MODEL IGX Make-Up Air Unit Installation, Operation and Maintenance Manual Part # 462876 **FOR YOUR SAFETY** If you smell gas: 1. Open windows. 2. Don t touch electrical switches. 3. Extinguish any open flame. 4. Immediately call your gas supplier. **WARNING** Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating, and maintenance instructions thoroughly before installing or servicing this equipment. **FOR YOUR SAFETY** The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. Indirect Gas Fired Unit Installations Units are listed for installation in the United States and Canada Installation of gas fired duct furnaces must conform with local building codes. In the absence of local codes, installation must conform to the National Fuel Gas code, ANSI Z223.1 or in Canada, CAN/CGA-B149 installation codes. All electrical wiring must be in accordance with the regulation of the National Electric Code, ANSI/NFPA No. 70. Unit is approved for installation downstream from refrigeration units. In these conditions, condensate could form in the duct furnace and provision must be made to dispose of the condensate.
TABLE OF CONTENTS Storage and Lifting Instructions.....2 Installation Indoor Mounting Horizontal and Downblast.......3 Outdoor Mounting Horizontal and Downblast Discharge....................4 Horizontal and Downblast Discharge with Optional Mixing Box........5 Downblast Discharge Optional with Combination Extension........6-7 Venting for Indoor units......8-17 Control Center Layout.............18 Start-Up Electrical....................19 Mixing Box..................20 Blower......................21 Furnace..................22-27 Evaporative Cooling........28-29 Cooling Coils.................30 Trouble Shooting Blower......................31 Furnace.....................32 Evaporative Cooling...........33 Maintenance Routine.....................34 Furnace.....................35 Evaporative Cooling...........36 Cooling Coils.................37 Documentation................38-39 Unit Layout......................40 Warranty........................40 REPORT ANY DAMAGED EQUIPMENT TO THE SHIPPER IMMEDIATELY! All units are shipped on a skid or packaged to minimize damage during shipment. The transporting carrier has the responsibility for delivering all items in their original condition as received from Greenheck. The individual receiving the equipment is responsible for inspecting the unit for obvious or hidden damage, recording any damage on the bill of lading before acceptance and filing a claim (if required) with the final carrier. Some accessory items are stored inside the unit during shipping. Care must be taken during installation to prevent damage to units. STORAGE When a fan is not going to be in service for an extended amount of time, certain procedures should be followed to keep the fan in proper operating condition. Rotate fan wheel monthly and purge bearings once every three months (If storage of fan is in a humid, dusty or corrosive atmosphere, purge the bearings once a month). Cover unit with tarp to protect from dirt and moisture (Note: do not use a black tarp as this will promote condensation) Energize fan motor once every three months Store belts flat to keep them from warping and stretching Store unit in location which does not have vibration After storage period, purge grease before putting fan into service Improper storage which results in damage to the fan will void the warranty. 2
**IMPORTANT** All factory provided lifting lugs must be used when lifting any unit. Failure to comply with this safety precaution could result in property damage, serious injury or death. LIFTING Greenheck make-up air units must be lifted by the factory supplied lifting lugs only. The unit must also remain upright as shipped, during lifting. THE USE OF ALL LIFTING LUGS IS MANDATORY WHEN LIFTING. All access doors and panels must be closed during lifting to avoid damage. To prevent damage to the unit cabinetry, use spreader bars. Spreader bars must be in position to stop cables from rubbing the unit frame or panels. Before hoisting into position, test lift to insure stability and balance. Avoid twisting or uneven lifting of the unit. Installation Instructions for: Indoor Mounted Arrangement HZ and DB Use spreader bar Step 1 Install Unit Using the factory provided lifting lugs, position the unit in general area of mounting location. Before lifting the unit into place, test lift the unit to verify stability and balance. Lift and secure the unit into position with threaded hanging rods and fasteners to be attached to one of the following: Mounting Brackets (optional accessory) Platform (provided by others) Rails (provided by others) Lifting Lugs Figure 1 Lifting Lugs Step 2 Install Ductwork Good duct practices should be followed for all ductwork All ducts should be done in accordance with SMACNA and AMCA guidelines. Attach and secure the ductwork using self tapping screws. Greenheck recommends attaching ductwork to collar using a rubber duct section at the unit to minimize vibration. Step 3 Install Venting Ductwork The instructions for the indoor venting are listed on the following pages. Refer to your unit submittal to determine the correct venting option instructions to follow. 3
Installation Instructions for: Roof Mounted Arrangement HZ and DB Step 1 Install Curb/Equipment Support(s) Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach curb to roof and flash into place. When attaching the equipment support(s) to the roof, remove metal cover, flash to wooden nailer and reinstall cover. Metal Cover Equipment Support Roof Curb Step 2 Install Ductwork Good duct practices should be followed for all ductwork All ducts should be done in accordance with SMACNA and AMCA guidelines. Arrangement DB: The use of a duct adapter is recommended on a downblast arrangement to properly align the ductwork with the supply unit. The duct adapter is only a guide and is not intended to be used as support for the ductwork. Attach and secure the ductwork using self tapping screws. Greenheck recommends attaching ductwork to collar using a rubber duct section at the unit to minimize vibration. Use spreader bar and lifting lugs. Step 3 Apply Sealant Before installing unit, apply a sealant around the perimeter of the curb and duct adapter(s) to seal and isolate the fan and minimize vibration. Note: Supply duct adapter applies to arrangement DB only. Figure 2 Step 4 Install Unit Use a crane and a spreader bar hooked to the factory lifting lugs (as shown in the diagram) to lift and center the unit on the curb/equipment support(s). NOTE: THE USE OF ALL LIFTING LUGS IS MANDATORY WHEN LIFTING UNIT. Use self-tapping sheet metal screws to fasten unit to the curb/equipment support(s). Step 5 Assemble and Attach Weatherhood The weatherhood can now be assembled and attached to the installed unit. Assembly instructions are included with the weatherhood panels. If the optional Evaporative Cooling module was selected, this step does not apply. Reference the Installation Instructions for the Evaporative Cooling module. 4
Installation Instructions for: Roof Mounted with Optional Mixing Box Arrangements HZ and DB Step 1 Install Curb/Equipment Support(s) Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach curb to roof and flash into place. When attaching the equipment support(s) to the roof, remove metal cover, flash to wooden nailer and reinstall cover. Step 2 Install Ductwork Good duct practices should be followed for all ductwork All ducts should be done in accordance with SMACNA and AMCA guidelines. Mixing Box (Arrangement HZ and DB) Supply Air (Arrangement DB only) Metal Cover Equipment Support Arrangement DB: The use of a duct adapter is recommended on a downblast arrangement to properly align the ductwork with the supply unit. The duct adapter is only a guide and is not intended to be used as support for the ductwork. Attach and secure the ductwork using self tapping screws. Greenheck recommends attaching ductwork to collar using a rubber duct section at the unit to minimize vibration. Use spreader bar and lifting lugs. Step 3 Apply Sealant Before installing unit, apply a sealant around the perimeter of the return air duct and supply duct adapter to seal and isolate the fan and minimize vibration. Note: Supply duct adapter applies to arrangement DB only. Step 4 Install Unit Use a crane and a spreader bar hooked to the factory lifting lugs (as shown in the diagram) to lift and center the unit on the curb/equipment support(s). NOTE: THE USE OF ALL LIFTING LUGS IS MANDATORY WHEN LIFTING UNIT. Use self-tapping sheet metal screws to fasten unit to the curb/equipment support(s). Step 5 Assemble and Attach Weatherhood The weatherhood can now be assembled and attached to the installed unit. Assembly instructions are included with the weatherhood panels. If the optional Evaporative Cooling module was selected, this step does not apply. Reference the Installation Instructions for the Evaporative Cooling module. Figure 2A 5
Installation Instructions for: Roof Mounted with Optional Combination Extension Downblast Discharge Arrangement DBC Step 1 Install Curb/Equipment Support(s) Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach curb to roof and flash into place. When attaching the equipment support(s) to the roof, remove metal cover, flash to wooden nailer and reinstall cover. Metal Cover Equipment Support Roof Curb Step 2 Install Combination Extension Install combination extension over curb, use wood screws to lag in place. Locate extension so the tall vented side is over the exhaust opening, as shown in illustration. Supply Exhaust 1 inch Inside Flange Step 3 Install Ductwork Good duct practices should be followed for the remaining ductwork. The use of a duct adapter is recommended to properly align the ductwork with the supply unit. The duct adapter is only a guide and is not intended to be used as support for the ductwork. Exhaust fan ductwork must be built in accordance with NFPA 96 and any local codes. Ductwork terminating at the fan should be square in shape or of smooth transition so as not to affect the fan performance. Supply Ductwork by Others Exhaust Ductwork by Others Exhaust Duct Installed Step 4 Apply Sealant Before installing exhaust fan and supply unit, apply a sealant around the perimeter of the exhaust and supply duct adapter to seal and isolate the fan and minimize vibration. Sealant Supply Duct with Duct Adapter Installed 6
Step 5 Install Exhaust Fan Install CUBE exhaust fan on curb extension. Fasten with self-tapping sheet metal screws through existing holes in curb cap. NFPA 96 requires the exhaust fan be hinged. Model CUBE Exhaust Fan Greenheck offers an optional hinge kit with restraining cables and a grease trap with drain connection. Install these options at this time. NOTE: Installing the exhaust fan prior to the supply unit will allow for easier installation of options. Step 6 Install Supply Unit Use a crane and a spreader bar hooked to the factory lifting lugs (as shown in the diagram) to lift and center the unit on the curb/equipment support(s). NOTE: THE USE OF ALL LIFTING LUGS IS MANDATORY WHEN LIFTING UNIT. Use self-tapping sheet metal screws to fasten unit to the curb/equipment support(s). Use spreader bar and lifting lugs. Use caution to avoid damaging exhaust fan when installing supply unit. Step 7 Assemble and Attach Weatherhood The weatherhood can now be assembled and attached to the installed unit. Assembly instructions are included with the weatherhood panels. If the optional Evaporative Cooling module was selected, this step does not apply. Reference the Installation Instructions for the Evaporative Cooling module. Figure 3 7
General Venting and Combustion Air 1. Do not install units in locations where flue products can be drawn into adjacent building openings such as windows, fresh air intakes, etc. Distance from vent terminal to adjacent public walkways, adjacent buildings, operable windows, and building openings shall conform with the local codes. In the absence of local codes, installation shall conform with the National Fuel Gas Code, ANSI Z223.1, or the CAN/CGA B-149 Installation Codes. 2. Building materials that will be affected by flue gases should be protected. 3. Avoid locating in an area where deep snow is likely to accumulate. During the winter months, keep snow clear on the access side of the unit to prevent any blockage of combustion air inlet or flue exhaust openings (outdoor units only). 4. Maintain minimum horizontal clearance of 4 feet from electric meters, gas meters, regulators, and relief equipment. In Canada, the minimum clearance is 6 feet. 5. Local codes may supercede any of the above provisions. 6. Be sure that the minimum clearances to combustible materials are maintained. Unit Clearances to Combustible Materials Indoor units, clearance from combustible material are determined by the National Fuel Gas Code and/or other local codes. Outdoor units, the combustion blower discharge must be located a minimum of 42 inches from any combustible materials. Venting Instructions: Outdoor Units 1. Do not modify or obstruct the combustion air inlet cover or the combustion blower weatherhood. 2. During winter months, periodically clear snow from the access side of the unit to prevent blockage of the inlet and exhaust openings. 3. Do not add vents other than those supplied by the manufacturer. Combustion Blower Exhaust Weatherhood Combustion Air Inlet Cover 8
Venting Instructions: Indoor Units 1. Installation of venting must conform with local building codes. In the absence of local codes, installation must conform with the National Fuel Gas Code, ANSI Z223.1 or in Canada, CAN/CGA- B149 installations codes. 2. The classification for vertical and horizontal venting of all units is category III. The ANSI requirements for vents classified as category III is that they must be gas tight. Seal the joints with a metallic tape or silastic suitable for temperatures up to 350 degrees F. the venting system shall be installed in accordance with these instructions. 3. All pipe is field supplied by others. For the vent pipe, use pipe approved for a category III appliance or single wall, 26 gauge or heavier galvanized vent pipe. For the combustion air pipe on separated combustion units, sealed single-wall galvanized air pipe is recommended. Refer to the National Fuel Gas Code for additional piping guidelines. 4. Select the vent and combustion air pipe size from the tables (1) and (2) shown on the following pages. Select the size of the vent and combustion air pipe that fits the flue outlet and combustion air intake. Use only the pipe size specified. 5. Install the vent and combustion air pipes with minimum downward slopes (from the unit) of 1/4 inch per foot, suspend securely from overhead structures at points no greater than 3 feet apart. Fasten individual pipe lengths together with at least three corrosion resistant sheet metal screws. 6. For the vent pipe, a minimum of 12 inches of straight pipe is recommended at the flue outlet before any elbows. 7. Avoid venting through unheated spaces if possible. To minimize condensation, insulate any vent runs greater than 5 feet that must pass through an unheated space. 8. For the combustion air pipes, long runs in cold climates may require insulation to prevent the buildup of condensation on the outside of the pipes where the pipe passes through heated spaces. 9. Vertical combustion air pipes should be fitted with a tee with a drip leg and clean out cap to prevent any moisture in the combustion air pipe from entering the unit. The drip leg should be cleaned out periodically during the heating season. 10. For separated combustion systems, the wall thickness for the purpose of venting is 1 inch minimum, 48 inches maximum. Venting Methods for Indoor Units Standard Indoor Venting (uses building air for combustion) Separated Combustion Concentric Venting (uses outside air for combustion, one exterior roof or wall penetration) Separated Combustion 2-Pipe Venting (uses outside air for combustion, two exterior roof or wall penetrations) For each method, the units can be vented horizontally through an exterior wall or vertically through the roof. Refer to the following pages for specific venting instructions. Construct the vent system for the selected method, as shown in these instructions. When looking in the direction of airflow, the venting is on the right side of the unit. VENT LENGTHS FOR EXHAUST AND COMBUSTION AIR Furnace Vent Standard Separated Combustion Separated Size Lengths Indoor Concentric Combustion 2-pipe 100-300 350-400 min 5 ft. 5 ft. 5 ft. max 70 ft. 70 ft. 70 ft. min 5 ft. 5 ft. 5 ft. max 70 ft. 70 ft. 50 ft. 9
Venting Instructions: Standard Indoor Units Standard Indoor Venting This refers to using one penetration through an exterior wall or roof for venting the flue exhaust. The combustion air is supplied from the air inside the building. Units must not be installed in a potentially explosive, flammable, or corrosive atmosphere. To prevent premature heat exchanger failure, do not locate units where chlorinated, halogenated, or acid vapors are present in the atmosphere. Vent Construction To vent using this method, the vent terminal supplied with the units must be used. Construct the vent system as shown in drawings and reference the tables for vent pipe sizes. The minimum vent length is 5 feet and the maximum vent length is 70 feet. The total equivalent vent length must include elbows. The equivalent length of a 4 inch elbow is 6 feet and the equivalent length of a 6 inch elbow is 10 feet. Combustion Air Requirements When units are installed in tightly sealed buildings, provisions should be made to supply adequate amount of infiltration air from the outside. The rule of thumb is that an opening of one square inch should be provided for every 1000 BTU per hour of input rating. Standard Horizontal Venting A = 12 inches Exterior Wall A EXHAUST Air Inlet Pitch vent pipe downward from furnace.25 inches per foot Exhaust Vent Terminal 10
Venting Instructions: Standard Indoor Units Standard Indoor Venting Furnace Size Flue Outlet 100-150 4 inch 200-400 6 inch All measurements shown are diameters. Table 1 Standard Vertical Venting Building Roof Exhaust Vent Terminal A1 A = 12 inch minimum A1 = 12 inch minimum, but should size according to expected snow depth. A EXHAUST Air Inlet 11
Venting Instructions: Concentric Venting Concentric venting allows both the vent pipe and combustion air pipe to pass through one hole in the exterior of a building. This can be accomplished by horizontal venting through an exterior wall or vertical venting through the roof. A vent kit is required for either method of venting. **WARNING** The concentric venting adapter is not designed for installations on the exterior of buildings. Refer to the following diagrams and instructions for proper installation instructions. Installing the Concentric Venting Adapter 1. Determine the location of the Concentric Venting Adapter (CVA) based on the method of venting to be used (horizontal or vertical) and any clearances that must be maintained (follow all codes referenced in these instructions). Field supplied mounting brackets are used to mount the CVA to the wall or roof. It can be mounted flush to the wall or it can be offset. 2. Determine the length of the mounting brackets and fabricate from corrosion resistant material. Using corrosion resistant screws, fasten the mounting brackets to the CVA. 3. Determine the length of the vent pipe that must be attached to the vent outlet on the concentric side of the box. Make sure to add the thickness of the wall or roof and the length of the mounting brackets. Attach the proper length of pipe to the CVA using three corrosion resistant sheet metal screws and seal this joint using metallic tape, silastic, or caulk suitable for temperatures up to 350 degrees F. If using metallic tape, wrap the tape around the pipe two full turns. 4. Determine the length of the combustion air pipe that must be attached to the combustion air intake on the concentric side of the CVA. Cut the pipe length making sure to add the thickness of the wall or roof and the length of the mounting brackets. Slide the combustion air pipe over the vent pipe and attach the proper length of pipe to the CVA using three corrosion resistance sheet metal screws. 5. Place the entire CVA assembly (with piping and support bracket attached) through the hole in the wall or roof and verify that all distances and pipe lengths requirements as specified in these instructions are net. Attach this assembly to the wall or roof using appropriate fasteners. Non-Concentric Side Vent Connections Concentric Side Vent Connections Furnace Flue Air Flue Air Size Outlet Inlet Outlet Inlet 100-150 4 inches 4 inches 4 inches 6 inches 200-400 6 inches 6 inches 6 inches 8 inches All measurements shown are diameters. Table 2 12
Venting Instructions: Concentric Venting Adapter CVA-4 Flue Outlet Concentric Side Air Inlet Concentric Side CVA Air Inlet Non-Concentric Side Flue Outlet Non-Concentric Side Concentric Venting Adapter - 4 inch diameter (CVA-4) Venting Instructions: Concentric Venting Adapter CVA-6 Flue Outlet Concentric Side Air Inlet Concentric Side CVA Air Inlet Non-Concentric Side Flue Outlet Non- Concentric Side Concentric Venting Adapter - 6 inch diameter (CVA-6) 13
Venting Instructions: Concentric Venting - Horizontal 1. The vent pipe must terminate with the vent terminal (supplied in the venting kit) for horizontal venting. The venting kit includes the concentric venting adapter, vent termination cap and the air inlet guard. 2. The combustion air pipe must terminate at least 2 inches from the wall. this will prevent water from running down the wall and into the pipe and allows for easy installation of the combustion air intake guard. 3. Caulk between the wall and the air intake pipe. 4. Maintain 12 inches from the combustion air inlet guard to the back of the vent terminal. 5. Now attach the combustion air intake guard by placing the guard on the end of the pipe. Bend the mounting tabs over and onto the pipe. Fasten the guard to the intake pipe using non-corrosive screws. Horizontal Venting A = 12 inch minimum B = 2 inch minimum C = Field supplied mounting brackets Exterior Wall C B A Exhaust Vent Terminal EXHAUST COMBUSTION AIR C Combustion Air Inlet Guard Pitch vent pipe downward from furnace.25 inches per foot Separated Combustion Concentric Venting Kit - Horizontal Furnace Size 100-150 mbh 200-400 mbh Kit contents: (1) 4 inch vent terminal (1) 6 inch vent terminal (1) 6 inch inlet guard (1) 8 inch inlet guard (1) concentric adapter (1) concentric adapter All measurements shown are diameters. The venting parts listed above are supplied by Greenheck. All vent piping is FIELD SUPPLIED by others. 14
Venting Instructions: Concentric Venting - Vertical 1. The vent must terminate with the vent terminal, supplied in the vent kit. 2. The combustion air pipe must terminate with the cap (supplied in the venting kit). This cap is specially designed to work with the concentric vent system. The venting kit includes the concentric adapter box, vent termination cap, and an air inlet terminal. 3. The bottom of the air intake pipe must terminate above the snow line, or at least 12 inches above the roof, which ever is greater. 4. The bottom of the vent cap must terminate at least 12 inches above the top of the air intake cap. 5. To attach the caps, slide the combustion air cap over the vent pipe and fasten it to the combustion air pipe with at least 3 non corrosive fastener. 6. Caulk the gap between the combustion air cap and the vent pipe with silicone sealant, or other appropriate sealants suitable for metal to metal contact and temperatures of 350 degrees F. Vertical Venting A = 12 inch minimum A1= 12 inch minimum, but should size according to expected snow depth. B = 12 inches C = Field supplied mounting brackets Building Roof B Exhaust Vent Terminal Combustion Air Inlet Terminal A1 C A A EXHAUST COMBUSTION AIR C Tee with drip leg and cleanout cap Separated Combustion Concentric Venting Kit - Vertical Furnace Size 100-150 mbh 200-400 mbh Kit contents: (1) 4 inch vent terminal (1) 6 inch vent terminal (1) 6 inch inlet terminal (1) 8 inch inlet terminal (1) concentric adapter (1) concentric adapter All measurements shown are diameters. The venting parts listed above are supplied by Greenheck. All vent piping is FIELD SUPPLIED by others. 15
Venting Instructions: 2-Pipe Horizontal 1. Construct the vent system as shown below. Looking in the direction of airflow, the venting is on the right side of unit. 2. The termination of horizontally vented systems must extend 12 inches beyond the exterior surface of an exterior wall. 3. The combustion air pipe must be a minimum of 12 inches below the vent pipe and 24 inches from the exterior wall. 4. Support the vent and combustion air pipe as shown below. Horizontal Venting A = 24 inch minimum B = 12 inch minimum C = 12 inch minimum Exterior Wall B A Exhaust Vent Terminal EXHAUST COMBUSTION AIR C Combustion Air Inlet Terminal Pitch vent pipe downward from furnace.25 inches per foot Field Supplied Support Brackets Separated Combustion 2-Pipe Venting Kit - Horizontal Furnace Size 100-150 mbh 200-400 mbh Kit contents: (2) 4 inch vent terminal (2) 6 inch vent terminal All measurements shown are diameters. The venting parts listed above are supplied by Greenheck. All vent piping is FIELD SUPPLIED by others. 16
Venting Instructions: 2-Pipe Vertical 1. Construct the vent system as shown below. Looking in the direction of airflow, the venting is on the right side of unit. 3. The vent must terminate at least 12 inches above and 12 inches horizontally from the combustion air inlet. 2. The bottom of the combustion air cap must be located above the snow line or 12 inches above the roof, which ever is greater. Vertical Venting A = 12 inch minimum A1 = 12 inch minimum, but should size according to expected snow depth. B = 24 inch minimum C = 12 inch minimum Exhaust Vent Terminal B C A1 A Combustion Air Inlet Terminal A A EXHAUST COMBUSTION AIR Tee with drip leg and cleanout cap. Separated Combustion 2-Pipe Venting Kit - Vertical Furnace Size 100-150 mbh 200-400 mbh Kit contents: (2) 4 inch vent terminal (2) 6 inch vent terminal All measurements shown are diameters. The venting parts listed above are supplied by Greenheck. All vent piping is FIELD SUPPLIED by others. 17
Control Center Layout DANGER! High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician. Before connecting power to the unit, read and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached inside the door(s) of the unit. All wiring should be done in accordance with the National Electrical Code ANSI/NFPA-70 latest edition and any local codes that may apply. In Canada, wiring should be done in accordance with the Canadian Electrical Code. The equipment must be properly grounded. 2 3 4 6 5 1 Figure 4: Unit Control Center 1. Main Power Connection - Recommended location is directly above the horizontal divider that separates the blower and control center access panels. Bring the main power and optional exhaust fan wiring into the unit at this location. 2. Control Transformer - Provides 24 Volt power for fan and the furnace controls. 3. Transformer Fuses - Provides proper fusing for control transformer. 4. Motor Fuses - Provides proper fusing for supply and exhaust fan motors. 5. Motor Starters - 24 Volt magnetic contacts for starting motors, comes standard with electronic overload. Can be provided with auxiliary contacts. Optional Exhaust Starter and Fusing (Shown) 6. Terminal Strip - 24 Volt power at strip for control wiring. Note: This is a typical control center, an exact wiring diagram is shipped with the unit. 18
Start-Up Instructions: Electrical CAUTION! Any wiring deviations may result in personal injury or property damage. Greenheck is not responsible for any damage to, or failure of the unit caused by incorrect field wiring. Sequence for Wiring Units For all units: 1. The unit s nameplate states the voltage and total amperage (MCA s) required. The main feeder supplying power to the unit should be sized for the nameplate voltage and amperage. 2. For the main power connection, a field supplied opening will be needed. The recommended location is through the control center cabinet, refer to figure 4. 3. Bring the supply power to the unit and connect to the disconnect switch. Make sure that the disconnect lugs are securely tightened. 4. Connect optional remote control panel wiring to terminal strip in the control center. Greenheck s standard control voltage is 24 VAC. 5. Wire any optional remote temperature selectors at this time. These wires should be in shielded cable or separate conduit. 6. When an optional convenience outlet is provided, a separate power supply (115/60/1) must be provided to the receptacle. This circuit must be on a ground fault breaker. 7. Wire power lead for CUBE exhaust fan through side breather tube. The power lead should be of sufficient length as to allow the CUBE fan to hinge open and to allow service of the burner controls. NOTE: Any wiring running through the unit in the airstream must be protected by flexible conduit, metal clad cable or raceways. 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. 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. 19
Start-Up Instructions: Optional Mixing Box Control Options: Night Setback requires field wiring from unit to the thermostat. This options enables a make-up unit to operate in 100% return air mode at night (unoccupied periods) so that a desired space temperature may be maintained at the lowest operational cost. During daytime (occupied) hours, the unit operates as a 100% make-up air unit with furnace(s) controlled off a field adjustable discharge temperature setting. This package includes a Deluxe Programmable Thermostat with a time clock that enables the customer to program occupied and unoccupied operation periods. Building Pressure Control requires field wiring from the unit to the factory provided remote control panel. This option enables outdoor air and return air dampers modulate to maintain the desired building pressure. The building pressure set point is field adjustable using a photohelic gauge mounted on a factory provided remote control panel. Potentiometer Control requires field wiring from the unit to the factory provided remote control panel. This option enables manual control of the outdoor air and return air damper positions. Damper positions are controlled with a potentiometer mounted on a remote control panel. Mixing Box Figure 5: Mixing Box with optional filters and dampers 20
Start-Up Instructions: Blower System Pre-Start Check List 1. Disconnect and lock-out all power switches to fan. 2. Check all fasteners, set screws and locking collars on the fan, bearings, drive, motor base and accessories for tightness. 3. Rotate the fan wheel by hand and assure no parts are rubbing. 1. Check Voltage Before starting the unit compare the supplied voltage with the unit s nameplate voltage and the motor voltage. 2. Check Blower Rotation If the blower is rotating in the wrong direction, the unit will move some air but not perform properly. To check the rotation, open the blower access door and run the blower momentarily to determine the rotation. To reverse the rotation, turn the power off and use the following procedure: Rotation For single phase units, rewire the motor per the instructions on the motor. Blower For three phase Housing units, interchange any two power leads. This can be done at the motor starter. 3. Check for Vibration Check for unusual noise, vibration or overheating of bearings. Excessive vibration maybe experienced during initial start-up. Left unchecked, excessive vibration can cause a multitude of problems, including structural and/or component failure. Many conditions can be discovered by careful observation. If observation cannot locate the source of vibration, a qualified technician using vibration analysis equipment should be consulted. If the problem is wheel unbalance, in-place balancing can be done providing there is access to the fan wheel. 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. Refer to the Troubleshooting section of this manual if a problem develops. 4. Check the V-belt drive for proper alignment and tension. Special Tools Required Voltage meter Tachometer Amperage meter 4. Air Volume Check and Measurement Along with the building balance, the units air volume (cfm) should be measured and compared with its rated air volume. The most accurate way to measure the air volume is by using the pitot traverse method in the ductwork away from the blower. Other methods can be used but should be proven and accurate. To adjust the air volume, change the fan rpm or the system losses. See Trouble Shooting in this manual. 5. Measure Motor Voltage, Amperage and Fan rpm All access doors must be installed except the control center door. Measure and record the input voltage and motor amperage(s). To measure the fan rpm, the blower door will need to be removed. Minimize measurement time because the motor may over amp with the door removed. Compare measured amps to the motor nameplate full load amps and correct if over amping. See the Trouble Shooting section in this manual. 6. Settings for Optional Components Optional Freeze Protection: This shuts down the blower if the output temperature is below the set point. A timer allows the blower to operate during start-up. This will reset when turned off. Typical settings are: Discharge temperature = 45 F Timer = 5 minutes Optional 2 Hour Time Delay: This allows the unit to operate for up to 2 hours after the control panel switch has been turned off. The timer is adjustable. Optional Inlet Air Sensor: This shuts down the heater if the incoming air temperature is higher than the set point. this switch will automatically reset as temperature decreases. A typical setting is 60 F. 21
Start-Up Instructions: Furnace **WARNING** If the information in this manual is not followed exactly, a fire or explosion may result in property damage, personal injury or loss of life. FOR YOUR SAFETY IF YOU SMELL GAS: 1. Open windows 2. Don t touch electrical switches 3. Extinguish any open flames 4. Immediately call your gas supplier 5. The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous. Furnace Performance Data Air Temperature Rise Through Unit ( F) Furnace Input Output 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Qty. Model (MBH) (MBH) CFM 1 PVF 100 100 80 2963 2469 2116 1852 1646 1481 1347 1235 1140 1058 988 926 871 823 780 741 1 PVF 150 150 120 4444 3704 3175 2778 2469 2222 2020 1852 1709 1587 1481 1389 1307 1235 1170 1111 1 PVF 200 200 160 5926 4938 4233 3704 3292 2963 2694 2469 2279 2116 1975 1852 1743 1646 1559 1481 1 PVF 250 250 200 7407 6173 5291 4630 4115 3704 3367 3086 2849 2646 2469 2315 2179 2058 1949 1852 1 PVF 300 300 240 8889 7407 6349 5556 4938 4444 4040 3704 3419 3175 2963 2778 2614 2469 2339 2222 1 PVF 350 350 280 10370 8642 7407 6481 5761 5185 4714 4321 3989 3704 3457 3241 3050 2881 2729 2593 1 PVF 400 400 320 11852 9877 8466 7407 6584 5926 5387 4938 4558 4233 3951 3704 3486 3292 3119 2963 2 PVF 250 500 400 14815 12346 10582 9259 8230 7407 6734 6173 5698 5291 4938 4630 4357 4115 3899 3704 2 PVF 300 600 480 NA 14815 12698 11111 9877 8889 8081 7407 6838 6349 5926 5556 5229 4938 4678 4444 2 PVF 350 700 560 NA NA 14815 12963 11523 10370 9428 8642 7977 7407 6914 6481 6100 5761 5458 5185 2 PVF 400 800 640 NA NA NA 14815 13169 11852 10774 9877 9117 8466 7901 7407 6972 6584 6238 5926 3 PVF 350 1,050 840 NA NA NA NA NA NA 14141 12963 11966 11111 10370 9722 9150 8642 8187 7778 3 PVF 400 1,200 960 NA NA NA NA NA NA NA 14815 13675 12698 11852 11111 10458 9877 9357 8889 Ratings shown are for elevations up to 2000 ft. For higher elevations, the input should be reduced by 4% per 1000 ft. of elevation above sea level. In Canada, from 2000 to 4500 ft in elevation, the unit must be derated to 90% of the input listed above. The unit shall also be used in accordance with standard CGA 2.17. 22
Start-Up Instructions: Furnace - Gas Connection Gas Supply Pressure Requirements Natural: 6 to 14 in. wc LP: 11 to 14 in. wc 1. Single furnaces (furnace input 100 to 400 MBH) have a single 3 4 inch connection. Double furnaces (furnace input 500 to 800 MBH) have two 3 4 inch connections, and triple furnaces (furnace input 1050 to 1200 MBH have three 3 4 inch connections. 2. When connecting the gas supply, the length of the run must be considered in determining the pipe size to avoid excessive pressure drop. Refer to a Gas Engineer s Handbook for gas pipe capacities. 3. A drip leg should be installed in the pipe run to the unit. 4. Install an easily accessible ground joint union and a manual shut off valve (these are required by some local codes) for emergency shut off and easy servicing of the controls. 5. A 1 8 inch NPT plugged tap shall be installed immediately ahead of the gas supply connection to the furnace. 6. After gas piping is completed, carefully check all piping connections for gas leaks. Use soap solution or equivalent for testing. DO NOT use a flame or other source of ignition to check for gas leaks. 7. When leak testing pressures above 14 in. wc ( 1 2 psi), close the field installed shutoff valve, disconnect the furnace and its gas train from the gas supply line, and plug the supply line before testing. 8. When leak testing at pressures equal to or less than 14 in. wc ( 1 2 psi) close the field-installed shutoff valve to isolate the unit from the gas supply line before testing. From Gas Manual Shut Off Gas Valve Cock Ground Joint Union To Controls 1/8 in. Plugged 6 in. Trap Recommended Piping to Controls 23
Start-Up Instructions: Furnace - Control Center WARNING!!! Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage. All appliances must be wired strictly in accordance with wiring diagram furnished with the unit. Any wiring different from the diagram could result in a hazard to persons and property. Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C. 1. Installation of wiring must conform with local building codes. In the absence of local codes, installation must conform to the National Electric Code ANSI/NFPA 70-Latest Edition. Unit must be electrically grounded in conformance with this code. In Canada, wiring must comply with CSA C22.1, Canadian Electrical Code. 2. All furnaces are provided with a wiring diagram located on the inside of the access panel. 3. The combustion blower motor will not run unless the furnace is turned on and the gas controls are calling for heat. Furnace Control Center Layout 1 13 2 3 4 9 6 5 10 12 11 8 7 Figure 7: Furnace Control Center 1. Maxitrol Amplifier - Converts the signal from the discharge air stat to a working voltage to control the modulating gas valve. (Electronic Modulation Only) 2. Discharge Temperature Dial Control - Sets the desired discharge temperature(electronic Modulation Only). 3. Combustion Blower - Exhausts the products of combustion from the furnace tubes. 4. Ignition Controller - Continually monitors, analyzes, and controls the proper operation of the gas burner. 5. Air Pressure Switch - Tests to ensure the combustion blower is operating. 6. Time delay relay 7. Combination Gas Valve - Contains main pressure regulator, safety shut-off valves, and manual shut off knob. 8. Modulating Gas Valve - Modulates gas to main burner for proper furnace discharge temperature. (Electronic Modulation Only) 9. Manifold Pressure Test Port - Used for checking the manifold gas pressure. 10. High Limit - Protects furnace from over heating. Auto reset device. 11. Discharge Air Sensor - Measures discharge air temperature. 12. Igniter - Ignites burner by sparking. 13. Flame Sensor - Ensures that each burner has ignited. 24
Start-Up Procedure 1. Turn off power to the unit at the disconnect switch. Close all manual gas valves. 2. Check that all gas and electrical connections are weatherized. 3. Make sure that the combustion air inlet and the combustion blower discharge are free from obstructions. 4. Inspect the unit to make sure that no damage has occurred during installation. 5. With the Furnace control center access panel removed, connect a U tube manometer to the manifold pressure test port (Figure 7, item 9). This will be used for checking the manifold gas pressure. 6. Set the thermostat or discharge temperature controls to lowest setting. 7. Open all manual gas valves including the combination gas valve. 8. Call for heat with the thermostat or discharge temperature controls and allow the burner to light. Greenheck indirect furnaces are equipped with an automatic spark ignition system which automatically lights the burner. DO NOT attempt to light the burners manually. 9. After the burner is lit, check to make sure that the supply blower is operating. 10. Verify that the gas controls sequence properly (see Sequence of Operation below). 11. Check the manifold gas pressure (see Burner Adjustments). 12. If burner is cycling off and on frequently, then the discharge sensor (Figure 7, item 11) may need to be relocated in the ductwork down stream from the unit. Sequence of Operation Power-up/Standby After power is supplied to the unit: 1. The ignition control will reset and perform a selfcheck routine. 2. The diagnostic LED will flash for up to four seconds. 3. The ignition control will begin scanning the thermostats. Heat Mode When the thermostat or discharge temperature controls call for heat: 1. The ignition control will check that the pressure switch for the combustion blower is open. 2. The combustion blower will be energized and the 15-second pre-purge begins. 3. The gas valve is energized and the igniter will spark for up to 10 seconds. Natural Gas - If a flame is not sensed during the trial for ignition, two additional trials will be attempted before going into lockout for one hour. LP Gas - If a flame is not sensed during the trial for ignition, the control will go into lockout for one hour. 4. When a flame is sensed, sparking stops immediately. The gas valve and combustion blower remain energized. 5a. Stage control: The burner will light at 100% fire and remain there for 10 seconds. The thermostat will then operate the burners at high or low fire, depending on the demand for heat. 5b. Electronic Modulation - The burner will light at 100% fire and remain there for 10 seconds. The main burner gas valve will then modulate from 100% down to 50% as needed. If the burner remains on low fire for an extended period of time, the burner will shut off and re-light as necessary. 6. The ignition control constantly monitors the thermostat or discharge temperature control, pressure switch, and burner flame to assure proper operation. 7. When the thermostat or discharge temperature controls are satisfied, the combination gas valve is de-energized and the combustion blower shuts off following a 30-second post-purge period. Recovery from Lockout The ignition control will automatically reset after 1 hour if the thermostat is still calling for heat. Prior to 1 hour, a manual reset (cycle power to unit) is required. The thermostat may be reset or the power interrupted for a period of 5 seconds. See Trouble Shooting in this manual for Ignition Control Diagnostics. 25
Furnace Controls Staged Temperature Controls The furnace stage controls are located in the furnace control center. The discharge temperature setting is located on the control furthest to the left (See Figure 8). One control is provided for each stage of heating. The offset and differential settings for each stage are preset at the factory; however, field adjustment may be required to get the best control for your application. See literature provided for information on setting these controls. The following are the descriptions of the furnace controls available. 2 Stage (100-400 MBH) 2 stage furnace (50%, 100%) 2 Stage (500-800 MBH) 1st furnace 1 stage (50%) 2nd furnace 1 stage (100%) 3 Stage (1050-1200 MBH) 1st furnace 1 stage (33%) 2nd furnace 1 stage (67%) 3rd furnace 1 stage (100%) 4 Stage (500-800 MBH) 1st furnace 2 stage (25%, 50%) 2nd furnace 2 stage (75%, 100%) 6 Stage (1050-1200 MBH) 1st furnace 2 stage (17%, 33%) 2nd furnace 2 stage (50%, 67%) 3rd furnace 2 stage (83%, 100%) Figure 8: Staged Control High and Low Fire Settings for Staged Burner Controls Setting Manifold Pressure for Two Stage Gas Control 1. Set the unit to high fire by setting the discharge temperature control or thermostat to its maximum setting. If the ambient temperature is warm, the unit may not stay at high fire. 2. Measure the burner manifold pressure at the manifold pressure test port (see Figure 7) using a U tube manometer. The pressure on high fire should be 3.5 inches wc for natural gas and 10 inches wc for LP gas. To change the pressure, adjust the regulator adjustment screw on the combination gas valve. Clockwise rotation will decrease the gas pressure and counter clockwise rotation will increase the gas pressure. 3. Set the unit to low fire by removing the wire from the high fire terminal on the combination gas valve (See Figure 9). Clockwise rotation will decrease the gas pressure and counter clockwise rotation will increase the gas pressure. 4. The manifold pressure on low fire for natural gas should be.88 inches wc and for LP gas, 2.5 inches wc. To change the pressure, use the low fire adjustment screw on the combination gas valve. Solenoid High Fire Adjustment Low Fire Adjustment High Fire Terminal Figure 9: Combination Gas Valve 26
Electronic Modulation Temperature Controls A Discharge Temperature Dial is used for temperature control for electronic modulation. The temperature dial will be located in the furnace control center. If a remote panel has been ordered, the Discharge Temperature Dial will be located on the panel. The Electronic Modulation (100-400 MBH) will modulate from 50% to 100% of furnace input. High and Low Fire Settings for Electronic Modulation Check the high and low gas pressures on initial start up per instructions below. These settings are pre-set at the factory, but can be adjusted in the field if necessary. Set the high fire first and the low fire second. The low fire must always be checked if the high fire is changed. Modulating Valve Low fire adjustment B Combination Gas Valve High fire adjustment A Figure 10: Electronic Modulation Valves 1. Set the unit to high fire by placing a jumper between terminals 7 and 8 on the Maxitrol amplifier. 2. Measure the burner manifold pressure for each furnace at the pressure test port (see Figure 7) using a high quality manometer that can measure low gas pressures. The pressure at high fire should be 3.5 in. wc for natural gas and 10.0 in. wc for LP Gas. To change the pressure, adjust the high fire screw (under cap screw) on the combination gas valve. Clockwise rotation will decrease the gas pressure and counter clockwise rotation will increase gas pressure. 3. To get the unit to low fire: Remove the wire from terminal 3 on the amplifier and isolate it from touching anything. Set the discharge temperature selector to the highest setting. If there is a room override thermostat, turn the dial to the highest setting. 4. Measure the manifold pressure on low fire, it should be 0.88 in. wc for natural gas and 2.5 in. wc for LP gas. 5. To adjust the low fire, remove the by pass cap (A) and turn screw (B) as shown in diagram. Adjust the screw indicated in Figure 10 on the modulating valve. Clockwise rotation will decrease gas the pressure and counter clockwise rotation will increase gas pressure. 6. Reconnect wire to terminal 3. 7. Remove jumper and place all wires back to where they were and plug the manifold pressure port. 27
Installation Instructions for: Optional Evaporative Cooling Section When mounting this section, it is important that it is level to ensure proper operation and water drainage. Piping should be of adequate size to provide sufficient supply of water to meet the maximum demand of the unit. Field Installation 1. Evaporative cooling sections for housing 32 units ship separately. After the base unit and the equipment support rail is installed, the evaporative cooing section may be installed. This section must be installed level for proper operation. A weather tight seal is required between the evaporative cooling section and base unit. Apply a heavy bead of caulk around the airstream opening to create weather tight seal. Using a spreader bar and factory lifting lugs (see Figure 11), lift and center the cooling section on the equipment support. Make sure that the U-shaped flange on the evaporative cooling section fits over the flange of the base unit. Use self tapping screws to fasten the cooling section to the base unit along the top and down both sides (see Figure 11). Fasten at the top through the flanges. Fasten along the sides from inside the cooling section. Remove Figure 11: Evaporative Installation cooling section access doors and evaporative media for access to the side fastening points. Start-Up Instructions: Optional Evaporative Cooling Evaporative Cooling Section Overflow Supply Line Manual Shutoff Valve Trap Manual Shutoff Valve Drain Line Figure 12: Evaporative Piping 1. After the unit is set in place, run the overflow and drain lines to the exterior fittings on the unit. The supply line can be attached at the downstream side of the evaporative section. A manual shut off valve should be mounted in the supply line near the unit for servicing purposes. The drain line should have an air vent for clean out purposes. Also, a trap should be installed in the drain line to prevent sewer gas from being drawn into the unit (see Figure 12). 2. The cooler will be prewired by the factory. Housing size 32 units ship in separate sections and will need to be field wired to the 2 x 4 handy box in the cooling section. Wires should be run in a metal conduit from terminals 1 and 10 to the junction box. 3. Check to make sure that the pump filter is around the pump inlet. 4. Turn the water on and allow the pan to fill up with water. The float should be adjusted to provide 2 inches of water depth in the sump. 28