Greenheck Fan VSU User Manual

Part #457831

VSU Make-Up Air Unit

Installation, Operation and Maintenance Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions

product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

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

Model VSU

Optional Service

Platform Shown

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 Electric Code (CEC) in Canada.

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.

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.

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.

Model VSU Make-Up Air Unit

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Receiving

Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notiﬁcation on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be ﬁlled out by the carrier upon arrival and the Trafﬁc Department. If damaged upon arrival, ﬁle claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

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.

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 WD-40® 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.

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.

Model VSU Make-Up Air

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Table of Contents

Building Wall

Concrete Slab

Approx. Stand Feet Locations

Required with service

platform only

Unit Control Side

Installation

Filter/Stand Section . . . . . . . . . . . . . . . . . . . . . .3-4

Burner/Blower Section ..................... 4

Ductwork ................................ 4

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . 5

Direct Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Start-Up

Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Direct Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12

Operation

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting

Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-17

Maintenance

Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19

Fall .................................... 19

Reference

Typical Control Center Layout . . . . . . . . . . . . . . 20

Typical Gas Train Layout ................... 20

Start-Up Check List . . . . . . . . . . . . . . . . . . . . . . 21

Maintenance Log . . . . . . . . . . . . . . . . . . . . . .22-23

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

1. Filter/Stand Section

The unit should be mounted on a concrete slab four inches thick with a proper gravel drainage bed. Allow one foot on each side of the unit as shown in the Concrete Slab and Unit Footprint drawing below.

Concrete Slab Dimensions

Housing Size 40

A 78

B 135

C 43

D 54

E 111

All dimensions are shown in inches.

Concrete Slab and Unit Footprint

The ﬁlter section ships inside the stand (see drawing on next page). After the unit is set on the slab, it can be anchored through the stand feet. The unit footprint of the unit is shown above.

Greenheck recommends having a three foot clearance on the controls side and a two foot clearance on the other three sides of the unit for serviceability.

The following statement pertains to direct gas units only. When ordered with insulation, this unit has a

zero-inch clearance tolerance to any combustibles, on all sides and top. Without insulation, the clearance tolerance is six inches.

Model VSU Make-Up Air

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Installation continued

2. Burner/Blower Section

Use a crane and a spreader bar hooked to the factory lifting lugs (shown below) to lift and center the unit onto the ﬁlter stand section. The sections can be caulked together, but it is not needed with the water kickouts provided with this section.

4. Complete Installation

A typical horizontal discharge installation is shown. Gas and/or electrical lines can be connected at this time.

For upblast units, a duct elbow may be needed to turn the ductwork into the building. Follow proper ductwork methods recommended by AMCA to make this elbow to minimize duct losses.

3. Install Ductwork

This table shows the duct sizes and straight lengths recommended for optimal performance (AMCA Publication 201-90). Using duct sizes less than recommended will affect fan performance. Good duct installation practices should be followed for the remaining ductwork. See the drawings in the Dimensional Data section for duct locations.

Recommended Supply Ductwork Sizes

VSU

Blower Size

220 68 x 26 inches 117 inches

Model VSU Make-Up Air

Duct

Size

Straight Duct

Length

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Dimensional Data

Upblast Discharge Elevation View

F H

Lifting Lugs

Gas Controls*

Electrical Controls

24^

*Direct Gas units only ^Standard factory clearance. Additional stand heights are available from the factory.

Unit Dimensional Data Blower Dimensional Data Unit Weight

Housing

Size

40 111 54 95 144 (20) 20x25 220 26 20 68 12 2000 lbs. 700 lbs.

All dimensions are shown in inches. * Weights will vary with blower and horsepower.

A B C E Filters

Blower

Size

F H J K Blower/Heater* Stand/Filter

Model VSU Make-Up Air

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Installation of Direct Gas Piping

T o

Controls

Gas Cock

From

Gas

Supply

6 in. Trap

1/8 in. Plugged Ta p

Ground Joint Union

IMPORTANT

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

WARNING

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

WARNING

If pressure testing in excess of 1/2 psig (3.5 kPa), the heater and manual shutoff valve must be disconnected from the supply gas line.

WARNING

If pressure testing at or below 1/2 psig (3.5 kPa), the heater must be isolated from the supply gas line by closing its manual shutoff valve.

IMPORTANT

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

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.

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

Direct Gas Nameplate

AGAINST

SCFM “ W.C.

CONTE

Minimum gas pressure for maximum output

MIN BTU/HR BTU/H MIN

MIN GAS PRESSURE FOR MAX OUTPUT

“ W.C.

PRESSION DE GAZ MIN POUR PUISSANCE MAX

MAX GAS PRESSURE

“ W.C.

PRESSION DE GAZ MAX

MAX BURNER PRESSURE DROP

“ W.C.

PERTE MAX DE PRESSION DANS LE BRULEUR

DESIGN ∆T ∆T NORMALE

Maximum gas pressure

“ W.C.

PSI

EXTERNAL STATIC PRESSURE

PRESSION STATIQUE EXTERIEURE

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 (by others) is required to reduce the pressure. The regulator must have a listed leak limiting device or it must be vented to the outdoors.

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 Greenheck.

Model VSU Make-Up Air

Supply Gas Line

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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

To Burner

Safety

Shut-off Valves

From Supply

Optional Vent Line

5. Test the System for Leaks

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

WARNING

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.

Model VSU Make-Up Air

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Start-Up - Blower

SUP HP

MCA

EXH HP

MOP

VOLTS HZ PH

Unit’s Total MCA

Voltage, Hertz, Phase

SUP HP

MCA

EXH HP

MOP

VOLTS HZ PH

Voltage, Hertz, Phase

Blower

Housing

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 EQUIPMENT REQUIRED

Required and recommended tools. Equivalent products may be used.

Voltage & Amperage Meter

Thermometer

Micro Amp Meter

U-Tube Manometer

Tachometer

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

Manufacturer: Fluke Model: 177 Phone: 1-800-44-FLUKE www.fluke.com

Manufacturer: Fluke Model: 50 Phone: 1-800-44-FLUKE www.fluke.com Manufacturer: Fluke Model: 116 Phone: 1-800-44-FLUKE www.fluke.com Manufacturer: Dwyer Model: Slack Tube Phone: 1-219-897-8000 www.dwyer-inst.com Manufacturer: Monarch Model: Pocket Tach 100 Phone: 1-800-999-3390 www.monarchinstrument.com

WARNING

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.

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.

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.

1. Check the Voltage

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

Electrical Nameplate

Model VSU Make-Up Air

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