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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 APEX
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,
including environmental. 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 fan wheel faster than maximum
cataloged fan RPM. Adjustments to fan speed
significantly 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.
®
Energy Recovery Ventilator
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 may be equipped with a compressed
refrigerant system. If a leak in the system should
occur, immediately evacuate and ventilate 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.
Model APEX Energy Recovery Ventilator
Document 462255
APEX
1
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Summary of Contents for Greenheck APEX Series
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Page 1: General Safety Information
Document 462255 Energy Recovery Ventilator APEX ® 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. -
Page 2: Table Of Contents
Table of Contents Routine Maintenance General Safety Information . . . . . . . . . . . . . . . . . . .1 Receiving, Handling and Storage . -
Page 3: Receiving, Handling And Storage
Receiving The unit should be stored at least 3½ in. (89 mm) off the floor on wooden blocks covered with moisture proof Upon receiving the product check to make sure all items paper or polyethylene sheathing. Aisles between parts are accounted for by referencing the bill of lading to and along all walls should be provided to permit air ensure all items were received. -
Page 4: Product Overview
Product Overview Electric Post-Heaters The optional post-heater is used as a heat source for The unit brings in fresh, outdoor air and removes the building and is integrated into the supply airstream. stale, exhaust air. Prior to discharging the exhaust air, A temperature sensor (with a field-adjustable set point) the energy recovery wheel transfers energy from the is mounted in the supply airstream after the post-heater... -
Page 5: Service Clearances And Access Locations
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. -
Page 6: Handling
Handling Roof Curb Mounting While this unit was constructed with quality and Rooftop units require curbs to be mounted first. The dependability in mind, damage still may occur during duct connections must be located so they will be clear handling of the unit for installation. of structural members of the building. -
Page 7: Rail Mounting/Layout
POOR GOOD POOR GOOD Rail Mounting / Layout Ductwork Connections 1. Rails designed to handle the weight of the unit Examples of poor and good fan-to-duct connections should be positioned as shown on the diagram (rails are shown. Airflow out of the fan should by others). -
Page 8: Electrical Installation
Electrical Installation 2. Determine the Size of Electric Heater Wiring An optional electric heater may require a separate power supply. The power connection should WARNING be made to the factory-provided electric heater The roof lining contains high voltage wiring. To prevent disconnect and must be compatible with the ratings electrocution, do not puncture the interior or exterior on the nameplate, supply power voltage, phase and... -
Page 9: Typical Control Center Components
On/Off/Auto Switch & Indictor Light Wiring Typical Control Center Components ON/OFF/AUTO SWITCH & INDICATOR LIGHT WIRING 1. Main Disconnect TERMINAL BLOCKS IN UNIT CONTROL CENTER 2. Motor Starter - Exhaust Air Fan #1 3. Motor Starter - Exhaust Air Fan #2 4. -
Page 10: Piping Installation Optional Coil Piping
Piping Installation Direct Expansion (DX) Coils (Split DX) 1. Piping should be in accordance with accepted Optional Coil Piping industry standards. Pipework should be supported Factory-installed cooling and heating components are independently of the coils. Undue stress should not mounted in the coil section of the unit. The coil section be applied at the connection to coil headers. -
Page 11: Unit Overview
Unit Overview Optional Component Overview Basic Unit Economizer The unit is pre-wired such that when a call for outside The energy wheel operation can be altered to take air is made (via field-supplied 24 VAC control signal advantage of economizer operation (free cooling). wired to unit control center), the supply fan, exhaust fan, Two modes are available: and energy wheel are energized and optional motorized... -
Page 12: Frost Control
Frost Control mounted in the return air intake. Follow instructions supplied with sensor for installation and wiring details. Extremely cold outdoor air temperatures can cause Rotation Sensor moisture condensation and frosting on the energy recovery wheel. Frost control is an optional feature that The rotation sensor monitors energy wheel rotation. -
Page 13: Start-Up
Start-Up Unit Start-Up Procedure The unit will be in operational mode during start-up. Use DANGER necessary precautions to avoid injury. All data must be collected while the unit is running. In order to measure Electric shock hazard. Can cause injury or death. volts and amps, the control center door needs to be Before attempting to perform any service or open and the unit energized. -
Page 14: Pre-Start-Up Checklist
Pre-Start-Up Checklist Every installation requires a comprehensive start-up Disconnect and lock-out all power switches. to ensure proper operation of the unit. As part of that Remove any foreign objects that are located in the process, the following checklist must be completed and energy recovery unit. -
Page 15: Optional Accessories Checklist
Optional Accessories Checklist Refer to the respective sections in this Installation, Operation and Maintenance Manual for detailed information. Refer to wiring diagram in unit control center to determine what electrical accessories were provided. Factory Default Frost Control Application / Operation Section: Setting 5ºF Frost Control set point... -
Page 16: Components Start-Up
Components Start-Up Push the wheel cassette back into the unit and plug in the power connector. Turn the main power supply Energy Wheel back on and then observe the operation of the wheel by opening the wheel access door slightly. Remove filters if The energy wheel is installed in the unit’s airstream with necessary to observe the wheel. -
Page 17: Vibration
Fan RPM Tighten all fasteners and set screws securely and realign drive pulleys after adjustment. Check pulleys and belts Supply fan and exhaust fan will have an adjustable for proper alignment to avoid unnecessary belt wear, motor pulley (on 15 HP and below) preset at the factory noise, vibration and power loss. -
Page 18: Optional Components Start-Up
Optional Components Start-Up Economizer Dirty Filter Switch Relevant Set Points To adjust the switch, the unit must be running with all of the access doors in place, except for the 1. MAT SET The mixed air temperature set point after compartment where the switch is located (exhaust the energy wheel. -
Page 19: Frost Control
Frost Control MODULATE WHEEL STOP WHEEL Timed Exhaust OA/RA OA/RA Temp Temp 1. Remove power from unit. Temp Enthalpy Temp Enthalpy Differential Differential 2. Jumper the frost indicating wheel pressure switch in DRYBLB SET the unit control center. MAT SET 3. -
Page 20: Variable Frequency Drives
RIVE SPEED = 40 Hz. DRIVE SPEED = 40 Hz. DRIVE SPEED = 40 Hz. at Greenheck. This option is not available on the J1000. TO SC CONTACT CLOSED (BY OTHERS) S5 TO SC CONTACT CLOSED (BY OTHERS) RIVE SPEED = 30 Hz. - Page 21 Modulating Control for Fan Speed Proportional Control (0-10 VDC) Setting Setting Parameter Parameter V1000 J1000 V1000 J1000 A1-01 Access Level B1-17 VFD Start-Up Setting B1-17 VFD Start-Up Setting C6-02 Carrier Frequency C6-02 Carrier Frequency D2-02 Ref Lower Limit D2-02 Ref Lower Limit E2-01 Motor Rated FLA Analog Frequency Reference...
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Page 22: Routine Maintenance
Routine Maintenance 1. Lubrication Apply lubricant where required DANGER 2. Dampers Check for unobstructed operation Electric shock hazard. Can cause injury or death. Before attempting to perform any service or 3. Blower Wheel and Fasteners maintenance, turn the electrical power to the unit to Check for cleanliness OFF at disconnect switch(es). -
Page 23: Fan Motors
each belt is on the same side of the drive. Belt dressing Shaft bearings are the most critical moving part of a should never be used. fan. Therefore, special attention should be given to keeping the bearings clean and well lubricated. Proper Do not install new belts on worn sheaves. -
Page 24: Coils
Coils Door Seals Coils must be cleaned to maintain maximum Slip-on type vinyl seal is installed on the perimeter of performance. Check coils once per year under normal the door openings. Seal should be inspected at least operating conditions and if dirty, brush or vacuum clean. annually to ensure that seal is still pliable and intact. -
Page 25: Energy Wheel
Energy Wheel Maintenance Cleaning WARNING Maintenance or cleaning of the wheel segments Whenever performing maintenance or inspections, should be done with the segments removed from always disconnect the power source. the wheel cassette to avoid splashing liquids or cleaning agents inside the cabinet. If the energy wheel Inspection appears excessively dirty, it should be cleaned to The wheel should be inspected semiannually in... -
Page 26: Troubleshooting Unit
Troubleshooting – Unit Symptom Possible Cause Corrective Action Blown fuse or open circuit breaker. Replace fuse or reset circuit breaker and check amps. Defective motor or capacitor. Replace. Blower fails to Motor overloaded. Reset VFD and check amps. operate Check for On/Off switches. Check for correct supply voltage. Electrical. -
Page 27: Energy Wheel
Troubleshooting - Energy Wheel Symptom Possible Cause Corrective Action Refer to Adjust the Air Seals found in the Components Start- Air seals are too tight. Up section. Energy wheel does NOT turn Broken belt. Replace. No power to wheel motor. Make sure wheel drive is plugged in. -
Page 28: Maintenance Log
_________________________________________________ _________________________________________________ Our Commitment As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications without notice. Specific Greenheck product warranties are located on greenheck.com within the product area tabs and in the Library under Warranties.
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