Related Manuals for Rheem 90RJ Series
Summary of Contents for Rheem 90RJ Series
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Page 1: Safety Precautions
INSTALLATION INSTRUCTIONS FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH EFFICIENCY CONDENSING GAS FURNACES 90RJ AND 90TJ SERIES 92-24161-32-08 SUPERSEDES 92-24161-32-07... -
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 ICECO products CONTENTS meet current Federal OSHA Guidelines for safety. California Proposition 65 Safety Precautions ....................1 warnings are required for certain products, which are not covered by the Installation Check List ....................2 OSHA standards. General Information....................4 California's Proposition 65 requires warnings for products sold in California Safety Information ....................5 that contain, or produce, any of over... -
Page 4: General Information
GENERAL INFORMATION The 90RJ and 90TJ series furnaces CSA-INTERNATIONAL Install this furnace in accordance with are design-certified by CSA for use the American National Standard 8501 East Pleasant Valley Road with natural and propane gases as Cleveland, Ohio 44131-5575 Z223.1 – latest edition entitled follows: “National Fuel Gas Code”... -
Page 5: 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 COMMERCIALLY AVAILABLE REFER TO THE FURNACE RATING GARAGE, IT MUST BE INSTALLED PLATE. -
Page 6: Location Requirements And Considerations
LOCATION REQUIREMENTS AND CONSIDERATIONS GENERAL INFORMATION 1. IMPORTANT: If installing the 3. IMPORTANT: Install the furnace WARNING unit over a finished ceiling or level. If it is not level, condensate DO NOT USE THIS FURNACE living area, be certain to install an cannot drain properly, possibly DURING CONSTRUCTION IF AIR auxiliary condensate drain pan... - Page 7 at 5 or 6 watts per foot at FIGURE 4 120V. HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS IMPORTANT: Support this unit when installed. Since this furnace PIPE is suitable for attic or crawl space installation, it may be installed on combustible wood flooring or by using support brackets.
- Page 8 FIGURE 5 CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS I392...
- Page 9 FIGURE 6 CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS I393...
- Page 10 FIGURE 7 CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS I520...
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Page 11: 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 12: Venting And Combustion Air Piping
4. Connect the furnace to the end of the unit. Make the NOTE: DO NOT take return air supply air plenum. connection air tight to prevent from bathrooms, kitchens, pulling combustion gases from furnace rooms, garages, utility or 5. Connect the return air ducting to an adjacent fuel-burning laundry rooms, or cold areas. - Page 13 removed from a vent system serving When the furnace is installed in the CEMENTING JOINTS other appliances, the vent system is same space with other gas Properly seal all joints in the PVC likely to be too large to properly vent appliances such as a water heater, be vent using the following materials and the remaining attached appliances.
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Page 14: 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) 45,000 14' x 20' OR 16' x 18' • Printing inks, paint removers, WARNING 60,000 15' x 25' OR 19' x 20'... - Page 15 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 16 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 17: 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 18 “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 19 FIGURE 16 OTHER THAN DIRECT VENT TERMINAL CLEARANCES...
- Page 20 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 21 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 22 • 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 23 CONCENTRIC TERMINATIONS VERTICAL/HORIZONTAL CONCENTRIC VENT KIT NO. RXGY-E03 This kit is for vertical/horizontal intake air/vent runs and may be installed through roofs and sidewalls. One 5” diameter hole is required for the installation. See Figure 18 for the general layout. Complete installation instructions are included with the kit.
- Page 24 FIGURE 19 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 25 FIGURE 21 DIRECT VENT TERMINAL CLEARANCES...
- Page 26 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 22. by the following guidelines. 5. Do not locate too close to shrubs CAUTION 1.
- Page 27 FIGURE 23 FIGURE 24 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 28 CONNECTING TO FURNACE FIGURE 25 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. COMBUSTION “O” RING AIR ADAPTER TOP PLATE NOTE: UPFLOW FURNACE WHEN COMBUSTION AIR INLET IS IN...
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Page 29: 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 30 REVERSING THE TRAP IMPORTANT: Do not connect into UPFLOW UNITS FILLING THE TRAP a common drain line with an air The trap may be moved to the right FILL THE TRAP ASSEMBLY WITH conditioner evaporator coil drain side for right side drainage. Open the WATER BEFORE OPERATING THE located above the furnace.
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Page 31: Converting Downflow To Horizontal
CONVERTING DOWNFLOW TO HORIZONTAL CONDENSATE DRAIN 8. Attach the gasket onto the trap 12. IMPORTANT: There are two assembly so that the gasket options when choosing a height FOR HORIZONTAL holes on the gasket line up with for the condensate riser: INSTALLATION the holes on the trap assembly. -
Page 33: Gas Supply And Piping
GAS SUPPLY AND PIPING GAS SUPPLY FIGURE 34 GAS PIPING INSTALLATION UPFLOW WARNING THIS FURNACE IS EQUIPPED AT GROMMET THE FACTORY FOR USE ON MAIN GAS NATURAL GAS ONLY. NOTE: WHEN GAS LINE VALVE TOP VIEW OF GAS LINE AND VALVE IS IN OPT. - Page 34 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 35 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 36 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 37 FIGURE 39 MANIFOLD PRESSURE READING FIGURE 40 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 38: Electrical Wiring
ELECTRICAL WIRING sense flame if L1 and L2 are reversed. integrated furnace control. The low See Figure 41. voltage wiring should be sized as shown. Make all electrical connections in WARNING accordance with the latest edition of the NOTE: Do not use 24 volt control National Electrical Code ANSI/NFPA70 wiring smaller than No. -
Page 39: Accessories
fireplace, sun rays, lamps, televisions, FURNACE TWINNING UT ELECTRONIC CONTROLS radios or air streams from registers. 1028-928 CONTROL BOARD INSTALLATIONS Refer to instructions packed with the 1. Single Stage Operation thermostat for “heater” selection or (See Figure 41) Twinning operation of two furnaces, adjustment. - Page 40 FIGURE 43 UT Electronic Controls 1028-928 CONTROL BOARD, TWINNING CONNECTION -- SINGLE STAGE OPERATION Control Board 1 Control Board 2...
- Page 41 FIGURE 44 UT ELECTRONIC CONTROLS 1028-928 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION Control Board 1 Control Board 2...
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Page 42: High Altitude Instructions
90+ HIGH ALTITUDE NATURAL GAS The following are examples of orifice sizing using the National Fuel Gas INSTRUCTIONS CAUTION Code Appendix F. For a simplified estimation of orifice size based on THE NATIONAL FUEL GAS CODE 90RJ/90TJ HIGH ALTITUDE heating value and elevation, use (NFGC) GUIDELINES SHOULD BE Tables 5 and 6. - Page 44 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 45: Start-Up Procedures
START-UP PROCEDURES This furnace is equipped with a direct induced draft blower operates for the second igniter warm-up period, the gas valve opens and the control ignition device. Each time the room complete heating cycle. looks for a flame signal for up to 8 thermostat calls for heat, the ignitor 4. - Page 46 Sequence if the system doesn’t light or doesn’t sense flame: 1. On a call for heat, the control runs the inducer for 30 seconds TABLE 9 to pre-purge. METER TIME 2. After the 30-second pre-purge, the spark igniter energizes. The METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES inducer continues to run.
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Page 47: Air Flow
AIR FLOW INSTALLER MUST ADJUST THE TEMPERATURE RISE TO FIGURE 46 THIS "MIDDLE" POINT AS TEMPERATURE RISE MEASUREMENT The importance of proper air flow over the CLOSELY AS POSSIBLE. heat exchanger cannot be over ALSO, THE TEMPERATURE emphasized. RISE SHOULD NEVER BE ABOVE OR FALL BELOW THE CAUTION STATED RANGE. - Page 48 TABLE 10 90 PLUS AIR FLOW PERFORMANCE – 90RJ & 90TJ MODELS CFM @ ESP MODEL BLOWER/ SPEED MOTOR HP 90RJ04 11 x 7 / MED-LO MED-HI 1140 1110 1085 1045 1010 HIGH 1360 1320 1280 1235 1195 1140 1080 90TJ04 11 x 7 / MED-LO...
- Page 49 SETTING BLOWER GAS FURNACE (DIRECT FIGURE 48 TIMINGS DRIVE) INSTRUCTIONS UT Electronic Controls 1028-928 BLOWER OFF TIMINGS FOR CHANGING BLOWER The Honeywell UT ELECTRONIC SPEED CONTROLS and Invensys Climate Controls IFC’S (Integrated Furnace Controls) have three or four quick WARNING connect terminals for connecting the DISCONNECT THE ELECTRICAL motor speed leads.
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Page 50: Maintenance
MAINTENANCE TABLE 12 FILTER SIZES WARNING UPFLOW FILTER SIZES FURNACE INPUT BOTTOM SIDE QUANTITY THESE INSTRUCTIONS ARE WIDTH MBTUH SIZE SIZE INTENDED AS AN AID TO " 45, 60, 75 " X 25" " X 25" QUALIFIED SERVICE 21" 90, 105 "... - Page 51 FIGURE 52 FILTER LOCATIONS UPFLOW JACKET JACKET ANGLE DRILL (2) JACKET 3/16" DIA. HOLES ANGLE DETAIL ATTACH WITH SHEET METAL 8.000 SCREWS (2 REQÕD) 4.875 FILTER ROD FILTER ROD SUPPORT SUPPORT ANGLE ANGLE AE-60520-01 1.531 FILTER SUPPORT FILTER SUPPORT ANGLE ANGLE (SEE ANGLE DETAIL) (SEE ANGLE DETAIL)
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Page 52: Wiring Diagrams
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 53: Troubleshooting
FIGURE 53 90RJ 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 54 FIGURE 54 90RJ MODELS WITH UT ELECTRONIC CONTROLS 1012-925 OR INVENSYS CLIMATE CONTROLS ICC-H1MC7-01 CONTROL BOARD & HSI...
- Page 55 FIGURE 55 90RJ MODELS WITH UT ELECTRONIC CONTROLS 1012-925 OR INVENSYS CLIMATE CONTROLS ICC-H1MC7-01 CONTROL BOARD & HSI...
- Page 56 MANUFACTURED BY ICECO ® 5600 OLD GREENWOOD ROAD, FORT SMITH, ARKANSAS, 72908 CM 0905...