(-)GRK AND (-)GTK SERIESpts.myrheem.com/.../Furnaces/IO/92-24161-36-07_GRK_GTK.pdf · 2011. 4....

92-24161-36-07SUPERSEDES 92-24161-36-06

INSTALLATION INSTRUCTIONSFOR UPFLOW AND DOWNFLOW/HORIZONTALHIGH EFFICIENCY CONDENSING TWO-STAGEGAS FURNACES(-)GRK AND (-)GTK SERIES

INSTALLATION CHECK LISTREFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

______ Adequate pipe size

______ Correct supply pressure (during furnace operation)

______ Manifold pressure

______ No gas leaks

______ L.P. Kit Number (if applicable)

ELECTRICAL

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

______ Polarity observed

______ Furnace properly grounded

______ Adequate wire size

FURNACE INSTALLATION

______ Adequate clearance to combustibles

______ Adequate clearance for service (at front)

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 connectedand 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

______ Exhaust Vent Temperature

TERMINATIONS – DIRECT VENT

VERTICAL

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

______ Correct relationship – exhaust to intake

HORIZONTAL/VERTICAL – CONCENTRIC (RXGY-E03)

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

______ Intake “Y” rotated above center

______ Exhaust sloped toward furnace

HORIZONTAL – STANDARD (RXGY-D02, -D03)


______ 12" min. above grade/snow level

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


______ Above anticipated snow level

VENTING – NON-DIRECT VENT

______ in. diameter – exhaust pipe

______ ft. of pipe – exhaust

______ no. of elbows

TERMINATION – NON-DIRECT VENT

VERTICAL

______ 12" min. above roof/snow level

HORIZONTAL – STANDARD

______ 12" min. above grade/snow level

HORIZONTAL – ALTERNATE

______ Above anticipated snow level

_____________________________ Model Number

_____________________________ Serial Number

_____________________________ Date of Installation

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CONTENTS

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

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

General Information..................................................................................................4

Safety Information ....................................................................................................5

Location Requirements and Considerations ............................................................6

Ducting ...................................................................................................................11

Venting and Combustion Air Piping .......................................................................13

Combustion and Ventilation Air..............................................................................15

Vent Pipe Installation..............................................................................................18

Condensate Drain/Neutralizer................................................................................30

Gas Supply and Piping...........................................................................................34

Electrical Wiring......................................................................................................39

Accessories ............................................................................................................40

Furnace Twinning...................................................................................................41

High Altitude Installations .......................................................................................44

Start-Up Procedures...............................................................................................47

Air Flow...................................................................................................................50

Maintenance...........................................................................................................53

Troubleshooting......................................................................................................56

Wiring Diagram.......................................................................................................58

IMPORTANT: All Rheem productsmeet current Federal OSHA Guidelinesfor safety. California Proposition 65warnings are required for certainproducts, which are not covered by theOSHA standards.

California's Proposition 65 requireswarnings for products sold in Californiathat contain, or produce, any of over600 listed chemicals known to the Stateof California to cause cancer or birthdefects such as fiberglass insulation,lead in brass, and combustion productsfrom natural gas.

All “new equipment” shipped for sale inCalifornia will have labels stating thatthe product contains and/or producesProposition 65 chemicals. Although wehave not changed our processes,having the same label on all ourproducts facilitates manufacturing andshipping. We cannot always know“when, or if” products will be sold in theCalifornia market.

You may receive inquiries fromcustomers about chemicals found in, orproduced by, some of our heating andair-conditioning equipment, or found innatural gas used with some of ourproducts. Listed below are thosechemicals and substances commonlyassociated with similar equipment inour industry and other manufacturers.

• Glass Wool (Fiberglass) Insulation• Carbon Monoxide (CO)• Formaldehyde• Benzene

More details are available at theWebsites for OSHA (OccupationalSafety and Health Administration), atwww.osha.gov and the State ofCalifornia's OEHHA (Office ofEnvironmental Health HazardAssessment), at www.oehha.org.Consumer education is important sincethe chemicals and substances on thelist are found in our daily lives. Mostconsumers are aware that productspresent safety and health risks, whenimproperly used, handled andmaintained.

NOTE: A load calculation must beperformed to properly determine therequired furnace BTU size for thestructure. Also, the duct must be properlydesigned and installed for proper airflow.Existing ductwork must be inspected forproper size and sealed system. Properairflow is necessary for both user comfortand equipment performance.Before opening the furnace carton andinstallation of the furnace, verify the datatags on the carton and inside thefurnace, match and is what was orderedfrom the local distributor. Also, check forany damage to the furnace beforeinstallation.IMPORTANT: Proper application,installation and maintenance of thisfurnace and system is a must ifconsumers are to receive the full benefitsfor which they have paid.The (-)GRK- and (-)GTK- series furnacesare design-certified by CSA for use withnatural and propane gases as follows:

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1. As non-direct vent central forced airfurnaces taking combustion air fromthe installation area or using airducted from the outside.

2. As direct vent central forced airfurnaces with all combustion airsupplied directly to the furnaceburners through a special air intakesystem outlined in theseinstructions.Install this furnace inaccordance with the AmericanNational Standard Z223.1 – latestedition entitled “National Fuel GasCode” (NFPA54) and requirementsor codes of the local utilities orother authorities having jurisdiction.This is available from the following:

National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

GENERAL INFORMATION

FIGURE 1UPFLOW FURNACE COMPONENTS

ITEMNO. PART NAME1 CONDENSATE TRAP2 DOOR SWITCH3 JUNCTION BOX4 TRANSFORMER5 PRESSURE SWITCHES6 EXHAUST TRANSITION7 CONNECTOR8 OUTLET AIR PIPE

9 SHIPPING PLUG (TO BE REMOVED)10 FLAME SENSOR11 OVERTEMPERATURE SWITCH12 TOP PLATE13 BURNER14 IGNITER15 COMBUSTION AIR INLET16 OPTIONAL AIR INLET (UPFLOW UNITS ONLY)17 OPTIONAL GAS INLET18 GAS VALVE

19 INDUCED DRAFT BLOWER20 CAPACITORS21 BLOWER22 LOW VOLTAGE TERMINAL23 CONTROL MOUNTING PLATE24 FILTER / SOLID METAL BASEPLATE (UPFLOWUNITS ONLY)25 BURNER COVER PLATE

(DOWNFLOW/HORIZONTAL UNITS ONLY)

NOTE: A PARTS BAG IS INCLUDED WITH THE FURNACE. IF A NEWPARTS BAG NEEDS TO BE ORDERED, USE THE FOLLOWING PARTNUMBERS: AS-100717-01 FOR -GRK-60, -GRK-75, GRK-90 AND GRK-105AS-100717-02 FOR -GRK-120

DOWNFLOW/HORIZONTAL FURNACE COMPONENTS

NOTE: A PARTS BAG IS INCLUDED WITH THE FURNACE. IF A NEWPARTS BAG NEEDS TO BE ORDERED, USE THE FOLLOWING PARTNUMBERS: AS-100717-03 FOR -GTK-60, -GTK-75, GTK-90, GTK-105AND -GTK-120

AIRFLOW

9

8

4

17

1125

10

18

5

19

20

21

2

3 15 12 23 22

71

14613

AIRFLOW

CSA-INTERNATIONAL8501 East Pleasant Valley RoadCleveland, Ohio 44131-5575Install units in Canada in accordancewith CSA-B149, local installationcodes and authorities havingjurisdiction. CSA-B149 is availablefrom:CSA-INTERNATIONAL178 Rexdale Blvd.Toronto, OntarioCanada M9W, 1R3NOTE: It is our recommendation thatany HVAC equipment which weresubject to flooding be replaced toavoid any risk of property damage,personal injury or death. Also, ourposition that the immersion by floodwaters compromises any HVACproducts thus voiding this warranty.

5

NEVER TEST FOR GAS LEAKSWITH AN OPEN FLAME. USE ACOMMERCIALLY AVAILABLESOAP SOLUTION MADESPECIFICALLY FOR THEDETECTION OF LEAKS TO CHECKALL CONNECTIONS, ASSPECIFIED IN GAS SUPPLY ANDPIPING SECTION OF THESEINSTRUCTIONS.

ALWAYS INSTALL FURNACE TOOPERATE WITHIN THEFURNACE'S INTENDEDTEMPERATURE-RISE RANGEWITH A DUCT SYSTEM WHICHHAS AN EXTERNAL STATICPRESSURE WITHIN THEALLOWABLE RANGE, ASSPECIFIED IN DUCTING SECTIONOF THESE INSTRUCTIONS. SEEALSO FURNACE RATING PLATE.

WHEN A FURNACE IS INSTALLEDSO THAT SUPPLY DUCTS CARRYAIR CIRCULATED BY THEFURNACE TO AREAS OUTSIDETHE SPACE CONTAINING THEFURNACE, THE RETURN AIRSHALL ALSO BE HANDLED BYDUCT(S) SEALED TO THEFURNACE CASING ANDTERMINATING OUTSIDE THESPACE CONTAINING THEFURNACE.

WHEN THIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BE INSTALLEDSO THE BURNERS AND IGNITIONSOURCE ARE LOCATED NO LESSTHAN 18 INCHES ABOVE THEFLOOR. THIS IS TO REDUCE THERISK OF IGNITING FLAMMABLEVAPORS WHICH MAYBE PRESENT IN A GARAGE.ALSO, THE FURNACE MUST BELOCATED OR PROTECTED TOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOLLOWTHESE WARNINGS CAN CAUSE AFIRE OR EXPLOSION, RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

THE FURNACE MAY BE USEDFOR HEATING OF BUILDINGS ORSTRUCTURES UNDERCONSTRUCTION.

INSTALLATION MUST COMPLYWITH ALL INSTALLATIONINSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDERTHERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TOTHE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATEAND TEMPERATURE RISE PERRATING PLATE MARKING;

• MEANS FOR PROVIDINGOUTDOOR AIR REQUIRED FORCOMBUSTION;

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

• CLEAN FURNACE, DUCT WORKAND COMPONENTS UPONSUBSTANTIAL COMPLETIONOF THE CONSTRUCTIONPROCESS, AND VERIFYFURNACE OPERATINGCONDITIONS INCLUDINGIGNITION, INPUT RATE,TEMPERATURE RISE ANDVENTING, ACCORDING TO THEINSTRUCTIONS AND CODES.

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

SAFETY INFORMATION

DO NOT OPERATE THE SYSTEMWITHOUT FILTERS. A PORTIONOF THE DUST ENTRAINED IN THEAIR MAY TEMPORARILY LODGEIN THE AIR DUCT RUNS AND ATTHE SUPPLY REGISTERS. ANYCIRCULATED DUST PARTICLESWILL BE HEATED AND CHARREDBY CONTACT WITH THEFURNACE HEAT EXCHANGER.THIS SOOTY RESIDUE WILL SOILCEILINGS, WALLS, DRAPES,CARPETS AND OTHERHOUSEHOLD ARTICLES. SOOTDAMAGE MAY ALSO RESULTWITH, OR WITHOUT, FILTERS INPLACE, WHEN CERTAIN TYPESOF CANDLES ARE BURNED, ORCANDLEWICKS ARE LEFTUNTRIMMED.

COMBUSTION PRODUCTS MUSTBE DISCHARGED OUTDOORS.CONNECT THIS FURNACE TO ANAPPROVED VENT SYSTEM ONLY,AS SPECIFIED IN VENT PIPEINSTALLATION SECTION OFTHESE INSTRUCTIONS.

PROVIDE ADEQUATECOMBUSTION AND VENTILATIONAIR TO THE FURNACE SPACE ASSPECIFIED IN THE COMBUSTIONAND VENTILATION AIR SECTIONOF THESE INSTRUCTIONS.

INSTALL THIS FURNACE ONLY INA LOCATION AND POSITION ASSPECIFIED IN THE LOCATIONREQUIREMENTS ANDCONSIDERATIONS SECTION OFTHESE INSTRUCTIONS. PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR TO THEFURNACE SPACE AS SPECIFIEDIN THE VENTING SECTION OFTHESE INSTRUCTIONS.

USE ONLY WITH TYPE OF GASAPPROVED FOR THIS FURNACE.REFER TO THE FURNACE RATINGPLATE.

DO NOT INSTALL THIS FURNACEIN A MOBILE HOME!! THISFURNACE IS NOT APPROVED FORINSTALLATION IN A MOBILEHOME. DOING SO COULD CAUSEFIRE, PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

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FIGURE 2HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP

GENERAL INFORMATION

DO NOT INSTALL THIS FURNACEIN A MOBILE HOME!! This furnaceis not approved for installation in amobile home. Doing so could causeFIRE, PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

WHEN THIS FURNACE ISINSTALLED IN A RESIDENTIALGARAGE, IT MUST BE INSTALLEDSO THE BURNERS AND IGNITIONSOURCE ARE LOCATED NO LESSTHAN 18 INCHES ABOVE THEFLOOR. THIS IS TO PREVENTTHE RISK OF IGNITINGFLAMMABLE VAPORS WHICHMAY BE PRESENT IN A GARAGE.ALSO, THE FURNACE MUST BELOCATED OR PROTECTED TOAVOID PHYSICAL DAMAGE BYVEHICLES. FAILURE TO FOLLOWTHESE WARNINGS CAN CAUSE AFIRE OR EXPLOSION, RESULTINGIN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

1. IMPORTANT: If installing the unitover a finished ceiling or livingarea, be certain to install anauxiliary condensate drain panunder the entire unit. Thisauxiliary drain pan should extendunder any evaporator coilinstalled with the furnace and theopen portion of the condensatedrain assembly. See“Condensate Drain/Neutralizer”section for more details.

2. IMPORTANT: If using a coolingevaporator coil with this furnace:

a. be sure the air passes overthe heat exchanger beforepassing over the coolingcoil. The cooled air passingover the warm ambient airinside the heat exchangertubes can causecondensation inside the tubesresulting in corrosion andeventual failure.

b. install a parallel duct systemto divert all the air from thefurnace allowing it to passover the cooling coil only. Usedampers or other means toprevent chilled air frompassing over the heatexchanger.

If these are manual dampers, theymust be equipped to prevent heatingor cooling operation unless thedamper is in the full heat or coolposition.

3. IMPORTANT: Install the furnacelevel. If it is not level, condensatecannot drain properly, possiblycausing furnace shut down.

NOTE: These furnaces are approvedfor installation in attics, as well asalcoves, utility rooms, closets andcrawlspaces. Provisions must bemade to prevent freezing ofcondensate.

4. IMPORTANT: If this furnace isinstalled in a garage, attic and/orany unconditioned space, install aself-regulating heat tape aroundthe condensate trap and along theentire length of the condensatedrain in the unconditioned space.When the condensing horizontalgas furnace is installed in anunconditioned space where thetemperature would be capable ofreaching close to or below 32°F

! WARNING

! WARNING

(0°C), a self-regulating heat tapeis required on the condensatedrain, along with an insulationwrap. The heat tape should meetthe following requirements:

a. The heat tape must be ULlisted.

b. The heat tape must beinstalled per themanufacturer’s instructions forthe entire length of drain pipein the unconditioned space.

c. The heat tape should be ratedat 5 or 6 watts per foot at120V

IMPORTANT: Support this unitwhen installed. Since this furnaceis suitable for attic or crawl spaceinstallation, it may be installed oncombustible wood flooring or byusing support brackets.

5. IMPORTANT: If installing in autility room, be sure the door iswide enough to:

a. allow the largest part of thefurnace to pass; or

b. allow any other appliance(such as a water heater)to pass.

c. allow service clearance

LOCATION REQUIREMENTS AND CONSIDERATIONS

I526

DRAINPIPE

HEATTAPE

TRAP

AIRFLOW

7

Upflow furnaces are shipped with abottom closure panel installed.When bottom return air is used,remove the panel by removing thetwo screws attaching the panel tothe front base angle. See filtersection for details.

COMBUSTIBLE MATERIAL MUSTNOT BE PLACED ON OR AGAINSTTHE FURNACE JACKET. THEAREA AROUND THE FURNACEMUST BE KEPT CLEAR AND FREEOF ALL COMBUSTIBLEMATERIALS INCLUDINGGASOLINE AND OTHERFLAMMABLE VAPORS ANDLIQUIDS. PLACEMENT OFCOMBUSTIBLE MATERIALS ON,AGAINST OR AROUND THEFURNACE JACKET CAN CAUSEAN EXPLOSION OR FIRERESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. THE HOMEOWNERSHOULD BE CAUTIONED THATTHE FURNACE AREA MUST NOTBE USED AS A BROOM CLOSETOR FOR ANY OTHER STORAGEPURPOSES.

CLEARANCE -ACCESSIBILITYThe design of forced air furnaces withinput ratings as listed in the tableunder Figure 4 are certified by CSA-International for the clearances tocombustible materials shown ininches.

See name/rating plate and clearancelabel for specific model number andclearance information.

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

NOTE: Use recommended 24”clearance if accessibility clearancesare greater than fire protectionclearances.

UPFLOW FURNACES ARE DESIGN-CERTIFIED FOR INSTALLATIONON COMBUSTIBLE FLOORS.NOTE, HOWEVER, THATFURNACES MUST NOT BEINSTALLED DIRECTLY ONCARPETING, TILE OR OTHERCOMBUSTIBLE MATERIAL OTHERTHAN WOOD FLOORING.INSTALLATION ON ACOMBUSTIBLE MATERIAL CANRESULT IN FIRE, CAUSINGPROPERTY DAMAGE, PERSONALINJURY OR DEATH.

! WARNING

THIS FURNACE IS NOTAPPROVED OR RECOMMENDEDFOR INSTALLATION ON ITS BACK,WITH ACCESS DOORS FACINGUPWARDS OR IN ANYHORIZONTAL CONFIGURATION.

SITE SELECTION1. Select a site in the building near

the center of the proposed, orexisting, duct system.

2. Give consideration to the ventsystem piping when selecting thefurnace location. Be sure theventing system can get from thefurnace to the termination withminimal length and elbows.

3. Locate the furnace near theexisting gas piping. Or, if runninga new gas line, locate thefurnace to minimize the lengthand elbows in the gas piping.

4. Locate the furnace to maintainproper clearance to combustiblesas shown in the following tables.

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

! WARNING

CAUTION!

! WARNING

FIGURE 3HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

GASPIPE

TRAP

EXHAUSTFAN

ELECTRICALCONDUIT

INTAKEVENT

I522

AIRFLOW

NOTE: Do not block furnace access with support rods. Maintain clearances recommended in Figure6. Allow enough space for proper service maintenance or replacement of the heat exchanger andblower assembly.

8

FIGURE 4CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS

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FIGURE 5CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS

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FIGURE 6CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS

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DUCTINGProper air flow is required for thecorrect operation of this furnace.Too little air flow can cause erraticoperation and can damage the heatexchanger. The duct system mustcarry the correct amount of air forheating and cooling if summer airconditioning is used.

Size the ducts according toacceptable industry standards andmethods. The total static pressuredrop of the air distribution systemshould not exceed 0.5" w.c.

NEVER ALLOW THE PRODUCTSOF COMBUSTION FROM THEFLUE TO ENTER THE RETURN AIRDUCTWORK OR THE CIRCULATEDAIR SUPPLY. ALL RETURNDUCTWORK MUST BEADEQUATELY SEALED ANDSECURED TO THE FURNACEWITH SHEET METAL SCREWS;AND JOINTS, TAPED. ALL OTHERDUCT JOINTS MUST BE SECUREDWITH APPROVED CONNECTIONSAND SEALED AIRTIGHT. WHENAN UPFLOW FURNACE ISMOUNTED ON A PLATFORM WITHRETURN THROUGH THE BOTTOM,IT MUST BE SEALED AIRTIGHTBETWEEN THE FURNACE ANDTHE RETURN AIR PLENUM. THEFLOOR OR PLATFORM MUSTPROVIDE SOUND PHYSICALSUPPORT OF THE FURNACEWITHOUT SAGGING, CRACKS, ORGAPS, AROUND THE BASE,PROVIDING A SEAL BETWEENTHE SUPPORT AND THE BASE.

FAILURE TO PREVENTPRODUCTS OF COMBUSTIONFROM BEING CIRCULATED INTOTHE LIVING SPACE CAN CREATEPOTENTIALLY HAZARDOUSCONDITIONS, INCLUDINGCARBON MONOXIDE POISONINGTHAT COULD RESULT INPERSONAL INJURY OR DEATH.

DO NOT, UNDER ANYCIRCUMSTANCES, CONNECTRETURN OR SUPPLY DUCTWORKTO OR FROM ANY OTHER HEATPRODUCING DEVICE SUCH AS AFIREPLACE INSERT, STOVE, ETC.DOING SO MAY RESULT IN FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PERSONAL INJURYOR PROPERTY DAMAGE.

IMPORTANT: Some high efficiencyfilters have a greater than normalresistance to air flow. This canadversely affect furnace operation.BE SURE TO CHECK AIR FLOW.

IMPORTANT: When using outside air,design and adjust the system to maintaina return air temperature ABOVE 55° Fduring the heating season.

NOTE: Return air grilles and warm airregisters must not be obstructed orclosed.

UPFLOW UNITS1. Position the unit to minimize long

runs of duct or runs of duct withmany turns and elbows.

2. Open the return air compartment.

UPFLOW FURNACE: A SOLID METALBASE PLATE MUST REMAIN IN THEFURNACE BOTTOM WHEN USINGSIDE AIR RETURN. FAILURE TOINSTALL A BASE PLATE COULDCAUSE THE PRODUCTS OFCOMBUSTION TO CIRCULATE INTOTHE LIVING SPACE AND CREATEPOTENTIALLY HAZARDOUSCONDITIONS, INCLUDING CARBONMONOXIDE POISONING OR DEATH.FOR BOTTOM RETURN, REMOVESOLID METAL BASE PLATE.

a. Cut an opening in the side. Theopening should be cut the fullwidth and height of the knockoutson the unit. See Figure 7.

NOTE: Where the maximum air flowis 1800 CFM or more, both sides orthe bottom must be used for returnair.

3. Connect the return duct or returnair cabinet to the unit. Make theconnection air tight to prevententraining combustion gasesfrom an adjacent fuel-burningappliance.

4. Be sure to have adequatespace for the unit filter.

NOTE: DO NOT take return airfrom bathrooms, kitchens,furnace rooms, garages, utility orlaundry rooms, or cold areas.

NOTE: DO NOT use a rear airreturn.

5. If summer air conditioning isdesired, position the indoor coilon the supply-air side of the unit.Insure that no air can bypass thiscoil.

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

IMPORTANT: If a flexible ductconnector must be used, itMUST be rated for a minimumtemperature of 250°F.continuous.

! WARNING

FIGURE 7UPFLOW CUTOUT AND DRILL INFORMATION

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

! WARNING

12

DOWNFLOW UNITS1. Position the unit to minimize long

runs of duct or runs of duct withmany turns and elbows.

2. If summer air conditioning isdesired, position the indoor coilon the supply-air side of the unit.Insure that no air can bypass thiscoil.

3. If installing on a combustible floorand not using an airconditioning plenum, install thespecial non-combustible floorbase. See Table 1 and Figure 8.

THE DOWNFLOW FURNACEDESIGN IS CERTIFIED FORINSTALLATION ON A NON-COMBUSTIBLE FLOOR. USE THESPECIAL BASE SPECIFIED ONTHE FURNACE CLEARANCELABEL. FAILURE TO INSTALL THESPECIAL BASE MAY RESULT INFIRE, PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.THIS SPECIAL BASE IS SHIPPEDFROM THE FACTORY AS ANACCESSORY.

4. Connect the furnace to thesupply air plenum.

5. Connect the return air ducting tothe return air opening at the topof the unit. Make the connectionair tight to prevent entrainingcombustion gases from anadjacent fuel-burning appliance.

NOTE: In downflowconfiguration, return air cut out isnot permitted.

6. Be sure to have adequatespace for the unit filter.

NOTE: DO NOT take return air

from bathrooms, kitchens, furnacerooms, garages, utility or laundryrooms, or cold areas.

HORIZONTAL UNITIMPORTANT: THIS FURNACE MAYONLY BE INSTALLED SO AS WHENFACING THE FRONT OF THEFURNACE, SUPPLY AIR ISDISCHARGED ON THE LEFT HANDSIDE.

1. Position the unit to minimize longruns of duct or runs of duct withmany turns and elbows.

2. If summer air conditioning isdesired, position the indoor coil onthe supply air side of the unit.Insure that no air can bypass thiscoil.

3. Connect the furnace to the supplyair plenum.

4. Connect the return air ducting tothe return air opening at the rightend of the unit. Make theconnection air tight to preventpulling combustion gases from anadjacent fuel-burning appliance.

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

5. Be sure to have adequate spacefor the unit filter.

NOTE: DO NOT take return airfrom bathrooms, kitchens, furnacerooms, garages, utility or laundryrooms, or cold areas.

! WARNING

FIGURE 8NON-COMBUSTIBLE FLOOR BASE

TABLE 1NON-COMBUSTIBLE FLOOR BASES

Floor Base SizeNo. Cabinet

RXGC-B17 17

RXGC-B21 21

RXGC-B24 24

13

GENERAL INFORMATION

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SECTION.FAILURE TO PROPERLY VENTTHIS FURNACE CAN CAUSECARBON MONOXIDE POISONINGOR AN EXPLOSION OR FIRE,RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

This furnace removes both sensibleand latent heat from the combustionflue gases. Removal of latent heatresults in condensation of flue gaswater vapor. This condensed watervapor drains from the secondary heatexchanger and out of the unit into adrain trap.

When installed as a non-direct ventfurnace, only exhaust piping isrequired and inside combustion airmay be used. Refer to section on“COMBUSTION & VENTILATION AIRFOR FURNACE INSTALLATIONS.”

Direct vent installations require adedicated combustion air and ventingsystem. All air for combustion is takenfrom the outside atmosphere and allcombustion products are dischargedto the outdoors.

The combustion air and vent pipefittings must conform to AmericanNational Standards Institute (ANSI)and American Society for TestingMaterials (ASTM) standardsD1785 (Schedule 40 PVC), D2665(PVC-DWV), D2241 (SDR-21 andSDR26-26 PVC), D2661 (ABS-DWV)or F628 (Schedule 40 ABS-DWV).

IMPORTANT: The plastic combustionair and venting components are ofSchedule 40 PVC. If using ABSpiping, ensure that the solventcement is compatible for joining PVCto ABS components or use amechanical connection that canwithstand the vent temperatures andare corrosion resistant.

NOTE: Schedule 40 ABS-DWV pipeand fittings may be used as analternate to PVC pipe for thecombustion air inlet and vent pipes.

NOTE: Cellular core PVC is alsoapproved for use. It must be schedule40PVC-DWV cellular pipe for non-pressure applications andmanufactured under ASTM F-891.

NOTE: With the furnace correctlyvented, the inducer will moveapproximately 25 cfm per 100,000Btu’s.

IMPORTANT: No part of thecombustion air and vent pipes mayrun under ground.

OVERTEMPERATURESAFETY SWITCHESFurnaces are equipped with safetyswitches in the control compartmentto protect against overtemperatureconditions caused by inadequatecombustion air supply. The switchesare located in the burnercompartment. If a switch is tripped itmust be manually reset.

DO NOT JUMPER THESEDEVICES! IF ONE OF THESESWITCHES SHOULD TRIP, AQUALIFIED INSTALLER, SERVICEAGENCY OR THE GAS SUPPLIERMUST BE CALLED TO CHECKAND/OR CORRECT FORADEQUATE COMBUSTION AIRSUPPLY. DO NOT RESET THESWITCHES WITHOUT TAKINGCORRECTIVE ACTION TO ASSURETHAT AN ADEQUATE SUPPLY OFCOMBUSTION AIR IS MAINTAINEDUNDER ALL CONDITIONS OFOPERATION. FAILURE TO DO SOCAN RESULT IN CARBONMONOXIDE POISONING ORDEATH. IF THIS UNIT IS MOUNTEDIN A CLOSET, THE DOOR MUSTBE CLOSED WHEN MAKING THISCHECK.

REPLACE THESE SWITCHESONLY WITH THE IDENTICALREPLACEMENT PART.

EXISTING VENT SYSTEMSWhen the installation of this furnacereplaces an existing furnace that isremoved from a vent system servingother appliances, the vent system islikely to be too large to properly ventthe remaining attached appliances.The following steps should befollowed with each applianceremaining connected to the originalcommon vent system. Place theappliance to be tested in operation,while the other appliances remainingconnected to the common ventsystem are not in operation. Test theoperation of each applianceindividually by the following method.1. Permanently seal any unused

openings in the common ventingsystem.

2. Visually inspect the ventingsystem for proper size andhorizontal pitch and determinethat there is no blockage,restriction, leakage, corrosion orother deficiencies which couldcause an unsafe condition.

3. If practical, close all buildingdoors, windows and all doorsbetween the space where theappliances remaining connectedto the common venting systemare located.Turn on clothes dryers and anyappliance not connected to thecommon venting system. Turn onany exhaust fans, such as rangehoods and bathroom exhausts,so they will operate at maximumspeed. Do not operate a summerexhaust fan. Close fireplacedampers.

4. Follow the lighting instructions.Place the appliance beinginspected into operation. Adjustthe thermostat so the appliancewill operate continuously.

5. Test for spillage at the draft hoodrelief opening after 5 minutes of

VENTING AND COMBUSTION AIR PIPING

! WARNING

! WARNING

14

CEMENTING JOINTSProperly seal all joints in the PVCvent using the following materials andprocedures.PVC CLEANER-PRIMER ANDPVC MEDIUM-BODY SOLVENTCEMENTIMPORTANT: After cutting pipe,remove all ragged edges and burrs.This is important to prevent reductionin pressure drop throughout thesystem.1. Cut pipe end square. Chamfer

edge of pipe. Clean fitting socketand pipe joint area of all dirt,grease and moisture.

2. After checking pipe and socketfor proper fit, wipe socket andpipe with cleaner-primer. Applya liberal coat of primer to insidesurface of socket and outside ofpipe. Read instructions includedwith the primer for properapplication.

3. Apply a thin coat of cementevenly in the socket. Quicklyapply a heavy coat of cement tothe pipe end and insert pipe intofitting with a slight twistingmovement until it bottoms out.NOTE: Cement must be fluid; ifnot, recoat.

4. Hold the pipe in the fitting for 30seconds to prevent the taperedsocket from pushing the pipe outof the fitting.

5. Wipe all excess cement from thejoint with a rag. Allow 15 minutesbefore handling. Cure time variesaccording to fit, temperature andhumidity.

NOTE: Stir the solvent cementfrequently while using. Use a naturalbristle brush or the dauber suppliedwith the can. The proper brush size isone inch.IMPORTANT: For Proper Installation

DO NOT use solvent cement thathas become curdled, lumpy orthickened.DO NOT thin. Observe shelfprecautions printed on containers.For application below 32°F, use onlylow-temperature-type solventcement.

main burner operation. Use theflame of a match or candle, orsmoke from a cigarette, cigaror pipe.

6. After it has been determined thateach appliance that remainsconnected to the commonventing system properly vents(when tested as outlined above),return doors, windows, exhaustfans, fireplace dampers and anyother gas-burning appliance totheir previous conditions of use.

7. If improper venting is observedduring any of the above tests, thecommon venting system must beresized.

When the furnace is installed in thesame space with other gasappliances such as a water heater, besure there is an adequate supply ofcombustion and ventilation air for theother appliances. Do not delete orreduce the combustion air supplyrequired by the other gas appliancesin this space. See Z223.1, NationalFuel Gas Code (NFPA54) fordetermining the combustion airrequirements for gas appliances. Anunconfined space must have at least50 cubic feet (volume) for each1,000 BTUH of the total input of allappliances in the space. If the openspace containing the appliances is ina building with tight construction(contemporary construction), outsideair may still be required for theappliances to burn and vent properly.Outside air openings should be sizedthe same as for a confined space.IMPORTANT: Only the current ventinstructions apply. All 90 Plus GasFurnaces cannot be common vented.

JOINING PIPE AND FITTINGS

PVC SOLVENT CEMENTS ANDPRIMERS ARE HIGHLYFLAMMABLE. PROVIDEADEQUATE VENTILATION AND DONOT ASSEMBLE NEAR HEATSOURCE OR AN OPEN FLAME. DONOT SMOKE. AVOID SKIN OR EYECONTACT. OBSERVE ALLCAUTIONS AND WARNINGSPRINTED ON MATERIALCONTAINERS. FAILURE TOFOLLOW THESE GUIDELINESMAY RESULT IN FIRE, EXPLOSIONOR ASPHYXIATION CAUSINGPERSONAL INJURY OR DEATH.All pipe, fittings, solvent cement,primers and procedures mustconform to American NationalStandard Institute and AmericanSociety for Testing and Materials(ANSI/ASTM) standards in the U.S.Pipe and Fittings - ASTM-D1785,D2466, D2665, D2231, D2661 andF628.PVC Primer and Solvent Cement -ASTM-D2564ABS Pipe and Fittings - Use ABSPrimer and Solvent Cement D2235Procedure for Cementing Joints -ASTM-D2855IMPORTANT: The plastic combustionair and venting components are ofPVC. If using ABS piping, ensure thatthe solvent cement is compatible forjoining PVC to ABS components oruse a mechanical connection that canwithstand the vent temperatures andare corrosion resistant.

! WARNING

15

NON-DIRECTFURNACE INSTALLATIONS

THE FURNACE AND ANY OTHERFUEL-BURNING APPLIANCE MUSTBE PROVIDED WITH ENOUGHFRESH AIR FOR PROPERCOMBUSTION AND VENTILATIONOF THE FLUE GASES. MOSTHOMES WILL REQUIRE THATOUTSIDE AIR BE SUPPLIED INTOTHE FURNACE AREA. FAILURETO DO SO CAN CAUSEPERSONAL INJURY OR DEATHFROM CARBON MONOXIDEPOISONING.

Adequate facilities for providing air forcombustion and ventilation must beprovided in accordance with section5.3, “Air for Combustion andVentilation” of the National Fuel GasCode, ANSI Z223.1 (latest edition) orapplicable provisions for the localbuilding codes, and not obstructed soas to prevent the flow of air to thefurnace.

IMPORTANT: Air for combustion andventilation must not come from acorrosive atmosphere. Any failuredue to corrosive elements in theatmosphere is excluded fromwarranty coverage.

The following types of installation(but not limited to the following) willrequire OUTDOOR AIR forcombustion, due to chemicalexposures:

• 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 substancesin the combustion air supply (but notlimited to the following) will alsorequire OUTDOOR AIR forcombustion:

• 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 asperchloroethylene)

• 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 acid-forming chemicals such as sulphur,fluorine and chlorine. These elementsare found in aerosol sprays,detergents, bleaches, cleaningsolvents, air fresheners, paint andvarnish removers, refrigerants andmany other commercial andhousehold products. When burned ina gas flame, vapors from theseproducts form acid compounds. Theacid compounds increase the dewpoint temperature of the flue productsand are highly corrosive after theycondense.

ALL FURNACE INSTALLATIONSMUST COMPLY WITH THENATIONAL FUEL GAS CODE ANDLOCAL CODES TO PROVIDEADEQUATE COMBUSTION ANDVENTILATION AIR FOR THEFURNACE. FAILURE TO DO SOCAN RESULT IN EXPLOSION,FIRE, PROPERTY DAMAGE,CARBON MONOXIDE POISONING,PERSONAL INJURY OR DEATH.

Combustion air requirements aredetermined by whether the furnace isin an open (unconfined) area or in aconfined space such as a closet orsmall room.

EXAMPLE 1:FURNACE LOCATED IN ANUNCONFINED SPACE

Using indoor air for combustion.

An unconfined space must have atleast 50 cubic feet for each 1,000BTUH of the total input for allappliances in the space. Here are afew examples of the room sizesrequired for different inputs. The sizesare based on 8-foot ceilings.

BTUH Minimum Sq. Feet Typical Room SizeInput 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 thefurnace is in a building with tightconstruction, outside air may still berequired for the furnace to operateand vent properly. Outside airopenings should be sized the sameas for a confined space.

EXAMPLE 2:FURNACE LOCATED IN ACONFINED SPACE

A confined space (any space smallerthan shown above as “unconfined”)must have openings into the spacewhich are located in accordance withthe requirements set forth in thefollowing subsections A and B. Sizethe openings by how they areconnected to the heated area or tothe outside,and by the input of all appliances inthe space.

If confined space is within a buildingwith tight construction, combustion airmust be taken from outdoors or areafreely communicating with theoutdoors.

A. USING INDOOR AIR FORCOMBUSTION

IMPORTANT: Air should not betaken from a heated space with afireplace, exhaust fan or otherdevice that may produce anegative pressure.

If combustion air is taken from theheated area, the openings musteach have at least 100 squareinches of free area. Each openingmust have at least one square inchof free area for each 1,000 BTUHof total input in the space. Hereare some examples of typicalopenings required.

COMBUSTION AND VENTILATION AIR

! WARNING

! WARNING

16

BTUH Free AreaInput Each Opening

45,000 100 square inches






B. USING OUTDOOR AIR FORCOMBUSTION

IMPORTANT: Do not take air froman attic space that is equippedwith power ventilation.

The confined space mustcommunicate with the outdoors inaccordance with Methods 1 or 2.The minimum dimension of airopenings shall not be less than 3inches. Where ducts are used,they shall be of the same cross-sectional area as the free area ofthe openings to which theyconnect.

Method 1Two permanent openings, onelocated within 12 inches of the topand one located within 12 inchesof the bottom of the enclosure,shall be provided. The openingsshall communicate directly, or byducts, with the outdoors or spaces(crawl or attic) that freelycommunicate with the outdoors.

a. Where directly communicatingwith the outdoors or where

communicating to the outdoorsthrough vertical ducts as shown inFigure 10, each opening shallhave a minimum free area of 1square inch for each 4,000 BTUHof total appliance input rating in theenclosure.

BTUH Free Area Round PipeInput Each Opening Size

45,000 11.25 square inches 4"






b. Where communicating withoutdoors through horizontal ducts,each opening shall have aminimum free area of 1 squareinch for each 2,000 BTUH of totalinput rating of all equipment in theenclosure (see Figure 11).

Here are some typical sizes:








FIGURE 10AIR FROM ATTIC/CRAWL SPACE

FIGURE 11OUTSIDE AIR USING A HORIZONTAL DUCT

FIGURE 9AIR FROM HEATED SPACE

NOTE:EACH OPENING SHALLHAVE A FREE AREA OFNOT LESS THAN ONESQUARE INCH PER 1,000BTU PER H0UR OF THETOTAL INPUT RATING OFALL EQUIPMENT IN THEENCLOSURE, BUT NOTLESS THAN 100 SQUAREINCHES.

GASWATERHEATER

FURNACE

GASWATERHEATER

GASWATERHEATER

FURNACE FURNACE

12" MAX.12"

MAX.

1 SQ. INCH PER4000 BTUH INLET AIR

OUTLET AIR 1 SQ. INCHPER 2000 BTUH

INLET AIR 1 SQ. INCHPER 2000 BTUH

1 SQ. INCH PER4000 BTUH

OUTLET AIR

OP

TIO

NA

L 1

SQ

. IN

CH

PE

R 4

000

BT

UH

INL

ET

AIR

VENTILATEDATTIC GABLE ORSOFFIT VENTS

GABLEVENTOUTLET AIR

IN ATTICMUST BEABOVEINSULATION

17

FIGURE 12COMBUSTION AIR FITTING

Method 2 (not shown)One permanent opening, locatedwithin 12 inches of the top of theenclosure, shall be permittedwhere the equipment hasclearances of at least 1 inch fromthe sides and back and 6 inchesfrom the front of the appliance.The opening shall directlycommunicate with the outdoors orcommunicate through a vertical orhorizontal duct to the outdoors orspaces (crawl or attic) that freelycommunicate with the outdoors,and shall have a minimum freearea of:

a. 1 square inch for each 3,000BTUH of the total input rating of allequipment located in the enclosureand








b. Not less than the sum of theareas of all vent connectors in theconfined space.

If unit is installed where there is anexhaust fan, sufficient ventilationmust be provided to prevent theexhaust fan from creating a negativepressure.

Combustion air openings must not berestricted in any manner.

CONSULT LOCAL CODES FORSPECIAL REQUIREMENTS.

CONNECTION TOFURNACEIMPORTANT: When indoorcombustion air is used, the inlet airopening at the furnace must beprotected from accidental blockage.(See Figure 12).

UPFLOW

DOWNFLOW/HORIZONTAL

2" PVCDOUBLEELBOW

TOPOPTION

EXHAUST

2" PVC ELBOW

SIDEOPTION

2" PVCDOUBLEELBOW*

COMBUSTION AIREXHAUST

ATTACH DOUBLE ELBOW TO INTAKE AIRCOLLAR AND SECURE WITH TWO SHEETMETAL SCREWS TO PREVENT ACCIDENTALBLOCKAGE OF INTAKE AIR OPENING.

*NOTE: WHEN FURNACE IS INSTALLED IN A HORIZONTAL POSITIONONLY ONE 90° ELBOW IS REQUIRED. INSTALL THE ELBOW SO THEOPEN END IS POINTED DOWNWARD.

ATTACH DOUBLE ELBOW TO TOP INLETAIR OPENING OR 90° ELBOW TO SIDEINLET AIR OPENING TO PREVENTACCIDENTAL BLOCKAGE OF INTAKEOPENING. PLUG OPENING NOT USED.

I337I336

PREDRILL FOR SCREWS.

18

ELEVATED SINGLE PIPE ALTERNATE TEE TERMINATIONSee Figure 14. The tee termination may be elevated up to 24 inches above thewall penetration if required for anticipated snow levels. Use 2 long-sweep, 2-in.PVC elbows and 2-in. PVC pipe, attaching the tee so it is 12 inches from the wall.

NON-DIRECT VENTINSTALLATIONGUIDELINESIMPORTANT: Failure to correctly followall venting guidelines may result inerratic furnace operation, freeze-up ofcombustion air or exhaust air piping orsooting of the furnace.All exhaust piping must be installed incompliance with Part 7, “Venting ofEquipment,” of the latest edition of theNational Fuel Gas Code NPFA54/ ANSIZ223.1-, local codes or ordinances andthese instructions.1. Vertical piping is preferred.2. All horizontal piping must slope

upward a minimum of 1/4 inch perfoot of run so that condensate drainstoward the furnace.

3. All horizontal runs must besupported at least every 4 feet. Nosags or dips are permitted.

4. IMPORTANT: Do not common ventwith any other appliance. Do notinstall in the same chase or chimneywith a metal or high temperatureplastic pipe from another gas or fuel-burning appliance unless therequired minimum clearances tocombustibles are maintainedbetween the pvc pipe and otherpipes.

5. All vent runs through unconditionedspaces where below-freezingtemperatures are expected shouldbe insulated with 1-in. thick,medium-density, foil-facedfiberglass. An equivalent “arm-a-flex” or “rub-a-tex” insulation mayalso be used as long as there is noheat tape applied to the vent pipe.For horizontal runs where water maycollect, wrap the vent pipe with self-regulating 3 or 5 watt heat tape. Theheat tape must be U.L. listed andinstalled per the manufacturer’sinstructions.

6. The minimum vent pipe length is5 feet.

7. Extend the exhaust pipe a minimumof 18” from the cabinet before turningvent.

8. Vent cannot be ran underground.

FIGURE 13TEE TERMINAL – FOR STANDARDHORIZONTAL NON-DIRECTINSTALLATION

VENT

12" 12" MIN. ABOVEGRADE OR

SNOW LEVEL

NUMBERS OF ELBOWS45° 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 30 25 20

Alternate 25 20 1560,000

3”Standard 120 120 115

Alternate 120 120 110

3”Standard 110 105 95

75,000 (A*)Alternate 80 70 65

3”Standard 110 105 95

75,000 (B*)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 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FOR

ALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4. NO SCREENS MAY BE USED TO COVER EXHAUST.*A = 17-1/2” CABINET WIDTH B = 21) CABINET WIDTH

FURNACEINPUT

VENT PIPE INSTALLATION

PIPESIZE

TERMINATION

TABLE 2UPFLOW UNITSFOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM INDOORS

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

NUMBERS OF ELBOWS45° OR 90°


1-2 3-4 5-6

2”Standard 40 35 30

Alternate 30 25 2060,000

3”Standard 120 120 120

Alternate 110 105 100

3”Standard 120 120 120

75,000 (A*)Alternate 100 95 85

3”Standard 120 120 120

75,000 (B*)Alternate 100 95 85

90,000 3”Standard 110 105 95

Alternate 50 40 35

105,000 3”Standard 65 60 55

Alternate 50 40 35

120,000 3”Standard 40 35 30

Alternate 40 35 30

NOTES:1. *N.R. - NOT RECOMMENDED.2. MAXIMUM OF 6 - 90 DEGREE ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FOR

ALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4. NO SCREENS MAY BE USED TO COVER EXHAUST.*A = 17-1/2” CABINET WIDTH B = 21” CABINET WIDTH

FURNACEINPUT

PIPESIZE

TERMINATION

TABLE 3DOWNFLOW/HORIZONTAL UNITSFOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM INDOORS


19

STANDARD INSTALLATIONSThe single-pipe system requires anexhaust pipe only. Combustion air maybe taken from the furnace installationarea or ducted to the furnace area fromthe outside.

Size the exhaust pipe as specified inTable 2. This table lists the maximumallowable length in feet of the exhaustpipe that may be used for all furnaceinputs as related to the number ofelbows required and the termination.(See shaded area.)

Vertical through-the-roof installations donot require a vent termination. Use 2-in.PVC pipe extending a minimum of 12inches above the anticipated level ofsnow accumulation. See exhaust piperequirements, Figure 18. When 3-in.vent pipe is used from furnace to theroof, reduce it to 2 inches beforepenetrating the roof. A maximum of 18inches of 2-in. pipe may be used belowthe roof. Maximum exposed vent lengthabove the roof line is 30”. Total 2” ventlength is a maximum of 48”.

Horizontal vent terminations require a2-in. PVC tee positioned 12 inches fromthe outside wall. See exhaust piperequirements, Figure 28. When 3-in.pipe is used from the furnace to theoutside wall, reduce it to 2 inchesbefore penetrating the wall. A maximumof 18 inches of 2-in. pipe may be usedinside the wall.

An alternate termination may be usedas shown in Figure 14 to clearanticipated snow levels. The tee maybe raised up to 24 inches above thewall penetration. Use two long-sweepradius bend, 2-in. PVC elbows and alength of 2-in. PVC pipe so that theelbows are on 24-in. centers.

NOTE: Extend the exhaust a minimumof 18" from the furnace top plate beforeturning vent.

NON-DIRECT VENT TERMINATIONLOCATION REQUIREMENTS

MOISTURE IN THE COMBUSTIONPRODUCTS CONDENSES AS ITLEAVES THE TERMINATION. THISCONDENSATE CAN FREEZE ONEXTERIOR WALLS, UNDER THEEAVES, AND ON SURROUNDINGOBJECTS. SOME DISCOLORATIONIS TO BE EXPECTED. HOWEVER,IMPROPER LOCATION ORINSTALLATION CAN CAUSESTRUCTURAL OR EXTERIOR FINISHDAMAGE TO THE BUILDING.

Non-direct venting locationrequirements are slightly different insome cases than direct venting. Installa non-direct vent with the followingminimum clearances.See Figure 15.

1. Locate the bottom of the ventterminal at least 12 inches abovegrade. Increase the 12-in.minimum to keep the terminalopenings above the level of snowaccumulation, where applicable.

2. The vent shall not terminate overpublic walkways or over an areawhere condensate or vapor couldcreate a nuisance or hazard.

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

4. The vent terminal shall have aminimum horizontal clearance of4 feet from electric meters, gasmeters, regulators and reliefequipment.

5. 6 feet from an inside cornerformed by two exterior walls –10 feet is the recommendeddistance.

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

7. Avoid areas where drippingcondensate may cause problems,such as above planters, patios, oradjacent to windows wheresteam may cause fogging.

! CAUTION

In addition to the minimum clearanceslisted above, the vent location shouldalso be governed by the followingguidelines.

1. Do not terminate under any kindof patio or deck. If running thevent under a deck, insulate it toinsure no condensate freezesand blocks the pipe.

2. Do not locate on the side of abuilding with prevailing winterwinds. This will help preventmoisture from freezing on wallsand overhangs (under eaves).

3. Do not extend vent directlythrough brick or masonrysurfaces. Use a rust-resistantsheet metal or plastic backingplate behind vent.

4. Do not locate too close to shrubsas condensate may stunt or killthem.

5. Minimum vertical clearances of 1foot are recommended foroverhangs up to 1 foot horizontal.The vertical clearance should beincreased equally for eachadditional increase in horizontaloverhang to a maximum verticalclearance of 6 feet.

6. Caulk all cracks, seams andjoints within 6 feet horizontallyand above and below vent.

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

FIGURE 14ALTERNATE HORIZONTAL TERMINATION FOR NON-DIRECT VENTINSTALLATIONS

12"

FROM

24"MAX.

PIPESUPPORTSTRAP

OUTSIDEWALL

I198

20

FIGURE 15OTHER THAN DIRECT VENT TERMINAL CLEARANCES

Nat

ural

Gas

and

Pro

pan

e In

stal

latio

n C

ode

Nat

iona

l Fue

l Gas

Cod

e

Can

adia

n In

stal

lati

on

sU

S In

stal

lati

on

sC

anad

ian

Inst

alla

tio

ns

US

Inst

alla

tio

ns

21

TABLE 5DOWNFLOW/HORIZONTAL UNITS FOR DIRECT VENT APPLICATIONS - AIR FORCOMBUSTION PROVIDED FROM OUTDOORS


1 - 2 3 - 4 5 - 6

1 - 2 3 - 4 5 - 6

DIRECT VENTINSTALLATIONS

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SECTION.FAILURE TO PROPERLY VENTTHIS FURNACE CAN CAUSECARBON MONOXIDE POISONINGOR AN EXPLOSION OR FIRE,RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.Direct vent installations require adedicated combustion air and ventingsystem. All air for combustion is takenfrom the outside atmosphere and allcombustion products are discharged tothe outdoors. Therefore, noventilation or combustion airopenings are required.IMPORTANT: The plastic combustionair and venting components are ofSchedule 40 PVC. If using ABS pipingensure that the solvent cement iscompatible for joining PVC to ABScomponents or use a mechanicalconnection that can withstand the venttemperatures and are corrosionresistant.

INSTALLATION GUIDELINESAll exhaust piping must be installed incompliance with Part 7, “Venting ofEquipment,” of the latest edition of theNational Fuel Gas Code NPFA54/ANSI Z223.1-, local codes orordinances and these instructions.1. Vertical piping is preferred.2. All horizontal piping must slope

upward a minimum of 1/4 inchper foot of run so that condensatedrains toward the furnace.

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

4. IMPORTANT: Do not commonvent with any other appliance. Donot install in the same chase orchimney with a metal or hightemperature plastic pipe fromanother gas or fuel-burningappliance unless the requiredminimum clearances tocombustibles are maintainedbetween the PVC pipe and otherpipes. Minimum 3 ft. clearancerequired between combustion airinlet and any other exhaust.

5. For horizontal runs where watermay collect, wrap the vent pipewith self-regulating 3 or 5 wattheat tape. The heat tape must beU.L. listed and installed per themanufacturer’s instructions.

6. The minimum, pipe length is5 feet for combustion air andexhaust.

7. Do not install elbows back toback. Allow at least 15” betweenelbows.

Size the exhaust and combustion airintake pipes as specified in Table 4 orTable 5. This table lists the maximum

! WARNING

Standard/Concentric RXGY-D02/RXGY-E03/RXGY-G01 65 60 5545,000 2”

Alternate RXGY-D02 55 50 45

Standard/Concentric RXGY-D02/RXGY-E03/RXGY-G01 40 35 302”

Alternate RXGY-D02 20 15 1060,000



75,000 (A*) 3”Standard/Concentric RXGY-D03/RXGY-E03/RXGY-G01 120 120 120


75,000 (B*) 3”Standard/Concentric RXGY-D03/RXGY-E03/RXGY-G01 100 100 100








NOTES:1.N.R. - NOT RECOMMENDED.2.MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.

3.A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4.CONCENTRIC TERMINATION NO. RXGY-E03 IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.5.USE KITS RXGY-DO2 (2") OR RXGY-D03 (3") FOR STANDARD OR ALTERNATE THRU-THE-WALL VENTING.6.USE KITS RXGY-D04 FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.7.NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.*A = 171⁄2” CABINET WIDTHB = 21” CABINET WIDTH

FURNACEINPUT

PIPESIZE

TERMINATION

VENT TERMINATIONKIT RECOMMENDED(RXGY-D0* Kits for

Horizontal Venting Only)

NUMBER OF ELBOWS45° or 90°


TABLE 4UPFLOW UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM OUTDOORS

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


Alternate RXGY-D02 30 25 2060,000



75,000 (A*) Standard/Concentric RXGY-D03/RXGY-E03/RXGY-G01 120 120 120

75,000 (B*)3”






Standard/Concentric RXGY-D03/RXGY-E03/RXGY-G01 40 35 30

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


NOTES:1.N.R. - NOT RECOMMENDED.2.MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.

3.A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.4.CONCENTRIC TERMINATION NO. RXGY-E03 IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.5.USE KITS RXGY-DO2 (2") OR RXGY-D03 (3") FOR STANDARD OR ALTERNATE THRU-THE-WALL VENTING.6.USE KITS RXGY-D04 FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.7.NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.*A = 171⁄2” CABINET WIDTHB = 21” CABINET WIDTH

FURNACEINPUT

PIPESIZE

TERMINATION

VENT TERMINATIONKIT RECOMMENDED(RXGY-D0* Kits for

Horizontal Venting Only)

NUMBER OF ELBOWS45° or 90°


22

COMBUSTION AIR FORDIRECT VENTINSTALLATIONSTHE COMBUSTION AIR SYSTEMDESIGNED FOR THIS FURNACEMUST BE USED.

When this furnace is installed as adirect vent forced air furnace, allcombustion air is supplied directly tothe burner through a special air inletsystem outlined in these instructions.This system consists of field-suppliedSchedule 40 or 26 SDR-PVC pipeand one of the following horizontalvent termination kits: RXGY-D02,RXGY-D03, RXGY-D04, orRXGY-E03.

NOTE: Schedule 40 ABS-DWV pipeand fittings may be used as analternate to PVC pipe for thecombustion air inlet and vent pipes.

The combustion air for this furnace issupplied directly from the outdoorsthrough the combustion air inletsystem.

When the furnace is installed in thesame space with other gasappliances, such as a water heater,be sure there is an adequate supplyof combustion and ventilation air forthe other appliances. Do not delete orreduce the combustion air supplyrequired by the other gas appliancesin this space. See Z223.1, NationalFuel Gas Code (NFPA54) for deter-mining the combustion airrequirements for gas appliances. Anunconfined space must have at least50 cubic feet (volume) for each1,000 BTUH of the total input of allappliances in the space. If the openspace containing the appliances is ina building with tight construction(contemporary construction), outsideair may still be required for theappliances to burn and vent properly.Outside air openings should be sizedthe same as for a confined space.

STANDARD TERMINATIONSSTANDARD VERTICALTERMINATIONS

COMBUSTION AIR PIPING

Use two medium-radius sweepelbows to keep the inlet downward to

prevent entry of rain. See Figure 18for the proper relationship ofcombustion air to exhausttermination.

STANDARD HORIZONTALTERMINATIONS

COMBUSTION AIR PIPING

When 3-in. pipe is used between thefurnace and outside wall, reduce itto 2 inches before penetrating thewall. Up to 18 inches of 2-in. pipemay be used inside the wall.

The standard horizontal intake airtermination for all models is a 2-in.PVC coupling with a wind deflectorvane (provided) attached. Cut a21/4-in. length of 2-in. PVC pipe.Connect this pipe and another 2-in.PVC coupling to the coupling at thewall. The outer coupling mustterminate 4 inches from the wall.

IMPORTANT: To ensure properfurnace operation, the supplied vanemust be installed in the verticalposition with PVC solvent as shown inFigure 19, Detail B.

The combustion air inlet terminalmust be located with respect to theexhaust terminal as shown in Figure19, Detail C.

IMPORTANT: All furnaces withhorizontal air intakes, except thoseusing concentric vent kit RXGY-E03,must have a drain tee assembly andtrap installed as close to the furnaceas possible. This is to drain any waterthat may be in the combustion airpipe to prevent it from entering thefurnace combustion chamber.

These parts are included in kitsRXGY-D02 (for 2-in. pipe), RXGY-D03 (for 3-in. pipe) and RXGY-D04(special for the 120,000 BTU furnaceinstalled with the alternate horizontaltermination). Attach the trap to thebottom of the tee with PVC solvent.Connect the other end to a suitabledrain, as to the downstream of acondensate trap on the furnace.

STANDARD VERTICALTERMINATIONS

EXHAUST VENT PIPING

Vertical through-the-roof ventapplications do not require anexhaust terminal. The exhaust ventmust terminate at least 12 inchesabove the combustion intake airtermination. The exhaust vent formodels with inputs of 90,000 through

120,000 BTUH is 2-in. PVC pipe120,000 BTUH models withexcessively long runs require 21/2”.Refer to Table 4 for properapplication. This mustbe reduced to 11/2“ the last12 inches for models with inputs of45,000 through 75,000 BTUH.See Figure 18.

STANDARD HORIZONTALTERMINATIONS

EXHAUST PIPING

For direct vent systems the standardtermination is 2-in. PVC pipeextending 12 inches from the wall forfurnaces with inputs from 105,000 to120,000 BTUH. Install a 2-in. couplingat the outside wall to prevent thetermination from being pushedinward. When 3-in. pipe is usedbetween the furnace and outside wall,reduce to 2 inches before penetratingthe wall. The standard termination is11/2 -in. PVC pipe extending outward12 inches from the wall for modelswith inputs of 45,000 to 75,000BTUH. Install a 2-in. to 11/2-in.coupling at the outside wall to preventpushing the termination back into thewall. See Figure 19, Detail A.

The combustion air and exhaustterminations must be at least 12inches above grade and must beoriented with respect to each other asshown in Figure 19, Detail B. Refer tosection on alternate venting optionswhen higher snow levels areanticipated.

ALTERNATETERMINATIONSALTERNATE HORIZONTALDIRECT VENT TERMINATIONS

RXGY-D02, -D03 AND -D04

The combustion air and exhaustterminations may be raised amaximum of 24 inches above thewall penetration to maintain therequired 12 inch clearance abovegrade or snow level. See Figure 16.Size the pipe length according toTable 4 and Table 5.

Review the following guidelines:

• Size the entire vent systemaccording to the alternate, notstandard, termination shown inTable 4 and Table 5.

allowable length in feet of the exhaustand combustion air intake pipes thatmay be used for all furnace inputs asrelated to the number of elbowsrequired and the termination (seeshaded area).NOTE: Extend the exhaust a minimumof 18" from the furnace top platebefore turning vent.8. The maximum exposed vent

length (above the roof line) is 30”.

23

FIGURE 16ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

SEE DETAIL A

24” MAX.

PIPESUPPORTSTRAP

3” MAX.NOTE: 3-1/2”MAX. WHEND04 KIT ISUSED.

EXHAUST VENT21/2" PVC FOR MODELS WITH 120,000 BTU INPUT(KIT NO. RXGY-D04)

2" PVC FOR MODELS WITH INPUTS OF 90,000 AND120,000 BTU. REDUCE TO 11/2" FOR MODELS WITHINPUTS OF 45,000 THRU 75,000 BTU (SEE DETAIL A).ELBOWS AND RISERS ARE 2" PVC.

INTAKE VENT21/2" PVC FOR MODELS WITH120,000 BTU INPUT.2" PVC ELBOWS AND RISERMODELS WITH INPUTS OF 45,000THRU 105,000 BTU.USE KIT NO. RXGY-D02 WHEN 2" PIPEIS USED BETWEEN FURNACE ANDOUTSIDE WALL. USE KIT NO. RXGY-D03WHEN 3" PIPE IS USED.

I339

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

• All elbows installed on the exteriorof the building must be of the longsweep nature.

• As required for the horizontal pipingran within the structure, any piperan horizontal outside the structuremust slope upward a minimum of1/4” per foot run so that condensatedrains toward the furnace.

From the top elbow in the exhaustpipe, extend a length of PVC pipeoutward so that it terminates exactly12 inches from the wall. See Figure16. Reduce the exhaust pipeextension to is 11/2 inch pipe for45,000 BTUH through 75,000 BTUHunits.

The 45,000 BTUH unit only uses kitRXGY-D02. The 60,000 BTUH and75,000 BTUH units may use kitsRXGY-D02 or RXGY-D03 dependingon pipe lengths and number ofelbows. Use kit RXGY-D03 with90,000 BTUH through 120,000 BTUHunits. The RXGY-D04 kit onlyapplies to the 120,000 BTUH unitusing an alternate termination andexcessively long runs. See Table 4.

The following are parts lists for theRXGY-D02, RXGY-D03 and RXGY-D04 alternate horizontal direct venttermination kits:

RXGY-D021. 2-in. tee with reducer assembly2. 1/2-in. PVC 6-in. dia. trap3. PVC vane4. 2-in. PVC elbow5. 11/2-in. PVC nipple with coupling6. PVC strap7. vent template

RXGY-D031. 3-in. tee with reducer assembly2. 1/2-in. PVC 6-in. dia. trap3. PVC vane4. 2-in. PVC elbow5. PVC strap6. vent template

RXGY-D041. 21/2-in. PVC elbow2. 3" x 21/2" PVC bushing3. 21/2" x 61/2" long PVC pipe4. 21/2" x 16" long PVC pipe5. 21/2" x 21" long PVC pipe6. PVC vane7. 3-in. tee with reducer assembly8. 6-in. dia. 1/2-in. PVC trap9. PVC strap

10. vent template

NOTE: The RXGY-D04 kit onlyapplies to the 120,000 BTUH unitusing an alternate termination andexcessively long runs.

3”

4”EXHAUST VANE

INTAKE OPTIONALINTAKE

DETAIL BEXHAUST / INTAKE RELATIONSHIP

DETAIL AEXHAUST VENT FOR

MODELS WITHINPUT OF 45,000 THRU

75,000 BTU

DETAIL CCOMBUSTION AIR

TERMINATION

4" FROMWALL

12"FROMWALL

1-1/2"PIPE

12" FROMWALL

24

FIGURE 17CONCENTRIC VENT KIT NO. RXGY-E03

SIDEWALL ASSEMBLY

ROOF INSTALLATION

1" MAXIMUM

FIELD-SUPPLIEDSTRAP

ITEM No. DESCRIPTION

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

B 4" PVC PIPE SCHEDULE 40 -- 24" LONG

C 3" x 3" x 4" SPECIAL CONCENTRIC FITTING

D 3" x 45° STREET ELBOW (FIELD SUPPLIED)

E PVC RAINCAP

E

B

A

C

D

E

B

A

C

D

CONCENTRIC TERMINATIONSVERTICAL/HORIZONTAL CONCENTRIC VENTKIT NO. RXGY-E03

This kit is for vertical/horizontalintake air/vent runs and may beinstalled through roofs or sidewalls.One 5” diameter hole is required forthe installation. See Figure 17 forthe general layout. Completeinstallation instructions are includedwith the kit.

MAINTAIN 12 IN.MINIMUM CLEARANCEABOVE HIGHESTANTICIPATED SNOWLEVEL. MAXIMUM OF24 IN. ABOVE ROOF.

NOTE: • Support must be field installedto secure termination kit to structure.

• No screens may be used to covercombustion air and exhaust.

25

FIGURE 18STANDARD VERTICAL DIRECT VENTING

FIGURE 19STANDARD HORIZONTAL DIRECT VENTING

I407

3" MAX.SEPARATION

36" MAX. COMBUSTION AIRPIPE

12" MIN.SEPARATION

12" MIN. ABOVEROOF LEVELROOF LINEEXHAUST PIPE

COMBUSTION AIR PIPE

SUPPLY AIR

RETURN AIR

EXHAUST VENT

3"MAX.

EXHAUSTVENT

ROOF LINE

COMBUSTIONAIR PIPE

12"MIN.

12"MIN.

ANTICIPATEDSNOW LEVEL

COMBUSTIONAIR PIPE

3"MAX.EXHAUST

VENT

12"MIN.

12"MIN.

3"

MAX.

12" MIN. 12" MIN. ABOVE

ANTICIPATED SNOW LEVEL

NOTES:

1 INCREASE THE 12-IN. MINIMUMTO KEEP TERMINAL OPENINGABOVE ANTICIPATED LEVEL OFSNOW ACCUMULATION WHEREAPPLICABLE.

2 WHEN 3-IN. DIAM. PIPE IS USED,REDUCE TO 2-IN. DIAMETER BEFOREPENETRATING ROOF. A MAXIMUMOF 18 IN. OF 2-IN. PIPE MAY BEUSED BEFORE PASSINGTHROUGH ROOF.

3 SUPPORT VERTICAL PIPE EVERY 6FEET.

4 EXHAUST TERMINATION - TERMINATETHE LAST 12 INCHES WITH 2” PVC PIPEON 90,000 AND 120,000 BTUH MODELS.REDUCE AND TERMINATE THE LAST12 INCHES WITH 11/2” PVC PIPE ON45,000 THROUGH 75,000 BTUHMODELS. SEE DETAIL A.

5 30” MAXIMUM EXPOSED VENTLENGTH.

6 THE COMBUSTION AIR PIPE MUSTTERMINATE IN THE SAME PRESSUREZONE AS THE EXHAUST PIPE.

7 NO SCREENS MAY BE USED TOCOVER COMBUSTION AIR ANDEXHAUST.

PITCHED ROOF INSTALLATIONS

NOTES:

1 SUPPORT HORIZONTAL PIPEEVERY FOUR FEET.

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

3 18 IN. MAXIMUM. 2 IN. DIAMETER PIPE MAYBE USED INSIDE THE WALL.

4 DETAIL “A” - EXHAUST TERMINATIONTERMINATE THE LAST 12 INCHES WITH 2”PVC PIPE ON 90,000 AND 120,000 BTUHMODELS. REDUCE AND TERMINATE THELAST 12 INCHES WITH 11/2” PVC PIPE ON45,000 THROUGH 75,000 BTUH MODELS.

5 INCREASE THE 12 IN. MINIMUM ABOVEGRADE TO KEEP TERMINAL OPENINGSABOVE ANTICIPATED LEVEL OF SNOWACCUMULATION WHERE APPLICABLE.

6 DETAIL “B”, INSTALL WIND DEFLECTORVANE IN 2 IN. PVC COUPLING IN VERTICALPOSITION USING PVC SOLVENT.THE COMBUSTION AIR TERMINATION MUSTBE IN THE SAME PRESSURE ZONE AS THEEXHAUST TERMINATION.

7 THE COMBUSTION AIR PIPE MUSTTERMINATE IN THE SAME PRESSUREZONE AS THE EXHAUST PIPE.

8 NO SCREENS MAY BE USED TO COVERCOMBUSTION AIR AND EXHAUST.

9 NO ELBOWS CAN BE INSTALLED ATTERMINATION.

3”

12”

4”

4”

SEE DETAIL A

VANE 2” PVCCOUPLING

12” MIN. ABOVEGRADE LEVEL 5

SEE DETAIL B

2” OR 3” TEEW/DRAIN TRAP

RETURN AIR

TRAP

SUPPLY AIR

EXHAUST PIPE

COMBUSTION AIR PIPE

CONNECTTO DRAIN

12”

4”EXHAUST

INTAKE OPTIONALINTAKE

DETAIL CEXHAUST / INTAKE RELATIONSHIP

EXHAUST TERMINATION

DETAIL A

COMBUSTION AIR TERMINATION

DETAIL B

1 23

I407

3

5

5

5

4

6

1

6

2

48” MAX

30” MAX

4

530” MAX

EXHAUSTTERMINATION

DETAIL A

12”

26

LOCATION REQUIREMENTSHORIZONTAL DIRECT VENTS

THE COMBUSTION PRODUCTSAND MOISTURE IN THE FLUEGASES WILL CONDENSE AS THEYLEAVE THE TERMINATION. THECONDENSATE CAN FREEZE ONTHE EXTERIOR WALL, UNDERTHE EAVES AND ONSURROUNDING OBJECTS. SOMEDISCOLORATION TO THEEXTERIOR OF THE BUILDING ISTO BE EXPECTED. HOWEVER,IMPROPER LOCATION ORINSTALLATION CAN RESULT INSTRUCTURAL OR EXTERIORFINISH DAMAGE TO THEBUILDING AND MAYRECIRCULATE PRODUCTS OFCOMBUSTION INTO THECOMBUSTION AIR TERMINAL ANDFREEZE.

The vent must be installed with thefollowing minimum clearances. SeeFigures 20 and 21.

1. The bottom of the vent terminaland the air inlet shall be locatedat least 12 inches above grade.Increase the 12-in. minimum tokeep the terminal openingsabove the level of snowaccumulation, where applicable.

2. The vent shall not terminate overpublic walkways or over an areawhere condensate or vapor couldcreate a nuisance or hazard.

3. The vent terminal shall belocated at least one foot from anyopening through which fluegases could enter a building.

4. The vent terminal shall be atleast 3 feet above any forced airinlet located within 10 feet,except the combustion air inlet ofa direct vent appliance.

5. The vent terminal shall have aminimum horizontal clearance of4 feet from electric meters, gasmeters, regulators and reliefequipment.

6. Locate the furnace combustionair inlet minimum of 3 feet fromthe vent of any other gas or fuelburning appliance or clothesdryer to prevent recirculation ofthe flue gases into the furnacecombustion air inlet. The onlyexception to this requirement isthe case of multiventing two ormore furnaces, which is coveredin the section on multiventing inthese instructions.

In addition to the minimum clearanceslisted above, the vent locationshould also be governed by thefollowing guidelines.

1. Do not terminate under anykind of patio or deck. If runningthe vent under a deck, insulateit to insure no condensatefreezes and blocks the pipe.

2. Do not terminate behind any areathat may allow the flue productsto become stagnant andrecirculate.

3. Do not locate on the side of abuilding with prevailing winterwinds. This will help preventmoisture from freezing on wallsand overhangs (under eaves).

4. Do not extend vent directlythrough brick or masonrysurfaces. Use a rust-resistantsheet metal or plastic backingplate behind vent.

5. Do not locate too close to shrubsas condensate may stunt orkill them.

6. Minimum vertical clearances of 1foot are recommended foroverhangs up to 1 foot horizontal.The vertical clearance should beincreased equally for eachadditional increase in horizontaloverhang to a maximum verticalclearance of 6 feet.

7. Caulk all cracks, seams andjoints within 6 feet horizontallyand above and below vent.

8. Painted surfaces must be soundand in good condition with nocracking, peeling, etc. Paintedsurfaces will requiremaintenance.

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

FIGURE 20MOISTURE ZONES

! CAUTION

2 FT. SQ. SHEET METAL PLATE ON BRICK ORMASONRY SURFACE RECOMMENDED, BUTNOT REQUIRED BY CODE.

27

FIGURE 21DIRECT VENT TERMINAL CLEARANCES≤

Nat

ural

Gas

and

Pro

pan

e In

stal

latio

n C

ode

Nat

iona

l Fue

l Gas

Cod

e

Can

adia

n In

stal

lati

on

sU

S In

stal

lati

on

sC

anad

ian

Inst

alla

tio

ns

US

Inst

alla

tio

ns

28

FIGURE 23TWO FURNACE VENTING THROUGH WALL

8"

MAXIMUM 1" DISTANCE

FROM WALL

MINIMUM 12" ABOVE GRADE

6' MINIMUM10' RECOMMENDED

FIGURE 22TWO FURNACE VENTING THROUGH ROOF

CONCENTRIC VENTING CONCENTRIC VENTING

MINIMUM 12” ABOVE AVERAGESNOW ACCUMULATION. MAXIMUM

OF 24 IN. ABOVE ROOF.

COMBUSTIONAIR INTAKE2” PVC

12” MIN. A

BOVE

SNOW LEVEL

6” MIN.

10” RECOMMENDED

COMBUSTIONAIR INTAKE2” PVC COUPLINGWITH VALVE INVERTICAL POSITION

EXHAUST VENT

6” MINIMUM10” RECOMMENDED

MAXIMUM 1”DISTANCE

FROM WALL

MINIMUM 12”ABOVE GRADE

SEE CONCENTRIC VENT INSTALLATIONINSTRUCTIONS.

SEE CONCENTRICVENT INSTALLATIONINSTRUCTIONS

TWO-PIPE VENTING TWO-PIPE VENTING

3" MIN.24" MAX.

8" MIN.24" MAX.

3" MIN.24" MAX.

8" MIN.24" MAX.

MULTIVENTINGIF VENTING TWO OR MOREFURNACES NEAR EACH OTHER ISREQUIRED, EACH FURNACEMUST BE INDIVIDUALLY VENTED– NO COMMON VENTING ISPERMITTED. See Figures 22 and 23for positioning of the terminations.When more than two furnaces are tobe vented, there must be at least 4feet between the first two furnacesand the third, etc.

29

FIGURE 24UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION

I329

CONDENSATE TRAP

CONNECTOR

INDUCED DRAFTBLOWER

PLUG OPT. COMBUSTIONAIR POSITION

NOTE:WHEN COMBUSTION AIR IS INOPTIONAL POSITION SWAP LOCATIONOF 2" PVC MALE ADAPTER AND “O”RING WITH PLUG.

EXHAUST TRANSITION

EXHAUSTOUTLET AIR PIPE

EXHAUSTVENT CAP/PLUG

TOP PLATE

“O” RING COMBUSTIONAIR ADAPTER

DRAIN HOSES(AS SHIPPED FROM

FACTORY)

CONNECTING TO FURNACEIMPORTANT: Clean and debur allpipe cuts. The shavings must not beallowed to block the exhaust,combustion air or condensate drainpipes.

UPFLOW FURNACEThe exhaust pipe connection is a 2-in.female PVC pipe fitting extendingthrough the left side of the furnace topplate. This opening has a protectivecap which should be removed justprior to installing the exhaust pipe.When 2-in. pipe is used, connect itdirectly to this fitting. When 3-in. pipeis used, connect a 2 to 3-in. couplingto this fitting with a short piece of 2-in.PVC pipe.

The combustion air connectionis at the right side of the top plate.An alternate combustion airconnection may be made on the rightside of the jacket. This opening has aplastic cap. A combustion airconnection fitting is supplied with thefurnace and it must be installed in thefurnace by screwing it into theopening. Make sure the rubber“O-ring” supplied with the furnace isused with this fitting. See Figure 24.

DOWNFLOW/HORIZONTALFURNACEThe exhaust pipe connection is a 2-in.female PVC pipe fitting extendingthrough the right side of the furnacetop cover. This opening has a pro-tective cap which should be removedjust prior to installing the exhaustpipe. When 3-in. pipe is used,connect a 2 to 3-in. coupling to thisfitting with a short piece of 2-in. PVCpipe.

The combustion air connection is a 2-in. extruded hole on the left side ofthe top plate. When a 2-in. pipe isused, attach a 2-in. PVC couplingover this hole with RTV sealant, drilltwo pilot holes, and add two sheetmetal screws through the couplinginto the extrusion to secure it in placebefore piping. When 3-in. pipe isused, connect a 2 to 3-in. coupling tothis fitting with a short piece of 2-in.PVC pipe. See Figure 25.

FIGURE 25DOWNFLOW/HORIZONTAL COMBUSTION AIR AND VENT PIPE CONNECTION

EXHAUST VENTCAP/PLUG

EXHAUSTPIPE - PVC

EXHAUSTCONNECTOR

EXHAUSTTRANSITION

TOP PLATE

COUPLING

COMBUSTIONAIR CHASE

EXHAUSTOUTLET AIR PIPE

a103101

NOTE:ATTACH COUPLING TOEXTRUDED COLLARWITH TWO SCREWS. PUTBEAD OF SILICONEAROUND BASE BEFOREMOUNTING COUPLING.

INDUCED DRAFTBLOWER

30

CONDENSATE DRAIN/NEUTRALIZER

FIGURE 26UPFLOW CONDENSATE DRAIN

GENERAL INFORMATION

DO NOT RUN DRAIN OUTDOORS.FREEZING OF CONDENSATE CANCAUSE PROPERTY DAMAGE.IMPORTANT: Do not connect into acommon drain line with an air con-ditioner evaporator coil drain. A blockedor restricted drain line can result inover-flow of the coil pan and negate thefurnace blocked drain shutoff control.FILL TRAP ASSEMBLY WITHWATER BEFORE OPERATING THEFURNACE. This can be done byremoving the drain hosefrom the trap and pouring about acup of water into the vent trap. Waterwill flow into the house drain when thetrap is full.If local codes require, install acondensate neutralizer cartridge in thedrain line. Install cartridge in horizontalposition only. Also install an overflowline if routing to a floor drain. SeeFigure 26. If no floor drain is available, install acondensate pump that is resistant toacidic water. Pumps are available fromyour local distributor. If pump used isnot resistant to acidic water, acondensate neutralizer must be usedahead of the pump. The condensatepump must have an auxiliary safetyswitch to prevent operation of thefurnace and resulting overflow ofcondensate in the event of pumpfailure. The safety switch must be wiredthrough the “R” circuit only (low voltage)to provide operation in either heating orcooling modes.

UPFLOW MODELSThe condensate drain trap is located inthe blower compartment on the left-hand side of the jacket. A short piece of1/2-in. PVC pipe and a 1/2-in. tee areprovided. Connect the 1/2-in. pipe to theelbow on the trap and the tee to thispipe so that the open end is upward.Run a drain tube from the bottom of thetee to a floor drain or condensatepump.IMPORTANT: The upflow model onlyhas a new drain system. There is a thirdport on the drain trap (marked by a redcap) for the hose attached to theinduced draft motor. Remove plug ininducer drain hose and remove cap offdrain trap before connecting inducerdrain hose to drain trap. All three hosesMUST be attached during operation ofthe furnace. Be sure all three hoses aresecured to the drain trap using the hoseclamps provided in the parts bag.

IMPORTANT: If installing the unit overa finished ceiling or living area, becertain to install an auxiliary condensatedrain pan under the entire unitextending out under the condensatetee. IMPORTANT: There are two optionswhen choosing a height for thecondensate riser:CONDENSATE OVERFLOW: With a 5inch riser installed above the tee, ablocked drain will result in overflow fromthe riser. FURNACE SHUTDOWN: To cause thefurnace to shut down when a blockeddrain is present, install a riser which is aminimum of 1013/16“. If the furnace isinstalled in an attic, crawlspace or otherarea where freezing temperatures mayoccur, the furnace drain can freezewhile shut off for long periods of time.

Use a solvent cement that iscompatible with PVC material. Cut thedrain hoses to the appropriate lengthand connect to the trap with hoseclamps. Tighten the clamps withpliers and check for leaks afterattaching.

IMPORTANT: The inducer drain hosemust slant downward away frominducer. If the hose is not slanted,the inducer will fill with water andcause the pressure switch to open,causing nuisance failures orintermittent operation.

! CAUTION

I408

1013/16

CONDENSATE TRAP

TO FLOOR DRAIN OR CONDENSATE PUMP

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

DRAIN LINENEUTRALIZER CARTRIDGE (OPTIONAL)

NOTE:SEE UPFLOW MODELNOTES FOR PIPEHEIGHT

NOTE: CONNECTINDUCER DRAIN HOSETO SMALLER PORT ONCONDENSATE TRAP.

NOTE: INDUCERDRAIN HOSEMUST SLANTDOWNWARDAWAY FROMINDUCER.

CONDENSATE TRAP

31

FIGURE 27UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

REVERSING THE TRAPUPFLOW UNITS

The trap may be moved to the rightside for right side drainage. Open theknockout for the drain on the rightside of the cabinet. Remove thebracket holding the trap from the leftside. Seal the left side drain hole witha plug provided in the cloth bag withthe furnace. Position the mountingbracket and trap so that the drainelbow is centered in the hole onthe right. See Figure 27.

Drill two 1/8” holes in the cabinet tomount the bracket. Mount the trapand bracket to the right side with thedrain elbow pointing through theknockout. Connect the 1/2-in. pipe andtee as noted above. Route the drainhoses behind the control box, cut tothe appropriate length, and connect tothe trap with hose clamps. Fill trapwith water.

IMPORTANT: Do not allow any sagsor kinks in the hoses. This preventsproper condensate flow.

IMPORTANT: Do not connect intoa common drain line with an airconditioner evaporator coil drain. Ablocked or restricted drain line canresult in overflow of the coil pan andnegate the furnace blocked drainshutoff control.

DOWNFLOW MODELS

IMPORTANT: There are two optionswhen choosing a height for thecondensate riser:

CONDENSATE OVERFLOW: With a13⁄4 inch riser installed above the tee,a blocked drain will result in overflowfrom the riser.

FURNACE SHUTDOWN: To causethe furnace to shut down when ablocked drain is present, install a riserwhich is a minimum of 51⁄2”. If thefurnace is installed in an attic,crawlspace or other area wherefreezing temperatures may occur, thefurnace drain can freeze while shutoff for long periods of time. Provisionsmust be made to prevent freezing ofcondensate. (See Figure 2)

Use a solvent cement that iscompatible with PVC material.

CUT DRAIN HOSES ASREQUIREDAND CONNECT TOINLETS ON TOPOF CONDENSATETRAP

DRAINRISER

TEE

DRAINEXTENSION

PROPER DRAIN SLOPE REQUIRED(NO KINKS ALLOWED)

CONDENSATE TRAPSHEETMETAL IFCMOUNTING PLATE

TO FLOORDRAIN

A039407

FIGURE 28DOWNFLOW CONDENSATE DRAIN

CONDENSATE TRAP

DRAIN LINE

a103101

TO FLOOR DRAIN OR CONDENSATE PUMP

NOTE:DRAIN VENT NEEDSTO BE ABOVECOLLECTOR BOXDRAIN SPOUT.

NEUTRALIZER CARTRIDGE(OPTIONAL)

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

MINIMUM HEIGHTOPEN TOP

32

CONDENSATE DRAINFOR HORIZONTALINSTALLATIONRefer to Figure 30 for Steps 1-4.This unit is shipped factory ready fordownflow installation. Thecondensate trap assembly and drainhoses require conversion forhorizontal installation. Remove theexisting condensate trap with the unitin the upright position.1. Remove the burner compartment

door from the unit.2. Remove the two screws from the

right side of the furnace jacketwhich support the trap mountingbracket. Remove the twoplastic plugs on either side of thetrap outlet hole and discard.

3. Remove the (L-shaped) clearvinyl drain tube ➂ from the top ofthe existing trap ➀.Do not disconnect the short endfrom the furnace collector box.

4. Remove the ribbed drain tube ➃from the existing trap ➀ and theexhaust transition ➄. Discard thistube. Retain the clamps for futureuse. Additional clamps areprovided in the parts bag if anyclamps are damaged duringconversion process.

NOTE: The following steps shouldtake place with the furnace in thehorizontal position.Refer to Figure 31 for Steps 6-11.5. Locate the parts bag in the

burner compartment. Install twoplastic plugs ➅ in the side of thejacket from bottom side up.

6. Fill the trap assembly ➆ with acup of water.

7. Attach the gasket ➇ onto the trapassembly so that the gasketholes on the gasket line up withthe holes on the trap assembly.

8. Insert the trap assembly withgasket up through the existinghole in the jacket and securefrom inside the jacket. Use twoscrews provided. Screw downinto the two “ears” molded intoeither side of the trap. Snug thetrap assembly against thefurnace jacket compressing thegasket slightly to eliminate anyair leaks. Do not overtighten!

9. Attach the black molded rubber90° elbow ➈ to the straight spouton the trap top using a blacknylon clamp ➉. Attach the otherend of the rubber elbow to thespout ➋ located on the exhausttransition ➄ using a black nylonclamp.

10. Take the ribbed tube used indownflow position off thecollector box. Attach one end ofthe horizontal ribbed tube tothe collector box. Clamp the hosetight with black nylon clamp.Then attach the other end of theribbed tube to the 45° elbow

molded into the top of the trapassembly. Clamp the hose tightwith black nylon clamp. Thehorizontal ribbed tube is 6.7” inlength.NOTE: Use the horizontal ribbedtube in all horizontal applicationexcept for the 07B. This model hasa longer distance between thecollector and horizontal drain trap.Use the ribbed tube forhorizontal application on the 07Bmodels only.IMPORTANT: Tighten all clampconnections with a pair of pliersand check for leaks afterconversion is complete.

11. IMPORTANT: There are twooptions when choosing a height forthe condensate riser:CONDENSATE OVERFLOW: Witha 13⁄4 inch riser installed above thetee, a blocked drain will result inoverflow from the riser.FURNACE SHUTDOWN: Tocause the furnace to shut downwhen a blocked drain is present,install a riser which is a minimumof 51⁄2”. If the furnace is installed inan attic, crawlspace or other areawhere freezing temperatures mayoccur, the furnace drain can freezewhile shut off for long periods oftime. Provisions must be made toprevent freezing of condensate(see Figure 2).Use a solvent cement that iscompatible with PVC material.

NOTE: See location requirements andcombustion section for additionalrecommendations.

FILLING THE TRAPFILL THE TRAP ASSEMBLY WITHWATER BEFORE OPERATING THEFURNACE. Do this by removing the

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

NOTE: Fill the trap assembly withwater every heating season.

DOWNFLOW UNITS

To convert to left side drainage, firstremove the drainage hoses from thetrap. Remove the trap from itsmounting bracket, rotate it 180°, andmount in place with the drainageelbow pointing to the left. Reattachthe drain hoses. Remove the plasticdrainage knockout from the left side.See Figure 29.

IMPORTANT: When changing to theleft side, interchange the rubberbushing on the right side with the holeplug on the left side. The hole plugmust be in place to assure that thecontrol compartment is sealed.

A length of 1/2-in. PVC pipe isprovided for left hand drainage. Glueone end of the pipe to the elbow inthe trap. Cut the pipe so that itextends through the left cabinet sideone inch. Connect the 1/2-in. tee to thepipe with a riser and drain tube aslisted above. Use the plastic plugfrom the left side drainage knockoutto seal the right side drainageknockout.

IMPORTANT: Do not connect intoa common drain line with an airconditioner evaporator coil drain. Ablocked or restricted drain line canresult in overflow of the coil pan andnegate the furnace blocked drainshutoff control.

B

C

A

D

A

E

F

G

H

I

J

K

E

C

L

C

L

FIGURE 29HORIZONTAL CONDENSATE TRAP CONNECTION

MANUAL GAS VALVE

UNION

DRIP LEG

BURNERS

MANIFOLD

GAS VALVEI524

33

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34

GAS SUPPLY AND PIPINGGAS SUPPLY

THIS FURNACE IS EQUIPPED ATTHE FACTORY FOR USE ONNATURAL GAS ONLY.CONVERSION TO LP GASREQUIRES A SPECIAL KIT ISAVAILABLE AT THEDISTRIBUTOR. FAILURE TO USETHE PROPER CONVERSION KITCAN CAUSE FIRE, CARBONMONOXIDE POISONING,EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. See the conversion kitindex supplied with the furnace.This index identifies the proper LPGas Conversion Kit required foreach particular furnace.

IMPORTANT: Any additions,changes or conversions required forthe furnace to satisfactorily meet theapplication should be made by aqualified installer, service agency orthe gas supplier, using factory-specified or approved parts.

IMPORTANT: Connect this furnaceonly to gas supplied by a commercialutility.

IMPORTANT: U.L. or CSArecognized fuel gas and COdetector(s) are recommended in allapplications, and their installationshould be in accordance with themanufacturer’s recommendationsand/or local laws, rules, regulations orcustoms.

GAS PIPINGInstall the gas piping according to alllocal codes and regulations of theutility company.

If possible, run a separate gas supplyline directly from the meter to thefurnace. Consult the local gascompany for the location of themanual main shut-off valve. The gasline and manual gas stop must beadequate in size to prevent unduepressure drop and never smallerthan the pipe size to the gas valveon the furnace. Refer to Table 6 forthe recommended gas pipe size. SeeFigure 32 for typical gas pipeconnections.

Install a ground joint union within 3ft. of the cabinet to easily removethe gas valve assembly. Install amanual gas stop valve in the gasline outside the furnace casing.The manual gas stop should bereadily accessible to turn the gas

! WARNING

FIGURE 32GAS PIPING INSTALLATION

GROMMET

TOP VIEW OF GAS LINE AND VALVEIN OPT. POSITION

NOTE: WHEN GAS LINEIS IN OPT. POSITION,SWAP LOCATION OFGROMMET AND PLUG.

OPT. GAS LINEPOSITION

PLUG(IN NORMALPOSITION)

MANIFOLDPRESSURETAP

IGNITOR

MANIFOLD

GAS VALVEUNION

DRIP LEG

GROMMET(IN NORMALPOSITION)

4 TO 5 FEETABOVEFLOOR REQ’DBY SOMEUTILITIES.

MANUALGAS

STOP

BURNERS

GROMMET

TOP VIEW OF GAS LINE AND VALVEIN OPT. POSITION

MANUALGAS

STOP

4 TO 5 FEET ABOVEFLOOR REQ’D BYSOME UTILITIES.

GROMMET(IN NORMALPOSITION)

DRIP LEG

UNION

GAS VALVE

BURNERSMANIFOLD

IGNITOR

MANIFOLDPRESSURETAP

PLUG(IN NORMALPOSITION)

NOTE: WHEN GASLINE IS IN OPT.POSITION, SWAPLOCATION OFGROMMET ANDPLUG.

DOWNFLOW

I328

UPFLOW

MANUAL GAS STOP

UNION

DRIP LEG

BURNERS

MANIFOLD

GAS VALVEI524

IMPORTANT: DO NOT RUN A FLEXIBLE GAS CONNECTOR INSIDE THEUNIT. Extend the 1/2" black pipe from the gas valve to the outside of thecabinet.

HORIZONTAL

35

NEVER PURGE A GAS LINE INTOTHE COMBUSTION CHAMBER.NEVER USE MATCHES, FLAME ORANY IGNITION SOURCE FORCHECKING LEAKAGE. FAILURE TOADHERE TO THIS WARNING CANCAUSE A FIRE OR EXPLOSIONRESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.

To check for gas leakage, use anapproved chloride-free soap and watersolution, or other approved method.

FIGURE 33TYPICAL GAS VALVE

GAS VALVE #60-101921-02

supply on or off. Install a drip leg inthe gas supply line as close to thefurnace as possible. Always use apipe compound resistant to the actionof liquefied petroleum gases on allthreaded connections.

IMPORTANT: When making gas pipeconnections, use a back-up wrench toprevent any twisting of the main gasvalve and manifold. Do notovertighten gas valve on pipe.

Any strains on the gas valve canchange the position of the gas orificesin the burners. This can cause erraticfurnace operation.

IMPORTANT: Do not run a flexiblegas connector inside the furnace. Thegas pipe gasket in the cabinet doesnot seal around a flexible gas line.

If local codes allow the use of aflexible gas appliance connector,always use a new listed connector.Do not use a connector which haspreviously serviced another gasappliance. Massachusetts lawrequires that all flexible connectors beless than 36”.

It is important to have all openingsin the cabinet burner compartmentsealed for proper furnaceoperation.

IMPORTANT: ENSURE that thefurnace gas valve not be subjected tohigh gas line supply pressures.

DISCONNECT the furnace and itsindividual manual gas stop from thegas supply piping during anypressure testing that exceeds 1/2PSIG. (3.48 kPa).

GAS PRESSURENatural gas supply pressure shouldbe 5" to 10.5" w.c. LP gas supplypressure should be 11" to 13" w.c.This pressure must be maintainedwith all other gas-fired appliancesin operation.

The minimum gas supply pressure tothe gas valve for proper furnace inputadjustments is 5" w.c. for natural gas,however 6" to 7" is recommended.The minimum gas supply pressure is11" w.c. for LP gas.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT)NEED TO BE CHANGED. SEE THESECTION TITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.

! WARNING

TABLE 6NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)

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

Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80

1/2 132 92 73 63 56 50 46 433/4 278 190 152 130 115 105 96 901 520 350 285 245 215 195 180 170

1-1/4 1,050 730 590 500 440 400 370 3501-1/2 1,600 1,100 890 760 670 610 560 530

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

Gas Input of Furnace (BTU/HR)Cu. Ft. Per Hr. Required = Heating Value of Gas (BTU/FT3)The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may bedetermined by consulting the local natural gas utility or the LP gas supplier.

GAS VALVEThis furnace has a 24-volt gas valve.It has ports for measuring supply andmanifold gas pressure. The valvebody contains a pressure regulator tomaintain proper manifold gaspressure.

A control switch is on the valve body.It can be set to only the “ON” or“OFF” positions. The gas valve is aslow-opening valve. See Figure 33.

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

CAUTION!

GAS CONTROLSWITCH

INLETPRESSURETAP

OUTLETPRESSURETAP

LOW FIREMANIFOLDPRESSUREADJUSTMENT

HIGH FIREMANIFOLDPRESSUREADJUSTMENT

36

TABLE 7

LP CONVERSIONIMPORTANT: LP gas from trucksused to transport liquid-basedfertilizers can contain chemicals thatwill damage the furnace. Verify thatyour gas supplier does not use thesame truck to transport materialsother than LP.

For LP conversion, a new gas valve isrequired. The new gas valve isincluded in the LP kit. The correct LPorifices should be selected based onthe altitude of the installation (seechart below). Orifices included in thekit are for sea level to 2000 ft.(1.15mm) and 3000 to 4000 ft.(1.10mm) The LP Gas Valve Kit isFP19. Orifices for elevations 4000 ft.and above must be ordered. Refer toTable 7.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTEDAND THAT THE SIZE OF THEBURNER ORIFICES BE RE-CALCULATED BASED ONELEVATION AND GAS HEATINGVALUE. THE BURNER ORIFICESMAY (OR MAY NOT) NEED TO BECHANGED. SEE THE SECTIONTITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.

NOTE: Furnace conversion to LP gasmust be performed by a qualifiedinstaller, service agency or the gassupplier.

To change the gas valve and orificespuds for either conversion to LP or forelevation:

1. Shut off the manual main gas valveand remove the gas manifold.

2. Replace the orifice spuds.

3. For LP conversion ONLY, Removethe gas valve.

4. Reassemble in reverse order. InLP applications, use the new gasvalve provided in the LPconversion kit.

5. Attach the notice label alerting thenext service technician that thefurnace has been converted to LPgas.

6. Turn the gas supply back on andcheck for proper operation, leaksand manifold pressure. SeeFigures 34 and 36.

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

ORIFICE ORDERINGINFORMATIONOrifice sizes are selected by adding the2-digit drill size required in the orificepart number. Drill sizes available are 39through 64; metric sizes available1.10mm (-90) and 1.15mm (-91):

Orifice Part Number 62-22175-(drillsize)

Example 1:# 60 drill size orifice requiredPart # 62-22175-60

Example 2:1.15mm drill size orifice requiredPart # 62-22175-91

NOTE: Do not plug or drill out orifices.

BTU Input (per OrificeAltitude burner) 15000 Size

0 to 2000 ft. 15000 1.15 mm (factory)

2000’-3000’ 13200 1.15 mm

3000’-4000’ 12600 1.10 mm

4000’-5000’ 12000 #58

5000’-6000’ 11400 #59

6000’-7000’ 10800 #60

7000’-8000’ 10200 #62

8000’-9000’ 9600 #63

9000’-10000’ 9000 #64

SETTING GAS PRESSUREThe maximum gas supply pressureto the furnace should be 10.5" w.c.natural gas, or 13" w.c. LP gas. Theminimum supply gas pressure to thegas valve should be 5" w.c. naturalgas or 11" w.c. LP gas. A properlycalibrated U-Tube manometer isrequired for accurate gas pressuremeasurements.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTEDAND THAT THE SIZE OF THEBURNER ORIFICES BE RE-CALCULATED BASED ONELEVATION AND GAS HEATINGVALUE. THE BURNER ORIFICESMAY (OR MAY NOT) NEED TO BECHANGED. SEE THE SECTIONTITLED “HIGH ALTITUDEINSTALLATIONS” OF THIS BOOKFOR INSTRUCTIONS.

Supply Gas Pressure Measure-ment. A line pressure tap is on theinput side of the gas valve. SeeFigure 34.

1. With gas shut off to the furnaceat the manual gas stop outsidethe unit, remove the inputpressure tap plug.

2. Connect a U-Tube manometer tothe pressure tap.

3. Turn on the gas supply andoperate the furnace and all othergas-fired units on the same gasline as the furnace.

4. Note or adjust the line gaspressure to give:

A. 5" - 10.5" w.c. for natural gas.

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

5. Shut off the gas at the manualgas stop and remove theU-Tube manometer.

6. Replace the pressure tap plugbefore turning on the gas. Turnon gas and check for leaks.

If the supply gas line pressure isabove these ranges, install an in-linegas regulator to the furnace fornatural gas units. With LP gas, havethe LP supplier reduce the linepressure at the regulator.

If supply gas line pressure is belowthese ranges, either remove anyrestrictions in the gas supply piping orenlarge the gas pipe. See Tables 6and 8. With LP gas, have the LPsupplier adjust the line pressure atthe regulator.

CAUTION!

CAUTION!

37

TABLE 8LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

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

Nominal Length of Pipe, FeetIron PipeSize, Inches 10 20 30 40 50 60 70 80 90 100 125 150

1/2 275 189 152 129 114 103 96 89 83 78 69 633/4 567 393 315 267 237 217 196 182 173 162 146 1321 1,071 732 590 504 448 409 378 346 322 307 275 252

1-1/4 2,205 1,496 1,212 1,039 913 834 771 724 677 630 567 5111-1/2 3,307 2,299 1,858 1,559 1,417 1,275 1,181 1,086 1,023 976 866 787

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

Example (LP): Input BTU requirement of unit, 120,000Equivalent length of pipe, 60 ft. = 3/4" IPS required.

FIGURE 34MANIFOLD PRESSURE TAP

Manifold Gas PressureMeasurement. Natural gasmanifold pressure should be 3.5"w.c.; LP gas manifold pressureshould be 10" w.c. Only smallvariations on gas pressure should bemade by adjusting the pressureregulator.

1. With the gas shut off at themanual gas stop, remove thepressure tap plug in the gasmanifold or the gas valve outlet.See Figure 34.

2. Connect a U-Tube manometer tothis pressure tap. See Figure 36.

3. Turn on the gas supply andoperate the furnace in high heatmode.

4. Note or adjust the manifold gaspressure to give:

A. 3.5" w.c. for natural gas highfire.

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

5. To adjust the pressure regulatorfor high fire, remove the regulatorcap located on the side of theregulator. See Figure 24.

6. Turn the adjustment screwclockwise to increasre pressureor counterclockwise to decreasepressure.

7. Securely replace the regulatorcap for high fire.

8. Operate the furnace in lowspeed.

9. Note or adjust the manifoldpressure to give:

A. 1.7" w.c. for natural gas lowfire.

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

10. To adjust the pressure regulatorfor low fire, remove the regulatorcap on the top of the regulator.See Figure 35.

11. Turn the adjustment screwclockwise to increase pressure orcounterclockwise to decreasepressure.

12. Securely replace the regulatorcap for low fire.

13. Verify pressures for high and lowfire operation.

14. Shut off gas at the manual gasvalve and remove the U-Tubemanometer.

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

MANIFOLDPRESSURETAP

FIGURE 35TYPICAL GAS VALVE

INLETPRESSURE TAP

OUTLETPRESSURETAP

HIGH FIREMANIFOLDPRESSUREADJUSTMENT

LOW FIREPRESSUREMANIFOLDADJUSTMENT

38

FIGURE 36TYPICAL MANIFOLD PRESSURE READING

39

For the proper connection, refer to theappropriate wiring diagram located onthe inside cover of the furnace controlbox and in these instructions.

NOTE: UPFLOW MODELS ONLYThe electrical junction box may bemoved to the right side if necessary. Aknockout is provided. Seal the oppositehole with plug provided.

NOTE: L1 (hot) and N (neutral) polaritymust be observed when making fieldconnections to the furnace. The ignitioncontrol may not sense flame if L1 andNeutral are reversed at junction box.See Figure 37.

FIGURE 38LINE VOLTAGE CONNECTIONS

UT ELECTRONIC CONTROLS 1095-102 & 1095-104 CONTROL BOARDS

ELECTRICAL WIRING

TURN OFF ELECTRIC POWER ATFUSE BOX OR SERVICE PANELBEFORE MAKING ANY ELECTRICALCONNECTIONS. FAILURE TO DO SOCAN CAUSE ELECTRICAL SHOCKRESULTING IN PERSONAL INJURYOR DEATH.

NOTE: Electric to furnace must besupplied by commercial utility. Propervoltage is 110-125 volts.

THE CABINET MUST HAVE ANUNINTERRUPTED GROUNDACCORDING TO THE LATESTEDITION OF THE NATIONALELECTRICAL CODE, ANSI/ NFPA70-OR IN CANADA, THE CANADIANELECTRICAL CODE, CSA-C221 ORLOCAL CODES THAT APPLY. DONOT USE GAS PIPING AS ANELECTRICAL GROUND. A GROUNDSCREW IS PROVIDED IN THEJUNCTION BOX. FAILURE TO DO SOCAN CAUSE ELECTRICAL SHOCKRESULTING IN PERSONAL INJURYOR DEATH.

IMPORTANT: If servicing IFC, be sure toreplace grounding screw. See Figure 37.

NOTE: If grounding screw is notreplaced, furnace will not operate.Flame cannot be sensed.

THIS FURNACE IS EQUIPPED WITH ABLOWER DOOR SAFETY SWITCH.DO NOT DISABLE THIS SWITCH.FAILURE TO FOLLOW THISWARNING CAN RESULT INELECTRICAL SHOCK, PERSONALINJURY OR DEATH.

IMPORTANT: The furnace must beinstalled so that the electricalcomponents are protected from water(condensate).

Before proceeding with the electricalconnections, be certain that the voltage,frequency and phase corresponds tothat specified on the furnace ratingplate. For single furnace application,maximum over-current protection is 15amperes.

Use a separate fused branch electricalcircuit containing a properly sized fuseor circuit breaker. Run this circuit directlyfrom the main switch box to an electricaldisconnect that is readily accessible andlocated within site of the furnace.Connect from the electrical disconnectto the junction box on the left side of thefurnace, inside the blower compartment.

! WARNING

! WARNING

! WARNING

Make all electrical connections inaccordance with the latest edition ofthe National Electrical CodeANSI/NFPA70 and local codes havingjurisdiction.

These may be obtained from:

National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

CSA - International178 Rexdale Blvd.Etobicoke (Toronto), OntarioCanada M9W, 1R3

FIGURE 37GROUNDING CONNECTIONS

JUNCTIONBOX

CONTROL IS GROUNDED WHENATTACHED TO BLOWER

LOWVOLTAGETERMINALS

CONTROLMOUNTINGPLATE

BLOWERCOMPARTMENT

I409-3

GROUNDINGSCREW

40

ELECTRONIC AIR CLEANERElectronic air cleaner line voltage powercan be supplied from the screw terminal“EAC” and a line voltage neutral screwterminal on the control board. This willpower the electronic air cleanerwhenever the circulating air blower is inoperation.

HUMIDIFIERLine voltage power can be suppliedfrom screw terminal “HUM” to a linevoltage neutral screw terminal on thecontrol board. This will power thehumidifier during a normal heatsequence after the blower has turnedon.NOTE: Maximum current of 1.0 Ampfor each option.

FIELD-INSTALLED OPTIONAL ACCESSORIESTHERMOSTATNOTE: Do not use 24 volt control wiringsmaller than No. 18 AWG.

A single- or two-stage thermostat may beused, however, a two-stage thermostat isrecommended for optimum performance.

The room thermostat must be compatiblewith the integrated furnace control on thefurnace. Generally, all thermostats thatare not of the “current robbing” type arecompatible with the integrated furnacecontrol being used.

Install the room thermostat in accordancewith the instruction sheet in the box withthe thermostat. Run the thermostat leadwires inside the control compartment.Connect the thermostat as shown on thewiring diagram. Never install thethermostat on an outside wall or where itwill be influenced by drafts, concealedhot or cold water pipes, lighting fixtures,radiation from fireplace, rays of sun,lamps, television, radios or air streamsfrom registers. Refer to the instructionspacked with the thermostat for bestanticipator adjustment or selection.Locate the thermostat approximately fivefeet up from the floor.

HEAT ANTICIPATOR SETTINGS

If a current reading taken at thethermostat is not performed, an initialsetting of .15 amps is recommended.Adjust as needed to improve comfortlevel.

ISOLATION RELAYIMPORTANT: Not all electronicthermostats are compatible with thefurnace control system. Some mayrequire an isolation relay.

If an isolation relay is required (part 42-25104-01), install it as close to theIntegrated Furnace Control (IFC) aspossible. Use a single-pole, single-throwrelay with a 24-volt operating coil. Therelay contacts should be designed for 24-volt loads.

Connect one end of the operating coil tothe thermostat “W” terminal. Connect theother end of the coil to the “C” terminalon the IFC. See Figure 39.

Connect one side of the normally opencontacts to the IFC “W” terminal.

When the thermostat calls for heat, itpowers the 24-volt operating coil. Thiscloses the relay contacts and conductspower from terminal 3 and 4 to terminal“W” on the IFC and starts the furnaceignition sequence.

FIGURE 39ISOLATION RELAY

ST-A0804-01

41

FURNACE TWINNINGINSTALLATIONSNOTE: Run furnaces as individualfurnaces before trying to twin or whentroubleshooting.Twinning operation of two furnaces,installed side-by-side, connected by acommon duct system with main powersupplied by the same source, andcontrolled by a common thermostat canbe done with the UT Electronic Controls1095-102 and 1095-104 integratedcontrol boards.➀ Only twin identical furnaces with

identical control boards.

➁ Furnaces must have same heatingand blower capacity.

➂ Only bottom returns can be used.(Upflow models only)

➃ No more than two furnaces canshare the same supply and return.

IMPORTANT: Twinning furnaces mustoperate off the same phase of power.

It should be noted that both blowers willrun simultaneously when there is a callfor heating, cooling or fan.The status LED will display blink code 5if twinning is not set up properly (seeTroubleshooting diagram).

IMPORTANT: Only two furnaces on asingle thermostat.

NOTE: Furnaces that are twinnedcannot share a common return orsupply ducts.

TWO-STAGE TWINNING OPERATIONUSING A SINGLE-STAGETHERMOSTATA two-stage thermostat will give themost optimum performance. Thefurnace (when twinned) can operateusing a single-stage thermostat. For thefirst twelve minutes of operation, thefurnace will run at low fire. If thethermostat does not satisfy in twelveminutes, the furnaces will automaticallyswitch to high fire and will run on highfire until the thermostat is satisfied. SeeFigure 41 for the wiring diagram for thisconfiguration.

UT ELECTRONIC CONTROLS 1095-102 AND 1095-104 IFCTwo-Stage Operation

(See Figure 42)a. Control board "ONE" is on

furnace connected to thethermostat.

b. The 24 VAC supply to bothcontrol boards must be inphase with each other.

c. Connect the "C," "W1," “W2,”“Y,” and "TWIN" terminals tocounterparts on each control.

d. Both control boards must haveswitch #3 of SW1 in the"TWIN" position. See Figure42 for wiring diagram.

42

FIGURE 41UT Electronic Controls 1095-102 AND 1095-104 IFC, TWINNING CONNECTION -- SINGLE STAGE OPERATION

43

FIGURE 42UT ELECTRONIC CONTROLS 1095-102 AND 1095-104 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION

44

90+ HIGH ALTITUDEINSTRUCTIONS

NATURAL GAS

THE NATIONAL FUEL GAS CODE(NFGC) GUIDELINES SHOULD BEFOLLOWED WHEN CONVERTINGTHESE FURNACES FOR HIGHALTITUDE OPERATION.

ELEVATIONS ABOVE 2000 FTREQUIRE THAT THE FURNACEINPUT RATING BE ADJUSTED ANDTHAT THE SIZE OF THE BURNERORIFICES BE RE-CALCULATEDBASED ON ELEVATION AND GASHEATING VALUE. THE BURNERORIFICES MAY (OR MAY NOT) NEEDTO BE CHANGED. THE FOLLOWINGEXAMPLES SHOW HOW TODETERMINE IF AN ORIFICE CHANGEWILL BE NECESSARY AND HOW TODETERMINE THE NEW ORIFICE SIZE.

IN CANADA, AS AN ALTERNATE TOSIZING THE BURNER ORIFICE, THEMANIFOLD GAS PRESSURE MAY BEADJUSTED. THIS METHOD ISCOVERED LATER IN THIS SECTION.THIS METHOD OF ADJUSTINGMANIFOLD PRESSURE MAY ONLYBE USED IN CANADIANINSTALLATIONS.

34" 90 Plus furnaces installed at highelevations require the installation of ahigh altitude kit for proper operation. Thehigh altitude kit consists of a highaltitude pressure switch that replacesthe pressure switch attached to theinduced draft blower.

The pressure switch must be installedat elevations above 5000 ft. Elevationsabove 2000 ft. require the furnace to bede-rated 4% per thousand feet.

The necessary high altitude kits to usewith -GRK & -GTK furnace models arelisted below:

NOTE: 278 Option Code is available on-GRK models only.

Alternately, furnaces can be orderedfrom the factory already converted forhigh altitude elevations. The factoryoption for high altitude elevations wouldbe ordered as a 278 option (example; a105k BTU upflow furnace which isfactory converted for high altitudeelevations would have the modelnumber -GRK-10EZAJS278). Thesefactory converted furnaces come with apressure switch for high-altitudeelevations already attached. Also,different burner orifices are installed atthe factory which are one drill sizesmaller (#51 DMS) than standard -GRKgas furnaces (#50 DMS). The smallerorifice is installed to accommodate foraverage heating values expected inmost high altitude areas and a required

4% per thousand feet reduction ininput as specified by the NationalFuel Gas Code (NFGC). Specificorifices should always be recalculatedfor all high altitude installations asoutlined below. Orifices should bechanged, if necessary, based on gasheating value and elevation.

NOTE: Factory installed orifices arecalculated and sized based on a sealevel Natural Gas heating value of1075 BTU per cubic ft. Regionalreduced heating values may nullifythe need to change orifices except atextreme altitudes.

The following are examples of orificesizing using the National Fuel GasCode Appendix F. For a simplifiedestimation of orifice size based onheating value and elevation, useTables 8 and 9, however calculationsare the best method.

Example: 900 BTU/ft3 RegionalNatural Gas Heating Value

I / H = Q15000 / 900 = 16.68 ft3/hr

I = Sea Level input (per burner):15000H = Sea Level Heating Value: 900Q = 16.68 ft3 Natural Gas per hour.

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

From Table F.4 of National Fuel GasCode Handbook, 2002Orifice required at 5000 ft. elevation(4% de-rate per thousand ft.): #50Orifice required at 8000 ft. elevation(4% de-rate per thousand ft.): #51

! CAUTION

! CAUTION

Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)IMPORTANT: 90 Plus Models only. Do not use this chart for any 80 Plus Models.

Burner Input (per burner) 15,000 BTU @ Sea LevelSea level 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 toto 1999 ft 2999 ft 3999 ft 4999 ft 5999 ft 5999 ft 7999 ft 8999 ft

47 48 48 49 49 49 50 5048 49 49 49 50 50 50 5149 50 50 50 51 51 51 5250 51 51 51 51 52 52 5251 51 52 52 52 53 53 53

Annual Avg. HeatValue (btu per ft3)

850900

100010751170

TABLE 9

High Altitude Kit -GRK Furnace Inputs

45,000, 60,000

RXGY-F18 (17” cabinets)& 75,000

(21” cabinet) BTU’sRXGY-F19 75,000 (17” cabinet)RXGY-F20 90,000 (21”)RXGY-F21 120,000 (24”)RXGY-F22 105,000 (21”)

High Altitude Kit -GTK Furnace InputsRXGY-F29 60,000 (17”)RXGY-F30 75,000 (17” & 21”)RXGY-F31 90,000 (21”)RXGY-F32 105,000 (21”)RXGY-F33 120,000 (24”)

HIGH ALTITUDE KITInstaller must make necessary burnerorifice and pressure switch changes asindicated in the table below:

-GRK PRESSURE SWITCH CHANGES

INPUTHIGH ALTITUDE SET POINT SET POINT

KIT NO. HIGH FIRE LOW FIRE

45,000 RXGY-F18 -1.08 NO CHANGE60,000 RXGY-F18 -1.08 NO CHANGE75,000 (N) RXGY-F19 -0.80 -0.4075,000 (W) RXGY-F18 -1.08 NO CHANGE90,000 RXGY-F20 -1.15 NO CHANGE105,000 RXGY-F19 -0.80 NO CHANGE120,000 RXGY-F21 -0.50 -0.30

-GTK PRESSURE SWITCH CHANGES

INPUTHIGH ALTITUDE

KIT HIGH FIRE LOW FIRE

60,000 RXGY-F29 -1.0 -0.875,000 (N) RXGY-F30 -0.8 -0.675,000 (W) RXGY-F30 -0.8 -.0690,000 RXGY-F31 -0.9 -.06105,000 RXGY-F32 -0.7 -.04120,000 RXGY-F33 -0.4 -0.3

NOTE: Orifices are no longer suppliedwith kit.

45

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46

Example: 1050 BTU/ft3 RegionalNatural Gas Heating Value

I / H = Q15000 / 1050 = 14.63 ft.3

I = Sea Level input (per burner): 15000H = Sea Level Heating Value: 1050Q = 14.28 ft.3 Natural Gas per hour.

From Table F.1 of National Fuel GasCode Handbook, 2002 (3.5” w.c. column)Orifice required at Sea Level: #50From Table F.4 of National Fuel GasCode Handbook, 2002Orifice required at 5000 ft. elevation (4%de-rate per thousand ft.): #51Orifice required at 8000 ft. elevation (4%de-rate per thousand ft.): #52

LP GAS AT HIGH ALTITUDEELEVATIONSLP Gas is a manufactured gas that hasconsistent heating value across mostregions.

The NFGC guidelines are used with thefollowing exception:

The recommended LP Gas high altitudeorifice selections differ slightly in that theNFGC LP orifice chart, as they are notaccurate for Rheem products. TheNational Fuel Gas Code LP orifices arebased on an 11" of water columnpressure at the orifice, which differs fromRheem products that use 10" of watercolumn at the orifice. This differencerequires a deviation from the NFGCorifice size recommendations. The SeaLevel input should still be reduced by 4%per thousand ft. and the orifice size mustbe selected based on the reduced inputselection shown in Table 11.

ORIFICE ORDERINGINFORMATIONIMPORTANT: Do not plug or drill outorifices.

Orifice sizes are selected by adding the2-digit drill size required in the orificepart number. Drill sizes available are 39through 64; metric sizes available1.10mm (-90) and 1.15mm (-91):

Orifice Part Number 62-22175-(drillsize)

Example 1:#60 drill size orifice requiredPart # 62-22175-60

Example 2:1.15mm drill size orifice requiredPart # 62-22175-91

ALTERNATE METHOD FORCANADIAN HIGH-ALTITUDE DERATEIn Canada, unless an orifice changeis specifically mandated by localcodes, an alternate method of altitudederation through a reduction inmanifold pressure is acceptable asdescribed in Table 12.

The information in Table 12 is basedon a heating value of 1000 BTU percubic feet of natural gas, and 2500BTU per cubic feet of LP gas.

IMPORTANT: Actual input rates mustbe measured on-site with manifoldpressure adjustment to ensure that anactual 10% reduction in input rate isachieved.

Once this field adjustment has beenmade, the label shown in Figure 40must be affixed in a conspicuouslocation on the front of the furnacecabinet:

NOTE: This label is supplied in theinformation packet shipped with eachfurnace.

TABLE 11IMPORTANT: 90+ MODELS ONLY. DO NOT USE THIS CHARTFOR ANY 80 PLUS MODELS.LP GAS ORIFICE DRILL SIZE (4% PER 1000 FT DE-RATE)

Altitude Input (per burner) 15000 Orifice Size

0 to 2000 ft 15000 1.15 mm (factory)

2001 to 3000 13200 1.15 mm

3001 to 4000 12600 1.10 mm

4001 to 5000 12000 #58

5001 to 6000 11400 #59

6001 to 7000 10800 #60

7001 to 8000 10200 #62

8001 to 9000 9600 #63

9001 to 10000 9000 #64

FIGURE 40MANIFOLD PRESSURE-CHANGE LABEL

TABLE 12ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATEIMPORTANT: 90+ MODELS ONLY. DO NOT USE THIS CHART FOR ANY 80 PLUS MODELS.

NATURAL GAS LP GAS

ALTITUDE INPUT OUTPUTORIFICE

SIZEMANIFOLDPRESSURE

0’ - 2000’

45,00060,00075,00090,000

105,000120,000

40,50054,00067,50081,00094,500108,000

#50 3.5” W.C.

2001’ - 4500’

40,50054,00067,50081,00094,500

108,000

36,45048,60060,75072,90085,05097,200

#51 3.0” W.C.

ALTITUDE INPUT OUTPUTORIFICE

SIZEMANIFOLDPRESSURE

0’ - 2000’

45,00060,00075,00090,000105,000120,000

40,50054,00067,50081,00094,500108,000

1.15mm 10” W.C.

2001’ - 4500’

40,50054,00067,50081,00094,500108,000

36,45048,60060,75072,90085,05097,200

1.10mm 7.6” W.C.

THE MANIFOLD PRESSURE OF THIS APPLIANCE HASBEEN FIELD ADJUSTED TO OBTAIN THE CORRECTINPUT RATING FOR INSTALLATION AT ALTITUDES

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

LA PRESSION DU DISTRIBUTEUR D’ALIMENTATIONDE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIND’OBTENIR LA BONNE PUISSANCE D’ENTRÉE POUR

UNE INSTALLATION ENTRE 2000 ET 4500 PIEDSD’ALTITUDE. 92-24399-01-01

47

START-UP PROCEDURESDIRECT SPARK IGNITIONLIGHTING INSTRUCTIONSThis appliance is equipped with a directspark ignition device. This device lightsthe main burners each time the roomthermostat (closes) calls for heat. Seelighting instructions on the furnace.

During initial start-up, it is not unusualfor odor or smoke to come out of anyroom registers. It is recommended toensure proper ventilation by openingwindows and doors, before initial firing.

The furnace has a negative pressureswitch that is a safety during a call forheat. The induced draft blower must pulla negative pressure on the heatexchanger to close the negativepressure switch. The induced draftblower must maintain at least thenegative pressure switch set point forthe furnace to operate. If the induceddraft blower fails to close or maintain theclosing of the negative pressure switch,a “no heat call” would result.

TO START FURNACE1. BE SURE THAT THE MANUAL GAS

STOP HAS BEEN IN THE “OFF”POSITION FOR AT LEAST FIVEMINUTES. DO NOT ATTEMPT TOMANUALLY LIGHT THE MAINBURNERS. FAILURE TO FOLLOWTHIS WARNING CAN CAUSE AFIRE OR AN EXPLOSIONRESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.

2. Set the room thermostat to the lowestsetting.

3. Remove furnace panel.4. Turn the gas control knob to the “ON”

position, or set the gas control switchto the “ON” position.

5. Securely replace furnace panel.6. Turn on the manual gas stop and the

electrical power.7. Set the room thermostat to “Heat”

and adjust to desired roomtemperature.

8. Complete installation checklist.

SHOULD OVERHEATING OCCUR ORTHE GAS SUPPLY FAIL TO SHUTOFF, SHUT OFF THE MANUAL GASSTOP TO THE APPLIANCE BEFORESHUTTING OFF THE ELECTRICALSUPPLY. FAILURE TO DO SO CANCAUSE AN EXPLOSION OR FIRERESULTING IN PROPERTY DAMAGE,PERSONAL INJURY OR DEATH.

IGNITOR PLACEMENT,ALIGNMENT & LOCATIONIgnition failure may be a result ofimproper ignitor alignment caused duringa service call or other work done to thefurnace in the field. When performing anywork on the burner, heat exchanger, etc.,the technician must check alignment ofthe spark ignitor. Misalignment of theignitor could cause a failure to light orrough ignition. The correct ignitoralignment is shown in Figure 43.

Sequence of operation with a singlestage thermostata. Connect the “W” terminal on the

thermostat to the W2 terminal on theIFC. Do not connect any wire to “W”on IFC when using a single-stagethermostat.

b. When there is a call for heat, the “R”and “W2” contacts close and the IFCruns a self check routine to verify thatboth of the pressure switch contactsare open. The limit switch contactsare constantly monitored.

c. The induced draft motor starts on highuntil the low and high pressure switchcontacts close (a maximum of 60seconds), and then runs for a 30-second pre-purge. After the 30-second pre-purge, the spark ignitorenergizes and the high stage of thegas valve opens, lighting the burners.

d. After the gas valve energizes, theremote flame sensor must proveignition for one second using the

process of flame rectification. If theburners do not light or flame is notsensed, the system goes throughanother ignition sequence. It doesthis up to 4 times.

e. The IBM starts on low speed 20seconds after the burners light andflame is sensed. The induced draftmotor and gas valve switch to lowspeed. The furnace operates onlow fire for 12 minutes and then, ifthe thermostat is not satisfied,shifts to high fire, causing the draftinducer to go to high speed, thegas valve to 100% and the mainblower goes to high-fire heatingspeed.

f. When the thermostat cycle ends,the gas valve de-energizes, andthe burners go out.

g. The draft inducer will continuerunning for a 10 second postpurge.

h. The main blower will run for for theuser-defined blower-off delay (thistiming is field adjustable, for 90,120 150, or 180 seconds). SeeFigure 44 for switch settings.

Sequence if the system doesn’tlight or doesn’t sense flame:a. If flame is not sensed within 8

seconds after the gas valveenergizes, the valve and the ignitorare de-energized. The induceddraft motor will, stop momentarily,and then restart to check PSoperation.

b. The ignition process goes throughthree more tries.

c. If there is no ignition after thefourth trial, the furnace goes intosoft lockout for one hour.

d. The sequence repeats after a onehour delay and continuesrepeating until ignition issuccessful or the call for heat isterminated.

e. To reset the lockout, break powereither at the thermostat or at theunit disconnect switch for 30

! WARNING

! WARNING

FIGURE 43UPFLOW OPTIMUM IGNITOR LOCATION DOWNFLOW/HORIZONTAL OPTIMUM IGNITOR LOCATION

48

seconds. The furnace will then gothrough another set of trials forignition.

f. If flame is established andmaintained during the trial forignition period and flame is lost,the gas valve is de-energized, thedraft inducer stops after a 10-second post-purge. The blowermotor runs at the high-fire or low-fire heating speed (depending onstate when flame was lost) until itcompletes the blower-off delay.When the blower-off delay is over,the control initiates another ignitiontrial period by starting the inducerfor the pre-purge. The control willrecycle up to 5 flame losses (4 re-cycles) within a single call for heatbefore going into lockout.

TO SHUT DOWN FURNACE1. Set the room thermostat to its

lowest setting.2. Shut off the gas to main burners

by setting the gas control switch tothe “OFF” position, or by turningthe manual gas stop closed.

Sequence of operation with twostage thermostat

Connect W1 on thermostat to W onIFC. Connect W2 on thermostat toW2 on IFC.

Call for 1st stage heat

a. R and W thermostat contacts closeand the IFC runs a self checkroutine. After the IFC verifies thatboth sets of pressure switchcontacts are open, the induceddraft motor starts on high until bothpressure switch contacts close (amaximum of 60 seconds).

b. After a 30 second pre-purge thespark igniter energizes and the gasvalve (high stage) opens, lightingthe burners.

c. After the burners light, the remoteflame sensor must prove ignition. Ifthe burners do not light or flamecannot be proven, the system goesthrough another ignition sequence.It does this up to 4 times.

d. Twenty seconds after flame sense,the main blower energizes on lowspeed, the gas valve drops to lowfire, and the inducer drops to lowspeed. The furnace continues torun on low until the call for heat issatisfied or the second-stagecontacts close. If the first-stage callfor heat is satisfied the gas valvede-energizes and the induced draftmotor continues running for a 10second post purge time. The mainblower runs for the user-definedblower-off delay (this timing is fieldadjustable). See Figure 44 forswitch settings.

Call for 2nd stage heat after 1ststage

R and W2 thermostat contacts close,calling for 2-stage heat. The induceddraft motor then switches to highspeed and the high pressure switchcontacts will close. The gas valveswitches to high fire and the mainblower switches to high-fire heatingspeed.

2nd stage heat satisfied, 1st stageheat still required.R and W2 thermostat contacts open(W1 to R remains closed). Theinduced draft motor switches to lowspeed, the main blower motorswitches to low-fire heating speedand the gas valve changes to low.The furnace continues to run in thismode until the first-stage heat call issatisfied. The system will shut downas noted in “d,” under first-stage callfor heat.

Call for second-stage heat with noother existing heat call present.a-c. Same operation as call for first-

stage heatd. Main blower starts on high

speed 20 seconds after gasvalve energizes. The furnacecontinues to run on high untilthe W2 contacts open. If W2 andW1 open at the same time (bothhigh & low stages are satisfied),the gas valve de-energizes andthe inducer continues to run for a10-second post-purge. The mainblower runs for the user selectedblower-off delay. See Figure 44for switch settings.

NOTE: Under certain conditions thefurnace may alternate between lowand high fire continuously. Thisoperation is based on demand fromthe thermostat and is controlled bythe thermostat. This operation isnormal and can be expected at timesto maintain optimum comfort.

SETTING BLOWER TIMINGThe UT ELECTRONIC CONTROLSIFC has four quick connect terminalsfor connecting the motor speed leads.These are:

1. FAN SPEED/LOW — motor runson this speed when thethermostat is in the “FAN ON”position or when in low-fireheating speed heat.

2. COOL — connect desiredcooling speed.

3. HEAT — connect desired high-fire heating speed.

4. HEAT/COOL — connect desiredspeed when high heating andcooling speed are the same.

High fire and low fire blower timingare the same.

IMPORTANT: Do not connect anymotor speeds to “HEAT” and “COOL”if you use the “HEAT/COOL” terminal.

FIGURE 44UT ELECTRONIC CONTROLS 1095-102 &1095-104 BLOWER OFF TIMING

SW1 SW2 HEAT COOL

OFF OFF 90 40

OFF ON 150 30

ON OFF 120 60

ON ON 180 90

NOTE: Switch number 4 must be in“OFF” position for all applications.

49

ADJUSTING OR CHECKINGFURNACE INPUTA properly calibrated manometer orgauge is required for accurate gaspressure readings.

NATURAL GAS1. When adjusting the furnace input,

the high fire input should bechecked. The high fire manifoldpressure should be 3.5’ W.C.Follow these steps to be sure thefurnace is high fire mode:

a. With a single stage thermostat, thefurnace runs for 12 minutes on lowfire before shifting to high fire. Tobe certain that it is on high fire,jump terminals “W” and “W2” onthe control board in the blowercompartment.

b. With a two stage thermostat, setthe thermostat to its highest settingto keep the furnace operating in thehigh fire mode.

2. To adjust high fire manifoldpressure, remove the adjustmentcover screw on the outlet end ofthe gas valve and turn theadjustment screw clockwise toincrease the pressure andcounterclockwise to reduce thepressure. Replace the cover screwsecurely. See Figure 36.

3. The low fire manifold pressureshould be 1.7” W.C. As mentionedabove, the furnace remains in thelow fire mode for 12 minutes upona heat call with a single stagethermostat. With a two stagethermostat, disconnect thethermostat lead to the “W2”terminal on the IFC and the furnacewill remain in the low fire mode. Toadjust the pressure, remove theregulator cover, on top of the valve,and adjust as noted under Step 2,above. After the adjustmentreplace the screw cover securely.

NOTE: Use a 3/32” allen wrench orsmall-blade screwdriver for makingthe pressure adjustment.

LP GASOn furnaces using LP gas, the LP gassupply pressure must be set between11.0" and 13.0" W.C. by means of thetank or branch supply regulators. Setthe furnace manifold pressure at 10"W.C. on high fire and 4.8" W.C. onlow fire at the gas control valve. Forelevations up to 8,000 feet, ratingplate inputs apply. For high altitudes(elevations 5,000 ft. and over), theorifice spud must be changed.

SETTING INPUT RATEThe furnace is shipped from thefactory with #50 orifices. With -278option code, furnaces will be shippedwith #51 orifice for elevations of 5000ft. They are sized for natural gashaving a heating value of 1075BTU/cu. ft. and a specific gravity of.60.

Since heating values vary geo-graphically, the manifold pressureand/or gas orifice size may need tobe changed to adjust the furnace toits nameplate input. Consult the localgas utility to obtain the yearly averageheating value and orifice size requiredto fire each individual burner at15,000 BTU/HR.

Proper input is important to preventover firing of the furnace beyond itsdesign-rated input. NEVER SETINPUT ABOVE THAT SHOWN ONTHE RATING PLATE.

To check furnace input:

1. Make certain that all other gasappliances are shut off, with theexception of pilot burners.

2. Start the furnace

3. Time the meter to measure thetime required to burn one cubic footof gas. See Table 13.

TABLE 13METER TIME

METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACESEQUIPPED FOR NATURAL OR LP GAS

HEATING VALUE OF GAS BTU PER CU. FT.METER

900 1000 1040 1100 2500 (LP)INPUT SIZE

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

ONE 1 12 1 20 1 23 1 28 3 20

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

ONE 0 54 1 0 1 3 1 6 2 30

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

ONE 0 44 0 48 0 50 0 53 2 0

75,000 TEN 7 12 8 0 8 19 8 48 20 0

ONE 0 36 0 40 0 42 0 44 1 40

90,000 TEN 6 0 6 40 7 0 7 20 16 40

ONE 0 31 0 34 0 36 0 38 1 26

105,000 TEN 5 10 5 40 6 0 6 20 14 20

ONE 0 27 0 30 0 31 0 33 1 15

120,000 TEN 4 30 5 0 5 10 5 30 12 30

Heating Value of Gas (BTU/FT3) x 3600 x correction factorFormula: Input BTU/HR =

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

50

AIR FLOWThe importance of proper air flow over theheat exchanger cannot be overemphasized.

IT IS IMPORTANT THAT EACH DUCTSYSTEM BE SIZED AND INSTALLEDFOR THE SPECIFIC APPLICATION BYPROPERLY APPLYING THEAPPROPRIATE INDUSTRY ACCEPTEDSTANDARD. IF LESS THAN MINIMUMSTANDARDS ARE APPLIED, THEEQUIPMENT USER COULD EXPECTTO EXPERIENCE HIGHER UTILITYBILLS, MAJOR COMPONENTFAILURE, VARYING DEGREES OF AIRNOISE OR OTHER UNSATISFACTORYISSUES, OVER WHICH THEEQUIPMENT MANUFACTURER HASNO CONTROL.

TEMPERATURE RISE CHECK

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

1. Insert a thermometer in the supplyair duct as close to the furnace aspossible yet out of a direct line fromthe heat exchanger. See Figure 45.

2. Insert a thermometer in the return airduct as close to the furnace aspossible.

3. Operate the furnace. High fire andlow fire heating modes have thesame temperature rise range.

4. When the thermometer in the supplyair duct stops rising (approximatelyfive minutes), subtract the return airtemperature from the supply airtemperature. The difference is thetemperature rise.

5. Compare the measured temperaturerise to the approved temperature riserange listed on the furnace nameplate. See Figure 46.

If the measured temperature rise is abovethe approved range, the air flow is toolow. More air must be moved by speedingup the blower, by removing restrictions inthe duct system, or by adding moresupply or return air duct. If the measuredtemperature rise is below the approvedrange, the air flow is too much. Use lowerspeed tap on the multi-speed blower.

THE MEASURED TEMPERATURERISE SHOULD BE AS CLOSE TO THEMIDDLE OF THE STATED RANGE AS

FIGURE 45TEMPERATURE RISE MEASUREMENT

FIGURE 46TYPICAL FURNACE NAME PLATE

POSSIBLE. FOR EXAMPLE, IF THERISE RANGE IS 40 TO 70 DEGREES,THE MOST IDEAL RISE WOULD BE55 DEGREES (THE MIDDLE OF THERISE RANGE). IN ALLAPPLICATIONS, THE INSTALLERMUST ADJUST THE TEMPERATURERISE TO THIS "MIDDLE" POINT ASCLOSELY AS POSSIBLE. ALSO,THE TEMPERATURE RISE SHOULDNEVER BE ABOVE OR FALL BELOWTHE STATED RANGE. DOING SOCOULD CAUSE DAMAGE TO THEHEAT EXCHANGER ORINTERMITTENT OPERATION WHICHCOULD CAUSE INJURY OR DEATHAND WILL VOID THEMANUFACTURER'S WARRANTYFOR THIS PRODUCT.

! WARNING

! CAUTION

51

! WARNING

GAS FURNACE (DIRECTDRIVE) INSTRUCTIONSFOR CHANGING BLOWERSPEED

DISCONNECT THE ELECTRICALSUPPLY TO THE FURNACEBEFORE ATTEMPTING TOCHANGE THE BLOWER SPEED.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN PERSONAL INJURY OR DEATH.

The blower motor is wired for blowerspeeds required for normal operationas shown.

If additional blower speed taps areavailable (leads connected to “M1”and “M2” on the IFC), speeds may bechanged if necessary to fitrequirements of the particularinstallation. Reconnect the unusedmotor leads to “M1” or “M2.” Checkmotor lead color for speeddesignation.

Heating speeds should not bereduced where it could cause thefurnace air temperature to rise toexceed the maximum outlet airtemperature specified for the unit.

IMPORTANT: Any combination ofmotor taps to the IFC can be usedprovided the temperature rise iswithin the specified range when inhigh or low heat and that there isenough airflow in the cooling mode.When changing the motor tapspeeds, the temperature rise must bechecked on both heat speeds andtemperature drop in cooling must bechecked again after the change ismade to ensure that the temperaturesare within the required specifiedranges.

52

TABLE 14

90 PLUS AIR FLOW PERFORMANCE

CFM @ ESPMODEL BLOWER/ SPEED

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

UPFLOW MODELS

(-)GRK-04 11 x 7 / 1/2 LOW 805 780 760 720 685 645 605*M-LO 920 885 850 810 775 730 690M-HI 1140 1110 1085 1045 1010 950 890HIGH 1360 1320 1280 1235 1195 1140 1080

(-)GRK-06 11 x 7 / 1/2 LOW 770 740 710 675 645 605 570*M-LO 880 845 815 790 760 715 670M-HI 1060 1025 990 960 925 880 835HIGH 1260 1215 1175 1135 1100 1040 985

(-)GRK-07(A) 11 X 7 / 1/2 LOW 780 745 710 675 640 595 555M-LO 880 850 825 785 750 702 655*M-HI 1090 1050 1010 970 925 875 825HIGH 1300 1255 1210 1160 1110 1055 1005

(-)GRK-07(B) 12 X 7 / 3/4 LOW 1105 1095 1080 1050 1030 1010 990*M-LO 1290 1275 1260 1220 1195 1170 1140M-HI 1480 1435 1415 1390 1370 1300 1255HIGH 1705 1665 1615 1570 1540 1475 1400

(-)GRK-09 12 X 11 / 3/4 LOW 1235 1210 1185 1150 1120 1075 1035M-LO 1490 1465 1440 1405 1375 1315 1255*M-HI 1720 1670 1620 1600 1580 1520 1460HIGH 2100 2050 2000 1955 1910 1825 1745



DOWNFLOW/HORIZONTAL MODELS

(-)GTK-06 11 X 7 / 1/2 LOW 795 760 730 695 660 615 570*M-LO 910 885 860 815 770 725 680M-HI 1115 1080 1045 1005 965 920 875HIGH 1365 1315 1270 1225 1180 1125 1070

(-)GTK-07(A) 11 X 7 / 1/2 LOW 780 750 720 675 635 595 555M-LO 890 860 835 790 750 705 660*M-HI 1100 1060 1025 980 940 890 845HIGH 1340 1295 1250 1200 1150 1090 1025

(-)GTK-07(B) 11 X 7 / 3/4 LOW 1185 1160 1140 1115 1095 1065 1040*M-LO 1405 1375 1350 1310 1270 1235 1195M-HI 1595 1560 1525 1480 1440 1380 1325HIGH 1835 1780 1730 1675 1625 1555 1480



(-)GTK-12 11 X 10 / 3/4 LOW 1285 1250 1215 1235 1260 1230 1200*M-HI 1590 1565 1540 1505 1475 1425 1375M-HI 1840 1820 1800 1750 1700 1645 1590HIGH 2315 2250 2185 2110 2040 1965 1890

* Factory-Set High Heating speedA = 17 1⁄2" Cabinet SizeB = 21" Cabinet SizeNOTE: Units tested with filters in place.

53

FIGURE 48FILTER LOCATIONS

I528

HORIZONTAL

I413

DOWNFLOW

AIRFLOW

HORIZONTAL

MAINTENANCE

THESE INSTRUCTIONS AREINTENDED AS AN AID TOQUALIFIED SERVICE PERSONNELFOR PROPER INSTALLATION,ADJUSTMENT AND OPERATIONOF THIS UNIT. READ THESEINSTRUCTIONS THOROUGHLYBEFORE ATTEMPTINGINSTALLATION OR OPERATION.FAILURE TO FOLLOW THESEINSTRUCTIONS MAY RESULT INIMPROPER INSTALLATION,ADJUSTMENT, SERVICE ORMAINTENANCE, POSSIBLYRESULTING IN FIRE, ELECTRICAL

SHOCK, CARBON MONOXIDEPOISONING, EXPLOSION,PROPERTY DAMAGE, PERSONALINJURY OR DEATH.

TABLE 15FILTER SIZES

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE QUANTITYWIDTH MBTUH SIZE SIZE

171/2" 45, 60, 75A 153/4" X 25" 153/4" X 25" 121" 75B, 90, 105 191/4" X 25" 153/4" X 25" 1

241/2" 120 223/4" X 25" 153/4" X 25" 1

DOWNFLOW/HORIZONTAL FILTER SIZES

FURNACE INPUT QUANTITYWIDTH MBTUH SIZE

171/2" 60, 75A 12" X 20" 221" 75B, 90, 105 12" X 20" 2

241/2" 120 14" X 20" 2

! WARNING

54

FIGURE 47BOTTOM PANEL REMOVALFILTER LOCATION

JACKET ASSEMBLY

REMOVESOLID BOTTOM

NOTE:BACK FLANGE OF SOLID BOTTOM FITSUNDERNEATH JACKET. SIDES AND FRONTFLANGES FIT OVER FLANGES ON JACKET.

SCREW(2) REQ’D.

JACKET ASSEMBLY

FILTER

SOLIDBOTTOM

FILTERROD

SOLID BOTTOM REMOVAL

FILTER & ROD LOCATION

FILTER AND ROD ASSEMBLY

OD

FILTERSUPPORTANGLE

FILTER

FILTER ROD

JACKET

I332

FILTERROD45-24095-01

FILTER

FILTERSUPPORTANGLEAE-61883-01

FILTER RODSUPPORTANGLEAE-60520-01

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

CUT-OUT USINGEMBOSSED ANGLES

AS A GU IDE FORPROPER SI ZE

CUT-OUT AND DRILL DETAIL

JACKET

JACKET

ANGLE

FILTER RODSUPPORTANGLE

FILTER SUPPORTANGLE(SEE ANGLE DETAIL)

ATTACH WITHSHEET METALSCREWS (2 REQÕD)

ANGLE DETAIL

ROD & FILTER SUPPORT ANGLE ASSEMBLY

FILTER RODSUPPORTANGLEAE-60520-01

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

UPFLOW BOTTOM RETURN

UPFLOW SIDE RETURN

AIRFLOW

AIRFLOW

SOLIDBOTTOM

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

SOLIDBOTTOM

55

it is recommended that a qualifiedinstaller, service agency, or the gassupplier annually inspect the fluepassageways, the vent system andthe main burners for continued safeoperation. Pay particular attention todeterioration from corrosion or othersources.

• IMPORTANT: It is recommendedthat at the beginning and atapproximately half way through theheating season, a visual inspectionbe made of the main burner flamesfor the desired flame appearance bya qualified installer, service agencyor the gas supplier. If the flames aredistorted and/or there is evidence ofback pressure, check the vent andinlet air system for blockage. If thereis carbon and scale in the heatexchanger tubes, the heatexchanger assembly should bereplaced.

HOLES IN THE VENT PIPE ORHEAT EXCHANGER CAN CAUSETOXIC FUMES TO ENTER THEHOME, RESULTING IN CARBONMONOXIDE POISONING ORDEATH. THE VENT PIPE OR HEATEXCHANGER MUST BEREPLACED IF THEY LEAK.

• IMPORTANT: It is recommendedthat at the beginning of the heatingseason, the flame sensor becleaned with steel wool by aqualified installer, service agency orthe gas supplier.

• IMPORTANT: It is recommendedthat at the beginning of the heatingseason, the condensate trap beinspected for debris or blockage andbe filled with water. A blockedcondensate trap can cause water toback up into the primary heatexchanger and lead to nuisancetripping of the overtemperatureswitches.

• IMPORTANT: It is recommendedthat at the beginning of the heatingseason, the condensate neutralizerif used be replaced by a qualifiedinstaller, service agency or the gassupplier.

• IMPORTANT: It is recommendedthat an annual inspection andcleaning of all furnace markings bemade to assure legibility. Attach areplacement marking, which can beobtained through the distributor, ifany are found to be illegible ormissing.

TROUBLESHOOTINGRefer to Figure 49.

WIRING DIAGRAMSFigure 50 is a complete wiringdiagram for the furnace.

DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTENANCE.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTING INPERSONAL INJURY OR DEATH.

FILTER MAINTENANCEHave your qualified installer, serviceagency or the gas supplier instruct youon how to access your filters for regular maintenance.

FILTERSFilter application and placement arecritical to airflow, which may affect theheating and cooling systemperformance. Reduced airflow canshorten the life of the system’s majorcomponents, such as motor, limits, heatexchanger, evaporator coil orcompressor. Consequently, werecommend that the return air ductsystem have only one filter location.The most common location will beinside the furnace or a filter base. Forsystems with a return air filter grille ormultiple filter grilles, can have a filterinstalled at each of the return airopenings. Your HVAC professional canshow you where they have installed thefilter(s).

If high efficiency filters or electronic aircleaners are used in the system, it isimportant that the airflow is not reducedto maximize system performance andlife. Always verify that the system’sairflow is not impaired by the filteringsystem that has been installed, byperforming a temperature rise andtemperature drop test.

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

DO NOT DOUBLE FILTER THERETURN AIR DUCT SYSTEM. DONOT FILTER THE SUPPLY AIR DUCTSYSTEM.

NOTE: Some filters must be resized tofit certain units and applications. SeeTable 15 and Figures 36 & 37.

1. 21” - 75,000(B), 90,000 & 105,000BTUH units require removal of a3.5-in. segment of filter and frameto get the proper width for a sidefilter.

2. 24.5” - 120,000 BTUH unit requiresremoval of a 7" segment of filterand frame to get the proper widthfor a side filter.

DO NOT OPERATE THE SYSTEMWITHOUT FILTERS. A PORTION OFTHE DUST ENTRAINED IN THE AIRMAY TEMPORARILY LODGE IN THEAIR DUCT RUNS AND AT THE

SUPPLY REGISTERS. ANYRECIRCULATED DUST PARTICLESWILL BE HEATED AND CHARREDBY CONTACT WITH THE FURNACEHEAT EXCHANGER. THIS RESIDUEWILL SOIL CEILINGS, WALLS,DRAPES, CARPETS AND OTHERHOUSEHOLD ARTICLES AND MAYRESULT IN UNPLEASANT ODORS.

LUBRICATIONIMPORTANT: DO NOT attempt tolubricate the bearings on the blowermotor or the induced draft blowermotor. Addition of lubricants can reducethe motor life and void the warranty.

The blower motor and induced draftblower motor are permanentlylubricated by the manufacturer and donot require further attention.

The blower motor and induced draftblower motor must be cleanedperiodically by a qualified installer,service agency, or the gas supplier toprevent the possibility of overheatingdue to an accumulation of dust and dirton the windings or on the motorexterior. And, as suggested elsewherein these instructions, the air filtersshould be kept clean. Dirty filters canrestrict airflow. The motor dependsupon sufficient air flowing across andthrough it to keep from overheating.

SYSTEM OPERATIONINFORMATIONAdvise The Customer

1. Keep the air filters clean. Theheating system will operate better,more efficiently and moreeconomically.

2. Arrange the furniture and drapesso that the supply air registers andthe return air grilles areunobstructed.

3. Close doors and windows. This willreduce the heating load on thesystem.

4. Avoid excessive use of kitchenexhaust fans.

5. Do not permit the heat generatedby television, lamps or radios toinfluence the thermostat operation.

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

7. IMPORTANT: Replace all blowerdoors and compartment coversafter servicing the furnace. Do notoperate the unit without all panelsand doors securely in place.

8. Explain proper operation of thesystem.

ANNUAL INSPECTION• The furnace should operate for many

years without excessive scale build-up in the flue passageways. However,

! WARNING

! CAUTION

! WARNING

56

FIGURE 49TROUBLESHOOTING CHART

Go toF

Go toI

HAZARDOUS VOLTAGELINE VOLTAGECONNECTIONS

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

57

FIGURE 49TROUBLESHOOTING CHART (CONTINUED)

Go toD

Go toD

Go toC

Go toF

1

58

FIGURE 50WIRING DIAGRAM

60 CM 1105

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