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INSTALLATION INSTRUCTIONS
FOR UPFLOW/HORIZONTAL TWO STAGE
GAS FURNACES
(-)802P
UPFLOW/HORIZONTAL SERIES
(-)(-)80MDP UPFLOW/HORIZONTAL SERIES
ISO 9001:2008
Factory Use Only
ST-A1220-01-X0
U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are rec-
ommended in all applications, and their installation should be in accordance with the
manufacturer's recommendations and/or local laws, rules, regulations, or customs.
92-24161-146-02
SUPERSEDES 92-24161-146-01
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Summary of Contents for Rheem (-)802PA050314MSA
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Page 1: Installation Instructions
INSTALLATION INSTRUCTIONS FOR UPFLOW/HORIZONTAL TWO STAGE GAS FURNACES (-)802P UPFLOW/HORIZONTAL SERIES (-)(-)80MDP UPFLOW/HORIZONTAL SERIES ST-A1220-01-X0 U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are rec- ommended 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: Table Of Contents
TABLE OF CONTENTS 1 TABLE OF CONTENTS..... . . 2 11 TWINNING ....... . 32 Furnace Twinning Installations . -
Page 3: General Information
GENERAL INFORMATION NOTE: A heat loss calculation should be performed to properly The (-)802P/(-)(-)80MDP series furnaces are design certified by determine the required furnace BTU size for the structure. Also, CSA for use with natural and propane gases as follows: the duct must be properly designed and installed for proper air- As a Category I furnace, it may be vented vertically with type B- flow. -
Page 4: Receiving
GENERAL INFORMATION (cont.) Install this furnace in accordance with the American National Stan- CALIFORNIA RESIDENTS ONLY dard Z223.1 – latest edition entitled “National Fuel Gas Code” IMPORTANT: All manufacturer products meet current Federal (NFPA54) or, for Canada, CSA B149.1; Canadian Natural Gas OSHA Guidelines for safety. -
Page 5: Checklist
Installation Instructions remain with the furnace as a reference guide to the servicing contractor. We recommend that performance and installation data be recorded for future reference on this sheet to meet service and warranty obligations so that job site information is available when required. Installation Checklist REFER TO INSTALLATION INSTRUCTIONS G S SUPPLY... -
Page 6: Safety Information
SAFETY INFORMATION W RNING W RNING DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! COMBUSTION AND VENTILATION AIR MUST BE PRO- THIS FURNACE IS NOT APPROVED FOR INSTALLATION VIDED TO THE FURNACE AS REQUIRED BY THE NA- IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, TIONAL FUEL-GAS CODE (U.S.) AND CSA B149.1 PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. -
Page 7: Important Information About Efficiency And Quality
SAFETY W RNING W RNING BLOWER AND BURNERS MUST NEVER BE OPERATED DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM WITHOUT THE BLOWER DOOR IN PLACE. THIS IS TO AND DRAW POLLUTANTS SUCH AS DIRT, DUST, FUMES PREVENT DRAWING GAS FUMES (WHICH COULD CON- AND ODORS INTO THE HOME CAUSING PROPERTY TAIN HAZARDOUS CARBON MONOXIDE) INTO THE DAMAGE. -
Page 8: Location Requirements
LOCATION REQUIREMENTS GENERAL INFORMATION W RNING W RNING WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL THIS FURNACE IS NOT APPROVED OR RECOMMENDED GARAGE, IT MUST BE INSTALLED SO THE BURNERS FOR INSTALLATION ON ITS BACK, WITH ACCESS DOORS AND IGNITION SOURCE ARE LOCATED NO LESS THAN FACING UPWARDS. -
Page 9: Upflow Dimensions And Clearance Table
LOCATION REQUIREMENTS GENERAL INFORMATION (cont.) W RNING W RNING UPFLOW AND HORIZONTAL FURNACES ARE DESIGN- COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON CERTIFIED FOR INSTALLATION ON COMBUSTIBLE OR AGAINST THE FURNACE JACKET. THE AREA FLOORS. NOTE, HOWEVER, THAT FURNACES MUST NOT AROUND THE FURNACE MUST BE KEPT CLEAR AND BE INSTALLED DIRECTLY ON CARPETING, TILE OR FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING... - Page 10 FIGURE 4 UPFLOW/HORIZONTAL DIMENSIONS...
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Page 11: Ducting
DUCTING Proper air flow is required for the correct operation of this UPFLOW INSTALLATIONS furnace. Restricted air flow can cause erratic operation and 1. Position the unit to minimize long runs of duct or runs can damage the heat exchanger. The duct system must of duct with many turns and elbows. - Page 12 DUCTING NOTE: FIGURE 5 SOLID BASE PLATE PROVIDED WITH (-)801P MODELS ONLY. WHEN SOLID BASE PLATE IS USED . TAPE AROUND BOTTOM FLANGES OF CABINET BEFORE THE UNIT IS INSTALLED. SOLID BASE FLANGE FITS UNDER CABINET BOTTOM LIFT UP, PULL OUT 1.
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Page 13: Horizontal Units
DUCTING HORIZONTAL UNITS FIGURE 9 HORIZONTAL RETURN AIR DUCT 1. Position the unit to minimize long runs of duct or runs of (LEFT-HAND AIRFLOW POSITION SHOWN) duct with many turns and elbows. 2. Unit can be mounted left or right side airflow configuration. 3. -
Page 14: Combustion And Ventilation Air
COMBUSTION AND VENTILATION AIR COMBUSTION AIR REQUIREMENTS • Halogen type refrigerants IMPORTANT: This is not a direct vent furnace. eview venting • Cleaning solvents (such as perchloroethylene) instructions before installing. • Printing inks, paint removers, varnishes, etc. • Hydrochloric acid W RNING •... - Page 15 COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES FURNACE LOCATED IN A CONFINED SPACE ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE, NFPA 54 AND LOCAL rating which is smaller than that which is specified in Table 1 as CODES TO PROVIDE ADEQUATE COMBUSTION AND A confined space is defined as any space for a given furnace input VENTILATION AIR FOR THE FURNACE.
- Page 16 COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES TABLE 9 : MINIMUM FREE AREA REQUIRED T BLE 3: MINIMUM FREE RE REQUIRED T BLE 5: MINIMUM FREE RE REQUIRED TABLE 1 1: MINIMUM FREE AREA REQUIRED FOR EACH OPENING (WHEN TWO OPENINGS FOR E CH OPENING (WHEN TWO OPENINGS FOR E CH OPENING (WHEN TWO OPENINGS...
- Page 17 COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES FIGURE 12 FIGURE 11 VENT PENETRATIONS VENT PENETRATIONS NON-DIRECT VENT FOR NON DIRECT VENT FURNACES NON-DIRECT VENT FOR NON DIRECT VENT FURNACES AIR FROM ATTIC CRAWL SPACE OUTSIDE AIR AIR FROM ATTIC CRAWL SPACE AIR FROM ATTIC...
- Page 18 COMBUSTION AND VENTILATION AIR (cont.) It is also acceptable to run the condensate drain (or refriger- C UTION ant) line access over the air intake hole as long as a 1" mini- mum clearance is maintained. COMBUSTION AIR INTAKES CANNOT BE TERMINATED Combustion air openings must not be restricted in any manner.
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Page 19: Venting
COMBUSTION AND VENTILATION AIR (cont.) VENTING GENERAL INFORMATION IMPORTANT APPLICATION NOTES When the furnace is used as a replacement, the existing vent The furnace must be vented in accordance with these instructions, system should be inspected to assure that there are no obstruc- National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas In- tions, blockage, or any signs of corrosion and is properly sized for stallation Code, CSA-B149.1 &... -
Page 20: Special Vent Systems (Svs)
COMBUSTION AND VENTILATION AIR (cont.) VERTICAL VENT SYSTEMS: Single appliance venting of a fan assisted furnace into a tile-lined 1. A gas vent shall terminate above the roof surface with a listed masonry chimney is prohibited. The chimney must be lined with cap or listed roof assembly. - Page 21 COMBUSTION AND VENTILATION AIR (cont.) FIGURE 17 1. STANDARD 3” FLUE CONNECTION. 2. 4” ADAPTER - OPTIONAL SEE NATIONAL FUEL GAS CODE FOR SIZING OPTIONS FRESH AIR INLET ST-A1220-09-01 ST-A1220-09 FIGURE 18 DEDICATED VENTING THROUGH CHIMNEY WITH “B-1” VENT...
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Page 22: Power Vent Systems
COMBUSTION AND VENTILATION AIR (cont.) POWER VENT SYSTEMS 1. Visually inspect the venting system for proper size and hori- zontal pitch and determine that there is no blockage, restric- When vertical venting is not possible, the only acceptable method tion, leakage, corrosion or other deficiencies which could for horizontal venting is with the use of Tjernlund model GPAK- cause an unsafe condition. -
Page 23: Gas Supply
GAS SUPPLY GAS SUPPLY AND PIPING NATURAL GAS AND PROPANE IMPORTANT SAFETY INFORMATION AND WILL RISE, POSSIBLY ACCUMULATING IN (LIQUEFIED PETROLEUM GAS / LPG) HIGHER PORTIONS OF THE STRUCTURE. SAFETY • IF A GAS LEAK IS PRESENT OR SUSPECTED: - DO NOT ATTEMPT TO FIND THE CAUSE YOUR- SELF. -
Page 24: Gas Piping
GAS SUPPLY GAS PIPING IMPORTANT: When making gas pipe connections, use a back-up wrench to prevent any twisting of the control assembly and gas valve. Do not overtighten the connection. THIS FURNACE IS EQUIPPED AT THE FACTORY Any strains on the gas valve can change the position of the gas FOR USE ON NATURAL GAS ONLY. -
Page 25: Gas Pressure
GAS SUPPLY (cont.) GAS PRESSURE IMPORTANT: ENSURE that the furnace gas valve is not to be subjected to high gas line supply pressures. FIGURE 20 TYPICAL GAS VALVE (WHITE RODGERS) DISCONNECT the furnace and its individual manual gas stop OUTLET PRESSURE TAP from the gas supply piping during any pressure testing that ex- HIGH-FIRE ceeds 1/2 PSIG. -
Page 26: Setting Gas Pressure
GAS SUPPLY (cont.) GAS PRESSURE SETTING GAS PRESSURE The maximum gas supply pressure to the furnace ELEVATIONS ABOVE 2000 FT. REQUIRE THAT THE must not exceed 10.5" w.c. natural gas, or 13" w.c. LP FURNACE INPUT RATING BE ADJUSTED AND THAT gas. -
Page 27: Lp Conversion
LP CONVERSION NOTE: The valve can be converted to use liquified petroleum 4. Turn the gas supply back on and check for proper oper- (LP) gas by replacing the pressure regulator spring with the ation and manifold pressure. conversion kit spring. This LP kit spring allows the regulator 5. -
Page 28: Electrical Wiring
ELECTRICAL WIRING ELECTRICAL WIRING These may be obtained from: National Fire Protection Association, Inc. Batterymarch Park TURN OFF ELECTRIC POWER AT FUSE BOX OR Quincy, MA 02269 SERVICE PANEL BEFORE MAKING ANY ELECTRI- CAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PER- FIGURE 22 SONAL INJURY OR DEATH. -
Page 29: Thermostat
ELECTRICAL WIRING REVERSING ELECTRICAL CONNECTION & THERMOSTAT 7. Using a flat screwdriver, squeeze the retaining arms on the NOTE: Do not use 24 volt control wiring smaller than No. 18 door switch and gently pry the door switch from it’s opening. AWG. -
Page 30: Accessories
ACCESSORIES ELECTRONIC AIR CLEANER FILTERS (See Figure 26) Line voltage power can be supplied from the terminal labeled Keep filters clean at all times. A filter is not provided with the “EAC” and a line voltage neutral terminal on the control board. furnace, but one must be field-supplied and installed. - Page 31 FIELD INSTALLED OPTION ACCESSORIES (cont.) FIGURE 26 FILTER LOCATIONS FLANGE WRAPS AROUND BACK AND SCREWS TO THE REAR OF THE FURNCE, AT THE LOCATIONS PROVIDED CUT OUT USING EMBOSSED ANGLES AS A GUIDE FOR PROPER SIZE 23” X 14” FIELD SUPPLIED FILTER RXGF-CD ACCESSORY FILTER RACK ST-A1220-07-X0...
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Page 32: Twinning
Twinning operation of two furnaces, installed side-by-side, UT ELECTRONIC CONTROLS connected by a common duct system with main power 1095-300 CONTROL BOARD supplied by the same source, and controlled by a common (62-104059-01) thermostat can be done with the UT Electronic Controls 1095-300 integrated control boards. -
Page 36: High Altitude
HIGH ALTITUDE NATURAL GAS AT HIGH ALTITUDES From Table F.1 of National Fuel Gas Code Handbook, 2002 (3.5 W RNING w.c. column). Orifice required at Sea Level: #40 INSTALLATION OF THIS FURNACE AT ALTITUDES ABOVE 2000 FT (610 m) SHALL BE IN ACCORDANCE WITH From Table F.4 of National Fuel Gas Code Handbook, Orifice re- quired at 5000 ft. - Page 37 TABLE 8 SUPPLEMENTAL ORIFICE SIZE CHART NATURAL GAS ORIFICE SELECTION BASED ON HEATING VALUE & ELEVATION* Notes: 1. All (-)80+ units are factory equiped with orifices sized for 1050 sea level heating value gas. 2. Local utilities adjust the sea level heating value of gasses used at higher elevations to compensate for appliance operation at altitude. Installer must be aware of the local heating value (sea level standard) to use the chart below.
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Page 38: Lp Gas At High Altitudes
LP GAS (TABLE 9) based on an 11" of water column pressure at the orifice, which dif- fers from products that use 10" of water column at the orifice. This NOTE: Keep any parts removed during LP conversion procedure difference requires a deviation from the NFGC orifice size recom- stored with the product literature for future use. -
Page 39: Startup Procedures
START-UP PROCEDURES This furnace is equipped with a direct ignition control. Each time SEQUENCE OF OPERATION the room thermostat calls for heat, the ignitor lights the main UT ELECTRONIC CONTROLS burners directly. See the lighting instructions on the furnace. Integrated Controls with Direct Spark Ignition. TO START THE FURNACE 1. -
Page 40: Diagnostics And Fault Codes
DIAGNOSTICS AND FAULT CODES Sequence of display: A. The first two-digit fault will be displayed once as described All furnace controls come standard with a 7-segment diagnostic above. display. During standby mode with no fault codes present, the B. The upper-most horizontal segment of the seven-segment display will read “0”... -
Page 41: Lockout
LOCKOUT HARD LOCKOUT All lockout conditions can be cleared immediately provided that the original fault causing the lockout is cleared and power to the Three conditions shall cause a hard lockout: unit is cycled off and then back on again or (soft lockout only) if a 1. -
Page 42: Field Selections & Adjustments
A dipswitch bank; SW1 is provided for some field adjust- Selection* Selection ments. Heating blower off delay, cooling (and heat-pump) 30 seconds blower off delay, display (7-Segment) orientation and fault Note: Factory setting = 30 seconds clear are the adjustments and functions that can be han- 45 seconds dled using the dipswitches. -
Page 43: Fault Clear
FIELD SELECTIONS –– DIPSWITCHES (continued) Auto Stage; SW6 & SW7 AutoStage, 15 minutes on low, then to high with call There are applications where a single stage thermostat is on “W1” used with the two stage furnace. With this application the furnace will initially operate in the low heat stage. -
Page 44: Timing Diagram
TABLE 10 TIMING DIAGRAM ST-A1205-10-X0 The maximum gas supply pressure to the furnace should To change orifice spuds, shut off the manual gas valve and be 10.5" w.c. for natural gas and 13.0" w.c. for L.P. The remove the gas manifold. On LP gas furnaces, the LP gas minimum gas supply pressure for purposes of input adjust- supply pressure must be set between 11"... -
Page 45: Adjusting Or Checking Furnace Input . 44 22 Setting Input Rate
TABLE 11 METER TIME (%!%)&!*(%&*+&(*+/!%,&"+0&,%-.+0,&1.)&+.)("$&*+2/!&)"!*+3&.1&1/)+"-%,&%4/*22%0&1.)&+"!/)"$& 3",&.)&$525 <%"!*+3&="$/%&.1&3",&>#!/?1! (%!%)&,*B%& *+2/!& :777 :7D7 ::77 ;677 >#!/?<)A >1! ?)%=A " !" & 678777 !& & %& & & & & "& & "% & 968777 & #& & & & & & '& %&... -
Page 46: Airflow
AIRFLOW The importance of proper air flow over the heat exchanger cannot FIGURE 31 be over emphasized. TEMPERATURE RISE MEASUREMENT C UTION IT IS IMPORTANT THAT EACH DUCT SYSTEM BE SIZED AND INSTALLED FOR THE SPECIFIC APPLICATION BY PROPERLY APPLYING THE APPROPRIATE INDUSTRY AC- CEPTED STANDARD. -
Page 47: Blower Speed Selection
TABLE 12 IR FLOW PERFORM NCE – (-)802P/(-)(-)80MDP SERIES MODELS CFM ir Delivery Motor HP External Static Pressure, ” W.C. Model Blower Size, Speed Tap Low** (-)802P 050314MS Med. Lo* 1030 1018 1006 (-)(-)80MDP050 30S 11 x 6 Med. Hi 1129 1132 1112... -
Page 48: Safety Features
SAFETY FEATURES LIMIT CONTROL PRESSURE SWITCH The high limit cut-off temperature is set at the factory and cannot This furnace is equipped with a normally-open pressure switches be adjusted. The temperature setting prevents the air tempera- that monitors pressure conditions within the furnace vent system ture leaving the furnace from exceeding the maximum outlet air during the heating cycle. -
Page 49: Maintenance
MAINTENANCE MAINTENANCE THESE INSTRUCTIONS ARE INTENDED AS AN AID TO FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POI- QUALIFIED SERVICE PERSONNEL FOR PROPER IN- SONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL STALLATION, ADJUSTMENT AND OPERATION OF THIS INJURY OR DEATH. UNIT. READ THESE INSTRUCTIONS THOROUGHLY BE- DISCONNECT MAIN ELECTRICAL POWER TO THE FORE ATTEMPTING INSTALLATION OR OPERATION. -
Page 50: System Operation Information
ADVISE THE CUSTOMER or radios to influence the thermostat operation. 6. Except for the mounting platform, keep all combustible 1. Keep the air filters clean. The heating system will oper- articles 3 feet from the furnace and vent system. ate better, more efficiently and more economically. 7. -
Page 51: Troubleshooting
FIGURE 33 DIAGNOSTICS FLOWCHART Fault NOTE: Always verify gas valve inlet and outlet gas pressure. DESCRIPTION CODE FLAME (AMBER) LED CODES KEY TO ABBREVIATIONS Priority OFF = No Flame Presen t IBM = Indoor Blower Motor Standby RAPID BLINK = Unexpected Flame IDM = Induced Draft Motor Compressor on (cooling or heat pump heat) SLOW BLINK = Marginal Flame Sense... -
Page 52: Wiring Diagram
FIGURE 34 FOR MODELS WITH UT ELECTRONIC CONTROLS 1028-928 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION CM 0814...
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