Greenheck KSU Installation Manual
Installation, Operation and Maintenance Instructions
for MAKE-UP AIR UNITS
with Direct Fired Gas Heater Option
(for natural or LP gas)
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.
When suspending this unit the following ANSI standards must be followed: the standard for
aircraft hangars, ANSI/NFPA 409-1985; the standard for parking structures, ANSI/NFPA 88A1985; and the standard for repair garages, ANSI/NFPA 88B-1985.
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
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.
This manual is the
property of the owner,
and is required for future
maintenance.
Please leave it with the
owner when you complete
the job.
Part # 456857
January 2001
GREENHECK
P.O. BOX 410 SCHOFIELD, WISCONSIN 54476-0410
PH. 715-359-6171
www.greenheck.com
®
R R
C
ETL Listed
2
TABLE OF CONTENTS
Gas Piping Instructions ...................................................................Pg. 3
System Startup...........................................................................Pgs. 4-5
Sequence of Operation ...................................................................Pg. 6
Trouble Shooting .......................................................................Pgs. 7-8
Maintenance ...................................................................................Pg. 9
Canadian Requirements.................................................................Pg.10
SSOV Leak Test Procedure ............................................................Pg.10
System Startup Documentation ....................................................Pg. 11
Gas Train Diagram .......................................................................Pg. 12
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 of parts which prove to be defective during the warranty period will be
repaired or replaced at our option.
The motor is warranted by the motor manufacturer for a period of one year. Should the motor prove defective
during this period, it should be returned to an authorized motor service station.
Greenheck will not be responsible for any installation or removal costs
.
Unit Installation
This unit should be installed according to the Greenheck IOM:
# 456856 for model TSU
# 457615 for model KSU
# 457831 for model VSU
Due to continuing research, Greenheck reserves the right to change specifications without notice.
3
Piping Guidelines
All gas piping must be installed in accordance with the National Fuel Gas Code ANSI/Z223.1 - latest edition 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; which should be
carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
The nameplate on the direct gas section door describes all the requirements about the gas being supplied to
the unit. For typical operation size 10 through size 30 units need a minimum of 6 in. to a maximum of 14 in. wg
for natural gas and 2 to 6 in. wg pressure for LP gas. Sizes 40 and 50 need a min. of 1/2 PSI to a max. of 5 PSI.
When the supply pressure exceeds the maximum pressure an additional regulator (furnished by others) is
needed to step down the pressure. The regulators in the unit are used to adjust the maximum output
temperature of the unit. Piping should be of adequate size to provide a sufficient supply of gas to meet the
maximum demand with minimal pressure loss between the meter and the unit.
A manual shut off valve (gas cock) and a 1/8 in.
plugged tapping and a 6 in. drip leg must be installed
prior to the gas train and must be accessible for
connection to test gauge.Connections are to be made
by a qualified installer and are not furnished by
Greenheck.
Finally, check for leaks in the supply lines to
the unit. The factory piping has been checked
for leaks, but should be rechecked due to
shipping and installation. See leak test
warnings above.
All piping should be clean and free of any
foreign matter. Foreign material entering the
gas train can cause problems with the valves,
regulators, and the burner.
Gas Piping Instructions
Location of Gas Connection
Warnings
Leak Testing Components
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. See page 10 for safety shut off valve leak testing.
High Pressure Testing
The heater and its individual shutoff valve must be disconnected from the gas supply piping system during
any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 KPa).
The heater must be isolated from the gas supply system by closing its individual manual shutoff valve during
any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 psig (3.5 KPa).
From
Gas
Gas Cock
1/8 in. Plugged Tap
6 in. Trap
Ground Joint Union
Make-Up Air Unit
Standard Inlet Gas Pipe Size
Max. 400,000 1,375,000 2,475,000 4,400,000
<400,000
BTUs 1,375,000 2,475,000 4,400,000 5,500,000
Pipe
3
/4 in. 1in. 11/2 in. 2 in. 21/2 in.
Size
Gas Line Connection
Housing 40
Direct Gas
Train Door
Gas Line Connection
Housing 50
Housing Size 40 & 50
Housing Size 10-30
Gas Line
Connection
4
SYSTEM STARTUP
For proper unit function and safety, follow everything in this startup procedure in the order presented. This to be
done after the electrical (see base unit IOM GFC #456856) and gas connections are complete.
• Voltage meter
• Incline manometer or equivalent
Special Tools Required • Tachometer
• Thermometer
• Amperage meter
See IOM GFC #456856 (TSU) or GFC #457831 (VSU) before completing these steps.
1. Check Gas Pressure
Check the gas pressure with the unit’s nameplate pressure requirements.
2. Burner Air Pressure Differential
Proper air velocity over the burner is critical on a direct fired gas unit. If the air velocity is not within
specifications, the unit will not operate efficiently, can produce excess carbon
monoxide (CO) or other gases, and may have sporadic shutdowns. Proper air
velocity is determined by measuring the static pressure drop across the burner.
To measure the static pressure drop, the fan should be running and be
discharging 70° air. Using an incline manometer or equivalent, insert one sensor
into the entering air access opening (plugged test port) and the other on the
downstream side, through the view port (see page 12 for locations). The proper
static pressure reading should be from .625 in. to .675 in.
If this reading is higher or lower and the air quantity (cfm) delivered to the building
is acceptable, then the burner baffles will need to be adjusted (see diagram).
Open the burner access door. Using a wrench loosen the 4 screws to adjust the
baffles. To increase the static pressure loss, decrease the opening size and to
decrease the loss, increase the opening size. The top and bottom baffles should
be of equal distance from the burner. Tighten the baffle fasteners, replace the
door, turn unit on, and recheck the loss. This process may need to be repeated
until the proper pressure reading is attained. This adjustment will change the air
quantity delivered by the unit and therefore should be rechecked (see start up in Base Unit IOM).
3. Pilot Pressure
The pilot pressure is preset at the factory and should not require adjustment. Pilot pressure will vary by unit
size.
4. Set Maximum Discharge Temperature
Do not set the burner based on gas pressure. The burner's maximum fire rate needs to be set or the unit will
over fire at startup causing unit shutdowns. To do this, the inlet air and outlet air temperatures of the unit need
to be measured with the burner on high fire.
a. Determine Required Temperature Rise
Based on the geographical area, determine the winter design temperature. Subtract the winter design
temperature from the desired output temperature to get the required temperature rise.
Desired output temperature - winter design temperature = temperature rise.
( Example: for Schofield, WI 70° - (-15°) = 85°F)
b. Set unit to Run at high fire.
1. On Maxitrol Series 14 systems remove and isolate the wire attached to terminal #4 of the A1014 amplifier.
2. On Maxitrol Series 44 systems remove and isolate the wire attached to terminal #3 of the A1044 amplifier.
Adjustable
Top Baffle
Air Flow
Burner
Adjustable
Bottom Baffle
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