Rheem Furnace Installation Manual(1)

92-24161-84-01SUPERSEDES 92-24161-84-00

INSTALLATION INSTRUCTIONSFOR UPFLOW, DOWNFLOW/HORIZONTAL HIGHEFFICIENCY CONDENSINGTWO-STAGE GASFURNACESRGRM, RGTM 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 Temperature

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, -D03) – US(RXGY-D02A, RXGY-D03A) – CANADA


______ 12" min. above grade/snow level

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


______ 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 Number

_____________________________ Date of Installation

2

3

CONTENTS

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

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

General Information..................................................................................................4

Safety Information ....................................................................................................6

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

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

Venting and Combustion Air Piping .......................................................................15

Combustion and Ventilation Air..............................................................................17

Vent Pipe Installation..............................................................................................20

Condensate Drain/Neutralizer................................................................................33

Gas Supply and Piping...........................................................................................37

Electrical Wiring......................................................................................................41

Accessories ............................................................................................................42

High Altitude Installations .......................................................................................43

Start-Up Procedures...............................................................................................44

Integrated Furnace Control and ECM Motor Settings............................................45

Air Flow...................................................................................................................48

Maintenance...........................................................................................................50

Troubleshooting......................................................................................................53

Wiring Diagram.......................................................................................................55

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.

NOTE: A load calculation must beperformed to properly determine therequired furnace BTU size for thestructure. Also, the duct must be properlydesigned and installed for proper airflow.Existing ductwork must be inspected forproper size and sealed system. Properairflow is necessary for both user comfortand equipment performance.Before opening the furnace carton andinstallation of the furnace, verify the datatags on the carton and inside thefurnace, match and is what was orderedfrom the local distributor. Also, check forany damage to the furnace beforeinstallation.IMPORTANT: Proper application,installation and maintenance of thisfurnace and system is a must ifconsumers are to receive the full benefitsfor which they have paid.The RGRM and RGTM series furnacesare design-certified by CSA for use withnatural and propane gases as follows:

4

1. As non-direct vent central forced airfurnaces taking combustion air fromthe installation area or using airducted from the outside.

2. As direct vent central forced airfurnaces with all combustion airsupplied directly to the furnaceburners through a special air intakesystem outlined in theseinstructions.Install this furnace inaccordance with the AmericanNational Standard Z223.1 – latestedition entitled “National Fuel GasCode” (NFPA54) and requirementsor codes of the local utilities orother authorities having jurisdiction.This is available from the following:

National Fire Protection Association, Inc.Batterymarch ParkQuincy, MA 02269

GENERAL INFORMATION

FIGURE 1UPFLOW FURNACE COMPONENTS

25

26

ITEMNO. PART NAME1 CONDENSATE TRAP2 DOOR SWITCH3 JUNCTION BOX4 TRANSFORMER5 PRESSURE SWITCHES6 EXHAUST TRANSITION7 CONNECTOR8 OUTLET AIR PIPE

9 SHIPPING PLUG (TO BE REMOVED)10 FLAME SENSOR*11 OVERTEMPERATURE SWITCH*12 TOP PLATE13 BURNER14 IGNITER*15 COMBUSTION AIR INLET16 OPTIONAL AIR INLET (UPFLOW UNITS ONLY)17 OPTIONAL GAS INLET18 GAS VALVE

19 INDUCED DRAFT BLOWER20 CAPACITOR*21 BLOWER22 LOW VOLTAGE TERMINAL23 CONTROL MOUNTING PLATE24 FILTER / SOLID METAL BASEPLATE

(UPFLOW UNITS ONLY)25 POWER FACTOR CORRECTION CHOICE*26 AIR CIRCULATING BLOWER*

*These components may be only partially visible in this photo.NOTE: A PARTS BAG IS INCLUDED WITH THE FURNACE. IF A NEW PARTS BAG NEEDS TO BE ORDERED, USE THE FOLLOWING PARTNUMBERS: AS-100717-01 FOR -GRM-45, -GRM-60, -GRM-75, GRM-90 AND GRM-105 AS-100717-02 FOR -GRM-120.

AIRFLOW

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

Install units in Canada in accordancewith CSA-B149, local installationcodes and authorities havingjurisdiction. CSA-B149 is availablefrom:

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

NOTE: It is our recommendation thatany HVAC equipment which weresubject to flooding be replaced toavoid any risk of property damage,personal injury or death. Also, ourposition that the immersion by floodwaters compromises any HVACproducts thus voiding this warranty.

DOWNFLOW/HORIZONTAL FURNACE COMPONENTS

9

8

4

17

1125

10

18

5

19

20

21

2

3 15 12 23 22

71

14613

AIRFLOW

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 COILSTHAT ARE LOCATED IN ANY AREAOF A STRUCTURE WHERE DAMAGETO THE BUILDING OR BUILDINGCONTENTS MAY OCCUR AS ARESULT OF AN OVERFLOW OF THECOIL DRAIN PAN OR A STOPPAGEIN THE PRIMARY CONDENSATEDRAIN PIPING. SEE ACCESSORIESSECTION OF THESE INSTRUCTIONSFOR AUXILIARY HORIZONTALOVERFLOW PAN INFORMATION(MODEL RXBM).

RECEIVINGImmediately upon receipt, all cartonsand contents should be inspected fortransit damage. Units with damagedcartons should be opened immediately.If damage is found, it should be notedon the delivery papers, and a damageclaim filed with the last carrier.• After unit has been delivered to jobsite, remove carton taking care not todamage unit.

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

NOTICE

IMPORTANT INFORMATIONABOUT EFFICIENCY ANDINDOOR AIR QUALITYCentral cooling and heating equipmentis only as efficient as the duct systemthat carries the cooled or heated air. Tomaintain efficiency, comfort and goodindoor air quality, it is important to havethe proper balance between the airsupplied to each room and the airreturning to the cooling and heatingequipment.

Proper balance and sealing of the ductsystem improves the efficiency of theheating and air conditioning systemand improves the indoor air quality ofthe home by reducing the amount ofairborne pollutants that enter homesfrom spaces where the ductwork and /or equipment is located. Themanufacturer and the U.S.Environmental Protection Agency’sEnergy Star Program recommend thatcentral duct systems be checked by aqualified contractor for proper balanceand sealing.

DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM AND DRAWPOLLUTANTS SUCH AS DIRT,DUST, FUMES AND ODORS INTOTHE HOME CAUSING PROPERTYDAMAGE. FUMES AND ODORSFROM TOXIC, VOLATILE ORFLAMMABLE CHEMICALS, ASWELL AS AUTOMOBILE EXHAUSTAND CARBON MONOXIDE (CO),CAN BE DRAWN INTO THE LIVINGSPACE THROUGH LEAKING DUCTSAND UNBALANCED DUCTSYSTEMS CAUSING PERSONALINJURY OR DEATH (SEE FIGURE 2).• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUST BESEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDING CARBONMONOXIDE FROM MIGRATINGINTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCH ASWATER HEATERS OR BOILERS -ALL JOINTS, SEAMS, ANDOPENINGS IN THE EQUIPMENTAND DUCT MUST ALSO BESEALED TO PREVENTDEPRESSURIZATION OF THESPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDINGCARBON MONOXIDE INTO THELIVING SPACE.

NOTICE

WARNING!

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:“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.

FIGURE 2MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

5

! WARNING

! WARNING

! WARNING

! WARNING

SAFETY INFORMATION

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

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.

6

IMPORTANT!THE COMMONWEALTH OFMASSACHUSETTS REQUIRESCOMPLIANCE WITH REGULATION248 CMR 4.00 AND 5.00 FORINSTALLATION OF THROUGH-THE-WALL VENTED GASAPPLIANCES AS FOLLOWS:

(a) For all side wall horizontallyvented gas fueled equipment installedin every dwelling, building or structureused in whole or in part for residentialpurposes, including those owned oroperated by the Commonwealth andwhere the side wall exhaust venttermination is less than seven (7) feetabove finished grade in the area ofthe venting, including but not limitedto decks and porches, the followingrequirements shall be satisfied:

1. INSTALLATION OF CARBONMONOXIDE DETECTORS. At thetime of installation of the side wallhorizontal vented gas fueledequipment, the installing plumber orgasfitter shall observe that a hardwired carbon monoxide detector withan alarm and battery back-up isinstalled on the floor level where thegas equipment is to be installed. Inaddition, the installing plumber orgasfitter shall observe that a batteryoperated or hard wired carbonmonoxide detector with an alarm isinstalled on each additional level ofthe dwelling, building or structureserved by the side wall horizontalvented gas fueled equipment. It shallbe the responsibility of the propertyowner to secure the services ofqualified licensed professionals forthe installation of hard wired carbonmonoxide detectors.

a. In the event that the side wallhorizontally vented gas fueledequipment is installed in a crawlspace or an attic, the hard wiredcarbon monoxide detector with alarmand battery back-up may be installedon the next adjacent floor level.

b. In the event that the requirementsof this subdivision can not be met atthe time of completion of installation,the owner 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 beinstalled.

2. APPROVED CARBONMONOXIDE DETECTORS. Eachcarbon monoxide detector as requiredin accordance with the aboveprovisions shall comply with NFPA

720 and be ANSI/UL 2034 listed andIAS certified.

3. SIGNAGE. A metal or plasticidentification plate shall bepermanently mounted to the exteriorof the building at a minimum height ofeight (8) feet above grade directly inline with the exhaust vent terminal forthe horizontally vented gas fueledheating appliance or equipment. Thesign shall read, in print size no lessthan one-half (1/2) inch in size, “GASVENT DIRECTLY BELOW. KEEPCLEAR OF ALL OBSTRUCTIONS”.

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;and

2. 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; and

2. 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; and

2. 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

! WARNING

DO NOT OPERATE THE SYSTEMWITHOUT 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.

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

NOTICE

NOTICE

7

! WARNINGNEVER 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.

! WARNINGALWAYS 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.

! WARNINGWHEN 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.

! WARNINGWHEN 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.

! WARNINGTHE FURNACE MAY BE USEDFOR HEATING OF BUILDINGS ORSTRUCTURES UNDERCONSTRUCTION.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, DUCTWORK AND COMPONENTSUPON SUBSTANTIALCOMPLETION OF THECONSTRUCTION PROCESS,AND VERIFY FURNACEOPERATING CONDITIONSINCLUDING IGNITION, INPUTRATE, TEMPERATURE RISEAND VENTING, ACCORDING TOTHE INSTRUCTIONS ANDCODES.

! WARNINGDUCT 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 FIGURE2).• 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 THAT ARE LOCATED INANY AREA OF A STRUCTUREWHERE DAMAGE TO THEBUILDING OR BUILDINGCONTENTS MAY OCCUR AS ARESULT OF AN OVERFLOW OFTHE COIL DRAIN PAN OR ASTOPPAGE IN THE PRIMARYCONDENSATE DRAIN PIPING.SEE ACCESSORIES SECTION OFTHESE INSTRUCTIONS FORAUXILIARY HORIZONTALOVERFLOW PAN INFORMATION(MODEL RXBM).

GENERAL INFORMATION

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.

orb. 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.

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. IMPORTANT: If this furnace isinstalled in a garage, attic and/orany unconditioned space, install aself-regulating heat tape aroundthe condensate trap and along theentire length of the condensatedrain in the unconditioned space.When the condensing horizontalgas furnace is installed in anunconditioned space where thetemperature would be capable ofreaching close to or below 32°F

! WARNING

! WARNING

(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.

c. The heat tape should be ratedat 5 or 6 watts per foot at120V. See Figure 3.

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.

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

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

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

c. allow service clearance

LOCATION REQUIREMENTS AND CONSIDERATIONS

8

FIGURE 3HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP

I526

DRAINPIPE

HEATTAPE

TRAP

AIRFLOW

Upflow furnaces are shipped with abottom closure panel installed.When bottom return air is used,remove the panel by removing thetwo screws attaching the panel tothe front base angle. See filtersection for details.

COMBUSTIBLE 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.

CLEARANCE -ACCESSIBILITYThe design of forced air furnaces withinput ratings as listed in the tablesunder Figures 5, 6, 7 are certified byCSA-International for the clearancesto combustible materials shown ininches.

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 FURNACES 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.

! WARNING

THIS FURNACE IS NOTAPPROVED OR RECOMMENDEDFOR INSTALLATION ON ITS BACK,WITH ACCESS DOORS FACINGUPWARDS OR IN ANYHORIZONTAL CONFIGURATION.

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.See Figure 4.

4. Locate the furnace to maintainproper clearance to combustiblesas shown in following Figures 5,6, 7.

DO NOT LIFT THE UNIT BY THEHEAT EXCHANGER TUBES.DOING SO CAN DAMAGE THEHEAT EXCHANGER ASSEMBLY.

! WARNING

CAUTION!

! WARNING

9

FIGURE 4HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

GASPIPE

TRAP

EXHAUSTFAN

ELECTRICALCONDUIT

INTAKEVENT

I522

AIRFLOW

10

FIGURE 5CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS

I392

UPF

LOW

MODELS

MINIM

UM

CLEA

RAN

CE(IN.)

LEFT

RIGHT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0417

1 /2

1611/32

155 /8

215

1325/32

00

01

2*0

111

0617

1 /2

1611/32

155 /8

215

1325/32

00

01

2*0

117

07A

171 /2

1611/32

155 /8

215

1325/32

00

01

2*0

123

07B

2119

27/32

191 /8

218

1 /2

179 /32

00

01

2*0

145

0921

1927/32

191 /8

218

1 /2

179 /32

00

01

2*0

148

1021

1927/32

191 /8

218

1 /2

179 /32

00

01

2*0

152

1224

1 /2

2311/32

225 /8

222

2025/32

00

01

2*0

160

*Aserviceclearanceof

atleast2

4inches

isrecommendedin

fronto

fallfurnaces.

SUPPLY

AIR

RETURN

AIR

AIRFLOW

OPTIONALRETURNAIR

CUTOUT(EITHERSIDE)*

*BOTHSIDESFOR1800

CFM

OPTIONAL

RETURN

AIRCUTOUT

(EITHERSIDE)*

I392.DGN

2DIA.K

NOCKOUT

ALT.G

ASCONNECTION

267 ⁄1

6

275 ⁄8

2DIA.

GASCONNECTION

11

FIGURE 6CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS

I393

DOWNFLOW

MODELS

MINIM

UM

CLEA

RAN

CE(IN.)

LEFT

RIGHT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0617

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

0117

07A

171 ⁄2

1611⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

0123

07B

2119

27/32

193 /16

218

1 /2

179 /32

00

01

2*0

123

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

7 ⁄80

00

12*

0160


atleast2

4inches

isrecommendedin

fronto

fallfurnaces.

NOTE:INDOWNFLOWCONFIGURATION,RETURNAIRCUTOUTISNOTPERMITTED.

AIRFLOW

SUPPLY

AIR

RETURN

AIR

A103501.DGN

2DIA.

ALT.G

ASCONNECTION

2513⁄16

43⁄8

2DIA.

GAS

CONNECTION

12

FIGURE 7CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS

I520

HORIZONTA

LMODELS

MINIM

UM

CLEA

RAN

CE(IN.)

LEFT

RIGHT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0617

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

0117

07A

171 ⁄2

1611⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

0123

07B

2119

27⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

123

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

7 ⁄80

00

12*

0160


atleast2

4inches

isrecommendedin

fronto

fallfurnaces.

NOTE:Inhorizontalconfiguration,returnaircutoutisnotpermitted.

Horizontalleft-handairflowonly.

IMPORTANT:Thisfurnaceisnotapprovedorrecommendedfor

installationonitsback,withaccessdoorsfacingupwards.

AIRFLOW

DRAIN

TRAPLOCATION

SUPPLY

AIR

RETURNAIR

A103601.DGN

2DIA.

GAS

CONNECTION

2DIA.

ALT.G

AS

CONNECTION

43⁄8

2513⁄16

1313

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.

SOME HEATING AIRFLOWVALUES MAY BE HIGHER THANTHOSE REQUIRED FOR COOLING.BE SURE TO SIZE DUCT FOR THEMAXIMUM POSSIBLE AIRFLOWVALUE.Size the ducts according toacceptable industry standards andmethods. The total static pressuredrop of the air distribution systemshould not exceed 0.5" w.c.

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 FLOWAND STATIC PRESSURE.

IMPORTANT:When using outside air,design and adjust the system to maintaina return air temperature ABOVE 55° Fduring the heating season.

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

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 SOLID METALBASE PLATE MUST REMAIN IN THEFURNACE BOTTOM WHEN USINGSIDE AIR RETURN. FAILURE TOINSTALL A BASE PLATE COULDCAUSE THE PRODUCTS OFCOMBUSTION TO CIRCULATE INTOTHE LIVING SPACE AND CREATEPOTENTIALLY HAZARDOUSCONDITIONS, INCLUDING CARBONMONOXIDE POISONING OR DEATH.FOR BOTTOM RETURN, REMOVESOLID METAL BASE PLATE.

a. Cut an opening in the side. Theopening should be cut the fullwidth and height of the knockoutson the unit. See Figure 8.

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 supply-air side of the unit.Insure that no air can bypass thiscoil.

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.

! WARNING

! WARNING

FIGURE 8UPFLOW CUTOUT AND DRILL INFORMATION

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

! WARNING

14

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 supply-air side of the unit.Insure that no air can bypass thiscoil.

3. If installing on a combustible floorand not using an airconditioning plenum, install thespecial non-combustible floorbase. See Table 1 and Figure 9.

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.

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.

NOTE: In downflowconfiguration, return air cut out isnot permitted.

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

NOTE: DO NOT take return airfrom bathrooms, kitchens, furnacerooms, garages, utility or laundryrooms, or cold areas.

HORIZONTAL UNITIMPORTANT: THIS FURNACE MAYONLY BE INSTALLED SO AS WHENFACING THE FRONT OF THEFURNACE, SUPPLY AIR ISDISCHARGED ON THE LEFT HANDSIDE.

1. Position the unit to minimize longruns of duct or runs of duct withmany turns and elbows.

2. If summer air conditioning isdesired, position the indoor coil onthe supply air side of the unit.Insure that no air can bypass thiscoil.

3. Connect the furnace to the supplyair 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 from anadjacent fuel-burning appliance.

NOTE: In horizontal configuration,return air cut out is not permitted.

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

NOTE: DO NOT take return airfrom bathrooms, kitchens, furnacerooms, garages, utility or laundryrooms, or cold areas.

! WARNING

FIGURE 9NON-COMBUSTIBLE FLOOR BASE

TABLE 1NON-COMBUSTIBLE FLOOR BASES

Floor Base SizeNo. Cabinet

(-)XGC-B17 17

(-)XGC-B21 21

(-)XGC-B24 24

15

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.

The combustion air and vent pipefittings must conform to AmericanNational Standards Institute (ANSI)and American Society for TestingMaterials (ASTM) standardsD1785 (Schedule 40 PVC), D2665(PVC-DWV), D2241 (SDR-21 andSDR26-26 PVC), D2661 (ABS-DWV)or F628 (Schedule 40 ABS-DWV).

IN CANADA, PRODUCTSCERTIFIED FOR INSTALLATIONAND INTENDED TO BE VENTEDWITH PLASTIC VENT SYSTEMS(PVC, CPVC) MUST USE VENTSYSTEMS THAT ARE CERTIFIEDTO THE STANDARD FOR TYPE BHGAS VENTING SYSTEMS, ULCS636.THE COMPONENTS OF THECERTIFIED MATERIAL MUST NOTBE INTERCHANGEDWITH OTHERVENT SYSTEMS OR UNLISTEDPIPE/FITTINGS.PLASTIC COMPONENTS ANDSPECIFIED PRIMERS AND GLUESOF THE CERTIFIED SYSTEM MUSTBE FROM A SINGLE SYSTEMMANUFACTURER AND NOTINTERMIXED WITH OTHERSYSTEM MANUFACTURER’SPARTS.NOTE: INLET AIR PIPING IS NOTCONSIDERED TO BE A PART OFTHE “VENTING SYSTEM”. THE

REQUIREMENT THAT VENTMATERIAL BE CERTIFIED TO ULCS636 DOES NOT APPLY TO INLETAIR PIPING.

IMPORTANT: The plastic combustionair and venting components are ofSchedule 40 PVC. If using ABSpiping, ensure that the solventcement is compatible for joining PVCto ABS components or use amechanical connection that canwithstand the vent temperatures andis corrosion resistant.

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

NOTE: Cellular core PVC is alsoapproved for use. It must be schedule40PVC-DWV cellular pipe for non-pressure applications andmanufactured under ASTM F-891.

NOTE:With the furnace correctlyvented, the inducer will moveapproximately 25 cfm per 100,000Btu’s.

IMPORTANT: No part of thecombustion air and vent pipes mayrun under ground.

OVERTEMPERATURESAFETY SWITCHESFurnaces are equipped with safetyswitches in the control compartmentto protect against overtemperatureconditions caused by inadequatecombustion air supply. The switchesare 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 SYSTEMSWhen 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 rangehoods 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.

VENTING AND COMBUSTION AIR PIPING

! WARNING

! WARNING ! WARNING

16

1. Cut pipe end square. Chamferedge 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.

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.

When the furnace is installed in thesame space with other gasappliances such as a water heater, besure there is an adequate supply ofcombustion and ventilation air for theother appliances. Do not delete orreduce the combustion air supplyrequired by the other gas appliancesin this space. See Z223.1, NationalFuel Gas Code (NFPA54) fordetermining 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.IMPORTANT: Only the current ventinstructions apply. All 90 Plus GasFurnaces cannot be common vented.

JOINING PIPE ANDFITTINGS

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 GUIDELINESMAY RESULT IN FIRE, EXPLOSIONOR ASPHYXIATION CAUSINGPERSONAL INJURY OR DEATH.All pipe, fittings, solvent cement,primers and procedures mustconform to American NationalStandard Institute and AmericanSociety for Testing and Materials(ANSI/ASTM) standards as shownbelow:

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.

! WARNING

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

17

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

18

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 where

communicating to the outdoorsthrough vertical ducts as shown inFigure 11, 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 (see Figure 12).

Here are some typical sizes:








FIGURE 11AIR FROM ATTIC/CRAWL SPACE

FIGURE 12OUTSIDE AIR USING A HORIZONTAL DUCT

FIGURE 10AIR 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

OPTIONAL1SQ.INCHPER4000

BTUHINLETAIR

VENTILATEDATTIC GABLE ORSOFFIT VENTS

GABLEVENTOUTLET AIR

IN ATTICMUST BEABOVEINSULATION

19

FIGURE 13COMBUSTION AIR FITTING

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.(See Figure 13).

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 A HORIZONTAL POSITIONONLY ONE 90° ELBOW IS REQUIRED. INSTALL THE ELBOW SO THEOPEN 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.

I337I336

PREDRILL FOR SCREWS.

20

NON-DIRECT VENTINSTALLATIONGUIDELINESIMPORTANT: Failure to correctly followall venting guidelines may result inerratic furnace operation, freeze-up ofcombustion air or exhaust air piping orsooting of the furnace.All exhaust piping must be installed incompliance with Part 7, “Venting ofEquipment,” of the latest edition of theNational Fuel Gas Code NPFA54/ ANSIZ223.1-, local codes or ordinances andthese instructions.1. Vertical piping is preferred.2. All horizontal piping must slope

upward a minimum of 1/4 inch perfoot of run so that condensate drainstoward the furnace.

3. All horizontal runs must besupported at least every 4 feet. Nosags or dips are permitted.

4. IMPORTANT: Do not common ventwith any other appliance. Do notinstall in the same chase or chimneywith a metal or high temperatureplastic pipe from another gas or fuel-burning appliance unless therequired minimum clearances tocombustibles are maintainedbetween the pvc pipe and otherpipes.

5. All vent runs through unconditionedspaces where below-freezingtemperatures are expected shouldbe insulated with 1-in. thick,medium-density, foil-facedfiberglass. An equivalent “arm-a-flex” or “rub-a-tex” insulation mayalso be used as long as there is noheat tape applied to the vent pipe.For horizontal runs where water maycollect, wrap the vent pipe with self-regulating 3 or 5 watt heat tape. Theheat tape must be U.L. listed andinstalled per the manufacturer’sinstructions.

6. The minimum vent pipe length is5 feet.

7. Extend the exhaust pipe a minimumof 18” from the cabinet before turningvent.

8. Vent cannot be ran underground.

FIGURE 14TEE TERMINAL – FOR STANDARDHORIZONTAL NON-DIRECTINSTALLATION

VENT

12" 12" MIN. ABOVEGRADE OR

SNOW LEVEL

NUMBERS OF ELBOWS45° OR 90°

Medium / Long Radius ONLY

1-2 3-4 5-6

2”Standard 60 55 50

45,000Alternate 55 50 45


Alternate 25 20 1560,000

3”Standard 120 120 115

Alternate 120 120 110

3”Standard 45 40 NR

75,000Alternate NR NR NR


90,000Alternate 60 50 45

105,000 3” Standard 45 40 NR

120,000 3”Standard 70 65 55

Alternate 40 30 25

NOTES:1. *N.R. - NOT RECOMMENDED.2. MAXIMUM OF 4 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FORALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.

3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4. NO SCREENS MAY BE USED TO COVER EXHAUST.*A = 17-1/2” CABINET WIDTH B = 21) CABINET WIDTH

FURNACEINPUT

VENT PIPE INSTALLATION

PIPESIZE

TERMINATION

TABLE 1UPFLOW UNITSFOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTIONPROVIDED FROM INDOORS

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

ELEVATED SINGLE PIPEALTERNATETEETERMINATIONSee Figure 15. The tee termination maybe elevated up to 24 inches above thewall penetration if required for anticipatedsnow levels. Use 2 long-sweep, 2-in.PVC elbows and 2-in. PVC pipe,attaching the tee so it is 12 inches fromthe wall.

NUMBERS OF ELBOWS45° OR 90°


1-2 3-4

2”Standard 50 40

Alternate 40 3060,000

3”Standard 50 40

Alternate 50 40

3”Standard 50 40

75,000Alternate 50 40

90,000 3”Standard 50 40

Alternate 50 40

105,000 3”Standard 50 40

Alternate 50 40

NOTES:1. *N.A. - NOT APPLICABLE.2. MAXIMUM OF 4 - 90 DEGREE ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FOR

ALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4. NO SCREENS MAY BE USED TO COVER EXHAUST.

*A = 17-1/2” CABINET WIDTH B = 21” CABINET WIDTH

FURNACEINPUT

PIPESIZE

TERMINATION

TABLE 2DOWNFLOW/HORIZONTAL UNITSFOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTIONPROVIDED FROM INDOORS

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

21

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 inTables 1 and 2. These tables list themaximum allowable length in feet of theexhaust pipe that may be used for allfurnace inputs as related to the numberof elbows required and the termination.

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”. Total 2” ventlength is a maximum of 48”.

Horizontal vent terminations require a2-in. PVC tee positioned 12 inches fromthe outside wall. See exhaust piperequirements, Figures 19 and 20. When3-in. pipe is used from the furnace tothe outside 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 15 to clearanticipated snow levels. The tee maybe raised up to 24 inches above thewall penetration. Use two long-sweepradius bend, 2-in. PVC elbows and alength of 2-in. PVC pipe so that theelbows are on 24-in. centers.

NOTE: Extend the exhaust a minimumof 18" from the furnace top plate beforeturning vent.

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 ORINSTALLATION CAN CAUSESTRUCTURAL OR EXTERIOR FINISHDAMAGE TO THE BUILDING.

Non-direct venting locationrequirements are slightly different insome cases than direct venting. Installa non-direct vent with the followingminimum clearances.See Figure 16.

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.

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

! CAUTION

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.

7. Do not terminate in any area thatmay allow flue gases to stagnate.

FIGURE 15ALTERNATE HORIZONTAL TERMINATIONFOR NON-DIRECT VENTINSTALLATIONS

NOTE:NOT APPLICABLE TORGRM-07EYBGS MODELRGRM-07EMAES MODELRGRM-10EZAJS MODEL

12"

FROM

24"MAX.

PIPESUPPORTSTRAP

OUTSIDEWALL

I198

22

FIGURE 16OTHER THAN DIRECT VENT TERMINAL CLEARANCES

Nat

ural

Gas

and

Pro

pan

eIn

stal

latio

nC

od

eN

atio

nalF

uelG

asC

od

e

Can

adia

nIn

stal

lati

on

sU

SIn

stal

lati

on

sC

anad

ian

Inst

alla

tio

ns

US

Inst

alla

tio

ns

2”Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 50 40

Alternate RXGY-D02/RXGY-D02A 40 3060,000


Alternate RXGY-D03/RXGY-D03A 50 40

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 4075,000 3”


Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-D03A/RXGY-G02 50 4090,000 3”

Alternate RXGY-D03/RXGH-D03A 50 40

Standard/Concentric RXGY-D03/RXGY-D03A/RXGH-E03A/RXGY-G02 50 40105,000 3”


23

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 discharged tothe outdoors. Therefore, noventilation or combustion airopenings are required.IMPORTANT: The plastic combustionair and venting components are ofSchedule 40 PVC. If using ABS pipingensure that the solvent cement iscompatible for joining PVC to ABScomponents or use a mechanicalconnection that can withstand the venttemperatures 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 slope

upward 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. Minimum 3 ft. clearancerequired between combustion airinlet and any other exhaust.

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, pipe length is5 feet for combustion air andexhaust.

7. Do not install elbows back toback. Allow at least 15” betweenelbows.

Size the exhaust and combustion airintake pipes as specified in Tables 3and 4. These tables list the maximum

! WARNING

Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/GXGY-G02 50 4045,000 2”


Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 40 352”

Alternate RXGY-D02/RXGY-D02A 20 1560,000



75,000 3” Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 45 40



105,000 3” Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 45 40



FURNACEINPUT

PIPESIZE

TERMINATION VENT TERMINATIONKIT RECOMMENDED

1 - 2 3 - 4

NUMBER OF ELBOWS45 or 90 Degrees


TABLE 3UPFLOW UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTIONPROVIDED FROM OUTDOORS

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

NOTES:1. N.A. - NOT APPLICABLE2. MAXIMUM OF 4 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.

TABLE 4DOWNFLOW/HORIZONTAL UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTIONPROVIDED FROM OUTDOORS

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

FURNACEINPUT

PIPESIZE

TERMINATION VENT TERMINATIONKIT RECOMMENDED

1 - 2 3 - 4

NUMBER OF ELBOWS22.5, 45 or 90 Degrees


NOTES:1. N.A. - NOT APPLICABLE2. MAXIMUM OF 4 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.

24

allowable length in feet of the exhaustand combustion air intake pipes thatmay be used for all furnace inputs asrelated to the number of elbowsrequired and the termination.NOTE: Extend the exhaust a minimumof 18" from the furnace top platebefore turning vent.8. The maximum exposed vent

length (above the roof line) is 30”.

COMBUSTION AIR FORDIRECTVENTINSTALLATIONSTHE 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/D02A, RXGY-D03/D03A, RXGY-D04/D04A, or RXGY-E03A. Kitsending with an “A” meet CanadianULC-5636 requirements.

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.

STANDARDTERMINATIONSSTANDARD VERTICALTERMINATIONS

COMBUSTION AIR PIPING

Use two medium-radius sweepelbows to keep the inlet downward toprevent entry of rain. See Figure 19for 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.

IMPORTANT: To ensure properfurnace operation, the supplied vanemust be installed in the verticalposition with PVC solvent as shown inFigure 20, Detail B.

The combustion air inlet terminalmust be located with respect to theexhaust terminal as shown in Figure20, Detail C.

IMPORTANT: All furnaces withhorizontal air intakes, except thoseusing concentric vent kit RXGY-E03/E03A, must have a drain teeassembly and trap installed as closeto the furnace as possible. This is todrain any water that may be in thecombustion air pipe to prevent it fromentering the furnace combustionchamber.

These parts are included in kitsRXGY-D02/D02A (for 2-in. pipe),RXGY-D03/D03A (for 3-in. pipe) andRXGY-D04/D04A (special for the120,000 BTU furnace installed withthe alternate horizontal termination).Attach the trap to the bottom of thetee with PVC solvent. Connect theother end to a suitable drain, as to thedownstream of a condensate trap onthe 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 45,000 through120,000 BTUH is 2-in. PVC pipe120,000 BTUH models withexcessively long runs require 21/2”.Refer to Tables 3 and 4 for properapplication. This mustbe reduced to 11/2“ the last12 inches for models with inputs of45,000 through 75,000 BTUH.See Figure 19.

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 is2 in. PVC pipe extending outward 12inches from the wall. See Figure 19,Detail A.

The combustion air and exhaustterminations must be at least 12inches above grade and must beoriented with respect to each other asshown in Figure 20, Detail B. Refer tosection on alternate venting optionswhen higher snow levels areanticipated.

ALTERNATETERMINATIONSALTERNATE HORIZONTALDIRECT VENT TERMINATIONS

RXGY-D02/D02A, -D03/D03A AND -D04/D04A

The combustion air and exhaustterminations may be raised amaximum of 24 inches above thewall penetration to maintain therequired 12 inch clearance abovegrade or snow level. See Figure 17.Size the pipe length according toTables 3 and 4.

Review the following guidelines:

• Size the entire vent systemaccording to the alternate, notstandard, termination shown inTables 3 and 4.

25

FIGURE 17ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

SEE DETAIL A

PIPESUPPORTSTRAP

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

2" PVC FOR MODELS WITH INPUTS OF 45,000 AND120,000 BTU. (SEE DETAIL A). ELBOWS AND RISERSARE 2" PVC.

INTAKE VENT21/2" PVC FOR MODELS WITH120,000 BTU INPUT.2" PVC ELBOWS AND RISERMODELS WITH INPUTS OF 45,000THRU 90,000 BTU.USE KIT NO. RXGY-D02/D02A WHEN 2"PIPE IS USED BETWEEN FURNACE ANDOUTSIDE WALL. USE KIT NO. RXGY-D03/D03A WHEN 3" PIPE IS USED.

I339

• 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 Figure17.

The 45,000 BTUH unit only uses kitRXGY-D02/D02A. The 60,000 BTUHand 75,000 BTUH units may use kitsRXGY-D02/D02A or RXGY-D03/D03A depending on pipe lengthsand number of elbows. Use kitRXGY-D03/D03A with 90,000 BTUHthrough 120,000 BTUH units. TheRXGY-D04/D04A kit only applies tothe 120,000 BTUH unit using analternate termination andexcessively long runs. See Tables 3and 4.

The following are parts lists for theRXGY-D02/D02A, RXGY-D03/D03Aand RXGY-D04/D04A alternatehorizontal direct vent termination 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 kit onlyapplies to the 120,000 BTUH unitusing an alternate termination andexcessively long runs.

3”

36” MAX.EXHAUST VANE

INTAKE OPTIONALINTAKE

DETAIL BEXHAUST / INTAKE RELATIONSHIP

DETAIL CCOMBUSTION AIRTERMINATION

4" FROMWALL

12" FROMWALL

NOTE:NOT APPLICABLE TORGRM-07EYBGS MODELSRGRM-07EMAES MODELSRGRM-10EZAJS MODELS

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

24” MAX.60” MAX.

26

FIGURE 18CONCENTRIC 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

CONCENTRICTERMINATIONSVERTICAL/HORIZONTALCONCENTRIC VENTKIT NO. RXGY-E03A

This kit is for vertical/horizontalintake air/vent runs and may beinstalled through roofs or sidewalls.One 5” diameter hole is required forthe installation. See Figure 18 forthe general layout. Completeinstallation instructions are includedwith the kit.

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

NOTE: • Support must be field installedto secure termination kit to structure.

• No screens may be used to covercombustion air and exhaust.

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

3” Concentric Kit – Item # 196006

27

FIGURE 19STANDARD VERTICAL DIRECT VENTING

FIGURE 20STANDARD HORIZONTAL DIRECT VENTING

I407

3" MAX.SEPARATION

36" MAX. 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 LEV

EL

NOTES:

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

2 WHEN 3-IN. DIAM. PIPE IS USED,REDUCE TO 2-IN. DIAMETER BEFOREPENETRATING ROOF. A MAXIMUMOF 18 IN. OF 2-IN. PIPE MAY BEUSED BEFORE PASSINGTHROUGH ROOF.

3 SUPPORT VERTICAL PIPE EVERY 6FEET.

4 EXHAUST TERMINATION - TERMINATETHE LAST 12 INCHES WITH 2” PVC PIPEON 45,000 AND 120,000 BTUH MODELS.SEE DETAIL A.

5 30” MAXIMUM EXPOSED VENTLENGTH.

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

7 NO SCREENS MAY BE USED TOCOVER COMBUSTION AIR ANDEXHAUST. 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 45,000 AND 120,000 BTUHMODELS.

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 VERTICALPOSITION USING PVC SOLVENT.THE COMBUSTION AIR TERMINATION MUSTBE IN THE SAME PRESSURE ZONE AS THEEXHAUST TERMINATION.

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

8 NO SCREENS MAY BE USED TO COVERCOMBUSTION AIR AND EXHAUST.

9 NO ELBOWS CAN BE INSTALLED ATTERMINATION.

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

3

5

5

5

4

6

1

6

2

48” MAX

30” MAX

4

530” MAX

EXHAUSTTERMINATION

DETAIL A

12”

28

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 21 and 22.

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 minimum clearanceslisted above, the vent locationshould also be governed by thefollowing 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 masonrysurfaces. Use a rust-resistantsheet metal or plastic backingplate behind vent.

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.

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.

FIGURE 21MOISTURE ZONES

! CAUTION

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

29

FIGURE 22DIRECT VENT TERMINAL CLEARANCES

Nat

ural

Gas

and

Pro

pan

eIn

stal

latio

nC

od

eN

atio

nalF

uelG

asC

od

e

Can

adia

nIn

stal

lati

on

sU

SIn

stal

lati

on

sC

anad

ian

Inst

alla

tio

ns

US

Inst

alla

tio

ns

30

FIGURE 24TWO FURNACE VENTING THROUGH WALL

FIGURE 23TWO FURNACE VENTING THROUGH ROOF

CONCENTRIC VENTING CONCENTRIC VENTING

MINIMUM 12” ABOVE AVERAGESNOW ACCUMULATION. MAXIMUM

OF 24 IN. ABOVE ROOF.

COMBUSTIONAIR INTAKE2” PVC

12” M

IN.ABOVE

SNOW

LEVEL

6’ MIN.

10”RECO

MMENDED

COMBUSTIONAIR INTAKE2” PVC COUPLINGWITH VALVE INVERTICAL POSITION

EXHAUST VENT

6’ MINIMUM10” RECOMMENDED

MAXIMUM 1”DISTANCEFROM WALL

MINIMUM 12”ABOVE GRADE

SEE CONCENTRIC VENT INSTALLATIONINSTRUCTIONS.

SEE CONCENTRICVENT INSTALLATIONINSTRUCTIONS

TWO-PIPE VENTING TWO-PIPE VENTING

3" MIN.24" MAX.

8" MIN.24" MAX.

3" MIN.24" MAX.

8" MIN.24" MAX.

MULTIVENTINGIF VENTING TWO OR MOREFURNACES NEAR EACH OTHER ISREQUIRED, EACH FURNACEMUST BE INDIVIDUALLY VENTED– NO COMMON VENTING ISPERMITTED. See Figures 23 and 24for positioning of the terminations.When more than two furnaces are tobe vented, there must be at least 4feet between the first two furnacesand the third, etc.

31

NOTE: The vent illustration in Figure26 can be used for non-direct ventterminations also.

RXGY-G02 Side Wall VentThis termination is for horizontalventing only.IMPORTANT: Do not install on theprevailing winter wind side of thestructure. Observe same clearancespecified 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.

FIGURE 25VENT KIT INSTALLATION OPTIONS

EXHAUST

AIR

INTAKE

FIGURE 26TYPICAL INSTALLATIONS For 45000 thru 120000 BTUH models-

reduce to a length between 12 inchesand 30 inches of 2 inch pipe.

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.

32

FIGURE 27UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION

I329

CONDENSATE TRAP

CONNECTOR

INDUCED DRAFTBLOWER

PLUG OPT. COMBUSTIONAIR POSITION

NOTE:WHEN COMBUSTION AIR IS INOPTIONAL POSITION SWAP LOCATIONOF 2" PVC MALE ADAPTER AND “O”RING WITH PLUG.

EXHAUST TRANSITION

EXHAUSTOUTLET AIR PIPE

EXHAUSTVENT CAP/PLUG

TOP PLATE

“O” RING COMBUSTIONAIR ADAPTER

DRAIN HOSES(AS SHIPPED FROM

FACTORY)

CONNECTING TO FURNACEIMPORTANT: Clean and debur allpipe cuts. The shavings must not beallowed to block the exhaust,combustion air or condensate drainpipes.

UPFLOW FURNACEThe 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 combustion air connectionis at the right side of the top plate.An alternate combustion airconnection may be made on the rightside of the jacket. This opening has aplastic cap. A combustion 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 27.

DOWNFLOW/HORIZONTALFURNACEThe exhaust pipe connection is a 2-in.female 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 3-in. pipe is used,connect a 2 to 3-in. coupling to thisfitting with a short piece of 2-in. PVCpipe.

The combustion air connection is a 2-in. extruded hole on the left side ofthe top plate. When a 2-in. pipe isused, attach a 2-in. PVC couplingover this hole with RTV sealant, drilltwo pilot holes, and add two sheetmetal screws through the couplinginto the extrusion to secure it in placebefore piping. When 3-in. pipe isused, connect a 2 to 3-in. coupling tothis fitting with a short piece of 2-in.PVC pipe. See Figure 28.

FIGURE 28DOWNFLOW/HORIZONTAL COMBUSTION AIR AND VENT PIPE CONNECTION

EXHAUST VENTCAP/PLUG

EXHAUSTPIPE - PVC

EXHAUSTCONNECTOR

EXHAUSTTRANSITION

TOP PLATE

COUPLING

COMBUSTIONAIR CHASE

EXHAUSTOUTLET AIR PIPE

a103101

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

INDUCED DRAFTBLOWER

33

CONDENSATE DRAIN/NEUTRALIZER

FIGURE 29UPFLOW 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. A blockedor restricted drain line can result inover-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. See 29.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: The upflow model onlyhas a new drain system. There is a thirdport on the drain trap (marked by a redcap) for the hose attached to theinduced draft motor. Remove plug ininducer drain hose and remove cap offdrain trap before connecting inducerdrain hose to drain trap. All three hosesMUST be attached during operation ofthe furnace. Be sure all three hoses aresecured to the drain trap using the hoseclamps provided in the parts bag.

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 a 5inch riser installed above the tee, ablocked drain will result in overflow fromthe riser.FURNACE SHUTDOWN: To cause thefurnace to shut down when a blockeddrain 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 iscompatible with PVC material. Cut thedrain hoses to the appropriate lengthand connect to the trap with hoseclamps. Tighten the clamps withpliers and check for leaks afterattaching.

IMPORTANT: The inducer drain hosemust slant downward away frominducer. If the hose is not slanted,the inducer will fill with water andcause the pressure switch to open,causing nuisance failures orintermittent operation.

! CAUTION

I408

1013/16

CONDENSATE TRAP

TO FLOOR DRAIN OR CONDENSATE PUMP

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

DRAIN LINENEUTRALIZER CARTRIDGE (OPTIONAL)

NOTE:SEE UPFLOW MODELNOTES FOR PIPEHEIGHT

NOTE: CONNECTINDUCER DRAIN HOSETO SMALLER PORT ONCONDENSATE TRAP.

NOTE: INDUCERDRAIN HOSEMUST SLANTDOWNWARDAWAY FROMINDUCER.

CONDENSATE TRAP

34

FIGURE 30UPFLOW 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 30.Drill two 1/8” holes in the cabinet tomount the bracket. Mount the trapand bracket to the right side with thedrain elbow pointing through theknockout. Connect the 1/2-in. pipe andtee as noted above. Route the drainhoses behind the control box, cut tothe appropriate length, and connect tothe trap with hose clamps. Fill trapwith water.IMPORTANT: Do not allow any sagsor kinks in the hoses. This preventsproper condensate flow.IMPORTANT: Do not connect intoa common drain line with an airconditioner evaporator coil drain. Ablocked or restricted drain line canresult in overflow of the coil pan andnegate the furnace blocked drainshutoff control.

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. Provisionsmust be made to prevent freezing ofcondensate.Use a solvent cement that iscompatible with PVC material.

To convert downflow models to left-hand drain, a kit ((-)XGY-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 32.

To convert to left side drainage,remove the long molded hose fromthe 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. Reattach

CUT DRAIN HOSES ASREQUIREDAND CONNECT TOINLETS ON TOPOF CONDENSATETRAP

DRAINRISER

TEE

DRAINEXTENSION

PROPER DRAIN SLOPE REQUIRED(NO KINKS ALLOWED)

CONDENSATE TRAPSHEETMETAL IFCMOUNTING PLATE

TO FLOORDRAIN

A039407

the long black molded hose. Use the 2-9/16” length of black hose included inthe(-)XGY-H01 kit between the trap andexhaust transition. Clamp hoses tightwith white nylon clamps.

Remove the plug from the 2” alternatedrain hole (see Figure 32) and replaceit with the 2” rubber grommet suppliedin the (-)XGY- H01 downflow alternatedrain kit. Also, remove the 1-5/8”grommet supplied in the primary drainhole and replace it with the 1-5/8”diameter plug that is also supplied inthe (-)XGY-H01 downflow alternatedrain kit. Both the hole-plug andgrommet must be in place to insure agood seal in the burner compartment.

A length of 1/2” black PVC pipe isalso provided in the (-)XGY-H01downflow alternate drain kit. Glueone end of the pipe to the elbow inthe trap. Cut the pipe so that itextends through the alternate drainhole in the left side of the cabinet oneinch. Connect the 1/2” PVC tee(supplied with the furnace) to thepipe with a 1-3/4” riser. Use the 1-5/8” plug supplied in the (-)XGY-H01downflow alternate drain kit to sealthe right side drainage 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 negate thefurnace blocked-drain shutoff control.

FIGURE 31DOWNFLOW CONDENSATE DRAIN

CONDENSATE TRAP

DRAIN LINE

NOTE:DRAIN VENT NEEDSTO BE ABOVECOLLECTOR BOXDRAIN SPOUT.

NEUTRALIZER CARTRIDGE(OPTIONAL)

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

MINIMUM HEIGHTOPEN TOP

TO FLOOR DRAIN OR CONDENSATE PUMP

a103101

35

CONDENSATE DRAINFOR HORIZONTALINSTALLATIONRefer to Figure 33 for Steps 1-4.This unit is shipped factory ready fordownflow installation. Thecondensate trap assembly and drainhoses require conversion forhorizontal installation. Remove theexisting condensate trap with the unitin the upright position.1. Remove the burner compartment

door from the unit.2. Remove the two screws from the

right side of the furnace jacketwhich support the trap mountingbracket. Remove the twoplastic plugs on either side of thetrap outlet hole and discard.

3. Remove the black molded 90°hose � from the top of theexisting trap � and furnacecollector box. Cut 1.0 inch fromthe long end of the hose. NOTE:Exception – do not shorten the90° hose on the 07B furnace!The 07B has a longer distancebetween the collector box andhorizontal drain trap.

4. Remove the double-elbow blackmolded hose � from the exhausttransition �. Discard this hoseand the downflow trap.

NOTE: The following steps shouldtake place with the furnace in thehorizontal position.Refer to Figure 34 for Steps 6-11.5. Locate the parts bag in the

burner compartment. Install twoplastic plugs � in the side of thejacket from bottom side up.

6. Fill the trap assembly � with acup of water.

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

8. 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!

9. 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.

10. Attach the 90° end of the moldedhose to the collector box.Clamp the hose tight with whitenylon clamp. Then attach thelong end of the molded hose to

the 45° elbow molded into the topof the trap assembly. Clamp thehose tight with white nylon clamp.IMPORTANT: Tighten all clampconnections with a pair of pliersand check for leaks afterconversion is complete.

11. IMPORTANT: There are twooptions when choosing a height forthe condensate riser:CONDENSATE OVERFLOW: Witha 13⁄4 inch riser installed above thetee, a blocked drain will result inoverflow from the riser.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 installed inan attic, crawlspace or other areawhere freezing temperatures mayoccur, the furnace drain can freezewhile shut off for long periods oftime. Provisions must be made toprevent freezing of condensate(see Figure 3).Use a solvent cement that iscompatible with PVC material.

NOTE: See location requirements andcombustion section for additionalrecommendations.

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.

B

C

A

D

E

F

G

H

I

J

K

E

L

FIGURE 32DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

UNION

DRIP LEG

BURNERS

MANIFOLD

CONDENSATE TRAP

DRAINVENT

DRAINEXTENSION

TEE

TO FLOORDRAIN ORCONDENSATEPUMP

ROTATE TRAP180° ANDINSTALL RIGIDPIPE FROMELBOW TOOPPOSITESIDE OFJACKET ASSHOWN.

EXISTINGDRAIN HOLE.PLUG WITH1 5/8” PLUGSUPPLIED INKIT.

ALTERNATEDRAIN HOLELOCATEDHERE ONJACKET.(REMOVEPLASTIC PLUGAND REPLACEWITHGROMMET).

36

FIGURE33

UPRIGHTPOSITION:REMOVALOFEXISTINGDOWNFLOWCONDENSATETRAP

FIGURE34

HORIZONTALPOSITION:CONDENSATETRAPINSTALLATION

FORHORIZONTALOPERATION

I534

CONDENSATETRAPCONVERSIONFROMDOWNFLOWTO

HORIZONTA

LINSTA

LLATION

37

GAS SUPPLY AND PIPINGGAS SUPPLY

THIS FURNACE IS EQUIPPED ATTHE FACTORY FOR USE ONNATURAL GAS ONLY.CONVERSION TO LP GASREQUIRES A SPECIAL KIT ISAVAILABLE AT THEDISTRIBUTOR. 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: U.L. or CSArecognized fuel gas and COdetector(s) are recommended in allapplications, and their installationshould be in accordance with themanufacturer’s recommendationsand/or local laws, rules, regulations orcustoms.

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

If possible, run a separate gas supplyline directly from the meter to thefurnace. Consult the local gascompany for the location of themanual main shut-off valve. The gasline and manual gas stop must beadequate in size to prevent unduepressure drop and never smallerthan the pipe size to the gas valveon the furnace. Refer to Table 5 forthe recommended gas pipe size. SeeFigure 35 for typical gas pipeconnections.

Install a ground joint union within 3ft. of the cabinet to easily removethe gas valve assembly. Install amanual gas stop valve in the gasline outside the furnace casing.The manual gas stop should bereadily accessible to turn the gas

! WARNING

FIGURE 35GAS 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.

MANUALGASSTOP

BURNERS

GROMMET

TOP VIEW OF GAS LINE AND VALVEIN OPT. POSITION

MANUALGASSTOP

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 STOP

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 thecabinet.

HORIZONTAL

38

NEVER PURGE A GAS LINE INTOTHE COMBUSTION CHAMBER.NEVER USE MATCHES, FLAME ORANY IGNITION SOURCE FORCHECKING LEAKAGE. FAILURE TOADHERE TO THIS WARNING CANCAUSE A FIRE OR EXPLOSIONRESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.

To check for gas leakage, use anapproved chloride-free soap and watersolution, or other approved method.

supply on or off. Install a drip leg inthe gas supply line as close to thefurnace as possible. Always use apipe compound resistant to the actionof liquefied petroleum gases on allthreaded connections.

IMPORTANT:When making gas pipeconnections, use a back-up wrench toprevent any twisting of the main gasvalve and manifold. Do notovertighten gas valve on pipe.

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 furnace. Thegas pipe gasket in the cabinet doesnot seal around a flexible gas line.

If local codes allow the use of aflexible gas appliance connector,always use a new listed connector.Do not use a connector which haspreviously serviced another gasappliance. Massachusetts lawrequires that all flexible connectors beless than 36”.

It is important to have all openingsin the cabinet burner compartmentsealed for proper furnaceoperation.

IMPORTANT: ENSURE that thefurnace gas valve not be subjected tohigh gas line supply pressures.

DISCONNECT the furnace and itsindividual manual gas stop from thegas supply piping during anypressure testing that exceeds 1/2PSIG. (3.48 kPa).

GAS PRESSURENatural gas supply pressure shouldbe 5" to 10.5" w.c. LP gas supplypressure should be 11" to 13" w.c.This pressure must be maintainedwith all other gas-fired appliancesin operation.

The minimum gas supply pressure tothe gas valve for proper furnace inputadjustments is 5" w.c. for natural gas,however 6" to 7" is recommended.The minimum gas supply pressure is11" w.c. for LP gas.

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)NEED TO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.

! WARNING

TABLE 5NATURAL 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.

GAS VALVEThis furnace has a 24-volt gas valve.It has ports for measuring supply andmanifold gas pressure. The valvebody contains a pressure regulator tomaintain proper manifold gaspressure.

A control switch is on the valve body.It can be set to only the “ON” or“OFF” positions. The gas valve is aslow-opening valve. See Figures 36and 38.

When energized, it takes 6 to 8seconds to fully open.

CAUTION!

FIGURE 36TYPICAL GAS VALVE (WHITE RODGERS)

INLETPRESSURE TAP

OUTLETPRESSURETAP

HIGH FIREMANIFOLDPRESSUREADJUSTMENT

LOW FIREPRESSUREMANIFOLDADJUSTMENT

9. Turn on the gas supply and checkunit thoroughly for gas leaks usingsoap solution.

10. Follow lighting instructions to putfurnace into operation.

11. Operate thermostat to check unitoperation.

DO NOT USE AN OPEN FLAME.

NOTE: If you have a singlethermostat, the furnace will starton high fire then switches to lowfire and will continue on low fire for12 minutes and then if thermostatis not satisfied, shifts to high fire.With a 2-stage thermostat, whenthere is a call for low heat (1ststage), the furnace will start onhigh fire then switch to low fireuntil the call for heat is satisfied or2nd stage contacts close.

TO CONVERT GAS VALVETO LP GAS ANDCHECK/ADJUST GASPRESSURE1. See Honeywell envelope kit#396021 for proper LP regulatorspring and instructions. (SeeFigures 38 & 39.)

2. The LP gas supply pressure mustbe set between 11 and 13” W.C. bymeans of the tank or branch supplyregulators.

39

LP CONVERSIONThe valve can be converted to useliquified petroleum (LP) gas by replacingthe pressure regulator spring with theconversion kit spring. This LP kit springallows the regulator to maintain theproper manifold pressure for LP gas.See Figure 37.

NOTE: Order the correct LP conversionkit from the furnace manufacturer. Referto the latest “L.P. Conversion Kit Index”shipped with the furnace or seeRheemote.net and PTS for latestversion. Furnace conversion to LP gasmust be performed by a qualifiedinstaller, service agency or the gassupplier.

ORIFICE INSTALLATIONLP Gas is a manufactured gas that hasconsistent heating value across mostregions.

The Sea Level input should still bereduced by 3.5-4% per thousand ft. andthe orifice size must be selected basedon the reduced input selection chartbelow.

TO CHANGE BURNERORIFICE

1.

TURN OFF ELECTRICALPOWER AND MAIN GASSUPPLY BEFORE BEGINNINGMODIFICATION. FAILURE TODO SO CAN RESULT INELECTRICAL SHOCK OREXPLOSION CAUSINGPROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

2. Disconnect union ahead ofcombination gas valve.

3. Disconnect leads from gas valve.

4. Remove the 4 screws holding themanifold assembly to the mainburner assembly.

5. Replace the L.P. stem/springassembly from kit as shown inFigures 38 and 39.

6. Remove each existing orifice fromthe manifold assembly using aratchet with a 7/16 socket. Replacewith orifices from the kit. Screw theorifices in hand tight and secure inplace with a quarter turn with theratchet.

7. Reinstall the manifold assembly onthe burner assembly with the 4screws removed in step 4.

8. Reconnect the leads to the gasvalve, union, and electrical powerto furnace.

FIGURE 37TYPICAL LP KIT CONTENTS

Altitude Orifice Size

0 to 5000� 1.15 mm

5000�-8000� 1.10 mm

WARNING!

WARNING!

3. The furnace manifold pressureshould be 10” W.C. for high fireand 4.8” W.C. for low fire. Thesepressures can be checked byconnecting a properly calibratedmanometer or gauge to themanifold pressure tap on theoutlet end of the valve. Check andadjust pressures as follows:

a. For full input pressure removeadjustment screw cover onoutlet end of valve and turnadjustment screw clockwise toincrease pressure andcounterclockwise to reducepressure. Replace theadjustment cover screwsecurely.

b. For low fire pressure, removethe regulator cover on top ofvalve and adjust as notedabove.

NOTE: Use 3/32” allen wrenchfor making pressureadjustments. See Figures 38 &39.

COMPLETINGCONVERSION1. Using a ball point indelible pen,record the following information onthe conversion label.

a.Conversion kit number.

b.Date of conversion.

c. Installer’s name, address andtelephone number.

d.Burner orifice size.

40

2. Place completed conversion labeladjacent to the rating plate.

3. Install the burner compartmentaccess door.

4. Run furnace through complete cycleto check operation.

FIGURE 38GAS VALVE 60-24394-01 (HONEYWELL)

FIGURE 39

INLETPRESSURETAP

HIGH FIREMANIFOLDPRESSUREADJUSTMENT

OUTLETPRESSURETAP

LOW FIRE MANIFOLDPRESSURE ADJUSTMENT

GAS CONTROL TURNKNOB ON/OFF

41

accessible and located within site andarm’s reach of the furnace. Connectfrom the electrical disconnect to thejunction box on the left side of thefurnace, inside the blower compartment.For the 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. Aknockout is provided. Seal the oppositehole with plug provided.

NOTE: L1 (hot) and N (neutral) polaritymust be observed when making fieldconnections to the furnace. The ignitioncontrol may not sense flame if L1 andNeutral are reversed. When L1 andNeutral are reversed, a diagnostic codeof 6 blinks followed by a pause and 6

FIGURE 40LINE VOLTAGE CONNECTIONS

UT ELECTRONIC CONTROLS 1095-206 CONTROL BOARD

ELECTRICAL WIRING

TURN OFF ELECTRIC POWER ATFUSE BOX OR SERVICE PANELBEFORE MAKING ANY ELECTRICALCONNECTIONS. FAILURE TO DO SOCAN CAUSE ELECTRICAL SHOCKRESULTING IN PERSONAL INJURYOR DEATH.

NOTE: Electric to furnace must besupplied by commercial utility. Propervoltage is 110-125 volts.

THE CABINET MUST HAVE ANUNINTERRUPTED GROUNDACCORDING TO THE LATESTEDITION OF THE NATIONALELECTRICAL CODE, ANSI/ NFPA70-OR IN CANADA, THE CANADIANELECTRICAL CODE, CSA-C221 ORLOCAL CODES THAT APPLY. DONOT USE GAS PIPING AS ANELECTRICAL GROUND. A GROUNDSCREW IS PROVIDED IN THEJUNCTION BOX. FAILURE TO DO SOCAN CAUSE ELECTRICAL SHOCKRESULTING IN PERSONAL INJURYOR DEATH.

THIS FURNACE IS EQUIPPED WITH ABLOWER DOOR SAFETY SWITCH.DO NOT DISABLE THIS SWITCH.FAILURE TO FOLLOW THISWARNING 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 the voltage,frequency and phase corresponds tothat specified on the furnace ratingplate. For single furnace application,maximum over-current protection is 15amperes.

Use a separate fused branch electricalcircuit containing a properly sized fuseor circuit breaker. Route this circuitdirectly from the main switch box to anelectrical disconnect that is readily

! WARNING

! WARNING

! WARNING

blinks will be displayed on the controlboard “Status” L.E.D. See Figure 40.

Make all electrical connections inaccordance with the latest edition ofthe National Electrical CodeANSI/NFPA70 and local codes havingjurisdiction.

These may be obtained from:

National Electric CodeNational Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

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

42

setting of .15 amps is recommended.Adjust as needed to improve comfortlevel.

ISOLATION RELAYIMPORTANT: NOT ALL ELECTRONICNIGHT SETBACK THERMOSTATSARE COMPATIBLE WITH THEFURNACE CONTROL SYSTEM.SOME MAY REQUIRE AN ISOLATIONRELAY.If an isolation relay is needed, install itas close to the control board aspossible. Use a single-pole, single-throw relay with a 24 volt operating coil.The relay contacts should be designedfor 24 volt loads.Connect one end of the operating coilto the thermostat “W” terminal.Connect the other end of the coil to the“C” terminal on the control board. Connect a jumper from the coilterminal connected to the thermostat toone of the normally open relaycontacts. Connect the other side of the normallyopen relay contacts to the control board“W” terminal if using a two stagethermostat. Connect that one side of thenormally open relay contacts to thecontrol board “W” terminal if using asingle stage thermostat. See Figure 41for wiring details.

When the thermostat calls for heat, itpowers the 24 volt operating coil. Thiscloses the relay contacts andconducts power from terminal 3 and 4to terminal “W” on the control boardand starts the furnace ignitionsequence. See Figure 42. NOTE: Use of an isolation relaywith the two stage furnace is notnormally needed.

ELECTRONIC AIR CLEANERElectronic air cleaner line voltagepower can be supplied from the screwterminal “EAC” and a line voltageneutral screw terminal on the controlboard. This will power the electronicair cleaner whenever the circulatingair 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 during a normal heatsequence after the blower has turnedon.NOTE: Maximum current of 1.0 Ampfor each option.

FIELD-INSTALLED OPTIONAL ACCESSORIESTHERMOSTATNOTE: Do not use 24 volt control wiringsmaller than No. 18 AWG. (Refer toTable 6.)See Figure 41 for thermostat wiringoptions.A single- or two-stage thermostat may beused, however, a two-stage thermostat isrecommended for optimum performance.The room thermostat must be compatiblewith the integrated furnace control on thefurnace. Generally, all thermostats thatare not of the “current robbing” type arecompatible with the integrated furnacecontrol being used.Install the room thermostat in accordancewith the instruction sheet in the box withthe thermostat. Run the thermostat leadwires inside the control compartment.Connect the thermostat as shown on thewiring diagram. Never install thethermostat on an outside wall or where itwill be influenced by drafts, concealedhot or cold water pipes, lighting fixtures,radiation from fireplace, rays of sun,lamps, television, radios or air streamsfrom registers. Refer to the instructionspacked with the thermostat for bestanticipator adjustment or selection.Locate the thermostat approximately fivefeet up from the floor.HEAT ANTICIPATOR SETTINGSIf a current reading taken at thethermostat is not performed, an initial

FIGURE 41THERMOSTAT WIRING OPTIONS

2 HEAT - 1 COOL

2 HEAT - 2 COOLRGPR’S AND RGLR’S

ONLY

1 HEAT, 1 COOL(OPTION A) TIMED STAGING W/1

STAGE HEAT T-STAT (AFTER F3507DATE CODE (AUGUST 2007))

1 HEAT, 1 COOL(OPTION B) 100% HEAT ALWAYS -- NO

TIMED STAGING

43

90+ HIGH ALTITUDEINSTRUCTIONS

NATURAL GASThe RGRM and RGTM models does notrequire any changes for high altitudeapplication in the U.S.

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

The NFGC guidelines are used with thefollowing exception:

See the “L.P. Conversion” Section onpage 39 for U.S. application.

ORIFICE ORDERINGINFORMATIONIMPORTANT: Do not plug or drill outorifices.

Orifice 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-ALTITUDE DERATEIn Canada, unless an orifice changeis specifically mandated by localcodes, an alternate method of altitudederation through a reduction inmanifold pressure is acceptable asdescribed 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 43must be affixed in a conspicuouslocation on the front of the furnacecabinet:

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

FIGURE 42BASIC ISOLATION RELAY – SEE FIGURE 41 FOR DETAILS

ST-A0804-01

TABLE 6FIELD WIRE SIZE FOR 24 VOLT CONTROL CIRCUITS

SOLID COPPER WIRE - AWG

3.0 16 14 12

2.5 16 14 12

2.0 18 16 14

50 100 150

LENGTH OF RUN - FEET �

� Wire length equals twice the run distanceNOTE: Do not use 24 volt control wiring smaller than No. 18.

THER

MOST

ATLO

AD-A

MPS

TABLE 7ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATEIMPORTANT: 90+ MODELS ONLY. DO NOT USE THIS CHART FOR ANY 80 PLUS MODELS.

NATURAL GAS LP GAS

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

#51 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

1.10mm 7.6” W.C.

FIGURE 43MANIFOLD PRESSURE-CHANGE LABEL

THE MANIFOLD PRESSURE OF THIS APPLIANCE HASBEEN FIELD ADJUSTED TO OBTAIN THE CORRECTINPUT RATING FOR INSTALLATION AT ALTITUDES

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

LA PRESSION DU DISTRIBUTEUR D’ALIMENTATIONDE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIND’OBTENIR LA BONNE PUISSANCE D’ENTRÉE POURUNE INSTALLATION ENTRE 2000 ET 4500 PIEDS

D’ALTITUDE. 92-24399-01-01

44

START-UP PROCEDURESDIRECT SPARK IGNITIONLIGHTING INSTRUCTIONSThis appliance is equipped with a directspark ignition device. This device lightsthe main burners each time the roomthermostat (closes) calls for heat. Seelighting instructions on the furnace.

During initial start-up, it is not unusualfor odor or smoke to come out of anyroom registers. It is recommended toensure proper ventilation by openingwindows and doors, before initial firing.

The furnace has a negative pressureswitch that is a safety during a call forheat. The induced draft blower must pulla negative pressure on the heatexchanger to close the negativepressure switch. The induced draftblower must maintain at least thenegative pressure switch set point forthe furnace to operate. If the induceddraft blower fails to close or maintain theclosing of the negative pressure switch,a heat call would be prevented until theproblem is cleared.

TO START FURNACE1. Remove the control access door.

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

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

4. Turn the gas control knob to the “On”position, or move the gas controllever to the “On” position.

5. Replace the control access door.6. Turn on the electrical power.7. Set the room thermostat to a pointabove room temperature to light themain burners. After the burners are lit,set room thermostat to a desiredtemperature.

TO SHUT DOWN FURNACE1. Set the room thermostat to off and itslowest setting.

2. Turn manual gas stop to the closedposition.

3. Turn off the electrical power to thefurnace.

4. Remove burner compartment door.5. Move the main gas valve knob orlever to the off position.

6. Replace the burner compartmentdoor.

SHOULD OVERHEATING OCCUR ORTHE GAS SUPPLY FAIL TO SHUTOFF, SHUT OFF THE MANUAL GASVALVE TO THE APPLIANCE BEFORESHUTTING OFF THE ELECTRICALSUPPLY. FAILURE TO DO SO CANCAUSE AN EXPLOSION OR FIRERESULTING IN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.IGNITOR PLACEMENT,ALIGNMENT & LOCATIONIgnition failure may be a result ofimproper ignitor alignment caused duringa service call or other work done to thefurnace in the field. When performing anywork on the burner, heat exchanger, etc.,the technician must check alignment ofthe spark ignitor. Misalignment of theignitor could cause a failure to light orrough ignition. The correct ignitoralignment is shown in Figure 44.

SEQUENCE OF OPERATIONSee the section of this book titled“Electrical Wiring - Thermostat” for awiring diagram showing how to connect athermostat.

SINGLE-STAGE HEATTHERMOSTATNOTE: Single-stage heat operation isdetermined by the position of thejumper at P7 on the control board.Options are: 5 minutes between 1stand 2nd stage, or 12 minutes between1st and 2nd stage (see Figure 45).

For single-stage operation, “W” fromthe thermostat must be connected to“W” on the furnace control.

Do not leave jumper at P7 in the“NONE” position when using a single-stage thermostat with the timedstaging feature. If the jumper is left on“NONE”, the furnace will never reachhigh heat (100% heat). NOTE:Whenthere is a low heat call present at thetime of ignition, this furnace will lighton high fire heat and immediately dropto low fire as soon as flame is sensed.This can sometimes appear to beignition on low heat stage but this isnot the case. Listen carefully to hearthe inducer and gas valve relaysswitch to low fire after ignition when alow heat call is present. If a high heatcall is present at the time of ignition,both ignition and steady state heat willoccur at high fire and there will be nochange in operation after ignition.

a. Connect the “W” terminal on thethermostat to the “W” terminal onthe control board.

b. When there is a call for heat, the“R” and “W” contacts close and theIFC runs a self check routine toverify that the pressure switchcontacts are open. The limit switchcontacts are constantly monitored.

c. The induced draft motor starts onhigh speed. After a 30 second pre-purge, the spark ignitor energizesand the high fire gas valve opens,lighting the burners.

d. After the gas valve opens, theremote flame sensor must proveignition for one second using theprocess of flame rectification. If theburners do not light, the system

! WARNING

! WARNING

FIGURE 44UPFLOW OPTIMUM IGNITOR LOCATION DOWNFLOW/HORIZONTAL OPTIMUM IGNITOR LOCATION

45

goes through another ignitionsequence. It does this up to 4 times.

e. The inducer and gas valveimmediately drop to low fire, the mainblower starts on low heat speed 20seconds after the flame is sensed. Thefurnace operates on low fire for 5 or 12minutes and then, if the thermostat isnot satisfied, shifts to high fire, causingthe draft inducer to go to high speed,the gas valve to shift to 100% and themain blower to high heat speed. (Insome models low and high fire haveidentical main blower airflow CFM.)

f. When the thermostat cycle ends, thegas valve closes, and the burners goout.

g. The draft inducer will continue runningfor a 10 second post purge.

h. The main blower runs for 80-180seconds on high heat speed or 90-180seconds on low heat speed (thistiming is field adjustable). See Figure47 for switch settings.

Sequence if the system doesn’t lightor doesn’t sense flamea. If flame is not sensed within 8 secondsafter the gas valve opens, the valvecloses and the ignitor is de-energized.The induced draft motor will run for 60seconds on high, and then beginsanother heat cycle.

b. The ignition process goes through 3more attemps.

c. If there is no ignition after the 4th trial,the furnace goes into soft lockout forone hour.

d. The sequence repeats after a onehour delay and continues repeatinguntil ignition is successful or the callfor heat is terminated.

e. To reset the lockout, break powereither at the thermostat or at the unitdisconnect switch for 5 to 10 seconds.The furnace then goes throughanother set of trials for ignition(provided call for heat is still present).

f. If flame is established and maintainedduring the trial for ignition period andflame is lost, the gas valve is de-energized, the draft inducer completesthe post purge, and control shuts offthe inducer, senses the open pressureswitch and begins the ignitionsequence again from pre-purge. Theindoor blower motor will be energizedand/or remain energized on low speedfor low fire and heat speed for high firefor the selected delay off time.The control initiates another ignitiontrial period. The control will recycle upto 5 flame losses (4 re-cycles) within asingle call for heat before going intolockout.

TWO STAGE HEAT THERMOSTATConnect “W1” and “W2” terminals on thethermostat to “W” and “W2” terminals onthe control board.See the section of this book titled“Electrical Wiring - Thermostat” for awiring diagram showing how to connect athermostat.

NOTE:When there is a low heat callpresent at the time of ignition, thisfurnace will light on high fire heat and

immediately drop to low fire as soon asflame is sensed. This can sometimesappear to be ignition on low heat stagebut this is not the case. Listen carefully tohear the inducer and gas valve relaysswitch to low fire after ignition when a lowheat call is present. If a high heat call ispresent at the time of ignition and steadystate heat will occur at high fire and therewill be no change in operation afterignition.

Call for 1st stage heata. The “R” and “W” thermostat contactsclose and the control module runs aself-check routine. After the controlmodule verifies that both sets ofpressure switch contacts are open, theinduced draft motor starts on high untilthe low pressure switch contacts close(a maximum of 60 seconds).

b. After a 30 second pre-purge the sparkigniter energizes and the high fire gasvalve opens, lighting the burners.

c. After the burners light, the remoteflame sensor must prove ignition. If theburners do not light, the system goesthrough another ignition sequence. Itdoes this up to 4 times.

d. The furnace immediately dropsinducer and gas value to low fire aftersensing flame. The main blower startson low-heat speed 20 seconds afterthe flame is proven. The furnacecontinues to run on low fire until thecall for heat is satisfied or the 2ndstage contacts close. If the 1st stagecall for heat is satisfied the gas valvecloses and the induced draft motorcontinues running for a 10 second postpurge time. the main blower runs forits blower off delay (this timing is fieldadjustable). See Figure 45 for switchsettings.

Call for 2nd stage heat after 1st stageThe “R” and “W2” thermostat contactsclose, calling for 2 stage heat. Theinduced draft motor switches to highspeed and the high pressure switchcontacts close. The gas valve switches tohigh fire and the main blower switches tohigh heat speed.

2nd stage heat satisfied, 1st stageheat still requiredThe “R” and “W2” thermostat contactsopen. The induced draft motorswitches to low speed, the mainblower motor switches to low heatspeed and the gas valve changes tolow fire. The furnace continues to runin this mode until the 1st stage heatcall is satisfied. The system will shutdown as noted in “d,” under 1st stagecall for heat.NOTE: Under extreme coldconditions, the 2-stage thermostatmay call for the furnace to cyclebetween 1st and 2nd stage operation.

INTEGRATED FURNACECONTROL & ECM MOTORSETTINGSThese furnaces have ECM blowermotors. These motors deliver aconstant level of air flow over a widerange of external static pressures (0.1to 0.8� W.C.).There is a bank of 12 dip switches(SW1) on the control board whichdefine the operation of the ECMmotor. (See Table 8.) (See Figure 47.)Many of these switches (except forswitches 9 and 12) are actually brokendown into dip switch pairs. Thefollowing switches are paired 1 & 2, 3

FIGURE 45

éFACTORYSETTING

TABLE 8DIP SWITCH BANK SW1

SWITCHES FUNCTION1 & 2 Heat Rise Adjustment

3 & 4 Not Used

5 & 6 Nominal Cooling/Heat Pump Air Flow

7 & 8+ Latent/Sensible Airflow Adjustment

9 Continuous Fan Airflow

10 & 11* On DemandDehumidification

Settings

12 1 or 2 Stage Cool

46

& 4, 5 & 6, 7 & 8, and 10 & 11. Theassignments of the switch pairs areshown in Table 8 and Figure 46.*IMPORTANT: Only traditionalhumidistats will work with this feature.Dehumidistats will not work properlywith this feature.

HEATING AIRFLOWADJUSTMENTSThe furnace is shipped with low and highfire heating airflows. These are set fromthe factory to let the furnace operate atthe mid point of the temperature riserange. The temperature may vary slightlydue to furnace input manufacturingtolerances and voltage variations.

In the heating mode, the ECM motor isprogrammed to ramp up to its targetCFM over a fifteen (15) second period.After any of the user selected “Off”delays the ECM motor will ramp down to50% of steady state CFM forapproximately thirty (30) seconds. Themotor will then ramp down to off.

COOLING AIRFLOWADJUSTMENTSSee Table 13 for airflow options.Furnaces are shipped from the factory setfor maximum cooling airflow. Adjustmentsto the cooling airflow may be made usingswitches 7 and 8 as shown in Table 9.

TWO-STAGE COOLINGSELECTIONDipswitch SW1, Position #12 on theIntegrated Furnace Control (IFC) shipsfrom the factory in the “ON” position. Thisdipswitch is to be used to designate singleor two-stage cooling to the IFC. The “ON”(as now shipped) position designates asingle-stage air conditioning system orheating-only application. The “OFF”position designates a two-stage airconditioning system. Turn the switch tothe “OFF” position when using two-stagecooling with separate contactors, Y1 andY2. Failure to do this will mean that the airconditioner will never go into low stage.

2-Stage Cooling Systems = #12 OFF1-Stage Cooling Systems = #12 ON

CONTINUOUS FANADJUSTMENTSThere are two options for the adjustmentof continuous fan. With switch 9 “ON” thespeed will be high fan. With switch 9“OFF” the speed will be low fan.

SETTING BLOWER OFFTIMINGS FOR COOLINGAND HEAT PUMPOPERATIONThere is a jumper (P6) on the mainfurnace control board for settingblower off timings. (See Figure 45.)

DEHUMIDIFICATIONThe interface control has two optional24 volt AC only inputs. The “B”terminal input is provided for heatpump applications. This signal comesfrom a heat pump thermostat and tellsthe heat pump to switch its reversingvalve to heat mode. If this “B” signal isalso routed to the furnace control, allairflow adjust switches (7 & 8 of SW1)and “On Demand Dehumidification”are bypassed in the heat mode only.The airflow will remain at the normalairflow as selected by switches 5 & 6throughout the heat mode. This allowsthe user to have a switched (reduced)airflow adjustment for dehumidificationor the “On Demand Dehumidification”in cooling mode, but not the adversehumidity and heat rise effects of usingthese adjustments during a heatpump’s heat mode. The “B” terminaldoes not apply to gas operation.

The “On Demand Dehumidification”(ODD) input allows the user to haveautomatic dehumidification that iscontrolled by the user’s humidistatsetting. Dehumidistats are notcompatible with the furnace control.When the humidity exceeds thehumidistat setting, it routes a 24 volt,AC only, signal to the “On DemandDehumidification” terminal.Conversely, it will route 0 volts (turnoff) when a call for dehumidification isrequired. When no voltage is presenton ODD and the ODD feature isenabled (see Table 12), cooling airflowis decreased 15%. This results inhigher latent capacity and increasesthe level of comfort. This feature isonly available in the cooling mode.

NOTE: Use a 3/32” allen wrench orsmall-blade screwdriver for makingthe pressure adjustment.

FIGURE 47

FIGURE 46BLOWER OFF TIMINGSUTEC 1095-101 CONTROL WITH INTERFACE BOARD AND ECM MOTOR

OFF

ON

HEAT TEMP RISE ADJUST

NOT USED

COOLING, H/P AIR FLOW

LATENT/SENSIBLE AIR FLOW ADJUSTMENT

CONTINUOUS FAN AIR FLOW

DEHUMIDIFICATION SETTINGS2 STAGE COOLING (OFF = 2 STAGE COOL, ON = 1 STAGE COOL)

TABLE 9AIR FLOW ADJUSTMENT (SWITCHES 7 & 8)

Switch Air FlowSelection Adjustment

A No AdjustmentB +10%C -10%D No Adjustment

47

TABLE 11

TEMPERATURE RISE BY MODEL

NominalTemperature Rise

(°C)

NominalTemperature Rise

(°F)Model Speed

LOW HEAT 30 16.7

HIGH HEAT 45 25.0

LOW HEAT 50 27.8

HIGH HEAT 55 30.6

LOW HEAT 50 27.8

HIGH HEAT 55 30.6

LOW HEAT 35 19.4

HIGH HEAT 50 27.8

LOW HEAT 40 22.2

HIGH HEAT 50 27.8

LOW HEAT 45 25.0

HIGH HEAT 55 30.6

LOW HEAT 55 30.6

HIGH HEAT 65 36.1

LOW HEAT 40 22.2

HIGH HEAT 45 25.0

LOW HEAT 40 22.2

HIGH HEAT 45 25.0

LOW HEAT 40 22.2

HIGH HEAT 45 25.0

LOW HEAT 45 25.0

HIGH HEAT 50 27.8

RGRM-04*MAES

RGRM-06*MAES

RGRM-07*MAES

RGRM-07*YBGS

RGRM-09*ZAJS

RGRM-10*ZAJS

RGRM-12*RAJS

RGTM-06*MAES

RGTM-07*RBGS

RGTM-09*ZAJS

RGTM-10*RBJS

NOTE: Temperature Rise could be adjusted by changing dip switches as shown in Table 10.

TABLE 10HEAT RISE ADJUSTMENTS

Profile SW1-1 & SW1-2 Temperature Rise (°F)A OFF/OFF Nominal Setting - See Table 13B ON/OFF Nominal +15°FC OFF/ON Nominal +8°FD ON/ON Nominal -8°F

48

TABLE 12COOLING AIRFLOW SELECTIONS

45000 90000Profile SW1-5 & SW1-6 60000 75000B 105000

75000A 120000

A OFF/OFF 1200CFM HI / 1600 CFM HI / 2000 CFM HI /900 CFM Low 1200 CFM Low 1500 CFM Low

B ON/OFF 1000 CFM HI / 1200 CFM HI / 1600 CFM HI /750 CFM Low 900 CFM Low 1200 CFM Low

C OFF/ON 800 CFM HI / 1000 CFM HI / 1400 CFM HI /600 CFM Low 750 CFM Low 1050 CFM Low

D ON/ON 600 CFM HI / 800 CFM HI / 600 CFM HI /450 CFM Low 600 CFM Low 1200 CFM Low

TABLE 13OPTIMIZED AIRFLOW OPTIONS (SWITCHES 10 & 11 OF SW1)

Switch Air FlowSelection Adjustment

A 15% Less cooling AirflowB Normal Cooling Air Flow for Table 11C On Demand Dehumidification (Humidistat controls cooling airflow)D Normal Cooling Air Flow

49

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 THEEQUIPMENT MANUFACTURER HASNO 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. High fire andlow fire heating modes have thesame temperature rise range.

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 AS

FIGURE 48TEMPERATURE RISE MEASUREMENT

FIGURE 49TYPICAL FURNACE NAME PLATE

POSSIBLE. FOR EXAMPLE, IF THERISE RANGE IS 40 TO 70 DEGREES,THE MOST IDEAL RISE WOULD BE55 DEGREES (THE MIDDLE OF THERISE RANGE). IN ALLAPPLICATIONS, THE INSTALLERMUST ADJUST THE TEMPERATURERISE TO THIS "MIDDLE" POINT ASCLOSELY AS POSSIBLE. ALSO,THE TEMPERATURE RISE SHOULDNEVER BE ABOVE OR FALL BELOWTHE STATED RANGE. DOING SOCOULD CAUSE DAMAGE TO THEHEAT EXCHANGER ORINTERMITTENT OPERATION WHICHCOULD CAUSE INJURY OR DEATHAND WILL VOID THEMANUFACTURER'S WARRANTYFOR THIS PRODUCT.

! WARNING

! CAUTION

AIR CONDITIONING DIVISIONFORT SMITH, ARKANSAS

50

FIGURE 50FILTER LOCATIONS

I528

HORIZONTAL

I413

DOWNFLOW

AIRFLOW

HORIZONTAL

MAINTENANCE

THESE INSTRUCTIONS AREINTENDED AS AN AID TOQUALIFIED SERVICE PERSONNELFOR PROPER INSTALLATION,ADJUSTMENT AND OPERATIONOF THIS UNIT. READ THESEINSTRUCTIONS THOROUGHLYBEFORE ATTEMPTINGINSTALLATION OR OPERATION.FAILURE TO FOLLOW THESEINSTRUCTIONS MAY RESULT INIMPROPER INSTALLATION,ADJUSTMENT, SERVICE ORMAINTENANCE, POSSIBLYRESULTING IN FIRE, ELECTRICAL

SHOCK, CARBON MONOXIDEPOISONING, EXPLOSION,PROPERTY DAMAGE, PERSONALINJURY OR DEATH.

TABLE 14FILTER SIZES

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE QUANTITYWIDTH MBTUH SIZE SIZE

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

DOWNFLOW/HORIZONTAL FILTER SIZES

FURNACE INPUT QUANTITYWIDTH MBTUH SIZE

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

! WARNING

51

FIGURE 51BOTTOM PANEL REMOVALFILTER LOCATION

JACKET ASSEMBLY

REMOVESOLID BOTTOM

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

SCREW(2) REQ’D.

JACKET ASSEMBLY

FILTER

SOLIDBOTTOM

FILTERROD

SOLID BOTTOM REMOVAL

FILTER & ROD LOCATION

FILTER AND ROD ASSEMBLY

ODS

FILTERSUPPORTANGLE

FILTER

FILTER ROD

JACKET

I332

I

FILTERROD45-24095-01

FILTER

FILTERSUPPORTANGLEAE-61883-01

FILTER RODSUPPORTANGLEAE-60520-01

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

CUT-OUT AND DRILL DETAILR

JACKET

JACKET

ANGLE

FILTER RODSUPPORTANGLE

FILTER SUPPORTANGLE(SEE ANGLE DETAIL)

ATTACH WITHSHEET METALSCREWS (2 REQÕD)

ANGLE DETAIL

CROD & FILTER SUPPORT ANGLE ASSEMBLY

F

FILTER RODSUPPORTANGLEAE-60520-01

FILTER SUPPORTANGLE(SEE ANGLE DETAIL)AE-61883-01

UPFLOW BOTTOM RETURN

UPFLOW SIDE RETURN

AIRFLOW

AIRFLOW

SOLIDBOTTOM

NOTE: Use both side returns for 1800 CFM or more.

SOLIDBOTTOM

52

it is recommended that a qualifiedinstaller, service agency, or the gassupplier annually inspect the fluepassageways, the vent system andthe main burners for continued safeoperation. Pay particular attention todeterioration from corrosion or othersources.

• 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.

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 andbe filled with water. A blockedcondensate trap can cause water toback up into the primary heatexchanger and lead to nuisancetripping of the overtemperatureswitches.

• 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.

TROUBLESHOOTINGRefer to Figure 52.

There are four diagnostic LED’s onthe furnace control. These are labeledflame, status, power and CFM.

DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTENANCE.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTING INPERSONAL INJURY OR DEATH.

FILTER MAINTENANCEHave your qualified installer, serviceagency or the gas supplier instruct youon how to access your filters forregular maintenance.

FILTERSFilter application and placement arecritical to airflow, which may affect theheating and cooling systemperformance. Reduced airflow canshorten the life of the system’s majorcomponents, such as motor, limits, heatexchanger, evaporator coil orcompressor. Consequently, werecommend that the return air ductsystem have only one filter location.The most common location will beinside the furnace or a filter base. Forsystems with a return air filter grille ormultiple filter grilles, can have a filterinstalled at each of the return airopenings. Your HVAC professional canshow you where they have installed thefilter(s).

If high efficiency filters or electronic aircleaners are used in the system, it isimportant that the airflow is not reducedto maximize system performance andlife. Always verify that the system’sairflow is not impaired by the filteringsystem that has been installed, byperforming a temperature rise andtemperature drop test.

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

DO NOT DOUBLE FILTER THERETURN AIR DUCT SYSTEM. DONOT FILTER THE SUPPLY AIR DUCTSYSTEM.

NOTE: Some filters must be resized tofit certain units and applications. SeeTable 14 and Figures 50 & 51.

1. 21” - 75,000(B), 90,000 & 105,000BTUH units require removal of a3.5-in. segment of filter and frameto get the proper width for a sidefilter.

2. 24.5” - 105,000 and 120,000 BTUHunit requires removal of a 7"segment of filter and frame to getthe proper width for a side filter.

DO NOT OPERATE THE SYSTEMWITHOUT FILTERS. A PORTION OFTHE DUST ENTRAINED IN THE AIRMAY TEMPORARILY LODGE IN THEAIR DUCT RUNS AND AT THE

SUPPLY REGISTERS. ANYRECIRCULATED DUST PARTICLESWILL BE HEATED AND CHARREDBY CONTACT WITH THE FURNACEHEAT EXCHANGER. THIS RESIDUEWILL SOIL CEILINGS, WALLS,DRAPES, CARPETS AND OTHERHOUSEHOLD ARTICLES AND MAYRESULT IN UNPLEASANT ODORS.

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

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 and dirton the windings or on the motorexterior. And, as suggested elsewherein these instructions, the air filtersshould be kept clean. Dirty filters canrestrict airflow. The motor dependsupon sufficient air flowing across andthrough it to keep from overheating.

SYSTEM OPERATIONINFORMATIONAdvise The Customer

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

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

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

4. Avoid excessive use of kitchenexhaust fans.

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

6. Except for the mounting platform,keep all combustible articles 3 feetfrom the furnace and vent system.

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

8. Explain proper operation of thesystem.

ANNUAL INSPECTION• The furnace should operate for manyyears without excessive scale build-up in the flue passageways. However,

! WARNING

! CAUTION

! WARNING

53

FLAME LED

The FLAME LED is an indication of thepresence of flame.

OFF – No flame is detected.

Rapid Blink – Unexpected Flame

Slow Blink – Marginal Flame Sense

Steady ON – Normal Flame Detected

STATUS LED

The STATUS LED is an indication of afault present.

Steady ON – Normal Fault detected.

1 Blink – Ignition failure – 1 HR lockout

2 Blinks – Pressure switch stuck open– switch will not close when inducer ison.

3 Blinks – Limit switch open – mainlimit or roll-out control.

4 Blinks – Pressure switch stuckclosed. Switch will not open.

5 Blinks – Not applicable.

6 Blinks – Line and Neutral reversed.

POWER LED

The POWER LED is an indication of24ac power to the board.

OFF – No power (24VAC) to controlboard.

ON – Control is powered.

CFM LED

The CFM LED is an indication of targetairflow. This is a reasonably closeapproximation of the airflow pushed bythe blower motor through the furnace.Because of manufacturing and

measurement tolerances, air density,humidity, ambient air temperature andother things, the CFM actuallymeasured may vary significantly fromthis target value.

One Blink represents 100 CFM of targetairflow. A half blink represents approx.50 CFM. When the blink sequence iscomplete, there will be a noticeablepause of approximately one secondbefore the sequence repeats. Forexample, if elevent and one half blinksare counted followed by a one secondpause and then eleven and one halfblinks are counted again, the targetairflow is approximtely 1150 CFM.Because the resolution of this method isonly 50 CFM (half-blinks), the actualtaget CFM could be anywhere between1125 CFM and 1175 CFM. And, sincethis is TARGET airflow, the actualairflow measured could be muchdifferent than this.’

The CFM LED is intended to be forreference only. The CFM airflowreported by the furnace control throughblinks of this LED should be only usedas a guide to determineAPPROXIMATE airflow and is notintended as a laboratory-gradeinstrument for determining preciseairflow through the furnace.

WIRING DIAGRAMFigure 53 is a complete wiring diagramfor the furnace.

54

FIGURE 52TROUBLESHOOTING CHART

or IFC not properly grounded.

Go ToNext Page

55

FIGURE 52TROUBLESHOOTING CHART (CONTINUED)

56 CM 1009

FIGURE 53WIRING DIAGRAM

Rheem Furnace Installation Manual(1)

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