Greenheck Fan 470656 manual

Installation, Operation and Maintenance Manual Please read and save these instructions. Read car efully before attempting to assemble, install, operate or maintain the product described. Pr otect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or pr operty damage! Reta[...]

2 Receiving Upon receiving the pr oduct, check to make sure all items are accounted for by r eferencing the bill of lading to ensure all items wer e received. Inspect each crate for shipping damage before accepting delivery . Notify the carrier if any damage is noticed. The carrier will make notification on the delivery receipt acknowledging any d[...]

3 T able of Contents Installation Clearance to Combustibles/Service Clearances ... 3 Indoor Unit ................................. 4 Unit Arrangement DB / HZ .................. 4-5 Roof Mounted Unit – Arrangement DBC ....... 5-6 Optional Evaporative Cooling Module ........... 7 V enting – Outdoor ........................... 7 Indoor , All Units[...]

4 NOTE T o prevent pr emature heat exchanger failur e, do not locate units where chlorinated, halogenated, or acid vapors are pr esent. 3. Install V ent Piping Refer to the Indoor V enting Instructions. Refer to your unit submittal to determine the correct venting option. 1. Install Hangers Install threaded hangers fr om ceiling supports. When loca[...]

5 Exhaust Supply 1 inch Inside Flange Metal Cover Equipment Support Roof Curb Roof Curb and Equipment Support Complete Rooftop Installation 5. Assemble and Attach W eatherhood The weatherhood can now be assembled and attached to the unit. Detailed assembly instructions can be found with the weatherhood. If the optional evaporative cooling module wa[...]

6 Installation of Roof Mounted Unit Arrangement DBC, continued Supply Duct with Duct Adapter Installed Exhaust Duct Installed Sealant Sealing Ductwork Installing Supply Unit Complete Combination Installation NOTE Installing the exhaust fan prior to the supply unit will allow for easier installation of options. NOTE NFP A 96 requir es that the exhau[...]

7 Installation of V enting for Outdoor Units W ARNING Do not install units in locations where flue pr oducts can be drawn into adjacent building openings such as windows, fresh air intakes, etc. Distance fr om vent terminal to adjacent public walkways, adjacent buildings, operable windows, and building openings shall conform with the local codes. I[...]

8 W ARNING The following guidelines must be followed for all 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. For the exhaust pipe, use pipe approved for a category[...]

9 Installation of Standar d Indoor V enting Standard Indoor V enting uses 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 atmospher e. T o prevent pr emature heat exchanger[...]

10 NOTE V ent piping is supplied by others and not supplied by manufacturer . Installation of Concentric V enting (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. A concentric venting adapter (CV A) is required for concentric venting. The concentric venti[...]

11 Concentric V enting – V ertical Refer to the diagram below for venting on vertical concentric systems. Maintain at least 12 inches between the top of the combustion air inlet terminals and the bottom of the exhaust terminal. (Dim. B). The bottom of the combustion air intake pipe must terminate above the snow line or at least 12 inches above th[...]

12 4. Install Combustion Air Pipe Attach a field-supplied combustion air pipe to the concentric side of the CV A. Be sure to pr ovide enough combustion air piping to pass through the r oof 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 t[...]

13 2. Install Combustion Air Pipe Run a combustion air pipe from the unit’ s combustion air intake through the exterior wall to the outdoors. The combustion air pipe must terminate at least 12 inches from the combustion vent pipe and 24 inches from the exterior surface of the outside wall. Attach the combustion air inlet guard to the end of the c[...]

14 1. Install Exhaust Pipe Run an exhaust pipe from the unit’ s combustion exhaust through the r oof to the outdoors. The exhaust pipe must terminate at least 12 inches above the outside surface of the roof. This clearance may need to be increased to accommodate snow accumulation. Attach the exhaust vent terminal to the end of the exhaust pipe. 2[...]

15 Installation - Electrical Wiring IMPORT ANT Before connecting power to the unit, r ead and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached on the inside of the control center door(s). IMPORT ANT All wiring should be done in accordance with the latest edition of the National Electrical Code ANSI/ N[...]

16 NOTE Large evaporative coolers may requir e a separate power supply . 6. Wir e the Evaporative Cooler (optional) Reference the ladder diagram on the inside of the control center door for corr ect wiring of the pump and the optional water valves. 7. Install Economizer Sensors (optional) All economizer options (EC) requir e an outdoor air temperat[...]

17 Installation of Gas Piping IMPORT ANT All gas piping must be installed in accordance with the latest edition of the National Fuel Gas Code ANSI/Z223.1 and any local codes that may apply . In Canada, the equipment shall be installed in accordance with the Installation Code for Gas Burning Appliances and Equipment (CGA B149) and Provincial Regulat[...]

18 Installation - Evaporative Cooler Piping (optional) Evaporative Cooling with Auto Drain and Fill Auto Drain & Fill Evaporative Piping 1. Install the W ater Supply Line Supply line opening requir ements vary by unit size and arrangement and are field-supplied. Connect the water supply line to the float valve through the supply line opening [...]

19 NOTE The following instructions are pr ovided for evaporative coolers equipped with the W ater Wizard™ only . Additional instructions are pr ovided for evaporative coolers equipped with the auto drain and fill or bleed-off. W ARNING Disconnect and lock-out all power and gas before performing any maintenance or service to the unit. Failure to d[...]

20 Installation - Dir ect Expansion (DX) Coil Piping (optional) 3. Wir e the Solenoid(s) Wire the supply line solenoid and drain solenoid as shown on the unit’ s wiring diagram in the control center . 4. Wir e the T emperature Sensor If the evaporative cooler shipped separate from the unit, the temperature sensor must be wir ed. The sensor wire i[...]

21 NOTE If a hot gas bypass kit was provided by others, r efer to the manufacturer’ s instructions. NOTE Failure to obtain a high vacuum indicates a gr eat deal of moisture or a small leak. Br eak the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks. If no leaks ar e found, continue vacuuming the coil until the des[...]

22 1. V erify Coil Hand Designation Check the coil hand designation to ensure that it matches the system. Coils are generally plumbed with the supply connection located on the bottom of the leaving air -side of the coil and the return connection at the top of the entering air -side of the coil. This arrangement provides a counter flow heat exchang[...]

23 Start-Up - Blower Refer to the Start-Up Checklist in the Reference Section Before Pr oceeding Further! Pre Start-Up Check Rotate the fan wheel by hand and make sure no parts are rubbing. Check the V -belt drive for proper alignment and tension (a guide for proper belt tension and alignment is provided in the Belt Maintenance section). Check fast[...]

24 6. Set-up Optional Components Adjust the settings on the optional components. See the Control Center Layout in the Refer ence section for location of optional components. • HeatingInletAirSensor T ypical setting: 60-70ºF • CoolingInletAirSensor T ypical setting: 75ºF • BuildingFreezePr otection T ypica[...]

25 Start-Up - Furnaces (all units) IMPORT ANT For the unit to function properly , all stage or modulation valves must be set for high and low fire. NOTE There ar e five furnace control options available. Be sure to r efer to the specific instructions for your control type. IMPORT ANT Multi furnace units may use a combination of the available contro[...]

26 Start-Up - 2:1 Staged Contr ol 1. Send Unit to High Fir e Send the unit to high fire by setting the temperature selector to its maximum setting. 2. Check the High Fir e Manifold Pressur e Using a manometer , measure the burner manifold pressur e at the manifold pressur e test port. Refer to the Gas T rain Layout in the Reference section for the[...]

27 W ARNING Once the high and low fire have been set, be sur e the press the Function key to end high fir e mode. The middle LED light, L2, will stop flashing when high fire mode is of f. NOTE Step 5-7 are for adjusting the discharge air setting. The discharge air temperature setting is factory set to the recommended 70ºF . Only adjust the setting[...]

28 NOTE The room override function r equires a field-supplied thermostat to be installed in the space and to be wired between terminal 31 and 32 in the unit’ s control center . Reference the unit ladder diagram. 11. Edit the Setting Use the Up or Down key to change the room override setting. When the correct setting is displayed, pr ess the Enter[...]

29 Start-Up - 2:1 Electr onic Modulation 1. Send Unit to High Fir e T ur n the temperature selector to its maximum setting to send the unit to high fire. 2. Check the High Fir e Manifold Pressur e With the unit at high fire, use a manometer to measur e the burner manifold pressure at the manifold pr essure test port. See the Gas T rain Layout in [...]

30 Start-Up - 4:1 Electr onic Modulation 2. Check the High Fir e Manifold Pressur e Before setting high fir e on the EXA valve, turn the regulator scr ew on the combination valve all the way in (increase pr essure). Using a manometer , measure the high fire manifold pressur e at the pressur e test port. Refer to the Gas T rain Layout in the Refer[...]

31 NOTE The following steps are for adjusting the discharge air setting. The discharge air temperature setting is factory set to the recommended 70ºF . Only adjust the setting if needed. NOTE After modifying a setting, the Enter key must be pressed to save the change. If the Enter key is not pressed the display will r eturn to the Setpoints Menu w[...]

32 3. Set the Enthalpy Changeover Set Point (optional) If using an economizer , the enthalpy changeover setting must be set. If differ ential temperature or differ ential enthalpy control is used, set the enthalpy changeover set point to D . If outside air temperature or enthalpy refer ence is used, set the enthalpy changeover set point to the desi[...]

33 Start-Up - Evaporative Cooling (optional) Leaving Air Entering Air 45º 15º NOTE A jumper will need to be installed in the control center to power the evaporative pumps with the blower(s) off. Refer ence the unit’ s ladder diagram to determine proper terminals. IMPORT ANT Check the media for minerals after two weeks of service and adjust the [...]

34 NOTE Steps 6 through 8 ar e provided to adjust the minimum cooling temperature. The minimum cooling is preset to the factory r ecommended 75ºF (24ºC). Only adjust if needed. NOTE The inlet air sensor function overrides and shuts down the evaporative cooler if the outside temperature falls below the minimum cooling temperature. 8. Exit Pr ogram[...]

35 NOTE The Freeze T emperatur e is preset to the factory recommended 45ºF . Steps 9-11 should only be completed if the Freeze T emperatur e needs adjustment. NOTE The Freeze T emperatur e is the temperature at which the supply solenoid closes and the drain solenoid opens to drain the supply line, preventing possible freeze damage. A drain solenoi[...]

36 Building Pressur e Control — a variable frequency drive is controlled accor ding to input from a pressur e sensing device. T ur n both knobs to the upper most pressur e setting. Y ou may have to remove the outdoor pr essure tap tubing. V A V systems should go to maximum speed. Set both knobs at the lowest setting and the V A V systems should g[...]

37 Building Pressur e Control - a modulating spring return actuator is used to control the r eturn air amounts. The return air damper modulates from fully open to fully closed based on a signal from a remote pr essure sensing device. T ur n both knobs to the upper most pressur e setting. Y ou may have to remove the outdoor pr essure tap tubing. The[...]

38 Sequence of Operation 2:1 Staged Sequence 1. Exhaust Fan Contact (S1) Manually Closed (optional) • PowerpassesthroughN.C.contactonexhaustfan overload (ST2 OL), which is closed if exhaust fan (M2) has not overloaded • Powerpassestoexhaustfanstarter(ST2) • N.O.contactonexhaustfan[...]

39 Sequence of Operation 2:1 Modulation Sequence 1. Exhaust Fan Contact (S1) Manually Closed (optional) • PowerpassesthroughN.C.contactonexhaustfan overload (ST2 OL), which is closed if exhaust fan (M2) has not overloaded • Powerpassestoexhaustfanstarter(ST2) • N.O.contactonexhaust?[...]

40 Sequence of Operation 2:1 Modulation Sequence, continued • N.O.contactoncoolrelay(RC)isenergizedand closed • Powerpassestoevaporativecoolingpump(P1) *If DX or chilled water coils are used rather than an evaporative cooler , the cooling sequence of operation will depend on the coil controls. [...]

41 Program Revision Number T o access the program r evision number from the default display , press the Up or Down key until the display reads F##, J## or I## . The two numbers following the letter indicate the revision number . For example, F12 indicates program F , r evision twelve. Optional Room Override (ROt) When the room override function is [...]

42 4. Ignition Contr oller (IC1) Sequence of Operation • TheN.O.contactonairprovingswitch(PS2)isopen • Theignitioncontroller(IC1)energizestheinduction relay (IR) • N.O.contactoninductionrelay(IR)closes • Powerpassestoandenergizesthecombustion [...]

43 Sequence of Operation 8:1 Staged Contr ol 1. Exhaust Fan Contact (S1) Manually Closed (optional) • PowerpassesthroughN.C.contactonexhaustfan overload (ST2 OL), which is closed if exhaust fan (M2) has not overloaded • Powerpassestoexhaustfanstarter(ST2) • N.O.contactonexhaustfan[...]

44 Sequence of Operation 8:1 Staged Contr ol, continued • N.O.contactoncoolrelay(RC)isenergizedand closed • Powerpassestoevaporativecoolingpump(P1) *If DX or chilled water coils are used rather than an evaporative cooler , the cooling sequence of operation will depend on the coil controls. Cool[...]

45 NOTE Only models IG-HV and IGX-HV with options EC-1, 2, 3 or 4 use an economizer . Operation - Economizer Option EC-1 (Outside Air T emperature Reference) This option uses one dry bulb temperature sensor field-installed in the inlet of the unit. A second dry bulb temperature sensor is factory-installed in the discharge of the unit. After a call[...]

46 Proper supply power at main disconnect Check Main V oltage (See Blower Start-Up Step #1) Main Disconnect (DS1) Off (T urn Main Disconnect DS1 On) Primary Fuses Blown (Replace Fuses) 24 V AC between terminals R and X? Main T ransformer (TR1) Defective (Replace T ransformer) 24 V AC between terminals G and X? Supply Switch (S2) Off (T urn Supply S[...]

47 Motor Over Amps T r oubleshooting Air volume too high? Adjust drives or increase external static pressur e as needed. (Reference Blower Start-Up Step #5) Motor horsepower too low? Resize motor . Motor voltage correct? Provide pr oper power supply . (Reference Blower Start-Up Step #1) Blower rotation corr ect? Reverse blower rotation. (Reference [...]

48 Insufficient Airflow T r oubleshooting Damper(s) not fully opened? Adjust damper linkage(s), or replace faulty actuator(s). (Damper actuators may take a few minutes to open) Filters dirty or clogged? Clean or replace filters. (Reference Filters in the Maintenance section) Blower speed too low? Adjust drives as needed. (Reference Blower Start-U[...]

49 Excessive Noise or Vibration T r oubleshooting Sheaves aligned? Align sheaves. (Reference V -Belt Drives in the Maintenance section) Wheel(s) unbalanced? Clean and/or balance wheel(s). Belts worn or loose? Replace worn belts or tighten loose belts. (Reference V -Belt Drives in the Maintenance section) Ye s Ye s No No Ye s Bearings worn or need l[...]

50 Single or 2:1 Stage Furnace W ill Not Light T r oubleshooting Ignition controller (IC#) red LED blinks 7 times or is on Ignition controller (IC1) failed. (Replace ignition controller) High limit (HLC1) open? Discharge temperatur e was above high limit setting. Wait for high limit to cool and reset. 24 V AC acr oss A and 21? Discharge air selecto[...]

51 2:1 Modulating Furnace W ill Not Light T r oubleshooting Ignition controller (IC#) red LED blinks 7 times or is on Ignition controller (IC1) failed (Replace ignition controller) 24 V AC acr oss A and T? Discharge air selector (TS3) impr operly set or faulty Adjust setting (see staged start-up) or replace sensor 24 V AC acr oss S and T? Heat tran[...]

52 T r oubleshooting 24 V AC acr oss terminals S and T? Discharge temperatur e was above high limit control (HLC1) Wait for high limit to cool and reset Inlet air sensor contact open Adjust inlet air sensor setting (refer to 4:1 Modulation Start-Up section) Furnace controller (SC1) defective Replace furnace controller (SC1) 24 V AC acr oss 22 and 2[...]

53 4:1 Modulating Furnace W ill Not Light T r oubleshooting Ignition controller (IC#) red LED blinks 7 times or is on Ignition controller(s) (IC#) failed Replace faulty ignition controller(s) High limit switch (HLC#) open? Discharge temperatur e was above high limit setting Let cool, then reset high limit. Ye s Ye s No Ignition controller (IC#) red[...]

54 8:1 Staged Furnace W ill Not Light T r oubleshooting With the combustion blower (CM) off, is the N.O. airflow switch (PS2) closed? Continues on next page... Airflow switch (PS2) defective Replace defective airflow switch (PS2) Ye s No 24 V AC acr oss terminals S and T? Discharge temperatur e was above high limit control (HLC1) Wait for high lim[...]

55 Ignition controller (IC#) red LED blinks 7 times or is on Ignition controller(s) (IC#) failed Replace faulty ignition controller(s) Ye s ... continued from previous page. Does the combustion relay (R9 or CR) close? Internal high limit tripped (temperature above set point) Let temperatures cool Internal inlet air sensor open Adjust inlet air sens[...]

56 Evaporative Cooler does not Operate (Recirculating pump) Supply fan must be on for cooler to operate T r oubleshooting W ater Blows through Evaporative Cooler W ater supply greater than evaporation and bleed-off rate? Use the main supply valve to reduce the supply of water Air velocity greater than specified? Reduce the air velocity through the[...]

57 W ater Wizar d™ — Improper W ater Supply T r oubleshooting 1. Adjust the Manual Supply V alve Adjust the manual supply valve (refer to Start-Up, W ater Wizard™). If the r ecommended water pr essure does not provide enough water , increase the pr essure until the desired water supply is achieved. If the recommended water pr essure pr ovides[...]

58 Maintenance - Routine CAUTION Lock-out the gas and the electrical power to the unit before performing any maintenance or service operations to this unit. V -Belt Drives V -belt drives must be checked on a regular basis for wear , tension, alignment, and dirt accumulation. Check the tension by measuring the deflection in the belt as shown below [...]

59 Filters Filter maintenance is generally limited to cleaning and replacement. If aluminum mesh filters are installed, they can be washed in warm soapy water . An adhesive spray can be added to aluminum mesh filters to increase their ef ficiency . If disposable filters are installed, they can be checked by holding up to a light source. If ligh[...]

60 Maintenance - Fall CAUTION Lock-out the gas and the electrical power to the unit before performing any maintenance or service operations to this unit. High Limit The high limit switch may have tripped over the summer; it should be checked and reset if necessary . Gas Line Remove the drip leg and clean any liquid or debris that may have accumulat[...]

61 Flushing Coils Manufacturer r ecommends the use of inhibited glycol (such as propylene or ethylene) to flush water coils to protect against fr eezing. Additionally , the use of inhibited glycol provides corr osion protection. The table below indicates the percentage of glycol requir ed to prevent fr eezing in a coil at a given outdoor air freez[...]

62 Exhaust Air Outlet Combustion Air Intake C D A B Airflow A B C D E F 3/4-inch Gas Connection Combustion Air Inlet Exhaust Outlet Discharge End Refer ence - Model IG V enting Connection Location Refer ence - Model IGX V enting Connection Location Flue Connection Size (diameter in inches) IG Housing Standard Non-Concentric Concentric Exhaust Exhau[...]

63 Refer ence - Model IG (Single or 2 Stage) 3/4 inch Gas Supply Connection Staged Gas V alve Manifold Gas Pressur e T est Port 1. Supply Motor Starter - 24 volt magnetic contacts for starting supply motor . 2. Supply Overload - Provides electronic overload protection to supply motor . 3. Low V oltage T ransformer - Provides low voltage to fan/heat[...]

64 Refer ence - Model IG (8:1 Staged) 1 2 7 8 9 15 4 6 14 5 12 21 23 25 3 10 11 13 16 17 18 18 19 20 22 24 NOTE This is a typical blower control center , the control center in your unit may be differ ent. Reference the ladder diagram on the inside of the control center door for a unit specific wiring diagram. 1. Supply Motor Starter - 24 volt magne[...]

65 1. Supply Motor Starter - 24 volt magnetic contacts for starting supply motor . 2. Supply Overload - Provides electronic overload protection to supply motor . 3. Low V oltage T ransformer - Provides low voltage to fan/heat/cooling enable controls, modulating furnace controls and optional evaporative cooling controls. 4. Control T erminal Block -[...]

66 Refer ence - Model IG (4:1 Modulation) NOTE This is a typical blower control center , the control center in your unit may be differ ent. Reference the ladder diagram on the inside of the control center door for a unit specific wiring diagram. 1 2 7 8 9 15 5 12 22 24 4 6 14 3 10 11 13 16 17 19 20 21 18 18 23 25 26 1. Supply Motor Starter - 24 vol[...]

67 1. Supply Motor Starter - 24 volt magnetic contacts for starting supply motor . 2. Supply Overload - Provides electronic overload protection to supply motor . 3. Low V oltage T ransformer - Provides low voltage to fan/heat/cooling enable controls. 4. Control T erminal Block - Provides wiring access to controls. 5. Fan Relay - Allows power to pas[...]

68 Refer ence - Model IGX (Single or 2 Stage) NOTE This is a typical furnace control center , the control center in your unit may be differ ent. Reference the ladder diagram on the inside of the control center door for a unit specific wiring diagram. 1 2 3 4 5 5 6 7 9 8 Manifold Gas Pressur e T est Port 3/4 inch Gas Supply Connection Staged Gas V a[...]

69 1. Low V oltage T ransformer - Provides low voltage to the ignition controller and amplifier . 2. Control T erminal Block - Provides wiring access to heat controls. 3. Control T erminal Block - Provides wiring access to heat controls. 4. Ignition Controller - Controls the ignition of the furnace. Maintains safe operation of the fur nace. 5. Amp[...]

70 Performance T able The following table gives the air volume in cubic feet per minute that is requir ed to provide the desir ed temperature rise for a given heating input. Model IG has a maximum 7,000 CFM capacity . Input (MBH) Output (MBH) T emperature Rise (ºF) 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 100 80 2963 2469 2116 1852 1646 14[...]

71 Start-Up Checklist Unit Model Number ____________________________ (e.g. IGX-120-H32-DB) Unit Serial Number ____________________________ (e.g. 10111000) Start-Up Date ____________________________ Start-Up Personnel Name ____________________________ Start-Up Company ____________________________ Phone Number ____________________________ Pre Start-U[...]

72 Maintenance Log Date __________________ Time _____________ AM/PM Notes:___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date __________________ Time ___[...]