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Greenheck DGX Installation, Operation And Maintenance Manual
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Greenheck DGX Installation, Operation And Maintenance Manual

Greenheck DGX Installation, Operation And Maintenance Manual

Make-up air unit
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MODEL DG / DGX (Direct Spark)
Make-Up Air Unit
Installation, Operation and Maintenance Manual
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
**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.
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 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.
The use and storage of gasoline or other
flammable vapors and liquids in open
containers in the vicinity of this appliance
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
**IMPORTANT**
®
FOR YOUR SAFETY
is hazardous.
**WARNING**
equipment.
Part # 464043

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Summary of Contents for Greenheck DGX

  • Page 1 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.
  • Page 2 TABLE OF CONTENTS Installation Troubleshooting Unit - Indoor ..... . .3 Blower ......32 Unit - Arrangement DB/HZ .
  • Page 3 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 Hangers or c-channel and angle iron (supplied by others) Unit should be used.
  • Page 4 Installation - Arrangement DB / HZ Step 1 Install Curb and/or Equipment Roof Curb Support(s) Position curb/equipment support(s) on the roof Metal Cover (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. Equipment Support Attach curb to roof and flash into place.
  • Page 5 Installation - Roof Mounted Unit Arrangement DBC Step 1 Install Curb/Equipment Roof Curb Support(s) Position curb/equipment support(s) on the roof Metal Cover (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 Equipment Support necessary.
  • Page 6 Installing the exhaust fan prior to the supply unit will allow for easier installation of options. Step 6 Install Exhaust Options Install optional Greenheck hinge kit with restraining cables and grease trap with drain connection. Figure 11. Exhaust Fan Step 7 Install Supply Unit...
  • Page 7 Installation - Evaporative Cooler (Optional) NOTE! Small evaporative coolers ship attached to the base unit and require no additional mounting. Metal Cover Step 1 Locate Equipment Support(s) Position equipment support(s) on the roof (reference the CAPS submittal for placement of equipment Equipment support(s) in relation to the unit).
  • Page 8 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. IMPORTANT! Greenheck’s standard control voltage is 24 VAC.
  • Page 9 ALARM performed before the blower is run. DIRTY FILTERS (OPTIONAL) Two Position Damper Control GREENHECK ® Turn the recirculating switch on the remote control Figure 19. 2-Position Damper 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.
  • Page 10 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.
  • Page 11 Supply gas connections must be made by a qualified installer 6 in. Trap and are not furnished by Greenheck. See figure #23. Figure 23. Supply Gas Line Step 4 Test the System for Leaks...
  • Page 12 Installation - Evaporative Cooling Piping (Optional) Evaporative Cooling with Recirculating Pump. Supply Line Supply Line Valve Drain Line Valve Overflow Drain Line Trap Figure 24. Recirculating Evaporative Piping IMPORTANT! All supply solenoids, valves and all traps must be below the roofline or be otherwise protected from freezing.
  • Page 13 Installation - Evaporative Cooling Piping (Optional) Evaporative Cooling with Auto Drain and Fill Evaporative Cooling Supply Line Section Sump Overflow Sump Drain Valve A To Water Supply Valve C Valve B Drain Line Figure 26. Auto-Drain and Fill Evaporative Piping IMPORTANT! The supply line should be of adequate size and pressure to resupply the amount of water lost due to bleed-off and evaporation.
  • Page 14 To Media Pressure CAUTION! Gauge Any wiring deviations may result in personal injury Sump or property damage. Greenheck is not responsible Drain Manual for any damage to, or failure of the unit caused by Supply Valve incorrect final wiring. Roof...
  • Page 15 Installation - Direct Expansion (DX) Coil Piping (Optional) IMPORTANT! Guidelines for the installation of direct expansion cooling coils have been provided to insure 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.
  • Page 16 Installation - Direct Expansion (DX) Coil Piping (Optional) Step 1 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.
  • Page 17 Installation - Chilled Water Coil Piping (Optional) IMPORTANT! Guidelines for the installation of the cooling coil have been provided to insure 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.
  • Page 18 Installation - Building Pressure Control (Optional) Step 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. See figure #35 Step 2 Run Pressure Tap Lines A pressure tap line must be run from the pressure tap...
  • Page 19 Start-Up - Blower Pre-Start-Up Check Rotate the fan wheel by hand and make sure no parts WARNING! are rubbing. Check the V-belt drive for proper Disconnect and lock-out all power and gas before alignment and tension (a guide for proper belt tension performing any maintenance or service to the and alignment is provided in the belt maintenance unit.
  • Page 20 Start-Up - Blower Step 3 Check for Vibration Check for unusual noise, vibration or overheating of the bearings. Reference the troubleshooting section for corrective actions. IMPORTANT! IMPORTANT! Excessive vibration may be experienced during Generally, fan vibration and noise is transmitted the initial start-up.
  • Page 21 Start-Up - Direct Gas IMPORTANT! IMPORTANT! For proper unit function and safety, follow the This start-up should begin after all of the start-up procedure in the exact order that it is installation procedures and the Blower start-up presented. have been completed. Step 1 Check the Supply Gas Pressure Check the supply gas pressure and compare it with the unit’s nameplate pressure requirements.
  • Page 22 Start-Up - Direct Gas 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.
  • Page 23 Start-Up - Direct Gas Step 4 Set the Low Fire Time Delay Set the low fire time delay to 75% of its maximum MAX BTU/HR MIN BTU/HR setting. See figure #44 or #45 for the location of the BTU/H MAX BTU/H MIN time delay setting.
  • Page 24 Start-Up - Direct Gas Step 5 Set the Maximum Firing Rate (...continued) Maximum While monitoring the units temperature rise, set the firing rate maximum firing rate by adjusting the regulator (shown adjustment in figure #46) until the designed temperature rise is achieved.
  • Page 25 Start-Up - Direct Gas Step 7 Set the Unit’s Operating Temperature Set the operating temperature. The operating temperature setting depends on which Maxitrol controller is used and the desired space temperature. See figure #48 or #49. Maxitrol Series 14 Maxitrol Series 44 (Discharge temperature control) (Space temperature control) IMPORTANT!
  • Page 26 Start-Up - Evaporative Cooling (Optional) Step 1 Check the Installation 45° The media may have been removed during installation, so its orientation should be double checked. The media should be installed with the steeper flute angle sloping down toward the entering air side.
  • Page 27 Start-Up - Water Wizard™ (Optional) Step 1 Open the Solenoid Confirm that the manual water supply valve is closed. Press and hold the Function Button for one second. L3 will begin blinking (short on, long off), indicating that Flow Test Mode is active and the supply solenoid is open.
  • Page 28 Start-Up - Water Wizard™ Step 6 Adjust the Minimum Cooling Temperature While in the Program Menu, use the Up and Down Keys to navigate the Menu Options until “toF” is displayed (see figure #55). Press the Enter Key to access the selected Menu Option setting. Use the Up and Down Keys to adjust the Minimum Figure 55.
  • Page 29 Operation - Recirculating / VAV Units Burner By-Pass Damper The self adjusting burner by-pass damper is a device used in variable volume and recirculation units. Its function is to maintain proper combustion by providing a constant airflow over the burner when outside air volumes are changed.
  • Page 30 Operation - Electrical Electrical Sequence Direct Gas Burner Sequence 1. Exhaust Fan Switch (S1) Closed 1. Supply Fan Switch Closed • Power passes to exhaust starter(s) ST2(3) • Power passes to the supply fan and heat switch • N.O. exhaust starter switches are energized and closed 2.
  • Page 31 Operation - Water Wizard™ Up Key Function Key Enter Key Down Key Figure 59. Water Wizard User Interface Drain Mode 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. To deactivate Drain Mode and unlock the drain solenoid, simultaneously press the Function and Enter Keys again.

  • Page 32: Troubleshooting

    Troubleshooting Blower Does Not Operate 115 Vac across Check Main Voltage terminals 102 and 101? (See Blower Start-Up Step #1) Main Disconnect (DS1) Off (Turn Main Disconnect DS1 On) Primary Fuses (FU6) or Secondary Fuses (FU7) Blown (Replace Fuses) Main Transformer (TR1) Defective 24 Vac across (Replace Transformer TR1) terminals R and X?
  • Page 33 Troubleshooting Heater Does Not Operate Does not attempt to light (No visible spark) 24 Vac across terminals W1 and X? Heat Switch (S3) Off (Turn Heat Switch S3 On) Heat Switch Not Wired (Wire Heat Switch S3) 115 Vac across terminals 102 and 101? Secondary Fuses (FU7) Blown (Replace Fuses)
  • Page 34 Troubleshooting Heater Does Not Operate Attempts to light but no flame (Visible spark) Is the low fire set properly (Direct Gas Start-Up Step #6) Adjust the low fire setting (Reference Direct Gas Start-Up Step #6) Check inlet gas pressure. (Direct Gas Start-Up Step #1) Gas pressure between the min and max shown on the direct gas label?
  • Page 35 Troubleshooting Water Blows through Evaporative Cooler Are the headers in place and Replace headers and/or move the headers. located near the entering side of (Reference Evaporative Cooler Start-Up Step #1) the media? Water supply greater than Use the main supply valve to reduce the supply of water. evaporation and bleed-off rate? Air velocity greater than Reduce the air velocity through the media.

  • Page 36: Excessive Noise Or Vibration

    Troubleshooting Excessive Noise or Vibration Replace worn belts or tighten loose belts. Belts worn or loose? (Reference V-Belt drive maintenance in the maintenance section) Align sheaves Sheaves aligned? (Reference V-Belt drive maintenance in the maintenance section) Wheel(s) unbalanced? Clean and/or balance wheel(s). Bearings worn or need Replace worn bearings or lubricate bearings as needed.
  • Page 37 Troubleshooting Water Wizard (Improper Water Supply) NOTE! NOTE! If the water supply is too high, the media will be If the water supply is too low, the media will saturated and excessive water will be draining continuously appear dry. from the sump tank. NOTE! Some water drainage is desirable to reduce mineral deposits but should be minimized to best utilize the Water Wizard.
  • Page 38 Maintenance - Routine 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 IMPORTANT! V-belt drives must be checked on a regular basis for Premature or frequent belt failures can be caused by wear, tension, alignment and dirt accumulation.
  • Page 39 Bearings IMPORTANT! The bearings for Greenheck fans are carefully Lubricate bearings prior to periods of extended selected to match the maximum load and operating shutdowns or storage and rotate shaft monthly conditions of the specific class, arrangement and fan to aid in corrosion prevention.
  • Page 40 Maintenance - Routine Filters IMPORTANT! Filter maintenance is generally limited to cleaning and When reinstalling filters be sure to install replacement. them with the airflow in the correct direction. An airflow direction arrow is If aluminum mesh filters are installed, they can be washed in located on the side of the filters.
  • Page 41 Maintenance - Fall Start-Up Repeat the Blower Start-Up procedure #5 and Direct Gas Start-Up procedure #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.
  • Page 42 Maintenance - Fall Winterizing Chilled Water Coils During the winter, chilled water coils need to be protected against freezing. Greenheck recommends protecting the coils by either blowing-out the coils or by flushing the coils. Blowing-Out Coils Flushing Coils • Isolate the coil from the rest of the system by...
  • Page 43 Maintenance - Log Job Information Job Name: ____________________________________ Service Organization: _____________________________ Address: ______________________________________ Address: ________________________________________ City: ________________ State: ________ Zip: _______ City: ________________ State: ________ Zip: _________ Phone: __________________ Fax:_________________ Phone: __________________ Fax: ___________________ Contact Person: _______________________________ Work Done By: ___________________________________ Field Start-Up Documentation Name Plate Information Model: ________________________________________...
  • Page 44 Maintenance - Log Maintenance Log Date Time Notes:...
  • Page 45 Maintenance - Log Maintenance Log Date Time Notes:...
  • Page 46 Reference Typical Gas Train Layout less than 400 MBH Burner Differential Pressure Sensor (Airflow Switch) To Burner High Gas Pressure Switch Combination Low Gas (Optional) Shut-off Pressure Switch Modulating Valve/Regulator (Optional) Valve Burner Manual Shut-off Valve Low Gas Pressure Test Port High Gas Pressure Test...
  • Page 47 Reference Control Center Layout Figure 67. Direct Spark Gas Control Center Heating/Cooling Inlet Air Sensor (Optional) - Ductstat that automatically de-energizes burner when inlet air temperature rises above set point, or shuts down cooling when temperature falls below set point. Flame Safeguard/Spark Generator - Monitors flame, shuts down unit when unsafe conditions are detected.
  • Page 48 Warranty Greenheck warrants this equipment to be free from defects in material and workmanship for a period of one year from the purchase date. Any units or parts which prove defective during the warranty period will be replaced at our option when returned to our factory, transportation prepaid.

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