INSTALLATION INSTRUCTIONS FOR UPFLOW (RGDG & RGDJ), … · 2015. 9. 28. · 92-23531-70-01 SUPERSEDES 92-23531-70-00 INSTALLATION INSTRUCTIONS FOR UPFLOW (RGDG & RGDJ), UPFLOW/HORIZONTAL

92-23531-70-01SUPERSEDES 92-23531-70-00

INSTALLATION INSTRUCTIONSFOR UPFLOW (RGDG & RGDJ), UPFLOW/HORIZONTAL(RGPH & RGPJ), HORIZONTAL ONLY (RGVH & RGVJ)AND DOWNFLOW (RGLH & RGLJ) INDUCED DRAFTGAS FURNACES

!

If the information in these instructions is not followed exactly, afire or explosion may result, causing property damage, personalinjury or death.

THESE INSTRUCTIONS AREINTENDED AS AN AID TOQUALIFIED SERVICEPERSONNEL FOR PROPERINSTALLATION, ADJUSTMENTAND OPERATION OF THISUNIT. READ THESEINSTRUCTIONS THOROUGHLYBEFORE ATTEMPTINGINSTALLATION OROPERATION. FAILURE TOFOLLOW THESEINSTRUCTIONS MAY RESULTIN IMPROPER INSTALLATION,ADJUSTMENT, SERVICE ORMAINTENANCE, POSSIBLYRESULTING IN FIRE,ELECTRICAL SHOCK, CARBONMONOXIDE POISONING,EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

Do Not Destroy this Manual.Please read carefully and keepin a safe place for futurereference by a serviceman.

WARNING

Recognize this symbol as an indication of Important Safety Information!!

— Do not store or use gasoline or otherflammable vapors and liquids, or othercombustible materials in the vicinity of thisor 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 gassupplier’s instructions.

• If you cannot reach your gas supplier,call the fire department.

• Do not return to your home untilauthorized by the gas supplier or firedepartment.

— DO NOT RELY ON SMELL ALONE TODETECT LEAKS. DUE TO VARIOUSFACTORS, YOU MAY NOT BE ABLE TOSMELL FUEL GASES.• U.L. recognized fuel gas and CO

detectors are recommended in allapplications, and their installation shouldbe in accordance with the manufacturer’srecommendations and/or local laws,rules, regulations, or customs

— Improper installation, adjustment, alteration,service or maintenance can cause injury,property damage or death. Refer to thismanual. Installation and service must beperformed by a qualified installer, serviceagency or the gas supplier.

WARNING!

PROPOSITION 65: THIS FURNACE CONTAINS FIBERGLASSINSULATION. RESPIRABLE PARTICLES OF FIBERGLASS AREKNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER.EXHAUST GAS FROM THIS FURNACE CONTAINS CHEMICALS,INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OFCALIFORNIA TO CAUSE BIRTH DEFECTS OR OTHER REPRO-DUCTIVE HARM.

WARNING!

FOR YOUR SAFETY!

2

Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction issometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Makecopies of the checklist and complete one for every Low Profile Furnace service call for your records.

INSTALLATION CHECKLIST(Refer to this manual for specifics.)

GAS SUPPLY

Adequate pipe size

No gas leaks

Proper supply and manifold gas pressure (check with an accurate U-tube manometer with the furnace and all other gasappliances operating.)

ELECTRICAL

Correct thermostat and subbase Thermostat model Subbase model

Correct thermostat mode and setting

Correct line supply voltage

Correct polarity (important with hot surface ignition)

Correct furnace ground to electrical panel

DC microamp (µA) flame signal (hot surface ignition units)

Correct control voltage

Measure and set heat anticipator amperage

Air conditioning low voltage wires connected to terminals “Y” “C” - not with wire nuts

VENTING

Correct vent pipe diameter and length (according to AGA/GAMA tables) Vent connection size

Correct venting material (according to AGA/GAMA tables)

Correct lining for masonry chimneys

Adequate clearance from combustibles

Proper negative pressure reading in the vent

Vent pipe secured to induced draft blower housing

COMBUSTION AIR

Proper source of combustion air

Correct combustion air opening size

FURNACE INSTALLATION

Adequate clearance from combustibles

Adequate clearance for service

Proper air temperature rise (See furnace rating plate)

External static pressure inches w.c.

Correct filter(s)

Correct cooling coil or accessories (if equipped)

Adequate supply and return air ducting Return Air Duct Size Supply Air Duct Size

Air ducts sealed to prevent leakage

3

IMPORTANT: TO INSURE PROPER INSTALLATION AND OPERATION OFTHIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TOATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIRTHIS PRODUCT. UPON UNPACKING OF THE FURNACE, INSPECT ALLPARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.

CONTENTS

Safety Precautions ...................................................................................................1

Installation Check List ..............................................................................................2

Location Requirements and Considerations ............................................................4

Combustion and Ventilation Air ..............................................................................10

Vent Pipe Installation..............................................................................................13

Gas Supply and Piping...........................................................................................16

Electrical Wiring......................................................................................................20

Accessories ............................................................................................................21

Start-Up Procedures...............................................................................................26

Air Flow...................................................................................................................29

Maintenance...........................................................................................................34

Troubleshooting......................................................................................................36

Wiring Diagrams.....................................................................................................43

➤ Installation Instructions are updated on a regular basis. This is done asproduct changes occur or if new information becomes available. In thispublication, an arrow (➤) denotes changes from the previous edition or additionalnew material.

GENERAL INFORMATION1. IMPORTANT: If furnace operation

is required during construction, andair ladened with corrosivecompounds such as chlorine andfluorine are present, provisionsmust be taken to provide cleanoutdoor combustion and ventilationair to the furnace. Compounds ofchlorine and fluorine, when burnedwith combustion air, form acidswhich will cause corrosion of a heatexchanger. Some of thesecompounds are found in paneling,dry wall, tile adhesives, paints,stains and varnishes, solvents andmasonry cleaning materials.

2. NOTE: This furnace is shipped withheat exchanger support bracketsinstalled under the back of the heatexchanger. These may be removedbefore installation, but it is notrequired.

LOCATION

THIS FURNACE IS NOT APPROVEDFOR INSTALLATION IN A MOBILEHOME. DO NOT INSTALL THISFURNACE IN A MOBILE HOME.INSTALLATION IN A MOBILE HOMECOULD CAUSE FIRE, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.

3. IMPORTANT: This furnace is notapproved or recommended forinstallation on its back, with accessdoors facing upwards.

4. This furnace is suitable forinstallation in buildings constructed

on-site. This heating unit should becentralized with respect to the heatdistribution system as much aspracticable. When installed in autility room, the door of the roomshould be wide enough to allow thelargest part of the furnace to enter,or to permit the replacement ofanother appliance, such as a waterheater.

5. IMPORTANT: If installing the unitover a finished ceiling or livingarea, be certain to install anauxiliary condensate drain panunder any evaporator coil installedwith the furnace.

6. NOTE: These furnaces areapproved for installation in attics, aswell as alcoves, utility rooms,closets and crawlspaces. Provisions

must be made to prevent freezing ofcondensate.

7. IMPORTANT: Support this unitwhen installed. Since this furnaceis suitable for attic or crawl spaceinstallation, it may be installed oncombustible wood flooring or byusing support brackets. See Figure1.

8. IMPORTANT: If installing in autility room, be sure the door iswide enough to:

a. allow the largest part of thefurnace to pass; or

b. allow any other appliance (suchas a water heater) to pass.

4

The RGDG/RGDJ/RGLH/RGLJ andRGPH/RGPJ/RGVH/RGVJ seriesfurnaces are design certified byAGA/CGA for use with natural andpropane gases as follows:

As a Category I furnace, it may bevented vertically with type B-1 ventpipe and also may be commonvented as described in theseinstructions.

This furnace should be installed inaccordance with the American NationalStandard Z223.1 - latest edition booklet

entitled “National Fuel Gas Code”(NFPA 54) (in Canada, CAN/CGAB149.1 and .2 Installation Codes forgas burning appliances), and therequirements or codes of the local utilityor other authority having jurisdictionincluding local plumbing or waste watercodes.

Additional helpful publications availablefrom the “National Fire ProtectionAssociation” are: NFPA-90A –Installation of Air Conditioning andVentilating Systems 1985 or latest

edition. NFPA-90B – Warm Air Heatingand Air Conditioning Systems 1984.

These publications are available from:

National Fire Protection Association,Inc.

Batterymarch ParkQuincy, MA 02269

Canadian Gas Association178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3

GENERAL INFORMATION

LOCATION REQUIREMENTS AND CONSIDERATIONS

WARNING!

FIGURE 1HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

EXHAUSTVENT

GASPIPE

ELECTRICALCONDUIT

ST-A0799-01

5

REDUCED CLEARANCE (IN.)

Model A B C D E Left Right Back Top Front Vent Ship.Side Side Wgts.

04, 05 14 1227⁄32 103⁄8 ➀ 111⁄2 0 4➁ 0 1 3 6➂ 85 lbs.

06, 07 171⁄2 1611⁄32 121⁄8 ➀ 15 0 3➁ 0 1 3 6➂ 105 lbs.

10(A) 171⁄2 1611⁄32 121⁄8 ➀ 15 0 3➁ 0 1 3 6➂ 115 lbs.

10(B) 21 1927⁄32 137⁄8 ➀ 181⁄2 0 0 0 1 3 6➂ 120 lbs.

12 241⁄2 2311⁄32 155⁄8 ➀ 22 0 0 0 1 3 6➂ 140 lbs.

15 241⁄2 2311⁄32 155⁄8 ➀ 22 0 0 0 1 3 6➂ 150 lbs.

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)UPFLOW AND UPFLOW/HORIZONTAL MODELS

TOP

LEFT SIDE

FRONT

RIGHT SIDE

BOTTOM

241⁄2

2613⁄16

265⁄8

2411⁄32

2411⁄32

19⁄32

9⁄16

247⁄16

281⁄16

265⁄8

143⁄8111⁄2

34

13⁄8 DIA.

23

15

20D

7⁄8 DIA.

7⁄8 DIA.

19⁄3219⁄32

3⁄4

143⁄8111⁄2

11⁄4

2317⁄32

C

GAS CONNECTION

ELECTRICAL CONNECTION

OPTIONAL RETURN AIR CUTOUT(EITHER SIDE) FOR USE WITH

EXTERNAL SIDE FILTER FRAME

LOW VOLTAGE

E

A

B

R.A.

S.A.

➀ May require 3( to 4( or 3( or 5( adapter.➁ May be 0( with type B vent.➂ May be 1( with type B vent.

FIGU

RE

2U

PFLO

W A

ND

UP

FLOW

/HO

RIZ

ON

TA

L DIM

EN

SIO

NS

6

FIGU

RE

3

REDUCED CLEARANCE (IN.)


04, 05 14 1227⁄32 103⁄8 ➀ 13 1⁄8 0 4➁ 0 1 3 6➂ 85 lbs.

06, 07 171⁄2 1611⁄32 121⁄8 ➀ 16 5⁄8 0 3➁ 0 1 3 6➂ 105 lbs.

10(A) 171⁄2 1611⁄32 121⁄8 ➀ 16 5⁄8 0 3➁ 0 1 3 6➂ 115 lbs.

10(B) 21 1927⁄32 137⁄8 ➀ 20 1⁄8 0 0 0 1 6 6➂ 120 lbs.

12 241⁄2 2311⁄32 155⁄8 ➀ 23 5⁄8 0 0 0 1 3 6➂ 140 lbs.

15 241⁄2 2311⁄32 155⁄8 ➀ 23 5⁄8 0 0 0 1 3 6➂ 150 lbs.

TOP BOTTOM

241⁄2193⁄4

C A

B D

LOW VOLTAGE

GAS CONNECTION

ELECTRIC CONNECTION

ES.A.

R.A.

265⁄8

2613⁄16

63⁄16

203⁄8

233⁄8

5⁄8 5⁄8

3⁄4

5⁄8

34

233⁄8

203⁄8

63⁄16

247⁄16

265⁄8

201⁄8

281⁄16

7⁄8 DIA.

1⁄2 DIA.

13⁄8 DIA.


CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)DOWNFLOW MODELS

7

FIGU

RE

4REDUCED CLEARANCE (IN.)


04, 05 14 1227⁄32 103⁄8 ➀ 111⁄2 0 4➁ 0 1 3 6➂ 85 lbs.

06, 07 171⁄2 1611⁄32 121⁄8 ➀ 15 0 3➁ 0 1 3 6➂ 105 lbs.

10(A) 171⁄2 1611⁄32 121⁄8 ➀ 15 0 3➁ 0 1 3 6➂ 115 lbs.

10(B) 21 1927⁄32 137⁄8 ➀ 181⁄2 0 0 0 1 3 6➂ 120 lbs.

12 241⁄2 2311⁄32 155⁄8 ➀ 22 0 0 0 1 3 6➂ 140 lbs.

15 241⁄2 2311⁄32 155⁄8 ➀ 22 0 0 0 1 3 6➂ 150 lbs.

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)HORIZONTAL “ONLY” MODELS


TOP VIEW

FRONT

BOTTOM VIEW

LEFT END RIGHT END

19⁄32

D

BAC

281⁄16

241⁄2

2613⁄16

2411⁄32

2317⁄32

265⁄8

143⁄8111⁄2

111⁄2

11⁄4143⁄8

3⁄419⁄32

19⁄32

2411⁄32

265⁄8247⁄1620

34

E

13⁄8 DIA.7⁄8 DIA.

7⁄8 DIA.

S.A.

GASCONNECTION

LOWVOLTAGE

ELECTRICALCONNECTION

R.A.

IMPORTANT: This furnace is not approved or recommended forinstallation on its back, with access doors facing upwards.

CLEARANCE –ACCESSIBILITYThe design of forced air furnaces withinput ratings as listed in the tables onthe following pages are certified byA.G.A. Laboratories and CGA for theclearances to combustible materialsshown in inches.

See name/rating plate and clearancelabel for specific model number andclearance information.

Service clearance of at least 24 inchesis recommended in front of all furnaces.

ACCESSIBILITY CLEARANCES,WHERE GREATER, MUST TAKEPRECEDENCE OVER FIREPROTECTION CLEARANCES.

UPFLOW AND HORIZONTALINSTALLATION — Certified for use oncombustible floor.

FURNACES MUST NOT BEINSTALLED DIRECTLY ONCARPETING, TILE OR OTHERCOMBUSTIBLE MATERIAL OTHERTHAN WOOD FLOORING.INSTALLATION ON ACOMBUSTIBLE MATERIAL CANRESULT IN FIRE CAUSINGPROPERTY DAMAGE, SEVEREPERSONAL INJURY OR DEATH.

UNIT DESIGN IS CERTIFIED FORINSTALLATION ON NON-COMBUSTIBLE FLOOR. A SPECIALCOMBUSTIBLE FLOOR SUB-BASEIS REQUIRED WHEN INSTALLINGON A COMBUSTIBLE FLOOR.FAILURE TO INSTALL THE SUB-BASE MAY RESULT IN FIRE,PROPERTY DAMAGE, PERSONALINJURY OR DEATH. THIS SPECIALBASE IS OFFERED AS ANACCESSORY FROM THE FACTORY.SEE THE CLEARANCE LABELLOCATED INSIDE THE FURNACEFOR THE APPROPRIATE MODELNUMBER.

THE SPECIAL BASE IS NOTREQUIRED WHEN THE FURNACE ISINSTALLED ON TOP OF AN AIRCONDITIONING PLENUM.

A gas-fired furnace for installation in aresidential garage must be installed sothat the burner(s) and the ignitionsource are located not less than 18(above the floor and the furnace islocated or protected to avoid physicaldamage by vehicles.

KEPT CLEAR AND FREE OF ALLCOMBUSTIBLE MATERIALSINCLUDING GASOLINE AND OTHERFLAMMABLE VAPORS ANDLIQUIDS. PLACEMENT OFCOMBUSTIBLE MATERIALS ON,AGAINST OR AROUND THEFURNACE JACKET CAN CAUSE ANEXPLOSION OR FIRE RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.THE HOMEOWNER SHOULD BECAUTIONED THAT THE FURNACEAREA MUST NOT BE USED AS ABROOM CLOSET OR FOR ANYOTHER STORAGE PURPOSES.

DUCTINGProper air flow is required for thecorrect operation of this furnace. Toolittle air flow can cause erraticoperation and can damage the heatexchanger. The duct system mustcarry the correct amount of air forheating and cooling if summer airconditioning is used.

Size the ducts according to acceptableindustry standards and methods. Thetotal static pressure drop of the entiresystem should not exceed 0.5( w.c.

IMPORTANT: Some high efficiencyfilters have a greater than normalresistance to air flow. This canadversely affect furnace operation. BESURE TO CHECK AIR FLOW if usingany filter other than the factory-provided filter.

NEVER ALLOW PRODUCTS OFCOMBUSTION OR THE FLUEPRODUCTS TO ENTER THERETURN AIR DUCTWORK, OR THECIRCULATING AIR SUPPLY. ALLRETURN DUCTWORK MUST BEADEQUATELY SEALED ANDSECURED TO THE FURNACE WITHSHEET METAL SCREWS, ANDJOINTS TAPED. WHEN A FURNACEIS MOUNTED ON A PLATFORM,WITH RETURN THROUGH THEBOTTOM, IT MUST BE SEALEDAIRTIGHT BETWEEN THE FURNACEAND THE RETURN AIR PLENUM.THE RETURN AIR PLENUM MUSTBE PERMANENTLY ENCLOSED.NEVER USE A DOOR AS A PART OFTHE RETURN AIR PLENUM. THEFLOOR OR PLATFORM MUSTPROVIDE SOUND PHYSICALSUPPORT OF THE FURNACE,WITHOUT SAGGING, CRACKS,

UPFLOW UNIT DESIGN REQUIRESA SOLID METAL BASE PLATE (SEETABLE ON PAGE 8 OR FURNACECLEARANCE LABEL FOR PARTNUMBER) MUST BE IN PLACEWHEN THE FURNACE ISINSTALLED WITH SIDE OR REARAIR RETURN DUCTS. FAILURE TOINSTALL A BASE PLATE COULDCAUSE PRODUCTS OFCOMBUSTION TO BE CIRCULATEDINTO THE LIVING SPACE ANDCREATE POTENTIALLYHAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING.

When coils are used with air handlersor furnaces and installed above afinished ceiling or living area, it isrecommended that an auxiliary sheetmetal condensate drain pan befabricated and installed under entireunit. Failure to do so can result inproperty damage.

SITE SELECTION1. Select a site in the building near the

center of the proposed, or existing,duct system.

2. Give consideration to the ventsystem piping when selecting thefurnace location. Be sure the ventingsystem can get from the furnace tothe termination with minimal lengthand elbows.

3. Locate the furnace near the existinggas piping. Or, if running a new gasline, locate the furnace to minimizethe length and elbows in the gaspiping.

4. Locate the furnace to maintainproper clearance to combustibles asshown in the preceding tables.

COMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET OR WITHINTHE SPECIFIED CLEARANCES OFTHE VENT PIPE. THE AREAAROUND THE FURNACE MUST BE

8

CAUTION!

WARNING!

WARNING!

WARNING!

TABLE 1

FURNACE BASE BASEWIDTH PLATE NO. PLATE SIZE14( RXGB-D14 115⁄8( x 239⁄16(

171⁄2( RXGB-D17 151⁄8( x 239⁄16(

21( RXGB-D21 185⁄8( x 239⁄16(

241⁄2( RXGB-D24 255⁄8( x 239⁄16(

GAPS, ETC., AROUND THE BASE ASTO PROVIDE A SEAL BETWEENTHE SUPPORT AND THE BASE.

FAILURE TO PREVENT PRODUCTSOF COMBUSTION FROM BEINGCIRCULATED INTO THE LIVINGSPACE CAN CREATE POTENTIALLYHAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING THAT COULD RESULTIN PERSONAL INJURY OR DEATH.

DO NOT, UNDER ANYCIRCUMSTANCES, CONNECTRETURN OR SUPPLY DUCTWORKTO OR FROM ANY OTHER HEATPRODUCING DEVICE SUCH AS AFIREPLACE INSERT, STOVE, ETC.DOING SO MAY RESULT IN FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PERSONAL INJURYOR PROPERTY DAMAGE.

BLOWER AND BURNERS MUSTNEVER BE OPERATED WITHOUTTHE BLOWER DOOR IN PLACE.THIS IS TO PREVENT DRAWINGGAS FUMES (WHICH COULDCONTAIN HAZARDOUS CARBONMONOXIDE) INTO THE HOME THATCOULD RESULT IN PERSONALINJURY OR DEATH.

UPFLOW UNITS1. Position the unit to minimize long

runs or runs with many turns andelbows.

2. Open the return air compartment.

a. If using side or back return air,install the bottom base.

A SOLID METAL BASE PLATE, SEETABLE 1, OR FURNACECLEARANCE LABEL FOR PARTNUMBER MUST BE IN PLACEWHEN THE FURNACE ISINSTALLED WITH SIDE OR REARAIR RETURN DUCTS. FAILURE TOINSTALL A BASE PLATE COULDCAUSE PRODUCTS OFCOMBUSTION TO BE CIRCULATEDINTO THE LIVING SPACE ANDCREATE POTENTIALLYHAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING OR DEATH.

b. Cut an opening in the side orback. The opening should be cutthe full width of the knockouts onthe unit.

NOTE: Where the maxiumum air flowis 1800 CFM or more, both sides or thebottom must be used for return air.

3. Connect the return duct or return aircabinet to the unit. Make theconnection air tight to prevententraining combustion gases froman adjacent fuel-burning appliance.

4. Be sure to have adequate spacefor the unit filter.

NOTE: DO NOT take return air frombathrooms, kitchens, furnace rooms,garages, utility or laundry rooms, orcold areas.

5. If summer air conditioning is desired,position the indoor coil on the top ofthe unit. Insure that no air canbypass this coil.

6. Connect the supply air plenum to thefurnace plenum opening.

DOWNFLOW UNITS1. Position the unit to minimize long


2. If summer air conditioning is desired,position the indoor coil on thebottom of the unit. Insure that no aircan bypass this coil.

3. If installing on a combustible floorand not using an air conditioningplenum, install the specialcombustible floor base. See Figure 4.

THE DOWNFLOW FURNACEDESIGN IS CERTIFIED FORINSTALLATION ON A NON-COMBUSTIBLE FLOOR. USE THESPECIAL BASE SPECIFIED ON THEFURNACE CLEARANCE LABEL.FAILURE TO INSTALL THE SPECIALBASE MAY RESULT IN FIRE,PROPERTY DAMAGE, PERSONALINJURY OR DEATH. THIS SPECIAL

BASE IS SHIPPED FROM THEFACTORY AS AN ACCESSORY.

4. Connect the furnace to the supplyair plenum.

5. Connect the return air ducting to thereturn air opening at the top of theunit. Make the connection air tight toprevent entraining combustiongases from an adjacent fuel-burningappliance.



HORIZONTAL UNITS1. Position the unit to minimize long


2. If summer air conditioning is desired,position the indoor coil on the supplyair side of the unit. Insure that no aircan bypass this coil.

3. Connect the furnace to the supplyair plenum.

4. Secure the four angle bracketsshipped with the unit to the return airopening. See Figure 6. Connect thereturn air ducting to the return airopening at the top of the unit. Makethe connection air tight to prevententraining combustion gases froman adjacent fuel-burning appliance.



9

FIGURE 5COMBUSTIBLE FLOOR BASE

WARNING!

WARNING!

WARNING!

10

THIS FURNACE AND ANY OTHERFUEL-BURNING APPLIANCE MUSTBE PROVIDED WITH ENOUGHFRESH AIR FOR PROPERCOMBUSTION AND VENTILATIONOF THE FLUE GASES. MOSTHOMES WILL REQUIRE THATOUTSIDE AIR BE SUPPLIED INTOTHE FURNACE AREA. FAILURE TODO SO CAN CAUSE DEATH FROMCARBON MONOXIDE POISONING.

Adequate facilities for providing air forcombustion and ventilation must beprovided in accordance with section5.3, Air for Combustion andVentilation, of the National Fuel GasCode, ANSI, Z223.1 latest edition orCAN/CGA B149.1 and .2 or, applicableprovisions for the local building codes,and not obstructed so as to prevent theflow of air to the furnace.

OVERTEMPERATURESAFETY SWITCHESThis furnace is equipped with safetyswitches in the control compartment toprotect against overtemperatureconditions caused by inadequatecombustion air supply. The switchesare located just above the burners onthe furnace center panel on upflow anddownflow models and also on eachside of the burners onupflow/horizontal and horizontal “only”models, and must be manually reset iftripped. DO NOT jumper this switch. Ifthis switch should trip, a qualified

FIGURE 6HORIZONTAL RETURN AIR DUCT

FIGURE 7AIR FROM HEATED SPACE

furnace installer, service agency or thegas supplier should be called to checkand/or correct for adequate combustionair supply. If this unit is mounted in acloset, the door must be closed whenmaking this check of the installation.

DO NOT reset the overtemperatureswitch without taking corrective actionto assure that an adequate supply ofcombustion air is maintained under allconditions of operation.

Replace this switch only with theidentical replacement part.

IMPORTANT: Air for combustion andventilation must not come from acorrosive atmosphere. Any failure dueto corrosive elements in theatmosphere is excluded from warrantycoverage.

The following types of installation mayrequire OUTDOOR AIR forcombustion, due to chemicalexposures:

• Commercial buildings• Buildings with indoor pools• Furnaces installed in laundry rooms• Furnaces in hobby or craft rooms• Furnaces installed near chemical

storage areas.

Exposure to the following substancesin the combustion air supply may alsorequire OUTDOOR AIR forcombustion:

• Permanent wave solutions• Chlorinated waxes and cleaners• Chlorine-based swimming pool

chemicals• Water softening chemicals• De-icing salts or chemicals• Carbon tetrachloride• Halogen type refrigerants• Cleaning solvents (such as

perchloroethylene)• Printing inks, paint removers,

varnishes, etc.• Hydrochloric acid• Cements and glues• Antistatic fabric softeners for clothes

dryers• Masonry acid washing materials

COMBUSTION AND VENTILATION AIRWARNING!

FOUR ANGLE BRACKETS ARE SHIPPED WITH EACHUNIT THAT CAN BE INSTALLED HORIZONTALLY. THESEBRACKETS MAY BE USED TO SECURE THE RETURNAIR DUCT TO A HORIZONTAL UNIT.

Combustion air must be free of acidforming chemicals; such as sulphur,fluorine and chlorine. These elementsare found in aerosol sprays,detergents, bleaches, cleaningsolvents, air fresheners, paint andvarnish removers, refrigerants andmany other commercial and householdproducts. Vapors from these productswhen burned in a gas flame form acidcompounds. The acid compoundsincrease the dew point temperature ofthe flue products and are highlycorrosive after they condense.

ALL FURNACE INSTALLATIONSMUST COMPLY WITH THENATIONAL FUEL GAS CODE ANDLOCAL CODES TO PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR FOR THEFURNACE. FAILURE TO DO SO CANCREATE HAZARDOUS CONDITIONSRESULTING IN PROPERTYDAMAGE, BODILY INJURY ORDEATH FROM SMOKE, FIRE ORCARBON MONOXIDE.

Combustion air requirements aredetermined by whether the furnace isin an open (unconfined) area or in aconfined space such as a closet orsmall room.

EXAMPLE 1.FURNACE LOCATED IN ANUNCONFINED SPACE

Using indoor air for combustion.

An unconfined space must have atleast 50 cubic feet for each 1,000 Btuhof the total input for all appliances inthe space. Here are a few examples ofthe room sizes required for differentinputs. The sizes are based on 8 footceilings.

Btuh Minimum Sq. Feet Typical Room SizeInput With 8' Ceiling With 8' Ceiling

45,000 281 12*x24* or 16*x18*

50,000 312 14*x24* or 18*x18*

67,500 421 15*x28* or 20*x21*

75,000 469 15*x31* or 20*x24*

100,000 625 20*x31* or 25*x25*

125,000 833 23*x34* or 26*x30*

150,000 938 25*x38* or 30*x31*

If the open space containing thefurnace is in a building with tightconstruction (contemporaryconstruction), outside air may still berequired for the furnace to operate andvent properly. Outside air openingsshould be sized the same as for aconfined space.

11

WARNING!

FIGURE 8AIR FROM ATTIC/CRAWL SPACE

EXAMPLE 2.FURNACE LOCATED IN ACONFINED SPACE

A confined space (any space smallerthan shown above as “unconfined”)must have openings into the spacewhich are located in accordance withthe requirements set forth in thefollowing subsections A and B. Size theopenings by how they are connected tothe heated area or to the outside, andby the input of all appliances in thespace.

If confined space is within a buildingwith tight construction, combustion airmust be taken from outdoors or areafreely communicating with theoutdoors.

A. USING INDOOR AIR FORCOMBUSTION

IMPORTANT: Air should not be takenfrom a heated space with a fireplace,exhaust fan or other device that mayproduce a negative pressure.

If combustion air is taken from theheated area, the openings musteach have at least 100 squareinches of free area. Each openingmust have at least one square inchof free area for each 1,000 Btuh oftotal input in the space. Here aresome examples of typical openingsrequired.

Btuh Free AreaInput Each Opening

45,000 100 Square Inches100,000 100 Square Inches150,000 150 Square Inches

B. USING OUTDOOR AIR FORCOMBUSTION

IMPORTANT: NEVER TAKECOMBUSTION AIR FROM ANATTIC SPACE THAT ISEQUIPPED WITH POWERVENTILATION.

The confined space mustcommunicate with the outdoorsaccording to Methods 1 and 2. Theminimum air opening dimensionshall not be less than 3 inches.When using ducts, they shall be ofthe same cross-sectional area asthe free area of the openings towhich they connect.

Method 1

Provide two permanent openings,one located within 12 inches of thetop and one located within 12 inchesof the bottom of the enclosure. Eachopening shall communicate directly,or by ducts, with the outdoors orspaces (crawl or attic) that freelycommunicate with the outdoors.

a. Where directly communicatingwith the outdoors or wherecommunicating to the outdoorsthrough VERTICAL DUCTS, eachopening shall have a minimumfree area of 1 square inch foreach 4000 BTUH of totalappliance input rating in theenclosure. Here are typical ductsizes.

a. One square inch for each 3000BTUH of the total input rating of allequipment located in the enclosure,AND

b. Not less than the sum of the areasof all vent connectors in the confinedspace.

IMPORTANT: IF THE FURNACE IS INA LOCATION WITH AN EXHAUSTFAN, THERE MUST BE SUFFICIENTVENTILATION TO PREVENT THEEXHAUST FAN FROM CREATING ANEGATIVE PRESSURE IN THEROOM.

Combustion air openings must NOTBE RESTRICTED in any manner.

CONSULT LOCAL CODES FORSPECIAL REQUIREMENTS.

Air opening in the furnace casing front,return air grilles, and warmm airregisters must not be obstructed.

b. Where communicating withoutdoors through HORIZONTALDUCTS, each opening shall havea minimum free area of 1 squareinch for each 2000 BTUH oftotal input rating for all equipmentin the enclosure. Here are typicalduct sizes.

12

FIGURE 9OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

Method 2

One permanent opening, located within12 inches of the top of the enclosure,shall be permitted where theequipment has clearances of at least 1inch from the sides and back and 6inches from the front of the appliance.The opening shall directlycommunicate with the outdoors orcommunicate through a vertical orhorizontal duct to the outdoors orspaces (crawl or attic) that freelycommunicate with the outdoors andhave a minimum free area of:

VERTICAL OUTDOOR AIROPENING DIMENSIONS

BTUH Free Area RoundInput Each Opening Pipe Size

45,000 11.25 sq. inches 4(

50,000 12.50 sq. inches 4(

67,500 16.90 sq. inches 5(

75,000 18.75 sq. inches 5(

100,000 25.00 sq. inches 6(

125,000 31.25 sq. inches 7(

150,000 37.50 sq. inches 7(

HORIZONTAL OUTDOOR AIROPENING DIMENSIONS

BTUH Free Area RoundInput Each Opening Pipe Size

45,000 22.50 sq. inches 6(

50,000 25.00 sq. inches 6(

67,500 33.75 sq. inches 7(

75,000 37.50 sq. inches 7(

100,000 50.00 sq. inches 8(

125,000 62.50 sq. inches 9(

150,000 75.00 sq. inches 10(

GENERAL INFORMATIONThe furnace must be vented inaccordance with these instructions,National Fuel Gas Code, ANSI Z223.1and/or the Natural Gas InstallationCode, CAN/CGA-B149.1 & .2 andrequirements or codes of the local utilityor other authority having jurisdiction.

DEVICES ATTACHED TO THE FLUEOR VENT FOR THE PURPOSE OFREDUCING HEAT LOSS UP THECHIMNEY HAVE NOT BEEN TESTEDAND HAVE NOT BEEN INCLUDED INTHE DESIGN CERTIFICATION OFTHIS FURNACE. WE, THEMANUFACTURER, CANNOT ANDWILL NOT BE RESPONSIBLE FORINJURY OR DAMAGE CAUSED BYTHE USE OF SUCH UNTESTEDAND/OR UNCERTIFIED DEVICES,ACCESSORIES OR COMPONENTS.

DRAFT INDUCER

VENT PIPE ATTACHING HOLESMUST BE PREDRILLED IN THEDRAFT INDUCER COLLAR TOPREVENT PLASTIC MATERIALFROM CRACKING. DRILL 1/8(DIAMETER HOLES THROUGH THEVENT PIPE AND COLLAR AND USE#8 SCREWS TO ATTACH. SEEFIGURE 10. FAILURE TO FOLLOWTHIS WARNING CAN CAUSERECIRCULATION OF FLUEPRODUCTS CAUSING CARBONMONOXIDE POISONINGRESULTING IN PERSONAL INJURYOR DEATH.

IMPORTANT APPLICATIONNOTESWhen the furnace is used as areplacement, the existing vent systemshould be inspected to assure thatthere are no obstructions, blockage, orany signs of corrosion.

NOTE: WHEN THE VENT TABLEPERMITS MORE THAN ONEDIAMETER OF PIPE FOR ACONNECTOR OR VENT, THESMALLEST PERMITTED DIAMETERMUST BE USED,

VENT PIPE MAY BE TYPE “B-1,”EITHER RIGID OR SUITABLEFLEXIBLE CONSTRUCTION THATCARRIES A U.L. LISTING.

COMMON VENTING IS ALLOWEDWITH VERTICAL B-1 VENTSYSTEMS, AND LINED MASONRYCHIMNEYS. FOLLOW THENATIONAL FUEL GAS CODE, ANSIZ223.1 AND/OR THE NATURAL GASINSTALLATION CODE, CAN/CGA-B149.1 & .2 FOR PROPERINSTALLATION PRACTICES.

SINGLE WALL VENT CONNECTORSTO “B-1 VENT OR MASONRYCHIMNEYS” MAY BE USED UNDERTHE GUIDELINES OF THENATIONAL FUEL GAS CODE, ANSIZ223.1 AND/OR THE NATURAL GASINSTALLATION CODE, CAN/CGA-B149.1 & .2.

The entire length of the ventconnector shall be readilyaccessible for inspection, cleaningand replacement.

13

WARNING!

WARNING!

FURNACE CATEGORYINFORMATIONThis furnace is shipped as a Category Itype induced draft furnace. A CategoryI furnace operates with a nonpositivevent pressure and has a vent gastemperature at least 140°F above thedew point of the vent gases. ACategory I type may be a draft hoodequipped furnace or have a fanassisted combustion system (induceddraft). The inducer is used to pull flueproducts through the combustionchamber and as they leave thefurnace, most of the energy has beendissipated. The buoyant effect of theflue gases provides venting to theoutdoors.

During the off cycle, the inducer is offand there is very little flow through thevent, cooling the vent. During the oncycle there is no dilution airflow, aswith a draft hood type furnace.Although the vent heats up rapidlywithout dilution air, the flue productscontain more water vapor, whichresults in a higher dew pointtemperature. It is most important thatyou follow the guidelines in theseinstructions to prevent the possibleformation of condensation in theventing system.

As a Category I furnace it may bevented vertically with type B-1 ventpipe and also may be common vented,as described in these instructions.

FIGURE 10ATTACHING TO DRAFT INDUCER COLLAR

VENTING

14

“B-1” VERTICAL VENTINGType “B-1” vents must be installed inaccordance with the terms of theirlistings and the vent manufacturer’sinstructions.

“B-1” vents must be supported andspaced in accordance with their listingsand the manufacturer’s instructions. Allvents must be supported to maintaintheir minimum clearances fromcombustible material.

VERTICAL VENTING

CategorizedFurnace Vent

Input Size Required45K 3(50K 3(67K *4(75K *4(

100K *4(125K *4(150K *5(

*NOTE: All furnaces have a 3( ventconnection as shipped from the factory. A 3(to 4( or 3( to 5( vent transition is required onall but the 45,000 and 50,000 BTUH modelswhen vertically vented or common ventedwith metal vent pipes. THE VENTTRANSITION CONNECTION MUST BEMADE AT THE FURNACE VENT EXIT. Itmust originate with an adapter if required, atthe furnace flue collar and terminate eitherin a listed cap or roof assembly. Whencommon venting, the vent connector sizemay differ from the above diametersdepending on application. See ANSIZ21.47-1993/CAN/CGA-2.3-M93 or latestedition tables.

VERTICAL VENT SYSTEMS:1. A gas vent shall terminate above the

roof surface with a listed cap orlisted roof assembly. Gas vents 12inches in size or smaller with listedcaps shall be permitted to beterminated in accordance withFigure 11, provided they are at least8 feet from a vertical wall or similarobstruction. All other gas vents shallterminate not less than 2 feet abovethe highest point where they passthrough the roof and at least 2 feethigher than any portion of a buildingwithin 10 feet.

2. A type B gas vent shall terminate atleast 5 feet in vertical height abovethe highest connected equipmentdraft hood or flue collar.

3. Must rise 1⁄4( per foot away from thefurnace on horizontal runs and besupported with straps or hangers soit has no sags or dips. Supports at 4foot intervals and at all elbows arerecommended.

4. The vent connector must bemechanically fastened to the outletcollar of the furnace with at least (2)

SPECIAL VENT SYSTEMS (SVS)IMPORTANT: IT IS RHEEM’SPOSITION NOW THAT NEWINSTALLATIONS OF ANY HTPV PIPEUSED IN A CATEGORY III VENTAPPLICATION, INCLUDINGSELKIRK’S SELVENT™ II HTPVPRODUCT, SHOULD CEASEIMMEDIATELY.

POWER VENT SYSTEMSWhen vertical venting is not possible,the only acceptable method forhorizontal venting is with the use ofTjernlund model GPAK-1TR or FieldControls models SWG-4R powerventer. Type B vent pipe and fittingsmust be used. Common venting is notpermitted

All application and installationinstructions supplied with the powerventer must be followed.

Please address all questions regardingpower venter installation, agencylistings and furnace model compatibilityto:

Tjernlund Products, Inc.(800) 255-4208 or (612) 426-2993

Field Controls L.L.C.(800) 742-8368 or (919) 522-0214

sheet metal screws except ventconnectors that are B-1 material.These shall be assembled inaccordance with the manufacturer’sinstructions. See Figure 9.

NOTE: Refer to the National Fuel GasCode, ANSI Z223.1 and/or the NaturalGas Installation Code, CAN/CGA-B149.1 & .2.

Single appliance venting of a fanassisted furnace into a tile-linedmasonry chimney is prohibited. Thechimney must be lined with either TypeB vent or with a listed, single wall,metal lining system. ReferenceNational Fuel Gas Code, ANSI Z223.1and/or the Natural Gas InstallationCode, CAN/CGA-B149.1 & .2. SeeFigure 11 for typical B-1 vent chase.

DO NOT CONNECT THIS FURNACETO A CHIMNEY USED TO VENT ASOLID FUEL APPLIANCE (WOOD ORCOAL). VENTING WITH A SOLIDFUEL APPLIANCE CAN LEAD TOIMPROPER FUNCTIONING OF THEUNIT, AND DUE TO SOOTING, THEPOSSIBILITY OF FIRE RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

FIGURE 11TYPICAL VENTING WITH “B-1” VENT

WARNING!

3. Insofar as is practical, close allbuilding doors, windows and alldoors between the space where theappliances remaining connected tothe common venting system arelocated. Turn on clothes dryers andany appliance not connected to thecommon venting system. Turn onany exhaust fans, such as rangehoods and bathroom exhausts, sothey will operate at maximum speed.Do not operate a summer exhaustfan. Close fireplace dampers.

4. Follow the lighting instructions.Place the appliance being inspectedinto operation. Adjust the thermostatso the appliance will operatecontinuously.

5. Test for spillage at the draft hoodrelief opening after 5 minutes ofmain burner operation. Use theflame of a match or candle, orsmoke from a cigarette, cigar, orpipe.

EXISTING VENT SYSTEMSIMPORTANT RETROFITVENTING INSTRUCTIONSIf this furnace is a replacementinstallation, ALWAYS INSPECT theexisting vent system to be sure thereare no obstructions, blockages, orsigns of corrosion.

When the existing furnace is removedfrom a venting system serving otherappliances, the venting is likely to betoo large to properly vent theremaining attached appliances.

The following steps shall be followedwith each appliance that remainsconnected to the common ventingsystem, while the other appliances thatremain connected to the commonventing systems are not in operation.

NOTE: WHEN THE VENT TABLEPERMITS MORE THAN ONEDIAMETER OF PIPE FOR ACONNECTOR OR VENT, THESMALLEST PERMITTED DIAMETERMUST BE USED.

1. Seal any unused openings in thecommon venting system.

2. Visually inspect the venting systemfor proper size and horizontal pitchand determine that there is noblockage, restriction, leakage,corrosion or other deficiencies whichcould cause an unsafe condition.

15

FIGURE 12DEDICATED VENTING THROUGHCHIMNEY WITH “B-1” VENT

6. After it has been determined thateach appliance that remainsconnected to the common ventingsystem properly vents (when testedas outlined above) return doors,windows, exhaust fans, fireplacedampers and any other gas-burningappliance to their previousconditions of use.

7. If improper venting is observedduring any of the above tests, thecommon venting system must beresized. Refer to National Fuel GasCode, ANSI Z223.1 and/or theNatural Gas Installation Code,CAN/CGA-B149.1 & .2.

FIGURE 13GAS PIPING INSTALLATION

UPFLOW & DOWNFLOW

16

GAS SUPPLY AND PIPINGGAS SUPPLY

THIS FURNACE IS EQUIPPED ATTHE FACTORY FOR USE ONNATURAL GAS ONLY. CONVER-SION TO LP GAS REQUIRES ASPECIAL KIT SUPPLIED BY THEDISTRIBUTOR OR MANU-FACTURER. MAILING ADDRESSESARE LISTED ON THE FURNACERATING PLATE, PARTS LIST ANDWARRANTY. FAILURE TO USETHE PROPER CONVERSION KITCAN CAUSE FIRE, CARBONMONOXIDE POISONING,EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.

See the conversion kit indexsupplied with the furnace. Thisindex identifies the proper LP GasConversion Kit required for eachparticular furnace.

IMPORTANT: Any additions,changes or conversions required forthe furnace to satisfactorily meet theapplication should be made by aqualified installer, service agency orthe gas supplier, using factory-specified or approved parts.

IMPORTANT: Connect this furnaceonly to gas supplied by a commercialutility.

IMPORTANT: A U.L. recognizedfuel gas and CO detector(s) arerecommended in all applications,and their installation should be inaccordance with the detectormanufacturer’s recommendationsand/or local laws, rules, regulations orcustoms.

GAS PIPINGInstall the gas piping according to alllocal codes and regulations of theutility company.

If possible, run a separate gas supplyline directly from the meter to thefurnace. Consult the local gascompany for the location of themanual main shut-off valve. The gasline and manual gas valve must beadequate in size to prevent unduepressure drop and never smallerthan the pipe size to the com-bination gas valve on the furnace.Refer to Table 2 for the recom-mended pipe size for natural gas andTable 3 for LP gas pipe sizes.

! WARNING

HORIZONTAL

IMPORTANT: It is permissible to runflexible gas connector inside the unit toa piece of black pipe.

Install a ground joint union inside thecabinet to easily remove the controlvalve assembly. Install a manualshut-off valve in the gas line outsidethe furnace casing. The valve shouldbe readily accessible to turn the gassupply on or off. Install a drip leg in thegas supply line as close to the furnaceas possible. Always use a pipecompound resistant to the action ofliquefied petroleum gases on allthreaded connections.

IMPORTANT: When making gas pipeconnections, use a back-up wrench toprevent any twisting of the controlassembly and gas valve.

Any strains on the gas valve canchange the position of the gas orificesin the burners. This can cause erraticfurnace operation.

IMPORTANT: ENSURE that thefurnace gas control valve not besubjected to high gas line supplypressures.

DISCONNECT the furnace and itsindividual shut-off valve from the gassupply piping during any pressuretesting that exceeds 1/2 p.s.i.g. (3.48kPa).

17

GAS PRESSURENatural gas supply pressure shouldbe 5" to 7( w.c. LP gas supplypressure should be 11( to 14( w.c.This pressure must be maintainedwith all other gas-fired appliances inoperation. Never exceed a maximumgas supply pressure of 14( w.c. withany fuel.

The minimum supply pressure to thegas valve for proper furnace inputadjustments is 5( w.c. for natural gas,however 6( to 7( is recommended. Theminimum supply pressure is 11( w.c.for LP gas.

NEVER PURGE A GAS LINE INTOTHE COMBUSTION CHAMBER.NEVER USE MATCHES, FLAME ORANY IGNITION SOURCE FORCHECKING LEAKAGE. FAILURE TOFOLLOW THIS WARNING CANCAUSE AN EXPLOSION OR FIRERESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.

To check for gas leakage, use anapproved chloride-free soap and watersolution, an electronic combustible gasdetector (see Figure 14), or otherapproved method.

! WARNING

FIGURE 14ELECTRONIC COMBUSTIBLEGAS DETECTOR

FIGURE 15LP KIT CONTENTS

FIGURE 16HOSE CONNECTION TO LINE PRESSURE TAP

LP CONVERSIONThe valve can be converted to useliquefied petroleum (LP) gas byreplacing the pressure regulator springwith the conversion kit spring. This LPkit spring allows the regulator tomaintain the proper manifold pressurefor LP gas. The correct burner LPorifices are included inthe kit. See Figure 14.

NOTE: Order the correct LP conversionkit from the furnace manufacturer.Furnace conversion to LP gas mustbe performed by a qualifiedtechnician.

To change orifice spuds for eitherconversion to LP or for elevation:

1. Shut off the manual main gasvalve and remove the gasmanifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

Consult the tables at right if there is anyquestion concerning orifice sizing.

4. Turn the gas supply back on andcheck for proper operation andmanifold pressure.

5. Attach the notice label alerting thenext service technician that thefurnace has been converted to LPgas.

NOx MODELSWhen converting furnaces equippedwith NOx inserts to LP gas, remove theNOx insert assemblies. Steps forremoval are listed below:

1. Turn off all electrical power and thegas supply to the furnace.

2. Remove the burner door from thefurnace.

3. Remove the igniter assembly –handle with care.

4. Remove the two screws attachingthe NOx insert retainer brackets tothe center panel. Pull the retainerrod.

5. Put the two screws back into theholes in the center panel.

6. Re-install the igniter and burnerassemblies.

7. Replace burner door.

8. Turn on electrical power and gassupply to the unit.

18

RATING PLATE ELEVATIONINPUT

BTU/HR 0 TO 7,999 FT. 8,000 FT. AND ABOVE

NATURAL GAS HEATING VALUE @ 1,000 BTU/FT3, SPECIFIC GRAVITY 0.62MANIFOLD PRESSURE @ 3.5( W.C.

45,000 43 45

50,000 42 43

67,500 43 45

75,000 42 43

100,000 42 43

125,000 42 43

150,000 42 43

L.P. GAS HEATING VALUE @ 2,475 BTU/FT3, SPECIFIC GRAVITY 1.52/MANIFOLD PRESSURE @ 10( W.C.

45,000 54 55

50,000 54 55

67,500 54 55

75,000 54 55

100,000 54 55

125,000 54 55

150,000 54 55

ORIFICE SIZING CHART


BTU/HR 0 TO 1,999 FT. 2,000 FT. TO 4,500 FT.


45,000 43 45

50,000 42 43

67,500 43 45

75,000 42 43

100,000 42 43

125,000 42 43

150,000 42 43


45,000 54 55

50,000 54 55

67,500 54 55

75,000 54 55

100,000 54 55

125,000 54 55

150,000 54 55

ORIFICE SIZING CHART (CANADA)

TABLE 2NATURAL 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 specificgravity of 0.60 (natural gas).

Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80

1/2 132 92 73 63 56 50 46 433/4 278 190 152 130 115 105 96 901 520 350 285 245 215 195 180 170

1-1/4 1,050 730 590 500 440 400 370 3501-1/2 1,600 1,100 890 760 670 610 560 530

After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hourrequired for the gas input rating of the furnace. By formula:

Gas Input of Furnace (BTU/HR)Cu. Ft. Per Hr. Required = Heating Value of Gas (BTU/FT3)

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may bedetermined by consulting the local natural gas utility or the LP gas supplier.

TABLE 3LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 incheswater column inlet pressure).(Based on a Pressure Drop of 0.5 Inch Water Column)

Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 63

3/4 567 393 315 267 237 217 196 182 173 162 146 132

1 1,071 732 590 504 448 409 378 346 322 307 275 252

1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511

1-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787

2 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

Example (LP): Input BTU requirement of unit, 150,000Equivalent length of pipe, 60 ft. = 3/4" IPS required.

19

SETTING GAS PRESSUREThe maximum gas supply pressureto the furnace should be 7( w.c.natural gas, or 14( w.c. LP gas. Theminimum supply gas pressure to thegas valve should be 5" w.c. natural gasor 11" w.c. LP gas. A properlycalibrated U-Tube manometer isrequired for accurate gas pressuremeasurements.

Supply Gas Pressure Measurement.A line pressure tap is on the input sideof the gas valve.

1. With gas shut off to the furnace atthe manual gas valve outside theunit, remove the input pressure tapplug.

2. Connect a U-Tube manometer tothe pressure tap. See Figure 15.

3. Turn on the gas supply andoperate the furnace and all othergas-fired units on the same gasline as the furnace.

4. Note or adjust the line gaspressure to give:

A. 5( - 7( w.c. for natural gas.

B. 11( - 14( w.c. for LP gas.

5. Shut off the gas at the manual gasvalve and remove theU-Tube manometer.

6. Replace the pressure tap plugbefore turning on the gas.

If the supply gas line pressure is abovethese ranges, install an in-line gasregulator to the furnace for natural gasunits. With LP gas, have the LPsupplier reduce the line pressure at theregulator.

If supply gas line pressure is belowthese ranges, either remove anyrestrictions in the gas supply piping orenlarge the gas pipe. See Tables 2 and3. With LP gas, have the LP supplieradjust the line pressure at theregulator.

20

TURN OFF ELECTRIC POWER ATTHE FUSE BOX OR SERVICE PANELBEFORE MAKING ANYELECTRICAL CONNECTIONS.

ALSO, THE GROUND CONNECTIONMUST BE COMPLETED BEFOREMAKING LINE VOLTAGECONNECTIONS. FAILURE TO DOSO CAN RESULT IN ELECTRICALSHOCK, SEVERE PERSONALINJURY OR DEATH.

IMPORTANT: THE FURNACE MUSTBE INSTALLED SO THAT THEELECTRICAL COMPONENTS AREPROTECTED FROM WATER(FURNACE CONDENSATE).

ELECTRICAL CONNECTIONS

THE CABINET MUST BEPERMANENTLY GROUNDED. AGROUND SCREW IS PROVIDED INTHE JUNCTION BOX FOR THISPURPOSE. FAILURE TO DO SO CANRESULT IN FIRE, ELECTRICALSHOCK, PERSONAL INJURY ORDEATH.

The electrical supply requirements arelisted on the furnace rating plate.

Use a separate fused branch electricalcircuit containing a properly sized fuseor circuit breaker. Run this circuitdirectly from the main switch box to anelectrical disconnect which must bereadily accessible and located withinsight of the furnace. Connect from thedisconnect to the junction box on theleft side of the furnace, inside thecontrol compartment. See appropriatewiring diagram.

NOTE: The electrical junction boxinside the furnace control compartmentmay be relocated to the right side ifnecessary. A knockout is provided.

NOTE: L1 (hot) and L2 (neutral)polarity must be observed whenmaking field connections to thefurnace. The ignition control on electricignition models will not sense flame ifL1 and L2 are reversed.

Installation of the electric supply lineshould be in accordance with theNational Electric Code ANSI/NFPA No.70, latest edition, or CanadianElectrical Code Part 1 - CSA StandardC22.1 and local building codes.

This can be obtained from:

National Fire Protection AssociationBatterymarch ParkQuincy, MA 02269

Canadian Standards Association178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3

WARNING!

WARNING!

ELECTRICAL WIRING

as shown on the wiring diagram. Neverinstall the thermostat on an outsidewall or where it will be influenced bydrafts, concealed hot or cold waterpipes, lighting fixtures, radiation fromfireplace, rays of sun, lamps, television,radios or air streams from registers.Refer to the instructions packed withthe thermostat for best anticipatoradjustment or selection or see below.

HEAT ANTICIPATOR SETTINGS

For adjusting the thermostat heatanticipator setting; (a) add the currentdraw of the various components in thesystem or (b) measure the current flowon either the R or W thermostat circuitand set the thermostat heat anticipatoraccording to the current flowmeasured.

The room thermostat must becompatible with the integrated furnacecontrol on the furnace. All thermostatsavailable from the furnacemanufacturer’s Parts Department areacceptable. Generally, all thermostatsthat are not of the “current robbing”type are compatible with the integratedfurnace control we use.

NOTICE: An isolation relay can beadded to prevent any compatibilityproblems that may occur. Use a single-pole, single-throw relay with a 24-voltAC coil. The contacts should be ratedfor .5 amps minimum at 24 volts. SeeFigure 17.

Install the room thermostat inaccordance with the instruction sheetin the box with the thermostat. Run thethermostat lead wires inside the controlcompartment. Connect the thermostat

THERMOSTAT

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.

3.02.52.0

161618

141416

121214

101212

101212

101010

50 100 150 200 250 300Length of Run – Feet (1)

The

rmo

stat

Lo

ad -

Am

ps

① The total wire length is the distance from the furnace to thethermostat and back to the furnace.

NOTE: Do not use 24 volt control wiring smaller than No. 18.

FIGURE 17ISOLATION RELAY

ST-A0804-01

21

FIELD INSTALLED OPTIONACCESSORIESELECTRONIC AIR CLEANER1. Electronic air cleaner line voltage

power can be supplied from thescrew terminal “EAC” and a linevoltage neutral screw terminal onthe control board. See Figure 18.This will power the electronic aircleaner whenever the circulating airblower is in operation.

HUMIDIFIER2. Humidifier line voltage power can be

supplied from screw terminal “HUM”to a line voltage neutral screwterminal on the control board. SeeFigure 18. This will power thehumidifier whenever the burner is onand the circulating air blower isoperating in the heating mode.

NOTE: Maximum current –1.0 ampsfor each option.

FURNACE TWINNINGINSTALLATIONSIMPORTANT: TWINNING OF RGDJ,RGPJ, RGLJ AND RGVJ UNITSREQUIRES AN ACCESSORYTWINNING KIT. REFER TO THESPECIFICATION SHEET FORPROPER KIT. DO NOT ATTEMPT TOTWIN THESE MODELS BY USINGTHE INSTRUCTIONS BELOW.

Twinning operation of two furnaces,installed side-by-side, connected by acommon duct system with main powersupplied by the same source, andcontrolled by a common thermostat canbe done with the HoneywellS9201E2001, UTEC 1012-920 or WhiteRodgers 50A62-101 integrated controlboards.

The “OK” LED will flash if twinning isnot set up properly.

HONEYWELL S9201E2001CONTROL BOARD

1. Single Stage Operation(See Figure 19)

a. Control board “ONE” isconnected to the thermostat.

b. Remove the jumper betweenthe “XMIT” and “RCV”terminals.

c. Connect wire from “XMIT”terminal of board “ONE” to“RCV” terminal of board “TWO.”

d. Connect wire from “RCV”terminal of board “ONE” to“XMIT” terminal of board“TWO.”

e. Connect wire between thegrounds.

f. Connect wire between the two“W” thermostat terminals.

2. Two Stage Operation(See Figure 20)

a. Repeat steps a, b, c, d and eabove.

b. Connect “W1” of thermostat to“W” on control board “ONE”.

c. Connect “W2” of thermostat to“W” on control board “TWO”.

UTEC 1012-920 OR WHITERODGERS 50A62-101 CONTROLBOARD

1. Single Stage Operation(See Figure 21)

a. Control board “ONE” is onfurnace connected to thethermostat.

b. The 24 VAC supply to bothcontrol boards must be in phasewith each other.

c. Connect the “C,” “W” and“TWIN” terminals tocounterparts on each control.

d. Both control boards must haveswitch #3 in the “ON” position.

e. Control board “ONE” must havethe switch #4 in the “1st” stageposition. The other controlboard must have switch #4 inthe “2nd” position for single ortwo stage heat operation.

2. Two Stage Operation(See Figure 22)

a. Follow above instructions.Switch #4 on control board“TWO” must be in “2nd” stageposition (i.e. control board #2must be the 2nd stage).

b. Connect “W2” on thermostat to“W” on control board “TWO”.

FIGURE 18LINE VOLTAGE CONNECTIONSHONEYWELL S9201E2001, UTEC 1012-920 AND WHITE RODGERS 50A62-101 CONTROL BOARD

UTEC 1012-925 CONTROL BOARD

I334

I677

22

I400

FIGURE 19HONEYWELL NO. S9201E2001 CONTROL BOARDTWINNING CONNECTION SINGLE STAGE OPERATION

23

FIGURE 20HONEYWELL NO. S9201E2001 CONTROL BOARDTWINNING CONNECTION TWO STAGE OPERATION

I400

24

FIGURE 21UTEC NO. 1012-920 OR WHITE RODGERS 50A62-101 CONTROL BOARDTWINNING CONNECTION SINGLE STAGE OPERATION

I398

25

FIGURE 22UTEC NO. 1012-920 OR WHITE RODGERS 50A62-101 CONTROL BOARDTWINNING CONNECTION TWO STAGE OPERATION

I399

26

HOT SURFACE IGNITIONLIGHTING INSTRUCTIONSThis appliance is equipped with a hotsurface silicon carbide ignition device.This device lights the main burners eachtime the room thermostat (closes) callsfor heat. See lighting instructions on thefurnace.IMPORTANT: FOR Nox MODELS –Make a visual inspection of the Noxinserts to ensure they are in properposition and have not become dislodgedduring shipping or time in the warehouse.TO START FURNACE

1. BE SURE THAT THE MANUAL GASCONTROL HAS BEEN IN THE“OFF” POSITION FOR AT LEASTFIVE MINUTES. DO NOT ATTEMPTTO MANUALLY LIGHT THE MAINBURNERS. FAILURE TO FOLLOWTHIS WARNING CAN CAUSE AFIRE OR AN EXPLOSIONRESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.

2. Set the room thermostat to the lowestsetting.

3. Turn the gas control knob to the “On”position, or move the gas control leverto the “On” position.

4. Replace the control access door.5. Turn on the electrical power.6. Set the room thermostat to a point

above room temperature to light themain burners. After the burners are lit,set room thermostat to a desiredtemperature.

TO SHUT DOWN FURNACE1. Set the room thermostat to its lowest

setting.2. Shut off the gas to main burners by

turning the gas control knob to the“Off” position, or by depressing thegas control lever and moving it to the“Off” position.

SHOULD OVERHEATING OCCUR ORTHE GAS SUPPLY FAIL TO SHUTOFF, SHUT OFF THE MANUAL GASVALVE TO THE APPLIANCE BEFORESHUTTING OFF THE ELECTRICALSUPPLY. FAILURE TO DO SO CANCAUSE AN EXPLOSION OR FIRERESULTING IN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

SEQUENCE OF OPERATIONHoneywell or UTEC IntegratedControls with Hot Surface Ignition.1. Each time the thermostat contacts

close, the induceddraft blower (inducer) begins aprepurge cycle.

2. The air proving negative pressureswitch(es) closes.

WARNING!

3. 30 seconds after the pressureswitch(es) close, the hot surfaceigniter heats for 30 seconds to fulltemperature. The induced draft bloweroperates for the complete heatingcycle.

4. After the 30-second igniter warm up,the gas valve opens for a9-second trial for ignition.

5. The igniter lights the gas burners andstays energized for the first 8seconds after the gas valve opens.

6. 8 seconds after the gas valve opensthe remote flame sensor mustprove flame ignition for one secondusing the process of flamerectification. If the burners don’t light,the system goes through anotherignition sequence. It does this up tofour times.

7. The main blower starts 20 secondsafter the burners ignite.

8. When the thermostat cycle ends, thegas valve closes, the burners go out,the induced draft blower runs for a 5-second post-purge, and the negativepressure switch(es) open.

9. The main blower continues until timedoff by the setting on the integratedfurnace control board.

Sequence if the system doesn’t lightor doesn’t sense flame:1. On a call for heat, the control runs the

inducer for 30 seconds to prepurge. 2. After the 30-second prepurge, the hot

surface igniter heats for 30 seconds.The inducer continues to run.

3. After the 30-second igniter warm up,the gas valve opens for a9-second trial for ignition. The inducercontinues and the igniter staysenergized.

4. If flame is not sensed during the 9thsecond after the gas valve opens, thegas valve closes, and the igniter de-energizes.

5. After a 30 second inter-purge, theigniter heats for 30 seconds. After 30seconds, the gas valve opens for 9seconds. If no flame is sensed, itcloses the gas valve, the igniter de-energizes, Both the main blowerand the inducer operate for 180seconds before the next ignitiontrial.

6. It repeats this process up to fourtimes. At the end of the last try, theinducer stops immediately. Thesystem is in “soft” lock out.

7. The above sequence will repeat aftera one hour delay. It will continuerepeating until ignition is successful orthe call for heat is terminated.

8. To reset the lock out, make andbreak power either at thethermostat or at the unitdisconnect switch for 5 to 10seconds. It then goes throughanother set of trials for ignition.

WHITE RODGERS 50A62-101 WITHHOT SURFACE IGNITION1. Each time the thermostat contacts

close, the induced draft blower(inducer) begins a pre-purge cycle.

2. The air proving negative pressureswitch(es) close.

3. 10 seconds after the pressureswitch(es) close, the hot surfaceigniter heat up for 20 seconds to fulltemperature.

4. After the 20 second igniter warm-up,the gas valve opens for an 8-second trial for ignition.

5. The igniter lights the gas burners andstays energized for one (1) secondafter flame is sensed.

6. 7 seconds after the gas valve opensthe remote flame sensor mustprove flame ignition for one secondusing the process of flamerectification. If the burners do not light,the system goes through anotherignition sequence. It does this up tofour times.

7. When the thermostat cycle ends, thegas valve closes, the burners go out,the induced draft blower runs for a 5-second post-purge, and the negativepressure switch(es) open.

9. The main blower continues until timedoff by the setting on the integratedfurnace control board.

Sequence if the system doesn’t lightor doesn’t sense flame:1. On a call for heat, the control runs the

inducer for 10 seconds to pre-purge.2. After the 10 second pre-purge, the hot

surface igniter heats for 20 seconds.The inducer continues to run.

3. After the 20-second igniter warms up,the gas valve opens for an 8-secondtrial for ignition. The inducer continuesand the igniter stays energized.

4. If flame is not sensed during the 8thsecond after the gas valve 9opens,the gas valve closes, and the igniterde-energizes.

5. After a 30 second inter-purge, theigniter heats for 20 seconds. After 20seconds, the gas valve opens for 8seconds. If no flame is sensed, itcloses the gas valve, the igniter de-energizes. Both the main blowerand the inducer operate for 180seconds before the next ignitiontrial.

6. It retries up to four times. At the end ofthe last try, the inducer stopsimmediately. The system is in “soft”lock out.

7. The above sequence will repeat aftera one hour delay. It will continuerepeating until ignition is successful orthe call for heat is terminated.

8. To reset the lock out, make andbreak power either at thethermostat or at the unitdisconnect switch for 5 to 10seconds. It then goes throughanother set of trials.

WARNING!

START-UP PROCEDURE

METER TIME IN MINUTES AND SECONDS FOR NORMALINPUT RATING OF FURNACES EQUIPPED FOR NATURAL

OR LP GAS

INPUTBTU/HR

METERSIZE

CU. FT.

HEATING VALUE OF GAS BTU PER CU. FT.900 1000 1040 1100 2500

MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.ONE 1 12 1 20 1 23 1 28 3 2045,000 TEN 12 0 13 20 13 50 14 40 33 20

ONE 1 5 1 12 1 15 1 18 3 2050,000 TEN 10 50 12 00 12 30 13 12 30 00

ONE 0 48 0 53 0 55 0 59 2 1367,500 TEN 8 0 8 53 9 15 9 50 22 13

ONE 0 44 0 48 0 50 0 53 2 075,000 TEN 7 12 8 0 8 19 8 48 20 0

ONE 0 33 0 36 0 38 0 40 1 30100,000 TEN 5 24 6 0 6 15 6 36 15 0

ONE 0 26 0 29 0 30 0 32 1 12125,000 TEN 4 19 4 48 5 0 5 17 12 0

ONE 0 31 0 24 0 25 0 26 1 0150,000 TEN 3 36 4 0 4 10 4 20 10 0

Heating Value of Gas (BTU/Ft3) x 3600Input BTU/HR =

Time in Seconds (for 1 cu.ft.) of Gas

TABLE 4

FIGURE 25UTEC - 925BLOWER OFF TIMINGS

OFF TIME SWITCH 1 SWITCH 2

90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON

(TIMER ISRED BLOCKON BOARD)

I335

27

SETTING BLOWER TIMINGSThe Honeywell and UTEC controlboards have four quick connectterminals for connecting the motorspeed leads. These are:

1. FAN SPEED — motor runs on thisspeed when the thermostat is in the“FAN” position.

2. COOL — connect desired coolingspeed.

3. HEAT — connect desired heatingspeed.

4. HEAT/COOL — connect desiredspeed when heating and coolingspeed are the same.

IMPORTANT: Do not connect anymotor speeds to “HEAT” and “COOL” ifyou use the “HEAT/COOL” terminal.

5. If heating and continuous speed arethe same, jump across “FAN” and“HEAT” terminals.

See Figures 23, 24 and 25 for instructionsfor setting the blower “OFF” timings.

GAS FURNACE (DIRECTDRIVE) INSTRUCTIONS FORCHANGING BLOWER SPEED

DISCONNECT THE ELECTRICALSUPPLY TO THE FURNACE BEFOREATTEMPTING TO CHANGE THEBLOWER SPEED. FAILURE TO DOSO CAN CAUSE ELECTRICALSHOCK RESULTING IN SEVEREPERSONAL INJURY OR DEATH.

The blower motor is wired for blowerspeeds required for normal operationas shown.

If additional blower speed taps areavailable (leads connected to “M1” and“M2” on the electronic control), speedsmay be changed if necessary to fitrequirements of the particularinstallation. Reconnect the unused

FIGURE 23UTEC -920 OR WHITE RODGERS50A62-101 BLOWER OFFTIMINGS

FIGURE 24HONEYWELL E2001BLOWER OFF TIMINGS


90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON


90 SEC. ON OFF

120 SEC. OFF OFF

160 SEC. OFF ON

180 SEC. ON ON

TW

IN2n

dS

ING

LE

1st

NOTE: SWITCHES 3 & 4 ARE USEDFOR TWINNING APPLICATIONS.

ON

(TIMER ISRED BLOCKON BOARD)

I402

I335

WARNING!

motor leads to “M1” or “M2.” Checkmotor lead color for speed designation.

Heating speeds should not be reducedwhere it could cause the furnace airtemperature to rise to exceed themaximum outlet air temperaturespecified for the unit.

IMPORTANT: Always check airtemperature rise after changing theheating speed for any reason.

ADJUSTING OR CHECKINGFURNACE INPUTThe maximum gas supply pressure tothe furnace should be 7( W.C. fornatural gas. The minimum gas supplypressure for purposes of inputadjustment to the furnace should be 5(W.C.

A properly calibrated manometer orgauge is required for accurate gaspressure readings.

The manifold pressure should be set at3.5( W.C. for natural gas. Only smallvariations in the gas flow should bemade by means of the pressureregulator adjustment. In no caseshould the final manifold pressure varymore than plus or minus 0.3( W.C.from the above specified pressures.

To adjust the pressure regulator:

1. Remove the regulator cap.

2. Turn the adjustment screwclockwise to increase pressure orcounterclockwise to decreasepressure.

3. Replace the regulator cap securely.

28

Furnaces for use on LP gas, the LPgas supply pressure must be setbetween 11.0( and 14.0( W.C. bymeans of the tank or branch supplyregulators. The furnace manifoldpressure should be set at 10( W.C. atthe gas control valve. For elevationsup to 8,000 feet, rating plate inputratings apply. For high altitudes(elevations 8,000 and over) and forany necessary major changes in thegas flow rate the orifice spud must bechanged.

To change orifice spuds:

1. Shut off the manual main gas valveand remove the gas manifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

4. Turn the gas supply back on andcheck for proper operation andmanifold pressure.

Check of input is important to preventover firing of the furnace beyond itsdesign-rated input. NEVER SETINPUT ABOVE THAT SHOWN ONTHE RATING PLATE.

To check furnace input:

1. Make certain that all other gasappliances are shut off, with theexception of pilot burners.

2. Start the furnace

3. Time the meter to measure the timerequired to burn one cubic foot ofgas.

4. Use Table 4 to determine input rate.


BTU/HR 0 TO 7,999 FT. 8,000 FT. AND ABOVE


45,000 43 45

50,000 42 43

67,500 43 45

75,000 42 43

100,000 42 43

125,000 42 43

150,000 42 43


45,000 54 55

50,000 54 55

67,500 54 55

75,000 54 55

100,000 54 55

125,000 54 55

150,000 54 55

ORIFICE SIZING CHART


BTU/HR 0 TO 1,999 FT. 2,000 FT. TO 4,500 FT.


45,000 43 45

50,000 42 43

67,500 43 45

75,000 42 43

100,000 42 43

125,000 42 43

150,000 42 43


45,000 54 55

50,000 54 55

67,500 54 55

75,000 54 55

100,000 54 55

125,000 54 55

150,000 54 55

ORIFICE SIZING CHART (CANADA)

FIGURE 27FURNACE NAME PLATE

29

The importance of proper air flow overthe heat exchanger cannot be overemphasized. One of the most commoncauses of heat exchanger failure isoverheating due to low air flow. An airflow table is located inside the blowerdoor and on the following pages.

TEMPERATURE RISE CHECK

To determine if the air flow is correct,make a temperature rise check.

1. Insert a thermometer in the supplyair duct as close to the furnace aspossible yet out of a direct linefrom the heat exchanger. SeeFigure 26.

2. Insert a thermometer in the returnair duct as close to the furnace aspossible.

3. Operate the furnace.

4. When the thermometer in thesupply air duct stops rising(approximately five minutes),subtract the return air temperaturefrom the supply air temperature.The difference is the temperaturerise.

5. Compare the measuredtemperature rise to the approvedtemperature rise range listed onthe furnace name plate. SeeFigure 27.

If the measured temperature rise isabove the approved range, the air flowis too low. More air must be moved byspeeding up the blower, by removingrestrictions in the duct system, or byadding more supply or return air duct. Ifthe measured temperature rise is belowthe approved range, the air flow is toomuch. Use lower speed tap on themulti-speed blower.

Ideally the measured temperature riseshould be in the middle of the range.

FIGURE 26TEMPERATURE RISE MEASUREMENT

AIR FLOW

30

BLOWER PERFORMANCE DATA – RGDG & RGPH UPFLOW/HORIZONTAL MODELS

BLOWER PERFORMANCE DATA – RGLH DOWNFLOW MODELS

31

BLOWER PERFORMANCE DATA – RGVH HORIZONTAL MODELS

BLOWER PERFORMANCE DATA – RGDJ & RGPJ UPFLOW/HORIZONTAL MODELS

32

BLOWER PERFORMANCE DATA – RGLJ DOWNFLOW MODELS ONLY

BLOWER PERFORMANCE DATA – RGVJ HORIZONTAL MODELS

33

SAFETY FEATURESLIMIT CONTROLThe high limit cut-off is set at thefactory and cannot be adjusted. It iscalibrated to prevent the airtemperature leaving the furnace fromexceeding the maximum outlet airtemperature. If temperature exceedsthe maximum outlet air temperature,the limit will shut the furnace down.Reasons which could cause the outlettemperature to exceed the range arefailed indoor blower, dirty filters, etc.

OVER TEMPERATURESAFETY SWITCHESFurnaces are equipped with safetyswitches to protect againstovertemperature conditions in thecontrol compartment caused byinadequate combustion air supply. Inthe event of an overtemperaturecondition, the switch will shut thefurnace down. The switch for thededicated UPFLOW FURNACE andDOWNFLOW is located just above theburners on the blower divider panel.Switches for the UPFLOW/HORIZONTAL AND HORIZONTAL

ONLY HOT SURFACE IGNITIONFURNACES are located on either sideof the burner brackets and just abovethe burners on the blower dividerpanel. If a switch is tripped, it must bemanually reset. DO NOT jumper thisswitch. If this switch should trip, aqualified installer, service agency orthe gas supplier should be called tocheck and/or correct for adequatecombustion air supply. If this unit ismounted in a closet, the door must beclosed when making this check.

A failed inducer motor would be acause of inadequate combustion air.

DO NOT reset the over temperatureswitch without taking corrective actionto assure that an adequate supply ofcombustion air is maintained under allconditions of operation. Replace thisswitch only with the identicalreplacement part.

PRESSURE SWITCHThis furnace has a pressure switch forsensing a blocked vent condition. It isnormally open and closes when theinduced draft blower starts, indicatingair flow through the combustionchamber. As stated, a blocked ventcondition will cause the pressureswitch to remain open as will a failedinducer, a crack in the pressure switchhose, etc.

LUBRICATION

The blower motor and induced draftmotor are prelubricated by themanufacturer and do not requirefurther attention.

The motor must be cleanedperiodically by a qualified installer,service agency, or the gas supplier toprevent the possibility of overheatingdue to an accumulation of dust and dirton the windings or on the motorexterior. And, as suggested elsewherein these instructions, the air filtersshould be kept clean because dirtyfilters can restrict airflow and the motordepends upon sufficient air flowingacross and through it to keep fromoverheating.

FIGURE 28DOWNFLOW BLOWER REMOVAL

FIGURE 30BOTTOM RETURN

DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTENANCE.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN SEVERE PERSONAL INJURY ORDEATH.

FILTERSNOTE: RGDJ, RGPJ, RGVJ, RGLJand RGVH models are not factoryequipped with filters. Filters must befield installed.

Keep the air filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air dry thoroughlyand reinstall.

1. 14(-45,000 and 50,000 btuh unitrequires removal of 31⁄2( segment offilter and frame to get proper widthfor a bottom filter.

2. 21(-100,000 btuh unit requiresremoval of 31⁄2( segment of filter andframe to get proper width for a sidefilter.

3. 241⁄2(-125,000 and 150,000 btuhunits require removal of 7( segmentof filter and frame to get properwidth for a side filter.

TABLE 5 FILTER SIZES

34

MAINTENANCEWARNING!

FIGURE 29RESIZING FILTERS & FRAME

*NOTE: Some filters must beresized to fit certain units andapplications.

SOLID BOTTOM MAY BE ORDERED AS AN OPTION FROM THE FACTORY.

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE QUANTITYWIDTH BTUH SIZE SIZE

14 45 & 50 121⁄4" X 25" 153⁄4" X 25" 1171/2" 67, 75 & 100 153⁄4" X 25" 153⁄4" X 25" 1

21" 100 191⁄4" X 25" 153⁄4" X 25" 1241/2" 125 & 150 223⁄4" X 25" 153⁄4" X 25" 1

DOWNFLOW FILTER SIZES

FURNACE INPUT SIZE QUANTITYWIDTH BTUH

14" 45 & 50 14" X 20" 1171/2" 67, 75 & 100 12" X 20" 221" 100 12" X 20" 2

241/2" 125 & 150 14" X 20" 2Unit Unit Filter Rod Filter Rod Bottom SideSize Width 203/4" 241/4"

AE-61659-02 AE-61659-0345,000 14" 1 Cut Off 31/2" As is50,000 14" 1 Cut Off 31/2" As is67,500 171/2" 1 Cut Off 31/2" As is75,000 171/2" 1 Cut Off 31/2" As is

100,000 171/2" 1 Cut Off 31/2" As is100,000 171/2" 1 As is Cut Off 31/2"125,000 241/2" 1 As is Cut Off 31/2"150,000 241/2" 1 As is Cut Off 31/2"

35

FIGURE 31FILTER RETAINING RODS (SIDE RETURN)

FIGURE 32DOWNFLOW FILTER INSTALLATION

36

IMPORTANT: Do not operate thesystem for extended periods withoutfilters. A portion of the dust entrainedin the air may temporarily lodge in theair duct runs and at the supplyregisters. Any recirculated dustparticles will be heated and charred bycontact with the furnace heatexchanger. This residue will soilceilings, walls, drapes, carpets, andother household articles.

SYSTEM OPERATIONINFORMATIONAdvise The Customer1. Keep the air filters clean. The

heating system will operate better,more efficiently and moreeconomically.

2. Arrange the furniture and drapes sothat the supply air registers and thereturn air grilles are unobstructed.

3. Close doors and windows. This willreduce the heating load on thesystem.

4. Avoid excessive use of kitchenexhaust fans.

5. Do not permit the heat generated bytelevision, lamps or radios toinfluence the thermostat operation.

6 Except for the mounting platform,keep all combustible articles threefeet from the furnace and ventsystem.

7. IMPORTANT: Replace all blowerdoors and compartment covers afterservicing the furnace. Do notoperate the unit without all panelsand doors securely in place.

8. Proper operation of the system withconstant air circulation.

ANNUAL INSPECTIONThe furnace should operate for manyyears without excessive scale build-upin the flue passageways, however, it isrecommended that a qualified installer,service agency, or the gas supplieractually inspect the flue passageways,the vent system and the main and pilotburners for continued safe operationpaying particular attention todeterioration from corrosion or othersources.

HOLES IN THE VENT PIPE OR HEATEXCHANGER CAN CAUSE TOXICFUMES TO ENTER THE HOMERESULTING IN CARBONMONOXIDE POISONING OR DEATH.THE VENT PIPE OR HEATEXCHANGER MUST BE REPLACEDIF THEY LEAK.

If during inspection the fluepassageways and vent system aredetermined to require cleaning, thefollowing procedures should befollowed (by a qualified installer,service agency, or gas supplier):

1. Turn off electrical power to thefurnace and set the thermostatlever to the lowest temperature.

2. Shut off the gas supply to thefurnace either at the meter or ata manual valve in the supplypiping.

3. Remove burner door. On downflowmodels, the blower door andburner door flange must also beremoved.

4. Disconnect gas supply piping fromgas valve.

5. Remove screws (4) connecting theburner tray to the center panel.

6. Disconnect wiring to the gas valve.Make sure to mark all wiresdisconnected for properreconnection.

7. Remove burner tray and manifoldassembly from the unit.

8. Remove all screws in the unit topplate. Remove the top plate alongwith connecting pressure switchfrom the unit.

9. Remove screws connecting draftinducer to center panel. Alsoremove wiring to draft inducer atthis time.

10. Remove screws (11) on perimeterof heat exchanger. If hot surfaceignition is present, remove theconnecting screws along withassociated wiring at this time.

11. In an upward and forward motion,lift heat exchanger from the unit.

12. Flush each heat exchanger tubewith water from a hose and blowout with air to remove excessivemoisture. If heat exchanger isblocked, especially with soot, andcannot be flushed, it must bereplaced.

13. Reassemble (steps 1 through 11 inreverse order.

• IMPORTANT: It is recommendedthat at the beginning of the heatingseason and approximately midwayin the heating season a visualinspection be made of the mainburner flames and pilot flame onstanding pilot models for the desiredflame appearance by a qualifiedinstaller, service agency, or the gassupplier.

• IMPORTANT: It is alsorecommended that at the beginningof the heating season, the flamesensor on hot surface ignitionmodels be cleaned with steel woolby a qualified installer, serviceagency, or the gas supplier.

• IMPORTANT: It is recommendedthat an annual inspection andcleaning of all furnace markings bemade to assure legibility. Attach areplacement marking, which can beobtained through the distributor, ifany are found to be eligible ormissing.

IMPORTANT: FOR Nox MODELS –At the beginning of the heating seasona visual inspection of the Nox shouldbe made to ensure they have notbecome obstructed by insects nests oranything else which may effectperformance.

REPLACEMENT PARTSContact your local distributor for acomplete parts list. See enclosedsheet.

TROUBLESHOOTINGRefer to Figures 33, 34, and 35 fordetermining cause of unit problems.

WIRING DIAGRAMFigures 36, 37 and 38 are completewiring diagrams for the furnace andpower sources.

WARNING!

FIGURE 33INTEGRATED FURNACE CONTROL (IFC) TROUBLESHOOTING GUIDEFOR UTEC 1012-920 & HONEYWELL S9201E2001 (115 VAC IGNITER)

START

1. SET FAN SWITCH TO AUTO2. SET THERMOSTAT TO

CALL FOR HEAT

INDUCED DRAFT MOTOR(IDM) STARTS

30 SEC. PREPURGE

IGNITER WARMS UPAND GLOWS RED

34 SECONDS WARMUP

MAIN BURNERLIGHTS

• REMOVE (IFC) COVER, CHECK LIGHTS

POWER LED ON • CHECK LINE VOLTAGE POWER• CHECK LOW VOLTAGE TRANSFORMER

MICROPROCESSOR STATUS LED ON REPLACE (IFC)NOTE: “OK” LED WILL FLASH TOINDICATE TWINNING CIRCUIT FAULTS.

CHECK FOR 24 VAC FROM CHECK THERMOSTATTERMINAL “W” TO “C” ON IFC WIRING

• CHECK LIMITS, (CLOSED)• CHECK WIRING

• CHECK PRESSURE SWITCH, (OPEN) REPLACE SWITCH

IF THE PRESSURE SWITCH DOESN’TCLOSE WITHIN 60 SEC. THE IDM WILLSTOP FOR 5 MIN. AND RETRY

• CHECK FOR 115VAC TO IDM MOTOR REPLACE (IFC)IF WIRING TO

IDM MOTOR IS OK

REPLACE IDM MOTOR

• CHECK FOR BLOCKED VENT REPLACE SWITCH• CHECK AIR PROVING SWITCH (CLOSED)

• CHECK WIRING TO IGNITER REPLACE (IFC)• CHECK FOR 115 VAC AT IGNITER, IF WIRING TOTERMINALS AND AT (IFC) TERMINALS IGNITER IS OK

REPLACE IGNITER

SYSTEM WILL ATTEMPT TO LIGHT 4 TIMES. VOLTAGE IS PRESENTAT THE VALVE FOR ONLY 9 SECONDS DURING EACH TRIAL FORIGNITION (SYSTEM WILL GO INTO A 1-HOUR LOCKOUT AFTER4 TRIES). THE BLOWER AND INDUCED DRAFT BLOWER WILL RUN180 SEC. IF THE FIRST IGNITION TRIAL FAILS TO SENSE FLAME

• CHECK FOR 24 VAC ACROSS THE VALVE ANDVALVE TERMINALS ON THE (IFC)

• CHECK IGNITER POSITION• CHECK FOR GAS FLOW TO AND FROM VALVE

REPLACE VALVE REPLACE (IFC)IF WIRING TOVALVE IS OK

37

WARNINGDISCONNECT POWER BEFORESERVICING.SERVICE MUST BE BY A TRAINED,QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGELINE VOLTAGECONNECTIONS

FLOW CHART CONTINUED ON NEXT PAGE

NO

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

NO

YES

NO

NO

NO

NO

NO

➤

38

NOTE: STATIC DISCHARGE CAN DAMAGE INTEGRATED FURNACE CONTROL (IFC)

MAIN BURNERREMAINS POWERED

AND LIT

INDOOR BLOWER MOTORSTARTS 20 SECONDS

AFTER GAS VALVE OPENS

SYSTEM RUNSUNTIL CALL FOR

HEAT ENDS

TURN THERMOSTAT TO OFFVALVE SHUTS OFF

FLAME OFF

IDM MOTOR STOPS AFTER 5 SEC.

INDOOR BLOWER MOTORSTOPS AFTER

90/120/160/180 SECONDS

TROUBLESHOOTING ENDS

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THENRESET SYSTEM

• CHECK POLARITY OF 115VAC SUPPLY• CHECK CONTINUITY OF GROUND WIRE• CHECK INSULATION OF IGNITER LEADS• CHECK FLAME SENSE CURRENT (YELLOW LED)

LED IS ON IF FLAME CURRENT IS GOOD.IT FLASHES IF CURRENT IS MARGINAL.

• TURN POWER OFF TO UNIT• CLEAN FLAME SENSOR WITH STEEL WOOL IF LED FLASHES• RESTORE POWER TO UNIT

• IF CHECKS ARE OK, REPLACE (IFC)

• CHECK FOR 115VAC ACROSS REPLACE (IFC) IFBLOWER MOTOR AND BLOWER WIRING TO BLOWERMOTOR TERMINALS (HEAT AND MOTOR IS OKNEUTRAL) ON (IFC)

REPLACE BLOWER MOTOR


• CHECK CONTINUITY OF GROUND WIRE. NOTE: IF GROUND ISPOOR OR ERRATIC, SHUTDOWN MAY OCCUR OCCASIONALLYEVEN THOUGH OPERATION IS NORMAL AT THE TIMEOF CHECKOUT.• CHECK FLAME SENSE CURRENT

• CHECK FOR EXCESSIVE HEAT AT IGNITER BASE(TEMP. ABOVE 1000 F (538 C) CAUSES SHORT TO GROUND)

• TURN POWER OFF TO UNIT• CLEAN FLAME SENSOR WITH STEEL WOOL• RESTORE POWER TO UNIT


• CHECK FOR PROPER THERMOSTAT OPERATION• REMOVE VALVE LEAD AT (IFC)IF VALVE CLOSED, RECHECK THERMOSTAT ANDWIRING. IF NOT, REPLACE VALVE.

• CHECK FOR OPEN LIMIT.• REPLACE (IFC)

• CHECK FOR OPEN LIMIT.REPLACE (IFC)

REPEAT PROCEDURE UNTIL TROUBLE FREEOPERATION IS OBTAINED.

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

• CHECK FOR BLOCKED VENT• CHECK AIR PROVING SWITCH (CLOSED)

• CHECK WIRING TO IGNITER• CHECK FOR 60 TO 90VAC AT IGNITER,TERMINALS AND AT (IFC) TERMINALS

39

FIGURE 34INTEGRATED FURNACE CONTROL (IFC) WHITE RODGERS 50A62-101(SILICON-NITRIDE IGNITER)

1. SET FAN SWITCH TO AUTO2. SET THERMOSTAT TO CALL

FOR HEAT

START

NO

NO

YES

YES

YES

YES

YES

NOINDUCED DRAFT BLOWERMOTOR STARTS

THE IFC WILLPERFORM A SELF-TEST OF THE IGNITERAND DRAFT MOTORCIRCUIT. IF THERE ISAN IGNITER FAULT,BAD CONNECTION TOTHE IGNITER, OR ABAD GROUNDCONNECTION, THEDRAFT MOTOR WILLSTOP AFTER A FEWSECONDS AND LOCK-OUT.

YES

NOPRE-PURGE CONTINUESIGNITER WARMS UP

AND GLOWS RED20 SECONDS WARMUP

YES

10 SEC. PREPURGE

REPLACE (IFC)

NO REPLACE SWITCH

NOREPLACE (IFC)IF WIRING TO

DRAFT MOTOR IS OK

NO REPLACE SWITCH

NOREPLACE (IFC)IF WIRING TOIGNITER IS OK

NO CHECK THERMOSTATWIRING

• CHECK LINE VOLTAGE POWER• CHECK LOW VOLTAGE TRANSFORMER

WHITE-RODGERS 50A62-101INTEGRATED FURNACE CONTROL (IFC)

TROUBLESHOOTING GUIDE(SILICON-NITRIDE IGNITER)

POWER LED ON

IF THE PRESSURE SWITCH DOESN’TCLOSE WITHIN 60 SEC. THE IOM WILLSTOP FOR 5 MIN. AND RETRY


MICROPROCESSOR STATUS “OK” LED ONNOTE: “OK” LED WILL FLASH TO INDICATETWINNING CIRCUIT FAULTS

• CHECK FOR 115VAC TO DRAFT MOTOR

REPLACE IOM MOTOR

CHECK FOR 24 VAC FROM“W” TO “C” ON IFC


• CHECK PRESSURE SWITCH, (OPEN)

YES

REPLACE IGNITER

NO

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• CHECK CONTINUITY OF GROUND WIRE. NOTE: IF GROUND ISPOOR OR ERATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVENTHOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.• CHECK FLAME SENSE CURRENT

• CHECK FOR EXCESSIVE HEAT AT IGNITER BASE.• TURN POWER OFF TO UNIT.• CLEAN FLAME SENSOR WITH STEEL WOOL.• RESTORE POWER TO UNIT.


40

YES

NO

NO

MAIN BURNERLIGHTS

YES

NOMAIN BURNER REMAINS

POWERED AND LIT

YES

YES

YES

NOSYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

NOINDOOR BLOWER MOTORSTARTS 20 SECONDS

AFTER BURNERS LIGHT

YES


REPLACE VALVE REPLACE (IFC) IF WIRINGTO VALVE IS OK

REPLACE (IFC) IFWIRING TO BLOWERMOTOR IS OK


• CHECK POLARITY OF 115VAC SUPPLY• CHECK CONTINUITY OF GROUND WIRE• CHECK INSULATION ON IGNITER LEADS• CHECK FLAME SENSE CURRENT (YELLOW LED)

LED IS ON IF FLAME CURRENT IS GOOD.IT FLASHES IF CURRENT IS MARGINAL.• TURN POWER OFF TO UNIT.• CLEAN FLAME SENSOR WITH STEEL WOOL IF LED FLASHES• RESTORE POWER TO UNIT


SYSTEM WILL ATTEMPT TO LIGHT 4 TIMES. VOLTAGE IS PRESENT AT THEVALVE FOR ONLY 8 SECONDS DURING EACH TRIAL FOR IGNITION (SYSTEMWILL GO INTO A 1-HOUR LOCKOUT AFTER 4 TRIES), THE SEQUENCE WILLREPEAT AFTER A ONE HOUR DELAY. IT WILL CONTINUE UNTIL IGNITION ISSUCCESSFUL OR THE CALL FOR HEAT IS TERMINATED. THE BLOWER ANDINDUCED DRAFT BLOWER WILL RUN 100 SECONDS. IF THE FIRST AND SECONDIGNITION TRIAL FAILS TO SENSE FLAME

• CHECK FOR 24VAC ACROSS THE VALVE ANDVALVE TERMINALS ON THE (IFC)

NO• CHECK IGNITER POSITION,• CHECK FOR GAS FLOW TO AND FROM VALVE.

• CHECK FOR 115VAC ACROSS BLOWERMOTOR AND BLOWER MOTOR TERMINALS(HEAT AND NEUTRAL) ON (IFC)

NOTURN THERMOSTAT TO OFFVALVE SHUTS OFF

FLAME OFF

• CHECK FOR PROPER THERMOSTAT OPERATION.• REMOVE VALVE LEAD AT (IFC)IF VALVE CLOSED, RECHECK THERMOSTAT ANDWIRING IF NOT, REPLACE VALVE

YES

NOIDM MOTOR STOPSAFTER 5 SEC.


• CHECK FOR OPEN LIMIT,REPLACE (IFC)

YES

NOINDOOR BLOWER MOTOR

STOPS AFTER90/120/160/180 SECONDS


REPEAT PROCEDURE UNTIL TROUBLEFREEOPERATION IS OBTAINED.

92-22744-11-02

FIGURE 35INTEGRATED FURNACE CONTROL (IFC) UTEC 1012-925 (115 VAC IGNITER)

1. SET FAN SWITCH TO AUTO2. SET THERMOSTAT TO CALL

FOR HEAT

41

START

WARNINGDISCONNECT POWER BEFORESERVICING.SERVICE MUST BE BY A TRAINED,QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGELINE VOLTAGECONNECTIONS

NO

NO

YES

YES

YES

YES

YES

NO

!

INDUCED DRAFT BLOWERMOTOR STARTS

YES

NOPURGE CONTINUESIGNITER WARMS UP

AND GLOWS RED30 SECONDS WARMUP

YES

5 SEC. PREPURGE

REPLACE (IFC)

NO REPLACE SWITCH

NOREPLACE (IFC)IF WIRING TO

DRAFT MOTOR IS OK

NO REPLACE SWITCH

NOREPLACE (IFC)IF WIRING TOIGNITER IS OK

NO CHECK THERMOSTATWIRING

• CHECK LINE VOLTAGE POWER• CHECK LOW VOLTAGE TRANSFORMER

NOTE: STATIC DISCHARGE CAN DAMAGE INTEGRATED FURNACE CONTROL (IFC)• “OK” LED BLINKS TO INDICATE EXTERNAL FAULTS:(1) BLINK FOLLOWED BY A 2 SEC. PAUSE - 1 HOUR LOCKOUT(2) BLINKS FOLLOWED BY A 2 SEC. PAUSE - PRESSURE SWITCH IS OPEN(3) BLINKS FOLLOWED BY A 2 SEC. PAUSE - LIMIT SWITCH IS OPEN(4) BLINKS FOLLOWED BY A 2 SEC. PAUSE - PRESSURE SWITCH SHORTED

INTEGRATED FURNACE CONTROL (IFC)TROUBLESHOOTING GUIDE

(115 VAC IGNITER)

CHECK FOR 24 VACPOWER FROM “R”TO “C” ON IFC

IF THE PRESSURE SWITCH DOESN’TCLOSE WITHIN 60 SEC. THE IOM WILLSTOP FOR 5 MIN. AND RETRY


MICROPROCESSOR STATUS “OK” LED ON

• CHECK FOR 115VAC TO DRAFT MOTOR

REPLACE DRAFT MOTOR

CHECK FOR 24 VAC FROM“W” TO “C” ON IFC


• CHECK PRESSURE SWITCH, (OPEN)

YES

REPLACE IGNITER

• CHECK FOR BLOCKED VENT• CHECK AIR PROVING SWITCH (CLOSED)

• CHECK WIRING TO IGNITER• CHECK FOR 115VAC AT IGNITER,TERMINALS AND AT (IFC) TERMINALS

42

YES

NO

NO

MAIN BURNERREMAINS POWERED

AND LIT

YES

YES

YES

NOMAIN BURNERREMAINS POWERED

AND LIT

NOINDOOR BLOWER MOTORSTARTS 20 SECONDS

AFTER GAS VALVE OPENS

YES


REPLACE VALVE IF NOFLOW THRU VALVE

REPLACE (IFC) IF WIRINGTO VALVE IS OK

REPLACE (IFC) IFWIRING TO BLOWERMOTOR IS OK


• CHECK POLARITY OF 115VAC SUPPLY• CHECK CONTINUITY OF GROUND WIRE• CHECK INSULATION ON IGNITER LEADS• CHECK FLAME SENSE CURRENT (YELLOW LED)

LED IS ON IF FLAME CURRENT IS GOOD.IT FLASHES IF CURRENT IS MARGINAL.• TURN POWER OFF TO UNIT.• CLEAN FLAME SENSOR WITH STEEL WOOL IF LED FLASHES• RESTORE POWER TO UNIT



• CHECK CONTINUITY OF GROUND WIRE, NOTE: IF GROUND ISPOOR OR ERATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVENTHOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.• CHECK FLAME SENSE CURRENT

• CHECK FOR EXCESSIVE HEAT AT IGNITER BASE, (TEMP.ABOVE 1000 F (538 C) CAUSES SHORT TO GROUND)

• TURN POWER OFF TO UNIT.• CLEAN FLAME SENSOR WITH STEEL WOOL.• RESTORES POWER TO UNIT.


SYSTEM WILL ATTEMPT TO LIGHT 4 TIMES. VOLTAGE IS PRESENT AT THEVALVE FOR ONLY 8 SECONDS DURING EACH TRIAL FOR IGNITION (SYSTEMWILL GO INTO A 1-HOUR LOCKOUT AFTER 4 TRIES), THE BLOWER ANDINDUCED DRAFT BLOWER WILL RUN 100 SEC. IF THE SECOND IGNITIONTRIAL FAILS TO SENSE FLAME

• CHECK FOR 24VAC ACROSS THE VALVE ANDVALVE TERMINALS ON THE (IFC)

NO• CHECK IGNITER POSITION,• CHECK FOR GAS FLOW TO AND FROM VALVE.

• CHECK FOR 115VAC ACROSS BLOWERMOTOR AND BLOWER MOTOR TERMINALS(HEAT AND NEUTRAL) ON (IFC)

NOTURN THERMOSTAT TO OFFVALVE SHUTS OFFFLAME GOES OUT

• CHECK FOR PROPER THERMOSTAT OPERATION.• REMOVE VALVE LEAD AT (IFC)IF VALVE CLOSED, RECHECK THERMOSTAT ANDWIRING IF NOT, REPLACE VALVE

YES

NODRAFT MOTOR STOPSAFTER 5 SEC.



YES

NOINDOOR BLOWER MOTOR

STOP AFTER90/120/160/180 SECONDS


REPEAT PROCEDURE UNTIL TROUBLEFREEOPERATION IS OBTAINED.

92-22744-10-00

FIGURE 36FOR MODELS WITH UTEC 1012-920 OR HONEYWELL S9201E2001 INTEGRATED FURNACE CONTROL

43

44

FIGURE 37FOR MODELS WITH WHITE RODGERS 50A62-101 INTEGRATED FURNACE CONTROL

45

FIGURE 38FOR MODELS WITH UTEC 1012-925 INTEGRATED FURNACE CONTROL

46

47

48 CM 398

Rheem Manufacturing CompanyAir Conditioning DivisionFort Smith, Arkansas

Documents

INSTALLATION INSTRUCTIONS FOR UPFLOW (RGDG & RGDJ), … · 2015. 9. 28. · 92-23531-70-01 SUPERSEDES 92-23531-70-00 INSTALLATION INSTRUCTIONS FOR UPFLOW (RGDG & RGDJ), UPFLOW/HORIZONTAL