Form I-RDF (Version A.3) Obsoletes I-RDF (Version A.2) T Applies to: N P M TY UA E RO LITY SYST RA DU CT WA R Q C U S TO M E R CQS STA RT-UP AG C Installation S PROC CY E EN VERGE S N ON Indoor or Outdoor, Gas, DirectFired Makeup Air/Heating Systems Reznor® Model RDF Series 3 Model RDF with Outside Air Hood ! WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
TABLE OF CONTENTS 1.0 General...............................................2 6.0 Mechanical.........................................9 1.1 Hazard Labels and Notices........... 2 1.2 General Description ..................... 3 1.3 Warranty........................................ 3 1.4 Installation Codes/Requirements . 3 2.0 Location..............................................4 7.0 Electrical Supply and Wiring..........17 3.0 Uncrating/ Preparation......................4 8.0 Controls..................
1.2 General Description The information in this manual applies to Reznor® Model RDF Series 3 direct-fired makeup air heating systems. The typical system consists of a direct-fired, natural gasfueled burner, and a draw-through blower housed in a weatherized cabinet. The system may be installed either indoors or outdoors. This direct-fired makeup air system provides tempered makeup air.
1.0 General (cont'd) 1.4 Installation Codes/Requirements (cont'd) 2.0 Location Location must comply with clearances in Paragraph 4.1. Makeup air should enter at the highest point practical. By doing this, the fresh air will entrain dust laden air at the ceiling and move it toward the point of exhaust. Also, fresh air directed downward from the roof or ceiling will mix with hot ceiling air resulting in improved distribution of heat in the building.
4.2 Dimensions FIGURE 1 - Dimensions (inches and mm) * RDF-2 and RDF-3 systems have double hinged doors as illustrated. Control compartment on RDF-1 has a single hinged door. ** Configuration is for RDF-2 and RDF-3. The supply connection on the RDF-1 systems is above the control wiring connection.
5.0 Mounting (cont'd) 5.1 Weights NOTE: Net weights are approximate for the standard system. Optional equipment is not included. Net Weight of Basic Model RDF System Sizes 1-20 1-40 1-50 1-65 2-80 2-120 3-180 3-260 lbs 915 925 935 950 1455 1505 2410 2480 kg 415 420 424 431 670 683 1093 1125 5.2 Rigging All units are mounted on a full curb cap base furnished with four lifting lugs for attaching rigging. To prevent damage to the cabinet, use spreader bars with the rigging chains.
FIGURE 4 - Dimensions of Optional Roof Curb (Option CJ3) - Shipped Separately NOTE: Drawing is not proportional for all sizes. IMPORTANT NOTE: Area enclosed by roof curb must comply with clearance to combustible materials. If the roof is constructed of combustible materials, area within the roof curb must be ventilated, left open, or covered with non-combustible material which has an "R" value of at least 5.
5.0 Mounting (cont'd) 5.4 Mounting on a Roof Curb (cont'd) Roof Curb Installation Instructions (cont'd) FIGURE 6 - Divider Locations for Bottom Ductwork Openings NOTES: • Drawing is not proportional for all sizes. • 3/4" (19mm) measurement is the width of the flanges where the roof curb mates with the heater. Flange surface must be sealed. • When cutting duct openings in the roof, cut opening(s) 1” (25mm) larger than duct size opening for installation clearance.
6.0 Mechanical FIGURE 7 - Gas Supply Connection 6.1 Gas Piping and Pressures All piping must be in accordance with the requirements of the National Fuel Gas Code ANSI/Z223.1 (latest edition) or CSA B149.1 and B149.2. Gas supply piping installation must conform with good practice and with all local codes. Read this section of the installation manual to determine the minimum gas supply pressure required to provide a maximum gas capacity.
6.0 Mechanical (cont'd) Manifold Option with Gas Control Option Manifold Size MBH 250 500 750 1000 1250 1500 1750 2000 2500 3000 6.1 Gas Piping and Pressures (cont'd) Supply Pressure Requirement by Manifold Option (cont'd) Minimum Supply Gas Pressure ("w.c.) for Full Fire BM75 AG1 Nat 4.0 5.3 7.5 1" Pro 1.4 1.9 2.7 BM76 BM77 BM78 BM79 BM80 AG 30, 31, 32, 33, 36, 37, 47, 48, or 51 AG3 Nat 4.0 5.0 6.8 1" Pro N/A N/A N/A Nat 4.1 5.8 8.5 12.4 1" Pro 1.6 2.3 3.3 4.7 Nat 4.3 6.2 9.5 1" Pro 1.5 2.
6.2 Unit Inlet Air 6.2.
6.0 Mechanical (cont'd) 6.2 Unit Inlet Air (cont'd) 6.2.1 Outside Air Hood or Indoor Filter Cabinet (cont'd) Outside Air Hood or Filter Cabinet Assembly and Installation Instructions for ITEM 2 in the Table on page 11 - Refer to FIGURES 11A-11N.
Step 1 B - Sub-assemble Top and Bottom Filter Channels and Filter Blockoff Plates (AS6 & AS7) Parts Required - Top and bottom filter channel; top and bottom filter blockoff plates; and 14 screws (1/2" long) Assemble the top blockoff plate and the top filter channel being sure the filter channel groove is on the same side as the 90° bend in the blockoff plate but directed away from it. Use seven screws to attach the top blockoff plate to the top filter channel.
6.0 Mechanical (cont'd) 6.2.1 Outside Air Hood or Indoor Filter Cabinet (cont'd) Assembly and Installation Instructions for ITEM 2 in the Table on page 11 (cont'd) 6.2 Unit Inlet Air (cont'd) 3. Attach Assembled Cabinet Section Step 3 - Attach Filter Cabinet to System On the air inlet opening side of the system cabinet, remove the sheetmetal screws from the bottom rear inset and the screws across the top edge. Align the edges of the inlet hood cabinet section with the grooves in the system cabinet.
Step 5. - Install Filters, Block Off Sections and Door Panels On hoods with filters, position filters and blockoffs on filter racks. If the systems has an optional dirty filter switch, follow the instructions on page 19 to connect the sensing tubes. Slide the "door" panels into position on each side of the cabinet section. Fasten each panel with two 1/2" long screws. 6.2.2 Evaporative Cooling Module If installing an evaporative cooling module, it is shipped separately.
6.0 Mechanical (cont'd) FIGURE 12 - Belt Tension FIGURE 13 - Split Taper Bushing 3 Cap Screws 2 Push-Off Holes 6.4 Blowers, Drives, and Motors 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 excessive motor and blower bearing wear.
7.0 Electrical Supply and Wiring All electrical wiring and connections including electrical grounding must be in accordance with the National Electric Code ANSI/NFPA No. 70 (latest edition) or the Canadian Electrical Code Part 1-C.S.A. Standard C22.1. Check any local ordinances or utility company requirements that apply. Run a separate line voltage supply directly from the building electrical panel to the disconnect switch for the system.
7.0 Electrical Supply and Wiring (cont'd) Control Wiring (cont'd) there is a brief description of the optional electrical controls used for airflow. Refer to the operation manual, Form O-ADF/RDF, for additional control information. FIGURE 14 - Location of Gas Connection, Electrical Supply Connection, and Control Wiring Connections on RDF Series 3 Direct-Fired Systems Disconnect Switch Location NOTES: * RDF-2 and RDF-3 Series 3 systems have double hinged doors as illustrated.
attach the negative pressure tube so that it will sense the pressure at the blower side of the filter rack. (NOTE: Tubing shipped is the same length for all sizes of systems; cut to the appropriate length for the smaller systems.) 4) If required, cut the tubing to the proper lengths. Using the clamps provided, attach the ends of the tubing to the filter rack at about center height being careful not to kink or compress the tubing.
8.
IMPORTANT: To eliminate shipping damage to the switch contacts, the manufacturer reduced the span adjustment to zero before shipping. The span should be adjusted prior to using the switch. (If the switch has been installed, disconnect the vent tube so that the null switch is in a neutral position.
(NOTE: Locations may not be identical, but controls should be similar.).
Startup Diagnostic Lights 1. Prepare system for startup testing -Attach a slope gauge (0 to 1.0" scale) to the tubing connections in the control compartment. The two connections are located just left of the electrical box. Remove the caps on the 1/8" NPT test connections and attach the slope gauge. (The recommended method for attaching the slope gauge is to use field-supplied 1/8" female NPT x 1/4" OD barbed hose connections.) Connect a "U"-tube manometer to the main burner pressure tap.
9.0 Check-Test Start (cont'd) Startup (cont'd) 2. Measure burner differential air pressure (cont'd) Turn on the disconnect switch and re-check the slope gauge. If air pressure differential is within the limits of -.25" to -.75" w.c., no further adjustment is required. If the air pressure differential is not within those limits, re-adjust the blower speed. When the differential air pressure is within the limits, check the motor amp draw with an ammeter to be sure that the motor is not overloaded.
5. Verification of inlet gas pressure -- If, with the blower and burner operating, the inlet main gas pressure measured in Step 3 does not correspond to the minimum stated on the rating plate, check the main burner inlet gas pressure. If the main inlet gas pressure is lower than stated on the rating plate, full burner firing rate will not be achieved. Check main gas supply service regulator for adjustment. Turn disconnect switch OFF. Re-connect the "U"-tube manometer to the main burner pressure tap.
APPENDIX Model Sizes Maximum Capacity (MBH) CFM Range Maximum Temperature Rise Maximum Discharge Temperature Typical Control Amps (24V) Net Weight (lbs) Gas Connection (inches) REFERENCES I-RDF, PN148384R5, Page 26 Technical Data 1-20-3 400 1, 000 3,000 120°F 1-40-3 600 2,000 4,500 120°F 1-50-3 750 3,000 6,000 120°F 1-65-3 750 4,000 6,500 120°F 2-80-3 1500 6,000 12,000 120°F 2-120-3 1500 9,000 16,000 120°F 3-180-3 2500 11,000 20,000 120°F 3-260-3 3000 16,000 28,000 120°F 120°F 120°F 120°F 120°
INDEX A Air Controls 4 B Blower Pulley 16 Blowers 16 Blower Speed Adjustment 16 Burner differential air pressure 23 C Check-Test Start 22 Clearances 4 Installation Codes/Requirements 3 Computer Control 21 Contact 28 Control Wiring 17 Convenience Outlet 17 Roof Curb 7 D Description 3 Dimensions 5 Disconnect Switch 17 Door Switch 20 Drives 16 Duct Opening Dimensions 8 Ductwork 15 Ductwork Openings 8 E Electrical Supply 17 Evaporative Cooling Module 15 F Dirty Filter Light 18 Indoor Filter Cabinet
INSTALLATION RECORD - to be completed by the installer: Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ ________________________________________________________ Phone _________________________________ Distributor (company from which the unit was purchased): Company _______________