Reznor RPBL 1050 Installation, Operation And Maintanance Manual Download

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Form I-SSCBL/RPBL, P/N 149159 R8, Page 1

Form I-SSCBL/RPBL (Version E.3)

Obsoletes

I-SSCBL/RPBL (Version E.2)

Applies to:

Model SSCBL

and Model RPBL

Packaged Systems

INSTALLATION / OPERATION / MAINTENANCE

PROCE

T-

ODUCT

WAR

NVERGENT

ALITY SYSTE

CQS

Indoor,

Separated-Combustion

Model SSCBL

WARNING:

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury, death, or

property damage.
Be sure to read and understand the installation, operation, and service instructions in

this manual.
Improper installation, adjustment, alteration, service, or maintenance can cause

serious injury, death, or property damage.

—

Do not store or use gasoline or other flammable vapors and liquids in the vicinity

of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

•

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.

—

Installation and service must be performed by a qualified installer, service agency,

or the gas supplier.

Outdoor, Power Vented

Model RPBL

Summary of Contents for RPBL 1050

Page 1: ...rvice instructions in this manual Improper installation adjustment alteration service or maintenance can cause serious injury death or property damage Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building ...

Page 2: ...ral 2 1 1 Hazard Labels and Notices 2 1 2 General Installation Information 3 1 3 Warranty 3 1 4 Installation Codes 3 2 0 Furnace Location 3 3 0 Uncrating and Preparation 4 3 1 Uncrating and Inspecting 4 3 2 Preparing for Installation 4 4 0 Dimensions and Clearances 5 4 1 Dimensions 5 4 2 Clearances 8 5 0 Suspension and Mounting 8 5 1 Weights 8 5 2 Suspension Model SSCBL 8 5 3 Indoor Mounting on Fi...

Page 3: ... designed and manufactured in accordance with the ANSI definition of separated combustion That definition reads Separated Combustion System Appliance A system consisting of an appliance and a vent cap s supplied by the manufacturer and 1 combustion air connections between the appliance and the outside atmosphere and 2 flue gas connections between the appliance and vent cap of a type s specified by...

Page 4: ...ucts Check the rating plate for the gas specifications of the furnace and electrical character istics of the unit to be sure that they are compatible with the gas and electric supplies at the installation site Shipped Separate Components Read this booklet and become familiar with the installation requirements of your par ticular furnace If you do not have knowledge of local requirements check with...

Page 5: ...ches mm 400 58 7 8 1495 47 5 8 1210 56 1 8 1426 45 1 2 1156 500 600 47 7 8 1216 36 5 8 930 45 1 8 1146 34 1 2 876 700 1050 53 3 8 1356 42 1 8 1070 50 5 8 1286 40 1016 800 1200 58 7 8 1495 47 5 8 1210 56 1 8 1426 45 1 2 1156 457 SSCBL Size E Suspension Dimensions No of Hangers F G H inches mm inches mm inches mm inches mm 400 83 1 2 2121 59 9 16 1513 54 3 8 1381 27 3 32 688 6 500 600 109 1 2 2781 4...

Page 6: ...56 1070 1286 1016 400 800 1200 inches 58 7 8 47 5 8 56 1 8 45 1 2 mm 1495 1210 1426 1156 Model Size with Downturn Opt AQ5 or AQ8 E F inches mm inches mm RPBL 400 No 83 3 4 2127 Yes 107 3 4 2737 60 5 16 1532 500 600 700 800 No 109 3 4 2788 Yes 133 3 4 3397 86 5 16 2192 1050 1200 No 135 3 4 3448 Yes 159 3 4 4058 112 5 16 2853 Approximate Gas Connection Location Size Drawing Location Approximate Dist...

Page 7: ...rnace length on page 5 SSCBL or RPBL Size 500 600 700 1050 400 800 1200 A inches 47 3 4 53 1 4 58 3 4 mm 1213 1353 1492 B inches 34 1 2 40 45 1 2 mm 876 1016 1156 C inches 45 1 8 50 5 8 56 1 8 mm 1146 1286 1426 D inches 56 3 8 62 67 3 8 mm 1432 1575 1711 E Without Downturn inches 59 3 8 64 7 8 70 3 8 mm 1508 1648 1788 With Downturn inches 83 3 8 88 7 8 94 3 8 mm 2118 2257 2397 F Without Downturn i...

Page 8: ...l installed systems must be level Model and Size Net Weight lbs and kg 400 500 600 700 800 1050 1200 SSCBL lbs 849 1104 1104 1184 1245 1476 1565 kg 385 500 500 537 565 670 710 RPBL lbs 849 1104 1104 1184 1245 1476 1565 kg 385 500 500 537 565 670 710 A Model SSCBL unit is equipped with a load bearing curb cap which forms an integral part of the unit The curb cap is welded at all joints and has susp...

Page 9: ... unit is equipped with a load bearing curb cap which forms an integral part of the unit This curb cap is welded at all joints and has a skirt which fits over a roof curb to provide a weatherproof installation Holes are provided at the curb cap corners for lifting the unit These holes do not interfere with unit weather proofing The curb cap is not designed to be placed directly on the roof surface ...

Page 10: ...ntire width of the system supporting the 4x4 wooden rails at the recommended locations Do not enclose the area under the furnace leave space for ventilation WARNINGS Do not close or block the openings under each end of a system mounted on 4x4 treated wooden rails the space under the furnace MUST be left open for ventilation If cross supports are used under the 4x4 rails do not enclose the area und...

Page 11: ... 4851 4991 5512 5652 D inches 50 13 16 39 13 16 45 5 16 50 13 16 45 5 16 50 13 16 mm 1291 1011 1151 1291 1151 1291 Wt lbs 253 257 269 280 296 308 kg 115 117 122 127 134 140 C and D are roof opening dimensions Field installed means that the cooling coil cabinet with or without the downturn is factory assembled and shipped separately The roof curb is sized to accommodate the complete length of the s...

Page 12: ... Openings for ductwork should be 1 25mm larger than the duct size for installation clearance 5 4 Mounting Outdoor Model cont d 5 0 Suspension and Mounting cont d 5 4 4 Mounting on a Roof Curb Model RPBL cont d 3 Level the roof curb To ensure a good weathertight seal between the curb cap and the roof curb the roof curb must be leveled in both directions with no twist end to end Shim level as requir...

Page 13: ...ll 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 sys tem The 1 8 plugged tapping in the shutoff valve provides connection for supply line pressure test gauge The National Fuel Gas Code requires the installation of a trap with a minimum 3 drip leg L...

Page 14: ... the rating plate for minimum gas sup ply pressure Minimum supply pressure requirements vary based on size of burner and the gas control option Most units require a minimum of 5 w c of natural gas as stated above but larger sizes with electronic modulation require a minimum of 6 w c natural gas supply pressure For Propane When the heater leaves the factory the combination valve is set so that the ...

Page 15: ...or atmospheres highly laden with chlorinated vapors See Hazard Levels page 2 6 2 1 1 Specific Venting Requirements Model SSCBL read all venting information before installing 1 Vent Combustion Air Kit ordered with the heater as either Option CC2 or Option CC6 All Model SSCBL installations require a vent combustion air kit for each furnace sec tion Follow the instructions on pages 19 21 to install a...

Page 16: ...1M 2 4M 1 2M The outside terminal portion of the inlet air pipe is 8 in diameter The 5 I D diameter double wall vent pipe runs through the 8 inlet air pipe See FIGURE 13 page 17 The outdoor lengths depend on the installation Outdoor vent length requirements are listed in the installation instructions for the horizontal and vertical vent combustion air kits 5 Joints Seals Provide pipe as specified ...

Page 17: ... wall or Category III vent pipe in accordance with the requirements of the pipe manufacturer Support single wall vertical pipe in accordance with accepted industry practices Do not rely on the heater or the adapter box for support of either horizontal or vertical pipes Use non combustible supports on vent pipe 7 Clearance Do not enclose the vent pipe or place pipe closer than 6 152mm to combustibl...

Page 18: ... on direction of airflow join the pipes with either a taper type reducer or enlarger Refer to illustrations in FIGURE 14 for pipe connec tion requirements at the concentric adapter box Do NOT make actual connections until after reading the instructions and length require ments for installing the vent combustion air kit The connection requirements are the same for both vertical and horizontal syste...

Page 19: ...or the horizontal vent terminal are shown below Also select a location that complies with adjoining building clearances as shown in FIGURE 17 page 21 Products of combustion can cause discoloring of some building finishes and deteriora tion of masonry materials Applying a clear silicone sealant that is normally used to pro tect concrete driveways can protect masonry materials If discoloration is an...

Page 20: ... minimum requirements See FIGURE 17 to determine lengths of each segment and calculate the total length required The vent pipe extending through the box and the inlet air pipe must be one piece of double wall vent pipe without joints The transition to the single wall or Category III vent pipe run must be a maximum of 6 152mm from the heater side of the box b Install double wall terminal vent pipe ...

Page 21: ...s attached first be sure the baffle strips are positioned correctly when attaching the vent terminal pipe to the vent run 9 Seal the vent pipe Verify that the double wall section of vent pipe has a slight downward drop 1 4 per foot 6mm per 305mm toward the vent terminal end Use 10 Attach the indoor combustion air pipe If using 6 pipes attach the single wall combustion air pipe run to the collar on...

Page 22: ...r Pipe Run s Use the type of pipe specified Requirement No 2 page 15 and comply with the attachment requirements in Requirement No 3 page 15 Length must comply with Requirement No 4 pages 15 16 Seal all joints Due to the high temperature do not enclose the exhaust pipes or place pipes closer than 6 152 mm to combustible material Provide supports for the pipes Extend the runs to close to the roof a...

Page 23: ...flash the combustion air pipe to the roof Flashing is field supplied 6 Determine the length and install the double wall vent pipe a Determine the length See FIGURE 21 to determine the required length of the vent pipe The vent pipe extending through the box and the inlet air pipe must be one piece of double wall vent pipe without joints FIGURE 21 Assemble Concentric Adapter Box Outdoor Combustion A...

Page 24: ...to the single wall pipe or Category III vent pipe run A taper type reducer is required Seal the circumference of the pipe and the opening of the box with silicone sealant Seal the area around the pipe completely 7 On the outside slide the combustion air inlet over the vent pipe and fasten the collar to the combustion air pipe with sheetmetal screws See FIGURE 23 Seal the opening at the top between...

Page 25: ... bottom of the vent cap The option package includes the 5 vent cap the adapter assembly and the seal plate One package is required for each furnace section The vent pipe and supports are field supplied The straight pipe connecting the furnace to the 90 elbow must be at least 18 457mm in length 6 2 2 Venting Outdoor Power Vented Model RPBL The screened flue gas and combustion air openings are locat...

Page 26: ...es a louver assembly designed to help eliminate moisture from the inlet air Complete installation instructions are packaged with the air hood option FIGURE 27 Dimensions of Outside Air Hood Option AS2 The width of the outside air hood is the same as the width of a blower cabinet NOTE Either a manufacturer designed optional air inlet hood as shown in FIGURE 27 or an evaporative cooling module as sh...

Page 27: ...ood 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 c Tighten t...

Page 28: ...amper Set Screw Outside Air Damper Arm Return Air Damper Arm Rod for Return Air Damper Damper Motor FIGURE 30C Example of Outside Air and Return Air Damper Linkage Inlet Air Damper Linkage When units are equipped with dampers the dampers are closed during shipment When there are both return air and outside air dampers the return damper linkage must be adjusted prior to use 1 Loosen the set screw o...

Page 29: ...essure tap to monitor building pressure To maintain a negative building pressure reverse the functions of the high and low pressure taps In either case be sure that the outdoor vent is protected from the wind and screened from insects 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 p...

Page 30: ... 06 0 08 10000 N A 0 30 0 24 5000 0 08 0 10 0 12 11000 N A 0 36 N A 6000 0 12 0 14 0 17 12000 N A 0 42 N A 7000 0 16 0 20 0 23 13000 N A 0 50 N A 8000 N A 0 25 0 31 1200 3 Size 400 Furnaces and 1 BL Blower 7400 0 08 0 16 0 19 9000 N A 0 31 0 40 8000 0 10 0 21 0 25 10000 N A 0 39 N A 9000 0 13 0 26 0 31 11000 N A 0 46 N A 10000 N A 0 33 0 39 12500 N A 0 60 N A 11000 N A 0 40 0 47 700 2 Size 350 Fur...

Page 31: ...tional Evaporative Cooling Module is factory assembled for field attachment to the blower cabinet duct and base are shipped knocked down for field assembly Evaporative cooling provides excellent comfort cooling at low initial equipment and installation costs and low operating and maintenance costs Direct evaporative cool ing works solely on the principle that water in direct contact with a moving ...

Page 32: ...a Annually scale and dirt should be washed off the entering surface of the media Remove the pad retainers and screen See Steps 1 3 and 6 8 of Media Replacement Instructions Clean the media using a garden hose mild soap and a soft bristled brush When the media becomes too clogged with mineral deposits and dirt that it cannot be cleaned the pads should be replaced The average pad life expectancy is ...

Page 33: ...tep 1 Water Feed Line and Distribution Piping Annually the water supply line and the water distribution line either PVC pipe or water sock should be flushed of debris and contaminants 1 Remove the media pads following the instructions above 2 Remove the water feed line from the downstream side of the ball valve and unscrew the water bleed line barbed hose fitting 3 Force a fresh water supply up th...

Page 34: ...e 7 NOTE If the system is being installed on an indoor Model SSCBL consult the fac tory regarding installation WARNINGS Do NOT attach the cooling coil cabinet before lifting the packaged blower furnace system into position Lift the cooling coil cabinet separately Do NOT attach the cooling coil cabinet while the furnace is in operation Using the parts shipped inside the cooling coil cabinet see lis...

Page 35: ... sure all holes are free of burrs First Hole 1 Remove the control side door on the discharge plenum 2 Locate the discharge damper motor Connected to the motor are three wires in lengths adequate to reach the furnace section Top of Assembled Duct Flange Connectors Bottom of Assembled Duct Flange Connectors Assemble with only one side piece FIGURE 40A 1 Place the cooling coil cabinet on the curb 2 R...

Page 36: ...ocate the mounting screw illustrated Measure up 6 152mm At same centerline as the screw drill the first 7 8 hole Second Hole 1 Remove the cooling coil access panel s 2 Locate the coil blockoff plate Measure up 4 102mm from the bottom of the blockoff plate At that location find the center point of the blockoff plate and drill a 7 8 hole The hole should be approximately even with the hole drilled in...

Page 37: ... both cabinets and the entire row across the cooling coil cabinet b Remove row of screws on the cooling coil cabinet a Remove corner screws on the cooling coil cabinet a Remove corner screws on furnace 6 3 6 Optional Cooling Coil Cabinet Option AU cont d 7 Install the Cabinet Side Filler Panels See FIGURE 40J Place a piece of the supplied insulation against the inner panel of the cooling coil cabi...

Page 38: ...lush etc Ductwork Material Rectangular duct should be constructed of not lighter than No 26 U S gauge galvanized iron or No 24 B S gauge aluminum Ductwork Structure All duct sections 24 610mm inches or wider and over 48 1219mm inches in length should be cross broken on top and bottom and should have standing seams or angle iron braces Joints should be S and drive strip or locked Through Masonry Wa...

Page 39: ...heck Belt Tension Check belt tension Proper 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 exces sive motor and blower bearing 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 44 After correct tension is achieved re tighten the loc...

Page 40: ...pulley grooves and are not angled from pulley to pulley 7 Check motor amps with an amp meter The maximum motor amp rating on the nameplate must not be exceeded 8 When installation is complete check for proper operation Blower Pulley Some blower pulleys require the use of a split taper bushing in the blower pulley These split taper bushings must be loosened in order to remove the pul ley Follow the...

Page 41: ...line wiring but should not be interpreted as the exact motor amps See the motor rating plate for exact motor specifications Do not exceed amp rating on the motor nameplate Venter motor amps for a 115 volt or 575 volt unit are 1 5 amps venter motor amps for a 208 230 or 460 volt unit are 8 amps 7 0 Electrical Supply and Controls 7 1 General All electrical wiring and connections including electrical...

Page 42: ... Maxitrol temperature selector potentiometer a pressure null switch or a combination of these controls Each of these should be installed according to the manufacturer s instructions packaged with the heater Field Control Wiring Length and Gauge Total Wire Length Distance from Unit to Control Minimum Recommended Wire Gauge 150 75 18 gauge 250 125 16 gauge 350 175 14 gauge 7 0 Electrical Supply and ...

Page 43: ...Dampers 26 Optional Two Position or Modulating Damper Motor 27 Optional Outside Air Damper 28 Optional Potentiometer 29 Optional Filters 30 Blower Motor 31 Optional Control Relays as required 8 maximum 32 Auto Reset Reverse Flow Limit 33 Optional Return Air Firestat 34 Low Voltage Terminal Strip 35 Line Voltage Terminal Strip 36 Control Transformer 37 Control Transformer as required 38 Optional Da...

Page 44: ...he heat exchanger to the blower compart ment thus breaking the circuit to the electric gas valve and preventing burner opera tion The optional high ambient limit control functions to shut off the burner when the enter ing outside air reaches a set temperature The temperature setting is field adjustable from 0 100 F For location see FIGURE 46 Item 21 8 7 Combustion Air Proving Switch The combustion...

Page 45: ...tor maintaining constant gas input under wide variations in gas supply pressure See instructions packed with the unit for specific gas valve specifications wiring and operating instructions 8 8 3 Optional Two Stage Operation Makeup Air On systems with more than one furnace section there are two methods of achieving multiple stage makeup air operation In addition for each of these methods there are...

Page 46: ...nd 19 8 0 Controls cont d 8 8 Gas Controls cont d FIGURE 47 Ductstat Control in Option AG3 AG4 and AG5 Factory set as listed in TABLES A and B Adjustable range 0 100 F markings are on the dial 8 8 3 Optional Two Stage Operation Makeup Air cont d The makeup air control options with the complete two stage ductstat Options AG3 AG4 AG5 installed in the heater discharge use a ductstat See FIGURE 47 wit...

Page 47: ...e regulator supplying 3 5 w c pressure to the main operating valve Refer to the wiring diagram supplied with the furnace for proper wiring connections Electronic modulation for heating controlled by a specially designed room thermo stat 60 85 F is identified as Option AG7 Electronic modulation control systems for makeup air applications controlled by a duct sensor and temperature selector 55 90 F ...

Page 48: ... 2 0 95 w c 0 1 75 w c 0 5 8 0 Controls cont d 8 8 Gas Controls cont d 8 8 4 Optional Electronic Modulation cont d Electronic Modulation between 25 and 100 Firing Rate Options AG39 AG40 AG41 AG42 cont d The furnace with this type of electronic modulation will ignite at any input rate in the available range and will maintain average thermal efficiencies equal to or greater than the thermal efficien...

Page 49: ...ers Follow the steps and example to determine appropriate setpoints Follow the instruc tions to locate and set the controllers EXAMPLE 3600 CFM Power vented 100 Outside Air 10 F Outdoor Winter Design 75 F Desired Supply Air TSP2 75 46 x 75 10 75 46 x 85 35 9 TSP3 75 73 x 75 10 75 73 x 85 12 9 Set Stage Heat 2 Controller to 36 F Set Stage Heat 3 Controller to 13 F Calculate the Setpoints with Three...

Page 50: ... that the wiring connections are secure Computer Controlled Electronic Modulation between 25 and 100 Firing Rate Option AG40 and AG42 The furnace functions and is equipped in the same way as for Options AG39 and AG41 except that the temperature settings are selected through field supplied computer soft ware and there is no temperature selector or duct sensor The furnace is equipped with a Maxitrol...

Page 51: ...257472 for a unit with recycling gas control Option AH2 or P N 257473 for Option AH3 gas control with lockout Option codes are listed on the unit wiring diagram CAUTION Due to high voltage on pilot spark wire and pilot electrode do not touch when energized See Hazard Levels page 2 Pilot All pilots are vertical target type with lint free feature Pilot flame should be approximately 1 1 4 in length P...

Page 52: ...ly matches voltage rating of the furnace Refer to the rating plate Check all field wiring against the wiring diagram Be sure that wire gauges are as required for the electrical load Check that fuses or circuit breakers are in place and sized correctly Option AG41 or AG42 set the heat stage controllers See Paragraph 8 7 4 Gas Supply Checks Check piping for leaks and proper gas line pressure Bleed g...

Page 53: ...t will not reduce yellowing check for gas leaks at the control manifold or orifice fitting 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 Raising temperature setting drives burner on or to full fire Using ...

Page 54: ...iring See Paragraph 7 0 for wiring requirements CAUTION When cleaning wearing eye protection is recommended NOTE Use only factory authorized replacement parts Single Stage Valve Two Stage Valve 1 8 INLET Pressure Tap 1 8 Outlet Pressure Tap 1 8 INLET Pressure Tap 1 8 Outlet Pressure Tap FIGURE 57 Connect manometer to inlet pressure tap to check gas flow shutoff 2 With the manual valve turned off t...

Page 55: ... valve before placing the heater in operation NOTE Operational pressure settings and instructions for checking pressure settings are in Paragraph 6 2 In the event the pilot flame is short and or yellow check the pilot orifice for blockage caused by lint or dust accumulation Remove the pilot orifice and clean with air pres sure DO NOT REAM THE ORIFICE Check and clean the aeration slot in the pilot ...

Page 56: ...e heat exchanger remove the burner rack assembly See Paragraph 10 2 2 permitting access to the inside of the heat exchanger tubes Clean the tubes using a 1 2 diameter furnace brush A mirror and flashlight are helpful in examining the narrow section of each tube Remove any accumulated dust and soot 10 2 4 Venter Motor Power venter motors are permanently lubricated No oiling is required 10 2 5 Blowe...

Page 57: ...se wire connections b Check and tighten all wiring connections 3 Ignition control does not power main valve 3 a Loose wire connections a Check and tighten all wiring connections b Flame sensor grounded Pilot lights spark continues b Be certain flame sensor lead is not grounded or insulation or ceramic is not cracked Replace as required c Gas pressure incorrect c Adjust gas pressure See Paragraph 6...

Page 58: ...Form I SSCBL RPBL P N 149159 R8 Page 58 ...

Page 59: ...s 14 Gas Valve 54 H Hazard Labels 2 Horizontal Vent Instructions 19 20 Horizontal Vent Kit 19 Horizontal Vent Kit Option CC6 19 I Ignition Controller 51 Ignition System 51 Inlet Guard 19 Installation Codes 3 Installation Information 3 Installation Instructions for Horizontal Vent Kit 19 Installation Instructions for Vertical Vent Kit 22 Installation of Model SSCBL with Vertical Vent 25 INSTALLATIO...

Page 60: ..._________________________ ________________________________________________________ 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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Reznor RPBL 1050, Installation, Operation And Maintanance Manual

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