MODEL DG/DGX - Greenheck-USAwebmedia.greenheck.com/iomuser/IOM/463555 DG DGX Pilot...1. Open windows...
Transcript of MODEL DG/DGX - Greenheck-USAwebmedia.greenheck.com/iomuser/IOM/463555 DG DGX Pilot...1. Open windows...
Part # 463555
®
**WARNING**
Disconnect and secure all electrical power to the“OFF” position prior to inspection or servicing.Failure to comply with this safety precaution
could result in serious injury or death.
**IMPORTANT**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.
FOR YOUR SAFETY
If you smell gas1. Open windows2. Don’t touch electrical switches3. Extinguish any open flames4. Immediately call your gas supplier
Report any damaged equipment to the shipper immediately!All units are shipped on a skid or packaged to minimize damage during shipment. The transporting carrier hasthe responsibility for delivering all items in their original condition as received from Greenheck. The individualreceiving the equipment is responsible for inspecting the unit for obvious or hidden damage, recording anydamage on the bill of lading before acceptance and filing a claim (if required) with the final carrier. Someaccessory items are stored inside the unit during shipping. Care must be taken during installation to preventdamage to units.
FOR YOUR SAFETY
The use and storage of gasoline or otherflammable vapors and liquids in open
containers in the vicinity of this applianceis 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 thisequipment.
General
Maintenance
Tro
ublesho
oting
Op
eration
Start-U
pInstallatio
nR
eferenceMODEL DG/DGXMake-Up Air Unit
Installation, Operation and Maintenance Manual
2
TABLE OF CONTENTSG
ener
al
InstallationUnit - Indoor . . . . . . . . . . . . . . . . . . . . . . .3Unit - Arrangement DB/HZ . . . . . . . . . . . .4Unit - Arrangement DBC . . . . . . . . . . . .5-6Evaporative Cooler . . . . . . . . . . . . . . . . . .7Electrical Wiring . . . . . . . . . . . . . . . . . . .8-9Direct Gas Piping . . . . . . . . . . . . . . . .10-11Evaporative Cooler Piping . . . . . . . . .12-13Direct Expansion (DX) Coil Piping . . .14-15Chiller Water Coil Piping . . . . . . . . . . . . .16Building Pressure Control . . . . . . . . . . . .17
I
Start UpBlower . . . . . . . . . . . . . . . . . . . . . . . . .18-19Direct Gas . . . . . . . . . . . . . . . . . . . . . .20-25Evaporative Cooling . . . . . . . . . . . . . . . .26
S
OperationRecirculating/VAV Units . . . . . . . . . . . . .27Electrical . . . . . . . . . . . . . . . . . . . . . . . . .28
O
TroubleshootingBlower . . . . . . . . . . . . . . . . . . . . . . . . . . .29Heater . . . . . . . . . . . . . . . . . . . . . . . . .30-32Evaporative Cooling . . . . . . . . . . . . . . . .33Vibration . . . . . . . . . . . . . . . . . . . . . . . . . .34
T
ReferenceGas Train Layout . . . . . . . . . . . . . . . . . . .41Control Center Layout . . . . . . . . . . . . . . .42Notes . . . . . . . . . . . . . . . . . . . . . . . . . . .43Warranty . . . . . . . . . . . . . . . . . . .Backcover
MaintenanceRoutine . . . . . . . . . . . . . . . . . . . . . . . .35-37Fall . . . . . . . . . . . . . . . . . . . . . . . . .38-39Log . . . . . . . . . . . . . . . . . . . . . . . . . . .40
M
R
GeneralTable of Contents . . . . . . . . . . . . . . . . . . .2
G
STORAGEWhen a unit is not going to be in service for an extended amount of time, certain procedures should be followedto keep the unit in proper operating condition:
• Plug all piping• Rotate fan wheel monthly and purge bearings once every one to three months (depending on environment).• Energize fan motor once every three months• Store belts flat to keep them from warping and stretching• Store unit in location without vibration• Cover unit with tarp to protect from dirt and moisture• After storage period, purge grease before putting fan into service
NOTE!Do not cover unit with a black tarp, this would
promote condensation.
NOTE!Improper storage which results in damage to the
unit will void the warranty.
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Installation - Indoor InstallationInstallatio
n
Step 1 Install HangersInstall threaded hangers from ceiling supports. When locating hangers, allow enough room to open accesspanel(s). Two nuts must be used on the end of each threaded hanger. Ceiling supports are supplied by others.
Step 2 Install UnitUsing sheet metal screws, attach theweatherhood/thru-wall/filter section to theblower/burner section. The flange on theweatherhood/thru-wall/filter section should overlapthe flange on the blower/burner section.
Raise the assembled unit into place.
Using two nuts per hanger, fasten the unit supports tothe hangers under the unit. Appropriate unit supports,such as the optional Greenheck hanging bracket kitor 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 toprovide a safe environment for service andmaintenance, additional measures must be taken tosecure the unit in all directions.
Step 3 Seal Wall OpeningApply sealant around the perimeter of theweatherhood to prevent water penetration and draftsinto the building.
NOTE!Two nuts must be used on each end of each
threaded hanging rod for proper support.
NOTE!Good duct practices should be followed for all ductwork. Ductwork should be installed in accordancewith SMACNA and AMCA guidelines, NFPA 96 and any local codes. Reference the CAPS submittal for
duct sizes.
Sealant
UnitSupports
CeilingSupports
Hangers
Ductwork
Step 6 Seal Weatherhood SeamUsing an appropriate sealant, seal the seam betweenthe weatherhood and the unit.
4
Step 3 Apply SealantApply an appropriate sealant around the perimeter ofthe curb and duct adapter(s) to isolate fan vibrationand prevent water penetration.
Step 1 Install Curb and/or EquipmentSupport(s)
Position curb/equipment support(s) on the roof(reference the CAPS submittal for placement ofcurb/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 theequipment support(s) to the roof, remove metal cover,flash to wooden nailer and reinstall cover.
Step 2 Install DuctworkGood duct practices should be followed for allductwork. All ductwork should be installed inaccordance with SMACNA and AMCA guidelines,NFPA 96 and all local codes. Reference the CAPSsubmittal for ductwork sizes.
Step 4 Install UnitUse a crane and a set of spreader bars hooked to thefactory lifting lugs to lift and center the unit on thecurb/equipment support(s).
Use self-tapping sheet metal screws to fasten the unitto the curb/equipment support(s).
Step 5 Assemble and AttachWeatherhood
The weatherhood can now be assembled andattached to the unit. Detailed assembly instructionscan be found with the weatherhood. If the optionalevaporative cooling module was selected, this stepdoes not apply, refer to the installation instructions forthe optional evaporative cooling module.
Supply Air Duct Work(Arrangement DB only)Optional Return Air Duct
(Arrangement HZ and DB)
Sealant
Installation - Arrangement DB / HZIn
stal
latio
n
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.
NOTE!The use of a duct adapter is recommended on a
downblast (DB) arrangement to align theductwork with the supply unit and is only a guide
and is not to be used as support for theductwork.
Metal Cover
EquipmentSupport
Roof Curb
Supply Duct with DuctAdapter Installed
Exhaust Duct Installed
Sealant
SupplyDuctworkby Others
ExhaustDuctworkby Others
Metal Cover
EquipmentSupport
Roof Curb
Exhaust
Supply
1 inch InsideFlange
Step 1 Install Curb/EquipmentSupport(s)
Position curb/equipment support(s) on the roof(reference the CAPS submittal for placement ofcurb/equipment support(s) in relation to the unit).Verify that all unit supports are level, shim ifnecessary. Attach curb to roof and flash into place.Attach the equipment support(s) to the roof, removemetal cover, flash to wooden nailer and reinstallcover.
Step 2 Install Combination Extension Install combination extension over curb. Lag intoplace using wood screws. Locate the extension sothe tall vented side is over the exhaust opening.
Installation - Roof Mounted Unit Arrangement DBCInstallatio
n
Step 4 Apply SealantApply an appropriate sealant around the perimeter ofthe curb and duct adapter(s) to isolate fan vibrationand prevent water penetration.
5
NOTE!The use of a duct adapter is recommended on a
downblast (DBC) arrangement to align theductwork with the supply unit and is only a guide
and is not to be used as support for theductwork.
Step 3 Install DuctworkGood duct practices should be followed for allductwork. All ductwork should be installed inaccordance with SMACNA and AMCA guidelines,NFPA 96 and any local codes. Reference the CAPSsubmittal for ductwork size and location.
6
Model CUBEExhaust Fan
Step 5 Install Exhaust FanFasten exhaust fan to curb extension with self-tapping sheet metal screws.
Step 6 Install Exhaust OptionsInstall optional Greenheck hinge kit with restrainingcables and grease trap with drain connection.
Step 7 Install Supply UnitUse a crane and a set of spreader bars hooked to thefactory lifting lugs to lift and center the unit on thecurb/equipment support(s).
Use self-tapping sheet metal screws to fasten the unitto the curb/equipment support(s).
Installation - Roof Mounted Unit Arrangement DBC
Step 8 Assemble and AttachWeatherhood
The weatherhood can now be assembled and/orattached to the unit. Detailed assembly instructionscan be found with the weatherhood. If the optionalevaporative cooling module was selected, this stepdoes not apply, refer to the installation instructions forthe optional evaporative cooling module.
Inst
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tion
NOTE!Installing the exhaust fan prior to the supply unit
will allow for easier installation of options.
NOTE!NFPA 96 requires that the exhaust fan be hinged.
NOTE!The use of all lifting lugs and a set of spreader
bars is mandatory when lifting unit.
Step 9 Seal Weatherhood SeamUsing an appropriate sealant, seal the seam betweenthe weatherhood and the unit.
NOTE! Some units come with the weatherhood attached
and step 5 may not apply.
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NOTE!When mounting the evaporative cooler, it isimportant that it is level to ensure proper
operation and water drainage.
Installation - Evaporative Module (Optional)Installatio
n
Step 1 Locate Equipment Support(s)Position equipment support(s) on the roof (referencethe CAPS submittal for placement of equipmentsupport(s) in relation to the unit). Verify that all unitsupports are level, shim if necessary. Attachequipment support to the roof, remove metal cover,flash to wooden nailer and reinstall cover.
Step 2 Apply SealantApply an appropriate sealant around the airstreamopening to create an air tight seal.
Step 3 Set Evaporative Cooling ModuleUse a crane and a set of spreader bars hooked to thefactory lifting lugs to lift and center the module on theequipment support(s). The flange on the evaporativecooler should overlap the flange on the unit.
Step 4 Secure Cooling Module to UnitUse self tapping screws to fasten the cooling moduleto the base unit along the top and down both sides.Fasten at the top through the flanges. To fasten thesides, the media must be removed. To remove themedia, first remove the access panel on theevaporative module and disconnect the evaporativepump(s). The media will now slide out. With the mediaremoved, you can access the side fastening pointsinside the evaporative module. With all the screws inplace, reinstall the media, reconnect the pumps andreinstall the access panel.
NOTE!Small evaporative coolers ship attached to thebase unit and require no additional mounting.
NOTE!The use of all lifting lugs and a set of spreaderbars is mandatory when lifting the evaporative
cooling module.
Metal Cover
EquipmentSupport
Sealant
Step 4 Wire the Optional Convenience OutletThe convenience outlet requires a separate 115V power supply circuit. The circuit must include short circuitprotection which may need to be supplied by others.
Step 3 Connect the Main PowerConnect the main power lines to the disconnect switch and main grounding lug(s). Torque field connections to20 in-lbs. See the control center layout in the reference section for main disconnect and grounding lug(s)locations.
Installation - Electrical Wiring
CAUTION!If replacement wire is required, it must have a
temperature rating of at least 105°C, except forenergy cut-off or sensor lead wire which must be
rated to 150°C.
CAUTION!Any wiring deviations may result in personal injury or property damage. Greenheck is not responsible
for any damage to, or failure of the unit caused by incorrect final wiring.
Inst
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tion
DANGER!High voltage electrical input is needed for this
equipment. This work should be performed by aqualified electrician.
IMPORTANT!All wiring should be done in accordance with the
latest edition of the National Electric CodeANSI/NFPA-70 and any local codes that mayapply. In Canada, wiring should be done in
accordance with the Canadian Electrical Code.
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.
Step 1 Determine the Size of the MainPower Lines
The units nameplate states the voltage and the unit’stotal amps. The main power lines to the unit shouldbe sized accordingly.
Step 2 Provide the Opening(s) for theElectrical Connections
Electrical openings vary by unit size and arrangementand are field supplied.
MODEL
VOLTS
SUP HP
MARK
AMPS
HTZ PH
S/N
EXH HP
Voltage, Hertz,and Phase
Unit’s TotalAmps
IMPORTANT!Before connecting power to the unit, read and understand the following instructions and wiringdiagrams. Complete wiring diagrams are attached on the inside of the control center door(s).
IMPORTANT!Greenheck’s standard control voltage is 24 VAC.
Control wire resistance should not exceed 0.75 ohms (approximately 285 feet total length for 14 gaugewire; 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 5amps 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.
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Step 5 Wire the AccessoriesReference the ladder diagram on the inside of thecontrol center door for correct wiring of the followingaccessories:
Step 6 Wire the Optional EvaporativeCooler
Reference the ladder diagram on the inside of thecontrol center door for correct wiring of the pump andthe optional auto-drain and flush.
Step 7 Check Recirculation / VAVOperation
Two Position Damper ControlTurn the recirculating switch on the remote controlpanel to each position and confirm that the return airdamper adjusts accordingly. The damper actuatormay take a few minutes to open or close.
Two SpeedTurn the fan speed switch on the remote controlpanel to each positions and confirm that the fanspeed adjusts accordingly
Potentiometer ControlTo test potentiometer operation, turn thepotentiometer to the two extremes. With 80/20recirculation, confirm that the return air damper fullyopens and fully closes. The damper actuator maytake a few minutes to open or close. With variablevolume, make sure the fan goes to maximum andminimum speed.
Building Pressure ControlSee I-15 for building pressure set-up and operationcheck.
NOTE! Large evaporative coolers may require a
separate power supply.
NOTE! TSCP has number-to-number wiring.
NOTE! Wiring to the Selectrastat, Maxitrol 14
(discharge temperature selector) or 44 (roomoverride) should be in separate conduit or run
with shielded cable.
Installation - Electrical WiringInstallatio
n
NOTE!For maintenance issues associated with variable
frequency drives, consult the drive’s manualsupplied with the unit. The drives are
programmed at the factory and should not needany adjustment during installation and start up.
For kitchen applications, the drive may belocated in the kitchen or in the unit.
NOTE!Blower start-up (S-1), steps 1-4 should be
performed before the blower is run.
• Selectra Stat• Room Override• Blower Switch• Heat Switch
• Indicating Lights• Dirty Filter Indicator • TSCP• KSCP
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7065
75
80
85
90
60
55
(OPTIONAL)
BLOWER
DIRTY FILTERS
MAIN VALVES
ALARM
EXHAUST
SUPPLY
HEAT
(OPTIONAL)
GREENHECK®�
PHOTOHELIC
70
6575
80
85
90
60
55
(OPTIONAL)
BLOWER
DIRTY FILTERS
MAIN VALVES
ALARM
EXHAUST
SUPPLY
HEAT
(OPTIONAL)
GREENHECK®
7065
75
80
85
90
60
55
GREENHECK®�
(OPTIONAL)
BLOWER
DIRTY FILTERS
MAIN VALVES
ALARM
RECIRCULATION
EXHAUST
SUPPLY
HEAT
(OPTIONAL)
2-Position Damper Control
Building Pressure Control
Potentiometer Control
10
Installation - Direct Gas PipingIn
stal
latio
n
Step 1 Determine the Supply Gas RequirementsThe unit’s direct gas nameplate states the requirements for the gas being supplied to the unit.
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 inaccordance with the Installation Code for Gas Burning Appliances and Equipment (CGA B149) and
Provincial Regulations for the class. Authorities having jurisdiction should be consulted beforeinstallations are made.
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 gasleaks with an open flame.
WARNING!If pressure testing in excess of 1/2 psig (3.5
kPa), the heater and manual shutoff valve mustbe disconnected from the supply gas line.
WARNING!If pressure testing at or below 1/2 psig (3.5 kPa),the heater must be isolated from the supply gas
line by closing its manual shutoff valve.
IMPORTANT!All piping should be clean and free of any foreignmatter. Foreign material entering the gas traincan damage the valves, regulators and burner.
“W.C.
“W.C.
“W.C.
F
PSI
“W.C.
“W.C.
MAX BTU/HRBTU/H MAX
NORMAL MANIFOLDPRESSUREPRESSION D’ADMISSIONNORMALE
MIN GASPRESSUREPRESSION DE GAZ
MIN BURNERPRESSURE DROPPERTE MIN DE PRESSIONDANS LE BRULEUR
TYPE OF GASNATURE DU GAZ
MIN BTU/HRBTU/H MIN
MIN GAS PRESSUREFOR MAX OUTPUTPRESSION DE GAZ MINPOUR PUISSANCE MAX
MAX BURNERPRESSURE DROPPERTE MAX DE PRESSIONDANS LE BRULEUR
MAX GASPRESSUREPRESSION DE GAZMAX
DESIGN ∆T∆T NORMALE
EQUIPPED FOR
CONCU POUR
SCFM “W.C.
EXTERNAL STATIC PRESSURE
PRESSION STATIQUE EXTERIEURE
AGAINST
CONTE
Minimum andmaximum gas
pressures
Minimum gaspressure for
maximum output
Type of Gas
IMPORTANT!Do NOT connect the unit to gas types other thanwhat is specified and do NOT connect the unit
to gas pressures that are outside of the pressurerange shown on the label.
11
Installation - Direct Gas PipingInstallatio
n
From Gas
Supply
Gas Cock
1/8 in. Plugged Tap
6 in. Trap
Ground Joint Union
Make-Up Air Unit
Step 3 Connect the Supply Gas LineA manual shut off valve (gas cock), 1/8 in. pluggedtest port and 6 in. drip leg must be installed prior tothe gas train. The valve and the test port must beaccessible for the connection of a test gauge. Supplygas connections must be made by a qualified installerand are not furnished by Greenheck
Step 2 Install Additional Regulator ifRequired
When the supply gas pressure exceeds the maximumgas pressure shown on the direct gas nameplate, anadditional regulator (by others) is required to reducethe pressure. The regulator must have a listed leaklimiting device or it must be vented to the outdoors.
Step 4 Pipe the Optional Vent LineIf an optional vent line is located between the safetyshutoff valves it must be piped to the outdoors.
Step 5 Test the System for LeaksCheck both the supply lines and the factory piping forleaks. Apply a soap and water solution to all pipingand watch for bubbling which indicates a leak.
WARNING!The factory piping has been checked for leaks, but should be rechecked due to shipping and
installation.
WARNING!NEVER test for a gas leak with an open flame.
NOTE!The regulator located inside the unit is used toadjust the unit’s maximum output temperature.
NOTE!Reference the National Fuel Gas Code for
additional vent line requirements.
Safety Shut-offValves
Vent LineSolonoid
To Burner
Ven
t Li
ne
To Outdoors
From Supply
12
Installation - Evaporative Cooling Piping
Evaporative Cooling with Recirculating Pump.
Inst
alla
tion
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.
Step 1 Install the Water Supply LineConnect the water supply line to the float valve in theevaporative cooling unit. Install a manual shutoffvalve in the supply line as shown above.
Step 2 Install the Drain LineConnect an unobstructed drain line with a manualshut-off valve from the sump overflow to the maindrain line as shown above. A trap should be used toprevent sewer gas from being drawn into the unit.
Step 3 Check/Adjust Water LevelCheck the water level in the sump tank. The waterlevel should be above the pump intake and below theoverflow. Adjust the float as needed to achieve theproper water level.
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 analternate method must be used to protect the lines and media.
IMPORTANT!All supply solonoids, valves and all traps must be below the roofline or be otherwise protected from
freezing.
6 in. min.
6 in. min.
SupplyLine
Overflow
Trap
Drain LineValve
DrainLine
Supply LineValve
13
Installation - Evaporative Cooling PipingInstallatio
n
IMPORTANT!The supply line should be of adequate size and pressure to resupply the amount of water lost due to
bleed-off and evaporation. The drain line should be the same size or larger than the supply line.
CAUTION!All solenoids valves and traps must be installedbelow the roof to protect the supply water line
from freezing. If they cannot be installed belowthe roof, an alternative method must be used to
protect the lines from freezing
IMPORTANT!The supply solenoid (Valve A) is NOT the same asthe drain solenoids (Valve B and Valve C). Make
sure to use the proper solenoid for eachlocation. Check you local code requirements for
proper installation of this type of system.
Step 1 Install the Water Supply LineConnect the water supply line to the float valve in the unit. Install the 1/2 in. normally closed solenoid (Valve A)in the supply line as shown above. Install the 1/4 in. normally open solenoid (Valve B) between the supply lineand the drain line as shown above.
Step 2 Install the Drain LineConnect an unobstructed drain line to the sump drain.Install the 3/4 in. normally open solenoid (Valve C)between the sump drain connection and the drainline. A trap should be used to prevent sewer gas frombeing drawn into the unit.
Evaporative Cooling with Auto Drain and FillEvaporative Cooling
Section Supply Line
Sump Overflow
Sump Drain
Drain Line
Valve A
To Water Supply
Valve B
Valve C
Step 3 Check/Adjust Water LevelCheck the water level in the sump tank. The waterlevel should be above the pump intake and below theoverflow. Adjust the float as needed to achieve theproper water level.
6 in. min.
6 in. min.
14
Installation - Direct Expansion (DX) Coil Piping
IMPORTANT!Guidelines for the installation of direct expansion cooling coils have been provided to insure properperformance 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 shouldperform the installation and maintenance of any coil. Protective equipment such as safety glasses,
steel toe boots and gloves are recommended during the installation and maintenance of the coil.
IMPORTANT!All field brazing and welding should be
performed using high quality materials and aninert gas purge (such as nitrogen) to reduceoxidation of the internal surface of the coil.
IMPORTANT!All field piping must be self supporting and
flexible enough to allow for the thermalexpansion of the coil.
Inst
alla
tion
CoilSuction Header
Distributor
Equalizer Line
Nozzle
Liquid Line
Expansion Valve
Suction Line
Remote Sensing BulbStraps
Suction Connection
General
Hot Gas By-Pass
(by others)
(by others)
15
Step 7 Evacuate and Charge the CoilUse 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 thecoil to 500 microns or less then close the valve between the pump and the system. If the vacuum holds to 500microns or less for one minute, the system is ready to be charged or refrigerant in another portion of the systemcan be opened to the coil. A steady rise in microns would indicate that moisture is still present and that the coilshould be further vacuumed until the moisture has been removed.
6 in. min.
6 in. min.
Step 8 Install the Drain LineConnect an unobstructed drain line to the drain pan.A trap should be used to prevent sewer gas frombeing drawn into the unit.
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.
Step 6 Check Coil Piping for LeaksPressurize the coil to 100 psig with dry nitrogen or other suitable gas. The coil should be left pressurized for aminimum of 10 minutes. If the coil holds the pressure, the hook-up can be considered leak free. If the pressuredrops by 5 psig or less, re-pressurize the coil and wait another 10 minutes. If the pressure drops again there islikely one or more small leaks which should be located and repaired. Pressure losses greater than 5 psigindicate a large leak that should be isolated and repaired.
Step 1 Verify Nozzle PlacementInspect the refrigerant distributor and verify that thenozzle is in place. The nozzle is generally held inplace by a retaining ring or is an integral part of thedistributor itself.
Step 2 Install the Optional Hot Gas Bypass Kit (By Others)If a hot gas bypass kit was ordered with the coil, install it now. Consult the IOM from the bypass kit supplier forcomplete installation instructions. Align the side port with the hot gas line prior to brazing into place.
Step 3 Install Suction LineInstall a suction line from the compressor to the suction connection.
Step 4 Install the Thermal Expansion Valve (TEV) (By Others)Follow the TEV manufacturer’s recommendations for installation to avoid damaging the valve. If the valve isexternally equalized, use a tubing cutter to cut off the plugged end of the factory installed equalizer line. Use ade-burring tool to remove any loose metal from the equalizer line and attach it to the TEV. If the valve isinternally equalized, the factory installed equalizer line can be left as is.
Step 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 lineat the 3 or 9 o’clock position and insulated.
Installation - Direct Expansion (DX) Coil PipingInstallatio
n
RetainerRing Nozzle Distributor
NOTE!If a hot gas bypass kit was ordered, the nozzlewill not be located in the distributor, it will be
located in the hot gas bypass kit.
IMPORTANT!All traps must be installed below the roofline or
be otherwise protected from freezing.
16
Step 1 Verify Coil Hand DesignationCheck the coil hand designation to insure that itmatches the system. Coils are generally plumbed withthe supply connection located on the bottom of theleaving air-side of the coil and the return connectionat the top of the entering air side of the coil. Thisarrangement provides a counter flow heat exchangerand positive coil drainage.
Step 2 Check the Coil for LeaksPressurize the coil to 100 psig with dry nitrogen or other suitable gas. The coil should be left pressurized for aminimum of 10 minutes. If the coil holds the pressure, the hook-up can be considered leak free. If the pressuredrops by 5 psig or less, re-pressurize the coil and wait another 10 minutes. If the pressure drops again there islikely one or more small leaks which should be located and repaired. Pressure losses greater than 5 psigindicate a large leak that should be isolated and repaired.
Step 3 Connect the Supply and Return LinesConnect the supply and return lines as shown above.
Installation - Chilled Water Coil Piping
IMPORTANT!Guidelines for the installation of the cooling coil have been provided to insure proper performance ofthe coils and their longevity. These are general guidelines that may have to be tailored to meet thespecific 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 bootsand gloves are recommended during the installation and maintenance of the coil.
IMPORTANT!When installing couplings, do not apply unduestress to the connection. Use a backup pipe
wrench to avoid breaking the weld between thecoil connection and the header.
IMPORTANT!All field piping must be self supporting. Systempiping should be flexible enough to allow for thethermal expansion and contraction of the coil.
Step 4 Install the Drain LineConnect an unobstructed drain line to the drain pan.A trap should be installed to prevent sewer gas frombeing drawn into the unit.
Hot Return
Connection
Cold Supply
Connection
Entering Air Leaving Air
IMPORTANT!All traps must be installed below the roofline or
be otherwise protected from freezing.
6 in. min.
6 in. min.
Inst
alla
tion
17
Step 1 Mount Pressure TapUsing the factory provided bracket, mount thepressure tap to the outside of the unit. Choose alocation out of the prevailing winds and away fromsupply or exhaust fans to assure accurate readings.
Step 2 Run Pressure Tap LineA pressure tap line must be run to from the pressuretap mounted on the outside of the unit to the lowpressure tap on the back of the photohelic gage(pictured middle right). Fifty feet of tubing is suppliedwith the unit.
Step 3 Set the Building PressureThe pressure gage (pictured bottom right) is used toset the desired building pressure. The pressure is setby adjusting the knobs for the upper and lowerpressure limits. Typical settings are 0.0 in. wc for thelower and 0.10 in. wc for the upper pressure setting.
Step 4 Check Control System
Before the unit is left in service, the recirculationcontrol system should be tested. This can beaccomplished by turning both knobs to the uppermost pressure setting. You may have to remove theoutdoor pressure tap tubing. The return air dampershould close (VAV systems should go to max speed).Then set both knobs at the lowest setting, and thedamper should open (VAV systems should go tominimum speed). It may take one to two minutes forthe damper to reach the desired position. Reset thecorrect pressure limits before starting the unit. Thepicture on the bottom right shows a typical photohelicsetting. The needle in this photo indicates a negativebuilding pressure. During correct operation theindicating needle will remain between or near thesetting needles.
Installation - Building Pressure Control (Optional)
Low Pressure TapTo Outside
FactoryWiring
Pressure Setting Knobs
Pressure SettingNeedles
Pressure IndicatingNeedle
Installation
NOTE!Blower start-up (S-1), steps 1-4 should be
performed before the blower is run.
18
Start Up - BlowerS
tart
-Up
MODEL
VOLTS
SUP HP
MARK
AMPS
Hz PH
S/N
EXH HPVoltage, Hertz,and Phase
Step 1 Check the VoltageBefore starting the unit, compare the supplied voltage, hertz, and phase with the unit and motor’s nameplateinformation.
Step 2 Check the Blower RotationOpen the blower access door and run the blower momentarily to determine the rotation. Arrows are placed onthe blower scroll to indicate the proper direction or reference the example below.
IMPORTANT!If the blower is rotating inthe wrong direction, theunit will move some air,but will not perform asdesigned. Be sure to
perform a visual inspectionto guarantee the correct
blower rotation.Blower
Rotation
Housing
SPECIAL EQUIPMENT REQUIREDBelow is a list of special tools that are required. A recommended model is shown, but equivalentproducts may be used.
Description Manufacture-Model Phone WebsiteVoltage Meter Fluke-23 1-800-44-FLUKE www.fluke.comAmperage Meter Fluke-23 1-800-44-FLUKE www.fluke.comThermometer Fluke-50 1-800-44-FLUKE www.fluke.comU-Tube manometer Dwyer-Slack Tube 1-219-897-8000 www.dwyer-inst.comTachometer Monarch-Pocket Tach 100 1-800-999-3390 www.monarchinstruments.com
WARNING!Disconnect and lock-out all power and gas before
performing any maintenance or service to theunit. Failure to due so could result in serious
injury or death and damage to equipment.
Pre-Start Up CheckRotate the fan wheel by hand and make sure no partsare rubbing. Check the V-belt drive for properalignment and tension (a guide for proper belt tensionand alignment is provided in the belt maintenancesection). Check fasteners, set screws and lockingcollars on the fan, bearings, drive, motor base andaccessories for tightness.
NOTE!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
manufactures instructions.
19
Start Up - BlowerS
tart-Up
Step 4 Motor CheckMeasure the motor’s voltage, amps and RPM’s and compare to the specifications.
Step 5 Air Volume Measurement andCheck
Measure the unit’s air volume (CFM) and compare itwith its rated air volume. If the air volume is off, adjustthe fan’s RPM’s by changing the drive.
Step 6 Set-up Optional ComponentsAdjust the settings on the optional components. See the control center layout in the reference section forlocation of optional components.
• Heating Inlet Air Sensor (typical setting: 60-70ºF)
• Cooling Inlet Air Sensor (typical setting: 75ºF)
• Building Freeze Protection (typical setting: 5 min at 45ºF)
• Dirty Filter Gauge (typical setting: settings vary greatly for each unit)
• Solid Fuel Time Delay (typical setting varies per application)
NOTE!The most accurate way to measure the airvolume is by using a pitot traverse method
downstream of the blower. Other methods canbe 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.
Step 3 Check for VibrationCheck for unusual noise, vibration or overheating of the bearings. Reference the troubleshooting section forcorrective actions.
IMPORTANT!Excessive vibration may be experienced during
the initial start-up. Left unchecked, it can causea multitude of problems including structural
and/or component failure.
IMPORTANT!Generally, fan vibration and noise is transmittedto other parts of the building by the ductwork.To minimize this undesirable effect, the use of
heavy canvas duct connectors is recommended.
20
Step 1 Check the Supply Gas PressureCheck the supply gas pressure and compare it with the unit’s nameplate pressure requirements. Adjust thesupply regulator as needed until the supply gas pressure is within the specified range.
Sta
rt-U
p
IMPORTANT!For proper unit function and safety, follow thestart-up procedure in the exact order that it is
presented.
“W.C.
“W.C.
“W.C.
F
PSI
“W.C.
“W.C.
MAX BTU/HRBTU/H MAX
NORMAL MANIFOLDPRESSUREPRESSION D’ADMISSIONNORMALE
MIN GASPRESSUREPRESSION DE GAZ
MIN BURNERPRESSURE DROPPERTE MIN DE PRESSIONDANS LE BRULEUR
TYPE OF GASNATURE DU GAZ
MIN BTU/HRBTU/H MIN
MIN GAS PRESSUREFOR MAX OUTPUTPRESSION DE GAZ MINPOUR PUISSANCE MAX
MAX BURNERPRESSURE DROPPERTE MAX DE PRESSIONDANS LE BRULEUR
MAX GASPRESSUREPRESSION DE GAZMAX
DESIGN ∆T∆T NORMALE
EQUIPPED FOR
CONCU POUR
SCFM “W.C.
EXTERNAL STATIC PRESSURE
PRESSION STATIQUE EXTERIEURE
AGAINST
CONTE
Minimum andmaximum gas
pressures
IMPORTANT!This start-up should begin after all of the
installation procedures and the Electrical start-up have been completed.
Start Up - Direct Gas
Step 2 Check the Pilot Gas PressureCheck the pilot gas pressure. The recommended gas pressure is 3 in. wc. Adjust the pilot regulator as needed.See the gas train layout in the reference section for the location of the pilot pressure test port and pilot regulator.
Step 3 Set the Optional High and Low Gas Pressure SwitchesRemove the cover on the high and low gas pressure switches and set the switch trip points. See the gas trainlayout in the reference section for the location of the high and low gas pressure switches. The high gas setting istypically 8 in. wc. and the low gas setting is typically 3 in. wc.
NOTE!The purpose of the high and low gas pressure switches is to automatically shut down the burner if theinlet gas pressure is too low for the burner to safely light, or if the manifold pressure is to high for the
burner to operate properly.
21
7
6
0.625 - 0.675 in. W.C.
Start Up - Direct GasS
tart-Up
Step 4 Set the Burner Air PressureDifferential
With the fan running and discharging 70°F air,connect a U-Tube manometer to the outer sensingprobes (see below) and measure the static pressureacross the burner.
The proper static pressure should be between 0.625and 0.675 inches w.c. Evenly adjust the baffles aboveand below the burner, keeping the burner centered inthe opening until the required pressure is obtained.
Outer Sensing Probes
AdjustableTop Baffle
Air Flow
Burner
AdjustableBottom Baffle
IMPORTANT!Proper air velocity over the burner is critical on direct fired gas units. If the air velocity is not withinthe unit specifications, the unit will not operate efficiently, may have sporadic shutdowns and may
produce excessive carbon monoxide (CO) or other gases.
NOTE!To increase the static pressure decrease the
opening. To decrease the static pressureincrease the opening.
IMPORTANT!This process may need to be repeated until theproper pressure is achieved. This adjustment
will change the air quantity delivered by the unitand therefore the air quantity delivered should berechecked. Refer to the blower start up section.
NOTE!When required pressure is obtained be sure to
reconnect the outer sensing probes.
22
Remove the wirefrom terminal #4to send the unitto maximum fire
Start Up - Direct Gas
Maxitrol Series 14(7 or 8 terminals)
Sta
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Low fire time delaysetting
(75% of maximum)
Remove the wire from the #3 terminalto send the unit to maximum fire
Maximum dischargetemperature setting
(100°F Typical)
Minimumdischarge
temperaturesetting
(50°F Typical)
Low fire time delaysetting
(75% of maximum)
Maxitrol Series 44(9 terminals)
Step 6 Set the Maximum Firing RatesMonitor the units actual temperature rise by placing athermocouple in the unit’s inlet and a second in thedischarge, three duct diameters downstream of theburner.
Send the unit to maximum fire by disconnecting andisolating the proper wire on the Maxitrol amplifier.(Terminal #4 for Maxitrol 14, #3 for Maxitrol 44 asshown below).
Continues on next page...
Step 5 Set the Low Fire Time DelaySet the low fire time delay to 75% of its maximumsetting. See the drawings below for the location ofthe time delay setting.
WARNING!Do not set the burner maximum firing rate basedon gas pressure. It should be set based on theunit’s designed temperature rise shown on the
direct gas label.
“W.C.
F
PSI
MAX BTU/HRBTU/H MAX
NORMAL MANIFOLDPRESSUREPRESSION D’ADMISSIONNORMALE
MIN GASPRESSUREPRESSION DE GAZ
MIN BURNERPRESSURE DROPPERTE MIN DE PRESSIONDANS LE BRULEUR
TYPE OF GASNATURE DU GAZ
MIN BTU/HRBTU/H MIN
MIN GAS PRESSUREFOR MAX OUTPUTPRESSION DE GAZ MINPOUR PUISSANCE MAX
MAX BURNERPRESSURE DROPPERTE MAX DE PRESSIONDANS LE BRULEUR
MAX GASPRESSUREPRESSION DE GAZMAX
DESIGN ∆T∆T NORMALE
EQUIPPED FOR
CONCU POUR
SCFM “W.C.
EXTERNAL STATIC PRESSURE
PRESSION STATIQUE EXTERIEURE
AGAINST
CONTE
23
Step 6 Set the Maximum Firing Rate (...continued)While monitoring the units temperature rise, set the maximum firing rate by adjusting the regulator (as shownbelow) until the designed temperature rise is achieved. After setting the maximum firing rate, reconnect the wireto the amplifier.
IMPORTANT!Setting the maximum firing rate during mild
weather conditions may cause the high limit totrip out during extreme conditions requiring
manual resetting.
NOTE!Gas trains are equipped with either separateregulators and modulating valves or with a
combined modulating regulator.
NOTE!Clockwise rotation increases the temperature rise, counterclockwise rotation decreases the
temperature rise.
Remove cap to accessmaximum firing rate
adjustment
Separate Regulator andModulating Valve
Combined ModulatingRegulator
Maximum firing rateadjustment
Start Up - Direct GasS
tart-Up
24
Start Up - Direct Gas
Step 7 Set the Minimum Firing RateDisconnect and isolate one of the wires running to themodulating valve to send the unit to its minimumfiring rate. Set the minimum firing rate by adjustingthe needle valve as shown in the figures below.
After setting the minimum firing rate, shut off the pilotto ensure that the flame safeguard can still read themain flame signal. Reconnect the wire to themodulating valve and open the pilot shut-off valve.
Remove one wire tosend the unit to theminimum firing rate.
Minimumfiring rate
adjustment
Remove one wire tosend the unit to theminimum firing rate.
NOTE!Gas trains are equipped with either separate regulators and modulating valv0es or with a combined
modulating regulator.
NOTE!On units with a 42 inch or greater burner, the flame safe guard will automatically shut off the pilot
after the burner has been ignited.
IMPORTANT!The proper setting for the minimum firing rateresults in a small ribbon of continuous flame
across the entire burner.
IMPORTANT!Do not allow the disconnected wire to come incontact with a potential ground, damage to the
amplifier or transformer could result.
Sta
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NOTE!Adjusting the maximum and minimum fire may require the inlet air sensor to be initially set higher thandesired in order to start the burner(s). Once high and low fire have been set, the inlet air sensor should
be turned down to the desired temperature.
NOTE!Counterclockwise rotation increases the
minimum fire rate setting, clockwise rotationdecreases the setting.
Separate Regulator andModulating Valve
Combined ModulatingRegulator
Minimum firing rateadjustment
25
Step 9 Flame Signal Check To measure the flame signal connect a standard DCvoltmeter to the flame amplifier test jacks + and -(com) as shown to the right. The flame signal shouldbe above 1.25 VDC and steady.
Check the flame signal with the burner at pilot only,minimum fire, mid fire and high fire.
NOTE!If the fame signal is not above 1.25 VDC andsteady, consult the troubleshooting section.
Start Up - Direct Gas
Step 8 Set the Unit’s Operating TemperatureSet the operating temperature. The operating temperature setting depends on which Maxitrol controller is usedand the desired space temperature.
Maxitrol Series 14(Discharge temperature control)
Set the dischargetemperature (65°F Typical)
IMPORTANT!The Maxitrol Series 14 should be set to the
desired discharge temperature. Thetemperature selector may be built into theamplifier or may be a stand-alone dial. Thestand-alone dial may be mounted remotely.
Maxitrol Series 44(Space temperature control)
IMPORTANT!The Maxitrol Series 44 should be set to the
desired room temperature. The selectrastatmust be mounted in the space.
Set the spacetemperature (70°F Typical)
Start-U
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26
Step 6 Adjust the Water Bleed-Off RateThe water bleed-off rate is dependent on the water’s mineral content. The bleed-off should be adjusted basedon media’s mineral deposits after two weeks of service. See the picture below for location of bleed-off valve.
Step 8 Put the Unit into ServiceRemove the jumper, and energize the blower(s). Verify proper operation.
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Start Up - Evaporative Cooling
Step 1 Check the InstallationThe media may have been removed during installation, so itsorientation should be double checked. The media should beinstalled with the steeper flute angle sloping down toward theentering air side. See the figure on the right.
Verify that the stainless steel caps and distribution headersare in place. The headers should be located over the mediatowards the entering air side. The caps should be placed overthe headers.
Leaving AirEntering Air
45°
15°
Step 2 Check the Pump FilterCheck that the pump filter is around the pump inlet. See the picture below.
Step 3 Fill the Sump and Adjust the FloatTurn on the water supply and allow the pan to fill. Adjust the float valve to shut-off the water supply when thesump is filled to within 1 in. of the bottom of the overflow. See the picture below.
Step 5 Check the Flow RateThe pumps should provide enough water to saturate the media in 45 to 60 seconds. Consult the factory, ifadequate flow is not achieved.
Bleed-OffValve
Overflow
PumpFilter
Threaded FloatAdjustment
SupplyConnection
FloatValve
Step 7 Set the Optional Auto Drain and FillSet the auto drain and fill timer and temperature settings. Timer settings are t1: 1.0, 10min and t2: 0.4, 60hTemperature is typically set to 45ºF. See the pictures below.
IMPORTANT!Check the media for minerals after two weeks of service and adjust the bleed-off rate accordingly.
NOTE!A jumper will need to be installed in the controlcenter to power the evaporative pumps with the
blower(s) off. Reference the unit’s ladderdiagram to determine proper terminals.
EvaporativeTimer
t2 settings
t1 settings
EvaporativeFreeze Protection
TemperatureSetting
Step 4 Break-in the MediaOpen the bleed-off valve completely and saturate themedia with the blower(s) off for no less than 20minutes.
27
Operation - Recirculating / VAV Units
Manual Quadrant Damper ControlA manual quadrant damper in the return air flow controls the amount of recirculated air. This damper can beadjusted by hand and locked in position for either 100% outside air or maximum recirculation air.
2-Position Damper ControlA 2-position spring return actuator is used to control the return air amounts. The damper moves from open toclosed. If power is cut to the unit, the damper will fail close. The volume of recirculation air is set in the factoryby baffles in the return air opening. These baffles should not be removed or adjusted in the field.
Potentiometer ControlA modulating spring return actuator is used to control the return air amounts. The damper moves from fully opento fully closed. The amount of return air is determined by the position of a remote potentiometer.
Building Pressure ControlA modulating spring return actuator is used to control the return air amounts according to input from a pressuresensing device. The recirculation damper moves from fully open to fully closed.
2-Speed ControlA 2-speed motor is used to control air volumes. The motor can be switched to low or high speed from a remotecontrol panel. One half or one third reduction motors are used.
Potentiometer ControlA variable frequency drive is controlled by input from a remote speed selector (potentiometer). This unit allowseasy manual adjustment of make-up air volumes.
Building Pressure ControlA variable frequency drive is controlled according to input from a pressure sensing device.
Variable Frequency DrivesFor maintenance issues associated with the variable frequency drives, please consult the drive’s manualsupplied with the unit. The drives are programmed in the factory and should not need any adjustment duringinstallation and start up. For kitchen applications, the drive is located in the kitchen, not in the unit.
The self adjusting burner by-pass damper is a device used in variable volume and recirculation units. Its functionis to maintain proper combustion by providing a constant air flow over the burner when outside air volumes arechanged. It is located underneath the burner as shown in the picture below.
Burner By-Pass Damper
80/20 Operation (Optional)
Variable Volume Operation (Optional)
Burner
By-PassDamper
WARNING!The burner by-pass damper is set-up at the
factory. The weights and springs should not beadjusted in the field. The damper may not fully
close during minimum outside air mode.
Op
eration
28
Operation - Electrical
1. Exhaust Fan Switch (S1) Closed• Power passes to exhaust starter(s) ST2(3)• N.O. exhaust starter switches are energized
and closed• Power passes to exhaust fans• Exhaust fans start
2. Supply Fan Switch (S2) Closed• N.O. contact(s) ST2(3) are closed• Power passes to optional freeze protection
relay (FZ1) and if temperature is acceptableN.C. contact (FZ1) remains closed
• Power passes to damper which opens• When damper is fully opened, damper relay
(D1) is energized and N.O. damper limit switch(DL1) closes.
• Power passes to and energizes supply starterrelay (ST1)
• Supply starter contact (ST1) closes and powerreaches and energizes supply fan
• Supply fan starts
4. Evaporative Cooling Switch (S4)Closed*• N.O. contact ST1(AUX) is energized and closed• Power passes to and energizes cool relay (R1)• N.O. contact R1 is energized and closed • Power passes to evaporative cooling pump (P1)
*If DX or chilled water coils are used rather thanan evaporative cooler, the cooling sequence ofoperation will depend on the coil controls.Cooling coil controls are supplied by others.
3. Heat Switch (S3) Closed• Power passes to N.O. ST1 which is energized
and closed• Power passes to inlet air sensor contact (TS1)
which is energized and closed if proper inlet airtemperature is present
• Power passes to and energizes heat relay (R2)• N.O. heat relay contact (R2) closes• Power passes to and energizes terminal 5 of
the Flame Safe Guard (FSG)• Power passes to N.C. high limit control contact
(HLC1) which is closed if the temperatrue hasremained below the high limit set point
• Power passes to N.O. and N.C. gas pressurecontacts (PS1) which are both closed if gaspressure is within the set range
• Power passes to terminal 6 of the FSG• FSG begins direct gas burner sequence (see
direct gas sequence)
1. Supply Fan Switch Closed• Power passes to the supply fan and heat switch
2. Heat Switch Closed• Power passes to the heat relay then to the
Flame Safe Guard
3. Flame Safe Guard (FSG) Sequence• Checks for proper air flow• Verifies no flame present at burner• Initiates 10 second prepurge• Sends power to open pilot valve (V1) and
energizes the spark generator (SG1) (clicking ofthe spark generator may be heard).
• Tries for up to 10 seconds to light pilot andconfirm flame.
• Powers the main gas valves (V2 and V3) open• Shuts down spark generator• Continuously monitors the flame and airflow• Performs self diagnostic check every five
seconds
Electrical Sequence Direct Gas Burner Sequence
Op
erat
ion
2929
Troubleshooting
115 Vac between terminals 102 and 101?
Check Main Voltage(See Blower Start-Up Step #1)Main Disconnect (DS1) Off
(Turn Main Disconnect DS1 On)Primary Fuses (FU6) or Secondary Fuses (FU7) Blown
(Replace Fuses)Main Transformer (TR1) Defective
(Replace Transformer TR1)24 Vac between terminals R and X?
Secondary Fuse (FU8) Blown(Replace Fuses)
Main Transformer (TR1) Defective(Replace Transformer)
24 Vac between terminals 8 and X?
Supply Fan Overload (ST1 OL) Tripped(Reset and check motor amps, reference blower start-up #4)
24 Vac between terminals 7 and X?
Damper Limit Switch (DL1) Holding(Wait for actuator to open fully or adjust limit switch)
Damper Limit Switch Jumper Missing(Install jumper, reference the units ladder diagram for terminals)
24 Vac between terminals 6 and X?
Optional Exhaust Fan Interlocks (ST2-ST5) Open(Correct/Replace)
Freeze Protection (FZ1) Tripped(Reset)
24 Vac between terminals G and X?
Supply Switch (S2) Off(Turn Supply Switch S2 On)
Fire system contact (FSC) tripped(Correct/Replace)
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Note: At this time the supply contactor (ST1) should pull in passingpower to the supply motor and the blower should start.
Yes
Blower Does Not Operate
Broken Fan Belt(Replace - Reference maintenance section)
Defective motor or capacitor(Repair/Replace)
Blown Motor Fuse(Replace)
One or more legs of 3 phase is out(Restore missing legs)
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Troubleshooting
24 Vac between terminals W1 and X?
Heat Switch (S3) Off (Turn Heat Switch S3 On)Heat Switch Not Wired
(Wire Heat Switch S3)115 Vac between
terminals 102 and 101?
Secondary Fuses (FU7) Blown(Replace Fuses)
Main Transformer (TR1) Defective(Replace Transformer TR1)
115 Vac between terminals 105 and 101?
High/Low Gas Pressure Switch (PS1) Tripped(Correct gas pressure and reset)
(Reference Direct Gas Start-Up Step #2 and 3)
115 Vac between terminals 104 and 101?
High Limit (HLC1) Tripped(Reset/Replace High Limit HLC1)(Check on cause of control loss)
Continuity between terminals 109 and 110?
Note: The power light on the flame safeguard should blinkapproximately every 5 seconds as it performs a self-diagnostics check.
115 Vac between terminals 103 and 101?
Inlet Air Senor (TS1) Holding(Adjust TS1 setting -- Reference blower start-up step 6)
Heat Relay (R2) Defective(Replace Heat Relay R2)
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Air Flow Switch (PS2) Holding for Proper Air Flow(Correct air flow across burner)
(Reference Direct Gas Start-Up Step #4)
Yes
At this time the heater should attempt to light(The pilot light on the flame safeguard should illuminate)
Heater Does Not OperateDoes not attempt to light (No visible spark)
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Troubleshooting
No
Check for proper pilot pressure.(Direct Gas Start-up #2)
Check inlet gas pressure.(Direct Gas Start-Up Step #1)
Note: The minimum and maximum gas pressures for your unit areshown on the direct gas label. Reference start-up procedure #1
Gas pressure between the minand max shown on the direct gas
label? Correct gas pressure(Reference Direct gas Start-Up Step #1)
Proper spark?Crossed flame and spark wires
(Uncross wires and reconnect)Incorrect spark plug gap
(Set spark plug gap to 0.062 in.)Defective spark plug
(Replace spark plug)
Pressure drop across the burnerbetween 0.60 and 0.65 in. wc?
Adjust burner baffles(Reference Direct Gas Start-Up Step #4)
Check for proper air flow(Direct Gas Start-Up Step #4) Note: The air flow may satisfy the air flow switch, but may make
lighting the pilot difficult. Adjust the pressure drop across the burnerto 0.625 in. wc shown in Direct Gas Start-Up Step #4.
Air in the gas line?Purge gas line
(Verify gas at the pilot)
No
No
Yes
No
No
Yes
Yes
Yes
Yes
No
Note: A high pilot pressure will make lighting more difficult. Lower thepilot pressure in increments until the unit lights. Then set the pilot per
the instruction in Direct Gas start-up procedure #2)
Yes
Adjust the pilot pressure(Reference Direct Gas Start-Up Step #2)
Heater Does Not OperateAttempts to light but no visible pilot (Visible spark)
Pilot pressure correct?
Yes
With proper air flow, gas pressure and spark, the unit should light.
If problems remain, consult the factory
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Troubleshooting
Does the flame signal remainconstant?
Measure the flame signal whenthere is a visible pilot Note: The flame signal should be steady and above 1.25 Vdc with a
visible pilot.Reference Direct Gas Start-Up Step #9
Flame signal greater than 1.25 Vdc?
Unit is not grounded(Properly ground unit)
Flame rod is grounding out(Adjust the flame rod to avoid contact with the burner or the unit)
Cracked porcelain on flame rod(Replace flame rod)
Is the minimum firing rate setcorrectly?
Adjust the minimum firing rate(Reference Direct Gas Start-Up Step #6)
Check the minimum firing rate?(Direct Gas Start-Up Step #6)
Note: Burners greater than 36 in. in length use an interrupted pilot.The pilot is turned off 10 seconds after lighting the main burner and theflame safeguard monitors the main flame instead of the pilot flame. Ifthe minimum fire is set to low, the flame safeguard may not be able to
sense it.
Pressure drop across the burnerbetween 0.625 and 0.675 in. wc?
Note: When the pressure is low or marginal and the unit beginsheating the air density will change, this can cause the pressure to dropbelow the minimum setting. Also, low air flow can cause the flame to
walk out of the burner and away from the flame sensor causing the unitto recycle.
Check for proper air flow(Direct Gas Start-Up Step #4)
Adjust burner baffles(Reference Direct Gas Start-Up Step #4)
No
No
No
Yes
Yes
If the signal slowly drops off, typically the air flow is too low(Reference Blower Start-Up Step #6)
If it suddenly drops to zero, the flame rod is grounding out.(Adjust the flame rod to avoid contact with the burner or the unit)
Yes
Yes
Heater Does Not OperateVisible pilot
No
If the flame signal is above 1.25 Vdc and constant the maingas valves will remain open until the call for heat is
interrupted, or the unit is shut down.
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Troubleshooting
Water Blows through Evaporative Cooler
Water supply greater thanevaporation and bleed-off rate?
Use the main supply valve to reduce the supply of water.
Air velocity greater thanspecified?
Reduce the air velocity through the media.(Reference Evaporative Cooler Start-Up Step #1)
Are the headers in place andlocated near the entering side of
the media?
Replace headers and/or move the headers.(Reference Evaporative Cooler Start-Up Step #1)
Yes
No
Yes
Yes
No
Note: At this time the evaporative cooler should be operating withoutwater blowing through.
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Troubleshooting
Excessive Noise or Vibration
Note: At this time noise and vibration should be at acceptable levels.
Sheaves aligned?Align sheaves
(Reference V-Belt drive maintenance in the maintenance section)
Wheel(s) unbalanced? Clean and/or balance wheel(s).
Belts worn or loose?Replace worn belts or tighten loose belts.
(Reference V-Belt drive maintenance in the maintenance section)
Yes
Yes
No
No
Yes
Bearings worn or needlubrication?
Replace worn bearings or lubricate bearings as needed.(Reference bearing maintenance in the maintenance section)
Yes
No
Wheel(s) rubbing on inlet? Adjust wheel(s) or inlet.Yes
No
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35
Maintenance - Routine
CAUTION!Lock-out the gas and the electrical power to the unit before performing any maintenance or service
operations to this unit.
IMPORTANT!Do not install new belts on worn
sheaves. If the sheaves havegrooves worn in them, they mustbe replaced before new belts are
installed.
IMPORTANT!Premature or frequent belt failures can be caused by
improper belt tension, or misaligned sheaves.
Abnormally low belt tensionwill cause squealing on start-
up, excessive belt flutter,slippage and overheated
sheaves
Abnormally high belt tensionor drive misalignment willcause excessive bearingloads and may result infailure of the fan and/or
motor bearings.
IMPORTANT!When replacing V-belts on
multiple groove drives all beltsshould be changed to provide
uniform drive loading.
Belt Span
Deflection = Belt Span
64
IMPORTANT!Do not pry belts on or off the
sheave. Loosen belt tension untilbelts can be removed by simplylifting the belts off the sheaves.
V-Belt DrivesV-belt drives must be checked on a regular basis forwear, tension, alignment and dirt accumulation.
Check the alignment by using a straight edge acrossboth sheaves as shown below.
Check the tension by measuring the deflection in thebelt as shown below.
Maintenance
36
Maintenance - RoutineM
aint
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Recommended Bearing Lubrication Schedule for Greenheck FansRelubrication Schedule in Months*
BearingsThe bearings for Greenheck fans are carefullyselected to match the maximum load and operatingconditions of the specific class, arrangement and fansize. The instructions provided in this manual andthose provided by the bearing manufacturer willminimize any bearing problems.
Fan RPM Bearing Bore Size (inches)1/2 - 1 1 1/8 - 1 1/2 1 5/8 - 1 7/8 1 15/16 - 2 3/16 2 7/16 - 3
250 6 6 6 6 6500 6 6 6 5 4750 6 5 4 3 31000 5 3 2 1 11250 5 3 2 1 11500 5 2 1 1 0.52000 5 1 1 0.5 0.25
* Suggested initial greasing interval is based on 12 hour per day operation and 150°F maximum housing temperature. For continuous (24 hour) operation, decrease greasing interval by 50%
- 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 in. bore size, and 4-5 shots above 2 in. bore sizes with a hand grease gun.
- For roller bearings add 4 shot of grease up to 2 in. bore size, and 8 shots for 2 in.-5 in. 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
below should be used:Mobil 532 Texaco Multifak #2 B Shell Alavania #2Mobilux #2 Texaco Premium #2 Exxon Unirex N2
IMPORTANT!Lubricate bearings prior to periods of extendedshutdowns or storage and rotate shaft monthly
to aid in corrosion prevention. If the fan isstored more than three months, purge thebearings with new grease prior to start-up.
MotorsMotor maintenance is generally limited to cleaningand lubrication (where applicable).
Cleaning should be limited to exterior surfaces only.Removing dust and grease build-up on the motorassures proper motor cooling.
Motors supplied with grease fittings should begreased in accordance with the manufacturer’srecommendations.
IMPORTANT!Do not allow water or solvents to enter the motor
or bearings. Motors and bearings should neverbe sprayed with steam, water or solvents.
IMPORTANT!Greasing motors is only intended when fittings
are provided. Many motors are permanentlylubricated, requiring no additional lubrication.
WheelsWheels require little attention when moving clean air.Occasionally oil and dust may accumulate on thewheel causing imbalance. When this occurs thewheel and housing should be cleaned to assureproper operation.
37
Maintenance - Routine
FiltersFilter maintenance is generally limited to cleaning andreplacement.
If aluminum mesh filters are installed, they can be washed inwarm soapy water.
An adhesive spray can be added to aluminum mesh filters toincrease their efficiency.
If disposable filters are installed, they can be check byholding up to a light source. If light cannot pass through thefilter, it should be replaced.
IMPORTANT!When reinstalling filters be sure to install
them with the airflow in the correctdirection. 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 asthe original filters provided with the unit.
Evaporative CoolersThe media should be periodically brushed lightly with a softbristle brush in an up and down motion while flushing withwater. This aids in reducing the amount of mineral build-up.
For large amounts of mineral build up, clean or replace themedia and increase the water bleed-off or flush rate.
The cooling media has a useful life of 3 to 5 years dependingon the water quality and the bleed-off or flush rate.
Leaving AirEntering Air
45°
15°
IMPORTANT!Replacement media should be from the same
manufacturer and be the same size as the originalmedia provided with the unit.
IMPORTANT!When reinstalling the evaporative media,make sure that it is installed correctly.Reference the drawing shown below.
Cooling CoilsInspect the coil for signs of corrosion and/or leaks. Repairany leaks as required.
Inspect the coil’s surface for foreign material. If the coilsurface need cleaning, clean the coil from the leaving air-sideso that foreign material will be washed out of the coil ratherthan pushed farther in.
Inspect and clean the drain pan to prevent the growth ofalgae and other organisms.
IMPORTANT!Be sure to read and follow the
manufacturer’s recommendations beforeusing any cleaning fluid.
WARNING!Repair and replacement of the coil and
the connecting piping, valves, etc.,should be performed by a qualified
individual.
Chilled Water CoilsTest the circulating fluid for sediment, corrosive products,biological contaminants and make the necessary correctivemeasures.
Maintain adequate fluid velocities and proper filtering of thefluid.
If automatic air vents are not utilized, periodic venting of thecoil is recommended to remove accumulated air.
CAUTION!Caution should be used to avoid injurywhen venting the coil. High pressure
and/or high temperature fluids can causeserious injuries.
Maintenance
38
Maintenance - Fall
Start-UpRepeat the Blower Start-Up procedure #5 and Direct Gas Start-Up procedure #1, 2 and 4. This will ensure thatthe gas and air are set properly before the heating season begins, and should lead to trouble free operation allwinter.
High LimitThe high limit switch may have tripped over the summer, it should be check and reset if necessary.
BurnerInspect the burner for accumulation of scales on boththe upstream and downstream sides of the mixingplates. Any scaling or foreign material should beremoved with a wire brush.
Visually check that all holes in the mixing plates areclear. If any burner ports are plugged (even partially),clear them with a piece of wire or another appropriatetool. The proper mixing plate hole diameter is 2.4mm.
Replace or tighten any loose or missing fasteners onthe mixing plates. Always use zinc plated or stainlesssteel fasteners.
Inspect and clean the flame and spark rod.Occasional replacement of the flame rod and sparkrod may be necessary to insure optimum unitperformance.
If a UV sensor is used instead of a flame rod, thesensor’s lens should be cleaned at least once a year.The sensor may require more frequent cleaning,depending on the operation environment and shouldbe check periodically over the heating season.
Evaporative CoolersThe water should be shut off and all the lines drained when the outside temperature drops below 45°F.
Remove drain plugs for the winter.
Clean all interior parts of any mineral deposits or foreign materials that may have built up during the coolingseason.
Replace any worn or non-functioning parts.
WARNING!Do not enlarge burner ports when clearing a
blockage, performance could be affected.
NOTE!Flame rods can last many years, but because ofthermal expansion of the porcelain, flame rods
can fail over time.
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39
Maintenance - Fall
% Ethylene Glycol Freeze PointBy Volume (°F)
0 3210 2520 1630 340 -1350 -3460 -55
% Propylene Glycol Freeze PointBy Volume (°F)
0 3210 2620 1930 840 -750 -2860 -60
Winterizing Chilled Water CoilsDuring the winter, chilled water coils need to be protected against freezing. Greenheck recommends protectingthe coils by either blowing-out the coils or by flushing the coils.
Blowing-Out Coils• Isolate the coil from the rest of the system by
closing the valves on both the supply and returnlines.
• Drain the coil by opening all drain valves and/orthe drain plug. Remove the vent plug to aid inthe draining process.
• Once the coil has been fully drained, a blowercan be hooked-up to the caps. The air vent anddrain plug are not suitable locations for hooking-up the blower.
• Close the vent drain plug on the header to whichthe blower is connected and open the drainvalve or cap on the other header.
• Operate the blower for 45 minutes and thencheck if the coil is dry. A mirror placed in thedischarge will become fogged if moisture ispresent. Repeat this procedure until the coil isdry and no fog appears on the mirror.
• Let the coil stand for several minutes then blowit out again. If water comes out, repeat theblowing operation.
• Leave all plugs out and drains open until thethreat of freezing has passed.
Flushing CoilsGreenheck recommends the use of inhibited glycoldesigned for HVAC applications for corrosionprotection. The use of uninhibited glycol canproduced formicary corrosion in copper tubing.
The complete filling of water coils with an inhibitedglycol solution for freeze protection can be expensive,but in some instances it is more cost effective.Residual glycol fluid can be left in the coil without thethreat of freeze damage, provided the correctconcentration of inhibited glycol is used. Therecovered fluid can then be used to flush other coils.
It is important to select an inhibited glycol solutionthat will protect the coil from the lowest possibletemperature that may be experience over the coldseason. See the following table for concentrationrecommendations.
Maintenance
40
Date Time Notes:
Job Information
Job Name: ____________________________________
Address: ______________________________________
City: ________________ State: ________ Zip: _______
Phone: __________________ Fax:_________________
Contact Person: _______________________________
Service Organization: _____________________________
Address: ________________________________________
City: ________________ State: ________ Zip: _________
Phone: __________________ Fax: ___________________
Work Done By: ___________________________________
Name Plate Information
Model: ________________________________________
Volts: ___________ Hertz: __________ Phase: ______
Amps: __________________ Mark: ________________
Supply hp: _____________ Exhaust hp: ___________
Serial Number:_________________________________
Motor Voltage:
Motor Amperage:
Fan rpm:
Maintenance Log
Field Start-Up Documentation
Actual Voltage: Hertz: Phase:
Actual Amperage:
Blower Rotation
Air Volume Design cfmActual cfm
High Fire Manifold Pressure:
Low Fire Manifold Pressure:
Mai
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Maintenance - Log
41
Reference
Typical Gas Train Layout 400 - 800 MBH
Typical Gas Train Layout > 800 MBH
High GasPressure Switch
(optional)
Low GasPressure Switch
(optional)
Manual PilotShut-off Valve
PilotRegulator
PilotSolonoid
Burner GasPressureTest Port
Burner DifferentialPressure Sensor
Pilot Gas PressureTest Port
Burner ManualShut-off Valve
ModulatingValve
Safety Shut-offValves
Regulator
High GasPressure Switch
(optional)
Low GasPressure Switch
(optional)
Manual PilotShut-off Valve
PilotRegulator
PilotSolonoid
Burner GasPressureTest Port
Burner DifferentialPressure Sensor
Pilot Gas PressureTest Port
Burner ManualShut-off Valve
Modulating/RegulatorValve
Safety Shut-offValves
Reference
42
Reference
1. Heating/Cooling Inlet Air Sensor (Optional) - Ductstat that automatically de-energizes burner when inlet air temperature rises above set point, or shuts down cooling when temperature falls below set point.
2. Flame Safeguard - Monitors flame, shuts-down unit when unsafe conditions are detected.
3. High Limit - Prevents unit from discharging air above a setpoint.
4. Building Freeze Protection (Optional) - Prevents unit from discharging air below a setpoint after a time delay.
5. Heat/Cool Relay - Allows power to pass to Flame Safeguard or cooling unit.
6. Terminal Strip - 24 Volt power strip for control wiring.
7. Main Disconnect - On/Off switch, provides single point power connection to unit.
8. Grounding Lugs - Completes electrical circuit
9. Motor Starters - 24 Volt magnetic contacts for starting motors, comes standard with electronic overload, may be provided with auxiliary contacts.
10. Spark Generator - Causes the spark rod to spark and ignite the flame.
11. Amplifier - Controls modulating valve, assures the desired temperature is delivered.
12. Low Voltage Transformer - Reduces voltage to the Maxitrol system.
13. Control Transformer - Provides 24 Volts for controls.
14. Secondary fuses - Provides proper fusing for all electrical components other than the motors.
15. Motor Fuses - Provides proper fusing for supply and exhaust fan motor(s).
1210 11
1
54
32
14
6
8
7 9
1513
Control Center Layout
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Notes:R
eference
#463555 DG/DGX IOM FS Rev 1 December 2003
WarrantyGreenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from thepurchase date. Any units or parts which prove defective during the warranty period will be replaced at our option whenreturned to our factory, transportation prepaid.
Motors are warranted by the motor manufacturer for a period of one year. Should motors furnished by Greenheck provedefective during this period, they should be returned to the nearest authorized motor service station. Greenheck will notbe responsible for any removal or installation costs.
Due to continuing research, Greenheck reserves the right to change specifications without notice.
This manual is the property of the owner, and is required for future maintenance.Please leave it with the owner when you complete the job.
GREENHECK P.O. BOX 410 SCHOFIELD, WISCONSIN 54476-0410
PH. 715-359-6171www.greenheck.com
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Copyright © 2003 Greenheck Fan Corp.