NOTICE: The information contained on the following page(s) was produced prior to May 1, 2014. On that date Reznor became part of Nortek, Inc. References to any other company affiliations are no longer valid. ©2014 Reznor, LLC. All Rights Reserved. Trademark notice: Reznor is registered in at least the United States.
Form I-XE/CRGB/RPB (Version C) ® Obsoletes Form I-XE/RGB /RPB (Version B) Installation / Operation / Maintenance Applies to: Model Series XE, CRGB, RPB Packaged Duct Furnace Assemblies Table of Contents Para. Installation and Operation ......... 1-29 Check Installation and Start-Up ... 30 Optional Accessories ................. 31-36 Service/Maintenance .................. 37-41 Page ... 1-30 . 30-31 . 31-41 . 41-44 Index by Page Number Adjusting Blower Speed ...............................
1. Approval and Installation Codes The models covered in this manual are design certified or approved duct furnaces that are factory assembled with air handing components, creating a unified packaged furnace/blower system. The packaged system models listed on page 1 are design-certified to ANSI and CSA Standards by the Canadian Standards Association. All models are approved for installation in the United States. All models except Model CRGB and Model HCRGB are approved for installation in Canada.
. Dimensions FIGURE 1A - Dimensions (inches and mm) of Indoor/Gravity Vented System Dimensions of Model (H)XE with Standard Blower Cabinet (Standard blower cabinet has "full open" end and will not accommodate dampers. An optional cabinet is available with a smaller horizontal inlet that will accommodate dampers; see dimensional drawing below. An optional bottom inlet will also accommodate dampers.
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FIGURE 1C Dimensions, Outdoor/ Power-Vented Model Series RPB Model A B C D 28-5/8 727 34-1/8 867 39-5/8 1006 47-7/8 1216 47-7/8 1216 53-3/8 1362 58-7/8 1470 17-3/8 441 22-7/8 581 28-3/8 721 36-5/8 930 36-5/8 930 42-1/8 1070 47-5/8 1210 25-7/8 657 31-3/8 797 36-7/8 937 45-1/8 1146 45-1/8 1146 50-5/8 1286 56-1/8 1426 15-1/4 387 20-3/4 527 26-1/4 667 34-1/2 876 34-1/2 876 40 1016 45-1/2 1156 S ize 125 150, 175 200, 225 (H)-RPB 250 300 350 400 inches mm inches mm inches mm inches mm inches mm inche
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5. Clearances Provide clearance to combustibles as shown in the table. Clearance to combustibles is defined as the minimum distance from the heater to a surface or object that is necessary to ensure that a surface temperature of 90°F above the surrounding ambient temperature is not exceeded. Clearance is also required to sides of furnace for combustion air space and for convenient installation and burner control system service.
7A. Suspending/Mounting Indoor, GravityVented Models XE/HXE (cont'd) WARNING: Unit must be level for proper operation. Do not place or add additional weight to a suspended unit. See Hazard Levels, page 2. Suspending Furnaces These indoor, packaged furnace/blower systems have four-point suspension. See hanger dimensions in Paragraph 4, FIGURE 1A. At each suspension point, the unit is factory-equipped with a free-turning, female, 1" (NPT) pipe hanger.
FIGURE 6A - Mounting Support Dimensions (inches/mm) A 75, 100, 125 150, 175 200, 225 250, 300 350 400 75, 100, 125 150, 175 200, 225 250, 300 350 400 B 4x4 Treated Lumber With With ShippedWith Factory- Shippe dSe parate Standard Installed Separate C ooling C oil Heater Downturn C ooling C abinet with and Plenum C oil Downturn Blower Cabinet C abinet Ple num Package (O ption AQ ) (O ption AU) (O ption AU) "A" "A" "A" "B" 60-5/8" 84-9/16" 98-3/8" 122-1/4" 24-5/16" 60-5/8" 60-5/8" 60-5/8" 60-5/8"
7B. Mounting Outdoor Models on a Roof Curb (cont'd) *Optional Downturn Plenum FIGURE 8 Optional Roof Curb Blower Cabinet Furnace For top 4 holes (2 on each side) at both joints, from inside the curb insert (4) 5/16 x 1 lag screws and (4) 5/16 lockwashers. Lift Holes (4 corners) Curb Cap For bottom 4 holes (2 on each side) at both joints, from outside of the curb insert (4) 5/16-18 x 3/4 long cap screws. Attach with 5/16 lockwashers and 5/16-18 hex nuts.
Roof Curb Dimensions (mm) S ize 75, 100, 125 150, 175 200, 225 250, 300 350 400 Option CJ1 - Roof Curb for (H)CRGB and (H)RPB A B C** D** 1540 618 1446 522 1540 757 1446 662 1540 897 1446 802 1540 1106 1446 1011 1540 1246 1446 1151 1540 1384 1446 1291 Option CJ2 - Roof Curb for (H)CRGB and (H)RPB with FactoryInstalled Downturn Plenum Option AQ5 or AQ8 2148 2148 2148 2148 2148 A 618 757 897 1106 1246 B 2053 2053 2053 2053 2053 C** 522 662 802 1011 1151 D** **, *** See Notes under chart on the bot
8A. Gravity-Vented Models XE/HXE (cont'd) Venting Requirements - Indoor Models (cont'd) (b) Use double-wall, Type B vent pipe which is recommended for the reduction or elimination of condensate problems. Where extreme conditions are present and condensate is anticipated, install a trap for collecting condensate. 8. The vent connection may be made into a suitable permanent chimney or into a gas vent.
FIGURE 9C - Optional Stack Extension applies only to Furnaces with Suffix "Z" in their Model No. Three guy wires, spaced 120° apart, fastened to the vent cap collar and furnace top with sheetmetal screws. FIGURE 11B - Installation of the Vent Cap (included in the option package) and the field-supplied Piping and Supports Gravity Vent Cap 5 Vent Cap, P/N 110052 Support angles for flue pipe. Recommended size is 1/2x1/2, 20 gauge 4 (1.2M) 4 ft (1.2M) 5 dia Flue Pipe 5 dia 90° Elbow 8C.
10. Duct Connections (cont'd) • Requirements and Suggestions (cont'd) • • • • Through Masonry Walls - No warm air duct should come in contact with masonry walls. Insulate around all air duct through masonry walls with not less than 1/2" (1" is recommended) of insulation. Through Unheated Space - Insulate all exposed warm air ducts passing through an unheated space with at least 1/2" (1" is recommended) of insulation. Duct Supports - Suspend all ducts securely from adjacent buildings members.
Gas Connection to Single-Stage Valve (Not Gas Supply Line Size) Applies to all M odels in this Manual Sizes 75-250 Natural Propane 1/2" 1/2" Sizes 300-400 Natural Propane 3/4" 1/2" Pipe joint compounds (pipe dope) shall be resistant to the action of liquefied petroleum gas or any other chemical constituents of the gas being supplied. Install a ground joint union and manual shutoff valve upstream of the unit control system, as shown in FIGURES 16 and 17.
11. Gas Pressures (cont'd) Manifold or Orifice Pressure Settings (cont'd) as stated above, but Sizes 350 and 400 with electronic modulation require a minimum of 6" w.c. natural gas supply pressure. Sizes 300 and 350 with mechanical modulation require 7" w.c. is recommended rather than a spring type gauge due to the difficulty of maintaining calibration of a spring type gauge. 2) Open the valve and operate the heater. Measure the gas pressure to the manifold.
FIGURE 19 - Location of Standard and Optional Controls - Outdoor Systems 27 30 31 42 41 32 33 34 35 36 37 38 39 40 1 2 3 4 5 6 43 Optional Downturn Plenum (Option AQ) 26 29 25 28 24 23 22 21 20 1. Opt Auto Reset Freezestat 2. Combustion Air Pressure Switch (power-vented) 3. Opt Discharge Air Firestat 4. Ignition Controller 5. Optional Maxitrol Discharge Air Sensor (Opt AG8 or 9) 6. Optional Two-Stage Controller (Opt AG3) or Maxitrol Amplifier (Opt AG7, 8, or 9) 7.
12. Electrical Supply and Connections (cont'd) Wiring Requirements for Maxitrol Systems (cont'd) switch, a heat/vent/cool switch, a potentiometer, a thermostat, and/or a Maxitrol temperature selector. Consoles are shipped separately for remote installation and may be either mounted on a wall or recessed. may cause the unit to function erratically or may destroy the amplifier. If shielded wires are used, shield must be insulated and grounded at the amplifier location only.
Model XE/HXE, Indoor, Gravity-Vented Furnace with Two-Stage Gas Valve DISCONNECT SWITCH (SEE NOTES) 6 BLOWER MOTOR CONTACTOR CONTACTS T1 L1 LINE 1/60 OR 3/60 8 9 L3 T3 L2 T2 WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W INTERNALLY PROTECTED BLOWER MOTOR R OR BK 7 R R OR W 10 GRD G BK 11 Y B 12 FIELD CONTROL WIRING TOTAL WIRE MINIMUM RECOMMENDED LENGTH WIRE SIZE 150 FEET #18 GA. 250 FEET #16 GA. 350 FEET #14 GA.
Typical Wiring Diagrams (cont'd) Model CRGB , Outdoor, Gravity-Vented Furnace with Standard Single-Stage Gas Valve 5 DISCONNECT SWITCH (SEE NOTES) 6 BLOWER MOTOR CONTACTOR CONTACTS T1 L1 INTERNALLY PROTECTED BLOWER MOTOR R OR BK LINE 1/60 OR 3/60 7 8 9 L3 T3 L2 T2 R R OR W 10 GRD G BK 11 WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W W FIELD WIRING TOTAL WIRE MINIMUM RECOMMENDED LENGTH WIRE SIZE 150 FEET #18 GA. 250 FEET #16 GA.
Model CRGB , Outdoor, Gravity-Vented Furnace with Two-Stage Gas Valve 4 5 DISCONNECT SWITCH (SEE NOTES) 6 BLOWER MOTOR CONTACTOR CONTACTS L1 T1 R OR BK LINE/1/60 OR LINE/3/60 7 8 L3 T3 L2 T2 WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W INTERNALLY PROTECTED BLOWER MOTOR R R OR W 9 10 G GRD FACTORY WIRING 11 BK 12 FIELD WIRING W OPTIONAL FACTORY WIRING OPTIONAL FIELD WIRING 13 L1 L2 14 8 16 8 17 BL Y 40 VA.
Typical Wiring Diagrams (cont'd) Model RPB, Outdoor, Power-Vented Furnace with Standard Single-Stage Gas Valve DISCONNECT SWITCH (SEE NOTES) BLOWER MOTOR CONTACTOR CONTACTS 6 L1 INTERNALLY PROTECTED BLOWER MOTOR T1 R OR BK LINE 1/60 OR 3/60 7 8 9 L3 T3 L2 T2 R R OR W 10 WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W GRD G BK 11 W 12 VENTER MOTOR & CAPACITOR TIME DELAY RELAY CONTACTS 13 L1 BK BK L1 BK 1 BK F 3 BK L2
Model RPB, Outdoor, Power-Vented Furnace with Two-Stage Gas Valve 5 DISCONNECT SWITCH (SEE NOTES) BLOWER MOTOR CONTACTOR CONTACTS 6 INTERNALLY PROTECTED BLOWER MOTOR T1 L1 R OR BK LINE 1/60 OR 3/60 7 8 9 L3 T3 L2 T2 R R OR W 10 GRD G BK 11 12 L1 13 L1 BK BK BK 1 L2 VENTER MOTOR & CAPACITOR TIME DELAY RELAY CONTACTS L1 WIRING CODE BLACK - BK BROWN - BR RED - R ORANGE - O YELLOW - Y GREEN - G BLUE - BL PURPLE - PR WHITE - W W 3 F BK BK L2 W L2 14 R BK 15 LINE VOLT BK
13. Blowers, Belts and Drives Optional Variable Frequency Drive Check belt tension. Proper FIGURE 20 - Check Belt Tension belt tension is important to the long life of the belt and motor. A loose belt will cause wear and slippage. Too much tension will cause excessive motor and blower bearing 3/4 (19mm) wear. Adjust the belt tension by turning the adjusting screw on the motor base until the belt can be depressed 3/4" (19mm). (See FIGURE 20.
controls or miswiring, and will require correction of the cause of failure and the replacement of the fan and limit control and wiring before the unit can be returned to service. See Hazard Levels, page 2. 16. Fan Control 1. A fan control provides for the following control of the blower. (a) After the gas valve opens, there is a time delay of blower operation to prevent the discharge of cold air. (b) Blower operation continues after the thermostat is satisfied as determined by the fan time delay. 2.
23. Optional 2-Stage Operation Makeup Air Application (cont'd) temperature rise of the furnace in the installation dictates the limits of the ductstat temperature setting. Depending on the option selection, the factory-installed sensor is either field-connected by capillary tubing to the unit-mounted ductstat (FIGURE 21) or electrically connected to a remote electronic temperature selector (FIGURE 22). The remote temperature selector is available with or without a display module.
25B. Computer Controlled Electronic Modulation between 50% and 100% Firing Rate (Option AG21) With this option the furnace is equipped with a Maxitrol signal conditioner which operates much the same way as the amplifier above to control the regulator valve. The conditioner accepts an input signal of either 4-20 milliamps or 0-10 volts from a customer-supplied control device such as a computer. With the dip switches on the conditioner in the "on" positions, the conditioner accepts a 4-20 milliamp signal.
25. Optional Electronic Modulation (cont'd) 25C. and 25D. Electronic Modulation between 20% 28% and 100% Firing Rate (cont'd) Is there 24 volts between Terminal 2 on #1 Time Delay Relay and Terminal 7? Troubleshooting Guide for Checking Bypass Combustion Air Damper Safety Circuit on Model RPB with Option AG39 or AG40 NO Is there 24 volts between Terminal 84 and Terminal 7? General Instructions: For each step, check to ensure that the wiring is not defective and that the wiring connections are secure.
b) Short to ground in the high tension lead and/or ceramic insulator. c) Pilot spark gap should be approximately 7/64". FIGURE 26 Johnson Controls Metasys® Unit is located in the blower cabinet Flame Sensing Probe High Tension Lead Burner Rack Front Pilot Orifice Spark Electrode 1/4± 1/32 (6.38mm±.79) Johnson Controls Metasys® Unit Centerline of 23/32 first burner (18.
28. Burner and Carryovers (cont'd) lighter tube carryover and one flash carryover.) Propane gas burners are equipped with one flash carryover and a regulated gas lighter tube system. OUTDOOR Gravity-Vented Furnace (Model Series CRGB ) - Natural gas burners are equipped with a gas lighter tube carryover on the orifice end of the burner rack and a flash carryover on the other end. Propane gas burners are equipped with one flash carryover and a regulated gas lighter tube system.
Check installation after start-up With the unit in operation, measure manifold gas pressure. High fire manifold pressure for natural gas should be 3.5" w.c. and 10" w.c. for propane gas. See Paragraph 11. Turn the unit off and on, pausing two minutes between each cycle. Observe for smooth ignition. On two-stage or modulating burner systems, manipulate temperature adjustment slowly up and down to see if control is sequencing or modulating properly.
31. 100% Outside Air Hood (cont'd) Hood Installation Instructions (cont'd) 3. Bottom Panel - Position the air hood bottom panel so that it is to the inside of the two side panels and above the factory-installed support angle. Attach to the side panels. If the bottom panel does not rest tightly against the support angle, follow these instructions to adjust the position of the support angle: a) Slightly loosen (do not remove the screws). b) Slide the support angle up so that it is against the bottom panel.
metering water system, it will not have these controls but will have a solenoid valve with a timer assembly for controlling water flow. Installation Instructions - Evaporative Cooling Module The evaporative cooling module is factory assembled, installed and wired. No additional roof mounting is necessary. Follow these instructions to field connect the water supply and make necessary checks and adjustments before operating the cooling module.
33. Optional Evaporative Cooling Module (outdoor models) (cont'd) Bleed Line (cont'd) Discharging a quantity of water by "bleed off" will limit the concentration of undesirable minerals in the water being circulated through the cooling module. Minerals buildup because evaporation only releases "pure water vapor" causing the concentration of contaminants in the water to increase as the evaporation process continues. The minerals accumulate on the media, in the water lines, on the pump, and in the reservoir.
Replacement Part No.
34.
4. Adjustment of the Switch - The "HIGH" actuation point of the null switch is indicated on a calibrated scale secured to the transparent range screw enclosure. Building pressure is set by turning the adjustment screw. The "Low" actuation point is set by adjusting the span of the null by turning the span adjustment screw. The span range is .01 to .03" w.c. IMPORTANT: To eliminate shipping damage to the switch contacts, the manufacturer reduced the span adjustment to zero before shipping.
35. Optional Filter Rack and Filters (cont'd) 35B.
Factory-Supplied Parts for Attaching Cabinet to Furnace Description Qty 75, 100 125 150, 175 200, 225 250, 300 350 107426 107427 107428 107429 106338 106339 Top/Bottom Duct Connectors 2 14" 16-3/4" 21-1/4" 27-3/4" 36" 41-1/2" 106395, 19-1/2" (495mm) long 2 Side Duct Connectors Connectors 105171 8 #14 x 3/4" long Sheetmetal Screws 172357 1 Left Side Filler Panel 172358 1 Right Side Filler Panel 1 172360 172361 172362 172363 172359 Top Filler Panel 172546 Insulation, 1"x42"x9", for Side Filler Panels 2 (_) (
36. Optional Cooling Coil Cabinet, Option AU (Outdoor Models) (cont'd) Installation Instructions (cont'd) 6. Prepare Cabinets to Install Filler Panels (See FIGURE 46H) a) At the side corners of both the cooling coil cabinet and the furnace, remove the factory-installed screws that attach the cabinet tops. b) Across the edge of the cooling coil cabinet, remove the row of screws that attach the top. the blockoff plate and drill a 7/8" hole.
FIGURE 46K Top Filler Panel Installed FIGURE 46J Side Filler Panel Installed Furnace Section with Door Panel Removed Cooling Coil Cabinet with Downturn Plenum Attach side filler panel with sheetmetal screws. 8. Install the Cabinet Top Filler Panel (See FIGURE 46K) a) Remove the backing from the gasket strip, and adhere it along the edge of the bottom of the top filler panel.
38. Burner Rack Removal Instructions 1. 2. 3. 4. 5. 6. 7. Turn off the gas supply. Turn off the electric supply. Remove control access side panel. Disconnect the pilot tubing and flame sensor lead (spark pilot). Mark and disconnect electric valve leads. Uncouple the union in the gas supply. Remove sheetmetal screws in the top corners of the burner rack assembly. 8. Pull "drawer-type" burner rack out of the furnace. To disassemble the burner rack: 1.
Indoor, Gravity Vent Models XE/HXE (See FIGURE 50) 1) Remove the screws (the number varies depending on unit size) along the bottom of the front baffle and the three on each end. Slide the front baffle out of the furnace. 2) Remove the screws that attach the tube baffle hold-down plate to the rear flue baffle. 3) Pull the "V" baffles out of the heat exchanger.
41. Troubleshooting (cont'd) Troubleshooting the Optional Evaporative Cooling Module (Refer to Paragraph 33.) WARNING: Disconnect the power before servicing the cooling module. Failure to do so can cause electrical shock, personal injury or death. Problem Pump does not run. Unit is calling for cooling (i.e. console control switch is in cooling position) and reservoir is full. Required water level (3") not maintained (pump and float control system) Probable Cause 1. Electrical connections 2.
