Greenheck DGX User Manual

Page 1

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

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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.

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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

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Page 4

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

Page 5

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

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Page 6

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.

Page 7

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.

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Page 8

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

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Page 9

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.

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Page 10

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)

Page 11

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

Page 12

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.

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Page 13

7. Evacuate and Charge the Coil

6 in. min.

Hot Return Connection

Cold Supply Connection

Entering Air

Leaving Air

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

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

Drain

Trap

IMPORTANT

6 in. min.

Installation of Chilled Water Coil Piping (optional)

IMPORTANT

Guidelines for the installation of the cooling coil have been provided to ensure 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. Appropriate protective equipment is 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 Pilot Ignition Make-Up Air 13

6 in. min.

Page 14

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.

High Pressure

Factory

Wiring

Low Pressure

Tap

to outside

Connections for Photohelic Gauge

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 TOOLS REQUIRED

• Voltage Meter (with wire probes)

• Amperage Meter

• Pressure Gauges – (refrigerant)

• Tachometer

• Thermometer

• U-Tube Manometer

WARNING

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

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

Pressure Setting Knobs

Typical Photohelic Gauge

1. Check the Voltage

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

VOLTS HZ PH

SUP HP

Unit’s Total MCA

Electrical Nameplate

MCA

Voltage, Hertz, Phase

MOP

2. Check the Blower Rotation

Open the blower access door and run the blower momentarily to determine the rotation.

Arrows are placed on the blower scroll to indicate the proper direction or reference the example shown to the right.

Blower

Housing

Blower Rotation

Model DG / DGX Pilot Ignition Make-Up Air14

Page 15

NOTE

To reverse the rotation on three phase units, disconnect and lock-out the power, then interchange any two power leads.

NOTE

To reverse the rotation on single phase units, disconnect and lock-out the power, then rewire the motor per the manufacturer’s instructions.

IMPORTANT

If the blower is rotating in the wrong direction, the unit will move some air, but will not perform as designed. Be sure to perform a visual inspection to guarantee the correct blower rotation.

NOTE

The most accurate way to measure the air volume is by using a pitot traverse method downstream of the blower. Other methods can be used but should be proven and accurate.

IMPORTANT

Changing the air volume can significantly increase the motor’s amps. If the air volume is changed, the motor’s amps must be checked to prevent overloading the motor.

NOTE

To ensure accuracy, the dampers are to be open when measuring the air volume.

3. Check for Vibration

Check for unusual noise, vibration or overheating of the bearings. Reference the Troubleshooting section for corrective actions.

IMPORTANT

Excessive vibration may be experienced during the initial start-up. Left unchecked, it can cause a multitude of problems including structural and/or component failure.

IMPORTANT

Generally, fan vibration and noise is transmitted to other parts of the building by the ductwork. To minimize this undesirable effect, the use of heavy canvas duct connectors is recommended.

4. Motor Check

Measure the motor’s voltage, amps and RPM. Compare to the speciﬁcations. Motor amps can be reduced by lowering the motor RPM or increasing system static pressure.

IMPORTANT

Additional starters and overloads may be provided in the make-up air control center for optional exhaust blowers. Any additional overloads must be checked for proper voltage, amps and RPMs.

6. Set-Up Optional Components

Adjust the settings on the optional components. See the Control Center Layout in the Reference section for location of optional components.

• Heating Inlet Air Sensor Typical setting: 60-70ºF

• Cooling Inlet Air Sensor Typical setting: 75ºF

• Building Freeze Protection Typical setting: 5 minutes; 45ºF

• Dirty Filter Gauge Typical setting: Settings vary greatly for each

unit. See Reference section for adjusting information.

5. Air Volume Measurement and Check

Measure the unit’s air volume (cfm) and compare it with it’s rated air volume. If the measured air volume is off, adjust the fan’s RPM by changing/adjusting the drive.

Model DG / DGX Pilot Ignition Make-Up Air 15

Page 16

Start-Up - Direct Gas

IMPORTANT

For proper unit function and safety, follow the startup procedure in the exact order that it is presented.

IMPORTANT

This start-up should begin after all of the installation procedures and the blower start-up have been completed.

1. Check the Supply Gas Pressure

Check the supply gas pressure and compare it with the unit’s nameplate pressure requirements. Adjust the supply regulator as needed until the supply gas pressure is within the speciﬁed range (see below). The nameplate is located on the outside of the unit on the control panel side.

Minimum and maximum gas

pressures for maximum output

IMPORTANT

Proper air velocity over the burner is critical on direct fired gas units. If the air velocity is not within the unit specifications, the unit will not operate efficiently, may have sporadic shutdowns, and may produce excessive carbon monoxide (CO) or other gases.

4. Set the Burner Air Pressure Differential

With all access panels in place, the fan running and discharging 70ºF (21ºC) air, connect a U-Tube manometer to the outer sensing probes (see below) and measure the static pressure across the burner.

Outer Sensing Probes

Pressure Switch

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

SCFM

AGAINST

CONTE

“ 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

“ W.C.

PSI

Type of gas

Direct Gas Nameplate

2. Check the Pilot Gas Pressure

The recommended gas pressure is 3 in. wg. Adjust the pilot regulator as needed. See the Gas Train Layout in the Reference section for the location of the pilot pressure test port and pilot regulator.

3. Check the Optional High and Low Gas Pressure Switches

Check the settings on the high and low gas pressure switches. The high gas setting is typically 8in. wg (2kPa) and the low gas setting is typically 3 in. wg (0.7kPa). The switches are set at the factory and should not need adjustment. Adjust the settings if needed. See the Gas Train Layout diagram in the Reference section for the high and low pressure switch location.

IMPORTANT

The purpose of the high and low gas pressure switches is to automatically shut down the burner if the inlet gas pressure is too low for the burner to safely light, or if the manifold pressure is too high for the burner to operate properly.

U-Tube Manometer

Measuring the Pressure Drop

0.625 - 0.675 in. wc

The proper static pressure

Adjustable Top Bafﬂe

Airﬂow

Burner

should be between 0.625 and

0.675 inches wg (155.68 and

168.64 Pa). If needed, evenly adjust the bafﬂes above and below the burner, keeping

Adjustable Bottom Bafﬂe

the burner centered in the opening until the required

Burner and Bafﬂes

pressure is obtained.

NOTE

The pressure drop was set at the factory and may not need adjustment.

NOTE

When required pressure is obtained, be sure to reconnect the outer sensing probes.

IMPORTANT

This process may need to be repeated until the proper pressure is achieved. This adjustment will change the air quantity delivered by the unit and therefore the air quantity delivered should be rechecked. Refer to the Blower Start-Up section.

NOTE

To increase the static pressure, decrease the opening. To decrease the static pressure, increase the opening.

Model DG / DGX Pilot Ignition Make-Up Air16

Page 17

5. Set the Low Fire Time Delay

Set the low ﬁre time delay to 75% of its maximum setting. See corresponding image(s) for the location of the time delay setting.

NOTE

The low fire time delay must be set high enough to provide at least 10 seconds of low fire while the unit tries to light.

6. Set the Maximum Firing Rate

Monitor the unit’s actual temperature rise by placing a thermocouple in the unit’s inlet and a second in the discharge, three duct diameters downstream of the burner.

Send the unit to maximum ﬁre by disconnecting and isolating the wire connected to Terminal 3 on the Maxitrol 14 or 44. See images on next page.

While monitoring the unit’s temperature rise, set the maximum ﬁring rate by adjusting the regulator until the designed temperature rise is achieved. After setting the maximum ﬁring rate, reconnect the wire to the ampliﬁer.

NOTE

Clockwise rotation increases the temperature rise, counterclockwise rotation decreases the temperature rise.

NOTE

The minimum setting for the maximum firing rate may be higher than required. This is acceptable, the burner will modulate as needed.

Regulators and Modulating Valves

Remove cap to access

maximum firing rate

adjustment

Minimum firing

rate adjustment

Remove one wire to

send the unit to the minimum firing rate

NOTE

Do not set the burner maximum firing rate based on gas pressure. It should be set based on the unit’s designed temperature rise shown on the direct gas label.

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

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

“ W.C.

PSI

IMPORTANT

Setting the maximum firing rate during mild weather conditions may cause the high limit to trip out during extreme conditions requiring manual resetting.

NOTE

Gas trains are equipped with either separate regulators and modulating valves or with a combined modulating valve.

Separate Regulator and Modulating Valves

Minimum firing

rate adjustment

Remove one wire to send the unit

to the minimum firing rate

Maximum firing rate adjustment

Combined Modulating Regulator

7. Set the Minimum Firing Rate

Disconnect and isolate one of the wires running to the modulating valve to send the unit to its minimum ﬁring rate. Set the minimum ﬁring rate by adjusting the needle valve.

After setting the minimum ﬁring rate, shut off the pilot to ensure that the ﬂame safeguard can still read the main ﬂame signal. Reconnect the wire to the modulation valve and open the pilot shut-off valve.

Model DG / DGX Pilot Ignition Make-Up Air 17

Page 18

IMPORTANT

The proper minimum firing rate setting results in a small ribbon of continuous flame which covers the flame rod and runs across the entire burner.

IMPORTANT

Do not allow the disconnected wire to come in contact with a potential ground. Damage to the amplifier or transformer could result.

IMPORTANT

On units with a burner 42 inches or greater, the flame safeguard will automatically shut off the pilot after the burner has been ignited.

NOTE

Adjusting the maximum and minimum firing rate requires the inlet air sensor to be set higher than the outdoor air temperature in order to start the burner(s). Once high and low fire have been set, the inlet air sensor should be set to the desired temperature.

NOTE

Counterclockwise rotation increases the minimum fire rate setting, clockwise rotation decreases the setting.

8. Set the Unit’s Operating Temperature

Set the operating temperature. The method to set the operating temperature depends upon which Maxitrol controller is used.

Maxitrol Series 14 - The Maxitrol Series 14 should be set to the desired discharge temperature mode. Place dipswitch in the “UP” position for local control and in the “DOWN” position for remote control. Keep LFST dipswitch in the “UP” position at all times for 10 second delay. Fig. A is required for remote control.

Maxitrol Series 44 - The Maxitrol Series 44 should be set to the desired discharge temperature. The temperature selector is a stand-alone dial. The standalone dial may be mounted remotely.

Set the space temperature Typical: 70

(shown as Space Temperature Control)

Minimum discharge

temperature setting

Low fire time delay setting

(75% of maximum)

Series 44 Temperature Setting

Remove wire attached

to terminal 3 to send

(Typical: 50ºF)

Maxitrol Series 44 — 9 terminals

unit into maximum fire

Maximum discharge

temperature setting

(Typical: 100ºF)

Maxitrol SC25S - The SC25S is an analog signal converter that will change a 0-10 VDC or a 4-20 mA control signal provided by an owner-supplied Building Management System into an output level capable of driving the modulating gas valve.

The SC25S also limits the minimum and maximum discharge air temperatures. Reference the unitspeciﬁc wiring diagram and Maxitrol data sheets included in the IOM packet.

Discharge

temperature

dipswitch

Set the discharge temp Typical 65°F Minimum: Typical: 55°F Maximum: Typical: 90°F

Maxitrol Series 14 — 8 terminals

Model DG / DGX Pilot Ignition Make-Up Air18

Remove wire attached to terminal 3

to send unit into maximum fire

Low fire

setting

(LFST)

dipswitch

Fig. A

Place a jumper wire across the T1

and T2 terminals (labeled sensor)

to send the unit into maximum fire.

Remove the wire on

terminal 3 to send the

unit into minimum fire.

9. Flame Signal Check

To measure the ﬂame signal connect a standard DC voltmeter to the ﬂame ampliﬁer test jacks + and

- (com) as shown to the right. The ﬂame signal should be above 1.25 VDC and steady.

Check the ﬂame signal with the burner at pilot only, minimum ﬁre, mid ﬁre and high ﬁre. If the flame

signal is not above 1.25 VDC and steady, consult the Troubleshooting section.

DC Voltmeter and

Flame Ampliﬁer

Page 19

Start-Up - Evaporative Cooling Recirculating (optional)

1. Check the Installation

The media may have been removed during installation, so its orientation should be double

Entering Air

checked. The media should be installed with the steeper ﬂute angle sloping down

Media Orientation

towards the entering air side.

Verify that the stainless steel caps and distribution headers are in place. The headers should be located over the media towards the entering air side. The caps should be placed over the headers.

2. Check the Pump Filter

Check that the pump ﬁlter is around the pump inlet.

3. Fill the Sump and Adjust the Float

Turn on the water supply and allow the sump tank to ﬁll. Adjust the ﬂoat valve to shut-off the water supply when the sump is ﬁlled to within 1 inch of the bottom of the overﬂow.

4. Break-In the Media

Open the bleed-off valve completely and saturate the media with the blower(s) off for no less than 20minutes.

NOTE

A jumper will need to be installed in the control center to power the evaporative pumps with the blower(s) off. Reference the unit’s ladder diagram to determine proper terminals.

5. Check the Flow Rate

The pumps should provide enough water to saturate the media in 45 to 60 seconds. Consult the factory, if adequate ﬂow is not achieved.

45º

Leaving Air

15º

to 45º F and is not adjustable. The auto drain and ﬁll outdoor air sensor should be installed in an area that is shaded from direct sunlight so the outside air sensor probe will detect an accurate air temperature.

Set the Timer Scale and Settings dials:

• T1 timer setting set to 10 and timer scale set to 1d for 1 day of operation

• T2 timer setting set to 10 and the timer scale

set to 10m for 10 minutes of drain time

Timer Scale

Timer

Settings

Timer Scale

Settings

Auto Drain and Flush Timer

8. Put the Unit into Service

Remove the jumper, and energize the blower(s). Verify proper operation.

IMPORTANT

Check the media for minerals after two weeks of service and adjust the bleed-off rate accordingly.

Bleed-Off

Valve

Overflow

Pump

Filter

Supply

Connection

Float

Valve

Threaded Float

Adjustment

6. Adjust the Water Bleed-Off Rate

The water bleed-off rate is dependent on the water’s mineral content. The bleed-off should be adjusted based on the media’s mineral deposits after two weeks of service.

7. Set the Optional Auto Drain and Fill

This system will automatically drain the sump tank and ﬁll it with fresh water at the ﬁeld-adjustable intervals, typically once every 24 hours. This ﬂushes mineral build-up and debris from the tank to promote low maintenance and increase media pad life.

In addition, the system will protect the evaporative cooler from freezing by draining the sump tank and supply line when the outside temperatures fall below the set point of the outside air sensor. This is set

Evaporative Cooler Set-Up

Model DG / DGX Pilot Ignition Make-Up Air 19

Page 20

Start-Up - Water Wizard™ (optional)

L1 L2 L3

4. Close Solenoid

With the pressure set, press the Function key for one second to deactivate Flow Test Mode

and allow the supply solenoid to close.

Function

Enter

Water Wizard™ User Interface

Key Function Description

Down

1. Open the Solenoid

Conﬁrm that the manual water supply valve

is closed. Press and hold the Function key for one second. L3 will begin blinking (short on, long off), indicating that Flow Test Mode is active and the supply solenoid is open.

2. Set the Water Pressure

With the solenoid open, set the supply

water pressure to the correct setting from the following tables. Use the manual supply valve to adjust the supply pressure. A pressure gauge is provided between the manual supply valve and the media.

WARNING

Opening the manual supply valve will allow water to pass to the media. Be sure the sump is safely draining before opening the manual supply valve.

NOTE

The manual supply valve ships closed and must be adjusted for proper performance.

Recommended Water Pressure Chart

Housing

Size

DG-10 26

DG-20 66 74

DG-30 84* 35

DGX-12 30 20

DGX-22

DGX-32

DGX-35 120* 61

DGX-38 180* 37

DGX-42 216* 51

*Multiple media sections. Values represent total media width.

The recommended water pressure is based on media width. Refer to the table provided for proper water pressure settings.

Media Width

(inches)

⁄4 19

⁄4 36

60 61

66 72

96* 42

NOTE

Water Pressure

(in. wg)

5. Check Media

Start the cooling cycle and check the media after one hour of operation. If the media is continuously dry or if too much water is draining from the sump tank, refer to Troubleshooting, Water Wizard™.

NOTE

Steps 6 through 8 are provided to adjust the minimum cooling temperature. The minimum cooling is preset to the factory recommended 75ºF (24ºC). Only adjust if needed.

NOTE

The inlet air sensor function overrides and shuts down the evaporative cooler if the outside temperature falls below the minimum cooling temperature.

6. Enter Program Mode

Press and hold

the Enter key for three seconds. The display will read “Pro” when Program Mode is active.

Program Display

7. Adjust the Minimum Cooling Temperature

While in the

Program Menu,

use the Up and

Down keys to

navigate the

Menu Options

until “toF” is

Minimum Cooling

Temperature Display

displayed. Press the Enter key to access the selected Menu Option setting.

Use the Up and Down keys to adjust the Minimum Cooling Temperature as needed. Press the Enter key to save the Minimum Cooling Temperature setting and return to the Program Menu.

NOTE

The enter key must be pressed to save the new minimum cooling temperature.

8. Exit Program Mode

After ten seconds of idle time the controller will exit Program Mode.

3. Break-In Media

Leave the supply solenoid open to saturate and break-in media for 20 minutes with the blower off.

Model DG / DGX Pilot Ignition Make-Up Air20

Page 21

NOTE

The Freeze Temperature is preset to the factory recommended 45ºF. Steps 9-11 should only be completed if the Freeze Temperature needs adjustment.

NOTE

The Freeze Temperature is the temperature at which the supply solenoid closes and the drain solenoid opens to drain the supply line, preventing possible freeze damage. A drain solenoid is required for this option.

9. Enter Program Mode

Press and hold

the Enter key for three seconds. The display will read “Pro” when Program Mode is active.

Program Display

10. Adjust the Freeze Temperature

While in Program Mode, use the Up and Down

keys to navigate

through the

Menu Options

until “Frt” is

displayed. Press the Enter key to access the selected Menu Option setting.

Freeze Temperature

Display

Use the Up and Down keys to adjust the Freeze Temperature setting as needed. Press the Enter key to set the Freeze Temperature and return to the Program Menu.

NOTE

The enter key must be pressed to save the new freeze temperature.

11. Exit Program Mode

After ten seconds of idle time the controller will exit Program Mode.

Operation - Water Wizard™ (optional)

CAUTION

The sump drain line must be clear and draining to a safe location before using Flow Test Mode.

CAUTION

Be aware of the water level in the sump tank at all times when using the Flow Test Mode.

Program Mode

Program Mode allows the user to view the Program Menu and edit the factory default settings. To access Program Mode and view the Program Menu, press and hold the Enter key for three seconds. While viewing the Program Menu, press the Up and Down keys to scroll through the Menu Options. To view the setting of the selected Menu Option, press the Enter key. To edit the setting, press the Up or Down key while viewing the setting. To save the setting and return to the Program Menu, press the Enter key. To return to the Program Menu without saving the change, wait 10 seconds. To exit Program Mode from the Program Menu, wait 10 seconds.

WARNING

Changing the default settings will significantly affect performance. Only change a setting after reading and understanding this entire manual.

WARNING

The Enter key must be pressed to save any changes made to a setting.

Dry Bulb Temperature

The dry bulb temperature is visible on the home screen. If a number is not visible, wait 15 seconds and use the Up and Down keys until a number is displayed.

Wet Bulb Temperature

To view the Wet Bulb Temperature, simultaneously press and hold the Up and Down keys.

Indicating Lights

Three indicating lights are located across the top of the display to indicate the status of the Water Wizard™.

Drain Mode locks open the drain solenoid and

drains the supply line between the supply solenoid and the media. To activate Drain Mode simultaneously, press the Function and Enter keys (L2 will light). To deactivate Drain Mode and unlock the drain solenoid, simultaneously press the Function and Enter keys again.

Flow Test Mode - Activating Flow Test Mode

opens the supply solenoid and allows water to pass to the manual supply valve. To activate Flow Test Mode, press and hold the Function key for one second (L3 will ﬂash). To deactivate Flow Test Mode and allow the supply solenoid to close, press and hold the Function key again for one second.

Indicating

Light

Light Status

On Off

Call for

cooling

Drain

solenoid

open

Cooling onCooling

Model DG / DGX Pilot Ignition Make-Up Air 21

call for

cooling

Drain

solenoid

closed

off

Blinking

Long on, short off

Call for cooling.

Outdoor

temperature

lockout.

N/A

Supply solenoid

locked closed

Blinking

Short on, long off

N/A

Supply solenoid

open. (Drain

solenoid closed).

Flow test

mode active

Page 22

Check Operation - VAV Units

(optional)

NOTE

Blower Start-Up, Steps 1-5 should be performed before the blower is run.

NOTE

For maintenance issues associated with variable frequency drives, consult the drive’s manual supplied with the unit. The drives are programmed at the factory and should not need any adjustment during installation and start-up. For kitchen applications, the drive may be located in the kitchen or in the unit.

Variable Volume Operation

The variable volume option is recommended when a building’s exhaust volume may vary. This option enables the make-up air volume to track with the exhaust volume, providing only the amount of makeup air required. Control strategies include 2-speed VFD motors and modulating blowers. Before the unit is left in service, the variable volume control system should be tested.

2-Speed VFD Motor

A variable frequency drive (VFD) is used on a single speed motor to control air volumes. The VFD is factory-programmed for 2 speed operation. It can be switched to low or high speed from a remote control panel. Turn the fan speed switch on the remote control panel to each position and conﬁrm that the fan speed adjusts accordingly.

Modulating

Potentiometer Control - a variable frequency drive is controlled by input from a remote speed selector (potentiometer). This unit allows easy manual adjustment of make-up air volumes. To test potentiometer operation, turn the potentiometer to the two extremes. With variable volume, make sure the fan goes to maximum and minimum speed.

When the potentiometer is at 0, the fan speed will be at its minimum. When the potentiometer is at 100, the fan will be at its maximum speed.

Potentiometer

EXHAUST

(OPTIONAL)

SUPPLY

HEAT

Control

BLOWERS

MAIN VALVES

DIRTY FILTERS

(OPTIONAL)

Building Pressure Control a variable frequency drive is controlled according to input from

EXHAUST

SUPPL Y

HEA T

(OPTIONAL)

BLOWER

MAIN V AL VES

a pressure sensing device.

Turn both knobs to the upper most pressure setting. You may

DIRTY FIL TERS

(OPTIONAL)

have to remove the outdoor pressure tap tubing. VAV systems should go to maximum speed. Set

PHOTOHELIC

both knobs at the lowest setting and the VAV systems should go to minimum speed.

Reset the correct pressure limits before starting the unit.

Indicating

This picture depicts a typical

Pressure

Needle

Building

Pressure Control

Pressure

Setting

Needles

photohelic setting. Typical settings are 0.0 inch wc for the lower pressure setting and 0.10 inch wc for the upper pressure setting. The needle indicates a negative building pressure. During correct operation, the indicating needle will remain between or near the setting needles.

Pressure Setting Knobs

Photohelic Gauge

External Signal - a variable frequency drive is

controlled according to input from an external 2-10VDC or 4-20 mA signal (by others).

A 2 VDC or 4 mA signal will send the blower to low speed. The blower will go to maximum speed with a 10 VDC or 20 mA signal.

Variable Kitchen Control - a variable frequency drive is controlled by input from a remote speed control. This unit allows automatic adjustment of make-up air volumes based on varying cooking loads.

Burner Bypass Damper (optional)

The self-adjusting burner bypass damper is a device used in variable volume units. Its function is to maintain proper combustion by providing a constant airﬂow over the burner when outside air volumes are changed. It is located underneath the burner as shown in the picture.

WARNING

The burner bypass damper is set-up at the factory. The weights should not be adjusted in the field. The damper may not fully close during minimum outside air mode.

Burner

Bypass Damper

Burner Bypass Damper

Model DG / DGX Pilot Ignition Make-Up Air22

Page 23

Outside Air

Check Operation - Recirculating Units (optional)

NOTE

Blower Start-Up, steps 1-5 should be performed before the blower is run.

Recirculation Operation

The recirculation operation option is recommended when the ventilation equipment provides the primary source of heating for the space. A minimum of 20% outdoor air is mixed with up to 80% ﬁltered recirculated air. Control strategies include 2-position and modulating dampers. Before the unit is left in service, the recirculation control system should be tested.

20%

80-0%

(100-20%)

Adjustable

Recirculated Air

(0-80%)

Bypass Bafﬂe

Adjustable Bypass Bafﬂe

An adjustable bafﬂe is provided in the lower (bypass) airstream. The bafﬂe is factory preset, but may require ﬁeld adjustment to account for various installation variables. Adjust to maintain approximately 20% of total airﬂow across the burner and 80% through the bypass.

2-Position Damper

A 2-position spring return actuator is used to control the return air amounts. The damper moves from open to closed. If power is cut to the unit, the outdoor air damper will fail to close.

Turn the recirculating switch on the remote control panel to each position and conﬁrm that the return air damper adjusts accordingly. The damper actuator may take a few minutes to open or close.

Modulating

Potentiometer Control - a modulating spring return actuator is used to control the return air amounts. The return air damper modulates from fully open to fully closed based on a signal from a remote potentiometer.

To test potentiometer operation, turn the potentiometer to the two extremes. With 80/20 recirculation,

Supply Air

EXHAUST

SUPPL Y

HEA T

RECIRCULA TION

(OPTIONAL)

BLOWER

MAIN V AL VES

DIRTY FIL TERS

(OPTIONAL)

2-Position

Damper Control

BLOWERS

EXHAUST

(OPTIONAL)

SUPPLY

MAIN VALVES

HEAT

DIRTY FILTERS

(OPTIONAL)

Potentiometer

Control

conﬁrm that the return air damper fully opens and fully closes. When the potentiometer is at 0, the return air damper will open. When the potentiometer is at 100, the return air damper will close. The damper actuator may take a few minutes to open or close.

Building Pressure Control - a modulating spring return actuator is used to control the return air

EXHAUST

SUPPL Y

HEA T

(OPTIONAL)

BLOWER

MAIN V AL VES

amounts. The return air damper modulates from fully open to fully closed based on a signal from a

DIRTY FIL TERS

(OPTIONAL)

remote pressure sensing device.

Turn both knobs to the upper

PHOTOHELIC

most pressure setting. You may have to remove the outdoor pressure tap tubing. The return air damper should close.

Building

Pressure Control

Set both knobs at the lowest setting and the damper should open. It may take one to two minutes for the damper to reach the desired position.

Reset the correct pressure limits before starting the unit.

Pressure

Indicating

Needle

Pressure

Setting

Needles

This picture shows a typical photohelic setting. Typical settings are 0.0 inch wc for the lower and 0.10 inch wc for the upper pressure setting. The needle in this photo indicates a negative building pressure. During correct operation, the indicating needle will remain between or near the setting needles.

Pressure Setting Knobs

Photohelic Gauge

External Signal - a modulating spring return actuator

is used to control the return air amounts. Return air damper modulates from fully open to fully closed based on an external 2-10 VDC or 4-20 mA signal (by others).

The return air damper will close with a 10 VDC or 20mA signal. The return air damper should open with a 2VDC or 4mA signal. The damper actuator may take a few minutes to open or close.

Model DG / DGX Pilot Ignition Make-Up Air 23

Page 24

Operation - Electrical

Electrical Sequence

1. Exhaust Fan Contact (S1) Closed (optional)

• Power passes to N.C. exhaust overload contact (ST2 OL) (optional)

• Power passes to exhaust starter(s) (ST2)

• N.O. exhaust starter switches are energized and closed

• Power passes to exhaust fans

• Exhaust fan(s) (M2) start

2. Supply Fan Contact (S2) Closed

• Power passes through N.C. ﬁeld-supplied ﬁre contact (FSC)

• Power passes through N.O. exhaust fan contact (ST2) which is closed when the exhaust relay (ST2) is activated (optional)

• Power passes to N.C. supply overload contact (ST1OL)

• Power passes through N.C. contact on optional freeze protection timer (RT4) which remains closed if the temperature has remained above the set point

• Power passes to optional inlet damper (D1) which opens

• When damper is fully opened, damper relay (D1) is energized and optional N.O. damper limit switch (DL1) closes

• Power passes to and energizes supply starter relay (RF)

• Power passes to N.O. fan contact (RF) which is energized and closed

• Supply starter (ST1) is energized

• Supply starter contact (ST1) closes and power reaches and energizes supply fan

• Supply fan (M1) starts

2. Heat Contact (S4) Closed

• Power passes to N.O. fan relay (RF) which is energized and closed

• Power passes to optional inlet air sensor contact (TS4) which is energized and closed if the inlet air temperature is below the set point

• Power passes to and energizes the heat relay (RH)

• N.O. heat relay contact (RH) closes

• Power passes to and energizes terminal 5 of the Flame Safeguard (FSG). Power light on FSG is on.

• Power passes to N.C. high limit control contact (HLC1) which is closed if temperature has remained below set point

• Power passes to optional N.O. and N.C. high and low gas pressure contacts (PS4 and PS3), which are both closed if gas pressure is within the set range

• Power passes to terminal 6 of the Flame Safeguard (FSG)

• Power begins direct gas burner sequence (see Direct Gas Burner Sequence)

4. Optional Evaporative Cooling Contact (S4) Closed*

• N.O. contact on fan relay (RF) is energized and closed

• Power passes to optional inlet air sensor contact (TS4) which is energized and closed if the inlet air temperature is above the set point

• Power passes to and energizes cool relay (RC)

• N.O. contact on cool relay (RC) is energized and closed

• Power passes to optional evaporative cooling pump (P1)

*If DX or chilled water coils are used rather than an evaporative cooler, the cooling sequence of operation will depend on the coil controls. Cooling coil controls are supplied by others.

Direct Gas Burner Sequence

1. Supply Fan Contact Closed

• Power passes to the supply fan and heat switch

2. Heat Contact Closed

• Power passes to the heat relay then to the Flame Safeguard

3. Flame Safeguard (FSG) Sequence

• Checks for proper airﬂow

• Veriﬁes no ﬂame present at burner

• Initiates 15 second prepurge

• Sends power to open pilot gas valve (V1) and energizes the spark generator (SG)

• Tries for up to 10 seconds to light pilot and conﬁrm ﬂame

• Powers the main gas valves (V2) open

• Shuts down spark generator (SG)

• Continuously monitors the ﬂame and airﬂow

• Performs self-diagnostic check every ﬁve seconds

Model DG / DGX Pilot Ignition Make-Up Air24

Page 25

Troubleshooting

Blower Does Not Operate

Proper supply power at

main disconnect

Yes

24 VAC between

terminals R and X?

Yes

24 VAC between

terminals G and X?

Yes

24 VAC across

terminals 3 and X?

Yes

24 VAC across

terminals 4 and X?

Check Main Voltage

(See Blower Start-Up – Step #1)

Main Disconnect (DS1) Off

(Turn Main Disconnect DS1 On)

Primary Fuses Blown

(Replace Fuses)

Main Transformer (TR1) Tripped

(Reset Transformer)

Main Transformer (TR1) Defective

(Replace Transformer)

Supply Switch (S2) Off

(Turn Supply Switch (S2) On)

Fire system contact (FSC) tripped/not installed

(Correct/Replace)

Supply Fan Overload (ST1 OL) Tripped

(Reset and check motor amps, reference Blower Start-Up – Step #4)

Optional Exhaust Fan Interlocks (ST2-ST5) Open

(Correct/Replace)

Yes

24 VAC across A2 and A1 on

supply contactor (ST1)

Yes

(Optional) Freeze Protection (RT4) Tripped

(Cycle Power and Reset)

(Optional) Damper Limit Switch (DL1) Holding

(Wait for actuator to open fully or adjust limit switch)

(Optional) Damper Limit Switch Jumper Missing

(Install jumper, reference the units ladder diagram for terminals)

Fan Relay (RF) is not energized

(Check for loose connection) (Repair or replace relay)

Broken Fan Belt

(Replace - reference V-Belt Drives in the Maintenance section)

Defective motor or capacitor

(Repair/Replace)

Blown Motor Fuse

(Replace)

One or more legs of 3 phase is out

(Restore missing legs)

At this time the supply contactor (ST1) should

pull in, passing power to the supply motor

and the blower should start.

Model DG / DGX Pilot Ignition Make-Up Air 25

Page 26

Troubleshooting

Motor Overamps

Air volume too high?

Actual static pressure

lower than design?

Blower rotation correct?

Yes

Motor voltage correct?

Yes

Motor horsepower too low?

Yes

Adjust drives or increase external

static pressure as needed.

(Reference Blower Start-Up – Step #5)

Yes

Adjust drives to reduce blower RPM.

(Reference Blower Start-Up – Step #5)

Reverse blower rotation.

(Reference Blower Start-Up – Step #2)

Provide proper power supply.

(Reference Blower Start-Up – Step #1)

Yes

Resize motor.

Shorted windings in motor?

Yes

Everything is working

properly, consult factory.

Yes

Replace motor.

Model DG / DGX Pilot Ignition Make-Up Air26

Page 27

Troubleshooting

Insufﬁcient Airﬂow

Damper(s) not fully opened?

System static losses too high?

Blower speed too low?

Filters dirty or clogged?

Leaks in ductwork?

Yes

Adjust damper linkage(s), or replace faulty actuator(s).

(Damper actuators may take a few minutes to open)

Yes

Reduce losses by improving ductwork.

Yes

Adjust drives as needed.

(Reference Blower Start-Up – Step #5)

Yes

Clean or replace filters.

(Reference Filters in the Maintenance section).

Yes

Repair leaks.

Belt slipping?

Yes

Everything is working properly,

consult factory.

Too Much Airﬂow

Blower speed too high?

Filters not in place?

Insufﬁcient external static

pressure?

Yes

Replace or tighten belt.

(Reference V-Belt Drives in the Maintenance section)

Yes

Adjust drives as needed.

(Reference Blower Start-Up – Step #5)

Yes

Install filters.

Yes

Everything is working properly,

consult factory.

Increase external static pressure.

Model DG / DGX Pilot Ignition Make-Up Air 27

Page 28

Troubleshooting

Excessive Noise or Vibration

Belts worn or loose?

Sheaves aligned?

Yes

Wheel(s) unbalanced?

Bearings worn or need

lubrication?

Wheel(s) rubbing on inlet?

Yes

Replace worn belts or tighten loose belts.

(Reference V-Belt Drives in the Maintenance section)

Align sheaves.

(Reference V-Belt Drives in the Maintenance section)

Yes

Clean and/or balance wheel(s).

Yes

Replace worn bearings or lubricate bearings as needed.

(Reference Bearings in the Maintenance section)

Yes

Adjust wheel(s) or inlet.

At this time noise and vibration should

be at acceptable levels.

Model DG / DGX Pilot Ignition Make-Up Air28

Page 29

Troubleshooting

Heater Does Not Operate

Does not attempt to light (No visible spark)

24 VAC between

terminals W1 and X?

Yes

115 VAC between

terminals 102 and 101?

Yes

115 VAC between

terminals 103 and 101?

Yes

115 VAC between

terminals 104 and 101?

Yes

115 VAC between

terminals 106 and 101?

Yes

Continuity between

terminals 107 and 108?

Heat Switch (S4) Off

(Turn Heat Switch (S4) On)

Heat Switch Not Wired

(Wire Heat Switch (S4))

Primary Fuses Blown

(Replace Fuses)

Main Transformer (TR4) Defective

(Replace Transformer)

(Optional) Inlet Air Sensor (TS4) Holding

(Adjust TS4 setting. Reference Blower Start-Up – Step #6)

Heat Relay (RH) Defective

(Replace Heat Relay (RH))

The power light on the flame safeguard should

blink approximately every 5 seconds as it

performs a self-diagnostics check.

High Limit (HLC1) Tripped

(Reset/Replace High Limit (HLC1))

(Check on cause of control loss)

(Optional) High/Low Gas Pressure Switch(es)

(PS3 and PS4) Tripped

(Correct gas pressure and reset)

(Reference Direct Gas Start-Up – Steps #2 and #3)

Airflow Switch (PS2) Holding for Proper Airflow

Yes

(Correct airﬂow across burner)

(Reference Direct Gas Start-Up – Step #4)

At this time the heater should attempt to light.

(The pilot light on the ﬂame safeguard should illuminate).

Model DG / DGX Pilot Ignition Make-Up Air 29

Page 30

Troubleshooting

Heater Does Not Operate

Attempts to light, but no pilot (visible spark)

Check inlet gas pressure.

(Direct Gas Start-Up Step #1)

Yes

Gas pressure between the

minimum and maximum shown

on the direct gas label?

Yes

Air in the gas line?

Check for proper airﬂow

(Direct Gas Start-Up Step #4)

Yes

Pressure drop across the burner

between 0.625 and 0.675 in. wg?

Yes

Note: The minimum and maximum gas pressures

for your unit are shown on the direct gas label.

(Reference Direct Gas Start-Up – Step #1)

Correct gas pressure

(Reference Direct Gas Start-Up – Step #1)

Yes

Purge gas line

(Verify gas at the pilot)

Note: The airflow may satisfy the airflow switch,

but may make lighting the pilot difficult. Adjust the

pressure drop across the burner between 0.625 and

0.675 in. wg shown in Direct Gas Start-Up – Step #4

Adjust burner baffles

(Reference Direct Gas Start-Up – Step #4)

Proper spark?

Yes

Check for proper pilot pressure

(Direct Gas Start-Up Step #2)

Pilot pressure correct?

Yes

Crossed flame and spark wires

(Uncross wires and reconnect)

Incorrect spark plug gap

(Set spark plug gap to 0.062 in.)

Defective spark plug

(Replace spark plug)

Note: A high pilot pressure will make lighting more

difficult. Lower the pilot pressure in increments

until the unit lights. Then set the pilot per the

instruction in Direct Gas Start-Up – Step. #2

Adjust the pilot pressure

(Reference Direct Gas Start-Up – Step #2)

With proper airflow, gas pressure and spark,

the unit should light.

If problems remain, consult the factory

Model DG / DGX Pilot Ignition Make-Up Air30

Page 31

Troubleshooting

Heater Does Not Operate

Visible pilot

Measure the ﬂame signal

when there is a visible pilot

Flame signal greater

than 1.25 VDC

Yes

Check for proper airﬂow

(Direct Gas Start-Up Step #4)

Pressure drop across the burner

between 0.625 and 0.675 in. wg?

Yes

Note: The flame signal should be steady and

above 1.25 VDC with a visible pilot.

(Reference Direct Gas Start-Up – Step #9)

Unit is not grounded

(Properly ground unit)

Flame rod is grounding out

(Adjust the ﬂame rod to avoid contact with the burner or the unit)

Cracked porcelain on flame rod

(Replace ﬂame rod)

Note: When the pressure is low or marginal and the unit

begins heating, the air density will change. This can cause

the pressure to drop below the minimum setting. Also, low

airflow can cause the flame to walk out of the burner and

away from the flame sensor, causing the unit to recycle.

Adjust burner baffles

(Reference Direct Gas Start-Up – Step #4)

Check the minimum ﬁring rate

(Direct Gas Start-Up Step #7

Is the minimum ﬁring rate

set correctly?

Yes

Does the ﬂame signal

remain constant?

Yes

Note: Burners greater than 36 inches in length use an

interrupted pilot. The pilot is turned off 10 seconds after

lighting the main burner and the flame safeguard monitors the

main flame instead of the pilot flame. If the minimum fire is

set too low, the flame safeguard may not be able to sense it.

Adjust the minimum firing rate

(Reference Direct Gas Start-Up – Step #7)

If the signal slowly drops off, typically the airflow is too low

(Reference Blower Start-Up – Step #5)

If it suddenly drops to zero, the flame rod is grounding out

(Adjust the ﬂame rod to avoid contact with the burner or the unit)

If the flame signal is above 1.25 VDC and constant,

the main gas valves will remain open until the call

for heat is interrupted or the unit is shut down.

Model DG / DGX Pilot Ignition Make-Up Air 31

Page 32

Troubleshooting

Evaporative Cooler does not Operate (Recirculating pump)

Supply fan must be on for cooler to operate

24 VAC between terminals

Y1 and X

Yes

24 VAC between terminal A2 on

Cooling Relay (RC) and X

Yes

115 VAC between terminals

102 and 101

Yes

115 VAC between terminal

114 and 101

Cool switch (S4) off

(Turn cool switch (S4) on)

Cool switch not wired

(Wire cool switch (S4))

Optional inlet air sensor (TS4) holding

(Adjust TS4 setting. Reference Blower Start-Up – Step #6)

Cooling transformer (TR4) defective

(Replace transformer)

Cooling relay (RC) is not energized

(Check for loose connections)

(Repair or replace relay)

Yes

At this time the evaporative cooler pumps should be on

Water Blows through Evaporative Cooler

Are the headers in place and

located near the entering

air side of the media?

Yes

Water supply greater than

evaporation and bleed-off rate?

Air velocity greater than

speciﬁed?

(Reference Evaporative Cooling Recirculating Start-Up – Step #1)

Yes

Use the main supply valve to reduce the supply of water

Yes

Replace headers and/or move the headers

Reduce the air velocity through the media

(Reference Blower Start-Up – Step #5)

At this time the evaporative cooler should be

operating without water blowing through

Model DG / DGX Pilot Ignition Make-Up Air32

Page 33

Troubleshooting

Water Wizard™ — Improper Water Supply

NOTE

If the water supply is too low, the media will continuously appear dry.

NOTE

If the water supply is too high, the media will be saturated and excessive water will be draining from the sump tank.

NOTE

Some water drainage is desired to keep the media flushed, but it should be minimized to utilize the Water Wizard.

1. Adjust the Manual Supply Valve

Adjust the manual supply valve (refer to Start-Up, Water Wizard™). If the recommended water pressure does not provide enough water, increase the pressure until the desired water supply is achieved. If the recommended water pressure provides too much water, decrease the water pressure until the desired water supply is achieved.

CAUTION

Only proceed to Steps 2 and 3 if Step 1 does not correct the problem.

NOTE

Changing the On Time Factor by (1) will change the water supply by approximately 3%.

IMPORTANT

The Enter key must be pressed to save the new On Time Factor.

4. Exit Program Mode

After 15 seconds of idle time the controller will automatically exit Program Mode

2. Enter Program Mode

Press and hold

the Enter key for three seconds to enter Program Mode. The display will read “Pro” when Program Mode is active.

Program Display

3. Adjust the On Time Factor

While in the Program Menu, use the Up and Down keys to navigate through the menu options until “ont” is displayed.

With “ont” displayed, press the Enter key to access the setting.

With the setting displayed, use the Up and Down keys to adjust the setting as needed.

Increase the factor to increase the water supply or decrease the factor to decrease the water supply.

Press the Enter key to save the new On Time Factor and return to the Program Menu.

On Time Factor Display

Model DG / DGX Pilot Ignition Make-Up Air 33

Page 34

Maintenance - Routine

MOTOR

FAN

MOTOR

CAUTION

Lock-out the gas and the electrical power to the unit before performing any maintenance or service operations to this unit.

V-Belt Drives

V-belt drives must be checked on a regular basis for wear, tension, alignment, and dirt accumulation.

Check the tension by measuring the deﬂection in the belt as shown below.

Check the alignment by using a straight edge across both sheaves as shown below.

IMPORTANT

Premature or frequent belt failures can be caused by improper belt tension, or misaligned sheaves.

• Abnormally high belt tension or drive misalignment will cause excessive bearing loads and may result in failure of the fan and/or motor bearings.

• Abnormally low belt tension will cause squealing on start-up, excessive belt flutter, slippage, and overheated sheaves.

IMPORTANT

Do not pry belts on or off the sheave. Loosen belt tension until belts can be removed by simply lifting the belts off the sheaves.

IMPORTANT

When replacing V-belts on multiple groove drives, all belts should be changed to provide uniform drive loading.

IMPORTANT

Do not install new belts on worn sheaves. If the sheaves have grooves worn in them, they must be replaced before new belts are installed.

Belt Span

Drive Alignment

Deﬂection =

Belt Span

Belt Tension

Wheels

Wheels require little attention when moving clean air. Occasionally oil and dust may accumulate on the wheel causing imbalance. When this occurs the wheel and housing should be cleaned to assure proper operation.

Bearings

The bearings for our fans are carefully selected to match the maximum load and operating conditions of the speciﬁc class, arrangement and fan size. The instructions provided in this manual and those provided by the bearing manufacturer will minimize any bearing problems.

IMPORTANT

Lubricate bearings prior to periods of extended shutdowns or storage and rotate shaft monthly to aid in corrosion prevention. If the fan is stored more than three months, purge the bearings with new grease prior to start-up.

Recommended Bearing Lubrication Schedule

(in months*)

Fan

RPM

250 6 6 6 6 6

500 6 6 6 5 4

750 6 5 4 3 3

1000 5 3 2 1 1

1250 5 3 2 1 1

1500 5 2 1 1 0.5

2000 5 1 1 0.5 0.25

*Suggested initial greasing interval is based on 12 hour per

day operation and 150°F maximum housing temperature. For continuous (24 hour) operation, decrease greasing interval by 50%

• If extended grease lines are present, relubricate while in operation, only without endangering personnel.

• For ball bearings (operating) relubricate until clean grease is seen purging at the seals. Be sure not to unseat the seal by over lubricating.

• For ball bearings (idle) add 1-2 shots of grease up to 2 inch bore size, and 4-5 shots above 2 inch bore sizes with a hand grease gun.

• For roller bearings add 4 shots of grease up to 2 inch bore size, and 8 shots for 2-5 inch bore size with a hand grease gun.

• Adjust relubrication frequency based on condition of purged grease.

• A high quality lithium based grease conforming to NLGI Grade 2 consistency, such as those listed here:

Mobil 532 Mobilux #2

⁄2 - 1 11⁄8 - 11⁄2 15⁄8 - 17⁄8 115⁄16 - 23⁄16 27⁄16 - 3

Bearing Bore Size (inches)

Texaco Multifak #2 Texaco Premium #2

B Shell Alavania #2 Exxon Unirex #2

Snow Accumulation

Clear snow away from roof mounted units. Keep the snow clear of the intake and access doors.

Model DG / DGX Pilot Ignition Make-Up Air34

Page 35

Entering Air

Motors

Motor maintenance is generally limited to cleaning and lubrication (where applicable).

Cleaning should be limited to exterior surfaces only. Removing dust and grease build-up on the motor assures proper motor cooling.

Motors supplied with grease ﬁttings should be greased in accordance with the manufacturer’s recommendations.

IMPORTANT

Do not allow water or solvents to enter the motor or bearings. Motors and bearings should never be sprayed with steam, water or solvents.

IMPORTANT

Greasing motors is only intended when fittings are provided. Many motors are permanently lubricated, requiring no additional lubrication.

Filters

Filter maintenance is generally limited to cleaning and replacement.

If aluminum mesh ﬁlters are installed, they can be washed in warm soapy water.

An adhesive spray can be added to aluminum mesh ﬁlters to increase their efﬁciency.

If disposable ﬁlters are installed, they can be checked by holding up to a light source. If light cannot pass through the ﬁlter, it should be replaced.

IMPORTANT

When reinstalling filters, be sure to install them with the airflow in the correct direction. An airflow direction arrow is located on the side of the filters.

IMPORTANT

Replacement filters should be from the same manufacturer and the same size as the original filters provided with the unit.

Chilled Water Coils

Test the circulating ﬂuid for sediment, corrosive products and biological contaminants. Make the necessary corrective measures.

Maintain adequate ﬂuid velocities and proper ﬁltering of the ﬂuid.

If automatic air vents are not utilized, periodic venting of the coil is recommended to remove accumulated air.

Evaporative Coolers

The media should be periodically brushed lightly with a soft bristle brush in an up and down motion while ﬂushing with water. This aids in reducing the amount of mineral build-up.

For large amounts of mineral build-up, clean or replace the media and increase the water bleed-off or ﬂush rate.

The cooling media has a useful life of 3 to 5 years depending on the water quality and the bleed-off or ﬂush rate.

IMPORTANT

When reinstalling the evaporative media, make sure that it is installed correctly. Reference the drawing shown below.

IMPORTANT

Replacement media should be from the same manufacturer and be the same size as the original media provided with the unit.

45º

Leaving Air

15º

Media Orientation

Cooling Coils

WARNING

Repair and replacement of the coil and the connecting piping, valves, etc., should be performed by a qualified individual.

Inspect the coil for signs of corrosion and/or leaks. Repair any leaks as required.

Inspect the coil’s surface for foreign material. If the coil surface needs cleaning, clean the coil from the leaving air-side so that foreign material will be washed out of the coil rather than pushed farther in.

Inspect and clean the drain pan to prevent the growth of algae and other organisms.

IMPORTANT

Be sure to read and follow the manufacturer’s recommendations before using any cleaning fluid.

CAUTION

Caution should be used to avoid injury when venting the coil. High pressure and/or high temperature fluids can cause serious injuries.

Model DG / DGX Pilot Ignition Make-Up Air 35

Page 36

Maintenance - Fall

Start-Up

Repeat the Blower Start-Up Step #5 and Direct Gas Start-Up Steps #1, #2 and #3. This will ensure that the gas and air are set properly before the heating season begins and should lead to trouble free operation all winter.

High Limit

The high limit switch may have tripped over the summer; it should be checked and reset if necessary.

Burner

Inspect the burner for accumulation of scales on both the upstream and downstream sides of the mixing plates. Any scaling or foreign material should be removed with a wire brush.

Visually check that all holes in the mixing plates are clear. If any burner ports are plugged (even partially), clear them with a piece of wire or another appropriate tool.

Replace or tighten any loose or missing fasteners on the mixing plates. Always use zinc plated or stainless steel fasteners.

Inspect and clean the ﬂame and spark rod. Occasional replacement of the ﬂame rod and spark rod may be necessary to ensure optimum unit performance.

WARNING

Do not enlarge burner ports when clearing a blockage, performance could be affected.

NOTE

Flame rods can last many years, but because of thermal expansion of the porcelain, flame rods can fail over time.

Gas Train

The gas connections, joints and valves should be checked annually for tightness. Apply a soap and water solution or other approved leak test solution to all piping; watch for bubbling which indicates a leak. Other leak testing methods can be used.

Evaporative Coolers

The water should be shut off and all the lines drained when the outside temperature drops below 45ºF.

Remove drain plugs for the winter.

Clean all interior parts of any mineral deposits or foreign materials that may have built-up during the cooling season.

Replace any worn or non-functioning parts.

Winterizing Chilled Water Coils

During the winter, chilled water coils need to be protected against freezing. Manufacturer recommends protecting the coils by either blowing-out the coils or by ﬂushing the coils.

Blowing-Out Coils

1. Close valves on the supply and return lines.

2. Open drain valves and/or drain plug. Remove vent plug to allow coil to drain faster.

3. After coil is fully drained, connect a blower to the caps. Do not connect the blower to the air vent or drain plug.

4. Close the vent plug on the header that the blower is connected to. Open the drain valve or cap on the other header.

5. Turn on blower for 30 minutes. Place mirror at discharge. If the mirror fogs up, repeat procedure until no fog appears on the mirror.

6. After drying the coil, wait a few minutes then repeat Step #5.

7. Leave drains open and do not install plugs until beginning of cooling season.

Flushing Coils

Manufacturer recommends the use of inhibited glycol (such as propylene or ethylene) to ﬂush water coils to protect against freezing. Additionally, the use of inhibited glycol provides corrosion protection.

The table below indicates the percentage of glycol required to prevent freezing in a coil at a given outdoor air freeze point. Completely ﬁll coil with solution. Drain coil. Residual glycol ﬂuid per these concentrations can be left in the coil without concern of freezing. Recovered ﬂuid can be used to ﬂush other coils.

Percent of

Ethylene

Glycol

by Volume

0 32 0 0 32 0

10 25 -4 10 26 -3

20 16 -9 20 19 -7

30 3 -16 30 8 -13

40 -13 -25 40 -7 -22

50 -34 -37 50 -28 -33

60 -55 -48 60 -60 -51

Freeze Point

ºF ºC ºF ºC

Percent of

Propylene

Glycol

by Volume

Freeze Point

Model DG / DGX Pilot Ignition Make-Up Air36

Page 37

Reference

Typical Gas Train Layout with Modulating Valve (Pilot Ignition)

Burner Differential

Pressure Sensor

High Gas Pressure

Switch (optional)

Burner Gas

Pressure Test Port

Airﬂow

Burner Manual

Shut-Off Valve

Modulating

Valve

Pilot Solenoid

Pilot Gas Pressure

Test Port

Low Gas Pressure

Switch (optional)

Safety Shut-Off Valves Regulator

Pilot Regulator

Manual Pilot

Shut-Off Valve

Typical Gas Train Layout with Modulating Regulator (Pilot Ignition)

Burner Differential

Pressure Sensor

Airﬂow

High Gas Pressure

Switch (optional)

Burner Gas

Pressure Test Port

Pilot Gas Pressure

Test Port

Modulating/Regulator

Valve

Burner Manual

Shut-Off Valve

Safety Shut-Off Valves

Pilot Solenoid

Low Gas Pressure

Switch (optional)

Pilot Regulator

Manual Pilot

Shut-Off Valve

Model DG / DGX Pilot Ignition Make-Up Air 37

Page 38

Reference

Typical Control Center Layout

13 23

1. Supply Motor Starter — 24 volt magnetic contacts for starting supply motor.

2. Supply Overload — provides electronic overload protection to supply motor.

3. Low Voltage Transformer — provides low voltage to fan/heat/cooling enable controls.

4. Control Terminal Block — provides wiring access to controls.

5. Fan Relay — allows power to pass to energize motor starter.

6. High Voltage Enclosure — provides protection from high voltage circuits.

7. Auxiliary Contact (optional) — provides one normally closed and one normally open contact for other equipment.

8. Exhaust Motor Starter (optional) — 24 Volt magnetic contacts for starting exhaust motor.

9. Exhaust Overload (optional) — provides electronic overload protection to exhaust motor.

10. Transformer Fuse (optional) — provides proper fusing for cooling transformer.

11. Terminal Block — provides wiring access to high voltage circuits.

12. Exhaust Fuses (optional) — provides proper fusing for exhaust fan motor(s).

13. Dirty Filter Switch (optional) — monitors ﬁlter pressure drop, turns on indicating light when pressure drop is above ﬁeld-adjustable set point.

14. Inlet Air Sensor (optional) — outdoor air stat that automatically controls the heating and/or cooling based on outdoor air temperature.

15. Remote Temperature Selector (optional) — allows for remote temperature set point.

16. Heat Relay — allows power to pass to heating controls.

17. Heating Terminal Block — provides wiring access to heating controls.

18. Flame Safeguard — monitors ﬂame, shuts down unit when unsafe conditions are detected.

27 29

1 7 8

2 9

19. High Limit — prevents unit from discharging air above a set point.

20. Low Voltage Transformer — reduces voltage to Maxitrol system.

21. Ampliﬁer — controls modulating valve, assures the desired temperature is delivered.

22. Spark Generator — provides spark to ignite the burner.

23. Transformer — provides voltage to Flame Safeguard and optional evaporative cooling pump.

24. Cooling Relay (optional) — allows power to pass to cooling controls.

25. Cooling Terminal Block (optional) — provides wiring access to cooling controls.

26. Low Voltage Transformer (optional) — reduces voltage to cooling controls.

27. Reset Timer (optional) — resets cooling system to run a time interval.

28. Auto Drain Relay (optional) — assures supply pump does not operate during drain interval. Allows pump to operate in cooling mode.

29. Cooling Timer (optional) — allows for automatic draining of the evaporative cooling system based on time schedule.

Dirty Filter Switch

Common

Normally Open

Normally Closed

Negative pressure after the filters

Positive pressure before the filters

CCW to decrease trip point CW to increase trip point

Model DG / DGX Pilot Ignition Make-Up Air38

Page 39

Reference

Start-Up Checklist

Unit Model Number_______________________________ (e.g. DGX-120-H32-DB)

Unit Serial Number _______________________________ (e.g. 10111000)

Start-Up Date ____________________________________

Start-Up Personnel Name _________________________

Start-Up Company _______________________________

Phone Number ___________________________________

Pre Start-Up Checklist – check boxes as items

are completed. oCheck tightness of all factory wiring connections oVerify control wiring wire gauge oHand-rotate blower to verify free rotation oVerify supply voltage to the main disconnect oVerify the supply gas pressure oVerify remote controls wiring

Start-Up Blower Checklist – refer to Blower

Start-Up section for further detail.

oCheck line voltage L1-L2 ________

L2-L3 ________ L1-L3 ________

o Check blower rotation

oCheck for vibration oSupply fan RPM _______ RPM oMotor nameplate amps _______ Amps oActual motor amps _______ Amps oActual CFM delivered _______ CFM

Start-Up Direct Gas – refer to Direct Gas Start-Up

section for further detail.

oCheck supply gas pressure

________ Maximum

________ Minimum

________ Actual

oCheck Pilot Gas Pressure

________ Actual Setting Typical 3.0 in. wg

oSet optional High Gas Pressure Switch

________ Actual Setting Typical 8.0 in. wg

oSet optional Low Gas Pressure Switch

________ Actual Setting Typical 3.0 in. wg

oSet Burner Pressure Differential

________ Actual Setting Typical 0.65 in. wg

oSet the maximum firing rate

________ temp rise

oSet the minimum firing rate

________ check

oSet the unit’s operating temperature

________ ºF

Optional Accessories – refer to Blower Start-Up

section, Step #6 for further detail. o Heating Inlet Air Sensor _______ Actual Setting Typical setting 60º-70ºF

o Cooling Inlet Air Sensor _______ Actual Setting Typical setting 75ºF

o Building Freeze Protection _______ Actual Setting Typical setting 5 minutes; 45ºF

o Dirty Filter Gauge _______ Actual Setting Typical setting varies

Model DG / DGX Pilot Ignition Make-Up Air 39

Page 40

Maintenance Log

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Date __________________ Time _____________ AM/PM

Notes:___________________________________________

_________________________________________________

Our Commitment

As a result of our commitment to continuous improvement, Greenheck reserves the right to change speciﬁcations without notice.

Speciﬁc Greenheck product warranties are located on greenheck.com within the product area tabs and in the Library under Warranties.

Greenheck catalog Direct Gas-Fired Make-Up Air, Models DGK, DG and DGX, provides additional information describing the equipment, fan performance, available accessories, and speciﬁcation data.

Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com

AMCA Publication 410-96, Safety Practices for Users and Installers of Industrial and Commercial Fans, provides additional safety information. This publication can be obtained from AMCA International, Inc. at www.amca.or