Rheem (-)GRC-04EMAES, Installation Instructions Manual

Page 1: ...EFFICIENCY CONDENSING GAS FURNACES GRC GTC SERIES U L recognized fuel gas and CO carbon monoxide detectors are recommended in all applications and their installation should be in accordance with the m...

Page 2: ...er exhaust pipe ft of pipe intake air no of elbows intake air ft of pipe exhaust pipe no of elbows exhaust pipe Exhaust vent temp TERMINATIONS DIRECT VENT VERTICAL Intake 12 min above roof snow level...

Page 3: ...N AIR TEMPERATURE MAINTAINED BETWEEN 55 F 13 C AND 80 F 27 C AND CLEAN FURNACE DUCT WORK AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS AND VERIFY FURNACE OPERATING CONDITIONS...

Page 4: ...gases but identified special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance...

Page 5: ...ls known to the State of California to cause cancer or birth defects such as fiberglass insulation lead in brass and combustion products from natural gas All new equipment shipped for sale in Californ...

Page 6: ...149 is available from CSA INTERNATIONAL 178 Rexdale Blvd Toronto Ontario Canada M9W 1R3 GENERAL INFORMATION FIGURE 1 UPFLOW FURNACE FIGURE 2 DOWNFLOW HORIZONTAL FURNACE ITEM ITEM NO PART NAME NO PART...

Page 7: ...SEALED TO PREVENT DEPRESSURIZATION OF THE SPACE AND POSSIBLE MIGRATION OF COMBUSTION BYPRODUCTS INCLUDING CARBON MONOXIDE INTO THE LIVING SPACE IMPROPER INSTALLATION OR INSTALLATION NOT MADE IN ACCORD...

Page 8: ...with this furnace a be sure the air passes over the heat exchanger before passing over the cooling coil The cooled air passing over the warm ambient air inside the heat exchanger tubes can cause cond...

Page 9: ...or crawl space installation it may be installed on combustible wood flooring or by using support brackets See Figure 5 5 IMPORTANT If installing in a utility room be sure the door is wide enough to a...

Page 10: ...8 2 15 13 25 32 0 0 0 1 2 0 117 07 17 1 2 16 11 32 15 5 8 2 15 13 25 32 0 0 0 1 2 0 124 07 21 19 27 32 19 3 16 2 18 1 2 17 3 8 0 0 0 1 2 0 137 09 21 19 27 32 19 1 8 2 18 1 2 17 9 32 0 0 0 1 2 0 148 1...

Page 11: ...5 8 2 16 5 8 13 7 8 0 0 0 1 2 0 117 07 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 137 09 21 19 11 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 148 10 24 1 2 23 11 32 22 5 8 2 23 5 8 20 7 8 0 0 0 1 2 0...

Page 12: ...6 5 8 13 7 8 0 0 0 1 2 0 117 07 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 137 09 21 19 27 32 19 3 16 2 20 1 8 17 3 8 0 0 0 1 2 0 148 10 24 1 2 23 11 32 22 5 8 2 23 5 8 20 5 8 0 0 0 1 2 0 160 A s...

Page 13: ...ition the unit to minimize long runs of duct or runs of duct with many turns and elbows 2 Open the return air compartment UPFLOW FURNACE A SOLID METAL BASE PLATE MUST BE INSTALLED IN THE FURNACE BOTTO...

Page 14: ...Standards Institute ANSI and American Society for Testing Materials ASTM standards as shown below VENTING AND COMBUSTION AIR PIPING WARNING 4 Connect the furnace to the supply air plenum 5 Connect the...

Page 15: ...system serving other appliances the vent system is likely to be too large to properly vent the remaining attached appliances The following steps should be followed with each appliance remaining connec...

Page 16: ...temperature of 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...

Page 17: ...losure BTUH Free 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...

Page 18: ...the outdoors or spaces crawl or attic that freely communicate with the outdoors and shall have a minimum free area of a 1 square inch for each 3 000 BTUH of the total input rating of all equipment loc...

Page 19: ...pipe and other pipes 5 All vent runs through unconditioned spaces where below freezing temperatures are expected should be insulated with 1 in thick medium density foil faced fiberglass An equivalent...

Page 20: ...IMPROPER LOCATION OR INSTALLATION CAN CAUSE STRUCTURAL OR EXTERIOR FINISH DAMAGE TO THE BUILDING Non direct venting location requirements are slightly different in some cases than direct venting Insta...

Page 21: ...21 FIGURE 17 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 22: ...be used for all furnace inputs as related to the number of elbows required and the termination see shaded area 7 The maximum exposed vent length above the roof line is 30 WARNING Standard Concentric...

Page 23: ...solvent IMPORTANT To ensure proper furnace operation the supplied vane must be installed in the vertical position as shown in Figure 21 Detail B The combustion air inlet terminal must be located with...

Page 24: ...d number of elbows See Table 2 The following are parts lists for the RXGY D02 or D02A RXGY D03 or D03A alternate horizontal direct vent termination kits RXGY D02 D02A 1 2 in tee with reducer assembly...

Page 25: ...L CONCENTRIC VENT KIT NO RXGY E03A This kit is for vertical horizontal intake air vent runs and may be installed through roofs and sidewalls One 5 diameter hole is required for the installation See Fi...

Page 26: ...EVERY 6 FEET 5 EXHAUST TERMINATION TERMINATE THE LAST 12 INCHES WITH 2 PVC PIPE ON 45 000 AND 105 000 BTUH MODELS 6 30 MAXIMUM EXPOSED VENT LENGTH PITCHED ROOF INSTALLATIONS NOTES 1 SUPPORT HORIZONTA...

Page 27: ...27 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 28: ...bustion air inlet minimum of 3 feet from the vent of any other gas or fuel burning appliance or clothes dryer to prevent recirculation of the flue gases into the furnace combustion air inlet The only...

Page 29: ...IS PERMITTED See Figures 24 and 25 for positioning of the terminations When more than two furnaces are to be vented there must be at least 4 feet between the first two furnaces and the third etc FIGUR...

Page 30: ...prevent possibility of condensate freeze up or recirculation do not install vent kits one above the other NOTE The vent illustration in Figure 27 can be used for Non direct vent terminations also FIG...

Page 31: ...pe fitting extending through the right side of the furnace top cover This opening has a pro tective cap which should be removed just prior to installing the exhaust pipe When 2 in pipe is used con nec...

Page 32: ...drain or condensate pump IMPORTANT If installing the unit over a finished ceiling or living area be certain to install an auxiliary condensate drain pan under the entire unit extending out under the...

Page 33: ...with the 1 5 8 diameter plug that is also supplied in the RXGY H01 downflow alternate drain kit Both the hole plug and grommet must be in place to insure a good seal in the burner compartment A lengt...

Page 34: ...ort the trap mounting bracket Remove the two plastic plugs on either side of the trap outlet hole and discard 4 Remove the black molded 90 hose from the top of the existing trap and from the furnace c...

Page 35: ...IGHT POSITION REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP FIGURE 36 HORIZONTAL POSITION CONDENSATE TRAP INSTALLATION FOR HORIZONTAL OPERATION I534 CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO HORIZONT...

Page 36: ...upply line directly from the meter to the furnace Consult the local gas company for the location of the manual main shut off valve The gas line and manual gas valve must be adequate in size to prevent...

Page 37: ...operation IMPORTANT ENSURE that the furnace gas control valve not be subjected to high gas line supply pressures DISCONNECT the furnace and its individual shut off valve from the gas supply piping dur...

Page 38: ...lected based on the reduced input selection chart below To change orifice spuds for either conversion to LP or for elevation 1 Shut off the manual main gas valve and remove the gas manifold 2 Replace...

Page 39: ...the same gas line as the furnace 4 Note or adjust the line gas pressure to give A 5 10 5 w c for natural gas B 11 13 w c for LP gas 5 Shut off the gas at the manual gas valve and remove the U Tube ma...

Page 40: ...42 MANIFOLD PRESSURE READING FIGURE 43 UPFLOW GROUNDING CONNECTIONS JUNCTION BOX CONDENSATE TRAP CONTROL IS GROUNDED WHEN ATTACHED TO BLOWER LOW VOLTAGE TERMINALS IFC MOUNTING PLATE BLOWER COMPARTMEN...

Page 41: ...ncy and phase corresponds to that specified on the furnace rating plate For single furnace application maximum over current protection is 15 amperes Use a separate fused branch electrical circuit cont...

Page 42: ...cted to the thermostat b The 24 VAC supply to both control boards must be in phase with each other c Connect the C W and TWIN terminals to counterparts on each control d Both control boards must have...

Page 43: ...43 FIGURE 46 UT Electronic Controls 1028 928 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION Control Board 1 Control Board 2...

Page 44: ...44 FIGURE 47 UT ELECTRONIC CONTROLS 1028 928 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION Control Board 1 Control Board 2...

Page 45: ...n Table 8 is based on a heating value of 1000 BTU per cubic feet of natural gas and 2500 BTU per cubic feet of LP gas IMPORTANT Actual input rates must be measured on site with manifold pressure adjus...

Page 46: ...zed 4 If flame is not sensed during the 8th second after the gas valve opens the gas valve closes and the igniter de energizes 5 After a 10 second post purge the inducer stops and the control verifies...

Page 47: ...UT RATE The furnace is shipped from the factory with 50 orifices They are sized for natural gas having a heating value of 1075 BTU cu ft and a specific gravity of 60 Since heating values vary geo grap...

Page 48: ...erature rise 5 Compare the measured temperature rise to the approved temperature rise range listed on the furnace name plate See Figure 50 If the measured temperature rise is above the approved range...

Page 49: ...2 x 11 Med Hi 1710 1665 1620 1570 1540 1475 1410 305 x 279 High 2010 1955 1900 1855 1810 1710 1610 Low 794 765 735 704 672 633 594 GTC 04 1 2 373 Med Lo 890 866 842 811 779 750 721 EMAES 11 x 7 Med Hi...

Page 50: ...tegrated furnace control Do not connect anything to H or C GAS FURNACE DIRECT DRIVE INSTRUCTIONS FOR CHANGING BLOWER SPEED DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE T...

Page 51: ...y thoroughly and reinstall NOTE Some filters must be resized to fit certain units and applications See Table 11 and Figures 54 and 55 1 21 90 000 105 000 BTUH units require removal of a 3 5 in segment...

Page 52: ...WITH SHEET METAL SCREWS 2 REQ D ANGLE DETAIL CUT OUT AND DRILL DETAIL ROD FILTER SUPPORT ANGLE ASSEMBLY FILTER AND ROD ASSEMBLY FILTER ROD SUPPORT ANGLE FILTER SUPPORT ANGLE FILTER FILTER ROD JACKET I...

Page 53: ...ions the air filters should be kept clean Dirty filters can restrict airflow The motor depends upon sufficient air flowing across and through it to keep from overheating SYSTEM OPERATION INFORMATION A...

Page 54: ...ring ignition trial If yes go to F Did a limit open during ignition trial If yes go to D Check line voltage between HEAT and NEUTRAL on IFC Check wires connections and continuity between IFC and IBM C...

Page 55: ...FIGURE 57 GRC MODELS WITH UT ELECTRONIC CONTROLS 1028 928 SPARK IGNITION 55...

Page 56: ...FIGURE 58 GTC MODELS WITH UT ELECTRONIC CONTROLS 1028 928 SPARK IGNITION 56 CM 0709...