Installation and Service Manual “IHR/ISHR/HR/R
Contents
1. 11 Wlan D U 12 13 IH ISH RHFA IH ISH RMUA IH ISH H RHFB IH ISH H RMUB IH ISH H RHVA IH ISH H RHVB 160 250 400 600 200 320 500 800 1000 1600 210 300 250 420 600 1200 80 80 83 90 90 103 1 2 110 1 2 110 1 2 113 1 2 120 1 2 120 1 2 131 131 30 5 8 41 3 8 52 1 8 65 1 2 131 131 15 1 2 15 1 2 13 3 4 13 3 4 13 3 4 13 3 4 15 1 2 15 1 2 113 3 8 113 1 8 19 1 2 30 1 4 41 47 3 8 113 3 8 113 3 8 85 5 8 85 5 8 98 7 8 105 7 8 105 7 8 108 7 8 116 1 4 116 1 4 114 1 2 114 1 2 17 7 8 28 5 8 39 3 8 52 3 4 114 1 2 114 1 2 118 5 8 118 5 8 21 7 8 32 5 8 43 3 8 56 3 8 118 5 8 118 5 8 19 3 8 19 7 8 14 1 4 16 19 3 8 19 7 8 19 3 8 19 7 8 11 3 4 11 3 4 6 1 2 6 1 2 10 11 3 4 11 3 4 NOTES 1 Duct dimensions are approximate Certified prints furnished on request SHIPPING INFORMATION Truck Base unit factory assembled except for gravity vent caps and remote mounted controls Optional roof curb evaporative cooling air washer section or RHFA RMUA RHVA 500 600 800 and RHFB RMUB RHVB 1000 1200 1600 Intake hood with birdscreen shipped in separate crate Downstream duct furnaces on all 1000 1200 1600 models shipped in separate crate HR R OUTDOOR SYSTEMS Dimensions H RHF and H RHV Models with Intake and Discharge Plenums FRESH AIR INTAKE W2. IH ISH H RHFA RMUA RHVA 100 100 000 100 000 76 000 80 000 IH ISH H RHFA RMUA RHVA 125 125 000 125 000 95 000 100 000 IH ISH H RHFA RMUA RHVA 160 160 000 160 000 121 600 128 000 IH ISH H RHFA RMUA RHVA 210 210 000 210 000 159 600 168 000 IH ISH H RHFA RMUA RHVA 250 250 000 250 000 190 000 200 000 IH ISH H RHFA RMUA RHVA 300 300 000 300 000 228 000 240 000 IH ISH H RHFA RMUA RHVA 400 400 000 400 000 304 000 320 000 IH ISH H RHFA RMUA RHVA 600 300 000 600 000 456 000 480 000 IH ISH H RHFA RMUA RHVA 800 400 000 800 000 608 000 640 000 IH ISH H RHFB RMUB RHVB 200 100 000 200 000 152 000 160 000 IH ISH H RHFB RMUB RHVB 250 125 000 250 000 190 000 200 000 IH ISH H RHFB RMUB RHVB 320 160 000 320 000 243 200 296 000 IH ISH H RHFB RMUB RHVB 420 210 000 420 000 319 200 336 000 IH ISH H RHFB RMUB RHVB 500 250 000 500 000 380 000 400 000 IH ISH H RHFB RMUB RHVB 600 300 000 600 000 456 000 480 000 IH ISH H RHFB RMUB RHVB 800 400 000 800 000 608 000 640 000 IH ISH H RHFB RMUB RHVB 1000 250 000
3. 2 4 Yrs 1 1 2 Yrs 1 1 2 Yrs 1 2 Yrs 1 Yr 6 Mos 4 Mos 4 Mos 3 Mos TYPE OF SERVICE Infrequent operation or light duty in clean atmosphere 8 16 Hrs Day in clean relatively dry atmosphere 12 24 Hrs Day heavy duty or if moisture is present Heavy duty in dirty tions high ambients moisture laden atmosphere vibration dusty loca Recommended Greases Use the following greases or equivalent grease unless a special grease is specified on the nameplate MANUFACTURER CHEVRON SHELL TRADE NAME SR 2 DOLIUM R Maas EH nance EE 3606 Yost Avenue Hastings Nebraska 6891 1966 Phone 402 463 9821 Fax 402 462 8006 www hastingshvac com E mail sales hastingshvac com ISHRDV 1 Ces April 2008 M EEE Installation and Service Manual IHRDV ISHRDV HRDV SERIES INDOOR OUTDOOR GAS DUCT FURNACE Notice Read These Instructions Before Installation Inspect unit on arrival for any shipping damage This furnace has been test fired for at least 15 minutes to prove out all phases of operation If any part is missing or damaged notify the carrier at once A paf CERTIFIED WARNING Improper installation adjustment alteration service or maintenance can cause property damage injury or death Read the installation operating and maintenance instructions thoroughly before installing or servicing this equipment 4
4. combustion air inlet A property line A direction facing combustible materials or openings of surrounding buildings A venting system shall not terminate within 1m of the following Above a gas meter regulator assembly within 1m horizontally of the vertical centerline of the regulator An oil tank or an oil tankfill inlet The inside corner of an L shaped structure A venting system shall not terminate within 3m of the following Above grade level or any surface that may support snow ice or debris See pages 13 AND 14 for recommended flue vent arrangements I S HRDV HORIZONTAL FLUE SIZING Unit Type Flue Pipe Diameter Maximum Length of Flue Pipe I S HRDV 100 4 0 IN 82 0 FT I S HRDV 125 4 0 IN 82 0 FT I S HRDV 160 4 0 IN 82 0 FT I S HRDV 210 6 0 IN 72 0 FT I S HRDV 250 6 0 IN 72 0 FT I S HRDV 300 6 0 IN 72 0 FT I S HRDV 400 6 0 IN 72 0 FT Table 1 5 Gas Supply NOTE PIPING MUST CONFORM TO STANDARDS OF THE NATIONAL BOARD OF FIRE UNDER WRITERS CAN CGA B149 AND ALL APPLICABLE GOVERNING CODES INSTALL MANUAL MAIN SHUT OFF VALVE UPSTREAM OF APPLIANCE GAS TRAIN OUTSIDE OF THE CONFINES OF THE APPLIANCE IN ACCORDANCE WITH CURRENT INSTALLATON CODES Pipe sizing for the direct line from a N G meter or L P tank is based on a minimum 7 W C pressure at the meter for natural gas minimum 12 W C for L P gas Pipe sizes are suggested by the following table Noo
5. 1 000 000 760 000 800 000 IH ISH H RHFB RMUB RHVB 1200 300 000 1 200 000 912 000 960 000 IH ISH H RHFB RMUB RHVB 1600 400 000 1 600 000 1 216 000 1 280 000 AIL IH ISH and H series units are 80 efficient TL SET THIS CONTROL TO 110 DEGREES THERE IS NO OTHER SETTING ADJUSTMENT This control is to protect the modusnap valve bulb from exceeding 120 degrees DC SET THIS CONTROL TO 2 TO 3 DEGREES ABOVE MODUSNAP VALVE SETTING Honeywell Modusnap Valve Model Size 400 Temperature Settings of Controls Modusnap Valve TL and DC MODUSNAP VALVE SET THIS CONTROL 2 TO 3 DEGREES ABOVE ROOM THERMOSTAT SET POINT This is to allow for temperature loss through duct work and room loss Dial 1 2 Degrees 60 65 75 80 MODUSNAP VALVE SETTINGS 7 8 90 95 9 100 ROOM THERMOSTAT SET AT ANY TEMPERATURE OCCUPANT WANTS JUST SO LONG AS THE MODUSNAP VALVE IS SET PROPERLY OPERATION When the unit is in the winter mode the fan is on bringing outside air into the building The furnace is on and the modusnap valve is set at 73 degrees room set a 70 degrees example the modusnap valve is modulating at this point maintaining the discharge of 73 degrees When the room thermostat calls for more heat the bypass valve opens and full rate of gas is supplied to burner for full heat until the room thermostat is satisfied NOTE In the event the discharge
6. 4 Faulty flame rod igniter lead ground wire connections or inoperative ignition module 5 Inoperative main gas valve Main Burners Shutdown Before Call for Heat Is Satisfied 1 Faulty limit switch 2 Interrupted gas supply to unit or faulty main gas valve 3 Faulty system ground flame sensing circuit or wiring connections 4 System goes into safety lockout 10096 lockout models ONLY 5 Faulty ignition module Call for Heat Ends But Main Burners Continue Operation 1 Faulty thermostat controller or short circuit in re spective wiring CORRECTIVE MEASURES Adjust pilot to surround end of flame rod about 3 8 Flame must be soft and quiet If a problem develops in the flame sensing circuit pilot flame may NOT be detected to conduct a flame sensing current even though high voltage ignition spark is satis factory If the flame rod is faulty and cleaning does not correct the igniter burner assembly must be replaced Inspect and correct as necessary igniter lead and ground wire connections If ignition continues to spark replace module Replace limit switch See item 5 of Pilot Fails to Light in this section See item 1 of Pilot Fails to Light in this section See item 2 of Pilot Lights But Ignition Spark Continues in this section To test ignition module check low voltage across MV and MV PV terminals If no or inadequate voltage is detected replace module If voltage
7. Adjust setting See modulating or two stage gas controls item 10 of INSTALLATION PRECAUTIONS Consult manufacturer for proper spud size before changing or gas company before adjusting regulator Be sure gas supply pipe size to unit is adequate Check for slipping belts and proper blower speed plugged filters if used dirty blower impeller blades or any airflow obstructions and excessive system static pressure Correct as necessary Clean tubes See CLEANING on page 10 Replace main valve or operator Inspect and replace as necessary NATURE OF TROUBLE CORRECTIVE MEASURES 3 Blower motor cutting out on overload Check for high or low voltage Check for faulty motor or motor overload 4 Inadequate air delivery from blower See item 2 of Insufficient Heat Delivery in this section 5 Poor air flow patterns through furnace See ILLUSTRATIONS on page 15 Resonance on L P Gas Units 1 Reduce gas input slightly If condition persists consult manufacturer Modulating or Two Stage Gas Controls 1 Consult manufacturer G CLEANING NOTE SOOT DIRT ETC WILL PREVENT PROPER COMBUSTION FOR NORMAL AIR CONDTIONS CLEAN UNIT PRIOR TO HEATING SEASON WITH A PERIODIC INSPECTION AT LEAST ONCE A MONTH THROUGHOUT THE DURATION OF THE SEASON AND CLEAN AS NECESSARY IN HEAVILY CONTAMINATED AREAS INSPECTION AND POSSIBLE CLEANING MAY BE REQUIRED MORE FREQUENT LY DURING THE HEATING SEASON CLEAN FLUE TUBES BURNERS AND PI
8. Immediately call gas supplier WARNING FOR YOUR SAFETY FOR YOUR SAFETY i If you smell gas The use and storage of gasoline or other 1 Open windows flammable vapors and liquids open 2 Don ttouch electrical switches containers in the vicinity of this appliance is 3 Extinguish any open flame hazardous Table of Contents AX sio c Ec Page 2 Installation Precatlofis ders feud ue ue pret ee ee a des Wasa dede dece Pages 2 and 3 G ater CI RN Pages 3 to 6 e Regulations e Location e Venting e Gas Supply e Electrical D Electronic 6121 pem 7 E e si x M E ete eedem de eL I al Pages 7 F Trouble Shoolrigisss ces ge Sv e pod ee dier ieee ha Bad See hands desta Pages 8 to 11 CECI narro eee Page 11 and 12 H Flue Vent Arrangement Pages 13 and 14 l asus k eee a ea AGS Page 15 amp 16 Wi Fa etory SerNICe u a E Page 16 A PURPOSE The Hastings 1 IS HRDV series is a complete line of duct furnaces suitable for both INDOOR or OUTDOOR APPLICATIONS The 1 IS HRDV models100 400 are design certified by A G A and C G A and approved for installation either upstream or downstream from cooling coils used in air conditioning systems and for applications where make up air is specified The purpose of this manual is to present a guid
9. trouble must be isolated and corrected A 10096 shutoff design may be used for natural and L P gas It provides a 90 second gas trial for pilot ignition If pilot does not light within the trial time module deactivates pilot valve 10096 safety lockout but continues spark for pilot ignition This system may be reset at the thermostat or controller and trial for ignition resumed If pilot still fails to ignite trouble must be isolated and corrected E OPERATION WARNING USE CAUTION ON FOLLOWING PROCEDURES 1 Purge all air from gas piping 2 Carefully follow lighting instructions shown on the SPECIFICATION PLATE for electric ignition and main burner operation 3 Adjust pilot burner to a quiet blue flame Flame must surround the end of the flame rod for proper operation of the flame sensing circuit No combustion air adjustment is required on main burners 4 Pressure regulator setting must NOT be changed except under qualified supervision If necessary contact gas company before adjusting 5 With the unit firing a maximum input the gas line pressure should be maintained at designated inches of W C marked under MINIMUM SUPPLY PRESSURE on the specification plate On multiple unit installations each furnace should be checked in sequence Then with all units firing at maximum rate the line pressure should be at least the minimum marked on the specification plate 6 After the line pressure has been established MANIFOLD PRESSUR
10. 0 FT I S HRDV 160 4 0 IN 82 0 FT I S HRDV 210 6 0 IN 72 0 FT I S HRDV 250 6 0 IN 72 0 FT I S HRDV 300 6 0 IN 72 0 FT I S HRDV 400 6 0 IN 72 0 FT Table Il Gas Supply Piping Suggested pipe sizing for direct line from meter or propane tank is found in Table Ill These sizes are based on 6 to 7 w c pressure at the meter for natural gas 11 w c for propane gas with 3 w c pressure drop schedule 40 pipe and fittings TABLE III Input in 1000 s Maximum Distance x BTU Hr from Meter Propane 50 feet 3 y TORO TES 100 feet 1 60 feet 1 159346 175 100 feet 1 1 30 feet 1 UL 200 to 250 120 feet 1 250 feet 1 75 feet 1 200 200 feet 1X 50 feet 1 3691949 100 feet 1 35 feet 1 BOR 80 feet 1 300 feet 2 2 600 50 feet 1X 200 feet 2 2 30 feet 1X vd 125 feet 2 2 80 feet 2 2 1990 200 feet 2 2 50 feet 2 2 150 feet 25 25 30 feet 2 2 1600 80 feet 25 2 250 feet 3 3 The BTU input and output of these systems are listed in Table IV See page 10 On units receiving inlet gas pressure in excess of 14 w c a high gas pressure regulator must be provided for each heater section TABLE IV Unit BTU Hr Input per Heater Total BTU Hr Input Total BTU Hr Output
11. above a paved sidewalk or a paved driveway that is located between two buildings and that serves both buildings The exit terminals of mechanical draft systems shall not be less than 2 14m above grade when located adjacent to a paved sidewalk or driveway A venting system shall not direct flue gases towards brickwork siding or other construction in such a manner that may cause damage from heat or condensate from the flue gases A vent system shall not direct flue gases so as to jeopardize people overheat combustible structures or enter buildings A venting system shall not terminate within 1 8m of the following A window door or mechanical air supply inlet of any building including soffit openings gas service regulator vent outlet A combustion air inlet A property line A direction facing combustible materials or openings of surrounding buildings A venting system shall not terminate within 1m of the following Above a gas meter regulator assembly within 1m horizontally of the vertical centerline of the regulator An oil tank or an oil tankfill inlet The inside corner of an L shaped structure A venting system shall not terminate within 3m of the following Above grade level or any surface that may support snow ice or debris KI S HRDV HORIZONTAL FLUE SIZING Unit Type Flue Pipe Diameter Maximum Length of Flue Pipe I S HRDV 100 4 0 IN 82 0 FT I S HRDV 125 4 0 IN 82
12. and safe operation however it is suggested that the furnace be located above the installation surface on a field fabricated base and should be high enough to prevent any form of moisture from entering the unit Be sure that the roof joists or other obstructions will not interfere with the discharge and return air ducts OM The discharge and return air ducts should be correctly sized for securing to the furnace and all connections exposed to the weather must be moisture tight A high temperature caulking 250 or sheet metal flashing may be used for this purpose A weathertight seal must be provided where ducts enter through the roof Field installed ductwork on the unit discharge end must be secured to the flanges on the heat exchanger and not on unit front cabinet Failure to properly install could cause fire explosion damage to equipment or even death 9 Provide tight fitting inspection panels in duct work both upstream and downstream close to the furnace These panels must be large enough so that the heat exchanger can be easily inspected Venting 1 The 1 IS HRDV model furnace is equipped with a power venter and is complete as received 2 Nofurther venting of unit is required for outdoor installation HRDV 3 Venting is required on all indoor installations ISHRDV and IHRDV units a Positive pressure flue vent is recommended for installations inside building Provide for the ISHRDV and IHRDV Series For the requi
13. inches Bottom 0 inches For installation downstream from refrigeration systems See section on ILLUSTRATIONS for dimensions of individual furnaces 4 Install in airplane hangars in accordance with the current ANSI NFPA 409 Latest Revisions Standard on Aircraft Hangars and in public garages in accordance with the current ANSI NFFPA BB Latest Revisions Standards for Garages and with CANI B149 Codes A clearance of 10 feet must be provided from the bottom of the heater to the top surface of wings or engine enclosures of the highest aircraft to be housed in the hangar and a minimum clearance of 8 feet from the door in other sections such as offices and shops connected with hangar and in public garages Also the heaters must be so located that they will be protected from damage by aircraft cranes scaffolding etc and must be accessible for servicing and adjustment Standard ANSI NFPA 88 Latest revisions specifies that the heater must be so located that the clearance to combustible materials conform with NFPA Nos 52 and 54 and that such material must not attain a temperature over 160 by continued operation of the heater 5 f two furnaces are to be used in a side by side application they must be installed so that the ENDS OPPOSITE the control access doors ADJOIN 6 A 4 inch frame is an integral part of the appliance and may be installed directly on the floor or roof or other combustible construction For ease of service
14. is satis factory inspect main gas valve Check all wiring connections between ignition module and main gas valve and correct as necessary If module and wiring inspections are satisfactory replace main gas valve or valve operator Replace limit switch Check gas supply Inspect main gas valve for proper operation Replace main valve or operator as necessary If ground is poor nuisance shutdowns may occur occasionally even though burner operation is normal at the time of an inspection Test continuity of ignioter lead and ignition module ground wire Correct as necessary as necessary Inspect flame rod Clean or replace if needed Check and correct wiring connections between module and main gas valve See item 6 of Pilot Fails to Light in this section If all previous checks are satisfactory and burners con tinue to shutdown replace module Repair or replace NATURE OF TROUBLE 2 Main gas valve stuck in open position or inoperative module Delayed or Rough Ignition 1 Obstruction in main burner spuds 2 Burners covered with foreign matter Burner Flames Flashback and Burning at Spuds 1 Gas input too low 2 Burners or flue tubes covered by foreign matter CORRECTIVE MEASURES Remove MV lead at ignition module If valve does not close replace valve or operator as necessary If main gas valve and thermostat controller are okay replace module Remove spuds clean and replace Clean burners See CL
15. raising front of burner pushing burner forward against the hold down clip until venturi end of burner is free of support Remove burners next to pilot last and replace these burners first Remove ribbon cotter pin and carefully pry ribbon from slot Clean ribbon with brush and blow off dust Replace ribbon and cotter pin Replace burners making certain that they seat properly in place Failure to re seat burner assemblies properly could result in fire explosion equipment damage or death Cleaning Pilot 1 2 Disconnect tubing from pilot body remove igniter lead and detach pilot burner assembly from support Remove pilot orifice fitting Using a small brush clean pilot burner assembly orifice and flame rod Blow off loose particles Assemble and install in original position Adjust pilot flame to surround flame rod tip about 3 8 Flame must be soft not hard noisy or yellow 12 INDOOR WITH SEPERATED COMBUSTION INSTALLATION VERTICAL HORIZONTAL FLUE FIPE pee ASA ASAS AASA POSITIVE PRESSURE VENT FLUE REQUIRED INSIDE BUILDING IF EXHAUST FAN IS USED DURING THE HEATING SEASON PROVIDE ADEQUATE MAKE UP AIR AND COMBUSTION INSTALL IN AIRPLANE HANGARS IN ACCORDANCE WITH CURRENT NFPA ND 408 STANDARD DN AIRCRAFT HANGARS AND IN PUBLIC GARAGES IN ACCORDANCE CURRENT NFPA NO 88 STANDARD FOR GARAGES SEE PACE 4 FOR DETAILS CLEARANCES INSTALLATION INDOOR MODELS THE NINMUM CLEARANCES FR
16. 2 6 2 6 2 6 2 6 2 6 2 6 DD 2 6 2 6 2 6 2 6 2 6 2 6 2 6 4 6 4 6 4 6 4 6 4 6 4 6 I FACTORY SERVICE Periodic service on any piece of mechanical equipment is necessary for efficient operation If a service problem arises Hastings HVAC Inc has a nationwide service organization available to provide professional assistance to help you with a solution to that problem Two inbound Watts lines to the home offices enables you to consult with qualified factory service personnel For needed parts appliance data or assistance on a service problem contact the service department of Hastings HVAC Inc Also when ordering replacement parts be sure to specify the following 1 Model and serial number of unit 2 Type of gas or fuel 3 Make of electric valve and voltage To contact Hastings HVAC Inc Service Department outside of Nebraska call 800 228 4243 or 228 4270 or write Hastings HVAC Inc 3606 Yost Avenue Hastings Nebraska 68901 1966 Telephone 402 463 9821 HASTINGS voc EEB eA 5 3606 Yost Avenue Hastings Nebraska 68901 1966 Phone 402 463 9821 Fax 402 462 8006 www hastingshvac com E mail sales hastingshvac com
17. 3 carefully to avoid marring or picking up grease and dirt Do not lubricate B Using minimum adjusting screw 9 set manifold pressure to furnace manufacturer s specifications C Replace plunger and spring retainer spring and maximum adjusting screw in proper order TOP HOUSING COVER PLATE SEAL GASKET MAXIMUM ADJUSTMENT SCREW MAXIMUM ADJUSTMENT SPRING SOLENOID MINIMUM ADJUSTMENT SPRING PLUNGER MINIMUM ADJUSTMENT SCREW 10 MINIMUM ADJUSTMENT SCREW STOP tO gt G N ES ES Preliminary Circuit Analysis In order to diagnose the cause of problems in this system it is necessary to determine certain values It is helpful to have an AC and DC voltmeter and an ohmmeter capable of reading O to 15 000 ohms For ease in troubleshooting it is necessary to rewire the system replacing the discharge air sensor with a 4500 ohm 7 watt test resistor Modulating Function Test Connect a DC voltmeter to amplifier terminals 1 and 2 If more convenient the meter may be attached to the MR valve terminals Rotate temperature selection knob to maximum setting the DC volts should read zero The voltage should gradually increase to at least 20 volts when the temperature selector is slowly rotated to its minimum generally over a 39 to 4 range Automatic Valve Function After the electronic modulation function is tested a voltage reading must be taken across the automatic gas valve These volt
18. 3 8 5678 43 3 8 43 3 8 56 7 8 cc E 69 5 8 69 5 8 74 5 8 NOTE All dimensions in inches RD models 100 400 are A G A C G A design certified 15 Dimensions Indoor Models 25 ae AA overall 2 12 4 A Overall Venter Outlet Combh Air Inlet Venter Outlet J 4 Separated Comb Ve 4 Inlet Openin g 2 Pc Door y 191 34 ff den type Combustion air opening ER duct connector Alternate i 7 onboth sides sla Standard turned outa 7 Air Q M Wes lii Gus D Flow Flow This furnace and extra support channel furnished 1136 on 500 00 amp 3015 m 800 A units only This furnace furnished on 500 B 60 B and 800 B units only SIDE VIEW Gas and electrical openings in base pan Removable side panel for access to controls FRONT VIEW ISHRDV IHRDV MODEL NO 100 125 160 210 250 300 400 500 A 500 600 600 B 800 A 800 B A 30 41 41 521 16 521 16 65 52 1 16 52 1 16 65 V5 AA 104 104 i 131 B 18 18 28 94 28 39 Ye 39 V5 52 39 2 39 2 52 BB 87 87 114 21 8 21 8 32 32 43 43 56 43 43 56 CC 69 74 76 D 6 6 6 6 6 6 6
19. E should be as marked on the specification plate If the unit is equipped with modulating gas controls they must be in the HIGH FIRE POSITION when manifold pressure is read Furnace may be severely overfired if regulator is adjusted without this precaution and factory warranty is VOID if heaters are operated in excess of rated BTU inputs 7 lf a fan control is used check to be sure blower starts within two minutes after gas ignition 8 Check entering and discharge air temperature to make certain that heat rise does NOT exceed limits specified see item 8 of INSTALLATION PRECAUTIONS through ANY PORTION of the heat exchanger Locate thermom eters in representative temperature zones of the duct system both upstream and downstream of the furnace and to find the difference of the respective readings The heat rise temperature may be changed by increasing blower speed to lower the temperature or by decreasing the blower speed to raise the temperature 9 Check for proper operation of the limit switch Refer to item 13 of INSTALLATION PRECAUTIONS 10 To maintain proper air circulation through the heating system twice a year check blower sheaves for align ment and belts for tension Inspect for residual accumulation on impeller blades and follow blower manufac turer s instructions for lubrication and maintenance F TROUBLE SHOOTING Pilot Fails to Light Flame Burns Erratically or Goes Out 1 oO NATURE OF TROUBLE Improper too h
20. EANING on pages 11 and 12 Adjust pressure regulator or increase supply pipe size to unit It may be necessary to consult gas company See CLEANING on pages 11 and 12 If faulty consult manufacturer Burner Flames Are Yellow or Tend to Float under Flue Tubes 1 Gas input too high due to oversize main burner spuds or gas supply pressure in excess of 8 ounces approx imately 14 W C 2 Dirty burner ribbons or flue tubes 3 Insufficient combustion air Consult manufacturer for proper spud size before changing or gas company before adjusting regulator or decreasing size of supply piping to unit See CLEANING on page 11 and 12 Make sure air inlets of unit are open Clean unit If condition still exists see item 1 of INSTALLATION PRECAUTIONS Blower Fails to Operate within 2 Minutes after Burners Ignite 1 Faulty blower wiring connections motor or fan controls 2 Fan control set too high 3 Thermostatic fan control Insufficient Heat Delivery from Furnace 1 Undersized spuds or manifold pressure below mark ing on specification plate 2 Inadequate air delivery from blower 3 Dirty flue tubes Furnace Overheats or Cycles on Limit Switch 1 Main gas valve faulty Stuck in open position 2 Faulty limit switch or fan control if used Inspect and correct wiring connections as necessary Connect line voltage directly to motor If motor operates replace fan control if non adjustable
21. H RHVA 160 1200 IH ISH H RHFA IH ISH H RMUA IH ISH H RHVA 210 1285 IH ISH H RHFA IH ISH H RMUA IH ISH H RHVA 250 1560 IH ISH H RHFA IH ISH H RMUA IH ISH H RHVA 300 1625 IH ISH H RHFA IH ISH H RMUA IH ISH RHVA 400 1840 IH ISH H RHFA IH ISH H RMUA IH ISH H RHVA 600 3350 IH ISH RHFA IH ISH H RMUA IH ISH RHVA 800 3880 IH ISH H RHFB IH ISH H RMUB IH ISH H RHVB 200 1445 IH ISH H RHFB IH ISH H RMUB IH ISH H RHVB 250 1525 IH ISH H RHFB IH ISH H RMUB IH ISH H RHVB 320 1610 IH ISH H RHFB IH ISH H RMUB IH ISH H RHVB 420 1800 IH ISH H RHFB IH ISH H RMUB IH ISH H RHVB 500 2025 IH ISH RHFB IH ISH RMUB IH ISH RHVB 600 2125 IH ISH RHFB IH ISH RMUB IH ISH RHVB 800 2545 IH ISH RHFB IH ISH RMUB IH ISH RHVB 1000 4520 IH ISH RHFB IH ISH RMUB IH ISH RHVB 1200 4800 IH ISH RHFB IH ISH RMUB IH ISH RHVB 1600 5765 This weight is the maximum that would be encountered on the system with all available options installed If a specific weight is required contact the manufacturer or consult catalog 2 At least four 4 lines minimum and suitable spreaders should be used to lift
22. ISIRHS 1 April 2008 EM Installation and Service Manual IHR ISHR HR R SERIES INDOOR OUTDOOR SYSTEMS Supplement to RD Series Rooftop Gas Duct Furnace Manual ISHRDV 1 Notice Read These Instructions Before Installation Inspect unit on arrival for any shipping damage This unit has been test fired for at least 15 minutes to prove out all phases of operation If any part is missing or damaged notify the carrier at once TABLE OF CONTENTS Page IH ISH RHF IH ISH H RMU and IH ISH H Unit Dimensions 1 2 H RHF and H RHV Unit Dimensions with D Intake and ae Plenums and Curbs gt ze n 2 3 RMU and H RHV Unit Dimensions with Optional Deos Pleriums and ORO DERE b Ep hua MERERI GN Ra AME 4 5 SNIPPA eee ae a E E 5 uie ipe ec 5 NYS Vea OM usu cousa uu aqa EE 6 adios nd doxet wes cendsascaedudemaasienxedacndesecaueecandanacs pr 6 Ev eK O 7 8 Gas PIPING u 0 Operation of Mechanical Modulating 10 Operation of Electronic Modulating Valve
23. ITH BIRDSCREEN REMOVABLE PANEL FOR DUCT REMOVABLE PANEL FOR CONNECTION AND INSPECTION DUCT CONNECTION AND DRAIN PAN INSPECTION 7 OPTIONAL MIXING t yL4 DAMPERS DISCHARGE AIR RETURN AIR DUCT BE DNA DUCT CONNECTION CONNECTION 1 FL SECTION FURNACE FURNACE DISCHARGE ANGE TURNED TURNED UP BANK A BANK B PLENUM 17 1 2 FLANGE AROUND PERIMETER OF PLENUM BASE FRAME SERVES AS CURB COUNTER FLASHING REAR VIEW SIDE ELEVATION FRONT VIEW Dimensions Roof Curbs for Intake and Discharge Plenums OUTLINE OF UNIT WITH PLENUMS E BLOWER SUPPORT FURNISHED FOR H RHVA 600 AND 800 AND H RHVB 1000 THRU 1600 MODELS PLAN VIEW OUTLINE OF UNIT WITH PLENUMS BLOWER SUPPORT ROOF LINE ELEVATION Plenum Curb Relationship PLENUM FRAME 1 INSULATION WOOD NAILER e CURB 1 2 X 3 1 8 FRAME gt NEOPRENE SEALING STRIP 1 INSULATION ALL PARTS SHOWN ARE FURNISHED WITH CURBS H RHFB H RHVA NOTES 1 Inlet plenum is shown for units with mixing dampers This includes louver assembly drain pan and fresh air intake with birdscreen For 100 return air applications inlet plenum furnished without louver assembly and drain pan Birdscreen is replaced with cover plate Duct Furnace Bank B furnished with RHFB H RHVB models only Standard flashing and mopping procedures are recomm
24. LOT BEFORE THEY BECOME BADLY FOULED Cleaning Flues 1 Outdoor units a g Remove burner drawer assembly To accomplish close manual gas valve to unit and break main gas supply at union Cut furnace electrical supply Unscrew the two quick fasteners at the bottom of the control access panel Pull bottom of panel away slightly and allow panel to drop Remove panel and disconnect applicable electric wiring Remove retaining tabs at each end of the burner drawer and slide drawer assembly out of the furnace Remove the screws holding top panel and lift panel off Remove the screws from bottom flange of the collector box cover and lift cover off Remove the screws from bottom flange of the collector box Remove the two screws from the venter motor support at the right heater leg and disconnect the three conductor cables at the junction box Lift collector box off Power venter assembly will remain attached to the collector box Lift flue baffles from tubes Clean the inner surfaces of flue tubes using a 1 1 2 or 1 3 4 long handled wire brush Clean and replace flue baffles Remove dirt from bottom pan and clean burners before replacing drawer assembly 2 Indoor Units a b Disconnect exhaust flue from unit flange Disconnect separated combustion air flue from unit flange ISHRDV models only Remove the 4 screws holding the top portion of the burner control vestibule door around the power venter outlet R
25. OM COMBUSTIBLE MATERIAL ARE AS FOLLOWS CONTROL SIDE WOTH OF UNT OPPOSITE CONTROL SDE 6 INCHES TOP OF UNIT E 6 NCHES BOTTON INCHES HORIZONTAL FLUE 6 DIA VENT PPE TYPE RECOMMENDED VERTICAL FLUE SUPPORT STRAPS REQUIRED EVERY 5 FEET HORIZONTALY AND AT ELBOWS TO PREVENT SAGGING TEE WITH CONDENSATE DRAIN FITTING COMBUSTION AIR INLET MUST BE AT LEAST 12 MINMUM SEPERATION FROM EXHAUST EITHER TO THE SDE OR BELOW NEVER ABOVE THE EXHAUST OUTLET INDOOR HEATER INSTALLATION VERTICAL HORIZONTAL FLUE PIPE RECONNENDED m POSITIVE PRESSURE VENT FLUE REQUIRED NSDE BULDING IF EXHAUST FAN IS USED DURING THE HEATING SEASON PROVODE ADEQUATE MAKE UP AR AND COMBUSTION INSTALL IN ARPLANE HANGARS IN ACCORDANCE WITH CURRENT NFPA NO 4D9 STANDARD ON AIRCRAFT HANGARS AND IN PUBLIC GARAGES IN ACCORDANCE WITH CURRENT NFPA NO 8 amp STANDARD FOR GARAGES SEE PAGE 4 FOR DETAILS CLEARANCES INSTALLATION NDOCR MODELS THE NINMUM CLEARANCES FROM COMBUSTIBLE MATERIAL ARE AS FOLLOWS CONTRDL SDE OPPOSITE CONTROL SIDE TOP OF UNIT SUPPORT STRAPS REQURED EVERY 5 FEET HORIZONTALY AND AT ELBOWS TO PREVENT SAGGING TEE WITH CONDENSATE DRAIN FITTING HORIZONTAL FLUE 3 8 HOLE FOR DRAINAGE HASTINGS HVAC H ILLUSTRATIONS Air Flow Through Furnace With Bottom Discharge Blower With Top Discharge Blower With Vertical Discharge Blower Diverters Wi
26. S AS CURB x i gt 47 1 2 G COUNTER FLASHING REAR VIEW SIDE ELEVATION FRONT VIEW Dimensions Roof Curbs for Discharge Plenums Only Plenum Curb Relationship PLENUM FRAME m ou OF UNIT WITH DISCHARGE PLENUM 1 INSULATION WOOD NAILER SUPPORTS FOR H 600 800 CURB __ 1 2 X 3 1 8 NEOPRENE AND H RMUB 1000 FRAME SEALING STRIP me Rear Support Curb Relationship 1 INSULATION K mu J 24 3 4 UNIT BASE REAR SUPPORT FOR SIDE CHANNELS H RMUA 100 THRU PLAN VIEW 400 AND H RMUB 600 NEOPRENE STRIP OUTLINE OF UNIT WITH DISCHARGE PLENUM NM DISCHARGE i CURB 16 1 POT ROOF LINE Y ELEVATION ALL PARTS SHOWN ARE FURNISHED WITH CURBS NOTES 1 Duct Furnace Bank B furnished with RMUB RHVB models only 2 Standard flashing and mopping procedures are recommended for curb opening rear support and gas and electrical roof penetrations 3 Deck curb available to provide covered island under complete unit with opening for supply air 4 High air delivery may necessitate a second Fresh Air Damper and or Intake Hood with Birdscreen Check Pressure Drop Chart on page 3 and Blower Motor Capability on page 4 4 RMUA RHVA H RMUB H RHVB 100 amp 125 160 amp 210 250 amp 300 400 600 amp 800 500 amp 600 800 1000
27. TDOOR INSTALLATIONS 2 Refer to items 1 2 5 6 9 10 12 15 and 16 of INSTALLATION PRECAUTIONS 3 REQUIRED MINIMUM CLEARANCES to combustible material are as follows CLEARANCES INSTALLATION Outdoor Models The minimum clearances from combustible material are as follows Control Side Width of Unit Opposite Control Side 6 inches 18 recommended for servicing Top of Unit Unobstructed Discharge and Return Air Sides 12 inches Bottom inches For installation downstream from refrigeration systems CLEARANCES INSTALLATIION Indoor Models The minimum clearances from combustible material are as follows Control Side Width of Unit Opposite Control Side 6 inches 18 recommended for servicing Top of Unit 6 inches Discharge and Return Air Sides 12 inches Bottom O inches For installation downstream from refrigeration systems See section on ILLUSTRATIONS for dimensions of individual furnaces 4 Install in airplane hangars in accordance with the current ANSI NFPA 409 Latest Revisions Standard on Aircraft Hangars and in public garages in accordance with the current ANSI NFFPA BB Latest Revisions Standards for Garages and with CANI B149 Codes A clearance of 10 feet must be provided from the bottom of the heater to the top surface of wings or engine enclosures of the highest aircraft to be housed in the hangar and a minimum clearance of 8 feet from the door in other sections such as offices and shops con
28. ach sweep elbow two and one half feet for termination tee and ten feet for each short radius elbow A gradually tapered vent pipe transition is required for IISHRDV 100 IISHRDV 125 and I ISHRDV 160 units when using 4 inch vent pipe When possible locate horizontal vent hoods that do not face the direction of prevailing winds to diminish the possibility of back draft situations For U S A standards vent systems must conform to the latest edition of the National Fuel Gas Code Pd and the latest edition of NFPA 211 or as follows Not less than 7 feet above grade when located adjacent to public walk ways AT least feet above any forced air inlet located within 10 feet At least 4 feet below 4 feet horizontally from or 1 foot above any door window or gravity air inlet into any building At least 1 foot above grade or at least 1 foot above the normally expected snow accumulation level Directed such as to not jeopardize people At least 4 feet from electric meters gas meters regulators and relief equipment Sealing or shielding of exposed surfaces with a corrosion resistant material may be required to prevent staining or deterioration of building materials and Not less than 2 feet from an adjacent building In Canada vent systems must conform to the latest edition of the Natural gas and Propane Installation Code edd B149 1 or CAN CGA B149 2 or as follows A venting system shall not terminate underneath a veranda porch or deck or
29. age readings will be approximately 24 V AC with the temperature selection knob at maximum setting zero volts AC with the selector at minimum setting The relay switching action should occur when the modulating voltage is between 15 and 19V DC If these voltage readings are observed as noted it is proved that the amplifier and temperature selector are operating properly After testing remove the resistor and reconnect the discharge air sensor Maintenance Motors should be relubricated according to the manufacturer s lubrication instructions 2 Filters must be cleaned cleanable type or replaced throw away type with like filters as often as necessary so as not to restrict air delivery gt Twice a year check belts and sheaves for alignment and belt tension When a belt is replaced shorten center distance between sheaves by loosening motor bolts and sliding motor on support On units requiring multiple belts use a matched set 5 The following procedure is recommended for tensioning belts A Measure span length X shown in Figure B At the center of span length X apply a force perpendicular to the span and large enough to deflect belt 1 64 for each inch of span length Example The required deflection for a 40 span would be 40 64 or 5 8 C Compare the force applied with the values given in Table V If force is between the minimum and maximum range shown the drive tension should be satisfactor
30. amp Up A 20 15 16 31 11 16 42 7 16 55 7 8 117 7 16 42 7 16 55 7 8 117 7 16 B 24 7 16 35 3 16 45 15 16 59 3 8 120 15 16 45 15 16 59 3 8 120 15 16 63 67 67 70 97 7 16 100 7 16 D 23 3 16 33 15 16 44 11 16 58 1 8 44 11 16 58 1 8 2 77 112 84 1 2 84 1 2 87 1 2 94 19 32 114 15 16 117 15 16 125 1 32 F 99 1 2 106 1 2 106 1 2 109 1 2 116 19 32 136 15 16 139 15 16 147 1 32 G 17 3 16 27 15 16 38 11 16 52 3 16 113 15 16 38 11 16 58 3 16 113 15 16 H 3 8 3 8 3 8 3 8 1 4 3 8 3 8 1 4 J E 33 1 16 63 1 2 K 36 3 36 SHIPPING The unit is shipped by either common carrier or flat bed trailer Consult with the factory on number of sections per load 1 TRUCK The intake hood with Birdscreen is shipped in a separate crate on all Outdoor H RHFA H RMUA H RHVA 500 600 and 800 and Outdoor H RHFB H RMUB H RHVB 1000 1200 and 1600 systems Downstream heaters of all Outdoor Indoor IH ISH H RHFB IH ISH H RMUB IH ISH H RHVB 1000 1200 and 1600 are shipped in a separate crate 2 The remote control panel when provided is shipped unmounted HOISTING UNIT 1 The weight of the systems is shown in Table I IH ISH H RHFA Unit IH ISH H RMUA TABLE IH ISH H RHVA 100 Maximum Weight Lbs 1115 IH ISH H RHFA IH ISH H RMUA IH ISH H RHVA 125 1155 IH ISH H RHFA IH ISH H RMUA IH ISH
31. continuously or whenever the gas valve opens NOTE AS AN ADDED PRECAUTION INSTALL EITHER AN AIR PROVING SWITCH OR A SINGLE POLE NORMALLY OPEN RELAY IN THE ELECTRIC GAS VALVE CIRCUIT THE AIR PROVING SWITCH WOULD SENSE AIR CIRCULATION THROUGH THE SYSTEM THE RELAY WOULD BE ENERGIZED BY THE LOAD SIDE OF THE BLOWER MOTOR STARTER EITHER SWITCH WOULD THEN ACTIVATE THE GAS VALVE TO OPEN BUT ONLY WHEN THE BLOWER WAS OPERATING The high limit control switch is a safety control that provides protection if furnace overheats due to blower failure restricted air flow or faulty controls If unit overheats the limit switch breaks the circuit to the electric gas valve and closes gas supply When the temperature of the heat exchanger drops to a safe degree the limit switch automatically rests and permits the gas valve to open again Cause of trouble must be corrected IMMEDIATELY to avoid serious damage to the furnace The limit switch is a safety control NOT AN OPERATING CONTROL Special precautions for furnaces used in conjunction with AIR COOLING and MAKE UP AIR SYSTEMS a Type 409 STAINLESS STEEL heat exchangers may be used in all applications but is recommended for make up air systems where inlet air temperature is ABOVE 40 F b If furnace is used in either make up air or air cooling applications significant quantities of condensate may form Field installed ductwork on the unit discharge end must be secured to the flanges on the heat exchang
32. damage will result Refer to section on CLEANING for recommended frequency WARNING Installer Service Technician must remove burner tray to inspect burner assemblies to insure proper alignment Prior to installing gas supply line to unit gas inlet remove the L locking bracket and disconnect the electrical connections and slide the burner tray out of the heater Once inspection is completed replace the burner tray assembly and install the L locking bracket Failure to perform this inspection could result in fire explosion loss of warranty or even death Firing rate must NOT be increased above the BTU input shown on the specification plate For U S installations at elevations above 2 000 feet 610 M the appliance shall be derated 4 percent for each 1 000 feet 305 M of elevation above sea level For Canadian installations appliances are certified for altitudes of O to 2 000 feet 0 610 M and 2 000 to 4 500 feet 610 1 370 M High altitude ratings may be obtained by a change in orifice size and or manifold pressure Contact the manufacturer or gas company before changing spud sizes or pressure regulator setting Use inch socket wrench to remove spuds NOTE L P GAS UNITS ARE EQUIPPED WITH SPECIAL TAPER REAMED SPUDS WHICH MUST NOT BE RESIZED IN THE FIELD Air starvation is common cause of heat exchanger burn out Air handling system design MUST POSITIVELY ASSURE adequate and evenly distributed air flow through the heat exchange
33. e for proper installation operation and maintenance of the 1 IS HRDV furnace and to supplement BUT NOT TO REPLACE the services of qualified field service personnel This manual should be made readily available to operating personnel as an aid in maintenance and trouble shooting If there are questions pertaining to the installation or operation of this unit consult manufacturer WARNING B INSTALLATION PRECAUTIONS NOTE GUARANTEE OF THIS EQUIPMENT IS SUBJECT TO CONFORMANCE WITH THE FOLLOWING Heater Location Requirements Outdoor units with poor venting pilot outage and other undesirable operating conditions may be caused by a negative pressure condition or high pressure zones created by walls or other obstructions Therefore the furnace must be located as far as possible from the source of such turbulence and at least six feet from the edge of the roof Indoor units must NOT be operated in the presence of CHLORINATED SOLVENTS Even slight traces of chlorine combined with products of combustion will cause serious damage Indoor units must have adequate COMBUSTION AIR If heaters are installed in a closed room provide outside opening of one square inch per 1 000 BTU for combustion air alone Indoor units must not operate in an area with a negative air pressure condition Provide adequate MAKE UP AIR Indoor units installed where there is sawdust lint soot dirt etc areas of high air contamination must be cleaned FREQUENTLY or serious
34. emove burner control vestibule door by turning bottom latches on door Pull the door away by pulling the bottom rail on the door outward On some models a 2 piece door is provided 2 screws hold the top portion of the door in place Remove Screws and remove top door portion 11 m Remove burner drawer assembly To accomplish close manual gas valve to unit and break main gas supply at union Cut furnace electrical supply Unscrew the two quick fasteners at the bottom of the control access panel Pull bottom of panel away slightly and allow panel to drop Remove panel and disconnect applicable electric wiring Remove retaining tabs at each end of the burner drawer and slide drawer assembly out of the furnace Remove the screws holding top panel and lift panel off Remove the screws from bottom flange of the collector box cover and lift cover off Remove the screws from bottom flange of the collector box Remove the two screws from the venter motor support at the right heater leg and disconnect the three conductor cables at the junction box Lift collector box off Power venter assembly will remain attached to the collector box Lift flue baffles from tubes Clean the inner surfaces of flue tubes using a 1 1 2 or 1 3 4 long handled wire brush Clean and replace flue baffles Remove dirt from bottom pan and clean burners before replacing drawer assembly Cleaning Burners 1 6 Burners can be removed from drawer assembly by
35. ended for curb openings and gas and electrical roof penetrations Deck curb available to provide covered island under complete unit with openings for supply and return air Rear Support Curb Relationship UNIT BASE SIDE CHANNELS NEOPRENE STRIP Pe RHFB H RHVB 100 amp 125 160 amp 210 250 amp 300 400 600 amp 800 200 amp 250 320 amp 420 500 amp 600 800 1000 amp Up 20 15 16 31 11 16 42 7 16 55 7 8 117 7 16 20 15 16 31 11 16 42 7 16 55 7 8 117 7 16 24 7 16 35 3 16 45 15 16 59 3 8 120 15 16 24 7 16 35 3 16 45 15 16 59 3 8 120 15 16 74 3 4 81 3 4 81 3 4 84 3 4 92 105 3 16 112 3 16 112 3 16 115 3 16 122 7 16 82 89 89 92 99 3 16 112 7 16 119 7 16 119 7 16 122 7 16 129 5 8 126 133 133 136 143 3 16 156 7 16 163 7 16 163 7 16 166 7 16 173 5 8 17 3 16 27 15 16 38 11 16 52 3 16 113 15 16 17 3 16 27 15 16 38 11 16 52 346 113 15 16 3 8 3 8 1 4 1 4 23 23 60 HR R OUTDOOR SYSTEMS Dimensions H RMU and H RHV Models with Discharge Plenums Only FRESH AIR INTAKE WITH BIRDSCREEN REMOVABLE PANEL FOR DUCT CONNECTION AND INSPECTION OPTIONAL INTAKE DAMPER DISCHARGE AIR DUCT BLOWER FURNACE DISCHARGE CONNECTION 1 SECTION BANK A PLENUM FLANGE TURNED UP Fre AROUND PERIMETER OF PLENUM BASE FRAME SERVE
36. er and not on unit front cabinet Failure to properly install could cause fire explosion damage to equipment or even death Venting I ISHRDV indoor duct furnaces Venting must be installed by a qualified installer in accordance with all local codes In the absence of local codes venting must be installed in accordance with the latest edition of the National Fuel Gas Code ANSI Z2223 1 NFPA 70 Part 7 venting of equipment In Canada venting must be in accordance with the latest edition of the Natural Gas Installation Code CAN CGA B149 1 propane installation code CAN CGA BA49 2 A bult in power venter is provided do not connect into any additional mechanical draft systems operating under a positive pressure Improper installation can create a hazardous condition such as explosion fire carbon monoxide poisoning resulting in property damage personal injury or death INSTALLATION Regulations Installation of this appliance must conform to applicable federal state and local codes and regulations and with guidelines established by A GA American Gas Association NFPA National Fire Protection Association N E C National Electrical Code the National Board of Fire Underwriters and CAN CGA B149 Listed are codes appearing in this text the Associations and their addresses where they may be obtained 1 The National Fuel Gas Code 2 AI NFPA codes National Electrical Code Contact American Gas Association Administrative Co
37. ge end must be secured to the flanges on the heat exchanger and not on unit front cabinet Failure to properly install could cause fire explosion damage to equipment or even death 9 Provide tight fitting inspection panels in duct work both upstream and downstream close to the furnace These panels must be large enough so that the heat exchanger can be easily inspected Venting The 1 IS HRDV model furnace is equipped with a power venter and is complete as received No further venting of unit is required for outdoor installation HRDV Venting is required on all indoor installations ISHRDV and IHRDV units 1 2 3 a b c j Positive pressure flue vent is recommended for installations inside building Provide for the ISHRDV and IHRDV Series For the requirement of positive pressure flue vent review local codes Pitch vent pipe up toward outlet 1 4 per foot for condensate drainage Type B gas vent is recommended for flue venting above roof lines or external wall penetrations Straight vertical runs out through the roof are preferred Vertical stack must be a minimum of five feet high Vertical flue stacks shall be terminated with an approved cap The maximum horizontal vent pipe length for these heaters is shown in table Il A total equivalent horizontal vent pipe length can be calculated using equivalent straight pipe lengths for tees and elbows reducing the maximum horizontal vent pipe length by six feet for e
38. igh or low gas pressure at unit Obstruction in pilot line or orifice Inoperative pilot gas valve or valve operator No or inadequate spark across igniter sensor gap Improper pilot Flame either too small or flame lifts System goes into safety lockout 100 lockout models ONLY Venter Running But No Spark Or Pilot Vent proving switches not made CORRECTIVE MEASURES Make sure all manual gas cocks are open Check gas pressure at main valve to be certain it conforms to MINIMUM SUPPLY PRESSURE marked on the specification plate In any case pressure is NOT to exceed 14 W C for natural or L P gas Regulate gas pressure or change supply pipe size to maintain proper inlet pressure Regulate gas pressure or change supply pipe size to maintain proper inlet pressure Adjust pilot flame to surround end of flame rod about 3 8 inch See CLEANING instructions Check all manual gas cocks Inspect wiring connections between ignition module and pilot valve or operator Correct as necessary Check low voltage across PV and MV PV terminals on module If previous inspections are satisfactory replace pilot valve or operator If no or in adequate voltage is detected on module test replace module Check for line voltage low voltage power supply and transformer all wiring connections improper ground blown fuse in ignition module if applicable faulty high limit switch voltage leaks in igniter lead or crac
39. individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 2 PSIG 11 The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than PSIG NOTE CHECK ALL GAS CONNECTIONS FOR LEAKS A SOAP SOLUTION SHOULD BE USED FOR THIS PURPOSE NEVER USE A TORCH OR FLAME OF ANY KIND Electrical NOTE UNIT MUST BE ELECTRICALLY GROUNDED AND ALL WIRING MUST BE DONE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE ANSI NFPA 70 Latest Revisions CSA 22 1 CANADIAN ELECTRICAL CODE AND ALL APPLICABLE GOVERNING CODES 1 Acomplete wiring diagram is included with this appliance 2 Allexternal wiring must be run within approved weatherproof outdoor applications conduit 3 Check specification plate on furnace for voltage and ampere requirements 4 The power supply lines must be 14 ga wire or larger depending on the ampere requirement of the unit 5 If any of the original wiring or cable as supplied with the appliance is to be replaced it must be replaced with 16 ga AWM 6 strand 2 64 PVC 105 CUL and CSA approved wiring Refer to items 11 12 and 13 of INSTALLATION PRECAUTIONS A non adjustable limit control switch is attached to the heat exchanger side and is located on the control end of the furnace behind acce
40. ked flame rod insulator and proper igniter sensor gap approximately 1 8 Correct as necessary If igniter still does not spark replace ignition module If pilot is too small clean pilot line primary air openings and pilot orifice If flame lifts reduce gas pressure For both conditions adjust pilot flame to surround end of flame rod about 3 8 Flame must be soft and quiet Reset thermostat controller and try again for ignition To reset adjust thermostat to a point below room temp erature or switch off controller Wait for a minimum of 60 seconds then adjust thermostat above room temperature or switch controller on If ignition is not made within the 90 second trial period the system goes into safety lock out again Check gas supply line and low voltage supply ground limit switch all wiring connections ig nitions module and gas valves Correct as necessary Replace Venter motor end switch Replace vent proving air switch Improve venting practices Improve on negative pressure in room Replace ignition wire Replace ignition control module 1 Pilot flame does not contact flame rod sufficiently 2 Faulty flame rod igniter lead ground wire connec NATURE OF TROUBLE Pilot Lights But Ignition Spark Continues tions or inoperative ignition module Main Burners Fail to Light 1 Faulty limit switch Stuck in open position 2 Pilot flame too small 3 Improper too high or low gas pressure at unit
41. ll deliver necessary air to bot 06 tom of heat exchanger irect air to bottom if connecting duct is less than 5 long Duct turns must be installed to direct air to bottom of heater WARNING Air must flow evenly through the entire heat exchanger Otherwise the bottom or tubes on one side will overheat causing damage and voiding the warranty Heat exchanger must be installed downstream of blower Dimensions Outdoor Model overall Venter outlet 3 4 7 This fumace and extra dac i anda Flange type support channel fumished ote Combustion air opening duct connector on 500 600 amp 800 A 4 n on both sides 2114 gt AT tumed out 3 4 7 only Flow m m Gas opening s yl Bectrical single connection SIDE MEW y 718 E u 3 xis FRONT MEW i Support channels T CC rail 412 Gas and electric openings in base pan Removable side panel for access to controls This fumace fumished on 500 B 600 B and 800 B only HRDV MODEL NO 100 125 160 210 250 300 400 500 A 500 B 600 A 600 B 800 A 800 B A 305 8 305 8 413 8 413 8 413 8 521 16 65 1 2 52 1 16 52 1 16 65 1 2 AA 104 18 10416 131 B 18 18 28 3 4 28 3 4 39 1 2 39 1 2 527 8 39 1 2 39 1 2 52 718 87 3 4 87 3 4 11458 C 217 8 217 8 325 8 325 8 433 8 43
42. nected with hangar and in public garages Also the heaters must be so located that they will be protected from damage by aircraft cranes scaffolding etc and must be accessible for servicing and adjustment Standard ANSI NFPA 88 Latest revisions specifies that the heater must be so located that the clearance to combustible materials conform with NFPA Nos 52 and 54 and that such material must not attain a temperature over 160 by continued operation of the heater 5 If two furnaces are to be used in a side by side application they must be installed so that the ENDS OPPOSITE the control access doors ADJOIN 6 A 4 inch frame is an integral part of the appliance and may be installed directly on the floor or roof or other combustible construction For ease of service and safe operation however it is suggested that the furnace be located above the installation surface on a field fabricated base and should be high enough to prevent any form of moisture from entering the unit 7 Be sure that the roof joists or other obstructions will not interfere with the discharge and return air ducts 8 The discharge and return air ducts should be correctly sized for securing to the furnace and all connections exposed to the weather must be moisture tight A high temperature caulking 250 F or sheet metal flashing may be used for this purpose A weathertight seal must be provided where ducts enter through the roof Field installed ductwork on the unit dischar
43. ntact National Fire Protection Association Inc 1515 Wilson Boulevard Batterymarch Park Arlington Virginia 22209 Quincy Massachusetts 02269 3 Standard of National Board of Fire Underwriters 4 Canadian Gas Association Contact National Board of Fire Underwriters Contact Canadian Gas Association 85 John Street 178 Rexdale Boulevard New York New York 10036 Etobicoke Ontario Canada M9W 1R3 Location NOTE AMERICAN INSTALLATIONS MUST CONFORM WITH THE NATIONAL FUEL GAS CODE AMERICAN NATIONAL STANDARD ANSI Z223 1 Latest Revisions AND ALL APPLICABLE GOVERNING BUILDING CODES CANADIAN INSTALLATIONS MUST CONFORM WITH CAN CGA B149 Latest Revisions 1 The 1 ISHRDV Furnace has been designed for INDOOR OR HRDV FOR OUTDOOR INSTALLATIONS 2 Referto items 1 2 5 6 9 10 12 15 and 16 of INSTALLATION PRECAUTIONS 3 REQUIRED MINIMUM CLEARANCES to combustible material are as follows CLEARANCES INSTALLATION Outdoor Models The minimum clearances from combustible material are as follows Control Side Width of Unit Opposite Control Side 6 inches Top of Unit Unobstructed Discharge and Return Air Sides 12 inches Bottom 0 inches For installation downstream from refrigeration systems CLEARANCES INSTALLATIION Indoor Models The minimum clearances from combustible material are as follows Control Side Width of Unit Opposite Control Side 6 inches Top of Unit 6 inches Discharge and Return Air Sides 12
44. r See ILLUSTRATIONS on page 15 The furnace must be installed downstream from or on the POSITIVE PRESSURE SIDE of the air circulating blower Air flow through the furnace may be in either direction However on units with an air distribution baffle assembly the air flow must enter the furnace from the baffle side If entering air is desired from the opposite side the baffle assembly must be relocated to that side of the heat exchanger High SCFM models do not require this baffle assembly and are recognized by the suffix letter H in the furnace model number Example IHRDV 400HME High SCFM model furnaces require heating air temperature rise be maintained at between 10 to 60 F On units with the baffle assembly temperature rise must be maintained between 40 to 100 F Filters if used must be cleaned or replaced as often as is necessary so as not to restrict air delivery Furnaces installed in areas of high air contamination may require FREQUENT cleaning Refer to section on 15 C CLEANING for recommended frequency The 1 IS HRDV furnaces are design certified for operation with modulating or two stage gas controls When either modulating or two stage controls are ordered a thermostatic type fan control switch must NOT be used With these gas controls constant fan operation simultaneous fan and gas valve operation or a fan time delay relay must be employed If a fan control is not used the blower must operate
45. rement of positive pressure flue vent review local codes b Pitch vent pipe up toward outlet 74 per foot for condensate drainage c Type gas vent is recommended for flue venting above roof line or external wall penetrations d Straight vertical runs out through the roof are preferred Vertical stack must be a minimum of five feet high j Vertical flue stacks shall be terminated with an approved cap The maximum horizontal vent pipe length for these heaters is shown in table 1 A total equivalent horizontal vent pipe length can be calculated using equivalent straight pipe lengths for tees and elbows reducing the maximum horizontal vent pipe length by six feet for each sweep elbow two and one half feet for termination tee and ten feet for each short radius elbow A gradually tapered vent pipe transition is required for I ISHRDV 100 I ISHRDV 125 and I ISHRDV 160 units when using 4 inch vent pipe When possible locate horizontal vent hoods that do not face the direction of prevailing winds to diminish the possibility of back draft situations For U S A standards vent systems must conform to the latest edition of the National Fuel Gas Code and the latest edition of NFPA 211 or as follows Not less than 7 feet above grade when located adjacent to public walk ways AT least feet above any forced air inlet located within 10 feet Atleast 4 feet below 4 feet horizontally from 1 foot above any door window or gra
46. se INPUT IN 1000 S MAXIMUM DISTANCE NATURAL L P BTU HR FROM METER GAS GAS up to 50 50 feet 50 to 125 40 feet Ya 100 feet 1 Ya 126 to 180 60 feet 1 100 feet 1w 17 181 to 250 30 feet 1 120 feet 1 1 200 feet 1 1 251 to 300 75 feet 1 1 200 feet 12 1 301 to 400 50 feet 1 1 125 feet 16 1 For larger installations or longer piping runs consult gas company If more than 72 PSIG 14 in W C pressure is available a high pressure regulator would be required Pipe sizing may be reduced On heating systems with more than one duct furnace a high gas pressure regulator is required for each heater section Refer to items 3 and 4 of INSTALLATION PRECAUTIONS Pipe joint compound should be resistant to the action of L P gas Install a DIRT TRAP tee nipple and cap at connection to each furnace For ease of servicing an additional union and manual gas valve should be installed adjacent to the furnace exterior An approved readily accessible manual gas valve should be joined to a ground joint type union immediately upstream and connected to the appliance manifold piping 8 A 1 8 plugged tapping accessible for test gage connection must be installed immediately upstream of the gas supply connection to the appliance 9 The furnace must NOT be operated without a leak limiting orifice installed in the unit pressure regulator vent if applicable 10 The appliance and its
47. ss panel The furnace thermostat must be installed according to the wiring diagram and a suitable site located to protect it from tampering and damage Do NOT expose thermostats to jarring or physical shocks either before or after installation 6 D ELECTRONIC IGNITION All I IS HRDV series furnaces are equipped with a solid state design intermittent pilot ignition system This electronic system consists of an ignition control module combination pilot burner igniter sensor sensor or flame rod assembly and igniter sensor lead Activated by the units 24V transformer and controlled by a field installed thermostat or controller module will first perform a safe start check which tests its internal components for a false pilot flame condition If satisfactory the module then energizes the pilot gas valve to open and generates 15 000 V peak capacitive discharge ignition spark to ignite pilot burner When pilot is established the flame monitoring circuit of module responds to the presence of flame detected by the flame rod and discontinues ignition spark The main gas valve is then energized to open pilot lights main burners and burner operation continues until call for heat is satisfied Module then deactivates both pilot and main gas valves and unit shuts down Two types of ignition control modules are utilized A non 10096 shutoff design is used with natural gas ONLY It provides continuous spark for pilot ignition but if pilot does not light
48. temperature gets up to 110 degrees the TL will cycle the bypass valve during the room override mode When the room thermostat is satisfied the furnace will return to discharge temperature of 73 degrees when the heat exchanger cools down from the high fire condition The 400 Model has an additional bypass without any valve control This is called a minimum rate tube M R T During mild weather the modusnap valve will cycle on minimum flow while the M R T is flowing gas For its control the DC will cycle the main shut off valves to maintain discharge temperature There is no gas flow to burner when DC is satisfied unless the unit has a room override option on the DC circuit ALL MODEL SIZES SMALLER THAN THE 400 OPERATION Settings are the same as above except less the M R T and DC control Valve Adjustments See bulletin MT2035 for additional M MR valve information Note High Fire Adjustment should be checked whenever Low Fire Adjustment is changed Disconnect wire from amplifier terminal 3 remove cover plate 2 High Fire Adjustments Low Fire Adjustments A Using the maximum adjustment screw 4 set A Remove maximum adjusting screw 4 spring 5 manifold pressure to furnace manufacturer s and plunger 8 A small magnet is useful for this specifications purpose B Replace cover plate 2 on Modulator Regulator CAUTION The plunger is a precision part Handle valve and reconnect wire to amplifier terminal
49. the unit or flat platform lift with proper lifting weight ability should be used Unit must be slinged properly with multiple lifting points to prevent the unit from sagging 3 On units with either inlet or discharge plenums or both suitable slings must be provided for support be neath the unit minimum of four support slings are required Additional sling supports may be needed for long pieces of equipment WARNING The mechanical or structural engineer should be contacted before moving unit across the roof deck 5 INSTALLATION 1 The unit may be installed on a field fabricated mounting frame or support a factory roof curb mounting frame or a slab The following items are important in this regard A Be sure that roof joist or support will not interfere with discharge and return air ducts B Be sure frame or support is square level and not twisted C Field fabricated frame support or slab must be high enough to prevent any form of moisture from enter ing unit D All joints on frame must be sealed with caulking compound E Field fabricated curb should be insulated with at least 1 72 thick rigid type insulation F The roof curb should be counterflashed and sealed before unit is installed 2 The discharge and return air duct if required should be correctly sized for securing to factory installed plenums when provided or to unit Duct connection s exposed to the weather must be watertight A weathertight seal m
50. tts 02269 Standard of National Board of Fire Underwriters 4 Canadian Gas Association Contact National Board of Fire Underwriters Contact Canadian Gas Association 85 John Street 178 Rexdale Boulevard New York New York 10036 Etobicoke Ontario Canada M9W 1R3 ELECTRICAL Unit must be electrically grounded and all wiring must be done in accordance with applicable local codes and the National Electrical Code In order to determine the size of the power supply lines check the electrical specification plate located on the unit for ampere requirements On units not ordered with a disconnect switch it is recommended that a weatherproof disconnect switch be mounted on or near the unit Connect power supply lines from main disconnect switch to unit disconnect switch Install thermostat RHF and RHV only or remote control station if supplied according to wiring diagram Thermostats and remote control stations must be installed in a suitably protected and secure location to prelude tampering and damage Thermostats must not be exposed to physical shocks or jarring either before or after installation LOCATION NOTE AMERICAN INSTALLATIONS MUST CONFORM WITH THE NATIONAL FUEL GAS CODE AMERICAN NATIONAL STANDARD ANSI Z223 1 Latest Revisions AND ALL APPLICABLE GOVERNING BUILDING CODES CANADIAN INSTALLATIONS MUST CONFORM WITH CAN CGA B149 Latest Revisions 1 The I IS HRDV Furnace has been designed for INDOOR OR HRDV FOR OU
51. ust be provided where duct s comes through the roof WARNING 1 Field Installed ductwork on the unit discharge end must be secured to the flanges on the heat exchanger and not on unit front cabinet Failure to properly install could cause fire explosion damage to equipment or even death Installer Service Technician must remove burner tray to inspect burner assemblies to insure proper alignment Disconnect gas supply line to unit gas inlet remove the L locking bracket and disconnect the electrical connections and slide the burner tray out of the heater Once inspection is completed replace the burner tray assembly and install the L locking bracket Failure to perform this inspection could result in fire explosion loss of warranty or even death Installation of this appliance must conform to applicable federal state and local codes and regulations and with guidelines established by A G A American Gas Association NFPA National Fire Protection Association N E C National Electrical Code the National Board of Fire Underwriters and CAN CGA B149 Listed are the codes appearing in this text the Associations and their addresses where they may be obtained 1 oof The National Fuel Gas Code 2 All NFPA codes National Electrical Code Contact American Gas Association Administrative Contact National Fire Protection Association Inc 1515 Wilson Boulevard Batterymarch Park Arlington Virginia 22209 Quincy Massachuse
52. vity air inlet into any building Atleast 1 foot above grade or at least 1 foot above the normally expected snow accumulation level Directed such as to not jeopardize people Atleast 4 feet from electric meters gas meters regulators and relief equipment Sealing or shielding of exposed surfaces with a corrosion resistant material may be required to prevent staining or deterioration of building materials and Not less than 2 feet from an adjacent building In Canada vent systems must conform to the latest edition of the Natural gas and Propane Installation Code GANS 1 or 149 2 or as follows A venting system shall not terminate underneath a veranda porch or deck or above a paved sidewalk or a paved driveway that is located between two buildings and that serves both buildings The exit terminals of mechanical draft systems shall not be less than 2 14m above grade when located adjacent to a paved sidewalk or driveway A venting system shall not direct flue gases towards brickwork siding or other construction in such a manner that may cause damage from heat or condensate from the flue gases A vent system shall not direct flue gases so as to jeopardize people overheat combustible structures or enter buildings venting system shall not terminate within 1 8m of the following A window door or mechanical air supply inlet of any building including soffit openings A gas service regulator vent outlet
53. y force below the minimum value indicates an undertensioned belt and a force that exceeds the maximum value indicates an overtensioned belt 6 Lubricate main fan bearing with a high grade lithium base grease Perform at least every quarter three months or schedule according to equipment use TABLE V Belt Cross Section Motor Pulley Pitch Deflection Force marked on belt Diameter Minimum Maximum 3 0 3 6 2 62 16 3 25 lbs A 3 8 4 8 3 Ibs 4 Ibs 5 0 7 0 3 25 Ibs 5 Ibs 3 4 4 2 3 Ibs 5 Ibs B 4 4 5 6 4 Ibs 5 87 Ibs 5 8 8 6 5 25 lbs 7 87 lbs 242 FIGURE I DEFLECTION 1 64 PER INCH OF SPAN LUBRICATION INSTRUCTIONS FOR MOTORS Some small motors have sealed for life bearings which require no relubrication Regreasable bearings are shipped with a high quality wide temperature range grease in the bearings Motors can be regreased by stopping the motor removing drain plug and pumping new grease into fill hole Run motor with drain plug removed until excess grease has been discharged minimum 10 min Stop motor and replace drain plug Units that operate at speeds greater than 1800 RPM should be lubricated on a more frequent maintenance schedule depending on duty cycle Use a low pressure grease gun and avoid overgreasing SUGGESTED REGREASING INTERVALS SERVICE MOTOR HORSEPOWER UNDER 50 50 100 100 UP 3 5 Yrs 2 4 Yrs 2 Yrs
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