Greenheck Fan APEX-200 User Manual

Energy Recovery Ventilator

Model: APEX-200

INSTALLATION, OPERATION, & MAINTENANCE MANUAL

PART #462255

READ AND SAVE THESE INSTRUCTIONS

INSTALLATION SUPPLEMENT

Refer to the following installation supplement for APEX

units supplied with a Temperature Control Package:

Temperature Control Package, Part #461468

Refer to the following installation supplement for APEX

units supplied with a Greenheck roof curb, Model GKD:

APEX Roof Curb IOM, Part #462831

SAVE THIS MANUAL

This manual is the property of the owner, and is required for future maintenance. This manual should remain with each APEX unit when the job is complete.

Energy recovery wheels certified by the ARI Air-to-Air Energy Recovery Ventilation Equipment Certification Program in accordance with ARI Standard 1060. Actual performance in packaged equipment may vary. Certified Ratings are available in the Certified Product Directory at http://www.ari.org/directories/erv

RECEIVING AND HANDLING

The APEX is thoroughly inspected and test run at the factory. However, damage may occur during shipping and handling. Upon delivery, inspect the unit for both obvious and hidden damage. If damage is found, record all necessary information on the bill of lading and file a claim with the final carrier. In addition, ensure all accessory items are present. Some accessory items are stored inside the unit during shipping.

SAFETY WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read this installation, operation, and maintenance manual thoroughly before installing or servicing this equipment.

WARRANTY

Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the purchase date. The energy recovery wheel is warranted to be free from defects in material and workmanship for a period of five years from the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory, transportation prepaid.

Motors are warranted by the motor manufacturer for a period of one year. Should motors furnished by Greenheck prove defective during this period, they should be returned to the nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . 3

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Unit weights . . . . . . . . . . . . . . . . . . . . . . .4

Recommended roof openings . . . . . . . .4

Roof curb mounting . . . . . . . . . . . . . . . .4

Rail mounting . . . . . . . . . . . . . . . . . . . . . 5

Weatherhoods / Dampers . . . . . . . . . . . 5

Electrical connections . . . . . . . . . . . . . .6

Service Clearances . . . . . . . . . . . . . . . . . 7

Access Locations . . . . . . . . . . . . . . . . . . 7

Dimensional Data . . . . . . . . . . . . . . . . . . .7

Access Door Descriptions . . . . . . . . . . .7

Coil Application Recommendations . . . 8

Water coils . . . . . . . . . . . . . . . . . . . . . . . 8

DX coils . . . . . . . . . . . . . . . . . . . . . . . . . 8

Drain pan trap piping . . . . . . . . . . . . . . . 9

Electric Heater Application/Operation .9

Variable Frequency Drive . . . . . . . . . . . .9

Frost Control Application/Operation . .10 Economizer Application/Operation . . .11

Optional Accessories . . . . . . . . . . . .12-13

Start-Up Checks . . . . . . . . . . . . . . . . . . 14

Fan information . . . . . . . . . . . . . . . . . . 15

Fan belt drives . . . . . . . . . . . . . . . . . . . .16

Fan RPM . . . . . . . . . . . . . . . . . . . . . . . .16

Vibration . . . . . . . . . . . . . . . . . . . . . . . . .17

Energy recovery wheel . . . . . . . . . . . . 17

Routine Maintenance . . . . . . . . . . . . . . 18

Lubrication / Dampers / Belts . . . . . . .18

Motors . . . . . . . . . . . . . . . . . . . . . . . . . .19

Wheel and fasteners . . . . . . . . . . . . . . .19

Bearings . . . . . . . . . . . . . . . . . . . . . . . . .19

Filters / Door Seals . . . . . . . . . . . . . . . 20

Coil Maintenance . . . . . . . . . . . . . . . . . . .21

Maintenance . . . . . . . . . . . . . . . . . . . . .21

Winterizing . . . . . . . . . . . . . . . . . . . . . .21

Energy Recovery Wheel Maintenance 22

Accessing energy recovery wheel . . . .22

Removing wheel segments . . . . . . . . .22

Cleaning wheel segments . . . . . . . . . . .23

Wheel belt / Wheel bearings . . . . . . . .23

Parts List . . . . . . . . . . . . . . . . . . . . . . . . .24

Sequence of Operation . . . . . . . . . . . . .25

Airflow Troubleshooting . . . . . . . . . . . .26

General Troubleshooting . . . . . . . . .27-28

When a unit is not going to be in service for an extended amount of time, certain procedures should be followed to keep the fans in proper operating condition.

• Rotate fan wheel monthly and purge grease from bearings once every three months

• Cover unit with tarp to protect from dirt and moisture (Note: do not use a black tarp as this will promote condensation)

• Energize fan motor once every three months

• Store belts flat to keep them from warping and stretching

• Store unit in location which does not have vibration

• After storage period, purge grease from fan bearings before putting fan into service

If storage of unit is in a humid, dusty or corrosive atmosphere, rotate the fan and purge the bearings once a month. Improper storage which results in damage to the unit or components will void the warranty.

Table of Contents

Storage

The APEX brings in fresh, outdoor air and removes stale, exhaust air. Prior to discharging the exhaust air, the energy recovery wheel transfers energy from the exhaust air to the outdoor air at an efficiency of 70-80%. Simply put, this unit preconditions the outdoor air to save money on heating and cooling costs. This particular unit also has cooling and heating options available after the recovery wheel to further condition the fresh air temperature if desired.

Fresh Outdoor Air

Exhaust Air discharged outside

Exhaust Air from building

Preconditioned Air sent to RTU or AHU

Optional Cooling & Heating Coils

Energy Recovery Wheels

Top View

Side View

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. See Service Clearances for more details.

Lifting

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

2) To assist in determining rigging requirements, weights are shown on next page.

3) Unit must be lifted by the eight lifting lugs provided on base structure.

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

5) Two spreader bars must span the unit to prevent damage to the cabinet by the lift cables.

6) Always test-lift the unit to check for proper balance and rigging before hoisting to desired location.

7) Never lift units by weatherhoods.

8) Never lift units in windy conditions.

9) Preparation of curb and roof openings should be completed prior to lifting unit to the roof.

10) Do not use fork lifts for handling unit.

Lift using lifting lugs and spreader bars

FIGURE 1: Example diagram of lifting the APEX

SAFETY 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.

Installation

Basic Unit Operation

Recommended Roof Openings

Model A B C D

APEX-200 86 44 68.75 44

All dimensions shown are in inches.

FIGURE 2: Recommended roof openings.

Rooftop units require curbs to be mounted first. The duct connections must be located so they will be clear of structural members of the building.

1. Factory Supplied Roof Curbs

Roof curbs are Model GKD, which are shipped in a knockdown kit and require field assembly (by others). Assembly instructions are included with the curb.

2. Cut Roof Opening and Locate Curb

Layout the unit roof openings such that the supply discharge & exhaust inlet of the unit will line up with the corresponding ductwork (refer to Recommended Roof Openings). Do not make openings larger than necessary. Be sure to allow for the recommended service clearances. Keep the supply inlet of the unit away from any other exhaust fans. Likewise, position the exhaust discharge opening away from fresh air intakes of any other equipment.

3. Install Curb

Locate curb over roof opening and fasten in place. Check that the diagonal dimensions are within ±

⁄8 inch of each other and adjust as necessary. Shim as required to level.

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.

5. Duct Work

Installation of all ducts should be done in accordance with SMACNA and AMCA guidelines.

Model L W

APEX-200 283.5 92.0

Roof Curb Mounting

Curb Outside Dimensions

Dimensions shown are in inches.

FIGURE 3: Duct dimensions.

Installation

0.75

6.00

Unit Approx. Weight (lbs)

APEX-200 (without coils) 9,000 APEX-200 (with HW & CW coils) 12,000

Unit Weights (dry weights)

Duct Size: 80 in. x 30 in.

Dimensions based on Greenheck-supplied roof curb only!

FIGURE 4: Roof curb details.

Exhaust

Air

Intake

Outdoor

Air

Discharge

2.50 From Inside Curb To Recommended Roof Opening

IDE OF UNI

1.2

2 IN. INSULATI

ROOF CURB

FIGURE 5: Isometric view of APEX on rails. FIGURE 6: Side view of APEX on rails.

Weatherhoods

Supply weatherhood will be factory mounted. There are two exhaust weather hoods shipped separately as a kit with instructions on how to mount (refer to Page 7 for hood locations).

Dampers

Backdraft dampers are always included as an integral part of the exhaust hood assemblies. Motorized outdoor air and exhaust air dampers are optional and are factory mounted (and wired) at the inlet.

An optional motorized damper is also available for recirculation mode. This damper allows 100% recirculation of exhaust air through the coils for continued tempering of the space during unoccupied mode (i.e. no outdoor air being brought in). This damper is mounted and wired at the factory.

Rail Mounting

Rail Layout

• Rails designed to handle the weight of the APEX should be positioned as shown on the diagrams below (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 APEX unit (see FIGURE 6).

• Rails should run the width of the unit and extend beyond the unit a minimum of 12 inches on each side (see FIGURE 5).

• Set unit on rails.

52.00

UST

aus

Outdoor

ood

Installation

Intak

Exh

t Ai

Discharge Hoo

EXHA

PENIN

160.

DISCHARGE

118.

PPL

PENIN

Electrical Connections

The electrical supply must be compatible with that shown on the nameplate: voltage, phase, and amperage capacity. Connect power to the unit per the unit specific wiring diagram located on the inside of the control center access door. The wiring diagram indicates which electrical accessories were provided on the unit. The electrical supply line must be properly fused and conform to local and national electrical codes.

All internal electrical components are pre-wired at the factory. To determine what specific electrical accessories were provided with the unit, refer to the unit specific wiring diagram located in the unit control center. Field electrical connections required:

1) supply power to the main disconnect (See FIGURE 7, Item #1). A door interlocking safety disconnect is provided as a standard feature.

2) low voltage control power to the 24 VAC control circuit (See FIGURE 7, Item #7). IMPORTANT: Use minimum 14 ga. wire for 24 volt control power. Control wire resistance should not

exceed 0.75 ohms (approximately 285 feet total length for 14 ga. wire; 455 feet total length for 12 ga. wire). If wire resistance exceeds 0.75 ohms, an industrial-style, plug-in relay should be added to the unit control center and wired in place of the remote switch (typically between terminal blocks R and G on the control strip — See FIGURE 7, Item #7). 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.

Control wires should not be run inside the same conduit as that carrying the supply power. The unit must be electrically grounded in accordance with the current National Electrical Code, ANSI/NFPA-70.

Note: Standard factory installed electric pre-heaters and post-heaters have their own disconnect separate

from the unit disconnect. Thus, each electric heater requires its own separate power connection.

1. Main Disconnect

2. Motor Starter — Exhaust Air Fan #1

3. Motor Starter — Exhaust Air Fan #2

4. Motor Starter — Outdoor Air Fan

5. Energy Wheels Motor Contactor

6. Control Power Transformer (24 VAC Secondary)

7. 24 VAC Terminal strip

8. Fuses for the control circuit, wheel drive transformer, and blower motors.

9. Energy Wheel Motor Transformer (230 VAC Secondary - for units with primary voltage greater than 230 VAC) (transformer not shown)

Typical Control Center Components

FIGURE 7: Typical control center components.

SAFETY DANGER!

Electric shock hazard. Can cause injury or

death. All wiring should be performed by a

qualified electrician. 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.

SAFETY CAUTION!

Verify power before wiring the supply and

control voltage. Greenheck is not

responsible for any damage to, or failure of

the unit caused by incorrect field wiring.

Installation

Service Clearances / Access Locations

APEX-200 units require minimum clearances for access on all sides for routine maintenance. Filter replacement, drain pan inspection and cleaning, energy wheel cassette inspection, fan bearing lubrication and belt adjustment, are examples of routine maintenance that must be performed. Blower and motor assemblies, energy recovery wheel cassettes, coil and filter sections are always provided with a service door or panel for proper component access. Clearances for component removal may be greater than the service clearances.

Contact Greenheck for component removal clearance.

FIGURE 8: Clearances for service on APEX-200

Exterior Dimensions

Model

ABCDEFGH*I*

APEX-200 287.75 96.5 92.5 58.75 15.75 31 10.75 24.63 25.125

Dimensional Data / Access Door Descriptions

Installation

Following is a list of items accessible through the access doors shown on the diagram at the left. Some items are optional and may not have been provided.

1) Exhaust blower #1, energy recovery wheel #1 maintenance (segment removal for cleaning)

2) Half of supply filters

3) Exhaust filters (refer to Filter Maintenance). Energy recovery wheel motors, belts, and seals

4) Supply blower, motor, and drives

5) Supply blower and drives

6) Coil drain pan and electric heater

7) Control center, variable frequency drives, and temperature control package

8) Half of supply filters

9) Exhaust blower #2, energy recovery wheel #2 maintenance (segment removal for cleaning)

10) Outdoor air damper, electric preheater, frost control sensors, and economizer sensors

11) Aluminum mesh filters (both sides of hood)

Width (just unit): 96.5

Width (including lifting lugs): 99.875

Overall Width (with exhaust hoods): 146.75

Overall Length (with outdoor air hood): 303.5

(All dimensions shown are in inches.)

* G, H, & I typical both sides of unit

FIGURE 9: Dimensional data and access door locations.

36 in.

29 in.

96 in.

Exhaust

Outdoor Air

Intake Hood

Hood

2 in.

Filters

Wheel Cassettes

Exhaust

Air

Inlet

Coil

Section

Control

Exhaust

Hood

Center

Water Coils

1. Piping should be in accordance with accepted industry standards. Pipework should be supported independently of the coils. Water connections are male N.P.T iron pipe. When installing couplings, do not apply undue stress to the connection extending through the unit. Use a backup pipe wrench to avoid breaking the weld between coil connection and header.

2. Connect the WATER SUPPLY TO THE BOTTOM CONNECTION on the air leaving side and the WATER RETURN TO THE TOP CONNECTION on the air entering side. To ensure proper venting, an external air vent in the piping is recommended. Connecting the supply and/or return in any other manner will result in very poor performance. Be sure to replace factory installed grommets around coil connections if removed for piping. Failure to replace grommets will result in water leakage into the unit and altered performance.

3. The air vent at the uppermost point should be temporarily opened during system start-up to release all of the air from the coil. To maintain heat transfer capacity, periodically vent any air in coil.

4. Water coils are not normally recommended for use with entering air temperatures below 40

F; however, the energy recovery wheel maintains a pre-coil temperature higher than 40oF. No control system can be depended on to be 100% safe against freeze-up with water coils. Glycol solutions or brines are the only safe media for operation of water coils with low entering air temperatures.

CONTINUOUS WATER CIRCULATION THROUGH THE COIL AT ALL TIMES IS HIGHLY RECOMMENDED.

5. Pipe sizes for the system must be selected on the basis of the head (pressure) available from the circulation pump. The velocity should not exceed 6 feet per second and the friction loss should be approximately 3 feet of water column per 100 feet of pipe.

6. For chilled water coils, the condensate drain pipe should be sized adequately to ensure the condensate drains properly. See Drain Pan Traps and FIGURE 11.

Direct Expansion (DX) Coils

1. Piping should be in accordance with accepted industry standards. Pipework should be supported independently of the coils. Undue stress should not be applied at the connection to coil headers.

2. The condensate drain pipe should be sized adequately to ensure the condensate drains properly. See Drain Pan Traps and FIGURE 11.

3. When connecting suction and liquid connections make sure the coil is free from all foreign material. Make sure all joints are tight and free of leakage. Be sure to replace factory installed grommets around coil connections if removed for piping.

4. Greenheck does not supply condensing units; for further instruction on DX coil installation and operation contact your condensing unit manufacturer.

Coil Application Recommendations

Factory installed cooling and heating components are mounted in the coil section of the unit. The coil section is downstream of the energy wheel on the supply air side of the unit.

See FIGURE 10 for coil connection location. Coil connections are located external to the unit as shown. Coil connections that are not external have been ordered from the factory with interior or exhaust airstream coil connections.

Note: DX coil liquid connections are accessible through

access doors shown in FIGURE 10.

FIGURE 10

Water coil

connections

Installation

Water coil

connections

DX coil liquid connection access door

Drain Pan Traps

Drain lines and traps should be run full size or larger from the drain pan connection (drain pan connection is 1.25-inch diameter female thread). Drain pans should have drain lines and traps to permit the condensate from the coils to drain freely. On all units with drain pans, the trap depth and the distance between the trap outlet and the drain pan outlet should be twice the static pressure in the drain pan section under normal operation to assure the trap remains sealed.

Electric Heater Application/Operation

Factory installed electric post-heaters can be provided to warm the air leaving the energy recovery wheel to a user specified discharge temperature. Electric heaters are available in 208, 230, or 460 VAC (refer to heater nameplate for voltage).

Post-heaters are standard as 4-stage, step control. Step control heaters are designed with multiple stages made up of equal increments of heating capability. For example, an 80 kW heater with four stages will be composed of four 20-kW stages. Post-heaters come standard with a discharge temperature sensor (with

field adjustable set point). The four stages will come on one at a time until the discharge temperature set point is satisfied). Post-heaters are not single point wired (see Electrical Connections).

Post-heaters supplied with Greenheck temperature control package are 3-stage with binary control that provides 7 steps of heating. For example, a 35 kW heater with three stages will be composed of 5, 10, and 20 kW stages. The stages essentially ‘mix and match’ to provide heat output from 5 kW to 35 kW, in 5 kW increments.

FIGURE 11: Drain pan trap dimensions.

Installation

Variable Frequency Drive for Fans (E7 Series by Yaskawa)

(see page 13 for VFD on energy recovery wheel)

Factory installed VFDs for the fans are programmed at the factory per the settings shown in TABLE 1 below (see FIGURE 12 for key pad). VFDs are shipped with a jumper between A1 to +V to allow the unit to turn on at full speed until the appropriate control signal can be applied. Remove the jumper when wiring the appropriate .0-10 Vdc control signal. See FIGURE 13. Refer to the instruction manual that ships with the unit when making adjustments. A copy of the manual can be found online at www.drives.com. For technical support, contact Yaskawa direct at 1-800-927-5292.

TABLE 1: Factory settings for VFD used on fans

FIGURE 13: Control signal to VFD

FIGURE 12: VFD key pad & LCD

Parameters Setting Comment A1-01 Access Level 2 Advanced Level A1-04 Password 0 Leave as default b1-01 (Frequency) Ref Source 1 Terminal - Analog Input A1 b1-02 Run (Command) Source 1 Contact Closure on S1 C1-01 Accl Time 1 30 Seconds C1-02 Decel Time 2 30 Seconds d2-01 Ref Upper Limit 100% % of E1-04 d2-02 Ref Lower Limit 50% % of E1-04 E1-04 Max Frequency 60 Hz Ref for d2-01, d2-02, H3-03 E2-01 Motor Rated FLA ? A Nameplate amps H3-02 Terminal A1 Gain 100% 10V = 60 Hz, 100% of E1-04 H3-03 Terminal A1 Bias 50% 0V = 30 Hz, 50% of E1-04 L8-10 Cooling Fan Operation 0 Fan only during RUN O2-03 User Defaults 1 Saves setting as user defaults

Set defaults by A1-03 = 1110

A1-01 Access Level 0 Operation Only

6 in. min.

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