Greenheck Fan Ventilation Hood APEX 200 User Manual

PART #462255  
READ AND SAVE THESE INSTRUCTIONS  
Energy Recovery Ventilator  
®
Model:  
APEX-200  
INSTALLATION, OPERATION, & MAINTENANCE MANUAL  
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  
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.  
INSTALLATION SUPPLEMENT  
SAVE THIS MANUAL  
Refer to the following installation supplement for APEX  
units supplied with a Temperature Control Package:  
Temperature Control Package, Part #461468  
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.  
Refer to the following installation supplement for APEX  
units supplied with a Greenheck roof curb, Model GKD:  
APEX Roof Curb IOM, Part #462831  
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Basic Unit Operation  
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  
Energy Recovery Wheels  
Exhaust Air  
discharged outside  
Top View  
Fresh  
Outdoor Air  
efficiency of 70-80%.  
Simply put, this unit  
preconditions the  
Exhaust Air  
discharged outside  
Optional Cooling &  
Heating Coils  
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.  
Side View  
Fresh  
Outdoor Air  
Preconditioned Air  
sent to RTU or AHU  
Exhaust Air  
from building  
Installation  
The system design and installation should follow  
accepted industry practice, such as described in the  
ASHRAE Handbook.  
SAFETY WARNING  
All factory provided lifting lugs must be used  
when lifting the units. Failure to comply with  
this safety precaution could result in  
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.  
property damage, serious injury, or death.  
Lift using lifting lugs  
and spreader bars  
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.  
FIGURE 1: Example diagram of lifting the APEX  
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Installation  
Unit Weights (dry weights)  
Unit  
Approx. Weight (lbs)  
APEX-200 (without coils)  
9,000  
APEX-200 (with HW & CW coils)  
12,000  
Recommended Roof Openings  
Model  
A
B
C
D
APEX-200  
86  
44  
68.75  
44  
Exhaust  
Air  
Intake  
Outdoor  
Air  
Discharge  
A
All dimensions shown are in inches.  
W
Curb Outside Dimensions  
Model  
L
W
C
D
L
B
2.50  
From Inside Curb  
To Recommended  
Roof Opening  
APEX-200 283.5  
92.0  
FIGURE 2: Recommended roof openings.  
Dimensions shown are in inches.  
Roof Curb Mounting  
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  
Duct Size:  
80 in. x 30 in.  
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.  
FIGURE 3: Duct dimensions.  
3. Install Curb  
Locate curb over roof opening and fasten in place.  
Check that the diagonal dimensions are within ±18  
inch of each other and adjust as necessary. Shim as  
required to level.  
BASE  
SIDE OF UNIT  
2.00  
4. Set the Unit  
6.00  
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.  
2.00  
2 IN. INSULATION  
1.25  
0.75  
5. Duct Work  
ROOF CURB  
Installation of all ducts should be done in  
accordance with SMACNA and AMCA guidelines.  
FIGURE 4: Roof curb details.  
Dimensions based on Greenheck-supplied roof curb only!  
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Installation  
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.  
Outdoor  
Air  
Intake  
Hood  
Exhaust Air  
Discharge Hood  
EXHAUST  
SUPPLY  
INLET  
OPENING  
DISCHARGE  
OPENING  
7.00  
52.00  
118.00  
160.00  
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.  
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Installation  
Electrical Connections  
SAFETY DANGER!  
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.  
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.  
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  
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.  
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.  
Typical Control Center Components  
1. Main Disconnect  
9. Energy Wheel Motor Transformer (230 VAC  
Secondary - for units with primary voltage  
greater than 230 VAC) (transformer not shown)  
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)  
1
7. 24 VAC Terminal strip  
8. Fuses for the control circuit, wheel drive  
transformer, and blower motors.  
6
8
7
5
3
2
4
FIGURE 7: Typical control center components.  
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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.  
Exhaust  
H ood  
36 in.  
Outdoor Air  
Intake H ood  
29 in.  
Exhaust  
Air  
Inlet  
Coil  
Sec tion  
2 in.  
Filters  
W heel Cassettes  
96 in.  
Control  
Center  
36 in.  
Exhaust  
H ood  
FIGURE 8: Clearances for service on APEX-200  
Dimensional Data / Access Door Descriptions  
Exterior Dimensions  
Model  
A
B
C
D
E
F
G
H*  
I*  
APEX-200 287.75 96.5  
92.5 58.75 15.75  
31  
10.75 24.63 25.125  
Width (just unit): 96.5  
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  
Width (including lifting lugs):  
Overall Width (with exhaust hoods):  
Overall Length (with outdoor air hood):  
99.875  
146.75  
303.5  
(All dimensions shown are in inches.)  
3) Exhaust filters (refer to Filter Maintenance).  
Energy recovery wheel motors, belts, and seals  
4) Supply blower, motor, and drives  
4
5
C
5) Supply blower and drives  
6) Coil drain pan and electric heater  
2
3
E
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)  
7
1
6
8
D
10  
I
11  
9
F
H
A
B
G
* G, H, & I typical both sides of unit  
FIGURE 9: Dimensional data and access door locations.  
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Installation  
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.  
Water coil  
connections  
DX coil liquid  
connection  
access door  
Note: DX coil liquid connections are accessible through  
access doors shown in FIGURE 10.  
Water Coils  
Water coil  
connections  
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.  
FIGURE 10  
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 40oF; 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.  
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Installation  
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.  
6 in. min.  
6 in. min.  
FIGURE 11: Drain pan trap dimensions.  
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).  
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  
Post-heaters are standard as 4-stage, step control.  
Step control heaters are designed with multiple stages provides 7 steps of heating. For example, a 35 kW  
made up of equal increments of heating capability. For heater with three stages will be composed of 5, 10,  
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  
and 20 kW stages. The stages essentially ‘mix and  
match’ to provide heat output from 5 kW to 35 kW, in  
5 kW increments.  
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  
technical support, contact Yaskawa direct at 1-800-927-5292.  
Parameters  
Setting Comment  
A1-01 Access Level  
2
0
Advanced Level  
A1-04 Password  
Leave as default  
Terminal - Analog Input A1  
Contact Closure on S1  
Seconds  
FIGURE 12: VFD key pad & LCD  
b1-01 (Frequency) Ref Source  
b1-02 Run (Command) Source  
C1-01 Accl Time 1  
1
1
30  
30  
C1-02 Decel Time 2  
Seconds  
d2-01 Ref Upper Limit  
d2-02 Ref Lower Limit  
E1-04 Max Frequency  
E2-01 Motor Rated FLA  
H3-02 Terminal A1 Gain  
H3-03 Terminal A1 Bias  
L8-10 Cooling Fan Operation  
O2-03 User Defaults  
100% % of E1-04  
50% % of E1-04  
60 Hz Ref for d2-01, d2-02, H3-03  
? A Nameplate amps  
100% 10V = 60 Hz, 100% of E1-04  
50% 0V = 30 Hz, 50% of E1-04  
0
1
Fan only during RUN  
Saves setting as user defaults  
Set defaults by A1-03 = 1110  
Operation Only  
FIGURE 13: Control signal to VFD  
A1-01 Access Level  
0
TABLE 1: Factory settings for VFD used on fans  
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Installation  
Frost Control Application/Operation  
Extremely cold outdoor air temperatures can cause moisture condensation and frosting on the energy recovery  
wheel. Frost control is an optional feature that will prevent/control wheel frosting. Three options are available:  
1) Timed Exhaust frost control  
2) Electric preheat frost control  
3) Modulating wheel frost control  
Indoor RH @ 70°F  
Frost Threshold Temp  
20%  
30%  
40%  
-10°F  
-5°F  
0°F  
All of these options are provided with a thermostat (with  
probe) mounted in the supply air inlet compartment (see  
FIGURE 15) and a pressure sensor to monitor pressure drop  
TABLE 2: Frost threshold temperatures  
across the wheel. The typical temperature setting corresponds to the indoor air relative humidity as shown in  
Table 2 and represents when frost can occur. An increase in pressure drop would indicate that frost is  
occurring. Both the pressure sensor AND the outdoor air temperature sensor must trigger in order to initiate  
frost control. The two sensors together insure that frost control is only initiated during a real frost condition. The  
following explains the three options in more detail.  
Timed exhaust frost control includes a timer in addition to the thermostat and  
pressure sensor. When timed exhaust frost control is initiated, the timer will turn the  
supply blower on and off to allow the warm exhaust air to defrost the energy recovery  
wheel. Default factory settings are 5 minutes off and 30 minutes on. Use the following  
test procedure for troubleshooting.  
A1  
B1  
15  
0.8 0.6  
1.0 0.4  
0.2  
Dip  
Switch  
0
T2  
1 MIN T2  
Timer  
Scale  
Testing (refer to FIGURE 14)  
1 MIN T1  
• Jumper the pressure switch. Set the Timer Scale for T1 and T2 to 1  
minute. Set the Timer Settings for T1 and T2 to 1.0. Set the dip switch to  
the down position.  
0.8 0.6  
1.0 0.4  
0.2  
0
T1  
16  
18  
A2  
Turn the temperature sensor up as high as possible. The supply blower  
should cycle on for one minute, then turn off for one minute.  
• After testing, set the Timer Scale as follows: T1 = 10 minutes, T2 = 1 hour  
• Set the Timer Settings as follows: T1 = 0.5, T2 = 0.5. The timer is now set  
for 5 minutes off and 30 minutes on. Remember to remove the jumper.  
FIGURE 14  
Electric preheat frost control includes an electric heater (outdoor air inlet) and an air pressure switch  
(outdoor air outlet) in addition to the thermostat and pressure sensor on wheel. When electric preheat frost  
control is initiated, the electric pre-heater will turn on and warm the air entering the energy wheel to avoid  
frosting. Use the following test procedure for troubleshooting.  
Testing  
Turn the thermostat as high as it will go and jumper the wheel pressure  
sensor. The heater should turn on.  
• If it doesn’t, either put the supply side doors on or temporarily jumper the  
air pressure switch to avoid nuisance tripping of the pressure switch.  
Remember to remove the jumpers.  
Modulating wheel frost control includes a variable frequency drive in addition to the thermostat and pressure  
sensor. When modulating wheel frost control is initiated, the variable frequency drive will reduce the speed of  
the wheel. Reducing the speed of the energy wheel reduces its effectiveness, which keeps the exhaust air  
condition from reaching saturation, thus, eliminating condensation and frosting. If the outdoor air temperature is  
greater than the frost threshold temperature OR the pressure differential is less than the set point, the wheel will  
run at full speed. If the outdoor air temperature is less than the frost threshold temperature AND the pressure  
differential is greater than the set point, the wheel will run at minimum speed until the pressure differential falls  
below the set point. The temperature and pressure differential set points are set at the factory, but are field-  
adjustable. The variable frequency drive will be fully programmed at the factory.  
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Installation  
Economizer Application/Operation  
The energy recovery wheel operation can be altered to take advantage of economizer operation (free cooling).  
Two modes are available: 1) De-energizing the wheel or 2) Modulating the wheel.  
De-energizing the wheel is accomplished with a signal from a Temperature or Enthalpy sensor mounted in  
the supply air inlet compartment (see FIGURE 15). This Primary sensor will de-energize the energy wheel when  
the outdoor air temperature (factory default is 65°F) or enthalpy (factory default is the ‘D’ setting) is below the  
field adjustable set point. An Override temperature sensor is also furnished in the supply air inlet compartment  
to deactivate economizer mode (see FIGURE 15). The Override (with field adjustable set point) is set at some  
temperature lower than the Primary sensor (factory default is 50°F). Effectively, the two sensors create a  
deadband where the energy recovery wheel will not operate and free cooling from outside can be brought into  
the building unconditioned.  
Testing (terminals referenced below are in the unit control center — see FIGURE 7, Item #7)  
Temperature sensor with Override  
FIGURE 15  
Turn both Temperature and Override thermostats down  
as low as they go. The wheel should be rotating.  
Turn the Temperature sensor up as high as it goes, and  
keep the Override sensor as low as it will go. The wheel  
should stop rotating.  
Enthalpy Sensor  
(Primary Sensor)  
Timed Exhaust  
Frost Control  
Turn both sensors as high as they will go. The wheel  
should start rotating.  
Override  
• Set the Temperature sensor at desired point for  
economizer operation to begin. Set the Override sensor  
at desired point for economizer operation to end  
(factory default is 65°F and 50°F, respectively).  
Probes  
Enthalpy sensor with Override  
• A factory-installed 620 ohm resistor is connected across terminals SR and +. The Override sensor  
should be turned down below current temperature in unit. Turn the unit on; LED on the sensor should  
be off. Confirm continuity across terminals 1 and 2 and no continuity across terminals 2 and 3.  
• Disconnect the 620 ohm resistor from terminals SR and +. LED should turn on. Confirm continuity  
across terminals 2 and 3 and no continuity across terminals 1 and 2.  
Turn Override sensor above current temperature in unit. Confirm continuity across terminals 3 and 6.  
Set the Override sensor to the desired point for economizer operation to end (factory default is 50°F).  
• Reconnect the factory-installed jumper.  
Modulating the Wheel  
In applications in which an internal heat gain is present in the space, the rotational speed of the energy wheel  
may be modulated (via variable frequency drive) to avoid overheating the space during the winter. The speed of  
the energy wheel will be controlled in response to the discharge temperature set point.  
Sequence of Operation: The variable frequency drive is fully programmed at the factory. A call for cool’ must  
be field wired to the unit (terminals provided in unit - refer to wiring diagram in unit control center) to allow for  
initiation of economizer mode. When the space calls for cooling, factory supplied controls will drive the  
following wheel operations:  
TOA > TRA  
TOA < TRA and TOA > TSA  
TOA < TRA and TOA < TSA  
:
:
:
Wheel runs at full speed (maximum energy recovery)  
Wheel is stopped (no energy recovery)  
Wheel will modulate to maintain discharge temperature  
where (TOA) is the outdoor air temperature set point, (TRA) is the return air temperature set point, and (TSA) is the  
supply air discharge thermostat set point (nominal 60°F – not adjustable).  
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Optional Accessories  
Rotation Sensor  
The rotation sensor monitors energy recovery wheel rotation. If the wheel should stop rotating, the sensor will  
close a set of contacts in the unit control center. Field wiring of a light (or other alarm) to these contacts will  
notify maintenance personnel when a failure has occurred.  
Dirty Filter Sensor  
Dirty filter sensors monitor pressure drop across the outdoor air filters, exhaust air filters, or both. If the  
pressure drop across the filters exceeds the set point (set at factory), the sensor will close a set of contacts in  
the unit control center. Field wiring of a light (or other alarm) to these contacts will notify maintenance  
personnel when filters need to be replaced.  
Temperature Control Package  
Temperature control package allows for stand-alone operation  
of energy recovery units provided with supplemental cooling  
and heating. Controller can be ordered for discharge or room  
control. Room control would require a room thermostat (or  
other call for heat) be wired to the controller. A remote panel  
option is also available to allow set points and other controller  
parameters to be adjusted from a remote location. For  
additional information, refer to the following documents:  
Catalog: Temperature Control Package  
IOM: Temperature Control Package, Part #461468  
CO2 Sensor  
This accessory is often used to provide a modulating control signal to a variable frequency drive to raise and  
lower airflow in relationship to the CO2 levels in the space. This strategy is often referred to as Demand Control  
Ventilation and provides further energy savings to the system.  
Service Outlet  
120 VAC GFCI service outlet ships loose for field installation.  
Requires separate power source so power is available when unit  
main disconnect is turned off for servicing.  
Vapor Tight Lights  
Vapor tight lights provide light to each of the  
compartments in the energy recovery unit. The  
lights are wired to a switch mounted on the  
outside of the unit. The switch requires a separate  
power source to allow for power to the lights  
when the unit main disconnect is off for servicing.  
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Optional Accessories  
Remote Control Panel  
The remote panel is a series of junction boxes ganged together  
and includes a stainless steel face plate. The remote panel is  
available with a number of different alarm lights and switches to  
control the unit. The remote panel ships loose and requires  
mounting and wiring in the field. Refer to “Remote Panel Wiring  
Schematics” (Part #461368) for instructions on wiring the remote  
panel to the 24 VAC terminal strip in the energy recovery unit  
control center.  
The remote panel is available with the following options:  
1) Unit on/off switch  
2) Unit on/off light  
3) 7-day time clock  
4) Hand/off/auto switch  
5) Time delay override  
6) Exhaust air dirty filter light  
7) Outdoor air dirty filter light  
8) Economizer light  
9) Frost control light  
10) Wheel rotation sensor light  
Variable Frequency Drive for Energy Recovery Wheel (GPD-305 Series by Yaskawa)  
Factory installed VFD for the energy recovery wheel are  
programmed at the factory per the settings shown in TABLE 4  
below. Refer to the instruction manual that ships with the unit  
when making adjustments. A copy of the manual can be found  
direct at 1-800-927-5292.  
Parameters  
Setting Comment  
n01  
n02  
n03  
n09  
n16  
n17  
n29  
n30  
n31  
n32  
n36  
n40  
n41  
n42  
n58  
n01  
Access Level  
1
1
n01 - n79 can be read or set  
Operation Method  
Reference Selection  
Max Frequency  
Accl Time 1  
Terminal  
2
0-10 Vdc (mod. wheel econ.)  
60 Hz  
10  
Seconds  
Seconds  
Decel Time 2  
10  
VFD key pad & LCD  
Jog Frequency  
6 Hz  
Ref Upper Limit  
Ref Lower Limit  
Motor Rated FLA  
Multi-Function Input  
Frequency Detection  
Analog Freq. Ref. Gain  
Analog Freq. Ref. Bias  
Freq. Dectection Level  
Access Level  
100% % of n09  
0% % of n09  
? A  
10  
4
0
99  
Inverse acting  
Inverse acting  
5.9 Hz  
0
n01 read or set; n02-n79 read  
TABLE 4: Factory settings for VFD used on energy recovery wheel  
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Unit Start-Up  
SAFETY CAUTION!  
SAFETY DANGER!  
Use caution when removing access panels or other  
unit components, especially while standing on a  
ladder or other potentially unsteady base. Access  
panels and unit components can be heavy and  
serious injury may occur.  
Electric shock hazard. Can cause injury or death.  
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!  
Do not operate energy recovery ventilator without the  
filters and birdscreens installed. They prevent the entry  
of foreign objects such as leaves, birds, etc.  
For proper unit function and safety, follow everything in this start-up procedure in the order presented. Perform  
procedure after the electrical connections are complete.  
Pre-Start Check List  
1. Disconnect and lock-out all power switches.  
2. Remove any foreign objects that are located in the energy recovery unit.  
3. Check all fasteners, set screws, and locking collars on the fans, bearings, drives, motor bases and  
accessories for tightness.  
4. Rotate the fan wheels and energy recovery wheels by hand and ensure no parts are rubbing. If rubbing  
occurs, refer to the following Fan or Energy Recovery Wheel section.  
5. Check the fan belt drives for proper alignment and tension (see following Fan Belt section).  
6. Filters can load up with dirt during construction. Replace any dirty pleated filters and clean the  
aluminum mesh filters in the intake hood (refer to Routine Maintenance section).  
7. Verify that dampers open and close properly.  
Special Tools Required  
Voltage meter  
• Amperage meter (with wire probes)  
• Incline manometer or equivalent  
Tachometer  
• Thermometer  
Energy Recovery Wheel  
(2 per unit)  
Refer to Page 3 for Airflow Diagram  
Outdoor Air Pleated Filters  
(both sides of unit)  
*Motorized Outdoor Air  
Intake Damper Location  
Outdoor Air Intake Hood  
(contains aluminum  
mesh filters)  
Plenum  
Supply Fan  
Forward Curved Exhaust Fan  
(one on each side of unit)  
Exhaust Air Pleated Filters  
(access inside unit)  
*Coil Section  
(connections this  
side or internal)  
*Motorized Exhaust Air Intake Damper Location  
(integral backdraft damper in exhaust hoods)  
*Indicates an optional accessory.  
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Unit Start-Up  
Supply Fan (Plenum Type)  
The APEX-200 contains one plenum supply fan located on the end of the  
unit opposite the outdoor air intake (see beginning of Unit Start-Up section  
for diagram of unit layout). Efficient fan performance can be maintained by  
having the correct radial gap and overlap. These items should be checked  
before start-up and after the fan has been in operation for 24 hours.  
Radial Gap: Radial gap is  
adjusted by loosening the inlet  
Overlap  
cone/ring on the wheel. If  
additional adjustment is required  
to maintain a constant radial gap,  
loosening the bearing bolts and  
centering the wheel is acceptable  
as a secondary option.  
A
Overlap: Proper overlap is  
obtained by loosening the wheel  
hub from the shaft and adjusting  
Radial  
Gap  
the wheel to maintain an ‘A’  
FIGURE 16: Radial gap  
3
dimension of 11716 ± 8 inches  
and overlap  
(see FIGURE 16).  
Spring Vibration Isolators on Supply Fan  
Three to four Z-brackets prevent unwanted fan and isolator movement  
during shipping. Proper unit operation requires the removal of these  
brackets.  
1. Remove the 5/16 in. hex head bolts from each Z-bracket and fan base.  
2. Pull Z-bracket out from the fan base.  
3. Replace the bolts to their original position in the fan base.  
Exhaust Fans (Forward Curved Type)  
The APEX-200 contains two forward curved exhaust fans located on  
either side of the unit (see Basic Unit Operation). These forward curved  
fans should be checked for free rotation. If any binding occurs, check  
for concealed damage and foreign objects in the fan housing. Be sure  
to check the belt drives per the start-up recommendations in the  
following section.  
Fan Performance Modifications  
Due to job specification revisions, it may be necessary to  
adjust or change the sheave or pulley to obtain the desired  
airflow at the time of installation. Start-up technician must  
check blower amperage to ensure that the amperage listed  
on the motor nameplate is not exceeded. Amperage to be  
tested with access doors closed and ductwork installed.  
SAFETY CAUTION!  
When operating conditions of the fan are to be  
changed (speed, pressure, temperature, etc.),  
consult Greenheck to determine if the unit can  
operate safely at the new conditions.  
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Unit Start-Up  
Fan Belt Drives  
The fan belt drive components, when supplied by Greenheck Fan Corporation, have been carefully selected for  
the unit's specific operating condition. Caution: utilizing different components than those supplied could result in  
unsafe operating conditions which may cause personal injury or failure of the following components: 1) Fan  
Shaft, 2) Fan Wheel, 3) Bearings, 4) Belt, 5) Motor. Tighten all fasteners and set screws securely and realign drive  
pulleys after adjustment. Check pulleys and belts for proper alignment to avoid unnecessary belt wear, noise,  
vibration and power loss. Motor and drive shafts must be parallel and pulleys in line (see FIGURES 17 & 18).  
Belt Drive Installation  
1. Remove the protective coating from the end of the fan shaft and ensure  
that it is free of nicks and burrs.  
2. Check fan and motor shafts for parallel and angular alignment.  
3. Slide sheaves on shafts - do not drive sheaves on as this may result in  
bearing damage.  
4. Align fan and motor sheaves with a straight-edge or string and tighten.  
5. Place belts over sheaves. Do not pry or force belts, as this could result in  
damage to the cords in the belts.  
6. With the fan off, adjust the belt tension by moving the motor base. (See  
FIGURE 17: Aligning  
belt tensioning procedures in the Routine Maintenance section of this  
sheaves with a  
straight edge  
manual). When in operation, the tight side of the belts should be in a  
straight line from sheave to sheave with a slight bow on the slack side.  
WRONG  
WRONG  
WRONG  
CORRECT  
FIGURE 18: Proper alignment of motor and drive shaft.  
Direction of Fan Wheel Rotation  
Blower access is labeled on unit. Check for proper wheel rotation by momentarily  
n
o
i
t
energizing the fan. Rotation is determined by viewing the wheel from the drive side and  
should match the rotation decal affixed to the fan housing (see FIGURE 19). If the wheel  
is rotating the wrong way, direction can be reversed by interchanging any two of the  
three electrical leads. Check for unusual noise, vibration, or overheating of bearings.  
Refer to the “Troubleshooting” section of this manual if a problem develops.  
Airflow  
a
t
o
R
Fan RPM  
Supply fan will have a fixed motor pulley. Exhaust fans will have an adjustable motor  
pulley (on 15 HP and below) preset at the factory to the customer specified RPM. Fan  
speed can be increased or decreased by adjusting the pitch diameter of the motor pulley.  
Multi-groove variable pitch pulleys must be adjusted an equal number of turns open or  
closed. For the exhaust blowers, any increase in fan speed represents a substantial  
increase in load on the motor. Always check the motor amperage reading and compare it  
to the amperage rating shown on the motor nameplate when changing fan RPM.  
For Exhaust Fans. All access doors must be installed except the control center door.  
Close off as much of the exhaust blower access opening as possible while measuring the  
amp draw. Do not operate units with access doors open or without proper ductwork in  
place as the exhaust motors will overload.  
FIGURE 19  
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Unit Start-Up  
Vibration  
Excessive vibration maybe experienced during initial start-up. Left unchecked, excessive vibration can cause a  
multitude of problems, including structural and/or component failure. The most common sources of vibration  
are listed below.  
1. Wheel Unbalance  
2. Drive Pulley Misalignment  
3. Incorrect Belt Tension  
Many of these conditions can be discovered by careful observation. Refer to  
the troubleshooting section of this manual for corrective actions. If  
observation cannot locate the source of vibration, a qualified technician using  
4. Bearing Misalignment  
vibration analysis equipment should be consulted. If the problem is wheel  
5. Mechanical Looseness  
unbalance, in-place balancing can be done.  
6. Faulty Belts  
7. Drive Component Unbalance  
8. Poor Inlet/Outlet Conditions  
9. Foundation Stiffness  
Generally, fan vibration and noise is transmitted to other parts of the building  
by the ductwork. To eliminate this undesirable effect, the use of heavy canvas  
connectors is recommended.  
Energy Recovery Wheel  
The APEX contains two energy recovery wheels (see  
FIGURES 20 & 21). These wheels are inspected for  
proper mechanical operation at the factory. However,  
during shipping and handling, shifting can occur that may  
affect wheel operation. Wheels are accessible through the  
access doors marked "Energy Wheel Cassette Access".  
Due to the size and weight of these wheels, they remain  
stationary and all maintenance is performed in place.  
There is ample room inside the unit to perform energy  
recovery wheel servicing.  
Turn the energy recovery wheels by hand to verify free  
operation. The wheel should rotate smoothly and should  
FIGURE 20: Inside layout of APEX unit  
not wobble.  
Drive Belt  
Inspect the drive belt. Make sure the belt rides smoothly through the pulley and over the wheel rim.  
Air Seals  
Air seals are located around the perimeter of the  
wheel and across the face of the wheel (both sides of  
wheel). Check that these seals are secure and in  
Bearing Support  
good condition.  
Adjustable  
Air Seals  
Air seals which are too tight will prevent proper  
rotation of the energy recovery wheel. Air seal  
clearance may be checked by placing a sheet of  
paper, to act as a feeler gauge, against the wheel  
face. To adjust the air seals, loosen all eight seal  
retaining screws. These screws are located on the  
bearing support that spans the length of the cassette  
through the wheel center. These seals are located on  
each side of the wheel; be sure to check both of  
them. Adjust the seals such that they tug slightly on  
the sheet of paper as the wheel is turned. Tighten the  
retaining screws.  
Label showing  
cassette serial #  
and date code  
Drive Belt  
Drive Pulley  
Replace access doors and apply power. Observe that  
the wheels rotate freely at about 60 RPM. If wheels  
do not rotate or are binding, contact your local  
representative.  
FIGURE 21: Energy recovery wheel components  
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Routine Maintenance  
SAFETY CAUTION!  
SAFETY DANGER!  
Use caution when removing access panels or other  
unit components, especially while standing on a  
ladder or other potentially unsteady base. Access  
panels and unit components can be heavy and  
serious injury may occur.  
Electric shock hazard. Can cause injury or death.  
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.  
Once the unit has been put into  
operation, a routine  
maintenance program should  
be set up to preserve reliability  
and performance. Items to be  
included in this program are:  
• Lubrication  
• Dampers  
• Bearings  
• Filter Maintenance  
• Coil Maintenance  
• Energy Wheel Cassette  
• Fan Belts  
Motors  
• Wheel & Fasteners  
Lubrication  
Check all moving components for proper lubrication. Apply lubrication where required. Any components  
showing excessive wear should be replaced to maintain the integrity of the unit and ensure proper operation.  
Dampers  
Check all dampers to ensure they open and close properly and without binding. Backdraft dampers can be  
checked by hand to determine if blades open and close freely. Apply power to motorized dampers to ensure  
the actuator opens and closes the damper as designed.  
Fan Belts  
Belts must be checked on a regular basis for wear, tension, alignment, and dirt accumulation. Premature or  
frequent belt failures can be caused by improper belt tension (either too loose or too tight) or misaligned  
sheaves. Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result  
in failure of the fan and/or motor bearings. Conversely, loose belts will cause squealing on start-up, excessive  
belt flutter, slippage, and overheated sheaves. Both loose and tight belts can cause fan vibration.  
When replacing belts on multiple groove drives, all belts should be changed to provide uniform drive loading.  
Do not pry belts on or off the sheave. Loosen belt tension until belts can be removed by simply lifting the belts  
off the sheaves. After replacing belts, ensure that slack in each belt is on the same side of the drive. Belt  
dressing should never be used.  
Do not install new belts on worn sheaves. If the sheaves have grooves worn in them, they must be replaced  
before new belts are installed.  
Be  
l
t
Span  
The proper belt setting is the lowest tension at  
which the belts will not slip under peak load  
operation (see FIGURE 22). For initial tensioning,  
D
ef  
lect  
io  
n
=
64  
1
set the belt deflection at 64-inch for each inch of  
belt span (measured half-way between sheave  
centers). For example, if the belt span is 64 inches,  
the belt deflection should be 1 inch (using  
moderate thumb pressure at mid-point of the  
drive). Check belt tension two times during the first  
24 hours of operation and periodically thereafter.  
B
e
lt  
Span  
FIGURE 22: Proper fan belt settings  
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Routine Maintenance  
Motors  
Motor maintenance is generally limited to cleaning and lubrication. Cleaning  
should be limited to exterior surfaces only. Removing dust and grease  
buildup on the motor housing assists proper motor cooling. Never wash-  
down motor with high pressure spray. Greasing of motors is only intended  
when fittings are provided. Many fractional motors are permanently  
lubricated for life and require no further lubrication. Motors supplied with  
grease fittings should be greased in accordance with the manufacturer's  
recommendations. When motor temperature does not exceed 104°F (40°C),  
the grease should be replaced after 2000 hours of running time.  
Wheel & Fasteners  
Wheels require very little attention when moving clean air. Occasionally oil and dust may accumulate on the  
wheel causing imbalance. When this occurs the wheel and housing should be cleaned to ensure smooth and  
safe operation. Inspect fan impeller and housing for fatigue, corrosion or wear.  
Routinely check all fasteners, set screws and locking collars on the fan, bearings, drive, motor base and  
accessories for tightness. A proper maintenance program will help preserve the performance and reliability  
designed into the fan.  
Bearings  
Shaft bearings are the most critical  
Recommended Bearing Lubrication Schedule for APEX Fans  
moving part of a fan. Therefore,  
Relubrication Schedule in Months*  
special attention should be given to  
Bearing Bore (inches)  
keeping the bearings clean and well  
lubricated. Proper lubrication  
provides for reduction in friction and  
wear, transmission and dissipation  
of heat, extended bearing life and  
prevention of rust.  
Fan  
12-1 1 18-1 12 1 58-1 78 1 1516 - 2 716 - 3 316 - 3 1516- 4 1516 -  
RPM  
2 316  
3
3
2
1
0.5  
3 12  
2
1
0.5  
0.5  
4 12  
2
1
0.5  
0.25  
5 12  
1
0.5  
0.25  
0.25  
750  
6
6
5
5
5
4
3
2
4
3
2
1
3
2
1
1
1000  
1250  
1500  
* Suggested initial greasing interval is based on 12 hour per day operation. For continuous (24 hour)  
operation, decrease greasing interval by 50%.  
In order for a lubricant to fulfill these  
tasks, the proper grease applied at  
regular intervals is required. See the  
recommended bearing lubrication  
schedule. If unusual conditions  
exist, such as temperatures below  
32°F, temperatures above 200°F,  
moisture, or contaminants - more  
frequent lubrication is required.  
-
-
For ball bearings, add 1-2 shots of grease up to 2 inch bore sizes, and 4-5 shots of grease above 2 inch  
bore sizes with hand grease gun.  
For roller bearings, relubricate with 4 shots of grease up to 2 inch bore size and 8 shots for 2-5 inch  
bore size.  
Adjust lubrication frequency based on condition of purged grease.  
A high quality lithium base grease conforming to NLGI Grade 2 consistency, such as those listed below,  
should be used.  
-
-
MOBILITH SHC 220  
MOBILITH AW2  
TEXACO MULTIFAK AFB2  
TEXACO PREMIUM RB  
SHELL ALVANIA #2  
EXXON UNIREX N2  
WARNING: Lubricate bearings prior to periods of extended shutdowns or storage and rotate shaft monthly to  
aid in preventing corrosion. If the fan is stored more than three months, the bearings should be  
purged with new grease prior to start-up.  
With the unit off, add grease very  
slowly with a manual grease gun  
until a slight bead of grease forms at the seal. Be careful not to  
unseat the seal by over lubricating or using excessive pressure. A  
guide to the amount of grease to be used is to fill 30% to 60% of  
available space in the bearing and housing. Never mix greases  
made with different bases. This will cause a breakdown of the  
grease and possible failure of the bearing.  
In addition to lubricating the bearings at specified intervals, set  
screws in the bearing collars should be checked for tightness. A  
bearing collar which has loosened will cause premature failure of  
the fan shaft. Fasteners attaching the bearings to the drive frame  
should also be checked.  
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Routine Maintenance  
External Filter Maintenance  
FIGURE 23:  
Aluminum mesh, 2-inch deep filters are located in the  
supply weatherhood (if the weatherhood option was  
purchased). Filters should be checked and cleaned on  
a regular basis for best efficiency. The frequency of  
cleaning depends upon the cleanliness of the incoming  
air. These filters should be cleaned prior to start-up.  
Outdoor air  
intake hood  
mesh filter  
access.  
To access these filters, remove bottom bolt in the  
access door on the side of the weatherhood (one  
access door on each side of weatherhood). Slide the  
access door up and then pull bottom out to remove  
door. Then, slide the filters out (see FIGURE 23).  
Clean filters by rinsing with a mild detergent in warm  
water. After the filters are dry, an adhesive spray,  
available at most filter distributors, may be applied to  
increase filter efficiency.  
TABLE 4: Filter size and quantities.  
Internal  
Quantity Quantity  
Supply  
16  
Model  
Filter Size  
Exhaust  
16  
Internal Filter Maintenance  
APEX-200 20 in. x 20 in.  
The APEX will typically be provided with 2-inch, pleated  
filters in the outdoor air and exhaust airstreams. These  
filters should be checked per a routine maintenance  
schedule and replaced as necessary to ensure proper  
airflow through the unit. See TABLE 4 for pleated filter  
size and quantity for each unit.  
Outdoor Air Filters: Access to the outdoor air filters is  
through the doors labeled as “Filter Access” (both  
sides of unit). The filters are stacked two high and four  
deep. They can be removed by pulling on the strap  
mechanism (see FIGURE 24). Be sure to replace strap  
mechanism to assist with filter replacement for next  
maintenance interval.  
Exhaust Air Filters: Access to the exhaust filters is  
through the door labeled “Coil Access”. You must enter  
the unit to get at the exhaust filter access door. This  
door is located in the divider between the airstreams  
(see FIGURE 25). Open the door and pull the exhaust  
filters up and out of the “V” bank rack.  
FIGURE 24: Strap mechanism used to  
remove outdoor air filters.  
Door Seal Maintenance  
Slip-on type vinyl seal is installed on the perimeter of  
the door openings of the APEX. Seal should be  
inspected at least annually to ensure that seal is still  
pliable and intact.  
FIGURE 25: Access to exhaust air filters.  
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Routine Maintenance  
Coil Maintenance  
Filters upstream of the coil should be checked regularly. If the filters are dirty, they should be cleaned or  
replaced. It is important that the coils stay clean to maintain desired airflow (refer to Filters in this section).  
1. Coils must be clean to obtain maximum performance. Check once a year under normal operating  
conditions and, if dirty, brush or vacuum clean. Soiled fins reduce the capacity of the coil, demand more  
energy from the fan, and create an environment for odor and bacteria to grow and spread through the  
conditioned zone. High pressure water (700 Psi or less) may be used to clean coils with fin thickness over  
0.0095 inches thick. TEST THE SPRAY PRESSURE over a small corner of the coil to determine if the fins  
will withstand the spray pressure.  
For coils with fragile fins or high fin density, foaming chemical sprays and washes are available. Many coil  
cleaners contain harsh chemicals, so they must be used with caution by qualified personnel only. Care  
must be taken not to damage the coils, including fins, while cleaning.  
CAUTION: Fin edges are sharp.  
2. Drain pans in any air conditioning unit will have some moisture in them, therefore, algae and other  
organisms will grow due to airborne spores and bacteria. Periodic cleaning is necessary to prevent this  
build-up from plugging the drain and causing the  
drain pan to overflow. Inspect twice a year to avoid  
the possibility of overflow. Also, drain pans should be  
kept clean to prevent the spread of disease. Cleaning  
should be performed by qualified personnel.  
SAFETY CAUTION!  
Biological hazard. May cause disease. Cleaning  
should be performed by qualified personnel.  
Winterizing Coils  
Coil freeze-up can be caused by such things as air stratification and  
failure of outdoor air dampers and/or preheat coils. Routine draining of  
water cooling coils for winter shutdown cannot be depended upon as  
insurance against freeze-up. Severe coil damage may result. It is  
recommended that all coils be drained as thoroughly as possible and then  
treated in the following manner.  
Fill each coil independently with an antifreeze solution using a small  
circulating pump and again thoroughly drain. Check freezing point of  
antifreeze before proceeding to next coil. Due to a small amount of water  
always remaining in each coil, there will be diluting effect. The small  
amount of antifreeze solution remaining in the coil must always be  
concentrated enough to prevent freeze-up.  
NOTE: Carefully read instructions for mixing antifreeze solution used.  
Some products will have a higher freezing point in their natural state than  
when mixed with water.  
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Routine Maintenance  
Energy Recovery Wheel Maintenance  
Annual inspection of the energy recovery wheel is  
recommended. Units ventilating smoking lounges  
and other non-clean air spaces should have  
energy recovery wheel inspections more often  
based upon need. Inspections for smoke  
ventilation applications are recommended  
bimonthly to quarterly until a regular schedule  
can be established.  
ACCESSING ENERGY RECOVERY WHEEL  
The APEX has two energy recovery wheels. Open  
the exhaust blower access doors to access each  
wheel (FIGURE 26). The energy recovery wheel  
cassettes do not slide out due to their size and  
weight.  
FIGURE 26: Access to wheel through exhaust  
blower door.  
**WARNING: Disconnect power to the unit  
before performing any type of service.**  
Bracket Segment Retainer  
REMOVING THE ENERGY RECOVERY WHEEL SEGMENTS  
Steel retainers are located on  
Lift Away  
From Segment  
the inside of the wheel rim  
(FIGURE 27). Push the retainer  
toward center of wheel, then  
lift up and away to release  
segments (FIGURE 28 & 29).  
Catch-  
Segment Retainer  
Inside of Wheel Rim  
Spoke  
Push Toward Center  
FIGURE 27: Wheel retaining arms.  
IMPORTANT! PLACE RETAINERS BACK IN THE ORIGINAL POSITION  
BEFORE ROTATING THE ENERGY RECOVERY WHEEL.  
OTHERWISE DAMAGE TO RETAINER WILL OCCUR.  
FIGURE 28: Wheel segment retaining arms  
FIGURE 29: Wheel segment removed to  
rotated for removal.  
allow for cleaning.  
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Routine Maintenance  
CLEANING ENERGY RECOVERY WHEEL SEGMENTS  
If the wheel appears excessively dirty, it should be cleaned to ensure maximum operating efficiency. Only  
excessive buildup of foreign material needs to be removed. DISCOLORATION AND STAINING OF ENERGY  
RECOVERY WHEEL DOES NOT AFFECT ITS PERFORMANCE.  
Thoroughly spray wheel matrix with household cleaner such as Fantastic or equivalent. Gently rinse with  
warm water and using a soft brush remove any heavier accumulation. A detergent/water solution can also be  
used. Avoid aggressive organic solvents, such as acetone. The energy recovery wheel segments can be soaked  
in the above solution overnight for stubborn dirt or accumulation.  
After cleaning is complete, shake the excess water from the wheel or segments. Dry wheel or segments before  
placing them back into the cassette. Place wheel or segments back into cassette by reversing removal  
procedures.  
** DO NOT CLEAN ENERGY RECOVERY WHEEL SEGMENTS WITH WATER IN EXCESS OF 140°F  
** DO NOT DRY ENERGY RECOVERY WHEEL SEGMENTS IN AIR IN EXCESS OF 140°F.  
Energy Recovery Wheel Belt  
Inspect belts each time filters are replaced. Belts that look  
chewed up or are leaving belt dust near the motor pulley  
may indicate a problem with the wheel. Be sure to inspect  
wheel for smooth and unrestricted rotation. If a belt  
requires replacement, contact the local Greenheck  
representative. Instructions for replacement will ship with  
the new belt.  
FIGURE 30: Wheel belt & pulley  
Energy Recovery Wheel Bearings  
In the unlikely event that a wheel bearing fails, access  
is available through the access door above the exhaust  
blower discharge. Remove the plate shown in Figure 31  
to access bearing.  
FIGURE 31: Wheel bearing access  
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Parts List  
4
5
8
10  
6
7
2
3
9
1
11  
Model APEX  
(shown with optional chilled  
water and hot water coils)  
3
1. Supply blower  
- Plenum fan  
7. Exhaust weatherhood with birdscreen and integral  
backdraft damper (2 per unit)  
- Adjustable motor mount for belt tensioning  
- Adjustable sheaves for speed control  
8. Supply air filter racks for 2 in. pleated, 30%  
efficient filters (2 straight racks for supply)  
2. Exhaust blower (2 per unit - each side)  
- Forward curved fan  
9. Exhaust air filter racks for 2 in. pleated, 30%  
efficient filters (v-bank rack accessed inside unit)  
- Adjustable motor mount for belt tensioning  
- Adjustable sheaves for speed control  
10. Electrical control box (standard features)  
- Single point power  
3. Vibrations isolators (4 per blower)  
- Neoprene (exhaust blowers)  
- Spring (supply blower)  
- Disconnect interlocked with access door  
- Motor starters for the supply blower, exhaust  
blowers and energy wheel motors  
4. Energy recovery wheel cassette (2 per unit)  
5. Removable energy recovery wheel segments  
- 24 VAC, control circuit with terminal strip  
11. Coil section houses supply air tempering options  
- DX or chilled water for cooling  
6. Supply weatherhood with 2 in. aluminum mesh  
filters  
- Electric or hot water heat for heating  
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Sequence of Operation  
Basic Unit  
The APEX unit is pre-wired such that when a call for outside air is made (via field supplied 24 VAC control  
signal wired to unit control center), the supply fan, exhaust fan and energy wheel are energized and the  
motorized dampers open. The APEX unit can be supplied with or without heating and cooling coils. For units  
with coils, controls can be supplied by Greenheck (refer to the Temperature Control IOM, Part #461468, for  
sequence of operation) or by the controls contractor. If supplied by the controls contractor, they would provide,  
mount, and wire any temperature controllers and temperature or relative humidity sensors required for the unit  
to discharge air at the desired conditions.  
Summer Operation  
Outdoor air is preconditioned (temperature and moisture levels are decreased) by the transfer of energy from  
the cooler, drier exhaust air via the energy recovery wheel.  
Units supplied with cooling coils can further cool the air coming off the wheel and strip out moisture to levels at  
or below room design. A heating coil downstream of the cooling coil can reheat the air to a more comfortable  
discharge temperature to the space.  
Economizer Operation: See Economizer Application/Operation section  
Winter Operation  
Outdoor air is preconditioned (temperature and moisture levels are increased) by the transfer of energy from the  
warmer, more humid exhaust air via the energy recovery wheel.  
Units supplied with heating coils can further heat the air coming off the wheel to levels at or above room  
design.  
Frost Control Operation: See Frost Control Application/Operation section  
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Troubleshooting Airflow  
Test and Balance Report  
The test and balance report (TAB) is utilized to determine whether the appropriate amount of outdoor air and  
exhaust air is being supplied and removed from a building, respectively. There are no set rules on what  
information must be included in a TAB report. As such, if a TAB report indicates that the airflow on a unit is low,  
prior to contacting the factory, please determine the following information:  
Model Number  
Serial Number  
Name Plate Information  
Voltage  
Hertz  
Phase  
Outdoor Air Fan Amps  
Exhaust Fan Amps  
Outdoor Air Fan Horsepower  
Exhaust Fan Horsepower  
Design Airflow  
Outdoor Air  
Exhaust  
Measured Airflow  
Outdoor Air  
Exhaust  
Measured Data  
Blower Rotation  
Outdoor Air Fan RPM  
Exhaust Fan RPM  
Outdoor Air Fan Amp Draw  
Exhaust Fan Amp Draw  
Pressure Drop Across Energy Recovery Wheel  
Outdoor Air Side  
Exhaust Side  
Airflow problems can often be tied back to improper ductwork installation. Be sure to install ductwork in  
accordance with SMACNA and AMCA guidelines.  
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Troubleshooting  
Symptom  
Possible Cause  
Corrective Action  
Blown fuse or open circuit  
breaker.  
Replace fuse or reset circuit breaker and check amps.  
Defective motor or capacitor.  
Motor starter overloaded.  
Electrical.  
Replace.  
Blower Fails to  
Operate  
Reset starter and check amps.  
Check for On/Off switches. Check for correct supply voltage.  
Check for broken or loose belts. Tighten loose pulleys.  
Drive.  
Control power (24 VAC) wiring  
run is too long (resistance  
Shorten wiring run to mechanical room or install a relay  
which will turn unit on/off (C/F for relay information).  
should not exceed 0.75 ohms).  
Motor Starters  
Chatter” or Do  
Not Pull In  
Incoming supply power is  
less than anticipated. Voltage  
supplied to starter coil must  
be within +10% / -15% of  
nominal voltage stated on  
the coil.  
Need to increase supply power or use a special control  
transformer which is sized for the actual supply power.  
Cfm too high.  
Check cfm and adjust drives if needed.  
Static pressures are higher or  
lower than design.  
If higher, ductwork should be improved.  
If lower, fan rpm should be lower.  
Blower rotation is incorrect.  
Motor voltage incorrect.  
Motor horsepower too low.  
Check rotation and reverse if necessary.  
Motor Over Amps  
Check motor nameplate versus supplied voltage.  
See specifications and catalog for fan curves to determine if  
horsepower is sufficient.  
Shorted windings in motor.  
Unit damper not fully open.  
Replace motor.  
Adjust damper linkage or replace damper motor.  
System static pressure too high. Improve ductwork to eliminate losses using good duct  
practices.  
Blower speed too low.  
Check for correct drives and rpm with catalog data.  
For 3-phase see Fan Wheel Rotation on page 16.  
Fan wheels are operating  
backwards.  
Low Airflow (cfm)  
Dirty filter or energy wheel.  
Leaks in ductwork.  
Follow cleaning procedures on pages 20 and 23.  
Repair.  
Elbows or other obstructions  
may be obstructing fan outlet.  
Correct or improve ductwork.  
Belt slippage.  
Adjust belt tension.  
Blower fan speed too high.  
Filter(s) not in place.  
Check for correct fan rpm. Decrease fan speed if necessary.  
Install filters.  
High Airflow (cfm)  
Insufficient static pressure (Ps)  
(airflow resistance).  
Induce Ps into system ductwork. Make sure grilles and  
access doors are installed. Decrease fan speed if necessary.  
* Always provide the unit model and serial number when requesting parts or service information. * Always check motor amps and compare to nameplate rating.  
®
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Troubleshooting  
Symptom  
Possible Cause  
Corrective Action  
One or Both  
Blowers Turn Off  
Intermittently and  
Back on After  
Blower fan motor overloads are Decrease fan speed.  
tripping and auto-resetting.  
Exhaust Only frost control  
sensors are tripping.  
Adjust frost temperature sensor set point as needed.  
About 2 Minutes  
Air seals are too tight.  
See Energy Recovery Wheel on page 17.  
Economizer” sensors are  
operating.  
Adjust temperature or enthalpy set points as needed.  
Energy Wheel  
Does NOT Turn  
No power to wheel motor.  
Make sure wheel drive is plugged in. Verify power is  
available.  
Wheel drive belt.  
Check for loose or broken belts. Replace belts (consult  
factory).  
Wheel motor overloads are  
tripping, due to rubbing  
between wheel and air seals.  
Recheck air seals, make sure they are not too tight. See  
Energy Recovery Wheel on page 17.  
Energy Wheel  
Runs Intermittently  
Fan wheel rubbing on inlet.  
Adjust wheel and/or inlet cone. Tighten wheel hub or bearing  
collars on shaft.  
Bearings.  
Replace defective bearing(s). Lubricate bearing(s). Tighten  
collars and fasteners.  
Wheel out of balance.  
Replace or rebalance.  
Loose wheel on shaft.  
Tighten wheel setscrew.  
Tighten sheave setscrew.  
Loose motor or blower sheave.  
Belts too loose.  
Belts too tight.  
Adjust belt tension after 24 hours of operation.  
Excessive Noise or  
Vibration  
Loosen to maintain a 3/8 inch deflection per foot of span  
between sheaves.  
Worn belt.  
Replace.  
Motor base or blower loose.  
Buildup of material on wheel.  
Bearing and drive misaligned.  
Tighten mounting bolts.  
Clean wheel and housing.  
Realign.  
Noise being transmitted by  
duct.  
Make sure ductwork is supported properly. Make sure duct-  
work metal thickness is sized for proper stiffness. Check duct  
size at discharge to ensure that air velocities are not too high.  
* Always provide the unit model and serial number when requesting parts or service information. * Always check motor amps and compare to nameplate rating.  
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.  
As a result of our commitment to continuous improvement,  
Greenheck reserves the right to change specificaions without notice.  
GREENHECK  
#462255 APEX IOM FS  
Rev. 1 March 2004  
Copyright © 2004 Greenheck Fan Corp.  
P.O. BOX 410 SCHOFIELD, WISCONSIN 54476-0410  
PH. 715-359-6171  
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