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INSTALLATION INSTRUCTIONS
FOR UPFLOW, UPFLOW/HORIZONTAL,
AND DOWNFLOW INDUCED DRAFT GAS FURNACES
(-)GPH, (-)GPJ, (-)GLH & (-)GLJ SERIES
92-24161-08-03
SUPERSEDES 92-24161-08-02
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Table of Contents
Troubleshooting
Related Manuals for Rheem GPH series
Summary of Contents for Rheem GPH series
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Page 1: Installation Instructions
Click anywhere in this document to return to HVAC inspection, Installation, Diagnosis, Repair information at InspectAPedia.com INSTALLATION INSTRUCTIONS FOR UPFLOW, UPFLOW/HORIZONTAL, AND DOWNFLOW INDUCED DRAFT GAS FURNACES (-)GPH, (-)GPJ, (-)GLH & (-)GLJ SERIES 92-24161-08-03 SUPERSEDES 92-24161-08-02... -
Page 2: Installation Check List
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... -
Page 3: Table Of Contents
CONTENTS Safety Precautions ....................4 Installation Check List ....................2 General Information....................5 Location Requirements and Considerations ............5 Combustion and Ventilation Air................10 Vent Pipe Installation....................13 Gas Supply and Piping...................16 Electrical Wiring......................20 Accessories ......................21 Start-Up Procedures....................24 Air Flow........................26 Maintenance......................30 Troubleshooting......................33 Wiring Diagrams.....................35 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. -
Page 4: Safety Precautions
SAFETY INFORMATION WARNING WARNING WARNING USE ONLY WITH TYPE OF GAS NEVER TEST FOR GAS LEAKS WHEN THIS FURNACE IS APPROVED FOR THIS FURNACE. WITH AN OPEN FLAME. USE A INSTALLED IN A RESIDENTIAL REFER TO THE FURNACE RATING COMMERCIALLY AVAILABLE GARAGE, IT MUST BE INSTALLED PLATE. -
Page 5: General Information
GENERAL INFORMATION The (-)GLH/(-)GLJ and (-)GPH/(-)GPJ (NFPA 54) (in Canada, CSA B149.1 and Air Conditioning Systems 1984. series furnaces are design certified by and .2 Installation Codes for gas These publications are available from: CSA for use with natural and propane burning appliances), and the National Fire Protection Association, gases as follows:... - Page 6 FIGURE 2 UPFLOW AND UPFLOW/HORIZONTAL DIMENSIONS...
- Page 7 FIGURE 3 DOWNFLOW DIMENSIONS...
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Page 8: Site Selection
CLEARANCE – NUMBER) BE IN PLACE WHEN THE PLACEMENT OF COMBUSTIBLE FURNACE IS INSTALLED WITH SIDE MATERIALS ON, AGAINST OR ACCESSIBILITY OR REAR AIR RETURN DUCTS. AROUND THE FURNACE JACKET The design of forced air furnaces with FAILURE TO INSTALL A BASE PLATE CAN CAUSE AN EXPLOSION OR input ratings as listed in the tables on COULD CAUSE PRODUCTS OF... -
Page 9: Horizontal Units
THE RETURN AIR PLENUM. THE 1. Position the unit over the supply air WARNING FLOOR OR PLATFORM MUST plenum and connect. A SOLID METAL BASE PLATE, (SEE PROVIDE SOUND PHYSICAL a. If installing on a combustible floor TABLE 1) MUST BE IN PLACE SUPPORT OF THE FURNACE, and not using an evaporator WHEN THE FURNACE IS... -
Page 10: Combustion And Ventilation Air
COMBUSTION AIR FIGURE 5 REQUIREMENTS HORIZONTAL RETURN AIR DUCT 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:... - Page 11 Combustion air must be free of acid FIGURE 7 forming chemicals; such as sulphur, AIR FROM ATTIC/CRAWL SPACE 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.
- Page 12 B: Method 1 B: Method 2 Provide two permanent openings, One permanent opening, located within IMPORTANT: If the furnace is in a one located within 12 inches of the 12 inches of the top of the enclosure, location with an exhaust fan, there top and one located within 12 shall be permitted where the must be sufficient ventilation to prevent...
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Page 13: Vent Pipe Installation
VENTING FIGURE 9 ATTACHING TO DRAFT INDUCER COLLAR 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, CSA-B149.1 & .2 and requirements or codes of the local utility or other authority having jurisdiction. - Page 14 “B-1” VERTICAL VENTING FIGURE 10 TYPICAL VENTING WITH “B-1” VENT 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.
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Page 15: Power Vent Systems
POWER VENT SYSTEMS EXISTING VENT SYSTEMS the common venting system are located. Turn on clothes dryers and IMPORTANT RETROFIT When vertical venting is not possible, any appliance not connected to the the only acceptable method for VENTING INSTRUCTIONS common venting system. Turn on horizontal venting is with the use of any exhaust fans, such as range If this furnace is a replacement... -
Page 16: Gas Supply And Piping
GAS SUPPLY AND PIPING GAS SUPPLY FIGURE 12 GAS PIPING INSTALLATION WARNING UPFLOW & DOWNFLOW 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. -
Page 17: Gas Pressure
GAS PRESSURE LP CONVERSION NOx MODELS IMPORTANT: The maximum gas NOTE: For installation, see specific LP When converting furnaces equipped supply pressure to the furnace should kit installation instructions. with NOx inserts to LP gas, remove the be 10.5” w.c. for natural gas and 13” NOx insert assemblies. -
Page 18: Setting Gas Pressure
SETTING GAS PRESSURE FIGURE 13 TYPICAL HOSE CONNECTION TO LINE PRESSURE TAP The maximum gas supply pressure to the furnace should be 10.5” w.c. natural gas, or 13” w.c. LP gas. The minimum supply gas pressure to the gas valve should be 5" w.c. natural gas or 11"... - Page 19 ADJUSTING OR CHECKING 3. Time the meter to measure the time value of 1000 BTU per cubic feet of natural gas, and 2500 BTU per cubic required to burn one cubic foot of FURNACE INPUT feet of LP gas. gas. NATURAL GAS: IMPORTANT: Actual input rates must 4.
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Page 20: Electrical Wiring
ELECTRICAL WIRING FIGURE 15 ISOLATION RELAY WARNING 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. -
Page 21: Accessories
UT ELECTRONIC CONTROLS FIGURE 16 1028-928 CONTROL BOARD LINE VOLTAGE CONNECTIONS 1. Single Stage Operation UT ELECTRONIC CONTROLS 1028-928 CONTROL BOARDS (See Figure 17) a. Control board "ONE" is on furnace connected to the thermostat. b. The 24 VAC supply to both control boards must be in phase I677 with each other. - Page 22 FIGURE 17 UT Electronic Controls 1028-928 CONTROL BOARD, TWINNING CONNECTION -- SINGLE STAGE OPERATION I400 a099201...
- Page 23 FIGURE 18 UTEC 1028-928 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION a099301...
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Page 24: Start-Up Procedures
START-UP PROCEDURE LIGHTING INSTRUCTIONS 6. It retries up to four times. At the end of WARNING the last try, the inducer stops. The This appliance is equipped with either a SHOULD OVERHEATING OCCUR OR system is in “soft” lock out. direct spark ignition device or a hot THE GAS SUPPLY FAIL TO SHUT 7. - Page 25 5. After 5 seconds of inter-purge, the GAS FURNACE (DIRECT FIGURE 19 igniter heats for 30 seconds. After 30 DRIVE) INSTRUCTIONS FOR UT Electronic Controls 1028-928 seconds, the gas valve opens for 9 seconds. If no flame is sensed, it BLOWER OFF TIMINGS CHANGING BLOWER SPEED closes the gas valve, the igniter de-...
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Page 26: Air Flow
AIR FLOW FIGURE 22 TEMPERATURE RISE MEASUREMENT 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. - Page 27 BLOWER PERFORMANCE DATA – (-)GPH UPFLOW/HORIZONTAL MODELS BLOWER PERFORMANCE DATA – (-)GLH DOWNFLOW MODELS...
- Page 28 BLOWER PERFORMANCE DATA – (-)GPJ UPFLOW/HORIZONTAL MODELS BLOWER PERFORMANCE DATA – (-)GLJ DOWNFLOW MODELS ONLY...
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Page 29: Safety Features
LUBRICATION FIGURE 24 The indoor blower motor and induced DOWNFLOW BLOWER REMOVAL draft motor are prelubricated by the motor manufacturer and do not require further attention. The motors 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... -
Page 30: Maintenance
MAINTENANCE FIGURE 25 RESIZING FILTERS & FRAME WARNING 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: (-)GPJ, and (-)GLJ models are not factory equipped with filters. - Page 31 FIGURE 27 FILTER RETAINING ROD (SIDE RETURN) FILTER 45-24095-01 FILTER ROD SUPPORT ANGLE AE-60520-01 FILTER SUPPORT ANGLE AE-61883-01 FILTER ROD SUPPORT ANGLE AE-60520-01 FILTER SUPPORT ANGLE (SEE ANGLE DETAIL) AE-61883-01 FIGURE 28 DOWNFLOW FILTER INSTALLATION...
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Page 32: Annual Inspection
IMPORTANT: Do not operate the ANNUAL INSPECTION 12. Flush each heat exchanger tube system for extended periods without with water from a hose and blow The furnace should operate for many filters. A portion of the dust entrained in out with air to remove excessive years without excessive scale build-up the air may temporarily lodge in the air moisture. -
Page 33: Troubleshooting
FIGURE 29 TROUBLESHOOTING FLOWCHART PREPURGE (continued on next page) - Page 34 FIGURE 29 TROUBLESHOOTING FLOWCHART (CONTINUED) 92-22744-19-01...
- Page 35 FIGURE 30 FOR MODELS WITH UT ELECTRONIC CONTROLS 1028-928 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION...
- Page 36 FIGURE 31 FOR MODELS WITH UT ELECTRONIC CONTROLS 1012-925 INTEGRATED FURNACE CONTROL AND HOT SURFACE IGNITION CM 0103...