Rheem R802P-ZSA, R802P-ZSB User Manual

R802P-ZSA,ZSB

Parts List

03-October-2017

This parts list is current as of the above revision date.

See http://www.rheempartslists.net/92-42801-R802P-ZSA,ZSB.pdf for the current revision.

80% Gas Furnaces - 2 Stage

Table of Contents

Model Explanation................................................................................................................... Page 3

Parts Numbers

Panels - Miscellaneous(1)....................................................................................... Page 4

Panels - Miscellaneous(2)....................................................................................... Page 5

Electrical Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6

Blower Group.................................................................................................... Page 7

Heat Exchanger-Burner Group................................................................................... Page 8

Gas Controls .................................................................................................... Page 8

Orifice Selection Chart........................................................................................... Page 9

Drawings/Photographs

Exploded View ................................................................................................. Page 10

Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 11

Burner Assembly ............................................................................................... Page 12

NOx Insert Assembly ........................................................................................... Page13

Notes .......................................................................................................................... Page 14

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92-42801-R802P-ZSA,ZSB

03-October-2017

MODEL EXPLANATION

R 8 0 2 P A 0 5 0 3 1 4 Z S A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

(1) TRADEBRAND IDENTIFICATION (7) AIRFLOW
3 = Up to 3 tons
(2) SERIES 4 = Up to 4 tons
80% Efficient 5 = Up to 5 tons

(3) STAGE - TWO (2) (8) CABINETWIDTH
14 = 14.0 inch
(4) MOTORTYPE 17 = 17.5 inch
P = PSC Premium 21 = 21.0 inch
24 = 24.5 inch
(5) MAJOR REVISION
A = 1st Design Series (9) CONFIGURATION
Z = Down Flow, Zero Clearance
(6) HEATING INPUT DESIGNATION
050 = 50,000 BTU/HR (10) STANDARD/Nox
075 = 75,000 BTU/HR S = Standard
100 = 98,000 BTU/HR X = NOx
125 = 125,000 BTU/HR
150 = 150,000 BTU/HR (11) MINOR REVISION
A = First Time Release in Plant 124
B = Manfactured in Plant 152

SERIAL NUMBER EXPLANATION

W 0 8 1 4 9 9 9 9

(1) (2) (3) (4)
(1) PLANT CODE
(2) WEEK (DATE CODE)
(3) YEAR
(4) PRODUCTION NUMBER
Note: For Gas Code, see Control System Gas Code on Rating Plate

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MODEL

No. Notes

1 2 Jacket (See Note 2) N/A N/A N/A
2 Top Plate AE-66981-09 AE-66981-10 AE-66981-10
3 Blower/Filter Door AS-105092-01 AS-105092-02 AS-105092-02
4 Burner Compartment Door AS-101733-11 AS-101734-11 AS-101734-11

Plug Button - 1-3/16 in. opening (2) 45-22980-01 45-22980-01 45-22980-01

Door Angle AE-66980-01 AE-66980-02 AE-66980-02
5 Mounting Control Plate See Blower Group
6 Junction Box AE-61475-02 AE-61475-02 AE-61475-02
7 Junction Box Cover AE-61476-02 AE-61476-02 AE-61476-02
8 Flue Pipe AE-66691-14 AE-66691-14 AE-66691-14
9 Flue Pipe Enclosure AE-66982-01 AE-66982-01 AE-66982-01

10 Flue Pipe Enclosure Door AE-66983-01 AE-66983-01 AE-66983-01
11 Rear Baffle AE-66994-01 AE-66994-02 AE-66994-02
12 NOx InsertRetainer See Heat Exchanger, Burner Manifold Group
13 NOx BurnerInserts See Heat Exchanger, Burner Manifold Group
14 Pressure Switch See Electrical Group
15 Door Switch - Push Button See Electrical Group
16 Limit - Main Limit (Heat Exchanger Panel) See Electrical Group
17 Limit - Manual Reset (Burner Compartment) See Electrical Group
18 Limit - Heat Assisted (Blower Housing) See Electrical Group
19 Transformer See Electrical Group
20 Induced Draft Blower w/Gasket See Electrical Group
21 Blower Assembly See Blower Group
27 Heat Exchanger Assembly See Heat Exchanger Group
28 Heat Exchanger Bracket See Heat Exchanger Group
37 Gas Valve See Gas Controls
38 Integrated Furnace Control Board (IFC) See Gas Controls

Touch-upPaint - Granite/Steel Gray (Aerosol) PD523018 PD523018 PD523018

Touch-upPaint - Granite/Steel Gray (Paint Pens) PD523019 PD523019 PD523019

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

PANELS, SHEET METAL PARTS

R802PA

050

3

14

ZS(A/B)/ZX(A/B)

R802PA

075

3

17

ZS(A/B)/ZX(A/B)

R802PA

100

3

17

ZS(A/B)/ZX(A/B)

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MODEL

No. Notes

1 2 Jacket (See Note 2) N/A N/A N/A
2 Top Plate AE-66981-11 AE-66981-12 AE-66981-12
3 Blower/Filter Door AS-105092-03 AS-105092-04 AS-105092-04
4 Burner Compartment Door AS-101735-11 AS-101736-11 AS-101736-11

Plug Button - 1-3/16 in. opening (2) 45-22980-01 45-22980-01 45-22980-01

Door Angle AE-66980-03 AE-66980-04 AE-66980-04
5 Mounting Control Plate See Blower Group
6 Junction Box AE-61475-02 AE-61475-02 AE-61475-02
7 Junction Box Cover AE-61476-02 AE-61476-02 AE-61476-02
8 Flue Pipe AE-66691-14 AE-66691-14 AE-66691-14
9 Flue Pipe Enclosure AE-66982-01 AE-66982-01 AE-66982-01

10 Flue Pipe Enclosure Door AE-66983-01 AE-66983-01 AE-66983-01
11 Rear Baffle AE-66994-03 AE-66994-04 AE-66994-04
12 NOx InsertRetainer See Heat Exchanger, Burner Manifold Group
13 NOx BurnerInserts See Heat Exchanger, Burner Manifold Group
14 Pressure Switch See Electrical Group
15 Door Switch - Push Button See Electrical Group
16 Limit - Main Limit (Heat Exchanger Panel) See Electrical Group
17 Limit - Manual Reset (Burner Compartment) See Electrical Group
18 Limit - Heat Assisted (Blower Housing) See Electrical Group
19 Transformer See Electrical Group
20 Induced Draft Blower w/Gasket See Electrical Group
21 Blower Assembly See Blower Group
27 Heat Exchanger Assembly See Heat Exchanger Group
28 Heat Exchanger Bracket See Heat Exchanger Group
37 Gas Valve See Gas Controls
38 Integrated Furnace Control Board (IFC) See Gas Controls

Touch-upPaint - Granite/Steel Gray (Aerosol) PD523018 PD523018 PD523018

Touch-upPaint - Granite/Steel Gray (Paint Pens) PD523019 PD523019 PD523019

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

PANELS, SHEET METAL PARTS

R802PA

100

5

21

ZS(A/B)/ZX(A/B)

R802PA

125

5

24

ZS(A/B)/ZX(A/B)

R802PA

150

5

24

ZS(A/B)/ZX(A/B)

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MODEL

No. Notes

14 Stk PressureSwitch 42-106209-01 42-106209-01 42-106209-01
15 Door Switch - Push Button 42-22692-06 42-22692-06 42-22692-06
16 Stk Limit- Main Limit (Heat Exchanger Panel) 47-25349-15 47-25349-13 47-25349-05
17 Stk Limit- Manual Reset (Burner Compartment) 47-22861-03 47-22861-03 47-22861-03
18 Stk Limit- Heat Assisted (Blower Housing) 47-22860-06 47-22860-06 47-22860-06
19 Stk Transformer w/Fuse 46-24124-03 46-24124-03 46-24124-03
20 Stk InducedDraft Blower w/Gasket 70-101888-01 70-101888-01 70-101888-02

Integrated Furnace Control Board (IFC) SeeGas Controls

Wiring Harness - 9 pin to Roll-Out, Gas Valve, Main Limit, etc. 45-105291-01 45-105291-01 45-105291-01

Wiring Harness - Main Harness (9 pin to 7 pin on IFC) 45-105290-01 45-105290-01 45-105290-01

Wiring Harness - 4 pin to IDM 45-105293-01 45-105293-01 45-105293-02

Wire Assembly - 3 pin (Junction Box to Twist Lock) 45-24371-58 45-24371-58 45-24371-58

No. Notes

14 Stk PressureSwitch 42-106209-01 42-106209-01 42-106209-01
15 Door Switch - Push Button 42-22692-06 42-22692-06 42-22692-06
16 Stk Limit- Main Limit (Heat Exchanger Panel) 47-25349-03 47-25349-17 47-25349-05
17 Stk Limit- Manual Reset (Burner Compartment) 47-22861-03 47-22861-03 47-22861-03
18 Stk Limit- Heat Assisted (Blower Housing) 47-22860-06 47-22860-06 47-22860-06
19 Stk Transformer w/Fuse 46-24124-03 46-24124-03 46-24124-03
20 Stk InducedDraft Blower w/Gasket 70-101888-02 70-101888-02 70-101888-02

Integrated Furnace Control Board (IFC) SeeGas Controls

Wiring Harness - 9 pin to Roll-Out, Gas Valve, Main Limit, etc. 45-105291-01 45-105291-01 45-105291-01

Wiring Harness - Main Harness (9 pin to 7 pin on IFC) 45-105290-01 45-105290-01 45-105290-01

Wiring Harness - 4 pin to Induced Draft Motor 45-105293-02 45-105293-02 45-105293-02

Wire Assembly - 3 pin (Junction Box to Twist Lock) 45-24371-58 45-24371-58 45-24371-58

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

ELECTRIC GROUP

MODEL
INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

ELECTRIC GROUP

R802PA

050

3

14

ZS(A/B)/ZX(A/B)

R802PA

100

5

21

ZS(A/B)/ZX(A/B)

R802PA

075

3

17

ZS(A/B)/ZX(A/B)

R802PA

125

5

24

ZS(A/B)/ZX(A/B)

R802PA

100

3

17

ZS(A/B)/ZX(A/B)

R802PA

150

5

24

ZS(A/B)/ZX(A/B)

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03-October-2017

MODEL

No. Notes

21 Stk Blower Assembly (Includes items 22-26) AS-61697-46 AS-61697-50 AS-61697-50

5 Control Mounting Plate AE-67877-02 AE-67877-02 AE-67877-02

22 Blower Housing AS-61674-19 AS-61674-21 AS-61674-21
23 Stk Blower Motor 51-24070-01 51-26002-01 51-26002-01
24 Motor Mount (4) AE-61698-02 AE-61698-02 AE-61698-02

Screws - Motor Mount (12) 63-22153-01 63-22153-01 63-22153-01

25 Stk Blower Wheel 70-22683-01 70-22688-01 70-22688-01
26 Stk Capacitor- Blower Motor 43-101666-43 43-101666-42 43-101666-42
18 Limit - Heat Assisted (Blower Housing) See ElectricalGroup

No. Notes

21 Stk Blower Assembly (Includes items 22-26) AS-61697-46 AS-61697-50 AS-61697-50

5 Control Mounting Plate AE-67877-02 AE-67877-02 AE-67877-02

22 Blower Housing (includes wheel) 70-61674-19 70-61674-05 70-61674-05
23 Stk Blower Motor 51-24070-01 51-26002-01 51-26002-01
24 Motor Mount (4) AE-61698-02 AE-61698-02 AE-61698-02

Screws - Motor Mount (12) 63-22153-01 63-22153-01 63-22153-01

25 Stk Blower Wheel 70-22683-01 70-22688-01 70-22688-01
26 Stk Capacitor- Blower Motor 43-101666-43 43-101666-42 43-101666-42
18 Limit - Heat Assisted (Blower Housing) See ElectricalGroup

No. Notes

21 Stk Blower Assembly (Includes items 22-26) AS-61697-52 AS-61697-52 AS-61697-52

5 Control Mounting Plate AE-67877-02 AE-67877-02 AE-67877-02

22 Blower Housing AS-61674-22 AS-61674-22 AS-61674-22
23 Stk Blower Motor 51-103220-01 51-103220-01 51-103220-01
24 Motor Mount (4) AE-61698-02 AE-61698-02 AE-61698-02

Screws - Motor Mount (12) 63-22153-01 63-22153-01 63-22153-01

25 Stk Blower Wheel 70-20602-01 70-20602-01 70-20602-01
26 Stk Capacitor- Blower Motor 43-101666-43 43-101666-43 43-101666-43
18 Limit - Heat Assisted (Blower Housing) See ElectricalGroup

No. Notes

21 Stk Blower Assembly (Includes items 22-26) AS-61697-52 AS-61697-52 AS-61697-52

5 Control Mounting Plate AE-67877-02 AE-67877-02 AE-67877-02

22 Blower Housing (includes wheel) 70-61674-28 70-61674-28 70-61674-28
23 Stk Blower Motor 51-103220-01 51-103220-01 51-103220-01
24 Motor Mount (4) AE-61698-02 AE-61698-02 AE-61698-02

Screws - Motor Mount (12) 63-22153-01 63-22153-01 63-22153-01

25 Stk Blower Wheel 70-20602-01 70-20602-01 70-20602-01
26 Stk Capacitor- Blower Motor 43-101666-43 43-101666-43 43-101666-43
18 Limit - Heat Assisted (Blower Housing) See ElectricalGroup

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

BLOWER GROUP

MODEL
INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

BLOWER GROUP

MODEL
INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

BLOWER GROUP

MODEL
INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

BLOWER GROUP

R802PA

050

3

14

ZSA/ZXA

R802PA

050

3

14

ZSB/ZXB

R802PA

100

5

21

ZSA/ZXA

R802PA

100

5

21

ZSB/ZXB

R802PA

075

3

17

ZSA/ZXA

R802PA

075

3

17

ZSB/ZXB

R802PA

125

5

24

ZSA/ZXA

R802PA

125

5

24

ZSB/ZXB

R802PA

100

3

17

ZSA/ZXA

R802PA

100

3

17

ZSB/ZXB

R802PA

150

5

24

ZSA/ZXA

R802PA

150

5

24

ZSB/ZXB

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03-October-2017

MODEL

No. Notes

12 NOx Insert Retainer (ZXA, ZXB)

13 NOx Burner Inserts(ZXA, ZXB)
27 Stk HeatExchanger Assembly (ZSA, ZSB) AS-66997-23 AS-100561-01 AS-66997-07

27 Stk HeatExchanger Assembly (ZXA, ZXB) AS-66997-25 AS-100561-02 AS-66997-16
28 Heat Exchanger Bracket - Left Side AE-102680-01 AE-67846-02 AE-67846-02
28 Heat Exchanger Bracket - Right Side AE-102680-02 AE-67846-02 AE-67846-02
32 Stk Burner Assembly AS-60993-02 AS-60993-03 AS-60993-04
33 Burner Support AE-60997-01 AE-60997-02 AE-60997-03
34 Burner Support Bracket (2) AE-61588-02 AE-61588-02 AE-61588-02

Burner Cover Plate AE-101080-01 AE-101080-02 AE-101080-03

Burner Cover Plate (NOx variants) AE-101080-11 AE-101080-12 AE-101080-13

35 Stk Manifold (w/o Orifices) 81-102427-01 81-102427-02 81-102427-03
36 Burner Orifice - Natural Gas See Orifice Selection Chart
36 Burner Orifice - LP See Orifice Selection Chart
36 Number of Orifices (2) (3) (4)

No. Notes

12 NOx Insert Retainer (ZXA, ZXB)

13 NOx Burner Inserts(ZXA, ZXB)
27 Stk HeatExchanger Assembly (ZSA, ZSB) AS-66997-04 AS-66997-05 AS-66997-06

27 Stk HeatExchanger Assembly (ZXA, ZXB) AS-66997-17 AS-66997-18 AS-66997-19
28 Heat Exchanger Bracket - Left Side AE-67846-02 AE-67846-02 AE-67846-02
28 Heat Exchanger Bracket - Right Side AE-67846-02 AE-67846-02 AE-67846-02
32 Stk Burner Assembly AS-60993-04 AS-60993-05 AS-60993-06
33 Burner Support AE-60997-03 AE-60997-04 AE-60997-05
34 Burner Support Bracket (2) AE-61588-02 AE-61588-02 AE-61588-02

Burner Cover Plate AE-101080-03 AE-101080-04 AE-101080-05

Burner Cover Plate (NOx variants) AE-101080-13 AE-101080-14 AE-101080-15

35 Stk Manifold (w/o Orifices) 81-102427-03 81-102427-04 81-102427-05
36 Burner Orifice - Natural Gas See Orifice Selection Chart
36 Burner Orifice - LP See Orifice Selection Chart
36 Number of Orifices (4) (5) (6)

No. Notes

37 Stk GasValve - Natural Gas 60-101921-01
37 Stk,1 Gas Valve - LP See Note 1
38 Stk Integrated Furnace Control Board (IFC) 62-104059-01
39 Stk FlameSensor 62-23543-01
40 Stk Ignitor 62-24164-04

Ignitor Bracket AE-61885-02

LP Conversion Kit:

Stk LP Conversion Kit FP-32

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

HEAT EXCHANGER, BURNER / MANIFOLD

MODEL
INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

HEAT EXCHANGER, BURNER / MANIFOLD

MODEL
GAS CODE

GAS CONTROLS

R802PA

050

3

14

ZS(A/B)/ZX(A/B)

AE-67872-01

(1)

AS-67875-01

(1)

R802PA

100

5

21

ZS(A/B)/ZX(A/B)

AE-67872-03

(1)

AS-67875-01

(3)

R802PA

JK

R802PA

075

3

17

ZS(A/B)/ZX(A/B)

AE-67872-02

(1)

AS-67875-01

(2)

R802PA

125

5

24

ZS(A/B)/ZX(A/B)

AE-67872-04

(1)

AS-67875-01

(4)

R802PA

100

3

17

ZS(A/B)/ZX(A/B)

AE-67872-03

(1)

AS-67875-01

(3)

R802PA

150

5

24

ZS(A/B)/ZX(A/B)

AE-67872-05

(1)

AS-67875-01

(5)

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03-October-2017

CAUTION: Selection of the correct Natural Gas Orifice requires the following information for the specific installation:

1) Altitude in of the installation (ft.).

2) Average energy content of the Natural Gas fuel from the local supplier (BTU/cu. ft.).
For detailed information and instructions for Orifice selection, see the Gas Furnace LP Conversion Kit Index 92-21519-70 and the latest edition of the
National Fuel Gas Code Handbook, or the National Standard of Canada, Natural Gas and Propane Installation Code,CAN B149.1.
CAUTION:This information is provided for replacement purposes only. Conversion for operation at High Altitude must be done using the kit specified
on the product specification sheet for the unit.

NOTE:This Orifice sizing chart is based on 25,000 BTU/HR per burner.
NOTE: Factory installed orifices are calculated and sized based on a Natural Gas heating value of 1075 BTU/cu. ft. and an elevation of 0 - 3000 ft.
Elevation (ft.)

EnergyValue

(BTU/cu. ft.)

850 62-22175-38 62-22175-39 62-22175-40 62-22175-41 62-22175-41 62-22175-42 62-22175-42 62-22175-43
900 62-22175-40 62-22175-41 62-22175-42 62-22175-42 62-22175-42 62-22175-43 62-22175-43 62-22175-44

975 62-22175-41 62-22175-42 62-22175-42 62-22175-42 62-22175-43 62-22175-43 62-22175-44 62-22175-44
1075 62-22175-42 62-22175-42 62-22175-43 62-22175-43 62-22175-43 62-22175-44 62-22175-44 62-22175-45
1170 62-22175-43 62-22175-44 62-22175-44 62-22175-44 62-22175-45 62-22175-45 62-22175-46 62-22175-47

CAUTION: Selection of the correct LP Orifice requires the altitude of the specific installation (ft.).
For detailed information and instructions for Orifice selection, see the Gas Furnace LP Conversion Kit Index 92-21519-70 and the latest edition of the
National Fuel Gas Code Handbook (NFG), or the National Standard of Canada, Natural Gas and Propane Installation Code,CAN B149.1.
CAUTION:This information is provided for replacement purposes only. Conversion to LP or for operation at High Altitude should be done using the
kit(s) specified on the product specification sheet for the unit.

NOTE:This Orifice sizing chart is based on 25,000 BTU/HR per burner. Also, the chart is developed using the specified pressure setting of 10 in. water column
instead of the 11.0 in water column used by the NFG and CANB149.1.
NOTE: Orifices supplied in the LP Conversion Kit are calculated and sized based on an altitude of 0 - 4000 ft.

Elevation (ft.) Orifice

0 - 2000 62-22175-54
2001 - 3000 62-22175-54
3001 - 4000 62-22175-54
4001 - 5000 62-22175-54
5001 - 6000 62-22175-54
6001 - 7000 62-22175-54
7001 - 8000 62-22175-55
8001 - 9000 62-22175-55

9001 - 10000 62-22175-55

0 - 1999 2000 - 2999 3000 - 3999 4000 - 4999 5000 - 5999 6000 - 6999 7000 - 7999 8000 - 8999

80% GAS FURNACE - ORIFICE SELECTION CHART - NATURALGAS

80% GAS FURNACE - ORIFICE SELECTION CHART - LP

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Exploded View

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Blower Assembly

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Burner Assembly

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NOx Insert Assembly

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03-October-2017

NOTES

Stk It is recommended that stock be maintained for this part.

N/A Not Applicable

1 Order Gas Valve for Natural Gas along with LP Conversion Kit.
2 Jacket is not available for replacement.

P.O. Box 17010

Fort Smith, AR 72917-7010