Greenheck DGX User Manual

Document 470651

Model DG / DGX Pilot Ignition

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!

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 DG / DGX Pilot Ignition 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 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 Pilot Ignition Make-Up Air2

Table of Contents

Installation of Indoor Unit

Installation

Clearance to Combustibles/Service Clearances . 3

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

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

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

Optional Evaporative Cooling Module ......... 6

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

Direct Gas Piping ......................... 8

Optional Evaporative Cooler Piping ........... 9

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

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

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

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

Start-Up

Blower ................................. 14

Direct Gas .............................. 16

Optional Evaporative Cooling Recirculating ... 19

Optional Water Wizard™ .................. 20

Operation

Optional Water Wizard™ .................. 21

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

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

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

Troubleshooting

Blower ................................. 25

Motor Overamps ......................... 26

Insufficient / Too Much Airflow .............. 27

Excessive Noise or Vibration ............... 28

Direct Gas Heat .......................... 29

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

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

Maintenance

Routine ................................ 34

Fall .................................... 36

Reference

Gas Train Layouts ........................ 37

Control Center Layout / Dirty Filter Switch .... 38

Start-Up Check List ...................... 39

Maintenance Log ..................Backcover

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)

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

Ceiling Supports

optional hanging bracket kit or c-channel and angle iron (supplied by others)

Hangers

should be used.

Indoor Mounting

Using self-tapping screws, attach ductwork to unit.

In order to prevent the unit from swinging and to provide a safe environment for service and maintenance, additional measures must be taken to secure the unit in all directions.

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 Pilot Ignition Make-Up Air 3

Installation of

Metal Cover

Equipment Support

Roof Curb

Arrangement DB / HZ / UB

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

Position curb and/or equipment/leg support(s) on the roof (reference the CAPS submittal for placement 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/leg support(s) to the roof, remove metal cover, ﬂash to wooden nailer and reinstall cover.

Curb and Equipment Support

3. Apply Sealant

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

Supply Air Ductwork

(Arrangement DB only)

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

Leg Supports

Unit Proﬁle and Leg Support

2. Install Ductwork

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

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.

Model DG / DGX Pilot Ignition Make-Up Air4

Complete Rooftop Installation

Installation of Roof Mounted Unit

Supply Ductwork by Others

Exhaust Ductwork by Others

Supply Duct with Duct Adapter Installed

Exhaust Duct Installed

Sealant

Metal Cover

Equipment Support

Roof Curb

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.

Curb and Equipment Support

NOTE

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

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.

2. Install Combination Curb Adaptor

Install combination curb adaptor over curb, use wood screws to lag in place. Locate extension so the tall louvered side is over the exhaust opening, as shown in illustration. Caulk extension to combination curb adaptor. Fasten extension to curb adaptor with #12 sheet metal screws (ﬁeld-provided).

Exhaust

Supply

Combination Extension

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.

Exhaust Fan

Installing Exhaust Fan

NOTE

NFPA 96 requires the exhaust fan to be hinged.

6. Install Exhaust Options

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

Ductwork

Model DG / DGX Pilot Ignition Make-Up Air 5

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.

Model DG / DGX Pilot Ignition Make-Up Air6

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

Equipment Support

if necessary. Attach equipment support to the roof, remove metal cover, ﬂash to wooden nailer and reinstall cover.

Sealant

2. Apply Sealant

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

Sealant

3. Set Evaporative Cooling Module

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

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

Securing

Evaporative Module

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.

5. Seal Evaporative Module Seam

Using an appropriate sealant, seal the seam between the evaporative cooling module and the unit.

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 high voltage 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. Manufacturer is not responsible for any damage to, or failure of the unit caused by incorrect final wiring.

IMPORTANT

Manufacturer’s standard control voltage is 24VAC. Control wire resistance should not exceed

0.75ohms (approximately 285 feet total length for 14gauge wire; 455 feet total length for 12gauge wire). If the resistance exceeds 0.75 ohms, an industrial-style plug-in relay should be wired in place of the remote switch. The relay must be rated for at least 5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to chatter or not pull in, resulting in contactor failures and/or motor failures.

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).

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 optional 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 Pilot Ignition Make-Up Air 7

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 manufacturer.

Controls

Gas Cock

Ground Joint Union

From

Gas

Supply

1/8 in. Plugged Tap

6 in. Trap

Supply Gas Line

Model DG / DGX Pilot Ignition Make-Up Air8

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.

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 or other approved leak test 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.

Installation Evaporative Cooler Piping (optional)

Evaporative Cooling with Recirculating Pump

Supply Line

Supply Line Valve

Drain Line Valve

(normally open)

Drain Line

Trap

Recirculating Evaporative Piping

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.

(normally closed)

Overﬂow

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 shut off valve (by others) is required for the evaporative cooler drain line.

A trap should be used to prevent sewer gas from being drawn into the unit. Refer to drain trap

Drain

Trap

6 in. min.

diagram.

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 Pilot Ignition Make-Up Air 9

Installation Evaporative Cooler

Sump Overﬂow

Trap

Drain Line

Sump Drain

Supply Line

VALVE A

Supply Solenoid

(normally closed)

VALVE C

Sump Drain Solenoid

(normally open)

VALVE B

Supply Line Drain Solenoid

(normally open)

Piping (optional)

Evaporative Cooling with Auto Drain and Fill

Auto Drain and Fill Evaporative Piping

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.

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

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.

continued

IMPORTANT

CAUTION

IMPORTANT

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 and Fill Evaporative Piping drawing shown 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

Drain

Trap

6 in. min.

trap drawing.

3. Check/Adjust Water Level

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

Assm.

Number

852178

Part numbers subject to change.

Model DG / DGX Pilot Ignition Make-Up Air10

Auto Drain & Flush Valves

(when provided by Manufacturer)

Mfg. Part

Number

461262 8210G2 Supply Closed

461263 8262G262

461264 8210G35

ASCO

Part

Number

Solenoid

Type

Supply

Line

Drain

Sump

Drain

De-Energized

Position

Open

Diameter Qty.

1/2 inch

(12.7 mm)

1/4 inch

(6.35 mm)

3/4 inch

(19.05 mm)

Installation of Water Wizard™ (optional)

Evaporative Cooling with the Water Wizard™

NOTE

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

WARNING

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

Water Wizard™ Valves

(when provided by Manufacturer)

Mfg.

Unit

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.

Assm.

Number

461262 8210G2 Supply Closed

852370

383086 8210G34

383088 8210G9 Supply Closed

852371

383086 8210G34

Part

ASCO

Part

Number

Solenoid

Type

Supply

Line

Drain

Supply

Line

Drain

De-Energized

Position

Open

Diameter Qty.

1/2 inch

(12.7 mm)

1/2 inch

(12.7 mm)

3/4 inch

(19.05 mm)

1/2 inch

(12.7 mm)

To Media

Sump Drain

Trap

Roof Line

Pressure Gauge

Manual Supply Valve

Supply Line Drain Solenoid

(normally open)

Supply Solenoid

(normally closed)

Factory Installed

Field

Installed

Water Wizard™ Installation

3. Wire the Solenoid(s)

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

4. Wire the Temperature Sensor

If the evaporative cooler shipped separate from the unit, the temperature sensor must be wired. The sensor wire is bundled inside the discharge end of the evaporative cooler. Wire the sensor wire to the unit’s control center. Refer to ladder diagram for proper connections.

NOTE

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

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 manufacturer (if ordered) or by others.

CAUTION

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

Model DG / DGX Pilot Ignition Make-Up Air 11

Installation of Direct Expansion (DX)

(by others)

Coil Piping (optional)

IMPORTANT

Guidelines for the installation of direct expansion cooling coils have been provided to ensure proper performance and longevity of the coils. These are general guidelines that may have to be tailored to meet the specific requirements of any one job. As always, a qualified party or individual should perform the installation and maintenance of any coil. Appropriate protective equipment is 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.

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

Liquid line openings vary by coil size and circuiting and are ﬁeld-supplied. Follow the TXV 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 TXV. If the valve is internally equalized, the factory-installed equalizer line can be left as is

Thermal

(by others)

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

Distributor

Access Panel

Distributor

Location

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

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.

General Installation

NOTE

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

Thermal

(by others)

Installation with Hot Gas Bypass

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.

Model DG / DGX Pilot Ignition Make-Up Air12

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