Start-Up Procedures - Rheem RGRK SERIES Installation Instructions Manual

START-UP PROCEDURES

A gas furnace's firing rate, temperature
rise and operation should be checked
after installation. During this process we
recommend that doors and windows be
opened, smoke alarms disabled
temporarily, as furnaces may have
some residual smoke and odor upon
initial operation through the first heating
cycle. We do all we can to control our
manufacturing processes, but it is
possible to have this issue on certain
sizes and models on occasion. Failure
to follow this caution could result in a
nuisance smoke (fire call) or other
smoke or odor complaint from the
customer.
DIRECT SPARK IGNITION
LIGHTING INSTRUCTIONS
This appliance is equipped with a direct
spark ignition device. This device lights
the main burners each time the room
thermostat (closes) calls for heat. See
lighting instructions on the furnace.
During initial start-up, it is not unusual
for odor or smoke to come out of any
room registers. It is recommended to
ensure proper ventilation by opening
windows and doors, before initial firing.
The furnace has a negative pressure
switch that is a safety during a call for
heat. The induced draft blower must pull
a negative pressure on the heat
exchanger to close the negative
pressure switch. The induced draft
blower must maintain at least the
negative pressure switch set point for
the furnace to operate. If the induced
draft blower fails to close or maintain the
closing of the negative pressure switch,
a "no heat call" would result.
WARNING
TO START FURNACE
1. BE SURE THAT THE MANUAL GAS
STOP HAS BEEN IN THE "OFF"
POSITION FOR AT LEAST FIVE
MINUTES. DO NOT ATTEMPT TO
MANUALLY LIGHT THE MAIN
BURNERS. FAILURE TO FOLLOW
THIS WARNING CAN CAUSE A
FIGURE 47
UPFLOW OPTIMUM IGNITOR LOCATION
FIRE OR AN EXPLOSION
RESULTING IN PROPERTY
DAMAGE, PERSONAL INJURY OR
DEATH.
2. Set the room thermostat to the lowest
setting.
3. Remove furnace panel.
4. Turn the gas control knob to the "ON"
position, or set the gas control switch
to the "ON" position.
5. Securely replace furnace panel.
6. Turn on the manual gas stop and the
electrical power.
7. Set the room thermostat to "Heat" and
adjust to desired room temperature.
8. Complete installation checklist.
WARNING
SHOULD OVERHEATING OCCUR OR
THE GAS SUPPLY FAIL TO SHUT
OFF, SHUT OFF THE MANUAL GAS
STOP TO THE APPLIANCE BEFORE
SHUTTING OFF THE ELECTRICAL
SUPPLY. FAILURE TO DO SO CAN
CAUSE AN EXPLOSION OR FIRE
RESULTING IN PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
IGNITOR PLACEMENT,
ALIGNMENT & LOCATION
Ignition failure may be a result of
improper ignitor alignment caused during
a service call or other work done to the
furnace in the field. When performing any
work on the burner, heat exchanger, etc.,
the technician must check alignment of
the spark ignitor. Misalignment of the
ignitor could cause a failure to light or
rough ignition. The correct ignitor
alignment is shown in Figure 47.
Sequence of operation with a single
stage heat thermostat
NOTE: Single-stage operation is
determined by the position of the jumper
at position P7 of the control board.
Options are 5 minutes between first and
second stage or 12 minutes between
first and second stage (see Figure 48).
Do not leave jumper at P7 in the
"NONE" position when using a single-
DOWNFLOW/HORIZONTAL OPTIMUM IGNITOR LOCATION
stage thermostat with the timed
staging feature. If the jumper is left
on "NONE", the furnace will never
reach high heat (100% heat).
For single-stage operation, "W" from
the thermostat must be connected to
"W" on the furnace control.
See the section of this book titled
"Electrical Wiring – Thermostat" for a
wiring diagram showing how to
connect a thermostat (see Figure
41).
a. Connect the "W" terminal on the
thermostat to the "W" terminal on
the IFC. Do not connect any wire
to "W" on IFC when using a single-
stage thermostat.
b. When there is a call for heat, the
"R" and "W2" contacts close and
the IFC runs a self check routine to
verify that both of the pressure
switch contacts are open. The limit
switch contacts are constantly
monitored.
c. The induced draft motor starts on
high until the low and high
pressure switch contacts close (a
maximum of 60 seconds), and
then runs for a 30-second pre-
purge. After the 30-second pre-
purge, the spark ignitor energizes
and the high stage of the gas valve
opens, lighting the burners.
d. After the gas valve energizes, the
remote flame sensor must prove
ignition for one second using the
process of flame rectification. If the
burners do not light or flame is not
sensed, the system goes through
another ignition sequence. It does
this up to 4 times.
e. The IBM starts on low speed 20
seconds after the burners light and
flame is sensed. The induced draft
motor and gas valve switch to low
speed. The furnace operates on
low fire for 12 minutes and then, if
the thermostat is not satisfied,
shifts to high fire, causing the draft
inducer to go to high speed, the
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