RPJ II Furnace Manual

The RPJ II Furnace is a high-efficiency residential heating system with advanced combustion technology, variable-speed blower motor, electronic ignition, built-in diagnostics, multiple heating stages, and smart thermostat compatibility. Designed for natural gas or propane operation with AFUE ratings up to 98%, this furnace features durable stainless steel heat exchangers, quiet operation, and comprehensive safety controls. Below are key sections for safety, features, installation, setup, operation, and troubleshooting.

Features at a Glance

Key components: Stainless steel heat exchanger, variable-speed blower motor, electronic ignition system, control board with diagnostics, gas valve, pressure switches, flame sensor, and thermostat connections.

Feature	Description
Heat Exchanger	Stainless steel construction for durability and efficiency
Blower Motor	Variable-speed ECM motor for quiet operation
Ignition System	Electronic hot surface ignition
Control Board	Microprocessor with LED diagnostic codes
Gas Valve	Modulating for precise temperature control
Pressure Switches	Safety verification of proper venting
Flame Sensor	Confirms burner ignition
Thermostat Connections	Compatible with conventional and smart thermostats
Air Filter	Standard 1-inch or 4-inch media filter compatible
Vent Connections	PVC piping for direct vent operation

Installation

Unpack and inspect contents. Position in approved location with proper clearances.

1. Gas connection: Use approved gas piping; pressure test for leaks before connection.
2. Electrical connection: Connect to 120V AC power with proper grounding.
3. Vent system: Install PVC vent pipes according to manufacturer specifications.
4. Ductwork: Connect supply and return ducts with proper sealing.
5. Condensate drain: Route to approved drain location.

WARNING! Installation must be performed by qualified HVAC technician. Gas leaks can cause explosion or fire. Ensure proper ventilation and combustion air supply.

First-Time Setup

Power on furnace; follow startup sequence.

1. System check: Verify all connections are secure and proper.
2. Gas pressure adjustment: Set manifold pressure to specifications.
3. Blower speed settings: Adjust for proper airflow and temperature rise.
4. Thermostat configuration: Program heating cycles and fan operation.
5. Test operation: Run through complete heating cycle to verify performance.

CAUTION! Never bypass safety controls. Ensure proper combustion air and venting before operation.

Specifications

• Heating Capacity: 40,000 to 120,000 BTU/hr models available
• Efficiency: Up to 98% AFUE
• Fuel Type: Natural gas or propane (conversion kit required)
• Electrical: 120V AC, 60Hz, 15 amp circuit
• Blower Motor: Variable-speed ECM
• Stages: Single-stage, two-stage, or modulating operation
• Sound Level: As low as 65 dB in operation
• Vent Material: 2" or 3" PVC Schedule 40
• Operating Temp Range: -30°F to 120°F ambient
• Warranty: 20-year heat exchanger, 10-year parts

Controls and Settings

Access control board via front panel. LED status lights indicate system operation and fault codes.

Thermostat Controls: HEAT/COOL/OFF mode selection, temperature setpoint, fan AUTO/ON operation, system programming.

Heating Stages: Single-stage (on/off), two-stage (low/high heat), modulating (incremental heat). Blower Settings: Adjustable speeds for heating and continuous fan operation. Diagnostic Codes: LED flash patterns indicate specific system faults and operational status.

Connecting Components

Gas supply: Black iron pipe with sediment trap. Electrical: 120V AC power with disconnect switch. Thermostat: 2-wire to 8-wire compatible.

1. Turn off gas and electrical power before making connections.
2. Match wire colors to terminal designations (R, W, Y, G, C).
3. Use proper pipe sealant for gas connections - no Teflon tape.
4. Ensure vent pipes slope properly toward furnace for condensate drainage.

Tip: Always use a manometer to verify proper gas pressure settings after installation.

Operating Procedures

Normal heating operation with thermostat control.

1. Set thermostat to HEAT mode and desired temperature.
2. System initiates: Inducer motor starts, pressure switch verifies, igniter heats.
3. Gas valve opens, burner ignites, flame sensor confirms.
4. Blower motor starts after heat exchanger warm-up delay.
5. System cycles off when thermostat setpoint is reached.
6. Blower continues running during post-purge cycle.

WARNING! Never operate furnace with access panels removed. Keep combustible materials away from furnace. Install carbon monoxide detectors in living areas.

Maintenance Features

Self-diagnostics: LED fault codes indicate specific issues. Filter monitoring: Reminder for regular filter changes. Safety shutdown: Automatic shutoff for unsafe conditions.

Care & Cleaning

Turn off power before servicing. Replace air filters monthly during heating season. Annual professional inspection recommended.

CAUTION! Do not use compressed air to clean heat exchanger. Never operate without air filter. Keep burners and flame sensor clean.

Regulatory Information

ANSI Z21.47: Certified for gas-fired central furnaces. UL 1995: Standard for heating and cooling equipment. Meets DOE energy efficiency standards. For support, contact manufacturer technical service at 1-800-555-HEAT or visit www.rpjfurnace.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power/thermostat/safety lockout	Check circuit breaker; verify thermostat settings; reset power.
No heat	Gas supply/ignition	Verify gas valve on; check pilot/igniter; inspect flame sensor.
Short cycling	Dirty filter/overheating	Replace air filter; check airflow restrictions; verify temperature rise.
Blower not running	Motor/control board	Check capacitor; verify control board signals; inspect motor.
Unusual noises	Mechanical issues	Inspect blower wheel; check inducer motor; verify heat exchanger.

Reset: Power cycle furnace at disconnect switch or circuit breaker.

Service: 1-800-555-HEAT; www.rpjfurnace.com