Roberts Gorden Combat IDF Series Installation, Operation & Service Manual
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Roberts Gorden Combat IDF Series Installation, Operation & Service Manual

Roberts Gorden Combat IDF Series Installation, Operation & Service Manual

Indirect, gas/oil-fired, industrial air handler
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FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local fuel
supplier after leaving the building.
Follow the fuel supplier's
instructions.
8. If you cannot reach your fuel
supplier, call the Fire Department.
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clear-
ances to combustibles away from
equipment.
Some objects will catch fire or explode
when placed close to equipment.
Failure to follow these instructions can
result in death, injury or property
damage.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or property
damage. Read the installation, operation and service
manual thoroughly before installing or servicing
this equipment.
Installation must be done by a registered installer/
contractor qualified in the installation and service of
gas/oil-fired heating equipment or your fuel supplier.
NOT FOR RESIDENTIAL USE
© 2012 Roberts-Gordon LLC
Combat
Indirect, Gas/Oil-Fired,
Industrial Air Handler
Installation, Operation &
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Roberts-Gordon LLC
1250 William Street
P.O. Box 44
Buffalo, New York 14240-0044
Telephone: +1.716.852.4400
Fax: +1.716.852.0854
Toll Free: 800.828.7450
www.robertsgordon.com
www.rg-inc.com
IDF-Series
®
Service Manual
IDF 35
IDF 45
IDF 50
IDF 65
IDF 75
IDF 85
IDF 100
IDF 125
IDF 150
Installer
Owner
P/N 131100NA Rev A 11/12
IDF 175
IDF 200
IDF 225
IDF 250
IDF 275
IDF 300
IDF 350
IDF 400
IDF 450

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Summary of Contents for Roberts Gorden Combat IDF Series

  • Page 1 FOR YOUR SAFETY If you smell gas: 1. Open windows. Combat IDF-Series ® 2. DO NOT try to light any appliance. 3. DO NOT use electrical switches. 4. DO NOT use any telephone in your building. 5. Extinguish any open flame. 6.

  • Page 3: Pour Votre Securite

    POUR VOTRE SECURITE Si vous sentez une odeur de gaz: Combat IDF-Series 1. Ouvrez les fenêtres. ® 2. N’essayez PAS d’allumer un appareil. 3. N’utilisez PAS d’interrupteurs électriques. 4. N’utilisez PAS de téléphone dans votre bâtiment. 5. Eteignez toute flamme nue. 6.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: Air Handler Safety..........1 SECTION 14: Service Platform ..........60 1.1 Description of Operation..........1 SECTION 15: Dampers ............63 1.2 Inspection and Setup ........... 1 15.1 Discharge Damper Installation......... 63 1.3 Safety Labels and Their Placement ......1 15.2 Inlet Damper Installation ..........
  • Page 6 25.4 General Start-up Procedures (All Fuels) ....132 25.5 Blower Start-Up ............. 132 25.6 Burner Start-Up............132 25.7 Gas Pressure Adjustments........133 25.8 Oil Pressure Adjustments........134 25.9 Gas Fired Equipment Start-Up Procedures.... 136 25.10 Oil Fired Equipment Start-Up Procedures .... 137 25.11 Accessories and Controls Start-Up ......
  • Page 7 TABLE OF FIGURES Figure 47: Discharge Damper Installation for Horizontal Air Handler with Bottom Discharge ......64 Figure 1: Indoor Upright (Models 35 - 100) ....... 2 Figure 48: Inlet Damper ............65 Figure 2: Indoor Upright (Models 125 - 450) ......3 Figure 49: Discharge Heads ...........
  • Page 8 Modulating Burner with Input Less Than 2,500 MBH Figure 97: Wiring Diagram for Oil-Fired Air Handler with XL- (732.7 kW) ............100 Compliant Manifold and High/Low/Off Burner with Figure 80: Wiring Diagram for Gas-Fired Air Handler with FM- Input Less Than 1,000 MBH (293.1 kW) ....118 Compliant Manifold and Fully- Figure 98: Wiring Diagram for Oil-Fired Air Handler with XL- Modulating Burner with Input 2,500 to 5,000 MBH...
  • Page 9 LIST OF TABLES Table 1: Recommended Torque Settings....... 13 Table 2: Legend ..............16 Table 3: Cabinet Dimensions (Models 35 - 125) ....16 Table 4: Estimated Shipping Weights (Models 35 - 125) ..17 Table 5: Estimated Shipping Weights - Burners (Models 35 - 125) ............

  • Page 11: Section 1: Air Handler Safety

    SECTION 1: A ANDLER AFETY SECTION 1: AIR HANDLER SAFETY Your Safety is Important to Us! 1.1 Description of Operation This symbol is used throughout This air handler is an indirect, gas and/or oil-fired, the manual to notify you of appliance.

  • Page 12: California Proposition 65

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 1.4 California Proposition 65 In accordance with California Proposition 65 requirements, a warning label must be placed in a 1.5 Label Placement highly visible location on the outside of the equipment (i.e., near equipment’s serial plate). See label placement drawings on Page 2, Figure 1 through Page 10, Figure 11 for label location.

  • Page 13: Figure 2: Indoor Upright (Models 125 - 450)

    SECTION 1: A ANDLER AFETY FIGURE 2: Indoor Upright (Models 125 - 450) Item Part Number Description 91040025 Logo Label 91070002 Severe Injury Hazard Label 91070001 Electric Shock Hazard Label 91070004 Fire Hazard Label 91070005 Fall Hazard Label 91070006 Burn Hazard Label 3 of 171...

  • Page 14: Figure 3: Indoor Horizontal (Models 35 -100)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 3: Indoor Horizontal (Models 35 -100) Item Part Number Description 91070002 Severe Injury Hazard Label 91040025 Logo Label 91070001 Electric Shock Hazard Label 91070004 Fire Hazard Label 91070006 Burn Hazard Label 91070005 Fall Hazard Label 4 of 171...

  • Page 15: Figure 4: Indoor Horizontal (Models 125 - 450)

    SECTION 1: A ANDLER AFETY FIGURE 4: Indoor Horizontal (Models 125 - 450) Item Part Number Description 91070002 Severe Injury Hazard Label 91040025 Logo Label 91070001 Electric Shock Hazard Label 91070004 Fire Hazard Label 91070006 Burn Hazard Label 91070005 Fall Hazard Label 5 of 171...

  • Page 16: Figure 5: Outdoor Upright (Models 35 - 100)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 5: Outdoor Upright (Models 35 - 100) Item Part Number Description 91070002 Severe Injury Hazard Label 91040025 Logo Label 91070001 Electric Shock Hazard Label 91070004 Fire Hazard Label 91070006 Burn Hazard Label 91070005 Fall Hazard Label 6 of 171...

  • Page 17: Figure 6: Outdoor Upright (Models 125 - 400)

    SECTION 1: A ANDLER AFETY FIGURE 6: Outdoor Upright (Models 125 - 400) Item Part Number Description 91070002 Severe Injury Hazard Label 91070004 Fire Hazard Label 91070005 Fall Hazard Label 91070006 Burn Hazard Label 91040025 Logo Label 91070001 Electric Shock Hazard Label 7 of 171...

  • Page 18: Figure 7: Outdoor Horizontal (Models 35 - 100)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 7: Outdoor Horizontal (Models 35 - 100) Item Part Number Description 91070002 Severe Injury Hazard Label 91040025 Logo Label 91070001 Electric Shock Hazard Label 91070004 Fire Hazard Label 91070006 Burn Hazard Label 91070005 Fall Hazard Label 8 of 171...

  • Page 19: Figure 8: Outdoor Horizontal (Models 125 - 400)

    SECTION 1: A ANDLER AFETY FIGURE 8: Outdoor Horizontal (Models 125 - 400) Item Part Number Description 91040025 Logo Label 91070002 Severe Injury Hazard Label 91070001 Electric Shock Hazard Label 91070004 Fire Hazard Label 91070005 Fall Hazard Label 91070006 Burn Hazard Label 9 of 171...

  • Page 20: Figure 9: Control Enclosure Door (Inside)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 9: Control Enclosure Door (Inside) Item Part Number Description ETL Label FIGURE 10: 8.1 Remote Panel Item Part Number Description 91070009 Electric Shock Hazard Label (mini) FIGURE 11: 8.5 Remote Panel Item Part Number Description 91070009 Electric Shock Hazard Label (mini)

  • Page 21: Section 2: Installer Responsibility

    SECTION 2: I NSTALLER ESPONSIBILITY SECTION 2: INSTALLER RESPONSIBILITY • To assemble or install any accessories or associated duct work using best building WARNING practices. • To properly size supports and hanging materials. Explosion Hazard Equipment must have access to uncontaminated air at all times.

  • Page 22: Corrosive Chemicals

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 2.1 Corrosive Chemicals 2.2 Required Equipment and Materials When lifting of the equipment is required, the CAUTION installing contractor is responsible for supplying or arranging for the appropriate lifting equipment so that the air handler and accessories may be placed in a safe manner.

  • Page 23: Section 3: Critical Considerations

    SECTION 3: C RITICAL ONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS Clearances to combustibles do not denote WARNING clearances for accessibility. Minimum clearance for access is 48" (122 cm). Minimum clearance for accessibility applies to the control enclosure, blower access panel and filter access panel (when equipped).

  • Page 24: Section 4: National Standards And Applicable Codes

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.1 Fuel Codes 4.3 Aircraft Hangars The type of fuel appearing on the nameplate Installation in aircraft hangars must be in must be the type of fuel used. Installation must accordance with the following codes: comply with national and local codes and United States: Refer to Standard for Aircraft...

  • Page 25: Parking Structures And Repair Garages

    SECTION 4: N ATIONAL TANDARDS AND PPLICABLE ODES 4.6 Venting 4.4 Parking Structures and Repair Garages This air handler must be vented in accordance Installation in garages must be in accordance with the requirements within this manual and with the following codes: with the following codes and any state, United States: Standard for Parking Structures provincial or local codes which may apply:...

  • Page 26: Section 5: Specifications

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 5: SPECIFICATIONS horsepower (HP) may increase from the specifications given. Dimension and estimated weight tables apply to both upright and horizontal air handlers of the same The legend below is a list of abbreviations used in model.

  • Page 27: Figure 13: Horizontal Model Dimensions (Models 35 - 125)

    SECTION 5: S PECIFICATIONS FIGURE 13: Horizontal Model Dimensions (Models 35 - 125) PLAN VIEW SIDE VIEW Table 4: Estimated Shipping Weights (Models 35 - 125) Housings Filters Dampers Weatherizing Service Platform Heat Coil Fresh Air Blower Blower Addtl. Model Blower Mix Box V-Bank Inlet...

  • Page 28: Figure 14: Upright Model Dimensions (Models 150 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 6: Estimated Shipping Weights - Motors (Models 35 - 125) Size HP Standard (lb) (kg) 15.9 15.9 20.4 20.4 31.8 38.6 70.3 99.8 124.7 136.1 163.3 226.8 249.5 362.9 430.9 Weight (lb) 2-Speed Weight (kg) 31.8...

  • Page 29: Figure 15: Horizontal Model Dimensions (Models 150 - 450)

    SECTION 5: S PECIFICATIONS FIGURE 15: Horizontal Model Dimensions (Models 150 - 450) PLAN VIEW SIDE VIEW Table 8: Estimated Shipping Weights (Models 150 - 450) Housings Filters Dampers Weatherizing Service Platform Heat Coil Fresh Air Blower Blower Addtl. Model Blower Mix Box V-Bank...

  • Page 30: Table 10: Estimated Shipping Weights - Motors (Models 150 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 10: Estimated Shipping Weights - Motors (Models 150 - 450) Motor Size (HP) Standard Motor (lb) Weight (kg) 15.9 15.9 20.4 20.4 31.8 38.6 70.3 99.8 124.7 136.1 163.3 226.8 249.5 362.9 430.9 2-Speed Motor (lb)

  • Page 31: Figure 16: Percentage Of Airflow Capacity

    SECTION 5: S PECIFICATIONS FIGURE 16: Percentage of Airflow Capacity FIGURE 17: Internal Static Pressure 60,000 60,000 A. Heat exchanger E. Blower module (10,1940) (10,1940) B. Discharge louvers F. Mixing Box C. V-bank filter section G. Discharge damper and D. Fresh air intake down discharge plenum 55,000 55,000...
  • Page 32 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Total Static .50 in wc / .75 in wc / 1.00 in wc / 1.25 in wc / 1.50 in wc / 1.75 in wc / 2.00 in wc / 2.25 in wc 2.50 in wc Pressure 1.25 mbar...
  • Page 33 SECTION 5: S PECIFICATIONS Total Static .50 in wc / .75 in wc / 1.00 in wc / 1.25 in wc / 1.50 in wc / 1.75 in wc / 2.00 in wc / 2.25 in wc 2.50 in wc Pressure 1.25 mbar 1.87 mbar...

  • Page 34: Table 13: Sound Data

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 13: Sound Data Model Octave Band Noise (Hz) 35/45 50/65 75/85/100 150/175 200/225 250/275/300 350/400/450 From Free-Stand- ing Blower at 6 ft 1000 (1.8 m) (dBA) 2000 4000 Sound Pressure 8000 Levels From Ducted Inlet or Ducted Outlet Blower at 5 ft.

  • Page 35: Section 6: Lifting An Air Handler

    SECTION 6: L IFTING AN ANDLER SECTION 6: LIFTING AN AIR HANDLER 5. Prepare the installation location to be ready to accept the air handler (i.e. roof curb or mount- WARNING ing stand). 6. Verify that the lifting equipment can handle the air handler’s weight and the required reach.

  • Page 36: Figure 18: Lifting A Horizontal Air Handler

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 18: Lifting a Horizontal Air Handler FIGURE 19: Lifting an Upright Air Handler 26 of 171...

  • Page 37: Section 7: Air Handler Assembly

    SECTION 7: A ANDLER SSEMBLY SECTION 7: AIR HANDLER ASSEMBLY WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 38: Figure 20: Air Handler Assembly - Horizontal (Models 150 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 20: Air Handler Assembly - Horizontal (Models 150 - 450) Caulk seams before attaching seam strips 1/2" Bolt Washer Cage Nut Welded on Burner Section Caulk all seams after seam strip is attached. Seam Strip Detail Quantity of 1/2"...

  • Page 39: Figure 21: Air Handler Assembly - Upright (Models 150 - 450)

    SECTION 7: A ANDLER SSEMBLY FIGURE 21: Air Handler Assembly - Upright (Models 150 - 450) 1/2" Nut Lock Washer and Washer 1/2" Bolt Washer Quantity of 1/2" Nuts, Model Bolts, Flat/Lock Washers 150/175 200/225 250/300 350/450 29 of 171...

  • Page 40: Section 8: Vibration Isolators

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 8: VIBRATION ISOLATORS WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 41: Neoprene Or Spring Isolators For Hanger-Mounted Units

    SECTION 8: V IBRATION SOLATORS FIGURE 23: Pad Isolator Installation Instructions Unit Waffle Pad Isolator 2" (5.08 cm) x 2" (5.08 cm) Curb Angle Curb 8.2 Neoprene or Spring Isolators for Hanger- It is supplied with a rectangular steel housing which Mounted Units incorporates the neoprene element or spring.

  • Page 42: Figure 24: Hanging Isolators

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL hardware). Neoprene style is normally selected when Equipment should be hung at its proper eleva- noise is also a consideration besides vibration. The tion by using temporary fixtures that can be spring style is normally selected when the concern is removed after vibration isolators are installed strictly vibration.

  • Page 43: Figure 26: Hanging Rods' Installation Instructions (Models 35 - 125)

    SECTION 8: V IBRATION SOLATORS FIGURE 26: Hanging Rods’ Installation Instructions (Models 35 - 125) 33 of 171...

  • Page 44: Figure 27: Hanging Rods' Installation Instructions (Models 150 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 27: Hanging Rods’ Installation Instructions (Models 150 - 450) 34 of 171...

  • Page 45: Neoprene Or Spring Isolators For Pad-Mounted Units

    SECTION 8: V IBRATION SOLATORS 8.3 Neoprene or Spring Isolators for Pad- Mounted Units The mount style is available in either a neoprene version or spring. It is used to support and isolate the air handler from a base pad or structural frame. 8.3.1 Neoprene Mount Isolator The neoprene mount is a single piece unit and design to be bolted directly to the bottom support...

  • Page 46: Figure 29: Pad Mounting Instructions For Neoprene Isolator (Models 35 - 125)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 29: Pad Mounting Instructions for Neoprene Isolator (Models 35 - 125) 36 of 171...

  • Page 47: Figure 30: Pad Mounting Instructions For Neoprene Isolator (Models 150 - 450)

    SECTION 8: V IBRATION SOLATORS FIGURE 30: Pad Mounting Instructions for Neoprene Isolator (Models 150 - 450) 37 of 171...

  • Page 48: Spring Mount Isolator

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 8.4 Spring Mount Isolator The spring mount is supplied with a rectangular steel housing which incorporates the spring and load tensioning adjustment bolt. It is equipped with neoprene stabilizers to provide lateral control without binding.

  • Page 49: Figure 32: Pad Mounting Instructions For Spring Isolator (Models 35 - 125)

    SECTION 8: V IBRATION SOLATORS FIGURE 32: Pad Mounting Instructions for Spring Isolator (Models 35 - 125) 39 of 171...

  • Page 50: Figure 33: Pad Mounting Instructions For Spring Isolator (Models 150 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 33: Pad Mounting Instructions for Spring Isolator (Models 150 - 450) 40 of 171...

  • Page 51: Section 9: Roof Curb

    SECTION 9: R SECTION 9: ROOF CURB WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices. tices to avoid falling.

  • Page 52: Figure 34: Roof Curb

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 34: Roof Curb Table 15: Roof Curb Dimensions Model A (Height) C (Length)* 16" (40.6 cm) 24" (61.0 cm) (Width) Burner and Blower Filter Section Mixing Box Section Curb Curb Sections (in) 16.0 24.0 59.0...

  • Page 53: Air Handler Mounting To Roof Curb

    SECTION 9: R Table 16: Roof Curb Weights Model 16" (40.6 cm) High Curb 24" (61.0 cm) High Curb Burner and Blower Filter Section Mixing Box Burner and Blower Filter Section Mixing Box Sections Section Sections Section (lb) 200.0 70.0 70.0 266.0 93.1...

  • Page 54: Figure 36: Curb Mounting (Models 150 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 36: Curb Mounting (Models 150 - 450) 44 of 171...

  • Page 55: Section 10: Upright Stand

    SECTION 10: U PRIGHT TAND SECTION 10: UPRIGHT STAND WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 56: Figure 37: Upright Stand Detail (Models 35 - 100)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 37: Upright Stand Detail (Models 35 - 100) Quantity of 1/4" Nuts, Model Bolts, Flat/Lock Washers 35/45 50/65/75 85/100 Weight Model lbs (kg) (in) 35/45 (cm) 91.4 152.4 76.2 (31.8) (in) 50/60/75 (cm) 91.4 182.9...

  • Page 57: Figure 39: Stand Mounting Detail (Models 125 - 450)

    SECTION 10: U PRIGHT TAND FIGURE 39: Stand Mounting Detail (Models 125 - 450) Short Sides of Air Handler (Control Enclosure Sides) Long Sides of Air Handler (Non-Control Enclosure Sides) Model (in) 40.5 (cm) 102.9 231.1 (in) 53.5 150/175 (cm) 135.9 269.2 (in)

  • Page 58: Section 11: Filter Section

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 11: FILTER SECTION WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 59: Filter Section Installation - Horizontal Air Handlers (Models 35 - 450)

    SECTION 11: F ILTER ECTION 11.1 Filter Section Installation - Once caulk has been applied, the provided roof Horizontal Air Handlers (Models 35 - 450) seam cover should be drill screwed over the caulked seam every 12" (30.5 cm) with the provided drill For installation directly onto the inlet of the air screws.

  • Page 60: Filter Section Installation - Upright Air Handlers (Models 35 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 11.2 Filter Section Installation - Upright Air Handlers (Models 35 - 450) For installation directly onto the inlet of the air handler, use the supplied hardware and bolt the filter section to the air handler through pre-drilled holes. If the air handler and filter section are to be set on a stand, mount the filter section on the stand first and then install the air handler.

  • Page 61: Section 12: Mixing Box

    SECTION 12: M IXING SECTION 12: MIXING BOX WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 62: Figure 42: Mixing Box Section Installation On Horizontal Air Handler

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 42: Mixing Box Section Installation on Horizontal Air Handler Caulk seams before attaching seam strips Bolt Washer Lock Washer and Washer Caulk all seams after seam strip is attached. Seam Strip Detail Quantity of 1/4"...

  • Page 63: Mixing Box Section Installation - Upright Air Handlers (Models 35 - 450)

    SECTION 12: M IXING 12.2 Mixing Box Section Installation - Upright Air For installation onto the filter section, first install filter Handlers (Models 35 - 450) section onto the inlet of the air handler as per Page 50, Section 11.2 and then use the supplied hardware For installation directly onto the inlet of the air and bolt the mixing box section to the filter section handler, use the supplied hardware and bolt the...

  • Page 64: Section 13: Inlet Hoods

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 13: INLET HOODS WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 65: Inlet Hood Installation (Models 35 - 125)

    SECTION 13: I NLET OODS 13.1 Inlet Hood Installation (Models 35 - 125) Inlet hoods for models 35 - 125 are shipped in one piece. To install the inlet hood on the cabinet of the air handler, use the supplied hardware. Before mounting to air handler, install bird screens to inlet of air handler with zip ties (supplied by others) and sandwich between the air handler and the inlet hood.

  • Page 66: Inlet Hood Installation (Models 150 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 13.2 Inlet Hood Installation (Models 150 - 450) Inlet hoods for models 150 - 450 are shipped in five pieces (four hood sections and one brace). Before mounting inlet hood to air handler, install bird screens to inlet of air handl;er with zip ties (supplied by others) and sandwich between the air handler and the inlet hood.
  • Page 67 SECTION 13: I NLET OODS Step 13.2.2 Attach assembly to inlet section of air handler using supplied hardware. 1/2" Bolt Lock Washer Washer and Washer 1/2" Nut Quantity of 1/2" Nuts, Model Bolts, Flat/Lock Washers 150/175 200/225 250/300 350/450 Step 13.2.3 Use supplied drill screws to fasten the smaller two pieces together.
  • Page 68 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 13.2.4 Use supplied drill screws to attach assembly made in Step 13.2.3 to the larger section of the inlet hood that was attached to the air handler in Step 13.2.2. Drill Screws 58 of 171...
  • Page 69 SECTION 13: I NLET OODS Step 13.2.5 Drill screw factory supplied hood support channel through side of support and side flanges of inlet hood. Drill Screws NOTE: This view shown with half of the hood hidden to show support. Step 13.2.6 Drill screw factory supplied hood support to bottom flange at base of air handler.

  • Page 70: Section 14: Service Platform

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 14: SERVICE PLATFORM WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 71: Figure 45: Horizontal Service Platform (Models 35 - 450)

    SECTION 14: S ERVICE LATFORM FIGURE 45: Horizontal Service Platform (Models 35 - 450) Weight Model Burner and Blower Filter Mixing Box Burner and Blower Filter Mixing Box Sections Section Section Sections Section Section (in) 72.0 42.0 90.0 26.0 45.0 (lb) 480.0 240.0...

  • Page 72: Figure 46: Upright Service Platform (Models 35 - 450)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 46: Upright Service Platform (Models 35 - 450) Model Weight (in) 72.0 42.0 30.0 (lb) 480.0 35/45 (cm) 182.9 106.7 76.2 (kg) 217.7 (in) 72.0 42.0 28.0 (lb) 480.0 50/60/75 (cm) 182.9 106.7 71.1 (kg)

  • Page 73: Section 15: Dampers

    SECTION 15: D AMPERS SECTION 15: DAMPERS WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices. tices to avoid falling.

  • Page 74: Inlet Damper Installation

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 47: Discharge Damper Installation for Horizontal Air Handler with Bottom Discharge To install the inlet damper to the face of the air Table 17: Lag Bolts handler, drive sheet metal screws or pop rivets Model Quantity of Lag Bolts Recommended (supplied by others) through the flanges into the air...

  • Page 75: Figure 48: Inlet Damper

    SECTION 15: D AMPERS FIGURE 48: Inlet Damper 65 of 171...

  • Page 76: Section 16: Discharge Heads And Discharge Louvers

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 16: DISCHARGE HEADS AND DISCHARGE LOUVERS WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 77: Discharge Louvers' Installation

    SECTION 16: D ISCHARGE EADS AND ISCHARGE OUVERS FIGURE 49: Discharge Heads Model Weight (in) 24.0 50.0 21.5 (lb) 80.0 35/45 (cm) 60.9 127.0 54.6 (kg) 36.3 (in) 24.0 58.0 21.5 (lb) 105.0 50/65/75 (cm) 60.9 147.3 54.6 (kg) 47.6 (in) 24.0 58.0...

  • Page 78: Figure 50: Double Deflection Discharge Louvers

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 50: Double Deflection Discharge Louvers Model Weight (in) 21.5 24.0 (lb) 70.0 35/45 (cm) 54.6 127.0 60.9 (kg) 31.8 (in) 21.5 24.0 (lb) 95.0 50/65/75 (cm) 54.6 147.3 60.9 (kg) 43.1 (in) 24.0 (lb) 130.0...

  • Page 79: Section 17: Duct Considerations

    SECTION 17: D ONSIDERATIONS SECTION 17: DUCT CONSIDERATIONS that the air handler is servicing. On horizontal runs, it is recommended that ductwork be supported every 6' The air handler has been designed to operate at the (1.8 m) for ductwork that has a cross section of 10 ft specific air volume and external static pressure that (0.9 m ) or less and every 4' (1.2 m) for ductwork...

  • Page 80: Section 18: Venting

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 18: VENTING All joints must be sealed. Type "B" vents are not acceptable. WARNING Do not support the weight of the vent pipe on the equipment's flue pipe extension. Vent pipe must be self supporting.

  • Page 81: Heat Exchanger Condensate Drain Connection

    SECTION 18: V ENTING 18.3 Heat Exchanger Condensate Drain Connection Indirect fired air handlers are provided with a male NPT condensate drain connection. Refer to the air handler drawings for the exact location. This connection must be extended away from the air handler for proper drainage.

  • Page 82: Section 19: Burners

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 19: BURNERS Oil burners use pressure atomization for proper combustion. WARNING The "Type J" burner is used on gas-fired air handlers with an input of 300 - 2,200 MBH (87.9 - 644.8 kW). See Page 72, Figure 52.

  • Page 83: Burner Pilot Assemblies

    SECTION 19: B URNERS FIGURE 53: Typical "Type C" Burner 19.2 Burner Pilot Assemblies All "Type C" burners use an ultraviolet scanner. All burners are preset at the factory for proper operation "Type J" burners on the air handlers can utilize either and firing rate.

  • Page 84: Figure 55: "Type J" Burner With Ultraviolet Scanner - Natural Gas Or Lpg

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL See Page 74, Table 19 for standard burner collar account when performing combustion diameter / flange size. Consult factory for non- performance. For example: For each 30° F (33.3° standard burners as collar diameters / flanges may C) change in the air temperature, a 1% change in vary.

  • Page 85: Figure 56: "Type C" Burner With Ignition Electrode - Natural Gas Or Lpg

    SECTION 19: B URNERS FIGURE 56: "Type C" Burner with Ignition Electrode - Natural Gas or LPG NOTE: "Type C" Gas Burner - The arc from the electrode tip should jump from the tip to the body of pilot housing and should be lined up with the hole in the backside of pilot housing, so that the blower air passing through this hole will cause the arc to flag or move around.

  • Page 86: Figure 57: "Type C" Burner With Ignition Electrode - Oil

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 57: "Type C" Burner with Ignition Electrode - Oil 76 of 171...

  • Page 87: Section 20: Gas Piping For Gas-Fired Air Handlers

    SECTION 20: G IPING IRED ANDLERS SECTION 20: GAS PIPING FOR GAS-FIRED AIR HANDLERS pressure gas regulator and safety shut off valve. For minimum inlet gas pressures refer to Page 78, WARNING Table 20. Explosion Hazard Leak test all components of gas/oil piping before operation.

  • Page 88: Table 20: Gas Manifold Size

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 20: Gas Manifold Size Gas NPT Minimum Inlet Gas Minimum Heat Output Maximum Heat Input Connection Pressure Model in wc 1.00 1.00 1.00 1.00 10.0 1.00 10.0 1.25 1.00 10.0 1,060 1.25 1.00 10.0 1,250...

  • Page 89: Figure 58: Manifold Diagram For Gas-Fired Air Handler With Any

    SECTION 20: G IPING IRED ANDLERS FIGURE 58: Manifold Diagram for Gas-Fired Air Handler with any FM-Compliant Manifold/XL-Compli- ant Manifold Rated for Less Than 1,000 MBH (293 kW) and with On/Off or High/Low/Off Burners 79 of 171...

  • Page 90: Figure 59: Manifold Diagram For Gas-Fired Air Handler With Any Fm-Compliant Manifold/Xl-Compliant Manifold Rated For Less Than 1,000 Mbh (293 Kw) And With Modulating Burner

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 59: Manifold Diagram for Gas-Fired Air Handler with any FM-Compliant Manifold/XL-Compli- ant Manifold Rated for Less Than 1,000 MBH (293 kW) and with Modulating Burner 80 of 171...

  • Page 91: Figure 60: Manifold Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold Rated For More Than 1,000 Mbh (293 Kw) And With On/Off Or High/Low/Off Burner

    SECTION 20: G IPING IRED ANDLERS FIGURE 60: Manifold Diagram for Gas-Fired Air Handler with XL-Compliant Manifold Rated for More Than 1,000 MBH (293 kW) and with On/Off or High/Low/Off Burner 81 of 171...

  • Page 92: Figure 61: Manifold Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold Rated For More Than 1,000 Mbh (293 Kw) And With Modulating Burner

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 61: Manifold Diagram for Gas-Fired Air Handler with XL-Compliant Manifold Rated for More Than 1,000 MBH (293 kW) and with Modulating Burner 82 of 171...

  • Page 93: Gas Manifold Venting

    SECTION 20: G IPING IRED ANDLERS 20.3 Gas Manifold Venting Natural Gas and Propane Installation Code. Vent valves fitted on XL-compliant manifolds must be Gas supply piping must conform to best building piped to the atmosphere outside the structure. This is practices and local codes.

  • Page 94: Line Pressure Test - Leak Testing

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 63: Location of Side Orifice 20.6 Line Pressure Test - Leak Testing The air handler and its individual shut-off valve must be disconnected from the gas supply piping systems during any pressure testing of that system at test pressures in excess of 1 PSIG (68.9 mbar).

  • Page 95: Section 21: Oil Piping For Oil-Fired Air Handlers

    SECTION 21: O IPING IRED ANDLERS SECTION 21: OIL PIPING FOR OIL-FIRED AIR HANDLERS FIGURE 64: Two-Pipe Oil System WARNING TO NOZZLE Explosion Hazard Leak test all components of gas/oil piping before operation. Gas/oil can leak if piping is not installed properly.

  • Page 96: Line Pressure Test - Leak Testing

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 21.2 Line Pressure Test - Leak Testing FIGURE 66: Webster 3450 RPM Blower Motor Driven Oil Pump The air handler and its individual shut-off valve must be disconnected from the oil supply piping systems during any pressure testing of that system at test pressures.

  • Page 97: Figure 68: Fm Or Xl-Compliant Manifold For Air Handlers With Suntec Pump And High/Low/Off Burner

    SECTION 21: O IPING IRED ANDLERS FIGURE 68: FM or XL-Compliant Manifold for Air Handlers with Suntec Pump and High/Low/Off Burner FIGURE 69: FM or XL-Compliant Manifold for Air Handlers with Webster Pump and High/Low/Off Burner 87 of 171...

  • Page 98: Figure 70: Fm Or Xl-Compliant Manifold For Air Handlers With Webster Pump And Fully-Modulating Burner

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 70: FM or XL-Compliant Manifold for Air Handlers with Webster Pump and Fully-Modulating Burner 88 of 171...

  • Page 99: Section 22: Combination Gas And Oil Burners

    SECTION 22: C OMBINATION URNERS SECTION 22: COMBINATION GAS AND OIL BURNERS Burners are available that burn both natural gas/LPG WARNING and oil. They have an independent manifold and ignition system for each fuel. They share the flame safeguard control and control linkage - See Page 89, Figure 71.

  • Page 100: Switching Between Fuels

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 22.1 Switching Between Fuels (when switching from oil to gas). Failure to do this can result in pump failure. To connect/disconnect the There are two methods of switching between natural pump, the connection coupling is located inside of gas/LPG and oil.

  • Page 101: Fully-Automatic Change Over

    SECTION 22: C OMBINATION URNERS 22.3 Fully-Automatic Change Over In this optional method, a fuel transfer switch (located on the burner) will energize the appropriate manifold and ignition systems. The oil pump, mounted remotely from the burner and equipped with its own drive motor, does not require manual connection/ disconnection.

  • Page 102: Section 23: Electrical

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 23: ELECTRICAL 23.2.1 Remote Panel Mounting Distance DANGER If the interconnection wiring between the remote panel and the air handler control enclosure is run in a single conduit, the wire run can be as long as 200' (60.9 m).

  • Page 103: Table 22: Safety Systems

    SECTION 23: E LECTRICAL Table 22: Safety Systems surrounding the heat exchanger reaches the limit set point of 250° F (121.1° C), the high temperature limit Safety Controls Location Voltage Air Handler Control switch will open the circuit to the air handler's control Fan / Limit Switch Enclosure system and shut it down.
  • Page 104 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL during commissioning. If either switch senses a pressure which is lower (low gas pressure switch) or higher (high gas pressure switch) than its set point, then the switch will open and lock out, shutting the burner down. The switch will have to be reset manually, once the condition has been corrected.

  • Page 105: Figure 74: Wiring Diagram Key

    SECTION 23: E LECTRICAL FIGURE 74: Wiring Diagram Key 95 of 171...

  • Page 106: Figure 75: Wiring Diagram For Gas-Fired Air Handler With Fm-Compliant Manifold And On/Off Burner With Input Less Than 2,500 Mbh (732.7 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 75: Wiring Diagram for Gas-Fired Air Handler with FM-Compliant Manifold and On/Off Burner with Input Less Than 2,500 MBH (732.7 kW) 96 of 171...

  • Page 107: Figure 76: Wiring Diagram For Gas-Fired Air Handler With Fm-Compliant Manifold And High/Low/Off Burner With Input Less Than 2,500 Mbh (732.7 Kw)

    SECTION 23: E LECTRICAL FIGURE 76: Wiring Diagram for Gas-Fired Air Handler with FM-Compliant Manifold and High/Low/Off Burner with Input Less Than 2,500 MBH (732.7 kW) 97 of 171...

  • Page 108: Figure 77: Wiring Diagram For Gas-Fired Air Handler With Fm-Compliant Manifold And High/Low/Off Burner With Input 2,500 To 5,000 Mbh (732.7 - 1465.4 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 77: Wiring Diagram for Gas-Fired Air Handler with FM-Compliant Manifold and High/Low/Off Burner with Input 2,500 to 5,000 MBH (732.7 - 1465.4 kW) 98 of 171...

  • Page 109: Figure 78: Wiring Diagram For Gas-Fired Air Handler With Fm-Compliant Manifold And High/Low/Off Burner With Input More Than 5,000 Mbh (1465.4 Kw)

    SECTION 23: E LECTRICAL FIGURE 78: Wiring Diagram for Gas-Fired Air Handler with FM-Compliant Manifold and High/Low/Off Burner with Input More Than 5,000 MBH (1465.4 kW) 99 of 171...

  • Page 110: Figure 79: Wiring Diagram For Gas-Fired Air Handler With Fm- Compliant Manifold And Fully

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 79: Wiring Diagram for Gas-Fired Air Handler with FM-Compliant Manifold and Fully- Modulating Burner with Input Less Than 2,500 MBH (732.7 kW) 100 of 171...

  • Page 111: Figure 80: Wiring Diagram For Gas-Fired Air Handler With Fm-Compliant Manifold And Fully-Modulating Burner With Input 2,500 To 5,000 Mbh (732.7 - 1465.4 Kw)

    SECTION 23: E LECTRICAL FIGURE 80: Wiring Diagram for Gas-Fired Air Handler with FM-Compliant Manifold and Fully- Modulating Burner with Input 2,500 to 5,000 MBH (732.7 - 1465.4 kW) 101 of 171...

  • Page 112: Figure 81: Wiring Diagram For Gas-Fired Air Handler With Fm-Compliant Manifold And Fully-Modulating Burner With Input More Than 5,000 Mbh (1465.4 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 81: Wiring Diagram for Gas-Fired Air Handler with FM-Compliant Manifold and Fully- Modulating Burner with Input More Than 5,000 MBH (1465.4 kW) 102 of 171...

  • Page 113: Figure 82: Wiring Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold And On/Off Burner With Input Less Than 1,000 Mbh (293.1 Kw)

    SECTION 23: E LECTRICAL FIGURE 82: Wiring Diagram for Gas-Fired Air Handler with XL-Compliant Manifold and On/Off Burner with Input Less Than 1,000 MBH (293.1 kW) 103 of 171...

  • Page 114: Figure 83: Wiring Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold And On/Off Burner With Input 1,000 To 2,500 Mbh (293.1 - 732.7 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 83: Wiring Diagram for Gas-Fired Air Handler with XL-Compliant Manifold and On/Off Burner with Input 1,000 to 2,500 MBH (293.1 - 732.7 kW) 104 of 171...

  • Page 115: Figure 84: Wiring Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold And High/Low/Off Burner With Input Less Than 1,000 Mbh (293.1 Kw)

    SECTION 23: E LECTRICAL FIGURE 84: Wiring Diagram for Gas-Fired Air Handler with XL-Compliant Manifold and High/Low/Off Burner with Input Less Than 1,000 MBH (293.1 kW) 105 of 171...

  • Page 116: Figure 85: Wiring Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold And High/Low/Off Burner With Input 1,000 To 5,000 Mbh (293.1 - 1465.4 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 85: Wiring Diagram for Gas-Fired Air Handler with XL-Compliant Manifold and High/Low/Off Burner with Input 1,000 to 5,000 MBH (293.1 - 1465.4 kW) 106 of 171...

  • Page 117: Figure 86: Wiring Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold And High/Low/Off Burner With Input More Than 5,000 Mbh (1465.4 Kw)

    SECTION 23: E LECTRICAL FIGURE 86: Wiring Diagram for Gas-Fired Air Handler with XL-Compliant Manifold and High/Low/Off Burner with Input More Than 5,000 MBH (1465.4 kW) 107 of 171...

  • Page 118: Figure 87: Wiring Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold And Fully-Modulating Burner With Input Less Than 1,000 Mbh (293.1 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 87: Wiring Diagram for Gas-Fired Air Handler with XL-Compliant Manifold and Fully- Modulating Burner with Input Less Than 1,000 MBH (293.1 kW) 108 of 171...

  • Page 119: Figure 88: Wiring Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold And Fully-Modulating Burner With Input 1,000 To 5,000 Mbh (293.1 - 1465.4 Kw)

    SECTION 23: E LECTRICAL FIGURE 88: Wiring Diagram for Gas-Fired Air Handler with XL-Compliant Manifold and Fully- Modulating Burner with Input 1,000 to 5,000 MBH (293.1 - 1465.4 kW) 109 of 171...

  • Page 120: Figure 89: Wiring Diagram For Gas-Fired Air Handler With Xl-Compliant Manifold And Fully-Modulating Burner With Input More Than 5,000 Mbh (1465.4 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 89: Wiring Diagram for Gas-Fired Air Handler with XL-Compliant Manifold and Fully- Modulating Burner with Input More Than 5,000 MBH (1465.4 kW) 110 of 171...

  • Page 121: Figure 90: Wiring Diagram For Oil-Fired Air Handler With Fm-Compliant Manifold And On/Off Burner With Input Less Than 2,500 Mbh (732.7 Kw)

    SECTION 23: E LECTRICAL FIGURE 90: Wiring Diagram for Oil-Fired Air Handler with FM-Compliant Manifold and On/Off Burner with Input Less Than 2,500 MBH (732.7 kW) 111 of 171...

  • Page 122: Figure 91: Wiring Diagram For Oil-Fired Air Handler With Fm-Compliant Manifold And High/Low/Off Burner With Input Less Than 2,500 Mbh (732.7 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 91: Wiring Diagram for Oil-Fired Air Handler with FM-Compliant Manifold and High/Low/Off Burner with Input Less Than 2,500 MBH (732.7 kW) 112 of 171...

  • Page 123: Figure 92: Wiring Diagram For Oil-Fired Air Handler With Fm-Compliant Manifold And High/Low/Off Burner With Input More Than 2,500 Mbh (732.7 Kw)

    SECTION 23: E LECTRICAL FIGURE 92: Wiring Diagram for Oil-Fired Air Handler with FM-Compliant Manifold and High/Low/Off Burner with Input More Than 2,500 MBH (732.7 kW) 113 of 171...

  • Page 124: Figure 93: Wiring Diagram For Oil-Fired Air Handler With Fm-Compliant Manifold And Fully-Modulating Burner With Input Less Than 2,500 Mbh (732.7 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 93: Wiring Diagram for Oil-Fired Air Handler with FM-Compliant Manifold and Fully- Modulating Burner with Input Less Than 2,500 MBH (732.7 kW) 114 of 171...

  • Page 125: Figure 94: Wiring Diagram For Oil-Fired Air Handler With Fm-Compliant Manifold And Fully-Modulating Burner With Input More Than 2,500 Mbh (732.7 Kw)

    SECTION 23: E LECTRICAL FIGURE 94: Wiring Diagram for Oil-Fired Air Handler with FM-Compliant Manifold and Fully- Modulating Burner with Input More Than 2,500 MBH (732.7 kW) 115 of 171...

  • Page 126: Figure 95: Wiring Diagram For Oil-Fired Air Handler With Xl-Compliant Manifold And On/Off Burner With Input Less Than 1,000 Mbh (293.1 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 95: Wiring Diagram for Oil-Fired Air Handler with XL-Compliant Manifold and On/Off Burner with Input Less Than 1,000 MBH (293.1 kW) 116 of 171...

  • Page 127: Figure 96: Wiring Diagram For Oil-Fired Air Handler With Xl-Compliant Manifold And On/Off Burner With Input Less Than 2,500 Mbh (732.7 Kw)

    SECTION 23: E LECTRICAL FIGURE 96: Wiring Diagram for Oil-Fired Air Handler with XL-Compliant Manifold and On/Off Burner with Input Less Than 2,500 MBH (732.7 kW) 117 of 171...

  • Page 128: Figure 97: Wiring Diagram For Oil-Fired Air Handler With Xl-Compliant Manifold And High/Low/Off Burner With Input Less Than 1,000 Mbh (293.1 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 97: Wiring Diagram for Oil-Fired Air Handler with XL-Compliant Manifold and High/Low/Off Burner with Input Less Than 1,000 MBH (293.1 kW) 118 of 171...

  • Page 129: Figure 98: Wiring Diagram For Oil-Fired Air Handler With Xl-Compliant Manifold And High/Low/Off Burner With Input More Than 1,000 Mbh (293.1 Kw)

    SECTION 23: E LECTRICAL FIGURE 98: Wiring Diagram for Oil-Fired Air Handler with XL-Compliant Manifold and High/Low/Off Burner with Input More Than 1,000 MBH (293.1 kW) 119 of 171...

  • Page 130: Figure 99: Wiring Diagram For Oil-Fired Air Handler With Xl-Compliant Manifold And Fully-Modulating Burner With Input Less Than 1,000 Mbh (293.1 Kw)

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 99: Wiring Diagram for Oil-Fired Air Handler with XL-Compliant Manifold and Fully- Modulating Burner with Input Less Than 1,000 MBH (293.1 kW) 120 of 171...

  • Page 131: Figure 100: Wiring Diagram For Oil-Fired Air Handler With Xl-Compliant Manifold And Fully-Modulating Burner With Input More Than 1,000 Mbh (293.1 Kw)

    SECTION 23: E LECTRICAL FIGURE 100: Wiring Diagram for Oil-Fired Air Handler with XL-Compliant Manifold and Fully- Modulating Burner with Input More Than 1,000 MBH (293.1 kW) 121 of 171...

  • Page 132: Section 24: Sequence Of Operation

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 24: SEQUENCE OF OPERATION DANGER Electrical Shock Hazard Disconnect electric before service. More than one disconnect switch may be required to disconnect electric from equipment. Equipment must be properly grounded. Failure to follow these instructions can result in death or electrical shock.

  • Page 133: Remote Panel Options

    SECTION 24: S EQUENCE OF PERATION FIGURE 101: Air Handler Configurations Mixing Box with MUA - MAKE UP AIR FR - FIXED RETURN Potentiometer Control Outside Air Outside Air Bottom Discharge Bottom Return Bottom Discharge AM - AIR MANAGEMENT Mixing Box with Pressure Gauge Control Outside Air Bottom Return...

  • Page 134: Basic Sequence Of Operation

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 24.2.2 8.5 Remote Panels The blower and burner will operate as needed for the application to maintain airflow and temperature. 8.5 Remote Panel for Air Handlers with On/ Off or High/Low/Off Burners The On-Off / Staged / Modulating temperature controller (whether space / discharge / return air) would be set from here.
  • Page 135 SECTION 24: S EQUENCE OF PERATION airflow switch, the burner ignition system is achieved if needed. Smooth oil light-off is further energized. achieved by the use of a solenoid valve bypass system, which allows a reduced amount of oil to flow After the pilot flame or main flame is proven by the at light-off and then switches to the high fire rate flame detector, the main and blocking valves are...

  • Page 136: Figure 102: Wiring Subbase And Sequence Chart For Rm7897 Burner Control Module

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 102: Wiring Subbase and Sequence Chart for RM7897 Burner Control Module 126 of 171...

  • Page 137: Figure 103: Wiring Subbase And Sequence Chart For Rm7800 Burner Control Module

    SECTION 24: S EQUENCE OF PERATION FIGURE 103: Wiring Subbase and Sequence Chart for RM7800 Burner Control Module 127 of 171...

  • Page 138: Night Setback Options

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 24.4 Night Setback Options outside air sensor. The range of thermostat is 25 - 100° F (-3.9 - 37.8° C). 24.4.1 Night Setback with Occupied/Unoccupied Switch This option provides manual control of occupied and 24.5.3 Low Limit Control unoccupied cycles, operated by an occupied/ This option shuts down the air handler when the...
  • Page 139 SECTION 24: S EQUENCE OF PERATION 24.5.9 Audible Alarm for Flame Failure This option sounds an alarm upon burner failure. It includes an alarm bell/horn (mounted on the air handler's control panel or remote panel). 24.5.10 Service Receptacle Powered by Others This option provides a service receptacle.

  • Page 140: Section 25: Start-Up Procedures

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 25: START-UP PROCEDURES DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 141: Mechanical

    SECTION 25: S TART ROCEDURES Installation Code and Annual Inspections: FIGURE 104: Sheave Alignment All installation and service of ROBERTS GORDON ® Correct Alignment equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts-Gordon LLC and conform to all requirements set forth in the ®...

  • Page 142: Electrical

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 105: Belt Tension 25.4 General Start-up Procedures (All Fuels) Belt Span A thoroughly qualified burner technician should be employed to provide the initial burner start up. Before beginning start up, the technician should thoroughly study and become familiar with the exact sequence of operation and all other details of the specific flame safeguard control system being used.

  • Page 143: Gas Pressure Adjustments

    SECTION 25: S TART ROCEDURES do not repeatedly cycle the burner. Specific setting at a valve gas flow of approximately 40 instructions relative to component sequencing are percent, which is adequate for safe light-off until the provided in the flame safeguard manufacturer's final setting can be determined.

  • Page 144: Oil Pressure Adjustments

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 9. Replace the wiring compartment cover. 25.8.1 Oil Pressure Adjustments for On/Off Burner The on-off system uses a single stage, high suction To adjust low fire on a fully-modulating burner, the lift oil pump with a simplex oil nozzle. The nozzle oil butterfly metering valve controls the adjustment flow rate is set by adjusting the oil pump pressure means.

  • Page 145: Figure 110: Oil Pressure Adjustment High/Low/Off Burner With Suntec Pump

    SECTION 25: S TART ROCEDURES firing rates. 6894 mbar) range and at high fire in the 180 to 225 PSI (12410 - 15513 mbar) range, but both pressures At light off, the main oil solenoid valves are will vary according to the specific nozzle being used, energized, allowing fuel to the nozzle.

  • Page 146: Gas Fired Equipment Start-Up Procedures

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL combustion air dampers and the modulating oil valve the low gas pressure switch, if supplied, to in the nozzle return line through mechanical linkage. make its circuit). At main flame light-off, the normally-closed oil valve 3.

  • Page 147: Oil Fired Equipment Start-Up Procedures

    SECTION 25: S TART ROCEDURES damper linkage operation to achieve 8.5 to the burner is started, the flame safeguard con- 10% CO and 0% CO at the full high fire input trol will not detect flame and should go into a safety lockout mode requiring manual reset of rate position.

  • Page 148: Accessories And Controls Start-Up

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL the modulating motor through its full travel to ensure that the linkage moves freely and that the travel limits on the metering device and air dampers are not exceeded. Refer to the burner manufacturer's bulletin for oil pump pressure settings.

  • Page 149: Section 26: Maintenance

    SECTION 26: M AINTENANCE SECTION 26: MAINTENANCE DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 150: General

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 26.1 General First 8 Hours of Operation Check belts and adjust as required (See Page 131, Section 25.1.2). Though belts were properly adjusted at the factory, they will stretch after the first few hours of operation.

  • Page 151: Table 25: Motor Lubrication Intervals

    SECTION 26: M AINTENANCE Blower Bearing The blower bearings should be re-lubricated every 3,000 hours of operation Lubrication or 6 months, whichever occurs first. The recommended lubricant is Shell Alva- nia #2 or S3 grease. To re-lubricate the blower pillow block/flange bearings, be sure that the grease fittings on the bearing housing (or air handler cabinet wall in the case of extended grease lines) are clean.

  • Page 152: Manifold And Controls

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 26.4 Manifold and Controls Manifold Periodically check fuel control assembly, and internal and external piping for leaks. Relief vent lines to outdoors on fuel controls should be checked to ensure against blockage caused by insects or any other substance. Clean as required.

  • Page 153: Section 27: Replacement Parts

    SECTION 27: R EPLACEMENT ARTS SECTION 27: REPLACEMENT PARTS WARNING DANGER Electrical Shock Hazard Explosion Hazard Carbon Monoxide Hazard Fire Hazard Use only genuine ROBERTS GORDON ® replacement parts per this installation, operation and service manual. Failure to follow these instructions can result in death, electric shock, injury or property damage. Replacement parts list is for general indirect fired applications and MAY NOT BE APPLICABLE FOR your specific unit configuration.
  • Page 154 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Description Mfg. Model Number Part Number BUSHING, FIXED PULLEY, 1.625" SF158 82200850 BUSHING, FIXED PULLEY, 2.9375" SF21516 82200900 BUSHING, FIXED PULLEY, 2.6875" SF21116 14173900 BUSHING, FIXED PULLEY, 2.125" SF218 82201000 BUSHING, FIXED PULLEY, 2.1875" SF2316 82200860 BUSHING, FIXED PULLEY, 2.375"...
  • Page 155 SECTION 27: R EPLACEMENT ARTS Description Mfg. Model Number Part Number PULLEY, FIXED-2B X 25.0 SF 82100630 PULLEY, FIXED-2B X 3.4 PD SH 14228901 PULLEY, FIXED-2B X 4.2 PD SH 82100360 PULLEY, FIXED-2B X 4.4 PD SH 82100370 PULLEY, FIXED-2B X 4.6 PD SDS 82100380 PULLEY, FIXED-2B X 4.8 PD SDS 82100390...
  • Page 156 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Description Mfg. Model Number Part Number PULLEY, FIXED-4B X 6.6 PD SD 82101140 PULLEY, FIXED-4B X 6.8 PD SD 82101150 PULLEY, FIXED-4B X 7.0 PD SK 82101160 PULLEY, FIXED-4B X 7.4 PD SK 82101170 PULLEY, FIXED-4B X 8.0 PD SK 82101180...

  • Page 157: Replacement V-Belts

    SECTION 27: R EPLACEMENT ARTS Description Mfg. Model Number Part Number PULLEY, VARIABLE- 3B X 8.0-9.4 1-7/8 82102500 PULLEY, VARIABLE- 4B X 4.5-5.9 1-5/8 14228912 PULLEY, VARIABLE- 4B X 4.5-5.9 1-7/8 82102610 PULLEY, VARIABLE- 4B X 5.0-6.4 1-5/8 82102640 PULLEY, VARIABLE- 4B X 5.5-6.9 1-7/8 82102680 PULLEY, VARIABLE- 4B X 6.0-7.4 1-5/8 82102701...
  • Page 158 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Description Part Number V-BELT B-074 33689474 V-BELT B-075 33689475 V-BELT B-076 33689476 V-BELT B-077 33689477 V-BELT B-078 33689478 V-BELT B-079 33689479 V-BELT B-080 33689480 V-BELT B-081 33689481 V-BELT B-082 33689482 V-BELT B-083 33689483 V-BELT B-084 33689484 V-BELT B-085...

  • Page 159: Replacement Damper Components

    SECTION 27: R EPLACEMENT ARTS Description Part Number V-BELT BX-97 33689597 V-BELT BX-98 33689598 V-BELT BX-99 33689599 V-BELT BX-100 33689500 V-BELT BX-103 33689501 V-BELT BX-105 33689505 V-BELT BX-108 33689508 V-BELT BX-113 33689513 V-BELT BX-116 33689516 V-BELT BX-117 33689517 V-BELT BX-120 33689520 V-BELT BX-128 33689528...

  • Page 160: Replacement Manifold Components

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Description Mfg. Model Number Part Number SEALED COMBUSTION AIR INTAKE COLLAR JR15/30 J20502 143132-11 SEALED COMBUSTION AIR INTAKE COLLAR JR50 J20505 143132-13 27.5 Replacement Manifold Components Description Mfg. Model Number Part Number BUTTERFLY VALVE - 1" (ECLIPSE FULL PORT) 4BV-AB 13591019 BUTTERFLY VALVE - 1"...

  • Page 161: Replacement Electrical Components

    SECTION 27: R EPLACEMENT ARTS Description Mfg. Model Number Part Number SOLENOID VENT VALVE-1" JB821453 82500110 SOLENOID VENT VALVE-1.25" 8215C63 82500120 SOLENOID VENT VALVE-1.5" 8215C73 11056500 SOLENOID VENT VALVE-3/4" 8215G33 82500280 27.6 Replacement Electrical Components Description Mfg. Model Number Part Number AMPLIFIER-FLAME ROD R7847A1033 15159802...

  • Page 162: Replacement Filters

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Description Mfg. Model Number Part Number MOTOR PROTECTOR, TOGGLE- 4-6.3 AMPS GV2ME10 14320210 MOTOR PROTECTOR, TOGGLE- 6-10 AMPS GV2ME14 14320214 MOTOR PROTECTOR, TOGGLE- 9-14 AMPS GV2ME16 14320216 OVERLOAD-.4-.63 AMPS LRD04 14320801 OVERLOAD-.63-1 AMPS LRD05 14320802 OVERLOAD- 1.6-2.5 AMPS...
  • Page 163 SECTION 27: R EPLACEMENT ARTS Description Mfg. Model Number Part Number LIGHT-TOP HAT/RED/120V/NEON (NEDCO) 1050C1 14297310 LIGHT-TOP HAT/WHITE/120V/NEON (NEDCO) 1050C4 14297312 LOW LIMIT SWITCH WITH 10FT SENSOR 8563100141 14016902 LOW LIMIT SWITCH WITH 20FT SENSOR 8563100151 14016903 NULL PRESSURE SWITCH.01-.20 1640-0 11050300 OUTDOOR THERMOSTAT...

  • Page 164: Section 28: Troubleshooting

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 28: TROUBLESHOOTING DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 165: Initial Checks

    SECTION 28: T ROUBLESHOOTING The following is divided into two basic categories - fan problems and burner problems. In some cases, they interrelate. In order to use this effectively, you should familiarize yourself with both categories. 28.1 Initial Checks When encountering any abnormal operation or fault conditions of the equipment, all troubleshooting should start with the following initial checks.

  • Page 166: Supply Fan

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 28.2 Supply Fan PROBLEM POSSIBLE CAUSE SOLUTION Blower motor does not run Damper limit switch not closed or inoperative. Repair or replace switch. Motor thermal over-loads tripped. For tripped condition-reset. Fuses blown or missing. Replace.

  • Page 167: Burner

    SECTION 28: T ROUBLESHOOTING 28.3 Burner PROBLEM POSSIBLE CAUSE SOLUTION Burner Fails to Start Defective On/Off or fuel transfer switch. Replace. Control circuit has an open control contact. Check limits, proof of closure switch and others as applicable. Bad fuse or switch open on in-coming power Correct as required.

  • Page 168: Gas Operation

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Burner (continued) PROBLEM POSSIBLE CAUSE SOLUTION Occasional Lockouts for No Occasional low voltage supply. Have local utility correct. Apparent Reason Occasional low gas supply pressure. Have local utility correct. Air leak in oil suction line or check valve not Correct as required.

  • Page 169: Oil Operation

    SECTION 28: T ROUBLESHOOTING Gas Operation (continued) PROBLEM POSSIBLE CAUSE SOLUTION Carbon Monoxide Flame impingement on cold start-up of heat Reduce firing rate to correct input Readings on Gas Firing exchanger caused by excessive firing rate. volume. Incorrect gas/air ratios. Readjust burner to correct CO levels, reducing CO formation to appropriate level.
  • Page 170 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Oil Operation (continued) PROBLEM POSSIBLE CAUSE SOLUTION Oil Flame Ignites, but then Flame scanner lens dirty. Remove and clean. Flame Safeguard Control Scanner sight tube blocked or dirty. Check and clean. Locks Out on Safety. Flame scanner defective.
  • Page 171 SECTION 28: T ROUBLESHOOTING Oil Operation (continued) PROBLEM POSSIBLE CAUSE SOLUTION White Smoke Formation Oil/Air ratios incorrect due to excess air, or oil flow Readjust for proper fuel input, CO2 on Oil Firing is too low. and smoke reading. Gray or Black Smoke Defective or dirty oil nozzle.

  • Page 172: Burner Control Module

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 28.6 Burner Control Module BLINK CODE SYSTEM FAILURE RECOMMENDED TROUBLESHOOTING Code 1-1 *Low AC Line 1. Check the relay module and display module Low AC Line detected. Voltage* connections. 2. Reset and sequence the relay module. Code 1-2*AC Quality Excessive noise or device 3.
  • Page 173 SECTION 28: T ROUBLESHOOTING Burner Control Module (continued) BLINK CODE SYSTEM FAILURE RECOMMENDED TROUBLESHOOTING Code 3-1*Running/Inter- Running or Lockout Interlock 1. Check wiring; correct any errors. lock Switch Problem* fault during Pre-Purge. 2. Inspect the fan; make sure there is no air intake blockage and that it is supply-ing air.
  • Page 174 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Burner Control Module (continued) BLINK CODE SYSTEM FAILURE RECOMMENDED TROUBLESHOOTING Code 4-3*Flame Amplifier Flame not sensed, or sensed 1. Check wiring; correct any errors. Problem* when it should be on or off. 2. Make sure the flame amplifier and flame detector are compatible.
  • Page 175 SECTION 28: T ROUBLESHOOTING Burner Control Module (continued) BLINK CODE SYSTEM FAILURE RECOMMENDED TROUBLESHOOTING Code 6-3*Device Specific* Fault with special OEM input 1. Check wiring and operation of special OEM inputs. circuits. 2. Reset and sequence the relay module. 3. If fault reappears, remove power from the device, reapply power, then reset and sequence the relay module.

  • Page 176: Roberts Gordon

    IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 28.7 ROBERTS GORDON ® IDF Start-Up Procedures DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.
  • Page 177 SECTION 28: T ROUBLESHOOTING l a i l l a Type of Gas: Gas Fired Gas Pressure at Train Inlet Flame Signal Readings Net Stack Temperature t i s " Gas Pressure at Train Inlet High Fire Low Fire Combustion Efficiency High Fire CO2 or O2 (Specify) Low Fire %...
  • Page 178 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Control Settings General Fan Limit (Fan switch set to 110, HYS Pot set at 15) Burner Air Flow Operating Full Mod. High Fire Purge Full Mod. Low Fire Start Full Mod Cycling On/Low Fire Start Freeze Stat: 3 Min.-35 Outdoor Stat: 65 High Temp Limit [set to 200°...
  • Page 179 SECTION 28: T ROUBLESHOOTING START-UP "NO HEAT" Place all disconnects in "ON" position and test for 120 V on transformer secondary to ground before turning the selector switch to "SUMMER" mode. The unit will start up in the "no heat" mode. Check for the correct rotation of supply blower.
  • Page 180 IDF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 170 of 171...

  • Page 181: Section 29: The Roberts Gordon

    SECTION 29: T ROBERTS GORDON ® ® IDF-S OMBAT ERIES ARRANTY The data plate and/or serial number are removed, SECTION 29: THE ROBERTS GORDON ® defaced, modified or altered in any way. COMBAT ® IDF-SERIES WARRANTY The ownership of the ROBERTS GORDON ®...

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