Greenheck PVe User Manual

Document 472846

Heat Recovery 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 PVe

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 Electric Code (CEC) in Canada.

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

3. Unit must be securely and adequately 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.

Model PVe Heat Recovery Unit

Receiving

Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notification on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be filled out by the carrier upon arrival and reported to the Traffic Department. If damaged upon arrival, file claim with carrier. 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.

OUTDOOR — Units designed for outdoor applications

may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed.

The fan should be placed on a level surface to prevent water from leaking into the unit. The unit should be elevated on an adequate number of wooden blocks so that it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight, and space for periodic inspection. To minimize water accumulation, place all unit parts on blocking supports so that rain water will run off.

Do not cover parts with plastic film or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.

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 lintfree 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® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40

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,

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

® or the equivalent.

bearings, drive, motor base, and accessories for tightness.

are rubbing.

Model PVe Heat Recovery Unit

OUTDOOR

Table of Contents

Product Overview

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

Installation

Unit Dimensions and Weights . . . . . . . . 4

Access Panel Description and Locations . . . 4

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

Handling . . . . . . . . . . . . . . . . . 5

Lifting . . . . . . . . . . . . . . . . . . 5

Roof Curb Mounting . . . . . . . . . . . . 6

Curb Outside Dimensions and Weights . . . . 6

Rail Mounting/Layout . . . . . . . . . . . 7

Ductwork Connections . . . . . . . . . . . 7

Electrical Installation

General Electrical Information . . . . . . . . 8

Field-Provided Disconnect . . . . . . . . . 9

Discharge Air Temperature Sensor . . . . . . 9

Control Center Components . . . . . . . . . 9

Optional Accessory Wiring Schematics . . . . 10

Piping Installation

Condensate Drain Trap . . . . . . . . . . . 11

Unit Overview . . . . . . . . . . . . . . . 11

Optional Component Overview

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

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

Variable Frequency Drives . . . . . . . . . 12

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

Dirty Filter Sensor . . . . . . . . . . . . . 12

Service Outlet . . . . . . . . . . . . . . 12

Vapor Tight Lights . . . . . . . . . . . . . 12

Unit Start-Up

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

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

Start-Up Procedure . . . . . . . . . . . . 13

Voltage Imbalance . . . . . . . . . . . . . 13

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

Start-Up Checklist. . . . . . . . . . . . . 14

Optional Accessories Checklist . . . . . . . 14

Start-Up Components

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

Vibrations . . . . . . . . . . . . . . . .16

Optional Start-Up Components

Dirty Filter Switch . . . . . . . . . . . . . 16

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

Variable Frequency Drives . . . . . . . . 17-18

Routine Maintenance Checklist

Overview. . . . . . . . . . . . . . . . . 19

General . . . . . . . . . . . . . . . . . 19

Procedures. . . . . . . . . . . . . . 20-21

Parts List . . . . . . . . . . . . . . . . . 21

Troubleshooting

Airﬂow. . . . . . . . . . . . . . . . . . 22

Unit . . . . . . . . . . . . . . . . . . . 23

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

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

The unit brings in fresh outdoor air and removes stale exhaust air from the building. Prior to discharging the exhaust air, the plate heat exchanger transfers energy from the exhaust air to the incoming outdoor air. When used in the cooling mode, heat energy is transferred from incoming outdoor air to the exhaust air. Simply put, this unit preconditions the outdoor air to save money on heating and cooling costs.

AIR

SIDE VIEW

RETURN DUCT

SUPPLY DUCT

Model PVe Heat Recovery Unit

Installation

Unit Dimensions and Weights

Bypass Damper

Outdoor Air Hood

Face

Filters

Damper

FiltersFilters

Face/Bypass Damper

Plate Heat Exchanger

Top view

Plate Heat

Exchanger

Exhaust Air Hood

Control Center

Access Panel Description and Location

Filters

Optional OA (Outdoor Air) Damper Optional RA (Return Air) Damper

Optional Face and Bypass Dampers Plate Heat Exchanger

Side view

Approx.

Unit Size A B C D E

Weight

PVe-20 104.1 59.7 41.5 20.3 20.7 1300

PVe-35 104.1 59.7 49.2 25.2 17.7 1600

PVe-45 110.6 59.7 61.1 25.2 19.0 2100

PVe-55 116.5 59.7 76.1 25.2 23.8 2700

All dimensions are shown in inches.

(lbs.)

Plate Heat Exchanger

Control Center

Blowers

Model PVe Heat Recovery Unit

Service Clearances

CLEARANCE

Unit Size A B C D

PVe-20 36 36 36 60

PVe-35 48 36 36 60

PVe-45 60 36 36 60

PVe-55 72 36 36 60

All dimensions are shown in inches. The weatherhoods include 2-inch aluminum mesh filters that are removed out of the end of the hood as shown in this drawing and require extra clearance for removal.

Lifting

WARNING

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

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

2. To assist in determining rigging requirements, weights are provided in the Installation, Unit Dimensions and Weights section of this manual.

3. Unit must be lifted by all lifting lugs provided on base structure.

4. Rigger to use suitable mating hardware to attach to unit lifting lugs.

5. Spreader bar(s) must span the unit to prevent damage to the cabinet by the lift cables.

Handling

While this unit was constructed with quality and dependability in mind, damage still may occur during handling of the unit for installation. Exercise extreme caution to prevent any damage from occurring to the refrigerant system. This unit could contain a system pressurized with refrigerant that, if damaged, could leak into the atmosphere or cause bodily harm due to the extreme cold nature of expanding refrigerant. Use protective equipment such as gloves and safety glasses to minimize or prevent injury in case of a system leak during installation.

The system design and installation should follow accepted industry practice, such as described in the ASHRAE Handbook. Adequate space should be left around the unit for piping coils and drains, filter replacement, and maintenance. Sufficient space should be provided on the side of the unit for routine service and component removal should that become necessary.

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.

Lifting with a Forklift

Unit base rail includes forklift lifting locations. Use weights in the Installation, Unit Dimensions and Weights section of this manual to determine forklift size requirements.

Model PVe Heat Recovery Unit

Rooftop units require curbs to be mounted first, in accordance with their appropriate instructions. Curb unit is to be installed and then duct connections are to be made prior to setting of the unit.

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.

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.

1. Factory Supplied Roof Curbs: Roof curbs are Model GKD. The GKD ships in a knockdown kit (which includes duct adapter) and requires ﬁeld assembly by others. Assembly instructions are included with the GKD curbs.

2. Install Curb: Locate the assembled curb over roof opening and verify precise location of curb relative to the roof opening, in accordance with dimensions given previously. Fasten curb loosely in place and then shim as needed to ensure a level installation. Tighten roof fastening hardware and then recheck for level. Verify that diagonal dimensions of installed curb are plus or minus 1/8-inch of each other.

3. Install Ductwork: Install needed ductwork in accordance with SMACNA and AMCA guidelines. Duct adapter is provided to support ducts prior to setting the unit.

4. Install Insulation: One-inch deep insulation pans are provided with the curb assembly. Set the insulation pans per instructions and then install insulation in the pans prior to setting the unit. Insulation is not provided by the unit manufacturer, it is to be supplied by others.

5. Set the Unit: Lift unit to a point directly above the curb and duct openings. Guide unit carefully while lowering in order to align with duct openings. The roof curb will seat in a recess in the base of the unit. Verify that the unit is properly seated on the curb and is level.

Curb Outside Dimensions and WeightsRoof Curb Mounting

Unit Size L W

PVe-20 99.4 36.8 195

PVe-35 99.4 44.6 216

PVe-45 105.9 56.3 261

PVe-55 111.7 71.3 316

All dimensions are shown in inches.

Unit Side

1.895

4.844

Roof Curb

1.549

0.775

Dimensions are shown in inches.

Curb Cap Details for Factory Supplied Roof Curbs

Unit Base

Insulation Pan

Curb Weight

(lbs.)

Model PVe Heat Recovery Unit

Rail Mounting / Layout

POOR

1. Rails designed to handle the weight of the unit should be positioned as shown on the diagram (rails by others).

2. Make sure that rail positioning does not interfere with the supply air discharge opening or the exhaust air intake opening on the unit. Avoid areas dimensioned “B or C” below.

3. Rails should run the width of the unit and extend beyond the unit a minimum of 12 inches on each side.

4. Set unit on rails.

Isometric view of unit on rails

Ductwork Connections

Examples of poor and good fanto-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

Unit Size Blower Size Duct Size Straight Duct Length

PVe-20 9 14 x 14 36

PVe-35 10 20 x 20 36

PVe-45 12 20 x 20 36

PVe-55 15 28 x 28 60

All dimensions are 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

A B

Side view of unit on rails

Unit Size A

B* C* D

PVe-20 5 14 13.25 7.75

PVe-35 5 14 12.00 6.50

PVe-45 5 14 15.50 10.5

PVe-55 5 14 18.75 13.25

All dimensions are shown in inches. *Zones B and C identify regions/zones where rails may not be place due to ductwork.

Model PVe Heat Recovery Unit

Electrical Installation

WARNING

The roof lining contains high voltage wiring. To prevent electrocution, do not puncture the interior or exterior panels of the roof.

WARNING

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

For units with a gas furnace, if you turn off the power supply, turn off the gas.

IMPORTANT

Before connecting power to the unit, read and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached on the inside of the control center door(s).

IMPORTANT

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

IMPORTANT

The equipment must be properly grounded and bonded. Any wiring running through the unit in the airstream must be protected by metal conduit, metal clad cable or raceways.

CAUTION

If replacement wire is required, it must have a temperature rating of at least 105°C, except for an energy cut-off or sensor lead wire which must be rated to 150°C.

DANGER

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

CAUTION

Any wiring deviations may result in personal injury or property damage. Manufacturer is not responsible for any damage to, or failure of the unit caused by incorrect final wiring.

1. Determine the Size of the Main Power Lines The unit’s nameplate states the voltage and the unit’s MCA. The main power lines to the unit should be sized accordingly. The nameplate is located on the outside of the unit on the control panel side.

2. Provide the Opening(s) for the Electrical Connections

Electrical openings vary by unit size and arrangement and are ﬁeld-supplied.

3. Connect the Power Supplies Connect the main power lines and electric heater power lines to the disconnect switches or terminal blocks and main grounding lug(s). Torque ﬁeld connections to manufacturer’s recommendations.

4. Wire the Optional Convenience Outlet The convenience outlet requires a separate 115V power supply circuit. The circuit must include short circuit protection which may need to be supplied by others.

5. Connect Field-Wired Low Voltage Components Most factory-supplied electrical components are prewired. To determine what electrical accessories require additional ﬁeld-wiring, refer to the unitspeciﬁc wiring diagram located on the inside of the control center access door.

Control wires should not be run inside the same

conduit as that carrying the supply power. Make sure that ﬁeld-supplied conduit does not interfere with access panel operation. All low voltage wiring should be run in conduit wherever it may be exposed to the weather.

The low voltage control circuit is 24 VAC and

control wiring should not exceed 0.75 ohms. If wire resistance exceeds 0.75 ohms, an isolation relay should be added to the unit control center and wired in place of the remote switch (typically between terminal blocks R and G on the terminal strip. The relay must be rated for at least 5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to “chatter” or not pull in which can cause contactor failures and/or motor failures.

Model PVe Heat Recovery Unit

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