Greenheck PVF Installation Manual

Page 1

Part #461006

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

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.

could result in personal injury and/or property damage! Retain instructions for future reference.

Indirect Gas-Fired Furnaces

Model PVF

General Safety Information

Model PVF Indirect Gas Furnace, available in Energy Recovery models ERH, ERCH, HRE and VersiVent. For unit speciﬁc information, refer to the respective Installation, Operation and Maintenance Manual.

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 does.

• All electrical wiring must be in accordance with the regualtion of the National Electric Code, ANSI/ NFPA 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.

Table of Contents

Installation

Location . . . . . . . . . . . . . . . . . . . . . . . 3

Venting for Outdoor Units. . . . . . . . . . . . . . 3

Venting for Indoor Units. . . . . . . . . . . . . . . 3

Standard Indoor Venting . . . . . . . . . . . . . . 4

Furnace Connection Locations . . . . . . . . . . . 5

Concentric Venting . . . . . . . . . . . . . . . . 6-7

Two Pipe Venting . . . . . . . . . . . . . . . . . 8-9

Electrical Wiring . . . . . . . . . . . . . . . . . . .10

Furnace Control Center Layout. . . . . . . . . . .10

Gas Piping . . . . . . . . . . . . . . . . . . . . . .11

Start-Up Operation

Start-Up, General . . . . . . . . . . . . . . . . . .12

Furnace Controls . . . . . . . . . . . . . . . . 12-13

Sequence of Operation. . . . . . . . . . . . . .14

Performance Data . . . . . . . . . . . . . . . . .14

Troubleshooting . . . . . . . . . . . . . . . . . .15

Routine Maintenance . . . . . . . . . . . . . . .16

Model PVF Indirect Gas-Fired Furnace

® ®

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Model PVF Indirect Gas-Fired Furnace

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Installation – Location

1. 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.

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

3. Avoid locating in an area where deep snow is likely to accumulate. During the winter months, keep snow clear on the access side of the unit to prevent any blockage of combustion air inlet or ﬂue exhaust openings.

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

5. Local codes may supercede any of the above provisions.

6. Be sure that the minimum clearances to combustible materials are maintained.

7. To prevent premature heat exchanger failure, do not locate units where chlorinated, halogenated, or acid vapors are present.

8. Units must not be installed in a potentially explosive, ﬂammable, or corrosive atmosphere.

For additional information on installation of the energy recovery unit, refer to the respective units Installation, Operation, and Maintenance (IOM) manuals:

Unit Clearances to Combustible Materials

Outdoor

Indoor

Combustion blower discharge must be located

42 inches from any cmobustible materials

Clearances are determined by the National Fuel

Gas Code and/or other local codes.

Installation of Venting for Outdoor Units

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

2. During the winter months, periodically clear snow from access side of unit to prevent blockage of the inlet and exhaust openings.

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

Installation of Venting for Indoor Units

There are three venting methods for indoor mounted units. For each method, the units can be vented horizontally through an exterior wall or vertically through the roof. Speciﬁc venting instructions are provided for each method and shown in the following pages. Construct the vent system as shown in these instructions. Refer to your unit speciﬁc submittal to determine the applicable venting option.

The venting method options are:

Standard Indoor Venting

• uses building air for combustion

• vents exhaust to outdoors

• one exterior roof or wall penetration

Separated Combustion Concentric Venting

• uses outside air for combustion

• vents exhaust to outdoors

• one exterior roof or wall penetration

Separated Combustion 2-Pipe Venting

• uses outside air for combustion

• vents exhaust to outdoors

• two exterior roof or wall penetrations

The following guidelines must be adhered to for all indoor units:

1. Venting installation 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 installation codes.

2. For Standard Indoor Venting, use exhaust 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 Separated Combustion venting, sealed singlewall 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. The drip leg should be cleaned out periodically during the heating season.

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.

NOTE

Vent piping is supplied by others, not Greenheck.

NOTE

Vent piping is supplied by others, not Greenheck.

Model PVF Indirect Gas-Fired Furnace

Page 4

Installation of Standard Indoor Venting

Standard Indoor Venting uses one penetration through an exterior wall or roof for venting the ﬂue exhaust. The combustion air is scavenged from the air inside the building (no piping required). When units are installed in tightly sealed buildings, provisions should be made to supply an 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 BTUs per hour of input rating.

Vent terminals must be used (one vent terminal included with each furnace). Construct the vent system as shown in the Horizontal and Vertical drawings below and reference the Vent Pipe Diameter table for the correct vent pipe diameters.

A = 12 in. minimum

Exterior

Wall

EXHAUST

Air Inlet

Exhaust

Vent

Terminal

Pitch vent pipe

downward from

furnace

1/4 inch per foot

Vent Length Limitations

Refer to table for minimum and maximum vent lengths. 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

Length

Horizontal 5 70

Vertical 10 70

Minimum

(feet)

Maximum

(feet)

Vent Pipe Diameter

Select the vent pipe diameter. Use only the speciﬁed pipe size.

Furnace

Size

(MBH)

100 - 150 4 6

200 - 400 6 8

Exhaust (inches)

Combustion

(inches)

Installing Exhaust Vent Pipe

Install the vent pipe with a minimum downward slope (from the unit) of 1/4-inch per foot (horizontal venting only). 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.

Seal Opening

Using an appropriate method, seal the wall/roof opening around the exhaust pipe.

Standard Indoor Venting - Horizontal

Roof Line

EXHAUST

Air Inlet

A = 12 inch minimum

B = 12 inch minimum but

should size according to expected snow depth

Exhaust Vent

Terminal

Standard Indoor Venting - Vertical

Model PVF Indirect Gas-Fired Furnace

Page 5

Furnace Connection Locations Model ERH, ERCH, HRE

Combustion Air Inlet

Exhaust Outlet

3/4 inch Gas Connection

Furnace Connection Locations Model VersiVent

Exhaust Outlet

3/4 inch Gas Connection

ERH

ERCH

HRE

Furnace

(MBH)

100-150 23.75 24.438 24.438 3.75 10.50 16.625

100-150 23.75 24.50 24.50 6.00 12.75 18.875

200-250 23.75 23.50 24.125 6.00 25.125 32.25

150 26.63 27.25 27.25 6.00 12.75 18.875

200-300 26.63 26.38 27.00 6.00 22.50 29.63

300-400 37.63 37.38 38.00 6.00 25.00 32.125

A B C D E F

VersiVent

45, 65

45, 65, 90

Furnace

(MBH)

75 19.587 14.372 15.638 18.083

100 19.587 14.372 15.638 18.083

150 8.092 13.872 12.838 19.208

200 8.092 13.872 12.838 19.208

250 8.092 13.872 15.686 19.208

300 8.092 13.872 17.709 19.208

350-400 8.092 13.372 21.838 19.208

A B C D

Model PVF Indirect Gas-Fired Furnace

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Installation of Concentric Venting

ÿ4.00 COLLAR WITH

CRIMPED END (ÿ3 7/8 +/- 1/16

ÿ6 COLLAR WITH CRIMPED

END (ÿ5 7/8+/- 1/16 AFTER

CRIMPING)

ÿ6 COLLAR WITH CRIMPED

END (ÿ5 7/8+/- 1/16 AFTER

CRIMPING)

(General)

Concentric venting allows the exhaust pipe and combustion air pipe to pass through a single hole in the roof or wall of the building. A concentric venting adapter (CVA) is required for concentric venting.

Depending upon whether the furnace was ordered for Horizontal or Vertical concentric venting, each indirect gas furnace will ship with the following items:

Horizontal

Venting

Vertical Venting

The concentric venting adapter is designed for indoor installations and should never be installed on the exterior of the building. The exhaust pipe must terminate with the vent terminal. For horizontal venting, the combustion air pipe must terminate with the inlet guard. For vertical venting, the combustion air pipe must terminate with the inlet terminal.

a. Exhaust Pipe Vent Terminal b. Concentric Venting Adapter c. Inlet Guard

a. Exhaust Pipe Vent Terminal b. Concentric Venting Adapter c. Inlet Terminal

Horizontal Venting

Refer to the diagram below for venting on horizontal concentric systems. Maintain at least 12 inches from the combustion air inlet guard to the exhaust vent terminal (Dim. B). To prevent water from running into the combustion air pipe and to allow for easy installation of the combustion air inlet guard, the combustion air pipe must terminate at least 2 inches from the exterior surface of the outside wall (Dim. A).

A = 2 inch minimum

B =

12 inch minimum

Mounting

Bracket

COMBUSTION AIR

EXHAUST

Mounting

Bracket

Pitch vent pipe downward from

furnace 1/4 inch per foot

Exterior

Wall

Exhaust

Vent

Terminal

Combustion

Air Inlet

Guard

CVA-4

4-inch Concentric

Venting Adapter

Combustion Air Connection

Concentric Side

6-inch Concentric

Venting Adapter

Exhaust Connection

Concentric Side

CVA

CVA-6

Vertical Venting

Refer to the diagram below for venting on vertical concentric systems. Maintain at least 12 inches between the top of the combustion air inlet terminal and the bottom of the exhaust vent terminal (Dim. B). The bottom of the combustion air inlet terminal must terminate above the snow line, or at least 12 inches above the roof, which ever is greater (Dim. A). A tee with cleanout must be provided on the combustion air and exhaust pipe to prevent debris from entering the heat exchanger.

A = 12 inch minimum but

should size according to

expected snow depth B = 12 inch minimum C = 12 inch minimum

Roofline

Mounting

Bracket

COMBUSTION AIR

Exhaust Vent Terminal

Combustion Air

Inlet Terminal

Mounting

Bracket

EXHAUST

Combustion Air Connection

Non-Concentric Side

Top View

Model PVF Indirect Gas-Fired Furnace

Exhaust Connection

Non-Concentric Side

Tee with drip leg

and cleanout cap

Page 7

Concentric Vent Connection Diameter

Vent terminals must be used (one vent terminal included with each furnace). Construct the vent system as shown in the Horizontal and Vertical drawings on previous page and reference the table for the correct vent connection diameters.

Furnace

Size

(MBH)

100 - 150 4 6

200 - 400 6 8

Exhaust (inches)

Combustion

(inches)

Vent Length

Vent

Length

Horizontal 5 70

Vertical 10 70

Minimum

(feet)

Maximum

(feet)

is 10feet.

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).

2. Attach Mounting Brackets

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

5. Install CVA Assembly

Place the CVA assembly through the wall/roof and

verify that all minimum clearance requirements as

speciﬁed in these instructions are met. Secure the

CVA assembly to the wall/ceiling with mounting

brackets and corrosion resistant sheet metal screws.

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. For vertical

venting, include the required tees with drip legs and

clean outs.

Combustion Air

Connection

Furnace

Control

Center

Access

Exhaust

Connection

3. Install Exhaust Pipe

Slide the exhaust pipe through the CVA. Provide enough exhaust piping to pass through the wall (or ﬂoor) 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.

4. Install Combustion Air Pipe

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

For horizontal venting, 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.

For vertical venting, 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.

7. Install Combustion Air Inlet Guard/

Terminal and Exhaust Vent Terminal

Slide the combustion air inlet guard (for horizontal

venting) or the inlet terminal (for vertical venting) 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.

8. Seal Opening

Seal the opening between the wall/ﬂoor and the air

intake pipe using an appropriate method.

Model PVF Indirect Gas-Fired Furnace

Page 8

Installation of Two Pipe Venting

Horizontal Venting

Refer to the diagram below for venting on horizontal two pipe systems. Maintain at least 12 inches of clearance between the exhaust pipe termination and the exterior surface of the outside wall (Dim. A). The combustion air pipe must be a minimum of 12 inches below the exhaust pipe (Dim. C) and 12 inches from the exhaust pipe vent terminal (Dim. B). A minimum of 1 inch and a maximum of 48 inches of building wall thickness is required for separated combustion vent pipe.

A = 2 inch minimum

B =

12 inch minimum

C =

12 inch minimum

EXHAUST

Pitch vent pipe

downward from

furnace

1/4 inch per foot

Two (2) Field

Supplied Support

Brackets

COMBUSTION AIR

Vertical Venting

Refer to the diagram below for venting on vertical two pipe systems. 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 (Dim. A). The exhaust must terminate at least 12 inches above (Dim. B) and 12 inches horizontally (Dim. C) from the combustion air inlet.

Exterior

Wall

Exhaust

Vent

Terminal

Combustion

Air Inlet

Terminal

Two Pipe Vent Connection Diameter

Vent terminals must be used (two vent terminals included with each furnace). Construct the vent system as shown in the Horizontal and Vertical drawings on this page and reference the table at the right for the correct vent connection diameters.

Furnace

Size

(MBH)

100 - 150 4 6

200 - 400 6 8

Exhaust (inches)

Vent Length

Refer to the table for minimum and maximum vent lengths. 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

Vent

Length

Horizontal 5 70

Vertical 10 70

Minimum

(feet)

10feet.

1. Install Combustion Air Pipe

Run a combustion air pipe from the unit’s combustion air intake through the exterior wall/roof to the outdoors.

For horizontal venting, the combustion air pipe must terminate at least 12 inches from the exhaust pipe vent terminal. Attach the combustion air inlet terminal to the end of the combustion air pipe. Using ﬁeld supplied mounting brackets, support the combustion air pipe as needed.

For vertical venting, the combustion air pipe must terminate at least 12 inches above the roof. This clearance may need to be increased to accommodate snow accumulation.

Combustion

(inches)

Maximum

(feet)

Combustion Air

Inlet Terminal

Roofline

A = 12 inch minimum but should size

B = 12 inch minimum C = 12 inch minimum D = 12 inch minimum

Model PVF Indirect Gas-Fired Furnace

Exhaust Vent

EXHAUST

COMBUSTION AIR

according to expected snow depth

Terminal

Tee with drip leg

and cleanout cap

Combustion Air

Connection

Furnace

Control

Center

Access

Page 9

2. Install Exhaust Pipe

Run an exhaust pipe from the unit’s combustion exhaust through the exterior wall/roof to the outdoors.

For horizontal venting, the exhaust pipe must terminate at least 12 inches from the exterior surface of the outside wall and at least 12 inches above the combustion air pipe. Attach exhaust vent terminal to the end of the exhaust pipe. Using ﬁeld supplied mounting brackets, support the exhaust pipe as needed.

For vertical venting, maintain at least 12 inches between the bottom of the exhaust vent terminal and the top of the combustion air inlet terminal. Maintain at least 12 inches horizontally between the exhaust vent and the combustion air inlet. Attach exhaust vent terminal to the end of the exhaust pipe.

3. Seal Openings

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

Model PVF Indirect Gas-Fired Furnace

Page 10

Installation of Electric Wiring Furnace Control Center Layout

WARNING

Disconnect power supply before making wiring connections to prevent electrical shock and equipment damage.

WARNING

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.

WARNING

Any original factory wiring that requires replacement must be replaced with wiring material having a temperature rating of at least 105°C

1. Installation of wiring must conform with local building codes. In the absence of local codes, installation must conform to the National Electric Code ANSI/NFPA 70-Latest Edition. Unit must be electrically grounded in conformance with this code. In Canada, wiring must comply with CSA C22.1, Canadian Electrical Code.

2. All furnaces are provided with a wiring diagram located on the inside of the access panel. Refer to this wiring diagram for all wiring connections.

3. The combustion blower motor will not run unless the furnace is turned on and the gas controls are calling for heat.

1. Two-stage temperature controls - Controls the furnace stages based on the unit discharge temperature.

2. Combustion blower - Exhausts the products of combustion from the furnace tubes.

3. Ignition controller - Continually monitors, analyzes, and controls the proper operation of the gas burner.

4. Manifold pressure test port (1/4-inch pipe thread)

- Used for checking the manifold gas pressure.

5. Time delay relay - Allows burner to stay at high ﬁre for 10 seconds upon being lit.

6. Air pressure switch - Tests to ensure the combustion blower is operating.

7. Two-stage gas valve - Contains main pressure regulator, safety shut-off valves, and manual shut off knob. It controls the furnace to 50% or 100% ﬁre.

8. Ignitor - Provides spark for burner ignition.

9. Flame sensor - Ensures that each burner has

ignited.

Model PVF Indirect Gas-Fired Furnace

Page 11

Installation of Gas Piping

TSU-1 - 56.5"

1.5"

TSU-2 - 61.5"

1.5"

TSU-3 - 67.5"

1.5"

of Supply Duct

TSU Gas Connection

Gas Section Door

Direct Gas Nameplate

Gas Pressure Requirements

Natural:

*Falling below minimum gas pressure requirements will

reduce the MBH output. In turn, the unit will not be able to fully condition the space on peak heating days. If gas pressure is simply too low for requirements, we recommend the local gas company be contacted to determine if a booster pump would be feasible.

From

Gas

Gas Cock

6 in. Trap

Recommended Piping to Controls

1. Furnaces (input 100 to 400 MBH) have a single 3/4inch, female pipe thread connection.

*6 to 14 in. wg

LP:

*11 to 14 in. wg

Ground Joint Union

1/8 in. Plugged

To Controls

2. 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.

3. A 6-inch drip leg should be installed in the pipe run to the unit.

4. Install an easily accessible ground joint union and a manual shut off valve (these are required by some local codes) for emergency shut off and easy servicing of the controls.

5. A 1/8 inch NPT plugged tap shall be installed immediately ahead of the gas supply connection to the furnace.

6. After gas piping is completed, carefully check all piping connections for gas leaks. Use soap solution or equivalent for testing. DO NOT use a ﬂame or other source of ignition to check for gas leaks.

7. When leak testing pressures above 14 in. wg (1/2 psi), close the ﬁeld installed shutoff valve, disconnect the furnace and its gas train from the gas supply line, and plug the supply line before testing.

8. When leak testing at pressures equal to or less than 14 in. wg (1/2 psi) close the ﬁeld-installed shutoff valve to isolate the unit from the gas supply line before testing.

Model PVF Indirect Gas-Fired Furnace

Page 12

Start-Up

1. Turn off power to the unit at the disconnect switch. Close all manual gas valves.

2. Check that all gas and electrical connections are weatherized.

3. Make sure that the combustion air inlet and the combustion blower discharge are free from obstructions.

4. Inspect the unit to make sure that no damage has occurred during installation.

5. With the furnace control center access panel removed, connect a U tube manometer to the manifold pressure test port (refer to the Control Center Layout under Installation). This will be used for checking the manifold gas pressure.

6. Set the thermostat or discharge temperature controls to lowest setting.

7. Open all manual gas valves including the combination gas valve and turn power on.

8. Call for heat with the thermostat or discharge temperature controls and allow the burner to light. Greenheck duct furnaces are equipped with an automatic spark ignition system which automatically lights the burner. DO NOT attempt to light the burners manually.

9. After the burner is lit, check to make sure that the supply blower is operating.

10. Verify that the gas controls sequence properly (see Sequence of Operation).

11. Check the manifold gas pressure (see Burner

Adjustments on following pages).

Furnace Controls

Staged Temperature Controls

For Energy Recovery Units without Temperature Control Package

The furnace stage controls are located in the furnace control center. One control is provided for each stage of heating. The discharge temperature setting is located on the control furthest to the left. The offset and differential settings for each stage are preset at the factory; however, ﬁeld-adjustments may be made to get the best control for your application. See the literature provided with the controls for further information.

Staged Temperature

Controls

For Energy Recovery Units with Temperature Control Package

If two-stage control is ordered with a Temperature Control Package, the controller in the unit’s main control center will control the stages of heating. The temperature set point may be adjusted on the controller (See Temperature Controller IOM).

Turndown Modulation

Two Stage 2 : 1 50%, 100%

Electronic Modulation 2 : 1 50% - 100%

Staged Burner Adjustments

Setting Manifold Pressure for Two Stage Gas Control

1. Set the unit to high ﬁre by setting the discharge temperature control or thermostat to its maximum setting. If the ambient temperature is warm, the unit may not stay at high ﬁre.

2. Measure the burner manifold pressure at the manifold pressure test port (see Control Center Layout on page 10) using a “U” tube manometer. The pressure on high ﬁre should be 3.5 in. wg for natural gas and 10 in. wg for LP gas. To change the pressure, adjust the regulator adjustment screw on the combination gas valve. Clockwise rotation will decrease the gas pressure and counter clockwise rotation will increase the gas pressure.

3. Set the unit to low ﬁre by removing the wire from the high ﬁre terminal on the combination gas valve. Clockwise rotation will decrease the gas pressure and counter clockwise rotation will increase the gas pressure.

4. The manifold pressure on low ﬁre for natural gas should be 0.88 in. wg and 2.5 in. wg for LP gas. To change the pressure, use the low ﬁre adjustment screw on the combination gas valve.

Solenoid

High Fire Adjustment

Low Fire Adjustment

High Fire Terminal

Model PVF Indirect Gas-Fired Furnace

Combination Gas Valve

Page 13

Electronic Modulation Temperature Controls

Combination Gas Valve

High ﬁre adjustment

Low Fire Operation

3. Remove the wire from terminal 3 on the ampliﬁer

and isolate it from touching anything. Set the discharge temperature selector to the highest setting. If there is a room override thermostat, turn the dial to the highest setting.

4. Measure the manifold pressure on low ﬁre, it

should be 0.88 in. wg for natural gas and 2.5 in. wg for LP gas.

5. To adjust the low ﬁre, remove the bypass cap (A)

and turn screw (B) as shown in diagram. Adjust the screw indicated on the modulating valve. Clockwise rotation will decrease gas pressure and counterclockwise rotation will increase gas pressure.

6. Reconnect wire to terminal 3.

7. Remove jumper and place all wires back to where

they were and plug the manifold pressure port.

Modulating Valve

Low ﬁre adjustment

Electronic Modulation Valves

For Energy Recovery Units without Temperature Control Package

A Discharge Temperature Dial is used for temperature control for electronic modulation. The temperature dial will be located in the furnace control center.

For Energy Recovery Units with Temperature Control Package

The Temperature Controller in the unit’s main control center will provide the electronic modulation control.

High and Low Fire Settings for Electronic Modulation

Check the high and low gas pressures on initial start up per the instructions below. These settings are preset at the factory, but should be adjusted in the ﬁeld if necessary. Set the high ﬁre ﬁrst and the low ﬁre second. The low ﬁre must always be checked if the high ﬁre is changed.

High Fire Operation

1. Place a jumper between terminals 7 and 8 on the Maxitrol ampliﬁer.

2. Measure the burner manifold pressure at each furnace at the pressure test port (see Control Center Layout under Installation) using a high quality manometer that can measure low gas pressures. The pressure at high ﬁre should be

3.5in. wg for natural gas and 10.0 in. wg for LP gas. To change the pressure, adjust the high ﬁre screw (under cap screw) on the combination gas valve. Clockwise rotation will decrease the gas pressure and counter clockwise rotation will increase gas pressure.

Manifold Pressure (inches wg)

Natural Gas LP

Low High Low High

2 : 1 Electronic Modulation 3.5 0.88 10 2.5

Model PVF Indirect Gas-Fired Furnace

Page 14

Sequence of Operation

Power-up/Standby

After power is supplied to the unit:

1. The ignition control will reset and perform a selfcheck routine.

2. The diagnostic LED will ﬂash for up to four seconds.

3. The ignition control will begin scanning the thermostats.

Heat Mode

When the thermostat or discharge temperature controls call for heat:

1. The ignition control will check that the pressure switch for the combustion blower is open.

2. The combustion blower will be energized and the 15-second pre-purge begins.

3. The gas valve is energized and the ignitor will spark for up to 10 seconds.

Natural Gas – If a ﬂame is not sensed during

the trial for ignition, two additional trials will be attempted before going into lockout for one hour.

LP Gas – If a ﬂame is not sensed during the trial

for ignition, the control will go into lockout for one hour.

4. When a ﬂame is sensed, sparking stops immediately. The gas valve and combustion blower remain energized.

5a. Two-stage control – The burner will light at

100% ﬁre and remain there for 10 seconds. The thermostat will then operate the burners at high or low ﬁre, depending on the demand for heat.

5b. Electronic Modulation – The burner will light at

100% ﬁre and remain there for 10 seconds. The main burner gas valve will then modulate from 100% down to 50% as needed. If the burner remains on low ﬁre for an extended period of time, the burner will shut off and re-light as necessary.

6. The ignition control constantly monitors the thermostat, pressure switch, and burner ﬂame to assure proper operation.

7. When the thermostat or discharge temperature controls are satisﬁed, the main valve is deenergized and the combustion blower shuts off following a 30-second post-purge period.

Recovery from Lockout

The ignition control will automatically reset after one hour if the thermostat is still calling for heat. Prior to one hour, a manual reset (cycle power to unit) is required. The thermostat may be reset or the power interrupted for a period of 5 seconds. See page 7 for Ignition Control Diagnostics.

Performance Data

Model

Number

PVF 100 100 80 3704 2963 2469 2116 1852 1646 1481 1347 1235 1140 1058 988 926 871 823 780 741

PVF 150 150 120 5556 4444 3704 3175 2778 2469 2222 2020 1852 1709 1587 1481 1389 1307 1235 1170 1111

PVF 200 200 160 7407 5926 4938 4233 3704 3292 2963 2694 2469 2279 2116 1975 1852 1743 1646 1559 1481

PVF 250 250 200 9259 7407 6173 5291 4630 4115 3704 3367 3086 2849 2646 2469 2315 2179 2058 1949 1852

PVF 300 300 240 11111 8889 7407 6349 5556 4938 4444 4040 3704 3419 3175 2963 2778 2614 2469 2339 2222

PVF 350 350 280 12963 10370 8642 7407 6481 5761 5185 4714 4321 3989 3704 3457 3241 3050 2881 2729 2593

PVF 400 400 320 14815 11852 9877 8466 7407 6584 5926 5387 4938 4558 4233 3951 3704 3486 3292 3119 2963

Input

(MBH)

Output

(MBH)

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Ratings shown are for elevations up to 2000 ft. For higher elevations, the input should be reduced by 4% per 1000 ft. of elevation above sea level. In Canada, from 2000 to 4500 ft in elevation, the unit must be derated to 90% of the input listed above. The unit shall also be used in accordance with standard CGA 2.17.

Air Temperature Rise Through Unit (°F)

CFM

Model PVF Indirect Gas-Fired Furnace

Page 15

Troubleshooting

LED Indication Error Mode

Steady On Internal control failure

1 flash Airflow fault

2 flashes Flame with no call for heat

3 flashes Ignition lockout

Ignition Control Diagnostic LED

During normal operation, the LED is shut off. The LED will be on or ﬂashing during a fault condition. If a fault condition is occurring, turn the unit off and on again. If the LED is still ﬂashing, refer to the following troubleshooting section.

Airﬂow Fault (1 Flash)

An airﬂow fault may occur for the following reasons:

• An airﬂow switch continually monitors the combustion airﬂow during an ignition sequence. During the initial call for heat, if the pressure switch contacts are in the closed position for 30seconds without an output to the combustion blower, an airﬂow fault will be declared. The control will remain in this mode with the combustion blower off.

• After the combustion blower output (L1 and IND) is energized and the airﬂow switch remains open for more than 30 seconds, an airﬂow fault will be declared. The control will stay in this mode with the combustion blower on, waiting for the airﬂow switch to close.

• If the airﬂow signal is lost while the burner is ﬁring, the control will immediately de-energize the gas valve and the combustion blower will remain on. If the call for heat remains, the control will wait for proper airﬂow to return. If proper airﬂow is not detected after 30 seconds, an airﬂow fault will be declared. If proper airﬂow is detected at any time, a normal ignition sequence will begin.

Once proper airﬂow is detected, the normal Sequence of Operation for ignition will follow (see page 14).

Flame Fault (2 Flashes)

If the main valve fails to close completely and maintains a ﬂame, the full-time ﬂame sense circuit will detect it and energize the combustion blower. Should the main valve later close completely and remove the ﬂame signal, the combustion blower will be deenergized.

Ignition Lockout (3 Flashes)

Possible Cause Solution

Manual gas valve not open Open manual valve

Air in the gas line Bleed gas line

Supply gas pressure too high or too low

Loose wire connections Check for tight wire connections

No spark…

a. Tranformer failure

b. Spark electrode

c. Spark cable shorted to ground Replace spark cable

d. Ignition controller not grounded Check unit airﬂow and manifold pressure

High limit control tripper Check unit airﬂow and manifold pressure

Faulty combination gas valve

Faulty ignition control

Check that supply pressure is between 6 and 14 in. wg for natural gas and between 11 and 14 in. wg for LP

Check primary and secondary voltages of transformer. Replace if necessary

Ensure spark gap is 1/8 inch and ceramic insulator is not cracked. Replace if necessary. Electrode is NOT ﬁeld adjustable.

If 24 volts is measured between terminals MV and common, but valve remains closed, replace valve

Check diagnostic LED for steady on and for voltage between V1 and V2. If no voltage is present, replace ignition control.

Model PVF Indirect Gas-Fired Furnace

Page 16

Routine Maintenance

WARNING

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. Use caution and do not allow water or solvents to enter the motor or bearings. Under no circumstances should motors or bearings be sprayed with steam, water or solvents. The motor bearings are pre-lubricated and sealed, requiring no further lubrication.

Burners and Oriﬁces

Before each heating season, examine the burners and gas oriﬁces to make sure they are clear of any debris such as spider webs, etc. Clean burner as follows:

• Turn off both electrical and gas supplies to the unit.

• Disconnect union between manifold and gas valve.

• Remove manifold and burner assembly.

• Inspect and clean oriﬁces and burners as necessary. Avoid using any hard or sharp instruments which could cause damage to the oriﬁces or burners.

a. Remove any soot deposits from the burner

with a wire brush.

b. Clean the ports with an aerosol degreaser or

compressed air.

c. Wipe the inside of the burner clean. Cleaning

the burner with a degreaser will slow the future buildup of dirt.

• Before reinstalling the burner assembly, look down the heat exchanger tubes to make sure they are clear of any debris.

• Reinstall manifold and burner assembly, reconnect wire leads, and gas supply piping.

• Turn on the electrical power and gas supply.

• Follow the start-up procedure to light the burners and verify proper operation.

Heat Exchanger

The heat exchanger should be checked annually for cracks and discoloration of the tubes. If a crack is detected, the heat exchanger should be replaced before the unit is put back into operation. If the tubes are dark gray, airﬂow across the heat exchanger should be checked to make sure the blower is operating properly.

Flue Collector Box

The ﬂue passageway and ﬂue collector box should be inspected prior to each heating season and cleared of any debris.

Electrical Wiring

The electrical wiring should be checked annually for loose connections or wiring deterioration.

Gas Train

The gas train connections, joints and valves should be checked annually for tightness.

Replacement Parts

When ordering replacement parts, include the complete unit model number and serial number listed on the unit rating plate.

Warranty

Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the shipment 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. Motors are warranted by the motor manufacturer for a period of one year. Should motors furnished by Greenheck prove defective during this period, they should be returned to the nearest authorized motor service station. Greenheck will not be responsible for any removal or installation costs.

As a result of our commitment to continuous improvement, Greenheck reserves the right to change speciﬁcations without notice.

Phone: (715) 359-6171 • Fax: (715) 355-2399 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com