Related Manuals for Rheem 801V Series
Summary of Contents for Rheem 801V Series
- Page 1 INSTALLATION INSTRUCTIONS FOR (-)801V UPFLOW/HORIZONTAL SINGLE STAGE ULTRA LOW NOx (LESS THAN 14 ng/J) GAS FURNACES WITH ECM BLOWER. ST-A1252-26-00 92-24161-168-03...
-
Page 2: Table Of Contents
TABLE OF CONTENTS 1 TABLE OF CONTENTS ..... . 2 10 STARTUP PROCEDURES ....30 Sequence of Operation . -
Page 3: General Information
GENERAL INFORMATION NOTE: A heat loss calculation should be performed to properly The Single Stage Variable Speed Ultra Low NOx series furnaces determine the required furnace BTU size for the structure . Also, are design certified by CSA for use with natural gas 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 flow . -
Page 4: Receiving
GENERAL INFORMATION (cont.) changes is imperative. MATERIAL INFORMATION Install this furnace in accordance with the American National Standard Z223 .1 – latest edition entitled “National Fuel Gas Code” All manufacturer products meet current Federal OSHA Guide- (NFPA54) and requirements or codes of the local utilities or other lines for safety . -
Page 5: Checklist
Installation Instructions remain with the furnace as a reference guide to the servicing contractor. We recommend 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 that performance and installation data be recorded for future reference on this sheet to meet service and war- obligations so that job site information is available when required. -
Page 6: Safety Information
SAFETY INFORMATION WARNINGS WARNING WARNING 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 IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, NATIONAL FUEL-GAS CODE (U.S.) AND CSA B149.1 (CANADA) AND THE COMBUSTION AND VENTILATION PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. -
Page 7: Important Information About Efficiency And Quality
SAFETY INFORMATION WARNING WARNING 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 AND ODORS INTO THE HOME CAUSING PROPERTY CONTAIN HAZARDOUS CARBON MONOXIDE) INTO DAMAGE. -
Page 8: Location Requirements
LOCATION REQUIREMENTS GENERAL INFORMATION WARNING WARNING 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 AND IGNITION SOURCE ARE LOCATED NO LESS THAN DOORS FACING UPWARDS. - Page 9 LOCATION REQUIREMENTS GENERAL INFORMATION (cont.) WARNING WARNING UPFLOW AND HORIZONTAL FURNACES ARE DE- COMBUSTIBLE MATERIAL MUST NOT BE PLACED SIGN-CERTIFIED FOR INSTALLATION ON COMBUS- ON OR AGAINST THE FURNACE JACKET. THE AREA TIBLE FLOORS. NOTE, HOWEVER, THAT FURNACES AROUND THE FURNACE MUST BE KEPT CLEAR AND MUST NOT BE INSTALLED DIRECTLY ON CARPETING, FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING TILE OR OTHER COMBUSTIBLE MATERIAL OTHER...
-
Page 10: Upflow/Horizontal Dimensions And Clearance Table
FIGURE 4 UPFLOW/HORIZONTAL DIMENSIONS... -
Page 11: Ducting
DUCTING UPFLOW INSTALLATIONS Proper air flow is required for the correct operation of this furnace . Restricted air flow can cause erratic operation 1 . Position the unit to minimize long runs of duct or runs and can damage the heat exchanger . The duct system of duct with many turns and elbows . - Page 12 DUCTING FIGURE 5 FIGURE 5 NOTE: NOTE: SOLID BASE PLATE PROVIDED WITH (-)801T SOLID BASE PLATE PROVIDED WITH (-)801T MODELS ONLY . MODELS ONLY. WHEN SOLID BASE PLATE IS USED, TAPE WHEN SOLID BASE PLATE IS USED, TAPE AROUND BOTTOM FLANGES OF CABINET BEFORE THE UNIT IS INSTALLED .
-
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 configura- tion . -
Page 14: Combustion And Ventilation Air
COMBUSTION AND VENTILATION AIR COMBUSTION AIR REQUIREMENTS • Halogen type refrigerants IMPORTANT: This is not a direct vent furnace. Review vent- • Cleaning solvents (such as perchloroethylene) ing instructions before installing. • Printing inks, paint removers, varnishes, etc . • Hydrochloric acid WARNING •... -
Page 15: Furnace Located In Unconfined Space
COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES FURNACE LOCATED IN A CONFINED WARNING SPACE ALL FURNACE INSTALLATIONS MUST COMPLY WITH A confined space is defined as any space for a given furnace THE NATIONAL FUEL GAS CODE, NFPA 54 AND LOCAL input rating which is smaller than that which is specified in Table CODES TO PROVIDE ADEQUATE COMBUSTION AND 1 as minimum for an “unconfined”... - Page 16 COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES TABLE 5: MINIMUM FREE AREA REQUIRED TABLE 3: MINIMUM FREE AREA REQUIRED FOR EACH OPENING (WHEN TWO OPENINGS FOR EACH OPENING (WHEN TWO OPENINGS ARE USED) WITH A FURNACE: ARE USED) WITH A FURNACE: 1.
-
Page 17: Combustion Air From Attic
COMBUSTION AND VENTILATION AIR (cont.) COMBUSTION AIR REQUIREMENTS: CONFINED AND UNCONFINED SPACES FIGURE 8 FIGURE 7 OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET AIR FROM ATTIC/CRAWL SPACE FIGURE 12 FIGURE 11 VENT PENETRATIONS VENT PENETRATIONS NON-DIRECT VENT for non direct vent furnaces NON-DIRECT VENT for non direct vent furnaces OUTSIDE AIR... -
Page 18: 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 instruc- system should be inspected to assure that there are no obstruc- tions, National Fuel Gas Code, ANSI Z223 .1 and requirements tions, blockage, or any signs of corrosion and is properly sized or codes of the local utility or other authority having jurisdiction . -
Page 19: Special Vent Systems (Svs)
COMBUSTION AND VENTILATION AIR (cont.) VERTICAL VENT SYSTEMS: Single appliance venting of a fan assisted furnace into a tile- 1 . A gas vent shall terminate above the roof surface with a listed lined masonry chimney is prohibited . The chimney must be lined cap or listed roof assembly . -
Page 20: Existing Vent Systems
COMBUSTION AND VENTILATION AIR (cont.) FIGURE 15 DEDICATED VENTING THROUGH CHIMNEY WITH “B-1” VENT EXISTING VENT SYSTEMS 2 . Insofar as is practical, close all building doors, windows and all doors between the space where the appliances remaining IMPORTANT RETROFIT connected to the common venting system are located . -
Page 21: Gas Supply
GAS SUPPLY GAS SUPPLY AND PIPING IMPORTANT SAFETY INFORMATION • IF A GAS LEAK IS PRESENT OR SUSPECTED: - DO NOT ATTEMPT TO FIND THE CAUSE YOUR- NATURAL GAS SAFETY SELF. - NEVER USE AN OPEN FLAME TO TEST FOR GAS SUPPLY GAS LEAKS. -
Page 22: Gas Piping
GAS SUPPLY GAS PIPING Install a ground joint union outside the cabinet and within 3 feet to easily remove the control valve assembly. Install a manual shut-off valve in the gas line outside the furnace cas- ing. The valve should be readily accessible to turn the gas supply on or off . -
Page 23: Gas Pressure
GAS SUPPLY (cont.) GAS PRESSURE IMPORTANT: ENSURE that the furnace gas valve is not to be FIGURE 17B subjected to high gas line supply pressures . INLET PRESSURE (“T” FITTING) TAP DISCONNECT the furnace and its individual manual gas stop from the gas supply piping during any pressure testing that exceeds ½... -
Page 24: Setting Gas Pressure
GAS SUPPLY (cont.) SETTING GAS PRESSURE MANIFOLD GAS PRESSURE MEASUREMENT The maximum gas supply pressure to the furnace must not exceed 10.5” w.c. natural gas. The minimum supply gas Natural gas manifold pressure should be 3.5” w.c. Only pressure to the gas valve should be 59 w .c . natural gas . A prop- small variations in gas pressure should be made by adjusting erly calibrated manometer is required for accurate gas pressure the pressure regulator . -
Page 25: 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 ELEC- TRICAL CONNECTIONS. FAILURE TO DO SO CAN FIGURE 22 CAUSE ELECTRICAL SHOCK RESULTING IN PER- FIGURE 18... -
Page 26: Thermostat
ELECTRICAL WIRING RELOCATING ELECTRICAL CONNECTION & THERMOSTAT 7 . Using a flat screwdriver, squeeze the retaining arms on the Install the room thermostat in accordance with the instruction door switch and gently pry the door switch from it’s opening. sheet packed in the box with the thermostat . Run the thermostat lead wires inside the blower compartment and connect to low 8 . -
Page 27: Thermostat Wiring
ELECTRICAL WIRING THERMOSTAT WIRING FIGURE 21 FIGURE 22 TYPICAL DUAL FUEL APPLICATION- 2-STAGE HEAT PUMP TYPICAL 1-STAGE DUAL-FUEL THERMOSTAT AND USING A TYPICAL 2-STAGE THERMOSTAT DUAL-FUEL APPLICATION Typical Typical 2-Stage 2-Stage Two-Stage Two-Stage Furnace Furnace Heat Pump Heat Pump Thermostat Control Thermostat Control... -
Page 28: Accessories
ACCESSORIES FIELD INSTALLED OPTIONAL ACCESSORIES ELECTRONIC AIR CLEANER NOTE: Maximum current – 1 .0 amps for each option (humidifier or electronic air cleaner) . Line voltage power can be supplied from the terminal labeled FILTERS “EAC” and a line voltage neutral terminal on the control board . (See Figures 26 and 27) This will power the electronic air cleaner whenever the circulat- Keep filters clean at all times . - Page 29 ACCESSORIES FIELD INSTALLED OPTION ACCESSORIES (cont.) FIGURE 26 HORIZONTAL HORIZONTAL FILTER KITS FILTER KITS 17.5” CABINET: RXGF-F17 21.0” CABINET: RXGF-F21 RXGF-CC ACCESSORT FILTER RACK FIELD SUPPLIED FILTER ST-A1252-22-00 ST-A1252-22-00...
-
Page 30: Startup Procedures
START-UP PROCEDURES SEQUENCE OF OPERATIONS This furnace is equipped with an intermittent pilot control . Each Learning/Calibration Cycle Configuration: time the room thermostat calls for heat, the ignitor lights the pilot A call for heat closes R and W on the control . The IFC (Internal which lights the burner directly . -
Page 31: Timing Diagram
TIMING DIAGRAM On this page are timing diagrams for heat sequences . These diagrams assume no faults are present during the heat call . TABLE 7 80+ ULN CALIBRATION CYCLE ST-A1252-17-00 ST-A1252-17-00 80+ ULN CALIBRATION CYCLE TABLE 8 80+ ULN NORMAL HEAT CYCLE ST-A1252-18-00 ST-A1252-18-00... -
Page 32: Diagnostics And Fault Codes
FAULT CODES FAULT CODES DIAGNOSTICS AND FAULT CODES 5 . When the main limit has been open during a gas heat call for more than 150 seconds and has not yet re-closed, the All furnace controls come standard with a 7-segment diagnostic fault codes “61”... -
Page 33: Lockout
1-STAGE LOCKOUT LOCKOUT All lockout conditions can be cleared immediately provided that HARD LOCKOUT 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 1. -
Page 34: Fault Codes And Solutions
TABLE 9 FAULT CODES FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS DUAL FAULTS DISPLAYED The method for displaying a two-digit fault is to display the first digit (most significant) digit for one second immediately followed by the second digit - which is also displayed for a duration of one second. A 1/2 second pause is then displayed. Cycle repeats until the fault is cleared. -
Page 35: Failed Ignition
TABLE 9 FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS FAILED IGNITION STATUS: Up to three failed ignitions will not constitute a critical condition. Critical condition (with no heating operation) is only noted when the furnace has failed to ignite four or more times consecutively. After four failed ignition attempts, the IFC enters one-hour lockout and the dual faults "11 "... - Page 36 TABLE 9 FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS FLAME LOST AFTER ESTABLISHED STATUS: Flame loss is not a critical fault. Subsequent ignition attempts will follow and normal operation should resume. However, a lost flame can often be followed by failed ignition attempts then a one-hour lockout. Once the status has reached one-hour lockout, the fault condition is critical (although attempts at ignition will be made again after the 1 hour lockout).
- Page 37 TABLE 9 FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS MAIN LIMIT OPEN/AUXILIARY LIMIT OPEN STATUS: This is a critical fault. The furnace will not operate in gas heat modes but all other modes (e.g. cooling) should function. DESCRIPTION: The main limit auxiliary limit has opened or is sensed to be opened. This normally means that the temperature inside the heat exchanger area or blower area has gone above a certain predetermined critical value and heating operation is not permitted until the limit cools to within normal parameters.
- Page 38 MANUAL RESET OVER-TEMPERATURE SWITCH OPEN STATUS: This is a critical fault. The furnace will not operate in gas heat modes but all other modes (e.g. cooling) should function. DESCRIPTION: The Manually Reset Limit Control (M.R.L.C.) is also known by the name over temperature switch. There can be several on any given furnace.
- Page 39 TABLE 9 FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS COMBUSTION PRESSURE SWITCH CLOSED WHEN SHOULD BE OPEN STATUS: This is a critical fault. The furnace will not operate in gas heat modes but all other modes (e.g. cooling) should function if present simultaneously with a heating call (e.g. defrost call in dual-fuel mode). DESCRIPTION: The combustion pressure switch should not be closed when the inducer is not running.
- Page 40 TABLE 9 FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS COMBUSTION PRESSURE SWITCH OPEN WHEN SHOULD BE CLOSED STATUS: This is a critical fault. The furnace will not operate in gas heat modes but all other modes (e.g. cooling) should function if present simultaneously with a heating call (e.g. defrost call in dual-fuel mode). DESCRIPTION: This fault indicates that the pressure switch is open when the inducer is energized.
- Page 41 TABLE 9 FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS BLOWER FAULT - DEAD BLOWER STATUS: This is a critical fault. The furnace will not operate in any mode. DESCRIPTION: The blower has failed critically or there is a critical motor fault - such as thermal limit trip that prevents the blower motor from running.
- Page 42 TABLE 9 FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS VENTURI AIR INLET PRESSURE SWITCH OPEN STATUS: This is a critical fault. The furnace will not operate in gas heat modes but all other modes (e.g. cooling) should function if present simultaneously with a heating call (e.g. defrost call in dual-fuel mode). DESCRIPTION: There is an obstruction at or near the inlet of the fuel and air mixing venturi.
-
Page 43: Field Selections & Adjustments
FIELD SELECTIONS & ADJUSTMENTS FIELD SELECTIONS –– DIPSWITCHES A dipswitch bank; SW1 is provided for some field adjustments . Heat Blower-Off Delay; SW2 & SW3 A means of controlling the HEAT speed blower “off” delay time Heating blower off delay, cooling (and heat-pump) blower off is provided . -
Page 44: Fault Clear
FIELD SELECTIONS & ADJUSTMENTS FAULT CLEAR MANUAL FAULT CLEAR; SW4 within 30 seconds . When this action is detected within 30 sec- onds, the fault code memory buffer shall be cleared . Be sure Faults will automatically be cleared from the fault buffer after to return the dipswitch to the original state (on or off) or is in the one week . -
Page 45: Setting Input Rate
FIELD SELECTIONS & ADJUSTMENTS TABLE 10 METER TIME METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATINGS OF FURNACES EQUIPPED FOR NATURAL GAS HEATING VALUE OF GAS (BTU/FT INPUT METER SIZE 1030 1070 (BTU/HR) /REV) 50,000 70,000 98,000 Formula: Input BTU/HR = Heating Value of Gas (BTU/ft ) ×... -
Page 46: High Altitude
HIGH ALTITUDE INSTALLATION T h i s U l t r a L o w N O x f u r n a c e m a i n t a i n s A d j u s t t h e i n p u t r a t e... -
Page 47: Temperature Rise Check
TYPICAL FURNACE NAME PLATE 3 . Operate the furnace . 4 . When the thermometer in the supply air duct stops rising (ap- RHEEM SALES COMPANY, INC. proximately five minutes), subtract the return air temperature FORT SMITH, ARKANSAS from the supply air temperature . The difference is the tem- perature rise . -
Page 48: Ecm Motor Operation And Cfm Adjustments
AIRFLOW TABLE 11 AIR FLOW PERFORMANCE – ULTRA LOW NOx SERIES MODELS WITH ECM MOTOR (-)801VA050417MUA Full Ton SW 3/4 Half Ton SW 3/4 SW 1/2 Cooling Nominal +10% Nominal Tonnage Tonnage OFF/OFF ON/OFF OFF/ON High 4 -TON 1498 1648 3 .5 TON 1348 ON/OFF... -
Page 49: Safety Features
ECM MOTOR OPERATION controlled from the thermostat “Y” terminal . When the “Y” or “R” thermostat circuit is opened a 30 second delay will occur before The ECM (Brushless permanent magnet) motor used on the the blower motor will cycle . In the heating mode the furnace con- blower in this product is programmed to operate over a wide trol board controls the ECM through the blower relay . -
Page 50: Unit Operation With Two-Stage Cooling
UNIT OPERATION WITH TWO-STAGE FIGURE 31 COOLING ECM MOTOR SETTINGS The R801V unit provides distinct airflows for two-stage cooling. Unit operation is defined as: • Y1 – First Stage Cooling • Y2 – Second Stage Cooling A 24VAC signal provides input for the cooling stages . NOTE: A 24VAC input to the Y2 terminal overrides the input to the Y1 terminal . -
Page 51: Heating Airflow Adjustments
HEATING AIRFLOW ADJUSTMENTS FIGURE 34 9 10 9 10 9 10 9 10 FIGURE 33 HEATING AIRFLOW ADJUSTMENTS COOLING SWITCH 9 SWITCH 10 AIRFLOW SELECTION POSITIONS POSITIONS ADJUSTMENT HEATING MAXIMUM SWITCH 5 SWITCH 6 LATENT REMOVAL (WITH- SELECTION AIRFLOW POSITIONS POSITIONS OUT ODD INPUT) ADJUSTMENT... - Page 52 TABLE 15 SWITCH 9 SWITCH 10 (-)801VA POSITION POSITION INPUT NONE 1273 050417 24VAC 1124 1498 NONE 1273 070417 24VAC 1124 1498 NONE 1130 1506 100521 24VAC 1329 1772 IMPORTANT: A humidistat or dehumidifying thermostat MUST be connected to the “ODD” and “R” pigtails when using this set- ting.
-
Page 53: Safety Features
SAFETY FEATURES LIMIT CONTROL PRESSURE SWITCHES The high limit cut-off temperature is set at the factory and This furnace is equipped with (2) normally-open pressure cannot be adjusted . The temperature setting prevents the air switches that monitor pressure conditions within the furnace temperature leaving the furnace from exceeding the maximum vent system during the heating cycle . -
Page 54: Maintenance
MAINTENANCE MAINTENANCE THESE INSTRUCTIONS ARE INTENDED AS AN AID BLY RESULTING IN FIRE, ELECTRICAL SHOCK, CAR- TO QUALIFIED SERVICE PERSONNEL FOR PROPER BON MONOXIDE POISONING, EXPLOSION, PROPERTY INSTALLATION, ADJUSTMENT AND OPERATION DAMAGE, PERSONAL INJURY OR DEATH. OF THIS UNIT. READ THESE INSTRUCTIONS THOR- DISCONNECT MAIN ELECTRICAL POWER TO THE OUGHLY BEFORE ATTEMPTING INSTALLATION OR UNIT BEFORE ATTEMPTING ANY MAINTENANCE. -
Page 55: System Operation Information
RESULTING IN CARBON MONOXIDE POISON- ING OR DEATH. THE VENT PIPE OR HEAT EX- CHANGER MUST BE REPLACED IF THEY LEAK. REPLACEMENT PARTS Homeowners please visit www .rheem .com for product Replacement parts division visit information . http://www .rheemparts .com/Catalog/ DIAGNOSTICS Refer to fault codes for determining cause of unit problems . - Page 56 FIGURE 35 FOR MODELS WITH UT ELECTRONIC CONTROLS 1194-200 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION 115 VAC 24 VAC 3 AMP FUSE HEAT COOL NEUTRALS LINE DISC CM 0223...
Need help?
Do you have a question about the 801V Series and is the answer not in the manual?
Questions and answers