Greenheck ECV-10 Installation Manual

Page 1

Document 480955

Energy Core Ventilators

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:

ECV-10

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. 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.

DANGER

Always disconnect power before working on or near this equipment. Lock and tag the disconnect switch or breaker to prevent accidental power up.

CAUTION

When servicing the unit, the internal components may be hot enough to cause pain or injury. Allow time for cooling before servicing.

CAUTION

Precaution should be taken in explosive atmospheres.

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 Electrical Code (CEC) in Canada.

2. All moving parts must be free to rotate without striking or rubbing any stationary objects.

3. Unit must be securely and adequately grounded.

4. Do not spin fan wheel faster than maximum cataloged fan RPM. Adjustments to fan speed significantly effects 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. Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces or chemicals. Replace cord immediately if damaged.

6. Verify that the power source is compatible with the equipment.

7. Never open access doors to the unit while it is running.

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Receiving

Upon receiving the product, check to ensure all items are accounted for by referencing the delivery receipt or packing list. Inspect each crate or carton for shipping damage before accepting delivery. Alert the carrier of any damage detected. The customer will make a notion of damage (or shortage of items) on the delivery receipt and all copies of the bill of lading which is countersigned by the delivering carrier. If damaged, immediately contact your Greenheck Representative. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

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. Location of 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.

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 the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40® or the equivalent.

506 (Ashland Inc.) or

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 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.

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Table of Contents

Product Overview

Product Overview . . . . . . . . . . . . . 3

Standard Components . . . . . . . . . . . 3

Installation

Dimensional Data . . . . . . . . . . . . . 4

Indoor Mounting Options . . . . . . . . . . 4

Outdoor Mounting Options . . . . . . . . . 4

Recommended Roof Openings & Weights . . . 5

Service Clearances . . . . . . . . . . . . 5

Access Panel Locations . . . . . . . . . . 6

Handling . . . . . . . . . . . . . . . . . 6

Lifting . . . . . . . . . . . . . . . . . . 6

Roof Curb Mounting . . . . . . . . . . . . 7

Curb Outside Dimensions and Weights . . . . 7

Ductwork Connections . . . . . . . . . . . 8

Rail Mounting / Layout . . . . . . . . . . . 8

Electrical Information

General Electrical Information . . . . . . . . 9

Control Center Components . . . . . . . . . 10

Optional Accessory Wiring Schematics . . . . 10

Unit Overview

Basic Unit . . . . . . . . . . . . . . . . 11

Optional Component Overview

Economizer . . . . . . . . . . . . . . . 12

Frost Control . . . . . . . . . . . . . . . 12

Sensor . . . . . . . . . . . . . . . 12

Dirty Filter Switch . . . . . . . . . . . . . 12

Start-Up

General . . . . . . . . . . . . . . . . . 13

Pre Start-Up Checklist . . . . . . . . . . . 13

Special Tools Required . . . . . . . . . . . 13

Start-Up Checklist . . . . . . . . . . . . . 13

Optional Accessories Checklist . . . . . . . 14

Start-Up Components

Fans . . . . . . . . . . . . . . . . . . 15

EC Motors . . . . . . . . . . . . . . . . 15

Optional Start-Up Components

Dirty Filter Switch . . . . . . . . . . . . . 15

Economizer . . . . . . . . . . . . . . . 16

Frost Control . . . . . . . . . . . . . . . 16

Routine Maintenance . . . . . . . . . . 17-18

Troubleshooting

Economizer Alarms . . . . . . . . . . . . 19

Airﬂow. . . . . . . . . . . . . . . . . . 20

Unit . . . . . . . . . . . . . . . . . .21-22

Maintenance Log . . . . . . . . . . . . . 23

Our Commitment . . . . . . . . . Backcover

The ECV brings in fresh, outdoor air and removes stale, exhaust air. Prior to discharging the exhaust air, the energy recovery core transfers energy from the exhaust air to the outdoor air at an efficiency of 50-60%. Simply put, this unit preconditions the outdoor air to save money on heating and cooling costs.

Standard Components

Outdoor Air Weatherhood

Outdoor air weatherhood will 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 intake.

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Installation

Dimensional Data

Unit Size

Exterior Dimensions Unit Opening Dimensions

ABC D E F G

ECV-10 54.8 28.9 43.9 18.4 x 15.9 13.6 x 13.6 8.2 x 11.3 16.5 x 11.5

All dimensions are in inches.

Unit Size

Intake and Discharge Options

Bottom Top Side End

OA Intake X X

SA Discharge X X

RA Intake X X

EA Discharge X X

Indoor Mounting Options

EXHAUST AIR

DISCHARGE

SUPPLY AIR

DISCHARGE

OUTDOOR AIR INTAKE

SUPPLY AIR DISCHARGE

EXHAUST AIR DISCHARGE

OUTDOOR AIR INTAKE

(NON ELECTRICAL SIDE)

End Connections Top and Bottom Connections

Outdoor Mounting Options

EXHAUST AIR DISCHARGE

SUPPLY AIR DISCHARGE

(NON ELECTRICAL SIDE)

RETURN AIR INTAKE

EXHAUST AIR DISCHARGE

OUTDOOR AIR INTAKE

RETURN AIR INTAKE

SUPPLY AIR DISCHARGE

(NON ELECTRICAL SIDE)

RETURN AIR INTAKE

OUTDOOR AIR INTAKE

Outdoor Air Discharge Bottom Outdoor Air Discharge End

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Recommended Roof Openings & Weights

Position the unit roof opening such that the supply discharge and return 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.

When cutting only duct openings, cut opening 1-inch (25 mm) 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 “R” 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 1-inch must be maintained between the outside edges of the duct and combustible material in accordance with NFPA Standard 90A.

Service Clearances

The ECV-10 unit requires minimum clearances to perform routine maintenance, such as filter replacement and energy core inspection. Blower and motor assemblies, energy recovery core 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 drawing below for these dimensions.

CORE

CONTROL PANEL

4.4

5.2

18.5

13.5

RETURN

AIR INTAKE

13.3 3.4

SUPPLY AIR DISCHARGE

CONTROL PANEL

7.0

10.2

Unit Size Approx. Weight (lbs.)

ECV-10 485

All dimensions are in inches. *Weight assumes outdoor unit with filters, weatherhoods, outdoor air intake damper, controls and internal double-wall sheet metal.

F H

Recommended Service Clearances

Unit Size A B C D E F G H

ECV-10 102.9 120.8 35.5 28.9 22 36 54.8 30

All dimensions are in inches.

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Access Panel Locations

The ECV is provided with access panels on both sides of the unit. The nonelectrical side can be placed against a wall. Clearance to the electrical side is essential to provide access to the control center and component maintenance.

Electrical Side

Handling

While this unit was constructed with quality and dependability in mind, damage still may occur during handling of the unit for 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 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

WARNING

All factory provided lifting lugs must be used when lifting the unit. Failure to comply with this safety precaution could result in property damage, serious injury or death.

1. Before lifting, be sure that all shipping material has been removed from unit.

2. To assist in determining rigging requirements, weights are shown under the Recommended Roof Openings & Weights section.

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.

Control Center

Core

Filters

Inlet Dampers

Bypass Damper

Blowers

Energy Core Ventilator

Nonelectrical Side

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.

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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. The GKD ships in a knockdown kit (includes duct adapter) and requires ﬁeld assembly (by others). Assembly instructions are included.

2. 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 unit operation, it is important that the installation be level. Shim as required to level.

3. 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.

4. 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.

Curb Outside Dimensions and Weights

Unit Size A B Curb Weight (lbs.)

ECV-10 52.2 26.3 60

All dimensions are in inches. Weight is for 14-inch high model GKD curbs.

Side of Unit

Roof Curb

Curb Cap Details for Factory Supplied Roof Curbs

Unit Size A

ECV-10 1.9 5.3 4.3 4.3 0.8

All dimensions are in inches.

BCDE

Base

1-inch Insulation

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Ductwork Connections

POOR

Examples of poor and good fan-to-duct connections are shown. 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

Model Blower Size Duct Size Straight Duct Length

ECV-10 10-6 14 x 14 36 ft.

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 intended 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.

• 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.

Length of Straight Duct

GOOD

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 extend beyond the unit a minimum of 12 inches on each side.

• Set unit on rails.

Unit Size A

ECV-10 4.2 11.5

All dimensions are in inches.

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Electrical Information

The unit must be electrically grounded in accordance with the current National Electrical Code, ANSI/NFPA 70. In Canada, use current CSA 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 be 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 delay fuses and size according to the rating plate.

If power supply is desired through bottom of unit, run the wiring through the curb, cut a hole in the cabinet bottom, and wire to the disconnect switch. Seal penetration in cabinet bottom to prevent leakage.

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.

Key: V1, V2, V3 = line voltages as measured

VA (average) = (V1 + V2 + V3) / 3

VD = Line voltage (V1, V2 or V3) that deviates farthest from average (VA)

Formula: % Voltage Imbalance = [100 x (VA-VD)] / VA

WARNING

To prevent injury or death due to electrocution or contact with moving parts, lock disconnect switch open.

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 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.

Field Control Wiring Length/Gauge

Total

Wire Length

125 ft. 18 200 ft. 16 300 ft. 14 450 ft. 12

Minimum

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.

If wire resistance exceeds 0.75 ohms, an industrialstyle, 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 (located on the 24 VAC terminal strip under the 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.

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 105ºC.

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Typical Control Center Components

1. Main Disconnect (nonfusible, lockable)

2. Motor Starter – Exhaust Air Fan

3. Motor Starter – Outdoor Air Fan

4. Speed Controllers (Supply & Exhaust)

5. 24 VAC Control Transformer

6. 24 VAC Terminal Strip

Optional Control Center Components

7. Economizer Controller

8. Dirty Filter Pressure Switches

9. BMS Controller

10. Frost Control Timer

11. Thermostat

Optional Accessory Wiring Schematics

Remote Panel

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

• Dirty filter light

• Economizer light

• Frost control light

7-Day Timer

On/Off/Auto Switch & Indictor Light Wiring

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CONTROL CENTER DOOR

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Dirty Filter Indicator

(powered by others)

Unit Overview

Basic Unit

The unit is prewired such that when a call for outside air is made (via field-supplied 24 VAC control signal wired to unit control center), the supply and exhaust fans are energized and optional motorized dampers open. The unit is normally interlocked (24 volt) to the rooftop air handler. When the rooftop air handler starts, the auxiliary contactor in the air handler closes to start the unit.

Summer Operation

Outdoor air is preconditioned (temperature and moisture levels are decreased) by the transfer of energy from the cooler, drier exhaust air through the energy recovery core. The preconditioned air is typically mixed with return air going back to the air handler for final conditioning.

Winter Operation

Outdoor air is preconditioned (temperature and moisture levels are increased) by the transfer of energy from the warmer, more humid exhaust air through the energy recovery core. The preconditioned air is typically mixed with return air going back to the air handler for final conditioning.

Exhaust Air

Supply Air

82° F

88 grains/lb.

Outdoor Air

95° F

125 grains/lb.

Summer

Operation

Return Air

75° F

50% RH

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Optional Component Overview

Economizer

The energy core operation can be altered to take advantage of economizer operation (free cooling). Two modes are available:

1. Bypass damper

2. Independent blower control

Bypass damper: An integral bypass damper will cycle into a bypass condition allowing cool air to flow past the energy recovery core rather than flow through it. When outdoor air conditions are not suitable for economizer operation, the damper will remain closed. Economizer mode is initiated by temperature or enthalpy and dependent on the sensor. To eliminate unnecessary control sequences and the concern of overloading fans. Energizing the bypass damper is accomplished one of two ways:

1. The outdoor air temperature is <40ºF or >65ºF.

2. The outdoor air temperature is <40ºF or >65ºF DB or >55˚F dew point.

Independent blower control: The unit will have the capability to receive an external signal to power off the supply fan.

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 complete. The dirty filter switch is mounted in the unit control center.

Frost Control

Extremely cold outdoor air temperatures in combination with higher indoor humidity levels, can cause moisture condensation and frosting on the energy recovery core. Timed exhaust frost control is an optional feature available to prevent and/or control core frosting.

This option is provided with a temperature sensor installed in the exhaust airstream to measure the temperature of the air leaving the core. When the exhaust air temperature drops below 32ºF, frost control is initiated.

Timed exhaust includes a timer in addition to the temperature sensor. If the exhaust air temperature is below 32ºF, the supply blower is cycled approximately 30 minutes on and 5 minutes off to allow the warm exhaust air to heat the core. Once the exhaust air temperature rises above 32ºF, the supply blower is no longer cycled.

CO2 Sensor

The factory-provided sensors can be set to reference a set point for on/off operation.

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Start-Up

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 switch(es). Unit may have multiple power supplies.

WARNING

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.

Do not operate energy core ventilator 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.

General Start-Up Information

Every installation requires a comprehensive startup 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 Number _______________________________

Unit Serial Number _______________________________

Start-Up Date _______________________________

Start-Up Personnel Name __________________________

Start-Up Company _______________________________

Phone Number _______________________________

Pre Start-Up Checklist – check as items are

completed.

 Disconnect and lock-out all power switches  Remove any foreign objects that are located in the

energy recovery unit.

 Check all fasteners, set-screws, and locking collars

on the fans, bearings, drives, motor bases and accessories for tightness.

(e.g. ECV-10)

(e.g. 04C99999 or 10111000)

 Rotate the fan wheels by hand to ensure no parts

are rubbing. If rubbing occurs, refer to Start-Up section for more information.

 Check the fan belt drives for proper alignment

and tension (refer to Start-Up section for more information).

 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).

SPECIAL TOOLS REQUIRED

• Voltage Meter (with wire probes)

• Amperage Meter

• Thermometer

• Tachometer

• Incline Manometer or Equivalent

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 & amps, the control center door must be open, and the unit energized using a crescent wrench to turn the disconnect handle.

Check line voltage at unit disconnect _______ L1-L2 volts

_______ L2-L3 volts _______ L1-L3 volts

Motor Amp Draw

• Supply Fan • Exhaust Fan _______ L1 amps ______ L1 amps _______ L2 amps ______ L2 amps _______ L3 amps ______ L3 amps

Fan RPM _______ Supply Fan ______ Exhaust Fan

Correct fan rotation direction Supply Fan Yes / No Exhaust Fan Yes / No

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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 Set Point 32ºF

Differential 2ºF Timer Refer to page 16

Economizer Application / Operation section:

Yes No Economizer (temperature)

Set Point 65ºF

Offset 25ºF

Differential 2ºF

Yes No Economizer (enthalpy)

Set Point D

Optional Accessories section: Operational

Yes No OA Dirty Filter Sensor Yes No N/A

Yes No EA Dirty Filter Sensor Yes No N/A

Yes N o C O

Yes No Remote Control Panel Yes No N/A

Sensor 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

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Start-Up Components

Airflow

Optional Start-Up Components

Fans

The unit contains two forwardcurved (supply and exhaust) fans. 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.

Forward-Curved Fan

Check Blower Wheel Rotation

First, hand rotate the blower to ensure that the wheel is not rubbing against the scroll. If the blower is rotating in the wrong direction, the unit will move some air but not perform properly.

To check the rotation, open the blower access

panel, and run the blower momentarily to determine the rotation.

Forward Curved

CAUTION

When operating conditions of the fan are to be changed (speed, pressure, temperature, etc.), consult Greenheck to determine if the unit can operate safely at the new conditions.

Optional EC Motor

Features

Soft start – All motors feature soft start technology which eliminates inrush current at start-up. The motors will reliably start at any speed setting.

Overload protection – If the motor becomes overloaded, it will automatically reduce its speed until it is no longer overloaded. This means that the motor will never operate in the “service factor” which is possible with many AC motors. The motor and control are electrically protected with lightning surge protection.

Optional Dirty Filter Switch

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.

1. Open the ﬁlter compartment and place a sheet of plastic or cardboard over 50% of the ﬁlter media.

2. Replace the ﬁlter compartment door.

3. Check to see if there is power at the alert signal leads (refer to electrical diagram).

4. Whether there is power or not, turn the adjustment screw on the dirty ﬁlter gauge (clockwise if you did not have power, counter-clockwise if you did have power) until the power comes on or just before the power goes off.

5. Open the ﬁlter compartment and remove the obstructing material.

6. 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.

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Optional Economizer

Relevant Set Points

1. MAT SET The outdoor air temperature set point after the energy core. The control will open/close the bypass damper to maintain temperature as best as it can. (Set point menu, default 53°F )

2. LOW T LOCK The set point for the low temperature mechanical cooling lockout. (Set point menu, default 32°F)

3. DRYBLB SET The outdoor air set point to call for economizer. (Set point menu, default 63°F)

4. AUX1 O The controllers operating sequence structure. (Set point menu, default ‘None’)

5. ERV OAT SP The set point for low temperature economizer lockout. This is the low temperature set point when AUX1 O is set to ERV. (Set point menu, default 40°F)

Using the Keypad with Settings and Parameters

To use the keypad when working with Set points, System and Advanced Settings, Checkout tests, and Alarms:

1. Navigate to the desired menu.

2. Press currently displayed menu.

3. Use the and buttons to scroll to the desired parameter.

4. Press currently displayed item.

5. Press the button to increase (change) the displayed parameter value.*

6. Press the displayed parameter value.

7. Press (enter) to accept the displayed value and store it in non-volatile RAM.

8. CHANGE STORED displays.

9. Press parameter.

10. Press parameter.

When values are displayed, pressing and holding the automatically increment.

(enter) to display the ﬁrst item in the

(enter) to display the value of the

button to increase (change) the

(enter) to return the current menu

(escape) to return to the current menu

or button causes the display to

Optional Frost Control

Timed Exhaust

1. Remove power from unit.

2. Jumper the temperature indicating sensor in the unit control center. Thermostat controller has a pre-set temperature of 32ºF.

3. Set the frost control timer scale for T1 and T2 to 5m. Set the timer settings for T1 and T2 to 30.

4. Add power to the unit. Blower should cycle on for 30 minutes, then turn off for 5 minutes.

5. Remove power from unit and remove jumpers that were placed. Re-set timer settings.

• T1 timer setting set to 5 and

timer scale set to 10m for 5 minutes of blower off time.

• T2 timer setting set to 5 and

timer scale set to 1h for 30 minutes of blower on time.

Timer Scale

Timer

Settings

Timer Scale

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Routine Maintenance

DANGER

CAUTION

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:

Lubrication

Apply lubrication where required

Dampers

Check for unobstructed operation

Fan Belts

Check for wear, tension, alignment

Motors

Check for cleanliness

Blower Wheel & Fasteners

Check for cleanliness Check all fasteners for tightness Check for fatigue, corrosion, wear

Bearings

Check for cleanliness Check set screws for tightness Lubricate as required

External Filter

Check for cleanliness - clean if required

Internal Filter

Check for cleanliness - replace if required

Door Seal

Check if intact and pliable

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

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 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 & 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.

Bearings

Most bearings are permanently lubricated and require no further lubrication under normal use. Normal use being considered -20ºF to 120ºF 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.

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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 prior to start-up.

Clean filters by rinsing with a mild detergent in warm water.

Internal Filter Maintenance

The 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 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

Pleated Filter Size and Quantities

Unit Size Size

ECV-10 20 x 25 1 1

All dimensions in inches.

Outdoor Air Filters: Access to the outdoor air filters is through the door labeled as “Filter Access” on the sides of the unit.

Exhaust Air Filters: Access to the exhaust air filters is through the door labeled as “Filter Access” on the sides of the unit.

Refer to Access Panel Location section for additional information on filter locations.

Supply

Qty.

Exhaust

Qty.

Energy Recovery Core

Annual inspection of the energy recovery core is recommended. Units ventilating smoking lounges and other nonclean air spaces should have energy recovery core inspections more often based upon needs.

Accessing the energy recovery core - Disconnect the power to the ECV. Remove access panel.

Removing the energy recovery core - Once the energy core access doors are removed, the core can be pulled from the housing. To replace the core, reverse the procedure.

Recommended cleaning procedure - First, remove the energy recovery core by following the instructions on this page.

Once the core is removed, gently vacuum the surfaces of the core to remove the dirt and debris that has accumulated.

Frequency of cleaning - A regular cleaning cycle must be established for the energy recovery core in order to maintain optimum sensible and latent energy transfer. In reasonably clean environments such as schools, offices or retail stores, the energy recovery core should be inspected annually and cleaned as needed.

WARNING

Do not wash, soak in water or use detergents and cleaners on the core. This will result in a damaged core.

Failure to follow a regular cleaning cycle for the energy recovery core can result in significant energy transfer performance losses.

Door Seal Maintenance

A bulb seal is installed on the perimeter of the door frame. Inspect at least annually to ensure that the seal is still intact.

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Troubleshooting - Economizer Alarms

Addressing Alarms

Alarms will signify a faulty sensor. When this occurs, verify all connections to the sensor and controller are secure. Press enter twice to clear the alarm. If the issue persists, consult the factory.

Clearing Alarms

Once the alarm has been identified and the cause has been removed (e.g. replaced faulty sensor), the alarm can be cleared from the display.

To clear an alarm, perform the following:

1. Navigate to the desired alarm.

2. Press the

3. ERASE? displays.

4. Press (enter).

5. ALARM ERASED displays.

6. Press return to the previous menu.

If an alarm still exists after you clear it, it redisplays within 5 seconds.

(enter).

(escape) to complete the action and

NOTE

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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

Nameplate 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 Fan Amp Draw

Airflow problems can often be tied back to improper ductwork installation. Be sure to install ductwork in accordance with SMACNA and AMCA guidelines.

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Troubleshooting – Unit

Symptom Possible Cause Corrective Action

Blown fuse or open circuit breaker.

Defective motor or capacitor. Replace.

Replace fuse or reset circuit breaker and check amps.

Blower fails to

operate

Motor starters

“chatter” or

do not pull in

Motor over amps

Motor starter overloaded. Reset starter and check amps.

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. Check cfm and adjust drives if needed.

Static pressures are higher or lower than design.

Blower rotation is incorrect. Check rotation and reverse if necessary.

Motor voltage incorrect.

Motor horsepower too low.

Shorted windings in motor. Replace motor.

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. Consult factory for relay information.

Need to increase supply power or use a special control transformer which is sized for the actual supply power.

If higher, ductwork should be improved. If lower, fan rpm should be lower.

Check motor nameplate versus supplied voltage.

See specifications and catalog for fan curves to determine if horsepower is sufficient.

Low airflow (cfm)

High airflow (cfm)

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

System static pressure too high.

Blower speed too low.

Fan wheels are operating backwards.

Dirty filter or energy core.

Leaks in ductwork. Repair.

Elbows or other obstructions may be obstructing fan outlet.

Belt slippage. Adjust belt tension.

Blower fan speed too high.

Filter(s) not in place. Install filters.

Insufficient static pressure (Ps) (airflow resistance).

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.

Correct or improve ductwork.

Check for correct fan rpm. Decrease fan speed if necessary.

Induce Ps into system ductwork. Make sure grilles and access doors are installed. Decrease fan speed if necessary.

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

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Troubleshooting – Unit

Symptom Possible Cause Corrective Action

One or both

blowers turn off

intermittently and

back on after

about 2 minutes

Frost control sensors are tripping.

Adjust frost temperature sensor set point as needed.

Fan wheel rubbing on inlet.

Bearings.

Excessive noise

or vibration

Always have a completed Pre Start-Up Checklist, unit Start-Up Checklist, and Optional Accessories Checklist prior to requesting parts or service information.

Motor base or blower loose. Tighten mounting bolts.

Bearing and drive misaligned. Realign.

Noise being transmitted by duct.

Adjust wheel and/or inlet cone. Tighten wheel hub or bearing collars on shaft.

Replace defective bearing(s). Lubricate bearings. Tighten collars and fasteners.

Make sure ductwork is supported properly. Make sure ductwork metal thickness is sized for proper stiffness. Check duct size at discharge to ensure that air velocities are not too high.

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