Rheem RGEA16 Installation Instructions Manual
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Rheem RGEA16 Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
PACKAGE GAS ELECTRIC
FEATURING EARTH-FRIENDLY R-410A REFRIGERANT
RGEA16 UP TO 16 SEER (2-5 TONS)
Seasonal Energy Efficiency Ratio (SEER)
—
10.6
Uses least energy
Annual Fuel Utilization Efficiency -
THIS MODEL
81.0%
MID
78%
82%
88%
ISO 9001:2008
RGEA16
16.0
©
16.05
AFUE
HIGH
97%
(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.
r e f r i g e r a n t
92-21916-79-01
SUPERSEDES 92-21916-79-00

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  • Page 1 INSTALLATION INSTRUCTIONS PACKAGE GAS ELECTRIC FEATURING EARTH-FRIENDLY R-410A REFRIGERANT r e f r i g e r a n t RGEA16 UP TO 16 SEER (2-5 TONS) Seasonal Energy Efficiency Ratio (SEER) RGEA16 16.0 — © 10.6 16.05 Uses least energy...

  • Page 2: Table Of Contents

    E. Replacement Parts..................32 F. Charging......................32 XI. Units with ECM Blower Motors (RGEA16 Models Only) ........33 A. ECM Motor Interface Control and Settings (RGEA16 Units Only) ....33 B. Transformer Protection ...................34 C. Using the Onboard LED to Determine Blower CFM........34 D. Unit Operation with Two-Stage Cooling ............35 E.

  • Page 3: Safety Information

    I. S FETY INFORM TION W RNING 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 REPRODUC- TIVE HARM.
  • Page 4 W RNING 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.
  • Page 5 W RNING DO NOT JUMPER THIS DEVICE! DO NOT reset the overtemperature control without taking corrective action to assure that an adequate supply of combus- tion 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.

  • Page 6: Introduction

    II. INTRODUCTION W RNING This booklet contains the installation and operating instructions for your combination gas IMPORTANT: ALL MANUFACTUR- heating/electric cooling unit. There are some precautions that should be taken to derive ER PRODUCTS MEET CURRENT maximum satisfaction from it. Improper installation can result in unsatisfactory operation FEDERAL OSHA GUIDELINES FOR or dangerous conditions.

  • Page 7: R-410A Refrigerant

    2. Quick Reference Guide For R-410 • 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. •...

  • Page 8: High Pressure Control

    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.
  • Page 9 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: Low suction pressure •...

  • Page 10: Unit Dimensions

    V. UNIT DIMENSIONS FOR CLE R NCES SEE FIGURE 3. FIGURE 3 30% ± 2% OUTDOOR FAN GRILLE OUTDOOR COIL AND COMPRESSOR ACCESS PROTECTIVE GRILLE FLUE EXHAUST 21% ± 2% 29% ± 2% SIDE 20% ± 2% RETURN DUCT OPENING FIELD POWER THREADED WIRE ENTRANCE...
  • Page 11 ” ⁄ ” SIDE RETURN ⁄ ” ⁄ ” DUCT TYP. TYP. OPENING SHOWN WITH DUCT COVERS REMOVED. MODEL “A” RGEA16 HEIGHT ⁄ ” 036, 048, SIDE VIEW SIDE VIEW FLUE EXHAUST HOOD SUPPLY ENTRANCE ⁄ ” OUTDOOR ⁄ ”...

  • Page 12: Installation

    VI. INST LL TION . GENER L 1. PRE-INSTALLATION CHECK-POINTS — Before attempting any installation, care- fully 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...

  • Page 13: Attaching Exhaust And Combustion Air Inlet Hoods

    FIGURE 4 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 anticipat- ed maximum snow depth for your area. Do not locate unit in an area where exces- sive snow drifting may block combustion air inlet.

  • Page 14: Cover Panel Installation/Conversion Procedure

    FIGURE 6 COMBUSTION AIR INLET HOOD & EXHAUST HOOD INSTALLATION FIGURE 5 PITCHING UNIT TO INSURE PROPER CONDENSATE DRAINAGE. EXHAUST COMBUSTION HOOD W/(4) AIR INLET SCREWS HOOD W/(4) SCREWS I655 D. COVER P NEL INST LL TION/CONVERSION PROCEDURE 1. HORIZONTAL TO DOWNFLOW a.
  • Page 15 FIGURE 7 FIGURE 5 COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW COVER GASKET DETAIL FOR UNITS SHIPPED FOR DOWNFLOW APPLICATION BEING CONVERTED TO SIDE DISCHARGE APPLICATION BEING CONVERTED TO SIDE DISCHARGE SUPPLY/RETURN AIR COVER FIGURE 8 FIGURE 6 TAPE AROUND FLANGE COVER GASKET DETAIL FOR UNITS SHIPPED FOR SIDE DISCHARGE COVER GASKET DETAIL FOR UNITS SHIPPED FOR SIDE DISCHARGE...

  • Page 16: Clearances

    FIGURE 11 CLEARANCES left side of unit. (See Figure 11.) 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.
  • Page 17 FIGURE 12 FIGURE 10 EXCEPTION TO NON-COMBUSTIBLE FLOORING REQUIREMENT EXCEPTION TO NON-COMBUSTIBLE FLOORING REQUIREMENT BOTH ENDS MUST BE SIDEFLOW SIDEFLOW OPEN FOR SUPPLY RETURN PLENUM DOWNFLOW PLENUM CONNECTION OR SIDEFLOW CONNECTION DUCTWORK TO PROVIDE NOMINAL VENTILATION 4 x 4 TIMBER (SIDES ONLY) 3-1/2”...

  • Page 18: Return Air

    FIGURE 15 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 indi- cated. Run ducts as directly as possible to supply and return outlets. Use of non-flam- mable weatherproof flexible connectors on both supply and return connections at unit to reduce noise transmission is recommended.

  • Page 19: Filters

    FIGURE 16 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 inspec- tion and cleaning. Filters must have adequate face area for the rated air quantity of the unit.
  • Page 20 FIGURE 17 FIGURE 15 ROOFCURB ROOFCURB FIGURE 18 FIGURE 16 RETURN PLENUM ROOFCURB ROOFCURB MAX. ROOFTOP UNIT GASKET MAX. SUPPLY INSULATION PLENUM PANELS TIE DOWN SCREW MAX. ROOFCURB NAILING STRIP DUCT DUCT FLANGE (NOT TO EXCEED 1() ROOF FLASHING INSULATION ROOFING NAILING CANT STRIP...

  • Page 21: Gas Supply, Condensate Drain And Piping

    VII. G S SUPPLY, CONDENS TE DR IN ND VII. PIPING . G S 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.

  • Page 22: Lp Conversion Two Stage Gas Heat

    W RNING 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.

  • Page 23: Adjusting Or Checking Furnace Input

    TABLE 2 LP GAS PIPE CAPACITY TABLE (CU. FT./HR.) Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column inlet pressure). (Based on a Pressure Drop of 0.5 Inch Water Column) Nominal Length of Pipe, Feet Iron Pipe...

  • Page 24: Condensate Drain

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

  • Page 25: Hook Up

    TABLE 4 BRANCH CIRCUIT COPPER WIRE SIZE (BASED ON 1% VOLTAGE DROP)* SUPPLY WIRE LENGTH-FEET 45 50 BRANCH CIRCUIT AMPACITY *Taken from National Electric Code NOTES: 1. Wire size based on 60°C rated wire insulation and 30°C Ambient Temp. (86°F). 2.

  • Page 26: Internal Wiring

    Refer to instructions packed with the thermostat for “heater” selection or adjustment. Refer to the RGEA16 Specification Sheets for a list of recommended thermostats. TABLE 6 TABLE 6 FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS SOLID COPPER WIRE - AWG.

  • Page 27: Furnace Section Controls And Ignition System

    IX. FURN CE SECTION CONTROLS ND IGNITION SYSTEM . NORM L FURN CE OPER TING SEQUENCE (TWO ST GE G S HE T FOR RGE 16) This unit is equipped with a two stage integrated direct spark ignition control. NORMAL HEAT MODE A.

  • Page 28: Operating Instructions

    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.

  • Page 29: 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. W RNING SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, SHUT OFF THE MANUAL GAS VALVE TO THE APPLIANCE BEFORE SHUT-...

  • Page 30: Furnace Section Maintenance

    B. FURN CE SECTION M INTEN NCE The unit’s furnace should operate for many years without excessive scale build-up in flue passageways; however, it is recommended that a qualified installer, service agency, or the gas supplier annually inspect the flue passageways, the exhaust system and the burners for continued safe operation, paying particular attention to deterioration from corrosion or other sources.

  • Page 31: Lubrication

    C. LUBRIC TION IMPORTANT: DO NOT attempt to lubricate the bearings on the blower motor or the induced draft blower motor. Addition of lubricants can reduce the motor life and void the warranty. The blower motor and induced draft blower motor are prelubricated by the manufacturer and do not require further attention.

  • Page 32: Replacement Parts

    3. If the coil is coated with oil or grease, clean it with a mild detergent-and-water solu- tion. Rinse the coil thoroughly with water. IMPORTANT: Do not use excessive water pressure. Excessive water pressure can bend the fins and tubing of the coil and lead to inadequate unit performance.

  • Page 33: Units With Ecm Blower Motors (Rgea16 Models Only)

    . ECM MOTOR INTERF CE CONTROL ND SETTINGS (RGE 16 UNITS ONLY) The RGEA16 series units use ECM blower motors to deliver a constant level of airflow over a wide range of external static pressures (up to 1.0" W.C.). The interface board provides the required communications between the thermostat/IFC and the ECM blower motor.

  • Page 34: Transformer Protection

    FIGURE 23 DO NOT WIRE DIRECTLY TO THIS BOARD. THERMOSTAT SHOULD ECM INTERFACE BOARD BE WIRED TO PIGTAILS LOCATED BELOW THE CONTROL BOX. FIRST-STAGE COOLING INPUT SECOND-STAGE COOLING INPUT (THIS BOARD IS LOCATED IN THE BLOWER SECTION) TABLE 7 SWITCH FUNCTIONS FIGURE 24 ECM MOTOR SETTINGS Switch...

  • Page 35: Unit Operation With Two-Stage Cooling

    950 CFM • Illuminate dimly 10 seconds, repeat sequence D. UNIT OPER TION WITH TWO-ST GE COOLING The RGEA16 unit provides distinct airflows for two-stage cooling. (See Figure 23.) Unit opera- tion is defined as: • Y1 – First Stage Cooling •...
  • Page 36 FIGURE 26 COOLING “ON” DELAY PROFILES INTERFACE BOARD SWITCH...
  • Page 37 FIGURE 27 BLOWER “OFF” DELAY PROFILES INTERFACE BOARD SWITCH...

  • Page 38: Heating Airflow Adjustments

    F. HE TING IRFLOW DJUSTMENTS FIGURE 28 HEATING AIRFLOW ADJUSTMENTS HEATING SELECTION SWITCH 5 SWITCH 6 AIRFLOW POSITION POSITION ADJUSTMENT NONE -10% NONE Heating airflow may be adjusted +10% or –10% from nominal airflow using switches 5 & 6. Refer to Figure 28 for switch positions to achieve the desired adjustments in airflow. NOTE: Continuous fan speed is NOT affected by switches 5 &...

  • Page 39: Cooling Mode Dehumidification

    H. COOLING MODE DEHUMIDIFIC TION n Explanation of On Demand Dehumidification Use “On-Demand Dehumidification” (ODD) is an optional feature of the ECM interface board. The ODD allows the user to have automatic dehumidification in the cooling mode that is controlled by the user’s dehumidifying thermostat or humidistat setting.
  • Page 40 RGE 16048 893 1360 preprogrammed amount to maximize latent removal. When high humidity is detected, the cooling airflow as shown in Table 12. RGE 16060 1063 1573 TABLE 12 SWITCH SWITCH 9 RGEA16 POSITION INPUT POSITION NONE 24VAC NONE 1020 24VAC...

  • Page 41: General Data

    GENER L D T - RGE 16 MODELS NOMIN L SIZES 2-5 TONS [7-15.8 kW] RGEA16 Series 024AJV06 2,T 036ACV062 036ACV082 036ACV102 Cooling Performance Con nued -> i l o y t i SEER 13.5/12.4 13.4/12.3 13.4/12.3 13.4/12.3 AHRI Rated CFM (1st / 2nd stage) [L/s]...
  • Page 42 GENER L D T - RGE 16 MODELS NOMIN L SIZES 2-5 TONS [7-15.8 kW] Model RGEA16 Series 036AJV06(2,T) 036AJV08(2,T) 036AJV10(2,T) 048ACV082 Cooling Performance Con nued -> i l o y t i SEER 13.4/12.3 13.4/12.3 13.4/12.3 12.7/11.5 AHRI Rated CFM (1st / 2nd stage) [L/s]...
  • Page 43 GENER L D T - RGE 16 MODELS NOMIN L SIZES 2-5 TONS [7-15.8 kW] RGEA16 Series 048ACV102 048AJV08(2,T) 048AJV10(2,T) 060ACV102 Cooling Performance Con nued -> i l o y t i SEER 12.7/11.5 12.7/11.5 12.7/11.5 12/10.7 AHRI Rated CFM (1st / 2nd stage) [L/s]...
  • Page 44 GENER L D T - RGE 16 MODELS NOMIN L SIZES 2-5 TONS [7-15.8 kW] RGEA16 Series 060AJV10(2,T) Cooling Performance Gross Cooling Capacity (2nd Stage) Btu [kW] 60,500 [17.73] SEER 14.2 12.7/10.7 AHRI Rated CFM (1st / 2nd stage) [L/s]...

  • Page 45: Miscellaneous

    XIII. MISCELL NEOUS ELECTRICAL DATA – RGEA16 SERIES 024 JV 036 CV 036 JV 048 CV 048 JV 060 CV 060 JV Unit Operating 197-253 197-253 197-253 197-253 197-253 197-253 197-253 Voltage Range Volts 208/230 208/230 208/230 208/230 208/230 208/230...

  • Page 46: Airflow Performance Data

    XIV. IRFLOW PERFORM NCE D T INDOOR IRFLOW PERFORM NCE FOR 2-5 TON P CK GE G S ELECTRIC UNITS–RGE 16 DIRECT DRIVE...

  • Page 47: Wiring Diagrams

    XV. WIRING DI GR MS FIGURE 30 WIRING DIAGRAM...
  • Page 48 FIGURE 31 WIRING DIAGRAM...

  • Page 49: Charge Charts

    XVI. CH RGE CH RTS FIGURE 32 SYSTEM CHARGE CHARTS RGEA16 – 2 TON COOLING 1st (LOW) STAGE CHARGE CHART R-410A REFRIGERANT °...
  • Page 50 FIGURE 33 SYSTEM CHARGE CHARTS RGEA16 – 2 TON COOLING 2nd (HIGH) STAGE CHARGE CHART R-410A REFRIGERANT °...
  • Page 51 FIGURE 34 SYSTEM CHARGE CHARTS RGEA16 – 3 TON COOLING 1st (LOW) STAGE CHARGE CHART R-410A REFRIGERANT °...
  • Page 52 FIGURE 35 SYSTEM CHARGE CHARTS RGEA16 – 3 TON COOLING 2nd (HIGH) STAGE CHARGE CHART R-410A REFRIGERANT °...
  • Page 53 FIGURE 36 SYSTEM CHARGE CHARTS RGEA16 – 4 TON COOLING 1st (LOW) STAGE CHARGE CHART R-410A REFRIGERANT...
  • Page 54 FIGURE 37 SYSTEM CHARGE CHARTS RGEA16 – 4 TON COOLING 2nd (HIGH) STAGE CHARGE CHART R-410A REFRIGERANT...
  • Page 55 FIGURE 38 SYSTEM CHARGE CHARTS RGEA16 – 5 TON COOLING 1st (LOW) STAGE CHARGE CHART R-410A REFRIGERANT...
  • Page 56 FIGURE 39 SYSTEM CHARGE CHARTS RGEA16 – 5 TON COOLING 2nd (HIGH) STAGE CHARGE CHART R-410A REFRIGERANT...

  • Page 57: Troubleshooting

    XVII. TROUBLESHOOTING COOLING TROUBLE SHOOTING CHART FIGURE 40 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. Unit will not run •...
  • Page 58 FIGURE 41 15 SECOND PREPURGE IS NEGATIVE PRESSURE SYSTEM CLOSED? (BOTH ON 2 STAGE HT) THE SYSTEM WILL ATTEMPT TO LIGHT 3 TIMES (4 TIMES 2 STG HT) WITH A 60 SECOND INTER-PURGE BETWEEN TRIES. IF AFTER THE THIRD TIME THE BURNERS DO NOT LIGHT, THE SYSTEM WILL LOCK OUT.

  • Page 59: Comfort Alert Diagnostic Chart

    XVIII. COMFORT LERT DI GNOSTIC CH RT FIGURE 42 SINGLE PHASE UNIT Status LED Status LED Description Status LED Troubleshooting Information Green “POWER” Module has power Supply voltage is present at module terminals Red “TRIP” Thermostat demand signal 1. Compressor internal overload is open Y1 is present, but the 2.
  • Page 60 FIGURE 43 3 PHASE UNIT Status LED Status LED Description Status LED Troubleshooting Information Green “POWER” Module has power Supply voltage is present at module terminals Red “TRIP” Thermostat demand signal 1. Compressor internal overload is open Y1 is present, but the 2.

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