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INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
DJ(E,S) & DG SERIES
INDIRECT GAS OR OIL FIRED HEATING UNITS
INDOOR AND OUTDOOR MODELS
CANADIAN
HEAD OFFICE
AND FACTORY
1401 HASTINGS CRES. SE
CALGARY, ALBERTA
T2G 4C8
Ph: (403) 287-4774
Fx: 888-364-2727
SALES OFFICES ACROSS CANADA AND USA
Retain instructions with unit and maintain in a legible condition.
Please give model number and serial number when contacting
FOR
UNIT MODEL NO. _________________
UNIT SERIAL NO. _________________
SERVICED BY: ___________________
TEL. NO: ________________________
USA
HEAD OFFICE
AND FACTORY
rd
32050 W. 83
DESOTO, KANSAS
66018
Ph: (913) 583-3181
Fx: (913) 583-1406
factory for information and/or parts.
www.engineeredair.com
EASTERN FACTORY
STREET
1175 TWINNEY DRIVE
NEWMARKET, ONTARIO
Ph: (905) 898-1114
Fx: (905) 898-7244
CANADIAN
L3Y 5V7
May 12 R2
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Table of Contents
Related Manuals for Engineered air DG SERIES
Summarization of Contents
INTRODUCTION AND SAFETY
Owner Responsibilities
Defines user duties and consequences of non-compliance.
Fire/Explosion Hazard Warning
Critical safety alert about gas hazards.
WARRANTY AND HAZARDS
Limited Warranty Terms and Conditions
Specifies warranty period, coverage, and exclusions.
Chemical Hazard Impact
Warning on damage from corrosive cleaning chemicals.
PARTS, RECEIVING, AND STORAGE
Replacement Parts and Procedures
Guidance on obtaining and using replacement parts.
Unit Receiving and Inspection
Steps for checking unit condition upon arrival.
Temporary Storage Guidelines
Best practices for storing units before installation.
INSTALLATION CODES AND STANDARDS
Canadian Installation Code Compliance
Adherence to Canadian electrical and gas codes.
US Installation Code Compliance
Adherence to US electrical and gas codes.
MINIMUM CLEARANCE REQUIREMENTS
Combustible and Service Clearances
Table detailing required clearances for safety and service access.
LIFTING AND MOUNTING PROCEDURES
Safe Lifting Practices and Warnings
Methodologies for safely lifting units.
Unit Mounting Methods
Describes base, suspended, and roof curb mounting options.
ASSEMBLY, SHIPPING, AND WIRING
Split Unit Assembly Instructions
Guidance for assembling split unit sections.
Shipping Material Removal
Instructions for removing protective shipping materials.
Split Unit Field Wiring
Connecting wiring for split units.
SERVICE CONNECTIONS AND GAS INSTALLATION
Piping, Electrical, and Control Connections
Rules for making service connections.
Natural Gas & Propane Installation
Requirements for installing gas fuel lines.
FUEL SYSTEMS AND DRAINAGE
Gas Line Leak Testing
Procedure for testing gas supply piping integrity.
Oil Installation Requirements
Guidelines for installing oil fuel systems.
Indoor Unit Condensate Drain
Proper installation of condensate drains.
VENTING PRODUCTS OF COMBUSTION
Indoor Venting Specifications
Requirements for venting indoor units.
Outdoor Venting Specifications
Requirements for venting outdoor units.
DUCT FURNACE AND ELECTRICAL INSTALLATION
Duct Furnace Installation Details
Specifics for installing duct furnaces.
General Electrical Installation
Overview of electrical installation practices.
ELECTRICAL WIRING SPECIFICATIONS
24V Field Wiring Size Chart
Table for selecting wire gauge based on load and distance.
Temporary Power Generation Cautions
Warnings about generator power quality and warranty.
SENSORS AND COIL CONNECTIONS
Duct Mounted Temperature Sensor
Installation instructions for discharge air temperature sensors.
Coil Connection Procedures
Guidelines for connecting fluid coils.
DRAIN TRAPS AND COIL PREPARATION
Drain Trap Sizing and Installation
Requirements for proper drain trap setup.
Coil Flushing and Degreasing
Pre-use cleaning procedure for coils.
HEAT TRANSFER FLUIDS AND START-UP
Heat Transfer Fluid Considerations
Importance of fluid selection and potential damage.
Pre-Startup Task Checklist
Essential steps before initial unit operation.
Initial Unit Start-Up Guide
Step-by-step procedure for starting the unit.
START-UP CHECKLIST ITEMS
Voltage and Amperage Checks
Measuring voltage and amperage draw during operation.
Gas/Oil Line Purge and Leak Checks
Purging gas/oil lines and checking connections.
Air System Balance and Damper Adjustments
Ensuring proper air flow and damper settings.
Fan Limit Control Settings Adjustment
Adjusting fan limit and fan switch settings.
OPERATION AND CONTROL SYSTEMS
General Operating Safety Precautions
Safety warnings during unit operation.
Air System Commissioning Importance
Emphasizing air balance for system performance.
Unit Control System Overview
Information on unit functions and programmable controls.
SAFETY SHUTOFF VALVE TEST AND GAS MANIFOLD
Safety Shutoff Valve Leak Test Procedure
Step-by-step guide to test valve tightness.
Maximum Safety Shutoff Valve Leakage Rates
Table of acceptable bubble rates for valve testing.
Gas Manifold Safety Device Checks
Recommendation for annual safety device checks.
OPERATIONAL CHECK FOR GAS UNITS
Pre-Operation Checks for Gas Units
Steps before starting gas-fired units.
Gas Burner Ignition Sequence
Detailed steps for gas burner ignition.
Gas Pressure and Combustion Verification
Verifying gas and manifold pressures.
OPERATIONAL CHECK FOR OIL UNITS
Pre-Operation Checks for Oil Units
Steps before starting oil-fired units.
Oil Burner Ignition and Flame Stability
Procedures for oil burner ignition and flame control.
Oil Burner Combustion Smoke Test
Performing a smoke test for oil burners.
COMBUSTION AND FINAL UNIT CHECK
Gas Manifold Pressure at High Fire
Verifying manifold pressure at high fire.
CO and O2 Combustion Readings
Measuring combustion gases for efficiency.
Safety Controls and Limits Verification
Ensuring safety controls and limits are operational.
ELECTRODE DETAIL AND SHUT-DOWN PROCEDURES
Spark Electrode Gap Specification
Details on spark electrode gap and gasket.
Service Shut Down Procedure
Steps for safely shutting down the unit for service.
EMERGENCY SHUT DOWN AND CONTROL SETTINGS
Emergency Shut Down Procedure
Steps for immediate unit shutdown.
Start-Up After Extended Shutdown
Procedures for restarting after long periods.
Recommended Control Settings
Default settings for various unit controls.
MAINTENANCE AND BELT ADJUSTMENT
General Maintenance Precautions
Warnings and tips for performing maintenance safely.
Electrical System Maintenance Checks
Checks for wiring, voltage, and contactors.
V-Belt Adjustment and Alignment
Procedures for adjusting and aligning V-belts.
SET SCREWS AND BEARING TORQUES
Set Screw Tightening and Checks
Checking and tightening set screws on rotating parts.
Bearing Setscrew Torque Specifications
Torque values for bearing setscrews by shaft diameter.
FAN BEARING LUBRICATION
Dodge Ball Bearing Lubrication Schedule
Re-lubrication schedule for Dodge ball bearings.
Dodge Spherical Roller Bearing Lubrication
Re-lubrication schedule for Dodge spherical bearings.
BEARING AND MOTOR LUBRICATION
Dodge Split Pillow Block Bearing Lubrication
Re-lubrication for Dodge split pillow block bearings.
Static Oil Lubrication of Bearings
Guidelines for static oil lubrication of bearings.
Motor Lubrication Recommendations
Referencing motor manufacturer for lubrication needs.
MOTOR LUBRICATION AND BURNER MAINTENANCE
Recommended Motor Lubrication Intervals
Table for motor relubrication based on hours/HP.
Gas Burner Inspection and Cleaning
Annual inspection of gas burners for scale and blockages.
Oil Burner Inspection and Cleaning
Annual inspection and cleaning of oil burners.
FILTERS AND COIL MAINTENANCE
Filter Replacement and Cleaning
Guidelines for changing and cleaning filters.
Coil Cleaning and Winterization
Procedures for cleaning coils and winterizing water coils.
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