Installation, Operation and Maintenance Manual

Part #461006 Indirect Gas-Fired Furnaces Installation, Operation and Maintenance Manual Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference. Model PVF General Safety Information Model PVF Indirect Gas Furnace, available in Energy Recovery models ERH, ERCH, HRE and VersiVent. For unit specific information, refer to the respective Installation, Operation and Maintenance Manual. 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, NSI Z223.1 or in Canada, CN/CG-B149 installation does. ll electrical wiring must be in accordance with the regualtion of the National Electric Code, NSI/ NFP 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 Installation Location....................... 3 Venting for Outdoor Units.............. 3 Venting for Indoor Units............... 3 Standard Indoor Venting.............. 4 Furnace Connection Locations........... 5 Concentric Venting................ 6-7 Two Pipe Venting................. 8-9 Electrical Wiring.................. 10 Furnace Control Center Layout.......... 10 Gas Piping..................... 11 Start-Up Operation Start-Up, General..................12 Furnace Controls................ 12-13 Sequence of Operation............. 14 Performance Data................ 14 Troubleshooting..................15 Routine Maintenance.............. 16 WRNING 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. 1 Model PVF Indirect Gas-Fired Furnace

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Installation Location 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, NSI Z223.1, or the CN/CG B-149 Installation Codes. 2. Building materials that will be affected by flue gases should be protected. 3. void 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. 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. 7. To prevent premature heat exchanger failure, do not locate units where chlorinated, halogenated, or acid vapors are present. 8. Units must not be installed in a potentially explosive, flammable, or corrosive atmosphere. For additional information on installation of the energy recovery unit, refer to the respective units Installation, Operation, and Maintenance (IOM) manuals: Outdoor Indoor Unit Clearances to Combustible Materials Combustion blower discharge must be located 42 inches from any cmobustible materials Clearances are determined by the National Fuel Gas Code and/or other local codes. Installation of Venting for Outdoor Units 1. Do not modify or obstruct the combustion air inlet cover or the combustion blower weatherhood. 2. During the winter months, periodically clear snow from access side of unit to prevent blockage of the inlet and exhaust openings. 3. Do not add any vents other than those supplied by the manufacturer. NOTE Vent piping is supplied by others, not Greenheck. Installation of Venting for Indoor Units There are three venting methods for indoor mounted units. For each method, the units can be vented horizontally through an exterior wall or vertically through the roof. Specific venting instructions are provided for each method and shown in the following pages. Construct the vent system as shown in these instructions. Refer to your unit specific submittal to determine the applicable venting option. The venting method options are: Standard Indoor Venting uses building air for combustion vents exhaust to outdoors one exterior roof or wall penetration Separated Combustion Concentric Venting uses outside air for combustion vents exhaust to outdoors one exterior roof or wall penetration Separated Combustion 2-Pipe Venting uses outside air for combustion vents exhaust to outdoors two exterior roof or wall penetrations The following guidelines must be adhered to for all indoor units: 1. Venting installation must conform with local building codes. In the absence of local codes, installation must conform with the National Fuel Gas Code, NSI Z223.1 or in Canada, CN/ CG-B149 installation codes. 2. For Standard Indoor Venting, use exhaust pipe approved for a category III appliance or single wall, 26 gauge or heavier galvanized vent pipe. The piping is required to be gas tight by NSI. 3. For Separated Combustion venting, sealed singlewall galvanized air pipe is recommended. 4. The joints must be sealed with a metallic tape or silastic suitable for temperatures up to 350ºF. 5. minimum of 12 inches of straight vent pipe is recommended after the exhaust connection and before any elbows. 6. Vertical combustion air pipes should be fitted with a tee, 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. 7. To reduce condensation, insulate any vent runs greater than 5 feet. 8. ll vent pipe connections should be made with at least three corrosion resistant sheet metal screws. 9. Refer to the National Fuel Gas Code for additional piping guidelines. NOTE Vent piping is supplied by others, not Greenheck. Model PVF Indirect Gas-Fired Furnace 3

Installation of Standard Indoor Venting Standard Indoor Venting uses one penetration through an exterior wall or roof for venting the flue exhaust. The combustion air is scavenged from the air inside the building (no piping required). When units are installed in tightly sealed buildings, provisions should be made to supply an 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 BTUs per hour of input rating. Vent terminals must be used (one vent terminal included with each furnace). Construct the vent system as shown in the Horizontal and Vertical drawings below and reference the Vent Pipe Diameter table for the correct vent pipe diameters. = 12 in. minimum EXHUST ir Inlet Pitch vent pipe downward from furnace 1/4 inch per foot Exterior Wall Exhaust Vent Terminal Vent Length Limitations Refer to table for minimum and maximum vent lengths. 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. Vent Length Minimum (feet) Maximum (feet) Horizontal 5 70 Vertical 10 70 Vent Pipe Diameter Select the vent pipe diameter. Use only the specified pipe size. Furnace Size (MBH) Exhaust (inches) Combustion (inches) 100-150 4 6 200-400 6 8 Installing Exhaust Vent Pipe Install the vent pipe with a minimum downward slope (from the unit) of 1/4-inch per foot (horizontal venting only). Securely suspend the pipe from overhead structures at points no greater than 3 feet apart. ttach the vent terminal to the end of the exhaust pipe. Seal Opening Using an appropriate method, seal the wall/roof opening around the exhaust pipe. Standard Indoor Venting - Horizontal Roof Line B Exhaust Vent Terminal EXHUST ir Inlet = 12 inch minimum B = 12 inch minimum but should size according to expected snow depth Standard Indoor Venting - Vertical 4 Model PVF Indirect Gas-Fired Furnace

Furnace Connection Locations Model ERH, ERCH, HRE Furnace Connection Locations Model VersiVent C B Combustion ir Inlet Exhaust Outlet Exhaust Outlet 3/4 inch Gas Connection F E C D 3/4 inch Gas Connection B D ERH ERCH HRE Furnace (MBH) B C D E F 20 100-150 23.75 24.438 24.438 3.75 10.50 16.625 45 100-150 23.75 24.50 24.50 6.00 12.75 18.875 45 200-250 23.75 23.50 24.125 6.00 25.125 32.25 55 150 26.63 27.25 27.25 6.00 12.75 18.875 55 200-300 26.63 26.38 27.00 6.00 22.50 29.63 90 300-400 37.63 37.38 38.00 6.00 25.00 32.125 VersiVent Furnace (MBH) B C D 45 75 19.587 14.372 15.638 18.083 45, 65 100 19.587 14.372 15.638 18.083 45, 65 150 8.092 13.872 12.838 19.208 45, 65, 90 200 8.092 13.872 12.838 19.208 45, 65, 90 250 8.092 13.872 15.686 19.208 45, 65, 90 300 8.092 13.872 17.709 19.208 45, 65, 90 350-400 8.092 13.372 21.838 19.208 Model PVF Indirect Gas-Fired Furnace 5

Installation of Concentric Venting (General) Concentric venting allows the exhaust pipe and combustion air pipe to pass through a single hole in the roof or wall of the building. concentric venting adapter (CV) is required for concentric venting. Depending upon whether the furnace was ordered for Horizontal or Vertical concentric venting, each indirect gas furnace will ship with the following items: Horizontal Venting Vertical Venting a. Exhaust Pipe Vent Terminal b. Concentric Venting dapter c. Inlet Guard a. Exhaust Pipe Vent Terminal b. Concentric Venting dapter c. Inlet Terminal Horizontal Venting Refer to the diagram below for venting on horizontal concentric systems. Maintain at least 12 inches from the combustion air inlet guard to the exhaust vent terminal (Dim. B). To prevent water from running into the combustion air pipe and to allow for easy installation of the combustion air inlet guard, the combustion air pipe must terminate at least 2 inches from the exterior surface of the outside wall (Dim. ). = 2 inch minimum B = 12 inch minimum Mounting Bracket COMBUSTION IR Exterior Wall B The concentric venting adapter is designed for indoor installations and should never be installed on the exterior of the building. The exhaust pipe must terminate with the vent terminal. For horizontal venting, the combustion air pipe must terminate with the inlet guard. For vertical venting, the combustion air pipe must terminate with the inlet terminal. Pitch vent pipe downward from furnace 1/4 inch per foot EXHUST Mounting Bracket Exhaust Vent Terminal Combustion ir Inlet Guard CV-4 4-inch Concentric Venting dapter CV-6 6-inch Concentric Venting dapter Vertical Venting Refer to the diagram below for venting on vertical concentric systems. Maintain at least 12 inches between the top of the combustion air inlet terminal and the bottom of the exhaust vent terminal (Dim. B). The bottom of the combustion air inlet terminal must terminate above the snow line, or at least 12 inches above the roof, which ever is greater (Dim. ). tee with cleanout must be provided on the combustion air and exhaust pipe to prevent debris from entering the heat exchanger. Combustion ir Connection Concentric Side Exhaust Connection Concentric Side = 12 inch minimum but should size according to expected snow depth B = 12 inch minimum C = 12 inch minimum Roofline B Exhaust Vent Terminal Combustion ir Inlet Terminal CV Mounting Bracket C COMBUSTION IR EXHUST Mounting Bracket Combustion ir Connection Non-Concentric Side Exhaust Connection Non-Concentric Side C Tee with drip leg and cleanout cap Top View 6 Model PVF Indirect Gas-Fired Furnace

Concentric Vent Connection Diameter Vent terminals must be used (one vent terminal included with each furnace). Construct the vent system as shown in the Horizontal and Vertical drawings on previous page and reference the table for the correct vent connection diameters. Vent Length Refer to table for minimum and maximum vent lengths. 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. Furnace Size (MBH) Exhaust (inches) Combustion (inches) 100-150 4 6 200-400 6 8 Vent Length Minimum (feet) Maximum (feet) Horizontal 5 70 Vertical 10 70 1. Determine Venting Location Determine the location of the concentric venting adapter (CV) based on any clearances that must be maintained (follow all codes referenced in these instructions). 2. ttach Mounting Brackets ttach field supplied, corrosion resistant, mounting brackets to the CV using corrosion resistant sheet metal screws. 3. Install Exhaust Pipe Slide the exhaust pipe through the CV. Provide enough exhaust piping to pass through the wall (or floor) and provide the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake. With all required clearances satisfied, attach the exhaust pipe to the CV. 4. Install Combustion ir Pipe ttach a field supplied combustion air pipe to the concentric side of the CV. For horizontal venting, provide enough combustion air piping to pass through the wall and provide the minimum clearance of 2 inches between the combustion air intake and the exterior surface of the outside wall. For vertical venting, provide enough combustion air piping to pass through the roof and provide the minimum clearance of 12 inches between the combustion air intake and the exterior surface of the roof. This clearance may need to be increased to allow for snow accumulation. Be sure to maintain the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake. 5. Install CV ssembly Place the CV assembly through the wall/roof and verify that all minimum clearance requirements as specified in these instructions are met. Secure the CV assembly to the wall/ceiling with mounting brackets and corrosion resistant sheet metal screws. 6. ttach CV ssembly to Unit ttach the exhaust pipe to the unit s combustion exhaust. Using an additional combustion air pipe, connect the unit s combustion air supply intake to the combustion air connection on the CV. For vertical venting, include the required tees with drip legs and clean outs. Combustion ir Connection IG Furnace Control Center ccess Exhaust Connection 7. Install Combustion ir Inlet Guard/ Terminal and Exhaust Vent Terminal Slide the combustion air inlet guard (for horizontal venting) or the inlet terminal (for vertical venting) over the exhaust pipe and fasten it to the combustion air pipe. ttach the exhaust vent terminal to the discharge end of the exhaust piping. 8. Seal Opening Seal the opening between the wall/floor and the air intake pipe using an appropriate method. Model PVF Indirect Gas-Fired Furnace 7

Installation of Two Pipe Venting Horizontal Venting Refer to the diagram below for venting on horizontal two pipe systems. Maintain at least 12 inches of clearance between the exhaust pipe termination and the exterior surface of the outside wall (Dim. ). The combustion air pipe must be a minimum of 12 inches below the exhaust pipe (Dim. C) and 12 inches from the exhaust pipe vent terminal (Dim. B). minimum of 1 inch and a maximum of 48 inches of building wall thickness is required for separated combustion vent pipe. Pitch vent pipe downward from furnace 1/4 inch per foot = 2 inch minimum B = 12 inch minimum C = 12 inch minimum Two (2) Field Supplied Support Brackets EXHUST Exhaust Vent Terminal COMBUSTION IR Exterior Wall B C Combustion ir Inlet Terminal Vertical Venting Refer to the diagram below for venting on vertical two pipe systems. The combustion air pipe must terminate at least 12 inches above the roof. This clearance may need to be increased to accommodate for snow accumulation (Dim. ). The exhaust must terminate at least 12 inches above (Dim. B) and 12 inches horizontally (Dim. C) from the combustion air inlet. Two Pipe Vent Connection Diameter Vent terminals must be used (two vent terminals included with each furnace). Construct the vent system as shown in the Horizontal and Vertical drawings on this page and reference the table at the right for the correct vent connection diameters. Vent Length Refer to the table for minimum and maximum vent lengths. 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. Furnace Size (MBH) Exhaust (inches) Combustion (inches) 100-150 4 6 200-400 6 8 Vent Length Minimum (feet) Maximum (feet) Horizontal 5 70 Vertical 10 70 1. Install Combustion ir Pipe Run a combustion air pipe from the unit s combustion air intake through the exterior wall/roof to the outdoors. For horizontal venting, the combustion air pipe must terminate at least 12 inches from the exhaust pipe vent terminal. ttach the combustion air inlet terminal to the end of the combustion air pipe. Using field supplied mounting brackets, support the combustion air pipe as needed. For vertical venting, the combustion air pipe must terminate at least 12 inches above the roof. This clearance may need to be increased to accommodate snow accumulation. Roofline Combustion ir Inlet Terminal B Exhaust Vent Terminal Combustion ir Connection D COMBUSTION IR D EXHUST Tee with drip leg and cleanout cap IG Furnace Control Center ccess = 12 inch minimum but should size according to expected snow depth B = 12 inch minimum C = 12 inch minimum D = 12 inch minimum 8 Model PVF Indirect Gas-Fired Furnace

2. Install Exhaust Pipe Run an exhaust pipe from the unit s combustion exhaust through the exterior wall/roof to the outdoors. For horizontal venting, the exhaust pipe must terminate at least 12 inches from the exterior surface of the outside wall and at least 12 inches above the combustion air pipe. ttach exhaust vent terminal to the end of the exhaust pipe. Using field supplied mounting brackets, support the exhaust pipe as needed. For vertical venting, maintain at least 12 inches between the bottom of the exhaust vent terminal and the top of the combustion air inlet terminal. Maintain at least 12 inches horizontally between the exhaust vent and the combustion air inlet. ttach exhaust vent terminal to the end of the exhaust pipe. 3. Seal Openings Using an appropriate method, seal the wall/roof openings around the piping. Model PVF Indirect Gas-Fired Furnace 9

Installation of Electric Wiring Furnace Control Center Layout WRNING Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage. WRNING ll appliances must be wired strictly in accordance with wiring diagram furnished with the unit. ny wiring different from the diagram could result in a hazard to persons and property. WRNING 4 9 3 1 2 ny original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105 C 6 1. Installation of wiring must conform with local building codes. In the absence of local codes, installation must conform to the National Electric Code NSI/NFP 70-Latest Edition. Unit must be electrically grounded in conformance with this code. In Canada, wiring must comply with CS C22.1, Canadian Electrical Code. 2. ll furnaces are provided with a wiring diagram located on the inside of the access panel. Refer to this wiring diagram for all wiring connections. 3. The combustion blower motor will not run unless the furnace is turned on and the gas controls are calling for heat. 8 5 7 1. Two-stage temperature controls - Controls the furnace stages based on the unit discharge temperature. 2. Combustion blower - Exhausts the products of combustion from the furnace tubes. 3. Ignition controller - Continually monitors, analyzes, and controls the proper operation of the gas burner. 4. Manifold pressure test port (1/4-inch pipe thread) - Used for checking the manifold gas pressure. 5. Time delay relay - llows burner to stay at high fire for 10 seconds upon being lit. 6. ir pressure switch - Tests to ensure the combustion blower is operating. 7. Two-stage gas valve - Contains main pressure regulator, safety shut-off valves, and manual shut off knob. It controls the furnace to 50% or 100% fire. 8. Ignitor - Provides spark for burner ignition. 9. Flame sensor - Ensures that each burner has ignited. 10 Model PVF Indirect Gas-Fired Furnace

Installation of Gas Piping Gas Pressure Requirements Natural: LP: *6 to 14 in. wg *11 to 14 in. wg *Falling below minimum gas pressure requirements will reduce the MBH output. In turn, the unit will not be able to fully condition the space on peak heating days. If gas pressure is simply too low for requirements, we recommend the local gas company be contacted to determine if a booster pump would be feasible. From Gas Gas Cock Ground Joint Union To Controls 1/8 in. Plugged 6 in. Trap Recommended Piping to Controls 1. Furnaces (input 100 to 400 MBH) have a single 3/4 inch, female pipe thread connection. 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. 6-inch 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. 1/8 inch NPT plugged tap shall be installed immediately ahead of the gas supply connection to the furnace. 6. fter 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. wg (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. wg (1/2 psi) close the field-installed shutoff valve to isolate the unit from the gas supply line before testing. Model PVF Indirect Gas-Fired Furnace 11

Start-Up 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 (refer to the Control Center Layout under Installation). 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 and turn power on. 8. Call for heat with the thermostat or discharge temperature controls and allow the burner to light. Greenheck duct furnaces are equipped with an automatic spark ignition system which automatically lights the burner. DO NOT attempt to light the burners manually. 9. fter 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). 11. Check the manifold gas pressure (see Burner djustments on following pages). Furnace Controls Staged Temperature Controls For Energy Recovery Units without Temperature Control Package The furnace stage controls are located in the furnace control center. One control is provided for each stage of heating. The discharge temperature setting is located on the control furthest to the left. The offset and differential settings for each stage are preset at the factory; however, field-adjustments may be made to get the best control for your application. See the literature provided with the controls for further information. Staged Temperature Controls For Energy Recovery Units with Temperature Control Package If two-stage control is ordered with a Temperature Control Package, the controller in the unit s main control center will control the stages of heating. The temperature set point may be adjusted on the controller (See Temperature Controller IOM). Turndown Modulation Two Stage 2 : 1 50%, 100% Electronic Modulation 2 : 1 50% - 100% Staged Burner djustments 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 Control Center Layout on page 10) using a U tube manometer. The pressure on high fire should be 3.5 in. wg for natural gas and 10 in. wg 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. 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 0.88 in. wg and 2.5 in. wg for LP gas. To change the pressure, use the low fire adjustment screw on the combination gas valve. Solenoid High Fire djustment Low Fire djustment High Fire Terminal Combination Gas Valve 12 Model PVF Indirect Gas-Fired Furnace

Electronic Modulation Temperature Controls B Combination Gas Valve High fire adjustment Low Fire Operation 3. 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. wg for natural gas and 2.5 in. wg for LP gas. 5. To adjust the low fire, remove the bypass cap () and turn screw (B) as shown in diagram. djust the screw indicated on the modulating valve. Clockwise rotation will decrease gas pressure and counterclockwise 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. Modulating Valve Low fire adjustment Manifold Pressure (inches wg) Natural Gas LP Low High Low High 2 : 1 Electronic Modulation 3.5 0.88 10 2.5 Electronic Modulation Valves For Energy Recovery Units without Temperature Control Package Discharge Temperature Dial is used for temperature control for electronic modulation. The temperature dial will be located in the furnace control center. For Energy Recovery Units with Temperature Control Package The Temperature Controller in the unit s main control center will provide the electronic modulation control. High and Low Fire Settings for Electronic Modulation Check the high and low gas pressures on initial start up per the instructions below. These settings are preset at the factory, but should 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. High Fire Operation 1. Place a jumper between terminals 7 and 8 on the Maxitrol amplifier. 2. Measure the burner manifold pressure at each furnace at the pressure test port (see Control Center Layout under Installation) using a high quality manometer that can measure low gas pressures. The pressure at high fire should be 3.5 in. wg for natural gas and 10.0 in. wg 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. Model PVF Indirect Gas-Fired Furnace 13

Sequence of Operation Power-up/Standby fter 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 ignitor 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. Two-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, pressure switch, and burner flame to assure proper operation. 7. When the thermostat or discharge temperature controls are satisfied, the main valve is deenergized and the combustion blower shuts off following a 30-second post-purge period. Recovery from Lockout The ignition control will automatically reset after one hour if the thermostat is still calling for heat. Prior to one 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 page 7 for Ignition Control Diagnostics. Performance Data Model Number Input Output (MBH) (MBH) ir Temperature Rise Through Unit ( F) 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 PVF 100 100 80 3704 2963 2469 2116 1852 1646 1481 1347 1235 1140 1058 988 926 871 823 780 741 PVF 150 150 120 5556 4444 3704 3175 2778 2469 2222 2020 1852 1709 1587 1481 1389 1307 1235 1170 1111 PVF 200 200 160 7407 5926 4938 4233 3704 3292 2963 2694 2469 2279 2116 1975 1852 1743 1646 1559 1481 PVF 250 250 200 9259 7407 6173 5291 4630 4115 3704 3367 3086 2849 2646 2469 2315 2179 2058 1949 1852 PVF 300 300 240 11111 8889 7407 6349 5556 4938 4444 4040 3704 3419 3175 2963 2778 2614 2469 2339 2222 PVF 350 350 280 12963 10370 8642 7407 6481 5761 5185 4714 4321 3989 3704 3457 3241 3050 2881 2729 2593 PVF 400 400 320 14815 11852 9877 8466 7407 6584 5926 5387 4938 4558 4233 3951 3704 3486 3292 3119 2963 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 CG 2.17. CFM 14 Model PVF Indirect Gas-Fired Furnace

Troubleshooting LED Indication Error Mode Steady On Internal control failure 1 flash irflow fault 2 flashes Flame with no call for heat 3 flashes Ignition lockout Ignition Control Diagnostic LED During normal operation, the LED is shut off. The LED will be on or flashing during a fault condition. If a fault condition is occurring, turn the unit off and on again. If the LED is still flashing, refer to the following troubleshooting section. irflow Fault (1 Flash) n airflow fault may occur for the following reasons: n airflow switch continually monitors the combustion airflow during an ignition sequence. During the initial call for heat, if the pressure switch contacts are in the closed position for 30 seconds without an output to the combustion blower, an airflow fault will be declared. The control will remain in this mode with the combustion blower off. Ignition Lockout (3 Flashes) fter the combustion blower output (L1 and IND) is energized and the airflow switch remains open for more than 30 seconds, an airflow fault will be declared. The control will stay in this mode with the combustion blower on, waiting for the airflow switch to close. If the airflow signal is lost while the burner is firing, the control will immediately de-energize the gas valve and the combustion blower will remain on. If the call for heat remains, the control will wait for proper airflow to return. If proper airflow is not detected after 30 seconds, an airflow fault will be declared. If proper airflow is detected at any time, a normal ignition sequence will begin. Once proper airflow is detected, the normal Sequence of Operation for ignition will follow (see page 14). Flame Fault (2 Flashes) If the main valve fails to close completely and maintains a flame, the full-time flame sense circuit will detect it and energize the combustion blower. Should the main valve later close completely and remove the flame signal, the combustion blower will be deenergized. Possible Cause Manual gas valve not open Solution Open manual valve ir in the gas line Supply gas pressure too high or too low Loose wire connections No spark a. Tranformer failure b. Spark electrode c. Spark cable shorted to ground Replace spark cable Bleed gas line Check that supply pressure is between 6 and 14 in. wg for natural gas and between 11 and 14 in. wg for LP Check for tight wire connections Check primary and secondary voltages of transformer. Replace if necessary Ensure spark gap is 1/8 inch and ceramic insulator is not cracked. Replace if necessary. Electrode is NOT field adjustable. d. Ignition controller not grounded Check unit airflow and manifold pressure High limit control tripper Faulty combination gas valve Faulty ignition control Check unit airflow and manifold pressure If 24 volts is measured between terminals MV and common, but valve remains closed, replace valve Check diagnostic LED for steady on and for voltage between V1 and V2. If no voltage is present, replace ignition control. Model PVF Indirect Gas-Fired Furnace 15

Routine Maintenance WRNING Turn off all gas and electrical power to the unit before performing any maintenance or service operations to this unit. Combustion Blower Motor Motor maintenance is generally limited to cleaning. Cleaning should be limited to exterior surfaces only. Removing dust and grease build-up on the motor housing assures proper motor cooling. Use caution and do not allow water or solvents to enter the motor or bearings. Under no circumstances should motors or bearings be sprayed with steam, water or solvents. The motor bearings are pre-lubricated and sealed, requiring no further lubrication. Burners and Orifices Before each heating season, examine the burners and gas orifices to make sure they are clear of any debris such as spider webs, etc. Clean burner as follows: Turn off both electrical and gas supplies to the unit. Disconnect union between manifold and gas valve. Remove manifold and burner assembly. Inspect and clean orifices and burners as necessary. void using any hard or sharp instruments which could cause damage to the orifices or burners. a. Remove any soot deposits from the burner with a wire brush. b. Clean the ports with an aerosol degreaser or compressed air. c. Wipe the inside of the burner clean. Cleaning the burner with a degreaser will slow the future buildup of dirt. Before reinstalling the burner assembly, look down the heat exchanger tubes to make sure they are clear of any debris. Reinstall manifold and burner assembly, reconnect wire leads, and gas supply piping. Turn on the electrical power and gas supply. Follow the start-up procedure to light the burners and verify proper operation. Heat Exchanger The heat exchanger should be checked annually for cracks and discoloration of the tubes. If a crack is detected, the heat exchanger should be replaced before the unit is put back into operation. If the tubes are dark gray, airflow across the heat exchanger should be checked to make sure the blower is operating properly. Flue Collector Box The flue passageway and flue collector box should be inspected prior to each heating season and cleared of any debris. Electrical Wiring The electrical wiring should be checked annually for loose connections or wiring deterioration. Gas Train The gas train connections, joints and valves should be checked annually for tightness. Replacement Parts When ordering replacement parts, include the complete unit model number and serial number listed on the unit rating plate. Warranty Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the shipment date. ny 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. s a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications without notice. Phone: (715) 359-6171 Fax: (715) 355-2399 E-mail: gfcinfo@greenheck.com Website: www.greenheck.com 16 461006 Model PVF Indirect Gas-Fired Furnace, Rev. 4, September 2008 Copyright 2008 Greenheck Fan Corporation