Rheem R802V-ZSA, R802V-ZSB User Manual

R802V-ZSA,ZSB

Parts List

12-November-2018

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

See http://www.rheempartslists.net/92-42800-R802V-ZSA,ZSB.pdf for the current revision.

80% Gas Furnaces - 2 Stage

Table of Contents

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

Parts Numbers

Panels - Miscellaneous .. ... ... ................ ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... .. Page 4

Electrical Group . ... ... ................ ... ... ... ... ... ... ... ... ... ............. ... ... ... ... ... ... ... ... ... ....... Page5

Blower Group.. ... ................ ... ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ............ Page 6

Heat Exchanger-Burner Group.. ... ................ ... ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... . Page 7

Gas Controls .. ... ... ............. ... ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ............ Page 7

Orifice Selection Chart.. ... ................ ... ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ... Page 8

Drawings/Photographs

Exploded View ... ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ................ ... ... ... ... ... Page 9

Blower Assembly ... ... ................ ... ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ...... Page10

Burner Assembly .. ... ... ................ ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ... .... Page 11

NOx Insert Assembly .. ... ... ................ ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ... Page12

Blower Assembly ... ... ................ ... ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ...... Page10

Notes/Disclaimer . ... ... ... ............. ... ... ... ... ... ... ... ... ... ................ ... ... ... ... ... ... ... ... ................ ... ... ... Page14

Page 2 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

MODEL EXPLANATION

R 8 0 2 V A 0 7 5 3 1 7 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
V = ECM 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

Page 3 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

MODEL

No. Notes

1 2 Jacket (SeeNote 2) N/A N/A N/A N/A
2 Top Plate AE-66981-10 AE-66981-11 AE-66981-11 AE-66981-12
3 Blower/Filter Door AS-105092-42 AS-105092-43 AS-105092-43 AS-105092-44
4 Burner Compartment Door AS-101734-11 AS-101735-11 AS-101735-11 AS-101736-11

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

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

10 Flue Pipe Enclosure Door AE-66983-01 AE-66983-01 AE-66983-01 AE-66983-01
11 Rear Baffle AE-66994-02 AE-66994-06 AE-66994-06 AE-66994-04
12 NOx Insert Retainer See Heat Exchanger, Burner Manifold Group
13 NOx Burner Inserts See Heat Exchanger,Burner ManifoldGroup
14 Pressure Switch See Electrical Group
15 Door Switch - Push Button See Electrical Group
16 Limit - Main Limit (HeatExchanger 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 Blowerw/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-up Paint - Granite/Steel Gray(Aerosol) PD523018 PD523018 PD523018 PD523018

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

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

PANELS, SHEET METAL PARTS

R802VA

075

3

17

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

R802VA

075

4

21

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

R802VA

100

5

21

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

R802VA

125

5

24

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

Page 4 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

MODEL

No. Notes

14 Stk Pressure Switch 42-106209-01 42-106209-01 42-106209-01 42-106209-01
15 Door Switch - Push Button 42-22692-06 42-22692-06 42-22692-06 42-22692-06
16 Stk Limit - Main Limit (Heat Exchanger Panel) 47-25349-13 47-25349-16 47-25349-02 47-25349-12
17 Stk Limit - Manual Reset (Burner Compartment) 47-22861-03 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 47-22860-06
19 Stk Transformer 46-102856-01 46-102856-01 46-102856-01 46-102856-01
20 Stk Induced Draft Blower w/Gasket 70-101888-01 70-101888-01 70-101888-02 70-101888-02

Integrated Furnace Control Board (IFC) See Gas Controls

Wiring Harness Assembly (4pin to 4 pin, IFC to IBM) 45-102785-01 45-102785-01 45-102785-01 45-102785-01

Memory Module forIFC 47-104778-55 47-104778-56 47-104778-57 47-104778-58

Power FactorChoke (PFC) N/A 46-24256-02 46-24256-02 46-24256-02

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

Wiring Harness - 9 pinto 7 pin on IFC 45-105290-01 45-105290-01 45-105290-01 45-105290-01

Wiring Harness - 4 pinto IDM 45-105293-01 45-105293-01 45-105293-02 45-105293-02

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

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

ELECTRIC GROUP

R802VA

075

3

17

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

R802VA

075

4

21

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

R802VA

100

5

21

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

R802VA

125

5

24

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

Page 5 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

MODEL

No. Notes

21 Stk Blower Assembly (Includes items 22-26) AS-105345-01 AS-105345-02 AS-105345-03 AS-105345-03

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

22 Blower Housing AS-61674-21 AS-61674-22 AS-61674-22 AS-61674-22
23 Stk Blower Motor 51-102602-01 51-102603-01 51-102605-01 51-102605-01
24 Motor Mount (4) AE-61956-01 AE-61956-01 AE-61956-01 AE-61956-01

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

25 Stk Blower Wheel 70-24254-02 70-23111-20 70-23111-20 70-23111-20
18 Limit - Heat Assisted (Blower Housing) See Electrical Group

No. Notes

21 Stk Blower Assembly (Includes items 22-26) AS-105345-01 AS-105345-02 AS-105345-03 AS-105345-03

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

22 Blower Housing 70-61674-21 70-61674-22 70-61674-22 70-61674-22
23 Stk Blower Motor 51-102602-01 51-102603-01 51-102605-01 51-102605-01
24 Motor Mount (4) AE-61956-01 AE-61956-01 AE-61956-01 AE-61956-01

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

25 Stk Blower Wheel 70-24254-02 70-23111-20 70-23111-20 70-23111-20
18 Limit - Heat Assisted (Blower Housing) See Electrical Group

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

BLOWER GROUP

MODEL
INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

BLOWER GROUP

R802VA

075

3

17

ZSA/ZXA

R802VA

075

3

17

ZSB/ZXB

R802VA

075

4

21

ZSA/ZXA

R802VA

075

4

21

ZSB/ZXB

R802VA

100

5

21

ZSA/ZXA

R802VA

100

5

21

ZSB/ZXB

R802VA

125

5

24

ZSA/ZXA

R802VA

125

5

24

ZSB/ZXB

Page 6 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

MODEL

No. Notes

12 NOx Insert Retainer (ZXA, ZXB)

13 NOx Burner Inserts (ZXA, ZXB)
27 Stk Heat Exchanger Assembly (ZSA, ZSB) AS-100561-01 AS-66997-22 AS-66997-04 AS-66997-05

27 Stk Heat Exchanger Assembly (ZXA, ZXB) AS-100561-02 AS-66997-24 AS-66997-17 AS-66997-18
28 Heat Exchanger Bracket- Left Side AE-67846-02 AE-67846-02 AE-67846-02 AE-67846-02
28 Heat Exchanger Bracket- Right Side AE-67846-02 AE-67846-02 AE-67846-02 AE-67846-02
32 Stk Burner Assembly AS-60993-03 AS-60993-03 AS-60993-04 AS-60993-05
33 Burner Support AE-60997-02 AE-60997-02 AE-60997-03 AE-60997-04
34 Burner Support Bracket (2) AE-61588-02 AE-61588-02 AE-61588-02 AE-61588-02

Burner CoverPlate AE-101080-02 AE-101080-02 AE-101080-03 AE-101080-04

Burner CoverPlate (NOx variants) AE-101080-12 AE-101080-12 AE-101080-13 AE-101080-14

35 Stk Manifold (w/o Orifices) 81-102427-02 81-102427-02 81-102427-03 81-102427-04
36 Burner Orifice - Natural Gas See Orifice Selection Chart
36 Burner Orifice - LP SeeOrifice Selection Chart
36 Number of Orifices (3) (3) (4) (5)

No. Notes

37 Stk Gas Valve - Natural Gas 60-101921-01 60-101921-01 60-101921-01
37 Stk,1 GasValve - LP See Note 1 See Note 1 See Note 1
38 Stk Integrated Furnace Control Board (IFC) 62-104061-02 62-104061-04 62-104061-05

Memory Module forIFC

39 Stk Flame Sensor 62-23543-01 62-23543-01 62-23543-01
40 Stk Ignitor 62-24164-04 62-24164-04 62-24164-04

Ignitor Bracket AE-61885-02 AE-61885-02 AE-61885-02

LP Conversion Kit:

Stk LP Conversion Kit FP-32 FP-32 FP-32

No. Notes

Outdoor Sensor Kit RXGY-J02

INPUT
AIRFLOW
CABINETWIDTH
CONFIGURATION

HEAT EXCHANGER, BURNER / MANIFOLD

MODEL
GAS CODE

GAS CONTROLS

MODEL
GAS CODE

ACCESSORY KIT

R802VA

075

3

17

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

AE-67872-02

(1)

AS-67875-01

(2)

R802VA

JL

See Electric

Group

R802VA

ALL

R802VA

075

4

21

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

AE-67872-02

(1)

AS-67875-01

(2)

R802VA

KJ

See Electric

Group

R802VA

100

21

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

AE-67872-03

(1)

AS-67875-01

(3)

R802VA

KR

See Electric

Group

R802VA

5

125

5

24

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

AE-67872-04

(1)

AS-67875-01

(4)

Page 7 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

CAUTION: Selection ofthe 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 LPConversion Kit Index 92-21519-70 and thelatest edition of the
National Fuel Gas Code Handbook, or the National Standard of Canada, Natural Gas andPropane 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 basedon a Natural Gas heating value of 1075BTU/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 ofthe correct LP Orifice requires the altitude of the specific installation (ft.).
For detailed information and instructions for Orifice selection, see the Gas Furnace LPConversion Kit Index 92-21519-70 and thelatest edition of the
National Fuel Gas Code Handbook (NFG), or the National Standard of Canada, Natural Gasand 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 settingof 10 in. water column
instead of the 11.0 inwater column used by the NFG and CANB149.1.
NOTE: Orifices supplied inthe LP Conversion Kit are calculated andsized based on an altitude of 0 - 4000ft.

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 - NATURAL GAS

80% GAS FURNACE - ORIFICE SELECTION CHART - LP

Page 8 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

Exploded View

Page 9 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

Blower Assembly

Page 10 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

Burner Assembly

Page 11 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

NOx Insert Assembly

Page 12 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

Blower Assembly

Page 13 of 14

12-November-2018

92-42800-R802V-ZSA,ZSB

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.

DISCLAIMER: This document is intended to provide general replacement parts information to aid qualified
service personnel in the repair of these models. The complete Model and Serial Number of the unit under repair
should be specified when selecting and ordering replacement parts. Specifications and illustrations are subject
to change without notice. Document 92-42800-R802V-ZSA,ZSB supersedes all previous parts lists for these
models. See http://www.rheempartslists.net/92-42800-R802V-ZSA,ZSB for the latest revision of this document.
The manufacturer assumes no obligation for errors or omissions. Service personnel must verify the proper and
safe operation of equipment after the replacement of any original components.

P.O. Box 17010

Fort Smith, AR 72917-7010