Greenheck 470654 User Manual

Document 470654
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Installation, Operation and Maintenance Manual
Installation, Operation and Maintenance Manual
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the
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
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.
result in personal injury and/or property damage! Retain instructions for future reference.
with Direct-Fired Gas Heater
Model VSU
3. Motor must be securely and adequately grounded.
4. Do not spin fan wheel faster than the maximum cataloged fan rpm. Adjustments to fan speed significantly affects motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.
5. Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces, or chemicals. Replace cord immediately if damaged.
6. Verify that the power source is compatible with the equipment.
7. Never open blower access doors while the fan is running.
General Safety Information
Only qualified personnel should install this unit. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards. Other considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.
1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electric Code (CEC) in Canada.
2. The rotation of the wheel is critical. It must be free to rotate without striking or rubbing any stationary objects.
DANGER
Always disconnect power before working on or near a unit. Lock and tag the disconnect switch or breaker to prevent accidental power up.
CAUTION
When servicing the unit, motor may be hot enough to cause pain or injury. Allow motor to cool before servicing.
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Do not touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
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.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.
Model VSU Make-Up Air Unit
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Receiving
Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading to ensure all items were 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 damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be filled out by the carrier upon arrival and reported to the Traffic Department. If damaged upon arrival, file claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.
Unpacking
Verify that all required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Confirmation of shipment(s) must be limited to only items on the bill of lading.
Handling
Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged finish may reduce ability of unit to resist corrosion.
Storage
Units are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the unit and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.
Inspection and Maintenance during Storage
While in storage, inspect fans once per month. Keep a record of inspection and maintenance performed.
If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the fan wheel by hand ten to fifteen revolutions to distribute lubricant on motor. Every three months, the fan motor should be energized. If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.
Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or fine emery paper and oil. Do not destroy the continuity of the surfaces. Wipe thoroughly clean with Tectyl
®
506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl
®
511M Rust Preventive or WD-40®
or the equivalent.
REMOVING FROM STORAGE — As units are removed
from storage to be installed in their final location, they should be protected and maintained in a similar fashion, until the equipment goes into operation.
Prior to installing the unit and system components, inspect the unit assembly to make sure it is in working order.
1. Check all fasteners, set screws on the fan, wheel,
bearings, drive, motor base, and accessories for tightness.
2. Rotate the fan wheel(s) by hand and assure no parts
are rubbing.
OUTDOOR — Units designed for outdoor applications
may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed.
The fan should be placed on a level surface to prevent water from leaking into the unit. The unit should be elevated on an adequate number of wooden blocks so that it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight, and space for periodic inspection. To minimize water accumulation, place all unit parts on blocking supports so that rain water will run off.
Do not cover parts with plastic film or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.
Model VSU Make-Up Air
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Table of Contents
General Safety Information ....................1
Receiving, Handling and Storage ...............2
Product Overview ............................4
Subassembly Overview:
Filter Section / Vertical Mounting Stand ..........4
Optional Service Platform .....................4
Burner, Blower and Control Center Overview ......5
Burner Subassembly .......................6
Control Center ............................6
Dampers ...................................6
Installation
Concrete Slab ..............................7
Service and Access Clearance .................7
Clearance to Combustibles ....................7
Burner/Blower Section ........................7
Install Ductwork .............................7
Complete Installation .........................8
Optional Service Platform ..................8-9
Electrical Wiring ............................10
Direct Gas Piping ...........................11
Building Pressure Control, optional .............12
Start-Up
Checklist .................................13
Blower ................................14-15
Direct Gas .............................15-18
Operation
Optional VAV Units ..........................19
Optional Recirculating Units ..................20
Electrical ...............................20-21
Troubleshooting
Blower Does Not Operate ....................22
Motor Overamps ...........................23
Insufficient Airflow ..........................24
Too Much Airflow ...........................24
Excessive Noise or Vibration ..................25
Heater Does Not Operate (Pilot Ignition) ......26-28
Heater Does Not Operate (Direct Spark) ......29-30
Maintenance
Routine ...................................31
V-Belt Drives .............................31
Motors ..................................31
Wheels .................................31
Filters ..................................31
Bearings ................................32
Fall ......................................32
Start-Up ................................32
High Limit ...............................32
Gas Train ................................32
Reference
Typical Gas Train Layout ..................33-34
Control Center Layout .......................35
Maintenance Log .....................Backcover
Our commitment
.....................Backcover
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Model VSU Make-Up Air
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Product Overview
Subassemblies
The model is a vertically-configured make-up air unit designed for outdoor installations. It contains a highly efficient direct-fired gas burner to provide a heat source for the building or to simply temper the air. The unit is designed to provide sufficient air to replace air that is exhausted from the building and will also produce heat as needed. The make-up air volume produced by the unit can be regulated in a number of different ways, depending on the characteristics of the building.
The unit draws in fresh, outdoor air through a filter bank in the bottom of the unit and it then moves upward through a combustion chamber or through an optional burner bypass damper. A blower mounted in the top of the unit then forces the air into the building ductwork.
Airflow Arrangement
The unit can be ordered in a number of different configurations to provide 100% outdoor air or 80% recirculated air and 20% outdoor air. These units can also be ordered with a variable air volume (VAV) capability for flexibility in response to building air handling needs.
100% Outdoor Air
If the unit is configured only for 100% outdoor air, it draws outdoor air as needed through the filter bank at the bottom. The air moves upward through the combustion chamber and then it is blown into the building through user-supplied ductwork. The supply air volume is typically constant and can only be altered by changing the blower or motor pulleys.
80/20 Recirculated Air
When the unit is used as a primary heat source for the building, the unit will draw 80% of the needed air from the building and mix it with a minimum of 20% fresh outdoor air. Outdoor air is drawn through the combustion chamber and then mixed with the indoor air after the direct-fired gas heater has heated the air. The supply air volume is typically constant but the percentage of recirculated air can be modulated.
Variable Air Volume (VAV)
The VAV function can be selected when the outdoor air volume required by the building varies. This requires the installation of one bypass damper and selection of an appropriate motor/blower control system. This may involve installation of a Variable Frequency Drive (VFD) controller. Both bypass damper and VFD are factory installed.
Filter Section / Vertical Mounting Stand
The filter section of the unit is factory installed in the mounting stand and shipped ready for installation on the concrete mounting pad. Each filter unit has a large access panel on the control end of the unit except for the housing size 50, which has an access door on both ends. Filters are either 2 in. thick pleated paper or 2in. thick permanent metal type. Filters are changed by removing the access door(s) and sliding the filters in or out on their tracks.
The unit’s vertical mounting stand is fabricated of heavy-gauge, painted angle iron and flat stock steel. The nominal 24 in. high stand will support the entire unit so that the bottom of the filter unit is held 24 in. above ground level. For housing size 50, a nominal 48 in. high stand is minimum. In locations where heavy snowfall is common, greater minimum clearance should be specified in order to minimize the possibility of clogging filters with snow or debris. The stand with filter bank is shipped to the jobsite as a separate assembly. The unit filter bank is permanently installed in the mounting stand prior to shipment.
Optional Service Platform
A service platform is available for permanent attachment to the mounting stand. The platform is shipped unassembled and requires field assembly. It is attached to the vertical mounting stand by installing bolts with spacers between the two assemblies. The service platform should be attached to the unit only after the burner and blower assemblies are permanently set in place. Ladders are not provided by factory.
Model VSU Make-Up Air
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Burner, Blower and Control Center Section
The burner section, blower section and control center of the unit are all combined into one assembly which is installed in the field on top of the filter and stand section. The burner section is the lowest part of the burner / blower unit and it sits directly on the filter assembly. The burner section contains the gas train with its own access door and directly above that is the control center door. A number of different options are available for the gas train, whick include type, size and location of burners and many different ignition and safety controls.
The blower section of the unit consists of one motor and either one or two forward curved blowers. It is the top­most assembly in the unit. If two blowers are used, their drive shafts are connected and driven by a single motor. Supply air discharge openings may be located either on the side wall of the unit for horizontal discharge, or may be configured for upblast discharge through the roof of the unit. One large access door is located directly above the control center, for inspection and maintenance of the motor and blower(s).
Blowers
Control Center/
Gas Train
Filters
Burner
Open View
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Model VSU Make-Up Air
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Gas Train
(Burner Subassembly)
Burner Subassembly
The burner subassembly consists of the gas train with its controls, valves, pressure regulator, burner(s), and combustion chamber. The primary gas connection to the gas train is made through the side wall grommet into the factory-supplied female pipe fitting.
Dampers
There are four locations where optional dampers may be found. An optional motorized intake damper may be located horizontally on the bottom of the burner section. A patented passive control damper may be found adjacent to the burner opening plates if a VAV is ordered and a motorized damper may be installed vertically on the side of the burner section if recirculating air mode is chosen. In addition, an outlet damper may be shipped with the unit for field installation.
Optional Field-Installed
Outlet Damper
Optional Motorized
Recirculating Damper
Control Center
The control center is located on the end of the unit, directly above the gas train access door. The control center contains electronic components and some elctromechanical devices that monitor and control the operation of the entire unit. A unit-specific wiring diagram is affixed to the inside of the access door.
High voltage supply wiring terminates at a manual on/off switch located on the face or the side of the unit, adjacent to the control center.
Low voltage control wiring from the building terminates on the terminal strips.
Passive Control Damper
Optional Motorized
Intake Damper
Manual High Voltage
On/Off Switch
with Lockout
Model VSU Make-Up Air
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Installation
Concrete Slab
The first step in unit installation is to pour a concrete slab capable of holding the unit weight as a base. The slab should have a proper gravel drainage bed.
Concrete Slab Dimensions
Housing Size A B C D E
20 64 64 42 37 37 30 77 76 42 49 49 40 78 135 42 51 108 50 87 180 42 60 153
All dimensions are shown in inches.
NOTE
If optional service platform is included, a minimum of 42 inches must be added to Dimension B.
Building Wall
Approx. Stand Feet Locations
Concrete Slab
Burner/Blower Section
Use a crane and a spreader bar hooked to the factory lifting lugs (shown below) to lift and center the unit onto the filter stand section. The sections should be caulked together.
Spreader Bar
A
12
D
E
12
B
Concrete Slab and Unit Footprint
Unit Control Side
Required with service
platform only
C
Service and Access Clearance
The slab should be positioned to allow 3 feet of clearance on the control end of the unit and 2 feet of clearance on the other three sides. Housing size 50 requires 3 feet of clearance on both ends because of filters access. Note that the concrete forms a 1 foot wide apron on all four sides of the unit unless a 42 in. extension is added to the control end of the unit.
Clearance to Combustibles
Floor Top Sides Ends
Insulated/
Units
Non Insulated
Units
Clearance to combustibles is defined as the minimum distance required between the heater and adjacent combustible surfaces to ensure the adjacent surface’s temperature does not exceed 90 degrees above the ambient temperature.
0 in.
(0 mm)
0 in.
(0 mm)
0 in.
(0 mm)
6 in.
(152.4 mm)
0 in.
(0 mm)
6 in.
(152.4 mm)
0 in.
(0 mm)
6 in.
(152.4 mm)
Install Ductwork
This table shows the duct sizes and straight lengths recommended for optimal performance (AMCA Publication 201-90). Using duct sizes less than recommended will affect fan performance. Good duct installation practices should be followed for the remaining ductwork.
Recommended Supply Ductwork Sizes
VSU
Blower Size
108 10x13 32
109 14x13 38
110 16x14 42
112 18x16 48
115 19x16 49
118 24x22 64
120 28x28 79
218 68x24 114
220 68x26 118
225 104x37 175
230 104x37 203
Duct Size
(in.)
Straight Duct Length
(in.)
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Model VSU Make-Up Air
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Complete Installation
A typical horizontal discharge installation is shown. Gas and/or electrical lines can be connected at this time.
For upblast units, a duct elbow may be needed to turn the ductwork into the building. Follow proper ductwork methods recommended by AMCA to make this elbow to minimize duct losses.
Installation of Optional Service Platform
TOOLS REQUIRED
• (2) 9/16 in. sockets or wrenches
• Drill with 7/16 in. drill bit and 5/16 in. drill bit
• A crane or forklift is recommended for assembly and attachment.
Service Platform Material List
(1) Left Hand Rail with
Safety Chains
(1) Platform Base Unit with
predrilled holes for hand rails, legs and attachments.
Fasteners
(3)
(2)
(18)
(1) Right Hand Rail
Hex Head Bolts
3/8 in. x 1-1/2 in.
Thread Cutting
Screws
3/8 in. x 1 in.
Hex Head Bolts
3/8 in. x 3/4 in.
(2) Legs
(1) Leg Cross Member
Model VSU Make-Up Air
8
(27)
Hex Head Nuts
3/8 in.
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Assembly
1. Position platform base as shown below in FigureA with the grate side up.
2. Attach the left and right handrails to the platform base with (3/8 in. x 3/4 in.) hex head bolts and (3/8 in.) hex nuts as shown in Figure A. Use six bolts and nuts on each rail.
3. Raise the platform base, grate side up, with a crane or forklift.
4. Attach legs to the slots on sides of platform base with two (3/8 in. x 3/4 in.) hex head bolts and (3/8in.) hex nuts.
6. Facing the control panel side of the unit, find the center of the housing and drill a (7/16 in.) hole through the housing and support stand (3/8 in.) above the form line as shown in FigureC.
3/8 inch
Form Line
12
inches
12 inches
Figure C
Next, drill two more (7/16 in.) holes through the
housing and support stand (12 in.) on either side of the center hole, (3/8 in.) above the form line. These holes are used to attach the platform base to the unit.
7. Attach the service platform to the control panel side of the housing by inserting the three (3/8 in. x 1-1/2in.) bolts of platform base into the three holes of the housing. Securely fasten with three (3/8 in.) hex nuts.
8. Level service platform if necessary by adjusting legs and then attach leg cross member with two (3/8 in. x 3/4 in.) hex head bolts and 3/8 in. hex head nuts.
9. Securely fasten all nuts and bolts. Make sure all nuts and bolts are tight.
10. Attach arm rails of service platform to the housing by first drilling a 5/16 in. hole through the housing at the attachment point as shown in Figure D. Secure arm rails to the housing with (3/8 in. x 1 in.) thread cutting screws. Be sure not to over-tighten screws.
11. Attach safety chains to the right hand rail, across the entryway. Assembly is complete.
Figure A
5. Fasten three (3/8 in. x 1-1/2 in.) hex head bolts into the side of the platform base. Secure each bolt with two (3/8 in.) hex head nuts placed back to back on each bolt as shown in Figure B. These bolts will be used to attach the platform base
Figure B
to the unit.
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Attachment Points
for Step 11
Figure D
Model VSU Make-Up Air
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Installation of 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 edition of the National Electric Code ANSI/ NFPA70 and any local codes that may apply. In Canada, wiring should be done in accordance with the Canadian Electrical Code.
IMPORTANT
The equipment must be properly grounded. Any wiring running through the unit in the airstream must be protected by metal conduit, metal clad cable or raceways.
CAUTION
If replacement wire is required, it must have a temperature rating of at least 105ºC, except for an energy cut-off or sensor lead wire which must be rated to 150ºC.
DANGER
High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician.
CAUTION
Any wiring deviations may result in personal injury or property damage. Manufacturer is not responsible for any damage to, or failure of the unit caused by incorrect final wiring.
IMPORTANT
Manufacturer’s standard control voltage is 24VAC. Control wire resistance should not exceed 0.75ohms (approximately 285 feet total length for 14gauge wire; 455 feet total length for 12gauge wire). If the resistance exceeds 0.75 ohms, an industrial-style plug-in relay should be wired in place of the remote switch. The relay must be rated for at least 5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to chatter or not pull in, resulting in contactor failures and/or motor failures.
Determine the Size of the Main Power Lines
The unit’s nameplate states the voltage and the unit’s MCA. The main power lines to the unit should be sized accordingly. The nameplate is located on the outside of the unit on the control panel side.
Determine the Size of Electric Heater Wiring
An optional electric heater may require a separate power supply. The power connection should be made to the factory provided electric heater disconnect and
must be compatible with the ratings on the nameplate, supply power voltage, phase and amperage. Consult ANSI/NFPA 70 and CSA C22.1 for proper conductor sizing.
Connect the Main Power
Connect the main power lines to the disconnect switch and main grounding lug(s). Torque field connections to manufacturer’s recommendations.
Wire the Optional Convenience Outlet
The convenience outlet requires a separate 115V power supply circuit. The circuit must include short circuit protection which may need to be supplied by others.
Wire the Optional Accessories
Reference the ladder diagram on the inside of the control center door for correct wiring of the following accessories:
• Selectra Stat • Indicating Lights
• Room Override • Dirty Filter Indicator
Blower Switch TSCP
Heat Switch KSCP
NOTE
Wiring to the Selectra Stat should be in separate conduit or run with shielded cable.
NOTE
TSCP has number-to-number wiring.
NOTE
Large evaporative coolers may require a separate power supply.
Connect Field-Wired Low Voltage Components
Most factory-supplied electrical components are prewired. To determine what electrical accessories require additional field-wiring, refer to the unit-specific wiring diagram located on the inside of the control center access door.
The low voltage control circuit is 24 VAC and control wiring should not exceed 0.75 ohms.
Control wires should not be run inside the same conduit as that carrying the supply power. Make sure that field-supplied conduit does not interfere with access panel operation. All low voltage wiring should be run in conduit wherever it may be exposed to the weather.
If wire resistance exceeds 0.75 ohms, an industrial­style, plug-in relay should be added to the unit control center and wired in place of the remote switch (typically between terminal blocks R and G on the terminal strip). The relay must be rated for at least 5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to “chatter” or not pull in which can cause contactor failures and/or motor failures.
Model VSU Make-Up Air
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Installation of Direct 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 and Equipment (CGA B149) and Provincial Regulations for the class. Authorities having jurisdiction should be consulted before installations are made.
WARNING
All components of this or any other gas-fired heating unit must be leak tested prior to placing the unit into operation. A soap and water solution should be used to perform this test. NEVER test for gas leaks with an open flame.
WARNING
If pressure testing in excess of 1/2 psig (3.5kPa), the heater and manual shutoff valve must be disconnected from the supply gas line.
WARNING
If pressure testing at or below 1/2 psig (3.5kPa), the heater must be isolated from the supply gas line by closing its manual shutoff valve.
IMPORTANT
All piping should be clean and free of any foreign matter. Foreign material entering the gas train can damage the valves, regulators and burner.
IMPORTANT
Do NOT connect the unit to gas types other than what is specified and do NOT connect the unit to gas pressures that are outside of the pressure range shown on the label.
NOTE
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.
Determine the Supply Gas Requirements
The unit’s direct gas nameplate states the requirements for the gas being supplied to the unit. The direct gas nameplate is located on the outside of the unit on the control center side.
Minimum gas pressure for
maximum output
MAX BTU/HR BTU/H MAX
NORMAL MANIFOLD PRESSURE PRESSION DÕADMISSION NORMALE
MIN GAS PRESSURE PRESSION DE GAZ
MIN BURNER PRESSURE DROP PERTE MIN DE PRESSION DANS LE BRULEUR
TYPE OF GAS NATURE DU GAZ
EQUIPPED FOR
CONCU POUR
Type of gas
AGAINST
SCFM
CONTE
Direct Gas Nameplate
MIN BTU/HR BTU/H MIN
MIN GAS PRESSURE FOR MAX OUTPUT
“ WC
PRESSION DE GAZ MIN POUR PUISSANCE MAX
MAX GAS PRESSURE
“ WC
PRESSION DE GAZ MAX
MAX BURNER PRESSURE DROP
“ WC
PERTE MAX DE PRESSION DANS LE BRULEUR
DESIGN ΔT ΔT NORMALE
“ WC
Maximum gas pressure
“ WC
“ WC
PSI
F
EXTERNAL STATIC PRESSURE
PRESSION STATIQUE EXTERIEURE
Install Additional Regulator if Required
When the supply gas pressure exceeds the maximum gas pressure shown on the direct gas nameplate, an additional regulator (by others) is required to reduce the pressure. The regulator must have a listed leak limiting device or it must be vented to the outdoors.
NOTE
The regulator located inside the unit is used to adjust the unit’s maximum output temperature.
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Model VSU Make-Up Air
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