REZNOR X-TSL Indoor Gas Fired Gravity Vented Duct Furnace User Manual

REZNOR X-TSL Indoor Gas Fired Gravity Vented Duct Furnace

Specifications:

• Unit Sizes: 75, 100, 125, 140, 170, 200, 225, 250, 300, 350, 400 (MBTUh)
• Input heating capacity: 75,000 – 400,000 BTUh
• Output heating capacity (80%): 60,000 – 320,000 BTUh
• Air volume with finger-baffles: CFM meter3/hr
• Air volume without finger-baffles: CFM meter3/hr
• Gas connection, natural gas: 1/2 or 3/4 inch
• Gas connection, propane: 1/2 inch
• Flue diameter: 5, 6, 7 (round), 8 (oval), 10 (oval), 12 (oval)
• Full load amps (115V): 0.2 amp
• Unit control amps (24V): 0.3 amp
• Certification: Design-certified by the Canadian Standards Association to ANSI Z83.8a and CSA 2.6

Features:
The Model X duct furnace is a gas-fired, indoor, commercial/industrial, gravity-vented unit. It comes with various factory-installed and field- installed options.

Factory-Installed Options:
AA1, AA2, AB1, AB2, AB3, AB4, AB5, AB6, AC1, AC2, AD1, AD2, AE1, AE2, AF1, AF2, AGA, AG1, AG2, AG3, AG8, AG15, AG21, AH2, AH3, AK1, AK2, AK3, AK9

Field-Installed Options:

• AG7, AG9, CE1, CE2, CL1, CL9, CL22, CL33, CL52, CM1, CM1B, CS1

Installation Codes:
It is important to avoid installing the furnace in extremely drafty areas as it can shorten the life of the heat exchanger and cause safety problems.

Combustion Air Requirements:
The unit is designed to take combustion air from the space in which it is installed and is not intended for connection to an outside combustion air intake duct. Connecting the furnace to an outside combustion air intake duct voids the warranty and can result in hazardous operations.

Product Usage Instructions

Unit Size Selection:
Choose the appropriate unit size based on your heating capacity requirements. Refer to the specifications for available unit sizes and their corresponding heating capacity.

Gas Connection:
For natural gas connection, use a 1/2 or 3/4 inch gas connection depending on the unit model. For a propane gas connection, use a 1/2-inch gas connection.

Flue Installation:
Select the appropriate flue diameter and shape based on your installation requirements. The unit supports flue diameters of 5, 6 (round), 7 (round), 8 (oval), 10 (oval), and 12 (oval). Ensure proper installation of the flue according to the manufacturer’s instructions and applicable codes.

Finger-Baffles:
The unit comes with finger baffles for air volume control. If you require high CFM conversion, the finger-baffles need to be removed. This conversion should only be performed by a qualified service agency per the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction.

Certification and Rating Plate:
The duct furnaces covered in this manual are design-certified by the Canadian Standards Association to ANSI Z83.8a and CSA 2.6 for use with natural or propane gas. The correct firing rate and gas type are indicated on the rating plate attached to the unit. Ensure you refer to the rating plate for electrical characteristics as well.

FAQ:

• Q: Can I connect the furnace to an outside combustion air intake duct?
  A: No, connecting the furnace to an outside combustion air intake duct voids the warranty and can cause hazardous operation. The unit is designed to take combustion air from the space in which it is installed.

• Q: How do I convert to high CFM?
  A: To convert to high CFM, the finger baffles need to be removed. This conversion should only be done by a qualified service agency per the manufacturer’s instructions and applicable codes.

Unit Sizes
These duct furnaces are available in eleven unit sizes based on 75,000–400,000 BTUh input.

Features

• 120V supply
• 80% thermal efficient
• Aluminized-steel burner with SST insert
• Aluminized-steel heat exchanger
• Intermittent spark pilot
• Single-stage combination gas valve (standard)
• Natural gas or propane
• Fan control and high limit safety control
• Horizontal or vertical flue discharge
• Blocked vent safety limit
• Side access for burner and controls
• Designed for field-connection to 24V thermostat for automatic operation

Factory-Installed Options

temperature selector
AG21| Electronic modulation with Maxitrol signal conditioner and gas regulator
AH2| Intermittent spark pilot (not available on propane units)
AH3| Intermittent spark pilot with timed lockout
AK1| 115/1/60 voltage
AK2| 208/1/60 voltage
AK3| 230/1/60 voltage
AK9| 460/1/60 voltage
BG3A–BG3Z| Various relay options
BW1| Air flow pressure proving switch
CGA| Canadian installation rating plate and vent cap
AG7| Electronic modulation with room thermostat
---|---
AG9| Electronic modulation with 2:1 turndown ratio and remote temperature selector
CE1| Manual shutoff valve, natural gas
CE2| Manual shutoff valve, propane
CL1| Single-stage thermostat
CL9| Electronic modulating room override
CL22| Two-stage thermostat
CL33| Two-stage digital thermostat
CL52| Single-stage digital thermostat
CM1| Locking cover for CL1 thermostat
CM1B| Locking cover for CL22 and CL33 thermostats
CN1A–CN3Z| Various remote switch options
CP2, CP3, CP4| Indoor disconnect switches (US only)
CP5–CP8| Outdoor raintight disconnect switches (US only)
CP41, CP58| Indoor disconnect switch (Canada only)
CP42, CP59| Outdoor raintight disconnect switches (Canada only)
CS1| Condensate drain flange

Technical Data

.2
Output heating capacity (80%)| BTUh| 60,000| 80,000| 100,000| 120,000| 140,000| 160,000| 180,000| 200,000| 240,000| 280,000| 320,000
kW| 17 .6| 23 .4| 29 .3| 35 .2| 41 .0| 46 .9| 52 .8| 58 .6| 70 .3| 82 .1| 93 .8

Air volume with finger-baffles

| CFM| 610–

1105

| 815–

1475

| 1020–

1840

| 1225–

2210

| 1430–

2580

| 1635–

2945

| 1840–

3315

| 2045–

3685

| 2455–

4420

| 2865–

5160

| 3275–

5895

meter 3 /hr| 1036–

1877

| 1385–

2506

| 1733–

3126

| 2081–

3755

| 2429–

4383

| 2778–

5003

| 3126–

5632

| 3474–

6261

| 4171–

7509

| 4867–

8767

| 5564–

10,015

Air volume without finger- baffles *****| CFM| 735–

2765

| 980–

3685

| 1225–

4605

| 1475–

5530

| 1720–

6450

| 1965–

7370

| 2210–

8295

| 2455–

9215

| 2945–

11,060

| 3440–

12,900

| 3930–

14,745

meter 3 /hr| 1249–

4698

| 1665–

6261

| 2081–

7824

| 2506–

9395

| 2922–

10,958

| 3338–

12,521

| 3755–

14,093

| 4171–

15,656

| 5003–

18,790

| 5844–

21,916

| 6677–

25,051

Temperature rise| ° F| 50–90
20–75 *
Gas connection, natural gas|

inch

| 1/2| 3/4
Gas connection, propane| 1/2
Flue diameter (and shape)| 5

(round)

| 6

(round)

| 7

(oval)

| 8

(oval)

| 8

(round)

| 10

(oval)

| 12

(oval)

Full load amps (115V)| ****

amp

| 0 .2
Unit control amps (24V)| 0 .3
***** High CFM conversion requires removal of the finger baffles . This conversion shall be done by a qualified service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction .

Certification

The duct furnaces covered in this manual are design-certified by the Canadian Standards Association to ANSI Z83.8a and CSA 2.6 for use with either natural or propane gas. The type of gas for which the furnace is equipped and the correct firing rate are shown on the rating plate attached to the unit. Electrical characteristics are shown on the unit rating plate.

Installation Codes

These units must be installed in accordance with local building codes. In the absence of local codes, in the United States, the unit must be installed in accordance with the National Fuel Gas Code (NFPA54/ANSI Z223.1, latest edition). A Canadian installation must be in accordance with the Installation Code for Gas Burning Appliances and Equipment (CAN/CGA B149.1). These codes are available from CSA Information Services, 1-800-463-6727. Local authorities having jurisdiction should be consulted before installation is made to verify local codes and installation procedure requirements.

Special installations (aircraft hangars/garages):
Installations in aircraft hangars should be in accordance with the Standard for Aircraft Hangars (ANSI/NFPA No. 409, latest edition), in public garages in accordance with the Standard for Parking Structures, (ANSI/NFPA No. 88A, latest edition), and for repair garages in accordance with the Standard for Repair Garages (ANSI/NFPA No. 88B, latest edition). The latest edition of ANSI/NFPA-88 specifies that overhead heaters must be installed at least 8 feet above the floor. In Canada, installations in aircraft hangars should be in accordance with the requirements of the enforcing authorities and in public garages in accordance with CSA B149 codes.

Unit Location

WARNING
Avoid installing a furnace in extremely drafty areas. Extreme drafts can shorten the life of the heat exchanger and/or cause safety problems.

• A duct furnace is designed for connection to an inlet and an outlet duct and depends on an external air handler. Location must be in accordance with Clearances section.
• There are a variety of factors such as system application, building structure, dimensions, and weight that contribute to selecting the location. Read the installation information in this manual and select a location that complies with the requirements.

Combustion Air Requirements

WARNING
The unit is designed to take combustion air from the space in which it is installed and is not designed for connection to an outside combustion air intake duct. Connecting this furnace to an outside combustion air intake duct voids the warranty and could cause hazardous operation.

• Requirements for combustion air and ventilation air depend upon whether the unit is located in a confined or unconfined space. A confined space is defined as a space whose volume is <50 cubic feet per 1,000 BTUh of the installed appliance input rating. An unconfined space is defined as a space whose volume is ≥50 cubic feet per 1,000 BTUh of the installed appliance input rating.
• Sufficient air must enter the equipment location to replace the air exhausted through the vent system. Refer to the installation manual for further information on confined spaces and combustion air requirements.

Hazards of Chlorine

NOTE:
Remember, chlorine is heavier than air. This fact should be kept in mind when determining the installation location of heaters and building exhaust systems.

The presence of chlorine vapors in the combustion air of heating equipment presents a potential corrosion hazard. Chlorine, found usually in the form of Freon or degreaser vapors, when exposed to flame will precipitate from the compound and form a solution with any condensation present in the heat exchanger or associated parts. The result is hydrochloric acid, which readily attacks all metals, including 300 grade stainless steel. Care should be taken to separate these vapors from the combustion process. This may be done by wise location of the unit with regard to exhausters or prevailing wind directions.

Venting Requirements

• Safe operation of any gas-fired equipment requires a properly operating vent system, correct provision for combustion air, and regular maintenance and inspection.
• Install the vent in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code (ANSI Z223.1, latest edition) or an applicable provision of national, state, or local codes. A Canadian installation must be in accordance with the Installation Code for Gas Burning Appliances and Equipment (CSA B149.1) and applicable local codes.
• Refer to the installation manual for further information on venting requirements.

Vent Configuration

| Vent Pipe Diameter (Inches)| Vertical Height of Vent (Feet (Meters))
---|---|---
6 (1.8)| 8 (2.4)| 10 (3.0)| 15 (4.6)| 20 (6.1)| 30 (9.1)
Maximum Horizontal Run (Feet (Meters))
Double-wall type B connector and double-wall

type B vent

| 5| 6 (1 .8)| 8 (2 .4)| 10 (3 .0)| 16 (4 .9)| 20 (6 .1)| 20 (6 .1)
6| 16 (4 .9)| 30 (9 .1)| 40 (12 .2)
7 or 8| 6 (1 .8)| 16 (4 .9)| 20 (6 .1)| 30 (9 .1)| 30 (9 .1)| 40 (12 .2)
10 or 12

Single-wall metal pipe

| 5| 2 (0 .6)| 5 (1 .5)| 5 (1 .5)| 5 (1 .5)| —|

—

6| 10 (3 .0)| 10 (3 .0)| 10 (3 .0)
7| 2 (0 .6)| 10 (3 .0)| 15 (4 .6)| 15 (4 .6)| 15 (4 .6)
8, 9, 10, or 12| 20 (6 .1)| 20 (6 .1)

Ductwork Requirements

CAUTION

• Joints where ducts attach to furnace must be sealed securely to prevent air leakage into draft hood or burner rack area. Leakage can cause poor combustion, poor performance, and pilot problems and can shorten heat exchanger life.
• IMPORTANT: A minimum horizontal duct length of 18 inches (457 mm) is required at the furnace discharge before any vertical rise is made in front of the draft hood relief opening. This is required to prevent interference with the built-in draft hood.

Refer to the installation manual for further information on ductwork requirements.

Clearances
The unit must be installed so that clearances are provided for combustion air space, for convenient installation and burner control service, and for proper spacing from combustible construction. Clearance to combustibles is defined as the necessary minimum distance from the heater to a surface or object that ensures that a surface temperature does not exceed 90°F above the surrounding ambient temperature. Units must be installed so that clearances are as follows:

***** To have sufficient space to remove the drawer-type burner rack.

Dimensions

NOTES:

Inches (mm)

• Standard airflow may be reversed by changing direction of heat exchanger air baffles.
• Burner and control access shown left-hand side. Specify right-hand side for opposite access and connections.

Inches (mm)
A| 35 (889)| 35-3/4 (908)| 36 (914)
B| 14-1/4 (362)| 17 (432)| 19-3/4 (502)| 22-1/2 (572)| 25-1/4 (641)| 28 (711)| 33-1/2 (851)| 39 (991)| 44-1/2 (1130)
C| 35-11/16 (906)| 38-1/8 (968)
D| 14-5/8 (371)| 17-3/8 (441)| 20-1/8 (511)| 22-7/8 (581)| 25-5/8 (651)| 28-3/8 (721)| 33-7/8 (860)| 39-3/8 (1000)| 44-7/8 (1140)
E| 4-3/8 (111)| 7-1/8 (181)| 9-7/8 (251)| 12-5/8 (321)| 15-3/8 (391)
F| 4 (102)| 5 (127)| 6 (152)
H| 5/8 (16)| 1-3/8 (35)| 1-5/8 (41)
J| 12-1/2 (318)| 15-1/4 (387)| 18 (457)| 20-3/4 (527)| 23-1/2 (597)| 26-1/4 (667)| 31-3/4 (806)| 37-1/4 (946)| 42-3/4 (1086)
K| 7-1/4 (184)| 9-9/16 (243)
L| 7-7/16 (189)| 7-5/8 (194)
M| 4-5/8 (117)| 6 (152)| 7-3/8 (187)| 8-3/4 (222)| 10-1/8 (257)| 11-1/2 (292)| 13-7/8 (352)| 16-5/8 (422)| 19-3/8 (492)

Weights

Type

| Unit Size (MBTUh)
---|---
75, 100| 125| 150| 175| 200| 225| 250| 300| 350| 400
Pounds (kg)
Unit| 150 (68)| 163 (74)| 182 (83)| 186 (84)| 224 (102)| 231 (105)| 276 (125)| 286 (130)| 320 (145)| 355 (161)
Shipping| 170 (77)| 200 (91)| 220 (100)| 230 (104)| 275 (125)| 290 (132)| 350 (159)| 360 (163)| 390 (177)| 420 (191)

Duct Furnace Airflow

• The duct furnace must be installed on the positive pressure side of the field-supplied blower.
• The air distribution must be even over the entire heat exchanger. Turning vanes should be employed in elbows or turns in the air inlet to ensure proper air distribution.
• The air throughput must be within the CFM range stated on the heater rating plate.
• If it is determined that the blower CFM is greater than allowed or desirable, refer to the installation manual for determining the correct size of bypass duct required or for instructions on converting the furnace for a higher CFM application.
• To determine temperature rise, the inlet and outlet air temperatures should be measured at points not affected by heat radiating from the heat exchanger. The following table lists the approved temperature rise range with the required CFM and the internal pressure drop for each size of unit.

CFM/Pressure Drop (IN WC)
80% Thermal Efficient
50°F| 1105/0 .23| 1475/0 .43| 1840/0 .50| 2210/0 .38| 2580/0 .52| 2945/0 .42| 3315/0 .53| 3685/0 .40| 4420/0 .58| 5160/0 .65| 5895/0 .67
60°F| 920/0 .15| 1225/0 .29| 1535/0 .33| 1840/0 .26| 2150/0 .35| 2455/0 .28| 2765/0 .36| 3070/0 .28| 3685/0 .39| 4300/0 .44| 4915/0 .45
70°F| 790/0 .10| 1050/0 .21| 1315/0 .25| 1580/0 .19| 1840/0 .26| 2105/0 .22| 2370/0 .27| 2630/0 .23| 3160/0 .29| 3685/0 .31| 4210/0 .32
80°F| 690/0 .06| 920/0 .15| 1150/0 .21| 1380/0 .15| 1610/0 .19| 1840/0 .17| 2070/0 .22| 2300/0 .22| 2765/0 .25| 3225/0 .25| 3685/0 .25
90°F| 610/0 .04| 815/0 .11| 1020/0 .18| 1225/0 .12| 1430/0 .16| 1635/0 .14| 1840/0 .17| 2045/0 .21| 2455/0 .22| 2865/0 .23| 3275/0 .19
With Finger Baffles Removed
20°F| 2765/0 .62| 3685/1 .08| 4605/1 .16| 5530/0 .85| 6450/1 .19| 7370/1 .00| 8295/1 .28| 9215/0 .90| 11,060/1 .26| 12,900/1 .23| 14,745/1 .23
30°F| 1840/0 .28| 2455/0 .5| 3070/0 .53| 3685/0 .39| 4300/0 .54| 4915/0 .45| 5530/0 .58| 6140/0 .41| 7370/0 .57| 8600/0 .56| 9830/0 .56
40°F| 1380/0 .16| 1840/0 .28| 2300/0 .28| 2765/0 .21| 3225/0 .29| 3685/0 .25| 4145/0 .31| 4605/0 .22| 5530/0 .32| 6450/0 .31| 7370/0 .31
50°F| 1105/0 .12| 1475/0 .16| 1840/0 .21| 2210/0 .15| 2580/0 .18| 2945/0 .16| 3315/0 .21| 3685/0 .15| 4420/0 .21| 5160/0 .19| 5895/0 .19
60°F| 920/0 .10| 1225/0 .14| 1535/0 .15| 1840/0 .12| 2150/0 .15| 2455/0 .12| 2765/0 .15| 3070/0 .11| 3685/0 .15| 4300/0 .14| 4915/0 .15
75°F| 735/0 .10| 980/0 .12| 1225/0 .12| 1475/0 .11| 1720/0 .12| 1965/0 .11| 2210/0 .12| 2455/0 .08| 2945/0 .11| 3440/0 .11| 3930/0 .11

Gas Supply

Gas Supply Pressure
The unit is equipped for a maximum gas supply pressure of 1/2 psi, 3.4 kPa, or 14 IN WC.

NOTES:
Supply pressure higher than 1/2 psi requires the installation of an additional service regulator external to the unit.

PRESSURE TESTING SUPPLY PIPING

• Test pressures above 1/2 psi—disconnect the heater and manual valve from the gas supply line to be tested. Cap or plug the supply line.
• Test pressures below 1/2 psi—before testing, close the manual valve on the heater.

Gas Supply Piping

• All piping must be in accordance with requirements outlined in the National Fuel Gas Code (ANSI/Z223.1, latest edition) or the Natural Gas and Propane Installation Code (CSA B149.1).
• Duct furnaces are orificed for operation with natural gas having a heating value of 1,000 (±50) BTU per cubic foot or with propane gas having a heating value of 2,500 (±100) BTU per cubic foot. Sizing of gas supply lines depends on piping capacity and is based on cubic feet per hour based on a 0.3 IN WC pressure drop, a 0.6 specific gravity for natural gas at 1,000 BTU per cubic feet, and a 1.6 specific gravity for propane at 2,550 BTU per cubic feet. If the gas at the installation does not meet this specification, consult the factory for proper orificing.
• Variables for sizing gas supply lines are listed in the table below. When sizing supply lines, consider the possibility of future expansion and increased requirements. Refer to the National Fuel Gas Code for additional information on line sizing.

Length of Pipe (Feet)

| Diameter of Pipe (Inches)
---|---
1/2| 3/4| 1| 1- 1/4| 1- 1/2| 2
Natural Gas| Propane| Natural Gas| Propane| Natural Gas| Propane| Natural Gas| Propane| Natural Gas| Propane| Natural Gas| Propane
Cubic Feet per Hour
20| 92| 56| 190| 116| 350| 214| 730| 445| 1100| 671| 2100| 1281
30| 73| 45| 152| 93| 285| 174| 590| 360| 890| 543| 1650| 1007
40| 63| 38| 130| 79| 245| 149| 500| 305| 760| 464| 1450| 885
50| 56| 34| 115| 70| 215| 131| 440| 268| 670| 409| 1270| 775
60| 50| 31| 105| 64| 195| 119| 400| 244| 610| 372| 1105| 674
70| 46| 28| 96| 59| 180| 110| 370| 226| 560| 342| 1050| 641
80| 43| 26| 90| 55| 170| 104| 350| 214| 530| 323| 990| 604
90| 40| 24| 84| 51| 160| 98| 320| 195| 490| 299| 930| 567
100| 38| 23| 79| 48| 150| 92| 305| 186| 460| 281| 870| 531
125| 34| 21| 72| 44| 130| 79| 275| 168| 410| 250| 780| 476
150| 31| 19| 64| 39| 120| 73| 250| 153| 380| 232| 710| 433
175| 28| 17| 59| 36| 110| 67| 225| 137| 350| 214| 650| 397
200| 26| 16| 55| 34| 100| 61| 210| 128| 320| 195| 610| 372

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.
• 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.

For more information on Reznor HVAC products:

• Contact your local Reznor representative at 1-800-695-1901
• Refer to the manuals and additional consumer materials found at www.reznorhvac.com.

Specifications and illustrations subject to change without notice or incurring obligations. Latest version of this document is available at www.reznorhvac.com.
©2023 Nortek Global HVAC LLC, O’Fallon, MO. All rights reserved.
X-TSL (10-23) REV-A

References

• Reznor HVAC

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