Rheem **96MDV series, 95P series, 95MSP series Installation Instructions Manual

ISO 9001:2008

INSTALLATION INSTRUCTIONS

FOR 4 POSITION CONDENSING TWO-STAGE, COMMUNICATING GAS FURNACES W/ECM BLOWER

(-)96V SERIES & (-)(-)96MDV SERIES

U.L. and/or C.S.A. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all applications, and their installation should be in accordance with the manufacturer’s recommendations and/or local laws, rules, regulations, or customs.

 Factory Use Only

92-24161-124-06

SUPERSEDES 92-24161-124-05

TABLE OF CONTENTS

1 TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . 2

2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . 3

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

California Proposition 65 Note . . . . . . . . . . . . . . . . . . 4

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . 6

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Contents

Important Information About Efficiency and Quality. . 7

Commonwealth of Massachusetts Note . . . . . . . . . . 8

4 LOCATION REQUIREMENTS . . . . . . . . . . . . . . . . . 9

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Clearance Accessibility. . . . . . . . . . . . . . . . . . . . . . . 10

Clearance Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5 FIELD CONVERSION . . . . . . . . . . . . . . . . . . . . . . . 12

General Conversion Instructions and Tips. . . . . . . . 12

Lists of Materials for Parts Bag and

Conversion Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Conversion Table of Contents . . . . . . . . . . . . . . . . . 14

Upflow with Vertical Vent. . . . . . . . . . . . . . . . . . . 15-16

Upflow with Left Side Vent . . . . . . . . . . . . . . . . . 17-18

Downflow with Right Vent (Non Zero Clearance)

Downflow Zero-Clearance . . . . . . . . . . . . . . . . . 23-27

Horizontal Right with Right Vent . . . . . . . . . . . . . 28-30

Horizontal Right with Vertical Vent . . . . . . . . . . . 31-33

Horizontal Left with Right Vent . . . . . . . . . . . . . . 34-38

Horizontal Left with Left Vent . . . . . . . . . . . . . . . 39-41

6 DUCTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7 VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

General Venting Requirements and Guidelines

(All Instructions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Venting and Combustion Air Piping

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Piping Requirements . . . . . . . . . . . . . . . . . . . . . . 46

Vent Pipe Sizing and Maximum Lengths . . . . 48-49

Equivalent Vent Length. . . . . . . . . . . . . . . . . . . . . 48

Polypropylene Vent Products . . . . . . . . . . . . . . . . 50

Termination Requirements . . . . . . . . . . . . . . . . . . 51

Non-Direct Venting . . . . . . . . . . . . . . . . . . . . . . . . . 52

Non-Direct Venting in an Unconfined Space . . . . 52

Non-Direct Venting in a Confined Space . . . . . . . 52

Non-Direct Venting Terminations . . . . . . . . . . . . . 55

Non-Direct Venting Termination Clearances . . . . 57

Direct Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Option 1: Standard Vertical Direct Vent

Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Option 2: Standard Horizontal Direct Vent

Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Option 3: Variants of Standard Horizontal

Direct Vent Termination. . . . . . . . . . . . . . . . . . . 60

Option 4: Alternate Horizontal Direct Vent

Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Option 5: Variants of Alternate Horizontal

Direct Vent Termination. . . . . . . . . . . . . . . . . . . 61

Optional Termination Angles for Alt. Horizontal and Variant of Alt. Horizontal Direct-Vent Terminations (Options 4 and 5) . . . 62 Option 6 & 7: Vertical and Horizontal Concentric Vent Termination (RXGY-E02A and

RXGY-E03A) . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

19-22

Options 8 & 9:Sidewall Vent Kit for Direct Vent

Termination (RXGY-G02 & RXGY-G01) . . . . . . 64

Direct Venting Termination Clearances . . . . . . . . 65

Multiventing of Direct Vent Furnaces . . . . . . . . . . 66

8 CONDENSATE DRAIN AND DRAIN

NEUTRALIZER . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9 GAS SUPPLY AND PIPING

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

10 LP CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . 74

11 Setting the Gas Pressure. . . . . . . . . . . . . . . . . . . . 75

12 ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . 76

Reversing the Electrical Connection . . . . . . . . . . . . 76

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

13 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Electronic Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . 78

Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

14 TWINNING (NOT PERMITTED) . . . . . . . . . . . . . . . 78

15 HIGH ALTITUDE INSTALLATIONS . . . . . . . . . . . . 80

Natural Gas at High Altitudes . . . . . . . . . . . . . . . . . . 80

LP Gas at High Altitudes. . . . . . . . . . . . . . . . . . . . . . 82

16 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

17 SEQUENCE OF OPERATIONS . . . . . . . . . . . . . . . 83

18 INTEGRATED FURNACE CONTROL . . . . . . . . . . 84

19 HUMIDIFICATION/DEHUMIDIFICATION . . . . . . . . 86

20 DIPSWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

21 MODEL DATA CARD. . . . . . . . . . . . . . . . . . . . . . . . 92

22 DUAL 7-SEGMENT DISPLAY. . . . . . . . . . . . . . . . . 92

23 PUSHBUTTON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

24 SUPPLY & OUTDOOR AIR TEMP SENSORS. . . . 97

25 AUXILIARY INPUTS . . . . . . . . . . . . . . . . . . . . . . . . 98

26 THERMOSTAT WIRING DIAGRAMS . . . . . . . . . . . 99

Communicating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Legacy (Non-Communicating) . . . . . . . . . . . . . . . . 101

27 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

28 TIMING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . 103

29 ADJUSTING AND CHECKING FURNACE

INPUT RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

30 SETTING INPUT RATE . . . . . . . . . . . . . . . . . . . . . 104

31 AIRFLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

32 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 107

33 REPLACEMENT PARTS. . . . . . . . . . . . . . . . . . . . 107

34 DIAGNOSTICS AND TROUBLESHOOTING . . . . 108

Normal Operation Codes . . . . . . . . . . . . . . . . . . . . 108

Fault Codes with Descriptions and Solutions . . . . 109

Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Replacing the Furnace Control. . . . . . . . . . . . . . . . 118

Diagnosing Blower Motor Issues . . . . . . . . . . . . . . 119

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . 121

Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

GENERAL INFORMATION

OTE: A heat loss calculation should be performed to

properly determine the required furnace BTU size for the structure. Also, the duct must be properly designed and installed for proper airflow. Existing ductwork must be inspected for proper size and to make sure that it is properly sealed. Proper airflow is necessary for both user comfort and equipment performance.

Before opening the furnace carton, verify that the data tags on the carton specify the furnace model number that was ordered from the distributor and are correct for the installation. If not, return the unit without opening the carton. If the model number is correct, open the carton and verify that the furnace rating label specifies the same furnace model number that is specified on the carton label. If the model numbers do not match, return the furnace to the distributor.

IMPORTANT: Proper application, installation and maintenance of this furnace and system is a must if consumers are to receive the full benefits for which they have paid.

The (-)96V and (-)(-)96MDV series furnaces are designcertified by CSA for use with natural and propane gases as follows:

FIGURE 1

FURNACE COMPONENTS

1. As non-direct vent central forced air furnaces taking ombustion air from the installation area or using air

ucted from the outside.

General Information

2. As direct vent central forced air furnaces with all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions.Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code” (NFPA54) or, for Canada, CSA B149.1; Canadian Natural Gas and Propane Installation Code and requirements or codes of the local utilities or other authorities having jurisdiction. This is available from the following:

National Fire Protection Association, Inc. Batterymarch Park Quincy, MA 02269

CSA-INTERNATIONAL 5060 Spectrum Way Mississauga, Ontario Canada L4W5N6 Online: www.csa.ca

ITEM

NO. DESCRIPTION

1 CONDENSATE TRAP 2 DOOR SWITCH 3 JUNCTION BOX 4 TRANSFORMER 5 WATER SENSOR (2) 6 PRESSURE SWITCHES,

HIGH & LOW STAGE 7 EXHAUST TRANSITION 8 COUPLING (ELBOW TO TRANSITION) 9 EXHAUST

10 SHIPPING PLUG 11 FLAME SENSOR 12 OVER TEMPERATURE SWITCH 13 TOP PLATE 14 BURNER 15 IGNITER 16 COMBUSTION AIR INLET 17 GAS VALVE 18 INDUCED DRAFT BLOWER (IDB) 19 POWER FACTOR CORRECTION CHOKE

(PFC) (NOT USED ON THE 42KBTU,

56KBTU AND 70KBTU)

20 CONTROL MOUNTING PLATE 21 BLOWER 22 LOW VOLTAGE TERMINAL 23 COUPLING (IDB TO ELBOW) 24 FURNACE CONTROL

ST-A1205-01

GENERAL INFORMATION (cont.)

In Canada installations must comply with CSA B149.1.

Install units in Canada in accordance with CSA-B149, local installation codes and authorities having jurisdiction.

SA-B149.1 is available from:

CSA INTERNATIONAL 5060 Spectrum Way Mississauga, Ontario Canada L4W 5N6

online: www.csa.ca

General Information

NOTICE: Any equipment immersed in water (including by flooding) must be replaced. Equipment and products immersed in water will have operation adversely affected thereby voiding the warranty.

RECEIVING

Immediately upon receipt, all cartons and contents should be inspected for transit damage. Units with damaged cartons should be opened immediately. If damage is found, it should be noted on the delivery papers, and a damage claim filed with the last carrier.

• After unit has been delivered to job site, remove carton taking care not to damage unit.

• Check the unit rating plate to be sure equipment matches job specifications.

• Read the entire instructions before starting the installation.

• Install the unit in such a way as to allow necessary access for service.

• Always remove the solid metal base pan from the top of the furnace. The base pan is installed in this location for shipping purposes only and should never remain in the as-shipped location after installation.

• Install the unit with a 1/4” to 1/2” forward slope (toward front) to ensure proper drainage.

• Install the unit in accordance with any local code which may apply and the national codes. Latest editions are available from: “National Fire Protection Association, Inc., Batterymarch Park, Quincy, MA 02269.” These publications are:

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

Code.

• NFPA90A Installation of Air Conditioning and Ventilat-

ing Systems.

• NFPA90B Installation of warm air heating and air con-

ditioning systems.

• In Canada CSA 22.2 Canadian Electrical Code.

• In Canada CSA B149.1; Canadian Natural Gas and

Propane Installation Code.

CALIFORNIA RESIDENTS ONLY

MPORTANT: All manufacturer products meet current

Federal OSHA Guidelines for safety. California Proposition 65 warnings are required for certain products, which are not covered by the OSHA standards.

California's Proposition 65 requires warnings for products sold in California that contain, or produce, any of over 600 listed chemicals known to the State of California to cause cancer or birth defects such as fiberglass insulation, lead in brass, and combustion products from natural gas.

All “new equipment” shipped for sale in California will have labels stating that the product contains and/or produces Proposition 65 chemicals. Although we have not changed our processes, having the same label on all our products facilitates manufacturing and shipping. We cannot always know “when, or if” products will be sold in the California market.

You may receive inquiries from customers about chemicals found in, or produced by, some of our heating and airconditioning equipment, or found in natural gas used with some of our products. Listed below are those chemicals and substances commonly associated with similar equipment in our industry and other manufacturers.

• Glass Wool (Fiberglass) Insulation

• Carbon Monoxide (CO)

• Formaldehyde

• Benzene

More details are available at the Websites for OSHA (Occupational Safety and Health Administration), at www.osha.gov of Environmental Health Hazard Assessment), at www.oehha.org. Consumer education is important since the chemicals and substances on the list are found in our daily lives. Most consumers are aware that products present safety and health risks, when improperly used, handled and maintained.

and the State of California's OEHHA (Office

Installation Instructions remain with the furnace as a reference guide to the servicing contractor. We recommend that performance and installation data be recorded for future reference on this sheet to meet service and warranty

bligations so that job site information is available when required.

Installation Checklist

REFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

______ Correct pipe size (record size)

______ Correct supply pressure (during furnace operation)

______ (record pressure)

______ Manifold pressure (record upstream pressure)

______ No gas leaks

______ L.P. Kit Number (if applicable) (record kit number)

ELECTRICAL

______ 115 V.A.C. supply (Dedicated Circuit)

(record voltage)

______ Polarity observed

______ Furnace properly grounded

______ Correct wire size (record type and gauge)

FURNACE INSTALLATION

______ Correct clearance to combustibles (record

______ clearance)

______ Correct clearance for service (at front) (record

______ clearance)

DUCT STATIC PRESSURE

______ in. w.c. on heating speed (record static pressure)

______ in. w.c. on cooling speed (record static pressure)

______ Air temperature rise in heat (record air temperature

______ rise)

______ Air temperature rise in cool (record air temperature

______ rise)

______ ft. of pipe – exhaust pipe (record length)

______ no. of elbows – exhaust pipe (record number of

______ elbows)

______ Exhaust Vent Temperature (record temperature)

TERMINATIONS – DIRECT VENT

VERTICAL

______ Intake – 12" [305mm] min. above roof/snow level

(record height above anticipated snow level) or, in Canada, intake and exhaust vents conform with CSA B149.1; Canadian Natural Gas and Propane Installation Code

______ Correct relationship – exhaust to intake

HORIZONTAL/VERTICAL – CONCENTRIC (RXGY-E03A)

______ Intake – 12" [305mm] min. above roof/snow level

(record height above anticipated snow level) or, in Canada, intake and exhaust vents conform with CSA B149.1; Canadian Natural Gas and Propane Installation Code

______ Exhaust sloped down toward furnace

______ Correct distances (horizontal and vertical) –

exhaust to intake

______ 12" [305mm] min. above grade/snow level (record

height above anticipated snow level) or, in Canada, intake and exhaust vents conform with CSA B149.1; Canadian Natural Gas and Propane Installation Code

______ Above anticipated snow level (record maximum

______ anticipated snow level)

VENTING – NON-DIRECT VENT

______ in. diameter – exhaust pipe (record diameter)

______ ft. of pipe – exhaust (record length)

General Information

CONDENSATE LINE

______ Trap filled with water

______ Vented

______ Sloped toward drain

______ Condensate drain line hoses connected and

______ clamped

______ Freeze protection (if necessary)

VENTING – DIRECT VENT

______ in. diameter – intake pipe (record diameter)

______ in. diameter – exhaust pipe (record diameter)

______ ft. of pipe – intake air (record length)

______ no. of elbows – intake air (record number of

______ elbows)

______ no. of elbows (record number of elbows)

TERMINATION – NON-DIRECT VENT

VERTICAL

______ 12" [305mm] min. above roof/snow level (record

height above anticipated snow level) or, in Canada, intake and exhaust vents conform with CSA B149.1; Canadian Natural Gas and Propane Installation Code

HORIZONTAL – STANDARD

______ 12" [305mm] min. above grade/snow level (record

height above anticipated snow level) or, in Canada, intake and exhaust vents conform with CSA B149.1; Canadian Natural Gas and Propane Installation Code

SAFETY INFORMATION

WARNING

DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME. DOING SO COULD CAUSE FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

INSTALL THIS FURNACE ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS.

WARNING

IMPROPER INSTALLATION, OR INSTALLATION NOT MADE IN ACCORDANCE WITH THE CSA INTERNATIONAL (CSA) CERTIFICATION OR THESE INSTRUCTIONS, CAN RESULT IN UNSATISFACTORY OPERATION AND/OR DANGEROUS CONDITIONS AND ARE NOT COVERED BY THE MANUFACTURER’S WARRANTY.

Safety Information

WARNING

DO NOT BYPASS, JUMPER, OR REMOVE ANY SAFETY SWITCH FROM THE FURNACE CONTROL CIRCUIT. IF A SAFETY SWITCH CAUSES THE FURNACE TO SHUT DOWN OR OPERATE INTERMITTENTLY, IT IS AN INDICATION OF A POTENTIAL SAFETY HAZARD THAT MUST BE ADDRESSED BY A QUALIFIED TECHNICIAN, SERVICE AGENCY OR THE GAS SUPPLIER. DO NOT RESET SAFETY CONTROLS WITHOUT CORRECTIVE ACTION AND/OR VERIFICATION OF PROPER SAFE OPERATION BY A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER.

REPLACE ANY SAFETY CONTROL COMPONENT ONLY WITH IDENTICAL OEM REPLACEMENT PARTS. WHEN A NEW SAFETY SWITCH IS INSTALLED, IT MUST BE TESTED FOR A MINIMUM OF 15 MINUTES WITH THE FURNACE OPERATING AT MAXIMUM INPUT RATE AND WITH BOTH BLOWER AND BURNER DOOR INSTALLED. IF THE FURNACE IS INSTALLED IN A CLOSET, THE CLOSET DOOR MUST ALSO BE CLOSED FOR THIS TEST. REPEAT THE TEST AT THE MINIMUM INPUT RATE IF THE FURNACE IS A MULTI-STAGE FURNACE.

WARNING

USE ONLY WITH THE TYPE OF GAS APPROVED FOR THIS FURNACE. REFER TO THE FURNACE RATING PLATE.

WARNING

NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME. USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS, AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE INSTRUCTIONS.

WARNING

COMBUSTION AND VENTILATION AIR MUST BE PROVIDED TO THE FURNACE AS REQUIRED BY THE NATIONAL FUEL-GAS CODE (U.S.) AND CSA B149.1 (CANADA) AND THE COMBUSTION AND VENTILATION AIR SECTION OF THESE INSTRUCTIONS.

STI

WHEN A FURNACE IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BY THE FURNACE TO AREAS OUTSIDE THE SPACE CONTAINING THE FURNACE, THE RETURN AIR SHALL ALSO BE HANDLED BY DUCT(S) SEALED TO THE FURNACE CASING AND TERMINATING OUTSIDE THE SPACE CONTAINING THE FURNACE.

WHENEVER THE FACTORY RETURN-AIR CONNECTION IS NOT USED IT MUST BE SEALED. A SOLID METAL BASE PLATE MUST BE INSTALLED AND SEALED. FACTORY BASE PLATES ARE AVAILABLE AS ACCESSORY ITEMS. (PART NUMBERS ARE LISTED IN THE SPEC SHEET FOR THE FURNACE.) FAILURE TO INSTALL AND SEAL THE BASE PLATE AND RETURN AIR DUCT CONNECTIONS MAY ALLOW CARBON MONOXIDE AND OTHER CONTAMINANTS TO BE DRAWN INTO THE CONDITIONED AIR SPACE AND DISTRIBUTED THROUGHOUT THE HEATED SPACE.

DO NOT OPERATE THE SYSTEM WITHOUT FILTERS. A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPPLY REGISTERS. ANY CIRCULATED DUST PARTICLES WILL BE HEATED AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER. THIS SOOTY RESIDUE WILL SOIL CEILINGS, WALLS, DRAPES, CARPETS AND OTHER HOUSEHOLD ARTICLES. SOOT DAMAGE MAY ALSO RESULT WITH, OR WITHOUT, FILTERS IN PLACE, WHEN CERTAIN TYPES OF CANDLES ARE BURNED, OR CANDLEWICKS ARE LEFT UNTRIMMED.

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER THIS FURNACE AND ANY INSTALLED EVAPORATOR COIL THAT IS LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGE TO THE BUILDING OR BUILDING CONTENTS MAY OCCUR AS A RESULT OF AN OVERFLOW OF THE FURNACE CONDENSATE DISPOSAL SYSTEM OR THE COIL DRAIN PAN OR A STOPPAGE IN THE PRIMARY CONDENSATE DRAIN PIPING.

LLA

WARNING

VEN C

SAFETY

WARNING

ALWAYS INSTALL THE FURNACE TO OPERATE WITHIN THE FURNACE’S INTENDED TEMPERATURE-RISE RANGE WITH A DUCT SYSTEM WHICH HAS AN EXTERNAL STATIC PRESSURE WITHIN THE ALLOWABLE RANGE, AS SPECIFIED IN THE DUCTING SECTION OF THESE INSTRUCTIONS. SEE ALSO FURNACE RATING PLATE.

THE FURNACE MAY BE USED FOR HEATING OF BUILDINGS OR STRUCTURES UNDER CONSTRUCTION.

INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

PROPER VENT INSTALLATION;

FURNACE OPERATING UNDER THERMOSTATCONTROL; RETURN AIR DUCT SEALED TO THE FURNACE;

AIR FILTERS IN PLACE;SET FURNACE INPUT RATE AND TEMPERATURERISE PER RATING PLATE MARKINGS; MEANS FOR PROVIDING OUTDOOR AIR RE-

QUIRED FOR COMBUSTION; RETURN AIR TEMPERATURE MAINTAINED BE-

TWEEN 55°F (13°C) AND 80°F (27°C); AND CLEAN FURNACE, DUCT WORK AND COMPO-

NENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY THAT THE FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE, TEMPERATURE RISE AND VENTING, ACCORDING TO THE INSTRUCTIONS AND CODES.

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY

Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality, it is important to have the proper balance between the air supplied to each room and the air returning to the cooling and heating equipment.

Proper balance and sealing of the duct system improves the efficiency of the heating and air conditioning system and improves the indoor air quality of the home by reducing the amount of airborne pollutants that enter homes from spaces where the ductwork and / or equipment is located. The manufacturer and the U.S. Environmental Protection Agency’s Energy Star Program recommend that central duct systems be checked by a qualified contractor for proper balance and sealing.

WARNING

DUCT LEAKS CAN CREATE AN UNBALANCED SYSTEM AND DRAW POLLUTANTS SUCH AS DIRT, DUST, FUMES AND ODORS INTO THE HOME CAUSING PROPERTY DAMAGE. FUMES AND ODORS FROM TOXIC, VOLATILE OR FLAMMABLE CHEMICALS, AS WELL AS AUTOMOBILE EXHAUST AND CARBON MONOXIDE (CO), CAN BE DRAWN INTO THE LIVING SPACE THROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH (SEE FIGURE 2).

• IF AIR-MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN GARAGES OR OFF-GARAGE STORAGE AREAS - ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST BE SEALED TO LIMIT THE MIGRATION OF TOXIC FUMES AND ODORS INCLUDING CARBON MONOXIDE FROM MIGRATING INTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT OR DUCTWORK IS LOCATED IN SPACES CONTAINING FUEL BURNING APPLIANCES SUCH AS WATER HEATERS OR BOILERS ALL JOINTS, SEAMS, AND OPENINGS IN THE EQUIPMENT AND DUCT MUST ALSO BE SEALED TO PREVENT DEPRESSURIZATION OF THE SPACE AND POSSIBLE MIGRATION OF COMBUSTION BYPRODUCTS INCLUDING CARBON MONOXIDE INTO THE LIVING SPACE.

WARNING

BLOWER AND BURNERS MUST NEVER BE OPERATED WITHOUT THE BLOWER DOOR IN PLACE. THIS IS TO PREVENT DRAWING GAS FUMES (WHICH COULD CONTAIN HAZARDOUS CARBON MONOXIDE) INTO THE HOME THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

FIGURE 2

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

Safety Information

Adapted from Residential Duct Diagnostics and Repair, with permission of Air Conditioning Contractors of America (ACCA).

COMMONWEALTH OF MASSACHUSETTS NOTE

IMPORTANT! THE COMMONWEALTH OF MASSACHUSETTS REQUIRES COMPLIANCE WITH REGULATION 248 CMR 4.00 AND 5.00 FOR INSTALLATION OF THROUGH-THE-WALL VENTED GAS APPLIANCES AS FOLLOWS:

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal

vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall ob-

Safety Information

serve that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS.

Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP

CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the

ide wall horizontally vented gas fueled equipment shall

s not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

1/4" MIN. TO 1/2" MAX. TILT

TOWARD THE FRONT

OF THE CABINET IN ALL

INSTALLATIONS AND

ORIENTATIONS

1/4" MIN. TO 1/2" MAX. TILT

TOWARD THE FRONT

OF THE CABINET IN ALL

INSTALLATIONS AND

ORIENTATIONS

UPFLOW / DOWNFLOW

HORIZONTAL (LEFT OR RIGHT)

GENERAL INFORMATION

1. IMPORTANT: If installing the unit over a finished ceil-

2. IMPORTANT: If using a cooling evaporator coil with

If these are manual dampers, they must be equipped to prevent heating or cooling operation unless the damper is in the full heat or cool position.

3. IMPORTANT: Furnace must be installed level from

NOTE: These furnaces are approved for installation in attics, as well as alcoves, utility rooms, closets and crawlspaces. Provisions must be made to prevent freezing of condensate.

FREEZE PROTECTION

For installations where the furnace may reach temperatures below 32°F (0°C) (such as an alcove or attic installation), the installer must take precautions to ensure that the drain trap and connected drain pipe do not freeze. Local codes and practices should be followed in order to prevent freezing.

If the drain trap is installed within the furnace cabinet, no freeze protection is required. When the trap is mounted outside or partially outside the cabinet, it must be pro-

LOCATION REQUIREMENTS

WARNING

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES [450MM] ABOVE THE FLOOR. THIS IS TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO, THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES. FAILURE TO FOLLOW THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

ing or living area, be certain to install an auxiliary condensate drain pan under the entire unit. This auxiliary drain pan should extend under any evaporator coil installed with the furnace and the open portion of the condensate drain assembly. See “Condensate Drain/Neutralizer” section for more details.

this furnace, be sure the air passes over the heat exchanger before passing over the cooling coil. The cooled air passing over the warm ambient air inside the heat exchanger tubes can cause condensation inside the tubes resulting in corrosion and eventual failure.

front-to-back or with a slight tilt such that the back of the furnace is up to 1/2” higher than the front of the furnace as shown in Figure 3.

ected from freezing. Regardless of the location of the

t drain trap, any exposed drain piping must be protected from freezing as required by local practices or codes. A UL or CSA listed heat tape or UL or CSA approved heating cable with a rating of 3-6 watts per foot is acceptable protection when installed and maintained in accordance with the manufacturer’s instructions. Good installation practices necessitate that the installer verify heat tape operation in accordance with the manufacturer’s instructions at the time of installation.

IMPORTANT: Support this unit when installed. Since this furnace is suitable for attic or crawl space installation, it may be installed on combustible wood flooring or by using support brackets.

FIGURE 3

BACK FRONT

0-1/2 HIGHER

THAN FRONT OF FURNACE

BACK FRONT

0-1/2 HIGHER

THAN FRONT

OF FURNACE

ST-A1194-13-X0

Location

NOTE:

HORIZONTAL LEFT ORIENTATION DEPICTED IN ILLUSTRATION. HORIZONTAL RIGHT ORIENTATION IS SIMILAR IN INSTALLATION.

OPTION - B

2” - 3” PIPE

OPTION - A

2” PIPE

8”

6”

LOCATION REQUIREMENTS

GENERAL INFORMATION (cont.)

WARNING

THIS FURNACE IS NOT APPROVED OR RECOMMENDED FOR INSTALLATION ON ITS BACK, WITH ACCESS DOORS FACING UPWARDS.

SITE SELECTION

1. Select a site in the building near the center of the proposed, or existing, duct system.

2. Give consideration to the vent system piping when selecting the furnace location. Be sure the venting system can get from the furnace to the termination with minimal length and elbows.

3. Locate the furnace near the existing gas piping. Or, if running a new gas line, locate the furnace to minimize the length and elbows in the gas piping. See Figure 5.

4. Locate the furnace to maintain proper clearance to combustibles as shown in following Figure 6.

WARNING

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

CLEARANCE – ACCESSIBILITY

Location

The design of forced air furnaces with input ratings as listed in the tables under Figure 6 are certified by CSA-International for the clearances to combustible materials shown in inches.

See name/rating plate and clearance label for specific model number and clearance information.

Service clearance of at least 24 inches (30 cm) is recommended in front of all furnaces.

NOTE: Use recommended 24” (30 cm) clearance if accessibility clearances are greater than fire protection clearances.

For downflow non-zero clearance furnace installations, the minimum clearance required on the right side of the furnace is shown in Figure 4. If this clearance cannot be maintained, a downflow zero-clearance kit; RXGY-ZK will need to be installed.

WARNING

UPFLOW FURNACES ARE DESIGNINSTALLATION ON COMBUSTIBLE FLOORS. NOTE, HOWEVER, THAT FURNACES MUST NOT BE INSTALLED DIRECTLY ON CARPETING, TILE OR OTHER COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING. INSTALLATION ON A COMBUSTIBLE MATERIAL CAN RESULT IN FIRE, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET. THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. PLACEMENT OF COMBUSTIBLE MATERIALS ON, AGAINST OR AROUND THE FURNACE JACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THE HOMEOWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES.

FIGURE 4

NOTE: These

dimensions refer to furnace clearance only. For required vent clearances and supports, refer to vent manufacturer’s instructions.

NOTE: THESE ILLUSTRATIONS ARE INTENTIONALLY GENERIC.

NOTE: SOME PARTS OF YOUR FURNACE MAY APPEAR DIFFERENT.

FIGURE 5

CLEARANCE FLUE VENT TO WALL

”

ST-A1194-40-X0

”

CERTIFIED FOR

ST-A1194-05-X0

FIGURE 6

TOPBOTTOM

FRONTLEFT SIDE RIGHT SIDE

RIGHT BACK TOP FRONT VENT

(-)96VA040

(-)(-)96MDV040

(-)96VA060

(-)(-)96MDV060

(-)96VA070

(-)(-)96MDV070

(-)96VA085

(-)(-)96MDV085

(-)96VA100

(-)(-)96MDV100

(-)96VA115

(-)(-)96MDV115

0 0 0 1 2 0

SHIPPING

WEIGHTS

MINIMUM CLEARANCE (IN.)

MODEL

LEFT

SIDE

UNIT DIMENSIONS

(CLEARANCE TO COMBUSTIBLES)

.62

34.00

23.33

25.44

26.19

22.63

25.81

26.31

8.00

11.03

17.50

18.13

26.11

29.05

32.65

24.19

22.31

OPTIONAL TRAP

LOCATION

(HORIZONTAL)

OPTIONAL CONDENSATE

DRAIN (DOWNFLOW)

GAS

CONNECTION

OPTIONAL COMBUSTION

VENT LOCATION

OPTIONAL TRAP

LOCATION

(HORIZONTAL)

OPTIONAL VENT

AIR INLET

CONDENSATE DRAIN

(UPFLOW)

ELECTRICAL CONNECTION

LINE VOLTAGE

ELECTRICAL CONNECTION

LOW VOLTAGE

22.96

23.80

8.00

11.00

17.44

29.05

26.17

32.88

23.00

14.00

28.06

1.12

29.62

.62

19.83

OPTIONAL LINE VOLTAGE

WIRING

OPTIONAL LOW VOLTAGE

WIRING

OPTIONAL CONDENSATE

DRAIN (UPFLOW)

TRAP LOCATION

(HORIZONTAL)

OPTIONAL

GAS CONNECTION

OPTIONAL

CONDENSATE DRAIN

(DOWNFLOW)

1.76

1.66

24.86

26.26

19.83

SUPPLY

AIR

23.21

1.62

1.67

24.91

.30

19.77

.65

RETURN

AIR

OPTIONAL

VENT OUTLET

KNOCKOUT

OPTIONAL COMBUSTION

AIR INLET KNOCKOUT

SUPPLY AND RETURN DEPICTED AS UPFLOW CONFIGURATION.

FLANGE CONFIGURATION WILL VARY DEPENDING ON INS TALLATION ORIENTATION.

A B C

17 1/2 16 17/64 16 13/64

21 19 49/ 64 19 45/64

24 1/2 23 17/64 23 13/64

FLANGE DIMENSIONS

*A SERVICE CLEARANCE OF AT LEAST 24” IS RECOMMENDED IN FRONT OF ALL FURNACES

0 0 0 1 2 0

UNIT DIMENSIONS (CLEARANCE TO COMBUSTIBLES)

ST-A1194-01-X0

Location

FIELD CONVERSIONS

CONDENSATE PVC/HOSE OPTIONS

BULKHEAD COUPLING

CONDENSATE DRAINIAGE HAS OPTIONS FOR 3/4" OR 1/2" PVC CONNECTIONS. THE BULKHEAD COUPLING CONNECTS THE RUBBER HOSES FROM INSIDE THE UNIT TO THE PVC PIPE EXTERIOR OF THE UNIT. PVC PIPE CAN BE CEMENTED DIRECTLY TO THE COUPLING AND THE TRAP WITH PROPER PVC CEMENT AND PRIMER.

/2" PVC

IPE

3/4" PVC

TEE

RUBBER HOSE CONNECTION

PVC FITTING/PIPE

3/4" PVC

OUPLING

IN ADDITION TO PVC CONNECTIONS, THE CONDENSATE TRAP CAN ACCOMODATE A 5/8" RUBBER HOSE WITH A HOSE CLAMP WHEN LOCATED INSIDE THE UNIT. PLIERS ARE NECCESSARY TO ADD OR REMOVE CLAMP.

NOTE: IMPROPER HOSE CONNECTIONS WILL PREVENT CONDENSATE FROM DRAINING.

CONDENSATE TRAP

THE CONDENSATE TRAP HAS 2 SIDES PLEASE NOTE THEIR LOCATIONS FOR DRAIN CONNECTIONS DURING CONVERSION.

OUT TO DRAIN

COLLECTOR BOX

IN FROM

IN FROM FLUE

ELBOW OR COUPLING

1/4" VENT IN

FROM COLLECTOR BOX

GENERAL CONVERSION INSTRUCTIONS

ST-A1194-37-01

-2010°

CONVERSION AND INSTALLATION

ONSIDERATIONS

ALL CONVERSIONS REQUIRE THE CONDENSATE PLUMBING TO HAVE DECLINE IN THE DIRECTION OF THE WATER FLOW.

WHEN INSTALLING AND MOVING CONDENSATE PLUMBING THE HOSES SHOULD BE FREE OF KINKS FOR PROPER WATER FLOW.

WHEN DRAIN HOSE OR CONDENSATE TRAP HOSE ROUTING CHANGES ARE NECESSARY BE SURE TO PLUG OR CAP ANY UNUSED HOSE TAPS.

THE INDUCER COUPLING COMES FROM THE FACTORY WITH A 10

TILT FOR UP FLOW INSTALLATIONS. WHEN CONVERTED TO DOWN FLOW THE COUPLING REQUIRES A ROTATION A MINIMUM OF 10

FROM HORIZONTAL AS SHOWN.

HORIZONTAL INSTALLATIONS REQUIRE CONDENSATE TRAP TO BE MOUNTED EXTERNALLY BELOW THE UNIT:

-USE CAUTION-MOUNT THE TRAP AFTER THE UNIT IS AT THE POINT OF INSTALLATION TO PREVENT DAMAGE TO THE TRAP DURING TRANSPORT.

-HAND TIGHTEN SCREWS WHEN MOUNTING THE TRAP OR THE BULKHEAD COUPLING TO THE CABINET TO PREVENT DAMAGE TO THE MOUNTING FLANGE.

-USE PROPER FREEZE PROTECTION IF REQUIRED.

-ALLOW MINIMUM OF 6" BELOW THE FURNACE FOR CLEARANCE.

10-20°

TILT ON INDUCER COUPLING

GROUND

LEVEL

MIDLINE

WORM DRIVE

CLAMP

COUPLING

THE WORM DRIVE FOR THE HOSE CLAMPS USED ON THE FLUE TRANSITION COUPLING OR THE IDB COUPLING MUST BE ABOVE THE LEVEL MIDLINE WHEN IN THE HORIZONTAL POSITION AS DETAILED HERE.

IF THE IDB COUPLING IS REMOVED, IT MUST BE REPLACED IN THE PROPER ORIENTATION. AN ARROW IS PRESENT ON THE COUPLING TO INDICATE THE DIRECTION OF EXHAUST FLOW. MAKE SURE THE ARROW POINTS IN THE CORRECT DIRECTION.

NOTE:

Field Conversions

FIELD CONVERSIONS

PARTS BAG (PROVIDED WITH UNIT)

CONVERSION KIT RXGY-CK

CONVERSION KIT RXGY-ZK

(X2)

2-5/8" FLUSH

MOUNT PLUG

1/2" DRAIN

HOSE E

INTAKE

OUPLING

.559" CONDENSATE

TRAP DRAIN PLUG

#8 X 1/2"

SCREW

(X2)

INTAKE

PIPE

1/4" BLACK

VENT TUBE

BULKHEAD COUPLING

HOSE DOUBLE ELBOWTUBE C

HOSE CLAMP

INTAKE AIR

DIFFUSER

#8 X 1/2"

SCREW

(

X4)

#8 X 1/2"

SCREW

(X10)

5/8" DRAIN

HOSE B

CONDENSATE TRAP

BRACKET (DOWN FLOW)

2" PVC VANE

1/4" HOLE

PLUG

1/2" DRAIN

HOSE F

1/2" DRAIN

HOSE G

CONDENSATE TRAP GASKET

2" PIPE GROMMET

(

3.375)

1/2" VINYL

CAP (YELLOW)

PIPE COLLAR

GASKET ASSEMBLY

(X2)

ST-A1194-38-03

GENERAL PARTS REQUIRED FOR CONVERSIONS

(X3)

FLUE PIPE ASSEMBLY W/ O-RING

O-RING

Field Conversions

SEE NEXT PAGE FOR APPLICABLE CONFIGURATIONS

FIELD CONVERSIONS

AIRFLOW

FIELD CONVERSION TO VARIOUS CONFIGURATIONS

Furnaces can be converted in the field from upflow (as-shipped) to downflow, horizontal left or horizontal right as necessary. In addition, there are different venting options, including a zero-clearance option, to give the installer flexibility in locating the venting for this furnace.

LISTS OF MATERIALS FOR PARTS BAGS AND CONVERSION KITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 12

GENERAL CONVERSION INSTRUCTIONS AND TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 13

UPFLOW WITH VERTICAL VENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 15-16

UPFLOW WITH LEFT SIDE VENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 17-18

(REQUIRES CONVERSION KIT RXGY-CK)

DOWNFLOW WITH RIGHT VENT (NON-ZERO CLEARANCE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 19-22

(REQUIRES CONVERSION KIT RXGY-CK)

DOWNFLOW ZERO-CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 23-27

(REQUIRES CONVERSION KIT RXGY-CK AND ZEROCLEARANCE KIT RXGY-ZK)

HORIZONTAL RIGHT WITH RIGHT VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 28-30

(REQUIRES CONVERSION KIT RXGY-CK)

HORIZONTAL RIGHT WITH VERTICAL VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 31-33

(REQUIRES CONVERSION

Field Conversions

KIT RXGY-CK)

HORIZONTAL LEFT WITH RIGHT VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 34-38

(REQUIRES CONVERSION

KIT RXGY-CK AND ZERO-

CLEARANCE KIT RXGY-ZK)

HORIZONTAL LEFT WITH LEFT VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg 39-41

(REQUIRES CONVERSION

KIT RXGY-CK)

IRFLOW

AIRFLOW

TUBE C

CUT TO FIT

CABINET WIDTH

NOTE: PLIERS NECCESSARY TO ADD OR REMOVE CLAMPS

4b - RIGHT SIDE DRAIN OPTION

4b1 - CUT TUBE “C” TO FIT CORRESPONDING CABINET WIDTH. 4b2 - INSERT TUBE “C” INTO END “2” OF HOSE- DOUBLE ELBOW 4b3 - SLIDE TWO WIRE CLAMPS OVER TUBE “C”, SLIDE ONE WIRE CLAMP OVER END “1” OF HOSE - DOUBLE ELBOW. 4b4 - INSTALL TUBE “C” WITH HOSE CLAMP AS SHOWN TO HOSE “A” “PRE ASSEMBLED”. 4b5 - ATTACH HOSE - DOUBLE ELBOW TO BULKHEAD COUPLING POSITION WIRE HOSE CLAMP.

HOSE A

TUBE C

HOSE A

4a - LEFT SIDE DRAIN OPTION

ATTACH HOSE A (PRE-INSTALLED) TO BULKHEAD COUPLING. INSTALL HOSE CLAMP ON HOSE OVER BULK HEAD COUPLING.

INSTALL BULKHEAD COUPLING USING (2) SCREWS. INSTALL IN JACKET WITH THE BARBED FITTING POINTED INTO THE VESTIBULE.

INSTALL

OPTION DRAIN RIGHT

DETERMINE RIGHT OR LEFT DRAIN OPTION. LOCATE 7/8" HOLE IN JACKET SIDE. REMOVE PLUG - DISCARD. DRILL (2) Ø 1/8" HOLES FOR THE BULKHEAD COUPLING.

DRILL 1/8”

/8” PLUG

ISCARD

OPTION DRAIN LEFT

7/8” PLUG

DISCARD

INSTALL INTAKE COUPLING IN TOP PLATE.

INSTALL

UPFLOW VERTICAL VENT

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

ST-A1194-28-03

PARTS NEEDED:

PARTS NEEDED FOR THIS CONVERSION REQUIRE ITEMS FROM THE PARTS BAG ONLY. NO OTHER CONVERSION KITS ARE NEEDED.

TUBE C

ULKHEAD

COUPLING

FROM PARTS BAG (PROVIDED WITH UNIT)

(X2)

#8 X 1/2"

SCREW

OSE

CLAMP

INTAKE

COUPLING

W/ NUT

DRILL

1/8" DRILL BIT

PLIERS

1/4" HEX HEAD DRIVER

TUBING CUTTER

TOOLS/MATERIALS NEEDED:

" * 3

- 0 8

(X3)

HOSE -

DOUBLE ELBOW

HOSE -

OUBLE ELBOW

Field Conversions

ST-A1194-28-03

Notes:

Checklist:

__ ALL DRAIN PORTS ARE PLUGGED

__ UNIT HAS FORWARD PITCH

__ HEAT TAPE INSTALLED(IF REQUIRED)

__ VERIFY ALL HOSES ARE SECURE AND FULLY SEATED.

__ CONFIRM THAT ALL HOSES ARE FREE OF KINKS

__ CONFIRM ALL HOSES AND OTHER DRAIN PARTS HAVE A SLOPE IN DIRECTION OF WATER FLOW

__ ALL CLAMPS AND COUPLINGS ARE TIGHTENED

Field Conversions

DRILL 1/8" DRILL BIT

PLIERS FLAT HEAD SCREWDRIVER

5/16 HEX HEAD DRIVER

1/4" HEX HEAD DRIVER

TUBING CUTTER

TOOLS/MATERIALS NEEDED:

UPFLOW LEFT VENT

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

ST-A1194-29-03

PARTS NEEDED:

(X2)

FROM PARTS BAG (PROVIDED W/UNIT)

INTAKE

COUPLING

W/ NUT

BULKHEAD

COUPLING

#8 X 1/2"

SCREW

TUBE C

HOSE

CLAMP

INSTALL BULKHEAD COUPLING USING (2) SCREWS. INSTALL IN JACKET WITH THE BARBED FITTING POINTED INTO THE VESTIBULE.

DETERMINE RIGHT OR LEFT DRAIN OPTION. LOCATE 7/8" HOLE IN JACKET SIDE. REMOVE PLUG - DISCARD. DRILL (2)

ø1/8" HOLES FOR THE BULKHEAD COUPLING.

DRILL 1/8”

DISCARD

OPTION DRAIN RIGHT

DRILL 1/8”

DISCARD

OPTION DRAIN LEFT

2a - INSTALL 2-5/8" FLUSH MOUNT PLUG IN TOP PLATE. 2b - INSTALL 2" PIPE GROMMET AS SHOWN. 2c - INSTALL INTAKE COUPLING AS SHOWN.

2-5/8”

1a - REMOVE FLUE TRANSITION, TRANSITION COUPLING, AND ELBOW.

(NOTE: REMOVE INDUCER COUPLING W/ELBOW FOR EASIER REMOVAL).

1b - REMOVE 3-3/8" FLUSH MOUNT PLUG FROM JACKET - DISCARD. 1c - RELOCATE 2-3/8" FLUSH MOUNT PLUG FROM JACKET TO TOP PLATE.

-LO

DISCARD

IDB COUPLING

(RETAIN)

FLUE TRANSITION (DISCARD)

TRANSITION COUPLING (DISCARD)

ELBOW (DISCARD)

FROM CONVERSION KIT RXGY-CK

2-3/8" PIPE

ROMMET

2-5/8" FLUSH MOUNT PLUG

PARTS NEEDED FOR THIS CONVERSION REQUIRE THE OUTLINED ITEMS FROM THE PARTS BAG AND CONVERSION KIT RXGY-CK. YOU MUST HAVE THESE PARTS BEFORE PROCEEDING.

" * 3 '

- 0 8

NOTE:

(X3)

HOSE -

DOUBLE

ELBOW

SEE CRITICAL HOSE CLAMP LOCATION NOTE IN THE GENERAL COVERSION INSTRUCTIONS.

Field Conversions

(

X3)

HOSE A

UBE C

UT TO FIT

CABINET WIDTH

HOSE A

a - LEFT SIDE DRAIN OPTION

ATTACH HOSE A (PRE-INSTALLED) TO BULKHEAD COUPLING. P

LACE CLAMP OVER HOSE ON BULKHEAD COUPLING.

Checklist:

ST-A1194-29-03

Notes:

NOTE: PLIERS NECCESSARY TO ADD OR REMOVE CLAMPS

HOSE -

DOUBLE ELBOW

5b - RIGHT SIDE DRAIN OPTION

5b1 - CUT TUBE “C” TO FIT CORRESPONDING CABINET WIDTH. 5b2 - INSERT TUBE “C” INTO END “2” OF HOSE- DOUBLE ELBOW 5b3 - SLIDE TWO WIRE CLAMPS OVER TUBE “C”, SLIDE ONE WIRE CLAMP OVER END “1” OF HOSE - DOUBLE ELBOW. 5b4 - INSTALL TUBE “C” WITH HOSE CLAMP AS SHOWN TO HOSE “A” “PRE ASSEMBLED”. 5b5 - ATTACH HOSE - DOUBLE ELBOW TO BULKHEAD COUPLING POSITION WIRE HOSE CLAMP.

__ VERIFY ALL HOSES ARE SECURE AND FULLY SEATED.

__ CONFIRM THAT ALL HOSES ARE FREE OF KINKS.

__ CONFIRM ALL HOSES AND OTHER DRAIN PARTS HAVE A SLOPE IN DIRECTION OF WATER FLOW

__ BOTH WORM DRIVES ON THE HOSE CLAMPS OF THE IDB COUPLING MUST BE LOCATED ON THE TOP OF THE COUPLING. SEE LOCATION DETAIL IN THE GENERAL CONVERSION INSTRUCTIONS AT THE BEGINNING OF THIS SECTION.

__ ALL CLAMPS AND COUPLINGS ARE TIGHTENED

__ ALL DRAIN PORTS ARE PLUGGED

__ UNIT HAS FORWARD PITCH

__ HEAT TAPE INSTALLED(IF REQUIRED)

Field Conversions

DOWNFLOW W/ RIGHT VENT (NON-ZERO CLEARANCE)

PARTS NEEDED FOR THIS CONVERSION REQUIRE ITEMS

DOWNFLOW W/ RIGHT VENT (NON-ZERO CLEARANCE)

PARTS NEEDED FOR THIS CONVERSION REQUIRE ITEMS

DOWNFLOW W/ RIGHT VENT (NON-ZERO CLEARANCE)

PARTS NEEDED FOR THIS CONVERSION REQUIRE ITEMS

DOWNFLOW W/ RIGHT VENT (NON-ZERO CLEARANCE)

PARTS NEEDED:

(X2)

ROM PARTS BAG (PROVIDED WITH UNIT)

(X3)

FROM THE YOU MUST HAVE THE PARTS OUTLINED BELOW BEFORE PROCEEDING.

PARTS NEEDED:

ROM PARTS BAG (PROVIDED WITH UNIT)

FROM THE PARTS BAG AND CONVERSION KIT YOU MUST HAVE THE PARTS OUTLINED BELOW BEFORE PROCEEDING.

HOSE -

OUBLE

ELBOW

AND CONVERSION KIT RXGY-CK.

YOU MUST HAVE THE PARTS OUTLINED BELOW BEFORE

FROM CONVERSION KIT RXGY-CK

2-5/8" FLUSH

2" PIPE GROMMET

#8 X 1/2"

SCREW

HOSE

CLAMP

FROM CONVERSION KIT RXGY-CK

2-5/8" FLUSH

8 X 1/2"

SCREW

(X4)

TUBE C

CONDENSATE TRAP DRAIN PLUG .559”

COUPLING

INTAKE AIR

DIFFUSER

CONDENSATE

TRAP BRACKET

INTAKE

COUPLING

W/ NUT

BULKHEAD COUPLING

1/4" BLACK

CONDENSATE

TRAP BRACKET

NOTE: STEPS 1- 5 SHOWN WITH FURNACE IN “AS SHIPPED CONDITION”

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

DRILL (1) 1/8" DRILL BIT

TOOLS/MATERIALS NEEDED:

2-5/8" FLUSH

MOUNT PLUG

(

3.375)

NOTE: STEPS 1- 5 SHOWN WITH FURNACE IN “AS SHIPPED CONDITION”

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

(1) 3/16" DRILL BIT PLIERS

TOOLS/MATERIALS NEEDED:

2-5/8" FLUSH

MOUNT PLUG

NOTE: STEPS 1- 5 SHOWN WITH FURNACE IN “AS SHIPPED CONDITION”

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

(1) 1/4" HEX HEAD DRIVER (1) 5/16 HEX HEAD DRIVER

TOOLS/MATERIALS NEEDED:

5/8" DRAIN

HOSE B

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

FLAT HEAD SCREWDRIVER

TUBING CUTTER

TRAP BRACKET

(DOWN FLOW)

1/2" DRAIN

HOSE E

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

FLAT HEAD SCREWDRIVER

1/4" BLACK

VENT TUBE

TRAP BRACKET

(DOWN FLOW)

TRANSITION COUPLING (DISCARD)

FLUE TRANSITION (DISCARD)

ELBOW (DISCARD)

IDB COUPLING (RETAIN)

2-5/8"

TRANSITION COUPLING (DISCARD)

FLUE TRANSITION (DISCARD)

ELBOW (DISCARD)

IDB COUPLING (RETAIN)

2-5/8"

INSTALL

VENT HOSE (DISCARD)

HOSE “D” (RETAIN)

DISCARD

VENT HOSE (DISCARD)

HOSE “D” (RETAIN)

IF THE IDB COUPLING IS REMOVED, IT MUST BE REPLACED IN THE PROPER ORIENTATION. AN ARROW IS PRESENT ON THE COUPLING TO INDICATE THE DIREC-

NOTE:

IF THE IDB COUPLING IS REMOVED, IT MUST BE REPLACED IN THE PROPER ORIENTATION. AN ARROW IS PRESENT ON THE COUPLING TO INDICATE THE DIREC-

1a - REMOVE FLUE TRANSITION, TRANSITION COUPLING, AND ELBOW.

(NOTE: REMOVE COUPLING ON INDUCER WITH ELBOW FOR EASIER REMOVAL)

1b - REMOVE TRAP AND HOSES. RETAIN HOSE D FOR LATER USE.

(NOTE:TO REMOVE TRAP REMOVE (2) SCREWS AND PULL STRAIGHT OUT).

1a - REMOVE FLUE TRANSITION, TRANSITION COUPLING, AND ELBOW.

(NOTE: REMOVE COUPLING ON INDUCER WITH ELBOW FOR EASIER REMOVAL)

1b - REMOVE TRAP AND HOSES. RETAIN HOSE D FOR LATER USE.

(NOTE:TO REMOVE TRAP REMOVE (2) SCREWS AND PULL STRAIGHT OUT).

2a-REMOVE 3-3/8" FLUSH MOUNT PLUG FROM JACKET - DISCARD. 2b-RELOCATE 2-3/8" FLUSH MOUNT PLUG FROM JACKET TO TOP PLATE. 2c-RELOCATE 1/2" VINYL CAP (YELLOW) IN INDUCER COUPLING. 2d-INSTALL 2-5/8" FLUSH PLUG IN TOP PLATE.

1a - REMOVE FLUE TRANSITION, TRANSITION COUPLING, AND ELBOW.

(NOTE: REMOVE COUPLING ON INDUCER WITH ELBOW FOR EASIER REMOVAL).

1b - REMOVE TRAP AND HOSES. RETAIN HOSE D FOR LATER USE.

(NOTE:TO REMOVE TRAP REMOVE (2) SCREWS AND PULL STRAIGHT OUT).

TION OF EXHAUST FLOW. MAKE SURE THE ARROW POINTS IN THE CORRECT DIRECTION.

TION OF EXHAUST FLOW. MAKE SURE THE ARROW POINTS IN THE CORRECT

ST-A1194-30-02

2a-REMOVE 3-3/8" FLUSH MOUNT PLUG FROM JACKET - DISCARD. 2b-RELOCATE 2-3/8" FLUSH MOUNT PLUG FROM JACKET TO TOP PLATE. 2c-RELOCATE 1/2" VINYL CAP (YELLOW) IN INDUCER COUPLING.

Field Conversions

ST-A1194-30-02

ROTATE UNIT

5a - PRE-DRILL (2) Ø 3/16" HOLES IN JACKET AS SHOWN FOR CONDENSATE TRAP BRACKET. 5b - ROTATE UNIT 180°

DRILL (2)

Ø3/16" HOLES

.559

DRAIN PLUG

DISCARD

4a - REMOVE THE SMALL MOUNTING BRACKET AND THE .403" DRAIN PLUG - DISCARD. 4b - INSTALL THE DOWN FLOW CONDENSATE TRAP BRACKET WITH (2) SCREWS AS SHOWN. 4c - INSTALL .559" DRAIN PLUG IN THE CONDENSATE TRAP.

3a - RELOCATE .403" DRAIN PLUG IN THE COLLECTOR BOX. 3b - INSTALL 2" PIPE GROMMET 3c - INTAKE COUPLING IN JACKET AS SHOWN. 3d - INSERT AIR DIFFUSER INTO COUPLING UNTIL TABS ARE SEATED.

INSERT AIR DIFFUSER UNTIL TABS ARE FULLY SEATED

INSTALL

NOTE: DIFFUSER MAY HAVE A TENDENCEY TO FALL OUT OF THE COUPLING AT THIS STEP. THE INSTALLER MAY ELECT TO INSTALL THE DIFFUSER AFTER ROTATING THE FURNACE TO THE HORIZONTAL POSITION.

Field Conversions

9b - RIGHT SIDE DRAIN OPTION ATTACH HOSE A (FACTORY INSTALLED) TO BULKHEAD COUPLING.

OPTION

DRAIN RIGHT SIDE

HOSE A

ATTACH SIDE "2" TO BULKHEAD COUPLING

OPTION

DRAIN LEFT SIDE

TUBE C

CUT TO FIT

CABINET WIDTH

TUBE C

HOSE B

INSTALL BULKHEAD COUPLING USING (2) SCREWS. INSTALL IN JACKET WITH THE BARBED FITTING POINTED INTO THE VESTIBULE.

INSTALL

1/8" DRILL

DISCARD

7/8" PLUG

1/8" DRILL

DISCARD

7/8" PLUG

DETERMINE RIGHT OR LEFT DRAIN OPTION. LOCATE 7/8" HOLE IN JACKET SIDE AND REMOVE PLUG - DISCARD. DRILL (2)

1/8" HOLES FOR BULKHEAD COUPLING.

OPTION: RIGHT DRAIN

OPTION: LEFT DRAIN

HOSE E

HOSE D

6b - INSTALL CONDENSATE TRAP BY MOUNTING BRACKET TO JACKET USING (2) SCREWS 6c - CUT 1/4” VENT TUBE TO FIT (APPROX. 10-1/2"). INSTALL AS SHOWN. 6d - INSTALL HOSE D (REMOVED IN STEP 1) FROM INDUCER COUPLING TO THE FLUE TAP IN THE CONDENSATE TRAP. 6e - INSTALL HOSE E FROM COLLECTOR BOX TO TOP OF CONDENSATE TRAP.

-2010°

APPROXIMATELY 10-20° TILT

N INDUCER COUPLING

GROUND

ROTATE INDUCER COUPLING TO ENSURE DOWNWARD FLOW OF CONDENSATE FROM FLUE VENTING

OTE:

USE SOAPY WATER TO FACILITATE EASY

OSE AND TUBE ASSEMBLY

1/4” TUBE CUT

TO FIT (APPROX

10-1/2”)

ST-A1194-30-02

NOTE: REMAINING STEPS SHOWN WITH FURNACE IN DOWN FLOW ORIENTATION

EE CRITICAL HOSE CLAMP LOCATION NOTE

IN THE GENERAL COVERSION INSTRUCTIONS.

(X3)

9a - LEFT SIDE DRAIN OPTION.

9a-1 - REMOVE HOSE “A” (FACTORY INSTALLED) ON CONDENSATE TRAP & REPLACE WITH HOSE “B” REUSING SUPPLIED CLAMP. 9a-2 - CUT TUBE “C” ON MARKED LINES CORRESPONDING TO CABINET WIDTH. 9a-3 - SLIDE (2) WIRE CLAMPS OVER TUBE “C” AND (1) WIRE CLAMP OVER SIDE “2” OF HOSE-DOUBLE ELBOW. 9a-4 - CONNECT HOSE - DOUBLE ELBOW END “1” TO TUBE “C”, CONNECT END “2” TO BULKHEAD COUPLING. CONFIRM ALL (4) CLAMPS ARE PLACED CORRECTLY.

NOTE: PLIERS NECCESSARY TO ADD OR REMOVE CLAMPS

Field Conversions

ST-A1194-30-02

Notes:

Checklist:

__ VERIFY ALL HOSES ARE SECURE AND FULLY SEATED.

_ ALL DRAIN PORTS ARE PLUGGED

__ UNIT HAS FORWARD PITCH

__ HEAT TAPE INSTALLED(IF REQUIRED)

__ CONFIRM THAT ALL HOSES ARE FREE OF KINKS

__ CONFIRM ALL HOSES AND OTHER DRAIN PARTS HAVE A SLOPE IN DIRECTION OF WATER FLOW

__ BOTH WORM DRIVES ON THE HOSE CLAMPS OF THE IDB COUPLING MUST BE LOCATED ON THE TOP OF THE COUPLING. SEE LOCATION DETAIL IN THE GENERAL CONVERSION INSTRUCTIONS AT THE BEGINNING OF THIS SECTION

__ ALL CLAMPS AND COUPLINGS ARE TIGHTENED

__ DOUBLE CHECK DIFFUSER IS INSTALLED IN INTAKE COUPLING

Field Conversions

DOWN FLOW ZERO CLEARANCE

PARTS NEEDED FOR THIS CONVERSION REQUIRE ITEMS FROM THE PARTS BAG

DOWN FLOW ZERO CLEARANCE

PARTS NEEDED FOR THIS CONVERSION REQUIRE ITEMS

PARTS BAG, CONVERSION KIT RXGY-CK

DOWN FLOW ZERO CLEARANCE

PARTS NEEDED FOR THIS CONVERSION REQUIRE ITEMS

AND RXGY-ZK

FROM PARTS BAG(PROVIDED W/UNIT)

COUPLING

PARTS NEEDED:

FROM PARTS BAG(PROVIDED W/UNIT)

INTAKE

COUPLING

W/ NUT

BULKHEAD COUPLING

PARTS NEEDED:

FROM PARTS BAG(PROVIDED W/UNIT)

#8 X 1/2" SCREW

(X2)

HOSE

LAMP

PARTS NEEDED:

FROM THE PARTS BAG YOU MUST HAVE THE OUTLINED PARTS FROM THESE KITS BEFORE PROCEEDING.

(X3)

TUBE C

PARTS BAG, CONVERSION KIT RXGY-CK

YOU MUST HAVE THE OUTLINED PARTS FROM THESE KITS BEFORE PROCEEDING.

HOSE -

DOUBLE ELBOW

INTAKE AIR

DIFFUSER

AND RXGY-ZK.

YOU MUST HAVE THE OUTLINED PARTS FROM THESE KITS BEFORE PROCEEDING.

HOSE -

DOUBLE ELBOW

ROM CONVERSION KIT RXGY-CK

2-5/8" FLUSH

MOUNT PLUG

#8 X 1/2"

SCREW

(X4)

FROM ZERO-CLEARANCE CONVERSION KIT RXGY-ZK

ROM CONVERSION KIT RXGY-CK

1/4" BLACK

VENT TUBING

#8 X 1/2"

SCREW

FROM ZERO-CLEARANCE CONVERSION KIT RXGY-ZK

.559" CONDENSATE

TRAP DRAIN PLUG

5/8" DRAIN

HOSE B

1/2" DRAIN

HOSE E

.559" CONDENSATE

TRAP DRAIN PLUG

CONDENSATE

TRAP BRACKET

(

DOWN FLOW)

O-RING

#8 X 1/2"

SCREW

(X10)

ELECTRIC DRILL

TOOLS/MATERIALS NEEDED:

PIPE

COLLAR/GASKET

ASSEMBLY

(X2)

TOOLS/MATERIALS NEEDED:

3/16" DRILL BIT

INTAKE

PIPE

TOOLS/MATERIALS NEEDED:

TUBING CUTTER 1/4" HEX HEAD DRIVER 5/16 HEX HEAD DRIVER

INTAKE

FLUE PIPE

ASSEMBLY

PVC GLUE AND PRIMER HAMMER

1/4" HEX HEAD DRIVER 5/16 HEX HEAD DRIVER

W/ O-RING

FLUE PIPE

ASSEMBLY

PVC GLUE AND PRIMER

W/ O-RING

O-RING

1/8" DRILL BIT

NOTE: STEPS 1- 4 SHOWN WITH FURNACE IN “AS SHIPPED CONDITION”

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

PLIERS

TRANSITION COUPLING (RETAIN)

FLUE TRANSITION (DISCARD)

ELBOW “RETAIN”

NOTE: STEPS 1- 4 SHOWN WITH FURNACE IN “AS SHIPPED CONDITION”

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

5/16 HEX HEAD DRIVER

TRANSITION COUPLING (RETAIN)

FLUE TRANSITION (DISCARD)

ELBOW “RETAIN”

NOTE: STEPS 1- 4 SHOWN WITH FURNACE IN “AS SHIPPED CONDITION”

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

FLAT HEAD SCREWDRIVER

5/16 HEX HEAD DRIVER

2-5/8"

INSTALL

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

FLAT HEAD SCREWDRIVER

NOTE: THESE CONVERSION INSTRUCTIONS ARE INTENTIONALLY GENERIC, SOME PARTS MAY BE DIFFERENT IN YOUR FURNACE

IDB COUPLING (RETAIN)

VENT HOSE (RETAIN)

HOSE “D” (RETAIN)

IDB COUPLING (RETAIN)

VENT HOSE (RETAIN)

HOSE “D” (RETAIN)

1a - REMOVE ELBOW, (2) COUPLINGS, AND FLUE TRANSITION. (RETAIN ELBOW AND COUPLINGS FOR LATER USE.)

(NOTE: REMOVE COUPLING ON INDUCER WITH ELBOW FOR EASIER REMOVAL).

1b - REMOVE TRAP AND HOSES. RETAIN HOSE D FOR LATER USE.

(NOTE: TO REMOVE TRAP REMOVE (2) SCREWS AND PULL STRAIGHT OUT).

1a - REMOVE ELBOW, (2) COUPLINGS, AND FLUE TRANSITION. (RETAIN ELBOW AND COUPLINGS FOR LATER USE.)

(NOTE: REMOVE COUPLING ON INDUCER WITH ELBOW

1b - REMOVE TRAP AND HOSES. RETAIN HOSE D FOR LATER USE.

(NOTE: TO REMOVE TRAP REMOVE (2) SCREWS AND PULL STRAIGHT OUT).

1b - REMOVE TRAP AND HOSES. RETAIN HOSE D FOR LATER USE.

(NOTE: TO REMOVE TRAP REMOVE (2) SCREWS AND PULL STRAIGHT OUT).

2a - INSTALL 2-5/8" FLUSH MOUNT PLUG.

2b - REMOVE LEFT 2-3/8" FLUSH PLUG IN BLOWER SHELF - DISCARD.

2c - RELOCATE RIGHT 2-3/8" FLUSH MOUNT PLUG FROM BLOWER SHELF TO TOP PLATE.

2d - RELOCATE .403" DRAIN PLUG IN THE COLLECTOR BOX.

2a - INSTALL 2-5/8" FLUSH MOUNT PLUG.

2b - REMOVE LEFT 2-3/8" FLUSH PLUG IN BLOWER SHELF - DISCARD.

2c - RELOCATE RIGHT 2-3/8" FLUSH MOUNT PLUG FROM BLOWER SHELF TO TOP PLATE.

2d - RELOCATE .403" DRAIN PLUG IN THE COLLECTOR BOX.

DISCARD

2b - REMOVE LEFT 2-3/8" FLUSH PLUG IN BLOWER SHELF - DISCARD.

2c - RELOCATE RIGHT 2-3/8" FLUSH MOUNT PLUG FROM BLOWER SHELF TO

2d - RELOCATE .403" DRAIN PLUG IN THE COLLECTOR BOX.

ST-A1194-31-04

Field Conversions

IF THE IDB COUPLING IS REMOVED, IT MUST BE REPLACED IN THE PROPER O

RIENTATION. AN ARROW IS

NOTE: IF THE IDB COUPLING IS

REMOVED, IT MUST BE REPLACED IN THE PROPER O

RIENTATION. AN ARROW IS

NOTE:

ALL

RIENTATION. AN ARROW IS PRESENT ON THE COUPLING TO INDICATE THE DIRECTION OF EXHAUST FLOW. MAKE SURE THE ARROW P

OINTS IN THE CORRECT

DIRECTION.

RIENTATION. AN ARROW IS PRESENT ON THE COUPLING TO INDICATE THE DIRECTION OF EXHAUST FLOW. MAKE SURE THE ARROW P

OINTS IN THE CORRECT

DIRECTION.

INSTALL HOSE E ON COLLECTOR BOX AS SHOWN. LET THE OPEN END HANG FREE UNTIL STEP 11.

NOTE: USE SOAPY WATER TO FACILITATE EASY HOSE AND TUBE ASSEMBLY

RELOCATE JUNCTION BOX AND DOOR SWITCH SEE ELECTRICAL WIRING SECTION

REMOVE KNOCKOUTS

INSTALL HOSE E ON COLLECTOR BOX AS SHOWN. LET THE OPEN END HANG FREE UNTIL STEP 11.

USE SOAPY WATER TO FACILITATE EASY HOSE AND TUBE ASSEMBLY

RELOCATE JUNCTION BOX AND DOOR SWITCH SEE ELECTRICAL WIRING SECTION

REMOVE KNOCKOUTS

4a - RE-INSTALL ELBOW AND COUPLINGS (REMOVED IN STEP 1) IN THE ORIENTATION AS SHOWN. 4b - RELOCATE 1/2" VINYL CAP (YELLOW) ON INDUCER COUPLING TO OPPOSITE SIDE.

NOTE: LEAVE COUPLING CLAMP CONNECTIONS LOOSE UNTIL STEP 11.

USE SOAPY WATER TO FACILITATE EASY HOSE AND TUBE ASSEMBLY

RELOCATE JUNCTION BOX AND DOOR SWITCH

4a - RE-INSTALL ELBOW AND COUPLINGS (REMOVED IN STEP 1) IN THE ORIENTATION AS SHOWN. 4b - RELOCATE 1/2" VINYL CAP (YELLOW) ON INDUCER COUPLING TO

NOTE: LEAVE COUPLING CLAMP CONNECTIONS LOOSE UNTIL STEP 11.

4a - RE-INSTALL ELBOW AND COUPLINGS (REMOVED IN STEP 1) IN THE

4b - RELOCATE 1/2" VINYL CAP (YELLOW) ON INDUCER COUPLING TO

NOTE: LEAVE COUPLING CLAMP CONNECTIONS LOOSE UNTIL STEP 11.

ROTATE UNIT

SEE ELECTRICAL WIRING SECTION FOR INSTRUCTIONS

DRILL (2)

1/8" HOLES IN BLOWER SHELF

5a - ROTATE UNIT 180° 5b - REMOVE KNOCKOUTS WITH HAMMER AND FLAT HEAD SCREWDRIVER. 5c - THE JUNCTION BOX WILL HAVE TO BE RELOCATED FOR FLUE PIPE INSTALLATION.

SEE ELECTRICAL WIRING SECTION FOR INSTRUCTIONS. 5d - RE-DRILL (2) Ø1/8" HOLES IN BLOWER SHELF AS SHOWN FOR FLUE PIPE ASSEMBLY. 5e - PRE-DRILL (2) Ø3/16" HOLES IN JACKET AS SHOWN FOR CONDENSATE TRAP BRACKET.

5b - REMOVE KNOCKOUTS WITH HAMMER AND FLAT HEAD SCREWDRIVER. 5c - THE JUNCTION BOX WILL HAVE TO BE RELOCATED FOR FLUE PIPE INSTALLATION.

5d - RE-DRILL (2) Ø1/8" HOLES IN BLOWER SHELF AS SHOWN FOR FLUE PIPE ASSEMBLY. 5e - PRE-DRILL (2) Ø3/16" HOLES IN JACKET AS SHOWN FOR CONDENSATE TRAP BRACKET.

DRILL (2)

3/16" HOLES

DIFFUSER FULLY SEATED

.559

DRAIN PLUG

(X2)

.559

DRAIN PLUG

DISCARD

FULLY SEATED

INSTALL INTAKE COUPLING IN BLOWER SHELF HOLE AS SHOWN.

INSERT AIR DIFFUSER INTO COUPLING UNTIL TABS ARE SEATED.

INSTALL INTAKE COUPLING IN BLOWER

INSERT AIR DIFFUSER INTO COUPLING

7a - REMOVE THE SMALL MOUNTING BRACKET AND THE .403" DRAIN PLUG - DISCARD.

7b - INSTALL .559" DRAIN PLUG IN CONDENSATE TRAP.

7c - INSTALL DOWN FLOW CONDENSATE TRAP BRACKET WITH (2) SCREWS AS SHOWN.

7a - REMOVE THE SMALL MOUNTING BRACKET AND THE .403" DRAIN PLUG - DISCARD.

7b - INSTALL .559" DRAIN PLUG IN CONDENSATE TRAP.

7c - INSTALL DOWN FLOW CONDENSATE TRAP BRACKET WITH (2) SCREWS AS SHOWN.

7a - REMOVE THE SMALL MOUNTING BRACKET AND THE .403" DRAIN PLUG - DISCARD.

7c - INSTALL DOWN FLOW CONDENSATE TRAP BRACKET WITH (2) SCREWS AS SHOWN.

ST-A1194-31-04

Field Conversions

/8" DRILL

1/8" DRILL

DISCARD

DISCARD 7/8" PLUG

DETERMINE RIGHT OR LEFT DRAIN OPTION. LOCATE 7/8" HOLE IN JACKET SIDE REMOVE PLUG - DISCARD. DRILL (2)

1/8" HOLES FOR THE BULKHEAD COUPLING.

LEFT DRAIN OPTION

7/8" PLUG

DETERMINE RIGHT OR LEFT DRAIN OPTION. LOCATE 7/8" HOLE IN JACKET SIDE REMOVE PLUG - DISCARD.

1/8" HOLES FOR THE BULKHEAD COUPLING.

LEFT DRAIN OPTION

RIGHT DRAIN OPTIONRIGHT DRAIN OPTION

INSTALL BULKHEAD COUPLING USING (2) SCREWS. INSTALL IN JACKET WITH THE BARBED FITTING POINTED INTO THE VESTIBULE.

INSTALL IN JACKET WITH THE BARBED FITTING POINTED INTO THE VESTIBULE.

COVER PLATE

“BOTTOM

10a

“BOTTOM”

PRE-DRILL 1/8"

HOLES AND

ATTACH W/SCREWS

(2) PLACES

X10

O-RING

PVC GLUE JOINTPVC GLUE JOINT

10b

INSTALL SCREWS

10c

10a - INSTALL INTAKE PIPE

SLIDE INTAKE PIPE THROUGH THE LEFT SIDE KNOCKOUT ON COVER PLATE CLEAN AND PVC GLUE TO INTAKE COUPLING AS SHOWN

10b - INSTALL FLUE PIPE ASSEMBLY

INSERT FLUE PIPE ASSEMBLY THROUGH RIGHT SIDE KNOCKOUT ON COVER PLATE (NOTE: SLIDE FROM UNDER PLATE).

SLIDE ANGLED END THROUGH OPENING IN BLOWER SHELF AND ALIGN WITH ELBOW COUPLING.

SECURE PIPE ASSEMBLY TO BLOWER SHELF WITH (2) SCREWS AS SHOWN. ENSURE O-RING IS PROPERLY SEATED.

10c - SLIDE PIPE COLLAR ASSEMBLIES FROM STEP 7 OVER THE (2) PIPES AND DRILL (8)

PVC GLUE JOINT