Greenheck IGX Installation, Operation And Maintenance Manual
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Greenheck IGX Installation, Operation And Maintenance Manual

Greenheck IGX Installation, Operation And Maintenance Manual

Make-up air unit
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MODEL IGX
Make-Up Air Unit
Installation, Operation and Maintenance Manual
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
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.
**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**
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.
Part # 462876

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  • Page 1 Part # 462876 MODEL IGX Make-Up Air Unit Installation, Operation and Maintenance Manual **FOR YOUR SAFETY** If you smell gas: Open windows. Don’t touch electrical switches. Extinguish any open flame. Immediately call your gas supplier. **WARNING** **FOR YOUR SAFETY** Improper installation, adjustment,...

  • Page 2: Table Of Contents

    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.

  • Page 3: Horizontal And Downblast

    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.

  • Page 4: Horizontal And Downblast Discharge

    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 Apply Sealant...

  • Page 5: With Optional Mixing Box

    Attach and secure the ductwork using self tapping Use spreader bar screws. and lifting lugs. Greenheck recommends attaching ductwork to collar using a rubber duct section at the unit to minimize vibration. Step 3 Apply Sealant Before installing unit, apply a sealant around the...

  • Page 6: Combination Extension

    Installation Instructions for: Roof Mounted with Optional Combination Extension Downblast Discharge Arrangement DBC Step 1 Install Curb/Equipment Support(s) Roof Curb Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of Metal Cover curb/equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary.
  • Page 7 Model CUBE through existing holes in curb cap. NFPA 96 Exhaust Fan requires the exhaust fan be hinged. Greenheck offers an optional hinge kit with restraining cables and a grease trap with drain connection. Install these options at this time.

  • Page 8: Venting For Indoor Units

    General Venting and Combustion Air 1. Do not install units in locations where flue products 4. Maintain minimum horizontal clearance of 4 feet can be drawn into adjacent building openings such from electric meters, gas meters, regulators, and as windows, fresh air intakes, etc. Distance from relief equipment.
  • Page 9 Venting Instructions: Indoor Units 1. Installation of venting must conform with local minimum downward slopes (from the unit) of 1/4 building codes. In the absence of local codes, inch per foot, suspend securely from overhead installation must conform with the National Fuel structures at points no greater than 3 feet apart.
  • Page 10 Venting Instructions: Standard Indoor Units Standard Indoor Venting Vent Construction This refers to using one penetration through an To vent using this method, the vent terminal supplied exterior wall or roof for venting the flue exhaust. The with the units must be used. Construct the vent system combustion air is supplied from the air inside the as shown in drawings and reference the tables for vent building.
  • Page 11 Venting Instructions: Standard Indoor Units Standard Indoor Venting Furnace Flue Size Outlet 100 - 150 4 inch 200 - 400 6 inch All measurements shown are diameters. Table 1 Standard Vertical Venting Exhaust Vent Building Roof Terminal A = 12 inch minimum A1 = 12 inch minimum, but should size according to expected snow depth.
  • Page 12 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.
  • Page 13 Venting Instructions: Concentric Venting Adapter CVA-4 Flue Outlet Concentric Side Air Inlet Concentric Side Air Inlet Concentric Venting Non-Concentric Side Adapter - 4 inch diameter Flue Outlet (CVA-4) Non-Concentric Side Venting Instructions: Concentric Venting Adapter CVA-6 Flue Outlet Concentric Side Air Inlet Concentric Side Concentric Venting...
  • Page 14 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.
  • Page 15 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.
  • Page 16 100 - 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.
  • Page 17 100 - 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.

  • Page 18: Control Center Layout

    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.

  • Page 19: Start-Up

    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.

  • Page 20: Mixing Box

    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.

  • Page 21: Blower

    Start-Up Instructions: Blower System Pre-Start Check List 4. Check the V-belt drive for proper alignment and tension. 1. Disconnect and lock-out all power switches to fan. 2. Check all fasteners, set screws and locking collars Special Tools Required on the fan, bearings, drive, motor base and •...

  • Page 22: Furnace

    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: Open windows 2. Don’t touch electrical switches 3.
  • Page 23 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) 6. After gas piping is completed, carefully check all have a single ⁄...
  • Page 24 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. •...
  • Page 25 8. Call for heat with the thermostat or discharge switch. Close all manual gas valves. temperature controls and allow the burner to light. Greenheck indirect furnaces are equipped with an 2. Check that all gas and electrical connections are automatic spark ignition system which weatherized.
  • Page 26 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;...

  • Page 27: Furnace

    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.

  • Page 28: Evaporative Cooling

    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.
  • Page 29 5. The water bleed-off rate will now need to be Note: Evaporative media may foam for a short adjusted. This measurement is 3 to 6 percent of period following the initial start-up. Leave the the media flow rate. The recommended media flow bleed-off valve fully open until the foaming rate is 1 ⁄...

  • Page 30: Cooling Coils

    When connecting suction and liquid connections make sure the coil is free from all foreign material. Make sure all joints are tight and free of leakage. Greenheck does not supply compressor or condensing units, for further instruction on DX coil installation and operation contact your compressor and/or condenser manufacturer.

  • Page 31: Trouble Shooting

    Trouble Shooting Instructions: Blower System Symptom Possible Cause Solution Blower fails Blown fuse or open circuit breaker Replace fuse or reset circuit breaker and to operate check amps Broken fan belt Replace Defective motor or capacitor Replace Motor starter overloaded Reset starter and check amps Motor overamps cfm too high...

  • Page 32: Furnace

    Trouble Shooting Instructions: Furnace Ignition Control Diagnostic LED LED Indication Error Mode During normal operation, the LED is shut off. The LED will be on Steady on Internal control failure or flashing during a fault condition. If a fault condition is 1 flash Air flow fault occurring, turn the unit off and on again.

  • Page 33: Evaporative Cooling

    Trouble Shooting Instructions: Optional Evaporative Cooling Symptom Solution Insufficient water A. Check water level in base pan. The level should be at 2 inches. volume or recirculation B. Check the pump filter at the inlet. Clean the filter if clogged or dirty. pump not operating C.

  • Page 34: Routine

    Maintenance Instructions: Routine Greenheck recommends these procedures to insure trouble free operation of this unit. It is especially important to maintain heater units for clean and efficient operation. Most unit failures can be attributed to poor setup or poor maintenance.

  • Page 35: Furnace

    Maintenance Instructions: Furnace CAUTION!!! 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.

  • Page 36: Evaporative Cooling

    Maintenance Instructions: Optional Evaporative Cooling Regularly scheduled maintenance is the key to peak 5. At the beginning of each cooling season, the upright performance, minimized cost, and extended life of the recirculating pump should have the shaft oiled and evaporative cooler. The following is a checklist of spun to eliminate the potential of seizing and pump items that need to be looked at on a regular basis.

  • Page 37: Cooling Coils

    Maintenance Instructions: Optional Cooling Coils COIL MAINTENANCE 1. Coils must be clean to obtain maximum performance. Check once a year under normal operating conditions and, if dirty, brush or vacuum clean. Soiled fins reduce the capacity of the coil, demand more energy from the fan, and create an environment for odor and bacteria to grow and spread through the conditioned zone.

  • Page 38: Documentation

    Documentation Date Problem Resolution...
  • Page 39 Maintenance Documentation Job Information Service Organization: _____________________________ Job Name: ____________________________________ Address: ________________________________________ Address: ______________________________________ City: ________________ State: ________ Zip: _________ City: ________________ State: ________ Zip: _______ Phone: __________________ Fax: ___________________ Phone: __________________ Fax:_________________ Work Done By: ___________________________________ Contact Person: _______________________________ Field Start-Up Documentation Name Plate Information Model: ________________________________________...

  • Page 40: Unit Layout

    Warranty Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory, transportation prepaid.

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