Roberts Gorden Combat IDF-450 Manuals

Manuals and User Guides for Roberts Gorden Combat IDF-450. We have 2 Roberts Gorden Combat IDF-450 manuals available for free PDF download: Installation, Operation & Service Manual, Specifications

Roberts Gorden Combat IDF-450 Installation, Operation & Service Manual (182 pages)

Indirect, Gas/Oil-Fired, Industrial Air Handler

Brand: Roberts Gorden | Category: Air Handlers | Size: 6 MB

Pour Votre Securite
3
Table of Contents
5
Section 1: Air Handler Safety
11
Description of Operation
11
Inspection and Setup
11
Safety Labels and Their Placement
11
California Proposition 65
12
Label Placement
12
Figure 1: Indoor Upright (Models 35 - 100)
12
Figure 2: Indoor Upright (Models 125 - 450)
13
Figure 3: Indoor Horizontal (Models 35 -100)
14
Figure 4: Indoor Horizontal (Models 125 - 450)
15
Figure 5: Outdoor Upright (Models 35 - 100)
16
Figure 6: Outdoor Upright (Models 125 - 400)
17
Figure 7: Outdoor Horizontal (Models 35 - 100)
18
Figure 8: Outdoor Horizontal (Models 125 - 400)
19
Figure 9: Control Enclosure Door (Inside)
20
Figure 10: 8.1 Remote Panel
20
Figure 11: 8.5 Remote Panel
20
Section 2: Installer Responsibility
21
Corrosive Chemicals
22
Required Equipment and Materials
22
Section 3: Critical Considerations
23
Required Clearances to Combustibles
23
Hardware
23
Table 1: Recommended Torque Settings
23
Section 4: National Standards and Applicable Codes
24
Fuel Codes
24
Installation Codes
24
Aircraft Hangars
24
Parking Structures and Repair Garages
25
Electrical
25
Venting
25
High Altitude
25
Section 5: Specifications
26
Figure 12: Upright Model Dimensions (Models 35 - 125)
26
Table 2: Legend
26
Table 3: Cabinet Dimensions (Models 35 - 125)
26
Figure 13: Horizontal Model Dimensions (Models 35 - 125)
27
Table 4: Estimated Shipping Weights (Models 35 - 125)
27
Table 5: Estimated Shipping Weights - Burners (Models 35 - 125)
27
Figure 14: Upright Model Dimensions (Models 150 - 450)
28
Table 6: Estimated Shipping Weights - Motors (Models 35 - 125)
28
Table 7: Cabinet Dimensions (Models 150 - 450)
28
Figure 15: Horizontal Model Dimensions (Models 150 - 450)
29
Table 8: Estimated Shipping Weights (Models 150 - 450)
29
Table 9: Estimated Shipping Weights - Burners (Models 150 - 450)
29
Table 10: Estimated Shipping Weights - Motors (Models 150 - 450)
30
Table 11: Model Number and Capacity
30
Figure 16: Percentage of Airflow Capacity
31
Figure 17: Internal Static Pressure
31
Table 12: Blower Motor Horsepower Selection (Includes Drive Losses)
31
Table 13: Sound Data
34
Section 6: Lifting an Air Handler
35
Lifting an Air Handler
35
Figure 18: Lifting a Horizontal Air Handler
36
Figure 19: Lifting an Upright Air Handler
36
Section 7: Air Handler Assembly
37
Table 14: Roof Seam Cover Drill Screws
37
Figure 20: Air Handler Assembly - Horizontal (Models 150 - 450)
38
Figure 21: Air Handler Assembly - Upright (Models 150 - 450)
39
Section 8: Vibration Isolators
40
Waffle Pad Isolator
40
Figure 22: Waffle Pad Isolator
40
Neoprene or Spring Isolators for Hanger-Mounted Units
41
Figure 23: Pad Isolator Installation Instructions
41
Figure 24: Hanging Isolators
42
Figure 25: Hanger Isolators' Installation Instructions
42
Figure 26: Hanging Rods' Installation Instructions (Models 35 - 125)
43
Figure 27: Hanging Rods' Installation Instructions (Models 150 - 450)
44
Neoprene or Spring Isolators for Pad-Mounted Units
45
Figure 28: Pad Mounting of Neoprene Isolator
45
Figure 29: Pad Mounting Instructions for Neoprene Isolator (Models 35 - 125)
46
Figure 30: Pad Mounting Instructions for Neoprene Isolator (Models 150 - 450)
47
Spring Mount Isolator
48
Figure 31: Pad Mounting of Spring Isolator
48
Figure 32: Pad Mounting Instructions for Spring Isolator (Models 35 - 125)
49
Figure 33: Pad Mounting Instructions for Spring Isolator (Models 150 - 450)
50
Section 9: Roof Curb
51
Roof Curb Assembly and Installation
51
Figure 34: Roof Curb
52
Table 15: Roof Curb Dimensions
52
Air Handler Mounting to Roof Curb
53
Figure 35: Curb Mounting (Models 35 -125)
53
Table 16: Roof Curb Weights
53
Figure 36: Curb Mounting (Models 150 - 450)
54
Section 10: Upright Stand
55
Upright Stand Installation
55
Attaching Air Handler to Stand
55
Figure 37: Upright Stand Detail (Models 35 - 100)
56
Figure 38: Upright Stand Detail (Models 125 - 450)
56
Figure 39: Stand Mounting Detail (Models 125 - 450)
57
Section 11: Filter Section
58
Filter Section Installation - Horizontal Air Handlers (Models 35 - 450)
59
Figure 40: Filter Section Installation on Horizontal Air Handler
59
Filter Section Installation - Upright Air Handlers (Models 35 - 450)
60
Figure 41: Filter Section Installation on Upright Air Handler
60
Section 12: Mixing Box
61
Mixing Box Section Installation - Horizontal Air Handlers (Models 35 - 450)
61
Figure 42: Mixing Box Section Installation on Horizontal Air Handler
62
Mixing Box Section Installation - Upright Air Handlers (Models 35 - 450)
63
Figure 43: Mixing Box Section Installation on Upright Air Handler
63
Section 13: Inlet Hoods
64
Inlet Hood Installation (Models 35 - 125)
65
Figure 44: Inlet Hood Installation to Air Handler (Models 35 - 125)
65
Inlet Hood Installation (Models 150 - 450)
66
Section 14: Service Platform
70
Figure 45: Horizontal Service Platform (Models 35 - 450)
71
Figure 46: Upright Service Platform (Models 35 - 450)
72
Section 15: Dampers
73
Discharge Damper Installation
73
Inlet Damper Installation
74
Figure 47: Discharge Damper Installation for Horizontal Air Handler with Bottom Discharge
74
Table 17: Lag Bolts
74
Figure 48: Inlet Damper
75
Section 16: Discharge Heads and Discharge Louvers
76
Discharge Heads' Installation
76
Discharge Louvers' Installation
77
Figure 49: Discharge Heads
77
Figure 50: Double Deflection Discharge Louvers
78
Section 17: Duct Considerations
79
Inlet Duct Work
79
Return Air Duct
79
Discharge Duct Work
79
Table 18: Minimum Discharge Duct Connection Size
79
Section 18: Venting
80
General Venting Requirements
80
Recommended Flue Venting Practices
80
Heat Exchanger Condensate Drain Connection
81
Figure 51: Condensate Drain
81
Section 19: Burners
82
Principle of Operation
82
Figure 52: Typical "Type J" Burner
82
Burner Pilot Assemblies
83
Combustion Air Intake Collar
83
Figure 53: Typical "Type C" Burner
83
Figure 54: "Type J" Burner with Flame Rod - Natural Gas Only (Not for Use with LPG)
83
Figure 55: "Type J" Burner with Ultraviolet Scanner - Natural Gas or LPG
84
Table 19: Combustion Air Duct Collar Sizing
84
Figure 56: "Type C" Burner with Ignition Electrode - Natural Gas or LPG
85
Figure 57: "Type C" Burner with Ignition Electrode - Oil
86
Section 20: Gas Piping for Gas-Fired Air Handlers
87
Gas Manifolds
87
Gas Piping and Pressures
87
Table 20: Gas Manifold Size
88
Figure 58: Manifold Diagram for Gas-Fired Air Handler with any
89
High/Low/Off Burners
89
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
90
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
91
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
92
Gas Manifold Venting
93
Gas Piping
93
Pressure Test Ports
93
Figure 62: Test Port Location
93
Line Pressure Test - Leak Testing
94
Figure 63: Location of Side Orifice
94
Section 21: Oil Piping for Oil-Fired Air Handlers
95
Oil Piping and Pressures
95
Figure 64: Two-Pipe Oil System
95
Line Pressure Test - Leak Testing
96
Pressure Test Ports
96
Oil Manifolds
96
Figure 65: Suntec Two Step Pump
96
FM or XL-Compliant Manifold for Air Handlers with Suntec Pump and On/Off Burner
96
Figure 68: FM or XL-Compliant Manifold for Air Handlers with Suntec Pump and High/Low/Off Burner
97
Figure 69: FM or XL-Compliant Manifold for Air Handlers with Webster Pump and High/Low/Off Burner
97
Figure 70: FM or XL-Compliant Manifold for Air Handlers with Webster Pump and Fully-Modulating Burner
98
Section 22: Combination Gas and Oil Burners
99
Figure 71: Typical Linkage for a Combination Gas/Oil Burner
99
Switching between Fuels
100
Semi-Automatic Change over
100
Figure 72: Burner Oil Pump Shaft Coupling Location
100
Fully-Automatic Change over
101
Figure 73: Remote Oil Pump
101
Section 23: Electrical
102
Wiring and Electrical Connections
102
Remote Panel
102
Motor Current Draw
102
Control Current Draw
102
Safety Systems
102
Table 21: Control Voltage Wiring for All Control Systems
102
Table 22: Safety Systems
103
Figure 74: Wiring Diagram Key
105
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)
106
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)
107
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)
108
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)
109
Figure 79: Wiring Diagram for Gas-Fired Air Handler with FM- Compliant Manifold and Fully
110
Modulating Burner with Input Less than 2,500 MBH (732.7 Kw)
110
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)
111
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)
112
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)
113
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)
114
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)
115
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)
116
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)
117
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)
118
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)
119
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)
120
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)
121
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)
122
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)
123
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)
124
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)
125
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)
126
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)
127
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)
128
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)
129
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)
130
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)
131
Section 24: Sequence of Operation
132
Air Handler Configuration
132
Table 23: Configuration Chart
132
Remote Panel Options
133
Figure 101: Air Handler Configurations
133
Basic Sequence of Operation
134
Figure 102: Wiring Subbase and Sequence Chart for RM7897 Burner Control Module
136
Figure 103: Wiring Subbase and Sequence Chart for RM7800 Burner Control Module
137
Night Setback Options
138
Other Control Options
138
Section 25: Start-Up Procedures
140
Mechanical
141
Figure 104: Sheave Alignment
141
Electrical
142
Airflow
142
General Start-Up Procedures (All Fuels)
142
Blower Start-Up
142
Burner Start-Up
142
Figure 105: Belt Tension
142
Table 24: Deflection Force of V-Belts
142
Gas Pressure Adjustments
143
Figure 106: Low Fire Adjustment for High/Low/Off Burner
143
Oil Pressure Adjustments
144
Figure 107: Low Fire Adjustment for Fully-Modulating Burner with Linkage Adjustment
144
Figure 108: Low Fire Adjustment for Fully-Modulating Burner with Stop Screw Adjustment
144
Figure 109: Oil Pressure Adjustments for On/Off Burner
144
Figure 110: Oil Pressure Adjustment High/Low/Off Burner with Suntec Pump
145
Figure 111: Oil Pressure Adjustments for High/Low/Off Burner with Webster Pump
145
Gas Fired Equipment Start-Up Procedures
146
Figure 112: Oil Pressure Adjustments for Fully-Modulating Burner with Webster Pump
146
Oil Fired Equipment Start-Up Procedures
147
Accessories and Controls Start-Up
148
Section 26: Maintenance
149
General
150
Unit Exterior
150
Blower Section
150
Table 25: Motor Lubrication Intervals
151
Manifold and Controls
152
Burner
152
Dampers
152
Filters
152
Motor and Drive Components
152
Section 27: Replacement Parts
153
Replacement Blower Components
153
Replacement V-Belts
157
Replacement Damper Components
159
Replacement Burner Components
159
Replacement Manifold Components
160
Replacement Electrical Components
161
Replacement Filters
162
Miscellaneous Replacement Parts
162
Section 28: Troubleshooting
164
Initial Checks
165
Supply Fan
166
Burner
167
Gas Operation
168
Oil Operation
169
Burner Control Module
172
Blink Code
172
System Failure
172
Roberts Gordon
176
IDF Start-Up Procedures
176
SECTION 29: the ROBERTS GORDON
181
IDF-Series Warranty
181

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