Rheem RGRK SERIES Installation Instructions Manual
  1. Manuals
  2. Brands
  3. Rheem Manuals
  4. Furnace
  5. RGRK SERIES
  6. Installation instructions manual

Rheem RGRK SERIES Installation Instructions Manual

For upflow and downflow/horizontal high efficiency condensing two-stage gas furnaces
Hide thumbs
Table of Contents

Advertisement

Quick Links

INSTALLATION INSTRUCTIONS
FOR UPFLOW AND DOWNFLOW/HORIZONTAL
HIGH EFFICIENCY CONDENSING TWO-STAGE
GAS FURNACES
RGRK, RGRL, AND RGTK SERIES
ISO 9001:2008
U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all
applications, and their installation should be in accordance with the manufacturer's
recommendations and/or local laws, rules, regulations, or customs.
92-24161-36-22
SUPERSEDES 92-24161-36-21

Advertisement

Table of Contents
loading

Related Manuals for Rheem RGRK SERIES

Summary of Contents for Rheem RGRK SERIES

  • Page 1: Safety Precautions

    INSTALLATION INSTRUCTIONS FOR UPFLOW AND DOWNFLOW/HORIZONTAL HIGH EFFICIENCY CONDENSING TWO-STAGE GAS FURNACES RGRK, RGRL, AND RGTK SERIES U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all applications, and their installation should be in accordance with the manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

  • Page 2: Installation Check List

    INSTALLATION CHECK LIST TERMINATIONS – DIRECT VENT REFER TO INSTALLATION INSTRUCTIONS GAS SUPPLY VERTICAL ______ Intake – 12" min. above roof/snow level ______ Adequate pipe size ______ Correct supply pressure (during furnace operation) ______ Correct relationship – exhaust to intake ______ Manifold pressure ______ No gas leaks HORIZONTAL/VERTICAL –...

  • Page 3: Table Of Contents

    IMPORTANT: All manufacturer products meet current Federal OSHA CONTENTS Guidelines for safety. California Safety Precautions ....................1 Proposition 65 warnings are required for certain products, which are not Installation Check List ....................2 covered by the OSHA standards. General Information....................4 California's Proposition 65 requires warnings for products sold in California Safety Information ....................6 that contain, or produce, any of over...

  • Page 4: General Information

    GENERAL INFORMATION NOTE: A load calculation must be follows: performed to properly determine the 1. As non-direct vent central forced air CSA-INTERNATIONAL required furnace BTU size for the furnaces taking combustion air from 8501 East Pleasant Valley Road structure. Also, the duct must be properly the installation area or using air Cleveland, Ohio 44131-5575 designed and installed for proper airflow.
  • Page 5 FIGURE 2 IMPORTANT INFORMATION MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES ABOUT EFFICIENCY AND INDOOR AIR QUALITY Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality, it is important to have the proper balance between the air...

  • Page 6: Safety Information

    SAFETY INFORMATION WARNING WARNING WARNING NEVER TEST FOR GAS LEAKS WHEN THIS FURNACE IS USE ONLY WITH TYPE OF GAS WITH AN OPEN FLAME. USE A APPROVED FOR THIS FURNACE. INSTALLED IN A RESIDENTIAL REFER TO THE FURNACE RATING COMMERCIALLY AVAILABLE GARAGE, IT MUST BE INSTALLED PLATE.
  • Page 7 IMPORTANT! WARNING 4. INSPECTION. The state or local gas inspector of the side wall THE COMMONWEALTH OF horizontally vented gas fueled DUCT LEAKS CAN CREATE AN MASSACHUSETTS REQUIRES equipment shall not approve the UNBALANCED SYSTEM AND DRAW COMPLIANCE WITH REGULATION installation unless, upon inspection, POLLUTANTS SUCH AS DIRT, DUST, 248 CMR 4.00 AND 5.00 FOR...

  • Page 8: Location Requirements And Considerations

    LOCATION REQUIREMENTS AND CONSIDERATIONS GENERAL INFORMATION WARNING b. install a parallel duct system (0°C), a self-regulating heat tape to divert all the air from the is required on the condensate DO NOT INSTALL THIS FURNACE furnace allowing it to pass drain, along with an insulation IN A MOBILE HOME!! This furnace is over the cooling coil only.

  • Page 9: Site Selection

    CAUTION Upflow furnaces are shipped with a bottom closure panel installed. When CLEARANCE - THIS FURNACE IS NOT bottom return air is used, remove the ACCESSIBILITY panel by removing the two screws APPROVED OR RECOMMENDED The design of forced air furnaces with attaching the panel to the front base FOR INSTALLATION ON ITS BACK, input ratings as listed in the table...
  • Page 10 FIGURE 5 CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS I392...
  • Page 11 FIGURE 6 CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS I393...
  • Page 12 FIGURE 7 CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS I520...

  • Page 13: Ducting

    DUCTING Proper air flow is required for the IMPORTANT: When using outside air, NOTE: Where the maximum air flow correct operation of this furnace. design and adjust the system to maintain is 1800 CFM or more, both sides or 1 Too little air flow can cause erratic a return air temperature ABOVE 55°...
  • Page 14 DOWNFLOW UNITS NOTE: DO NOT take return air from bathrooms, kitchens, furnace 1. Position the unit to minimize long rooms, garages, utility or laundry runs of duct or runs of duct with rooms, or cold areas. many turns and elbows. 2.

  • Page 15: Venting And Combustion Air Piping

    VENTING AND COMBUSTION AIR PIPING REQUIREMENT THAT VENT REPLACE THESE SWITCHES MATERIAL BE CERTIFIED TO ULC ONLY WITH THE IDENTICAL GENERAL INFORMATION S636 DOES NOT APPLY TO INLET REPLACEMENT PART. WARNING AIR PIPING. VENT TERMINATIONS AND CONCENTRIC TERMINATIONS READ AND FOLLOW ALL MUST BE APPROVED BY THE INSTRUCTIONS IN THIS SECTION.

  • Page 16: Joining Pipe And Fittings

    6. After it has been determined that 1. Cut pipe end square. Chamfer each appliance that remains edge of pipe. Clean fitting socket JOINING PIPE AND connected to the common and pipe joint area of all dirt, FITTINGS venting system properly vents WARNING grease and moisture.

  • Page 17: Combustion And Ventilation Air

    COMBUSTION AND VENTILATION AIR NON-DIRECT perchloroethylene) FURNACE INSTALLATIONS Input With 8' Ceiling With 8' Ceiling • Printing inks, paint removers, WARNING varnishes, etc. 45,000 14' x 20' OR 16' x 18' 60,000 15' x 25' OR 19' x 20' • Hydrochloric acid THE FURNACE AND ANY OTHER 75,000 15' x 31' OR 20' x 24'...
  • Page 18 FIGURE 10 Input Each Opening AIR FROM HEATED SPACE 45,000 100 square inches 60,000 100 square inches 75,000 100 square inches 90,000 100 square inches 105,000 105 square inches 120,000 120 square inches B. USING OUTDOOR AIR FOR NOTE: COMBUSTION EACH OPENING SHALL HAVE A FREE AREA OF IMPORTANT: Do not take air from...
  • Page 19 CONSULT LOCAL CODES FOR One permanent opening, located within 12 inches of the top of the SPECIAL REQUIREMENTS. BTUH Free Area Round Pipe enclosure, shall be permitted Input Each Opening Size where the equipment has 45,000 15.00 square inches 4" clearances of at least 1 inch from CONNECTION TO 60,000...

  • Page 20: Vent Pipe Installation

    VENT PIPE INSTALLATION TABLE 2 UPFLOW UNITS NON-DIRECT VENT FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM INDOORS INSTALLATION GUIDELINES IMPORTANT: Failure to correctly follow MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE all venting guidelines may result in NUMBERS OF ELBOWS erratic furnace operation, freeze-up of 45°...
  • Page 21 STANDARD INSTALLATIONS Non-direct venting location In addition to the minimum clearances requirements are slightly different in listed above, the vent location should The single-pipe system requires an some cases than direct venting. Install also be governed by the following exhaust pipe only. Combustion air may a non-direct vent with the following guidelines.
  • Page 22 FIGURE 16 OTHER THAN DIRECT VENT TERMINAL CLEARANCES...

  • Page 23: Direct Vent Installations

    TABLE 4 DIRECT VENT UPFLOW UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM OUTDOORS INSTALLATIONS WARNING MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE READ AND FOLLOW ALL NUMBER OF ELBOWS INSTRUCTIONS IN THIS SECTION. 45 or 90 Degrees FURNACE PIPE...
  • Page 24 allowable length in feet of the exhaust prevent entry of rain. See Figure 19 termination. The exhaust vent for and combustion air intake pipes that models with inputs of 90,000 through for the proper relationship of may be used for all furnace inputs as 120,000 BTUH is 2-in.
  • Page 25 • Insulate the entire length of vent FIGURE 17 pipe, between the elbow where the ALTERNATE HORIZONTAL DIRECT VENT TERMINATION pipe exits the wall and the elbow where the termination is made, with EXHAUST VENT " PVC FOR MODELS WITH 120,000 BTU INPUT a closed-cell insulation, such as (KIT NO.
  • Page 26 CONCENTRIC NOTE: The following IPEX brand TERMINATIONS concentric termination (System 636) may be purchased in the field and VERTICAL/HORIZONTAL used in place of factory supplied kits: CONCENTRIC VENT 3” Concentric Kit – Item # 196006 KIT NO. (-)XGY-E03A This kit is for vertical/horizontal intake air/vent runs and may be installed through roofs or sidewalls.
  • Page 27 FIGURE 19 STANDARD VERTICAL DIRECT VENTING 3" EXHAUST MAX. VENT COMBUSTION AIR PIPE 12" 3" MAX. MIN. SEPARATION 3" EXHAUST 12” MAX. VENT 12" 36" MAX. EXHAUST COMBUSTION AIR COMBUSTION MIN. TERMINATION PIPE AIR PIPE 12" DETAIL A MIN. 12" MIN. 30”...
  • Page 28 In addition to the minimum clearances 5. Do not locate too close to shrubs listed above, the vent location as condensate may stunt or LOCATION REQUIREMENTS should also be governed by the kill them. HORIZONTAL DIRECT VENTS following guidelines. 6. Minimum vertical clearances of 1 CAUTION foot are recommended for 1.
  • Page 29 FIGURE 22 DIRECT VENT TERMINAL CLEARANCES...
  • Page 30 FIGURE 23 FIGURE 24 TWO FURNACE VENTING THROUGH ROOF TWO FURNACE VENTING THROUGH WALL TWO-PIPE VENTING TWO-PIPE VENTING COMBUSTION AIR INTAKE 2”PVC 3" MIN. 24" MAX. COMBUSTION AIR INTAKE 2”PVC COUPLING WITH VALVE IN VERTICAL POSITION EXHAUST VENT 3" MIN. 24"...
  • Page 31 NOTE: Install the vent and air intake NOTE: The vent illustration in Figure piping into the vent plate openings. 26 can be used for non-direct vent (-)XGY-G02 Side Wall Vent This termination for horizontal venting Seal all gaps between the pipes and terminations also.
  • Page 32 FIGURE 27 CONNECTING TO FURNACE IMPORTANT: Clean and debur all UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION pipe cuts. The shavings must not be allowed to block the exhaust, combustion air or condensate drain pipes. “O”RING COMBUSTION AIR ADAPTER TOP PLATE NOTE: UPFLOW FURNACE WHEN COMBUSTION AIR IS IN...

  • Page 33: Condensate Drain/Neutralizer

    CONDENSATE DRAIN/NEUTRALIZER IMPORTANT: If installing the unit over Use a solvent cement that is a finished ceiling or living area, be compatible with PVC material. Cut the GENERAL INFORMATION CAUTION certain to install an auxiliary condensate drain hoses to the appropriate length drain pan under the entire unit and connect to the trap with hose extending out under the condensate...
  • Page 34 FIGURE 30 REVERSING THE TRAP UPFLOW UNITS UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION The trap may be moved to the right PROPER DRAIN SLOPE REQUIRED side for right side drainage. Open the (NO KINKS ALLOWED) CUT DRAIN HOSES AS knockout for the drain on the right REQUIRED side of the cabinet.
  • Page 35 CONDENSATE DRAIN FIGURE 32 FOR HORIZONTAL DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION INSTALLATION Refer to Figure 33 for Steps 1-4. This unit is shipped factory ready for downflow installation. The DRAIN UNION condensate trap assembly and drain VENT hoses require conversion for DRAIN horizontal installation.

  • Page 37: Gas Supply And Piping

    GAS SUPPLY AND PIPING FIGURE 35 GAS SUPPLY GAS PIPING INSTALLATION WARNING UPFLOW THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON GROMMET MANUAL NATURAL GAS ONLY. NOTE: WHEN GAS LINE STOP CONVERSION TO LP GAS IS IN OPT. POSITION, TOP VIEW OF GAS LINE AND VALVE REQUIRES A SPECIAL KIT IS SWAP LOCATION OF...

  • Page 38: Gas Pressure

    use a pipe compound resistant to the TABLE 6 action of liquefied petroleum gases on all threaded connections. NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.) IMPORTANT: When making gas pipe connections, use a back-up wrench to 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).

  • Page 39: Setting Gas Pressure

    LP CONVERSION SETTING GAS PRESSURE IMPORTANT: LP gas from trucks spuds for either conversion to LP or for The maximum gas supply pressure used to transport liquid-based elevation: natural gas, or 13" w.c. LP gas. The to the furnace should be 10.5" w.c. fertilizers can contain chemicals that 1.
  • Page 40 be 3.5" w.c.; LP gas manifold FIGURE 37 pressure should be 10" w.c. Only MANIFOLD PRESSURE TAP small variations on gas pressure should be made by adjusting the pressure regulator. 1. With the gas shut off at the manual gas stop, remove the pressure tap plug in the gas manifold or the gas valve outlet.
  • Page 41 FIGURE 39 TYPICAL MANIFOLD PRESSURE READING...

  • Page 42: Electrical Wiring

    ELECTRICAL WIRING WARNING furnace. Connect from the electrical board “Status” L.E.D. See Figure 40. disconnect to the junction box on the left Make all electrical connections in TURN OFF ELECTRIC POWER AT side of the furnace, inside the blower accordance with the latest edition of FUSE BOX OR SERVICE PANEL compartment.

  • Page 43: Accessories

    FIGURE 41 THERMOSTAT WIRING OPTIONS 2 HEAT - 1 COOL 1 HEAT, 1 COOL (OPTION A) TIMED STAGING W/1 STAGE HEAT T-STAT (AFTER F3507 DATE CODE (AUGUST 2007) 2 HEAT - 2 COOL 1 HEAT, 1 COOL (OPTION B) 100% HEAT ALWAYS -- NO TIMED STAGING THERMOSTAT FIELD-INSTALLED OPTIONAL ACCESSORIES NOTE: Do not use 24 volt control wiring...

  • Page 44: Furnace Twinning

    TABLE 9 FIELD WIRE SIZE FOR 24 VOLT CONTROL CIRCUITS SOLID COPPER WIRE - AWG LENGTH OF RUN - FEET ΠΠWire length equals twice the run distance NOTE: Do not use 24 volt control wiring smaller than No. 18. FIGURE 42 ISOLATION RELAY Both controls must have jumper P7 in...
  • Page 45 FIGURE 43 UT Electronic Controls 1095-201 IFC, TWINNING CONNECTION -- SINGLE STAGE OPERATION...
  • Page 46 FIGURE 44 UT ELECTRONIC CONTROLS 1095-202 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION...
  • Page 47 FIGURE 45 UT ELECTRONIC CONTROLS 1095-202 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION...

  • Page 48: High Altitude Installations

    90+ HIGH ALTITUDE HIGH ALTITUDE KIT Alternately, furnaces can be ordered from the factory already converted for INSTRUCTIONS Installer must make necessary burner high altitude elevations. The factory orifice and pressure switch changes as option for high altitude elevations NATURAL GAS indicated in the table below: would be ordered as a 278 option CAUTION...

  • Page 50: Altitude Derate

    36,450 pressure at the orifice, which differs from 54,000 48,600 54,000 48,600 67,500 60,750 67,500 60,750 Rheem products that use 10" of water 2001’ - 4500’ 3.0” W.C. 2001’ - 4500’ 1.10mm 7.6” W.C. 81,000 72,900 81,000 72,900 column at the orifice. This difference...

  • Page 51: Start-Up Procedures

    START-UP PROCEDURES A gas furnace’s firing rate, temperature FIRE OR AN EXPLOSION stage thermostat with the timed RESULTING IN PROPERTY rise and operation should be checked staging feature. If the jumper is left DAMAGE, PERSONAL INJURY OR after installation. During this process we on “NONE”, the furnace will never recommend that doors and windows be DEATH.
  • Page 52 gas valve to 100% and the main b. After a 30 second pre-purge the spark Main blower starts on high speed blower goes to high-fire heating igniter energizes and the gas valve 20 seconds after gas valve speed. (high stage) opens, lighting the energizes.
  • Page 53 ADJUSTING OR CHECKING FURNACE INPUT A properly calibrated manometer or TABLE 14 gauge is required for accurate gas METER TIME pressure readings. NATURAL GAS 1. When adjusting the furnace input, METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES EQUIPPED FOR NATURAL OR LP GAS the high fire input should be checked.

  • Page 54: Air Flow

    RISE RANGE IS 40 TO 70 DEGREES, FIGURE 49 THE MOST IDEAL RISE WOULD BE AIR FLOW TEMPERATURE RISE MEASUREMENT The importance of proper air flow over the 55 DEGREES (THE MIDDLE OF THE heat exchanger cannot be over RISE RANGE). IN ALL emphasized.
  • Page 55 GAS FURNACE (DIRECT DRIVE) INSTRUCTIONS FOR CHANGING BLOWER SPEED WARNING DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. The blower motor is wired for blower speeds required for normal operation as shown.
  • Page 56 TABLE 15 90 PLUS AIR FLOW PERFORMANCE CFM @ ESP MODEL BLOWER/ SPEED MOTOR HP UPFLOW MODELS (-)GRL-04 11 X 7 / ⁄ *M-LO M-HI 1140 1110 1085 1045 1010 HIGH 1360 1320 1280 1235 1195 1140 1080 (-)GRL-07(A) 11 X 7 / ⁄...

  • Page 57: Maintenance

    TABLE 16 MAINTENANCE WARNING FILTER SIZES THESE INSTRUCTIONS ARE UPFLOW FILTER SIZES INTENDED AS AN AID TO FURNACE INPUT BOTTOM SIDE QUANTITY QUALIFIED SERVICE PERSONNEL WIDTH MBTUH SIZE SIZE FOR PROPER INSTALLATION, " 45, 60, 75A " X 25" " X 25" ADJUSTMENT AND OPERATION 21"...
  • Page 58 UPFLOW BOTTOM RETURN FIGURE 52 BOTTOM PANEL REMOVAL JACKET ASSEMBLY FILTER LOCATION JACKET ASSEMBLY REMOVE SOLID BOTTOM AIRFLOW FILTER FILTER FILTER & ROD LOCATION NOTE: BACK FLANGE OF SOLID BOTTOM FITS UNDERNEATH JACKET. SIDES AND FRONT SCREW FLANGES FIT OVER FLANGES ON JACKET. (2) REQ’D.

  • Page 59: Troubleshooting

    WARNING SUPPLY REGISTERS. ANY it is recommended that a qualified RECIRCULATED DUST PARTICLES installer, service agency, or the gas WILL BE HEATED AND CHARRED BY supplier annually inspect the flue DISCONNECT MAIN ELECTRICAL CONTACT WITH THE FURNACE passageways, the vent system and POWER TO THE UNIT BEFORE HEAT EXCHANGER.
  • Page 60 FIGURE 53 TROUBLESHOOTING CHART Go To Next Page...
  • Page 61 FIGURE 53 TROUBLESHOOTING CHART (CONTINUED)

  • Page 62: Wiring Diagram

    FIGURE 54 WIRING DIAGRAM...
  • Page 64 CM 0510...

This manual is also suitable for:

Rgrl seriesRgtk series

Table of Contents