Greenheck Fan HRE-90, HRE-45, HRE-55, HRE-20 User Manual

**WARNING**

DISCONNECT AND SECURE TO THE "OFF" POSITION ALL ELECTRICAL POWER TO THE UNITS

PRIOR TO INSPECTION OR SERVICING. FAILURE TO COMPLY WITH THIS SAFETY PRECAUTION

COULD RESULT IN SERIOUS INJURY OR DEATH.

**IMPORTANT**

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.

PART #461248

READ AND SAVE THESE INSTRUCTIONS

HEAT RECOVERY UNIT

WITH EVAPORATIVE COOLING

Models: HRE-20, 45, 55, & 90

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Indirect Evaporative Cooler

(Exhaust/Scavenger Airstream)

Direct Evaporative Cooler

(Outdoor/Supply Airstream)

GENERAL

Greenheck Energy Recovery units with Tempering are thoroughly inspected and test run at the factory. However, damage may occur during handling and shipping. Consequently, it is important to inspect the unit for visible and concealed damage before beginning installation. Report any damage to the shipper immediately. In addition, assure all accessory items are present. Some accessory items are stored inside the unit during shipping. Care must be taken during installation to prevent damage to units.

TABLE OF CONTENTS

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

Unit Weights . . . . . . . . . . . . . . . . . . . . .3

Recommended Roof Openings . . . . . . .3

Roof Curb Mounting . . . . . . . . . . . . . . .4

Duct Work Connections . . . . . . . . . . . . 4

Weatherhoods . . . . . . . . . . . . . . . . . . . 4

Electrical . . . . . . . . . . . . . . . . . . . . . . . .5

Service Clearances . . . . . . . . . . . . . . . . 6

Evaporative Cooling Modules . . . . . 7-10

Evap Module Start-Up . . . . . . . . . . . . . .7

Water Control Options . . . . . . . . . . . . . .8

Trouble Shooting . . . . . . . . . . . . . . . . . .9

Maintenance . . . . . . . . . . . . . . . . . . . .10

Water Coil Recommendations . . . . . . 11

Electric Heater Application/Operation 12 Frost Control Application/Operation .13

Dirty Filter Switch Operation . . . . . . . .13

Economizer Application/Operation . . .14

Auto Dry Cycle . . . . . . . . . . . . . . . . . . .14

Start Up Checks . . . . . . . . . . . . . . . . . . 15

Fan wheel . . . . . . . . . . . . . . . . . . . . . . 15

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

Energy Recovery Wheel . . . . . . . . . . . 16

Coils . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

Belts . . . . . . . . . . . . . . . . . . . . . . . . . .17

Motors . . . . . . . . . . . . . . . . . . . . . . . . .17

Blower Wheel and Fasteners . . . . . . . .17

Vibration . . . . . . . . . . . . . . . . . . . . . . .18

Filters . . . . . . . . . . . . . . . . . . . . . . . . . 18

Coil Maintenance . . . . . . . . . . . . . . . . .19

Energy Recovery Wheel Maint . . . . . . 20

Accessing Energy Recovery Wheel . . .20

Removing Wheel Segments . . . . . . . .21

Cleaning Wheel Segments . . . . . . . . .21

Parts List . . . . . . . . . . . . . . . . . . . . . . . .22

Unit Trouble Shooting . . . . . . . . . . .23-24

STORAGE

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.

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.

See pages 6 and 7 for more detail on appropriate clearances.

LIFTING

Units must be lifted as it ships from the factory. All units are equipped with lifting lugs. THE USE OF ALL

LIFTING LUGS IS MANDATORY WHEN LIFTING.

Lifting should only be done with all access doors closed to avoid damaging the unit. To prevent damage to the unit cabinetry, use spreader bars. Spreader bars must be in position to stop cables from rubbing the frame or panels. Before hoisting into position, test lift to insure stability and balance. Avoid twisting or uneven lifting of the unit. Never lift units by weatherhoods.

Lift using lifting lugs and spreader bar

FIGURE 1

Unit Size Approx. Weight (lbs)

HRE-20 1500

HRE-45 2300

HRE-55 3000

HRE-90 5000

UNIT WEIGHTS (dry weights)

RECOMMENDED ROOF OPENING

EXHAUST

INLET

SUPPLY

OUTLET

Model U V

HRE-20 46 37

HRE-45 54 39

HRE-55 65 47

HRE-90 85 49

All dimensions shown are in inches.

FIGURE 2

Length of Straight Duct

GOOD

POOR

FIGURE 4

DUCT WORK CONNECTIONS

Examples of good and poor fan-to-duct connections are shown below (See FIGURE 4). 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.

SUPPLY WEATHERHOOD

Supply weatherhood will be factory mounted.

EXHAUST WEATHERHOOD

The exhaust weatherhood is shipped separately as a kit with its own instructions.

EXHAUST DAMPERS

Backdraft dampers for exhaust discharge are mounted in the unit. Motorized dampers are shipped loose (inside HRE) and must be field installed.

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 opening such that the supply discharge & exhaust inlet of the unit will line up with the corresponding ductwork (refer to Recommended Roof Openings on page 3). Be sure to allow for the recommended service clearances. Keep the supply inlet of the unit away from any other exhaust fans.

3. 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. Shim as required to level. Lower unit onto curb by following the LIFTING instructions on page 3 of this manual. Note, roof curbs fit inside the unit base.

4. Install Duct Work

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

Model L W

HRE-20 93 51

HRE-45 100.5 60.63

HRE-55 112.75 71.5

HRE-90 125.75 90.75

ROOF CURB MOUNTING

Curb Outside Dimensions

All dimensions shown are in inches.

FIGURE 3

Main Disconnect

Off

Exhaust

Hood

Control Center

Intake

Hood

INSTALLATION (continued)

ELECTRICAL CONNECTIONS

The electrical supply must be compatible with that shown on the nameplate: voltage, phase, and amperage capacity. 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. Field electrical connections only need to be made inside the unit to the main disconnect (See FIGURE 5, Item #1) and the 24 volt control circuit (See FIGURE 5, Item #7). A door interlocking safety disconnect is provided as standard feature.

Note: Standard factory installed electric post heaters have their own disconnect separate from the unit

disconnect. Thus, electric post heaters require a separate power connection.

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 (between terminal blocks 2 and 3 on the control strip — See FIGURE 5, 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.

1. Main Disconnect

2. Motor Starter — Exhaust/Scavenger Air Fan

3. Motor Starter — Outdoor Air Fan

4. Motor Contactor — Energy Wheel

5. Control Power Transformer (24 VAC Secondary)

6. Energy Wheel Motor Transformer (230 VAC Secondary) (for HRE-20 & HRE-45 units with primary voltage greater than 230 Vac)

7. 24 VAC Terminal strip

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

TYPICAL CONTROL CENTER COMPONENTS

FIGURE 5

Wheel Cassette

2 in. filters

Direct

Evap

Section

Exhaust Air

Intake

Electrical Box

Access Panel

Cassette

Slides Out

52 in.

Clearance with

IG Heater

0 in.

Clearance without

IG Heater

Exhaust

Hood

Outdoor Air Hood

IG Heater

*48 in. **64 in.

36 in.

TOP VIEW

Indirect

Evap

Section

SERVICE CLEARANCES / ACCESS PANEL LOCATIONS for Model HRE

HRE-20, 45, 55, and 90 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 cassette, 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,

refer to FIGURES 6 and 7 below for these dimensions.

FIGURE 6

Wheel Cassette

2 in. filters

Exhaust Air

Intake

Electrical Box

Access Panel

52 in.

Clearance with

IG Heater

0 in.

Clearance without

IG Heater

Exhaust

Hood

Outdoor Air Hood

IG Heater

42 in.

TOP VIEW

Direct

Evap

Section

Indirect

Evap

Section

FIGURE 7

Clearances for service and component removal on HRE-20 and HRE-45

*Clearance for energy wheel removal on HRE-20. **Clearance for energy wheel removal on HRE-45.

Clearances for service on HRE-55 and HRE-90

1. After the energy recovery unit is set in place, run the overflow and drain lines to the exterior fittings on the evaporative cooler (drain & overflow connections at unit are

⁄4

-inch female pipe thread). The supply line can be attached at the downstream side of the evaporative cooler. A manual shut off valve should be mounted in the supply line near the unit for servicing purposes. Also, a trap should be installed in the drain line to prevent sewer gas from being drawn into the unit (see Figure 8).

2. The cooler will be prewired by the factory.

3. Check to make sure that the pump filter is around the pump inlet.

4. Turn the water on and allow the pan to fill up with water. The float should be adjusted to provide 2 inches of water depth in the sump.

5. Saturate the media without any airflow through the unit. A jumper wire is required on the terminal strip to provide power to the evaporative cooler pump (see the wiring diagram for the proper location). This saturation process will break-in the media and minimize the odors associated with the media. The media’s break-in period should be no less than 20 minutes. When the process is complete, remove the jumper wires in the control center.

Note: Evaporative media may foam for a short

period following the initial start-up. Leave the bleed-off valve fully open until the foaming stops.

6. After the media break-in period, the water flow rate over the media needs to be checked. The pumps should provide enough water to saturate the media in 1-3 minutes. If adequate flow rate is not achieved, consult with the factory.

7. The water bleed-off rate will now need to be adjusted. This measurement is 3 to 6 percent of the media flow rate. The recommended flow rate is 1

⁄2 to 2 GPM per square foot of media pad top area (see table at right). After the unit has been installed and running for two weeks the unit should be checked for mineral deposits. If there are deposits, the bleed-off rate needs to be increased. Some areas of the country have water with greater amounts of dissolved minerals requiring a higher bleed-off rate.

8. Verify that both airflow and system static pressure are in agreement with the specifications. If these conditions are met, check for water carry over from the discharge side of the media. If carry over is observed, check the distribution header for

holes or tears and the water standoff tube for blockage.

9. After all final adjustments are made, remove the jumper wires and replace all access panels. The unit is now ready for operation.

It is important to mount the heat recovery unit level to ensure proper operation and water drainage. Piping should be of adequate size to provide sufficient supply of water to meet the maximum demand of the evaporative coolers.

Evap Module Start-Up

Evaporative Cooling Modules

Roof Curb

Roof Line

Drain

Line

Trap

Overflow

Drain Line

Manual Shutoff

Valve

Evaporative

Cooling

Media

Manual Shutoff Valve

Supply Line

Sump

Side of HRE Unit

Indirect Evaporative Cooler

(Exhaust/Scavenger Airstream)

Direct Evaporative Cooler

(Outdoor/Supply Airstream)

FIGURE 8

Unit Size Media Pad Top Area

HRE-20 1.5 ft

HRE-45 2 ft

HRE-55 2.5 ft

HRE-90 3.3 ft

Auto Drain and Fill with Freeze Protection

This system will automatically drain the sump tank and fill it with fresh water at the field adjustable intervals, typically once every 24 hours. This flushes mineral build-up and debris from the tank to promote low maintenance and increase media pad life. In addition, the system will protect the evaporative cooler from freezing by draining the sump tank and supply line when the outside temperatures fall below the set point of the outside air sensor. Typically, this is set at 45º to 50º F. The auto drain and fill control box should be installed in an area that is shaded from direct sunlight so the outside air sensor probe will detect an accurate air temperature.

Plumbing (see FIGURE 9)

1. Run water supply line to the unit and install Water Supply Solenoid Valve (A) in this line as close to the water source as possible.

2. Install Drain Solenoid Valve (B) in the supply line as indicated below. From the outlet on the drain valve, run line to a suitable drain location.

3. Run an unobstructed drain line from the sump overflow to the drain as shown below.

4. Install Sump Drain Solenoid Valve (C) in the drain line from the sump as indicated below. From the outlet on this drain valve, run a line to a suitable drain location.

Note: Water Supply Solenoid Valve

(A) is not the same as the Drain Solenoid valves (B) and (C). Make sure to use the proper valve for each location. Check your local code requirements for proper installation of this type of system. Additional drain and supply plumbing may be needed to meet your local code.

Caution: All solenoid valves A, B, and C must be installed below the roof to protect the supply water line from freezing. If these valves cannot be installed below the roof, an alternate method must be used to protect these lines from freezing.

WATER CONTROL OPTIONS FOR EVAPORATIVE COOLING

Side of HRE Unit

Sump Drain Pipe

Sump Overflow Pipe

Sump Drain

Solenoid Valve (C)

Trap

Drain Solenoid Valve (B)

Evaporative

Cooling

Media

Sump

Roof Curb

Roof Line

Water Supply

Solenoid Valve (A)

Supply Line

Drain

Line

+ 16 hidden pages