Reznor MAPS RCB Operation Manual
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Reznor MAPS RCB Operation Manual

Reznor MAPS RCB Operation Manual

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Form O-MAPSIII Cabinet D (Version D)
Obsoletes Form O-MAPSIII Cabinet D (Version C)
Operation / Maintenance / Service
®
Applies to:
Models RCB, RDB, RDCB,
RDDB, RECB, and REDB
®
™
Cabinet "D" Sizes
R-410A
CQS
CQS
Refrigerant
DANGER
This unit contains R-410A high pressure refrigerant. Hazards exist that could
result in personal injury or death. Installation, maintenance, and service should
only be performed by an HVAC technician qualified in R-410A refrigerant and
using proper tools and equipment. Due to much higher pressure of R-410A
refrigerant, DO NOT USE service equipment or tools designed for R22
refrigerant.
IMPORTANT: Do not release refrigerant to the atmosphere! If required service
procedures include the adding or removing of refrigerant, the service technician
must comply with all federal, state and local laws. The procedures discussed
in this manual should only be performed by a qualified HVAC technician.
Form O-MAPSIII Cabinet D, P/N 222918R9, Page 1

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  • Page 1 Form O-MAPSIII Cabinet D (Version D) Obsoletes Form O-MAPSIII Cabinet D (Version C) Operation / Maintenance / Service ® Applies to: Models RCB, RDB, RDCB, RDDB, RECB, and REDB ® ™ Cabinet "D" Sizes R-410A Refrigerant DANGER This unit contains R-410A high pressure refrigerant. Hazards exist that could result in personal injury or death.

  • Page 2: Table Of Contents

    Table of Contents 1.0 General ..............2 4.0 Gas Heat Section Maintenance - Models RDCB and RDDB ........21-33 2.0 Maintenance Requirements ......3-5 4.1 Heat Exchanger, Burner, and Venter 2.1 Maintenance Schedule ........3 Maintenance .............21 2.2 Control Locations ..........4 4.2 Gas Heat Section Controls ........26 2.3 MAPSIII D Cabinet Sizes ........5 4.3 Gas Train ............30 3.0 Maintenance/Service Procedures ....

  • Page 3: Maintenance Requirements

    2.0 Maintenance This unit will operate with a minimum of maintenance. To ensure long life and satis- factory performance, a system that is operating under normal conditions should be Requirements inspected according to the Maintenance Schedule. If in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent inspec- tion is recommended.

  • Page 4: Control Locations

    2.0 Maintenance Requirements (cont'd) 2.2 Control Locations FIGURE 1 - Access Panels and High and Low Voltage Control Locations Door Hinge Locked Unlocked Heater Controls Access Door Control Compartment Access Door The filter, coil, and fan/motor cabinet doors can be opened from the left or Gas Heat right.

  • Page 5: Mapsiii D Cabinet Sizes

    2.3 MAPSIII D Model Cabinet Gas Heat Section Size Electric Heat Section Model Cabinet Sizes Size RDCB -500 -600 -700 -800 -1000 -1200 -1400 -1600 RECB120 RECB180 Gas Heat Section Size Electric Heat Section Model Cabinet Model Size RDDB -500 -600 -700 -800 -1000 -1200 -1400 -1600 REDB120 REDB180...

  • Page 6: Drive Components

    3.0 Maintenance/ 3.2 Drive Components Service Bearings - Bearings with a grease fitting should be lubricated twice a year with a high temperature, moisture-resistant grease. (Type NLGI-1 or -2 standard grease is recom- Procedures mended.) Be sure to clean the grease fitting before adding grease. Add grease with a (cont'd) handgun until a slight bead of grease forms at the seal.

  • Page 7: Coil Maintenance

    3.4 Coil Inspect all cooling system coils at the beginning of the cooling season or more often if needed. Follow the cleaning instructions below. If additional cleaning is required or if a Maintenance coil must be removed for any reason, consult the factory. Be prepared to provide rating plate and installation information.
  • Page 8 3.0 Maintenance/Service Procedures (cont'd) Suction Line Ø 1.375 3.4 Coil Maintenance (cont'd) Suction Line Ø 0.875 FIGURE 4 (cont'd) - Coil Circuits (Views are from the control side of the system.) Suction Line Ø 1.375 (See compressor locations on page 12.) RCB/RDCB/RECB 480 and Condenser Coils by Circuit RDB/RDDB/REDB 538, 564, and 602...

  • Page 9: Check Refrigerant Pressure And Temperatures (Subcooling And Superheat)

    3.5 Check DANGER Refrigerant The refrigeration circuits are high pressure systems. Hazards Pressure and exist that could result in personal injury or death. Removal, Temperatures installation, and service of this scroll compressor must be (subcooling and performed by a technician qualified in R-410A refrigerant. superheat) DO NOT USE tools or service equipment designed for R22 refrigerant.

  • Page 10: Compressor Maintenance And Replacement

    3.0 Maintenance/Service Procedures (cont'd) 3.5 Check Refrigerant Pressure and Temperatures (subcooling and superheat) (cont'd) Temperature/Pressure Conversion Chart R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant R-410A Refrigerant Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature °F °C °F °C °F °C °F °C -48.3 56.4...
  • Page 11 Please use the following 13 steps as a checklist, taking each item in order before proceeding to the next. If more information is required, contact the Reznor Service Department for Reznor products.
  • Page 12 3.0 Maintenance/ 3.6 Compressor Maintenance (cont'd) Service  Step 2. Determine Cause of Initial Failure (cont'd) Procedures (cont'd) Compressor Oil Charge (POE Oil) Compressor Important NOTES: These R-410A compressors use a polyolester (POE) Model lubricant. Types of recommended POE oil are Copeland Ultra 22 CC, Copeland Ultra 32 CC, Copeland Ultra 32-3MAF, Mobil EAL™, Arctic 22 CC, Uniqema Emkarate RL32CF, ZP57K3E 1538...
  • Page 13 Compressor Staging for Cooling (applies to Models RCB, RDB, RDCB, RDDB RECB, REDB) Compressor Cooling Staging MAPSIII Cabinet D Circuit Tonnage A+C+D DH or E (RDB/RDDB/REDB 418) DH or E (RDB/RDDB/REDB 444) DH or E (RDB/RDDB/REDB 484) A+C+D DH or E (RDB/RDDB/REDB 538) DH or E (RDB/RDDB/REDB 564) DH or E (RDB/RDDB/REDB 602) A+B+D...
  • Page 14 □ 3.0 Maintenance/ Step 4. Install New Filter Driers (cont'd) Service monitor pressure drop across the drier. (NOTE: Suction line filter drier must be Procedures removed after 72 hours of operation.) Step 12 includes the remaining procedures required for cleanup of a burnout. (cont'd) Continue to Step 5.
  • Page 15 CAUTION: Do not leave a circuit open to the atmosphere any longer than minimum required for installation. POE oil in the compressor is extremely susceptible to moisture absorption. Evacuation will not remove moisture from POE oil. □ Step 8. Check the Electrical System After the system has been evacuated, reconnect the electrical plug to the compressor or the wires to the compressor terminals.
  • Page 16 3. Maintenance/ Approximate R410-A Refr igerant Charge (lbs) by Model Size and Compressor for Each Circuit (See FIGURE 5, page 12, to identify location.) Service Procedures D Cabinet Models Compressor Circuit and Size E or DH (cont'd) RCB/RDCB/RECB 360 10.0 13.0 3.6 Compressor RCB/RDCB/RECB 480...
  • Page 17 CAUTION: Be sure to connect pressure gauges to the suction and discharge lines before system start-up so that compressor rotation can be checked immediately. Scroll compressors will be destroyed if allowed to operate in the wrong direction. See Hazard Levels, page 2. Record the ambient temperature.

  • Page 18: Thermostatic Expansion Valves

    □ 3. Maintenance/ Step 11. Check Subcooling and Superheat. (cont'd) Service Follow the procedures in Paragraph 3.5 to check subcooling and superheat. Procedures □ Step 12. (Select the procedure that applies.) (cont'd) IF the oil measured in Step 2 was significantly less than in the table on page 12 or the acid test in Step 2 indicated a burnout, do the following: 3.6 Compressor Maintenance...

  • Page 19: Dampers And Damper Controls

    Model & Size Compressor Circuit Sporlan No. Connection Sizes 220556 BBIZE-8-GA 5/8x7/8x1/4 220556 BBIZE-8-GA 5/8x7/8x1/4 RCB/RDCB/RECB 220558 BBIZE-15-GA 7/8x1-1/8x1/4 220558 BBIZE-15-GA 7/8x1-1/8x1/4 RDB/RDDB/REDB E or DH (RDB/RDDB/REDB 658 only) 234987 BBIZE-4-GA 1/2x7/8x1/4 658/684/722 E or DH (RDB/RDDB/REDB 684 only) 220555 BBIZE-6-GA 5/8x7/8x1/4 E or DH (RDB/RDDB/REDB 722 only)
  • Page 20 3.0 Maintenance Procedures (cont'd) 3.9 Other Controls (cont'd) 3.9.1 Programmable Digital Controller and Sensors (cont'd) FIGURE 6 - Airflow and Sensor Locations Dirty Filter Switch Sensor Dirty Filter Switch Sensor Condenser Section (entering air side) (leaving air side) Filters Coils Outside Air Sensor Discharge...

  • Page 21: Gas Heat Section Maintenance - Models

    CAUTION: Touching the operating hot gas bypass valve can cause a burn. Use caution when checking and adjusting the valve. See Hazard Levels, page 2. If a hot gas bypass valve needs to be replaced, use only a factory-authorized replace- ment for R410-A refrigerant.
  • Page 22 4.0 Gas Heat FIGURE 7 - View of the Heat Section showing Access to the Section Heat Exchanger by Removing the Venter Assembly and the Maintenance Heat Exchanger Access Panel (cont'd) 4.1 Heat Exchanger, Burner, & Venter Maintenance Heat Exchanger Access Panel (cont'd) Venter...
  • Page 23 With the burner removed in Paragraph 4.1.2, shine a light into each heat exchanger section. With the light shining into the heat exchanger, observe the outside for visible light. Repeat this procedure with each heat exchanger section. If any light is observed, replace the heat exchanger. If it is determined that the heat exchanger needs to be replaced, contact your distributor or representative for replacement information.
  • Page 24 4.0 Gas Heat 4.1 Heat Exchanger, Burner, & Venter Maintenance (cont'd) Section 4.1.2 Instructions for Inspecting/Cleaning the Burner (cont'd) Maintenance of the burner end caps. Remove the screws that hold the end caps to the burner (cont'd) housing. Lightly tap end caps to remove. Clean all foreign material from the burner and venturi.
  • Page 25 Instructions to Re-Assemble the Gas Heat Section (Refer back to 4.1.4 Re-Assemble FIGURES 7, 8, and 9.) the Heat Exchanger Panel, Burner, Gas 1. Re-attach the Heat Exchanger Panel - Re-attach the access panel being sure to Train, and Venter use all of the screws.

  • Page 26: Gas Heat Section Controls

    4. Gas Heat 4.2 Gas Heat Section Controls Section 4.2.2 Ignition System (Natural Gas only) Maintenance The modulating furnace has the control module in the control compartment (FIGURES (cont'd) 12 and 13A) with an additional board (FIGURE 13B) attached directly to the side of the burner to control spark.
  • Page 27 Modulating Gas 1) Call for Heat - The IQ controller calls for heat (there is a closure between "R" and "W" and at least 2 VDC to the analog input). The ignition system circuit board will check Control Sequence of the modulating valve position and move to lightoff position.
  • Page 28 Ignition Controller on Non-Modulating Gas-Fired Furnace on 4. Gas Heat MAPS D Sizes 1000, 1200, 1400, or 1600 with Two Furnaces Section (cont'd) Maintenance (cont'd) Do not attempt to disassemble the control module. However, each heating season check the lead wires for insulation deterioration and good connections. 4.2 Heat Section Proper operation of the direct spark ignition system requires a minimum flame signal of Controls...
  • Page 29 Ignition System If flame is not established on the 4th trial for ignition (initial try plus 3 re-tries), the circuit board de-energizes the gas valve and goes into lockout. The circuit board goes to one Fault Modes - Non- flash on the green LED to indicate ignition failure lockout. Modulating Furnace Limit Switch Operation - The limit switch is ignored unless a call for heat is present of D Cabinet with Size...

  • Page 30: Gas Train

    4. Gas Heat Location: The gas train is visible with the heat section door open. See component Section identification in FIGURE 15. Service: Carefully remove external dirt from the valves and check the wiring connec- Maintenance tions. Annually, in preparation for the heating season, check the dual, single-stage (cont'd) operating valve to be sure that it shuts gas flow off completely.
  • Page 31 FIGURE 18 - Ball Valve with Actuator in Modulating Gas Control Manifold Ball Valve Actuator Ball Valve Shaft Modulates the Gas Flow Actuator Setscrew (shown on the right or closed position) Ball Valve with actuator removed (for illustration only); do not remove actuator. Inspect the position of the ball valve shaft.

  • Page 32: Other Gas Heat Section Controls

    4.0 Gas Heat Section Maintenance (cont'd) 4.3 Gas Train (cont'd) Modulating System Gas Valve Adjustment Instructions (cont'd) If the manifold pressure does not match the value in and then manually open the ball valve to the 100% the chart and the ball valve is fully or close to fully open position noted in Step No.
  • Page 33 Switch Settings Modulating Burner Full Rate - and P/N's Heat Section Natural Gas Setpoint Label Switch Light Off Equilibrium Size Color (Cold) (Hot) Brown 201160 201159 Brown 201160 201159 1000 Brown 201160 1200 201159 1400 Brown 201160 1600 201159 Gas Non-Modulating Burner Full Heat Section Setpoint Label...

  • Page 34: Electric Heat Section Maintenance - Models Recb And Redb

    5.0 Electric Heat Section Maintenance - Models RECB and REDB (cont'd) Electric Heating Elements and Controls (cont'd) FIGURE 24 - Electric Heating Element Electric Heat Cassette Assembly Elements (includes electric heat elements) Fuse Panel (See FIGURE 25.) Air Sensing Tube Electric Heat Control Panel (See FIGURE 25.) Access Panel attached to Electric...

  • Page 35: Troubleshooting

    6.0 Troubleshooting IMPORTANT: Do not release refrigerant to the atmosphere! If 6.1 Troubleshooting required service procedures include the adding or removing of - RCB, RDB, refrigerant, the service technician must comply with all federal, RDCB, RDDB, state and local laws. The procedures discussed in this manual RECB, REDB should only be performed by a qualified HVAC technician.

  • Page 36: Troubleshooting The Heat Section

    6.0 Troubleshooting 6.1 Troubleshooting - RCB, RDB, RDCB, RDDB, RECB, REDB (cont'd) (cont'd) General Refrigeration Circuit - applies to all Models (cont'd) SYMPTOM POSSIBLE CAUSE REMEDY G. High suction 1. Excessive load on evaporator coil. 1. Check superheat (Paragraph 3.5). Check for high entering wet bulb temperature. pressure Check for excessive air.
  • Page 37 6.2.2 General Troubleshooting - Gas Heat Section, Models RDCB and RDDB PROBLEM PROBABLE CAUSE REMEDY Venter motor 1. No power to unit. 1. Turn on power; check supply fuses or main circuit breaker. will not start 2. No 24 volt power to ignition system circuit board. 2. Check control transformer output. 3.
  • Page 38 6.0 Troubleshooting 6.2 Troubleshooting Heat Section (cont'd) (cont'd) 6.2.2 General Troubleshooting - Gas Heat Section (cont'd) 6.2.2.1 Troubleshooting the non-modulating furnace (cont'd) Operating and Control Status - Green LED Codes Steady ON ..Normal Operation, No call for heat Troubleshooting Fast Flash ..
  • Page 39 Normal Furnace Operation Display LED Display Heat Mode Description OFF Mode (OFF) System Idle - Control board has power, no faults found, no call for heat. System is purging the heat exchanger – No gas on, no flame, venter motor runs for the PURGE Mode (Pur) specified purge timings.
  • Page 40 6.2 Troubleshooting Heat Section (cont'd) 6.2.2.2 Troubleshooting the Modulating Gas Control (cont'd) Gas Heat Section Modulating Control FUNCTIONAL ALERTS (cont'd) Lost Flame The flame sensor signal has been A. Flame sensor coated 1. Clean flame rod sensor. (AO2) lost after flame is established B.
  • Page 41 Gas Heat Section Modulating Control LOCKOUT ERRORS Code Alert Description Probable Causes Solutions Ignition Board Ignition board start-up checks A. Faulty transformer 1. Check 24-volt transformer for correct output. Failure (888) have detected an error. 2. Check connections and wiring to control board and other components connected to the 24 volt source.
  • Page 42 6.2 Troubleshooting Heat Section (cont'd) 6.2.2.2 Troubleshooting the Modulating Gas Control (cont'd) Gas Heat Section Modulating Control LOCKOUT ERRORS (ccont'd) Code Alert Description Probable Causes Solutions Gas Sensor The gas transducer reading A. Modulating actuator/ball 1 Perform modulating system gas valve alignment Failure (EO6) is too low compared to valve not properly aligned...

  • Page 43: Index

    INDEX SUPERHEAT 9 Recommended superheat 9 Ball Valve and Actuator in HAZARD INTENSITY Superheat 17 Gas Control Option AG70 LEVELS 2 Dirty Filter Switch 5 Heat Exchanger 21 Braze 14 Heat Section Controls 25 Burner 21 Outside Air Hood 5 Temperature/Pressure Cleaning the Burner 23 Hot Gas Bypass Valve 20...

  • Page 44: References

    REFERENCES The Installation Manual, Control Instructions, this Operation/Maintenance Manual, and applicable supplier instructions are shipped with the unit. The literature listed below is currently available or will be soon at www.RezSpec.com or from your Reznor Repre- ® sentative (1-800-695-1901). Installation Manual, Form I-MAPSIII&IV for Cabinets A, B, C, & D Control Instructions, Form CP-MAPS D15/D16/D17/D18 Replacement Parts, Form P-MAPSIII&IV...

This manual is also suitable for:

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