Larkin XDGK-109-H15 Installation Manual
Make-Up Air Unit
Installation, Operation, and Maintenance Manual
Part # 474614
Model XDGK
FOR YOUR SAFETY
If you smell gas
1. Open windows
2. Don’t touch electrical switches
3. Extinguish any open flames
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!
Disconnect all electrical power to the fan and
secure to the “OFF” position prior to inspection
or servicing. Failure to comply with this safety
precaution could result in serious injury or death.
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.
IMPORTANT!
All factory provided lifting lugs must be used when lifting any unit. Failure to comply with this safety
precaution could result in property damage, serious injury or death.
Report any damaged equipment to the shipper immediately!
All units are shipped on a skid or packaged to minimize damage during shipment. The transporting carrier
has the responsibility of delivering all items in their original condition as received from Larkin. The individual
receiving the equipment is responsible for inspecting the unit for obvious or hidden damage, recording any
damage on the bill of lading before acceptance and filing a claim (if required) with the final carrier. Some
accessory items are stored inside the unit during shipping. Care must be taken during installation to prevent
damage to units.
Please read and save these instructions for future reference. Read carefully before attempting to assemble, install, operate
or maintain the unit. Failure to comply with instruction could result in personal injury and/or property damage!
Upon receiving unit, check for any damage that may have occurred during transit and report it immediately to the shipper.
Also check to see that all accessory items are accounted for.
December 2008
Table of Contents
Installation
Clearances to Combustibles &
Services Clearances.................. 2
Unit — Arrangement DB/HZ .............. 3
Hinged Weatherhood — XDGK-H25........ 4
Electrical Wiring........................ 5
Direct Gas Piping .....................6-7
Maintenance
Routine............................19-20
Fall ................................. 20
Start-up Check List .................... 21
Maintenance Log...................... 21
Reference
Start-Up
Blower ..............................8-9
Direct Gas .........................10-13
Gas Train Layout XDGK-H15 - <400 MBH .. 22
Control Center Layout XDGK-H15 ........ 22
Gas Train Layout XDGK-H25 <800MBH.... 23
Control Center Layout XDGK-H25 ........ 23
Troubleshooting
Blower .............................. 14
Heater, General ....................... 14
Heater, XDGK-H15 .................... 15
Heater, XDGK-H25 ..................16-17
Excessive Noise or Vibration ............ 18
STORAGE
When a unit is not going to be in service for an extended period of time, certain procedures should be followed
to keep the unit in proper operating condition:
• Plug all piping
• Rotate fan wheel monthly.
• Energize fan motor once every three months
• Store belts flat to keep them from warping and stretching
• Store unit in location without vibration
• Cover unit with tarp to protect from dirt and moisture
NOTE!
Do not cover unit with a black tarp, this would
promote condensation.
NOTE!
Improper storage which results in damage to the
unit will void the warranty.
Clearance to Combustibles / Service Clearances
Floor Top Sides Ends
Insulated Units 0 inches (0 mm) 0 inches (0 mm) 0 inches (0 mm) 0 inches (0 mm)
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 42 inches (1066.8 mm) on the controls side of the unit
Clearances for component removal may be greater than the service clearances listed.
2
Installation - Arrangement DB / HZ
SUPPLY
DUCT
B
23 in.
(584 mm)
A
23 in.
(584 mm)
27.5 in.
(699 mm)
Curb Length Actual
27.5 in.
(699 mm)
Curb
Width
Actual
Recommended Roof Opening
(center in curb)
Center Supply Duct
in Roof Opening
Airflow
D
Step 1 Install Curb or Equipment Support(s)
Roof Curb
Position curb/equipment support(s) on the roof (reference
the CAPS submittal for placement of curb/equipment
support(s) in relation to the unit). Verify that unit supports
are level, shim if necessary. Attach curb to roof and flash
into place. Attach the equipment support(s) to the roof,
remove metal cover, flash to wooden nailer and reinstall
cover. Refer to roof curb detail.
NOTE!
Roof Curb Detail
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 support for the ductwork.
Step 2 Install Ductwork
Good duct practices should be followed for all ductwork. All
ductwork should be installed in accordance with SMACNA
and AMCA guidelines, NFPA 96 and all local codes.
Supply
Model
Duct Size
(A x B)
Curb to Center
Supply Duct (C)
XDGK-109-H15 13 x 14
XDGK-112-H15 16 x 18
XDGK-115-H25 18 x 22
XDGK-118-H25 22 x 24
All dimensions shown are in inches.
Distance from
right side of
14½ 27½ x 27½XDGK-110-H15 14 x 16
20 45½ x 45½
Curb
Dimension
Actual
(D x E)
Step 3 Apply Sealant
Apply an appropriate sealant around the perimeter
of the curb to isolate fan vibration and prevent water
penetration.
Airflow
Note: Roof openings can be as large as the curb size minus
3-1/2 in. or as small as the duct size plus 1/2 in.
Supply Duct width (B) is centered over Curb width (E).
Supply Length (A) may not be centered over Curb Length (D).
Roof Opening Details
Supply Air Ductwork
(Arrangement DB only)
A
SUPPLY
DUCT
E
B
C
Sealant
Step 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). Prior to disconnecting from
crane, adjust support legs on the intake of the unit.
Use self-tapping sheet metal screws to fasten the unit
to the curb/equipment support(s).
NOTE!
The use of all lifting lugs and a set of spreader bars
is mandatory when lifting the unit.
Ductwork and Sealant Application
Placement of Unit
3
Installation - Hinged Weatherhood
Tools Required:
• 5/6-inch nut runner
• Caulk gun with weatherproof sealant
The XDGK-H25 weatherhood is folded-up and shipped
on top of the unit. To install:
Step 1 Rotate sides up on weatherhood
a. Run two sheet metal screws where shown to hold
side in rotated position. Pilot holes are provided.
b. Rotate opposite side up on weatherhood and
repeat step 1A.
Step 2 Rotate assembly forward
Step 3 Fasten weatherhood sides to the
unit
Screw the sides of the weatherhood to the unit. Pilot
holes are provided.
Step 4 Caulk Seams
Caulk all seams with an appropriate weatherproof
sealant.
Step 5 Install filter tracks
Install the two center filter tracks which were shipped
inside the unit.
a. Slide the tabbed end of each track into the slot
at the bottom of the intake opening on the unit
housing.
b. Rotate the tracks up to the top outer edge of the
weatherhood such that the weatherhood edge
slides into the slot in the tracks.
Step 6 Insert filters
Insert the factory provided aluminum mesh intake
filter(s) into the track located in the face of the
weatherhood. Filters slide in from the top. Be sure
the filters are properly orientated (an airflow direction
arrow is located on the side of the filters). Insert the
retaining screws on the sides of the weatherhood,
three (3) per side, to keep the filters in place.
Rotate sides up, install screws.
Rotate Assembly forward.
See Step 3.
Center filter track.
(2 pieces)
Slot in unit.
4
Installation - Electrical Wiring
IMPORTANT!
Before connecting power to the unit, read and understand the following instructions and wiring diagrams.
Complete wiring diagrams are attached to the inside of the control center door(s).
IMPORTANT!
All wiring should be done in accordance with the
latest edition of the National Electrical Code ANSI/
NFPA-70 and any local codes that may apply. In
Canada, wiring should be done in accordance with
the Canadian Electrical Code.
IMPORTANT!
The equipment must be properly grounded.
Any wiring running through the unit in the airstream
must be protected by metal conduit, metal clad
cable or raceways.
CAUTION!
If replacement wire is required, it must have a
temperature rating of at least 105ºC, except for
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. Larkin is not responsible for any
damage to, or failure of the unit caused by incorrect final wiring.
Step 1 Determine the Size of the Main
Power Lines
The unit nameplate states the voltage and the unit’s
total MCA. The main power lines to the unit should be
sized accordingly. The nameplate is located on the
outside of the unit on the control panel side.
Unit’s MCA
VOLTS HZ PH
Voltage, Hertz,
and Phase
Step 2 Provide the Opening(s) for the
Electrical Connections
Electrical openings vary by unit size and arrangement
and are field supplied.
SUP HP
MCA
Electrical Nameplate
EXH HP
MOP
Step 3 Connect the Main Power
Connect the main power lines to the disconnect switch and main grounding lug(s). Torque field connections
to 20 in-lbs. See the control center layout in the reference section for main disconnect and grounding lug(s)
locations.
5
Installation - 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!
If pressure testing in excess of 1/2 psig
(3.5 kPa), the heater and manual shutoff valve must
be disconnected from the supply gas line.
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.
WARNING!
If pressure testing at or below 1/2 psig (3.5 kPa),
the heater must be isolated from the supply gas line
by closing its manual shutoff valve.
IMPORTANT!
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.
Step 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.
Maximum gas
pressure
Minimum gas
pressure for
maximum output
Type of Gas
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
AGAINST
SCFM “ W.C.
CONTE
“ W.C.
“ W.C.
“ W.C.
MIN BTU/HR
BTU/H MIN
MIN GAS PRESSURE
FOR MAX OUTPUT
PRESSION DE GAZ MIN
POUR PUISSANCE MAX
MAX GAS
PRESSURE
PRESSION DE GAZ
MAX
MAX BURNER
PRESSURE DROP
PERTE MAX DE PRESSION
DANS LE BRULEUR
DESIGN DT
DT NORMALE
EXTERNAL STATIC PRESSURE
PRESSION STATIQUE EXTERIEURE
“ W.C.
“ W.C.
PSI
F
Direct Gas Nameplate
6
Installation - Direct Gas Piping
Step 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.
Step 3 Connect the Supply Gas Line
A manual shut off valve (gas cock), 1/8 in. (3.175 mm)
plugged test port and 6 in. (152.4 mm) 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 Larkin.
This assembly must be installed in the inlet of the gas
train. When installed, the manual shut off valve (gas
cock) will be outside of the unit and will shutoff all gas
to the unit.
NOTE!
The regulator located inside the unit is used to
adjust the unit’s maximum output temperature.
Gas Cock
Ground Joint Union
From
Gas
Supply
1/8 in. Plugged Tap
6 in. Trap
Supply Gas Line
To
Controls
Step 4 Test the System for Leaks
Check both the supply lines and the factory piping for
leaks. Apply a soap and water solution to all piping
WARNING!
NEVER test for a gas leak with an open flame.
and watch for bubbling which indicates a leak.
WARNING!
The factory piping has been checked for leaks, but should be rechecked due to shipping and installation.
7
Start-Up - Blower
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. Remove any shipping
fasteners from the blower vibration isolators.
WARNING!
Check the housing, blower, weatherhood, and ductwork for foreign objects and debris before the blower is run.
SPECIAL EQUIPMENT REQUIRED
Below is a list of special tools that are required. A recommended model is shown, but equivalent
products may be used.
Description Manufacturer-Model Phone Website
Voltage Meter Fluke-177 1-800-44-FLUKE www.fluke.com
Amperage Meter Fluke-177 1-800-44-FLUKE www.fluke.com
Thermometer Fluke-50 1-800-44-FLUKE www.fluke.com
Micro Amp Meter Fluke-116 1-800-44-FLUKE www.fluke.com
U-Tube manometer Dwyer-Slack Tube 1-219-897-8000 www.dwyer-inst.com
Tachometer Monarch-Pocket Tach 100 1-800-999-3390 www.monarchinstrument.com
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.
Step 1 Check the Voltage
Before starting the unit, compare the supplied voltage, hertz, and phase with the unit and motor’s nameplate
information. The nameplate is located on the outside of the unit on the control panel side.
VOLTS HZ PH
EXH HP
MOP
Voltage, Hertz,
and Phase
SUP HP
MCA
Electrical Nameplate
Step 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.
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.
Rotation
Blower
Housing
Blower Rotation
8
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