Reznor RP Installation, Operation And Maintenance Manual
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Reznor RP Installation, Operation And Maintenance Manual

Outdoor duct furnace
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OUTDOOR DUCT FURNACE INSTALLATION, OPERATION,
AND MAINTENANCE
RP
• Failure to follow safety warnings exactly could result in serious injury, death, or property
damage.
• Improper installation, adjustment, alteration, service, or maintenance can cause serious injury,
death, or property damage.
• Installation and service must be performed by a qualified installer, service agency, or the gas
supplier.
• Be sure to read and understand the installation, operation, and service instructions in this
manual.
• 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 phone remote from the building. Follow the gas
supplier's 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.
MODELS RP AND HRPD
 ⚠ DANGER ⚠ 
FIRE OR EXPLOSION HAZARD
WHAT TO DO IF YOU SMELL GAS
Revision: RP-HRPD-IOM (07-22) 132210-B
Supersedes: I-RP-HRPD (04-21) 132210-A
HRPD

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Summary of Contents for Reznor RP

  • Page 1 Revision: RP-HRPD-IOM (07-22) 132210-B Supersedes: I-RP-HRPD (04-21) 132210-A OUTDOOR DUCT FURNACE INSTALLATION, OPERATION, AND MAINTENANCE MODELS RP AND HRPD HRPD  ⚠ DANGER ⚠  FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could result in serious injury, death, or property damage.

  • Page 2: Table Of Contents

    Burners and Carryover System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 RP-HRPD-IOM (07-22) 132210-B...

  • Page 3: General Information

    . The type of gas for which the furnace is equipped, the correct firing rate, and electrical requirements are shown on the unit’s rating plate . • Model HRPD is dual model RP furnaces configured for higher CFM capacity . References Table 1.

  • Page 4: Important Safety Information

    If you do not have knowledge of local requirements, check with the local gas company or any other local agencies who might have requirements concerning this installation. • The instructions in this manual apply only to duct furnace models RP and HRPD. Installation Codes These units must be installed in accordance with local building codes .

  • Page 5: Warranty

    . Furnace air throughput is not adjusted within the range specified on the rating plate . e . Duct furnace is installed in a process or drying application without factory authorization (any use in a process or drying application voids agency certification) . Dimensions Figure 1. Model RP Dimensions (Refer to Table RP-HRPD-IOM (07-22) 132210-B...
  • Page 6 GENERAL INFORMATION—CONTINUED Dimensions—Continued Table 2. RP Dimensions Unit Size Dimension 150, 175 200, 225 250, 300 (See Figure Inches ±1/8 (mm ±3) 30-15/16 (786) 36-7/16 (914) 41-15/16 (1065) 50-3/16 (1275) 55-11/16 (1414) 61-3/16 (1554) 28-1/2 (648) 34 (864) 39-1/2 (1003)

  • Page 7: Weights

    Before installation, check the supporting structure to ensure that it has sufficient load-carrying capacity to support Table 4, which lists unit weight based on unit size . the weight of the unit . Refer to Table 4. Weights RP Unit Size 150, 175 200, 225 250, 300 Model...

  • Page 8: Hazards Of Chlorine

    • 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 an authorized Reznor distributor . If you are an authorized Distributor, follow the FOB freight policy procedures .
  • Page 9 Table 7. High Air Throughput Minimum Maximum RP Unit Size 1225 4605 1475 5530 1720 6450 1965 7370 2210 8295 2455 9215 2945 11,060 3440 12,900 3930 14,745 ⚠ DANGER ⚠ • This conversion shall be done by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction.
  • Page 10 . Adhere label to unit on clean dry surface adjacent to rating plate . Table 4 . Test unit for proper operation ensuring that air throughput is in accordance with (date) (name & address of company making this conversion) 263308 Figure 5. Field Conversion Label RP-HRPD-IOM (07-22) 132210-B...

  • Page 11: Reverse Airflow Conversion

    Leakage can cause poor combustion, poor performance, and pilot problems and can shorten heat exchanger life. NOTE: Make adjustments to ductwork as necessary to obtain a temperature rise and static pres- sure within the ranges specified on the heater rating plate. RP-HRPD-IOM (07-22) 132210-B...

  • Page 12: Ductwork Requirements

    . Form U-channels to seal sides (see DETAIL A) and drill and lock with sheet metal screws . • Connection dimensions: connection dimensions (inches (mm)) are shown in Figure 8 Table and listed in DETAIL A Figure 7. Connecting Ductwork to Furnace RP-HRPD-IOM (07-22) 132210-B...

  • Page 13: Discharge Air Temperature Sensor Installation

    . Refer to following formula for calculating sensor placement . This example assumes cross-sectional dimensions for supply ductwork of 24 × 12 inches (610 × 305 mm): RP-HRPD-IOM (07-22) 132210-B...
  • Page 14 . For all options, ensure that all sensor wires are connected in accordance with wiring diagram provided with unit . DETAIL A: OPTIONS AG8, AG9, AG39, AND AG41 DETAIL B: OPTIONS AG15 AND AG17 Figure 9. Discharge Air Temperature Sensor and Holder RP-HRPD-IOM (07-22) 132210-B...

  • Page 15: Duct Furnace Airflow

    Table 9 Table 10 list the approved temperature rise range with the required CFM and the internal pressure drop for each size of unit . Table 9. Model RP Pressure Drop and Temperature Rise Temperature Rise* Unit Size 50°F 60°F 70°F...

  • Page 16: Bypass Duct Construction

    . Locate the bypass duct on the side of the furnace opposite the controls and 2 inches from the heat exchanger side panel . Extend the bypass duct 18 inches (457 mm) beyond the furnace on both the inlet and outlet ends . Determine the correct size of the bypass duct as follows: RP-HRPD-IOM (07-22) 132210-B...
  • Page 17 CFM for furnace being installed . For example: model RP unit size 150 @ 50°F temperature rise = pressure drop of 0.38 and CFM of 2,210 . 2 . Subtract allowable CFM from blower CFM to determine how much air must be diverted through bypass duct . For example: blower CFM of 3,000 −...

  • Page 18: Piping Connections

    • All piping must be in accordance with requirements outlined in the National Fuel Gas Code ANSI/Z223 .1 (latest Installation Codes edition) or the Natural Gas and Propane Installation Code CSA B149 .1 (refer to section) . • Gas supply piping installation should conform with good practice and with local codes . RP-HRPD-IOM (07-22) 132210-B...

  • Page 19: Supply Piping Connections

    • After all connections are made, disconnect the pilot supply at the control valve and bleed the system of all air . Reconnect the pilot line and leak test all connections by brushing on a soap solution . • Gas connections sizes are listed in Table 13 . RP-HRPD-IOM (07-22) 132210-B...
  • Page 20 INSTALLATION—CONTINUED Piping Connections—Continued Supply Piping Connections—Continued DETAIL A DETAIL B DETAIL C Figure 13. Gas Connections Table 13. Gas Connection Sizes RP Unit Size 125–250 300–400 Gas Type HRPD Unit Size 250–500 600–800 Connection Size (Inches (mm)) Natural gas 1/2 (13)

  • Page 21: Electrical Connections

    NOTE: 24V transformer has 20VA capacity . Table 15. Control Wiring Sizes Distance from Unit to Control Minimum Recommended Wire Gauge Total Wire Length (Feet (Meters)) (AWG) (Feet (Meters)) 75 (23) 150 (46) 125 (38) 250 (76) 175 (53) 350 (107) RP-HRPD-IOM (07-22) 132210-B...

  • Page 22: Controls

    . Combination Gas Valve ⚠ WARNING ⚠ The combination gas valve is the prime safety shutoff. To ensure positive closure, all gas supply lines must be free of dirt or scale before connecting the unit. RP-HRPD-IOM (07-22) 132210-B...

  • Page 23: Combustion Air Proving Switch

    • There are two methods of achieving multiple-stage makeup air operation . In addition, for each of these methods, there are two types of control mechanisms . Consult the wiring diagram on the furnace to identify the optional control system: option AG3, AG4, AG15, or AG17 . RP-HRPD-IOM (07-22) 132210-B...
  • Page 24 (see Figure 14, DETAIL B) . Ductstat Bulb (A) Remote Temperature Selector (B) Stage-Adder Typical Duct Furnace Module Front (Discharge) View DETAIL A: OPTIONS AG3 AND AG4 DETAIL B: OPTIONS AG15 AND AG17 Figure 14. Ductstat Options RP-HRPD-IOM (07-22) 132210-B...

  • Page 25: Optional Ductstat With Capillary Tubing (Options Ag3 And Ag4)

    MV-3, AG9 is identified as MV-4, AG21 is identified as MV-A, AG39 is identified as MP-1, and AG40 is identified as MP-2 . AG39 and AG40 are available only on model RP . AG41 is identified as MP3 and AG42 is identified as MP4 .

  • Page 26: Computer-Controlled Electronic Modulation Between 50% And 100% Firing Rate (Option Ag21)

    Electronic Modulation Between 20–28% and 100% Firing Rate (Options AG39 and AG41) NOTE: Option AG39 is available only with model RP natural gas units and is not available on unit size 350. Option AG41 is available only with model HRPD natural gas units and is not available on unit size 700.
  • Page 27 Terminal 7? Terminal 2? Replace the Replace ignition primary manifold permissive pressure switch. relay. Figure 17. Troubleshooting Guide for Checking Bypass Combustion Air Damper Safety Circuit on Units with Option AG39, AG40, AG41, or AG42 RP-HRPD-IOM (07-22) 132210-B...

  • Page 28: Electronic Modulation Between 20-28% And 100% Firing Rate (Options Ag40 And Ag42)

    Electronic Modulation Between 20–28% and 100% Firing Rate (Options AG40 and AG42) NOTE: Option AG40 is available only with model RP natural gas units and is not available on unit size 350. Option AG42 is available only with model HRPD natural gas units and is not available on unit size 700.

  • Page 29: Burners And Carryover System

    . If step c indicates leak, locate leak by brushing soapy solution on all fittings—bubbles will appear at any leaks . e . Repair any leaks and repeat test . ‰ Check to ensure that flue discharge openings are free from obstructions . RP-HRPD-IOM (07-22) 132210-B...

  • Page 30: Startup

    • Always comply with the combustion air requirements in the installation codes and instructions. • Combustion air at the burner should be regulated only by manufacturer-provided equipment. NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. RP-HRPD-IOM (07-22) 132210-B...

  • Page 31: Adjustments

    • Deration is necessary to compensate for low atmospheric pressure at high elevations. Generally this will require obtaining the gas heating value from the local gas utility and replacing the burner orifices. RP-HRPD-IOM (07-22) 132210-B...
  • Page 32 4 . Thread replacement gas orifices into gas manifold . To prevent cross-threading, hand-tighten orifices into gas manifold until snug and then tighten one-half to one turn using wrench . ⚠ DANGER ⚠ DO NOT use an open flame to check for gas leaks. RP-HRPD-IOM (07-22) 132210-B...

  • Page 33: Conversion To Lp (Propane)

    NOTE: The same type of controller may also be used as the optional high ambient limit control (option BN2) and as the mixed air controller that is part of air control options AR12, AR13, AR15, and AR16. 3 . Adjust each controller to setpoint as determined by calculation in step 1 . RP-HRPD-IOM (07-22) 132210-B...

  • Page 34: Maintenance

    2 . With field-installed manual valve closed to prevent flow to gas valve, connect manometer to 1/8-inch FPT INLET pressure tap (see Figure 19) . 3 . With field-installed manual valve closed, turn up thermostat to fire unit and to allow unit to go through one trial for ignition . RP-HRPD-IOM (07-22) 132210-B...

  • Page 35: Burner Rack Maintenance

    . Remove screws and lift out pilot burner . 3 . Clean burner rack in accordance with instructions in Cleaning Pilot and Burners section . 4 . Re-assemble and re-install burner rack by reversing above steps, being careful not to create any unsafe conditions . RP-HRPD-IOM (07-22) 132210-B...

  • Page 36: Cleaning Pilot And Burners

    . Use a fine wire to dislodge any stubborn particles from the burner ports . 8 . Clean the burner rack carryover systems using compressed air . RP-HRPD-IOM (07-22) 132210-B...

  • Page 37: Spark Ignition System Maintenance

    . Remove accumulated dust and grease deposits from heat exchanger tubes and baffles using brush and/or air hose . Reverse Airflow Conversion d . Re-install baffles in accordance with section . e . Secure ductwork as necessary . RP-HRPD-IOM (07-22) 132210-B...
  • Page 38 . (4) For model RP unit size 400, remove inner baffle from flue collection box: on control side, align inner baffle with slot in collection box edge and pull inner baffle until it clears heat exchanger . Remove screw at each end and slide flue diverter out of furnace .

  • Page 39: Troubleshooting

    1 . Incorrect manifold pressure Check manifold pressure (refer to Measure and Adjust Manifold (Outlet) air during Gas Pressure section) operation 2 . Blower set for too low temperature rise Decrease blower speed or increase static pressure RP-HRPD-IOM (07-22) 132210-B...

  • Page 40: Installation Record (To Be Completed By Installer)

    For more information, contact your Factory Representative. Specifications and illustrations subject to change without notice or incurring obligations . Latest version of this manual is available at www.reznorhvac.com . ©2022 Nortek Global HVAC LLC, O’Fallon, MO . All rights reserved . RP-HRPD-IOM (07-22) 132210-B...

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