Reznor RP 400 Installation, Operation And Maintenance Manual
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Reznor RP 400 Installation, Operation And Maintenance Manual

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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 (01-23) 132210-D
Supersedes: RP-HRPD-IOM (10-22) 132210-C
HRPD

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  • Page 1 Revision: RP-HRPD-IOM (01-23) 132210-D Supersedes: RP-HRPD-IOM (10-22) 132210-C 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

    TABLE OF CONTENTS GENERAL INFORMATION ................3 References .

  • Page 3: General Information

    TABLE OF CONTENTS—CONTINUED ADJUSTMENTS..................31 Measure and Adjust Manifold (Outlet) Gas Pressure .

  • Page 4: Important Safety Information-Continued

    GENERAL INFORMATION—CONTINUED Important Safety Information—Continued ⚠ DANGER ⚠ • Gas-fired appliances are not designed for use in hazardous atmospheres containing flammable vapors or combustible dust, in atmospheres containing chlorinated or halogenated hydrocarbons, or in applications with airborne silicone substances. • Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death.

  • Page 5: Dimensions

    Dimensions NOTES: Inches (mm) Standard airflow may be reversed by changing direction of heat exchanger air baffles. Burner and control access shown left-hand side. Specify right-hand side for opposite access and connections. 1-21/32 (42) 8-15/32 (215) THERMOSTAT CONNECTION (19) 1-1/8 (29) 38-17/32 (457) (979)
  • Page 6 GENERAL INFORMATION—CONTINUED Dimensions—Continued NOTES: Inches (mm) Standard airflow may be reversed by changing direction of heat exchanger air baffles. Burner and control access shown left-hand side. Specify right-hand side for opposite access and connections. 8-15/32 THERMOSTAT (215) CONNECTION (19) 1-1/8 (29) 38-17/32 (457) 50-1/4...

  • Page 7: Weights

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

  • Page 8: Installation

    • 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 ⚠ 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. If the information in these instructions is not followed exactly, a fire, an explosion, or the production of carbon monoxide may cause property damage, personal injury, or loss of life.
  • Page 10 INSTALLATION—CONTINUED Pre-Installation Modifications—Continued High CFM Conversion—Continued 2 . Remove side finger baffles (see Figure a . At entering air side of heat exchanger, locate side finger baffles and remove two side finger baffle screws from each baffle . b . Remove both side finger baffles . SCREWS SCREWS SIDE FINGER BAFFLE...

  • Page 11: Reverse Airflow Conversion

    Reverse Airflow Conversion Duct furnaces are equipped with directional air baffles between the heat exchanger tubes . Facing the control compartment of the furnace, the standard direction of airflow is from left to right . If the installation site requires airflow Figure from right to left, the unit may be field-adapted by reversing the position of the directional air baffles (see as follows:...

  • Page 12: Ductwork Requirements

    INSTALLATION—CONTINUED Duct Connections—Continued Ductwork Requirements • Type: the type of duct installation to be used depends in part on the construction type of the roof (wood joist, steel bar joist, steel truss, or pre-cast concrete) and ceiling (hung, flush, etc .) . •...

  • Page 13: Discharge Air Temperature Sensor Installation

    Figure 8. Ductwork Connection Dimensions (Refer to Table Table 8. Ductwork Connection Dimensions Unit Size Dimension G RP Models HRPD Models Inches Millimeters 15-1/4 150, 175 300, 350 20-3/4 200, 225 26-1/4 250, 300 500, 600 34-1/2 1016 45-1/2 1156 Figure Discharge Air Temperature Sensor Installation •...
  • Page 14 INSTALLATION—CONTINUED Duct Connections—Continued Discharge Air Temperature Sensor Installation—Continued 4 × 12 × 24 5 �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� �������� × � = 96 �������� �������� �������� ℎ �������� �������� 3.14 4 ×...

  • Page 15: Duct Furnace Airflow

    Duct Furnace Airflow • The duct furnace must be installed on the positive pressure side of the field-supplied blower . • The air distribution must be even over the entire heat exchanger . Turning vanes should be employed in elbows or turns in the air inlet to ensure proper air distribution (refer to Duct Furnace Blower Connections section) .

  • Page 16: Bypass Duct Construction

    INSTALLATION—CONTINUED Duct Connections—Continued Duct Furnace Blower Connections—Continued STRAIGHT THROUGH AIR BLOWER CONNECTION BLOWER CONNECTION WITH ELBOWS UP OR DOWN BLOWER CONNECTION WITH ELBOWS RIGHT OR LEFT Figure 10. Duct Furnace Blower Connections Bypass Duct Construction When the air throughput CFM is greater than desirable or permissible for the unit, a bypass duct (see Figure may be constructed .
  • Page 17 Figure 11. Bypass Duct Dimensions 1 . Refer to Table 9 Table 10 to determine pressure drop and allowable 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 .

  • Page 18: Piping Connections

    INSTALLATION—CONTINUED Venting Connections—Continued DETAIL A DETAIL B Figure 12. Optional Vertical Flue Discharge Piping Connections Gas Supply Pressure The unit is equipped for a maximum gas supply pressure of 1/2 psi, 3 .5 kPa, or 14 IN WC . NOTES: Supply pressure higher than 1/2 psi requires the installation of an additional service regulator external to the unit.

  • Page 19: Supply Piping Connections

    • The heater is orificed for operation with natural gas having a heating value of 1,000 (±50) BTU per cubic foot or with propane gas having a heating value of 2,550 (±100) BTU per cubic foot . Sizing of gas supply lines depends on piping capacity and is based on cubic feet per hour based on a 0 .3 IN WC pressure drop, a 0 .6 specific gravity for natural gas at 1,000 BTU per cubic feet, and a 1 .6 specific gravity for propane at 2,550 BTU per cubic feet .
  • 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) 3/4 (19) Propane 1/2 (13)

  • Page 21: Electrical Connections

    Electrical Connections ⚠ CAUTION ⚠ • If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C, except for the limit control, optional bypass damper combustion air safety circuit (option AG39, AG40, AG41, or AG42), and sensor lead wires, which must be rated at 150°C.

  • Page 22: Controls

    INSTALLATION—CONTINUED Electrical Connections—Continued Control Wiring—Continued • Thermostat: A 24V thermostat must be used to actuate low voltage gas controls . If line voltage from the thermostat to the unit is desired, consult the factory representative . Thermostats should be located 5 feet (1 .5 meters) above the floor on an inside wall, not in the path of warm or cold air currents and not in corners where air may be pocketed .

  • Page 23: Combustion Air Proving Switch

    All furnaces are equipped with a 24V combination gas valve that includes the automatic electric ON/OFF valve controlled by the room thermostat, the pressure regulator, the safety pilot valve, and the manual shutoff valve . The standard combination gas valve allows for single-stage control from a single-stage, 24V thermostat . Combustion Air Proving Switch ⚠...
  • Page 24 CONTROLS—CONTINUED Optional Two-Stage Control (Makeup Air Application)—Continued • Option AG3 or AG15: Comparable to the two-stage heating units . Instead of control from a two-stage room thermostat, the discharge air temperature is monitored and the two-stage gas valve is controlled by a two-stage ductstat .

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

    Optional Ductstat with Capillary Tubing (Options AG3 and AG4) Figure 14, DETAIL A has an adjustable range between 0°F and 100°F with a The unit-mounted ductstat shown in fixed differential of 3°F . Due to different CFM settings and outside air temperatures, the average downstream outlet temperature may not match the ductstat setting exactly .

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

    CONTROLS—CONTINUED Optional Electronic Modulation—Continued Computer-Controlled Electronic Modulation Between 50% and 100% Firing Rate (Option AG21) • With option AG21, the furnace is equipped with a Maxitrol signal conditioner (see Figure 15) that operates much the same way as the amplifier above to control the regulator valve . The signal conditioner accepts an input signal of either 4–20 milliamps or 0–10V from a customer-supplied control device such as a computer .
  • Page 27 General Instructions: For each step, Is there 24 volts Go to between Terminal 2 on #1 check to ensure that the wiring is not Troubleshooting Time Delay Relay and Chart for heater. defective and that the wiring connec- Terminal 7? tions are secure.

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

    CONTROLS—CONTINUED Optional Electronic Modulation—Continued Electronic Modulation Between 20–28% and 100% Firing Rate (Options AG39 and AG41)—Continued • When the valve receives a call for heat from the amplifier and pilot is established, gas flow from the single-stage valve goes to both the modulating valve and the regulated lighter tube system . When the signal from the amplifier to the modulating valve requires less-than-high fire operation, the modulating valve functions to lessen the gas flow to the burner to reduce the input rate to that which is necessary to maintain the desired temperature .

  • Page 29: Burners And Carryover System

    • Intermittent spark ignition safety pilot systems: There are two types of intermittent spark pilots: one type shuts off the pilot gas flow between the cycles and the other not only shuts off the pilot gas flow between cycles but also has a lockout device that stops the gas flow to the pilot if the pilot fails to light in 120 seconds .

  • Page 30: Startup

    OPERATION—CONTINUED Startup 1 . Close all panels tightly . 2 . Turn ON electric and gas supply to furnace . 3 . Adjust thermostat or ductstat so that call for heat exists . 4 . Observe for complete sequencing of safety pilot and ignition (refer to Table 19) .

  • Page 31: Adjustments

    ADJUSTMENTS Measure and Adjust Manifold (Outlet) Gas Pressure Measuring manifold gas pressure cannot be done until the heater is in operation (refer to Startup section) . • For natural gas: When the heater leaves the factory, the combination valve is set so that the outlet gas pressure of a single-stage valve or high fire of a two-stage valve is regulated to 3 .5 IN WC .
  • Page 32 ADJUSTMENTS—CONTINUED Measure and Adjust Manifold (Outlet) Gas Pressure—Continued High Elevation (>2,000 Feet/609 Meters) Installations—Continued For high elevation (>2,000 feet/609 meters) installations that require orifice replacement, replace the burner orifices as follows: 1 . Determine model number and rated input (BTUh) from unit’s rating plate . 2 .

  • Page 33: Conversion To Lp (Propane)

    5 . Check all connections for gas leaks using commercial leak-detecting fluid or rich soap and water solution . Leaks are indicated by presence of bubbles . If leak is detected, tighten connection . If leak cannot be stopped by tightening connection, replace part(s) .

  • Page 34: Maintenance

    MAINTENANCE ⚠ WARNING ⚠ If you turn OFF the power supply, turn OFF the gas. ⚠ CAUTION ⚠ When cleaning, wearing eye protection is recommended. NOTE: Use only factory-authorized replacement parts. This unit will operate with a minimum of maintenance . To ensure long life and satisfactory performance, a furnace that is operating under normal conditions should be inspected every 4 months .

  • Page 35: Burner Rack Maintenance

    1/8-INCH OUTLET LOW FIRE PRESSURE TAP REGULATOR HIGH FIRE REGULATOR ADJUSTING REGULATOR ADJUSTING SCREW ADJUSTING SCREW SCREW 1/8-INCH INLET 1/8-INCH OUTLET PRESSURE TAP 1/8-INCH INLET PRESSURE TAP PRESSURE TAP SINGLE-STAGE VALVE TWO-STAGE VALVE Figure 19. Combination Gas Valve Test Connections 4 .

  • Page 36: Cleaning Pilot And Burners

    MAINTENANCE—CONTINUED Maintenance Procedures—Continued Cleaning Pilot and Burners ⚠ WARNING ⚠ To prevent injury when cleaning pilot and burners, wearing eye protection is recommended. ⚠ CAUTION ⚠ To prevent damage to pilot orifice, do not ream the orifice. If the pilot flame appears short and/or yellow, check the pilot orifice for blockage caused by lint or dust accumulation . 1 .

  • Page 37: Spark Ignition System Maintenance

    Spark Ignition System Maintenance ⚠ WARNING ⚠ Due to high voltage on pilot spark wire and pilot electrode, do not touch when energized. NOTE: When checking for spark with the pilot burner assembly removed from the burner rack, the pilot assembly must be grounded to the heater for proper spark. 1 .
  • Page 38 MAINTENANCE—CONTINUED Maintenance Procedures—Continued Heat Exchanger Cleaning—Continued 2 . Clean heat exchanger inner surfaces (combustion gas side): NOTES: • For cleaning the inner surfaces of the heat exchanger, an air hose, a long (18- to 24-inch) stiff brush of 1/2-inch diameter or heavy wire with steel wool securely attached, a flashlight, and a mirror are needed.

  • Page 39: Troubleshooting

    TROUBLESHOOTING NOTE: If the furnace is equipped with electronic modulation option AG39, AG40, AG41, or AG42, for additional troubleshooting guidelines. Figure 17 Table 21. General Troubleshooting Symptom Probable Cause Remedy A . Venter 1 . No power to furnace Turn ON power and check supply fuses or circuit breaker motor will 2 .

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

    INSTALLATION RECORD (TO BE COMPLETED BY INSTALLER) Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ Phone ________________________________________________________ Distributor (company from which the unit was purchased): Company ________________________________________________________ Contact ________________________________________________________ Address ________________________________________________________ ________________________________________________________ Phone ________________________________________________________ Model ________________ Serial No.______________________________ Date of Installation ____________ Specific installation notes (i.e., location, amps, gas pressure, temperature, voltage, adjustments, warranty, etc.): ________________________________________________________________________________________ ________________________________________________________________________________________...

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