Rheem RGFE, RGJF, RGGE Installation Instructions Manual

INSTALLATION INSTRUCTIONS

FOR RGFE UPFLOW, RGGE DOWNFLOW & RGJF DEDICATED HORIZONTAL HIGH EFFICIENCY MODULATING CONDENSING GAS FURNACES

RGJF

RGFE

RGGE

SEE PAGE 112

SEE PAGE 122

This Memory Card must be removed (broken away) from the furnace control when the control is replaced. The card must be inserted into the connector at J15 of the replacement control. Failure to retain this memory card with the furnace when replacing the furnace control could result in no operation when the furnace control is replaced.

MODULATING THERMOSTAT

INSTALLATION

MODULATING

COMMUNICATING

THERMOSTAT

INSTALLATION

ISO 9001:2008

WARNING

DO NOT EXCHANGE MEMORY CARDS BETWEEN 2 OR MORE DIFFERENT FURNACES. DOING SO COULD RESULT IN UNEXPECTED OPERATION – INCLUDING INADEQUATE AIRFLOW DURING HEATING (AND OTHER MODES) OR A LOSS OF HEAT.

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!

IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

PROPOSITION 65 WARNING: THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

— Do not store or use gasoline or other flammable vapors and liquids, or other combustible materials

in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions

• If you cannot reach your gas supplier, call the fire department.

• Do not return to your home u

— DO NOT RELY ON SMELL ALONE TO DETECT LEAKS. DUE TO VARIOUS FACTORS, YOU MAY NOT

BE ABLE TO SMELL FUEL GASES.

• U.L. recognized fuel gas and CO 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.

— Improper installation, adjustment, alteration, service or maintenance can cause injur

damage or death. Refer to this manual. Installation and service must be performed by a qualified installer, service agency or the gas supplier. In the commonwealth of Massachusetts, installation must be performed by a licensed plumber or gas fitter for appropriate fuel.

ntil authorized by the gas supplier or fire department.

y, property

92-24161-75-00

IMPORTANT: All Rheem 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 ga

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 air-cond

itioning 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

and the State of

California's OEHHA (Office 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.

Installation Instructions are updated on a regular basis. This is done as product changes occur or if new information becomes available. In this publication, an arrow ➤ denotes changes from the previous edition or additional new material.

TABLE OF CONTENTS

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

INSTALLATION CHECK LIST...................................................................................................................................5

GENERAL INFORMATION .......................................................................................................................................6

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY..............................................8

LOCATION REQUIREMENTS AND CONSIDERATIONS.......................................................................................9

CLEARANCE-ACCESSIBILITY....................................................................................................................10

SITE SELECTION .........................................................................................................................................11

DIMENSIONS AND CLEARANCE TO COMBUSTIBLES...........................................................................12

UPFLOW MODELS.............................................................................................................................12

DOWNFLOW MODELS......................................................................................................................13

HORIZONTAL MODELS.....................................................................................................................14

DUCTING ......................................................................................................................................................15

SUPPLYAIR SENSOR .................................................................................................................................17

VENTING AND COMBUSTION AIR PIPING.........................................................................................................18

INSTALLATION WITH PRE-EXISTING VENT SYSTEMS..........................................................................18

JOINING PIPE AND FITTINGS....................................................................................................................19

CEMENTING JOINTS...................................................................................................................................19

NON-DIRECT VENT PIPE INSTALLATION ...........................................................................................................20

DIRECT VENT PIPE INSTALLATION ....................................................................................................................24

CONCENTRIC TERMINATIONS..................................................................................................................26

HORIZONTALTERMINATIONS...................................................................................................................28

CONDENSATE DRAIN / OPTIONAL NEUTRALIZER ..........................................................................................34

CONVERTING DOWNFLOW/HORIZONTAL MODELS TO HORIZONTAL CONFIGURATION.........................36

GAS SUPPLYAND PIPING ....................................................................................................................................39

GAS VALVE...................................................................................................................................................40

LP CONVERSION.........................................................................................................................................42

ELECTRICAL WIRING............................................................................................................................................45

ACCESSORIES.......................................................................................................................................................47

ELECTRONIC AIR CLEANER......................................................................................................................47

HUMIDIFICATIONAND DEHUMIDIFICATION............................................................................................47

OTHER ACCESSORIES ..............................................................................................................................49

TYPICAL WIRING ACCESSORIES FOR COMMUNICATING RESIDENTIAL SYSTEMS............49-50

HIGH ALTITUDE INSTALLATIONS ........................................................................................................................51

LP GAS AT HIGH ALTITUDE ELEVATIONS................................................................................................53

ZONING SYSTEMS......................................................................................................................................54

INSTALLATION WITH NON-COMMUNICATING, HIGH-EFFICIENCY PREMIUM COOLING

SYSTEMS ...................................................................................................................................................54

INTEGRATED FURNACE CONTROL ...................................................................................................................55

CONNECTORS AND COMPONENTS OF FURNACE CONTROL ...........................................................55

SPECIAL CONFIGURATION – COMM T-STAT AND NON-COMM CONDENSER ..................................56

MEMORY CARD...........................................................................................................................................60

RULES FOR WRITING, DISTRIBUTION AND ARBITRATION OF MULTIPLE COPIES OF

FURNACE SHARED DATA FOR COMMUNICATING-CAPABLE FURNACES ..............................60

REPLACING THE FURNACE CONTROL...................................................................................................63

DIPSWITCHES .............................................................................................................................................66

FURNACE OPERATION USING NON-COMMUNICATING MODULATING,

MODULATING AND TWO-STAGE T-STATS.....................................................................................69

COMMUNICATING SYSTEMS....................................................................................................................73

WIRING FOR COMMUNICATIONS...................................................................................................73

STARTUP FOR SYSTEMS CONFIGURED WITH COMMUNICATIONS........................................74

CONTINUOUS FAN OPERATION IN COMMUNICATING MODE...................................................75

ACTIVE FAULT CODES WITH COMMUNICATING SYSTEMS.......................................................75

FURNACE USER MENUS ...........................................................................................................................75

STATUS 1 ............................................................................................................................................76

STATUS 2 ............................................................................................................................................78

2 WK HIST...........................................................................................................................................78

LIFE HIST............................................................................................................................................79

FAULT HISTORY.................................................................................................................................79

UNIT INFO...........................................................................................................................................79

SETUP.................................................................................................................................................79

DIPSWITCH.........................................................................................................................................80

DUAL-FUEL OPERATION ............................................................................................................................80

START-UP PROCEDURES ....................................................................................................................................81

SEQUENCE OF OPERATION.....................................................................................................................83

SETTING INPUT RATE................................................................................................................................83

MAINTENANCE.......................................................................................................................................................84

TROUBLESHOOTING CHART ..............................................................................................................................87

NORMAL OPERATING CODES (TABLE 20) ........................................................................................................89

FURNACE FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS (TABLE 21)..................................90-105

WIRE DIAGRAM – STEPPER / SERVO MODULATING VALVE (FUEL CODES HA OR HB).........................106

WIRE DIAGRAM – SOLENOID CONTROLLED MODULATING VALVE (FUEL CODES HG OR HH)............107

THERMOSTATS ....................................................................................................................................................108

NON-COMMUNICATING THERMOSTATS...............................................................................................108

THERMOSTAT WIRING (WITH WIRING DIAGRAMS) ............................................................................109

APPLICATIONS.....................................................................................................................................................112

MODULATING, TOUCH-SCREEN, NON-COMMUNICATING THERMOSTAT ((-)HC-TST412MDMS)..112

COMMUNICATING THERMOSTATS.........................................................................................................122

(-)HC-TST501CMMS PROGRAMMABLE COMMUNICATING THERMOSTAT............................124

(-)HC-TST550CMMS FULL COLOR, PROGRAMMABLE COMMUNICATING THERMOSTAT...128

IMPORTANT: To insure proper installation and operation of this product, completely read all instructions prior to attempting to assemble, install, operate, maintain or repair this product. Upon unpacking of the furnace, inspect all parts for damage prior to installation and start-up.

SAFETY INFORMATION

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 observe 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 horizon-

tally 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 subdi 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 mount-

ed 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 equip-

ment. 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”.

vision can not be met at the

4. INSPECTION. The state or local gas

inspector of the side wall horizontally

vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes car-

bon monoxide detectors and signage

installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through

4. (b) EXEMPTIONS: The following equip-

ment 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 a

2. Product Approved side wall horizon-

tally 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.

wall horizontally vented gas equipment

provides a venting system design or venting system components with the equip

ment, 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 fue 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 in tion instructions.

(e) A copy of all installation instructions for all Product Approved side wall hori-

zontally 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.

dopted by the Board; and

led equipment does not provide

stalla-

WARNING

INSTALL THIS FURNACE ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS. PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TOTHE FURNACE SPACE AS SPECIFIED IN THE VENTING SECTION OF THESE INSTRUCTIONS.

WARNING

PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE FURNACE SPACE AS SPECIFIED IN THE COMBUSTION AND VENTILATION AIR SECTION OF THESE INSTRUCTIONS.

WARNING

COMBUSTION PRODUCTS MUST BE DISCHARGED OUTDOORS. CONNECT THIS FURNACE TO AN APPROVEDVENT SYSTEM ONLY, AS SPECIFIED IN VENT PIPE INSTALLATION SECTION OF THESE INSTRUCTIONS.

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 TION INSTRUCTIONS.

WARNING

THIS FURNACE IS NOT APPROVED OR RECOMMENDED FOR INSTALLATION ON ITS BACK, WITH ACCESS DOORS FACING UPWARDS, ORWITH SUPPLY AIR DISCHARGING TO THE RIGHTHAND SIDE WHEN FACING THE FRONT OF THE FURNACE. SEE FIGURES 6 AND 7 FOR PROPER INSTALLATION OF HORIZONTAL MODELS.

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

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

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 ABOVE THE FLOOR. THIS ISTO REDUCE 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. FAILURETO FOLLOW THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WARNING

USE OF THIS FURNACE IS ALLOWED DURING CONSTRUCTION IF THE FOLLOWING TEMPORARY INSTALLATION REQUIREMENTS ARE MET. INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATE AND

TEMPERATURE RISE PER RAT-

ING PLATE MARKING;

• MEANS FOR PROVIDING OUT-

DOOR AIR REQUIRED FOR COM-

BUSTION;

• RETURN AIR TEMPERATURE

MAINTAINED BETWEEN 55°F

(13°C) AND 80°F (27°C); AND;

• CLEAN FURNACE, DUCT WORK

AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE,TEMPERATURE RISE AND VENTING, ACCORDINGTO THE INSTRUCTIONS.

WARNING

DO NOT JUMPER OR OTHERWISE BYPASS OVERTEMPERATURE OR ANY OTHER LIMITS OR SWITCHES ON THE FURNACE. IF ONE OF THESE LIMITS OR SWITCHES SHOULD TRIP OR OPEN, THE USER IS TO BE INSTRUCTED TO CALL A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. FOR MANUALLY RESETABLE SWITCHES,THE USER IS FURTHER INSTRUCTED TO NEVER RESET THE SWITCH, BUT TO CALL A QUALIFIED TECHNICIAN. MANUAL RESET SWITCHES MAY REQUIRE FURTHER CORRECTIVE ACTIONS. FAILURE TO FOLLOWTHIS WARNING COULD RESULT IN CARBON MONOXIDE POISONING, SERIOUS INJURY OR DEATH. IF THE UNIT IS INSTALLED IN A CLOSET,THE DOOR MUST BE CLOSED WHEN MAKINGTHIS CHECK. INSTALLERS AND TECHNICIANS ARE INSTRUCTED TO REPLACE ANY LIMIT OR SAFETY SWITCH/DEVICE ONLY WITH IDENTICAL REPLACEMENT PARTS.

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 INTOTHE LIVING SPACETHROUGH LEAKING DUCTS AND UNBALANCED DUCT SYSTEMS CAUSING PERSONAL INJURY OR DEATH (SEE FIGURE 5).

• 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 INTOTHE LIVING SPACE.

WARNING

ALWAYS INSTALL FURNACETO 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 DUCTING SECTION OF THESE INSTRUCTIONS. SEE ALSO FURNACE RATING PLATE.

WARNING

WHEN A FURNACE IS INSTALLED SO THAT SUPPLY DUCTS CARRY AIR CIRCULATED BYTHE FURNACETO 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 CONTAININGTHE FURNACE.

NOTICE

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 CONDI-TIONS AND ARE NOT COVERED BY THE UNIT WARRANTY.

NOTICE

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPORATOR COILS OR UNITS CONTAINING EVAPORATOR COILS THAT ARE 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 COIL DRAIN PAN OR A STOPPAGE IN THE PRIMARY CONDENSATE DRAIN PIPING. SEE ACCESSORIES SECTION OF THESE INSTRUCTIONS FOR AUXILIARY HORIZONTAL OVERFLOW PAN INFORMATION (MODEL RXBM).

WARNING

DO NOT EXCHANGE MEMORY CARDS BETWEEN 2 OR MORE DIFFERENT FURNACES. DOING SO COULD RESULT IN UNEXPECTED OPERATION – INCLUDING INADEQUATE AIRFLOW DURING HEATING (AND OTHER MODES OR A LOSS OF HEAT).

INSTALLATION CHECK LIST

REFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

Adequate pipe size

Correct supply pressure (during furnace operation)

Manifold pressure

No gas leaks

ELECTRICAL

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

Polarity observed

Furnace properly grounded (Earth ground)

Adequate wire size

FURNACE INSTALLATION

Adequate clearance to combustibles

Adequate clearance for service (at front)

DUCT STATIC PRESSURE

in. w.c. on heating speed

in. w.c. on cooling spe

Air temperature rise

CONDENSATE LINE

Trap filled with water

Vented

Sloped toward drain

Condensate drain line hoses connected and clamped

TERMINATIONS – DIRECT VENT

VERTICAL

Intake – 12" min. above roof/snow level

Correct relationship – exhaust to intake

VERTICAL – CONCENTRIC (RXGY-E03A)

Intake – 12" min. above roof/snow level

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

-D03A)

Correct relationship – exhaust to intake

12" min. above grade/snow level

ORIZONTAL – ALTERNATE (RXGY-D02, -D02A, -D03,

-D03A, -D04 OR -D04A)

Correct relationship – exhaust to intake

Above anticipated snow level

HORIZONTAL – CONCENTRIC (RXGY-E03A)

12" min. above grade/snow level

Intake “Y” rotated above center

Exhaust sloped toward furnace

VENTING – NON-DIRECT VENT (VERTICAL ONLY)

in. diameter – exhaust pipe

ft. of pipe – exhaust

no. of elbows

TERMINATION – NON-DIRECT VENT (VERTICAL ONLY)

12" min. above roof/snow level

Freeze protection (if necessary)

______ Neutralizer (if needed)

VENTING – DIRECT VENT

in. diameter – intake pipe

in. diameter – exhaust pipe

ft. of pipe – intake air

no. of elbows – intake air

ft. of pipe – exhaust pipe

no. of elbows – exhaust pipe

HORIZONTAL – STANDARD

12" min. above grade/snow level

HORIZONTAL – ALTERNATE

Above anticipated snow level

Model #

Serial #

Date

of installation

GENERAL INFORMATION

The RGFE, RGGE and RGJF series furnaces are design-certified by CSA for use with natural and L.P. gases as follows:

• 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.

• As non-direct, central forced air fur-

nace taking combustion air from the installation area or using air ducted from the outside.

• IMPORTANT: Proper application,

installation and maintenance of this

furnace are required if consumers are to receive the full benefits for which they have paid.

Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code” (NFPA54, 90A and 90B) 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 - U.S. 8501 East Pleasant Valley Road Cleveland, Ohio, 44131

Canadian installations must be installed in accordance with CSA, local installation codes and

authorities having jurisdiction.

CSA is available from: CSA International - Canada

178 Rexdale Blvd.

Etobicoke (Toronto), Ontario, Canada M9W-1R3

FIGURE 1

UPFLOW FURNACE RGFE (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

➤ FIGURE 2

DOWNFLOW FURNACE RGGE (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

ITEM

NO. PART NAME

1 CONDENSATE TRAP

2 DOOR SWITCH

3 JUNCTION BOX

4 TRANSFORMER

5 PRESSURE SWITCH ASSEMBLY

6 EXHAUST TRANSITION

7 CONNECTOR

8 MAIN LIMIT

9 EXHAUST AIR PIPE

10 VENT CAP SHIPPING PLUG

11 FLAME SENSOR

12 OVERTEMPERATURE SWITCH

ITEM

NO. PART NAME

13 TOP PLATE

14 BURNER

15 IGNITER

16 COMBUSTION AIR INLET

17 GAS VALVE

18 INDUCED DRAFT BLOWER

19 POWER FACTOR CHOKE

20 INTEGRATED FURNACE CONTROL

21 BLOWER MOTOR

22 BLOWER HOUSING

ITEM

NO. PART NAME

1 GAS VALVE

2 PRESSURE SWITCH ASSEMBLY

3 BLOWER HOUSING

4 POWER FACTOR CHOKE

5 BLOWER MOTOR

6 DOOR SWITCH

7 JUNCTION BOX

8 COMBUSTION AIR INLET

9 HALC

10 TOP PLATE

11 VENT CAP SHIPPING PLUG

ST-A1123-01_1 ST-A1123-01_2

12 OUTLET AIR PIPE

ITEM

NO. PART NAME

13 INTEGRATED FURNACE CONTROL

14 TRANSFORMER

15 INDUCED DRAFT BLOWER

16 CONNECTOR

17 EXHAUST TRANSITION

18 CONDENSATE TRAP

19 IGNITER

20 OVERTEMPERATURE SWITCH

21 BURNER

22 FLAME SENSOR

➤ FIGURE 3

DEDICATED HORIZONTAL FURNACE RGJF (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

ITEM

NO. PART NAME

1 GAS VALVE

2 CAPACITOR (FOR INDUCER)

3 LOW PRESSURE SWITCH

4 HIGH PRESSURE SWITCH

5 BLOWER HOUSING

6 POWER FACTOR CHOKE

7 BLOWER MOTOR

8 DOOR SWITCH

9 JUNCTION BOX

10 COMBUSTION AIR INLET

11 HALC

12 TOP PLATE

13 VENT CAP PLUG

ITEM

NO. PART NAME

14 OUTLET AIR PIPE

15 INTEGRATED FURNACE CONTROL

16 TRANSFORMER

17 INDUCED DRAFT BLOWER

18 CONNECTOR

19 EXHAUST TRANSITION

20 CONDENSATE TRAP

21 IGNITER

22 OVERTEMPERATURE SWITCH

23 BURNER

24 FLAME SENSOR

25 FACTORY-INST

ALLED STREET ELBOW

ST-A107801.S01

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 being 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 andair 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 INTOTHE 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

4).

• 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.

NOTICE

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 CONDI-TIONS AND ARE NOT COVERED BY THE UNIT WARRANTY.

NOTICE

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMEND-

ED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPORATOR COILS OR UNITS CONTAINING EVAPORATOR COILS THAT ARE LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGE TO THE BUILDING OR BUILDING CON-

TENTS MAY OCCUR AS A RESULT

OF AN OVERFLOW OF THE COIL

DRAIN PAN OR A STOPPAGE IN THE

PRIMARY CONDENSATE DRAIN PIP-

ING. SEE ACCESSORIES SECTION

OF THESE INSTRUCTIONS FOR

AUXILIARY HORIZONTAL OVER-

FLOW PAN INFORMATION (MODEL

RXBM).

FIGURE 4

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

RECEIVING

Immediately upon receipt, all cartons

and contents should be inspected for

transit damage. Units with damaged

cartons should be opened immedi-

ately. 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 for unit

size, electric heat, coil, voltage,

phase, etc. to be sure equipment

matches what is required for the

job specification.

• Read the entire instructions before

starting the installation.

• Some building codes require extra

cabinet insulation and gasketing when unit is installed in attic applications.

• If

installed in an unconditioned space, apply caulking around the power wires, control wires, refrigerant tubing and condensate line where they enter the cabinet. Seal the power wires on the inside

where they exit conduit opening.

Caulking is required to prevent air leakage into and condensate from

forming inside the unit, control box,

and on electrical controls.

• Install the unit in such a way as to

allow necessary access to the coil/filter rack and blower/control compartment.

• Install the unit in a level position to

ensure proper condensate drainage. Make sure unit is level in both directions within 1/8”.

• Install the unit in accordance with

any local code which may apply and the national codes. Latest edi-

tions 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 Ventilating Systems.

• NFPA90B Installation of warm air

heating and air conditioning systems.

• The equipment has been evaluat-

ed in accordance with the Code of Federal Regulations, Chapter XX, Part 3280.

LOCATION REQUIREMENTS AND CONSIDERATIONS

GENERAL INFORMATION

CAUTION

DO NOT USE THIS FURNACE DURING CONSTRUCTION IF AIR LADEN CORROSIVE COMPOUNDS ARE PRESENT SUCH AS CHLORINE AND FLUORINE. OTHERWISE, PROVISIONS MUST BE TAKEN TO PROVIDE CLEAN, UNCONTAMINATED COMBUSTION AND VENTILATION AIR TO THE FURNACE. FURNACE COMBUSTION AND VENTILATION AIR CONTAMINATED WITHTHESE COMPOUNDS FORMS ACIDS DURING COMBUSTION WHICH CORRODES THE HEAT EXCHANGER AND COMPONENT PARTS. SOME OF THESE CONTAMINANTS ARE FOUND IN, BUT NOT LIMITED TO, PANELING, DRY WALL, ADHESIVES, PAINTS, STAINS, VARNISHES, SEALERS, AND MASONRY CLEANING MATERIALS.

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

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 ABOVE THE FLOOR. THIS IS TO REDUCE 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 FOLLOWTHESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1. IMPORTANT: If installing the unit

over a finished ceiling or living

area, be certain to install an auxil-

iary condensate drain pan under the entire unit. Extend this auxil- iary drain pan under any evaporator coil installed with the furnace and the open portion of the con-

densate drain assembly. See

“Condensate Drain/Neutralizer”

section for more details.

2. IMPORTANT: If using a cooling

evaporator coil with 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 sion and eventual failure.

3. IMPORTANT: Install the furnace

level. If it is not level, condensate cannot drain properly, possibly causing furnace shut down.

NOTE: These furnaces are approved for installation in attics, as well as alcoves, utility rooms, closets and crawlspaces. Make provisions to pre-

vent freezing of condensate.

4. IMPORTANT: If this furnace is

installed in a garage, attic or any other unconditioned space, a selfregulating heat tape must be installed around the condensate trap and along the entire length of the condensate drain in the unconditioned space.

The heat tape should meet the following requirements:

a. The heat tape must be UL listed. b. Install the heat tape per the

c. The heat tape should be rated

FIGURE 5

DOWNFLOW HORIZONTAL FURNACE WITH HEAT TAPE ON CONDENSATETRAP

DRAIN PIPE

A086701

tubes resulting in corro-

manufacturer’s instructions for the entire length of drain pipe in the unconditioned space.

at 3 or 5 watts per foot at 120V.

SUPPLY AIR

HEAT TAPE

TRAP

5. IMPORTANT: If installing in a

utility room, be sure the door is wide enough to:

a. allow the largest part of the

furnace to pass; or

b. allow any other appliance

(such as a water heater) to pass.

6. Install the furnace level and plumb. If it is not level, condensate cannot drain properly, possibly causing furnace to shut down.

IMPORTANT: Do not attempt to twin the modulating furnace. The characteristics of the ECM blower motor preclude twinning applications.

RETURN AIR

FIGURE 6

DOWNFLOW/HORIZONTAL FURNACE INSTALLED IN HORIZONTAL POSITION W/SUPPORT BRACKETS

THIS FURNACE IS NOT APPROVED OR RECOMMENDED FOR INSTALLATION ON ITS BACK, WITH ACCESS DOORS FACING UPWARDS, ORWITH SUPPLY AIR DISCHARGING TO THE RIGHT

GAS PIPE

TRAP

CAUTION

SUPPLY AIR

INTAKE VENT

ELECTRICAL CONDUIT

EXHAUST VENT

RETURN AIR

E FOLLOWING MODELS INCLUDE THE ADDITIONAL BRACKET (WHICH MUST BE REMOVED) ON THE BLOWER ASSEMBLY:

RGFE/RGGE/RGJF-09EZCMS RGFE/RGGE/RGJF-10EZCMS RGFE/RGGE/RGJF-12ERCMS

HAND SIDE WHEN FACING THE FRONT OF THE FURNACE.

SEE FIGURES 6 AND 7 FOR PROPER INSTALLATION OF HORIZONTAL MODELS.

FIGURE 7

REMOVING SHIPPING BRACKET

CLEARANCE ACCESSIBILITY

The design of forced air furnaces with models as listed in the tables under Figures 9 and 10 are certified by CSA Laboratories 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 is recommended in front of all furnaces.

FOR PURPOSES OF SERVICING THIS APPLIANCE, ACCESSIBILITY CLEARANCES, WHERE GREATER, SHOULD TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES.

A086801

WARNING

FURNACES MUST NOT BE INSTALLED DIRECTLY ON CARPET, TILE OR OTHER COMBUSTIBLE MATERIAL. INSTALLATION ON A COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING MAY RESULT IN FIRE CAUSING DAMAGE, PERSONAL INJURY OR DEATH.

-GGE FURNACES MAY NOT

BE INSTALLED DIRECTLYTO A COMBUSTIBLE FLOOR. A SPECIAL FLOOR BASE IS REQUIRED.

-GFE upflow furnaces and -GGE downflow furnaces are designed and certified for installation on combustible (wood only) floors.

-GGE downflow furnaces may be installed on a cased evaporator coil mounted on a combustible (wood only) floor or (for installations without an evaporator coil) installed on a special base for combustible floors mounted to a combustible (wood only) floor.The nece

ssary floor base for installing a -GGE furnace in the downflow configuration to a combustible (wood only) floor is an accessory sold through finished goods. Following is a list of floor base models by furnace input size (see Figure 8).

RGGE

Furnace Special Base For

BTU’s Combustible Floors

60, 75 RXGC-B17

90, 105 RXGC-B21

120 RXGC-B24

Upflow furnaces are shipped with a bottom closure panel installed. When bottom return air is used, remove the panel by removing the two screws attaching the panel to the front base angle. See filter section for details (see Figure 12).

92-24379-01

CAUTION

SOME MODELS HAVE A SHIPPING BRACKET INSTALLED TO PROTECT THE BLOWER ASSEMBLY DURING SHIPPING.

LOCATE AND REMOVE THE SHIPPING BRACKET FROM THE SIDE OF THE BLOWER HOUSING BEFORE OPERATING UNIT. SEE FIGURE 7.

FIGURE 8

BASE FOR COMBUSTIBLE FLOORS

SITE SELECTION

1. Select a site in the building near

the center of the proposed, or exist-

ing, duct system.

2. Give consideration to the vent system piping when selecting the furnace location. Vent from the furnace to the termination with minimal length and elbows.

3. Locate the furnace near the exist-

ing gas piping. If running a new gas

line, locate the furnace to minimize

the length and elbows in the gas piping.

4. Locate the furnace to maintain proper clearance to combu as shown in Figures 9, 10 & 11.

stibles

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 A USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES.

REA MUST NOT BE

FIGURE 9

PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS

A039201

RGFE

UPFLOW MODELS

AIRFLOW

NOTE: For 1800 or more CFM, both side

returns must be used when not using a

bottom return configuration.

AO39201

FIGURE 10

DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, DOWNFLOW MODELS

RGGE

(Downflow Configuration)

FOR MODELS INSTALLED AS DOWNFLOW ONLY

AIRFLOW

FIGURE 11



DIMENSIONS AND CLEARANCES TO COMBUSTIBLES, HORIZONTAL MODELS

NOTE: For 1800 or more CFM, both side

returns must be used when not using a

FACING THE FRONT OF THE FUR-

ONLY BE INSTALLED SO AS WHEN

IMPORTANT:THIS FURNACE MAY

NACE, SUPPLY AIR IS DIS-

CHARGED ON THE LEFT HAND

SIDE.

(RETURN)(SUPPLY)

bottom return configuration.

INSTALLED AS

configuration.)

(FUEL CODE HB ONLY)

HORIZONTAL ONLY

RGJF (ALL) & RGGE

on RGGE models – only

(Be sure to check the fuel code

furnaces with HB fuel codes

can be installed in horizontal

AIRFLOW

DUCTING

Proper airflow is required for the correct operation of this furnace. Too little airflow can cause erratic operation and can damage the heat

exchanger. The supply and return duct

must carry the correct amount of air for heating and cooling if summer air conditioning is used.

Size the ducts according to acceptable

industry standards and methods. The total static pressure drop of the supply

and return duct should not exceed 0.2"

w.c.

WARNING

NEVER ALLOWTHE PRODUCTS OF COMBUSTION FROMTHE FLUE TO ENTER THE RETURN AIR DUCTWORK ORTHE CIRCULATED AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE

WITH SHEET METAL SCREWS;

AND JOINTS,TAPED. SECURE ALL OTHER DUCT JOINTS WITH APPROVED CONNECTIONS AND SEAL AIRTIGHT.WHEN A FURNACE IS MOUNTED ON A PLATFORM WITH RETURN THROUGH THE BOTTOM, IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE ANDTHE RETURN AIR PLENUM.THE FLOOR OR PLATFORM MUST PROVIDE PHYSICAL SUPPORT OFTHE FURNACEWITHOUT SAGGING, CRACKS, OR GAPS AROUND THE BASE, PROVIDING A SEAL BETWEEN THE SUPPORT AND THE BASE.

FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTOTHE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONINGTHAT COULD RESULT IN PERSONAL INJURY OR DEATH.

DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN OR SUPPLY DUCTWORK TO OR FROM ANY OTHER HEAT PRODUCING DEVICE SUCH AS A FIREPLACE INSERT, STOVE, ETC. DOING SO MAY RESULT IN FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY OR PROPERTY DAMAGE.

IMPORTANT: Some high efficiency filters

have a greater than normal resistance to airflow. This can adversely affect furnace operation. Be sure to check airflow if using any filter other than the factory-provided filter.

UPFLOW UNITS

1. Position the unit to minimize long

runs of duct or runs of duct with many turns and elbows.

WARNING

UPFLOW FURNACE: BASE PLATE MUST BE INSTALLED IN THE FURNACE BOTTOM WHEN USING SIDE AIR RETURN. FAILURE TO INSTALL A BASE PLATE COULD CAUSETHE PRODUCTS OF COMBUSTION TO CIRCULATE INTOTHE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING OR DEATH.

A SOLID METAL

2. Open the return air compartment.

a. If using side return air, do not

remove the bottom base.

b. Cut an opening in the side .

The opening should be cut the full width of the knockouts on the

unit.

NOTE: When using side return, return air plenums, RXGR-C17B, C21B and C24B are available from the factory.

c. Remove the bottom base, if

using bottom return air. Remove the panel by removing the two screws attaching the base to the front base angle. See Figure 12.

NOTE: Where the maximum

airflow is 1800 CFM or more, both sides or the bottom must be used for return air.

3. Connect the return duct or return air cabinet to the unit. Make the connection air tight to prevent entra

ining combustion gases from

an adjacent fuel-burning appli-

ance.

4. Be sure to have adequate

space for the unit filter. NOTE: DO NOT take return air

from bathrooms, kitchens, furnace rooms, garages, utility or laundry rooms, or cold areas. DO NOT use a rear air return.

5. If summer air conditioning is desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

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

IMPOR

TANT: If a flexible duct

connector must be used, it MUST be rated for a minimum temperature of 250°F. continuous.

FIGURE 12

BOTTOM PANEL REMOVAL

NOTE: FILTERAND FILTER-ROD ARE SHIPPED ON TOP OF SOLID BOTTOM. REMOVE FILTER AND FILTER ROD TO ACCES SOLID BOTTOM

ADS-5422-01

DOWNFLOW UNITS

1. Position the unit to minimize long

runs of duct or runs of duct with many turns and elbows.

2. If summer air conditioning is desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

3. If installing on a combustible floor

and not using an air conditioning plenum, install the special base for

combustible floors. See Figure 8.

WARNING

THE DOWNFLOW FURNACE DESIGN IS CERTIFIED FOR INSTALLATION ON A NON-COMBUSTIBLE FLOOR USE THE SPECIAL BASE SPECIFIED ON THE FURNACE CLEARANCE LABEL. FAILURE TO INSTALLTHE SPECIAL BASE MAY RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.THIS SPECIAL BASE IS SHIPPED FROM THE FACTORY AS AN ACCESSORY.

4. Connect the furnace to the supply air plenum.

5. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combus-

tion gases from an adjacent fuel-

burning appliance.

6. Be sur

eto have adequate space

for the unit filter. NOTE: DO NOT take return air

from bathrooms, kitchens, furnace rooms, garages, utility or laundry rooms, or cold areas.

 Return air can come from : (1) outside the building, (2) from return air ducting from several inside rooms, or (3) a combination of the two. When using

outside air, design and adjust the sys-

tem to maintain a return air temperature above 55°F during the heating season. If return air comes from both inside and outside the building, design the ducting system with a diverting damper so that the volume of return air entering the furnace equals that which would normally enter thr furnace. Any duct opening pulling return air from the outside must not be any higher nor closer than 10 feet to the fur-

nace exhaust vent.

ough the return air intake of the

SUPPLY AIR SENSOR

Each furnace comes shipped from the factory with a supply air sensor. Install the sensor, in the supply air plenum trunk, with two, field supplied, #8 sheet metal screws, using the following guidelines:

1. 12” downstream of the evaporator coil, if installed.

2. If no evaporator coil is used, locate the sensor out of direct line-of-site of the heat exchanger and not closer than 18” downstream of the furnace outlet.

3. Attach the supply air sensor wires onto the terminals marked “SA Sensor” on the integrated furnace control board (See Figure 13).

4. Do not extend the supply-air sensor

wire. NOTE: Improper placement of the

supply air sensor can adversely affect furnace temperature rise.

NOTE: In downflow circumstances where building construction does not allow for the placement of the sensor to fall within these parameters, the supply air sensor should not be connected. This means that the furnace will run under default parameters. When running under default parameters, the “82” code will appear for 90 seconds. After that, the fault code will be stored in the control board’s memory and will show only upon power cycling. Default airflow

parameters can be manually adjusted.

See section discussing Integrated Furnace Control (IFC) board in this manual.

For communicating systems, the supply air se off so that a fault code will not be displayed at all. This can be done in the furnace setup menu of a communicating thermostat. See the section of this manual titled Communicating Systems under sub-section titled Furnace User Menus (Setup).

nsor input can be turned

FIGURE 13

SUPPLY AIR SENSOR TERMINALS

VENTING AND COMBUSTION AIR PIPING

GENERAL INFORMATION

WARNING

READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURETO PROPERLY VENT THIS FURNACE OR PROTECT IT FROM INADEQUATE COMBUSTION AIR CAN CAUSE CARBON MONOXIDE POISONING, AN EXPLOSION OR FIRE, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

OVERTEMPERATURE SAFETY SWITCHES

Furnaces are equipped with safety switches in the burner compartment to protect against over temperature conditions. If a switch is tripped, it must be manually reset.

WARNING

DO NOT JUMPER OVERTEMPERATURE OR ANY OTHER SAFETY SWITCHES! IF ONE OF THESE OVER TEMPERATURE SWITCHES SHOULD TRIP, CALL A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. DO NOT RESET THE SWITCHES WITHOUTTAKING CORRECTIVE ACTION. FAILURE TO DO SO CAN RESULT IN CARBON MONOXIDE POISONING OR DEATH. IF THIS UNIT IS INSTALLED IN A CLOSET, THE DOOR MUST BE CLOSEDWHEN MAKING THIS CHECK.

REPLACETHE OVER TEMPERATURE SAFETY SWITCHES ONLY WITH THE IDENTICAL REPLACEMENT PART.

WARNING

IN CANADA, PRODUCTS CERTIFIED FOR INSTALLATION AND INTENDED TO BE VENTEDWITH PLASTIC VENT SYSTEMS (PVC, CPVC) MUST USE VENT SYSTEMS THAT ARE CERTIFIED TO THE STANDARD FOR TYPE BH GAS VENTING SYSTEMS, ULC S636.

THE COMPONENTS OF THE CERTIFIED MATERIAL MUST NOT BE INTERCHANGED WITH OTHER VENT SYSTEMS OR UNLISTED PIPE/FITTINGS.

PLASTIC COMPONENTS AND SPECIFIED PRIMERS AND GLUES OF THE CERTIFIED SYSTEM MUST BE FROM A SINGLE SYSTEM MANUFACTURER AND NOT INTERMIXED WITH OTHER SYSTEM MANUFACTURER’S PARTS.

NOTE: INLET AIR PIPING IS NOT CONSIDERED TO BE A PART OF THE “VENTING SYSTEM”.THE REQUIREMENT THATVENT MATERIAL BE CERTIFIED TO ULC S636 DOES NOT APPLY TO INLET AIR PIPING.

INSTALLATION WITH PRE-EXISTING VENT SYSTEMS

When the installation of this furnace

replaces an existing furnace that is

removed from a vent system serving other appliances (such as a water

heater), the existing vent system is likely

to be too large to proper remaining attached appliances.

Follow the steps below with each appliance remaining connected to the original common vent system. Place the appliance to be tested in operation, while the other appliances remaining connected to the common vent system are not in operation. Test the operation of each appliance individually by the following method.

1. Permanently seal any unused openings in the common venting system.

2. Visually inspect the venting system f

or proper size and horizontal pitch

and determine that there is no blockage, restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

3. If practical, close all building doors, windows and all doors between the space where the appliances remaining connected to the common venting system are located. Turn on clothes dryers and any appliance not connected to the

ly vent the

common venting system. Turn

on any exhaust fans, such as

range hoods and ba

exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close

fireplace dampers.

4. Follow the lighting instructions. Place the appliance being

inspected into operation. Adjust

the thermostat so the appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined each appliance that remains connected to the common venting system properly vents (when tested as outlined above), return

doors, windows, exhaust fans,

fireplace dampers and any other gas-burning appliance to their previous conditions of use.

7. If improper venting is observed during any of the above tests,

resize the common venting sys-

tem. Refer to latest edition of the National Fuel Gas Code ANSI Z223.1, or the CSA-GAMA venting tables for Category I furnaces

NOTE: For U.S. installations only. Schedule 40 ABS-DWV pipe and fittings may be used as an alternate to PVC pipe for the combustion air inlet and vent pipes.

NOTE: For U.S. installations only. Cellular core PVC is also approved for use. It must be schedule 40 PVC-DWV cellular pipe manufactured under ASTM F-891.

throom

that

JOINING PIPE AND FITTINGS

WARNING

PVC SOLVENT CEMENTS AND PRIMERS ARE HIGHLY FLAMMABLE. PROVIDE ADEQUATE VENTILATION AND DO NOT ASSEMBLE COMPONENTS NEAR HEAT SOURCE OR AN OPEN FLAME. DO NOT SMOKE. AVOID SKIN OR EYE CONTACT. OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON MATERIAL CONTAINERS. FAILURETO FOLLOW THESE GUIDELINES MAY RESULT IN FIRE, EXPLOSION OR ASPHYXIATION CAUSING PERSONAL INJURY OR DEATH.

All pipe, fittings, solvent cement, primers and procedures must conform to American National Standard Institute and American Society for Testing and Materials (ANSI/ASTM) standards as shown below:

IMPORTANT: The plastic combustion air and venting components are MADE of PVC. If using ABS piping, ensure that the solvent cement is compatible for

joining PVC to ABS components or use

a mechanical connection that can withstand the vent temperatures and is corrosion resistant.

CEMENTING JOINTS

Properly seal all joints in the PVC vent

using the following materials and procedures:

PVC CLEANER-PRIMER AND PVC MEDIUM-BODY SOLVENT CEMENT

IMPORTANT: After cutting pipe, remove all ragged edges and burrs. This is important to prevent increase in pressure drop throughout the system.

1. Cut pipe end square. Chamfer edge of pipe. Clean fitting socket and

pipe joint area of all dirt, grease and

moisture.

2. After checking pipe and socket for proper fit, wipe socket cleaner-primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe. READ INSTRUCTIONS INCLUDED WITH THE PRIMER FOR PROPER INSTALLATION.

and pipe with

3. Apply a thin coat of cement evenly in the socket. Quickly apply a heavy coat of cement to the pipe end and insert pipe into fitting with a slight twisting movement until it bottoms out.

NOTE: Cement must be fluid; if not, recoat.

4. Hold the pipe in the fitting for 30 seconds to prevent the tapered socket from pushing the pipe out of the fitting.

5. Wipe all excess cement from the joint with a rag. Allow 15 minutes

before handling. Cure time varies according to fit, temperature and humidity.

NOTE: Stir the solvent cement frequently while using. Use a natural bristle, one inch wide brush or the applicator supplied with the can.

IMPORTANT: For Proper Installation DO NOT use solvent cement that has become curdled, lumpy or thickened. DO NOT thin. Observe shelf precautions printed on containers. For application below 32°F, use only low-temperature-type solvent cement.

For correct installation of the vent pipe, follow the instructions provided by the manufacturers of the pipe, primer and solvent.

PIPE & FITTING MATERIAL

Schedule 40 PVC (Pipe) D1785 Schedule 40 PVC (Cellular Core Pipe) F891 Schedule 40 PVC (Fittings) D2466 SDR-21PVC (Pipe) D2241 SDR-26 PVC (Pipe) D2241 Schedule 40 ABS Cellular Core DWV (Pipe) F628 Schedule 40 ABS (Pipe) D1527 Schedule 40 ABS (Fittings) D2468 ABS-DWV (Drain Waste & Vent)

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

(Pipe & Fittings)

ASTM

SPECIFICATION

D2661

D2665

NON-DIRECT VENT PIPE INSTALLATION

(FOR VERTICALTERMINATIONS ONLY)

COMBUSTION AIR

WARNING

ALWAYS PROVIDE THIS FURNACE AND ANY OTHER FUEL BURNING APPLIANCE WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES. MOST BUILDING CODES REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE DEATH FROM CARBON MONOXIDE POISONING.

Provide adequate facilities for combustion and ventilation air in accordance with section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANS Z223.1 - latest edition; CAN/CGA B149.1 and .2, or applicable provisions of the local building codes. These combustion and ventilation facilities must not be obstructed.

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any furnace failure due to corrosive elements in

the atmosphere is excluded from

warranty coverage.

The following types of installation (but not limited to the following) REQUIRE OUTDOOR AIR for combustion, d

to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry

rooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemical

storage areas.

Exposure to the following substances

in the combustion air supply (but not limited to the following) also REQUIRE OUTDOOR AIR for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine-based swimming pool

chemicals

• Water softening chemica

• De-icing salts or chemicals

• Carbon Tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as per-

chloroethylene)

• Printing inks, paint removers,

varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Anti-static fabric softeners for

clothes dryers

• Masonry acid washing materials

Combustion air must be free of acid forming chemicals such as sulphur, fluorine, and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cl vents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products. Vapors from these products when burned in a gas flame form acid compounds. The acid compounds increase the dew point temperature of the flue products and produce highly corrosive condensate.

eaning sol-

WARNING

ALL FURNACE INSTALLATIONS MUST COMPLY WITHTHE NATIONAL FUEL GAS CODE AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN RESULT IN EXPLOSION, FIRE, PROPERTY DAMAGE, CARBON MONOXIDE POISONING, PERSONAL INJURY OR DEATH.

Combustion air requirements are determined by whether the furnace is in an open (unconfined) area or in a confined space such as a closet or small room.

FURNACE LOCA UNCONFINED SPACE

Using indoor air for combustion.

An unconfined space must have at least 50 cubic feet for each 1,000 BTUH of the total input for all appliances in the space. Here are a

few examples of the room sizes

required for different inputs. The

sizes are based on 8 foot ceilings.

See Table 1.

TABLE 1

UNCONFINED SPACE DIMENSIONS

BTUH Minimum Sq. Feet Typical Room Size

Input With 8 foot Ceiling

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

75,000 469 15' x 32' OR 20' x 24'

90,000 563 20' x 28' OR 24' x 24'

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

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

If the open space containing the furnace is in a building constructed to severely limit outside air infiltration (contemporary energy efficient construction methods), o still be required for the furnace to operate and vent properly. Outside

air openings should be sized the

same as for a confined space.

TED IN AN

utside air may

FURNACE LOCATED IN A CONFINED SPACE.

A confined space (any space smaller than shown before as “unconfined”) must have openings into

the space, which are located in accordance with the requirements set forth in the following subsections A and B. The open-

ings must be sized by how they

connect to the heated area or to the outside, and by the input of all appliances in the space.

If the confined space is within a building with tight construction, combustion air must be taken fro

m outdoors or areas freely communicating with the outdoors.

TABLE 2

INDOOR AIR OPENING DIMENSIONS

BTUH Free Area

Input Each Opening

60,000 100 square inches

75,000 100 square inches

90,000 100 square inches

105,000 105 square inches

120,000 120 square inches

FIGURE 14

AIR FROM HEATED SPACE

A. USING INDOOR AIR FOR

COMBUSTION

IMPORTANT: DO NOT take air from

a heated space with a fireplace,

exhaust fan or other device that may

produce a negative pressure.

If combustion air is taken from the heated area (see Figure 14), the openings must each have at least

100 square inches of free area.

Each opening must have at least

one square inch of free area for each 1,000 BTUH of total input in

the space. See Table 2.

B. USING OUTDOOR AIR FOR

COMBUSTION

IMPORTANT: Do not take air from

an attic space that is equipped with power ventilation.

The confined space must communicate with the outdoors in accordance with Methods 1 or 2. The minimum dimension of air openings shall not be less than 3 inches. Where ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect.

Method 1 Two permanent openings, one locat-

ed within 12 inches of the top and one located within 12 inches of the bottom of the enclosure, shall be pro-

vided. The openings shall communi-

cate directly, or by ducts, with the out-

doors or spaces (crawl or attic) that

freely communicate with the out-

doors.

a. Where directly communicating

with the outdoors or where communicating to the outdoors through vertical ducts as shown in Figure 15, each opening shall have a minimum free area of 1 square inch for each 4000 BTUH of total appliance input rating in the enclosure. See Table 3.

A077501

TABLE 3

VERTICAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size

60,000 15.00 square inches 5"

75,000 18.75 square inches 5"

90,000 22.50 square inches 6"

105,000 26.25 square inches 6"

120,000 30.00 square inches 7"

b. Where communicating with out-

doors through horizontal ducts,

each opening shall have a minimum free area of 1 square inch for each 2000 BTUH of total input rating of all equipment in the enclosure. See Table 4 and Figure 16.

TABLE 4

HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size

60,000 30.00 square inches 7"

75,000 37.50 square inches 7"

90,000 45.00 square inches 8"

105,000 52.50 square inches 9"

120,000 60.00 square inches 9"

Method 2 One permanent opening, located within 12 inches of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance. The opening shall directly communicate with the outdoors or communicate through a vertical or

horizontal duct to the outdoors or

spaces (crawl or attic) that freely communicate with the outdoors, and shall have a minimum free area of:

a. One square inch for each 3000

BTUH of the total input rating of all equipment located in the enclosure (see Table 5), and

Combustion air openings must not be restricted in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

FIGURE 15

AIR FROM ATTIC/CRAWL SPACE

A077601

FIGURE 16

OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

b. Not less than the sum of the

areas of all vent connectors in the confined space.

If the unit is installed where there is

an exhaust fan, sufficient ventilation

must be provided to prevent the

exhaust fan from creating a negative

pressure.

TABLE 5

VERTICAL OR HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size

60,000 20.00 square inches 6" 75,000 25.00 square inches 6"

90,000 30.00 square inches 7" 105,000 35.00 square inches 7" 120,000 40.00 square inches 8"

A077701

INSTALLATION GUIDELINES

IMPORTANT: When installed as a non-

direct furnace, only vertical terminations

are allowed. Do not use horizontal termi-

nations when the furnace is installed with a non-direct vent.

All exhaust vent piping must be installed

in compliance with Part 7, Venting of Equipment, of the latest edition of the National Fuel Gas Code NFPA 54/ANSI A223.1, or CAN/CGA-B149.1 and .2, local codes or ordinances and these instructions.

7. The minimum vent length is 5 feet.

8. All piping through the roof is 2".

When using 3" pipe, reduce to 2" within 18" of the inside of the roof.

9. Vertical through-the-roof installations do not require any special vent termination. Use 2" PVC

pipe extending a minimum of 12

inches above the anticipated level of snow accumulation.

10. Elbows must be a mini

mum of

15” apart.

11. No screens may be used to cover combustion air or

exhaust.

VENTING GUIDELINES - Non-

Direct

Vent

1. IMPORTANT: Do not common vent

with any other appliance. Do not install in the same chase or chimney with a metal or high temperature plastic pipe from another gas or fuel-burning appliance unless the required minimum clearances to combustibles are maintained between the PVC pipe and other pipes.

2. Use only medium or long radius

sweep elbows, such as PVC-DWV elbows.

NOTE: For upflow and downflow

installations, extend the exhaust

pipe a minimum of 18" vertically above t

he furnace cabinet before

turning the vent.

3. Vertical vent piping is preferred.

4. Install all horizontal piping as fol-

lows:

• Slope horizontal vent piping

upward a minimum of 1/4" per foot of run so that condensate drains toward the furnace.

• Support horizontal vent piping at

least every four feet. No sags or dips are permitted.

5. Insulate all vent runs through unconditioned spaces where below-

freezing temperatures are expected,

with 1" thick medium density, foil

ced fiber glass or equivalent

Rubatex/Armaflex insulation. For horizontal runs where water may collect and freeze, wrap the vent

pipe with self-regulating, 3 or 5 Watt heat tape. The heat tape must be U.L. listed and installed per the manufacturer’s instructions.

6. All piping between the furnace and the roof penetration is 2" or 3" as specified in Table 6. Table 6 lists the

maximum allowable exhaust vent

pipe length for the number of elbows used, based on the furnace

size.

PORTANT: Use Only standard

vertical terminations when installing the modulating furnace as a nondirect vent appliance.

➤ TABLE 6

NON-DIRECT VENT APPLICATIONS

MAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST PIPE

UPFLOW FURNACES RGFE

NUMBER OF ELBOWS

22°, 45° OR 90°

MEDIUM / LONG RADIUS ONLY

1-2 3-4 5-6

40'

120'

20' 120' 110' 110'

35'

120'

15' 120' 105' 105'

30'

120'

10'

120'

95' 95'

FURNACE

INPUT

60,000

75,000

90,000 105,000 120,000

PIPE SIZE

(VERTICAL VENT

TERMINATIONS

ONLY)

TERMINATION

2" 3" 2" 3" 3" 3"

STANDARD STANDARD STANDARD STANDARD STANDARD STANDARD

3" 45' 35' 30'STANDARD

DOWNFLOW AND HORIZONTAL FURNACES RGGE AND RGJF

FURNACE

INPUT

PIPE SIZE

(VERTICAL VENT

TERMINATIONS

ONLY)

TERMINATION

STANDARD

60,000

3" 2"

STANDARD STANDARD

75,000

90,000 105,000 120,000

NOTES:

1. N.R. - NOT RECOMMENDED.

2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT. MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.

3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.

4. CONCENTRIC TERMINATION NO. RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.

5. USE KITS RXGY-D02 OR D02A (2") OR RXGY-D03 OR D03A (3") FOR STANDARD OR ALTERNATE THRU-THE-WALL VENTING.

6. USE KITS RXGY-D04 OR D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS

7. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.

* A = 17

B = 21” CABINET WIDTH

3" 3" 3" 40' 35' 30'STANDARD

⁄2” CABINET WIDTH

STANDARD STANDARD STANDARD

NUMBER OF ELBOWS

22°, 45° OR 90°

MEDIUM / LONG RADIUS ONLY

1-2 3-4 5-6

30'

120'

20'

120'

90' 45'

25'

120'

15'

120'

80' 40'

WITH LONG RUNS.

20'

120'

10'

120'

75' 35'

DIRECT VENT PIPE INSTALLATION

WARNING

READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURETO PROPERLY VENT THIS FURNACE CAN CAUSE CARBON MONOXIDE POISONING OR AN EXPLOSION OR FIRE, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Direct vent installations require a dedicated combustion air and venting system. All air for combustion is taken from outside and all combustion products are discharged to the outdoors.

Therefore, no ventilation or combustion air openings are required.

INSTALLATION GUIDELINES

All exhaust piping must be installed in

compliance with Part 7, “Venting of Equipment,” of the latest edition of the National Fuel Gas Code NPFA 54, 90A and 90B ANSI Z223.1-, local codes or ordinances and these instructions.

1. IMPORTANT: Do not common

vent with any other appliance. Do not install in the same chase or chimney with a metal or high temperature plastic pipe from another gas or fuel-burning appliance unless the required minimum clearances to maintained between the approved PVC pipe and other pipes.

2. Use only medium or long radius

sweep elbows.

NOTE: For all installations. Extend

the combustion air exhaust pipe a

minimum of 18" vertically above the furnace cabinet before turning the vent.

3. Vertical piping is preferred.

4. Install all horizontal piping as fol-

lows:

• Slope horizontal vent piping

upward a minimum of 1/4" per foot of run so that condensate drains toward the furnace.

• Support h

least every four feet. No sags or dips are permitted.

combustibles are

orizontal vent piping at

➤ TABLE 7

DIRECT VENT APPLICATIONS

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

UPFLOW RGFE FURNACES

NUMBER OF ELBOWS

FURNACE

INPUT

60,000

75,000

90,000

105,000

120,000

PIPE SIZE

TERMINATION

STANDARD

CONCENTRIC

ALTERNATE

STANDARD

CONCENTRIC

ALTERNATE

STANDARD STANDARD

CONCENTRIC

ALTERNATE

STANDARD

CONCENTRIC

ALTERNATE

STANDARD

CONCENTRIC

ALTERNATE

STANDARD

CONCENTRIC

ALTERNATE ALTERNATE

VENT

TERMINATION KIT

RECOMMENDED

RXGY-D02A/G02A

RXGY-E03A/G02A

RXGY-D02A

RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D03A RXGY-D02A/G02A RXGY-D0

3A/G02A

RXGY-E03A/G02A

RXGY-D03A RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D03A RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D03A

RXGY-D03/G02A

RXGY-E03A/G02A

RXGY-D03A

RXGY-D04A

⁄2°, 45° OR 90°

MEDIUM / LONG

RADIUS ONLY

1-2 5-6

3-4

40'

35'

25'

30'

120'

105'

110'

15'

20'

120'

100'

95'

110' 105' 95'

50' 40' 35'

110' 105' 95'

50' 40' 35'

45' 35' 30'

105' 95' 90'

DOWNFLOW AND DOWNFLOW/HORIZONTAL RGGE AND RGJF

NUMBER OF ELBOWS

FURNACE

INPUT

60,000

75,000

90,000

105,000

120,000

NOTES:

1. N.R. - NOT RECOMMENDED.

2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT. MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.

3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.

4. CONCENTRIC TERMINATION NO. RXGY-E03 IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.

5. USE KITS RXGY-DO2 (2") OR RXGY-D03 (3") FOR STANDARD OR ALTERNATE THRU-THE-WALL VENTING.

6. USE KITS RXGY-D04 FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.

7. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.

* A = 171⁄2” CABINET WIDTH

B = 21” CABINET WIDTH

** ALTERNATE VENT NOT PERMITTED ON DOWNFLOW/HORIZONTAL MODELS.

PIPE SIZE

TERMINATION

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

STANDARD

CONCENTRIC

VENT

TERMINATION KIT

RECOMMENDED

RXGY-D02A/G02A

RXGY-E03A/G02A

RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D02A/G02A

RXGY-E03A/G02A

RXGY-D03A/G02A

RXGY-E03A/G02A

GY- D03A/G02A

RXGY-E03A/G02A

RXGY-D03A/G02A

RXGY-E03A/G02A

RXGY-D03A/G02A

RXGY-E03A/G02A

⁄2°, 45° OR 90°

MEDIUM / LONG

RADIUS ONLY

1-2 5-6

3-4

30' 25' 20'

30' 25' 20' 120' 120' 120' 120' 120' 120'

15'

20'

15'

20'

120'

70'

60'

70'

60'

45'

40'

45'

40'

35'

40'

35'

30'

20'

120'

100'

10'

120'

85'

10'

10' 120' 120'

55'

35'

30'

FIGURE 17

STANDARD VERTICAL DIRECT VENTING UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)

DETAIL A

EXHAUST TERMINATION

12”

NOTES:

THE COMBUSTION AIR PIPE

MUST TERMINATE IN THE SAME PRESSURE ZONE AS THE EXHAUST PIPE.

INCREASE THE 12-IN. MINIMUM

TO KEEP TERMINAL OPENING ABOVE ANTICIPATED LEVEL OF SNOW ACCUMULATIONWHERE APPLICABLE.

WHEN 3-IN. DIAM. PIPE IS USED,

REDUCE TO 2-IN. DIAMETER BEFORE PENETRATING ROOF. A MAXIMUM OF 18 IN. OF 2-IN. PIPE MAY BE USED BEFORE PASSINGTHROUGH ROOF.

SUPPORT VERTICAL PIPE EVERY 6

FEET. EXHAUSTTERMINATION - TERMINATE

THE LAST 12 INCHES WITH 2” PVC PIPE ON 90,000 AND 120,000 BTUH MODELS. REDUCE AND TERMINATE THE LAST 12 INCHES WITH 1 PIPE ON 60,000 THROUGH 75,000 BTUH MODELS.

SEE DETAIL A.

/2” PVC

5. Insulate all vent runs through unconditioned spaces where

below-freezing temperatures are expected with 1" thick medium

density, foil faced fiber glass or

equivalent Rubatex/Armaflex insulation. For horizontal runs where

water may collect, wrap the vent pipe with self-regulating, 3 or 5 Watt heat tape. The heat tape must be U.L. listed and installed per the manufacturer’s instructions.

6. All piping between the furnace and the roof or outside wall pe tration is 2" or 3" as specified in

Table 7. Table 7 lists the maxi-

mum allowable length for the

exhaust vent pipe and intake air

pipe for the number of elbows used, based on the type of termi-

nation and furnace size.

7. The minimum vent length is 5 feet.

8. All piping through the roof or outside wall is 2". When using 3"

pipe, reduce to 2" within 18" of the inside of the roof or outside wall (except 120,000 BTUH model using the RXGY-D04 or D04A Horizontal Vent Kit).

9. Terminate the vent using one of the following termination options.

ne-

10. Elbows must be a minimum of 15” apart.

11. No screens may be used to cover

combustion air or exhaust.

VERTICAL TERMINATIONS

STANDARD VERTICAL TERMINATIONS

Combustion Air Piping um-radius sweep elbows to keep the inlet downward and prevent the entry of rain. The inlet opening of the com-

bustion air termination must be a minimum of 12" above the anticipated level of snow accumulation.

Exhaust Vent Piping

must terminate at least 12 inches above the combustion air termination inlet. The 2" vent pipe used to penetrate the roof must be reduced to 1 1/2" PVC for the last 12" for the 60,000 and 75,000 BTUH furnace models. No reduction of the 2" pipe is necessary for the 90,000 through 120,000 BTUH

models. The maximum length of the exposed vent pipe above the roof is

30".

(See Figure 16)

: Use two medi-

: The exhaust vent

ST-A0407-00

CONCENTRIC TERMINATIONS

CONCENTRIC VENT KIT NO. RXGY-E03A (SEE FIGURE 18)

This kit is for vertical and horizontal

intake air/vent runs. One 5-in. diameter hole is required for installation. See Figure 18 for the general layout. Complete installation instructions are included with the kit.

FIGURE 18

CONCENTRIC VENT KIT NO. RXGY-E03A (DIRECT VENT INSTALLATIONS)

ITEM No. DESCRIPTION

1 2.5 24 33 43 5 PVC RAINCAP

" PVC PIPE SCHEDULE 40 -- 37.125" LONG " PVC PIPE SCHEDULE 40 -- 24" LONG " x3" x4" SPECIAL CONCENTRIC FITTING " x 45° STREET ELBOW (FIELD SUPPLIED)

NOTE: The following IPEX brand concentric terminations (System 636) may be purchased in the field

and used in

place of factory supplied kits: 3” Concentric Kit – Item # 196006

VERTICAL INSTALLATION

MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF.

HORIZONTAL INSTALLATION

FIELD-SUPPLIED STRAP

NOTE: AIR INTAKE NOT

ORIENTATION SENSITIVE.

1" MAXIMUM

NOTE: Drain tee is not needed for the inlet pipe.

INSTALLATION – RXGY-G02A Side Wall Vent

INSTALLATION – RXGY-G02 Side Wall Vent

This termination for horizontal venting only. This termination for direct vent application only.

Important: Do no install on the prevailing winter wind side of the structure Note: Multi-venting-No common venting.

FIGURE 19

VENT KIT INSTALLATION OPTIONS

?? ? ?

EXHAUST

AIR INTAKE

NOTE: Install the vent and air intake piping into the vent plate openings. Seal all gaps between the pipes and wall. Be Sure To Use Silicone Sealant to seal the vent pipe to the vent cap to permit field disassembly for annual inspection and cleaning. Also seal all pipe penetrations in wall. To prevent possibility of condensate freeze-up or recirculation, do not install vent kits one above the other.

FIGURE 20

TYPICAL INSTALLATION

For 90000 thru 120000 BTUH modelsreduce to a length between 12 inches and 30 inches of 2 inch pipe. For 60000 thru 75000 BTUH modelswhen 3 inch pipe is used: reduce last 30 inches to 18 inches of 2 inch pipe and 12 inches of 1-1/2 inch pipe to maintain velocity. Note: Vent should protrude a maximum of 2-1/4” beyond vent plate. Air intake should protrude a maximum of 1inch beyond vent plate.

Seal all wall cavities

ST-A1075

HORIZONTAL TERMINATIONS

STANDARD HORIZONTAL TERMINA-

(SEE FIGURE 21)

TIONS

NOTE: All furnaces with horizontal air intakes (except those using horizontal

concentric vent kit RXGY-E03A) must have a drain tee assembly and trap

installed in the combustion air pipe as close to the furnace as possible. This is to drain any water that may enter the combustion air pipe to prevent it from entering the furnace vestibule area.

These parts are included in horizontal

vent kits RXGY-D02A, RXGY-D03A and RXGY-D04A.

NOTE: The combustion air and exhaust terminations must be at least 12 inches above grade or anticipated snow levels.

Use alternate horizontal terminations

when termination locations are limited and higher snow levels are anticipated.

NOTE: Ensure the location of the combustion air inlet with respect to the

exhaust vent terminal complies with

Figure 21, detail C.

Combustion Air Piping

: Use a 2" PVC coupling with a wind deflector vane (provided) installed as follows:

1. Install a 2" coupling to the combustion air pipe at the outside wall to prevent the termination from being pushed inward.

2. Cut a 2 1/4" length of 2" PVC pipe and connect this to the coupling.

3. Connect another 2" coupling to the end of the 2 1/4" length of pipe. Terminate this outer coupling 4 inches from the wall.

4. Attach the vane in the final 2" coupling in the vertical position with PVC cement.

IMPORTANT: To insure proper furnace operation, install the vane in the vertical position as shown in Figure 21, Detail B. Failure to install the vane properly can result in nuisance tripping of the pressure switch.

Exhaust Vent Piping: 60,000 and 75,000 BTUH models: Install a 2" to 1 1/2" reducer coupling at the outside wall to prevent the termination from being pushed inward. Reduce the 2" vent pipe used to penetrate the wall to 1 1/2" PVC for the last 12" of the run.

Terminate the 1 1/2" PVC exhaust

vent at least 12 inches from the outside wall.

90,000 through 120,000 BTUH models: Install a 2" coupling at the

outside wall to prevent the termination from being pushed inward. No reduction of the 2" pipe used to penetrate the wall is necessary.

Terminate the 2" PVC exhaust vent

at least 12 inches from the outside wall.

FIGURE 21

STANDARD HORIZONTAL DIRECT VENTING UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW/HORIZONTAL MODELS)

NOTES:

SUPPORT HORIZONTAL

➀

PIPE EVERY FOUR FEET. WHEN 3 IN. PIPE IS USED REDUCE TO

➁

2 IN. BEFORE PENETRATING OUTSIDE WALL.

18 IN. MAXIMUM. 2 IN. DIAMETER

➂

PIPE MAY BE USED INSIDE THE WALL.

DETAIL“A” - EXHAUSTTERMINATION

➃

TERMINATETHE LAST 12 INCHES WITH 2” PVC PIPE ON 90,000 AND 120,000 BTUH MODELS. REDUCE AND TERMINATE THE LAST 12 INCH-

/2” PVC PIPE ON 60,000

ES WITH 1 THROUGH 75,000 BTUH MODELS.

INCREASE THE 12 IN. MINIMUM

➄

ABOVE GRADE TO KEEP TERMINAL OPENINGS ABOVE ANTICIPATE D LEVEL OF SNOW ACCUMULATION WHERE APPLICABLE.

DETAIL“B”, INSTALLWIND DEFLEC-

➅

TOR VANE IN 2 IN. PVC COUPLING IN VERTICAL POSITION USING PVC SOLVENT.

THE COMBUSTION AIR TERMINATION MUST BE IN THE SAME PRESSURE ZONE AS THE EXHAUSTTERMINATION.

EXHAUST/INTAKE RELATIONSHIP

DETAIL C

NO SCREENS OR ELBOWS AT THE END OF THE PIPES

DETAIL C

DETAIL A

12”

EXHAUST TERMINATION

COMBUSTION AIR TERMINATION

DETAIL B

ST-A0407-00

ALTERNATE HORIZONTAL TERMINATIONS (See Figure 22)

NOTE: This method is not permitted

on modulation downflow/horizontal

(RGGE or RGJF) models.

NOTE: The combustion air and

exhaust terminations must be at least

12 inches above grade or anticipated

snow levels. Alternate horizontal ter-

minations allow the combustion air

and exhaust terminations to be raised a maximum of 60 inches above the

wall penetrations to maintain the required clearance.

NOTE: If combustion air vent pipe is extended more than 24 inches, insulate the vent pipe between the two outside 90° elbows with closed cell

insulation such as rubatex, armaflex

or equivalent.

NOTE: Ensure the location of the combustion air inlet with respect to

the exhaust vent terminal complies

with Figure 22.

Combustion Air Piping

: Use a 2" PVC elbow with a wind deflector vane (provided) installed as follows:

1. Install a 2" elbow to the combustion air pipe at the outside wall to prevent the termination from being pushed inward.

2. Cut an adequate length of 2" PVC pipe as needed to clear the anticipated snow level and connect this to the elbow.

3. Connect another 2" elbow to the end of the pipe such that the inlet is facing away from the wall. This outer coupling must terminate 4 inches from the wall.

4. Attach

the vane in the final 2" elbow in the vertical position with PVC solvent.

IMPORTANT: To insure proper furnace operation, the supplied vane must be installed in the vertical position as shown in Figure 21, Detail B.

FIGURE 22

ALTERNATE HORIZONTAL DIRECT VENTTERMINATION

SEE DETAIL A

3" MAX. NOTE: 3-1/2" MAX. WHEN D04 KIT IS USED.

EXHAUST VENT 21/2" PVC FOR MODELS WITH 120,000 BTUH INPUT (KIT NO. RXGY-D04A)

2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000 BTUH. REDUCE TO 11/2" FOR MODELS WITH INPUTS OF 60,000 AND 75,000 BTUH. ELBOWS AND RISERS ARE 2" PVC.

12" FROM WALL

PIPE SUPPORT STRAP

DETAIL C

EXHAUST/INTAKE RELATIONSHIP

NOTE: If combustion air vent pipe is extended more

than 24 inches, insulate the vent pipes between the two outside 90° elbows with closed cell insulation

such as rubatex, armaflex, or equivalent.

Exhaust Vent Piping

1. Install a 2" elbow to the exhaust vent

pipe at the outside wall to prevent the termination from being pushed inward.

2. Cut an adequate length of 2" PVC pipe as needed to insure proper loca-

tion of the exhaust vent termination

with respect to the combustion air inlet and connect this to the elbow.

3. Connect another 2" elbow to the end of the pipe such that the inlet is facing away from the wall.

INTAKEVENT 21/2" PVC FOR MODELS WITH 120,000 BTUH INPUT.

2" PVC ELBOWS AND RISER MODELS WITH INPUTS OF 75,000 THRU 120,000 BTUH.

USE KIT NO. RXGY-D02 OR D02A WHEN 2" PIPE IS USED BETWEEN FURNACE AND OUTSIDE WALL. USE KIT NO. RXGY-D03 OR D03A WHEN 3" PIPE IS USED.

DETAIL A

EXHAUST VENT FOR

MODELS WITH INPUT OF

60,000 AND 75,000 BTU

I339

Exhaust Vent Termination:

60,000 and 75,000 BTUH models: Reduce the 2" vent pipe used to

penetrate the wall and extend the

terminations to 1 1/2" PVC for the last 12" of the run. Install a 2" to 1 1/2" reducer bushing in the last 2" elbow. Connect a length of 1 1/2"

PVC pipe such that the exhaust vent

terminates at least 12 inches from the outside wall. See Figure 22, Detail A.

90,000 through 120,000 BTUH models: No reduction of the 2" pipe used

to penetrate the wall is necessary.

Terminate the 2" PVC exhaust vent

at least 12 inches from the outside wall.

120,000 BTUH model with the RXGY-D04A Horizontal Vent Kit:

Venting and terminations install the

same as above except the 2" pipe

and connectors are replaced with 2 1/2" pipe and connectors.

LOCATION REQUIREMENTS HORIZONTAL DIRECT VENTS

CAUTION

THE COMBUSTION PRODUCTS AND MOISTURE IN THE FLUE GASES WILL CONDENSE AS THEY LEAVETHE TERMINATION. THE CONDENSATE CAN FREEZE ON THE EXTERIOR WALL, UNDER THE EAVES AND ON SURROUNDING OBJECTS. SOME DISCOLORATIONTOTHE EXTERIOR OF THE BUILDING IS TO BE EXPECTED. HOWEVER, IMPROPER LOCATION OR INSTALLATION CAN RESULT IN STRUCTURAL OR EXTERIOR FINISH DAMAGETOTHE BUILDING AND MAY RECIRCULATE PRODUCTS OF COMBUSTION INTOTHE COMBUSTION AIR TERMINAL AND FREEZE.

NOTE: In Canada vent terminations

must be in accordance with the current CSA-B149 Gas Installation Code and/or local codes.

The vent must be installed with the following minimum clearances. See Figures 23 and 24.

1. Locate the bottom of the vent terminal and the air inlet at least 12 inches above grade. Increase the 12-in. minimum to keep the terminal openings above the level of snow accumulation, where applicable.

2. Do not terminate the vent over public walkways or over an area where condensate or vapor could create a

nuisance or hazard.

3. Locate the vent terminal at least one foot from any opening through which flue gases could enter a building.

4. Locate the vent terminal at least 3 feet above any forced air inlet

located within 10 feet, except the

combustion air inlet of a direct vent appliance.

5. Allow the vent terminal minimum

horizontal clearance of 4 feet from

electric meters, gas meters, regulators and relief equipment.

6. Locate the furnace combustion air inlet a sufficient distance from the vent of any other gas or fuel burning appliance or electric clothes dryer to prevent recirculation of the flue gases into the furnace com-

bustion air inlet. The only exception

to this requirement is the case of multiventing two or more furnaces, which is covered in the section on multiventing in these instructions.

In addition to the minimum clearances listed above, the ven be governed by the following guidelines.

1. Do not terminate under any kind of patio or deck. If running the vent under a deck, insulate it to insure

no condensate freezes and blocks

the pipe. The insulation must be waterproof.

For vent considerations, the edge of the deck must be considered the outside wall.

2. Do not terminate behind any area that may allow the flue products to become stagnant and recirculate.

3. Do not locate on the side of a building with pre winds. This will help prevent mois-

ture from freezing on walls and

overhangs (under eaves).

4. Do not extend vent directly

through brick or masonry surfaces. Use a rust-resistant sheet metal or plastic backing plate behind vent. See Figure 15.

5. Do not locate too close to shrubs as condensate may stunt or kill them.

FIGURE 23

MOISTURE ZONES

t location should

vailing winter

6. Minimum vertical clearances of 1 foot are recommended for over-

hangs up to 1 foot horizontal.

The vertical clearance should be increased equ

tional increase in horizontal overhang to a maximum vertical

clearance of 6 feet.

7. Caulk all cracks, seams and

joints within 6 feet horizontally

as well as 6 feet above and below vent. See Figure 23.

8. Painted surfaces must be sound and in good condition with no cracking, peeling, etc. Painted surfaces will require maintenance.

9. Do not expose 3" x 2" reducer/

bushing to outdoor ambient temperatures.

ally for each addi-

MULTIVENTING

IF VENTINGTWO OR MORE FURNACES NEAR EACH OTHER IS REQUIRED, EACH FURNACE MUST BE INDIVIDUALLY VENTED – NO COMMON VENTING IS PERMITTED. See Figures 25 and 26 for posi-

tioning of the terminations. When

2 FT. SQ. SHEET METAL PLATE ON BRICK OR MASONRY SURFACE RECOMMENDED, BUT NOT REQUIRED BY CODE.

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