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Greenheck Fan IG/IGX Make-Up Air Unit 470656 User's Manual

1. MCA MOP Unit s Total MCA Electrical Nameplate 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 Torque field connections to 20 in lbs 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 accessories e Selectra Stat e Dirty Filter Indicator e Room Override e TSCP e Blower Switch e KSCP e Heat Switch e Economizer Activator e Indicating Lights Room Stat NOTE Wiring to the Selectra Stat or room override should be in separate conduit or run with shielded cable NOTE The TSCP and KSCP remote panels have number to number wiring Model IG IGX Make Up Air J 6 Wire the Evaporative Cooler optional Reference the ladder diagram on the inside of the control center door for correct wiring of the pump and the optional water valves NOTE Large evaporative coolers may require a separate power supply 7 Install Economizer Sensors optional All economizer options EC require an outdoor air temperature or ent
2. J Model IG IGX Make Up Air 7 Install Supply Unit Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the unit on the extension equipment support s Use self tapping sheet metal screws to fasten the unit to the extension equipment support s Installing Supply Unit The use of all lifting lugs and a set of spreader bars is mandatory when lifting unit NOTE Be sure to complete the outdoor venting installation instructions NOTE Some units come with the weatherhood attached and step 8 may not apply 8 Assemble and Attach Weatherhood The weatherhood can now be assembled and or attached to the unit Detailed assembly instructions can be found with the weatherhood If the optional evaporative cooling module was selected this step does not apply refer to the Installation Instructions for the Optional Evaporative Cooling Module section page 7 9 Seal Weatherhood Seam Using an appropriate sealant seal the seam between the weatherhood and the unit Complete Combination Installation Installation of Evaporative Cooling Module optional NOTE Small evaporative coolers ship attached to the base unit and require no additional mounting 1 Locate Equipment Support s 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 necessa
3. Factory High Wiring ete space Low Pressure Tap to outside Connections for Photohelic Gauge 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 Typical settings are 0 0 in wg for the lower and 0 10 in wg for the upper pressure setting Pressure Indicating Needle j Pressure Setting Needles Pressure Setting Knobs Typical Photohelic Gauge Settings 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 do so could result in serious injury or death and damage to equipment SPECIAL TOOLS REQUIRED e Voltage Meter with wire probes e Amperage Meter e Micro Amp Meter e Pressure Gauges refrigerant e Tachometer e Thermometer e Incline manometer or equivalent WARNING Check the housing blower and ductwork for any foreign objects be
4. Reference Model IG 16 Stage Controller Provides 8 stage control of the furnace 8 1 Staged 17 Airflow Switch Monitors the airflow inside the heat exchanger 18 Ignition Controller Controls the ignition of the furnace Maintains safe operation of the furnace 19 Evaporative Cooling Fuses Optional Provides proper fusing to evaporative cooling pump and controls 20 Transformer Fuse Optional Provides proper fusing for evaporative cooling transformer 21 Cooling Relay Optional Allows power to pass to cooling controls 22 Reset Timer Optional Resets cooling system to run a time interval This is a typical blower control center the control 23 Auto Drain Relay Optional Assures supply center in your unit may be different Reference the pump does not operate during drain interval ladder diagram on the inside of the control center Allows pump to operate in cooling mode BOGE or A Unit Spee Winna dagran 24 Cooling Timer Optional Allows for automatic 1 Supply Motor Starter 24 volt magnetic contacts draining of the evaporative cooling system based for starting supply motor on time schedule 2 Supply Overload
5. 24 VAC is supplied to ignition controller IC1 and amplifier AMP If the discharge air sensor TS2 reading is less than the temperature selector TS3 setting the amplifier AMP sends a call for heating to the ignition controller IC1 4 Ignition Controller IC1 Sequence of Operation The N O contact on air proving switch PS2 is open The ignition controller IC1 energizes the combustion blower relay CR N O contact on combustion blower relay CR closes Power passes to and energizes the combustion blower CM The N O contact on air proving switch PS2 closes The ignition controller IC1 begins a 15 second pre purge The high fire relay RT3 is energized and the N O contact on high fire relay RT3 closes The main gas valve MV fully opens 100 and the modulating gas valve MOD opens to high fire Igniter begins sparking 10 second trial for ignition begins The furnace will light at high fire 100 When the flame is detected the igniter stops sparking The furnace will remain at high fire 100 for at least 10 seconds High fire contact RT3 will open Furnace modulates to maintain the temperature selector TS3 set point 5 High Fire Low Fire Sequence of Operation 6 The furnace lights at and remains at high fire 100 for 10 seconds If the discharge temperature sensor TS2 reading is above the temperature selector TS3 set point and furnace is not at low fire the amplifier will
6. 3704 3367 3086 2849 2646 2469 2315 2179 2058 1949 1852 300 240 8889 7407 6349 5556 4938 4444 4040 3704 3419 3175 2963 2778 2614 2469 2339 2222 350 280 10370 8642 7407 6481 5761 5185 4714 4321 3989 3704 3457 3241 3050 2881 2729 2593 400 320 11852 9877 8466 7407 6584 5926 5387 4938 4558 4233 3951 3704 3486 3292 3119 2963 500 400 14815 12346 10582 9259 8230 7407 6734 6173 5698 5291 4938 4630 4357 4115 3899 3704 600 480 NA 14815 12698 11111 9877 8889 8081 7407 6838 6349 5926 5556 5229 4938 4678 4444 700 560 NA NA 14815 12963 11523 10370 9428 8642 7977 7407 6914 6481 6100 5761 5458 5185 800 640 NA NA NA 14815 13169 11852 10774 9877 9117 8466 7901 7407 6972 6584 6238 5926 1050 840 NA NA NA NA NA NA 14141 12963 11966 11111 10370 9722 9150 8642 8187 7778 1200 960 NA NA NA NA NA NA NA 14815 13675 12698 11852 11111 10458 9877 9357 8889 Model IG IGX Make Up Air BA Reference Start Up Checklist Start Up Checklist Unit Model Number e g IGX 120 H32 DB 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 tightnes
7. 4 1 Modulation 005 30 31 Optional Economizer 200000 0e 32 Optional Evaporative Cooling 33 Optional Water Wizard 34 35 Operation Optional Water Wizard 000 eae 35 Optional VAV Units 20000 eee 36 Optional Recirculating Units 55 37 A Sequence of Operation Furnace 271 Staged arrra ana Fag ee eee es 38 2 1 Modulation 2 2 0 0 ccc eee eee 39 40 Operation of Controller 4 1 Modulation 8 1 Staged Controller 40 41 Sequence of Operation Furnace 4 1 Modulation 0 000 c ee eee 41 42 ST Staged asserted REE EEE 43 44 Ignition Controller 0 cee ee 44 ECONOMIZED siisocsciabacceaeieomscdena Faas 45 Troubleshooting BIOWGF scias 9 stain sews ees we on sea worn 46 Motor Over AMPS 0000 cece cece eee 47 Insufficient Too Much Airflow 48 Excessive Noise Vibration 49 Furnace Staged 220 0c eee eee eee 50 2 1 Modulation 005 51 4 1 Modulation 005 52 53 8 1 Staged bcc een ee teeta ie 54 55 Optional Evaporative Cooling 56 Optional Water Wizard 2 00005 57 Maintenance Routine 2 ssc eee cates eee eee eee eas 58 59 Falzes reaa ah ape Sean ate eee eae 60 61 Reference Vent Connections 0 0 cece eee 62 Model IG Single or 2 Stage 6 0c eee eee 63 GED STAG ers udrea ale geese weds 6
8. Excessive Noise or Vibration Belts worn or loose Sheaves aligned Yes Wheel s unbalanced Bearings worn or need lubrication Yes Yes Yes Yes Replace worn belts or tighten loose belts Reference V Belt Drives in the Maintenance section Align sheaves Reference V Belt Drives in the Maintenance section Clean and or balance wheel s Replace worn bearings or lubricate bearings as needed Reference Bearings in the Maintenance section Adjust wheel s or inlet At this time noise and vibration should be at acceptable levels Model IG IGX Make Up Air EX Troubleshooting Single or 2 1 Stage Furnace Will Not Light 24 VAC across R and X No Main disconnect DS1 open or defective he Close repair or replace Main transformer TR1 fault Replace main transformer 24 VAC across W1 and X No Yes Heat Switch S4 open Turn Heat Switch S4 on 24 VAC across 22 and 21 Ne Yes Heating Transformer TR2 Fault Replace heating transformer 24 VAC across 24 VAC and No 21 on SC1 controller Optional inlet air sensor TS4 open Adjust setting Reference Blower Start Up Step 6 Heat relay RH is not energized No Check for loose connections Repair or replace heat relay RH 24 VAC across A and 21 Discharge air selector TS2 improperly set or faulty Yes Adjust setting see Staged Start Up or replace sensor Furnace stage one contact SC1 defective stage only Yes Repla
9. This picture shows a typical photohelic setting Typical settings are 0 0 in wg for the lower and 0 10 in wg for the upper pressure setting The needle in this photo indicates a negative building pressure During correct V operation the indicating Pressure Setting Knobs needle will remain between or near the setting needles Pressure Indicating Pressure Setting Needle Needles 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 close with a 10 VDC or 20 mA signal The return air damper should open with a 2 VDC or 4mA signal The damper actuator may take a few minutes to open or close Model IG IGX Make Up Air Sequence of Operation 2 1 Staged Sequence 1 Exhaust Fan Contact S1 Manually Closed 0 N e ew ptional Power passes through N C contact on exhaust fan overload ST2 OL which is closed if exhaust fan M2 has not overloaded Power passes to exhaust fan starter ST2 N O contact on exhaust fan starter ST2 is energized and closed Power passes to and energizes exhaust fan M2 Supply Fan Contact S2 Manually Closed Power passes through N C field supplied fire contact FSC Power passes through optional N O contact on exhaust fan starter ST2 which is closed when the o
10. natural gas and 10 in wg for LP gas If needed use the high fire adjustment screw on the combination gas valve to adjust the high fire manifold pressure Counterclockwise rotation will decrease the gas pressure and clockwise rotation will increase the gas pressure High Fire Adjustment Low Fire Adjustment High Fire Terminal 3 Send Unit to Low Fire Remove and isolate the wire from the high fire terminal on the combination gas valve to send the unit to low fire 4 Check the Low Fire Manifold Pressure Using a manometer measure the burner manifold pressure at the manifold pressure test port Refer to the Gas Train Layout in the Reference section for the test port location Two Stage Manifold Pressure in wg Natural Gas LP The pressure on low fire should be 7 8 in wg for natural gas and f Low Fire 7 8 2 1 2 2 1 2 in wg for LP gas High Fire 3 1 2 10 If needed use the low fire adjustment screw on the combination gas valve to adjust the low fire manifold pressure Counterclockwise rotation will decrease the gas pressure and clockwise rotation will increase the gas pressure Once the low fire manifold pressure is set reattach the high fire wire to the high fire terminal 5 Reset the Temperature Setting Reset the temperature setting on the temperature selector to the desired setting EX Model IG IGX Make Up Air Start Up 8 1 Staged Control IMPORTANT 8 1 staged furnaces use
11. Connection Location Exhaust Air Outlet C wer Combustion Air Intake F Airflow D D c oA E Ay teas k B 4 x Flue Connection Size diameter in inches IGX Furnace Size z Housing MBH A B Cc D Standard Non Concentric Concentric Exhaust Exhaust Intake Exhaust Intake 100 4 45 8 45 23 43 27 90 4 0 4 0 4 0 4 0 6 0 12 150 4 45 8 45 23 43 27 90 4 0 4 0 4 0 4 0 6 0 200 5 64 9 64 23 97 30 90 6 0 6 0 6 0 6 0 8 0 250 5 64 9 64 23 97 30 90 6 0 6 0 6 0 6 0 8 0 150 4 45 8 45 29 38 33 85 4 0 4 0 4 0 4 0 6 0 200 5 67 9 67 24 97 31 90 6 0 6 0 6 0 6 0 8 0 250 5 67 9 67 24 97 31 90 6 0 6 0 6 0 6 0 8 0 22 300 5 67 9 67 24 97 31 90 6 0 6 0 6 0 6 0 8 0 350 5 67 9 67 19 01 25 94 6 0 6 0 6 0 6 0 8 0 400 5 67 9 67 19 01 25 94 6 0 6 0 6 0 6 0 8 0 500 5 67 9 67 24 97 31 90 6 0 6 0 6 0 6 0 8 0 600 5 67 9 67 24 97 31 90 6 0 6 0 6 0 6 0 8 0 350 5 96 9 71 28 31 35 24 6 0 6 0 6 0 6 0 8 0 400 5 96 9 71 28 31 35 24 6 0 6 0 6 0 6 0 8 0 500 5 96 9 71 28 31 35 24 6 0 6 0 6 0 6 0 8 0 32 600 5 96 9 71 28 31 35 24 6 0 6 0 6 0 6 0 8 0 700 5 96 9 71 28 31 35 24 6 0 6 0 6 0 6 0 8 0 800 5 96 9 71 28 31 35 24 6 0 6 0 6 0 6 0 8 0 1050 5 96 9 71 28 31 35 24 6 0 6 0 6 0 6 0 8 0 1200 5 96 9 71 28 31 35 24 6 0 6 0 6 0 6 0 8 0 Dimensions are in inches Dimensions A and C are not needed for standard venting A Model IG IGX Make Up Air A Reference Model IG 16 Stage Controller Provides single or two stage control of the furnace Single or 2 Stage 17 Airflow
12. Line and Thermal Expansion Valve TEV By Others Liquid line openings vary by coil size and circuiting and are field supplied Follow the TEV recommendations for installation to avoid damaging the valve If the valve is externally equalized use a tubing cutter to cut off the plugged end of the factory installed equalizer line Use a de burring tool to remove any loose metal from the equalizer line and attach it to the TEV If the valve is internally equalized the factory installed equalizer line can be left as is Suction Header Coil Distributor Equalizer Line Liquid Line Nozzle Thermal Expansion Valve by others Suction Line Remote Sensing Bulb Straps Suction Connection General Installation 5 Mount the Remote Sensing Bulb By Others The expansion valve s remote sensing bulb should be securely strapped to the horizontal run of the suction line at the 3 or 9 o clock position and insulated 6 Check Coil Piping for Leaks Pressurize the coil to 100 psig with dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes If the coil holds the pressure the hook up can be considered leak free If the pressure drops by 5 psig or less re pressurize the coil and wait another 10 minutes If the pressure drops again there is likely on
13. Provides electronic overload 25 Dirty Filter Switch Optional Monitors filter protection to supply motor pressure drop Turns on indicating light when 3 Low Voltage Transformer Provides low voltage pressure drop is above field adjustable set point to fan heat cooling enable controls staged a aia ie furnace controls and optional evaporative cooling A Gas Spn controls Gas Staged Gas j a y i n Pressure Valves onnecHonN 4 Control Terminal Block Provides wiring access Test Port A Gas Pressure to controls ee L Test Port 5 Fan Relay Allows power to pass to energize Manifold Large motor starter N Manifold 6 Control Terminal Block Provides wiring access to fan heat cooling enable controls 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 Exhaust Fuses Optional Provides proper fusing for exhaust fan motor s 11 Building Freeze Protection Timer Optional Prevents the discharge of cold air into the building 12 Heat Relay Allows power to pass to heating controls 13 Low Voltage Transformer Provides low voltage to the ignition controller 14 Heating Terminal Block Provides wiring access to heating controls 15 Inlet Air Sensor Opti
14. Switch Monitors the airflow inside the heat exchanger 18 Ignition Controller Controls the ignition of the furnace Maintains safe operation of the furnace 19 Evaporative Cooling Fuses Optional Provides proper fusing to evaporative cooling pump and controls 20 Transformer Fuse Optional Provides proper fusing for evaporative cooling transformer 21 Cooling Relay Optional Allows power to pass to cooling controls 22 Reset Timer Optional Resets cooling system to run a time interval This is a typical blower control center the control 23 Auto Drain Relay Optional Assures supply center in your unit may be different Reference the pump does not operate during drain interval ladder diagram on the inside of the control center Allows pump to operate in cooling mode door for a unit specific wiring diagram 24 Cooling Timer Optional Allows for automatic draining of the evaporative cooling system based on time schedule 25 Dirty Filter Switch Optional Monitors filter pressure drop Turns on indicating light when pressure drop is above field adjustable set point 1 Supply Motor Starter 24 volt magnetic contacts for starting supply motor 2 Supply Overload Provides elec
15. blower CM The N O contact on air proving switch PS2 closes Power passes to and energizes air proving switch relay R9 N O contacts on air proving switch R9 closes The ignition controller IC completes a 30 second pre purge The main gas valve MV fully opens 100 Igniter begins sparking 10 second trial for ignition begins The furnace will light The stage controller SC1 will choose which stage to light the furnace at based on the discharge air temperature setting dtS FX Program Menu and the outside air temperature TS1 When the flame is detected the igniter stops sparking The furnace will remain at high fire 100 for 20 seconds The stage controller SC1 will stage the main gas valves MV as needed between low fire high fire and off If the furnace is at low fire and the discharge temperature sensor TS2 reading remains above the discharge air temperature setting dtS FX Program Menu for more than six minutes the furnace will shut down Staging Control Sequence of Operation If the discharge temperature TS2 is below the discharge air temperature set point dtS FX Program Menu the furnace will stage up If the discharge temperature TS2 is above the discharge air temperature set point dtS FX Program Menu the furnace will stage down If the discharge temperature TS2 is above the discharge air temperature set point dtS FX Program Menu and the furnace is at low fire the furnace will sh
16. corrosive atmosphere To prevent premature heat exchanger failure do not locate unit where chlorinated halogenated or acid vapors are present When units are installed in tightly sealed buildings provisions should be made to supply an adequate amount of infiltration air from the outside The rule of thumb is that an opening of one square inch should be provided for every 1000 BTUs per hour of input rating Vent terminals must be used Construct the vent system as shown in the drawings Reference the Vent Pipe Diameter table and Exhaust Vent Pipe table for additional details Exterior lt Wall A 12 inch minimum Pitch vent pipe downward from furnace Y4 inch per foot m A e EXHAUST Exhaust Vent Terminal lt Air Inlet K Standard Indoor Venting Horizontal A 12 inch minimum B 12 inch minimum but should size E ones y lt Exhaust Vent Terminal B A Roof Line Le gt gt lN 2 5 q a lt A gt lt Air Inlet Standard Indoor Venting Vertical Vent Pipe Diameter Select the vent pipe diameter Use only the specified pipe diameter Furnace Size Exhaust Pipe Diameter MBH inches 75 175 4 200 400 6 Installing Exhaust Vent Pipe Install the vent pipe with a mi
17. discharge air sensor TS2 set point the furnace stage 1 contact SC1 will open and the furnace will shut down If the furnace is at low fire 50 and the discharge temperature is below the discharge air sensor TS2 set point the furnace stage 2 contact SC2 will close and the furnace will go to high fire 6 Optional Evaporative Cooling Contact S4 Closed N O contact on fan relay RF is energized and closed Power passes through N O contact on optional inlet air sensor 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 evaporative cooling pump P1 If DX or chilled water coils are used rather than an evaporative cooler the cooling sequence of operation will depend on the coil controls Cooling coil controls are supplied by others Sequence of Operation 1 0 2 1 Modulation Sequence Exhaust Fan Contact S1 Manually Closed ptional Power passes through N C contact on exhaust fan overload ST2 OL which is closed if exhaust fan M2 has not overloaded Power passes to exhaust fan starter ST2 N O contact on exhaust fan starter ST2 is energized and closed Power passes to and energizes exhaust fan M2 Supply Fan Contact S2 Manually Closed Power passes through N C field supplied fire contact FSC Power passes through optional N O cont
18. during drain interval Allows pump to operate in cooling mode Cooling Timer Optional Allows for automatic draining of the evaporative cooling system based on time schedule Dirty Filter Switch Optional Monitors filter pressure drop Turns on indicating light when pressure drop is above field adjustable set point Test Port 3 4 inch i Gas Supply Connection Staged Gas Valve Modulating Gas Valve Model IG IGX Make Up Air J Reference Model IG 4 1 Modulation This is a typical blower control center the control center in your unit may be different Reference the ladder diagram on the inside of the control center door for a unit specific wiring diagram 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 modulating furnace controls and optional evaporative cooling controls 4 Control Terminal Block Provides wiring access to controls 5 Fan Relay Allows power to
19. failure do not locate units where chlorinated halogenated or acid vapors are present Units with an economizer are designed for either 0 30 outside air HV 1 31 75 outside air HV 2 or 100 return air HV 3 Refer to the CAPS submittal for the unit s ventilation type NOTE HV 1 and HV 2 use economizer controls EC or MB NOTE Economizer control may use outside air temperature reference EC 1 outside enthalpy reference EC 2 differential temperature reference EC 3 or differential temperature reference EC 4 Economizer control may use a potentiometer MB 1 2 10 VDC signal MB 2 4 20mA signal MB 3 or a manual quadrant MB 4 1 Verify Sensor Installation All economizer options EC require an outdoor air temperature or enthalpy sensor to be field installed inside of the weatherhood and field wired to terminals SO and SO on the economizer Economizer options EC 3 and EC 4 require an outdoor air temperature or enthalpy sensor to be field installed in the return air duct and field wired to terminals SR and SR on the economizer Verify that all economizer sensors needed for your application are properly installed and wired 2 Set Minimum Outside Air Set the minimum outside air position HV 1 is designed for 0 30 outside air and HV 2 is designed for 31 75 outside air All economizer options EC 1 EC 2 EC 3 and EC 4 and option MB 1 use a potentiometer to set the minimum outside air
20. farther in Inspect and clean the drain pan to prevent the growth of algae and other organisms IMPORTANT Be sure to read and follow the manufacturer s recommendations before using any cleaning fluid CAUTION Caution should be used to avoid injury when venting the coil High pressure and or high temperature fluids can cause serious injuries Model IG IGX Make Up Air EX Maintenance Fall High Limit The high limit switch may have tripped over the summer it should be checked and reset if necessary CAUTION Lock out the gas and the electrical power to the unit before performing any maintenance or service operations to this unit Gas Line Remove the drip leg and clean any liquid or debris that may have accumulated Once the drip leg is cleaned reattach it Gas Train The gas connections joints and valves should be checked annually for tightness Apply a soap and water solution to all piping watch for bubbling which indicates a leak Other leak testing methods can be used Vent Piping Remove any debris from the drip legs on the combustion air and exhaust pipes Burners and Orifices Before each heating season examine the burners and gas orifices to make sure they are clear of any debris such as spider webs etc Clean burner as follows e Turn off both electrical and gas supplies to the unit e Disconnect union between manifold and gas valve e Remove manifold and burner assembly e Inspect and cle
21. modulation controller 21 Transformer Fuse Optional Provides proper fusing to low voltage transformer 22 Cooling Relay Optional Allows power to pass to cooling controls 23 Reset Timer Optional Resets cooling system to run a time interval 24 Auto Drain Relay Optional Assures supply pump does not operate during drain interval Allows pump to operate in cooling mode 25 Cooling Timer Optional Allows for automatic draining of the evaporative cooling system based on time schedule 26 Dirty Filter Switch Optional Monitors filter pressure drop Turns on indicating light when pressure drop is above field adjustable set point Modulating Gas Pressure Gas Valve p Test Port L o i lt 3 4 inch Manifold y igi pet ee Staged Connection o Gas Valve A Reference Model IGX 16 Cooling Relay Optional Allows power to pass to cooling controls Blower Control Center 17 Reset Timer Optional Resets cooling system to run a time interval 18 Auto Drain Relay Optional Assures supply pump does not operate during drain interval Allows pump to operate in cooling mode 19 Cooling Timer Optional Allows for automatic draining of the evaporative cooling system based on time schedule 20 Dirty Filter Switch Optional Monitors filter pressure drop Turns on indicating light when pressure drop is above field
22. 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 5 Air Volume Measurement amp Check Measure the unit s air volume CFM and compare it with its rated air volume If the measured air volume is off adjust the fan s RPM by changing adjusting the drive Model IG IGX Make Up Air EX 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 e Heating Inlet Air Sensor Typical settin
23. of Arrangement DB HZ 1 Install Curb and or Equipment Support s Position curb equipment support s on the roof reference the CAPS submittal for placement of curb equipment support s in relation to the unit Verify that unit supports are level shim if necessary Attach curb to roof and flash into place Attach the equipment support s to the roof remove metal cover flash to wooden nailer and reinstall cover Equipment Support Roof Curb and Equipment Support 2 Install Ductwork 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 Reference the CAPS submittal for ductwork sizes Supply Air Ductwork Arrangement DB only The use of a duct adapter is recommended ona downblast DB arrangement to align the ductwork with the supply unit The duct adapter is only a guide and is not to be used as support for the ductwork 3 Apply Sealant Apply an appropriate sealant around the perimeter of the curb and duct adapter s to isolate fan vibration and prevent water penetration 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 equipment support s Use self tapping sheet metal screws to fasten the unit to the curb equipment support s Setting Unit NOTE The use of all lifting lugs and a set of spreader bars
24. of these 92722 eo 2 2 a controllers The following are the green LED codes of operation GREEN LED Indications NORMAL OPERATION Flash Code Flash Code Indication Steady on Flame detected main burner on 0 1 second on off Controller is sparking 0 5 second on off Purge or inter purge time 0 5 second on 4 5 second off Retry or recycle time The following are the red LED codes of error RED LED Indications ERROR OPERATION Flash Code Flash Code Indication Blinks 1 time No flame in trial time error Blinks 2 times Flame sense circuit error Blinks 3 times Valve circuit error Blinks 4 times Flame loss error Blinks 6 times Airflow error Blinks 7 times Ground or internal error Steady on Line voltage frequency error Operation Economizer NOTE Only models IG HV and IGX HV with options EC 1 2 3 or 4 use an economizer Option EC 1 Outside Air Temperature Reference This option uses one dry bulb temperature sensor field installed in the inlet of the unit A second dry bulb temperature sensor is factory installed in the discharge of the unit After a call for cooling the outside air temperature is compared to the economizer set point If the outside air temperature is above the economizer set point the economizer sends the dampers to the minimum outside air position and calls for mechanical cooling If the outside air temperature
25. 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 Water Wizard Valves when provided by manufacturer A Mfg ASCO gt Unit Assembly Solenoid De Energized Model Number ean kak Type Position Diameter Qty Number Number IGX 461262 8210G2 Supply Closed hee 1 H12 H22 852370 Ls 383086 8210634 fi open Vich 4 lt 9000 cfm L Drain 12 7 mm 383088 821069 Supply Closed re 1 IGX H32 29000 cfm 852371 Supply 1 2 inch 383086 8210G34 Line Open 12 7 mm 1 Drain Part numbers subject to change 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 roofline 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 NOTE Solenoid s may be provided by manufacturer if ordered or by others CAUTION Any wiring deviations may result in persona
26. switch on the remote control panel to each position and confirm that the fan speed adjusts accordingly Modulating Potentiometer Control a variable frequency drive is controlled by input from a remote m speed selector potentiometer This Sm O unit allows easy manual adjustment of make up air volumes To test potentiometer operation turn the potentiometer to the two extremes om o 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 Control EJ Model IG IGX Make Up Air Building Pressure Control a variable frequency drive is Breu O controlled according to input from a gm O gt pressure sensing device Turn both knobs to the upper most pressure setting You may have to remove the outdoor pressure tap tubing VAV systems should go to 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 photohelic setting Typical settings are 0 0 in wg for the lower pressure setting and 0 10 in wg for the upper pressure setting The needle indicates a negative building pressure During correct operation the indicating needle will remain between or near the s
27. the cooling sequence of operation e Power passes to and energizes the combustion will depend on the coil controls Cooling coil controls are blower CM sending it to high speed supplied by others e The N O contact on air proving switch PS2 and high pressure switch PS5 closes e The ignition controller IC1 begins a 15 second pre purge e The main gas valve MV fully opens 100 and the modulating gas valve MOD opens to high fire e Igniter begins sparking e 10 second trial for ignition begins e The furnace will light at high fire 100 e When the flame is detected the igniter stops sparking e The furnace will remain at high fire 100 for 30 seconds e The modulation controller SC1 will adjust the modulating gas valve MOD and the combustion blower CM as needed between low and high fire e The modulating controller SC1 will monitor the high pressure switch PS5 and run the furnace at low fire if the high pressure switch is not satisfied 5 High Fire Low Fire Sequence of Operation e The furnace lights at and remains at high fire 100 for 30 seconds e If the discharge temperature sensor TS2 reading is above the discharge temperature setting dtS FX Program Menu and the furnace is not at low fire the modulating controller SC1 will adjust the modulating gas valve MOD down until the discharge temperature sensor TS2 reading equals the discharge temperature setting dtS FX Program Menu e If th
28. 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 reported to the Traffic Department If damaged upon arrival file claim with carrier Any physical damage to the unit after acceptance is not the responsibility of the manufacturer 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 p
29. two manifolds and two staged gas valves per furnace The high and low fire manifold pressure must be checked and properly set on each manifold IMPORTANT Confirm that the discharge air sensor is installed in the duct at least three duct diameters downstream of the furnace 1 Send the Unit to High Fire For the furnace to light the heat switch must be closed or jumpered out Reference the unit ladder diagram for proper terminals to jumper To send the unit to high fire press and hold the Up Down and Enter keys The middle LED light L2 will flash on the screen when the unit is forced to high fire The unit will remain at high fire until the Function key is pressed middle LED light L2 will stop flashing L1 L2 L3 Function O Up Enter Down WARNING Once the unit is forced to high fire it will remain at high fire until the Function key is pressed Forcing the unit to high fire during warm or hot weather conditions may cause the high limit switch to trip If the switch trips it will reset once the discharge air temperature has reached a safe level 2 Check the High Fire Manifold Pressure Using a manometer measure the high fire burner manifold pressure for each furnace at the pressure test port Refer to the Gas Train Layout in the Reference section for the test port location The recommended high fire manifold pressure is 3 1 2 in wg for natural gas and 10 in wg for LP gas If needed adjus
30. 4 2 1 Modulation 0000 eee 65 4 1 Modulation 66 Model IGX Blower Control Center 67 Single or 2 Stage 2 2 eee eee 68 O21 Staged oes soe ees ae eae weet aD 68 2 1 Modulation 0000ee 69 4 1 Modulation 69 Performance Table 00 cece eee eeeaee 70 Start Up Checklist 0 2020200 eee 71 Maintenance Log eeeeeeeee Backcover Warranty ss 05 cesses es cease ee esas Backcover Clearance to Combustibles Service Clearances Floor Top Sides Ends Indirect Fired Units 0 inches 0 mm 0 inches 0 mm 0 inches 0 mm 0 inches 0 mm Clearance to combustibles is defined as the minimum distance required between the heater and adjacent combustible surfaces to ensure the adjacent surface s temperature does not exceed 90 degrees above the ambient temperature Reference venting guidelines for combustion blower clearances Recommended Minimum Service Clearances Housing 32 42 inches 1067 mm on the and less controls side of the unit Clearances for component removal such as evaporative cooler media should be 6 in wider than the width of the module itself Model IG IGX Make Up Air JE Installation of Indoor Unit To prevent premature heat exchanger failure do not locate units where chlorinated halogenated or acid vapors are present 1 Install Hangers Install threaded hangers fr
31. L2 L3 Function O Up Enter amp Down Water Wizard User Interface Key Function Description 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 Setpoints Menu press and hold the Function key for three seconds While viewing the Setpoints Menu press the Up or Down key 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 Setpoints Menu press the Enter key To return to the Setpoints Menu without saving the change wait 15 seconds To exit Program Mode from the Setpoints Menu wait 15 seconds WARNING Changing the default settings will significantly affect performance Only change a setting after reading and understanding this entire manual NOTE The Enter key must be pressed to save any changes made to a setting Inlet Air Sensor iAS The inlet air sensor monitors the temperature of the inlet air If the inlet air is above the sensor s set point the inlet air sensor shuts off the furnace and continues to supply the warm outside air The inlet air sensor is preset to the factory recommended 65 F for 8 1 and 60 F for 4 1 Discharge Air Temperature dtS The discharge air temperature setting is the temperature that the unit will discharge The discharge air
32. Line Valve Drain Line Valve normally closed normally open A T Drain Line gt Ta Overflow Trap gt Recirculating Evaporative Piping IMPORTANT All supply solenoids valves and all traps must be below the roofline 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 2 Install the Drain Line Connect an unobstructed drain line to the drain and overflow connections on the evaporative cooler A manual shut off valve by others is required for the evaporative cooler drain line A trap Joo should be used to prevent sewer gas from being drawn into the unit 3 Check Adjust Water Level Check the water level in the sump
33. OOR 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 sign
34. Part 470656 IG IGX Make Up Air Unit P GREENHECK Building Value in Air Installation Operation and Maintenance Manual 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 could result in personal injury and or property damage Retain instructions for future reference 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
35. VAC across A2 and A1 on supply contactor ST1 EG Model IG IGX Make Up Air 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 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 4 Optional Exhaust Fan Interlocks ST2 ST5 Open Correct Replace Optional Freeze Protection RT4 Tripped Reset 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 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 Troubleshooting Motor Over Amps Yes Air volume too high Adjust drives or increase external static pressure as needed Reference Blower Start Up Step 5 Actual static pressure Ye
36. a 8 1 Staged Control Multi Furnace Units Light On Off Blinking L1 n a n a n a L2 n a n a Alarm L3 Program Mode n a eee iad A Sequence of Operation 4 1 Electronic Modulation 1 Exhaust Fan Contact S1 Manually Closed optional e Power passes through N C contact on exhaust fan overload ST2 OL which is closed if exhaust fan M2 has not overloaded e Power passes to exhaust fan starter ST2 e N O contact on exhaust fan starter ST2 is energized and closed Power passes to and energizes exhaust fan M2 Supply Fan Contact S2 Manually Closed e Power passes through N C field supplied fire contact FSC e Power passes through optional N O contact on exhaust fan starter ST2 which is closed when the optional exhaust starter ST2 is activated e Power passes through N C contact on supply starter overload ST1 OL which is closed if the supply fan has not overloaded e Power passes through N C contact on optional freeze protection timer RT4 which is closed if the temperature has remained above the set point e Power passes to and energizes optional inlet damper D1 which opens e Power passes through optional damper limit switch DL1 which is energized and closed if the optional inlet damper is open It may take several minutes for the damper to fully open and for the damper limit switch to close e Power passes to and energizes fan relay RF e Power passes through N O contact on fan relay RF wh
37. act on exhaust fan starter ST2 which is closed when the optional exhaust starter ST2 is activated Power passes through N C contact on supply starter overload ST1 OL which is closed if the supply fan has not overloaded Power passes through N C contact on optional freeze protection timer RT4 which is closed if the temperature has remained above the set point Power passes to and energizes optional inlet damper D1 which opens Power passes through optional damper limit switch DL1 which is energized and closed if the optional inlet damper is open It may take several minutes for the damper to fully open and for the damper limit switch to close Power passes to and energizes fan relay RF Power passes through N O contact on fan relay RF which is closed once the fan relay RF is activated Power passes to and energizes starter relay ST1 N O contact on supply fan starter ST1 is energized and closed Supply fan M1 starts Heat Contact S4 Manually Closed Power passes through N O contact on fan relay RF which is energized and closed if the supply fan M1 is on Power passes through the N C contact on optional inlet air sensor TS4 which is closed if inlet air temperature is below set point Power passes to and energizes the heat relay RH Power passes to N C contact on high temperature limit control HLC1 which remains closed if it has not been tripped N O contact on heat relay RH closes
38. adjust the modulating gas valve MOD down until the discharge temperature sensor TS2 reading equals the temperature selector TS3 setting If the discharge temperature sensor TS2 reading is below the temperature selector TS3 set point and the furnace is not at high fire the amplifier will adjust the modulating gas valve MOD up until the discharge temperature sensor TS2 reading equals the temperature selector TS3 setting If the furnace is at low fire and the discharge temperature sensor TS2 reading is above the temperature selector TS3 set point the amplifier will end the call for heat and the ignition controller IC1 will shut down the furnace Optional Evaporative Cooling Contact S4 Closed N O contact on fan relay RF is energized and closed Power passes through N O contact on optional inlet air sensor TS4 which is energized and closed if the inlet air temperature is above the set point Power passes to and energizes cool relay RC Model IG IGX Make Up Air Ef Sequence of Operation 2 1 Modulation Sequence continued N O contact on cool relay RC is energized and closed Power passes to evaporative cooling pump P1 If DX or chilled water coils are used rather than an evaporative cooler the cooling sequence of operation will depend on the coil controls Cooling coil controls are supplied by others EQ Model IG IGX Make Up Air Operation 4 1 Modulation and 8 1 Staged Controller L1
39. adjustable set point This is a typical blower control center the control center in your unit may be different Reference the ladder diagram on the inside of the control center door for a unit specific wiring diagram 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 Auxiliary Contact Optional Provides one normally closed and one normally open contact for other equipment 7 Exhaust Motor Starter Optional 24 volt magnetic contacts for starting exhaust motor 8 Exhaust Overload Optional Provides electronic overload protection to exhaust motor 9 Exhaust Fuses Optional Provides proper fusing for exhaust fan motor s 10 Building Freeze Protection Timer Optional Prevents the discharge of cold air into the building 11 Heat Relay Allows power to pass to heating controls 12 Low Voltage Transformer Provides low voltage to the optional evaporative cooling controls 13 Inlet Air Sensor Optional Outdoor air stat that automat
40. an orifices and burners as necessary Avoid using any hard or sharp instruments which could cause damage to the orifices or burners Remove any soot deposits from the burner with a wire brush Clean the ports with an aerosol degreaser or compressed air Wipe the inside of the burner clean Cleaning the burner with a degreaser will slow the future build up of dirt e Before reinstalling the burner assembly look down the heat exchanger tubes to make sure they are clear of any debris e Reinstall manifold and burner assembly reconnect wire leads and gas supply piping e Turn on the electrical power and gas supply e Follow the start up procedure to light the burners and verify proper operation B Model IG IGX Make Up Air Heat Exchanger The heat exchanger should be checked annually for cracks If a crack is detected the heat exchanger should be replaced before the unit is put back into operation Also airflow across the heat exchanger should be checked to make sure the blower is operating properly Flue Collector Box The flue passageway and flue collector box should be inspected prior to each heating season and cleared of any debris Electrical Wiring The electrical wiring should be checked annually for loose connections or deterioration Replacement Parts When ordering replacement parts include the complete unit model number and serial number listed on the unit nameplate Evaporative Coolers The water shoul
41. ata additional safety information This publication can be obtained from AMCA International Inc at www amca org AIGREENHECK Building Value in Air Phone 715 359 6171 Fax 715 355 2399 e E mail gfcinfo greenheck com Web site www greenheck com 470656 IG IGX Make Up Air Rev 5 May 2012 Copyright 2012 Greenheck Fan Corporation
42. ce furnace stage one contact High limit HLC1 open Discharge temperature was above high limit setting Wait for high limit to cool and reset Ignition controller IC red LED wes blinks 7 times or is on Ignition controller IC1 failed Replace ignition controller Ignition controller IC red LED wes blinks 6 times Combustion blower CM not functioning Replace combustion blower or relay CR Air proving switch PS2 defective Ignition controller IC Ves Replace air proving switch red LED blinks 1 time 2 times or 4 times Improper manifold pressure Yes Set high and low manifold pressure refer to Single Stage or 2 1 Staged Control Start Up section Faulty spark rod or spark gap does not equal 1 8 inch Replace spark rod or adjust gap to 1 inch Everything is working properly consult factory BJ Model IG IGX Make Up Air Troubleshooting 2 1 Modulating Furnace Will Not Light 24 VAC across R and X No Yes 24 VAC across W1 and X He Yes 24 VAC across S and T No Yes 24 VAC across C and T Yes 24 VAC across A and T No Yes Ignition controller IC ie red LED Z blinks 7 times or is on Ignition controller IC E red LED blinks 6 times Ignition controller IC ee red LED blinks 1 time 2 times or 4 times Yes Everything is working properly consult factory Main disconnect DS1 open or defective Close repair or replace Main transformer TR1 fault Repla
43. ce main transformer Heat switch S4 open or not wired Close or replace heat switch S4 Heat transformer TR5 fault Replace heating transformer Discharge temperature was above high limit control HLC1 Wait for high limit to cool and reset Optional inlet air sensor contact TS4 open Adjust setting reference Blower Start Up Step 6 Heat relay RH is not energized Check for loose connections Repair or replace heat relay RH Discharge air selector TS3 improperly set or faulty Adjust setting see staged start up or replace sensor Ignition controller IC1 failed Replace ignition controller Combustion blower CM not functioning Replace combustion blower or relay CM Air proving switch PS2 defective Replace air proving switch Improper manifold pressure Set high and low manifold pressure refer to the 2 1 Electronic Modulation Start Up section Faulty spark rod or spark gap does not equal 1 8 inch Replace spark rod or adjust gap to inch Model IG IGX Make Up Air E3 Troubleshooting 4 1 Modulating Furnace Will Not Light 24 VAC across R and X Main disconnect DS1 open or defective Close repair or replace Main transformer TR1 fault Replace main transformer 24 VAC across W1 and X Heat switch S4 open or not wired Close or replace heat switch S4 24 VAC across 22 and 21 Heat transformer TR2 fault Replace heating transformer N O contact on heat relay RH closed Heat relay RH is n
44. change to the inlet air sensor setting 10 Edit the Setting Use the Up or Down key to edit the inlet air setting When the correct setting is displayed press the Enter key to save the setting and return to the Setpoints menu Steps 11 and 12 are provided for adjusting the room override setting Only adjust the setting if the room override function is desired The room override function temporarily changes the discharge air temperature to the room override setting if a room thermostat is not satisfied 11 Access the Room Override Setting From the Setpoints Menu use the Up or Down key to navigate through the menu options until the display reads rot Once the display reads rot press the Enter key The display will change to the room override setting The room override function requires a field supplied thermostat to be installed in the space and to be wired between terminal 31 and 32 in the unit s control center 12 Edit the Setting Use the Up or Down key to change the room override setting When the correct setting is displayed press the Enter key to save the setting and return to the Setpoints menu After modifying a setting the Enter key must be pressed to save the change If the Enter key is not pressed the display will return to the Setpoints Menu without saving the change Model IG IGX Make Up Air EX Start Up Economizer optional To prevent premature heat exchanger
45. ction This is a typical furnace control center the control center in your unit may be different Reference the ladder diagram on the inside of the control center door for a unit specific wiring diagram 1 Low Voltage Transformer Provides low voltage to the ignition controller and amplifier 2 Control Terminal Block Provides wiring access to heat controls 3 Control Terminal Block Provides wiring access to heat controls 4 Ignition Controller Controls the ignition of the furnace Maintains safe operation of the furnace 5 Amplifier Controls the modulating valve based on the input from the temperature selector and the discharge air sensor 6 Temperature Selector Allows the user to adjust discharge air temperature 7 Combustion Blower Contact Passes power to the combustion blower 8 Airflow Switch Monitors the airflow inside the heat exchanger to ensure proper combustion airflow 9 High Fire Relay Allows furnace to ignite on high fire door for a unit specific wiring diagram 10 11 Low Voltage Transformer Provides low voltage to the ignition controller Low Voltage Transformer Provides low voltage to the 4 1 electronic modulation controller Low Voltage Transformer Provides low voltage to the amplifier Control Terminal Block Provides wiring access to controls Control Terminal Block Provides wiring access to controls Input Converter Receives and converts signal fr
46. d be shut off and all the lines drained when the outside temperature drops below 45 F 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 Winterizing Chilled Water Coils During the winter chilled water coils need to be protected against freezing Manufacturer recommends protecting the coils by either blowing out the coils or by flushing the coils ara Out Coils Close valves on the supply and return lines 7 Open drain valves and or drain plug Remove vent plug to allow coil to drain faster 3 After coil is fully drained connect a blower to the caps Do not connect the blower to the air vent or drain plug 4 Close the vent plug on the header that the blower is connected to Open the drain valve or cap on the other header 5 Turn on blower for 30 minutes Place mirror at discharge If the mirror fogs up repeat procedure until no fog appears on the mirror 6 After drying the coil wait a few minutes then repeat Step 5 7 Leave drains open and do not install plugs until beginning of cooling season Flushing Coils Manufacturer recommends the use of inhibited glycol such as propylene or ethylene to flush water coils to protect against freezing Additionally the use of inhibited glycol provides corrosion protection The table below indicates the percentage of glycol
47. damper position The potentiometer is located on the economizer for options EC 1 EC 2 EC 3 and EC 4 The potentiometer may be factory mounted in the unit control center or field mounted in the space for option MB 1 MB 2 and MB 3 use an external signal from a building management system to position the dampers MB 4 uses a manual quadrant located on the inlet damper to position the dampers EA Model IG IGX Make Up Air IMPORTANT The outside air volume must be measured and compared to the total air volume when setting the minimum outside air The minimum outside air should never be set based on the inlet damper or potentiometer position 3 Set the Enthalpy Changeover Set Point optional If using an economizer the enthalpy changeover setting must be set If differential temperature or differential enthalpy control is used set the enthalpy changeover set point to D If outside air temperature or enthalpy reference is used set the enthalpy changeover set point to the desired setting from the following table Enthalpy Changeover Setting ee Temperature CF A 73 B 70 c 67 D 63 Temperature at 50 relative humidity see the Honeywell W7212 Economizer instructions for set points at other humidities For options EC 3 and EC 4 the enthalpy changeover set point is the temperature at which the economizer will send the dampers to the minimum outside air position 4 Program Optional Roo
48. e vertical concentric venting instructions If venting horizontally through the wall refer to the horizontal concentric venting instructions NOTE Vent piping is supplied by others and not supplied by manufacturer CVA 4 CVA 6 4 inch Concentric 6 inch Concentric Venting Adapter Venting Adapter Combustion Air Connection Concentric Side Exhaust Connection Concentric Side CVA 4 X Combustion Air Connection Exhaust Connection Non Concentric Side Non Concentric Side Top View ELJ Model IG IGX Make Up Air Concentric Venting Horizontal Refer to the diagram below for venting on horizontal concentric systems Maintain at least 12 inches from the combustion air inlet guard to the exhaust vent terminal Dim B To prevent water from running into the combustion air pipe and to allow for easy installation of the combustion air inlet guard the combustion air pipe must terminate at least 2 inches from the exterior surface of the outside wall Dim A A 2 inch minimum Exterior B 12 inch minimum lt Wall A B k Mounting Bracket gt racKel a EXHAUST gt Exhaust Vent COMBUSTION AIR Terminal Mounting 7 Bracket Combustion Pitch vent pipe downward Air Inlet Guard from furnace 1 4 inch per foot Vent Connection Diameter Vent terminals must be used o
49. e National Electrical Code ANSI NFPA 70 e Unit is approved for installation downstream from refrigeration units In these conditions condensate could form in the duct furnace and provision must be made to dispose of the condensate Table of Contents Installation Clearance to Combustibles Service Clearances 3 indoor WANT goss osx xed tee ad ace nr ale aca etre gusset orcs 4 Unit Arrangement DB HZ 0 20000 4 5 Roof Mounted Unit Arrangement DBC 5 6 Optional Evaporative Cooling Module 7 Venting Outdoor 2 eee 7 Indoor All Units 00020005 8 Standard Indoor 00 cece eee 9 Concentric General 10 Concentric Horizontal 10 11 Concentric Vertical 11 12 Two Pipe Horizontal 13 Two Pipe Vertical 14 Electrical Wiring 332 22s20008s0008 ene ea ee 15 16 Gas PIPING 2 2s5 2 5250 eh ce ren ave see wa eawes 17 Optional Evaporative Cooler Piping 18 19 Optional Water Wizard 0 19 20 Optional Direct Expansion DX Coil Piping 20 21 Optional Chilled Water Coil Piping 22 Optional Building Pressure Control 22 Start Up BIOWGF foe ee ata een hen eee end ads 23 24 Furnace All Units 0 000 cece eee eee 25 Single Stage 0c eee eee anns 25 2A Slag desakan eE Ma ees 26 8 1 Staged casa tow Giceaehs iden 26 28 2 1 Modulation 000005 29
50. e discharge temperature sensor TS2 reading is below the discharge temperature setting dtS FX Program Menu and the furnace is not at high fire the modulating controller SC1 will adjust the modulating gas valve MOD up until the discharge temperature sensor TS2 reading equals the discharge temperature setting dtS FX Program Menu 6 Optional Evaporative Cooling Contact S4 Closed e N O contact on fan relay RF is energized and closed e Power passes through N O contact on inlet air sensor TS4 which is energized and closed if the inlet air temperature is above the set point PA Model IG IGX Make Up Air Sequence of Operation 1 0 a 8 1 Staged Control Exhaust Fan Contact S1 Manually Closed ptional Power passes through N C contact on exhaust fan overload ST2 OL which is closed if exhaust fan M2 has not overloaded Power passes to exhaust fan starter ST2 N O contact on exhaust fan starter ST2 is energized and closed Power passes to and energizes exhaust fan M2 Supply Fan Contact S2 Manually Closed Power passes through N C field supplied fire contact FSC Power passes through optional N O contact on exhaust fan starter ST2 which is closed when the optional exhaust starter ST2 is activated Power passes through N C contact on supply starter overload ST1 OL which is closed if the supply fan has not overloaded Power passes through N C contact on optional freeze protecti
51. e exterior surface of the roof This clearance may need to be increased to allow for snow accumulation Be sure to maintain the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake 5 Install CVA Assembly Place the CVA assembly through the roof and verify that all minimum clearance requirements as specified in these instructions are met Secure the CVA assembly to the ceiling with corrosion resistant sheet metal screws through the mounting brackets 6 Attach CVA Assembly to Unit Attach the exhaust pipe to the unit s combustion exhaust Using an additional combustion air pipe connect the unit s combustion air supply intake to the combustion air connection on the CVA Be sure to include the required tee s with drip legs and clean outs EEA Model IG IGX Make Up Air 7 Install Combustion Air Inlet Guard and Exhaust Vent Terminal Slide the combustion air terminal over the vent pipe and fasten it to the combustion air pipe Attach the exhaust vent terminal to the discharge end of the exhaust piping 8 Seal Opening Seal the opening between the roof line and the air intake pipe using an appropriate method Installation of Two Pipe Venting Horizontal Refer to the diagram below for venting on horizontal concentric systems Maintain at least 12 inches of clearance between the exhaust pipe termination and the exterior surface of the exterior wall Dim A The combustion a
52. e furnace 12 1 Electronic Modulation Start Up Single Stage Control 1 Send Unit to High Fire Send the unit to high fire by setting the temperature selector to its maximum setting POR 2 Check the High Fire Manifold Pressure Using a manometer measure the burner manifold pressure at the manifold pressure test port Refer to the Gas Train Layout in the Reference section for the test port location The pressure on high fire ingle St Manifol should be 3 1 2 in wg for Pinge Snar Paa Pressure in wg TA ai Natural Gas LP LP gas High Fire 3 1 2 10 If needed use the high fire adjustment screw on the staged gas valve to adjust the high fire manifold pressure 5S High Fire Adjustment x will decrease the gas pressure and clockwise rotation will increase the gas pressure 3 Reset the Temperature Setting Reset the temperature setting on the temperature selector to the desired setting Model IG IGX Make Up Air EX Start Up 2 1 Staged Control 1 Send Unit to High Fire Send the unit to high fire by setting the temperature selector to its maximum setting 2 Check the High Fire Manifold Pressure Using a manometer measure the burner manifold pressure at the manifold pressure test port Refer to the Gas Train Layout in the Reference section for the test port location Temperature Selector The pressure on high fire should be 3 1 2 in wg for
53. e inside of the control center ladder diagram on the inside of the control center door for a unit specific wiring diagram 1 Low Voltage Transformer Provides low voltage to the ignition controller 2 Low Voltage Transformer Provides low voltage to the ignition stage controller 3 Control Terminal Block Provides wiring access to heat controls 4 Control Terminal Block Provides wiring access to heat combustion blower controls 5 Stage Controller Provides single or two stages of furnace control based on discharge air temperature set point 6 Ignition Controller Controls the ignition of the furnace Maintains safe operation of the furnace 7 Combustion Blower Contact Passes power to the combustion blower 8 Airflow Switch Monitors the airflow inside the heat exchanger to ensure proper combustion airflow 9 High Fire Relay Allows furnace to ignite on high fire E Model IG IGX Make Up Air door for a unit specific wiring diagram 11 Low Voltage Transformer Provides low voltage to the staged controller Low Voltage Transformer Provides low voltage to the ignition controllers Control Terminal Block Provides wiring access to controls Control Terminal Block Provides wiring access to controls Input Converter Receives and converts signal from Building Management Systems BMS Stage Controller Provides eight stages of control based on discharge temperature set point Ignition Contr
54. e is less than the return air temperature the economizer will modulate the dampers to achieve a 55 F mixed air temperature If the outside air temperature is less than the return air temperature but a 55 F mixed air temperature cannot be achieved the programmable room thermostat may call for mechanical cooling Option EC 4 Differential Enthalpy Control This option uses one enthalpy sensor field installed in the inlet of the unit A second enthalpy sensor is field installed in the return air duct A dry bulb temperature sensor is factory installed in the discharge of the unit After a call for cooling the economizer compares the outdoor and return air enthalpies If the outdoor air enthalpy is greater than the return air enthalpy the economizer sends the dampers to the minimum outside air position and sends a call for mechanical cooling If the outside enthalpy is less than the return air enthalpy the economizer will modulate the dampers to achieve a 55 F mixed air temperature If the outside enthalpy is less than the return air temperature but a 55 F mixed air temperature cannot be achieved the programmable room thermostat may call for mechanical cooling Model IG IGX Make Up Air EE Troubleshooting Blower Does Not Operate Proper supply power at main disconnect 24 VAC between terminals R and X 24 VAC between terminals G and X 24 VAC across terminals 3 and X 24 VAC across terminals 4 and X 24
55. e manifold pressure at the pressure test port Refer to the Gas Train Layout in the Reference section for the test port location The recommended high fire manifold pressure is 3 1 2 in wg for natural gas and 10 in wg for LP gas If needed adjust the high fire screw on the shut High Fire off valve to set the high gaiustment fire manifold pressure Counterclockwise rotation will decrease the gas pressure and clockwise rotation will increase the gas pressure EJ Model IG IGX Make Up Air To enter the high fire setting mode press and hold button 1 until the LED lights solid red Release The valve is now in the high fire setting mode Press or hold button 2 to decrease gas flow Each button press equates to the minimum available step size and will decrease flow slowly Holding the button down auto steps and eliminates the need to continuously press the button Use this feature to rapidly decrease the flow Press or hold button 1 to increase gas flow Each button press equates to the minimum available step size and will increase flow slowly Holding the button down auto steps and eliminates the need to continuously press the button Use this feature to rapidly decrease the flow High fire setting should be 3 5 in wg for natural gas and 10 0 in wg for LP gas To save high fire setting simultaneously hold button 1 and 2 until the LED turns off NOTE Controls left in the high fire set
56. e or more small leaks which should be located and repaired Pressure losses greater than 5 psig indicate a large leak that should be isolated and repaired 7 Evacuate and Charge the Coil Use a vacuum pump to evacuate the coil and any interconnecting piping that has been open to the atmosphere Measure the vacuum in the piping using a micron gauge located as far from the pump as possible Evacuate the coil to 500 microns or less and then close the valve between the pump and the system If the vacuum holds to 500 microns or less A for one minute the system is ready to be charged or refrigerant in another portion of the system can be opened to the coil A steady rise in microns would indicate that moisture is still present and that the coil should be further vacuumed until the moisture has been removed Failure to obtain a high vacuum indicates a great deal of moisture or a small leak Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks If no leaks are found continue vacuuming the coil until the desired vacuum is reached 8 Install the Drain Line Connect an unobstructed drain oo line to the drain pan A A Drain Trap trap should be used to prevent sewer gas from being drawn into the unit IMPORTANT All traps must be installed below the roof line or be otherwise protected from freezing Model IG IGX Make Up Air EX Installation of Chilled Water Coil Piping op
57. e remote control panel to each EERS position and confirm that the return Q air damper adjusts accordingly The damper actuator may take a few 2 Position minutes to open or close Damper Control 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 E extremes Confirm that the return air damper fully opens and fully closes When the potentiometer is at 0 the return air damper will open When the Qos potentiometer is at 100 the return air damper will close The damper p actuator may take a few minutes to KJ open or close Potentiometer Control Building Pressure 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 pressure sensing device Turn both knobs to the upper most pressure setting You may have to remove the outdoor pressure tap tubing The return air damper should close Building Pressure Control Set both knobs at the lowest setting and the damper should open It may take one to two minutes for the damper to reach the desired position Reset the correct pressure limits before starting the unit
58. ed the N O contact for furnace stage controller will close Power will be supplied to the ignition controller IC1 which will begin its sequence of operation Ef Model IG IGX Make Up Air 4 Ignition Controller IC1 Sequence of Operation The N O contact on air proving switch PS2 is open The ignition controller IC1 energizes the combustion blower relay CR N O contact on combustion blower relay CR closes Power passes to and energizes the combustion blower CM The N O contact on air proving switch PS2 closes The ignition controller IC1 begins a 15 second pre purge The high fire relay RT3 is energized and the N O contact on high fire relay RT3 closes The main gas valve MV fully opens 100 Igniter begins sparking 10 second trial for ignition begins The furnace will light at high fire 100 When the flame is detected the igniter stops sparking The furnace will remain at high fire 100 for at least 10 seconds High fire contact RT3 will open Furnace stages to maintain the discharge air temperature set point SC1 High Fire Low Fire Sequence of Operation The furnace lights at high fire 100 and remains at high fire for 10 seconds If the discharge temperature is above the discharge air sensor TS2 set point the N O furnace stage 2 controller contact SC2 will open and the furnace will go to low fire 50 If the furnace is at low fire 50 and the discharge temperature is above the
59. el Gas Code and or other local codes EJ Model IG IGX Make Up Air Venting Methods There are three venting methods for indoor mounted units For each method the units can be vented horizontally through an exterior wall or vertically through the roof Specific venting instructions are provided for each method and shown in the following pages Construct the vent system as shown in these instructions Refer to your unit specific submittal to determine the applicable venting option The venting method options are Standard Indoor Venting e uses building air for combustion e vents exhaust to outdoors e one exterior roof or wall penetration Separated Combustion Concentric Venting e uses outside air for combustion e vents exhaust to outdoors e one exterior roof or wall penetration Separated Combustion 2 Pipe Venting e uses outside air for combustion e vents exhaust to outdoors e two exterior roof or wall penetrations For each method the units can be vented horizontally through an exterior wall or vertically through the roof Refer to the specific venting instructions for your unit Construct the vent system as shown in these instructions Installation of Standard Indoor Venting Standard Indoor Venting uses one penetration through an exterior wall or roof for venting the flue exhaust The combustion air is supplied from the air inside the building Units must not be installed in a potentially explosive flammable or
60. er 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 7 Set the Optional Auto Drain and Fill Set the auto drain fill timer and temperature settings Temperature is typically set to 45 F 7 C Timer settings are t1 1 0 10min t2 0 4 60h 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 Pump Valve Filter Threaded Float Adjustment Supply Float Connection Valve Temperature Setting t2 settings lt a r t1 settings LA eee Evaporative Timer Evaporative Freeze Protection Model IG IGX Make Up Air EE Start Up Water Wizard optional Li 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 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 performa
61. er manifold pressure Set high and low manifold pressure refer to 8 1 Staged Start Up section Faulty spark rod or spark gap does not equal 1 8 inch Replace spark rod or adjust gap to 1 inch Internal high limit tripped temperature above set point Let temperatures cool Internal inlet air sensor open Adjust inlet air sensor setting refer to 8 1 Staged Start Up section Combustion relay R9 or CR defective Replace defective combustion relay R9 or CR Combustion blower fuse FU9 blown Replace combustion blower fuse FU9 Combustion blower CM defective Replace defective combustion blower CM Airflow switch PS2 defective Replace defective airflow switch PS2 Airflow relay R9 defective Replace defective airflow relay R9 Model IG IGX Make Up Air EJ Troubleshooting Evaporative Cooler does not Operate Recirculating pump Supply fan must be on for cooler to operate 24 VAC between terminals Y1 and X Cool switch S4 off turn cool switch S4 on Cool switch not wired wire cool switch S4 24 VAC between terminal A2 on Cooling Relay RC and X Optional inlet air sensor TS4 holding Adjust TS4 setting Reference Blower Start Up Step 6 115 VAC between terminals tala Cooling transformer TR4 defective Replace transformer 115 VAC between terminal 114 and 101 Cooling relay RC is not energized Check for loose connections Repair or replace relay At this time the evaporative cooler p
62. et C je Exhaust Vent Combustion Terminal gt Air Inlet K Lo Terminal B JA 4 y A lt Roof Line a 5 cc 3 lt z x fij El Q t5 lt D gt 4 lt Tee with drip leg and lt _ D gt clean out cap A 12 inch minimum but should size according to expected snow depth B 24 inch minimum C 12 inch minimum D 12 inch minimum Vent Connection Diameter Vent terminals must be used Construct the vent system as shown in the drawings and refer to the table for the correct vent connection diameters Furnace Size Exhaust Combustion MBH inches inches 75 175 4 4 200 400 6 6 Vent Length Refer to table for minimum and maximum vent lengths The minimum vent length is 10 feet and the maximum vent length is 70 feet The total equivalent vent length must include elbows The equivalent length of a 4 inch elbow is 6 feet and the equivalent length of a 6 inch elbow is 10 feet Vent Minimum Maximum Length feet feet Vertical 10 70 EE Model IG IGX Make Up Air 1 Install Exhaust Pipe Run an exhaust pipe from the unit s combustion exhaust through the roof to the outdoors The exhaust pipe must terminate at least 12 inches above the outside surface of the roof This clearance may need to be i
63. eter Qty Number Number yp 1 2 inch 461262 8210G2 Supply Closed 12 7 mm 1 Supply 852178 461263 82626262 Line Open TE MIEN Drai 6 35 mm rain Sump 3 4 inch 461264 8210635 Drain Open 19 05 mm 1 Part numbers subject to change A 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 inch normally closed solenoid Valve A in the supply line Install the 1 4 inch normally open solenoid Valve B between the supply line and the drain line as shown 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 a prevent sewer gas from Drain Trap being drawn into the unit Refer to Drain Trap drawing 3 Check Adjust Water Level Check the water level in the sump tank The water level should be above the pump intake and below the overflow Adjust the float as needed to achieve the proper water level 6 in min Installation of Water Wizard optional Evaporative Cooling with the Water Wizard The following instructions are provided for evaporative coolers equipped with the Water Wizard only Additional instructions are
64. etting needles Building Pressure Control Pressure Indicating Needle Pressure Setting Needles Pressure Setting Knobs Photohelic Gauge External Signal a variable frequency drive is controlled according to input from an external 2 10 VDC or 4 20 mA signal by others 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 a remote speed control This unit allows automatic adjustment of make up air volumes based on varying cooking loads 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 Recirculation can vary from 100 return air to 100 outside 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 O c ose A MAIN VALVES Turn the recirculating switch on D o th
65. 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 Listed Intertek 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 Model IG IGX Make Up Air EE Receiving Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading
66. fore 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 Voltage Hertz Phase VOLTS HZ PH SUP HP MCA MOP Unit s Total jo Electrical Nameplate 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 Blower Housing Blower Rotation To reverse the rotation on three phase units disconnect and lock out the power then interchange any two power leads 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
67. form the installation and maintenance of any coil Protective equipment such as safety glasses steel toe boots and gloves are recommended during the installation and maintenance of the coil IMPORTANT All field brazing and welding should be performed using high quality materials and an inert gas purge such as nitrogen to reduce oxidation of the internal surface of the coil IMPORTANT All field piping must be self supporting and flexible enough to allow for the thermal expansion of the coil 1 Locate the Distributor s by Removing the Distributor Access Panel Distributor Access Panel Distributor Suction Header Coil Equalizer Line Nozzle Liquid Line Thermal Expansion Valve by others Hot Gas By Pass by others ae Hot Gas Side Port Suction Line Straps Remote Sensing Bulb P Suction Connection Installation with Hot Gas Bypass 2 Verify Nozzle Placement Inspect the refrigerant distributor and verify that the nozzle is in place The nozzle is 6 generally held in place Seine by a retaining ring oris Ring Nozzle an integral part of the distributor itself Distributor Nozzle Placement NOTE If a hot gas bypass kit was provided by others refer to the manufacturer s instructions 3 Install Suction Line Install suction line s from the compressor to the suction connection s which are stubbed through the side of the cabinet 4 Install the Liquid
68. g 60 70 F e Cooling Inlet Air Sensor Typical setting 75 F e Building Freeze Protection Typical setting 5 minutes 45 F e Dirty Filter Gauge Typical setting Settings vary greatly for each unit See Reference section for adjusting information If your unit is equipped with a 4 1 modulation or 8 1 staged control the inlet air sensor and building freeze protection may be included in the furnace controller If this is the case instructions for setting the inlet air sensor and building freeze protection are included in the Furnace Start Up EZ Model IG IGX Make Up Air Start Up Furnaces all units IMPORTANT For the unit to function properly all stage or modulation valves must be set for high and low fire NOTE There are five furnace control options available Be sure to refer to the specific instructions for your control type IMPORTANT Multi furnace units may use a combination of the available control options Each furnace must be set up per the specific instructions for its control type IMPORTANT Multi furnace units will use one stage or electronic modulation controller per unit and one or two ignition controller s per furnace Each furnace will have its own gas valve s Each valve must be set for high and low fire To force the unit to light for set up purposes the heat switch must be closed or jumpered out See the Ladder Diagram on the inside of the control center door for proper terminals to
69. halpy sensor to be field installed inside of the weatherhood and field wired to terminals SO and SO on the economizer Economizer options EC 3 and EC 4 require an outdoor air temperature or enthalpy sensor to be field installed in the return air duct and field wired to terminals SR and SR on the economizer The sensors are provided by the factory and ship with the unit 8 Install Discharge Air Sensor optional For units with 8 1 16 1 or 24 1 staged turndown install the discharge air sensor at least three duct diameters downstream of the heat exchanger The discharge air sensor can be found in the unit s control center 9 Install DDC Interface Optional Some units may use an external signal from a building management system to control the dampers and or discharge air temperature Reference the unit ladder diagram for the correct wiring E Model IG IGX Make Up Air Installation of 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 IMPORTANT All piping should be clean and free of any foreign material Foreign material entering the gas t
70. he 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 Light Status Indicating On off Blinking Blinking Light Long on short off Sho
71. he supply gas pressure exceeds the maximum gas pressure shown on the unit s nameplate an additional regulator by others is required to reduce Me pressures TE Supply Gas Pressure Range regulator must have a in wg listed leak limiting device Minimum Maximum or it must be Sonic 5 a vented to the as outdoors LP 10 14 3 Connect the Supply Gas Line A manual shut off valve gas cock 1 8 inch plugged test port and 6 inch 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 H contro connections sacos a B must be made by Sg a qualified 0 7 installer and are not furnished by manufacturer Ground oe 1 8 in Plugged Tap lt 6 in Trap Supply Gas Line 4 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 WARNING The factory piping has been checked for leaks but should be rechecked due to shipping and installation Model IG IGX Make Up Air Installation Evaporative Cooler Piping optional Evaporative Cooling with Recirculating Pump Supply Line a A Supply
72. heaves e Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result in failure of the fan and or motor bearings e 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 Deflection Belt Span Belt Span Belt Tension Drive Alignment Snow Accumulation Clear snow away from roof mounted units Keep the snow clear of the intake and access doors EJ Model IG IGX Make Up Air 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 bea
73. iate method Concentric Venting Vertical Refer to the diagram below for venting on vertical concentric systems Maintain at least 12 inches between the top of the combustion air inlet terminals and the bottom of the exhaust terminal Dim B The bottom of the combustion air intake pipe must terminate above the snow line or at least 12 inches above the roof whichever is greater A tee with cleanout must be provided on the combustion air and exhaust pipe to prevent debris from entering the heat exchanger LS Vent A 12 inch minimum but should size according to expected snow depth 4 Terminal B 12 inch minimum 5 C 12 inch minimum y A lt Combustion Air Inlet Terminal A Roof Line A Mounting Mounting Bracket 5 x Bracket 2 lt lt x w E n gt fan Q f O lt C gt 4 lt Tee with m drip leg and lt C gt clean out cap Vent Connection Diameter Vent terminals must be used Construct the vent system as shown in the drawings and refer to the table for the correct vent connection diameters Non Concentric Vent Concentric Vent Connection Diameter Connection Diameter Furnace Exhaust Combustion Air Exhaust Combustion Air Size MBH inches inches inches inches 75 175 4 4 4 6 200 400 6 6 6 8 Vent Leng
74. ically controls the heating and or cooling based on outdoor air temperature 14 Evaporative Cooling Fuses Optional Provides proper fusing to evaporative cooling pump and controls 15 Transformer Fuse Optional Provides proper fusing for evaporative cooling transformer A Model IG IGX Make Up Air Reference Model IGX Reference Model IGX Single or 2 Stage 8 1 Staged Manifold Small Manifold eo D A oe S NN Gas 1 2 y Test Po 1 2 Test Port o D _ Large Manifold 6 B 7 l m Staged Gas Valve q 4 scared Gas Pressure 3 4 inch ys e 10 Test Pot p Staged Gas Supply 3 4 inch Gas Supply v O ey Connection 7 Gas Valve Connection g o T a gt g e This is a typical furnace control center the control This is a typical furnace control center the control center in your unit may be different Reference the center in your unit may be different Reference the ladder diagram on th
75. ich is closed once the fan relay RF is activated e Power passes to and energizes starter relay ST1 e N O contact on supply fan starter ST1 is energized and closed e Supply fan M1 starts Heat Contact S4 Manually Closed e Power passes through N O contact on fan relay RF which is energized and closed if the supply fan M1 is on e Power passes to and energizes the heat relay RH e N O contact on heat relay RH closes e Power passes to N C contact on high temperature limit control HLC1 which remains closed if it has not been tripped e 24 VAC is supplied to ignition controller IC1 e The modulating controller SC1 compares the inlet air temperature to the inlet air set point iAS FX Program Menu If the inlet air temperature is below the set point the modulating controller SC1 closes N O contact FUR 1 and sends a call for heat to the ignition controller IC1 N e g Model IG IGX Make Up Air EQ Sequence of Operation 4 1 Electronic Modulation continued 4 Ignition Controller IC1 Sequence of Operation e Power passes to and energizes cool relay RC e The N O contact on air proving switch PS2 is open N O contact on cool relay RC is energized and e The ignition controller IC1 energizes the induction closed relay IR e Power passes to evaporative cooling pump P1 e N O contact on induction relay IR closes If DX or chilled water coils are used rather than an evaporative cooler
76. imum setting to send the unit to high fire 2 Check the High Fire Manifold Pressure With the unit at high fire use a manometer to measure the burner manifold pressure at the manifold pressure test port See the Gas Train Layout in the Reference section for the manifold pressure test port location Temperature Selector The recommended high fire manifold pressure is 3 1 2 in wg for natural gas and 10 in wg for LP gas If needed use the high fire adjustment screw on the shut off gas valve to adjust the high fire manifold pressure Counterclockwise pi rotation will decrease the gas pressure and clockwise rotation will increase the gas pressure 3 Send Unit to Low Fire Remove and isolate one wire from the modulating gas valve terminal to send the unit to low fire 4 Check the Low Fire Manifold Pressure With the unit at low fire use a manometer to measure the burner manifold pressure at the manifold pressure test port See the Gas Train Layout in the Reference section for the manifold pressure test port location High Fire Adjustment The recommended low 2 1 Manifold Pressure fire manifold pressure is in wg 7 8 in wg for Natural Gas LP natural gas and Low Fire 7 8 2 1 2 2 1 2 in wg gt x for LP gas High Fire 3 1 2 10 If needed use the low fire adjustment screw on the modulating gas valve to adjust the low fire manifold pressure Counterclockwise rotation will dec
77. ing a setting the Enter key must be pressed to save the change If the Enter key is not pressed the display will return to the setpoints menu without saving the change 5 Access the Setpoints Menu Press and hold the Function key for three seconds to access the Setpoints Menu The display will read SEt A 6 Access the Discharge Air Temperature Setting Using the Up or Down key scroll through the Setpoints Menu until the display reads dtS then press the Enter key The display will change to the discharge air temperature setting 7 Edit the Setting Use the Up or Down key to change the discharge air temperature setting When the correct setting is displayed press the Enter key to save the setting and return to the Setpoints Menu Steps 8 9 are provided for adjusting the inlet air set point The inlet air sensor is preset to the factory recommended 65 F only adjust if needed The inlet air sensor monitors the temperature of the inlet air If the inlet air is above the sensor s set point the inlet air sensor shuts off the furnace and continues to supply the warm outside air 8 Access the Inlet Air Sensor Setting From the Setpoints Menu use the Up or Down key to navigate through the menu options until the display reads iAS Once the display reads iAS press the Enter key The display will change to the inlet air sensor setting 9 Edit the Setting Use the Up or Down key t
78. ir pipe must be a minimum of 12 inches from the exhaust pipe and 24 inches from the exterior surface of the outside wall Dim B A minimum of 1 inch and a maximum of 48 inches of building wall thickness is required for separated combustion vent pipe A 12 inch minimum B 24 inch minimum C 12 inch minimum Exterior lt Wall Exhaust Vent Terminal lt B gt A EXHAUST gt y K Cc nee vere pipa lt COMBUSTION AIR downward 7 from furnace N a 14 inch per foot Two 2 field supplied Combustion Air Inlet support brackets Terminal Vent Connection Diameter Vent terminals must be used The optional vent kit includes two terminals Construct the vent system as shown in the drawings and refer to the table for the correct vent connection diameters Furnace Size Exhaust Combustion MBH inches inches 75 175 4 4 200 400 6 6 Vent Length Refer to table for minimum and maximum vent lengths The minimum vent length is 5 feet and the maximum vent length is 50 feet The total equivalent vent length must include elbows The equivalent length of a 4 inch elbow is 6 feet and the equivalent length of a 6 inch elbow is 10 feet Vent Minimum Maximum Length feet feet Horizontal 5 50 1 Install Exhaust Pipe Run an exhaust pipe from
79. is between the economizer set point and 55 F the economizer sends the dampers to the 100 outside air position If the outside air is less than 55 F the economizer modulates the dampers to achieve a 55 F mixed air temperature Option EC 2 Outside Air Enthalpy Reference This option uses one enthalpy sensor field installed in the inlet of the unit A dry bulb temperature sensor is installed in the discharge of the unit After a call for cooling the outside air enthalpy is compared to the field adjustable enthalpy changeover set point If the outside air enthalpy is less than the set point the dampers will modulate to provide a 55 F mixed air temperature If the outside air enthalpy is greater than the set point the economizer sends the damper to the minimum outside air position and sends a call for mechanical cooling Option EC 3 Differential Temperature Control This option uses one dry bulb temperature sensor field installed in the inlet of the unit A second dry bulb temperature sensor is field installed in the return air duct A third dry bulb temperature sensor is factory installed in the discharge of the unit After a call for cooling the economizer compares the outdoor and return air temperatures If the outdoor air temperature is greater than the return air dry bulb temperature the economizer sends the dampers to the minimum outside air position and sends a call for mechanical cooling If the outside air temperatur
80. is mandatory when lifting the unit NOTE Some units come with the weatherhood attached and step 5 may not apply 5 Assemble and Attach Weatherhood The weatherhood can now be assembled and attached to the unit Detailed assembly instructions can be found with the weatherhood If the optional evaporative cooling module was selected this step does not apply refer to the installation instructions for the Optional Evaporative Cooling Module section page 7 6 Seal Weatherhood Seam Using an appropriate sealant seal the seam between the weatherhood and the unit I Complete Rooftop Installation Installation of Roof Mounted Unit Arrangement DBC 1 Install Curb Equipment Support s Position curb equipment support s on the roof reference the CAPS submittal for placement of curb equipment support s in relation to the unit Verify that all unit supports are level shim if necessary Attach curb to roof and flash into place Attach the equipment support s to the roof remove metal cover flash to wooden nailer and reinstall cover tooo x lt Roof Curb and Equipment Support NOTE Refer to Outdoor Venting instructions when locating the unit 2 Install Combination Curb Adaptor Install combination curb adaptor over curb use wood screws to lag in place Locate extension so the tall louvered side is over the exhaust opening as shown in illustration Caulk extension to combination curb adaptor Fasten exten
81. ium 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 Chilled Water Coils Test the circulating fluid for sediment corros
82. ive products and biological contaminants Make the necessary corrective measures Maintain adequate fluid velocities and proper filtering of the fluid If automatic air vents are not utilized periodic venting of the coil is recommended to remove accumulated air 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 Entering Air Media Orientation Cooling Coils WARNING Repair and replacement of the coil and the connecting piping valves etc should be performed by a qualified individual Inspect the coil for signs of corrosion and or leaks Repair any leaks as required Inspect the coil s surface for foreign material If the coil surface needs cleaning clean the coil from the leaving air side so that foreign material will be washed out of the coil rather than pushed
83. jumper out If the unit is equipped with an independent inlet air sensor not incorporated into the stage or modulation controller the unit will not light unless the outside air temperature is less than the inlet air sensor setting If the outside air is greater than the inlet air sensor setting turn the setting to its maximum position When set up is complete reset the inlet air sensor to the proper temperature If the unit is equipped with a stage or electronic modulation controller that includes an inlet air sensor function the inlet air sensor will be overridden when the unit is forced to high fire Available Control Options Single Furnace Units 1 1 Staged one 1 stage furnace 2 1 Staged one 2 stage furnace 8 1 Staged one 8 stage furnace 2 1 Electronic i Modulation one 2 1 modulating furnace 4 1 Electronic Modulation one 4 1 modulating furnace Two Furnace Units 1 1 Staged two independent 1 stage furnaces 2 1 Staged two independent 1 stage furnaces 4 1 Staged two independent 2 stage furnaces 16 1 Staged one 8 stage and one 1 stage furnace one 4 1 modulating and 8 1 Electronic Modulation one 2 stage furnace Three Furnace Units 1 1 Staged three independent 1 stage furnaces 3 1 Staged three independent 1 stage furnaces 6 1 Staged three independent 2 stage furnaces 24 1 Staged one 8 stage and two 1 stage furnaces one 4 1 modulating one 2 stage and one 1 stag
84. l O Determine furnace control type 1 Stage 2 Stage 8 Stage 2 1 Mod 4 1 Mod O Check supply gas pressure Maximum Minimum Actual O Set the High Manifold pressure in wg O Set the Low Manifold pressure in wg A Model IG IGX Make Up Air Maintenance Log Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Date Time AM PM Date Time AM PM Notes Notes Warranty Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the shipment date Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory transportation prepaid Motors are warranted by the motor manufacturer for a period of one year Should motors furnished by Greenheck prove defective during this period they should be returned to the nearest authorized motor service station Greenheck will not be responsible for any removal or installation costs As a result of our commitment to continuous improvement Greenheck reserves the right to change specifications without notice Greenheck Catalogs IG IGX IG HV and IGX HV provide AMCA Publication 410 96 Safety Practices for Users and additional information describing the equipment fan Installers of Industrial and Commercial Fans provides performance available accessories and specification d
85. l injury or property damage Manufacturer is not responsible for any damage to or failure of the unit caused by incorrect final wiring Model IG IGX Make Up Air REJ Installation of Water Wizard continued To Media al Pressure Gauge Factory Installed Sump Drain A Manual Supply Valve 7 Roof Line WA SSS S A J Supply Solenoid e c normally closed A er y Supply Line Drain Solenoid Field normally open Installed Trap gt WVA Water Wizard Installation 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 terminals Al2 and AIC on the terminal strip in the unit s control center NOTE The Water Wizard start up must be completed for proper performance EX Model IG IGX Make Up Air Installation Direct Expansion DX Coil Piping optional IMPORTANT Guidelines for the installation of direct expansion cooling coils have been provided to ensure proper performance and longevity of the coils These are general guidelines that may have to be tailored to meet the specific requirements of any one job As always a qualified party or individual should per
86. lay 10 Adjust the Freeze Temperature O While in Program Mode use the Up and Down keys to navigate O through the Menu Options until Frt is displayed Press the Enter key to access the selected Menu Freeze Temperature Option setting Display 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 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 A 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 t
87. ling the unit WARNING Do not install units in locations where flue products can be drawn into adjacent building openings such as windows fresh air intakes etc Distance from vent terminal to adjacent public walkways adjacent buildings operable windows and building openings shall conform with the local codes In the absence of local codes installation shall conform with the National Fuel Gas Code ANSI Z223 1 or the CAN CGA B 149 Installation Codes WARNING The following guidelines must be followed for all outdoor units 1 Building materials that will be affected by flue gases should be protected 2 Maintain minimum horizontal clearance of 4 feet from electric meters gas meters regulators and relief equipment In Canada the minimum clearance is 6 feet The combustion blower discharge on outdoor units must be located a minimum of 42 inches from any combustible materials Do not modify or obstruct the combustion air inlet cover or the combustion blower weatherhood Do not add vents other than those supplied by the manufacturer During the winter keep the unit clear of snow to prevent any blockage of the combustion venting 2 Install Stack Optional Clearance may require an exhaust stack Install an exhaust stack as needed to the exhaust connection on the unit Install a vent terminal on the exhaust pipe Model IG IGX Make Up Air Installation of Venting for Indoor Units WARNING The foll
88. m Stat Program the optional room stat Separate detailed instructions for programming the room stat ship with the optional room stat Start Up Evaporative Cooling optional 1 Check the Installation The media may have been removed during installation so its orientation should be double checked The media e 94 should be installed with the steeper a flute angle sloping 1 down towards 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 in 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 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 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 6 Adjust the Water Bleed Off Rate The wat
89. mended 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 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 3 Adjust the On Time Factor While in the O Program Menu use the Up and O 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 Increase the factor to increase the water supply or decrease the factor to decrease the water supply Press the Enter key to save the new On Time Factor and return to the Program Menu A Model IG IGX Make Up Air Maintenance Routine 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 below Check the alignment by using a straight edge across both sheaves as shown below IMPORTANT Premature or frequent belt failures can be caused by improper belt tension or misaligned s
90. nce 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 The recommended water pressure for the model IGX is set based on media width model IG is set based on air volume A table is provided for each Be sure to refer to the correct table IGX Media Width Water Pressure Housing inches in wg 12 30 20 43 36 22 48 42 60 61 66 72 96 42 Multiple media sections Value represents total media width Model IG Water Pressure CFM Range in wg 800 3500 50 3501 7000 74 3 Break In Media Leave the supply solenoid open to saturate and break in media for 20 minutes with the blower off EZ Model IG IGX Make Up Air 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 Steps 6 through 8 are provided to adjust the minimum cooling temperature The minimum cooling is preset to the factory recommended 75 F 24 C Only adjust if needed The inlet ai
91. ncreased to accommodate snow accumulation Attach the exhaust vent terminal to the end of the exhaust pipe 2 Install Combustion Air Pipe Run a combustion air pipe from the unit s combustion air intake through the roof to the outdoors The combustion air pipe must terminate at least 12 inches horizontally and vertically from the combustion exhaust pipe and at least 24 inches from the exterior surface of the roof These clearances may need to be increased to accommodate for expected snow accumulation Attach the combustion air terminal to the end of the combustion air pipe 3 Seal Roof Penetration Using an appropriate method seal the roof openings around the vent pipes INTAKE END Exhaust Connection Model IG Exhaust Connection Model IGX DISCHARGE Combustion Air Connection Model IG Combustion Air Connection Model IGX Installation 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 Electrical Code ANSI NFPA 70 and any local codes that may apply In Canada wiring should be done in accordance with the Canadian Electrical Code CAUTION If replacement wire is required it must have a temperature rating of at least 105 C e
92. nded 70 F Only adjust the setting if needed 6 Access the Setpoints Menu Press and hold the Function key for three seconds to access the Setpoints Menu The display will read SEt when Setpoints Mode is active 7 Access the Discharge Air Temperature Setting Use the Up or Down keys to scroll through the Setpoints Menu options until the display reads dtS then press the Enter key The display will change to the discharge air temperature setting 8 Edit the Setting Use the Up or Down keys to change the discharge air temperature setting When the correct setting is displayed press the Enter key to save the setting and return to the Setpoints Menu After modifying a setting the Enter key must be pressed to save the change If the Enter key is not pressed the display will return to the Setpoints Menu without saving the change Steps 9 thru 10 are provided for adjusting the inlet air set point The inlet air sensor is preset to the factory recommended 60 F only adjust if needed The inlet air sensor monitors the temperature of the inlet air If the inlet air is above the sensor s set point the inlet air sensor shuts off the furnace and continues to supply the warm outside air 9 Access the Inlet Air Sensor Setting From the Setpoints Menu use the Up or Down key to navigate through the menu options until the display reads iAS Once the display reads iAS press the Enter key The display will
93. ne vent terminal included with each furnace Construct the vent system as shown in the drawings and refer to the table for the correct vent connection diameters Concentric Vent Connection Diameter Non Concentric Vent Connection Diameter Furnace Exhaust Combustion Air Exhaust Combustion Air Size MBH inches inches inches inches 75 175 4 4 4 6 200 400 6 6 6 8 Vent Length Refer to table for minimum and maximum vent lengths The total equivalent vent length must include elbows The equivalent length of a 4 inch elbow is 6 feet and the z z ivalent I th Vent Minimum Maximum equiva eni teng Length feet feet of a 6 inch elbow Fan i F is 10 feet orizonta 7 1 Determine Venting Location Determine the location of the concentric venting adapter CVA based on any clearances that must be maintained follow all codes referenced in these instructions 2 Attach Mounting Brackets Attach field supplied corrosion resistant mounting brackets to the CVA using corrosion resistant sheet metal screws 3 Install Exhaust Pipe Slide the exhaust pipe through the CVA Provide enough exhaust piping to pass through the wall or floor and provide the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake With all required clearances satisfied attach the exhaust pipe to the CVA INTAKE END Exhaust Co
94. ng Let cool then reset high limit Ignition controller s IC failed Replace faulty ignition controller s Pressure switch PS2 failure Repair or replace pressure switch PS2 Combustion blower CM not functioning Replace fusing FU7 combustion blower or relay CM Secondary transformer TR6 defective Replace secondary transformer TR6 Furnace controller SC1 defective Replace furnace controller SC 1 Amplifier AMP defective Replace amplifier AMP Improper manifold pressure Set high and low manifold pressure refer to 4 1 Electronic Modulation Start Up section Faulty spark rod or spark gap does not equal 1 8 inch Replace spark rod or adjust gap to inch Model IG IGX Make Up Air EX Troubleshooting 8 1 Staged Furnace Will Not Light 24 VAC across R and X 24 VAC across W1 and X 24 VAC across 22 and 21 N O contact on heat relay RH closed DT1 displayed on furnace controller SC1 OT1 displayed on furnace controller SC1 Blank screen on furnace controller SC1 24 VAC across terminals S and T With the combustion blower CM off is the N O airflow switch PS2 closed Continues on next page EZ Model IG IGX Make Up Air Main disconnect DS1 open or defective Close repair or replace Main transformer TR1 fault Replace main transformer Heat switch S4 open or not wired Close or replace heat switch S4 Heat transformer TR2 fault Replace heating transf
95. nimum downward slope from the unit of 1 4 inch per foot horizontal venting only Securely suspend the pipe from overhead structures at points no greater than 3 feet apart The minimum vent length is 5 feet for horizontal and 10 feet for vertical The maximum vent length is 70 feet The total equivalent vent length must include elbows The equivalent length of a 4 inch elbow is 6 feet and the equivalent length of a 6 inch elbow is 10 feet Attach the vent terminal to the end of the exhaust pipe Vent Minimum Maximum Length feet feet Horizontal 5 70 Vertical 10 70 Model IG IGX Make Up Air JE Installation of Concentric Venting General Concentric venting allows the exhaust pipe and combustion air pipe to pass through a single hole in the roof or wall of the building A concentric venting adapter CVA is required for concentric venting The concentric venting adapter is designed for indoor installations and should never be installed on the exterior of the building The exhaust pipe must terminate with the vent terminal For horizontal venting the combustion air pipe must terminate with the combustion air guard For vertical venting the combustion air pipe must terminate with the inlet terminal Depending on what was ordered one of these vent terminals will be provided in the optional venting kit along with the concentric venting adapter CVA If venting vertically through the roof refer to th
96. nnection Model IG Exhaust Connection Model IGX DISCHARGE Combustion Air Connection Model IG Combustion Air Connection Model IGX 4 Install Combustion Air Pipe Attach a field supplied combustion air pipe to the concentric side of the CVA Be sure to provide enough combustion air piping to pass through the wall and provide the minimum clearance of 2 inches between the combustion air intake and the exterior surface of the outside wall Be sure to maintain the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake 5 Install CVA Assembly Place the CVA assembly through the wall and verify that all minimum clearance requirements as specified in these instructions are met Secure the CVA assembly to the wall with corrosion resistant sheet metal screws through the mounting brackets 6 Attach CVA Assembly to Unit Attach the exhaust pipe to the unit s combustion exhaust Using an additional combustion air pipe connect the unit s combustion air supply intake to the combustion air connection on the CVA 7 Install Combustion Air Inlet Guard and Exhaust Vent Terminal Slide the combustion air inlet guard over the exhaust pipe and fasten it to the combustion air pipe Attach the exhaust vent terminal to the discharge end of the exhaust piping on the outside of the building 8 Seal Opening Seal the opening between the wall and the air intake pipe using an appropr
97. o change the inlet air setting When the correct setting is displayed press the Enter key to save the setting and return to the Setpoints Menu After modifying a setting the Enter key must be pressed to save the change If the Enter key is not pressed the display will return to the Setpoints Menu without saving the change Steps 10 11 are provided for adjusting the room override setting Only adjust the setting if the room override function is desired The room override function temporarily changes the discharge air temperature to the room override setting if the room thermostat is not satisfied Model IG IGX Make Up Air 10 Access the Room Override Setting From the Setpoints Menu use the Up or Down key to navigate through the menu options until the display reads rot Once the display reads rot press the Enter key The display will change to the room override setting The room override function requires a field supplied thermostat to be installed in the space and to be wired between terminal 31 and 32 in the unit s control center Reference the unit ladder diagram 11 Edit the Setting Use the Up or Down key to change the room override setting When the correct setting is displayed press the Enter key to save the setting and return to the Setpoints Menu EE Model IG IGX Make Up Air Start Up 2 1 Electronic Modulation 1 Send Unit to High Fire Turn the temperature selector to its max
98. ollers Controls the ignition of the furnace Maintains safe operation of the furnace Contactor Relay Allows power to pass to the combustion blower contact Air Proving Switch Relay Functions as a relay for the pressure switch Combustion Blower Contact Passes power to the combustion blower Airflow Switch Monitors the airflow inside the heat exchanger Reference Model IGX 2 1 Modulation co 5 S Manifold 1 Va 6 Gas Pressure V Test Port an Modulating Gas Valve Staged Gas Valve mie 3 4 inch Gas Supply Connection This is a typical furnace control center the control center in your unit may be different Reference the ladder diagram on the inside of the control center Reference Model IGX 4 1 Modulation Manifold i n Gas Pressure V Test Port a Modulating Staged Gas Valve Ts 1k 5 TT Gas Valve 6 Co 3 4 inch Gas Supply z Conne
99. om Building Management System BMS Ignition Controllers Controls the ignition of the furnace Maintains safe operation of the furnace Modulation Controller Provides 4 1 modulation turndown control of furnace based on the discharge air temperature Amplifier Controls the modulating valve based on the input from the modulation controller settings and discharge air temperature sensor reading Combustion Blower Relay Passes power to the variable speed combustion blower Airflow Switches Monitors the airflow inside the heat exchanger to ensure proper combustion airflow Model IG IGX Make Up Air EX Reference Performance Table Performance Table The following table gives the air volume in cubic feet per minute that is required to provide the desired temperature rise for a given heating input Model IG has a maximum 7 000 CFM capacity Input Output Temperature Rise F MBH MBH 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 100 80 2963 2469 2116 1852 1646 1481 1347 1235 1140 1058 988 926 871 823 780 741 150 120 4444 3704 3175 2778 2469 2222 2020 1852 1709 1587 1481 1389 1307 1235 1170 1111 200 160 5926 4938 4233 3704 3292 2963 2694 2469 2279 2116 1975 1852 1743 1646 1559 1481 250 200 7407 6173 5291 4630 4115
100. om ceiling supports When locating hangers allow enough room to open access panel s Two nuts must be used on the end of each threaded hanger Ceiling supports are supplied by others 2 Install Unit Raise the unit into place Using two nuts per hanger fasten the unit supports to hangers under the unit Appropriate unit supports such as the optional manufacturer hanging bracket kit or c channel and angle iron supplied by others should be used Using self tapping screws attach ductwork to unit In order to prevent the unit from swinging and to provide a safe environment for service and maintenance additional measures must be taken to secure the unit in all directions Ceiling Supports Ductwork Two nuts must be used on each end of each threaded hanging rod for proper support WARNING All factory provided lifting lugs must be used when lifting any unit Failure to comply with this safety precaution could result in property damage serious injury or death 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 Reference the CAPS submittal for duct sizes 3 Install Vent Piping Refer to the Indoor Venting Instructions Refer to your unit submittal to determine the correct venting option NOTE Vent piping is supplied by others and not supplied by manufacturer EJ Model IG IGX Make Up Air Installation
101. on timer RT4 which is closed if the temperature has remained above the set point Power passes to and energizes optional inlet damper D1 which opens Power passes through optional damper limit switch DL1 which is energized and closed if the optional inlet damper is open It may take several minutes for the damper to fully open and for the damper limit switch to close Power passes to and energizes fan relay RF Power passes through N O contact on fan relay RF which is closed once the fan relay RF is activated Power passes to and energizes starter relay ST1 N O contact on supply fan starter ST1 is energized and closed Supply fan M1 starts Heat Contact S4 Manually Closed Power passes through N O contact on fan relay RF which is energized and closed if the supply fan M1 is on Power passes to and energizes the heat relay RH N O contact on heat relay RH closes The stage controller SC1 compares the inlet air temperature to the inlet air set point iAS FX Program Menu If the inlet air temperature is below the discharge air setting dtS FX Program Menu the stage controller sends a call for heat to the ignition controller IC1 Ignition Controller IC1 Sequence of Operation The N O contact on air proving switch PS2 is open The stage controller SC1 energizes the combustion blower relay CR N O contact on combustion blower relay CR closes Power passes to and energizes the combustion
102. on to exhaust motor Exhaust Fuses Optional Provides proper fusing for exhaust fan motor s 11 Building Freeze Protection Timer Optional Prevents the discharge of cold air into the building Heat Relay Allows power to pass to heating controls Low Voltage Transformer Provides low voltage to the ignition controller Heating Terminal Block Provides wiring access to heating controls Inlet Air Sensor Optional Outdoor air stat that automatically controls the heating and or cooling based on outdoor air temperature 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Gas Pressure l Manifold Amplifier Controls the modulating valve based on the input from the temperature selector and the discharge air sensor Airflow Switch Monitors the airflow inside the heat exchanger Temperature Selector Allows the user to adjust discharge air temperature Ignition Controller Controls the ignition of the furnace Maintains safe operation of the furnace Evaporative Cooling Fuses Optional Provides proper fusing to evaporative cooling pump and controls Transformer Fuse Optional Provides proper fusing for evaporative cooling transformer Cooling Relay Optional Allows power to pass to cooling controls Reset Timer Optional Resets cooling system to run a time interval Auto Drain Relay Optional Assures supply pump does not operate
103. onal Outdoor air stat that automatically controls the heating and or cooling based on outdoor air temperature Z Model IG IGX Make Up Air A Reference Model IG 2 1 Modulation This is a typical blower control center the control center in your unit may be different Reference the ladder diagram on the inside of the control center door for a unit specific wiring diagram 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 modulating furnace controls and optional evaporative cooling controls 4 Control Terminal Block Provides wiring access to controls 5 Fan Relay Allows power to pass to energize motor starter 6 Control Terminal Block Provides wiring access to fan heat cooling enable controls 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 protecti
104. ormer Heat relay RH is not energized Check for loose connections Repair of replace heat relay RH Discharge air sensor TS2 not wired or defective Wire or replace discharge air sensor TS2 Outdoor air sensor TS1 not wired or defective Wire or replace outdoor temperature sensor TS1 Furnace controller SC1 defective or not powered Replace or wire furnace controller SC1 Discharge temperature was above high limit control HLC1 Wait for high limit to cool and reset Inlet air sensor contact open Adjust inlet air sensor setting refer to 8 1 Staged Start Up section Furnace controller SC1 defective Replace furnace controller SC1 Airflow switch PS2 defective Replace defective airflow switch PS2 Troubleshooting 8 1 Staged Furnace Will Not Light continued from previous page With the combustion blower CM on for at least 30 seconds is there 24 VAC across T and A or E Ignition controller IC red LED blinks 7 times or is on Ignition controller IC red LED blinks 1 time 2 times or 4 times Cycle power to the unit and wait 30 seconds Does the combustion relay R9 or CR close Does the combustion blower CM run Does the combustion blower stop after 30 seconds of operation Everything is working properly consult factory Furnace controller SC1 defective Replace furnace controller SC1 Ignition controller s IC failed Replace faulty ignition controller s Improp
105. ot energized Check for loose connections Repair or replace heat relay RH DT1 displayed on furnace controller SC1 Discharge air sensor TS2 not wired or defective Wire or replace discharge air sensor TS2 OT1 displayed on furnace controller SC1 Outdoor air sensor TS1 not wired or defective Wire or replace outdoor temperature sensor TS1 Blank screen on furnace controller SC1 Furnace controller SC1 defective or not powered Replace or wire furnace controller SC1 24 VAC across terminals S and T Discharge temperature was above high limit control HLC1 Wait for high limit to cool and reset Inlet air sensor contact open Adjust inlet air sensor setting refer to 4 1 Modulation Start Up section Furnace controller SC1 defective Replace furnace controller SC 1 Yes Continues on next page EA Model IG IGX Make Up Air Troubleshooting 4 1 Modulating Furnace Will Not Light continued from previous page High limit switch HLC open Ignition controller IC red LED blinks 7 times or is on Ignition controller IC red LED blinks 6 times 24 VAC between terminals 1 and 2 on the Amplifier AMP 10 VDC between terminals 5 and 6 on the Amplifier AMP 24 VDC between terminals 3 and 4 on the Amplifier AMP Ignition controller IC red LED blinks 1 time 2 times or 4 times Everything is working properly consult factory Discharge temperature was above high limit setti
106. owing guidelines must be followed for all indoor units 1 Installation of venting must conform with local building codes In the absence of local codes installation must conform with the National Fuel Gas Code ANSI Z223 1 or in Canada CAN CGA B149 installations codes For the exhaust pipe use pipe approved fora category Ill appliance or single wall 26 gauge or heavier galvanized vent pipe The piping is required to be gas tight by ANSI For the combustion air pipe on separated combustion units sealed single wall galvanized air pipe is recommended The joints must be sealed with a metallic tape or Silastic suitable for temperatures up to 350 F A minimum of 12 inches of straight vent pipe is recommended after the exhaust connection and before any elbows Vertical combustion air pipes should be fitted with a tee drip leg and clean out cap to prevent any moisture in the combustion air pipe from entering the unit To reduce condensation insulate any vent runs greater than 5 feet All vent pipe connections should be made with at least three corrosion resistant sheet metal screws Refer to the National Fuel Gas Code for additional piping guidelines NOTE Vent piping is supplied by others and not supplied by manufacturer NOTE The drip leg should be cleaned out periodically during the heating season NOTE Clearances from combustible material for indoor units are determined by the National Fu
107. pass to energize motor starter 6 Control Terminal Block Provides wiring access to fan heat cooling enable controls 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 Exhaust Fuses Optional Provides proper fusing for exhaust fan motor s 11 Building Freeze Protection Timer Optional Prevents the discharge of cold air into the building 12 Heat Relay Allows power to pass to heating controls 13 Low Voltage Transformer Provides low voltage to the ignition controller 14 Heating Terminal Block Provides wiring access to heating controls 15 Inlet Air Sensor Optional Outdoor air stat that automatically controls the heating and or cooling based on outdoor air temperature ER Model IG IGX Make Up Air 16 Modulation Controller Provides 4 1 modulating turndown control of the furnace 17 Amplifier Controls the modulating valve based on the input from the modulation controller settings and the discharge air sensor 18 Airflow Switch Monitors the airflow inside the heat exchanger 19 Ignition Controller Controls the ignition of the furnace Maintains safe operation of the furnace 20 Modulation Controller Optional Provides proper fusing to
108. ptional exhaust starter ST2 is activated Power passes through N C contact on supply starter overload ST1 OL which is closed if the supply fan has not overloaded Power passes through N C contact on optional freeze protection timer RT4 which is closed if the temperature has remained above the set point Power passes to and energizes optional inlet damper D1 which opens Power passes through optional damper limit switch DL1 which is energized and closed if the optional inlet damper is open It may take several minutes for the damper to fully open and for the damper limit switch to close Power passes to and energizes fan relay RF Power passes through N O contact on fan relay RF which is closed once the fan relay RF is activated Power passes to and energizes starter relay ST1 N O contact on supply fan starter ST1 is energized and closed Supply fan M1 starts Heat Contact S4 Manually Closed Power passes through N O fan relay RF which is energized and closed if the supply fan M1 is on Power passes through N C contact on optional inlet air sensor TS4 which is closed if inlet air temperature is below the set point Power passes to and energizes the heat relay RH N O contact on heat relay RH closes 24 VAC is supplied to stage controller SC1 If the discharge temperature is less than the set point on the discharge air sensor TS2 and the high temperature limit control HLC1 has not been tripp
109. r sensor function overrides and shuts down the evaporative cooler if the outside temperature falls below the minimum cooling temperature 6 Enter Program Mode ED 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 O 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 Option setting Minimum Cooling Temperature Display 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 The Freeze Temperature is preset to the factory recommended 45 F Steps 9 11 should only be completed if the Freeze Temperature needs adjustment 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 Disp
110. rain can cause damage 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 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 WARNING When leak testing pressures equal to or less than 14 in wg 3 5 kPa first close the field installed shutoff valve to isolate the unit from the gas supply line 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 NOTE Each furnace has a single 3 4 inch connection 1 Determine the Supply Gas Requirements The unit s nameplate states the requirements for the gas being supplied to the unit Minimum gas pressure for maximum output MAX BTLHR NORMAL MANIFOLD SURE PRESSION DOADMISSION NORMALE MNGAS PRESSURE PRESSION DE GAZ EQUIPPED FOR AGANST EXTERNAL STATIC PRESSURE NC CONCU POUR CONTE PRESSION STATIQUE EXTERIEURE Type of gas Maximum gas pressure Indirect Gas Nameplate 2 Install Additional Regulator if Required When t
111. rease the gas pressure and clockwise rotation will increase the gas pressure Terminal Once the low fire is set reattach the disconnected wire to the modulating valve and reset the temperature selector Low Fire Adjustment NOTE The low fire manifold pressure should always be rechecked after adjusting the high fire NOTE Once the high and low fire manifold pressures are properly set reset the discharge air temperature to the desired setting Model IG IGX Make Up Air EX Start Up 4 1 Electronic Modulation 1 Send the Unit to High Fire To send the unit to high fire press and hold the Up Down and Enter keys The unit will remain at high fire until the Function key is pressed Function Ov Down Enter WARNING If the unit is forced to high fire it will remain at high fire until the Function key is pressed After modifying a setting the Enter key must be pressed to save the change If the Enter key is not pressed the display will return to the Program Menu without saving the change Forcing the unit to high fire in mild weather conditions may cause the high limit switch to trip If the switch trips it will reset once the discharge air temperature is at a safe level 2 Check the High Fire Manifold Pressure Before setting high fire on the EXA valve turn the regulator screw on the combination valve all the way in increase pressure Using a manometer measure the high fir
112. recautions 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 1 Plug all piping 2 Store belts flat to keep them from warping and stretching 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 7 C and 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 B Model IG IGX Make Up Air moisture build up Leave coverings loose to permit air circulation and to allow for periodic inspection The unit should be stored at least 3 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 OUTD
113. required to prevent freezing in a coil at a given outdoor air freeze point Completely fill coil with solution Drain coil Residual glycol fluid per these concentrations can be left in the coil without concern of freezing Recovered fluid can be used to flush other coils Percent of Percent of Freeze Point Freeze Point Ethylene Propylene Glycol Glycol by Volume by Volume Model IG IGX Make Up Air K3 Reference Model IG Venting Connection Location Exhaust Outlet Combustion Air Inlet Discharge End Venting Location Dimensions fet A B Cc D E G Housing 10 3 89 5 12 9 12 11 59 23 11 27 58 20 3 91 3 89 7 89 11 62 25 34 32 27 30 3 91 3 89 7 89 11 62 25 34 32 27 Dimensions are in inches Dimensions B and E are not needed for standard venting A round adapter should be used for the exhaust connection Flue Connection Size diameter in inches IG Standard Non Concentric Concentric 1 Housing Exhaust Exhaust Intake Exhaust Intake A 3 4 inch Gas Connection 10 au 2o 4 0 a 20 6 0 6 0 6 0 6 0 8 0 cal eae 30 6 0 6 0 6 0 6 0 8 0 Reference Model IGX Venting
114. rings 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 Bearing Bore Size inches RPM 2 1 1 1 1 1 J1 6 2 6 26 3 250 6 6 6 6 6 500 6 6 6 5 4 750 6 5 4 3 3 1000 5 3 2 1 1 1250 5 3 2 1 1 1500 5 2 1 1 0 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 e If extended grease lines are present relubricate while in operation only without endangering personnel e For ball bearings operating relubricate until clean grease is seen purging at the seals Be sure not to unseat the seal by over lubricating e 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 e 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 e Adjust relubrication frequency based on condition of purged grease e A high quality lithium based grease conforming to NLGI Grade 2 consistency such as those listed here Mobil 532 Texaco Multifak 2 B Shell Alavania 2 Mobilux 2 Texaco Prem
115. rops by 5 psig or less re pressurize the coil and wait another 10 minutes If the pressure drops again there is likely one or more small leaks which should be located and repaired Pressure losses greater than 5 psig indicate a large leak that should be isolated and repaired 3 Connect the Supply amp Return Lines Connect the supply and return lines as shown above 4 Install the Drain Line Connect an unobstructed l O E drain line to the drain pan A trap should be installed Drain Trap Hot Return _ Connection O Entering eaving Le Air i Air i Cold Supply O lt Connection 6 in min to prevent sewer gas from being drawn into the unit IMPORTANT All traps must be installed below the roof line or be otherwise protected from freezing EA Model IG IGX Make Up Air Installation of Building Pressure Control optional 1 Mount Pressure Tap Using the factory provided bracket mount the pressure tap to the Se r E outside of the unit Choose a location out of the prevailing lt winds and away from 4 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
116. rt on long off Call for cooling L1 Call for No cal for Outdoor temperature N A cooling cooling lockout Drain Drain L2 solenoid solenoid N A open closed Supply solenoid open Drain solenoid closed Cooling Cooling on ofi Supply solenoid L3 locked closed Flow test mode active Model IG IGX Make Up Air H 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 2 Speed VFD Motor A variable frequency drive VFD is used on a single speed motor to control air volumes The VFD is factory programmed for 2 speed operations It can be switched to low or high speed from a remote control panel Turn the fan speed
117. ry Attach equipment support to the roof remove metal cover flash to wooden nailer and reinstall cover 2 Apply Sealant Apply an appropriate sealant around the airstream opening to create an air tight seal 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 a equipment support s Metal Cover x Equipment Support Equipment Support Sealant The flange on the evaporative cooler should overlap the flange on the unit Placing Evaporative Module 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 To fasten the sides the media must be removed To remove the media first remove the access panel on the evaporative module and disconnect the evaporative pump s The media will now slide out With the media removed you can access the side fastening points inside the evaporative module With all the screws in place reinstall the media reconnect the pumps and reinstall the access panel ee When mounting the evaporative cooler it is important that it is level to ensure proper operation and water drainage Securing Evaporative Module Installation of Venting for Outdoor Units 1 Follow Guidelines All of the following guidelines must be followed when instal
118. s lower than design Adjust drives to reduce blower RPM Reference Blower Start Up Step 5 Blower rotation correct Reverse blower rotation Reference Blower Start Up Step 2 Motor voltage correct Provide proper power supply Reference Blower Start Up Step 1 Yes Motor horsepower too low Resize motor Shorted windings in motor Yes Yes e Replace motor Everything is working properly consult factory A Model IG IGX Make Up Air Troubleshooting Insufficient Airflow Yes Damper s not fully opened Adjust damper linkage s or replace faulty actuator s Damper actuators may take a few minutes to open System static losses too high L S Reduce losses by improving ductwork Ye Blower speed too low Adjust drives as needed Reference Blower Start Up Step 5 Yes Filters dirty or clogged Clean or replace filters Reference Filters in the Maintenance section Leaks in ductwork Yes Repair leaks Belt slipping Replace or tighten belt Reference V Belt Drives in the Maintenance section Everything is working properly consult factory Too Much Airflow Blower speed too high Adjust drives as needed Reference Blower Start Up Step 5 Filters not in place Insufficient external static pressure Increase external static pressure Everything is working properly consult factory EEJ Model IG IGX Make Up Air Troubleshooting
119. s 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 OOOOOd Start Up Blower Checklist refer to Blower Start Up section for further detail O Check line voltage L1 L2 L2 L3 L1 L3 O Check blower rotation O Check for vibration O Supply fan RPM RPM O Motor nameplate amps Amps O Actual motor amps Amps O Actual CFM delivered CFM Optional Accessories refer to Blower Start Up section Step 6 for further detail O Heating inlet air sensor Actual Setting Typical Setting 60 70 F O Cooling inlet air sensor Actual Setting Typical Setting 75 F O Building freeze protection Actual Setting Typical Setting 5 min 45 F O Dirty filter gauge Actual Setting Typical Setting varies Start Up Indirect Gas refer to Furnace Start Up section for further detail Furnace 1 O Determine furnace control type 1 Stage 2 Stage 8 Stage 2 1 Mod 4 1 Mod O Check supply gas pressure Maximum Minimum Actual O Set the High Manifold pressure in wg O Set the Low Manifold pressure in wg O Setthe unit s operating temperature degrees F Furnace 2 Optional O Determine furnace control type 1 Stage 2 Stage 8 Stage 2 1 Mod 4 1 Mod O Check supply gas pressure Maximum Minimum Actual O Set the High Manifold pressure in wg O Set the Low Manifold pressure in wg Furnace 3 Optiona
120. s 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 40e 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 A 3 After storage period purge grease before putting fan into service Indirect Gas Fired Unit Installations Units are listed for installation in the United States and Canada e Installation of gas fired duct furnaces must conform with local building codes In the absence of local codes installation must conform to the National Fuel Gas code ANSI 2223 1 or in Canada CAN CGA B149 installation codes e All electrical wiring must be in accordance with the regulation of th
121. sion to curb adaptor with 12 sheet metal screws field provided Exhaust 1 inch Inside Flange Combination Extension 3 Install Ductwork Good duct practices should be followed for all ductwork All ductwork should be installed in accordance with SMACNA and AMCA guidelines NFPA 96 and any local codes Reference the CAPS submittal for ductwork size and location Exhaust Ductwork by Others i Supply i Ductwork by Others Ductwork The use of a duct adapter is recommended ona downblast DBC arrangement to align the ductwork with the supply unit The duct adapter is only a guide and is not to be used as support for the ductwork Model IG IGX Make Up Air JE Installation of Roof Mounted Unit Arrangement DBC continued 4 Apply Sealant Apply an appropriate sealant around the perimeter of the curb and duct adapter s to isolate fan vibration and prevent water penetration Exhaust Duct Installed NX Supply Duct with Duct Adapter Installed Sealing Ductwork 5 Install Exhaust Fan Fasten exhaust fan to curb extension with self tapping sheet metal screws Exhaust Fan Installing Exhaust Fan NOTE Installing the exhaust fan prior to the supply unit will allow for easier installation of options 6 Install Exhaust Options Install optional hinge kit with restraining cables and grease trap with drain connection NOTE NFPA 96 requires that the exhaust fan be hinged
122. t the high fire screws on each staged gas valve to set both high fire manifold pressures Counterclockwise rotation will decrease the gas pressure and clockwise rotation will increase the gas pressure Low Fire Adjustment High Fire Adjustment High Fire Terminal 3 Send the Unit to Low Fire Disconnect and isolate the wire from the high fire terminal to send the unit to low fire 4 Check the Low Fire Manifold Pressure Measure each valve s low fire manifold pressure The recommended low fire manifold pressure is 7 8 in wg for natural gas and 2 1 2 in wg for LP If needed use the low fire adjustment screw on each staged gas valve to properly set both low manifold settings Counterclockwise rotation will decrease the gas pressure and clockwise rotation will increase the gas pressure When the low fire manifold pressure is properly set reattach the disconnected Eight Stage Manifold wire to the high fire Pressure in wg terminal allow the heat Natural Gas LP switch to close aos 7 ai or remove the jumper High Fire 3 1 2 10 WARNING Once the high and low fire have been set be sure the press the Function key to end high fire mode The middle LED light L2 will stop flashing when high fire mode is off Step 5 7 are for adjusting the discharge air setting The discharge air temperature setting is factory set to the recommended 70 F Only adjust the setting if needed After modify
123. tank The water level should be above the pump intake and below the overflow Adjust the float as needed to achieve the proper water level EEJ Model IG IGX Make Up Air Evaporative Cooling with Auto Drain and Fill Supply Line an Sump Overflow a VALVE A Supply Solenoid normally closed feaz Sump Drain VALVE C VALVE B Sump Drain Solenoid ea normally open i Trap gt Supply Line Drain Solenoid j Drain Line normally open Auto Drain amp Fill Evaporative Piping IMPORTANT The supply line should be of adequate size and pressure to resupply the amount of water lost due to bleed off and evaporation The drain line should be the same size or larger than the supply line CAUTION All 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 IMPORTANT The supply solenoid Valve A is NOT the same as the drain solenoids Valve B and Valve C Make sure to use the proper solenoid for each location Check your local code requirements for proper installation of this type of system Auto Drain amp Flush Valves when provided by manufacturer Mfg ASCO F ae Part Part sri ae Diam
124. temperature is preset to the factory recommended 70 F The actual discharge air temperature is the default display Outside Air Temperature OAt To temporarily display the outside air temperature use the Up or Down key until the display reads OAt then press the Enter key Program Revision Number To access the program revision number from the default display press the Up or Down key until the display reads F J or The two numbers following the letter indicate the revision number For example F72 indicates program F revision twelve Optional Room Override ROt When the room override function is triggered the discharge air temperature 70 F default is temporarily changed to the room override setting 90 F default When the room override function is released the discharge air temperature returns to the default temperature Indicating Lights Three indicating lights are located across the top of the display to indicate the status of the furnace 4 1 Electronic Modulation Light On Off Blinking L1 Call for Heat No call for heat High fire Call for heat No call for heat L2 sent to ignition sent to ignition High fire controller controller La_ Cemetion fan Combustion en High 8 1 Staged Control Single Furnace Units Light On Off Blinking L1 Call for heat No call for heat N A L2 n a n a High fire L3 Burner interlock n a n
125. th Refer to table for minimum and maximum vent lengths The total equivalent vent length must include elbows The equivalent length of a 4 inch elbow is 6 feet and the Vent Minimum Maximum equivalent length Length feet feet of a 6 inch elbow Vertical 10 70 is 10 feet 1 Determine Venting Location Determine the location of the concentric venting adapter CVA based on any clearances that must be maintained follow all codes referenced in these instructions Model IG IGX Make Up Air E 2 Attach Mounting Brackets Attach field supplied corrosion resistant mounting brackets to the CVA using corrosion resistant sheet metal screws 3 Install Exhaust Pipe Slide the exhaust pipe through the CVA Provide enough exhaust piping to pass through the roof and provide the minimum clearance of 12 inches between the exhaust pipe termination and the combustion air intake With all required clearances satisfied attach the exhaust pipe to the CVA INTAKE END Exhaust Connection Model IG Exhaust Connection Model IGX DISCHARGE Combustion Air Connection Model IG Combustion Air Connection Model IGX 4 Install Combustion Air Pipe Attach a field supplied combustion air pipe to the concentric side of the CVA Be sure to provide enough combustion air piping to pass through the roof and provide the minimum clearance of 12 inches between the combustion air intake and th
126. the unit s combustion exhaust through the exterior wall to the outdoors The exhaust pipe must terminate at least 12 inches from the outside surface of the outside wall Attach exhaust vent terminal to the end of the exhaust pipe Using field supplied mounting brackets support the exhaust pipe as needed A 2 Install Combustion Air Pipe Run a combustion air pipe from the unit s combustion air intake through the exterior wall to the outdoors The combustion air pipe must terminate at least 12 inches from the combustion vent pipe and 24 inches from the exterior surface of the outside wall Attach the combustion air inlet guard to the end of the combustion air pipe Using field supplied mounting brackets support the combustion air pipe as needed 3 Seal Wall Openings Using an appropriate method seal the wall openings around the piping INTAKE END Exhaust Connection Model IG Exhaust Connection Model IGX DISCHARGE Combustion Air Connection Model IG Combustion Air Connection Model IGX Model IG IGX Make Up Air E Installation of Two Pipe Venting Vertical Refer to the diagram below for venting on vertical concentric systems The combustion air pipe must terminate at least 12 inches above the roof This clearance may need to be increased to accommodate for snow accumulation The exhaust must terminate at least 12 inches above and 12 inches horizontally from the combustion air inl
127. ting mode will default to the current setting after 5 minutes of inactivity 3 Exit High Fire Mode Press the Function key to exit high fire mode 4 Send Unit to Low Fire Remove the cover on the modulating gas valve Press and hold button 2 until the LED light blinks red release The unit is now in low fire 5 Check the Low Fire Manifold Pressures With the unit at low fire use a manometer to check the manifold pressure Refer to the Gas Train Layout in the Reference section for the test port location The recommended low fire manifold pressure is 1 3 in wg for natural 4 1 Modulation Manifold Pressure in wg d1 0i Natural Gas LP gas and 1 0 in Low Fire 1 3 1 wg for LP gas High Fire 3 1 2 10 To adjust the low fire gas pressure use button 1 and 2 on the gas valve Button 1 will increase the gas pressure while button 2 will decrease the gas pressure Each time the button is pressed it corresponds to the minimum available step size and will slowly change the gas pressure Holding the button down will rapidly change the gas pressure To save the low fire setting stimutaneously hold buttons 1 and 2 until the LED turns off Note If the valve remains in the low fire setting mode for more than five 5 minutes it will revert back to its previous setting The following steps are for adjusting the discharge air setting The discharge air temperature setting is factory set to the recomme
128. tional IMPORTANT Guidelines for the installation of the cooling coil have been provided to ensure proper performance of the coils and their longevity These are general guidelines that may have to be tailored to meet the specific requirements of any one job As always a qualified party or individual should perform the installation and maintenance of the coil Protective equipment such as safety glasses steel toe boots and gloves are recommended during the installation and maintenance of the coil When installing couplings do not apply undue stress to the connection Use a backup pipe wrench to avoid breaking the weld between the coil connection and the header All field piping must be self supporting System piping should be flexible enough to allow for the thermal expansion and contraction of the coil 1 Verify Coil Hand Designation Check the coil hand designation to ensure that it matches the system Coils are generally plumbed with the supply connection located on the bottom of the leaving air side of the coil and the return connection at the top of the entering air side of the coil This arrangement provides a counter flow heat exchanger and positive coil drainage 2 Check the Coil for Leaks Pressurize the coil to 100 psig with dry nitrogen or other suitable gas The coil should be left pressurized for a minimum of 10 minutes If the coil holds the pressure the hook up can be considered leak free If the pressure d
129. tronic overload protection to supply motor 3 Low Voltage Transformer Provides low voltage to fan heat cooling enable controls staged Gas Staged Gas furnace controls and optional evaporative cooling Pressure Valve qo Test Port controls fon PARS lt 3 4 inch 4 Control Terminal Block Provides wiring access Manifold P iJ n ee to controls N Connection 5 Fan Relay Allows power to pass to energize motor starter 6 Control Terminal Block Provides wiring access to fan heat cooling enable controls 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 Exhaust Fuses Optional Provides proper fusing for exhaust fan motor s 11 Building Freeze Protection Timer Optional Prevents the discharge of cold air into the building 12 Heat Relay Allows power to pass to heating controls 13 Low Voltage Transformer Provides low voltage to the ignition controller 14 Heating Terminal Block Provides wiring access to heating controls 15 Inlet Air Sensor Optional Outdoor air stat that automatically controls the heating and or cooling based on outdoor air temperature R Model IG IGX Make Up Air EE
130. umps should be on Water Blows through Evaporative Cooler Are the headers in place and located near the entering air side of the media Replace headers and or move the headers Water supply greater than evaporation and bleed off rate Use the main supply valve to reduce the supply of water Air velocity greater than specified 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 EJ Model IG IGX Make Up Air Troubleshooting 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 NOTE Changing the On Time Factor by 1 will change the water supply by approximately 3 IMPORTANT The Enter key must be pressed to save the new On Time Factor 4 Exit Program Mode After 15 seconds of idle time the controller will Some water drainage is desired to keep the media automatically exit Program Mode flushed but it should be minimized to utilize the Water Wizard saturated and excessive water will be draining from the sump tank 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 recom
131. ut off If the furnace is at high fire and the discharge air temperature setting dtS FX Program Menu is not satisfied the furnace will remain at high fire If the furnace is at low fire and the discharge air temperature setting dtS FX Program Menu is satisfied the furnace will shut off 6 Optional Evaporative Cooling Contact S4 Closed N O contact on fan relay RF is energized and closed Power passes through N O contact on optional inlet air sensor TS4 which is energized and closed if the inlet air temperature is above the set point Power passes to and energizes cool relay RC Model IG IGX Make Up Air EE Sequence of Operation 8 1 Staged Control continued e N O contact on cool relay RC is energized and closed e Power passes to evaporative cooling pump P1 If DX or chilled water coils are used rather than an evaporative cooler the cooling sequence of operation will depend on the coil controls Cooling coil controls are supplied by others EZ Model IG IGX Make Up Air Operation and Errors Ignition Controller The green LED light indicates NORMAL operation while the red LED light indicates an ERROR operation This controller is found only in the furnace control center It has an LED indicator light on the top right of the controller that will flash GREEN for NORMAL operation or tt ene E RED for an ERROR Some E 3 furnace configurations 43 killall lala dal al have two
132. xcept for energy cut off or sensor lead wire which must be rated to 150 C IMPORTANT The equipment must be properly grounded Any wiring running through the unit in the airstream must be protected by metal conduit metal clad cable or raceways 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 total 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 SUP HP EXH HP

Greenheck Fan IG/IGX Make-Up Air Unit 470656 User's Manual

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