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Greenheck PVG User Manual

Greenheck PVG
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Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety information. Failure
to comply with instructions could result in personal injury and/or property damage!
Indirect Gas-Fired Heat Modules 1
General Safety Information
These indirect gas-fired furnaces are commonly used
in many different manufacturer’s ventilating products.
For unit-specific information, refer to the Installation,
Operation and Maintenance manual (IOM) for the unit in
which this furnace is installed.
Both the furnace units are listed for installation in the
United States and in Canada.
Installation of gas-fired duct furnaces must conform
with local building codes. In the absence of local
building codes, installation must conform to the
National Fuel Gas code, ANSI Z223.1 or in Canada,
CAN/CGA-B149 Installation codes.
All electrical wiring must be in accordance with the
regulations of the National Electric Code, ANSI/
NFPA-70.
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.
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 injury or
death. Read the installation, operating and
maintenance instructions thoroughly before
installing or servicing this equipment.
Recognized Component
®
®
Document 474645
Model PVF and PVG
Indirect Gas-Fired Heat Modules
Model PVF
Model PVG

Table of Contents

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Greenheck PVG Specifications

General IconGeneral
BrandGreenheck
ModelPVG
CategoryGas Heater
LanguageEnglish

Summary

General Safety Information

Unit Information

Furnace Model Number

Location and recording of the unit's model number.

Burner Control Turndown

How to find and calculate the burner turndown ratio.

Furnace Serial Number

Location of the unit's serial number for identification.

ETL Listing

Information on ETL testing and recognition for gas-fired heat modules.

Furnace Control Center

Furnace Control Center Components

List and location of components in a typical control center.

Typical Furnace Control Logic

Diagram illustrating the control flow for electronic modulation.

Typical Furnace, Electrical and Control Components

Component Descriptions

Details on microprocessors, sensors, controllers, valves, and other parts.

Gas-Fired Burner Turndown

Electronic Modulation

How electronic modulation achieves variable firing rates.

Two Stage Valve

Operation of two-stage valves for 2:1 turndown.

Combinations

Various combinations of turndown control options.

Installation of Venting for Outdoor Units

Follow Guidelines

General installation rules for outdoor venting.

Install Stack (optional)

Instructions for installing an optional exhaust stack.

Installation of Venting for Indoor Units

Venting Methods

Standard Indoor Venting

Description of standard venting using building air for combustion.

Installation of Standard Indoor Venting

Vent Pipe Diameter

Table for selecting the correct vent pipe diameter.

Installing Exhaust Vent Pipe

Procedures for installing the exhaust vent pipe.

Installation of Concentric Venting

Concentric Venting – Horizontal

Specific guidance for horizontal concentric venting.

Vent Connection Diameter

Table for vent connection diameters for concentric systems.

Vent Length

Minimum and maximum vent lengths, including elbow equivalents.

Determine Venting Location

Guidance on choosing the correct CVA location.

Attach Mounting Brackets

How to attach mounting brackets for the CVA.

Concentric Venting – Vertical

Vent Connection Diameter

Table for vent connection diameters for vertical concentric systems.

Vent Length

Minimum and maximum vent lengths for vertical systems.

Determine Venting Location

Guidance on choosing the correct CVA location.

Attach Mounting Brackets

How to attach mounting brackets for the CVA.

Installation of Two Pipe Venting – Horizontal

Vent Connection Diameter

Table for vent connection diameters for horizontal two-pipe systems.

Vent Length

Minimum and maximum vent lengths for horizontal two-pipe systems.

Installation of Two Pipe Venting – Vertical

Vent Length

Minimum and maximum vent lengths for vertical two-pipe systems.

Vent Connection Diameter

Table for vent connection diameters for vertical two-pipe systems.

Installation of Control Wiring

Installation of Discharge Air Sensor

Installation of Gas Piping

Test the System for Leaks

Procedure for performing leak tests on gas piping.

Connect the Supply Gas Line

Steps for connecting the gas supply line to the unit.

Determine the Gas Supply Requirements

Sequence of Operation

Start-Up / Standby

Initial checks and standby operation sequence.

Heat Mode

Step-by-step process when the unit is in heat mode.

Recovery from Lockout

Procedure for recovering the unit from a lockout state.

Performance Data

Gas Valves

Overview of typical Single Stage Valve

Description and features of single stage gas valves.

Overview of typical Two Stage Valve

Description and features of two stage gas valves.

Overview of typical Selectra Valve

Description and features of Selectra valves for modulation.

Overview of typical Modulating Valve

Description and features of modulating gas valves.

Start-Up - Furnaces (all units)

With 4:1 Turndown Electronic Modulation

Specific start-up procedures for 4:1 turndown modulation.

Adjust High Fire and Low Fire Settings

Modulating Valve High Fire Setting

Step-by-step guide to set the high fire pressure.

Modulating Valve Low Fire Setting

Step-by-step guide to set the low fire pressure.

With 2:1 Turndown Electronic Modulation

With 8 Stage Combustion

With Single Stage

With 2 Stage Combustion

With Combination Turndown Configurations

Troubleshooting-Ignition Controller

GREEN LED Indications - NORMAL OPERATION

Meanings of green LED codes for normal operation.

RED LED Indications - ERROR OPERATION

Meanings of red LED codes for error conditions.

Airflow Fault

Causes and troubleshooting for airflow faults (6 red flashes).

Flame Fault

Causes and troubleshooting for flame faults (2 red flashes).

Troubleshooting

4:1 Modulating Furnace Will Not Light

Diagnostic flowchart for a furnace not lighting.

4:1 Modulating Furnace Will Not Light

Troubleshooting

2:1 Modulating Furnace Will Not Light

Diagnostic flowchart for a 2:1 modulating furnace not lighting.

Troubleshooting

8 Stage Furnace Will Not Light

Diagnostic flowchart for an 8 stage furnace not lighting.

8 Stage Furnace Will Not Light

Troubleshooting

Single or 2:1 Stage Furnace Will Not Light

Diagnostic flowchart for single or 2:1 stage furnaces not lighting.

Reference - FX Controller

LED Status Indicators

Explanation of LED status lights on the controller.

Controller Interface Key Function Description

Description of the controller's buttons and interface.

Stand-alone Furnace Control

How the FX controller manages furnaces without microprocessors.

Program Mode

Guide to accessing and using the controller's program mode.

Inlet Air Sensor (IAS) (optional)

Information on the optional inlet air sensor.

Discharge Air Temperature (dtS)

Explanation of the discharge air temperature setting.

Outside Air Temperature (OAt)

How to display the outside air temperature.

Field Adjustments

Go to High Fire Mode

Procedure to set the controller to high fire mode.

Return to Normal Operation

How to return the controller to normal operation.

Accessing Controller Settings

How to access setpoints, discharge air, inlet air, and room override.

Furnace Control with Microprocessor Control

Maintenance

Component Maintenance

Procedures for blower motor, burners, orifices, heat exchanger, flue collector.

System Checks

Annual checks for electrical wiring, gas train tightness, and parts.

Maintenance Log

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