Installation Instructions: For Upflow, Downflow/Horizontal High Efficiency Condensing Two-Stage Gas Furnaces

INSTALLATION INSTRUCTIONS
FOR UPFLOW, DOWNFLOW/HORIZONTAL HIGH

EFFICIENCY CONDENSING TWO-STAGE GAS
FURNACES
RGRM, RGTM SERIES
U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all
applications, and their installation should be in accordance with the manufacturer’s
recommendations and/or local laws, rules, regulations, or customs.
ISO 9001:2008
92-24161-84-11
SUPERSEDES 92-24161-84-10
INSTALLATION CHECK LIST
REFER TO INSTALLATION INSTRUCTIONS TERMINATIONS – DIRECT VENT
VERTICAL
GAS SUPPLY
______ Adequate pipe size ______ Intake – 12" min. above roof/snow level
______ Correct supply pressure (during furnace operation) ______ Correct relationship – exhaust to intake
______ Manifold pressure
HORIZONTAL/VERTICAL – CONCENTRIC (RXGY-E03A)
______ No gas leaks
______ Intake – 12" min. above roof/snow level
______ L.P. Kit Number (if applicable)
______ Intake “Y” rotated above center
ELECTRICAL
______ Exhaust sloped toward furnace
______ 115 V.A.C. supply (Single Circuit)
______ Polarity observed HORIZONTAL – STANDARD (RXGY-D02, -D03) – US

(RXGY-D02A, RXGY-D03A) – CANADA
______ Furnace properly grounded
______ Correct relationship – exhaust to intake
______ Adequate wire size
______ 12" min. above grade/snow level

FURNACE INSTALLATION
______ Adequate clearance to combustibles HORIZONTAL – ALTERNATE

(RXGY-D02, -D03 OR -D04) – US
______ Adequate clearance for service (at front) (RXGY-D02A, -D03A, -D04A) – CANADA
DUCT STATIC PRESSURE ______ Correct relationship – exhaust to intake
______ in. w.c. on heating speed ______ Above anticipated snow level
______ in. w.c. on cooling speed

VENTING – NON-DIRECT VENT
______ Air temperature rise
______ in. diameter – exhaust pipe
CONDENSATE LINE
______ ft. of pipe – exhaust
______ Trap filled with water
______ no. of elbows
______ Vented
______ Sloped toward drain TERMINATION – NON-DIRECT VENT
______ Condensate drain line hoses connected VERTICAL

and clamped
______ 12" min. above roof/snow level
______ Freeze protection (if necessary)
HORIZONTAL – STANDARD
VENTING – DIRECT VENT
______ 12" min. above grade/snow level
______ in. diameter – intake pipe
______ in. diameter – exhaust pipe HORIZONTAL – ALTERNATE
______ ft. of pipe – intake air ______ Above anticipated snow level
______ no. of elbows – intake air

_____________________________ Model Number
______ ft. of pipe – exhaust pipe
_____________________________ Serial Number
______ no. of elbows – exhaust pipe
_____________________________ Date of Installation
______ Exhaust Vent Temperature
2
IMPORTANT: All manufacturer
products meet current Federal OSHA
CONTENTS
Guidelines for safety. California
Safety Precautions ...................................................................................................1
Proposition 65 warnings are required
for certain products, which are not Installation Check List ..............................................................................................2
covered by the OSHA standards.
General Information..................................................................................................4
California's Proposition 65 requires
warnings for products sold in California Safety Information ....................................................................................................7
that contain, or produce, any of over
600 listed chemicals known to the State Location Requirements and Considerations ............................................................9
of California to cause cancer or birth
defects such as fiberglass insulation, Ducting ...................................................................................................................14
lead in brass, and combustion products Venting and Combustion Air Piping .......................................................................16
from natural gas.
All “new equipment” shipped for sale in Combustion and Ventilation Air ..............................................................................18
California will have labels stating that Vent Pipe Installation..............................................................................................21
the product contains and/or produces
Proposition 65 chemicals. Although we Condensate Drain/Neutralizer ................................................................................34
have not changed our processes,
having the same label on all our Gas Supply and Piping...........................................................................................38
products facilitates manufacturing and
Electrical Wiring......................................................................................................41
shipping. We cannot always know
“when, or if” products will be sold in the Accessories ............................................................................................................42
California market.
You may receive inquiries from High Altitude Installations .......................................................................................43
customers about chemicals found in, or Start-Up Procedures...............................................................................................46
produced by, some of our heating and
air-conditioning equipment, or found in Integrated Furnace Control and ECM Motor Settings............................................48
natural gas used with some of our
products. Listed below are those Two Stage 90’s w/Elm (GRM’s & GTM’s) ..............................................................50
chemicals and substances commonly
Air Flow...................................................................................................................52
associated with similar equipment in
our industry and other manufacturers. Maintenance...........................................................................................................53
• Glass Wool (Fiberglass) Insulation
Troubleshooting ................................................................................................57-58
• Carbon Monoxide (CO)
• Formaldehyde Wiring Diagram.......................................................................................................59
• Benzene
More details are available at the
Websites for OSHA (Occupational
Safety and Health Administration), at
www.osha.gov and the State of
California's OEHHA (Office of
Environmental Health Hazard
Assessment), at www.oehha.org.
Consumer education is important since
the chemicals and substances on the
list are found in our daily lives. Most
consumers are aware that products
present safety and health risks, when
improperly used, handled and
maintained.
3
GENERAL INFORMATION
NOTE: A load calculation must be 2. As direct vent central forced air CSA-INTERNATIONAL
performed to properly determine the furnaces with all combustion air 178 Rexdale Blvd.
required furnace BTU size for the supplied directly to the furnace Toronto, Ontario
structure. Also, the duct must be properly burners through a special air intake Canada M9W, 1R3
designed and installed for proper airflow. system outlined in these NOTE: It is our recommendation that
Existing ductwork must be inspected for instructions.Install this furnace in any HVAC equipment which were
proper size and sealed system. Proper accordance with the American subject to flooding be replaced to
airflow is necessary for both user comfort National Standard Z223.1 – latest avoid any risk of property damage,
and equipment performance. edition entitled “National Fuel Gas personal injury or death. Also, our
Before opening the furnace carton and Code” (NFPA54) and requirements position that the immersion by flood
installation of the furnace, verify the data or codes of the local utilities or waters compromises any HVAC
tags on the carton and inside the other authorities having jurisdiction. products thus voiding this warranty.
furnace, match and is what was ordered This is available from the following:
NOTE: Models having option code 320
from the local distributor. Also, check for
National Fire Protection Association, Inc. added at the end of the model number
any damage to the furnace before
Batterymarch Park designation are shipped factory ready
installation.
Quincy, MA 02269 for a horizontal only installation. The
IMPORTANT: Proper application, drain trap for downflow installation is
installation and maintenance of this CSA-INTERNATIONAL not included in the parts bag for these
furnace and system is a must if 8501 East Pleasant Valley Road appliances.
consumers are to receive the full benefits Cleveland, Ohio 44131-5575
IMPORTANT: Remove bracket from
for which they have paid. Install units in Canada in accordance models where applicable. See
The RGRM and RGTM series furnaces with CSA-B149, local installation codes Figure 1.
are design-certified by CSA for use with and authorities having jurisdiction.
natural and propane gases as follows: CSA-B149 is available from:
1. As non-direct vent central forced air
furnaces taking combustion air from
the installation area or using air
FIGURE 1
ducted from the outside.
4
FIGURE 2
UPFLOW FURNACE COMPONENTS DOWNFLOW/HORIZONTAL FURNACE COMPONENTS
AIRFLOW 3 15 12 23 22
9
2
8
21 4
20
AIRFLOW
25
19
26
18
17
10
1
25 11 7 14
13 6
ITEM 9 SHIPPING PLUG (TO BE REMOVED) 19 INDUCED DRAFT BLOWER
NO. PART NAME 10 FLAME SENSOR* 20 CAPACITOR*
1 CONDENSATE TRAP 11 OVERTEMPERATURE SWITCH* 21 BLOWER
2 DOOR SWITCH 12 TOP PLATE 22 LOW VOLTAGE TERMINAL
3 JUNCTION BOX 13 BURNER 23 CONTROL MOUNTING PLATE
4 TRANSFORMER 14 IGNITER* 24 FILTER / SOLID METAL BASEPLATE
5 PRESSURE SWITCHES 15 COMBUSTION AIR INLET (UPFLOW UNITS ONLY)
6 EXHAUST TRANSITION 16 OPTIONAL AIR INLET (UPFLOW UNITS ONLY) 25 POWER FACTOR CORRECTION CHOICE*
7 CONNECTOR 17 OPTIONAL GAS INLET 26 AIR CIRCULATING BLOWER*
8 OUTLET AIR PIPE 18 GAS VALVE
*These components may be only partially visible in this photo.
NOTE: A PARTS BAG IS INCLUDED WITH THE FURNACE. IF A NEW PARTS BAG NEEDS TO BE ORDERED, USE THE FOLLOWING PART
NUMBERS: AS-100717-01 FOR -GRM-45, -GRM-60, -GRM-75, GRM-90 AND GRM-105 AS-100717-02 FOR -GRM-120.
5
IMPORTANT INFORMATION FIGURE 3
ABOUT EFFICIENCY AND MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES
INDOOR AIR QUALITY

Central cooling and heating equipment
is only as efficient as the duct system
that carries the cooled or heated air. To
maintain efficiency, comfort and good
indoor air quality, it is important to have
the proper balance between the air
supplied to each room and the air
returning to the cooling and heating
equipment.
Proper balance and sealing of the duct
system improves the efficiency of the
heating and air conditioning system
and improves the indoor air quality of
the home by reducing the amount of
airborne pollutants that enter homes
from spaces where the ductwork and /
or equipment is located. The
matches what is required for the
manufacturer and the U.S. NOTICE job specification.
Environmental Protection Agency’s IMPROPER INSTALLATION, OR
Energy Star Program recommend that • Read the entire instructions before
INSTALLATION NOT MADE IN starting the installation.
central duct systems be checked by a ACCORDANCE WITH THE CSA
qualified contractor for proper balance INTERNATIONAL (CSA) • Some building codes require extra
CERTIFICATION OR THESE cabinet insulation and gasketing
and sealing. when unit is installed in attic
INSTRUCTIONS, CAN RESULT IN
UNSATISFACTORY OPERATION applications.
! WARNING AND/OR DANGEROUS CONDI- • If installed in an unconditioned
DUCT LEAKS CAN CREATE AN TIONS AND ARE NOT COVERED BY space, apply caulking around the
UNBALANCED SYSTEM AND DRAW THE UNIT WARRANTY. power wires, control wires,
POLLUTANTS SUCH AS DIRT, refrigerant tubing and condensate
DUST, FUMES AND ODORS INTO NOTICE line where they enter the cabinet.
THE HOME CAUSING PROPERTY IN COMPLIANCE WITH Seal the power wires on the inside
DAMAGE. FUMES AND ODORS RECOGNIZED CODES, IT IS where they exit conduit opening.
FROM TOXIC, VOLATILE OR RECOMMENDED THAT AN Caulking is required to prevent air
FLAMMABLE CHEMICALS, AS AUXILIARY DRAIN PAN BE leakage into and condensate from
WELL AS AUTOMOBILE EXHAUST INSTALLED UNDER ALL forming inside the unit, control box,
AND CARBON MONOXIDE (CO), EVAPORATOR COILS OR UNITS and on electrical controls.
CAN BE DRAWN INTO THE LIVING CONTAINING EVAPORATOR COILS
SPACE THROUGH LEAKING DUCTS • Install the unit in such a way as to
THAT ARE LOCATED IN ANY AREA allow necessary access to the
AND UNBALANCED DUCT OF A STRUCTURE WHERE DAMAGE
SYSTEMS CAUSING PERSONAL coil/filter rack and blower/control
TO THE BUILDING OR BUILDING compartment.
INJURY OR DEATH (SEE FIGURE 3). CONTENTS MAY OCCUR AS A
• IF AIR-MOVING EQUIPMENT OR RESULT OF AN OVERFLOW OF THE • Install the unit in a level position to
DUCTWORK IS LOCATED IN COIL DRAIN PAN OR A STOPPAGE ensure proper condensate
GARAGES OR OFF-GARAGE IN THE PRIMARY CONDENSATE drainage. Make sure unit is level in
STORAGE AREAS - ALL JOINTS, DRAIN PIPING. SEE ACCESSORIES both directions within 1/8”.
SEAMS, AND OPENINGS IN THE SECTION OF THESE INSTRUCTIONS • Install the unit in accordance with
EQUIPMENT AND DUCT MUST BE FOR AUXILIARY HORIZONTAL any local code which may apply
SEALED TO LIMIT THE OVERFLOW PAN INFORMATION and the national codes. Latest
MIGRATION OF TOXIC FUMES (MODEL RXBM). editions are available from:
AND ODORS INCLUDING CARBON “National Fire Protection
MONOXIDE FROM MIGRATING Association, Inc., Batterymarch
INTO THE LIVING SPACE. RECEIVING Park, Quincy, MA 02269.” These
• IF AIR-MOVING EQUIPMENT OR Immediately upon receipt, all cartons publications are:
DUCTWORK IS LOCATED IN and contents should be inspected for • ANSI/NFPA No. 70-(Latest Edition)
SPACES CONTAINING FUEL transit damage. Units with damaged National Electrical Code.
BURNING APPLIANCES SUCH AS cartons should be opened immediately.
WATER HEATERS OR BOILERS - If damage is found, it should be noted • NFPA90A Installation of Air
ALL JOINTS, SEAMS, AND on the delivery papers, and a damage Conditioning and Ventilating
OPENINGS IN THE EQUIPMENT claim filed with the last carrier. Systems.
AND DUCT MUST ALSO BE • After unit has been delivered to job • NFPA90B Installation of warm air
SEALED TO PREVENT site, remove carton taking care not to heating and air conditioning
DEPRESSURIZATION OF THE damage unit. systems.
SPACE AND POSSIBLE • The equipment has been
MIGRATION OF COMBUSTION • Check the unit rating plate for unit
size, electric heat, coil, voltage, evaluated in accordance with the
BYPRODUCTS INCLUDING Code of Federal Regulations,
CARBON MONOXIDE INTO THE phase, etc. to be sure equipment
Chapter XX, Part 3280.
LIVING SPACE.
6
SAFETY INFORMATION
IMPORTANT! 720 and be ANSI/UL 2034 listed and but identifies “special venting
IAS certified. systems”, the following requirements
THE COMMONWEALTH OF shall be satisfied by the manufacturer:
MASSACHUSETTS REQUIRES 3. SIGNAGE. A metal or plastic
COMPLIANCE WITH REGULATION identification plate shall be 1. The referenced “special venting
248 CMR 4.00 AND 5.00 FOR permanently mounted to the exterior system” instructions shall be included
INSTALLATION OF THROUGH- of the building at a minimum height of with the appliance or equipment
THE-WALL VENTED GAS eight (8) feet above grade directly in installation instructions; and
APPLIANCES AS FOLLOWS: line with the exhaust vent terminal for 2. The “special venting systems” shall
the horizontally vented gas fueled be Product Approved by the Board,
(a) For all side wall horizontally heating appliance or equipment. The
vented gas fueled equipment installed and the instructions for that system
sign shall read, in print size no less shall include a parts list and detailed
in every dwelling, building or structure than one-half (1/2) inch in size, “GAS
used in whole or in part for residential installation instructions.
VENT DIRECTLY BELOW. KEEP
purposes, including those owned or CLEAR OF ALL OBSTRUCTIONS”. (e) A copy of all installation
operated by the Commonwealth and instructions for all Product Approved
where the side wall exhaust vent 4. INSPECTION. The state or local side wall horizontally vented gas
termination is less than seven (7) feet gas inspector of the side wall fueled equipment, all venting
above finished grade in the area of horizontally vented gas fueled instructions, all parts lists for venting
the venting, including but not limited equipment shall not approve the instructions, and/or all venting design
to decks and porches, the following installation unless, upon inspection, instructions shall remain with the
requirements shall be satisfied: the inspector observes carbon appliance or equipment at the
monoxide detectors and signage completion of the installation.
1. INSTALLATION OF CARBON installed in accordance with the
MONOXIDE DETECTORS. At the provisions of 248 CMR 5.08(2)(a) 1
time of installation of the side wall through 4.
horizontal vented gas fueled
equipment, the installing plumber or (b) EXEMPTIONS: The following
gasfitter shall observe that a hard equipment is exempt from 248 CMR ! WARNING
wired carbon monoxide detector with 5.08(2)(a)1 through 4:
an alarm and battery back-up is USE ONLY WITH TYPE OF GAS
1. The equipment listed in Chapter 10 APPROVED FOR THIS FURNACE.
installed on the floor level where the entitled “Equipment Not Required To REFER TO THE FURNACE RATING
gas equipment is to be installed. In Be Vented” in the most current edition PLATE.
addition, the installing plumber or of NFPA 54 as adopted by the Board;
gasfitter shall observe that a battery and WARNING
!
operated or hard wired carbon
monoxide detector with an alarm is 2. Product Approved side wall INSTALL THIS FURNACE ONLY IN
installed on each additional level of horizontally vented gas fueled A LOCATION AND POSITION AS
the dwelling, building or structure equipment installed in a room or SPECIFIED IN THE LOCATION
served by the side wall horizontal structure separate from the dwelling, REQUIREMENTS AND
building or structure used in whole or CONSIDERATIONS SECTION OF
vented gas fueled equipment. It shall THESE INSTRUCTIONS. PROVIDE
be the responsibility of the property in part for residential purposes.
ADEQUATE COMBUSTION AND
owner to secure the services of (c) MANUFACTURER VENTILATION AIR TO THE
qualified licensed professionals for REQUIREMENTS – GAS FURNACE SPACE AS SPECIFIED
the installation of hard wired carbon EQUIPMENT VENTING SYSTEM IN THE VENTING SECTION OF
monoxide detectors. PROVIDED. When the manufacturer THESE INSTRUCTIONS.
a. In the event that the side wall of Product Approved side wall
horizontally vented gas fueled horizontally vented gas equipment
provides a venting system design or ! WARNING
equipment is installed in a crawl
space or an attic, the hard wired venting system components with the PROVIDE ADEQUATE
carbon monoxide detector with alarm equipment, the instructions provided COMBUSTION AND VENTILATION
and battery back-up may be installed by the manufacturer for installation of AIR TO THE FURNACE SPACE AS
the equipment and the venting SPECIFIED IN THE COMBUSTION
on the next adjacent floor level. AND VENTILATION AIR SECTION
system shall include:
b. In the event that the requirements OF THESE INSTRUCTIONS.
of this subdivision can not be met at 1. Detailed instructions for the
the time of completion of installation, installation of the venting system
the owner shall have a period of thirty design or the venting system ! WARNING
(30) days to comply with the above components; and
COMBUSTION PRODUCTS MUST
requirements; provided, however, that 2. A complete parts list for the venting BE DISCHARGED OUTDOORS.
during said thirty (30) day period, a system design or venting system. CONNECT THIS FURNACE TO AN
battery operated carbon monoxide (d) MANUFACTURER APPROVED VENT SYSTEM ONLY,
detector with an alarm shall be REQUIREMENTS – GAS AS SPECIFIED IN VENT PIPE
installed. INSTALLATION SECTION OF
EQUIPMENT VENTING SYSTEM THESE INSTRUCTIONS.
2. APPROVED CARBON NOT PROVIDED. When the
MONOXIDE DETECTORS. Each manufacturer of a Product Approved
carbon monoxide detector as required side wall horizontally vented gas
in accordance with the above fueled equipment does not provide
provisions shall comply with NFPA the parts for venting the flue gases,
7
! WARNING ! WARNING ! WARNING
DO NOT OPERATE THE SYSTEM WHEN THIS FURNACE IS THE FURNACE MAY BE USED
WITHOUT FILTERS. A PORTION INSTALLED IN A RESIDENTIAL FOR HEATING OF BUILDINGS OR
OF THE DUST ENTRAINED IN THE GARAGE, IT MUST BE INSTALLED STRUCTURES UNDER
AIR MAY TEMPORARILY LODGE SO THE BURNERS AND IGNITION CONSTRUCTION.
IN THE AIR DUCT RUNS AND AT SOURCE ARE LOCATED NO LESS INSTALLATION MUST COMPLY
THE SUPPLY REGISTERS. ANY THAN 18 INCHES ABOVE THE WITH ALL INSTALLATION
CIRCULATED DUST PARTICLES FLOOR. THIS IS TO REDUCE THE INSTRUCTIONS INCLUDING:
WILL BE HEATED AND CHARRED RISK OF IGNITING FLAMMABLE
BY CONTACT WITH THE VAPORS WHICH MAY • PROPER VENT INSTALLATION;
FURNACE HEAT EXCHANGER. BE PRESENT IN A GARAGE. • FURNACE OPERATING UNDER
THIS SOOTY RESIDUE WILL SOIL ALSO, THE FURNACE MUST BE THERMOSTATIC CONTROL;
CEILINGS, WALLS, DRAPES, LOCATED OR PROTECTED TO
CARPETS AND OTHER AVOID PHYSICAL DAMAGE BY • RETURN AIR DUCT SEALED TO
HOUSEHOLD ARTICLES. SOOT VEHICLES. FAILURE TO FOLLOW THE FURNACE;
DAMAGE MAY ALSO RESULT THESE WARNINGS CAN CAUSE A • AIR FILTERS IN PLACE;
WITH, OR WITHOUT, FILTERS IN FIRE OR EXPLOSION, RESULTING
PLACE, WHEN CERTAIN TYPES IN PROPERTY DAMAGE, • SET FURNACE INPUT RATE
OF CANDLES ARE BURNED, OR PERSONAL INJURY OR DEATH. AND TEMPERATURE RISE PER
CANDLEWICKS ARE LEFT RATING PLATE MARKING;
UNTRIMMED. • MEANS FOR PROVIDING
! WARNING OUTDOOR AIR REQUIRED FOR
DUCT LEAKS CAN CREATE AN COMBUSTION;
! WARNING UNBALANCED SYSTEM AND • RETURN AIR TEMPERATURE
NEVER TEST FOR GAS LEAKS DRAW POLLUTANTS SUCH AS MAINTAINED BETWEEN 55°F
WITH AN OPEN FLAME. USE A DIRT, DUST, FUMES AND ODORS (13°C) AND 80°F (27°C); AND
COMMERCIALLY AVAILABLE INTO THE HOME CAUSING • CLEAN FURNACE, DUCT
SOAP SOLUTION MADE PROPERTY DAMAGE. FUMES WORK AND COMPONENTS
SPECIFICALLY FOR THE AND ODORS FROM TOXIC, UPON SUBSTANTIAL
DETECTION OF LEAKS TO CHECK VOLATILE OR FLAMMABLE COMPLETION OF THE
ALL CONNECTIONS, AS CHEMICALS, AS WELL AS CONSTRUCTION PROCESS,
SPECIFIED IN GAS SUPPLY AND AUTOMOBILE EXHAUST AND AND VERIFY FURNACE
PIPING SECTION OF THESE CARBON MONOXIDE (CO), CAN OPERATING CONDITIONS
INSTRUCTIONS. BE DRAWN INTO THE LIVING INCLUDING IGNITION, INPUT
SPACE THROUGH LEAKING RATE, TEMPERATURE RISE
DUCTS AND UNBALANCED DUCT AND VENTING, ACCORDING TO
! WARNING SYSTEMS CAUSING PERSONAL THE INSTRUCTIONS AND
ALWAYS INSTALL FURNACE TO INJURY OR DEATH (SEE FIGURE CODES.
OPERATE WITHIN THE 3).
FURNACE'S INTENDED • IF AIR-MOVING EQUIPMENT OR NOTICE
TEMPERATURE-RISE RANGE DUCTWORK IS LOCATED IN
WITH A DUCT SYSTEM WHICH GARAGES OR OFF-GARAGE IMPROPER INSTALLATION, OR
HAS AN EXTERNAL STATIC STORAGE AREAS - ALL JOINTS, INSTALLATION NOT MADE IN
PRESSURE WITHIN THE SEAMS, AND OPENINGS IN THE ACCORDANCE WITH THE CSA
ALLOWABLE RANGE, AS EQUIPMENT AND DUCT MUST INTERNATIONAL (CSA)
SPECIFIED IN DUCTING SECTION BE SEALED TO LIMIT THE CERTIFICATION OR THESE
OF THESE INSTRUCTIONS. SEE MIGRATION OF TOXIC FUMES INSTRUCTIONS, CAN RESULT IN
ALSO FURNACE RATING PLATE. AND ODORS INCLUDING UNSATISFACTORY OPERATION
CARBON MONOXIDE FROM AND/OR DANGEROUS CONDI-
MIGRATING INTO THE LIVING TIONS AND ARE NOT COVERED
! WARNING SPACE. BY THE UNIT WARRANTY.
WHEN A FURNACE IS INSTALLED • IF AIR-MOVING EQUIPMENT OR
SO THAT SUPPLY DUCTS CARRY DUCTWORK IS LOCATED IN NOTICE
AIR CIRCULATED BY THE SPACES CONTAINING FUEL
FURNACE TO AREAS OUTSIDE BURNING APPLIANCES SUCH IN COMPLIANCE WITH
THE SPACE CONTAINING THE AS WATER HEATERS OR RECOGNIZED CODES, IT IS
FURNACE, THE RETURN AIR BOILERS - ALL JOINTS, SEAMS, RECOMMENDED THAT AN
SHALL ALSO BE HANDLED BY AND OPENINGS IN THE AUXILIARY DRAIN PAN BE
DUCT(S) SEALED TO THE EQUIPMENT AND DUCT MUST INSTALLED UNDER ALL
FURNACE CASING AND ALSO BE SEALED TO PREVENT EVAPORATOR COILS OR UNITS
TERMINATING OUTSIDE THE DEPRESSURIZATION OF THE CONTAINING EVAPORATOR
SPACE CONTAINING THE SPACE AND POSSIBLE COILS THAT ARE LOCATED IN
FURNACE. MIGRATION OF COMBUSTION ANY AREA OF A STRUCTURE
BYPRODUCTS INCLUDING WHERE DAMAGE TO THE
CARBON MONOXIDE INTO THE BUILDING OR BUILDING
! WARNING LIVING SPACE. CONTENTS MAY OCCUR AS A
DO NOT INSTALL THIS FURNACE RESULT OF AN OVERFLOW OF
IN A MOBILE HOME!! THIS THE COIL DRAIN PAN OR A
FURNACE IS NOT APPROVED FOR STOPPAGE IN THE PRIMARY
INSTALLATION IN A MOBILE CONDENSATE DRAIN PIPING.
HOME. DOING SO COULD CAUSE SEE ACCESSORIES SECTION OF
FIRE, PROPERTY DAMAGE, THESE INSTRUCTIONS FOR
PERSONAL INJURY OR DEATH. AUXILIARY HORIZONTAL
OVERFLOW PAN INFORMATION
(MODEL RXBM).
8
LOCATION REQUIREMENTS AND CONSIDERATIONS
GENERAL INFORMATION or
(0°C), a self-regulating heat tape
! WARNING b. install a parallel duct system
is required on the condensate
to divert all the air from the
DO NOT INSTALL THIS FURNACE drain, along with an insulation
furnace allowing it to pass
IN A MOBILE HOME!! This furnace wrap. The heat tape should meet
over the cooling coil only. Use
is not approved for installation in a the following requirements:
dampers or other means to
mobile home. Doing so could cause
prevent chilled air from a. The heat tape must be UL
FIRE, PROPERTY DAMAGE,
passing over the heat listed.
PERSONAL INJURY OR DEATH.
exchanger.
b. The heat tape must be
! WARNING If these are manual dampers, they installed per the
WHEN THIS FURNACE IS must be equipped to prevent heating manufacturer’s instructions for
INSTALLED IN A RESIDENTIAL or cooling operation unless the the entire length of drain pipe
GARAGE, IT MUST BE INSTALLED damper is in the full heat or cool in the unconditioned space.
SO THE BURNERS AND IGNITION position.
c. The heat tape should be rated
SOURCE ARE LOCATED NO LESS 3. IMPORTANT: Install the furnace at 5 or 6 watts per foot at
THAN 18 INCHES ABOVE THE level. If it is not level, condensate 120V. See Figure 4.
FLOOR. THIS IS TO PREVENT cannot drain properly, possibly
IMPORTANT: Support this unit
THE RISK OF IGNITING causing furnace shut down.
when installed. Since this furnace
FLAMMABLE VAPORS WHICH
NOTE: These furnaces are approved is suitable for attic or crawl space
MAY BE PRESENT IN A GARAGE.
for installation in attics, as well as installation, it may be installed on
ALSO, THE FURNACE MUST BE
alcoves, utility rooms, closets and combustible wood flooring or by
LOCATED OR PROTECTED TO
crawlspaces. Provisions must be using support brackets.
AVOID PHYSICAL DAMAGE BY
made to prevent freezing of 5. IMPORTANT: If installing in a
VEHICLES. FAILURE TO FOLLOW
condensate. utility room, be sure the door is
THESE WARNINGS CAN CAUSE A
FIRE OR EXPLOSION, RESULTING 4. IMPORTANT: If this furnace is wide enough to:
IN PROPERTY DAMAGE, installed in a garage, attic and/or a. allow the largest part of the
PERSONAL INJURY OR DEATH. any unconditioned space, install a furnace to pass; or
self-regulating heat tape around b. allow any other appliance
1. IMPORTANT: If installing the unit
the condensate trap and along the (such as a water heater)
over a finished ceiling or living
entire length of the condensate to pass.
area, be certain to install an
drain in the unconditioned space. c. allow service clearance
auxiliary condensate drain pan
When the condensing horizontal
under the entire unit. This
gas furnace is installed in an
auxiliary drain pan should extend
unconditioned space where the
under any evaporator coil
temperature would be capable of
installed with the furnace and the
reaching close to or below 32°F
open portion of the condensate
drain assembly. See
“Condensate Drain/Neutralizer”
section for more details. FIGURE 4
HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP
2. IMPORTANT: If using a cooling AI
evaporator coil with this furnace,: RF
LO
W
a. be sure the air passes over
the heat exchanger before
passing over the cooling
coil. The cooled air passing
over the warm ambient air
inside the heat exchanger
tubes can cause DRAIN
PIPE
condensation inside the tubes
resulting in corrosion and
eventual failure.
HEAT
TAPE
TRAP
I526
9
! CAUTION CLEARANCE - Upflow furnaces are shipped with a
bottom closure panel installed.
THIS FURNACE IS NOT ACCESSIBILITY When bottom return air is used,
APPROVED OR RECOMMENDED The design of forced air furnaces with remove the panel by removing the
FOR INSTALLATION ON ITS BACK, input ratings as listed in the tables two screws attaching the panel to
WITH ACCESS DOORS FACING under Figures 6, 7, 8 are certified by the front base angle. See filter
UPWARDS OR IN ANY CSA-International for the clearances section for details.
HORIZONTAL CONFIGURATION. to combustible materials shown in
inches. ! WARNING
See name/rating plate and clearance COMBUSTIBLE MATERIAL MUST
SITE SELECTION label for specific model number and NOT BE PLACED ON OR AGAINST
1. Select a site in the building near clearance information. THE FURNACE JACKET. THE
the center of the proposed, or AREA AROUND THE FURNACE
Service clearance of at least 24 MUST BE KEPT CLEAR AND FREE
existing, duct system.
inches is recommended in front of OF ALL COMBUSTIBLE
2. Give consideration to the vent all furnaces. MATERIALS INCLUDING
system piping when selecting the NOTE: Use recommended 24” GASOLINE AND OTHER
furnace location. Be sure the clearance if accessibility clearances FLAMMABLE VAPORS AND
venting system can get from the are greater than fire protection LIQUIDS. PLACEMENT OF
furnace to the termination with clearances. COMBUSTIBLE MATERIALS ON,
minimal length and elbows. AGAINST OR AROUND THE
! WARNING FURNACE JACKET CAN CAUSE
3. Locate the furnace near the
existing gas piping. Or, if running UPFLOW FURNACES ARE DESIGN- AN EXPLOSION OR FIRE
CERTIFIED FOR INSTALLATION RESULTING IN PROPERTY
a new gas line, locate the
ON COMBUSTIBLE FLOORS. DAMAGE, PERSONAL INJURY OR
furnace to minimize the length
NOTE, HOWEVER, THAT DEATH. THE HOMEOWNER
and elbows in the gas piping.
FURNACES MUST NOT BE SHOULD BE CAUTIONED THAT
See Figure 5. THE FURNACE AREA MUST NOT
INSTALLED DIRECTLY ON
4. Locate the furnace to maintain CARPETING, TILE OR OTHER BE USED AS A BROOM CLOSET
proper clearance to combustibles COMBUSTIBLE MATERIAL OTHER OR FOR ANY OTHER STORAGE
as shown in following Figures 6, THAN WOOD FLOORING. PURPOSES.
7, 8. INSTALLATION ON A
COMBUSTIBLE MATERIAL CAN
! WARNING RESULT IN FIRE, CAUSING
DO NOT LIFT THE UNIT BY THE PROPERTY DAMAGE, PERSONAL
HEAT EXCHANGER TUBES. INJURY OR DEATH.
DOING SO CAN DAMAGE THE
HEAT EXCHANGER ASSEMBLY.
FIGURE 5
HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS
GAS
PIPE
INTAKE
VENT
ELECTRICAL
CONDUIT
AI EXHAUST
RF FAN
LO
W
TRAP
I522
10
UPFLOW MODELS MINIMUM CLEARANCE (IN.)
LEFT RIGHT SHIP
MODEL A B C D E F BACK TOP FRONT VENT
SIDE SIDE WGTS
FIGURE 6
04 171/2 1611/32 155/8 2 15 1325/32 0 0 0 1 2* 0 111

06 171/2 1611/32 155/8 2 15 1325/32 0 0 0 1 2* 0 117
07B 21 1927/32 191/8 2 181/2 179/32 0 0 0 1 2* 0 145
SUPPLY RETURN 09 21 1927/32 191/8 2 181/2 179/32 0 0 0 1 2* 0 148

AIR AIR 10 21 1927/32 191/8 2 181/2 179/32 0 0 0 1 2* 0 152
12 241/2 2311/32 225/8 2 22 2025/32 0 0 0 1 2* 0 160
*A service clearance of at least 24 inches is recommended in front of all furnaces.

CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS
AIRFLOW
267⁄16
2 DIA. 2 DIA. KNOCKOUT

GAS CONNECTION ALT. GAS CONNECTION
275⁄8
OPTIONAL
RETURN
OPTIONAL RETURN AIR AIR CUTOUT
CUTOUT (EITHER SIDE)* (EITHER SIDE)*
I392.DGN
I392
*BOTH SIDES FOR 1800 CFM AND ABOVE
11
12
DOWNFLOW MODELS MINIMUM CLEARANCE (IN.)
LEFT RIGHT SHIP
SIDE SIDE WGTS
FIGURE 7
06 171⁄2 1611⁄32 155⁄8 2 165⁄8 137⁄8 0 0 0 1 2* 0 117

07A 171⁄2 1611⁄32 155⁄8 2 165⁄8 137⁄8 0 0 0 1 2* 0 123
07B 21 1927/32 193/16 2 181/2 179/32 0 0 0 1 2* 0 123
09 21 1927⁄32 193⁄16 2 201⁄8 173⁄8 0 0 0 1 2* 0 148
RETURN SUPPLY
AIR AIR 10 21 1927⁄32 193⁄16 2 201⁄8 173⁄8 0 0 0 1 2* 0 152

CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS
AIRFLOW
2513⁄16
2 DIA. 2 DIA.
GAS ALT. GAS CONNECTION
CONNECTION
43⁄8
A103501.DGN
I393
NOTE: IN DOWNFLOW CONFIGURATION, RETURN AIR CUTOUT IS NOT PERMITTED.
HORIZONTAL MODELS MINIMUM CLEARANCE (IN.)
LEFT RIGHT SHIP
SIDE SIDE WGTS
FIGURE 8
06 171⁄2 1611⁄32 155⁄8 2 165⁄8 137⁄8 0 0 0 1 2* 0 117

07A 171⁄2 1611⁄32 155⁄8 2 165⁄8 137⁄8 0 0 0 1 2* 0 123
07B 21 1927⁄32 193⁄16 2 201⁄8 173⁄8 0 0 0 1 2* 0 123
09 21 1927⁄32 193⁄16 2 201⁄8 173⁄8 0 0 0 1 2* 0 148
2 DIA.
GAS 10 21 1927⁄32 193⁄16 2 201⁄8 173⁄8 0 0 0 1 2* 0 152
CONNECTION
AIRFLOW
CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS
SUPPLY
AIR
RETURN AIR
DRAIN TRAP LOCATION
43⁄8
2 DIA.
ALT. GAS
CONNECTION
2513⁄16
NOTE: In horizontal configuration, return air cutout is not permitted.
Horizontal left-hand airflow only.
IMPORTANT: This furnace is not approved or recommended for

installation on its back, with access doors facing upwards.
A103601.DGN
I520
13
DUCTING
Proper air flow is required for the IMPORTANT: When using outside air, NOTE: Where the maximum air flow
correct operation of this furnace. design and adjust the system to maintain is 1800 CFM or more, both sides or
Too little air flow can cause erratic a return air temperature ABOVE 55° F the bottom must be used for return
operation and can damage the heat during the heating season. air.
exchanger. The duct system must
carry the correct amount of air for NOTE: Return air grilles and warm air 3. Connect the return duct or return
heating and cooling if summer air registers must not be obstructed or air cabinet to the unit. Make the
conditioning is used. closed. connection air tight to prevent
entraining combustion gases
! WARNING from an adjacent fuel-burning
UPFLOW UNITS
SOME HEATING AIRFLOW appliance.
VALUES MAY BE HIGHER THAN 1. Position the unit to minimize long
THOSE REQUIRED FOR COOLING. runs of duct or runs of duct with 4. Be sure to have adequate
BE SURE TO SIZE DUCT FOR THE many turns and elbows. space for the unit filter.
MAXIMUM POSSIBLE AIRFLOW NOTE: DO NOT take return air
VALUE. 2. Open the return air compartment.
from bathrooms, kitchens,
Size the ducts according to ! WARNING furnace rooms, garages, utility or
acceptable industry standards and laundry rooms, or cold areas.
methods. The total static pressure UPFLOW FURNACE: A SOLID METAL
drop of the air distribution system BASE PLATE MUST REMAIN IN THE NOTE: DO NOT use a rear air
should not exceed 0.5" w.c. FURNACE BOTTOM WHEN USING return.
SIDE AIR RETURN. FAILURE TO 5. If summer air conditioning is
! WARNING INSTALL A BASE PLATE COULD desired, position the indoor coil
NEVER ALLOW THE PRODUCTS CAUSE THE PRODUCTS OF on the supply-air side of the unit.
OF COMBUSTION FROM THE COMBUSTION TO CIRCULATE INTO Insure that no air can bypass this
FLUE TO ENTER THE RETURN AIR THE LIVING SPACE AND CREATE coil.
DUCTWORK OR THE CIRCULATED POTENTIALLY HAZARDOUS
AIR SUPPLY. ALL RETURN CONDITIONS, INCLUDING CARBON 6. Connect the supply air plenum to
DUCTWORK MUST BE MONOXIDE POISONING OR DEATH. the furnace plenum opening.
ADEQUATELY SEALED AND FOR BOTTOM RETURN, REMOVE
SECURED TO THE FURNACE IMPORTANT: If a flexible duct
WITH SHEET METAL SCREWS; SOLID METAL BASE PLATE. connector must be used, it
AND JOINTS, TAPED. ALL OTHER a. Cut an opening in the side. The MUST be rated for a minimum
DUCT JOINTS MUST BE SECURED opening should be cut the full temperature of 250°F.
WITH APPROVED CONNECTIONS width and height of the knockouts continuous.
AND SEALED AIRTIGHT. WHEN on the unit. See Figure 9.
AN UPFLOW FURNACE IS
MOUNTED ON A PLATFORM WITH
RETURN THROUGH THE BOTTOM, FIGURE 9
IT MUST BE SEALED AIRTIGHT UPFLOW CUTOUT AND DRILL INFORMATION
BETWEEN THE FURNACE AND
THE RETURN AIR PLENUM. THE JACKET
FLOOR OR PLATFORM MUST
PROVIDE SOUND PHYSICAL
SUPPORT OF THE FURNACE
WITHOUT SAGGING, CRACKS, OR
GAPS, AROUND THE BASE,
PROVIDING A SEAL BETWEEN
THE SUPPORT AND THE BASE.
FAILURE TO PREVENT DRILL (2)
PRODUCTS OF COMBUSTION 3/16" DIA.
FROM BEING CIRCULATED INTO HOLES
THE LIVING SPACE CAN CREATE
POTENTIALLY HAZARDOUS
CONDITIONS, INCLUDING
CARBON MONOXIDE POISONING
THAT COULD RESULT IN
PERSONAL INJURY OR DEATH. 8.000
DO NOT, UNDER ANY
CIRCUMSTANCES, CONNECT
RETURN OR SUPPLY DUCTWORK 4.875
TO OR FROM ANY OTHER HEAT
PRODUCING DEVICE SUCH AS A
FIREPLACE INSERT, STOVE, ETC.
DOING SO MAY RESULT IN FIRE,
CARBON MONOXIDE POISONING,
EXPLOSION, PERSONAL INJURY 1.531
OR PROPERTY DAMAGE.
IMPORTANT: Some high efficiency
filters have a greater than normal
resistance to air flow. This can
adversely affect furnace operation.
BE SURE TO CHECK AIR FLOW
AND STATIC PRESSURE.
14 14
DOWNFLOW UNITS NOTE: DO NOT take return air
from bathrooms, kitchens, furnace
1. Position the unit to minimize long
rooms, garages, utility or laundry
runs of duct or runs of duct with
rooms, or cold areas.
many turns and elbows.
2. If summer air conditioning is
desired, position the indoor coil HORIZONTAL UNIT
on the supply-air side of the unit. IMPORTANT: THIS FURNACE MAY
Insure that no air can bypass this ONLY BE INSTALLED SO AS WHEN
coil. FACING THE FRONT OF THE
3. If installing on a combustible floor FURNACE, SUPPLY AIR IS
and not using an air DISCHARGED ON THE LEFT HAND
conditioning plenum, install the SIDE.
special non-combustible floor 1. Position the unit to minimize long
base. See Table 1 and Figure 10. runs of duct or runs of duct with
many turns and elbows.
! WARNING
2. If summer air conditioning is
THE DOWNFLOW FURNACE desired, position the indoor coil on
DESIGN IS CERTIFIED FOR the supply air side of the unit.
INSTALLATION ON A NON- Insure that no air can bypass this
COMBUSTIBLE FLOOR. USE THE coil.
SPECIAL BASE SPECIFIED ON
THE FURNACE CLEARANCE 3. Connect the furnace to the supply
LABEL. FAILURE TO INSTALL THE air plenum.
SPECIAL BASE MAY RESULT IN 4. Connect the return air ducting to
FIRE, PROPERTY DAMAGE, the return air opening at the right
PERSONAL INJURY OR DEATH. end of the unit. Make the
THIS SPECIAL BASE IS SHIPPED connection air tight to prevent
FROM THE FACTORY AS AN pulling combustion gases from an
ACCESSORY. adjacent fuel-burning appliance.
4. Connect the furnace to the NOTE: In horizontal configuration,
supply air plenum. return air cut out is not permitted.
5. Connect the return air ducting to 5. Be sure to have adequate space
the return air opening at the top for the unit filter.
of the unit. Make the connection NOTE: DO NOT take return air
air tight to prevent entraining from bathrooms, kitchens, furnace
combustion gases from an rooms, garages, utility or laundry
adjacent fuel-burning appliance. rooms, or cold areas.
NOTE: In downflow
configuration, return air cut out is
not permitted.
6. Be sure to have adequate
space for the unit filter.
FIGURE 10
NON-COMBUSTIBLE FLOOR BASE
TABLE 1
NON-COMBUSTIBLE FLOOR BASES
Floor Base Size

No. Cabinet
(-)XGC-B17 17
(-)XGC-B21 21
(-)XGC-B24 24
15
VENTING AND COMBUSTION AIR PIPING
GENERAL INFORMATION REQUIREMENT THAT VENT
MATERIAL BE CERTIFIED TO ULC
EXISTING VENT SYSTEMS
S636 DOES NOT APPLY TO INLET When the installation of this furnace
! WARNING AIR PIPING. replaces an existing furnace that is
IMPORTANT: The plastic combustion removed from a vent system serving
READ AND FOLLOW ALL
air and venting components are of other appliances, the vent system is
INSTRUCTIONS IN THIS SECTION.
Schedule 40 PVC. If using ABS likely to be too large to properly vent
FAILURE TO PROPERLY VENT
piping, ensure that the solvent the remaining attached appliances.
THIS FURNACE CAN CAUSE
CARBON MONOXIDE POISONING cement is compatible for joining PVC The following steps should be
OR AN EXPLOSION OR FIRE, to ABS components or use a followed with each appliance
RESULTING IN PROPERTY mechanical connection that can remaining connected to the original
DAMAGE, PERSONAL INJURY withstand the vent temperatures and common vent system. Place the
OR DEATH. is corrosion resistant. appliance to be tested in operation,
while the other appliances remaining
This furnace removes both sensible NOTE: Schedule 40 ABS-DWV pipe
connected to the common vent
and latent heat from the combustion and fittings may be used as an
system are not in operation. Test the
flue gases. Removal of latent heat alternate to PVC pipe for the
operation of each appliance
results in condensation of flue gas combustion air inlet and vent pipes.
individually by the following method.
water vapor. This condensed water NOTE: Cellular core PVC is also
vapor drains from the secondary heat 1. Permanently seal any unused
approved for use. It must be schedule openings in the common venting
exchanger and out of the unit into a 40PVC-DWV cellular pipe for non-
drain trap. system.
pressure applications and
When installed as a non-direct vent manufactured under ASTM F-891. 2. Visually inspect the venting
furnace, only exhaust piping is system for proper size and
NOTE: With the furnace correctly horizontal pitch and determine
required and inside combustion air vented, the inducer will move
may be used. Refer to section on that there is no blockage,
approximately 25 cfm per 100,000 restriction, leakage, corrosion or
“COMBUSTION & VENTILATION AIR Btu’s.
FOR FURNACE INSTALLATIONS.” other deficiencies which could
IMPORTANT: No part of the cause an unsafe condition.
Direct vent installations require a combustion air and vent pipes may
dedicated combustion air and venting 3. If practical, close all building
run under ground. doors, windows and all doors
system. All air for combustion is taken
from the outside atmosphere and all between the space where the
appliances remaining connected
combustion products are discharged OVERTEMPERATURE to the common venting system
to the outdoors.
SAFETY SWITCHES are located.
The combustion air and vent pipe Turn on clothes dryers and any
fittings must conform to American Furnaces are equipped with safety appliance not connected to the
National Standards Institute (ANSI) switches in the control compartment common venting system. Turn on
and American Society for Testing to protect against overtemperature any exhaust fans, such as range
Materials (ASTM) standards conditions caused by inadequate hoods and bathroom exhausts,
D1785 (Schedule 40 PVC), D2665 combustion air supply. The switches so they will operate at maximum
(PVC-DWV), D2241 (SDR-21 and are located in the burner speed. Do not operate a summer
SDR26-26 PVC), D2661 (ABS-DWV) compartment. If a switch is tripped it exhaust fan. Close fireplace
or F628 (Schedule 40 ABS-DWV). must be manually reset. dampers.
! WARNING ! WARNING 4. Follow the lighting instructions.
Place the appliance being
IN CANADA, PRODUCTS DO NOT JUMPER THESE
inspected into operation. Adjust
CERTIFIED FOR INSTALLATION DEVICES! IF ONE OF THESE
the thermostat so the appliance
AND INTENDED TO BE VENTED SWITCHES SHOULD TRIP, A
will operate continuously.
WITH PLASTIC VENT SYSTEMS QUALIFIED INSTALLER, SERVICE
(PVC, CPVC) MUST USE VENT AGENCY OR THE GAS SUPPLIER 5. Test for spillage at the draft hood
SYSTEMS THAT ARE CERTIFIED MUST BE CALLED TO CHECK relief opening after 5 minutes of
TO THE STANDARD FOR TYPE BH AND/OR CORRECT FOR main burner operation. Use the
GAS VENTING SYSTEMS, ULC ADEQUATE COMBUSTION AIR flame of a match or candle, or
S636. SUPPLY. DO NOT RESET THE smoke from a cigarette, cigar
THE COMPONENTS OF THE SWITCHES WITHOUT TAKING or pipe.
CERTIFIED MATERIAL MUST NOT CORRECTIVE ACTION TO ASSURE
BE INTERCHANGED WITH OTHER THAT AN ADEQUATE SUPPLY OF
VENT SYSTEMS OR UNLISTED COMBUSTION AIR IS MAINTAINED
PIPE/FITTINGS. UNDER ALL CONDITIONS OF
PLASTIC COMPONENTS AND OPERATION. FAILURE TO DO SO
SPECIFIED PRIMERS AND GLUES CAN RESULT IN CARBON
OF THE CERTIFIED SYSTEM MUST MONOXIDE POISONING OR
BE FROM A SINGLE SYSTEM DEATH. IF THIS UNIT IS MOUNTED
MANUFACTURER AND NOT IN A CLOSET, THE DOOR MUST
INTERMIXED WITH OTHER BE CLOSED WHEN MAKING THIS
SYSTEM MANUFACTURER’S CHECK.
PARTS.
REPLACE THESE SWITCHES
NOTE: INLET AIR PIPING IS NOT
CONSIDERED TO BE A PART OF ONLY WITH THE IDENTICAL
THE “VENTING SYSTEM”. THE REPLACEMENT PART.
16
6. After it has been determined that
each appliance that remains
JOINING PIPE AND 1. Cut pipe end square. Chamfer
edge of pipe. Clean fitting socket
connected to the common FITTINGS and pipe joint area of all dirt,
venting system properly vents grease and moisture.
(when tested as outlined above), ! WARNING 2. After checking pipe and socket
return doors, windows, exhaust PVC SOLVENT CEMENTS AND for proper fit, wipe socket and
fans, fireplace dampers and any PRIMERS ARE HIGHLY pipe with cleaner-primer. Apply
other gas-burning appliance to FLAMMABLE. PROVIDE a liberal coat of primer to inside
their previous conditions of use. ADEQUATE VENTILATION AND DO surface of socket and outside of
7. If improper venting is observed NOT ASSEMBLE NEAR HEAT pipe. Read instructions included
during any of the above tests, the SOURCE OR AN OPEN FLAME. DO with the primer for proper
common venting system must be NOT SMOKE. AVOID SKIN OR EYE application.
resized. CONTACT. OBSERVE ALL 3. Apply a thin coat of cement
When the furnace is installed in the CAUTIONS AND WARNINGS evenly in the socket. Quickly
same space with other gas PRINTED ON MATERIAL apply a heavy coat of cement to
appliances such as a water heater, be CONTAINERS. FAILURE TO the pipe end and insert pipe into
sure there is an adequate supply of FOLLOW THESE GUIDELINES fitting with a slight twisting
combustion and ventilation air for the MAY RESULT IN FIRE, EXPLOSION movement until it bottoms out.
other appliances. Do not delete or OR ASPHYXIATION CAUSING
PERSONAL INJURY OR DEATH. NOTE: Cement must be fluid; if
reduce the combustion air supply not, recoat.
required by the other gas appliances All pipe, fittings, solvent cement,
in this space. See Z223.1, National primers and procedures must 4. Hold the pipe in the fitting for 30
Fuel Gas Code (NFPA54) for conform to American National seconds to prevent the tapered
determining the combustion air Standard Institute and American socket from pushing the pipe out
requirements for gas appliances. An Society for Testing and Materials of the fitting.
unconfined space must have at least (ANSI/ASTM) standards as shown 5. Wipe all excess cement from the
50 cubic feet (volume) for each below: joint with a rag. Allow 15 minutes
1,000 BTUH of the total input of all before handling. Cure time varies
appliances in the space. If the open according to fit, temperature and
space containing the appliances is in CEMENTING JOINTS humidity.
a building with tight construction Properly seal all joints in the PVC NOTE: Stir the solvent cement
(contemporary construction), outside vent using the following materials and frequently while using. Use a natural
air may still be required for the procedures. bristle brush or the dauber supplied
appliances to burn and vent properly. PVC CLEANER-PRIMER AND with the can. The proper brush size is
Outside air openings should be sized PVC MEDIUM-BODY SOLVENT one inch.
the same as for a confined space. CEMENT IMPORTANT: For Proper Installation
IMPORTANT: Only the current vent IMPORTANT: After cutting pipe,
instructions apply. All 90 Plus Gas DO NOT use solvent cement that
remove all ragged edges and burrs. has become curdled, lumpy or
Furnaces cannot be common vented. This is important to prevent reduction thickened.
in pressure drop throughout the
system. DO NOT thin. Observe shelf
precautions printed on containers.
For application below 32°F, use only
low-temperature-type solvent
cement.
PIPE & FITTING MATERIAL ASTM

SPECIFICATION
Schedule 40 PVC (Pipe) D1785
Schedule 40 PVC (Cellular Core Pipe) F891
Schedule 40 PVC (Fittings) D2466
SDR-21PVC (Pipe) D2241
SDR-26 PVC (Pipe) D2241
Schedule 40 ABS Cellular Core DWV (Pipe) F628
Schedule 40 ABS (Pipe) D1527
Schedule 40 ABS (Fittings) D2468
ABS-DWV (Drain Waste & Vent)
(Pipe & Fittings) D2661
PVC-DWV (Drain Waste & Vent)

(Pipe & Fittings) D2665
17
COMBUSTION AND VENTILATION AIR
NON-DIRECT
FURNACE INSTALLATIONS • Cleaning solvents (such as BTUH Minimum Sq. Feet Typical Room Size
perchloroethylene) Input With 8' Ceiling With 8' Ceiling
• Printing inks, paint removers, 45,000 281 14' x 20' OR 16' x 18'
! WARNING
varnishes, etc. 60,000 375 15' x 25' OR 19' x 20'
THE FURNACE AND ANY OTHER 75,000 469 15' x 31' OR 20' x 24'
• Hydrochloric acid
FUEL-BURNING APPLIANCE MUST 90,000 563 20’ x 28’ OR 24’ x 24’
BE PROVIDED WITH ENOUGH • Cements and glues
105,000 657 20' x 33' OR 26' x 25'
FRESH AIR FOR PROPER • Antistatic fabric softeners for
120,000 750 25' x 30' OR 24' x 32'
COMBUSTION AND VENTILATION clothes dryers
OF THE FLUE GASES. MOST • Masonry curing and acid washing If the open space containing the
HOMES WILL REQUIRE THAT materials furnace is in a building with tight
OUTSIDE AIR BE SUPPLIED INTO Combustion air must be free of acid- construction, outside air may still be
THE FURNACE AREA. FAILURE forming chemicals such as sulphur, required for the furnace to operate
TO DO SO CAN CAUSE fluorine and chlorine. These elements and vent properly. Outside air
PERSONAL INJURY OR DEATH are found in aerosol sprays, openings should be sized the same
FROM CARBON MONOXIDE detergents, bleaches, cleaning as for a confined space.
POISONING. solvents, air fresheners, paint and
EXAMPLE 2:
Adequate facilities for providing air for varnish removers, refrigerants and
FURNACE LOCATED IN A
combustion and ventilation must be many other commercial and
CONFINED SPACE
provided in accordance with section household products. When burned in
5.3, “Air for Combustion and a gas flame, vapors from these A confined space (any space smaller
Ventilation” of the National Fuel Gas products form acid compounds. The than shown above as “unconfined”)
Code, ANSI Z223.1 (latest edition) or acid compounds increase the dew must have openings into the space
applicable provisions for the local point temperature of the flue products which are located in accordance with
building codes, and not obstructed so and are highly corrosive after they the requirements set forth in the
as to prevent the flow of air to the condense. following subsections A and B. Size
furnace. the openings by how they are
connected to the heated area or to
IMPORTANT: Air for combustion and ! WARNING the outside,
ventilation must not come from a
ALL FURNACE INSTALLATIONS and by the input of all appliances in
corrosive atmosphere. Any failure
MUST COMPLY WITH THE the space.
due to corrosive elements in the
atmosphere is excluded from NATIONAL FUEL GAS CODE AND If confined space is within a building
warranty coverage. LOCAL CODES TO PROVIDE with tight construction, combustion air
ADEQUATE COMBUSTION AND must be taken from outdoors or area
The following types of installation VENTILATION AIR FOR THE freely communicating with the
(but not limited to the following) will FURNACE. FAILURE TO DO SO outdoors.
require OUTDOOR AIR for CAN RESULT IN EXPLOSION,
combustion, due to chemical A. USING INDOOR AIR FOR
FIRE, PROPERTY DAMAGE,
exposures: COMBUSTION
CARBON MONOXIDE POISONING,
• Commercial buildings PERSONAL INJURY OR DEATH. IMPORTANT: Air should not be
• Buildings with indoor pools taken from a heated space with a
Combustion air requirements are
fireplace, exhaust fan or other
• Furnaces installed in laundry rooms determined by whether the furnace is
device that may produce a
• Furnaces in hobby or craft rooms in an open (unconfined) area or in a
negative pressure.
• Furnaces installed near chemical confined space such as a closet or
small room. If combustion air is taken from the
storage areas.
heated area, the openings must
Exposure to the following substances EXAMPLE 1: each have at least 100 square
in the combustion air supply (but not FURNACE LOCATED IN AN inches of free area. Each opening
limited to the following) will also UNCONFINED SPACE must have at least one square inch
require OUTDOOR AIR for of free area for each 1,000 BTUH
combustion: Using indoor air for combustion.
of total input in the space. Here
• Permanent wave solutions An unconfined space must have at are some examples of typical
least 50 cubic feet for each 1,000 openings required.
• Chlorinated waxes and cleaners
BTUH of the total input for all
• Chlorine-based swimming pool appliances in the space. Here are a
chemicals few examples of the room sizes
• Water softening chemicals required for different inputs. The sizes
• De-icing salts or chemicals are based on 8-foot ceilings.
• Carbon tetrachloride
• Halogen type refrigerants
18
BTUH Free Area
Input Each Opening
FIGURE 11
AIR FROM HEATED SPACE
45,000 100 square inches
NOTE:
EACH OPENING SHALL
B. USING OUTDOOR AIR FOR HAVE A FREE AREA OF
NOT LESS THAN ONE
COMBUSTION SQUARE INCH PER 1,000
BTU PER H0UR OF THE
IMPORTANT: Do not take air from FURNACE
TOTAL INPUT RATING OF
an attic space that is equipped ALL EQUIPMENT IN THE
ENCLOSURE, BUT NOT
with power ventilation. GAS
LESS THAN 100 SQUARE
WATER
INCHES.
The confined space must HEATER
communicate with the outdoors in

accordance with Methods 1 or 2.
The minimum dimension of air
openings shall not be less than 3
inches. Where ducts are used,
they shall be of the same cross-
sectional area as the free area of communicating to the outdoors b. Where communicating with
the openings to which they through vertical ducts as shown in outdoors through horizontal ducts,
connect. Figure 12, each opening shall each opening shall have a
Method 1 have a minimum free area of 1 minimum free area of 1 square
Two permanent openings, one square inch for each 4,000 BTUH inch for each 2,000 BTUH of total
located within 12 inches of the top of total appliance input rating in the input rating of all equipment in the
and one located within 12 inches enclosure. enclosure (see Figure 13).
of the bottom of the enclosure, BTUH Free Area Round Pipe Here are some typical sizes:
shall be provided. The openings Input Each Opening Size
BTUH Free Area Round Pipe
shall communicate directly, or by 45,000 11.25 square inches 4" Input Each Opening Size
ducts, with the outdoors or spaces 60,000 15.00 square inches 5" 45,000 22.50 square inches 6"
(crawl or attic) that freely 75,000 18.75 square inches 5" 60,000 30.00 square inches 6"
communicate with the outdoors.
90,000 22.50 square inches 6" 75,000 37.50 square inches 7"
a. Where directly communicating 105,000 26.25 square inches 6" 90,000 45.00 square inches 8"
with the outdoors or where 120,000 30.00 square inches 6" 105,000 52.50 square inches 8"
120,000 60.00 square inches 9"
FIGURE 12 FIGURE 13
AIR FROM ATTIC/CRAWL SPACE OUTSIDE AIR USING A HORIZONTAL DUCT
GABLE
OUTLET AIR VENT
IN ATTIC
VENTILATED
MUST BE
ATTIC GABLE OR
ABOVE
SOFFIT VENTS
INSULATION
OPTIONAL 1 SQ. INCH PER 4000 BTUH INLET AIR
OUTLET AIR 1 SQ. INCH

1 SQ. INCH PER PER 2000 BTUH
4000 BTUH
OUTLET AIR
FURNACE FURNACE
GAS GAS
WATER WATER
HEATER HEATER
INLET AIR 1 SQ. INCH

12"
MAX. PER 2000 BTUH
12" MAX.
1 SQ. INCH PER

4000 BTUH INLET AIR
19
Method 2 (not shown) BTUH Free Area Round Pipe CONSULT LOCAL CODES FOR
One permanent opening, located Input Each Opening Size SPECIAL REQUIREMENTS.
within 12 inches of the top of the 45,000 15.00 square inches 4"
enclosure, shall be permitted
where the equipment has
60,000 16.67 square inches 5" CONNECTION TO
clearances of at least 1 inch from 75,000 25.00 square inches 6" FURNACE
the sides and back and 6 inches 90,000 30.00 square inches 6" IMPORTANT: When indoor
from the front of the appliance. 105,000 35.00 square inches 7" combustion air is used, the inlet air
The opening shall directly 120,000 40.00 square inches 7" opening at the furnace must be
communicate with the outdoors or protected from accidental blockage.
communicate through a vertical or b. Not less than the sum of the (See Figure 14).
horizontal duct to the outdoors or areas of all vent connectors in the
spaces (crawl or attic) that freely confined space.
communicate with the outdoors,
If unit is installed where there is an
and shall have a minimum free
exhaust fan, sufficient ventilation
area of:
must be provided to prevent the
a. 1 square inch for each 3,000 exhaust fan from creating a negative
BTUH of the total input rating of all pressure.
equipment located in the enclosure
Combustion air openings must not be
and
restricted in any manner.
FIGURE 14
COMBUSTION AIR FITTING
DOWNFLOW/HORIZONTAL
2" PVC
DOUBLE ATTACH DOUBLE ELBOW TO INTAKE AIR
UPFLOW ELBOW* COLLAR AND SECURE WITH TWO SHEET
2" PVC METAL SCREWS TO PREVENT ACCIDENTAL
DOUBLE BLOCKAGE OF INTAKE AIR OPENING.
ATTACH DOUBLE ELBOW TO TOP INLET ELBOW
AIR OPENING OR 90° ELBOW TO SIDE
INLET AIR OPENING TO PREVENT
ACCIDENTAL BLOCKAGE OF INTAKE PREDRILL FOR SCREWS.
OPENING. PLUG OPENING NOT USED.
EXHAUST
COMBUSTION AIR
EXHAUST TOP
OPTION
2" PVC ELBOW
SIDE
OPTION
I337
I336
*NOTE: WHEN FURNACE IS INSTALLED IN A HORIZONTAL POSITION

ONLY ONE 90° ELBOW IS REQUIRED. INSTALL THE ELBOW SO THE
OPEN END IS POINTED DOWNWARD.
20
VENT PIPE INSTALLATION
TABLE 2
NON-DIRECT VENT UPFLOW UNITS
INSTALLATION FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION
PROVIDED FROM INDOORS
GUIDELINES MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE
IMPORTANT: Failure to correctly follow NUMBERS OF ELBOWS
all venting guidelines may result in FURNACE PIPE 45° OR 90°
TERMINATION Medium / Long Radius ONLY
erratic furnace operation, freeze-up of INPUT SIZE
combustion air or exhaust air piping or 1-2 3-4 5-6
sooting of the furnace. Standard 60 55 50
All exhaust piping must be installed in 45,000 2”
Alternate 55 50 45
compliance with Part 7, “Venting of
Equipment,” of the latest edition of the Standard 30 25 20
2”
National Fuel Gas Code NPFA54/ ANSI 60,000
Alternate 25 20 15
Z223.1-, local codes or ordinances and Standard 120 120 115
these instructions. 3”
Alternate 120 120 110
1. Vertical piping is preferred. Standard 45 40 NR
75,000 3”
2. All horizontal piping must slope Alternate NR NR NR
upward a minimum of 1/4 inch per
Standard 90 85 75
foot of run so that condensate drains 90,000 3”
toward the furnace. Alternate 60 50 45
3. All horizontal runs must be 105,000 3” Standard 45 40 NR
supported at least every 4 feet. No Standard 70 65 55
120,000 3”
sags or dips are permitted. Alternate 40 30 25
4. IMPORTANT: Do not common vent NOTES:
with any other appliance. Do not 1. *N.R. - NOT RECOMMENDED.
2. MAXIMUM OF 4 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FOR
install in the same chase or chimney ALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.
with a metal or high temperature 3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.
4. NO SCREENS MAY BE USED TO COVER EXHAUST.
plastic pipe from another gas or fuel- *A = 17-1/2” CABINET WIDTH B = 21) CABINET WIDTH
burning appliance unless the
required minimum clearances to
combustibles are maintained TABLE 3
between the pvc pipe and other DOWNFLOW/HORIZONTAL UNITS
pipes. FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION
PROVIDED FROM INDOORS
5. All vent runs through unconditioned MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE
spaces where below-freezing
NUMBERS OF ELBOWS
temperatures are expected should 45° OR 90°
FURNACE PIPE
be insulated with 1-in. thick, INPUT SIZE
medium-density, foil-faced
1-2 3-4
fiberglass. An equivalent “arm-a-
flex” or “rub-a-tex” insulation may Standard 50 40
2”
also be used as long as there is no Alternate 40 30
heat tape applied to the vent pipe. 60,000
Standard 50 40
For horizontal runs where water may 3”
Alternate 50 40
collect, wrap the vent pipe with self-
Standard 50 40
regulating 3 or 5 watt heat tape. The 75,000 3”
Alternate 50 40
heat tape must be U.L. listed and
installed per the manufacturer’s Standard 50 40
90,000 3”
instructions. Alternate 50 40
Standard 50 40
6. The minimum vent pipe length is 105,000 3”
5 feet with 15” between elbows. Alternate 50 40
7. Extend the exhaust pipe a minimum NOTES:
1. *N.A. - NOT APPLICABLE.
of 18” from the cabinet before turning 2. MAXIMUM OF 4 - 90 DEGREE ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FOR
ALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.
vent. 3. A 45 OR 22.5 DEGREE ELBOW IS CONSIDERED ONE ELBOW.
8. Vent cannot be run underground. 4. NO SCREENS MAY BE USED TO COVER EXHAUST.
*A = 17-1/2” CABINET WIDTH B = 21” CABINET WIDTH
FIGURE 15
TEE TERMINAL – FOR STANDARD
HORIZONTAL NON-DIRECT ELEVATED SINGLE PIPE
INSTALLATION ALTERNATE TEE
TERMINATION
VENT See Figure 16. The tee termination may
be elevated up to 24 inches above the
wall penetration if required for anticipated
12" 12" MIN. ABOVE
GRADE OR snow levels. Use 2 long-sweep, 2-in.
SNOW LEVEL PVC elbows and 2-in. PVC pipe,
attaching the tee so it is 12 inches from
the wall.
21
STANDARD INSTALLATIONS Non-direct venting location In addition to the minimum clearances
The single-pipe system requires an requirements are slightly different in listed above, the vent location should
exhaust pipe only. Combustion air may some cases than direct venting. Install also be governed by the following
be taken from the furnace installation a non-direct vent with the following guidelines.
area or ducted to the furnace area from minimum clearances. 1. Do not terminate under any kind
the outside. See Figure 17. of patio or deck. If running the
Size the exhaust pipe as specified in 1. Locate the bottom of the vent vent under a deck, insulate it to
Tables 2 and 3. These tables list the terminal at least 12 inches above insure no condensate freezes
maximum allowable length in feet of the grade. Increase the 12-in. and blocks the pipe.
exhaust pipe that may be used for all minimum to keep the terminal 2. Do not locate on the side of a
furnace inputs as related to the number openings above the level of snow building with prevailing winter
of elbows required and the termination. accumulation, where applicable. winds. This will help prevent
Vertical through-the-roof installations do 2. The vent shall not terminate over moisture from freezing on walls
not require a vent termination. Use 2-in. public walkways or over an area and overhangs (under eaves).
PVC pipe extending a minimum of 12 where condensate or vapor could 3. Do not extend vent directly
inches above the anticipated level of create a nuisance or hazard. through brick or masonry
snow accumulation. See exhaust pipe 3. 4 feet below, 4 feet horizontally surfaces. Use a rust-resistant
requirements, Figure 20. When 3-in. from, or 1 foot above any door, sheet metal or plastic backing
vent pipe is used from furnace to the window soffit, under eave vent or plate behind vent.
roof, reduce it to 2 inches before gravity air inlet to the building.
penetrating the roof. A maximum of 18 4. Do not locate too close to shrubs
inches of 2-in. pipe may be used below 4. The vent terminal shall have a as condensate may stunt or kill
the roof. Maximum exposed vent length minimum horizontal clearance of them.
above the roof line is 30”. Total 2” vent 4 feet from electric meters, gas 5. Minimum vertical clearances of 1
length is a maximum of 48”. meters, regulators and relief foot are recommended for
equipment. overhangs up to 1 foot horizontal.
Horizontal vent terminations require a
2-in. PVC tee positioned 12 inches from 5. 6 feet from an inside corner The vertical clearance should be
the outside wall. See exhaust pipe formed by two exterior walls – increased equally for each
requirements, Figures 20 and 21. When 10 feet is the recommended additional increase in horizontal
3-in. pipe is used from the furnace to distance. overhang to a maximum vertical
the outside wall, reduce it to 2 inches 6. Locate it 3 feet above any forced clearance of 6 feet.
before penetrating the wall. A maximum air inlet located within 10 feet. 6. Caulk all cracks, seams and
of 18 inches of 2-in. pipe may be used Any fresh air or make-up air inlet, joints within 6 feet horizontally
inside the wall. such as for a dryer or furnace and above and below vent.
An alternate termination may be used area, is considered a forced air 7. Do not terminate in any area that
as shown in Figure 16 to clear inlet. may allow flue gases to stagnate.
anticipated snow levels. The tee may 7. Avoid areas where dripping
be raised up to 24 inches above the condensate may cause problems,
wall penetration. Use two long-sweep such as above planters, patios, or
radius bend, 2-in. PVC elbows and a adjacent to windows where
length of 2-in. PVC pipe so that the steam may cause fogging.
elbows are on 24-in. centers.
NOTE: Extend the exhaust a minimum
of 18" from the furnace top plate before
turning vent.
FIGURE 16
ALTERNATE HORIZONTAL TERMINATION
NON-DIRECT VENT TERMINATION FOR NON-DIRECT VENT
LOCATION REQUIREMENTS INSTALLATIONS
! CAUTION NOTE: 12
"
OM
NOT APPLICABLE TO FR
MOISTURE IN THE COMBUSTION RGRM-07EYBGS MODEL
PRODUCTS CONDENSES AS IT RGRM-07EMAES MODEL
LEAVES THE TERMINATION. THIS RGRM-10EZAJS MODEL
CONDENSATE CAN FREEZE ON OUTSIDE
EXTERIOR WALLS, UNDER THE WALL
EAVES, AND ON SURROUNDING PIPE
OBJECTS. SOME DISCOLORATION SUPPORT
24" STRAP
IS TO BE EXPECTED. HOWEVER, MAX.
IMPROPER LOCATION OR
INSTALLATION CAN CAUSE
STRUCTURAL OR EXTERIOR FINISH
DAMAGE TO THE BUILDING.
I198
22
FIGURE 17
OTHER THAN DIRECT VENT TERMINAL CLEARANCES
Canadian Installations US Installations Canadian Installations US Installations
Natural Gas and Propane Installation Code

National Fuel Gas Code
23
DIRECT VENT TABLE 4
UPFLOW UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION
INSTALLATIONS PROVIDED FROM OUTDOORS
MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE
! WARNING
NUMBER OF ELBOWS
READ AND FOLLOW ALL FURNACE PIPE VENT TERMINATION 45 or 90 Degrees
INSTRUCTIONS IN THIS SECTION. INPUT SIZE KIT RECOMMENDED
FAILURE TO PROPERLY VENT 2 4
THIS FURNACE CAN CAUSE
CARBON MONOXIDE POISONING Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/GXGY-G02 60 50
45,000 2”
OR AN EXPLOSION OR FIRE, Alternate RXGY-D02/RXGY-D02A 50 40
RESULTING IN PROPERTY Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 40 35
DAMAGE, PERSONAL INJURY 2”
OR DEATH. Alternate RXGY-D02/RXGY-D02A 40 35
60,000
Direct vent installations require a Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 60 50
3”
dedicated combustion air and venting Alternate RXGY-D03/RXGY-D03A 50 40
system. All air for combustion is taken 3” Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 40
from the outside atmosphere and all 75,000
combustion products are discharged to Alternate RXGY-D03/RGXY-D03A 50 40
the outdoors. Therefore, no Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 40
ventilation or combustion air 90,000 3”
Alternate RXGY-D03/RXGY-D03A 40 30
openings are required.
3” Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 40
IMPORTANT: The plastic combustion 105,000
air and venting components are of Alternate RXGY-D03/RGXY-D03A 50 40
Schedule 40 PVC. If using ABS piping Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 40
ensure that the solvent cement is 120,000 3”
compatible for joining PVC to ABS
components or use a mechanical NOTES:
connection that can withstand the vent 1. N.A. - NOT APPLICABLE
2. MAXIMUM OF 4 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.
temperatures and are corrosion MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.
resistant. 3. A 45 DEGREE ELBOW IS CONSIDERED ONE ELBOW.
4. CONCENTRIC TERMINATION NO. RXGY-E03/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.
5. USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATE
INSTALLATION GUIDELINES THRU-THE-WALL VENTING.
6. USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.
All exhaust piping must be installed in 7. KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.
compliance with Part 7, “Venting of 8. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.
Equipment,” of the latest edition of the
National Fuel Gas Code NPFA54/
ANSI Z223.1-, local codes or
ordinances and these instructions.
1. Vertical piping is preferred. TABLE 5
2. All horizontal piping must slope DOWNFLOW/HORIZONTAL UNITS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION
upward a minimum of 1/4 inch PROVIDED FROM OUTDOORS
per foot of run so that condensate MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE
drains toward the furnace. NUMBER OF ELBOWS
3. All horizontal runs must be FURNACE PIPE VENT TERMINATION 22.5, 45 or 90 Degrees
supported at least every 4 feet. INPUT SIZE KIT RECOMMENDED
No sags or dips are permitted. 1-2 3-4
4. IMPORTANT: Do not common Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 50 40
vent with any other appliance. Do 2”
not install in the same chase or Alternate RXGY-D02/RXGY-D02A 40 30
60,000
chimney with a metal or high Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 40
temperature plastic pipe from 3”
another gas or fuel-burning
appliance unless the required Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 40
75,000 3”
minimum clearances to Alternate RXGY-D03/RXGY-D03A 50 40
combustibles are maintained Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-D03A/RXGY-G02 50 40
between the PVC pipe and other 90,000 3”
pipes. Minimum 3 ft. clearance Alternate RXGY-D03/RXGH-D03A 50 40
required between combustion air Standard/Concentric RXGY-D03/RXGY-D03A/RXGH-E03A/RXGY-G02 50 40
inlet and any other exhaust. 105,000 3”
5. For horizontal runs where water
may collect, wrap the vent pipe NOTES:
1. N.A. - NOT APPLICABLE
with self-regulating 3 or 5 watt 2. MAXIMUM OF 4 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS IN ALTERNATE TERMINATION KIT.
heat tape. The heat tape must be MEDIUM OR LONG SWEEP ELBOWS MAY BE USED.
3. A 45 DEGREE ELBOW IS CONSIDERED ONE ELBOW.
U.L. listed and installed per the 4. CONCENTRIC TERMINATION NO. RXGY-E03/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.
manufacturer’s instructions. 5. USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATE
THRU-THE-WALL VENTING.
6. The minimum, pipe length is 6. USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.
5 feet for combustion air and 7. KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.
exhaust. 8. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.
7. Do not install elbows back to

back. Allow at least 15” between
elbows.
Size the exhaust and combustion air
intake pipes as specified in Tables 4
and 5. These tables list the maximum
24
allowable length in feet of the exhaust STANDARD TERMINATIONS STANDARD VERTICAL
and combustion air intake pipes that TERMINATIONS
may be used for all furnace inputs as STANDARD VERTICAL
related to the number of elbows TERMINATIONS EXHAUST VENT PIPING
required and the termination. Vertical through-the-roof vent
COMBUSTION AIR PIPING
NOTE: Extend the exhaust a minimum applications do not require an
of 18" from the furnace top plate Use two medium-radius sweep exhaust terminal. The exhaust vent
before turning vent. elbows to keep the inlet downward to must terminate at least 12 inches
8. The maximum exposed vent prevent entry of rain. See Figure 20 above the combustion intake air
length (above the roof line) is 30”. for the proper relationship of termination. The exhaust vent for
combustion air to exhaust models with inputs of 45,000 through
termination. 120,000 BTUH is 2-in. PVC pipe
COMBUSTION AIR FOR 120,000 BTUH models with
DIRECT VENT STANDARD HORIZONTAL excessively long runs require 21/2”.
INSTALLATIONS TERMINATIONS Refer to Tables 3 and 4 for proper
application. This must
THE COMBUSTION AIR SYSTEM COMBUSTION AIR PIPING be reduced to 11/2“ the last
DESIGNED FOR THIS FURNACE When 3-in. pipe is used between the 12 inches for models with inputs of
MUST BE USED. furnace and outside wall, reduce it 45,000 through 75,000 BTUH.
When this furnace is installed as a to 2 inches before penetrating the See Figure 20.
direct vent forced air furnace, all wall. Up to 18 inches of 2-in. pipe
combustion air is supplied directly to may be used inside the wall. STANDARD HORIZONTAL
the burner through a special air inlet TERMINATIONS
The standard horizontal intake air
system outlined in these instructions. EXHAUST PIPING
This system consists of field-supplied termination for all models is a 2-in.
Schedule 40 or 26 SDR-PVC pipe PVC coupling with a wind deflector For direct vent systems the standard
and one of the following horizontal vane (provided) attached. Cut a termination is 2-in. PVC pipe
vent termination kits: RXGY- 21/4-in. length of 2-in. PVC pipe. extending 12 inches from the wall for
D02/D02A, RXGY-D03/D03A, RXGY- Connect this pipe and another 2-in. furnaces with inputs from 105,000 to
D04/D04A, or RXGY-E03A. Kits PVC coupling to the coupling at the 120,000 BTUH. Install a 2-in. coupling
ending with an “A” meet Canadian wall. The outer coupling must at the outside wall to prevent the
ULC-5636 requirements. terminate 4 inches from the wall. termination from being pushed
inward. When 3-in. pipe is used
NOTE: Schedule 40 ABS-DWV pipe IMPORTANT: To ensure proper between the furnace and outside wall,
and fittings may be used as an furnace operation, the supplied vane reduce to 2 inches before penetrating
alternate to PVC pipe for the must be installed in the vertical the wall. The standard termination is
combustion air inlet and vent pipes. position with PVC solvent as shown in 2 in. PVC pipe extending outward 12
The combustion air for this furnace is Figure 21, Detail B. inches from the wall. See Figure 20,
supplied directly from the outdoors The combustion air inlet terminal Detail A.
through the combustion air inlet must be located with respect to the The combustion air and exhaust
system. exhaust terminal as shown in Figure terminations must be at least 12
When the furnace is installed in the 21, Detail C. inches above grade and must be
same space with other gas IMPORTANT: All furnaces with oriented with respect to each other as
appliances, such as a water heater, shown in Figure 21, Detail B. Refer to
horizontal air intakes, except those
be sure there is an adequate supply section on alternate venting options
using concentric vent kit RXGY-
of combustion and ventilation air for when higher snow levels are
the other appliances. Do not delete or E03/E03A, must have a drain tee anticipated.
reduce the combustion air supply assembly and trap installed as close
required by the other gas appliances to the furnace as possible. This is to
drain any water that may be in the ALTERNATE
in this space. See Z223.1, National TERMINATIONS
Fuel Gas Code (NFPA54) for deter- combustion air pipe to prevent it from
mining the combustion air entering the furnace combustion ALTERNATE HORIZONTAL
requirements for gas appliances. An chamber. DIRECT VENT TERMINATIONS
unconfined space must have at least These parts are included in kits RXGY-D02/D02A, -D03/D03A AND -
50 cubic feet (volume) for each RXGY-D02/D02A (for 2-in. pipe), D04/D04A
1,000 BTUH of the total input of all RXGY-D03/D03A (for 3-in. pipe) and
appliances in the space. If the open The exhaust termination may be
RXGY-D04/D04A (special for the raised a maximum of 60 inches
space containing the appliances is in
120,000 BTU furnace installed with above the wall penetration to maintain
a building with tight construction
(contemporary construction), outside the alternate horizontal termination). the required 12 inch clearance above
air may still be required for the Attach the trap to the bottom of the grade or snow level. See Figure 18.
appliances to burn and vent properly. tee with PVC solvent. Connect the Size the pipe length according to
Outside air openings should be sized other end to a suitable drain, as to the Tables 4 and 5.
the same as for a confined space. downstream of a condensate trap on Review the following guidelines:
the furnace.
• Size the entire vent system
according to the alternate, not
standard, termination shown in
Tables 4 and 5.
25
• Insulate the entire length of vent
pipe, between the elbow where the FIGURE 18
ALTERNATE HORIZONTAL DIRECT VENT TERMINATION
pipe exits the wall and the elbow NOTE:
where the termination is made, with NOT APPLICABLE TO EXHAUST VENT
a closed-cell insulation, such as RGRM-07EYBGS MODELS 2 /2" PVC FOR MODELS WITH 120,000 BTU INPUT
1
RGRM-07EMAES MODELS (KIT NO. RXGY-D04)

“Arm-a-Flex” or “Rub-a-Tex” with a RGRM-10EZAJS MODELS 2" PVC FOR MODELS WITH INPUTS OF 45,000 AND
minimum of 1/2” thickness. 120,000 BTU. (SEE DETAIL A). ELBOWS AND RISERS
ARE 2" PVC.
• All elbows installed on the exterior

INTAKE VENT
of the building must be of the long 21/2" PVC FOR MODELS WITH
sweep nature. 120,000 BTU INPUT.
2" PVC ELBOWS AND RISER
MODELS WITH INPUTS OF 45,000
• As required for the horizontal piping SEE DETAIL A THRU 90,000 BTU.
ran within the structure, any pipe USE KIT NO. RXGY-D02/D02A WHEN 2"
12" FROM PIPE IS USED BETWEEN FURNACE AND
ran horizontal outside the structure WALL OUTSIDE WALL. USE KIT NO. RXGY-
D03/D03A WHEN 3" PIPE IS USED.
must slope upward a minimum of
1/4” per foot run so that condensate
drains toward the furnace. 4" FROM
WALL
From the top elbow in the exhaust

pipe, extend a length of PVC pipe 60” MAX. PIPE
outward so that it terminates exactly SUPPORT
STRAP
12 inches from the wall. See Figure
18.
The 45,000 BTUH unit only uses kit 3”

RXGY-D02/D02A. The 60,000 BTUH
and 75,000 BTUH units may use kits
RXGY-D02/D02A or RXGY-
D03/D03A depending on pipe lengths
EXHAUST VANE
and number of elbows. Use kit 4” MAX.
RXGY-D03/D03A with 90,000 BTUH
through 120,000 BTUH units. The
RXGY-D04/D04A kit only applies to
INTAKE OPTIONAL
the 120,000 BTUH unit using an INTAKE DETAIL C
alternate termination and COMBUSTION AIR
DETAIL B TERMINATION
excessively long runs. See Tables 4 EXHAUST / INTAKE RELATIONSHIP
and 5. I339
The following are parts lists for the

RXGY-D02/D02A, RXGY-D03/D03A RXGY-D03/D03A RXGY-D02A
and RXGY-D04/D04A alternate 1. 3-in. tee with reducer assembly 1. 2” Tee assembly w/1⁄2” drain
2. 1⁄2-in. PVC 6-in. dia. trap connection
horizontal direct vent termination kits:
3. PVC vane 2. 1⁄2” PVC-5” diameter trap
RXGY-D02/D02A 4. 2-in. PVC elbow 3. Wind deflector vane
1. 2-in. tee with reducer assembly 5. PVC strap 4. Vent template
2. 1⁄2-in. PVC 6-in. dia. trap
6. vent template
3. PVC vane RXGY-D03A
4. 2-in. PVC elbow RXGY-D04/D04A
1. 21⁄2-in. PVC elbow 1. 3” Tee assembly w/1⁄2” drain
5. 11⁄2-in. PVC nipple with coupling connection
6. PVC strap 2. 3" x 21⁄2" PVC bushing
3. 21⁄2" x 61⁄2" long PVC pipe 2. 1⁄2” PVC-5” diameter trap
7. vent template 3. Wind deflector vane
4. 21⁄2" x 16" long PVC pipe
5. 21⁄2" x 21" long PVC pipe 4. Vent Template
6. PVC vane
7. 3-in. tee with reducer assembly RXGY-D04A
8. 6-in. dia. 1⁄2-in. PVC trap 1. 3” Tee assembly w/1⁄2” drain
9. PVC strap connection
10. vent template 2. 1⁄2” PVC-6” diameter trap
3. Wind deflector vane
4. Vent template
NOTE: The RXGY-D04/D04A kit only
applies to the 120,000 BTUH unit
using an alternate termination and
excessively long runs.
26
CONCENTRIC NOTE: The following IPEX brand
TERMINATIONS concentric termination (System 636)
may be purchased in the field and
VERTICAL/HORIZONTAL used in place of factory supplied kits:
CONCENTRIC VENT
3” Concentric Kit – Item # 196006
KIT NO. RXGY-E03A
This kit is for vertical/horizontal
intake air/vent runs and may be
installed through roofs or sidewalls.
One 5” diameter hole is required for
the installation. See Figure 19 for
the general layout. Complete
installation instructions are included
with the kit.
FIGURE 19 ROOF INSTALLATION MAINTAIN 12 IN.

CONCENTRIC VENT KIT NO. RXGY-E03A MINIMUM CLEARANCE
A ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
E 24 IN. ABOVE ROOF.
SIDEWALL ASSEMBLY
FIELD-SUPPLIED B
STRAP E
C
A
1" MAXIMUM
B C
D
D
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) NOTE: • Support must be field installed
to secure termination kit to structure.
• No screens may be used to cover
E PVC RAINCAP combustion air and exhaust.
27
FIGURE 20
STANDARD VERTICAL DIRECT VENTING
3"
EXHAUST MAX.
VENT COMBUSTION
AIR PIPE
3" MAX. 12"
MIN.
4 SEPARATION 6 3" EXHAUST
12” MAX. VENT
36" MAX. COMBUSTION AIR 12"
EXHAUST COMBUSTION
TERMINATION PIPE 1 AIR PIPE
12"
MIN.
DETAIL A MIN.
12" MIN.
30” MAX SEPARATION
5 48” MAX 12"
12" MIN. ABOVE
ROOF LEVEL
MIN. 5
EXHAUST PIPE ROOF LINE
ANTICIPATED
SNOW LEVEL
ROOF LINE
NOTES: 2 5
INCREASE THE 12-IN. MINIMUM
1 TO KEEP TERMINAL OPENING
ABOVE ANTICIPATED LEVEL OF
SNOW ACCUMULATION WHERE
APPLICABLE. COMBUSTION AIR PIPE
WHEN 3-IN. DIAM. PIPE IS USED, SUPPLY AIR 3" .
2 REDUCE TO 2-IN. DIAMETER BEFORE EXHAUST VENT MA
X
EL
PENETRATING ROOF. A MAXIMUM EV
OF 18 IN. OF 2-IN. PIPE MAY BE VE OW L
USED BEFORE PASSING 3 BO N
. A ED S
THROUGH ROOF. MIN AT
. 12" TICIP
3 SUPPORT VERTICAL PIPE EVERY 6 MIN AN
FEET. 12"
EXHAUST TERMINATION - TERMINATE
4 THE LAST 12 INCHES WITH 2” PVC PIPE
ON 45,000 AND 120,000 BTUH MODELS.
RETURN AIR
SEE DETAIL A.
30” MAXIMUM EXPOSED VENT
30” MAX
5
5 LENGTH.
THE COMBUSTION AIR PIPE MUST
6 TERMINATE IN THE SAME PRESSURE
ZONE AS THE EXHAUST PIPE.
NO SCREENS MAY BE USED TO
7 COVER COMBUSTION AIR AND
EXHAUST. PITCHED ROOF INSTALLATIONS
I407
FIGURE 21
STANDARD HORIZONTAL DIRECT VENTING
12”
1 2
3 4
EXHAUST TERMINATION
DETAIL A
12”
SUPPLY AIR
2” OR 3” TEE
EXHAUST PIPE W/DRAIN TRAP 4” SEE DETAIL A
COMBUSTION AIR PIPE 4”
NOTES:
SUPPORT HORIZONTAL PIPE 12” MIN. ABOVE
1 EVERY FOUR FEET. GRADE LEVEL 5
TRAP
WHEN 3 IN. PIPE IS USED REDUCE TO 2 IN.
2 BEFORE PENETRATING OUTSIDE WALL.
18 IN. MAXIMUM. 2 IN. DIAMETER PIPE MAY
3 BE USED INSIDE THE WALL. CONNECT SEE DETAIL B
DETAIL “A” - EXHAUST TERMINATION TO DRAIN
4 TERMINATE THE LAST 12 INCHES WITH 2”
PVC PIPE ON 45,000 AND 120,000 BTUH
MODELS. 3”
INCREASE THE 12 IN. MINIMUM ABOVE RETURN AIR
5 GRADE TO KEEP TERMINAL OPENINGS
ABOVE ANTICIPATED LEVEL OF SNOW
ACCUMULATION WHERE APPLICABLE.
DETAIL “B”, INSTALL WIND DEFLECTOR
6 VANE IN 2 IN. PVC COUPLING IN VERTICAL
POSITION USING PVC SOLVENT. EXHAUST
THE COMBUSTION AIR TERMINATION MUST 4”
BE IN THE SAME PRESSURE ZONE AS THE
EXHAUST TERMINATION. VANE 2” PVC
THE COMBUSTION AIR PIPE MUST COUPLING
7 TERMINATE IN THE SAME PRESSURE
ZONE AS THE EXHAUST PIPE.
NO SCREENS MAY BE USED TO COVER INTAKE OPTIONAL
8 COMBUSTION AIR AND EXHAUST. INTAKE
9 NO ELBOWS OR “T”S CAN BE INSTALLED
AT TERMINATION.
6 DETAIL C
COMBUSTION AIR TERMINATION EXHAUST / INTAKE RELATIONSHIP
DETAIL B I407
28
LOCATION REQUIREMENTS In addition to the minimum
clearances listed above, the vent
5. Do not locate too close to shrubs
as condensate may stunt or
HORIZONTAL DIRECT VENTS location should also be governed kill them.
by the following guidelines. 6. Minimum vertical clearances of 1
! CAUTION 1. Do not terminate under any foot are recommended for
kind of patio or deck. If running overhangs up to 1 foot horizontal.
THE COMBUSTION PRODUCTS
the vent under a deck, insulate The vertical clearance should be
AND MOISTURE IN THE FLUE
it to insure no condensate increased equally for each
GASES WILL CONDENSE AS THEY
freezes and blocks the pipe. additional increase in horizontal
LEAVE THE TERMINATION. THE
2. Do not terminate behind any area overhang to a maximum vertical
CONDENSATE CAN FREEZE ON
that may allow the flue products clearance of 6 feet.
THE EXTERIOR WALL, UNDER
THE EAVES AND ON to become stagnant and 7. Caulk all cracks, seams and
SURROUNDING OBJECTS. SOME recirculate. joints within 6 feet horizontally
DISCOLORATION TO THE 3. Do not locate on the side of a and above and below vent.
EXTERIOR OF THE BUILDING IS building with prevailing winter 8. Painted surfaces must be sound
TO BE EXPECTED. HOWEVER, winds. This will help prevent and in good condition with no
IMPROPER LOCATION OR moisture from freezing on walls cracking, peeling, etc. Painted
INSTALLATION CAN RESULT IN and overhangs (under eaves). surfaces will require
STRUCTURAL OR EXTERIOR maintenance.
4. Do not extend vent directly
FINISH DAMAGE TO THE
through brick or masonry 9. Do not expose 3" x 2" reducer/
BUILDING AND MAY
surfaces. Use a rust-resistant bushing to outdoor ambient
RECIRCULATE PRODUCTS OF
sheet metal or plastic backing temperatures.
COMBUSTION INTO THE
plate behind vent.
COMBUSTION AIR TERMINAL AND
FREEZE.
The vent must be installed with the
following minimum clearances. See
Figures 22 and 23.
FIGURE 22
1. The bottom of the vent terminal MOISTURE ZONES
and the air inlet shall be located
at least 12 inches above grade.
Increase the 12-in. minimum to
keep the terminal openings
above the level of snow
accumulation, where applicable.
2. The vent shall not terminate over
public walkways or over an area
where condensate or vapor could
create a nuisance or hazard.
3. The vent terminal shall be
located at least one foot from any
opening through which flue
gases could enter a building.
4. The vent terminal shall be at
least 3 feet above any forced air
inlet located within 10 feet,
except the combustion air inlet of
a direct vent appliance. 2 FT. SQ. SHEET METAL PLATE ON BRICK OR
MASONRY SURFACE RECOMMENDED, BUT
5. The vent terminal shall have a NOT REQUIRED BY CODE.
minimum horizontal clearance of
4 feet from electric meters, gas
meters, regulators and relief
equipment.
6. Locate the furnace combustion
air inlet minimum of 3 feet from
the vent of any other gas or fuel
burning appliance or clothes
dryer to prevent recirculation of
the flue gases into the furnace
combustion air inlet. The only
exception to this requirement is
the case of multiventing two or
more furnaces, which is covered
in the section on multiventing in
these instructions.
29
30
FIGURE 23
DIRECT VENT TERMINAL CLEARANCES
Canadian Installations US Installations Canadian Installations US Installations
Natural Gas and Propane Installation Code

National Fuel Gas Code
FIGURE 24 FIGURE 25
TWO FURNACE VENTING THROUGH ROOF TWO FURNACE VENTING THROUGH WALL
TWO-PIPE VENTING TWO-PIPE VENTING
COMBUSTION
AIR INTAKE E
OV
2” PVC AB EL
N. V
” MI LE
12 NO W
S
3" MIN. ED
N. D
24" MAX. MI EN
6’ MM
O
REC
’
10
COMBUSTION
AIR INTAKE
2” PVC COUPLING
WITH VALVE IN
VERTICAL POSITION
EXHAUST VENT
3" MIN.
24" MAX.
CONCENTRIC VENTING CONCENTRIC VENTING
8" MIN.
24" MAX.
MINIMUM 12” ABOVE AVERAGE

SNOW ACCUMULATION. MAXIMUM
OF 24 IN. ABOVE ROOF.
6’ MINIMUM
10’ RECOMMENDED
MINIMUM 12”
ABOVE GRADE
MAXIMUM 1”
DISTANCE
FROM WALL
SEE CONCENTRIC SEE CONCENTRIC VENT INSTALLATION

VENT INSTALLATION 8" MIN. INSTRUCTIONS.
INSTRUCTIONS 24" MAX.
MULTIVENTING
IF VENTING TWO OR MORE
FURNACES NEAR EACH OTHER IS
REQUIRED, EACH FURNACE
MUST BE INDIVIDUALLY VENTED
– NO COMMON VENTING IS
PERMITTED. See Figures 24 and 25
for positioning of the terminations.
When more than two furnaces are to
be vented, there must be at least 4
feet between the first two furnaces
and the third, etc.
31
RXGY-G02 Side Wall Vent NOTE: Install the vent and air intake
piping into the vent plate openings.
NOTE: The vent illustration in Figure
27 can be used for non-direct vent
This termination is for horizontal Seal all gaps between the pipes and terminations also.
venting only. wall. Be Sure To Use Silicone
IMPORTANT: Do not install on the Sealant to seal the vent pipe to the
prevailing winter wind side of the vent cap to permit field disassembly
structure. Observe same clearance for annual inspection and cleaning.
specified for horizontal, standard Also seal all pipe penetrations in wall.
termination. To prevent possibility of condensate
NOTE: Multi-venting-No common freeze-up or recirculation, do not
venting. install vent kits one above the
other.
FIGURE 26
VENT KIT INSTALLATION OPTIONS
EXHAUST
AIR
INTAKE
FIGURE 27
TYPICAL INSTALLATIONS For 45000 thru 120000 BTUH models-
reduce to a length between 12 inches
and 30 inches of 2 inch pipe.
Note: Vent should protrude a

maximum of 2-1/4” beyond vent plate.
air intake should protrude a maximum
of 1 inch beyond vent plate.
Seal all wall cavities.
32
CONNECTING TO FURNACE FIGURE 28
IMPORTANT: Clean and debur all UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION
pipe cuts. The shavings must not be
allowed to block the exhaust,
combustion air or condensate drain “O” RING COMBUSTION
pipes. AIR ADAPTER
TOP PLATE NOTE:
UPFLOW FURNACE EXHAUST WHEN COMBUSTION AIR IS IN
OPTIONAL POSITION SWAP LOCATION
The exhaust pipe connection is a 2-in. VENT CAP/PLUG
OF 2" PVC MALE ADAPTER AND “O”
female PVC pipe fitting extending EXHAUST
OUTLET AIR PIPE RING WITH PLUG.
through the left side of the furnace top
plate. This opening has a protective
cap which should be removed just PLUG OPT. COMBUSTION
prior to installing the exhaust pipe. AIR POSITION
When 2-in. pipe is used, connect it

directly to this fitting. When 3-in. pipe
is used, connect a 2 to 3-in. coupling
to this fitting with a short piece of 2-in.
PVC pipe.
The combustion air connection INDUCED DRAFT
is at the right side of the top plate. BLOWER
An alternate combustion air EXHAUST TRANSITION
connection may be made on the right
side of the jacket. This opening has a CONNECTOR
plastic cap. A combustion air
connection fitting is supplied with the
furnace and it must be installed in the
furnace by screwing it into the
opening. Make sure the rubber
“O-ring” supplied with the furnace is CONDENSATE TRAP
used with this fitting. See Figure 28.
DRAIN HOSES
I329
DOWNFLOW/HORIZONTAL (AS SHIPPED FROM
FACTORY)
FURNACE
The exhaust pipe connection is a 2-in.
female PVC pipe fitting extending
FIGURE 29
through the right side of the furnace DOWNFLOW/HORIZONTAL COMBUSTION AIR AND VENT PIPE CONNECTION
top cover. This opening has a pro-
tective cap which should be removed
just prior to installing the exhaust TOP PLATE EXHAUST VENT
pipe. When 3-in. pipe is used, CAP/PLUG
connect a 2 to 3-in. coupling to this COUPLING
fitting with a short piece of 2-in. PVC

pipe. NOTE:
ATTACH COUPLING TO
The combustion air connection is a 2- EXTRUDED COLLAR
in. extruded hole on the left side of WITH TWO SCREWS. PUT
BEAD OF SILICONE
the top plate. When a 2-in. pipe is AROUND BASE BEFORE EXHAUST
used, attach a 2-in. PVC coupling MOUNTING COUPLING. PIPE - PVC
over this hole with RTV sealant, drill
two pilot holes, and add two sheet COMBUSTION
AIR CHASE
metal screws through the coupling
into the extrusion to secure it in place
before piping. When 3-in. pipe is EXHAUST
CONNECTOR
used, connect a 2 to 3-in. coupling to
this fitting with a short piece of 2-in.
INDUCED DRAFT EXHAUST
PVC pipe. See Figure 29. BLOWER OUTLET AIR PIPE
EXHAUST
TRANSITION
a103101
33
CONDENSATE DRAIN/NEUTRALIZER
GENERAL INFORMATION IMPORTANT: If installing the unit over
a finished ceiling or living area, be
Use a solvent cement that is
compatible with PVC material. Cut the
! CAUTION certain to install an auxiliary condensate drain hoses to the appropriate length
drain pan under the entire unit and connect to the trap with hose
DO NOT RUN DRAIN OUTDOORS. extending out under the condensate clamps. Tighten the clamps with
FREEZING OF CONDENSATE CAN tee. pliers and check for leaks after
CAUSE PROPERTY DAMAGE. IMPORTANT: There are two options attaching.
IMPORTANT: Do not connect into a when choosing a height for the
condensate riser: IMPORTANT: The inducer drain hose
common drain line with an air con- must slant downward away from
ditioner evaporator coil drain. A blocked CONDENSATE OVERFLOW: With a 5
inch riser installed above the tee, a inducer. If the hose is not slanted,
or restricted drain line can result in the inducer will fill with water and
over-flow of the coil pan and negate the blocked drain will result in overflow from
the riser. cause the pressure switch to open,
furnace blocked drain shutoff control. causing nuisance failures or
FURNACE SHUTDOWN: To cause the
FILL TRAP ASSEMBLY WITH furnace to shut down when a blocked intermittent operation.
WATER BEFORE OPERATING THE drain is present, install a riser which is a
FURNACE. This can be done by minimum of 1013/16“. If the furnace is
removing the drain hose installed in an attic, crawlspace or other
from the trap and pouring about a area where freezing temperatures may
cup of water into the vent trap. Water occur, the furnace drain can freeze
will flow into the house drain when the while shut off for long periods of time.
trap is full.
If local codes require, install a FIGURE 30
condensate neutralizer cartridge in the UPFLOW CONDENSATE DRAIN
drain line. Install cartridge in horizontal
position only. Also install an overflow
line if routing to a floor drain. See 29.
If no floor drain is available, install a
condensate pump that is resistant to
acidic water. Pumps are available from
your local distributor. If pump used is
not resistant to acidic water, a
condensate neutralizer must be used
ahead of the pump. The condensate
pump must have an auxiliary safety NOTE: INDUCER
switch to prevent operation of the DRAIN HOSE
furnace and resulting overflow of NOTE: MUST SLANT
condensate in the event of pump SEE UPFLOW MODEL
1013/ 16
DOWNWARD
failure. The safety switch must be wired NOTES FOR PIPE
HEIGHT AWAY FROM
through the “R” circuit only (low voltage) INDUCER.
to provide operation in either heating or
cooling modes.
UPFLOW MODELS
The condensate drain trap is located in
the blower compartment on the left-
hand side of the jacket. A short piece of
1/2-in. PVC pipe and a 1/2-in. tee are DRAIN LINE CONDENSATE TRAP
provided. Connect the 1/2-in. pipe to the NEUTRALIZER CARTRIDGE (OPTIONAL)
elbow on the trap and the tee to this
pipe so that the open end is upward. OVERFLOW LINE
(REQUIRED ONLY WHEN
Run a drain tube from the bottom of the OPTIONAL NEUTRALIZER
tee to a floor drain or condensate CARTRIDGE IS USED.)
pump.
TO FLOOR DRAIN OR CONDENSATE PUMP
IMPORTANT: The upflow model only
has a new drain system. There is a third
port on the drain trap (marked by a red
cap) for the hose attached to the
induced draft motor. Remove plug in
inducer drain hose and remove cap off
drain trap before connecting inducer
drain hose to drain trap. All three hoses NOTE: CONNECT
MUST be attached during operation of INDUCER DRAIN HOSE
the furnace. Be sure all three hoses are TO SMALLER PORT ON
secured to the drain trap using the hose CONDENSATE TRAP.
clamps provided in the parts bag.
CONDENSATE TRAP I408
34
REVERSING THE TRAP FIGURE 31
UPFLOW UNITS UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION
The trap may be moved to the right PROPER DRAIN SLOPE REQUIRED
side for right side drainage. Open the (NO KINKS ALLOWED)
knockout for the drain on the right CUT DRAIN HOSES AS
REQUIRED
side of the cabinet. Remove the AND CONNECT TO
bracket holding the trap from the left INLETS ON TOP
side. Seal the left side drain hole with OF CONDENSATE
TRAP
a plug provided in the cloth bag with
the furnace. Position the mounting
bracket and trap so that the drain
elbow is centered in the hole on
the right. See Figure 31.
Drill two 1/8” holes in the cabinet to
mount the bracket. Mount the trap DRAIN
and bracket to the right side with the RISER
drain elbow pointing through the
knockout. Connect the 1/2-in. pipe and TEE
tee as noted above. Route the drain
hoses behind the control box, cut to
the appropriate length, and connect to DRAIN
the trap with hose clamps. Fill trap EXTENSION
with water.
TO FLOOR
IMPORTANT: Do not allow any sags SHEETMETAL IFC CONDENSATE TRAP DRAIN
or kinks in the hoses. This prevents MOUNTING PLATE A039407
proper condensate flow.
IMPORTANT: Do not connect into
a common drain line with an air FIGURE 32
DOWNFLOW CONDENSATE DRAIN
conditioner evaporator coil drain. A NOTE:
DRAIN VENT NEEDS
blocked or restricted drain line can TO BE ABOVE
result in overflow of the coil pan and COLLECTOR BOX
negate the furnace blocked drain DRAIN SPOUT.
shutoff control.
MINIMUM HEIGHT
OPEN TOP
DOWNFLOW MODELS
IMPORTANT: There are two options OVERFLOW LINE
(REQUIRED ONLY WHEN
when choosing a height for the OPTIONAL NEUTRALIZER
condensate riser: CARTRIDGE IS USED.)
CONDENSATE OVERFLOW: With a

13⁄4 inch riser installed above the tee,
a blocked drain will result in overflow
from the riser.
FURNACE SHUTDOWN: To cause
the furnace to shut down when a
blocked drain is present, install a riser
which is a minimum of 51⁄2”. If the CONDENSATE TRAP
furnace is installed in an attic,
crawlspace or other area where DRAIN LINE
freezing temperatures may occur, the
furnace drain can freeze while shut NEUTRALIZER CARTRIDGE
(OPTIONAL)
off for long periods of time. Provisions
TO FLOOR DRAIN OR CONDENSATE PUMP
must be made to prevent freezing of
condensate. a103101
Use a solvent cement that is the long black molded hose. Use the 2- A length of 1/2” black PVC pipe is
compatible with PVC material. 9/16” length of black hose included in also provided in the (-)XGY-H01
To convert downflow models to left- the downflow alternate drain kit. Glue
hand drain, a kit ((-)XGY-H01) must (-)XGY-H01 kit between the trap and one end of the pipe to the elbow in
be ordered from the distributor. The exhaust transition. Clamp hoses tight the trap. Cut the pipe so that it
kit includes a 24” piece of 1⁄2” black with white nylon clamps. extends through the alternate drain
PVC pipe, a 2-9/16” length of black Remove the plug from the 2” alternate hole in the left side of the cabinet one
hose, a 2” rubber grommet, a 1-5/8” drain hole (see Figure 33) and replace inch. Connect the 1/2” PVC tee
plug and instructions. Note the it with the 2” rubber grommet supplied (supplied with the furnace) to the
location of the alternate drain hole as in the (-)XGY- H01 downflow alternate pipe with a 1-3/4” riser. Use the 1-
shown in Figure 33. drain kit. Also, remove the 1-5/8” 5/8” plug supplied in the (-)XGY-H01
To convert to left side drainage, grommet supplied in the primary drain downflow alternate drain kit to seal
remove the long molded hose from hole and replace it with the 1-5/8” the right side drainage hole.
the trap. Remove the double-elbow diameter plug that is also supplied in IMPORTANT: Do not connect into a
black molded hose from the trap and the (-)XGY-H01 downflow alternate common drain line with an air
exhaust transition and discard. drain kit. Both the hole-plug and conditioner evaporator coil drain
Remove the trap from its mounting grommet must be in place to insure a located above the furnace. A blocked
bracket, rotate it 180 degrees and good seal in the burner compartment. or restricted drain line can result in
mount in place with the drainage overflow of the coil pan and negate the
elbow pointing to the left. Reattach furnace blocked-drain shutoff control.
35
CONDENSATE DRAIN FIGURE 33
FOR HORIZONTAL DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION
INSTALLATION
Refer to Figure 34 for Steps 1-4.
This unit is shipped factory ready for
downflow installation. The DRAIN
UNION
VENT
condensate trap assembly and drain
hoses require conversion for DRAIN
EXISTING
horizontal installation. Remove the EXTENSION
DRAIN HOLE.
existing condensate trap with the unit PLUG WITH
in the upright position. TEE 1 5/8” PLUG
SUPPLIED IN
1. Remove the burner compartment DRIP LEG KIT.
door from the unit.
2. Remove the two screws from the ALTERNATE
right side of the furnace jacket DRAIN HOLE ROTATE TRAP
180° AND
which support the trap mounting LOCATED
INSTALL RIGID
HERE ON
bracket. B Remove the two JACKET. PIPE FROM
plastic plugs on either side of the (REMOVE ELBOW TO
BURNERS
trap outlet hole and discard. PLASTIC PLUG OPPOSITE
AND REPLACE TO FLOOR SIDE OF
3. Remove the black molded 90° MANIFOLD
WITH DRAIN OR JACKET AS
hose ➂ C from the top of the GROMMET). CONDENSATE SHOWN.
existing trap ➀A and furnace PUMP CONDENSATE TRAP
collector box. Cut 1.0 inch from
the long end of the hose. NOTE:
Exception – do not shorten the
90° hose on the 07B furnace!
The 07B has a longer distance the 45° elbow molded into the top
of the trap assembly. Clamp the
FILLING THE TRAP
between the collector box and
horizontal drain trap. hose tight with white nylon clamp. FILL THE TRAP ASSEMBLY 9 WITH
4. Remove the double-elbow black IMPORTANT: Tighten all clamp WATER BEFORE OPERATING THE
molded hose ➀ D from the exhaust connections with a pair of pliers FURNACE. Do this by removing the
transition ➀.
E Discard this hose and check for leaks after drain hose from the trap or from the
and the downflow trap. conversion is complete. connection to the secondary coil.
NOTE: The following steps should 11. IMPORTANT: There are two Pour about a cup of water into the
take place with the furnace in the options when choosing a height for vent trap. Any excess water flows into
horizontal position. the condensate riser: the house drain when the trap is full.
Refer to Figure 35 for Steps 6-11. CONDENSATE OVERFLOW: With
a 13⁄4 inch riser installed above the NOTE: Fill the trap assembly with
5. Locate the parts bag in the water every heating season.
burner compartment. Install two tee, a blocked drain will result in
plastic plugs ➅F in the side of the
overflow from the riser.
jacket from bottom side up. FURNACE SHUTDOWN: To
6. Fill the trap assembly ➆ G with a
cause the furnace to shut down
cup of water. when a blocked drain is present,
install a riser which is a minimum
7. Attach the gasket ➇ H onto the trap
of 51⁄2”. If the furnace is installed in
assembly so that the gasket an attic, crawlspace or other area
holes on the gasket line up with where freezing temperatures may
the holes on the trap assembly. occur, the furnace drain can freeze
8. Insert the trap assembly with while shut off for long periods of
gasket up through the existing time. Provisions must be made to
hole in the jacket and secure prevent freezing of condensate
from inside the jacket. Use two (see Figure 4).
screws provided. Screw down Use a solvent cement that is
into the two “ears” molded into compatible with PVC material.
either side of the trap. Snug the
trap assembly against the NOTE: See location requirements and
furnace jacket compressing the combustion section for additional
gasket slightly to eliminate any recommendations.
air leaks. Do not overtighten!
9. Attach the black molded rubber
90° elbow ➈I to the straight spout
on the trap top using a white
nylon clamp ➉. J Attach the other
end of the rubber elbow to the
spout ➋ K located on the exhaust
transition ➄E using a white nylon
clamp.
10. Attach the 90° end of the molded
hose L to the collector box.
Clamp the hose tight with white
nylon clamp. Then attach the
long end of the molded hose to
36
CONDENSATE TRAP CONVERSION FROM DOWNFLOW TO
HORIZONTAL INSTALLATION
FIGURE 34 FIGURE 35
UPRIGHT POSITION: REMOVAL OF EXISTING DOWNFLOW CONDENSATE TRAP HORIZONTAL POSITION: CONDENSATE TRAP INSTALLATION
FOR HORIZONTAL OPERATION
I534
37
GAS SUPPLY AND PIPING
GAS SUPPLY FIGURE 36
GAS PIPING INSTALLATION
! WARNING UPFLOW
THIS FURNACE IS EQUIPPED AT

THE FACTORY FOR USE ON MANUAL GROMMET
GAS
NATURAL GAS ONLY. STOP TOP VIEW OF GAS LINE AND VALVE NOTE: WHEN GAS LINE
CONVERSION TO LP GAS IN OPT. POSITION IS IN OPT. POSITION,
SWAP LOCATION OF
REQUIRES A SPECIAL KIT IS BURNERS GROMMET AND PLUG.
AVAILABLE AT THE
DISTRIBUTOR. FAILURE TO USE
OPT. GAS LINE
THE PROPER CONVERSION KIT 4 TO 5 FEET POSITION
CAN CAUSE FIRE, CARBON ABOVE PLUG
FLOOR REQ’D
MONOXIDE POISONING, BY SOME
(IN NORMAL
POSITION)
EXPLOSION, PROPERTY UTILITIES.
DAMAGE, PERSONAL INJURY OR MANIFOLD
DEATH. See the conversion kit PRESSURE
GROMMET TAP
index supplied with the furnace. (IN NORMAL
This index identifies the proper LP POSITION) IGNITOR
Gas Conversion Kit required for MANIFOLD
each particular furnace. DRIP LEG
GAS VALVE
IMPORTANT: Any additions, UNION
changes or conversions required for DOWNFLOW
the furnace to satisfactorily meet the
application should be made by a
qualified installer, service agency or MANUAL GROMMET
GAS
the gas supplier, using factory- STOP TOP VIEW OF GAS LINE AND VALVE NOTE: WHEN GAS
LINE IS IN OPT.
specified or approved parts. IN OPT. POSITION
POSITION, SWAP
LOCATION OF
IMPORTANT: Connect this furnace GROMMET AND
only to gas supplied by a commercial PLUG.
utility. 4 TO 5 FEET ABOVE
IMPORTANT: U.L. or CSA FLOOR REQ’D BY GAS VALVE
SOME UTILITIES.
recognized fuel gas and CO PLUG
detector(s) are recommended in all GROMMET (IN NORMAL
(IN NORMAL POSITION)
applications, and their installation POSITION)
should be in accordance with the
manufacturer’s recommendations
and/or local laws, rules, regulations or MANIFOLD
PRESSURE
customs. TAP
DRIP LEG I328
MANIFOLD
GAS PIPING UNION BURNERS IGNITOR
Install the gas piping according to all HORIZONTAL

local codes and regulations of the MANUAL GAS STOP
utility company.
If possible, run a separate gas supply
line directly from the meter to the UNION
furnace. Consult the local gas
company for the location of the
manual main shut-off valve. The gas
line and manual gas stop must be DRIP LEG
adequate in size to prevent undue
pressure drop and never smaller
than the pipe size to the gas valve
on the furnace. Refer to Table 6 for
the recommended gas pipe size. See BURNERS
Figure 36 for typical gas pipe
connections. MANIFOLD
Install a ground joint union within 3

ft. of the cabinet to easily remove
the gas valve assembly. Install a GAS VALVE
I524
manual gas stop valve in the gas
line outside the furnace casing. IMPORTANT: DO NOT RUN A FLEXIBLE GAS CONNECTOR INSIDE THE
The manual gas stop should be UNIT. Extend the 1/2" black pipe from the gas valve to the outside of the
readily accessible to turn the gas cabinet.
38
supply on or off. Install a drip leg in
the gas supply line as close to the TABLE 6
NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)
furnace as possible. Always use a
pipe compound resistant to the action Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific
of liquefied petroleum gases on all gravity of 0.60 (natural gas).
threaded connections. Nominal Length of Pipe, Feet
Iron Pipe
IMPORTANT: When making gas pipe Size, Inches 10 20 30 40 50 60 70 80
connections, use a back-up wrench to 1/2 132 92 73 63 56 50 46 43
prevent any twisting of the main gas 3/4 278 190 152 130 115 105 96 90
valve and manifold. Do not 1 520 350 285 245 215 195 180 170
1-1/4 1,050 730 590 500 440 400 370 350
overtighten gas valve on pipe. 1-1/2 1,600 1,100 890 760 670 610 560 530
Any strains on the gas valve can After the length of pipe has been determined, select the pipe size which will provide the minimum cubic feet per hour
change the position of the gas orifices required for the gas input rating of the furnace. By formula:
in the burners. This can cause erratic Gas Input of Furnace (BTU/HR)
Cu. Ft. Per Hr. Required =
Heating Value of Gas (BTU/FT3)
furnace operation. The gas input of the furnace is marked on the furnace rating plate. The heating value of the gas (BTU/FT3) may be
IMPORTANT: Do not run a flexible determined by consulting the local natural gas utility or the LP gas supplier.
gas connector inside the furnace. The
gas pipe gasket in the cabinet does
not seal around a flexible gas line.
FIGURE 37 HIGH FIRE
If local codes allow the use of a TYPICAL GAS VALVE (WHITE RODGERS) MANIFOLD
flexible gas appliance connector, PRESSURE
ADJUSTMENT
always use a new listed connector.
Do not use a connector which has
previously serviced another gas
appliance. Massachusetts law
requires that all flexible connectors be
less than 36”. LOW FIRE
PRESSURE
It is important to have all openings MANIFOLD
in the cabinet burner compartment ADJUSTMENT
sealed for proper furnace
operation.
IMPORTANT: ENSURE that the
furnace gas valve not be subjected to
high gas line supply pressures.
DISCONNECT the furnace and its
individual manual gas stop from the
OUTLET
gas supply piping during any PRESSURE
pressure testing that exceeds 1/2 TAP
PSIG. (3.48 kPa). INLET
PRESSURE TAP
GAS PRESSURE
Natural gas supply pressure
should be 5" to 10.5" w.c. LP gas
supply pressure should be 11" to ! WARNING GAS VALVE
13" w.c. This pressure must be This furnace has a 24-volt gas valve.
NEVER PURGE A GAS LINE INTO It has ports for measuring supply and
maintained with all other gas-fired
appliances in operation. THE COMBUSTION CHAMBER. manifold gas pressure. The valve
NEVER USE MATCHES, FLAME OR body contains a pressure regulator to
The minimum gas supply pressure to ANY IGNITION SOURCE FOR
the gas valve for proper furnace input maintain proper manifold gas
CHECKING LEAKAGE. FAILURE TO pressure.
adjustments is 5" w.c. for natural gas, ADHERE TO THIS WARNING CAN
however 6" to 7" is recommended. CAUSE A FIRE OR EXPLOSION A control switch is on the valve body.
The minimum gas supply pressure is RESULTING IN PROPERTY It can be set to only the “ON” or
11" w.c. for LP gas. “OFF” positions. The gas valve is a
DAMAGE, PERSONAL INJURY OR
DEATH. slow-opening valve. See Figure 37.
! CAUTION
To check for gas leakage, use an When energized, it takes 6 to 8
ELEVATIONS ABOVE 2000 FT
approved chloride-free soap and water seconds to fully open.
REQUIRE THAT THE FURNACE
INPUT RATING BE ADJUSTED AND solution, or other approved method.
THAT THE SIZE OF THE BURNER
ORIFICES BE RE-CALCULATED
BASED ON ELEVATION AND GAS
HEATING VALUE. THE BURNER
ORIFICES MAY (OR MAY NOT)
NEED TO BE CHANGED. SEE THE
SECTION TITLED “HIGH ALTITUDE
INSTALLATIONS” OF THIS BOOK
FOR INSTRUCTIONS.
39
LP CONVERSION FIGURE 38
The valve can be converted to use TYPICAL LP KIT CONTENTS
liquified petroleum (LP) gas by replacing
the pressure regulator spring with the
conversion kit spring. This LP kit spring
allows the regulator to maintain the
proper manifold pressure for LP gas.
See Figure 38 for an example of a
conversion kit for a Honeywell gas
valve. A similar kit is available for a
White Rodgers gas valve.
NOTE: Order the correct LP conversion
kit from the furnace manufacturer. Refer
to the latest “L.P. Conversion Kit Index”
shipped with the furnace or see
Rheemote.net and PTS for latest
version. Furnace conversion to LP gas
must be performed by a qualified
installer, service agency or the gas
supplier.
ORIFICE INSTALLATION
LP Gas is a manufactured gas that has
consistent heating value across most
regions.
The Sea Level input should still be
reduced by 3.5-4% per thousand ft. and
the orifice size must be selected based
on the reduced input selection chart
below.
TO CHANGE BURNER
10. Follow lighting instructions to put manometer or gauge to the
ORIFICE furnace into operation. manifold pressure tap on the
Refer to Table 10, page 45 for elevation outlet end of the valve. Check and
and corresponding LP gas orifice size. 11. Operate thermostat to check unit adjust pressures as follows:
operation.
1. a. For full input pressure remove
! WARNING
! WARNING adjustment screw cover and
TURN OFF ELECTRICAL turn adjustment screw to
POWER AND MAIN GAS DO NOT USE AN OPEN FLAME. increase or reduce pressure, as
SUPPLY BEFORE BEGINNING NOTE: If you have a single necessary. Replace the
MODIFICATION. FAILURE TO thermostat, the furnace will start adjustment cover screw
DO SO CAN RESULT IN securely.
on high fire then switches to low
ELECTRICAL SHOCK OR fire and will continue on low fire for b. For low fire pressure, remove
EXPLOSION CAUSING 12 minutes and then if thermostat the regulator cover on top of
PROPERTY DAMAGE, valve and adjust as noted
is not satisfied, shifts to high fire.
PERSONAL INJURY OR DEATH. above and make adjustments
With a 2-stage thermostat, when as necessary. Replace cover
2. Disconnect union ahead of there is a call for low heat (1st
combination gas valve. when done.
stage), the furnace will start on
3. Disconnect leads from gas valve. high fire then switch to low fire NOTE: Use 3/32” allen wrench
for making pressure
4. Remove the 4 screws holding the until the call for heat is satisfied or adjustments.
manifold assembly to the main 2nd stage contacts close.
burner assembly.
COMPLETING
5. Replace the L.P. stem/spring TO CONVERT GAS VALVE CONVERSION
assembly from kit per instructions TO LP GAS AND 1. Using a ball point indelible pen,
supplied with the kit. CHECK/ADJUST GAS record the following information on
6. Remove each existing orifice from PRESSURE the conversion label.
the manifold assembly using a
ratchet with a 7/16 socket. Replace 1. Consult the conversion kit index for a. Conversion kit number.
with orifices from the kit. Screw the your furnace based on the furnace
serial number. The kit will provide b. Date of conversion.
orifices in hand tight and secure in
place with a quarter turn with the LP springs and more detailed c. Installer’s name, address and
ratchet. instructions for changing the telephone number.
springs.
7. Reinstall the manifold assembly on d. Burner orifice size.
the burner assembly with the 4 2. The LP gas supply pressure must
screws removed in step 4. be set between 11 and 13” W.C. by 2. Place completed conversion label
means of the tank or branch supply adjacent to the rating plate.
8. Reconnect the leads to the gas regulators.
valve, union, and electrical power 3. Install the burner compartment
to furnace. 3. The furnace manifold pressure access door.
should be 10” W.C. for high fire and
9. Turn on the gas supply and check 4.8” W.C. for low fire. These 4. Run furnace through complete
unit thoroughly for gas leaks using pressures can be checked by cycle to check operation and
soap solution. connecting a properly calibrated temperature rise.
40
ELECTRICAL WIRING
accessible and located within site and blinks will be displayed on the control
! WARNING arm’s reach of the furnace. Connect board “Status” L.E.D. See Figure 39.
TURN OFF ELECTRIC POWER AT from the electrical disconnect to the Make all electrical connections in
FUSE BOX OR SERVICE PANEL junction box on the left side of the accordance with the latest edition of
BEFORE MAKING ANY ELECTRICAL furnace, inside the blower compartment. the National Electrical Code
CONNECTIONS. FAILURE TO DO SO For the proper connection, refer to the ANSI/NFPA70 and local codes having
CAN CAUSE ELECTRICAL SHOCK appropriate wiring diagram located on jurisdiction.
RESULTING IN PERSONAL INJURY the inside cover of the furnace control
OR DEATH. box and in these instructions. These may be obtained from:
NOTE: Electric to furnace must be NOTE: UPFLOW MODELS ONLY National Electric Code
The electrical junction box may be National Fire Protection
supplied by commercial utility. Proper
moved to the right side if necessary. A Association, Inc.
voltage is 110-125 volts.
knockout is provided. Seal the opposite Batterymarch Park
hole with plug provided. Quincy, MA 02269
! WARNING
NOTE: L1 (hot) and N (neutral) polarity CSA Standards
THE CABINET MUST HAVE AN must be observed when making field
UNINTERRUPTED GROUND CSA - International
connections to the furnace. The ignition 178 Rexdale Blvd.
ACCORDING TO THE LATEST control may not sense flame if L1 and
EDITION OF THE NATIONAL Etobicoke (Toronto), Ontario
Neutral are reversed. When L1 and
ELECTRICAL CODE, ANSI/ NFPA70- Canada M9W, 1R3
Neutral are reversed, a diagnostic code
OR IN CANADA, THE CANADIAN of 6 blinks followed by a pause and 6
ELECTRICAL CODE, CSA-C221 OR
LOCAL CODES THAT APPLY. DO
NOT USE GAS PIPING AS AN
ELECTRICAL GROUND. A GROUND
SCREW IS PROVIDED IN THE
JUNCTION BOX. FAILURE TO DO SO
CAN CAUSE ELECTRICAL SHOCK
FIGURE 39
RESULTING IN PERSONAL INJURY LINE VOLTAGE CONNECTIONS
OR DEATH.
UT ELECTRONIC CONTROLS 1095-206 CONTROL BOARD
! WARNING
THIS FURNACE IS EQUIPPED WITH A
BLOWER DOOR SAFETY SWITCH.
DO NOT DISABLE THIS SWITCH.
FAILURE TO FOLLOW THIS
WARNING CAN RESULT IN
ELECTRICAL SHOCK, PERSONAL
INJURY OR DEATH.
IMPORTANT: The furnace must be
installed so that the electrical
components are protected from water
(condensate).
Before proceeding with the electrical
connections, be certain that the voltage,
frequency and phase corresponds to
that specified on the furnace rating
plate. For single furnace application,
maximum over-current protection is 15
amperes.
Use a separate fused branch electrical
circuit containing a properly sized fuse
or circuit breaker. Route this circuit
directly from the main switch box to an
electrical disconnect that is readily
41
FIGURE 40
THERMOSTAT WIRING OPTIONS
2 HEAT - 1 COOL
1 HEAT, 1 COOL
(OPTION A) TIMED STAGING W/1
STAGE HEAT T-STAT (AFTER F3507
DATE CODE (AUGUST 2007))
2 HEAT - 2 COOL
RGPR’S AND RGLR’S 1 HEAT, 1 COOL
ONLY (OPTION B) 100% HEAT ALWAYS -- NO
TIMED STAGING
THERMOSTAT FIELD-INSTALLED OPTIONAL ACCESSORIES

NOTE: Do not use 24 volt control wiring
smaller than No. 18 AWG. (Refer to setting of .15 amps is recommended. When the thermostat calls for heat, it
Table 7.) Adjust as needed to improve comfort powers the 24 volt operating coil. This
level. closes the relay contacts and
See Figure 40 for thermostat wiring conducts power from terminal 3 and 4
options. ISOLATION RELAY to terminal “W” on the control board
A single- or two-stage thermostat may be IMPORTANT: NOT ALL ELECTRONIC and starts the furnace ignition
used, however, 1a two-stage thermostat is NIGHT SETBACK THERMOSTATS sequence. See Figure 41.
recommended for optimum performance. ARE COMPATIBLE WITH THE ➢ NOTE: Use of an isolation relay
The room thermostat must be compatible FURNACE CONTROL SYSTEM. with the two stage furnace is not
with the integrated furnace control on the SOME MAY REQUIRE AN ISOLATION normally needed.
furnace. Generally, all thermostats that RELAY.
are not of the “current robbing” type are If an isolation relay is needed, install it ELECTRONIC AIR CLEANER
compatible with the integrated furnace as close to the control board 1as Electronic air cleaner line voltage
control being used. possible. Use a single-pole, single- power can be supplied from the screw
Install the room thermostat in accordance throw relay with a 24 volt operating coil. terminal “EAC” and a line voltage
with the instruction sheet in the box with The relay contacts should be designed neutral screw terminal on the control
the thermostat. Run the thermostat lead for 24 volt loads. board. This will power the electronic
wires inside the control compartment. Connect one end of the operating coil air cleaner whenever the circulating
Connect the thermostat as shown on the to the thermostat “W” terminal. air blower is in operation.
wiring diagram. Never install the Connect the other end of the coil to the
thermostat on an outside wall or where it “C” terminal on the control board. HUMIDIFIER
will be influenced by drafts, concealed Line voltage power can be supplied
hot or cold water pipes, lighting fixtures, ➢ Connect a jumper from the coil
terminal connected to the thermostat to from screw terminal “HUM” to a line
radiation from fireplace, rays of sun, voltage neutral screw terminal on the
lamps, television, radios or air streams one of the normally open relay
contacts. control board. This will power the
from registers. Refer to the instructions humidifier during a normal heat
packed with the thermostat for best ➢ Connect the other side of the normally sequence after the blower has turned
anticipator adjustment or selection. open relay contacts to the control board on.
Locate the thermostat approximately five “W” terminal if using a two stage
feet up from the floor. thermostat. Connect that one side of the NOTE: Maximum current of 1.0 Amp
normally open relay contacts to the for each option.
HEAT ANTICIPATOR SETTINGS
control board “W” terminal if using a
If a current reading taken at the single stage thermostat. See Figure 40
thermostat is not performed, an initial for wiring details.
42
altitude pressure switch that replaces
TABLE 7 the pressure switch attached to the
FIELD WIRE SIZE FOR 24 VOLT CONTROL CIRCUITS
induced draft blower.
SOLID COPPER WIRE - AWG
3.0 16 14 12
HIGH ALTITUDE KIT
Installer must make necessary burner
THERMOSTAT
LOAD - AMPS
2.5 16 14 12 orifice and pressure switch changes
2.0 18 16 14 as indicated in the table below:
50 100 150 (-)GRM PRESSURE SWITCH CHANGES
LENGTH OF RUN - FEET ➀ HIGH ALTITUDE SET POINT SET POINT
INPUT KIT NO. HIGH FIRE LOW FIRE
➀ Wire length equals twice the run distance
NOTE: Do not use 24 volt control wiring smaller than No. 18. 45,000 RXGY-F18 -1.08 NO CHANGE
60,000 RXGY-F18 -1.08 NO CHANGE
75,000 (N) N/A NO CHANGE NO CHANGE
75,000 (W) N/A NO CHANGE NO CHANGE
FIGURE 41 90,000 RXGY-F20 -1.15 NO CHANGE
BASIC ISOLATION RELAY – SEE FIGURE 40 FOR DETAILS 105,000 RXGY-42 -1.08 -0.50
120,000 RXGY-F21 -0.50 -0.30
(-)GTM PRESSURE SWITCH CHANGES

HIGH ALTITUDE
INPUT KIT HIGH FIRE LOW FIRE
60,000 RXGY-F29 -1.0 -0.8
75,000 (N) RXGY-F30 -0.8 -0.6
75,000 (W) RXGY-F30 -0.8 -.06
90,000 RXGY-F31 -0.9 -.06
105,000 RXGY-F32 -0.7 -.04
120,000 RXGY-F33 -0.4 -0.3
NOTE: Orifices are no longer

supplied with kit.
The pressure switch must be installed
at elevations above 5000 ft.
Elevations above 2000 ft. require the
furnace to be de-rated 4% per
thousand feet.
Alternately, furnaces can be ordered
from the factory already converted for
high altitude elevations. The factory
option for high altitude elevations
would be ordered as a 278 option
ST-A0804-01
(example; a 105k BTU upflow furnace
which is factory converted for high
90+ HIGH ALTITUDE EXAMPLES SHOW HOW TO altitude elevations would have the
DETERMINE IF AN ORIFICE CHANGE model number (-)GRM-1DEZAJS278).
INSTRUCTIONS WILL BE NECESSARY AND HOW TO These factory converted furnaces
NATURAL GAS DETERMINE THE NEW ORIFICE SIZE. come with a pressure switch for high-
! CAUTION IN CANADA, AS AN ALTERNATE TO altitude elevations already attached.
SIZING THE BURNER ORIFICE, THE Also, different burner orifices are
INSTALLATION OF THIS FURNACE MANIFOLD GAS PRESSURE MAY BE installed at the factory which are one
AT ALTITUDES ABOVE 2000 FT (610 ADJUSTED. THIS METHOD IS drill size smaller (#51 DMS) than
m) SHALL BE IN ACCORDANCE COVERED LATER IN THIS SECTION. standard (-)GRM gas furnaces (#50
WITH LOCAL CODES, OR IN THE THIS METHOD OF ADJUSTING DMS). The smaller orifice is installed
ABSENCE OF LOCAL CODES, THE MANIFOLD PRESSURE MAY ONLY to accommodate for average heating
NATIONAL FUEL GAS CODE, ANSI BE USED IN CANADIAN values expected in most high altitude
Z223.1/NFPA 54 OR NATIONAL INSTALLATIONS.
STANDARD OF CANADA, NATURAL areas and a required 4% per
GAS AND PROPANE INSTALLATION 34" 90 Plus furnaces installed at high thousand feet reduction in input as
CODE, CAN B149.1. elevations require the installation of a specified by the National Fuel Gas
high altitude kit for proper operation. The Code (NFGC). Specific orifices
INSTALLATION OF THIS APPLIANCE high altitude kit consists of a high should always be recalculated for all
AT OR ABOVE 5000 FT (1525 m)
SHALL BE MADE IN ACCORDANCE
WITH THE LISTED HIGH ALTITUDE TABLE 8
CONVERSION KIT AVAILABLE WITH Natural Gas Orifice Drill Size (4% per 1000 ft. De-Rate)
THIS FURNACE. IMPORTANT: 90 Plus Models only. Do not use this chart for any 80 Plus Models.
! CAUTION
Burner Input (per burner) 15,000 BTU @ Sea Level
ELEVATIONS ABOVE 2000 FT Annual Avg. Heat Sea level 2000 to 3000 to 4000 to 5000 to 6000 to 7000 to 8000 to
REQUIRE THAT THE FURNACE Value (btu per ft3) to 1999 ft 2999 ft 3999 ft 4999 ft 5999 ft 5999 ft 7999 ft 8999 ft
INPUT RATING BE ADJUSTED AND 850 47 48 48 49 49 49 50 50
THAT THE SIZE OF THE BURNER 900 48 49 49 49 50 50 50 51
ORIFICES BE RE-CALCULATED
BASED ON ELEVATION AND GAS 1000 49 50 50 50 51 51 51 52
HEATING VALUE. THE BURNER 1075 50 51 51 51 51 52 52 52
ORIFICES MAY (OR MAY NOT) NEED 1170 51 51 52 52 52 53 53 53
TO BE CHANGED. THE FOLLOWING
43
44
TABLE 9
SUPPLEMENTAL ORIFICE SIZE CHART
90 Plus ONLY models with 15,000 Btu's per Burner. DO NOT USE THIS CHART FOR ANY 80 PLUS MODEL.
NATURAL GAS QUICK REFERENCE CHART FOR ORIFICE SELECTION, AT 3.5" W.C. AND APPROXIMATE FINAL FIRING RATES
Sea Sea Level 90 Plus Heat ELEVATION CHART (NFG recommended orifice based on 4% derate for each 1000 foot of elevation, based
Level Cubic Value at on the intersection of the orifice required at Sea Level and the elevation required below)
Orifice Foot at 15,000 Btu’s
Size 3.5" W.C. per Burner 0-999 1000-1999 2000-2999 3000-3999 4000-4999 5000-5999 6000-6999 7000-7999 8000-8999 9000-9999
46 18.57 808 46 46 47 47 47 48 48 49 49 50
47 17.52 856 47 47 48 48 49 49 49 50 50 51
48 16.36 917 48 48 49 49 49 50 50 50 51 51
49 15.2 987 49 49 50 50 50 51 51 51 52 52
50 13.92 1078 50 50 51 51 51 51 52 52 52 53
51 12.77 1175 51 51 51 52 52 52 52 53 53 53
Final Firing Rate per Burner 15,000 14,400 13,800 13,200 12,600 12,000 11,400 10,800 10,200 9,600
All calculations are performed by using the first three columns of information only. Before beginning any calculations, determine the
individual burner Btu size and heating value at Sea Level for the installation site. Each value shown in the Heat Value column is per
burner at 3.5" W.C.
NOTE:
Heat Value at Sea Level, for the location of the installation, is available from the Natural Gas Supplier to that site. Orifices for all altitudes are based
on Sea Level values.
Divide the individual burner capacity (15,000 for 90 plus) by the Heat Value for the site to determine the Cubic Foot value at Sea Level, or divide
burner capacity by the Cubic Foot value for the Heat Value. Once you have either the Cubic Foot Value or the Heat Value you can estimate the Sea
Level orifice for the site. To select the corresponding high altitude orifice, locate the site elevation on the chart above and the orifice required at Sea
Level from your calculation in the first column. The correct high altitude orifice that must be installed in each individual burner is the intersection of
these two points on the chart above.
Orifice sizes are selected by adding
TABLE 10 the 2-digit drill size required in the
IMPORTANT: 90+ MODELS ONLY. DO NOT USE THIS CHART
orifice part number. Drill sizes
FOR ANY 80 PLUS MODELS.
available are 39 through 64; metric
LP GAS ORIFICE DRILL SIZE (4% PER 1000 FT DE-RATE)
sizes available 1.10mm (-90) and
Altitude Input (per burner) 15000 Orifice Size 1.15mm (-91):
0 to 2000 ft 15000 1.15 mm (factory) Orifice Part Number 62-22175-(drill
2001 to 3000 13200 1.15 mm size)
3001 to 4000 12600 1.10 mm Example 1:
#60 drill size orifice required
4001 to 5000 12000 #58 Part # 62-22175-60
5001 to 6000 11400 #59
Example 2:
6001 to 7000 10800 #60 1.15mm drill size orifice required
7001 to 8000 10200 #62 Part # 62-22175-91
ALTERNATE METHOD FOR

high altitude installations as outlined LP GAS AT HIGH ALTITUDE
below. Orifices should be changed, if ELEVATIONS CANADIAN HIGH-
necessary, based on gas heating value LP Gas is a manufactured gas that has ALTITUDE DERATE
and elevation. consistent heating value across most In Canada, unless an orifice change
NOTE: Factory installed orifices are regions. is specifically mandated by local
calculated and sized based on a sea The NFGC guidelines are used with the codes, an alternate method of altitude
level Natural Gas heating value of 1075 following exception: deration through a reduction in
BTU per cubic ft. Regional reduced manifold pressure is acceptable as
heating values may nullify the need to The recommended LP Gas high altitude described in Table 11.
change orifices except at extreme orifice selections differ slightly in that the
NFGC LP orifice chart, as they are not The information in Table 11 is based
altitudes. accurate for Rheem products. The on a heating value of 1000 BTU per
The following are examples of orifice National Fuel Gas Code LP orifices are cubic feet of natural gas, and 2500
sizing using the National Fuel Gas Code based on an 11" of water column BTU per cubic feet of LP gas.
Appendix F. For a simplified estimation pressure at the orifice, which differs from IMPORTANT: Actual input rates must
of orifice size based on heating value Rheem products that use 10" of water be measured on-site with manifold
and elevation, use Tables 8 and 9, column at the orifice. This difference pressure adjustment to ensure that an
however calculations are the best requires a deviation from the NFGC actual 10% reduction in input rate is
method. orifice size recommendations. The Sea achieved.
Level input should still be reduced by
Example: 900 BTU/ft3 Regional 4% per thousand ft. and the orifice size Once this field adjustment has been
Natural Gas Heating Value must be selected based on the reduced made, the label shown in Figure 44
input selection shown in Table 10. must be affixed in a conspicuous
I/H=Q location on the front of the furnace
15000 / 900 = 16.68 ft3/hr cabinet:
ORIFICE ORDERING
I = Sea Level input (per burner): 15000 INFORMATION NOTE: This label is supplied in the
H = Sea Level Heating Value: 900 information packet shipped with each
Q = 16.68 ft3 Natural Gas per hour. IMPORTANT: Do not plug or drill out
orifices. furnace.
From Table F.1 of National Fuel Gas
Code Handbook, 2002 (3.5” w.c.
TABLE 11
column) ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATE
Orifice required at Sea Level: #48 IMPORTANT: 90+ MODELS ONLY. DO NOT USE THIS CHART FOR ANY 80 PLUS MODELS.
From Table F.4 of National Fuel Gas NATURAL GAS LP GAS
Code Handbook, 2002 ALTITUDE INPUT OUTPUT
ORIFICE MANIFOLD
ALTITUDE INPUT OUTPUT
ORIFICE MANIFOLD
SIZE PRESSURE SIZE PRESSURE
Orifice required at 5000 ft. elevation (4%
45,000 40,500 45,000 40,500
de-rate per thousand ft.): #50 60,000 54,000 60,000 54,000
Orifice required at 8000 ft. elevation (4% 0’ - 2000’
75,000 67,500
#50 3.5” W.C. 0’ - 2000’
75,000 67,500
1.15mm 10” W.C.
90,000 81,000 90,000 81,000
de-rate per thousand ft.): #51 105,000 94,500 105,000 94,500
120,000 108,000 120,000 108,000
Example: 1050 BTU/ft3 Regional 40,500 36,450 40,500 36,450
Natural Gas Heating Value 54,000 48,600 54,000 48,600
67,500 60,750 67,500 60,750
2001’ - 4500’ #51 3.0” W.C. 2001’ - 4500’ 1.10mm 7.6” W.C.
I/H=Q 81,000 72,900 81,000 72,900
94,500 85,050 94,500 85,050
15000 / 1050 = 14.63 ft.3 108,000 97,200 108,000 97,200
I = Sea Level input (per burner): 15000

H = Sea Level Heating Value: 1050
Q = 14.28 ft.3 Natural Gas per hour. FIGURE 42
MANIFOLD PRESSURE-CHANGE LABEL
From Table F.1 of National Fuel Gas THE MANIFOLD PRESSURE OF THIS APPLIANCE HAS
Code Handbook, 2002 (3.5” w.c. BEEN FIELD ADJUSTED TO OBTAIN THE CORRECT
column) INPUT RATING FOR INSTALLATION AT ALTITUDES
Orifice required at Sea Level: #50 BETWEEN 2,000 FEET AND 4,500 FEET ELEVATION.
From Table F.4 of National Fuel Gas
Code Handbook, 2002 LA PRESSION DU DISTRIBUTEUR D’ALIMENTATION
Orifice required at 5000 ft. elevation (4% DE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIN
de-rate per thousand ft.): #51 D’OBTENIR LA BONNE PUISSANCE D’ENTRÉE POUR
Orifice required at 8000 ft. elevation (4% UNE INSTALLATION ENTRE 2000 ET 4500 PIEDS
de-rate per thousand ft.): #52 D’ALTITUDE. 92-24399-01-01
45
START-UP PROCEDURES
DIRECT SPARK IGNITION 5. Replace the control access door. SINGLE-STAGE HEAT
THERMOSTAT
6. Turn on the electrical power.
LIGHTING INSTRUCTIONS NOTE: Single-stage heat operation is
7. Set the room thermostat to a point
This appliance is equipped with a direct above room temperature to light the determined by the position of the
spark ignition device. This device lights main burners. After the burners are lit, jumper at P7 on the control board.
the main burners each time the room set room thermostat to a desired Options are: 5 minutes between 1st
thermostat (closes) calls for heat. See temperature. and 2nd stage, or 12 minutes between
lighting instructions on the furnace. 1st and 2nd stage (see Figure 44).
During initial start-up, it is not unusual TO SHUT DOWN FURNACE For single-stage operation, “W” from
for odor or smoke to come out of any 1. Set the room thermostat to off and its the thermostat must be connected to
room registers. It is recommended to lowest setting. “W” on the furnace control.
ensure proper ventilation by opening 2. Turn manual gas stop to the closed Do not leave jumper at P7 in the
windows and doors, before initial firing. position. “NONE” position when using a single-
The furnace has a negative pressure 3. Turn off the electrical power to the stage thermostat with the timed
switch that is a safety during a call for furnace. staging feature. If the jumper is left on
heat. The induced draft blower must pull 4. Remove burner compartment door. “NONE”, the furnace will never reach
a negative pressure on the heat 5. Move the main gas valve knob or high heat (100% heat). NOTE: When
exchanger to close the negative lever to the off position. there is a low heat call present at the
pressure switch. The induced draft 6. Replace the burner compartment time of ignition, this furnace will light
blower must maintain at least the door. on high fire heat and immediately drop
negative pressure switch set point for to low fire as soon as flame is sensed.
the furnace to operate. If the induced ! WARNING This can sometimes appear to be
draft blower fails to close or maintain the SHOULD OVERHEATING OCCUR OR ignition on low heat stage but this is
closing of the negative pressure switch, THE GAS SUPPLY FAIL TO SHUT not the case. Listen carefully to hear
a heat call would be prevented until the OFF, SHUT OFF THE MANUAL GAS the inducer and gas valve relays
problem is cleared. VALVE TO THE APPLIANCE BEFORE switch to low fire after ignition when a
SHUTTING OFF THE ELECTRICAL low heat call is present. If a high heat
TO START FURNACE SUPPLY. FAILURE TO DO SO CAN call is present at the time of ignition,
1. Remove the control access door. CAUSE AN EXPLOSION OR FIRE both ignition and steady state heat will
RESULTING IN PROPERTY DAMAGE, occur at high fire and there will be no
! WARNING PERSONAL INJURY OR DEATH. change in operation after ignition.
2. BE SURE THAT THE MANUAL GAS
IGNITOR PLACEMENT, a. Connect the “W” terminal on the
CONTROL HAS BEEN IN THE ALIGNMENT & LOCATION thermostat to the “W” terminal on
“OFF” POSITION FOR AT LEAST Ignition failure may be a result of the control board.
FIVE MINUTES. DO NOT ATTEMPT improper ignitor alignment caused during b. When there is a call for heat, the
TO MANUALLY LIGHT THE MAIN a service call or other work done to the “R” and “W” contacts close and the
BURNERS. FAILURE TO FOLLOW furnace in the field. When performing any IFC runs a self check routine to
THIS WARNING CAN CAUSE A work on the burner, heat exchanger, etc., verify that the pressure switch
FIRE OR AN EXPLOSION the technician must check alignment of contacts are open. The limit switch
RESULTING IN PROPERTY the spark ignitor. Misalignment of the contacts are constantly monitored.
DAMAGE, PERSONAL INJURY OR ignitor could cause a failure to light or
DEATH. rough ignition. The correct ignitor c. The induced draft motor starts on
alignment is shown in Figure 43. high speed. After a 30 second pre-
3. Turn off the furnace electrical power purge, the spark ignitor energizes
and set the room thermostat to the and the high fire gas valve opens,
lowest setting. SEQUENCE OF OPERATION lighting the burners.
4. Turn the gas control knob to the “On” See the section of this book titled d. After the gas valve opens, the
position, or move the gas control “Electrical Wiring - Thermostat” and remote flame sensor must prove
lever to the “On” position. Figure 40 for a wiring diagram showing ignition for one second using the
how to connect a thermostat.
FIGURE 43
UPFLOW OPTIMUM IGNITOR LOCATION DOWNFLOW/HORIZONTAL OPTIMUM IGNITOR LOCATION
46
process of flame rectification. If the d. The sequence repeats after a one flame is sensed. This can sometimes
burners do not light, the system goes hour delay and continues repeating appear to be ignition on low heat
through another ignition sequence. It until ignition is successful or the call for stage but this is not the case. Listen
does this up to 4 times. heat is terminated. carefully to hear the inducer and gas
e. The inducer and gas valve e. To reset the lockout, break heat call at valve relays switch to low fire after
immediately drop to low fire, the main the thermostat or power at the unit ignition when a low heat call is
blower starts on low heat speed 20 disconnect switch for 5 to 10 seconds. present. If a high heat call is present
seconds after the flame is sensed. The The furnace then goes through at the time of ignition and steady state
furnace operates on low fire for 5 or 12 another set of trials for ignition heat will occur at high fire and there
minutes and then, if the thermostat is (provided call for heat is still present). will be no change in operation after
not satisfied, shifts to high fire, causing ignition.
the draft inducer to go to high speed, f. If flame is established and maintained
during the trial for ignition period and Call for 1st stage heat
the gas valve to shift to 100% and the
main blower to high heat speed. (In flame is lost, the gas valve is de- a. The “R” and “W” thermostat
some models low and high fire have energized, the draft inducer completes contacts close and the control
identical main blower airflow CFM.) the post purge, and control shuts off module runs a self-check routine.
the inducer, senses the open pressure After the control module verifies
f. When the thermostat cycle ends, the switch and begins the ignition that both sets of pressure switch
gas valve closes, and the burners go sequence again from pre-purge. The contacts are open, the induced
out. indoor blower motor will be energized draft motor starts on high until both
g. The draft inducer will continue running and/or remain energized on low speed the low and high pressure switch
for a 10 second post purge. for low fire and heat speed for high fire contacts close (a maximum of 60
for the selected delay off time. seconds).
h. The main blower runs for 80-180
seconds on high heat speed or 90-180 The control initiates another ignition b. After a 30 second pre-purge the
seconds on low heat speed (this trial period. The control will recycle up spark igniter energizes and the high
timing is field adjustable). See Figure to 5 flame losses (4 re-cycles) within a fire gas valve opens, lighting the
45 for switch settings. single call for heat before going into burners.
lockout. c. After the burners light, the remote
Sequence if the system doesn’t light
or doesn’t sense flame flame sensor must prove ignition. If
TWO STAGE HEAT THERMOSTAT the burners do not light, the system
a. If flame is not sensed within 8 seconds Connect “W1” and “W2” terminals on the goes through another ignition
after the gas valve opens, the valve thermostat to “W” and “W2” terminals on sequence. It does this up to 4
closes and the ignitor is de-energized. the control board. times.
The induced draft motor will run for 60
seconds on high, and then begins See the section of this book titled d. The furnace immediately drops
another heat cycle. “Electrical Wiring - Thermostat” for a inducer and gas value to low fire
wiring diagram showing how to connect a after sensing flame. The main
b. The ignition process goes through 3 thermostat. blower starts on low-heat speed 20
more attemps. seconds after the flame is proven.
NOTE: When there is a low heat call
c. If there is no ignition after the 4th trial, present at the time of ignition, this The furnace continues to run on
the furnace goes into soft lockout for furnace will light on high fire heat and low fire until the call for heat is
one hour. immediately drop to low fire as soon as satisfied or the 2nd stage contacts
close. If the 1st stage call for heat is
FIGURE 44
é
FACTORY
SETTING
47
satisfied the gas valve closes and the
induced draft motor continues running
2nd stage heat satisfied, 1st stage
heat still required
INTEGRATED FURNACE
for a 10 second post purge time. the The “R” and “W2” thermostat contacts
CONTROL & ECM MOTOR
main blower runs for its blower off
delay (this timing is field adjustable).
open. The induced draft motor switches SETTINGS
to low speed, the main blower motor These furnaces have ECM blower
See Figure 44 for switch settings.
switches to low heat speed and the gas motors. These motors deliver a
Call for 2nd stage heat after 1st stage valve changes to low fire. The furnace constant level of air flow over a wide
The “R” and “W2” thermostat contacts continues to run in this mode until the 1st range of external static pressures (0.1
close, calling for 2 stage heat. The stage heat call is satisfied. The system to 0.8ⴖ W.C.).
induced draft motor switches to high will shut down as noted in “d,” under 1st There is a bank of 12 dip switches
speed and the low and high pressure stage call for heat. (SW1) on the control board which
switch contacts close. The gas valve NOTE: Under extreme cold conditions, define the operation of the ECM
switches to high fire and the main blower motor. (See Table 12.) (See Figure
the 2-stage thermostat may call for the
switches to high heat speed. 46.) Many of these switches (except
furnace to cycle between 1st and 2nd
stage operation. for switches 9 and 12) are actually
TABLE 12 broken down into dip switch pairs. The
DIP SWITCH BANK SW1 following switches are paired 1 & 2, 3
& 4, 5 & 6, 7 & 8, and 10 & 11. The
SWITCHES FUNCTION assignments of the switch pairs are
1&2 Heat Rise Adjustment shown in Table 11 and Figure 45.
3&4 Not Used
5 & 6 Nominal Cooling/Heat Pump Air Flow
7 & 8+ Latent/Sensible Airflow Adjustment
9 Continuous Fan Airflow
10 & 11* On Demand
Dehumidification
Settings
12 1 or 2 Stage Cool
48
Figure 45: 2-Stage, 90+ ECM Dipswitch Map
5&6 = Cooling Select IFC #62-103189-01 / UT 1095-206 DIPSWITCH MAP
-05 MODEL
SW1-5 / * = Factory Position
-06
SW1-6 -07B -09 -10 -12 9 = Cont Fan Speed
-07A
1200 HI/ 1600 HI/ 1900 HI/ 1800 HI/ 2000 HI/ SW1-9 = ON, APPROX. CONTINUOUS FAN AIRFLOW
OFF/OFF * -GTM -GRM
900 Low 1200 Low 1500 Low 1500 Low 1500 Low SW1-1 SW1-2
1000 HI/ 1400 HI/ 1600 HI/ 1600 HI/ 1600 HI/ 06 07 09 10 04 06 07-M 07-Y 09 -10 12
ON/OFF
750 Low 1050 Low 1200 Low 1200 Low 1200 Low OFF* OFF* 800 1100 1350 1450 850 750 750 1200 1300 1400 1250
800 HI/ 1200 HI/ 1400 HI/ 1400 HI/ 1400 HI/ ON OFF 500 750 1000 1100 500 550 550 850 850 1050 950
OFF/ON
600 Low 900 Low 1050 Low 1050 Low 1050 Low OFF ON 650 900 1200 1250 650 600 700 1000 1050 1150 1050
600 HI/ 1000 HI/ 1200 HI/ 1200 HI/ 1200 HI/
ON/ON ON ON 1050 1500 1750 1850 1150 850 900 1550 1600 1200 1450
450 Low 750 Low 900 Low 900 Low 900 Low
SW1-9 = OFF*, Airflow = 60% of the above value.
3&4 Not
Used
All Switches
Shown in
Factory 10&11 = Dehumidification
Default SW1-10 / DEHUMIDIFICATION
SW1-11 SELECTION
Positions 15% LESS COOLING
OFF/OFF
AIRFLOW
1&2 = Heat Rise Adjust NORMAL COOLING
Low Fire High Fire ON/OFF *
AIRFLOW
Published D-SW1-1, 2= A-SW1-1, 2= C-SW1-1, 2= B-SW1-1, 2= Published D-SW1-1, 2= A-SW1-1, 2= C-SW1-1, 2= B-SW1-1, 2=
Model Low Temp Low Temp ON-DEMAND DE-
ON/ON OFF/OFF* OFF/ON ON/OFF ON/ON OFF/OFF* OFF/ON ON/OFF OFF/ON
Rise Range Approx. Approx. Approx. Approx. Rise Range Approx. Approx. Approx. Approx. HUMIDIFICATION
Temp Rise Temp Rise Temp Rise Temp Rise Temp Rise Temp Rise Temp Rise Temp Rise NORMAL COOLING
04(-)MCKS 15°-45°F 23°F 30°F 38°F 45°F 30°F-60°F 38°F 45°F 53°F 60°F ON/ON
AIRFLOW
06(-)MCKS 35°-65°F 43°F 50°F 58°F 65°F 40°-70°F 48°F 55°F 63°F 70°F
07(-)MAES 35°-65°F 43°F 50°F 58°F 65°F 40°-70°F 48°F 55°F 63°F 70°F
07(-)YBGS 20°-50°F 28°F 35°F 43°F 50°F 35°-65°F 43°F 50°F 58°F 65°F
7&8 = Cooling Trim
09(-)ZAJS 25°-55°F 33°F 40°F 48°F 55°F 35°-65°F 43°F 50°F 58°F 65°F
UPFLOW
SW1-7 / SW1-8 COOLING
10(-)ZAJS 30°-60°F 38°F 43°F 53°F 60°F 40°70°F 48°F 55°F 63°F 70°F AIRFLOW TRIM
12(-)RAHS 40°-70°F 48°F 55°F 63°F 70°F 50°-80°F 58°F 65°F 73°F 80°F
06(-)MCKS 35°-65°F 38°F 43°F 54°F 60°F 40°-70°F 43°F 50°F 57°F 63°F
OFF/OFF * NONE
07(-)YBGS 20°-50°F 33°F 40°F 47°F 55°F 35°-65°F 38°F 45°F 52°F 60°F ON/OFF +10%
09(-)ZAJS 25°-55°F 33°F 40°F 48°F 55°F 35°-65°F 38°F 45°F 52°F 60°F OFF/ON -10%
DOWNFLOW
10(-)ZAJS 30°-60°F 38°F 45°F 53°F 60°F 40°-70°F 38°F 50°F 57°F 65°F ON/ON NONE
49
* = Factory Default Position
TWO STAGE 90’S W/ECM (GRM’S & GTM’S)
ADDITIONAL COOLING
FIGURE 46 BLACK IS SWITCH
SPEEDS FOR SINGLE-
STAGE COOLING
APPLICATIONS
In addition to the listed cooling airflows
for single-stage cooling the installer
has the option of using the first-stage
cooling airflow of the furnace for full
cooling airflow speed. This is done by
simply connecting a single-stage
thermostat’s “Y’ terminal to the furnace
control’s “Y1” terminal. The terminal
HEATING AIRFLOW TWO-STAGE COOLING “Y2” of the furnace control is left
disconnected. In this case, the airflow
ADJUSTMENTS SELECTION delivered by the furnace for full cooling
The furnace is shipped with low and high Dipswitch SW1, Position #12 on the would be the same as the airflow for
fire heating airflows. These are set from Integrated Furnace Control (IFC) ships first-stage cooling of a two-stage
the factory to let the furnace operate at from the factory in the “ON” position. cooling system. This gives the user
the mid point of the temperature rise This dipswitch is to be used to designate more options for cooling airflow. Figure
range. The temperature may vary slightly single or two-stage cooling to the IFC. 45 indicates the approximate cooling
due to furnace input manufacturing The “ON” (as now shipped) position airflow for both first and second stage.
tolerances and voltage variations. designates a single-stage air
conditioning system or heating-only NOTE: The dipswitch SW1-12 must
In the heating mode, the ECM motor is be set to the “OFF” position for this
programmed to ramp up to its target application. The “OFF” position
designates a two-stage air conditioning particular configuration in order to
CFM over a fifteen (15) second period. system or a single stage cooling system utilize the first-stage cooling input
After any of the user selected “Off” where the cooling airflow used is the 1st which is inoperative when the
delays the ECM motor will ramp down to stage cooling input as described in the dipswitch is “ON”. The furnace control
50% of steady state CFM for section of this document titled Additional is shipped from the factory with this
approximately thirty (30) seconds. The Cooling Speeds for Single Stage switch in the “ON” position so it will
motor will then ramp down to off. Cooling Applications. Turn the switch to need to be turned “OFF” in order to
the “OFF” position when using two-stage utilize this feature.
COOLING AIRFLOW cooling with separate contactors, Y1 and
ADJUSTMENTS
Y2. Failure to do this will mean that the CONTINUOUS FAN
air conditioner will never go into low
The furnace motor is programmed to stage. ADJUSTMENTS
provide cooling airflows of 11⁄2, 2, 21⁄2 and 2-Stage Cooling Systems = #12 OFF There are two options for the
3 tons in the RGRM-04*MAES, RGRM- 1-Stage Cooling Systems = #12 ON adjustment of continuous fan. With
06*MAES and RGRM-07*MAES and of 1-Stage Cooling using Low Cool = #12 switch 9 “ON” the speed will be high
21⁄2, 3, 31⁄2, and 4 tons are available in the Stage Cooling using Low Cool = OFF fan. With switch 9 “OFF” the speed
RGRM-07*YBGS units. Airflows of 3, 31⁄2,
4 and 5 tons are available in the RGRM- will be low fan.
09EZAJS, RGRM-10EZAJS, RGRM-
12ERAJS units. See table for airflow
options. Furnaces are shipped from the
factory set for maximum cooling airflow. SW1-9 = ON, APPROX. CONTINUOUS FAN AIRFLOW
Adjustments to the cooling airflow may SW1-1 S1-W2 06
-GTM -GRM
be made using switches 7 and 8 as 07 09 10 04 06 07-M 07-Y 09 -10 12
shown in Figure 45. OFF* OFF* 800 1100 1350 1450 850 750 750 1200 1300 1400 1250
ON OFF 500 750 1000 1100 500 550 550 850 850 1050 950
OFF ON 650 900 1200 1250 650 600 700 1000 1050 1150 1050
ON ON 1050 1500 1750 1850 1150 850 900 1550 1600 1200 1450
SW1-9 = OFF*, Airflow = 60% of the above value.
TABLE 13
HEAT RISE ADJUSTMENTS
Profile SW1-1 & SW1-2 Temperature Rise (°F)
A OFF/OFF Nominal Setting - See Figure 45
B ON/OFF Nominal +15°F
C OFF/ON Nominal +8°F
D ON/ON Nominal -8°F
50
SETTING BLOWER OFF cation (ODD) when not using a humidi-
stat, or thermostat with a dehumidifi-
NATURAL GAS
1. When adjusting the furnace input,
TIMINGS FOR COOLING AND cation feature. Switch selection lowers the high fire input should be
HEAT PUMP OPERATION airflow CFM continuously by about 15% checked. The high fire manifold
There is a jumper (P6) on the main by turning “off” the input to the ODD pressure should be 3.5’ W.C.
furnace control board for setting blower terminal. SWITCHES SHOULD BE LEFT Follow these steps to be sure the
off timings. (See Figure 44.) AT THE FACTORY DEFAULT furnace is high fire mode:
SETTINGS TO PREVENT LOWER a. With a single stage thermostat,
DEHUMIDIFICATION THAN EXPECTED AIRFLOW. the furnace runs for 12 minutes
The interface control has two optional 24 (ODD) ON-DEMAND- on low fire before shifting to high
volt AC only inputs. The “B” terminal input DEHUMIDIFICATION WITH HUMIDI- fire. To be certain that it is on
is provided for heat pump applications. STAT, OR THERMOSTAT, WITH high fire, connect terminals “R”,
This signal comes from a heat pump DEHUMIDIFICATION FEATURE. “W” and “W2” together on the
thermostat and tells the heat pump to Normal airflow is reduced by a pre- control board in the blower
switch its reversing valve to heat mode. If programmed amount to maximize latent compartment.
this “B” signal is also routed to the moisture removal. Zero voltage will be b. With a two stage thermostat, set
furnace control, all airflow adjust switches supplied to the ODD terminal, under high the thermostat to its highest
(7 & 8 of SW1) and “On Demand humidity, and the CFM will be dropped setting to keep the furnace
Dehumidification” are bypassed in the approximately 15%. When humidity is operating in the high fire mode.
heat mode only. The airflow will remain at low, 24 Volts will be supplied to the ODD 2. To adjust high fire manifold
the normal airflow as selected by terminal, with CFM based on settings pressure, remove the adjustment
switches 5 & 6 throughout the heat mode. made to terminal pairs for cooling airflow cover screw on the outlet end of the
This allows the user to have a switched and airflow adjustments. Be sure to use a gas valve and turn the adjustment
(reduced) airflow adjustment for humidistat with these settings or airflow screw clockwise to increase the
dehumidification or the “On Demand will be reduced. When no voltage is pressure and counterclockwise to
Dehumidification” in cooling mode, but present on ODD and the ODD feature is reduce the pressure. Replace the
not the adverse humidity and heat rise enabled (see Table 18), cooling airflow is cover screw securely. See Figure
effects of using these adjustments during decreased 15%. This results in higher 27.
a heat pump’s heat mode. The “B” latent capacity and increases the level of 3. The low fire manifold pressure
terminal does not apply to gas operation. comfort. This feature is only available in should be 1.7” W.C. As mentioned
the cooling mode. above, the furnace remains in the
The “On Demand Dehumidification” low fire mode for 12 minutes upon
(ODD) input allows the user to have *IMPORTANT: Only traditional a heat call with a single stage
automatic dehumidification that is humidistats will work with this feature. thermostat. With a two stage
controlled by the user’s humidistat setting. Dehumidistats will not work properly with thermostat, disconnect the
Dehumidistats are not compatible with the this feature. thermostat lead to the “W2”
furnace control. On Demand Dehumidifi- terminal on the IFC and the furnace
ADJUSTING OR CHECKING will remain in the low fire mode. To
FURNACE INPUT adjust the pressure, remove the
A properly calibrated manometer or regulator cover, on top of the valve,
gauge is required for accurate gas and adjust as noted under Step 2,
pressure readings. above. After the adjustment
replace the screw cover securely.
51
AIR FLOW POSSIBLE. FOR EXAMPLE, IF THE
RISE RANGE IS 40 TO 70 DEGREES, FIGURE 47
TEMPERATURE RISE MEASUREMENT
The importance of proper air flow over the THE MOST IDEAL RISE WOULD BE
heat exchanger cannot be over 55 DEGREES (THE MIDDLE OF THE
emphasized. RISE RANGE). IN ALL
APPLICATIONS, THE INSTALLER
! CAUTION MUST ADJUST THE TEMPERATURE
IT IS IMPORTANT THAT EACH DUCT RISE TO THIS "MIDDLE" POINT AS
SYSTEM BE SIZED AND INSTALLED CLOSELY AS POSSIBLE. ALSO,
FOR THE SPECIFIC APPLICATION BY THE TEMPERATURE RISE SHOULD
PROPERLY APPLYING THE NEVER BE ABOVE OR FALL BELOW
APPROPRIATE INDUSTRY ACCEPTED THE STATED RANGE. DOING SO
STANDARD. IF LESS THAN MINIMUM COULD CAUSE DAMAGE TO THE
STANDARDS ARE APPLIED, THE HEAT EXCHANGER OR
EQUIPMENT USER COULD EXPECT INTERMITTENT OPERATION WHICH
TO EXPERIENCE HIGHER UTILITY COULD CAUSE INJURY OR DEATH
BILLS, MAJOR COMPONENT AND WILL VOID THE
FAILURE, VARYING DEGREES OF AIR MANUFACTURER'S WARRANTY
NOISE OR OTHER UNSATISFACTORY FOR THIS PRODUCT.
ISSUES, OVER WHICH THE
EQUIPMENT MANUFACTURER HAS
NO CONTROL.
TEMPERATURE RISE CHECK
To determine if the air flow is correct,
make a temperature rise check.
1. Insert a thermometer in the supply
air duct as close to the furnace as FIGURE 48
TYPICAL FURNACE NAME PLATE
possible yet out of a direct line from
the heat exchanger. See Figure 47. AIR CONDITIONING DIVISION
FORT SMITH, ARKANSAS
2. Insert a thermometer in the return air
duct as close to the furnace as
possible.
3. Operate the furnace. High fire and
low fire heating modes have the
same temperature rise range.
4. When the thermometer in the supply
air duct stops rising (approximately
five minutes), subtract the return air
temperature from the supply air
temperature. The difference is the
temperature rise.
5. Compare the measured temperature
rise to the approved temperature rise
range listed on the furnace name
plate. See Figure 48.
If the measured temperature rise is above
the approved range, the air flow is too
low. More air must be moved by speeding
up the blower, by removing restrictions in
the duct system, or by adding more
supply or return air duct. If the measured
temperature rise is below the approved
range, the air flow is too much. Use lower
speed tap on the multi-speed blower.
! WARNING
THE MEASURED TEMPERATURE
RISE SHOULD BE AS CLOSE TO THE
MIDDLE OF THE STATED RANGE AS
52
MAINTENANCE TABLE 14
FILTER SIZES
! WARNING UPFLOW FILTER SIZES
THESE INSTRUCTIONS ARE FURNACE INPUT BOTTOM SIDE
QUANTITY
INTENDED AS AN AID TO WIDTH MBTUH SIZE SIZE
QUALIFIED SERVICE PERSONNEL 17 /2"

1 45, 60, 75A 15 /4" X 25"
3 15 /4" X 25"
3 1
FOR PROPER INSTALLATION, 21" 75B, 90, 105 191/4" X 25" 153/4" X 25" 1
241/2" 120 223/4" X 25" 153/4" X 25" 1
ADJUSTMENT AND OPERATION
OF THIS UNIT. READ THESE DOWNFLOW/HORIZONTAL FILTER SIZES
INSTRUCTIONS THOROUGHLY FURNACE INPUT
SIZE QUANTITY
WIDTH MBTUH
BEFORE ATTEMPTING
INSTALLATION OR OPERATION. 171/2" 60, 75A 12" X 20" 2
21" 75B, 90, 105 12" X 20" 2
FAILURE TO FOLLOW THESE
241/2" 120 14" X 20" 2
INSTRUCTIONS MAY RESULT IN
IMPROPER INSTALLATION,
ADJUSTMENT, SERVICE OR SHOCK, CARBON MONOXIDE
MAINTENANCE, POSSIBLY POISONING, EXPLOSION,
RESULTING IN FIRE, ELECTRICAL PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
FIGURE 49
FILTER LOCATIONS
DOWNFLOW
AIRFLOW
I413
HORIZONTAL
HORIZONTAL
I528
53
FIGURE 50 UPFLOW BOTTOM RETURN
BOTTOM PANEL REMOVAL JACKET ASSEMBLY
FILTER LOCATION
JACKET ASSEMBLY
REMOVE
SOLID BOTTOM
AIRFLOW
FILTER
FILTER ROD
FILTER & ROD LOCATION
NOTE:
BACK FLANGE OF SOLID BOTTOM FITS
SCREW UNDERNEATH JACKET. SIDES AND FRONT
(2) REQ’D. FLANGES FIT OVER FLANGES ON JACKET.
SOLID BOTTOM REMOVAL

JACKET
UPFLOW SIDE RETURN

DRILL (2)
3/16" DIA.
HOLES
8.000
4.875
1.531
AIRFLOW SOLID
BOTTOM
CUT-OUT AND DRILL DETAIL

R
JACKET
JACKET
ANGLE
JACKET
FILTER
FILTER
ANGLE DETAIL
ATTACH WITH FILTER

FILTER
SHEET METAL ROD
ROD
SCREWS (2 REQÕD) 45-24095-01
FILTER ROD
ROD FILTER ROD
OD
SUPPORT
SUPPORT SUPPORT
S
ANGLE ANGLE
AE-60520-01 AE-60520-01
FILTER FILTER
FILTER
FILTER SUPPORT
SUPPORT
ANGLE SUPPORT
SUPPORT
ANGLE
(SEE ANGLE DETAIL) ANGLE
ANGLE SOLID
(SEE ANGLE DETAIL)
SOLID AE-61883-01 AE-61883-01 BOTTOM
BOTTOM I332
ROD & FILTER SUPPORT ANGLE ASSEMBLY FILTER AND ROD ASSEMBLY
I
NOTE: Use both side returns for 1800 CFM or more.
54
SUPPLY REGISTERS. ANY it is recommended that a qualified
! WARNING RECIRCULATED DUST PARTICLES installer, service agency, or the gas
DISCONNECT MAIN ELECTRICAL WILL BE HEATED AND CHARRED supplier annually inspect the flue
POWER TO THE UNIT BEFORE BY CONTACT WITH THE FURNACE passageways, the vent system and
ATTEMPTING ANY MAINTENANCE. HEAT EXCHANGER. THIS RESIDUE the main burners for continued safe
FAILURE TO DO SO CAN CAUSE WILL SOIL CEILINGS, WALLS, operation. Pay particular attention to
DRAPES, CARPETS AND OTHER deterioration from corrosion or other
ELECTRICAL SHOCK RESULTING IN
HOUSEHOLD ARTICLES AND MAY sources.
PERSONAL INJURY OR DEATH. RESULT IN UNPLEASANT ODORS. • IMPORTANT: It is recommended
FILTER MAINTENANCE LUBRICATION
that at the beginning and at
Have your qualified installer, service approximately half way through the
agency or the gas supplier instruct you IMPORTANT: DO NOT attempt to heating season, a visual inspection
on how to access your filters for lubricate the bearings on the blower be made of the main burner flames
regular maintenance. motor or the induced draft blower for the desired flame appearance by
motor. Addition of lubricants can reduce a qualified installer, service agency
the motor life and void the warranty. or the gas supplier. If the flames are
FILTERS The blower motor and induced draft
distorted and/or there is evidence of
Filter application and placement are back pressure, check the vent and
blower motor are permanently
critical to airflow, which may affect the inlet air system for blockage. If there
lubricated by the manufacturer and do
heating and cooling system is carbon and scale in the heat
not require further attention.
performance. Reduced airflow can exchanger tubes, the heat
shorten the life of the system’s major The blower motor and induced draft exchanger assembly should be
components, such as motor, limits, heat blower motor must be cleaned replaced.
exchanger, evaporator coil or periodically by a qualified installer,
compressor. Consequently, we service agency, or the gas supplier to ! WARNING
recommend that the return air duct prevent the possibility of overheating
due to an accumulation of dust and dirt HOLES IN THE VENT PIPE OR
system have only one filter location. HEAT EXCHANGER CAN CAUSE
The most common location will be on the windings or on the motor
exterior. And, as suggested elsewhere TOXIC FUMES TO ENTER THE
inside the furnace or a filter base. For HOME, RESULTING IN CARBON
systems with a return air filter grille or in these instructions, the air filters
should be kept clean. Dirty filters can MONOXIDE POISONING OR
multiple filter grilles, can have a filter DEATH. THE VENT PIPE OR HEAT
installed at each of the return air restrict airflow. The motor depends
upon sufficient air flowing across and EXCHANGER MUST BE
openings. Your HVAC professional can REPLACED IF THEY LEAK.
show you where they have installed the through it to keep from overheating.
filter(s). • IMPORTANT: It is recommended
If high efficiency filters or electronic air SYSTEM OPERATION that at the beginning of the heating
season, the flame sensor be
cleaners are used in the system, it is INFORMATION cleaned with steel wool by a
important that the airflow is not reduced Advise The Customer qualified installer, service agency or
to maximize system performance and the gas supplier.
life. Always verify that the system’s 1. Keep the air filters clean. The
airflow is not impaired by the filtering heating system will operate better, • IMPORTANT: It is recommended
system that has been installed, by more efficiently and more that at the beginning of the heating
performing a temperature rise and economically. season, the condensate trap be
temperature drop test. 2. Arrange the furniture and drapes inspected for debris or blockage and
so that the supply air registers and be filled with water. A blocked
Keep the filter(s) clean at all times. condensate trap can cause water to
Vacuum dirt from filter, wash with the return air grilles are
unobstructed. back up into the primary heat
detergent and water, air dry thoroughly exchanger and lead to nuisance
and reinstall. 3. Close doors and windows. This will tripping of the overtemperature
DO NOT DOUBLE FILTER THE reduce the heating load on the switches.
RETURN AIR DUCT SYSTEM. DO system.
• IMPORTANT: It is recommended
NOT FILTER THE SUPPLY AIR DUCT 4. Avoid excessive use of kitchen that at the beginning of the heating
SYSTEM. exhaust fans. season, the condensate neutralizer
NOTE: Some filters must be resized to 5. Do not permit the heat generated if used be replaced by a qualified
fit certain units and applications. See by television, lamps or radios to installer, service agency or the gas
Table 14 and Figures 51 & 52. influence the thermostat operation. supplier.
1. 21” - 75,000(B), 90,000 & 105,000 6. Except for the mounting platform, • IMPORTANT: It is recommended
BTUH units require removal of a keep all combustible articles 3 feet that an annual inspection and
3.5-in. segment of filter and frame from the furnace and vent system. cleaning of all furnace markings be
to get the proper width for a side made to assure legibility. Attach a
filter. 7. IMPORTANT: Replace all blower replacement marking, which can be
doors and compartment covers obtained through the distributor, if
2. 24.5” - 105,000 and 120,000 BTUH after servicing the furnace. Do not
unit requires removal of a 7" any are found to be illegible or
operate the unit without all panels missing.
segment of filter and frame to get and doors securely in place.
the proper width for a side filter.
8. Explain proper operation of the TROUBLESHOOTING
! CAUTION system. Refer to Figure 51.
DO NOT OPERATE THE SYSTEM
WITHOUT FILTERS. A PORTION OF ANNUAL INSPECTION There are four diagnostic LED’s on
the furnace control. These are labeled
THE DUST ENTRAINED IN THE AIR • The furnace should operate for many flame, status, power and CFM.
MAY TEMPORARILY LODGE IN THE years without excessive scale build-
AIR DUCT RUNS AND AT THE up in the flue passageways. However,
55
FLAME LED measurement tolerances, air density,
The FLAME LED is an indication of the humidity, ambient air temperature and
presence of flame. other things, the CFM actually
measured may vary significantly from
OFF – No flame is detected. this target value.
Rapid Blink – Unexpected Flame One Blink represents 100 CFM of target
Slow Blink – Marginal Flame Sense airflow. A half blink represents approx.
50 CFM. When the blink sequence is
Steady ON – Normal Flame Detected complete, there will be a noticeable
pause of approximately one second
STATUS LED before the sequence repeats. For
example, if elevent and one half blinks
The STATUS LED is an indication of a
are counted followed by a one second
fault present.
pause and then eleven and one half
Steady ON – Normal Fault detected. blinks are counted again, the target
1 Blink – Ignition failure – 1 HR lockout airflow is approximtely 1150 CFM.
Because the resolution of this method is
2 Blinks – Pressure switch stuck only 50 CFM (half-blinks), the actual
open – switch will not close when taget CFM could be anywhere between
inducer is on. 1125 CFM and 1175 CFM. And, since
3 Blinks – Limit switch open – main this is TARGET airflow, the actual
limit or roll-out control. airflow measured could be much
different than this.’
4 Blinks – Pressure switch stuck
closed. Switch will not open. The CFM LED is intended to be for
reference only. The CFM airflow
5 Blinks – Not applicable. reported by the furnace control through
6 Blinks – Line and Neutral reversed. blinks of this LED should be only used
as a guide to determine
POWER LED APPROXIMATE airflow and is not
intended as a laboratory-grade
The POWER LED is an indication of instrument for determining precise
24ac power to the board. airflow through the furnace.
OFF – No power (24VAC) to control
board.
WIRING DIAGRAM
ON – Control is powered. Figure 52 is a complete wiring diagram
for the furnace.
CFM LED
The CFM LED is an indication of target
airflow. This is a reasonably close
approximation of the airflow pushed by
the blower motor through the furnace.
Because of manufacturing and
56
FIGURE 51
TROUBLESHOOTING CHART
or IFC not properly grounded.
Go To
Next Page
57
FIGURE 51
TROUBLESHOOTING CHART (CONTINUED)
58
FIGURE 52
WIRING DIAGRAM – RGLM DOWNFLOW
59
60 CM 0913

Installation Instructions: For Upflow, Downflow/Horizontal High Efficiency Condensing Two-Stage Gas Furnaces

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Installation Instructions: For Upflow, Downflow/Horizontal High Efficiency Condensing Two-Stage Gas Furnaces

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INSTALLATION INSTRUCTIONS

FOR UPFLOW, DOWNFLOW/HORIZONTAL HIGH

______ Polarity observed HORIZONTAL – STANDARD (RXGY-D02, -D03) – US

______ 12" min. above grade/snow level

______ Adequate clearance to combustibles HORIZONTAL – ALTERNATE

DUCT STATIC PRESSURE ______ Correct relationship – exhaust to intake

______ in. w.c. on cooling speed

______ Sloped toward drain TERMINATION – NON-DIRECT VENT

______ Condensate drain line hoses connected VERTICAL

______ in. diameter – exhaust pipe HORIZONTAL – ALTERNATE

______ no. of elbows – intake air

INDOOR AIR QUALITY

04 171/2 1611/32 155/8 2 15 1325/32 0 0 0 1 2* 0 111

SUPPLY RETURN 09 21 1927/32 191/8 2 181/2 179/32 0 0 0 1 2* 0 148

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

2 DIA. 2 DIA. KNOCKOUT

06 171⁄2 1611⁄32 155⁄8 2 165⁄8 137⁄8 0 0 0 1 2* 0 117

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

06 171⁄2 1611⁄32 155⁄8 2 165⁄8 137⁄8 0 0 0 1 2* 0 117

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

DRAIN TRAP LOCATION

IMPORTANT: This furnace is not approved or recommended for

Floor Base Size

PIPE & FITTING MATERIAL ASTM

PVC-DWV (Drain Waste & Vent)

communicate with the outdoors in

OUTLET AIR 1 SQ. INCH

INLET AIR 1 SQ. INCH

1 SQ. INCH PER

2" PVC ELBOW

*NOTE: WHEN FURNACE IS INSTALLED IN A HORIZONTAL POSITION

Canadian Installations US Installations Canadian Installations US Installations

Natural Gas and Propane Installation Code

7. Do not install elbows back to

RGRM-07EMAES MODELS (KIT NO. RXGY-D04)

• All elbows installed on the exterior

From the top elbow in the exhaust

The 45,000 BTUH unit only uses kit 3”

The following are parts lists for the

FIGURE 19 ROOF INSTALLATION MAINTAIN 12 IN.

ITEM No. DESCRIPTION

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

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

COMBUSTION AIR PIPE 4”

Canadian Installations US Installations Canadian Installations US Installations

Natural Gas and Propane Installation Code

TWO-PIPE VENTING TWO-PIPE VENTING

CONCENTRIC VENTING CONCENTRIC VENTING

MINIMUM 12” ABOVE AVERAGE

SEE CONCENTRIC SEE CONCENTRIC VENT INSTALLATION

Note: Vent should protrude a

Seal all wall cavities.

When 2-in. pipe is used, connect it

fitting with a short piece of 2-in. PVC

CONDENSATE TRAP I408

CONDENSATE OVERFLOW: With a

THIS FURNACE IS EQUIPPED AT

Install the gas piping according to all HORIZONTAL