Greenheck XG-FCI User manual

Installation, Operation and Maintenance Manual
Fan Powered Air Terminal Units (ATU)

Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety information. Failure
to comply with these instructions will result in voiding of the product warranty and may result in personal injury
and/or property damage.
Fan Powered Air Terminal Units2
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. 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 Association (NFPA), and the Canadian
Electrical Code (CEC), where applicable.
2. Unit must be securely and adequately grounded.
3. Verify that the power source is compatible with
the equipment.
4. Electrical equipment should be transported, stored,
installed, and operated only in the environment for
which it is designed.
5. Never open fan access doors while the fan is running.
Table of Contents
General - Safety Information. . . . . . . . . . . . . . 2
Receiving Inspection and
Hanging/Installation Requirements . . . . . . . . . . 3
General - Model Number Code . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . 7
Document 1041403
Model XG-FCI, XG-FVI,
XG-FCL, XG-FVL, XG-FCQ
Fan Powered ATU
®

Fan Powered Air Terminal Units 3
DANGER
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.
WARNING
Always disconnect power before working on or near
a unit. Use appropriate lockout tagout procedures 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.
NOTICE: This appliance is not intended for use by
persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person
responsible for their safety. Children should be super-
vised to ensure that they do not play with the appliance.
Receiving Inspection and
Hanging/Installation Requirements
Prior to removing the shipping materials, visually inspect
the packing materials. There should be a black plastic
strip wrapped in the clear plastic stretch wrap. If this
black plastic strip is missing, the shipment may have
been repacked by the shipper and you should make a
note of this on the shipping documents and inform the
delivering carrier. If any damage or other concerns are
present, make a note of this on the shipping documents
and inform the delivering carrier.
After unpacking the Fan Powered Air Terminals, check
for shipping damage. If any shipping damage is found,
report it immediately to the delivering carrier.
Always store the product in a clean dry location prior to
installation.
Units with controls are not recommended for use in
ambient temperatures greater than 95ºF. For protection
of controls, do not store in temperatures above 135ºF.
General - Model Number Code
The model number code provides basic identification of the unit.
XG -FCI 504 - 12 - 00 -NA
Brand
Greenheck
Model
FCI, FVI, FCL,
FVL, FCQ
Series
1, 2, 3,
4, 5, 6,
7, 8, 9
Case
01-, 02-, 03-,
04-, 05-, 06-,
07-, 08-, 09-,
10-, 12-, 14-,
16-, 20-, 24-
Inlet 1
04-, 05-, 06-,
07-, 08-, 09-,
10-, 12-, 14-,
16-, 12OV-,
14OV-, 16OV-,
14X10-, 16X10-,
20X10-, 22X10-,
8X16-, 18X16-,
20X16-, 24X16-
Inlet 2
00-, 04-, 05-,
06-, 07-, 08-,
09-, 10-, 12-,
14-, 16-
Attenuator
IDA, NA,
IA, DA

Fan Powered Air Terminal Units4
Hanger brackets and Rod
(5/16” minimum)
Primary air inlet
Installation
CAUTION: HAZARD OF EQUIPMENT DAMAGE
Do not use the flow sensor, connecting tubing or damper shaft as a lift point. Damage to the components
may result.
NOTICE: Unit is not recommended for installation above 2,000 m.
The Fan Powered Air Terminal should be suspended from the building structure in a horizontal plane with the bottom
access panel facing down.
Do not obstruct the bottom access panels or side-mounted control enclosure cover. Use the required mounting
method prescribed for rectangular duct per the job specification. An alternate method involves using hanging straps
located at both ends of the Fan Powered Air Terminal correctly sized to support the unit weight. (See figure 1)
Figure 1 - Hanging Straps
Figure 2 -Optional Hanger Brackets and Hanger Rods
Fan Powered Air Terminals may also be suspended with factory-supplied and field-installed hanger brackets and
field-supplied and installed hanger rods. (See figure 2)

Fan Powered Air Terminal Units 5
NOTICE: Trapeze hangers are not recommended as
they can block the bottom access panels for the motor
and blower.
Fan Powered Air Terminal Units are not designed nor
suitable for outdoor use.
In advance of start-up, verify all electrical connections
are tight and the correct voltage is supplied to the Fan
Powered Air Terminal Unit per the rated voltage listed on
the unit label. If factory-supplied controls are present,
review all wiring diagrams to assure a complete working
knowledge.
IMPORTANT
If equipped with pneumatic controls, the orientation
of the Fan Powered Air Terminal unit is critical. The
pneumatic controls must be mounted right side up.
The Fan Powered Air Terminal must be level within +
or – 10 degrees of horizontal, both parallel to the airflow
and at right angle of airflow. The control side of the Fan
Powered Air Terminal is labeled with an arrow indicating
up. Unless otherwise noted, most electric, analog
electronic and digital controls are not position sensitive
and may be installed in any orientation.
AIR FILTER
NOTICE: Fan powered air terminal units come standard
with a filter rack and filter on the induction inlet. The
filter should be changed on a regular basis to maintain
adequate induction airflow.
MINIMUM CLEARANCE FOR ACCESS
Fan Powered Air Terminals require sufficient space to
allow servicing of the controls, motor/blower and electric
reheat (if applicable) and single point power hookup. A
minimum of 3” of vertical clearance is required below the
bottom of the unit. Horizontal clearance requirements
are dependent upon access panel dimensions which are
indicated on the appropriate submittal. For control panel
access, a minimum of 18” is recommended. See the
appropriate submittal for control panel location.
CAUTION
These clearance recommendations are not meant to
preclude NEC requirements or local building codes
that may be applicable, which are the responsibility of
the installing contractor.
CONNECTING DUCT WORK
NOTICE: Do not insert duct work inside the inlet collar
of the Fan Powered Air Terminal. Inlet duct should be
installed in accordance with SMACNA guidelines.
1. Slip each inlet duct over the inlet collar of the Fan
Powered Air Terminal.
2. Fasten and seal the connection by method prescribed
by job specification.
3. The diameter of the inlet duct in inches must be equal
to the listed size of the Fan Powered Air Terminal;
e.g., a duct that actually measures 8 inches must
be fitted to a size 8-inch Fan Powered Air Terminal.
The inlet tube of the Fan Powered Air Terminal is
manufactured 1/8” smaller than the listed size in
order to fit inside the duct.
4. If an inlet air flow sensor is installed, it is
recommended the installer provide a minimum of 3
duct diameters of straight duct at the Fan Powered
Air Terminal inlet.
5. The outlet end of the Fan Powered Air Terminal is
designed for use with slip and drive duct connections
(flanged outlets optional).
6. A rectangular duct the size of the Air Terminal outlet
should be attached. (Refer to submittal for correct
size.)
FIELD ELECTRICAL WIRING
DANGER
High voltage electrical supply is needed for this
equipment. The control cabinet contains live electrical
parts. Contacting these parts with power applied may
cause serious injury or even death. This work should
only be performed by a qualified electrician.
All field wiring must comply with local building codes
and NEC. (ANSI/NFPA 70).
When applicable, electrical control and piping diagrams
are attached to the inside of the control enclosure cover
of the Fan Powered Air Terminal.
Use copper only conductors with insulation rated 75ºC.
The Fan Powered Air Terminal must be properly
grounded per NEC 424-14 and 250.
Always check product label for voltage and current
data to determine the proper wire size and overcurrent
protection.
The control panel cover must be closed or in place
before applying electric power to the Fan Powered Air
Terminal.
These recommendations are not meant to preclude
NEC requirements or other applicable local building
codes and are the sole responsibility of the installing
contractor.

Fan Powered Air Terminal Units6
NOTICE: If the unit is not ordered with an internal
disconnecting device then a disconnection device that
shall disconnect all phases must be provided by the
customer and incorporated in the fixed wiring.
FAN POWERED AIR TERMINALS
WITH ELECTRIC REHEAT
WARNING
Fan Powered Air Terminals must not be operated
without downstream ductwork in place. Failure to
have downstream ductwork installed will expose the
line voltages and high temperature present in the
operating heater elements. Contact with these heater
elements may cause serious injury or death.
• Prior to installation always inspect the electric heating
coils for damage.
• All electric reheat is balanced by kW per stage.
• The installing electrician should rotate the electric
reheat stages by phase in order to balance the
building’s electrical load.
• The “UP” arrow orientation must be followed to
prevent nuisance tripping or over heating which will
cause damage to the electric heater and or building.
FAN POWERED AIR TERMINALS
WITH HOT WATER COILS
CAUTION:
HAZARD OF EQUIPMENT DAMAGE
The copper tubing should not be used as lift points.
Always inspect the hot water coils for damage prior to
installing the Fan Powered Air Terminal.
• The hot water coil casing must be field insulated.
• The hot water coils do not have drip pans and are not
suitable for use as cooling coils.
• The hot water coil maximum water operating
temperature is 195°F.
• The hot water coils are leak tested to 300 psi, with
a minimum burst pressure of 2000 psi at ambient
temperature.
CONTROLS
NOTICE: Fan Powered Air Terminals with digital
controls, if factory programmed, incorporate specific
communication addresses. Installing the Fan Powered
Air Terminal in a different location than noted on the Fan
Powered Air Terminal label and building plans may result
in excessive start-up labor and is the sole responsibility
of the contractor.
For information on controls provided by other
manufacturers and installed on the Air Terminals,
contact the local branch or dealer.
INLET FLOW SENSOR
Fan Powered Air Terminals are shipped with factory-
installed (where applicable) pressure differential inlet
flow sensors in the primary inlet. See figure 3 for
calibration curve and K factors. Bypass Air Terminals
offer an optional downstream flow sensor for field
installation a minimum of 3 feet downstream of
box discharge.

Fan Powered Air Terminal Units 7
Investigating Noise Complaints
• Noise from a Single Duct Air Terminal can be due to a
variety of conditions and can be difficult to eliminate.
• The first step is to isolate the type, source and
direction.
• Generally, noise heard at the air outlet is considered a
discharge type.
• Noise heard through the ceiling is considered radiated
noise.
• For detailed information concerning noise
transmission in buildings, refer to AHRI Standard
885-2008, “Procedure for estimating occupied space
sound levels in the application of air terminals and
air outlets”.
Discharge Noise
• This is usually caused by high static pressure or
little to no internal duct lining downstream of the Air
Terminal.
• It can sometimes be caused by the air outlet itself.
• Air outlet generated sounds can be reduced by
reducing flow or increasing an outlet size.
• Reducing static pressure, flow or adding additional
downstream attenuation materials will reduce
discharge sounds from the Air Terminal.
Radiated Noise
• Radiated noise is most commonly associated with Fan
Powered Terminals.
Electric Duct Heater
CAUTION
Use extreme care if testing the electric heater with
power on.
The control cabinet contains live electrical parts.
Contacting these parts with the power applied may
cause serious injury or death.
This unit should be serviced by a licensed electrician
or a similarly qualified electrical service technician.
If the electric heater does not operate:
• Check electric power into the unit and verify the input
power agrees with the label data.
• Verify the Air Terminal is installed properly (according
to the airflow orientation).
• Review the wiring diagram attached to the inside of
the control enclosure cover to verify the field wiring is
correct with proper gauge wire, overcurrent protection
and properly grounded.
If the electric heater cycles on and off:
• Verify the airflow is uniformly distributed across the
face of the heater elements.
• Check for obstructions in the duct or insufficient
airflow. (70 cfm per kW required)
If conditioned space fails to warm up:
• Verify the electric heater controls and thermostat are
compatible and wired properly.
• Relocate the room thermostat if it is located in a
position that is too warm.
If condition space overheats:
• Verify the electric heater controls and room thermostat
are compatible and wired properly.
• Relocate the room thermostat if it is located in a
position that is too cold.
• Verify the air distribution to the space is appropriate
for the required thermal load.
Troubleshooting

Fan Powered Air Terminal Units8
Specific Electric Heater Troubleshooting Procedures:
PROBLEM: Heater Does Not Energize
Cause Solution
Power not properly
connected to the
heater
1. With a voltmeter, check the power wiring terminals to ensure proper voltage is available to
the heater element side of the power terminal block or to the field side of the disconnect
switch, power fusing or circuit breaker.
2. If proper voltage is not present, check the terminal studs for proper wiring and check power
source for power.
Disconnect switch,
toggle switch or
circuit breaker are
set to OFF position
1.Set disconnect switch, toggle switch or circuit breaker to ON position.
Power fuses are
blown or circuit
breaker is tripped
1. Replace fuse(s) with same type and amperage as those provided with the heater from the
manufacturer or reset circuit breaker by first setting circuit breaker to OFF position then
resetting to ON position.
2. With an ammeter, check amp draw on the power lines.
3. For heaters with fusing, amp draw should not exceed the fuse amperage.
4. Amp draw should not exceed the circuit breaker rated value.
5. If the amp draw is excessive, check the power supply as described above for power
voltage.
6. If fuses blow or circuit breaker trips again, check for a short.
7. If no short is present and the power supply wiring/voltage are correct, contact factory for
further assistance.
Manual reset
safety switch
has tripped
1.Push the reset safety button on back of safety reset. The manual safety reset is located
inside the control enclosure cover near the bottom on the heater element header.
Airflow/static
switch is not
engaging
1. Jumper out the airflow/static switch by connecting the lead attached to the normally open
terminal to the normally closed terminal.
2. If the heater starts operating, two conditions could exist.
A.The airflow/static switch may be defective.
B.There is insufficient airflow to make the switch.
3. To verify available static pressure, disconnect the pneumatic tubing from the HI side of the
airflow/static switch and connect to a magnehelic gauge.
4. Available static pressure should be 0.05 in. wg +/- 0.03 in. wg to be safe.
5. If available static pressure is in a dead band, between the two ranges, the airflow/static
switch will not engage and could cause chattering of the contacts. Some method must be
devised to increase the available static pressure.
6. If sufficient static pressure is available, check to ensure the pneumatic tubing is connected
to the correct port (HI) on the airflow/static switch.

Fan Powered Air Terminal Units 9
Specific Electric Heater Troubleshooting Procedures:
PROBLEM: Heater Does Not Energize
Cause Solution
Automatic Safety
Reset Switch is
bad
1. Allow the duct temperature to cool down below 90ºF.
2. If the heater still does not energize, jumper out the automatic safety reset switch.
3. If the heater now energizes, contact the factory for a replacement automatic safety
reset switch.
Manual Safety
Reset Switch
is bad
1. Allow the duct temperature to cool down below 90ºF.
2. If the heater still does not energize, perform the following:
A. On heaters with the manual safety reset switch connected in the backup contact circuit,
jumper out the manual safety reset switch.
B. If the backup contactor now engages, contact the factory for a replacement manual
safety reset switch.
C. If the backup contactor fails to engage, there is a problem in the backup contactor
holding coil.
D. Use an ohmmeter to check continuity of the holding coil on the backup contactor.
E. If bad, contact factory for replacement backup contactor.
Insufficient airflow
across the electric
heating elements
1. The minimum allowable airflow across the heating elements is 70 cfm/kW.
2. Unless this recommended minimum airflow is met, the leaving air temperature of the heater
will be greater than the safety reset switch limits. This will cause nuisance tripping of the
safety reset switch.
3. Reset the minimum airflow across the heating elements during a call for heat at
70 cfm/kW.
WARNING
On all troubleshooting that requires working inside the heater casing, disconnect the power first! Jumpers used for
diagnostic purposes should be removed before returning the heater to normal operation.

Fan Powered Air Terminal Units10
Figure 3 - Multi-Quadrant Averaging Flow Sensor
4
5
6 7 8 9
10 12
14
16
12 Oval 14 Oval 16 Oval
14x8 16x8
18x16 20x16 24x16
0.01
0.02
0.03
0.05
0.07
0.1
0.2
0.4
0.7
1.0
1.5
20 30 40 60 80 100 200 300 400 600 800
1000 2000 3000 4000 6000 8000
10000
Sensor ΔP
Flow Rate (cfm)
Logarithmic Flow Rate vs Pressure Drop
MODEL INLET SIZE K FACTOR
XG-TH, XG-FCI,
XG-FCQ
XG-FVI, XG-DD
XG-DH, XG-BP
XG-RT, XG-RA
XG-TL (4 to 10)
XG-FCl C2 (4 to 8)
XG-FVL C2 (4 to 8)
04 Rnd 300
05 Rnd 375
06 Rnd 540
07 Rnd 760
08 Rnd 990
09 Rnd 1250
10 Rnd 1640
12 Rnd 2350
14 Rnd 3250
16 Rnd 4100
XG-TL (12) 12 Flat Oval 2270
XG- TL (14) &
XG-FVL C6 14 Flat Oval 2850
XG- TL (16) 16 Flat Oval 3550
XG-FVL C4 14x8 Rect 2450
XG-FCl C4 16x8 Rect 2770
XG-FCI, XG-FCQ, &
XG-FVI C7 18x16 Rect 6200
XG-TH 20 20x16 Rect 6430
XG-TH 24 24x16 Rect 7270
Note: K-factor is the
calibration flow constant
at 1 in. wg delta P
SIZE D (in.)
04 Rnd 4
05 Rnd 5
06 Rnd 6
07 Rnd 7
08 Rnd 8
09 Rnd 9
10 Rnd 10
12 Rnd 12
14 Rnd 14
16 Rnd 16
SIZE W (in.) H (in.)
12 FLat Oval 13 10
14 FLat Oval 16.25 10
16 FLat Oval 16.25 10
SIZE W (in.) H (in.)
14x8 Rect 14 10
16x8 Rect 16 10
20x16 Rect 20 10
24x16 Rect 24 16
K Factor
Round Flat Oval Rectangle

Fan Powered ATU • Rev. 2, October 2023 Copyright 2024 © Greenheck Fan Corporation11
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.
Product warranties can be found online at Greenheck.com, either on the specific product page or in the literature
section of the website at Greenheck.com/Resources/Library/Literature.
®
Phone: [phone] • Fax: [phone] • Parts: 800.355.5354 • E-mail: [email protected] • Website: www.greenheck.com
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