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

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

INSTALLATION INSTRUCTIONS

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

RGRA/RGRJ AND RGTA/RGTJ SERIES

92-23531-16-09

SUPERSEDES 92-23531-16-08

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

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

WARNING

Recognize this symbol as an indication of Important Safety Information!

— Do not store or use gasoline or other

flammable vapors and liquids, or other combustible materials in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

• Do not return to your home until authorized by the gas supplier or fire department.

— DO NOT RELY ON SMELL ALONE TO

DETECT LEAKS. DUE TO VARIOUS FACTORS, YOU MAY NOT BE ABLE TO SMELL FUEL GASES.

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

— Improper installation, adjustment, alteration,

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

WARNING

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

WARNING

FOR YOUR SAFETY

INSTALLATION CHECK LIST

REFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

Adequate pipe size Correct supply pressure (during furnace operation) Manifold pressure No gas leaks

ELECTRICAL

115 V.A.C. supply (Single Circuit) Polarity observed Furnace properly grounded Adequate wire size

FURNACE INSTALLATION

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

DUCT STATIC PRESSURE

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

CONDENSATE LINE

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

and clamped Freeze protection (if necessary)

VENTING – DIRECT VENT

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

TERMINATIONS – DIRECT VENT

VERTICAL

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

VERTICAL – CONCENTRIC (RXGY-E02)

Intake – 12" min. above roof/snow level

HORIZONTAL – STANDARD (RXGY-D02, -D03)

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

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

Correct relationship – exhaust to intake Above anticipated snow level

HORIZONTAL – CONCENTRIC (RXGY-C01)

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

VENTING – NON-DIRECT VENT

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

TERMINATION – NON-DIRECT VENT

VERTICAL

12" min. above roof/snow level

HORIZONTAL – STANDARD

12" min. above grade/snow level

HORIZONTAL – ALTERNATE

Above anticipated snow level

IMPORTANT: TO INSURE PROPER INSTALLATION AND OPERATION OF THIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TO ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIR THIS PRODUCT. UPON UNPACKING OF THE FURNACE, INSPECT ALL PARTS FOR DAMAGE PRIOR TO INSTALLATION AND START-UP.

CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

GENERAL INFORMATION

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

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

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

FIGURE 1 UPFLOW FURNACE

FIGURE 2 DOWNFLOW/HORIZONTAL FURNACE

Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code” (NFPA54) and requirements or codes of the local utilities or other authorities having jurisdiction. This is available from the following:

National Fire Protection

Association, Inc. Batterymarch Park Quincy, MA 02269

American Gas Association 1515 Wilson Blvd. Arlington, VA 22209

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

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

2425262728

ITEM ITEM

NO. PART NAME NO. PART NAME

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

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

ITEM ITEM

NO. PART NAME NO. PART NAME

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

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

COVER GROUND

10 11 12 13 14 15 16

2223

GAS INLET

OPTIONAL COMBUSTION AIR INLET

I409 I409

GAS INLET

PVC

GENERAL INFORMATION

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

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

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

FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR. THIS IS TO PREVENT THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO, THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES. FAILURE TO FOLLOW THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

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

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

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

a. be sure the air passes over

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

b. install a parallel duct system

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

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

WARNING

IMPORTANT: Install the furnace level. If it is not level,

condensate cannot drain properly, possibly causing furnace shut down.

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

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

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

LOCATION REQUIREMENTS AND CONSIDERATIONS

FIGURE 3 HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP

DRAIN PIPE

HEAT TAPE

TRAP

I526

a. The heat tape must be UL

listed.

b. The heat tape must be

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

c. The heat tape should be rated

at 5 or 6 watts per foot at 120V.

IMPORTANT: Support this unit when installed. Since this

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

IMPORTANT: If installing in a utility room, be sure the door is wide enough to:

a. allow the largest part of the

furnace to pass; or

b. allow any other appliance

(such as a water heater) to pass.

7. IMPORTANT: This furnace is

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

CLEARANCE ACCESSIBILITY

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

FIGURE 4 HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

GAS PIPE

TRAP

EXHAUST FAN

ELECTRICAL CONDUIT

INTAKE VENT

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

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

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

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

Upflow furnaces are shipped with a bottom closure panel installed. When bottom return air is used, remove the panel by removing the two screws attaching the panel to the front base angle. See Figure 5.

WARNING

I522

SITE SELECTION

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

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

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

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

WARNING

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

FIGURE 5 BOTTOM PANEL REMOVAL

JACKET ASSEMBLY

SOLID BOTTOM

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

SCREW (2) REQ’D.

JACKET ASSEMBLY

FILTER

FILTER ROD

SOLID BOTTOM REMOVAL

FILTER & ROD LOCATION

ADS 5422-01

FIGURE 6 CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS

UPFLOW MODELS MINIMUM CLEARANCE (IN.)

LEFT RIGHT SHIP

MODEL A B C D E F

SIDE SIDE

BACK TOP FRONT VENT

WGTS

04 17

/2 16

/32 15

/8 21513

/32 00012*0 111

06 17

/2 16

/32 15

/8 21513

/32 00012*0 117

07 17

/2 16

/32 15

/8 21513

/32 00012*0 123

09 21 19

/32 19

/8 218

/217

/32 00012*0 148

10 21 19

/32 19

/8 218

/217

/32 00012*0 152

12 24

/2 23

/32 22

/8 22220

/32 00012*0 160

I392

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

FIGURE 7 CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS

DOWNFLOW MODELS MINIMUM CLEARANCE (IN.)

LEFT RIGHT SHIP

MODEL A B C D E F

SIDE SIDE

BACK TOP FRONT VENT

WGTS

04 17

/32

216

00012*0 111

06 17

/2 16

/32 15

/8 216

/813

/8 00012*0 117

07 17

2 16

32 15

8 216

813

8 00012*0 123

09 21 19

32 19

16 220

817

8 00012*0 148

10 21 19

32 19

16 220

817

8 00012*0 152

12 24

2 23

32 22

8 223

820

8 00012*0 160

I393

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

➤ FIGURE 8 CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS

DOWNFLOW MODELS MINIMUM CLEARANCE (IN.)

LEFT RIGHT SHIP

MODEL A B C D E F

SIDE SIDE

BACK TOP FRONT VENT

WGTS

04 17

/2 16

/32 15

/8 216

/813

/8 00012*0 111

06 17

/2 16

/32 15

/8 216

/813

/8 00012*0 117

07 17

/2 16

/32 15

/8 216

/813

/8 00012*0 123

07 21 19

/32 19

/16 220

/817

/8 00012*0 123

09 21 19

/32 19

/16 220

/817

/8 00012*0 148

10 21 19

/32 19

/16 220

/817

/8 00012*0 152

12 24

/2 23

/32 22

/8 223

/820

/8 00012*0 160

I520

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

⁄8 DIA.

ALT. CONDENSATE

DRAIN

⁄8 DIA.

GAS

CONNECTION

TOP

LEFT SIDE FRONT

BOTTOM

RIGHT SIDE

⁄16

⁄64

⁄16

⁄8

⁄32

⁄16

⁄32

⁄16

⁄18

⁄32

⁄16

⁄4

⁄16

⁄8 DIA.

ALT. GAS

CONNECTION

⁄8 DIA.

CONDENSATE

DRAIN

COMBUSTION

AIR INLET

LOW VOLTAGE

RETURN

AIR

VENT OUTLET

⁄32

ELECT.

CONN.

⁄32

⁄4

SUPPL

⁄16

DUCTING

Proper air flow is required for the correct operation of this furnace. Too little air flow can cause erratic operation and can damage the heat exchanger. The duct system must carry the correct amount of air for heating and cooling if summer air conditioning is used.

Size the ducts according to acceptable industry standards and methods. The total static pressure drop of the air distribution system should not exceed 0.5" w.c.

NEVER ALLOW THE PRODUCTS OF COMBUSTION FROM THE FLUE TO ENTER THE RETURN AIR DUCTWORK OR THE CIRCULATED AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE WITH SHEET METAL SCREWS; AND JOINTS, TAPED. ALL OTHER DUCT JOINTS MUST BE SECURED WITH APPROVED CONNECTIONS AND SEALED AIRTIGHT. WHEN AN UPFLOW FURNACE IS MOUNTED ON A PLATFORM WITH RETURN THROUGH THE BOTTOM, IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE AND THE RETURN AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT OF THE FURNACE WITHOUT SAGGING, CRACKS, OR GAPS, AROUND THE BASE, PROVIDING A SEAL BETWEEN THE SUPPORT AND THE BASE.

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

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

IMPORTANT: Some high efficiency filters have a greater than normal resistance to air flow. This can adversely affect furnace operation. BE SURE TO CHECK AIR FLOW if using any filter other than the factoryprovided filter.

UPFLOW UNITS

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

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

do not remove the bottom base.

b. Cut an opening in the side or

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

c. Remove the bottom base if

using bottom return air.

NOTE: Where the maximum air flow is 1800 CFM or more, both sides or the bottom must be used for return air.

3. Connect the return duct or return air cabinet to the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

4. Be sure to have adequate

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

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

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

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

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

be rated for a minimum

temperature of 250

°F.

continuous.

DOWNFLOW UNITS

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

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

3. If installing on a combustible floor

and not using an air conditioning plenum, install the special

non-combustible floor base. See Figure 9.

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

4. Connect the furnace to the supply air plenum.

5. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

6. Be sure to have adequate

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

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

WARNING

FIGURE 9 COMBUSTIBLE FLOOR BASE

GENERAL INFORMATION

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

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

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

COMBUSTION & VENTILATION AIR

FOR FURNACE INSTALLATIONS.” Direct vent installations require a

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

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

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

IMPORTANT: The plastic combustion air and venting components are of Schedule 40 PVC. If using ABS

piping, ensure that the solvent cement is compatible for joining PVC to ABS components or use a mechanical connection that can withstand the vent temperatures and are corrosion resistant.

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

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

OVERTEMPERATURE SAFETY SWITCHES

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

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

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

REPLACE THESE SWITCHES ONLY WITH THE IDENTICAL REPLACEMENT PART.

EXISTING VENT SYSTEMS

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

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

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

2. Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage, restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

3. If practical, close all building doors, windows and all doors between the space where the appliances remaining connected to the common venting system are located. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

VENTING AND COMBUSTION AIR PIPING

WARNING

HORIZONTAL UNIT

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

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

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

3. Connect the furnace to the supply air plenum.

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

entraining combustion gases from an adjacent fuel-burning appliance.

5. Be sure to have adequate

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

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

CEMENTING JOINTS

Properly seal all joints in the PVC vent using the following materials and procedures.

PVC CLEANER-PRIMER AND PVC MEDIUM-BODY SOLVENT CEMENT

IMPORTANT:

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

1. Cut pipe end square. Chamfer edge of pipe. Clean fitting socket and pipe joint area of all dirt, grease and moisture.

2. After checking pipe and socket for proper fit, wipe socket and pipe with cleaner-primer. Apply a liberal coat of primer to inside surface of socket and outside of pipe. Read instructions included with the primer for proper application.

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

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

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

5. Wipe all excess cement from the joint with a rag. Allow 15 minutes before handling. Cure time varies according to fit, temperature and humidity.

NOTE: Stir the solvent cement frequently while using. Use a natural bristle brush or the dauber supplied with the can. The proper brush size is one inch.

IMPORTANT: For Proper Installation

DO NOT use solvent cement that has become curdled, lumpy or thickened.

DO NOT thin. Observe shelf precautions printed on containers.

For application below 32°F, use only low-temperature-type solvent cement.

4. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so the appliance will operate continuously.

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

6. After it has been determined that each appliance that remains connected to the common venting system properly vents (when tested as outlined above), return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conditions of use.

7. If improper venting is observed during any of the above tests, the common venting system must be resized. Refer to latest edition of the National Fuel Gas Code ANSI Z223.1, 1992 or the AGAGAMA venting tables for Category I furnaces.

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

JOINING PIPE AND FITTINGS

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

All pipe, fittings, solvent cement, primers and procedures must conform to American National Standard Institute and American Society for Testing and Materials (ANSI/ASTM) standards in the U.S.

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

PVC Primer and Solvent Cement ASTM-D2564

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

Procedure for Cementing Joints ASTM-D2855

IMPORTANT: The plastic combustion air and venting components are of PVC. If using ABS piping, ensure that the solvent cement is compatible for joining PVC to ABS components or use a mechanical connection that can withstand the vent temperatures and are corrosion resistant.

WARNING

NON-DIRECT FURNACE INSTALLATIONS

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

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

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

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

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

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemical storage areas.

Exposure to the following substances in the combustion air supply (but not limited to the following) will also require OUTDOOR AIR for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine-based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry curing and acid washing materials

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

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

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

EXAMPLE 1: FURNACE LOCATED IN AN UNCONFINED SPACE

Using indoor air for combustion.

An unconfined space must have at least 50 cubic feet for each 1,000 BTUH of the total input for all appliances in the space. Here are a few examples of the room sizes required for different inputs. The sizes are based on 8-foot ceilings.

BTUH Minimum Sq. Feet Typical Room Size

Input With 8' Ceiling With 8' Ceiling

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

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

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

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

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

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

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

EXAMPLE 2: FURNACE LOCATED IN A CONFINED SPACE

A confined space (any space smaller than shown above as “unconfined”) must have openings into the space which are located in accordance with the requirements set forth in the following subsections A and B. Size the openings by how they are connected to the heated area or to the outside, and by the input of all appliances in the space.

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

A. USING INDOOR AIR FOR

COMBUSTION

IMPORTANT: Air should not be taken from a heated space with a fireplace, exhaust fan or other device that may produce a negative pressure.

If combustion air is taken from the heated area, the openings must each have at least 100 square inches of free area. Each opening must have at least one square inch of free area for each 1,000 BTUH of total input in the space. Here are some examples of typical openings required.

COMBUSTION AND VENTILATION AIR

WARNING

BTUH Free Area

Input Each Opening

45,000 100 square inches

60,000 100 square inches

75,000 100 square inches

90,000 100 square inches

105,000 105 square inches

120,000 120 square inches

B. USING OUTDOOR AIR FOR

COMBUSTION

IMPORTANT: Do not take air from an attic space that is equipped with power ventilation.

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

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

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

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

BTUH Free Area Round Pipe

Input Each Opening Size

45,000 11.25 square inches 4"

60,000 15.00 square inches 5"

75,000 18.75 square inches 5"

90,000 22.50 square inches 6"

105,000 26.25 square inches 6"

120,000 30.00 square inches 6"

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

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

Here are some typical sizes.

BTUH Free Area Round Pipe Input Each Opening Size

45,000 22.50 square inches 6"

60,000 30.00 square inches 6"

75,000 37.50 square inches 7"

90,000 45.00 square inches 8"

105,000 52.50 square inches 8"

120,000 60.00 square inches 9"

Method 2 One permanent opening, located within 12 inches of the top of the enclosure, shall be permitted

FIGURE 11 AIR FROM ATTIC/CRAWL SPACE

FIGURE 12 OUTSIDE AIR USING A HORIZONTAL DUCT

FIGURE 10 AIR FROM HEATED SPACE

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

TOTAL

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

GAS

WATER

HEATER

FURNACE

GAS

WATER

HEATER

GAS

WATER

HEATER

FURNACE

12" MAX.

12"

MAX.

1 SQ. INCH PER 4000 BTUH INLET AIR

OUTLET AIR 1 SQ. INCH

PER 2000 BTUH

INLET AIR 1 SQ. INCH

PER 2000 BTUH

1 SQ. INCH PER

4000 BTUH

OUTLET AIR

OUTLET AIR IN ATTIC MUST BE ABOVE INSULATION

OPTIONAL 1 SQ. INCH PER 4000 BTUH INLET AIR

VENTILATED ATTIC GABLE OR SOFFIT VENTS

GABLE

VENT

FIGURE 13 COMBUSTION AIR FITTING

UPFLOW DOWNFLOW/HORIZONTAL

2" PVC DOUBLE ELBOW

TOP OPTION

EXHAUST

2" PVC ELBOW

SIDE OPTION

2" PVC DOUBLE ELBOW*

COMBUSTION AIR

EXHAUST

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

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

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

I337 I336

where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance. The opening shall directly communicate with the outdoors or communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors, and shall have a minimum free area of:

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

BTUH Free Area Round Pipe

Input Each Opening Size

45,000 15.00 square inches 4"

60,000 16.67 square inches 5"

75,000 25.00 square inches 6"

90,000 30.00 square inches 6"

105,000 35.00 square inches 7"

120,000 40.00 square inches 7"

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

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

Combustion air openings must not be restricted in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

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

CONNECTION TO FURNACE

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

ELEVATED SINGLE PIPE ALTERNATE TEE TERMINATION

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

NON-DIRECT VENT INSTALLATION

GUIDELINES

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

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

1. Vertical piping is preferred.

2. All horizontal piping must slope upward a minimum of

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

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

IMPORTANT: DO NOT COMMON VENT WITH ANY OTHER APPLIANCE. DO NOT INSTALL IN THE SAME CHASE OR CHIMNEY WITH A METAL OR HIGH TEMPERATURE PLASTIC PIPE FROM ANOTHER GAS OR FUELBURNING APPLIANCE UNLESS THE REQUIRED MINIMUM CLEARANCES TO COMBUSTIBLES ARE MAINTAINED BETWEEN THE PVC PIPE AND OTHER PIPES.

FIGURE 14 TEE TERMINAL – FOR STANDARD HORIZONTAL SINGLE PIPE INSTALLATION

FIGURE 15 ALTERNATE HORIZONTAL TERMINATION FOR NON-DIRECT VENT INSTALLATIONS

12"

FROM

24"

MAX.

PIPE SUPPORT STRAP

OUTSIDE WALL

VENT

12"

12" MIN. ABOVE

GRADE OR

SNOW LEVEL

I198

NUMBERS OF ELBOWS

45° OR 90°

Medium / Long Radius ONLY

1-2 3-4 5-6

45,000 2”

Standard 60 55 50

Alternate 55 50 45

2”

Standard 35 30 25

Alternate 30 25 20

60,000

3”

Standard 120 120 115

Alternate 120 120 110

2”

Standard 20 15 10

Alternate NR NR NR

75,000

3”

Standard 110 105 95

Alternate 80 70 65

90,000 3”

Standard 90 85 75

Alternate 60 50 45

105,000 3”

Standard 80 75 65

Alternate 50 40 35

120,000 3”

Standard 70 65 55

Alternate 40 30 25

NOTES:

1. *N.R. - NOT RECOMMENDED.

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

➤ A 45° DEGREE ELBOW IS CONSIDERED ONE ELBOW.

FURNACE

INPUT

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

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

VENT PIPE INSTALLATION

PIPE SIZE

TERMINATION

“rub-a-tex” insulation may also be used as long as there is no heat tape applied to the vent pipe. For horizontal runs where water may collect, wrap the vent pipe with self-regulating 3 or 5 watt heat tape. The heat tape must be U.L. listed and installed per the manufacturer’s instructions.

6. The minimum vent pipe length is 5 feet.

STANDARD INSTALLATIONS

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

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

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

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

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

NON-DIRECT VENT TERMINATION LOCATION REQUIREMENTS

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

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

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

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

2. The vent shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard.

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

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

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

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

CAUTION

FIGURE 16 NON-DIRECT VENT TERMINATION CLEARANCES

I133

SOFFIT VENTS

FRESH AIR INTAKE

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

INSIDE CORNER

ELECTRIC METER

10* RECOMMENDED

12( MIN.

UP TO10**

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

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

1. Do not terminate under any kind of patio or deck. If running the vent under a deck, insulate it to insure no condensate freezes and blocks the pipe.

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

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

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

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

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

DIRECT VENT INSTALLATIONS

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

ventilation or combustion air openings are required.

IMPORTANT: The plastic combustion air and venting components are of Schedule 40 PVC. If using ABS piping ensure that the solvent cement is compatible for joining PVC to ABS components or use a mechanical connection that can withstand the vent temperatures and are corrosion resistant.

INSTALLATION GUIDELINES

1. Vertical piping is preferred.

2. All horizontal piping must slope upward a minimum of

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

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

IMPORTANT: DO NOT COMMON VENT WITH ANY OTHER APPLIANCE. DO NOT INSTALL IN THE SAME CHASE OR CHIMNEY WITH A METAL OR HIGH TEMPERATURE PLASTIC PIPE FROM ANOTHER GAS OR FUEL-BURNING APPLIANCE UNLESS THE REQUIRED MINIMUM CLEARANCES TO COMBUSTIBLES ARE MAINTAINED BETWEEN THE PVC PIPE AND OTHER PIPES.

5. All vent runs through unconditioned spaces where belowfreezing temperatures are expected should be insulated with 1-in. thick, medium-density, foil-faced fiberglass. An equivalent “arm-a-flex” or “rub-atex” insulation may also be used as long as there is no heat tape applied to the vent pipe. For horizontal runs where water may collect, wrap the vent pipe with self-regulating 3 or 5 watt heat tape. The heat tape must be

WARNING

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

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

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

6. The minimum vent pipe length is 5 feet.

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

FURNACE

INPUT

PIPE SIZE

TERMINATION

VENT TERMINATION KIT RECOMMENDED

(RXGY-D0* Kits for

Horizontal Venting Only)

1 - 2 3 - 4 5 - 6

NUMBER OF ELBOWS

45° or 90°

Medium / Long Radius ONLY

Standard RXGY-D02 65 60 55

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

55 50 45

Alternate RXGY-D02

Standard RXGY-D02 40 35 30

2” Concentric RXGY-C01/RXGY-E02

30 25 20

Alternate RXGY-D02

60,000

Standard RXGY-D03 120 120 120

3” Concentric RXGY-C01/RXGY-E02

110 105 100

Alternate RXGY-D03

Standard RXGY-D02 20 15 10

2” Concentric Not Recommended

NR NR NR

Alternate Not Recommended

75,000

Standard RXGY-D03 120 120 120

3” Concentric RXGY-C01/RXGY-E02

100 95 85

Alternate RXGY-D03

Standard RXGY-D03 110 105 95

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

50 40 35

Alternate RXGY-D03

Standard RXGY-D03 110 105 95

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

50 40 35

Alternate RXGY-D03

Standard RXGY-D03 105 100 90

120,000 3”

Concentric RXGY-C01/RXGY-E02

45 35 30

Alternate RXGY-D03

Alternate RXGY-D04 105 95 90

NOTES:

1. N.R. - NOT RECOMMENDED.

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

3. ➤ A 45 DEGREE ELBOW IS CONSIDERED ONE ELBOW.

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

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

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

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

➤ALTERNATE TERMINATIONS

ALTERNATE HORIZONTAL DIRECT VENT TERMINATIONS

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

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

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

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

COMBUSTION AIR FOR DIRECT VENT INSTALLATIONS

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

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

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

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

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

STANDARD TERMINATIONS

STANDARD VERTICAL TERMINATIONS

COMBUSTION AIR PIPING Use two medium-radius sweep

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

STANDARD HORIZONTAL TERMINATIONS

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

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

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

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

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

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

➤ IMPORTANT: All furnaces with

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

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

STANDARD VERTICAL TERMINATIONS

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

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

runs require 2

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

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

STANDARD HORIZONTAL TERMINATIONS

EXHAUST PIPING For direct vent systems the standard

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

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

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

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

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