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  9. Reznor XE Series User manual

Reznor XE Series User manual

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Form I-XE/CRGB/RPB, Mfg No. 131782 Rev 4, Page 1
®
Installation/Operation/Maintenance
FormI-XE/CRGB/RPB(VersionB)
ObsoletesFormI-XE/RGB/RPB(VersionA)
Model Series XE, CRGB, RPB
Packaged Duct Furnace
Assemblies
Index by Page Number
GENERAL
Installation should be done by a qualified agency in accordance with the instructions in this
manual and in compliance with all codes and requirements of authorities having jurisdiction.
The instructions in this manual apply to the packaged systems listed below.
FORYOURSAFETY
If you smell gas:
1.Openwindows.
2.Don'ttouch electrical switches.
3.Extinguishanyopenflame.
4.Immediatelycall yourgassupplier.
FORYOURSAFETY
Theuseandstorageofgasolineorotherflammablevaporsandliquidsin
opencontainersinthevicinity of this applianceishazardous.
WARNING: Improper installation, adjustment, alteration, service, or
maintenance can cause property damage, injury or death. Read the
installation,operation,andmaintenanceinstructionsthoroughlybefore
installingorservicingthisequipment.
WARNING: 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
applicationswithairbornesiliconesubstances.SeeHazardLevels,Page2.
Table of Contents Para. Page
Installation and Operation ......... 1-29 ... 1-30
Check Installation and Start-Up ... 30 . 30-31
Optional Accessories ................. 31-36 . 31-41
Service/Maintenance .................. 37-41 . 41-44
Adjusting Blower Speed ............................... 24
Optional Air Flow Proving Switch .............. 24
Opt High Ambient Limit Control .................. 25
AquaSaver Timer Adjustment ........................ 34
Belts ...............................................................24
Blocked Vent Switch ...................................... 25
Blower Motors ............................................... 24
Blower Rotation ............................................. 24
Burner Air Adjustment .................................. 30
Burner Rack Removal ..................................... 42
Burners ........................................................... 29
Carryover System ........................................... 29
Check Installation and Start-Up ....................30
Chlorines .......................................................... 7
Cleaning Pilot and Main Burners .................. 42
Cleaning the Heat Exchanger ........................ 42
Clearances ........................................................ 7
Optional Cooling Coil Cabinet ..................... 38
Combustion Air Requirements ........................ 7
Condensate Drain .......................................... 13
Location of Controls ...................................... 17
Cooling Coil Cabinet .................................... 38
Optional Dampers and Controls ....................35
Dimensional Data ............................................ 3
Direct Digital Control System ....................... 29
Discharge Dampers ........................................ 39
Disconnect Switch ......................................... 17
Duct Connections .......................................... 13
Optional Ductstat .......................................... 26
Electrical Supply and Connections ............... 16
Optional Electronic Modulation .................. 26
Opt Evaporative Cooling Module ................ 32
Optional Fan Control .................................... 25
Optional Dirty Filter Switch ......................... 38
Filter Arrangements .......................................38
Optional Filter Rack and Filters .................... 37
Gas Piping and Pressures .............................. 14
Gas Valve ........................................................ 41
General ............................................................. 1
Hazard Intensity Levels ................................... 2
Ignition Controller ......................................... 29
Installation Codes ............................................ 2
Limit Control .................................................24
Manifold Pressure Setting ............................. 15
Optional Mechanical Modulation ................. 26
Mounting Furnaces (Indoor) ........................... 8
Mounting Outdoor Models ............................. 8
Optional Equipment ...................................... 31
100% Outside Air Hood ................................31
Pilot and Ignition Systems ............................ 29
Reverse Flow, Limit Control .......................... 25
Roof Curb Assembly and Installation .............. 9
30% Screened Air Hood Opening ................ 32
Optional 4-foot Stack Extension ................... 12
Start-Up .......................................................... 30
Suspending Furnaces ....................................... 8
Troubleshooting ............................................43
Optional Two-Stage Operation ..................... 25
Uncrating ......................................................... 2
Valve ............................................................... 25
Variable Frequency Drive .............................. 24
Vent Cap Installation .....................................12
Optional Power Venting ................................ 12
Venting ........................................................... 11
Venting Requirements .................................... 11
Optional Vertical Flue Discharge .................. 13
Warranty ........................................................... 2
Wiring Diagrams ............................................18
Characteristics
Installation Vent CFM Thermal
Efficiency
XE Standard
HXE High
CRGB Standard
HCRGB High
RPB Standard
HRPB High
80%
Model Series
Designation
Power
Indoor
Outdoor
Gravity
Form I-XE/CRGB/RPB, Page 2
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, creat-
ing a unified packaged furnace/blower system. The packaged system
models listed on page 1 are design-certified toANSI and CSAStandards
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.All furnaces are
approved for use with either natural gas or propane. The type of fuel for
which the furnace is equipped and the correct firing rate are shown on
the rating plate attached to the unit. Electrical characteristics are shown
on both the motor nameplate and the unit rating plate.
These units must be installed in accordance with local building codes. In
the absence of local codes, in the United States, the unit must be in-
stalled in accordance with the National Fuel Gas Code NFPA54/ANSI
Z223.1 (latest edition). A Canadian installation must be in accordance
with the CSA B149.1 Natural Gas and Propane Installation Code. These
codes are available from CSA Information Services, 1-800-463-6727.
Localauthoritieshavingjurisdictionshould be consulted before installa-
tion is made to verify local codes and installation procedure require-
ments.
Special Installations (Aircraft Hangars/Garages)
Installations in aircraft hangars should be in accordance with NFPANo.
409 (latest edition), Standard forAircraft Hangars; in public garages in
accordance with NFPA No. 88A (latest edition), Standard for Parking
Structures; and for repair garages in accordance with NFPA No. 88B
(latest edition), Standard for Repair Garages. In Canada, installations in
aircraft hangars should be in accordance with the requirements of the
enforcing authorities, and in public garages in accordance with CSA
B149.1 codes.
WARNING: To ensure safety, follow the lighting
instructions located on the outlet box cover plate
in the heater section of the packaged furnace
assembly.
HAZARDINTENSITYLEVELS
usedforWarningsinthisManual
1. DANGER:Failuretocomplywillresultin
severepersonalinjuryordeathand/or
propertydamage.
2. WARNING:Failuretocomplycouldresultin
severepersonalinjuryordeathand/or
propertydamage.
3. CAUTION:Failuretocomplycouldresultin
minorpersonalinjuryand/orpropertydam-
age.
WARRANTY:Warranty is void if......
a. Packaged furnacesareusedinatmospheres containing
flammablevaporsoratmospherescontaining
chlorinatedorhalogenatedhydrocarbonsorany
contaminant(silicone,aluminiumoxide,etc.)that
adherestothe sparkignitionflamesensing probe.
b. Wiringisnotin accordance withthediagramfurnished
withtheheater.
c. Unitisinstalledwithoutproperclearancesto
combustiblematerialsorwithoutproperventilationand
airforcombustion.(See Paragraphs 5and 6.)
d. Furnaceairthroughputisnotadjustedwithintherange
specifiedontheratingplate.
3. Uncrating and Preparation
This furnace was test operated and inspected at the factory prior to
crating and was in operating condition. If the equipment has incurred
any damage in shipment, document the damage with the carrier and
contact your Reznor distributor.
Check the rating plate for the gas specifications and electrical character-
istics of the furnace to be sure that they are compatible with the gas and
electric at the installation site. Read this booklet and become familiar
with the installation requirements of your particular model. If you do
not have knowledge of local requirements, check with the local gas
company or any other local agencies who might have requirements
concerning this installation. Before beginning, make preparations for
necessary supplies, tools, and manpower.
Check to see if there are any field-installed options that need to be
assembled to the furnace prior to installation.
Option Parts - Some gas control options will have parts either shipped
loose with the heater or shipped separately. If your unit is equipped
with any of the following gas control options, be sure these parts are
available at the job site.
Other shipped-separate options could include a roof curb, a cooling coil
cabinet, a screened outside air hood, a gas shutoff valve, a condensate
drain fitting, a thermostat, a different control switch, a power venter, a
remote console, a manual fan switch, a vertical vent terminal, a gas
supply regulator, and/or a disconnect switch. Or, if equipped with an
optionalevaporative cooling module, awater hammer arrestor orfill and
drain or freeze kit could be shipped separately.
Heatin
g
-- Gas O
p
tion AG7
Control O
p
tion Thermostat, P/N 48033
Makeu
p
Air -- O
p
tion AG3, AG6, AG8 or AG13
Gas Control Control Switch, P/N 29054
O
p
tions O
p
tion AG9
Remote Temperature Selector, P/N 48042
(If an o
p
tional Control Switch, P/N 29054
remote console O
p
tion AG15
is ordered, the Remote Temperature Selector, P/N 115848
control switch Stage Adder Module, P/N 115849
is mountedon Control Switch, P/N 29054
the console.) O
p
tion AG16
Remote Temperature Selector, P/N 115848
Stage Adder Module, P/N 115849
Remote Display Module, P/N 115852
Control Switch, P/N 29054
Option AG39
Remote Temperature Selector, P/N 174849
2. Warranty
Refer to limited warranty information on the warranty card in the
"Owner's Envelope".
Form I-XE/CRGB/RPB, Mfg No. 131782 Rev 4, Page 3
4. Dimensions
FIGURE1A-Dimensions(inchesandmm)ofIndoor/GravityVentedSystem
3/4 (19)
JGF
B
WCX
K
A
59 (1499)
4 (102)
2-1/8
(54)
Blower Furna e
Gas
Top View Side View
AIRFLOW
Control Wiring
Entran e
Supply Wiring
Entran e
Furna eBlower
E18
(457)
3/4 (19)
H
K
3-5/8 (92)
8 (203)
3/4
(19)
(4)Mounting So kets
1 IPS free turning
female pipe thread
1-3/4 (44)
JGF
B
WCX
K
A
60 (1524)
4 (102)
2-1/8
(54)
Blower
Furna e
Gas
Top View Side View
AIRFLOW
Control Wiring
Entran e
Supply Wiring
Entran e
Furna eBlower
19-1/2
(495)
18
(457)
3/4 (19)
H
K
3-5/8 (92)
8 (203)
3/4
(19)
(4)Mounting So kets
1 IPS free turning
female pipe thread
C
3-1/4 (83)
D
19-1/2
(495)
3-1/4 (83)
Verti al return air
opening is apped
at the fa tory.
DimensionsofModel (H)XEwith Standard BlowerCabinet (Standard blower cabinethas "fullopen" endandwill not accommo-
date 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.)
DimensionsofModel (H)XE withOptional BlowerCabinet (Optionalblower cabinethas ahorizontal inletthat will accommodate
dampers. The cabinet also has a bottom inlet that is shipped with a cap; the bottom inlet will accommodate dampers.)
Dimension Key:
A x 18" (457mm) = Discharge Opening
B= Hanger Centerline - Furnace Section
C x E = Return Air Opening with Standard Cabinet
C x 19-1/2" (495mm) = Return Air Openings with Optional Cabinet
X= Hanger Centerline - Standard and Optional Blower Cabinet
Dimensions (inches andmm) - Gravity-Vented/Indoor Models XE/HXE
Gas Connection
Natural Propane
inches 12-1/2 13-1/2 17-3/8 9-1/2 27-3/4 18 1/2 1/2 3-3/4 32-1/4 36-1/2 5 Rd 22 16-1/4
mm 318 343 441 241 705 457 13 13 95 819 927 127 Rd 559 413
inches 12-1/2 13-1/2 17-3/8 9-1/2 27-3/4 18 1/2 1/2 3-3/4 32-1/4 36-1/2 6 Rd 22 16-1/4
mm 318 343 441 241 705 457 13 13 95 819 927 152 Rd 559 413
inches 15-1/4 16-1/4 17-3/8 9-1/2 27-3/4 18 1/2 1/2 3-3/4 32-1/4 36-1/2 7 Ov 22 16-1/4
mm 387 413 441 241 705 457 13 13 95 819 927 178 Ov 559 413
inches 20-3/4 21-3/4 23 9-1/2 27-3/4 19-3/8 1/2 1/2 2-3/8 32-1/4 36-1/2 8 Ov 27-1/2 21-3/4
mm 527 552 584 241 705 492 13 13 60 819 927 203 Ov 699 552
inches 26-1/4 27-1/4 28-3/8 12-1/2 30-3/4 18 1/2 1/2 2-1/4 35-1/4 38 8 Rd 33 27-1/4
mm 667 692 721 318 781 457 13 13 57 895 965 203 Rd 838 692
inches 34-1/2 35-1/2 36-5/8 12-1/2 30-3/4 18 1/2 1/2 2-1/4 35-1/4 38 10 Ov 41-1/4 35-1/2
mm 876 902 930 318 781 457 13 13 57 895 965 254 Ov 1048 902
inches 34-1/2 35-1/2 36-5/8 12-1/2 30-3/4 18 3/4 1/2 2-1/4 35-1/4 38 10 Ov 41-1/4 35-1/2
mm 876 902 930 318 781 457 19 13 57 895 965 254 Ov 1048 902
inches 40 41 42-1/8 12-1/2 30-3/4 19-3/8 3/4 1/2 7/8 35-1/4 38 12 Ov 46-3/4 41
mm 1016 1041 1070 318 781 492 19 13 22 895 965 305 Ov 1187 1041
inches 45-1/2 46-1/2 47-5/8 12-1/2 30-3/4 18 3/4 1/2 2-1/4 35-1/4 38 12 Ov 52-1/4 46-1/2
mm 1156 1181 1210 318 781 457 19 13 57 895 965 305 Ov 1327 1181
100
125
ABSize
75
350
400
150,
175
200,
225
250
300
CDEF WXGH J K
Form I-XE/CRGB/RPB, Page 4
4. Dimensions (cont'd)
86-11/16 (2202)
Blower
Cabinet Furna e
Airflow
Field Control
Wiring
Entran e
39-3/16*
(995)
Optional
Downturn
Plenum
Cabinet
A
38-1/8*
*
(968)
Field Wiring
(line voltage)
Gas Curb Cap
C
B
38-5/8 (981)
4-3/32
(104) 19-1/2
(495)
19-1/2
(495)
85-13/16 (2180)
Optional
Return
Air Inlet
Verti al
Dis harge
1-1/32
(26)
4-1/4
(108) 4-1/4
(108)
Left Side View with Verti al Dis har
g
e
Front View with
Opt ional Verti al Dis harge
(Downturn Plenum Option AQ5 or AQ8)
4-3/32
(104)
5 (127)
19-1/2
(495)
4-5/8
(117)
31-11/32
(796)
43-17/32 (1106)
S reened
Outside
Air Hood -
Option AS2
5 (127)
19-1/2
(495) Blower
Cabinet
1-1/32 (26) 61-3/8 (1559)
Control Wiring
Entran e
Furna e
Airflow
8-1/2(215)
11-1/4(286)
18
(457)
3/4(19)
3/4(19)
39-3/16*
(995)
Curb Cap
Gas
Field Wiring
(line voltage)
61-7/8 (1572)
A
38-1/8**
(968)
3/4(19) 3/4(19)
D
B
C
Left Side View with Horizontal Dis harge Front View with
Standard Horizontal Dis harge
NOTES:
*Height from top of
cabinet to top of curb
cap.
**Height from top of
cabinet to bottom of
cabinet side.
*** If system has a cooling
coil cabinet, add length
dimension on page 6 for full
system length.
**** The two-position
discharge dampers in
Option AQ8 fit in the
discharge air opening. The
damper motor fits inside the
downturn plenum cabinet.
For dimensions with
downturn plenum cabinet
with a cooling coil cabinet,
see page 6.
FIGURE1B-
Dimensions,
Outdoor/
Gravity-
VentedModel
SeriesCRGB
Vent Cap Gas Connection
I.D. Height Extension Natural Propane
inches 28-5/8 17-3/8 25-7/8 12-1/2 6 9 None 1/2 1/2
mm 727 441 657 318 152 229 None 13 13
inches 28-5/8 17-3/8 25-7/8 15-1/4 8 11-1/2 None 1/2 1/2
mm 727 441 657 387 203 292 None 13 13
inches 34-1/8 22-7/8 31-3/8 20-3/4 8 11-1/2 None 1/2 1/2
mm 867 581 797 527 203 292 None 13 13
inches 39-5/8 28-3/8 36-7/8 26-1/4 10 15 None 1/2 1/2
mm 1006 721 937 667 254 381 None 13 13
inches 47-7/8 36-5/8 45-1/8 34-1/2 10 15 None 1/2 1/2
mm 1216 930 1146 876 254 381 None 13 13
inches 47-7/8 36-5/8 45-1/8 34-1/2 10 15 None 3/4 1/2
mm 1216 930 1146 876 254 381 None 19 13
inches 53-3/8 42-1/8 50-5/8 40 12 14-1/8 plus 12 3/4 1/2
mm 1362 1070 1286 1016 305 359 plus 305 19 13
inches 58-7/8 47-5/8 56-1/8 45-1/2 12 14-1/8 plus 12 3/4 1/2
mm 1470 1210 1426 1156 305 359 plus 305 19 13
Standard Horizontal Air Inlet 19-1/2 (495) x B
Optional Return Air Opening (bottom) 19-1/2 (495) x B
Standard Horizontal Discharge Air Opening 18 (457) x D
Optional Vertical Discharge Air Opening(Option AQ5 or AQ8 Downturn Plenum****) 19-1/2 (495) x B
**** for downturn plenum with coolingcoil cabinet, see page 6.
75,
100
125
175
225
250
300
350
CRGB,
HCRGB
D
Model
Series
Air O
p
enin
g
Dimensions
Size ABC
400
Form I-XE/CRGB/RPB, Mfg No. 131782 Rev 4, Page 5
86-11/16 (2202)
Blower
Cabinet
Furna e
Airflow
Field Control
Wiring
Entran e
39-3/16*
(995)
Optional
Downturn
Plenum
Cabinet
A
38-1/8**
(968)
Field Wiring
(line voltage)
Gas Curb Cap
C
B
38-5/8 (981)
4-3/32
(104) 19-1/2
(495)
19-1/2
(495) 85-13/16 (2180)
Optional
Return
Air Inlet
Verti al
Dis harge
1-1/32
(26)
4-1/4
(108) 4-1/4
(108)
Left Side View with Verti al Dis harge
Front View with
Opt ional Verti al Dis harge
(Downturn Plenum Option AQ5 or AQ8)
4-3/32
(104)
5 (127)
19-1/2
(495)
4-5/8
(117)
31-11/32
(796)
43-17/32 (1106)
S reened
Outside
Air Hood -
Option AS2
5 (127)
19-1/2
(495)
Blower
Cabinet
1-1/32 (26) 61-3/8 (1559)
Control Wiring
Entran e
Furna e
Airflow
Curb Cap
Gas
Field Wiring
(line voltage)
61-7/8 (1572)
A
38-1/8**
(968)
3/4(19) 3/4(19)
D
B
C
Left Side View with Horizontal Dis harge Front View with
Standard Horizontal Dis harge
3/4(19)
3/4(19)
39-3/16*
(995)
18
(457)
11-1/4(286)
8-1/2(215)
FIGURE1C-
Dimensions,Outdoor/
Power-VentedModel
Series RPB
NOTES:
*Height from top of
cabinet to top of curb
cap.
**Height from top of
cabinet to bottom of
cabinet side.
*** If system has a cooling
coil cabinet, add length
dimension on page 6 for full
system length.
**** The two-position
discharge dampers in
Option AQ8 fit in the
discharge air opening. The
damper motor fits inside
the downturn plenum
cabinet. For dimensions
with downturn plenum
cabinet with a cooling coil
cabinet, see page 6.
Gas Connection
Natural Propane
inches 28-5/8 17-3/8 25-7/8 15-1/4 1/2 1/2
mm 727 441 657 387 13 13
inches 34-1/8 22-7/8 31-3/8 20-3/4 1/2 1/2
mm 867 581 797 527 13 13
inches 39-5/8 28-3/8 36-7/8 26-1/4 1/2 1/2
mm 1006 721 937 667 13 13
inches 47-7/8 36-5/8 45-1/8 34-1/2 1/2 1/2
mm 1216 930 1146 876 13 13
inches 47-7/8 36-5/8 45-1/8 34-1/2 3/4 1/2
mm 1216 930 1146 876 19 13
inches 53-3/8 42-1/8 50-5/8 40 3/4 1/2
mm 1362 1070 1286 1016 19 13
inches 58-7/8 47-5/8 56-1/8 45-1/2 3/4 1/2
mm 1470 1210 1426 1156 19 13
AirOpenings: Dimensions
Standard Horizontal Air Inlet 19-1/2 (495) x B
Optional Return Air Opening (bottom) 19-1/2 (495) x B
Standard Horizontal Discharge Air Opening 18 (457) x D
19-1/2 (495) x B
****for downturn plenum with cooling coil cabinet, see page 6.
CD
Model Size AB
Optional Vertical Discharge Air Opening (with Option AQ5 or AQ8
Downturn Plenum****)
300
350
400
(H)-RPB
125
150, 175
200, 225
250
Form I-XE/CRGB/RPB, Page 6
D
7/8 (22) 7/8 (22)
2 (51)
Side View
DX Coil
Cabinet
Drain Pan
Outlet
(1 FPVC)
Su tion Line
Conne tion
(1-5/8 or 2-1/8)
14-1/2
(368)
6-5/8
(168)
G
F (Inside of Curb Cap)
E (Curb Cap Length)
Liquid Line
Conne tion Kno kouts
(alternate lo ations)
2-3/8
(60)
3-1/2(89)
3-1/4(83)
Bottom View
DX Coil
Cabinet
Coil
Header
Housing
Dimensions(inches ±1/8;mm± 3)
4. Dimensions (cont'd)
NOTE: For the length of a system with a cooling coil cabinet, see the
table on the left. Cooling coil cabinet is shipped separately and attached
in the field. See page 10 for roof curb dimensions.
Furnace Size 75, 100,
125 150,
175 200,
225 250,
300 350 400
inches 28-1/2 34 39-1/2 47-3/4 53-1/4 58-3/4
mm 724 864 1003 1213 1353 1492
inches 15-1/4 20-3/4 26-1/4 34-1/2 40 45-1/2
mm 387 52 667 876 1016 1156
inches 25-7/8 31-3/8 36-7/8 45-1/8 50-5/8 56-1/8
mm 657 797 937 1146 1286 1426
inches 37-1/8 42-5/8 48-1/8 56-3/8 62 67-3/8
mm 943 1083 1222 1432 1575 1711
inches 40 45-5/8 51 59-3/8 64-7/8 70-3/8
mm 1016 1159 1295 1508 1648 1788
inches 64 69-5/8 75 83-3/8 88-7/8 94-3/8
mm 1626 1768 1905 2118 2257 2397
inches 38-1/8 43-5/8 49-1/8 57-3/8 63 68-3/8
mm 968 1108 1248 1457 1600 1737
inches 62-1/8 67-5/8 73-1/8 81-3/8 87 92-3/8
mm 1578 1718 1857 2067 2210 2346
inches 19-1/2 22-1/4 25 29-1/8 31-7/8 34-5/8
mm 495 565 635 740 810 879
inches 17-3/8 22-7/8 28-3/8 45-1/8 50-5/8 56-1/8
mm 441 581 721 1146 1286 1426
A
B
C
D
E
F
G
J
Without
Downturn
With
Downturn
Without
Downturn
With
Downturn
ChilledWaterCoolingCoilCabinetinOptionsAU2,AU11,AU12
Refrigerant
R22(DX)
Coil
Cabinet-
Options
AU3,AU13,
AU14
DownturnPlenumCabinet(factoryattachedto
eithertypeofCoolingCoilCabinet)
Front View
DX Coil
Cabinet with
Horizontal
Dis harge
(Option AU3)
Liquid Line
Conne tions
(7/8 or 1-3/8)
5-1/8 (130)
8 (203)
3/4
(19)
3/4
(19)
A
B
3/4
(19)
18
(457)
44-1/4
(1124)
12-1/2
(318)
16-1/4
(413)
C
11-1/4
(286)
Side View
Chilled
Water Coil
Cabinet
F
(Inside of Curb Cap)
E
(Curb Cap Length)
D
7/8 (22)
Supply
Conne tion
2-1/2 NPT
G
7/8 (22)
Return
Conne tion
2-1/2 NPT
Coil Vent
1/2 NPT
Coil Drain
Conne tion
1/2 NPT
Drain Pan
Conne tion
1 FPVC)
6-5/8
(168)
38-3/8
(975)
15-1/4
(387)
Front View
CW Coil
Cabinet with
Horizontal
Dis harge
(Option AU2)
44-1/4
(1124)
18
(457)
3/4
(19)
11-1/4
(286)
C
A
B
3/4
(19)
Side View
Optional
Downturn
Plenum
Cabinet
4-1/4
(108)
19-1/2 (495)
Dis harge Air
J
(Dis harge Air)
C
Front View
Optional
Downturn
Plenum
Cabinet
Side View
Optional
Downturn
Plenum
Cabinet
4-1/4
(108)
4-1/4
(108)
Discharge Damper Note: Optional two-position discharge dampers
in Option AU12 or AU14 fit in the discharge air opening. The
damper motor fits inside the downturn cabinet. See field wiring
instructions in Paragraph 36.
FIGURE1D-
OptionalCooling
CoilCabinetswith
DXorChilled
WaterCoil, with
orwithout
DownturnPlenum
Cabinet(Applies
toOutdoor
Models)
inches mm inches mm inches mm inches mm
75, 100, 125 29-1/8 740 37-1/8 943 98-1/2 2502 121-5/8 3069
150, 175 34-5/8 879 42-5/8 1083 104 2642 127-1/2 3229
200, 225 40-1/8 1019 48-1/8 1222 109-1/2 2781 132-5/8 3369
250, 300 47-1/8 1197 55-1/8 1400 117-3/4 2991 140-7/8 3578
350 53-3/8 1356 61-3/8 1559 123-3/8 3134 146-1/2 3721
400 58-7/8 1495 66-7/8 1698 128-3/4 3270 151-7/8 3858
Model
Series
CRGB and
RPB Size
w/Cooling
Coil Cabinet
w/Downturn
w/Chilled
Water Coil
Cabinet
Width of Cabinets (not
curb )Length of All System
Cabinets (not curb )
w/DX Coil
Cabinet
w/Cooling
Coil Cabinet
only
Form I-XE/CRGB/RPB, Mfg No. 131782 Rev 4, Page 7
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.
6. Combustion Air Requirements
6A. Indoor, Gravity-Vented Models XE/HXE
These furnaces are designed to take combustion air from the space in
which the furnace is installed. The air that enters into the combustion
process is vented to the outdoors. Sufficient air must enter the equip-
ment location to replace the air exhausted through the vent system.
Modern construction methods involve the greater use of insulation,
improved vapor barriers and weather-stripping, with the result that
buildings generally are much tighter structurally than they have been in
the past. The combustion air supply for gas-fired equipment can be
affected by these construction conditions because infiltration that would
have existed in the past may not be adequate. Extensive use of exhaust
fans aggravates the situation. In the past the filtration of outside air
assumedin heat loss calculations (oneair change per hour)was assumed
to be sufficient. However, current construction methods may now re-
quire the introduction of outside air through wall openings or ducts.
Requirementsfor combustionair andventilation airdepend uponwhether
the unit is located in a confined or unconfined space. An "unconfined
space" is defined as a space whose volume is not less than 50 cubic feet
per 1000 BTUH of the installed appliance. Under all conditions, enough
air must be provided to ensure there will not be a negative pressure
condition within the equipment room or space. A positive seal must be
madein all return-airconnections and ducts.Even a slightleak can create
a negative pressure condition in a confined space and affect combustion.
WARNING:Thesegravity-vented,indoorfurnaces
aredesignedtotakecombustionairfromthespace
inwhichthefurnaceisinstalledandarenotdesigned
for connection to outside combustion air intake
ducts. Use of outside air ducts voids the warranty
andcouldcause hazardous operation.See Hazard
Levels, page 2.
Indoor, Gravity-Vented Furnace Located in a
Confined Space
Do not install a unit in a confined space without providing wall open-
ings leading to and from the space. Provide openings near the floor and
ceiling for ventilation and air for combustion as shown in FIGURE 2,
depending on the combustion air source as noted in Items 1, 2 and 3.
Add total BTUH of all appliances in the confined space and divide by
figures below for square inch free area size of each (top and bottom)
opening.
1.Air from inside the building - openings 1 square inch free area per
1000 BTUH. Never less than 100 square inches free area for each open-
ing.See (1) inFIGURE 2.
2.Airfromoutsidethroughduct- openings 1 square inch free area per
2000 BTUH. See (2) in FIGURE 2.
3.Air direct from outside - openings 1 square inch free area per 4000
BTUH. See (3) in FIGURE2.
NOTE: For further details on supplying combustion air to confined
space, see National Fuel Gas CodeANSI Z223.1a (latest edition) 5.3.3.
6B. CombustionAir for Gravity-Vented,
Outdoor Model Series CRGB
Combustion air enters through the screened air intakes located in the
furnace section access doors.
6C. Combustion Air for Power-Vented,
Outdoor Model
Series RPB
The combustion air and flue gas
openings are carefully designed
screened openings located on the
side of the unit just above the con-
trol access panel. Location of the
flue opening directly above the air
intakeis designed todiscourage re-
circulation of combustion prod-
ucts.See FIGURE3.
6D. Chlorine -All Models
The presence of chlorine vapors in the combustion air of gas-fired heat-
ing equipment presents a potential corrosion hazard. Chlorine will,
when exposed to flame, precipitate from the compound, usually freon
or degreaser vapors, and go into solution with any condensation that is
present in the heat exchanger or associated parts. The result is hydro-
chloricacid which readily attacks allmetals including 300grade stainless
steel.
Care should be taken to separate these vapors from the combustion
process. This may be done by wise location of the furnace with regard
toexhausters orprevailing wind direction. Remember, chlorineis heavier
than air. This fact should be kept in mind when determining installation
locations of heating equipment and building exhaust systems.
7. Suspending/Mounting
7A. Suspending/Mounting Indoor, Gravity-
Vented Models XE/HXE
Location - Before suspending the furnace, check the supporting struc-
ture to verify that it has sufficient load-carrying capacity to support the
weight of the unit.
Approximate Net Weight - Indoor Furnaces
Size 75-100 125 150-175 200-225 250-300 350 400
lbs 233 295 332 386 494 515 576
kg 106 134 151 175 224 234 261
WARNING:Avoidinstallingaunitinanextremely
draftyarea.Extreme drafts can shortenthelifeof
theheat exchanger and/orcausesafety problems.
FIGURE2-
ConfinedSpace:A
spacewhosevolume
is less than 50
cubicfeet per1000
BTUHofthe
installedappliance
inputrating
Confined
Spa e
(1)
(1)
(2)
(2)
(3)
(3)
Flue Produ ts
Outlet
Combustion
Air Inlet
FIGURE3-CombustionAir
Intake,Power-Vented
Models
REQUIRED CLEARANCES
Sides Bottom
Model Series Top Control Opposite To
Combustibles To Non-
Combustibles
(H)XE 6"
(152mm) 6"
(152mm) 3" (76mm) 0
(H)RPB,
(H)CRGB 36"
(915mm) 6"
(152mm) 0 * 0
(H)CRGB 30' (9M)radius fromcenterofvent cap to obstructions
such as walls,parapets orcupolas
Width of
furnace
plus 6"
(152mm)
* When installed on a roof curb on a combustible roof, the roof area enclosed
within the curb must be either ventilated, left open, or covered with non-
combustible material which has an "R" value at least 5.0. See FIGURE8, page 10.
Form I-XE/CRGB/RPB, Page 8
Curb Cap Base
Outdoor systems are equipped with a load bearing curb cap which
forms an integral part of the unit. This curb cap has welded joints and
has a "skirt" which fits over a roof curb to provide a weatherproof
installation. Four holes are provided at the curb cap corners for lifting
the unit. These holes do not interfere with unit weatherproofing. The
curb cap is not designed to be placed directly on the roof surface.
The system may be mounted on an optional roof curb purchased with
the unit, a field-supplied roof curb, or field-supplied supports. If the
system has a downturn plenum and/or a bottom return air opening, a
roof curb is recommended to provide a weatherproof installation as well
as more workable clearances for ductwork. If the unit has an optional
cooling coil cabinet, the cabinet is shipped separately and attached in
the field. The cooling coil cabinet has a curb cap base that "matches and
extends" the length of the system base.
Mounting on Field-Supplied Supports (without a roof curb) - Prior
to installation, be sure that the method of support is in agreement with
all local building codes and is suited to the climate. If considering this
typeof installation insnow areas, it is recommended that the 4x4wooden
rails underneath the system be on cross-support structure at least 12"
higher than the roof surface (see support locations in FIGURE 6B).
Whether the supports are being mounted directly on the roof or being
placed "up" on additional structure, the horizontal length of the system
should be supported by two 4x4 treated wooden rails. Cut the rails to
the appropriate length (Dimension "A") in FIGURE 6A. (NOTE: Al-
though dimensions are included for units with a downturn plenum cabi-
net, it is strongly recommended that a full roof curb be used on an
installation with a downturn plenum cabinet and/or a bottom return air
duct.)
Space the 4x4 wooden rails (See "B" Dimension, FIGURE 6A) so that
the curb cap "skirt" will fit over the edge of the boards with the rails
setting inside the horizontal length of the curb cap.
If the rails are being laid directly on the roof, position them as shown in
FIGURE6A. Set the system on the rails, leaving the "ends" underneath
open for ventilation.
WARNING: Unit must be level for proper
operation.Donotplace oraddadditionalweightto
a suspended unit. See Hazard Levels, page 2.
Suspending Furnaces
These indoor, packaged furnace/blower systems have four-point sus-
pension. See hanger dimensions in Paragraph 4, FIGURE 1A.At each
suspension point, the unit is factory-equipped with a free-turning, fe-
male, 1" (NPT) pipe hanger. Suspend by connecting the pipe hanger to
a 1" threaded pipe. See the suspension method on the left in FIGURE4.
As an alternative method, the factory-installed pipe hanger may be
removed and the heater suspended as illustrated on the right in FIG-
URE4.
Standard Assembly
Installer Repla ed Assembly
1 Pipe Flange Washer Nut Assembly
1 Pipe
Threaded
So ket
Washer Nut
Assembly
3/8 Rod
(Standard
Assembly
Removed)
A ess through
the side panel
Heater Top
FIGURE5-SupportLocationsforIndoorSystems
7B. Mounting Outdoor Model Series CRGB
and RPB
Rigging-Lifting holes are providedfor rigging. Use spreaderbars when
lifting to prevent chains or cables from damaging the unit. If the unit is
being mounted on a roof curb, apply caulking to the roof curb prior to
liftingthe unit to theroof and settingit on the curb.See FIGURE8,page
10.
If the system includes an outside air hood and/or a shipped-separate
cooling coil cabinet, attach them after the unit is in place.
If the system includes a cooling coil cabinet, the cooling coil cabinet
must be lifted to the roof separately, set on the roof curb or supports,
and attached to the furnace.
WARNING: Do not support an indoor/gravity-
vented system with four corner support legs. The
systemrequireshorizontalsupport atcabinetjoint
as illustrated in FIGURE 5. Bottom clearance to
combustiblesmustbe observed.
7A. Suspending/Mounting Indoor, Gravity-
Vented Models XE/HXE (cont'd)
Location - When selecting a location for an outdoor installation, posi-
tion the unit so that the air inlet will not be facing into the prevailing
wind.
When the unit is mounted on a roof over 20 ft (6 M) high, has parapet
walls or obstructions within 30 ft (9.1M), or is subject to winds over 25
mph, installation of a power-vented unit (Model Series RPB) is recom-
mended.
Blower Se tion
Furna e
Se tion
Airflow
Support the unit at ea h end and where the blower abinet and
furna e se tion join. Support at abinet joint must extend
horizontally supporting both se tions.
FIGURE4-SuspensionMethods
Mounting Indoor Furnaces
Indoor packaged systems require six support locations. See FIGURE5.
All supports must be non-combustible.
Size 75,100 125 150,175 200,225 250,300 350 400
CRGB lbs 439 472 510 529 573 624 655
Series kg 199 214 231 240 260 283 297
RPB lbs -- 482 520 534 588 630 662
Series kg -- 219 236 242 267 286 300
Approximate NetWeight (lbs/kg)-Optional Cooling Coil Cabinet
Size 150,175 200,225 250,300 350 400
DX lbs 464 551 661 753 848
kg 269 250 300 342 385
DX with lbs 593 689 813 914 1018
Downturn kg 269 313 369 415 462
Chilled lbs 457 544 654 746 841
Water kg 207 247 297 338 381
lbs 586 682 806 907 1011
kg 266 309 366 411 459
Approximate Net Weight (lbs/kg) - Outdoor Systems
(blower andfurnace sections only)
75,100, 125
377
167
490
222
(includes approximate weight of a coil with 12fpi)
171
497
225
369
Chilled
Water with
Downturn
Form I-XE/CRGB/RPB, Mfg No. 131782 Rev 4, Page 9
FIGURE6A-MountingSupportDimensions(inches/mm)
A
B
4x4 Treated Lumber
Leave both
ends open
for ventilation.
Blower
Cabinet
Furna e
Se tion
Field
Supplied
Du t
4x4 Treated
Lumber = Cross Support Lo ations
Field
Supplied
Du t
FIGURE6B-Cross-SupportLocations
The field-supplied, weather-resistant cross-support structure must be
adequate for the weight of the system (including air conditioning coil if
applicable), and all cross-supports should run the entire width of the
system supporting the 4x4 wooden rails at the recommended locations.
If the treated wooden rails are not being placed directly on the roof
surface, cross-supports should be placed underneath the rails at the
ends of the unit and at all cabinet "joints" (between the blower cabinet
and the furnace section; between the furnace and the optional downturn
plenum or coil cabinet; and between a coil cabinet and a downturn
plenum).See FIGURE6B.
Mounting on a Roof Curb - Whether using an optional roof curb
available with the system or a field-supplied curb, the curb must be
secure, square and level. The top surface of the roof curb must be
caulked with 1/4" x 1-1/4" sealant tape or two 1/4" beads of suitable
sealant. The unit must be sealed to the curb to prevent water leakage
into the curb area due to wind blown rain and capillary action. Except
for the curb assembly details which are specific to the optional roof
curb available with the system, the information and requirements in
this section apply to all curbs. See FIGURE 8, page 10, and the curb
installation instructions below.
FIGURE7-Duct Opening DimensionsinRelationtoRoof
CurbOption-inches(mm)
1-5/8
(41)
1-5/8
(41)
1-5/8 (41)
1-5/8 (41)
1-5/8 (41)
1-5/8 (41)
19-1/2
(495)
19-1/2
(495)
HH
G
Return
Duct
Supply
Duct
Roof Curb
1-5/8
(41)
1-5/8
(41)
•1-5/8" (41mm) is the measurement from duct opening to
inside edge of roof curb.
• Duct openings should be 1" larger than the duct size for
installation clearance.
RoofCurbAssemblyandInstallationInstructions(Referto
FIGURE8,page10)
Curbs are shipped unassembled. Field assembly and mounting on the
roof are the responsibility of the installer.All required hardware neces-
sary to complete the assembly is supplied.
Before installing roof curb, verify that the size is correct for the
system being installed.
1. Position curb cross rails and curb side rails as illustrated in
FIGURE 8, page 10. If there are two side pieces to a side, fasten
them with splice plates and hardware as illustrated in the splicing
detail drawing. Join the corners as illustrated in the corner detail.
2. Check the assembly for squareness. Adjust the roof curb so that
the diagonal measurements are equal within a tolerance of + or -
1/8" (3mm).
3. Level the roof curb. To ensure a good weather tight 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 required
and secure curb to roof deck before proceeding with flashing.
4. Install field-supplied flashing.
5. Before placing the unit into position, apply furnished 1/4" x
1-1/4" foam sealant tape to top surface of curb, making good butt
joint at corners. The unit must be sealed to the curb to prevent
water leakage into the curb area due to blown rain and capillary
action.
Model G
Series HWith Downturn w/Cooling Coil Cabinet
CRGB and Plenum, Option w/Downturn, Options
RPB Sizes AQ5 or AQ8 AU 11, 12, 13, or 14
75, 100, 17-3/8" 38-5/8" 75-31/32"
125 441mm 981mm 1930mm
150, 175 22-7/8 38-5/8 81-15/32
581mm 981mm 2069mm
200, 225 28-3/8 38-5/8 86-31/32
721mm 981mm 2209mm
250, 300 36-5/8 38-5/8 95-1/4
930mm 981mm 2419mm
350 42-1/8 38-5/8 100-3/4
1070mm 981mm 2559mm
400 47-5/8 38-5/8 106-1/4
1210mm 981mm 2699mm
Bottom Duct Connections - The blower section and optional down-
turn plenum have duct flanges for connection to return air and supply
air ducts. Duct opening sizes and curb spacing shown in FIGURE 7 is
for currently manufactured curbs that are available from the system
manufacturer.
Standard
Heater
and
Blower
Package
With Factory-
Installed
Downturn
Plenum
Cabinet
(Option AQ)
With
Shipped-
Separate
Cooling
Coil
Cabinet
(Option AU)
With Shipped-
Separate
Cooling Coil
Cabinet with
Downturn
Plenum
(Option AU)
All
Configurations
"A" "A" "A" "A" "B"
75, 100,
125 60-5/8" 84-9/16" 98-3/8" 122-1/4" 24-5/16"
150, 175 60-5/8" 84-9/16" 103-7/8" 127-7/8" 29-13/16"
200, 225 60-5/8" 84-9/16" 109-3/8" 133-3/8" 35-5/16"
250, 300 60-5/8" 84-9/16" 117-5/8" 141-5/8" 43-9/16"
350 60-5/8" 84-9/16" 123-1/8" 147-1/8" 49-1/16"
400 60-5/8" 84-9/16" 128-5/8" 152-5/8" 54-1/2"
75, 100,
125 1540mm 2148mm 2499mm 3105mm 618mm
150, 175 1540mm 2148mm 2638mm 3248mm 757mm
200, 225 1540mm 2148mm 2778mm 3388mm 897mm
250, 300 1540mm 2148mm 2988mm 3597mm 1106mm
350 1540mm 2148mm 3127mm 3737mm 1246mm
400 1540mm 2148mm 3267mm 3877mm 1384mm
Model Series CRGB
and RPB Sizes
Form I-XE/CRGB/RPB, Page 10
*Optional
Downturn Plenum
Furna e
Blower
Cabinet
Curb
Cap
1-7/8
(48mm)
Roof
Curb
16 (406mm)
1-7/8
(48mm)
AC
D
Return
Du t
Supply
Du t
1-7/8(48mm)
1-1/2
(38mm)
Lift Holes
(4 orners)
B
** Cand Dare 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 system. The
shipped-separate cooling coil cabinet with or without a downturn must be lifted to the roof separately
from the packaged system, set on the roof curb, and attached to the furnace section (see instructions
beginningon page 38).
16
(406mm)
1-7/8(48mm)
4
(102mm)
2 x 6 Wood Nailer
1-1/2 x 3 lb
Fiberglass
Flashed b the
installer (flashing must
be under lip of curb)
Lag Screw
Cap
Screws
For top 4 holes (2 on
each side) at both joints,
from inside the curb insert
(4) 5/16 1 lag screws
and (4) 5/16 lockwashers.
For bottom 4 holes (2 on each side) at both
joints, from outside of the curb insert (4)
5/16-18 3/4 long cap screws. Attach with
5/16 lockwashers and 5/16-18 he nuts.
(Inside
of Curb)
7B. Mounting Outdoor Models on a Roof Curb (cont'd)
Curb Cap
Counter Flashing
(b installer)
Cant Strip
(b installer)
MUST be sealed
between curb cap
and roof curb
2 x 6
Wood
Nailer
Insulation
16
(406 mm)
Curb Height
Cabinet
Curb Cap Skirt
Weld, bolt, or lag screw curb to deck structure.
Roof Curb
Roofing Felts
(b others)
IMPORTANT: Top surface of curb MUST be sealed. See instructions above.
* Illustration is shown with an Option AQ5 or AQ8 downturn plenum. The system can have a
variety of configurations which affect installation.
• If the system does not have a downturn plenum, the discharge is horizontal.
• Downturn plenum Options AQ5 and AQ8 are factory installed to be lifted to the roof
and set on the roof curb as part of the packaged system.
• If the system has an Option AU2 or AU3 cooling coil cabinet, the discharge is horizontal. If
the system has an AU11, AU12, AU13, AU14 cooling coil cabinet, there is a downturn
plenum with vertical discharge. Options AU2, AU3, AU11, AU12, AU13, and AU14 are
not factory installed. Options AU2, AU3, AU11, AU12, AU13, and AU14 must be
lifted to the roof separately from the packaged system, set on the roof curb, and
attached to the furnace.
FIGURE8-
OptionalRoofCurb Splicing
Detail
Corner Detail
Curb Section
Typical
Curb
Detail
IMPORTANT: Area enclosed
by the roof curb must comply with
clearance to combustible materials.
If roof is constructed of combustible
materials, area within curb must be either ventilated, left open, or covered
with non-combustible material which has an "R" value of at least 5.0. If
area within curb is left open, higher radiated sound levels may result.
RoofCurbDimensions(inches)
Size 75, 100,
125 150, 175 200, 225 250, 300 350 400 Size 75, 100,
125 150, 175 200, 225 250, 300 350 400
A60-5/8 60-5/8 60-5/8 60-5/8 60-5/8 60-5/8 A98-3/8 103-7/8 109-3/8 117-21/32 123-5/32 128-21/32
B24-5/16 29-13/16 35-5/16 43-9/16 49-1/16 54-1/2 B24-5/16 29-13/16 35-5/16 43-9/16 49-1/16 54-1/2
C** 56-15/16 56-15/16 56-15/16 56-15/16 56-15/16 56-15/16 C** 94-5/8 100-1/8 105-5/8 113-29/32 119-13/32 124-29/32
D** 20-9/16 26-1/16 31-9/16 39-13/16 45-5/16 50-13/16 D** 20-9/16 26-1/16 31-9/16 39-13/16 45-5/16 50-13/16
A84-9/16 84-9/16 84-9/16 84-9/16 84-9/16 84-9/16 A122-3/8 127-7/8 133-3/8 141-21/32 147-5/32 152-21/32
B24-5/16 29-13/16 35-5/16 43-9/16 49-1/16 54-1/2 B24-5/16 29-13/16 35-5/16 43-9/16 49-1/16 54-1/2
C** 80-13/16 80-13/16 80-13/16 80-13/16 80-13/16 80-13/16 C** 118-5/8 124-1/8 129-5/8 137-29/32 143-13/32 148-29/32
D** 20-9/16 26-1/16 31-9/16 39-13/16 45-5/16 50-13/16 D** 20-9/16 26-1/16 31-9/16 39-13/16 45-5/16 50-13/16
Option CJ4 - Roof Curb for (H)CRGB and (H)RPB with Field-
Installed*** Cooling Coil Cabinet Option AU2 or AU3
Option CJ5 - Roof Curb for (H)CRGB and (H)RPB with
F
ield-
Installed*** Cooling Cabinet and Downturn Plenum Option AU11,
AU12, AU13, or AU14
Option CJ2 - Roof Curbfor (H)CRGB and (H)RPB with Factory-
Installed Downturn Plenum Option AQ5 or AQ8
Option CJ1 - Roof Curbfor (H)CRGB and(H)RPB