Greenheck TSU Installation Manual

Part # 464441

**WARNING**

Disconnect and secure all electrical power to the

“OFF” position prior to inspection or servicing.

Failure to comply with this safety precaution

could result in serious injury or death.

**IMPORTANT**

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.

FOR YOUR SAFETY

If you smell gas

1. Open windows

2. Don’t touch electrical switches

3. Extinguish any open flames

4. Immediately call your gas supplier

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.

FOR YOUR SAFETY

The use and storage of gasoline or other

flammable vapors and liquids in open

containers in the vicinity of this appliance

is hazardous.

**WARNING**

Improper installation, adjustment, alteration,

service or maintenance can cause property

damage, injury or death. Read the installation,

operating, and maintenance instructions

thoroughly before installing or servicing this

equipment.

MaintenanceTroubleshooting

OperationStart-UpInstallation

Reference

MODEL TSU

Make-Up Air Unit

Installation, Operation and Maintenance Manual

TABLE OF CONTENTS

Installation

Unit - Slab Mounted . . . . . . . . . . . . . . . . . .I-1

Unit - Rail Mounted . . . . . . . . . . . . . . . . . . .I-2

Unit - Curb Mounted . . . . . . . . . . . . . . . . . .I-3

Filter Section / Weatherhood . . . . . . . . . . .I-5

Evaporative Cooler . . . . . . . . . . . . . . . . . . .I-6

Evaporative Cooling Piping . . . . . . . . . . . . .I-7

Water Wizard™ Evaporative Control . . . . .I-9

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . .I-10

Direct Gas Piping . . . . . . . . . . . . . . . . . . . . .I-13

Building Pressure Control . . . . . . . . . . . . . .I-15

Start-Up

Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . .S-1

Direct Gas . . . . . . . . . . . . . . . . . . . . . . . . . .S-3

Evaporative Cooling . . . . . . . . . . . . . . . . . .S-9

Water Wizard™ Evaporative Controls . . . .S-11

Operation

Recirculating/VAV Units . . . . . . . . . . . . . . .O-1

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . .O-2

Water Wizard™ Evaporative Control . . . . .O-3

Troubleshooting

Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T-1

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T-2

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . .T-5

Evaporative Cooler . . . . . . . . . . . . . . . . . . .T-6

Water Wizard™ Evaporative Control . . . . .T-7

Reference

Gas Train Layout . . . . . . . . . . . . . . . . . . . . .R-1

Control Center Layout . . . . . . . . . . . . . . . . .R-2

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . .R-2

Maintenance

Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M-1

Fall . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M-4

Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M-5

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 - Slab Mounted Unit

I - 1

Step 1 Pour Concrete Slab

Pour the concrete slab. The slab should be one foot larger than the unit on all sides. The slab should be at least four inches thick and poured on a bed of gravel to ensure proper drainage. Allow the concrete slab to properly cure before installing the unit.

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.

Step 2 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 concrete slab. Fasten the unit to the slab through the factory provided lifting lugs.

NOTE!

The use of all lifting lugs and a set of spreader

bars is mandatory when lifting the unit.

Step 3 Attach Ductwork

Refer to the CAPS submittal for the duct size and location. Greenheck recommends attaching ductwork using a rubber duct section at the unit to reduce vibration. An appropriate sealant should be used around the discharge opening of the unit to create a weather tight seal.

total unit si Recommen thick. Slab should of gravel fo

NOTE!

For easy installation, it is recommended that the weatherhood, filter section or evaporative cooler be

installed after the base unit.

I - 2

NOTE!

The use of all lifting lugs and a set of spreader

bars is mandatory when lifting the unit.

Installation - Rail Mounted Unit

Step 1 Install Rails

Install the rails. The rails should be located 6 - 12 inches in from the sides of the unit. The rails should extend at least six inches past the intake and discharge ends of the unit. Rails are field supplied by other and are not supplied by Greenheck.

Step 1 Rail Mountin

For proper support, rails s 6-12 in. in from sides of un at least 6 in. beyond both and filter section.

Rails located 6-12 in. in from sides of unit.

Rails extends 6 in. from end of filter section

Rails extends 6 in. from discharge end of unit

Step 2 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 rails.

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.

NOTE!

For easy installation, it is recommended that the weatherhood, filter section or evaporative cooler

be installed after the base unit.

Step 3 Attach Ductwork

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 1 Install Curb

Position curb on the roof (refer to the CAPS submittal section for placement of curb in relation to the unit). Verify that the curb is level, shim if necessary. Attach curb to roof and flash into place.

Step 2 Install Ductwork

If the unit has a downblast (DB) discharge, install the supply air duct now.

If the unit requires a return air duct, install it now.

If the unit has a horizontal (HZ) discharge, wait until the base unit is installed before installing the supply duct.

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. Refer to the CAPS submittal for the ductwork sizes.

Installation - Curb Mounted Unit

I - 3

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 to be used as ductwork support.

Sealant

I - 4

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.

Use self-tapping sheet metal screws to fasten the unit to the curb.

NOTE!

The use of all lifting lugs and a set of spreader

bars is mandatory when lifting the unit.

NOTE!

For easy installation, it is recommended that the weatherhood, filter section or evaporative cooler be

installed after the base unit.

Step 5 Install Ductwork

If the unit has a downblast (DB) discharge, the ductwork was installed in step 2.

If the unit has a horizontal (HZ) discharge, apply an appropriate sealant around the discharge of the unit to create a weather tight seal. Then using sheet metal screws, attach the ductwork to the unit.

Installation - Curb Mounted Unit

Installation - Filter Section and Weatherhood

Step 1 Apply Sealant

Apply an appropriate sealant around the intake end of the base unit to create a weather tight seal.

Step 3 Apply Sealant

Apply an appropriate sealant around the intake end of the filter section to create a weather tight seal.

Step 2 Install Filter Section

Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the filter section on the intake end of the base unit. The flange along the top of the filter section should overlap the flange along the top of the base unit.

Use self-tapping sheet metal screws to fasten the filter section to the base unit across the top and down the sides.

If filters are not installed in the filter section, install them now. Airflow arrows are located on the filters to ensure proper installation.

Step 4 Install Weatherhood

Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the assembled weatherhood on the intake end of the base unit. The flange along the top of the weatherhood should overlap the flange along the top of the filter section.

Use self-tapping sheet metal screws to fasten the weatherhood to the filter section across the top and down the sides.

Step 5 Install Inlet Air Sensor (Optional)

If the unit is equipped with an inlet air sensor, the sensor may need to be installed. The sensor and tubing can be found bundled inside the control center of the unit. The sensor should be installed inside of the weatherhood with the tubing run inside of the unit.

NOTE!

The use of all lifting lugs and a set of spreader

bars is mandatory when lifting the filter section.

NOTE!

The use of all lifting lugs and a set of spreader

bars is mandatory when lifting the weatherhood.

NOTE!

Installation instructions for the filter section and weatherhood apply only to non-evaporative cooling

units. For evaporative cooling units, skip to the evaporative cooler installation instructions.

Sealant

I - 5

I - 6

NOTE!

When mounting the evaporative cooler, it is

important that it is level to ensure proper

operation and water drainage.

Installation - Evaporative Cooler (Optional)

Step 1 Locate Equipment Support(s)

Position equipment support(s) on the roof (refer to the CAPS submittal for the general location of the equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Equipment supports are supplied by others and not supplied by Greenheck.

Step 2 Install Evaporative Cooling

Module

Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the evaporative cooling module on the equipment support(s). The flange along the top of the evaporative cooler should overlap the flange along the top of the base unit.

Step 3 Secure Cooling Module to Unit

Use self-tapping screws to fasten the cooling module to the base unit. The cooler should be fastened to the base unit across the top and down both sides.

To fasten along the top, run fasteners through the flange joining the two sections.

To fasten the sides, from inside the unit, run fasteners down both sides of the opening between the base unit and the evaporative cooler.

Step 5 Connect Dirty Filter Switch (Optional)

If a dirty filter switch is located in the control center, connect the low pressure tap on the dirty filter switch to the low pressure tap inside the junction box on the evaporative cooler. Tubing is included in the control center.

NOTE!

The use of all lifting lugs and a set of spreader bars is mandatory when lifting the evaporative

cooling module.

Sealant

Equipment

Supports

Step 4 Install Inlet Air Sensor (Optional)

If the unit is equipped with an inlet air sensor, the sensor may need to be installed. The sensor and tubing can be found bundled inside the control center of the unit. The sensor should be installed inside of the louvered intake, upstream and clear of the evaporative cooling media. The tubing should be run inside of the unit.

I - 7

Installation - Evaporative Cooling Piping (Optional)

Evaporative Cooling with Recirculating Pump.

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.

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. Install a drain line from the sump overflow to the drain line. A trap (as shown to the right) should be used to prevent sewer gas from being drawn into the unit.

Step 3 Check/Adjust Water Level

Check the water level in the sump tank. The water level should be above the pump intake and below the overflow. Adjust the float as needed to achieve the proper water level.

CAUTION!

Provisions must be taken to prevent damage to the evaporative cooling section during freezing

conditions. The sump, drain lines and supply lines must be drained prior to freezing conditions or an

alternate method must be used to protect the lines and media.

IMPORTANT!

All solenoids, valves and all traps must be below the roofline or be otherwise protected from freezing.

6 in. min.

Supply

Line

Overflow

Trap

Drain Line

Valve

Drain

Line

Supply Line

Valve

I - 8

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 supply water 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 1/2 in. normally closed solenoid (Valve A) in the supply line as shown above. Install the 1/4 in. 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 3/4 in. normally open solenoid (Valve C) between the sump drain connection and the drain line. A trap (as shown to the right) should be used to prevent sewer gas from being drawn into the unit.

Evaporative Cooling with Auto Drain and Fill

Sump

Step 3 Check/Adjust Water Level

Check the water level in the sump tank. The water level should be above the pump intake and below the overflow. Adjust the float as needed to achieve the proper water level.

6 in. min.

Evaporative Coolin

ectio

Sump Overflo

Drai

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

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. A trap (as shown to the right) should be installed in the drain 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

NOTE!

The following instructions are provided for evaporative coolers equipped with the Water Wizard only.

I - 9

I - 10

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.

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.

MODEL

VOLTS

SUP HP

MARK

AMPS

HTZ PH

S/N

EXH HP

Voltage, Hertz,

and Phase

Unit’s Total

Amps

IMPORTANT!

Before connecting power to the unit, read and understand the following instructions and wiring

diagrams. Complete wiring diagrams are attached to 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.

I - 11

Step 4 Wire the Optional Convenience Outlet

The convenience outlet requires a separate 115V power supply circuit. The circuit must include short circuit protection which may need to be supplied by others.

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 control center layout in the reference section for main disconnect and grounding lug(s) locations.

Installation - Electrical Wiring

Step 2 Provide the Opening(s) for the Electrical Connections

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

Step 5 Wire the Accessories

Reference the ladder diagram on the inside of the control center door for correct wiring of the following accessories:

NOTE!

TSCP has number-to-number wiring.

NOTE!

Wiring to the Selectrastat, Maxitrol 14

(discharge temperature selector) or 44 (room

override) should be in separate conduit or run

with shielded cable.

• Selectrastat

• Room Override

• Blower Switch

• Heat Switch

• Indicating Lights

• Dirty Filter Indicator

• TSCP

I - 12

Step 6 Wire the Optional Evaporative Cooler

Reference the ladder diagram on the inside of the control center door for correct wiring of the optional pump and the optional auto-drain and flush. Wiring instructions for the optional Water Wizard are included in the Water Wizard installation instructions.

Step 7 Check Recirculation / VAV

Operation

Two Position Damper Control

Turn the recirculating switch on the remote control panel to each position and confirm that the return air damper adjusts accordingly. The damper actuator may take a few minutes to open or close.

Two Speed

Turn the fan speed switch on the remote control panel to each position and confirm that the fan speed adjusts accordingly

Potentiometer Control

To test potentiometer operation, turn the potentiometer to the two extremes. With 80/20 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 I-15 for building pressure set-up and operation check.

NOTE!

Large evaporative coolers may require a separate power supply.

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 and start-up.

For kitchen applications, the drive may be

located in the kitchen or in the unit.

NOTE!

Blower start-up (S-1), steps 1-4 should be

performed before the blower is run.

(OPTIONAL)

BLOWER

DIRTY FILTERS

MAIN VALVES

ALARM

EXHAUST

SUPPLY

HEAT

(OPTIONAL)

GREENHECK

®

PHOTOHELIC

(OPTIONAL

)

BLOWE

DIRTY FILTERS

MAIN VALVES

ALARM

EXHAUST

SUPPLY

HEA

(OPTIONAL

)

GREENHE

GREENHECK

®

(OPTIONAL)

BLOWER

DIRTY FILTERS

MAIN VALVES

ALARM

RECIRCULATION

EXHAUST

SUPPLY

HEAT

(OPTIONAL)

2-Position Damper Control

Building Pressure Control

Potentiometer Control

I - 13

Installation - Direct Gas Piping

Step 1 Determine the Supply Gas Requirements

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

IMPORTANT!

All gas piping must be installed in accordance with the latest edition of the National Fuel Gas Code

ANSI/Z223.1 and any local codes that may apply. In Canada, the equipment shall be installed in

accordance with the Installation Code for Gas Burning Appliances and Equipment (CGA B149) and

Provincial Regulations for the class. Authorities having jurisdiction should be consulted before

installations are made.

WARNING!

All components of this or any other gas-fired heating unit must be leak tested prior to placing the unit

into operation. A soap and water solution should be used to perform this test. NEVER test for gas

leaks with an open flame.

WARNING!

If pressure testing in excess of 1/2 psig

(3.5 kPa), the heater and manual shutoff valve

must be disconnected from the supply gas line.

WARNING!

If pressure testing at or below 1/2 psig (3.5 kPa),

the heater must be isolated from the supply gas

line by closing its manual shutoff valve.

IMPORTANT!

All piping should be clean and free of any foreign

matter. Foreign material entering the gas train

can damage the valves, regulators and burner.

“W.C.

PSI

“W.C.

MAX BTU/HR BTU/H MAX

NORMAL MANIFOLD PRESSURE PRESSION D’ADMISSION NORMALE

MIN GAS PRESSURE PRESSION DE GAZ

MIN BURNER PRESSURE DROP PERTE MIN DE PRESSION DANS LE BRULEUR

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 BURNER PRESSURE DROP PERTE MAX DE PRESSION DANS LE BRULEUR

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.

+ 33 hidden pages

Greenheck TSU Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual