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Reznor RPB User Manual

Reznor RPB
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Revision: RPB-IOM (06-22) 131782-B
MODEL RPB
OUTDOOR PACKAGED DUCT FURNACE AND BLOWER
INSTALLATION, OPERATION, AND MAINTENANCE
Supersedes: I-RPB (04-21) 131782-A
 ⚠ DANGER ⚠ 
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in serious injury, death, or property
damage.
Improper installation, adjustment, alteration, service, or maintenance can cause serious injury,
death, or property damage.
Installation and service must be performed by a qualified installer, service 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 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.
DO NOT DESTROY. PLEASE READ CAREFULLY. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

Table of Contents

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Questions and Answers:

Reznor RPB Specifications

General IconGeneral
Efficiency80% AFUE
Ignition TypeDirect Spark Ignition
Heat Exchanger MaterialAluminized Steel
Fuel TypeNatural Gas or Propane
Thermostat CompatibilityStandard 24 VAC thermostat
DimensionsVaries by model
WeightVaries by model

Summary

General Information

References

Lists related technical manuals and their part numbers.

Important Safety Information

Details DANGER, WARNING, CAUTION, and NOTE statements for safe operation.

Warranty

Outlines conditions that void the unit's warranty.

Installation Codes

Specifies compliance with local, national, and Canadian building and gas codes.

Dimensions

Provides key measurement data for unit installation and clearances.

Weights

Lists unit weights to ensure supporting structure capacity.

Clearances

Specifies minimum distances required from the unit to combustible surfaces.

Location

Provides guidance on selecting a safe and appropriate installation site for the unit.

Hazards of Chlorine

Warns about corrosion risks from chlorine vapors in combustion air.

Combustion Air Requirements

Describes the importance of proper airflow for safe and efficient operation.

Curb Cap Base

Details the function and installation of the unit's integrated curb cap.

Installation

Uncrating/Unpacking

Instructions for safely removing the unit from its packaging and checking for damage.

Shipped-Separate Parts

Lists optional components that may be shipped loose with the unit.

Mounting Support Structure

Guidance on selecting and installing secure support structures for the unit.

Bottom Duct Connections

Details on connecting supply and return air ducts to the unit's base.

Optional Curb (Option CJ1 or CJ2) Assembly

Instructions for assembling and installing optional roof curbs.

Field-Supplied Support Structure

Guidelines for creating custom support structures using field-provided materials.

Mounting

Procedures for safely lifting and positioning the unit onto its support structure.

Duct Connections

Requirements and suggestions for connecting supply and return air ducts to the unit.

100% Outside Air Hood (Option AS2)

Installation details for the screened hood for 100% outside air intake.

Screened Air Hood for 30% Outside Air Opening

Information on installing the screened hood for 30% outside air.

Evaporative Cooling Module (Option AS3, AS4, AS5, or AS8)

Notes on factory-installed cooling modules and field connections.

Discharge Air Temperature Sensor Installation

Steps for correctly installing sensors to monitor discharge air temperature.

Venting Connections

Guidelines for connecting the flue and combustion air vents for safe operation.

Piping Connections

Covers requirements for connecting gas, water, and electrical lines to the unit.

Electrical Connections

Control Wiring

Details on wiring optional controls and system components for proper function.

Controls

Thermostat

Requirements for selecting and installing a thermostat for unit operation.

Remote Console

Information on available remote consoles and their functions.

Combustion Air Proving Switch

Explains the function of the switch ensuring proper venting flow.

Blower Fan Control

Details on how the blower fan is controlled, including time delays.

Limit Control

Describes the high limit switch that shuts off gas on motor failure or low airflow.

Reverse Flow Limit Control

Explains the automatic-reset control that prevents operation during reverse airflow.

High Ambient Limit Control

Details the optional control that shuts off the burner in high ambient temperatures.

Airflow Proving Switch (Makeup Air with Option BW1)

Function of the switch ensuring adequate airflow before firing.

Variable Frequency Drive

Information on programming and operating the VFD for motor speed control.

Combination Gas Valve

Description of the primary safety shutoff valve and its components.

Optional Two-Stage Control (Heating Only Application)

Explains the two-stage gas valve and thermostat control.

Optional Two-Stage Control (Makeup Air Application)

Details on two-stage makeup air units controlled by a ductstat.

Optional Ductstat with Capillary Tubing (Option AG3)

Information on the unit-mounted ductstat and its adjustment.

Optional Ductstat with Electronic Remote Setpoint Module (Option AG15)

Instructions for field-wiring remote temperature selectors.

Optional Electronic Modulation

Overview of electronic modulation options and their identification.

Computer-Controlled Electronic Modulation Between 50% and 100% Firing Rate (Option AG21)

Details on using a signal conditioner with computer control.

Electronic Modulation Between 20–28% and 100% Firing Rate (Option AG39)

Information on AG39 modulation system and gas train.

Electronic Modulation Between 20–28% and 100% Firing Rate (Option AG40)

Details on AG40 modulation system and signal conditioner.

Dampers and Damper Controls

Information on damper operation and linkage adjustment.

Pressure Null Switch

Explains the switch used for controlling outside air dampers and building pressure.

Dirty Filter Switch

Description of the switch that indicates when filters need cleaning or replacement.

Pilot and Ignition Systems

Pilot

Details on the horizontal pilot location, gas pressure, and flame length adjustment.

Intermittent Spark Ignition Safety Pilot Systems

Explains the two types of intermittent spark pilots and lockout features.

Ignition Controller

Describes the function of the ignition controller in providing spark and safety.

Burners and Carryover System

Information on burner construction, removal, and maintenance.

Operation

Pre-Startup Checklist

Essential checks before initial unit operation to ensure safety and proper function.

Startup

Step-by-step instructions for safely starting the furnace.

Post-Startup Checklist

Checks to perform after initial startup for proper operation.

Adjustments

Belts, Blowers, and Drives

Covers checking and adjusting belt tension and motor alignment.

Adjusting Blower Speed

Procedures for adjusting blower speed to achieve desired outlet temperature.

Reversing Blower Rotation

Instructions on how to change the direction of blower motor rotation.

Blower Motor Load and Amp Adjustment

Guidance on checking and adjusting motor amps and load.

Pressure Null Switch Adjustment

Steps for adjusting the pressure null switch for damper control.

Measure and Adjust Manifold (Outlet) Gas Pressure

Procedures for measuring and setting gas pressure at the manifold.

High Elevation (>2,000 Feet/609 Meters) Installations

Specific considerations for installing units at high altitudes.

Conversion to LP (Propane)

Instructions for converting the unit from natural gas to propane.

Dirty Filter Switch Adjustment

Steps for setting the dirty filter switch to indicate filter status.

Burner Air Shutter Adjustment

Procedures for adjusting air shutters for optimal combustion.

Damper Linkage Adjustment

Instructions for adjusting the linkage for return and outside air dampers.

Maintenance

Service Checklist

Annual maintenance tasks to ensure long life and performance.

Maintenance Procedures

General procedures for maintaining the unit's components.

Combination Gas Valve Maintenance

Steps for checking the gas valve's shutoff capability.

Burner Rack Maintenance

Procedures for removing, cleaning, and reassembling the burner rack.

Cleaning Pilot and Burners

Instructions for cleaning pilot assemblies and main burners.

Spark Ignition System Maintenance

Checks and troubleshooting for the spark ignition system.

Heat Exchanger Cleaning

Procedures for cleaning both the circulating air and combustion gas sides of the heat exchanger.

Troubleshooting

General Troubleshooting

A comprehensive guide to diagnosing and resolving common unit issues.

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