Rheem RRNL-B, RRNL-C, RRPL-B Installation Manual

INSTALLATION INSTRUCTIONS

ISO 9001:2008

Seasonal Energy Efficiency Ratio (SEER)

Annual Fuel Utilization Efficiency -

AFUE

HIGHMID

13.0 14.0 16.0

80.0%

RRNL RRPL RRRL

THIS MODEL

10.6

—

Uses least energy

➞

16.05

78% 82% 88% 97%

PACKAGE GAS ELECTRIC

FEATURING EARTH-FRIENDLY R-410A REFRIGERANT RRNL-B/C 13 SEER (2-5 TONS) RRPL-B 14 SEER (2-5 TONS) RRRL-C UP TO 16 SEER (2-5 TONS)

(14 SEER &

ABOVE)

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

SUPERSEDES 92-21916-30-08

92-21916-30-09

TABLE OF CONTENTS

I. Safety Information .................................................................................................3

II. Introduction............................................................................................................6

III. Checking Product Received..................................................................................6

IV. Specifications ........................................................................................................6

A. General .............................................................................................................6

B. Major Components............................................................................................6

C.R-410A Refrigerant...........................................................................................6

D.Comfort Alert System........................................................................................7

1. Comfort Alert.................................................................................................7

2. High Pressure Control...................................................................................8

3. Low Pressure Control....................................................................................8

4. Comfort Alert With Active Protection.............................................................8

V. Unit Dimensions ..................................................................................................11

VI. Installation ...........................................................................................................13

A. General ...........................................................................................................13

1. Pre-Installation Check................................................................................13

2. Location Considerations.............................................................................13

B. Outside Installation..........................................................................................13

C.Attaching Exhaust and Combustion Air Inlet Hoods .......................................14

D.Cover Panel Installation/Conversion Procedure .............................................15

1. Horizontal to Downflow ...............................................................................15

2. Downflow to Horizontal ...............................................................................15

E. Clearances......................................................................................................15

F. Rooftop Installation .........................................................................................17

G.Ductwork .........................................................................................................17

H.Return Air........................................................................................................19

I. Filters...............................................................................................................20

VII. Gas Supply, Condensate Drain and Piping.........................................................22

A. Gas Connection ..............................................................................................22

B. LP Conversion Single Stage Gas Heat...........................................................23

C.LP Conversion Two Stage Gas Heat..............................................................24

D.NOx Models ....................................................................................................24

E. Adjusting or Checking Furnace Input..............................................................24

F. Condensate Drain...........................................................................................25

VIII. Wiring ..................................................................................................................25

A. Power Supply..................................................................................................25

B. Hook Up ..........................................................................................................27

C.Internal Wiring.................................................................................................27

D.Thermostat......................................................................................................27

IX. Furnace Section Controls and Ignition System ...................................................28

A. Normal Furnace Operating Sequence Single Stage Gas Heat.......................28

B. Normal Furnace Operating Sequence Two Stage Gas Heat..........................28

C.Operating Instructions.....................................................................................30

D.Burners............................................................................................................31

E. Manual Reset Overtemperature Control .........................................................31

D.Pressure Switch..............................................................................................31

G.Limit Control....................................................................................................31

X. System Operating Information.............................................................................31

A. Advise the Customer.......................................................................................31

B. Furnace Section Maintenance ........................................................................31

C.Lubrication.......................................................................................................32

D.Cooling Section Maintenance .........................................................................32

E. Replacement Parts..........................................................................................33

F. Charging..........................................................................................................33

G.Blower Motor Speed Adjustments...................................................................33

XI. Units with ECM Blower Motors (RRRL-B Models Only)......................................36

A. ECM Motor Interface Control and Settings (RRRL Units Only).......................36

B. Transformer Protection ...................................................................................37

C.Using the Onboard LED to Determine Blower CFM........................................37

D.Unit Operation with Two-Stage Cooling..........................................................38

E. Cooling Airflow Adjustments ...........................................................................38

F. Heating Airflow Adjustments...........................................................................41

G.Cooling Delay Profiles.....................................................................................41

H.Cooling Mode Dehumidification ......................................................................42

I. On Demand Dehumidification Airflow Adjustment ..........................................42

XII. General Data..................................................................................................44-66

XIII. Miscellaneous.................................................................................................67-71

XIV. Airflow Performance Data ..............................................................................72-76

XV. Wiring Diagrams.............................................................................................77-87

XVI. Charge Charts..............................................................................................88-103

XVII. Troubleshooting..........................................................................................104-105

XVIII. Comfort Alert Diagnostic Chart...................................................................106-107

I. SAFETY INFORMATION

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

THE MANUFACTURER’S WARRANTY DOES NOT COVER ANY DAMAGE OR DEFECT TO THE AIR CONDITIONER CAUSED BY THE ATTACHMENT OR USE OF ANY COMPONENTS, ACCESSORIES OR DEVICES (OTHER THAN THOSE AUTHORIZED BY THE MANUFACTURER) INTO, ONTO OR IN CONJUNCTION WITH THE AIR CONDITIONER. YOU SHOULD BE AWARE THAT THE USE OF UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES MAY ADVERSELY AFFECT THE OPERATION OF THE AIR CONDITIONER AND MAY ALSO ENDANGER LIFE AND PROPERTY. THE MANUFACTURER DISCLAIMS ANY RESPONSIBILITY FOR SUCH LOSS OR INJURY RESULTING FROM THE USE OF SUCH UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES.

WARNING

UNITS ARE NOT DESIGN CERTIFIED TO BE INSTALLED INSIDE THE STRUCTURE. DOING SO CAN CAUSE INADEQUATE UNIT PERFORMANCE AS WELL AS PROPERTY DAMAGE AND CARBON MONOXIDE POISONING RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

THESE UNITS ARE DESIGNED CERTIFIED FOR OUTDOOR INSTALLATION ONLY. INSTALLATION INSIDE ANY PART OF A STRUCTURE CAN RESULT IN INADEQUATE UNIT PERFORMANCE AS WELL AS PROPERTY DAMAGE. INSTALLATION INSIDE CAN ALSO CAUSE RECIRCULATION OF FLUE PRODUCTS INTO THE CONDITIONED SPACE RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

THIS UNIT MUST NOT BE INSTALLED DIRECTLY ON WOOD FLOORING, CLASS A, CLASS B OR CLASS C ROOF COVERING MATERIALS, OR ANY OTHER COMBUSTIBLE STRUCTURE EXCEPT AS SPECIFIED IN FIGURE 16. FAILURE TO ADHERE TO THIS WARNING CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN DUCTWORK TO ANY OTHER HEAT PRODUCING DEVICE SUCH AS FIREPLACE INSERT, STOVE, ETC. UNAUTHORIZED USE OF SUCH DEVICES MAY RESULT IN FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY, OR PROPERTY DAMAGE.

WARNING

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. ALL OTHER DUCT JOINTS MUST BE SECURED WITH APPROVED CONNECTIONS AND SEALED AIRTIGHT.

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

WARNING

DO NOT USE AN OPEN FLAME TO CHECK FOR LEAKS. THE USE OF AN OPEN FLAME CAN RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

THIS UNIT 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, PERSONAL INJURY, PROPERTY DAMAGE OR DEATH.

WARNING

TURN OFF THE MAIN ELECTRICAL POWER AT THE BRANCH CIRCUIT DISCONNECT CLOSEST TO THE UNIT BEFORE ATTEMPTING ANY WIRING. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

WARNING

DO NOT ATTEMPT TO MANUALLY LIGHT THIS FURNACE WITH A MATCH OR ANY OPEN FLAME. ATTEMPTING TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

WARNING

THE SPARK IGNITOR AND IGNITION LEAD FROM THE IGNITION CONTROL ARE HIGH VOLTAGE. KEEP HANDS OR TOOLS AWAY TO PREVENT ELECTRICAL SHOCK. SHUT OFF ELECTRICAL POWER BEFORE SERVICING ANY OF THE CONTROLS. FAILURE TO ADHERE TO THIS WARNING CAN RESULT IN PERSONAL INJURY OR DEATH.

WARNING

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 RESULT IN AN EXPLOSION OR FIRE CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH!

WARNING

DO NOT JUMPER THIS DEVICE! DO NOT reset the overtemperature control without taking corrective action to assure that an adequate supply of combustion air is maintained under all conditions of operation. Failure to do so can result in carbon monoxide poisoning or death. Replace this control only with the identical replacement part.

WARNING

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

HOLES IN THE EXHAUST TRANSITION OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME. THE EXHAUST TRANSITION OR HEAT EXCHANGER MUST BE REPLACED IF THEY HAVE HOLES OR CRACKS IN THEM. FAILURE TO DO SO CAN CAUSE CARBON MONOXIDE POISONING RESULTING IN PERSONAL NJURY OR DEATH.

WARNING

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING MAINTENANCE. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK OR SEVERE PERSONAL INJURY OR DEATH.

WARNING

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING THE UNIT. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.

WARNING

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING TO CHANGE BLOWER SPEEDS. FAILURE TO DO SO MAY RESULT IN ELECTRICAL SHOCK OR SEVERE PERSONAL INJURY OR DEATH.

WARNING

DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE. FAILURE TO SHUT OFF POWER CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

CAUTION

R-410A systems operate at higher pressures than R-22 systems. Do not use R-22 service equipment or components on R-410A equipment.

WARNING

IMPORTANT: ALL MANUFACTURER PRODUCTS MEET CURRENT FEDERAL OSHA GUIDELINES FOR SAFETY. CALIFORNIA PROPOSITION 65 WARNINGS ARE REQUIRED FOR CERTAIN PRODUCTS, WHICH ARE NOT COVERED BY THE OSHA STANDARDS.

CALIFORNIA'S PROPOSITION 65 REQUIRES WARNINGS FOR PRODUCTS SOLD IN CALIFORNIA THAT CONTAIN, OR PRODUCE, ANY OF OVER 600 LISTED CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER OR BIRTH DEFECTS SUCH AS FIBERGLASS INSULATION, LEAD IN BRASS, AND COMBUSTION PRODUCTS FROM NATURAL GAS.

ALL “NEW EQUIPMENT” SHIPPED FOR SALE IN CALIFORNIA WILL HAVE LABELS STATING THAT THE PRODUCT CONTAINS AND/OR PRODUCES PROPOSITION 65 CHEMICALS. ALTHOUGH WE HAVE NOT CHANGED OUR PROCESSES, HAVING THE SAME LABEL ON ALL OUR PRODUCTS FACILITATES MANUFACTURING AND SHIPPING. WE CANNOT ALWAYS KNOW “WHEN, OR IF” PRODUCTS WILL BE SOLD IN THE CALIFORNIA MARKET.

YOU MAY RECEIVE INQUIRIES FROM CUSTOMERS ABOUT CHEMICALS FOUND IN, OR PRODUCED BY, SOME OF OUR HEATING AND AIR-CONDITIONING EQUIPMENT, OR FOUND IN NATURAL GAS USED WITH SOME OF OUR PRODUCTS. LISTED BELOW ARE THOSE CHEMICALS AND SUBSTANCES COMMONLY ASSOCIATED WITH SIMILAR EQUIPMENT IN OUR INDUSTRY AND OTHER MANUFACTURERS.

• GLASS WOOL (FIBERGLASS) INSULATION

• CARBON MONOXIDE (CO)

• FORMALDEHYDE

• BENZENE

MORE DETAILS ARE AVAILABLE AT THE WEBSITES FOR OSHA (OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION), AT WWW.OSHA.GOV OF CALIFORNIA'S OEHHA (OFFICE OF ENVIRONMENTAL HEALTH HAZARD ASSESSMENT), AT WWW.OEHHA.ORG. EDUCATION IS IMPORTANT SINCE THE CHEMICALS AND SUBSTANCES ON THE LIST ARE FOUND IN OUR DAILY LIVES. MOST CONSUMERS ARE AWARE THAT PRODUCTS PRESENT SAFETY AND HEALTH RISKS, WHEN IMPROPERLY USED, HANDLED AND MAINTAINED.

AND THE STATE

CONSUMER

II. INTRODUCTION

This booklet contains the installation and operating instructions for your combination gas heating/electric cooling unit. There are some precautions that should be taken to derive maximum satisfaction from it. Improper installation can result in unsatisfactory operation or dangerous conditions.

Read this booklet and any instructions packaged with separate equipment required to make up the system prior to installation. Give this booklet to the owner and explain its provisions. The owner should retain this booklet for future reference.

III. CHECKING PRODUCT RECEIVED

Upon receiving the unit, inspect it for any damage from shipment. Claims for damage, either shipping or concealed, should be filed immediately with the shipping company. IMPORTANT: Check the unit model number, heating size, electrical characteristics, and accessories to determine if they are correct.

IV. SPECIFICATIONS

A. GENERAL

The Combination Gas Heating/Electric Cooling Rooftop is available in 40,60, 80 and 100 BTU/Hr. heating inputs and cooling capacities of 2, 2 cooling. Units are convertible from end supply and return to bottom supply and return by relocation of supply and return air access panels. See cover installation detail.

The units are weatherized for mounting outside of the building.

WARNING

The information on the rating plate is in compliance with the FTC and DOE rating for single phase units. The following information is for three phase units which are not covered under the DOE certification program.

1. The energy consumption of the ignition system used with this unit is 9 watts.

2. The efficiency rating of this unit is a product thermal efficiency rating determined under continuous operating conditions independent of any installed system.

B. MAJOR COMPONENTS

The unit includes a hermetically-sealed refrigerating system (consisting of a compressor, condenser coil, evaporator coil with thermostatic expansion valve), a circulation air blower, a condenser fan, a heat exchanger assembly, gas burner and control assembly, combustion air motor and fan, and all necessary internal electrical wiring. The cooling system of these units is factory-evacuated, charged with R-410A refrigerant and performance tested. Refrigerant amount is indicated on rating plate.

C. R410A REFRIGERANT

All units are factory charged with R-410A refrigerant.

1. Specification of R-410A:

Application: R-410A is not a drop-in replacement for R-22; equipment designs must accommodate its higher pressures. It cannot be retrofitted into R-22 units.

Pressure: The pressure of R-410A is approximately 60% (1.6 times) greater than R-

22. Recovery and recycle equipment, pumps, hoses and the like need to have design

pressure ratings appropriate for R-410A. Manifold sets need to range up to 800 psig high-side and 250 psig low-side with a 550 psig low-side retard. Hoses need to have a service pressure rating of 800 psig. Recovery cylinders need to have a 400 psig service pressure rating. DOT 4BA400 or DOT BW400.

Combustibility: At pressures above 1 atmosphere, mixture of R-410A and air can become combustible. R-410A and air should never be mixed in tanks or supply

lines, or be allowed to accumulate in storage tanks. Leak checking should never be done with a mixture of R-410A and air. Leak checking can be performed safely

with nitrogen or a mixture of R-410A and nitrogen.

⁄2, 3, 31⁄2 , 4 and 5 nominal tons of

2. Quick Reference Guide For R-410A

• R-410A refrigerant operates at approximately 60% higher pressure (1.6 times) than R-

22. Ensure that servicing equipment is designed to operate with R-410A.

• R-410A refrigerant cylinders are pink.

• R-410A, as with other HFC’s is only compatible with POE oils.

• Vacuum pumps will not remove moisture from POE oil.

• R-410A systems are to be charged with liquid refrigerants. Prior to March 1999, R410A refrigerant cylinders had a dip tube. These cylinders should be kept upright for equipment charging. Post March 1999 cylinders do not have a dip tube and should be inverted to ensure liquid charging of the equipment.

• Do not install a suction line filter drier in the liquid line.

• A liquid line filter drier is standard on every unit.

• Desiccant (drying agent) must be compatible for POE oils and R-410A

3. Evaporator Coil / TXV

The thermostatic expansion valve is specifically designed to operate with R-410A. DO NOT use an R-22 TXV. The existing evaporator must be replaced with the factory specified TXV evaporator specifically designed for R-410A.

4. Tools Required For Installing & Servicing R-410A Models

Manifold Sets:

-Up to 800 PSIG High side

-Up to 250 PSIG Low Side

-550 PSIG Low Side Retard

FIGURE 1

LED DESCRIPTION

Manifold Hoses:

-Service Pressure Rating of 800 PSIG

Recovery Cylinders:

-400 PSIG Pressure Rating

-Dept. of Transportation 4BA400 or BW400

CAUTION

R-410A systems operate at higher pressures than R-22 systems. Do not use R-22 service equipment or components on R-410A equipment.

D. COMFORT ALERT™ SYSTEM (2-STAGE MODELS ONLY)

1. Comfort Alert™

The Comfort Alert™ diagnostics module is for troubleshooting air conditioning system failures. By monitoring and analyzing data from the compressor and the thermostat demand, the module can accurately detect the cause of electrical and system-related failures without any external sensors. A flashing LED indicator communicates the ALERT code and guides the service technician more quickly and accurately to the root cause of a problem.

POWER LED (Green): indicates voltage is present at the power connection of the module.

ALERT LED (Yellow): communicates an abnormal system condition through a unique flash code. The ALERT LED will flash a number of times consecutively, pause and then repeat the process. The number of consecutive flashes, defined as the Flash Code, correlates to a particular abnormal condition. Detailed descriptions of specific ALERT Flash Codes are shown in the Comfort Alert Diagnosis Chart in this manual.

TRIP LED (Red): indicates there is a demand signal from the thermostat but no current to the compressor is detected by the module. The TRIP LED typically indicates the compressor internal overload protector is open or may indicate missing high voltage supply power to the compressor.

When an abnormal system condition occurs, the Comfort Alert module displays the appropriate ALERT and/or TRIP LED. The yellow ALERT LED will flash a number

of times consecutively, pause and then repeat the process. To identify a Flash Code number, count the number of consecutive flashes.

IMPORTANT: Every time the module powers up, the last ALERT Flash Code that occurred prior to shut down is displayed for one minute. The module will continue to display the flash code until the condition returns to normal or if 24VAC power is removed from the module.

The control box cover allows access to the Comfort Alert™ status LEDs. An abbreviated Comfort Alert™ diagnostic chart is provided on the control box cover.

2. High Pressure Control (HPC)

The high pressure control (HPC) keeps the compressor from operating in pressure ranges, which can cause damage to the compressor. This is an auto-reset control that opens near 610 PSIG and closes once the system pressure drops below 420 PSIG.

The high pressure control is wired in the 24VAC side of the control circuitry.

3. Low Pressure Control (LPC)

The low pressure control (LPC) keeps the compressor from operating in pressure ranges that can cause damage to the compressor. This is an auto-reset control that opens near 90 PSIG and closes once the system pressure rises above 135 PSIG.

The low pressure control is wired in the common side of the control circuitry.

4. Comfort Alert With Active Protection

A two-stage cooling thermostat is required for proper unit operation. Manufacturer recommends the use of thermostats that provide active compressor pro-

tection via the L terminal when the Comfort-Alert module on the unit is connected to the L terminal on the thermostat.

FIGURE 3

FIGURE 2

WHITE-RODGERS 90-SERIES THERMOSTAT

The Comfort Alert diagnostics module diagnoses system and electrical problems in the air conditioning system. Abnormal conditions are indicated by flashing ALERT codes on the yellow LED on the Comfort Alert module. The flash codes are transmitted to the thermostat when the L terminal on the Comfort Alert Module is connected to the L terminal on the thermostat. The White-Rodgers 1F95-CA397 thermostat displays a CHECK SYSTEM icon that flashes at the same rate as the yellow ALERT LED on the Comfort Alert module. Turn this feature ON to achieve protection, enabling the thermostat to identify certain fault codes when compressor damage is possible and react to those codes by turning the compressor off.

NOTE: The Comfort Alert™ module does not provide safety protection! It does not disconnect power from the unit.

Comfort Alert™ Flash Codes 1 – Long Run Time 2 – System Pressure Trip 3 – Short Cycling 4 – Locked Rotor 5 – Open Circuit 6 – Open Start Circuit 7 – Open Run Circuit 8 – Welded Contactor 9 – Low Voltage

See Figures 61 and 62 (Comfort Alert Diagnostic Charts) for more troubleshooting information.

Active protection occurs under the following conditions:

1) Flash Code 2 - System Pressure Trip Condition: Four consecutive compressor protector trips occur where the average run time until trip is between 1 minute and 15 minutes Possible causes:

Active Thermostat Reaction:

2) Flash Code 3 - Short Cycling Condition: A pattern of short cycling emerges where the run time for the previous four cycles is less than three minutes each. Possible causes:

Active Thermostat Reaction:

Low suction pressure

• Low pressure switch is open

• Low system charge Blocked condenser coil Restricted condenser air flow

The thermostat will cycle the system ON for 5 minutes and OFF for five minutes to verify system fault. If this ON/OFF cycling repeats for 30 ten-minute cycles, the thermostat concludes there is a system problem and implements a hard lockout.

High head pressure

• High pressure switch is open

• System overcharged

• Non-condensables in system Faulty thermostat Intermittent contactor

The thermostat will cycle the system ON for 5 minutes and OFF for five minutes to verify the system fault. If this ON/OFF cycling repeats for 30 ten-minute cycles, the thermostat concludes there is a system problem and implements a hard lockout.

3) Flash Code 4 - Locked Rotor Condition: The compressor internal overload trips where the average run time is less than 15 seconds. Possible causes:

Active Thermostat Reaction:

4) Flash Code 6 - Open Start Circuit Condition: Current is detected in the run circuit but not in the start circuit. Possible causes:

Bad run capacitor Low line voltage Excessive liquid refrigerant in compressor Compressor bearings are seized Faulty hard start components

The thermostat implements a hard lockout once this error is sensed.

Bad run capacitor Open circuit in compressor start wiring or connections. Compressor start winding is damaged

Active thermostat reaction:

5) Flash Code 7 - Open Run Circuit Condition: Open circuit in compressor run wiring or connections. Compressor run winding is damaged.

Active Thermostat Reaction:

Resetting the White-Rodgers Thermostat After a Hard Lockout

The White-Rodgers thermostat will automatically reset after a hard lockout once the Comfort Alert trouble code has been cleared.

The thermostat implements a hard lockout after 3 hours.

V. UNIT DIMENSIONS

FOR CLEARANCES SEE FIGURE 4.

FIGURE 4

OUTDOOR COIL PROTECTIVE GRILLE

OUTDOOR FAN GRILLE AND COMPRESSOR ACCESS

29% ± 2%

FLUE EXHAUST

30% ± 2%

20% ± 2%

21% ± 2%

SIDE RETURN DUCT OPENING

THREADED PVC CONDENSATE DRAIN CONNECTION (3/4 NPT)

SUCTION PRESSURE SERVICE PORT

LIQUID PRESSURE SERVICE PORT

TOP VIEW

479⁄16”

FIELD CONTROL WIRE ENTRANCE

FIELD POWER WIRE ENTRANCE

FLUE EXHAUST HOOD

COMBUSTION AIR INLET HOOD

5013⁄16”

BOTTOM RETURN DUCT OPENING

BLOWER/EVAPORATOR ACCESS PANEL

CORNER WEIGHTS

% OF TOTAL UNIT

BOTTOM VIEW

451⁄16”

INSIDE

191⁄2”

141⁄4”

TYP.

SIDE SUPPLY DUCT OPENING

WEIGHT

13⁄16”

TYP.

153⁄8”

11⁄2”

TYP.

497⁄16” INSIDE

BOTTOM SUPPLY DUCT OPENING

OUTDOOR FAN GRILLE & COMPRESSOR ACCESS

313⁄16”

33⁄16”

49⁄10”

FIGURE 4 (CONTINUED)

MODELS

RRNL & RRPL

B024, B030,

B036

B042, B048,

B060, C060

FRONT VIEW

471⁄2”

MODEL

RRRL

B024

B036, B048,

B060

207⁄8”

2211⁄16”

HEIGHT

“A”

3515⁄16”

75⁄16”

227⁄8”

1315⁄16”

21⁄2”

SIDE SUPPLY DUCT OPENING

3515⁄16”

BACK VIEW

39⁄16”

15”

191⁄8” 47⁄8”

131⁄4”

47⁄16”

81⁄2”

TYP.

SHOWN WITH DUCT COVERS REMOVED.

143⁄16”

TYP.

133⁄4”

TYP.

SIDE RETURN DUCT OPENING

FILTER ACCESS PANEL (FOR UNIT MOUNTED FILTER ACCESSORY)

SIDE VIEW

527⁄16”

OUTDOOR COIL PROTECTIVE GRILLE

SIDE VIEW

FLUE EXHAUST HOOD

GAS SUPPLY ENTRANCE

1015⁄16”

111⁄16”

BLOWER/ EVAPORATOR ACCESS PANEL

VI. INSTALLATION

A. GENERAL

1. PRE-INSTALLATION CHECK-POINTS — Before attempting any installation, carefully consider the following points:

Structural strength of supporting members

(Rooftop Installation) Clearances and provision for servicing Power supply and wiring Gas supply and piping Air duct connections and sizing Drain facilities and connections Location for minimum noise and vibration

2. LOCATION CONSIDERATIONS (CORROSIVE ENVIRONMENT) The metal parts of this unit may be subject to rust or deterioration if exposed to a

corrosive environment. This oxidation could shorten the equipment’s useful life. Corrosive elements include, but are not limited to, salt spray, fog or mist in seacoast areas, sulphur or chlorine from lawn watering systems, and various chemical contaminants from industries such as paper mills and petroleum refineries.

If the unit is to be installed in an area where contaminants are likely to be a problem, give special attention to the equipment location and exposure.

1. Avoid having lawn sprinkler heads spray directly on the unit cabinet.

2. In coastal areas locate the unit on the side of the building away from the waterfront.

3. Shielding by a fence or shrubs may give some protection.

WARNING

DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

1. Frequent washing of the cabinet, fan blade and coil with fresh water will remove most of the salt or other contaminants that build up on the unit.

2. Regular cleaning and waxing of the cabinet with a good automobile polish will provide some protection.

3. Use a good liquid cleaner several times a year to remove matter that will not wash off with water.

Several different types of protective coatings are offered in some areas. These coatings may provide some benefit, but the effectiveness of such coating materials cannot be verified by the equipment manufacturer.

The best protection is frequent cleaning, maintenance and minimal exposure to contaminants.

B. OUTSIDE INSTALLATION

WARNING

(Typical outdoor slab installation is shown in Figure 5.)

1. Select a location where external water drainage cannot collect around unit.

FIGURE 5

OUTSIDE SLAB INSTALLATION. CLOSET DISTRIBUTION SYSTEM. SLAB FLOOR CONSTRUCTION

2. Provide a slab sufficiently high enough above grade to prevent surface water from entering the unit. Where snowfall is anticipated, mount the unit above the anticipated maximum snow depth for your area. Do not locate unit in an area where excessive snow drifting may block combustion air inlet.

3. Pitch the slab approximately

⁄2” so that the unit will be pitched toward the drain. See

Figure 6.

4. The location of the unit should be such as to provide proper access for inspection and servicing as shown in Figure 12.

5. Locate unit where operating sounds will not disturb owner or neighbors. The slab should be isolated from the foundation wall.

6. Locate unit so roof runoff water does not pour directly on the unit. Provide gutter or other shielding at roof level.

C. ATTACHING EXHAUST AND COMBUSTION AIR INLET HOODS

IMPORTANT: Do not operate this unit without the exhaust and combustion air inlet hood properly installed. These hoods are shipped in a carton in the return air compartment inside the unit and must be attached when the unit is installed. See Figure 7.

To attach exhaust and combustion air inlet hood:

1. Remove 3 screws securing filter access panel and remove filter access panel. For location of filter access panel, see Figure 4.

2. Remove both exhaust and combustion air inlet hoods from their carton, located inside the return air compartment.

3. Attach filter access panel.

4. Attach the combustion air inlet hood and the exhaust hood each with 4 screws as shown

in Figure 7. Screws are in parts bag shipped in the burner compartment.

5. Vent the unit using the flue exhaust hood, as supplied from the factory, without alteration

or addition. The only exception is with factory approved additions. Consult your local utility or other authority having jurisdiction for accepted venting techniques.

FIGURE 6

PITCHING UNIT TO INSURE PROPER CONDENSATE DRAINAGE.

FIGURE 7

COMBUSTION AIR INLET HOOD & EXHAUST HOOD INSTALLATION

EXHAUST HOOD W/(4) SCREWS

I655

COMBUSTION AIR INLET HOOD W/(4) SCREWS

D. COVER PANEL INSTALLATION/CONVERSION PROCEDURE

1. HORIZONTAL TO DOWNFLOW a. Remove screws and covers from the supply and return bottom sections. NOTE:

Rotate the supply cover 90° and remove.

b. Install gasket (supplied with parts bag) around perimeter of cover on the insulated

side. See Figure 9.

c. Secure covers to the side of the unit using existing screws and those supplied in

the parts bag.

2. DOWNFLOW TO HORIZONTAL a. Remove screws and covers from the supply and return bottom sections. b. Install gasket (supplied with parts bag) around perimeter of cover as illustrated in

Figure 8.

c. Install covers in the unit bottom with the insulated side up. NOTE: Supply cover

must be inserted through supply opening with narrow side toward unit. Once cover is through opening, rotate 90° and slip back flange of cover under tab at the back of bottom duct opening. See Figure 11.

d. Secure supply cover to base of unit with 2 screws, engaging prepunched holes in

raised duct opening flange.

e. Secure return covers to base of unit with screws engaging prepunched holes in

raised duct opening flange.

WARNING

E.CLEARANCES

The following minimum clearances must be observed for proper unit performance and serviceability. See Figure 12.

1. Provide 48” minimum clearance at front of the unit. Provide 24” minimum clearance on right side of unit. If economizer is used, a 24” minimum clearance is required on

FIGURE 5

COVER GASKET DETAILFOR UNITS SHIPPED FOR DOWNFLOW APPLICATION BEING CONVERTED TO SIDE DISCHARGE

TAPE AROUND FLANGE

SUPPLY/RETURN AIR COVER

FIGURE 6

COVER GASKET DETAILFOR UNITS SHIPPED FOR SIDE DISCHARGE APPLICATION BEING CONVERTED TO DOWNFLOW

TAPE AROUND FLANGE

SUPPLY/RETURN AIR COVER

I654

FIGURE 7

DUCT COVER INSTALLATION SIDE MOUNTING

I264

RETURN

DUCT COVER

(ATTACH WITH 6 SCREWS)

SUPPLY

DUCT COVER

(ATTACH WITH 6 SCREWS)

FIGURE 8

DUCT COVER INSTALLATION BASE PAN MOUNTING

I265

BASE PAN

SUPPLYDUCT COVER

(INSULATION SIDE UP), ATTACH WITH TWO SCREWS.

RETURN DUCT COVER (INSULATION SIDE UP , ATTACH WITH 4 SCREWS)

SUPPLYDUCT COVER

ROTATE SUPPLY COVER 90° AFTER IT IS INSERTED THROUGH OPENING. SLIP FLANGE OF COVER UNDER LANCE AT BACK OF BOTTOM SUPPLY DUCT OPENING. SEE DETAILAT LEFT. THEN SECURE COVER BY INSTALLING 2 SCREWS USING HOLE NEAREST THE OUTSIDE OF UNIT.

LANCE AT BACK OF BOTTOM SUPPLYDUCT OPENING

FIGURE 8

COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW APPLICATION BEING CONVERTED TO SIDE DISCHARGE

FIGURE 9

COVER GASKET DETAIL FOR UNITS SHIPPED FOR SIDE DISCHARGE APPLICATION BEING CONVERTED TO DOWNFLOW

FIGURE 10

DUCT COVER INSTALLATION SIDE MOUNTING

FIGURE 11

DUCT COVER INSTALLATION BASE PAN MOUNTING

FIGURE 12

CLEARANCES

left side of unit. (See Figure 12.) If no economizer is required, then a 12” clearance is required on left side of unit.

2. Provide 60” minimum clearance between top of unit and maximum 3 foot overhang.

3. Unit is design certified for 2” minimum clearance between supply duct and a combustible structure for the first 3 feet of duct. 0” clearance is allowed after 3 feet.

F. ROOFTOP INSTALLATION

1. Before locating the unit on the roof, make sure that the roof structure is adequate to support the weight involved. (See electrical & physical tables in this book for weight of unit.) THIS IS VERY IMPORTANT AND THE INSTALLER’S RESPONSIBILITY.

2. For rigging and roofcurb details, see Figures 17, 18, and 19.

3. The location of the unit on the roof should be such as to provide proper access for inspection and servicing.

IMPORTANT: If unit will not be put into service immediately, block off supply and return air openings to prevent excessive condensation.

G. DUCTWORK

The installing contractor should fabricate ductwork in accordance with local codes. Use industry manuals as a guide when sizing and designing the duct system. Contact Air Conditioning Contractors of America, 1513 16th St. N.W., Washington, D.C. 20036.

WARNING

FIGURE 10

EXCEPTION TO NON-COMBUSTIBLE FLOORING REQUIREMENT

I458

BOTH ENDS MUST BE OPEN FOR DOWNFLOW OR SIDEFLOW DUCTWORK TO PROVIDE VENTILATION

COMBUSTIBLE STRUCTURE

1” MIN.

NOMINAL 4 x 4 TIMBER (SIDES ONLY)

SIDEFLOW

SUPPLY

PLENUM

CONNECTION

SUPPLY

PLENUM

(DOWNFLOW)

RETURN PLENUM

(DOWNFLOW)

SIDEFLOW

RETURN PLENUM

CONNECTION

3-1/2” MIN.

FIGURE 13

EXCEPTION TO NON-COMBUSTIBLE FLOORING REQUIREMENT

FIGURE 14

FLAT ROOFTOP INSTALLATION, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. MOUNTED ON ROOFCURB, PITCH UNIT TOWARD DRAIN.

FIGURE 15

PITCHED ROOFTOP INSTALLATION, ON ANGLE-IRON STAND, SIDE FLOW DUCTWORK, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. PITCH UNIT TOWARD DRAIN.

FIGURE 16

PITCHED ROOFTOP INSTALLATION, ON ROOFJACK, DOWNFLOW DUCTWORK, ATTIC OR DROP CEILING DISTRIBUTING SYSTEM. PITCH UNIT TOWARD DRAIN.

Place the unit as close to the conditioned space as possible allowing clearances as indicated. Run ducts as directly as possible to supply and return outlets. Use of non-flammable weatherproof flexible connectors on both supply and return connections at unit to reduce noise transmission is recommended.

On ductwork exposed to outside temperature and humidity, use a minimum of 2” of insulation and a vapor barrier. Distribution system in attic, furred space or crawl space should be insulated with at least 2” of insulation. cient for ductwork inside the air conditioned space.

Provide balancing dampers for each branch duct in the supply system. Properly support ductwork from the structure.

IMPORTANT: In the event that the return air ducts must be run through an “unconfined” space containing other fuel burning equipment, it is imperative that the user/homeowner must be informed against future changes in construction which might change this to a “confined space.” Also, caution the user/homeowner against any future installation of additional equipment (such as power ventilators, clothes dryers, etc., within the existing unconfined and/or confined space which might create a negative pressure within the vicinity of other solid, liquid, or gas fueled appliances.

⁄2” to 1” thick insulation is usually suffi-

H. RETURN AIR

WARNING

FIGURE 17

LIFTING DETAIL.

. FILTERS

The installer must install field supplied filters in the return air duct. A field installed filter grille is recommended for easy and convenient access to the filters for periodic inspection and cleaning. Filters must have adequate face area for the rated air quantity of the unit. See air delivery tables for recommended filter size. A field installed internal filter kit RXRY-B01 is available.

I342

RETURN PLENUM

MAX.

/2 MAX.

/8 MAX.

INSULATION PANELS

NAILING STRIP

CAULK ALL JOINTS WATERTIGHT

SUPPLY PLENUM

DUCT FLANGE (NOT TO EXCEED 1()

ROOFCURB

FIGURE 15

ROOFCURB

I255

**BY CONTRACTOR

**FOR INSTALLATION OF DUCT AS SHOWN, USE RECOMMENDED

DUCT SIZES FROM ROOFCURB INSTALLATION INSTRUCTIONS. FOR DUCT FLANGE ATTACHMENT TO UNIT, SEE UNIT INSTALLATION INSTRUCTIONS (FIGURE 1) FOR SIZE OF DUCT OPENINGS.

ROOFTOP UNIT

TIE DOWN SCREW *

ROOFCURB

ROOF FLASHING

ROOFING *

CANT STRIP *

ROOF DECK *

GASKET

NAILING STRIP

INSULATION

INSULATION *

** DUCT *

FIGURE 16

ROOFCURB

FIGURE 18

ROOFCURB

FIGURE 19

ROOFCURB

FIGURE 20

DUCTWORK COVER INSTALLATION DETAIL

FIGURE 21

RESIDENTIAL ROOFTOP DUCTWORK INSTALLATION DETAIL.

VII.GAS SUPPLY, CONDENSATE DRAIN AND

FIGURE 19

SUGGESTED GAS PIPING

FROM GAS METER

Factory supplied grommet must be utilized.

MANUAL GAS SHUT-OFF VALVE

UNIT GAS SUPPLY CONNECTION

ROOF OR GROUND LEVEL INSTALLATION

Nominal

Iron Pipe

Size,

Inches

Equivalent Length of Pipe, Feet

10 20 30 40 50 60 70 80

/2 132 92 73 63 56 50 46 43

/4 278 190 152 130 115 105 96 90

1520350285245215195180170 11/4 1,050 730 590 500 440 400 370 350 11/2 1,600 1,100 890 760 670 610 560 530

TABLE 1

GAS PIPE CAPACITYTABLE (CU. FT./HR.)

VII.PIPING

A. GAS CONNECTION

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

1. Install gas piping in accordance with local codes and regulations of the local utility company. In the absence of local codes, the installation must conform to the specifications of the National Fuel Gas Code, ANSI Z223.1 - latest edition.

NOTE: The use of flexible gas connectors is not permitted. NOTE: The Commonwealth of Massachusetts requires the gas shut-off valve to be

a T-handle gas cock.

2. Connect the gas line to the gas pipe inlet opening provided into the 1/2” inlet valve. See Figure 5 for typical piping.

3. Size the gas line to the furnace adequate enough to prevent undue pressure drop and never less than 1/2”.

4. Install a drip leg or sediment trap in the gas supply line as close to the unit as possible.

5. Install an outside ground joint union to connect the gas supply to the control assembly at the burner tray.

6. Gas valves have been factory installed. Install a manual gas valve where local codes specify a shut-off valve outside the unit casing. (See Figure 22.)

7. Make sure piping is tight. A pipe compound resistant to the action of liquefied

petroleum gases must be used at all threaded pipe connections.

8. 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 factory-specified or approved parts. In the commonwealth of Massachusetts, installation must be performed by a licensed plumber or gas fitter for appropriate fuel.

IMPORTANT: Disconnect the furnace and its individual shutoff valve from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 psig or isolate the system from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of this gas supply system at pressures equal to or less than 1/2 PSIG.

FIGURE 22

SUGGESTED GAS PIPING

WARNING

DO NOT USE AN OPEN FLAME TO CHECK FOR LEAKS. THE USE OF AN OPEN FLAME CAN RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

TO CHECK FOR GAS LEAKS, USE A SOAP AND WATER SOLUTION OR OTHER APPROVED METHOD. DO NOT USE AN OPEN FLAME.

IMPORTANT: Check the rating plate to make certain the appliance is equipped to burn the type of gas supplied. Care should be taken after installation of this equipment that the gas control valve not be subjected to high gas supply line pressure.

In making gas connections, avoid strains as they may cause noise and damage the controls. A backup wrench is required to be used on the valve to avoid damage.

The capacities of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.5 in. and specific gravity of 0.60 (natural gas) are shown in Table 2.

After determining the pipe length, select the pipe size which will provide the minimum cubic feet per hour re quired for the gas input rating of the furnace. By formula:

Gas Input of Furnace

Cu. Ft. Per Hr. Required =

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT L.P. gas supplier.

(BTU/HR) Heating Value of Gas

(BTU/FT

) may be determined by consulting the local natural gas utility or the

)

B. LP CONVERSION SINGLE STAGE GAS HEAT

WARNING

Convert the valve 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 23.

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

Conversion Kit Index shipped with unit for proper LP kit number. Furnace conversion to LP gas must be performed by a qualified technician.

FIGURE 23

C. LP CONVERSION TWO STAGE GAS HEAT

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)

TABLE 2

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

Nominal Iron Pipe Size, Inches

10 20 30 40 50 60 70 80 90 100 125 150

275 189 152 129 114 103 96 89 83 78 69 63

567 393 315 267 237 217 196 182 173 162 146 132 1,071 732 590 504 448 409 378 346 322 307 275 252 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

1/2 3/4

1 1-1/4 1-1/2

Length of Pipe, Feet

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

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

WARNING

Convert the valve to use liquefied petroleum (LP) gas by replacing with the gas valve supplied in the conversion kit. The LP gas valve maintains the proper manifold pressure for LP gas. The correct burner LP orifices are included in the kit.

IMPORTANT: To remove the natural gas valve, remove the four screws securing the manifold pipe to the burner tray. Remove the manifold pipe with gas valve attached.

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

Conversion Kit Index shipped with unit for proper LP kit number. Furnace conversion to LP gas must be performed by a qualified technician.

D. NOx MODELS

When converting units equipped with NOx inserts to LP gas, the stainless steel mesh inserts in the entrance of the tubular exchangers are not required to meet SCAQMD NOx emission levels. Carefully remove these inserts before firing this furnace on LP gas. This furnace is not designed to operate on LP gas with the NOx inserts in place.

Step by step instructions on removing the NOx inserts and retaining rod are included in the Conversion Kit Installation Instructions.

E. ADJUSTING OR CHECKING FURNACE INPUT

– Natural Gas Line Pressure 5” - 10.5” W.C. – LP Gas Line Pressure 11” - 13” W.C.

– Natural Gas Manifold Pressure 3.5” W.C – LP Gas Manifold Pressure - 10” W.C.

Supply and manifold pressure taps are located on the gas valve body 1/8” N.P.T. Use a properly calibrated manometer gauge for accurate gas pressure readings. Only small variations in the gas flow should be made by means of the pressure regulator

adjustment. Furnaces functioning on LP gas must be set 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.

To adjust the pressure regulator, remove the regulator cap and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure. Then replace

the regulator cap securely.

Any necessary major changes in the gas flow rate should be made by changing the size of the burner orifices. To change orifice spuds, shut off the manual main gas valve and remove the gas manifold.

For elevations up to 2,000 feet, rating plate input ratings apply. For high altitudes (elevations over 2,000 ft.), see conversion kit index 92-21519-47 for derating and orifice spud sizes.

Check of input is important to prevent over-firing of the furnace beyond its designrated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE. Use the following table or formula to determine input rate.

Cu. Ft. Per Hr. Required =

Heating Value of Gas (BTU/Cu. Ft.) x 3600

Time in Seconds (for 1 Cu. Ft.) of Gas

Start the furnace and measure the time required to burn one cubic foot of gas. Prior to

ONE 1 21 1 30 1 34 1 39 3 45

40,000

TEN 13 30 15 0 15 36 16 30 37 30

ONE 0 54 1 0 1 3 1 6 2 30

60,000

TEN 9 0 10 0 10 24 11 0 25 0

ONE 0 41 0 45 0 47 0 50 1 53

80,000

TEN 6 45 7 30 7 48 8 15 18 45

ONE 0 33 0 36 0 38 0 40 1 30

100,000

TEN 5 24 6 0 6 15 6 36 15 0

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.

TABLE 3

checking the furnace input, make certain that all other gas appliances are shut off, with the exception of pilot burners. Time the meter with only the furnace in operation.

IMPORTANT NOTE FOR ALTITUDES ABOVE 2,000 FEET (610 METERS): The main burner orifices in your furnace and in these kits are sized for the nameplate input and intended for installations at elevations up to 2,000 feet in the USA or Canada, or for elevations of 2,000 - 4,500 feet (610 -1,373 meters) in Canada if the unit has been derated at the factory. For elevations above 2,000 feet (610 meters) IN THE USA ONLY (see ANSI-Z223.1), the burner orifices must be sized to reduce the input 4% for each 1,000 feet (305 meters) above sea level.

NOTICE: DERATING OF THE HEATING INPUT FOR HIGH ALTITUDE IN THE FIELD IS UNLAWFUL IN CANADA (REFER TO CAN/CGA 2.17). UNITS INSTALLED IN ALTITUDES GREATER THAN 2,000 FEET (610 METERS) MUST BE SHIPPED FROM THE FACTORY OR FROM A FACTORY AUTHORIZED CONVERSION STATION WITH THE HEATING INPUT DERATED BY 10% SO AS TO OPERATE PROPERLY IN ALTITUDES FROM 2,000 - 4,500 FEET (610 - 1,373 METERS).

F. CONDENSATE DRAIN

The evaporator coil condensate drain ends with a threaded 3/4” nominal PVC stub. A trap is built in for proper condensate drainage and to prevent debris from being drawn into the unit. Do not connect the drain to a closed sewer line. Connection to a vented sewer line is allowed. It is recommended that a PVC cement not be used so that the drain line can be easily cleaned in the future.

IMPORTANT: DO NOT INSTALL AN EXTERNAL TRAP. DOING SO CAN CAUSE IMPROPER DRAINAGE OF THE CONDENSATE AND RESULT IN FLOODING WITHIN THE UNIT.

VIII.WIRING

A. POWER SUPPLY

WARNING

1. All wiring should be made in accordance with the National Electrical Code.

200 6 4 4 4 3 3 2 2 150 8 6 6 4 4 4 3 3 100 10 8 8 6 6 6 4 4

50 14 12 10 10 8 8 6 6

15 20 25 30 35 40 45 50

TABLE 4

BRANCH CIRCUIT COPPER WIRE SIZE (BASED ON 1% VOLTAGE DROP)*

SUPPLY WIRE

LENGTH-FEET

*Taken from National Electric Code

BRANCH CIRCUIT AMPACITY

AWG Copper AWG Aluminum Connector Type and Size

Wire Size Wire Size (or equivalent)

#12 #10 T & B Wire Nut PT2 #10 # 8 T & B Wire Nut PT3 # 8 # 6 Sherman Split Bolt TSP6 # 6 # 4 Sherman Split Bolt TSP4 # 4 # 2 Sherman Split Bolt TSP2

TABLE 5

Consult the local power company to determine the availability of sufficient power to operate the unit. Check the voltage at power supply to make sure it corresponds to the unit’s RATED VOLTAGE REQUIREMENT. Install a branch circuit disconnect near the rooftop, in accordance with the N.E.C., C.E.C. or local codes.

2. It is important that proper electrical power is available at the unit. Voltage should not vary more than 10% from that stamped on the unit nameplate. On three phase units, phases must be balanced within 3%.

3. For branch circuit wiring (main power supply to unit disconnect), the minimum wire size for the length of run can be determined from Table 4 using the circuit ampacity found on the unit rating plate. Use the smallest wire size allowable in Table 4 from the unit disconnect to unit. The disconnect must be in sight and readily accessible of the unit.

NOTES:

1. Wire size based on 60°C rated wire insulation and 30°C Ambient Temp. (86°F).

2. For more than 3 conductors in a raceway or cable, see the N.E.C. for derating the ampacity of each conductor.

When installed, the unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code,

ANSI/NFPA 70, if an external electrical source is utilized.

IMPORTANT: THIS UNIT IS AP PROVED FOR USE WITH COPPER CONDUCTORS

CONNECTED TO UNIT CONTACTOR.

ONLY WARRANTY MAY BE JEOPARDIZED IF ALUMINUM WIRE IS CONNECTED TO

UNIT CONTACTOR. Special instructions apply for power wiring with aluminum conductors: Warranty

is void if connections are not made per instructions.

Attach a length (6” or more) of recommended size copper wire to the unit contactor terminals L1 and L3 for single phase, L1, L2 and L3 for three phase.

Select the equivalent aluminum wire size from the tabulation below: Splice copper wire pigtails to aluminum wire with U.L. recognized connectors for copper-

aluminum splices. Please exercise the following instructions very carefully to obtain a positive and lasting connection:

1. Strip insulation from aluminum conductor.

2. Coat the stripped end of the aluminum wire with the recommended inhibitor, and wire brush the aluminum surface through inhibitor. INHIBITORS: Brundy-Pentex “A”; Alcoa-No. 2EJC; T & B-KPOR Shield.

3. Clean and recoat aluminum conductor with inhibitor.

4. Make the splice using the above listed wire nuts or split bolt connectors.

5. Coat the entire connection with inhibitor and wrap with electrical insulating tape.

B. HOOK-UP

To wire unit, refer to the following hook-up diagram (see Figure 24). Refer to Figure 4 for location of wiring entrances. Wiring to be done in the field between the unit and devices not attached to the unit, or

between separate devices which are field installed and located, shall conform with the temperature limitation for Type T wire [63°F rise (35°C)] when installed in accordance with the manufacturer’s instructions.

FIGURE 24

WIRE HOOK-UP DIAGRAM

FOR INTERNAL WIRING SEE WIRING LABEL ATTACHED TO UNIT

CHASSIS GROUND

CONTACTOR

T2 T3

STAGE

ODD

GAS

HEAT

ONLY)

LOW VOLTAGE

WIRE LEADS

L2 L3

Y GRWCY2 L

*L2 connection 3Phase only

HIGH VOLTAGE

DISCONNECT

SWITCH

YGRWC Y2 L

THERMOSTAT

Y - COOLING (LOW STAGE IN 2 STAGE SYSTEMS) G - FAN ONLY R - 24V W - HEATING (LOW HEAT 2 STAGE GAS HEAT) C - COMMON Y2 - HIGH STAGE COOLING (TWO STAGE ONLY) L - ALERT CODES (OPTIONAL WITH COMFORT ALERT

L - AND COMPATIBLE THERMOSTAT)

ODD - ON-DEMAND DEHUMIDIFICATION W2 - HEATING (HIGH HEAT 2 STAGE GAS)

ODDW2W2

C. INTERNAL WIRING

IMPORTANT: Some single phase units are equipped with a single pole contactor. Caution must be exercised when servicing as only one leg of the power supply is broken with the contactor.

A diagram of the internal wiring of this unit is located under the electrical box cover and in this manual. If any of the original wire as supplied with the appliance must be replaced, the wire gauge and insulation must be same as original wiring.

Transformer is factory wired for 230 volts on 208/230 volt models and must be changed for 208 volt applications. See unit wiring diagram for 208 volt wiring.

D. THERMOSTAT

The room thermostat must be compatible with the spark ignition control on the unit. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control. Two stage units (5 ton) require use of a thermostat capable of 2 stages of cooling. (See Section IV.) See chart below for recommendations. The low voltage wiring should be sized as shown in Table 6.

Install the room thermostat in accordance with the instruction sheet packed in the box with the thermostat. Never install the thermostat on an outside wall or where it will be influenced by drafts, concealed hot or cold water pipes or ducts, lighting fixtures, radiation from fireplace, sun rays, lamps, televisions, radios or air streams from registers. Refer to instructions packed with the thermostat for “heater” selection or adjustment.

Refer to the RRNL-/RRPL-/RRRL- Specification Sheets for a list of recommended thermostats.

IX. FURNACE SECTION CONTROLS AND

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.

3.0 16 14 12 10 10 10

2.5 16 14 12 12 12 10

2.0 18 16 14 12 12 10 50 100 150 200 250 300

Length of Run – Feet (1)

Thermostat Load - Amps

TABLE 6

(1) The total wire length is the distance from the furnace to the thermostat and back to the furnace.

NOTE: DO NOT USE CONTROL WIRING SMALLER THAN NO. 18 AWG.

IGNITION SYSTEM

A. NORMAL FURNACE OPERATING SEQUENCE (SINGLE STAGE GAS HEAT)

This unit is equipped with an integrated direct spark ignition control.

1. The thermostat calls for heat.

2. The control board will run a self check to verify that the limit control and manual reset overtemperature control are closed and that the pressure switch is open. If so, the induced draft blower (inducer) begins a prepurge cycle.

3. The air proving negative pressure switch closes.

4. 15 seconds after the pressure switch closes, the gas valve opens and the spark is initiated for a 7 second trial for ignition.

5. Burners ignite and flame sensor proves all burners have lit.

6. The circulating air blower is energized after 30 seconds.

7. The control board enters a normal operation loop in which all safety controls are monitored continuously.

8. Thermostat is satisfied and opens.

9. The gas valve is de-energized and closes, shutting down the burner flame.

10. The control board will de-energize the inducer after a five second post purge.

11. The circulating air blower is de-energized after 90 seconds.

• The integrated control board has a three ignition system.

• After a total of three trials for ignition without sensing main burner flame, the system goes into a 100% lockout mode.

• After one hour, the ignition control repeats the prepurge and ignition cycles for 3 tries and then goes into 100% lockout mode again.

• It continues this sequence of cycles and lockout each hour until ignition is successful or power is interrupted.

• During the lockout mode, neither the spark ignition control or gas valve will be energized until the system is reset by turning the thermostat to the “OFF” position or interrupting the electrical power to the unit for 3 seconds or longer.

• The induced draft blower and main burner will shut off when the thermostat is satisfied.

• The circulating air blower will start and run on the heating speed if the thermostat fan switch is in the “ON” position.

The integrated furnace control is equipped with diagnostic LED. The LED is lit continuously when there is power to the control, with or without a call for heat. If the LED is not lit, there is either no power to the control or there is an internal component failure within the control, and the control should be replaced.

If the control detects the following failures, the LED will flash on for approximately 1/4 sec-

ond, then off for 3/4 second for designated failure detections. 1 Flash: Failed to detect flame within the three tries for ignition. 2 Flash: Pressure switch or induced draft blower problem detected. 3 Flash: High limit or auxiliary limit open. 4 Flash: Flame sensed and gas valve not energized or flame sensed with no “W” signal. 5 Flash: Overtemperature switch open.

B. NORMAL FURNACE OPERATING SEQUENCE (TWO STAGE GAS HEAT

FOR RRRL-C)

This unit is equipped with a two stage integrated direct spark ignition control.

TABLE 6

NORMAL HEAT MODE

A. Call For First Stage (low fire) Only:

1. Zone thermostat contacts close, a call for first stage (low fire) heat is initiated.

2. Control runs self check.

3. Control checks the high-limit switch for normally closed contacts, each pressure switch for normally open contacts, and all flame rollout switches for continuity.

4. Control energizes high inducer speed.

5. Control checks pressure switches for closure.

6. If pressure switches are closed, the control starts a 30 second prepurge.

7. After prepurge timeout, control initiates spark for 2 seconds minimum, 7 second maximum ignition trial, initiates 30 second, second stage (high fire) warm up timing.

8. Control detects flame, de-energizes spark and initiates 30 second delay on blower timing.

9. After a fixed 30 seconds indoor blower delay on, the control energizes the indoor blower.

10. After the 30 second second stage warmup period control checks thermostat input. If only W1 is called for, W2 is de-energized and the control starts a 5 second off delay on the W2 inducer speed.

11. After fixed 5 seconds the gas valve shifts to low and the W2 inducer speed is de-energized.

12. Control enters normal operating loop where all inputs are continuously checked.

B. Call For Second Stage, After First

Stage Established; Starting from A.11:

1. If a call for second stage (high fire) is initiated after a call for first stage heat is established, the control energizes the W2 inducer speed assures the high-fire pressure switch is closed and energizes the second stage of the gas valve.

2. Control enters normal operating loop where all inputs are continuously checked.

C. Second Stage Satisfied; First Stage

Still Called For; Starting From B.2:

1. Once the call for second stage is satisfied, the control starts a 30 second off delay on W2 inducer and reduces the gas valve to first stage.

2. Control enters normal operating loop where all inputs are continuously checked.

D. First Stage Satisfied:

1. Zone thermostat is satisfied.

2. Control de-energizes gas valve.

3. Control senses loss of flame.

4. Control initiates 5 second inducer postpurge and 90 second indoor blower delay off.

5. Control de-energizes inducer blower.

6. Control de-energizes indoor blower.

7. Control in the stand by mode with solid red LED.

E. First Stage and Second Stage

Removed Simultaneously:

1. Upon a loss of W1 and W2 the gas valve is de-energized.

2. Upon a loss of flame, the inducer will complete a 5 second postpurge and the indoor blower will complete a 90 second delay off.

3. Control in the stand by mode with solid red LED.

The integrated control is a four-ignition system. After a total of four cycles without sensing main burner flame, the system goes into a 100%

lockout mode. After one hour, the ignition control repeats the prepurge and ignition cycles for 4 tries and then go into 100% lockout mode again. It continues this sequence of cycles and lockout each hour until ignition is successful or power is interrupted. During the lockout mode, neither the ignitor or gas valve will be energized until the system is reset by turning the thermostat to the “OFF” position or interrupting the electrical power to the unit for 3 seconds or longer. The induced draft blower and main burner will shut off when the thermostat is satisfied.

The circulating air blower will start and run on the heating speed if the thermostat fan switch is in the “ON” position.

If the control detects the following failures, the LED will flash on for approximately 1/4 second, then off for 3/4 second for designated failure detections.

1 Flash: Failed to detect flame within the four tries for ignition. 2 Flash: Pressure switch or induced draft blower problem detected. 3 Flash: High limit or auxiliary limit open. 4 Flash: Flame sensed and gas valve not energized or flame sensed with no “W” signal. 5 Flash: Overtemperature switch open.

C. OPERATING INSTRUCTIONS

This appliance is equipped with a direct spark intermittent ignition device. This device lights the main burners each time the room thermostat (closes) calls for heat. See operating instructions on the back of the furnace/controls access panel.

WARNING

DO NOT ATTEMPT TO MANUALLY LIGHT THIS FURNACE WITH A MATCH OR ANY OPEN FLAME. ATTEMPTING TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

TO START THE FURNACE

1. STOP! Read the safety information on the Operating Instructions Label located on this appliance.

WARNING

IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.

2. Set the thermostat to its lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do NOT

5. Remove control door/access panel.

6. Move switch to the “OFF” position.

7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP!

• Do not try to light any appliance.

• Do not touch any electric 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. If you don’t smell gas, go to the next step.

8. Move the switch from “OFF” position to “ON” position.

9. Replace the control door.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

12. If the appliance will not operate, follow the instructions below on how to shut down the furnace.

try to light the burner by hand.

WARNING

The initial start-up on a new installation may require the control system to be energized for some time until any air has bled through the system and fuel gas is available at the burners.

TO SHUT DOWN FURNACE

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Remove control door.

4. Move switch to the “OFF” position.

5. Replace control door.

+ 78 hidden pages

Rheem RRNL-B, RRNL-C, RRPL-B Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual