Greenheck DGX Installation, Operation And Maintenance Manual

Industrial space heating

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®
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!
Model DGX

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.
®
Industrial Space Heating
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.
DGX Industrial Space Heating
Document 4760655
Model DGX
1

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Summary of Contents for Greenheck DGX

  • Page 1: General Safety Information

    Document 4760655 Model DGX Industrial Space Heating ® 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.
  • Page 2 Receiving The unit should be stored at least 3½ in. (89 mm) off the floor on wooden blocks covered with moisture proof Upon receiving the product, check to make sure all paper or polyethylene sheathing. Aisles between parts items are accounted for by referencing the bill of lading and along all walls should be provided to permit air to ensure all items were received.
  • Page 3: Table Of Contents

    Table of Contents Clearance to Combustibles / Service Clearances Installation Clearance to Combustibles/Service Clearances . . 3 Floor Sides Ends Indoor Unit ....... 4 Insulated/ 0 inches 0 inches...
  • Page 4: Indoor Unit

    Installation of Indoor Unit NOTE 1. Install Hangers Good duct practices should be followed for all ductwork. Ductwork should be installed in accordance Install threaded hangers from ceiling supports. When with SMACNA and AMCA guidelines, NFPA 96 and locating hangers, allow enough room to open access any local codes.
  • Page 5: Unit Arrangement Db / Hz

    Installation of Arrangement DB / HZ 4. Install Unit Use a crane and a set of spreader bars hooked to the 1. Install Curb and/or Equipment Support(s) factory lifting lugs to lift and center the unit on the curb/ Position curb/equipment support(s) on the roof equipment support(s).
  • Page 6: Diffuser

    Installation of Diffuser and Remote 2. Install TSCP When installing the TSCP Space Heat Remote Panel (TSCP) Panel, the location is critical to performance of the Greenheat™ System. The TSCP should be installed five NOTE to six feet above the floor. It is recommended that the The location of the discharge diffuser and the TSCP TSCP be installed on an outside wall, in the space, and Space Heat Remote Panel are critical for optimum...
  • Page 7: Electrical Wiring

    Installation of Electrical Wiring 1. Determine the Size of the Main Power Lines The unit’s nameplate states the voltage and the unit’s IMPORTANT MCA. The main power lines to the unit should be sized Before connecting power to the unit, read and accordingly.
  • Page 8: Gas Piping

    Installation of Gas Piping 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 IMPORTANT nameplate is located on the outside of the unit on the All gas piping must be installed in accordance control center side.
  • Page 9: Blower

    4. Pipe the Optional Vent Line Start-Up - Blower If an optional vent line is located between the safety Refer to the Start-Up Checklist in the Reference shutoff valves it must be piped to the outdoors. section before proceeding further! WARNING Pre Start-Up Check Reference the National Fuel Gas Code for additional...
  • Page 10: Blower

    2. Check the Blower Rotation 5. Air Volume Measurement and Check Open the blower access door and run Measure the unit’s air volume (cfm) and compare it with the blower momentarily to determine it’s rated air volume. If the measured air volume is off, the rotation.
  • Page 11: Direct Gas

    Start-Up Direct Gas Start-Up Direct Gas Start-Up Direct Gas • 100% Outside Air IMPORTANT IMPORTANT For proper unit function and safety, follow the start-up Proper air velocity over the burner is critical on direct procedure in the exact order that it is presented. fired gas units.
  • Page 12: 50/50 Recirculation

    Start-Up Direct Gas 5. Set the Low Fire Time Delay Set the low fire time delay to 75% of its maximum • 50/50 Recirculation setting. See below for location of the time delay setting. 6. Set the Maximum Firing Rate IMPORTANT Monitor the unit’s actual temperature rise by placing Proper air velocity over the burner is critical on direct...
  • Page 13 Start-Up Direct Gas 7. Set the Minimum Firing Rate continued Disconnect and isolate one of the wires running to the modulating valve to send the unit to its minimum firing IMPORTANT rate. Set the minimum firing rate by adjusting the needle Setting the maximum firing rate during mild weather valve as shown in the diagrams on this page.
  • Page 14 Start-Up Direct Gas continued NOTE For units without a 7 day time clock, skip Steps #9 and #10. 9. Set Nighttime Temperature Set the nighttime temperature setting to the desired nighttime space temperature, the nighttime temperature setting is located inside the TSCP Space Heat remote panel which should be mounted in the space.
  • Page 15: Electrical Without 7-Day Timer

    Operation - Electrical Sequence • Power passes through N.O. contact on fan relay (RF), which is energized and closed • Without 7-Day Timer • Power passes to and energizes the heat relay (RH) 1. Switch (S2) in Summer Mode • Power passes through N.O. contact on heat relay •...
  • Page 16: Electrical With 7-Day Timer

    Operation - Electrical Sequence • Power passes to and energizes supply fan starter (ST1) With 7-Day Timer • N.O. contact on supply fan starter (ST1) is 1. Switch (S2) in Summer Mode energized and closed • Power passes through N.C. field-supplied fire •...
  • Page 17: Troubleshooting

    Troubleshooting Blower Does Not Operate Proper supply power at main disconnect Check Main Voltage (See Blower Start-Up – Step #1) Main Disconnect (DS1) Off (Turn Main Disconnect DS1 On) Primary Fuses Blown (Replace Fuses) 24 VAC between terminals R and X? Main Transformer (TR1) Defective (Replace Transformer) 24 VAC between...
  • Page 18: Motor

    Troubleshooting Motor Overamps Air volume too high? Adjust drives or increase external static pressure as needed. (Reference Blower Start-Up – Step #5) Actual static pressure lower than design? Adjust drives to reduce blower RPM. Blower rotation correct? Reverse blower rotation. (Reference Blower Start-Up –...
  • Page 19: Insufficient Airflow / Too Much Airflow

    Troubleshooting Insufficient Airflow Damper(s) not fully opened? Adjust damper linkage(s), or replace faulty actuator(s). (Damper actuators may take a few minutes to open) System static losses too high? Reduce losses by improving ductwork. Blower speed too low? Adjust drives as needed. Filters dirty or clogged? Clean or replace filters.
  • Page 20: Excessive Noise Or Vibration

    Troubleshooting Excessive Noise or Vibration Belts worn or loose? Replace worn belts or tighten loose belts. (Reference V-Belt Drives in the Maintenance section) Sheaves aligned? Align sheaves. (Reference V-Belt Drives in the Maintenance section) Wheel(s) unbalanced? Clean and/or balance wheel(s). Bearings worn or need lubrication? Replace worn bearings or lubricate bearings as needed.
  • Page 21: Heater

    Troubleshooting Heater Does Not Operate Does not attempt to light (No visible spark) 24 VAC between terminals W1 and X? Heat Switch (S4) Off (Turn Heat Switch (S4) On) Heat Switch Not Wired (Wire Heat Switch (S4)) 115 VAC between terminals 102 and 101? Primary Fuses Blown (Replace Fuses)
  • Page 22 Troubleshooting Heater Does Not Operate Attempts to light, but no pilot (visible spark) Check inlet gas pressure. Note: The minimum and maximum gas pressures (Direct Gas Start-Up Step #1) for your unit are shown on the direct gas label. (Reference Direct Gas Start-Up – Step #1) Gas pressure between the minimum and maximum shown on the direct gas label?
  • Page 23: Heater

    Troubleshooting Heater Does Not Operate Visible pilot Measure the flame signal Note: The flame signal should be steady and when there is a visible pilot above 1.25 VDC with a visible pilot. (Reference Direct Gas Start-Up – Step #11) Flame signal greater than 1.25 VDC Unit is not grounded (Properly ground unit)
  • Page 24: Routine

    Maintenance - Routine Snow Accumulation CAUTION Clear snow away from roof mounted units. Keep the Lock-out the gas and the electrical power to the snow clear of the intake and access doors. unit before performing any maintenance or service Motors operations to this unit.
  • Page 25 Bearings Filters The bearings for manufacturer fans are carefully Filter maintenance is generally limited to cleaning and selected to match the maximum load and operating replacement. conditions of the specific class, arrangement and fan If aluminum mesh filters are installed, they can be size.
  • Page 26: Fall

    Maintenance - Fall Start-Up Gas Train Repeat the Blower Start-Up Step #5 and Direct Gas The gas connections, joints and valves should be Start-Up Step #1, 2 and 4a or 4b. This will ensure that checked annually for tightness. Apply a soap and water the gas and air are set properly before the heating solution to all piping;...
  • Page 27: Reference

    Reference Typical Gas Train Layout 400 – 800 MBH Pilot Solenoid Burner Differential Pilot Gas Pressure Pressure Sensor Pilot Regulator Test Port Airflow Modulating Manual Pilot Valve Shut-Off Valve Low Gas Pressure Burner Manual Switch (optional) Shut-Off Valve High Gas Pressure Switch (optional) Burner Gas Safety Shut-Off Valves...
  • Page 28: Control Center Layout / Dirty Filter Switch

    Reference Typical Control Center Layout 1. Supply Motor Starter — 24 volt magnetic contacts 8. Heat Relay — allows power to pass to heating for starting supply motor. controls. 2. Supply Overload — provides electronic overload 9. Heating Terminal Block — provides wiring access to protection to supply motor.
  • Page 29: Start-Up Checklist

    Reference Start-Up Checklist Start-Up Direct Gas – refer to Direct Gas Start- Up section for further detail. Unit Model Number _______________________________ (e.g. DGX-120-GH100-1600) Check supply gas pressure Unit Serial Number ________________________________ ________ Maximum (e.g. 10111000) ________ Minimum Start-Up Date ____________________________________ ________ Actual Start-Up Personnel Name _________________________ Set optional High Gas Pressure Switch...
  • Page 30: Maintenance Log

    Maintenance Log Date ___________________Time _____________ AM/PM Date ___________________Time _____________ AM/PM Notes: ___________________________________________ Notes: ___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date ___________________Time _____________ AM/PM Date ___________________Time _____________ AM/PM Notes: ___________________________________________ Notes: ___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date ___________________Time _____________ AM/PM...
  • Page 31 Maintenance Log Date ___________________Time _____________ AM/PM Date ___________________Time _____________ AM/PM Notes: ___________________________________________ Notes: ___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date ___________________Time _____________ AM/PM Date ___________________Time _____________ AM/PM Notes: ___________________________________________ Notes: ___________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ _________________________________________________ Date ___________________Time _____________ AM/PM...
  • Page 32: Our Commitment

    This publication can be obtained from AMCA International, Inc. at www.amca.org. ® Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com 470655 • DGX Industrial Space Heating, Rev. 4, February 2013 Copyright 2013 © Greenheck Fan Corporation...

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