Rheem RGFG Installation Instructions Manual
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Rheem RGFG Installation Instructions Manual

Upflow high efficiency modulating condensing gas furnaces
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INSTALLATION INSTRUCTIONS

FOR RGFG UPFLOW HIGH EFFICIENCY MODULATING
CONDENSING GAS FURNACES
RGFG
WARNING
DO NOT EXCHANGE MEMORY CARDS BETWEEN 2 OR MORE DIFFERENT FURNACES. DOING
SO COULD RESULT IN UNEXPECTED OPERATION – INCLUDING INADEQUATE AIRFLOW DUR-
ING HEATING (AND OTHER MODES) OR A LOSS OF HEAT.
ISO 9001:2008
SEE PAGE 92
COMMUNICATING
SEE PAGE 106
RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY
INFORMATION!
IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION
MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER
INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS
THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR
MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISON-
ING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
PROPOSITION 65 WARNING: THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF
CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
— Do not store or use gasoline or other flammable vapors and liquids, or other combustible materials
in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions
• If you cannot reach your gas supplier, call the fire department.
• Do not return to your home until authorized by the gas supplier or fire department.
— DO NOT RELY ON SMELL ALONE TO DETECT LEAKS. DUE TO VARIOUS FACTORS, YOU MAY NOT
BE ABLE TO SMELL FUEL GASES.
• U.L. recognized fuel gas and CO detectors are recommended in all applications, and their installa-
tion should be in accordance with the manufacturer's recommendations and/or local laws, rules
regulations, or customs.
— Improper installation, adjustment, alteration, service or maintenance can cause injury, property
damage or death. Refer to this manual. Installation and service must be performed by a qualified
installer, service agency or the gas supplier. In the commonwealth of Massachusetts, installation
must be performed by a licensed plumber or gas fitter for appropriate fuel.
MODULATING
THERMOSTAT
INSTALLATION
MODULATING
THERMOSTAT
INSTALLATION
92-24161-104-01
SUPERSEDES 92-24161-104-00

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  • Page 1: Installation Instructions

    INSTALLATION INSTRUCTIONS FOR RGFG UPFLOW HIGH EFFICIENCY MODULATING CONDENSING GAS FURNACES RGFG MODULATING THERMOSTAT INSTALLATION SEE PAGE 92 MODULATING COMMUNICATING THERMOSTAT INSTALLATION SEE PAGE 106 WARNING DO NOT EXCHANGE MEMORY CARDS BETWEEN 2 OR MORE DIFFERENT FURNACES. DOING SO COULD RESULT IN UNEXPECTED OPERATION – INCLUDING INADEQUATE AIRFLOW DUR- ING HEATING (AND OTHER MODES) OR A LOSS OF HEAT.

  • Page 2: Table Of Contents

    TYPICAL WIRING ACCESSORIES FOR COMMUNICATING RESIDENTIAL SYSTEMS ....39 We cannot always know “when, or if” HIGH ALTITUDE INSTALLATIONS IN THE U.S....................41 products will be sold in the California RGFG- HIGH ALTITUDE CONVERSION ....................41 market. LP GAS AT HIGH ALTITUDE ELEVATIONS....................43 ZONING SYSTEMS............................44...

  • Page 3: Safety Information

    SAFETY INFORMATION WARNING IMPORTANT! 4. INSPECTION. The state or local gas inspector of the side wall horizontally THE COMMONWEALTH OF MASSA- INSTALL THIS FURNACE ONLY IN vented gas fueled equipment shall not CHUSETTS REQUIRES COMPLIANCE A LOCATION AND POSITION AS approve the installation unless, upon WITH REGULATION 248 CMR 4.00 SPECIFIED IN THE LOCATION...
  • Page 4 WARNING WARNING WARNING WHEN THIS FURNACE IS INSTALLED DO NOT JUMPER OR OTHERWISE ALWAYS INSTALL FURNACE TO IN A RESIDENTIAL GARAGE, IT BYPASS OVERTEMPERATURE OR OPERATE WITHIN THE FUR- MUST BE INSTALLED SO THE BURN- ANY OTHER LIMITS OR SWITCHES NACE'S INTENDED TEMPERA- ERS AND IGNITION SOURCE ARE ON THE FURNACE.

  • Page 5: 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 VERTICAL –...

  • Page 6: General Information

    GENERAL INFORMATION The RGFG series furnaces are furnace are required if consumers CSA International - U.S. design-certified by CSA for use with are to receive the full benefits for 8501 East Pleasant Valley Road natural and L.P. gases as follows: which they have paid.

  • Page 7: Important Information About Efficiency And Indoor Air Quality

    IMPORTANT INFORMA- matches what is required for the NOTICE job specification. TION ABOUT EFFICIENCY IMPROPER INSTALLATION, OR • Read the entire instructions before AND INDOOR AIR INSTALLATION NOT MADE IN starting the installation. ACCORDANCE WITH THE CSA QUALITY • Some building codes require extra INTERNATIONAL (CSA) CERTIFICA- cabinet insulation and gasketing TION OR THESE INSTRUCTIONS,...

  • Page 8: Location Requirements And Considerations

    LOCATION REQUIREMENTS AND CONSIDERATIONS densate drain assembly. See 5. IMPORTANT: If installing in a GENERAL INFORMATION “Condensate Drain/Neutralizer” utility room, be sure the door is CAUTION section for more details. wide enough to: DO NOT USE THIS FURNACE 2. IMPORTANT: If using a cooling a.

  • Page 9: Clearance-Accessibility

    INCLUDE THE ADDITIONAL to minimize the length and BRACKET (WHICH MUST BE elbows in the gas piping. REMOVED) ON THE BLOWER 4. Locate the furnace to maintain ASSEMBLY: proper clearance to combustibles RGFG-09EZCMS as shown in Figure 4. RGFG-10EZCMS RGFG-12ERCMS...

  • Page 10: Dimensions And Clearance To Combustibles

    FIGURE 4 PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS AIRFLOW AO39201...

  • Page 11: Ducting

    DUCTING FAILURE TO PREVENT PROD- 2. Open the return air compartment. UCTS OF COMBUSTION FROM a. If using side return air, do not Proper airflow is required for the correct BEING CIRCULATED INTO THE remove the bottom base. operation of this furnace. LIVING SPACE CAN CREATE b.

  • Page 12: That Contain, Or Produce, Any Of Over Venting And Combustion Air Piping

    VENTING AND COMBUSTION AIR PIPING GENERAL INFORMATION TEM MUST BE FROM A SINGLE 6. After it has been determined that each appliance that remains con- SYSTEM MANUFACTURER AND nected to the common venting NOT INTERMIXED WITH OTHER WARNING system properly vents (when SYSTEM MANUFACTURER’S tested as outlined above), return READ AND FOLLOW ALL...

  • Page 13: Cementing Joints

    There are several different types of CEMENTING JOINTS 5. Wipe all excess cement from the elbows that can be used for con- joint with a rag. Allow 15 minutes Properly seal all joints in the PVC vent structing a vent system. The draw- before handling.

  • Page 14: Non-Direct Vent Pipe Installation

    NON-DIRECT VENT PIPE INSTALLATION (FOR VERTICAL TERMINATIONS ONLY) COMBUSTION AIR The following types of installation (but WARNING not limited to the following) REQUIRE ALL FURNACE INSTALLATIONS OUTDOOR AIR for combustion, due WARNING MUST COMPLY WITH THE to chemical exposures: NATIONAL FUEL GAS CODE AND ALWAYS PROVIDE THIS FUR- •...
  • Page 15 B. USING OUTDOOR AIR FOR FURNACE LOCATED IN A A. USING INDOOR AIR FOR COMBUSTION COMBUSTION CONFINED SPACE. A confined space (any space small- IMPORTANT: DO NOT take air from IMPORTANT: Do not take air from er than shown before as “uncon- a heated space with a fireplace, an attic space that is equipped with fined”) must have openings into...
  • Page 16 b. Where communicating with out- Combustion air openings must not be doors through horizontal ducts, restricted in any manner. each opening shall have a minimum CONSULT LOCAL CODES FOR SPE- free area of 1 square inch for each CIAL REQUIREMENTS. 2000 BTUH of total input rating of all equipment in the enclosure.

  • Page 17: Installation Guidelines

    MAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST PIPE with any other appliance. Do not install in the same chase or chim- UPFLOW FURNACES RGFG ney with a metal or high tempera- ture plastic pipe from another gas or MAX. EQUIVALENT LENGTH...

  • Page 18: Direct Vent Pipe Installation

    DIRECT VENT APPLICATIONS MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE READ AND FOLLOW ALL INSTRUCTIONS IN THIS SEC- UPFLOW RGFG FURNACES TION. FAILURE TO PROPERLY MAX. EQUIVALENT VENT THIS FURNACE CAN LENGTH OF VENT (SEE...
  • Page 19 FIGURE 9 STANDARD VERTICAL DIRECT VENTING UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS) DETAIL A EXHAUST 12” TERMINATION (90, 105 & 120K MODELS) PIPE REDUCTION NOT REQUIRED ON 60 & 75K BTU MODELS NOTES: THE COMBUSTION AIR PIPE MUST TERMINATE IN THE SAME PRESSURE ZONE AS THE EXHAUST PIPE.

  • Page 20: Concentric Terminations

    CONCENTRIC TERMINATIONS NOTE: The following IPEX brand con- centric terminations (System 636) may CONCENTRIC VENT KIT be purchased in the field and used in NO. RXGY-E03A (SEE FIGURE 10) place of factory supplied kits: This kit is for vertical and horizontal 3”...
  • Page 21 INSTALLATION – RXGY-G02A Side Wall Vent FIGURE 11 VENT KIT INSTALLATION OPTIONS FIGURE 12 For 90000 thru 120000 BTUH models- TYPICAL INSTALLATION reduce to a length between 12 inches and 30 inches of 2 inch pipe. Note: Vent should protrude a maximum of 2-1/4”...
  • Page 22 HORIZONTAL TERMINATIONS NOTE: Ensure the location of the com- IMPORTANT: To insure proper fur- nace operation, install the vane in bustion air inlet with respect to the All horizontal venting must be done the vertical position as shown in exhaust vent terminal complies with with direct venting (2 pipe).
  • Page 23 ALTERNATE HORIZONTAL TERMI- FIGURE 14 NATIONS (See Figure 14) ALTERNATE HORIZONTAL DIRECT VENT TERMINATION EXHAUST VENT NOTE: The combustion air and " PVC FOR MODELS WITH 120,000 BTUH INPUT (KIT NO. RXGY-D04A) exhaust terminations must be at least 2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000 12 inches above grade or anticipated BTUH.

  • Page 24: Location Requirements

    LOCATION REQUIREMENTS In addition to the minimum clearances 6. Minimum vertical clearances of 1 listed above, the vent location should foot are recommended for over- HORIZONTAL DIRECT VENTS be governed by the following guide- hangs up to 1 foot horizontal. lines.
  • Page 25 FIGURE 16 DIRECT VENT TERMINAL CLEARANCES...
  • Page 26 FIGURE 17 FIGURE 18 TWO FURNACE VENTING THROUGH WALL TWO FURNACE VENTING THROUGH ROOF TWO-PIPE VENTING TWO-PIPE VENTING EXHAUST VENT MODELS 06-07 TO BE REDUCED TO 1-1/2” PVC LAST 12” . 3” MININUM 24” MAXIMUM 3” MININUM 24” MAXIMUM CONCENTRIC VENTING CONCENTRIC VENTING 8”...
  • Page 27 FIGURE 19 UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION (GAS VALVE MAY BE DIFFERENT THAN SHOWN) ST-A1157-01 FIGURE 20 UPFLOW MODELS -- COMBUSTION AIR FITTING...

  • Page 28: Condensate Drain/Optional Neutralizer

    CONDENSATE DRAIN/OPTIONAL NEUTRALIZER GENERAL INFORMATION FIGURE 21 UPFLOW CONDENSATE DRAIN CAUTION (GAS VALVE MAY BE DIFFERENT THAN SHOWN) DO NOT RUN DRAIN OUTDOORS. FREEZING OF CONDENSATE CAN CAUSE PROPERTY DAMAGE. IMPORTANT: Do not connect into a com- mon drain line with an air conditioner evaporator coil drain located below the furnace.
  • Page 29 IMPORTANT: There are two options FIGURE 22 when choosing a height for the con- UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION densate riser: (NO KIT REQUIRED) CONDENSATE OVERFLOW: With a ⁄ inch riser installed above the tee, a blocked drain will result in overflow from the riser.

  • Page 30: Gas Supply And Piping

    GAS SUPPLY AND PIPING FIGURE 23 GAS SUPPLY GAS PIPING -- UPFLOW INSTALLATION (GAS VALVE MAY BE DIFFERENT THAN SHOWN) WARNING GROMMET NOTE: THIS FURNACE IS EQUIPPED TOP VIEW OF GAS LINE AND WHEN GAS LINE IS IN OPT. MANUAL VALVE AT THE FACTORY FOR USE ON POSITION, SWAP LOCATION...

  • Page 31: Gas Valve

    to the combination gas valve on the GAS PRESSURE FIGURE 24 furnace. Refer to Table 9 for the recom- GAS VALVE Natural gas supply pressure should mended gas pipe size for natural gas STEPPER CONTROL-FUEL CODE HA be 5" to 10.5" w.c. LP gas supply OR HB and Table 10 for L.P.
  • Page 32 TABLE 9 NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.) Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas). Nominal Length of Pipe, Feet Iron Pipe Size, Inches 1-1/4...

  • Page 33: Lp Conversion

    TIONS” OF THIS BOOK FOR well will need to be removed. INSTRUCTIONS. High altitude installations above 5,000 feet are not permitted with RGFG fur- nace models. FIGURE 25 NOTE: Order the correct LP conver- sion kit available from the local distrib- SERVO CONTROLLED GAS VALVE SUPPLY PRESSURE TAP AND LP JUMPER WELL utor.

  • Page 34: Setting Gas Pressure

    FICES MAY (OR MAY NOT) NEED TO CAUTION FIGURE 26 BE CHANGED. SEE THE SECTION LP JUMPER INSTALLED ON SERVO MODU- ELEVATIONS ABOVE 2000 FT TITLED “HIGH ALTITUDE INSTALLA- LATING GAS VALVE WITH PINS NOT CON- REQUIRE THAT THE FURNACE TIONS”...

  • Page 35: Electrical Wiring

    ELECTRICAL WIRING ate wiring diagram located on the inside Make all electrical connections in WARNING cover of the furnace control box and in accordance with the latest edition of these instructions. the National Electrical Code TURN OFF ELECTRIC POWER AT ANSI/NFPA70 –...
  • Page 36 ELECTRICAL CHECKS 3. With the unit operating, use a volt- meter to measure the voltage from Line Power Check control voltage terminal “W” to ter- The furnace must have a nominal 115 minal “C” on the furnace control volt power supply for proper operation. board.

  • Page 37: Accessories

    ACCESSORIES on the I.F.C. This means that the termi- (II thru IV). With the optional nals are connected directly to the con- humidistat, two separate co nditions tacts of a board-mounted relay. The coil must be met before humidification FIELD-INSTALLED of the relay is controlled by the micro- can begin 1).
  • Page 38 the jumper between “R” and FIGURE 33 “HUM STAT” on the furnace WIRING FOR OPTIONAL DEHUMIDIFICATION OPERATION AND HUMIDIFICATION WITH OPTION- control. Installing this AL HUMIDIFIER (HUMIDIFIER WITH INTERNAL POWER SUPPLY) (FOR USE WITH NON-COMMU- jumper will operate the NICATING THERMOSTATS) humidifier any time there is a heat call.

  • Page 39: Other Accessories

    15%. cation can be accomplished The Rheem Serial Communicating C. HUMIDIFICATION AND DEHUMIFI- using a humidistat as shown in (CC2) system allows accessories to Figures 32 or 33. These figures...
  • Page 40 when BOTH the condenser and thermostat are serial communicating devices. If the condenser is non- communicating (traditional, legacy 24VAC controlled) this diagram is not valid. METHOD BLOWER CONTACTS WIRING CONFIGURATION ACTIVATION NORMALLY When 24 VAC is applied to Y1 at the furnace control in a OPEN communicating system a SYSTEM BUSY message appears on the thermostat.

  • Page 41: High Altitude Installations In The U.s

    HIGH ALTITUDE INSTALLATIONS IN THE U.S. RGFG- HIGH ALTITUDE EXAMPLES Example: 1050 BTU/ft Regional Natural Gas Heating Value CONVERSION The following are examples of orifice sizing using the National Fuel Gas I / H = Q WARNING Code Appendix F. For a simplified esti- 15000 / 1050 = 14.63 ft...

  • Page 43: Lp Gas At High Altitude Elevations

    The information in Table 14 is based on the NFGC LP orifice chart, as they are a heating value of 1000 BTU per cubic not accurate for the RGFG gas fur- feet of natural gas, and 2500 BTU per naces. The National Fuel Gas Code LP cubic feet of LP gas.

  • Page 44: Furnace Installation With Non-Communicating High Efficiency Premium Cooling Or Heat Pump Systems

    In accordance with Rheem/Ruud cool- icing with excess bypass cooling. Also, ing equipment installation instructions, if the zoning equipment manufacturer...

  • Page 45: Integrated Furnace Control

    INTEGRATED FURNACE CONTROL (I.F.C.) FIGURE 36 MODULATING CLIMATE-TALK COMMUNICATING FURNACE CONTROL (RHEEM # 62-102783-01) SEVEN SEGMENT would represent heating mode operat- For example, if “C” is displayed fol- ing at 70% of firing rate (“H0” repre- lowed by “12” (toggling), this would DISPLAY: sents 100% heat).
  • Page 46 FIGURE 37 WHEN VIEWING THE SEVEN-SEGMENT DISPLAY THE BOTTOM OF THE DIGITS IS ON THE RIGHT SIDE OF THE CONTROL BOARD, CLOSER TO THE THERMOSTAT TERMINAL BLOCK. FOUR (4) EXAMPLES ARE SHOWN. THIS EXAMPLE IS 61 NOT 19 THIS EXAMPLE IS h7 NOT L4 THIS EXAMPLE IS 25 NOT 52 THIS EXAMPLE IS 33 NOT EE ST-A1183-01...

  • Page 47: Vac Thermostat Inputs

    CONTINUOUS FAN MODE: SPECIAL CONFIGURATION Pin 2 to Inducer Rx – COMMUNICATING THER- “F” is displayed. This is then toggled Pin 3 to inducer GND with two numbers which indicate the MOSTAT AND FURNACE Pin 4 to inducer Tx CFM of the main circulating blower WITH A NON- divided by 100.
  • Page 48 FIGURE 39 15-PIN CONNECTOR; J1 WITH PIN DESIGNATIONS Pin 2 to stepper modulating gas valve Additionally, the pin designations for network. The blower motor does not connector Pin 2 (RX) the connector are specified below: communicate on the same commu- nications buss as the furnace, con- Pin 3 to stepper modulating gas valve Pin 1.

  • Page 49: Memory Card

    R-J11 CONNECTOR (E109) assumed that there is not valid commu- Valid Furnace Shared Data is defined as furnace shared data for nications established. Check wiring to WARNING the furnace series in question with make sure that all points are connected the correct motor horsepower.
  • Page 50 The memory card is the default mem- 2. by attaching the furnace b. If valid furnace shared data is ory location to be used first when control to a communicating available from the network and there is any conflict. If the memory network (e.g.

  • Page 51: Replacing The Furnace Control

    and/or er priority fault is not also present When replacing the furnace control, (in which case the higher priority be sure to match the dipswitch set- III. does not match the horsepower fault is displayed) (see fault code tings of the original control on the of the attached motor (“d6”- priority list).

  • Page 52: Dipswitches

    DIPSWITCHES S3-1 and S3-2. Furnaces with ½ HP Consult Figures 40, 41 and 42 and motors will have a maximum target air- Table 17 for target airflow settings NOTE: The integrated furnace control flow setting of 1200 CFM. Furnace with and adjustments based on the posi- does not recognize switch setting 1 HP motors will have a maximum tar-...
  • Page 53 TABLE 17 COOLING AIRFLOW SELECTIONS FOR NON-COMMUNICATING CONDENSERS MODULATING FURNACE COOLING AIRFLOW RATES, 1/2 HP (1200 CFM Max) motor settings (applies only to systems configured with non-communicating condenser). Y1 & Y2 Y2 Single Y1, Low S5-2 S3, Pos. 2 S3, Pos. 1 Notes High Stage...
  • Page 54 FIGURE 41 DIPSWITCH BANK S4 TEST MODE SELECT ST-A1164-01 To set the furnace for normal Switch (SW2-1) Call Voltage at “HUM” Action oper ation: COOL Normal Cool (c or C) 1. Set the thermostat mode to OFF. COOL Dehum Cool (cd or Cd) Always allow furnace to complete Heat Hum Contacts Closed.

  • Page 55: Furnace Operation Using Non-Communicating Modulating

    FIGURE 42 DIPSWITCH BANK S5 COOLING / O.D.D. SELECT ST-A1171-01 FURNACE OPERATION See the section of this document titled After the blower on-delay period, the THERMOSTATS (under the sub-sec- furnace will respond to the thermo- USING NON-COMMUNICAT- tion titled NON-COMMUNICATING stat demand by adjusting the gas ING MODULATING, SINGLE- THERMOSTATS) for information on...
  • Page 56 FIGURE 43 DIPSWITCH BANK S1 HEAT AIRFLOW ADJUSTMENT Placing S5-2 in the “ON” position will NOTE: All dip switches on S1 will be establish the low (Y1) cooling airflow at shipped in the “OFF” position. S5-1 = ODD “ON” or “OFF” select. This ½...
  • Page 57 FIGURE 44 DIPSWITCH BANK S2 TERMINATION AND BIAS SELECTIONS than 50 CFM above any increment of CLEARING DIAGNOSTIC 100, the value will be rounded to the FAULT CODES FROM BIAS / TERMINATION lesser 100 value and the lesser value THE BUFFER will be displayed.

  • Page 58: Communicating Systems

    11, 45, 46 and 57. connecting the furnace to an approved ClimateTalk communicat- ing thermostat and approved Rheem or Ruud communicating condenser. The only approved configuration is to install dedicated wires directly...

  • Page 59: Startup For Systems Configured With Communications

    STARTUP FOR SYSTEMS CON- FIGURE 45 FIGURED WITH COMMUNICA- WIRING DIAGRAM – COMMUNICATING CONFIGURATION TIONS WARNING INSTALLATION OF LINE VOLTAGE AND GAS MUST BE PERFORMED ACCORDING TO INSTRUCTIONS WRITTEN IN THIS MANUAL. FAIL- URE TO DO SO COULD RESULT IN INJURY OR DEATH. When the furnace is configured for communications, the components on the network (i.e.

  • Page 60: Furnace User Menus

    When the system has found all neces- This will continue until the high cooling FURNACE USER MENUS sary components, the text area of the call information is provided from the NOTICE: ALL TEMPERATURE communicating thermostat will go blank. condenser. Once the max cooling CFM VALUES DISPLAYED IN USER This is an indicator that the system is value has been transmitted by the con-...

  • Page 61: Status 1

    FIGURE 46a MENU TREE ST-A1167-01-01 The thermostat menus give active infor- 1. MAIN LIMIT – Indicates the state of the vestibule. This event should mation for various parameters and per- the main limit – either opened or rarely (if ever) happen but can mit some installation options to be closed.
  • Page 62 FIGURE 46b MENU TREE – CONTINUED ST-A1167-01-02 4. APPROX IND RPM – Indicates the 7. GAS VLV PRCNT – Indicates the “OFF”, “MARGINAL”, “GOOD” approximate speed of the inducer in firing rate of the modulating gas and “UNEXPECTED”. A margin- valve.

  • Page 63: Status 2

    should be very close. The value can 4. BLOWER CYCLS – Indicates the The final item in this menu is also be tracked through the blinking number of cycles of operation (i.e.: “CLEAR FAULTS”. The options are decimal point on the seven segment the number of times it turned on “yES”...
  • Page 64 2. MIN HEAT ADJ - This selection per- 5. RESET ALL DFLTS – This selec- 4. LO HEAT ADJ – Displays the mits the adjustment of the low heat tion restores all items in the value selected at SW3, positions airflow.

  • Page 65: Dual-Fuel Operation

    100 PRCNT TEST – (SW2-2 = OFF DUAL-FUEL OPERATION IN COMMU- NICATING MODE and SW2-3 = ON) Represents the mode of operation which will provide Systems configured for dual-fuel opera- 100% heat rate for any heat call – tion will include a communicating con- regardless of the rate transmitted by denser with a reversing valve.

  • Page 66: Start-Up Procedures

    START-UP PROCEDURES TO START THE FURNACE TO SHUT DOWN WARNING THE FURNACE LIGHTING INSTRUCTIONS FAILURE TO REPLACE THE 1. Set the room thermostat to its This appliance is equipped with a hot BURNER DOOR CAN CAUSE lowest setting and turn to “OFF” surface ignition device.
  • Page 67 TABLE 20 NORMAL OPERATION CODES LOW COOLING MODE CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: C DESCRIPTION: Indicates low cooling for legacy systems only. This code is not used in communicating systems. DESCRIPTION: This code indicates the furnace is in cooling mode (any stage) for communicating systems) high stage only for legacy systems.

  • Page 68: Sequence Of Operation

    SEQUENCE OF TABLE 21 OPERATION METER TIME Heating Cycle Initiation METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES The heating cycle is always initiated by EQUIPPED FOR NATURAL OR LP GAS a 24 volt signal on W of the thermostat HEATING VALUE OF GAS BTU PER CU.

  • Page 69: Maintenance

    MAINTENANCE TABLE 22 FILTER SIZES WARNING DISCONNECT MAIN ELECTRICAL UPFLOW FILTER SIZES POWER TO THE UNIT BEFORE FURNACE INPUT BOTTOM SIDE QUANTITY WIDTH KBTUH SIZE SIZE ATTEMPTING ANY MAINTE- /2" 60 AND 75 /4" X 25" /4" X 25" NANCE. FAILURE TO DO SO CAN 21"...
  • Page 70 FIGURE 49 UPFLOW -- SIDE FILTER LOCATIONS CUT-OUT AND DRILL DETAIL ROD & FILTER SUPPORT ANGLE ASSEMBLY...

  • Page 71: Annual Inspection

    IMPORTANT: It is recommended that 4. Avoid excessive use of kitchen CAUTION exhaust fans. at the beginning of the heating sea- DO NOT OPERATE THE SYSTEM son, the flame sensor be cleaned with 5. Do not permit the heat generated WITHOUT FILTERS.

  • Page 72: Troubleshooting Chart

    FIGURE 50 TROUBLESHOOTING CHART...

  • Page 73: Troubleshooting Chart

    FIGURE 50 (CONTINUED) TROUBLESHOOTING CHART – CONTINUED...

  • Page 74: Normal Operating Codes (Table 23)

    TABLE 23 NORMAL OPERATION CODES LOW COOLING MODE CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: C DESCRIPTION: Indicates low cooling for legacy systems only. This code is not used in communicating systems. DESCRIPTION: This code indicates the furnace is in cooling mode (any stage) for communicating systems) high stage only for legacy systems.

  • Page 75: Furnace Fault Codes With Descriptions And Solutions (Table 24)

    TABLE 24 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS FAULT CODES NOTE: The text in the “DISPLAYED TEXT” box shows combinations of upper-case and lower-case letters. Upper-case letters are used in the message displayed at the thermostat active fault screen. For example, the text CARD-HARDware CoNFLiCT indicates that the message displayed at the thermostat active fault screen will be CARD-HARD CNFLCT.
  • Page 76 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 77 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 78 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 79 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 80 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 81 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED IGNiter FAIL CODE AT DUAL 7-SEGMENT DISPLAY OF IFC & FAULT AREA OF COMM. THERMOSTAT : 16 MESSAGES TO HOMEOWNER AT COMM. THERMOSTAT: "CALL FOR SERVICE " & "CHECK FURNACE". MESSAGE IN FAULT AREA OF COMM.
  • Page 82 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 83 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 84 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 85 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED when the inducer is energized at high speed. (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 86 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED when the inducer is energized at low (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 87 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 88 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGES)
  • Page 89 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED (TABLE CONTINUES ON FOLLOWING PAGE)
  • Page 90 TABLE 24 (CONTINUED) FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...

  • Page 91: Wire Diagram - Stepper / Servo Modulating Valve (Fuel Codes Ha Or Hb)

    FIGURE 51 WIRING DIAGRAM – STEPPER MODULATING GAS VALVE (FUEL CODE HU) (FURNACE MODEL IS RGFE & RGGE)

  • Page 92: Thermostats

    THERMOSTATS NON-COMMUNICATING With a single-stage non-communicat- FIGURE 52 ing thermostat (installed as shown in THERMOSTATS 24-VOLT TERMINALS Figure 56), during a call for heat, the THERMOSTAT WIRING furnace will operate as follows: Phase 1: 0 to 5 minutes = 40% of NOTE: For fully modulating function furnace capacity with a non-communicating thermostat,...
  • Page 93 FIGURE 53 WIRING DIAGRAM FOR MODULATING HEAT (NO DUAL FUEL) (NON-COMMUNICATING) NON-COMMUNICATING MODULATING THERMOSTAT Y (Y V / W2 * (Y THERMOSTAT MODEL: (-)HC-TST401MDMS REMOTE SENSOR: F1451378 (1) FOR REMOTE SENSOR INSTALLATION *2 STAGE COOLING ONLY SEE THERMOSTAT INSTALLATION INSTRUCTIONS **WARNING: DO NOT APPLY 24VAC TO THE V/W2 TERMINAL ON THE IFC (THIS IS OFTEN DONE DURING SETUP, TROUBLESHOOTING AND/OR DIAGNOSING PROBLEMS).
  • Page 94 FIGURE 55 FULLY MODULATING – TYPICAL DUAL FUEL APPLICATION - TWO STAGE HEAT PUMP (NON-COMMUNICATING) **WARNING: DO NOT APPLY 24VAC TO THE V/W2 TERMINAL ON THE IFC (THIS IS OFTEN DONE DURING SETUP, TROUBLESHOOTING AND/OR DIAGNOSING PROBLEMS). DOING SO WILL DAMAGE THE THERMOSTAT. FIGURE 56 WIRING DIAGRAM FOR SINGLE-STAGE HEAT (NON-COMMUNICATING) 1-STAGE ELECTRONIC THERMOSTAT*...
  • Page 95 FIGURE 57 WIRING DIAGRAM FROM TWO-STAGE HEAT (NON-COMMUNICATING) FIGURE 58 WIRING DIAGRAM – SPECIAL CONFIGURATION: COMMUNICATING THERMOSTAT AND FURNACE WITH NON-COMMUNICATING CONDENSER NOTE: DEHUMIDIFICATION FUNCTION FROM A COMMUNICAT- ING THERMOSTAT WILL NOT BE POSSIBLE WITH THIS CONFIGURATION. ST-A1173-01...

  • Page 96: Applications

    Model Programming Choices Non-Programmable 5/1/1 Day 7 Day (-)HC-TST401MDMS FURNACE OPERATION WITH A TWO- thermostat will cause damage to STAGE THERMOSTAT the unit. Rear view of thermostat Model Programming Choices To set the furnace for operation with (-)HC-TST412MDMS Non-Programmable 5/1/1 Day 7 Day 2.
  • Page 97 THERMOSTAT QUICK REFERENCE Home Screen Description Figure 61 – Home Screen Display Figure 52 – Home Screen Display Room Temperature Day of Week Set Temperature Time of Day Temperature UP/Down used for System modifying set point Switch as well as to navigating the menus Enters comfort Switch...
  • Page 98 INSTALLER/CONFIGURATION MENU To enter the menu: Press the Menu touch key. Press and hold for 5 seconds the Installer Config touch key. This displays menu item #1 in Table 25 below. Press to advance to the next menu item or to return to a previous menu item.
  • Page 99 INSTALLER/CONFIGURATION MENU 1) This control can be configured for: 11) Select Continuous Backlight In low lighting condi- MS2 Multi-Sta ge System (2 heat/2 cool) tions, display backlight improves the display contrast. HP1 Hea t Pump with one stage of compressor When C terminal is connected, selecting dL On will turn (2 heat/1 cool) the backlight on continuously.
  • Page 100 INSTALLER/CONFIGURATION MENU 25) Select Remote Temperature Sensor This control 20) Heat Temperature Limit Range This f eature adjusts the highest setpoint temperature for heat. The default allows one wired remote temperature sensor (indoor or outdoor) be connected to it and indicates the measured setting is 99 F.
  • Page 101 OPERATING YOUR THERMOSTAT IMPORTANT! Program Override (Temporary Override) Choose the Fan Setting (Auto or On or Prog) Press buttons to adjust the temperature. This will Fan Auto is the most commonly selected setting and runs the fan only when the heating or cooling system is on. override the temperature setting for a (default) four hour Fan On selection runs the fan continuously for increased air override period.
  • Page 102 PROGRAMMING Automatic Daylight Saving Calculation Automatic Schedule The Real Time Clock will adjust automatically for daylight This feature provides a method to program every day with savings time, in the following manner until 2007: the most popular time and temperature profile using one key Increment one hour at 2 AM on the first Sunday of April and press.
  • Page 103 PROGRAMMING Energy Saving Factory Pre-Program The (-)HC-TST401MDMS thermostats are programmed with the energy saving settings shown in Table 26 below for all days of the week. If this program suits your needs, simply set the thermostat clock and press the RUN button. Table 26 below shows the factory set heating and cooling schedule for all days of the week.
  • Page 104 PROGRAMMING Dual Fuel Temperature Set Point Wired Remote Temperature Sensing The Thermostat can monitor outside temperature through an One remote temperature sensor can be installed indoor or outdoor remote sensor if installed and switch to gas heat and outdoor and connected to the thermostat by a maximum inhibit the compressor when in heat pump mode and outside cable length of 100 meters (300 ft).

  • Page 105: Troubleshooting

    TROUBLESHOOTING Reset Operation Note: When thermostat is reset, installer configuration menu settings and programming will reset to factory settings. If a voltage spike or static discharge blanks out the display or causes erratic thermostat operation, you can reset the thermostat by removing the wires from terminals R and C (do not short them together) and removing batteries for 2 minutes.

  • Page 106: Communicating Thermostats

    Figures 63 and 64 are wiring diagrams for connecting the furnace to an approved ClimateTalk communicating thermostat and approved Rheem or Ruud communicating condenser. The only approved configuration for fully communicating systems is to install...
  • Page 107 SPECIAL CONFIGURATION nect the thermostat and condenser to Once the communicating wiring is the furnace control. properly installed and the furnace is – COMMUNICATING THER- connected to line voltage, the sys- MOSTAT AND FURNACE tem can be turned on. The thermo- NOTE: A heat pump condenser cannot WITH A NON-COMMUNI- stat will display the following text:...

  • Page 108: Hc-Tst501Cmms Programmable Communicating Thermostat

    The order in which these messages will FIGURE 65 be displayed will depend on which com- WIRING DIAGRAM – COMMUNICATING CONFIGURATION ponents are energized first. The order listed here assumes that the furnace VIEWING DETAILED FAULT MESSAGES and condenser are energized at the same time.
  • Page 109 Entering and Viewing the Furnace FIGURE 66 Main Menu and Sub Menus: Figure WIRING DIAGRAM – COMMUNICATING CONFIGURATION 66 demonstrates how to view and enter the furnace user menu and subsequent sub-menus with the (-)HC- TST501CMMS communicating thermo- stat. To get into the submenus, use the up and down arrow keys of the thermo- stat to display the desired menu and press the “Installer Config”...
  • Page 110 Making Setup Changes: Figure 67 FIGURE 67 demonstrates how to make changes to WIRING DIAGRAM – COMMUNICATING CONFIGURATION the SETUP sub-menu with the (-)HC- TST501CMMS communicating thermo- stat. IN THIS EXAMPLE, WE WANT TO CHANGE THE “MAX HEAT ADJUST” TO –15%. FIRST, ENTER THE SETUP MENU AS DESCRIBED IN “ENTERING THE FURNACE MAIN MENU”...
  • Page 111 Escaping or Returning from Menus: FIGURE 68 Figure 68 demonstrates how to escape WIRING DIAGRAM – COMMUNICATING CONFIGURATION from a menu back to the main screen or how to return to a previous menu level using the (-)HC-TST501CMMS communicating thermostat. ST-A1118-01-1...

  • Page 112: Hc-Tst550Cmms Full Color, Programmable Communicating Thermostat

    (-)HC-TST550CMMS FULL TIPS FOR NAVIGATING FURNACE Viewing Furnace Fault USER MENUS USING THE (-)HC- Messages with the (-)HC- COLOR, PROGRAMMABLE TST550CMMS THERMOSTAT TST550CMMS Thermostat COMMUNICATING THER- MOSTAT To enter a particular user menu on the (-)HC-TST550CMMS, full color communicating thermostat follow the directions below.

  • Page 113: Viewing Furnace User Menus With The (-)Hc-Tst550Cmms Thermostat

    VIEWING FURNACE FIGURE 72 USER MENUS WITH THE ENTER THE ADVANCED INSTALLER MENU. (-)HC-TST550CMMS 1. From the main screen, press the left THERMOSTAT and right arrow keys together at the same To enter a particular user menu on time for at least 3 the (-)HC-TST550CMMS, full color seconds.

  • Page 114: Changing Furnace Setup Items On The (-)Hc-Tst550Cmms Thermostat

    CHANGING FURNACE FIGURE 77 SETUP ITEMS ON THE ENTER THE ADVANCED INSTALLER MENU. (-)HC-TST550CMMS 1. From the main screen, press the left THERMOSTAT and right arrow keys together at the same To change a particular furnace time for at least 3 user setup item on the (-)HC- seconds.
  • Page 115 FIGURE 81 SELECT THE SETUP ITEM TO BE ADJUSTED (MAX HEAT ADJ%) 5. Use the up and down arrow keys to view and navigate to the desired setup Home menu item. Once the desired menu item is highlighted, press the “M” key to enter the sub menu.
  • Page 116 FIGURE 84 UPDATE SUCCESSFUL 8. This screen; Update Successful will be displayed briefly upon successfully changing the setting. 9. To escape from this menu, press the Enter (to return to the furnace user menus) or Home button or just wait a few minutes and the main screen will appear again.

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