Table of Contents
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INSTALLATION INSTRUCTIONS
FOR HIGH EFFICIENCY CONDENSING GAS FURNACES
GF901U UPFLOW SERIES
GF901D DOWNFLOW/HORIZONTAL SERIES
Upflow Models
Model Number
Input (Btu)
GF901U045AS36
GF901U060AS36
GF901U075AS36
GF901U105AS60
105,000
GF901U120AS60
120,000
ISO 9001:2008
Tons
45,000
3
60,000
3
75,000
3
5
5
Downflow/Horizontal Models
Model Number
GF901D045AS36
GF901D060AS36
GF901D075AS36
GF0-1D105AS60
GF901D120AS60
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.
Input (Btu)
Tons
45,000
3
60,000
3
75,000
3
105,000
5
120,000
5
92-24161-82-04
SUPERSEDES 92-24161-82-03
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Table of Contents
Related Manuals for Rheem GF901U Series
Summary of Contents for Rheem GF901U Series
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Page 1: Safety Precautions
INSTALLATION INSTRUCTIONS FOR HIGH EFFICIENCY CONDENSING GAS FURNACES GF901U UPFLOW SERIES GF901D DOWNFLOW/HORIZONTAL SERIES Upflow Models Downflow/Horizontal Models Model Number Input (Btu) Tons Model Number Input (Btu) Tons GF901U045AS36 45,000 GF901D045AS36 45,000 GF901U060AS36 60,000 GF901D060AS36 60,000 GF901U075AS36 75,000 GF901D075AS36 75,000 GF901U105AS60 105,000 GF0-1D105AS60... -
Page 2: Installation Check List
INSTALLATION CHECK LIST REFER TO INSTALLATION INSTRUCTIONS GAS SUPPLY TERMINATIONS – DIRECT VENT Adequate pipe size VERTICAL Correct supply pressure (during furnace operation) Intake – 12" min. above roof/snow level Manifold pressure Correct relationship – exhaust to intake No gas leaks HORIZONTAL/VERTICAL –... -
Page 3: Table Of Contents
IMPORTANT: All manufacturer CONTENTS products meet current Federal OSHA Guidelines for safety. California Safety Precautions ....................1 Proposition 65 warnings are required for certain products, which are not Installation Check List ....................2 covered by the OSHA standards. Safety Information ....................4 California's Proposition 65 requires warnings for products sold in California General Information .....................10 that contain, or produce, any of over... -
Page 4: Safety Information
SAFETY INFORMATION WARNING WARNING WARNING WHEN A FURNACE IS INSTALLED NEVER TEST FOR GAS LEAKS USE ONLY WITH TYPE OF GAS SO THAT SUPPLY DUCTS CARRY WITH AN OPEN FLAME. USE A APPROVED FOR THIS FURNACE. AIR CIRCULATED BY THE COMMERCIALLY AVAILABLE REFER TO THE FURNACE RATING FURNACE TO AREAS OUTSIDE... - Page 5 WARNING WARNING WARNING IF THE INFORMATION IN THESE – DO NOT STORE OR USE DUCT LEAKS CAN CREATE AN INSTRUCTIONS IS NOT GASOLINE OR OTHER UNBALANCED SYSTEM AND FOLLOWED EXACTLY, A FIRE OR FLAMMABLE VAPORS AND DRAW POLLUTANTS SUCH AS EXPLOSION MAY RESULT, LIQUIDS, OR OTHER DIRT, DUST, FUMES AND ODORS...
- Page 6 NOTICE WARNING WARNING NEVER ALLOW THE PRODUCTS IMPROPER INSTALLATION, OR UPFLOW AND HORIZONTAL OF COMBUSTION FROM THE INSTALLATION NOT MADE IN FURNACES ARE DESIGN- FLUE TO ENTER THE RETURN AIR ACCORDANCE WITH THE CSA CERTIFIED FOR INSTALLATION DUCTWORK OR THE CIRCULATED INTERNATIONAL (CSA) ON COMBUSTIBLE FLOORS.
- Page 7 WARNING WARNING CAUTION THE COMBUSTION PRODUCTS THE DOWNFLOW FURNACE PVC SOLVENT CEMENTS AND AND MOISTURE IN THE FLUE DESIGN IS CERTIFIED FOR PRIMERS ARE HIGHLY GASES WILL CONDENSE AS THEY INSTALLATION ON A NON- FLAMMABLE. PROVIDE LEAVE THE TERMINATION. THE COMBUSTIBLE FLOOR.
- Page 8 CAUTION CAUTION WARNING ELEVATIONS ABOVE 2000 FT THE MEASURED TEMPERATURE ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE RISE SHOULD BE AS CLOSE TO REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED INPUT RATING BE ADJUSTED THE MIDDLE OF THE STATED AND THAT THE SIZE OF THE AND THAT THE SIZE OF THE RANGE AS POSSIBLE.
- Page 9 IMPORTANT! 2. APPROVED CARBON MONOXIDE 1. Detailed instructions for the DETECTORS. Each carbon monoxide installation of the venting system THE COMMONWEALTH OF detector as required in accordance with design or the venting system MASSACHUSETTS REQUIRES the above provisions shall comply with components;...
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Page 10: General Information
GENERAL INFORMATION These 90% Condensing Gas CSA-INTERNATIONAL Install this furnace in accordance with Furnaces are design-certified by CSA the American National Standard 8501 East Pleasant Valley Road for use with natural and propane Cleveland, Ohio 44131-5575 Z223.1 – latest edition entitled gases as follows: “National Fuel Gas Code”... - Page 11 IMPORTANT INFORMATION FIGURE 3 ABOUT EFFICIENCY AND MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES INDOOR AIR QUALITY Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality, it is important to have the proper balance between the air...
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Page 12: Location Requirements And Considerations
LOCATION REQUIREMENTS AND CONSIDERATIONS GENERAL INFORMATION 1. IMPORTANT: If installing the unit 3. IMPORTANT: Install the furnace WARNING over a finished ceiling or living level. If it is not level, condensate DO NOT USE THIS FURNACE area, be certain to install an cannot drain properly, possibly DURING CONSTRUCTION IF AIR auxiliary condensate drain pan... - Page 13 c. The heat tape should be rated FIGURE 5 at 5 or 6 watts per foot at HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS 120V. IMPORTANT: Support this unit PIPE when installed. Since this furnace is suitable for attic or crawl space installation, it may be installed on combustible wood flooring or by INTAKE...
- Page 14 FIGURE 6 CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS I392...
- Page 15 FIGURE 7 CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS I393...
- Page 16 FIGURE 8 CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS I520...
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Page 17: Ducting
DUCTING UPFLOW UNITS 5. If summer air conditioning is desired, position the indoor coil 1. Position the unit to minimize long Proper air flow is required for the on the top of the unit. Insure that runs of duct or runs of duct with correct operation of this furnace. -
Page 18: Venting And Combustion Air Piping
4. Connect the furnace to the 4. Connect the return air ducting to 5. Be sure to have adequate supply air plenum. the return air opening at the right space for the unit filter. end of the unit. Make the 5. - Page 19 conditions caused by inadequate 4. Follow the lighting instructions. D2665, D2231, D2661 and F628. combustion air supply. The switches for Place the appliance being PVC Primer and Solvent Cement - the upflow and downflow models are inspected into operation. Adjust the ASTM-D2564 located in the burner compartment.
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Page 20: Combustion And Ventilation Air
COMBUSTION AND VENTILATION AIR NON-DIRECT FURNACE INSTALLATIONS • Halogen type refrigerants BTUH Minimum Sq. Feet Typical Room Size Input With 8' Ceiling With 8' Ceiling • Cleaning solvents (such as 45,000 14' x 20' OR 16' x 18' perchloroethylene) WARNING 60,000 15' x 25' OR 19' x 20' •... - Page 21 BTUH Free Area FIGURE 11 Input Each Opening AIR FROM HEATED SPACE 45,000 100 square inches 60,000 100 square inches 75,000 100 square inches 90,000 100 square inches 105,000 105 square inches 120,000 120 square inches NOTE: EACH OPENING SHALL B.
- Page 22 Method 2 CONNECTION TO BTUH Free Area Round Pipe (Not Shown) Input Each Opening Size FURNACE One permanent opening, located 45,000 15.00 square inches 4" within 12 inches of the top of the IMPORTANT: When indoor 60,000 16.67 square inches 5"...
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Page 23: Vent Pipe Installation
VENT PIPE INSTALLATION NON-DIRECT VENT TABLE 1 FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION INSTALLATION PROVIDED FROM INDOORS GUIDELINES MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE IMPORTANT: Failure to correctly follow all venting guidelines may NUMBERS OF ELBOWS result in erratic furnace operation, 45°... - Page 24 “rub-a-tex” insulation may also be INSTALLATION CAN CAUSE 7. Avoid areas where dripping used as long as there is no heat STRUCTURAL OR EXTERIOR condensate may cause problems, tape applied to the vent pipe. For FINISH DAMAGE TO THE such as above planters, patios, or horizontal runs where water may BUILDING.
- Page 25 FIGURE 17 OTHER THAN DIRECT VENT TERMINAL CLEARANCES...
- Page 26 DIRECT VENT TABLE 2 INSTALLATIONS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM OUTDOORS WARNING MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. NUMBER OF ELBOWS VENT TERMINATION FAILURE TO PROPERLY VENT 45°...
- Page 27 COMBUSTION AIR FOR STANDARD HORIZONTAL Refer to Table 2 for proper application. This must TERMINATIONS DIRECT VENT be reduced to 1” or 1 “ the last INSTALLATIONS COMBUSTION AIR PIPING 12 inches for models with inputs of THE COMBUSTION AIR SYSTEM When 3-in.
- Page 28 • Insulate the entire length of vent FIGURE 18 pipe, between the elbow where the ALTERNATE HORIZONTAL DIRECT VENT TERMINATION pipe exits the wall and the elbow EXHAUST VENT where the termination is made, with " PVC FOR MODELS WITH 120,000 BTU INPUT (KIT NO.
- Page 29 CONCENTRIC NOTE: The following IPEX brand concentric terminations (System 636) TERMINATIONS may be purchased in the field and VERTICAL/HORIZONTAL used in place of factory supplied kits: CONCENTRIC VENT 2” Concentric Kit – Item # 196005 KIT NO. RXGY-E03 3” Concentric Kit – Item 3 196006 This kit is for vertical/horizontal intake air/vent runs and may be installed through roofs and...
- Page 30 RXGY-G02 SIDE WALL VENT NOTE: Install the vent and air intake NOTE: The vent illustration in Figure piping into the vent plate openings. 21 can be used for Non-direct vent This termination for horizontal venting Seal all gaps between the pipes and terminations also.
- Page 31 FIGURE 22 STANDARD VERTICAL DIRECT VENTING 3" UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW MODELS) EXHAUST MAX. VENT COMBUSTION AIR PIPE 12" 3" MAX. MIN. SEPARATION 12" MIN. 12” 3" EXHAUST MAX. VENT EXHAUST COMBUSTION AIR COMBUSTION TERMINATION PIPE AIR PIPE 12"...
- Page 32 FIGURE 24 DIRECT VENT TERMINAL CLEARANCES≤...
- Page 33 LOCATION REQUIREMENTS In addition to the minimum surfaces, unless a rust-resistant clearances listed above, the vent sheet metal or plastic backing HORIZONTAL DIRECT VENTS location should also be governed plate behind vent. See Figure 25. by the following guidelines. 5. Do not locate too close to shrubs CAUTION 1.
- Page 34 FIGURE 26 FIGURE 27 TWO FURNACE VENTING THROUGH ROOF TWO FURNACE VENTING THROUGH WALL TWO-PIPE VENTING TWO-PIPE VENTING EXHAUST VENT MODELS 06-07 TO BE REDUCED TO 1-1/2” PVC LAST 12”. 3” MINIMUM 24” MAXIMUM 3” MINIMUM 24” MAXIMUM CONCENTRIC VENTING CONCENTRIC VENTING 8”...
- Page 35 CONNECTING TO FURNACE FIGURE 28 UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION IMPORTANT: Clean and debur all pipe cuts. The shavings must not be allowed to block the exhaust, inlet or condensate drain pipes. “O” RING COMBUSTION AIR ADAPTER TOP PLATE NOTE: UPFLOW FURNACE WHEN COMBUSTION AIR INLET IS IN...
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Page 36: Condensate Drain/Neutralizer
CONDENSATE DRAIN/NEUTRALIZER GENERAL INFORMATION drain is present, install a riser which is a CONDENSATE OVERFLOW: With a minimum of 10 ⁄ ”. If the furnace is ⁄ inch riser installed above the tee, installed in an attic, crawlspace or other a blocked drain will result in overflow CAUTION area where freezing temperatures may... - Page 37 DOWNFLOW UNITS FIGURE 32 To convert downflow models to left- HORIZONTAL CONDENSATE DRAIN hand drain, a kit (RXGY-H01) must be ordered from the distributor. The kit includes a 24” piece of 1/2” black PVC pipe, a 2-9/16” length of black hose, a 2”...
- Page 38 Remove the plug from the 2” alternate IMPORTANT: Do not connect into a drain hole (see Figure 34) and common drain line with an air replace it with the 2” rubber grommet conditioner evaporator coil drain supplied in the RXGY- H01 downflow located above the furnace.
- Page 39 CONDENSATE DRAIN FIGURE 35 FOR HORIZONTAL CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO HORIZONTAL INSTALLATION UPRIGHT POSITION: REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP INSTALLATION Refer to Figure 35 for Steps 1-4. This unit is shipped factory ready for downflow installation. The condensate trap assembly and drain hoses require conversion for horizontal installation.
- Page 40 Clamp the hose tight with white FILLING THE TRAP nylon clamp. Then attach the long end of the molded hose to the 45° FILL THE TRAP ASSEMBLY WITH elbow molded into the top of the WATER BEFORE OPERATING THE trap assembly. Clamp the hose FURNACE.
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Page 41: Gas Supply And Piping
GAS SUPPLY AND PIPING GAS SUPPLY FIGURE 37 GAS PIPING INSTALLATION UPFLOW WARNING THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON GROMMET MAIN GAS NATURAL GAS ONLY. NOTE: WHEN GAS LINE VALVE TOP VIEW OF GAS LINE AND VALVE IS IN OPT. - Page 42 Install a ground joint union inside TABLE 3 the cabinet to easily remove the NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.) control valve assembly. Install a manual shut-off valve in the gas Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific line outside the furnace casing.
- Page 43 2. Replace the orifice spuds. in that the NFGC LP orifice chart, as sizes available 1.10mm (-90) and 3. Reassemble in reverse order. they are not accurate for Rheem 1.15mm (-91): products. The National Fuel Gas 4. Turn the gas supply back on and...
- Page 44 SETTING GAS PRESSURE The maximum gas supply pressure Supply Gas Pressure Measure- 6. Replace the pressure tap plug to the furnace should be 10.5" w.c. ment. A line pressure tap is on the before turning on the gas. natural gas, or 13" w.c. LP gas. The input side of the gas valve.
- Page 45 FIGURE 42 MANIFOLD PRESSURE READING FIGURE 43 UPFLOW GROUNDING CONNECTIONS LOW VOLTAGE TERMINALS JUNCTION CONDENSATE TRAP MOUNTING PLATE BLOWER COMPARTMENT CONTROL IS GROUNDED WHEN ATTACHED TO BLOWER I409-3...
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Page 46: Electrical Wiring
ELECTRICAL WIRING furnace. The ignition control may not integrated furnace control. The low sense flame if L1 and L2 are reversed. voltage wiring should be sized as See Figure 44. shown. NOTE: Electric to furnace must be Make all electrical connections in NOTE: Do not use 24 volt control supplied by a commercial utility. -
Page 47: Accessories
fireplace, sun rays, lamps, televisions, FURNACE TWINNING radios or air streams from registers. INSTALLATIONS Refer to instructions packed with the thermostat for “heater” selection or Twinning operation of two furnaces, adjustment. installed side-by-side, connected by a common duct system with main ACCESSORIES power supplied by the same source. -
Page 48: High Altitude Instructions
90+ HIGH ALTITUDE NATURAL GAS NOTE: Factory installed orifices are calculated and sized based on a sea INSTRUCTIONS CAUTION level Natural Gas heating value of 1075 BTU per cubic ft. Regional INSTALLATION OF THIS FURNACE 90 PLUS CONDENSATING reduced heating values may nullify AT ALTITUDES ABOVE 2000 FT (610 the need to change orifices except at GAS FURNACES HIGH... - Page 50 CANADIAN HIGH-ALTITUDE Rheem products that use 10 of water column at the orifice. This difference DERATE requires a deviation from the NFGC orifice size recommendations. The Sea...
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Page 51: Start-Up Procedures
START-UP PROCEDURES Sequence if the system doesn’t A gas furnace’s firing rate, temperature WARNING rise and operation should be checked light or doesn’t sense flame: after installation. During this process we SHOULD OVERHEATING OCCUR OR 1. On a call for heat, the control recommend that doors and windows be THE GAS SUPPLY FAIL TO SHUT runs the inducer for 30 seconds... - Page 52 TABLE 9 METER TIME METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS HEATING VALUE OF GAS BTU PER CU. FT. METER 1000 1040 1100 2500 (LP) INPUT SIZE BTU/HR CU. FT. MIN.
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Page 53: Air Flow
AIR FLOW INSTALLER MUST ADJUST THE FIGURE 47 TEMPERATURE RISE TO THIS TEMPERATURE RISE MEASUREMENT "MIDDLE" POINT AS CLOSELY AS The importance of proper air flow over the POSSIBLE. ALSO, THE heat exchanger cannot be over TEMPERATURE RISE SHOULD emphasized. NEVER BE ABOVE OR FALL BELOW THE STATED RANGE. - Page 54 TABLE 10 90 PLUS AIR FLOW PERFORMANCE – UPFLOW & DOWNFLOW/HORIZONTAL MODELS CFM @ ESP TONS BTU INPUT BLOWER/ SPEED MOTOR HP UPFLOW 11 x 7 / ⁄ 805 [380] 780 [368] 760 [358] 720 [340] 685 [323] 645 [304] 605 [285] 45,000 MED-LO...
- Page 55 SETTING BLOWER GAS FURNACE (DIRECT FIGURE 49 TIMINGS DRIVE) INSTRUCTIONS UT Electronic Controls 1097-200 BLOWER OFF TIMINGS FOR CHANGING BLOWER NOTE: This does not apply to these SPEED models. The heat tap functions as the continuous fan tap as well. WARNING See Figure 49 for instructions for setting the blower “OFF”...
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Page 56: Maintenance
MAINTENANCE TABLE 11 FILTER SIZES WARNING UPFLOW FILTER SIZES PART FURNACE INPUT BOTTOM SIDE QUANTITY THESE INSTRUCTIONS ARE WIDTH MBTUH SIZE SIZE INTENDED AS AN AID TO 54-24094-01 " 45, 60, 75A " X 25" 15 " X 25" QUALIFIED SERVICE 54-24094-02 21"... - Page 57 FIGURE 50 UPFLOW FILTER LOCATIONS JACKET JACKET ANGLE JACKET FILTER FILTER ANGLE DETAIL AIRFLOW FILTER FILTER ATTACH WITH 45-24095-01 SHEET METAL SCREWS (2 REQÕD) FILTER ROD FILTER ROD FILTER ROD SUPPORT SUPPORT SUPPORT ANGLE ANGLE ANGLE FILTER FILTER SUPPORT FILTER SUPPORT SUPPORT FILTER SUPPORT ANGLE...
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Page 58: Wiring Diagram
4. Avoid excessive use of kitchen CAUTION WARNING exhaust fans. DO NOT OPERATE THE SYSTEM HOLES IN THE VENT PIPE OR 5. Do not permit the heat generated FOR EXTENDED PERIODS HEAT EXCHANGER CAN CAUSE by television, lamps or radios to WITHOUT FILTERS. -
Page 59: Troubleshooting
FIGURE 51 UPFLOW MODELS W/INTEGRATED FURNACE CONTROL (IFC) UT Electronic Controls 1012-925 (115 VAC IGNITER) INTEGRATED FURNACE CONTROL (IFC) WARNING TROUBLESHOOTING GUIDE HAZARDOUS VOLTAGE DISCONNECT POWER BEFORE SERVICING. NOTE: Most failures are not due to the IFC. Double check all other LINE VOLTAGE SERVICE MUST BE BY A TRAINED, QUALIFIED possibilities, including the ground connection, before replacing the IFC. - Page 60 FIGURE 52 MODELS WITH UT ELECTRONIC CONTROLS 1097-200...
- Page 61 FIGURE 53 MODELS WITH UT ELECTRONIC CONTROLS 1097-200...
- Page 64 CM 0611...