Greenheck DGK Installation Manual
Part #468695
®
Model DGK Make-Up Air
Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully before attempting to assemble,
install, operate or maintain the product described. Protect yourself and others by observing all safety
information. Failure to comply with instructions could result in personal injury and/or property damage!
Model DGK
General Safety Information
Only qualified personnel should install this unit.
Personnel should have a clear understanding of these
instructions and should be aware of general safety
precautions. Improper installation can result in electric
shock, possible injury due to coming in contact with
moving parts, as well as other potential hazards. Other
considerations may be required if high winds or seismic
activity are present. If more information is needed,
contact a licensed professional engineer before moving
forward.
1. Follow all local electrical and safety codes, as well
as the National Electrical Code (NEC), the National
Fire Protection Agency (NFPA), where applicable.
Follow the Canadian Electrical Code (CEC) in
Canada
2. The rotation of the wheel is critical. It must be free
to rotate without striking or rubbing any stationary
objects.
3. Motor must be securely and adequately grounded.
4. Do not spin fan wheel faster than the maximum
cataloged fan rpm. Adjustments to fan speed
significantly affects motor load. If the fan RPM is
changed, the motor current should be checked to
make sure it is not exceeding the motor nameplate
amps.
5. Do not allow the power cable to kink or come in
contact with oil, grease, hot surfaces, or chemicals.
Replace cord immediately if damaged.
6. Verify that the power source is compatible with the
equipment.
7. Never open blower access doors while the fan is
running.
DANGER
Always disconnect power before working on or
near a unit. Lock and tag the disconnect switch or
breaker to prevent accidental power up.
CAUTION
When servicing the unit, motor may be hot enough
to cause pain or injury. Allow motor to cool before
servicing.
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. Do not touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
FOR YOUR SAFETY
The use and storage of gasoline or other
flammable vapors and liquids in open
containers in the vicinity of this appliance is
hazardous.
WARNING
Improper installation, adjustment,
alteration, service or maintenance can
cause property damage, injury or death.
Read the installation, operating and
maintenance instructions thoroughly before
installing or servicing this equipment.
®
Model DGK Make-Up Air
1
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
reported to the Traffic Department. If damaged upon
arrival, file claim with carrier. Any physical damage to
the unit after acceptance is not the responsibility of
manufacturer.
Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Confirmation of shipment(s) must be limited to only
items on the bill of lading.
Handling
Units are to be rigged and moved by the lifting brackets
provided or by the skid when a forklift is used. Location
of brackets varies by model and size. Handle in such
a manner as to keep from scratching or chipping the
coating. Damaged finish may reduce ability of unit to
resist corrosion.
Storage
Units are protected against damage during shipment. If
the unit cannot be installed and operated immediately,
precautions need to be taken to prevent deterioration of
the unit during storage. The user assumes responsibility
of the unit and accessories while in storage. The
manufacturer will not be responsible for damage during
storage. These suggestions are provided solely as a
convenience to the user.
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 inches (89 mm)
off the floor on wooden blocks covered with moisture
proof paper or polyethylene sheathing. Aisles between
parts and along all walls should be provided to permit
air circulation and space for inspection.
OUTDOOR
Units designed for outdoor applications may be stored
outdoors, if absolutely necessary. Roads or aisles for
portable cranes and hauling equipment are needed.
The fan should be placed on a level surface to prevent
water from leaking into the unit. The unit should be
elevated on an adequate number of wooden blocks so
that it is above water and snow levels and has enough
blocking to prevent it from settling into soft ground.
Locate parts far enough apart to permit air circulation,
sunlight, and space for periodic inspection. To minimize
water accumulation, place all unit parts on blocking
supports so that rain water will run off.
Do not cover parts with plastic film or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.
Inspection and Maintenance during
Storage
While in storage, inspect fans once per month. Keep a
record of inspection and maintenance performed.
If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the fan wheel by hand ten to fifteen
revolutions to distribute lubricant on motor. Every three
months, the fan motor should be energized. If paint
deterioration begins, consideration should be given to
touch-up or repainting. Fans with special coatings may
require special techniques for touch-up or repair.
Machined parts coated with rust preventive should be
restored to good condition promptly if signs of rust
occur. Immediately remove the original rust preventive
coating with petroleum solvent and clean with lintfree cloths. Polish any remaining rust from surface
with crocus cloth or fine emery paper and oil. Do not
destroy the continuity of the surfaces. Wipe thoroughly
clean with Tectyl® 506 (Ashland Inc.) or the equivalent.
For hard to reach internal surfaces or for occasional
use, consider using Tectyl® 511M Rust Preventive or
WD-40® or the equivalent.
Model DGK Make-Up Air
2
®
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.
Table of Contents
Installation
Clearance to Combustibles/Service Clearances .. 3
Unit Arrangement DB / HZ ................... 4
Hinged Weatherhood - DGK-H25 ............. 5
Electrical Wiring ........................... 5
Direct Gas Piping .......................... 6
Start-Up
Start-Up Checklist ......................... 7
Blower .................................. 8
Direct Gas .............................9-11
Troubleshooting
Blower ................................. 12
Heater, General .......................... 12
Heater DGK-H15 ......................... 13
Heater DGK-H25 .......................14-15
Excessive Noise or Vibration ................ 16
Maintenance
Routine ................................. 17
Fall .................................... 17
Reference
Gas Train Layout DGK-H15 - <400 MBH ...... 18
Control Center Layout DGK-H15 ............. 18
Gas Train Layout DGK-H25 - <800 MBH ...... 19
Control Center Layout DGK-H25 ............. 19
Warranty ..........................Backcover
Clearance to Combustibles
Floor Top Sides Ends
Insulated Units 0 inches 0 inches 0 inches 0 inches
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° above the ambient temperature.
Service Clearances
Recommended Minimum Service Clearances
Housing 32 and less
Clearances for component removal may be greater than the
service clearances listed
.
42 inches on the
controls side of the unit
®
Model DGK Make-Up Air
3
Installation of Arrangement DB / HZ
SUPPLY
DUCT
B
23 in.
(584 mm)
A
23 in.
(584 mm)
27.5 in.
(699 mm)
Curb Length Actual
27.5 in.
(699 mm)
Curb
Width
Actual
Recommended Roof Opening
(center in curb)
Center Supply Duct
in Roof Opening
Airflow
1. Install Curb 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. Refer to roof curb
detail.
3. Apply Sealant: Apply an appropriate sealant around
the perimeter of the curb to isolate fan vibration and
prevent water penetration.
Supply Air Ductwork
(Arrangement DB only)
Sealant
NOTE
Roof Curb
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.
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.
Supply
Model
Duct Size
(A x B)
Curb to Center
Supply Duct (C)
DGK-109-H15 13 x 14
DGK-112-H15 16 x 18
DGK-115-H25 18 x 22
DGK-118-H25 22 x 24
All dimensions shown are in inches.
Distance from
right side of
14½ 27½ x 27½DGK-110-H15 14 x 16
20 45½ x 45½
Curb
Dimension
Actual
(D x E)
The use of all lifting brackets and a set of spreader
bars is mandatory when lifting unit.
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).
Airflow
D
A
SUPPLY
DUCT
B
C
E
Roof Opening Details
Note: Roof openings can be as large as the curb size minus
3½ in. or as small as the duct size plus ½ in.
Supply Duct width (B) is centered over Curb width (E).
Supply Length (A) may not be centered over Curb Length (D).
Model DGK Make-Up Air
4
®
Installation of Hinged Weatherhood
SUP HP
MCA
MOP
VOLTSHZPH
Installation of Electrical Wiring
TOOLS REQUIRED
• 5/16-inch nut runner
• Caulk gun with weatherproof sealant
The DGK-H25 weatherhood is folded-up and shipped
on top of the unit:
To install:
1. Rotate one side up on
weatherhood.
a. Run two sheet metal
screws where shown
to hold side in rotated
position. Pilot holes are
provided.
b. Rotate opposite side up on weatherhood and
repeat step 1A.
2. Rotate assembly forward.
3. Screw the sides of the
weatherhood to the unit.
Pilot holes are provided.
4. Caulk all seams with an
appropriate weatherproof
sealant.
5. Install the two center filter
tracks which were shipped
inside the unit.
Rotate sides up, install screws.
Rotate Assembly forward.
See Step 3.
a. Slide the tabbed end of each track into the slot
at the bottom of the intake opening on the unit
housing.
b. Rotate the tracks up to the top outer edge of the
weatherhood such that the weatherhood edge
slides into the slot in the tracks.
IMPORTANT
Before connecting power to the unit, read and
understand the following instructions and the wiring
diagrams. Complete wiring diagrams are attached to
the inside of the control center door(s).
All wiring should be done in accordance with the
latest edition of the National Electrical Code ANSI/
NFPA 70 and any local codes that may apply. In
Canada, wiring should be done in accordance with
the Canadian Electrical Code.
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 any of the original wire must be replaced, the
replacement wire must have a temperature rating of
at least 105°C, except for energy cut-off or sensor
lead wire which must be rated to 150°C.
Any wiring deviations may result in personal injury or
property damage. Manufacturer is not responsible
for any damage to or failure of the unit caused by
incorrect final wiring.
DANGER
High voltage electrical input is needed for this
equipment. This work should be performed by a
qualified electrician.
1. Determine the Size of the Main Power Lines: The
unit nameplate states the unit’s voltage and total
MCA. The main power lines to the unit should be
sized accordingly. The nameplate is located on the
outside of the unit on the control panel side.
Center filter track.
(2 pieces)
Slot in unit.
6. Insert the factory provided aluminum mesh intake
filter(s) into the track located in the face of the
weatherhood. Filters slide in from the top. Be sure
the filters are properly orientated (an airflow direction
arrow is located on the side of the filters). Insert the
retaining screws on the sides of the weatherhood,
three (3) per side, to keep the filters in place.
®
Voltage, Hertz, Phase
VOLTSHZPH
SUP HP
MCA
Unit’s Total MCA
Electrical Nameplate
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. See the
control center layouts in the Reference section for
main disconnect and ground lug(s) locations.
Model DGK Make-Up Air
5
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.
All piping should be clean and free of any foreign
matter. Foreign material entering the gas train can
damage the valves, regulators and burner.
Do NOT connect the unit to gas types other than
what is specified and do NOT connect the unit to
gas pressures that are outside of the pressure range
shown on the label.
WARNING
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.
If pressure testing in excess of 1/2 psig (3.5 kPa),
the heater and manual shutoff valve must be
disconnected from the supply gas line.
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.
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 manufacturer.
This assembly must be installed in the inlet of the
gas train. When installed, the manual shut off valve
(gas cock) will be outside of the unit and will shutoff
all gas to the unit.
To
Controls
Gas Cock
Ground Joint Union
From
Gas
Supply
1/8 in. Plugged Tap
6 in. Trap
Supply Gas Line
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 D’ADMISSION
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
SCFM
AGAINST
CONTE
“ W.C.
“ W.C.
“ 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.
“ W.C.
4. Test the System for Leaks: Check both the supply
lines and the factory piping for leaks. Apply a soap
and water solution to all piping and watch for
bubbling which indicates a leak.
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.
PSI
F
Model DGK Make-Up Air
6
Direct Gas Nameplate
®
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