voltage Hertz Phase VOLTS HZ PH SUP HP EXH HP MCA
29. e jiggled to remove it Do not use a hammer or otherwise force the segment because these are high value items and are not built to withstand abuse Whenever retaining clips are opened they should be closed as soon as possible If the wheel should rotate when a clip is open the clip will jam against the bearing support bar and could cause damage Segment Retaining Clip A Cleaning Maintenance or cleaning of the wheel segments should be done with the segments removed from the wheel cassette to avoid splashing liquids or cleaning agents inside the cabinet If the energy wheel appears excessively dirty it should be cleaned to ensure maximum operating efficiency Only excessive buildup of foreign materials needs to be removed DISCOLORATION AND STAINING OF ENERGY RECOVERY WHEEL DOES NOT AFFECT ITS PERFORMANCE Thoroughly spray the wheel matrix with a household cleaner such as Fantastik or the equivalent Gently rinse with warm water and use a soft brush to remove any heavy accumulations A detergent water solution can also be used Avoid aggressive organic solvents such as acetone Wheel segments can be soaked in the above solution overnight for removal of stubborn dirt or accumulations After cleaning is complete shake excess water from the wheel or segments Dry the wheel or segments before putting them back into the cassette Reassembly When reinstalling the segments be sure to install them with the correct face toward
30. e spaces between the inner and outer tubes Depending on whether the unit is functioning in a cooling or a heating capacity heat is rejected from one tube to the other EZ Model ERCH HP Energy Recovery Unit Liquid Line Filter Drier The liquid line filter drier prevents moisture and foreign matter from entering the thermal expansion valve It is located in the compressor compartment Hot Gas Bypass Valve On units equipped with hot bypass hot gas from the compressor is injected into the liquid line of the airside coil after the TXV This process starts when suction gas temperatures drop below 28 F which is 32 34 F coil surface temperature Hot gas helps the airside coil from freezing up and the compressor from cycling The valve is factory set but should be field adjusted to maintain a suction pressure of 90 psi Valve Adjustment To adjust the valve connect a pressure gauge to the suction line and block the entering air to the coil The valve should begin to open when the suction pressure drops to approximately 58 PSIG the valve will feel warm to the touch Adjustments are made by first removing the cap on the valve and then turning the adjusting stem counterclockwise to decrease the pressure Allow several minutes between adjustments for system to stabilize When adjustment is complete replace the cap on the valve Reversing Valve Each compressor is equipped with a reversing valve to reverse the direction of refrigeran
31. eals under Start Up Energy Wheel section Heat Pump Overview Every unit has a complete sealed refrigeration system that is ready for connection to a water source The heat pump has all the typical DX components and also has refrigerant reversing valve s to enable the System to work in both heating and cooling modes Factory Installed Heat Pump System Components Thermostatic Expansion Valve TXV Each compressor is equipped with a thermal expansion valve The valve controls the flow of liquid refrigerant entering the evaporator coil by maintaining a constant factory set superheat of 10 F Refrigerant Distributor Attached to the TXV is a refrigerant distributor The refrigerant distributor evenly distributes the refrigerant to each circuit of the airside coil to provide optimum performance Airside Coil Each unit uses a single refrigerant coil known as an airside coil If two compressors are used in the unit then the airside coil will be a split configuration so that each compressor has a dedicated portion of the airside coil Depending on whether the unit is in cooling or heating mode the airside coil will function as either a condensing coil or an evaporator coil See also Subassemblies Coils Coaxial Refrigerant to Water Heat Exchanger The unit uses one coaxial heat exchanger per compressor essentially a tube inside a tube Water flows through the inner copper tube and compressed refrigerant is forced through th
32. ed 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 e 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 Rail Mounting Layout Rails designed to handle the weight of the unit 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 unit Avoid area dimensioned B below Rails should run the width of the unit and extend beyond the unit a minimum of 12 inches on each side e Set unit on rails Outdoor Air Intake Hood Supply Exhaust Opening L zu mE I B L A Side view of unit on rails Isometric view of unit Rail Mounting Unit Size A B ERCH HP 20 5 0 41 0 ERCH HP 45 7 0 41 9 ERCH HP 55 5 5 53 0 ERCH HP 90 6 0 59 0 All dimensions are in inches Exhaust Weatherhood The exhaust weatherhood is shipped separately as a kit with its own instructions Model ERCH HP Energy Recovery Unit Start Up Unit 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
33. eflection 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 be 1 inch using moderate thumb pressure at mid point of the drive Check belt tension two times during the first 24 hours of operation and periodically thereafter Belt Span 64 Deflection Belt Span Fan Motors 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 with high pressure spray Greasing of motors is only intended when fittings are provided Many fractional motors are permanently lubricated for life and require no further lubrication Fan 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 Fan Bearings Most bearings are permanently lubricated and require no further lubrication under normal u
34. electrical power to unit to OFF at disconnect switch es Unit may have multiple power supplies CAUTION 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 This unit requires minimal maintenance to operate properly To ensure proper operation and longevity the following items should be completed The items in this list assume a relatively clean air environment and may require attention more frequently in a dirty or dusty area If this unit contains an indirect gas heater refer to the Installation Operation and Maintenance Manual provided with the unit for maintenance purposes A Certified Technician should complete all refrigerant systems checks Maintenance Frequency Monthly 1 External Filter Check for cleanliness clean if required 2 Internal Filter Check for cleanliness replace if required 3 Condensate Drain if applicable Inspect and clean refill with water 4 Bearings Lubricate per the schedule in the Fan Bearings section Semiannually 1 Fan Belts Check for wear tension alignment 2 Check for belt wear Check pulley bearings and motor 3 Bearings Lubricate per the schedule in the Fan Bearings section Annually It is recommended that the annual inspection and maintenance occur at the start of the cooling season After completin
35. emoved in order to permit installation of the P trap drain kit Model ERCH HP Energy Recovery Unit EJ 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 d of structural members of the building nido 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 it Assembly instructions are included with the curb mg Install Curb Locate curb over roof opening and 1 INCH INSULATION fasten in place Reference Installation Unit Weights and Recommended Roof Openings in this manual Check that the diagonal dimensions are within 1 8 ROOF CURB gt inch of each other and adjust as necessary For proper Curb Cap Details for Factory Supplied Roof Curbs coil drainage and unit operation it is important that the installation be level Shim as required to level Curb Cap Dimensions Install Ductwork Unit Size A B c D E Installation of all ERCH HP 20 2 00 2 00 1 00 0 88 0 75 ducts should be done ERCH HP 45 2 00 4 25 2 00 1 31 0 50 in accordance with ERCH HP 55 2 00 4 25 2 00 1 31 0 50 SMACNA and AMCA ERCH HP90 2 00 425 200 131 0 50 guidelines Duct adapter provided to support ducts prior to setting the unit S
36. et 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 dimensions are in inches Set the Unit Curb Outside Dimensions and Curb Weights Ibs Unit Size L Weight ERCH HP 20 104 88 51 00 310 ERCH HP 45 115 75 60 63 400 ERCH HP 55 129 88 71 50 510 ERCH HP 90 148 13 90 75 720 All dimensions are in inches Weights are for 12 inch high curbs Roof curb details including duct locations dimensions are available on the roof curb assembly instructions Model ERCH HP Energy Recovery Unit Ductwork Connections Examples of poor and good fan to duct connections are shown below 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 Recommended Discharge Duct Size and Length Unit Size poss Duct Size NE ERCH HP 20 9 14x14 36 ERCH HP 45 10 20 x 20 36 ERCH HP 55 12 20 x 20 36 ERCH HP 90 15 28 x 28 60 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 intend
37. for cooling the wheel VFD modulates wheel speed to maintain the discharge temperature set point Optional Frost Control The DDC controller will output a signal when wheel frosting is occurring which is determined by a temperature set point OA 5 F 2 hysterisis adjustable and wheel pressure drop increase e Preheat When frosting is occurring the preheater is energized to defrost the wheel Once the pressure drop decreases below the set point the preheater is de energized e Timed Exhaust When frosting is occurring the supply blower is cycled off The exhaust blower shall continue to run allowing the warm exhaust air to defrost the wheel After the 10 minute cycle the supply fan are re energized to continue normal operation Alarms Indication DDC shall have one digital output for remote indication of an alarm condition e Wheel Rotation Alarm Monitors wheel rotation and sends a signal to controller after a 15 second time delay with no rotation that signals the DDC to activate an alarm Energy Wheel Maintenance WARNING Whenever performing maintenance or inspections always disconnect the power source Inspection The wheel should be inspected semiannually in accordance with the maintenance schedule Maintenance of the wheel consists mainly of inspecting the wheel for cleanliness and then checking the drive motor belt and pulley for wear If the wheel layers appear dirty the wheel should be
38. g the checklist follow the unit start up checklist provided in the manual to ensure the refrigeration system operates in the intended matter 1 Lubrication Apply lubrication where required 2 Dampers Check for unobstructed operation EJ Model ERCH HP Energy Recovery Unit 3 Motors Check for cleanliness 4 Fan Belts Check for wear tension alignment 5 Blower Wheel amp Fasteners Check for cleanliness Check all fasteners for tightness Check for fatigue corrosion wear 6 Bearings Lubricate per the schedule in the Fan Bearings section 7T Door Seal Check if intact and pliable 8 Wiring Connections Check all connections for tightness 9 Inspect all coils for cleanliness Clean if required 10 Inspect exterior and interior of entire unit for surface rust If rust is found remove rust and coat the blemished area with an appropriate protectant Heat Pump An annual inspection of the heat pump system by a licensed refrigeration mechanic is recommended 1 Inspect entire heat pump for cleanliness 2 Record performance data for volts amps and water temperature differences both heating and cooling 3 Compare annual data to recorded start up data Maintenance Procedures Lubrication 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 Dampers
39. gnal 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 65 F 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 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 Temperature Sensor with Override e Turn both temperature and override thermostats down as low as they go The wheel should be rotating e 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 e Turn both sensors as high as they will go The wheel should start rotating e 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 65 F and 50 F respectively Enthalpy Sensor with Override e Turn unit power off Disconnect C7400 solid state enthalpy sensor from terminal So on the enthalpy controller Also disconnect the 620 ohm resistor
40. heat pump module Unit Protection Module UPM a Refrigerant High Efficiency Reversing Scroll Type Valves Compressors Coaxial Refrigerant to Water Heat Exchangers ater Intake and Discharge Connections Heat Pump Module 6 Model ERCH HP Energy Recovery Unit Optional Electric Heaters There are two optional electric heaters available One is a preheater and is used to prevent frost buildup on the energy wheel It is located directly in front of the intake air filter assembly The second optional heater is used as a supplementary emergency heat source for the building and is integrated into the supply airstream Optional Electric Preheater Location Optional Electric Heater Location Supply Air Motor and Blower Assembly Optional Indirect Gas Furnace An optional indirect gas furnace may be installed and provides supplementary emergency heat to the building A complete Installation Operation and Maintenance Manual for the furnace is provided with the unit A unit specific wiring diagram is located inside the furnace housing access door Indirect Gas Furnace 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 75 116 ERCH HP 45 69 5 86 122 ERCH HP 55 79 5 101 134 ERCH HP 90 99 5 123 147 All dimensions shown are in inches Unit Weights
41. ile the unit is running In order to measure volts and amps the control center door must be open and the unit energized using a crescent wrench to turn the disconnect handle O Make sure Pre Start Up checklist is complete O Jumper R to R to Y1 and R to Y2 if applicable on the control board L1 Turn the disconnect on After 3 minutes compressors will come on Make sure all fans and compressors are rotating the correct direction L1 Allow the unit to run until the refrigerant system stabilizes Approximately 1 2 minutes Voltage Imbalance In a 3 phase system excessive voltage imbalance between phases will cause motors to overheat and eventually fail Maximum allowable imbalance is 296 To determine voltage imbalance use recorded voltage measurements in this formula Key V1 V2 V3 line voltages as measured VA average V1 V2 3 VD Line voltage V1 V2 or V3 that deviates farthest from average VA Formula 96 Voltage Imbalance 100 x VA VD VA Model ERCH HP Energy Recovery Unit EE Unit Start Up Checklist Line Voltage Check at unit disconnect L1 L2 Volts L2 L3 Volts L1 L8 Volts Motor Amp Draw Supply Motor Amps L1 __ L2 Amps L3 Exhaust Motor Amps L1 L2 L3 Fan RPM Supply Fan RPM Exhaust Fan RPM Correct fan rotation direction Supply Fan Yes No Exhaust Fan Yes No Energy Wheel Motor L1 L
42. int and the anti short cycle time delay has expired If unit is employing a fresh water system no anti freeze protection it is extremely important to have the Freeze switch set to 35 F in order to shutdown the unit at the appropriate leaving water temperature and protect your heat pump from freezing if a freeze sensor is included Crankcase Heater A crankcase heater is installed around the base of each compressor in the unit to boil off any liquid refrigerant that may be absorbed into the oil during idle periods It is recommended the heater operate 24 hours prior to the compressors being started Model ERCH HP Energy Recovery Unit Refrigeration System Schematic lt FILTER DRIER gt WATER OUT AIR FLOW 8 a COAXIAL HEAT w zo EXCHANGER COIL S E 55 lt WATER IN OPTIONAL MODULATION 1 HOT CAS REHEAT CHECK VALVE m t CHECK VALVE CHECK VALVE THERMAL EXPANSION VALVE a LOW PRESSURE EQUALIZER LINE AND TEST Lm Bie AN gt LI A REVERSING HOT GAS BYPASS VALVE EQUALIZER LINE Y HIGH PRESSURE 2 AND TEST 3 REFRIGERANT FLOW DIRECTION THROUGH AIR SIDE COIL IS 2 SHOWN ABOVE IN COOLING MODE E 1 8 Typical Operating Conditions Location Refriger
43. irside Coil Optional Heat Pump Reheat Coil Dampers There are four locations where dampers are optionally installed Motorized Exhaust Air Damper Gravity Type Exhaust Damper i Exhaust Hood Electrical Box Exhaust Air Filters Wheel Cassette L T I Filters Coil Section Indirect Gas Heater pulcre ura Ml Ooutdoor Air Hood Motorized Recirculating Air Damper Motorized Outdoor Air Intake Damper Energy Wheel The energy wheel rotates through both the outdoor air and the exhaust airstreams removing both sensible heat energy and latent moisture from one airstream and transferring it to the other airstream The energy wheel itself is comprised of segments which can be removed for servicing Bearing Support Adjustable Air Seals Label showing cassette serial number and date code Drive Belt Drive Pulley Filters There are three locations in the unit where filters will be found Two inch thick MERV 8 eod pleated filters Electrical Box Exhaust Air Intake Filters roi Wheel Cassette Lo J T Filters Coil Section
44. lers are by others 8 Model ERCH HP Energy Recovery Unit Typical Control Center Components individual components and locations will vary Main disconnect non fusible lockable Motor starter exhaust air fan Motor starter outdoor air fan k 2 ooouoon rom Motor contactor energy wheel 24 VAC control transformer 24 VAC terminal strip Fuses for blower motors Grounding lug Distributor block Compressor fuse blocks Terminal block Optional Control Center Components 12 DDC controller 13 Dirty filter pressure switches 14 Economizer module 15 Thermostats for Economizer module Energy recovery wheel frost control 16 Terminal block 17 Frost control pressure switch 18 Energy recovery wheel VFD O 09 r Y 00 gt p Component 6 Detail of Terminal Strip Refer to Heat Pump System section for components in compressor compartment Model ERCH HP Energy Recovery Unit Electrical Controls Optional Frost Control Extremely cold outdoor air temperatures can cause moisture condensation and frosting on the enthalpy wheel Frost control is an optional feature tha
45. motor nameplate versus supplied voltage See specifications and catalog for fan curves to Motor horsepower too low eee E determine if horsepower is sufficient 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 Pamwheels are on atina backwards For 3 phase direction can be reversed by P 9 interchanging any two of the three electrical leads Dirty filter Follow cleaning procedures in Routine Maintenance section Elbows or other obstructions may be obstructing farn outlet Correct or improve ductwork Belt slippage Adjust belt tension Check for correct fan rpm Decrease fan speed if necessary Filter s not in place Install filters Induce Ps into system ductwork Make sure grilles and access doors are installed Decrease fan speed if necessary Adjust wheel and or inlet cone Tighten wheel hub or Fan wheel rubbing on inlet bearing collars on shaft Replace defective bearing s Lubricate bearings Tighten collars and fasteners Loosen to maintain a 3 8 inch deflection per foot of Belts too tight span between sheaves Motor base or blower loose Tighten mounting bolts Buildup of material on wheel Clean wheel and housing Make sure ductwork is supported properly Make
46. oads while reducing the amount of cycles per compressor Simply put this unit preconditions the outdoor air to save money on heating and cooling costs and then provides supplemental heating and cooling by means of a highly efficient heat pump Heat Pump Airside Heating and Cooling Coil Heat Pump Compressor s Heat Pump Module component locations will vary Outdoor Air Intake Filters Energy Wheel Cassette ial Reheat Mega Coil Heat Exchanger Supply Air Motor amp Blower a Model ERCH HP Energy Recovery Unit Refrigerant to Water Models and Capacities This unit is manufactured in four different platform sizes 20 45 55 and 90 Each platform has multiple options for heating and cooling capacities All 4 5 and 6 ton capacity units have a single scroll type compressor and all other units have two scroll type compressors and use a split airside heat pump coil Heat Pump Capacity Unit Size Tons ERCH HP 20 4 5 6 8 10 12 5 15 15 17 5 20 20 25 30 ERCH HP 45 ERCH HP 55 ERCH HP 90 Subassemblies Coils The airside coil is connected to the heat pump compressor s and is the primary vehicle for heating and cooling of the building A reheat coil is optionally available and is installed in the supply airstream adjacent to the airside coil The reheat coil is also connected to the heat pump but is used only when the unit is in cooling mode Heat Pump A
47. on the delivery receipt acknowledging any damage to the product All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier A Carrier Inspection Report should be filled out by the carrier upon arrival and filed with the Traffic Department If damaged upon arrival file claim with carrier Any physical damage to the unit after acceptance is not the responsibility of the manufacturer Unpacking Verify that all required parts and the correct quantity of each item have been received If any items are missing report shortages to your local representative to arrange for obtaining missing parts Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space Confirmation of shipment s must be limited to only items on the bill of lading Handling Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used Number and location of lifting brackets varies by model and size Handle each piece in such a manner as to keep from scratching or chipping the coating Damaged finish may reduce ability of the unit to resist corrosion 2 Model ERCH HP Energy Recovery Unit Storage Units are protected against damage during shipment If the unit cannot be installed and operated immediately precautions need to be taken to prevent deterioration of the unit during storage The user assumes
48. ormed Blower and motor assemblies energy 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 drawings for these dimensions ERCH HP 20 ERCH HP 45 ERCH HP 55 ERCH HP 90 8 Model ERCH HP Energy Recovery Unit I 36 IN EXHAUST HOOD 36 IN ACCESS PANEL ACCESS PANEL ACCESS PANEL ACCESS PANEL ELECTRICAL BOX FILTERS EXHAUST AIR INTAKE OUTDOOR AIR HOOD FILTERS ro WHEEL CASSETTE ACCESS PANEL 36 IN MINIMUM COIL SECTION IG HEATER T ACCESS PANEL 48 IN ACCESS PANEL 64 IN ACCESS PANEL 521 CLEARANCE WITH IG HEATER Clearances for service and component removal on ERCH HP 20 and ERCH HP 45 Clearance for energy wheel removal on ERCH HP 20 Clearance for energy wheel removal on ERCH HP 45 I 421N EXHAUST HOOD 421N ACCESS PANEL ACCESS PANEL ACCESS PANEL SSS ACCESS PANEL ACCESS PANEL ELECTRICAL BOX FILTERS
49. ounded 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 3 pe 8B MU B DANGER e Always disconnect power before working on or near this equipment Lock and tag the disconnect switch or breaker to prevent accidental power up e f 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 ME Receiving Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received Inspect each crate for shipping damage before accepting delivery Notify the carrier if any damage is noticed The carrier will make notification
50. place any dirty pleated filters and clean the aluminum mesh filters in the intake hood O Verify that non motorized dampers open and close properly O Check the tightness of all factory wiring connections O Verify control wire gauge O Verify diameter seal settings on the energy recovery wheel O Verify proper drain trap installation O Check condensing fans for any damage or misalignment Spin the blades and make sure they don t contact any parts and are free turning without any resistance Look over the piping system Inspect for oil at all tubing connections Oil typically highlights a leak in the system Inspect all coils within the unit Fins may get damaged in transit or during construction Carefully straighten fins with a fin comb Ifthere is an indirect gas fired furnace in this unit refer to the maual provided with this unit for Pre Start Up information O This unit contains a crankcase heater for each compressor which needs power supplied to it 24 hours prior to start up If start up is scheduled in 24 hours unlock the disconnect power and energize unit SPECIAL TOOLS REQUIRED Voltage Meter with wire probes Amperage Meter Pressure Gauges refrigerant Tachometer e Thermometer e Incline manometer or equivalent Start Up Procedure The unit will be in operational mode during start up Use necessary precautions to avoid injury All data must be collected wh
51. rclockwise 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 Model ERCH HP Energy Recovery Unit Bl Energy Wheel Start Up If selected the energy wheel is installed in the unit s airstream with one half of the wheel in the intake airstream and one half in the exhaust airstream Air leakage between the two airstreams has to be kept to a minimum and the wheel has air seals that must be adjusted for that purpose The seals must be adjusted at time of start up The wheel can be accessed through the door labeled Energy Wheel Access Bearing Support Adjustable Air Seals Label showing cassette serial number and date code Drive Belt Drive Pulley Drive Belt Inspect the drive belt Make sure the belt rides smoothly in the pulley and around the outside of the wheel Note the directional arrow and data information shown in the image Motor Pulley and Belt Adjust the Air Seals The first step in wheel seal adjustment is to make sure the unit power supply is locked out Disconnect the wiring to the wheel module and pull the wheel cassette out of the cabinet on its tracks Large cassettes are not removable Then slowly rotate the wheel by hand to make sure there is no binding or misalignmen
52. responsibility of the unit and accessories while in storage The manufacturer will not be responsible for damage during storage These suggestions are provided solely as a convenience to the user Inspection and Maintenance during Storage While in storage inspect units once per month Keep a record of inspection and maintenance performed If moisture or dirt accumulations are found on parts the source should be located and eliminated At each inspection rotate all moving components by hand ten to fifteen revolutions to distribute lubricant on motor and bearings If paint deterioration begins consideration should be given to touch up or repainting Units with special coatings may require special techniques for touch up or repair Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur Immediately remove the original rust preventive coating with petroleum solvent and clean with lint free cloths Polish any remaining rust from surface with crocus cloth or fine emery paper and oil Do not destroy the continuity of the surfaces Wipe clean thoroughly with Tectyl amp 506 Ashland Inc or the equivalent For hard to reach internal surfaces or for occasional use consider using Tectyl amp 511M Rust Preventive or WD 40 or the equivalent Table of Contents General Safety Information 1 Receiving Handling and Storage 2 Product Overview
53. rhead or valve Check bulb location and clamping Adjust superheat Replace expansion valve power head Room load too large Reduce the load or add more equipment Overcharged Check pressures and subcooling Check thermal expansion setting and calibrate Thermal expansion valve setting superheat Condenser fan not running or running Check electrical circuit and fuse Check fan cycling backwards controls High load conditions Add more equipment or reduce load Always have a completed Pre Start Up Checklist and Unit Start Up Checklist prior to requesting parts or service information Model ERCH HP Energy Recovery Unit Troubleshooting Refrigeration Circuit Symptom Possible Cause Corrective Action Refrigerant undercharge Check pressures and subcooling Blower running backward Interchange any two wires from 3 phase 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 Refrigerant leak Check System for leaks Repair leaks and add Low suction refrigerant ENSIS Check defrost system Clean the coil eck defrost system Clean the coil Evaporator dirty or iced up or airflow restricted Check fan operation Check airflow Plugged liquid line filter drier Replace filter drier Improper suction pressure regulator setting Check setting and correct as required Expansion valve defecti
54. ross the filter drier at 50 PSIG for R 410A Always have a completed Pre Start Up Checklist and Unit Start Up Checklist prior to requesting parts or service information H Model ERCH HP Energy Recovery Unit EJ Troubleshooting Refrigeration Circuit Symptom Posisie Gauss corrective action but cuts out on high pressure switch Check high side equalized pressure reading with Air or non condensables in system i equivalent outdoor temperature activates at 600 PSIG for Restriction in discharge or liquid line Check refrigerant line pressures check thermal R410A expansion valves Reheat valve and bypass valve not opening Check valves or valve circuit board Low voltage Check voltage Check running amperage and conditions described under Low suction pressure symptoms High suction and discharge pressures Check thermal expansion valve setting check for air in system If compressor is hot allow compressor to cool for Defective compressor overload e Compressor cuts out two hours Recheck for open circuit on thermal overload Improper refrigerant charge Check subcooling Improperly wired Review wiring schematics Compressor hums Defective start or run capacitor Check run capacitor for compressor and fan motor but will not start Defective relay start Replace relay Motor winding damaged Verify amp draws Internal compressor mechanical damage Replace Always have a completed Pre Start Up Che
55. rs 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 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 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 pressure on the blower side of filters Positive pressure connection is toward the back or bottom of the switch senses pressure at air inlet side of filters 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 The adjusting screw is located on the top of the switch Open the filter compartment and place a sheet of plastic or cardboard over 5096 of the filter media Replace the filter compartment door Check to see if there is power at the alert signal leads Whether there is power or not turn the adjustment screw on the dirty filter gauge clockwise if you did not have power counte
56. se Normal use being considered 20 F to 120 F and in a relatively clean environment Some bearings are relubricatable 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 Shaft bearings are the most critical moving part of a fan Therefore special attention should be given to keeping the bearings clean and well lubricated Proper lubrication provides for reduction in friction and wear transmission and dissipation of heat extended bearing life and prevention of rust In order for a lubricant to fulfill these tasks the proper grease applied at regular intervals is required Refer to the recommended bearing lubrication schedule Bearing Lubrication Schedule for Plenum Fans Relubrication Schedule in Months Fan Shaft Diameter in Inches RPM to 1 1 1 175 1 to 1 11 6 to 25 To 250 6 6 6 6 500 6 6 6 5 750 6 5 4 3 1000 6 4 3 2 1250 5 3 2 1 1500 5 2 1 1 2000 5 1 1 5 2500 4 5 5 25 3000 4 5 25 25 4000 3 25 25 25 5000 2 25 25 25 If unusual conditions exist temperatures below 32 F or above 200 F moisture or contaminants more frequent lubrication is required With the unit running add grease very slowly with a manual grease gun until a slight bead of grease forms at
57. shipping material has been removed from unit 2 To assist in determining rigging requirements weights are provided in the Installation Unit Weights and Recommended Roof Opening section of this manual 3 Unit must be lifted by all lifting lugs provided on base structure 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 6 Always test lift the unit to check for proper balance and rigging before hoisting to desired location 7 Never lift units by weatherhoods 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 supplied by others has been applied to the curb prior to lifting the unit and setting on curb 11 Do not use fork lifts for handling unit WARNING 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 Unit weights assume rooftop configuration with weatherhoods filters outdoor air damper six row DX coil integral condensing section and an indirect gas fired furnace Lifting Lugs On some models one lifting lug may be positioned directly in front of the condensate drain connection Any lifting lug that is located as shown should be r
58. sure ductwork metal thickness is sized for proper stiffness Check duct size at discharge to ensure that air velocities are not too high Blower fan speed too high Insufficient static pressure Ps airflow resistance Bearings Noise being transmitted by duct Always have a completed Pre Start Up Checklist and Unit Start Up Checklist prior to requesting parts or service information EJ Model ERCH HP Energy Recovery Unit H 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 Further problems will exist unless the true comply with all federal state and local laws The cause or problem is identified and corrected procedures discussed in this manual should only be performed by an EPA Certified Technician NOTE Unit is equipped with a phase loss phase reversal control If system does not start check phase of electrical supply Symptom Possible Cause Corrective Action Open disconnect switch or circuit breaker Close switch and or breaker Check voltage to contactor coil transformer slave Compressor contactor not closing relay system Replace parts as necessary Blown fuse or tripped breaker Check for reason and repair Replace fuse
59. switch es Unit may have multiple power supplies CAUTION 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 CAUTION Do not operate without the filters and birdscreens installed They prevent the entry of foreign objects such as leaves birds etc CAUTION Do not run unit during construction phase Damage to internal components may result and void warranty WARNING Unit was factory tested All blowers fans and compressors are set up to run correctly when supplied power If any one fan is running backwards or the compressor is making loud noises immediately turn off the power Switch two leads on the incoming power to the disconnect This will ensure proper operation of the unit Failure to comply may damage the compressors and void the warranty Do not jumper any safety devices when operating the unit This may damage components within or cause serious injury or death Do not operate compressor when the outdoor temperature is below 40 F Do not short cycle the compressor Allow 5 minutes between on cycles to prevent compressor damage Prior to starting up the unit power must be energized for 24 hours without a call for cooling to allow the compressor crankcase heaters time to boil off any liquid refrigerant present in the compressor DX s
60. t 9 alarm lights and switches to control the unit The remote ve panel ships loose and requires mounting and wiring in wig P the field a Economizer The remote panel is available with the following options 202 Rotation Sensor Unit on off switch I Unit on off light wc 8 wo Dirty Filter e 7 day time clock eHand off auto switch Dirty filter light Economizer light eFrost control light Wheel rotation sensor light PS3 Nc NO Dirty Filter Indicator power by others 7 Day Timer or On Off Switch NC C NO Dirty Filter 7 Day Timer Terminal Block in Unit s S1 Unit On Off Control Center nes 2 NS e For 7 Day Timer use blue and black wires Red wires should be capped off Heating Cooling Switches and Night Setback Hand Off Auto Switch Switch Timer S R st 00 Unit On Off S amp S6 de Econ First Stage Cooling Sn Te s7 6 Second Stage Cooling v n mus enter 228 Control Center Auto BMS 6 7 ND Hand Off Auto Switch allows the unit to m Off off 4 On Manual Operation s5 Night Setback Switch Auto Unit is controlled by BMS RTU etc NOTE RTU control
61. t The wheel should rotate smoothly and should not bind There is a perimeter seal located around the outside of the wheel and a diameter seal across the face of the wheel on both sides 1 Check to make sure that all air seals are secure and in good condition Retaining Screws Adjust the air seals by loosening all the air seal retaining screws on the bearing support see image for reference Using a piece of paper as a feeler gauge adjust the seals so they almost touch the face of the wheel while tugging slightly on the paper When the wheel is rotated there Bearing Support Bar showing air seal assembly A Model ERCH HP Energy Recovery Unit should be a slight tug on the paper Tighten the screws repeat the steps on the other set of seals Push the wheel cassette back into the unit and plug in the power connector Turn the main power supply back on and then observe the operation of the wheel by opening the wheel access door slightly Remove filters if necessary to observe the wheel Sequence of Operation Optional Economizer The economizer will be locked out when the outside air is lt 40 F 2 F hysteresis adjustable the unit is operating in dehumidification mode or there is a call for heating e Stop Wheel When economizer mode is enabled and there is a signal for cooling the wheel will stop rotating to allow free cooling e Modulate Wheel When economizer mode is enabled and there is a signal
62. t flow The valve is electrically actuated Access Ports For easy measurement and charging access several ports are provided throughout the system These can be used to measure system pressures and also charge or evacuate the system Heat Pump Controls Each unit is factory provided with a Unit Protection Module UPM that controls compressor operation and monitors the safety controls that protect the unit The UPM is a printed circuit board and is found in the heat pump module Safety controls include the following High pressure switch located in the refrigerant discharge line and wired across the HPC terminals on the UPM Low pressure switch located in the unit refrigerant suction line and wired across terminals LPC1 and LPC2 on the UPM The UPM includes the following features Anti Short Cycle Timer Five minute delay on break timer to prevent compressor short cycling Random Start Each controller has a unique random start delay ranging from 270 to 300 seconds to reduce the chances of multiple units simultaneously starting after initial power up or after a power interruption creating a large electrical spike Low Pressure Bypass Timer The low pressure switch is bypassed for 120 seconds after compressor start up to prevent nuisance low pressure lockouts during cold start up in the heating mode If the low pressure switch remains opened after 120 seconds the unit enters a soft lock Brownout Surge Power Interr
63. t will prevent control wheel frosting Three options are available 1 Timed Exhaust frost control 2 Electric preheat frost control 3 Modulating wheel frost control 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 enthalpy wheel The typical temperature setting corresponds to the indoor air relative humidity as shown in the Frost Threshold Frost Threshold Temperatures Temperatures Indoor RH Frost Threshold table and at 70 F Temperature represents when 20 10 F frost can occur 30 5 F An increase in 4096 O F 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 ensure that frost control is only initiated during a real frost condition Field wiring of a light or other alarm between 6 and C in the control center will notify personnel when unit is in frost control mode The following explains the three options in more detail 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 enthalpy wheel Default factory settings are 5 minutes off and 30 minutes on
64. the motor side of the cassette Note that one face of each segment is smooth and the other face has a reinforcing channel or support cut into the surface AA Wheel Segment Pulley Side Wheel Segment Motor Side 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 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 slide cassette halfway out of cabinet to access Contact the local Greenheck representative for detailed instructions on how to replace the bearing Model ERCH HP Energy Recovery Unit Energy Wheel Troubleshooting Symptom Possible Cause Corrective Action Air seals are too tight See air seals under Start Up Energy Wheel section Energy wheel does NOT turn Broken belt Replace No power to wheel motor Make sure wheel drive is plugged in Verify power is available Energy wheel runs intermittently Wheel motor overloads are tripping due to rubbing between wheel and air seals Recheck air seals make sure they are not too tight See Adjust the Air S
65. the seal Be careful not to unseat the seal by over lubricating or using excessive pressure A guide to the amount of grease to be used is to fill 3096 to 6096 of available space in the bearing and housing A high quality lithium based grease conforming to NLGI Grade 2 consistency such as those listed below should be used Mobil 532 Texaco Premium 2 B Shell Alvania 2 Mobilux 2 Texaco Multifak 2 Unirex 2 In addition to lubricating the bearings at specified intervals set screws in the bearing collars should be checked for tightness A bearing collar which has loosened will cause premature failure of the fan shaft Fasteners attaching the bearings to the drive frame should also be checked Model ERCH HP Energy Recovery Unit Internal Filter Maintenance The unit will typically be provided with 2 inch pleated filters in the supply airstream These filters should be checked per a routine maintenance schedule and replaced as necessary to ensure proper airflow through the 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 Aerostat Series 400 or Farr 30 308 Outdoor Air Filters Access to the outdoor air filters is through the door labeled as Filter Access on the access side of the unit Refer to Subassemblies Filters section for additional information on filter locations WARNING R
66. uption Protection The brownout protection in the UPM board will shut down the unit if the incoming power falls below 18 VAC The unit will remain off until a minimal incoming power of 18 VAC is detected Once proper power is restored the unit will start up within the random start time period Malfunction Output The controller has a set of wet contacts for remote fault indication or dry contacts for communication with a DDC controller or BMS The fault output will depend on the dip switch setting for ALARM If set to CONST a constant signal will be produced to indicate a fault has occurred and the unit requires inspection to determine the type of fault If it is set to PULSE a pulse signal is produced and a fault code is detected by a remote device indicating the fault The remote device must have a malfunction detection capability when the UPM board is set to PULSE Test Dip Switch A test dip switch is provided to reduce all time delay settings to five seconds during troubleshooting or verification of unit operation Note that operation of the unit while in test mode can lead to accelerated wear and premature failure of the unit The TEST switch must be set back to for normal operation Freeze Sensor This is optional and can be set to ignore or monitor a freeze sensor There are two configurable freeze points 35 F and 15 F The unit will enter a soft lockout until the temperature climbs above the set po
67. ure tap located at the supply discharge blower to ensure the tubing is connected and the tap is not blocked Remember to remove the jumpers 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 The variable frequency drive will be fully programmed at the factory Model ERCH HP Energy Recovery Unit EE Optional Economizer The energy 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 A field supplied call for cool Y1 is required De energizing the wheel is accomplished with a si
68. ve superheat too high or Adjust valve for proper superheat or replace the valve too small expansion valve if too small or defective Moisture in system Reclaim refrigerant check for leaks recharge ix Check subcooling check for leak Repair leak and Insufficient refrigerant charge add refrigerant Defective or improperly adjusted expansion Check superheating and adjust thermal expansion Low discharge valve valve pressure Check condenser controls and reset to obtain Faulty condenser temperature controls desired condensing temperature See High discharge pressure See High suction pressure Low airflow at evaporator s Check blower operation and airstream restrictions Incorrect unit selection oversized Contact factory Always have a completed Pre Start Up Checklist and Unit Start Up Checklist prior to requesting parts or service information Model ERCH HP Energy Recovery Unit H Troubleshooting Refrigeration Circuit Symptom Possible Cause Corrective Action Thoroughly defrost evaporator After defrost observe level add oil Check for leaks Check lines for proper slope and traps Excessive liquid refrigerant in the crankcase Adjust expansion valve for higher superheat Check crankcase heater Low or no oil pressure Worn oil pump Replace the oil pump Worn compressor bearings Replace the compressor Loose fitting on oil line or pump housing gasket Check and tighten system
69. xternal Filter 38 Coil Maintenance 38 Maintenance 39 Warranty ERR xx as RR ac Backcover Model ERCH HP Energy Recovery Unit EJ Product Overview This unit brings in fresh outdoor air and removes stale exhaust air from the building The intake and exhaust airstreams move through the unit in opposite directions in separate passages and each airstream passes through an energy wheel In cooling mode the energy wheel removes both heat and moisture from the incoming airstream and rejects it into the exhaust airstream In heating mode the energy wheel removes heat and humidity from the exhaust air and rejects it into the intake air thus reclaiming energy already expended to heat the building air In addition to the energy wheel this unit incorporates a packaged water source heat pump The heat pump System comes from the factory fully charged with refrigerant and is ready for connection to a water source upon arrival For purposes of providing temporary emergency heat an optional secondary heating source such as indirect gas furnace or electric heaters may also be installed The smaller tonnage units 4 6 tons contain a single compressor allowing for one stage of cooling Larger units 8 30 tons come standard with two compressors and a split airside coil This allows for staging of compressors to meet a wider range of outdoor air l
70. ystem is charged with refrigerant Start up must be performed by EPA Certified Technician IH Model ERCH HP Energy Recovery Unit 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 Unit Model No Unit Serial No Heat Pump Model No Energy Wheel Date Code Compressor 1 Model No Compressor 2 Model No Start Up Date Start Up Personnel Name Start Up Company Phone Number Pre Start Up Checklist O Disconnect and lock out all power switches O Remove any foreign objects that are located in the energy recovery unit O Check all fasteners set screws and locking collars on the fans bearings drives motor bases and accessories for tightness O Rotate the fan wheels and energy recovery wheels by hand and ensure no parts are rubbing O Check the fan belt drives for proper alignment and tension O Filters can load up with dirt during building construction Re

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