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Table of Contents
Para.
Installation and Operation ......... 1-29 ... 1-30
Check Installation and Start-Up ... 30 . 30-31
Optional Accessories ................. 31-36 . 31-41
Service/Maintenance .................. 37-41 . 41-44
Index by Page Number
Adjusting Blower Speed ............................... 24
Optional Air Flow Proving Switch
Opt High Ambient Limit Control .................. 25
AquaSaver Timer Adjustment ........................ 34
Belts ............................................................... 24
Blocked Vent Switch ...................................... 25
Blower Motors ............................................... 24
Blower Rotation ............................................. 24
Burner Air Adjustment .................................. 30
Burner Rack Removal ..................................... 42
Burners ........................................................... 29
Carryover System ........................................... 29
Check Installation and Start-Up .................... 30
Chlorines .......................................................... 7
Cleaning Pilot and Main Burners .................. 42
Cleaning the Heat Exchanger ........................ 42
Clearances ........................................................ 7
Optional Cooling Coil Cabinet ..................... 38
Combustion Air Requirements ........................ 7
Condensate Drain .......................................... 13
Location of Controls ...................................... 17
Cooling Coil Cabinet
.................................... 38
Optional Dampers and Controls .................... 35
Dimensional Data ............................................ 3
Direct Digital Control System ....................... 29
Discharge Dampers ........................................ 39
Disconnect Switch ......................................... 17
Duct Connections .......................................... 13
Optional Ductstat
.......................................... 26
Electrical Supply and Connections ............... 16
Optional Electronic Modulation
.................. 26
Opt Evaporative Cooling Module
................ 32
Optional Fan Control
.................................... 25
Optional Dirty Filter Switch ......................... 38
Filter Arrangements ....................................... 38
Optional Filter Rack and Filters .................... 37
Gas Piping and Pressures .............................. 14
Gas Valve ........................................................ 41
General ............................................................. 1
Hazard Intensity Levels ................................... 2
Ignition Controller ......................................... 29
Installation Codes ............................................ 2
Limit Control ................................................. 24
Manifold Pressure Setting ............................. 15
Optional Mechanical Modulation ................. 26
Mounting Furnaces (Indoor) ........................... 8
Mounting Outdoor Models
............................. 8
Optional Equipment ...................................... 31
100% Outside Air Hood ................................ 31
Pilot and Ignition Systems ............................ 29
Reverse Flow, Limit Control .......................... 25
Roof Curb Assembly and Installation .............. 9
30% Screened Air Hood Opening ................ 32
Optional 4-foot Stack Extension ................... 12
Start-Up .......................................................... 30
Suspending Furnaces ....................................... 8
Troubleshooting
............................................ 43
Optional Two-Stage Operation
..................... 25
Uncrating ......................................................... 2
Valve ............................................................... 25
Variable Frequency Drive .............................. 24
Vent Cap Installation ..................................... 12
Optional Power Venting ................................ 12
Venting ........................................................... 11
Venting Requirements .................................... 11
Optional Vertical Flue Discharge .................. 13
Warranty ........................................................... 2
Wiring Diagrams ............................................ 18
®
Page
If you smell gas:
1. Open windows.
2. Don't touch electrical switches.
3. Extinguish any open flame.
.............. 24
4. Immediately call your gas supplier.
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, operation, and maintenance instructions thoroughly before
installing or servicing this equipment.
WARNING: Gas-fired appliances are not designed for use in hazardous
atmospheres containing flammable vapors or combustible dust, in
atmospheres containing chlorinated or halogenated hydrocarbons, or in
applications with airborne silicone substances. See Hazard Levels, Page 2.
GENERAL
Installation should be done by a qualified agency in accordance with the instructions in this
manual and in compliance with all codes and requirements of authorities having jurisdiction.
The instructions in this manual apply to the packaged systems listed below.
Model Series
Designation
XE
HXE
CRGB
HCRGB
RPB
HRPB
Model Series XE, CRGB, RPB
Packaged Duct Furnace
Installation/Operation/Maintenance
Form I-XE/CRGB/RPB (Version B)
Obsoletes Form I-XE/RGB /RPB (Version A)
FOR YOUR SAFETY
FOR YOUR SAFETY
Characteristics
Installation
Vent
Indoor
Gravity
Outdoor
Power
Form I-XE/CRGB/RPB, Mfg No. 131782 Rev 4, Page 1
Assemblies
Thermal
CFM
Efficiency
Standard
High
Standard
80%
High
Standard
High
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Related Manuals for Reznor XE Series
Summary of Contents for Reznor XE Series
- Page 1 Model Series XE, CRGB, RPB Packaged Duct Furnace Assemblies Installation/Operation/Maintenance Form I-XE/CRGB/RPB (Version B) ® Obsoletes Form I-XE/RGB /RPB (Version A) Table of Contents Para. Page FOR YOUR SAFETY Installation and Operation ..1-29 ... 1-30 Check Installation and Start-Up ... 30 . 30-31 If you smell gas: Optional Accessories ....
- Page 2 Special Installations (Aircraft Hangars/Garages) any damage in shipment, document the damage with the carrier and contact your Reznor distributor. Installations in aircraft hangars should be in accordance with NFPA No. 409 (latest edition), Standard for Aircraft Hangars; in public garages in Check the rating plate for the gas specifications and electrical character- accordance with NFPA No.
- Page 3 4. Dimensions FIGURE 1A - Dimensions (inches and mm) of Indoor/Gravity Vented System Dimensions of Model (H)XE with Standard Blower Cabinet (Standard blower cabinet has "full open" end and will not accommo- date dampers. An optional cabinet is available with a smaller horizontal inlet that will accommodate dampers; see dimensional drawing below.
- Page 4 4. Dimensions (cont'd) FIGURE 1B - Model Vent Cap Gas Connection S ize Dimensions, I.D. Height Extension Natural Propane S eries Outdoor/ inches 28-5/8 17-3/8 25-7/8 12-1/2 None Gravity- None Vented Model inches 28-5/8 17-3/8 25-7/8 15-1/4 11-1/2 None Series CRGB None inches 34-1/8...
- Page 5 Gas Connection FIGURE 1C - Model S ize Dimensions, Outdoor/ Natural Propane Power-Vented Model inches 28-5/8 17-3/8 25-7/8 15-1/4 Series RPB inches 34-1/8 22-7/8 31-3/8 20-3/4 150, 175 inches 39-5/8 28-3/8 36-7/8 26-1/4 200, 225 1006 inches 47-7/8 36-5/8 45-1/8 34-1/2 (H)-RPB 1216...
- Page 6 4. Dimensions (cont'd) FIGURE 1D - 8 (203) 2 (51) 7/8 (22) 7/8 (22) Optional Cooling 5-1/8 (130) Refrigerant Coil Cabinets with R22 (DX) DX or Chilled Liquid Line Side View Connections Coil Water Coil, with DX Coil (7/8” or 1-3/8”) Coil (19) Cabinet -...
- Page 7 5. Clearances FIGURE 2 - Confined Space: A Provide clearance to combustibles as shown in the table. Clearance to space whose volume combustibles is defined as the minimum distance from the heater to a is less than 50 surface or object that is necessary to ensure that a surface temperature Confined cubic feet per 1000 of 90°F above the surrounding ambient temperature is not exceeded.
- Page 8 7A. Suspending/Mounting Indoor, Gravity- Approximate Net Weight (lbs/kg) - Outdoor Systems Vented Models XE/HXE (cont'd) (blower and furnace sections only) Size 75, 100 125 150, 175 200, 225 250, 300 350 400 WARNING: Unit must be level for proper CRGB 624 655 operation.
- Page 9 Bottom Duct Connections - The blower section and optional down- FIGURE 6A - Mounting Support Dimensions (inches/mm) turn plenum have duct flanges for connection to return air and supply air ducts. Duct opening sizes and curb spacing shown in FIGURE 7 is for currently manufactured curbs that are available from the system manufacturer.
- Page 10 7B. Mounting Outdoor Models on a Roof Curb (cont'd) *Optional FIGURE 8 - Downturn Plenum Splicing Optional Roof Curb Detail Furnace Blower Cabinet For top 4 holes (2 on each side) at both joints, Lift Holes from inside the curb insert (4 corners) (4) 5/16”...
- Page 11 Roof Curb Dimensions (mm) 75, 100, 75, 100, S ize 150, 175 200, 225 250, 300 S ize 150, 175 200, 225 250, 300 Option CJ4 - Roof Curb for (H)CRGB and (H)RPB with Field- Option CJ1 - Roof Curb for (H)CRGB and (H)RPB Installed*** Cooling Coil Cabinet Option AU2 or AU3 1540 1540...
- Page 12 * Reduce the vent pipe lengths as follows for each item: 45° Elbow - 7ft Control Compartment ® (2.1M); 90° Elbow - 15ft (4.6M); Reznor or Breidert Vent Cap - 10ft (3M). Access Panel ** If the venter outlet is 4", connect a taper-type "enlarger" to the vent outlet when installing 6"...
- Page 13 FIGURE 9C - Optional Stack Extension applies only to FIGURE 11B - Installation of the Vent Cap (included in the Furnaces with Suffix "Z" in their Model No. option package) and the field-supplied Piping and Supports Three guy wires, spaced 120° Gravity Vent Cap apart, fastened to the vent 5”...
- Page 14 • 10. Duct Connections (cont'd) Bottom Duct/Furnace Connections - On outdoor models, insert ducts from below roof deck through roof opening into the heater. Requirements and Suggestions (cont'd) Form 1" (25mm) flanges, fold over, and fasten with sheetmetal screws • inside heater.
- Page 15 quires the installation of a trap with a minimum 3" (76mm) drip leg. Local Gas Connection to Single-Stage Valve (Not Gas Supply Line Size) codes may require a minimum drip leg longer than 3" (76mm), typically 6" Applies to all M odels in this Manual (152mm).
- Page 16 11. Gas Pressures (cont'd) used both when the heater is in operation and on standby. Incorrect Manifold or Orifice Pressure Settings (cont'd) inlet pressure could cause excessive manifold gas pressure immedi- For Natural Gas: When the heater leaves the factory, the combination ately or at some future time.
- Page 17 FIGURE 19 - Location of Standard and Optional Controls - Outdoor Systems 41 1 32 33 34 35 36 37 38 39 40 30 31 Optional Downturn Plenum (Option AQ) 29 25 28 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 1.
- Page 18 CHASSIS GRND. OPERATING SEQUENCE NOTES 1. SET THERMOSTAT AT LOWEST SETTING. 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: 2. TURN ON POWER, MAIN AND PILOT MANUAL GAS VALVES. NONE 3. SET THERMOSTAT AT DESIRED SETTING. 2. THE FOLLOWING CONTROLS ARE SUPPLIED AS OPTIONAL EQUIPMENT: (A) FIRING RATE IS CONTROLLED BY THE THERMOSTAT.
- Page 19 OPTIONAL FIELD WIRING OPERATING SEQUENCE NOTES 1. SET THERMOSTAT SWITCH AT "OFF" POSITION. 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: 2. TURN ON POWER, MAIN AND PILOT MANUAL GAS VALVES. NONE 3. SET THERMOSTAT SWITCH AT "AUTO" POSITION.
- Page 20 TERMINAL BLOCK -- HEATER COMPARTMENT OPERATING SEQUENCE NOTES 1. SET THERMOSTAT AT LOWEST TEMPERATURE. 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: 2. TURN ON POWER AND MANUAL GAS VALVE TO UNIT. NONE 3. SET THERMOSTAT AT DESIRED TEMPERATURE.
- Page 21 #14 GA. OPERATING SEQUENCE NOTES 1. SET THERMOSTAT SWITCH AT "OFF" POSITION. 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: 2. TURN ON POWER AND MANUAL GAS VALVE TO UNIT. NONE 3. SET THERMOSTAT SWITCH AT "AUTO" POSITION.
- Page 22 1. SET THERMOSTAT AT LOWEST SETTING. NOTES 2. TURN ON POWER AND MANUAL GAS VALVE TO UNIT. 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: 3. SET THERMOSTAT AT DESIRED SETTING. NONE (A) FIRING RATE IS CONTROLLED BY THE THERMOSTAT.
- Page 23 OPTIONAL FIELD WIRING OPERATING SEQUENCE 1. SET THERMOSTAT SWITCH AT "OFF" POSITION. NOTES 1. THE FOLLOWING CONTROLS ARE SUPPLIED BY REZNOR FOR FIELD INSTALLATION: 2. TURN ON POWER AND MANUAL GAS VALVE TO UNIT. NONE 3. SET THERMOSTAT SWITCH AT "AUTO" POSITION.
- Page 24 13. Blowers, Belts and Drives Optional Variable Frequency Drive When an optional variable frequency drive is ordered, the motor oper- Check belt tension. Proper FIGURE 20 - Check Belt Tension ates on two speeds as determined by the electrical frequency. High belt tension is important to speed is used for cooling and low speed for heating.
- Page 25 controls or miswiring, and will require correction of The table below gives approximate water column negative pressure readings and switch setpoints for sea level operating conditions. the cause of failure and the replacement of the fan Startup Cold Equilibrium Factory Setpoint and limit control and wiring before the unit can be -1.05"...
- Page 26 23. Optional 2-Stage Operation - On outdoor models, mechanical modulation gas control is available with bypass. With the bypass option, the unit is equipped with a single- Makeup Air Application (cont'd) stage valve and relay. On call from a remote override thermostat, the temperature rise of the furnace in the installation dictates the limits of single-stage bypass valve cycles on at 100% fire.
- Page 27 25B. Computer Controlled Electronic Modu- outlet pressure setting higher than when it is used on a standard gas manifold. The pilot tubing connects to the pilot port on the single-stage lation between 50% and 100% Firing gas valve. When the valve receives a call for heat from the amplifier and Rate (Option AG21) pilot is established, gas flow from the single-stage valve goes to both the With this option the furnace is equipped with a Maxitrol signal condi-...
- Page 28 25. Optional Electronic Modulation (cont'd) 25C. and 25D. Electronic Modulation between 20% -28% and 100% Firing Rate (cont'd) Troubleshooting Guide for Checking Bypass Combustion Air Damper Is there 24 volts Go to between Terminal 2 on #1 Safety Circuit on Model Troubleshooting Time Delay Relay and RPB with Option AG39...
- Page 29 26. Direct Digital Control System - Option AH2, and spark pilot with lockout is Option AH3. NOTE: Outdoor units in Canada using propane, require lockout. Indoor units in Model Series CRGB and RPB U.S. and Canada, using propane require lockout. The heater is equipped with a specially programmed Johnson Controls Ignition Controller - As part of the intermittent safety pilot systems, ®...
- Page 30 28. Burner and Carryovers (cont'd) d) Attach pressure gauge readable to .1" w.c. and after turning gas on for ten seconds, turn gas supply off. No change in pressure INDOOR Gravity-Vented Furnace (Models XE/HXE) - Natural gas should occur over a three-minute period. burners are equipped with two flash carryover systems that receive a e) If either c) or d) above indicate a leak, locate leak by brushing supply of gas simultaneously with the main burner.
- Page 31 lockout control, if the pilot is not established within 120 seconds DANGER: The gas burner in this gas-fired (approximately), the unit locks out and must be reset by equipment is designed and equipped to provide safe, interrupting the power to the control circuit (See Lighting complete combustion.
- Page 32 31. 100% Outside Air Hood (cont'd) FIGURE 31 - Installation of Air Hood on Cabinets with 30% Outside Air Opening Options Hood Installation Instructions (cont'd) Remove two corner and 3. Bottom Panel - Position the air hood bottom panel so that it is to Blower compete row of screws Cabinet...
- Page 33 metering water system, it will not have these controls but will Instructions for Installing Optional Fill & Drain Kit have a solenoid valve with a timer assembly for controlling water NOTE: Follow instructions included in the valve packages for attaching flow.
- Page 34 33. Optional Evaporative Cooling Module (outdoor models) (cont'd) Bleed Line (cont'd) FIGURE 37A - Adjust Water A = Water rise Discharging a quantity of water by "bleed off" will limit the concentra- Flow with the Ball Valve in from PVC tion of undesirable minerals in the water being circulated through the FIGURE 36 Height...
- Page 35 Water Feed and Distribution Line - Annually, the water supply line M edia Pad Replacement Part No. (each) and the water distribution line (either PVC pipe or water sock) should Sizes Cellulose Fiber Glass Fiber be flushed of debris and contaminants. (inches) 6"...
- Page 36 34. Optional Dampers and Controls (cont'd) FIGURE 41A - Control FIGURE 41B - Location of Controls for 30% Outside Air Hood Locations for Air Inlet/ and Damper Options (AR6 or AR7) - Outdoor Models only Damper Options on Indoor Models XE/HXE 30% Outside Air Damper Blower Cabinet 1 Outside Air Damper...
- Page 37 35B. Filter Rack and Filters - Outdoor Model 4. Adjustment of the Switch - The "HIGH" actuation point of the null switch is indicated on a calibrated scale secured to the trans- Series CRGB and RPB parent range screw enclosure. Building pressure is set by turning Filter rack and filters are factory installed optional equipment.
- Page 38 35. Optional Filter Rack and Filters (cont'd) 35B. Filter Rack and Filters - Outdoor Models (cont'd) FIGURE 43 - Filter Sizes 75-125 Sizes 150-175 Sizes 200-225 Arrangements - Outdoor Models 20” 20” 20” (508mm) (508mm) (508mm) Key: Filter Code Filter Size 16 x 20 20 x 20 16 x 25...
- Page 39 Factory-Supplied Parts for Attaching Cabinet to Furnace Description Qty 75, 100 150, 175 200, 225 250, 300 107426 107427 107428 107429 106338 106339 106340 Top/Bottom Duct Connectors 14" 16-3/4" 21-1/4" 27-3/4" 36" 41-1/2" 47" 106395, 19-1/2" (495mm) long Side Duct Connectors Connectors 105171 #14 x 3/4"...
- Page 40 36. Optional Cooling Coil Cabinet, Option AU (Outdoor Models) (cont'd) Installation Instructions (cont'd) 6. Prepare Cabinets to Install Filler Panels (See FIGURE 46H) a) At the side corners of both the cooling coil cabinet and the the blockoff plate and drill a 7/8" hole. The hole should be furnace, remove the factory-installed screws that attach the approximately even with the hole drilled in the downturn cabinet tops.
- Page 41 Filler must be underneath the top FIGURE 46K - FIGURE Top Filler Panel panel. 46J - Installed Side Filler Panel Installed Cooling Coil Cabinet with Downturn Plenum Before the top filler panel is attached, remove the backing and Furnace adhere the gasket strip along the bottom of the outside edge so Section that any gaps between the top filler panel and the top panel of with Door...
- Page 42 38. Burner Rack Removal Screws B FIGURE 48 - Top Baffle Support Instructions When cleaning outer heat 1. Turn off the gas supply. exchanger 2. Turn off the electric supply. surface, remove 3. Remove control access side panel. directional 4. Disconnect the pilot tubing and flame sensor lead (spark pilot). air baffles.
- Page 43 Indoor, Gravity Vent Models XE/HXE (See FIGURE 50) FIGURE 50 - Remove "V" Baffles to Clean Inner Surface 1) Remove the screws (the number varies depending on unit size) of Heat Exchanger Tubes along the bottom of the front baffle and the three on each end. Rear Baffle Tube Baffle Holddown Plate Tube...
- Page 44 1-800-695-1901; www.RezSpec.com ©2006 Thomas & Betts Corporation, All rights reserved. MANUFACTURER OF HEATING, VENTILATING, AND AIR CONDITIONING SYSTEMS ® Trademark Note: Reznor is registered in the United States and other countries. Form I-XE/CRGB/RPB, Page 44 9/06 Form I-XE/CRGB/RPB (Version B)
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