Greenheck DG -H10 Installation Manual

Part #470652

DG/DGX Direct Spark Ignition

Make-Up Air Unit

Installation, Operation and Maintenance Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions

product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

could result in personal injury and/or property damage! Retain instructions for future reference.

2. The rotation of the wheel is critical. It must be free to rotate without striking or rubbing any stationary objects.

3. Motor must be securely and adequately grounded.

4. Do not spin fan wheel faster than the maximum cataloged fan rpm. Adjustments to fan speed signiﬁcantly affects motor load. If the fan RPM is changed, the motor current should be checked to make sure it is not exceeding the motor nameplate amps.

5. Do not allow the power cable to kink or come in contact with oil, grease, hot surfaces, or chemicals. Replace cord immediately if damaged.

6. Verify that the power source is compatible with the equipment.

7. Never open blower access doors while the fan is running.

General Safety Information

Only qualiﬁed personnel should install this unit. Personnel should have a clear understanding of these instructions and should be aware of general safety precautions. Improper installation can result in electric shock, possible injury due to coming in contact with moving parts, as well as other potential hazards. Other considerations may be required if high winds or seismic activity are present. If more information is needed, contact a licensed professional engineer before moving forward.

1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC), the National Fire Protection Agency (NFPA), where applicable. Follow the Canadian Electric Code (CEC) in Canada.

DANGER

Always disconnect power before working on or near a unit. Lock and tag the disconnect switch or breaker to prevent accidental power up.

CAUTION

When servicing the unit, motor may be hot enough to cause pain or injury. Allow motor to cool before servicing.

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. Do not touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.

FOR YOUR SAFETY

The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death. Read the installation, operating and maintenance instructions thoroughly before installing or servicing this equipment.

Model DG / DGX Direct Spark Ignition Make-Up Air

Receiving

Upon receiving the product check to make sure all items are accounted for by referencing the bill of lading to ensure all items were received. Inspect each crate for shipping damage before accepting delivery. Notify the carrier if any damage is noticed. The carrier will make notiﬁcation on the delivery receipt acknowledging any damage to the product. All damage should be noted on all the copies of the bill of lading which is countersigned by the delivering carrier. A Carrier Inspection Report should be ﬁlled out by the carrier upon arrival and the Trafﬁc Department. If damaged upon arrival, ﬁle claim with carrier. Any physical damage to the unit after acceptance is not the responsibility of Greenheck Fan Corporation.

Unpacking

Verify that all required parts and the correct quantity of each item have been received. If any items are missing, report shortages to your local representative to arrange for obtaining missing parts. Sometimes it is not possible that all items for the unit be shipped together due to availability of transportation and truck space. Conﬁrmation of shipment(s) must be limited to only items on the bill of lading.

Handling

Units are to be rigged and moved by the lifting brackets provided or by the skid when a forklift is used. Location of brackets varies by model and size. Handle in such a manner as to keep from scratching or chipping the coating. Damaged ﬁnish may reduce ability of unit to resist corrosion.

Storage

Units are protected against damage during shipment. If the unit cannot be installed and operated immediately, precautions need to be taken to prevent deterioration of the unit during storage. The user assumes responsibility of the unit and accessories while in storage. The manufacturer will not be responsible for damage during storage. These suggestions are provided solely as a convenience to the user.

INDOOR — The ideal environment for the storage of

units and accessories is indoors, above grade, in a low humidity atmosphere which is sealed to prevent the entry of blowing dust, rain, or snow. Temperatures should be evenly maintained between 30°F (-1°C) and 110°F (43°C) (wide temperature swings may cause condensation and “sweating” of metal parts). All accessories must be stored indoors in a clean, dry atmosphere.

Remove any accumulations of dirt, water, ice, or snow and wipe dry before moving to indoor storage. To avoid “sweating” of metal parts allow cold parts to reach room temperature. To dry parts and packages use a portable electric heater to get rid of any moisture build up. Leave coverings loose to permit air circulation and to allow for periodic inspection.

The unit should be stored at least 3½ in. (89 mm) off the ﬂoor on wooden blocks covered with moisture proof paper or polyethylene sheathing. Aisles between parts and along all walls should be provided to permit air circulation and space for inspection.

OUTDOOR — Units designed for outdoor applications

may be stored outdoors, if absolutely necessary. Roads or aisles for portable cranes and hauling equipment are needed.

The fan should be placed on a level surface to prevent water from leaking into the unit. The unit should be elevated on an adequate number of wooden blocks so that it is above water and snow levels and has enough blocking to prevent it from settling into soft ground. Locate parts far enough apart to permit air circulation, sunlight, and space for periodic inspection. To minimize water accumulation, place all unit parts on blocking supports so that rain water will run off.

Do not cover parts with plastic ﬁlm or tarps as these cause condensation of moisture from the air passing through heating and cooling cycles.

Inspection and Maintenance during Storage

While in storage, inspect fans once per month. Keep a record of inspection and maintenance performed.

If moisture or dirt accumulations are found on parts, the source should be located and eliminated. At each inspection, rotate the fan wheel by hand ten to ﬁfteen revolutions to distribute lubricant on motor. Every three months, the fan motor should be energized. If paint deterioration begins, consideration should be given to touch-up or repainting. Fans with special coatings may require special techniques for touch-up or repair.

Machined parts coated with rust preventive should be restored to good condition promptly if signs of rust occur. Immediately remove the original rust preventive coating with petroleum solvent and clean with lint-free cloths. Polish any remaining rust from surface with crocus cloth or ﬁne emery paper and oil. Do not destroy the continuity of the surfaces. Wipe thoroughly clean with Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to reach internal surfaces or for occasional use, consider using Tectyl® 511M Rust Preventive or WD-40® or the equivalent.

REMOVING FROM STORAGE — As units are removed

from storage to be installed in their ﬁnal location, they should be protected and maintained in a similar fashion, until the equipment goes into operation.

Prior to installing the unit and system components, inspect the unit assembly to make sure it is in working order.

1. Check all fasteners, set screws on the fan, wheel, bearings, drive, motor base, and accessories for tightness.

2. Rotate the fan wheel(s) by hand and assure no parts are rubbing.

Model DG / DGX Direct Spark Ignition Make-Up Air

Table of Contents

Installation

Clearance to Combustibles/Service Clearances . 3

Indoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Unit Arrangement DB / HZ / UB . . . . . . . . . . . . . . 4

Roof Mounted Unit — Arrangement DBC . . . . . 5-6

Optional Evaporative Cooler Module . . . . . . . . . . 6

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Direct Gas Piping . . . . . . . . . . . . . . . . . . . . . . . .8-9

Optional Evaporative Cooler Piping . . . . . . . . . 9-10

Optional Water Wizard™ . . . . . . . . . . . . . . . . . . 11

Optional Direct Expansion (DX) Coil Piping . . 12-13

Optional Chilled Water Coil Piping . . . . . . . . . . . 13

Optional Building Pressure Control . . . . . . . . . . 14

Start-Up

Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

Direct Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-18

Optional Evaporative Cooling Recirculating . . . 19

Optional Water Wizard™ . . . . . . . . . . . . . . . .20-21

Operation

Optional VAV Units . . . . . . . . . . . . . . . . . . . . . . . 22

Optional Recirculating Units . . . . . . . . . . . . . . . . 23

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Optional Water Wizard™ . . . . . . . . . . . . . . . . . . 25

Troubleshooting

Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Motor Overamps . . . . . . . . . . . . . . . . . . . . . . . . . 27

Insufficient / Too Much Airflow . . . . . . . . . . . . . . 28

Excessive Noise or Vibration . . . . . . . . . . . . . . . 29

Direct Gas Heat . . . . . . . . . . . . . . . . . . . . . . . .30-31

Optional Evaporative Cooling . . . . . . . . . . . . . . . 32

Optional Water Wizard™ . . . . . . . . . . . . . . . . . . 33

Maintenance

Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-36

Fall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Reference

Gas Train Layout . . . . . . . . . . . . . . . . . . . . . . . . . 38

Control Center Layout / Dirty Filter Switch . . . . 39

Start-Up Check List . . . . . . . . . . . . . . . . . . . . . . 40

Maintenance Log . . . . . . . . . . . . . . . . . . . . . .41-43

Warranty . . . . . . . . . . . . . . . . . . . . . . . . .Backcover

Clearance to Combustibles / Service Clearances

Floor Top Sides Ends

Insulated/

Units

Non Insulated

Units

Clearance to combustibles is defined as the minimum distance required between the heater and adjacent combustible surfaces to ensure the adjacent surface’s temperature does not exceed 90 degrees above the ambient temperature.

Recommended Minimum Service Clearances

Housing 32 and less

Housing 35 and higher

Clearances for component removal (such as evaporative cooler media) may be greater than the service clearances listed.

0 inches

(0 mm)

0 inches

(0 mm)

0 inches

(0 mm)

6 inches

(152.4 mm)

on the controls side of the unit

0 inches

(0 mm)

6 inches

(152.4 mm)

42 inches (1066.8 mm)

48 inches (1219.2 mm)

0 inches

(0 mm)

6 inches

(152.4 mm)

Installation of Indoor Unit

1. Install Hangers

Install threaded hangers from ceiling supports. When locating hangers, allow enough room to open access panel(s). Two nuts must be used on the end of each threaded hanger. Ceiling supports are supplied by others.

2. Install Unit

Using sheet metal screws, attach the weatherhood/ thru-wall/ﬁlter section to the blower/burner section. The ﬂange on the weatherhood/thru-wall/ﬁlter section should overlap the ﬂange on the blower/burner section.

Raise the assembled unit into place.

Using two nuts per hanger, fasten the unit supports to the hangers under the unit. Appropriate unit supports, such as the optional Greenheck hanging bracket kit or c-channel and angle iron (supplied by others) should be used.

Using self

Ceiling Supports

tapping screws, attach ductwork to unit.

In order to prevent the unit from swinging

Hangers

and to provide

Indoor Mounting

a safe environment for service and maintenance, additional measures must be taken to secure the unit in all directions.

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 accordance with SMACNA and AMCA guidelines, NFPA 96 and any local codes. Reference the CAPS submittal for duct sizes.

3. Seal Wall Opening

Apply sealant around the perimeter of the weatherhood to prevent water penetration and drafts into the building.

Seal Wall Opening

Ductwork

Unit Supports

Sealant

Model DG / DGX Direct Spark Ignition Make-Up Air

Installation of Arrangement DB / HZ / UB

1. Install Curb and/or Equipment Support(s)

Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/ equipment support(s) in relation to the unit). Verify that unit supports are level, shim if necessary. Attach curb to roof and ﬂash into place. Attach the equipment support(s) to the roof, remove metal cover, ﬂash to wooden nailer and reinstall cover.

Roof Curb

Metal Cover

Equipment Support

Roof Curb and Equipment Support

NOTE

The use of a duct adapter is recommended on a downblast (DB) arrangement to align the ductwork with the supply unit. The duct adapter is only a guide and is not to be used as a support for the ductwork.

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.

5. Assemble and Attach Weatherhood

The weatherhood can now be assembled and attached to the unit. Detailed assembly instructions can be found with the weatherhood. If the optional evaporative cooling module was selected, this step does not apply, refer to the Installation of the Optional Evaporative Cooling Module section, page 6.

6. Seal Weatherhood Seam

Using an appropriate sealant, seal the seam between the weatherhood and the unit.

Complete Rooftop Installation

2. Install Ductwork

Good duct practices should be followed for all ductwork. All ductwork should be installed in accordance with SMACNA and AMCA guidelines, NFPA 96 and all local codes. Reference the CAPS submittal for ductwork sizes.

3. Apply Sealant

Apply an appropriate sealant around the perimeter of the curb and duct

Supply Air Ductwork

(Arrangement DB only)

adapter(s) to isolate fan vibration and prevent water penetration.

Ductwork

Sealant

4. Install Unit

Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the unit on the curb/equipment support(s).

Use self-tapping sheet metal screws to fasten the unit to the curb/equipment support(s).

Setting Unit

Model DG / DGX Direct Spark Ignition Make-Up Air

Installation of Roof Mounted Unit

Supply Ductwork by Others

Exhaust Ductwork by Others

Supply Duct with Duct Adapter Installed

Exhaust Duct Installed

Sealant

Arrangement DBC

1. Install Curb/Equipment Support(s)

Position curb/equipment support(s) on the roof (reference the CAPS submittal for placement of curb/ equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach curb to roof and ﬂash into place. Attach the equipment support(s) to the roof, remove metal cover, ﬂash to wooden nailer and reinstall cover.

Roof Curb

4. Apply Sealant

Apply an appropriate sealant around the perimeter of the curb and duct adapter(s) to isolate fan vibration and prevent water penetration.

Metal Cover

Equipment

Support

Curb and Equipment Support

2. Install Combination Extension

Install combination extension over curb. Lag into place using wood screws. Locate the extension so the tall vented side is over the exhaust opening.

Supply

Combination Extension

Exhaust

1 inch Inside Flange

3. Install Ductwork

Good duct practices should be followed for all ductwork. All ductwork should be installed in accordance with SMACNA and AMCA guidelines, NFPA 96 and any local codes. Reference the CAPS submittal for ductwork size and location.

Sealing Ductwork

5. Install Exhaust Fan

Fasten exhaust fan to curb extension with self-tapping sheet metal screws. Installing the exhaust fan prior to the supply unit will allow for easier installation of options.

Model CUBE Exhaust Fan

Installing Exhaust Fan

NOTE

NFPA 96 requires the exhaust fan to be hinged.

6. Install Exhaust Options

Install optional Greenheck hinge kit with restraining cables and grease trap with drain connection.

Ductwork

The use of a duct adapter is recommended on a downblast (DBC) arrangement to align the ductwork

NOTE

with the supply unit. The duct adapter is only a guide and is not to be used as a support for the ductwork.

Model DG / DGX Direct Spark Ignition Make-Up Air

7. Install Supply Unit

Metal Cover

Equipment Support

Roof Curb

Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the unit on the extension/equipment support(s).

Use self-tapping sheet metal screws to fasten the unit to the extension/equipment support(s).

Installing Supply Unit

NOTE

The use of all lifting lugs and a set of spreader bars is mandatory when lifting unit.

NOTE

Some units come with the weatherhood attached and Step 8 may not apply.

8. Assemble and Attach Weatherhood

The weatherhood can now be assembled and/or attached to the unit. Detailed assembly instructions can be found with the weatherhood. If the optional evaporative cooling module was selected, this step does not apply, refer to the next section, Installation of the Optional Evaporative Cooling Module.

9. Seal Weatherhood Seam

Using an appropriate sealant, seal the seam between the weatherhood and the unit.

Complete Combination Installation

Installation of Evaporative Cooling Module (optional)

NOTE

Small evaporative coolers ship attached to the base unit and require no additional mounting.

1. Locate Equipment Support(s)

Position equipment support(s) on the roof (reference the CAPS submittal for placement of equipment support(s) in relation to the unit). Verify that all unit supports are level, shim if necessary. Attach equipment support to the roof, remove metal cover, ﬂash to wooden nailer and reinstall cover.

2. Apply Sealant

Apply an appropriate sealant around the airstream opening to create an air tight seal.

3. Set Evaporative Cooling Module

Use a crane and a set of spreader bars hooked to the factory lifting lugs to lift and center the module on the equipment support(s). The ﬂange on the evaporative cooler should overlap the ﬂange on the unit.

Placing Evaporative Module

NOTE

The use of all lifting lugs and a set of spreader bars is mandatory when lifting the evaporative cooling module.

4. Secure Cooling Module to Unit

Use self-tapping screws to fasten the cooling module to the base unit along the top and down both sides. Fasten at the top through the ﬂanges. To fasten the sides, the media must be removed. To remove the media, ﬁrst remove the access panel on the evaporative module and disconnect the evaporative pump(s). The media will now slide out. With the media removed, you can access the side fastening points inside the evaporative module. With all the screws in place, reinstall the media, reconnect the pumps and reinstall the access panel.

Securing Evaporative Module

Equipment Support

Sealant

Model DG / DGX Direct Spark Ignition Make-Up Air

NOTE

When mounting the evaporative cooler, it is important that it is level to ensure proper operation and water drainage.

Installation of Electrical Wiring

IMPORTANT

Before connecting power to the unit, read and understand the following instructions and wiring diagrams. Complete wiring diagrams are attached on the inside of the control center door(s).

IMPORTANT

All wiring should be done in accordance with the latest edition of the National Electric Code ANSI/ NFPA70 and any local codes that may apply. 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.

CAUTION

If replacement wire is required, it must have a temperature rating of at least 105ºC, except for an energy cut-off or sensor lead wire which must be rated to 150ºC.

DANGER

High voltage electrical input is needed for this equipment. This work should be performed by a qualified electrician.

CAUTION

Any wiring deviations may result in personal injury or property damage. Greenheck is not responsible for any damage to, or failure of the unit caused by incorrect final wiring.

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gauge wire; 455 feet total length for 12gauge wire). If the resistance exceeds 0.75 ohms, an industrial-style plug-in relay should be wired in place of the remote switch. The relay must be rated for at least 5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to chatter or not pull in, resulting in contactor failures and/or motor failures.

1. Determine the Size of the Main Power Lines

The unit’s nameplate states the voltage and the unit’s MCA. The main power lines to the unit should be sized accordingly. The nameplate is located on the outside of the unit on the control panel side.

Voltage, Hertz, Phase

VOLTS HZ PH

SUP HP

MCA

Unit’s Total MCA

Electrical Nameplate

EXH HP

MOP

2. Provide the Opening(s) for the Electrical Connections

Electrical openings vary by unit size and arrangement and are ﬁeld supplied.

3. Connect the Main Power

Connect the main power lines to the disconnect switch and main grounding lug(s). Torque ﬁeld connections to 20in.-lbs.

4. Wire the Optional Convenience Outlet

The convenience outlet requires a separate 115V power supply circuit. The circuit must include short circuit protection which may need to be supplied by others.

5. Wire the Optional Accessories

Reference the Ladder Diagram on the inside of the control center door for correct wiring of the following accessories:

• Selectra Stat

• Room Override

• Blower Switch

• Heat Switch

Wiring to the Selectra Stat should be in separate conduit or run with shielded cable.

TSCP has number-to-number wiring.

Large evaporative coolers may require a separate power supply.

• Indicating Lights

• Dirty Filter Indicator

• TSCP

• KSCP

NOTE

6. Wire the Optional Evaporative Cooler

Reference the Ladder Diagram on the inside of the control center door for correct wiring of the pump and the optional auto-drain and ﬂush.

Model DG / DGX Direct Spark Ignition Make-Up Air

Installation of Direct Gas Piping

IMPORTANT

All gas piping must be installed in accordance with the latest edition of the National Fuel Gas Code ANSI/Z223.1 and any local codes that may apply. In Canada, the equipment shall be installed in accordance with the Installation Code for Gas Burning Appliances and Equipment (CGA B149) and Provincial Regulations for the class. Authorities having jurisdiction should be consulted before installations are made.

WARNING

All components of this or any other gas-fired heating unit must be leak tested prior to placing the unit into operation. A soap and water solution should be used to perform this test. NEVER test for gas leaks with an open flame.

WARNING

When leak testing pressures that are equal to 14 in. wc (3.5kPa), first close the field-installed shutoff valve to isolate the unit from the gas supply line.

WARNING

When leak testing pressures that are above 14 in. wc (3.5kPa), close the field installed shutoff valve, disconnect the furnace and gas train from the gas supply line and plug the supply line before testing.

IMPORTANT

All piping should be clean and free of any foreign matter. Foreign material entering the gas train can damage the valves, regulators and burner.

IMPORTANT

Do NOT connect the unit to gas types other than what is specified and do NOT connect the unit to gas pressures that are outside of the pressure range shown on the label.

NOTE

When connecting the gas supply, the length of the run must be considered in determining the pipe size to avoid excessive pressure drop. Refer to a Gas Engineer’s Handbook for gas pipe capacities.

1. Determine the Supply Gas Requirements

The unit’s direct gas nameplate states the requirements for the gas being supplied to the unit. The direct gas nameplate is located on the outside of the unit on the control center side.

Minimum gas pressure for maximum output

MAX BTU/HR BTU/H MAX

NORMAL MANIFOLD PRESSURE PRESSION DÕADMISSION NORMALE

MIN GAS PRESSURE PRESSION DE GAZ

MIN BURNER PRESSURE DROP PERTE MIN DE PRESSION DANS LE BRULEUR

TYPE OF GAS NATURE DU GAZ

EQUIPPED FOR

CONCU POUR

Type of gas

AGAINST

SCFM

CONTE

Direct Gas Nameplate

“ W.C.

MIN BTU/HR BTU/H MIN

MIN GAS PRESSURE FOR MAX OUTPUT PRESSION DE GAZ MIN POUR PUISSANCE MAX

MAX GAS PRESSURE PRESSION DE GAZ MAX

MAX BURNER PRESSURE DROP PERTE MAX DE PRESSION DANS LE BRULEUR

DESIGN ∆T ∆T NORMALE

EXTERNAL STATIC PRESSURE

“ W.C.

PRESSION STATIQUE EXTERIEURE

Maximum gas pressure

“ W.C.

PSI

2. Install Additional Regulator if Required

When the supply gas pressure exceeds the maximum gas pressure shown on the direct gas nameplate, an additional regulator (by others) is required to reduce the pressure. The regulator must have a listed leak limiting device or it must be vented to the outdoors.

NOTE

The regulator located inside the unit is used to adjust the unit’s maximum output temperature.

3. Connect the Supply Gas Line

A manual shut off valve (gas cock), 1/8 in. plugged test port and 6 in. drip leg must be installed prior to the gas train. The valve and the test port must be accessible for the connection of a test gauge. Supply gas connections must be made by a qualiﬁed installer and are not furnished by Greenheck.

Model DG / DGX Direct Spark Ignition Make-Up Air

From

Gas

Supply

Gas Cock

1/8 in. Plugged Tap

Supply Gas Line

Ground Joint Union

6 in. Trap

Controls

4. Pipe the Optional Vent Line

If an optional vent line is located between the safety shutoff valves it must be piped to the outdoors.

WARNING

Reference the National Fuel Gas Code for additional vent line requirements.

Installation Evaporative Cooler Piping (optional)

Evaporative Cooling with Recirculating Pump

Supply

Line

Vent Line Solenoid

To Outdoors

Vent Line

To Burner

Safety

Shut-off Valves

Optional Vent Line

From Supply

5. Test the System for Leaks

Check both the supply lines and the factory piping for leaks. Apply a soap and water solution to all piping and watch for bubbling which indicates a leak.

WARNING

NEVER test for a gas leak with an open flame.

NOTE

The factory piping has been checked for leaks, but should be rechecked due to shipping and installation.

Supply

Line Valve

(Normally

Closed)

Drain Line Valve (Normally Open)

Drain Line

Trap

Recirculating Evaporative Piping

Overflow

IMPORTANT

All supply solenoids, valves and all traps must be below the roof line or be otherwise protected from freezing.

IMPORTANT

The supply line should be of adequate size and pressure to resupply the amount of water lost due to bleed-off and evaporation. The drain line should be the same size or larger than the supply line.

CAUTION

Provisions must be taken to prevent damage to the evaporative cooling section during freezing conditions. The sump, drain lines and supply lines must be drained prior to freezing conditions or an alternate method must be used to protect the lines and media.

1. Install the Water Supply Line

2. Install the Drain Line

Connect an unobstructed drain line to the drain and overﬂow connections on the evaporative cooler. A manual shut off valve (by others) is required for the evaporative cooler drain line.

A trap should be used to prevent

6 in. min.

sewer gas from being drawn into the unit. Refer to drain trap

Drain Trap

6 in. min.

diagram to the right.

3. Check/Adjust Water Level

Check the water level in the sump tank. The water level should be above the pump intake and below the overflow. Adjust the float as needed to achieve the proper water level.

Model DG / DGX Direct Spark Ignition Make-Up Air

Installation Evaporative Cooler Piping (optional)

Evaporative Cooling with Auto Drain and Fill

Sump Drain

VALVE C

Sump Drain Solenoid

(Normally Open)

VALVE B

Supply Line Drain Solenoid

(Normally Open)

Auto Drain & Fill Evaporative Piping

continued

Sump Overflow

Trap

Drain Line

Supply

Line

VALVE A

Supply Solenoid

(Normally Closed)

1. Install the Water Supply Line

Supply line opening requirements vary by unit size and arrangement and are ﬁeld supplied. Connect the water supply line to the ﬂoat valve through the supply line opening in the evaporative cooling unit. Install the 1/2 in. normally closed solenoid (Valve A) in the supply line. Install the 1/4 in. normally open solenoid (Valve B) between the supply line and the drain line. Refer to Auto Drain & Fill Evaporative Piping drawing on this page.

2. Install the Drain Line

Connect an unobstructed drain line to the sump drain overﬂow connection. Install the 3/4 in. normally open solenoid (Valve C) between the sump drain connection and the drain line. A trap should be used to prevent sewer gas from being drawn into the unit. Refer to drain trap drawing.

6 in. min.

Drain Trap

6 in. min.

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 installed below the roof to protect the supply water line from freezing. If they cannot be installed below the roof, an alternative method must be used to protect the lines from freezing.

IMPORTANT

The supply solenoid (Valve A) is NOT the same as the drain solenoids (Valve B and Valve C). Make sure to use the proper solenoid for each location. Check your local code requirements for proper installation of this type of system.

Auto Drain & Flush Valves

(when provided by Greenheck)

Assembly

Number

GFC

Part

Number

ASCO

Part

Number

Solenoid

Type

De-Energized

Position

Diameter

Qty.

3. Check/Adjust Water Level

Check the water level in the sump tank. The water level should be above the pump intake and below the overﬂow. Adjust the ﬂoat as needed to achieve the proper water level.

461262 8210G2

852178

Part numbers subject to change.

461263 8262G262

461264 8210G35

Model DG / DGX Direct Spark Ignition Make-Up Air

Supply Closed

Supply

Line

Drain

Sump

Drain

Open

1/2 inch

(12.7 mm)

1/4 inch

(6.35 mm)

3/4 inch

(19.05 mm)

Installation of Water WizardTM (optional)

Evaporative Cooling with the Water Wizard™

NOTE

The following instructions are provided for evaporative coolers equipped with the Water Wizard™ only. Additional instructions are provided for evaporative coolers equipped with the auto-drain and fill or bleed-off.

WARNING

Disconnect and lock-out all power and gas before performing any maintenance or service to the unit. Failure to do so could result in serious injury or death and damage to equipment.

Water Wizard™ Valves

(when provided by Greenheck)

Unit

Assembly

Model

DG -

H10/H20

DGX -

H12/H22

DGX - H32

(<9000 cfm)

DG - H30

DGX - H32

(≥9000 cfm)

DGX - H35,

H38, H42

Part numbers subject to change.

Number

852370

852371

GFC

ASCO

Part

Part No.

No.

461262 8210G2

383086 8210G34

383088 8210G9

383086 8210G34

Solenoid

Type

Supply Closed

Supply

Line

Drain

Supply Closed

Supply

Line

Drain

De-

Energized

Position

Diameter Qty.

Open

(19.05 mm)

Open

1/2 inch

(12.7 mm)

1/2 inch

(12.7 mm)

3/4 inch

1/2 inch

(12.7 mm)

To Media

Pressure

Gauge

Sump Drain

Manual Supply

Valve

Roof

Line

Trap

Supply Line Drain Solenoid

(Normally Open)

Water Wizard™ Installation

Supply Solenoid

(Normally Closed)

3. Wire the Solenoid(s)

Wire the supply line solenoid and drain solenoid as shown on the unit’s wiring diagram in the control center.

4. Wire the Temperature Sensor

If the evaporative cooler shipped separate from the unit, the temperature sensor must be wired. The sensor wire is bundled inside the discharge end of the

evaporative cooler. Wire the sensor wire to terminals AI2 and AIC on the terminal strip in the unit’s control center.

NOTE

The Water Wizard™ start-up must be completed for proper performance.

Factory

Installed

Field

Installed

1. Install Normally Closed Supply Line/ Solenoid

Connect the water supply line to the manual supply valve in the unit. Install the supply solenoid in the supply line, upstream of the manual supply valve and below the roof line.

2. Install Normally Open Drain Line/ Solenoid

Connect the drain line to the supply line between the manual supply valve and the supply solenoid. Install a drain solenoid in the drain line, below the roof line. A trap should be installed in the drain line.

NOTE

Solenoid(s) may be provided by Greenheck (if ordered) or by others.

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.

Model DG / DGX Direct Spark Ignition Make-Up Air

Installation of Direct Expansion (DX) Coil Piping (optional)

IMPORTANT

Guidelines for the installation of direct expansion cooling coils have been provided to insure proper performance and longevity of the coils. These are general guidelines that may have to be tailored to meet the specific requirements of any one job. As always, a qualified party or individual should perform the installation and maintenance of any coil. Protective equipment such as safety glasses, steel toe boots and gloves are recommended during the installation and maintenance of the coil.

IMPORTANT

All field brazing and welding should be performed using high quality materials and an inert gas purge (such as nitrogen) to reduce oxidation of the internal surface of the coil.

IMPORTANT

All field piping must be self-supporting and flexible enough to allow for the thermal expansion of the coil.

NOTE

If a hot gas bypass kit was provided by others, refer to the manufacturer’s instructions.

3. Install Suction Line

Install suction line(s) from the compressor to the suction connection(s) which are stubbed through the side of the cabinet.

4. Install the Liquid Line and Thermal Expansion Valve (TEV) (by others)

Liquid line openings vary by coil size and circuiting and are field supplied. Follow the TEV recommendations for installation to avoid damaging the valve. If the valve is externally equalized, use a tubing cutter to cut off the plugged end of the factory installed equalizer line. Use a de-burring tool to remove any loose metal from the equalizer line and attach it to the TEV. If the valve is internally equalized, the factory installed equalizer line can be left as is.

Coil

Liquid Line

Distributor

Equalizer Line

Nozzle

Suction Header

1. Locate the Distributor(s) by Removing the Distributor Access Panel

Distributor Access Panel

Thermal

(by others)

Installation with Hot Gas Bypass

2. Verify Nozzle Placement

Inspect the refrigerant distributor and verify that the nozzle is in place. The nozzle is generally held in place by a retaining ring or is an integral part of the distributor itself.

Retainer Ring

Nozzle Distributor

Nozzle Placement

Thermal Expansion Valve (by others)

Suction Line

Remote Sensing Bulb

Straps

General Installation

Suction Connection

5. Mount the Remote Sensing Bulb (by others)

The expansion valve’s remote sensing bulb should be securely strapped to the horizontal run of the suction line at the 3 or 9 o’clock position and insulated.

6. Check Coil Piping for Leaks

Pressurize the coil to 100 psig with dry nitrogen or other suitable gas. The coil should be left pressurized for a minimum of 10 minutes. If the coil holds the pressure, the hook-up can be considered leak free. If the pressure drops by 5 psig or less, re-pressurize the coil and wait another 10 minutes. If the pressure drops again there is likely one or more small leaks which should be located and repaired. Pressure losses greater than 5 psig indicate a large leak that should be isolated and repaired.

7. Evacuate and Charge the Coil

Use a vacuum pump to evacuate the coil and any interconnecting piping that has been open to the atmosphere. Measure the vacuum in the piping using a micron gauge located as far from the pump as possible. Evacuate the coil to 500 microns or less, and then close the valve between the pump and the system. If the vacuum holds to 500 microns or less

Model DG / DGX Direct Spark Ignition Make-Up Air

for one minute, the system is ready to be charged or

Hot Return Connection

Cold Supply Connection

Entering Air Leaving Air

refrigerant in another portion of the system can be opened to the coil. A steady rise in microns would indicate that moisture is still present and that the coil should be further vacuumed until the moisture has been removed.

NOTE

Failure to obtain a high vacuum indicates a great deal of moisture or a small leak. Break the vacuum with a charge of dry nitrogen or other suitable gas and recheck for leaks. If no leaks are found, continue vacuuming the coil until the desired vacuum is reached.

8. Install the Drain Line

Connect an unobstructed drain line to the drain pan. A trap should be used to prevent sewer gas from being drawn into the unit.

Drain Trap

6 in. min.

IMPORTANT

All traps must be installed below the roof line or be otherwise protected from freezing.

6 in. min.

Installation of Chilled Water Coil Piping (optional)

IMPORTANT

Guidelines for the installation of the cooling coil have been provided to insure proper performance of the coils and their longevity. These are general guidelines that may have to be tailored to meet the specific requirements of any one job. As always, a qualified party or individual should perform the installation and maintenance of the coil. Protective equipment such as safety glasses, steel toe boots and gloves are recommended during the installation and maintenance of the coil.

When installing couplings, do not apply undue stress to the connection. Use a backup pipe wrench to avoid breaking the weld between the coil connection and the header.

All field piping must be self-supporting. System piping should be flexible enough to allow for the thermal expansion and contraction of the coil.

1. Verify Coil Hand Designation

Check the coil hand designation to ensure that it matches the system. Coils are generally plumbed with the supply connection located on the bottom of the leaving air-side of the coil and the return connection at the top of the entering air-side of the coil. This arrangement provides a counter ﬂow heat exchanger and positive coil drainage.

2. Check the Coil for Leaks

3. Connect the Supply & Return Lines

Connect the supply and return lines as shown above.

4. Install the Drain Line

Connect an unobstructed drain line to the drain pan. A trap should be installed to prevent sewer gas from being drawn into the unit.

Drain

Trap

IMPORTANT

All traps must be installed below the roof line or be otherwise protected from freezing.

Model DG / DGX Direct Spark Ignition Make-Up Air

6 in. min.

Installation of Building Pressure Control (optional)

1. Mount Pressure Tap

Using the factory provided bracket, mount the pressure tap to the outside of the unit. Choose a location out of the prevailing winds and away from supply or exhaust fans to assure accurate readings.

2. Run Pressure Tap Lines

Run a pressure tap line from the pressure tap on the outside of the unit to the low pressure tap on the back of the photohelic gauge. Run a second pressure tap line from the high pressure tap on the back of the photohelic gauge to the space. Fifty feet of tubing is supplied with the unit.

Factory

Wiring

Low Pressure

Tap

to Outside

Connections for Photohelic Gauge

3. Set the Building Pressure

The pressure gauge is used to set the desired building pressure. The pressure is set by adjusting the knobs for the upper and lower pressure limits. Typical settings are

0.0 inch wc for the lower and 0.10 inch wc for the upper pressure setting.

Pressure Indicating

Needle

Pressure Setting

Needles

High Pressure

Tap

to Space

Start-Up - Blower

Refer to the Start-Up Checklist in the Reference section before proceeding further!

Pre Start-Up Check

Rotate the fan wheel by hand and make sure no parts are rubbing. Check the V-belt drive for proper alignment and tension (a guide for proper belt tension and alignment is provided in the Belt Maintenance section). Check fasteners, set screws and locking collars on the fan, bearings, drive, motor base, and accessories for tightness.

WARNING

Disconnect and lock-out all power and gas before performing any maintenance or service to the unit. Failure to due so could result in serious injury or death and damage to equipment.

SPECIAL EQUIPMENT REQUIRED

Required and recommended tools. Equivalent products may be used.

Voltage & Amperage Meter

Thermometer

Micro Amp Meter

U-Tube Manometer

Tachometer

Manufacturer: Fluke Model: 177 Phone: 1-800-44-FLUKE www.fluke.com

Manufacturer: Fluke Model: 50 Phone: 1-800-44-FLUKE www.fluke.com Manufacturer: Fluke Model: 116 Phone: 1-800-44-FLUKE www.fluke.com Manufacturer: Dwyer Model: Slack Tube Phone: 1-219-897-8000 www.dwyer-inst.com Manufacturer: Monarch Model: Pocket Tach 100 Phone: 1-800-999-3390 www.monarchinstrument.com

Pressure Setting Knobs

Typical Photohelic Gauge Settings

Model DG / DGX Direct Spark Ignition Make-Up Air

WARNING

Check the housing, blower, and ductwork for any foreign objects before running the blower.

1. Check the Voltage

Before starting the unit, compare the supplied voltage, hertz, and phase with the unit and motor’s nameplate information.

SUP HP

Unit’s Total MCA

Electrical Nameplate

Voltage, Hertz, Phase

VOLTS HZ PH

MCA

MOP

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