Nature Air RGRM-04*MAES, Installation Instructions Manual

Page 1: ... EFFICIENCY CONDENSING TWO STAGE GAS FURNACES RGRM RGTM SERIES ISO 9001 2008 U L recognized fuel gas and CO carbon monoxide detectors are recommended in all applications and their installation should be in accordance with the manufacturer s recommendations and or local laws rules regulations or customs ...

Page 2: ... air ______ ft of pipe exhaust pipe ______ no of elbows exhaust pipe ______ Exhaust Vent Temperature TERMINATIONS DIRECT VENT VERTICAL ______ Intake 12 min above roof snow level ______ Correct relationship exhaust to intake HORIZONTAL VERTICAL CONCENTRIC RXGY E03A ______ Intake 12 min above roof snow level ______ Intake Y rotated above center ______ Exhaust sloped toward furnace HORIZONTAL STANDAR...

Page 3: ... natural gas All new equipment shipped for sale in California will have labels stating that the product contains and or produces Proposition 65 chemicals Although we have not changed our processes having the same label on all our products facilitates manufacturing and shipping We cannot always know when or if products will be sold in the California market You may receive inquiries from customers a...

Page 4: ...g National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 GENERAL INFORMATION FIGURE 1 UPFLOW FURNACE COMPONENTS 25 26 ITEM NO PART NAME 1 CONDENSATE TRAP 2 DOOR SWITCH 3 JUNCTION BOX 4 TRANSFORMER 5 PRESSURE SWITCHES 6 EXHAUST TRANSITION 7 CONNECTOR 8 OUTLET AIR PIPE 9 SHIPPING PLUG TO BE REMOVED 10 FLAME SENSOR 11 OVERTEMPERATURE SWITCH 12 TOP PLATE 13 BURNER 14 IGNITER 15 COM...

Page 5: ...E HOME CAUSING PROPERTY DAMAGE FUMES AND ODORS FROM TOXIC VOLATILE OR FLAMMABLE CHEMICALS AS WELL AS AUTOMOBILE EXHAUST AND CARBON MONOXIDE CO CAN BE DRAWN INTO THE LIVING SPACE THROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH SEE FIGURE 2 IF AIR MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN GARAGES OR OFF GARAGE STORAGE AREAS ALL JOINTS SEAMS AND OPENINGS IN THE EQU...

Page 6: ...ide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade dire...

Page 7: ... INCLUDING PROPER VENT INSTALLATION FURNACE OPERATING UNDER THERMOSTATIC CONTROL RETURN AIR DUCT SEALED TO THE FURNACE AIR FILTERS IN PLACE SET FURNACE INPUT RATE AND TEMPERATURE RISE PER RATING PLATE MARKING MEANS FOR PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION RETURN AIR TEMPERATURE MAINTAINED BETWEEN 55 F 13 C AND 80 F 27 C AND CLEAN FURNACE DUCT WORK AND COMPONENTS UPON SUBSTANTIAL COMPLETIO...

Page 8: ...ey must be equipped to prevent heating or cooling operation unless the damper is in the full heat or cool position 3 IMPORTANT Install the furnace level If it is not level condensate cannot drain properly possibly causing furnace shut down NOTE These furnaces are approved for installation in attics as well as alcoves utility rooms closets and crawlspaces Provisions must be made to prevent freezing...

Page 9: ...ce if accessibility clearances are greater than fire protection clearances UPFLOW FURNACES ARE DESIGN CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORS NOTE HOWEVER THAT FURNACES MUST NOT BE INSTALLED DIRECTLY ON CARPETING TILE OR OTHER COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING INSTALLATION ON A COMBUSTIBLE MATERIAL CAN RESULT IN FIRE CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH WARNING THI...

Page 10: ...2 0 123 07B 21 19 27 32 19 1 8 2 18 1 2 17 9 32 0 0 0 1 2 0 145 09 21 19 27 32 19 1 8 2 18 1 2 17 9 32 0 0 0 1 2 0 148 10 21 19 27 32 19 1 8 2 18 1 2 17 9 32 0 0 0 1 2 0 152 12 24 1 2 23 11 32 22 5 8 2 22 20 25 32 0 0 0 1 2 0 160 A service clearance of at least 24 inches is recommended in front of all furnaces SUPPLY AIR RETURN AIR AIRFLOW OPTIONAL RETURN AIR CUTOUT EITHER SIDE BOTH SIDES FOR 1800...

Page 11: ...123 07B 21 19 27 32 19 3 16 2 18 1 2 17 9 32 0 0 0 1 2 0 123 09 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 148 10 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 152 12 24 1 2 23 11 32 22 5 8 2 23 5 8 20 7 8 0 0 0 1 2 0 160 A service clearance of at least 24 inches is recommended in front of all furnaces NOTE IN DOWNFLOW CONFIGURATION RETURN AIR CUTOUT IS NOT PERMITTED AIRFLOW SUPPLY AIR RETU...

Page 12: ... 20 1 8 17 3 8 0 0 0 1 2 0 148 10 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 152 12 24 1 2 23 11 32 22 5 8 2 23 5 8 20 7 8 0 0 0 1 2 0 160 A service clearance of at least 24 inches is recommended in front of all furnaces NOTE In horizontal configuration return air cutout is not permitted Horizontal left hand airflow only IMPORTANT This furnace is not approved or recommended for installation o...

Page 13: ...iciency filters have a greater than normal resistance to air flow This can adversely affect furnace operation BE SURE TO CHECK AIR FLOW AND STATIC PRESSURE IMPORTANT When using outside air design and adjust the system to maintain a return air temperature ABOVE 55 F during the heating season NOTE Return air grilles and warm air registers must not be obstructed or closed UPFLOW UNITS 1 Position the ...

Page 14: ...cut out is not permitted 6 Be sure to have adequate space for the unit filter NOTE DO NOT take return air from bathrooms kitchens furnace rooms garages utility or laundry rooms or cold areas HORIZONTAL UNIT IMPORTANT THIS FURNACE MAY ONLY BE INSTALLED SO AS WHEN FACING THE FRONT OF THE FURNACE SUPPLY AIR IS DISCHARGED ON THE LEFT HAND SIDE 1 Position the unit to minimize long runs of duct or runs ...

Page 15: ...r will move approximately 25 cfm per 100 000 Btu s IMPORTANT No part of the combustion air and vent pipes may run under ground OVERTEMPERATURE SAFETY SWITCHES Furnaces are equipped with safety switches in the control compartment to protect against overtemperature conditions caused by inadequate combustion air supply The switches are located in the burner compartment If a switch is tripped it must ...

Page 16: ...or the other appliances Do not delete or reduce the combustion air supply required by the other gas appliances in this space See Z223 1 National Fuel Gas Code NFPA54 for determining the combustion air requirements for gas appliances An unconfined space must have at least 50 cubic feet volume for each 1 000 BTUH of the total input of all appliances in the space If the open space containing the appl...

Page 17: ... the flue products and are highly corrosive after they condense ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE FAILURE TO DO SO CAN RESULT IN EXPLOSION FIRE PROPERTY DAMAGE CARBON MONOXIDE POISONING PERSONAL INJURY OR DEATH Combustion air requirements are determined by whether the furnace is i...

Page 18: ... Area Round Pipe Input Each Opening Size 45 000 11 25 square inches 4 60 000 15 00 square inches 5 75 000 18 75 square inches 5 90 000 22 50 square inches 6 105 000 26 25 square inches 6 120 000 30 00 square inches 6 b Where communicating with outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch for each 2 000 BTUH of total input rating of all equipment in...

Page 19: ...f the areas of all vent connectors in the confined space If unit is installed where there is an exhaust fan sufficient ventilation must be provided to prevent the exhaust fan from creating a negative pressure Combustion air openings must not be restricted in any manner CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS CONNECTION TO FURNACE IMPORTANT When indoor combustion air is used the inlet air open...

Page 20: ...OF ELBOWS 45 OR 90 Medium Long Radius ONLY 1 2 3 4 5 6 2 Standard 60 55 50 45 000 Alternate 55 50 45 2 Standard 30 25 20 Alternate 25 20 15 60 000 3 Standard 120 120 115 Alternate 120 120 110 3 Standard 45 40 NR 75 000 Alternate NR NR NR 3 Standard 90 85 75 90 000 Alternate 60 50 45 105 000 3 Standard 45 40 NR 120 000 3 Standard 70 65 55 Alternate 40 30 25 NOTES 1 N R NOT RECOMMENDED 2 MAXIMUM OF ...

Page 21: ...ing minimum clearances See Figure 16 1 Locate the bottom of the vent terminal at least 12 inches above grade Increase the 12 in minimum to keep the terminal openings above the level of snow accumulation where applicable 2 The vent shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard 3 4 feet below 4 feet horizontally from or 1 foot ab...

Page 22: ...22 FIGURE 16 OTHER THAN DIRECT VENT TERMINAL CLEARANCES Natural Gas and Propane Installation Code National Fuel Gas Code Canadian Installations US Installations Canadian Installations US Installations ...

Page 23: ...at least 15 between elbows Size the exhaust and combustion air intake pipes as specified in Tables 3 and 4 These tables list the maximum WARNING Standard Concentric RXGY D02 RXGY D02A RXGY E03A GXGY G02 50 40 45 000 2 Alternate RXGY D02 RXGY D02A 50 40 Standard Concentric RXGY D02 RXGY D02A RXGY E03A RXGY G02 40 35 2 Alternate RXGY D02 RXGY D02A 20 15 60 000 3 Standard Concentric RXGY D03 RXGY D03...

Page 24: ...oupling at the wall The outer coupling must terminate 4 inches from the wall IMPORTANT To ensure proper furnace operation the supplied vane must be installed in the vertical position with PVC solvent as shown in Figure 20 Detail B The combustion air inlet terminal must be located with respect to the exhaust terminal as shown in Figure 20 Detail C IMPORTANT All furnaces with horizontal air intakes ...

Page 25: ...D03 D03A with 90 000 BTUH through 120 000 BTUH units The RXGY D04 D04A kit only applies to the 120 000 BTUH unit using an alternate termination and excessively long runs See Tables 3 and 4 The following are parts lists for the RXGY D02 D02A RXGY D03 D03A and RXGY D04 D04A alternate horizontal direct vent termination kits RXGY D02 D02A 1 2 in tee with reducer assembly 2 1 2 in PVC 6 in dia trap 3 P...

Page 26: ...ontal intake air vent runs and may be installed through roofs or sidewalls One 5 diameter hole is required for the installation See Figure 18 for the general layout Complete installation instructions are included with the kit MAINTAIN 12 IN MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL MAXIMUM OF 24 IN ABOVE ROOF NOTE Support must be field installed to secure termination kit to structure ...

Page 27: ...EXHAUST PITCHED ROOF INSTALLATIONS NOTES 1 SUPPORT HORIZONTAL PIPE EVERY FOUR FEET 2 WHEN 3 IN PIPE IS USED REDUCE TO 2 IN BEFORE PENETRATING OUTSIDE WALL 3 18 IN MAXIMUM 2 IN DIAMETER PIPE MAY BE USED INSIDE THE WALL 4 DETAIL A EXHAUST TERMINATION TERMINATE THE LAST 12 INCHES WITH 2 PVC PIPE ON 45 000 AND 120 000 BTUH MODELS 5 INCREASE THE 12 IN MINIMUM ABOVE GRADE TO KEEP TERMINAL OPENINGS ABOVE...

Page 28: ...g appliance or clothes dryer to prevent recirculation of the flue gases into the furnace combustion air inlet The only exception to this requirement is the case of multiventing two or more furnaces which is covered in the section on multiventing in these instructions In addition to the minimum clearances listed above the vent location should also be governed by the following guidelines 1 Do not te...

Page 29: ...29 FIGURE 22 DIRECT VENT TERMINAL CLEARANCES Natural Gas and Propane Installation Code National Fuel Gas Code Canadian Installations US Installations Canadian Installations US Installations ...

Page 30: ...RECOMMENDED MAXIMUM 1 DISTANCE FROM WALL MINIMUM 12 ABOVE GRADE SEE CONCENTRIC VENT INSTALLATION INSTRUCTIONS SEE CONCENTRIC VENT INSTALLATION INSTRUCTIONS TWO PIPE VENTING TWO PIPE VENTING 3 MIN 24 MAX 8 MIN 24 MAX 3 MIN 24 MAX 8 MIN 24 MAX MULTIVENTING IF VENTING TWO OR MORE FURNACES NEAR EACH OTHER IS REQUIRED EACH FURNACE MUST BE INDIVIDUALLY VENTED NO COMMON VENTING IS PERMITTED See Figures 2...

Page 31: ... the pipes and wall Be Sure To Use Silicone Sealant to seal the vent pipe to the vent cap to permit field disassembly for annual inspection and cleaning Also seal all pipe penetrations in wall To prevent possibility of condensate freeze up or recirculation do not install vent kits one above the other FIGURE 25 VENT KIT INSTALLATION OPTIONS EXHAUST AIR INTAKE FIGURE 26 TYPICAL INSTALLATIONS For 450...

Page 32: ...air connection fitting is supplied with the furnace and it must be installed in the furnace by screwing it into the opening Make sure the rubber O ring supplied with the furnace is used with this fitting See Figure 27 DOWNFLOW HORIZONTAL FURNACE The exhaust pipe connection is a 2 in female PVC pipe fitting extending through the right side of the furnace top cover This opening has a pro tective cap...

Page 33: ...model only has a new drain system There is a third port on the drain trap marked by a red cap for the hose attached to the induced draft motor Remove plug in inducer drain hose and remove cap off drain trap before connecting inducer drain hose to drain trap All three hoses MUST be attached during operation of the furnace Be sure all three hoses are secured to the drain trap using the hose clamps p...

Page 34: ...ctions Note the location of the alternate drain hole as shown in Figure 32 To convert to left side drainage remove the long molded hose from the trap Remove the double elbow black molded hose from the trap and exhaust transition and discard Remove the trap from its mounting bracket rotate it 180 degrees and mount in place with the drainage elbow pointing to the left Reattach CUT DRAIN HOSES AS REQ...

Page 35: ...nylon clamp Attach the other end of the rubber elbow to the spout located on the exhaust transition using a white nylon clamp 10 Attach the 90 end of the molded hose to the collector box Clamp the hose tight with white nylon clamp Then attach the long end of the molded hose to the 45 elbow molded into the top of the trap assembly Clamp the hose tight with white nylon clamp IMPORTANT Tighten all cl...

Page 36: ...RIGHT POSITION REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP FIGURE 34 HORIZONTAL POSITION CONDENSATE TRAP INSTALLATION FOR HORIZONTAL OPERATION I534 CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO HORIZONTAL INSTALLATION ...

Page 37: ...l main shut off valve The gas line and manual gas stop must be adequate in size to prevent undue pressure drop and never smaller than the pipe size to the gas valve on the furnace Refer to Table 5 for the recommended gas pipe size See Figure 35 for typical gas pipe connections Install a ground joint union within 3 ft of the cabinet to easily remove the gas valve assembly Install a manual gas stop ...

Page 38: ...tion The minimum gas supply pressure to the gas valve for proper furnace input adjustments is 5 w c for natural gas however 6 to 7 is recommended The minimum gas supply pressure is 11 w c for LP gas ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE THE BURNER ORIFICES MAY OR ...

Page 39: ...ed input selection chart below TO CHANGE BURNER ORIFICE 1 TURN OFF ELECTRICAL POWER AND MAIN GAS SUPPLY BEFORE BEGINNING MODIFICATION FAILURE TO DO SO CAN RESULT IN ELECTRICAL SHOCK OR EXPLOSION CAUSING PROPERTY DAMAGE PERSONAL INJURY OR DEATH 2 Disconnect union ahead of combination gas valve 3 Disconnect leads from gas valve 4 Remove the 4 screws holding the manifold assembly to the main burner a...

Page 40: ...burner compartment access door 4 Run furnace through complete cycle to check operation FIGURE 38 GAS VALVE 60 24394 01 HONEYWELL FIGURE 39 INLET PRESSURE TAP HIGH FIRE MANIFOLD PRESSURE ADJUSTMENT OUTLET PRESSURE TAP LOW FIRE MANIFOLD PRESSURE ADJUSTMENT GAS CONTROL TURN KNOB ON OFF ...

Page 41: ... ANSI NFPA70 OR IN CANADA THE CANADIAN ELECTRICAL CODE CSA C221 OR LOCAL CODES THAT APPLY DO NOT USE GAS PIPING AS AN ELECTRICAL GROUND A GROUND SCREW IS PROVIDED IN THE JUNCTION BOX FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH THIS FURNACE IS EQUIPPED WITH A BLOWER DOOR SAFETY SWITCH DO NOT DISABLE THIS SWITCH FAILURE TO FOLLOW THIS WARNING CAN RESULT IN ELECT...

Page 42: ...r is in operation HUMIDIFIER Line voltage power can be supplied from screw terminal HUM to a line voltage neutral screw terminal on the control board This will power the humidifier during a normal heat sequence after the blower has turned on NOTE Maximum current of 1 0 Amp for each option FIELD INSTALLED OPTIONAL ACCESSORIES THERMOSTAT NOTE Do not use 24 volt control wiring smaller than No 18 AWG ...

Page 43: ... 43 must be affixed in a conspicuous location on the front of the furnace cabinet NOTE This label is supplied in the information packet shipped with each furnace FIGURE 42 BASIC ISOLATION RELAY SEE FIGURE 41 FOR DETAILS ST A0804 01 TABLE 6 FIELD WIRE SIZE FOR 24 VOLT CONTROL CIRCUITS SOLID COPPER WIRE AWG 3 0 16 14 12 2 5 16 14 12 2 0 18 16 14 50 100 150 LENGTH OF RUN FEET Wire length equals twice...

Page 44: ...PERSONAL INJURY OR DEATH IGNITOR PLACEMENT ALIGNMENT LOCATION Ignition failure may be a result of improper ignitor alignment caused during a service call or other work done to the furnace in the field When performing any work on the burner heat exchanger etc the technician must check alignment of the spark ignitor Misalignment of the ignitor could cause a failure to light or rough ignition The cor...

Page 45: ...e inducer and gas valve relays switch to low fire after ignition when a low heat call is present If a high heat call is present at the time of ignition and steady state heat will occur at high fire and there will be no change in operation after ignition Call for 1st stage heat a The R and W thermostat contacts close and the control module runs a self check routine After the control module verifies...

Page 46: ...PUMP OPERATION There is a jumper P6 on the main furnace control board for setting blower off timings See Figure 45 DEHUMIDIFICATION The interface control has two optional 24 volt AC only inputs The B terminal input is provided for heat pump applications This signal comes from a heat pump thermostat and tells the heat pump to switch its reversing valve to heat mode If this B signal is also routed t...

Page 47: ...36 1 LOW HEAT 40 22 2 HIGH HEAT 45 25 0 LOW HEAT 40 22 2 HIGH HEAT 45 25 0 LOW HEAT 40 22 2 HIGH HEAT 45 25 0 LOW HEAT 45 25 0 HIGH HEAT 50 27 8 RGRM 04 MAES RGRM 06 MAES RGRM 07 MAES RGRM 07 YBGS RGRM 09 ZAJS RGRM 10 ZAJS RGRM 12 RAJS RGTM 06 MAES RGTM 07 RBGS RGTM 09 ZAJS RGTM 10 RBJS NOTE Temperature Rise could be adjusted by changing dip switches as shown in Table 10 TABLE 10 HEAT RISE ADJUSTM...

Page 48: ...FM Low 900 CFM Low 1200 CFM Low C OFF ON 800 CFM HI 1000 CFM HI 1400 CFM HI 600 CFM Low 750 CFM Low 1050 CFM Low D ON ON 600 CFM HI 800 CFM HI 600 CFM HI 450 CFM Low 600 CFM Low 1200 CFM Low TABLE 13 OPTIMIZED AIRFLOW OPTIONS SWITCHES 10 11 OF SW1 Switch Air Flow Selection Adjustment A 15 Less cooling Airflow B Normal Cooling Air Flow for Table 11 C On Demand Dehumidification Humidistat controls c...

Page 49: ...ply air temperature The difference is the temperature rise 5 Compare the measured temperature rise to the approved temperature rise range listed on the furnace name plate See Figure 49 If the measured temperature rise is above the approved range the air flow is too low More air must be moved by speeding up the blower by removing restrictions in the duct system or by adding more supply or return ai...

Page 50: ... RESULT IN IMPROPER INSTALLATION ADJUSTMENT SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE ELECTRICAL SHOCK CARBON MONOXIDE POISONING EXPLOSION PROPERTY DAMAGE PERSONAL INJURY OR DEATH TABLE 14 FILTER SIZES UPFLOW FILTER SIZES FURNACE INPUT BOTTOM SIDE QUANTITY WIDTH MBTUH SIZE SIZE 171 2 45 60 75A 153 4 X 25 153 4 X 25 1 21 75B 90 105 191 4 X 25 153 4 X 25 1 241 2 120 223 4 X 25 153 4 X 25 1 D...

Page 51: ...T I332 I FILTER ROD 45 24095 01 FILTER FILTER SUPPORT ANGLE AE 61883 01 FILTER ROD SUPPORT ANGLE AE 60520 01 JACKET DRILL 2 3 16 DIA HOLES 8 000 4 875 1 531 CUT OUT AND DRILL DETAIL R JACKET JACKET ANGLE FILTER ROD SUPPORT ANGLE FILTER SUPPORT ANGLE SEE ANGLE DETAIL ATTACH WITH SHEET METAL SCREWS 2 REQÕD ANGLE DETAIL ROD FILTER SUPPORT ANGLE ASSEMBLY FILTER ROD SUPPORT ANGLE AE 60520 01 FILTER SUP...

Page 52: ...re they have installed the filter s If high efficiency filters or electronic air cleaners are used in the system it is important that the airflow is not reduced to maximize system performance and life Always verify that the system s airflow is not impaired by the filtering system that has been installed by performing a temperature rise and temperature drop test Keep the filter s clean at all times...

Page 53: ...ensity humidity ambient air temperature and other things the CFM actually measured may vary significantly from this target value One Blink represents 100 CFM of target airflow A half blink represents approx 50 CFM When the blink sequence is complete there will be a noticeable pause of approximately one second before the sequence repeats For example if elevent and one half blinks are counted follow...

Page 54: ...54 FIGURE 52 TROUBLESHOOTING CHART or IFC not properly grounded Go To Next Page ...

Page 55: ...55 FIGURE 52 TROUBLESHOOTING CHART CONTINUED ...

Page 56: ...56 CM 1009 FIGURE 53 WIRING DIAGRAM ...