Greenheck 470656 IG / IGX Installation and Operation Manual

Document 470656
IG/IGX Make-Up Air Unit
®
Installation, Operation and Maintenance Manual
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the
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 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.
Model IG / IGX Make-Up Air
1
Receiving
Upon receiving the product, check to ensure all
items are accounted for by referencing the delivery
receipt or packing list. Inspect each crate or carton
for shipping damage before accepting delivery. Alert
the carrier of any damage detected. The customer
will make notation of damage (or shortage of items)
on the delivery receipt and all copies of the bill of
lading which is countersigned by the delivering carrier.
If damaged, immediately contact your Greenheck
Representative. Any physical damage to the unit
after acceptance is not the responsibility of the
manufacturer.
Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative
to arrange for obtaining missing parts. Sometimes it
is not possible that all items for the unit be shipped
together due to availability of transportation and truck
space. Confirmation of shipment(s) must be limited to
only items on the bill of lading.
Handling
Units are to be rigged and moved by the lifting
brackets provided or by the skid when a forklift is
used. Location of brackets varies by model and size.
Handle in such a manner as to keep from scratching
or chipping the coating. Damaged finish may reduce
ability of unit to resist corrosion.
Storage
Units are protected against damage during shipment. If
the unit cannot be installed and operated immediately,
precautions need to be taken to prevent deterioration
of the unit during storage. The user assumes
responsibility of the unit and accessories while in
storage. The manufacturer will not be responsible
for damage during storage. These suggestions are
provided solely as a convenience to the user.
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 (-1°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
moisture build up. Leave coverings loose to permit air
circulation and to allow for periodic inspection.
2
Model IG / IGX Make-Up Air
The unit should be stored at least 3½ in. (89 mm) off
the floor on wooden blocks covered with moisture
proof paper or polyethylene sheathing. Aisles between
parts and along all walls should be provided to permit
air circulation and space for inspection.
OUTDOOR — Units designed for outdoor applications
may be stored outdoors, if absolutely necessary.
Roads or aisles for portable cranes and hauling
equipment are needed.
The fan should be placed on a level surface to prevent
water from leaking into the unit. The unit should be
elevated on an adequate number of wooden blocks so
that it is above water and snow levels and has enough
blocking to prevent it from settling into soft ground.
Locate parts far enough apart to permit air circulation,
sunlight, and space for periodic inspection. To
minimize water accumulation, place all unit parts on
blocking supports so that rain water will run off.
Do not cover parts with plastic film or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.
Inspection and Maintenance during Storage
While in storage, inspect fans once per month. Keep a
record of inspection and maintenance performed.
If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the fan wheel by hand ten to fifteen
revolutions to distribute lubricant on motor. Every three
months, the fan motor should be energized. If paint
deterioration begins, consideration should be given to
touch-up or repainting. Fans with special coatings may
require special techniques for touch-up or repair.
Machined parts coated with rust preventive should be
restored to good condition promptly if signs of rust
occur. Immediately remove the original rust preventive
coating with petroleum solvent and clean with lintfree cloths. Polish any remaining rust from surface
with crocus cloth or fine emery paper and oil. Do not
destroy the continuity of the surfaces. Wipe thoroughly
clean with Tectyl® 506 (Ashland Inc.) or the equivalent.
For hard to reach internal surfaces or for occasional
use, consider using Tectyl® 511M Rust Preventive or
WD-40® or the equivalent.
REMOVING FROM STORAGE — As units are removed
from storage to be installed in their final location,
they should be protected and maintained in a similar
fashion, until the equipment goes into operation.
Prior to installing the unit and system components,
inspect the unit assembly to make sure it is in working
order.
1. Check all fasteners, set screws on the fan,
wheel, bearings, drive, motor base, and
accessories for tightness.
2. Rotate the fan wheel(s) by hand and assure no
parts are rubbing.
3. Purge grease before putting fan into service.
®
Indirect Gas Fired Unit Installations
Units are listed for installation in the United States and
Canada.
• 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 Z223.1 or in Canada, CAN/
CGA-B149 installation codes.
• All electrical wiring must be in accordance with the
regulation of the National Electrical 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.
Table of Contents
Installation
Clearance to Combustibles/Service Clearances. . . 3
Indoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unit Arrangement DB / HZ . . . . . . . . . . . . . . . . . . 4-5
Roof Mounted Unit – Arrangement DBC . . . . . . . 5-6
Optional Evaporative Cooling Module . . . . . . . . . . . 7
Venting – Outdoor . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Indoor, All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Standard Indoor . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Concentric, General . . . . . . . . . . . . . . . . . . . . . . . 10
Concentric, Horizontal . . . . . . . . . . . . . . . . . . 10-11
Concentric, Vertical . . . . . . . . . . . . . . . . . . . . 11-12
Two Pipe, Horizontal . . . . . . . . . . . . . . . . . . . . . . 13
Two Pipe, Vertical. . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . 15-16
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Optional Evaporative Cooler Piping . . . . . . . . . 18-19
Optional Water Wizard™ . . . . . . . . . . . . . . . . . 19-20
Optional Direct Expansion (DX) Coil Piping. . . 20-21
Optional Chilled Water Coil Piping . . . . . . . . . . . . . 22
Optional Building Pressure Control . . . . . . . . . . . . 22
Optional Dirty Filter Switch. . . . . . . . . . . . . . . . . . . 23
Start-Up
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25
Furnace – All Units . . . . . . . . . . . . . . . . . . . . . . . . . 26
Single Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2:1 Staged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8:1 Staged . . . . . . . . . . . . . . . . . . . . . . . . . . . 27-29
4:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Optional Economizer . . . . . . . . . . . . . . . . . . . . 32-33
Optional Evaporative Cooling. . . . . . . . . . . . . . . . . 34
Optional Water Wizard™ . . . . . . . . . . . . . . . . . 35-36
Operation
Optional Water Wizard™ . . . . . . . . . . . . . . . . . . . . 36
Optional VAV Units . . . . . . . . . . . . . . . . . . . . . . . . . 37
Optional Recirculating Units . . . . . . . . . . . . . . . . . . 38
Sequence of Operation, Furnace
2:1 Staged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . 40-41
Operation of Controller
4:1 Modulation and 8:1 Staged Controller . . 41-42
®
Sequence of Operation, Furnace
4:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . 42-43
8:1 Staged . . . . . . . . . . . . . . . . . . . . . . . . . . . 44-45
Ignition Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Troubleshooting
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Motor Over Amps . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Insufficient / Too Much Airflow . . . . . . . . . . . . . . . . 48
Excessive Noise / Vibration . . . . . . . . . . . . . . . . . . 49
Furnace – Single or 2:1 Staged . . . . . . . . . . . . . . . 50
2:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . 52-53
8:1 Staged . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-55
Optional Evaporative Cooling. . . . . . . . . . . . . . . . . 56
Optional Water Wizard™ . . . . . . . . . . . . . . . . . . . . 57
Maintenance
Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-59
Fall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-61
Reference
Vent Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Model IG – Single or 2 Stage . . . . . . . . . . . . . . . . . 63
8:1 Staged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Model IGX – Blower Control Center. . . . . . . . . . . . 67
Single or 2 Stage . . . . . . . . . . . . . . . . . . . . . . . . . 68
8:1 Staged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4:1 Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Performance Table . . . . . . . . . . . . . . . . . . . . . . . . . 70
Start-Up Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . 71
Maintenance Log . . . . . . . . . . . . . . . . . Backcover
Commitment . . . . . . . . . . . . . . . . . . . . Backcover
Clearance to Combustibles /
Service Clearances
Indirect Fired
Units*
Floor
Top
Sides
Ends
0 inches
0 inches
0 inches
0 inches
(0 mm)
(0 mm)
(0 mm)
(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
3
Installation of Indoor Unit
Installation of Arrangement DB / HZ
NOTE
To prevent premature heat exchanger failure, do not
locate units where chlorinated, halogenated, or acid
vapors are present.
1. Install Hangers
Install threaded hangers from 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.
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.
Roof Curb
Metal Cover
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.
Ductwork
Ceiling Supports
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)
Hangers
Ductwork
NOTE
Unit Supports
Indoor Mounting
NOTE
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.
NOTE
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.
4
Model IG / IGX Make-Up Air
The use of a duct adapter is recommended on a
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
is mandatory when lifting the unit.
NOTE
Some units come with the weatherhood attached
and step 5 may not apply.
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 extension to curb adaptor with #12
sheet metal screws (field provided).
Exhaust
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.
1 inch
Inside
Flange
Supply
6. Seal Weatherhood Seam
Using an appropriate sealant, seal the seam between
the weatherhood and the unit.
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.
Complete Rooftop Installation
Exhaust
Ductwork
by Others
Supply
Ductwork
by Others
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.
Ductwork
NOTE
The use of a duct adapter is recommended on a
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.
Roof Curb
Metal Cover
Equipment
Support
Roof Curb and Equipment Support
NOTE
Refer to Outdoor Venting instructions when locating
the unit.
®
Model IG / IGX Make-Up Air
5
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.
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).
Exhaust Duct Installed
Sealant
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 Supply Unit
NOTE
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.
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
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.
NFPA 96 requires that the exhaust fan be hinged.
Complete Combination Installation
6
Model IG / IGX Make-Up Air
®
Installation of Evaporative Cooling
Module (optional)
NOTE
1. Follow Guidelines
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
Metal Cover
placement of equipment
support(s) in relation to
Equipment
the unit). Verify that all unit
Support
supports are level, shim if
necessary. Attach equipment
Equipment Support
support to the roof, remove
metal cover, flash to wooden nailer and
reinstall cover.
Sealant
2. Apply Sealant
Apply an appropriate sealant around the
airstream opening to create an air tight
seal.
Sealant
3. Set Evaporative Cooling Module
Use a crane and a
set of spreader bars
hooked to the factory
lifting lugs to lift and
center the module
on the equipment
support(s). The flange
on the evaporative
cooler should overlap
the flange on the unit.
Installation of Venting for Outdoor
Units
Placing Evaporative Module
NOTE
The use of all lifting lugs and a set of spreader bars is
mandatory when lifting the evaporative cooling 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
Securing Evaporative Module
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.
All of the following guidelines must be followed when
installing 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.
3. The combustion blower discharge on outdoor
units must be located a minimum of 42 inches
from any combustible materials.
4. Do not modify or obstruct the combustion
air inlet cover or the combustion blower
weatherhood.
5. Do not add vents other than those supplied by
the manufacturer.
6. 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.
NOTE
When mounting the evaporative cooler, it is
important that it is level to ensure proper operation
and water drainage.
®
Model IG / IGX Make-Up Air
7
Installation of Venting for Indoor
Units
WARNING
The following 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.
2. For the exhaust pipe, use pipe approved for a
category III appliance or single wall, 26 gauge
or heavier galvanized vent pipe. The piping is
required to be gas tight by ANSI.
3. For the combustion air pipe on separated
combustion units, sealed single-wall galvanized
air pipe is recommended.
4. The joints must be sealed with a metallic tape or
Silastic™ suitable for temperatures up to 350°F.
5. A minimum of 12 inches of straight vent pipe is
recommended after the exhaust connection and
before any elbows.
6. 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.
7. To reduce condensation, insulate any vent runs
greater than 5 feet.
8. All vent pipe connections should be made with at
least three corrosion resistant sheet metal screws.
9. Refer to the National Fuel Gas Code for additional
piping guidelines.
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
• uses building air for combustion
• vents exhaust to outdoors
• one exterior roof or wall penetration
Separated Combustion Concentric Venting
• uses outside air for combustion
• vents exhaust to outdoors
• one exterior roof or wall penetration
Separated Combustion 2-Pipe Venting
• uses outside air for combustion
• vents exhaust to outdoors
• two exterior roof or wall penetrations
NOTE
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.
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 Fuel Gas Code
and/or other local codes.
8
Model IG / IGX Make-Up Air
®
Installation of Standard Indoor
Venting
Vent Pipe Diameter
Select the vent pipe diameter. Use only the specified
pipe diameter.
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 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
Wall
A = 12 inch minimum
Pitch vent pipe
downward
from furnace
¼ inch per foot
Furnace Size
(MBH)
Exhaust Pipe Diameter
(inches)
75 - 175
4
200 - 400
6
Installing Exhaust Vent Pipe
Install the vent pipe with a minimum 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
Length
Minimum Maximum
(feet)
(feet)
Horizontal
5
70
Vertical
10
70
A
EXHAUST
Air Inlet
Exhaust
Vent
Terminal
Standard Indoor Venting - Horizontal
A = 12 inch minimum
B = 12 inch minimum,
but should size
according to expected
snow depth
Exhaust Vent
Terminal
B
EXHAUST
Roof Line
A
Air Inlet
Standard Indoor Venting - Vertical
®
Model IG / IGX Make-Up Air
9
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.
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).
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).
A = 2 inch minimum
B = 12 inch minimum
Exterior
Wall
Mounting
Bracket
A
B
EXHAUST
Pitch vent pipe
downward
from furnace
1/4 inch per foot
If venting vertically through the roof, refer to the
vertical concentric venting instructions. If venting
horizontally through the wall, refer to the horizontal
concentric venting instructions.
COMBUSTION AIR
Mounting
Bracket
Exhaust
Vent
Terminal
Combustion
Air Inlet Guard
Vent Connection Diameter
NOTE
Vent piping is supplied by others and not supplied
by manufacturer.
Vent terminals must be used (one 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.
Non-Concentric Vent
Concentric Vent
Connection Diameter Connection Diameter
Furnace Exhaust Combustion Air Exhaust Combustion Air
(inches)
(inches)
(inches)
Size (MBH) (inches)
75-175
4
4
4
6
200-400
6
6
6
8
Vent Length
CVA-4
CVA-6
4-inch Concentric
Venting Adapter
6-inch Concentric
Venting Adapter
Combustion Air Connection
Concentric Side
Exhaust Connection
Concentric Side
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
5
70
Horizontal
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).
CVA
2. Attach Mounting Brackets
Attach field-supplied, corrosion resistant mounting
brackets to the CVA using corrosion resistant sheet
metal screws.
Combustion Air Connection
Non-Concentric Side
Exhaust Connection
Non-Concentric Side
Top View
10 Model IG / IGX Make-Up Air
®
Concentric Venting – Vertical
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 Connection
(Model IGX)
Exhaust Connection
(Model IG)
DISCHARGE
END
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.
A = 12 inch minimum, but
should size according to
expected snow depth
B = 12 inch minimum
C = 12 inch minimum
Exhaust Vent
Terminal
B
Combustion Air
Inlet Terminal
A
Roof Line
Mounting
Bracket
4. Install Combustion Air Pipe
COMBUSTION AIR
Combustion Air Connection
(Model IG)
EXHAUST
Combustion Air Connection
(Model IGX)
Attach a field-supplied combustion air pipe to the
concentric side of the CVA.
Mounting
Bracket
C
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.
Tee with
drip leg and
clean-out cap
C
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 appropriate method.
®
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
(inches)
(inches)
(inches)
Size (MBH) (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
Vent
Minimum Maximum
equivalent length
Length
(feet)
(feet)
of a 6 inch elbow
10
70
Vertical
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 11
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.
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.
INTAKE END
Exhaust Connection
(Model IGX)
Exhaust Connection
(Model IG)
DISCHARGE
END
Combustion Air Connection
(Model IGX)
Combustion Air Connection
(Model IG)
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 the 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.
12 Model IG / IGX Make-Up Air
®
Installation of Two Pipe Venting –
Horizontal
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.
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 air 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).
3. Seal Wall Openings
A minimum of 1 inch and a maximum of 48 inches
of building wall thickness is required for separated
combustion vent pipe.
Using an appropriate method, seal the wall openings
around the piping.
INTAKE END
A = 12 inch minimum
B = 24 inch minimum
Exterior
Wall
C = 12 inch minimum
Exhaust
Vent
Terminal
Exhaust Connection
(Model IGX)
Exhaust Connection
(Model IG)
B
A
EXHAUST
C
Pitch vent pipe
downward
from furnace
¼ inch per foot
COMBUSTION AIR
DISCHARGE
END
Two (2) field-supplied
support brackets
Combustion
Air Inlet
Terminal
Vent Connection Diameter
Combustion Air Connection
(Model IGX)
Combustion Air Connection
(Model IG)
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
(MBH)
Exhaust
(inches)
Combustion
(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
Length
Horizontal
Minimum Maximum
(feet)
(feet)
5
50
1. Install Exhaust Pipe
Run an exhaust pipe from 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.
®
Model IG / IGX Make-Up Air 13
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 inlet.
C
Exhaust Vent
Terminal
Combustion
Air Inlet
Terminal
B
A
COMBUSTION AIR
EXHAUST
Roof Line
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 increased 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.
D
Tee with
drip leg and
clean-out cap
D
A = 12 inch minimum, but should size
according to expected snow depth
B = 24 inch minimum
C = 12 inch minimum
INTAKE END
Exhaust Connection
(Model IGX)
Exhaust Connection
(Model IG)
D = 12 inch minimum
Vent Connection Diameter
DISCHARGE
END
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
(MBH)
Exhaust
(inches)
Combustion
(inches)
75 - 175
4
4
200 - 400
6
6
Combustion Air Connection
(Model IGX)
Combustion Air Connection
(Model IG)
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
Length
Vertical
Minimum Maximum
(feet)
(feet)
10
14 Model IG / IGX Make-Up Air
70
®
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).
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
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.
VOLTS
HZ
PH
SUP HP
EXH HP
MCA
MOP
CAUTION
If replacement wire is required, it must have a
temperature rating of at least 105ºC, except for
energy cut-off or sensor lead wire which must be
rated to 150ºC.
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.
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:
• Selectra Stat
• Dirty Filter Indicator
• Room Override
• TSCP
• Blower Switch
• KSCP
• Heat Switch
• Economizer Activator
• 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 numberto-number wiring.
®
Model IG / IGX Make-Up Air 15
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 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.
The sensors are provided by the factory and ship with
the unit.
8. Install Discharge Air Sensor (optional)
For units with 1:1, 2:1, 3:1, 6:1, 8:1, 16:1 and 24:1
staged turndown; or 4:1, 8:1, and 12:1 electronic
modulation, the discharge air sensor must be installed
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.
16 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.
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 BTU/HR
BTU/H MAX
MIN BTU/HR
BTU/H MIN
NORMAL MANIFOLD
PRESSURE
PRESSION DÕADMISSION
NORMALE
“W.C.
MIN GAS PRESSURE
FOR MAX OUTPUT
PRESSION DE GAZ MIN
POUR PUISSANCE MAX
MIN GAS
PRESSURE
PRESSION DE GAZ
“W.C.
MAX GAS
PRESSURE
PRESSION DE GAZ
MAX
“W.C.
IMPORTANT
All piping should be clean and free of any foreign
material. Foreign material entering the gas train can
cause damage.
“W.C.
DESIGN 'T
'T NORMALE
TYPE OF GAS
NATURE DU GAZ
F
AGAINST
EQUIPPED FOR
CONCU POUR
PSI
SCFM
EXTERNAL STATIC PRESSURE
“W.C.
CONTE
PRESSION STATIQUE EXTERIEURE
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.
NOTE
When connecting the gas supply, the length of the
run must be considered in determining the pipe size
to avoid excessive pressure drop. Refer to a Gas
Engineer’s Handbook for gas pipe capacities.
NOTE
Each furnace has a single 3/4-inch connection.
Type of gas
Maximum gas pressure
Indirect Gas Nameplate
2. Install Additional Regulator if Required
When the supply gas pressure exceeds the maximum
gas pressure shown on the unit’s nameplate, an
additional regulator (by others) is required to reduce
the pressure. The
Supply Gas Pressure Range
regulator must have a
(in. wg)
listed leak limiting device
Minimum
Maximum
or it must be
Natural
6
14
vented to the
LP
10
14
outdoors.
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.
To
Supply gas
Controls
connections
Gas Cock
must be
Ground Joint Union
made by
From
Gas
a qualified Supply
1/8 in. Plugged Tap
installer
6 in. Trap
and are not
furnished by
manufacturer.
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 17
Installation - Evaporative Cooler Piping (optional)
Evaporative Cooling with Recirculating Pump
Evaporative Cooling with Auto Drain and Fill
Supply Line
Supply Line
Sump Overflow
Supply Line Valve
(by others)
Drain Line Valve
(by others)
Drain Line
Overflow
VALVE A
Supply Solenoid
(by others)
Sump Drain
VALVE C
Sump Drain Solenoid
(by others)
VALVE B
Supply Line Drain Solenoid
(by others)
Trap
Trap
Drain Line
Recirculating Evaporative Piping
Auto Drain & Fill Evaporative Piping
IMPORTANT
IMPORTANT
All supply solenoids, valves and all traps must be below
the roofline or be otherwise protected from freezing.
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.
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
should be used to
6 in. min.
prevent sewer gas
Drain
6 in. min.
from being drawn
Trap
into the unit.
3. Check/Adjust Water Level
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 & Flush Valves
(when provided by manufacturer)
Assembly
Number
852178
Mfg.
Part
Number
ASCO™
Part
Number
461262
8210G2
Solenoid De-Energized
Type
Position
Diameter
Qty.
Supply
Closed
1/2 inch
(12.7 mm)
1
461263 8262G262
Supply
Line
Drain
Open
1/4 inch
(6.35 mm)
1
461264
Sump
Drain
Open
3/4 inch
(19.05 mm)
1
8210G35
Part numbers subject to change.
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.
18 Model IG / IGX Make-Up Air
®
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
prevent sewer gas from
6 in. min.
being drawn into the
Drain
6 in. min.
unit. Refer to Drain Trap
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.
Installation of Water WizardTM (optional)
Evaporative Cooling with the Water Wizard™
NOTE
The following instructions are provided for
evaporative coolers equipped with the Water
Wizard™ only. Additional instructions are provided
for evaporative coolers equipped with the auto drain
and fill or bleed-off.
WARNING
Disconnect and lock-out all power and gas before
performing any maintenance or service to the unit.
Failure to do so could result in serious injury or
death and damage to equipment.
Water Wizard™ Valves
(when provided by manufacturer)
Unit
Model
Assembly
Number
Mfg. ASCO™
Solenoid De-Energized
Part
Part
Diameter Qty.
Type
Position
Number Number
461262 8210G2 Supply
IGX H12/H22
852370
Supply
IGX - H32
383086 8210G34 Line
(<9000 cfm)
Drain
Closed
1/2 inch
(12.7 mm)
1
Open
1/2 inch
(12.7 mm)
1
383088 8210G9
Supply
Closed
3/4 inch
(19.05 mm)
1
383086 8210G34
Supply
Line
Drain
Open
1/2 inch
(12.7 mm)
1
IGX - H32
(≥9000 cfm) 852371
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 personal 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 19
Installation of Water Wizard™
Installation - Direct Expansion (DX)
Coil Piping (optional)
continued
To Media
IMPORTANT
Pressure Gauge
Factory
Installed
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
perform 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.
Field
Installed
IMPORTANT
Sump Drain
Manual Supply Valve
Roof Line
Supply Solenoid
(normally closed)
Trap
Supply Line Drain Solenoid
(normally open)
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
AI2 and AIC on the terminal strip in the unit’s control
center.
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
NOTE
The Water Wizard™ start-up must be completed for
proper performance.
Distributor Access Panel
Thermal
(by others)
(by others)
Installation with Hot Gas Bypass
2. Verify Nozzle Placement
Inspect the refrigerant
distributor and verify
that the nozzle is in
place. The nozzle is
generally held in place
by a retaining ring or is
an integral part of
the distributor itself.
20 Model IG / IGX Make-Up Air
Retainer
Ring
Nozzle
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 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.
Coil
Suction Header
Distributor
Liquid Line
Equalizer Line
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.
NOTE
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
line to the drain pan. A
trap should be used to
prevent sewer gas from
being drawn into the
unit.
6 in. min.
Drain
Trap
6 in. min.
IMPORTANT
Nozzle
All traps must be installed below the roof line or be
otherwise protected from freezing.
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 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.
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
®
Model IG / IGX Make-Up Air 21
Installation of Chilled Water Coil
Piping (optional)
Installation of Building Pressure
Control (optional)
1. Mount Pressure Tap
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
Hot Return
designation to ensure that
Connection
it matches the system.
Coils are generally
Entering
Leaving
Air
Air
plumbed with the supply
connection located on
Cold Supply
Connection
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 drops 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.
Using the factory provided bracket, mount the
pressure tap to the
outside of the unit.
Choose a location
out of the prevailing
winds and away from
supply or exhaust
fans to assure
accurate readings.
2. Run Pressure Tap Lines
Run a pressure tap line from the pressure tap on the
outside of the unit to the low pressure tap on the back
of the photohelic gauge. Run a second pressure tap
line from the high pressure tap on the back of the
photohelic gauge to the space. Fifty feet of tubing is
supplied with the unit.
High
Pressure
Tap to
space
Factory
Wiring
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
Pressure Setting
Needles
3. Connect the Supply & Return Lines
Connect the supply and return lines as shown above.
4. Install the Drain Line
Connect an unobstructed
drain line to the drain pan.
A trap should be installed
to prevent sewer gas from
being drawn into the unit.
Pressure Setting Knobs
Typical Photohelic Gauge Settings
6 in. min.
Drain
Trap
6 in. min.
IMPORTANT
All traps must be installed below the roof line or be
otherwise protected from freezing.
22 Model IG / IGX Make-Up Air
®
Installation of Dirty Filter Switch
(optional)
To adjust the switch, the unit must be running with
all of the access doors in place, except for the
compartment where the switch is located (exhaust
intake compartment). The adjusting screw is located
on the top of the switch.
Setscrew (on front of switch) must
be manually adjusted after the
system is in operation.
Negative pressure connection is
toward the 'front or top' of the
switch. (Senses pressure on the
blower side of filters)
Positive pressure connection is toward the 'back or bottom'
of the switch. (Senses pressure at the inlet side of filters)
1. Open the filter compartment and place a sheet of
plastic or cardboard over 50% of the filter media.
2. Replace the filter compartment door.
3. Check to see if there is power at the alert signal
leads (refer to electrical diagram).
4. Whether there is power or not, turn the adjustment
screw on the dirty filter gauge - clockwise if you did
not have power, counterclockwise if you did have
power - until the power comes on or just before the
power goes off.
5. Open the filter compartment and remove the
obstructing material.
6. Replace the door and check to make sure that you
do not have power at the alert signal leads. The
unit is now ready for operation.
®
Model IG / IGX Make-Up Air 23
Start-Up - Blower
NOTE
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.
To reverse the rotation on three phase units,
disconnect and lock-out the power, then
interchange any two power leads.
NOTE
To reverse the rotation on single phase units,
disconnect and lock-out the power, then rewire the
motor per the manufacturer’s instructions.
IMPORTANT
If the blower is rotating in the wrong direction, the
unit will move some air, but will not perform as
designed. Be sure to perform a visual inspection to
guarantee the correct blower rotation.
3. Check for Vibration
Check for unusual noise, vibration or overheating of
the bearings. Reference the Troubleshooting section
for corrective actions.
SPECIAL TOOLS REQUIRED
•
•
•
•
•
•
•
IMPORTANT
Voltage Meter (with wire probes)
Amperage Meter
Micro Amp Meter
Pressure Gauges – (refrigerant)
Tachometer
Thermometer
Incline manometer or equivalent
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
WARNING
Check the housing, blower, and ductwork for any
foreign objects before running the blower.
1. Check the Voltage
Before starting the unit, compare the supplied voltage,
hertz, and phase with the unit and motor’s nameplate
Voltage, Hertz, Phase
information.
Generally, fan vibration and noise is transmitted
to other parts of the building by the ductwork. To
minimize this undesirable effect, the use of heavy
canvas duct connectors is recommended.
4. Motor Check
Measure the motor’s voltage, amps and RPM.
Compare to the specifications. Motor amps can be
reduced by lowering the motor RPM or increasing
system static pressure.
IMPORTANT
VOLTS
HZ
PH
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.
SUP HP
MCA
MOP
Unit’s Total MCA
5. Air Volume Measurement & Check
Electrical Nameplate
Arrows are placed on the
blower scroll to indicate the
proper direction or reference
the example shown.
24 Model IG / IGX Make-Up Air
tio
n
Ro
Open the blower access
door and run the blower
momentarily to determine the
rotation.
ta
2. Check the Blower Rotation
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.
Blower
Housing
Blower Rotation
®
NOTE
The most accurate way to measure the air volume is
by using a pitot traverse method downstream of the
blower. Other methods can be used but should be
proven and accurate.
IMPORTANT
Changing the air volume can significantly increase
the motor’s amps. If the air volume is changed,
the motor’s amps must be checked to prevent
overloading the motor.
NOTE
To ensure accuracy, the dampers are to be open
when measuring the air volume.
6. Set-up Optional Components
Adjust the settings on the optional components. See
the Control Center Layout in the Reference section for
location of optional components.
• Heating Inlet Air Sensor
Typical setting: 60-70ºF
• Cooling Inlet Air Sensor
Typical setting: 75ºF
• Building Freeze Protection
Typical setting: 5 minutes; 45ºF
• Dirty Filter Gauge
Typical setting: Settings vary greatly for each
unit. See Reference section for adjusting
information.
NOTE
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.
®
Model IG / IGX Make-Up Air 25
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 setup 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.
Available Control Options
Single Furnace Units
1:1 Staged
2:1 Staged
8:1 Staged
4:1 Electronic
Modulation
NOTE
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.
one 4:1 modulating furnace
Two Furnace Units
1:1 Staged
2:1 Staged
4:1 Staged
16:1 Staged
8:1 Electronic
Modulation
two independent 1-stage furnaces
two independent 1-stage furnaces
two independent 2-stage furnaces
one 8-stage and
one 1-stage furnace
one 4:1 modulating and
one 2-stage furnace
Three Furnace Units
1:1 Staged
3:1 Staged
6:1 Staged
24:1 Staged
NOTE
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 jumper out.
one 1-stage furnace
one 2-stage furnace
one 8-stage furnace
12:1 Electronic
Modulation
three independent 1-stage furnaces
three independent 1-stage furnaces
three independent 2-stage furnaces
one 8-stage and
two 1-stage furnaces
one 4:1 modulating,
one 2-stage and
one 1-stage furnace
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.
2. Check the High Fire
Manifold Pressure
Temperature
Selector
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
Single Stage Manifold
Pressure (in. wg)
should be 3-1/2 in. wg for
natural gas and
LP
Natural Gas
10 in. wg for
High Fire
10
3-1/2
LP gas.
If needed, use the high
fire adjustment screw
on the staged 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
3. Reset the Temperature Setting
Reset the temperature setting on the temperature
selector to the desired setting.
26 Model IG / IGX Make-Up Air
®
Start-Up - 2:1 Staged Control
Start-Up - 8:1 Staged Control
1. Send Unit to High Fire
IMPORTANT
Send the unit to high fire by setting
the temperature selector to its
Temperature
maximum setting.
8:1 staged furnaces use 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.
Selector
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 should be 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
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
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
Up
Enter
Down
WARNING
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)
The pressure on low fire
should be 7/8 in. wg
LP
Natural Gas
for natural gas and
Low Fire
2-1/2
7/8
2-1/2 in. wg for LP
High Fire
10
3-1/2
gas.
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
Once the unit is forced to high fire, it will remain at
high fire until the Function key is pressed.
NOTE
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, adjust 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.
Reset the temperature setting on the temperature
selector to the desired setting.
®
Model IG / IGX Make-Up Air 27
High Fire
Adjustment
Low Fire
Adjustment
High Fire
Terminal
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
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
7/8
2-1/2
Low Fire
or remove the
3-1/2
10
High Fire
jumper.
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.
NOTE
Step 5-7 are for adjusting the discharge air setting.
The discharge air temperature setting is factory set
to the recommended 70ºF. Only adjust the setting if
needed.
NOTE
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.
5. Access the Setpoints Menu
Press and hold the Function
key for three seconds to
access the Setpoints Menu.
The display will read “SEt.”
28 Model IG / IGX Make-Up Air
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.
NOTE
Steps 8 - 9 are provided for adjusting the inlet air
set point. The inlet air sensor is preset to the factory
recommended 65ºF, only adjust if needed.
NOTE
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 to 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.
NOTE
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.
NOTE
Steps 10 - 11 are provided for adjusting the room
override setting. Only adjust the setting if the room
override function is desired.
NOTE
The room override function temporarily changes
the discharge air temperature to the room override
setting if the room thermostat is not satisfied.
®
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.
NOTE
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.
®
Model IG / IGX Make-Up Air 29
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.
Up
Function
Enter
Down
NOTE
The FX05 controller's home screen will display
the program code that has been loaded onto this
controller.
If F09 of F10 is being viewed this is NOT a default
code on this controller, this is not a normal state.
If the display is showing anything other than F09
of F10, then this would indicate an alarm is being
displayed.
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.
NOTE
#2
LED
Light
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.
Controls left in the high fire setting 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
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 fire 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.
30 Model IG / IGX Make-Up Air
#1
NOTE
NOTE
If needed, adjust the high
fire screw on the shutoff valve to set the high
fire manifold pressure.
Counterclockwise rotation
will decrease the gas
pressure and clockwise
rotation will increase the
gas pressure.
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.
High Fire
Adjustment
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
4:1 Modulation Manifold
fire manifold pressure
Pressure (in. wg)
is 1/3 in. wg for natural
Natural Gas
LP
gas and 1.0 in.
1/3
1
Low Fire
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,
simultaneously 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.
NOTE
The following steps are for adjusting the discharge
air setting. The discharge air temperature setting is
factory set to the recommended 70ºF. 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.
NOTE
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.
NOTE
Steps 9 thru 10 are provided for adjusting the inlet
air set point. The inlet air sensor is preset to the
factory recommended 60ºF, only adjust if needed.
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.
NOTE
Steps 11 and 12 are provided for adjusting the room
override setting. Only adjust the setting if the room
override function is desired.
NOTE
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.
NOTE
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.
NOTE
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.
NOTE
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 change
to the inlet air sensor setting.
®
Model IG / IGX Make-Up Air 31
Start-Up - Economizer (optional)
NOTE
Only models IG-HV and IGX-HV with options EC-1,
2, 3 or 4 use an economizer.
NOTE
To prevent premature heat exchanger failure, do not
locate units where chlorinated, halogenated, or acid
vapors are present.
NOTE
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.
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.
NOTE
Program the optional room stat. Separate detailed
instructions for programming the room stat ship with
the optional room stat.
The following economizer sequences will function
to modulate the outdoor and return air dampers to
determine and maximize the availability of free cooling.
Although the Honeywell economizer controller contains
numerous set points, the adjustment of only a few is
necessary to ensure optimal performance.
Sequences
EC-1 Outdoor Air Temperature Reference
Relevant Set Points
1. MAT SET - The mixed air temperature set point.
The control will modulate the damper to maintain
temperature as best as it can (Set point menu,
Default 53°F )
2. LOW T LOCK - The set point for the low temperature
mechanical cooling lockout. (Set point menu, Default
32°F)
3. DRYBLB SET - The outdoor air set point to call for
economizer. (Set point menu, Default 63°F)
4. MIN POS - The minimum signal voltage sent to
the dampers. This must be set to 2 VDC. (Set point
menu, Default 2.8 VDC)
5. AUX1 O – The controllers operating sequence
structure. (Set point menu, Default ‘None’)
6. ERV OAT SP - The set point for low temperature
economizer lockout. This is the low temperature set
point when AUX1 O is set to ERV. (Set point menu,
Default 32°F)
7. STG3 DLY - Time delay after second cooling stage is
enabled (Advanced setup menu, Default 2 hrs.)
Using the Keypad with Settings and
Parameters
To use the keypad when working with Set points,
System and Advanced Settings, Checkout tests, and
Alarms:
1. Navigate to the desired menu.
2. Press (enter) to display the first item in the
currently displayed menu.
3. Use the and
parameter.
buttons to scroll to the desired
4. Press (enter) to display the value of the currently
displayed item.
5. Press the button to increase (change) the
displayed parameter value.a
This mode compares the outdoor air temperature to the
dry bulb temperature set point (DRYBLB SET). Once
the outdoor air temperature is less than DRYBLB SET,
the unit will modulate the position of the dampers to
maintain a predetermined mixed air temperature (MAT
SET).
6. Press the button to increase (change) the
displayed parameter value.a
EC-2 Outdoor Air Enthalpy Reference
8. CHANGE STORED displays.
This mode compares the outdoor air enthalpy to a
preset enthalpy curve. When the outdoor air conditions
are within this curve, the dampers will modulate to
maintain a mixed air temperature (MAT SET).
9. Press (enter) to return the current menu
parameter.
EC-3 Differential Temperature Reference
This mode compares the outdoor air temperature and
the return air temperatures. If the outdoor air is cooler
than the return, the dampers will modulate to maintain a
preset mixed air temperature (MAT SET).
7. Press (enter) to accept the displayed value and
store it in non-volatile RAM.
10. Press
(escape) to return to the current menu
parameter.
a When values are displayed, pressing and holding the
or button causes the display to automatically
increment.
EC-4 Differential Enthalpy Reference
This mode compares the outdoor air enthalpy and the
return air enthalpy. If the outdoor air enthalpy
32 Model IG / IGX Make-Up Air
®
Modulate Dampers
1. Navigate to the Checkout menu and press (Enter).
2. The cooling should turn off
3. Navigate to Damper Open and press (enter) twice to
run the test.
4. Voltage between terminals ACT 2-10 and ACT COM
should be 10 VDC. This will open the outdoor air
damper and close the return air damper
5. Press (escape), navigate to Damper Close and press
(enter) twice to run the test.
6. Voltage between terminal ACT 2-10 and ACT COM
should be 2 VDC. This will close the outdoor air
damper and open the return air damper.
®
Model IG / IGX Make-Up Air 33
Start-Up - Evaporative Cooling
Recirculating (optional)
1. Check the Installation
The media may
45º
have been removed
during installation,
so its orientation
Entering Air
Leaving Air
should be double
checked. The media
should be installed
15º
with the steeper
Media Orientation
flute angle sloping
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.
7. Set the Optional Auto Drain and Fill
This system will automatically drain the sump tank
and fill it with fresh water at the field-adjustable
intervals, typically once every 24 hours. This flushes
mineral build-up and debris from the tank to promote
low maintenance and increase media pad life.
In addition, the system will protect the evaporative
cooler from freezing by draining the sump tank and
supply line when the outside temperatures fall below
the set point of the outside air sensor. This is set
to 45º F and is not adjustable. The auto drain and
fill outdoor air sensor should be installed in an area
that is shaded from direct sunlight so the outside air
sensor probe will detect an accurate air temperature.
Set the Timer Scale and Settings dials:
• T1 timer setting set to 10 and timer scale set to
1d for 1 day of operation
• T2 timer setting set to 10 and the timer scale set
to 10m for 10 minutes of drain time
3. Fill the Sump and Adjust the Float
Turn on the water supply and allow the sump tank to
fill. Adjust the float valve to shut-off the water supply
when the sump is filled to within 1 inch of the bottom
of the overflow.
Timer
Scale
T1
Settings
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.
Timer
Settings
Timer
Scale
NOTE
A jumper will need to be installed in the control
center to power the evaporative pumps with the
blower(s) off. Reference the unit’s ladder diagram to
determine proper terminals.
5. Check the Flow Rate
The pumps should provide enough water to saturate
the media in 45 to 60 seconds. Consult the factory, if
adequate flow is not achieved.
NOTE
Manual Ball Valve
If too much water is flowing
to the media, the flow can be
adjusted using the manual ball
valve. If flow adjustments are
made, verify that sufficient water
is still being supplied to the
media to keep the entire pad wet
during normal operation. Too
high of a water flow can cause
water carryover problems.
T2
Settings
Auto Drain and Flush Timer
8. Put the Unit into Service
Remove the jumper and energize the blower(s). Verify
proper operation.
IMPORTANT
Check the media for minerals after two weeks of
service and adjust the bleed-off rate accordingly.
Bleed-Off
Valve
Pump
Filter
Supply
Connection
Float
Valve
Threaded Float
Adjustment
Overflow
6. Adjust the Water Bleed-Off Rate
The water bleed-off rate is dependent on the water’s
mineral content. The bleed-off should be adjusted
based on the media’s mineral deposits after two
weeks of service.
34 Model IG / IGX Make-Up Air
Evaporative Cooler Set-Up
®
Start-Up - Water Wizard™ (optional)
L1
L2
With the pressure set, press the Function key
for one second to deactivate Flow Test Mode
and allow the supply solenoid to close.
L3
Function
Up
Enter
Down
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 performance.
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.
NOTE
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
Housing
12
22
32
Media Width
(inches)
30
43¾
48
60
66
96*
4. Close Solenoid
Water Pressure
(in. wg)
20
36
42
61
72
42
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™.
NOTE
Steps 6 through 8 are provided to adjust the
minimum cooling temperature. The minimum cooling
is preset to the factory recommended 75ºF (24ºC).
Only adjust if needed.
NOTE
The inlet air sensor function overrides and shuts
down the evaporative cooler if the outside
temperature falls below the minimum cooling
temperature.
6. Enter Program Mode
Press and hold
the Enter key
for three seconds. The
display will read “Pro”
when Program Mode is
active.
Program Display
7. Adjust the Minimum Cooling
Temperature
While in the
Program Menu,
use the Up and
Down keys to
navigate the
Menu Options
Minimum Cooling
until “toF” is
Temperature Display
displayed. Press the
Enter key to access the selected Menu Option setting.
Use the Up and Down keys to adjust the Minimum
Cooling Temperature as needed. Press the Enter key
to save the Minimum Cooling Temperature setting and
return to the Program Menu.
NOTE
The Enter key must be pressed to save the new
minimum cooling temperature.
*Multiple media sections. Value represents total media width.
Model IG
CFM Range
Water Pressure
(in. wg)
800 – 3500
50
3501 – 7000
74
8. Exit Program Mode
After ten seconds of idle time the controller will exit
Program Mode.
3. Break-In Media
Leave the supply solenoid open to saturate and
break-in media for 20 minutes with the blower off.
®
Model IG / IGX Make-Up Air 35
NOTE
CAUTION
The Freeze Temperature is preset to the factory
recommended 45ºF. 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
Program Display
10. Adjust the Freeze Temperature
While in Program
Mode, use the Up
and Down keys to
navigate through
the Menu Options
until “Frt” is
displayed. Press the Enter
key to access the selected
Menu Option setting.
CAUTION
Be aware of the water level in the sump tank at all
times when using the Flow Test Mode.
NOTE
Press and hold
the Enter key
for three seconds. The
display will read “Pro”
when Program Mode is
active.
The sump drain line must be clear and draining to a
safe location before using 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.
Freeze Temperature
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)
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™.
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.
36 Model IG / IGX Make-Up Air
Light Status
Indicating
Light
On
Off
Blinking
Long on, short off
Blinking
Short on, long off
L1
Call for cooling.
Call for No call for
Outdoor temperature
cooling cooling
lockout.
L2
Drain
solenoid
open
Drain
solenoid
closed
N/A
Supply solenoid open.
Drain solenoid closed.
L3
Cooling
on
Cooling
off
Supply solenoid
locked closed
Flow test mode active
N/A
®
Check Operation - VAV Units
(optional)
Building Pressure Control —
a variable frequency drive is
controlled according to input from a
pressure sensing device.
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.
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.
BLOWER
EXHAUST
(OPTIONAL)
SUPPLY
MAIN VALVES
HEAT
DIRTY FILTERS
75
70
65
(OPTIONAL)
80
60
85
90
55
PHOTOHELIC
Building
Pressure Control
Reset the correct pressure limits
before starting the unit.
Pressure Indicating
Needle
Pressure Setting
Needles
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 makeup 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.
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 setting needles.
2-Speed VFD Motor
External Signal — a variable
frequency drive is controlled according to input from
an external 2-10 VDC or 4-20 mA signal (by others).
Variable Volume Operation
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 switch on the remote control
panel to each position and confirm that the fan speed
adjusts accordingly.
Pressure Setting Knobs
Photohelic Gauge
A 2 VDC or 4 mA signal will send the blower to low
speed. The blower will go to maximum speed with a
10 VDC or 20 mA signal.
Variable Kitchen Control — A variable frequency
drive is controlled by input from a remote speed
control. This unit allows automatic adjustment of
make-up air volumes based on varying cooking loads.
Modulating
Potentiometer Control — a variable frequency drive
is controlled by input from a remote
speed selector (potentiometer). This
unit allows easy manual adjustment
of make-up air volumes. To test
potentiometer operation, turn the
potentiometer to the two extremes.
With variable volume, make sure the
fan goes to maximum and minimum
speed.
BLOWERS
EXHAUST
(OPTIONAL)
SUPPLY
MAIN VALVES
HEAT
DIRTY FILTERS
75
70
65
80
60
(OPTIONAL)
85
55
90
When the potentiometer is at 0, the
fan speed will be at its minimum.
When the potentiometer is at 100,
Potentiometer
Control
the fan will be at its maximum speed.
®
Model IG / IGX Make-Up Air 37
Check Operation - Recirculating
Units (optional)
NOTE
Blower Start-Up, steps 1-5 should be performed
before the blower is run.
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.
BLOWER
EXHAUST
(OPTIONAL)
SUPPLY
MAIN VALVES
HEAT
DIRTY FILTERS
75
70
65
(OPTIONAL)
80
60
85
90
55
Turn both knobs to the upper most
pressure setting. You may have to
remove the outdoor pressure tap
tubing. The return air damper should
Building
close.
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.
PHOTOHELIC
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.
Reset the correct pressure limits before starting the
unit.
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
close.
EXHAUST
BLOWER
(OPTIONAL)
SUPPLY
MAIN VALVES
HEAT
RECIRCULATION
Turn the recirculating switch on
the remote control panel to each
position and confirm that the return
air damper adjusts accordingly. The
damper actuator may take a few
minutes to open or close.
DIRTY FILTERS
75
70
(OPTIONAL)
65
80
60
85
55
90
2-Position
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
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
potentiometer is at 100, the return
air damper will close. The damper
actuator may take a few minutes to
open or close.
BLOWERS
EXHAUST
(OPTIONAL)
SUPPLY
MAIN VALVES
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
operation, the indicating
needle will remain
between or near the setting
needles.
Pressure Indicating Pressure Setting
Needle
Needles
Pressure Setting Knobs
Photohelic Gauge
External Signal - a modulating spring return actuator
is used to control the return air amounts. Return air
damper modulates from fully open to fully closed
based on an external 2-10 VDC or 4-20 mA signal (by
others).
The return air damper will 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.
HEAT
DIRTY FILTERS
75
70
65
80
60
(OPTIONAL)
85
55
90
Potentiometer
Control
38 Model IG / IGX Make-Up Air
®
Sequence of Operation
2:1 Staged Sequence
1. Exhaust Fan Contact (S1) Manually Closed
(optional)
• 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)
2. 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 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
3. 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 tripped, 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
®
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)
5. 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 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.
Model IG / IGX Make-Up Air 39
Sequence of Operation
2:1 Modulation Sequence
1. Exhaust Fan Contact (S1) Manually Closed
(optional)
• 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)
2. 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 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
3. 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
• 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
40 Model IG / IGX Make-Up Air
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
• 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
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
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)
®
Sequence of Operation
Operation
2:1 Modulation Sequence, continued
4:1 Modulation and
8:1 Staged Controller
• 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.
L1
L2
L3
Function
Up
Enter
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 65ºF for 8:1 and
60ºF for 4:1.
Discharge Air Temperature (dtS)
The discharge air temperature setting is the
temperature that the unit will discharge. The discharge
air temperature is preset to the factory recommended
70ºF. 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.
®
Model IG / IGX Make-Up Air 41
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 I##. The two numbers following the letter
indicate the revision number. For example, F12 indicates
program F, revision twelve.
Optional Room Override (ROt)
When the room override function is triggered, the
discharge air temperature (70ºF default) is temporarily
changed to the room override setting (90ºF 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
L2
Call for heat
sent to ignition
controller
No call for heat
sent to ignition
controller
High fire
L3
Combustion fan Combustion fan
high speed
low speed
High fire
8:1 Staged Control
Light
(Single Furnace Units)
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/a
8:1 Staged Control
Light
(Multi Furnace Units)
On
Off
Blinking
L1
n/a
n/a
n/a
L2
n/a
n/a
Alarm
L3
Program Mode
n/a
Saving new
setting
Sequence of Operation
4:1 Electronic Modulation
1. Exhaust Fan Contact (S1) Manually Closed
(optional)
• 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)
2. 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 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
3. 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
• Power passes to N.C. contact on high temperature
limit control (HLC1), which remains closed if it has
not been tripped
• 24 VAC is supplied to ignition controller (IC1)
• 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)
42 Model IG / IGX Make-Up Air
®
Sequence of Operation
4:1 Electronic Modulation, continued
4. Ignition Controller (IC1) Sequence of Operation
• The N.O. contact on air proving switch (PS2) is open
• The ignition controller (IC1) energizes the induction
relay (IR)
• N.O. contact on induction relay (IR) closes
• Power passes to and energizes the combustion
blower (CM), sending it to high speed
• The N.O. contact on air proving switch (PS2) and
high pressure switch (PS5) closes
• The ignition controller (IC1) begins a 15 second
pre-purge
• 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 30
seconds
• The modulation controller (SC1) will adjust the
modulating gas valve (MOD) and the combustion
blower (CM) as needed between low and high fire
• 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
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 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.
5. High Fire – Low Fire Sequence of Operation
• The furnace lights at and remains at high fire
(100%) for 30 seconds
• 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)
• If the 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)
®
Model IG / IGX Make-Up Air 43
Sequence of Operation
8:1 Staged Control
1. Exhaust Fan Contact (S1) Manually Closed
(optional)
• 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)
2. 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 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
3. 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)
4. 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)
44 Model IG / IGX Make-Up Air
• 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
• 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
5. 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 shut 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)
®
Sequence of Operation
8:1 Staged Control, 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.
Operation and Errors Ignition Controller
NOTE
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
RED for an ERROR. Some
furnace configurations
have two of these
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
Model IG / IGX Make-Up Air 45
Troubleshooting
Blower Does Not Operate
Proper supply power at
main disconnect
No
Check Main Voltage
(See Blower Start-Up Step #1)
Main Disconnect (DS1) Off
(Turn Main Disconnect DS1 On)
Primary Fuses Blown
(Replace Fuses)
Yes
24 VAC between
terminals R and X?
No
Main Transformer (TR1) Defective
(Replace Transformer)
Yes
24 VAC between
terminals G and X?
No
Yes
24 VAC across
terminals 3 and X?
No
Yes
24 VAC across
terminals 4 and X?
No
Yes
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)
Yes
24 VAC across A2 and A1 on
supply contactor (ST1)
Supply Switch (S2) Off
(Turn Supply Switch (S2) On)
Fire system contact (FSC) tripped/not installed
(Correct/Replace)
No
(Optional) Damper Limit Switch (DL1) Holding
(Wait for actuator to open fully or adjust limit switch)
(Optional) Damper Limit Switch Jumper Missing
(Install jumper, reference the unit 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.
46 Model IG / IGX Make-Up Air
®
Troubleshooting
Motor Over Amps
Air volume too high?
Yes
Adjust drives or increase external
static pressure as needed.
No
(Reference Blower Start-Up Step #5)
Actual static pressure
lower than design?
Yes
Adjust drives to reduce blower RPM.
No
(Reference Blower Start-Up Step #5)
Blower rotation correct?
No
Reverse blower rotation.
Yes
(Reference Blower Start-Up Step #2)
Motor voltage correct?
No
Provide proper power supply.
Yes
(Reference Blower Start-Up Step #1)
Motor horsepower too low?
Yes
No
Shorted windings in motor?
Yes
Resize motor.
Yes
Replace motor.
Everything is working
properly, consult factory.
®
Model IG / IGX Make-Up Air 47
Troubleshooting
Insufficient Airflow
Damper(s) not fully opened?
Yes
Adjust damper linkage(s), or replace faulty actuator(s).
(Damper actuators may take a few minutes to open)
No
System static losses too high?
Yes
No
Blower speed too low?
Reduce losses by improving ductwork.
Yes
Adjust drives as needed.
(Reference Blower Start-Up – Step #5)
No
Filters dirty or clogged?
Yes
Clean or replace filters.
(Reference Filters in the Maintenance section)
No
Leaks in ductwork?
Yes
No
Belt slipping?
Repair leaks.
Yes
Replace or tighten belt.
(Reference V-Belt Drives in the Maintenance section)
Yes
Everything is working properly,
consult factory.
Too Much Airflow
Blower speed too high?
Yes
No
Filters not in place?
Adjust drives as needed.
(Reference Blower Start-Up – Step #5)
Yes
No
Install filters.
Insufficient external static
pressure?
Yes
No
Everything is working properly,
consult factory.
48 Model IG / IGX Make-Up Air
Increase external static pressure.
®
Troubleshooting
Excessive Noise or Vibration
Belts worn or loose?
Yes
Replace worn belts or tighten loose belts.
(Reference V-Belt Drives in the Maintenance section)
No
Sheaves aligned?
No
Align sheaves.
(Reference V-Belt Drives in the Maintenance section)
Yes
Wheel(s) unbalanced?
Yes
Clean and/or balance wheel(s).
No
Bearings worn or need
lubrication?
Yes
Replace worn bearings or lubricate bearings as needed.
(Reference Bearings in the Maintenance section)
No
Wheel(s) rubbing on inlet?
Yes
Adjust wheel(s) or inlet.
No
At this time noise and vibration should
be at acceptable levels.
®
Model IG / IGX Make-Up Air 49
Troubleshooting
Single or 2:1 Stage Furnace Will Not Light
24 VAC across R and X?
No
Main disconnect (DS1) open or defective
Close, repair or replace
Main transformer (TR1) fault
Replace main transformer
Yes
24 VAC across W1 and X?
No
Heat Switch (S4) open
(Turn Heat Switch (S4) on)
Yes
24 VAC across 22 and 21?
No
Heating Transformer (TR2) Fault
Replace heating transformer
Yes
24 VAC across 24 VAC and
21 on SC1 controller?
No
Yes
24 VAC across A and 21?
No
Discharge air selector (TS2) improperly set or faulty
Adjust setting (see Staged Start-Up) or replace sensor
Yes
High limit (HLC1) open?
Yes
Yes
Ignition controller (IC1) failed.
(Replace ignition controller)
No
Ignition controller (IC#)
red LED
blinks 6 times
Yes
No
Ignition controller (IC#)
red LED blinks
1 time, 2 times or 4 times
Yes
Everything is working
properly, consult factory.
50 Model IG / IGX Make-Up Air
Furnace stage one contact (SC1) defective (stage only)
Replace furnace stage one contact
Discharge temperature was above high limit setting.
Wait for high limit to cool and reset.
No
Ignition controller (IC#)
red LED
blinks 7 times or is on
Optional inlet air sensor (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)
Yes
Combustion blower (CM) not functioning
Replace combustion blower or relay (CR)
Air proving switch (PS2) defective.
Replace air proving switch
Improper manifold pressure
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 1⁄8 inch
®
Troubleshooting
2:1 Modulating Furnace Will Not Light
24 VAC across R and X?
No
Main disconnect (DS1) open or defective
Close, repair or replace
Main transformer (TR1) fault
Replace main transformer
Yes
24 VAC across W1 and X?
No
Heat switch (S4) open or not wired
Close or replace heat switch (S4)
Yes
24 VAC across S and T?
No
Yes
24 VAC across C and T?
Heat transformer (TR5) fault
Replace heating transformer
Discharge temperature was above high limit control (HLC1)
Wait for high limit to cool and reset.
No
Yes
24 VAC across A and T?
No
Discharge air selector (TS3) improperly set or faulty
Adjust setting (see staged start-up) or replace sensor
Yes
Ignition controller (IC#)
red LED
blinks 7 times or is on
Yes
Ignition controller (IC1) failed
(Replace ignition controller)
No
Ignition controller (IC#)
red LED
blinks 6 times
Yes
No
Ignition controller (IC#)
red LED blinks
1 time, 2 times or 4 times
Yes
Everything is working
properly, consult factory.
®
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)
Yes
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 1⁄8 inch
Model IG / IGX Make-Up Air 51
Troubleshooting
4:1 Modulating Furnace Will Not Light
24 VAC across R and X?
No
Main disconnect (DS1) open or defective
Close, repair or replace
Main transformer (TR1) fault
Replace main transformer
Yes
24 VAC across W1 and X?
No
Heat switch (S4) open or not wired
Close or replace heat switch (S4)
Yes
24 VAC across 22 and 21?
No
Heat transformer (TR2) fault
Replace heating transformer
Yes
N.O. contact on
heat relay (RH) closed?
No
Heat relay (RH) is not energized
Check for loose connections. Repair or replace heat relay (RH)
Yes
DT1 displayed
on furnace controller (SC1)?
Yes
Discharge air sensor (TS2) not wired or defective
Wire or replace discharge air sensor (TS2)
No
OT1 displayed
on furnace controller (SC1)?
Yes
Outdoor air sensor (TS1) not wired or defective
Wire or replace outdoor temperature sensor (TS1)
No
Blank screen
on furnace controller (SC1)?
Yes
Furnace controller (SC1) defective or not powered
Replace or wire furnace controller (SC1)
No
24 VAC across
terminals S and T?
Yes
Continues on next page...
52 Model IG / IGX Make-Up Air
No
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 (SC1)
®
Troubleshooting
4:1 Modulating Furnace Will Not Light
...continued from previous page
High limit switch (HLC#) open?
Yes
Discharge temperature was above high limit setting
Let cool, then reset high limit.
No
Ignition controller (IC#)
red LED blinks
7 times or is on
Yes
Ignition controller(s) (IC#) failed
Replace faulty ignition controller(s)
No
Ignition controller (IC#)
red LED blinks 6 times
Yes
No
24 VAC between terminals
1 and 2 on the Amplifier (AMP)
No
Secondary transformer (TR6) defective
Replace secondary transformer (TR6)
Yes
10 VDC between terminals
5 and 6 on the Amplifier (AMP)
No
Furnace controller (SC1) defective
Replace furnace controller (SC1)
Yes
24 VDC between terminals
3 and 4 on the Amplifier (AMP)
No
Amplifier (AMP) defective
Replace amplifier (AMP)
Yes
Ignition controller (IC#)
red LED blinks
1 time, 2 times or 4 times
No
Everything is working properly,
consult factory.
®
Pressure switch (PS2) failure
Repair or replace pressure switch (PS2)
Combustion blower (CM) not functioning
Replace fusing (FU7), combustion blower or relay (CM)
Yes
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 1⁄8 inch
Model IG / IGX Make-Up Air 53
Troubleshooting
8:1 Staged Furnace Will Not Light
24 VAC across R and X?
No
Main disconnect (DS1) open or defective
Close, repair or replace
Main transformer (TR1) fault
Replace main transformer
Yes
24 VAC across W1 and X?
No
Heat switch (S4) open or not wired
Close or replace heat switch (S4)
Yes
24 VAC across 22 and 21?
No
Heat transformer (TR2) fault
Replace heating transformer
Yes
N.O. contact on heat relay (RH)
closed?
No
Heat relay (RH) is not energized
Check for loose connections. Repair of replace heat relay (RH)
Yes
DT1 displayed on furnace
controller (SC1)?
Yes
Discharge air sensor (TS2) not wired or defective
Wire or replace discharge air sensor (TS2)
No
OT1 displayed on furnace
controller (SC1)?
Yes
Outdoor air sensor (TS1) not wired or defective
Wire or replace outdoor temperature sensor (TS1)
No
Blank screen on furnace
controller (SC1)?
Yes
Furnace controller (SC1) defective or not powered
Replace or wire furnace controller (SC1)
No
24 VAC across terminals
S and T?
No
Yes
With the combustion blower
(CM) off, is the N.O.
airflow switch (PS2) closed?
No
Yes
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)
Continues on next page...
54 Model IG / IGX Make-Up Air
®
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?
No
Furnace controller (SC1) defective
Replace furnace controller (SC1)
Yes
Ignition controller (IC#)
red LED
blinks 7 times or is on
Yes
Ignition controller(s) (IC#) failed
Replace faulty ignition controller(s)
No
Ignition controller (IC#)
red LED blinks
1 time, 2 times or 4 times
Yes
Improper manifold pressure
Set high and low manifold pressure
(refer to 8:1 Staged Start-Up section)
No
Faulty spark rod or spark gap does not equal 1/8 inch
Replace spark rod or adjust gap to 1⁄8 inch
Cycle power to the unit
and wait 30 seconds
Does the combustion relay
(R9 or CR) close?
No
Yes
Does the combustion
blower (CM) run?
No
Yes
Does the combustion
blower stop after
30 seconds of operation?
No
Everything is working properly,
consult factory.
®
Yes
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 55
Troubleshooting
Evaporative Cooler does not Operate (Recirculating pump)
Supply fan must be on for cooler to operate
24 VAC between terminals
Y1 and X
No
Cool switch (S4) off
(turn cool switch (S4) on)
Cool switch not wired
(wire cool switch (S4))
Yes
24 VAC between terminal A2 on
Cooling Relay (RC) and X
No
Optional inlet air sensor (TS4) holding
(Adjust TS4 setting. Reference Blower Start-Up – Step #6)
Yes
115 VAC between terminals
102 and 101
No
Cooling transformer (TR4) defective
(Replace transformer)
Yes
115 VAC between terminal
114 and 101
No
Cooling relay (RC) is not energized
(Check for loose connections)
(Repair or replace relay)
Yes
At this time the evaporative cooler pumps should be on
Water Blows through Evaporative Cooler
Are the headers in place and
located near the entering
air side of the media?
No
Replace headers and/or move the headers
Yes
Water supply greater than
evaporation and bleed-off rate?
Yes
Use the main supply valve to reduce the supply of water
No
Air velocity greater than
specified?
Yes
Reduce the air velocity through the media
(Reference Blower Start-Up – Step #5)
No
At this time the evaporative cooler should be
operating without water blowing through
56 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
saturated and excessive water will be draining from
the sump tank.
NOTE
Some water drainage is desired to keep the media
flushed, but it should be minimized to utilize the
Water Wizard™.
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
automatically exit Program Mode.
1. Adjust the Manual Supply Valve
Adjust the manual supply valve (refer to Start-Up,
Water Wizard™). If the recommended water pressure
does not provide enough water, increase the pressure
until the desired water supply is achieved. If the
recommended water pressure provides too much
water, decrease the water pressure until the desired
water supply is achieved.
CAUTION
Only proceed to Steps 2 and 3 if Step 1 does not
correct the problem.
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
Program Menu,
use the Up and
Down keys to
navigate through
the menu options
until “ont” is displayed.
With “ont” displayed, press the Enter key to access
the setting.
With the setting displayed, use the Up and Down keys
to adjust the setting as needed.
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.
®
Model IG / IGX Make-Up Air 57
Maintenance - Routine
Wheels
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.
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
Premature or frequent belt failures can be caused by
improper belt tension, or misaligned sheaves.
• Abnormally high belt tension or drive misalignment
will cause excessive bearing loads and may result
in failure of the fan and/or motor bearings.
• Abnormally low belt tension will cause squealing
on start-up, excessive belt flutter, slippage, and
overheated sheaves.
IMPORTANT
Lubricate bearings prior to periods of extended
shutdowns or storage and rotate shaft monthly to
aid in corrosion prevention. If the fan is stored more
than three months, purge the bearings with new
grease prior to start-up.
Recommended Bearing Lubrication Schedule
(in months*)
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.
Fan
RPM
Bearing Bore Size (inches)
⁄2 - 1
11⁄8 - 11⁄2
15⁄8 - 17⁄8
115⁄16 - 23⁄16
27⁄16 - 3
250
6
6
6
6
6
IMPORTANT
500
6
6
6
5
4
When replacing V-belts on multiple groove drives,
all belts should be changed to provide uniform drive
loading.
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
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
64
Belt Span
Belt Tension
Drive Alignment
Snow Accumulation
1
*Suggested initial greasing interval is based on 12 hour per
day operation and 150°F maximum housing temperature.
For continuous (24 hour) operation, decrease greasing
interval by 50%
• If extended grease lines are present, relubricate while in
operation, only without endangering personnel.
• For ball bearings (operating) relubricate until clean grease
is seen purging at the seals. Be sure not to unseat the seal
by over lubricating.
• For ball bearings (idle) add 1-2 shots of grease up to 2
inch bore size, and 4-5 shots above 2 inch bore sizes with
a hand grease gun.
• For roller bearings add 4 shots of grease up to 2 inch bore
size, and 8 shots for 2-5 inch bore size with a hand grease
gun.
• Adjust relubrication frequency based on condition of
purged grease.
• A high quality lithium based grease conforming to NLGI
Grade 2 consistency, such as those listed here:
Mobil 532
Mobilux #2
Texaco Multifak #2 B Shell Alavania #2
Texaco Premium #2 Exxon Unirex #2
Clear snow away from roof mounted units. Keep the
snow clear of the intake and access doors.
58 Model IG / IGX Make-Up Air
®
Motors
Evaporative Coolers
Motor maintenance is generally limited to cleaning
and lubrication (where applicable).
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.
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
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.
Filter maintenance is generally limited to cleaning and
replacement.
45º
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.
Entering Air
Leaving Air
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.
15º
Media Orientation
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
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.
Test the circulating fluid for sediment, corrosive
products and biological contaminants. Make the
necessary corrective measures.
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 farther in.
Maintain adequate fluid velocities and proper filtering
of the fluid.
Inspect and clean the drain pan to prevent the growth
of algae and other organisms.
If automatic air vents are not utilized, periodic venting
of the coil is recommended to remove accumulated
air.
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 59
Maintenance - Fall
High Limit
Heat Exchanger
The high limit switch may have tripped over the
summer; it should be checked and reset if necessary.
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.
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.
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.
Vent Piping
Evaporative Coolers
Remove any debris from the drip legs on the
combustion air and exhaust pipes.
The water should be shut off and all the lines drained
when the outside temperature drops below 45ºF.
Burners and Orifices
Remove drain plugs for the winter.
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:
Clean all interior parts of any mineral deposits or
foreign materials that may have built-up during the
cooling season.
•
•
•
•
•
•
•
•
Turn off both electrical and gas supplies to the unit.
Disconnect union between manifold and gas valve.
Remove manifold and burner assembly.
Inspect and clean 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.
Before reinstalling the burner assembly, look down
the heat exchanger tubes to make sure they are
clear of any debris.
Reinstall manifold and burner assembly, reconnect
wire leads and gas supply piping.
Turn on the electrical power and gas supply.
Follow the start-up procedure to light the burners
and verify proper operation.
60 Model IG / IGX Make-Up Air
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.
Blowing-Out Coils
1. Close valves on the supply and return lines.
2. 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
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
Ethylene
Glycol
by Volume
®
Freeze Point
ºF
ºC
Percent of
Propylene
Glycol
by Volume
Freeze Point
ºF
ºC
0
32
0
0
32
0
10
25
-4
10
26
-3
20
16
-9
20
19
-7
30
3
-16
30
8
-13
40
-13
-25
40
-7
-22
50
-34
-37
50
-28
-33
60
-55
-48
60
-60
-51
Model IG / IGX Make-Up Air 61
Reference - Model IG Venting Connection Location
Exhaust Outlet
Venting Location Dimensions
Combustion Air Inlet
Discharge End
IG
Housing
A
B
C
D
E
G
10
20
30
3.89
3.91
3.91
5.12
3.89
3.89
9.12
7.89
7.89
11.59
11.62
11.62
23.11
25.34
25.34
27.58
32.27
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.
F
E
Flue Connection Size (diameter in inches)
D
A
IG
Housing
10
20
30
3/4-inch Gas Connection
B
C
Standard
Exhaust
4.0
6.0
6.0
Non-Concentric
Exhaust
Intake
4.0
4.0
6.0
6.0
6.0
6.0
Concentric
Exhaust
Intake
4.0
6.0
6.0
8.0
6.0
8.0
Reference - Model IGX Venting Connection Location
Exhaust Air Outlet
Combustion Air Intake
Airflow
D
C
A
B
IGX
Housing
12
22
32
Furnace Size
(MBH)
A
B
C
D
100
150
200
250
150
200
250
300
350
400
500
600
350
400
500
600
700
800
1050
1200
4.45
4.45
5.64
5.64
4.45
5.67
5.67
5.67
5.67
5.67
5.67
5.67
5.96
5.96
5.96
5.96
5.96
5.96
5.96
5.96
8.45
8.45
9.64
9.64
8.45
9.67
9.67
9.67
9.67
9.67
9.67
9.67
9.71
9.71
9.71
9.71
9.71
9.71
9.71
9.71
23.43
23.43
23.97
23.97
29.38
24.97
24.97
24.97
19.01
19.01
24.97
24.97
28.31
28.31
28.31
28.31
28.31
28.31
28.31
28.31
27.90
27.90
30.90
30.90
33.85
31.90
31.90
31.90
25.94
25.94
31.90
31.90
35.24
35.24
35.24
35.24
35.24
35.24
35.24
35.24
Standard
Exhaust
4.0
4.0
6.0
6.0
4.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
Flue Connection Size (diameter in inches)
Non-Concentric
Concentric
Exhaust
Intake
Exhaust
Intake
4.0
4.0
4.0
6.0
4.0
4.0
4.0
6.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
4.0
4.0
4.0
6.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
6.0
6.0
6.0
8.0
Dimensions are in inches. Dimensions A and C are not needed for standard venting.
62 Model IG / IGX Make-Up Air
®
Reference - Model IG
(Single or 2 Stage)
22
11
24
20
17
5
12
21
23
19
10
25
14
13
4
6
7 8
1
16
15
16
18
2
9
3
NOTE
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, staged
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 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.
®
16. Stage Controller - Provides single or two stage
control of the furnace.
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.
23. Auto Drain Relay (Optional) - Assures supply
pump does not operate during drain interval.
Allows pump to operate in cooling mode.
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.
Gas
Pressure
Test Port
Manifold
Staged Gas
Valve
3/4 inch
Gas Supply
Connection
Model IG / IGX Make-Up Air 63
Reference - Model IG
(8:1 Staged)
24
22
25
11
5
12
21
23
19
20
17
10
16
13
4
14
6
7 8
1
15
18
2
9
18
3
NOTE
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, staged
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 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.
64 Model IG / IGX Make-Up Air
16. Stage Controller - Provides 8 stage control of the
furnace.
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.
23. Auto Drain Relay (Optional) - Assures supply
pump does not operate during drain interval.
Allows pump to operate in cooling mode.
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.
Gas
Pressure
Test Port
Small
Manifold
Staged Gas
Valves
3/4 inch
Gas Supply
Connection
Gas Pressure
Test Port
Large
Manifold
®
Reference - Model IG
(2:1 Modulation)
11
17
18
5
12
22
24
20
26
21
10
23
25
14
13
4
1
6
7 8
15
19
2
9
3
16
NOTE
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 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.
®
16. Amplifier - Controls the modulating valve based
on the input from the temperature selector and the
discharge air sensor.
17. Airflow Switch - Monitors the airflow inside the
heat exchanger.
18. Temperature Selector - Allows the user to adjust
discharge air temperature.
19. Ignition Controller - Controls the ignition of the
furnace. Maintains safe operation of the furnace.
20. Evaporative Cooling Fuses (Optional) - Provides
proper fusing to evaporative cooling pump and
controls.
21. Transformer Fuse (Optional) - Provides proper
fusing for evaporative cooling 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.
Gas Pressure
Test Port
3/4 inch
Gas Supply
Connection
Manifold
Staged
Gas Valve
Modulating
Gas Valve
Model IG / IGX Make-Up Air 65
Reference - Model IG
(4:1 Modulation)
25
23
11
21
18
5
12
22
24
20
10
26
18
16
13
4
1
14
6
7 8
15
19
2
9
3
17
NOTE
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 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.
66 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 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.
Gas Pressure
Test Port
Modulating
Gas Valve
Manifold
Staged
Gas Valve
3/4 inch
Gas Supply
Connection
®
Reference - Model IGX
(Blower Control Center)
14 15
9
3
12
10
4
6 7
1
17
8
19
18
16
11
5
2
13
20
16. Cooling Relay (Optional) - Allows power to pass
to cooling controls.
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 adjustable set point.
NOTE
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
automatically 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.
®
Model IG / IGX Make-Up Air 67
Reference - Model IGX
(Single or 2 Stage)
Reference - Model IGX
(8:1 Staged)
Manifold
5
5
Gas Pressure
Test Port
2
1
5 8 9
7
1
Small Manifold
Gas Pressure
Test Port
2
Large Manifold
6
3
7
3
Staged
Gas Valve
4
4
Staged
Gas Valve
7
9
3/4 inch
Gas Supply
Connection
6
10
Gas Pressure
Test Port
11
8
NOTE
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.
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.
68 Model IG / IGX Make-Up Air
3/4 inch Gas Supply
Connection
NOTE
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 staged controller.
2. Low Voltage Transformer - Provides low voltage
to the ignition controllers.
3. Control Terminal Block - Provides wiring access
to controls.
4. Control Terminal Block - Provides wiring access
to controls.
5. Input Converter - Receives and converts signal
from Building Management Systems (BMS).
6. Stage Controller - Provides eight stages of
control based on discharge temperature set point.
7. Ignition Controllers - Controls the ignition of the
furnace. Maintains safe operation of the furnace.
8. Contactor Relay - Allows power to pass to the
combustion blower contact.
9. Air Proving Switch Relay - Functions as a relay
for the pressure switch.
10. Combustion Blower Contact - Passes power to
the combustion blower.
11. Airflow Switch - Monitors the airflow inside the
heat exchanger.
®
Reference - Model IGX
(2:1 Modulation)
Reference - Model IGX
(4:1 Modulation)
Manifold
Manifold
5
6 10
9
3
1
Gas Pressure
Test Port
6
4
1
Gas Pressure
Test Port
2
7
2
4
3
5
Modulating
Gas Valve
Staged
Gas Valve
Modulating
Gas Valve
8
11
7
9
8
11
3/4 inch Gas Supply
Connection
NOTE
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.
®
Staged
Gas Valve
3/4 inch Gas Supply
Connection
NOTE
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.
2. Low Voltage Transformer - Provides low voltage
to the 4:1 electronic modulation controller.
3. Low Voltage Transformer - Provides low voltage
to the amplifier.
4. Control Terminal Block - Provides wiring access
to controls.
5. Control Terminal Block - Provides wiring access
to controls.
6. Input Converter - Receives and converts signal
from Building Management System (BMS).
7. Ignition Controllers - Controls the ignition of the
furnace. Maintains safe operation of the furnace.
8. Modulation Controller - Provides 4:1 modulation
turndown control of furnace based on the
discharge air temperature.
9. Amplifier - Controls the modulating valve based
on the input from the modulation controller
settings and discharge air temperature sensor
reading.
10. Combustion Blower Relay - Passes power to the
variable speed combustion blower.
11. Airflow Switches - Monitors the airflow inside
the heat exchanger to ensure proper combustion
airflow.
Model IG / IGX Make-Up Air 69
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
(MBH) (MBH)
Temperature Rise (ºF)
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
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
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
14815 12963 11523 10370
9428
8642
7977
7407
6914
6481
6100
5761
5458
5185
14815 13169 11852 10774
9877
9117
8466
7901
7407
6972
6584
6238
5926
14141 12963 11966 11111 10370
9722
9150
8642
8187
7778
14815 13675 12698 11852 11111 10458
9877
9357
8889
NA
800
640
NA
NA
NA
1050
840
NA
NA
NA
NA
NA
NA
1200
960
NA
NA
NA
NA
NA
NA
70 Model IG / IGX Make-Up Air
NA
100
®
Reference - 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 Indirect Gas – refer to Furnace Start-Up
section for further detail
Furnace 1
† Determine furnace control type:
1 Stage - 2 Stage - 8 Stage - 2:1 Mod. - 4:1 Mod.
† Check supply gas pressure
______________ Maximum
______________ Mininum
______________
Actual
Start-Up Company _______________________________
Phone Number
_______________________________
Pre Start-Up Checklist – check boxes as items
are completed.
† Check tightness of all factory wiring connections
† Verify control wiring wire gauge
† Hand-rotate blower to verify free rotation
† Verify supply voltage to the main disconnect
† Verify the supply gas pressure
† Verify remote controls wiring
† Set the High Manifold pressure __________in. wg
† Set the Low Manifold pressure __________in. wg
† Set the unit’s operating temperature _____in. wg
Furnace 2 (Optional)
† Determine furnace control type:
1 Stage - 2 Stage - 8 Stage - 2:1 Mod. - 4:1 Mod.
† Check supply gas pressure
______________ Maximum
______________ Mininum
______________
Actual
Start-Up Blower Checklist – refer to Blower
Start-Up section for further detail.
†Check line voltage
L1-L2 __________
L2-L3 __________
L1-L3 __________
†Check blower rotation
†Check for vibration
†Supply fan RPM
_________ RPM
†Motor nameplate amps
_________ Amps
†Actual motor
L1 _______ Amps
L2 _______ Amps
L3 _______ Amps
†Actual CFM delivered
_________ CFM
Optional Accessories – refer to Blower Start-Up
section, Step #6 for further detail.
† Heating Inlet Air Sensor
________
Actual Setting
Typical setting 60º-70ºF (15º-21ºC)
†Cooling Inlet Air Sensor
________
Actual Setting
Typical setting 75ºF (24ºC)
†Building Freeze Protection
________
† Set the High Manifold pressure __________in. wg
† Set the Low Manifold pressure __________in. wg
Furnace 3 (Optional)
† Determine furnace control type:
1 Stage - 2 Stage - 8 Stage - 2:1 Mod. - 4:1 Mod.
† Check supply gas pressure
______________ Maximum
______________ Mininum
______________
Actual
† Set the High Manifold pressure __________in. wg
† Set the Low Manifold pressure __________in. wg
Start-Up Evaporative Cooler (optional) – refer
to Evaporative Cooler Start-Up section for further
detail.
† Check media orientation
† Check for proper water flow to distribution
headers
† Check for distribution header orientation to
prevent water spillage
Actual Setting
Typical setting 5 minutes; 45ºF (7ºC)
†Dirty Filter Gauge
________
Actual Setting
Typical setting varies
®
Model IG / IGX Make-Up Air 71
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:___________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
_________________________________________________
Our Commitment
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.
Specific Greenheck product warranties are located on greenheck.com within the product area tabs and in the
Library under Warranties.
Greenheck catalogs IG, IGX, IG-HV and IGX-HV provide
additional information describing the equipment, fan
performance, available accessories, and specification data.
AMCA Publication 410-96, Safety Practices for Users and
Installers of Industrial and Commercial Fans, provides
additional safety information. This publication can be obtained
from AMCA International, Inc. at www.amca.org.
®
Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: [email protected] • Website: www.greenheck.com
72 470656 • IG / IGX Make-Up Air, Rev. 8, November 2014
Copyright 2014 © Greenheck Fan Corporation