Greenheck RV-35 Installation Manual
Part #474612
®
RV/RVE
Packaged Rooftop Ventilator
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!
Model RV/RVE
General Safety Information
Only qualied personnel should install and maintain 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.
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 wheel faster than maximum cataloged
fan RPM. Adjustments to fan speed signicantly
affect motor load. If the fan RPM is changed, the
motor current should be checked to make sure it is
not exceeding the motor nameplate amps.
5. Verify that the power source is compatible with the
equipment.
6. Never open access doors to the unit while it is
running.
WARNING
The roof lining contains high voltage wiring. To
prevent electrocution, do not puncture the interior or
exterior panels of the roof.
DANGER
• Always disconnect power before working on or near
this equipment. Lock and tag the disconnect switch
or breaker to prevent accidental power up.
• If this unit is equipped with optional gas accessories,
turn off gas supply whenever power is disconnected.
CAUTION
This unit is equipped with a compressed refrigerant
system. If a leak in the system should occur,
immediately evacuate the area. An EPA Certified
Technician must be engaged to make repairs or
corrections. Refrigerant leaks may also cause bodily
harm.
CAUTION
When servicing the unit, the internal components may
be hot enough to cause pain or injury. Allow time for
cooling before servicing.
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Packaged Rooftop Ventilator
1
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
notication on the delivery receipt acknowledging any
damage to the product. All damage should be noted on
all copies of the Bill of Lading which is countersigned by
the delivering carrier. A Carrier Inspection Report should
be lled out by the carrier upon arrival and led with the
Trafc Department. If damaged upon arrival, le claim
with the carrier. Any physical damage to the unit after
acceptance is not the responsibility of the manufacturer.
Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Conrmation 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. This model is not designed for forklifting.
Location and number of lifting points varies by model
and size and all provided lifting brackets must be used
to properly support the unit during handling. Handle
each unit in such a way as to keep from scratching or
chipping the coating. Damaged nish may reduce the
ability of the 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 during 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 the parts,
the source should be located and eliminated. At each
inspection, rotate all moving parts by hand ten to
fteen revolutions to distribute lubricant on motor and
bearings. If paint deterioration begins, consideration
should be given to touch-up or repainting. Units with
special coatings may require special techniques for
touch-up or repair.
Machined parts coated with rust preventative should
be restored to good condition promptly if signs of rust
occur. Immediately remove the original rust preventative
coating with petroleum solvent and clean with lint-free
cloths. Polish any remaining rust from the surface with
crocus cloth or ne emery paper and oil. Do not destroy
the continuity of the surfaces. Wipe clean thoroughly
with Tectyl® 506 (Ashland, Inc.) or the equivalent. For
hard to reach internal surfaces or for occasional use,
consider using Tectyl® 511M Rust Preventative or
WD-40
® or the equivalent.
Product Overview
A horizontally congured High Percentage Outdoor
Air unit designed for installation either indoors or
outdoors. Each unit has multiple options for cooling
and/or heating. The unit is designed to replace air that
is exhausted from the building and also heat and cool,
as needed. The air volume produced by the unit is
constant, but can be optionally modulated to provide a
variable air volume (VAV) and recirculation is also offered
as an option.
Cooling
Units have the following cooling options available:
• Packaged DX
• Split DX
• Chilled water coil
Units with packaged DX are shipped fully charged with
refrigerant and are ready for operation upon arrival.
Heating
There are three different optional heat sources that can
be ordered for this unit:
• Indirect gas-red furnace with one or two sets of
heat exchangers
• Electric heat with innitely variable SCR control
• Hot water coil
Airflow Arrangement
The unit is capable of Constant Air Volume (CAV),
Variable Air Volume (VAV), 100% Outdoor Air and have
recirculating air options.
Safety Listing
Models are listed per ANSI/UL 1995, Heating and
Cooling Equipment and are ETL Certied.
Supplemental Installation, Operation and
Maintenance Manuals
Refer to the following Greenheck Installation, Operation
and Maintenance Manuals for additional information:
• Indirect Gas-Fired Heat Modules
• PCO3 DDC Controller Operating Manual
• Housed Plenum Array, Plug and Plenum
Models and Capacities
The packaged rooftop ventilator is built on three
different platform sizes.
Model Cooling Capacity
RV-35/RVE-35 5 to 15 tons
RV-50/RVE-50 10 to 25 tons
RV-80/RVE-80 15 to 29 tons
Packaged Rooftop Ventilator
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Table of Contents
General Safety Information ...................1
Receiving, Handling, Storage .................2
Product Overview
Cooling ....................................2
Heating ....................................2
Airflow Arrangement .........................2
Safety Listing ...............................2
Supplemental Installation, Operation and
Maintenance Manuals .......................2
Models and Capacities .......................2
Subassemblies
Blower ....................................4
Coils ......................................4
Compressors ...............................4
Dampers ...................................4
Optional Barometric Relief Damper ..............4
Electric Heater ..............................4
Filters .....................................4
Indirect Gas-Fired Furnace ....................4
Packaged DX System ........................4
Split DX ...................................4
Vestibule ...................................4
Installation
Typical Unit Weights and Dimensions ............5
Service Clearances ...........................5
Additional Clearances for Packaged DX ..........6
Handling Concerns for Units with Package DX .....6
Lifting .....................................6
Roof Curb Mounting .........................7
Optional Piping Vestibule ......................7
Ductwork Configurations ......................7
Rail Mounting and Layout .....................8
Recommended Electrical and
Gas Supply Entry Locations ..................8
Gas Supply Piping ...........................8
Gas Connections ............................8
Electrical Information ........................9
Determine the Size of Main Power Lines ........9
Determine the Size of Electric Heater Wiring .....9
Provide the Opening(s) for the Electrical
Connections ..............................9
Connect the Power Supplies ..................9
Wire the Optional Convenience Outlet ..........9
Connect Field-Wired Low Voltage Components ...9
Field-Provided Disconnect ....................9
Plumbing / Piping Overview
Split DX / Water Coil Connections ..............10
Condensate Drain Trap ......................10
Control Center Components
Main Control Center .........................11
Optional Indirect Gas-Fired Furnace ............11
Component Operation
Phase Monitor .............................12
Variable Frequency Drive .....................12
Supply Fan VFD Sequence ...................12
Optional Exhaust Fan VFD Sequence ...........12
Factory-Installed Refrigeration System
Components ..............................13
Start-Up – Unit
Model and Serial Number ....................14
Pre-Start-Up Checklist .......................15
Special Tools Required ......................15
Start-Up Procedure .........................15
Voltage Imbalance ..........................15
Start-Up Checklist ..........................16
Start-Up – Components
Fan ......................................17
Supply Fan (Plenum Type) ....................17
Fan Wheel Rotation Direction .................17
Supply/Exhaust Fan .........................17
Vibration ..................................17
Discharge Air Temperature Sensor .............17
Optional Energy Wheel
Start-Up ..................................18
Drive Belt .................................18
Adjust the Air Seals .........................18
Sequence of Operation ......................18
Maintenance ...............................19
Inspection .................................19
Wheel Disassembly .........................19
Cleaning ..................................19
Reassembly ...............................19
Energy Recovery Wheel Belt ..................19
Energy Recovery Wheel Bearings ..............19
Energy Recovery Wheel - Troubleshooting .......20
Troubleshooting
Alarms
DDC Controller ..........................20
Phase Monitor ............................20
Variable Frequency Drive ...................20
Optional FX05 Furnace Controller ............20
Optional Digital Scroll Compressor Controller ...20
Unit ......................................21
Refrigeration Circuit ......................22-25
Routine Maintenance
Monthly ..................................26
Semiannually ..............................26
Annually ..................................26
Units with Packaged DX, Semiannually ..........26
Maintenance Procedures
Lubrication ................................26
Dampers ..................................26
Gas Furnace ...............................26
Fan Motors ................................27
Fan Wheel and Fasteners ....................27
Internal Filter Maintenance ...................27
Outdoor Air Filters ..........................27
External Filter Maintenance ...................27
Coil Maintenance ...........................27
Maintenance Log ....................Backcover
Warranty ...........................Backcover
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Packaged Rooftop Ventilator
3
Subassemblies
Blower
Either one or two plenum-type fans. All units are
equipped with a plenum fan for Supply Air and a second
may be selected for Exhaust (Relief) Air.
Coils
Evaporator coil (optional)
Condenser coil (optional, packaged DX only)
Water coil (optional)
Reheat coil (optional)
Compressors
Each unit having packaged DX will have either one
or two refrigerant compressors. Optionally, one the
compressors may be a digital scroll type compressor.
Dampers
Motorized intake air damper, motorized recirculating
damper. Optional return air damper. Optional gravitytype exhaust damper.
Optional Barometric Relief Damper
Used during economizer mode of the unit when building
pressure increases, relief damper will open due to over
pressurization.
Electric Heater
An SCR controlled electric heater (not shown) is
available on the units. It requires a separate power
supply and has its own control panel. See unit-specic
wiring diagram.
Filters
Two-inch thick metal mesh lters in the optional
Outdoor Weatherhood air intake, 2-inch thick pleated
paper MERV 8 (standard) or MERV 13 lters in the
airstream. Optional 4-inch thick lter bank with 2-inch
thick MERV8 and 2-inch thick MERV 13 pleated paper
Final Filters.
Indirect Gas-Fired Furnace
The optional model PVG furnace is available on housing
sizes 35 and 50. Housing size 80 uses the optional
model PVF furnace.
Packaged DX System
Any unit may be ordered with a packaged DX system.
It will include either one or two compressors, a
condenser coil(s) and evaporator coil(s) and all needed
components. Units that have packaged DX are charged
with R-410A refrigerant. Do not use tools or parts
designed for other refrigerants on these units.
Split DX
The unit may be ordered with a split DX system for
connection to a building cooling system.
Vestibule
Some units may be ordered with a factory-assembled
vestibule that is to be eld-attached to the side of the
unit. See lifting instructions.
Condenser Coils
(optional)
Packaged DX
Compressors
(optional)
Furnace Vest Plate
and
Furnace Control Center
(optional)
Open view of Model RVE showing optional condenser coil, fans and enthalpy wheel.
Condenser Fans
Main Control
Center
(optional)
Indirect Gas-Fired Furnace
(optional)
Energy Wheel (RVE)
(optional)
Plenum-Type
Supply Air Blower
Final Filters
(on coil face)
Intake Air
Damper
Plenum-Type
Exhaust Air Blower
Recirculating
Damper
Coils
(optional)
Weatherhood Filters
(metal mesh)
Packaged Rooftop Ventilator
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Installation
Typical Unit Weights and Dimensions
PLAN VIEW ELEVATION
LA
Supply Filters
DX Coil
Length Width
Control
Center
Supply Air
Discharge
Condensing
Section
H
Recirc
Damper
Optional
Piping Vestibule
Outdoor Air
Damper
Height
Indirect Gas
Heater
Weight
Unit
Outdoor Air
Weatherhood
W
J
Unit
Size
Return Air Inlet
A L W J J H
Outdoor Air
Weatherhood
RV-35 21.5 95.6 52.5 28.8 26.0 58.2 2,600 20x20
RV-50 21.5 108.8 64.0 32.0 26.0 70.5 3,600 20x25
RV-80 26.5 117.0 68.0 30.0 26.0 82.0 4,500 20x25
RVE-35 21.5 147.5 52.5 28.8 26.0 58.2 3,000 20x20
RVE-50 21.5 163.1 64.0 32.0 26.0 70.5 4,100 20x25
RVE-80 26.5 178.3 68.0 30.0 26.0 82.0 5,100 20x25
All dimensions are shown in inches. Weight is in pounds.
Note: If RV unit is ordered with optional exhaust (relief) fan, corresponding RVE dimensions will apply.
Supply
Blower
Compressors
Final Filter
Size
Service Clearances
Clearance
Unit Size ACS CC End OA End *NA from Unit *NA from CS *NA from Vest
RV-35/RVE-35 36 36 42 24 42 30
RV-50/RVE-50 36 36 42 24 42 30
RV-80/RVE-80 36 36 52 24 42 30
All dimensions are shown in inches.
*NA from Unit = no condensing section or piping vestibule
*NA from CS = condensing section
*NA from Vest = piping vestibule
OA End
CC End
ACS
Clearance
NA
ACS = Access
CC = Control Center
NA = Non-Access
OA = Outdoor Air Weatherhood
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Packaged Rooftop Ventilator
5
Additional Clearances for
Packaged DX Units
Packaged DX units require additional clearance
because they must have unrestricted air movement
around the condenser coil and condenser fans. Hot air
is being discharged from the condenser fans during
operation. Enough clearance must be provided to
avoid recirculation or coil starvation. When equipped
with condenser coils, the unit should never be placed
under an overhang or inside a building. A minimum of
48inches above the condenser fans is acceptable, but
unobstructed is strongly recommended.
Minimum 48 inches clearance
Condenser Fans
Minimum 42 inches
clearance
Lifting
1. Before lifting, be sure that all shipping materials
have been removed from unit.
2. To assist in determining rigging requirements,
weights are provided in the Unit Weights &
Dimensions section of this manual.
3. Unit must be lifted by all lifting lugs provided at top
of unit.
4. Spreader bars must span the unit to prevent
damage to the cabinet by the lift cables.
Use spreader bars to prevent damage to cabinet.
Condenser Coil
End view of roof top unit with Packaged DX
Handling Concerns for Units with
Packaged DX
Units having packaged DX have a system that is
pressurized with refrigerant and if it is damaged,
the refrigerant 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.
Before Lifting - Vestibule
Determine whether or not the unit has a vestibule that
must be eld-attached to the side of the unit. Vestibules
are shipped assembled but detached from the unit.
They have lifting lugs on them so they can also be lifted
by crane, but the installed location of the unit may make
it preferable to install the vestibule on the unit prior to
lifting.
Before Lifting - Field Power Access
Determine where high voltage and low voltage wiring is
to be brought into the cabinet. If wiring is to be brought
into the cabinet through the oor, see Alternate Supply
Entry Locations in this manual. If unit is to be installed
on a roof, cut access openings in the roof deck as
needed.
5. Always test-lift the unit to check for proper balance
and rigging before hoisting to desired location.
6. Never lift unit by weatherhood.
7. Never lift units in windy conditions.
8. Preparation of curb and roof openings should be
completed prior to lifting unit to the roof.
9. Check to be sure that gasketing (supplied by others)
has been applied to the top of the curb prior to
lifting the unit and setting on the curb.
10. Do not use fork lifts for handling unit.
Packaged Rooftop Ventilator
6
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Roof Curb Mounting
Roof curb details, including duct locations and
dimensions, are to be found in the roof curb assembly
instructions.
Rooftop units require curbs to be mounted rst. The
duct connections must be located so they will be clear
of structural members of the building.
1. Factory Supplied Roof Curbs
Roof curbs are Model GKD which are shipped in a
knockdown kit (includes duct adapters) and require
eld assembly (by others). Assembly instructions are
included with the curb kit.
2. Install Curb
Locate curb over roof opening and fasten in place.
Check that the diagonal dimensions are within ± 1/8
inch of each other and adjust as necessary. For proper
coil drainage and unit operation, it is important that the
installation be level. Shim the curb as required to level.
Install gasketing on top surface of curb (provided by
others).
3. Install Ductwork
Installation of all ducts should be done in accordance
with SMACNA and AMCA guidelines. Duct adapters are
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 t inside the unit base. Make sure
the unit is properly seated on the curb and level.
Optional Piping Vestibule
If the unit was ordered with the vestibule, the NA (NonAccess side) clearance dimension must be measured
from the vestibule.
L
W
Typical Unit with Piping Vestibule and
Factory-Supplied Curb Kit
Ductwork Configurations
NOTE
Downblast Discharge Ductwork - whenever
downblast discharge is used, the ductwork directly
beneath the unit must be connected with either a “T”
or an “L” configuration and the area directly beneath
the heat source must not have any openings such
as louvers or grates.
W
Typical Unit with Condensing Section and
Factory-Supplied Curb Kit
L
5. Install Vestibule
If unit was ordered with a vestibule and it has not yet
been attached to the unit, caulk and attach the vestibule
at this time.
®
No louvers or grates
Packaged Rooftop Ventilator
7
Rail Mounting and Layout
• The units may be installed on rails provided and
installed by others. Ensure that rails are designed to
handle the weight of the unit and provide proper load
distribution on building supports.
• Make sure that rail positioning does not interfere with
the openings on the unit.
• Rails should run the width of the unit and extend
beyond the unit a minimum of 12 inches on each side.
• Set unit on rails.
Each installation is unique and as a result, alternate
entry locations may be eld-located. Before using any
alternate entry location, verify the suitability of the
location and ensure the use of an alternate location
does not interfere with unit wiring, components or
functionality.
WARNING
Never drill holes in the roof of the unit! There is high
voltage wiring located between the inner and outer
roof panels. Damage to the wiring could cause severe
bodily harm or death.
Gas Supply Piping
Units with indirect gas-red furnaces require eldsupplied and installed gas supply piping.
Typical Unit Installed on Rails Supplied by Others
Recommended Electrical and Gas
Supply Entry Locations
Manufacturer recommends that electrical service and
gas supply be brought into the cabinet through the
end wall, as shown below. There are three penetrations
into the cabinet that are required; one for high voltage
supply wiring, one for low voltage control wiring and one
for either gas supply or high voltage supply wiring for an
electric heater.
Alternate Supply Entry Locations
Disconnect Switch for electric heater.
Present only if electric heat is selected.
Terminate heater supply wiring here.
From Gas Supply
Gas Cock
Bleeder Valve or
1/8 in Plugged Tap
Ground
Joint
Union
8 in. Trap
Gas to
Controls
Typical Gas Supply Piping Connection
Gas Connections
If this unit is equipped with an indirect gas-red furnace,
connection to an appropriate gas supply line will be
required. For complete information on installation
procedures for the optional gas furnace, refer the
Indirect Gas-Fired Heat IOM. See also Recommended
Electrical and Gas Locations in this manual.
Optional Main Disconnect Switch
(Terminate high voltage supply wiring
here or at power distribution block).
RECOMMENDED LOCATION
for low voltage control wiring.
RECOMMENDED LOCATION:
Factory-provided opening for gas
supply. If electric heat is ordered,
use this location for high voltage
supply wiring for heater.
RECOMMENDED LOCATION
for field-supplied high voltage
supply wiring.
Recommended Gas and Electric Supply Entry Locations
Packaged Rooftop Ventilator
8
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Electrical Information
WARNING
The roof lining contains high voltage wiring. To prevent
electrocution, do not puncture the interior or exterior
panels of the roof.
WARNING
To prevent injury or death due to electrocution or
contact with moving parts, lock disconnect switch
open.
For units with a gas furnace, if you turn off the power
supply, turn off the gas.
IMPORTANT
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 Electric Code ANSI/NFPA70
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 105ºC, except for an
energy cut-off or sensor lead wire which must be rated
to 150ºC.
DANGER
High voltage electrical input is needed for this
equipment. This work should be performed by a
qualified electrician.
CAUTION
Any wiring deviations may result in personal injury or
property damage. Manufacturer is not responsible
for any damage to, or failure of the unit caused by
incorrect final wiring.
Determine the Size of the Main Power
Lines
The unit’s nameplate states the voltage and the unit’s
MCA. The main power lines to the unit should be sized
accordingly. The nameplate is located on the outside of
the unit on the control panel side.
Determine the Size of Electric Heater
Wiring
An optional electric heater may require a separate
power supply. The power connection should be made
to the factory-provided electric heater disconnect and
must be compatible with the ratings on the nameplate,
supply power voltage, phase and amperage. Consult
ANSI/NFPA 70 and CSA C22.1 for proper conductor
sizing.
Provide the Opening(s) for the Electrical
Connections
Electrical openings vary by unit size and arrangement
and are eld-supplied.
Connect the Power Supplies
Connect the main power lines and electric heater power
lines to the disconnect switches or terminal blocks
and main grounding lug(s). Torque eld connections to
manufacturer’s recommendations.
Wire the Optional Convenience Outlet
The convenience outlet requires a separate 115V power
supply circuit. The circuit must include short circuit
protection which may need to be supplied by others.
Connect Field-Wired Low Voltage
Components
Most factory-supplied electrical components are
prewired. To determine what electrical accessories
require additional eld-wiring, refer to the unit-specic
wiring diagram located on the inside of the control
center access door.
The low voltage control circuit is 24 VAC and control
wiring should not exceed 0.75 ohms.
Control wires should not be run inside the same conduit
as that carrying the supply power. Make sure that
eld-supplied conduit does not interfere with access
panel operation. All low voltage wiring should be run in
conduit wherever it may be exposed to the weather.
If wire resistance exceeds 0.75 ohms, an 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.
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.
Field-Provided Disconnect
If eld-installing an additional disconnect switch, it
is recommended that there is at least four feet of
service room between the switch and system access
panels. When providing or replacing fuses in a fusible
disconnect, use dual element time delay fuses and size
according to the rating plate.
®
Packaged Rooftop Ventilator
9
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