Rheem RGPH, RGDJ, RGDG, RGPJ, RGLH Installation Instructions Manual

...

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92-23531-70-01

SUPERSEDES 92-23531-70-00

INSTALLATION INSTRUCTIONS

FOR UPFLOW (RGDG & RGDJ), UPFLOW/HORIZONTAL (RGPH & RGPJ), HORIZONTAL ONLY (RGVH & RGVJ) AND DOWNFLOW (RGLH & RGLJ) INDUCED DRAFT GAS FURNACES

If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury or death.

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Do Not Destroy this Manual. Please read carefully and keep in a safe place for future reference by a serviceman.

WARNING

Recognize this symbol as an indication of Important Safety Information!

— Do not store or use gasoline or other

flammable vapors and liquids, or other combustible materials 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.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

• Do not return to your home until authorized by the gas supplier or fire department.

— DO NOT RELY ON SMELL ALONE TO

DETECT LEAKS. DUE TO VARIOUS FACTORS, YOU MAY NOT BE ABLE TO SMELL FUEL GASES.

• U.L. recognized fuel gas and CO 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

— Improper installation, adjustment, alteration,

service or maintenance can cause injury, property damage or death. Refer to this manual. Installation and service must be performed by a qualified installer, service agency or the gas supplier.

WARNING

PROPOSITION 65: THIS FURNACE CONTAINS FIBERGLASS INSULATION. RESPIRABLE PARTICLES OF FIBERGLASS ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER. EXHAUST GAS FROM THIS FURNACE CONTAINS CHEMICALS, INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF CALIFORNIA TO CAUSE BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

WARNING

FOR YOUR SAFETY

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Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction is sometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Make copies of the checklist and complete one for every Low Profile Furnace service call for your records.

INSTALLATION CHECKLIST

(Refer to this manual for specifics.) GAS SUPPLY

Adequate pipe size No gas leaks Proper supply and manifold gas pressure (check with an accurate U-tube manometer with the furnace and all other gas

appliances operating.)

ELECTRICAL

Correct thermostat and subbase Thermostat model Subbase model Correct thermostat mode and setting Correct line supply voltage Correct polarity (important with hot surface ignition) Correct furnace ground to electrical panel DC microamp (

µA) flame signal (hot surface ignition units) Correct control voltage Measure and set heat anticipator amperage Air conditioning low voltage wires connected to terminals “Y” “C” - not with wire nuts

VENTING

Correct vent pipe diameter and length (according to AGA/GAMA tables) Vent connection size Correct venting material (according to AGA/GAMA tables) Correct lining for masonry chimneys Adequate clearance from combustibles Proper negative pressure reading in the vent Vent pipe secured to induced draft blower housing

COMBUSTION AIR

Proper source of combustion air Correct combustion air opening size

FURNACE INSTALLATION

Adequate clearance from combustibles Adequate clearance for service Proper air temperature rise (See furnace rating plate) External static pressure inches w.c.

Correct filter(s) Correct cooling coil or accessories (if equipped)

Adequate supply and return air ducting Return Air Duct Size Supply Air Duct Size

Air ducts sealed to prevent leakage

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IMPORTANT: TO INSURE PROPER INSTALLATION AND OPERATION OF THIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TO ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIR THIS PRODUCT. UPON UNPACKING OF THE FURNACE, INSPECT ALL PARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.

CONTENTS

Safety Precautions...................................................................................................1

Installation Check List ..............................................................................................2

Location Requirements and Considerations............................................................4

Combustion and Ventilation Air..............................................................................10

Vent Pipe Installation..............................................................................................13

Gas Supply and Piping...........................................................................................16

Electrical Wiring......................................................................................................20

Accessories............................................................................................................21

Start-Up Procedures...............................................................................................26

Air Flow...................................................................................................................29

Maintenance...........................................................................................................34

Troubleshooting......................................................................................................36

Wiring Diagrams.....................................................................................................43

➤ Installation Instructions are updated on a regular basis. This is done as product changes occur or if new information becomes available. In this publication, an arrow (➤) denotes changes from the previous edition or additional new material.

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GENERAL INFORMATION

1. IMPORTANT: If furnace operation

is required during construction, and air ladened with corrosive compounds such as chlorine and fluorine are present, provisions must be taken to provide clean outdoor combustion and ventilation air to the furnace. Compounds of chlorine and fluorine, when burned with combustion air, form acids which will cause corrosion of a heat exchanger. Some of these compounds are found in paneling, dry wall, tile adhesives, paints, stains and varnishes, solvents and masonry cleaning materials.

2. NOTE: This furnace is shipped with heat exchanger support brackets installed under the back of the heat exchanger. These may be removed before installation, but it is not required.

LOCATION

THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME. DO NOT INSTALL THIS FURNACE IN A MOBILE HOME. INSTALLATION IN A MOBILE HOME COULD CAUSE FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

IMPORTANT: This furnace is not approved or recommended for installation on its back, with access doors facing upwards.

4. This furnace is suitable for installation in buildings constructed

on-site. This heating unit should be centralized with respect to the heat distribution system as much as practicable. When installed in a utility room, the door of the room should be wide enough to allow the largest part of the furnace to enter, or to permit the replacement of another appliance, such as a water heater.

5. IMPORTANT: If installing the unit

over a finished ceiling or living area, be certain to install an

auxiliary condensate drain pan under any evaporator coil installed with the furnace.

6. 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 of condensate.

7. IMPORTANT: Support this unit

when installed. Since this furnace is suitable for attic or crawl space installation, it may be installed on combustible wood flooring or by using support brackets. See Figure

8. IMPORTANT: If installing in a

utility room, be sure the door is wide enough to:

a. allow the largest part of the

furnace to pass; or

b. allow any other appliance (such

as a water heater) to pass.

The RGDG/RGDJ/RGLH/RGLJ and RGPH/RGPJ/RGVH/RGVJ series furnaces are design certified by AGA/CGA for use with natural and propane gases as follows:

As a Category I furnace, it may be vented vertically with type B-1 vent pipe and also may be common vented as described in these instructions.

This furnace should be installed in accordance with the American National Standard Z223.1 - latest edition booklet

entitled “National Fuel Gas Code” (NFPA 54) (in Canada, CAN/CGA B149.1 and .2 Installation Codes for gas burning appliances), and the requirements or codes of the local utility or other authority having jurisdiction including local plumbing or waste water codes.

Additional helpful publications available from the “National Fire Protection Association” are: NFPA-90A – Installation of Air Conditioning and Ventilating Systems 1985 or latest

edition. NFPA-90B – Warm Air Heating and Air Conditioning Systems 1984.

These publications are available from:

National Fire Protection Association,

Inc. Batterymarch Park Quincy, MA 02269

Canadian Gas Association 178 Rexdale Blvd. Etobicoke (Toronto), Ontario Canada M9W, 1R3

GENERAL INFORMATION

LOCATION REQUIREMENTS AND CONSIDERATIONS

WARNING

FIGURE 1 HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

EXHAUST VENT

GAS PIPE

ELECTRICAL CONDUIT

ST-A0799-01

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REDUCED CLEARANCE (IN.)

Model A B C D E

Left Right

Back Top Front Vent

Ship.

Side Side Wgts.

04, 05 14 12

⁄32 103⁄8 ➀ 111⁄2 0 4➁ 0 1 3 6➂ 85 lbs.

06, 07 17

⁄2 1611⁄32 121⁄8 ➀ 15 0 3➁ 0 1 3 6➂ 105 lbs.

10(A) 17

⁄2 1611⁄32 121⁄8 ➀ 15 0 3➁ 0 1 3 6➂ 115 lbs.

10(B) 21 19

⁄32 137⁄8 ➀ 181⁄2 0 0 0 1 3 6➂ 120 lbs.

12 24

⁄2 2311⁄32 155⁄8 ➀ 22 0 0 0 1 3 6➂ 140 lbs.

15 24

⁄2 2311⁄32 155⁄8 ➀ 22 0 0 0 1 3 6➂ 150 lbs.

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES) UPFLOW AND UPFLOW/HORIZONTAL MODELS

TOP

LEFT SIDE

FRONT

RIGHT SIDE

BOTTOM

⁄2

⁄16

⁄8

⁄32

⁄16

⁄8

⁄2

⁄8 DIA.

⁄32

⁄4

⁄8

⁄2

⁄4

⁄32

GAS CONNECTION

ELECTRICAL CONNECTION

OPTIONAL RETURN AIR CUTOUT

(EITHER SIDE) FOR USE WITH

EXTERNAL SIDE FILTER FRAME

LOW VOLTAGE

A B

R.A.

S.A.

➀ May require 3( to 4( or 3( or 5( adapter. ➁ May be 0( with type B vent. ➂ May be 1( with type B vent.

FIGURE 2

UPFLOW AND UPFLOW/HORIZONTAL DIMENSIONS

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FIGURE 3

REDUCED CLEARANCE (IN.)

Model A B C D E

Left Right

Back Top Front Vent

Ship.

Side Side Wgts.

04, 05 14 12

⁄32 103⁄8 ➀ 13 1⁄8 0 4➁ 0 1 3 6➂ 85 lbs.

06, 07 17

⁄2 1611⁄32 121⁄8 ➀ 16 5⁄8 0 3➁ 0 1 3 6➂ 105 lbs.

10(A) 17

⁄2 1611⁄32 121⁄8 ➀ 16 5⁄8 0 3➁ 0 1 3 6➂ 115 lbs.

10(B) 21 19

⁄32 137⁄8 ➀ 20 1⁄8 0 0 0 1 6 6➂ 120 lbs.

12 24

⁄2 2311⁄32 155⁄8 ➀ 23 5⁄8 0 0 0 1 3 6➂ 140 lbs.

15 24

⁄2 2311⁄32 155⁄8 ➀ 23 5⁄8 0 0 0 1 3 6➂ 150 lbs.

TOP

BOTTOM

⁄2

⁄4

LOW VOLTAGE

GAS CONNECTION

ELECTRIC CONNECTION

S.A.

R.A.

⁄8

⁄16

⁄8

⁄4

⁄8

⁄16

⁄8

⁄16

⁄8 DIA.

⁄2 DIA.

⁄8 DIA.

➀ May require 3( to 4( or 3( or 5( adapter. ➁ May be 0( with type B vent. ➂ May be 1( with type B vent.

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES) DOWNFLOW MODELS

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FIGURE 4

REDUCED CLEARANCE (IN.)

Model A B C D E

Left Right

Back Top Front Vent

Ship.

Side Side Wgts.

04, 05 14 12

⁄32 103⁄8 ➀ 111⁄2 0 4➁ 0 1 3 6➂ 85 lbs.

06, 07 17

⁄2 1611⁄32 121⁄8 ➀ 15 0 3➁ 0 1 3 6➂ 105 lbs.

10(A) 17

⁄2 1611⁄32 121⁄8 ➀ 15 0 3➁ 0 1 3 6➂ 115 lbs.

10(B) 21 19

⁄32 137⁄8 ➀ 181⁄2 0 0 0 1 3 6➂ 120 lbs.

12 24

⁄2 2311⁄32 155⁄8 ➀ 22 0 0 0 1 3 6➂ 140 lbs.

15 24

⁄2 2311⁄32 155⁄8 ➀ 22 0 0 0 1 3 6➂ 150 lbs.

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES) HORIZONTAL “ONLY” MODELS

➀ May require 3( to 4( or 3( or 5( adapter. ➁ May be 0( with type B vent. ➂ May be 1( with type B vent.

TOP VIEW

FRONT

BOTTOM VIEW

LEFT END

RIGHT END

⁄32

⁄16

⁄2

⁄16

⁄32

⁄8

⁄2

⁄4

⁄8

⁄4

⁄32

⁄8

⁄16

⁄8 DIA.

S.A.

GAS CONNECTION

LOW VOLTAGE

ELECTRICAL CONNECTION

R.A.

IMPORTANT: This furnace is not approved or recommended for installation on its back, with access doors facing upwards.

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CLEARANCE – ACCESSIBILITY

The design of forced air furnaces with input ratings as listed in the tables on the following pages are certified by A.G.A. Laboratories and CGA for the clearances to combustible materials shown in inches.

See name/rating plate and clearance label for specific model number and clearance information.

Service clearance of at least 24 inches is recommended in front of all furnaces.

ACCESSIBILITY CLEARANCES, WHERE GREATER, MUST TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES.

UPFLOW AND HORIZONTAL

INSTALLATION — Certified for use on

combustible floor.

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, SEVERE PERSONAL INJURY OR DEATH.

UNIT DESIGN IS CERTIFIED FOR INSTALLATION ON NONCOMBUSTIBLE FLOOR. A SPECIAL COMBUSTIBLE FLOOR SUB-BASE IS REQUIRED WHEN INSTALLING ON A COMBUSTIBLE FLOOR. FAILURE TO INSTALL THE SUBBASE MAY RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THIS SPECIAL BASE IS OFFERED AS AN ACCESSORY FROM THE FACTORY. SEE THE CLEARANCE LABEL LOCATED INSIDE THE FURNACE FOR THE APPROPRIATE MODEL NUMBER.

THE SPECIAL BASE IS NOT REQUIRED WHEN THE FURNACE IS INSTALLED ON TOP OF AN AIR CONDITIONING PLENUM.

A gas-fired furnace for installation in a residential garage must be installed so that the burner(s) and the ignition source are located not less than 18( above the floor and the furnace is located or protected to avoid physical damage by vehicles.

KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. PLACEMENT OF COMBUSTIBLE MATERIALS ON, AGAINST OR AROUND THE FURNACE JACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES.

DUCTING

Proper air flow is required for the correct operation of this furnace. Too little air flow can cause erratic operation and can damage the heat exchanger. The duct system must carry the correct amount of air for heating and cooling if summer air conditioning is used.

Size the ducts according to acceptable industry standards and methods. The total static pressure drop of the entire system should not exceed 0.5( w.c.

IMPORTANT: Some high efficiency filters have a greater than normal resistance to air flow. This can adversely affect furnace operation. BE SURE TO CHECK AIR FLOW if using any filter other than the factoryprovided filter.

NEVER ALLOW PRODUCTS OF COMBUSTION OR THE FLUE PRODUCTS TO ENTER THE RETURN AIR DUCTWORK, OR THE CIRCULATING AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE WITH SHEET METAL SCREWS, AND JOINTS TAPED. WHEN A FURNACE IS MOUNTED ON A PLATFORM, WITH RETURN THROUGH THE BOTTOM, IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE AND THE RETURN AIR PLENUM. THE RETURN AIR PLENUM MUST BE PERMANENTLY ENCLOSED. NEVER USE A DOOR AS A PART OF THE RETURN AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT OF THE FURNACE, WITHOUT SAGGING, CRACKS,

UPFLOW UNIT DESIGN REQUIRES A SOLID METAL BASE PLATE (SEE TABLE ON PAGE 8 OR FURNACE CLEARANCE LABEL FOR PART NUMBER) MUST BE IN PLACE WHEN THE FURNACE IS INSTALLED WITH SIDE OR REAR AIR RETURN DUCTS. FAILURE TO INSTALL A BASE PLATE COULD CAUSE PRODUCTS OF COMBUSTION TO BE CIRCULATED INTO THE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING.

When coils are used with air handlers or furnaces and installed above a finished ceiling or living area, it is recommended that an auxiliary sheet metal condensate drain pan be fabricated and installed under entire unit. Failure to do so can result in property damage.

SITE SELECTION

1. Select a site in the building near the center of the proposed, or existing, duct system.

2. Give consideration to the vent system piping when selecting the furnace location. Be sure the venting system can get from the furnace to the termination with minimal length and elbows.

3. Locate the furnace near the existing gas piping. Or, if running a new gas line, locate the furnace to minimize the length and elbows in the gas piping.

4. Locate the furnace to maintain proper clearance to combustibles as shown in the preceding tables.

COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET OR WITHIN THE SPECIFIED CLEARANCES OF THE VENT PIPE. THE AREA AROUND THE FURNACE MUST BE

CAUTION

WARNING

TABLE 1

FURNACE BASE BASE

WIDTH

PLATE NO. PLATE SIZE

14( RXGB-D14 11

⁄8( x 239⁄16(

⁄2( RXGB-D17 151⁄8( x 239⁄16(

21( RXGB-D21 18

⁄8( x 239⁄16(

⁄2( RXGB-D24 255⁄8( x 239⁄16(

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GAPS, ETC., AROUND THE BASE AS TO PROVIDE A SEAL BETWEEN THE SUPPORT AND THE BASE.

FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN OR SUPPLY DUCTWORK TO OR FROM ANY OTHER HEAT PRODUCING DEVICE SUCH AS A FIREPLACE INSERT, STOVE, ETC. DOING SO MAY RESULT IN FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY OR PROPERTY DAMAGE.

BLOWER AND BURNERS MUST NEVER BE OPERATED WITHOUT THE BLOWER DOOR IN PLACE. THIS IS TO PREVENT DRAWING GAS FUMES (WHICH COULD CONTAIN HAZARDOUS CARBON MONOXIDE) INTO THE HOME THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

UPFLOW UNITS

1. Position the unit to minimize long runs or runs with many turns and elbows.

2. Open the return air compartment. a. If using side or back return air,

install the bottom base.

A SOLID METAL BASE PLATE, SEE TABLE 1, OR FURNACE CLEARANCE LABEL FOR PART NUMBER MUST BE IN PLACE WHEN THE FURNACE IS INSTALLED WITH SIDE OR REAR AIR RETURN DUCTS. FAILURE TO INSTALL A BASE PLATE COULD CAUSE PRODUCTS OF COMBUSTION TO BE CIRCULATED INTO THE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING OR DEATH.

b. Cut an opening in the side or

back. The opening should be cut the full width of the knockouts on the unit.

NOTE: Where the maxiumum air flow is 1800 CFM or more, both sides or the bottom must be used for return air.

3. Connect the return duct or return air cabinet to the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

4. 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.

5. If summer air conditioning is desired, position the indoor coil on the top of the unit. Insure that no air can bypass this coil.

6. Connect the supply air plenum to the furnace plenum opening.

DOWNFLOW UNITS

1. Position the unit to minimize long runs or runs with many turns and elbows.

2. If summer air conditioning is desired, position the indoor coil on the bottom of the unit. Insure that no air can bypass this coil.

3. If installing on a combustible floor

and not using an air conditioning

plenum, install the special

combustible floor base. See Figure 4.

THE DOWNFLOW FURNACE DESIGN IS CERTIFIED FOR INSTALLATION ON A NONCOMBUSTIBLE FLOOR. USE THE SPECIAL BASE SPECIFIED ON THE FURNACE CLEARANCE LABEL. FAILURE TO INSTALL THE SPECIAL BASE MAY RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THIS SPECIAL

BASE IS SHIPPED FROM THE FACTORY AS AN ACCESSORY.

4. Connect the furnace to the supply air plenum.

5. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

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 UNITS

1. Position the unit to minimize long runs or runs with many turns and elbows.

2. If summer air conditioning is desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

3. Connect the furnace to the supply air plenum.

4. Secure the four angle brackets shipped with the unit to the return air opening. See Figure 6. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

5. 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.

FIGURE 5 COMBUSTIBLE FLOOR BASE

WARNING

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THIS FURNACE AND ANY OTHER FUEL-BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE DEATH FROM CARBON MONOXIDE POISONING.

Adequate facilities for providing air for combustion and ventilation must be provided in accordance with section

5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI, Z223.1 latest edition or CAN/CGA B149.1 and .2 or, applicable provisions for the local building codes, and not obstructed so as to prevent the flow of air to the furnace.

OVERTEMPERATURE SAFETY SWITCHES

This furnace is equipped with safety switches in the control compartment to protect against overtemperature conditions caused by inadequate combustion air supply. The switches are located just above the burners on the furnace center panel on upflow and downflow models and also on each side of the burners on upflow/horizontal and horizontal “only” models, and must be manually reset if tripped. DO NOT jumper this switch. If this switch should trip, a qualified

FIGURE 6 HORIZONTAL RETURN AIR DUCT

FIGURE 7 AIR FROM HEATED SPACE

furnace installer, service agency or the gas supplier should be called to check and/or correct for adequate combustion air supply. If this unit is mounted in a closet, the door must be closed when making this check of the installation.

DO NOT reset the overtemperature switch without taking corrective action to assure that an adequate supply of combustion air is maintained under all conditions of operation.

Replace this switch only with the identical replacement part.

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.

The following types of installation may require OUTDOOR AIR for combustion, due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemical

storage areas.

Exposure to the following substances in the combustion air supply may also require OUTDOOR AIR for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine-based swimming pool

chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as

perchloroethylene)

• Printing inks, paint removers,

varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes

dryers

• Masonry acid washing materials

COMBUSTION AND VENTILATION AIR

WARNING

FOUR ANGLE BRACKETS ARE SHIPPED WITH EACH UNIT THAT CAN BE INSTALLED HORIZONTALLY. THESE BRACKETS MAY BE USED TO SECURE THE RETURN AIR DUCT TO A HORIZONTAL UNIT.

Page 11

Combustion air must be free of acid forming chemicals; such as sulphur, fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products. Vapors from these products when burned in a gas flame form acid compounds. The acid compounds increase the dew point 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 VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN CREATE HAZARDOUS CONDITIONS RESULTING IN PROPERTY DAMAGE, BODILY INJURY OR DEATH FROM SMOKE, FIRE OR CARBON MONOXIDE.

Combustion air requirements are determined by whether the furnace is in an open (unconfined) area or in a confined space such as a closet or small room.

EXAMPLE 1. FURNACE LOCATED IN AN UNCONFINED SPACE

Using indoor air for combustion.

An unconfined space must have at least 50 cubic feet for each 1,000 Btuh of the total input for all appliances

in the space. Here are a few examples of the room sizes required for different inputs. The sizes are based on 8 foot ceilings.

Btuh Minimum Sq. Feet Typical Room Size

Input With 8' Ceiling With 8' Ceiling

45,000 281 12*x24* or 16*x18* 50,000 312 14*x24* or 18*x18* 67,500 421 15*x28* or 20*x21*

75,000 469 15*x31* or 20*x24* 100,000 625 20*x31* or 25*x25* 125,000 833 23*x34* or 26*x30* 150,000 938 25*x38* or 30*x31*

If the open space containing the furnace is in a building with tight construction (contemporary construction), outside air may still be required for the furnace to operate and vent properly. Outside air openings should be sized the same as for a confined space.

WARNING

FIGURE 8 AIR FROM ATTIC/CRAWL SPACE

EXAMPLE 2. FURNACE LOCATED IN A CONFINED SPACE

A confined space (any space smaller than shown above as “unconfined”) must have openings into the space which are located in accordance with the requirements set forth in the following subsections A and B. Size the openings by how they are connected to the heated area or to the outside, and by the input of all appliances in the space.

If confined space is within a building with tight construction, combustion air must be taken from outdoors or area freely communicating with the outdoors.

A. USING INDOOR AIR FOR

COMBUSTION

IMPORTANT: Air should not be taken from a heated space with a fireplace, exhaust fan or other device that may produce a negative pressure.

If combustion air is taken from the heated area, the openings must each

have at least 100 square inches of free area. Each opening must have at least one square inch of free area for each 1,000 Btuh of total input in the space. Here are some examples of typical openings required.

Btuh Free Area

Input Each Opening

45,000 100 Square Inches 100,000 100 Square Inches 150,000 150 Square Inches

B. USING OUTDOOR AIR FOR

COMBUSTION

IMPORTANT: NEVER TAKE COMBUSTION AIR FROM AN ATTIC SPACE THAT IS EQUIPPED WITH POWER VENTILATION.

The confined space must communicate with the outdoors according to Methods 1 and 2. The minimum air opening dimension shall not be less than 3 inches. When using ducts, they shall be of the same cross-sectional area as the free area of the openings to which they connect.

Method 1

Provide two permanent openings, one located within 12 inches of the top and one located within 12 inches of the bottom of the enclosure. Each opening shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

a. Where directly communicating

with the outdoors or where communicating to the outdoors through VERTICAL DUCTS, each opening shall have a minimum free area of 1 square inch for each 4000 BTUH of total appliance input rating in the enclosure. Here are typical duct sizes.

Page 12

a. One square inch for each 3000

BTUH of the total input rating of all equipment located in the enclosure,

AND

b. Not less than the sum of the areas

of all vent connectors in the confined space.

IMPORTANT: IF THE FURNACE IS IN A LOCATION WITH AN EXHAUST FAN, THERE MUST BE SUFFICIENT VENTILATION TO PREVENT THE EXHAUST FAN FROM CREATING A NEGATIVE PRESSURE IN THE ROOM.

Combustion air openings must NOT BE RESTRICTED in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

Air opening in the furnace casing front, return air grilles, and warmm air registers must not be obstructed.

b. Where communicating with

outdoors through HORIZONTAL DUCTS, each opening shall have a minimum free area of 1 square inch for each 2000 BTUH of total input rating for all equipment in the enclosure. Here are typical duct sizes.

FIGURE 9 OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

Method 2

One permanent opening, located within 12 inches of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance. The opening shall directly communicate with the outdoors or communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors and have a minimum free area of:

VERTICAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Input Each Opening Pipe Size

45,000 11.25 sq. inches 4( 50,000 12.50 sq. inches 4( 67,500 16.90 sq. inches 5(

75,000 18.75 sq. inches 5( 100,000 25.00 sq. inches 6( 125,000 31.25 sq. inches 7( 150,000 37.50 sq. inches 7(

HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round

Input Each Opening Pipe Size

45,000 22.50 sq. inches 6( 50,000 25.00 sq. inches 6( 67,500 33.75 sq. inches 7(

75,000 37.50 sq. inches 7( 100,000 50.00 sq. inches 8( 125,000 62.50 sq. inches 9( 150,000 75.00 sq. inches 10(

Page 13

GENERAL INFORMATION

The furnace must be vented in accordance with these instructions, National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CAN/CGA-B149.1 & .2 and requirements or codes of the local utility or other authority having jurisdiction.

DEVICES ATTACHED TO THE FLUE OR VENT FOR THE PURPOSE OF REDUCING HEAT LOSS UP THE CHIMNEY HAVE NOT BEEN TESTED AND HAVE NOT BEEN INCLUDED IN THE DESIGN CERTIFICATION OF THIS FURNACE. WE, THE MANUFACTURER, CANNOT AND WILL NOT BE RESPONSIBLE FOR INJURY OR DAMAGE CAUSED BY THE USE OF SUCH UNTESTED AND/OR UNCERTIFIED DEVICES, ACCESSORIES OR COMPONENTS.

DRAFT INDUCER

VENT PIPE ATTACHING HOLES MUST BE PREDRILLED IN THE DRAFT INDUCER COLLAR TO PREVENT PLASTIC MATERIAL FROM CRACKING. DRILL 1/8( DIAMETER HOLES THROUGH THE VENT PIPE AND COLLAR AND USE #8 SCREWS TO ATTACH. SEE FIGURE 10. FAILURE TO FOLLOW THIS WARNING CAN CAUSE RECIRCULATION OF FLUE PRODUCTS CAUSING CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJURY OR DEATH.

IMPORTANT APPLICATION NOTES

When the furnace is used as a replacement, the existing vent system should be inspected to assure that there are no obstructions, blockage, or any signs of corrosion.

NOTE: WHEN THE VENT TABLE PERMITS MORE THAN ONE DIAMETER OF PIPE FOR A CONNECTOR OR VENT, THE SMALLEST PERMITTED DIAMETER MUST BE USED,

VENT PIPE MAY BE TYPE “B-1,” EITHER RIGID OR SUITABLE FLEXIBLE CONSTRUCTION THAT CARRIES A U.L. LISTING.

COMMON VENTING IS ALLOWED WITH VERTICAL B-1 VENT SYSTEMS, AND LINED MASONRY CHIMNEYS. FOLLOW THE NATIONAL FUEL GAS CODE, ANSI Z223.1 AND/OR THE NATURAL GAS INSTALLATION CODE, CAN/CGAB149.1 & .2 FOR PROPER INSTALLATION PRACTICES.

SINGLE WALL VENT CONNECTORS TO “B-1 VENT OR MASONRY CHIMNEYS” MAY BE USED UNDER THE GUIDELINES OF THE NATIONAL FUEL GAS CODE, ANSI Z223.1 AND/OR THE NATURAL GAS INSTALLATION CODE, CAN/CGAB149.1 & .2.

The entire length of the vent connector shall be readily accessible for inspection, cleaning and replacement.

WARNING

FURNACE CATEGORY INFORMATION

This furnace is shipped as a Category I

type induced draft furnace. A Category I furnace operates with a nonpositive vent pressure and has a vent gas temperature at least 140°F above the dew point of the vent gases. A Category I type may be a draft hood equipped furnace or have a fan assisted combustion system (induced draft). The inducer is used to pull flue products through the combustion chamber and as they leave the furnace, most of the energy has been dissipated. The buoyant effect of the flue gases provides venting to the outdoors.

During the off cycle, the inducer is off and there is very little flow through the vent, cooling the vent. During the on cycle there is no dilution airflow, as with a draft hood type furnace. Although the vent heats up rapidly without dilution air, the flue products contain more water vapor, which results in a higher dew point temperature. It is most important that you follow the guidelines in these instructions to prevent the possible formation of condensation in the venting system.

As a Category I furnace it may be vented vertically with type B-1 vent pipe and also may be common vented, as described in these instructions.

FIGURE 10 ATTACHING TO DRAFT INDUCER COLLAR

VENTING

Page 14

“B-1” VERTICAL VENTING

Type “B-1” vents must be installed in accordance with the terms of their listings and the vent manufacturer’s instructions.

“B-1” vents must be supported and spaced in accordance with their listings and the manufacturer’s instructions. All vents must be supported to maintain their minimum clearances from combustible material.

VERTICAL VENTING

Categorized

Furnace Vent

Input Size Required

45K 3( 50K 3( 67K *4(

75K *4( 100K *4( 125K *4( 150K *5(

*NOTE: All furnaces have a 3( vent connection as shipped from the factory. A 3( to 4( or 3( to 5( vent transition is required on all but the 45,000 and 50,000 BTUH models when vertically vented or common vented with metal vent pipes. THE VENT

TRANSITION CONNECTION MUST BE

MADE AT THE FURNACE VENT EXIT. It

must originate with an adapter if required, at the furnace flue collar and terminate either in a listed cap or roof assembly. When common venting, the vent connector size may differ from the above diameters depending on application. See ANSI Z21.47-1993/CAN/CGA-2.3-M93 or latest edition tables.

VERTICAL VENT SYSTEMS:

1. A gas vent shall terminate above the roof surface with a listed cap or listed roof assembly. Gas vents 12 inches in size or smaller with listed caps shall be permitted to be terminated in accordance with Figure 11, provided they are at least 8 feet from a vertical wall or similar obstruction. All other gas vents shall terminate not less than 2 feet above the highest point where they pass through the roof and at least 2 feet higher than any portion of a building within 10 feet.

2. A type B gas vent shall terminate at least 5 feet in vertical height above the highest connected equipment draft hood or flue collar.

3. Must rise

⁄4( per foot away from the furnace on horizontal runs and be supported with straps or hangers so it has no sags or dips. Supports at 4 foot intervals and at all elbows are recommended.

4. The vent connector must be mechanically fastened to the outlet collar of the furnace with at least (2)

SPECIAL VENT SYSTEMS (SVS)

IMPORTANT: IT IS RHEEM’S POSITION NOW THAT NEW INSTALLATIONS OF ANY HTPV PIPE USED IN A CATEGORY III VENT

APPLICATION, INCLUDING SELKIRK’S SELVENT™ II HTPV PRODUCT, SHOULD CEASE IMMEDIATELY.

POWER VENT SYSTEMS

When vertical venting is not possible, the only acceptable method for horizontal venting is with the use of Tjernlund model GPAK-1TR or Field Controls models SWG-4R power venter. Type B vent pipe and fittings must be used. Common venting is not permitted

All application and installation instructions supplied with the power venter must be followed.

Please address all questions regarding power venter installation, agency listings and furnace model compatibility to:

Tjernlund Products, Inc. (800) 255-4208 or (612) 426-2993

Field Controls L.L.C. (800) 742-8368 or (919) 522-0214

sheet metal screws except vent connectors that are B-1 material. These shall be assembled in accordance with the manufacturer’s instructions. See Figure 9.

NOTE: Refer to the National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CAN/CGAB149.1 & .2.

Single appliance venting of a fan assisted furnace into a tile-lined masonry chimney is prohibited. The chimney must be lined with either Type B vent or with a listed, single wall, metal lining system. Reference National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CAN/CGA-B149.1 & .2. See Figure 11 for typical B-1 vent chase.

DO NOT CONNECT THIS FURNACE TO A CHIMNEY USED TO VENT A SOLID FUEL APPLIANCE (WOOD OR COAL). VENTING WITH A SOLID FUEL APPLIANCE CAN LEAD TO IMPROPER FUNCTIONING OF THE UNIT, AND DUE TO SOOTING, THE POSSIBILITY OF FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

FIGURE 11 TYPICAL VENTING WITH “B-1” VENT

WARNING

Page 15

3. Insofar as is practical, close all building doors, windows and all doors between the space where the appliances remaining connected to the common venting system are located. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

EXISTING VENT SYSTEMS

IMPORTANT RETROFIT VENTING INSTRUCTIONS

If this furnace is a replacement installation, ALWAYS INSPECT the existing vent system to be sure there are no obstructions, blockages, or signs of corrosion.

When the existing furnace is removed from a venting system serving other appliances, the venting is likely to be too large to properly vent the remaining attached appliances.

The following steps shall be followed with each appliance that remains connected to the common venting system, while the other appliances that remain connected to the common venting systems are not in operation.

NOTE: WHEN THE VENT TABLE PERMITS MORE THAN ONE DIAMETER OF PIPE FOR A CONNECTOR OR VENT, THE SMALLEST PERMITTED DIAMETER MUST BE USED.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage, restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

FIGURE 12 DEDICATED VENTING THROUGH CHIMNEY WITH “B-1” VENT

6. After it has been determined that each appliance that remains connected to the common venting system properly vents (when tested as outlined above) return doors, windows, 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 be resized. Refer to National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CAN/CGA-B149.1 & .2.

Page 16

FIGURE 13 GAS PIPING INSTALLATION

UPFLOW & DOWNFLOW

GAS SUPPLY AND PIPING

GAS SUPPLY

THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT SUPPLIED BY THE DISTRIBUTOR OR MANUFACTURER. MAILING ADDRESSES ARE LISTED ON THE FURNACE RATING PLATE, PARTS LIST AND WARRANTY. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

See the conversion kit index supplied with the furnace. This index identifies the proper LP Gas Conversion Kit required for each particular furnace.

IMPORTANT: Any additions, changes or conversions required for the furnace to satisfactorily meet the application should be made by a qualified installer, service agency or the gas supplier, using factoryspecified or approved parts.

IMPORTANT: Connect this furnace only to gas supplied by a commercial utility.

IMPORTANT: A U.L. recognized fuel gas and CO detector(s) are recommended in all applications, and their installation should be in accordance with the detector manufacturer’s recommendations and/or local laws, rules, regulations or customs.

GAS PIPING

Install the gas piping according to all local codes and regulations of the utility company.

If possible, run a 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 size to prevent undue pressure drop and never smaller than the pipe size to the combination gas valve on the furnace.

Refer to Table 2 for the recommended pipe size for natural gas and Table 3 for LP gas pipe sizes.

WARNING

HORIZONTAL

IMPORTANT: It is permissible to run flexible gas connector inside the unit to a piece of black pipe.

Install a ground joint union inside the cabinet to easily remove the control valve assembly. Install a manual shut-off valve in the gas line outside

the furnace casing. The valve should

be readily accessible to turn the gas supply on or off. Install a drip leg in the gas supply line as close to the furnace as possible. Always use a pipe compound resistant to the action of liquefied petroleum gases on all threaded connections.

IMPORTANT: When making gas pipe connections, use a back-up wrench to prevent any twisting of the control assembly and gas valve.

Any strains on the gas valve can change the position of the gas orifices in the burners. This can cause erratic furnace 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 during any pressure

testing that exceeds 1/2 p.s.i.g. (3.48 kPa).

Page 17

GAS PRESSURE

Natural gas supply pressure should be 5" to 7

( w.c. LP gas supply

pressure should be 11( to 14( w.c.

This pressure must be maintained with all other gas-fired appliances in operation. Never exceed a maximum

gas supply pressure of 14( w.c. with any fuel.

The minimum 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 supply pressure is 11( w.c. for LP gas.

NEVER PURGE A GAS LINE INTO THE COMBUSTION CHAMBER. NEVER USE MATCHES, FLAME OR ANY IGNITION SOURCE FOR CHECKING LEAKAGE. FAILURE TO FOLLOW THIS WARNING CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

To check for gas leakage, use an approved chloride-free soap and water solution, an electronic combustible gas detector (see Figure 14), or other approved method.

WARNING

FIGURE 14 ELECTRONIC COMBUSTIBLE GAS DETECTOR

FIGURE 15 LP KIT CONTENTS

FIGURE 16 HOSE CONNECTION TO LINE PRESSURE TAP

Page 18

LP CONVERSION

The valve can be converted to use liquefied petroleum (LP) gas by replacing the pressure regulator spring with the conversion kit spring. This LP kit spring allows the regulator to maintain the proper manifold pressure for LP gas. The correct burner LP orifices are included in the kit. See Figure 14.

NOTE: Order the correct LP conversion kit from the furnace manufacturer.

Furnace conversion to LP gas must be performed by a qualified technician.

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 the orifice spuds.

3. Reassemble in reverse order.

Consult the tables at right if there is any question concerning orifice sizing.

4. Turn the gas supply back on and

check for proper operation and manifold pressure.

5. Attach the notice label alerting the next service technician that the furnace has been converted to LP gas.

NOx MODELS

When converting furnaces equipped with NOx inserts to LP gas, remove the NOx insert assemblies. Steps for removal are listed below:

1. Turn off all electrical power and the gas supply to the furnace.

2. Remove the burner door from the furnace.

3. Remove the igniter assembly –

handle with care.

4. Remove the two screws attaching the NOx insert retainer brackets to the center panel. Pull the retainer rod.

5. Put the two screws back into the holes in the center panel.

6. Re-install the igniter and burner assemblies.

7. Replace burner door.

8. Turn on electrical power and gas supply to the unit.

RATING PLATE ELEVATION

INPUT

BTU/HR 0 TO 7,999 FT. 8,000 FT. AND ABOVE

NATURAL GAS

HEATING VALUE @ 1,000 BTU/FT

, SPECIFIC GRAVITY 0.62

MANIFOLD PRESSURE @ 3.5( W.C. 45,000 43 45 50,000 42 43 67,500 43 45 75,000 42 43

100,000 42 43 125,000 42 43 150,000 42 43

L.P. GAS

HEATING VALUE @ 2,475 BTU/FT

, SPECIFIC GRAVITY 1.52/

MANIFOLD PRESSURE @ 10( W.C. 45,000 54 55 50,000 54 55 67,500 54 55 75,000 54 55

100,000 54 55 125,000 54 55 150,000 54 55

ORIFICE SIZING CHART

RATING PLATE ELEVATION

INPUT

BTU/HR 0 TO 1,999 FT. 2,000 FT. TO 4,500 FT.

NATURAL GAS

HEATING VALUE @ 1,000 BTU/FT

, SPECIFIC GRAVITY 0.62

MANIFOLD PRESSURE @ 3.5( W.C. 45,000 43 45 50,000 42 43 67,500 43 45 75,000 42 43

100,000 42 43 125,000 42 43 150,000 42 43

L.P. GAS

HEATING VALUE @ 2,475 BTU/FT

, SPECIFIC GRAVITY 1.52/

MANIFOLD PRESSURE @ 10( W.C. 45,000 54 55 50,000 54 55 67,500 54 55 75,000 54 55

100,000 54 55 125,000 54 55 150,000 54 55

ORIFICE SIZING CHART (CANADA)

Page 19

TABLE 2 NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas).

Nominal Length of Pipe, Feet Iron Pipe

Size, Inches 10 20 30 40 50 60 70 80

1/2 132 92 73 63 56 50 46 43 3/4 278 190 152 130 115 105 96 90

1 520 350 285 245 215 195 180 170 1-1/4 1,050 730 590 500 440 400 370 350 1-1/2 1,600 1,100 890 760 670 610 560 530

After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the furnace. By formula:

Gas Input of Furnace (BTU/HR)

Cu. Ft. Per Hr. Required =

Heating Value of Gas (BTU/FT3)

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may be determined by consulting the local natural gas utility or the LP gas supplier.

TABLE 3 LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column inlet pressure). (Based on a Pressure Drop of 0.5 Inch Water Column)

Nominal Length of Pipe, Feet Iron Pipe Size, Inches 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 63 3/4 567 393 315 267 237 217 196 182 173 162 146 132

1 1,071 732 590 504 448 409 378 346 322 307 275 252 1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 1-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787

2 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

Example (LP): Input BTU requirement of unit, 150,000

Equivalent length of pipe, 60 ft. = 3/4" IPS required.

SETTING GAS PRESSURE

The maximum gas supply pressure to the furnace should be 7( w.c.

natural gas, or 14( w.c. LP gas. The

minimum supply gas pressure to the gas valve should be 5" w.c. natural gas or 11" w.c. LP gas. A properly calibrated U-Tube manometer is required for accurate gas pressure measurements.

Supply Gas Pressure Measurement.

A line pressure tap is on the input side of the gas valve.

1. With gas shut off to the furnace at the manual gas valve outside the unit, remove the input pressure tap plug.

2. Connect a U-Tube manometer to the pressure tap. See Figure 15.

3. Turn on the gas supply and operate the furnace and all other gas-fired 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( - 14( w.c. for LP gas.

5. Shut off the gas at the manual gas valve and remove the U-Tube manometer.

6. Replace the pressure tap plug before turning on the gas.

If the supply gas line pressure is above these ranges, install an in-line gas regulator to the furnace for natural gas units. With LP gas, have the LP supplier reduce the line pressure at the regulator.

If supply gas line pressure is below these ranges, either remove any restrictions in the gas supply piping or enlarge the gas pipe. See Tables 2 and

3. With LP gas, have the LP supplier adjust the line pressure at the regulator.

Page 20

TURN OFF ELECTRIC POWER AT THE FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS.

ALSO, THE GROUND CONNECTION MUST BE COMPLETED BEFORE MAKING LINE VOLTAGE CONNECTIONS. FAILURE TO DO SO CAN RESULT IN ELECTRICAL SHOCK, SEVERE PERSONAL INJURY OR DEATH.

IMPORTANT: THE FURNACE MUST BE INSTALLED SO THAT THE ELECTRICAL COMPONENTS ARE PROTECTED FROM WATER (FURNACE CONDENSATE).

ELECTRICAL CONNECTIONS

THE CABINET MUST BE PERMANENTLY GROUNDED. A GROUND SCREW IS PROVIDED IN THE JUNCTION BOX FOR THIS PURPOSE. FAILURE TO DO SO CAN RESULT IN FIRE, ELECTRICAL SHOCK, PERSONAL INJURY OR DEATH.

The electrical supply requirements are listed on the furnace rating plate.

Use a separate fused branch electrical circuit containing a properly sized fuse or circuit breaker. Run this circuit directly from the main switch box to an electrical disconnect which must be readily accessible and located within sight of the furnace. Connect from the disconnect to the junction box on the left side of the furnace, inside the control compartment. See appropriate wiring diagram.

NOTE: The electrical junction box inside the furnace control compartment may be relocated to the right side if necessary. A knockout is provided.

NOTE: L1 (hot) and L2 (neutral) polarity must be observed when making field connections to the furnace. The ignition control on electric ignition models will not sense flame if L1 and L2 are reversed.

Installation of the electric supply line should be in accordance with the National Electric Code ANSI/NFPA No. 70, latest edition, or Canadian Electrical Code Part 1 - CSA Standard C22.1 and local building codes.

This can be obtained from:

National Fire Protection Association Batterymarch Park Quincy, MA 02269

Canadian Standards Association 178 Rexdale Blvd. Etobicoke (Toronto), Ontario Canada M9W, 1R3

WARNING

ELECTRICAL WIRING

as shown on the wiring diagram. Never install the thermostat on an outside wall or where it will be influenced by drafts, concealed hot or cold water pipes, lighting fixtures, radiation from fireplace, rays of sun, lamps, television, radios or air streams from registers. Refer to the instructions packed with the thermostat for best anticipator adjustment or selection or see below.

HEAT ANTICIPATOR SETTINGS

For adjusting the thermostat heat anticipator setting; (a) add the current draw of the various components in the system or (b) measure the current flow on either the R or W thermostat circuit and set the thermostat heat anticipator according to the current flow measured.

The room thermostat must be compatible with the integrated furnace control on the furnace. All thermostats available from the furnace manufacturer’s Parts Department are acceptable. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control we use.

NOTICE: An isolation relay can be added to prevent any compatibility problems that may occur. Use a singlepole, single-throw relay with a 24-volt AC coil. The contacts should be rated for .5 amps minimum at 24 volts. See Figure 17.

Install the room thermostat in accordance with the instruction sheet in the box with the thermostat. Run the thermostat lead wires inside the control compartment. Connect the thermostat

THERMOSTAT

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.

3.0

2.5

2.0

16 16 18

14 14 16

12 12 14

10 12 12

10 10 10

50 100 150 200 250 300

Length of Run – Feet (1)

Thermostat Load - Amps

① The total wire length is the distance from the furnace to the thermostat and back to the furnace. NOTE: Do not use 24 volt control wiring smaller than No. 18.

FIGURE 17 ISOLATION RELAY

ST-A0804-01

Page 21

FIELD INSTALLED OPTION ACCESSORIES

ELECTRONIC AIR CLEANER

1. Electronic air cleaner line voltage power can be supplied from the screw terminal “EAC” and a line voltage neutral screw terminal on the control board. See Figure 18. This will power the electronic air cleaner whenever the circulating air blower is in operation.

HUMIDIFIER

2. Humidifier line voltage power can be supplied from screw terminal “HUM” to a line voltage neutral screw terminal on the control board. See Figure 18. This will power the humidifier whenever the burner is on and the circulating air blower is operating in the heating mode.

NOTE: Maximum current –1.0 amps for each option.

FURNACE TWINNING INSTALLATIONS

IMPORTANT: TWINNING OF RGDJ, RGPJ, RGLJ AND RGVJ UNITS REQUIRES AN ACCESSORY TWINNING KIT. REFER TO THE SPECIFICATION SHEET FOR PROPER KIT. DO NOT ATTEMPT TO TWIN THESE MODELS BY USING THE INSTRUCTIONS BELOW.

Twinning operation of two furnaces, installed side-by-side, connected by a common duct system with main power supplied by the same source, and controlled by a common thermostat can be done with the Honeywell S9201E2001, UTEC 1012-920 or White Rodgers 50A62-101 integrated control boards.

The “OK” LED will flash if twinning is not set up properly.

HONEYWELL S9201E2001 CONTROL BOARD

1. Single Stage Operation (See Figure 19)

a. Control board “ONE” is

connected to the thermostat.

b. Remove the jumper between

the “XMIT” and “RCV” terminals.

c. Connect wire from “XMIT”

terminal of board “ONE” to “RCV” terminal of board “TWO.”

d. Connect wire from “RCV”

terminal of board “ONE” to “XMIT” terminal of board “TWO.”

e. Connect wire between the

grounds.

f. Connect wire between the two

“W” thermostat terminals.

2. Two Stage Operation (See Figure 20)

a. Repeat steps a, b, c, d and e

above.

b. Connect “W1” of thermostat to

“W” on control board “ONE”.

c. Connect “W2” of thermostat to

“W” on control board “TWO”.

UTEC 1012-920 OR WHITE RODGERS 50A62-101 CONTROL BOARD

1. Single Stage Operation (See Figure 21)

a. Control board “ONE” is on

furnace connected 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

switch #3 in the “ON” position.

e. Control board “ONE” must have

the switch #4 in the “1st” stage position. The other control board must have switch #4 in the “2nd” position for single or two stage heat operation.

2. Two Stage Operation (See Figure 22)

a. Follow above instructions.

Switch #4 on control board “TWO” must be in “2nd” stage position (i.e. control board #2 must be the 2nd stage).

b. Connect “W2” on thermostat to

“W” on control board “TWO”.

FIGURE 18 LINE VOLTAGE CONNECTIONS HONEYWELL S9201E2001, UTEC 1012-920 AND WHITE RODGERS 50A62101 CONTROL BOARD

UTEC 1012-925 CONTROL BOARD

I334

I677

Page 22

I400

FIGURE 19 HONEYWELL NO. S9201E2001 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION

Page 23

FIGURE 20 HONEYWELL NO. S9201E2001 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION

I400

Page 24

FIGURE 21 UTEC NO. 1012-920 OR WHITE RODGERS 50A62-101 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION

I398

Page 25

FIGURE 22 UTEC NO. 1012-920 OR WHITE RODGERS 50A62-101 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION

I399

Page 26

HOT SURFACE IGNITION LIGHTING INSTRUCTIONS

This appliance is equipped with a hot surface silicon carbide ignition device. This device lights the main burners each time the room thermostat (closes) calls for heat. See lighting instructions on the furnace.

IMPORTANT: FOR Nox MODELS –

Make a visual inspection of the Nox inserts to ensure they are in proper position and have not become dislodged during shipping or time in the warehouse.

TO START FURNACE

1. BE SURE THAT THE MANUAL GAS

CONTROL HAS BEEN IN THE “OFF” POSITION FOR AT LEAST FIVE MINUTES. DO NOT ATTEMPT TO MANUALLY LIGHT THE MAIN BURNERS. FAILURE TO FOLLOW THIS WARNING CAN CAUSE A FIRE OR AN EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

2. Set the room thermostat to the lowest setting.

3. Turn the gas control knob to the “On” position, or move the gas control lever to the “On” position.

4. Replace the control access door.

5. Turn on the electrical power.

6. Set the room thermostat to a point above room temperature to light the main burners. After the burners are lit, set room thermostat to a desired temperature.

TO SHUT DOWN FURNACE

1. Set the room thermostat to its lowest setting.

2. Shut off the gas to main burners by turning the gas control knob to the “Off” position, or by depressing the gas control lever and moving it to the “Off” position.

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, SHUT OFF THE MANUAL GAS VALVE TO THE APPLIANCE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SEQUENCE OF OPERATION

Honeywell or UTEC Integrated Controls with Hot Surface Ignition.

1. Each time the thermostat contacts close, the induced draft blower (inducer) begins a prepurge cycle.

2. The air proving negative pressure switch(es) closes.

WARNING

3. 30 seconds after the pressure

switch(es) close, the hot surface

igniter heats for 30 seconds to full

temperature. The induced draft blower operates for the complete heating cycle.

4. After the 30-second igniter warm up,

the gas valve opens for a 9-second trial for ignition.

5. The igniter lights the gas burners and

stays energized for the first 8 seconds after the gas valve opens.

6. 8 seconds after the gas valve opens

the remote flame sensor must prove flame ignition for one second

using the process of flame rectification. If the burners don’t light, the system goes through another ignition sequence. It does this up to four times.

7. The main blower starts 20 seconds after the burners ignite.

8. When the thermostat cycle ends, the gas valve closes, the burners go out, the induced draft blower runs for a 5- second post-purge, and the negative pressure switch(es) open.

9. The main blower continues until timed off by the setting on the integrated furnace control board.

Sequence if the system doesn’t light or doesn’t sense flame:

1. On a call for heat, the control runs the inducer for 30 seconds to prepurge.

2. After the 30-second prepurge, the hot surface igniter heats for 30 seconds. The inducer continues to run.

3. After the 30-second igniter warm up, the gas valve opens for a 9-second trial for ignition. The inducer continues and the igniter stays energized.

4. If flame is not sensed during the 9th second after the gas valve opens, the gas valve closes, and the igniter deenergizes.

5. After a 30 second inter-purge, the igniter heats for 30 seconds. After 30 seconds, the gas valve opens for 9 seconds. If no flame is sensed, it closes the gas valve, the igniter deenergizes, Both the main blower

and the inducer operate for 180 seconds before the next ignition trial.

6. It repeats this process up to four times. At the end of the last try, the inducer stops immediately. The

system is in “soft” lock out.

7. The above sequence will repeat after a one hour delay. It will continue repeating until ignition is successful or the call for heat is terminated.

8. To reset the lock out, make and

break power either at the thermostat or at the unit disconnect switch for 5 to 10

seconds. It then goes through

another set of trials for ignition.

WHITE RODGERS 50A62-101 WITH HOT SURFACE IGNITION

1. Each time the thermostat contacts close, the induced draft blower (inducer) begins a pre-purge cycle.

2. The air proving negative pressure switch(es) close.

3. 10 seconds after the pressure

switch(es) close, the hot surface

igniter heat up for 20 seconds to full

temperature.

4. After the 20 second igniter warm-up,

the gas valve opens for an 8second trial for ignition.

5. The igniter lights the gas burners and

stays energized for one (1) second after flame is sensed.

6. 7 seconds after the gas valve opens

the remote flame sensor must prove flame ignition for one second

using the process of flame rectification. If the burners do not light, the system goes through another ignition sequence. It does this up to four times.

7. When the thermostat cycle ends, the gas valve closes, the burners go out, the induced draft blower runs for a 5- second post-purge, and the negative pressure switch(es) open.

9. The main blower continues until timed off by the setting on the integrated furnace control board.

Sequence if the system doesn’t light or doesn’t sense flame:

1. On a call for heat, the control runs the inducer for 10 seconds to pre-purge.

2. After the 10 second pre-purge, the hot surface igniter heats for 20 seconds. The inducer continues to run.

3. After the 20-second igniter warms up, the gas valve opens for an 8-second trial for ignition. The inducer continues and the igniter stays energized.

4. If flame is not sensed during the 8th second after the gas valve 9opens, the gas valve closes, and the igniter de-energizes.

5. After a 30 second inter-purge, the igniter heats for 20 seconds. After 20 seconds, the gas valve opens for 8 seconds. If no flame is sensed, it closes the gas valve, the igniter deenergizes. Both the main blower

and the inducer operate for 180 seconds before the next ignition trial.

6. It retries up to four times. At the end of the last try, the inducer stops immediately. The system is in “soft”

lock out.

7. The above sequence will repeat after a one hour delay. It will continue repeating until ignition is successful or the call for heat is terminated.

8. To reset the lock out, make and

break power either at the thermostat or at the unit disconnect switch for 5 to 10

seconds. It then goes through

another set of trials.

WARNING

START-UP PROCEDURE

Page 27

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES EQUIPPED FOR NATURAL

OR LP GAS

INPUT

BTU/HR

METER

SIZE

CU. FT.

HEATING VALUE OF GAS BTU PER CU. FT.

900 1000 1040 1100 2500

MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

ONE 1 12 1 20 1 23 1 28 3 20

45,000

TEN 12 0 13 20 13 50 14 40 33 20

ONE 1 5 1 12 1 15 1 18 3 20

50,000

TEN 10 50 12 00 12 30 13 12 30 00

ONE 0 48 0 53 0 55 0 59 2 13

67,500

TEN 8 0 8 53 9 15 9 50 22 13

ONE 0 44 0 48 0 50 0 53 2 0

75,000

TEN 7 12 8 0 8 19 8 48 20 0

ONE 0 33 0 36 0 38 0 40 1 30

100,000

TEN 5 24 6 0 6 15 6 36 15 0

ONE 0 26 0 29 0 30 0 32 1 12

125,000

TEN 4 19 4 48 5 0 5 17 12 0

ONE 0 31 0 24 0 25 0 26 1 0

150,000

TEN 3 36 4 0 4 10 4 20 10 0

Heating Value of Gas (BTU/Ft3) x 3600

Input BTU/HR =

Time in Seconds (for 1 cu.ft.) of Gas

TABLE 4

FIGURE 25 UTEC - 925 BLOWER OFF TIMINGS

OFF TIME SWITCH 1 SWITCH 2

90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON

(TIMER IS RED BLOCK ON BOARD)

I335

SETTING BLOWER TIMINGS

The Honeywell and UTEC control boards have four quick connect terminals for connecting the motor speed leads. These are:

1. FAN SPEED — motor runs on this speed when the thermostat is in the “FAN” position.

2. COOL — connect desired cooling speed.

3. HEAT — connect desired heating speed.

4. HEAT/COOL — connect desired speed when heating and cooling speed are the same.

IMPORTANT: Do not connect any motor speeds to “HEAT” and “COOL” if you use the “HEAT/COOL” terminal.

5. If heating and continuous speed are the same, jump across “FAN” and “HEAT” terminals.

See Figures 23, 24 and 25 for instructions for setting the blower “OFF” timings.

GAS FURNACE (DIRECT DRIVE) INSTRUCTIONS FOR CHANGING BLOWER SPEED

DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE 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 electronic control), speeds may be changed if necessary to fit requirements of the particular installation. Reconnect the unused

FIGURE 23 UTEC -920 OR WHITE RODGERS 50A62-101 BLOWER OFF TIMINGS

FIGURE 24 HONEYWELL E2001 BLOWER OFF TIMINGS

OFF TIME SWITCH 1 SWITCH 2

90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON

OFF TIME SWITCH 1 SWITCH 2

90 SEC. ON OFF

120 SEC. OFF OFF

160 SEC. OFF ON

180 SEC. ON ON

TWIN

2nd

SINGLE

1st

NOTE: SWITCHES 3 & 4 ARE USED FOR TWINNING APPLICATIONS.

(TIMER IS RED BLOCK ON BOARD)

I402

I335

WARNING

motor leads to “M1” or “M2.” Check motor lead color for speed designation.

Heating speeds should not be reduced where it could cause the furnace air temperature to rise to exceed the maximum outlet air temperature specified for the unit.

IMPORTANT: Always check air temperature rise after changing the heating speed for any reason.

ADJUSTING OR CHECKING FURNACE INPUT

The maximum gas supply pressure to the furnace should be 7( W.C. for natural gas. The minimum gas supply pressure for purposes of input adjustment to the furnace should be 5( W.C.

A properly calibrated manometer or gauge is required for accurate gas pressure readings.

The manifold pressure should be set at

3.5( W.C. for natural gas. Only small variations in the gas flow should be made by means of the pressure regulator adjustment. In no case should the final manifold pressure vary more than plus or minus 0.3( W.C. from the above specified pressures.

To adjust the pressure regulator:

1. Remove the regulator cap.

2. Turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure.

3. Replace the regulator cap securely.

Page 28

Furnaces for use on LP gas, the LP gas supply pressure must be set between 11.0( and 14.0( W.C. by means of the tank or branch supply regulators. The furnace manifold pressure should be set at 10( W.C. at the gas control valve. For elevations up to 8,000 feet, rating plate input ratings apply. For high altitudes (elevations 8,000 and over) and for any necessary major changes in the gas flow rate the orifice spud must be changed.

To change orifice spuds:

1. Shut off the manual main gas valve and remove the gas manifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

4. Turn the gas supply back on and check for proper operation and manifold pressure.

Check of input is important to prevent over firing of the furnace beyond its design-rated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE.

To check furnace input:

1. Make certain that all other gas appliances are shut off, with the exception of pilot burners.

2. Start the furnace

3. Time the meter to measure the time required to burn one cubic foot of gas.

4. Use Table 4 to determine input rate.

RATING PLATE ELEVATION

INPUT

BTU/HR 0 TO 7,999 FT. 8,000 FT. AND ABOVE

NATURAL GAS

HEATING VALUE @ 1,000 BTU/FT

, SPECIFIC GRAVITY 0.62

MANIFOLD PRESSURE @ 3.5( W.C. 45,000 43 45 50,000 42 43 67,500 43 45 75,000 42 43

100,000 42 43 125,000 42 43 150,000 42 43

L.P. GAS

HEATING VALUE @ 2,475 BTU/FT

, SPECIFIC GRAVITY 1.52/

MANIFOLD PRESSURE @ 10( W.C. 45,000 54 55 50,000 54 55 67,500 54 55 75,000 54 55

100,000 54 55 125,000 54 55 150,000 54 55

ORIFICE SIZING CHART

RATING PLATE ELEVATION

INPUT

BTU/HR 0 TO 1,999 FT. 2,000 FT. TO 4,500 FT.

NATURAL GAS

HEATING VALUE @ 1,000 BTU/FT

, SPECIFIC GRAVITY 0.62

MANIFOLD PRESSURE @ 3.5( W.C. 45,000 43 45 50,000 42 43 67,500 43 45 75,000 42 43

100,000 42 43 125,000 42 43 150,000 42 43

L.P. GAS

HEATING VALUE @ 2,475 BTU/FT

, SPECIFIC GRAVITY 1.52/

MANIFOLD PRESSURE @ 10( W.C. 45,000 54 55 50,000 54 55 67,500 54 55 75,000 54 55

100,000 54 55 125,000 54 55 150,000 54 55

ORIFICE SIZING CHART (CANADA)

Page 29

FIGURE 27 FURNACE NAME PLATE

The importance of proper air flow over the heat exchanger cannot be over emphasized. One of the most common causes of heat exchanger failure is overheating due to low air flow. An air flow table is located inside the blower door and on the following pages.

TEMPERATURE RISE CHECK

To determine if the air flow is correct, make a temperature rise check.

1. Insert a thermometer in the supply air duct as close to the furnace as possible yet out of a direct line from the heat exchanger. See Figure 26.

2. Insert a thermometer in the return air duct as close to the furnace as possible.

3. Operate the furnace.

4. When the thermometer 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 temperature rise to the approved temperature rise range listed on the furnace name plate. See Figure 27.

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 air duct. If the measured temperature rise is below the approved range, the air flow is too much. Use lower speed tap on the multi-speed blower.

Ideally the measured temperature rise should be in the middle of the range.

FIGURE 26 TEMPERATURE RISE MEASUREMENT

AIR FLOW

Page 30

BLOWER PERFORMANCE DATA – RGDG & RGPH UPFLOW/HORIZONTAL MODELS

BLOWER PERFORMANCE DATA – RGLH DOWNFLOW MODELS

Page 31

BLOWER PERFORMANCE DATA – RGVH HORIZONTAL MODELS

BLOWER PERFORMANCE DATA – RGDJ & RGPJ UPFLOW/HORIZONTAL MODELS

Page 32

BLOWER PERFORMANCE DATA – RGLJ DOWNFLOW MODELS ONLY

BLOWER PERFORMANCE DATA – RGVJ HORIZONTAL MODELS

Page 33

SAFETY FEATURES

LIMIT CONTROL

The high limit cut-off is set at the factory and cannot be adjusted. It is calibrated to prevent the air temperature leaving the furnace from exceeding the maximum outlet air temperature. If temperature exceeds the maximum outlet air temperature, the limit will shut the furnace down. Reasons which could cause the outlet temperature to exceed the range are failed indoor blower, dirty filters, etc.

OVER TEMPERATURE SAFETY SWITCHES

Furnaces are equipped with safety switches to protect against overtemperature conditions in the control compartment caused by inadequate combustion air supply. In the event of an overtemperature condition, the switch will shut the furnace down. The switch for the dedicated UPFLOW FURNACE and DOWNFLOW is located just above the burners on the blower divider panel. Switches for the UPFLOW/ HORIZONTAL AND HORIZONTAL

ONLY HOT SURFACE IGNITION FURNACES are located on either side of the burner brackets and just above the burners on the blower divider panel. If a switch is tripped, it must be manually reset. DO NOT jumper this switch. If this switch should trip, a qualified installer, service agency or the gas supplier should be called to check and/or correct for adequate combustion air supply. If this unit is mounted in a closet, the door must be closed when making this check.

A failed inducer motor would be a cause of inadequate combustion air.

DO NOT reset the over temperature switch without taking corrective action to assure that an adequate supply of combustion air is maintained under all conditions of operation. Replace this switch only with the identical replacement part.

PRESSURE SWITCH

This furnace has a pressure switch for sensing a blocked vent condition. It is normally open and closes when the induced draft blower starts, indicating air flow through the combustion chamber. As stated, a blocked vent condition will cause the pressure switch to remain open as will a failed inducer, a crack in the pressure switch hose, etc.

LUBRICATION

The blower motor and induced draft motor are prelubricated by the manufacturer and do not require further attention.

The motor must be cleaned periodically by a qualified installer, service agency, or the gas supplier to prevent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor exterior. And, as suggested elsewhere in these instructions, the air filters should be kept clean because dirty filters can restrict airflow and the motor depends upon sufficient air flowing across and through it to keep from overheating.

FIGURE 28 DOWNFLOW BLOWER REMOVAL

Page 34

FIGURE 30 BOTTOM RETURN

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

FILTERS

NOTE: RGDJ, RGPJ, RGVJ, RGLJ and RGVH models are not

factory equipped with filters. Filters must be field installed.

Keep the air filters clean at all times. Vacuum dirt from filter, wash with detergent and water, air dry thoroughly and reinstall.

1. 14(-45,000 and 50,000 btuh unit

requires removal of 3

⁄2( segment of filter and frame to get proper width for a bottom filter.

2. 21(-100,000 btuh unit requires removal of 3

⁄2( segment of filter and frame to get proper width for a side filter.

3. 24

⁄2(-125,000 and 150,000 btuh units require removal of 7( segment of filter and frame to get proper width for a side filter.

TABLE 5 FILTER SIZES

MAINTENANCE

WARNING

FIGURE 29 RESIZING FILTERS & FRAME

*NOTE: Some filters must be resized to fit certain units and applications.

SOLID BOTTOM MAY BE ORDERED AS AN OPTION FROM THE FACTORY.

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE

QUANTITY

WIDTH BTUH SIZE SIZE

14 45 & 50 12

⁄4" X 25" 153⁄4" X 25" 1

171/2" 67, 75 & 100 15

⁄4" X 25" 153⁄4" X 25" 1

21" 100 19

⁄4" X 25" 153⁄4" X 25" 1

241/2" 125 & 150 22

⁄4" X 25" 153⁄4" X 25" 1

DOWNFLOW FILTER SIZES

FURNACE INPUT

SIZE QUANTITY

WIDTH BTUH

14" 45 & 50 14" X 20" 1

/2" 67, 75 & 100 12" X 20" 2

21" 100 12" X 20" 2

/2" 125 & 150 14" X 20" 2

Unit Unit Filter Rod Filter Rod Bottom Side Size Width 20

/4" 241/4"

AE-61659-02 AE-61659-03

45,000 14" 1 Cut Off 3

/2" As is 50,000 14" 1 Cut Off 31/2" As is 67,500 171/2" 1 Cut Off 31/2" As is 75,000 171/2" 1 Cut Off 31/2" As is

100,000 171/2" 1 Cut Off 31/2" As is 100,000 171/2" 1 As is Cut Off 31/2" 125,000 241/2" 1 As is Cut Off 31/2" 150,000 241/2" 1 As is Cut Off 31/2"

Page 35

FIGURE 31 FILTER RETAINING RODS (SIDE RETURN)

FIGURE 32 DOWNFLOW FILTER INSTALLATION

Page 36

IMPORTANT: Do not operate the system for extended periods without filters. A portion of the dust entrained in the air may temporarily lodge in the air duct runs and at the supply registers. Any recirculated dust particles will be heated and charred by contact with the furnace heat exchanger. This residue will soil ceilings, walls, drapes, carpets, and other household articles.

SYSTEM OPERATION INFORMATION

Advise The Customer

1. Keep the air filters clean. The heating system will operate better, more efficiently and more economically.

2. Arrange the furniture and drapes so that the supply air registers and the return air grilles are unobstructed.

3. Close doors and windows. This will reduce the heating load on the system.

4. Avoid excessive use of kitchen exhaust fans.

5. Do not permit the heat generated by television, lamps or radios to influence the thermostat operation.

6 Except for the mounting platform,

keep all combustible articles three feet from the furnace and vent system.

7. IMPORTANT: Replace all blower

doors and compartment covers after servicing the furnace. Do not operate the unit without all panels and doors securely in place.

8. Proper operation of the system with constant air circulation.

ANNUAL INSPECTION

The furnace should operate for many years without excessive scale build-up in the flue passageways, however, it is recommended that a qualified installer, service agency, or the gas supplier actually inspect the flue passageways, the vent system and the main and pilot burners for continued safe operation paying particular attention to deterioration from corrosion or other sources.

HOLES IN THE VENT PIPE OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME RESULTING IN CARBON MONOXIDE POISONING OR DEATH. THE VENT PIPE OR HEAT EXCHANGER MUST BE REPLACED IF THEY LEAK.

If during inspection the flue passageways and vent system are determined to require cleaning, the following procedures should be followed (by a qualified installer,

service agency, or gas supplier):

1. Turn off electrical power to the

furnace and set the thermostat lever to the lowest temperature.

2. Shut off the gas supply to the

furnace either at the meter or at a manual valve in the supply piping.

3. Remove burner door. On downflow models, the blower door and burner door flange must also be removed.

4. Disconnect gas supply piping from gas valve.

5. Remove screws (4) connecting the burner tray to the center panel.

6. Disconnect wiring to the gas valve.

Make sure to mark all wires disconnected for proper reconnection.

7. Remove burner tray and manifold assembly from the unit.

8. Remove all screws in the unit top plate. Remove the top plate along with connecting pressure switch from the unit.

9. Remove screws connecting draft inducer to center panel. Also remove wiring to draft inducer at this time.

10. Remove screws (11) on perimeter of heat exchanger. If hot surface ignition is present, remove the connecting screws along with associated wiring at this time.

11. In an upward and forward motion, lift heat exchanger from the unit.

12. Flush each heat exchanger tube with water from a hose and blow out with air to remove excessive moisture. If heat exchanger is blocked, especially with soot, and cannot be flushed, it must be replaced.

13. Reassemble (steps 1 through 11 in reverse order.

• IMPORTANT: It is recommended

that at the beginning of the heating season and approximately midway in the heating season a visual inspection be made of the main burner flames and pilot flame on standing pilot models for the desired flame appearance by a qualified installer, service agency, or the gas supplier.

• IMPORTANT: It is also

recommended that at the beginning of the heating season, the flame sensor on hot surface ignition models be cleaned with steel wool by a qualified installer, service agency, or the gas supplier.

• IMPORTANT: It is recommended

that an annual inspection and cleaning of all furnace markings be made to assure legibility. Attach a replacement marking, which can be obtained through the distributor, if any are found to be eligible or missing.

IMPORTANT: FOR Nox MODELS –

At the beginning of the heating season a visual inspection of the Nox should be made to ensure they have not become obstructed by insects nests or anything else which may effect performance.

REPLACEMENT PARTS

Contact your local distributor for a complete parts list. See enclosed sheet.

TROUBLESHOOTING

Refer to Figures 33, 34, and 35 for determining cause of unit problems.

WIRING DIAGRAM

Figures 36, 37 and 38 are complete wiring diagrams for the furnace and power sources.

WARNING

Page 37

FIGURE 33 INTEGRATED FURNACE CONTROL (IFC) TROUBLESHOOTING GUIDE FOR UTEC 1012-920 & HONEYWELL S9201E2001 (115 VAC IGNITER)

START

1. SET FAN SWITCH TO AUTO

2. SET THERMOSTAT TO CALL FOR HEAT

INDUCED DRAFT MOTOR

(IDM) STARTS

30 SEC. PREPURGE

IGNITER WARMS UP

AND GLOWS RED

34 SECONDS WARMUP

MAIN BURNER

LIGHTS

• REMOVE (IFC) COVER, CHECK LIGHTS POWER LED ON • CHECK LINE VOLTAGE POWER

• CHECK LOW VOLTAGE TRANSFORMER

MICROPROCESSOR STATUS LED ON REPLACE (IFC) NOTE: “OK” LED WILL FLASH TO INDICATE TWINNING CIRCUIT FAULTS.

CHECK FOR 24 VAC FROM CHECK THERMOSTAT TERMINAL “W” TO “C” ON IFC WIRING

• CHECK LIMITS, (CLOSED)

• CHECK WIRING

• CHECK PRESSURE SWITCH, (OPEN) REPLACE SWITCH

IF THE PRESSURE SWITCH DOESN’T CLOSE WITHIN 60 SEC. THE IDM WILL STOP FOR 5 MIN. AND RETRY

• CHECK FOR 115VAC 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 IGNITER, IF WIRING TO

TERMINALS AND AT (IFC) TERMINALS IGNITER IS OK

REPLACE IGNITER

SYSTEM WILL ATTEMPT TO LIGHT 4 TIMES. VOLTAGE IS PRESENT AT THE VALVE FOR ONLY 9 SECONDS DURING EACH TRIAL FOR IGNITION (SYSTEM WILL GO INTO A 1-HOUR LOCKOUT AFTER 4 TRIES). THE BLOWER AND INDUCED DRAFT BLOWER WILL RUN 180 SEC. IF THE FIRST IGNITION TRIAL FAILS TO SENSE FLAME

• CHECK FOR 24 VAC ACROSS THE VALVE AND

VALVE TERMINALS ON THE (IFC)

• CHECK IGNITER POSITION

• CHECK FOR GAS FLOW TO AND

FROM VALVE

REPLACE VALVE REPLACE (IFC)

IF WIRING TO

VALVE IS OK

WARNING

DISCONNECT POWER BEFORE SERVICING. SERVICE MUST BE BY A TRAINED, QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGE

LINE VOLTAGE CONNECTIONS

FLOW CHART CONTINUED ON NEXT PAGE

YES

➤

Page 38

NOTE: STATIC DISCHARGE CAN DAMAGE INTEGRATED FURNACE CONTROL (IFC)

MAIN BURNER

REMAINS POWERED

AND LIT

INDOOR BLOWER MOTOR

STARTS 20 SECONDS

AFTER GAS VALVE OPENS

SYSTEM RUNS

UNTIL CALL FOR

HEAT ENDS

TURN THERMOSTAT TO OFF

VALVE SHUTS OFF

FLAME OFF

IDM MOTOR STOPS AFTER 5 SEC.

INDOOR BLOWER MOTOR

STOPS AFTER

90/120/160/180 SECONDS

TROUBLESHOOTING ENDS

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN

RESET SYSTEM

• CHECK POLARITY OF 115VAC SUPPLY

• CHECK CONTINUITY OF GROUND WIRE

• CHECK INSULATION OF IGNITER LEADS

• CHECK FLAME SENSE CURRENT (YELLOW LED) LED IS 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)

• 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) GOES INTO LOCKOUT WAIT 30 SECONDS THEN

RESET SYSTEM

• CHECK CONTINUITY OF GROUND WIRE. NOTE: IF GROUND IS

POOR OR ERRATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.

• CHECK FLAME SENSE CURRENT

• 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

• RESTORE POWER TO UNIT

• IF CHECKS ARE OK, REPLACE (IFC)

• CHECK FOR PROPER THERMOSTAT OPERATION

• REMOVE VALVE LEAD AT (IFC) IF VALVE CLOSED, RECHECK THERMOSTAT AND WIRING. IF NOT, REPLACE VALVE.

• CHECK FOR OPEN LIMIT.

• REPLACE (IFC)

• CHECK FOR OPEN LIMIT. REPLACE (IFC)

REPEAT PROCEDURE UNTIL TROUBLE FREE

OPERATION IS OBTAINED.

YES

Page 39

• CHECK FOR BLOCKED VENT

• CHECK AIR PROVING SWITCH (CLOSED)

• CHECK WIRING TO IGNITER

• CHECK FOR 60 TO 90VAC AT IGNITER, TERMINALS AND AT (IFC) TERMINALS

FIGURE 34 INTEGRATED FURNACE CONTROL (IFC) WHITE RODGERS 50A62-101 (SILICON-NITRIDE IGNITER)

1. SET FAN SWITCH TO AUTO

2. SET THERMOSTAT TO CALL FOR HEAT

START

YES

INDUCED DRAFT BLOWER

MOTOR STARTS

THE IFC WILL PERFORM A SELFTEST OF THE IGNITER AND DRAFT MOTOR CIRCUIT. IF THERE IS AN IGNITER FAULT, BAD CONNECTION TO THE IGNITER, OR A BAD GROUND CONNECTION, THE DRAFT MOTOR WILL STOP AFTER A FEW SECONDS AND LOCKOUT.

YES

PRE-PURGE CONTINUES

IGNITER WARMS UP

AND GLOWS RED

20 SECONDS WARMUP

YES

10 SEC. PREPURGE

REPLACE (IFC)

REPLACE SWITCH

REPLACE (IFC)

IF WIRING TO

DRAFT MOTOR IS OK

REPLACE SWITCH

REPLACE (IFC) IF WIRING TO IGNITER IS OK

CHECK THERMOSTAT WIRING

• CHECK LINE VOLTAGE POWER

• CHECK LOW VOLTAGE TRANSFORMER

WHITE-RODGERS 50A62-101

INTEGRATED FURNACE CONTROL (IFC)

TROUBLESHOOTING GUIDE

(SILICON-NITRIDE IGNITER)

POWER LED ON

IF THE PRESSURE SWITCH DOESN’T CLOSE WITHIN 60 SEC. THE IOM WILL STOP FOR 5 MIN. AND RETRY

• REMOVE (IFC) COVER, CHECK LIGHTS

MICROPROCESSOR STATUS “OK” LED ON NOTE: “OK” LED WILL FLASH TO INDICATE TWINNING CIRCUIT FAULTS

• CHECK FOR 115VAC TO DRAFT MOTOR

REPLACE IOM MOTOR

CHECK FOR 24 VAC FROM “W” TO “C” ON IFC

• CHECK LIMITS, (CLOSED)

• CHECK WIRING

• CHECK PRESSURE SWITCH, (OPEN)

YES

REPLACE IGNITER

NOTE:

STATIC DISCHARGE CAN DAMAGE INTEGRATED FURNACE CONTROL (IFC)

WARNING

DISCONNECT POWER BEFORE

SERVICING.

SERVICE MUST BE BY A TRAINED,

QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGE

LINE VOLTAGE

CONNECTIONS

Page 40

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN RESET SYSTEM

• CHECK CONTINUITY OF GROUND WIRE. NOTE: IF GROUND IS POOR OR ERATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.

• CHECK FLAME SENSE CURRENT

• CHECK FOR EXCESSIVE HEAT AT IGNITER BASE.

• TURN POWER OFF TO UNIT.

• CLEAN FLAME SENSOR WITH STEEL WOOL.

• RESTORE POWER TO UNIT.

• IF CHECKS ARE OK, REPLACE (IFC)

YES

MAIN BURNER

LIGHTS

YES

MAIN BURNER REMAINS

POWERED AND LIT

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

INDOOR BLOWER MOTOR

STARTS 20 SECONDS

AFTER BURNERS LIGHT

YES

REPLACE BLOWER MOTOR

REPLACE VALVE

REPLACE (IFC) IF WIRING TO VALVE IS OK

REPLACE (IFC) IF WIRING TO BLOWER MOTOR IS OK

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN RESET SYSTEM

• CHECK POLARITY OF 115VAC SUPPLY

• CHECK CONTINUITY OF GROUND WIRE

• CHECK INSULATION ON IGNITER LEADS

• CHECK FLAME SENSE CURRENT (YELLOW LED) LED IS 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 ATTEMPT TO LIGHT 4 TIMES. VOLTAGE IS PRESENT AT THE VALVE FOR ONLY 8 SECONDS DURING EACH TRIAL FOR IGNITION (SYSTEM WILL GO INTO A 1-HOUR LOCKOUT AFTER 4 TRIES), THE SEQUENCE WILL REPEAT AFTER A ONE HOUR DELAY. IT WILL CONTINUE UNTIL IGNITION IS SUCCESSFUL OR THE CALL FOR HEAT IS TERMINATED. THE BLOWER AND INDUCED DRAFT BLOWER WILL RUN 100 SECONDS. IF THE FIRST AND SECOND IGNITION TRIAL FAILS TO SENSE FLAME

• CHECK FOR 24VAC ACROSS THE VALVE AND VALVE TERMINALS ON THE (IFC)

• CHECK IGNITER POSITION,

• CHECK FOR GAS FLOW TO AND FROM VALVE.

• CHECK FOR 115VAC ACROSS BLOWER MOTOR AND BLOWER MOTOR TERMINALS (HEAT AND NEUTRAL) ON (IFC)

TURN THERMOSTAT TO OFF

VALVE SHUTS OFF

FLAME OFF

• CHECK FOR PROPER THERMOSTAT OPERATION.

• REMOVE VALVE LEAD AT (IFC) IF VALVE CLOSED, RECHECK THERMOSTAT AND WIRING IF NOT, REPLACE VALVE

YES

IDM MOTOR STOPS

AFTER 5 SEC.

TROUBLESHOOTING ENDS

• CHECK FOR OPEN LIMIT, REPLACE (IFC)

YES

INDOOR BLOWER MOTOR

STOPS AFTER

90/120/160/180 SECONDS

• CHECK FOR OPEN LIMIT, REPLACE (IFC)

REPEAT PROCEDURE UNTIL TROUBLEFREE

OPERATION IS OBTAINED.

92-22744-11-02

Page 41

FIGURE 35 INTEGRATED FURNACE CONTROL (IFC) UTEC 1012-925 (115 VAC IGNITER)

1. SET FAN SWITCH TO AUTO

2. SET THERMOSTAT TO CALL FOR HEAT

START

WARNING

DISCONNECT POWER BEFORE SERVICING. SERVICE MUST BE BY A TRAINED, QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGE

LINE VOLTAGE CONNECTIONS

YES

INDUCED DRAFT BLOWER

MOTOR STARTS

YES

PURGE CONTINUES IGNITER WARMS UP

AND GLOWS RED

30 SECONDS WARMUP

YES

5 SEC. PREPURGE

REPLACE (IFC)

REPLACE SWITCH

REPLACE (IFC)

IF WIRING TO

DRAFT MOTOR IS OK

REPLACE SWITCH

REPLACE (IFC) IF WIRING TO IGNITER IS OK

CHECK THERMOSTAT WIRING

• CHECK LINE VOLTAGE POWER

• CHECK LOW VOLTAGE TRANSFORMER

NOTE: 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 SWITCH IS OPEN (3) BLINKS FOLLOWED BY A 2 SEC. PAUSE - LIMIT SWITCH IS OPEN (4) BLINKS FOLLOWED BY A 2 SEC. PAUSE - PRESSURE SWITCH SHORTED

INTEGRATED FURNACE CONTROL (IFC)

TROUBLESHOOTING GUIDE

(115 VAC IGNITER)

CHECK FOR 24 VAC POWER FROM “R” TO “C” ON IFC

IF THE PRESSURE SWITCH DOESN’T CLOSE WITHIN 60 SEC. THE IOM WILL STOP FOR 5 MIN. AND RETRY

• REMOVE (IFC) COVER, CHECK LIGHTS

MICROPROCESSOR STATUS “OK” LED ON

• CHECK FOR 115VAC TO DRAFT MOTOR

REPLACE DRAFT MOTOR

CHECK FOR 24 VAC FROM “W” TO “C” ON IFC

• CHECK LIMITS, (CLOSED)

• CHECK WIRING

• CHECK PRESSURE SWITCH, (OPEN)

YES

REPLACE IGNITER

• CHECK FOR BLOCKED VENT

• CHECK AIR PROVING SWITCH (CLOSED)

• CHECK WIRING TO IGNITER

• CHECK FOR 115VAC AT IGNITER, TERMINALS AND AT (IFC) TERMINALS

Page 42

YES

MAIN BURNER

REMAINS POWERED

AND LIT

YES

MAIN BURNER

REMAINS POWERED

AND LIT

INDOOR BLOWER MOTOR

STARTS 20 SECONDS

AFTER GAS VALVE OPENS

YES

REPLACE BLOWER MOTOR

REPLACE VALVE IF NO FLOW THRU VALVE

REPLACE (IFC) IF WIRING TO VALVE IS OK

REPLACE (IFC) IF WIRING TO BLOWER MOTOR IS OK

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN RESET SYSTEM

• CHECK POLARITY OF 115VAC SUPPLY

• CHECK CONTINUITY OF GROUND WIRE

• CHECK INSULATION ON IGNITER LEADS

• CHECK FLAME SENSE CURRENT (YELLOW LED) LED IS 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)

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN RESET SYSTEM

• CHECK CONTINUITY OF GROUND WIRE, NOTE: IF GROUND IS

POOR OR ERATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.

• CHECK FLAME SENSE CURRENT

• 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)

SYSTEM WILL ATTEMPT TO LIGHT 4 TIMES. VOLTAGE IS PRESENT AT THE VALVE FOR ONLY 8 SECONDS DURING EACH TRIAL FOR IGNITION (SYSTEM WILL GO INTO A 1-HOUR LOCKOUT AFTER 4 TRIES), THE BLOWER AND INDUCED DRAFT BLOWER WILL RUN 100 SEC. IF THE SECOND IGNITION

TRIAL FAILS TO SENSE FLAME

• CHECK FOR 24VAC ACROSS THE VALVE AND VALVE TERMINALS ON THE (IFC)

• CHECK IGNITER POSITION,

• CHECK FOR GAS FLOW TO AND FROM VALVE.

• CHECK FOR 115VAC ACROSS BLOWER MOTOR AND BLOWER MOTOR TERMINALS (HEAT AND NEUTRAL) ON (IFC)

TURN THERMOSTAT TO OFF

VALVE SHUTS OFF FLAME GOES OUT

• CHECK FOR PROPER THERMOSTAT OPERATION.

• REMOVE VALVE LEAD AT (IFC) IF VALVE CLOSED, RECHECK THERMOSTAT AND WIRING IF NOT, REPLACE VALVE

YES

DRAFT MOTOR STOPS

AFTER 5 SEC.

TROUBLESHOOTING ENDS

• CHECK FOR OPEN LIMIT, REPLACE (IFC)

YES

INDOOR BLOWER MOTOR

STOP AFTER

90/120/160/180 SECONDS

• CHECK FOR OPEN LIMIT, REPLACE (IFC)

REPEAT PROCEDURE UNTIL TROUBLEFREE

OPERATION IS OBTAINED.

92-22744-10-00

Page 43

FIGURE 36 FOR MODELS WITH UTEC 1012-920 OR HONEYWELL S9201E2001 INTEGRATED FURNACE CONTROL

Page 44

FIGURE 37 FOR MODELS WITH WHITE RODGERS 50A62-101 INTEGRATED FURNACE CONTROL

Page 45

FIGURE 38 FOR MODELS WITH UTEC 1012-925 INTEGRATED FURNACE CONTROL

Page 46

464748 CM 398

Page 47

Page 48

Rheem Manufacturing Company Air Conditioning Division Fort Smith, Arkansas

Rheem RGPH, RGDJ, RGDG, RGPJ, RGLH Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual