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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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Summary of Contents for Engineered air DJ Series
- Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL DJ(E,S) & DG SERIES INDIRECT GAS OR OIL FIRED HEATING UNITS INDOOR AND OUTDOOR MODELS UNIT MODEL NO. _________________ UNIT SERIAL NO. _________________ SERVICED BY: ___________________ TEL. NO: ________________________ CANADIAN CANADIAN HEAD OFFICE HEAD OFFICE EASTERN FACTORY AND FACTORY AND FACTORY...
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Page 2: Table Of Contents
DJ & DG MANUAL TABLE OF CONTENTS YOU HAVE RESPONSIBILITIES TOO............................... 3 INTRODUCTION ....................................3 SAFETY PRECAUTIONS ................................... 3 WARRANTY ....................................... 4 PARTS........................................ 5 RECEIVING ......................................5 TEMPORARY STORAGE .................................. 5 INSTALLATION ....................................6 CODES....................................... 6 MINIMUM CLEARANCE TO COMBUSTIBLES AND FOR SERVICE IN INCHES (mm)..............7 LIFTING...................................... -
Page 3: You Have Responsibilities Too
INTRODUCTION Engineered Air units are high quality products designed and manufactured to provide many years of trouble-free operation. We recommend that this manual be read thoroughly to ensure proper installation, efficient operation and proper maintenance of this equipment. -
Page 4: Warranty
Under no circumstances shall ENGINEERED AIR be liable to, nor be required to indemnify, Buyer or any third parties for any claims, losses, labour, expenses or damages (including special, indirect, incidental, or consequential damages) of... -
Page 5: Parts
Motor manufacturers have service centers that will repair or replace motors as required. Parts Other Than Motors: Contact the nearest Engineered Air sales office or factory. Be sure to include Model Number, Serial Number, date of installation and nature of failure along with the description of the parts required. -
Page 6: Installation
DJ & DG MANUAL INSTALLATION Warning: Only equipment bearing a CSA C22.2 No. 213 or UL 1604 rating plate (label) with an accompanying CSA Certification mark is suitable for installation in a hazardous location. The hazardous location must conform with the Class, Division, Group and temperature code (if shown) displayed on the rating plate (label). -
Page 7: Minimum Clearance To Combustibles And For Service In Inches (Mm)
DJ & DG MANUAL This unit shall be electrically grounded in accordance with the latest edition of the National Electrical Code (ANSI/NFPA 70), State and Local Codes and in accordance with the local authorities having jurisdiction. If the unit has not been provided with an electric disconnect switch, one of adequate ampacity shall be installed in accordance with Article 430 of the National Electrical Code (ANSI/NFPA 70). -
Page 8: Lifting
DJ & DG MANUAL LIFTING Engineered Air units are constructed on a structural steel base frame. The unit base frame is equipped with lifting lugs specifically located to facilitate proper lifting of the unit. Spreader bars must be used to keep rigging away from the unit cabinetry. -
Page 9: Shipping Materials
The gasket material provided for the split is open cell foam. Open cell foam is light and compresses easily. If the unit is mounted on a curb provided by Engineered Air there will also be gasket material for sealing the curb. The gasket material for curbs is closed cell foam. It is more dense than open cell foam and does not compress as easily. -
Page 10: Piping, Electrical Or Control Service Connections
DO NOT install anything that will interfere with equipment access or the rating plate. Engineered Air equipment is constructed with cabinet and floors designed to prevent water from entering the building through the installed unit. When ordered, factory installed pipe chases and/or electrical chases are built into the unit floor. -
Page 11: Gas Line Testing (External To The Unit)
DJ & DG MANUAL GAS LINE TESTING (EXTERNAL TO THE UNIT) The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any testing of that system at test pressures in excess of 0.5 psi (3.5 kPa). The appliance must be isolated from the gas supply system by closing its individual shutoff valve during any testing of that system at test pressure equal to or less than 0.5 psi (3.5 kPa). -
Page 12: Venting Products Of Combustion
A vertical chimney must be certified “A” or “L” or equivalent type on units without draft hoods. Type “B” vent is acceptable on units with Engineered Air draft hoods. The vent size shall be selected from appropriate approved Vent Table. -
Page 13: Duct Furnace Installation
DO NOT install anything that will interfere with equipment access or the rating plate. Engineered Air equipment is constructed with cabinet and floors designed to prevent water from entering the building through the installed unit. When ordered, factory installed pipe chases and/or electrical chases are built into the unit floor. -
Page 14: Recommended 24V Field Wiring Size
DJ & DG MANUAL The unit must be electrically grounded and all wiring must be installed in accordance with the National Electrical Code, ANSI/NFPA 70, and/or the Canadian Electric Code CSA 22-1 and to the approval of the authorities having jurisdiction. THE FLOOR OF THE UNIT HAS BEEN MADE WATER-RESISTANT. DO NOT CUT OR DRILL HOLES IN THE FLOOR OR USE PENETRATING FASTENERS. -
Page 15: Duct Mounted Te-6000-Ea3 Temperature Sensor
5 to 10 feet (1500 to 3000mm) downstream of the supply air connection to the Engineered Air unit. Avoid installing near duct transitions or elbows. Use twisted pair or shielded wiring. The ground shield should be grounded only at the unit control panel end. -
Page 16: Drain Traps
DJ & DG MANUAL Recovery, reuse, recycling, reclamation, and safe disposal of refrigerant is the only acceptable practice today. Venting of refrigerant into the atmosphere during installation or servicing is unacceptable. To avoid damage, use an accepted refrigerant recovery system whenever removing refrigerant. When working with refrigerants you must comply with all local government safety and environmental laws. -
Page 17: Heat Transfer Fluids
DJ & DG MANUAL HEAT TRANSFER FLUIDS The coil(s) provided have been selected for use with a specific heat transfer fluid as shown on the Submittal Record. Use of other fluids will result in different performance and can damage the coil(s). It is imperative to properly select and apply heat transfer fluids used in heating and cooling systems. - Page 18 DJ & DG MANUAL Check the amperage draw of each motor and compressor. Refer to unit or motor rating plate for full load amps. At the unit, check and record the voltage while it is running. For 3 phase power the phase to phase voltage imbalance should be less than 2%.
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Page 19: Operation
DJ & DG MANUAL Remove any packing material or debris and dispose appropriately. OPERATION Warning: This unit is connected to high voltages. Electrical shock or death could occur if instructions are not followed. This equipment contains moving parts that can start unexpectedly. Injury or death could occur if instructions are not followed. -
Page 20: Safety Shutoff Valve Leak Test
DJ & DG MANUAL SAFETY SHUTOFF VALVE LEAK TEST: Safety shutoff valves require a qualified technician to perform a leak (bubble) test to determine tightness of closure on a least an annual basis. A very small amount of leakage is normal. Valve leakage rates exceeding those noted in the table below require repair or valve replacement. -
Page 21: Operational Check For All Gas Fired Dj & Dg Units
DJ & DG MANUAL OPERATIONAL CHECK FOR ALL GAS FIRED DJ & DG UNITS The unit has been tested at the factory, gas consumption clocked, and all safety controls checked to ensure they operate. Field testing will confirm all components are operating properly after shipping and installation. -
Page 22: Operational Check For All Oil Fired Dj & Dg Units
DJ & DG MANUAL Check combustion as described in combustion and final checkout section (or if the unit contains DJM, DJT, G-TRAC, X-TRAC, DSTRAC etc. CONTROLS refer to those manuals for proper setup). Once the heat call is satisfied: a. Ignition controller de-energized. b. -
Page 23: Combustion And Final Unit Check For Units Without Trac Controls
DJ & DG MANUAL COMBUSTION AND FINAL UNIT CHECK FOR UNITS WITHOUT TRAC CONTROLS The heater has been test fired in the factory for firing rate and combustion. Field conditions may require small adjustments to be made. These checks should be done by a qualified service man. When the main flame is established, check the gas manifold pressure at the test point nearest the burner with the unit operating at high fire. -
Page 24: Electrode Detail
DJ & DG MANUAL ELECTRODE DETAIL The spark gap is 1/8" (3 mm). Ensure that there is a gasket between the electrode assembly and pilot box housing. HIGH TURNDOWN (RECTANGULAR) BURNER High Turndown (Rectangular) Burner Standard (Round) Burner 1.87 X 0.032 THICK QUICK CONNECT TERMINAL MALE 135°... -
Page 25: Emergency Shut Down
Engineered Air has no responsibility for and makes no express or implied warranties regarding mold or bacterial growth or any other indoor air quality issues. -
Page 26: Electrical
DJ & DG MANUAL To provide a maintenance history, It is recommended that the owner have a maintenance file for each unit. The following maintenance instructions are to be carried out each spring and fall or as otherwise indicated by qualified service personnel. Caution: Label all wires prior to removal when servicing controls or critical components. -
Page 27: Set Screws
DJ & DG MANUAL CAUTION: Excessive belt tension is the most frequent cause of belt wear, bearing wear and noise. SET SCREWS Check set screws on fan wheel, fan bearings, fan and motor pulleys for looseness on the shaft. Tighten where required. -
Page 28: Lubrication Of Dodge Fan Bearings
DJ & DG MANUAL 3/4" 1" 1 3/16" 1 7/16" 1 11/16" 1 15/16" 2 7/16" 2 15/16" Shaft Dia. (19mm) (25mm) (30mm) (37mm) (43mm) (49mm) (62mm) (75mm) 0.06 oz. 0.12 oz. 0.20 oz. 0.23 oz. 0.27 oz. 0.36 oz. 0.53 oz. -
Page 29: Motor Lubrication
DJ & DG MANUAL Shell Alvania No. 2 Mobil Mobilith AW2 Mobilith SHC100 Texaco Premium RB2 American Rykon Premium 2 Lubricate bearings prior to extended shutdown or storage and rotate shaft monthly to aid corrosion protection. Suggested Re-lubrication Schedule (Months)* for Dodge Spherical Roller Bearing – Split Pillow Blocks Speed (RPM) 1000... -
Page 30: Gas Manifold
DJ & DG MANUAL RECOMMENDED MOTOR LUBRICATION INTERVALS Up to 7.5 HP 10 to 40 HP Over 40 HP Hours Service Up to 5.6 kW 7.5 to 29.8 kW Over 29.8 kW Per Day 5 Years 3 Years 1.5 Years Less than 12 2 Years 1 Year... -
Page 31: Controls
Shake off excess water and re-install. These filters do not require an oil adhesive. Pleated Throwaway and/or Replaceable Media (Cartridge, Bag): Replacement filters can be obtained from any Engineered Air representative. In some applications the used filters/media may contain chemical or biological hazards. All local, regional and national regulations for safety and disposal should always be followed. - Page 32 DJ & DG MANUAL 32 of 34 May 12 R2...
- Page 33 DJ & DG MANUAL 33 of 34 May 12 R2...
- Page 34 DJ & DG MANUAL 34 of 34 May 12 R2...
- Page 35 START-UP RECORD Unit Serial Number: Date: Model: All shipping material removed. Fan setscrews checked for tightness. Incoming power Voltage measurements: Rotation correct. Amperage measurement: Gas line supply pressure: High fire " W. C. " W. C. Manifold gas pressure at high fire "...
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