Rheem RGRK-12ERAJS Series Installation Instructions Manual
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Rheem RGRK-12ERAJS Series Installation Instructions Manual

Rheem RGRK-12ERAJS Series Installation Instructions Manual

Upflow and downflow/horizontal high efficiency condensing two-stage gas furnaces
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INSTALLATION INSTRUCTIONS
FOR UPFLOW AND DOWNFLOW/HORIZONTAL
HIGH EFFICIENCY CONDENSING TWO-STAGE
GAS FURNACES
RGRK-12ERAJS, RGRL, AND RGTK SERIES
ISO 9001:2008
U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all
applications, and their installation should be in accordance with the manufacturer's
recommendations and/or local laws, rules, regulations, or customs.
92-24161-36-25
SUPERSEDES 92-24161-36-24

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Summary of Contents for Rheem RGRK-12ERAJS Series

  • Page 1: Safety Precautions

    INSTALLATION INSTRUCTIONS FOR UPFLOW AND DOWNFLOW/HORIZONTAL HIGH EFFICIENCY CONDENSING TWO-STAGE GAS FURNACES RGRK-12ERAJS, RGRL, AND RGTK SERIES 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.

  • Page 2: Installation Check List

    INSTALLATION CHECK LIST TERMINATIONS – DIRECT VENT REFER TO INSTALLATION INSTRUCTIONS VERTICAL GAS SUPPLY ______ Intake – 12" min. above roof/snow level ______ Adequate pipe size ______ Correct supply pressure (during furnace operation) ______ Correct relationship – exhaust to intake ______ Manifold pressure 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. General Information....................4 California's Proposition 65 requires warnings for products sold in California Safety Information ....................6 that contain, or produce, any of over...

  • Page 4: General Information

    GENERAL INFORMATION NOTE: A load calculation must be 1. As non-direct vent central forced air Install units in Canada in accordance performed to properly determine the furnaces taking combustion air from with CSA-B149, local installation required furnace BTU size for the the installation area or using air codes and authorities having structure.
  • Page 5 IMPORTANT INFORMATION FIGURE 2 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...

  • Page 6: Safety Information

    SAFETY INFORMATION WARNING WARNING WARNING NEVER TEST FOR GAS LEAKS WHEN THIS FURNACE IS USE ONLY WITH TYPE OF GAS WITH AN OPEN FLAME. USE A APPROVED FOR THIS FURNACE. INSTALLED IN A RESIDENTIAL REFER TO THE FURNACE RATING COMMERCIALLY AVAILABLE GARAGE, IT MUST BE INSTALLED PLATE.
  • Page 7 IMPORTANT! 4. INSPECTION. The state or local WARNING gas inspector of the side wall THE COMMONWEALTH OF horizontally vented gas fueled DUCT LEAKS CAN CREATE AN MASSACHUSETTS REQUIRES equipment shall not approve the UNBALANCED SYSTEM AND DRAW COMPLIANCE WITH REGULATION installation unless, upon inspection, POLLUTANTS SUCH AS DIRT, DUST, 248 CMR 4.00 AND 5.00 FOR...

  • Page 8: Location Requirements And Considerations

    LOCATION REQUIREMENTS AND CONSIDERATIONS GENERAL INFORMATION b. install a parallel duct system (0°C), a self-regulating heat tape WARNING to divert all the air from the is required on the condensate DO NOT INSTALL THIS FURNACE furnace allowing it to pass drain, along with an insulation IN A MOBILE HOME!! This furnace over the cooling coil only.
  • Page 9 CLEARANCE - Upflow furnaces are shipped with a CAUTION bottom closure panel installed. ACCESSIBILITY THIS FURNACE IS NOT When bottom return air is used, remove the panel by removing the APPROVED OR RECOMMENDED The design of forced air furnaces with two screws attaching the panel to FOR INSTALLATION ON ITS BACK, input ratings as listed in the table...
  • Page 10 FIGURE 5 CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS I392...
  • Page 11 FIGURE 6 CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS I393...
  • Page 12 FIGURE 7 CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS I520...

  • Page 13: Ducting

    DUCTING Proper air flow is required for the IMPORTANT: When using outside air, NOTE: Where the maximum air flow correct operation of this furnace. design and adjust the system to maintain is 1800 CFM or more, both sides or 1 Too little air flow can cause erratic a return air temperature ABOVE 55°...
  • Page 14 DOWNFLOW UNITS NOTE: DO NOT take return air from bathrooms, kitchens, furnace 1. Position the unit to minimize long rooms, garages, utility or laundry runs of duct or runs of duct with rooms, or cold areas. many turns and elbows. 2.

  • Page 15: Venting And Combustion Air Piping

    VENTING AND COMBUSTION AIR PIPING REQUIREMENT THAT VENT REPLACE THESE SWITCHES GENERAL INFORMATION MATERIAL BE CERTIFIED TO ULC ONLY WITH THE IDENTICAL S636 DOES NOT APPLY TO INLET REPLACEMENT PART. WARNING AIR PIPING. VENT TERMINATIONS AND CONCENTRIC TERMINATIONS READ AND FOLLOW ALL EXISTING VENT SYSTEMS MUST BE APPROVED BY THE INSTRUCTIONS IN THIS SECTION.
  • Page 16 6. After it has been determined that JOINING PIPE AND 1. Cut pipe end square. Chamfer each appliance that remains edge of pipe. Clean fitting socket FITTINGS and pipe joint area of all dirt, connected to the common venting system properly vents grease and moisture.

  • Page 17: Combustion And Ventilation Air

    COMBUSTION AND VENTILATION AIR NON-DIRECT FURNACE INSTALLATIONS • Cleaning solvents (such as BTUH Minimum Sq. Feet Typical Room Size Input With 8' Ceiling With 8' Ceiling perchloroethylene) WARNING 45,000 14' x 20' OR 16' x 18' • Printing inks, paint removers, 60,000 15' x 25' OR 19' x 20' varnishes, etc.
  • Page 18 BTUH Free Area FIGURE 10 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 19 Method 2 (not shown) CONSULT LOCAL CODES FOR BTUH Free Area Round Pipe SPECIAL REQUIREMENTS. One permanent opening, located Input Each Opening Size within 12 inches of the top of the 45,000 15.00 square inches 4" CONNECTION TO enclosure, shall be permitted 60,000 16.67 square inches 5"...

  • Page 20: Vent Pipe Installation

    VENT PIPE INSTALLATION TABLE 2 NON-DIRECT VENT UPFLOW UNITS INSTALLATION FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM INDOORS GUIDELINES MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE IMPORTANT: Failure to correctly follow NUMBERS OF ELBOWS 45°...
  • Page 21 STANDARD INSTALLATIONS Non-direct venting location In addition to the minimum clearances requirements are slightly different in listed above, the vent location should The single-pipe system requires an some cases than direct venting. Install also be governed by the following exhaust pipe only. Combustion air may a non-direct vent with the following guidelines.
  • Page 22 FIGURE 16 OTHER THAN DIRECT VENT TERMINAL CLEARANCES...
  • Page 23 DIRECT VENT TABLE 4 INSTALLATIONS UPFLOW UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM OUTDOORS MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE WARNING NUMBER OF ELBOWS READ AND FOLLOW ALL 45 or 90 Degrees FURNACE PIPE VENT TERMINATION...
  • Page 24 allowable length in feet of the exhaust prevent entry of rain. See Figure 19 termination. The exhaust vent for and combustion air intake pipes that models with inputs of 90,000 through for the proper relationship of may be used for all furnace inputs as 120,000 BTUH is 2-in.
  • Page 25 • Insulate the entire length of vent FIGURE 17 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 26 CONCENTRIC NOTE: The following IPEX brand concentric termination (System 636) TERMINATIONS may be purchased in the field and VERTICAL/HORIZONTAL used in place of factory supplied kits: CONCENTRIC VENT 3” Concentric Kit – Item # 196006 KIT NO. (-)XGY-E03A This kit is for vertical/horizontal intake air/vent runs and may be installed through roofs or sidewalls.
  • Page 27 FIGURE 19 STANDARD VERTICAL DIRECT VENTING 3" EXHAUST MAX. VENT COMBUSTION AIR PIPE 12" 3" MAX. MIN. SEPARATION 3" EXHAUST 12” MAX. VENT 12" 36" MAX. COMBUSTION AIR EXHAUST COMBUSTION MIN. TERMINATION PIPE AIR PIPE 12" DETAIL A MIN. 12" MIN. 30”...
  • Page 28 LOCATION REQUIREMENTS In addition to the minimum clearances 5. Do not locate too close to shrubs listed above, the vent location as condensate may stunt or HORIZONTAL DIRECT VENTS should also be governed by the kill them. following guidelines. 6. Minimum vertical clearances of 1 CAUTION foot are recommended for 1.
  • Page 29 FIGURE 22 DIRECT VENT TERMINAL CLEARANCES...
  • Page 30 FIGURE 23 FIGURE 24 TWO FURNACE VENTING THROUGH ROOF TWO FURNACE VENTING THROUGH WALL TWO-PIPE VENTING TWO-PIPE VENTING COMBUSTION AIR INTAKE 2” PVC 3" MIN. 24" MAX. COMBUSTION AIR INTAKE 2” PVC COUPLING WITH VALVE IN VERTICAL POSITION EXHAUST VENT 3"...
  • Page 31 (-)XGY-G02 Side Wall Vent NOTE: Install the vent and air intake NOTE: The vent illustration in Figure piping into the vent plate openings. 26 can be used for non-direct vent This termination for horizontal venting terminations also. Seal all gaps between the pipes and only.
  • Page 32 CONNECTING TO FURNACE FIGURE 27 UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION IMPORTANT: Clean and debur all pipe cuts. The shavings must not be allowed to block the exhaust, combustion air or condensate drain COMBUSTION “O” RING pipes. AIR ADAPTER TOP PLATE NOTE: UPFLOW FURNACE...

  • Page 33: Condensate Drain/Neutralizer

    CONDENSATE DRAIN/NEUTRALIZER GENERAL INFORMATION IMPORTANT: If installing the unit over Use a solvent cement that is a finished ceiling or living area, be compatible with PVC material. Cut the certain to install an auxiliary condensate drain hoses to the appropriate length CAUTION drain pan under the entire unit and connect to the trap with hose...
  • Page 34 REVERSING THE TRAP FIGURE 30 UPFLOW UNITS UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION The trap may be moved to the right PROPER DRAIN SLOPE REQUIRED side for right side drainage. Open the (NO KINKS ALLOWED) CUT DRAIN HOSES AS knockout for the drain on the right REQUIRED side of the cabinet.
  • Page 35 CONDENSATE DRAIN FIGURE 32 FOR HORIZONTAL DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION INSTALLATION Refer to Figure 33 for Steps 1-4. This unit is shipped factory ready for downflow installation. The DRAIN UNION VENT condensate trap assembly and drain hoses require conversion for DRAIN EXISTING horizontal installation.

  • Page 37: Gas Supply And Piping

    GAS SUPPLY AND PIPING GAS SUPPLY FIGURE 35 GAS PIPING INSTALLATION WARNING UPFLOW THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION GROMMET MANUAL TO LP GAS REQUIRES A SPECIAL NOTE: WHEN GAS LINE STOP TOP VIEW OF GAS LINE AND VALVE IS IN OPT.
  • Page 38 use a pipe compound resistant to the TABLE 6 action of liquefied petroleum gases on NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.) all threaded connections. Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific IMPORTANT: When making gas pipe gravity of 0.60 (natural gas).
  • Page 39 LP CONVERSION SETTING GAS PRESSURE The maximum gas supply pressure IMPORTANT: LP gas from trucks To change the gas valve and orifice to the furnace should be 10.5" w.c. used to transport liquid-based spuds for either conversion to LP or for natural gas, or 13"...
  • Page 40 Manifold Gas Pressure FIGURE 37 Measurement. Natural gas MANIFOLD PRESSURE TAP manifold pressure should be 3.5" w.c.; LP gas manifold pressure should be 10" w.c. Only small variations on gas pressure should be made by adjusting the pressure regulator. 1. With the gas shut off at the MANIFOLD manual gas stop, remove the PRESSURE...
  • Page 41 FIGURE 39 TYPICAL MANIFOLD PRESSURE READING...

  • Page 42: Electrical Wiring

    ELECTRICAL WIRING furnace. Connect from the electrical board “Status” L.E.D. See Figure 40. WARNING disconnect to the junction box on the left Make all electrical connections in TURN OFF ELECTRIC POWER AT side of the furnace, inside the blower accordance with the latest edition of FUSE BOX OR SERVICE PANEL compartment.

  • Page 43: Accessories

    FIGURE 41 THERMOSTAT WIRING OPTIONS 2 HEAT - 1 COOL 1 HEAT, 1 COOL (OPTION A) TIMED STAGING W/1 STAGE HEAT T-STAT (AFTER F3507 DATE CODE (AUGUST 2007) 2 HEAT - 2 COOL 1 HEAT, 1 COOL (OPTION B) 100% HEAT ALWAYS -- NO TIMED STAGING THERMOSTAT FIELD-INSTALLED OPTIONAL ACCESSORIES NOTE: Do not use 24 volt control wiring...

  • Page 44: Furnace Twinning

    TABLE 9 FIELD WIRE SIZE FOR 24 VOLT CONTROL CIRCUITS SOLID COPPER WIRE - AWG LENGTH OF RUN - FEET ΠΠWire length equals twice the run distance NOTE: Do not use 24 volt control wiring smaller than No. 18. FIGURE 42 ISOLATION RELAY Both controls must have jumper P7 in...
  • Page 45 FIGURE 43 UT Electronic Controls 1095-201 IFC, TWINNING CONNECTION -- SINGLE STAGE OPERATION...
  • Page 46 FIGURE 44 UT ELECTRONIC CONTROLS 1095-202 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION...
  • Page 47 FIGURE 45 UT ELECTRONIC CONTROLS 1095-202 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION...

  • Page 48: High Altitude Installations

    90+ HIGH ALTITUDE HIGH ALTITUDE KIT the factory which are one drill size smaller (#51 DMS) than standard INSTRUCTIONS Installer must make necessary burner (-)GRL gas furnaces (#50 DMS). The orifice and pressure switch changes as indicated in the table below: smaller orifice is installed to NATURAL GAS accommodate for average heating...
  • Page 50 67,500 60,750 67,500 60,750 2001’ - 4500’ 3.0” W.C. 2001’ - 4500’ 1.10mm 7.6” W.C. 81,000 72,900 Rheem products that use 10" of water 81,000 72,900 94,500 85,050 94,500 85,050 column at the orifice. This difference 108,000 97,200 108,000 97,200 requires a deviation from the NFGC orifice size recommendations.

  • Page 51: Start-Up Procedures

    START-UP PROCEDURES A gas furnace’s firing rate, temperature FIRE OR AN EXPLOSION stage thermostat with the timed rise and operation should be checked RESULTING IN PROPERTY staging feature. If the jumper is left after installation. During this process we DAMAGE, PERSONAL INJURY OR on “NONE”, the furnace will never recommend that doors and windows be DEATH.
  • Page 52 gas valve to 100% and the main b. After a 30 second pre-purge the spark Main blower starts on high speed blower goes to high-fire heating igniter energizes and the gas valve 20 seconds after gas valve speed. (high stage) opens, lighting the energizes.
  • Page 53 ADJUSTING OR CHECKING FURNACE INPUT A properly calibrated manometer or TABLE 14 gauge is required for accurate gas METER TIME pressure readings. NATURAL GAS METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS 1.

  • Page 54: Air Flow

    AIR FLOW RISE RANGE IS 40 TO 70 DEGREES, FIGURE 49 THE MOST IDEAL RISE WOULD BE TEMPERATURE RISE MEASUREMENT The importance of proper air flow over the 55 DEGREES (THE MIDDLE OF THE RISE RANGE). IN ALL heat exchanger cannot be over emphasized.
  • Page 55 GAS FURNACE (DIRECT DRIVE) INSTRUCTIONS FOR CHANGING BLOWER SPEED WARNING DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. The blower motor is wired for blower speeds required for normal operation as shown.
  • Page 56 TABLE 15 90 PLUS AIR FLOW PERFORMANCE CFM @ ESP MODEL BLOWER/ SPEED MOTOR HP UPFLOW MODELS (-)GRL-04 11 X 7 / ⁄ *M-LO M-HI 1140 1110 1085 1045 1010 HIGH 1360 1320 1280 1235 1195 1140 1080 (-)GRL-07(A) 11 X 7 / ⁄...

  • Page 57: Maintenance

    MAINTENANCE TABLE 16 FILTER SIZES WARNING UPFLOW FILTER SIZES THESE INSTRUCTIONS ARE FURNACE INPUT BOTTOM SIDE QUANTITY WIDTH MBTUH SIZE SIZE INTENDED AS AN AID TO " 45, 60, 75A " X 25" " X 25" QUALIFIED SERVICE PERSONNEL 21" 75B, 90, 105 "...
  • Page 58 FIGURE 52 UPFLOW BOTTOM RETURN BOTTOM PANEL REMOVAL JACKET ASSEMBLY FILTER LOCATION JACKET ASSEMBLY REMOVE SOLID BOTTOM AIRFLOW FILTER FILTER FILTER & ROD LOCATION NOTE: BACK FLANGE OF SOLID BOTTOM FITS UNDERNEATH JACKET. SIDES AND FRONT SCREW FLANGES FIT OVER FLANGES ON JACKET. (2) REQ’D.

  • Page 59: Troubleshooting

    SUPPLY REGISTERS. ANY it is recommended that a qualified WARNING RECIRCULATED DUST PARTICLES installer, service agency, or the gas supplier annually inspect the flue WILL BE HEATED AND CHARRED DISCONNECT MAIN ELECTRICAL BY CONTACT WITH THE FURNACE passageways, the vent system and POWER TO THE UNIT BEFORE HEAT EXCHANGER.
  • Page 60 FIGURE 53 TROUBLESHOOTING CHART Go To Next Page...
  • Page 61 FIGURE 53 TROUBLESHOOTING CHART (CONTINUED)
  • Page 62 FIGURE 54 WIRING DIAGRAM...
  • Page 63 FIGURE 55 WIRING DIAGRAM...
  • Page 64 CM 0111...

This manual is also suitable for:

Rgrl-12erajs seriesRgtk-12erajs series

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