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OUTDOOR DUCT FURNACE INSTALLATION, OPERATION,
AND MAINTENANCE
• Failure to follow safety warnings exactly could result in serious injury or property damage.
• Installation and service must be performed by a qualified installer, service agency or the gas
supplier.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or
any other appliance.
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call the fire department.
DO NOT DESTROY. PLEASE READ CAREFULLY. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
MODEL SERIES RG, RPV, AND RX
NOTE: Model CRX shown.
⚠ WARNING ⚠
FIRE OR EXPLOSION HAZARD
WHAT TO DO IF YOU SMELL GAS
Revision: I-RX-RG-RPV (09-19) PN1027501R0
Supersedes: D300536 (01-15) I-RX-RG-RPV
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Summary of Contents for Reznor RG Series
- Page 1 Revision: I-RX-RG-RPV (09-19) PN1027501R0 Supersedes: D300536 (01-15) I-RX-RG-RPV OUTDOOR DUCT FURNACE INSTALLATION, OPERATION, AND MAINTENANCE MODEL SERIES RG, RPV, AND RX NOTE: Model CRX shown. ⚠ WARNING ⚠ FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could result in serious injury or property damage. •...
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Page 2: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION ............................3 Important Safety Information ..........................3 Warranty ................................3 Applicability ................................4 Installation Codes ..............................4 Clearances ................................4 Dimensions ................................4 Weights .................................7 Gas Connections ..............................8 INSTALLATION .................................8 Uncrating................................8 Pre-Installation Checklist ............................8 Reversing Airflow by Changing Direction of Heat Exchanger Air Baffles ............8 Combustion Air Requirements ...........................9 Rigging and Mounting Furnace ........................11 Venting ................................11... -
Page 3: General Information
GENERAL INFORMATION This unit has been tested for capacity and efficiency so as to provide many years of safe and dependable comfort providing it is properly installed and maintained. With regular maintenance, this unit will operate satisfactorily year after year. Abuse, improper use, and/or improper maintenance can shorten the life of the appliance and create unsafe hazards. -
Page 4: Applicability
GENERAL INFORMATION—CONTINUED Applicability Table The instructions in this manual apply to the outdoor duct furnace models listed in Table 1. Model Applicability Vent Model Thermal Efficiency Standard High Gravity Standard HCRG High HCRX Standard Power High HRPV Installation Codes The outdoor duct furnaces covered in this manual are design-certified by the Canadian Standards Association to ANSI 283.8 and CAN/CGA 2.6 for use with either natural or propane gas. - Page 5 I-RX-RG-RPV (09-19) PN1027501R0...
- Page 6 GENERAL INFORMATION—CONTINUED Dimensions—Continued Table 3. Dimensions for Model Series RG Alphabetic Designation (See Figure Unit Model Size Dimension (inches ±1/8 (mm ±3)) 3-3/32 (79) 12-1/2 (318) 6 (152) 9 (229) 33-7/16 (849) 28-1/2 (724) 20-5/16 (516) 2 (51) 15-1/4 (387) (H)-RG,CRG 8 (203) 11-1/2 (292)
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Page 7: Weights
Figure 3. Model RX Series Dimensions (Refer to Table Table 5. Dimensions for Model Series RX Alphabetic Designation (See Figure Unit Model Size Dimension (inches ±1/8 (mm ±3)) 19-1/4 (489) 12-1/2 (318) 14 (356) 9 (229) 6 (152) 32-1/4 (819) 22 (559) 15-1/4 (387) 16-3/4 (425) -
Page 8: Gas Connections
This furnace was test operated and inspected at the factory prior to crating and was in operating condition. If the furnace has incurred any damage in shipment, document the damage with the transporting agency and immediately contact your Reznor distributor. Pre-Installation Checklist ‰... -
Page 9: Combustion Air Requirements
Figure 4. Heat Exchanger Air Baffles Duct furnaces are equipped with directional air baffles between the heat exchanger tubes. When facing the control compartment of the furnace, the standard direction or airflow is from left to right. Installations requiring direction of airflow from right to left when facing the control compartment will require repositioning the directional air baffles at the installation site. - Page 10 Combustion Air: Gravity-Vented Model Series RX and RG Both model RX and RG series furnaces have screened combustion air intake hoods in their doors. The intake hood on a model RG furnace is factory-installed. The intake hood on a model RX furnace requires field installation as follows: 1.
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Page 11: Rigging And Mounting Furnace
Lifting holes are provided at each of the four corners of the mounting support rails. Use spreader bars when lifting to prevent chains or cables from damaging the cabinet. RG series models may be placed directly on a slab or roof where support is adequate. - Page 12 INSTALLATION—CONTINUED Venting—Continued Gravity-Vented Outdoor Models (H)-RX,CRX,RG,CRG—Continued The gravity vent cap requires field installation. For furnaces that do not require vent cap extension (unit sizes 75–250 and high-efficiency size 300), align holes and attach vent cap to furnace flue collar using sheet metal screws. For furnaces that do require vent cap extension (standard-efficiency unit size 300 and all sizes 350 and 400), a 12-inch extension is necessary to raise the vent cap above the top of the furnace.
- Page 13 Guy Wire Figure 9. Flue Extension Guy Wires Power-Vented Outdoor Models (Model Series RPV) • For power-vented outdoor models, locate the furnace so that flue discharge is not directed at fresh air inlets. • Power-vented outdoor models have screened flue gas exhaust and combustion air intake openings located on the side of the furnace just above the control access panel as shown in Figure 5.
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Page 14: Condensate Drain
INSTALLATION—CONTINUED Venting—Continued Power-Vented Outdoor Models (Model Series RPV)—Continued • The option CC3 package (PN 45021) includes the 5-inch vent cap (PN 110052), the adapter assembly (PN 103025), and the venter seal plate (PN 43446). The 5-inch vent piping and support angles (recommended 1/2-inch × 1/2- Figure 10): inch, 20 gauge) are field-supplied. - Page 15 DETAIL A Figure 11. Duct Connections • Supply air duct/furnace horizontal connection: The seal between the furnace and the duct must be mechanical. Duct connection should be made with U-type flanges on the top and bottom of the connecting duct. Slide the duct over the flanges of the heater giving an airtight fit.
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Page 16: Duct Furnace Airflow Requirements
INSTALLATION—CONTINUED Duct Furnace Airflow Requirements The duct furnace must be installed on the positive pressure side of the field-supplied blower. Air throughput must be within the CFM range stated on the heater rating plate. The air distribution must be even over the entire heat exchanger. - Page 17 Duct Furnace Blower Connections ⚠ WARNING ⚠ The furnace must be installed on the positive pressure side of the air-circulating blower. Blower connection requirements are as follows: • Proper arrangements of the blower and the duct furnace with respect to the angle of approach of the duct connection and the arrangement of the discharge opening of the blower are shown in Figure •...
- Page 18 INSTALLATION—CONTINUED Duct Furnace Airflow Requirements—Continued Bypass Duct Sizing When the CFM of air throughput is greater than that which is desirable or permissible for the unit, a bypass duct (see Figure 14) may be constructed. Determine the correct size of the bypass duct as follows: Table 11 1.
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Page 19: Gas Piping And Pressures
Gas Piping and Pressures ⚠ DANGER ⚠ All components of a gas supply system must be leak tested prior to placing equipment in service. NEVER TEST FOR LEAKS WITH AN OPEN FLAME. Failure to comply could result in personal injury, property damage, or death. - Page 20 INSTALLATION—CONTINUED Gas Piping and Pressures—Continued (70mm) Model Series RG and RP Model Series RPV Model Series RX Figure 16. Gas Connection Location Table 13. Gas Supply Line Sizes Pipe Diameter (Inches) 1-1/4 1-1/2 Pipe Length Gas Type (Feet) Natural Propane Natural Propane Natural...
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Page 21: Electrical Supply And Connections
• For natural gas: Manifold gas pressure is regulated by the combination valve to 3.5 IN WC. Inlet pressure to the valve must be a minimum of 5 IN WC or as noted on the rating plate and a maximum of 14 IN WC. •... - Page 22 INSTALLATION—CONTINUED Electrical Supply and Connections—Continued Figure 17. Typical Wiring Diagram for Gravity-Vented Furnace with Standard Single-Stage Gas Valve (RG Series) I-RX-RG-RPV (09-19) PN1027501R0...
- Page 23 Figure 18. Typical Wiring Diagram for Gravity-Vented Furnace with Optional Two-Stage Gas Valve (RG Series) I-RX-RG-RPV (09-19) PN1027501R0...
- Page 24 INSTALLATION—CONTINUED Electrical Supply and Connections—Continued Disconnect Switch • A disconnect switch is a required part or this installation. Switches are available as options or parts or may be purchased locally. When ordered as an optional component, the disconnect switch is shipped separately. •...
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Page 25: Component Descriptions And Adjustments
Component Descriptions and Adjustments Limit Control The heater is equipped with a non-adjustable high limit switch that shuts OFF the gas in the event or motor failure, lack of air due to dirty filters, or restrictions at the inlet or outlet of the unit. Optional Fan Control •... - Page 26 INSTALLATION—CONTINUED Component Descriptions and Adjustments—Continued Optional Two-Stage Operation—Makeup Air Application • Two-stage makeup air units are equipped with a two-stage gas valve but instead of control from a two-stage room thermostat, the outlet air temperature is monitored and controlled by a two-stage ductstat. When the discharge air temperature drops to the setpoint, low fire is energized.
- Page 27 • Valve manufacturer’s specifications and operating instructions for the mechanical modulating valve may be found in the heater instruction envelope provided with the furnace. • The general location of the factory-installed sensor is shown in Figure 20. Access the sensor element as follows: a.
- Page 28 INSTALLATION—CONTINUED Component Descriptions and Adjustments—Continued Optional Electronic Modulation—Continued Figure 21. Maxitrol A200 Signal Conditioner Horizontal Pilot The horizontal pilot is located in the control end of the burner rack and is accessed by removing the control compartment panel. All pilots are target-type with the lint-free feature. Pilot gas pressure should be the same as supply line pressure (refer to Gas Piping and Pressures section).
- Page 29 4. If conditions in steps 1, 2, or 3 are normal and no spark occurs, replace ignition controller. 5. If main gas valve fails to open with normal full-sized pilot flame established, check following: a. If voltage between black and brown leads on main gas valve is 20–32VAC and there is no main gas flow with built-in manual valve in FULL OPEN position, main valve is defective.
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Page 30: Operation
INSTALLATION—CONTINUED Component Descriptions and Adjustments—Continued Burner Air Adjustment—Continued Adjust the burner air shutters as follows: 1. After furnace has been in operation for 15 minutes, close air shutters and observe flame for yellow-tipping. 2. Slotted screw on end manifold bracket moves air shutters and adjusts all burners simultaneously. If flame shows yellow-tipping, open shutters until yellow tip disappears by turning screw clockwise. -
Page 31: Startup Checklist
Startup Checklist NOTE: If the flame is extinguished during main burner operation, the safety switch closes the main valve and recycles the spark gap. On units equipped with a G770NGC-4 controller, which includes lockout control, if the pilot is not established within approximately 120 seconds, the unit locks out and must be reset by interrupting the power to the control circuit (refer to the lighting instructions provided with the furnace). -
Page 32: Maintenance
MAINTENANCE This unit will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a furnace operating under normal conditions should be inspected every four months. If the furnace is operating in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent inspection is recommended. Maintenance Schedule The following procedures should be carried out at least annually. - Page 33 3. Clean main burners and pilot burner as follows: a. Clean main burners using air pressure to blow out scale and dust accumulation from burner ports. b. Alternately blow air through burner ports and venturi. c. Use fine wire to dislodge any stubborn particles. Do not use anything that might change port size. d.
- Page 34 MAINTENANCE—CONTINUED Maintenance Procedures—Continued Heat Exchanger Maintenance—Continued Figure 24) 2. Remove V-shaped baffles from gravity-vented models (see as follows: a. Remove ends of flue gas collection box. b. On control side of furnace, remove block-off plate to gain access to collection box end. c.
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Page 35: Troubleshooting
TROUBLESHOOTING Table 16. General Troubleshooting Symptom Probable Cause Remedy Venter motor 1. No power to furnace Turn on power will not start Check supply fuses or circuit breaker (power-vented 2. No 24V power to venter relay Turn up thermostat model) Check control transformer output Check for loose or improper wire connections 3. -
Page 36: Installation Record
INSTALLATION RECORD (to be completed by the installer): Installer: Name _______________________________________________ Company _______________________________________________ Address _______________________________________________ _______________________________________________ _______________________________________________ Phone _________________________________ Distributor (company from which the unit was purchased): Company _______________________________________________ Contact _______________________________________________ Address _______________________________________________ _______________________________________________ _______________________________________________ Phone _________________________________ Model ________ Serial No. ________________Date of Installation _________ SPECIFIC INSTALLATION NOTES: (i.e., Location, Amps, Gas Pressure, Temperature, Voltage, Adjustments, Warranty, etc.) _________________________________________________________________...
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