Greenheck TSU Base Unit User Manual

Document 464441

Model TSU

®

Make-Up Air Unit

Installation, Operation and Maintenance Manual

Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety information. Failure
to comply with instructions could result in personal injury and/or property damage!

General Safety Information

Only qualified personnel should install this unit.
Personnel should have a clear understanding of these
instructions and should be aware of general safety
precautions. Improper installation can result in electric
shock, possible injury due to coming in contact with
moving parts, as well as other potential hazards. Other
considerations may be required if high winds or seismic
activity are present. If more information is needed,
contact a licensed professional engineer before moving
forward.

1. Follow all local electrical and safety codes, as well as
the National Electrical Code (NEC), the National Fire
Protection Agency (NFPA), where applicable. Follow
the Canadian Electrical Code (CEC) in Canada.

2. The rotation of the wheel is critical. It must be free
to rotate without striking or rubbing any stationary
objects.

3. Motor must be securely and adequately grounded.

4. Do not spin fan wheel faster than the maximum
cataloged fan rpm. Adjustments to fan speed
significantly affects motor load. If the fan RPM is
changed, the motor current should be checked to
make sure it is not exceeding the motor nameplate
amps.

5. Do not allow the power cable to kink or come in
contact with oil, grease, hot surfaces, or chemicals.
Replace cord immediately if damaged.

6. Verify that the power source is compatible with the
equipment.

7. Never open blower access doors while the fan is
running.

DANGER

Always disconnect power before working on or near a
unit. Lock and tag the disconnect switch or breaker to
prevent accidental power up.

CAUTION

When servicing the unit, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. Do not touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

FOR YOUR SAFETY

The use and storage of gasoline or other
flammable vapors and liquids in open
containers in the vicinity of this appliance is
hazardous.

WARNING

Improper installation, adjustment, alteration,
service or maintenance can cause
property damage, injury or death. Read the
installation, operating and maintenance
instructions thoroughly before installing or
servicing this equipment.

®

Make-Up Air Unit 1

Receiving

Upon receiving the product, check to ensure all items
are accounted for by referencing the delivery receipt or
bill of lading. Inspect each crate or carton for shipping
damage before accepting delivery. Alert the carrier
of any damage detected. The customer will make
a notation of damage (or shortage of items) on the
delivery receipt and all copies of the bill of lading which
is countersigned by the delivering carrier. If damaged,
immediately contact your Greenheck Representative.
Any physical damage to the unit after acceptance is not
the responsibility of manufacturer.

Unpacking

Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Confirmation of shipment(s) must be limited to only
items on the bill of lading.

Handling

Units are to be rigged and moved by the lifting brackets
provided or by the skid when a forklift is used. Location
of brackets varies by model and size. Handle in such
a manner as to keep from scratching or chipping the
coating. Damaged finish may reduce ability of unit to
resist corrosion.

Storage

Units are protected against damage during shipment. If
the unit cannot be installed and operated immediately,
precautions need to be taken to prevent deterioration of
the unit during storage. The user assumes responsibility
of the unit and accessories while in storage. The
manufacturer will not be responsible for damage during
storage. These suggestions are provided solely as a
convenience to the user.

INDOOR — The ideal environment for the storage of

units and accessories is indoors, above grade, in a
low humidity atmosphere which is sealed to prevent
the entry of blowing dust, rain, or snow. Temperatures
should be evenly maintained between 30°F
110°F (43°C) (wide temperature swings may cause
condensation and “sweating” of metal parts). All
accessories must be stored indoors in a clean, dry
atmosphere.

Remove any accumulations of dirt, water, ice, or snow
and wipe dry before moving to indoor storage. To avoid
“sweating” of metal parts allow cold parts to reach room
temperature. To dry parts and packages use a portable
electric heater to get rid of any moisture build up. Leave
coverings loose to permit air circulation and to allow for
periodic inspection.

(-1°C) and

The unit should be stored at least 3½ in. (89 mm) off the
floor on wooden blocks covered with moisture proof
paper or polyethylene sheathing. Aisles between parts
and along all walls should be provided to permit air
circulation and space for inspection.

OUTDOOR — Units designed for outdoor applications

may be stored outdoors, if absolutely necessary. Roads
or aisles for portable cranes and hauling equipment are
needed.

The fan should be placed on a level surface to prevent
water from leaking into the unit. The unit should be
elevated on an adequate number of wooden blocks so
that it is above water and snow levels and has enough
blocking to prevent it from settling into soft ground.
Locate parts far enough apart to permit air circulation,
sunlight, and space for periodic inspection. To minimize
water accumulation, place all unit parts on blocking
supports so that rain water will run off.

Do not cover parts with plastic film or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.

Inspection and Maintenance during Storage

While in storage, inspect fans once per month. Keep a
record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the fan wheel by hand ten to fifteen
revolutions to distribute lubricant on motor. Every three
months, the fan motor should be energized. If paint
deterioration begins, consideration should be given to
touch-up or repainting. Fans with special coatings may
require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be
restored to good condition promptly if signs of rust
occur. Immediately remove the original rust preventive
coating with petroleum solvent and clean with lint-free
cloths. Polish any remaining rust from surface with
crocus cloth or fine emery paper and oil. Do not destroy
the continuity of the surfaces. Wipe thoroughly clean
with Tectyl® 506 (Ashland Inc.) or the equivalent. For
hard to reach internal surfaces or for occasional use,
consider using Tectyl® 511M Rust Preventive or WD­40

® or the equivalent.

REMOVING FROM STORAGE — As units are removed

from storage to be installed in their final location, they
should be protected and maintained in a similar fashion,
until the equipment goes into operation.

Prior to installing the unit and system components,
inspect the unit assembly to make sure it is in working
order.

1. Check all fasteners, set screws on the fan, wheel,
bearings, drive, motor base, and accessories for
tightness.

2. Rotate the fan wheel(s) by hand and assure no
parts are rubbing.

Make-Up Air Unit2

®

Table of Contents

Installation – Slab Mounted Unit

Installation

Slab Mounted Unit ......................... 3

Rail Mounted Unit ......................... 4

Curb Mounted Unit ........................ 4

Filter Section and Weatherhood .............. 5

Evaporative Cooling Module (optional) ......... 5

Electrical Wiring ........................... 6

Direct Gas Piping .........................7-8

Optional Evaporative Cooler Piping ...........8-9

Optional Water Wizard™ ................... 10

Optional Building Pressure Control ........... 11

Optional Dirty Filter Switch ................. 11

Start-Up

Blower ................................. 12

Direct Gas ............................13-15

Optional Evaporative Cooling Recirculating .... 16

Optional Water Wizard™ .................17-18

Operation

Optional Water Wizard™ ................... 18

Optional VAV Units ........................ 19

Optional Recirculating Units ................ 20

Electrical ................................ 21

Troubleshooting

Blower ................................. 22

Motor Overamps ......................... 23

Insufficient / Too Much Airflow .............. 24

Excessive Noise or Vibration ................ 25

Heater ................................26-28

Optional Evaporative Cooling ............... 29

Optional Water Wizard™ ................... 30

Maintenance

Routine ...............................30-32

Fall .................................... 32

Reference

Gas Train Layouts ........................ 33

Control Center Layout .................... 34

Start-Up Check List ....................... 35

Maintenance Log ...................Backcover

Our Commitment ...................Backcover

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.

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 factory­provided lifting lugs.

NOTE

The use of all lifting lugs and a set of spreader bars in
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.

3. Attach Ductwork

Refer to the CAPS submittal for the duct size and
location. Manufacturer 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
weathertight seal.

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.

®

Make-Up Air Unit 3

Installation – Rail Mounted Unit

Installation – Curb Mounted Unit

1. Install Rails

Install the rails. The
rails should be located

Rails extend 6 inches

Rails extend 6 inches
from discharge end

from discharge end
of unit

of unit

Rails located 6 to 12 inches

Rails located 6 to 12 inches
in from sides of unit.

in from sides of unit.

6 to 12 inches in
from the sides of the
unit. The rails should
extend at least six
inches past the intake

Rails extend

Rails extend
6 inches from

6 inches from
end of filter section

end of filter section

and discharge ends
of the unit. Rails are
field-supplied by others

Spreader Bar

and are not supplied by
manufacturer.

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

The use of all lifting lugs and a set of spreader bars in
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.

3. Attach Ductwork

Refer to the CAPS submittal for the duct size and
location. Manufacturer 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 weathertight
seal.

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.

Make-Up Air Unit4

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.

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.

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.

3. Apply Sealant

Sealant

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

Spreader Bar

water penetration.

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.

NOTE

The use of all lifting lugs and a set of spreader bars in
mandatory when lifting the unit.

For easy installation, it is recommended that the
weatherhood, filter section or evaporative cooler be
installed after the base unit.

5. Install Ductwork

If the unit has a downblast (DB) discharge, the ductwork
should already be installed.

Refer to the CAPS submittal for the duct size and
location. Manufacturer 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 weathertight seal.

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.

®

Metal Cover

Equipment
Support

Installation – Filter Section and
Weatherhood

Installation of Evaporative Cooling
Module (optional)

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.

1. Apply Sealant

Apply an appropriate
sealant around the
intake end of the

Sealant

base unit to create a
weathertight seal.

NOTE

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

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

Sealant

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.

3. Apply Sealant

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

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.

NOTE

Small evaporative coolers ship attached to the base
unit and require no additional mounting.

1. Equipment Support(s) - consult factory

Position equipment support(s)
on the roof (reference
the CAPS submittal for
placement of equipment
support(s) in relation to
the unit). Verify that all unit
supports are level, shim if

Equipment Support

necessary. Attach equipment
support to the roof, remove metal
cover, flash to wooden nailer and
reinstall cover.

Sealant

2. Apply Sealant

Apply an appropriate sealant
around the airstream opening to
create an airtight seal.

Sealant

NOTE

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

3. Set Evaporative Cooling Module

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

4. Secure Cooling Module to Unit

Use self-tapping screws to fasten the cooling module to
the base unit along the top and down both sides. Fasten
at the top through the flanges.

NOTE

When mounting the evaporative cooler, it is important
that it is level to ensure proper operation and water
drainage.

®

Make-Up Air Unit 5

Installation of Electrical Wiring

IMPORTANT

Before connecting power to the unit, read and
understand the following instructions and wiring
diagrams. Complete wiring diagrams are attached on
the inside of the control center door(s).

IMPORTANT

All wiring should be done in accordance with the
latest edition of the National Electric Code ANSI/
NFPA70 and any local codes that may apply. In
Canada, wiring should be done in accordance with
the Canadian Electrical Code.

IMPORTANT

The equipment must be properly grounded. Any
high voltage wiring running through the unit in the
airstream must be protected by metal conduit, metal
clad cable or raceways.

CAUTION

If replacement wire is required, it must have a
temperature rating of at least 105ºC, except for an
energy cut-off or sensor lead wire which must be
rated to 150ºC.

DANGER

High voltage electrical input is needed for this
equipment. This work should be performed by a
qualified electrician.

CAUTION

Any wiring deviations may result in personal injury or
property damage. Manufacturer is not responsible
for any damage to, or failure of the unit caused by
incorrect final wiring.

IMPORTANT

Manufacturer’s standard control voltage is 24VAC.
Control wire resistance should not exceed 0.75ohms
(approximately 285 feet total length for 14gauge
wire; 455 feet total length for 12gauge wire). If the
resistance exceeds 0.75 ohms, an industrial-style
plug-in relay should be wired in place of the remote
switch. The relay must be rated for at least 5 amps
and have a 24 VAC coil. Failure to comply with these
guidelines may cause motor starters to chatter or not
pull in, resulting in contactor failures and/or motor
failures.

1. Determine the Size of the Main Power Lines

The unit’s nameplate states the voltage and the unit’s
MCA. The main power lines to the unit should be sized
accordingly. The nameplate is located on the outside of
the unit on the control panel side.

Voltage, Hertz, Phase

MODEL

VOLTS

AMPS

SUP HP

MARK

Electrical Nameplate

HZ PH

S/N

EXH HP

2. Provide the Opening(s) for the Electrical

Connections

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

3. Connect the Main Power

Connect the main power lines to the disconnect switch
and main grounding lug(s).

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.

5. Wire the Optional Accessories

Reference the Ladder Diagram on the inside of the
control center door for correct wiring of the following
optional accessories:

• Selectra Stat

• Room Override

• Blower Switch

• Heat Switch

• Indicating Lights

• Dirty Filter Indicator

• TSCP

• KSCP

NOTE

Wiring to the Selectra Stat should be in separate
conduit or run with shielded cable.

NOTE

TSCP has number-to-number wiring.

NOTE

Large evaporative coolers may require a separate
power supply.

6. Wire the 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.

Make-Up Air Unit6

®

Installation of Direct Gas Piping

IMPORTANT

All gas piping must be installed in accordance
with the latest edition of the National Fuel Gas
Code ANSI/Z223.1 and any local codes that may
apply. In Canada, the equipment shall be installed
in accordance with the Installation Code for Gas
Burning Appliances and Equipment (CGA B149) and
Provincial Regulations for the class. Authorities having
jurisdiction should be consulted before installations
are made.

WARNING

All components of this or any other gas-fired heating
unit must be leak tested prior to placing the unit into
operation. A soap and water solution should be used
to perform this test. NEVER test for gas leaks with an
open flame.

WARNING

When leak testing pressures that are equal to or less
than 14in.wc (3.5kPa), first close the field-installed
shutoff valve to isolate the unit from the gas supply
line.

WARNING

When leak testing pressures that are above 14 in.wc
(3.5kPa), close the field-installed shutoff valve,
disconnect the furnace and gas train from the gas
supply line and plug the supply line before testing.

IMPORTANT

All piping should be clean and free of any foreign
matter. Foreign material entering the gas train can
damage the valves, regulators and burner.

IMPORTANT

Do NOT connect the unit to gas types other than
what is specified and do NOT connect the unit to
gas pressures that are outside of the pressure range
shown on the label.

NOTE

When connecting the gas supply, the length of the
run must be considered in determining the pipe size
to avoid excessive pressure drop. Refer to a Gas
Engineer’s Handbook for gas pipe capacities.

1. Determine the Supply Gas Requirements

The unit’s direct gas nameplate states the requirements
for the gas being supplied to the unit. The direct gas
nameplate is located on the outside of the unit on the
control center side.

Minimum gas pressure for

maximum output

MAX BTU/HR
BTU/H MAX

NORMAL MANIFOLD
PRESSURE
PRESSION DÕADMISSION
NORMALE

MIN GAS
PRESSURE
PRESSION DE GAZ

MIN BURNER
PRESSURE DROP
PERTE MIN DE PRESSION
DANS LE BRULEUR

TYPE OF GAS
NATURE DU GAZ

EQUIPPED FOR

CONCU POUR

Type of gas

AGAINST

SCFM

CONTE

Direct Gas Nameplate

“ W.C.

“ W.C.

“ W.C.

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

MAX BURNER
PRESSURE DROP
PERTE MAX DE PRESSION
DANS LE BRULEUR

DESIGN ΔT
ΔT NORMALE

EXTERNAL STATIC PRESSURE

“ W.C.

PRESSION STATIQUE EXTERIEURE

Maximum gas pressure

“ W.C.

“ W.C.

PSI

F

2. Install Additional Regulator if Required

When the supply gas pressure exceeds the maximum
gas pressure shown on the direct gas nameplate, an
additional regulator is required to reduce the pressure.
The regulator must have a listed leak limiting device or it
must be vented to the outdoors.

NOTE

The regulator located inside the unit is used to adjust
the unit’s maximum output temperature.

3. Connect the Supply Gas Line

A manual shut off valve (gas cock), 1/8 in. plugged test
port and 6 in. 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 manufacturer.

Gas Cock

From

Gas

Supply

1/8 in. Plugged Tap

Ground Joint Union

6 in. Trap

To

Controls

Supply Gas Line

®

Make-Up Air Unit 7

4. Pipe the Optional Vent Line

If an optional vent line is located between the safety
shutoff valves, it must be piped to the outdoors.

WARNING

Reference the National Fuel Gas Code for additional
vent line requirements.

Vent Line Solenoid

to outdoors

Vent Line

Installation Evaporative Cooler
Piping (optional)

Evaporative Cooling with Recirculating Pump

Supply Line

Drain Line Valve

Drain Line

Supply Line Valve

Overflow

to burner

Safety Shut-Off Valves

Optional Vent Line

from supply

5. Test the System for Leaks

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

WARNING

NEVER test for a gas leak with an open flame.

NOTE

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

Trap

Recirculating Evaporative Piping

IMPORTANT

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

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

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.

1. Install the Water Supply Line

Supply line opening requirements vary by unit size and
arrangement and are field-supplied. Connect the water
supply line to the float valve through the supply line
opening in the evaporative cooling unit. Install a manual
shutoff valve in the supply line as shown above.

2. Install the Drain Line

Connect an unobstructed drain line to the drain and
overflow connections on the evaporative cooler. A shut
off valve (by others) is required for the evaporative
cooler drain line.

A trap should be used
to prevent water from
overflowing the sump
pump. Refer to drain

Drain

Trap

6 in. min.

6 in. min.

trap diagram.

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 and drain pipe as needed to
achieve the proper water level.

Make-Up Air Unit8

®

Installation Evaporative Cooler
Piping (optional)

Evaporative Cooling with Auto Drain and Fill

VALVE C

Sump Drain Solenoid

(normally open)

VALVE B

Supply Line Drain Solenoid

(normally open)

Auto Drain and Fill Evaporative Piping

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.

All solenoid 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.

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.

continued

Supply Line

Sump Overflow

Sump Drain

IMPORTANT

CAUTION

IMPORTANT

VALVE A

Supply Solenoid

(normally closed)

Trap

Drain Line

1. Install the Water Supply Line

Supply line opening requirements vary by unit size
and arrangement and are field-supplied. Connect the
water supply line to the float valve through the supply
line opening in the evaporative cooling unit. Install the
1/2 in. normally closed solenoid (Valve A) in the supply
line. Install the 1/4 in. normally open solenoid (ValveB)
between the supply line and the drain line. Refer to Auto
Drain and Fill Evaporative Piping drawing shown on this
page.

2. Install the Drain Line

Connect an unobstructed drain line to the sump drain
overflow connection. Install the 3/4 in. normally open
solenoid (Valve C) between the sump drain connection
and the drain line.

A trap should be
used to prevent
water from
overflowing the
sump pump. Refer to

Drain

Trap

6 in. min.

6 in. min.

drain trap diagram.

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 and drain pipe as needed to
achieve the proper water level.

Auto Drain & Flush Valves

(when provided by Manufacturer)

Assm.

Number

852178

Part numbers subject to change.

®

Mfg.
Part

Number

461262 8210G2 Supply Closed

461263 8262G262

461264 8210G35

ASCO

Part Num-

ber

Solenoid

Type

Supply

Line

Drain

Sump

Drain

De-Energized

Position

Open

Open

Diameter Qty.

1/2 inch

(12.7 mm)

1/4 inch

(6.35 mm)

3/4 inch

(19.05 mm)

1

1

1

Make-Up Air Unit 9

Installation of Water Wizard™ (optional)

Evaporative Cooling with the Water Wizard™

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.

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.

Three-Sided Evaporative Coolers

Housing

Size

H-50 21 26

1. Install Normally Closed 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
roof line.

2. Install Normally Open 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 should be installed in the drain line.

Water Pressure (in. wc)

Front Sides

3. Wire the Solenoid(s)

Wire the supply line solenoid and drain solenoid as
shown on the unit’s wiring diagram in the control center.

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 the unit’s control center.
Refer to ladder diagram for proper connections.

NOTE

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

NOTE

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

CAUTION

Any wiring deviations may result in personal injury or
property damage. Manufacturer is not responsible
for any damage to, or failure of the unit caused by
incorrect final wiring.

To Media

Sump Drain

Trap

Manual Supply Valve

Roof Line

Supply Line Drain Solenoid

(normally open)

Water Wizard™ Installation

Pressure Gauge

Supply Solenoid

(normally closed)

Factory

Installed

Field

Installed

Make-Up Air Unit10

®

Installation of Building Pressure
Control (optional)

Installation of Dirty Filter Switch
(optional)

1. Mount Pressure Tap

Using the factory-provided bracket, mount the pressure
tap to the outside of
the unit. Choose a
location out of the
prevailing winds and
away from supply
or exhaust fans to
assure accurate
readings.

2. Run Pressure Tap Lines

Run a pressure tap line from the pressure tap on the
outside of the unit to the low pressure tap on the back
of the photohelic gauge. Run a second pressure tap line
from the high pressure tap on the back of the photohelic
gauge to the space. Fifty feet of tubing is supplied with
the unit.

High Pressure

Factory

Wiring

Low Pressure

Tap

to outside

Connections for Photohelic Gauge

Tap

to space

3. Set the Building Pressure

The pressure gauge is used to set the desired building
pressure.

The pressure is set by adjusting the knobs for the upper
and lower pressure limits.

To adjust the switch, the unit must be running with all of
the access doors in place, except for the compartment
where the switch is located. The adjusting screw is
located on the top of the switch.

Setscrew (on front of switch) must
be manually adjusted after the
system is in operation.

Negative pressure connection is
toward the 'front or top' of the
switch. (Senses pressure on the

blower side of filters)

Positive pressure connection is toward the 'back or bottom'
of the switch. (Senses pressure at the inlet side of filters)

1. Open the filter compartment and place a sheet of
plastic or cardboard over 50% of the filter media.

2. Replace the filter compartment door.

3. Check to see if there is power at the alert signal
leads (refer to electrical diagram).

4. Whether there is power or not, turn the adjustment
screw on the dirty filter gauge - clockwise if you did
not have power, counterclockwise if you did have
power - until the power comes on or just before the
power goes off.

5. Open the filter compartment and remove the
obstructing material.

6. Replace the door and check to make sure that you
do not have power at the alert signal leads. The
unit is now ready for operation.

Pressure Indicating Needle Pressure Setting Needles

Pressure Setting Knobs

Typical Photohelic Gauge

®

Make-Up Air Unit 11

Start-Up - Blower

Refer to the Start-Up Checklist in the Reference
section before proceeding further!

Pre Start-Up Check

Rotate the fan wheel by hand and make sure no parts
are rubbing. Check the V-belt drive for proper alignment
and tension (a guide for proper belt tension and
alignment is provided in the Belt Maintenance section).
Check fasteners, set screws and locking collars on the
fan, bearings, drive, motor base, and accessories for
tightness.

WARNING

Disconnect and lock-out all power and gas before
performing any maintenance or service to the unit.
Failure to due so could result in serious injury or death
and damage to equipment.

SPECIAL TOOLS REQUIRED

• Voltage Meter (with wire probes)

• Amperage Meter

• Pressure Gauges – (refrigerant)

• Tachometer

• Thermometer

• U-tube manometer or equivalent

3. Check for Vibration

Check for unusual noise, vibration or overheating of the
bearings. Reference the Troubleshooting section for
corrective actions.

IMPORTANT

Excessive vibration may be experienced during
the initial start-up. Left unchecked, it can cause a
multitude of problems including structural and/or
component failure.

IMPORTANT

Generally, fan vibration and noise is transmitted
to other parts of the building by the ductwork. To
minimize this undesirable effect, the use of heavy
canvas duct connectors is recommended.

4. Motor Check

Measure the motor’s voltage, amps and RPM. Compare
to the specifications. Motor amps can be reduced by
lowering the motor RPM or increasing system static
pressure.

IMPORTANT

Additional starters and overloads may be provided in
the make-up air control center for optional exhaust
blowers. Any additional overloads must be checked
for proper voltage, amps and RPMs.

WARNING

Check the housing, blower, and ductwork for any
foreign objects before running the blower.

1. Check the Voltage

Before starting the unit, compare the supplied voltage,
hertz, and phase with the unit and motor’s nameplate
information.

2. Check the Blower Rotation

Open the blower access door and
run the blower momentarily to
determine the rotation.

Arrows are placed on the blower
scroll to indicate the proper
direction or reference the example
shown to the right.

n

n

o

o

i

i

t

t

a

a

t

t

o

o

R

R

Blower

Blower

Housing

Housing

Blower Rotation

Blower Rotation

NOTE

To reverse the rotation on three phase units,
disconnect and lock-out the power, then interchange
any two power leads.

NOTE

To reverse the rotation on single phase units,
disconnect and lock-out the power, then rewire the
motor per the manufacturer’s instructions.

IMPORTANT

If the blower is rotating in the wrong direction, the unit
will move some air, but will not perform as designed.
Be sure to perform a visual inspection to guarantee
the correct blower rotation.

5. Air Volume Measurement and Check

Measure the unit’s air volume (cfm) and compare it with
it’s rated air volume. If the measured air volume is off,
adjust the fan’s RPM by changing/adjusting the drive.

NOTE

The most accurate way to measure the air volume is
by using a pitot traverse method downstream of the
blower. Other methods can be used but should be
proven and accurate.

IMPORTANT

Changing the air volume can significantly increase
the motor’s amps. If the air volume is changed,
the motor’s amps must be checked to prevent
overloading the motor.

NOTE

To ensure accuracy, the dampers are to be open
when measuring the air volume.

6. Set-Up Optional Components

Adjust the settings on the optional components. See
the Control Center Layout in the Reference section for
location of optional components.

• Heating Inlet Air Sensor
Typical setting: 60-70ºF

• Cooling Inlet Air Sensor
Typical setting: 75ºF

• Building Freeze Protection
Typical setting: 5 minutes; 45ºF

• Dirty Filter Gauge
Typical setting: Settings vary greatly for each unit.

Make-Up Air Unit12

®

Start-Up - Direct Gas

IMPORTANT

For proper unit function and safety, follow the start-up
procedure in the exact order that it is presented.

IMPORTANT

This start-up should begin after all of the installation
procedures and the blower start-up have been
completed.

1. Check the Supply Gas Pressure

Check the supply gas pressure and compare it with
the unit’s nameplate pressure requirements. Adjust
the supply regulator as needed until the supply gas
pressure is within the specified range (see below). The
nameplate is located on the outside of the unit on the
control panel side.

Minimum and maximum gas

pressures for maximum output

IMPORTANT

Proper air velocity over the burner is critical on direct­fired gas units. If the air velocity is not within the unit
specifications, the unit will not operate efficiently, may
have sporadic shutdowns.

4. Set the Burner Air Pressure Differential

With all access panels in place, the fan running
and discharging 70ºF (21ºC) air, connect a U-Tube
manometer to the outer sensing probes (see below) and
measure the static pressure across the burner.

Outer Sensing Probes

Pressure Switch

MAX BTU/HR
BTU/H MAX

NORMAL MANIFOLD
PRESSURE
PRESSION DÕADMISSION
NORMALE

MIN GAS
PRESSURE
PRESSION DE GAZ

MIN BURNER
PRESSURE DROP
PERTE MIN DE PRESSION
DANS LE BRULEUR

TYPE OF GAS
NATURE DU GAZ

EQUIPPED FOR

CONCU POUR

SCFM

AGAINST

CONTE

“ W.C.

“ W.C.

“ W.C.

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

MAX BURNER
PRESSURE DROP
PERTE MAX DE PRESSION
DANS LE BRULEUR

DESIGN ΔT
ΔT NORMALE

EXTERNAL STATIC PRESSURE

“ W.C.

PRESSION STATIQUE EXTERIEURE

“ W.C.

“ W.C.

PSI

F

Type of gas

Direct Gas Nameplate

2. Check the Pilot Gas Pressure

The recommended gas pressure is 3 in. wg. Adjust the
pilot regulator as needed. See the Gas Train Layout
in the Reference section for the location of the pilot
pressure test port and pilot regulator.

3. Check the Optional High and Low Gas
Pressure Switches

Check the settings on the high and low gas pressure
switches. The high gas setting is typically 8in. wg
(2kPa) and the low gas setting is typically 3 in. wg
(0.7kPa). The switches are set at the factory and should
not need adjustment. Adjust the settings if needed. See
the Gas Train Layout diagram in the Reference section
for the high and low pressure switch location.

IMPORTANT

The purpose of the high and low gas pressure
switches is to automatically shut down the burner
if the inlet gas pressure is too low for the burner to
safely light, or if the manifold pressure is too high for
the burner to operate properly.

U-Tube Manometer

Measuring the Pressure Drop

7

0.625 - 0.675 in. wc

6

The proper static pressure

Adjustable
Top Baffle

Airflow

Burner

should be between 0.625 and

0.675 inches wg (155.68 and

168.64 Pa). If needed, evenly
adjust the baffles above and
below the burner, keeping the

Adjustable
Bottom Baffle

burner centered in the opening
until the required pressure is

Burner and Baffles

obtained.

NOTE

The pressure drop was set at the factory and may not
need adjustment.

NOTE

When required pressure is obtained, be sure to
reconnect the outer sensing probes.

IMPORTANT

This process may need to be repeated until the proper
pressure is achieved. This adjustment will change the
air quantity delivered by the unit and therefore the air
quantity delivered should be rechecked. Refer to the
Blower Start-Up section.

NOTE

To increase the static pressure, decrease the opening.
To decrease the static pressure, increase the opening.

®

Make-Up Air Unit 13

5. Set the Low Fire Time Delay

Set the low fire time delay to 75% of its maximum
setting. See corresponding image(s) for the location of
the time delay setting.

NOTE

The low fire time delay must be set high enough to
provide at least 10 seconds of low fire while the unit
tries to light.

6. Set the Maximum Firing Rate

Monitor the unit’s actual temperature rise by placing
a thermocouple in the unit’s inlet and a second in the
discharge, three duct diameters downstream of the
burner.

Send the unit to maximum fire by disconnecting and
isolating the wire connected to Terminal 3 on the
Maxitrol 14 or 44. On Maxitrol SC 25 system, place
jumper between T1 and T2 on the amplifier.

While monitoring the unit’s temperature rise, set the
maximum firing rate by adjusting the regulator until the
designed temperature rise is achieved. After setting the
maximum firing rate, reconnect the wire to the amplifier.

NOTE

Clockwise rotation increases the temperature rise,
counterclockwise rotation decreases the temperature
rise.

NOTE

The minimum setting for the maximum firing rate may
be higher than required. This is acceptable, the burner
will modulate as needed.

Regulators and Modulating Valves

Remove cap to access

maximum firing rate

adjustment

Minimum firing

rate adjustment

Remove one wire to

send the unit to the
minimum firing rate

NOTE

Do not set the burner maximum firing rate based on
gas pressure. It should be set based on the unit’s
designed temperature rise shown on the direct gas
label.

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

EQUIPPED FOR

CONCU POUR

AGAINST

SCFM

CONTE

Direct Gas Nameplate

“ W.C.

“ W.C.

“ W.C.

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

MAX BURNER
PRESSURE DROP
PERTE MAX DE PRESSION
DANS LE BRULEUR

DESIGN ΔT
ΔT NORMALE

EXTERNAL STATIC PRESSURE

“ W.C.

PRESSION STATIQUE EXTERIEURE

“ W.C.

“ W.C.

PSI

F

IMPORTANT

Setting the maximum firing rate during mild weather
conditions may cause the high limit to trip out during
extreme conditions requiring manual resetting.

NOTE

Gas trains are equipped with either separate
regulators and modulating valves or with a combined
modulating valve.

Separate Regulator and Modulating Valves

Minimum firing

rate adjustment

Remove one wire to send the unit

to the minimum firing rate

Maximum firing
rate adjustment

Combined Modulating Regulator

7. Set the Minimum Firing Rate

Disconnect and isolate one of the wires running to the
modulating valve to send the unit to its minimum firing
rate. Set the minimum firing rate by adjusting the needle
valve.

After setting the minimum firing rate, shut off the pilot
to ensure that the flame safeguard can still read the
main flame signal. Reconnect the wire to the modulation
valve and open the pilot shut-off valve.

Make-Up Air Unit14

®

IMPORTANT

The proper minimum firing rate setting results in a
small ribbon of continuous flame which covers the
flame rod and runs across the entire burner.

IMPORTANT

Do not allow the disconnected wire to come in
contact with a potential ground. Damage to the
amplifier or transformer could result.

IMPORTANT

On units with a burner 42 inches or greater, the flame
safeguard will automatically shut off the pilot after the
burner has been ignited.

NOTE

Adjusting the maximum and minimum firing rate
requires the inlet air sensor to be set higher than the
outdoor air temperature in order to start the burner(s).
Once high and low fire have been set, the inlet air
sensor should be set to the desired temperature.

NOTE

Counterclockwise rotation increases the minimum fire
rate setting, clockwise rotation decreases the setting.

8. Set the Unit’s Operating Temperature

Set the operating temperature. The method to set the
operating temperature depends upon which Maxitrol
controller is used.

Maxitrol Series 14 - The Maxitrol Series 14 should be
set to the desired discharge temperature mode. Place
dipswitch in the “UP” position for local control and in
the “DOWN” position for remote control. Keep LFST
dipswitch in the “UP” position at all times for 10 second
delay. Fig. A is required for remote control.

Remove wire attached to terminal 3

to send unit into maximum fire

Discharge

temperature

dipswitch

Set the discharge temp
Typical 65°F
Minimum: Typical: 55°F
Maximum: Typical: 90°F

Maxitrol Series 14 — 8 terminals

Low fire

setting

(LFST)

dipswitch

Fig. A

Maxitrol Series 44 - The Maxitrol Series 44 should be
set to the desired space temperature. The temperature
selector is a stand-alone dial. The stand-alone dial may
be mounted remotely.

Set the space temperature

Typical: 70ºF

Series 44 Temperature Setting

(shown as Space Temperature Control)

Minimum discharge
temperature setting

(Typical: 50ºF)

Low fire time
delay setting

(75% of maximum)

Maxitrol Series 44 — 9 terminals

Remove wire attached

to terminal 3 to send

unit into maximum fire

Maximum discharge

temperature setting

(Typical: 100ºF)

Maxitrol SC25S - The SC25S is an analog signal
converter that will change a 0-10 VDC or a 4-20 mA
control signal provided by an owner-supplied Building
Management System into an output level capable of
driving the modulating gas valve.

The SC25S also limits the minimum and maximum
discharge air
temperatures.
Reference the unit­specific wiring
diagram and Maxitrol
data sheets included
in the IOM packet.

9. Flame Signal Check

To measure the flame signal connect a standard DC
voltmeter to the flame
amplifier test jacks + and

- (com) as shown to the
right. The flame signal
should be above 1.25 VDC
and steady.

Check the flame signal
with the burner at pilot
only, minimum fire, mid fire
and high fire.

DC Voltmeter and Flame

Amplifier

IMPORTANT

If the flame signal is not above 1.25 VDC and steady,
consult the Troubleshooting section.

®

Make-Up Air Unit 15

Start-Up - Evaporative Cooling

r

Recirculating (optional)

1. Check the Installation

The media may have
been removed during
installation, so its
orientation should
be double checked.

Entering Air

The media should
be installed with the
steeper flute angle
sloping down towards

Media Orientation

the entering air side.

Verify that the stainless steel caps and distribution
headers are in place. The headers should be located
over the media towards the entering air side. The caps
should be placed over the headers.

2. Check the Pump Filter

Check that the pump filter is around the pump inlet.

3. Fill the Sump and Adjust the Float

Turn on the water supply and allow the sump tank to fill.
Adjust the float valve to shut-off the water supply when
the sump is filled to within 1 inch of the bottom of the
overflow.

4. Break-In the Media

Open the bleed-off valve completely and saturate the
media with the blower(s) off for no less than 20minutes.

NOTE

A jumper will need to be installed in the control center
to power the evaporative pumps with the blower(s)
off. Reference the unit’s ladder diagram to determine
proper terminals.

45º

Leaving Ai

15º

7. Set the Optional Auto Drain and Fill

This system will automatically drain the sump tank and
fill it with fresh water at the field-adjustable intervals,
typically once every 24 hours. This flushes mineral
build-up and debris from the tank to promote low
maintenance and increase media pad life.

In addition, the system will protect the evaporative
cooler from freezing by draining the sump tank and
supply line when the outside temperatures fall below
the set point of the outside air sensor. This is set to 45ºF
and is not adjustable. The auto drain and fill outdoor
air sensor should be installed in an area that is shaded
from direct sunlight so the outside air sensor probe will
detect an accurate air temperature.

Set the Timer Scale and Settings dials:

• T1 timer setting set to 10 and timer scale set to
1d for 1 day of operation

• T2 timer setting set to 10 and the timer scale set to
10m for 10 minutes of drain time

Timer

Scale

Timer

Settings

Timer

Scale

T1

Settings

T2

Settings

5. Check the Flow Rate

The pumps should provide enough water to saturate
the media in 45 to 60 seconds. Consult the factory if
adequate flow is not achieved.

NOTE

If too much water is flowing
to the media, the flow can be
adjusted using the manual ball
valve. If flow adjustments are
made, verify that sufficient water
is still being supplied to the
media to keep the entire pad wet
during normal operation. Too
high of a water flow can cause

Manual Ball Valve

water carryover problems.

6. Adjust the Water Bleed-Off Rate

The water bleed-off rate is dependent on the water’s
mineral content. The bleed-off should be adjusted
based on the media’s mineral deposits after two weeks
of service.

Auto Drain and Flush Timer

8. Put the Unit into Service

Remove the jumper and energize the blower(s). Verify
proper operation.

IMPORTANT

Check the media for minerals after two weeks of
service and adjust the bleed-off rate accordingly.

Bleed-Off

Valve

Overflow

Pump

Filter

Evaporative Cooler Set-Up

Supply

Connection

Float

Valve

Threaded Float

Adjustment

Make-Up Air Unit16

®

Start-Up - Water Wizard™ (optional)

L1 L2 L3

Function

Enter

Water Wizard™ User Interface

Key Function Description

1. Open the Solenoid

Confirm that the manual water supply valve is

closed. Press and hold the Function key for
one second. L3 will begin blinking (short on, long off),
indicating that Flow Test Mode is active and the supply
solenoid is open.

2. Set the Water Pressure

With the solenoid open, set the supply water

pressure to the correct setting from the following
tables. Use the manual supply valve to adjust the supply
pressure. A pressure gauge is provided between the
manual supply valve and the media.

WARNING

Opening the manual supply valve will allow water to
pass to the media. Be sure the sump is safely draining
before opening the manual supply valve.

NOTE

The manual supply valve ships closed and must be
adjusted for proper performance.

Three-Sided Evaporative Coolers

Housing

Size

H-50 21 26

Water Pressure (in. wc)

Front Sides

NOTE

The recommended water pressure is based on media
width. Refer to the table provided for proper water
pressure settings.

Up

Down

NOTE

Steps 6 through 8 are provided to adjust the minimum
cooling temperature. The minimum cooling is preset
to the factory recommended 75ºF (24ºC). Only adjust
if needed.

NOTE

The inlet air sensor function overrides and shuts down
the evaporative cooler if the outside temperature falls
below the minimum cooling temperature.

6. Enter Program Mode

Press and hold the

Enter key for three
seconds. The display will
read “Pro” when Program
Mode is active.

Program Display

7. Adjust the Minimum Cooling Temperature

While in the Program
Menu, use the Up and
Down keys to navigate
the Menu Options until
“toF” is displayed.
Press the Enter key

to access the selected Menu

Minimum Cooling

Temperature Display

Option setting.

Use the Up and Down keys to adjust the Minimum
Cooling Temperature as needed. Press the Enter key
to save the Minimum Cooling Temperature setting and
return to the Program Menu.

NOTE

The enter key must be pressed to save the new
minimum cooling temperature.

8. Exit Program Mode

After ten seconds of idle time the controller will exit
Program Mode.

3. Break-In Media

Leave the supply solenoid open to saturate and break-in
media for 20 minutes with the blower off.

4. Close Solenoid

With the pressure set, press the Function key for
one second to deactivate Flow Test Mode and

allow the supply solenoid to close.

5. Check Media

Start the cooling cycle and check the media after one
hour of operation. If the media is continuously dry or if
too much water is draining from the sump tank, refer to
Troubleshooting, Water Wizard™.

®

Make-Up Air Unit 17

NOTE

The Freeze Temperature is preset to the factory
recommended 45ºF. Steps 9-11 should only
be completed if the Freeze Temperature needs
adjustment.

NOTE

The Freeze Temperature is the temperature at which
the supply solenoid closes and the drain solenoid
opens to drain the supply line, preventing possible
freeze damage. A drain solenoid is required for this
option.

9. Enter Program Mode

Press and hold the

Enter key for three
seconds. The display will
read “Pro” when Program
Mode is active.

Program Display

10. Adjust the Freeze Temperature

While in Program

Mode, use the Up and

Down keys to navigate

through the Menu

Options until “Frt”

is displayed. Press
the Enter key to access the

Freeze Temperature

Display

selected Menu Option setting.

Use the Up and Down keys to adjust the Freeze
Temperature setting as needed. Press the Enter key to
set the Freeze Temperature and return to the Program
Menu.

NOTE

The enter key must be pressed to save the new freeze
temperature.

11. Exit Program Mode

After ten seconds of idle time the controller will exit
Program Mode.

CAUTION

The sump drain line must be clear and draining to a
safe location before using Flow Test Mode.

CAUTION

Be aware of the water level in the sump tank at all
times when using the Flow Test Mode.

Program Mode

Program Mode allows the user to view the Program
Menu and edit the factory default settings. To access
Program Mode and view the Program Menu, press and
hold the Enter key for three seconds. While viewing the
Program Menu, press the Up and Down keys to scroll
through the Menu Options. To view the setting of the
selected Menu Option, press the Enter key. To edit the
setting, press the Up or Down key while viewing the
setting. To save the setting and return to the Program
Menu, press the Enter key. To return to the Program
Menu without saving the change, wait 10 seconds.
To exit Program Mode from the Program Menu, wait
10seconds.

WARNING

Changing the default settings will significantly affect
performance. Only change a setting after reading and
understanding this entire manual.

WARNING

The Enter key must be pressed to save any changes
made to a setting.

Dry Bulb Temperature

The dry bulb temperature is visible on the home screen.
If a number is not visible, wait 15 seconds and use the
Up and Down keys until a number is displayed.

Wet Bulb Temperature

To view the Wet Bulb Temperature, simultaneously press
and hold the Up and Down keys.

Indicating Lights

Three indicating lights are located across the top of the
display to indicate the status of the Water Wizard™.

Operation - Water Wizard™ (optional)

Drain Mode locks open the drain solenoid and drains

the supply line between the supply solenoid and
the media. To activate Drain Mode simultaneously,
press the Function and Enter keys (L2 will light). To
deactivate Drain Mode and unlock the drain solenoid,
simultaneously press the Function and Enter keys again.

Flow Test Mode - Activating Flow Test Mode opens
the supply solenoid and allows water to pass to the
manual supply valve. To activate Flow Test Mode, press
and hold the Function key for one second (L3 will flash).
To deactivate Flow Test Mode and allow the supply
solenoid to close, press and hold the Function key again
for one second.

Make-Up Air Unit18

Indicating

Light

L1

L2

L3

On Off

Call for
cooling

Drain

solenoid

open

Cooling onCooling

No
call for
cooling

Drain

solenoid

closed

off

Light Status

Blinking

Long on, short off

Call for cooling.

Outdoor

temperature

lockout.

N/A

Supply solenoid

locked closed

Blinking

Short on, long off

N/A

Supply solenoid

open. (Drain

solenoid closed).

Flow test

mode active

®

Check Operation - VAV Units
(optional)

NOTE

Blower Start-Up, Steps 1-5 should be performed
before the blower is run.

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.

Variable Volume Operation

The variable volume option is recommended when
a building’s exhaust volume may vary. This option
enables the make-up air volume to track with the
exhaust volume, providing only the amount of make-up
air required. Control strategies include 2-speed VFD
motors and modulating blowers. Before the unit is left in
service, the variable volume control system should be
tested.

Modulating

Potentiometer Control - a variable frequency drive
is controlled by input from a remote
speed selector (potentiometer). This
unit allows easy manual adjustment
of make-up air volumes. To test
potentiometer operation, turn the
potentiometer to the two extremes.
With variable volume, make sure the
fan goes to maximum and minimum
speed.

When the potentiometer is at 0, the
fan speed will be at its minimum.
When the potentiometer is at 100,
the fan will be at its maximum speed.

Potentiometer

EXHAUST

(OPTIONAL)

SUPPLY

HEAT

70

75

65

80

60

85

55

90

Control

BLOWERS

MAIN VALVES

DIRTY FILTERS

(OPTIONAL)

Building Pressure Control - a
variable frequency drive is controlled
according to input from a pressure

EXHAUST

SUPPL Y

HEA T

(OPTIONAL)

BLOWER

MAIN V AL VES

sensing device.

Turn both knobs to the upper most
pressure setting. You may have to

DIRTY FIL TERS

70

75

65

80

(OPTIONAL)

60

85

55

90

remove the outdoor pressure tap
tubing. VAV systems should go to

PHOTOHELIC

maximum speed. Set both knobs
at the lowest setting and the VAV
systems should go to minimum speed.

Reset the correct pressure limits
before starting the unit.

This picture depicts a typical

Pressure

Indicating

Needle

Building

Pressure Control

Pressure

Setting

Needles

photohelic setting. The needle
indicates a negative building
pressure. During correct
operation, the indicating
needle will remain between or
near the setting needles.

External Signal - a variable
frequency drive is controlled
according to input from an
external 2-10VDC or 4-20 mA
signal (by others).

Pressure Setting Knobs

Photohelic Gauge

A 2 VDC or 4 mA signal will send the blower to low
speed. The blower will go to maximum speed with a 10
VDC or 20 mA signal.

Variable Kitchen Control - a variable frequency drive
is controlled by input from the kitchen control panel.
This unit allows automatic adjustment of make-up air
volumes based on varying cooking loads.

Burner Bypass Damper (optional)

The self-adjusting burner bypass damper is a device
used in variable volume
units. Its function is
to maintain proper
combustion by providing
a constant airflow over
the burner when outside
air volumes are changed.
It is located underneath
the burner as shown in
the picture.

Burner

Bypass Damper

Burner Bypass Damper

WARNING

The burner bypass damper is set-up at the factory.
The weights should not be adjusted in the field. The
damper may not fully close during minimum outside
air mode.

®

Make-Up Air Unit 19

Check Operation - Recirculating
Units (optional)

NOTE

Blower Start-Up, Steps 1-5 should be performed
before the blower is run.

Recirculation Operation

The recirculation operation option is recommended
when the ventilation equipment provides the primary
source of heating for the space. A minimum of 20%
outdoor air is mixed with up to 80% recirculated air.
Control strategies include 2-position and modulating
dampers. Before the unit is left in service, the
recirculation control system should be tested.

2-Position Damper

A 2-position spring return actuator is used to control
the return air amounts. The damper
moves from open to closed. If
power is cut to the unit, the outdoor
air damper will fail to the closed
position.

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.

Modulating

Potentiometer Control - a modulating spring return
actuator is used to control the return air amounts. The
return air damper modulates from fully open to fully
closed based on a signal from a
remote potentiometer.

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. When
the potentiometer is at 0, the return
air damper will close. When the
potentiometer is at 100, the return
air damper will open. The damper
actuator may take a few minutes to
open or close.

EXHAUST

SUPPL Y

HEA T

RECIRCULA TION

75

80

85

90

70

(OPTIONAL)

65

60

55

BLOWER

MAIN V AL VES

DIRTY FIL TERS

(OPTIONAL)

2-Position

Damper Control

BLOWERS

EXHAUST

(OPTIONAL)

SUPPLY

MAIN VALVES

HEAT

DIRTY FILTERS

70

75

65

80

85

(OPTIONAL)

60

55

90

Potentiometer

Control

Building Pressure Control - a floating point spring
return actuator is used to control
the return air amounts. The return
air damper modulates from fully
open to fully closed based on a
signal from a remote pressure
sensing device.

EXHAUST

SUPPL Y

HEA T

80

85

90

BLOWER

(OPTIONAL)

MAIN V AL VES

DIRTY FIL TERS

70

75

65

(OPTIONAL)

60

55

Turn both knobs to the upper most
pressure setting. You may have
to remove the outdoor pressure

PHOTOHELIC

tap tubing. The return air damper
should close.

Set both knobs at the lowest

Building Pressure

Control

setting and the damper should
open. It may take one to two
minutes for the damper to
reach the desired position.

Pressure

Indicating

Needle

Pressure

Setting

Needles

Reset the correct pressure
limits before starting the unit.

This picture shows a typical
photohelic setting. The needle
in this photo indicates a
negative building pressure.
During correct operation, the
indicating needle will remain
between or near the setting
needles.

Pressure Setting Knobs

Photohelic Gauge

External Signal - a modulating spring return actuator
is used to control the return air amounts. Return air
damper modulates from fully open to fully closed based
on an external 2-10 VDC or 4-20 mA signal (by others).

The return air damper will open with a 10 VDC or 20mA
signal. The return air damper will close with a 2VDC
or 4mA signal. The damper actuator may take a few
minutes to open or close.

Make-Up Air Unit20

®

Operation - Electrical

Electrical Sequence

Exhaust Fan Contact (S1) Closed (optional)

• Power passes to N.C. exhaust overload contact
(ST2 OL) (optional)

• Power passes to exhaust starter(s) (ST2)

• N.O. exhaust starter switches are energized and
closed

• Power passes to exhaust fans

• Exhaust fan(s) (M2) start

Supply Fan Contact (S2) Closed

• Power passes through N.C. field-supplied fire
contact (FSC)

• Power passes through N.O. exhaust fan contact
(ST2) which is closed when the exhaust relay (ST2)
is activated (optional)

• Power passes to N.C. supply overload contact
(ST1OL)

• Power passes through N.C. contact on optional
freeze protection timer (RT4) which remains closed if
the temperature has remained above the set point

• Power passes to optional inlet damper (D1) which
opens

• When damper is fully opened, optional N.O. damper
limit switch (DL1) closes

• Power passes to and energizes supply starter relay
(RF)

• Power passes to N.O. fan contact (RF) which is
energized and closed

• Supply starter (ST1) is energized

• Supply starter contact (ST1) closes and power
reaches and energizes supply fan

• Supply fan (M1) starts

Optional Evaporative Cooling Contact (S4)

Closed*

• N.O. contact on fan relay (RF) is energized and
closed

• Power passes to optional inlet air sensor contact
(TS4) which is energized and closed if the inlet air
temperature is above the set point

• Power passes to and energizes cool relay (RC)

• N.O. contact on cool relay (RC) is energized and
closed

• Power passes to optional evaporative cooling pump
(P1)

Direct Gas Burner Sequence

Supply Fan Contact Closed

• Power passes to the supply fan and heat switch

Heat Contact Closed

• Power passes to the heat relay then to the Flame
Safeguard

Flame Safeguard (FSG) Sequence

• Checks for proper airflow

• Verifies no flame present at burner

• Initiates 10 second prepurge

• Sends power to open pilot gas valve (V1) and
energizes the spark generator (SG)

• Tries for up to 10 seconds to light pilot and confirm
flame

• Powers the main gas valves (V2) open

• Shuts down spark generator (SG)

• Continuously monitors the flame and airflow

• Performs self-diagnostic check every five seconds

Heat Contact (S4) Closed

• Power passes to N.O. fan relay (RF or ST1) which is
energized and closed

• Power passes to optional inlet air sensor contact
(TS4) which is energized and closed if the inlet air
temperature is below the set point

• Power passes to and energizes the heat relay (RH)

• N.O. heat relay contact (RH) closes

• Power passes to and energizes terminal 5 of the
Flame Safeguard (FSG). Power light on FSG is on.

• Power passes to N.C. high limit control contact
(HLC1) which is closed if temperature has remained
below set point

• Power passes to optional N.O. and N.C. high and
low gas pressure contacts (PS4 and PS3), which are
both closed if gas pressure is within the set range

• Power passes to terminal 6 of the Flame Safeguard
(FSG)

• Power begins direct gas burner sequence
(see Direct Gas Burner Sequence)

®

Make-Up Air Unit 21

Troubleshooting

Blower Does Not Operate

Proper supply power at

main disconnect

Yes

24 VAC between

terminals R and X?

Yes

24 VAC between

terminals G and X?

Yes

24 VAC across

terminals 2 and X?

Yes

24 VAC across

terminals 4 and X?

No

No

No

No

No

Check Main Voltage

(See Blower Start-Up – Step 1)

Main Disconnect (DS1) Off

(Turn Main Disconnect DS1 On)

Primary Fuses Blown

(Replace Fuses)

Main Transformer (TR1) Tripped

(Reset Transformer)

Main Transformer (TR1) Defective

(Replace Transformer)

Supply Switch (S2) Off

(Turn Supply Switch (S2) On)

Fire system contact (FSC) tripped/not installed

(Correct/Replace)

Supply Fan Overload (ST1 OL) Tripped

(Reset and check motor amps, reference Blower Start-Up – Step 4)

Optional Exhaust Fan Interlocks (ST2-ST5) Open

(Correct/Replace)

Yes

24 VAC across A2 and A1 on

supply contactor (ST1)

Yes

(Optional) Freeze Protection (RT4) Tripped

(Cycle Power and Reset)

No

(Optional) Damper Limit Switch (DL1) Holding

(Wait for actuator to open fully or adjust limit switch)

(Optional) Damper Limit Switch Jumper Missing

(Install jumper, reference the unit’s ladder diagram for terminals)

Fan Relay (RF) is not energized

(Check for loose connection) (Repair or replace relay)

Broken Fan Belt

(Replace - reference V-Belt Drives in the Maintenance section)

Defective motor or capacitor

(Repair/Replace)

Blown Motor Fuse

(Replace)

One or more legs of 3 phase is out

(Restore missing legs)

At this time the supply contactor (ST1) should

pull in, passing power to the supply motor

and the blower should start.

Make-Up Air Unit22

®

Troubleshooting

Motor Overamps

Air volume too high?

No

Actual static pressure

lower than design?

No

Blower rotation correct?

Yes

Motor voltage correct?

Yes

Motor horsepower too low?

No

Yes

Adjust drives or increase external

static pressure as needed.

(Reference Blower Start-Up – Step 5)

Yes

Adjust drives to reduce blower RPM.

(Reference Blower Start-Up – Step 5)

No

Reverse blower rotation.

(Reference Blower Start-Up – Step 2)

No

Provide proper power supply.

(Reference Blower Start-Up – Step 1)

Yes

Resize motor.

Shorted windings in motor?

No

Everything is working

properly, consult factory.

Yes

Replace motor.

®

Make-Up Air Unit 23

Troubleshooting

Insufficient Airflow

Damper(s) not fully opened?

No

System static losses too high?

No

Blower speed too low?

No

Filters dirty or clogged?

No

Leaks in ductwork?

No

Yes

Adjust damper linkage(s), or replace faulty actuator(s).

(Damper actuators may take a few minutes to open)

Yes

Reduce losses by improving ductwork.

Yes

Adjust drives as needed.

(Reference Blower Start-Up – Step 5)

Yes

Clean or replace filters.

(Reference Filters in the Maintenance section).

Yes

Repair leaks.

Belt slipping?

Yes

Everything is working properly,

consult factory.

Too Much Airflow

Blower speed too high?

No

Filters not in place?

No

Insufficient external static

pressure?

No

Yes

Replace or tighten belt.

(Reference V-Belt Drives in the Maintenance section)

Yes

Adjust drives as needed.

(Reference Blower Start-Up – Step 5)

Yes

Install filters.

Yes

Everything is working properly,

consult factory.

Make-Up Air Unit24

Increase external static pressure.

®

Troubleshooting

Excessive Noise or Vibration

Belts worn or loose?

No

Sheaves aligned?

Yes

Wheel(s) unbalanced?

No

Bearings worn or need

lubrication?

No

Wheel(s) rubbing on inlet?

Yes

Replace worn belts or tighten loose belts.

(Reference V-Belt Drives in the Maintenance section)

No

Align sheaves.

(Reference V-Belt Drives in the Maintenance section)

Yes

Clean and/or balance wheel(s).

Yes

Replace worn bearings or lubricate bearings as needed.

(Reference Bearings in the Maintenance section)

Yes

No

Adjust wheel(s) or inlet.

At this time noise and vibration should

be at acceptable levels.

®

Make-Up Air Unit 25

Troubleshooting

Heater Does Not Operate

Does not attempt to light (No visible spark)

24 VAC between

terminals W1 and X?

Yes

115 VAC between

terminals 102 and 101?

Yes

115 VAC between

terminals 103 and 101?

Yes

115 VAC between

terminals 104 and 101?

Yes

115 VAC between

terminals 106 and 101?

Yes

115 VAC between

terminals 107 and 101?

No

No

No

No

No

No

Heat Switch (S4) Off

(Turn Heat Switch (S4) On)

Heat Switch Not Wired

(Wire Heat Switch (S4))

Primary Fuses Blown

(Replace Fuses)

Main Transformer (TR4) Defective

(Replace Transformer)

(Optional) Inlet Air Sensor (TS4) Holding

(Adjust TS4 setting. Reference Blower Start-Up – Step 6)

Heat Relay (RH) Defective

(Replace Heat Relay (RH))

The power light on the flame safeguard should

blink approximately every 5 seconds as it

performs a self-diagnostics check.

High Limit (HLC1) Tripped

(Reset/Replace High Limit (HLC1))

(Check cause of high limit trip)

(Optional) High/Low Gas Pressure Switch(es)

(PS3 and PS4) Tripped

(Correct gas pressure and reset)

(Reference Direct Gas Start-Up – Steps 2 and 3)

Yes

115 VAC between

terminals 108 and 101?

Yes

Make-Up Air Unit26

Flame safeguard detective.

No

Airflow Switch (PS2) Holding for Proper Airflow

(Correct airflow across burner)

(Reference Direct Gas Start-Up - Step 4)

At this time the heater should attempt to light.

(The pilot light on the flame safeguard should illuminate).

®

Troubleshooting

Heater Does Not Operate

Attempts to light, but no pilot (visible spark)

Check inlet gas pressure.

(Direct Gas Start-Up Step 1)

Gas pressure between the

minimum and maximum shown

on the direct gas label?

Yes

Air in the gas line?

No

Check for proper airflow

(Direct Gas Start-Up Step 4)

Pressure drop across the burner
between 0.625 and 0.675 in. wg?

Yes

Note: The minimum and maximum gas pressures

for your unit are shown on the direct gas label.

(Reference Direct Gas Start-Up – Step 1)

No

Correct gas pressure

(Reference Direct Gas Start-Up – Step 1)

Yes

Purge gas line

(Verify gas at the pilot)

Note: The airflow may satisfy the airflow switch,

but may make lighting the pilot difficult. Adjust the

pressure drop across the burner between 0.625 and

0.675 in. wg shown in Direct Gas Start-Up – Step 4

No

Adjust burner baffles

(Reference Direct Gas Start-Up – Step 4)

Proper spark?

Yes

Check for proper pilot pressure

(Direct Gas Start-Up Step 2)

Pilot pressure correct?

Yes

No

No

Crossed flame and spark wires

(Uncross wires and reconnect)

Incorrect spark plug gap

(Set spark plug gap to 0.062 in.)

Defective spark plug

(Replace spark plug)

Note: A high pilot pressure will make lighting more

difficult. Lower the pilot pressure in increments

until the unit lights. Then set the pilot per the

instruction in Direct Gas Start-Up – Step 2

Adjust the pilot pressure

(Reference Direct Gas Start-Up – Step 2)

With proper airflow, gas pressure and spark,

the unit should light.

If problems remain, consult the factory

®

Make-Up Air Unit 27

Troubleshooting

Heater Does Not Operate

Visible pilot

Measure the flame signal

when there is a visible pilot

Flame signal greater

than 1.25 VDC

Yes

Check for proper airflow

(Direct Gas Start-Up Step 4)

Pressure drop across the burner

between 0.625 and 0.675 in. wg?

Yes

Note: The flame signal should be steady and

above 1.25 VDC with a visible pilot.

(Reference Direct Gas Start-Up – Step 9)

No

Unit is not grounded

(Properly ground unit)

Flame rod is grounding out

(Adjust the flame rod to avoid contact with the burner or the unit)

Cracked porcelain on flame rod

(Replace flame rod)

Note: When the pressure is low or marginal and the unit
begins heating, the air density will change. This can cause
the pressure to drop below the minimum setting. Also, low

airflow can cause the flame to walk out of the burner and

away from the flame sensor, causing the unit to recycle.

No

Adjust burner baffles

(Reference Direct Gas Start-Up – Step 4)

Check the minimum firing rate

(Direct Gas Start-Up Step 7

Is the minimum firing rate

set correctly?

Yes

Does the flame signal

remain constant?

Yes

Note: Burners greater than 36 inches in length use an

interrupted pilot. The pilot is turned off 10 seconds after

lighting the main burner and the flame safeguard monitors the

main flame instead of the pilot flame. If the minimum fire is

set too low, the flame safeguard may not be able to sense it.

No

Adjust the minimum firing rate

(Reference Direct Gas Start-Up – Step 7)

Verify that the low fire start time in set correctly

No

If the signal slowly drops off, typically the airflow is too low

(Reference Blower Start-Up – Step 5)

If it suddenly drops to zero, the flame rod is grounding out

(Adjust the flame rod to avoid contact with the burner or the unit)

If the flame signal is above 1.25 VDC and constant,

the main gas valves will remain open until the call

for heat is interrupted or the unit is shut down.

Make-Up Air Unit28

®

Troubleshooting

Evaporative Cooler does not Operate (Recirculating pump)

Supply fan must be on for cooler to operate

24 VAC between terminals

Y1 and X

Yes

24 VAC between terminal A2 on

Cooling Relay (RC) and X

Yes

115 VAC between terminals

102 and 101

Yes

115 VAC between terminal

114 and 101

No

No

No

Cool switch (S4) off

(Turn cool switch (S4) on)

Cool switch not wired

(Wire cool switch (S4))

Optional inlet air sensor (TS4) holding

(Adjust TS4 setting. Reference Blower Start-Up – Step 6)

Cooling transformer (TR4) defective

(Replace transformer)

External 115 VAC power supply to terminals

102 and 101 not connected

(Connect power supply)

Cooling relay (RC) is not energized

(Check for loose connections)

(Repair or replace relay)

Yes

At this time the evaporative cooler pumps should be on

Water Blows through Evaporative Cooler

Are the headers in place and

located near the entering

air side of the media?

Yes

Water supply to great?

No

Air velocity greater than

specified?

No

No

(Reference Evaporative Cooling Recirculating Start-Up – Step 1)

Yes

Use the main supply valve to reduce the supply of water

Yes

Replace headers and/or move the headers

Reduce the air velocity through the media

(Reference Blower Start-Up – Step 5)

At this time the evaporative cooler should be

operating without water blowing through

®

Make-Up Air Unit 29

Troubleshooting

Maintenance - Routine

Water Wizard™ — Improper Water Supply

NOTE

If the water supply is too low, the media will
continuously appear dry.

NOTE

If the water supply is too high, the media will be
saturated and excessive water will be draining from
the sump tank.

NOTE

Some water drainage is desired to keep the media
flushed, but it should be minimized to utilize the Water
Wizard.

1. Adjust the Manual Supply Valve

Adjust the manual supply valve (refer to Start-Up, Water
Wizard™). If the recommended water pressure does not
provide enough water, increase the pressure until the
desired water supply is achieved. If the recommended
water pressure provides too much water, decrease
the water pressure until the desired water supply is
achieved.

CAUTION

Only proceed to Steps 2 and 3 if Step 1 does not
correct the problem.

CAUTION

Lock-out the gas and the electrical power to the
unit before performing any maintenance or service
operations to this unit.

V-Belt Drives

V-belt drives must be checked on a regular basis for
wear, tension, alignment, and dirt accumulation.

Check the tension by measuring the deflection in the
belt as shown.

Deflection =

Belt Span

Belt Tension

Check the alignment by using a straight edge across
both sheaves as shown.

Belt Span

64

2. Enter Program Mode

Press and hold the

Enter key for three
seconds to enter Program
Mode. The display will read
“Pro” when Program Mode is
active.

Program Display

3. Adjust the On Time Factor

While in the Program Menu, use the Up and

Down keys to navigate through the menu

options until “ont” is displayed.

With “ont” displayed,

press the Enter key to

access the setting.

With the setting displayed,
use the Up and Down keys to
adjust the setting as needed.

On Time Factor Display

Increase the factor to increase the water supply or
decrease the factor to decrease the water supply.

The Enter key must be pressed to save the new On
Time Factor and to return to the Program Menu.

NOTE

Changing the On Time Factor by (1) will change the
water supply by approximately 3%.

4. Exit Program Mode

After 15 seconds of idle time the controller will
automatically exit Program Mode.

Drive Alignment

IMPORTANT

Premature or frequent belt failures can be caused by
improper belt tension, or misaligned sheaves.

• Abnormally high belt tension or drive misalignment
will cause excessive bearing loads and may result
in failure of the fan and/or motor bearings.

• Abnormally low belt tension will cause squealing
on start-up, excessive belt flutter, slippage, and
overheated sheaves.

IMPORTANT

Do not pry belts on or off the sheave. Loosen belt
tension until belts can be removed by simply lifting the
belts off the sheaves.

IMPORTANT

When replacing V-belts on multiple groove drives,
all belts should be changed to provide uniform drive
loading.

IMPORTANT

Do not install new belts on worn sheaves. If the
sheaves have grooves worn in them, they must be
replaced before new belts are installed.

Make-Up Air Unit30

®

Snow Accumulation

Clear snow away from roof mounted units. Keep the
snow clear of the intake and access doors.

Wheels

Wheels require little attention when moving clean air.
Occasionally oil and dust may accumulate on the wheel
causing imbalance. When this occurs the wheel and
housing should be cleaned to assure proper operation.

Bearings

The bearings for our fans are carefully selected to
match the maximum load and operating conditions
of the specific class, arrangement and fan size. The
instructions provided in this manual and those provided
by the bearing manufacturer will minimize any bearing
problems.

IMPORTANT

Lubricate bearings prior to periods of extended
shutdowns or storage and rotate shaft monthly to aid
in corrosion prevention. If the fan is stored more than
three months, purge the bearings with new grease
prior to start-up.

Recommended Bearing Lubrication Schedule

(in months*)

Fan

RPM

25066666

50066654

75065433

1000 53211

1250 53211

1500 52110.5

2000 5 1 1 0.5 0.25

*Suggested initial greasing interval is based on 12 hour per
day operation and 150°F maximum housing temperature.
For continuous (24 hour) operation, decrease greasing
interval by 50%

• If extended grease lines are present, relubricate while in
operation without endangering personnel.

• For ball bearings (operating) relubricate until clean grease
is seen purging at the seals. Be sure not to unseat the seal
by over lubricating.

• For ball bearings (idle) add 1-2 shots of grease up to 2 inch
bore size, and 4-5 shots above 2 inch bore sizes with a
hand grease gun.

• For roller bearings add 4 shots of grease up to 2 inch bore
size, and 8 shots for 2-5 inch bore size with a hand grease
gun.

• Adjust relubrication frequency based on condition of
purged grease.

• A high quality lithium based grease conforming to NLGI
Grade 2 consistency, such as those listed here:

Mobil 532
Mobilux #2

1

⁄2 - 1 11⁄8 - 11⁄2 15⁄8 - 17⁄8 115⁄16 - 23⁄16 27⁄16 - 3

Bearing Bore Size (inches)

Texaco Multifak #2
Texaco Premium #2

B Shell Alavania #2
Exxon Unirex #2

Motors

Motor maintenance is generally limited to cleaning and
lubrication (where applicable).

Cleaning should be limited to exterior surfaces only.
Removing dust and grease build-up on the motor
assures proper motor cooling.

Motors supplied with grease fittings should be
greased in accordance with the manufacturer’s
recommendations.

IMPORTANT

Do not allow water or solvents to enter the motor
or bearings. Motors and bearings should never be
sprayed with steam, water or solvents.

IMPORTANT

Greasing motors is only intended when fittings are
provided. Many motors are permanently lubricated,
requiring no additional lubrication.

Filters

Filter maintenance is generally limited to cleaning and
replacement.

If aluminum mesh filters are installed, they can be
washed in warm soapy water.

An adhesive spray can be added to aluminum mesh
filters to increase their efficiency.

If disposable filters are installed, they can be checked
by holding up to a light source. If light cannot pass
through the filter, it should be replaced.

IMPORTANT

When reinstalling filters, be sure to install them with
the airflow in the correct direction. An airflow direction
arrow is located on the side of the filters.

IMPORTANT

Replacement filters should be from the same
manufacturer and the same size as the original filters
provided with the unit.

®

Make-Up Air Unit 31

Evaporative Coolers

The media should be periodically brushed lightly with
a soft bristle brush in an up and down motion while
flushing with water. This aids in reducing the amount of
mineral build-up.

For large amounts of mineral build-up, clean or replace
the media and increase the water bleed-off or flush rate.

The cooling media has a useful life of 3 to 5 years
depending on the water quality and the bleed-off or
flush rate.

IMPORTANT

When reinstalling the evaporative media, make sure
that it is installed correctly. Reference the drawing
shown below.

IMPORTANT

Replacement media should be from the same
manufacturer and be the same size as the original
media provided with the unit.

45º

Entering Air

Leaving Air

Maintenance - Fall

Start-Up

Repeat the Blower Start-Up Step 5 and Direct Gas
Start-Up Steps 1, 2 and 3. This will ensure that the
gas and air are set properly before the heating season
begins and should lead to trouble free operation all
winter.

High Limit

The high limit switch may have tripped over the
summer; it should be checked and reset if necessary.

Burner

Inspect the burner for accumulation of scales on both
the upstream and downstream sides of the mixing
plates. Any scaling or foreign material should be
removed with a wire brush.

Visually check that all holes in the mixing plates are
clear. If any burner ports are plugged (even partially),
clear them with a piece of wire or another appropriate
tool.

Replace or tighten any loose or missing fasteners on the
mixing plates. Always use zinc plated or stainless steel
fasteners.

Inspect and clean the flame and spark rod. Occasional
replacement of the flame rod and spark rod may be
necessary to ensure optimum unit performance.

Media Orientation

15º

WARNING

Do not enlarge burner ports when clearing a blockage,
performance could be affected.

NOTE

Flame rods can last many years, but because of
thermal expansion of the porcelain, flame rods can fail
over time.

Gas Train

The gas connections, joints and valves should be
checked annually for tightness. Apply a soap and water
solution or other approved leak test solution to all
piping; watch for bubbling which indicates a leak. Other
leak testing methods can be used.

Evaporative Coolers

The water should be shut off and all the lines drained
when the outside temperature drops below 45ºF.

Remove drain plugs for the winter.

Clean all interior parts of any mineral deposits or foreign
materials that may have built-up during the cooling
season.

Replace any worn or non-functioning parts.

Make-Up Air Unit32

®

Reference

Typical Gas Train Layout with Modulating Valve (Pilot Ignition)

Burner Differential

Pressure Sensor

High Gas Pressure

Switch (optional)

Burner Gas

Pressure Test Port

Airflow

Burner Manual

Shut-Off Valve

Modulating

Valve

Pilot Solenoid

Pilot Gas Pressure

Test Port

Low Gas Pressure

Switch (optional)

Safety Shut-Off Valves Regulator

Pilot Regulator

Manual Pilot

Shut-Off Valve

Typical Gas Train Layout with Modulating Regulator (Pilot Ignition)

Burner Differential

Pressure Sensor

Airflow

High Gas Pressure

Switch (optional)

Burner Gas

Pressure Test Port

Pilot Gas Pressure

Test Port

Modulating/Regulator

Valve

Burner Manual

Shut-Off Valve

Safety Shut-Off Valves

Pilot Solenoid

Low Gas Pressure

Switch (optional)

Pilot Regulator

Manual Pilot

Shut-Off Valve

®

Make-Up Air Unit 33

Reference

Typical Control Center Layout

13 23

22

14

18

17

19

20

21

1. Supply Motor Starter — 24 volt magnetic contacts
for starting supply motor.

2. Supply Overload — provides electronic overload
protection to supply motor.

3. Low Voltage Transformer — provides low voltage
to fan/heat/cooling enable controls.

4. Control Terminal Block — provides wiring access
to controls.

5. Fan Relay — allows power to pass to energize
motor starter.

6. High Voltage Enclosure — provides protection from
high voltage circuits.

7. Auxiliary Contact (optional) — provides one
normally closed and one normally open contact for
other equipment.

8. Exhaust Motor Starter (optional) — 24 volt
magnetic contacts for starting exhaust motor.

9. Exhaust Overload (optional) — provides electronic
overload protection to exhaust motor.

10. Transformer Fuse (optional) — provides proper
fusing for cooling transformer.

11. Terminal Block — provides wiring access to high
voltage circuits.

12. Exhaust Fuses (optional) — provides proper fusing
for exhaust fan motor(s).

13. Dirty Filter Switch (optional) — monitors filter
pressure drop, turns on indicating light when
pressure drop is above field-adjustable set point.

14. Inlet Air Sensor (optional) — outdoor air stat that
automatically controls the heating and/or cooling
based on outdoor air temperature.

15. Remote Temperature Selector (optional) — allows

25

27 29

15

26

28

10

11

3

4

24

16

5

6

12

178

29

for remote temperature set point.

16. Heat Relay — allows power to pass to heating
controls.

17. Heating Terminal Block — provides wiring access
to heating controls.

18. Flame Safeguard — monitors flame, shuts down
unit when unsafe conditions are detected.

19. High Limit — prevents unit from discharging air
above a set point.

20. Low Voltage Transformer — reduces voltage to
Maxitrol system.

21. Amplifier — controls modulating valve, assures the
desired temperature is delivered.

22. Spark Generator — provides spark to ignite the
burner.

23. Transformer — provides voltage to Flame
Safeguard and optional evaporative cooling pump.

24. Cooling Relay (optional) — allows power to pass to
cooling controls.

25. Cooling Terminal Block (optional) — provides wiring
access to cooling controls.

26. Low Voltage Transformer (optional) — reduces
voltage to cooling controls.

27. Reset Timer (optional) — resets cooling system to
run a time interval.

28. Auto Drain Relay (optional) — assures supply pump
does not operate during drain interval. Allows
pump to operate in cooling mode.

29. Cooling Timer (optional) — allows for automatic
draining of the evaporative cooling system based
on time schedule.

Make-Up Air Unit34

®

Reference

Unit Model Number ________________________________

(e.g. TSU-230-H50)

Unit Serial Number _________________________________

(e.g. 10111000)

Start-Up Date _____________________________________

Start-Up Personnel Name __________________________

Start-Up Company _________________________________

Phone Number ____________________________________

Pre Start-Up Checklist

Check boxes as items are completed.

 Check tightness of all factory wiring connections
 Verify control wiring wire gauge
 Hand-rotate blower to verify free rotation
 Verify supply voltage to the main disconnect
 Verify the supply gas pressure
 Verify remote controls wiring

Start-Up Blower Checklist

Refer to Blower Start-Up section for further detail.

 Check line voltage L1-L2 ____________

L2-L3 ____________
L1-L3 ____________

 Check blower rotation

 Check for vibration

 Supply fan RPM _____________ RPM

 Motor nameplate amps _____________ Amps

 Actual motor amps L1 _____________
L2 _____________
L3 _____________

 Actual CFM delivered _____________ CFM

Optional Accessories

Refer to Blower Start-Up section, Step #6 for further detail.

 Heating Inlet Air Sensor
________ Actual Setting

• Typical setting 60º-70ºF

Start-Up Direct Gas

Refer to Direct Gas Start-Up section for further detail.

 Check supply gas pressure

_________ Maximum
_________ Minimum
_________ Actual

 Check Pilot Gas Pressure
________ Actual Setting

• Typical 3.0 in. wg

 Set optional High Gas Pressure Switch
________ Actual Setting

• Typical 8.0 in. wg

 Set optional Low Gas Pressure Switch
________ Actual Setting

• Typical 3.0 in. wg

 Set Burner Pressure Differential
________ Actual Setting

• Typical 0.65 in. wg

 Set the maximum firing rate
________ Temp Rise

 Set the minimum firing rate
________ check

 Set the unit’s operating temperature
________ °F

Start-Up Evaporative Cooler (optional)
Refer to Evaporative Cooler Start-Up section for further detail.

 Check media orientation
 Check for proper water flow to distribution

headers

 Check for distribution header orientation to

prevent water spillage

 Cooling Inlet Air Sensor
________ Actual Setting

• Typical setting 75ºF

 Building Freeze Protection
________ Actual Setting

• Typical setting 5 minutes; 45ºF

 Dirty Filter Gauge
________ Actual Setting

• Typical setting varies

®

Make-Up Air Unit 35

Maintenance Log

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Date ___________________Time _____________ AM/PM

Notes: ___________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

_________________________________________________

Our Commitment

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

Specific Greenheck product warranties are located on greenheck.com within the product area tabs and in the
Library under Warranties.

Greenheck Centrifugal Upblast and Sidewall Exhaust catalog
provides additional information describing the equipment, fan
performance, available accessories, and specification data.

®

Phone: [phone] • Fax: [phone] • Parts: 800.355.5354 • E-mail: [e-mail] • Website: www.greenheck.com

464441 • TSU, Rev. 2, February 2015 Copyright 2015 © Greenheck Fan Corporation36

AMCA Publication 410-96, Safety Practices for Users and
Installers of Industrial and Commercial Fans, provides
additional safety information. This publication can be obtained
from AMCA International, Inc. at www.amca.org.