FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH EFFICIENCY …pts.myrheem.com › docstore › webdocs › ServiceDocs › histlib › ... · 2012-05-14 · in a mobile home!! this furnace

92-24161-16-20SUPERSEDES 92-24161-16-19

INSTALLATION INSTRUCTIONSFOR UPFLOW & DOWNFLOW/HORIZONTAL HIGHEFFICIENCY CONDENSING GAS FURNACESRGRA/RGRB/RGTA/RGRS/RGTS/RGRT SERIES

ISO 9001:2008

U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in allapplications, and their installation should be in accordance with the manufacturer’srecommendations and/or local laws, rules, regulations, or customs.

INSTALLATION CHECK LISTREFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

Adequate pipe size

Correct supply pressure (during furnace operation)

Manifold pressure

No gas leaks

L.P. Kit Number (if applicable)

ELECTRICAL

115 V.A.C. supply (Single Circuit)

Polarity observed

Furnace properly grounded

Adequate wire size

FURNACE INSTALLATION

Adequate clearance to combustibles

Adequate clearance for service (at front)

DUCT STATIC PRESSURE

in. w.c. on heating speed

in. w.c. on cooling speed

Air temperature rise

CONDENSATE LINE

Trap filled with water

Vented

Sloped toward drain

Condensate drain line hoses connectedand clamped

Freeze protection (if necessary)

VENTING – DIRECT VENT

in. diameter – intake pipe

in. diameter – exhaust pipe

ft. of pipe – intake air

no. of elbows – intake air

ft. of pipe – exhaust pipe

no. of elbows – exhaust pipe

Exhaust vent temp.

TERMINATIONS – DIRECT VENT

VERTICAL

Intake – 12" min. above roof/snow level

Correct relationship – exhaust to intake

HORIZONTAL/VERTICAL – CONCENTRIC (RXGY-E03A)

Intake – 12" min. above roof/snow level

Intake “Y” rotated above center

Exhaust sloped toward furnace

HORIZONTAL – STANDARD (RXGY-D02, -D02A, -D03,D03A)


12" min. above grade/snow level

HORIZONTAL – ALTERNATE (RXGY-D02, -D02A, -D03, -D03A, -D04 OR -D04A)


Above anticipated snow level

VENTING – NON-DIRECT VENT

in. diameter – exhaust pipe

ft. of pipe – exhaust

no. of elbows

TERMINATION – NON-DIRECT VENT

VERTICAL

12" min. above roof/snow level

HORIZONTAL – STANDARD

12" min. above grade/snow level

HORIZONTAL – ALTERNATE

Above anticipated snow level

Model Number

Serial #

Date of Installation

2

3

SAFETY INFORMATION

NEVER TEST FOR GAS LEAKSWITH AN OPEN FLAME. USE ACOMMERCIALLY AVAILABLESOAP SOLUTION MADESPECIFICALLY FOR THEDETECTION OF LEAKS TO CHECKALL CONNECTIONS, ASSPECIFIED IN GAS SUPPLY ANDPIPING SECTION OF THESEINSTRUCTIONS.

ALWAYS INSTALL FURNACE TOOPERATE WITHIN THEFURNACE'S INTENDEDTEMPERATURE-RISE RANGEWITH A DUCT SYSTEM WHICHHAS AN EXTERNAL STATICPRESSURE WITHIN THEALLOWABLE RANGE, ASSPECIFIED IN DUCTING SECTIONOF THESE INSTRUCTIONS. SEEALSO FURNACE RATING PLATE.

WHEN A FURNACE IS INSTALLEDSO THAT SUPPLY DUCTS CARRYAIR CIRCULATED BY THEFURNACE TO AREAS OUTSIDETHE SPACE CONTAINING THEFURNACE, THE RETURN AIRSHALL ALSO BE HANDLED BYDUCT(S) SEALED TO THEFURNACE CASING ANDTERMINATING OUTSIDE THESPACE CONTAINING THEFURNACE.

WHEN THIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BE INSTALLEDSO THE BURNERS AND IGNITIONSOURCE ARE LOCATED NO LESSTHAN 18 INCHES ABOVE THEFLOOR. THIS IS TO REDUCE THERISK OF IGNITING FLAMMABLEVAPORS WHICH MAYBE PRESENT IN A GARAGE.ALSO, THE FURNACE MUST BELOCATED OR PROTECTED TOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOLLOWTHESE WARNINGS CAN CAUSE AFIRE OR EXPLOSION, RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

INSTALLATION MUST COMPLYWITH ALL INSTALLATIONINSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDERTHERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TOTHE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATEAND TEMPERATURE RISE PERRATING PLATE MARKING;

• MEANS FOR PROVIDINGOUTDOOR AIR REQUIRED FORCOMBUSTION;

• RETURN AIR TEMPERATUREMAINTAINED BETWEEN 55°F(13°C) AND 80°F (27°C); AND

• CLEAN FURNACE, DUCT WORKAND COMPONENTS UPONSUBSTANTIAL COMPLETION OFTHE CONSTRUCTIONPROCESS, AND VERIFYFURNACE OPERATINGCONDITIONS INCLUDINGIGNITION, INPUT RATE,TEMPERATURE RISE ANDVENTING, ACCORDING TO THEINSTRUCTIONS.

! WARNING

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! WARNINGDO NOT OPERATE THE SYSTEMFOR EXTENDED PERIODSWITHOUT FILTERS. A PORTIONOF THE DUST ENTRAINED IN THEAIR MAY TEMPORARILY LODGEIN THE AIR DUCT RUNS AND ATTHE SUPPLY REGISTERS. ANYCIRCULATED DUST PARTICLESWILL BE HEATED AND CHARREDBY CONTACT WITH THEFURNACE HEAT EXCHANGER.THIS SOOTY RESIDUE WILL SOILCEILINGS, WALLS, DRAPES,CARPETS AND OTHERHOUSEHOLD ARTICLES. SOOTDAMAGE MAY ALSO RESULTWITH, OR WITHOUT, FILTERS INPLACE, WHEN CERTAIN TYPESOF CANDLES ARE BURNED, ORCANDLEWICKS ARE LEFTUNTRIMMED.

COMBUSTION PRODUCTS MUSTBE DISCHARGED OUTDOORS.CONNECT THIS FURNACE TO ANAPPROVED VENT SYSTEM ONLY,AS SPECIFIED IN VENT PIPEINSTALLATION SECTION OFTHESE INSTRUCTIONS.

! WARNINGDO NOT INSTALL THIS FURNACEIN A MOBILE HOME!! THISFURNACE IS NOT APPROVEDFOR INSTALLATION IN A MOBILEHOME. DOING SO COULD CAUSEFIRE, PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

PROVIDE ADEQUATECOMBUSTION AND VENTILATIONAIR TO THE FURNACE SPACE ASSPECIFIED IN THE COMBUSTIONAND VENTILATION AIR SECTIONOF THESE INSTRUCTIONS.

INSTALL THIS FURNACE ONLY INA LOCATION AND POSITION ASSPECIFIED IN THE LOCATIONREQUIREMENTS ANDCONSIDERATIONS SECTION OFTHESE INSTRUCTIONS. PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR TO THEFURNACE SPACE AS SPECIFIEDIN THE VENTING SECTION OFTHESE INSTRUCTIONS.

USE ONLY WITH TYPE OF GASAPPROVED FOR THIS FURNACE.REFER TO THE FURNACE RATINGPLATE.

4

DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM ANDDRAW POLLUTANTS SUCH ASDIRT, DUST, FUMES AND ODORSINTO THE HOME CAUSINGPROPERTY DAMAGE. FUMESAND ODORS FROM TOXIC,VOLATILE OR FLAMMABLECHEMICALS, AS WELL ASAUTOMOBILE EXHAUST ANDCARBON MONOXIDE (CO), CANBE DRAWN INTO THE LIVINGSPACE THROUGH LEAKINGDUCTS AND UNBALANCED DUCTSYSTEMS CAUSING PERSONALINJURY OR DEATH (SEE FIGURE3). • IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTBE SEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDINGCARBON MONOXIDE FROMMIGRATING INTO THE LIVINGSPACE.

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCHAS WATER HEATERS ORBOILERS - ALL JOINTS, SEAMS,AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTALSO BE SEALED TO PREVENTDEPRESSURIZATION OF THESPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDINGCARBON MONOXIDE INTO THELIVING SPACE.

IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCE WITH THE CSAINTERNATIONAL (CSA)CERTIFICATION OR THESEINSTRUCTIONS, CAN RESULT INUNSATISFACTORY OPERATIONAND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVEREDBY THE UNIT WARRANTY.

IN COMPLIANCE WITHRECOGNIZED CODES, IT ISRECOMMENDED THAT ANAUXILIARY DRAIN PAN BEINSTALLED UNDER ALLEVAPORATOR COILS OR UNITSCONTAINING EVAPORATORCOILS OR GAS FURNACES USEDWITH EVAPORATOR COILS THATARE LOCATED IN ANY AREA OF ASTRUCTURE WHERE DAMAGE TOTHE BUILDING OR BUILDINGCONTENTS MAY OCCUR AS ARESULT OF AN OVERFLOW OFTHE COIL DRAIN PAN OR ASTOPPAGE IN THE PRIMARYCONDENSATE DRAIN PIPING.

IMPORTANT!THE COMMONWEALTH OFMASSACHUSETTS REQUIRESCOMPLIANCE WITH REGULATION248 CMR 4.00 AND 5.00 FORINSTALLATION OF THROUGH-THE-WALL VENTED GAS APPLIANCESAS FOLLOWS:(a) For all side wall horizontally ventedgas fueled equipment installed in everydwelling, building or structure used inwhole or in part for residential purposes,including those owned or operated bythe Commonwealth and where the sidewall exhaust vent termination is lessthan seven (7) feet above finished gradein the area of the venting, including butnot limited to decks and porches, thefollowing requirements shall be satisfied:1. INSTALLATION OF CARBONMONOXIDE DETECTORS. At the timeof installation of the side wall horizontalvented gas fueled equipment, theinstalling plumber or gasfitter shallobserve that a hard wired carbonmonoxide detector with an alarm andbattery back-up is installed on the floorlevel where the gas equipment is to beinstalled. In addition, the installingplumber or gasfitter shall observe that abattery operated or hard wired carbonmonoxide detector with an alarm isinstalled on each additional level of thedwelling, building or structure served bythe side wall horizontal vented gasfueled equipment. It shall be theresponsibility of the property owner tosecure the services of qualified licensedprofessionals for the installation of hardwired carbon monoxide detectors.a. In the event that the side wallhorizontally vented gas fueledequipment is installed in a crawl spaceor an attic, the hard wired carbonmonoxide detector with alarm andbattery back-up may be installed on thenext adjacent floor level.b. In the event that the requirements ofthis subdivision can not be met at thetime of completion of installation, theowner shall have a period of thirty (30)days to comply with the aboverequirements; provided, however, thatduring said thirty (30) day period, abattery operated carbon monoxidedetector with an alarm shall be installed.2. APPROVED CARBON MONOXIDEDETECTORS. Each carbon monoxidedetector as required in accordance withthe above provisions shall comply withNFPA 720 and be ANSI/UL 2034 listedand IAS certified.3. SIGNAGE. A metal or plasticidentification plate shall be permanentlymounted to the exterior of the building ata minimum height of eight (8) feet abovegrade directly in line with the exhaustvent terminal for the horizontally ventedgas fueled heating appliance orequipment. The sign shall read, in printsize no less than one-half (1/2) inch insize, “GAS VENT DIRECTLY BELOW.KEEP CLEAR OF ALLOBSTRUCTIONS”.

4. INSPECTION. The state or localgas inspector of the side wallhorizontally vented gas fueledequipment shall not approve theinstallation unless, upon inspection,the inspector observes carbonmonoxide detectors and signageinstalled in accordance with theprovisions of 248 CMR 5.08(2)(a) 1through 4.(b) EXEMPTIONS: The followingequipment is exempt from 248 CMR5.08(2)(a)1 through 4:1. The equipment listed in Chapter 10entitled “Equipment Not Required ToBe Vented” in the most current editionof NFPA 54 as adopted by the Board;and2. Product Approved side wallhorizontally vented gas fueledequipment installed in a room orstructure separate from the dwelling,building or structure used in whole orin part for residential purposes.(c) MANUFACTURERREQUIREMENTS – GASEQUIPMENT VENTING SYSTEMPROVIDED. When the manufacturerof Product Approved side wallhorizontally vented gas equipmentprovides a venting system design orventing system components with theequipment, the instructions providedby the manufacturer for installation ofthe equipment and the ventingsystem shall include:1. Detailed instructions for theinstallation of the venting systemdesign or the venting systemcomponents; and2. A complete parts list for the ventingsystem design or venting system.(d) MANUFACTURERREQUIREMENTS – GASEQUIPMENT VENTING SYSTEMNOT PROVIDED. When themanufacturer of a Product Approvedside wall horizontally vented gasfueled equipment does not providethe parts for venting the flue gases,but identifies “special ventingsystems”, the following requirementsshall be satisfied by the manufacturer:1. The referenced “special ventingsystem” instructions shall be includedwith the appliance or equipmentinstallation instructions; and2. The “special venting systems” shallbe Product Approved by the Board,and the instructions for that systemshall include a parts list and detailedinstallation instructions.(e) A copy of all installationinstructions for all Product Approvedside wall horizontally vented gasfueled equipment, all ventinginstructions, all parts lists for ventinginstructions, and/or all venting designinstructions shall remain with theappliance or equipment at thecompletion of the installation.

! WARNING

NOTICE

NOTICE

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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

Safety Information ....................................................................................................3

General Information..................................................................................................6

Location Requirements and Considerations ............................................................8

Ducting ...................................................................................................................13

Venting and Combustion Air Piping .......................................................................14

Combustion and Ventilation Air ..............................................................................16

Vent Pipe Installation..............................................................................................19

Condensate Drain/Neutralizer ................................................................................32

Converting Downflow to Horizontal ........................................................................34

Gas Supply and Piping...........................................................................................36

LP Conversion........................................................................................................38

High Altitude Instructions........................................................................................39

Electrical Wiring......................................................................................................44

Accessories ............................................................................................................45

Furnace Twinning...................................................................................................45

Start-Up Procedures...............................................................................................48

Air Flow...................................................................................................................50

Maintenance...........................................................................................................53

Troubleshooting......................................................................................................56

Wiring Diagrams................................................................................................57-60

IMPORTANT: All manufacturerproducts meet current Federal OSHAGuidelines for safety. CaliforniaProposition 65 warnings are requiredfor certain products, which are notcovered by the OSHA standards.

California's Proposition 65 requireswarnings for products sold in Californiathat contain, or produce, any of over600 listed chemicals known to the Stateof California to cause cancer or birthdefects such as fiberglass insulation,lead in brass, and combustion productsfrom natural gas.

All “new equipment” shipped for sale inCalifornia will have labels stating thatthe product contains and/or producesProposition 65 chemicals. Although wehave not changed our processes,having the same label on all ourproducts facilitates manufacturing andshipping. We cannot always know“when, or if” products will be sold in theCalifornia market.

You may receive inquiries fromcustomers about chemicals found in, orproduced by, some of our heating andair-conditioning equipment, or found innatural gas used with some of ourproducts. Listed below are thosechemicals and substances commonlyassociated with similar equipment inour industry and other manufacturers.

• Glass Wool (Fiberglass) Insulation• Carbon Monoxide (CO)• Formaldehyde• Benzene

More details are available at theWebsites for OSHA (OccupationalSafety and Health Administration), atwww.osha.gov and the State ofCalifornia's OEHHA (Office ofEnvironmental Health HazardAssessment), at www.oehha.org.Consumer education is important sincethe chemicals and substances on thelist are found in our daily lives. Mostconsumers are aware that productspresent safety and health risks, whenimproperly used, handled andmaintained.

The RGRA/RGRB/RGTA/RGRS/RGTS/RGRT series furnaces aredesign-certified by CSA for use withnatural and propane gases as follows:

1. As non-direct vent central forcedair furnaces taking combustionair from the installation area orusing air ducted from the outside.

2. As direct vent central forced airfurnaces with all combustion airsupplied directly to the furnaceburners through a special airintake system outlined in theseinstructions.

Install this furnace in accordance withthe American National Standard

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Z223.1 – latest edition entitled“National Fuel Gas Code” (NFPA54)and requirements or codes of thelocal utilities or other authoritieshaving jurisdiction. This is availablefrom the following:

National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

CSA-INTERNATIONAL8501 East Pleasant Valley RoadCleveland, Ohio 44131-5575

Install units in Canada in accordancewith CSA-B149, local installation

codes and authorities havingjurisdiction. CSA-B149 is availablefrom:

CSA-INTERNATIONAL178 Rexdale Blvd.Toronto, OntarioCanada M9W, 1R3

NOTE:Models having option code 320added at the end of the model numberdesignation are shipped factory readyfor a horizontal only installation. Thedrain trap for downflow installation isnot included in the parts bag for theseappliances.

GENERAL INFORMATION

FIGURE 1UPFLOW FURNACE

FIGURE 2DOWNFLOW/HORIZONTAL FURNACE

ITEM ITEMNO. PART NAME NO. PART NAME

1 INDUCED DRAFT BLOWER 14 LOW VOLTAGE TERMINAL (THERMOSTAT)2 CAPACITOR 15 TRANSFORMER3 INLET AIR CHASE 16 PRESSURE SWITCH4 DOOR SWITCH 17 OUTLET AIR PIPE5 JUNCTION BOX 18 GAS VALVE6 INLET PIPE CONNECTOR 19 CONNECTOR7 TOP PLATE 20 EXHAUST TRANSITION8 CONTROL MOUNTING PLATE 21 CONDENSATE TRAP9 AUXILIARY LIMIT 22 IGNITER (HSI)10 SHIPPING PLUG 23 MANIFOLD11 EXHAUST CONNECTION 24 OVERTEMPERATURE SWITCH12 BLOWER 25 ROLLOUT SWITCH13 EXHAUST PIPE EXTENSION 26 FLAME SENSOR

27 BURNER

ITEM ITEMNO. PART NAME NO. PART NAME

1 CONDENSATE TRAP 13 TOP PLATE2 DOOR SWITCH 14 BURNER3 JUNCTION BOX 15 IGNITER (HSI ONLY)4 TRANSFORMER 16 COMBUSTION AIR INLET5 BLOCKED DRAIN PRESSURE SWITCH 17 GAS VALVE6 MAIN PRESSURE SWITCH 18 INDUCED DRAFT BLOWER7 EXHAUST TRANSITION 19 CAPACITOR 8 CONNECTOR 20 LOW VOLTAGE (THERMOSTAT)9 OUTLET AIR PIPE TERMINAL10 SHIPPING PLUG 21 CONTROL MOUNTING PLATE11 FLAME SENSOR 22 BLOWER12 OVERTEMPERATURE SWITCH

I409 I409

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“National Fire ProtectionAssociation, Inc., BatterymarchPark, Quincy, MA 02269.” Thesepublications are:

• ANSI/NFPA No. 70-(Latest Edition)National Electrical Code.

• NFPA90A Installation of AirConditioning and VentilatingSystems.

• NFPA90B Installation of warm airheating and air conditioningsystems.

• The equipment has beenevaluated in accordance with theCode of Federal Regulations,Chapter XX, Part 3280.

IMPORTANTINFORMATION ABOUTEFFICIENCY AND INDOORAIR QUALITYCentral cooling and heatingequipment is only as efficient as theduct system that carries the cooled orheated air. To maintain efficiency,comfort and good indoor air quality, itis important to have the properbalance between the air beingsupplied to each room and the airreturning to the cooling and heatingequipment. Proper balance and sealing of theduct system improves the efficiencyof the heating and air conditioningsystem and improves the indoor airquality of the home by reducing theamount of airborne pollutants thatenter homes from spaces where theductwork and / or equipment islocated. The manufacturer and theU.S. Environmental ProtectionAgency’s Energy Star Programrecommend that central duct systemsbe checked by a qualified contractorfor proper balance and sealing.

DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM ANDDRAW POLLUTANTS SUCH ASDIRT, DUST, FUMES AND ODORSINTO THE HOME CAUSINGPROPERTY DAMAGE. FUMESAND ODORS FROM TOXIC,VOLATILE OR FLAMMABLECHEMICALS, AS WELL ASAUTOMOBILE EXHAUST ANDCARBON MONOXIDE (CO), CANBE DRAWN INTO THE LIVINGSPACE THROUGH LEAKINGDUCTS AND UNBALANCED DUCTSYSTEMS CAUSING PERSONALINJURY OR DEATH (SEE FIGURE3). • IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTBE SEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDINGCARBON MONOXIDE FROMMIGRATING INTO THE LIVINGSPACE.

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCHAS WATER HEATERS ORBOILERS - ALL JOINTS, SEAMS,AND OPENINGS IN THEEQUIPMENT AND DUCT MUSTALSO BE SEALED TO PREVENTDEPRESSURIZATION OF THESPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDINGCARBON MONOXIDE INTO THELIVING SPACE.

IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCE WITH THE CSAINTERNATIONAL (CSA)CERTIFICATION OR THESEINSTRUCTIONS, CAN RESULT INUNSATISFACTORY OPERATIONAND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVERED BYTHE UNIT WARRANTY.

IN COMPLIANCE WITHRECOGNIZED CODES, IT ISRECOMMENDED THAT ANAUXILIARY DRAIN PAN BEINSTALLED UNDER ALLEVAPORATOR COILS OR UNITSCONTAINING EVAPORATOR COILSOR GAS FURNACES USED WITHEVAPORATOR COILS THAT ARELOCATED IN ANY AREA OF ASTRUCTURE WHERE DAMAGE TOTHE BUILDING OR BUILDINGCONTENTS MAY OCCUR AS ARESULT OF AN OVERFLOW OF THECOIL DRAIN PAN OR A STOPPAGEIN THE PRIMARY CONDENSATEDRAIN PIPING.

matches what is required for thejob specification.

• Read the entire instructions beforestarting the installation.

• Some building codes require extracabinet insulation and gasketingwhen unit is installed in atticapplications.

• If installed in an unconditionedspace, apply caulking around thepower wires, control wires,refrigerant tubing and condensateline where they enter the cabinet.Seal the power wires on the insidewhere they exit conduit opening.Caulking is required to prevent airleakage into and condensate fromforming inside the unit, control box,and on electrical controls.

• Install the unit in such a way as toallow necessary access to thecoil/filter rack and blower/controlcompartment.

• Install the unit in a level position toensure proper condensatedrainage. Make sure unit is level inboth directions within 1/8”.

• Install the unit in accordance withany local code which may applyand the national codes. Latesteditions are available from:

RECEIVINGImmediately upon receipt, all cartonsand contents should be inspected fortransit damage. Units with damagedcartons should be openedimmediately. If damage is found, itshould be noted on the deliverypapers, and a damage claim filedwith the last carrier. • After unit has been delivered to jobsite, remove carton taking care notto damage unit.

• Check the unit rating plate for unitsize, electric heat, coil, voltage,phase, etc. to be sure equipment

NOTICE

NOTICE

! WARNING

FIGURE 3MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

88

GENERAL INFORMATION

DO NOT USE THIS FURNACEDURING CONSTRUCTION IF AIRLADEN CORROSIVE COMPOUNDSARE PRESENT SUCH ASCHLORINE AND FLUORINE.OTHERWISE, PROVISIONS MUSTBE TAKEN TO PROVIDE CLEAN,UNCONTAMINATED COMBUSTIONAND VENTILATION AIR TO THEFURNACE. FURNACECOMBUSTION AND VENTILATIONAIR CONTAMINATED WITH THESECOMPOUNDS FORMS ACIDSDURING COMBUSTION WHICHCORRODES THE HEATEXCHANGER AND COMPONENTPARTS. SOME OF THESECONTAMINANTS ARE FOUND IN,BUT NOT LIMITED TO, PANELING,DRY WALL, ADHESIVES, PAINTS,STAINES, VARNISHES, SEALERS,AND MASONRY CLEANINGMATERIALS.

DO NOT INSTALL THIS FURNACEIN A MOBILE HOME!! This furnaceis not approved for installation in amobile home. Doing so could causeFIRE, PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

WHEN THIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BE INSTALLEDSO THE BURNERS AND IGNITIONSOURCE ARE LOCATED NO LESSTHAN 18 INCHES ABOVE THEFLOOR. THIS IS TO PREVENTTHE RISK OF IGNITINGFLAMMABLE VAPORS WHICHMAY BE PRESENT IN A GARAGE.ALSO, THE FURNACE MUST BELOCATED OR PROTECTED TOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOLLOWTHESE WARNINGS CAN CAUSE AFIRE OR EXPLOSION, RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

1. IMPORTANT: If installing the unitover a finished ceiling or livingarea, be certain to install anauxiliary condensate drain panunder the entire unit. Thisauxiliary drain pan should extendunder any evaporator coilinstalled with the furnace and theopen portion of the condensatedrain assembly. See“Condensate Drain/Neutralizer”section for more details.

2. IMPORTANT: If using a coolingevaporator coil with this furnace:

a. be sure the air passes overthe heat exchanger beforepassing over the coolingcoil. The cooled air passingover the warm ambient airinside the heat exchangertubes can causecondensation inside the tubesresulting in corrosion andeventual failure.

b. install a parallel duct systemto divert all the air from thefurnace allowing it to passover the cooling coil only. Usedampers or other means toprevent chilled air frompassing over the heatexchanger.

If these are manual dampers, theymust be equipped to prevent heatingor cooling operation unless thedamper is in the full heat or coolposition.

! WARNING

! WARNING

3. IMPORTANT: Install the furnacelevel. If it is not level, condensatecannot drain properly, possiblycausing furnace shut down.

NOTE: These furnaces are approvedfor installation in attics, as well asalcoves, utility rooms, closets andcrawlspaces. Provisions must bemade to prevent freezing ofcondensate.

4.

If this furnace is installed in agarage, attic and/or anyunconditioned space, install aself-regulating heat tapearound the condensate trapand along the entire length ofthe condensate drain in theunconditioned space. SeeFigure 4.

When the condensing horizontalgas furnace is installed in anunconditioned space where thetemperature would be capable ofreaching close to or below 32°F(0°C). a self-regulating heat tapeis required on the condensatedrain, along with an insulationwrap. The heat tape should meetthe following requirements:

a. The heat tape must be ULlisted.

b. The heat tape must beinstalled per themanufacturer’s instructions forthe entire length of drain pipein the unconditioned space.

FIGURE 4HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP

DRAINPIPE

HEATTAPE

TRAP

I526

WARNING!

LOCATION REQUIREMENTS AND CONSIDERATIONS

CAUTION!

9

SITE SELECTION1. Select a site in the building near

the center of the proposed, orexisting, duct system.

2. Give consideration to the ventsystem piping when selecting thefurnace location. Be sure theventing system can get from thefurnace to the termination withminimal length and elbows.

3. Locate the furnace near theexisting gas piping. Or, if runninga new gas line, locate thefurnace to minimize the lengthand elbows in the gas piping.

4. Locate the furnace to maintainproper clearance to combustiblesas shown in the following tables.

DO NOT LIFT THE UNIT BY THEHEAT EXCHANGER TUBES.DOING SO CAN CRACK THE HEATEXCHANGER ASSEMBLY ANDCAUSE CO2 TO BE RELEASEDINTO THE ENVIRONMENT, WHICHCAN RESULT IN PERSONALINJURY OR DEATH.

! WARNINGCOMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET. THEAREA AROUND THE FURNACEMUST BE KEPT CLEAR AND FREEOF ALL COMBUSTIBLEMATERIALS INCLUDINGGASOLINE AND OTHERFLAMMABLE VAPORS ANDLIQUIDS. PLACEMENT OFCOMBUSTIBLE MATERIALS ON,AGAINST OR AROUND THEFURNACE JACKET CAN CAUSEAN EXPLOSION OR FIRERESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. THE HOMEOWNERSHOULD BE CAUTIONED THATTHE FURNACE AREA MUST NOTBE USED AS A BROOM CLOSETOR FOR ANY OTHER STORAGEPURPOSES.

c. The heat tape should be ratedat 5 or 6 watts per foot at120V.

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. SeeFigure 5.

5. IMPORTANT: If installing in autility room, be sure the dooris wide enough to:

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

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

6. IMPORTANT: This furnace is notapproved or recommended forinstallation on its back, withaccess doors facing upwards.

CLEARANCE -ACCESSIBILITYThe design of forced air furnaces withinput ratings as listed in the tablesunder Figures 6, 7, and 8 are certifiedby CSA-International for theclearances to combustible materialsshown in inches.

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

Service clearance of at least 24inches is recommended in front ofall furnaces.

NOTE: Use recommended 24”clearance if accessibility clearancesare greater than fire protectionclearances.

UPFLOW AND HORIZONTALFURNACES ARE DESIGN-CERTIFIED FOR INSTALLATIONON COMBUSTIBLE FLOORS.NOTE, HOWEVER, THATFURNACES MUST NOT BEINSTALLED DIRECTLY ONCARPETING, TILE OR OTHERCOMBUSTIBLE MATERIAL OTHERTHAN WOOD FLOORING.INSTALLATION ON ACOMBUSTIBLE MATERIAL CANRESULT IN FIRE, CAUSINGPROPERTY DAMAGE, PERSONALINJURY OR DEATH.

FIGURE 5HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

! WARNING

GASPIPE

TRAP

EXHAUSTFAN

ELECTRICALCONDUIT

INTAKEVENT

I522

! WARNING

FIGURE 6CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS

UPF

LOW M

ODEL

SMIN

IMUM CLE

ARAN

CE (IN.)

LEFT

RIG

HT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0417

1 ⁄216

11⁄32

155 ⁄8

215

1325⁄32

00

01

2*0

111

0617

1 ⁄216

11⁄32

155 ⁄8

215

1325⁄32

00

01

2*0

117

0717

1 ⁄216

11⁄32

155 ⁄8

215

1325⁄32

00

01

2*0

124

0721

1927⁄32

193 ⁄1

62

181 ⁄2

173 ⁄8

00

01

2*0

137

0921

1927⁄32

191 ⁄8

218

1 ⁄217

9 ⁄32

00

01

2*0

148

1021

1927⁄32

191 ⁄8

218

1 ⁄217

9 ⁄32

00

01

2*0

152

1224

1 ⁄223

11⁄32

225 ⁄8

222

2025⁄32

00

01

2*0

160

10

I392

*A service

clearan

ce of a

t lea

st 24 inch

es is

reco

mmen

ded in fron

t of a

ll furnac

es.

SUPPLY

AIR

RETURN

AIR

AIRFLOW

2 D

IA.

GA

S C

ON

NE

CT

ION

27

3⁄8

26

7⁄16

2 D

IA.

GA

S C

ON

NE

CT

ION

11

FIGURE 7CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS

I393

DOWNFL

OW M

ODEL

SMIN

IMUM CLE

ARAN

CE (IN.)

LEFT

RIG

HT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0417

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

011

1

0617

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

011

7

0717

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

012

4

0721

1927⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

137

0921

1911⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

148

1021

1911⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

152

1224

1 ⁄223

11⁄32

225 ⁄8

223

5 ⁄820

7 ⁄80

00

12*

016

0

*A service

clearan

ce of a

t lea

st 24 inch

es is

reco

mmen

ded in fron

t of a

ll furnac

es.

NOTE:IN DOWNFLOW CONFIGURATION, OPTIONAL AIR CUTOUT IS NOT PERMITTED.

SUPPLY

AIR

RETURN

AIR

AIRFLOW

2 DIA.

ALT. G

AS

CONNECTION2513⁄16

43⁄8

2 DIA.

GAS CONNECTION

12

FIGURE 8CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS

I520

DOWNFL

OW M

ODEL

SMIN

IMUM CLE

ARAN

CE (IN.)

LEFT

RIG

HT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0417

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

011

1

0617

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

011

7

0717

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

012

4

0721

1927⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

137

0921

1927⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

148

1021

1927⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

152

1224

1 ⁄223

11⁄32

225 ⁄8

223

5 ⁄820

5 ⁄80

00

12*

016

0

*A service

clearan

ce of a

t lea

st 24 inch

es is

reco

mmen

ded in fron

t of a

ll furnac

es.

IMPORTANT:This furnace is not approved or recommended for

installation on its back, with access doors facing upwards.

2513⁄16

2 DIA.

ALT. G

AS

CONNECTION

43⁄8

2 DIA.

GAS

CONNECTION

13

DUCTINGProper air flow is required for thecorrect operation of this furnace.Too little 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 toacceptable industry standards andmethods. The total static pressuredrop of the air distribution systemshould not exceed 0.5" w.c.

NOTE: Return air grilles and warm airregisters must not be obstructed

NEVER ALLOW THE PRODUCTSOF COMBUSTION FROM THEFLUE TO ENTER THE RETURN AIRDUCTWORK OR THE CIRCULATEDAIR SUPPLY. ALL RETURNDUCTWORK MUST BEADEQUATELY SEALED ANDSECURED TO THE FURNACEWITH SHEET METAL SCREWS;AND JOINTS, TAPED. ALL OTHERDUCT JOINTS MUST BE SECUREDWITH APPROVED CONNECTIONSAND SEALED AIRTIGHT. WHENAN UPFLOW FURNACE ISMOUNTED ON A PLATFORM WITHRETURN THROUGH THE BOTTOM,IT MUST BE SEALED AIRTIGHTBETWEEN THE FURNACE ANDTHE RETURN AIR PLENUM. THEFLOOR OR PLATFORM MUSTPROVIDE SOUND PHYSICALSUPPORT OF THE FURNACEWITHOUT SAGGING, CRACKS, ORGAPS, AROUND THE BASE,PROVIDING A SEAL BETWEENTHE SUPPORT AND THE BASE.FAILURE TO PREVENTPRODUCTS OF COMBUSTIONFROM BEING CIRCULATED INTOTHE LIVING SPACE CAN CREATEPOTENTIALLY HAZARDOUSCONDITIONS, INCLUDINGCARBON MONOXIDE POISONINGTHAT COULD RESULT INPERSONAL 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.IMPORTANT: Some high efficiencyfilters have a greater than normalresistance to air flow. This canadversely affect furnace operation.BE SURE TO CHECK AIR FLOW.IMPORTANT: When using outsideair, design and adjust the system tomaintain a return air temperatureABOVE 50° F during the heatingseason.

UPFLOW UNITS1. Position the unit to minimize long

runs of duct or runs of duct withmany turns and elbows.

2. Open the return air compartment.

UPFLOW FURNACE: A SOLIDMETAL BASE PLATE MUST BEINSTALLED IN THE FURNACEBOTTOM WHEN USING SIDERETURN. FAILURE TO INSTALL ABASE PLATE COULD CAUSE THEPRODUCTS OF COMBUSTION TOCIRCULATE INTO THE LIVINGSPACE AND CREATE POTENTIAL -LY HAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING OR DEATH.

a. Cut an opening in the side.The opening should be cut the full width of theknockouts on the unit. SeeFigure 9.

NOTE: Where the maximum air flowis 1800 CFM or more, both sides orthe bottom must be used for returnair.

3. Connect the return duct or returnair cabinet to the unit. Make theconnection air tight to prevententraining combustion gasesfrom an adjacent fuel-burningappliance.

4. Be sure to have adequatespace for the unit filter.

NOTE: DO NOT take return airfrom bathrooms, kitchens,furnace rooms, garages, utility orlaundry rooms, or cold areas.

NOTE: DO NOT use a rear airreturn.

5. If summer air conditioning isdesired, position the indoor coilon the top of the unit. Insure thatno air can bypass this coil.

6. Connect the supply air plenum tothe furnace plenum opening.

IMPORTANT: If a flexible ductconnector must be used, itMUST be rated for a minimumtemperature of 250°F.continuous.

DOWNFLOW UNITS1. Position the unit to minimize long

runs of duct or runs of duct withmany turns and elbows.

2. If summer air conditioning isdesired, position the indoor coilon the bottom of the unit. Insurethat no air can bypass this coil.

3. If installing on a combustible floorand not using an airconditioning plenum, install thespecial non-combustible floorbase. See Figure 10.

THE DOWNFLOW FURNACEDESIGN IS CERTIFIED FORINSTALLATION ON A NON-COMBUSTIBLE FLOOR. USE THESPECIAL BASE SPECIFIED ONTHE FURNACE CLEARANCELABEL. FAILURE TO INSTALL THESPECIAL BASE MAY RESULT INFIRE, PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.THIS SPECIAL BASE IS SHIPPEDFROM THE FACTORY AS ANACCESSORY.

! WARNING

! WARNING

FIGURE 9CUTOUT AND DRILL INFORMATION

! WARNING

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

14

GENERAL INFORMATION

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SECTION.FAILURE TO PROPERLY VENTTHIS FURNACE CAN CAUSECARBON MONOXIDE POISONINGOR AN EXPLOSION OR FIRE,RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.This furnace removes both sensibleand latent heat from the combustionflue gases. Removal of latent heatresults in condensation of flue gaswater vapor. This condensed watervapor drains from the secondary heatexchanger and out of the unit into adrain trap.When installed as a non-direct ventfurnace, only exhaust piping isrequired and inside combustion airmay be used. Refer to section on“COMBUSTION & VENTILATION AIRFOR FURNACE INSTALLATIONS.”Direct vent installations require adedicated combustion air and ventingsystem. All air for combustion is takenfrom the outside atmosphere and allcombustion products are dischargedto the outdoors.

IN CANADA, PRODUCTSCERTIFIED FOR INSTALLATION

AND INTENDED TO BE VENTEDWITH PLASTIC VENT SYSTEMS(PVC, CPVC) MUST USE VENTSYSTEMS THAT ARE CERTIFIEDAND STAMPED TO THE STANDARDFOR TYPE BH GAS VENTINGSYSTEMS, ULC S636.THE COMPONENTS OF THECERTIFIED MATERIAL MUST NOTBE INTERCHANGED WITH OTHERVENT SYSTEMS OR UNLISTEDPIPE/FITTINGS.PLASTIC COMPONENTS ANDSPECIFIED PRIMERS AND GLUESOF THE CERTIFIED SYSTEM MUSTBE FROM A SINGLE SYSTEMMANUFACTURER AND NOT

INTERMIXED WITH OTHERSYSTEM MANUFACTURER’SPARTS.NOTE: INLET AIR PIPING IS NOTCONSIDERED TO BE A PART OFTHE “VENTING SYSTEM”. THEREQUIREMENT THAT VENTMATERIAL BE CERTIFIED TO ULCS636 DOES NOT APPLY TO INLETAIR PIPING. The combustion air and vent pipefittings must conform to AmericanNational Standards Institute (ANSI)and American Society for TestingMaterials (ASTM) standards asshown below:

VENTING AND COMBUSTION AIR PIPING

! WARNING

4. Connect the furnace to thesupply air plenum.

5. Connect the return air ducting tothe return air opening at the topof the unit. Make the connectionair tight to prevent entrainingcombustion gases from anadjacent fuel-burning appliance.

6. Be sure to have adequatespace for the unit filter.NOTE: DO NOT take return airfrom bathrooms, kitchens,furnace rooms, garages, utility orlaundry rooms, or cold areas.

HORIZONTAL UNITIMPORTANT: This furnace may onlybe installed so that when facing thefront of the furnace, supply air isdischarged on the left hand side.1. Position the unit to minimize long

runs or runs with many turns andelbows.

2. If summer air conditioning isdesired, position the indoor coilon the left end of the unit. Insurethat no air can bypass this coil.

3. Connect the furnace to thesupply air plenum.

4. Connect the return air ducting tothe return air opening at the rightend of the unit. Make theconnection air tight to preventpulling combustion gases froman adjacent fuel-burningappliance.

5. Be sure to have adequatespace for the unit filter.NOTE: DO NOT take return airfrom bathrooms, kitchens,furnace rooms, garages, utility orlaundry rooms, or cold areas.

FIGURE 10COMBUSTIBLE FLOOR BASE

VENTING AND COMBUSTION AIR PIPING*

U.S. PIPE & FITTING MATERIAL* ASTMSPECIFICATION

Schedule 40 PVC (Pipe) D1785

Schedule 40 PVC (Cellular Core Pipe) F891

Schedule 40 PVC (Fittings) D2466

SDR-21PVC (Pipe) D2241

SDR-26 PVC (Pipe) D2241

Schedule 40 ABS Cellular Core DWV (Pipe) F628

Schedule 40 ABS (Pipe) D1527

Schedule 40 ABS (Fittings) D2468

ABS-DWV (Drain Waste & Vent)(Pipe & Fittings) D2661

PVC-DWV (Drain Waste & Vent)(Pipe & Fittings) D2665

! WARNING

*Starting in 2007, Canada allows ULC-S636 PVC or CPVC only.

15

Pipe and Fittings - ASTM-D1785,D2466, D2665, D2231, D2661 andF628.PVC Primer and Solvent Cement -ASTM-D2564ABS Pipe and Fittings - Use ABSPrimer and Solvent Cement D2235Procedure for Cementing Joints -ASTM-D2855IMPORTANT: The plastic combustionair and venting components are ofPVC. If using ABS piping, ensure thatthe solvent cement is compatible forjoining PVC to ABS components oruse a mechanical connection that canwithstand the vent temperatures andare corrosion resistant.

CEMENTING JOINTSProperly seal all joints in the PVCvent using the following materials andprocedures.PVC CLEANER-PRIMER ANDPVC MEDIUM-BODY SOLVENTCEMENTIMPORTANT: After cutting pipe,remove all ragged edges and burrs.This is important to prevent reductionin pressure drop throughout thesystem.1. Cut pipe end square. Chamfer

edge of pipe. Clean fitting socketand pipe joint area of all dirt,grease and moisture.

2. After checking pipe and socketfor proper fit, wipe socket andpipe with cleaner-primer. Applya liberal coat of primer to insidesurface of socket and outside ofpipe. Read instructions includedwith the primer for properapplication.

3. Apply a thin coat of cementevenly in the socket. Quicklyapply a heavy coat of cement tothe pipe end and insert pipe intofitting with a slight twistingmovement until it bottoms out.NOTE: Cement must be fluid; ifnot, recoat.

4. Hold the pipe in the fitting for 30seconds to prevent the taperedsocket from pushing the pipe outof the fitting.

5. Wipe all excess cement from thejoint with a rag. Allow 15 minutesbefore handling. Cure time variesaccording to fit, temperature andhumidity.

NOTE: Stir the solvent cementfrequently while using. Use a naturalbristle brush or the dauber suppliedwith the can. The proper brush size isone inch.IMPORTANT: For Proper InstallationDO NOT use solvent cement thathas become curdled, lumpy orthickened.DO NOT thin. Observe shelfprecautions printed on containers.For application below 32°F, use onlylow-temperature-type solventcement.

OVERTEMPERATURESAFETY SWITCHESFurnaces are equipped with safetyswitches in the control compartmentto protect against overtemperatureconditions caused by inadequatecombustion air supply. The switchesfor the upflow and downflow modelsare located in the burnercompartment. If a switch is tripped itmust be manually reset.

DO NOT JUMPER THESEDEVICES! IF ONE OF THESESWITCHES SHOULD TRIP, AQUALIFIED INSTALLER, SERVICEAGENCY OR THE GAS SUPPLIERMUST BE CALLED TO CHECKAND/OR CORRECT FORADEQUATE COMBUSTION AIRSUPPLY. DO NOT RESET THESWITCHES WITHOUT TAKINGCORRECTIVE ACTION TO ASSURETHAT AN ADEQUATE SUPPLY OFCOMBUSTION AIR IS MAINTAINEDUNDER ALL CONDITIONS OFOPERATION. FAILURE TO DO SOCAN RESULT IN CARBONMONOXIDE POISONING ORDEATH. IF THIS UNIT IS MOUNTEDIN A CLOSET, THE DOOR MUSTBE CLOSED WHEN MAKING THISCHECK.REPLACE THESE SWITCHESONLY WITH THE IDENTICALREPLACEMENT PART.

EXISTING VENT SYSTEMS**In Canada see ULC-S636 requirements.When the installation of this furnacereplaces an existing furnace that isremoved from a vent system servingother appliances, the vent system islikely to be too large to properly ventthe remaining attached appliances.The following steps should befollowed with each applianceremaining connected to the originalcommon vent system. Place theappliance to be tested in operation,while the other appliances remainingconnected to the common ventsystem are not in operation. Test theoperation of each applianceindividually by the following method.1. Permanently seal any unused

openings in the common ventingsystem.

2. Visually inspect the ventingsystem for proper size andhorizontal pitch and determinethat there is no blockage,restriction, leakage, corrosion orother deficiencies which couldcause an unsafe condition.

3. If practical, close all buildingdoors, windows and all doorsbetween the space where theappliances remaining connectedto the common venting systemare located.Turn on clothes dryers and anyappliance not connected to thecommon venting system. Turn onany exhaust fans, such as range

hoods and bathroom exhausts,so they will operate at maximumspeed. Do not operate a summerexhaust fan. Close fireplacedampers.

4. Follow the lighting instructions.Place the appliance beinginspected into operation. Adjustthe thermostat so the appliancewill operate continuously.

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, cigaror pipe.

6. After it has been determined thateach appliance that remainsconnected to the commonventing system properly vents(when tested as outlined above),return doors, windows, exhaustfans, fireplace dampers and anyother gas-burning appliance totheir previous conditions of use.

7. If improper venting is observedduring any of the above tests, thecommon venting system must beresized. See vent tables in theseinstructions

When the furnace is installed in thesame space with other gas appliancessuch as a water heater, be sure thereis an adequate supply of combustionand ventilation air for the otherappliances. Do not delete or reducethe combustion air supply required bythe other gas appliances in this space.See Z223.1, National Fuel Gas Code(NFPA54) for determining thecombustion air requirements for gasappliances. An unconfined space musthave at least 50 cubic feet (volume) foreach 1,000 BTUH of the total input ofall appliances in the space. If the openspace containing the appliances is in abuilding with tight construction(contemporary construction), outsideair may still be required for theappliances to burn and vent properly.Outside air openings should be sizedthe same as for a confined space.

JOINING PIPE AND FITTINGS

PVC SOLVENT CEMENTS ANDPRIMERS ARE HIGHLYFLAMMABLE. PROVIDEADEQUATE VENTILATION AND DONOT ASSEMBLE NEAR HEATSOURCE OR AN OPEN FLAME. DONOT SMOKE. AVOID SKIN OR EYECONTACT. OBSERVE ALLCAUTIONS AND WARNINGSPRINTED ON MATERIALCONTAINERS. FAILURE TOFOLLOW THESE GUIDELINES MAYRESULT IN FIRE, EXPLOSION ORASPHYXIATION CAUSINGPERSONAL INJURY OR DEATH.All pipe, fittings, solvent cement,primers and procedures must conformto American National StandardInstitute and American Society forTesting and Materials (ANSI/ASTM)standards in the U.S.

! WARNING

! WARNING

16

NON-DIRECTFURNACE INSTALLATIONS

THE 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. FAILURETO DO SO CAN CAUSEPERSONAL INJURY OR DEATHFROM CARBON MONOXIDEPOISONING.

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) orapplicable provisions for the localbuilding codes, and not obstructed soas to prevent the flow of air to thefurnace.

IMPORTANT: Air for combustion andventilation must not come from acorrosive atmosphere. Any failuredue to corrosive elements in theatmosphere is excluded fromwarranty coverage.

The following types of installation(but not limited to the following) willrequire 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 chemicalstorage areas.

Exposure to the following substancesin the combustion air supply (but notlimited to the following) will alsorequire OUTDOOR AIR forcombustion:

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

• Water softening chemicals• De-icing salts or chemicals• Carbon tetrachloride• Halogen type refrigerants

• Cleaning solvents (such asperchloroethylene)

• Printing inks, paint removers,varnishes, etc.

• Hydrochloric acid• Cements and glues• Antistatic fabric softeners forclothes dryers

• Masonry curing and acid washingmaterials

Combustion air must be free of acid-forming 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 andhousehold products. When burned ina gas flame, vapors from theseproducts form acid compounds. Theacid compounds increase the dewpoint temperature of the flue productsand are highly corrosive after theycondense.

ALL FURNACE INSTALLATIONSMUST COMPLY WITH THENATIONAL FUEL GAS CODE ANDLOCAL CODES TO PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR FOR THEFURNACE. FAILURE TO DO SOCAN RESULT IN EXPLOSION,FIRE, PROPERTY DAMAGE,CARBON MONOXIDE POISONING,PERSONAL INJURY OR DEATH.

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 1,000BTUH of the total input for allappliances in the space. Here are afew examples of the room sizesrequired for different inputs. The sizesare based on 8-foot ceilings.

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

45,000 281 14' x 20' OR 16' x 18'

60,000 375 15' x 25' OR 19' x 20'

75,000 469 15' x 31' OR 20' x 24'

90,000 563 20’ x 28’ OR 24’ x 24’

105,000 657 20' x 33' OR 26' x 25'

120,000 750 25' x 30' OR 24' x 32'

If the open space containing thefurnace is in a building with tightconstruction, outside air may still berequired for the furnace to operateand vent properly. Outside airopenings should be sized the sameas for a confined 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. Sizethe openings by how they areconnected to the heated area or tothe outside,and by the input of all appliances inthe space.

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 betaken from a heated space with afireplace, exhaust fan or otherdevice that may produce anegative 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 BTUHof total input in the space. Hereare some examples of typicalopenings required.

COMBUSTION AND VENTILATION AIR

! WARNING

! WARNING

17

BTUH Free AreaInput Each Opening

45,000 100 square inches






B. USING OUTDOOR AIR FORCOMBUSTION

IMPORTANT: Do not take air froman attic space that is equippedwith power ventilation.

The confined space mustcommunicate with the outdoors inaccordance with Methods 1 or 2.The minimum dimension of airopenings shall not be less than 3inches. Where ducts are used,they shall be of the same cross-sectional area as the free area ofthe openings to which theyconnect.

Method 1Two permanent openings, onelocated within 12 inches of the topand one located within 12 inchesof the bottom of the enclosure,shall be provided. The openingsshall communicate directly, or byducts, with the outdoors or spaces(crawl or attic) that freelycommunicate with the outdoors.

a. Where directly communicatingwith the outdoors or wherecommunicating to the outdoors

through vertical ducts as shown inFigure 12, each opening shallhave a minimum free area of 1square inch for each 4,000 BTUHof total appliance input rating in theenclosure.

BTUH Free Area Round PipeInput Each Opening Size

45,000 11.25 square inches 4"






b. Where communicating withoutdoors through horizontal ducts,each opening shall have aminimum free area of 1 squareinch for each 2,000 BTUH of totalinput rating of all equipment in theenclosure (Seee Figure 13).

Here are some typical sizes:








FIGURE 12AIR FROM ATTIC/CRAWL SPACE

FIGURE 13OUTSIDE AIR USING A HORIZONTAL DUCT

FIGURE 11AIR FROM HEATED SPACE

NOTE:EACH OPENING SHALLHAVE A FREE AREA OFNOT LESS THAN ONESQUARE INCH PER 1,000BTU PER H0UR OF THETOTAL INPUT RATING OFALL EQUIPMENT IN THEENCLOSURE, BUT NOTLESS THAN 100 SQUAREINCHES.

GASWATERHEATER

FURNACE

GASWATERHEATER

GASWATERHEATER

FURNACE FURNACE

12" MAX.12"MAX.

1 SQ. INCH PER4000 BTUH INLET AIR

OUTLET AIR 1 SQ. INCHPER 2000 BTUH

INLET AIR 1 SQ. INCHPER 2000 BTUH

1 SQ. INCH PER4000 BTUHOUTLET AIR

OPTIONAL 1 SQ. INCH PER 4000 BTUH IN

LET AIR

VENTILATEDATTIC GABLE ORSOFFIT VENTS

GABLEVENTOUTLET AIR

IN ATTICMUST BEABOVEINSULATION

18

FIGURE 14COMBUSTION AIR FITTING

UPFLOW DOWNFLOW/HORIZONTAL

2" PVCDOUBLEELBOW

TOPOPTION

EXHAUST

2" PVC ELBOW

SIDEOPTION

2" PVCDOUBLEELBOW*

COMBUSTION AIREXHAUST

ATTACH DOUBLE ELBOW TO INTAKE AIRCOLLAR AND SECURE WITH TWO SHEETMETAL SCREWS TO PREVENT ACCIDENTALBLOCKAGE OF INTAKE AIR OPENING.

*NOTE: WHEN FURNACE IS INSTALLED IN AHORIZONTAL POSITION ONLY ONE 90°ELBOW IS REQUIRED. INSTALL THE ELBOWSO THE OPEN END IS POINTED DOWNWARD.

ATTACH DOUBLE ELBOW TO TOP INLETAIR OPENING OR 90° ELBOW TO SIDEINLET AIR OPENING TO PREVENTACCIDENTAL BLOCKAGE OF INTAKEOPENING. PLUG OPENING NOT USED.

I337 I336

Method 2(Not Shown)One permanent opening, locatedwithin 12 inches of the top of theenclosure, shall be permittedwhere the equipment hasclearances of at least 1 inch fromthe sides and back and 6 inchesfrom 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,and shall have a minimum freearea of:

a. 1 square inch for each 3,000BTUH of the total input rating of allequipment located in the enclosureand








b. Not less than the sum of theareas of all vent connectors in theconfined space.

If unit is installed where there is anexhaust fan, sufficient ventilationmust be provided to prevent theexhaust fan from creating a negativepressure.

Combustion air openings must not berestricted in any manner.

CONSULT LOCAL CODES FORSPECIAL REQUIREMENTS.

CONNECTION TOFURNACEIMPORTANT: When indoorcombustion air is used, the inlet airopening at the furnace must beprotected from accidental blockage.On upflow models, install a 90° elbowpointing downward in the side inlet airopening or a double elbow pointingdownward in the top inlet air opening.On downflow/horizontal models,install a double elbow in the top inletair opening. See Figure 14.

19

ELEVATED SINGLE PIPE ALTERNATE TEE TERMINATIONSee Figure 16. The tee termination may be elevated up to 24 inches above thewall penetration if required for anticipated snow levels. Use 2 medium-radius, 2-in.PVC elbows and 2-in. PVC pipe, attaching the tee so it is 12 inches from the wall.

NON-DIRECT VENTINSTALLATIONGUIDELINESIMPORTANT: Failure to correctlyfollow all venting guidelines mayresult in erratic furnace operation,freeze-up of combustion air orexhaust air piping or sooting of thefurnace.All exhaust piping must be installed incompliance with Part 7, “Venting ofEquipment,” of the latest edition of theNational Fuel Gas Code NPFA54/ANSI Z223.1-, local codes orordinances and these instructions.1. Vertical piping is preferred.2. All horizontal piping must slope

upward a minimum of 1/4 inchper foot of run so thatcondensate drains toward thefurnace.

3. All horizontal runs must besupported at least every 4 feet.No sags or dips are permitted.

4. IMPORTANT: Do not commonvent with any other appliance. Donot install in the same chase orchimney with a metal or hightemperature plastic pipe fromanother gas or fuel-burningappliance unless the requiredminimum clearances tocombustibles are maintainedbetween the PVC pipe and otherpipes.

5. All vent runs throughunconditioned spaces wherebelow-freezing temperatures areexpected should be insulatedwith 1-in. thick, medium-density,foil-faced fiberglass. Anequivalent “arm-a-flex” or

FIGURE 15TEE TERMINAL – FOR STANDARDHORIZONTAL SINGLE PIPEINSTALLATION

FIGURE 16ALTERNATE HORIZONTAL TERMINATION FOR NON-DIRECT VENTINSTALLATIONS

12"

FROM

24"MAX.

PIPESUPPORTSTRAP

OUTSIDEWALL

VENT

12" 12" MIN. ABOVEGRADE OR

SNOW LEVEL

I198

NUMBERS OF ELBOWS45° OR 90°

Medium / Long Radius ONLY

1-2 3-4 5-6

2”Standard 60 55 50

Alternate 55 50 4545,000

3”Standard 120 120 115

Alternate 120 120 110

2”Standard 35 30 25

Alternate 30 25 2060,000

3”Standard 120 120 115

Alternate 120 120 110

2” Standard 20 15 NR

RGT(A,S) Only Alternate NR NR NR

75,000 2” Standard 30 25 NR

RGR(B,T) Only Alternate NR NR NR

3”Standard 110 105 95

Alternate 80 70 65

90,000 3”Standard 90 85 75

Alternate 60 50 45

105,000 3”Standard 80 75 65

Alternate 50 40 35

120,000 3”Standard 70 65 55

Alternate 40 30 25

NOTES:

1. *N.R. - NOT RECOMMENDED.2. MAXIMUM OF 6 - 90 DEGREE ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FORALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.

3. A 45° DEGREE ELBOW IS CONSIDERED ONE ELBOW.

FURNACEINPUT

VENT PIPE INSTALLATION

PIPESIZE

TERMINATION

TABLE 1FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM INDOORS

MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE

20

“rub-a-tex” insulation may also beused as long as there is no heattape applied to the vent pipe. Forhorizontal runs where water maycollect, wrap the vent pipe withself-regulating 3 or 5 watt heattape. The heat tape must beU.L. listed and installed per themanufacturer’s instructions.

6. The minimum vent pipe length is5 feet.

STANDARD INSTALLATIONSThe single-pipe system requires anexhaust pipe only. Combustion air maybe taken from the furnace installationarea or ducted to the furnace area fromthe outside.

Size the exhaust pipe as specified inTable 1. This table lists the maximumallowable length in feet of the exhaustpipe that may be used for all furnaceinputs as related to the number ofelbows required and the termination.(See shaded area.)

Vertical through-the-roof installations donot require a vent termination. Use 2-in.PVC pipe extending a minimum of 12inches above the anticipated level ofsnow accumulation. See exhaust piperequirements, Figure 19. When 3-in.vent pipe is used from furnace to theroof, reduce it to 2 inches beforepenetrating the roof. A maximum of 18inches of 2-in. pipe may be used belowthe roof. Maximum exposed vent lengthabove the roof line is 30�.

Horizontal vent terminations require a2-in. PVC tee positioned 12 inches fromthe outside wall. See exhaust piperequirements, Figure 22. When 3-in.pipe is used from the furnace to theoutside wall, reduce it to 2 inchesbefore penetrating the wall. A maximumof 18 inches of 2-in. pipe may be usedinside the wall.

An alternate termination may be usedas shown in Figure 16 to clearanticipated snow levels. The tee maybe raised up to 24 inches above thewall penetration. Use two medium-radius bend, 2-in. PVC elbows and alength of 2-in. PVC pipe so that theelbows are on 24-in. centers.

NON-DIRECT VENT TERMINATIONLOCATION REQUIREMENTS

MOISTURE IN THE COMBUSTIONPRODUCTS CONDENSES AS ITLEAVES THE TERMINATION. THISCONDENSATE CAN FREEZE ONEXTERIOR WALLS, UNDER THEEAVES, AND ON SURROUNDINGOBJECTS. SOME DISCOLORATIONIS TO BE EXPECTED. HOWEVER,IMPROPER LOCATION OR

INSTALLATION CAN CAUSESTRUCTURAL OR EXTERIORFINISH DAMAGE TO THEBUILDING.

Non-direct venting locationrequirements are slightly different insome cases than direct venting. Installa non-direct vent with the followingminimum clearances.See Figure 17.

1. Locate the bottom of the ventterminal at least 12 inches abovegrade. Increase the 12-in.minimum to keep the terminalopenings above the level of snowaccumulation, where applicable.

2. The vent shall not terminate overpublic walkways or over an areawhere condensate or vapor couldcreate a nuisance or hazard.

3. 4 feet below, 4 feet horizontallyfrom, or 1 foot above any door,window soffit, under eave vent orgravity air inlet to the building.

4. The vent terminal shall have aminimum horizontal clearance of4 feet from electric meters, gasmeters, regulators and reliefequipment.

5. 6 feet from an inside cornerformed by two exterior walls –10 feet is the recommendeddistance.

6. Locate it 3 feet above any forcedair inlet located within 10 feet.Any fresh air or make-up air inlet,such as for a dryer or furnacearea, is considered a forced airinlet.

! CAUTION

7. Avoid areas where drippingcondensate may cause problems,such as above planters, patios, oradjacent to windows wheresteam may cause fogging.

In addition to the minimum clearanceslisted above, the vent location shouldalso be governed by the followingguidelines.

1. Do not terminate under any kindof patio or deck. If running thevent under a deck, insulate it toinsure no condensate freezesand blocks the pipe.

2. Do not locate on the side of abuilding with prevailing winterwinds. This will help preventmoisture from freezing on wallsand overhangs (under eaves).

3. Do not extend vent directlythrough brick or masonrysurfaces. Use a rust-resistantsheet metal or plastic backingplate behind vent.

4. Do not locate too close to shrubsas condensate may stunt or killthem.

5. Minimum vertical clearances of 1foot are recommended foroverhangs up to 1 foot horizontal.The vertical clearance should beincreased equally for eachadditional increase in horizontaloverhang to a maximum verticalclearance of 6 feet.

6. Caulk all cracks, seams andjoints within 6 feet horizontallyand above and below vent.

21

FIGURE 17OTHER THAN DIRECT VENT TERMINAL CLEARANCES

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22

DIRECT VENTINSTALLATIONS

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SECTION.FAILURE TO PROPERLY VENTTHIS FURNACE CAN CAUSECARBON MONOXIDE POISONINGOR AN EXPLOSION OR FIRE,RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

Direct vent installations require adedicated combustion air and ventingsystem. All air for combustion is takenfrom the outside atmosphere and allcombustion products are dischargedto the outdoors. Therefore, noventilation or combustion airopenings are required.

IMPORTANT: The plastic combustionair and venting components are ofSchedule 40 PVC. If using ABSpiping ensure that the solvent cementis compatible for joining PVC to ABScomponents or use a mechanicalconnection that can withstand thevent temperatures and are corrosionresistant.

INSTALLATION GUIDELINESAll exhaust piping must be installed incompliance with Part 7, “Venting ofEquipment,” of the latest edition of theNational Fuel Gas Code NPFA54/ANSI Z223.1-, local codes orordinances and these instructions.

1. Vertical piping is preferred.

2. All horizontal piping must slopeupward a minimum of 1/4 inchper foot of run so that condensatedrains toward the furnace.

3. All horizontal runs must besupported at least every 4 feet.No sags or dips are permitted.

4. IMPORTANT: Do not commonvent with any other appliance. Donot install in the same chase orchimney with a metal or hightemperature plastic pipe fromanother gas or fuel-burningappliance unless the requiredminimum clearances tocombustibles are maintainedbetween the PVC pipe and otherpipes.

5. For horizontal runs where watermay collect, wrap the vent pipewith self-regulating 3 or 5 wattheat tape. The heat tape must beU.L. listed and installed per themanufacturer’s instructions.

6. The minimum vent pipe length is5 feet.

Size the exhaust and combustion airintake pipes as specified in Table 2.This table lists the maximum allow-able length in feet of the exhaust andcombustion air intake pipes that maybe used for all furnace inputs asrelated to the number of elbowsrequired and the termination (seeshaded area).

7. The maximum exposed ventlength (above the roof line) is30�.

! WARNING

Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 65 60 5545,000 2”

Alternate RXGY-D02/RXGY-D02A 55 50 45

Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 40 35 302”

Alternate RXGY-D02/RXGY-D02A 30 25 2060,000

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 120 120 1203”


2“ Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A 20 15 NR

RGT(A,S) Alternate Not Recommended NR NR NR

2“ Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A 30 25 NR

75,000RGR(B,T) Alternate Not Recommended NR NR NR

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A 120 120 1203” Alternate RXGY-D03/RXGY-D03A 100 95 85





Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 45 35 30

120,000 3” Alternate RXGY-D03/RXGY-D03A 45 35 30


NOTES:1.N.R. - NOT RECOMMENDED.2.MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.3.A 45 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4.CONCENTRIC TERMINATION NO. RXGY-E03/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL

VENTING.5.USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATETHRU-THE-WALL VENTING.6.USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.7.KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.8.NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.

FURNACEINPUT

PIPESIZE

TERMINATIONVENT TERMINATIONKIT RECOMMENDED(RXGY-D0* Kits for

Horizontal Venting Only) 1 - 2 3 - 4 5 - 6

NUMBER OF ELBOWS45 or 90 Degrees

Medium / Long Radius ONLY

TABLE 2FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM OUTDOORS

MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE

23

ALTERNATETERMINATIONSALTERNATE HORIZONTALDIRECT VENT TERMINATIONS

KIT NOS. RXGY-D02, -D02A, -D03,D03A, -D04 AND -D04A

The combustion air and exhaustterminations may be raised amaximum of 60 inches above thewall penetration to maintain therequired 12 inch clearance abovegrade or snow level. See Figure 18.Size the pipe length according toTable 2.

IMPORTANT: The followingguidelines must be met whenextending beyond 24 inches of pipeon the exterior of the structure:

• Size the entire vent systemaccording to the alternate, notstandard, termination shown inTable 2.

COMBUSTION AIR FORDIRECT VENTINSTALLATIONSTHE COMBUSTION AIR SYSTEMDESIGNED FOR THIS FURNACEMUST BE USED.

When this furnace is installed as adirect vent forced air furnace, allcombustion air is supplied directly tothe burner through a special air inletsystem outlined in these instructions.This system consists of field-suppliedSchedule 40 or 26 SDR-PVC pipeand one of the following horizontalvent termination kits: RXGY-D02 orD02A, RXGY-D03 or D03A, RXGY-D04 or D04A, or RXGY-E03A.

NOTE: Schedule 40 ABS-DWV pipeand fittings may be used as analternate to PVC pipe for thecombustion air inlet and vent pipes.

The combustion air for this furnace issupplied directly from the outdoorsthrough the combustion air inletsystem.

When the furnace is installed in thesame space with other gasappliances, such as a water heater,be sure there is an adequate supplyof combustion and ventilation air forthe other appliances. Do not delete orreduce the combustion air supplyrequired by the other gas appliancesin this space. See Z223.1, NationalFuel Gas Code (NFPA54) for deter-mining the combustion airrequirements for gas appliances. Anunconfined space must have at least50 cubic feet (volume) for each1,000 BTUH of the total input of allappliances in the space. If the openspace containing the appliances is ina building with tight construction(contemporary construction), outsideair may still be required for theappliances to burn and vent properly.Outside air openings should be sizedthe same as for a confined space.

STANDARD TERMINATIONSSTANDARD VERTICALTERMINATIONS

COMBUSTION AIR PIPING

Use two medium-radius sweepelbows to keep the inlet downward toprevent entry of rain. See Figure 20for the proper relationship ofcombustion air to exhausttermination.

STANDARD HORIZONTALTERMINATIONS

COMBUSTION AIR PIPING

When 3-in. pipe is used between thefurnace and outside wall, reduce itto 2 inches before penetrating thewall. Up to 18 inches of 2-in. pipemay be used inside the wall.

The standard horizontal intake airtermination for all models is a 2-in.PVC coupling with a wind deflectorvane (provided) attached. Cut a21/4-in. length of 2-in. PVC pipe.Connect this pipe and another 2-in.PVC coupling to the coupling at thewall. The outer coupling mustterminate 4 inches from the wall. SeeFigure 21, Detail B, for vane location.Attach vane in vertical position withPVC solvent.

IMPORTANT: To ensure properfurnace operation, the supplied vanemust be installed in the verticalposition as shown in Figure 21, DetailB.

The combustion air inlet terminalmust be located with respect to theexhaust terminal as shown in Figure21, Detail C.

IMPORTANT: All furnaces withhorizontal air intakes, except thoseusing concentric vent kit RXGY-E03A,must have a drain tee assembly andtrap installed as close to the furnaceas possible. This is to drain any waterthat may be in the combustion airpipe to prevent it from entering thefurnace combustion chamber.

These parts are included in kits RXGY-D02 or D02A (for 2-in. pipe),RXGY-D03 or D03A (for 3-in. pipe)and RXGY-D04 or D04A (special forthe 120,000 BTU furnace installedwith the alternate horizontaltermination). Attach the trap to thebottom of the tee with PVC solvent.Connect the other end to a suitabledrain, as to the downstream of acondensate trap on the furnace.

STANDARD VERTICALTERMINATIONS

EXHAUST VENT PIPING

Vertical through-the-roof ventapplications do not require anexhaust terminal. The exhaust ventmust terminate at least 12 inchesabove the combustion intake airtermination. The exhaust vent formodels with inputs of 90,000 through120,000 BTUH is 2-in. PVC pipe120,000 BTUH models withexcessively long runs require 21/2”.

Refer to Table 2 for properapplication. This mustbe reduced to 1” or 11/2“ the last12 inches for models with inputs of45,000 through 75,000 BTUH.See Figure 24.

STANDARD HORIZONTALTERMINATIONS

EXHAUST PIPING

For direct vent systems the standardtermination is 2-in. PVC pipeextending 12 inches from the wall forfurnaces with inputs from 105,000 to120,000 BTUH. Install a 2-in. couplingat the outside wall to prevent thetermination from being pushedinward. When 3-in. pipe is usedbetween the furnace and outside wall,reduce to 2 inches before penetratingthe wall. The standard termination is11/2 -in. PVC pipe extending outward12 inches from the wall for modelswith inputs of 45,000 to 75,000BTUH. Install a 2-in. to 11/2-in.coupling at the outside wall to preventpushing the termination back into thewall. See Figure 21, Detail B.

The combustion air and exhaustterminations must be at least 12inches above grade and must beoriented with respect to each other asshown in Figure 21. Refer to sectionon alternate venting options whenhigher snow levels are anticipated.

24

FIGURE 18ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

• Insulate the entire length of ventpipe, between the elbow where thepipe exits the wall and the elbowwhere the termination is made, witha closed-cell insulation, such as“Arm-a-Flex” or “Rub-a-Tex” with aminimum of 1/2” thickness.

• All elbows installed on the exteriorof the building must be of the longsweep nature.

• As required for the horizontal pipingran within the structure, any piperan horizontal outside the structuremust slope upward a minimum of1/4” per foot run so that condensatedrains toward the furnace.

From the top elbow in the exhaustpipe, extend a length of PVC pipeoutward so that it terminates exactly12 inches from the wall. See Figure18. Reduce the termination pipeextension to is 11/2 inch pipe for45,000 BTUH through 75,000 BTUHunits.

The 45,000 BTUH unit only uses kit RXGY-D02 or D02A. The 60,000BTUH and 75,000 BTUH units mayuse kits RXGY-D02 or D02A or RXGY-D03 or D03A depending onpipe lengths and number of elbows.Use kit RXGY-D03 or D03A with90,000 BTUH through 120,000 BTUHunits. The RXGY-D04 or D04A kitonly applies to the 120,000 BTUHunit using an alternate terminationand long runs. See Table 2.

The following are parts lists for the RXGY-D02 or D02A, RXGY-D03 orD03A and RXGY-D04 or D04Aalternate horizontal direct venttermination kits:

RXGY-D02/D02A1. 2-in. tee with reducer assembly2. 1/2-in. PVC 6-in. dia. trap3. PVC vane4. 2-in. PVC elbow5. 11/2-in. PVC nipple with coupling6. PVC strap7. vent template

RXGY-D03/D03A1. 3-in. tee with reducer assembly2. 1/2-in. PVC 6-in. dia. trap3. PVC vane4. 2-in. PVC elbow5. PVC strap6. vent template

RXGY-D04/D04A1. 21/2-in. PVC elbow2. 3" x 21/2" PVC bushing3. 21/2" x 61/2" long PVC pipe4. 21/2" x 16" long PVC pipe5. 21/2" x 21" long PVC pipe6. PVC vane7. 3-in. tee with reducer assembly8. 6-in. dia. 1/2-in. PVC trap9. PVC strap10. vent template

NOTE: The RXGY-D04/-D04A kitonly applies to the 120,000 BTUH unitusing an alternate termination andexcessively long runs.

SEE DETAIL A

60” MAX.

PIPESUPPORTSTRAP

3” MAX.NOTE: 3-1/2”MAX. WHEND04 KIT ISUSED.

EXHAUST VENT21/2" PVC FOR MODELS WITH 120,000 BTU INPUT(KIT NO. RXGY-D04)

2" PVC FOR MODELS WITH INPUTS OF 90,000 AND120,000 BTU. REDUCE TO 11/2" FOR MODELS WITHINPUTS OF 45,000 THRU 60,000 BTU (SEE DETAIL A).ELBOWS AND RISERS ARE 2" PVC.

INTAKE VENT21/2" PVC FOR MODELS WITH120,000 BTU INPUT.2" PVC ELBOWS AND RISERMODELS WITH INPUTS OF 45,000THRU 120,000 BTU.USE KIT NO. RXGY-D02 WHEN 2" PIPEIS USED BETWEEN FURNACE ANDOUTSIDE WALL. USE KIT NO. RXGY-D03WHEN 3" PIPE IS USED.

I339

12” FROM WALL

3”

4”EXHAUST

INTAKE OPTIONALINTAKE

DETAIL BEXHAUST / INTAKE RELATIONSHIP

DETAIL AEXHAUST VENT FOR

MODELS WITHINPUT OF 45,000 THRU

60,000 BTU

12” FROM WALL

1 1/2” PIPE

RXGY-D02A1. 2” Tee assembly w/1⁄2” drain

connection2. 1⁄2” PVC-5” diameter trap3. Wind deflector vane4. Vent template


connection2. 1⁄2” PVC-5” diameter trap3. Wind deflector vane4. Vent Template


connection2. 1⁄2” PVC-6” diameter trap3. Wind deflector vane4. Vent template

25

FIGURE 19CONCENTRIC VENT KIT NO. RXGY-E03A

SIDEWALL ASSEMBLY

ROOF INSTALLATION

1" MAXIMUM

FIELD-SUPPLIEDSTRAP

ITEM No. DESCRIPTION

A 2.5" PVC PIPE SCHEDULE 40 -- 37.125" LONG

B 4" PVC PIPE SCHEDULE 40 -- 24" LONG

C 3" x 3" x 4" SPECIAL CONCENTRIC FITTING

D 3" x 45° STREET ELBOW (FIELD SUPPLIED)

E PVC RAINCAP

E

B

A

C

D

E

B

A

C

D

CONCENTRIC TERMINATIONSVERTICAL/HORIZONTAL CONCENTRIC VENTKIT NO. RXGY-E03A

This kit is for vertical/horizontalintake air/vent runs and may beinstalled through roofs andsidewalls. One 5” diameter hole isrequired for the installation. SeeFigure 19 for the general layout.Complete installation instructionsare included with the kit.

MAINTAIN 12 IN.MINIMUM CLEARANCEABOVE HIGHESTANTICIPATED SNOWLEVEL. MAXIMUM OF24 IN. ABOVE ROOF.

NOTE: The following IPEX brandconcentric terminations (System 636)may be purchased in the field andused in place of factory supplied kits:

3” Concentric Kit – Item # 196006

26

FIGURE 20STANDARD VERTICAL DIRECT VENTINGUPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW MODELS)

FIGURE 21STANDARD HORIZONTAL DIRECT VENTINGUPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW MODELS)

I407

3" MAX.SEPARATION

COMBUSTION AIRPIPE

12" MIN.SEPARATION

12" MIN. ABOVEROOF LEVELROOF LINEEXHAUST PIPE

COMBUSTION AIR PIPE

SUPPLY AIR

RETURN AIR

EXHAUST VENT

3"MAX.

EXHAUSTVENT

ROOF LINE

COMBUSTIONAIR PIPE

12"MIN.

12" MIN. ANTICIPATEDSNOW LEVEL

COMBUSTIONAIR PIPE

3"MAX.EXHAUST

VENT

12"MIN.

12" MIN.

3"

MAX.

12" MIN

. 12" MIN

. ABOV

E

ANTIC

IPATED

SNOW

LEVEL

5

NOTES:

1 THE COMBUSTION AIR PIPE MUSTTERMINATE IN THE SAME PRESSUREZONE AS THE EXHAUST PIPE.

2 INCREASE THE 12-IN. MINIMUMTO KEEP TERMINAL OPENINGABOVE ANTICIPATED LEVEL OFSNOW ACCUMULATION WHEREAPPLICABLE.

3 WHEN 3-IN. DIAM. PIPE IS USED,REDUCE TO 2-IN. DIAMETER BEFOREPENETRATING ROOF. A MAXIMUM OF18 IN. OF 2-IN. PIPE MAY BE USEDBEFORE PASSING THROUGH ROOF.

4 SUPPORT VERTICAL PIPE EVERY 6FEET.

5 EXHAUST TERMINATION - TERMINATETHE LAST 12 INCHES WITH 2” PVC PIPEON 90,000 AND 120,000 BTUH MODELS.REDUCE AND TERMINATE THE LAST12 INCHES WITH 11/2” PVC PIPE ON45,000 THROUGH 75,000 BTUHMODELS. SEE DETAIL A.

6 30” MAXIMUM EXPOSED VENTLENGTH.

PITCHED ROOF INSTALLATIONS

NOTES:

1 SUPPORT HORIZONTAL PIPEEVERY FOUR FEET.

2 WHEN 3 IN. PIPE IS USED REDUCE TO 2 IN.BEFORE PENETRATING OUTSIDE WALL.

3 18 IN. MAXIMUM. 2 IN. DIAMETER PIPE MAYBE USED INSIDE THE WALL.

4 DETAIL “A” - EXHAUST TERMINATIONTERMINATE THE LAST 12 INCHES WITH 2”PVC PIPE ON 90,000 AND 120,000 BTUHMODELS. REDUCE AND TERMINATE THELAST 12 INCHES WITH 11/2” PVC PIPE ON45,000 THROUGH 75,000 BTUH MODELS.

5 INCREASE THE 12 IN. MINIMUM ABOVEGRADE TO KEEP TERMINAL OPENINGSABOVE ANTICIPATED LEVEL OF SNOWACCUMULATION WHERE APPLICABLE.

6 DETAIL “B”, INSTALL WIND DEFLECTORVANE IN 2 IN. PVC COUPLING IN VERTICLEPOSITION USING PVC SOLVENT.THE COMBUSTION AIR TERMINATION MUSTBE IN THE SAME PRESSURE ZONE AS THEEXHAUST TERMINATION.

3”

12”

4”

4”

SEE DETAIL A

VANE 2” PVCCOUPLING

12” MIN. ABOVEGRADE LEVEL 5

SEE DETAIL B

2” OR 3” TEEW/DRAIN TRAP

RETURN AIR

TRAP

SUPPLY AIR

EXHAUST PIPE

COMBUSTION AIR PIPE

CONNECTTO DRAIN

12”

4”EXHAUST

INTAKE OPTIONALINTAKE

DETAIL CEXHAUST / INTAKE RELATIONSHIP

EXHAUST TERMINATION

DETAIL A

COMBUSTION AIR TERMINATION

DETAIL B

1 23

I407

4

5

5

5

12”

4

6

1

2

3

EXHAUSTTERMINATION

DETAIL A

30� MAX

30� MAX

27

FIGURE 22DIRECT VENT TERMINAL CLEARANCES≤

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LOCATION REQUIREMENTSHORIZONTAL DIRECT VENTS

THE COMBUSTION PRODUCTSAND MOISTURE IN THE FLUEGASES WILL CONDENSE AS THEYLEAVE THE TERMINATION. THECONDENSATE CAN FREEZE ONTHE EXTERIOR WALL, UNDERTHE EAVES AND ONSURROUNDING OBJECTS. SOMEDISCOLORATION TO THEEXTERIOR OF THE BUILDING ISTO BE EXPECTED. HOWEVER,IMPROPER LOCATION ORINSTALLATION CAN RESULT INSTRUCTURAL OR EXTERIORFINISH DAMAGE TO THEBUILDING AND MAYRECIRCULATE PRODUCTS OFCOMBUSTION INTO THECOMBUSTION AIR TERMINAL ANDFREEZE.

The vent must be installed with thefollowing minimum clearances. SeeFigures 22 & 23.

1. The bottom of the vent terminaland the air inlet shall be locatedat least 12 inches above grade.Increase the 12-in. minimum tokeep the terminal openingsabove the level of snowaccumulation, where applicable.

2. The vent shall not terminate overpublic walkways or over an areawhere condensate or vapor couldcreate a nuisance or hazard.

3. The vent terminal shall belocated at least one foot from anyopening through which fluegases could enter a building.

4. The vent terminal shall be atleast 3 feet above any forced airinlet located within 10 feet,except the combustion air inlet ofa direct vent appliance.

5. The vent terminal shall have aminimum horizontal clearance of4 feet from electric meters, gasmeters, regulators and reliefequipment.

6. Locate the furnace combustionair inlet minimum of 3 feet fromthe vent of any other gas or fuelburning appliance or clothesdryer to prevent recirculation ofthe flue gases into the furnacecombustion air inlet. The onlyexception to this requirement isthe case of multiventing two ormore furnaces, which is coveredin the section on multiventing inthese instructions.

In addition to the minimumclearances listed above, the ventlocation should also be governedby the following guidelines.

1. Do not terminate under anykind of patio or deck. If runningthe vent under a deck, insulateit to insure no condensatefreezes and blocks the pipe.

2. Do not terminate behind any areathat may allow the flue productsto become stagnant andrecirculate.

3. Do not locate on the side of abuilding with prevailing winterwinds. This will help preventmoisture from freezing on wallsand overhangs (under eaves).

4. Do not extend vent directlythrough brick or masonry

surfaces, unless a rust-resistantsheet metal or plastic backingplate behind vent. See Figure 23.

5. Do not locate too close to shrubsas condensate may stunt orkill them.

6. Minimum vertical clearances of 1foot are recommended foroverhangs up to 1 foot horizontal.The vertical clearance should beincreased equally for eachadditional increase in horizontaloverhang to a maximum verticalclearance of 6 feet.

7. Caulk all cracks, seams andjoints within 6 feet horizontallyand above and below vent.See Figure 23.

FIGURE 23MOISTURE ZONES

! CAUTION

2 FT. SQ. SHEET METAL PLATE ON BRICK ORMASONRY SURFACE RECOMMENDED, BUTNOT REQUIRED BY CODE.

29

FIGURE 24TWO FURNACE VENTING THROUGH ROOF

8"

MINIMUM 12" ABOVE AVERAGE SNOW ACCUMULATION. MAXIMUM

OF 24 IN. ABOVE ROOF.

8. Painted surfaces must be soundand in good condition with nocracking, peeling, etc. Paintedsurfaces will requiremaintenance.

9. Do not expose 3" x 2" reducer/bushing to outdoor ambienttemperatures.

MULTIVENTINGIF VENTING TWO OR MOREFURNACES NEAR EACH OTHER ISREQUIRED, EACH FURNACE MUSTBE INDIVIDUALLY VENTED – NOCOMMON VENTING IS PERMITTED.See Figures 24 and 25 for positioningof the terminations. When more thantwo furnaces are to be vented, theremust be at least 4 feet between thefirst two furnaces and the third, etc.

FIGURE 25TWO FURNACE VENTING THROUGH WALL

EXHAUST VENTMODELS 06-07TO BE REDUCED TO1-1/2” PVC LAST 12”.

3” MINIMUM24” MAXIMUM




TWO-PIPE VENTING

CONCENTRIC VENTING

SEE CONCENTRICVENT SECTION ON PAGE 23FOR MORE INFORMATION.

TWO-PIPE VENTING

CONCENTRIC VENTING

8"

MAXIMUM 1" DISTANCE

FROM WALL

MINIMUM 12" ABOVE GRADE

6' MINIMUM10' RECOMMENDED

SEE CONCENTRIC VENT SECTION ON PAGE 23 FOR MORE INFORMATION.

30

RXGY-G02 SIDE WALL VENTThis termination for horizontal ventingonly.

IMPORTANT: Do not install on theprevailing winter wind side of thestructure. Observe same clearancesspecified for horizontal, standardtermination.

NOTE: Multi-venting-No commonventing.

NOTE: Install the vent and air intakepiping into the vent plate openings.Seal all gaps between the pipes andwall. Be Sure To Use SiliconeSealant to seal the vent pipe to thevent cap to permit field disassemblyfor annual inspection and cleaning.Also seal all pipe penetrations in wall.To prevent possibility of condensatefreeze-up or recirculation, do notinstall vent kits one above theother.

NOTE: The vent illustration in Figure27 can be used for Non-direct ventterminations also.

FIGURE 27VENT KIT INSTALLATION OPTIONS

FIGURE 26VENT KIT INSTALLATION OPTIONS

B

EXHAUST

AIR INTAKE

A

For 90000 thru 120000 BTUH models-reduce to a length between 12 inchesand 30 inches of 2 inch pipe.for 45000 thru 75000 BTUH models-when 3 inch pipe is used: reduce last 30inches to 18 inches of 2 inch pipe and12 inches of 1-1/2 inch pipe tomaintainvelocity.Note: Vent should protrude amaximum of 2-1/4” beyond vent plate.Air intake should protrude a maximumof 1 inch beyond vent plate.

Seal all wall cavities

31

FIGURE 28UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION

CONNECTING TO FURNACEIMPORTANT: Clean and debur allpipe cuts. The shavings must not beallowed to block the exhaust, inlet orcondensate drain pipes.

UPFLOW FURNACE

The exhaust pipe connection is a 2-in.female PVC pipe fitting extendingthrough the left side of the furnace topplate. This opening has a protectivecap which should be removed justprior to installing the exhaust pipe.When 2-in. pipe is used, connect itdirectly to this fitting. When 3-in. pipeis used, connect a 2 to 3-in. couplingto this fitting with a short piece of 2-in.PVC pipe.

The inlet combustion air connectionis at the right side of the top plate.An alternate combustion inlet airconnection may be made on the rightside of the jacket. This opening has aplastic cap. A combustion inlet airconnection fitting is supplied with thefurnace and it must be installed in thefurnace by screwing it into theopening. Make sure the rubber“O-ring” supplied with the furnace isused with this fitting. See Figure 28.

DOWNFLOW/HORIZONTALFURNACE

The exhaust pipe connection is a 2-in.upflow only PVC pipe fitting extendingthrough the right side of the furnacetop cover. This opening has a pro-tective cap which should be removedjust prior to installing the exhaustpipe. When 2-in. pipe is used, con-nect it directly to this fitting. When3-in. pipe is used, connect with a2- to 3-in. coupling directly to the2-in. pipe.

The combustion inlet air connection isa 2-in. extruded hole on the left sideof the top plate. When a 2-in. pipe isused, attach a 2-in. PVC couplingover this hole with RTV sealant andalso add two sheet metal screwsthrough the coupling into theextrusion to secure it in place, andadd the required piping. When 3-in.pipe is required, use a 2- to 3-in.coupling and add the required piping.See Figure 29.

FIGURE 29DOWNFLOW/HORIZONTAL COMBUSTION AIR AND VENT PIPE CONNECTION

VENT CAP/PLUG

PIPE - PVC

CONNECTOR

EXHAUST TRANSITION

TOP PLATE

COUPLING

COMBUSTIONAIR CHASE

OUTLET AIR PIPE

I329

I329

NOTE:ATTACH COUPLING TOEXTRUDED COLLARWITH TWO SCREWS. PUTBEAD OF SILICONEAROUND BASE BEFOREMOUNTING COUPLING.

INDUCED DRAFTBLOWER

CONDENSATE TRAP

CONNECTOR

INDUCED DRAFTBLOWER

PLUG OPT. COMBUSTIONAIR INLET POSITION

NOTE:WHEN COMBUSTION AIR INLET IS INOPTIONAL POSITION SWAP LOCATIONOF INLET AIR ADAPTER AND “O” RINGWITH PLUG.

EXHAUST TRANSITION

OUTLET AIR PIPE

VENT CAP/PLUG

TOP PLATE

“O” RING COMBUSTIONAIR ADAPTER

32

FIGURE 31DOWNFLOW CONDENSATE DRAIN

CONDENSATE DRAIN/NEUTRALIZER

FIGURE 30UPFLOW CONDENSATE DRAIN

GENERAL INFORMATION

DO NOT RUN DRAIN OUTDOORS.FREEZING OF CONDENSATE CANCAUSE PROPERTY DAMAGE.IMPORTANT: Do not connect into acommon drain line with an air con-ditioner evaporator coil drain locatedbelow the furnace. A blocked orrestricted drain line can result in over-flow of the coil pan and negate thefurnace blocked drain shutoff control.FILL TRAP ASSEMBLY WITHWATER BEFORE OPERATING THEFURNACE. This can be done byremoving the drain hosefrom the trap and pouring about acup of water into the vent trap. Waterwill flow into the house drain when thetrap is full.If local codes require, install acondensate neutralizer cartridge in thedrain line. Install cartridge in horizontalposition only. Also install an overflowline if routing to a floor drain. SeeFigures 30 and 31. If no floor drain is available, install acondensate pump that is resistant toacidic water. Pumps are available fromyour local distributor. If pump used isnot resistant to acidic water, acondensate neutralizer must be usedahead of the pump. The condensatepump must have an auxiliary safetyswitch to prevent operation of thefurnace and resulting overflow ofcondensate in the event of pumpfailure. The safety switch must be wiredthrough the “R” circuit only (low voltage)to provide operation in either heating orcooling modes.

UPFLOW MODELSThe condensate drain trap is located inthe blower compartment on the left-hand side of the jacket. A short piece of1⁄2-in. PVC pipe and a 1⁄2-in. tee areprovided. Connect the 1⁄2-in. pipe to theelbow on the trap and the tee to thispipe so that the open end is upward.Run a drain tube from the bottom of thetee to a floor drain or condensatepump. IMPORTANT: If installing the unit overa finished ceiling or living area, becertain to install an auxiliary condensatedrain pan under the entire unitextending out under the condensatetee.IMPORTANT: There are two optionswhen choosing a height for thecondensate riser:CONDENSATE OVERFLOW: With a51⁄2 inch riser installed above the tee, ablocked drain will result in overflow fromthe riser.FURNACE SHUTDOWN: To cause thefurnace to shut down when a blocked

drain is present, install a riser which is aminimum of 1013⁄16”. If the furnace isinstalled in an attic, crawlspace or otherarea where freezing temperatures mayoccur, the furnace drain can freezewhile shut off for long periods of time. Use a solvent cement that is compatiblewith PVC material. Cut the drain hosesto the appropriate length and connect tothe trap with hose clamps. Tighten theclamps with pliers and check for leaksafter attaching.

DOWNFLOW MODELSIMPORTANT: There are two optionswhen choosing a height for thecondensate riser:

CONDENSATE OVERFLOW: With a13⁄4 inch riser installed above the tee,a blocked drain will result in overflowfrom the riser.FURNACE SHUTDOWN: To causethe furnace to shut down when ablocked drain is present, install a riserwhich is a minimum of 51⁄2”. If thefurnace is installed in an attic,crawlspace or other area wherefreezing temperatures may occur, thefurnace drain can freeze while shutoff for long periods of time. Use a solvent cement that iscompatible with PVC material.

! CAUTION

NEUTRALIZER CARTRIDGE(OPTIONAL)

CONDENSATE TRAP

DRAIN LINE

I408

I408

1013/16

CONDENSATE TRAP

TO FLOOR DRAIN OR CONDENSATE PUMP

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

DRAIN LINENEUTRALIZER CARTRIDGE (OPTIONAL)

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)


NOTE:SEE UPFLOW MODELNOTES FOR PIPEHEIGHT

NOTE:SEE DOWNFLOW MODELNOTES FOR PIPE HEIGHT

33

FIGURE 32UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

REVERSING THE TRAPUPFLOW UNITSThe trap may be moved to the rightside for right side drainage. Open theknockout for the drain on the rightside of the cabinet. Remove thebracket holding the trap from the leftside. Seal the left side drain hole witha plug provided in the cloth bag withthe furnace. Position the mountingbracket and trap so that the drainelbow is centered in the hole onthe right. See Figure 32.

Drill two holes in the cabinet to mountthe bracket. Mount the trap andbracket to the right side with the drainelbow pointing through the knockout.Connect the 1/2-in. pipe and tee asnoted above. Route the drain hosesbehind the control box, cut to theappropriate length, and connect to thetrap with hose clamps.

IMPORTANT: DO NOT ALLOW ANYSAGS OR KINKS IN THE HOSES.This prevents proper condensateflow.

IMPORTANT: Do not connect intoa common drain line with an airconditioner evaporator coil drainlocated above the furnace. A blockedor restricted drain line can result inoverflow of the coil pan and negatethe furnace blocked drain shutoffcontrol.

DOWNFLOW UNITSTo convert downflow models to left-hand drain, a kit (RXGY-H01) mustbe ordered from the distributor. Thekit includes a 24” piece of 1⁄2” blackPVC pipe, a 2-9/16” length of blackhose, a 2” rubber grommet, a 1-5/8”plug and instructions. Note thelocation of the alternate drain hole asshown in Figure 33.

First remove the long molded hosefrom the trap. Remove the double-elbow black molded hose from thetrap and exhaust transition anddiscard. Remove the trap from itsmounting bracket, rotate it 180°, andmount in place with drainage elbowpointing to the left. Reattach the longblack molded hose. Use the 2-9/16”length of black hose included in thekit between the trap and exhausttransition. Clamp the hoses tight withwhite nylon clamps.

Remove the plug from the 2” alternatedrain hole (see Figure 33) andreplace it with the 2” rubber grommetsupplied in the RXGY- H01 downflowalternate drain kit. Also, remove the1-5/8” grommet supplied in theprimary drain hole and replace it withthe 1-5/8” diameter plug that is alsosupplied in the RXGY-H01 downflowalternate drain kit. Both the hole-plugand grommet must be in place to

insure a good seal in the burnercompartment.

A length of 1/2” black PVC pipe is alsoprovided in the RXGY-H01 downflowalternate drain kit. Glue one end ofthe pipe to the elbow in the trap. Cutthe pipe so that it extends through thealternate drain hole in the left side ofthe cabinet one inch (see Figure 33).Connect the1/2” PVC tee (suppliedwith the furnace) to the pipe with a 1-3/4” riser. Use the 1-5/8” plugsupplied in the RXGY-H01 downflowalternate drain kit to seal the right sidedrainage hole.

IMPORTANT: Do not connect into acommon drain line with an airconditioner evaporator coil drainlocated above the furnace. A blockedor restricted drain line can result inoverflow of the coil pan and negatethe furnace blocked-drain shutoffcontrol.

To convert to left side drainage,remove the long molded hose from

CUT DRAIN HOSES ASREQUIREDAND CONNECT TOINLETS ON TOPOF CONDENSATETRAP

DRAINRISER

TEE

DRAINEXTENSION

PROPER DRAIN SLOPE REQUIRED(NO KINKS ALLOWED)

CONDENSATE TRAPIFC MOUNTING

PLATE

TO FLOORDRAIN

the trap. Remove the double-elbowblack molded hose from the trap andexhaust transition and discard.Remove the trap from its mountingbracket, rotate it 180 degrees andmount in place with the drainageelbow pointing to the left. Reattachthe long black molded hose. Use the2-9/16” length of black hose includedin the RXGY-H01 kit between the trapand exhaust transition. Clamp thehoses tight with white nylon clamps.

FILLING THE TRAPFILL THE TRAP ASSEMBLY WITHWATER BEFORE OPERATING THEFURNACE. Do this by removing thedrain hose from the trap or from theconnection to the secondary coil.Pour about a cup of water into thevent trap. Any excess water flows intothe house drain when the trap is full.

NOTE: Fill the trap assembly withwater every heating season.

I394

FIGURE 33DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

The kit includes a 24” piece of ½” black PVC pipe, a 2” rubber grommet, a 1-5/8” p

R

Glue

o

TEE

DRAINEXTENSION

DRAIN VENT

CONDENSATE TRAP

TO FLOORDRAIN OR

CONDENSATE PUMP

ALTERNATE DRAIN HOLELOCATED HERE ON JACKET.(REMOVE PLASTIC PLUG ANDREPLACE WITH GROMMET).

EXISTING DRAIN HOLE. PLUGWITH 15⁄8” PLUG SUPPLIEDIN KIT

ROTATE TRAP 180° ANDINSTALL RIGID PIPE FROMELBOW TO OPPSOITE SIDEOF JACKET AS SHOWN

I394

Refer to Figure 36 for Steps 6-11.

6. Locate the parts bag in theburner compartment. Install twoplastic plugs � in the side of thejacket from bottom side up.

7. Attach the gasket � onto the trapassembly so that the gasketholes on the gasket line up withthe holes on the trap assembly.

8. Fill the trap assembly � with 1/2cup of water.

9. Insert the trap assembly withgasket up through the existinghole in the jacket and securefrom inside the jacket. Use twoscrews provided. Screw downinto the two “ears” molded intoeither side of the trap. Snug thetrap assembly against thefurnace jacket compressing thegasket slightly to eliminate anyair leaks. Do not overtighten!

10. Attach the black molded rubber90° elbow � to the straight spouton the trap top using a whitenylon clamp � . Attach the otherend of the rubber elbow to thespout � located on the exhausttransition � using a white nylonclamp.

11. Attach the 90° end of the moldedhose � to the collector box.Clamp the hose tight with a white

CONDENSATE DRAINFOR HORIZONTALINSTALLATIONRefer to Figure 35 for Steps 1-5.

1. This unit is shipped factory readyfor downflow installation. Thecondensate trap assembly anddrain hoses require conversionfor horizontal installation.Remove the existing condensatetrap with the unit in the uprightposition.

IMPORTANT: This furnace mayonly be installed so that whenfacing the front of the furnace,supply air is discharged on theleft hand side.

2. Remove the burner compartmentdoor from the unit.

3. Remove the two screws from theright side of the furnace jacketwhich support the trap mountingbracket � . Remove the twoplastic plugs on either side of thetrap outlet hole and discard.

4. Remove the black molded 90°hose � from the top of theexisting trap � and from thefurnace collector box. Cut 1.0inch from the long end of thehose. NOTE: Exception – do notshorten the 90° hose on the 07Bfurnace! The 07B has a longerdistance between the collectorbox and the horizontal drain trap.

5. Remove the double-elbow blackmolded hose � from the exhausttransition �. Discard this hoseand the downflow trap. Retainthe clamps for future use.Additional clamps are provided inthe parts bag if any clamps aredamaged during conversionprocess.

NOTE: The following steps shouldtake place with the furnace in thehorizontal position.

34

FIGURE 34HORIZONTAL CONDENSATE DRAIN

I408

CONDENSATE TRAP

DRAIN LINE

NEUTRALIZER CARTRIDGE(OPTIONAL)


NOTE:SEE GENERAL NOTES FORHORIZONTAL MODELS FORPIPE HEIGHT.

OVERFLOW LINE(REQUIRED ONLY WHEN

OPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

nylon clamp. Then attach thelong end of the molded hose tothe 45° elbow molded into thetop of the trap assembly. Clampthe hose tight with white nylonclamp.

IMPORTANT: Tighten all clampconnections with a pair of pliersand check for leaks afterconversion is complete.

12. IMPORTANT: There are twooptions when choosing a heightfor the condensate riser:

CONDENSATE OVERFLOW:With a 13⁄4 inch riser installedabove the tee, a blocked drainwill result in overflow from theriser.

FURNACE SHUTDOWN: Tocause the furnace to shut downwhen a blocked drain is present,install a riser which is a minimumof 51⁄2”. If the furnace is installedin an attic, crawlspace or otherarea where freezingtemperatures may occur, thefurnace drain can freeze whileshut off for long periods of time.

Use a solvent cement that iscompatible with PVC material.

CONVERTING DOWNFLOW TO HORIZONTAL

C

A

D

B

E

F

G

H

L

I

J

K

E

35

FIGURE 35

UPRIGHT POSITION: REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP

FIGURE 36

HORIZONTAL POSITION: CONDENSATE TRAP IN

STALLATION

FOR HORIZONTAL OPERATION

I534

CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO

HORIZONTA

L IN

STA

LLATION

36

GAS SUPPLY AND PIPINGGAS SUPPLY

THIS FURNACE IS EQUIPPED ATTHE FACTORY FOR USE ONNATURAL GAS ONLY.CONVERSION TO LP GASREQUIRES A SPECIAL KITSUPPLIED BY THE DISTRIBUTOROR MANUFACTURER. MAILINGADDRESS IS LISTED ON THEWARRANTY. FAILURE TO USETHE PROPER CONVERSION KITCAN CAUSE FIRE, CARBONMONOXIDE POISONING,EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. See the conversion kitindex supplied with the furnace.This index identifies the proper LPGas Conversion Kit required foreach particular 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 carbon monoxidedetector(s) are recommended in allapplications,and their installation should be inaccordance with the manufacturer’srecommendations and/or local laws,rules, regulations or customs.

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 3 for the recom-mended gas pipe size. See Figure 37for typical gas pipe connections.

! WARNING

FIGURE 37GAS PIPING INSTALLATION

GROMMET

TOP VIEW OF GAS LINE AND VALVEIN OPT. POSITION

NOTE: WHEN GAS LINEIS IN OPT. POSITION,SWAP LOCATION OFGROMMET AND PLUG.

OPT. GAS LINEPOSITION

PLUG(IN NORMALPOSITION)

MANIFOLDPRESSURETAP

IGNITOR

MANIFOLD

GAS VALVEUNION

DRIP LEG

GROMMET(IN NORMALPOSITION)

4 TO 5 FEETABOVEFLOOR REQ’DBY SOMEUTILITIES.

MAIN GASVALVE

BURNERS

GROMMET

TOP VIEW OF GAS LINE AND VALVEIN OPT. POSITION

MAIN GASVALVE

4 TO 5 FEET ABOVEFLOOR REQ’D BYSOME UTILITIES.

GROMMET(IN NORMALPOSITION)

DRIP LEG

UNION

GAS VALVE

BURNERSMANIFOLD

IGNITOR

MANIFOLDPRESSURETAP

PLUG(IN NORMALPOSITION)

NOTE: WHEN GASLINE IS IN OPT.POSITION, SWAPLOCATION OFGROMMET ANDPLUG.

DOWNFLOW

I328

UPFLOW

MANUAL GAS VALVE

UNION

DRIP LEG

BURNERS

MANIFOLD

GAS VALVEI524

IMPORTANT: DO NOT RUN A FLEXIBLE GAS CONNECTOR INSIDE THEUNIT. Extend the 1/2" black pipe from the gas valve to the outside of the cabinet.Connect any flexible gas connector from there to the gas piping.

HORIZONTAL

37

FIGURE 39TYPICAL GAS VALVES

WHITE-RODGERS 36G55 SERIES

however 6� to 7� is recommended.The minimum 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. FAILURETO ADHERE TO THIS WARNINGCAN CAUSE A FIRE OREXPLOSION RESULTING INPROPERTY DAMAGE, PERSONALINJURY OR DEATH.

To check for gas leakage, use anapproved chloride-free soap andwater solution, an electronic com-bustible gas detector (see Figure 38),or other approved method.

GAS VALVEThis furnace has a 24-volt operatedvalve. It has ports for measuringsupply pressure and manifoldpressure. The valve body contains a

Install a ground joint union insidethe cabinet to easily remove thecontrol valve assembly. Install amanual shut-off valve in the gasline outside the furnace casing.The T-valve should be readilyaccessible to turn the gas supply onor off. Install a drip leg in the gassupply line as close to the furnace aspossible. 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: Do not run a flexiblegas connector inside the unit. If localcodes allow the use of a flexible gasappliance connector, always use anew listed connector. Do not use aconnector which has previouslyserviced another gas appliance.Massachusetts law requires that allflexibile connectors be less than 36�.

The gas pipe gasket in the cabinetdoes not seal around a flexi-ble gasconnector. It is important to have allopenings in the cabinet burnercompartment sealed for properfurnace 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 PSIG. (3.48 kPa).

GAS PRESSURENatural gas supply pressureshould be 5" to 10.5" w.c. LP gassupply pressure should be 11" to13" w.c. This pressure must bemaintained with all other gas-firedappliances in operation.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTEDAND THAT THE SIZE OF THEBURNER ORIFICES BE RE-CALCULATED BASED ONELEVATION AND GAS HEATINGVALUE. THE BURNER ORIFICESMAY (OR MAY NOT) NEED TO BECHANGED. SEE THE SECTIONTITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.

The minimum supply pressure to thegas valve for proper furnace inputadjustments is 5� w.c. for natural gas,

! WARNING

FIGURE 38ELECTRONIC COMBUSTIBLE GASDETECTOR

TABLE 3NATURAL 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.

pressure regulator to maintain propermanifold pressure. A manual control is on the valvebody. It can be set to only the “ON”or “OFF” positions. The gas valve isa slow-opening valve. See Figure 39.When energized, it takes 6 to 8seconds to fully open.

HONEYWELL VR8205 SERIES

! CAUTION

38

LP CONVERSIONNOTE: See Page 41 for CanadianHigh-Altitude Derate

IMPORTANT: LP gas from trucksused to transport liquid-basedfertilizers can contain chemicals thatwill damage the furnace. Verify thatyour gas supplier does not use thesame trucks to transport materialsother than LP.

The valve can be converted to useliquified petroleum (LP) gas byreplacing the pressure regulatorspring with the conversion kit spring.This LP kit spring allows the regulatorto maintain the proper manifoldpressure for LP gas.

NOTE: Order the correct LPconversion kit from the furnacemanufacturer. Furnace conversion toLP gas must be performed by aqualified installer, service agency orthe gas supplier.

ORIFICE INSTALLATIONLP Gas is a manufactured gas thathas consistent heating value acrossmost regions.

The NFGC guidelines are used withthe following exception:

The recommended LP Gas highaltitude orifice selections differ slightlyin that the NFGC LP orifice chart, asthey are not accurate for Rheemproducts. The National Fuel GasCode LP orifices are based on an 11�of water column pressure at theorifice, which differs from Rheemproducts that use 10� of water columnat the orifice. This difference requiresa deviation from the NFGC orificesize recommendations. The SeaLevel input should still be reduced by4% per thousand ft. and the orificesize must be selected based on thereduced input selection chart below.

To change orifice spuds for eitherconversion to LP or for elevation:1. Shut off the manual main gas

valve and remove the gasmanifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

4. Turn the gas supply back on andcheck for proper operation andmanifold pressure. See Figures41, 42 and 43.

5. Attach the notice label alertingthe next service technician thatthe furnace has been convertedto LP gas.

FIGURE 40TYPICAL LP KIT CONTENTS

ORIFICE ORDERINGINFORMATIONOrifice sizes are selected by addingthe 2-digit drill size required in theorifice part number. Drill sizesavailable are 39 through 64; metricsizes available 1.10mm (-90) and1.15mm (-91):

Orifice Part Number 62-22175-(drillsize)

Example 1:#60 drill size orifice requiredPart # 62-22175-60

Example 2:1.15mm drill size orifice requiredPart # 62-22175-91

Input (per Altitude burner) 15000 Orifice Size

0 to 2000 ft. 15000 1.15 mm (factory)

2000�-3000� 13200 1.15 mm

3000�-4000� 12600 1.10 mm

4000�-5000� 12000 #58

5000�-6000� 11400 #59

6000�-7000� 10800 #60

7000�-8000� 10200 #62

8000�-9000� 9600 #63

9000�-10000� 9000 #64

39

90+ HIGH ALTITUDEINSTRUCTIONS

RGRA/RGTA/RGRB/RGRS/RGTS/RGRT HIGHALTITUDE KITSAll RGRA/RGTA/RGRB/RGRS/RGTS/RGRT models can be converted forhigh altitude usig the appropriate HighAltitude Conversion Kits listed below.The kits can be ordered from thefactory. The kit includes pressureswitch(es) and instructions forconverting the furnace for elevationsabove 5,000 ft. The kit should neverbe used at elevations below 5,000 ft.In addition, the kit instructions detailhow to re-calculate burner orifice sizebased on gas heating value andelevation. The instructions are basedon a required 4% per thousand feetreduction in input as specified by theNational Fuel Gas Code (NFGC).Specific orifices should always berecalculated for all high altitudeinstallations as outlined below.Orifices should be changed, ifnecessary, based on gas heatingvalue and elevation.

High RGTA, RGRA, RGRBAltitude Kit RGRS, RGTS & RGRT RXGY-F04 105,000 BTU’sRXGY-F05 120,000RXGY-F06 45,000, 60,000 & 90,000RXGY-F07 75,000

RGRA/RGTA/RGRB/RGRS/RGTS/RGRT -HIGHALTITUDE OPTION#278Some furnaces can be ordered fromthe factory already converted for highaltitude elevations. The factory optionfor high altitude elevations would beordered as a 278 option (example: a105k BTU upflow furnace which isfactory converted for high altitudeelevations would have the modelnumber RGRA-10EZAJS278). Thesefactory converted furnaces come withpressure switches for high-altitudeelevations already attached. Also,different burner orifices are installedat the factory which are one drill sizesmaller (#51 DMS) than standard RGRA/RGTA/RGRB/RGRS/RGTS/RGRT gas furnaces (#50 DMS). Thesmaller orifice is installed toaccommodate for average heatingvalues expected in most high altitudeareas and a required 4% perthousand feet reduction in input asspecified by the National Fuel GasCode (NFGC). Specific orificesshould always be recalculated for allhigh altitude installations as outlinedbelow. Orifices should be changed, ifnecessary, based on gas heatingvalue and elevation.

NATURAL GAS

INSTALLATION OF THIS FURNACEAT ALTITUDES ABOVE 2000 FT (610m) SHALL BE IN ACCORDANCEWITH LOCAL CODES, OR IN THEABSENCE OF LOCAL CODES, THENATIONAL FUEL GAS CODE, ANSIZ223.1/NFPA 54 OR NATIONALSTANDARD OF CANADA, NATURALGAS AND PROPANE INSTALLATIONCODE, CAN B149.1.INSTALLATIN OF THIS APPLIANCEAT OR ABOVE 5000 FT (1525 m)SHALL BE MADE IN ACCORDANCEWITH THE LISTED HIGH ALTITUDECONVERSION KIT AVAILABLE WITHTHIS FURNACE.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT) NEEDTO BE CHANGED. THE FOLLOWINGEXAMPLES SHOW HOW TODETERMINE IF AN ORIFICE CHANGEWILL BE NECESSARY AND HOW TODETERMINE THE NEW ORIFICE SIZE.IN CANADA, AS AN ALTERNATE TOADJUSTING THE BURNER ORIFICESIZE, THE MANIFOLD GASPRESSURE MAY BE ADJUSTED.THIS METHOD IS COVERED LATERIN THIS SECTION. THIS METHOD OFADJUSTING MANIFOLD PRESSUREMAY ONLY BE USED IN CANADIANINSTALLATIONS.

34� 90 Plus furnaces installed at highelevations require the installation of ahigh altitude kit for proper operation. Thehigh altitude kit consists of a highaltitude pressure switch that replacesthe pressure switch attached to theinduced draft blower. The kit alsocontains gas orifices for high altitude.

The pressure switch must be installed atelevations above 5000 ft. Elevationsabove 2000 ft. require the furnace to bede-rated 4% per thousand feet.

NOTE: Factory installed orifices are

calculated and sized based on a sealevel Natural Gas heating value of1075 BTU per cubic ft. Regionalreduced heating values may nullifythe need to change orifices except atextreme altitudes.

The following are examples of orificesizing using the National Fuel GasCode Appendix F. For a simplifiedestimation of orifice size based onheating value and elevation, useTables 4 and 5. However,calculations are the best method.

Example: 900 BTU/ft3 RegionalNatural Gas Heating Value

I / H = Q15000 / 900 = 16.68 ft.3

I = Sea Level input (per burner):15000H = Sea Level Heating Value: 900Q = 16.68 ft3 Natural Gas per hour.

From Table F.1 of National Fuel GasCode Handbook, 2002 (3.5� w.c.column)Orifice required at Sea Level: #48

From Table F.4 of National Fuel GasCode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft.): #50Orifice required at 8000 ft. elevation(4% de-rate per thousand ft.): #51

Example: 1050 BTU/ft3 RegionalNatural Gas Heating Value

I / H = Q15000 / 1050 = 14.63 ft.3

I = Sea Level input (per burner):15000H = Sea Level Heating Value: 1050Q = 14.28 ft.3 Natural Gas per hour.

From Table F.1 of National Fuel GasCode Handbook, 2002 (3.5� w.c.column)Orifice required at Sea Level: #50

From Table F.4 of National Fuel GasCode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft.): #51Orifice required at 8000 ft. elevation(4% de-rate per thousand ft.): #52

Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)IMPORTANT: 90 Plus Models only. Do not use this chart for any 80 Plus Models

Burner Input (per burner) 15,000 BTU @ Sea Level

Annual Avg. HeatValue (btu per ft3)

850

900

1000

1075

1170

47 48 48 49 49 49 50 50

48 49 49 49 50 50 50 51

49 50 50 50 51 51 51 52

50 51 51 51 51 52 52 52

51 51 52 52 52 53 53 53

Sea levelto 1999 ft

2000 to2999 ft

3000 to3999 ft

4000 to4999 ft

5000 to5999 ft

6000 to6999 ft

7000 to7999 ft

8000 to8999 ft

! CAUTION

TABLE 4

! CAUTION

40

TABLE 5

SUPPLEMENTAL ORIFICE SIZE CHART

90 Plus ONLY models with 15,000 Btu's per Burner. D

O NOTUSE THIS CHART FOR ANY 80 PLUS MODEL.

NATURAL GAS QUICK REFERENCE CHART FOR ORIFICE SELECTION, AT 3.5" W.C. AND APPROXIMATE FINAL FIRING RATES

Final Firing Rate per Burner

Sea

Level

Orifice

Size

Sea Level

Cubic

Foot at

3.5" W.C.

90 Plus Heat

Value at

15,000 Btu’s

per Burner

0-999

1000-1999

2000-2999

3000-3999

4000-4999

5000-5999

6000-6999

7000-7999

8000-8999

9000-9999

ELEVATION CHART (NFG recommended orifice based on 4%

derate for each 1000 foot of elevation, based

on the intersection of the orifice required at Sea Level and the elevation required below)

4618.57

808

4646

4747

4748

4849

4950

4717.52

856

4747

4848

4949

4950

5051

4816.36

917

4848

4949

4950

5050

5151

4915.2

987

4949

5050

5051

5151

5252

5013.92

1078

5050

5151

5151

5252

5253

5112.77

1175

5151

5152

5252

5253

5353

15,000

14,400

13,800

13,200

12,600

12,000

11,400

10,800

10,200

9,600

All calculations are perform

ed by using the first three columns of inform

ation only. B

efore beginning any calculations, determine the

individual burner Btu size and heating value at Sea Level for the installation site. Each value shown in the Heat Value column is per

burner at 3.5" W.C.

NOTE:

Heat Value at Sea Level, for the location of the installation, is available from the Natural Gas Supplier to that site. Orifices for all altitudes are based

on Sea Level values.

Divide the individual burner capacity (15,000 for 90 plus) by the Heat Value for the site to determine the Cubic Foot value at Sea Level, or divide

burner capacity by the Cubic Foot value for the Heat Value. Once you have either the Cubic Foot Value or the Heat Value you can estimate the Sea

Level orifice for the site. To select the corresponding high altitude orifice, locate the site elevation on the chart above and the orifice required at Sea

Level from your calculation in the first column. The correct high altitude orifice that must be installed in each individual burner is the intersection of

these two points on the chart above.

41

TABLE 7ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATEIMPORTANT: 90 Plus Models only. Do not use this chart for any 80 Plus Models

NATURAL GAS LP GAS

FIGURE 41MANIFOLD PRESSURE-CHANGE LABEL

THE MANIFOLD PRESSURE OF THIS APPLIANCE HAS BEEN FIELD ADJUSTED TO OBTAIN THE CORRECT INPUT RATING FOR INSTALLATION AT ALTITUDES

BETWEEN 2,000 FEET AND 4,500 FEET ELEVATION.

LA PRESSION DU DISTRIBUTEUR D'ALIMENTATION DE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIN D'OBTENIR LA BONNE PUISSANCE D'ENTRÉE POUR

UNE INSTALLATION ENTRE 2000 ET 4500 PIEDS D'ALTITUDE.

92-24399-01-01

LP GAS AT HIGH ALTITUDEELEVATIONSORIFICE INSTALLATIONLP Gas is a manufactured gas that hasconsistent heating value across mostregions.

The NFGC guidelines are used with thefollowing exception:

The recommended LP Gas high altitudeorifice selections differ slightly in that theNFGC LP orifice chart, as they are notaccurate for Rheem products. TheNational Fuel Gas Code LP orifices arebased on an 11� of water columnpressure at the orifice, which differs fromRheem products that use 10� of watercolumn at the orifice. This differencerequires a deviation from the NFGCorifice size recommendations. The SeaLevel input should still be reduced by 4%per thousand ft. and the orifice size mustbe selected based on the reduced inputselection Table 6.

ALTITUDE INPUT OUTPUTORIFICESIZE

MANIFOLDPRESSURE

0’ - 2000’

45,00060,00075,00090,000105,000120,000

40,50054,00067,50081,00094,500108,000

#50 3.5” W.C.

2001’ - 4500’

40,50054,00067,50081,00094,500108,000

36,45048,60060,75072,90085,05097,200

#50 3.0” W.C.

ALTITUDE INPUT OUTPUTORIFICESIZE

MANIFOLDPRESSURE

0’ - 2000’

45,00060,00075,00090,000105,000120,000

40,50054,00067,50081,00094,500108,000

1.15mm 10” W.C.

2001’ - 4500’

40,50054,00067,50081,00094,500108,000

36,45048,60060,75072,90085,05097,200

1.15mm 7.6” W.C.

ORIFICE ORDERING INFORMATIONOrifice sizes are selected by adding the2-digit drill size required in the orificepart number. Drill sizes available are 39through 64; metric sizes available1.10mm (-90) and 1.15mm (-91):

Orifice Part Number 62-22175-(drillsize)

Example 1:# 60 drill size orifice requiredPart # 62-22175-60

Example 2:1.15mm drill size orifice requiredPart # 62-22175-91

ALTERNATE METHOD FORCANADIAN HIGH-ALTITUDEDERATEIn Canada, unless an orifice change isspecifically mandated by local codes,an alternate method of altitude derationthrough a reduction in manifoldpressure is acceptable as described in Table 7.

The information in Table 7 is basedon a heating value of 1000 BTU percubic feet of natural gas, and 2500BTU per cubic feet of LP gas.

IMPORTANT: Actual input rates mustbe measured on-site with manifoldpressure adjustment to ensure that anactual 10% reduction in input rate isachieved.

Once this field adjustment has beenmade, the label shown in Figure 41must be affixed in a conspicuouslocation on the front of the furnacecabinet:

NOTE: This label is supplied in theinformation packet shipped with eachfurnace.

TABLE 6LP GAS ORIFICE DRILL SIZE(4% PER 1000 FT DE-RATE)IMPORTANT: 90 Plus Models only. Do not usethis chart for any 80 Plus Models

Input (per Altitude burner) 15000 Orifice Size

0 to 2000 ft. 15000 1.15 mm (factory)

2000�-3000� 13200 1.15 mm

3000�-4000� 12600 1.10 mm

4000�-5000� 12000 #58

5000�-6000� 11400 #59

6000�-7000� 10800 #60

7000�-8000� 10200 #62

8000�-9000� 9600 #63

9000�-10000� 9000 #64

42

TABLE 8LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches watercolumn 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 69 633/4 567 393 315 267 237 217 196 182 173 162 146 1321 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 5111-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 7872 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, 120,000Equivalent length of pipe, 60 ft. = 3/4" IPS required.

SETTING GAS PRESSUREThe maximum gas supply pressureto the furnace should be 10.5" w.c.natural gas, or 13" w.c. LP gas. Theminimum supply gas pressure to thegas valve should be 5� w.c. naturalgas or 11� w.c. LP gas. A properlycalibrated U-Tube manometer isrequired for accurate gas pressuremeasurements.


Supply Gas Pressure Measure-ment. A line pressure tap is on theinput side of the gas valve.1. With gas shut off to the furnace

at the manual gas valve outsidethe unit, remove the inputpressure tap plug.

2. Connect a U-Tube manometer tothe pressure tap.

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� - 10.5� w.c. for natural gas.B. 11� - 13� w.c. for LP gas.

5. Shut off the gas at the manualgas valve and remove theU-Tube manometer.

FIGURE 42MANIFOLD PRESSURE TAP

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

If the supply gas line pressure isabove these ranges, install an in-linegas regulator to the furnace fornatural gas units. With LP gas, havethe LP supplier reduce the linepressure at the regulator. If supply gas line pressure is belowthese ranges, either remove anyrestrictions in the gas supply piping orenlarge the gas pipe. See Tables 3and 4. With LP gas, have the LPsupplier adjust the line pressure atthe regulator.


Manifold Gas PressureMeasurement. Natural gasmanifold pressure should be 3.5"w.c. LP gas manifold pressureshould be 10.0" w.c. Only smallvariations in gas pressure should bemade by adjusting the pressureregulator. 1. With the gas to the unit shut off

at the manual gas valve, removethe pressure tap plug in the gasmanifold. See Figure 42.

2. Connect a U-Tube manometer tothis pressure tap. See Figure 43.

3. Turn on the gas supply andoperate the furnace.

4. Note or adjust the manifold gaspressure to give:A. 3.5� w.c. for natural gas.B. 10.0� w.c. for LP gas.

5. To adjust the pressure regulator,remove the regulator cap.

6. Turn the adjustment screwclockwise to increase pressure,or counterclockwise to decreasepressure.

7. Securely replace the regulatorcap.

8. Shut off gas at the manual gasvalve and remove the U-Tubemanometer.

9. Replace the manifold pressuretap plug before turning onthe gas.

! CAUTION

! CAUTION

43

FIGURE 43MANIFOLD PRESSURE READING

44

sense flame if L1 and L2 are reversed.See Figure 44.Make all electrical connections inaccordance with the latest edition of theNational Electrical Code ANSI/NFPA70and local codes having jurisdiction.These may be obtained from:National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

CSA - International178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3

THERMOSTATThe room thermostat must be com-patible with the integrated furnacecontrol on the furnace. Generally, allthermostats that are not of the “currentrobbing” type are compatible with the

FIGURE 45ISOLATION RELAY

ST-A0804-01

FIGURE 44LINE VOLTAGE CONNECTIONS

UT ELECTRONIC CONTROLS 1028-928, 1028-928A

ELECTRICAL WIRING

TURN OFF ELECTRIC POWER ATFUSE BOX OR SERVICE PANELBEFORE MAKING ANYELECTRICAL CONNECTIONS.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN PERSONAL INJURY OR DEATH.

THE CABINET MUST HAVE ANUNINTERRUPTED GROUNDACCORDING TO THE LATESTEDITION OF THE NATIONALELECTRICAL CODE, ANSI/NFPA70- OR IN CANADA, THECANADIAN ELECTRICAL CODE,CSA-C221 OR LOCAL CODESTHAT APPLY. DO NOT USE GASPIPING AS AN ELECTRICALGROUND. A GROUND SCREW ISPROVIDED IN THE JUNCTIONBOX. FAILURE TO DO SO CANCAUSE ELECTRICAL SHOCKRESULTING IN PERSONALINJURY OR DEATH.

THIS FURNACE IS EQUIPPEDWITH A BLOWER DOOR SAFETYSWITCH. DO NOT DISABLE THISSWITCH. FAILURE TO FOLLOWTHIS WARNING CAN RESULT INELECTRICAL SHOCK, PERSONALINJURY OR DEATH.IMPORTANT: The furnace must beinstalled so that the electricalcomponents are protected from water(condensate).Before proceeding with the electricalconnections, be certain that thevoltage, frequency and phasecorresponds to that specified on thefurnace rating plate. For singlefurnace application, maximum over-current protection is 15 amperes.Use a separate fused branchelectrical circuit containing a properlysized fuse or circuit breaker. Run thiscircuit directly from the main switchbox to an electrical disconnect that isreadily accessible and located nearthe furnace. Connect from theelectrical disconnect to the junctionbox on the left side of the furnace,inside the blower compartment. Forthe proper connection, refer to theappropriate wiring diagram located onthe inside cover of the furnace controlbox and in these instructions.NOTE: UPFLOW MODELS ONLYThe electrical junction box may bemoved to the right side if necessary.A knockout is provided. Seal theopposite hole with plug provided.NOTE: L1 (hot) and L2 (neutral)polarity must be observed whenmaking field connections to thefurnace. The ignition control may not

! WARNING

! WARNING

! WARNING

integrated furnace control. The lowvoltage wiring should be sized asshown.NOTE: Do not use 24 volt controlwiring smaller than No. 18 AWG.NOTE: An isolation relay can beadded to prevent any compatibilityproblems that may occur. Use asingle-pole, single-throw relay with a24-volt AC coil. The contacts shouldbe rated for .5 amps minimum at 24volts. See Figure 45.Install the room thermostat inaccordance with the instruction sheetpacked in the box with the thermostat.Run the thermostat lead wires insidethe blower compartment and connectto low voltage terminals as shown onthe wiring diagram. Never install thethermostat on an outside wall orwhere it will be influenced by drafts,concealed hot or cold water pipes orducts, lighting fixtures, radiation from

UT ELECTRONIC CONTROLS 1097-200

45

FURNACE TWINNINGINSTALLATIONSTwinning operation with UT 1097-200control is possible with RheemTwinning Kit RXGP-F03. Consult thekit instructions for more information.

Twinning operation of two furnaces,installed side-by-side, connected by acommon duct system with mainpower supplied by the same source,and controlled by a commonthermostat can be done with the UT Electronic Controls 1028-928integrated control boards.

IMPORTANT: Only twin furnaces withidentical control boards.

IMPORTANT: Only bottom returnscan be used. No more than twofurnaces can share the same supplyand return. Furnaces must havesame heating and blower capacity.Twinning furnaces must operate offthe same phase of power.

It should be noted that both blowerswill run simultaneously when there isa call for heating, cooling or fan.

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

NOTE: Duct system must beadequate to provide correct airflow toeach furnace for supply and return.

UT ELECTRONIC CONTROLS1028-928 & 1028-928A CONTROLBOARD

1. Single Stage Operation(See Figure 46)a. Control board “ONE” is onfurnace connected to thethermostat.

b. The 24 VAC supply to bothcontrol boards must be inphase with 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.

2. Two Stage Operation(See Figure 47)a. Follow above instructions.Connect “W2” on thermostatto “W” on control board“TWO.”

fireplace, sun rays, lamps, televisions,radios or air streams from registers.Refer to instructions packed with thethermostat for “heater” selection oradjustment.

ACCESSORIESFIELD-INSTALLEDOPTION ACCESSORIESELECTRONIC AIR CLEANERLine voltage power can be suppliedfrom the screw terminal “EAC” and aline voltage neutral screw terminal onthe control board. This will power theelectronic air cleaner whenever thecirculating air blower is in operation.

HUMIDIFIERLine voltage power can be suppliedfrom screw terminal “HUM” to a linevoltage neutral screw terminal on thecontrol board. This will power thehumidifier whenever the burner ison and the circulating air blower isoperating in the heating mode.

NOTE: Maximum current – 1.0 ampsfor each option.

ALTERNATE (LEFT SIDE)DRAIN KIT - RXGY-H01 (DOWNFLOW MODELS ONLY)

46

FIGURE 46UT Electronic Controls 1028-928 & 1028-928A CONTROL BOARD, TWINNING CONNECTION -- SINGLE STAGE OPERATION

Control Board 1

Control Board 2

47

FIGURE 47 UT ELECTRONIC CONTROLS 1028-928 & 1028-928A CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION

Control Board 1

Control Board 2

48

START-UP PROCEDURESA gas furnace’s firing rate, temperaturerise and operation should be checkedafter installation. During this process werecommend that doors and windows beopened, smoke alarms disabledtemporarily, as furnaces may have someresidual smoke and odor upon initialoperation through the first heating cycle.We do all we can to control ourmanufacturing processes, but it ispossible to have this issue on certainsizes and models on occasion. Failure tofollow this caution could result in anuisance smoke (fire call) or other smokeor odor complaint from the customer.This furnace is equipped with a directignition device. Each time the roomthermostat calls for heat, the ignitor lightsthe main burners directly. See the lightinginstructions on the furnace.

TO START THE FURNACE1. Remove the burner compartmentcontrol access door.

2. IMPORTANT: Be sure that themanual gas control has been in the“OFF” position for at least fiveminutes. Do not attempt to manuallylight the main burners.

3. Turn off the furnace electrical powerand set the room thermostat to itslowest setting.

4. Turn the gas control knob to the “ON”position or move the gas control leverto the “On” position.

5. Replace the burner compartmentcontrol access door.

6. Turn on the furnace electrical power.7. Set the room thermostat to a pointabove room temperature to light themain burners.

8. After the burners are lit, set the roomthermostat to a desired temperature.

TO SHUT DOWNTHE FURNACE1. Set the room thermostat to its lowestsetting and wait for furnace to shutdown.

2. Remove the burner compartmentcontrol access door.

3. Shut off the gas to the main burnersby turning the gas control knob to the“OFF” position. See Figure 39.

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

SEQUENCE OF OPERATIONUT ELECTRONIC CONTROLS &INVESYS CLIMATE CONTROLSIntegrated Controls with Hot SurfaceIgnition.1. Each time the thermostat “W”(Heating) contacts close, the induceddraft blower (inducer) begins aprepurge cycle.

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

3. 5 seconds after the pressureswitch(es) close, the hot surfaceigniter begins heating for 30seconds to full temperature. Theinduced draft blower operates for thecomplete heating cycle.

4. After the 30-second igniter warm up,the gas valve opens for an8-second trial for ignition.

5. The igniter lights the gas burners andstays energized for the first 7seconds 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 approximately20 seconds after the burners ignite.

8. When the thermostat “W” (Heat Call)ends, the gas valve closes, theburners go out, the induced draftblower stops after a 10-second post-purge, and the negative pressureswitch(es) open.

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

Sequence if the system doesn’t light ordoesn’t sense flame:1. On a call for heat, the control runs theinducer for 35 seconds to prepurge.

2. 5 seconds into prepurge, the hotsurface igniter heats for 30 seconds.The inducer continues to run.

3. After the 30-second igniter warm up,the gas valve opens for an8-second trial for ignition. The inducercontinues and the igniter staysenergized.

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

5. After a 10-second post-purge, theinducer stops and the control verifiesthat the pressure switch has opened.Once the open pressure switch isconfirmed, the control begins the nextignition cycle by energizing theinducer for a pre-purge of 30 seconds.After the 30-second pre-purge, theigniter energizes and begins a 30-

second warm-up period (inducer isstill running). After a 30-secondigniter warm-up period (60 sec. ofind. running), the gas valve opensand the control looks for a flamesignal for up to 8 seconds. If noflame is sensed, the control goesinto “self-healing” mode, in whichthe blower and inducer both run forthree minutes before anotherignition attempt is made.

6. The control attempts to ignite up tofour times (first attempt followed bythree retries). After the fourthfailure to ignite, the control goesinto a one-hour “soft-lockout,”during which the control will notrespond to the thermostat heat call(W). The lockout can be reset byshutting off main power to thefurnace for five seconds, or byturning the heat call (W) from thethermostat off and then back on.Note that second and fourthignition attempts will have a 30-second pre-purge followed by a30-second igniter warm-up period.This prevents the igniter fromoverheating.

7. The above sequence will repeatafter a one hour delay. It willcontinue repeating until ignition issuccessful or the call for heat isterminated.

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.

UT Electronic Controls Direct SparkIgnition1. Each time the thermostat contactsclose, the induced draft blower(inducer) begins a prepurge cycle.

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

3. 30 seconds after the pressureswitch(es) close, the sparkigniter energizes. The induceddraft blower operates for thecomplete heating cycle.

4. After the spark igniter energizes,the gas valve opens for a 8second trial for ignition.

5. The igniter lights the gas burners.6. After the gas valve opens theflame sensor must prove flameignition for one second using theprocess of flame rectification. If theburners don’t light, the systemgoes through another ignitionsequence. It does this up to fourtimes.

! WARNING

49

ADJUSTING OR CHECKINGFURNACE INPUTThe maximum gas supply pressureto the furnace should be 7" w.c.for natural gas. The minimum gassupply pressure for purposes of inputadjustment to the furnace should be5" w.c.A properly calibrated magnehelicgauge or manometer is required foraccurate gas pressure readings.The manifold pressure should be setat 3.5" w.c. for natural gas. Onlysmall variations in the gas flowshould be made by means of thepressure regulator adjustment. In nocase should the final manifoldpressure vary more than plus orminus 0.3" w.c. from the above-specified pressures. To adjust thepressure regulator, remove theregulator cap and turn the adjustmentscrew clockwise to increase pressureor counterclockwise to decreasepressure. Then replace the regulatorcap securely. Any necessary majorchanges in the gas flow rate shouldbe made by changing the size of theburner orifices.To change orifice spuds, shut off themanual gas valve and remove thegas manifold. On LP gas furnaces,the LP gas supply pressure must beset between 11" and 14" 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 2,000 feet, rating plate input

TABLE 9METER TIME

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACESEQUIPPED FOR NATURAL OR LP GAS

HEATING VALUE OF GAS BTU PER CU. FT.METER

900 1000 1040 1100 2500 (LP)INPUT SIZEBTU/HR CU. FT. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

ONE 1 12 1 20 1 23 1 28 3 20

45,000 TEN 12 0 13 20 13 50 14 40 33 20

ONE 0 54 1 0 1 3 1 6 2 30

60,000 TEN 9 0 10 0 10 24 11 0 25 0

ONE 0 44 0 48 0 50 0 53 2 0

75,000 TEN 7 12 8 0 8 19 8 48 20 0

ONE 0 36 0 40 0 42 0 44 1 40

90,000 TEN 6 0 6 40 7 0 7 20 16 40

ONE 0 31 0 34 0 36 0 38 1 26

105,000 TEN 5 10 5 40 6 0 6 20 14 20

ONE 0 27 0 30 0 31 0 33 1 15

120,000 TEN 4 30 5 0 5 10 5 30 12 30

Heating Value of Gas (BTU/FT3) x 3600 x correction factorFormula: Input BTU/HR =

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

ratings apply. For high altitudes(elevations over 2,000 ft.), seeconversion kit index for derating andorifice spud sizes.Checking furnace input is importantto prevent over firing beyond itsdesign-rated input. NEVER SETINPUT ABOVE THAT SHOWN ONTHE RATING PLATE. Use the tableor formula in Table 9 to determineinput rate. Start the furnace andmeasure the time required to burnone cubic foot of gas. Prior tochecking the furnace input, makecertain that all other gas appliancesare shut off, with the exception ofpilot burners. Time the meter withonly the furnace in operation.

SETTING INPUT RATEThe furnace is shipped from thefactory with #50 orifices. They aresized for natural gas having a heatingvalue of 1075 BTU/cu. ft. and aspecific gravity of .60.Since heating values vary geo-graphically, the manifold pressureand/or gas orifice size may need tobe changed to adjust the furnace toits nameplate input. Consult the localgas utility to obtain the yearlyaverage heating value and orificesize required to fire each individualburner at 15,000 BTU/HR.

NOTE: Refer to the National FuelGas Code for high altitude rateadjustment above 2,000 ft.

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 stops after a10-second post-purge, and thenegative pressure switch(es) open.

9. The main blower continues untiltimed off by the setting on theintegrated furnace control board.

Sequence if the system doesn’t lightor doesn’t sense flame:1. On a call for heat, the control runs theinducer for 30 seconds to pre-purge.

2. After the 30-second pre-purge, thespark igniter energizes. The inducercontinues to run.

3. After the spark igniter energizes, thegas valve opens for an 8-second trialfor ignition. The inducer continuesand the igniter stays energized.

4. If flame is not sensed within 8seconds after the gas valve opens,the gas valve closes, the igniter de-energizes and:

5. The inducer completes a 10-secondpost-purge, the inducer stops, andthe control verifies that the pressureswitch has opened. Once the openpressure switch is confirmed, thecontrol begins the next ignition cycleby energizing the inducer for a pre-purge of 30 seconds. After the pre-purge, the igniter energizes and thegas valve opens (inducer continuesto run). If no flame is sensed on thesecond attempt, the control goes intoa “self-healing” mode, in which theblower and the inducer run for 3minutes before another ignitionattempt is made.NOTE: The following applies onlyto units manufactured before thirdQuarter 2003: After a 30-secondinter-purge (inducer runscontinuously), the igniter is energized,and the gas valve opens for 8seconds. If flame is not sensed in 8seconds, the gas valve is closed andthe igniter de-energizes. If no flame issensed on this second attempt, thecontrol goes into a “self-healing”mode, in which the blower andinducer run for 3 minutes beforeanother ignition attempt is made.

6. The control attempts to ignite up tofour times (first attempt followed bythree retries). After the fourth failureto ignite, the control goes into a one-hour “soft-lockout” during which thecontrol will not respond to thethermostat heat call (W). The lockoutcan be reset by shutting off mainpower to the furnace for five seconds,or by turning the heat call (W) fromthe thermostat off and then back on.

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

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

50

AIR FLOWThe importance of proper air flow over theheat exchanger cannot be overemphasized.

IT IS IMPORTANT THAT EACH DUCTSYSTEM BE SIZED AND INSTALLEDFOR THE SPECIFIC APPLICATION BYPROPERLY APPLYING THEAPPROPRIATE INDUSTRY ACCEPTEDSTANDARD. IF LESS THAN MINIMUMSTANDARDS ARE APPLIED, THEEQUIPMENT USER COULD EXPECTTO EXPERIENCE HIGHER UTILITYBILLS, MAJOR COMPONENTFAILURE, VARYING DEGREES OF AIRNOISE OR OTHER UNSATISFACTORYISSUES, OVER WHICH THEMANUFACTURER HAS NO CONTROL.

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 line fromthe heat exchanger. See Figure 48.

2. Insert a thermometer in the return airduct as close to the furnace aspossible.

3. Operate the furnace.

4. When the thermometer in the supplyair duct stops rising (approximatelyfive minutes), subtract the return airtemperature from the supply airtemperature. The difference is thetemperature rise.

5. Compare the measured temperaturerise to the approved temperature riserange listed on the furnace nameplate. See Figure 49.

If the measured temperature rise is abovethe approved range, the air flow is toolow. More air must be moved by speedingup the blower, by removing restrictions inthe duct system, or by adding moresupply or return air duct. If the measuredtemperature rise is below the approvedrange, the air flow is too much. Use lowerspeed tap on the multi-speed blower.

THE MEASURED TEMPERATURERISE SHOULD BE AS CLOSE TO THEMIDDLE OF THE STATED RANGE ASPOSSIBLE. FOR EXAMPLE, IF THERISE RANGE IS 40 TO 70 DEGREES,THE MOST IDEAL RISE WOULD BE 55DEGREES (THE MIDDLE OF THE RISERANGE). IN ALL APPLICATIONS, THE

FIGURE 48TEMPERATURE RISE MEASUREMENT

FIGURE 49TYPICAL FURNACE NAME PLATE

! WARNING

! CAUTION

INSTALLER MUST ADJUST THETEMPERATURE RISE TO THIS"MIDDLE" POINT AS CLOSELY ASPOSSIBLE. ALSO, THETEMPERATURE RISE SHOULDNEVER BE ABOVE OR FALLBELOW THE STATED RANGE.DOING SO COULD CAUSEDAMAGE TO THE HEATEXCHANGER OR INTERMITTENTOPERATION WHICH COULDCAUSE INJURY OR DEATH ANDWILL VOID THEMANUFACTURER'S WARRANTYFOR THIS PRODUCT.

AIR CONDITIONING DIVISIONFORT SMITH, ARKANSAS

51

TABLE 10, A

90 PLUS AIR FLOW PERFORMANCE – RGR(A,B)/RGTA) MODELS

CFM @ ESPMODEL BLOWER/ SPEEDMOTOR HP .1 .2 .3 .4 .5 .6 .7

RGRA-04 11 x 7 / 1⁄2 LOW 805 780 760 720 685 645 605*M-LO 920 885 850 810 775 730 690M-HI 1140 1110 1085 1045 1010 950 890HIGH 1360 1320 1280 1235 1195 1140 1080



RGTA-06 11 x 7 / 1⁄2 LOW 795 760 730 695 660 615 570*M-LO 910 885 860 815 770 725 680M-HI 1115 1080 1045 1005 965 920 875HIGH 1365 1315 1270 1225 1180 1125 1070

RGR(B,T)-07 11 X 7 / 1⁄2 LOW 780 745 710 675 640 595 555M-LO 880 850 825 785 750 702 655*M-HI 1090 1050 1010 970 925 875 825HIGH 1300 1255 1210 1160 1110 1055 1005

RGRA-07 11 X 7 / 1⁄2 LOW 780 750 720 675 635 595 555M-LO 890 860 835 790 750 705 660*M-HI 1100 1060 1025 980 940 890 845HIGH 1340 1295 1250 1200 1150 1090 1025

RGR(B,T)-07 12 X 7 1⁄2 / 3⁄4 LOW 1105 1095 1080 1050 1030 1010 990M-LO 1290 1275 1260 1220 1195 1170 1140M-HI 1480 1435 1415 1390 1370 1300 1255HIGH 1705 1665 1615 1570 1540 1475 1400

RGTA-07 12 X 7 1⁄2 / 3⁄4 LOW 1185 1160 1140 1115 1095 1065 1040M-LO 1405 1375 1350 1310 1270 1235 1195M-HI 1595 1560 1525 1480 1440 1380 1325HIGH 1835 1780 1730 1675 1625 1555 1480

RGRA-09 12 X 11 / 3⁄4 LOW 1235 1210 1185 1150 1120 1075 1035*M-LO 1490 1465 1440 1405 1375 1315 1255M-HI 1720 1670 1620 1600 1580 1520 1460HIGH 2100 2050 2000 1955 1910 1825 1745

RGTA-09 12 X 11 / 3⁄4 LOW 1155 1125 1100 1080 1060 1000 940*M-LO 1420 1400 1380 1365 1350 1260 1175M-HI 1605 1575 1550 1560 1570 1480 1390HIGH 2005 1965 1930 1890 1850 1765 1680





* Heating speed for cooling applicationsNOTE: CFM values represent furnace-only airflow ratings

52

FIGURE 51UT Electronic Controls 1097-200BLOWER OFF TIMINGS

! WARNING

SETTING BLOWERTIMINGSThe Honeywell UT ELECTRONICCONTROLS and Invensys ClimateControls IFC’S (Integrated FurnaceControls) have three or four quickconnect terminals for connecting themotor speed leads. These are:1. FAN SPEED — motor runs on

this speed when the thermostatis in the “FAN ON” position.

2. COOL — connect desiredcooling speed.

3. HEAT — connect desiredheating speed.

4. HEAT/COOL (not available onUT Electronic Controls-1097-200control board) or — connectdesired speed when heating andcooling speed are the same.

IMPORTANT: Do not connect anymotor speeds to “HEAT” and “COOL”if you use the “HEAT/COOL” terminal.5. If heating and continuous fan

speed are the same, “piggyback”jumper across “FAN” and “HEAT”terminals.

See Figures 50 & 51 for instructionsfor setting the blower “OFF” timings.If cooling speed and fan speed aredesired to be the same, this may beaccomplished by not connecting “Y”to the integrated furnace control.If desired for cool, fan and heat to allbe the same speed, then “piggyback”jumper “H/C” to “FAN” and do notconnect “Y” to the integrated furnacecontrol. Do not connect anything to“H” or “C.”

FIGURE 50UT Electronic Controls 1028-928& 1028-928A BLOWER OFFTIMINGS

OFF TIME SWITCH 1 SWITCH 2

90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON

TWIN

SINGLE

NOTE: SWITCH 3 IS USED FORTWINNING APPLICATIONS.

ON

I402

GAS FURNACE (DIRECTDRIVE) INSTRUCTIONSFOR CHANGING BLOWERSPEED

DISCONNECT THE ELECTRICALSUPPLY TO THE FURNACEBEFORE ATTEMPTING TOCHANGE THE BLOWER SPEED.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN PERSONAL 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),speeds may be changed if necessaryto fit requirements of the particularinstallation. Reconnect the unusedmotor leads to “M1” or “M2.” Checkmotor lead color for speeddesignation.Heating speeds should not bereduced where it could cause thefurnace air temperature to rise toexceed the maximum outlet airtemperature specified for the unit.IMPORTANT: Always check airtemperature rise after changing theheating speed for any reason.

TABLE 10, B

BLOWER PERFORMANCE DATA – RGRS/RGRT- MODELSMODEL BLOWER MOTOR BLOWERNUMBER SIZE H.P. SPEED

.1 .2 .3 .4 .5 .6 .7

LOW 805 780 760 720 685 645 605

RGRS-04EMAES 11 x 7 1/2 MED-LO 920 885 850 810 775 730 690MED-HI 1140 1110 1085 1045 1010 950 890HIGH 1360 1320 1280 1235 1195 1140 1080

LOW 830 845 815 790 760 715 670RGRS-06EMAES 11 x 7 1/2 MED 1060 1025 990 960 925 880 835

HIGH 1260 1215 1175 1135 1100 1040 985

LOW 880 850 825 785 750 702 655RGRT-07EMAES 11 x 7 1/2 MED 1090 1050 1010 970 925 875 825

HIGH 1300 1255 1210 1160 1110 1055 1005

LOW 1290 1275 1280 1220 1195 1170 1140RGRT-07EYBGS 12 x 7 3/4 MED 1480 1435 1415 1390 1370 1300 1255

HIGH 1705 1665 1615 1570 1540 1475 1400

LOW 1235 1210 1180 1150 1120 1075 1035RGRS-09EZAGS 12 x 11 1/2 MED 1490 1465 1445 1405 1375 1315 1255

HIGH 1300 1255 1210 1160 1110 1055 1005

LOW 1490 1465 1445 1405 1375 1315 1255RGRS-09EZAJS 12 x 11 3/4 MED 1720 1670 1620 1600 1580 1520 1460

HIGH 2100 2050 2000 1955 1910 1825 1745

LOW 1490 1445 1405 1375 1350 1295 1240RGRS-10EZAJS 12 x 11 3/4 MED 1710 1665 1620 1580 1540 1475 1410

HIGH 2010 1955 1900 1855 1810 1710 1610

LOW 1610 1580 1555 1515 1475 1415 1355RGRS-12ERAJS 11 x 10 3/4 MED 1870 1820 1775 1715 1660 1590 1520

HIGH 2115 2050 1990 1945 1900 1795 1690

CFM AIR DELIVERYEXTERNAL STATIC PRESSURE INCHES WATER COLUMN

53

THESE INSTRUCTIONS AREINTENDED AS AN AID TOQUALIFIED SERVICEPERSONNEL FOR PROPERINSTALLATION, ADJUSTMENTAND OPERATION OF THIS UNIT.READ THESE INSTRUCTIONSTHOROUGHLY BEFOREATTEMPTING INSTALLATIONOR OPERATION. FAILURE TOFOLLOW THESE INSTRUCTIONSMAY RESULT IN IMPROPERINSTALLATION, ADJUSTMENT,SERVICE OR MAINTENANCE,POSSIBLY RESULTING IN FIRE,ELECTRICAL SHOCK, CARBONMONOXIDE POISONING,EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTE-NANCE. FAILURE TO DO SO CANCAUSE ELECTRICAL SHOCKRESULTING IN PERSONALINJURY OR DEATH.

! WARNING

FILTERSKeep the filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air drythoroughly and reinstall.

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

NOTE: Some filters must be resizedto fit certain units and applications.See Table 11 and Figures 54 and 55.

1. 21” - 90,000 & 105,000 BTUHunits require removal of a

3.5-in. segment of filter andframe to get the proper widthfor a side filter.

2. 24.5” - 120,000 BTUH unitrequires removal of a 7" segmentof filter and frame to get theproper width for a side filter.

DO NOT OPERATE THE SYSTEMFOR EXTENDED PERIODSWITHOUT FILTERS.A PORTION OF THE DUST

TABLE 11FILTER SIZES

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE QUANTITYWIDTH MBTUH SIZE SIZE

171/2" 45, 60, 75 153/4" X 25" 153/4" X 25" 121" 90, 105 191/4" X 25" 153/4" X 25" 1241/2" 120 223/4" X 25" 153/4" X 25" 1

DOWNFLOW FILTER SIZES

FURNACE INPUT SIZE QUANTITYWIDTH MBTUH

171/2" 45, 60, 75 12" X 20" 221" 90, 105 12" X 20" 2241/2" 120 14" X 20" 2

MAINTENANCE

FIGURE 52BOTTOM PANEL REMOVAL

JACKET ASSEMBLY

SOLID BOTTOM

NOTE:BACK FLANGE OF SOLID BOTTOM FITSUNDERNEATH JACKET. SIDES AND FRONTFLANGES FIT OVER FLANGES ON JACKET.SCREW

(2) REQ’D.

JACKET ASSEMBLY

FILTER FILTERROD

SOLID BOTTOM REMOVAL

FILTER & ROD LOCATION

! CAUTION

54

FIGURE 53FILTER LOCATIONS

DOWNFLOW

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

JACKET

JACKET

ANGLE

FILTER RODSUPPORTANGLE

FILTER SUPPORTANGLE(SEE ANGLE DETAIL)

ATTACH WITHSHEET METALSCREWS (2 REQÕD)

ANGLE DETAIL

CUT-OUT AND DRILL DETAILROD & FILTER SUPPORT ANGLE ASSEMBLY

FILTER AND ROD ASSEMBLY


FILTERSUPPORTANGLE

FILTER

FILTER ROD

JACKET

I332

I413

UPFLOW

I528

HORIZONTAL


FILTER SUPPORTANGLE(SEE ANGLE DETAIL)

FILTERROD45-24095-01

FILTER

FILTERSUPPORTANGLE


55

HOLES IN THE VENT PIPE ORHEAT EXCHANGER CAN CAUSETOXIC FUMES TO ENTER THEHOME, RESULTING IN CARBONMONOXIDE POISONING ORDEATH. THE VENT PIPE OR HEATEXCHANGER MUST BEREPLACED IF THEY LEAK.

• IMPORTANT: It is recommendedthat at the beginning of the heatingseason, the flame sensor becleaned with steel wool by aqualified installer, service agency orthe gas supplier.

• IMPORTANT: It is recommendedthat at the beginning of the heatingseason, the condensate trap beinspected for debris or blockage. Ablocked condensate trap can causewater to back up into the primaryheat exchanger and lead tonuisance tripping of theovertemperature switches.

• IMPORTANT: It is recommendedthat at the beginning of the heatingseason, the condensate neutralizerif used be replaced by a qualifiedinstaller, service agency or the gassupplier.

• 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 illegible ormissing.

REPLACEMENT PARTSSee sheet enclosed with furnace forreplacement part information.

TROUBLESHOOTINGRefer to Figure 54 for determiningcause of unit problems.

WIRING DIAGRAMSFigures 55 through 58 are completewiring diagrams for the furnace andpower sources.

LUBRICATIONIMPORTANT: DO NOT attempt tolubricate the bearings on the blowermotor or the induced draft blowermotor. Addition of lubricants canreduce the motor life and void thewarranty.

The blower motor and induced draftblower motor are permanentlylubricated by the manufacturer and donot require further attention.

The blower motor and induced draftblower motor must be cleanedperiodically by a qualified installer,service agency, or the gas supplier toprevent the possibility of overheatingdue to an accumulation of dust anddirt on the windings or on the motorexterior. And, as suggestedelsewhere in these instructions, theair filters should be kept clean. Dirtyfilters can restrict airflow. The motordepends upon sufficient air flowingacross and through it to keep fromoverheating.

SYSTEM OPERATIONINFORMATIONAdvise The Customer

1. Keep the air filters clean. Theheating system will operatebetter, more efficiently and moreeconomically.

2. Arrange the furniture and drapesso that the supply air registersand the return air grilles areunobstructed.

3. Close doors and windows. Thiswill reduce the heating load onthe system.

4. Avoid excessive use of kitchenexhaust fans.

5. Do not permit the heat generatedby television, lamps or radios toinfluence the thermostatoperation.

6. Except for the mounting platform,keep all combustible articles 3feet from the furnace and ventsystem.

7. IMPORTANT: Replace all blowerdoors and compartment coversafter servicing the furnace. Donot operate the unit without allpanels and doors securely inplace.

8. Explain proper operation of thesystem with constant aircirculation.

ANNUAL INSPECTION• The furnace should operate formany years without excessive scalebuild-up in the flue passageways.However, it is recommended that aqualified installer, service agency, orthe gas supplier annually inspectthe flue passageways, the ventsystem and the main burners forcontinued safe operation. Payparticular attention to deteriorationfrom corrosion or other sources.

• IMPORTANT: It is recommendedthat at the beginning and atapproximately half way through theheating season, a visual inspectionbe made of the main burner flamesfor the desired flame appearance bya qualified installer, service agencyor the gas supplier. If the flames aredistorted and/or there is evidence ofback pressure, check the vent andinlet air system for blockage. If thereis carbon and scale in the heatexchanger tubes, the heatexchanger assembly should bereplaced.

! WARNINGENTRAINED IN THE AIR MAYTEMPORARILY LODGE IN THE AIRDUCT RUNS AND AT THE SUPPLYREGISTERS. ANY RECIRCULATEDDUST PARTICLES WILLBE HEATED AND CHARRED BYCONTACT WITH THE FURNACEHEAT EXCHANGER.THIS RESIDUE WILL SOILCEILINGS, WALLS, DRAPES,CARPETS AND OTHERHOUSEHOLD ARTICLES.

56

FIGURE 54MODELS W/INTEGRATED FURNACE CONTROL (IFC) UT Electronic Controls 1012-925 (115 VAC IGNITER)

GO TOE

WARNINGINTEGRATED FURNACE CONTROL (IFC)TROUBLESHOOTING GUIDE

HAZARDOUS VOLTAGELINE VOLTAGECONNECTIONS

DISCONNECT POWER BEFORE SERVICING.SERVICE MUST BE BY A TRAINED, QUALIFIEDSERVICE TECHNICIAN.

NOTE: Most failures are not due to the IFC. Double check all otherpossibilities, including the ground connection, before replacing the IFC.

NOTE: Always verify gas valve inlet and outlet gaspressure. KEY TO ABBREVIATIONS

IBM = Indoor Blower MotorIDM = Induced Draft MotorIFC = Integrated Furnace ControlPS = Pressure Switch(es)SE = Spark ElectrodeHSI = Hot-Surface IgnitionDSI = Direct-Spark Ignition

FLAME (AMBER) LED CODESOFF = No Flame PresentRAPID BLINK = Unexpected FlameSLOW BLINK = Marginal Flame SenseSTEADY ON = Normal Flame Sense

BLINK CODES (GREEN LED)1 Blink - Soft lockout

Reset System power andstart over from beginning

2 Blinks - PS Circuit opengo to point “F.”

3 Blinks - Limit circuit opengo to point “D.”

4 Blinks - PS Circuit closedGo to point “G.”

5 Blinks - Twin Fault (Optional)*Go to point “H.”

1) Set FAN switch to “AUTO”2) Set thermostat to call for heat (set temp. differ-

ential to greater than 10°F

Does the IDM Energize?

IDM Runs for 30 sec. pre-purge?

Spark Ignitor Electrode (SE) Energizesor HSI Ignitor Glowing?

Does Main Burner Light and stay lit? Is the gas valve energized?

PS dropping out? Check IFC*

Does IBM start on heat speed 20 secondsafter burners light?

Does main burner remain lit untilheat call ends?

Does thermostat maintain reasonable room temperature near setpoint?

Set thermostat to off position (W to C = ØV)

Does gas valve shut off immediately?

Does IDM shut off after ten second post-purge?

Does IBM shut off after a max. of 3 min?

ENDHeat-mode troubleshooting

“POWER” LED ON?

24V on W to IFC?

Is “STATUS” LED blinking,steady-on, or off?

Check IFC*.

Check IFC*.

Does IDM runindefinately.

Does IDM Run for 60 sec. and then off for Five minutes

- Check thermostat in “heat” mode,battery, wire, and connections.

SEE BLINK CODES

- Check 24V at IFC.- Check Fuse.- Check Door Switch and Line Power.- Check Transformer.- Check Breaker.

- Check PS contacts- Check wires for short.- Check IFC*.- Check switches and hoses for

water or moisture

- For Twinned units, check that both IFCs are set for “TWIN” and wiresare connected between “TWIN” terminals.

- Check IFC*.- For twinned units, ensure transformers are in phase.

(if out of phase, flame LED will be dim).- For non-twinned units, ensure “TWIN” is in the single (OFF) position.- For Twinned units – ensure both IFC‘s have same part number.

- Check PS, PS Hoses, and wires.- Check for blocked vent, excessive vent length or elbows, or

blocked heat exchanger.- Check IDM wired correctly.- Ensure against excessive wind, which can open pressure switch.- If downflow 90+, check aux. limit – shoud be closed- Check for intermittent P.S. operation.- Check switches and hoses for water or moisture.

- Check gas supply and manifold pressure.- Ensure L1 and Neutral not swapped on IFC and junction box.- Check SE alignment.- Check orifice or other restrictions to gas flow.- Check flame sense rod (clean with sandpaper).- Check flame carry over.

- Check wires, continuity, and connection between IFC and gas valve.- Ensure 24 V between appropriate pins on connector of IFC.- Ensure manual switch on valve is in the “ON” position.- 90+ check aux. limit open? Should be closed- 90+ upflow models – check drain pressure switch between IFC and

gas valve – should be closed – replace drain pressure switch if drainis not blocked or clear drain if blocked.

- Did a pressure switch open during ignition trial? If yes, go to F- Did a limit open during ignition trial? If yes, go to D

- Check line voltage between “HEAT” and “NEUTRAL” on IFC.- Check wires, connections, and continuity between IFC and IBM.- Check IBM capacitor.- Check IBM.

CHECK:- grounding on IFC and unit.- check for proper polarity between L1 & neutral.- flame sense rod (clean if necessary).- wire continually between flame sense rod and appropriate pin of

connector on IFC- flame carries across all burners, and all burners stay lit.

CHECK:AIRFLOW - ensure no restrictions, such as dirty filter, dampers, closed registers, etc.LIMITS - ensure good wire and connections between IFC and all limits. Make surelimits are not open when circulating air temperature is within a specified range.ROLLOUTS - ensure rollouts or overtemperature limits do not need to be reset. Makesure no flame rollout in burner compartment due to blocked flu or heat exchanger.OVERFIRE - ensure furnace is not overtemperature (temp rise is above stated range).Check gas valve, proper orifice size, gas pressure, etc.

Is Limit circuit or IDM wire through aux. limit open oropening and closing?Note: IFC Status LED should be blinking a Fault Code 3.

Is the IFC sensing a good flame: NOTE:Flame sense light should be steady-onwhen burners are lit. If flame LED blinking,or off, flame sense is low or absent.

Ensure thermostat is properly placed and not improperly affected byregisters, fans, sunlight, heat through walls, pipes, or wires in walls.

- Check heat anticipator setting. Furnace may need an isolation relay.- Check installation instructions under section titled “Isolation Relay” for

details.- Verify correct furnace sizing.

NOTE: If IFC goes into lockout (“STATUS LED will blink code “1”), shutoff main power to unit, wait 30 seconds and then reset power.

PROBLEMSTILL

PRESENT

“STATUS” LEDBLINKING

“FLAME” LED BLINKINGOR STEADY ON

If “E” did notresolve issue

Double check - Is W off at IFC?(W to C = ØV?)

Voltage present at gas valve? - Check gas valve.

SEE BLINK CODES

- Check IFC*.

Check IFC*.

*Most failures are not due to the IFC. Doublecheck all other possibilities, including theground connection or wire connections, beforereplacing the IFC.Ensure TSTAT is not in “FAN” position.

Is “STATUS” LED blinking?Is “FLAME” LED blinking or steady-on?

**System will attempt to light 4 times. Voltageis present at gas valve for only 7 seconds dur-ing each trial for ignition. The entire system willgo into a 1 hour lockout after 4 attempts. Themain blower and IDM will run 180 secondsbetween 2nd and 3rd ignition attempts.

- Check line voltage at IDM.- Check wires and connections between IDM and IFC.- Ensure line voltage on IDM pins of IFC connector.- Check IDM capacitor (90+ only).

CHECK BLINK CODES- Check for open limit or limit circuit.- Check for intermittent PS operation.- Check for vent restrictions.- Ensure vent lengths not excessive or

too small diameter.- Check for blocked heat exchanger.

FOR SPARK IGNITION- Check SE wire & connections.- Clean SE with sandpaper. Replace SE if necessary.- If problem persists, check IFC*.- Check SE gas and proper SE ground.- Check SE wire for spark arcing to metal before electrode.FOR HOT SURFACE IGNITION- Check ignitor connected.- Check ignitor wires.- Check ignitor resistance. If open circuit, low or high resistance, replace.- Check ignitor for fractures or cracking- Check ignitor placement.- If problem persists, check IFC*.

START

REPEAT THIS PROCEDURE UNTIL TROUBLE-FREE OPERATION IS OBTAINED.

NO

NO

NO

If “I” did notresolve issue.

NO NO

NO

NO

NO

NO

NONO

NO

NO

NO

NO

NO

NO

NO

BLINKING

YES

YES

YESYES

YES

YES

YES

YES

YES

YES

YES

YESYES

YES

YES

YES

YES

YES

STEADY-ON

I

D

F

H

E

G

YES

NO

YES

PREPURGE

IGNITION TRIAL

IBM “ON” DELAY

STEADY HEAT

END HEAT CALL

POST-PURGE

IBM “OFF” DELAY

STEADY OFF

NO

OFF

**

92-101654-01-00

GO TOF

GO TOI

57

FIGURE 55UPFLOW MODELS WITH UT ELECTRONIC CONTROLS 1028-928 & 1028-928A & SPARK IGNITION

58

FIGURE 56DOWNFLOW/HORIZONTAL MODELS WITH UT ELECTRONIC CONTROLS 1028-928 & 1028-928A & SPARK IGNITION

59

FIGURE 57UPFLOW MODELS WITH UT ELECTRONIC CONTROLS 1097-200

60 CM 1211

FIGURE 58DOWNFLOW/HORIZONTAL MODELS WITH UT ELECTRONIC CONTROLS 1097-200

FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH EFFICIENCY …pts.myrheem.com › docstore › webdocs › ServiceDocs › histlib › ... · 2012-05-14 · in a mobile home!! this furnace

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