Greenheck IG-IGX User Manual

Part # 464104

MODELS IG / IGX

Make-Up Air Unit

Installation, Operation and Maintenance Manual

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.

**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.

**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.

**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.

MaintenanceTroubleshootingOperationStart-UpInstallation Reference

Report any damaged equipment to the shipper immediately!

All units are shipped on a skid or packaged to minimize damage during shipment. The transporting carrier has the responsibility of 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. Some accessory items are stored inside the unit during shipping. Care must be taken during installation to prevent damage to units.

TABLE OF CONTENTS

STORAGE

When a unit is not going to be in service for an extended period of time, certain procedures should be followed to keep the unit in proper operating condition:

• Plug all piping

• Rotate fan wheel monthly and purge bearings once every one to three months (depending on environment)

• Energize fan motor once every three months

• Store belts flat to keep them from warping and stretching

• Store unit in location without vibration

• Cover unit with tarp to protect from dirt and moisture

• After storage period, purge grease before putting fan into service

NOTE!

Do not cover unit with a black tarp, this would

promote condensation.

NOTE!

Improper storage which results in damage to the

unit will void the warranty.

Installation

Unit - Indoor . . . . . . . . . . . . . . . . . . . . . . . . . .3

Unit - Arrangement DB/HZ . . . . . . . . . . . . . . .4

Unit - Arrangement DBC . . . . . . . . . . . . . . .5-6

Venting - Outdoor . . . . . . . . . . . . . . . . . . . . . . .7

Venting - Indoor (All Units) . . . . . . . . . . . . . . . .8

Venting - Standard Indoor . . . . . . . . . . . . . . . .9

Venting - Concentric (General) . . . . . . . . . . .10

Venting - Concentric (Horizontal) . . . . . . .11-12

Venting - Concentric (Vertical) . . . . . . . . .13-14

Venting - Two Pipe (Horizontal) . . . . . . . .15-16

Venting - Two Pipe (Vertical) . . . . . . . . . .17-18

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . .19-21

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . .22-23

Evaporative Cooler Piping . . . . . . . . . . . .24-25

Water Wizard™ Evaporative Control . . . . . .26

Direct Expansion (DX) Coil Piping . . . . . .27-29

Chilled Water Coil Piping . . . . . . . . . . . . . . . .30

Building Pressure Control . . . . . . . . . . . . . . .31

Start-Up

Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-33

Furnace (All Units) . . . . . . . . . . . . . . . . . . . . .34

Furnace (Single Stage) . . . . . . . . . . . . . . . . . .35

Furnace (2:1 Staged) . . . . . . . . . . . . . . . . . . .36

Furnace (8:1 Staged) . . . . . . . . . . . . . . . .37-41

Furnace (2:1 Modulation) . . . . . . . . . . . . . . . .42

Furnace (4:1 Modulation) . . . . . . . . . . . . .43-46

Mixing Box . . . . . . . . . . . . . . . . . . . . . . . .47-48

Water Wizard™ Evaporative Controller . .49-50

Evaporative Cooling . . . . . . . . . . . . . . . . . . . .51

Operation

Furnace (2:1 Staged) . . . . . . . . . . . . . . . . . . .52

Furnace (2:1 Modulation) . . . . . . . . . . . . . . . .53

4:1 Modulation / 8:1 Staged Controller . .54-55

Furnace (4:1 Modulation) . . . . . . . . . . . . . . . .56

Furnace (8:1 Staged) . . . . . . . . . . . . . . . . . . .57

Recirculating/VAV Units . . . . . . . . . . . . . . . . .58

Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Water Wizard™ Evaporative Controller . . . .60

Troubleshooting

Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . .63-64

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Furnace (Single Stage or 2:1 Staged) . . . . . .66

Furnace (2:1 Modulating) . . . . . . . . . . . . . . . .67

Furnace (4:1 Modulation) . . . . . . . . . . . . .68-69

Furnace (8:1 Staged) . . . . . . . . . . . . . . . .70-71

Water Wizard™ Evaporative Controller . . . .72

Reference

Vent Connections . . . . . . . . . . . . . . . . . . .80-81

Model IG (Single Stage or 2:1 Staged) . . . . .82

Model IG (8:1 Staged) . . . . . . . . . . . . . . . . . .83

Model IG (2:1 Modulating) . . . . . . . . . . . . . . .84

Model IG (4:1 Modulating) . . . . . . . . . . . . . . .85

Model IGX (Blower Control Center) . . . . . . . .86

Model IGX (Single Stage or 2:1 Staged) . . . .87

Model IGX (8:1 Staged) . . . . . . . . . . . . . . . . .88

Model IGX (2:1 Modulating) . . . . . . . . . . . . . .89

Model IGX (4:1 Modulating) . . . . . . . . . . . . . .90

Performance Table . . . . . . . . . . . . . . . . . . . . .91

Warranty . . . . . . . . . . . . . . . . . . . . . .Backcover

Maintenance

Routine . . . . . . . . . . . . . . . . . . . . . . . . . . .73-75

Fall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Log . . . . . . . . . . . . . . . . . . . . . . . . . . . .77-79

Step 3 Install Vent Piping

Refer to the indoor venting instructions I-6. Refer to your unit submittal to determine the correct venting option.

Step 2 Install Unit

Raise the unit into place.

Using two nuts per hanger, fasten the unit supports to hangers under the unit. Appropriate unit supports, such as the optional Greenheck hanging bracket kit or c-channel and angle iron (supplied by others) should be used.

Using self tapping screws, attach ductwork to unit.

In order to prevent the unit from swinging and to provide a safe environment for service and maintenance, additional measures must be taken to secure the unit in all directions.

Installation - Indoor

WARNING!

All factory provided lifting lugs must be used when lifting any unit. Failure to comply with this safety

precaution could result in property damage, serious injury or death.

Step 1 Install Hangers

Install threaded hangers from ceiling supports. When locating hangers, allow enough room to open access panel(s). Two nuts must be used on the end of each threaded hanger. Ceiling supports are supplied by others.

NOTE!

Good duct practices should be followed for all ductwork. Ductwork should be installed in accordance with SMACNA and AMCA guidelines, NFPA 96 and any local codes. Reference the CAPS submittal for

duct sizes.

NOTE!

Vent piping is supplied by others and not supplied by Greenheck.

NOTE!

Two nuts must be used on each end of each

threaded hanging rod for proper support.

Installation

NOTE!

To prevent premature heat exchanger failure, do not locate units where chlorinated, halogenated, or

acid vapors are present.

Installation

Step 1 Install Curb/Equipment

Support(s)

Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach curb to roof and flash into place. When attaching the equipment support(s) to the roof, remove metal cover, flash to wooden nailer and reinstall cover.

Supply Air Duct

(Arrangement DB only)

Return Air Duct

(with mixing box only)

Metal Cover

Equipment Support

Installation - Arrangement DB / HZ

Step 2 Install Ductwork

Good duct practices should be followed for all ductwork. All ductwork should be installed in accordance with SMACNA and AMCA guidelines, NFPA 96 and all local codes. Reference the CAPS submittal for ductwork sizes.

Step 3 Apply Sealant

Apply an appropriate sealant around the perimeter of the curb and duct adapter(s) to isolate fan vibration and prevent water penetration.

Step 4 Install Unit

Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the unit on the curb/equipment support(s).

Use self-tapping sheet metal screws to fasten the unit to the curb/equipment support(s).

NOTE!

The use of a duct adapter is recommended on a

downblast (DB) arrangement to align the

ductwork with the supply unit and is only a guide

and is not support for the ductwork.

NOTE!

The use of all lifting lugs and a set of spreader

bars is mandatory when lifting the unit.

NOTE!

Be sure to complete the outdoor venting

installation instructions.

NOTE!

Refer to the outdoor venting instructions when

locating the unit.

Supply Ductwork by Others

Exhaust Ductwork by Others

Installation - Arrangement DBC

Step 1 Install Curb/Equipment

Support(s)

Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach curb to roof and flash into place. Attach the equipment support(s) to the roof, remove metal cover, flash to wooden nailer and reinstall cover.

Step 2 Install Combination Extension

Install combination extension over curb. Lag into place using wood screws. Locate the extension so the tall, vented-side is over the exhaust opening.

NOTE!

The use of a duct adapter is recommended on a downblast (DBC) arrangement to align the ductwork

with the supply unit and is only a guide and is not support for the ductwork.

Step 3 Install Ductwork

Good duct practices should be followed for all ductwork. All ductwork should be installed in accordance with SMACNA and AMCA guidelines, NFPA 96 and any local codes. Reference the CAPS submittal for ductwork size and location.

Installation

NOTE!

Refer to the outdoor venting instructions when locating the unit.

Metal Cover

Equipment Support

Supply

Roof Curb

Exhaust

1 inch Inside Flange

Installation

Installation - Roof Mounted Unit Arrangement DBC

Step 5 Install Exhaust Fan

Fasten exhaust fan to curb extension with selftapping sheet metal screws.

Step 6 Install Exhaust Options

Install optional Greenheck hinge kit with restraining cables and grease trap with drain connection.

Step 7 Install Supply Unit

Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the unit on the curb/equipment support(s).

Use self-tapping sheet metal screws to fasten the unit to the curb/equipment support(s).

NOTE!

Installing the exhaust fan prior to the supply unit

will allow for easier installation of options.

NOTE!

The use of all lifting lugs and a set of spreader

bars is mandatory when lifting unit.

NOTE!

Be sure to complete the outdoor venting

installation instructions.

Step 4 Apply Sealant

Apply an appropriate sealant around the perimeter of the curb and duct adapter(s) to isolate fan vibration and prevent water penetration.

Supply Duct with Duct Adapter Installed

Exhaust Duct Installed

Sealant

Model CUBE Exhaust Fan

Installation - 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 openings shall conform with the local codes. In the

absence of local codes, installation shall conform with the National Fuel Gas Code, ANSI Z223.1, or the

CAN/CGA B-149 Installation Codes.

WARNING!

The following guidelines must be followed for all outdoor units:

1. Building materials that will be affected by flue gases should be protected.

2. Maintain minimum horizontal clearance of 4 feet from electric meters, gas meters, regulators, and relief equipment. In Canada, the minimum clearance is 6 feet.

3. The combustion blower discharge on outdoor units must be located a minimum of 42 inches from any combustible materials.

4. Do not modify or obstruct the combustion air inlet cover or the combustion blower weatherhood.

5. Do not add vents other than those supplied by the manufacturer.

6. During the winter, keep the unit clear of snow to prevent any blockage of the combustion venting.

NOTE!

Clearances from combustible material for indoor units are determined by the National Fuel Gas Code

and/or other local codes.

Step 1 Follow Guidelines

All of the following guidelines must be followed when installing the unit.

Step 2 Install Stack (Optional)

Clearance may require an exhaust stack. Install an exhaust stack as needed to the exhaust connection on the unit. Install a vent terminal on the exhaust pipe.

Installation

Installation - Venting for All Indoor Units

NOTE!

The drip leg should be cleaned out periodically during the heating season.

Venting Methods

There are three venting method for indoor mounted units. Specific venting instructions are provided for each

method. Refer to the specific instructions for the venting method listed in the CAPS submittal.

The venting method options are:

• Standard Indoor Venting (uses building air for combustion, vents outdoors, one roof or wall penetration)

• Separated Combustion 2-Pipe Venting (uses outside air for combustion, vents outdoor, two exterior roof or wall penetrations)

• Separated Combustion Concentric Venting (uses outside air for combustion, vents outdoors, one exterior roof or wall penetration)

NOTE!

For each method, the units can be vented horizontally through an exterior wall or vertically through the

roof. Refer to the specific venting instructions for your unit. Construct the vent system as shown in

these instructions.

NOTE!

Vent piping is supplied by others and not supplied by Greenheck.

Installation

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 exhaust pipe, use 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 ANSI.

3. For the combustion air pipe on separated combustion units, sealed single-wall galvanized air pipe is recommended.

4. The joints must be sealed with a metallic tape or silastic suitable for temperatures up to 350ºF.

5. A 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.

7. To reduce condensation, insulate any vent runs greater than 5 feet.

8. All 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.

Standard Horizontal Venting

A = 12 in. minimum

Pitch vent pipe

downward from

furnace

⁄4

inches per foot

Exhaust Vent

Terminal

EXHAUST

Exterior Wall

Air Inlet

Step 1 Select Vent Pipe Size

Select the vent pipe size from the table to the right. Use only the specified pipe size.

Step 2 Install Exhaust Vent Pipe

Install the vent pipe with minimum downward slope (from the unit) of 1⁄4 inch per foot. Securely suspend the pipe from overhead structures at points no greater than 3 feet apart. Attach the vent terminal to the end of the exhaust pipe.

Installation - Standard Indoor Venting

NOTE!

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 atmosphere. To prevent premature heat exchanger

failure, do not locate units where chlorinated, halogenated, or acid vapors are present.

NOTE!

When units are installed in tightly sealed

buildings, provisions should be made to supply

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 BTU per hour of input rating.

IMPORTANT!

Vent terminals must be used. Construct the vent

system as shown in drawings and reference the

tables for the correct vent pipe diameters. The minimum vent length is 5 feet for horizontal and 10 feet for vertical. The maximum vent length is

70 feet. 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.

Standard Vertical Venting

A = 12 inch minimum B = 12 inch minimum,

but should size according to expected snow depth.

EXHAUST

Exhaust Vent

Terminal

Air Inlet

Roof Line

Furnace Exhaust Pipe

Size (MBH) Diameter

75-175 4 inches

200-400 6 inches

Installation

WARNING!

The concentric venting adapter is designed for indoor installations and should never be installed on

the exterior of the building.

Installation - Concentric Venting (General)

NOTE!

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 is required for concentric venting.

NOTE!

If venting vertically through the roof, refer to the vertical concentric venting instructions. If venting

horizontally through the wall, refer to the horizontal concentric venting instructions.

CVA-4

(4 inch Concentric Venting Adapter)

CVA-6

(6 inch Concentric Venting Adapter)

Exhaust Connection

Concentric Side

Combustion Air Connection

Concentric Side

Exhaust Connection

Non-Concentric Side

Combustion Air Connection

Non-Concentric Side

CVA

NOTE!

The exhaust pipe must terminate with the vent terminal. The combustion air pipe must terminate with

the combustion air guard (horizontal venting) or terminal (vertical venting). Both are provided in the

optional venting kit along with the concentric venting adapter (CVA).

NOTE!

Vent piping is supplied by others and not supplied by Greenheck.

Installation

Step 1 Determine Venting Location

Determine the location of the concentric venting adapter (CVA) based on any clearances that must be maintained (follow all codes referenced in these instructions).

Step 2 Attach Mounting Brackets

Attach field supplied, corrosion resistant mounting brackets to the CVA using corrosion resistant sheet metal screws.

Installation - Concentric Venting (Horizontal)

EXHAUST

COMBUSTION AIR

Exterior Wall

Mounting

Bracket

Mounting

Bracket

Exhaust Pipe

Terminal

A = 2 inch minimum B = 12 inch minimum

Combustion Air

Inlet Guard

Pitch vent pipe downward from

furnace .25 inches per foot

NOTE!

All vent piping is FIELD SUPPLIED by others and

is not supplied by Greenheck.

NOTE!

The optional venting kit includes a concentric

venting adapter (CVA), vent terminal and guard.

NOTE!

Maintain at least 12 inches from the combustion air inlet guard to the vent terminal.

NOTE!

To prevent water from running into the combustion air pipe and to allow for easy installation of the

combustion air guard, the combustion air pipe must terminate at least 2 inches from the exterior

surface of the outside wall.

Non-Concentric Concentric

Vent Connection Diameter Vent Connection Diameter

Furnace Size Exhaust Combustion Exhaust Combustion

(MBH) (Inches) Air (Inches) (Inches) Air (Inches)

75 -175 4446

200 -400 6668

Installation

IMPORTANT!

Vent terminals must be used. Construct the vent system as shown in drawings and reference the

tables for the correct vent pipe diameters. The minimum vent length is 5 feet and the maximum vent

length is 70 feet. 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.

Step 4 Install Combustion Air Pipe

Attach a field supplied combustion air pipe to the concentric side of the CVA.

Be sure to 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.

Be sure to maintain the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake.

Step 5 Install CVA Assembly

Place the entire CVA assembly through the wall and verify that all minimum clearance requirements as specified in these instructions are met. Secure the CVA assembly to the wall with corrosion resistant sheet metal screws through the mounting brackets.

Step 6 Attach CVA Assembly to Unit

Attach 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 CVA.

Step 8 Seal Opening

Seal the opening between the wall and the air intake pipe using an appropriate method.

Step 7 Install Combustion Air Inlet Guard and Exhaust Vent Terminal

Slide the combustion air inlet guard over the exhaust pipe and fasten it to the combustion air pipe. Attach the exhaust vent terminal to the discharge end of the exhaust piping on the outside of the building.

Step 3 Install Exhaust Pipe

Slide the exhaust pipe through the CVA. Be sure to provide enough exhaust piping to pass

through the wall 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 CVA.

Installation - Concentric Venting (Horizontal)

Exhaust

Connection

(Model IG)

Exhaust Connection (Model IGX)

Combustion Air

Connection

(Model IG)

Combustion Air

Connection

(Model IGX)

Installation

Intake End

Discharge

End

Installation - Concentric Venting (Vertical)

NOTE!

All vent piping is FIELD SUPPLIED by others.

Exhaust Vent Terminal

Combustion Air

Inlet Terminal

Roofline

EXHAUST

COMBUSTION AIR

Tee with drip leg and

cleanout cap

A = 12 inch minimum, but should size

according to expected snow depth. B = 12 inch minimum C = 12 inch minimum

NOTE!

Maintain at least 12 inches of clearance between

the top of the combustion air inlet terminals and

the bottom of the exhaust terminal.

NOTE!

A tee with clean-out must be provided on the combustion air and exhaust pipe to prevent debris from

entering the heat exchanger.

NOTE!

The bottom of the combustion air intake pipe

must terminate above the snow line, or at least

12 inches above the roof, whichever is greater.

Mounting

Bracket

Mounting

Bracket

Step 1 Determine Venting Location

Determine the location of the concentric venting adapter (CVA) based on any clearances that must be maintained (follow all codes referenced in these instructions).

Step 2 Attach Mounting Brackets

Attach field supplied corrosion resistant mounting brackets to the CVA.

NOTE!

The optional venting kit includes a concentric

venting adapter (CVA), and two terminals.

Installation

IMPORTANT!

Vent terminals must be used. Construct the vent system as shown in drawings and reference the

tables for the correct vent pipe diameters. The minimum vent length is 10 feet and the maximum vent

length is 70 feet. 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.

Non-Concentric Concentric

Vent Connection Diameter Vent Connection Diameter

Furnace Size Exhaust Combustion Exhaust Combustion

(MBH) (inches) Air (inches) (inches) Air (Inches)

75 -175 4446

200 -400 6668

Installation - Concentric Venting (Vertical)

Step 3 Install Exhaust Pipe

Slide the exhaust pipe through the CVA. Be sure to provide enough exhaust piping to pass

through the roof 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 CVA.

Step 4 Install Combustion Air Pipe

Attach a field supplied combustion air pipe to the concentric side of the CVA. Be sure to 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.

Step 5 Install CVA Assembly

Place the entire CVA assembly through the roof and verify that all minimum clearance requirements as specified in these instructions are met. Secure the CVA assembly to the ceiling with corrosion resistant sheet metal screws through the mounting brackets.

Step 6 Attach CVA Assembly to Unit

Attach 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 CVA. Be sure to include the required tee’s with drip legs and clean outs.

Step 8 Seal Opening

Seal the opening between the roof and the air intake pipe using an appropriate method.

Step 7 Install Terminals

Slide the combustion air terminal over the vent pipe and fasten it to the combustion air pipe. Attach the exhaust vent terminal to the discharge end of the exhaust piping.

Installation

Exhaust

Connection

(Model IG)

Exhaust Connection (Model IGX)

Combustion Air

Connection

(Model IG)

Combustion Air

Connection (Model IGX)

Intake End

Discharge

End

Exterior Wall

EXHAUST

COMBUSTION AIR

Pitch vent pipe downward from

furnace 1⁄4 inches per foot

Field Supplied

Support Brackets

A = 12 inch minimum B = 24 inch minimum C = 12 inch minimum

Exhaust Vent Terminal

Combustion Air

Inlet Terminal

Installation - Two Pipe Venting (Horizontal)

NOTE!

All vent piping is FIELD SUPPLIED by others.

NOTE!

Maintain at least 12 inches of clearance between

the exhaust pipe termination and the exterior

surface of the exterior wall.

NOTE!

The combustion air pipe must be a minimum of

12 inches from the exhaust pipe and 24 inches

from the exterior surface of the outside wall.

NOTE!

Optional venting kit includes two vent terminals.

Installation

NOTE!

A minimum of 1 inch and a maximum of 48 inch of building wall thickness is required for separated

combustion vent pipe.

IMPORTANT!

Vent terminals must be used. Construct the vent system as shown in drawings and reference the

tables for the correct vent pipe diameters. The minimum vent length is 5 feet and the maximum vent

length is 50 feet. 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 Connection Diameter

Furnace Size Exhaust Combustion

(MBH) (Inches) Air (Inches)

75 - 175 4 4

200 - 400 6 6

Step 1 Install Exhaust Pipe

Run an exhaust pipe from the unit’s combustion exhaust through the exterior wall to the outdoors. The exhaust pipe must terminate at least 12 inches from the outside surface of the outside wall. Attach exhaust vent terminal to the end of the exhaust pipe. Using field supplied mounting brackets, support the exhaust pipe as needed.

Step 3 Seal Wall Openings

Using an appropriate method, seal the wall openings around the piping.

Step 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 combustion air pipe. Using field supplied mounting brackets, support the combustion air pipe as needed.

Installation - Two Pipe Venting (Horizontal)

Installation

Exhaust

Connection

(Model IG)

Exhaust Connection (Model IGX)

Combustion Air

Connection

(Model IG)

Combustion Air

Connection (Model IGX)

Intake End

Discharge

End

A = 12 inch minimum, but should size

according to expected snow depth. B = 24 inch minimum C = 12 inch minimum D = 12 inch minimum

EXHAUST

COMBUSTION AIR

Tee with drip leg and clean-out cap.

Combustion Air

Inlet Terminal

Exhaust Vent

Terminal

Installation - Two Pipe Venting (Vertical)

NOTE!

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.

NOTE!

The exhaust must terminate at least 12 inches

above and 12 inches horizontally from the

combustion air inlet.

NOTE!

All vent piping is FIELD SUPPLIED by others.

NOTE!

The optional vent kit includes two terminals.

Installation

IMPORTANT!

Vent terminals must be used. Construct the vent system as shown in drawings and reference the

tables for the correct vent pipe diameters. The minimum vent length is 10 feet and the maximum vent

length is 70 feet. 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 Connection Diameter

Furnace Size Exhaust Combustion

(MBH) (Inches) Air (Inches)

75 - 175 4 4

200 - 400 6 6

Installation

Step 1 Install Exhaust Pipe

Run an exhaust pipe from the unit’s combustion exhaust through the roof 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.

Step 3 Seal Roof Penetration

Using an appropriate method, seal the roof openings around the vent pipes.

Step 2 Install Combustion Air Pipe

Run a combustion air pipe from the unit’s combustion air intake through the roof to the outdoors. The combustion air pipe must terminate at least 12 inches horizontally and vertically from the combustion exhaust pipe and at least 24 inches from the exterior surface of the roof. These clearances may need to be increased to accommodate for expected snow accumulation. Attach the combustion air terminal to the end of the combustion air pipe.

Installation - Two Pipe Venting (Vertical)

Exhaust

Connection

(Model IG)

Exhaust Connection (Model IGX)

Combustion Air

Connection

(Model IG)

Combustion Air

Connection (Model IGX)

Intake End

Discharge

End

Installation - Electrical Wiring

CAUTION!

If replacement wire is required, it must have a

temperature rating of at least 105°C, except for

energy cut-off or sensor lead wire which must be

rated to 150°C.

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 final wiring.

DANGER!

High voltage electrical input is needed for this

equipment. This work should be performed by a

qualified electrician.

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.

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!

Greenheck’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.

Step 3 Connect the Main Power

Connect the main power lines to the disconnect switch and main grounding lug(s). Torque field connections to 20 in-lbs. See the blower control center layout in the reference section for main disconnect and grounding lug(s) locations.

Step 1 Determine the Size of the Main

Power Lines

The unit nameplate states the voltage and the unit’s total amps. The main power lines to the unit should be sized accordingly.

Step 2 Provide the Opening(s) for the

Electrical Connections

Electrical openings vary by unit size and arrangement and are field supplied.

MODEL

VOLTS

SUP HP

MARK

AMPS

HTZ PH

S/N

EXH HP

Voltage, Hertz,

and Phase

Unit’s Total

Amps

Installation

Step 5 Wire the Accessories

Reference the ladder diagram in the control center for correct wiring of the following accessories:

Step 6 Wire Optional Evaporative Cooler

Reference the ladder diagram on the inside of the control center door for correct wiring of the pump and the optional auto-drain and flush. If the Water Wizard was selected, the temperature sensor may need to be wired, refer to the Water Wizard start-up.

Step 7 Install Optional Economizer Sensors

All economizer options (EC) require an outdoor air temperature or enthalpy sensor to be field installed inside of the weatherhood and field wired to terminals SO+ and SO- on the economizer.

Economizer options EC-3 and EC-4 require an outdoor air temperature or enthalpy sensor to be field installed in the return air duct and field wired to terminals SR+ and SR- on the economizer.

The sensors are provided by the factory and ship with the unit.

NOTE!

Large evaporative coolers may require a separate power supply.

NOTE!

The TSCP and KSCP remote panels have number-to-number wiring.

NOTE!

Wiring to the Selectrastat or room override

should be in separate conduit or run with

shielded cable.

Installation - Electrical Wiring

• Selectrastat

• Room Override

• Blower Switch

• Heat Switch

• Indicating Lights

• Dirty Filter Indicator

• TSCP

• KSCP

• Mixing Box Actuator

• Room Stat

Step 4 Wire the Convenience Outlet (Optional)

The optional convenience outlet requires a separate 115V power supply circuit with short circuit protection by others.

Installation

75 80

(OPTIONAL)

BLOWER

DIRTY FILTERS

MAIN VALVES

ALARM

EXHAUST

SUPPLY

HEAT

(OPTIONAL)

GREENHECK

®

PHOTOHELIC

Step 9 Check Recirculation / VAV Operation (Optional)

Two Position Damper Control

Confirm that the return damper adjusts to each position of the recirculating switch. The damper actuator may take a few minutes to open or close.

Two Speed

Confirm that the fan speed adjusts to each position of the fan speed switch.

Potentiometer Control

To test potentiometer operation, turn the potentiometer to the two extremes. With recirculation, confirm that the return air damper fully opens and fully closes. The damper actuator may take a few minutes to open or close. With variable volume, make sure the fan goes to maximum and minimum speed.

Building Pressure Control

See page 31 for building pressure set-up and operation check.

Step 8 Install Discharge Air Sensor (Optional)

For units with 8:1, 16:1 or 24:1 staged turndown, install the discharge air sensor at least three duct diameters downstream of the heat exchanger. The discharge air sensor can be found in the unit’s control center.

Step 10 Install DDC Interface (Optional)

Some units may use an external signal from a building management system to control the dampers and/or discharge air temperature. Reference the unit ladder diagram for the correct wiring.

Installation - Electrical Wiring

NOTE!

For maintenance issues associated with variable frequency drives, consult the drive’s manual supplied

with the unit. The drives are programmed at the factory and should not need any adjustment during

installation or start-up. For kitchen applications, the drive may be located in the kitchen or in the unit.

(OPTIONAL

)

BLOWE

DIRTY FILTERS

MAIN VALVES

ALARM

EXHAUST

SUPPLY

HEA

(OPTIONAL

)

GREENHE

75 80

GREENHECK

®

(OPTIONAL)

BLOWER

DIRTY FILTERS

MAIN VALVES

ALARM

RECIRCULATION

EXHAUST

SUPPLY

HEAT

(OPTIONAL)

2-Position Damper ControlPotentiometer ControlPhotohelic Control

NOTE!

Blower start-up (S-1), steps 1-4 should be performed before the blower is run.

Installation - 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!

When leak testing pressures above 14 in. wc (1⁄2 psi), close the field installed shutoff valve,

disconnect the furnace and gas train from the

gas supply line and plug the supply line before

testing.

WARNING!

When leak testing pressures equal to or less

than 14 in. wc (1⁄2 psi), first close the field-

installed shutoff valve to isolate the unit from

the gas supply line.

NOTE!

Furnaces have a single 3⁄4 inch connection.

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.

IMPORTANT!

All piping should be clean and free of any foreign

material. Foreign material entering the gas train

can cause damage.

“W.C.

PSI

“W.C.

MAX BTU/HR BTU/H MAX

NORMAL MANIFOLD PRESSURE PRESSION D’ADMISSION NORMALE

MIN GAS PRESSURE PRESSION DE GAZ

TYPE OF GAS NATURE DU GAZ

MIN BTU/HR BTU/H MIN

MIN GAS PRESSURE FOR MAX OUTPUT PRESSION DE GAZ MIN POUR PUISSANCE MAX

MAX GAS PRESSURE PRESSION DE GAZ MAX

DESIGN ∆T ∆T NORMALE

EQUIPPED FOR

CONCU POUR

SCFM

“W.C.

EXTERNAL STATIC PRESSURE

PRESSION STATIQUE EXTERIEURE

AGAINST

CONTE

Minimum and

maximum gas

pressures

Minimum gas

pressure for

maximum output

Type of Gas

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.

Step 1 Determine the Supply Gas Requirements

The unit’s nameplate states the requirements for the gas being supplied to the unit.

Installation

Installation - Gas Piping

Step 3 Connect the Supply Gas Line

A manual shut off valve (gas cock), 1/8 inch plugged test port and 6 inch drip leg must be installed prior to the gas train. The valve and the test port must be accessible for the connection of a test gauge. Supply gas connections must be made by a qualified installer and are not furnished by Greenheck.

Step 2 Install Additional Regulator if

Required

When the supply gas pressure exceeds the maximum gas pressure shown on the unit’s 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.

From

Gas

Supply

Gas Cock

1/8 in. Plugged Tap

6 in. Trap

Ground Joint Union

Step 4 Test the System for Leaks

Check both the supply lines and the factory piping for leaks. Apply a soap and water solution to all piping and watch for bubbling which indicates a leak.

WARNING!

The factory piping has been checked for leaks, but should be rechecked due to shipping and

installation.

WARNING!

NEVER test for a gas leak with an open flame.

Supply Gas Pressure

Range (in. wc.)

Minimum Maximum Natural 6 14 LP 10 14

Make-Up

Air Unit

Installation - Evaporative Cooling Piping (Optional)

Evaporative Cooling with Bleed-Off

IMPORTANT!

The supply line should be of adequate size and

pressure to resupply the amount of water lost

due to bleed-off and evaporation. The drain line

should be the same size or larger than the

supply line.

NOTE!

The following instructions are provided for evaporative coolers with bleed-off only.

Additional instructions are provided for evaporative coolers equipped with the Water Wizard

or auto-drain and fill.

Step 1 Install the Water Supply Line

Connect the water supply line to the float valve in the evaporative cooling unit. Install a manual shutoff valve in the supply line as shown above.

Step 2 Install the Drain Line

Connect an unobstructed drain line with a manual shut-off valve from the sump drain to the main drain line as shown above. A trap should be used to prevent sewer gas from being drawn into the unit.

6 in. min.

Supply

Line

Overflow

Trap

Drain Line

Valve

Drain

Line

Supply Line

Valve

CAUTION!

All solenoids, valves and traps must be installed

below the roof to protect the water supply line

from freezing. If they cannot be installed below

the roof, an alternative method must be used to

protect the lines from freezing

Installation

Installation - Evaporative Cooling Piping (Optional)

IMPORTANT!

The supply line should be of adequate size and pressure to resupply the amount of water lost due to

bleed-off and evaporation. The drain line should be the same size or larger than the supply line.

CAUTION!

All solenoids, valves and traps must be installed

below the roof to protect the water supply line

from freezing. If they cannot be installed below

the roof, an alternative method must be used to

protect the lines from freezing

IMPORTANT!

The supply solenoid (Valve A) is NOT the same as

the drain solenoids (Valve B and Valve C). Make

sure to use the proper solenoid for each

location. Check your local code requirements for

proper installation of this type of system.

Step 1 Install the Water Supply Line

Connect the water supply line to the float valve in the unit. Install the

⁄2 inch normally closed solenoid (Valve A) in the supply line as shown above. Install the 1⁄4 inch normally open solenoid (Valve B) between the supply line and the drain line as shown above.

Step 2 Install the Drain Line

Connect an unobstructed drain line to the sump drain. Install the

⁄4 inch normally open solenoid (Valve C) between the sump drain connection and the drain line. A trap should be used to prevent sewer gas from being drawn into the unit.

Evaporative Cooling with Auto Drain and Fill

Sump

6 in. min.

Installation

NOTE!

The following instructions are provided for evaporative coolers with auto-drain and fill only. Additional

instructions are provided for evaporative coolers equipped with the Water Wizard or bleed-off.

Evaporative Coolin

ectio

Sump Overflo

Drai

Valve

upply Lin

Valve

To Water Suppl

Valve

Drain Lin

Evaporative Cooling with the Water Wizard

Installation - Water Wizard (Optional)

Step 3 Wire the Solenoid(s)

Wire the supply solenoid to terminals X and 25 in the control center. Wire the drain solenoid to terminals X and 26 in the control center.

Step 4 Wire the Temperature Sensor

If the evaporative cooler shipped separate from the unit, the temperature sensor must be wired. The sensor wire is bundled inside the discharge end of the evaporative cooler. Wire the sensor wire to terminals AI2 and AIC on the terminal strip in the unit’s control center.

Step 1 Install Supply Line/Solenoid

Connect the water supply line to the manual supply valve in the unit. Install the supply solenoid in the supply line, upstream of the manual supply valve and below the roofline.

Step 2 Install Drain Line/Solenoid

Connect the drain line to the supply line between the manual supply valve and the supply solenoid. Install a drain solenoid in the drain line, below the roof line.

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 final wiring.

NOTE!

The Water Wizard start-up must be completed for proper performance.

NOTE!

Solenoid(s) may be provided by Greenheck (if ordered) or by others.

WARNING!

Disconnect and lock-out all power and gas before performing any maintenance or service to the unit.

Failure to do so could result in serious injury or death and damage to equipment.

Drain Solenoid

Supply

Solenoid

Manual

Supply Valve

Pressure

Gauge

To Media

Sump

Drain

Roof Line

Trap

Installation

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.

Installation - Direct Expansion Coil Piping (Optional)

IMPORTANT!

Guidelines for the installation of direct expansion cooling coils have been provided to ensure proper

performance and longevity of the coils. These are general guidelines that may have to be tailored to

meet the specific requirements of any one job. As always, a qualified party or individual should

perform the installation and maintenance of any coil. Protective equipment such as safety glasses,

steel toe boots and gloves are recommended during the installation and maintenance of the coil.

IMPORTANT!

All field brazing and welding should be

performed using high quality materials and an

inert gas purge (such as nitrogen) to reduce

oxidation of the internal surface of the coil.

IMPORTANT!

All field piping must be self-supporting and

flexible enough to allow for the thermal

expansion of the coil.

General

Hot Gas Bypass

(by others)

Installation

Liquid Line

Equalizer Line

Nozzle

Expansion Valve

Suction Line

Remote Sensing Bulb

Suction Header

Distributor

Straps

Coil

Suction Connection

Step 1 Verify Nozzle Placement

Inspect the refrigerant distributor and verify that the nozzle is in place. The nozzle is generally held in place by a retaining ring or is an integral part of the distributor itself.

Step 2 Install the Optional Hot Gas Bypass Kit (By Others)

If a hot gas bypass kit was ordered with the coil, install it now. Consult the IOM from the bypass kit supplier for complete installation instructions. Align the side port with the hot gas line prior to brazing into place.

Step 3 Install Suction Line

Install a suction line from the compressor to the suction connection.

Step 4 Install the Thermal Expansion Valve (TEV) (By Others)

Follow the TEV manufacturer’s recommendations for installation to avoid damaging the valve. If the valve is externally equalized, use a tubing cutter to cut off the plugged end of the factory installed equalizer line. Use a de-burring tool to remove any loose metal from the equalizer line and attach it to the TEV. If the valve is internally equalized, the factory installed equalizer line can be left as is.

Step 5 Mount the Remote Sensing Bulb (By Others)

The expansion valve’s remote sensing bulb should be securely strapped to the horizontal run of the suction line at the 3 or 9 o’clock position and insulated.

Installation - Direct Expansion Coil Piping (Optional)

NOTE!

If a hot gas bypass kit was ordered, the nozzle will not be located in the distributor, it will be located in

the hot gas bypass kit.

Installation

Retainer Ring

Nozzle Distributor

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