Greenheck RV Series - User Manual

®
Document 695057
Models RV and RVE
Quick Start Guide
Models RV and RVE Quick Start Guide
This quick start document is intended to help with getting the initial unit startup completed, but does not replace the
IOM. Please read the IOM for all safety information and precautions before performing any work on the equipment.
Complete pre-start checks and blower start-up prior to this procedure.
Figure 2:
Typical Phase Monitor
Figure 3:
Refrigeration Values for Air
Cooled Condensing Systems
Operating
Pressure
107-145
PSI
125 PSI
Discharge
Pressure
250-460
PSI
375 PSI
Liquid
Pressure
Within 15
PSI of
discharge
365 PSI
Superheat 10-18ºF 12ºF
Compressor
Discharge
Temp.
120-
180ºF
135ºF
Subcooling 8-20ºF 15ºF
Cond Air:
In
55-95ºF
Cond Air:
Out
25-60ºF
20ºF
Delta T
Fans (*See Model RV/RVE Installation, Operation and Maintenance Manual)
1. Verify discharge air sensor installation at least three duct diameters downstream of the unit discharge.
(Field install)
2. Verify proper phasing of incoming power. See Figure 1 and Figure 2
3. Energize the unit supply and optional exhaust fan:
a. Connect terminal R to terminal G, R to W1 (if applicable), R to Y1 (if applicable) , and R to Y2 (if applicable).
4. Verify blower operation:
a. Check rotation: To reverse the rotation, disconnect and lockout the power, then interchange any two power
leads going to the motor.
b. Check motor amp draw: Compare to motor nameplate FLA - record reading in the *Start-up Report and reduce
airflow. If amp draw is greater than FLA, record any changes you make as well.
c. Check for excessive noise and vibration. If present, check fasteners between motor and impeller, motor and
frame, frame and unit block-off, and make sure they are tight. Check for contact between impeller and inlet
cone.
Energy Wheel (If Present,*see Model RV/RVE Installation, Operation and Maintenance Manual)
1. Verify energy wheel rotation direction (speed may vary depending on wheel model).
2. Check energy wheel motor amp draw, and compare to motor nameplate FLA and record in *Start-up Report.
Cooling (Requires minimum 55°F outdoor air temperature) (Repeat for each circuit)
1. Place a refrigeration manifold gauge set onto each refrigeration circuit.
a. Note: For the high side connection utilize the liquid line service valve.
2. Press the
program key on the Carel controller.
3. Scroll down to Ctrl Variables, press the
enter key.
4. Scroll down to Advanced, press the enter key.
5. Scroll down to Login, press the enter key.
6. Set password to 9998, press the enter key.
a. To change password, press enter when you first enter Login screen.
b. The cursor will move to underneath the first digit of the password. Scroll up/down to change the value.
c. Press enter to move the cursor to the next digit, and repeat the process until all 4 digits are correct. Then press
enter one last time.
7. After a moment the controller should put you back into the Advanced menu, if not press the
back button.
8. Scroll down to Manual Overrides, and press enter.
9. In the manual overrides menu, scroll to Manual Override Mode, and check the Enable Duration box.
a. To check the box, press enter once you reach Manual Override Mode. The cursor should appear over the box.
b. Press up or down to put an X in the box. Press enter again to select the time for which Override Mode will be
enabled. (Can be changed, but not necessary)
c. Press enter again to deselect everything.
10. Scroll to Unit On Off in the Manual Overrides menu.
11. Press enter and change the Override option to Manual and the Value option to On.
12. Press enter again to deselect Value.
13. Scroll to Cooling Ramp 1 in the Manual Overrides menu. (Note: Be careful, DO NOT do this on either
Compressor Override screen).
14. Set the Override option to Manual and the Demand option to 100%.
15. If hot gas reheat is present in unit, scroll to Hot Gas Reheat Ramp in Manual Overrides menu, and set Override
to Manual and Value to 0%.
16. Restrict the condensing coil until the high side pressure = 450 psig, not to exceed 525 psig.
Figure 1:
Phase Monitor Indicator
Lights Diagnostics
Run GREEN
Restart Delay
GREEN
Reverse Delay
RED
Unbalance/
Single Phase
RED
High/Low
Voltage
RED

Summary

Fans Startup Procedure

Verify Blower Operation

Checks for fan rotation, amp draw, noise, and vibration.

Energy Wheel Startup Procedure

Energy Wheel Verification

Check rotation direction and motor amp draw against nameplate FLA.

Cooling System Startup

Accessing Controller Settings

Steps to navigate the Carel controller to advanced settings and login.

Manual Overrides for Unit On;Off

Enabling manual override for unit power and setting it to 'On'.

Cooling Ramp and Reheat Configuration

Setting cooling ramp to Manual/100% demand and reheat to 0% if applicable.

Condensing Coil Pressure Restriction

Restricting the condensing coil pressure to 450-525 psig.

Condensing Fan and Refrigerant Charge

Verify fan operation and adjust refrigerant for proper subcooling and superheat.

Heating System Startup

Furnace Commissioning Steps

Accessing furnace commissioning and adjusting gas valve settings.

Overview

1. Fan Operation and Maintenance
2. Energy Wheel (If Present)
3. Cooling System (Requires minimum 55°F outdoor air temperature)
4. Refrigeration Values for Air Cooled Condensing Systems (Figure 3)
5. Cooling System Continued
6. Heating Start Up (If heating components are present)
7. Furnace Commissioning
8. Gas Pressure Settings (Figure 6)
9. High Fire Settings
10. Low Fire Settings

This document provides a quick start guide for the Greenheck Models RV and RVE, focusing on initial unit startup procedures for fans, energy wheels, cooling, and heating components. It emphasizes that this guide supplements, but does not replace, the full Installation, Operation, and Maintenance (IOM) manual, which should be consulted for all safety information and precautions. Pre-start checks and blower startup are prerequisites to following this procedure.

Fan Operation and Maintenance:

The guide outlines initial steps for fan setup, including verifying the discharge air sensor installation, ensuring proper phasing of incoming power (referencing Figure 1 for phase monitor indicator lights diagnostics and Figure 2 for a typical phase monitor), and energizing the unit's supply and optional exhaust fan by connecting terminals R to G, W1, Y1, and Y2 as applicable.

For blower operation, users must check rotation and reverse it if necessary by disconnecting and locking out power, then interchanging any two power leads to the motor. Motor amp draw must be checked against the motor nameplate FLA and recorded in a "Start-up Report." If the amp draw exceeds FLA, airflow should be reduced, and any changes made must be recorded. Excessive noise and vibration should be investigated by checking fasteners between the motor and impeller, motor and frame, frame and unit block-off, and ensuring they are tight. Contact between the impeller and inlet cone must also be checked.

Energy Wheel (If Present):

For units equipped with an energy wheel, the guide instructs users to verify its rotation direction (noting that speed may vary by wheel model) and check its motor amp draw against the motor nameplate FLA, recording the reading in the "Start-up Report."

Cooling System (Requires minimum 55°F outdoor air temperature):

The cooling section provides a detailed, step-by-step process for each refrigeration circuit.

1. Manifold Gauge Set Installation: A refrigeration manifold gauge set must be placed on each circuit, utilizing the liquid line service valve for the high side connection.
2. Carel Controller Access: The program key on the Carel controller is pressed, followed by navigating through "Ctrl Variables," "Advanced," and "Login" menus using the enter key.
3. Password Entry: The password "9998" is entered. To do this, press enter when first entering the Login screen. The cursor moves under the first digit, allowing adjustment with up/down keys. Press enter to move to the next digit, repeating until all four digits are correct, then press enter one last time.
4. Manual Overrides: After successful login, the controller should return to the "Advanced" menu (or use the back button if needed). Navigate to "Manual Overrides" and press enter.
5. Enable Duration: In the "Manual Overrides" menu, scroll to "Manual Override Mode" and check the "Enable Duration" box. Press enter when the cursor is over the box, use up/down to place an "X," then press enter again to select the duration for "Override Mode" (which can be changed but is not necessary). Press enter again to deselect.
6. Unit On/Off: Scroll to "Unit On Off" in "Manual Overrides," press enter, and change the "Override" option to "Manual" and the "Value" option to "On." Press enter again to deselect "Value."
7. Cooling Ramp 1: Scroll to "Cooling Ramp 1" in "Manual Overrides" (caution: do not use compressor override screens). Set the "Override" option to "Manual" and the "Demand" option to "100%."
8. Hot Gas Reheat (If Present): If hot gas reheat is present, scroll to "Hot Gas Reheat Ramp" in "Manual Overrides," and set "Override" to "Manual" and "Value" to "0%."
9. Condensing Coil Restriction: Restrict the condensing coil until the high side pressure reaches 450 psig, not exceeding 525 psig.

Refrigeration Values for Air Cooled Condensing Systems (Figure 3):

The guide provides a table of target refrigeration values:

• Operating Pressure: 107-145 PSI (Target: 125 PSI)
• Discharge Pressure: 250-460 PSI (Target: 375 PSI)
• Liquid Pressure: Within 15 PSI of discharge (Target: 365 PSI)
• Superheat: 10-18°F (Target: 12°F)
• Compressor Discharge Temp.: 120-180°F (Target: 135°F)
• Subcooling: 8-20°F (Target: 15°F)
• Cond Air: In: 55-95°F
• Cond Air: Out: 25-60°F (Target: 20°F Delta T)

Cooling System Continued:

10. Condensing Fan Operation: Verify operation and rotation of all condensing fans, ensuring blades do not contact the guard. Check fan amperage while running and ensure it is below FLA; contact Greenheck technical support if not.
11. System Stabilization: Allow the cooling system to run unimpeded for 10-15 minutes to stabilize.
12. Circuit A Subcooling: Measure Circuit A's subcooling (target 10-12°F) and record in the "Start-up Report." Add refrigerant if below 10°F (and sight glass is not clear); remove refrigerant if above 12°F.
13. Circuit A Superheat: Measure Circuit A's superheat (target 7-9°F) and record in the "Start-up Report." Adjust the TXV clockwise if below 7°F, and counter-clockwise if above 9°F.
14. Hot Gas Reheat (If Equipped): If the circuit has hot gas reheat, change the reheat percentage to 100% for 5 minutes (referencing step 15).
15. Circuit Subcooling (Reheat): Measure the circuit subcooling (target 10-12°F) and record in the "Start-up Report." Add refrigerant if below 10°F (and sight glass is not clear); remove refrigerant if above 12°F.
16. Circuit Superheat (Reheat): Measure the circuit superheat (target 7-9°F) and record in the "Start-up Report." Adjust the TXV clockwise if below 7°F, and counter-clockwise if above 9°F.
17. Reheat Percentage Adjustment: Change the reheat percentage to 0% and repeat steps 18-20.
18. Compressor Amp Draw: Measure and record the compressor amp draw, comparing it to the nameplate FLA, and record in the "Start-up Report."

Heating Start Up (If heating components are present):

1. Carel Controller Access: Press the program key, navigate to "Ctrl Variables," "Advanced," and "Login."
2. Password Entry: Enter "9998" as the password for service level access. The controller should then automatically exit the login screen.
3. Manual Overrides: Scroll down and enter the "Manual Overrides" menu.
4. Furnace Commissioning Prompt: Press the down key once, and the controller will prompt to press enter to begin IG furnace commissioning.
5. Enter Commissioning: Press enter on this screen to enter furnace commissioning.

Furnace Commissioning:

1. Adjust Outlet Pressure (Combination Valve):
   • Connect a manometer to the outlet pressure tap on the combination valve (Figure 4).
   • Adjust the outlet pressure using the outlet pressure adjustment screw (Figure 4).
2. Adjust High Fire Setting (Modulating Valve):
   • Connect a manometer to the test port on the burner manifold.
   • Press and hold button #1 until the LED on the modulating valve lights solid red. Release the button and observe the pressure on the manometer (Figure 5).
   • Adjust the modulating valve by pushing button #1 to increase pressure and button #2 to decrease pressure (Figures 5 & 6).
   • Save the High Fire setting by simultaneously pressing button #1 and #2 until the LED turns off.
3. Adjust Low Fire Setting (Mod Valve):
   • Press and hold button #2 until the LED blinks RED. Release the button and observe the pressure on the manometer (Figure 5).
   • Adjust the low fire setting by pushing button #1 to increase or button #2 to decrease pressure (Figures 5 & 6).
   • Save the Low Fire setting by simultaneously pressing button #1 and #2 until the LED turns off.
4. Repeat for High Turndown Furnaces: Repeat steps 2 and 3 for high turndown furnaces.
5. Verify Furnace Operation: Continue through the commissioning menu to verify proper furnace operation.

Gas Pressure Settings (Figure 6):

The guide provides a table for gas pressure settings:

• Natural Gas: 5 in. wg
• LP Gas: 11.5 in. wg

High Fire Settings:

• Natural Gas: 3.5 in. wg
• LP Gas: 10.0 in. wg

Low Fire Settings:

• Natural Gas: 0.3 in. wg
• LP Gas: 1.0 in. wg

For customer support, the document provides the number 1-866-478-2574. The document is identified as RV and RVE Quick Start Guide, Rev. 4, October 2019, with copyright 2019 Greenheck Fan Corporation.

Greenheck RV Series Specifications