Greenheck MiniCore User Manual

Document 479677

Energy Recovery Ventilator

Model MiniCore

Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. 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!

Energy recovery cores are certiﬁed by the AHRI Air-to-Air Energy Recovery Ventilation Equipment Certiﬁcation Program in accordance with AHRI Standard 1060. Actual performance in packaged equipment may vary.

Certiﬁed Ratings are available in the Certiﬁed Product Directory at www.ahridirectory.org

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 affects 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.

MiniCore

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 notation 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 Sales Representative. Any physical damage to the unit after acceptance is not the responsibility of manufacturer.

Unpacking

Verify that all required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Conﬁrmation of shipment(s) must be limited to only items on the bill of lading.

Handling

Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce ability of unit to resist corrosion.

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.

INDOOR — The ideal environment for the storage of

units and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Temperatures should be evenly maintained between 30°F (-1°C) and 110°F (43°C) (wide temperature swings may cause condensation and “sweating” of metal parts). All accessories must be stored indoors in a clean, dry atmosphere.

Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To avoid “sweating” of metal parts allow cold parts to reach room temperature. To dry parts and packages use a portable electric heater to get rid of any moisture build up. Leave coverings loose to permit air circulation and to allow for periodic inspection.

The unit should be stored at least 3½ in. (89 mm) off the ﬂoor on wooden blocks covered with moisture proof paper or polyethylene sheathing. Aisles between parts and along all walls should be provided to permit air circulation and space for inspection.

Inspection and Maintenance during Storage

While in storage, inspect fans 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 the fan wheel by hand ten to ﬁfteen revolutions to distribute lubricant on motor. Every three months, the fan motor should be energized. If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or ﬁne emery paper and oil. Do not destroy the continuity of the surfaces. Wipe thoroughly clean with Tectyl hard to reach internal surfaces or for occasional use, consider using Tectyl or the equivalent.

REMOVING FROM STORAGE — As units are removed

from storage to be installed in their ﬁnal location, they should be protected and maintained in a similar fashion, until the equipment goes into operation.

Prior to installing the unit and system components, inspect the unit assembly to make sure it is in working order.

1. Check all fasteners, set screws on the fan, wheel, bearings, drive, motor base, and accessories for tightness.

2. Rotate the fan wheel(s) by hand and assure no parts are rubbing.

506 (Ashland Inc.) or the equivalent. For

511M Rust Preventive or WD-40®

MiniCore

Table of Contents

Dimensional Data and Weights . . . . . . . . . . . . 3

Changing the Inlet Location . . . . . . . . . . . . . . 4

Changing the Discharge Location . . . . . . . . . . . 4

Service Clearances and Access Panel Locations . . . 4 Installation Hang Mounting with Hanging Vibration Isolators. . 4

Base Mounting with Base Vibration Isolators. . . . 5

Duct Connections . . . . . . . . . . . . . . . . . . 6

Electrical Connections

Unit Wiring Sequence . . . . . . . . . . . . . . . . 6

Frost Control . . . . . . . . . . . . . . . . . . . . 6

Wiring Schematics . . . . . . . . . . . . . . . . . . . 7

System Start-Up

Unit Documentation Record . . . . . . . . . . . . 8

Pre-Start-Up Checklist . . . . . . . . . . . . . . . 8

Start-Up Checklist . . . . . . . . . . . . . . . . . 8

General . . . . . . . . . . . . . . . . . . . . . . . 9

Check Voltage. . . . . . . . . . . . . . . . . . . . 9

Blower Wheel Rotation . . . . . . . . . . . . . . . 9

Air Volume Check & Measurement . . . . . . . . . 9

Voltage, Amperage and Fan RPM . . . . . . . . . 9

Routine Maintenance

General . . . . . . . . . . . . . . . . . . . . . . . 9

Fasteners and Set Screws . . . . . . . . . . . . . 9

Removal of Dust and Dirt . . . . . . . . . . . . . . 9

Internal Filters . . . . . . . . . . . . . . . . . . . . 9

Energy Core . . . . . . . . . . . . . . . . . . . . 10

Optional EC Motors . . . . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . 11

Maintenance Log. . . . . . . . . . . . . . . Backcover

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

Dimensional Data and Weights

Discharge End

MiniCore A A1 B C

All dimensions are in inches.

39.4 34.4 16.2 47.3 230

39.4 34.4 21.4 47.3 245

Filters

CoreCore

Discharge A

Intake End

Weight

(lbs.)

Discharge B

Discharge End

Intake End

Intake B

Intake A

MiniCore D E F G H J K L M

9.75 9.75 3.7 19.8 3.2 5.3 22.1 12 2.1

All dimensions are in inches.

9.75 9.75 3.7 19.8 5.8 5.3 22.1 12 4.7

MiniCore

Conﬁgurable Discharge & Intake Locations

The MiniCore comes standard with end connections. The option for conﬁgurable intake and discharge connections (shaded in below drawing) are available and can be interchanged based on application in the ﬁeld.

Outdoor Air

Exhaust Air Discharge

Outdoor Air Discharge

Changing the Discharge Location

Step 1 - Disconnect and lockout all power switches.

Step 2 – Remove the sheet metal block off from the

desired discharge location.

Step 3 – Cut the insulation from the desired discharge location opening.

Step 4 – Remove the backdraft damper from its current position and reinstall in the desired discharge location. The hinged door should be on the discharge end of the unit.

Step 5 – Glue the cut out insulation to the sheet metal block off. Install where the damper had been located.

Step 6 – Using a 1/2-inch wrench, remove the four (4) bolts from the discharge end of the unit that holds the blowers.

Step 7 – Remove the four (4) plastic plugs from the desired discharge location and reinstall the plastic plugs in the holes where the bolts were removed from in Step6.

Step 8 – Position the blowers to line up with the desired discharge location. The motor needs to be on the discharge end of the blower and unit. If the motor is positioned on the return side of the blower/unit, the motor/blower will interfere with the energy recovery core. The blower adjacent to the control center needs to be rotated 90°. The blower not adjacent to the control center needs to be ﬂipped and rotated such that the motor is now opposite the control center side of the unit. It may be necessary to unwire the motors.

Step 9 – Bolt the blowers in their desired locations. Securely reconnect and fasten all wires.

Intake

Exhaust Air Intake

Changing the Inlet Location

Step 1

- Remove the metal cover for optional inlet

location by unfastening the four (4) sheet metal screws holding it in place.

Step 2 - Hand bend ﬂanges out to form a duct collar in the newly uncovered intake opening.

Step 3 - Cut insulation.

Step 4 - Hand bend ﬂanges in on original intake and

replace metal cover removed in Step 1.

Service Clearances and Access Panel Locations

Recommended Service Clearances

The MiniCore requires minimum clearances to perform routine maintenance, such as ﬁlter replacement, energy core cleaning and fan inspection. Fan and motor assemblies, energy recovery core and ﬁlter sections are provided with a service door or panel for proper component access.

Access Panel Locations

• Outdoor and exhaust fans and motor

• Electrical connection

• Energy core and internal ﬁlters

Energy Core and Filter Access Panel

Electrical Input

MiniCore Inches

Energy Core and Filter Access Panel

MiniCore

Installation

The system design and installation should follow accepted industry practices, such as described in the ASHRAE Handbook and SMACNA.

Minimum service clearance should be provided on the side of the unit for routine service and component removal should it become necessary.

Before beginning installation see page 4 for appropriate service clearances

Hang Mounting with Hanging Vibration Isolators

• The hanging isolator kit includes four (4) isolators and required hardware.

• Locate the support rods as shown in the drawing.

• Assemble each isolator as shown below.

Base Mounting with Base Vibration Isolation

• The base isolators kit includes four (4) isolators, four (4) brackets and required hardware.

• Assemble and mount the isolators as shown in the ﬁgures below.

Factory-mounted bracket

Hanger bracket, factory-mounted

Hanging Vibration Isolator Assembly

Nut

MiniCore A B C

44.8 14 39.4

All dimensions are in inches.

44.8 19.2 39.4

1/2-inch threaded rod, provided by others

Lock Washer

Flat Washer

Isolator

Flat Washer

Lock Washer

Nut

3/8-inch bolt

Lock washer

Flat washer

Isolator

Base Vibration Isolator Assembly

Assembled and Mounted Isolator Detail

MiniCore

Duct 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, loud noise and excessive vibrations.

POOR

Length of Straight Duct

GOOD

Recommended Discharge Duct Size and Length

MiniCore

All dimensions are in inches.

ERV

Blower Size

10 9.75 43

Duct

Size

Straight Duct

Length

Electrical Connections

Before connecting power to the unit, read and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached inside the energy core and ﬁlter access panel of the unit.

All wiring should be done in accordance with the National Electrical Code ANSI/NFPA 70 latest edition and any local codes that may apply. In Canada, wiring should be done in accordance with the Canadian Electrical Code. The equipment must be properly grounded.

Electrical connections are located below the energy core and ﬁlter access panel . A knock out location is provided with the unit.

CAUTION

If any of the original wire must be replaced, the replacement wire must have a temperature rating of at least 105ºC.

DANGER

High voltage electrical input is required for this equipment. This work should be performed by a qualified electrician.

Unit Wiring Sequence

1. The unit’s nameplate contains the voltage and total amperage required. The wire supplying power to the unit should be sized accordingly.

2. The main power line should be connected to the appropriate terminal blocks.

Power may be routed to the MiniCore through the knock out under the control center.

3. Refer to the wiring diagrams in this manual or in the unit for controlling the MiniCore.

Timed Exhaust Frost Control

Extremely cold outdoor air temperatures can cause moisture condensation and frosting on the energy recovery core. Timed exhaust frost control is an optional feature that will prevent/control core frosting.

Timed exhaust frost control includes a timer as well as a thermodisc that is ﬁeld-installed in the outdoor air duct. When timed exhaust frost control is initiated, the timer will turn the supply blower off. Time exhaust using default timer setting will shut down the supply fan for 5 minutes every 30 minutes to allow exhaust to defrost energy core.

Use the Frost Control Test Procedure outlined below for troubleshooting.

Frost Control Test Procedure

1. Remove power from unit.

2. Jumper the temperature indicating thermodisc in the unit control center. Thermodisc has a pre-set temperature of 5ºF.

3. Set the frost control timer scale for T1 and T2 to 1m. Set the timer settings for T1 and T2 to 10.

4. Add power to the unit. Blower should cycle on for one minute, then turn off for one minute.

5. Remove power from unit and remove jumpers that were placed. Reset timer settings.

• T1 timer setting set to

5 and timer scale set

to 10m for 5 minutes of wheel off time.

• T2 timer setting set to

5 and timer scale set

to 1h for 30 minutes of wheel on time.

Timer Scale

Timer

Settings

Timer Scale

MiniCore

Wiring Schematics

Timed Exhaust Frost Control

COM

YELLOW

REMOTE PANEL

115/208/230V PRIMARY

24V SECONDARY

FIELD MOUNT

IN OUTDOOR

AIR DUCT

VIOLET

RED

ORANGE

BLACK

GROUND

115

208

230

FIELD TO CONNECT

TO TERMINAL DESIGNATED

WITH UNIT LINE VOLTAGE

CONNECT TERMINAL 15

FROM COMPONENT "T1"

WITH LINE VOLTAGE

PURPLE

T A OR B

INTERNAL JUNCTION BOX

MAIN UNIT

Potentiometer Control

(VERIFY MAIN UNIT POWER ON UNIT NAMEPLATE)

MAIN UNIT POWER -110/50/1-115/60/1

L2/NEUTRAL

L2 L1

GROUND

BLACK

WHITE

BLACK

WHITE

Solid State Speed Motor Control

(VERIFY MAIN UNIT POWER ON UNIT NAMEPLATE)

MAIN UNIT POWER - 110/50/1-115/60/1

L2/NEUTRAL

BLOWER MOTOR A

BLOWER MOTOR B

Legend

MA Blower Motor A MB Blower Motor B T1 Frost Control Timer

Typical Settings: t1 (OFF) = 5 min.

TH Thermostat; non-adjustable 5° setting.

Required to be mounted in outdoor air duct.

TR Transformer

t2 (ON) = 30 min.

GROUND

BLOWER A

SPEED CONTROLLER

ON OFF

BLOWER B

SPEED CONTROLLER

ON OFF

BLACK

BLOWER MOTOR A

BLOWER MOTOR B

MiniCore

System 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.

CAUTION

Use caution when removing access panels or other unit components, especially while standing on a ladder or other potentially unsteady base. Access panels and unit components can be heavy and serious injury may occur.

CAUTION

Do not operate without the filters installed. They prevent the entry of foreign objects such as leaves, birds, etc.

CAUTION

Do not run unit during construction phase. Damage to internal components may result and void warranty.

WARNING

Do not jumper any safety devices when operating the unit. This may damage components within or cause serious injury or death.

SPECIAL TOOLS

• Voltmeter

• Incline manometer or equivalent

• Tachometer

• Amperage meter

Every installation requires a comprehensive start-up to ensure proper operation of the unit. As part of that process, the following checklist must be completed and information recorded. Starting up the unit in accordance with this checklist will not only ensure proper operation, but will also provide valuable information to personnel performing future maintenance. Should an issue arise which requires factory assistance, this completed document will allow unit experts to provide quicker resolve. Qualiﬁed personnel should perform start-up to ensure safe and proper practices are followed.

Unit Documentation Record

Unit Model No. __________________________________

Unit Serial No. ____________________________________

Start-Up Date ____________________________________

Start-Up Personnel Name _________________________

Start-Up Company ________________________________

Phone Number ___________________________________

Pre-Start-Up Checklist

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.

 Filters can load up with dirt during building

construction. Replace any dirty pleated ﬁlters.

 Verify that non-motorized dampers open and close

properly.

 Check the tightness of all factory wiring

connections.

 Verify control wire gauge.

Start-Up Checklist

Line Voltage. Check at unit disconnect.

L1-L2 Volts

Motor Amp Draw

Supply Motor Amps L1 Amps L2 Amps

Exhaust Motor Amps L1 Amps L2 Amps

Fan RPM

Supply Fan RPM

Exhaust Fan RPM

Correct fan rotation direction?

Supply Fan Yes / No

Exhaust Fan Yes / No

MiniCore

General

Airflow

Check all fasteners and set screws for tightness. This is especially important for bearings and fan wheels Also, if dampers are not motorized, check that they open and close without binding.

Check Voltage

Before starting the unit compare the supplied voltage with the unit’s nameplate voltage and the motor voltage.

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.

Forward Curved

To check the rotation, open the blower access panel, and run the blower momentarily to determine the rotation.

Air Volume Check and Measurement

Along with the building balance, the unit’s airﬂow (cfm) should be measured and compared with its rated air volume. The MiniCore is direct drive, therefore balancing dampers or speed controls are required for airﬂow balancing. Air volume measurement must be conducted with access doors on the unit.

The most accurate way to measure the air volume is by using the pitot traverse method in the ductwork away from the blower. Other methods can be used, but should be proven and accurate.

To adjust the air volume, change the fan rpm or the system static pressure.

With all access panels on the unit, compare measured amps to the motor nameplate full load amps and correct if overamping.

Measure Motor Voltage, Amperage and FanRPM

All access doors must be installed, run the measurement leads through the provided electrical access hole in the bottom access panel of the MiniCore. Measure and record the input voltage and motor amperage(s).

With all access panels on the unit, compare measured amps to the motor nameplate full load amps and correct if overamping.

Routine Maintenance

WARNING

Disconnect all electrical power to the MiniCore prior to inspection or servicing. Failure to comply with this safety precaution could result in serious injury or death. Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating, and maintenance instructions thoroughly before installing or servicing this equipment.

After the MiniCore has been put into operation, an annual inspection and maintenance program should be set-up to preserve reliability and performance.

The MiniCore energy recovery ventilator requires very little maintenance. However, small problems left unchecked, over time, could lead to loss of performance or early motor failure. We recommend that the unit be inspected once a year.

The motor should be checked for lubrication at this time. Lubricate only those motors which have an oil hole provided. A few drops of all-purpose oil (SAE 20) will be sufﬁcient.

Fasteners and Set Screws

Any fan vibration has a tendency to loosen mechanical fasteners. A periodic inspection should include checking all fasteners and set screws for tightness. Particular attention should be paid to set screws attaching the fan wheel to the shaft. Loose bearing set screws will lead to premature failure of the fan shaft.

Removal of Dust and Dirt

The fan motor and wheel(s) should be checked for dust and dirt accumulation. Dirt buildup clogs cooling openings on the motor housing and causes motor overheating. Dirt buildup can contaminate bearing lubricant and collect on fan wheel blades causing loss of performance or premature failure. Cleaning can be accomplished by brushing off any dust that may have accumulated. Under no circumstances should motors or bearings be sprayed with steam or water. Even ﬁltered units can accumulate build up and should be checked when cleaning ﬁlters.

Maintenance to these components is achieved through the provided access panels.

Internal Filter Maintenance

Opening the access panel provides access to the two inches deep, pleated 30% efﬁcient ﬁlters. These ﬁlters should be checked regularly and cleaned or replaced as needed.

MiniCore

Internal

Filter Size

15 x 20 2

20 x 20 2

Quantity

MiniCore

Energy Core

Annual inspection of the energy recovery core is recommended. MiniCore units ventilating smoking lounges and other non-clean air spaces should have energy recovery core inspections more often based upon needs.

Accessing the energy recovery core - Disconnect the power to the MiniCore. 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.

WARNING

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

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.

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

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.

Locked rotor protection – If the motor ever encounters a locked-rotor scenario, the motor will automatically shut itself down. It will try to restart up to 3 times, and if after the 3rd time the motor will still not rotate, the motor will not attempt to start again until power is cycled.

Thermal protection – The motors have a one-shot fuse thermal protector. This is meant to protect the motor from a severe temperature rise. With the motor controller’s ability to software limit the speed, the fuse is used as a last resort to prevent a ﬁre.

RPM measurement – The motors have a small shaft extension on the end of the motor to measure motor RPM with either a contact or optical tachometer.

Operation and Wiring - Potentiometer Dial

These motors feature a potentiometer dial on the motor for speed adjustment. A small screwdriver can be used to make the speed adjustment. To increase the speed, rotate the dial clockwise. To decrease the speed, rotate the dial counterclockwise.

MiniCore

Troubleshooting

Symptom Possible Cause Corrective Action

Unit is NOT

Electrical

Check fuses/circuit breakers, replace if needed. Check for On/ Off switches. Check for correct supply voltage.

operating

Motor Check motor horsepower is correct and not tripping overloads.

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

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

Excessive noise

Fan wheel rubbing on inlet

Bearings

Wheel out of balance Clean, replace or rebalance.

Fan speed too low Increase fan speed.

Low airﬂow (cfm)

Dirty ﬁlters or energy core Replace ﬁlters and/or follow the cleaning procedures.

High static pressure

Incorrect fan-to-duct connections. Make sure dampers open appropriately. Increase fan speed

Fan speed too high Decrease fan speed.

High airﬂow (cfm)

Low static pressure

Make sure grilles, ﬁlters and access doors are installed. Decrease fan speed.

Always provide the unit model and serial number when requesting parts or service information. Always check motor amps and compare to nameplate rating.

MiniCore