Taylor RGFG Installation Instructions Manual

INSTALLATION INSTRUCTIONS

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

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!

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

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

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

in the vicinity of this or any other appliance.

— WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

• Do not return to your home 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. In the commonwealth of Massachusetts, installation must be performed by a licensed plumber or gas fitter for appropriate fuel.

ISO 9001:2008

FOR RGFG UPFLOW HIGH EFFICIENCY MODULATING CONDENSING GAS FURNACES

RGFG

MMOODDUULLAATTIINNG TTHHEERRMMOOSSTTAAT

IINNSSTTAALLLLAATTIIOON

SSEEEE PPAAGGEE 9922

MMOODDUULLAATTIINNGG

CCOOMMMMUUNNIICCAATTIINNGG

TTHHEERRMMOOSSTTAATT

IINNSSTTAALLLLAATTIIOONN

SSEEEE PPAAGGEE 110066

WARNING

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

T N

SUPERSEDES 92-24161-104-02

92-24161-104-03

IMPORTANT: All Rheem products

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

California's Proposition 65 requires warnings for products sold in California that contain, or produce, any of over 600 listed chemicals known to the State of California to cause cancer or birth defects such as fiberglass insulation, lead in brass, and combustion products from natural 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

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

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

TABLE OF CONTENTS

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

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

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

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY..............................................7

LOCATION REQUIREMENTS AND CONSIDERATIONS.......................................................................................8

CLEARANCE-ACCESSIBILITY......................................................................................................................9

SITE SELECTION...........................................................................................................................................9

DIMENSIONS AND CLEARANCE TO COMBUSTIBLES...........................................................................10

DUCTING.......................................................................................................................................................11

VENTING AND COMBUSTION AIR PIPING .........................................................................................................12

INSTALLATION WITH PRE-EXISTING VENT SYSTEMS..........................................................................12

JOINING PIPE AND FITTINGS....................................................................................................................12

CEMENTING JOINTS...................................................................................................................................13

NON-DIRECT VENT PIPE INSTALLATION...........................................................................................................14

DIRECT VENT PIPE INSTALLATION ....................................................................................................................18

CONCENTRIC TERMINATIONS..................................................................................................................20

CONDENSATE DRAIN / OPTIONAL NEUTRALIZER ..........................................................................................28

GAS SUPPLY AND PIPING....................................................................................................................................30

GAS VALVE...................................................................................................................................................31

LP CONVERSION.........................................................................................................................................33

ELECTRICAL WIRING............................................................................................................................................35

ACCESSORIES.......................................................................................................................................................37

ELECTRONIC AIR CLEANER......................................................................................................................37

HUMIDIFICATION AND DEHUMIDIFICATION............................................................................................37

OTHER ACCESSORIES ..............................................................................................................................39

TYPICAL WIRING ACCESSORIES FOR COMMUNICATING RESIDENTIAL SYSTEMS.................39

HIGH ALTITUDE INSTALLATIONS IN THE U.S....................................................................................................41

RGFG- HIGH ALTITUDE CONVERSION ....................................................................................................41

LP GAS AT HIGH ALTITUDE ELEVATIONS................................................................................................43

ZONING SYSTEMS......................................................................................................................................44

FURNACE INSTALLATION WITH NON-COMMUNICATING HIGH EFFICIENCY PREMIUM

COOLING OR HEAT PUMP SYSTEMS................................................................................................44

INTEGRATED FURNACE CONTROL ...................................................................................................................45

SEVEN SEGMENT DISPLAY.......................................................................................................................45

24 VAC THERMOSTAT INPUTS..................................................................................................................47

SPECIAL CONFIGURATION – COMM T-STAT AND NON-COMM CONDENSER..................................47

MEMORY CARD...........................................................................................................................................49

RULES FOR WRITING, DISTRIBUTION AND ARBITRATION OF MULTIPLE COPIES OF

FURNACE SHARED DATA FOR COMMUNICATING-CAPABLE FURNACES..............................49

REPLACING THE FURNACE CONTROL...................................................................................................51

DIPSWITCHES.............................................................................................................................................52

FURNACE OPERATION USING NON-COMMUNICATING MODULATING,

MODULATING AND TWO-STAGE T-STATS.....................................................................................55

COMMUNICATING SYSTEMS....................................................................................................................58

WIRING FOR COMMUNICATIONS...................................................................................................58

STARTUP FOR SYSTEMS CONFIGURED WITH COMMUNICATIONS........................................59

CONTINUOUS FAN OPERATION IN COMMUNICATING MODE...................................................60

ACTIVE FAULT CODES WITH COMMUNICATING SYSTEMS.......................................................60

FURNACE USER MENUS...........................................................................................................................60

STATUS 1............................................................................................................................................61

STATUS 2............................................................................................................................................63

2 WK HIST...........................................................................................................................................63

LIFE HIST............................................................................................................................................63

FAULT HISTORY.................................................................................................................................63

UNIT INFO...........................................................................................................................................63

SETUP.................................................................................................................................................63

DUAL-FUEL OPERATION............................................................................................................................65

START-UP PROCEDURES....................................................................................................................................66

SEQUENCE OF OPERATION.....................................................................................................................68

SETTING INPUT RATE................................................................................................................................68

MAINTENANCE.......................................................................................................................................................69

TROUBLESHOOTING CHART.........................................................................................................................72-73

NORMAL OPERATING CODES (TABLE 23)........................................................................................................74

FURNACE FAULT CODES WITH DESCRIPTIONS AND SOLUTIONS (TABLE 24)....................................75-90

WIRE DIAGRAM – STEPPER / SERVO MODULATING VALVE (FUEL CODES HA OR HB)...........................91

THERMOSTATS......................................................................................................................................................92

NON-COMMUNICATING THERMOSTATS.................................................................................................92

THERMOSTAT WIRING (WITH WIRING DIAGRAMS).........................................................................93-95

APPLICATIONS.......................................................................................................................................................96

MODULATING, TOUCH-SCREEN, NON-COMMUNICATING THERMOSTAT ((-)HC-TST412MDMS)....96

COMMUNICATING THERMOSTATS...................................................................................................................106

(-)HC-TST501CMMS PROGRAMMABLE COMMUNICATING THERMOSTAT......................................108

(-)HC-TST550CMMS FULL COLOR, PROGRAMMABLE COMMUNICATING THERMOSTAT.............112

VIEWING FURNACE USER MENUS WITH THE (-)HC-TST550CMMS THERMOSTAT.......................113

CHANGING FURNACE SETUP ITEMS ON THE (-)HC-TST550CMMS THERMOSTAT.......................114

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

SAFETY INFORMATION

IMPORTANT!

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

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

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of

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

a. In the event that the side wall 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”.

44..

INS

PECTION. T

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 equip-

ment is exempt from 248 CMR

5.08(2)(a)1 through 4:

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

he state or local gas

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

NEVER TEST FOR GAS LEAKS WITH AN OPEN FLAME. USE A COMMERCIALLY AVAILABLE SOAP SOLUTION MADE SPECIFICALLY FOR THE DETECTION OF LEAKS TO CHECK ALL CONNECTIONS, AS SPECIFIED IN GAS SUPPLY AND PIPING SECTION OF THESE TION INSTRUCTIONS.

WARNING

THIS FURNACE IS NOT APPROVED OR RECOMMENDED FOR INSTALLATION ON ITS BACK, WITH ACCESS DOORS FACING UPWARDS, OR WITH SUPPLY AIR DISCHARGING TO THE RIGHTHAND SIDE WHEN FACING THE FRONT OF THE FURNACE. SEE FIGURE 3 FOR PROPER INSTALLATION OF HORIZONTAL MODELS.

WARNING

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

WARNING

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

WARNING

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

WARNING

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

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATE AND TEMPERATURE RISE PER 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.

WARNING

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

WARNING

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

• 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.

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

WWHHEENN AA FFUURRNNAACCEE IISS IINNSSTTAALLLLEEDD

SO THAT SUPPLY DUCTS CARRY

CIRCULATED BY THE FUR-

AIR NACE 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.

NOTICE

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

NOTICE

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

WARNING

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

INSTALLATION CHECK LIST

REFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

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

ELECTRICAL

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

FURNACE INSTALLATION

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

DUCT STATIC PRESSURE

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

CONDENSATE LINE

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

and clamped

TERMINATIONS – DIRECT VENT

VERTICAL

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

VERTICAL – CONCENTRIC (RXGY-E03A)

Intake – 12" min. above roof/snow level

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

-D03A)

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

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

-D03A, -D04 OR -D04A)

Correct relationship – exhaust to intake Above anticipated snow level

HORIZONTAL – CONCENTRIC (RXGY-E03A)

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

VENTING – NON-DIRECT VENT (VERTICAL ONLY)

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

TERMINATION – NON-DIRECT VENT (VERTICAL ONLY)

12" min. above roof/snow level

Freeze protection (if necessary)

Neutralizer (if needed)

VENTING – DIRECT VENT

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

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

Model # Serial # Date of installation

HORIZONTAL – STANDARD

12" min. above grade/snow level

HORIZONTAL – ALTERNATE

Above anticipated snow level

GENERAL INFORMATION

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

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

• As non-direct, central forced air furnace taking combustion air from the installation area or using air ducted from the outside.

• IMPORTANT: Proper application, installation and maintenance of this

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

Install this furnace in accordance with the American National Standard Z223.1 – latest edition entitled “National Fuel Gas Code” (NFPA54, 90A and 90B) and requirements or codes of the local utilities or other authorities having jurisdiction. This is available from the following:

National Fire Protection

Association, Inc. Batterymarch Park Quincy, MA 02269

FIGURE 1

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

CSA International - U.S. 8501 East Pleasant Valley Road Cleveland, Ohio, 44131

Canadian installations must be installed in accordance with CSA, local installation codes and authorities having jurisdiction. CSA is available from:

CSA International - Canada 178 Rexdale Blvd. Etobicoke (Toronto), Ontario, Canada M9W-1R3

ITEM

NO. PART NAME

1 CONDENSATE TRAP

2 DOOR SWITCH

3 JUNCTION BOX

4 TRANSFORMER

5 PRESSURE SWITCH ASSEMBLY

6 EXHAUST TRANSITION

7 CONNECTOR

8 MAIN LIMIT

9 EXHAUST AIR PIPE

10 VENT CAP SHIPPING PLUG

11 FLAME SENSOR

12 OVERTEMPERATURE SWITCH

ITEM

NO. PART NAME

13 TOP PLATE

14 BURNER

15 IGNITER

16 COMBUSTION AIR INLET

17 GAS VALVE

18 INDUCED DRAFT BLOWER

19 POWER FACTOR CHOKE

20 INTEGRATED FURNACE CONTROL

21 BLOWER MOTOR

22 BLOWER HOUSING

23 INDUCER CONTROL MODULE

ST-A1156-01

IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR AIR QUALITY

Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality, it is important to have the proper balance between the air being supplied to each room and the air returning to the cooling and heating equipment.

Proper balance and sealing of the duct system improves the efficiency of the heating 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

2).

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

NOTICE

FIGURE 2

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

RECEIVING

Immediately upon receipt, all cartons and contents should be inspected for transit damage. Units with damaged cartons should be opened 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 edi-

tions are available from: “National Fire Protection Association, Inc., Batterymarch Park, Quincy, MA

02269.” These publications are:

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

• NFPA90A Installation of Air Conditioning and Ventilating Systems.

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

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

LOCATION REQUIREMENTS AND CONSIDERATIONS

GENERAL INFORMATION

CAUTION

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

WARNING

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

WARNING

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. Extend this auxiliary drain pan under any evaporator coil installed with the furnace and the open portion of the con-

densate drain assembly. See “Condensate Drain/Neutralizer” section for more details.

2. IMPORTANT: If using a cooling evaporator coil with this furnace. Be sure the air passes over the heat exchanger before passing over the cooling coil. The cooled air passing over the warm ambient air inside the heat exchanger tubes can cause condensation inside the tubes resulting in corrosion and eventual failure.

3. IMPORTANT: Install the furnace level. If it is not level, condensate cannot drain properly, possibly causing furnace shut down.

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

4. IMPORTANT: If this furnace is installed in a garage, attic or any other unconditioned space, a selfregulating heat tape must be installed around the condensate trap and along the entire length of the condensate drain in the unconditioned space.

The heat tape should meet the following requirements:

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

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

c. The heat tape should be rated

at 3 or 5 watts per foot at 120V.

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

a. allow the largest part of the

furnace to pass; or

b. allow any other appliance

(such as a water heater) to pass.

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

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

FIGURE 3

REMOVING SHIPPING BRACKET

92-24379-01

CLEARANCE ACCESSIBILITY

The design of forced air furnaces with models as listed in the tables under Figure 4 are certified by CSA Laboratories for the clearances to combustible materials shown in inches.

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

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

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

WARNING

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

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

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

CAUTION

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

LOCATE AND REMOVE THE SHIPPING BRACKET FROM THE SIDE OF THE BLOWER HOUSING BEFORE OPERATING UNIT. SEE FIGURE 3.

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

RGFG-09EZCMS RGFG-10EZCMS RGFG-12ERCMS

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. Vent from the furnace to the termination with minimal length and elbows.

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

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

FIGURE 4

PHYSICAL DIMENSIONS AND CLEARANCE TO COMBUSTIBLES, UPFLOW MODELS

A039201

RGFG

UPFLOW MODELS

AIRFLOW

NOTE: For 1800 or more CFM, both side

returns must be used when not using a

bottom return configuration.

AO39201

DUCTING

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

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

Size the ducts according to acceptable industry standards and methods. The total static pressure drop of the supply and return duct should not exceed 0.2" w.c.

WARNING

NEVER 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. SECURE ALL OTHER DUCT JOINTS WITH APPROVED CONNECTIONS AND SEAL AIRTIGHT. WHEN A FURNACE IS MOUNTED ON A PLATFORM WITH RETURN THROUGH THE BOTTOM, IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE AND THE RETURN AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE 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 airflow. This can adversely affect furnace operation. Be sure to check airflow if using any filter other than the factory-provided filter.

UPFLOW UNITS

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

WARNING

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

A SOLID METAL

2. Open the return air compartment. a. If using side return air, do not

remove the bottom base.

b. Cut an opening in the side .

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

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

c. Remove the bottom base, if

using bottom return air. Remove the panel by removing the two screws attaching the base to the front base angle. See Figure 5.

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

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

FIGURE 5

BOTTOM PANEL REMOVAL

ADS-5422-01

VENTING AND COMBUSTION AIR PIPING

GENERAL INFORMATION

WARNING

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

OVER TEMPERATURE SAFETY SWITCHES

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

WARNING

DO NOT JUMPER OVERTEMPERATURE OR ANY OTHER SAFETY SWITCHES! IF ONE OF THESE OVER TEMPERATURE SWITCHES SHOULD TRIP, CALL A QUALIFIED INSTALLER, SERVICE AGENCY OR THE GAS SUPPLIER. DO NOT RESET THE SWITCHES WITHOUT TAKING CORRECTIVE ACTION. FAILURE TO DO SO CAN RESULT IN CARBON MONOXIDE POISONING OR DEATH. IF THIS UNIT IS INSTALLED IN A CLOSET, THE DOOR MUST BE CLOSED WHEN MAKING THIS CHECK.

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

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. EXCEPTIONS INCLUDE

THE RXGY-G02, RXGY-G02C AND RXGY-E03A WHICH CAN BE MIXED WITH OTHER MANUFACTURER’S COMPONENTS PROVIDED THEY ARE CONSTRUCTED FROM LIKE MATERIALS.

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

INSTALLATION WITH PRE-EXISTING VENT SYSTEMS

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

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

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

2. Visually inspect the venting system 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.

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

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

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

JOINING PIPE AND FITTINGS

WARNING

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

In Canada, only approved vent materials, primers and solvents approved to ULC S636 must be used for venting.

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

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

CEMENTING JOINTS

EQUIVALENT VENTING – ASSIGNING VENT LENTGH TO

ELBOWS

This section applies to venting tables in both the NON-DIRECT and DIRECT VENT tables in this book. Vent tables are provided only in equivalent length and do not reference elbows or a maximum number of elbows. Instead, elbows are assigned a length as described below. The length determined for each elbow is subtracted from the max vent length in the tables to determine how much straight vent pipe (in ft) can still be used.

There are several different types of elbows that can be used for constructing a vent system. The drawings below show the dimensions of common ¼ bend and ¼ bend long sweep 90 degree elbows from ASTM 3311, Standard Specification for Drain, Waste and Vent (DWV) Plastic Fittings Patterns.

long sweep ¼ bend 90 degree (long radius) elbow has an equivalent length of 5 feet of straight pipe for either 2 or 3 inch plastic pipe. A standard 90° elbow has an equivalent length of 10 feet of pipe. This equivalent length can be used in circumstances where it might be necessary to lengthen the vent at the outside of the structure, such as in areas with large accumulations of snow in winter. Table 1 shows the equivalent lengths of different types of elbows:

Table 1

Fitting Type Equivalent Length

45° Standard Elbow 5 feet of pipe 90° Standard Elbow 10 feet of pipe 45° Long-Sweep Elbow 2-1/2 feet of pipe 90° Long-Sweep Elbow 5 feet of pipe

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

PVC CLEANER-PRIMER AND PVC MEDIUM-BODY SOLVENT CEMENT

NOTE: Follow vent manufacturer instructions for ULC S636 vent installations.

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

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

2. After checking pipe and socket for proper fit, wipe socket 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 INSTALLATION.

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 with new cement.

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

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)

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

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

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

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

EQUIVALENT VENTING

––

ASSIGNING VENT LENGTH TO ELBOWS

ASTM

SPECIFICATION

D2661

D2665

There are several different types of elbows that can be used for constructing a vent system. The drawings below show the dimensions of common 1/4 bend and 1/4 bend long sweep 90 degree elbows from ASTM 3311, Standard Specification for Drain, Waste and Vent (DWV) Plastic Fittings Patterns.

A long sweep 1/4 bend 90 degree (long radius) elbow has an equivalent length of 5 feet of straight pipe for either 2 or 3 inch plastic pipe. A standard 90° elbow has an equivalent length of 10 feet of pipe. This equivalent length can be used in circumstances where it might be necessary to lengthen the vent at the outside of the structure, such as in areas with large accumulations of snow in winter. Table 1 shows the equivalent lengths of different types of elbows:

With the equivalent length vent concept a vent system can be used any number of elbows and length of straight pipe as long as the maximum equivalent vent length is not exceeded.

Example: An RGFG-06 direct vent installation

needs a 31 foot long vent run with 5 elbows and 2 inch pipe.

31 feet of 2 inch pipe = 31

5 - 1/4 bend long sweep

elbows = 25

Since the maximum equivalent vent length for an RGFG-06 is 60 feet, this installation is acceptable.

If the same installation tried to use standard elbows: 31 feet of 2 inch pipe = 31

5 - standard 90 degree

TABLE 1

And this installation is not acceptable as it exceeds the 80 foot maximum listed for the RGFG-06 model.

equivalent feet

Total = 56

equivalent feet

= 50

equivalent feet

Total = 81

equivalent feet

NON-DIRECT VENT PIPE INSTALLATION

(FOR VERTICAL TERMINATIONS ONLY)

COMBUSTION AIR

WARNING

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

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

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

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

• Anti-static fabric softeners for clothes dryers

• Masonry acid washing materials

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

WARNING

ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE, CAN/CSA B149.1 (CANADA) AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN RESULT IN EXPLOSION, FIRE, PROPERTY DAMAGE, CARBON MONOXIDE POISONING, PERSONAL INJURY OR DEATH.

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

FURNACE 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. See Table 2.

TABLE 2

UNCONFINED SPACE DIMENSIONS

BTUH Minimum Sq. Feet Typical Room Size

Input With 8 foot Ceiling

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

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

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

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

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

If the open space containing the furnace is in a building constructed to severely limit outside air infiltration (contemporary energy efficient construction methods), 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.

FURNACE LOCATED IN A CONFINED SPACE.

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

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

ings must be sized by how they connect to the heated area or to the outside, and by the input of all appliances in the space.

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

TABLE 3

INDOOR AIR OPENING DIMENSIONS

BTUH Free Area

Input Each Opening

60,000 100 square inches

75,000 100 square inches

90,000 100 square inches

105,000 105 square inches

120,000 120 square inches

FIGURE 6

AIR FROM HEATED SPACE

A. USING INDOOR AIR FOR

COMBUSTION

IMPORTANT: DO NOT take air from

a heated space with a fireplace, exhaust fan or other device that may produce a negative pressure.

If combustion air is taken from the heated area (see Figure 6), the openings must each have at least

100 square inches of free area.

Each opening must have at least

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

the space. See Table 3.

B. USING OUTDOOR AIR FOR

COMBUSTION

IMPORTANT: Do not take air from

an attic space that is equipped with power ventilation.

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

Method 1 Two permanent openings, one 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 7, each opening shall have a minimum free area of 1 square inch for each 4000 BTUH of total appliance input rating in the enclosure. See Table 4.

A077501

TABLE 4

VERTICAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size

60,000 15.00 square inches 5"

75,000 18.75 square inches 5"

90,000 22.50 square inches 6"

105,000 26.25 square inches 6"

120,000 30.00 square inches 7"

b. Where communicating with out-

doors through horizontal ducts, each opening shall have a minimum free area of 1 square inch for each 2000 BTUH of total input rating of all equipment in the enclosure. See Table 5 and Figure 8.

TABLE 5

HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size

60,000 30.00 square inches 7"

75,000 37.50 square inches 7"

90,000 45.00 square inches 8"

105,000 52.50 square inches 9"

120,000 60.00 square inches 9"

Method 2 One permanent opening, located within 12 inches of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance. The opening shall directly communicate with the outdoors or communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors, and shall have a minimum free area of:

a. One square inch for each 3000

BTUH of the total input rating of all equipment located in the enclosure (see Table 6), and

Combustion air openings must not be restricted in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

FIGURE 7

AIR FROM ATTIC/CRAWL SPACE

A077601

FIGURE 8

OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

b. Not less than the sum of the

areas of all vent connectors in the confined space.

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

TABLE 6

VERTICAL OR HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Pipe

Input Each Opening Size 60,000 20.00 square inches 6" 75,000 25.00 square inches 6" 90,000 30.00 square inches 7"

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

A077701

INSTALLATION GUIDELINES

IMPORTANT: When installed as a non-

direct furnace, only vertical terminations are allowed. Do not use horizontal terminations when the furnace is installed with a non-direct vent.

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

7. The minimum vent length is 5 feet.

8. All piping through the roof is 2".

When using 3" pipe on 90, 105 and 120 kBtu furnaces, reduce to 2" within 18" of the inside of the roof.

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

pipe extending a minimum of 12 inches above the anticipated

maximum level of snow accumulation.

In Canada, the pipe must extend a minimum of 18” above the roof or maximum 24” above the roof without supports.

10. No screens may be used to cover combustion air or exhaust.

VVEENNTTIINNGG GGUUIIDDEELLIINNEESS -- NNoonn--DDiirreecctt VVeenntt

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

2. Use only medium or long radius

sweep elbows, such as PVC-DWV elbows.

3. Vertical vent piping is preferred.

4. Install all horizontal piping as follows:

• Slope horizontal vent piping

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

• Support horizontal vent piping at

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

5. Insulate all vent runs through unconditioned spaces where belowfreezing temperatures are expected, with 1" thick medium density, foil faced fiber glass or equivalent Rubatex/Armaflex insulation. For horizontal runs where water may collect and freeze, wrap the vent pipe with self-regulating, 3 or 5 Watt heat tape. The heat tape must be U.L. listed and installed per the manufacturer’s instructions.

6. All piping between the furnace and the roof penetration is 2" or 3" as specified in Table 7. Table 7 lists the maximum allowable exhaust vent pipe length for the number of elbows used, based on the furnace size.

IMPORTANT: Use Only standard vertical terminations when installing the modulating furnace as a nondirect vent appliance.

➤ TABLE 7 NON-DIRECT VENT APPLICATIONS

MAXIMUM ALLOWABLE LENGTH IN FEET OF EXHAUST PIPE

MAX EQUIVALENT VENT FOR UPFLOW RFGF FURNACES

(See Eq. Vent section on Page 13)

Model

2” Non-Direct Vent

3” Non-Direct Vent

RGFG-06EMCKS 80’ 80’ RGFG-07EMCKS 80’ 80’ RGFG-09EZCMS NR 80’ RGFG-10EZCMS NR 80’ RGFG-12ERCMS NR 80’

NOTES:

1. N.R. - NOT RECOMMENDED.

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

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

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

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

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

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

⁄2” CABINET WIDTH

* A = 17

B = 21” CABINET WIDTH

8. ALL HORIZONTAL VENTING MUST BE DONE WITH DIRECT VENTING (2-PIPE). FURNACES INSTALLED AS NON-DIRECT VENT MUST BE TERMINATED VERTICALLY.

DIRECT VENT PIPE INSTALLATION

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.

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

Therefore, no ventilation or combustion air openings are required.

INSTALLATION GUIDELINES

All exhaust piping must be installed in compliance with Part 7, “Venting of Equipment,” of the latest edition of the National Fuel Gas Code NPFA 54, 90A, 90B ANSI Z223.1-, CAN/CSA B149.1 (Canada), local codes or ordinances and these instructions.

2. Use only medium or long radius

sweep elbows.

NOTE: For all installations. Extend

the combustion air exhaust pipe a minimum of 18" vertically above the furnace cabinet before turning the vent.

3. Vertical piping is preferred.

4. Install all horizontal piping as follows:

• Slope horizontal vent piping upward a minimum of 1/4" per foot of run so that condensate drains toward the furnace.

• Support horizontal vent piping at least every four feet. No sags or dips are permitted.

In Canada, refer to manufacturer’s instructions for supporting ULC S636 venting.

➤ TABLE 8 DIRECT VENT APPLICATIONS

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

MAX EQUIVALENT VENT FOR UPFLOW RFGF FURNACES

(See Eq. Vent section on Page 13)

Model

2” Direct Vent

3” Direct Vent

RGFG-06EMCKS 80’ 80’ RGFG-07EMCKS 80’ 80’ RGFG-09EZCMS NR 80’ RGFG-10EZCMS NR 80’ RGFG-12ERCMS NR 80’

NOTES:

1. N.R. - NOT RECOMMENDED.

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

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

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

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

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

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

⁄2” CABINET WIDTH

* A = 17

B = 21” CABINET WIDTH

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

8. ALL HORIZONTAL VENTING MUST BE DONE WITH DIRECT VENTING (2-PIPE). FURNACES INSTALLED AS NON-DIRECT VENT MUST BE TERMINATED VERTICALLY.

FIGURE 9

12” MIN. SEPARATION

12” MIN. ROOF LEVEL

12” MIN. U.S. 18” MIN. CANADA SEPARATION

12” MIN. SEPARATION

12” MIN. U.S. 18” MIN. CANADA SEPARATION

12” MIN. SEPARATION

CANADA: MINIMUM 18” ABOVE ROOF OR 24” MAXIMUM ABOVE ROOF WITHOUT SUPPORT

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

DETAIL A

EXHAUST TERMINATION (90, 105 & 120K MODELS)

12”

NOTES:

THE COMBUSTION AIR PIPE

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

INCREASE THE 12-IN. MINIMUM

TO KEEP TERMINAL OPENING ABOVE ANTICIPATED LEVEL OF SNOW ACCUMULATION WHERE APPLICABLE.

WHEN 3-IN. DIAM. PIPE IS USED,

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

SUPPORT VERTICAL PIPE EVERY 6

FEET.

EEXXHHAAUUSSTT TTEERRMMIINNAATTIIOONN -- TTEERRMMIINNAATTEE

TTHHEE LLAASSTT 1122 IINNCCHHEESS WWIITTHH 22” PPVVCC PPIIPPEE OONN 9900,,000000 AANNDD 112200,,000000 BBTTUUHH MMOODDEELLSS..

SSEEEE DDEETTAAIILL AA..

5. Insulate all vent runs through unconditioned spaces where below-freezing temperatures are expected with 1" thick medium density, foil faced fiber glass or equivalent Rubatex/Armaflex insulation. For horizontal runs where water may collect, wrap the vent pipe with self-regulating, 3 or 5 Watt heat tape. The heat tape must be U.L. listed and installed per the manufacturer’s instructions.

6. All piping between the furnace and the roof or outside wall penetration is 2" or 3" as specified in Table 8. Table 8 lists the maximum allowable length for the exhaust vent pipe and intake air pipe for the number of elbows used, based on the type of termination and furnace size.

7. The minimum vent length is 5 feet for any termination.

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

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

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

10. No screens may be used to cover combustion air or exhaust.

VERTICAL TERMINATIONS

STANDARD VERTICAL TERMINATIONS

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

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

In Canada, the inlet pipe must extend a minimum of 18” above the roof or a maximum of 24” above the roof without support.

Exhaust Vent Piping must terminate at least 12 inches above the combustion air termination inlet. The maximum length of the exposed vent pipe above the roof is 30".

(See Figure 9)

: Use two medi-

: The exhaust vent

PIPE REDUCTION NOT REQUIRED ON 60 & 75K BTU MODELS

ST-A0407-00

CONCENTRIC TERMINATIONS

CCOONNCCEENNTTRRIICC VVEENNTT KKIITT NNOO.. RRXXGGYY--EE0033AA ((SSEEEE FFIIGGUURREE 1100))

This kit is for vertical and horizontal intake air/vent runs. One 5-in. diameter hole is required for installation. See Figure 10 for the general layout. Complete installation instructions are included with the kit.

FIGURE 10

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

ITEM No. DESCRIPTION

1 2.5 2 4 33 43 5 PVC RAINCAP

" PVC PIPE SCHEDULE 40 -- 37.125" LONG " PVC PIPE SCHEDULE 40 -- 24" LONG " x 3" x 4" SPECIAL CONCENTRIC FITTING " x 45° STREET ELBOW (FIELD SUPPLIED)

NNOOTTEE::

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

and used in

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

VVEERRTTIICCAALL IINNSSTTAALLLLAATTIIOONN

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

In Canada, maintain a minimum distance of 18” above the roof or 24” maximum without additional support.

HHOORRIIZZOONNTTAALL IINNSSTTAALLLLAATTIIOONN

FFIIEELLDD--SSUUPPPPLLIIEEDD SSTTRRAAPP

NOTE: AIR

ORIENTATION SENSITIVE.

INTAKE NOT

11"" MMAAXXIIMMUUMM

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

INSTALLATION – RXGY-G02(U.S.) & RXGY-G02C (Canada certified to ULC S636) Side Wall Vent

FIGURE 11

VENT KIT INSTALLATION OPTIONS

FIGURE 12

TYPICAL INSTALLATION

For all models installed with 3” pipereduce to a length between 12 inches and 30 inches of 2 inch pipe.

Note: Vent should protrude a

maximum of 2-1/4” beyond vent plate. Air intake should protrude a maximum of 1 inch beyond vent plate.

Seal all wall cavities.

ST-A1075

HORIZONTAL TERMINATIONS

All horizontal venting must be done with direct venting (2 pipe). Furnaces installed as non-direct vent must be terminated vertically.

STANDARD HORIZONTAL TERMINA TIONS

NOTE: A intakes (except those using horizontal concentric vent kit RXGY-E03A) must have a drain tee assembly and trap installed in the combustion air pipe as close to the furnace as possible. This is to drain any water that may enter the combustion air pipe to prevent it from entering the furnace vestibule area. These parts are included in horizontal vent kits RXGY-D02A, RXGY-D03Aand RXGY-D04A.

NNOOTTEE:: t above grade or anticipated snow levels. Use alternate horizontal terminations when termination locations are limited and higher snow levels are anticipated.

((SSEEEE FFIIGGUURREE 1133))

ll furnaces with horizontal air

The combustion air and exhaust

erminations must be at least 12 inches

NNOOTTEE:: b

ustion air inlet with respect to the

sure the location of the com-

exhaust vent terminal complies with Figure 13, detail C.

Combustion Air Piping coupling with a wind deflector vane (pro-

vided) installed as follows:

: Use a 2" PVC

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

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

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

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

IMPORTANT: To insure proper furnace operation, install the vane in the vertical position as shown in Figure 13, Detail B. Failure to install the vane properly can result in nuisance tripping of the pressure switch.

Exhaust Vent Piping

: 60,000 and 75,000 BTUH models: Use 2" pipe only for the entire length of the vent.

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

outside wall to prevent the termination from being pushed inward. No reduction of the 2" pipe used to penetrate the wall is necessary. Terminate the 2" PVC exhaust vent at least 12 inches from the outside wall.

FIGURE 13

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

NOTES:

SUPPORT HORIZONTAL

➀

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

➁

2 IN. BEFORE PENETRATING OUTSIDE WALL.

18 IN. MAXIMUM. 2 IN. DIAMETER

➂

PIPE MAY BE USED INSIDE THE WALL.

DETAIL “A” -

➃

TTEERRMMIINNAATTEE TTHHEE LLAASSTT 1122 IINNCCHHEESS WWIITTHH 22” PPVVCC PPIIPPEE OONN 9900,,000000 AANNDD 112200,,000000 BBTTUUHH MMOODDEELLSS..

INCREASE THE 12 IN. MINIMUM

➄

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

DETAIL “B”, INSTALL WIND DEFLEC-

➅

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

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

EEXXHHAAUUSSTT TTEERRMMIINNAATTIIOONN

EXHAUST/INTAKE RELATIONSHIP

DETAIL C

PIPE REDUCTION NOT REQUIRED

ON 60 & 75K MODELS W/2” PIPE. REDUCTION IS STILL REQUIRED WITH 3” PIPE.

NO SCREENS OR ELBOWS AT THE END OF THE PIPES

DETAIL C

DETAIL A

EXHAUST TERMINATION (3” PIPE ONLY)

COMBUSTION AIR TERMINATION

DETAIL B

12”

ST-A0407-00

ALTERNATE HORIZONTAL TERMINATIONS (See Figure 14)

NNOOTTEE:: exhaust

The combustion air and

terminations must be at least 12 inches above grade or anticipated snow levels. Alternate horizontal terminations allow the combustion air and exhaust terminations to be raised a maximum of 60 inches above the wall penetrations to maintain the required clearance.

NNOOTTEE:: extended

If combustion air vent pipe is

more than 24 inches, insulate the vent pipe between the two outside 90° elbows with closed cell insulation such as rubatex, armaflex or equivalent.

NNOOTTEE:: combust

Ensure the location of the

ion air inlet with respect to the exhaust vent terminal complies with Figure 14.

Combustion Air Piping

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

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

FIGURE 14

ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

SEE DETAIL A

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

EXHAUST VENT 211/2" PVC FOR MODELS WITH 120,000 BTUH INPUT (KIT NO. RXGY-D04A)

2" PVC FOR MODELS WITH INPUTS OF 90,000 THRU 120,000 BTUH. REDUCE TO 111/2" FOR MODELS WITH INPUTS OF 60,000 AND 75,000 BTUH. ELBOWS AND RISERS ARE 2" PVC.

12" FROM WALL

PIPE SUPPORT STRAP

DETAIL C

EXHAUST/INTAKE RELATIONSHIP

NOTE: If combustion air vent pipe is extended more

than 24 inches, insulate the vent pipes between the two outside 90° elbows with closed cell insulation such as rubatex, armaflex, or equivalent.

INTAKE VENT 211/2" PVC FOR MODELS WITH 120,000 BTUH INPUT.

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

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

DETAIL A

EXHAUST VENT FOR

MODELS WITH INPUT OF

60,000 AND 75,000 BTU

I339

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

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

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

IMPORTANT: To insure proper furnace operation, the supplied vane must be installed in the vertical position as shown in Figure 13, Detail B.

Exhaust Vent Piping

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

2. Cut an adequate length of 2" PVC pipe as needed to insure proper location of the exhaust vent termination with respect to the combustion air inlet and connect this to the elbow.

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

Exhaust Vent Termination: 60,000 and 75,000 BTUH models:

Use 2" pipe only for the entire length of the vent.

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

to penetrate the wall is necessary. Terminate the 2" PVC exhaust vent at least 12 inches from the outside wall.

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

Venting and terminations install the same as above except the 2" pipe and connectors are replaced with 2 1/2" pipe and connectors.

LOCATION REQUIREMENTS HORIZONTAL DIRECT VENTS

CAUTION

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

NOTE: In Canada vent terminations

must be in accordance with the current CAN/CSA B149.1 Gas Installation Code.

The vent must be installed with the following minimum clearances. See Figures 15 and 16.

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

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

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

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

5. Allow the vent terminal minimum horizontal clearance of 4 feet from electric meters, gas meters, regulators and relief equipment.

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

1. Do not terminate under any kind of patio or deck (exceptions for Canada are permitted under CAN/CSA B149.1). If running the vent under a deck, insulate it to insure no condensate freezes and blocks the pipe. The insulation must be waterproof.

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

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

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

4. Do not extend vent directly through brick or masonry surfaces. Use a rust-resistant sheet metal or plastic backing plate behind vent. See Figure 7.

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

FIGURE 15

MOISTURE ZONES

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

7. Caulk all cracks, seams and joints within 6 feet horizontally as well as 6 feet above and below vent. See Figure 15.

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

9. Do not expose 3" x 2" reducer/ bushing to outdoor ambient temperatures.

MULTIVENTING

IF VENTING TWO OR MORE FURNACES NEAR EACH OTHER IS REQUIRED, EACH FURNACE MUST BE INDIVIDUALLY VENTED – NO COMMON VENTING IS PERMITTED. See Figures 17 and 18 for posi-

tioning of the terminations. When

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

FIGURE 16

Natural Gas and Propane Installation Code

National Fuel Gas Code

Canadian Installations

US Installations

Canadian Installations

US Installations

1 ft. (30.5 cm)

4 ft. (1.22 m)

3 ft. (91 cm)

1 ft. (30.5 cm)

3 ft. (91 cm)

12 inches (30 cm) for

appliances > 10,000 BTUH

(3 kW) and < 100,000

BTUH (30 kW), 36 inches

(91 cm) for appliances >

100,000 BTUH (30 kW)

For clearances not specified in ANSI Z223.1 / NFPA 54 or CAN/CSA-B149, one of the following shall

be indicated:

DDIIRREECCTT VVEENNTT TTEERRMMIINNAALL CCLLEEAARRAANNCCEESS

FIGURE 17

MINIMUM 12" ABOVE AVERAGE

SNOW ACCUMULATION. MAXIMUM

OF 24 IN. ABOVE ROOF.

MAXIMUM 1"

DISTANCE

FROM WALL

MINIMUM 12"

ABOVE GRADE

6' MINIMUM

10' RECOMMENDED

TWO FURNACE VENTING THROUGH ROOF

FIGURE 18

TWO FURNACE VENTING THROUGH WALL

TWO-PIPE VENTING

EEXXHHAAUUSSTT VVEENNTT MMOODDEELLSS 0066--0077 NNOO VVEENNTT RREEDDUUCCTTIIOONN RREEQQUUIIRREEDD..

MMOODDEELLSS 0099--1122 TTOO BBEE

33”” MMIINNIINNUUMM 2244”” MMAAXXIIMMUUMM

RREEDDUUCCEEDD FFRROOMM 33”” PPVVCC TTOO 22”” PPVVCC BBEELLOOWW RROOOOFF LLIINNEE..

CONCENTRIC VENTING

88”” MMIINNIINNUUMM 2244”” MMAAXXIIMMUUMM

TWO-PIPE VENTING

66‘‘ MMIINNIIMMUUMM,,

1100‘‘ RREECCOOMMMMEENNDDEEDD ((UUSS))

33‘‘ MMIINNIIMMUUMM CCAANNAADDAA OONNLLYY..

33”” MMIINNIINNUUMM 2244”” MMAAXXIIMMUUMM

CONCENTRIC VENTING

MMIINNIIMMUUMM 1122”” AABBOOVVEE AAVVEERRAAGGEE

SSNNOOWW AACCCCUUMMUULLAATTIIOONN MMAAXXIIMMUUMM

OOFF 2244 IINN.. AABBOOVVEE RROOOOFF..

IINN CCAANNAADDAA MMIINNIIMMUUMM 1188”” AABBOOVVEE

RROOOOFF LLIINNEE OORR MMAAXXIIMMUUMM 2244””

WWIITTHHOOUUTT AADDDDIITTIIOONNAALL SSUUPPPPOORRTT..

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

CONNECTING TO FURNACE

IMPORTANT: Clean and deburr all

pipe cuts. The shavings must not be allowed to block the exhaust, inlet or condensate drain pipes.

IMPORTANT: When indoor combustion air is used, the inlet air opening at the furnace must be protected from accidental blockage. On downflow models, install a double elbow in the top inlet air opening.

SEE CONCENTRIC VENT SECTION ON PAGE 23 FOR MORE INFORMATION.

UPFLOW MODELS

The exhaust air pipe connection is a 2-in. female PVC pipe fitting extending through the left nace top plate. See Figure 19. This opening has a protective cap which should be removed just prior to installing the exhaust pipe. When 2in. pipe is used, connect it directly to this fitting. When 3-in. pipe is used, connect a 2 to 3-in. coupling to this fitting with a short piece of 2-in. PVC pipe.

The inlet combustion air connection is at the right An alternate combustion inlet air connection may be made on the right side of the jacket. The alternate con-

88”” MMIINNIINNUUMM 2244”” MMAAXXIIMMUUMM

side of the fur-

side of the top plate.

66‘‘ MMIINNIIMMUUMM,,

1100‘‘ RREECCOOMMMMEENNDDEEDD ((UUSS))

33‘‘ MMIINNIIMMUUMM CCAANNAADDAA OONNLLYY..

SEE CONCENTRIC VENT SECTION ON PAGE 20 FOR MORE INFORMATION.

nection opening has a plastic cap. A combustion inlet air connection fitting is supplied with the furnace and it must be installed in the furnace by screwing it into the opening. Make sure the rubber “O-ring” supplied with the furnace is used with this fitting. See Figure 19.

IMPORTANT: When using indoor combustion air, the furnace air opening must be protected from accidental blockage. Install a 2-inch 90° elbow pointing downward on the side or a double elbow pointing downward in the top opening.

FIGURE 19

UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

FIGURE 20

UPFLOW MODELS -- COMBUSTION AIR FITTING

ST-A1157-01

CONDENSATE DRAIN/OPTIONAL NEUTRALIZER

GENERAL INFORMATION

CAUTION

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

IMPORTANT: Do not connect into a com-

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

➤ IMPORTANT: If installing the unit over a finished ceiling or living area, be certain to install an auxiliary condensate drain pan under the entire unit extending out under the condensate tee. With the mini-

mum 5 or 13⁄4" for downflow models installed above the tee, a blocked drain will result in overflow from the riser. 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.

If required by local codes, 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 21). If 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.

When selecting neutralizer cartridges and condensate pumps, use the following data:

CONDENSATE PRODUCTION: MAX (ALL MODELS) = 1-2 gallons per hr.

⁄2" riser for upflow models

FIGURE 21

UPFLOW CONDENSATE DRAIN (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

ST-A1158-01

pH LEVEL:

3.2 - 4.5 using OUTDOOR air

2.2 - 4.5 using INDOOR air (neutral pH = 7.0)

UPFLOW MODELS

The condensate drain trap is located in the blower compartment on the left- hand side of the jacket. A short piece of 1⁄2-in. PVC pipe and a 1⁄2-in. tee are provided. Connect the 1⁄2-in. pipe to the elbow on the trap and the tee to this pipe so that the open end is upward. Run a drain tube from the bottom of the tee to a floor drain or condensate pump.

IMPORTANT: If installing the unit over a finished ceiling or living area, be certain to install an auxiliary condensate drain pan under the entire unit extending out under the condensate tee.

IMPORTANT: There are two options when choosing a height for the condensate riser:

CONDENSATE OVERFLOW: With a

⁄2inch 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.

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

FIGURE 22

UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION (NO KIT REQUIRED)

REVERSING THE TRAP

UPFLOW MODELS

The trap may be moved to the right side for right-side drainage. Open the knockout for the drain on the right side of the cabinet. Remove the bracket holding the trap from the left side. Seal the left side drain hole with a plug provided in the cloth bag with the furnace. Position the mounting bracket and trap so that the drain elbow is centered in the hole on the right. See Figure 22.

Drill two holes in the cabinet to mount the bracket. Mount the trap and bracket to the right side with the drain elbow pointing through the knockout. Connect the above. Route the drain hoses behind the top of the electric box, cut to the appropriate length, and connect to the trap with hose clamps.

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.

⁄2" pipe and tee as noted

ST-A1159-01

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

TTHHEE DDIISSTTRRIIBBUUTTOORR

USE THE PROPER CONVERSION KIT CAN CAUSE FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

See the conversion kit index supplied with the furnace. This index identifies the proper LP Gas Conversion Kit required for each particular furnace.

IMPORTANT: Any additions, changes

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

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

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

AAVVAAIILLAABBLLEE FFRROOMM

. FAILURE TO

FIGURE 23

GAS PIPING -- UPFLOW INSTALLATION (GAS VALVE MAY BE DIFFERENT THAN SHOWN)

MANUAL

GAS VALVE

4 TO 5 FT.

ABOVE FLOOR

REQ’D BY

SOME

UTILITIES.

GROMMET (IN NORMAL POSITION)

DRIP LEG

UNION

(TYPICAL INSTALLATION)

TTOOPP VVIIEEWW OOFF GGAASS LLIINNEE AANNDD

VVAALLVVEE

IINN OOPPTT.. PPOOSSIITTIIOONN

BURNERS

GROMMET

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

OPTIONAL GAS LINE POSITION

GAS VALVE

PLUG (IN NORMAL POSITION)

MANIFOLD

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

MANIFOLD PRESSURE TAP

A1122-01_1

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 man-

ual gas valve must be adequate in size to prevent undue pressure drop and never smaller than the pipe size

+ 86 hidden pages

Taylor RGFG Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual