Greenheck 470656 - Manual

5 Exhaust Supply 1 inch InsideFlange Metal Cover Equipment Support Roof Curb Roof Curb and Equipment Support Complete Rooftop Installation 5. Assemble and Attach Weatherhood The weatherhood can now be assembled and attached to the unit. Detailed assembly instructions can be found with the weatherhoo...

6 Installation of Roof Mounted Unit Arrangement DBC, continued Supply Duct withDuct 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 o...

7 Installation of Venting for Outdoor Units WARNING 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 ...

8 WARNING 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...

9 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 supplied from the air inside the building. Units must not be installed in a potentially explosive, flammable, or corrosive atmos...

10 NOTE Vent piping is supplied by others and not supplied by manufacturer. 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. A concentric venting adapter (CVA) is require...

11 Concentric Venting – Vertical 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...

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...

15 Installation - Electrical Wiring IMPORTANT Before connecting power to the unit, read and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached on the inside of the control center door(s). IMPORTANT All wiring should be done in accordance with the latest ...

17 Installation of Gas Piping IMPORTANT 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...

18 Installation - Evaporative Cooler Piping (optional) Evaporative Cooling with Auto Drain and Fill Auto Drain & Fill Evaporative Piping 1. Install the Water Supply Line Supply line opening requirements vary by unit size and arrangement and are field-supplied. Connect the water supply line to th...

19 NOTE The following instructions are provided for evaporative coolers equipped with the Water Wizard™ only. Additional instructions are provided for evaporative coolers equipped with the auto drain and fill or bleed-off. WARNING Disconnect and lock-out all power and gas before performing any maint...

20 Installation - Direct Expansion (DX) Coil Piping (optional) 3. Wire the Solenoid(s) Wire the supply line solenoid and drain solenoid as shown on the unit’s wiring diagram in the control center. 4. Wire the Temperature Sensor If the evaporative cooler shipped separate from the unit, the temperatur...

21 NOTE If a hot gas bypass kit was provided by others, refer to the manufacturer’s instructions. NOTE Failure to obtain a high vacuum indicates a great deal of moisture or a small leak. Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks. If no leaks are found...

22 1. Verify 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 ar...

23 Start-Up - Blower Refer to the Start-Up Checklist in the Reference Section Before Proceeding 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 provi...

25 Start-Up - Furnaces (all units) IMPORTANT For the unit to function properly, all stage or modulation valves must be set for high and low fire. NOTE There are five furnace control options available. Be sure to refer to the specific instructions for your control type. IMPORTANT Multi furnace units ...

26 Start-Up - 2:1 Staged Control 1. Send Unit to High Fire Send the unit to high fire by setting the temperature selector to its maximum setting. 2. Check the High Fire Manifold Pressure Using a manometer, measure the burner manifold pressure at the manifold pressure test port. Refer to the Gas Trai...

27 WARNING Once the high and low fire have been set, be sure the press the Function key to end high fire mode. The middle LED light, L2, will stop flashing when high fire mode is off. NOTE Step 5-7 are for adjusting the discharge air setting. The discharge air temperature setting is factory set to t...

28 NOTE The room override function requires 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 c...

29 Start-Up - 2:1 Electronic Modulation 1. Send Unit to High Fire Turn the temperature selector to its maximum setting to send the unit to high fire. 2. Check the High Fire Manifold Pressure With the unit at high fire, use a manometer to measure the burner manifold pressure at the manifold pressure ...

30 Start-Up - 4:1 Electronic Modulation 2. Check the High Fire Manifold Pressure Before setting high fire on the EXA valve, turn the regulator screw on the combination valve all the way in (increase pressure).Using a manometer, measure the high fire manifold pressure at the pressure test port. Refer...

32 3. Set the Enthalpy Changeover Set Point (optional) If using an economizer, the enthalpy changeover setting must be set. If differential temperature or differential enthalpy control is used, set the enthalpy changeover set point to D . If outside air temperature or enthalpy reference is used, set...

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. Reference the unit’s ladder diagram to determine proper terminals. IMPORTANT Check the media for minerals...

34 NOTE Steps 6 through 8 are provided to adjust the minimum cooling temperature. The minimum cooling is preset to the factory recommended 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...

35 NOTE The Freeze Temperature is preset to the factory recommended 45ºF. Steps 9-11 should only be completed if the Freeze Temperature needs adjustment. NOTE The Freeze Temperature is the temperature at which the supply solenoid closes and the drain solenoid opens to drain the supply line, preventi...

36 Building Pressure Control — a variable frequency drive is controlled according to input from a pressure sensing device.Turn both knobs to the upper most pressure setting. You may have to remove the outdoor pressure tap tubing. VAV systems should go to maximum speed. Set both knobs at the lowest s...

37 Building Pressure Control - a modulating spring return actuator is used to control the return air amounts. The return air damper modulates from fully open to fully closed based on a signal from a remote pressure sensing device.Turn both knobs to the upper most pressure setting. You may have to re...

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 st...

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 co...

41 Program Revision Number To access the program revision 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 , revision twelve. Optional Room Overr...

43 Sequence of Operation 8:1 Staged Control 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 sta...

44 Sequence of Operation 8:1 Staged Control, 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 control...

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 Temperature 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-insta...

46 Proper supply power at main disconnect Check Main Voltage (See Blower Start-Up Step #1) Main Disconnect (DS1) Off (Turn Main Disconnect DS1 On) Primary Fuses Blown (Replace Fuses) 24 VAC between terminals R and X? Main Transformer (TR1) Defective (Replace Transformer) 24 VAC between terminals G a...

47 Motor Over Amps Troubleshooting Air volume too high? Adjust drives or increase external static pressure as needed. (Reference Blower Start-Up Step #5) Motor horsepower too low? Resize motor. Motor voltage correct? Provide proper power supply. (Reference Blower Start-Up Step #1) Blower rotation co...

48 Insufficient Airflow Troubleshooting 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? Adju...

49 Excessive Noise or Vibration Troubleshooting 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...

50 Single or 2:1 Stage Furnace Will Not Light Troubleshooting Ignition controller (IC#) red LED blinks 7 times or is on Ignition controller (IC1) failed. (Replace ignition controller) High limit (HLC1) open? Discharge temperature was above high limit setting. Wait for high limit to cool and reset. 2...

51 2:1 Modulating Furnace Will Not Light Troubleshooting Ignition controller (IC#) red LED blinks 7 times or is on Ignition controller (IC1) failed (Replace ignition controller) 24 VAC across A and T? Discharge air selector (TS3) improperly set or faulty Adjust setting (see staged start-up) or repla...

52 Troubleshooting 24 VAC across terminals S and T? Discharge temperature 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 furn...

53 4:1 Modulating Furnace Will Not Light Troubleshooting 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 temperature was above high limit setting Let cool, then reset high lim...

54 8:1 Staged Furnace Will Not Light Troubleshooting 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) Yes No 24 VAC across terminals S and T? Discharge temperature was above h...

56 Evaporative Cooler does not Operate (Recirculating pump) Supply fan must be on for cooler to operate Troubleshooting Water Blows through Evaporative Cooler Water supply greater than evaporation and bleed-off rate? Use the main supply valve to reduce the supply of water Air velocity greater than s...

57 Water Wizard™ — Improper Water Supply Troubleshooting 1. Adjust the Manual Supply Valve Adjust the manual supply valve (refer to Start-Up, Water Wizard™). If the recommended water pressure does not provide enough water, increase the pressure until the desired water supply is achieved. If the reco...

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 measuri...

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 efficiency.If disposable filters are installed, they can be checked ...

61 Flushing Coils Manufacturer recommends the use of inhibited glycol (such as propylene or ethylene) to flush water coils to protect against freezing. Additionally, the use of inhibited glycol provides corrosion protection.The table below indicates the percentage of glycol required to prevent 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 Reference - Model IG Venting Connection Location Reference - Model IGX Venting Connection Location Flue Connection Size (diameter in inches) IG Housing St...

63 Reference - Model IG (Single or 2 Stage) 3/4 inch Gas Supply Connection Staged Gas Valve Manifold Gas Pressure Test 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 Voltage Tran...

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 Voltage Transformer - Provides low voltage to fan/heat/cooling enable controls. 4. Control Terminal Block - Provides wiring access to...

70 Performance Table The following table gives the air volume in cubic feet per minute that is required to provide the desired temperature rise for a given heating input. Model IG has a maximum 7,000 CFM capacity. Input (MBH) Output (MBH) Temperature Rise (ºF) 25 30 35 40 45 50 55 60 65 70 75 80 85 ...

72 Maintenance Log Date __________________ Time _____________ AM/PMNotes:___________________________________________________________________________________________________________________________________________________________________________________________________________________________________...