Rheem RGRA SERIES, Installation Instructions Manual

Page 1: ...er 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 Immediately call your gas supplier from a neighbor s...

Page 2: ...exhaust pipe ft of pipe intake air no of elbows intake air ft of pipe exhaust pipe no of elbows exhaust pipe TERMINATIONS DIRECT VENT VERTICAL Intake 12 min above roof snow level Correct relationship...

Page 3: ...nsiderations 5 Venting and Combustion Air Piping 12 Combustion and Ventilation Air 14 Vent Pipe Installation 17 Condensate Drain Neutralizer 27 Converting Downflow to Horizontal 29 Gas Supply and Pipi...

Page 4: ...ble from Canadian Gas Association 55 Scarsdale Road Don Mills Ontario Canada M3B 2R3 24 25 26 27 28 ITEM ITEM NO PART NAME NO PART NAME 1 INDUCED DRAFT BLOWER 15 LOW VOLTAGE TERMINAL 2 CAPACITOR 16 TR...

Page 5: ...ing evaporator coil 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 t...

Page 6: ...rtified by the AGA Laboratories and CGA Laboratories for the clearances to combustible materials shown in inches FIGURE 4 HORIZONTAL FURNACE INSTALLED W SUPPORT BRACKETS GAS PIPE TRAP EXHAUST FAN ELEC...

Page 7: ...MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASO LINE AND OTHER FLAMMABLE VAPORS AND LI...

Page 8: ...25 32 0 0 0 1 2 0 111 06 17 1 2 16 11 32 15 5 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 0 123 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 2...

Page 9: ...13 7 8 0 0 0 1 2 0 111 06 17 1 2 16 11 32 15 5 8 2 16 5 8 13 7 8 0 0 0 1 2 0 117 07 17 1 2 16 11 32 15 5 8 2 16 5 8 13 7 8 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...

Page 10: ...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 10 I520 A service clearance of at least 24 inches is recommended...

Page 11: ...ide or back return air do not remove the bottom base b Cut an opening in the side or back The opening should be cut the full width of the knockouts on the unit c Remove the bottom base if using bottom...

Page 12: ...ORRECT FOR ADEQUATE COMBUSTION AIR SUPPLY DO NOT RESET THE SWITCHES WITHOUT TAKING CORRECTIVE ACTION TO ASSURE THAT AN ADEQUATE SUPPLY OF COMBUSTION AIR IS MAINTAINED UNDER ALL CONDITIONS OF OPERATION...

Page 13: ...ws exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use 7 If improper venting is observed during any of the above tests the common venting system must...

Page 14: ...ure 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 VENTILATI...

Page 15: ...00 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 o...

Page 16: ...free area of a 1 square inch for each 3 000 BTUH of the total input rating of all equipment located in the enclosure and BTUH Free Area Round Pipe Input Each Opening Size 45 000 15 00 square inches 4...

Page 17: ...IRED MINIMUM CLEARANCES TO COMBUSTIBLES ARE MAINTAINED BETWEEN THE PVC PIPE AND OTHER PIPES 5 All vent runs through uncon ditioned spaces where below freezing temperatures are expected should be insul...

Page 18: ...ents are slightly different in some cases than direct venting Install a non direct vent with the following minimum clearances See Figure 16 1 Locate the bottom of the vent terminal at least 12 inches...

Page 19: ...llect wrap the vent pipe with self regulating 3 or 5 watt heat tape The heat tape must be WARNING TABLE 2 FOR DIRECT VENT APPLICATIONS AIR FOR COMBUSTION PROVIDED FROM OUTDOORS MAXIMUM ALLOWABLE LENGT...

Page 20: ...The standard horizontal intake air termination for all models is a 2 in PVC coupling with a wind deflector vane provided attached Cut a 21 4 in length of 2 in PVC pipe Connect this pipe and another 2...

Page 21: ...termination is made with a closed cell insulation such as Arm a Flex or Rub a Tex with a minimum of 1 2 thickness All elbows installed on the exterior of the building must be of the long sweep nature...

Page 22: ...pipe 5 21 2 x 21 long PVC pipe 6 PVC vane 7 3 in tee with reducer assembly 8 6 in dia 1 2 in PVC trap 9 PVC strap 10 vent template NOTE The RXGY D04 kit only applies to the 120 000 BTUH unit using an...

Page 23: ...2 PVC PIPE ON 90 000 THROUGH 120 000 BTUH MODELS REDUCE AND TERMINATE THE LAST 12 INCHES WITH 11 2 PVC PIPE ON 45 000 THROUGH 75 000 BTUH MODELS PITCHED ROOF INSTALLATIONS NOTES SUPPORT HORIZONTAL PIP...

Page 24: ...m horizontal clearance of 4 feet from electric meters gas meters regulators and relief equipment 6 The air inlet shall be located at least 10 feet horizontally from the vent of any other gas or fuel b...

Page 25: ...ntenance 9 Do not expose 3 x 2 reducer bushing to outdoor ambient temperatures MULTIVENTING IF VENTING TWO OR MORE FURNACES NEAR EACH OTHER IS REQUIRED EACH FURNACE MUST BE INDIVIDUALLY VENTED NO COMM...

Page 26: ...p 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 nect it directly to this fitting When 3 in pipe is used connect...

Page 27: ...o that the open end is upward Connect at least a 5 riser to the top of the tee and run a drain tube from the bottom of the tee to a floor drain or condensate pump IMPORTANT If installing the unit over...

Page 28: ...he left Reattach the drain hoses Remove the plastic drainage knockout from the left side See Figure 31 IMPORTANT When changing to the left side interchange the rubber bushing on the right side with th...

Page 29: ...pped factory ready for downflow installation The condensate trap assembly and drain hoses require conversion for horizontal installation Remove the existing condensate trap with the unit in the uprigh...

Page 30: ...IGHT POSITION REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP FIGURE 34 HORIZONTAL POSITION CONDENSATE TRAP INSTALLATION FOR HORIZONTAL OPERATION I534 CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO HORIZONT...

Page 31: ...separate gas supply 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 s...

Page 32: ...furnace and its individual shut off valve from the gas supply piping during any pressure testing that exceeds 1 2 p s i g 3 48 kPa GAS PRESSURE Natural gas supply pressure should be 5 to 7 w c LP gas...

Page 33: ...1 10 mm CANADIAN 0 2000 FT 2001 4500 FT Natural Gas 50 50 LP Gas 1 15 mm 1 15 mm 4 Turn the gas supply back on and check for proper operation and manifold pressure See Figures 39 40 and 41 5 Attach th...

Page 34: ...units on the same gas line as the furnace 4 Note or adjust the line gas pressure to give A 5 7 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 Tu...

Page 35: ...ELECTRICAL SHOCK PERSONAL INJURY OR DEATH IMPORTANT The furnace must be installed so that the electrical components are protected from water condensate Before proceeding with the electrical connection...

Page 36: ...44 ISOLATION RELAY TABLE 5 LOW VOLTAGE WIRING SOLID COPPER WIRE AWG 3 0 16 14 12 10 10 10 2 5 16 14 12 12 10 10 2 0 18 16 14 12 12 10 50 100 150 200 250 300 LENGTH OF RUN FEET The total wire length i...

Page 37: ...7 and Johnson Controls G961DAJ 2401 integrated control boards IMPORTANT TWINNING OF GRJ AND GTJ UNITS REQUIRES AN ACCESSORY TWINNING KIT REFER TO THE SPECIFICATION SHEET FOR PROPER KIT DO NOT ATTEMPT...

Page 38: ...38 FIGURE 45 HONEYWELL NO S9201E2001 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION I400...

Page 39: ...39 FIGURE 46 HONEYWELL NO S9201E2001 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION I401...

Page 40: ...40 FIGURE 47 UTEC NO 1012 920 1028 927 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION I398...

Page 41: ...41 FIGURE 48 UTEC NO 1012 920 1028 927 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION I398...

Page 42: ...42 FIGURE 49 JOHNSON CONTROLS G961DAJ 2401 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION I399...

Page 43: ...43 FIGURE 50 JOHNSON CONTROLS G961DAJ 2401 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION I399...

Page 44: ...e inducer continues and the igniter stays energized 4 If flame is not sensed during the ninth second after the gas valve opens the gas valve closes and the igniter de energizes 5 After a 30 second int...

Page 45: ...er firing beyond its design rated input NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE Use the following table or formula to determine input rate Start the furnace and measure the time required...

Page 46: ...meter in the supply air duct stops rising approximately five minutes subtract the return air temperature from the supply air temperature The difference is the temperature rise 5 Compare the measured t...

Page 47: ...1300 1255 HIGH 1705 1665 1615 1570 1540 1475 1400 RGTA 07 12 X 7 1 2 3 4 LOW 1185 1160 1140 1115 1095 1065 1040 M LO 1405 1375 1350 1310 1270 1235 1195 M HI 1595 1560 1525 1480 1440 1380 1325 HIGH 18...

Page 48: ...LOW 1235 1210 1180 1150 1120 1075 1035 MED 1490 1465 1445 1405 1375 1315 1255 HIGH 1720 1670 1620 1600 1580 1520 1460 RGTJ 09 12 X 11 1 2 LOW 1155 1125 1100 1080 1060 1000 940 MED 1420 1400 1380 1365...

Page 49: ...IN PERSONAL INJURY OR DEATH The blower motor is wired for blower speeds required for normal operation as shown If additional blower speed taps are available leads connected to M1 and M2 on the electr...

Page 50: ...width for a side filter 2 241 2 120 000 BTUH unit requires removal of a 7 segment of filter and frame to get the proper width for a side filter WARNING TABLE 9 FILTER SIZES UPFLOW FILTER SIZES FURNACE...

Page 51: ...GLES AS A GUIDE FOR PROPER SIZE JACKET JACKET ANGLE FILTER ROD SUPPORT ANGLE FILTER SUPPORT ANGLE SEE ANGLE DETAIL ATTACH WITH SHEET METAL SCREWS 2 REQ D ANGLE DETAIL CUT OUT AND DRILL DETAIL ROD FILT...

Page 52: ...uire further attention The blower motor and induced draft blower motor must be cleaned periodically by a qualified installer service agency or the gas supplier to prevent the possibility of overheatin...

Page 53: ...TO IDM MOTOR REPLACE IFC IF WIRING TO IDM MOTOR IS OK REPLACE IDM MOTOR CHECK FOR BLOCKED VENT REPLACE SWITCH CHECK AIR PROVING SWITCH CLOSED CHECK WIRING TO IGNITER REPLACE IFC CHECK FOR 115 VAC AT...

Page 54: ...NIT IF CHECKS ARE OK REPLACE IFC CHECK FOR 115VAC ACROSS REPLACE IFC IF BLOWER MOTOR AND BLOWER WIRING TO BLOWER MOTOR TERMINALS HEAT AND MOTOR IS OK NEUTRAL ON IFC REPLACE BLOWER MOTOR NOTE IF IFC GO...

Page 55: ...R CHECK LOW VOLTAGE TRANSFORMER CHECK IN LINE FUSE ON TRANSFORMER LOW VOLTAGE LINE INTEGRATED FURNACE CONTROL IFC TROUBLESHOOTING GUIDE SPARK IGNITION SYSTEM POWER LED ON IF THE PRESSURE SWITCH DOESN...

Page 56: ...ON IF FLAME CURRENT IS GOOD IT FLASHES IF CURRENT IS MARGINAL TURN POWER OFF TO UNIT CLEAN FLAME SENSOR WITH STEEL WOOL IF LED FLASHES RESTORE POWER TO UNIT IF CHECKS ARE OK REPLACE IFC SYSTEM WILL AT...

Page 57: ...STATIC DISCHARGE CAN DAMAGE INTEGRATED FURNACE CONTROL IFC OK LED BLINKS TO INDICATE EXTERNAL FAULTS 1 BLINK FOLLOWED BY A 2 SEC PAUSE 1 HOUR LOCKOUT 2 BLINKS FOLLOWED BY A 2 SEC PAUSE PRESSURE SWITC...

Page 58: ...CHECK FOR EXCESSIVE HEAT AT IGNITER BASE TEMP ABOVE 1000 F 538 C CAUSES SHORT TO GROUND TURN POWER OFF TO UNIT CLEAN FLAME SENSOR WITH STEEL WOOL RESTORES POWER TO UNIT IF CHECKS ARE OK REPLACE IFC SY...

Page 59: ...59 FIGURE 65 RGRA AND RGTA MODELS WITH HONEYWELL S9201E2001 OR UTEC 1012 920 CONTROL BOARD HSI 34 90 PLUS CONDENSING GAS FURNACE WIRING DIAGRAM...

Page 60: ...60 FIGURE 66 RGRA AND RGTA MODELS WITH UTEC 1028 927 OR JOHNSON CONTROLS G961DAJ 2401 CONTROL BOARD SPARK IGNITION 34 90 PLUS CONDENSING GAS FURNACE WIRING DIAGRAM...

Page 61: ...61 FIGURE 67 RGRJ AND RGTJ MODELS WITH UTEC1012 925 CONTROL BOARD HSI 34 90 PLUS CONDENSING GAS FURNACE WIRING DIAGRAM...

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Page 64: ...64 Rheem Manufacturing Company Air Conditioning Division Fort Smith Arkansas CM 1197...