Reznor DV User Manual

NOTICE:

The information contained on the following page(s) was produced

prior to May 1, 2014. On that date Reznor became part of

Nortek, Inc.

References to any other company afliations are no longer valid.

This manual refers to Reznor brand products that have been

discontinued for more than 10 years.

Some replacement parts may no longer be available from

our suppliers. Compatible parts may be substituted.

Please contact your Reznor Representative

with specic questions.

©2014 Reznor, LLC. All Rights Reserved.

Trademark notice: Reznor is registered in at least the United States.

0514 PDF Form Cover2

Indoor or Outdoor, Gas, Direct-

Fired, Makeup Air/Heating Systems

®

Index Page

Air Pressure ..................................... 4

Air Pressure Switches.................... 10

Blower Bearings ............................. 3

Burner ........................................ 4, 11

Circuit Indicator Board.................... 4

Control Locations............................ 8

Damper Motor .............................. 19

Direct-Fired Burner....................... 11

Dirty Filter Switch ........................ 19

Door Switch................................... 17

Drive Components .......................... 2

Electronic Circuit Board with

Diagnostic Lights ........................ 8

Emergency Cut Off ......................... 9

Evaporative Cooling Module ........... 5

Filters .............................................. 3

Firestat ........................................... 20

Freezestat ....................................... 20

Gas Control Systems .................... 11

Gas Pressure ................................... 3

Gas Pressure Switches................... 17

Ignition System .............................. 11

Inlet Air Controls ........................... 17

Limit Control................................... 9

Maintenance Schedule ..................... 2

Maintenance Section................. 2-7

Maintenance/Service Access ........... 2

Manifold Arrangements ................ 16

Operation/Service Section ...... 8-24

Outside Air Cutoff Control ............17

Photoelectric Smoke Detector ........ 20

Photohelic Pressure Sensor............ 19

Pilot Assembly ................................ 4

Potentiometer ................................. 19

Pressure Null Switch ..................... 19

Sensing Pressure Check................ 10

Troubleshooting ............................ 21

Wiring Diagram - In the main

electrical box on the unit

References:

Installation Manuals:
Model DV, Form RZ-NA I-DV

Model RDF, Form RZ-NA I-RDF
Model ADF(H), Form RZ-NA I-ADF

Replacement Parts Manual:
Form RZ-NA P-DV/RDF/ADF
or Form 740 for RDF; Form 741 for

DV, and Form 742 for ADF/ADFH

C E R T I F I E D

Operation/Maintenance/Service

Form RZ-NA O-DV/RDF/ADF

Obsoletes Form RZ-NA 440-OMS, 441-OMS, and 442-OMS

Applies to: Models DV, RDF, and ADF/ADFH

KEEP THIS BOOKLET FOR

MAINTENANCE AND

SERVICE REFERENCE.

FOR YOUR SAFETY
WARNING: The use and storage of gasoline or other flammable
vapors and liquids in the vicinity of this appliance is hazardous.

FOR YOUR SAFETY
If you smell gas:

1. Open windows.

2. Don't touch electrical switches.

3. Extinguish any open flame.

4. Immediately call your gas supplier.
WARNING: Improper installation, adjustment, alteration,

service, or maintenance can cause property damage, injury or
death. Read the installation, operation, and maintenance

instructions thoroughly before installing or servicing this
equipment.

WARNING: On makeup air heaters which also recir culate room
air, outside ventilation air must be provided in accordance with
the information shown on the heater rating plate.

Recirculation of room air may be hazardous in the presence of:

(a) Flammable solids, liquids, and gases;
(b) Explosive materials (e.g. grain dust, coal dust, gun powder,

etc.); or

(c) Substances which may become toxic when exposed to heat

(e.g. refrigerants, aerosols, etc.).

Operating/Maintenance/Service

The information in this manual applies to Model Series DV, RDF, and ADF direct-fired
heating/makeup air systems. As with any gas burning equipment, regular maintenance
procedures are required to ensure continued safety, reliability and efficiency of the instal­lation.

If service is required, this system should be serviced only by a qualified service person.
Service information in this booklet is intended as a guideline for a qualified gas-fired
equipment service person.

Form O-DV/RDF/ADF, P/N 148385, Page 1

DANGER: The gas burner in this dir ect gas-fir ed system is designed and equipped to pr ovide
safe, controlled complete combustion. However, if the installation does not permit the burner
to receive the proper supply of combustion air, complete combustion may not occur . The result
is incomplete combustion which produces carbon monoxide, a poisonous gas that can cause
death.
Always comply with the combustion air requirements in the installation codes and operating
instructions. The amount of air over the burner must be within the specified range. The burner
profile plates are set at the factory to match CFM requirements. Do not adjust the burner
profile plates without contacting the factory . F AILURE TO PROVIDE PROPER COMBUSTION
AIR CAN RESUL T IN A HEAL TH HAZARD WHICH CAN CAUSE PROPERTY DAMAGE,
SERIOUS INJURY, AND/OR DEA TH. Direct-fired installations should pr ovide for air changes
as required by the applicable installation codes.

MAINTENANCE
SECTION

Maintenance Codes

S = Safety (to avoid

personal injury and
/or property damage)

R = Continued Reliability
E = Efficient Operation

Maintenance
Schedule

This direct-fired makeup air system is designed to require only a minimum
amount of maintenance. Some maintenance procedures outlined in this Sec­tion require inspection only and some require action. Frequency requirements
of each maintenance procedure are listed in the Maintenance Schedule. De­pending on the environment and the number of operating hours, more fre­quent inspection and/or cleaning may be required to certain components.

Although maintenance requirements are minimal, the routine maintenance pro­cedures in this Section are necessary to ensure safe, reliable, and/or efficient
operation. The paragraphs which follow discuss the components and systems
that require routine inspection/maintenance. At the beginning of each para­graph, there is a code indicating why that maintenance procedure is necessary.
The legend for that code is shown on the left.

WARNING: Disconnect all power to the system before doing
any maintenance. Failure to do so may cause electrical shock,
personal injury, or death.

See Chart oLubricate bearings, Paragraph 1

Quarterly oCheck the filters, Paragraph 2

oCheck air pressure sensing tubes, Paragraph 4

Semi- oCheck blower belts, Paragraph 1
Annually oVerify gas pressures, Paragraph 3

oClean air pressure sensing tubes, Paragraph 4
oCheck indicator lights, Paragraph 5

Annually oCheck main burner and pilot assembly, Paragraph 6

1. Drive

R

Components

Form O-DV/RDF/ADF, P/N 148385, Page 2

The blower, motor and drive components are located in the blower cabinet.
Remove the panels required to access the component(s) being serviced.

1A. Blower Bearings

All blowers are Class I with pillow block bearings. Clean the fitting and add
type NLG-2 or -2 standard grade grease. Add grease with a handgun until a
slight bead of grease forms at the seal. Be careful not to unseat the seal by over
lubricating.

CAUTION: If the blower is unused for more than three months, the
bearings should be purged with new grease prior to startup.

Recommended Bearing

p

p

Lubrication Schedule in
Months

FIGURE 1 - Belt Tension

3/4 (19mm)

Bearing Bore Diameter (Inches)

RPM
to 1000 6 6 6
1001 - 1 500 5 5 5
1501 - 2 000 5 4 5

1/2 to 1 >1 to 1-1/2 >1-1/2 to 1- 15/16

NOTE: If unusual environmental conditions
exist ( temperatures below 32°F or above
200°F; moisture; or contaminants ) more
frequent lubrication is required.

1B. Blower Belts

Check belts for proper tension and wear. Adjust belt tension as needed. Re­place worn belts.
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. If adjustment is required, adjust belt tension
by means of the adjusting screw on the motor base until the belt can be de­pressed 1/2" to 3/4" (FIGURE 1). Tighten the lock nut on the adjusting screw.
Be sure the belt is aligned in the pulleys.

RE

2. Filters

Quantity and Size of
Filters by Model

3. Manifold Gas

S

Pressure

If the system includes filters, check the filters quarterly. Filters could be either
in an optional filter cabinet (DV/RDF/ADF) or in the optional inlet base (DV).

To access filters in a filter cabinet, remove the filter cabinet door panels. Clean
or replace as needed. If removed, be sure to put blockoff plates in filter rack.

If the filters are in the perimeter of the inlet base of a Model DV; they are two­inch permanent filters. Remove and clean the filters as needed.

Dis

Type

Thickness

Model RDF with Optional Filter Cabinet

1
2
3

Model ADF/ADFH with Optional Filter Cabinet

300
500

700, 1200

Model DV with Optional Filter Section

109, 112

115, 118

122, 125

Model DV with Inlet Base with Filters

109, 112
115, 118
122, 125

(5)12x30-5/8 (5)12x30-5/8 (10)10x16 (10)10x16 (5)12x32 (5)12x32

(5)12x20 (5)12x20 (5)12x20 (5)12x20 (5)12x20 (5)12x20
(5)12x25 (5)12x25 (5)12x25 (5)12x25 (5)12x26 (5)12x26
(5)12x25 (5)12x25 (5)12x25 (5)12x25 (5)12x25 (5)12x25

(5)12x30-5/8 (5)12x30-5/8 (5)12x32 (5)12x32 (5)12x32 (5)12x32

osable Permanent Pleated Disposable

1" 2" 1" 2" 1" 2"

- - (3)12x35 (4)12x35 - -

- - (4)12x35 (4)12x35 - -

- - (4)12x24 (4)12x24 - -

- - (12)12x35 (10)12x35 - -

- (4)16x16 (4)16x16 (4)16x16 (4)16x16 (4)16x16

- (4)16x20 (4)16x20 (4)16x20 (4)16x20 (4)16x20

- (6)16x20 (6)16x20 (6)16x20 (6)16x20 (6)16x20

- (6)16x25 (6)16x25 (6)16x25 (6)16x25 (6)16x25

- (16)16x16 (16)16x16 (16)16x16 (16)16x16 (16)16x16

- (6)16x25 (6)16x25 (6)16x25 (6)16x25 (6)16x25

- - - (8) 10x12 - -

---(8)15x20--

- - - (16)20x20 - -

Semiannually, check the gas pressure to the burner and to the pilot. Measure
both manifold pressure and pilot supply pressure with the blower in opera­tion. Verify against pressures listed on the rating plate.

Pilot
Regulator

Pilot Solenoid Valve

FIGURE 2 - Gas Pressure

Pilot Pressure Tap

Tap Locations

Valve

Gas

Supply

Inlet Pressure Ta

Valve

Regulator

Form O-DV/RDF/ADF, P/N 148385, Page 3

Manifold Pressure Tap

MAINTENANCE SECTION (cont'd)

4. Air Pressure

S

5. Circuit

R

Indicator
Board (check
lights)

FIGURE 3 - Circuit
Indicator Board,
P/N 151263

Profile plate sensing tubes should be checked quarterly and cleaned no less
than semiannually. If the sensing tubes become even partially blocked, false
pressure readings may be relayed. To clean, remove the screened end caps.
Clean the screens and the tubes, if necessary. Replace the cleaned end caps.
Check the pressure differential across the profile plate using a slope gauge.
Air pressure differential should be between -.25" and -.75" w.c.

To attach the slope gauge, open the control compartment door panel. Just
below the junction box, locate the tubing connections. Remove the cap at
each connection and attach the slope gauge using two field-supplied 1/4" x
1/8" female NPT barbed tubing connections. For instructions on measuring air
pressure, see Service Section, Paragraph 9.

The circuit indicator board is located in the control compartment electrical
box (See FIGURE 7). Check operation of all indicator lights by switching
lights that are not lit with one that is currently lit. Replace any burned out
indicator bulbs (P/N 125189).

Row of Bulbs

Check bulbs not
lit with other
bulbs; replace
any burned out
bulbs.

S

6. Main Burner
and Pilot
Assembly

CAUTION: W ear eye
protection while
pressure cleaning and
drilling.

WARNING: Do not
enlarge burner ports or
performance may be
drastically affected.

Form O-DV/RDF/ADF, P/N 148385, Page 4

For the most part, the burner and pilot are self cleaning. However, if the appli­cation is extremely dirty or dusty, cleaning of the burner and pilot may be
necessary. Inspect the burner annually. Follow these instructions. If it is neces­sary to replace any parts, use only factory-authorized replacements.

1)Turn off the gas and power supply to the system.

2)Remove the door panels in the burner/control cabinet. Locate the pilot.

3)Disconnect the two ignition wires (male and female quick connections)

and disconnect the flame sensor lead at the burner. Remove the setscrew
located in the ignitor tube (setscrew holds the brass bushing in place).
Carefully remove the brass bushing and the ignitor.

Check the hot surface ignitor for cracks or unusual deterioration. Check

the flame rod for integrity. Replace the flame rod (P/N 131188) and/or the
hot surface ignitor (P/N 121865) if not in good condition.

4)Clean the burner and pilot by back-flushing, using high pressure air (40-

80 lbs). Continue until dust particles are completely expelled from both
the upstream and downstream sides of the burner.

If air pressure does not unplug burner orifices or pilot tube, drill burner
orifices with a Size #50 drill and/or pilot tube with a Size #55 drill.

Inspect the upstream and downstream sides of the mixing plates. Remove
any accumulation of scale or foreign material with a wire brush. If any
mixing plate fasteners are loose or missing, tighten or replace. Always use
zinc plated or stainless fasteners.

If any cracks are present, replace that mixing plate. Because of the effect of
flame temperature on the metal, fasteners may be difficult to remove. Be
careful not to damage the gaskets that go between the mixing plates and the

FIGURE 4 - Burner End
Plate showing Hot Surface
Ignitor

NOTE: Model RDF units
manufactured prior to 3/96
have a spark ignition system.
Clean ultraviolet sensor and
spark plug. Replace as
needed.

FIGURE 5 - Direct Fired
Burner

W ARNING: Burner
profile plates are
factory set to match
CFM requirements. Do
not adjust profile plates
without contacting your
Sales Representative
for technical assistance.

Flame Sensor
(not shown)

Ignitor

Location

Pilot Tubing

Burner - Full length of the

burner is made up of a series

of 6" or 12" burner sections in

a linear or oval configuration.

Burner
End Plate

burner body. The gaskets are
designed to overlap approxi­mately 1/16" for airtight seal.

5)Follow Steps in reverse

order to re-install the pilot
assembly. Close all panels
and check for proper
operation.

Mixing

Plates

Burner
End Plate

RE

7. Optional
Evaporative
Cooling Module
(ADF/ADFH only)

Instructions for Replacing
Evaporative Cooling Media

Media - Over time, excessive amounts of mineral deposits will begin to buildup
on the media. Annually, scale and dirt should be washed off the entering sur­face of the media. Remove the pad retainers and screen. (See Steps 1-3 and 6­8 of Media Replacement Instructions.) Clean the media using a garden hose,
mild soap, and a soft bristled brush. When the media becomes too clogged
with mineral deposits and dirt that it cannot be cleaned, the pads should be
replaced. The average pad life is approximately three cooling seasons.

Select the correct replacement part numbers and order media pads from your
Distributor. Follow the instructions below and remove and replace pads as
shown in FIGURE 6.

ADF /
ADFH

300 24 x 12 2 105985 106021 106037 106029

500 24 x 12 3 105985 106021 106037 106029

700/ 48 x 12 4 107190 107194 107199 107201

1200 48 x 8- 5/ 8

1. Remove the three sheetmetal screws that hold the top pad retainer in

2. Remove the three sheetmetal screws that hold the bottom pad retainer in

3. Disengage the screen retainers from the sides of the media.

4. Disengage inlet screen from media pads and remove.

5. Slide all media pads horizontally away from the cooling module until

Media Pad

Sizes

(inches)

24 x 7- 7/ 8

24 x 9- 5/ 8

place. Release the top pad retainer from the cooling module.

place. Release bottom pad retainer from the cooling module.

clear of bottom reservoir pan. Dispose of properly.

Qty

1

1

1

Replacement Part No. (e ach)

Cellulose Fiber Glass Fiber

6" 12" 6" 12"

105986 106022 106038 106030

105989 106025 106041 106033

107191 107195 107200 107202

Form O-DV/RDF/ADF, P/N 148385, Page 5

MAINTENANCE SECTION (cont'd)

45°

Airflow

to Space

Outside

Airflow

7. Optional Evaporative Cooling Module (ADF/ADFH only) (cont'd))

Instructions for Replacing
Evaporative Cooling Media
(cont'd)

6. Replace media by sliding media pads over both support rails until back

stop is encountered. Media must be placed as shown in FIGURE 7.

7. Center screen on the incoming air side of the media.

8. Replace the two side screen retainers by fitting them between the side of
the media pad and the side of the cooling module. The retainers should
fit snugly, pinching the screen against the media pads.

9. Replace the bottom pad retainer by securing the retainer between the pad
and the reservoir pan. Fasten with the three sheet metal screws removed
in Step 2.

10. Replace the top pad retainer by securing the retainer between the pad
and top of the cooling module. Fasten with the three sheet metal screws
removed in Step 1.

FIGURE 6 - Removal and Replacement of
Evaporative Cooling Module Media

Pad

FIGURE 7 ­Media must be
installed
with 45°
angle sloping
downward
toward the
incoming outside
air.

Screen

Pad
Retainer

Screw

Other Evaporative
Cooling Module
Maintenance

IMPORTANT: The
media is made up of two
different sheets of cooling
material. Each sheet has its own unique angle.
When replacing the cooling media, BE CERTAIN
that the 45° angle slopes downward toward the
incoming outside air (as illustrated above). If the
media is not installed properly , water blowoff from
the media pads will occur .

Water Feed Line and PVC Distribution Piping - Annually, the water supply

line and PVC water distribution pipe should be flushed of debris and contami­nants.

1. Remove the media pads following the media replacement instructions.

2. Remove the water feed line from the downstream side of the ball valve

and unscrew the water bleed line barbed hose fitting.

3. Force a fresh water supply through the water inlet hose and thoroughly

flush the distribution pipe.

4. Reassemble being careful to install media with air flow direction as shown

in FIGURE 7.

Water Pump and Inlet Basket Screen (applies to system with float and pump
control) -- Annually, the pump and inlet basket screen should be removed,

disassembled, and cleaned.

Form O-DV/RDF/ADF, P/N 148385, Page 6

WARNING: Do not expose pump motor or any part of the
electrical box to water. Evaporative cooling pump is NOT
submersible.

1. Disconnect the power supply to the unit.

FIGURE 8 - Remove
Junction Box, Pump, and
Float Switch as an Assembly

(Actual assembly may not
appear exactly as in the photo.
Applies to evaporative
cooling module with float and
pump control system only . )

2. Remove the service panel and the junction box door. Disconnect the two­line voltage power supply wires from the terminal block inside the junc­tion box.

3. Disconnect the water feed line hose from the upstream side of the ball
valve.

4. Unscrew the four sheet metal screws holding the junction box to the
cooling module. Remove the junction box-pump-float switch assembly
(See Figure 8).

5. Dislodge the inlet basket screen from the pump and clean any buildup of
debris and dirt. Carefully remove the base cover plate from the bottom of
the pump. Using a mild soap solution, wash all deposits from the inside of
the pump and remove all debris from the impeller.

6. Reassemble the pump. Replace the parts in exact reverse order, being
careful that everything is returned to its proper position.

Pump
Motor

Junction Box (Note: Only 208V unit

will have a transformer in the junction box.)

Float

Switch

Pump

Carefully remove basket and
snap-on cover plate to clean
pump.

REFERENCE: Evaporative Cooling Module Troubleshooting
Guide, Paragraph 20, page 23.

Form O-DV/RDF/ADF, P/N 148385, Page 7