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Rheem RGRA SERIES - User Manual

Rheem RGRA SERIES
64 pages
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!
If the information in these instructions is not followed exactly, a
fire or explosion may result, causing property damage, personal
injury or death.
INSTALLATION INSTRUCTIONS
FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH
EFFICIENCY CONDENSING GAS FURNACES
RGRA/RGRJ AND RGTA/RGTJ SERIES
92-23531-16-09
SUPERSEDES 92-23531-16-08
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
REPRODUCTIVE HARM.
WARNING
!
FOR YOUR SAFETY
!

Questions and Answers:

Rheem RGRA SERIES Specifications

General IconGeneral
EfficiencyUp to 96% AFUE
TypeGas Furnace
Ignition SystemDirect Spark Ignition
Installation OptionsUpflow, Downflow, Horizontal
Fuel TypeNatural Gas or Propane
ConfigurationMulti-Position
IgnitionDirect Spark
Heat ExchangerStainless Steel
Vent TypePVC
WarrantyLimited Lifetime Heat Exchanger, 10-Year Parts
StagesSingle or Two-Stage

Summary

Installation Instructions

General Safety and Warning Information

Crucial safety warnings, precautions, and general safety information for furnace installation and operation.

Installation Check List

System Installation Checklist Items

A comprehensive checklist covering gas supply, electrical, furnace, and venting requirements.

General Information

Furnace Model Identification and Standards

Overview of RGRA/RGRJ/RGTA/RGTJ series, relevant codes, and industry standards.

Location Requirements and Considerations

Furnace Placement and Environmental Guidelines

Guidelines for furnace placement, clearances, and considerations for unconditioned spaces.

Clearance and Accessibility Requirements

Service Access and Combustible Material Clearances

Requirements for service accessibility and clearances to combustible materials for safe installation.

Site Selection Criteria

Furnace Location Selection Factors

Factors to consider when selecting the furnace site, including duct and gas piping proximity.

Ducting Requirements

Airflow and Duct Connection Guidelines

Proper airflow, duct sizing, and connection procedures for upflow and downflow units.

Venting and Combustion Air Piping

Venting and Air Supply System Guidelines

Procedures for venting, combustion air supply, safety switches, and existing vent systems.

Joining Pipe and Fittings

PVC Pipe and Fitting Cementing Procedures

Detailed steps for cementing PVC pipes and fittings, including safety warnings.

Combustion and Ventilation Air

Air Supply for Non-Direct Vent Installations

Requirements for adequate combustion and ventilation air for non-direct furnace installations.

Combustion Air for Direct Vent

Direct Vent Combustion Air Supply System

Specific requirements for the combustion air intake system in direct vent furnace installations.

Vent Pipe Installation

Non-Direct Vent Installation Guidelines

Rules and limitations for non-direct vent pipe installation, including length and elbow requirements.

Non-Direct Vent Termination Location

Vent Termination Clearances and Placement

Clearances and placement criteria for non-direct vent terminals to ensure safety and prevent nuisances.

Direct Vent Installations

Direct Vent Installation Guidelines and Tables

Installation procedures for direct vent systems, including pipe length, elbows, and termination tables.

Direct Vent Combustion Air and Exhaust

Direct Vent Piping Requirements

Specific piping requirements for combustion air and exhaust in direct vent furnace applications.

Location Requirements for Horizontal Direct Vents

Horizontal Direct Vent Termination Placement Rules

Placement and clearance rules for horizontal direct vent terminals to prevent condensate issues.

Multiventing Procedures

Guidelines for Venting Multiple Furnaces

Instructions and recommendations for venting two or more furnaces, emphasizing individual venting.

Connecting to Furnace

Combustion Air and Vent Pipe Connections

Procedures for connecting vent and combustion air pipes to the furnace for upflow and downflow models.

Condensate Drain and Neutralizer

Condensate Handling and Neutralization Steps

Instructions for setting up condensate drains, using neutralizers, and preventing overflows.

Reversing the Trap

Condensate Trap Drainage Configuration Options

Procedures for reconfiguring the condensate trap for alternative drainage sides on upflow/downflow units.

Condensate Drain for Horizontal Installation

Horizontal Condensate Trap Conversion Process

Detailed steps for converting the condensate trap assembly for horizontal furnace installation.

Gas Supply and Piping

Gas Supply and Piping Installation Procedures

Requirements for connecting the gas supply, piping, shut-off valves, and drip legs.

Gas Pressure Management

Gas Pressure Measurement and Adjustment Guide

Methods for measuring and adjusting supply and manifold gas pressures for optimal furnace input.

LP Conversion Procedures

Converting Furnace for LP Gas Use

Steps for converting the furnace to LP gas, including orifice changes and required labeling.

Setting Gas Pressure

Manifold Gas Pressure Adjustment and Verification

Procedures for setting and verifying manifold gas pressure for both natural gas and LP gas.

Electrical Wiring

Electrical Connections, Grounding, and Safety

Guidelines for safe electrical wiring, proper grounding, and component connections.

Thermostat and Low Voltage Wiring

Thermostat Compatibility and Low Voltage Wiring

Information on thermostat compatibility and proper low voltage wiring size and connections.

Accessories and Twinning

Optional Accessories and Furnace Twinning Kits

Details on field-installed accessories and procedures for twinning furnace units.

Start-Up Procedures

Furnace Start-Up Sequence and Operation

Step-by-step guide for starting the furnace, including sequence of operations and safety checks.

Adjusting Furnace Input

Calculating and Setting Furnace Input Rate

Method for measuring and adjusting furnace gas input rate using meter time and pressure.

Air Flow Management

Temperature Rise Check for Air Flow Verification

Procedure for checking air flow correctness by measuring temperature rise across the furnace.

Setting Blower Timings

Blower Speed and Off-Timing Adjustments

How to adjust blower speeds and set off-timings for heating, cooling, and fan operation.

Maintenance Procedures

Filter Maintenance and Resizing Instructions

Guidelines for cleaning, replacing, and resizing furnace filters for optimal performance.

System Operation and Inspection

Annual Inspection and Troubleshooting Reference

Recommendations for annual inspections, system operation advice, and troubleshooting references.

Troubleshooting Integrated Furnace Controls

IFC Troubleshooting Guide (Honeywell;UTEC)

Flowcharts for diagnosing issues with Honeywell S9201E2001 or UTEC 1012-920 control boards.

Troubleshooting Integrated Furnace Controls

IFC Troubleshooting Guide (UTEC;Johnson Spark Ignition)

Flowcharts for diagnosing issues with UTEC 1028-927 or Johnson Controls G961DAJ-2401 control boards.

Wiring Diagrams

Wiring Diagram (Honeywell;UTEC 1012-920)

Detailed wiring diagram for RGRA/RGTA models with Honeywell or UTEC 1012-920 control boards.

Wiring Diagrams

Wiring Diagram (UTEC 1028-927;Johnson G961 DAJ-2401)

Wiring diagram for RGRA/RGTA models with UTEC 1028-927 or Johnson Controls G961DAJ-2401 boards.

Wiring Diagrams

Wiring Diagram (UTEC 1012-925)

Wiring diagram for RGRJ/RGTJ models with UTEC 1012-925 control boards and HSI.

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