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Greenheck IG User Manual

Greenheck IG
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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.
1
General Safety Information
Only qualified personnel should install this unit.
Personnel should have a clear understanding of these
instructions and should be aware of general safety
precautions. Improper installation can result in electric
shock, possible injury due to coming in contact with
moving parts, as well as other potential hazards.
Other considerations may be required if high winds
or seismic activity are present. If more information
is needed, contact a licensed professional engineer
before moving forward.
1. Follow all local electrical and safety codes, as well
as the National Electrical Code (NEC), the National
Fire Protection Agency (NFPA), where applicable.
Follow the Canadian Electrical Code (CEC) in
Canada.
2. The rotation of the wheel is critical. It must be free
to rotate without striking or rubbing any stationary
objects.
3. Motor must be securely and adequately grounded.
4. Do not spin fan wheel faster than the maximum
cataloged fan rpm. Adjustments to fan speed
significantly affects motor load. If the fan RPM is
changed, the motor current should be checked to
make sure it is not exceeding the motor nameplate
amps.
5. Do not allow the power cable to kink or come
in contact with oil, grease, hot surfaces, or
chemicals. Replace cord immediately if damaged.
6. Verify that the power source is compatible with the
equipment.
7. Never open blower access doors while the fan is
running.
DANGER
Always disconnect power before working on or
near a unit. Lock and tag the disconnect switch or
breaker to prevent accidental power up.
CAUTION
When servicing the unit, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Do not touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
FOR YOUR SAFETY
The use and storage of gasoline or other
flammable vapors and liquids in open
containers in the vicinity of this appliance is
hazardous.
WARNING
Improper installation, adjustment,
alteration, service or maintenance can
cause property damage, injury or death.
Read the installation, operating and
maintenance instructions thoroughly before
installing or servicing this equipment.
®
Document 470656
IG/IGX Make-Up Air Unit
®
Model IG / IGX Make-Up Air

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Greenheck IG Specifications

General IconGeneral
MaterialStainless Steel
ListedUL 710
ApplicationCommercial Kitchens
Grease ExtractionBaffle Filters
LightingLED
Hood StyleIsland
Airflow CapacityVaries with size; consult Greenheck's performance data
UL CertificationUL 710 Listed
OptionsFire Suppression, Custom Sizes

Summary

General Safety Information

DANGER & CAUTION Statements

Critical safety warnings regarding power disconnection and hot surfaces during maintenance.

Safety Precautions and Warnings

Guidelines for gas smell, flammable vapors, and general warnings for safe operation.

Receiving, Handling, and Storage Procedures

Receiving and Handling Guidelines

Inspect shipments, follow proper rigging, and handle units to prevent damage.

Storage Recommendations and Maintenance

Guidelines for indoor/outdoor storage and periodic maintenance to prevent unit deterioration.

Unit Installation Requirements and Clearances

Indirect Gas Fired Unit Installation Guidelines

General installation guidelines, code compliance, and electrical/gas piping requirements.

Service Clearances

Table specifying minimum clearances for safe installation and service access.

Indoor Unit Installation Procedures

Hanger and Unit Installation Steps

Steps for installing hangers and securely mounting the indoor unit.

Ductwork and Sealant Application

Guidelines for installing ductwork and applying sealant for proper connection.

Roof Mounted Unit Installation (Arrangement DB / HZ)

Curb, Support, and Ductwork Installation

Procedures for installing roof curb, equipment support, and ductwork.

Roof Mounted Unit Installation (Arrangement DBC)

Curb/Support and Combination Adaptor Installation

Steps for installing roof curb, support, and combination curb adaptor.

Ductwork Installation Guidelines

Guidelines for installing ductwork according to industry standards and codes.

Roof Mounted Unit Installation (Arrangement DBC) Continued

Sealant, Fan, and Unit Installation

Applying sealant, installing exhaust fan, and mounting the supply unit.

Weatherhood Assembly and Sealing

Steps for assembling, attaching, and sealing the weatherhood.

Optional Module and Venting Installation

Evaporative Cooling Module Installation Steps

Procedures for installing the evaporative cooling module.

Venting for Outdoor Units Guidelines

Guidelines and warnings for installing venting on outdoor units.

Venting Installation Guidelines

Indoor Unit Venting Installation Requirements

Requirements for indoor unit venting, including materials and clearances.

Overview of Venting Methods

Description of standard, concentric, and 2-pipe venting options.

Standard Venting Installation Procedures

Standard Indoor Venting Installation Steps

Detailed steps for horizontal and vertical standard indoor venting.

Vent Pipe Sizing and Installation Guidance

Guidance on selecting vent pipe diameter and proper installation techniques.

Concentric Venting Installation Procedures

General Concentric Venting Guidelines

Explanation of concentric venting and the use of the concentric venting adapter.

Horizontal Concentric Venting Details

Specific instructions and diagrams for horizontal concentric venting.

Vent Connection and Length Specifications

Tables providing vent connection diameters and minimum/maximum lengths.

Concentric Venting Installation Procedures Continued

Vertical Concentric Venting Details

Specific instructions and diagrams for vertical concentric venting.

Exhaust Pipe and Combustion Air Pipe Installation

Steps for installing exhaust and combustion air pipes with the CVA.

CVA Assembly and Sealing Procedures

Procedures for installing and securing the CVA assembly and sealing openings.

Concentric Venting Installation Procedures Continued

CVA Assembly Installation and Securing

Steps for installing the CVA assembly through the roof and securing it.

Pipe Connection to Unit and CVA

Connecting exhaust and combustion air pipes to the unit and CVA assembly.

Two Pipe Venting Installation Procedures

Horizontal Two Pipe Venting Installation

Specific instructions for horizontal two-pipe venting.

Exhaust and Combustion Air Pipe Installation

Steps for installing exhaust and combustion air pipes through the wall.

Vent Connection and Length Specifications

Tables for vent connection diameters and minimum/maximum lengths.

Two Pipe Venting Installation Procedures Continued

Vertical Two Pipe Venting Installation

Specific instructions for vertical two-pipe venting.

Exhaust and Combustion Air Pipe Installation

Steps for installing exhaust and combustion air pipes through the roof.

Vent Connection and Length Specifications

Tables for vent connection diameters and minimum/maximum lengths.

Electrical Wiring Installation Procedures

General Electrical Wiring Requirements

Compliance with codes, grounding, and wire protection.

DANGER: High Voltage Safety Warning

Warning that high voltage work requires a qualified electrician.

Main Power and Accessory Wiring

Connecting main power lines and wiring optional accessories.

Electrical Wiring Installation Procedures Continued

Wiring Optional Cooler and Economizer Components

Instructions for wiring evaporative coolers and economizer sensors.

Installing DDC Interface Guidance

Guidance on installing a DDC interface for building management systems.

Gas Piping Installation Procedures

Gas Piping Code Compliance and Safety

Installation must follow codes; leak testing is critical.

Supply Gas Requirements and Connection

Determining gas requirements and connecting the supply line safely.

Evaporative Cooler Piping Installation

Recirculating and Auto Drain/Fill Piping Diagrams

Diagrams and notes for installing recirculating and auto drain/fill piping.

Water Supply and Drain Line Installation

Steps for installing water supply and drain lines, including traps.

Water Wizard™™ Installation Procedures

Water Wizard™™ System Specific Instructions

Specific instructions for installing Water Wizard™™ components.

Solenoid and Drain Line Connection

Connecting solenoids and drain lines according to the system design.

Water Wizard™™ Installation and DX Coil Piping

Wiring Water Wizard™™ Components

Wiring solenoids and temperature sensors for the Water Wizard™™.

Direct Expansion (DX) Coil Piping Guidelines

General guidelines for installing DX coils, emphasizing safety and proper techniques.

Direct Expansion (DX) Coil Piping Installation Continued

Suction, Liquid Line, and TEV Installation Steps

Procedures for installing suction, liquid lines, and the thermal expansion valve.

Coil Evacuation and Charging Procedures

Steps for evacuating the coil to 500 microns or less and charging the system.

Chilled Water Coil Piping and Building Pressure Control

Chilled Water Coil Installation Checks

Verifying coil hand, checking for leaks, and connecting lines.

Building Pressure Control Installation Steps

Mounting pressure taps, running lines, and setting building pressure.

Blower Start-Up Procedures

Pre Start-Up Checks and Tools Required

Performing pre-start-up checks and identifying required tools.

Blower Rotation and Voltage Verification

Verifying correct blower rotation direction and supply voltage.

Motor and Air Volume Performance Checks

Checking motor performance and measuring air volume (CFM).

Blower Start-Up Procedures Continued

Setting Optional Components

Adjusting settings for optional components like inlet air sensors and freeze protection.

Furnace Start-Up Procedures

Available Control Options Overview

Table outlining different furnace control options for various unit configurations.

Single Stage Control Start-Up Steps

Steps for performing start-up on single-stage furnace controls.

High Fire Manifold Pressure Check

Procedure to check and adjust high fire manifold pressure.

Staged Furnace Start-Up Procedures

2:1 Staged Control Start-Up Steps

Steps for starting up 2:1 staged control, including high/low fire pressure checks.

8:1 Staged Control Start-Up Steps

Steps for starting up 8:1 staged control, including high fire sequence initiation.

Staged Furnace Start-Up Procedures Continued

Low Fire Pressure Check and Setpoints Menu Access

Checking low fire pressure and accessing the Setpoints Menu.

Discharge Air and Inlet Air Sensor Settings

Adjusting discharge air temperature and inlet air sensor settings.

Staged Furnace Start-Up Procedures Continued

Room Override Setting Adjustment Procedure

Steps to access and edit the room override setting.

Electronic Modulation Furnace Start-Up

2:1 Electronic Modulation Start-Up Steps

Procedures for starting up a 2:1 electronic modulation furnace.

Manifold Pressure Checks and Adjustments

Steps for checking and adjusting high and low fire manifold pressures.

Electronic Modulation Furnace Start-Up Continued

4:1 Electronic Modulation Start-Up Steps

Procedures for starting up a 4:1 electronic modulation furnace.

High and Low Fire Manifold Pressure Checks

Detailed steps for checking and setting high/low fire manifold pressures.

Electronic Modulation Furnace Start-Up Continued

Setpoints Menu Navigation and Editing

How to access and modify setpoints like discharge air and inlet air temperature.

Economizer Start-Up Procedures

Sensor Installation and Minimum Air Settings

Verifying sensor installation and setting minimum outside air.

Enthalpy Changeover Set Point Configuration

Setting the enthalpy changeover point for optimal economizer operation.

Evaporative Cooling Start-Up Procedures

Recirculating Evaporative Cooler Start-Up Steps

Steps for checking installation, breaking in media, and setting auto-drain.

Media Break-In and Water Adjustment

Procedures for media break-in, flow rate check, and bleed-off rate adjustment.

Water Wizard™™ Start-Up Procedures

Water Wizard™™ Interface and Pressure Settings

Navigating the interface, opening solenoid, and setting water pressure.

Minimum Cooling Temperature Adjustment

How to enter program mode and adjust the minimum cooling temperature.

Water Wizard™™ Start-Up Procedures Continued

Freeze Temperature and Mode Operations

Adjusting freeze temperature and understanding Drain/Flow Test modes.

Status Lights and Program Mode Understanding

Understanding status lights and program mode functions.

Variable Volume Unit Operation Checks

VAV Unit Operation Testing Procedures

Testing VAV units, including 2-speed VFD, modulating, and pressure control.

Recirculating Unit Operation Checks

Recirculating Unit Operation Testing

Testing 2-position dampers, modulating dampers, and building pressure control.

Sequence of Operation - 2:1 Staged Furnace

Fan and Heat Contact Sequences

Describes the sequence for exhaust fan, supply fan, and heat activation.

Ignition Controller and High/Low Fire Sequences

Details ignition controller operation and the high/low fire sequence.

Sequence of Operation - 2:1 Modulation Furnace

Fan, Heat, and Ignition Controller Sequences

Describes fan, heat, and ignition controller operation sequences.

High/Low Fire Modulation Sequence Explanation

Explains how the furnace modulates between high and low fire.

Operation Modes and Settings

Program Mode Navigation and Settings

How to access and use the Program Mode for settings like Inlet Air and Discharge Air.

Program Information and Furnace Sequences

Program Revision and Indicating Lights

Understanding program revision numbers and furnace status lights.

Sequence of Operation - 4:1 Electronic Modulation

Steps describing the sequence of operation for 4:1 modulation.

Sequence of Operation - 4:1 Electronic Modulation Continued

Ignition Controller and High/Low Fire Sequences

Details ignition controller operation and high/low fire sequences for 4:1 modulation.

Sequence of Operation - 8:1 Staged Furnace

Fan, Heat, and Ignition Controller Sequences

Describes fan, heat, and ignition controller operational sequences.

Staging Control Sequence of Operation

Explains how the furnace stages based on temperature setpoints.

Ignition Controller Operation and Error Codes

Normal Operation LED Indications

Table describing normal operating status indicated by green LEDs.

Error Operation LED Indications

Table describing error conditions indicated by red LEDs.

Economizer Operation Modes

Economizer Operation Options (EC-1 to EC-4)

Explains how economizers function based on temperature or enthalpy references.

Troubleshooting - Blower Operation Issues

Blower Does Not Operate Diagnosis Flowchart

Flowchart to diagnose and resolve issues when the blower fails to operate.

Troubleshooting - Motor Performance Issues

Motor Over Amps Diagnosis Flowchart

Flowchart to diagnose and resolve motor over-amperage issues.

Troubleshooting - Airflow Issues

Insufficient Airflow Diagnosis Flowchart

Flowchart to diagnose and resolve insufficient airflow problems.

Excessive Airflow Diagnosis Flowchart

Flowchart to diagnose and resolve too much airflow problems.

Troubleshooting - Noise and Vibration Issues

Excessive Noise or Vibration Diagnosis Flowchart

Flowchart to identify and resolve causes of excessive noise or vibration.

Troubleshooting - Furnace Ignition Failures

Single/2:1 Stage Furnace Ignition Failure Diagnosis

Flowchart to diagnose why single or 2:1 stage furnaces won't ignite.

Troubleshooting - Furnace Ignition Failures Continued

2:1 Modulating Furnace Ignition Failure Diagnosis

Flowchart to diagnose why 2:1 modulating furnaces won't ignite.

Troubleshooting - Furnace Ignition Failures Continued

4:1 Modulating Furnace Ignition Failure Diagnosis

Flowchart to diagnose why 4:1 modulating furnaces won't ignite.

Troubleshooting - Furnace Ignition Failures Continued

4:1 Modulating Furnace Ignition Failure Diagnosis Continued

Continuation of troubleshooting for 4:1 modulating furnaces.

Troubleshooting - Furnace Ignition Failures Continued

8:1 Staged Furnace Ignition Failure Diagnosis

Flowchart to diagnose why 8:1 staged furnaces won't ignite.

Troubleshooting - Furnace Ignition Failures Continued

8:1 Staged Furnace Ignition Failure Diagnosis Continued

Continuation of troubleshooting for 8:1 staged furnaces.

Troubleshooting - Evaporative Cooler Issues

Cooler Not Operating Diagnosis

Flowchart for diagnosing why the evaporative cooler is not operating.

Water Blow-Through Diagnosis

Flowchart for diagnosing water blowing through the evaporative cooler.

Troubleshooting - Water Wizard™™ Issues

Improper Water Supply Diagnosis Flowchart

Flowchart to resolve issues with improper water supply to the Water Wizard™™.

Routine Maintenance Procedures

V-Belt Drives and Bearings Maintenance

Instructions for checking V-belt drives and lubricating bearings.

Wheel and Bearing Lubrication Schedule

Recommended lubrication intervals for bearings based on size and RPM.

Routine Maintenance Procedures Continued

Motor and Filter Maintenance Guidelines

Guidelines for motor cleaning/lubrication and filter maintenance.

Coil Maintenance Procedures

Procedures for maintaining chilled water and evaporative cooler coils.

Fall Maintenance Procedures

Seasonal Checks and Cleaning Tasks

Fall checks for high limit, gas train, burners, heat exchanger, and flue collector.

Winterizing Coils and Evaporative Coolers

Procedures for winterizing chilled water coils and evaporative coolers.

Coil Winterization Procedures

Flushing Coils with Glycol Solutions

Instructions for using glycol solutions to flush coils and prevent freezing.

Venting Reference Information

Model IG Venting Connection Locations

Diagrams and tables for IG model venting dimensions and flue connections.

Model IGX Venting Connection Locations

Diagrams and tables for IGX model venting dimensions and flue connections.

Control Center Reference - Model IG (Single or 2 Stage)

Model IG Component Identification List

Numbered list identifying components within the Model IG control center.

Control Center Reference - Model IG (8:1 Staged)

Model IG (8:1 Staged) Component Identification

Numbered list identifying components within the Model IG (8:1 Staged) control center.

Control Center Reference - Model IG (2:1 Modulation)

Model IG (2:1 Modulation) Component Identification

Numbered list identifying components within the Model IG (2:1 Modulation) control center.

Control Center Reference - Model IG (4:1 Modulation)

Model IG (4:1 Modulation) Component Identification

Numbered list identifying components within the Model IG (4:1 Modulation) control center.

Control Center Reference - Model IGX (Blower Control Center)

Model IGX Blower Control Center Component Identification

Numbered list identifying components within the Model IGX blower control center.

Furnace Control Center Reference - Model IGX

IGX Single or 2 Stage Furnace Controls

Component identification and diagrams for IGX single/2-stage furnaces.

IGX 8:1 Staged Furnace Controls

Component identification and diagrams for IGX 8:1 staged furnaces.

Furnace Control Center Reference - Model IGX Continued

IGX 2:1 Modulation Furnace Controls

Component identification and diagrams for IGX 2:1 modulation furnaces.

IGX 4:1 Modulation Furnace Controls

Component identification and diagrams for IGX 4:1 modulation furnaces.

Performance Data Reference

Model IG Performance Table

Table showing air volume requirements for heating input and temperature rise.

Start-Up Checklist and Procedures

Pre Start-Up and Blower Start-Up Checklists

Checklists to ensure all pre-start-up and blower start-up tasks are completed.

Indirect Gas Furnace Start-Up Checks

Checklists for verifying furnace control type, gas pressure, and manifold settings.

Maintenance Log and Company Information

Maintenance Log Entries Section

Section to record maintenance dates, times, and notes.

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