Rheem RGRJ series, RGRA series, RGTJ series, RGTA series Installation Instructions Manual

Page 1

If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury or death.

INSTALLATION INSTRUCTIONS

FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH EFFICIENCY CONDENSING GAS FURNA CES

RGRA/RGRJ AND RGTA/RGTJ SERIES

92-23531-16-09

SUPERSEDES 92-23531-16-08

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.

Do Not Destroy this Manual. Please read carefully and keep in a safe place for future reference by a serviceman.

WARNING

Recognize this symbol as an indication of Important Safety Information!

— 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 until authorized by the gas supplier or fire department.

— 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 injury, property damage or death. Refer to this manual. Installation and service must be performed by a qualified installer, service agency or the gas supplier.

WARNING

PROPOSITION 65: THIS FURNACE CONTAINS FIBERGLASS INSULATION. RESPIRABLE PARTICLES OF FIBERGLASS ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER. EXHAUST GAS FROM THIS FURNACE CONTAINS CHEMICALS, INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF CALIFORNIA TO CAUSE BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

WARNING

FOR YOUR SAFETY

Page 2

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 Adequate wire size

FURNACE INSTALLATION

Adequate clearance to combustibles Adequate clearance for service (at front)

DUCT STATIC PRESSURE

in. w.c. on heating speed in. w.c. on cooling speed Air temperature rise

CONDENSATE LINE

Trap filled with water Vented Sloped toward drain Condensate drain line hoses connected

and clamped Freeze protection (if necessary)

VENTING – DIRECT VENT

in. diameter – intake pipe in. diameter – exhaust pipe ft. of pipe – intake air no. of elbows – intake air ft. of pipe – exhaust pipe no. of elbows – exhaust pipe

TERMINATIONS – DIRECT VENT

VERTICAL

Intake – 12" min. above roof/snow level Correct relationship – exhaust to intake

VERTICAL – CONCENTRIC (RXGY-E02)

Intake – 12" min. above roof/snow level

HORIZONTAL – STANDARD (RXGY-D02, -D03)

Correct relationship – exhaust to intake 12" min. above grade/snow level

HORIZONTAL – ALTERNATE (RXGY-D02, -D03 OR -D04)

Correct relationship – exhaust to intake Above anticipated snow level

HORIZONTAL – CONCENTRIC (RXGY-C01)

12" min. above grade/snow level Intake “Y” rotated above center Exhaust sloped toward furnace

VENTING – NON-DIRECT VENT

in. diameter – exhaust pipe ft. of pipe – exhaust no. of elbows

TERMINATION – NON-DIRECT VENT

VERTICAL

12" min. above roof/snow level

HORIZONTAL – STANDARD

12" min. above grade/snow level

HORIZONTAL – ALTERNATE

Above anticipated snow level

Page 3

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.

CONTENTS

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

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

Location Requirements and Considerations............................................................5

Venting and Combustion Air Piping .......................................................................12

Combustion and Ventilation Air..............................................................................14

Vent Pipe Installation..............................................................................................17

Condensate Drain/Neutralizer................................................................................27

Converting Downflow to Horizontal........................................................................29

Gas Supply and Piping...........................................................................................31

Electrical Wiring......................................................................................................35

Accessories............................................................................................................37

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

Air Flow...................................................................................................................46

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

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

Wiring Diagrams.....................................................................................................59

➤ 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.

Page 4

GENERAL INFORMATION

The RGRA/RGRJ and RGTA/RGTJ series furnaces are design-certified by AGA/CGA for use with natural and propane gases as follows:

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

2. As direct vent central forced air furnaces with all combustion air supplied directly to the furnace burners through a special air intake system outlined in these instructions.

FIGURE 1 UPFLOW FURNACE

FIGURE 2 DOWNFLOW/HORIZONTAL FURNACE

Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code” (NFPA54) 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

American Gas Association 1515 Wilson Blvd. Arlington, VA 22209

Install units in Canada in accordance with CAN/CGA-B149, local installation codes and authorities having jurisdiction. CAN/CGA-B149 is available from:

Canadian Gas Association 55 Scarsdale Road Don Mills, Ontario, Canada M3B, 2R3

2425262728

ITEM ITEM

NO. PART NAME NO. PART NAME

1 INDUCED DRAFT BLOWER 15 LOW VOLTAGE TERMINAL 2 CAPACITOR 16 TRANSFORMER 3 INLET AIR CHASE 17 PRESSURE SWITCH 4 DOOR SWITCH 18 OUTLET AIR PIPE 5 JUNCTION BOX 19 GAS VALVE 6 INLET PIPE CONNECTOR 20 CONNECTOR 7 TOP PLATE 21 EXHAUST TRANSITION 8 ELECTRICAL BOX 22 CONDENSATE TRAP

9 AUXILLIARY LIMIT 23 IGNITER 10 CONTROL BOX COVER GROUND 24 MANIFOLD 11 VENT CAP PLUG 25 OVERTEMPERATURE SWITCH 12 EXHAUST CONNECTION 26 ROLLOUT SWITCH 13 BLOWER 27 SENSOR 14 EXHAUST PIPE EXTENSION 28 BURNER

ITEM ITEM

NO. PART NAME NO. PART NAME

1 CONDENSATE TRAP 13 TOP PLATE 2 DOOR SWITCH 14 BURNER 3 JUNCTION BOX 15 IGNITER 4 TRANSFORMER 16 COMBUSTION AIR INLET 5 BLOCKED DRAIN PRESSURE SWITCH 17 GAS VALVE 6 MAIN PRESSURE SWITCH 18 INDUCED DRAFT BLOWER 7 EXHAUST TRANSITION 19 LOW VOLTAGE TERMINAL 8 CONNECTOR 20 CAPACITOR

9 OUTLET AIR PIPE 21 ELECTRICAL BOX 10 VENT CAP PLUG 22 BLOWER 11 SENSOR 23 CONTROL BOX 12 OVERTEMPERATURE SWITCH

COVER GROUND

10 11 12 13 14 15 16

2223

GAS INLET

OPTIONAL COMBUSTION AIR INLET

I409 I409

GAS INLET

PVC

Page 5

GENERAL INFORMATION

IMPORTANT: If furnace operation is required during construction, and air ladened with corrosive compounds such as chlorine and fluorine are present, provisions must be taken to provide clean outdoor combustion and ventilation air to the furnace. Compounds of chlorine and fluorine, when burned with combustion air, form acids which will cause corrosion of a heat exchanger. Some of these compounds are found in paneling, dry wall, tile adhesives, paints, stains and varnishes, solvents and masonry curing and cleaning materials.

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.

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 PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO, THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES. FAILURE TO FOLLOW THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

IMPORTANT: If installing the unit over a finished ceiling or living area, be certain to install

an auxiliary condensate drain pan under the entire unit. This auxiliary drain pan should extend under any evaporator coil installed with the furnace.

IMPORTANT: If using a cooling evaporator coil with this furnace:

a. be sure the air passes over

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

b. install a parallel duct system

to divert all the air from the furnace allowing it to pass over the cooling coil only. Use dampers or other means to prevent chilled air from passing over the heat exchanger.

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

WARNING

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. Provisions must be made to prevent freezing of condensate.

IMPORTANT: If this furnace is installed in a garage, attic and/or any unconditioned space, install a self-regulating heat tape around the condensate trap and along the entire length of the condensate drain in the unconditioned space. See Figure 3.

When the condensing horizontal gas furnace is installed in an unconditioned space where the temperature would be capable of reaching close to or below 32°F (0°C). A SELF-REGULATING HEAT TAPE IS REQUIRED ON THE CONDENSATE DRAIN, ALONG WITH AN INSULATION WRAP. The heat tape should meet the following requirements:

LOCATION REQUIREMENTS AND CONSIDERATIONS

FIGURE 3 HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP

DRAIN PIPE

HEAT TAPE

TRAP

I526

Page 6

a. The heat tape must be UL

listed.

b. The heat tape must be

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

c. The heat tape should be rated

at 5 or 6 watts per foot at 120V.

IMPORTANT: Support this unit when installed. Since this

furnace is suitable for attic or crawl space installation, it may be installed on combustible wood flooring or by using support brackets. See Figure 4.

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.

7. IMPORTANT: This furnace is

not approved or recommended for installation on its back, with access doors facing upwards.

CLEARANCE ACCESSIBILITY

The design of forced air furnaces with input ratings as listed in the tables under Figures 6, 7 and 8 are certified by the AGA Laboratories and CGA Laboratories for the clearances to combustible materials shown in inches.

FIGURE 4 HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

GAS PIPE

TRAP

EXHAUST FAN

ELECTRICAL CONDUIT

INTAKE VENT

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, MUST TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES.

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

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 Figure 5.

WARNING

I522

Page 7

SITE SELECTION

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

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

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

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

WARNING

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

FIGURE 5 BOTTOM PANEL REMOVAL

JACKET ASSEMBLY

SOLID BOTTOM

NOTE: BACK FLANGE OF SOLID BOTTOM FITS UNDERNEATH JACKET. SIDES AND FRONT FLANGES FIT OVER FLANGES ON JACKET.

SCREW (2) REQ’D.

JACKET ASSEMBLY

FILTER

FILTER ROD

SOLID BOTTOM REMOVAL

FILTER & ROD LOCATION

ADS 5422-01

Page 8

FIGURE 6 CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS

UPFLOW MODELS MINIMUM CLEARANCE (IN.)

LEFT RIGHT SHIP

MODEL A B C D E F

SIDE SIDE

BACK TOP FRONT VENT

WGTS

04 17

/2 16

/32 15

/8 21513

/32 00012*0 111

06 17

/2 16

/32 15

/8 21513

/32 00012*0 117

07 17

/2 16

/32 15

/8 21513

/32 00012*0 123

09 21 19

/32 19

/8 218

/217

/32 00012*0 148

10 21 19

/32 19

/8 218

/217

/32 00012*0 152

12 24

/2 23

/32 22

/8 22220

/32 00012*0 160

I392

➤*A service clearance of at least 24 inches is recommended in front of all furnaces.

Page 9

FIGURE 7 CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS

DOWNFLOW MODELS MINIMUM CLEARANCE (IN.)

LEFT RIGHT SHIP

MODEL A B C D E F

SIDE SIDE

BACK TOP FRONT VENT

WGTS

04 17

/32

216

00012*0 111

06 17

/2 16

/32 15

/8 216

/813

/8 00012*0 117

07 17

2 16

32 15

8 216

813

8 00012*0 123

09 21 19

32 19

16 220

817

8 00012*0 148

10 21 19

32 19

16 220

817

8 00012*0 152

12 24

2 23

32 22

8 223

820

8 00012*0 160

I393

➤*A service clearance of at least 24 inches is recommended in front of all furnaces.

Page 10

➤ FIGURE 8 CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS

DOWNFLOW MODELS MINIMUM CLEARANCE (IN.)

LEFT RIGHT SHIP

MODEL A B C D E F

SIDE SIDE

BACK TOP FRONT VENT

WGTS

04 17

/2 16

/32 15

/8 216

/813

/8 00012*0 111

06 17

/2 16

/32 15

/8 216

/813

/8 00012*0 117

07 17

/2 16

/32 15

/8 216

/813

/8 00012*0 123

07 21 19

/32 19

/16 220

/817

/8 00012*0 123

09 21 19

/32 19

/16 220

/817

/8 00012*0 148

10 21 19

/32 19

/16 220

/817

/8 00012*0 152

12 24

/2 23

/32 22

/8 223

/820

/8 00012*0 160

I520

*A service clearance of at least 24 inches is recommended in front of all furnaces.

⁄8 DIA.

ALT. CONDENSATE

DRAIN

⁄8 DIA.

GAS

CONNECTION

TOP

LEFT SIDE FRONT

BOTTOM

RIGHT SIDE

⁄16

⁄64

⁄16

⁄8

⁄32

⁄16

⁄32

⁄16

⁄18

⁄32

⁄16

⁄4

⁄16

⁄8 DIA.

ALT. GAS

CONNECTION

⁄8 DIA.

CONDENSATE

DRAIN

COMBUSTION

AIR INLET

LOW VOLTAGE

RETURN

AIR

VENT OUTLET

⁄32

ELECT.

CONN.

⁄32

⁄4

SUPPL

⁄16

Page 11

DUCTING

Proper air flow is required for the correct operation of this furnace. Too little air flow can cause erratic operation and can damage the heat exchanger. The duct system 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 air distribution system should not exceed 0.5" w.c.

NEVER ALLOW THE PRODUCTS OF COMBUSTION FROM THE FLUE TO ENTER THE RETURN AIR DUCTWORK OR THE CIRCULATED AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE WITH SHEET METAL SCREWS; AND JOINTS, TAPED. ALL OTHER DUCT JOINTS MUST BE SECURED WITH APPROVED CONNECTIONS AND SEALED AIRTIGHT. WHEN AN UPFLOW FURNACE IS MOUNTED ON A PLATFORM WITH RETURN THROUGH THE BOTTOM, IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE AND THE RETURN AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT OF THE FURNACE WITHOUT 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 INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING THAT 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 air flow. This can adversely affect furnace operation. BE SURE TO CHECK AIR FLOW if using any filter other than the factoryprovided filter.

UPFLOW UNITS

1. Position the unit to minimize long runs of duct or runs of duct with many turns and elbows.

2. Open the return air compartment. a. If using side or back return air,

do not remove the bottom base.

b. Cut an opening in the side or

back. The opening should be cut the full width of the knockouts on the unit.

c. Remove the bottom base if

using bottom return air.

NOTE: Where the maximum air flow 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 entraining combustion gases from an adjacent fuel-burning appliance.

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.

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

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

IMPORTANT: If a flexible duct connector must be used, it MUST

be rated for a minimum

temperature of 250

°F.

continuous.

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 bottom 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

non-combustible floor base. See Figure 9.

THE DOWNFLOW FURNACE DESIGN IS CERTIFIED FOR INSTALLATION ON A NONCOMBUSTIBLE FLOOR. USE THE SPECIAL BASE SPECIFIED ON THE FURNACE CLEARANCE LABEL. FAILURE TO INSTALL THE 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 combustion gases from an adjacent fuel-burning appliance.

6. 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.

WARNING

FIGURE 9 COMBUSTIBLE FLOOR BASE

Page 12

GENERAL INFORMATION

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

This furnace removes both sensible and latent heat from the combustion flue gases. Removal of latent heat results in condensation of flue gas water vapor. This condensed water vapor drains from the secondary heat exchanger and out of the unit into a drain trap.

When installed as a non-direct vent furnace, only exhaust piping is required and inside combustion air may be used. Refer to section on “

COMBUSTION & VENTILATION AIR

FOR FURNACE INSTALLATIONS.” Direct vent installations require a

dedicated combustion air and venting system. All air for combustion is taken from the outside atmosphere and all combustion products are discharged to the outdoors.

The combustion air and vent pipe fittings must conform to American National Standards Institute (ANSI) and American Society for Testing Materials (ASTM) standards D1785 (Schedule 40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and SDR26-26 PVC), D2661 (ABS-DWV) or F628 (Schedule 40 ABS-DWV).

In Canada all combustion air and vent pipe must be CSA- or ULC-certified Schedule 40 PVC, PVC-DWV or ABS-DWV.

IMPORTANT: The plastic combustion air and venting components are of Schedule 40 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 are corrosion resistant.

NOTE: 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: Cellular core PVC is also approved for use. It must be schedule 40PVC-DWV cellular pipe for nonpressure applications and manufactured under ASTM F-891.

OVERTEMPERATURE SAFETY SWITCHES

Furnaces are equipped with safety switches in the control compartment to protect against overtemperature conditions caused by inadequate combustion air supply. The switches for the upflow and downflow models are located in the burner compartment. If a switch is tripped it must be manually reset.

DO NOT JUMPER THESE DEVICES! IF ONE OF THESE SWITCHES SHOULD TRIP, A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER MUST BE CALLED TO CHECK AND/OR CORRECT FOR ADEQUATE COMBUSTION AIR SUPPLY. DO NOT RESET THE SWITCHES WITHOUT TAKING CORRECTIVE ACTION TO ASSURE THAT AN ADEQUATE SUPPLY OF COMBUSTION AIR IS MAINTAINED UNDER ALL CONDITIONS OF OPERATION. FAILURE TO DO SO CAN RESULT IN CARBON

MONOXIDE POISONING OR DEATH. IF THIS UNIT IS MOUNTED IN A CLOSET, THE DOOR MUST BE CLOSED WHEN MAKING THIS CHECK.

REPLACE THESE SWITCHES ONLY WITH THE IDENTICAL REPLACEMENT PART.

EXISTING VENT SYSTEMS

When the installation of this furnace replaces an existing furnace that is removed from a vent system serving other appliances, the vent system is likely to be too large to properly vent the remaining attached appliances.

The following steps should be followed 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 for 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 common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

VENTING AND COMBUSTION AIR PIPING

WARNING

HORIZONTAL UNIT

IMPORTANT: THIS FURNACE MAY ONLY BE INSTALLED SO AS WHEN FACING THE FRONT OF THE FURNACE, SUPPLY AIR IS DISCHARGED ON THE LEFT HAND SIDE.

1. Position the unit to minimize long runs or runs with many turns and elbows.

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

3. Connect the furnace to the supply air plenum.

4. Connect the return air ducting to the return air opening at the right end of the unit. Make the connection air tight to prevent

entraining combustion gases from an adjacent fuel-burning appliance.

5. 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.

Page 13

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 reduction 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 and pipe with 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 application.

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 brush or the dauber supplied with the can. The proper brush size is one inch.

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.

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 that 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, the common venting system must be resized. Refer to latest edition of the National Fuel Gas Code ANSI Z223.1, 1992 or the AGAGAMA venting tables for Category I furnaces.

When the furnace is installed in the same space with other gas appliances such as a water heater, be sure there is an adequate supply of combustion and ventilation air for the other appliances. Do not delete or reduce the combustion air supply required by the other gas appliances in this space. See Z223.1, National Fuel Gas Code (NFPA54) or CAN/CGA-B149.1 and .2 for determining the combustion air requirements for gas appliances. An unconfined space must have at least 50 cubic feet (volume) for each 1,000 BTUH of the total input of all appliances in the space. If the open space containing the appliances is in a building with tight construction (contemporary construction), outside air may still be required for the appliances to burn and vent properly. Outside air openings should be sized the same as for a confined space.

JOINING PIPE AND FITTINGS

PVC SOLVENT CEMENTS AND PRIMERS ARE HIGHLY FLAMMABLE. PROVIDE ADEQUATE VENTILATION AND DO NOT ASSEMBLE NEAR HEAT SOURCE OR AN OPEN FLAME. DO NOT SMOKE. AVOID SKIN OR EYE CONTACT. OBSERVE ALL CAUTIONS AND WARNINGS PRINTED ON MATERIAL CONTAINERS. FAILURE TO 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 in the U.S.

Pipe and Fittings - ASTM-D1785, D2466, D2665, D2231, D2661 and F628.

PVC Primer and Solvent Cement ASTM-D2564

ABS Pipe and Fittings - Use ABS Primer and Solvent Cement D2235

Procedure for Cementing Joints ASTM-D2855

IMPORTANT: The plastic combustion air and venting components are 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 are corrosion resistant.

WARNING

Page 14

NON-DIRECT FURNACE INSTALLATIONS

THE FURNACE AND ANY OTHER FUEL-BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE PERSONAL INJURY OR DEATH FROM CARBON MONOXIDE POISONING.

Adequate facilities for providing air for combustion and ventilation must be provided in accordance with section

5.3, “Air for Combustion and Ventilation” of the National Fuel Gas Code, ANSI Z223.1-1992, CAN/CGA B149.1 and 2, or applicable provisions for the local building codes, and not obstructed so as to prevent the flow of air to the furnace.

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.

The following types of installation (but not limited to the following) will require OUTDOOR AIR for combustion, due 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) will also require OUTDOOR AIR for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine-based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry curing and acid washing materials

Combustion air must be free of acidforming chemicals such as sulphur, fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products. When burned in a gas flame, vapors from these products form acid compounds. The acid compounds increase the dew point temperature of the flue products and are highly corrosive after they condense.

ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE 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.

EXAMPLE 1: FURNACE LOCATED IN AN 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.

BTUH Minimum Sq. Feet Typical Room Size

Input With 8' Ceiling With 8' Ceiling

45,000 281 14' x 20' OR 16' x 18'

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

75,000 469 15' x 31' OR 20' x 24'

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

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

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

If the open space containing the furnace is in a building with tight construction, outside air may still be required for the furnace to operate and vent properly. Outside air openings should be sized the same as for a confined space.

EXAMPLE 2: FURNACE LOCATED IN A CONFINED SPACE

A confined space (any space smaller than shown above 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. Size the openings by how they are connected to the heated area or to the outside, and by the input of all appliances in the space.

If confined space is within a building with tight construction, combustion air must be taken from outdoors or area freely communicating with the outdoors.

A. USING INDOOR AIR FOR

COMBUSTION

IMPORTANT: Air should not be taken 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, 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. Here are some examples of typical openings required.

COMBUSTION AND VENTILATION AIR

WARNING

Page 15

BTUH Free Area

Input Each Opening

45,000 100 square inches

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

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 crosssectional area as the free area of the openings to which they connect.

Method 1 Two permanent openings, one located within 12 inches of the top and one located within 12 inches of the bottom of the enclosure, shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

a. Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts as shown in Figure 11, each opening shall

have a minimum free area of 1 square inch for each 4,000 BTUH of total appliance input rating in the enclosure.

BTUH Free Area Round Pipe

Input Each Opening Size

45,000 11.25 square inches 4"

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 6"

b. Where communicating with outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square

inch for each 2,000 BTUH of total input rating of all equipment in the enclosure.

Here are some typical sizes.

BTUH Free Area Round Pipe Input Each Opening Size

45,000 22.50 square inches 6"

60,000 30.00 square inches 6"

75,000 37.50 square inches 7"

90,000 45.00 square inches 8"

105,000 52.50 square inches 8"

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

FIGURE 11 AIR FROM ATTIC/CRAWL SPACE

FIGURE 12 OUTSIDE AIR USING A HORIZONTAL DUCT

FIGURE 10 AIR FROM HEATED SPACE

NOTE: EACH OPENING SHALL HAVE A FREE AREA OF NOT LESS THAN ONE SQUARE INCH PER 1,000 BTU PER H0UR OF THE

TOTAL

INPUT RATING OF ALL EQUIPMENT IN THE ENCLOSURE, BUT NOT LESS THAN 100 SQUARE INCHES.

GAS

WATER

HEATER

FURNACE

GAS

WATER

HEATER

GAS

WATER

HEATER

FURNACE

12" MAX.

12"

MAX.

1 SQ. INCH PER 4000 BTUH INLET AIR

OUTLET AIR 1 SQ. INCH

PER 2000 BTUH

INLET AIR 1 SQ. INCH

PER 2000 BTUH

1 SQ. INCH PER

4000 BTUH

OUTLET AIR

OUTLET AIR IN ATTIC MUST BE ABOVE INSULATION

OPTIONAL 1 SQ. INCH PER 4000 BTUH INLET AIR

VENTILATED ATTIC GABLE OR SOFFIT VENTS

GABLE

VENT

Page 16

FIGURE 13 COMBUSTION AIR FITTING

UPFLOW DOWNFLOW/HORIZONTAL

2" PVC DOUBLE ELBOW

TOP OPTION

EXHAUST

2" PVC ELBOW

SIDE OPTION

2" PVC DOUBLE ELBOW*

COMBUSTION AIR

EXHAUST

ATTACH DOUBLE ELBOW TO INTAKE AIR COLLAR AND SECURE WITH TWO SHEET METAL SCREWS TO PREVENT ACCIDENTAL BLOCKAGE OF INTAKE AIR OPENING.

➤ *NOTE: WHEN FURNACE IS INSTALLED IN A HORIZONTAL POSITION ONLY ONE 90° ELBOW IS REQUIRED. INSTALL THE ELBOW SO THE OPEN END IS POINTED DOWNWARD.

ATTACH DOUBLE ELBOW TO TOP INLET AIR OPENING OR 90° ELBOW TO SIDE INLET AIR OPENING TO PREVENT ACCIDENTAL BLOCKAGE OF INTAKE OPENING. PLUG OPENING NOT USED.

I337 I336

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. 1 square inch for each 3,000 BTUH of the total input rating of all equipment located in the enclosure and

BTUH Free Area Round Pipe

Input Each Opening Size

45,000 15.00 square inches 4"

60,000 16.67 square inches 5"

75,000 25.00 square inches 6"

90,000 30.00 square inches 6"

105,000 35.00 square inches 7"

120,000 40.00 square inches 7"

b. Not less than the sum of the areas of all vent connectors in the confined space.

If unit is installed where there is an exhaust fan, sufficient ventilation must be provided to prevent the exhaust fan from creating a negative pressure.

Combustion air openings must not be restricted in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

Return air grilles and warm air registers must not be obstructed.

CONNECTION TO FURNACE

IMPORTANT: When indoor combustion air is used, the inlet air opening at the furnace must be protected from accidental blockage. On upflow models, install a 90° elbow pointing downward in the side inlet air opening or a double elbow pointing downward in the top inlet air opening. On downflow/horizontal models, install a double elbow in the top inlet air opening. See Figure 13.

Page 17

ELEVATED SINGLE PIPE ALTERNATE TEE TERMINATION

See Figure 15. The tee termination may be elevated up to 24 inches above the wall penetration if required for anticipated snow levels. Use 2 medium-radius, 2-in. PVC elbows and 2-in. PVC pipe, attaching the tee so it is 12 inches from the wall.

NON-DIRECT VENT INSTALLATION

GUIDELINES

IMPORTANT: FAILURE TO CORRECTLY FOLLOW ALL VENTING GUIDELINES MAY RESULT IN ERRATIC FURNACE OPERATION, FREEZE-UP OF COMBUSTION AIR OR EXHAUST AIR PIPING OR SOOTING OF THE FURNACE.

All exhaust piping must be installed in compliance with Part 7, “Venting of Equipment,” of the latest edition of the National Fuel Gas Code NPFA54/ ANSI Z223.1-, CAN/CGA-B149, local codes or ordinances and these instructions.

1. Vertical piping is preferred.

2. All horizontal piping must slope upward a minimum of

/4 inch per foot of run so that condensate drains toward the furnace.

3. All horizontal runs must be supported at least every 4 feet. No sags or dips are permitted.

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 FUELBURNING APPLIANCE UNLESS THE REQUIRED MINIMUM CLEARANCES TO COMBUSTIBLES ARE MAINTAINED BETWEEN THE PVC PIPE AND OTHER PIPES.

FIGURE 14 TEE TERMINAL – FOR STANDARD HORIZONTAL SINGLE PIPE INSTALLATION

FIGURE 15 ALTERNATE HORIZONTAL TERMINATION FOR NON-DIRECT VENT INSTALLATIONS

12"

FROM

24"

MAX.

PIPE SUPPORT STRAP

OUTSIDE WALL

VENT

12"

12" MIN. ABOVE

GRADE OR

SNOW LEVEL

I198

NUMBERS OF ELBOWS

45° OR 90°

Medium / Long Radius ONLY

1-2 3-4 5-6

45,000 2”

Standard 60 55 50

Alternate 55 50 45

2”

Standard 35 30 25

Alternate 30 25 20

60,000

3”

Standard 120 120 115

Alternate 120 120 110

2”

Standard 20 15 10

Alternate NR NR NR

75,000

3”

Standard 110 105 95

Alternate 80 70 65

90,000 3”

Standard 90 85 75

Alternate 60 50 45

105,000 3”

Standard 80 75 65

Alternate 50 40 35

120,000 3”

Standard 70 65 55

Alternate 40 30 25

NOTES:

1. *N.R. - NOT RECOMMENDED.

2. MAXIMUM OF 6 - 90 DEGREE ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FOR ALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.

➤ A 45° DEGREE ELBOW IS CONSIDERED ONE ELBOW.

FURNACE

INPUT

➤TABLE 1 FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM INDOORS

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

VENT PIPE INSTALLATION

PIPE SIZE

TERMINATION

Page 18

“rub-a-tex” insulation may also be used as long as there is no heat tape applied to the vent pipe. 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. The minimum vent pipe length is 5 feet.

STANDARD INSTALLATIONS

The single-pipe system requires an exhaust pipe only. Combustion air may be taken from the furnace installation area or ducted to the furnace area from the outside.

Size the exhaust pipe as specified in Table 1. This table lists the maximum allowable length in feet of the exhaust pipe that may be used for all furnace inputs as related to the number of elbows required and the termination. (See shaded area.)

Vertical through-the-roof installations do not require a vent termination. Use 2-in. PVC pipe extending a minimum of 12 inches above the anticipated level of snow accumulation. See exhaust pipe requirements, Figure 20. When 3-in. vent pipe is used from furnace to the roof, reduce it to 2 inches before penetrating the roof. A maximum of 18 inches of 2-in. pipe may be used below the roof.

Horizontal vent terminations require a 2-in. PVC tee positioned 12 inches from the outside wall. See exhaust pipe requirements, Figure 21. When 3-in. pipe is used from the furnace to the outside wall, reduce it to 2 inches before penetrating the wall. A maximum of 18 inches of 2-in. pipe may be used inside the wall.

An alternate termination may be used as shown in Figure 15 to clear anticipated snow levels. The tee may be raised up to 24 inches above the wall penetration. Use two mediumradius bend, 2-in. PVC elbows and a length of 2-in. PVC pipe so that the elbows are on 24-in. centers.

NON-DIRECT VENT TERMINATION LOCATION REQUIREMENTS

MOISTURE IN THE COMBUSTION PRODUCTS CONDENSES AS IT LEAVES THE TERMINATION. THIS CONDENSATE CAN FREEZE ON EXTERIOR WALLS, UNDER THE EAVES, AND ON SURROUNDING OBJECTS. SOME DISCOLORATION IS TO BE EXPECTED. HOWEVER, IMPROPER LOCATION

OR INSTALLATION CAN CAUSE STRUCTURAL OR EXTERIOR FINISH DAMAGE TO THE BUILDING.

Non-direct venting location requirements are slightly different in some cases than direct venting. Install a non-direct vent with the following minimum clearances. See Figure 16.

1. Locate the bottom of the vent terminal 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. The vent shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard.

3. 4 feet below, 4 feet horizontally from, or 1 foot above any door, window soffit, under eave vent or gravity air inlet to the building.

4. The vent terminal shall have a minimum horizontal clearance of 4 feet from electric meters, gas meters, regulators and relief equipment.

5. 6 feet from an inside corner formed by two exterior walls – 10 feet is the recommended distance.

6. Locate it 3 feet above any forced air inlet located within 10 feet. Any fresh air or make-up air inlet, such as for a dryer or furnace area, is considered a forced air inlet.

CAUTION

FIGURE 16 NON-DIRECT VENT TERMINATION CLEARANCES

I133

SOFFIT VENTS

FRESH AIR INTAKE

*NOTE: FOR DISTANCES OVER 10* NO VERTICAL RESTRICTIONS APPLY.

INSIDE CORNER

ELECTRIC METER

10* RECOMMENDED

12( MIN.

UP TO10**

7. Avoid areas where dripping condensate may cause problems, such as above planters, patios, or adjacent to windows where steam may cause fogging.

In addition to the minimum clearances listed above, the vent location should also 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.

2. Do not locate on the side of a building with prevailing winter winds. This will help prevent moisture from freezing on walls and overhangs (under eaves).

3. Do not extend vent directly through brick or masonry surfaces. Use a rust-resistant sheet metal or plastic backing plate behind vent.

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

5. Minimum vertical clearances of 1 foot are recommended for overhangs up to 1 foot horizontal. The vertical clearance should be increased equally for each additional increase in horizontal overhang to a maximum vertical clearance of 6 feet.

6. Caulk all cracks, seams and joints within 6 feet horizontally and above and below vent.

Page 19

DIRECT VENT INSTALLATIONS

Direct vent installations require a dedicated combustion air and venting system. All air for combustion is taken from the outside atmosphere and all combustion products are discharged to the outdoors. Therefore, no

ventilation or combustion air openings are required.

IMPORTANT: The plastic combustion air and venting components are of Schedule 40 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 are corrosion resistant.

INSTALLATION GUIDELINES

1. Vertical piping is preferred.

2. All horizontal piping must slope upward a minimum of

/4 inch per foot of run so that condensate drains toward the furnace.

3. All horizontal runs must be supported at least every 4 feet. No sags or dips are permitted.

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.

5. All vent runs through unconditioned spaces where belowfreezing temperatures are expected should be insulated with 1-in. thick, medium-density, foil-faced fiberglass. An equivalent “arm-a-flex” or “rub-atex” insulation may also be used as long as there is no heat tape applied to the vent pipe. 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

WARNING

➤TABLE 2 FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM OUTDOORS

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

U.L. listed and installed per the manufacturer’s instructions.

6. The minimum vent pipe length is 5 feet.

Size the exhaust and combustion air intake pipes as specified in Table 2. This table lists the maximum allowable length in feet of the exhaust and combustion air intake pipes that may be used for all furnace inputs as related to the number of elbows required and the termination (see shaded area).

FURNACE

INPUT

PIPE SIZE

TERMINATION

VENT TERMINATION KIT RECOMMENDED

(RXGY-D0* Kits for

Horizontal Venting Only)

1 - 2 3 - 4 5 - 6

NUMBER OF ELBOWS

45° or 90°

Medium / Long Radius ONLY

Standard RXGY-D02 65 60 55

45,000 2” Concentric RXGY-C01/RXGY-E02

55 50 45

Alternate RXGY-D02

Standard RXGY-D02 40 35 30

2” Concentric RXGY-C01/RXGY-E02

30 25 20

Alternate RXGY-D02

60,000

Standard RXGY-D03 120 120 120

3” Concentric RXGY-C01/RXGY-E02

110 105 100

Alternate RXGY-D03

Standard RXGY-D02 20 15 10

2” Concentric Not Recommended

NR NR NR

Alternate Not Recommended

75,000

Standard RXGY-D03 120 120 120

3” Concentric RXGY-C01/RXGY-E02

100 95 85

Alternate RXGY-D03

Standard RXGY-D03 110 105 95

90,000 3” Concentric RXGY-C01/RXGY-E02

50 40 35

Alternate RXGY-D03

Standard RXGY-D03 110 105 95

105,000 3” Concentric RXGY-C01/RXGY-E02

50 40 35

Alternate RXGY-D03

Standard RXGY-D03 105 100 90

120,000 3”

Concentric RXGY-C01/RXGY-E02

45 35 30

Alternate RXGY-D03

Alternate RXGY-D04 105 95 90

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 DEGREE ELBOW IS CONSIDERED ONE ELBOW.

4. CONCENTRIC TERMINATION NO. RXGY-C01 IS FOR THRU-THE-WALL VENTING.

5. CONCENTRIC TERMINATION NO. RXGY-E02 IS FOR THRU-THE-ROOF VENTING.

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

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

Page 20

➤ALTERNATE TERMINATIONS

ALTERNATE HORIZONTAL DIRECT VENT TERMINATIONS

KIT NOS. RXGY-D02, -D03 AND -D04

The combustion air and exhaust terminations may be raised a maximum of 60 inches above the wall penetration to maintain the required 12 inch clearance above grade or snow level. See Figure 17. Size the pipe length according to Table 2.

IMPORTANT: The following guidelines must be met when extending beyond 24 inches of pipe on the exterior of the structure:

• Size the entire vent system according to the concentric, not standard, termination shown in Table 2.

COMBUSTION AIR FOR DIRECT VENT INSTALLATIONS

THE COMBUSTION AIR SYSTEM DESIGNED FOR THIS FURNACE MUST BE USED.

When this furnace is installed as a direct vent forced air furnace, all combustion air is supplied directly to the burner through a special air inlet system outlined in these instructions. This system consists of field-supplied Schedule 40 or 26 SDR-PVC pipe and one of the following horizontal vent termination kits: RXGY-D02, RXGY-D03, RXGY-D04, RXGY-C01 or RXGY-E02.

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

The combustion air for this furnace is supplied directly from the outdoors through the combustion air inlet system.

When the furnace is installed in the same space with other gas appliances, such as a water heater, be sure there is an adequate supply of combustion and ventilation air for the other appliances. Do not delete or reduce the combustion air supply required by the other gas appliances in this space. See Z223.1, National Fuel Gas Code (NFPA54) or CAN/CGA-B149.1 and .2 for determining the combustion air requirements for gas appliances. An unconfined space must have at least 50 cubic feet (volume) for each 1,000 BTUH of the total input of all appliances in the space. If the open space containing the appliances is in a building with tight construction (contemporary construction), outside air may still be required for the appliances to burn and vent properly. Outside air openings should be sized the same as for a confined space.

STANDARD TERMINATIONS

STANDARD VERTICAL TERMINATIONS

COMBUSTION AIR PIPING Use two medium-radius sweep

elbows to keep the inlet downward to prevent entry of rain. See Figure 20 for the proper relationship of combustion air to exhaust termination.

STANDARD HORIZONTAL TERMINATIONS

COMBUSTION AIR PIPING When 3-in. pipe is used between the

furnace and outside wall, reduce it to 2 inches before penetrating the wall. Up to 18 inches of 2-in. pipe may be used inside the wall.

The standard horizontal intake air termination for all models is a 2-in. PVC coupling with a wind deflector vane (provided) attached. Cut a 2

/4-in. length of 2-in. PVC pipe. Connect this pipe and another 2-in. PVC coupling to the coupling at the wall. The outer coupling must terminate 4 inches from the wall. See Figure 21, Detail B, for vane location. Attach vane in vertical position with PVC solvent.

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

The combustion air inlet terminal must be located with respect to the exhaust terminal as shown in Figure 21, Detail C.

➤ IMPORTANT: All furnaces with

horizontal air intakes, except those using horizontal concentric vent kit RXGY-C01, must have a drain tee assembly and trap installed as close to the furnace as possible. This is to drain any water that may be in the combustion air pipe to prevent it from entering the furnace combustion chamber.

These parts are included in kits RXGY-D02 (for 2-in. pipe), RXGYD03 (for 3-in. pipe) and RXGY-D04 (special for the 120,000 BTU furnace installed with the alternate horizontal termination). Attach the trap to the bottom of the tee with PVC solvent. Connect the other end to a suitable drain, as to the downstream of a condensate trap on the furnace.

STANDARD VERTICAL TERMINATIONS

EXHAUST VENT PIPING Vertical through-the-roof vent appli-

cations do not require an exhaust terminal. The exhaust vent must terminate at least 12 inches above the combustion intake air termination. The exhaust vent for models with inputs of 90,000 through 120,000 BTUH is 2-in. PVC pipe 120,000 BTUH models with excessively long

runs require 2

⁄2(. Refer to Table 2 for proper application. This must be reduced to 1( or 1

⁄2( the last 12 inches for models with inputs of 45,000 through 75,000 BTUH. See Figure 22.

STANDARD HORIZONTAL TERMINATIONS

EXHAUST PIPING For direct vent systems the standard

termination is 2-in. PVC pipe extending 12 inches from the wall for furnaces with inputs from 90,000 to 120,000 BTUH. Install a 2-in. coupling at the outside wall to prevent the termination from being pushed inward. When 3-in. pipe is used between the furnace and outside wall, reduce to 2 inches before penetrating the wall. The standard termination is 1

/2 -in. PVC pipe extending outward 12 inches from the wall for models with inputs of 45,000 to 75,000 BTUH. Install a 2-in. to 1

/2-in. coupling at the outside wall to prevent pushing the termination back into the wall. See Figure 21, Detail B.

The combustion air and exhaust terminations must be at least 12 inches above grade and must be oriented with respect to each other as shown in Figure 21. Refer to section on alternate venting options when higher snow levels are anticipated.

Page 21

FIGURE 17 ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

SEE DETAIL A

60( MAX.

PIPE SUPPORT STRAP

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

EXHAUST VENT FOR

MODELS WITH

INPUT OF 45,000 THRU

75,000 BTU

DETAIL A

EXHAUST VENT 21/2" PVC FOR MODELS WITH 120,000 BTU INPUT (KIT NO. RXGY-D04)

2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000 BTU. REDUCE TO 11/2" FOR MODELS WITH INPUTS OF 45,000 THRU 75,000 BTU. ELBOWS AND RISERS ARE 2" PVC.

INTAKE VENT 21/2" PVC FOR MODELS WITH 120,000 BTU INPUT.

2" PVC ELBOWS AND RISER MODELS WITH INPUTS OF 45,000 THRU 105,000 BTU.

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

FIGURE 18 VERTICAL CONCENTRIC VENT KIT - RXGY - E02

12" FIXED

48" MAX.

INLET AIR

12" ABOVE AVERAGE SNOW ACCUMULATION

INSTALL ROOF FLASHING

ROOF LINE

INLET AIR PIPE

USE 2" x 3" INCREASER IF VENT IS 3" PIPE (FIELD SUPPLIED)

VENT FROM FURNACE

INLET AIR FROM FURNACE, USE 3" x 2" BUSHING IF INLET IS 2" PIPE (FIELD SUPPLIED)

➀

➁

➂

➄

➃

➅

➆

➀ ➁ ➂

➃

➄

➅

➆

2" SCH40 PVC PIPE 3" TYPE SDR 26 PVC PIPE 2" x 3" BUSHING (MODIFIED) 3" x 3" x 3" WYE 2" x 4" COUPLING (MODIFIED) 3" x 45° STREET ELBOW 2" COUPLING

(FIELD SUPPLIED)

• Insulate the entire length of vent pipe, between the elbow where the pipe exits the wall and the elbow where the termination is made, with a closed-cell insulation, such as “Arm-a-Flex” or “Rub-a-Tex” with a minimum of 1/2( thickness.

• All elbows installed on the exterior of the building must be of the long sweep nature.

• As required for the horizontal piping ran within the structure, any pipe ran horizontal outside the structure must slope upward a minimum of 1/4( per foot run so that condensate drains toward the furnace.

From the top elbow in the exhaust pipe, extend a length of PVC pipe outward so that it terminates exactly 12 inches from the wall. See Figure

17. Reduce the termination pipe

extension to is 1

/2 inch pipe for 45,000 BTUH through 75,000 BTUH units.

The 45,000 BTUH unit only uses kit RXGY-D02. The 60,000 BTUH and 75,000 BTUH units may use kits RXGY-D02 or RXGY-D03 depending on pipe lengths and number of elbows. Use kit RXGY-D03 with 90,000 BTUH through 120,000 BTUH units. The RXGY-D04 kit only

applies to the 120,000 BTUH unit using an alternate termination and excessively long runs. See Table 2.

The following are parts lists for the RXGY-D02, RXGY-D03 and RXGYD04 alternate horizontal direct vent termination kits:

RXGY-D02

1. 2-in. tee with reducer assembly

/2-in. PVC 6-in. dia. trap

3. PVC vane

4. 2-in. PVC elbow

5. 1

/2-in. PVC nipple with coupling

6. PVC strap

7. vent template

RXGY-D03

1. 3-in. tee with reducer assembly

/2-in. PVC 6-in. dia. trap

3. PVC vane

4. 2-in. PVC elbow

5. PVC strap

6. vent template

I339

I338

12( FROM WALL

Page 22

HORIZONTAL CONCENTRIC TERMINATION

This kit is for horizontal intake air pipe runs and may be installed through walls up to 16 inches thick. See Figure 19. Complete installation instructions are supplied with the kits.

FIGURE 19 HORIZONTAL CONCENTRIC VENT KIT NO. RXGY-C01 (DIRECT VENT INSTALLATIONS)

RXGY-D04

1. 2

/2-in. PVC elbow

2. 3" x 2

/2" PVC bushing

3. 2

/2" x 61/2" long PVC pipe

4. 2

/2" x 16" long PVC pipe

5. 2

/2" x 21" long PVC pipe

6. PVC vane

7. ➤

3-in. tee with reducer assembly

8. 6-in. dia. 1/2-in. PVC trap

9. PVC strap

10. vent template

NOTE: The RXGY-D04 kit only applies to the 120,000 BTUH unit using an alternate termination and excessively long runs.

CONCENTRIC TERMINATIONS

ALTERNATE VERTICAL CONCENTRIC VENT KIT NO. RXGY-E02

This kit is for vertical intake air/vent runs and may be installed through roofs up to 9 inches thick. One 4

/8-in. diameter hole is required through the roof for the installation. See Figure 18 for the general layout. Complete installation instructions are included with the kit.

Page 23

FIGURE 20 STANDARD VERTICAL DIRECT VENTING UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW MODELS)

FIGURE 21 STANDARD HORIZONTAL DIRECT VENTING UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW MODELS)

I407

EXHAUST TERMINATION

➀

➁

3" MAX. SEPARATION

COMBUSTION AIR PIPE

12" MIN. SEPARATION

12" MIN. ABOVE ROOF LEVEL

ROOF LINE

EXHAUST PIPE

COMBUSTION AIR PIPE

SUPPLY AIR

RETURN AIR

EXHAUST VENT

➂

➃

MAX.

EXHAUST VENT

ROOF LINE

COMBUSTION AIR PIPE

12"

MIN.

12" MIN.

ANTICIPATED SNOW LEVEL

COMBUSTION AIR PIPE

MAX.

EXHAUST VENT

12"

MIN.

12" MIN.

3" MAX.

12" MIN.

12" MIN. ABOVE

ANTICIPATED SNOW LEVEL

➄

NOTES:

➀

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

➁

INCREASE THE 12-IN. MINIMUM TO KEEP TERMINAL OPENING ABOVE ANTICIPATED LEVEL OF SNOW ACCUMULATION WHERE APPLICABLE.

➂

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 PASSING THROUGH ROOF.

➃

SUPPORT VERTICAL PIPE EVERY 6 FEET.

➄

EXHAUST TERMINATION - TERMINATE THE LAST 12 INCHES WITH 2( PVC PIPE ON 90,000 THROUGH 120,000 BTUH MODELS. REDUCE AND TERMINATE THE LAST 12 INCHES WITH 1

⁄2( PVC PIPE ON 45,000

THROUGH 75,000 BTUH MODELS.

PITCHED ROOF INSTALLATIONS

NOTES:

➀

SUPPORT HORIZONTAL PIPE EVERY FOUR FEET.

➁

WHEN 3 IN. PIPE IS USED REDUCE TO 2 IN. BEFORE PENETRATING OUTSIDE WALL.

➂

18 IN. MAXIMUM. 2 IN. DIAMETER PIPE MAY BE USED INSIDE THE WALL.

➃

DETAIL “A” - EXHAUST TERMINATION TERMINATE THE LAST 12 INCHES WITH 2( PVC PIPE ON 90,000 THROUGH 120,000 BTUH MODELS. REDUCE AND TERMINATE THE LAST 12 INCHES WITH 1

⁄2( PVC PIPE

ON 45,000 THROUGH 75,000 BTUH MODELS.

➄

INCREASE THE 12 IN. MINIMUM ABOVE GRADE TO KEEP TERMINAL OPENINGS ABOVE ANTICIPATED LEVEL OF SNOW ACCUMULATION WHERE APPLICABLE.

➅

DETAIL “B”, INSTALL WIND DEFLECTOR VANE IN 2 IN. PVC COUPLING IN VERTICLE POSITION USING PVC SOLVENT.

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

12(

SEE DETAIL A

VANE

2( PVC COUPLING

12( MIN. ABOVE GRADE LEVEL

➄

SEE DETAIL B

2( OR 3( TEE

W/DRAIN TRAP

RETURN AIR

TRAP

SUPPLY AIR

EXHAUST PIPE

COMBUSTION AIR PIPE

CONNECT TO DRAIN

12(

EXHAUST

INTAKE

OPTIONAL

INTAKE

DETAIL C

EXHAUST / INTAKE RELATIONSHIP

EXHAUST TERMINATION

➃DETAIL A

COMBUSTION AIR TERMINATION

➅DETAIL B

➀➁

➂

I407

Page 24

LOCATION REQUIREMENTS HORIZONTAL DIRECT VENTS

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

NOTE: In Canada vent terminations should be done in accordance with the current CAN/CGA-B149 Gas Installation Code and/or local codes.

The vent must be installed with the following minimum clearances. See Figures 22 and 23.

1. The bottom of the vent terminal and the air inlet shall be located 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. The vent shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard.

3. The vent terminal shall be located at least one foot from any opening through which flue gases could enter a building.

4. The vent terminal shall be at least 3 feet above any forced air inlet located within 10 feet, except the combustion air inlet of a direct vent appliance.

5. The vent terminal shall have a minimum horizontal clearance of 4 feet from electric meters, gas meters, regulators and relief equipment.

6. The air inlet shall be located at least 10 feet horizontally from the vent of any other gas or fuel burning appliance or electric clothes drier. The only exception to this requirement is the case of multiventing two or more of these furnaces. For those specifics refer to the section on multiventing in these instructions.

In addition to the minimum clearances listed above, the vent location should also 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.

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 prevailing winter winds. This will help prevent moisture 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 19.

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

6. Minimum vertical clearances of 1 foot are recommended for overhangs up to 1 foot horizontal. The vertical clearance should be increased equally for each additional increase in horizontal overhang to a maximum vertical clearance of 6 feet.

7. Caulk all cracks, seams and joints within 6 feet horizontally and above and below vent. See Figure 23.

FIGURE 22 MOISTURE ZONES

FIGURE 23 DIRECT VENT MINIMUM CLEARANCES

CAUTION

Page 25

FIGURE 24 TWO FURNACE VENTING THROUGH ROOF

FIGURE 25 TWO FURNACE VENTING THROUGH WALL

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.

MULTIVENTING

IF VENTING TWO OR MORE FURNACES NEAR EACH OTHER IS REQUIRED, EACH FURNACE MUST BE INDIVIDUALLY VENTED – NO COMMON VENTING IS

PERMITTED. See Figures 24 and 25

for positioning of the terminations. When more than two furnaces are to be vented, there must be at least 4 feet between the first two furnaces and the third, etc.

Page 26

CONNECTING TO FURNACE

IMPORTANT: Clean and debur all pipe cuts. The shavings must not be allowed to block the exhaust, inlet or condensate drain pipes.

UPFLOW FURNACE

The exhaust pipe connection is a 2-in. female PVC pipe fitting extending through the left side of the furnace top plate. This opening has a protective cap which should be removed just prior to installing the exhaust pipe. When 2-in. pipe is used, connect it directly to this fitting. When 3-in. pipe is used, connect a 2 to 3-in. coupling to this fitting with a short piece of 2-in. PVC pipe.

The inlet combustion air connection is at the right side of the top plate. An alternate combustion inlet air connection may be made on the right side of the jacket. This opening has a plastic cap. A combustion inlet air connection fitting is supplied with the furnace and it must be installed in the furnace by screwing it into the opening. Make sure the rubber “O-ring” supplied with the furnace is used with this fitting. See Figure 26.

DOWNFLOW/HORIZONTAL FURNACE

The exhaust pipe connection is a 2-in. upflow only PVC pipe fitting extending through the right side of the furnace top cover. This opening has a protective cap which should be removed just prior to installing the exhaust pipe. When 2-in. pipe is used, connect it directly to this fitting. When 3-in. pipe is used, connect with a 2- to 3-in. coupling directly to the 2-in. pipe.

The combustion inlet air connection is a 2-in. extruded hole on the left side of the top plate. When a 2-in. pipe is used, attach a 2-in. PVC coupling over this hole with RTV sealant and also add two sheet metal screws through the coupling into the extrusion to secure it in place, and add the required piping. When 3-in. pipe is required, use a 2- to 3-in. coupling and add the required piping. See Figure 27.

FIGURE 26 UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION

FIGURE 27 DOWNFLOW/HORIZONTAL COMBUSTION AIR AND VENT PIPE CONNECTION

VENT CAP/PLUG

OUTLET AIR PIPE

PIPE - PVC

CONNECTOR

EXHAUST TRANSITION

PLUG OPT. COMBUSTION AIR INLET POSITION

COMBUSTION AIR ADAPTER

TOP PLATE

“O” RING

COUPLING

NOTE: ATTACH COUPLING TO EXTRUDED COLLAR WITH TWO SCREWS. PUT BEAD OF SILICONE AROUND BASE BEFORE MOUNTING COUPLING.

COMBUSTION AIR CHASE

INDUCED DRAFT BLOWER

CONDENSATE TRAP

NOTE: WHEN COMBUSTION AIR INLET IS IN OPTIONAL POSITION, SWAP LOCATION OF INLET AIR ADAPTER AND “O” RING WITH PLUG.

PVC

OUTLET AIR PIPE

I329

Page 27

FIGURE 29 DOWNFLOW CONDENSATE DRAIN

CONDENSATE DRAIN/NEUTRALIZER

FIGURE 28 UPFLOW CONDENSATE DRAIN

GENERAL INFORMATION

DO NOT RUN DRAIN OUTDOORS. FREEZING OF CONDENSATE CAN CAUSE PROPERTY DAMAGE.

IMPORTANT: Do not connect into a

common drain line with an air conditioner evaporator coil drain located below the furnace. A blocked or restricted drain line can result in overflow of the coil pan and negate the furnace blocked drain shutoff control.

FILL TRAP ASSEMBLY WITH WATER BEFORE OPERATING THE

FURNACE. This can be done by

removing the drain hose from the trap and pouring about a cup of water into the vent trap. Water will flow into the house drain when the trap is full.

If local codes require, install a condensate neutralizer cartridge in the drain line. Install cartridge in horizontal position only. Also install an overflow line if routing to a floor drain. See Figures 28 and 29.

If no floor drain is available, install a condensate pump that is resistant to acidic water. Pumps are available from your local distributor. If pump used is not resistant to acidic water, a condensate neutralizer must be used ahead of the pump. The condensate pump must have an auxiliary safety switch to prevent operation of the furnace and resulting overflow of condensate in the event of pump failure. The safety switch must be wired through the “R” circuit only (low voltage) to provide operation in either heating or cooling modes.

UPFLOW MODELS

The condensate drain trap is located in the blower compartment on the lefthand side of the jacket. A short piece of

/2-in. PVC pipe and a 1/2-in. tee are provided. Connect the 1/2-in. pipe to the elbow on the trap and the tee to this pipe so that the open end is upward. Connect at least a 5( riser to the top of the tee and run a drain tube from the bottom of the tee to a floor drain or condensate pump.

IMPORTANT: If installing the unit over a finished ceiling or living area, be certain to install an auxiliary condensate drain pan under the entire unit extending out under the condensate tee. With a 5 inch riser installed above the tee, a blocked drain will result in overflow from the riser.

To cause the furnace to shut down when a blocked drain is present, install a riser which is a minimum of 10

⁄16(. If the furnace is installed in an

attic, crawlspace or other area where

freezing temperatures may occur, the furnace drain can freeze while shut off for long periods of time.

Use a solvent cement that is compatible with PVC material. Cut the drain hoses to the appropriate length and connect to the trap with hose clamps. Tighten the clamps with pliers and check for leaks after attaching.

DOWNFLOW MODELS

The condensate trap is located on the right side of the cabinet in the burner compartment. A short piece of

/2-in. PVC pipe and a 1/2-in. tee are provided. Connect the 1/2-in. pipe to the elbow on the trap and the tee to this pipe so that the open end is upward. Connect a 51⁄2-in. riser to the top of the tee and run a drain tube from the bottom of the tee to a floor drain or condensate pump. Use a solvent cement that is compatible with PVC material.

CAUTION

NEUTRALIZER CARTRIDGE

(OPTIONAL)

TO FLOOR DRAIN OR CONDENSATE PUMP

NOTE: DRAIN VENT NEEDS TO BE ABOVE COLLECTOR BOX DRAIN SPOUT.

MINIMUM HEIGHT OPEN TOP

CONDENSATE TRAP

DRAIN LINE

I408

OVERFLOW LINE (REQUIRED ONLY WHEN OPTIONAL NEUTRALIZER CARTRIDGE IS USED.)

I408

MINIMUM HEIGHT OPEN TOP

DRAIN LINE CONDENSATE TRAP

TO FLOOR DRAIN OR CONDENSATE PUMP

NEUTRALIZER CARTRIDGE

(OPTIONAL)

OVERFLOW LINE (REQUIRED ONLY WHEN OPTIONAL NEUTRALIZER CARTRIDGE IS USED.)

Page 28

➤ FIGURE 30 UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

FIGURE 31 DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

REVERSING THE TRAP

UPFLOW UNITS

The trap may be moved to the right side for right side drainage. Open the knockout for the drain on the right side of the cabinet. Remove the bracket holding the trap from the left side. Seal the left side drain hole with a plug provided in the cloth bag with the furnace. Position the mounting bracket and trap so that the drain elbow is centered in the hole on the right. See Figure 30.

Drill two holes in the cabinet to mount the bracket. Mount the trap and bracket to the right side with the drain elbow pointing through the knockout. Connect the

/2-in. pipe and tee as noted above. Route the drain hoses behind the control box, cut to the appropriate length, and connect to the trap with hose clamps.

IMPORTANT: DO NOT ALLOW ANY SAGS OR KINKS IN THE HOSES. This prevents proper

condensate flow. IMPORTANT: Do not connect into

a common drain line with an air conditioner evaporator coil drain located above the furnace. A blocked or restricted drain line can result in overflow of the coil pan and negate the furnace blocked drain shutoff control.

DOWNFLOW UNITS

To convert to left side drainage, first remove the drainage hoses from the trap. Remove the trap from its mounting bracket, rotate it 180°, and mount in place with the drainage elbow pointing to the left. Reattach the drain hoses. Remove the plastic drainage knockout from the left side. See Figure 31.

IMPORTANT: When changing to the left side, interchange the rubber bushing on the right side with the hole plug on the left side. The hole plug must be in place to assure that the control compartment is sealed.

A length of 1/2-in. PVC pipe is provided for left hand drainage. Glue one end of the pipe to the elbow in the trap. Cut the pipe so that it extends through the left cabinet side one inch. Connect the

/2-in. tee to the pipe with a 5-in. riser and drain tube as listed above. Use the plastic plug from the left side drainage knockout to seal the right side drainage knockout.

IMPORTANT: Do not connect into a common drain line with an air conditioner evaporator coil drain located above the furnace. A blocked or restricted drain line can result in overflow of the coil pan and negate the furnace blocked drain shutoff control.

DRAIN

VENT

DRAIN

EXTENSION

TEE

TO FLOOR DRAIN OR

CONDENSATE PUMP

CUT DRAIN HOSES AS REQUIRED AND CONNECT TO INLETS ON TOP OF CONDENSATE TRAP

DRAIN VENT

TEE

DRAIN EXTENSION

PROPER DRAIN SLOPE REQUIRED

(NO KINKS ALLOWED)

CONDENSATE TRAP

SHEETMETAL

CONTROL BOX

TO FLOOR

DRAIN

CONDENSATE TRAP

ROTATE TRAP 180° AND INSTALL RIGID PIPE (SUPPLIED) FROM ELBOW TO OPPOSITE SIDE OF JACKET

FILLING THE TRAP

FILL THE TRAP ASSEMBLY WITH WATER BEFORE OPERATING THE FURNACE. Do this by removing the

drain hose from the trap or from the connection to the secondary coil. Pour about a cup of water into the vent trap. Any excess water flows into the house drain when the trap is full.

I394

Page 29

8. Attach the gasket ➇ onto the trap assembly so that the gasket holes on the gasket line up with the holes on the trap assembly.

9. Insert the trap assembly with gasket up through the existing hole in the jacket and secure from inside the jacket. Use two screws provided. Screw down into the two “ears” molded into either side of the trap. Snug the trap assembly against the furnace jacket compressing the gasket slightly to eliminate any air leaks. Do not

overtighten!

10. Attach the black molded rubber 90° elbow ➈ to the straight spout on the trap top using a black nylon clamp ➉. Attach the other end of the rubber elbow to the spout ➀ located on the exhaust transition ➄ using a black nylon clamp.

11. Attach the end of the ribbed tube ➂ to the 45° elbow molded into the top of the trap assembly using a black nylon clamp.

IMPORTANT: Tighten all clamp connections with a pair of pliers and check for leaks after conversion is complete.

12. Connect a 5 1/2 ( riser to the top of the tee and run a drain tube from the bottom of the tee to a floor drain or condensate pump. Use a solvent cement that is compatible with PVC material.

CONDENSATE DRAIN FOR HORIZONTAL INSTALLATION

Refer to Figure 33 for Steps 1-5.

1. This unit is shipped factory ready for downflow

installation. The condensate trap assembly and drain hoses require conversion for horizontal installation. Remove the existing condensate trap with the unit in the upright position.

2. Remove the burner compartment door from the unit.

3. Remove the two screws from the right side of the furnace jacket which support the trap mounting bracket ➁. Remove the two plastic plugs on either side of the trap outlet hole and discard.

4. Remove the (L-shaped) clear vinyl drain tube ➂ from the top of the existing trap ➀.

Do not

disconnect the short end

from the furnace collector box.

5. Remove the ribbed drain tube ➃ from the existing trap ➀ and the exhaust transition ➄. Discard this tube. Retain the clamps for future use. Additional clamps are provided in the parts bag if any clamps are damaged during conversion process.

NOTE: The following steps should take place with the furnace in the horizontal position.

Refer to Figure 34 for Steps 6-11.

6. Locate the parts bag in the burner compartment. Install two plastic plugs ➅ in the side of the jacket from bottom side up.

7. Fill the trap assembly ➆ with 1/2 cup of water.

FIGURE 32 DOWNFLOW CONDENSATE DRAIN

NEUTRALIZER CARTRIDGE

(OPTIONAL)

TO FLOOR DRAIN OR CONDENSATE PUMP

NOTE:

DRAIN VENT NEEDS

TO BE ABOVE

COLLECTOR BOX

DRAIN SPOUT.

MINIMUM HEIGHT

OPEN TOP

CONDENSATE TRAP

DRAIN LINE

I408

OVERFLOW LINE

(REQUIRED ONLY WHEN

OPTIONAL NEUTRALIZER

CARTRIDGE IS USED.)

Page 30

FIGURE 33 UPRIGHT POSITION: REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP

FIGURE 34 HORIZONTAL POSITION: CONDENSATE TRAP INSTALLATION FOR HORIZONTAL OPERATION

I534

CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO

HORIZONTAL INSTALLATION

Page 31

GAS SUPPLY AND PIPING

GAS SUPPLY

THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT SUPPLIED BY THE DISTRIBUTOR OR MANUFACTURER. MAILING ADDRESSES ARE LISTED ON THE FURNACE RATING PLATE, PARTS LIST AND WARRANTY. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. See the conversion kit index supplied with the furnace. This index identifies the proper LP Gas Conversion Kit required for each particular furnace.

IMPORTANT: Any additions,

changes or conversions required for the furnace to satisfactorily meet the application should be made by a qualified installer, service agency or the gas supplier, using factoryspecified or approved parts.

IMPORTANT: Connect this furnace only to gas supplied by a commercial utility.

IMPORTANT: A U.L. recognized fuel gas and CO detector(s) 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.

GAS PIPING

Install the gas piping according to all local codes and regulations of the utility company.

If possible, run a separate gas supply line directly from the meter to the furnace. Consult the local gas company for the location of the manual main shut-off valve. The gas

line and manual gas valve must be adequate in size to prevent undue pressure drop and never smaller than the pipe size to the combination gas valve on the furnace.

Refer to Table 3 for the recommended gas pipe size. See Figure 35 for typical gas pipe connections.

WARNING

FIGURE 35 GAS PIPING INSTALLATION

GROMMET

TOP VIEW OF GAS LINE AND VALVE

IN OPT. POSITION

NOTE: WHEN GAS LINE IS IN OPT. POSITION, SWAP LOCATION OF GROMMET AND PLUG.

OPT. GAS LINE POSITION

PLUG (IN NORMAL POSITION)

MANIFOLD PRESSURE TAP

IGNITOR

MANIFOLD

GAS VALVE

UNION

DRIP LEG

GROMMET (IN NORMAL POSITION)

4 TO 5 FEET ABOVE FLOOR REQ’D BY SOME UTILITIES.

MAIN GAS

VALVE

BURNERS

GROMMET

TOP VIEW OF GAS LINE AND VALVE

IN OPT. POSITION

MAIN GAS

VALVE

4 TO 5 FEET ABOVE FLOOR REQ’D BY SOME UTILITIES.

GROMMET (IN NORMAL POSITION)

DRIP LEG

UNION

GAS VALVE

BURNERS

MANIFOLD

IGNITOR

MANIFOLD PRESSURE TAP

PLUG (IN NORMAL POSITION)

NOTE: WHEN GAS LINE IS IN OPT. POSITION, SWAP LOCATION OF GROMMET AND PLUG.

DOWNFLOW

I328

UPFLOW

MANUAL GAS VALVE

UNION

DRIP LEG

BURNERS

MANIFOLD

GAS VALVE

I524

IMPORTANT: DO NOT RUN A FLEXIBLE GAS CONNECTOR INSIDE THE UNIT. Extend the 1/2" black pipe from the gas valve to the outside of the cabinet. Connect any flexible gas connector from there to the gas piping.

HORIZONTAL

Page 32

The minimum supply pressure to the gas valve for proper furnace input adjustments is 5" w.c. for natural gas, however 6" to 7" is recommended. The minimum supply pressure is 11" w.c. for LP gas.

NEVER PURGE A GAS LINE INTO THE COMBUSTION CHAMBER. NEVER USE MATCHES, FLAME OR ANY IGNITION SOURCE FOR CHECKING LEAKAGE. FAILURE TO ADHERE TO THIS WARNING CAN CAUSE A FIRE OR EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

To check for gas leakage, use an approved chloride-free soap and

Install a ground joint union inside the cabinet to easily remove the control valve assembly. Install a manual shut-off valve in the gas line outside the furnace casing.

The valve should be readily accessible to turn the gas supply on or off. Install a drip leg in the gas supply line as close to the furnace as possible. Always use a pipe compound resistant to the action of liquefied petroleum gases on all threaded connections.

IMPORTANT: When making gas pipe connections, use a back-up wrench to prevent any twisting of the control assembly and gas valve.

Any strains on the gas valve can change the position of the gas orifices in the burners. This can cause erratic furnace operation.

The gas pipe gasket in the cabinet does not seal around a flexi-ble gas connector. It is important to have all

openings in the cabinet burner compartment sealed for proper furnace operation.

IMPORTANT: ENSURE that the

furnace gas control valve not be subjected to high gas line supply pressures.

DISCONNECT the furnace and its individual shut-off valve from the gas supply piping during any pressure

testing that exceeds 1/2 p.s.i.g. (3.48 kPa).

GAS PRESSURE

Natural gas supply pressure should be 5" to 7" w.c. LP gas supply pressure should be 11" to 13" w.c.

This pressure must be

maintained with all other gas-fired appliances in operation. Do not

exceed a maximum gas supply pressure of 13" w.c. with any fuel.

WARNING

FIGURE 36 ELECTRONIC COMBUSTIBLE GAS DETECTOR

FIGURE 37 GAS VALVE

PRESSURE

CONTROL REGULATOR

KNOB ADJUSTMENT

TABLE 3 NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific gravity of 0.60 (natural gas).

Nominal Length of Pipe, Feet Iron Pipe

Size, Inches 10 20 30 40 50 60 70 80

1/2 132 92 73 63 56 50 46 43 3/4 278 190 152 130 115 105 96 90

1 520 350 285 245 215 195 180 170 1-1/4 1,050 730 590 500 440 400 370 350 1-1/2 1,600 1,100 890 760 670 610 560 530

After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour required for the gas input rating of the furnace. By formula:

Gas Input of Furnace (BTU/HR)

Cu. Ft. Per Hr. Required =

Heating Value of Gas (BTU/FT

)

The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may be determined by consulting the local natural gas utility or the LP gas supplier.

water solution, an electronic combustible gas detector (see Figure 36), or other approved method.

GAS VALVE

This furnace has a 24-volt operated valve. It has ports for measuring supply pressure and manifold pressure. The valve body contains a pressure regulator to maintain proper manifold pressure.

A manual control is on the valve body. It can be set to only the “ON” or “OFF” positions. The gas valve is a slow-opening valve. See Figure 37.

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

Page 33

LP CONVERSION

The valve can be converted to use liquified petroleum (LP) gas by replacing the pressure regulator spring with the conversion kit spring. This LP kit spring allows the regulator to maintain the proper manifold pressure for LP gas. The correct burner LP orifices are included in the kit. See Figure 38.

NOTE: Order the correct LP conversion kit from the furnace manufacturer.

Furnace conversion to LP gas must be performed by a qualified installer, service agency or the gas supplier.

To change orifice spuds for either conversion to LP or for elevation:

1. Shut off the manual main gas valve and remove the gas manifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

Consult the following table if there is any question concerning orifice sizing.

ORIFICE SIZES

US 0 - 7999 FT. 8000 FT. & ABOVE

Natural Gas #50 #51

LP Gas 1.15 mm 1.10 mm

CANADIAN 0 - 2000 FT. 2001-4500 FT.

Natural Gas #50 #50

LP Gas 1.15 mm 1.15 mm

4. Turn the gas supply back on and check for proper operation and manifold pressure. See Figures 39, 40 and 41.

5. Attach the notice label alerting the next service technician that the furnace has been converted to LP gas.

NOx MODELS

IMPORTANT: NOx inserts are not required when operating this furnace on LP gas.

When converting furnaces equipped with NOx inserts to LP gas, remove the NOx insert assemblies. Steps for removal are listed below:

1. Turn off all electrical power and the gas supply to the furnace.

2. Remove the burner door from the furnace.

3. Remove the igniter assembly –

handle with care.

4. Remove the two screws attaching the NOx insert retainer brackets to the center panel. Pull the retainer rod.

5. Put the two screws back into the holes in the center panel.

FIGURE 38 LP KIT CONTENTS

FIGURE 39 HOSE CONNECTION TO LINE PRESSURE TAP

6. Re-install the igniter and burner assemblies.

7. Replace burner door.

8. Turn on electrical power and gas supply to the unit.

Page 34

TABLE 4 LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

Maximum capacity of pipe in thousands of BTU per hour of undiluted liquefied petroleum gases (at 11 inches water column inlet pressure). (Based on a Pressure Drop of 0.5 Inch Water Column)

Nominal Length of Pipe, Feet Iron Pipe

Size, Inches 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 63 3/4 567 393 315 267 237 217 196 182 173 162 146 132

1 1,071 732 590 504 448 409 378 346 322 307 275 252 1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 511 1-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787

2 6,221 4,331 3,465 2,992 2,646 2,394 2,205 2,047 1,921 1,811 1,606 1,496

Example (LP): Input BTU requirement of unit, 150,000

Equivalent length of pipe, 60 ft. = 3/4" IPS required.

SETTING GAS PRESSURE

The maximum gas supply pressure to the furnace should be 7" w.c. natural gas, or 13" w.c. LP gas.

The minimum supply gas pressure to the gas valve should be 5" w.c. natural gas or 11" w.c. LP gas. A properly calibrated U-Tube manometer is required for accurate gas pressure measurements.

Supply Gas Pressure Measurement. A line pressure tap is on the

input side of the gas valve. See Figure 39.

1. With gas shut off to the furnace at the manual gas valve outside the unit, remove the input pressure tap plug.

2. Connect a U-Tube manometer to the pressure tap.

3. Turn on the gas supply and operate the furnace and all other gas-fired units on the same gas line as the furnace.

4. Note or adjust the line gas pressure to give:

A. 5" - 7" w.c. for natural gas. B. 11" - 13" w.c. for LP gas.

5. Shut off the gas at the manual gas valve and remove the U-Tube manometer.

6. Replace the pressure tap plug before turning on the gas.

If the supply gas line pressure is above these ranges, install an in-line gas regulator to the furnace for natural gas units. With LP gas, have

FIGURE 40 MANIFOLD PLUG LOCATION

the LP supplier reduce the line pressure at the regulator.

If supply gas line pressure is below these ranges, either remove any restrictions in the gas supply piping or enlarge the gas pipe. See Tables 3 and 4. With LP gas, have the LP supplier adjust the line pressure at the regulator.

Manifold Gas Pressure Measurement. Natural gas manifold pressure should be 3.5" w.c. LP gas manifold pressure should be 10.0" w.c. Only small

variations in gas pressure should be made by adjusting the pressure regulator.

1. With the gas to the unit shut off at the manual gas valve, remove the pressure tap plug in the gas manifold. See Figure 40.

2. Connect a U-Tube manometer to this pressure tap. See Figure 41.

3. Turn on the gas supply and operate the furnace.

4. Note or adjust the manifold gas pressure to give:

A. 3.5" w.c. for natural gas. B. 10.0" w.c. for LP gas.

5. To adjust the pressure regulator, remove the regulator cap.

6. Turn the adjustment screw clockwise to increase pressure, or counterclockwise to decrease pressure.

7. Securely replace the regulator cap.

8. Shut off gas at the manual gas valve and remove the U-Tube manometer.

9. Replace the manifold pressure tap plug before turning on the gas.

Page 35

FIGURE 42 UPFLOW GROUNDING CONNECTIONS

ELECTRICAL WIRING

TURN OFF ELECTRIC POWER AT FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, ANSI/ NFPA70-, OR IN CANADA, THE CANADIAN ELECTRICAL CODE, CSA-C221 OR LOCAL CODES THAT APPLY. DO NOT USE GAS PIPING AS AN ELECTRICAL GROUND. A GROUND SCREW IS PROVIDED IN THE JUNCTION BOX. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

THIS FURNACE IS EQUIPPED WITH A BLOWER DOOR SAFETY SWITCH. DO NOT DISABLE THIS SWITCH. FAILURE TO FOLLOW THIS WARNING CAN RESULT IN ELECTRICAL SHOCK, PERSONAL INJURY OR DEATH.

IMPORTANT: The furnace must be

installed so that the electrical components are protected from water (condensate).

Before proceeding with the electrical connections, be certain that the voltage, frequency and phase corresponds to that specified on the furnace rating plate. For single furnace application, maximum overcurrent protection is 15 amperes.

Use a separate fused branch electrical circuit containing a properly sized fuse or circuit breaker. Run this circuit directly from the main switch box to an electrical disconnect that is readily accessible and located near the furnace. Connect from the electrical disconnect to the junction box on the left side of the furnace, inside the blower compartment. For

FIGURE 41 MANIFOLD PRESSURE READING

WARNING

JUNCTION

BOX

CONDENSATE

TRAP

GREEN GROUND LEAD FOR

CONTROL BOX COVER

ELECTRIC CONTROL BOX COVER

BLOWER COMPARTMENT

LOW VOLTAGE TERMINALS

Page 36

the proper connection, refer to the appropriate wiring diagram located on the inside cover of the furnace control box and in these instructions.

NOTE: UPFLOW MODELS ONLY The electrical junction box may be moved to the right side if necessary. A knockout is provided. Seal the opposite hole with plug provided.

NOTE: L1 (hot) and L2 (neutral) polarity must be observed when making field connections to the furnace. The ignition control may not sense flame if L1 and L2 are reversed. See Figure 43.

Make all electrical connections in accordance with the latest edition of the National Electrical Code ANSI/NFPA70 – or in Canada, the Canadian Electrical Code Part 1-CSA Standard C22.1 and local codes having jurisdiction.

These may be obtained from: National Fire Protection

Association, Inc. Batterymarch Park Quincy, MA 02269

Canadian Standards Association 178 Rexdale Boulevard Rexdale, Ontario, Canada M9W 1R3

THERMOSTAT

The room thermostat must be compatible with the integrated furnace control on the furnace. All thermostats available from the furnace manufacturer’s Parts Department are acceptable. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control. The low voltage wiring should be sized as shown in Table 5.

FIGURE 44 ISOLATION RELAY

TABLE 5 LOW VOLTAGE WIRING

SOLID COPPER WIRE - AWG

3.0 16 14 12 10 10 10

2.5 16 14 12 12 10 10

2.0 18 16 14 12 12 10

50 100 150 200 250 300

LENGTH OF RUN - FEET ➀

➀➤ The total wire length is the distance from the furnace to the thermostat and back to the furnace.

NOTE: Do not use 24 volt control wiring smaller than No. 18.

THERMOSTAT

LOAD - AMPS

FIGURE 43 LINE VOLTAGE CONNECTIONS HONEYWELL S9201E2001 AND UTEC 1012-920 & 1028-927 CONTROL BOARDS

UTEC 1012-925 CONTROL BOARD

JOHNSON CONTROLS G961DAJ-2401 CONTROL BOARD

FURNACE CONTROL BOARD

TO THERMOSTAT

“W” TERMINAL

TO THERMOSTAT

“R” TERMINAL

Y G R W CTWIN

NOTE: Do not use 24 volt control wiring smaller than No. 18 AWG.

NOTICE: An isolation relay can be added to prevent any compatibility problems that may occur. Use a single-pole, single-throw relay with a 24-volt AC coil. The contacts should be rated for .5 amps minimum at 24 volts. See Figure 44.

Install the room thermostat in accordance with the instruction sheet packed in the box with the thermostat.

Run the thermostat lead wires inside the blower compartment and connect to low voltage terminals as shown on the wiring diagram. Never install the thermostat on an outside wall or where it will be influenced by drafts, concealed hot or cold water pipes or ducts, lighting fixtures, radiation from fireplace, sun rays, lamps, televisions, radios or air streams from registers. Refer to instructions packed with the thermostat for “heater” selection or adjustment.

I334

I677

Page 37

FIELD-INSTALLED OPTION ACCESSORIES

ELECTRONIC AIR CLEANER

Line voltage power can be supplied from the screw terminal “EAC” and a line voltage neutral screw terminal on the control board. This will power the electronic air cleaner whenever the circulating air blower is in operation.

HUMIDIFIER

Line voltage power can be supplied from screw terminal “HUM” to a line voltage neutral screw terminal on the control board. This will power the humidifier whenever the burner is on and the circulating air blower is operating in the heating mode.

NOTE: Maximum current – 1.0 amps for each option.

HIGH ALTITUDE KIT

Models installed at altitudes of 5,000 feet and above require a pressure switch change. These may be ordered under Option Code No. 278. Models with this option code will have the additional pressure switch and burner orifice packed with the furnace. The installer should replace the induced draft blower pressure switch installed on the furnace with the new pressure switch. The burner orifices should also be changed when required (See Table Below). The following high altitude kits are also available:

Kit No: RXGY-F04 – set point – 0.70" w.c.

RXGY-F05 – set point – 0.60" w.c.

RXGY-F06 – set point – 1.11" w.c.

RXGY-F07 – set point – 0.95" w.c.

The following is a list of furnace inputs and required pressure switches:

INPUT KIT NO. SET POINT MAKE POINT

45,000 RXGY-F06 1.11" w.c. 1.29" w.c.

60,000 RXGY-F06 1.11" w.c. 1.29" w.c.

75,000 RXGY-F07 0.95" w.c. 1.10" w.c..

90,000 RXGY-F06 1.11" w.c. 1.29" w.c..

105,000 RXGY-F04 0.70" w.c. 0.85" w.c.

120,000 RXGY-F05 0.60" w.c. 0.75" w.c.

ORIFICE SIZES

U.S. 0 - 7999 FT. 8000 FT. & ABOVE

Natural Gas #50 #51

LP Gas 1.15 mm 1.10 mm

CANADA 0 - 2000 FT. 2001 TO 4500

Natural Gas #50 #50

LP Gas 1.15 mm 1.15 mm

NOTICE: DO NOT make any attempt to rerate the furnace by changing gas orifices or the gas pressure. Allow the natural derate of the gas to occur.

The natural derate is approximately

1.8% per 1000 feet. No orifice sizing or other derate

procedures are necessary unless the natural gas exceeds 1075 BTU/cu. ft. at sea level or the LP gas exceeds 2500 BTU/cu. ft. at sea level. If the heating values exceed these levels, consult the manufacturer for the derate procedures.

FURNACE TWINNING INSTALLATIONS

Twinning operation of two furnaces, installed side-by-side, connected by a common duct system with main power supplied by the same source, and controlled by a common thermostat can be done with the Honeywell S9201E2001, UTEC 1012920 or 1028-927 and Johnson Controls G961DAJ-2401 integrated control boards.

IMPORTANT: TWINNING OF (-)GRJAND (-)GTJ- UNITS REQUIRES AN ACCESSORY TWINNING KIT. REFER TO THE SPECIFICATION SHEET FOR PROPER KIT. DO NOT ATTEMPT TO TWIN THESE MODELS BY USING THE INSTRUCTIONS BELOW.

It should be noted that both

blowers will run simultaneously when there is a call for heating, cooling or fan.

The “OK” LED will flash if twinning is not set up properly.

HONEYWELL S9201E2001 CONTROL BOARD

1. Single Stage Operation (See Figure 45)

a. Control board “ONE” is

connected to the thermostat.

b. Remove the jumper between

the “XMIT” and “RCV” terminals.

c. Connect wire from “XMIT”

terminal of board “ONE” to “RCV” terminal of board “TWO.”

d. Connect wire from “RCV”

terminal of board “ONE” to “XMIT” terminal of board “TWO.”

e. Connect wire between the

grounds.

f. Connect wire between the two

“W” thermostat terminals.

2. Two Stage Operation (See Figure 46)

a. Repeat steps a, b, c, d and e

above.

b. Connect “W1” of thermostat to

“W” on control board “ONE”.

c. Connect “W2” of thermostat to

“W” on control board “TWO”.

UTEC 1012-920 & 1028-927 CONTROL BOARDS

1. Single Stage Operation (See Figure 47)

a. Control board “ONE” is on

furnace connected to the thermostat.

b. The 24 VAC supply to both

control boards must be in phase with each other.

c. Connect the “C,” “W” and

“TWIN” terminals to counterparts on each control.

d. Both control boards must have

switch #3 in the “ON” position.

e. Control board “ONE” must

have the switch #4 in the “1st” position. The other control board must have switch #4 in the “ON” position for single stage heat operation. NOTE: The 1028-927 control board has no 4th, 1st-2nd switch, Staging is determined through “W” terminal connections only.

2. Two Stage Operation (See Figure 48)

a. Follow above instructions:

Switch #4 on control board “TWO” must be in “2nd” position. Control board “TWO” must be the slave (not connected to the thermostat) in two-stage operation.

b. Connect “W2” on thermostat

to “W” on control board “TWO”.

Johnson Controls G961DAJ-2401

1. Single Stage Operation (See Figure 49)

a. Control board “ONE” is on the

furnace connected to the thermostat.

b. The 24 VAC supply to both

control boards must be in phase with each other.

c. Connect the “C” “W” and

“TWIN” terminals to counterparts on each control.

d. Both control boards must have

switch #1 in the “ON” position.

e. Control board “ONE” must

have switch #2 in the “ON” position. The other control board must have switch #2 in the “OFF” position for single stage heat.

2. Two Stage Operation (See Figure 50)

a. Follow above instructions

except connect “W2” on the thermostat to “W” on control board “TWO.”

b. Control board “TWO” must be

the slave (not connected to the thermostat) in two-stage operation.

ACCESSORIES

Page 38

FIGURE 45 HONEYWELL NO. S9201E2001 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION

I400

Page 39

FIGURE 46 HONEYWELL NO. S9201E2001 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION

I401

Page 40

FIGURE 47 UTEC NO. 1012-920 & 1028-927 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION

I398

Page 41

FIGURE 48 UTEC NO. 1012-920 & 1028-927 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION

I398

Page 42

FIGURE 49 JOHNSON CONTROLS G961DAJ-2401 CONTROL BOARD TWINNING CONNECTION SINGLE STAGE OPERATION

I399

Page 43

FIGURE 50 JOHNSON CONTROLS G961DAJ-2401 CONTROL BOARD TWINNING CONNECTION TWO STAGE OPERATION

I399

Page 44

START-UP PROCEDURES

This furnace is equipped with a silicon carbide hot surface ignition (HSI) device. Each time the room thermostat calls for heat, the HSI lights the main burners directly See the lighting instructions on the furnace.

TO START THE FURNACE

1. Remove the burner compartment control access door.

2. IMPORTANT: Be sure that the manual gas control has been in the “OFF” position for at least five minutes. Do not attempt to manually light the main burners.

3. Turn off the furnace electrical power and set the room thermostat to its lowest setting.

4. Turn the gas control knob to the “ON” position.

5. Replace the burner compartment control access door.

6. Turn on the furnace electrical power.

7. Set the room thermostat to a point above room temperature to light the main burners.

8. After the burners are lit, set the room thermostat to a desired temperature.

TO SHUT DOWN THE FURNACE

1. Set the room thermostat to its lowest setting.

2. Remove the burner compartment control access door.

3. Shut off the gas to the main burners by turning the gas control knob to the “OFF” position. See Figure 36.

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, CLOSE THE MANUAL GAS VALVE FOR THE APPLIANCE BEFORE SHUTTING OFF THE ELECTRICAL SUPPLY. FAILURE TO DO SO CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

SEQUENCE OF OPERATION

Honeywell or UTEC Integrated Controls with Hot Surface Ignition.

1. Each time the thermostat contacts close, the induced draft blower (inducer) begins a prepurge cycle.

2. The air proving negative pressure switch(es) closes.

3. 30 seconds after the pressure

switch(es) close, the hot surface

igniter heats for 30 seconds to full

temperature. The induced draft blower operates for the complete heating cycle.

4. After the 30-second igniter warm up,

the gas valve opens for a 9-second trial for ignition.

5. The igniter lights the gas burners and stays energized for the first 8

seconds after the gas valve opens.

6. 8 seconds after the gas valve opens

the remote flame sensor must prove flame ignition for one

second using the process of flame rectification. If the burners don’t light, the system goes through another ignition sequence. It does this up to four times.

7. The main blower starts approximately 20 seconds after the burners ignite.

8. When the thermostat cycle ends, the gas valve closes, the burners go out, the induced draft blower stops after a 5-second post-purge, and the negative pressure switch(es) open.

9. The main blower continues until timed off by the setting on the integrated furnace control board.

Sequence if the system doesn’t light or doesn’t sense flame:

1. On a call for heat, the control runs the inducer for 30 seconds to prepurge.

2. After the 30-second prepurge, the hot surface igniter heats for 30 seconds. The inducer continues to run.

3. After the 30-second igniter warm up, the gas valve opens for a 9-second trial for ignition. The inducer continues and the igniter stays energized.

4. If flame is not sensed during the ninth second after the gas valve opens, the gas valve closes, and the igniter de-energizes.

5. After a 30 second inter-purge, the igniter heats for 30 seconds. After 30 seconds, the gas valve opens for 9 seconds. If no flame is sensed, it closes the gas valve, the igniter deenergizes. Both the inducer and

main blower operate for 180 seconds.

6. It retries up to four times. At the end of the last try, the inducer stops immediately. The system is in

“soft” lock out.

7. The above sequence will repeat after a one hour delay. It will continue repeating until ignition is successful or the call for heat is terminated.

8. To reset the lock out, make and

break power either at the thermostat or at the unit disconnect switch for 5 to 10

seconds. It then goes through

another set of trials for ignition.

UTEC or Johnson Controls Direct Spark Ignition

1. Each time the thermostat contacts close, the induced draft blower (inducer) begins a prepurge cycle.

2. The air proving negative pressure switch(es) closes.

3. 30 seconds after the pressure

switch(es) close, the spark

igniter energizes. The induced

draft blower operates for the complete heating cycle.

4. After the spark igniter energizes,

the gas valve opens for a 8 second trial for ignition.

5. The igniter lights the gas burners.

6. After the gas valve opens the

flame sensor must prove flame

ignition for one second using the

process of flame rectification. If the burners don’t light, the system goes through another ignition sequence. It does this up to four times.

7. The main blower starts 20 seconds after the burners ignite.

8. When the thermostat cycle ends, the gas valve closes, the burners go out, the induced draft blower stops after a 5-second post- purge, and the negative pressure switch(es) open.

9. The main blower continues until timed off by the setting on the integrated furnace control board.

Sequence if the system doesn’t light or doesn’t sense flame:

1. On a call for heat, the control runs the inducer for 30 seconds to prepurge.

2. After the 30-second pre-purge, the spark igniter energizes. The inducer continues to run.

3. After the spark igniter energizes, the gas valve opens for a 8second trial for ignition. The inducer continues and the igniter stays energized.

4. If flame is not sensed within 8 seconds after the gas valve opens, the gas valve closes, and the igniter de-energizes.

5. After a 30-second inter-purge, the igniter is energized, the gas valve opens for 8 seconds. If no flame is sensed, it closes the gas valve, the igniter de-energizes. Both the

main blower and the inducer operate for 180 seconds before the next ignition trial.

6. It retries up to four times. At the end of the last try, the inducer stops. The system is in “soft” lockout.

7. The above sequence will repeat after a one hour delay. It will continue repeating until ignition is successful or the call for heat is terminated.

8. To reset the lock out, make and

break power either at the thermostat or at the unit disconnect switch for 5 to 10

seconds. It then goes through

another set of trials for ignition.

WARNING

Page 45

ADJUSTING OR CHECKING FURNACE INPUT

The maximum gas supply pressure to the furnace should be 7" w.c. for natural gas. The minimum gas supply pressure for purposes of input adjustment to the furnace should be 5" w.c.

A properly calibrated magnehelic gauge or manometer is required for accurate gas pressure readings.

The manifold pressure should be set at 3.5" w.c. for natural gas. Only small variations in the gas flow should be made by means of the pressure regulator adjustment. In no case should the final manifold pressure vary more than plus or minus 0.3" w.c. from the abovespecified pressures. To adjust the pressure regulator, remove the regulator cap and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure. Then replace the regulator cap securely. Any necessary major changes in the gas flow rate should be made by changing the size of the burner orifices.

To change orifice spuds, shut off the manual gas valve and remove the gas manifold. On LP gas furnaces, the LP gas supply pressure must be set between 11" and 14" w.c. by means of the tank or branch supply regulators. The furnace manifold pressure should be set at 10" w.c. at the gas control valve. For elevations up to 2,000 feet, rating plate input ratings apply. For high altitudes (elevations over 2,000 ft.), see conversion kit index 92-21519-XX for derating and orifice spud sizes.

Checking furnace input is important to prevent over firing beyond its design-rated input. NEVER SET INPUT ABOVE THAT SHOWN ON THE RATING PLATE. Use the following table or formula to determine input rate. Start the furnace and measure the time required to burn one cubic foot of gas. Prior to checking the furnace input, make certain that all other gas appliances are shut off, with the exception of pilot burners. Time the meter with only the furnace in operation.

SETTING INPUT RATE

The furnace is shipped from the factory with #50 orifices. They are sized for natural gas having a heating value of 1075 BTU/cu. ft. and a specific gravity of .60.

Since heating values vary geographically, the manifold pressure and/or gas orifice size may need to be changed to adjust the furnace to its nameplate input. Consult the local gas utility to obtain the yearly average heating value and orifice size required to fire each individual burner at 15,000 BTU/HR.

TABLE 6 METER TIME

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES

EQUIPPED FOR NATURAL OR LP GAS

HEATING VALUE OF GAS BTU PER CU. FT.

METER

900 1000 1040 1100 2500 (LP)

INPUT SIZE

BTU/HR CU. FT. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC. MIN. SEC.

ONE 1 12 1 20 1 23 1 28 3 20

45,000 TEN 12 0 13 20 13 50 14 40 33 20

ONE 054101316230

60,000 TEN 9 0 10 0 10 24 11 0 25 0

ONE 04404805005320

75,000 TEN 7 1280819848200

ONE 0 36 0 40 0 42 0 44 1 40

90,000 TEN 6 0 6 40707201640

ONE 0 31 0 34 0 36 0 38 1 26

105,000 TEN 5 10 5 40606201420

ONE 0 27 0 30 0 31 0 33 1 15

120,000 TEN 4 30505105301230

Heating Value of Gas (BTU/FT

) x 3600

Formula: Input BTU/HR =

Time in Seconds (for 1 cu. ft.) of Gas

Page 46

AIR FLOW

The importance of proper air flow over the heat exchanger cannot be over emphasized. One of the most common causes of heat exchanger failure is overheating due to low air flow. An air flow table is located inside the blower door.

TEMPERATURE RISE CHECK

To determine if the air flow is correct, make a temperature rise check.

1. Insert a thermometer in the supply air duct as close to the furnace as possible yet out of a direct line from the heat exchanger. See Figure 51.

2. Insert a thermometer in the return air duct as close to the furnace as possible.

3. Operate the furnace.

4. When the thermometer in the supply air duct stops rising (approximately five minutes), subtract the return air temperature from the supply air temperature. The difference is the temperature rise.

5. Compare the measured temperature rise to the approved temperature rise range listed on the furnace name plate. See Figure 52.

If the measured temperature rise is above the approved range, the air flow is too low. More air must be moved by speeding up the blower, by removing restrictions in the duct system, or by adding more supply or return air duct. If the measured temperature rise is below the approved range, the air flow is too much. Use lower speed tap on the multi-speed blower.

Ideally the measured temperature rise should be in the middle of the range.

FIGURE 51 TEMPERATURE RISE MEASUREMENT

FIGURE 52 FURNACE NAME PLATE

Page 47

TABLE 7

90 PLUS AIR FLOW PERFORMANCE

CFM @ ESP

MODEL BLOWER/

SPEED

MOTOR HP .1 .2 .3 .4 .5 .6 .7

RGRA-04 11 x 7 /

/2 LOW 805 780 760 720 685 645 605

*M-LO 920 885 850 810 775 730 690

M-HI 1140 1110 1085 1045 1010 950 890

HIGH 1360 1320 1280 1235 1195 1140 1080

RGTA-04 11 x 7 /

/2 LOW 820 790 760 725 690 650 610

*M-LO 930 890 850 815 785 750 720

M-HI 1150 1120 1090 1045 1002 950 900 HIGH 1414 1365 1320 1270 1220 1165 1115

RGRA-06 11 x 7 /

/2 LOW 770 740 710 675 645 605 570

*M-LO 880 845 815 790 760 715 670

M-HI 1060 1025 990 960 925 880 835 HIGH 1260 1215 1175 1135 1100 1040 985

RGTA-06 11 x 7 /

/2 LOW 795 760 730 695 660 615 570

*M-LO 910 885 860 815 770 725 680

M-HI 1115 1080 1045 1005 965 920 875 HIGH 1365 1315 1270 1225 1180 1125 1070

RGRA-07 11 X 7 /

/2 LOW 780 745 710 675 640 595 555

M-LO 880 850 825 785 750 702 655

*M-HI 1090 1050 1010 970 925 875 825

HIGH 1300 1255 1210 1160 1110 1055 1005

RGTA-07 11 X 7 /

/2 LOW 780 750 720 675 635 595 555

M-LO 890 860 835 790 750 705 660

*M-HI 1100 1060 1025 980 940 890 845

HIGH 1340 1295 1250 1200 1150 1090 1025

RGRA-07 12 X 7

/2 / 3/4 LOW 1105 1095 1080 1050 1030 1010 990

M-LO 1290 1275 1260 1220 1195 1170 1140 M-HI 1480 1435 1415 1390 1370 1300 1255 HIGH 1705 1665 1615 1570 1540 1475 1400

RGTA-07 12 X 7

/2 / 3/4 LOW 1185 1160 1140 1115 1095 1065 1040

M-LO 1405 1375 1350 1310 1270 1235 1195 M-HI 1595 1560 1525 1480 1440 1380 1325 HIGH 1835 1780 1730 1675 1625 1555 1480

RGRA-09 12 X 11 /

/4 LOW 1235 1210 1185 1150 1120 1075 1035

*M-LO 1490 1465 1440 1405 1375 1315 1255

M-HI 1720 1670 1620 1600 1580 1520 1460 HIGH 2100 2050 2000 1955 1910 1825 1745

RGTA-09 12 X 11 /

/4 LOW 1155 1125 1100 1080 1060 1000 940

*M-LO 1420 1400 1380 1365 1350 1260 1175

M-HI 1605 1575 1550 1560 1570 1480 1390 HIGH 2005 1965 1930 1890 1850 1765 1680

RGRA-10 12 X 11 /

/4 LOW 1230 1205 1180 1155 1130 1090 1050

*M-LO 1490 1445 1405 1375 1350 1295 1240

M-HI 1710 1665 1620 1580 1540 1475 1410 HIGH 2010 1955 1900 1855 1810 1710 1610

RGTA-10 12 X 11 /

/4 LOW 1180 1150 1120 1100 1080 1025 970

*M-LO 1460 1425 1390 1375 1360 1280 1200

M-HI 1680 1645 1615 1585 1560 1490 1420 HIGH 2055 2000 1940 1880 1820 1745 1675

RGRA-12 11 X 10 /

/4 LOW 1320 1305 1290 1260 1230 1185 1140

*M-LO 1610 1580 1555 1515 1475 1415 1355

M-HI 1870 1820 1775 1715 1660 1590 1520 HIGH 2115 2050 1990 1945 1900 1795 1690

RGTA-12 11 X 10 /

/4 LOW 1285 1250 1215 1235 1260 1230 1200

*M-LO 1590 1565 1540 1505 1475 1425 1375

M-HI 1840 1820 1800 1750 1700 1645 1590 HIGH 2315 2250 2185 2110 2040 1965 1890

* Heating speed for cooling applications NOTE: Units tested with filters in place.

Page 48

TABLE 8

90 PLUS AIR FLOW PERFORMANCE – RGRJ & RGTJ MODELS

CFM @ ESP

MODEL BLOWER/

SPEED

MOTOR HP .1 .2 .3 .4 .5 .6 .7

RGRJ-04 11 x 7 /

/2 LOW 805 780 760 720 685 645 605

MED-LO 920 885 850 810 775 730 690 MED-HI 1140 1110 1085 1045 1010 950 890

HIGH 1360 1320 1280 1235 1195 1140 1080

RGTJ-04 11 x 7 /

/2 LOW 820 790 760 725 690 650 610

MED-LO 930 890 850 815 785 750 720 MED-HI 1150 1120 1090 1045 1002 950 900

HIGH 1414 1365 1320 1270 1220 1165 1115

RGRJ-06 11 x 7 /

/2 LOW 880 845 815 790 760 715 670

MED 1060 1025 990 960 925 880 835

HIGH 1260 1215 1175 1135 1100 1040 985

RGTJ-06 11 x 7 /

/2 LOW 910 885 860 815 770 725 680

MED 1115 1080 1045 1005 965 920 875

HIGH 1365 1315 1270 1225 1180 1125 1070

RGRJ-07 11 X 7 /

/2 LOW 880 850 825 785 750 702 655

MED 1090 1050 1010 970 925 875 825

HIGH 1300 1255 1210 1160 1110 1055 1005

RGTJ-07 11 X 7 /

/2 LOW 890 860 835 790 750 705 660

MED 1100 1060 1025 980 940 890 845

HIGH 1340 1295 1250 1200 1150 1090 1025

RGRJ-07 12 X 7 /

/2 LOW 1185 1160 1140 1115 1095 1065 1040

MED 1405 1375 1350 1310 1270 1235 1195

HIGH 1595 1560 1525 1480 1440 1380 1325

RGTJ-07 12 X 7 /

/2 LOW 1105 1095 1080 1050 1030 1010 990

MED 1290 1275 1260 1220 1195 1170 1140

HIGH 1480 1435 1415 1390 1370 1300 1255

RGRJ-07 12 X 7 /

/4 LOW 1405 1375 1350 1310 1270 1235 1195

MED 1595 1560 1525 1480 1440 1380 1325

HIGH 1835 1780 1730 1675 1625 1555 1480

RGTJ-07 12 X 7 /

/4 LOW 1290 1275 1260 1220 1195 1170 1140

MED 1480 1435 1415 1390 1370 1300 1255

HIGH 1705 1665 1615 1570 1540 1475 1400

RGRJ-09 12 X 11 /

/2 LOW 1235 1210 1180 1150 1120 1075 1035

MED 1490 1465 1445 1405 1375 1315 1255

HIGH 1720 1670 1620 1600 1580 1520 1460

RGTJ-09 12 X 11 /

/2 LOW 1155 1125 1100 1080 1060 1000 940

MED 1420 1400 1380 1365 1350 1260 1175

HIGH 1605 1575 1550 1560 1570 1480 1395

RGRJ-09 12 X 11 /

/4 LOW 1490 1465 1445 1405 1375 1315 1255

MED 1720 1670 1620 1600 1580 1520 1460

HIGH 2100 2050 2000 1955 1910 1825 1745

RGTJ-09 12 X 11 /

/24 LOW 1420 1400 1380 1365 1350 1260 1175

MED 1605 1575 1550 1560 1570 1480 1395

HIGH 2005 1965 1930 1890 1850 1765 1680

RGRJ-10 12 X 11 /

/2 LOW 1230 1205 1180 1155 1130 1090 1050

MED 1490 1445 1405 1375 1350 1295 1240

HIGH 1710 1665 1620 1580 1540 1475 1410

RGTJ-10 12 X 11 /

/2 LOW 1180 1150 1120 1100 1080 1025 970

MED 1460 1425 1390 1375 1360 1280 1200

HIGH 1680 1645 1615 1585 1560 1490 1420

RGRJ-10 12 X 11 /

/4 LOW 1490 1445 1405 1375 1350 1295 1240

MED 1710 1665 1620 1580 1540 1475 1410

HIGH 2010 1955 1900 1855 1810 1710 1610

RGTJ-10 12 X 11 /

/4 LOW 1460 1425 1390 1375 1360 1280 1200

MED 1680 1645 1615 1585 1560 1490 1420

HIGH 2055 2000 1940 1880 1820 1745 1675

RGRJ-12 11 X 10 /

/2 LOW 1320 1305 1290 1260 1230 1185 1140

MED 1610 1580 1555 1515 1475 1415 1355

HIGH 1870 1820 1775 1715 1 1590 1520

RGTJ-12 11 X 10 /

/2 LOW 1285 1250 1215 1235 1260 1230 1200

MED 1590 1565 1540 1505 1 1425 1375

HIGH 1840 1820 1800 1750 1700 1645 1590

RGRJ-12 11 X 10 /

/4 LOW 1610 1580 1555 1515 1475 1415 1355

MED 1870 1820 1775 1715 1660 1590 1520

HIGH 2115 2050 1990 1945 1900 1795 1690

RGTJ-12 11 X 10 /

/4 LOW 1590 1565 1540 1505 1475 1425 1375

MED 1840 1820 1800 1750 1700 1645 1590

HIGH 2315 2250 2185 2110 2040 1965 1890

* Heating speed for cooling applications NOTE: Units tested with filters in place.

Page 49

SETTING BLOWER TIMINGS

The Honeywell and UTEC control boards have four quick connect terminals for connecting the motor speed leads. These are:

1. FAN SPEED — motor runs on this speed when the thermostat is in the “FAN ON” position.

2. COOL — connect desired cooling speed.

3. HEAT — connect desired heating speed.

4. HEAT/COOL (not available on UTEC-925 control board) — connect desired speed when heating and cooling speed are the same.

IMPORTANT:

Do not connect any motor speeds to “HEAT” and “COOL” if you use the “HEAT/COOL” terminal.

5. If heating and continuous fan speed are the same, “piggyback” jumper across “FAN” and “HEAT” terminals.

See Figures 53, 54, 55 and 56 for instructions for setting the blower “OFF” timings.

If cooling speed and fan speed are desired to be the same, this may be accomplished by not connecting “Y” to the integrated furnace control.

If desired for cool, fan and heat to all be the same speed, then “piggyback” jumper “H/C” to “FAN” and do not connect “Y” to the integrated furnace control. Do not connect anything to “H” or “C.”

GAS FURNACE (DIRECT DRIVE) INSTRUCTIONS FOR CHANGING BLOWER SPEED

DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

The blower motor is wired for blower speeds required for normal operation as shown.

If additional blower speed taps are available (leads connected to “M1” and “M2” on the electronic control), speeds may be changed if necessary to fit requirements of the particular installation. Reconnect the unused motor leads to “M1” or “M2.” Check motor lead color for speed designation.

Heating speeds should not be reduced where it could cause the furnace air temperature to rise to exceed the maximum outlet air temperature specified for the unit.

IMPORTANT:

Always check air temperature rise after changing the heating speed for any reason.

FIGURE 54 JOHNSON CONTROLS G961DAJ-2401 BLOWER OFF TIMINGS

FIGURE 55 HONEYWELL E2001 BLOWER OFF TIMINGS

OFF TIME SWITCH 3 SWITCH 4

90 SEC. ON ON

120 SEC. OFF ON

160 SEC. ON OFF

180 SEC. OFF OFF

OFF TIME SWITCH 1 SWITCH 2

90 SEC. ON OFF

120 SEC. OFF OFF

160 SEC. OFF ON

180 SEC. ON ON

WARNING

TWINNED

MASTER

SINGLE

1ST

NOTE: SWITCHES 1 & 2 ARE USED FOR TWINNING APPLICATIONS.

(TIMER IS RED BLOCK ON BOARD)

I402

FIGURE 53 UTEC -920 & -927 BLOWER OFF TIMINGS

OFF TIME SWITCH 1 SWITCH 2

90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON

TWIN

2nd

SINGLE

1ST

NOTE: SWITCHES 3 & 4 ARE USED FOR TWINNING APPLICATIONS.

I402

I335

I402

FIGURE 56 UTEC - 925 BLOWER OFF TIMINGS

OFF TIME SWITCH 1 SWITCH 2

90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON

(TIMER IS RED BLOCK ON BOARD)

I335

Page 50

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

FILTERS

NOTE: RGRJ and RGTJ models do not come from the factory with filters installed. Filters must be field installed.

Keep the filters clean at all times. Vacuum dirt from filter, wash with detergent and water, air dry thoroughly and reinstall.

NOTE: Some filters must be resized to fit certain units and applications. See Table 9 and Figures 57, 58, 59, 60 and 61.

1. 21( - 90,000 & 105,000 BTUH units require removal of a 3

/2-in. segment of filter and frame to get the proper width for a side filter.

2. 24

/2( - 120,000 BTUH unit requires removal of a 7" segment of filter and frame to get the proper width for a side filter.

WARNING

TABLE 9 FILTER SIZES

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE

QUANTITY

WIDTH MBTUH SIZE SIZE

/2" 45, 60, 75 153/4" X 25" 153/4" X 25" 1

21" 90 AND 105 19

/4" X 25" 153/4" X 25" 1

/2" 120 223/4" X 25" 153/4" X 25" 1

DOWNFLOW FILTER SIZES

FURNACE INPUT

SIZE QUANTITY

WIDTH MBTUH

/2" 45, 60, 75 12" X 20" 2

21" 90, 105 12" X 20" 2

/2" 120 14" X 20" 2

FIGURE 57 RESIZING FILTERS AND FRAME

MAINTENANCE

FIGURE 58 BOTTOM PANEL REMOVAL

JACKET ASSEMBLY

SOLID BOTTOM

NOTE: BACK FLANGE OF SOLID BOTTOM FITS UNDERNEATH JACKET. SIDES AND FRONT FLANGES FIT OVER FLANGES ON JACKET.

SCREW (2) REQ’D.

JACKET ASSEMBLY

FILTER

FILTER ROD

SOLID BOTTOM REMOVAL

FILTER & ROD LOCATION

REMOVE SEGMENT TO SIZE AS REQUIRED

Page 51

FIGURE 59 FILTER LOCATIONS

FIGURE 60 DOWNFLOW

FIGURE 61

HORIZONTAL

JACKET

DRILL (2) 3/16" DIA. HOLES

8.000

4.875

1.531

CUT-OUT USING

EMBOSSED ANGLES

AS A GUIDE FOR

PROPER SIZE

JACKET

ANGLE

FILTER ROD SUPPORT ANGLE

FILTER SUPPORT ANGLE (SEE ANGLE DETAIL)

ATTACH WITH SHEET METAL SCREWS (2 REQ’D)

ANGLE DETAIL

CUT-OUT AND DRILL DETAIL

ROD & FILTER SUPPORT ANGLE ASSEMBLY

FILTER AND ROD ASSEMBLY

FILTER ROD SUPPORT ANGLE

FILTER SUPPORT ANGLE

FILTER

FILTER ROD

JACKET

I332

I413

UPFLOW

I528

Page 52

HOLES IN THE VENT PIPE OR HEAT EXCHANGER CAN CAUSE TOXIC FUMES TO ENTER THE HOME, RESULTING IN CARBON MONOXIDE POISONING OR DEATH. THE VENT PIPE OR HEAT EXCHANGER MUST BE REPLACED IF THEY LEAK.

• IMPORTANT: It is recommended that at the beginning of the heating season, the flame sensor be cleaned with steel wool by a qualified installer, service agency or the gas supplier.

• IMPORTANT: It is recommended that at the beginning of the heating season, the condensate trap be inspected for debris or blockage. A blocked condensate trap can cause water to back up into the primary heat exchanger and lead to nuisance tripping of the overtemperature switches.

• IMPORTANT: It is recommended that at the beginning of the heating season, the condensate neutralizer if used be replaced by a qualified installer, service agency or the gas supplier.

• IMPORTANT: It is recommended that an annual inspection and cleaning of all furnace markings be made to assure legibility. Attach a replacement marking, which can be obtained through the distributor, if any are found to be illegible or missing.

REPLACEMENT PARTS

Contact your local distributor for a complete parts list. See enclosed sheet.

TROUBLESHOOTING

Refer to Figures 62, 63 and 64 for determining cause of unit problems.

WIRING DIAGRAM

Figures 65, 66 and 67 are complete wiring diagrams for the furnace and power sources.

Do not operate the system for extended periods without filters. A portion of the dust entrained in the air may temporarily lodge in the air duct runs and at the supply registers. Any recirculated dust particles will be heated and charred by contact with the furnace heat exchanger. This residue will soil ceilings, walls, drapes, carpets and other household articles.

LUBRICATION

IMPORTANT: DO NOT attempt to lubricate the bearings on the blower motor or the induced draft blower motor. Addition of lubricants can reduce the motor life and void the warranty.

The blower motor and induced draft blower motor are permanently lubricated by the manufacturer and do not require further attention.

The blower motor and induced draft blower motor must be cleaned periodically by a qualified installer, service agency, or the gas supplier to prevent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor exterior. And, as suggested elsewhere in these instructions, the air filters should be kept clean. Dirty filters can restrict airflow. The motor depends upon sufficient air flowing across and through it to keep from overheating.

SYSTEM OPERATION INFORMATION

Advise The Customer

1. Keep the air filters clean. The heating system will operate better, more efficiently and more economically.

2. Arrange the furniture and drapes so that the supply air registers and the return air grilles are unobstructed.

3. Close doors and windows. This will reduce the heating load on the system.

4. Avoid excessive use of kitchen exhaust fans.

5. Do not permit the heat generated by television, lamps or radios to influence the thermostat operation.

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

7. IMPORTANT:

Replace all blower doors and compartment covers after servicing the furnace. Do not operate the unit without all panels and doors securely in place.

8. Explain proper operation of the system with constant air circulation.

ANNUAL INSPECTION

• The furnace should operate for many years without excessive scale build-up in the flue passageways. However, it is recommended that a qualified installer, service agency, or the gas supplier annually inspect the flue passageways, the vent system and the main burners for continued safe operation. Pay particular attention to deterioration from corrosion or other sources.

• IMPORTANT: It is recommended that at the beginning and at approximately half way through the heating season, a visual inspection be made of the main burner flames for the desired flame appearance by a qualified installer, service agency or the gas supplier. If the flames are distorted and/or there is evidence of back pressure, check the vent and inlet air system for blockage. If there is carbon and scale in the heat exchanger tubes, the heat exchanger assembly should be replaced.

CAUTION

WARNING

Page 53

FIGURE 62 MODELS WITH HONEYWELL S9201E2001 OR UTEC 1012-920 CONTROL BOARD INTEGRATED FURNACE CONTROL (IFC) TROUBLESHOOTING GUIDE (115 VAC IGNITER)

START

1. SET FAN SWITCH TO AUTO

2. SET THERMOSTAT TO CALL FOR HEAT

INDUCED DRAFT MOTOR

(IDM) STARTS

30 SEC. PREPURGE

IGNITER WARMS UP

AND GLOWS RED

30 SECONDS WARMUP

MAIN BURNER

LIGHTS

WARNING

DISCONNECT POWER BEFORE SERVICING. SERVICE MUST BE BY A TRAINED, QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGE LINE VOLTAGE CONNECTIONS CAN CAUSE PERSONAL INJURY OR DEATH

• REMOVE (IFC) COVER, CHECK LIGHTS POWER LED ON • CHECK LINE VOLTAGE POWER

• CHECK LOW VOLTAGE TRANSFORMER

REPLACE (IFC)

CHECK FOR 24 VAC FROM CHECK THERMOSTAT TERMINAL “W” TO “C” ON IFC WIRING

• CHECK LIMITS, (CLOSED)

• CHECK WIRING

• CHECK PRESSURE SWITCH, (OPEN) REPLACE SWITCH

IF THE PRESSURE SWITCH DOESN’T CLOSE WITHIN 60 SEC. THE IDM WILL STOP FOR 5 MIN. AND RETRY

• CHECK FOR 115VAC TO IDM MOTOR REPLACE (IFC) IF WIRING TO

IDM MOTOR IS OK

REPLACE IDM MOTOR

• CHECK FOR BLOCKED VENT REPLACE SWITCH

• CHECK AIR PROVING SWITCH (CLOSED)

• CHECK WIRING TO IGNITER REPLACE (IFC)

• CHECK FOR 115 VAC AT IGNITER, IF WIRING TO

TERMINALS AND AT (IFC) TERMINALS IGNITER IS OK

REPLACE IGNITER

SYSTEM WILL ATTEMPT TO LIGHT 4 TIMES. VOLTAGE IS PRESENT AT THE VALVE FOR ONLY 9 SECONDS DURING EACH TRIAL FOR IGNITION (SYSTEM WILL GO INTO A 1-HOUR LOCKOUT AFTER 4 TRIES). ➤THE SEQUENCE WILL REPEAT AFTER A ONE HOUR DELAY. IT WILL CONTINUE UNTIL IGNITION IS SUCCESSFUL OR THE CALL FOR HEAT IS TERMINATED. THE BLOWER AND INDUCED DRAFT BLOWER WILL RUN 180 SEC. IF THE FIRST AND SECOND IGNITION TRIALS FAIL TO SENSE FLAME

• CHECK FOR 24 VAC ACROSS THE VALVE AND

VALVE TERMINALS ON THE (IFC)

• CHECK IGNITER POSITION

• CHECK FOR GAS FLOW TO AND

FROM VALVE

REPLACE VALVE REPLACE (IFC)

IF WIRING TO

VALVE IS OK

FLOW CHART CONTINUED ON NEXT PAGE

YES

MICROPROCESSOR STATUS LED ON NOTE: “OK LED WILL FLASH TO INDICATE TWINNING CIRCUIT FAULTS.

Page 54

NOTE: STATIC DISCHARGE CAN DAMAGE INTEGRATED FURNACE CONTROL (IFC)

92-22744-08-08

MAIN BURNER

REMAINS POWERED

AND LIT

INDOOR BLOWER MOTOR

STARTS 20 SECONDS

AFTER GAS VALVE OPENS

SYSTEM RUNS

UNTIL CALL FOR

HEAT ENDS

TURN THERMOSTAT TO OFF

VALVE SHUTS OFF

FLAME OFF

IDM MOTOR STOPS AFTER 5 SEC.

INDOOR BLOWER MOTOR

STOPS AFTER

90/120/160/180 SECONDS

TROUBLESHOOTING ENDS

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN

RESET SYSTEM

• CHECK POLARITY OF 115VAC SUPPLY

• CHECK CONTINUITY OF GROUND WIRE

• CHECK INSULATION OF IGNITER LEADS

• CHECK FLAME SENSE CURRENT (YELLOW LED)

LED IS ON IF FLAME CURRENT IS GOOD. IT FLASHES IF CURRENT IS MARGINAL.

• TURN POWER OFF TO UNIT

• CLEAN FLAME SENSOR WITH STEEL WOOL IF LED FLASHES

• RESTORE POWER TO UNIT

• IF CHECKS ARE OK, REPLACE (IFC)

• CHECK FOR 115VAC ACROSS REPLACE (IFC) IF

BLOWER MOTOR AND BLOWER WIRING TO BLOWER MOTOR TERMINALS (HEAT AND MOTOR IS OK NEUTRAL) ON (IFC)

REPLACE BLOWER MOTOR

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN

RESET SYSTEM

• CHECK CONTINUITY OF GROUND WIRE. NOTE: IF GROUND IS

POOR OR ERRATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.

• CHECK FLAME SENSE CURRENT

• CHECK FOR EXCESSIVE HEAT AT IGNITER BASE (TEMP. ABOVE 1000 F (538 C) CAUSES SHORT TO GROUND)

• TURN POWER OFF TO UNIT

• CLEAN FLAME SENSOR WITH STEEL WOOL

• RESTORE POWER TO UNIT

• IF CHECKS ARE OK, REPLACE (IFC)

• CHECK FOR PROPER THEMOSTAT OPERATION

• REMOVE VALVE LEAD AT (IFC) IF VALVE CLOSED, RECHECK THERMOSTAT AND WIRING. IF NOT, REPLACE VALVE.

• CHECK FOR OPEN LIMIT.

• REPLACE (IFC)

• CHECK FOR OPEN LIMIT. REPLACE (IFC)

REPEAT PROCEDURE UNTIL TROUBLEFREE

OPERATION IS OBTAINED.

YES

Page 55

➤ FIGURE 63

INTEGRATED FURNACE CONTROL (IFC) UTEC 1028-927 OR

JOHNSON CONTROLS G961DAJ-2401 (SPARK IGNITION)

• CHECK FOR BLOCKED VENT

• CHECK AIR PROVING SWITCH (CLOSED)

• CHECK WIRING TO IGNITER

• CHECK FOR SPARK AT IGNITER,

ELECTRODE

1. SET FAN SWITCH TO AUTO

2. SET THERMOSTAT TO CALL

FOR HEAT

START

YES

INDUCED DRAFT BLOWER

MOTOR STARTS

YES

SPARK IGNITER ENERGIZES

YES

30 SEC. PREPURGE

REPLACE (IFC)

REPLACE SWITCH

REPLACE (IFC)

IF WIRING TO

DRAFT MOTOR IS OK

REPLACE SWITCH

REPLACE (IFC)

IF WIRING TO

IGNITER IS OK

CHECK THERMOSTAT

WIRING

• CHECK LINE VOLTAGE POWER

• CHECK LOW VOLTAGE TRANSFORMER

• CHECK “IN-LINE” FUSE ON TRANSFORMER

LOW VOLTAGE LINE

INTEGRATED FURNACE CONTROL (IFC)

TROUBLESHOOTING GUIDE

(SPARK IGNITION SYSTEM)

POWER LED ON

IF THE PRESSURE SWITCH DOESN’T

CLOSE WITHIN 60 SEC. THE IOM WILL

STOP FOR 5 MIN. AND RETRY

• REMOVE (IFC) COVER, CHECK LIGHTS

MICROPROCESSOR STATUS LED ON

NOTE: “OK” LED WILL FLASH TO INDICATE

TWINNING CIRCUIT FAULTS

• CHECK FOR 115VAC TO DRAFT MOTOR

REPLACE DRAFT MOTOR

CHECK FOR 24 VAC FROM

“W” TO “C” ON IFC

• CHECK LIMITS, (CLOSED)

• CHECK WIRING

• CHECK PRESSURE SWITCH, (OPEN)

YES

REPLACE IGNITER

NOTE: STATIC DISCHARGE CAN DAMAGE INTEGRATED FURNACE CONTROL (IFC)

W ARNING

DISCONNECT POWER BEFORE SERVICING. SERVICE MUST BE BY A TRAINED, QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGE LINE VOLTAGE CONNECTIONS CAN CAUSE PERSONAL INJURY OR DEATH

Page 56

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN RESET SYSTEM

• CHECK CONTINUITY OF GROUND WIRE. NOTE: IF GROUND IS POOR OR ERATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.

• CHECK FLAME SENSE CURRENT

• CHECK FOR EXCESSIVE HEAT AT IGNITER BASE.

• TURN POWER OFF TO UNIT.

• CLEAN FLAME SENSOR WITH STEEL WOOL.

• RESTORE POWER TO UNIT.

• IF CHECKS ARE OK, REPLACE (IFC)

YES

MAIN BURNER

LIGHTS

YES

MAIN BURNER REMAINS

POWERED AND LIT

YES

SYSTEM RUNS UNTIL

CALL FOR HEAT ENDS

INDOOR BLOWER MOTOR

STARTS 20 SECONDS

AFTER BURNER LIGHTS

YES

REPLACE BLOWER MOTOR

REPLACE VALVE IF NO FLOW THRU VALVE

REPLACE (IFC) IF WIRING TO VALVE IS OK

REPLACE (IFC) IF WIRING TO BLOWER MOTOR IS OK

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN RESET SYSTEM

• CHECK POLARITY OF 115VAC SUPPLY

• CHECK CONTINUITY OF GROUND WIRE

• CHECK INSULATION ON IGNITER

• CHECK FLAME SENSE CURRENT (YELLOW LED) LED IS ON IF FLAME CURRENT IS GOOD. IT FLASHES IF CURRENT IS MARGINAL.

• TURN POWER OFF TO UNIT.

• CLEAN FLAME SENSOR WITH STEEL WOOL IF LED FLASHES

• RESTORE POWER TO UNIT

• IF CHECKS ARE OK, REPLACE (IFC)

SYSTEM WILL ATTEMPT TO LIGHT 4 TIMES. VOLTAGE IS PRESENT AT THE VALVE FOR ONLY 8 SECONDS DURING EACH TRIAL FOR IGNITION (SYSTEM WILL GO INTO A 1-HOUR LOCKOUT AFTER 4 TRIES), THE BLOWER AND INDUCED DRAFT BLOWER WILL RUN 180 SEC. IF THE FIRST AND SECOND IGNITION TRIAL FAIL TO SENSE FLAME.

• CHECK FOR 24VAC ACROSS THE VALVE AND VALVE TERMINALS ON THE (IFC)

• CHECK IGNITER POSITION,

• CHECK FOR GAS FLOW TO AND FROM VALVE.

• CHECK FOR 115VAC ACROSS BLOWER MOTOR AND BLOWER MOTOR TERMINALS (HEAT AND NEUTRAL) ON (IFC)

TURN THERMOSTAT TO OFF

VALVE SHUTS OFF

FLAME OFF

• CHECK FOR PROPER THERMOSTAT OPERATION.

• REMOVE VALVE LEAD AT (IFC) IF VALVE CLOSED, RECHECK THERMOSTAT AND WIRING IF NOT, REPLACE VALVE

YES

DRAFT MOTOR STOPS AFTER

5 SEC.

TROUBLESHOOTING ENDS

• CHECK FOR OPEN LIMIT, REPLACE (IFC)

YES

INDOOR BLOWER MOTOR

STOPS AFTER

90/120/160/180 SECONDS

• CHECK FOR OPEN LIMIT, REPLACE (IFC)

REPEAT PROCEDURE UNTIL TROUBLEFREE

OPERATION IS OBTAINED.

92-22744-12-01

Page 57

FIGURE 64 INTEGRATED FURNACE CONTROL (IFC) UTEC 1012-925 (115 VAC IGNITER)

1. SET FAN SWITCH TO AUTO

2. SET THERMOSTAT TO CALL FOR HEAT

START

WARNING

DISCONNECT POWER BEFORE SERVICING. SERVICE MUST BE BY A TRAINED, QUALIFIED SERVICE TECHNICIAN.

HAZARDOUS VOLTAGE LINE VOLTAGE CONNECTIONS CAN CAUSE PERSONAL INJURY OR DEATH

YES

INDUCED DRAFT BLOWER

MOTOR STARTS

YES

PURGE CONTINUES

IGNITER WARMS UP

AND GLOWS RED

30 SECONDS WARMUP

YES

5 SEC. PREPURGE

REPLACE (IFC)

REPLACE SWITCH

REPLACE (IFC)

IF WIRING TO

DRAFT MOTOR IS OK

REPLACE SWITCH

REPLACE (IFC) IF WIRING TO IGNITER IS OK

CHECK THERMOSTAT WIRING

• CHECK LINE VOLTAGE POWER

• CHECK LOW VOLTAGE TRANSFORMER

NOTE: STATIC DISCHARGE CAN DAMAGE INTEGRATED FURNACE CONTROL (IFC)

• “OK” LED BLINKS TO INDICATE EXTERNAL FAULTS: (1) BLINK FOLLOWED BY A 2 SEC. PAUSE - 1 HOUR LOCKOUT (2) BLINKS FOLLOWED BY A 2 SEC. PAUSE - PRESSURE SWITCH IS OPEN (3) BLINKS FOLLOWED BY A 2 SEC. PAUSE - LIMIT SWITCH IS OPEN (4) BLINKS FOLLOWED BY A 2 SEC. PAUSE - PRESSURE SWITCH SHORTED

INTEGRATED FURNACE CONTROL (IFC)

TROUBLESHOOTING GUIDE

(115 VAC IGNITER)

CHECK FOR 24 VAC POWER FROM “R” TO “C” ON IFC

IF THE PRESSURE SWITCH DOESN’T CLOSE WITHIN 60 SEC. THE IOM WILL STOP FOR 5 MIN. AND RETRY

• REMOVE (IFC) COVER, CHECK LIGHTS

MICROPROCESSOR STATUS “OK” LED ON

• CHECK FOR 115VAC TO DRAFT MOTOR

REPLACE DRAFT MOTOR

CHECK FOR 24 VAC FROM “W” TO “C” ON IFC

• CHECK LIMITS, (CLOSED)

• CHECK WIRING

• CHECK PRESSURE SWITCH, (OPEN)

YES

REPLACE IGNITER

• CHECK FOR BLOCKED VENT

• CHECK AIR PROVING SWITCH (CLOSED)

• CHECK WIRING TO IGNITER

• CHECK FOR 115VAC AT IGNITER, TERMINALS AND AT (IFC) TERMINALS

Page 58

YES

MAIN BURNER

REMAINS POWERED

AND LIT

YES

MAIN BURNER

REMAINS POWERED

AND LIT

INDOOR BLOWER MOTOR

STARTS 20 SECONDS

AFTER GAS VALVE OPENS

YES

REPLACE BLOWER MOTOR

REPLACE VALVE IF NO FLOW THRU VALVE

REPLACE (IFC) IF WIRING TO VALVE IS OK

REPLACE (IFC) IF WIRING TO BLOWER MOTOR IS OK

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN RESET SYSTEM

• CHECK POLARITY OF 115VAC SUPPLY

• CHECK CONTINUITY OF GROUND WIRE

• CHECK INSULATION ON IGNITER LEADS

• CHECK FLAME SENSE CURRENT (YELLOW LED) LED IS ON IF FLAME CURRENT IS GOOD. IT FLASHES IF CURRENT IS MARGINAL.

• TURN POWER OFF TO UNIT.

• CLEAN FLAME SENSOR WITH STEEL WOOL IF LED FLASHES

• RESTORE POWER TO UNIT

• IF CHECKS ARE OK, REPLACE (IFC)

NOTE: IF (IFC) GOES INTO LOCKOUT WAIT 30 SECONDS THEN RESET SYSTEM

• CHECK CONTINUITY OF GROUND WIRE, NOTE: IF GROUND IS

POOR OR ERATIC, SHUTDOWN MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT.

• CHECK FLAME SENSE CURRENT

• CHECK FOR EXCESSIVE HEAT AT IGNITER BASE, (TEMP. ABOVE 1000 F (538 C) CAUSES SHORT TO GROUND)

• TURN POWER OFF TO UNIT.

• CLEAN FLAME SENSOR WITH STEEL WOOL.

• RESTORES POWER TO UNIT.

• IF CHECKS ARE OK, REPLACE (IFC)

• CHECK FOR 24VAC ACROSS THE VALVE AND VALVE TERMINALS ON THE (IFC)

• CHECK IGNITER POSITION,

• CHECK FOR GAS FLOW TO AND FROM VALVE.

• CHECK FOR 115VAC ACROSS BLOWER MOTOR AND BLOWER MOTOR TERMINALS (HEAT AND NEUTRAL) ON (IFC)

TURN THERMOSTAT TO OFF

VALVE SHUTS OFF

FLAME GOES OUT

• CHECK FOR PROPER THERMOSTAT OPERATION.

• REMOVE VALVE LEAD AT (IFC) IF VALVE CLOSED, RECHECK THERMOSTAT AND WIRING IF NOT, REPLACE VALVE

YES

DRAFT MOTOR STOPS

AFTER 5 SEC.

TROUBLESHOOTING ENDS

• CHECK FOR OPEN LIMIT, REPLACE (IFC)

YES

INDOOR BLOWER MOTOR

STOP AFTER

90/120/160/180 SECONDS

• CHECK FOR OPEN LIMIT, REPLACE (IFC)

REPEAT PROCEDURE UNTIL TROUBLEFREE

OPERATION IS OBTAINED.

92-22744-10-01

Page 59

FIGURE 65 RGRA AND RGTA MODELS WITH HONEYWELL S9201E2001 OR UTEC 1012-920 CONTROL BOARD & HSI 34" 90 PLUS CONDENSING GAS FURNACE WIRING DIAGRAM

Page 60

➤ FIGURE 66 RGRA AND RGTA MODELS WITH UTEC 1028-927 OR JOHNSON CONTROLS G961DAJ-2401 CONTROL BOARD & SPARK IGNITION 34" 90 PLUS CONDENSING GAS FURNACE WIRING DIAGRAM

Page 61

FIGURE 67 RGRJ AND RGTJ MODELS WITH UTEC1012-925 CONTROL BOARD & HSI 34" 90 PLUS CONDENSING GAS FURNACE WIRING DIAGRAM

Page 62

Page 63

Page 64

Rheem Manufacturing Company Air Conditioning Division Fort Smith, Arkansas

CM 1197

Rheem RGRJ series, RGRA series, RGTJ series, RGTA series Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual