Rheem RGRK SERIES, Installation Instructions Manual

Page 1: ...FICIENCY CONDENSING TWO STAGE GAS FURNACES RGRK RGRL AND RGTK SERIES ISO 9001 2008 U L recognized fuel gas and CO carbon monoxide detectors are recommended in all applications and their installation s...

Page 2: ...ke 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 relat...

Page 3: ...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 labe...

Page 4: ...rch Park Quincy MA 02269 GENERAL INFORMATION FIGURE 1 UPFLOW FURNACE COMPONENTS ITEM NO PART NAME 1 CONDENSATE TRAP 2 DOOR SWITCH 3 JUNCTION BOX 4 TRANSFORMER 5 PRESSURE SWITCHES 6 EXHAUST TRANSITION...

Page 5: ...THE 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 DUC...

Page 6: ...OOR 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 COMPLETION OF THE CONSTRUCTION PROCESS AND...

Page 7: ...l horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor...

Page 8: ...om passing over the heat exchanger If these are manual dampers they must be equipped to prevent heating or cooling operation unless the damper is in the full heat or cool position 3 IMPORTANT Install...

Page 9: ...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...

Page 10: ...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...

Page 11: ...23 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...

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...

Page 13: ...flow This can adversely affect furnace operation BE SURE TO CHECK AIR FLOW IMPORTANT When using outside air design and adjust the system to maintain a return air temperature ABOVE 55 F during the hea...

Page 14: ...ut 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...

Page 15: ...91 NOTE With the furnace correctly vented the inducer 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 SAFET...

Page 16: ...r 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...

Page 17: ...e 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...

Page 18: ...nput 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...

Page 19: ...s 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 C...

Page 20: ...d the exhaust pipe a minimum of 18 from the cabinet before turning vent 8 Vent cannot be ran underground FIGURE 14 TEE TERMINAL FOR STANDARD HORIZONTAL NON DIRECT INSTALLATION VENT 12 12 MIN ABOVE GRA...

Page 21: ...lowing 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 accumul...

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: ...Concentric RXGY D03 RXGY D03A RXGY E03A RXGY G02 45 40 NA 105 000 3 Alternate RXGY D03 RXGY D03A 45 40 NA Standard Concentric RXGY D03 RXGY D03A RXGY E03A RXGY G02 45 35 30 120 000 3 Alternate RXGY D...

Page 24: ...E03 E03A must have a drain tee assembly and trap installed as close to the furnace as possible This is to drain any water that may be in the combustion air pipe to prevent it from entering the furnac...

Page 25: ...s may use kits XGY D02 D02A or XGY D03 D03A depending on pipe lengths and number of elbows Use kit XGY D03 D03A with 90 000 BTUH downflow through 120 000 BTUH units or upflow 90 000 or 120 000 The XGY...

Page 26: ...tal 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 ar...

Page 27: ...XHAUST 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...

Page 28: ...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 whi...

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: ...ECOMMENDED 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 MA...

Page 31: ...ti venting No common venting NOTE Install the vent and air intake piping into the vent plate openings Seal all gaps between the pipes and wall Be Sure To Use Silicone Sealant to seal the vent pipe to...

Page 32: ...ir 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 fitti...

Page 33: ...w 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 dr...

Page 34: ...above the tee a blocked drain will result in overflow from the riser FURNACE SHUTDOWN To cause the furnace to shut down when a blocked drain is present install a riser which is a minimum of 51 2 If th...

Page 35: ...ylon 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...

Page 36: ...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 37: ...op 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 6 for the recommended gas pipe size See Figure 35 for typ...

Page 38: ...d with all other gas fired appliances in operation 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 mini...

Page 39: ...drill size orifice required Part 62 22175 60 Example 2 1 15mm drill size orifice required Part 62 22175 91 NOTE Do not plug or drill out orifices BTU Input per Orifice Altitude burner 15000 Size 0 to...

Page 40: ...U Tube manometer to this pressure tap See Figure 39 3 Turn on the gas supply and operate the furnace in high heat mode 4 Note or adjust the manifold gas pressure to give A 3 5 w c for natural gas high...

Page 41: ...41 FIGURE 39 TYPICAL MANIFOLD PRESSURE READING...

Page 42: ...0 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 E...

Page 43: ...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...

Page 44: ...single stage thermostat OPTION A To run both units together as a single stage furnace with NO staging 100 high heat always wire the two furnaces together as shown in Figure 43 Both controls must have...

Page 45: ...45 FIGURE 43 UT Electronic Controls 1095 201 IFC TWINNING CONNECTION SINGLE STAGE OPERATION...

Page 46: ...46 FIGURE 44 UT ELECTRONIC CONTROLS 1095 202 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION...

Page 47: ...47 FIGURE 45 UT ELECTRONIC CONTROLS 1095 202 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION...

Page 48: ...ALTITUDE KIT Installer must make necessary burner orifice and pressure switch changes as indicated in the table below GRK GRL PRESSURE SWITCH CHANGES INPUT HIGH ALTITUDE SET POINT SET POINT KIT NO HIG...

Page 49: ...12 600 12 000 11 400 10 800 10 200 9 600 All calculations are performed by using the first three columns of information only Before beginning any calculations determine the individual burner Btu size...

Page 50: ...n Table 13 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 adju...

Page 51: ...E RESULTING IN PROPERTY DAMAGE 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 d...

Page 52: ...flame sensor must prove ignition If the burners do not light or flame cannot be proven the system goes through another ignition sequence It does this up to 4 times d Twenty seconds after flame sense t...

Page 53: ...fire and 4 8 W C on low fire at the gas control valve For elevations up to 8 000 feet rating plate inputs apply For high altitudes elevations 5 000 ft and over the orifice spud must be changed SETTIN...

Page 54: ...ly 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 50 If the measured...

Page 55: ...ed motor leads to M1 or M2 on the Integrated Furnace Control Board IFC Check motor lead color for speed designation Heating speeds should not be reduced where it could cause the furnace air temperatur...

Page 56: ...1475 1415 1355 M HI 1870 1820 1775 1715 1660 1590 1520 HIGH 2115 2050 1990 1945 1900 1795 1690 DOWNFLOW HORIZONTAL MODELS GTK 06 11 X 7 1 2 LOW 795 760 730 695 660 615 570 M LO 910 885 860 815 770 725...

Page 57: ...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 16 FILT...

Page 58: ...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 ANG...

Page 59: ...ve 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 ve...

Page 60: ...60 FIGURE 53 TROUBLESHOOTING CHART or IFC not properly grounded Go To Next Page...

Page 61: ...61 FIGURE 53 TROUBLESHOOTING CHART CONTINUED...

Page 62: ...62 FIGURE 54 WIRING DIAGRAM...

Page 63: ...63...

Page 64: ...64 CM 0510...