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Greenheck Fan 55 Patio Heater User Manual

1. associated with the media The media s break in period should be no less than 20 minutes When the process is complete Side of HRE Unitas remove the jumper wires in the control center Note Evaporative media may foam for a short period Drain Line following the initial start up Leave the bleed off Coola valve fully open until the foaming stops N Media 5 After the media break in period the Tr Sump water flow rate over the media needs to be x checked The pumps should provide enough water to saturate the media in 1 3 Drain Valve minutes If adequate flow rate is Line Roof Curb not achieved adjust via water Roof Line flow adjustment device found on Manual Shutoff Valve water supply line running to evap header Supply Line Standard Trap and Supply Line Configuration 6 The water bleed off rate will now need to be adjusted Media Size Media Pad This measurement is 3 to 6 percent of the media flow wxhxd in Area rate The recommended flow rate is 11 2 to 2 GPM per square foot of media pad top area see table at HRE 20 ate b ie E ie E right Actual water to the unit will be based on the evaporation rate A water flow adjustment device is HRE 45 Supply 30 48x12 2 5 ft supplied and installed by Greenheck for ease of water Exhaust 24x 48x12 2 0 ft flow adjustments After the unit has been i
2. Model Width Overall Width Overall Length including Lifting Lugs with Exhaust Hood with Outdoor Air Hood HRE 20 59 5 75 116 HRE 45 69 5 86 122 HRE 55 79 5 101 134 HRE 90 99 5 123 147 All dimensions shown are in inches Following is a list of items accessible through the access doors shown on the diagram at the right Some items are optional and may not have been provided 1 Exhaust blower motor and drives 2 Aluminum mesh filters intake hood 3 Energy recovery wheel motor belt and seals Outdoor air filters Outdoor air intake damper optional Electric preheater optional Frost control sensors optional Economizer sensors optional 4 Direct evaporative cooler drain pan and pump optional 5a Outdoor air blower motor and drives without indirect gas furnace 5b Outdoor air blower motor and drives with indirect gas furnace 6 Control center All electrical controls VFDs for blowers optional VFD for energy recovery wheel optional 7 Indirect evaporative cooler drain pan and pump Exhaust air filters Exhaust air intake damper optional AV X ANN VY AN L Dimensional data and access door locations EVAPORATIVE COOLING MODULES Mount the heat recovery unit level to ensure proper operation and water drainage Piping should be of adequate size to pro
3. Amp Current Sensors analog or digital Drawing Labels Terminal Strip Labels OAF P Supply Fan Amps EF A Exhaust Fan Amps 28 START UP CHECKLIST FOR UNIT SAFETY DANGER SAFETY CAUTION Electric shock hazard Can cause injury or death Use caution when removing access panels or other Before attempting to perform any service or unit components especially while standing on a maintenance turn the electrical power to unit to OFF ladder or other potentially unsteady base Access at disconnect switch es Unit may have multiple panels and unit components can be heavy and power supplies serious injury may occur SAFETY CAUTION CAUTION Do not operate energy recovery ventilator without 3 the filters and birdscreens installed They prevent the entry of foreign objects such as leaves birds etc Do not run unit during construction phase Damage to internal components may result and void warranty 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
4. i All dimensions shown are in inches 050 Lia 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 inlet of the unit into prevailing wind and keep the supply inlet of the unit away from any other exhaust fans Likewise position the exhaust discharge opening away from fresh air intakes of any other equipment When cutting only duct openings cut opening 1 inch 25mm larger than duct size to allow clearance for installation Area enclosed by roof curb must comply with clearance to combustible materials If the roof is constructed of combustible materials area within the roof curb must be ventilated left open or covered with non combustible material which has an ORO value of at least 5 If area within curb is open higher radiated sound levels may result Where the supply or warm air duct passes thru a combustible roof a clearance of one inch must be maintained between the outside edges of the duct and combustible material in accordance with NFPA Standard 90A 3 ROOF CURB MOUNTING Rooftop units require curbs to be mounted first The duct connections must be located so they will be clear of structural members of the building 1 Factory Supplied Roof Curbs Roof curbs are Model GKD which are shipped in a
5. Bracket Segment Retainer Steel retainers are located on the inside of the wheel rim see diagram at right Push the retainer toward center of wheel then lift up and away to release segments see below Lift Away Push Toward Center IMPORTANT PLACE RETAINERS BACK IN THE ORIGINAL POSITION BEFORE ROTATING THE ENERGY RECOVERY WHEEL OTHERWISE DAMAGE TO RETAINER WILL OCCUR Wheel segment removed 38 ROUTINE MAINTENANCE CLEANING THE ENERGY RECOVERY WHEEL If the wheel appears excessively dirty it should be cleaned to ensure maximum operating efficiency Only excessive buildup of foreign material needs to be removed DISCOLORATION AND STAINING OF ENERGY RECOVERY WHEEL DOES NOT AFFECT ITS PERFORMANCE Thoroughly spray wheel matrix with household cleaner such as Fantastic or equivalent Gently rinse with warm water and using a soft brush remove any heavier accumulation A detergent water solution can also be used Avoid aggressive organic solvents such as acetone The energy recovery wheel segments can be soaked in the above solution overnight for stubborn dirt or accumulation After cleaning is complete shake the excess water from the wheel or segments Dry wheel or segments before placing them back into the cassette Place wheel or segments back into cassette by reversing removal procedures DO NOT CLEAN ENERGY RECOVERY WHEEL SEGMENTS WITH WATER IN EXCESS OF 140 F DO NOT DRY ENERGY RECOVERY WHEEL SEGME
6. 1 The media should be checked for mineral and foreign material deposits that have built up If these items are left on the media the life and performance of the unit will be greatly reduced Also there are risks of water carryover when this type of condition exists When signs of mineral build up are noticed you should increase the bleed off rate If this does not solve the problem chemicals may need to be added to the water The evaporative pads tend to be self cleaning Depending on water quality and system maintenance the useful life of the pads should be 3 to 5 years 2 The media should be periodically brushed lightly with a soft bristle brush in an up and down motion never brush side to side while flushing with water This will also aid in reducing the amount of foreign material build up 3 The water should be shut off and all the lines drained when the temperature drops below 50 F 4 When the evaporative cooler is going to be used for the first time each season it is recommended that the media be flushed with clean water for a period of 2 minutes see Evap Module Start Up 5 Atthe beginning of each cooling season the upright recirculating pump should have the shaft oiled and spun to eliminate the potential of seizing and pump burn out 6 If the cooling media was removed from the unit check to make sure that is not installed backwards If the media is installed backwards there will be large amounts of water ca
7. check the radial gap and overlap Adjust if necessary 29 START UP CHECKLIST FOR UNIT Special Tools Required Voltage Meter with wire probes Amperage Meter Incline manometer or equivalent Tachometer Thermometer Start Up Checklist The unit will be in operational mode during start up Use necessary precautions to avoid injury All data must be collected while the unit is running In order to measure volts amp amps the control center door must be open and the unit energized using a crescent wrench to turn the disconnect handle Line Voltage check at unit disconnect L1 L2 Volts L2 L3 Volts L1 L3 Volts Motor Amp Draw Supply Motor Amps L1 Amps L2 Amps L3 Amps Exhaust Motor Amps L1 Amps L2 Amps L3 Amps Fan RPM Supply Fan RPM Exhaust Fan RPM Correct fan rotation direction Supply Fan Yes No Exhaust Fan Yes No START UP CHECKLIST FOR EVAPORATIVE COOLER Evaporative coolers are an integral part of the unit and must be set up properly Doing so will ensure correct operation and avoid water or leakage problems HRE units will have one or two evaporative coolers The following checklist must be completed for each evaporative cooler Qualified personnel should perform installation and be present for start up to ensure safe and proper practices are followed Please refer to the Evaporative Cooling Modules section for detailed information on start up items below Indirect Evap Direct Evap Connect overflow line run bleed line
8. pleated 30 efficient filters 8 Electrical control box standard features Single point power Disconnect interlocked with access door Motor starters for the supply blower exhaust blower and energy wheel motors 24 Vac control circuit with terminal strip 9 Supply air tempering options Electric heat requires separate power Hot water heat Indirect gas heat 10 Exhaust blower Forward curved fan Adjustable motor mount for belt tensioning Adjustable sheaves for speed control 11 Indirect evaporative cooler 12 Direct evaporative cooler SEQUENCE OF OPERATION Basic Unit The HRE units are pre wired such that when a call for outside air is made via field supplied 24 VAC control signal wired to unit control center the supply fan exhaust fan and energy wheel are energized and the motorized dampers open The HRE units can be supplied with or without heating and cooling coils For units with coils controls can be supplied by Greenheck or by the controls contractor If supplied by the controls contractor they would provide mount and wire any temperature controllers and temperature or relative humidity sensors required for the unit to discharge air at the desired conditions Summer Operation A sensible wheel preconditions the outdoor air temperature is decreased by the transfer of energy from the cool exhaust air coming out of the indirect evaporative cooler Units supplied with a direct evaporative cool
9. 410 Schofield WI 54476 0410 715 359 6171 greenheck com 461248 IOM HRE FS Rev 4 April 2012 Copyright 2012 Greenheck Fan Corp
10. DIRECT EVAP DRAIN AND OVERFLOW CONNECTIONS Exhaust 14 EXHAUST AIR DISCHARGE COMPARTMENT EXHAUST AIR INTAKE COMPARTMENT OVERFLOW CONNECTIONS 3 4 INCH INDIRECT EVAP DRAIN AND TROUBLESHOOTING FOR EVAPORATIVE MODULE Insufficient water _ volume or recirculation pump not operating Irregular water distribution on cooling media Scale and mineral deposit formation on face of media Water Carry Over Inadequate cooling Excessive water discharge into drain Poor performance after cooling pad replacement A B If pump is not operating check Clogged or worn out pump Clogged header Water flow adjustment device Check water level in base pan The level should be at 1 inch Check the pump filter at the inlet Clean the filter if clogged or dirty wiring for loose connections and proper voltage Water distribution header orifices or media partially blocked or plugged Remove evaporative cooler from unit Disassemble and clean distribution header orifices and media Increase bleed rate Increase water flow rate Media is self cleaning with flow rate of 11 2 to 2 gpm per square foot of media top area Generally this flow rate prevents dissolved solvents from collecting on the media To prevent further trouble flush and clean the system more frequently Check water flow across the face of the media Irregular water distribution must be corrected
11. Jat 51 52 sa 54 s5 56 AM 16 S S ugg ini WIRED TO FR AND FC COMMON 0 VDC 30 Hz Eod 10 VDC 60 Hz FOR ONE 0 10 SIGNAL WIRE TO DRIVES IN PARALLEL OPTION 1 0 10 VDC CONTROL SEE VFD INSTALLATION MANUAL FOR MORE DETAIL USER TO PROVIDE ISOLATION AS REQUIRED 0 10 VDC CONTROL SIGNAL BY OTHERS FOR CONTINUOUS 60Hz OPERATION JUMPER TERMINALS FS AND FR WIRED TO 1 AND AC COMMON 0 VDC 30 Hz 10VDC 60 Hz Fd FOR ONE 0 10 SIGNAL WIRE TO DRIVES IN PARALLEL SEE VFD INSTALLATION MANUAL FOR MORE DETAIL FOR CONTINUOUS 60Hz OPERATION JUMPER TERMINALS A1 AND V OPTION 2 MULTI SPEED CONTROL USER TO PROVIDE CONTACTS AND ISOLATION AS REQUIRED 54 55 SC NEITHER S4 OR S5 CONTACT CLOSED DRIVE SPEED 60 Hz OPTION 2 MULTI SPEED CONTROL 54 TO SC CONTACT CLOSED BY OTHERS 20 DRIVE SPEED 30 Hz SEE VFD INSTALLATION MANUAL FOR MORE DETAIL TO CHANGE THE FACTORY SET Hz CHANGE THE FOLLOWING PARAMETERS PARAMETER A1 01 CHANGE TO 2 PARAMETER D1 01 FOR NEW 60Hz SETTING PARAMETER D1 02 FOR NEW 40Hz SETTING PARAMETER D1 03 FOR NEW 30Hz SETTING PARAMETER A1 01 CHANGE TO 0 USER TO PROVIDE CONTACTS AND ISOLATION AS REQUIRED DRIVE SPEED 40 Hz e re il NEITHER S5 OR S6 CONTACT CLOSED L 1 5TO SC CONTACT CLOSED BY OTHERS S5 S6 sN DRIVE SPEED 60 Hz DRIVE SPEED 30 Hz 1 S5 TO SN CON
12. One or Both Blowers Turn Off Intermittently and Back on After About 2 Minutes Energy Wheel Does NOT Turn Energy Wheel Runs Intermittently Excessive Noise or Vibration Always provide the unit model and serial number when requesting parts or service information Always check motor amps and compare to nameplate rating Possible Cause Blower fan motor overloads are tripping and auto resetting Exhaust Only frost control sensors are tripping Air seals are too tight Economizer sensors are operating No power to wheel motor Wheel drive belt Wheel motor overloads are tripping due to rubbing between wheel and air seals Fan wheel rubbing on inlet Bearings Wheel out of balance Loose wheel on shaft Loose motor or blower sheave Belts too loose Belts too tight Worn belt Motor base or blower loose Build up of material on wheel Bearing and drive misaligned Noise being transmitted by duct Corrective Action Decrease fan speed Adjust frost temperature sensor set point as needed See Energy Recovery Wheel under Unit Start Up section Adjust temperature or enthalpy set points as needed Make sure wheel drive is plugged in Verify power is available Check for loose or broken belts Replace belts consult factory Recheck air seals make sure they are not too tight See Energy Recovery Wheel under Unit Start Up Section Adjust wheel and or inlet cone Tighten wheel hub
13. Turn unit power on The 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 vam py ok economizer is working properly e Turn unit power off Reconnect C7400 solid state enthalpy sensor to terminal So Enthalpy Sensor with Override z 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 setpoint Enthalpy Controller Sequence of Operation The variable frequency drive is fully programmed at the factory refer to VFD section for more information 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 Toa gt Tra Wheel runs at full speed maximum energy recovery Toa lt Toa gt Tsa Wheel is stopped no ener
14. be factory mounted EXHAUST WEATHERHOOD The exhaust weatherhood is shipped separately as a kit with its own instructions DAMPERS Backdraft dampers are always included as an integral part of the exhaust hood assemblies Motorized outdoor air and exhaust air dampers are optional and are factory mounted and wired at the inlet ELECTRICAL INFORMATION The unit must be electrically grounded in accordance with the current National Electrical Code ANSI NFPA No 70 In Canada use current C S A Standard C22 1 Canadian Electrical Code Part 1 In addition the installer should be aware of any local ordinances or electrical company requirements that might apply System power wiring must be properly fused and conform to the local and national electrical codes System power wiring is to the unit main disconnect door interlocking disconnect switch standard on most units or distribution block and must be compatible with the ratings on the nameplate supply power voltage phase and amperage Minimum Circuit Amps MCA Maximum Overcurrent Protection MOP All wiring beyond this point has been done by the manufacturer and cannot be modified without affecting the unit s agency safety certification If field installing an additional disconnect switch it is recommended that there is at least four feet of service room between the switch and system access panels When providing or replacing fuses in a fusible disconnect use dual element time del
15. control is an optional feature that will prevent control wheel frosting Three options are available 1 Timed Exhaust frost control Indoor RH 70 F Frost Threshold Temp 2 Electric preheat frost control 209 3 Modulating wheel frost control 2 0 o All of these options are provided with a thermostat with 25 PE probe mounted in the outdoor air inlet compartment and 30 14 F a pressure sensor to monitor pressure drop across the Frost Threshold Temperatures wheel The typical temperature setting corresponds to the indoor air relative humidity as shown in the Frost Threshold Temperatures Table and represents when frost can occur An increase in 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 insure that frost control is only initiated during a real frost condition Field wiring of a light or other alarm between 6 amp C in the control center will notify personnel when unit is in frost control mode refer to Remote Panel Wiring schematics section for wiring details The following explains the three options in more detail Timed exhaust frost control includes a timer in addition to the thermostat and 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 energy recovery w
16. if you turn off the z jos power supply turn off the gas Most factory supplied electrical components are pre wired To determine what electrical accessories require additional field wiring refer to the unit specific wiring diagram located on the inside of the unit control center access door The low voltage control circuit is 24 Vac and control wiring should not exceed 0 75 ohms Refer to Field Control Wiring Length Gauge table for wire length maximums for a given wire gauge 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 Field Control Wiring Length Gauge Total Wire Length Minimum Wire Gauge 125 ft 18 200 ft 16 300 ft 14 450 ft 12 If wire resistance exceeds 0 75 ohms an industrial style plug in relay should be added to the unit control center and wired in place of the remote switch typically between terminal blocks R and G on the terminal strip refer to Typical Control Center Components 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 Note Standard factory installed electric post heaters have their own disconnect separate from the unit disconnect Thus each electric post heater requires its own separate power con
17. perform start up to ensure safe and proper practices are followed Unit Model Number e g HRE 55 Unit Serial Number e g 04C99999 Energy Wheel Date Code e g 0450 Start up date MM DD YYY Y Start up Personnel Name Start up Company Phone Number Pre Start Up Checklist check boxes as items are completed 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 If rubbing occurs refer to Start Up section for more information O Check the fan belt drives for proper alignment and tension refer to Start Up section for more information L1 Filters can load up with dirt during building construction Replace any dirty pleated filters and clean the aluminum mesh filters in the intake hood refer to Routine Maintenance section Verify that non motorized dampers open and close properly Check the tightness of all factory wiring connections Verify control wire gauge refer to the Electrical Connections section 0000 Verify diameter seal settings on the energy recovery wheel refer to Start Up section for more information LI Verify proper drain trap installation refer to Drain Trap section LI For plenum or BI fans
18. see above If this condition persists chemicals may need to be added Water pH should be maintained between 6 and 8 Irregular water distribution on face of media see above Average face velocity exceeds 550 fpm Decrease fan rpm and airflow Localized face velocities exceeding 550 fpm Air filters or media face area is partially blocked Clean or replace air filters and media Check the overflow for blockage Irregular water distribution over face of media see above Check for uniform airflow Check outside wet bulb temperature High wet bulb temperatures can decrease performance Check water flow rate over media Flow rate should be 11 2 to 2 gom per square foot of media top area Check the water bleed off rate and make sure that it is not excessive Pad installed backwards To get the performance from the cooling pads they must be installed properly The pads are manufactured with 15 45 degree flute angles The pads must always be installed with the steeper flute angle sloping down toward the entering air side See figure on right Check water level in base pan The level should be at 1 inch 2e gt Entering Air Leaving Air 15 EVAPORATIVE COOLING MAINTENANCE Regularly scheduled maintenance is the key to peak performance minimized cost and extended life of the evaporative cooler The following is a checklist of items that need to be looked at on a regular basis
19. settings shown below Refer to the instruction manual that ships with the unit when making adjustments A copy of the manual can be found online at www drives com For technical support contact Yaskawa direct at 1 800 927 5292 Yaskawa GPD 305 Drive Parameter Setting n01 Access Level 1 n30 Ref Upper Limit 100 or 66 n32 Motor Rated FLA Motor FLA n33 Elect Thermal Overload 1 n36 Multi Function input terminal S2 10 n40 Multi Function output MA MB MC 4 n41 Analog Freq Reference Gain 0 n42 Analog Freq Reference Bias 99 n46 Carrier Frequency 2 n58 Frequency Detection Level 20 n01 Access Level 0 36 inch wheel is 66 40Hz All other wheels are 100 60Hz 21 OPTIONAL ACCESSORIES Wiring Diagram Following is an example of a typical wiring diagram located in the unit control center This wiring diagram includes a legend highlighting which accessories were provided with the unit Factory wiring and field wiring are also indicated This particular example includes 1 variable frequency drives on the blowers requiring a modulating input 2 modulating energy recovery wheel with factory controls for economizer 3 energy recovery wheel rotation sensor 4 outdoor air and exhaust air dirty filter switches 5 motorized outdoor air and exhaust air intake dampers and 6 timed exhaust frost control Many other factory installed and wired accessories are available 051 5 MAIN POWER 2 TO
20. to Electrical Connections section for Field Control Wiring recommendations 7 Day Timer or On Off Switch 7 Day Timer Timer 1 KS Override S1 Unit On Off S For 7 Day Timer use blue and black wires Red wires should be capped off Hand Off Auto Switch Terminal Block in Unit Control Center Hand Off Auto Switch allows the unit to Off off On Manual Operation Auto Unit is controlled by BMS RTU etc NOTE RTU controllers are by others Terminal Block in Unit Control Center 25 OPTIONAL ACCESSORIES Remote Panel Wiring Schematics Indicator Lights powered by the ER Unit 5 Unit On Off x wA g Frost Control m Economizer Rotation Sensor a gt 30 PS2 NOM c NO Supply Dirty Filter n a Exhaust Dirty Filter Dirty Filter Indicator Power by Others PS2 eg ae Supply Dirty Filter P PS3 So No Exhaust Dirty Filter n Hot L1 Refer to Pressure Switch for voltage and load ratings 26 OPTIONAL ACCESSORIES Remote Panel Wiring Schematics Heating Cooling Switches and Night Setback Switch Timer 51 56 57 54 55 E S R me N c Unit On Off KQ o SY G Ec
21. 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 Belt Span The proper belt setting is the lowest tension 64 at which the belts will not slip under peak load operation For initial tensioning set the belt deflection 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 Belt Span operation and periodically thereafter Deflection Proper fan belt settings Fan Motors Motor maintenance is generally limited to cleaning and lubrication Cleaning should be limited to exterior surfaces only Removing dust and grease b
22. 2 Sensor Yes No N A Yes No Service Outlet Yes No N A Yes No Vapor Tight Lights Yes No N A Yes No Remote Control Panel Yes No N A Variable Frequency Drives section Operational Yes No Blower VFDs Yes No N A Yes No Wheel VFD Yes No N A Damper section Operational Yes No Outdoor Air Damper Yes No N A Yes No Exhaust Air Damper Yes No N A Yes No Night Setback Damper Yes No N A Yes No Indirect Gas Furnace refer to the PVF IOM Part 461006 for start up information Standard Indirect Evaporative Cooler Section refer to Evap Start Up checklist on following page Yes No Direct Evaporative Cooler Section refer to Evap Start Up checklist on following page 31 UNIT START UP Refer to Parts List section for component locations Fans Forward Curved Type The HRE Models contain a forward curved supply fan and a forward curved exhaust fan These forward curved fans should be checked for free rotation If any binding occurs check for concealed damage and foreign objects in the fan housing Be sure to check the belt drives per the start up recommendations in the following section Fan Performance Modifications Due to job specification revisions it may be necessary to adjust or change the sheave or pulley to obtain the desired SAFETY CAUTION airflow at the time of installation Start up technician must When operating conditions of the fan are to be check blower amperage to ensure that the amperage listed changed speed pressure tempe
23. 355 HRE 55 112 75 71 5 450 HRE 90 125 75 90 75 625 All dimensions shown are in inches ROOF CURB 1 INCH INSULATION Curb CAP Details for Factory Supplied Roof Curbs RAIL MOUNTING Rail Layout e Rails designed to handle the weight of the HRE should be positioned as shown on the diagram rails by others e Make sure that rail positioning does not interfere with the supply air discharge opening or the exhaust air intake opening on the HRE unit Avoid area dimensioned B below e 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 Rail Mounting Model A B HRE 20 5 1 25 0 SUPPLY EXHAUST HRE 45 7 1 25 1 OPENING ass HRE 55 5 7 35 0 90 6 6 36 1 Side view of HRE on rails All dimensions shown are in inches DUCTWORK CONNECTIONS Examples of good and poor 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 HRE Model HRE Blower Size Duct Size Straight Duct Length HRE 20 10 14x14 40 HRE 45 12 20 x 20 48 HRE 55 15 28 x 28 60 HRE 90 18 32 x 32 72 Dimensions shown are in inches SUPPLY WEATHERHOOD e Supply weatherhood will
24. 4 inch Water Supply Connection EA INLET Top View OA INLET __ gt 1 4 inch Water Supply Connection A d 0 875 Run 1 4 inch line up through 7 8 inch hole here and bring around end of sump to supply connection 11 WATER CONTROL OPTIONS FOR EVAPORATIVE COOLING AUTO DRAIN AND FILL WITH FREEZE PROTECTION This system will automatically drain the sump tank and fill it with gt gt Temperature fresh water at the field adjustable intervals typically once every 24 setting hours This flushes mineral build up and debris from the tank to Esetiings 31 promote low maintenance and increase media pad life In addition the system will protect the evaporative cooler from freezing o by draining the sump tank and supply line when the outside settings lt 9 temperatures fall below the set point of the outside air sensor e Typically this is set at 45 to 50 F The auto drain and fill outdoor air sensor should be installed in an area that is shaded from direct eee sunlight so the outside air sensor probe will detect an accurate air Evaporative Evaporative temperature Set the timer Timer settings are t1 1 0 10 min and Freeze Timer t2 0 4 60h Protection PLUMBING FOR AUTO DRAIN AND FILL 1 Run water supply line to the unit and install Water Supply Solenoid Valve A in this line as close to the water source as possible 2 Install Drain Soleno
25. ANCE WITH N E C POWER MUST BE OFF WHILE SERVICING USER INTERFACE CONNECTIONS USER TO VERIFY THAT TR1 CAN HANDLE THE VA LOAD OF INDICATOR DEVICES DIRTY FILTER INDICATOR SHOWN AS 24V POWER FROM UNIT PS2 NC No SUPPLY DIRTY A 50645 O FILTER SWITCH IN Nee Ll m NC c NO EXHAUST DIRTY R orpo O Jc FILTER SWITCH N Ne memes uli FROST CONTROL INDICATOR ROTATION INDICATOR OPTIONAL ACCESSORIES Rotation Sensor The rotation sensor monitors energy recovery 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 amp 12 in the unit control center will notify maintenance personnel when a failure has occurred refer to Remote Panel Wiring Schematics section for wiring details 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 filters 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 comple
26. ELAY DIRECT R10 UNIT RELAY 051 FAN SWITCH S2 ROTATION SENSOR REED SWITCH 53 ROTATION SENSOR REED SWITCH S4 CALL FOR HEAT SWITCH S5 BYPASS SWITCH 056 CALL FOR COOL SWITCH FIRST STAGE 57 CALL FOR COOL SWITCH SECOND STAGE ST MOTOR STARTER T1 FROST CONTROL TIMER TYPICAL SETTINGS t1 OFF 5 MIN t2 ON 30 MIN T2 ROTATION SENSOR TIMER T3 ROTATION SENSOR TIMER T4 ECONOMIZER WHEEL JOG TIMER TYPICAL SETTINGS t1 OFF 3 HRS t2 ON 10 SEC T5 EVAP DELAY OFF TIMER T6 COMPRESSOR MINIMUM OFF TIMER TYP 3 MIN T7 COMPRESSOR MINIMUM OFF TIMER TYP 3 MIN TR TRANSFORMER TS1 FROST CONTROL THERMOSTAT JUMPER HEAT CLOSES ON TEMP DECREASE TYPICAL SETTING 5 F TS2 ECONOMIZER LOW LIMIT THERMOSTAT JUMPER HEAT OPENS ON TEMP DECREASE TYP SETTING 20 OFFSET OR 50 F TS3 ECONOMIZER UPPER LIMIT THERMOSTAT JUMPER HEAT CLOSES ON TEMP DECREASE TYP SETTING 65 F 2 DIFF TS4 ROOM OVERRIDE SENSOR TS5 INLET AIR POST HEATER LOCKOUT THERMOSTAT AFTER WHEEL CLOSES ON TEMP DECREASE TYPICAL SETTING 65 F TS6 INLET AIR COMPRESSOR LOCKOUT THERMOSTAT JUMPER HEAT OPENS ON TEMP DECREASE TYPICAL SETTING 60 F 2 DIFF FACTORY SUPPLIED AND WIRED o FIELD WIRED FIELD CONTROL WIRING RESISTANCE SHOULD NOT EXCEED 0 75 OHM IF RESISTANCE EXCEEDS 0 75 OHM THEN CONSULT FACTORY USE 14 GAUGE MINIMUM WIRE THICKNESS FOR CONTROL WIRING REPLACEMENT FUSES MUST HAVE A MINIMUM I R RATING OF 5 KA CAUTION UNIT SHALL BE GROUND IN ACCORD
27. Fan Amp Draw Pressure Drop Across Energy Recovery Wheel Outdoor Air Side Exhaust Side Airflow problems can often be tied back to improper ductwork installation Be sure to install ductwork in accordance with SMACNA and AMCA guidelines 42 Troubleshooting Symptom Blower Fails to Operate Motor Starters Chatter or Do Not Pull In Motor Over Amps Low Airflow cfm High Airflow cfm Possible Cause Blown fuse or open circuit breaker Defective motor or capacitor Motor starter overloaded Electrical Drive Control power 24 Vac wiring run is too long resistance should not exceed 0 75 ohms Incoming supply power is less than anticipated Voltage supplied to starter coil must be within 10 15 of nominal voltage stated on the coil Cfm too high Static pressures are higher or lower than design Blower rotation is incorrect Motor voltage incorrect Motor horsepower too low Shorted windings in motor Unit damper not fully open System static pressure too high Blower speed too low Fan wheels are operating backwards Dirty filter or energy wheel Leaks in ductwork Elbows or other obstructions may be obstructing fan outlet Belt slippage Blower fan speed too high Filter s not in place Insufficient static pressure Ps airflow resistance Corrective Action Replace fuse or reset circuit breaker and check amp
28. NTS IN AIR IN EXCESS OF 140 F THE USE OF A PRESSURE WASHER TO CLEAN SEGMENTS IS NOT RECOMMENDED DAMAGE COULD RESULT 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 Ifa belt requires replacement contact the local Greenheck representative Instructions for replacement will ship with the new belt Wheel Belt amp Pulley Energy Recovery Wheel Bearings In the unlikely event that a wheel bearing fails access is available through the outdoor air filter door and through a removable plate in the divider in the unit accessed through the exhaust air filter door Contact the local Greenheck representative for detailed instructions on how to replace the bearing Wheel Bearing 39 PARTS LIST 40 Model HRE shown with indirect evaporative cooler optional direct evaporative cooler and indirect gas heater Supply blower Forward curved fan Adjustable motor mount for belt tensioning Adjustable sheaves for speed control Vibrations isolators quantity 4 per blower Neoprene Energy recovery wheel cassette Removable energy recovery wheel segments Optional supply weatherhood with 2 in aluminum mesh filter Optional exhaust weatherhood with birdscreen Optional supply and exhaust air filter racks for 2 in
29. Oo Check set screws for tightness L1 Oo Oo Lubricate as required L1 L1 L1 L1 External Filter Check for cleanliness clean if required o L1 L1 L1 Internal Filter Check for cleanliness replace if required L1 L1 L1 L1 Door Seal Check if intact and pliable L1 L1 L1 L1 Coil Maintenance Check for cleanliness coil and drain pan L1 Oo Winterizing Coils Drain Fill with antifreeze Drain L1 L1 L1 L1 Energy Recovery Wheel Check for cleanliness clean if required L1 L1 L1 L1 Check belt for wear o L1 Oo Oo Check pulley bearings and motor O L1 L1 Oo Evap Cooler Section Refer to Evaporative Cooler Maintenance section L1 L1 L1 0 35 ROUTINE MAINTENANCE 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 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
30. READ AND SAVE THESE INSTRUCTIONS PART 461248 HEAT RECOVERY UNIT B GREENHECK wiru ctEAT RECOVERY UNIT Building Value in Air Models HRE 20 45 55 amp 90 INSTALLATION OPERATION AND MAINTENANCE MANUAL RECEIVING AND HANDLING The HRE is thoroughly inspected and test run at the factory However damage may occur during shipping and handling Upon delivery inspect the unit for both obvious and hidden damage If damage is found record all necessary information on the bill of lading and file a claim with the final carrier In addition ensure all accessory items are present Some accessory items are stored inside the unit during shipping SAFETY WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read this installation operation and maintenance manual thoroughly before installing or servicing this equipment Installation and service must be performed by a qualified installer service agency or the gas supplier Liste Indirect Evaporative Cooler Exhaust Scavenger Airstream INSTALLATION SUPPLEMENT Refer to the following installation supplement for HRE units when supplied with Indirect Gas IG heating Model PVF Indirect Gas Fired Furnaces for Energy Recovery Units Part 461006 SAVE THIS MANUAL This manual is the property of the owner and is required for future maintenance This manual should remain with each HRE unit when the job is c
31. TACT CLOSED BY OTHERS SEE VFD INSTALLATION MANUAL FOR MORE DETAIL i rive SPEED 40 Hz Tl TO CHANGE THE FACTORY SET Hz CHANGE THE FOLLOWING PARAMETERS L 1 1 S6TO SN CONTACT CLOSED BY OTHERS PARAMETER n01 CHANGE TO 1 PARAMETER n21 FOR NEW 60Hz SETTING PARAMETER n22 FOR NEW 40Hz SETTING PARAMETER n23 FOR NEW 30Hz SETTING PARAMETER n01 CHANGE TO 0 OPTIONAL ACCESSORIES Factory Setpoints MODULATING CONTROL 0 10 VDC FOR FAN SPEED Variable frequency drives VFD for the blowers are factory setup to receive a 0 10 VDC signal wired in the field refer to previous page for terminal locations Most of the setpoints in the VFDs are factory defaults There are a few though that are changed at Greenheck and are shown in the tables below To gain access to change setpoints on the E7 drive parameter A1 01 needs to be set at 2 To gain access to change setpoints on the GPD 305 drive parameter n01 needs to be set at 1 To prevent access on either drive change the parameter to 0 Yaskawa E7 Drive Yaskawa GPD 305 Drive S1 to SN contact for On Off S1 to SC contact for On Off A1 0 10VDO referenced to AC Can use 15 VDC from V FR 0 10VDC referenced to FC Can use 12 VDC from FS Parameter Setting Parameter Setting A1 01 Access Level 2 n01 Access Level 1 C6 02 Carrier frequency 2 n31 Ref Lower Limit 5096 d2 02 Ref Lower Limit 50 n32 Motor Rated FLA Motor FLA E2 01 Motor Rated FLA Mot
32. UNIT 79 a ez 28 8 GROUND ES R3 EXHAUST FAN D MOTOR 7 SC FR E SUPPLY Ri MOTOR 0 10 VDC SEE BELOW FOR TERMINAL CONNECTIONS MULTI VOLTAGE PRIMARY 24 SECONDARY EXHAUST DAMPER VFD E O L EXHAUST FAN SUPPLY DAMPER VFD S OL SUPPLY FAN ENERGY WHEEL ROTATION SENSOR OA SENSOR 24 VAC SENSOR THERMOSTAT S TS1 THERMOSTAT CONTROLLER S FROST CONTROL 56 4 4 TR TRI 1 n TOFRAND FC ECONOMIZER CONTROL 620 OHM RESISTOR OR SR 207 ON VFD W RETURN AIR SENSOR SR OUTDOOR AIR so SENSOR 0 5 MIXED AIR T 2 sensor _ 11 3 4 22 LEGEND CC COMPRESSOR CONTACTOR CF CONDENSING FAN CONTACTOR CH COMPRESSOR SUMP HEATER D DAMPER DB POWER DISTRIBUTION BLOCK DL DAMPER LIMIT SWITCH DS DISCONNECT SWITCH EC ECONOMIZER CONTROLLER FCS CONDENSOR FAN CYCLE SWITCH FU FUSES FU5 CONTROL TRANSFORMER FUSES NOT ON CLASS II FZ1 FREEZE PROTECTION HPS HIGH PRESSURE SWITCH MANUAL RESET LPS LOW PRESSURE SWITCH PS1 WHEEL FROST PRESSURE SWITCH PS2 SUPPLY DIRTY FILTER PRESSURE SWITCH PS3 EXHAUST DIRTY FILTER PRESSURE SWITCH R1 ENERGY WHEEL RELAY CONTACTOR R2 OCCUPIED UNOCCUPIED RELAY R3 EXHAUST BLOWER VFD RELAY R4 SUPPLY BLOWER VFD RELAY R5 MODULATING WHEEL FROST CONTROL RELAY R6 ECONOMIZER RELAY R7 COMPRESSOR INTERLOCK RELAY R8 EVAP RELAY INDIRECT R9 EVAP R
33. ay fuses and size according to the rating plate If power supply is desired thru bottom of unit run the wiring through the curb cut a hole in the cabinet bottom and wire to the disconnect switch The electric supply to the unit must meet stringent requirements for the system to operate properly Voltage supply and voltage imbalance between phases should be within the following tolerances If the power is not within these voltage tolerances contact the power company prior to operating the system Voltage Supply See voltage use range on the rating plate Measure and record each supply leg voltage at all line disconnect switches Readings must fall within the allowable range on the rating plate Voltage Imbalance In a 3 phase system excessive voltage imbalance between phases will cause motors to overheat and eventually fail Maximum allowable imbalance is 2 To determine voltage imbalance use recorded voltage measurements in this formula Key V1 V2 V3 line voltages as measured VA average V1 V2 V3 VD Line voltage V1 V2 or V3 that deviates farthest from average VA Formula 96 Voltage Imbalance 100 x VA VD VA CAUTION If any of the original wire as supplied with the appliance must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C To prevent inj Brio to electrocution or WARNING Mete with Ed lock disconnect switch For units with a gas furnace
34. e vinyl seal is installed on the perimeter of the door openings Inspect at least annually to ensure that seal is still pliable and intact Outdoor air intake hood mesh filter access Filter Size and Quantities Mode iter Size Supply Exhaust HRE 20 20 in x 20 in 2 2 HRE 45 20 in x 25 in 3 3 HRE 55 16 in x 25 in 6 6 HRE 90 20 in x 20 in 8 8 37 ROUTINE MAINTENANCE Energy Recovery Wheel Maintenance Annual inspection of the energy recovery wheel is recommended Units ventilating smoking lounges and other non clean air spaces should have energy recovery wheel inspections more often based upon need Inspections for smoke ventilation applications are recommended bimonthly to quarterly until a regular schedule can be established ACCESSING ENERGY RECOVERY WHEEL The HRE units have one energy recovery wheel Open the outdoor air filter door to access the wheel For the HRE 20 and HRE 45 models the wheel cassette slides out Due to the size and weight of the HRE 55 and HRE 90 wheels they remain stationary and all maintenance is performed in place There is room inside the unit to perform energy recovery wheel servicing Filters must be removed to access stationary wheels WARNING Disconnect power to the unit before performing any type of service Access to wheel through outdoor air filter door REMOVING THE ENERGY RECOVERY WHEEL SEGMENTS Models HRE 20 45 55 amp 90
35. equire a trap design as shown If the internal static is believed to be higher consult factory 4in Refer to local codes to determine drainage requirements If draining onto to roof place a drip pad below drain to protect eiin roof If draining onto roof is not acceptable a drain line must be attached to the trap The drain line must be pitched away from the unit at least 1 8 in per foot On longer runs an air break should be used to ensure proper drainage Local codes may require drainage into a waste water system Drainage problems not only occur from improper drain trap design but also from lack of maintenance of the cooling coil compartment Algae can form in the drain pan and trap and cause reduced water flow which can in turn result in backup into the system Regular maintenance will prevent this from occurring If the drains have a cleanout opening be sure to close the opening after cleaning DRAIN AND OVERFLOW CONNECTION LOCATIONS Connection Locations in inches Model Outdoor Air Side Exhaust Side A B C D A B e D HRE 20 4 00 2 875 40 75 42 25 4 00 2 875 52 25 53 75 HRE 45 6 25 5 125 42 625 44 125 6 25 5 125 56 50 58 00 HRE 55 6 375 5 125 53 00 54 50 6 375 5 125 66 375 67 875 HRE 90 6 375 5 125 47 25 48 50 6 375 5 125 71 00 72 25 Outdoor Air OUTDOOR AIR INTAKE COMPARTMENT OUTDOOR AIR DISCHARGE COMPARTMENT B A d 3 4 INCH
36. ge to the unit or components will void the warranty BASIC OPERATION The HRE brings in fresh outdoor air and removes stale exhaust air For summer operation the exhaust air flows through an evaporative cooler indirect to lower the air temperature A sensible recovery wheel transfers energy from the exhaust air to the outdoor air at an efficiency of 70 80 to reduce the temperature of the outdoor air The outdoor air can then flow thru an optional evaporative cooler direct to further reduce the temperature of the outdoor air The sensible wheel also recovers heat from the exhaust in the winter to precondition the outdoor air Optional heaters are available after the wheel for final tempering 2 Exhaust Air discharged outside Outdoor Air i Indirect Evaporative exponen from ildin uie om building Cooler Optional Heater Direct Conditioned Air Evaporative sent to space Cooler INSTALLATION The system design and installation should follow accepted industry practice such as described in the ASHRAE Handbook SAFETY WARNING All factory provided lifting lugs must Adequate space should be left around the unit for piping be used when lifting the units Failure coils and drains filter replacement and maintenance to comply with this safety precaution Sufficient space should be provided on the side of the could result in property damage unit for routine service and component removal should serio
37. gy recovery Toa lt Tg and Toa lt Tsa Wheel will modulate to maintain discharge temperature where Toa is the outdoor air temperature set point Tp is the return air temperature set point and Tsa is the supply air discharge thermostat setpoint nominal 60jF D not adjustable 19 OPTIONAL ACCESSORIES Variable Frequency Drives for Blowers Optional factory installed wired and programmed variable frequency drives VFD may have been provided for modulating or multi speed control of the blowers One VFD is provided for each blower outdoor air and exhaust The VFDs provided are either Yaskawa model E7 or model GPD305 Refer to the tables on the next page for factory settings and field wiring requirements Refer to the unit control center for unit specific wiring diagram an example wiring diagram has been provided in this section for reference When making adjustments outside of the factory setpoints refer to Yaskawa VFD instruction manual which can be found online at www drives com For technical support contact Yaskawa direct at 1 800 927 5292 9 YASKAWA YASKAWA E7 GPD 305 J7 Lore yPRGM STOP E z z m OB lt oO MA MB MC s1Ts2 s3 54 55 sc FS FR FC AM AC uA p MA MB MC OPTION 1 0 10 VDC CONTROL USER TO PROVIDE ISOLATION AS REQUIRED 0 10 VDC CONTROL SIGNAL BY OTHERS E SC sP
38. heel Default factory settings are 5 minutes off and 30 minutes on Use the following test procedure for troubleshooting T2 Testing refer to diagram at right e Jumper the pressure switch Set the Timer Scale for T1 and T2 to 1 minute Set the Timer Settings for T1 and T2 to 1 0 Set the dip switch to the down position e 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 Timer 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 outdoor air inlet and an air pressure switch outdoor air outlet in addition to the thermostat and pressure sensor on wheel Refer to Electric Heater Application Operation for electric preheater location 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 Dip Switch Testing Turn the thermostat as high as it will go and jumper the wheel pressure sensor The heater should turn on e f it doesn t either put the supply side doors on or temporarily jumper the air pressure switch to avoid nuisance tripping of the pressure switch Remember to
39. heel operation The wheel is accessible through the access door marked Energy Wheel Cassette Access For the HRE 20 AND HRE 45 models the wheel cassette slides out Due to the size and weight of the HRE 55 AND HRE 90 wheels they remain stationary and all maintenance is performed in place There is room inside the unit to perform energy recovery wheel servicing Turn the energy recovery wheels by hand to verify free operation The wheel should rotate smoothly and should not wobble Inside layout of HRE unit Drive Belt Inspect the drive belt Make sure the belt rides smoothly through the pulley and over the wheel rim Air Seals Air seals are located around the perimeter of the wheel and across the face of the wheel both sides of wheel Check that these seals are secure andin Adjustable good condition Air Seals Bearing Support Check that the air seals located around the outside of the wheel and across the center both sides of wheel are secure and in good condition Air seal clearance is determined by placing a sheet of paper to act as a feeler gauge against the wheel face To access seals enter unit for HRE 55 amp HRE 90 or pull out the cassette for HRE 20 amp HRE 45 following the instructions in Energy Recovery Wheel Maintenance section To adjust the air seals Drive Belt loosen all eight seal retaining screws These screws are located on the bearing support that spans the Drive Pulley length of the ca
40. id Valve B in the supply line as indicated below From the outlet on the drain valve run line to a suitable drain location 3 Run an unobstructed drain line from the sump overflow to the drain trap as shown below 4 Install Sump Drain Solenoid Valve C in the drain line from the sump as indicated below From the outlet on this drain valve run a line to a suitable drain location Note Water Supply Solenoid Valve A is not the same as the Drain Solenoid valves B and C Make sure to use the proper valve for each location Check your local code requirements for proper installation of this type of system Additional drain and supply plumbing may be needed to meet your local code Caution All solenoid valves A B and C must be installed below the roof to protect the supply water line from freezing If these valves cannot be installed below the roof an alternate method must be used to protect these lines from freezing SIDE OF HRE UNIT SUMP DRAIN PIPE TO EACH EVAP SUMP OVERFLOW PIPE TO EACH EVAP EVAPORATIVE COOLING MEDIA WATER LINE CONNECTION AT FLOAT IS 1 4 INCH ROOF CURB ROOF LINE VIZII MIIAN SUMP DRAIN SOLENOID VALVE C NORMALLY OPEN 3 4 INCH PIPE SIZE WATER SUPPLY SOLENOID VALVE A NORMALLY CLOSED 1 2 INCH PIPE SIZE TRAP DRAIN SOLENOID VALVE B NORMALLY OPEN 1 4 INCH PIPE SIZE Trap amp Supply Line Configuration DRAIN LINE with Auto Dra
41. ignal to a variable frequency drive to raise and lower airflow in relationship to the CO2 levels in the space This strategy is often referred to as Demand Control Ventilation and provides further energy savings to the system Follow instructions supplied with sensor for installation and wiring details Service Outlet 120 VAC GFCI service outlet ships loose for field installation Requires separate power source so power is available when unit main disconnect is turned off for servicing Vapor Tight Lights Vapor tight lights provide light to each of the compartments in the energy recovery unit The lights are wired to a switch mounted on the outside of the unit The switch requires a separate power source to allow for power to the lights when the unit main disconnect is off for servicing 24 OPTIONAL ACCESSORIES Remote Control Panel and Wiring Schematics The remote panel is a series of junction boxes ganged together and includes a stainless steel face plate The remote panel is available with a number of different alarm lights and switches to control the unit The remote panel ships loose and requires mounting and wiring in the field The remote panel is available with the following options Unit on off switch Unit on off light 7 day time clock Hand off auto switch Time delay override Exhaust air dirty filter light Outdoor air dirty filter light Economizer light Frost control light Wheel rotation sensor light Refer
42. in and Fill SUPPLY LINE 12 THE FOLLOWING COMPONENTS SHIP FROM GREENHECK WITH HRE INSTALLATION WIRING AND POWER BY OTHERS PART DESCRIPTIONS GREENHECK P N QTY HOLDING VA INRUSH VA JOHNSON CONTROLLER 07458032 OUTDOOR AIR SENSOR 07458298 24 HOUR TIMER 07381940 VALVE DRAIN B 05461 VALVE SUMP DRAIN C 05461 VALVE WATER SUPPLY A 05461262 25 70 25 50 25 70 24V AC POWER AND WIRING BY OTHERS OUTDOOR AIR SENSOR oan SENSOR COM O OUTDOOR AIR SENSOR JOHNSON CONTROLLER JC Oil A2 TIMER n TIMER bos JC qu VALVE Lis 1 2 PIPE SIZE NC NC NO n VALVE B 1 4 PIPE SIZE NO VALVE C DRAIN TRAP 3 4 PIPE SIZE NO Cooling coils are provided with a stainless steel drain pan with 3 4 in female NPT drain connection A drain trap must be connected to the drain connection to allow excess water to flow out of the drain pan More importantly though due to the negative internal static of the cooling coil compartment installing the drain trap prevents outdoor air from being pulled into the drain pan and consequently forcing water out of the pan and into the unit To ensure the drain trap works properly the trap height must account for the difference in static pressure between ambient conditions outside the unit and the internal negative pressure of the cooling coil compartment For energy recovery units an assumption of 3 0 in wg differential will be sufficient This would r
43. ing coil can further cool the air coming off the wheel to levels near 55 F Economizer Operation See Economizer Application Operation section Winter Operation Outdoor air is preconditioned temperature is increased by the transfer of energy from the warmer exhaust air via the sensible recovery wheel Units supplied with heating coils can further heat the air coming off the wheel to levels at or above room design Frost Control Operation See Frost Control Application Operation section 41 Troubleshooting Airflow Test and Balance Report 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 3 Unit 4 Model Number Serial Number Name Plate Information Voltage Hertz Phase Outdoor Air Fan Amps Exhaust Fan Amps Outdoor Air Fan Horsepower Exhaust Fan Horsepower Design Airflow Outdoor Air Exhaust Measured Airflow Outdoor Air Exhaust Measured Data Blower Rotation Outdoor Air Fan RPM Exhaust Fan RPM Outdoor Air Fan Amp Draw Exhaust
44. into overflow 0 Connect drain line o Install trap O Connect water supply line L1 L1 For units with Auto Drain amp Fill with Freeze Protection Install wire and provide power to components L1 O Confirm temperature and timer settings L1 Pump filter clean and installed properly L1 Oo Saturate media per IOM L1 L1 Adjust bleed off rate per IOM Check for water carryover o Connect Call for Cooling signal o Remove jumper wire L1 O 30 OPTIONAL ACCESSORIES CHECKLIST Refer to the respective sections in this Installation Operation and Maintenance Manual for detailed information Refer to wiring diagram in unit control center to determine what electrical accessories were provided Provided with Unit Frost Control Application Operation section Setting Factory Default Yes No Frost Control Setpoint 5 F Differential 2 F Timer Refer to IOM Yes No Frost Control Modulating Refer to IOM Economizer Application Operation section Yes No Economizer temperature Setpoint 65 F Offset 20 F Differential 2 F Yes No Economizer enthalpy Setpoint B Yes No Economizer modulating Refer to IOM Optional Accessories section Operational Yes No Wheel Rotation Sensor Yes No N A Yes No OA Dirty Filter Sensor Yes No N A Yes No EA Dirty Filter Sensor Yes No N A Yes No CO
45. itted to dry once per week by allowing the blowers to run for 1 2 hours 10 A flush cycle should be performed weekly for one hour with the fans off IMPORTANT Replacement media should be from the same manufacturer and be the same size as the original media provided with the unit To remove media disconnect water line to evap header as shown below Then slide media section out of unit Sump will remain in unit If media is wet turn off water supply then turn on unit and allow air to flow thru media for 10 20 minutes This will dry the media out and make it lighter and easier to handle F OPTIONAL ACCESSORIES Electric Heater Application Operation Factory installed electric heaters can be provided for preheat and or post heat An electric preheater warms the outdoor air prior to the energy recovery wheel to prevent frosting on the wheel An electric post heater warms the air leaving the energy recovery wheel to a user specified discharge temperature Electric heaters are available in 208 230 or 460 Vac refer to heater nameplate for voltage Preheaters Preheaters are standard as 2 stage step control Step control heaters are designed with multiple stages made up of equal increments of heating capability For example a 10 kW heater with two stages will be composed of two 5 kW stages Preheaters are single point wired at the factory A temperature sensor with field adjustable set point is mounted in the outdoor airs
46. knockdown kit includes duct adapter and require field assembly by others Assembly instructions are included with the curb Install Curb Locate curb over roof opening and fasten in place Refer to Recommended Roof Openings Check that the diagonal dimensions are within 1 8 inch of each other and adjust as necessary For proper coil drainage and unit operation it is important that the installation be level Shim as required to level Install Ductwork Installation of all ducts should be done in accordance with SMACNA and AMCA guidelines Duct adapter provided to support ducts prior to setting the unit Set 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 SIDE OF UNIT d Curb Cap Dimensions Model B HRE 20 2 00 2 00 1 00 0 88 0 75 HRE 45 2 00 4 25 2 00 1 31 0 50 HRE 55 2 00 4 25 2 00 1 31 0 50 HRE 90 2 00 4 25 2 00 1 31 0 50 All dimensions shown are in inches Roof curb details including duct location dimensions are available on HRE roof curb assembly instructions Curb Outside Dimensions Curb Outside Dimensions Weight Model L 20 93 51 280 HRE 45 100 5 60 63
47. ld 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 prior to start up To access these filters remove bottom bolt in the access door on the side of the weatherhood Slide the access door up and then pull bottom out to remove door Then slide the filters out see figure at right Clean filters by rinsing with a mild detergent in warm water Internal Filter Maintenance The HRE units will typically be provided with 2 inch pleated filters in the outdoor air and exhaust airstreams These filters should be checked per a routine maintenance schedule and replaced as necessary to ensure proper airflow through the unit See table at right for pleated filter size and quantity for each 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 Aerostar Series 400 or Farr 30 30 Outdoor Air Filters Access to the outdoor air filters is through the door labeled as Filter Access on the outdoor air side of the unit Exhaust Air Filters Access to the exhaust air filters is through the door labeled as Filter Access on the exhaust air side of the unit Refer to Access Door Descriptions section for additional information on filter locations Door Seal Maintenance Slip on typ
48. ment 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 supply air inlet 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 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 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 ia Temperature Sensor with Override Enthalpy Sensor with Override Turn unit power off Disconnect C7400 solid state enthalpy sensor from terminal So on the enthalpy controller Also disconnect the 620 ohm resistor from terminal Sr on the enthalpy controller
49. nection TYPICAL CONTROL CENTER COMPONENTS 1 Main Disconnect non fusible lockable 2 Motor Starter Exhaust Air Fan Motor Contactor Energy Wheel 24 VAC Control Transformer 24 VAC Terminal strip Fuses for blower motors Motor Contactor Indirect Evap Pump Motor Contactor Direct Evap Pump 115 VAC Secondary V N a VAN y Motor Starter Outdoor Air Fan 1 Evap Pump Transformer 7 Exploded Detail of Terminal Strip OK jw O J mA ue y A m aa uaa mM SERVICE CLEARANCES ACCESS PANEL LOCATIONS HRE 20 45 55 and 90 units require minimum clearances for access on all sides for routine maintenance Filter replacement drain pan inspection and cleaning energy wheel cassette inspection fan bearing lubrication and belt adjustment are examples of routine maintenance that must be performed Blower and motor assemblies energy recovery wheel cassette coil and filter sections are always provided with a service door or panel for proper component access Clearances for component removal may be greater than the service clearances refer to drawings below for these dimensions HRE 20 45 36 in 2 Exhaust B Hood lt Access Panel 36 in gt Electrical Bo
50. nstalled and Supply 36 x 56x12 3 0 ft running for two weeks the unit should be checked for Exhaust 30x56 x12 2 5 ft mineral deposits If there are deposits the bleed off Supply 48 x 69 5 x 12 4 0 fe rate needs to be increased Some areas of the country HRE 90 Exhaust 40 x 69 5 x 12 3 3 ft have water with greater amounts of dissolved minerals requiring a higher bleed off rate 10 7 Verify that both airflow and system static pressure are in agreement with the specifications If these conditions are met check for water carry over from the discharge side of the media If carry over is observed check the distribution header for holes or tears and the water standoff tube for blockage 8 After all final adjustments are made remove the jumper wires connect call for cooling signal and replace all access panels The unit is now ready for operation Bleed Off Pump Supply Float Overflow Valve Filter Connection Valve Threaded Float Adjustment Water Flow Adjustment Device Pump and Float Components HRE WATER SUPPLY CONNECTION LOCATION Water Supply Connection Locations Model HRE 20 37 375 4 625 4 625 39 25 HRE 45 38 75 4 625 4 625 43 00 HRE 55 43 50 4 625 4 625 46 125 HRE 90 43 50 4 625 4 625 52 625 Dimensions from outside of unit in inches 0 875 Run 1 4 inch line up through 7 8 inch hole here and bring around end of sump to supply connection 1
51. omplete Direct Evaporative Cooler Outdoor Supply Airstream TABLE OF CONTENTS Storage and Basic Operation 2 3 Lift since arate cece cea men s rete dac P cre Cen 3 Unit Weights amp Recommended Roof lt 3 Roof Curb Mounting 4 Rail 5 Ductwork Connections 5 Electrical Information 6 7 Service Clearances 8 Dimensional Data Access Door Description 9 Evaporative Cooling Modules Evap Module Installation and Start Up 10 11 Water Supply Connection Location 11 Water Control Options 12 13 Drain amp Overflow Connection Locations 14 15 Maintenance 16 Optional Accessories 17 28 Electric Heater Application Operation 17 Frost Control Application Operation 18 Economizer Application Operation 19 Variable Frequency Drives 20 21 STORAGE Typical Wiring Diagram 22 Sensors and Lights 23 24 Remote Control Panel amp Wiring 25 27 Sensors Mounted by Factory 28 Start Up Checklist oak ate Sect Oeil eee es 29 30 Evaporative Cooler 30 Optional Access
52. on First Stage Cooling d E Second Stage Cooling SZ Heat Terminal Block in v s Unit Control S 6 Center 7 KN SJ 7 jr Night Setback Timer Night Setback Switch lt 27 OPTIONAL ACCESSORIES Sensors Mounted by Factory Factory mounted temperature pressure and current sensors are available in the locations indicated on the unit diagram below A list of available sensors is shown below The specific sensors provided on a given unit are labeled in the unit control center on the terminal strip Sensors are wired to the terminal strip to make it easy for the controls contractor to connect the Building Management System for monitoring purposes RA FILTER FROM INSIDE EXHAUST BLOWER OAAW COOL HEAT COIL CY coL ACC ENERGY WHEEL OA FILTER FROM OUSTIDE TO INSIDE SUPPLY BLOWER Temperature Sensors 1K Ohm RTD Drawing Labels Terminal Strip Labels OA Supply Inlet Temp OAAW OA After After Cooling Coil Temp OAD Supply Discharge Temp EAW Exhaust After Wheel Temp RAI RA Exhaust Inlet Temp Pressure Sensors analog or digital Drawing Labels Terminal Strip Labels OAF P OA Supply Filter Pressure OAW P Outdoor Air Wheel Pressure RAF P RA Exhaust Filter Pressure EW P Exhaust Wheel Pressure
53. ontrol center door Do not operate units with access doors open or without proper ductwork in place as the fan motors will overload Vibration Rotation Rotation Direction Excessive vibration may be experienced during initial start up Left unchecked excessive vibration can cause a multitude of problems including structural and or component failure The most common sources of vibration are listed below Bearing Misalignment Mechanical Looseness Faulty Belts Drive Component Unbalance Poor Inlet Outlet Conditions Foundation Stiffness unbalance in place balancing can be done 1 2 3 4 5 6 7 8 9 connectors is recommended Wheel Unbalance Many of these conditions can be discovered by careful observation Refer Drive Pulley Misalignment to the Troubleshooting section of this manual for corrective actions If Incorrect Belt Tension observation cannot locate the source of vibration a qualified technician using vibration analysis equipment should be consulted If the problem is wheel Generally fan vibration and noise is transmitted to other parts of the building by the ductwork To eliminate this undesirable effect the use of heavy canvas 33 UNIT START UP Energy Recovery Wheel The HRE models contain a sensible energy recovery wheel The wheels are inspected for proper mechanical operation at the factory However during shipping and handling shifting can occur that may affect w
54. or FLA n40 Multi Function output MA MB MC 0 H3 03 Terminal A1 Bias 50 n42 Analog Freq Reference Bias 50 02 03 User Defaults 1 n46 Carrier Frequency 2 A1 01 Access Level 0 n01 Access Level 0 Factory Setpoints MULTI SPEED CONTROL 1 3 OR 1 2 SPEED REDUCTION FOR FAN SPEED Yaskawa E7 Drive Yaskawa GPD 305 Drive S1 to SN contact for On Off 51 to SC contact for On Off Parameter Setting Parameter Setting A1 01 Access Level 2 n01 Access Level 1 b1 01 Frequency Reference Source 0 n03 Reference Selection 1 C6 02 Carrier frequency 2 n21 Frequency Reference 1 60Hz d1 01 Frequency Reference 1 60 n22 Frequency Reference 2 40Hz d1 02 Frequency Reference 2 40 n23 Frequency Reference 3 30Hz d1 03 Frequency Reference 3 30 n24 Frequency Reference 4 60Hz d1 04 Frequency Reference 4 60 n32 Motor Rated FLA Motor FLA E2 01 Motor Rated FLA Motor FLA n38 Multi function Input Sel 4 Term S4 6 02 03 User Defaults 1 n39 Multi function Input Sel 5 Term S5 7 A1 01 Access Level 0 n40 Multi Function output MA MB MC 0 n46 Carrier Frequency 2 n01 Access Level 0 Parameter n39 must be set to 7 before n38 can be set to 6 the drive does not allow these parameters to be the same number n39 default is 6 Variable Frequency Drives for Energy Recovery Wheel Factory installed VFD for the energy recovery wheel are programmed at the factory per the
55. or bearing collars on shaft Replace defective bearings s Lubricate bearings Tighten collars and fasteners Replace or rebalance Tighten wheel setscrew Tighten sheave setscrew Adjust belt tension after 24 hours of operation Loosen to maintain a 3 8 inch deflection per foot of span between sheaves Replace Tighten mounting bolts Clean wheel and housing Realign Make sure duct work is supported properly Make sure duct work metal thickness is sized for proper stiffness Check duct size at discharge to ensure that air velocities are not too high Warranty Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the purchase date The energy recovery wheel is warranted to be free from defects in material and workmanship for a period of five years from the purchase date Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory transportation prepaid Motors are warranted by the motor manufacturer for a period of one year Should motors furnished by Greenheck prove defective during this period they should be returned to the nearest authorized motor service station Greenheck will not be responsible for any removal or installation costs As a result of our commitment to continuous improvement Greenheck reserves the right to change specifications without notice E GREENHECK P O Box
56. ories 31 Fan lxxx RR EIER ERE 32 33 Energy Recovery Wheel 34 Routine Maintenance Checklist 35 Belts and 36 Blower Wheel and Fasteners 36 Bearings Filters and Door Seal 37 Energy Recovery Wheel Maintenance 38 Accessing Energy Recovery Wheel 38 Removing Wheel Segments 38 Cleaning Wheel Segments 39 Parts 5 40 Sequence of Operation 41 Troubleshooting Airflow 42 Unit Troubleshooting 43 and Backcover Backcover When a unit is not going to be in service for an extended amount of time certain procedures should be followed to keep the fans in proper operating condition e Rotate fan wheel monthly and purge grease from bearings once every three months Cover unit with tarp to protect from dirt and moisture Note do not use a black tarp as this will promote condensation e Energize fan motor once every three months e Store belts flat to keep them from warping and stretching e Store unit in location which does not have vibration e After storage period purge grease from fan bearings before putting fan into service If storage of unit is in a humid dusty or corrosive atmosphere rotate the fan and purge the bearings once a month Improper storage which results in dama
57. outine Maintenance section of this manual When in operation the tight side of the belts should be a straight line from sheave to sheave with a slight bow on the slack side WRONG WRONG WRONG CORRECT Proper alignment of motor and drive shaft 32 UNIT START UP Direction of Fan Wheel Rotation Blower access is labeled on unit Check for proper wheel rotation by momentarily energizing the fan Rotation is determined by viewing the wheel from the drive side and should match the rotation decal affixed to the fan housing see Rotation Direction figures If the wheel is rotating the wrong way direction can be reversed by interchanging any two of the three electrical leads Check for unusual noise vibration or overheating of bearings Refer to the Troubleshooting section of this manual if a problem develops Fan RPM Supply fan and exhaust fan will have an adjustable motor pulley on 15 HP and below preset at the factory to the customer specified RPM Fan speed can be increased or decreased by adjusting the pitch diameter of the motor pulley Multi groove variable pitch pulleys must be adjusted an equal number of turns open or closed Any increase in fan speed represents a substantial increase in load on the motor Always check the motor amperage reading and compare it to the amperage rating shown on the motor nameplate when changing fan RPM All access doors must be installed except the c
58. rature etc on the motor nameplate is not exceeded Amperage to be consult Greenheck to determine if the unit can tested with access doors closed and ductwork installed operate safely at the new conditions Fan Belt Drives The fan belt drive components when supplied by Greenheck have been carefully selected for the unit s specific operating condition Caution utilizing different components than those supplied could result in unsafe operating conditions which may cause personal injury or failure of the following components 1 Fan Shaft 2 Fan Wheel 3 Bearings 4 Belt 5 Motor Tighten all fasteners and set screws securely and realign drive pulleys after adjustment Check pulleys and belts for proper alignment to avoid unnecessary belt wear noise vibration and power loss Motor and drive shafts must be parallel and pulleys in line see below Belt Drive Installation 1 Remove the protective coating from the end of the fan shaft and assure that it is free of nicks and burrs 2 Check fan and motor shafts for parallel and angular alignment Slide sheaves on shafts do not drive sheaves on as this may result in bearing damage 4 Align fan and motor sheaves with a straight edge or string and tighten 5 Place belts over sheaves Do not pry or force belts as this could result in damage to the cords in the belts 6 With the fan off adjust the belt tension by moving the motor base See belt tensioning procedures in the R
59. 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 setpoint 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 setpoint the wheel will run at reduced speed until the pressure differential falls below the setpoint The temperature and pressure differential set points are set at the factory but are field adjustable refer to VFD section for more information The variable frequency drive will be fully programmed at the factory 18 OPTIONAL ACCESSORIES Economizer Application Operation The energy recovery wheel operation can be altered to take advantage of economizer operation free cooling Two modes are available 1 De energizing the wheel or 2 Modulating the wheel A field supplied call for cool Y1 is required De energizing the wheel is accomplished with a signal from a Temperature or Enthalpy sensor mounted in the supply air inlet compart
60. rry over downstream of the evaporative cooler Continuous operation in this manner may cause serious damage and void the warranty 7 At the end of each cooling season the evaporative cooler should be thoroughly cleaned A dispersant and biocide consult water treatment consultant for suitable materials and dosage levels should be recirculated for 12 to 24 hours prior to performing the following steps a Disconnect power to unit b Shut off all water to the unit 16 c Open evaporative cooling section door d Flush distribution headers and media for 20 minutes Turn off pumps and drain all water distribution piping headers etc f Dry media completely by running blowers 9 Brush media as described in Paragraph 2 and perform steps d and e again h Clean all remaining components i e sump pump etc of any mineral deposits or foreign materials i Replace all worn or non functioning parts j Reassemble the cooling unit k Close cooling section door I Turn the main disconnect ON leaving the cooling switch in the OFF position 8 If the evaporative cooler will be turned off during the cooling season for an extended period of time it is recommended that the media be dried out This can be accomplished by allowing the blowers to continue to run for 1 2 hours Doing so will prevent organic build up on the media and subsequent odors getting into the space 9 Media should be perm
61. s Replace Reset starter and check amps Check for On Off switches Check for correct supply voltage Check for broken or loose belts Tighten loose pulleys Shorten wiring run to mechanical room or install a relay which will turn unit on off C F for relay information Need to increase supply power or use a special control transformer which is sized for the actual supply power Check cfm and adjust drives if needed If higher ductwork should be improved If lower fan rpm should be lower Check rotation and reverse if necessary Check motor nameplate versus supplied voltage See specifications and catalog for fan curves to determine if horsepower is sufficient Replace motor Adjust damper linkage or replace damper motor Improve ductwork to eliminate losses using good duct practices Check for correct drives and rpm with catalog data For 3 phase see Direction of Fan Wheel Rotation under Unit Start Up section Follow cleaning procedures in Routine Maintenance section Repair Correct or improve ductwork Adjust belt tension Check for correct fan rom Decrease fan speed if necessary Install filters Induce Ps into system ductwork Make sure grilles and access doors are installed Decrease fan speed if necessary Always provide the unit model and serial number when requesting parts or service information Always check motor amps and compare to nameplate rating 43 Troubleshooting Symptom
62. ssette through the wheel center Tighten the screws so the air seals tug slightly on the sheet of paper Label showing cassette serial and date code Replace cassette into unit plug in wheel drive replace access door and apply power Observe by opening door slightly remove filters if necessary to view wheel that the wheel rotates freely at about 35 RPM 34 ROUTINE MAINTENANCE SAFETY DANGER SAFETY CAUTION Electric shock hazard Can cause injury or death Use caution when removing access panels or other Before attempting to perform any service or unit components especially while standing on a maintenance turn the electrical power to unit to OFF ladder or other potentially unsteady base Access at disconnect switch es Unit may have multiple panels and unit components can be heavy and power supplies serious injury may occur Once the unit has been put into operation a routine maintenance program should be set up to preserve reliability and performance Items to be included in this program are DATE DATE DATE DATE Lubrication Apply lubrication where required L1 L1 L1 L1 Dampers Check for unobstructed operation L1 L1 L1 L1 Fan Belts Check for wear tension alignment T Oo Motors Check for cleanliness L1 O Oo Blower Wheel amp Fasteners Check for cleanliness L1 Oo Oo Check all fasteners for tightness Check for fatigue corrosion wear L1 Oo Bearings Check for cleanliness L1 Oo
63. te The dirty filter switch is mounted in the exhaust inlet compartment next to the unit control center or in unit control center To adjust the switch the unit must be running with all of the access doors in place except for Setscrew on front of switch must be manually the compartment where the switch is located adjusted after the system is in operation exhaust inlet compartment Model ERV units require the opening around the control center to be covered with cardboard plywood etc to set up dirty filter switch The adjusting screw is located on the top of the switch Open the filter compartment and place a sheet of plastic or cardboard over 50 of the filter media Replace the filter compartment door Check to see if there is power at the alert signal leads refer to electrical diagram If there Negative pressure connection is toward the back or bottom is no power turn the adjustment screw on of the switch senses blower side of filters the dirty filter gauge clockwise until you have power Open the filter compartment and remove the obstructing material Replace the door and check to make sure that you do not have power at the alert signal leads The unit is now ready for operation Positive pressure connection is toward the front or top of the switch senses air inlet side of filters 23 OPTIONAL ACCESSORIES CO2 Sensor This accessory is often used to provide a modulating control s
64. tream after the preheater to turn the preheater on See Frost Control Application Operation for typical set points If the temperature falls below the set point the first stage of the preheater will turn on If the first stage does not satisfy the set point the second stage will also turn on Post heaters Post heaters are standard as SCR control Post heaters are not single point wired see Electrical Connections A temperature sensor with field adjustable set point is mounted in the outdoor airstream after the post heater to turn the post heater on A SCR heater provides an infinitely modulating control of the heat to provide an accurate discharge temperature A call for heat is required Post Heater Control Panel The post heater is not single point wired to the HRE control center Separate power must be supplied to the post heater disconnect located in unit control center Access to the post heater control panel is through the exhaust filter door The indirect evaporative cooling media must be removed from the unit along with the exhaust filters to access Electric Preheater The preheater is single point wired to the HRE control center Access to the preheater control panel is through the supply filter door Electric Post Heater 17 OPTIONAL ACCESSORIES Frost Control Application Operation Extremely cold outdoor air temperatures can cause moisture condensation and frosting on the energy recovery wheel Frost
65. uildup 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 amp 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 36 ROUTINE MAINTENANCE Bearings Most bearings are permanently lubricated and require not further lubrication under normal use Normal use being considered 20 F to 120 F and in a relatively clean environment Some bearings are re lubricatable and will need to be regreased depending on fan use Check your bearings for grease zert 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 External Filter Maintenance Aluminum mesh 2 inch deep filters are located in the supply weatherhood if the weatherhood option was purchased Filters shou
66. us injury or death that become necessary See Service Clearances Access Panel Locations section for more details LIFTING 1 Before lifting be sure that all shipping material has been removed from unit 2 To assist in determining rigging requirements weights are shown below 3 Unit must be lifted by the eight 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 8 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 UNIT WEIGHTS amp RECOMMENDED ROOF OPENING Lift using lifting lugs and spreader bar Unit Size Approx Dry Weight Approx Wet Weight U Ibs Ibs HRE 20 1660 1800 46 37 HRE 45 2580 2840 54 39 E HRE 55 2950 3320 65 47 i HRE 90 4750 5400 85 49 ser Unit weights assume indirect evap direct evap and IG furnace
67. vide sufficient supply of water to meet the maximum demand of the evaporative coolers EVAP MODULE INSTALLATION 1 After the energy recovery unit is set in place run the overflow and drain lines to the exterior fittings on the evaporative cooler drain amp overflow connections at unit are 1 inch male pipe thread The supply line can be attached at the downstream side of the evaporative cooler A manual shut off valve should be mounted in the supply line near the unit for servicing purposes Also a trap should be installed in the drain line to prevent air sewer gas from being drawn into the unit refer to Drain and Overflow Connection Locations and Drain Trap sections Run bleed line into overflow EVAP MODULE START UP Indirect Evaporative Cooler Exhaust Scavenger Airstream 1 The cooler will be prewired by the factory pumps are 115VAC 2 Check to make sure that the pump filter is around the pump inlet 3 Turn the water on and allow the sump to fill Adjust the float valve to shut off the water supply when the sump is filled to a 1 inch height Direct Evaporative Cooler Outdoor Supply Airstream 4 Open the bleed off valve completely and saturate the media without any airflow through the unit A jumper wire is required on the terminal strip to provide power to the evaporative cooler pump see the wiring diagram for the proper location This saturation process will break in the media and minimize the odors
68. x p 8 Indirect 2 o Era c Exhaust Air 0 in A ection Intake Clearance without 9 2 IG Heater Gi a 52 Clearance with IG Heater E 2 a g Direct 5 E i Evap E 5 Section 5 Lo of Access Panel o o9 oz amp 9 48 in 64 in 8 TOP VIEW Clearances for service and component removal on HRE 20 and HRE 45 Clearance for energy wheel removal on HRE 20 Clearance for energy wheel removal on HRE 45 HRE 55 c 90 o o o Exhaust B Hood lt Access Panel Electrical Box Clearance without IG Heater Intake p Indirect sei E Exhaust ir in N Access Panel gt Wheel Cassette Clearance with IG Heater o 8 p I S Direct o Evap S g Section i 9 5 2 Access Panel oO a H 2 42 in o 8 TOP VIEW lt Clearances for service and component removal on HRE 55 and HRE 90 DIMENSIONAL DATA ACCESS DOOR DESCRIPTIONS Exterior Dimensions B D E F G H l HRE 20 98 50 56 18 28 5 17 6 14 25 18 HRE 45 106 69 66 16 41 23 375 10 5 13 375 20 HRE 55 118 70 76 16 59 5 5 875 7 125 21 25 25 HRE 90 131 85 96 16 78 2 875 10 24 5 27 All dimensions shown are in inches Overall Exterior Dimensions

Greenheck Fan 55 Patio Heater User Manual

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