Montague DG Installation Manual
Part # 464044
®
**WARNING**
Disconnect and secure all electrical power to the
“OFF” position prior to inspection or servicing.
Failure to comply with this safety precaution
could result in serious injury or death.
**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.
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
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 Greenheck. 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.
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.
MaintenanceTroubleshooting
OperationStart-UpInstallation
Reference
GREENHEAT™ SYSTEM for INDUSTRIAL
SPACE HEATING -
MODEL DG / DGX
Installation, Operation and Maintenance Manual
TABLE OF CONTENTS
Installation
Unit - Indoor . . . . . . . . . . . . . . . . . . . . . .I-1
Unit - Arrangement DB/HZ . . . . . . . . . . .I-2
Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . .I-3
Remote Panel (TSCP) . . . . . . . . . . . . . . .I-3
Electrical Wiring . . . . . . . . . . . . . . . . . . . .I-4
Direct Gas Piping . . . . . . . . . . . . . . . . . . .I-5
I
Start-Up
Blower . . . . . . . . . . . . . . . . . . . . . . . . . .S-1
Direct Gas . . . . . . . . . . . . . . . . . . . . . . . .S-3
S
Operation
Electrical without 7 Day Timer . . . . . . .O-1
Electrical with 7 Day Timer . . . . . . . . . .O-2
O
Troubleshooting
Blower . . . . . . . . . . . . . . . . . . . . . . . . . . .T-1
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . .T-2
Vibration . . . . . . . . . . . . . . . . . . . . . . . . .T-5
T
Reference
Gas Train Layout 400-800 MBH . . . . . .R-1
Gas Train Layout > 800 MBH . . . . . . . .R-2
Control Center Layout . . . . . . . . . . . . . .R-3
Maintenance
Routine . . . . . . . . . . . . . . . . . . . . . . . . .M-1
Fall . . . . . . . . . . . . . . . . . . . . . . . . . .M-3
Log . . . . . . . . . . . . . . . . . . . . . . . . . .M-4
M
R
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 and purge bearings once every one to three months (depending on environment).
• 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
• After storage period, purge grease before putting fan into service
NOTE!
Do not cover unit with a black tarp, as this will
promote condensation.
NOTE!
Improper storage which results in damage to the
unit will void the warranty.
Installation - Indoor
I - 1
Step 1 Install Hangers
Install threaded hangers from ceiling supports. When locating hangers, allow enough room to open access
panel(s). Be sure to allow for the recommended diffuser height outlined in the diffuser installation instructions.
Two nuts must be used on the end of each threaded hanger. Ceiling supports are supplied by others. Refer to
figure #1.
Step 2 Install Unit
Using sheet metal screws, attach the
weatherhood/thru-wall/filter section to the
blower/burner section. The flange on the
weatherhood/thru-wall/filter section should overlap
the flange on the blower/burner section.
Raise the assembled unit into place.
Using two nuts per hanger, fasten the unit supports to
the hangers under the unit. Appropriate unit supports,
such as the optional Greenheck hanging bracket kit
or c-channel and angle iron (supplied by others)
should be used. Refer to figure #1.
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.
Step 3 Seal Wall Opening
Apply sealant around the perimeter of the
weatherhood to prevent water penetration and drafts
into the building. Refer to figure #2.
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.
Sealant
Unit
Supports
Ceiling
Supports
Hangers
Diffuser
Figure 1. Indoor Mounting
Figure 2. Sealing Wall Opening
Step 1 Install Curb
Position curb on the roof (reference the CAPS
submittal for placement of curb in relation to the unit).
Verify that the curb is level, shim if necessary. Attach
curb to roof and flash into place. Refer to figure #3.
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. Reference the CAPS submittal for ductwork sizes.
Be sure to allow for the recommended diffuser height outlined in the diffuser installation instructions.
Apply an appropriate sealant around the perimeter of the curb and duct adapter to isolate fan vibration and
prevent water penetration. Refer to figure #4.
Step 3 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. Use self-tapping sheet metal screws to fasten
the unit to the curb. See figure #5.
Step 4 Assemble and Install
Weatherhood
The weatherhood can now be assembled and
attached to the unit. Detailed assembly instructions
can be found with the weatherhood. Once the
weatherhood is installed, use an appropriate sealant
to seal the seam between the weatherhood and the
unit.
Supply Air Duct Work
(Arrangement DB only)
Sealant
Installation - Arrangement DB / HZ
I - 2
NOTE!
The use of all lifting lugs and a set of spreader
bars is mandatory when lifting the unit.
NOTE!
The use of a duct adapter is recommended on a
downblast (DB) arrangement to align the
ductwork with the supply unit and is only a guide
and is not to be used to support the ductwork.
er
Equipment
Support
Roof Curb
Figure 3. Roof Curb
Figure 4. Ductwork
Figure 5. Placing Unit
Figure 6. Complete Rooftop Installation
Installation - Diffuser and Remote Panel (TSCP)
I - 3
IMPORTANT!
The location of the discharge diffuser and the TSCP are critical for optimum performance of the
Greenheat space heat system.
IMPORTANT!
DO NOT install the TSCP in the blast area of the space heater or near any other source of heat.
Airflow Diffuser Height (ft.)
(cfm) Minimum Recommended Maximum
4,000 15 20 25
6,000 15 20 25
8,000 20 20-25 30
10,000 20 25-30 35
13,000 25 30-35 40
Step 1 Install Diffuser
Using self-tapping screws, attach diffuser to the
ductwork or unit. Be sure to maintain the
recommended floor to diffuser height. Refer to the
chart to the right for the recommended diffuser
height. See figures #7 and #8.
Step 2 Install TSCP
When installing the TSCP, the locataion is critical to performance of the Greenheat space heat system. The
TSCP should be installed 5-6 feet above the floor. It is recommended that the TSCP be installed on an outside
wall, in the space, and close to any source of infiltration such as dock doors. DO NOT install the TSCP in the
blast area of the heater or near any other source of heat. Refer to figure #9.
h
h
Blast Area
Recommended
TSCP Location
Indoor Mounted
Unit
Rooftop Unit
Figure 7. Thru-wall Diffuser Height Figure 8. Rooftop Diffuser Height
Figure 9. TSCP Location
I - 4
Step 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.
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.
Installation - Electrical Wiring
CAUTION!
If replacement wire is required, it must have a
temperature rating of at least 105°C, except for
energy cut-off or sensor lead wire which must be
rated to 150°C.
CAUTION!
Any wiring deviations may result in personal injury or property damage. Greenheck is not responsible
for any damage to, or failure of the unit caused by incorrect final wiring.
DANGER!
High voltage electrical input is needed for this
equipment. This work should be performed by a
qualified electrician.
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.
Step 1 Determine the Size of the Main
Power Lines
The unit’s nameplate states the voltage and the unit’s
total amps. The main power lines to the unit should
be sized accordingly. See figure #10.
Step 2 Provide the Opening(s) for the
Electrical Connections
Electrical openings vary by unit size and arrangement
and are field supplied.
MODEL
VOLTS
SUP HP
MARK
AMPS
HTZ PH
S/N
EXH HP
Voltage, Hertz,
and Phase
Unit’s Total
Amps
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!
Greenheck’s standard control voltage is 24 VAC.
Control wire resistance should not exceed 0.75 ohms (approximately 285 feet total length for 14 gauge
wire; 455 feet total length for 12 gauge wire). If the resistance exceeds 0.75 ohms, an industrial-style,
plug-in relay should be wired in place of the remote switch. The relay must be rated for at least
5 amps and have a 24 VAC coil. Failure to comply with these guidelines may cause motor starters to
chatter or not pull in, resulting in contactor failures and/or motor failures.
Step 5 Wire the Remote Panel (TSCP)
Reference the ladder diagram on the inside of the
control center door for correct wiring of the TSCP.
NOTE!
TSCP has number-to-number wiring to the
control center in the unit.
Figure 10. Electrical Nameplate
Installation - Direct Gas Piping
Step 1 Determine the Supply Gas Requirements
The unit’s direct gas nameplate states the requirements for the gas being supplied to the unit. See figure #11.
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.
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!
All piping should be clean and free of any foreign
matter. Foreign material entering the gas train
can damage the valves, regulators and burner.
“W.C.
“W.C.
“W.C.
F
PSI
“W.C.
“W.C.
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
MIN BTU/HR
BTU/H MIN
MIN GAS PRESSURE
FOR MAX OUTPUT
PRESSION DE GAZ MIN
POUR PUISSANCE MAX
MAX BURNER
PRESSURE DROP
PERTE MAX DE PRESSION
DANS LE BRULEUR
MAX GAS
PRESSURE
PRESSION DE GAZ
MAX
DESIGN ∆T
∆T NORMALE
EQUIPPED FOR
CONCU POUR
SCFM
“W.C.
EXTERNAL STATIC PRESSURE
PRESSION STATIQUE EXTERIEURE
AGAINST
CONTE
Minimum and
maximum gas
pressures
Minimum gas
pressure for
maximum output
Type of Gas
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.
I - 5
Figure 11. Direct Gas Nameplate
Installation - Direct Gas Piping
I - 6
From
Gas
Supply
Gas Cock
1/8 in. Plugged Tap
6 in. Trap
Ground Joint Union
Step 3 Connect the Supply Gas Line
A manual shut off valve (gas cock), 1/8 inch plugged
test port and 6 inch drip leg must be installed prior to
the gas train (see figure #12). The valve and the test
port must be accessible for the connection of a test
gauge. Supply gas connections must be made by a
qualified installer and are not furnished by Greenheck
Step 2 Install Additional Regulator if
Required
When the supply gas pressure exceeds the maximum
gas pressure shown on the direct gas nameplate (see
figure #11), 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 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. Refer
to figure #13.
Step 5 Test the System for Leaks
Check both the supply lines and the factory piping for
leaks. Apply a soap and water solution to all piping
and watch for bubbling which indicates a leak.
WARNING!
The factory piping has been checked for leaks, but should be rechecked due to shipping and
installation.
WARNING!
NEVER test for a gas leak with an open flame.
NOTE!
The regulator located inside the unit is used to
adjust the unit’s maximum output temperature.
NOTE!
Reference the National Fuel Gas Code for
additional vent line requirements.
Safety Shut-off
Valves
Vent Line
Solenoid
To Burner
Vent Line
To Outdoors
From Supply
Space Heat Unit
Figure 12. Supply Gas Line
Figure 13. Vent Line
Start-Up - Blower
S - 1
MODEL
VOLTS
SUP HP
MARK
AMPS
Hz PH
S/N
EXH HP
Voltage, Hertz,
and Phase
Step 1 Check the Voltage
Before starting the unit, compare the supplied voltage, hertz, and phase with the unit and motor’s nameplate
information. See figure #14.
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 or reference figure #15.
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.
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-23 1-800-44-FLUKE www.fluke.com
Amperage Meter Fluke-23 1-800-44-FLUKE www.fluke.com
Thermometer Fluke-50 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.monarchinstruments.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.
WARNING!
Check the housing, blower, weatherhood, filter section and ductwork for foreign objects and debris
before the blower is run.
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’s vibration isolators.
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.
Figure 14. Electrical Nameplate
Figure 15. Blower Rotation
Rotation
Blower
Housing
Start-Up - Blower
S - 2
Step 4 Motor Check
Measure the motor voltage, amps and RPM, and compare to the specifications on the motor’s nameplate.
Step 5 Air Volume Measurement and
Check
Measure the unit’s air volume (CFM) and compare it
with its rated air volume. If the air volume is off, adjust
the fan RPM by changing the drive.
Step 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.
• Building Freeze Protection (typical setting: 5 min at 45ºF)
• Dirty Filter Gauge (typical setting: settings vary greatly for each unit)
NOTE!
The most accurate way to measure the air
volume is by using a pilot 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.
Step 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.
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