Rheem RGPK - User Manual

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INSTALLATION INSTRUCTIONS

FOR UPFLOW/HORIZONTAL (RGPK) AND DOWNFLOW

(RGLK) TWO STAGE INDUCED DRAFT GAS FURNACES

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 POISONING,

EXPLOSION, PROPERTY

DAMAGE, PERSONAL INJURY

OR DEATH.

Do Not Destroy this Manual.

Please read carefully and keep

in a safe place for future

reference by a serviceman.

WARNING

Recognize this symbol as an indication of Important Safety Information!

— 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 installation 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.

WARNING

PROPOSITION 65: THIS FURNACE CONTAINS FIBERGLASS

INSULATION. RESPIRABLE PARTICLES OF FIBERGLASS ARE

KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER.

EXHAUST GAS FROM THIS FURNACE CONTAINS CHEMICALS,

INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF

CALIFORNIA TO CAUSE BIRTH DEFECTS OR OTHER REPRO-

DUCTIVE HARM.

WARNING

FOR YOUR SAFETY

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This manual describes the installation and operation of Rheem Upflow/Horizontal (RGLK) and Downflow (RGLK) Two Stage Induced Draft Gas Furnaces. These furnaces are designed for either upflow, horizontal, or downflow applications and are equipped with a two-stage induced draft blower and a two-stage main blower. They operate at full input and 70% of full input. The furnaces are certified by AGA/CGA for use with natural or propane gases.

Function Description

The Rheem RGLK series furnaces are designed to provide efficient heating for residential and commercial spaces. They feature a two-stage operation, allowing them to run at a lower capacity (70% of full input) for most heating demands, which can lead to increased efficiency and comfort. When higher heating is required, the furnace can switch to full input. The induced draft blower assists in expelling combustion gases, while the main blower circulates heated air throughout the building.

Important Technical Specifications

Fuel Type: Natural gas or propane gas (requires conversion kit for LP gas).
Efficiency: 70% of full input for two-stage operation.
Blower: Two-stage induced draft blower and two-stage main blower.
Installation: Upflow, horizontal, or downflow applications.
Clearances to Combustible Materials: Specific clearances are provided for top, bottom, left side, right side, back, front, and vent, varying by model and configuration (upflow/horizontal and downflow). For example, a 14" furnace model 05 in an upflow/horizontal configuration requires 12" on the right side, 10" on the left side, 0" on the back, 1" on the front, and 3" for the vent. Reduced clearances are possible with specific adapters.
Electrical: Requires 115VAC supply. Specific wiring diagrams are provided for single-stage and two-stage thermostat connections.
Gas Supply Pressure: Minimum supply pressure is 10.5" w.c. for natural gas and 11"-13" w.c. for LP gas. Maximum supply pressure is 0.5" w.c.
Manifold Pressure: 3.5" w.c. for natural gas and 10" w.c. for LP gas.
Airflow: Performance data tables provide CFM airflow at various external static pressures for different models and blower speeds (low, med-low, med-hi, hi).
Filter Sizes: Various filter sizes are specified for upflow and downflow models, ranging from 14" to 24.5" in width and 20" to 25" in length.

Usage Features

Two-Stage Operation: Allows for more precise temperature control and energy savings by operating at 70% capacity for most heating needs.
Thermostat Compatibility: Compatible with single-stage and two-stage thermostats. The manual provides wiring diagrams for both configurations.
Ventilation: Detailed instructions for proper venting, including vent pipe sizing, materials, and connections to existing vent systems. B-1 vent systems are supported, with specific requirements for vertical height and horizontal runs.
Combustion Air: Guidelines for ensuring adequate combustion air, including requirements for outdoor air and air from heated/attic/crawl spaces. Specific free area openings are provided based on BTU input.
LP Gas Conversion: The furnace can be converted to use LP gas with a specific conversion kit. Detailed instructions are provided for changing orifices and adjusting the gas valve.
Blower Control: The integrated furnace control board manages blower operation, with settings for continuous fan operation and different speeds for heating and cooling.
Temperature Rise Measurement: Instructions for checking the temperature rise across the furnace to ensure it falls within the specified range on the furnace nameplate.

Maintenance Features

Filter Maintenance: Regular cleaning or replacement of air filters is crucial for efficient operation. The manual provides instructions for filter installation and sizing.
Annual Inspection: It is recommended that the furnace be inspected annually by a qualified service agency. This includes checking the heat exchanger, burners, wiring, and overall operation.
Troubleshooting: A detailed troubleshooting guide is provided, including flowcharts for diagnosing issues with the integrated furnace control (IFC) board, such as induced draft errors, pressure switch problems, and igniter failures.
System Operation Information: Provides guidance on how to check the heating system, ensure proper airflow, and address common issues like excessive noise or odors.
Cleaning: Instructions for cleaning the induced draft blower and burner box.
Lubrication: The blower motor and induced draft motor are permanently lubricated and do not require further attention.
Component Replacement: Instructions for replacing components like the induced draft blower and main blower.

Safety Precautions

The manual emphasizes several safety warnings, including:

Carbon Monoxide Poisoning: Improper installation, operation, or maintenance can lead to carbon monoxide poisoning, which can cause serious injury or death.
Explosion/Fire Hazard: Failure to follow instructions regarding gas supply and clearances can result in fire or explosion.
Electrical Shock: Disconnecting main electrical power before servicing is crucial to prevent electrical shock.
Fiberglass Insulation: The furnace contains fiberglass insulation, which can cause cancer. Proper handling and personal protective equipment are recommended.
Chemicals: The furnace contains chemicals known to cause birth defects or reproductive harm.
Gas Leaks: Instructions on how to detect and respond to gas leaks, including immediately leaving the area and contacting the gas supplier.
Combustible Materials: Strict adherence to clearance requirements from combustible materials is essential to prevent fire.
Ventilation: Proper ventilation and combustion air supply are critical to prevent hazardous conditions.