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INSTALLATION INSTRUCTIONS
FOR RGFE UPFLOW, RGGE DOWNFLOW & RGJF DEDICATED
HORIZONTAL HIGH EFFICIENCY MODULATING CONDENSING
GAS FURNACES
RGFE
RGGE
ISO 9001:2008
RGJF
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.
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.
SEE PAGE 112
COMMUNICATING
SEE PAGE 122
This Memory Card must be removed (broken away) from the
furnace control when the control is replaced. The card must
be inserted into the connector at J15 of the replacement con-
trol. Failure to retain this memory card with the furnace when
replacing the furnace control could result in no operation
when the furnace control is replaced.
MODULATING
THERMOSTAT
INSTALLATION
MODULATING
THERMOSTAT
INSTALLATION
92-24161-75-00
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Summary of Contents for Rheem RGFE
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Page 1: Installation Instructions
INSTALLATION INSTRUCTIONS FOR RGFE UPFLOW, RGGE DOWNFLOW & RGJF DEDICATED HORIZONTAL HIGH EFFICIENCY MODULATING CONDENSING GAS FURNACES RGJF RGFE MODULATING THERMOSTAT INSTALLATION SEE PAGE 112 MODULATING COMMUNICATING THERMOSTAT INSTALLATION SEE PAGE 122 This Memory Card must be removed (broken away) from the furnace control when the control is replaced. -
Page 2: Table Of Contents
TABLE OF CONTENTS IMPORTANT: All Rheem products meet current Federal OSHA Guidelines SAFETY INFORMATION ............................3 for safety. California Proposition 65 INSTALLATION CHECK LIST...........................5 GENERAL INFORMATION ............................6 warnings are required for certain prod- IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY..........8 ucts, which are not covered by the LOCATION REQUIREMENTS AND CONSIDERATIONS..................9... -
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.
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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 RGFE, RGGE and RGJF series furnace are required if consumers CSA International - U.S. furnaces are design-certified by CSA are to receive the full benefits for 8501 East Pleasant Valley Road for use with natural and L.P. gases as which they have paid. - Page 7 ® FIGURE 3 DEDICATED HORIZONTAL FURNACE RGJF (GAS VALVE MAY BE DIFFERENT THAN SHOWN) ITEM ITEM PART NAME PART NAME GAS VALVE OUTLET AIR PIPE CAPACITOR (FOR INDUCER) INTEGRATED FURNACE CONTROL LOW PRESSURE SWITCH TRANSFORMER HIGH PRESSURE SWITCH INDUCED DRAFT BLOWER BLOWER HOUSING CONNECTOR POWER FACTOR CHOKE...
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Page 8: Important Information About Efficiency And Indoor Air Quality
matches what is required for the IMPORTANT INFORMA- NOTICE job specification. TION ABOUT EFFICIENCY IMPROPER INSTALLATION, OR • Read the entire instructions before INSTALLATION NOT MADE IN AND INDOOR AIR starting the installation. ACCORDANCE WITH THE CSA • Some building codes require extra QUALITY INTERNATIONAL (CSA) CERTIFICA- cabinet insulation and gasketing... -
Page 9: Location Requirements And Considerations
LOCATION REQUIREMENTS AND CONSIDERATIONS GENERAL INFORMATION densate drain assembly. See 5. IMPORTANT: If installing in a “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 10: Clearance-Accessibility
APPROVED OR RECOMMENDED BLOWER ASSEMBLY: floors mounted to a combustible FOR INSTALLATION ON ITS BACK, (wood only) floor. The necessary RGFE/RGGE/RGJF-09EZCMS WITH ACCESS DOORS FACING floor base for installing a -GGE fur- RGFE/RGGE/RGJF-10EZCMS UPWARDS, OR WITH SUPPLY AIR nace in the downflow configuration... -
Page 11: Site Selection
FIGURE 8 BASE FOR COMBUSTIBLE FLOORS SITE SELECTION 1. Select a site in the building near the center of the proposed, or exist- ing, duct system. 2. Give consideration to the vent sys- tem piping when selecting the fur- nace location. Vent from the fur- nace to the termination with mini- mal length and elbows. -
Page 12: California's Proposition 65 Requires Dimensions And Clearance To Combustibles
FIGURE 9 PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS AIRFLOW AO39201... -
Page 13: Downflow Models
FIGURE 10 DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, DOWNFLOW MODELS AIRFLOW... -
Page 14: Horizontal Models
FIGURE 11 DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, HORIZONTAL MODELS... -
Page 15: 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 16 Return air can come from : (1) out- DOWNFLOW UNITS side the building, (2) from return air 1. Position the unit to minimize long ducting from several inside rooms, or (3) runs of duct or runs of duct with a combination of the two. When using many turns and elbows.
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Page 17: Supply Air Sensor
SUPPLY AIR SENSOR NOTE: In downflow circumstances For communicating systems, the where building construction does not supply air sensor input can be turned Each furnace comes shipped from the allow for the placement of the sensor to off so that a fault code will not be factory with a supply air sensor. -
Page 18: Venting And Combustion Air Piping
VENTING AND COMBUSTION AIR PIPING GENERAL INFORMATION THE COMPONENTS OF THE common venting system. Turn on any exhaust fans, such as CERTIFIED MATERIAL MUST range hoods and bathroom WARNING NOT BE INTERCHANGED WITH exhausts, so they will operate at OTHER VENT SYSTEMS OR READ AND FOLLOW ALL maximum speed. -
Page 19: Cementing Joints
JOINING PIPE AND 3. Apply a thin coat of cement IMPORTANT: The plastic combustion evenly in the socket. Quickly air and venting components are MADE FITTINGS apply a heavy coat of cement to of PVC. If using ABS piping, ensure that WARNING the pipe end and insert pipe into the solvent cement is compatible for... -
Page 20: 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 21 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 22 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.
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Page 23: 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 RGFE ney with a metal or high tempera- ture plastic pipe from another gas or NUMBER OF ELBOWS... -
Page 24: 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 RGFE FURNACES TION. FAILURE TO PROPERLY VENT THIS FURNACE CAN NUMBER OF ELBOWS CAUSE CARBON MONOXIDE ⁄... - Page 25 FIGURE 17 STANDARD VERTICAL DIRECT VENTING UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS) DETAIL A 12” EXHAUST TERMINATION NOTES: THE COMBUSTION AIR PIPE MUST TERMINATE IN THE SAME PRESSURE ZONE AS THE EXHAUST PIPE. INCREASE THE 12-IN. MINIMUM TO KEEP TERMINAL OPENING ABOVE ANTICIPATED LEVEL OF SNOW ACCU- MULATION WHERE APPLICABLE.
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Page 26: 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 18) place of factory supplied kits: This kit is for vertical and horizontal 3”... - Page 27 INSTALLATION – RXGY-G02A Side Wall Vent INSTALLATION RXGY-G02 Side Wall Vent – This termination for horizontal venting only. This termination for direct vent application only. Important: Do no install on the prevailing winter wind side of the structure Note: Multi-venting-No common venting. FIGURE 19 VENT KIT INSTALLATION OPTIONS EXHAUST...
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Page 28: Horizontal Terminations
HORIZONTAL TERMINATIONS Combustion Air Piping: Use a 2" PVC Exhaust Vent Piping: coupling with a wind deflector vane (pro- 60,000 and 75,000 BTUH models: vided) installed as follows: Install a 2" to 1 1/2" reducer cou- STANDARD HORIZONTAL TERMINA- pling at the outside wall to prevent TIONS (SEE FIGURE 21) 1. - Page 29 ALTERNATE HORIZONTAL TERMI- FIGURE 22 NATIONS (See Figure 22) ALTERNATE HORIZONTAL DIRECT VENT TERMINATION EXHAUST VENT NOTE: This method is not permitted " PVC FOR MODELS WITH 120,000 BTUH INPUT on modulation downflow/horizontal (KIT NO. RXGY-D04A) 2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000 (RGGE or RGJF) models.
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Page 30: 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 31 FIGURE 24 DIRECT VENT TERMINAL CLEARANCES...
- Page 32 FIGURE 25 FIGURE 26 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 33 DOWNFLOW/HORIZONTAL ® FIGURE 27 MODELS UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION (GAS VALVE MAY BE DIFFERENT THAN SHOWN) NOTE: Combustion air inlet and exhaust “O” RING COMBUSTION AIR ADAPTER outlet air pipes are reversed for down- TOP PLATE flow and horizontal models from that of VENT CAP/PLUG NOTE: upflow.
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Page 34: Condensate Drain/Optional Neutralizer
CONDENSATE DRAIN/OPTIONAL NEUTRALIZER GENERAL INFORMATION FIGURE 31 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 35 IMPORTANT: There are two options diameter plug that is also supplied in RXGY-H01 when choosing a height for the con- the RXGY-H01 downflow alternate CONVERTING TO LEFT densate riser: drain kit. Both the hole-plug and grommet must be in place to insure a CONDENSATE OVERFLOW: With a DRAIN FOR DOWNFLOW good seal in the burner compartment.
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Page 36: Converting Downflow/Horizontal Models To Horizontal Configuration
CONVERTING DOWNFLOW/HORIZONTAL (RGGE WITH HB FUEL CODE ONLY) MODELS TO HORIZONTAL CONFIGU- See additional instructions 7. Fill the trap assembly ’ with 1/2 IMPORTANT: Tighten all clamp cup of water. connections with a pair of pliers on page 38 for instruc- and check for leaks after conver- 8. - Page 38 CONDENSATE DRAIN FURNACE SHUTDOWN: To NOTE: See location requirements cause the furnace to shut down and combustion section for additional FOR HORIZONTAL when a blocked drain is present, recommendations. (RGJF) INSTALLATION install a riser which is a minimum of 5 ⁄...
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Page 39: Gas Supply And Piping
GAS SUPPLY AND PIPING FIGURE 39 GAS SUPPLY GAS PIPING -- UPFLOW INSTALLATION (GAS VALVE MAY BE DIFFERENT WARNING THAN SHOWN) GROMMET THIS FURNACE IS EQUIPPED NOTE: TOP VIEW OF GAS LINE AND VALVE WHEN GAS LINE IS IN OPT. MANUAL IN OPT. -
Page 40: Gas Valve
to the combination gas valve on the GAS PRESSURE FIGURE 42 furnace. Refer to Table 8 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 9 for L.P. - Page 41 TABLE 8 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...
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Page 42: Lp Conversion
LP CONVERSION 2. Remove the gas valve and mani- 5. Re-attach the manifold assem- fold assembly. bly to the unit and connect the IMPORTANT: LP gas from trucks used gas line to the gas valve. 3. Replace the orifice spuds. to transport liquid-based fertilizers can 6. -
Page 43: Setting Gas Pressure
checked when converting the furnace CULATED BASED ON ELEVATION FIGURE 47 for LP operation. Figures 46 and 47 AND GAS HEATING VALUE. THE LP JUMPER INSTALLED ON SERVO MODU- below show the incorrect way and the BURNER ORIFICES MAY (OR MAY LATING GAS VALVE WITH PINS PROPERLY NOT) NEED TO BE CHANGED. - Page 44 ® SERVO GAS VALVE (FUEL ® SOLENOID GAS VALVE (FUEL NOTE: Only small variations in gas CODE: HA OR HB) MANIFOLD CODE: HG OR HH) MANIFOLD pressure should be made by ® ® GAS PRESSURE GAS PRESSURE adjusting the pressure regulator. ®...
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Page 45: 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 46 ELECTRICAL CHECKS Line Power Check The furnace must have a nominal 115 volt power supply for proper opera- tion. If there is not a consistent power supply, contact a licensed electrician to correct the problem. 1. With the blower compartment door off, manually hold the push button door switch in.
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Page 47: Accessories
1). There must be a call TWINNING: Twinning is NOT permitted nals are connected directly to the con- for heat and the blower must be on any modulating RGFE, RGGE or tacts of a board-mounted relay. The engaged and 2.) The humidistat RGJF furnace model. - Page 48 STAT” on the furnace con- FIGURE 56 trol. Installing this jumper WIRING FOR OPTIONAL DEHUMIDIFICATION OPERATION AND HUMIDIFICATION WITH will operate the humidifier OPTIONAL HUMIDIFIER (HUMIDIFIER WITH INTERNAL POWER SUPPLY) (FOR USE WITH any time there is a heat call. NON-COMMUNICATING THERMOSTATS) Without the jumper, the humidification call from the...
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Page 49: Other Accessories
RESIDENTIAL SYSTEMS CATION CONTROL Figures 55 (II) or 56 (III). (REQUIRES OPTIONAL HUMIDIFI- These figures show installation The Rheem Serial Communicating ER). of a humidifier with external and (CC2) system allows accessories to internal power supplies respec- be connected to shut down the sys- C1. - Page 50 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.
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Page 51: High Altitude Installations
Table 10 shows EQUIPMENT FAILURE. some quick conversions based on ele- HIGH ALTITUDE FIELD vation and gas heating value. This table CONVERSION KITS (RGFE MODELS) is combined and simplified from Tables F1 and F4 of the National Fuel Gas MODEL INPUT(BTU) KIT NO. -
Page 53: Lp Gas At High Altitude Elevations
Part #62-22175-60 the NFGC LP orifice chart, as they are Example 2: not accurate for the RGFE, RGGE or 1.15mm drill size orifice required RGJF gas furnaces. The National Fuel Part #62-22175-91 Gas Code LP orifices are based on an 11”... -
Page 54: Zoning Systems
If installed as a “bypass” system, the ured to achieve rated efficiency. installation must have an optional In accordance with Rheem/Ruud cool- freeze stat installed to prevent the coil ing equipment installation instructions, from icing with excess bypass cooling. -
Page 55: Integrated Furnace Control
INTEGRATED FURNACE CONTROL (I.F.C.) FIGURE 58 MODULATING CLIMATE-TALK COMMUNICATING FURNACE CONTROL (RHEEM # 62-102783-01) BIAS/TERM (COMM ONLY) (all must be on) 24 VAC THERMOSTAT ing performance will be realized only Optional equipment is required for with the fully modulating thermostat these features. -
Page 56: Special Configuration - Comm T-Stat And Non-Comm Condenser
FUSE (F1) minal labeled “W2” can be connected tional relays have been added to the to this terminal to activate the timed furnace control to allow this operation). A three-amp automotive-style (ATC staging feature of this furnace. The thermostat connections labeled blade type) fuse is supplied on- “Y1”... - Page 57 STEPPER GAS VALVE For troubleshooting purposes, follow the For troubleshooting purposes, follow wiring diagram and troubleshooting flow- the wiring diagram and troubleshoot- CONTROL (J16) chart supplied in this manual and on the ing flowchart supplied in this manual For furnaces equipped with a stepper inside of the furnace blower door.
- Page 58 FIGURE 60 15-PIN CONNECTOR; J1 WITH PIN DESIGNATIONS COMMUNICATING ECM For troubleshooting purposes, follow Pin 1 to communicating blower the wiring diagram and troubleshooting motor connector Pin 1 (+V) MOTOR COMMUNICATIONS flowchart supplied in this manual and (CONTROL) CONNECTION Pin 2 to communicating blower on the inside of the furnace blower motor connector Pin 2 (TX) (J10) (see Fig 58)
- Page 59 FIGURE 61 FOUR-PIN MOTOR CONTROL CONNECTION; J10 WITH PIN ASSIGNMENTS. WARNING: Do not route the orange igniter wire within 2 of the gas valve. Noise from the wire could cause failed ignition and loss of heat. SPARK IGNITION TRANS- IRREPRABLE DAMAGE TO EITHER one special circumstance where a THE FURNACE CONTROL (I.F.C.) OR communicating thermostat and non-...
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Page 60: Memory Card
installed. These L.E.D.’s will not ener- Furnace shared data is defined as WARNING gize if a traditional 24V thermostat data specific to a given furnace that only is used to control the furnace. is critical for proper furnace opera- DO NOT REPLACE THE FURNACE tion. - Page 61 nal furnace control (IFC) and FIGURE 62 retained with the furnace. When AN ATTACHED MEMORY CARD the new IFC is installed, the origi- nal memory card will be inserted into connector J15 of the IFC to impart the critical furnace shared data to the replacement control.
- Page 62 trol or a valid replacement b. If valid furnace shared data is and/or memory card ordered from available from the network and no V. is from an older furnace ProStock. memory card is present, a “d4” and is missing critical (MEM CARD INVALID) fault is newer furnace shared data displayed at the communicating...
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Page 63: Replacing The Furnace Control
REPLACING THE FUR- 3. If two memory cards present – d. If furnace shared data on the (attached to IFC and inserted in J15 inserted memory card does not NACE CONTROL of IFC), the memory card inserted support the motor manufacturer of In the event that the furnace control into J15 “wins”... - Page 64 FIGURE 64 REMOVE THE MEMORY CARD WHEN REPLACING THE FURNACE CONTROL. THIS PHOTO SHOWS THE CORRECT WAY TO REMOVE THE MEMO- RY CARD. DO NOT CUT THE TETHER. For communicatinig systems as a final confirmation of the correct shared data the model number should be verified by checking the furnace user menu under the sub menu titled “Unit Info.”...
- Page 65 FIGURE 65 ON A REPLACEMENT FURNACE CONTROL THE ORIGINAL MEMORY CARD FROM THE ORIGINAL FURNACE CONTROL SHOULD BE INSERTED INTO CONNECTOR J11 OF THE REPLACEMENT CONTROL. DOING THIS WILL GIVE THE REPLACEMENT CONTROL ITS IDENTITY. NOTE THAT THERE WILL BE TWO MEMORY CARDS – THE ORIGINAL (INSERTED INTO J11) AND THE REPLACEMENT (STILL ATTACHED TO THE REPLACE- MENT FURNACE CONTROL).
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Page 66: Dipswitches
DIPSWITCHES For non-communicating systems or Cooling airflow for non-communicat- communicating systems with a non- ing systems can be adjusted NOTE: The integrated furnace control communicating condenser (see section approximately +/- 10% by using the does not recognize switch setting titled SPECIAL CONFIGURATION – cool trim adjustment dipswitches;... - Page 67 FIGURE 67 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). YH Single YL Low 2 YL+YH High 2 SW2, Pos. 6 SW1, Pos. 2 SW1, Pos.
- Page 68 FIGURE 68 DIPSWITCH BANK SW2 TEST MODE SELECT To enter the Furnace Test Mode, Switch (SW2-1) Call Voltage at “ HUM” Action proceed as follows: COOL Normal Cool (c or C) 1 Switch the 115 volt power to the COOL Dehum Cool (cd or Cd) furnace OFF.
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Page 69: Furnace Operation Using Non-Communicating Modulating, Modulating And Two-Stage T-Stats
FURNACE OPERATION will instruct the furnace to perform as TWO-STAGE FUNCTION: follows: USING NON-COMMUNICAT- (Two-stage function only applies ING MODULATING, SIN- when both switches SW2-2 and 1 Normal ignition sequence SW2-3 are in the “ ON” position GLE-STAGE, AND TWO- 2 A calibration cycle will be performed and a two-stage thermostat is STAGE THERMOSTATS... - Page 70 FIGURE 69 DIPSWITCH BANK SW3 HEAT AIRFLOW ADJUSTMENT NOTE: TO CLEAR FAULT CODES IN THE FURNACE CONTROL, TURN SWITCH # SW3-3 ON, OFF, ON, OFF OR OFF, ON, OFF, ON WITHIN 30 SECONDS. THE RIGHT-MOST SEVEN-SEGMENT DISPLAY WILL FLASH THE UPPER AND LOWER HORIZONTAL MEMBERS ONCE AS CONFIRMATION THAT THE FAULTS HAVE BEEN CLEARED.
- Page 71 EXAMPLE 2 EXAMPLE 3 4) Set dip switches 1 to the “ON” position to override standard airflow PROBLEM: Temperature rise is too low PROBLEM: Temperature rise is too low at 100% firing rate. Set switch 2 to at 100% firing rate although it is within at 40% firing rate and is too high at the “ON”...
- Page 72 FIGURE 73 DIPSWITCH BANK SW4 TERMINATION AND BIAS SELECTIONS BIAS / TERMINATION The rightmost decimal on the display NOTE: The following fault codes will will blink one time for every 100 CFM of not be stored back-to-back in the These dipswitches will not be used for expected airflow whenever the blower fault buffer.
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Page 73: Communicating Systems
82, 11, 45, 46 & 57. approved ClimateTalk communicat- ing thermostat and approved Rheem or Ruud communicating condenser. The only approved configuration is... -
Page 74: Startup For Systems Configured With Communications
STARTUP FOR SYSTEMS CON- FIGURE 74 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 75: Continuous Fan Operation In Communicating Mode
When the system has found all neces- ACTIVE FAULT CODES WITH COM- FURNACE USER MENUS sary components, the text area of the MUNICATING SYSTEMS NOTICE: ALL TEMPERATURE communicating thermostat will go blank. Two levels of fault codes exist: (1) Non- VALUES DISPLAYED IN USER This is an indicator that the system is critical and (2) Critical. -
Page 76: Status 1
FIGURE 75a MENU TREE ® NOTE: There may be a delay of several seconds when accessing user menus or submenus. This is normal. ® NEXT PAGE The thermostat menus give active infor- 1. MAIN LIMIT – Indicates the state of the vestibule. - Page 77 FIGURE 75b MENU TREE – CONTINUED NOTE: There may be a ® ® delay of several seconds when accessing user menus or submenus. This is normal. TOTAL DAYS PWRD MOD HT HRS MOD HT CYCLS BLOWER HRS BLOWER CYCLES ® ®...
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Page 78: Status 2
10. BLOWER CFM – Indicates the CFM b. If the S.A.S. is not turned on attached (or not sensed), NA that the furnace control requests (see “SUPPLY AIR SENS” in will be displayed in the “SUP- from the blower motor. This value “SETUP”... -
Page 79: Life Hist
“LIFE HIST” menu – This menu gives When faults are cleared, the right are -15%, -7.5%, 0, +7.5% and information about the number of cycles seven segment display on the furnace +15%. Note that when a low and the amount of time spent in various control will flash the upper and lower heat adjustment is made, the modes of operation over the life of the... -
Page 80: List Are Found In Our Daily Lives. Most Dipswitch
NOTE: FOR DUAL-FUEL OPERA- 1. COOL AIRFLOW – Displays the – regardless of the rate transmit- TION, THE SUPPLY AIR SENSOR value of the cooling airflow select- ted by the thermostat. This MUST BE INSTALLED AND THE ed. See the section of this manual mode ends automatically after SELECTION FOR THIS SENSOR titled “DIPSWITCH”... -
Page 81: Start-Up Procedures
START-UP PROCEDURES FURNACE TEST MODE IGNITOR PLACEMENT, 1. Remove the burner compartment control access door. ALIGNMENT & LOCATION See the section of this manual titled 2. IMPORTANT: Be sure that the man- Ignition failure may be a result of “DIPSWITCH” under “SW-2” for ual gas control has been in the improper ignitor alignment caused dur- details about test mode. -
Page 82: Dehumidification Mode
TABLE 17 NORMAL OPERATION CODES NORMAL OPERATION CODES DISPLAYED TEXT CODE AT DUAL 7-SEGMENT DISPLAY OF IFC CODE DESCRIPTION NORMAL OPERATION CODES STANDBY MODE CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: 0 DESCRIPTION: This code is displayed anytime there is no fault code to display and no thermostat call present. The furnace is idle. -
Page 83: Sequence Of Operation
TO SHUT DOWN TABLE 18 THE FURNACE METER TIME 1. Set the room thermostat to its low- METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES est setting and turn to “OFF” posi- EQUIPPED FOR NATURAL OR LP GAS tion. -
Page 84: Maintenance
MAINTENANCE TABLE 19 WARNING FILTER SIZES DISCONNECT MAIN ELECTRICAL UPFLOW FILTER SIZES POWER TO THE UNIT BEFORE FURNACE INPUT BOTTOM SIDE QUANTITY WIDTH KBTUH SIZE SIZE ATTEMPTING ANY MAINTE- NANCE. FAILURE TO DO SO CAN /2" 60 AND 75 /4" X 25" /4"... - Page 85 FIGURE 79 UPFLOW -- SIDE FILTER LOCATIONS CUT-OUT AND DRILL DETAIL ROD & FILTER SUPPORT ANGLE ASSEMBLY FIGURE 80 FIGURE 81 DOWNFLOW -- FILTER INSTALLATION HORIZONTAL -- FILTER INSTALLATION A087001.S01 A087101.S01...
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Page 86: Annual Inspection
4. Avoid excessive use of kitchen IMPORTANT: It is recommended that 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 87: Troubleshooting Chart
FIGURE 82 TROUBLESHOOTING CHART MODULATING INTEGRATED FURNACE CONTROL (IFC) TROUBLESHOOTING GUIDE ECM = Constant CFM Blowers. (Electronically commutated motor) TSTAT = Thermostat. IDM = Induced Draft Motor (or Inducer). IFC = Integrated Furnace Control (or control board). 1) Set DIP switches SW2-2 to “OFF” and SW2-3 to PS = Pressure Switch(es). - Page 88 - Check test mode dip switches. Remove heat call by setting T-stat set point below - Make sure test mode has not room temperature. remove power to furnace and open expired (1 hour limit). blower door. Set dip switch SW2-2 to “ON” and SW2-3 to “OFF”.
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Page 89: Normal Operating Codes (Table 20)
TABLE 20 NORMAL OPERATION CODES NORMAL OPERATION CODES DISPLAYED TEXT CODE AT DUAL 7-SEGMENT DISPLAY OF IFC CODE DESCRIPTION NORMAL OPERATION CODES STANDBY MODE CODE AT DUAL 7-SEGMENT DISPLAY OF IFC: 0 DESCRIPTION: This code is displayed anytime there is no fault code to display and no thermostat call present. The furnace is idle. -
Page 90: Furnace Fault Codes With Descriptions And Solutions (Table 21)
TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS FAULT CODES DISPLAYED TEXT CODE AT DUAL 7-SEGMENT DISPLAY OF IFC & FAULT AREA OF COMM. THERMOSTAT MESSAGES TO HOMEOWNER AT COMM. THERMOSTAT MESSAGE IN FAULT AREA OF COMM. THERMOSTAT STATUS FAULT DESCRIPTION CODE... -
Page 91: Fault Codes
TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED 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 92 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 93 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 94 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 95 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 96 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 97 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 98 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 99 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 100 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED when the inducer is energized at high speed.
- Page 101 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED when the inducer is energized at low...
- Page 102 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 103 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 104 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
- Page 105 TABLE 21 FURNACE FAULT CODES EXPANDED W/DESCRIPTIONS AND SOLUTIONS – CONTINUED...
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Page 106: Wire Diagram - Stepper / Servo Modulating Valve (Fuel Codes Ha Or Hb)
FIGURE 83 WIRING DIAGRAM – STEPPER MODULATING GAS VALVE (FUEL CODE HA OR HB) (FURNACE MODEL IS RGFE & RGGE) -
Page 107: Wire Diagram - Solenoid Controlled Modulating Valve (Fuel Codes Hg Or Hh)
FIGURE 84 WIRING DIAGRAM – SOLENOID CONTROLLED GAS VALVE (FUEL CODE HG OR HH) (FURNACE MODEL RGGE, RGFE & RGJF) -
Page 108: Thermostats
THERMOSTATS NON-COMMUNICATING With a single-stage non-communicat- FIGURE 85 ing thermostat (installed as shown in THERMOSTATS 24-VOLT TERMINALS Figure 89), 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 109: Thermostat Wiring (With Wiring Diagrams)
FIGURE 86 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 110 FIGURE 88 FULLY MODULATING – TYPICAL DUAL FUEL APPLICATION - TWO STAGE HEAT PUMP (NON-COMMUNICATING) NON-COMMUNICATING THERMOSTAT (1) **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 89 WIRING DIAGRAM FOR SINGLE-STAGE HEAT (NON-COMMUNICATING) 1-STAGE ELECTRONIC THERMOSTAT*...
- Page 111 FIGURE 90 WIRING DIAGRAM FROM TWO-STAGE HEAT (NON-COMMUNICATING) 2-STAGE ELECTRONIC THERMOSTAT* (NON-COMMUNICATING) Y (Y **** **** NO MECHANICAL THERMOSTATS. 40% FIRING RATE IN TWO-STAGE OPERATION (DIP SWITCH SET SW2 — SWITCHES 1 & 2 ON). *** 65% and 100% FIRING RATE IN TWO-STAGE OPERATION (W & W2 ENERGIZED). **** 2 STAGE COOLING ONLY.
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Page 112: Applications
Model Programming Choices Non-Programmable 5/1/1 Day 7 Day (-)HC-TST401MDMS FURNACE OPERATION WITH A TWO- thermostat will cause damage to the unit. Rear view of thermostat STAGE THERMOSTAT Model Programming Choices To set the furnace for operation with 2. Place base over hole in wall and Non-Programmable 5/1/1 Day 7 Day (-)HC-TST412MDMS... - Page 113 THERMOSTAT QUICK REFERENCE Home Screen Description Figure 94 – 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 114 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 the table below. Press to advance to the next menu item or to return to a previous menu item.
- Page 115 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 116 INSTALLER/CONFIGURATION MENU 25) Select Remote Temperature Sensor This control 20) Heat Temperature Limit Range This f eature adjusts allows one wired remote temperature sensor (indoor or the highest setpoint temperature for heat. The default outdoor) be connected to it and indicates the measured setting is 99 F.
- Page 117 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 override the temperature setting for a (default) four hour the fan only when the heating or cooling system is on.
- Page 118 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 119 PROGRAMMING Energy Saving Factory Pre-Program The (-)HC-TST401MDMS thermostats are programmed with the energy saving settings shown in the table below for all days of the week. If this program suits your needs, simply set the thermostat clock and press the RUN button. The table below shows the factory set heating and cooling schedule for all days of the week.
- Page 120 PROGRAMMING Dual Fuel Temperature Set Point Wired Remote Temperature Sensing One remote temperature sensor can be installed indoor or The Thermostat can monitor outside temperature through an 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).
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Page 121: 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 122: Communicating Thermostats
Figures 96 through 97 below are wiring diagrams for connecting the furnace to an approved ClimateTalk communicat- ing thermostat and approved Rheem or Ruud communicating condenser. The only approved configuration for fully communicating systems is to install... -
Page 123: Special Configuration
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- For single stage condensers, a jumper MOSTAT AND FURNACE tem can be turned on. -
Page 124: Hc-Tst501Cmms Programmable Communicating Thermostat
The order in which these messages will FIGURE 98 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 125 Entering and Viewing the Furnace FIGURE 99 Main Menu and Sub Menus: Figure WIRING DIAGRAM – COMMUNICATING CONFIGURATION 99 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 126 Making Setup Changes: Figure 100 FIGURE 100 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 127 Escaping or Returning from Menus: FIGURE 101 Figure 101 below demonstrates how to WIRING DIAGRAM – COMMUNICATING CONFIGURATION escape from a menu back to the main screen or how to return to a previous menu level using the (-)HC- TST501CMMS communicating thermo- stat.
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Page 128: Hc-Tst550Cmms Full Color, Programmable Communicating Thermostat
(-)HC-TST550CMMS FULL Viewing Furnace Fault TIPS FOR NAVIGATING FURNACE USER MENUS USING THE (-)HC- COLOR, PROGRAMMABLE Messages with the (-)HC- TST550CMMS THERMOSTAT COMMUNICATING THER- TST550CMMS Thermostat MOSTAT To enter a particular user menu on the (-)HC-TST550CMMS, full color communicating thermostat follow the directions below. - Page 129 Viewing Furnace User FIGURE 105 Menus with the (-)HC- ENTER THE ADVANCED INSTALLER MENU. TST550CMMS 1. From the main Thermostat screen, press the left 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 130 CHANGING FURNACE FIGURE 110 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 131 FIGURE 114 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 132 FIGURE 117 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.