Rheem RGRK SERIES, RGRL SERIES, RGTK SERIES Installation Instructions Manual

Page 1

INSTALLATION INSTRUCTIONS

ISO 9001:2008

FOR UPFLOW AND DOWNFLOW/HORIZONTAL HIGH EFFICIENCY CONDENSING TWO-STAGE GAS FURNACES

RGRK, RGRL, AND RGTK SERIES

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

92-24161-36-22

SUPERSEDES 92-24161-36-21

Page 2

INSTALLATION CHECK LIST

REFER TO INSTALLATION INSTRUCTIONS

TERMINATIONS – DIRECT VENT

AS SUPPLY

______ Adequate pipe size

_____ Correct supply pressure (during furnace operation)

______ Manifold pressure

______ No gas leaks

_____ L.P. Kit Number (if applicable)

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)

VERTICAL

______ Intake – 12" min. above roof/snow level

______ Correct relationship – exhaust to intake

HORIZONTAL/VERTICAL – CONCENTRIC ((-)XGY-E03A)

______ Intake – 12" min. above roof/snow level

______ Intake “Y” rotated above center

______ Exhaust sloped toward furnace

HORIZONTAL – STANDARD ((-)XGY-D02, -D03) – US

((-)XGY-D02A, (-)XGY-D03A) – CANADA

______ Correct relationship – exhaust to intake

______ 12" min. above grade/snow level

HORIZONTAL – ALTERNATE

((-)XGY-D02, -D03 OR -D04) – US ((-)XGY-D02A, -D03A, -D04A) – CANADA

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

______ Correct relationship – exhaust to intake

______ Above anticipated snow level

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

______ no. of elbows – intake air

______ ft. of pipe – exhaust pipe

______ no. of elbows – exhaust pipe

______ Exhaust Vent Temperature

_____________________________ Model Number

_____________________________ Serial Number

_____________________________ Date of Installation

Page 3

IMPORTANT: All manufacturer products meet current Federal OSHA Guidelines for safety. California Proposition 65 warnings are required for certain products, which are not covered by the OSHA standards.

California's Proposition 65 requires

arnings for products sold in California

w that contain, or produce, any of over 600 listed chemicals known to the State

f California to cause cancer or birth

o defects such as fiberglass insulation, lead in brass, and combustion products

rom natural gas.

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

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

• Glass Wool (Fiberglass) Insulation

• Carbon Monoxide (CO)

• Formaldehyde

• Benzene

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

and the State of

CONTENTS

afety Precautions ...................................................................................................1

nstallation Check List ..............................................................................................2

eneral Information..................................................................................................4

afety Information ....................................................................................................6

ocation Requirements and Considerations ............................................................8

ucting ...................................................................................................................13

enting and Combustion Air Piping .......................................................................15

ombustion and Ventilation Air ..............................................................................17

ent Pipe Installation..............................................................................................20

Condensate Drain/Neutralizer................................................................................33

Gas Supply and Piping...........................................................................................37

Electrical Wiring......................................................................................................42

Accessories............................................................................................................43

Furnace Twinning...................................................................................................44

High Altitude Installations.......................................................................................48

Start-Up Procedures...............................................................................................51

Air Flow...................................................................................................................54

Maintenance...........................................................................................................57

Troubleshooting......................................................................................................59

Wiring Diagram.......................................................................................................62

Page 4

GENERAL INFORMATION

NOTE: A load calculation must be performed to properly determine the required furnace BTU size for the structure. Also, the duct must be properly designed and installed for proper airflow. Existing ductwork must be inspected for proper size and sealed system. Proper airflow is necessary for both user comfort and equipment performance.

Before opening the furnace carton and installation of the furnace, verify the data tags on the carton and inside the furnace, match and is what was ordered from the local distributor. Also, check for any damage to the furnace before installation.

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

The (-)GRK-, (-)GRL-, (-)GTK- series furnaces are design-certified by CSA for use with natural and propane gases as

FIGURE 1

UPFLOW FURNACE COMPONENTS

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.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

OWNFLOW/HORIZONTAL FURNACE COMPONENTS

AIRFLOW

CSA-INTERNATIONAL 8501 East Pleasant Valley Road Cleveland, Ohio 44131-5575

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

CSA-INTERNATIONAL 178 Rexdale Blvd. Toronto, Ontario Canada M9W, 1R3

NOTE: It is our recommendation that any HVAC equipment which were subject to flooding be replaced to avoid any risk of property damage, personal injury or death. Also, our position that the immersion by flood waters compromises any HVAC products thus voiding this warranty.

ITEM NO. PART NAME 1 CONDENSATE TRAP 2 DOOR SWITCH 3 JUNCTION BOX 4 TRANSFORMER 5 PRESSURE SWITCHES 6 EXHAUST TRANSITION 7 CONNECTOR 8 OUTLET AIR PIPE

NOTE: A PARTS BAG IS INCLUDED WITH THE FURNACE. IF A NEW PARTS BAG NEEDS TO BE ORDERED, USE THE FOLLOWING PART NUMBERS: AS-100717-01 FOR (-)GRL-45, (-)GRL-60, (-)GRK-75, (-)GRL90 AND (-)GRK-105 AS-100717-02 FOR (-)GRK-120

9 SHIPPING PLUG (TO BE REMOVED) 10 FLAME SENSOR 11 OVERTEMPERATURE SWITCH 12 TOP PLATE 13 BURNER 14 IGNITER 15 COMBUSTION AIR INLET 16 OPTIONAL AIR INLET (UPFLOW UNITS ONLY) 17 OPTIONAL GAS INLET 18 GAS VALVE

19 INDUCED DRAFT BLOWER 20 CAPACITORS 21 BLOWER 22 LOW VOLTAGE TERMINAL 23 CONTROL MOUNTING PLATE 24 FILTER / SOLID METAL BASEPLATE (UPFLOW UNITS ONLY) 25 BURNER COVER PLATE

NOTE: A PARTS BAG IS INCLUDED WITH THE FURNACE. IF A NEW PARTS BAG NEEDS TO BE ORDERED, USE THE FOLLOWING PART NUMBERS: AS-100717-03 FOR (-)GTK-60, (-)GTK-75, (-)GTK-90, (-)GTK105 AND (-)GTK-120

(DOWNFLOW/HORIZONTAL UNITS ONLY)

AIRFLOW

Page 5

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY

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

he proper balance between the air

t being supplied to each room and the air returning to the cooling and heating equipment.

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

WARNING

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

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

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

FIGURE 2

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

NOTICE

IMPROPER INSTALLATION, OR INSTALLATION NOT MADE IN ACCORDANCE WITH THE CSA INTERNATIONAL (CSA) CERTIFICATION OR THESE INSTRUCTIONS, CAN RESULT IN UNSATISFACTORY OPERATION AND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVERED BY THE UNIT WARRANTY.

NOTICE

IN COMPLIANCE WITH RECOGNIZED CODES, IT IS RECOMMENDED THAT AN AUXILIARY DRAIN PAN BE INSTALLED UNDER ALL EVAPORATOR COILS OR UNITS CONTAINING EVAPORATOR COILS THAT ARE LOCATED IN ANY AREA OF A STRUCTURE WHERE DAMAGE TO THE BUILDING OR BUILDING CONTENTS MAY OCCUR AS A RESULT OF AN OVERFLOW OF THE COIL DRAIN PAN OR A STOPPAGE IN THE PRIMARY CONDENSATE DRAIN PIPING. SEE ACCESSORIES SECTION OF THESE INSTRUCTIONS FOR AUXILIARY HORIZONTAL OVERFLOW PAN INFORMATION (MODEL (-)XBM).

RECEIVING

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

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

• Check the unit rating plate for unit size, electric heat, coil, voltage, phase, etc. to be sure equipment

matches what is required for the job specification.

• Read the entire instructions before starting the installation.

• Some building codes require extra cabinet insulation and gasketing when unit is installed in attic applications.

• If installed in an unconditioned space, apply caulking around the power wires, control wires, refrigerant tubing and condensate line where they enter the cabinet. Seal the power wires on the inside where they exit conduit opening. Caulking is required to prevent air leakage into and condensate from forming inside the unit, control box, and on electrical controls.

• Install the unit in such a way as to allow necessary access to the coil/filter rack and blower/control compartment.

• Install the unit in a level position to ensure proper condensate drainage. Make sure unit is level in both directions within 1/8”.

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

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

• NFPA90A Installation of Air Conditioning and Ventilating Systems.

• NFPA90B Installation of warm air heating and air conditioning systems.

• The equipment has been evaluated in accordance with the Code of Federal Regulations, Chapter XX, Part 3280.

Page 6

SAFETY INFORMATION

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME. USE A COMMERCIALLY AVAILABLE

OAP SOLUTION MADE

S SPECIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS, AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE INSTRUCTIONS.

WARNING

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

WARNING

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

WARNING

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

WARNING

HEN THIS FURNACE IS

W INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR. THIS IS TO REDUCE THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY

E PRESENT IN A GARAGE.

B 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.

WARNING

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

INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATE AND TEMPERATURE RISE PER RATING PLATE MARKING;

• MEANS FOR PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION;

• RETURN AIR TEMPERATURE MAINTAINED BETWEEN 55°F (13°C) AND 80°F (27°C); AND

• CLEAN FURNACE, DUCT WORK AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE, TEMPERATURE RISE AND VENTING, ACCORDING TO THE INSTRUCTIONS AND CODES.

Page 7

WARNING

NOTICE

IMPORTANT!

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

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

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time

of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

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

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

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide

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

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

KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local

gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR

5.08(2)(a)1 through 4:

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

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

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

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

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

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

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

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

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

Page 8

LOCATION REQUIREMENTS AND CONSIDERATIONS

GENERAL INFORMATION

. install a parallel duct system

WARNING

DO NOT INSTALL THIS FURNACE IN A MOBILE HOME!! This furnace is

not approved for installation in a mobile home. Doing so could cause

IRE, PROPERTY DAMAGE,

F PERSONAL INJURY OR DEATH.

WARNING

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR. THIS IS TO 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.

1. 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 and the open portion of the condensate drain assembly. See “Condensate Drain/Neutralizer” section for more details.

2. 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.

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.

3. IMPORTANT: Install the furnace

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

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

4. 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. 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

FIGURE 3

HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP

DRAIN PIPE

5. IMPORTANT: If installing in a

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:

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.

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.

c. allow service clearance

AIRF

LOW

HEAT TAPE

TRAP

I526

Page 9

CAUTION

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

ORIZONTAL CONFIGURATION.

SITE SELECTION

1. Select a site in the building near he center of the proposed, or

t 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

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

CLEARANCE ACCESSIBILITY

The design of forced air furnaces with input ratings as listed in the table under Figure 5 are certified by CSAInternational for the clearances to combustible materials shown in inches.

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

learance information.

Service clearance of at least 24 inches is recommended in front of all furnaces.

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

WARNING

UPFLOW 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 filter section for details.

WARNING

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

FIGURE 4

HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

GAS PIPE

INTAKE VENT

ELECTRICAL CONDUIT

AIRF

LOW

TRAP

NOTE: Do not block furnace access with support rods. Maintain clearances recommended in Figure

7. Allow enough space for proper service maintenance or replacement of the heat exchanger and blower assembly.

EXHAUST FAN

I522

Page 10

IGURE 5

CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS

WGTS

OPTIONAL

RETURN

AIR CUTOUT

(EITHER SIDE)*

I392.DGN

BACK TOP FRONT VENT

2 DIA. KNOCKOUT

ALT. GAS CONNECTION

SIDE SIDE

LEFT RIGHT SHIP

/32 0 0 0 1 2* 0 111

/32 0 0 0 1 2* 0 117

/32 0 0 0 1 2* 0 123

/32 0 0 0 1 2* 0 145

/8 2 15 13

UPFLOW MODELS MINIMUM CLEARANCE (IN.)

/32 15

/2 16

/2 17

/8 2 15 13

/8 2 18

/32 15

/32 19

/2 16

/32 0 0 0 1 2* 0 160

/32 0 0 0 1 2* 0 148

/32 0 0 0 1 2* 0 152

/2 17

/8 2 18

/8 2 22 20

/32 19

/32 22

/2 23

04 17

06 17

MODEL A B C D E F

09 21 19

10 21 19

07A 17

07B 21 19

RETURN

12 24

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

⁄8

AIR

AIRFLOW

*BOTH SIDES FOR 1800 CFM

GAS CONNECTION

AIR

SUPPLY

2 DIA.

⁄16

I392

CUTOUT (EITHER SIDE)*

OPTIONAL RETURN AIR

Page 11

IGURE 6

CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS

WGTS

BACK TOP FRONT VENT

SIDE SIDE

LEFT RIGHT SHIP

⁄8 0 0 0 1 2* 0 117

⁄8 0 0 0 1 2* 0 123

⁄8 0 0 0 1 2* 0 148

⁄8 0 0 0 1 2* 0 152

/32 0 0 0 1 2* 0 123

⁄8 13

/2 17

⁄8 2 16

/16 2 18

⁄8 0 0 0 1 2* 0 160

⁄8 17

⁄8 20

⁄8 2 23

⁄16 2 20

A103501.DGN

⁄16

2 DIA.

ALT. GAS CONNECTION

⁄8

⁄32 15

⁄32 19

/32 19

DOWNFLOW MODELS MINIMUM CLEARANCE (IN.)

MODEL A B C D E F

⁄2 16

06 17

07A 17

07B 21 19

⁄32 22

⁄2 23

09 21 19

10 21 19

12 24

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

AIR

SUPPLY

AIRFLOW

GAS

CONNECTION

2 DIA.

AIR

RETURN

I393

NOTE: IN DOWNFLOW CONFIGURATION, RETURN AIR CUTOUT IS NOT PERMITTED.

Page 12

IGURE 7

CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS

WGTS

A103601.DGN

BACK TOP FRONT VENT

SIDE SIDE

LEFT RIGHT SHIP

⁄8 0 0 0 1 2* 0 117

⁄8 0 0 0 1 2* 0 123

⁄8 0 0 0 1 2* 0 148

⁄8 0 0 0 1 2* 0 152

⁄8 0 0 0 1 2* 0 160

RETURN AIR

⁄8 13

⁄8 17

⁄8 2 16

⁄16 2 20

⁄32 15

⁄32 19

HORIZONTAL MODELS MINIMUM CLEARANCE (IN.)

⁄2 16

⁄8 20

NOTE: In horizontal configuration, return air cutout is not permitted.

Horizontal left-hand airflow only.

IMPORTANT: This furnace is not approved or recommended for

⁄8 2 23

⁄16 2 20

⁄32 19

⁄32 22

⁄2 23

installation on its back, with access doors facing upwards.

06 17

MODEL A B C D E F

09 21 19

10 21 19

07A 17

07B 21 19

12 24

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

AIRFLOW

⁄16

GAS

CONNECTION

2 DIA.

ALT. GAS

DRAIN TRAP LOCATION

⁄8

CONNECTION

AIR

SUPPLY

I520

Page 13

JACKET

DRILL (2) 3/16" DIA. HOLES

8.000

4.875

1.531

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.

WARNING

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.

IMPORTANT: When using outside air, design and adjust the system to maintain a return air temperature ABOVE 55° F during the heating season.

NOTE: Return air grilles and warm air registers must not be obstructed or closed.

UPFLOW UNITS

. Position the unit to minimize long

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

2. Open the return air compartment.

WARNING

UPFLOW FURNACE: A SOLID METAL BASE PLATE MUST REMAIN IN THE FURNACE BOTTOM WHEN USING SIDE AIR RETURN. FAILURE TO INSTALL A BASE PLATE COULD CAUSE THE PRODUCTS OF COMBUSTION TO CIRCULATE INTO THE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING OR DEATH. FOR BOTTOM RETURN, REMOVE SOLID METAL BASE PLATE.

a. Cut an opening in the side. The

opening should be cut the full width and height of the knockouts on the unit. See Figure 8.

FIGURE 8

UPFLOW CUTOUT AND DRILL INFORMATION

NOTE: Where the maximum air flow

is 1800 CFM or more, both sides or 1 side and the bottom must be used for return air.

3. Connect the return duct or return air cabinet to the unit. Make the

onnection air tight to prevent

c entraining combustion gases from an adjacent fuel-burning appliance.

4. Be sure to have adequate space

or the unit filter.

NOTE: DO NOT take return air

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

NOTE: DO NOT use a rear air return.

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

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

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

be rated for a minimum temperature of 250°F continuous.

1313

Page 14

OWNFLOW UNITS

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

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

3. If installing on a combustible floor

and not using an air conditioning plenum, install the special non-

combustible floor base. See Table 1 and Figure 9.

WARNING

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.

NOTE: In downflow configuration, return air cut out is not permitted.

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.

HORIZONTAL UNIT

IMPORTANT: THIS FURNACE MAY ONLY BE INSTALLED SO AS WHEN

ACING THE FRONT OF THE

F FURNACE, SUPPLY AIR IS DISCHARGED ON THE LEFT HAND SIDE.

1. Position the unit to minimize long uns of duct or runs of duct with

r many turns and elbows.

2. If summer air conditioning is

desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

3. 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 pulling combustion gases from an adjacent fuel-burning appliance.

NOTE: In horizontal configuration, return air cut out is not permitted.

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.

TABLE 1

NON-COMBUSTIBLE FLOOR BASES

Floor Base Size

No. Cabinet

(-)XGC-B17 17

(-)XGC-B21 21

(-)XGC-B24 24

FIGURE 9

NON-COMBUSTIBLE FLOOR BASE

Page 15

VENTING AND COMBUSTION AIR PIPING

EQUIREMENT THAT VENT

GENERAL INFORMATION

WARNING

READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. FAILURE TO PROPERLY VENT THIS FURNACE CAN CAUSE CARBON MONOXIDE POISONING

R AN EXPLOSION OR FIRE,

O 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).

WARNING

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

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

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

NOTE: INLET AIR PIPING IS NOT CONSIDERED TO BE A PART OF THE “VENTING SYSTEM”. THE

ATERIAL BE CERTIFIED TO ULC

636 DOES NOT APPLY TO INLET

IR PIPING. VENT TERMINATIONS

ND CONCENTRIC TERMINATIONS

UST BE APPROVED BY THE

ANUFACTURER AND CERTIFIED

LC-636.

MPORTANT: 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.

NOTE: With the furnace correctly vented, the inducer will move approximately 25 cfm per 100,000 Btu’s.

IMPORTANT: No part of the combustion air and vent pipes may run under ground.

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 are located in the burner compartment. If a switch is tripped it must be manually reset.

WARNING

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

ther appliances, the vent system is

o likely to be too large to properly vent the remaining attached appliances.

he following steps should be

T 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.

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.

Page 16

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.

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

ombustion and ventilation air for the

c 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) 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.

IMPORTANT: Only the current vent instructions apply. All 90 Plus Gas Furnaces cannot be common vented.

JOINING PIPE AND FITTINGS

WARNING

PVC SOLVENT CEMENTS AND PRIMERS ARE HIGHLY FLAMMABLE. PROVIDE ADEQUATE VENTILATION AND DO NOT ASSEMBLE NEAR HEAT

OURCE OR AN OPEN FLAME. DO

S 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 as shown below:

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

or proper fit, wipe socket and

f 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

ovement until it bottoms out.

m 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.

PIPE & FITTING MATERIAL

Schedule 40 PVC (Pipe) D1785

Schedule 40 PVC (Cellular Core Pipe) F891

Schedule 40 PVC (Fittings) D2466

SDR-21PVC (Pipe) D2241

SDR-26 PVC (Pipe) D2241

Schedule 40 ABS Cellular Core DWV (Pipe) F628

Schedule 40 ABS (Pipe) D1527

Schedule 40 ABS (Fittings) D2468

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

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

ASTM

SPECIFICATION

D2661

D2665

Page 17

COMBUSTION AND VENTILATION AIR

NON-DIRECT

erchloroethylene)

FURNACE INSTALLATIONS

WARNING

THE FURNACE AND ANY OTHER

UEL-BURNING APPLIANCE MUST

F 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 (latest edition) 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

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for

lothes 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.

WARNING

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

5,000 281 14' x 20' OR 16' x 18'

0,000 375 15' x 25' OR 19' x 20'

5,000 469 15' x 31' OR 20' x 24'

0,000 563 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.

BTUH Free Area

Page 18

nput Each Opening

5,000 100 square inches

0,000 100 square inches

5,000 100 square inches

90,000 100 square inches

105,000 105 square inches

120,000 120 square inches

IGURE 10

AIR FROM HEATED SPACE

B. USING OUTDOOR AIR FOR

COMBUSTION

MPORTANT: 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

WATER

HEATER

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

URNACE

NOTE:

ACH OPENING SHALL

E HAVE A FREE AREA OF NOT LESS THAN ONE

QUARE INCH PER 1,000

S BTU PER H0UR OF THE TOTAL INPUT RATING OF

LL EQUIPMENT IN THE

A ENCLOSURE, BUT NOT LESS THAN 100 SQUARE

NCHES.

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 (see Figure 12).

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 (not shown)

FIGURE 11

AIR FROM ATTIC/CRAWL SPACE

OUTLET AIR IN ATTIC MUST BE ABOVE INSULATION

1 SQ. INCH PER

4000 BTUH

OUTLET AIR

GAS

WATER

HEATER

GABLE

VENT

FURNACE

OPTIONAL1 SQ. INCH PER 4000 BTUH INLET AIR

1 SQ. INCH PER 4000 BTUH INLET AIR

VENTILATED ATTIC GABLE OR SOFFIT VENTS

12" MAX.

FIGURE 12

OUTSIDE AIR USING A HORIZONTAL DUCT

OUTLET AIR 1 SQ. INCH

FURNACE

GAS

WATER

HEATER

INLET AIR 1 SQ. INCH

12"

MAX.

PER 2000 BTUH

Page 19

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

orizontal duct to the outdoors or

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

. 1 square inch for each 3,000

a BTUH of the total input rating of all equipment located in the enclosure and

FIGURE 13

COMBUSTION AIR FITTING

TUH Free Area Round Pipe

nput Each Opening Size

5,000 15.00 square inches 4"

0,000 16.67 square inches 5"

5,000 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.

CONNECTION TO FURNACE

IMPORTANT: When indoor combustion air is used, the inlet air

pening at the furnace must be

o protected from accidental blockage. (See Figure 13).

UPFLOW

TTACH DOUBLE ELBOW TO TOP INLET

IR OPENING OR 90° ELBOW TO SIDE

NLET AIR OPENING TO PREVENT

CCIDENTALBLOCKAGE OF INTAKE

PENING. PLUG OPENING NOT USED.

XHAUST

T OPTION

I337

SIDE OPTION

2" PVC

OUBLE

D ELBOW

2" PVC ELBOW

" PVC

DOWNFLOW/HORIZONTAL

2 DOUBLE ELBOW*

COMBUSTION AIR

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

TTACH DOUBLE ELBOW TO INTAKE AIR

OLLAR AND SECURE WITH TWO SHEET

ETAL SCREWS TO PREVENT ACCIDENTAL

LOCKAGE OF INTAKE AIR OPENING.

REDRILL FOR SCREWS.

EXHAUST

I336

Page 20

VENT PIPE INSTALLATION

NON-DIRECT VENT INSTALLATION

GUIDELINES

IMPORTANT: Failure to correctly follow all venting guidelines may result in

rratic furnace operation, freeze-up of

e combustion air or exhaust air piping or sooting of the furnace.

ll exhaust piping must be installed in

A compliance with Part 7, “Venting of Equipment,” of the latest edition of the National Fuel Gas Code NPFA54/ ANSI Z223.1-, local codes or ordinances and these instructions.

1. Vertical piping is preferred.

2. All horizontal piping must slope upward a minimum of 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.

4. 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.

5. All vent runs through unconditioned spaces where below-freezing temperatures are expected should be insulated with 1-in. thick, medium-density, foil-faced fiberglass. An equivalent “arm-aflex” or “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 selfregulating 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.

7. Extend the exhaust pipe a minimum of 18” from the cabinet before turning vent.

8. Vent cannot be ran underground.

FIGURE 14

TEE TERMINAL – FOR STANDARD HORIZONTAL NON-DIRECT INSTALLATION

VENT

/4 inch per

TABLE 2 UPFLOW UNITS

FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM INDOORS

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

NUMBERS OF ELBOWS

FURNACE

INPUT

45,000

0,000

75,000

90,000

05,000 3”

120,000 3”

NOTES:

1. *N.A. - NOT APPLICABLE.

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

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

4. NO SCREENS MAY BE USED TO COVER EXHAUST.

*A = 17-1/2” CABINET WIDTH B = 21) CABINET WIDTH

PIPE SIZE

2”

3”

ERMINATION

1-2 3-4 5-6

Standard 60 55 50

Alternate 55 50 45

”

Standard 30 25 20

Alternate 25 20 15

tandard 120 120 115

lternate 120 120 110

tandard 45 40 NA

Alternate 45 45 NA

Standard 90 85 75

Alternate 60 50 45

Standard 45 40 NA

lternate NA NA NA

tandard 70 65 55

lternate 40 30 25

45° OR 90°

edium / Long Radius ONLY

TABLE 3 DOWNFLOW/HORIZONTAL UNITS

FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM INDOORS

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

NUMBERS OF ELBOWS

FURNACE

INPUT

60,000

75,000

90,000 3”

105,000 3”

120,000 3”

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.

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

4. NO SCREENS MAY BE USED TO COVER EXHAUST.

*A = 17-1/2” CABINET WIDTH B = 21” CABINET WIDTH

PIPE SIZE

2”

3”

TERMINATION

1-2 3-4 5-6

Standard 40 35 30

Alternate 30 25 20

Standard 120 120 120

Alternate 110 105 100

Standard 120 120 120

Alternate 100 95 85

Standard 110 105 95

Alternate 50 40 35

Standard 65 60 55

Alternate 50 40 35

Standard 40 35 30

Alternate 40 35 30

45° OR 90°

Medium / Long Radius ONLY

12"

12" MIN. ABOVE

GRADE OR

SNOW LEVEL

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 long-sweep, 2-in. PVC elbows and 2-in. PVC pipe, attaching the tee so it is 12 inches from the wall.

Page 21

TANDARD 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 2. 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 19. 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. Maximum exposed vent length above the roof line is 30”. Total 2” vent length is a maximum of 48”.

Horizontal vent terminations require a 2-in. PVC tee positioned 12 inches from the outside wall. See exhaust pipe requirements, Figure 29. 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 long-sweep radius bend, 2-in. PVC elbows and a length of 2-in. PVC pipe so that the elbows are on 24-in. centers.

NOTE: Extend the exhaust a minimum of 18" from the furnace top plate before turning vent.

NON-DIRECT VENT TERMINATION LOCATION REQUIREMENTS

CAUTION

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.

7. Avoid areas where dripping

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

FIGURE 15

ALTERNATE HORIZONTAL TERMINATION FOR NON-DIRECT VENT INSTALLATIONS

NOT APPLICABLE FOR: (-)GRL-07EYBGS MODEL (-)GRL-07EMAES MODEL (-)GRL-10EZAJS MODEL

OUTSIDE WALL

In addition to the minimum clearances listed above, the vent location should also be governed by the following guidelines.

. Do not terminate under any kind

of patio or deck. If running the

ent under a deck, insulate it to

v insure no condensate freezes and blocks the pipe.

2. Do not locate on the side of a building with prevailing winter

inds. This will help prevent

w moisture from freezing on walls and overhangs (under eaves).

3. Do not extend vent directly through brick or masonry

urfaces. Use a rust-resistant

s 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.

7. Do not terminate in any area that may allow flue gases to stagnate.

12"

ROM

PIPE

24"

MAX.

SUPPORT STRAP

I198

Page 22

IGURE 16

Natural Gas and Propane Installation Code

National Fuel Gas Code

Canadian Installations

US Installations

Canadian Installations

US Installations

THER THAN DIRECT VENT TERMINAL CLEARANCES

Page 23

DIRECT VENT INSTALLATIONS

WARNING

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.

orcombustion 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

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-, local codes or ordinances and these instructions.

1. Vertical piping is preferred.

2. All horizontal piping must slope upward a minimum of1/4 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.

4. 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. Minimum 3 ft. clearance required between combustion air inlet and any other exhaust.

5. 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, pipe length is 5 feet for combustion air and exhaust.

7. Do not install elbows back to back. Allow at least 15” between elbows.

Size the exhaust and combustion air intake pipes as specified in Table 4 or Table 5. This table lists the maximum

TABLE 4

UPFLOW UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION

ROVIDED FROM OUTDOORS

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

UMBER OF ELBOWS

5 or 90 Degrees

IPE

FURNACE

INPUT

60,000

90,000 3”

105,000 3”

NOTES:

TERMINATION

IZE

5,000 2”

5,000 3”

20,000 3”

1. N.A. - NOT APPLICABLE

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

. A 45 DEGREE ELBOW IS CONSIDERED ONE ELBOW.

4. CONCENTRIC TERMINATION NO. RXGY-E03/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.

5. USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATE THRU-THE-WALL VENTING.

6. USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.

. KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.

8. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST. (A*) = 17

Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/GXGY-G02 65 60 55

lternate RXGY-D02/RXGY-D02A 55 50 45

tandard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 40 35 30

2”

”

⁄2” CABINET (B*) = 21” CABINET

lternate RXGY-D02/RXGY-D02A 20 15 10

tandard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 120 120 120

Alternate RXGY-D03/RXGY-D03A 110 105 100

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 45 40 NA

Alternate RXGY-D03/RXGY-D03 45 40 NA

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 110 105 95

lternate RXGY-D03/RXGY-D03A 50 40 35

tandard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 45 40 NA

lternate RXGY-D03/RXGY-D03A 45 40 NA

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 45 35 30

lternate RXGY-D04/RXGY-D04A 45 35 30

ENT TERMINATION

IT RECOMMENDED

edium / Long Radius ONLY

- 2 3 - 4 5 - 6

TABLE 5

DOWNFLOW/HORIZONTAL UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM OUTDOORS

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

NUMBER OF ELBOWS

FURNACE

INPUT

60,000

75,000 3”

90,000 3”

105,000 3”

120,000 3” Alternate RXGY-D03/RXGY-D03A 40 35 30

NOTES:

PIPE

TERMINATION

SIZE

Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 40 35 30

2”

3”

1. N.A. - NOT APPLICABLE

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-E03/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.

5. USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATE THRU-THE-WALL VENTING.

6. USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.

7. KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.

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

⁄2” CABINET (B*) = 21” CABINET

(A*) = 17

Alternate RXGY-D02/RXGY-D02A 30 25 20

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 120 120 120

Alternate RXGY-D03/RXGY-D03A 110 105 100

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 120 120 120

Alternate RXGY-D03/RXGY-D03A 100 95 85

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-D03A/RXGY-G02 110 105 95

Alternate RXGY-D03/RXGH-D03A 50 40 35

Standard/Concentric RXGY-D03/RXGY-D03A/RXGH-E03A/RXGY-G02 65 60 55

Alternate RXGY-D03/RXGY-D03A 50 40 35

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 40 35 30

Alternate RXGY-D04/RXGY-D04A 45 35 30

VENT TERMINATION KIT RECOMMENDED

22.5, 45 or 90 Degrees

Medium / Long Radius ONLY

1 - 2 3 - 4 5 - 6

Page 24

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).

NOTE: Extend the exhaust a minimum of 18" from the furnace top plate before turning vent.

8. The maximum exposed vent length (above the roof line) is 30”.

COMBUSTION AIR FOR DIRECT VENT INSTALLATIONS

HE COMBUSTION AIR SYSTEM

T 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: (-)XGYD02/D02A, (-)XGY-D03/D03A, (-)XGY-D04/D04A, or (-)XGY-E03A.

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) 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 19 for the proper relationship of

ombustion air to exhaust

c 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

all. Up to 18 inches of 2-in. pipe

w may be used inside the wall.

The standard horizontal intake air

ermination for all models is a 2-in.

t PVC coupling with a wind deflector vane (provided) attached. Cut a

/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.

IMPORTANT: To ensure proper furnace operation, the supplied vane must be installed in the vertical position with PVC solvent as shown in Figure 20, Detail B.

The combustion air inlet terminal must be located with respect to the exhaust terminal as shown in Figure 20, Detail C.

IMPORTANT: All furnaces with horizontal air intakes, except those using concentric vent kit (-)XGYE03/E03A, 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 (-)XGY-D02/D02A (for 2-in. pipe), (-)XGY-D03/D03A (for 3-in. pipe) and (-)XGY-D04/D04A (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 applications 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 4 for proper application. This must be reduced to 1

/2“ the last 12 inches for models with inputs of 45,000 through 75,000 BTUH.

ee Figure 19.

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 105,000 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

/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 20, Detail A.

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 20, Detail B. Refer to section on alternate venting options when higher snow levels are anticipated.

ALTERNATE TERMINATIONS

ALTERNATE HORIZONTAL DIRECT VENT TERMINATIONS

(-)XGY-D02/D02A, -D03/D03A AND D04/D04A

The combustion air and exhaust terminations may be raised a maximum of 24 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 4 and Table 5.

Review the following guidelines:

• Size the entire vent system

according to the alternate, not standard, termination shown in Table 4 and Table 5.

Page 25

• 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

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 exhaust 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 (-)XGY-D02/D02A. The 60,000 BTUH and 75,000 BTUH downflow only units may use kits (-)XGY-D02/D02A or (-)XGY-D03/D03A depending on pipe lengths and number of elbows. Use kit (-)XGY-D03/D03A with 90,000 BTUH downflow through 120,000 BTUH units or

upflow 90,000 or

120,000. The (-)XGY-D04/D04A kit

only applies to the 120,000 BTUH unit using an alternate termination and excessively long runs. See Table 4.

The following are parts lists for the (-)XGY-D02/D02A, (-)XGY-D03/D03A and (-)XGY-D04/D04A alternate horizontal direct vent termination kits:

(-)XGY-D02/D02A

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

(-)XGY-D03/D03A

IGURE 17

LTERNATE HORIZONTAL DIRECT VENT TERMINATION

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

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

SEE DETAIL A

12" FROM WALL

” MAX.

3 NOTE: 3-1/2” MAX. WHEN

04 KIT IS

SED.

4”

EXHAUST / INTAKE RELATIONSHIP

NTAKE

24” MAX.

3”

XHAUST

DETAIL B

OPTIONAL

INTAKE

4" FROM WALL

PIPE SUPPORT STRAP

OMBUSTION AIR

TERMINATION

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

(-)XGY-D04/D04A

⁄2-in. PVC elbow

1. 2

2. 3" x 2

3. 2

4. 2

5. 2

⁄2" PVC bushing

⁄2" x 61⁄2" long PVC pipe

⁄2" x 16" long PVC pipe

⁄2" x 21" long PVC pipe

6. PVC vane

3-in. tee with reducer assembly

8. 6-in. dia.1⁄2-in. PVC trap

9. PVC strap

10. vent template

NOTE: The (-)XGY-D04/D04A kit only applies to the 120,000 BTUH unit using an alternate termination and excessively long runs.

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.

SE KIT NO. (-)XGY-D02/D02A WHEN 2"

IPE IS USED BETWEEN FURNACE AND

UTSIDE WALL. USE KIT NO. (-)XGY-

03/D03A WHEN 3" PIPE IS USED.

12" FROM WALL

-1/2"

IPE

ANE

EXHAUST VENT FOR

DETAIL C

MODELS WITH

NPUT OF 45,000 THRU

(-)XGY-D02A

1. 2” Tee assembly w/ connection

⁄2” PVC-5” diameter trap

3. Wind deflector vane

4. Vent template

(-)XGY-D03A

1. 3” Tee assembly w/ connection

⁄2” PVC-5” diameter trap

3. Wind deflector vane

4. Vent Template

(-)XGY-D04A

1. 3” Tee assembly w/ connection

⁄2” PVC-6” diameter trap

3. Wind deflector vane

4. Vent template

DETAIL A

75,000 BTU

I339

⁄2” drain

Page 26

CONCENTRIC TERMINATIONS

ERTICAL/HORIZONTAL

V CONCENTRIC VENT KIT NO. (-)XGY-E03A

This kit is for vertical/horizontal intake air/vent runs and may be installed through roofs or sidewalls. One 5” diameter hole is required for

he installation. See Figure 18 for

t the general layout. Complete installation instructions are included with the kit.

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

and

used in place of factory supplied kits:

3” Concentric Kit – Item # 196006

FIGURE 18

ONCENTRIC VENT KIT NO. (-)XGY-E03A

SIDEWALL ASSEMBLY

FIELD-SUPPLIED STRAP

ITEM No. DESCRIPTION

A 2.5" PVC PIPE SCHEDULE 40 -- 37.125" LONG

B4" PVC PIPE SCHEDULE 40 -- 24" LONG

C3" x 3" x 4" SPECIAL CONCENTRIC FITTING

D3" x 45° STREET ELBOW (FIELD SUPPLIED)

E PVC RAINCAP

1" MAXIMUM

ROOF INSTALLATION

NOTE: • Support must be field installed

to secure termination kit to structure.

• No screens may be used to cover combustion air and exhaust.

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

Page 27

IGURE 19

STANDARD VERTICAL DIRECT VENTING

EXHAUST TERMINATION

ETAIL A

EXHAUST PIPE

OTES:

NCREASE THE 12-IN. MINIMUM

TO KEEP TERMINAL OPENING ABOVE ANTICIPATED LEVEL OF SNOW

CCUMULATION WHERE APPLICABLE.

HEN 3-IN. DIAM. PIPE IS USED,

REDUCE TO 2-IN. DIAMETER BEFORE PENETRATING ROOF. A MAXIMUM

F 18 IN. OF 2-IN. PIPE MAY BE

O USED BEFORE PASSING THROUGH ROOF.

SUPPORT VERTICAL PIPE EVERY 6

EET.

F EXHAUST TERMINATION - TERMINATE

HE LAST 12 INCHES WITH 2” PVC PIPE

T ON 90,000 AND 120,000 BTUH MODELS. REDUCE AND TERMINATE THE LAST 12

NCHES WITH 1

I THROUGH 75,000 BTUH MODELS. SEE

ETAIL A.

D 30”MAXIMUM EXPOSED VENT LENGTH.

THE COMBUSTION AIR PIPE MUST

ERMINATE IN THE SAME PRESSURE

T ZONE AS THE EXHAUST PIPE.

O SCREENS MAY BE USED TO

COVER COMBUSTION AIR AND EXHAUST.

PVC PIPE ON 45,000

/2”

30” MAX

8” MAX

ROOF LINE

2”

" MAX.

3 SEPARATION

6" MAX.

COMBUSTION AIR

IPE

12" MIN.

EPARATION

12" MIN. ABOVE

OOF LEVEL

COMBUSTION AIR PIPE

SUPPLY AIR

RETURN AIR

EXHAUST

ENT

IN.

COMBUSTION

IR PIPE

MAX.

12" MIN.

IN.

EXHAUST

ENT

OOF LINE

MAX.

12" MIN.

ANTICIPATED

NOW LEVEL

COMBUSTION

IR PIPE

EXHAUST VENT

0” MAX

PITCHED ROOF INSTALLATIONS

AX.

ABO

ED SN

PAT

EVEL

W L

407

FIGURE 20

STANDARD HORIZONTAL DIRECT VENTING

SUPPLY AIR

EXHAUST PIPE

COMBUSTION AIR PIPE

NOTES:

SUPPORT HORIZONTAL PIPE

EVERY FOUR FEET. WHEN 3 IN. PIPE IS USED REDUCE TO 2 IN.

BEFORE PENETRATING OUTSIDE WALL. 18 IN. MAXIMUM. 2 IN. DIAMETER PIPE MAY

BE USED INSIDE THE WALL. DETAIL “A”- EXHAUST TERMINATION

TERMINATE THE LAST 12 INCHES WITH 2” PVC PIPE ON 90,000 AND 120,000 BTUH MODELS. REDUCE AND TERMINATE THE LAST 12 INCHES WITH 1 45,000 THROUGH 75,000 BTUH MODELS.

INCREASE THE 12 IN. MINIMUM ABOVE

GRADE TO KEEP TERMINAL OPENINGS ABOVE ANTICIPATED LEVELOF SNOW ACCUMULATION WHERE APPLICABLE.

DETAIL “B”, INSTALL WIND DEFLECTOR

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

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

THE COMBUSTION AIR PIPE MUST

TERMINATE IN THE SAME PRESSURE ZONE AS THE EXHAUST PIPE.

NO SCREENS MAY BE USED TO COVER

COMBUSTION AIR AND EXHAUST. NO ELBOWS CAN BE INSTALLED AT

TERMINATION.

/2” PVC PIPE ON

2” OR 3” TEE

W/DRAIN TRAP

RETURN AIR

VANE

TRAP

CONNECT TO DRAIN

2” PVC COUPLING

COMBUSTION AIR TERMINATION

DETAIL B

12”

4”

12” MIN. ABOVE GRADE LEVEL

SEE DETAIL B

SEE DETAIL A

4”

EXHAUST / INTAKE RELATIONSHIP

EXHAUST TERMINATION

DETAIL A

3”

EXHAUST

INTAKE

DETAIL C

OPTIONAL

INTAKE

I407

Page 28

LOCATION REQUIREMENTS HORIZONTAL DIRECT VENTS

CAUTION

THE COMBUSTION PRODUCTS AND MOISTURE IN THE FLUE GASES WILL CONDENSE AS THEY LEAVE THE TERMINATION. THE

ONDENSATE CAN FREEZE ON

C 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.

The vent must be installed with the following minimum clearances. See Figures 21 and 22.

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. Locate the furnace combustion air inlet minimum of 3 feet from the vent of any other gas or fuel burning appliance or clothes dryer to prevent recirculation of the flue gases into the furnace combustion air inlet. The only exception to this requirement is the case of multiventing two or more furnaces, which is covered in the section on multiventing in these instructions.

In addition to the minimum clearances

listed above, the vent location should also be governed by the following guidelines.

. Do not terminate under any kind

of patio or deck. If running the

ent under a deck, insulate it to

v 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

ecirculate.

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.

FIGURE 21

MOISTURE ZONES

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

ncreased equally for each

i additional increase in horizontal overhang to a maximum vertical clearance of 6 feet.

7. Caulk all cracks, seams and joints within 6 feet horizontally

nd above and below vent.

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.

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

Page 29

IGURE 22

Natural Gas and Propane Installation Code

National Fuel Gas Code

Canadian Installations

US Installations

Canadian Installations

US Installations

IRECT VENT TERMINAL CLEARANCES≤

Page 30

FIGURE 23

WO FURNACE VENTING THROUGH ROOF

WO-PIPE VENTING TWO-PIPE VENTING

OMBUSTION

C AIR INTAKE 2”PVC

FIGURE 24

WO FURNACE VENTING THROUGH WALL

ABO

EVEL

”

SNO

3" MIN.

24" MAX.

4" MAX.

”

" MIN.

” COM

NDE

COMBUSTION AIR INTAKE 2”PVC COUPLING WITH VALVE IN VERTICALPOSITION

XHAUST VENT

CONCENTRIC VENTING CONCENTRIC VENTING

" MIN.

8 4" MAX.

MINIMUM 12”ABOVE AVERAGE

SNOW ACCUMULATION. MAXIMUM

OF 24 IN.ABOVE ROOF.

6” MINIMUM

10” RECOMMENDED

MINIMUM 12”

MAXIMUM 1”

DISTANCE

FROM WALL

ABOVE GRADE

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 23 and 24

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.

SEE CONCENTRIC VENT INSTALLATION INSTRUCTIONS

8" MIN.

24" MAX.

SEE CONCENTRIC VENT INSTALLATION INSTRUCTIONS.

Page 31

(-)XGY-G02 Side Wall Vent

EXHAUST

AIR INTAKE

This termination for horizontal venting only.

MPORTANT: Do not install on the

prevailing winter wind side of the structure. Observe same clearance specified for horizontal, standard termination.

NOTE: Multi-venting-No common venting.

FIGURE 25

VENT KIT INSTALLATION OPTIONS

NOTE: Install the vent and air intake

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

one above the other.

NOTE: The vent illustration in Figure

26 can be used for non-direct vent terminations also.

FIGURE 26

TYPICAL INSTALLATIONS

Page 32

CONNECTING TO FURNACE

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

UPFLOW FURNACE

The exhaust pipe connection is a 2-in.

emale PVC pipe fitting extending

f 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 combustion air connection is at the right side of the top plate. An alternate combustion air connection may be made on the right side of the jacket. This opening has a plastic cap. A combustion 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 27.

DOWNFLOW/HORIZONTAL FURNACE

The exhaust pipe connection is a 2-in. female 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 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 combustion air connection is a 2in. 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, drill two pilot holes, and add two sheet metal screws through the coupling into the extrusion to secure it in place before piping. 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. See Figure 28.

IGURE 27

PFLOW COMBUSTION AIR AND VENT PIPE CONNECTION

O”RING

“

TOP PLATE

EXHAUST

VENT CAP/PLUG

EXHAUST

OUTLET AIR PIPE

EXHAUST TRANSITION

CONNECTOR

CONDENSATE TRAP

DRAIN HOSES

(AS SHIPPED FROM

FACTORY)

FIGURE 28

DOWNFLOW/HORIZONTAL COMBUSTION AIR AND VENT PIPE CONNECTION

TOP PLATE

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

COMBUSTION

IR ADAPTER

NOTE: WHEN COMBUSTION AIR IS IN

PTIONAL POSITION SWAP LOCATION

O OF 2" PVC MALE ADAPTER AND “O” RING WITH PLUG.

P AIR POSITION

I BLOWER

LUG OPT. COMBUSTION

NDUCED DRAFT

329

EXHAUST VENT CAP/PLUG

EXHAUST PIPE - PVC

EXHAUST CONNECTOR

EXHAUST OUTLET AIR PIPE

EXHAUST TRANSITION

a103101

Page 33

CONDENSATE DRAIN/NEUTRALIZER

GENERAL INFORMATION

CAUTION

O NOT RUN DRAIN OUTDOORS.

D FREEZING OF CONDENSATE CAN CAUSE PROPERTY DAMAGE.

IMPORTANT: Do not connect into a

common drain line with an air conditioner evaporator coil drain. A blocked or restricted drain line can result in over-flow 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 Figure 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.

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

rain pan under the entire unit

xtending out under the condensate

ee.

t IMPORTANT: There are two options

when choosing a height for the condensate riser: CONDENSATE OVERFLOW: With a 5 inch riser installed above the tee, a blocked drain will result in overflow from the riser. FURNACE SHUTDOWN: 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.

FIGURE 29

UPFLOW CONDENSATE DRAIN

NOTE: SEE UPFLOW MODEL NOTES FOR PIPE HEIGHT

Use a solvent cement that is compatible with PVC material. Cut the drain hoses to the appropriate length

nd connect to the trap with hose

lamps. Tighten the clamps with

liers and check for leaks after

ttaching.

MPORTANT: The inducer drain hose

ust slant downward away from

nducer. If the hose is not slanted,

he inducer will fill with water and

ause the pressure switch to open,

ausing nuisance failures or

ntermittent operation.

NOTE: INDUCER DRAIN HOSE MUST SLANT DOWNWARD AWAY FROM INDUCER.

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 a1/2-in. tee are provided. Connect the1/2-in. pipe to the elbow on the trap and the tee to this pipe so that the open end is upward. Run a drain tube from the bottom of the tee to a floor drain or condensate pump.

IMPORTANT: The upflow model only has a new drain system. There is a third port on the drain trap (marked by a red cap) for the hose attached to the induced draft motor. Remove plug in inducer drain hose and remove cap off drain trap before connecting inducer drain hose to drain trap. All three hoses MUST be attached during operation of the furnace. Be sure all three hoses are secured to the drain trap using the hose clamps provided in the parts bag.

TO FLOOR DRAIN OR CONDENSATE PUMP

NOTE: CONNECT INDUCER DRAIN HOSE TO SMALLER PORT ON CONDENSATE TRAP.

DRAIN LINE

NEUTRALIZER CARTRIDGE (OPTIONAL)

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

CONDENSATE TRAP

I408

Page 34

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

racket and trap so that the drain

b elbow is centered in the hole on the right. See Figure 30.

Drill two mount the bracket. Mount the trap and bracket to the right side with the drain elbow pointing through the knockout. Connect the 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. Fill trap with water.

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. A blocked or restricted drain line can result in overflow of the coil pan and negate the furnace blocked drain shutoff control.

DOWNFLOW MODELS

IMPORTANT: There are two options

when choosing a height for the condensate riser:

CONDENSATE OVERFLOW: With a

⁄4 inch riser installed above the tee,

1 a blocked drain will result in overflow from the riser.

FURNACE SHUTDOWN: To cause the furnace to shut down when a blocked drain is present, install a riser which is a minimum of 5 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. Provisions must be made to prevent freezing of condensate.

Use a solvent cement that is compatible with PVC material.

To convert downflow models to lefthand drain, a kit ((-)XGY-H01) must be ordered from the distributor. The kit includes a 24” piece of PVC pipe, a 2-9/16” length of black hose, a 2” rubber grommet, a 1-5/8” plug and instructions. Note the location of the alternate drain hole as shown in Figure 32.

To convert to left side drainage, remove the long molded hose from the trap. Remove the double-elbow black molded hose from the trap and exhaust transition and discard. Remove the trap from its mounting

/8” holes in the cabinet to

/2-in. pipe and

⁄2”. If the

⁄2” black

IGURE 30

PFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

PROPER DRAIN SLOPE REQUIRED

(NO KINKS ALLOWED)

SHEETMETAL IFC

MOUNTING PLATE

CONDENSATE TRAP

FIGURE 31

DOWNFLOW CONDENSATE DRAIN

CONDENSATE TRAP

DRAIN LINE

NEUTRALIZER CARTRIDGE

(OPTIONAL)

bracket, rotate it 180 degrees and mount in place with the drainage elbow pointing to the left. Reattach the long black molded hose. Use the 2-9/16” length of black hose included in the (-)XGY-H01 kit between the trap and exhaust transition. Clamp hoses tight with white nylon clamps.

Remove the plug from the 2” alternate drain hole (see Figure 32) and replace it with the 2” rubber grommet supplied in the (-)XGY- H01 downflow alternate drain kit. Also, remove the 1-5/8” grommet supplied in the primary drain hole and replace it with the 1-5/8” diameter plug that is also supplied in the (-)XGY-H01 downflow alternate drain kit. Both the hole-plug and grommet must be in place to insure a good seal in the burner compartment.

TO FLOOR DRAIN OR CONDENSATE PUMP

A length of 1/2” black PVC pipe is also provided in the (-)XGY-H01 downflow alternate drain kit. Glue one end of the pipe to the elbow in the trap. Cut the pipe so that it extends through the alternate drain hole in the left side of the cabinet one inch. Connect the 1/2” PVC tee (supplied with the furnace) to the pipe with a 1-3/4” riser. Use the 15/8” plug supplied in the (-)XGY-H01 downflow alternate drain kit to seal the right side drainage hole.

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.

UT DRAIN HOSES AS

EQUIRED

ND CONNECT TO

NLETS ON TOP

F CONDENSATE

RAP

RAIN

XTENSION

O FLOOR

RAIN

NOTE: DRAIN VENT NEEDS

O BE ABOVE

T COLLECTOR BOX DRAIN SPOUT.

MINIMUM HEIGHT OPEN TOP

VERFLOW LINE

O (REQUIRED ONLY WHEN OPTIONAL NEUTRALIZER

ARTRIDGE IS USED.)

DRAIN RISER

TEE

A039407

a103101

Page 35

CONDENSATE DRAIN FOR HORIZONTAL INSTALLATION

Refer to Figure 33 for Steps 1-4.

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.

1. Remove the burner compartment door from the unit.

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

3. Remove the black molded 90° hose ➂ from the top of the existing trap ➀ and furnace collector box. Cut 1.0 inch from the long end of the hose. NOTE: Exception – do not shorten the 90° hose on the 07B furnace! The 07B has a longer distance between the collector box and horizontal drain trap.

4. Remove the double-elbow black molded hose ➀ from the exhaust transition ➀. Discard this hose and the downflow trap.

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

Refer to Figure 34 for Steps 6-11.

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

6. Fill the trap assembly ➆ with a cup of water.

7. 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.

8. 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

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

10. Attach the 90° end of the molded hose to the collector box. Clamp the hose tight with white nylon clamp. Then attach the long end of the molded hose to

overtighten!

IGURE 32

OWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

DRAIN VENT

RAIN

XTENSION

TEE

DRIP LEG

ALTERNATE DRAIN HOLE LOCATED

ERE ON

H JACKET.

REMOVE

(

BURNERS

PLASTIC PLUG

ND REPLACE

MANIFOLD

ITH

W GROMMET).

TO FLOOR DRAIN OR

ONDENSATE

UMP

CONDENSATE TRAP

the 45° elbow molded into the top of the trap assembly. Clamp the hose tight with white nylon clamp.

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

11. IMPORTANT: There are two

options when choosing a height for the condensate riser:

CONDENSATE OVERFLOW: With

a 1

⁄4 inch riser installed above the

tee, a blocked drain will result in

UNION

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.

NOTE: Fill the trap assembly with water every heating season.

overflow from the riser. FURNACE SHUTDOWN: To

cause the furnace to shut down when a blocked drain is present, install a riser which is a minimum of 51⁄2”. 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. Provisions must be made to prevent freezing of condensate (see Figure 3).

Use a solvent cement that is compatible with PVC material.

NOTE: See location requirements and combustion section for additional recommendations.

EXISTING DRAIN HOLE. PLUG WITH

5/8”PLUG

1 SUPPLIED IN

IT.

ROTATE TRAP 180° AND INSTALLRIGID

IPE FROM

P ELBOW TO OPPOSITE SIDE OF

ACKET AS

J SHOWN.

Page 36

I534

CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO

HORIZONTAL INSTALLATION

FOR HORIZONTAL OPERATION

FIGURE 34

HORIZONTAL POSITION: CONDENSATE TRAP INSTALLATION

FIGURE 33

UPRIGHT POSITION: REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP

Page 37

GAS SUPPLY AND PIPING

GAS SUPPLY

WARNING

THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL KIT IS AVAILABLE AT THE DISTRIBUTOR. FAILURE TO USE THE PROPER CONVERSION KIT CAN CAUSE

IRE, CARBON MONOXIDE

F 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: U.L. or CSA 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 stop must be adequate in size to prevent undue pressure drop and never smaller than the pipe size to the gas valve on the furnace. Refer to Table 6 for the

recommended gas pipe size. See Figure 35 for typical gas pipe connections.

Install a ground joint union within 3 ft. of the cabinet to easily remove the gas valve assembly. Install a manual gas stop valve in the gas line outside the furnace casing. The manual gas

stop 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

FIGURE 35

AS PIPING INSTALLATION

UPFLOW

ROMMET

MANUAL

GAS

STOP

TO 5 FEET

4 ABOVE FLOOR REQ’D BY

OME

S UTILITIES.

GROMMET (IN NORMAL

OSITION)

DRIP LEG

NION

TOP VIEW OF GAS LINE AND VALVE

IN OPT. POSITION

URNERS

AS VALVE

OTE: WHEN GAS LINE

N IS IN OPT. POSITION, SWAP LOCATION OF

ROMMET AND PLUG.

OPT. GAS LINE

OSITION

PLUG (IN NORMAL

OSITION)

ANIFOLD

M PRESSURE TAP

GNITOR

MANIFOLD

DOWNFLOW

ROMMET

IGNITOR

OTE: WHEN GAS

N LINE IS IN OPT. POSITION, SWAP

OCATION OF

L GROMMET AND PLUG.

AS VALVE

PLUG (IN NORMAL POSITION)

MANIFOLD PRESSURE TAP

MANIFOLD

I328

ANUAL

G TOP

TO 5 FEET ABOVE

4 FLOOR REQ’D BY SOME UTILITIES.

GROMMET (IN NORMAL POSITION)

DRIP LEG

TOP VIEW OF GAS LINE AND VALVE

N OPT. POSITION

UNION

BURNERS

HORIZONTAL

MANUALGAS STOP

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.

Page 38

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 main gas valve and manifold. Do not overtighten gas valve on pipe.

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

IMPORTANT: Do not run a flexible gas connector inside the furnace. The

as pipe gasket in the cabinet does

g not seal around a flexible gas line.

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously serviced another gas appliance. Massachusetts law requires that all flexible connectors be less than 36”.

It is important to have all openings in the cabinet burner compartment sealed for proper furnace operation.

IMPORTANT: ENSURE that the

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

DISCONNECT the furnace and its individual manual gas stop from the gas supply piping during any pressure

testing that exceeds 1/2 PSIG. (3.48 kPa).

TABLE 6

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

apacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific

ravity of 0.60 (natural gas).

ominal Length of Pipe, Feet

N Iron Pipe

Size, Inches 10 20 30 40 50 60 70 80

/2 132 92 73 63 56 50 46 43

1 3/4 278 190 152 130 115 105 96 90

1-1/4 1,050 730 590 500 440 400 370 350

-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

equired for the gas input rating of the furnace. By formula:

he gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT

T determined by consulting the local natural gas utility or the LP gas supplier.

520 350 285 245 215 195 180 170

as Input of Furnace (BTU/HR)

Cu. Ft. Per Hr. Required =

G Heating Value of Gas (BTU/FT

)

may be

)

FIGURE 36

TYPICAL GAS VALVE

GAS VALVE #60-101921-02

AS CONTROL

WITCH

IGH FIRE

ANIFOLD

RESSURE

DJUSTMENT

LOW FIRE MANIFOLD PRESSURE ADJUSTMENT

GAS PRESSURE

Natural gas supply pressure should be 5" to 10.5" 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.

The minimum gas 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 gas supply pressure is 11" w.c. for LP gas.

ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND

CAUTION

THAT THE SIZE OF THE BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. SEE THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS”OF THIS BOOK FOR INSTRUCTIONS.

NEVER PURGE A GAS LINE INTO

INLET PRESSURE TAP

THE COMBUSTION CHAMBER.

WARNING

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 water solution, or other approved method.

GAS VALVE

This furnace has a 24-volt gas valve. It has ports for measuring supply and

OUTLET PRESSURE TAP

manifold gas pressure. The valve body contains a pressure regulator to maintain proper manifold gas pressure.

A control switch 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 36.

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

Page 39

LP CONVERSION

IMPORTANT: LP gas from trucks used to transport liquid-based fertilizers can contain chemicals that will damage the furnace. Verify that your gas supplier does not use the same truck to transport materials other than LP.

For LP conversion, a new gas valve is required. The new gas valve is included in the LP kit. The correct LP orifices should be selected based on the altitude of the installation (see chart below). Orifices included in the kit are for sea level to 2000 ft. (1.15mm) and 3000 to 4000 ft. (1.10mm) The LP Gas Valve Kit is FP19. Orifices for elevations 4000 ft. and above must be ordered. Refer to Table 7.

CAUTION

ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. SEE THE SECTION TITLED “HIGH ALTITUDE INSTALLATIONS”OF THIS BOOK FOR INSTRUCTIONS.

NOTE: Furnace conversion to LP gas

must be performed by a qualified installer, service agency or the gas supplier.

To change the gas valve and orifice

spuds for either conversion to LP or for

levation:

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

2. Replace the orifice spuds.

3. For LP conversion ONLY, Remove the gas valve.

4. Reassemble in reverse order. In LP applications, use the new gas valve provided in the LP conversion kit.

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

6. Turn the gas supply back on and check for proper operation, leaks and manifold pressure. See Figures 37 and 39.

NOTE: Orifices in the kit are sized for a heating value of 2500 BTU per cubic ft. for LP.

ORIFICE ORDERING INFORMATION

Orifice sizes are selected by adding the 2-digit drill size required in the orifice part number. Drill sizes available are 39 through 64; metric sizes available

1.10mm (-90) and 1.15mm (-91):

Orifice Part Number 62-22175-(drill size)

Example 1: # 60 drill size orifice required Part # 62-22175-60

Example 2:

1.15mm drill size orifice required Part # 62-22175-91

NOTE: Do not

TABLE 7

Altitude burner) 15000 Size

0 to 2000 ft. 15000 1.15 mm

2000’-3000’ 13200 1.15 mm

3000’-4000’ 12600 1.10 mm

4000’-5000’ 12000 #58

5000’-6000’ 11400 #59

6000’-7000’ 10800 #60

7000’-8000’ 10200 #62

8000’-9000’ 9600 #63

9000’-10000’ 9000 #64

plug or drill out orifices.

BTU Input (per Orifice

(factory)

SETTING GAS PRESSURE

The maximum gas supply pressure to the furnace should be 10.5" w.c. natural gas, or 13" w.c. LP gas. The

inimum supply gas pressure to the

m 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.

CAUTION

Supply Gas Pressure Measure-ment.

A line pressure tap is on the input side of the gas valve. See Figure 37.

1. With gas shut off to the furnace at the manual gas stop 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" - 10.5" w.c. for natural gas.

B. 11" - 13" w.c. for LP gas.

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

6. Replace the pressure tap plug before turning on the gas. Turn on gas and check for leaks.

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 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 6 and 8. With LP gas, have the LP supplier adjust the line pressure at the regulator.

Manifold Gas Pressure Measurement. Natural gas manifold pressure should

Page 40

IGURE 37

ANIFOLD PRESSURE TAP

ANIFOLD

RESSURE

P TAP

FIGURE 38

TYPICAL GAS VALVE

INLET PRESSURE TAP

HIGH FIRE MANIFOLD PRESSURE ADJUSTMENT

LOW FIRE PRESSURE MANIFOLD ADJUSTMENT

OUTLET PRESSURE TAP

TABLE 8

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

be 3.5" w.c.; LP gas manifold pressure should be 10" w.c. Only

small variations on gas pressure should be made by adjusting the pressure regulator.

1. With the gas shut off at the anual gas stop, remove the

m pressure tap plug in the gas manifold or the gas valve outlet. See Figure 37.

2. Connect a U-Tube manometer to

his pressure tap. See Figure 39.

3. Turn on the gas supply and

operate the furnace in high heat mode.

4. Note or adjust the manifold gas

pressure to give:

A. 3.5" w.c. for natural gas high fire.

B. 10" w.c. for LP gas high fire.

5. To adjust the pressure regulator

for high fire, remove the regulator cap located on the side of the regulator. See Figure 38.

6. Turn the adjustment screw

clockwise to increase pressure or counterclockwise to decrease pressure.

7. Securely replace the regulator

cap for high fire.

8. Operate the furnace in low

speed.

9. Note or adjust the manifold

pressure to give:

A. 1.7" w.c. for natural gas low fire.

B. 4.8" w.c. for LP gas low fire.

10. To adjust the pressure regulator for low fire, remove the regulator cap on the top of the regulator. See Figure 38.

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

12. Securely replace the regulator cap for low fire.

13. Verify pressures for high and low fire operation.

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

15. Replace the manifold pressure tap plug before turning on gas. Check for leak.

Example (LP): Input BTU requirement of unit, 120,000

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

Page 41

IGURE 39

YPICAL MANIFOLD PRESSURE READING

Page 42

ELECTRICAL WIRING

WARNING

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.

NOTE: Electric to furnace must be

supplied by commercial utility. Proper voltage is 110-125 volts.

WARNING

THE CABINET MUST HAVE AN UNINTERRUPTED GROUND ACCORDING TO THE LATEST EDITION OF THE NATIONAL ELECTRICAL CODE, ANSI/ NFPA70OR 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.

WARNING

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 over-current protection is 15 amperes.

Use a separate fused branch electrical circuit containing a properly sized fuse or circuit breaker. Route this circuit directly from the main switch box to an electrical disconnect that is readily accessible and located within site of the

furnace. Connect from the electrical disconnect to the junction box on the left side of the furnace, inside the blower compartment. For the proper connection, refer to the appropriate wiring diagram located on the inside

over of the furnace control box and in

c these instructions.

NOTE: UPFLOW MODELS ONLY

The electrical junction box may be moved to the right side if necessary. A

nockout is provided. Seal the opposite

k hole with plug provided.

NOTE: L1 (hot) and N (neutral) polarity must be observed when making field connections to the furnace. The ignition control may not sense flame if L1 and Neutral are reversed. When L1 and Neutral are reversed, a diagnostic code of 6 blinks followed by a pause and 6 blinks will be displayed on the control

FIGURE 40

LINE VOLTAGE CONNECTIONS

UT ELECTRONIC CONTROLS 1095-201 CONTROL BOARD

board “Status” L.E.D. See Figure 40.

Make all electrical connections in

ccordance with the latest edition of

a the National Electrical Code ANSI/NFPA70 and local codes having jurisdiction.

These may be obtained from:

National National Fire Protection

Batterymarch Park Quincy, MA 02269

CSA CSA - International 178 Rexdale Blvd. Etobicoke (Toronto), Ontario

Canada M9W, 1R3

Electric Code

Association, Inc.

Standards

Page 43

IGURE 41

HERMOSTAT WIRING OPTIONS

2 HEAT - 1 COOL

HEAT, 1 COOL

OPTION A) TIMED STAGING W/1

( TAGE HEAT T-STAT (AFTER F3507

ATE CODE (AUGUST 2007)

2 HEAT - 2 COOL

THERMOSTAT

NOTE: Do not use 24 volt control wiring smaller than No. 18 AWG. (Refer to Table 9.)

See Figure 41 for thermostat wiring options.

A single- or two-stage thermostat may be used, however, a two-stage thermostat is recommended for optimum performance.

The room thermostat must be compatible with the integrated furnace control on the furnace. Generally, all thermostats that are not of the “current robbing” type are compatible with the integrated furnace control being used.

Install the room thermostat in accordance with the instruction sheet in the box with the thermostat. Run the thermostat lead wires inside the control compartment. Connect the thermostat 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, lighting fixtures, radiation from fireplace, rays of sun, lamps, television, radios or air streams from registers. Refer to the instructions packed with the thermostat for best anticipator adjustment or selection. Locate the thermostat approximately five feet up from the floor.

HEAT ANTICIPATOR SETTINGS

If a current reading taken at the thermostat is not performed, an initial setting of .15 amps is recommended.

(OPTION B) 100% HEAT ALWAYS -- NO TIMED STAGING

1 HEAT, 1 COOL

FIELD-INSTALLED OPTIONAL ACCESSORIES

Adjust as needed to improve comfort level.

ISOLATION RELAY

IMPORTANT: NOT ALL ELECTRONIC

NIGHT SETBACK THERMOSTATS ARE COMPATIBLE WITH THE FURNACE CONTROL SYSTEM. SOME MAY REQUIRE AN ISOLATION RELAY.

If an isolation relay is needed, install it as close to the control board as possible. Use a single-pole, singlethrow relay with a 24 volt operating coil. The relay contacts should be designed for 24 volt loads.

Connect one end of the operating coil to the thermostat “W” terminal. Connect the other end of the coil to the “C” terminal on the control board.

➢ Connect a jumper from the coil terminal connected to the thermostat to one of the normally open relay contacts.

➢ Connect the other side of the normally open relay contacts to the control board “W” terminal if using a two stage thermostat. Connect that one side of the normally open relay contacts to the control board “W2” terminal if using a single stage thermostat.

When the thermostat calls for heat, it powers the 24 volt operating coil. This

closes the relay contacts and conducts power from terminal 3 and 4 to terminal “W” on the control board and starts the furnace ignition sequence. See Figure 42.

➢ NOTE: Use of an isolation relay with the two stage furnace is not normally needed.

ELECTRONIC AIR CLEANER

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 during a normal heat sequence after the blower has turned on.

NOTE: Maximum current of 1.0 Amp for each option.

ALTERNATE (LEFT SIDE) DRAIN KIT - (-)XGY-H01 (DOWNFLOW MODELS ONLY)

Page 44

TABLE 9

FIELD WIRE SIZE FOR 24 VOLT CONTROL CIRCUITS

THERMOSTAT

➀ Wire length equals twice the run distance

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

FIGURE 42

ISOLATION RELAY

SOLID COPPER WIRE - AWG

3.0 16 14 12

2.5 16 14 12

2.0 18 16 14

0 100 150

LOAD - AMPS

ENGTH OF RUN - FEET ➀

FURNACE TWINNING INSTALLATIONS

NOTE: Run furnaces as individual

furnaces before trying to twin or when troubleshooting.

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 UT Electronic Controls 1095-204 integrated control boards.

➀ Only twin identical furnaces with

identical control boards.

➁ Furnaces must have same heating

and blower capacity.

➂ Only bottom returns can be used.

(Upflow models only)

➃ No more than two furnaces (a pair)

can share the same supply and return.

NOTE: Duct system must be adequate to provide correct airflow to each furnace for supply and return.

IMPORTANT: Twinning furnaces must operate off the same phase of power.

ST-A0804-01

It should be noted that both blowers will run simultaneously when there is a call for heating, cooling or fan.

The status LED will display blink code 5 if twinning is not set up properly (refer to Troubleshooting diagram in the back of this manual).

IMPORTANT: Only two furnaces on a single thermostat.

UT ELECTRONIC CONTROLS 1095-201 or 204

TWO-STAGE TWINNING OPERATION USING A SINGLE-STAGE THERMOSTAT

A two-stage thermostat will give the most optimum performance. The furnace (when twinned) can operate using a single-stage thermostat.

OPTION A: To run both units together as a single-stage furnace with NO staging (100% high heat always) wire the two furnaces together as shown in Figure 43.

Both controls must have jumper P6 in the “TWIN” position (see Figure 48).

Both controls must have jumper P7 in the “5” or “7” position (see Figure 48).

OPTION B: Both controls must have jumper P6 in the “TWIN” position (see Figure 48).

Both controls must have jumper P7 in the “5” or “7” position (see Figure 48).

For the first fire or twelve minutes of operation, the furnace will run at low fire. If the thermostat does not satisfy in fire or twelve minutes, the furnaces will automatically switch to high fire and will run on high fire until the thermostat is satisfied. See Figure 43 for the wiring diagram for this configuration.

TWO-STAGE OPERATION

(See Figure 45)

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," "W1," “W2,”

“Y,” and "TWIN" terminals to counterparts on each control.

d. Both control boards must have

jumper P6 in the “TWIN” position (see Figure 48).

Both controls must have jumper P7 in the “NONE” position (see Figure 48).

Page 45

IGURE 43

T Electronic Controls 1095-201 IFC, TWINNING CONNECTION -- SINGLE STAGE OPERATION

Page 46

IGURE 44

UT ELECTRONIC CONTROLS 1095-202 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION

Page 47

FIGURE 45

UT ELECTRONIC CONTROLS 1095-202 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION

Page 48

0+ HIGH ALTITUDE

9 INSTRUCTIONS

NATURAL GAS

CAUTION

INSTALLATION OF THIS FURNACE AT ALTITUDES ABOVE 2000 FT (610 m) SHALL BE IN ACCORDANCE WITH

OCAL CODES, OR IN THE ABSENCE

L OF LOCAL CODES, THE NATIONAL FUEL GAS CODE, ANSI Z223.1/NFPA 54 OR NATIONAL STANDARD OF CANADA, NATURAL GAS AND PROPANE INSTALLATION CODE, CAN B149.1.

INSTALLATION OF THIS APPLIANCE AT OR ABOVE 5000 FT (1525 m) SHALL BE MADE IN ACCORDANCE WITH THE LISTED HIGH ALTITUDE CONVERSION KIT AVAILABLE WITH THIS FURNACE.

CAUTION

ELEVATIONS ABOVE 2000 FT REQUIRE THAT THE FURNACE INPUT RATING BE ADJUSTED AND THAT THE SIZE OF THE BURNER ORIFICES BE RE-CALCULATED BASED ON ELEVATION AND GAS HEATING VALUE. THE BURNER ORIFICES MAY (OR MAY NOT) NEED TO BE CHANGED. THE FOLLOWING EXAMPLES SHOW HOW TO DETERMINE IF AN ORIFICE CHANGE WILL BE NECESSARY AND HOW TO DETERMINE THE NEW ORIFICE SIZE.

IN CANADA, AS AN ALTERNATE TO SIZING THE BURNER ORIFICE, THE MANIFOLD GAS PRESSURE MAY BE ADJUSTED. THIS METHOD IS COVERED LATER IN THIS SECTION. THIS METHOD OF ADJUSTING MANIFOLD PRESSURE MAY ONLY BE USED IN CANADIAN INSTALLATIONS.

34" 90 Plus furnaces installed at high elevations require the installation of a high altitude kit for proper operation. The high altitude kit consists of a high altitude pressure switch that replaces the pressure switch attached to the induced draft blower.

IGH ALTITUDE KIT

Installer must make necessary burner orifice and pressure switch changes as indicated in the table below:

(-)GRK/(-)GRL PRESSURE SWITCH CHANGES

IGH ALTITUDE SET POINT SET POINT

INPUT

45,000 RXGY-F18 -1.08 NO CHANGE

0,000 RXGY-F18 -1.08 NO CHANGE

6 75,000 (N) N/A NO CHANGE NO CHANGE

5,000 (W) RXGY-F18 -1.08 NO CHANGE

0,000 RXGY-F20 -1.15 NO CHANGE

9 105,000 N/A NO CHANGE NO CHANGE

20,000 RXGY-F21 -0.50 -0.30

IT NO. HIGH FIRE LOW FIRE

Alternately, furnaces can be ordered from the factory already converted for high altitude elevations. The factory option for high altitude elevations would be ordered as a 278 option (example; a 105k BTU upflow furnace which is factory converted for high altitude elevations would have the model number (-)GRK-10EZAJS278 These factory converted furnaces come with a pressure switch for highaltitude elevations already attached. Also, different burner orifices are installed at the factory which are one drill size smaller (#51 DMS) than standard (-)GRK gas furnaces (#50

(-)GTK PRESSURE SWITCH CHANGES

INPUT

60,000 RXGY-F29 -1.0 -0.8

5,000 (N) RXGY-F30 -0.8 -0.6

7 75,000 (W) RXGY-F30 -0.8 -.06

0,000 RXGY-F31 -0.9 -.06

9 105,000 RXGY-F32 -0.7 -.04

20,000 RXGY-F33 -0.4 -0.3

IT HIGH FIRE LOW FIRE

IGH ALTITUDE

NOTE: Orifices are no longer supplied

with kit.

The pressure switch must be installed at elevations above 5000 ft. Elevations above 2000 ft. require the furnace to be de-rated 4% per thousand feet.

The necessary high altitude kits to use with (-)GRK/(-)GRL & (-)GTK furnace models are listed below:

DMS). The smaller orifice is installed to accommodate for average heating values expected in most high altitude areas and a required 4% per thousand feet reduction in input as specified by the National Fuel Gas Code (NFGC). Specific orifices should always be recalculated for all high altitude installations as outlined below. Orifices should be changed, if necessary, based on gas heating value and elevation.

NOTE: Factory installed orifices are calculated and sized based on a sea level Natural Gas heating value of 1075 BTU per cubic ft. Regional reduced heating values may nullify the need to change orifices except at extreme altitudes.

The following are examples of orifice

High Altitude Kit (-)GRK/(-)GRL Furnace Inputs

45,000, 60,000

RXGY-F18

(17” cabinets)

& 75,000

(21” cabinet) BTU’s RXGY-F20 90,000 (21”) RXGY-F21 120,000 (24”)

High Altitude Kit (-)GTK Furnace Inputs

RXGY-F29 60,000 (17”) RXGY-F30 75,000 (17” & 21”) RXGY-F31 90,000 (21”) RXGY-F32 105,000 (21”) RXGY-F33 120,000 (24”)

NOTE: 278 Option Code is available on (-)GRK/(-)GRL models only.

sizing using the National Fuel Gas Code Appendix F. For a simplified estimation of orifice size based on heating value and elevation, use Tables 8 and 10, however calculations are the best method.

Example: 900 BTU/ft

Regional

Natural Gas Heating Value

I / H = Q 15000 / 900 = 16.68 ft

/hr

I = Sea Level input (per burner): 15000 H = Sea Level Heating Value: 900 Q = 16.68 ft3Natural Gas per hour.

From Table F.1 of National Fuel Gas Code Handbook, 2002 (3.5” w.c. column) Orifice required at Sea Level: #48

From Table F.4 of National Fuel Gas

Code Handbook, 2002

Orifice required at 5000 ft. elevation (4% de-rate per thousand ft.): #50

Orifice required at 8000 ft. elevation (4% de-rate per thousand ft.): #51

TABLE 10

Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)

IMPORTANT: 90 Plus Models only. Do not use this chart for any 80 Plus Models.

Burner Input (per burner) 15,000 BTU @ Sea Level

Annual Avg. Heat

Value (btu per ft

Sea level 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to

)

to 1999 ft 2999 ft 3999 ft 4999 ft 5999 ft 5999 ft 7999 ft 8999 ft 850 900

1000 1075 1170

47 48 48 49 49 49 50 50 48 49 49 49 50 50 50 51 49 50 50 50 51 51 51 52 50 51 51 51 51 52 52 52 51 51 52 52 52 53 53 53

Page 49

8000-8999 9000-9999

7000-7999

6000-6999

5000-5999

4000-4999

3000-3999

2000-2999

1000-1999

0-999

ELEVATION CHART (NFG recommended orifice based on 4% derate for each 1000 foot of elevation, based

on the intersection of the orifice required at Sea Level and the elevation required below)

Value at

per Burner

15,000 Btu’s

90 Plus Heat

Cubic

Foot at

3.5" W.C.

Sea Level

46 18.57 808 46 46 47 47 47 48 48 49 49 50

47 17.52 856 47 47 48 48 49 49 49 50 50 51

48 16.36 917 48 48 49 49 49 50 50 50 51 51

Sea

Size

Level

Orifice

NATURAL GAS QUICK REFERENCE CHART FOR ORIFICE SELECTION, AT 3.5" W.C. AND APPROXIMATE FINAL FIRING RATES

TABLE 11

90 Plus ONLY models with 15,000 Btu's per Burner. DO NOT USE THIS CHART FOR ANY 80 PLUS MODEL.

SUPPLEMENTAL ORIFICE SIZE CHART

49 15.2 987 49 49 50 50 50 51 51 51 52 52

15,000 14,400 13,800 13,200 12,600 12,000 11,400 10,800 10,200 9,600

Final Firing Rate per Burner

51 12.77 1175 51 51 51 52 52 52 52 53 53 53

50 13.92 1078 50 50 51 51 51 51 52 52 52 53

burner capacity by the Cubic Foot value for the Heat Value. Once you have either the Cubic Foot Value or the Heat Value you can estimate the Sea

NOTE:

Heat Value at Sea Level, for the location of the installation, is available from the Natural Gas Supplier to that site. Orifices for all altitudes are based

All calculations are performed by using the first three columns of information only. Before beginning any calculations, determine the

individual burner Btu size and heating value at Sea Level for the installation site. Each value shown in the Heat Value column is per

burner at 3.5" W.C.

on Sea Level values.

Divide the individual burner capacity (15,000 for 90 plus) by the Heat Value for the site to determine the Cubic Foot value at Sea Level, or divide

these two points on the chart above.

Level orifice for the site. To select the corresponding high altitude orifice, locate the site elevation on the chart above and the orifice required at Sea

Level from your calculation in the first column. The correct high altitude orifice that must be installed in each individual burner is the intersection of

Page 50

TABLE 12

IMPORTANT: 90+ MODELS ONLY. DO NOT USE THIS CHART

OR ANY 80 PLUS MODELS.

P GAS ORIFICE DRILL SIZE (4% PER 1000 FT DE-RATE)

Altitude Input (per burner) 15000 Orifice Size

0 to 2000 ft 15000 1.15 mm (factory)

2001 to 3000 13200 1.15 mm

3001 to 4000 12600 1.10 mm*

4001 to 5000 12000 #58*

5001 to 6000 11400 #59**

6001 to 7000 10800 #60**

7001 to 8000 10200 #62**

8001 to 9000 9600 #63**

9001 to 10000 9000 #64**

** : -GRL-07 and -GRL-10 models use 1.15mm orifice

** : -GRL-07 model uses 1.15mm orifice

** : -GRL-10 model uses 1.10mm orifice

Example: 1050 BTU/ft3Regional Natural Gas Heating Value

I / H = Q 15000 / 1050 = 14.63 ft.

I = Sea Level input (per burner): 15000 H = Sea Level Heating Value: 1050 Q = 14.28 ft.

Natural Gas per hour.

From Table F.1 of National Fuel Gas Code Handbook, 2002 (3.5” w.c. column) Orifice required at Sea Level: #50 From Table F.4 of National Fuel Gas

Code Handbook, 2002

Orifice required at 5000 ft. elevation (4% de-rate per thousand ft.): #51 Orifice required at 8000 ft. elevation (4% de-rate per thousand ft.): #52

LP GAS AT HIGH ALTITUDE ELEVATIONS

LP Gas is a manufactured gas that has consistent heating value across most regions.

The NFGC guidelines are used with the following exception:

The recommended LP Gas high altitude orifice selections differ slightly in that the NFGC LP orifice chart, as they are not accurate for Rheem products. The National Fuel Gas Code LP orifices are based on an 11" of water column pressure at the orifice, which differs from Rheem products that use 10" of water column at the orifice. This difference requires a deviation from the NFGC orifice size recommendations. The Sea Level input should still be reduced by 4% per thousand ft. and the orifice size must be selected based on the reduced input selection shown in Table 12.

ALTERNATE METHOD FOR CANADIAN

HIGH-

ALTITUDE DERATE

In Canada, unless an orifice change is specifically mandated by local codes, an alternate method of altitude deration through a reduction in manifold pressure is acceptable as

escribed in Table 13.

The information in Table 13 is based on a heating value of 1000 BTU per cubic feet of natural gas, and 2500 BTU per cubic feet of LP gas.

IMPORTANT: Actual input rates must be measured on-site with manifold pressure adjustment to ensure that an actual 10% reduction in input rate is

ORIFICE ORDERING INFORMATION

IMPORTANT: Do not plug or drill out

orifices.

Orifice sizes are selected by adding the 2-digit drill size required in the orifice part number. Drill sizes available are 39 through 64; metric sizes available

1.10mm (-90) and 1.15mm (-91):

Orifice Part Number 62-22175-(drill size)

Example 1: #60 drill size orifice required Part # 62-22175-60

Example 2:

1.15mm drill size orifice required Part # 62-22175-91

TABLE 13

ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATE IMPORTANT: 90+ MODELS ONLY. DO NOT USE THIS CHART FOR ANY 80 PLUS MODELS.

NATURAL GAS LP GAS

ORIFICE

ALTITUDE

0’ - 2000’

2001’ - 4500’

INPUT

45,000 60,000 75,000

90,000 105,000 120,000

40,500

54,000

67,500

81,000

94,500 108,000

OUTPUT

40,500 54,000 67,500 81,000 94,500

108,000

36,450 48,600 60,750 72,900 85,050 97,200

FIGURE 46

MANIFOLD PRESSURE-CHANGE LABEL

THE MANIFOLD PRESSURE OF THIS APPLIANCE HAS

BETWEEN 2,000 FEET AND 4,500 FEET ELEVATION.

MANIFOLD

SIZE

PRESSURE

#50

3.5” W.C.

#51

3.0” W.C.

BEEN FIELD ADJUSTED TO OBTAIN THE CORRECT INPUT RATING FOR INSTALLATION AT ALTITUDES

achieved.

Once this field adjustment has been made, the label shown in Figure 46 must be affixed in a conspicuous location on the front of the furnace cabinet:

NOTE: This label is supplied in the information packet shipped with each furnace.

ALTITUDE

0’ - 2000’

2001’ - 4500’

INPUT

45,000 60,000 75,000

90,000 105,000 120,000

40,500

54,000

67,500

81,000

94,500 108,000

OUTPUT

40,500 54,000 67,500 81,000 94,500

108,000

36,450 48,600 60,750 72,900 85,050 97,200

ORIFICE

SIZE

1.15mm

1.10mm

MANIFOLD PRESSURE

10” W.C.

7.6” W.C.

LA PRESSION DU DISTRIBUTEUR D’ALIMENTATION

DE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIN

D’OBTENIR LA BONNE PUISSANCE D’ENTRÉE POUR

UNE INSTALLATION ENTRE 2000 ET 4500 PIEDS

D’ALTITUDE.

92-24399-01-01

Page 51

START-UP PROCEDURES

A gas furnace’s firing rate, temperature rise and operation should be checked after installation. During this process we recommend that doors and windows be opened, smoke alarms disabled temporarily, as furnaces may have some residual smoke and odor upon initial operation through the first heating cycle. We do all we can to control our manufacturing processes, but it is possible to have this issue on certain sizes and models on occasion. Failure to follow this caution could result in a nuisance smoke (fire call) or other smoke or odor complaint from the customer.

DIRECT SPARK IGNITION LIGHTING INSTRUCTIONS

This appliance is equipped with a direct spark ignition device. This device lights the main burners each time the room thermostat (closes) calls for heat. See lighting instructions on the furnace.

During initial start-up, it is not unusual for odor or smoke to come out of any room registers. It is recommended to ensure proper ventilation by opening windows and doors, before initial firing.

The furnace has a negative pressure switch that is a safety during a call for heat. The induced draft blower must pull a negative pressure on the heat exchanger to close the negative pressure switch. The induced draft blower must maintain at least the negative pressure switch set point for the furnace to operate. If the induced draft blower fails to close or maintain the closing of the negative pressure switch, a “no heat call” would result.

WARNING

TO START FURNACE

1. BE SURE THAT THE MANUAL GAS STOP HAS BEEN IN THE “OFF” POSITION FOR AT LEAST FIVE MINUTES. DO NOT ATTEMPT TO MANUALLY LIGHT THE MAIN BURNERS. FAILURE TO FOLLOW THIS WARNING CAN CAUSE A

FIRE OR AN EXPLOSION RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

2. Set the room thermostat to the lowest setting.

3. Remove furnace panel.

4. Turn the gas control knob to the “ON” position, or set the gas control switch to the “ON” position.

5. Securely replace furnace panel.

6. Turn on the manual gas stop and the electrical power.

7. Set the room thermostat to “Heat” and adjust to desired room temperature.

8. Complete installation checklist.

WARNING

SHOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF, SHUT OFF THE MANUAL GAS STOP TO 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.

IGNITOR PLACEMENT, ALIGNMENT & LOCATION

Ignition failure may be a result of improper ignitor alignment caused during a service call or other work done to the furnace in the field. When performing any work on the burner, heat exchanger, etc., the technician must check alignment of the spark ignitor. Misalignment of the ignitor could cause a failure to light or rough ignition. The correct ignitor alignment is shown in Figure 47.

Sequence of operation with a single stage heat thermostat NOTE: Single-stage operation is

determined by the position of the jumper at position P7 of the control board. Options are 5 minutes between first and second stage or 12 minutes between first and second stage (see Figure 48).

Do not leave jumper at P7 in the “NONE” position when using a single-

stage thermostat with the timed staging feature. If the jumper is left on “NONE”, the furnace will never reach high heat (100% heat).

For single-stage operation, “W” from the thermostat must be connected to “W” on the furnace control.

See the section of this book titled “Electrical Wiring – Thermostat” for a wiring diagram showing how to connect a thermostat (see Figure

41). a. Connect the “W” terminal on the

thermostat to the “W” terminal on the IFC. Do not connect any wire to “W” on IFC when using a singlestage thermostat.

b. When there is a call for heat, the

“R” and “W2” contacts close and the IFC runs a self check routine to verify that both of the pressure switch contacts are open. The limit switch contacts are constantly monitored.

c. The induced draft motor starts on

high until the low and high pressure switch contacts close (a maximum of 60 seconds), and then runs for a 30-second prepurge. After the 30-second prepurge, the spark ignitor energizes and the high stage of the gas valve opens, lighting the burners.

d. After the gas valve energizes, the

remote flame sensor must prove ignition for one second using the process of flame rectification. If the burners do not light or flame is not sensed, the system goes through another ignition sequence. It does this up to 4 times.

e. The IBM starts on low speed 20

seconds after the burners light and flame is sensed. The induced draft motor and gas valve switch to low speed. The furnace operates on low fire for 12 minutes and then, if the thermostat is not satisfied, shifts to high fire, causing the draft inducer to go to high speed, the

FIGURE 47

UPFLOW OPTIMUM IGNITOR LOCATION

DOWNFLOW/HORIZONTAL OPTIMUM IGNITOR LOCATION

Page 52

gas valve to 100% and the main blower goes to high-fire heating speed.

f. When the thermostat cycle ends, the

gas valve de-energizes, and the burners go out.

g. The draft inducer will continue

running for a 10 second post purge.

h. The main blower will run for for the

user-defined blower-off delay (this timing is field adjustable, for 90, 120 150, or 180 seconds at Jumper P6 on the furnace control board). See Figure 48 for switch settings.

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

a. If flame is not sensed within 8

seconds after the gas valve energizes, the valve and the ignitor are deenergized. The induced draft motor will, stop momentarily, and then restart to check PS operation.

b. The ignition process goes through

three more tries.

c. If there is no ignition after the fourth

trial, the furnace goes into soft lockout for one hour.

d. The sequence repeats after a one

hour delay and continues repeating until ignition is successful or the call for heat is terminated.

e. To reset the lockout, break power

either at the thermostat or at the unit disconnect switch for 30 seconds. The furnace will then go through another set of trials for ignition.

f. If flame is established and maintained

during the trial for ignition period and flame is lost, the gas valve is deenergized, the draft inducer stops after a 10-second post-purge. The blower motor runs at the high-fire or low-fire heating speed (depending on state when flame was lost) until it completes the blower-off delay. When the blower-off delay is over, the control initiates another ignition trial period by starting the inducer for the pre-purge. The control will recycle up to 5 flame losses (4 re-cycles) within a single call for heat before going into lockout.

TO SHUT DOWN FURNACE

1. Set the room thermostat to its lowest setting.

2. Shut off the gas to main burners by setting the gas control switch to the “OFF” position, or by turning the manual gas stop closed.

Sequence of operation with two stage thermostat

See the section of this book titled “Electrical Wiring - Thermostat” for a wiring diagram showing how to connect a thermostat.

Connect W1 on thermostat to W on IFC. Connect W2 on thermostat to W2 on IFC.

Call for 1st stage heat

a. R and W thermostat contacts close

and the IFC runs a self check routine. After the IFC verifies that both sets of pressure switch contacts are open, the induced draft motor starts on high until both pressure switch contacts close (a maximum of 60 seconds).

b. After a 30 second pre-purge the spark

igniter energizes and the gas valve (high stage) opens, lighting the burners.

c. After the burners light, the remote

flame sensor must prove ignition. If the burners do not light or flame cannot be proven, the system goes through another ignition sequence. It does this up to 4 times.

d. Twenty seconds after flame sense,

the main blower energizes on low speed, the gas valve drops to low fire, and the inducer drops to low speed. The furnace continues to run on low until the call for heat is satisfied or the second-stage contacts close. If the first-stage call for heat is satisfied the gas valve de-energizes and the induced draft motor continues running for a 10 second post purge time. The main blower runs for the user-defined blower-off delay (this timing is field adjustable at Jumper P6). See Figure 48 for switch settings.

Call for 2nd stage heat after 1st stage

R and W2 thermostat contacts close, calling for 2-stage heat. The induced draft motor then switches to high speed and the high pressure switch contacts will close. The gas valve switches to high fire and the main blower switches to high-fire heating speed.

2nd stage heat satisfied, 1st stage heat still required.

R and W2 thermostat contacts open (W1 to R remains closed). The induced draft motor switches to low speed, the main blower motor switches to low-fire heating speed and the gas valve changes to low. The furnace continues to run in this mode until the first-stage heat call is satisfied. The system will shut down as noted in “d,” under first-stage call for heat.

Call for second-stage heat with no other existing heat call present.

a-c. Same operation as call for first-stage

heat

FIGURE 48

TWO-STAGE, 80 PLUS IFC JUMPER SELECTIONS

d. Main blower starts on high speed

20 seconds after gas valve energizes. The furnace continues to run on high until the W2 contacts open. If W2 and W1 open at the same time (both high & low stages are satisfied), the gas valve de-energizes and the inducer continues to run for a 10second post-purge. The main blower runs for the user selected blower-off delay. See Figure 48 for switch settings.

NOTE: Under certain conditions the furnace may alternate between low and high fire continuously. This operation is based on demand from the thermostat and is controlled by the thermostat. This operation is normal and can be expected at times to maintain optimum comfort.

SETTING BLOWER TIMING

The UT ELECTRONIC CONTROLS IFC has four quick connect terminals for connecting the motor speed leads. These are:

1. FAN SPEED/LOW — motor runs on this speed when the thermostat is in the “FAN ON” position or when in low-fire heating speed heat.

2. COOL — connect desired cooling speed.

3. HEAT — connect desired highfire heating speed.

4. HEAT/COOL — connect desired speed when high heating and cooling speed are the same.

High fire and low fire blower timing are the same.

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

Page 53

DJUSTING OR CHECKING

URNACE INPUT

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

ATURAL GAS

1. When adjusting the furnace input, he high fire input should be

t checked. The high fire manifold pressure should be 3.5’ W.C. Follow these steps to be sure the furnace is high fire mode:

. With a single stage thermostat, the

furnace runs for 12 minutes on low fire before shifting to high fire. To be certain that it is on high fire, jump terminals “W” and “W2” on the control board in the blower compartment.

b. With a two stage thermostat, set

the thermostat to its highest setting to keep the furnace operating in the high fire mode.

2. To adjust high fire manifold

pressure, remove the adjustment cover screw on the outlet end of the gas valve and turn the adjustment screw clockwise to increase the pressure and counterclockwise to reduce the pressure. Replace the cover screw securely. See Figure 38.

3. The low fire manifold pressure

should be 1.7” W.C. As mentioned above, the furnace remains in the low fire mode for 12 minutes upon a heat call with a single stage thermostat. With a two stage thermostat, disconnect the thermostat lead to the “W2” terminal on the IFC and the furnace will remain in the low fire mode. To adjust the pressure, remove the regulator cover, on top of the valve, and adjust as noted under Step 2, above. After the adjustment replace the screw cover securely.

NOTE: Use a 3/32” allen wrench or small-blade screwdriver for making the pressure adjustment.

TABLE 14

METER TIME

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

INPUT SIZE

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

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

60,000 TEN 9010 0 10 24 11 0 25 0

75,000 TEN 7 12 80819 8 48 20 0

0,000 TEN 60640 70720 16 40

05,000 TEN 5 10 5 40 60620 14 20

20,000 TEN 4 30 50510 5 30 12 30

METER

ONE 1 12 1 20 1 23 1 28 3 20

ONE 0 54 101316230

ONE 0 44 0 48 0 50 0 53 20

ONE 0 36 0 40 0 42 0 44 1 40

ormula: Input BTU/HR =

LP GAS

On furnaces using LP gas, the LP gas supply pressure must be set between

11.0" and 13.0" W.C. by means of the tank or branch supply regulators. Set the furnace manifold pressure at 10" W.C. on high fire and 4.8" W.C. on low fire at the gas control valve. For elevations up to 8,000 feet, rating plate inputs apply. For high altitudes (elevations 5,000 ft. and over), the orifice spud must be changed.

QUIPPED FOR NATURAL OR LP GAS

EATING VALUE OF GAS BTU PER CU. FT.

00 1000 1040 1100 2500 (LP)

NE 0 31 0 34 0 36 0 38 1 26

NE 0 27 0 30 0 31 0 33 1 15

eating Value of Gas (BTU/FT

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

x 3600 x correction factor

)

SETTING INPUT RATE

The furnace is shipped from the factory with #50 orifices. With -278 option code, furnaces will be shipped with #51 orifice for elevations of 5000 ft. 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.

Proper input is important to prevent over firing of the furnace beyond its design-rated input. NEVER SET

INPUT ABOVE THAT SHOWN ON THE RATING PLATE.

To check furnace input:

1. Make certain that all other gas appliances are shut off, with the exception of pilot burners.

2. Start the furnace

3. Time the meter to measure the time required to burn one cubic foot of gas. See Table 14.

Page 54

AIR FLOW

The importance of proper air flow over the heat exchanger cannot be over

mphasized.

CAUTION

IT IS IMPORTANT THAT EACH DUCT SYSTEM BE SIZED AND INSTALLED FOR THE SPECIFIC APPLICATION BY PROPERLY APPLYING THE APPROPRIATE INDUSTRY ACCEPTED

TANDARD. IF LESS THAN MINIMUM

S STANDARDS ARE APPLIED, THE EQUIPMENT USER COULD EXPECT TO EXPERIENCE HIGHER UTILITY BILLS, MAJOR COMPONENT FAILURE, VARYING DEGREES OF AIR NOISE OR OTHER UNSATISFACTORY ISSUES, OVER WHICH THE EQUIPMENT MANUFACTURER HAS NO CONTROL.

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 49.

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

3. Operate the furnace. High fire and low fire heating modes have the same temperature rise range.

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 50.

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.

RISE RANGE IS 40 TO 70 DEGREES, THE MOST IDEAL RISE WOULD BE 55 DEGREES (THE MIDDLE OF THE RISE RANGE). IN ALL

PPLICATIONS, THE INSTALLER

UST ADJUST THE TEMPERATURE

M RISE TO THIS "MIDDLE" POINT AS CLOSELY AS POSSIBLE. ALSO, THE TEMPERATURE RISE SHOULD NEVER BE ABOVE OR FALL BELOW THE STATED RANGE. DOING SO COULD CAUSE DAMAGE TO THE HEAT EXCHANGER OR INTERMITTENT OPERATION WHICH

OULD CAUSE INJURY OR DEATH

C AND WILL VOID THE MANUFACTURER'S WARRANTY FOR THIS PRODUCT.

FIGURE 50

TYPICAL FURNACE NAME PLATE

AIR CONDITIONING DIVISION

FORT SMITH, ARKANSAS

IGURE 49

TEMPERATURE RISE MEASUREMENT

WARNING

THE MEASURED TEMPERATURE RISE SHOULD BE AS CLOSE TO THE MIDDLE OF THE STATED RANGE AS POSSIBLE. FOR EXAMPLE, IF THE

Page 55

GAS FURNACE (DIRECT DRIVE) INSTRUCTIONS FOR CHANGING BLOWER SPEED

WARNING

DISCONNECT THE ELECTRICAL

UPPLY TO THE FURNACE

S 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 IFC), speeds may be changed if necessary to fit requirements of the particular installation. Reconnect the unused motor leads to “M1” or “M2” on the Integrated Furnace Control Board (IFC). 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: Any combination of motor taps to the IFC can be used provided the temperature rise is within the specified range when in high or low heat and that there is enough airflow in the cooling mode. When changing the motor tap speeds, the temperature rise must be checked on both heat speeds and temperature drop in cooling must be checked again after the change is made to ensure that the temperatures are within the required specified ranges.

Page 56

TABLE 15

90 PLUS AIR FLOW PERFORMANCE

FM @ ESP

MODEL BLOWER/

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

(-)GRL-04 11 X 7 /

⁄

PEED

PFLOW MODELS

LOW 805 780 760 720 685 645 605

M-LO 920 885 850 810 775 730 690

-HI 1140 1110 1085 1045 1010 950 890

HIGH 1360 1320 1280 1235 1195 1140 1080

-)GRL-07(A) 11 X 7 /

(

⁄

OW 780 745 710 675 640 595 555

-LO 880 850 825 785 750 702 655

M *M-HI 1090 1050 1010 970 925 875 825 HIGH 1300 1255 1210 1160 1110 1055 1005

(-)GRL-06 11 X 7 /

⁄

LOW 770 740 710 675 645 605 570

*M-LO 880 845 815 790 760 715 670

-HI 1060 1025 990 960 925 880 835

IGH 1260 1215 1175 1135 1100 1040 985

(-)GRL-07(B) 12 X 7 /

(-)GRL-09** 12 X 11 /

⁄

LOW 1105 1095 1080 1050 1030 1010 990

M-LO 1290 1275 1260 1220 1195 1170 1140

-HI 1480 1435 1415 1390 1370 1300 1255

IGH 1705 1665 1615 1570 1540 1475 1400

LOW 1235 1210 1185 1150 1120 1075 1035

-LO 1490 1465 1440 1405 1375 1315 1255

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

(-)GRL-10** 12 X 11 /

⁄

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

(-)GRK-12** 11 X 10 /

⁄

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

DOWNFLOW/HORIZONTAL MODELS

(-)GTK-06 11 X 7 /

⁄

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

(-)GTK-07(A) 11 X 7 /

⁄

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

(-)GTK-07(B) 11 X 7 /

⁄

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

(-)GTK-09 12 X 11 /

⁄

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

(-)GTK-10 12 X 11 /

⁄

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

(-)GTK-12 11 X 10 /

⁄

LOW 1285 1250 1215 1235 1260 1230 1200 *M-HI 1590 1565 1540 1505 1475 1425 1375

M-HI 1840 1820 1800 1750 1700 1645 1590

HIGH 2315 2250 2185 2110 2040 1965 1890

* Factory-Set High Heating speed

⁄2" Cabinet Size

A = 17 B = 21" Cabinet Size NOTE: CFM valves represent furnace-only airflow ratings. **Where the maximum air flow is above 1800 CFM, we recommend both sides or 1 side and bottom to be used to maximize air flow.

Page 57

I528

HORIZONTAL

I413

MAINTENANCE

WARNING

THESE INSTRUCTIONS ARE

NTENDED AS AN AID TO

I QUALIFIED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE

NSTRUCTIONS THOROUGHLY

I BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE, POSSIBLY RESULTING IN FIRE, ELECTRICAL

TABLE 16

ILTER SIZES

UPFLOW FILTER SIZES

URNACE INPUT BOTTOM SIDE

IDTH MBTUH SIZE SIZE

45, 60, 75A 15

/2"

21" 75B, 90, 105 19

/2"

FURNACE INPUT

IDTH MBTUH

/2"

21" 75B, 90, 105 12" X 20" 2

/2" 120 14" X 20" 2

120 22

DOWNFLOW/HORIZONTAL FILTER SIZES

60, 75A 12" X 20" 2

X 25" 15

/4"

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

X 25" 15

/4"

IZE

SHOCK, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

QUANTITY

X 25" 1

UANTITY

FIGURE 51

ILTER LOCATIONS

DOWNFLOW

AIRFLOW

HORIZONTAL

Page 58

IGURE 52

FILTER AND ROD ASSEMBLY

FILTER SUPPORT ANGLE

FILTER

FILTER ROD

JACKET

I332

JACKET

DRILL (2) 3

/16" DIA.

HOLES

8.000

4.875

1.531

CUT-OUT AND DRILL DETAIL

JACKET

ANGLE

FILTER ROD SUPPORT ANGLE

FILTER SUPPORT ANGLE (SEE ANGLE DETAIL)

ATTACH WITH SHEET METAL SCREWS (2 REQÕD)

ANGLE DETAIL

ROD & FILTER SUPPORT ANGLE ASSEMBLY

BOTTOM PANEL REMOVAL

ILTER LOCATION

JACKET ASSEMBLY

REMOVE SOLID BOTTOM

CREW

S (2) REQ’D.

SOLID BOTTOM REMOVAL

UPFLOW BOTTOM RETURN

NOTE:

ACK FLANGE OF SOLID BOTTOM FITS

B UNDERNEATH JACKET. SIDES AND FRONT FLANGES FIT OVER FLANGES ON JACKET.

AIRFLOW

FILTER

ACKET ASSEMBLY

FILTER & ROD LOCATION

ILTER

F ROD

UPFLOW SIDE RETURN

SOLID BOTTOM

NOTE: Use both side returns for 1800 CFM or more.

AIRFLOW

FILTER SUPPORT ANGLE (SEE ANGLE DETAIL) AE-61883-01

FILTER ROD SUPPORT ANGLE AE-60520-01

SOLID BOTTOM

FILTER ROD SUPPORT ANGLE AE-60520-01

FILTER SUPPORT ANGLE AE-61883-01

SOLID BOTTOM

FILTER

FILTER ROD 45-24095-01

Page 59

WARNING

DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE.

AILURE TO DO SO CAN CAUSE

F ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

FILTER MAINTENANCE

Have your qualified installer, service

gency or the gas supplier instruct you

a on how to access your filters for regular maintenance.

FILTERS

Filter application and placement are critical to airflow, which may affect the heating and cooling system performance. Reduced airflow can shorten the life of the system’s major components, such as motor, limits, heat exchanger, evaporator coil or compressor. Consequently, we recommend that the return air duct system have only one filter location. The most common location will be inside the furnace or a filter base. For systems with a return air filter grille or multiple filter grilles, can have a filter installed at each of the return air openings. Your HVAC professional can show you where they have installed the filter(s).

If high efficiency filters or electronic air cleaners are used in the system, it is important that the airflow is not reduced to maximize system performance and life. Always verify that the system’s airflow is not impaired by the filtering system that has been installed, by performing a temperature rise and temperature drop test.

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

DO NOT DOUBLE FILTER THE RETURN AIR DUCT SYSTEM. DO NOT FILTER THE SUPPLY AIR DUCT SYSTEM.

NOTE: Some filters must be resized to fit certain units and applications. See Table 16 and Figures 51 & 52.

1. 21” - 75,000(B), 90,000 & 105,000 BTUH units require removal of a

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

2. 24.5” - 120,000 BTUH unit requires removal of a 7" segment of filter and frame to get the proper width for a side filter.

CAUTION

DO NOT OPERATE THE SYSTEM WITHOUT FILTERS. A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE

SUPPLY REGISTERS. ANY 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 AND MAY RESULT IN UNPLEASANT ODORS.

LUBRICATION

IMPORTANT: DO NOT attempt to lubricate the bearings on the blower motor or the induced draft blower

otor. Addition of lubricants can reduce

m 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.

ANNUAL INSPECTION

• The furnace should operate for many years without excessive scale buildup 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.