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RP-HRPD-IOM (07-22) 132210-B

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) .

Conversion to LP (Propane)

⚠ DANGER ⚠

Conversion to LP (propane) gas must be performed by qualified service personnel using a factory-

supplied conversion kit. Failure to use the proper conversion kit can cause fire, explosion, property 

damage, carbon monoxide poisoning, personal injury, or death.

If LP (propane) conversion is required, convert the unit in accordance with form 

OPT-GC

 listed in 

Table 1

 . When 

conversion is complete, verify that the input rate is correct .

Burner Air Shutter Adjustment

⚠ DANGER ⚠

Failure to adjust air shutters according to directions could cause property damage, personal injury, 

and/or death.

NOTES:

 

• A limited amount of yellow-tipping is permissible for liquefied petroleum gases. Natural gas 

should not display any yellow-tipping.

 

• When making the adjustment, close the air shutters no more than is necessary to eliminate the 

problem condition.

 

Air shutters are required on propane gas units but are optional on natural gas units . A slotted burner air adjustment 

screw on the end manifold bracket moves the air shutters and adjusts all burners simultaneously . Turn the adjustment 

screw clockwise to open the air shutter or counterclockwise to close the air shutter .

 

After the furnace has been in operation for 15 minutes, close the air shutter until the flame turns yellow . Open the 

shutter until yellow disappears .

Adjust Heat Stage Controllers (Model HRPD Units with Option AG41 or AG42)

Model HRPD units with option AG41 and AG42 have heat stage controllers that control operation of the two-stage 

furnace based on outside air temperature setpoints . Proper setpoints are important to ensure that the modulating 

furnace (

Heat Stage 1

) is always in control and avoids cycling . The proper setpoint for each controller must be 

determined from basic design information as follows:
1 .  Calculate controller settings for 

Heat Stage 2

 and 

Heat Stage 3

 in a system with two furnace sections using the 

following formulas in which 

T

SP

 = setpoints of heat stage controllers (T

SP2

 and T

SP3

)

T

SA

 = desired supply air 

temperature

, and 

T

D

 = design (minimum) entering air temperature

:

Setpoint for heat stage 2: T

SP2

 = T

SA

 − 0.46 (T

SA

 − T

D

)

Setpoint for heat stage 3: T

SP3

 = T

SA

 − 0.73 (T

SA

 − T

D

)

NOTE:  EXAMPLE: With 3,600 CFM, power-vented, 100% outside air, −10°F outdoor winter design, and 

75°F desired supply air, T

SP2

 = 75

 

− [0.46 × (75

 

− (−10))] = 75 − (0.46 × 85) = 35.9 and T

SP3

 = 75

 

− [0.73 

× (75

 

− (−10))] = 75 − (0.73 × 85) = 12.9. Set Heat #2 controller to 36°F and Heat #3 controller to 13°F.

2 .  Locate heat stage controllers marked 

Heat #2

 and 

Heat #3

 in inlet air section .

NOTE:  The same type of controller may also be used as the optional high ambient limit control 

(option BN2) and as the mixed air controller that is part of air control options AR12, AR13, AR15, 

and AR16.

3 .  Adjust each controller to setpoint as determined by calculation in step 1 .

Содержание HRPD

Страница 1: ...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...

Страница 2: ...Piping Connections 19 Electrical Connections 21 Control Wiring 21 CONTROLS 22 Thermostat 22 Fan Control 22 Limit Control 22 Combination Gas Valve 22 Combustion Air Proving Switch 23 Optional Two Stag...

Страница 3: ...g rate and electrical requirements are shown on the unit s rating plate Model HRPD is dual model RP furnaces configured for higher CFM capacity References TABLE OF CONTENTS CONTINUED OPERATION 29 Pre...

Страница 4: ...thoroughly before installing or servicing this equipment WARNING For your safety read the warning labels on the unit CAUTION These duct furnaces are not certified or approved for use in drying or proc...

Страница 5: ...spark ignition flame sensing probe b Wiring is not in accordance with the diagram furnished with the heater c Unit is installed without proper clearance to combustible materials or without proper ven...

Страница 6: ...Figure 1 Unit Size 125 150 175 200 225 250 300 350 400 Inches 1 8 mm 3 A 30 15 16 786 36 7 16 914 41 15 16 1065 50 3 16 1275 55 11 16 1414 61 3 16 1554 B 28 1 2 648 34 864 39 1 2 1003 47 3 4 1213 53 1...

Страница 7: ...provided Table 4 Weights Model RP Unit Size 125 150 175 200 225 250 300 350 400 HRPD Unit Size 250 300 350 400 500 600 700 800 Pounds kg RP 201 91 217 98 247 112 295 134 333 151 361 164 HRPD 402 182 4...

Страница 8: ...s Check to see if there are any field installed options that need to be connected to the furnace prior to installation Shipped separate options could include a gas shutoff valve a vertical vent termin...

Страница 9: ...cy performing this work assumes responsibility for the conversion of this appliance to provide for higher CFM Theseinstructionsaredesignedtopreparetheductfurnaceforincreasedairthroughputconversion pri...

Страница 10: ...ffle b Remove both side finger baffles Figure 4 Side Finger Baffle Removal 3 Install field conversion label see Figure 5 a Fill in field conversion label PN 263310 from literature bag b Adhere label t...

Страница 11: ...ket assembly on opposite end of heat exchanger and secure using field supplied sheet metal screws 4 Reinstall airflow baffles removed in step 1 and secure using existing screws Figure 6 Airflow Baffle...

Страница 12: ...1 inch is recommended of insulation Supports suspend all ducts securely from buildings members Do not support ducts from unit duct connections Access panels Install removable access panels see Figure...

Страница 13: ...ischarge sensor is field supplied Follow the instructions below to install the sensor in the ductwork 1 Determine distance of sensor from unit a Ensure that there is sufficient distance from outlet to...

Страница 14: ...nse air temperature as it flows through holes in holder 3 At selected ductwork location mark diamond shaped hole approximately 1 1 inch 25 25 mm required for sensor holder or round hole required for m...

Страница 15: ...40 3070 0 28 2630 0 23 2300 0 22 2045 0 21 300 4420 0 58 3685 0 39 3160 0 29 2765 0 25 2455 0 22 350 5160 0 65 4300 0 44 3685 0 31 3225 0 25 2865 0 23 400 5895 0 70 4915 0 50 4210 0 30 3685 0 30 3275...

Страница 16: ...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 11 may be constructed Locate the byp...

Страница 17: ...110 3290 9 229 1700 2100 2400 2700 2970 3200 3400 3600 3800 10 254 1920 2350 2760 3090 3650 4020 4300 4550 4800 See Figure 11 NOTE Not all capacities are covered above If your installation is not cove...

Страница 18: ...ater Gas Supply Piping DANGER All components of a gas supply system must be leak tested prior to placing equipment in service NEVER TEST FOR LEAKS WITH AN OPEN FLAME Failure to comply could result in...

Страница 19: ...ne Gas Natural Gas Propane Gas Cubic Feet per Hour 20 92 56 190 116 350 214 730 445 1100 671 2100 1281 30 73 45 152 93 285 174 590 360 890 543 1650 1007 40 63 38 130 79 245 149 500 305 760 464 1450 88...

Страница 20: ...ued Figure 13 Gas Connections Table 13 Gas Connection Sizes Gas Type RP Unit Size 125 250 300 400 HRPD Unit Size 250 500 600 800 Connection Size Inches mm Natural gas 1 2 13 3 4 19 Propane 1 2 13 NOTE...

Страница 21: ...y with fused disconnect switch should be run directly from the main electrical panel to the unit making connections in the junction box Disconnect switch A disconnect switch is a required part of this...

Страница 22: ...t Use either an optional thermostat available with the system or a field supplied thermostat Install according to the thermostat manufacturer s instructions Fan Control NOTE To replace the fan control...

Страница 23: ...odels HRPD Models Units Without Option AG39 AG40 AG41 or AG42 All 0 58 0 05 IN WC 1 05 IN WC 0 73 IN WC Units with Option AG39 AG40 AG41 or AG42 125 225 250 400 0 58 0 05 IN WC 1 30 0 20 IN WC 1 05 0...

Страница 24: ...es 64 F low stage furnace 2 68 F shutdown furnace 2 70 F low stage furnace 1 74 F shutdown furnace 1 AG4 HRPD 2 70 F 66 F full rate both furnaces 70 F shutdown furnace 1 74 F shutdown furnace 2 AG15 R...

Страница 25: ...n the heater rating plate AG7 is identified as MV 1 AG8 is identified as MV 3 AG9 is identified as MV 4 AG21 is identified as MV A AG39 is identified as MP 1 and AG40 is identified as MP 2 AG39 and AG...

Страница 26: ...ual to or greater than the thermal efficiency at full fire The gas train see Figure 16 includes a single stage gas valve a modulating valve and two gas pressure switches The burner rack is equipped wi...

Страница 27: ...gear motor Replace primary manifold pressure switch YES NO YES NO YES NO YES NO YES NO NO YES YES NO Measure manifold pressure during burner cycling When the manifold pressure is BELOW 1 0 w c is the...

Страница 28: ...is available only with model HRPD natural gas units and is not available on unit size 700 Depending on its size a furnace equipped with option AG40 or AG42 has a 20 28 turndown ratio With option AG40...

Страница 29: ...trolled flame stability without lifting or flashback with either natural or propane gas All burners are lightweight and are factory mounted in an assembly that permits all of the burners to be removed...

Страница 30: ...The result is incomplete combustion which produces carbon monoxide a poisonous gas that can cause death Safe operation of indirect fired gas burning equipment requires a properly operating vent syste...

Страница 31: ...when the heater is in operation and when it is on standby Incorrect inlet pressure could cause excessive manifold gas pressure immediately or at some future time NOTE A manometer fluid filled gauge i...

Страница 32: ...turn using wrench DANGER DO NOT use an open flame to check for gas leaks Table 20 High Elevation Burner Orifices Installation Elevation Feet Meters Installation Location RP Unit Size Natural Gas Propa...

Страница 33: ...rclockwise to close the air shutter After the furnace has been in operation for 15 minutes close the air shutter until the flame turns yellow Open the shutter until yellow disappears Adjust Heat Stage...

Страница 34: ...ion and clean as necessary Clean all dirt and grease from primary and secondary combustion air openings Power vent Check flue products outlet and clean as necessary Gravity vent Check vent cap or opti...

Страница 35: ...connect electric valve leads e Uncouple union in gas supply f Remove sheet metal screws in top corners of burner rack assembly g Pull drawer type burner rack out of furnace 2 Disassemble burner rack N...

Страница 36: ...l sensing probe and the pilot hood with an emery cloth and wipe off the ceramic insulator 4 Check the spark gap see Figure 20 which should be maintained to 7 64 inch Figure 20 Pilot Assembly Spark Gap...

Страница 37: ...a If voltage between black and brown leads on main gas valve is 20 32 VAC and there is no main gas flow with built in manual valve in FULL OPEN position main valve is defective b If there is no voltag...

Страница 38: ...ner Rack Maintenance section b Remove heat exchanger V baffles see Figure 22 1 Remove ends of flue gas collection box 2 On control side of furnace remove venter assembly and flue outlet duct to gain a...

Страница 39: ...l lockout device interrupting control circuit due to above causes Reset lockout by interrupting control at thermostat 9 Faulty combustion air proving switch Replace combustion air proving switch C Pil...

Страница 40: ...__________ Address ________________________________________________________ ________________________________________________________ Phone ________________________________________________________ Mode...

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