FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH ...pts.myrheem.com/docstore/webdocs/ServiceDocs/histlib/...series furnaces are design-certified by CSA for use with natural and propane gases

92-24161-16-04SUPERSEDES 92-24161-16-03

INSTALLATION INSTRUCTIONSFOR UPFLOW & DOWNFLOW/HORIZONTAL HIGHEFFICIENCY CONDENSING GAS FURNACES(-)GRA/(-)GRJ AND (-)GTA/(-)GTJ SERIES

INSTALLATION CHECK LISTREFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

Adequate pipe size

Correct supply pressure (during furnace operation)

Manifold pressure

No gas leaks

L.P. Kit Number (if applicable)

ELECTRICAL

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

Polarity observed

Furnace properly grounded

Adequate wire size

FURNACE INSTALLATION

Adequate clearance to combustibles

Adequate clearance for service (at front)

DUCT STATIC PRESSURE

in. w.c. on heating speed

in. w.c. on cooling speed

Air temperature rise

CONDENSATE LINE

Trap filled with water

Vented

Sloped toward drain

Condensate drain line hoses connectedand clamped

Freeze protection (if necessary)

VENTING – DIRECT VENT

in. diameter – intake pipe

in. diameter – exhaust pipe

ft. of pipe – intake air

no. of elbows – intake air

ft. of pipe – exhaust pipe

no. of elbows – exhaust pipe

Exhaust vent temp.

TERMINATIONS – DIRECT VENT

VERTICAL

Intake – 12" min. above roof/snow level

Correct relationship – exhaust to intake

HORIZONTAL/VERTICAL – CONCENTRIC (RXGY-E03)

Intake – 12" min. above roof/snow level

Intake “Y” rotated above center

Exhaust sloped toward furnace

HORIZONTAL – STANDARD (RXGY-D02, -D03)


12" min. above grade/snow level

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


Above anticipated snow level

VENTING – NON-DIRECT VENT

in. diameter – exhaust pipe

ft. of pipe – exhaust

no. of elbows

TERMINATION – NON-DIRECT VENT

VERTICAL

12" min. above roof/snow level

HORIZONTAL – STANDARD

12" min. above grade/snow level

HORIZONTAL – ALTERNATE

Above anticipated snow level

Model Number

Serial #

Date of Installation

2

3

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

CONTENTS

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

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

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

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

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

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

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

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

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

Condensate Drain/Neutralizer................................................................................29

Converting Downflow to Horizontal ........................................................................31

Gas Supply and Piping...........................................................................................33

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

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

Start-Up Procedures...............................................................................................43

Air Flow...................................................................................................................45

Maintenance...........................................................................................................49

Troubleshooting......................................................................................................52

Wiring Diagrams.....................................................................................................56

The (-)GRA/(-)GRJ and (-)GTA/(-)GTJseries furnaces are design-certified byCSA for use with natural and propanegases as follows:

1. As non-direct vent central forcedair furnaces taking combustionair from the installation area orusing air ducted from the outside.

2. As direct vent central forced airfurnaces with all combustion airsupplied directly to the furnaceburners through a special airintake system outlined in theseinstructions.

4

Install this furnace in accordance withthe American National StandardZ223.1 – latest edition entitled“National Fuel Gas Code” (NFPA54)and requirements or codes of thelocal utilities or other authoritieshaving jurisdiction. This is availablefrom the following:

National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

CSA-INTERNATIONAL8501 East Pleasant Valley RoadCleveland, Ohio 44131-5575

Install units in Canada in accordancewith CSA-B149, local installationcodes and authorities havingjurisdiction. CSA-B149 is availablefrom:

CSA-INTERNATIONAL178 Rexdale Blvd.Toronto, OntarioCanada M9W, 1R3

GENERAL INFORMATION

FIGURE 1UPFLOW FURNACE

FIGURE 2DOWNFLOW/HORIZONTAL FURNACE

ITEM ITEMNO. PART NAME NO. PART NAME

1 INDUCED DRAFT BLOWER 14 LOW VOLTAGE TERMINAL (THERMOSTAT)2 CAPACITOR 15 TRANSFORMER3 INLET AIR CHASE 16 PRESSURE SWITCH4 DOOR SWITCH 17 OUTLET AIR PIPE5 JUNCTION BOX 18 GAS VALVE6 INLET PIPE CONNECTOR 19 CONNECTOR7 TOP PLATE 20 EXHAUST TRANSITION8 CONTROL MOUNTING PLATE 21 CONDENSATE TRAP9 AUXILIARY LIMIT 22 IGNITER (HSI)10 SHIPPING PLUG 23 MANIFOLD11 EXHAUST CONNECTION 24 OVERTEMPERATURE SWITCH12 BLOWER 25 ROLLOUT SWITCH13 EXHAUST PIPE EXTENSION 26 FLAME SENSOR

27 BURNER

ITEM ITEMNO. PART NAME NO. PART NAME

1 CONDENSATE TRAP 13 TOP PLATE2 DOOR SWITCH 14 BURNER3 JUNCTION BOX 15 IGNITER (HSI ONLY)4 TRANSFORMER 16 COMBUSTION AIR INLET5 BLOCKED DRAIN PRESSURE SWITCH 17 GAS VALVE6 MAIN PRESSURE SWITCH 18 INDUCED DRAFT BLOWER7 EXHAUST TRANSITION 19 CAPACITOR 8 CONNECTOR 20 LOW VOLTAGE (THERMOSTAT)9 OUTLET AIR PIPE TERMINAL10 SHIPPING PLUG 21 CONTROL MOUNTING PLATE11 FLAME SENSOR 22 BLOWER12 OVERTEMPERATURE SWITCH

I409 I409

5

SAFETY INFORMATION

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

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

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

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

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

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

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

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

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

DO NOT USE THIS FURNACEDURING CONSTRUCTION IF AIRLADEN CORROSIVECOMPOUNDS ARE PRESENTSUCH AS CHLORINE ANDFLUORINE. OTHERWISE,PROVISIONS MUST BE TAKEN TOPROVIDE CLEAN,UNCONTAMINATEDCOMBUSTION AND VENTILATIONAIR TO THE FURNACE. FURNACECOMBUSTION AND VENTILATIONAIR CONTAMINATED WITH THESECOMPOUNDS FORMS ACIDSDURING COMBUSTION WHICHCORRODES THE HEATEXCHANGER AND COMPONENTPARTS. SOME OF THESECONTAMINANTS ARE FOUND IN,BUT NOT LIMITED TO, PANELING,DRY WALL, ADHESIVES, PAINTS,STAINS, VARNISHES, SEALERS,AND MASONRY CLEANINGMATERIALS.

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

6

GENERAL INFORMATION

DO NOT USE THIS FURNACEDURING CONSTRUCTION IF AIRLADEN CORROSIVECOMPOUNDS ARE PRESENTSUCH AS CHLORINE ANDFLUORINE. OTHERWISE,PROVISIONS MUST BE TAKEN TOPROVIDE CLEAN,UNCONTAMINATEDCOMBUSTION AND VENTILATIONAIR TO THE FURNACE. FURNACECOMBUSTION AND VENTILATIONAIR CONTAMINATED WITH THESECOMPOUNDS FORMS ACIDSDURING COMBUSTION WHICHCORRODES THE HEATEXCHANGER AND COMPONENTPARTS. SOME OF THESECONTAMINANTS ARE FOUND IN,BUT NOT LIMITED TO, PANELING,DRY WALL, ADHESIVES, PAINTS,STAINES, VARNISHES, SEALERS,AND MASONRY CLEANINGMATERIALS.

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

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

1. IMPORTANT: If installing theunit over a finished ceiling orliving area, be certain to installan auxiliary condensate drainpan under the entire unit. Thisauxiliary drain pan should extendunder any evaporator coilinstalled with the furnace and theopen portion of the condensatedrain assembly. See“Condensate Drain/Neutralizer”section for more details.

2. IMPORTANT: If using a coolingevaporator coil with thisfurnace:

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

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

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

! WARNING

! WARNING

3. IMPORTANT: Install thefurnace level. If it is not level,condensate cannot drainproperly, possibly causingfurnace shut down.

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

4.

If this furnace is installed in agarage, attic and/or anyunconditioned space, install aself-regulating heat tapearound the condensate trapand along the entire length ofthe condensate drain in theunconditioned space. SeeFigure 3.

When the condensing horizontalgas furnace is installed in anunconditioned space where thetemperature would be capable ofreaching close to or below 32°F(0°C). a self-regulating heat tapeis required on the condensatedrain, along with an insulationwrap. The heat tape should meetthe following requirements:

a. The heat tape must be ULlisted.

b. The heat tape must beinstalled per themanufacturer’s instructionsfor the entire length of drainpipe in the unconditionedspace.

FIGURE 3HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP

DRAINPIPE

HEATTAPE

TRAP

I526

WARNING!

LOCATION REQUIREMENTS AND CONSIDERATIONS

CAUTION!

7

SITE SELECTION1. Select a site in the building near

the center of the proposed, orexisting, duct system.

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

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

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

DO NOT LIFT THE UNIT BY THEHEAT EXCHANGER TUBES.DOING SO CAN CRACK THE HEATEXCHANGER ASSEMBLY ANDCAUSE CO2 TO BE RELEASEDINTO THE ENVIRONMENT, WHICHCAN RESULT IN PERSONALINJURY OR DEATH.

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

c. The heat tape should berated at 5 or 6 watts per footat 120V.

IMPORTANT: Support this unitwhen installed. Since thisfurnace is suitable for attic orcrawl space installation, it maybe installed on combustiblewood flooring or by using supportbrackets. See Figure 4.

5. IMPORTANT: If installing in autility room, be sure the dooris wide enough to:

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

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

6. IMPORTANT: This furnace isnot approved or recommendedfor installation on its back,with access doors facingupwards.

CLEARANCE -ACCESSIBILITYThe design of forced air furnaces withinput ratings as listed in the tablesunder Figures 5, 6, and 7 are certifiedby CSA-International for theclearances to combustible materialsshown in inches.

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

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

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

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

FIGURE 4HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

! WARNING

Upflow furnaces are shipped with abottom closure panel installed.When bottom return air is used,remove the panel by removing thetwo screws attaching the panel tothe front base angle. See Figure 50.

GASPIPE

TRAP

EXHAUSTFAN

ELECTRICALCONDUIT

INTAKEVENT

I522

! WARNING

8

FIGURE 5CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS

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FIGURE 6CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS

I393

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(IN.

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FIGURE 7CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS

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1111

DUCTINGProper air flow is required for thecorrect operation of this furnace.Too little air flow can cause erraticoperation and can damage the heatexchanger. The duct system mustcarry the correct amount of air forheating and cooling if summer airconditioning is used. Size the ducts according toacceptable industry standards andmethods. The total static pressuredrop of the air distribution systemshould not exceed 0.5" w.c.

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

NEVER ALLOW THE PRODUCTSOF COMBUSTION FROM THEFLUE TO ENTER THE RETURN AIRDUCTWORK OR THECIRCULATED AIR SUPPLY. ALLRETURN DUCTWORK MUST BEADEQUATELY SEALED ANDSECURED TO THE FURNACEWITH SHEET METAL SCREWS;AND JOINTS, TAPED. ALL OTHERDUCT JOINTS MUST BE SECUREDWITH APPROVED CONNECTIONSAND SEALED AIRTIGHT. WHEN ANUPFLOW FURNACE IS MOUNTEDON A PLATFORM WITH RETURNTHROUGH THE BOTTOM, IT MUSTBE SEALED AIRTIGHT BETWEENTHE FURNACE AND THE RETURNAIR PLENUM. THE FLOOR ORPLATFORM MUST PROVIDESOUND PHYSICAL SUPPORT OFTHE FURNACE WITHOUTSAGGING, CRACKS, OR GAPS,AROUND THE BASE, PROVIDING ASEAL BETWEEN THE SUPPORTAND THE BASE.FAILURE TO PREVENTPRODUCTS OF COMBUSTIONFROM BEING CIRCULATED INTOTHE LIVING SPACE CAN CREATEPOTENTIALLY HAZARDOUSCONDITIONS, INCLUDINGCARBON MONOXIDE POISONINGTHAT COULD RESULT INPERSONAL INJURY OR DEATH.DO NOT, UNDER ANYCIRCUMSTANCES, CONNECTRETURN OR SUPPLY DUCTWORKTO OR FROM ANY OTHER HEATPRODUCING DEVICE SUCH AS AFIREPLACE INSERT, STOVE, ETC.DOING SO MAY RESULT IN FIRE,CARBON MONOXIDE POISONING,EXPLOSION, PERSONAL INJURYOR PROPERTY DAMAGE.IMPORTANT: Some high efficiencyfilters have a greater than normalresistance to air flow. This canadversely affect furnace operation.BE SURE TO CHECK AIR FLOW.IMPORTANT: When using outsideair, design and adjust the system tomaintain a return air temperatureABOVE 50° F during the heatingseason.

UPFLOW UNITS1. Position the unit to minimize long

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

2. Open the return air compartment.

UPFLOW FURNACE: A SOLIDMETAL BASE PLATE MUST BEINSTALLED IN THE FURNACEBOTTOM WHEN USING SIDERETURN. FAILURE TO INSTALL ABASE PLATE COULD CAUSE THEPRODUCTS OF COMBUSTION TOCIRCULATE INTO THE LIVINGSPACE AND CREATE POTENTIAL-LY HAZARDOUS CONDITIONS,INCLUDING CARBON MONOXIDEPOISONING OR DEATH.

a. Cut an opening in the side.The opening should be cut the full width of theknockouts on the unit. SeeFigure 8.

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

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

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

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

NOTE: DO NOT use a rear airreturn.

5. If summer air conditioning isdesired, position the indoor coilon the top of the unit. Insure thatno air can bypass this coil.

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

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

DOWNFLOW UNITS1. Position the unit to minimize long

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

2. If summer air conditioning isdesired, position the indoor coilon the bottom of the unit. Insurethat no air can bypass this coil.

3. If installing on a combustible floorand not using an airconditioning plenum, install thespecial non-combustible floorbase. See Figure 9.

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

! WARNING

! WARNING

FIGURE 8CUTOUT AND DRILL INFORMATION

! WARNING

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

1212

GENERAL INFORMATION

READ AND FOLLOW ALLINSTRUCTIONS IN THIS SECTION.FAILURE TO PROPERLY VENTTHIS FURNACE CAN CAUSECARBON MONOXIDE POISONINGOR AN EXPLOSION OR FIRE,RESULTING IN PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.This furnace removes both sensibleand latent heat from the combustionflue gases. Removal of latent heatresults in condensation of flue gaswater vapor. This condensed watervapor drains from the secondary heatexchanger and out of the unit into adrain trap.When installed as a non-direct ventfurnace, only exhaust piping isrequired and inside combustion airmay be used. Refer to section on“COMBUSTION & VENTILATION AIRFOR FURNACE INSTALLATIONS.”Direct vent installations require adedicated combustion air and ventingsystem. All air for combustion is takenfrom the outside atmosphere and allcombustion products are dischargedto the outdoors.

The combustion air and vent pipefittings must conform to AmericanNational Standards Institute (ANSI)and American Society for TestingMaterials (ASTM) standardsD1785 (Schedule 40 PVC), D2665(PVC-DWV), D2241 (SDR-21 andSDR26-26 PVC), D2661 (ABS-DWV)or F628 (Schedule 40 ABS-DWV).NOTE: Cellular core PVC is alsoapproved for use. It must be schedule40PVC-DWV cellular pipemanufactured under ASTM F-891.IMPORTANT: The plasticcombustion air and ventingcomponents are of Schedule 40 PVC.If using ABS piping, ensure that thesolvent cement is compatible forjoining PVC to ABS components oruse a mechanical connection that canwithstand the vent temperatures andare corrosion resistant.NOTE: Schedule 40 ABS-DWV pipeand fittings may be used as analternate to PVC pipe for thecombustion air inlet and vent pipes.

OVERTEMPERATURESAFETY SWITCHESFurnaces are equipped with safetyswitches in the control compartmentto protect against overtemperatureconditions caused by inadequate

combustion air supply. The switchesfor the upflow and downflow modelsare located in the burnercompartment. If a switch is tripped itmust be manually reset.

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

EXISTING VENT SYSTEMSWhen the installation of this furnacereplaces an existing furnace that is

VENTING AND COMBUSTION AIR PIPING

! WARNING

! WARNING

4. Connect the furnace to thesupply air plenum.

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

6. Be sure to have adequatespace for the unit filter.NOTE: DO NOT take return airfrom bathrooms, kitchens,furnace rooms, garages, utility orlaundry rooms, or cold areas.

HORIZONTAL UNITIMPORTANT: THIS FURNACE MAYONLY BE INSTALLED SO ASWHEN FACING THE FRONT OFTHE FURNACE, SUPPLY AIR ISDISCHARGED ON THE LEFT HANDSIDE.1. Position the unit to minimize long

runs or runs with many turns andelbows.

2. If summer air conditioning isdesired, position the indoor coilon the left end of the unit. Insurethat no air can bypass this coil.

3. Connect the furnace to thesupply air plenum.

4. Connect the return air ducting tothe return air opening at the rightend of the unit. Make theconnection air tight to preventpulling combustion gases froman adjacent fuel-burningappliance.

5. Be sure to have adequatespace for the unit filter.NOTE: DO NOT take return airfrom bathrooms, kitchens,furnace rooms, garages, utility orlaundry rooms, or cold areas.

FIGURE 9COMBUSTIBLE FLOOR BASE

1313

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

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

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

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

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

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

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

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

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

openings in the common ventingsystem.

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

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

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

5. Test for spillage at the draft hoodrelief opening after 5 minutes ofmain burner operation. Use theflame of a match or candle, orsmoke from a cigarette, cigaror pipe.

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

7. If improper venting is observedduring any of the above tests, thecommon venting system must beresized. See vent tables in theseinstructions

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

JOINING PIPE AND FITTINGS

PVC SOLVENT CEMENTS ANDPRIMERS ARE HIGHLYFLAMMABLE. PROVIDEADEQUATE VENTILATION AND DONOT ASSEMBLE NEAR HEATSOURCE OR AN OPEN FLAME. DONOT SMOKE. AVOID SKIN OR EYECONTACT. OBSERVE ALLCAUTIONS AND WARNINGSPRINTED ON MATERIALCONTAINERS. FAILURE TOFOLLOW THESE GUIDELINES MAYRESULT IN FIRE, EXPLOSION ORASPHYXIATION CAUSINGPERSONAL INJURY OR DEATH.All pipe, fittings, solvent cement,primers and procedures mustconform to American NationalStandard Institute and AmericanSociety for Testing and Materials(ANSI/ASTM) standards in the U.S.Pipe and Fittings - ASTM-D1785,D2466, D2665, D2231, D2661 andF628.PVC Primer and Solvent Cement -ASTM-D2564ABS Pipe and Fittings - Use ABSPrimer and Solvent Cement D2235Procedure for Cementing Joints -ASTM-D2855IMPORTANT: The plasticcombustion air and ventingcomponents are of PVC. If using ABSpiping, ensure that the solventcement is compatible for joining PVCto ABS components or use amechanical connection that canwithstand the vent temperatures andare corrosion resistant.

! WARNING

1414

NON-DIRECTFURNACE INSTALLATIONS

THE FURNACE AND ANY OTHERFUEL-BURNING APPLIANCEMUST BE PROVIDED WITHENOUGH FRESH AIR FORPROPER COMBUSTION ANDVENTILATION OF THE FLUEGASES. MOST HOMES WILLREQUIRE THAT OUTSIDE AIR BESUPPLIED INTO THE FURNACEAREA. FAILURE TO DO SO CANCAUSE PERSONAL INJURY ORDEATH FROM CARBONMONOXIDE POISONING.

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

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

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

• Commercial buildings• Buildings with indoor pools• Furnaces installed in laundry rooms• Furnaces in hobby or craft rooms• Furnaces installed near chemical

storage areas.

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

• Permanent wave solutions• Chlorinated waxes and cleaners• Chlorine-based swimming pool

chemicals• Water softening chemicals• De-icing salts or chemicals• Carbon tetrachloride• Halogen type refrigerants

• Cleaning solvents (such asperchloroethylene)

• Printing inks, paint removers,varnishes, etc.

• Hydrochloric acid• Cements and glues• Antistatic fabric softeners for

clothes dryers• Masonry curing and acid washing

materials

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

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

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

EXAMPLE 1:FURNACE LOCATED IN ANUNCONFINED SPACE

Using indoor air for combustion.

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

BTUH Minimum Sq. Feet Typical Room SizeInput With 8' Ceiling With 8' Ceiling

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

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

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

90,000 563 20’ x 28’ OR 24’ x 24’

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

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

If the open space containing thefurnace is in a building with tightconstruction, outside air may still berequired for the furnace to operateand vent properly. Outside airopenings should be sized the sameas for a confined space.

EXAMPLE 2:FURNACE LOCATED IN ACONFINED SPACE

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

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

A. USING INDOOR AIR FORCOMBUSTION

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

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

COMBUSTION AND VENTILATION AIR

! WARNING

! WARNING

1515

BTUH Free AreaInput Each Opening

45,000 100 square inches






B. USING OUTDOOR AIR FORCOMBUSTION

IMPORTANT: Do not take airfrom an attic space that isequipped with powerventilation.

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

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

a. Where directly communicatingwith the outdoors or wherecommunicating to the outdoors

through vertical ducts as shown inFigure 11, each opening shallhave a minimum free area of 1square inch for each 4,000 BTUHof total appliance input rating in theenclosure.

BTUH Free Area Round PipeInput Each Opening Size

45,000 11.25 square inches 4"






b. Where communicating withoutdoors through horizontal ducts,each opening shall have aminimum free area of 1 squareinch for each 2,000 BTUH of totalinput rating of all equipment in theenclosure (Seee Figure 12).

Here are some typical sizes:








FIGURE 11AIR FROM ATTIC/CRAWL SPACE

FIGURE 12OUTSIDE AIR USING A HORIZONTAL DUCT

FIGURE 10AIR FROM HEATED SPACE

NOTE:EACH OPENING SHALLHAVE A FREE AREA OF NOTLESS THAN ONE SQUAREINCH PER 1,000 BTU PERH0UR OF THE TOTAL INPUTRATING OF ALLEQUIPMENT IN THEENCLOSURE, BUT NOTLESS THAN 100 SQUAREINCHES.

GASWATERHEATER

FURNACE

GASWATERHEATER

GASWATERHEATER

FURNACE FURNACE

12" MAX.12"

MAX.

1 SQ. INCH PER4000 BTUH INLET AIR

OUTLET AIR 1 SQ. INCHPER 2000 BTUH

INLET AIR 1 SQ. INCHPER 2000 BTUH

1 SQ. INCH PER4000 BTUH

OUTLET AIR

OP

TIO

NA

L 1

SQ

. IN

CH

PE

R 4

000

BT

UH

INLE

T A

IR

VENTILATEDATTIC GABLE ORSOFFIT VENTS

GABLEVENTOUTLET AIR

IN ATTICMUST BEABOVEINSULATION

1616

FIGURE 13COMBUSTION AIR FITTING

UPFLOW DOWNFLOW/HORIZONTAL

2" PVCDOUBLEELBOW

TOPOPTION

EXHAUST

2" PVC ELBOW

SIDEOPTION

2" PVCDOUBLEELBOW*

COMBUSTION AIREXHAUST

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

*NOTE: WHEN FURNACE IS INSTALLED IN AHORIZONTAL POSITION ONLY ONE 90°ELBOW IS REQUIRED. INSTALL THE ELBOWSO THE OPEN END IS POINTED DOWNWARD.

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

I337 I336

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

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








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

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

Combustion air openings must not berestricted in any manner.

CONSULT LOCAL CODES FORSPECIAL REQUIREMENTS.

CONNECTION TOFURNACEIMPORTANT: When indoorcombustion air is used, the inlet airopening at the furnace must beprotected from accidental blockage.On upflow models, install a 90° elbowpointing downward in the side inlet airopening or a double elbow pointingdownward in the top inlet air opening.On downflow/horizontal models,install a double elbow in the top inletair opening. See Figure 13.

1717

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

NON-DIRECT VENTINSTALLATIONGUIDELINESIMPORTANT: Failure to correctlyfollow all venting guidelines mayresult in erratic furnace operation,freeze-up of combustion air orexhaust air piping or sooting of thefurnace.All exhaust piping must be installed incompliance with Part 7, “Venting ofEquipment,” of the latest edition of theNational Fuel Gas Code NPFA54/ANSI Z223.1-, local codes orordinances and these instructions.1. Vertical piping is preferred.2. All horizontal piping must slope

upward a minimum of 1/4 inchper foot of run so thatcondensate drains toward thefurnace.

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

4. IMPORTANT: Do not commonvent with any other appliance.Do not install in the same chaseor chimney with a metal or hightemperature plastic pipe fromanother gas or fuel-burningappliance unless the requiredminimum clearances tocombustibles are maintainedbetween the PVC pipe and otherpipes.

5. All vent runs throughunconditioned spaces wherebelow-freezing temperatures areexpected should be insulatedwith 1-in. thick, medium-density,foil-faced fiberglass. Anequivalent “arm-a-flex” or

FIGURE 14TEE TERMINAL – FOR STANDARDHORIZONTAL SINGLE PIPEINSTALLATION

FIGURE 15ALTERNATE HORIZONTAL TERMINATION FOR NON-DIRECT VENTINSTALLATIONS

12"

FROM

24"MAX.

PIPESUPPORTSTRAP

OUTSIDEWALL

VENT

12" 12" MIN. ABOVEGRADE OR

SNOW LEVEL

I198

NUMBERS OF ELBOWS45° OR 90°

Medium / Long Radius ONLY

1-2 3-4 5-6

45,000 2”Standard 60 55 50

Alternate 55 50 45

2”Standard 35 30 25

Alternate 30 25 2060,000

3”Standard 120 120 115

Alternate 120 120 110

2”Standard 20 15 10

Alternate NR NR NR75,000

3”Standard 110 105 95

Alternate 80 70 65

90,000 3”Standard 90 85 75

Alternate 60 50 45

105,000 3”Standard 80 75 65

Alternate 50 40 35

120,000 3”Standard 70 65 55

Alternate 40 30 25

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

ALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.3. A 45° DEGREE ELBOW IS CONSIDERED ONE ELBOW.

FURNACEINPUT

VENT PIPE INSTALLATION

PIPESIZE

TERMINATION

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

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

1818

“rub-a-tex” insulation may also beused as long as there is no heattape applied to the vent pipe. Forhorizontal runs where water maycollect, wrap the vent pipe withself-regulating 3 or 5 watt heattape. The heat tape must beU.L. listed and installed per themanufacturer’s instructions.

6. The minimum vent pipe length is5 feet.

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

Size the exhaust pipe as specified inTable 1. This table lists the maximumallowable length in feet of the exhaustpipe that may be used for all furnaceinputs as related to the number ofelbows required and the termination.(See shaded area.)

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

Horizontal vent terminations require a2-in. PVC tee positioned 12 inches fromthe outside wall. See exhaust piperequirements, Figure 21. When 3-in.pipe is used from the furnace to theoutside wall, reduce it to 2 inchesbefore penetrating the wall. A maximumof 18 inches of 2-in. pipe may be usedinside the wall.

An alternate termination may be usedas shown in Figure 15 to clearanticipated snow levels. The tee maybe raised up to 24 inches above thewall penetration. Use two medium-radius bend, 2-in. PVC elbows and alength of 2-in. PVC pipe so that theelbows are on 24-in. centers.

NON-DIRECT VENT TERMINATIONLOCATION REQUIREMENTS

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

INSTALLATION CAN CAUSESTRUCTURAL OR EXTERIORFINISH DAMAGE TO THEBUILDING.

Non-direct venting locationrequirements are slightly different insome cases than direct venting. Installa non-direct vent with the followingminimum clearances.See Figure 16.

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

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

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

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

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

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

! CAUTION

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

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

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

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

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

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

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

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

19

FIGURE 16OTHER THAN DIRECT VENT TERMINAL CLEARANCES

Nat

ural

Gas

and

Pro

pan

e In

stal

latio

n C

ode

Nat

iona

l Fue

l Gas

Cod

e

Can

adia

n In

stal

lati

on

sU

S In

stal

lati

on

sC

anad

ian

Inst

alla

tio

ns

US

Inst

alla

tio

ns

20

DIRECT VENTINSTALLATIONS

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

Direct vent installations require adedicated combustion air and ventingsystem. All air for combustion is takenfrom the outside atmosphere and allcombustion products are dischargedto the outdoors. Therefore, noventilation or combustion airopenings are required.

IMPORTANT: The plasticcombustion air and ventingcomponents are of Schedule 40 PVC.If using ABS piping ensure that thesolvent cement is compatible forjoining PVC to ABS components oruse a mechanical connection that canwithstand the vent temperatures andare corrosion resistant.

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

1. Vertical piping is preferred.

2. All horizontal piping must slopeupward a minimum of 1/4 inchper foot of run so that condensatedrains toward the furnace.

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

4. IMPORTANT: Do not commonvent with any other appliance.Do not install in the same chaseor chimney with a metal or hightemperature plastic pipe fromanother gas or fuel-burningappliance unless the requiredminimum clearances tocombustibles are maintainedbetween the PVC pipe and otherpipes.

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

6. The minimum vent pipe length is5 feet.

Size the exhaust and combustion airintake pipes as specified in Table 2.This table lists the maximum allow-able length in feet of the exhaust andcombustion air intake pipes that maybe used for all furnace inputs asrelated to the number of elbowsrequired and the termination (seeshaded area).

7. The maximum exposed ventlength (above the roof line) is30�.

! WARNING

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

Alternate RXGY-D02 55 50 45

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

Alternate RXGY-D02 30 25 2060,000

Standard/Concentric RXGY-D03/RXGY-E03 120 120 1203”


Standard/Concentric RXGY-D02//RXGY-E03 20 15 10

75,000

2”Alternate Not Recommended NR NR NR

Standard/Concentric RXGY-D03/RXGY-E03 120 120 120

3” Alternate RXGY-D03 100 95 85





Standard/Concentric RXGY-D03/RXGY-E03 45 35 30

120,000 3” Alternate RXGY-D03 45 35 30


NOTES:1.N.R. - NOT RECOMMENDED.

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

3.A 45 DEGREE ELBOW IS CONSIDERED ONE ELBOW.

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

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

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

FURNACEINPUT

PIPESIZE

TERMINATION

VENT TERMINATIONKIT RECOMMENDED(RXGY-D0* Kits for

Horizontal Venting Only) 1 - 2 3 - 4 5 - 6

NUMBER OF ELBOWS45° or 90°

Medium / Long Radius ONLY

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

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

21

ALTERNATETERMINATIONSALTERNATE HORIZONTALDIRECT VENT TERMINATIONS

KIT NOS. RXGY-D02, -D03AND -D04

The combustion air and exhaustterminations may be raised amaximum of 60 inches above thewall penetration to maintain therequired 12 inch clearance abovegrade or snow level. See Figure 17.Size the pipe length according toTable 2.

IMPORTANT: The followingguidelines must be met whenextending beyond 24 inches of pipeon the exterior of the structure:

• Size the entire vent systemaccording to the alternate, notstandard, termination shown inTable 2.

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

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

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

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

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

STANDARD TERMINATIONSSTANDARD VERTICALTERMINATIONS

COMBUSTION AIR PIPING

Use two medium-radius sweepelbows to keep the inlet downward toprevent entry of rain. See Figure 19for the proper relationship ofcombustion air to exhausttermination.

STANDARD HORIZONTALTERMINATIONS

COMBUSTION AIR PIPING

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

The standard horizontal intake airtermination for all models is a 2-in.PVC coupling with a wind deflectorvane (provided) attached. Cut a21/4-in. length of 2-in. PVC pipe.Connect this pipe and another 2-in.PVC coupling to the coupling at thewall. The outer coupling mustterminate 4 inches from the wall. SeeFigure 20, Detail B, for vane location.Attach vane in vertical position withPVC solvent.

IMPORTANT: To ensure properfurnace operation, the suppliedvane must be installed in thevertical position as shown in Figure20, Detail B.

The combustion air inlet terminalmust be located with respect to theexhaust terminal as shown in Figure20, Detail C.

IMPORTANT: All furnaces withhorizontal air intakes, except thoseusing concentric vent kit RXGY-E03, must have a drain teeassembly and trap installed asclose to the furnace as possible.This is to drain any water that maybe in the combustion air pipe toprevent it from entering thefurnace combustion chamber.

These parts are included in kitsRXGY-D02 (for 2-in. pipe), RXGY-D03 (for 3-in. pipe) and RXGY-D04(special for the 120,000 BTUfurnace installed with the alternatehorizontal termination). Attach thetrap to the bottom of the tee withPVC solvent. Connect the otherend to a suitable drain, as to thedownstream of a condensate trapon the furnace.

STANDARD VERTICALTERMINATIONS

EXHAUST VENT PIPING

Vertical through-the-roof ventapplications do not require anexhaust terminal. The exhaust ventmust terminate at least 12 inchesabove the combustion intake airtermination. The exhaust vent formodels with inputs of 90,000 through120,000 BTUH is 2-in. PVC pipe120,000 BTUH models withexcessively long runs require 21/2”.

Refer to Table 2 for properapplication. This mustbe reduced to 1” or 11/2“ the last12 inches for models with inputs of45,000 through 75,000 BTUH.See Figure 23.

STANDARD HORIZONTALTERMINATIONS

EXHAUST PIPING

For direct vent systems the standardtermination is 2-in. PVC pipeextending 12 inches from the wall forfurnaces with inputs from 105,000 to120,000 BTUH. Install a 2-in. couplingat the outside wall to prevent thetermination from being pushedinward. When 3-in. pipe is usedbetween the furnace and outside wall,reduce to 2 inches before penetratingthe wall. The standard termination is11/2 -in. PVC pipe extending outward12 inches from the wall for modelswith inputs of 45,000 to 75,000BTUH. Install a 2-in. to 11/2-in.coupling at the outside wall to preventpushing the termination back into thewall. See Figure 20, Detail B.

The combustion air and exhaustterminations must be at least 12inches above grade and must beoriented with respect to each other asshown in Figure 20. Refer to sectionon alternate venting options whenhigher snow levels are anticipated.

22

FIGURE 17ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

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

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

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

From the top elbow in the exhaustpipe, extend a length of PVC pipeoutward so that it terminates exactly12 inches from the wall. See Figure17. Reduce the termination pipeextension to is 11/2 inch pipe for45,000 BTUH through 75,000 BTUHunits.

The 45,000 BTUH unit only uses kitRXGY-D02. The 60,000 BTUH and75,000 BTUH units may use kitsRXGY-D02 or RXGY-D03 dependingon pipe lengths and number ofelbows. Use kit RXGY-D03 with90,000 BTUH through 120,000 BTUHunits. The RXGY-D04 kit onlyapplies to the 120,000 BTUH unitusing an alternate termination andlong runs. See Table 2.

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

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

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

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

10. vent template

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

SEE DETAIL A

60” MAX.

PIPESUPPORTSTRAP

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

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

2" PVC FOR MODELS WITH INPUTS OF 90,000 AND120,000 BTU. REDUCE TO 11/2" FOR MODELS WITHINPUTS OF 45,000 THRU 60,000 BTU (SEE DETAIL A).ELBOWS AND RISERS ARE 2" PVC.

INTAKE VENT21/2" PVC FOR MODELS WITH120,000 BTU INPUT.2" PVC ELBOWS AND RISERMODELS WITH INPUTS OF 45,000THRU 120,000 BTU.USE KIT NO. RXGY-D02 WHEN 2" PIPEIS USED BETWEEN FURNACE ANDOUTSIDE WALL. USE KIT NO. RXGY-D03WHEN 3" PIPE IS USED.

I339

12” FROM W

ALL

3”

4”EXHAUST

INTAKE OPTIONALINTAKE

DETAIL BEXHAUST / INTAKE RELATIONSHIP

DETAIL AEXHAUST VENT FOR

MODELS WITHINPUT OF 45,000 THRU

60,000 BTU

12” FROM WALL

1 1/2” PIPE

23

FIGURE 18CONCENTRIC VENT KIT NO. RXGY-E03

SIDEWALL ASSEMBLY

ROOF INSTALLATION

1" MAXIMUM

FIELD-SUPPLIEDSTRAP

ITEM No. DESCRIPTION

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

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

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

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

E PVC RAINCAP

E

B

A

C

D

E

B

A

C

D

CONCENTRIC TERMINATIONSVERTICAL/HORIZONTAL CONCENTRIC VENTKIT NO. RXGY-E03

This kit is for vertical/horizontalintake air/vent runs and may beinstalled through roofs andsidewalls. One 5” diameter hole isrequired for the installation. SeeFigure 18 for the general layout.Complete installation instructionsare included with the kit.

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

24

FIGURE 19STANDARD VERTICAL DIRECT VENTINGUPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW MODELS)

FIGURE 20STANDARD HORIZONTAL DIRECT VENTINGUPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW MODELS)

I407

3" MAX.SEPARATION

COMBUSTION AIRPIPE

12" MIN.SEPARATION

12" MIN. ABOVEROOF LEVELROOF LINEEXHAUST PIPE

COMBUSTION AIR PIPE

SUPPLY AIR

RETURN AIR

EXHAUST VENT

3"MAX.

EXHAUSTVENT

ROOF LINE

COMBUSTIONAIR PIPE

12"MIN.

12" MIN. ANTICIPATEDSNOW LEVEL

COMBUSTIONAIR PIPE

3"MAX.EXHAUST

VENT

12"MIN.

12" MIN.

3"

MAX.

12" MIN. 12" M

IN. ABOVE

ANTICIPATED SNOW LEVEL

5

NOTES:

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

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

3 WHEN 3-IN. DIAM. PIPE IS USED,REDUCE TO 2-IN. DIAMETER BEFOREPENETRATING ROOF. A MAXIMUM OF18 IN. OF 2-IN. PIPE MAY BE USEDBEFORE PASSING THROUGH ROOF.

4 SUPPORT VERTICAL PIPE EVERY 6FEET.

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

6 30” MAXIMUM EXPOSED VENTLENGTH.

PITCHED ROOF INSTALLATIONS

NOTES:

1 SUPPORT HORIZONTAL PIPEEVERY FOUR FEET.

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

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

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

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

6 DETAIL “B”, INSTALL WIND DEFLECTORVANE IN 2 IN. PVC COUPLING IN VERTICLEPOSITION USING PVC SOLVENT.THE COMBUSTION AIR TERMINATIONMUST BE IN THE SAME PRESSURE ZONEAS THE EXHAUST TERMINATION.

3”

12”

4”

4”

SEE DETAIL A

VANE 2” PVCCOUPLING

12” MIN. ABOVEGRADE LEVEL 5

SEE DETAIL B

2” OR 3” TEEW/DRAIN TRAP

RETURN AIR

TRAP

SUPPLY AIR

EXHAUST PIPE

COMBUSTION AIR PIPE

CONNECTTO DRAIN

12”

4”EXHAUST

INTAKE OPTIONALINTAKE

DETAIL CEXHAUST / INTAKE RELATIONSHIP

EXHAUST TERMINATION

DETAIL A

COMBUSTION AIR TERMINATION

DETAIL B

1 23

I407

4

5

5

5

12”

4

6

1

2

3

EXHAUSTTERMINATION

DETAIL A

30� MAX

30� MAX

25

FIGURE 21DIRECT VENT TERMINAL CLEARANCES≤

Nat

ural

Gas

and

Pro

pan

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stal

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ode

Nat

iona

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l Gas

Cod

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lati

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S In

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anad

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Inst

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US

Inst

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2626

LOCATION REQUIREMENTSHORIZONTAL DIRECT VENTS

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

The vent must be installed with thefollowing minimum clearances. SeeFigures 21 & 22.

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

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

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

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

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

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

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

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

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

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

4. Do not extend vent directlythrough brick or masonry

surfaces, unless a rust-resistantsheet metal or plastic backingplate behind vent. See Figure 22.

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

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

7. Caulk all cracks, seams andjoints within 6 feet horizontallyand above and below vent.See Figure 22.

FIGURE 22MOISTURE ZONES

! CAUTION

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

FIGURE 23TWO FURNACE VENTING THROUGH ROOF

8"

MINIMUM 12" ABOVE AVERAGE SNOW ACCUMULATION. MAXIMUM

OF 24 IN. ABOVE ROOF.

2727

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

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

MULTIVENTINGIF VENTING TWO OR MOREFURNACES NEAR EACH OTHER ISREQUIRED, EACH FURNACE MUSTBE INDIVIDUALLY VENTED – NOCOMMON VENTING IS PERMITTED.See Figures 23 and 24 for positioningof the terminations. When more thantwo furnaces are to be vented, theremust be at least 4 feet between thefirst two furnaces and the third, etc.

FIGURE 24TWO FURNACE VENTING THROUGH WALL

EXHAUST VENTMODELS 06-07TO BE REDUCED TO1-1/2” PVC LAST 12”.

3” MINIMUM24” MAXIMUM




TWO-PIPE VENTING

CONCENTRIC VENTING

SEE CONCENTRICVENT SECTION ON PAGE 23FOR MORE INFORMATION.

TWO-PIPE VENTING

CONCENTRIC VENTING

8"

MAXIMUM 1" DISTANCE

FROM WALL

MINIMUM 12" ABOVE GRADE

6' MINIMUM10' RECOMMENDED

SEE CONCENTRIC VENT SECTION ON PAGE 23 FOR MORE INFORMATION.

2828

FIGURE 25UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION

CONNECTING TO FURNACEIMPORTANT: Clean and debur allpipe cuts. The shavings must not beallowed to block the exhaust, inlet orcondensate drain pipes.

UPFLOW FURNACE

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

The inlet combustion air connectionis at the right side of the top plate.An alternate combustion inlet airconnection may be made on the rightside of the jacket. This opening has aplastic cap. A combustion inlet airconnection fitting is supplied with thefurnace and it must be installed in thefurnace by screwing it into theopening. Make sure the rubber“O-ring” supplied with the furnace isused with this fitting. See Figure 25.

DOWNFLOW/HORIZONTALFURNACE

The exhaust pipe connection is a 2-in.upflow only PVC pipe fitting extendingthrough the right side of the furnacetop cover. This opening has a pro-tective cap which should be removedjust prior to installing the exhaustpipe. When 2-in. pipe is used, con-nect it directly to this fitting. When3-in. pipe is used, connect with a2- to 3-in. coupling directly to the2-in. pipe.

The combustion inlet air connection isa 2-in. extruded hole on the left sideof the top plate. When a 2-in. pipe isused, attach a 2-in. PVC couplingover this hole with RTV sealant andalso add two sheet metal screwsthrough the coupling into theextrusion to secure it in place, andadd the required piping. When 3-in.pipe is required, use a 2- to 3-in.coupling and add the required piping.See Figure 26.

FIGURE 26DOWNFLOW/HORIZONTAL COMBUSTION AIR AND VENT PIPE CONNECTION

VENT CAP/PLUG

PIPE - PVC

CONNECTOR

EXHAUST TRANSITION

TOP PLATE

COUPLING

COMBUSTIONAIR CHASE

OUTLET AIR PIPE

I329

I329

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

INDUCED DRAFTBLOWER

CONDENSATE TRAP

CONNECTOR

INDUCED DRAFTBLOWER

PLUG OPT. COMBUSTIONAIR INLET POSITION

NOTE:WHEN COMBUSTION AIR INLET IS INOPTIONAL POSITION SWAP LOCATIONOF INLET AIR ADAPTER AND “O” RINGWITH PLUG.

EXHAUST TRANSITION

OUTLET AIR PIPE

VENT CAP/PLUG

TOP PLATE

“O” RING COMBUSTIONAIR ADAPTER

2929

FIGURE 28DOWNFLOW CONDENSATE DRAIN

CONDENSATE DRAIN/NEUTRALIZER

FIGURE 27UPFLOW CONDENSATE DRAIN

GENERAL INFORMATION

DO NOT RUN DRAIN OUTDOORS.FREEZING OF CONDENSATE CANCAUSE PROPERTY DAMAGE.Important: Do not connect into acommon drain line with an air con-ditioner evaporator coil drain locatedbelow the furnace. A blocked orrestricted drain line can result in over-flow of the coil pan and negate thefurnace blocked drain shutoff control.FILL TRAP ASSEMBLY WITH WATERBEFORE OPERATING THEFURNACE. This can be done byremoving the drain hosefrom the trap and pouring about acup of water into the vent trap. Waterwill flow into the house drain when thetrap is full.If local codes require, install acondensate neutralizer cartridge in thedrain line. Install cartridge in horizontalposition only. Also install an overflowline if routing to a floor drain. SeeFigures 27 and 28. If no floor drain is available, install acondensate pump that is resistant toacidic water. Pumps are available fromyour local distributor. If pump used isnot resistant to acidic water, acondensate neutralizer must be usedahead of the pump. The condensatepump must have an auxiliary safetyswitch to prevent operation of thefurnace and resulting overflow ofcondensate in the event of pumpfailure. The safety switch must be wiredthrough the “R” circuit only (low voltage)to provide operation in either heating orcooling modes.

UPFLOW MODELSThe condensate drain trap is located inthe blower compartment on the left-hand side of the jacket. A short piece of1⁄2-in. PVC pipe and a 1⁄2-in. tee areprovided. Connect the 1⁄2-in. pipe to theelbow on the trap and the tee to thispipe so that the open end is upward.Run a drain tube from the bottom of thetee to a floor drain or condensatepump. IMPORTANT: If installing the unit overa finished ceiling or living area, becertain to install an auxiliary condensatedrain pan under the entire unitextending out under the condensatetee.IMPORTANT: There are two optionswhen choosing a height for thecondensate riser:CONDENSATE OVERFLOW: With a 51⁄2inch riser installed above the tee, ablocked drain will result in overflowfrom the riser.FURNACE SHUTDOWN: To cause thefurnace to shut down when a blocked

drain is present, install a riser which is aminimum of 1013⁄16”. If the furnace isinstalled in an attic, crawlspace or otherarea where freezing temperatures mayoccur, the furnace drain can freezewhile shut off for long periods of time.Use a solvent cement that is compatiblewith PVC material. Cut the drain hosesto the appropriate length and connect tothe trap with hose clamps. Tighten theclamps with pliers and check for leaksafter attaching.

DOWNFLOW MODELSIMPORTANT: There are two optionswhen choosing a height for thecondensate riser:

CONDENSATE OVERFLOW: With a13⁄4 inch riser installed above the tee,a blocked drain will result in overflowfrom the riser.FURNACE SHUTDOWN: To causethe furnace to shut down when ablocked drain is present, install a riserwhich is a minimum of 51⁄2”. If thefurnace is installed in an attic,crawlspace or other area wherefreezing temperatures may occur, thefurnace drain can freeze while shutoff for long periods of time.Use a solvent cement that iscompatible with PVC material.

! CAUTION

NEUTRALIZER CARTRIDGE(OPTIONAL)

CONDENSATE TRAP

DRAIN LINE

I408

I408

1013/16

CONDENSATE TRAP

TO FLOOR DRAIN OR CONDENSATE PUMP

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

DRAIN LINENEUTRALIZER CARTRIDGE (OPTIONAL)

OVERFLOW LINE(REQUIRED ONLY WHENOPTIONAL NEUTRALIZERCARTRIDGE IS USED.)


NOTE:SEE UPFLOW MODELNOTES FOR PIPEHEIGHT

NOTE:SEE DOWNFLOW MODELNOTES FOR PIPE HEIGHT

30

FIGURE 30DOWNFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

30

FIGURE 29UPFLOW OPPOSITE SIDE CONDENSATE TRAP CONNECTION

REVERSING THE TRAPUPFLOW UNITS

The trap may be moved to the rightside for right side drainage. Open theknockout for the drain on the rightside of the cabinet. Remove thebracket holding the trap from the leftside. Seal the left side drain hole witha plug provided in the cloth bag withthe furnace. Position the mountingbracket and trap so that the drainelbow is centered in the hole onthe right. See Figure 29.

Drill two holes in the cabinet to mountthe bracket. Mount the trap andbracket to the right side with the drainelbow pointing through the knockout.Connect the 1/2-in. pipe and tee asnoted above. Route the drain hosesbehind the control box, cut to theappropriate length, and connect to thetrap with hose clamps.

IMPORTANT: DO NOT ALLOWANY SAGS OR KINKS IN THEHOSES. This prevents propercondensate flow.

IMPORTANT: Do not connect intoa common drain line with an airconditioner evaporator coil drainlocated above the furnace. A blockedor restricted drain line can result inoverflow of the coil pan and negatethe furnace blocked drain shutoffcontrol.

DOWNFLOW UNITS

To convert to left side drainage, firstremove the drainage hoses from thetrap. Remove the trap from itsmounting bracket, rotate it 180°, andmount in place with the drainageelbow pointing to the left. Reattachthe drain hoses. Remove the plasticdrainage knockout from the left side.See Figure 30.

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

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

IMPORTANT: Do not connect intoa common drain line with an airconditioner evaporator coil drainlocated above the furnace. A blockedor restricted drain line can result inoverflow of the coil pan and negatethe furnace blocked drain shutoffcontrol.

CUT DRAIN HOSES ASREQUIREDAND CONNECT TOINLETS ON TOPOF CONDENSATETRAP

DRAINRISER

TEE

DRAINEXTENSION

PROPER DRAIN SLOPE REQUIRED(NO KINKS ALLOWED)

CONDENSATE TRAPIFC MOUNTING

PLATE

TO FLOORDRAIN

FILLING THE TRAPFILL THE TRAP ASSEMBLY WITHWATER BEFORE OPERATING THEFURNACE. Do this by removing thedrain hose from the trap or from theconnection to the secondary coil.Pour about a cup of water into thevent trap. Any excess water flows intothe house drain when the trap is full.

I394

I394

TEE

DRAINEXTENSION

DRAINRISER

TO FLOORDRAIN OR

CONDENSATE PUMPCONDENSATE TRAP

ROTATETRAP 180°AND INSTALLRIGID PIPE(SUPPLIED)FROMELBOW TOOPPOSITESIDE OFJACKET

3131

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

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

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

11. Attach the end of the ribbed tube➂ to the 45° elbow molded intothe top of the trap assemblyusing a black nylon clamp.

IMPORTANT: Tighten all clampconnections with a pair of pliersand check for leaks afterconversion is complete.

12. IMPORTANT: There are twooptions when choosing a heightfor the condensate riser:

CONDENSATE DRAINFOR HORIZONTALINSTALLATIONRefer to Figure 32 for Steps 1-5.

1. This unit is shipped factory readyfor downflow installation. Thecondensate trap assembly anddrain hoses require conversionfor horizontal installation.Remove the existing condensatetrap with the unit in the uprightposition.

2. Remove the burner compartmentdoor from the unit.

3. Remove the two screws from theright side of the furnace jacketwhich support the trap mountingbracket ➁ . Remove the twoplastic plugs on either side of thetrap outlet hole and discard.

4. Remove the (L-shaped) clearvinyl drain tube ➂ from the top ofthe existing trap ➀ .

Do not disconnect the short endfrom the furnace collector box.

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

NOTE: The following steps shouldtake place with the furnace in thehorizontal position.

Refer to Figure 33 for Steps 6-11.

6. Locate the parts bag in theburner compartment. Install twoplastic plugs ➅ in the side of thejacket from bottom side up.

7. Fill the trap assembly ➆ with 1/2cup of water.

FIGURE 31DOWNFLOW CONDENSATE DRAIN

I408

11

CONDENSATE TRAP

DRAIN LINE

NEUTRALIZER CARTRIDGE(OPTIONAL)


NOTE:SEE GENERAL NOTES FORHORIZONTAL MODELSFOR PIPE HEIGHT.

OVERFLOW LINE(REQUIRED ONLY WHEN

OPTIONAL NEUTRALIZERCARTRIDGE IS USED.)

CONDENSATE OVERFLOW:With a 13⁄4 inch riser installedabove the tee, a blocked drainwill result in overflow from theriser.

FURNACE SHUTDOWN: Tocause the furnace to shut downwhen a blocked drain is present,install a riser which is a minimumof 51⁄2”. If the furnace is installedin an attic, crawlspace or otherarea where freezingtemperatures may occur, thefurnace drain can freeze whileshut off for long periods of time.

Use a solvent cement that iscompatible with PVC material.

3232

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ION

3333

GAS SUPPLY AND PIPINGGAS SUPPLY

THIS FURNACE IS EQUIPPED ATTHE FACTORY FOR USE ONNATURAL GAS ONLY.CONVERSION TO LP GASREQUIRES A SPECIAL KITSUPPLIED BY THE DISTRIBUTOROR MANU-FACTURER. MAILINGADDRESS IS LISTED ON THEWARRANTY. FAILURE TO USETHE PROPER CONVERSION KITCAN CAUSE FIRE, CARBONMONOXIDE POISONING,EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURY ORDEATH. See the conversion kitindex supplied with the furnace.This index identifies the proper LPGas Conversion Kit required foreach particular furnace.

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

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

IMPORTANT: A U.L. recognizedfuel gas and CO detector(s) arerecommended in all applications,and their installation should be inaccordance with the manufacturer’srecommendations and/or local laws,rules, regulations or customs.

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

If possible, run a separate gas supplyline directly from the meter to thefurnace. Consult the local gascompany for the location of themanual main shut-off valve. The gasline and manual gas valve must beadequate in size to prevent unduepressure drop and never smallerthan the pipe size to the com-bination gas valve on the furnace.Refer to Table 3 for the recom-mended gas pipe size. See Figure 34for typical gas pipe connections.

! WARNING

FIGURE 34GAS PIPING INSTALLATION

GROMMET

TOP VIEW OF GAS LINE AND VALVEIN OPT. POSITION

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

OPT. GAS LINEPOSITION

PLUG(IN NORMALPOSITION)

MANIFOLDPRESSURETAP

IGNITOR

MANIFOLD

GAS VALVEUNION

DRIP LEG

GROMMET(IN NORMALPOSITION)

4 TO 5 FEETABOVE FLOORREQ’D BYSOMEUTILITIES.

MAIN GASVALVE

BURNERS

GROMMET

TOP VIEW OF GAS LINE AND VALVEIN OPT. POSITION

MAIN GASVALVE

4 TO 5 FEET ABOVEFLOOR REQ’D BYSOME UTILITIES.

GROMMET(IN NORMALPOSITION)

DRIP LEG

UNION

GAS VALVE

BURNERSMANIFOLD

IGNITOR

MANIFOLDPRESSURETAP

PLUG(IN NORMALPOSITION)

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

DOWNFLOW

I328

UPFLOW

MANUAL GAS VALVE

UNION

DRIP LEG

BURNERS

MANIFOLD

GAS VALVEI524

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

HORIZONTAL

3434

FIGURE 36TYPICAL GAS VALVES

HONEYWELLPRESSURE

CONTROL REGULATORKNOB ADJUSTMENT

NEVER PURGE A GAS LINE INTOTHE COMBUSTION CHAMBER.NEVER USE MATCHES, FLAME ORANY IGNITION SOURCE FORCHECKING LEAKAGE. FAILURETO ADHERE TO THIS WARNINGCAN CAUSE A FIRE OREXPLOSION RESULTING INPROPERTY DAMAGE, PERSONALINJURY OR DEATH.

To check for gas leakage, use anapproved chloride-free soap andwater solution, an electronic com-bustible gas detector (see Figure 35),or other approved method.

GAS VALVEThis furnace has a 24-volt operatedvalve. It has ports for measuringsupply pressure and manifoldpressure. The valve body contains apressure regulator to maintain propermanifold pressure.

Install a ground joint union insidethe cabinet to easily remove thecontrol valve assembly. Install amanual shut-off valve in the gasline outside the furnace casing.The T-valve should be readilyaccessible to turn the gas supply onor off. Install a drip leg in the gassupply line as close to the furnace aspossible. Always use a pipecompound resistant to the action ofliquefied petroleum gases on allthreaded connections.

IMPORTANT: When making gas pipeconnections, use a back-up wrench toprevent any twisting of the controlassembly and gas valve.

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

IMPORTANT: Do not run a flexiblegas connector inside the unit. If localcodes allow the use of a flexible gasappliance connector, always use anew listed connector. Do not use aconnector which has previouslyserviced another gas appliance.Massachusetts law requires that allflexibile connectors be less than 36”.

The gas pipe gasket in the cabinetdoes not seal around a flexi-ble gasconnector. It is important to have allopenings in the cabinet burnercompartment sealed for properfurnace operation.

IMPORTANT: ENSURE that thefurnace gas control valve not besubjected to high gas line supplypressures.

DISCONNECT the furnace and itsindividual shut-off valve from the gassupply piping during any pressuretesting that exceeds 1/2 PSIG. (3.48 kPa).

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

The minimum supply pressure to thegas valve for proper furnace inputadjustments is 5" w.c. for natural gas,however 6" to 7" is recommended.The minimum supply pressure is 11"w.c. for LP gas.

! WARNING

FIGURE 35ELECTRONIC COMBUSTIBLE GASDETECTOR

TABLE 3NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.)

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

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

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

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

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

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

A manual control is on the valvebody. It can be set to only the “ON”or “OFF” positions. The gas valve isa slow-opening valve. See Figure 36.

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

ROBERTSHAWCONTROL KNOB

3535

LP CONVERSIONNOTE: See Page 38 for CanadianHigh-Altitude Derate

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

The valve can be converted to useliquified petroleum (LP) gas byreplacing the pressure regulatorspring with the conversion kit spring.This LP kit spring allows the regulatorto maintain the proper manifoldpressure for LP gas. The correctburner LP orifices are included inthe kit. See Figure 37.

NOTE: Order the correct LPconversion kit from the furnacemanufacturer. Furnace conversionto LP gas must be performed by aqualified installer, service agencyor the gas supplier.

To change orifice spuds for eitherconversion to LP or for elevation:

1. Shut off the manual main gasvalve and remove the gasmanifold.

2. Replace the orifice spuds.

3. Reassemble in reverse order.

Consult the following table if there isany question concerning orificesizing.

ORIFICE SIZES

US 0 - 7999 FT. 8000 FT. & ABOVE

Natural Gas #50 #51

LP Gas 1.15 mm 1.10 mm

CANADIAN 0 - 2000 FT. 2001-4500 FT.

Natural Gas #50 #50

LP Gas 1.15 mm 1.15 mm

4. Turn the gas supply back on andcheck for proper operation andmanifold pressure. See Figures37, 38 and 39.

5. Attach the notice label alertingthe next service technician thatthe furnace has been convertedto LP gas.

FIGURE 37TYPICAL LP KIT CONTENTS

3636

TABLE 4LP GAS PIPE CAPACITY TABLE (CU. FT./HR.)

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

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

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

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

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

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

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

Supply Gas Pressure Measure-ment. A line pressure tap is on theinput side of the gas valve. SeeFigure 39.

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

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

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

4. Note or adjust the line gaspressure to give:

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

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

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

6. Replace the pressure tap plugbefore turning on the gas.

If the supply gas line pressure isabove these ranges, install an in-linegas regulator to the furnace fornatural gas units. With LP gas, have

FIGURE 39MANIFOLD PRESSURE TAP

the LP supplier reduce the linepressure at the regulator.

If supply gas line pressure is belowthese ranges, either remove anyrestrictions in the gas supply piping orenlarge the gas pipe. See Tables 3and 4. With LP gas, have the LPsupplier adjust the line pressure atthe regulator.

Manifold Gas PressureMeasurement. Natural gasmanifold pressure should be 3.5"w.c. LP gas manifold pressureshould be 10.0" w.c. Only smallvariations in gas pressure should bemade by adjusting the pressureregulator.

1. With the gas to the unit shut offat the manual gas valve, removethe pressure tap plug in the gasmanifold. See Figure 38.

2. Connect a U-Tube manometer tothis pressure tap. See Figure 39.

3. Turn on the gas supply andoperate the furnace.

4. Note or adjust the manifold gaspressure to give:

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

B. 10.0" w.c. for LP gas.

5. To adjust the pressure regulator,remove the regulator cap.

6. Turn the adjustment screwclockwise to increase pressure,or counterclockwise to decreasepressure.

7. Securely replace the regulatorcap.

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

9. Replace the manifold pressuretap plug before turning onthe gas.

3737

FIGURE 40MANIFOLD PRESSURE READING

FIGURE 41UPFLOW GROUNDING CONNECTIONS

JUNCTIONBOX

CONDENSATETRAP

CONTROL IS GROUNDEDWHEN ATTACHED TO BLOWER

LOW VOLTAGETERMINALS

IFCMOUNTINGPLATE

BLOWERCOMPARTMENT

I409-3

38

TABLE 5ALTERNATE METHOD FOR CANADIAN HIGH-ALTITUDE DERATE

NATURAL GAS LP GAS

FIGURE 42MANIFOLD PRESSURE-CHANGE LABEL

THE MANIFOLD PRESSURE OF THIS APPLIANCE HAS BEEN FIELD ADJUSTED TO OBTAIN THE CORRECT INPUT RATING FOR INSTALLATION AT ALTITUDES

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

LA PRESSION DU DISTRIBUTEUR D'ALIMENTATION DE CET APPAREIL A ÉTÉ AJUSTÉ SUR LES LIEUX AFIN D'OBTENIR LA BONNE PUISSANCE D'ENTRÉE POUR

UNE INSTALLATION ENTRE 2000 ET 4500 PIEDS D'ALTITUDE.

92-24399-01-01

ALTERNATE METHOD FORCANADIAN HIGH-ALTITUDEDERATEIn Canada, unless an orifice change isspecifically mandated by local codes, analternate method of altitude derationthrough a reduction in manifold pressureis acceptable as described in Table 5.

The information in Table 5 is based on aheating value of 1000 BTU per cubic feetof natural gas, and 2500 BTU per cubicfeet of LP gas.

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

Once this field adjustment has beenmade, the label shown in Figure 42 mustbe affixed in a conspicuous location onthe front of the furnace cabinet:

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

ALTITUDE INPUT OUTPUTORIFICE

SIZEMANIFOLDPRESSURE

0’ - 2000’

45,00060,00075,00090,000

105,000120,000

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

#50 3.5” W.C.

2001’ - 4500’

40,50054,00067,50081,00094,500

108,000

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

#50 3.0” W.C.

ALTITUDE INPUT OUTPUTORIFICE

SIZEMANIFOLDPRESSURE

0’ - 2000’

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

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

1.15mm 10” W.C.

2001’ - 4500’

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

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

1.15mm 7.6” W.C.

39

appropriate wiring diagram located onthe inside cover of the furnace controlbox and in these instructions.

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

NOTE: L1 (hot) and L2 (neutral) polaritymust be observed when making fieldconnections to the furnace. The ignitioncontrol may not sense flame if L1 and L2are reversed. See Figure 43.

Make all electrical connections inaccordance with the latest edition of theNational Electrical Code ANSI/NFPA70and local codes having jurisdiction.

FIGURE 44ISOLATION RELAY

ST-A0804-01

FIGURE 43LINE VOLTAGE CONNECTIONS

UT ELECTRONIC CONTROLS 1028-928 CONTROL BOARDS

UT ELECTRONIC CONTROLS 1012-925 CONTROL BOARD

I677

ELECTRICAL WIRING

TURN OFF ELECTRIC POWER ATFUSE BOX OR SERVICE PANELBEFORE MAKING ANYELECTRICAL CONNECTIONS.FAILURE TO DO SO CAN CAUSEELECTRICAL SHOCK RESULTINGIN PERSONAL INJURY OR DEATH.

THE CABINET MUST HAVE ANUNINTERRUPTED GROUNDACCORDING TO THE LATESTEDITION OF THE NATIONALELECTRICAL CODE, ANSI/NFPA70- OR IN CANADA, THECANADIAN ELECTRICAL CODE,CSA-C221 OR LOCAL CODESTHAT APPLY. DO NOT USE GASPIPING AS AN ELECTRICALGROUND. A GROUND SCREW ISPROVIDED IN THE JUNCTIONBOX. FAILURE TO DO SO CANCAUSE ELECTRICAL SHOCKRESULTING IN PERSONALINJURY OR DEATH.

THIS FURNACE IS EQUIPPEDWITH A BLOWER DOOR SAFETYSWITCH. DO NOT DISABLE THISSWITCH. FAILURE TO FOLLOWTHIS WARNING CAN RESULT INELECTRICAL SHOCK, PERSONALINJURY OR DEATH.

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

Before proceeding with the electricalconnections, be certain that thevoltage, frequency and phasecorresponds to that specified on thefurnace rating plate. For singlefurnace application, maximum over-current protection is 15 amperes.

Use a separate fused branchelectrical circuit containing a properlysized fuse or circuit breaker. Run thiscircuit directly from the main switchbox to an electrical disconnect that isreadily accessible and located nearthe furnace. Connect from theelectrical disconnect to the junctionbox on the left side of the furnace,inside the blower compartment. Forthe proper connection, refer to the

! WARNING

! WARNING

! WARNING

These may be obtained from:

National Fire ProtectionAssociation, Inc.

Batterymarch ParkQuincy, MA 02269

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

40

FIELD-INSTALLEDOPTION ACCESSORIESELECTRONIC AIR CLEANERLine voltage power can be suppliedfrom the screw terminal “EAC” and aline voltage neutral screw terminal onthe control board. NOTE: Spadeterminals only are provided on (-)GRJand (-)GTJ models. This will powerthe electronic air cleaner wheneverthe circulating air blower is inoperation.

HUMIDIFIERLine voltage power can be suppliedfrom screw terminal “HUM” to a linevoltage neutral screw terminal on thecontrol board. This will power thehumidifier whenever the burner ison and the circulating air blower isoperating in the heating mode.NOTE: Maximum current – 1.0 ampsfor each option.

NOTE: Humidifier output is notavailable on (-)GRJ and (-)GTJmodels.

HIGH ALTITUDE KITModels installed at altitudes of 5,000feet and above require a pressureswitch change. The installer mustreplace the induced draft blowerpressure switch installed on thefurnace with the new pressure switch.The burner orifices should also bechanged (as indicated by the LPConversion Kit Index).NOTE: DO NOT make any attempt torerate the furnace for high altitudes bychanging gas orifices or the gaspressure. Allow the natural derate ofthe gas to occur. Use themanufacturer’s kit in conjunction withNFGC Section 8.1.2.No orifice sizing or other derateprocedures are necessary unless thenatural gas exceeds 1075 BTU/cu. ft.at sea level or the LP gas exceeds2500 BTU/cu. ft. at sea level. If theheating values exceed these levels,consult the manufacturer for thederate procedures.

FURNACE TWINNINGINSTALLATIONSTwinning operation of two furnaces,installed side-by-side, connected by acommon duct system with mainpower supplied by the same source,and controlled by a commonthermostat can be done with the UT Electronic Controls 1028-928integrated control boards.IMPORTANT: Twinning of (-)GRJ-and (-)GTJ- units requires anaccessory twinning kit. Refer to thespecification sheet for proper kit. Donot attempt to twin these models byusing the instructions below.IMPORTANT: Only twin furnaceswith identical control boards.

IMPORTANT: Only bottom returnscan be used. No more than twofurnaces can share the same supplyand return. Furnaces must havesame heating and blower capacity.Twinning furnaces must operate offthe same phase of power.

It should be noted that both blowerswill run simultaneously when there isa call for heating, cooling or fan.The “OK” LED will flash if twinning isnot set up properly.

UT ELECTRONIC CONTROLS 1028-928 CONTROL BOARD1. Single Stage Operation

(See Figure 44)a. Control board "ONE" is on

furnace connected to thethermostat.

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

c. Connect the "C," "W" and"TWIN" terminals tocounterparts on each control.

d. Both control boards must haveswitch #3 in the "ON" position.

2. Two Stage Operation(See Figure 45)

a. Follow above instructions.Connect "W2" on thermostatto "W" on control board"TWO".

ACCESSORIESTHERMOSTATThe room thermostat must be com-patible with the integrated furnacecontrol on the furnace. Generally, allthermostats that are not of the“current robbing” type are compatiblewith the integrated furnace control.The low voltage wiring should besized as shown.

NOTE: Do not use 24 volt controlwiring smaller than No. 18 AWG.

NOTE: An isolation relay can beadded to prevent any compatibilityproblems that may occur. Use asingle-pole, single-throw relay with a24-volt AC coil. The contacts shouldbe rated for .5 amps minimum at 24volts. See Figure 43.

Install the room thermostat inaccordance with the instruction sheetpacked in the box with the thermostat.Run the thermostat lead wires insidethe blower compartment and connectto low voltage terminals as shown onthe wiring diagram. Never install thethermostat on an outside wall orwhere it will be influenced by drafts,concealed hot or cold water pipes orducts, lighting fixtures, radiation fromfireplace, sun rays, lamps, televisions,radios or air streams from registers.Refer to instructions packed with thethermostat for “heater” selection oradjustment.

41

FIGURE 45UT Electronic Controls 1028-928 CONTROL BOARD, TWINNING CONNECTION -- SINGLE STAGE OPERATION

Control Board 1

Control Board 2

42

FIGURE 46UT ELECTRONIC CONTROLS 1028-928 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION

Control Board 1

Control Board 2

43

START-UP PROCEDURESThis furnace is equipped with a directignition device. Each time the roomthermostat calls for heat, the ignitorlights the main burners directly. See thelighting instructions on the furnace.

TO START THE FURNACE1. Remove the burner compartment

control access door.2. IMPORTANT: Be sure that the

manual gas control has been in the“OFF” position for at least fiveminutes. Do not attempt to manuallylight the main burners.

3. Turn off the furnace electrical powerand set the room thermostat to itslowest setting.

4. Turn the gas control knob to the“ON” position or move the gascontrol lever to the “On” position.

5. Replace the burner compartmentcontrol access door.

6. Turn on the furnace electrical power.7. Set the room thermostat to a point

above room temperature to light themain burners.

8. After the burners are lit, set the roomthermostat to a desired temperature.

TO SHUT DOWNTHE FURNACE1. Set the room thermostat to its lowest

setting and wait for furnace to shutdown.

2. Remove the burner compartmentcontrol access door.

3. Shut off the gas to the main burnersby turning the gas control knob tothe “OFF” position. See Figure 36.

SHOULD OVERHEATING OCCUR ORTHE GAS SUPPLY FAIL TO SHUTOFF, CLOSE THE MANUAL GASVALVE FOR THE APPLIANCEBEFORE SHUTTING OFF THEELECTRICAL SUPPLY. FAILURE TODO SO CAN CAUSE AN EXPLOSIONOR FIRE RESULTING IN PROPERTYDAMAGE, PERSONAL INJURY ORDEATH.

SEQUENCE OF OPERATIONUT ELECTRONIC CONTROLSIntegrated Controls with Hot SurfaceIgnition.1. Each time the thermostat “W”

(Heating) contacts close, theinduced draft blower (inducer)begins a prepurge cycle.

2. The air proving negative pressureswitch(es) closes.

3. 5 seconds after the pressureswitch(es) close, the hot surfaceigniter begins heating for 30seconds to full temperature. Theinduced draft blower operates for thecomplete heating cycle.

4. After the 30-second igniter warm up,the gas valve opens for an8-second trial for ignition.

5. The igniter lights the gas burnersand stays energized for the first 7seconds after the gas valveopens.

6. 8 seconds after the gas valve opensthe remote flame sensor mustprove flame ignition for onesecond using the process of flamerectification. If the burners don’t light,the system goes through anotherignition sequence. It does this up tofour times.

7. The main blower startsapproximately 20 seconds after theburners ignite.

8. When the thermostat “W” (Heat Call)ends, the gas valve closes, theburners go out, the induced draftblower stops after a 10-secondpost-purge, and the negativepressure switch(es) open.

9. The main blower continues untiltimed off by the setting on theintegrated furnace control board.

Sequence if the system doesn’t lightor doesn’t sense flame:1. On a call for heat, the control runs

the inducer for 30 seconds toprepurge.

2. 5 seconds into prepurge, the hotsurface igniter heats for 30 seconds.The inducer continues to run.

3. After the 30-second igniter warm up,the gas valve opens for an8-second trial for ignition. Theinducer continues and the igniterstays energized.

4. If flame is not sensed during the 8thsecond after the gas valve opens,the gas valve closes, and the igniterde-energizes.

5. After a 10-second post-purge, theinducer stops and the control verifiesthat the pressure switch has opened.Once the open pressure switch isconfirmed, the control begins thenext ignition cycle by energizing theinducer for a pre-purge of 30seconds. After the 30-second pre-purge, the igniter energizes andbegins a 30-second warm-up period(inducer is still running). After a 30-second igniter warm-up period, thegas valve opens and the controllooks for a flame signal for up to 8seconds. If no flame is sensed, thecontrol goes into “self-healing”mode, in which the blower andinducer both run for three minutesbefore another ignition attempt ismade.NOTE: The following applies onlyto units manufactured before thirdQuarter 2003: After 5-second inter-purge, the control begins a 30-second pre-purge followed by a 30-second igniter warm-up period(inducer is still running). After the 30-second igniter warm-up period, the

gas valve opens and the controllooks for a flame signal for up to 8seconds. If no flame is sensed, thecontrol goes into “self-healing”mode, in which the blower andinducer both run for three minutesbefore another ignition attempt ismade.

6. The control attempts to ignite up tofour times (first attempt followed bythree retries). After the fourthfailure to ignite, the control goesinto a one-hour “soft-lockout,”during which the control will notrespond to the thermostat heat call(W). The lockout can be reset byshutting off main power to thefurnace for five seconds, or byturning the heat call (W) from thethermostat off and then back on.Note that second and fourthignition attempts will have a 30-second pre-purge followed by a 30-second igniter warm-up period.This prevents the igniter fromoverheating.

7. The above sequence will repeatafter a one hour delay. It willcontinue repeating until ignition issuccessful or the call for heat isterminated.

8. To reset the lock out, make andbreak power either at thethermostat or at the unitdisconnect switch for 5 to 10seconds. It then goes throughanother set of trials for ignition.

UT Electronic Controls Direct SparkIgnition1. Each time the thermostat contacts

close, the induced draft blower(inducer) begins a prepurge cycle.

2. The air proving negative pressureswitch(es) closes.

3. 30 seconds after the pressureswitch(es) close, the sparkigniter energizes. The induceddraft blower operates for thecomplete heating cycle.

4. After the spark igniter energizes,the gas valve opens for a 8second trial for ignition.

5. The igniter lights the gas burners.6. After the gas valve opens the

flame sensor must prove flameignition for one second using theprocess of flame rectification. If theburners don’t light, the systemgoes through another ignitionsequence. It does this up to fourtimes.

7. The main blower starts 20 secondsafter the burners ignite.

8. When the thermostat cycle ends,the gas valve closes, the burnersgo out, the induced draft blowerstops after a 10-second post-purge, and the negative pressureswitch(es) open.

9. The main blower continues untiltimed off by the setting on theintegrated furnace control board.

! WARNING

44

ADJUSTING OR CHECKINGFURNACE INPUTThe maximum gas supply pressureto the furnace should be 7" w.c.for natural gas. The minimum gassupply pressure for purposes of inputadjustment to the furnace should be5" w.c.A properly calibrated magnehelicgauge or manometer is required foraccurate gas pressure readings.The manifold pressure should be setat 3.5" w.c. for natural gas. Onlysmall variations in the gas flowshould be made by means of thepressure regulator adjustment. In nocase should the final manifoldpressure vary more than plus orminus 0.3" w.c. from the above-specified pressures. To adjust thepressure regulator, remove theregulator cap and turn the adjustmentscrew clockwise to increase pressureor counterclockwise to decreasepressure. Then replace the regulatorcap securely. Any necessary majorchanges in the gas flow rate shouldbe made by changing the size of theburner orifices.To change orifice spuds, shut off themanual gas valve and remove thegas manifold. On LP gas furnaces,the LP gas supply pressure must beset between 11" and 14" w.c. bymeans of the tank or branch supplyregulators. The furnace manifoldpressure should be set at 10" w.c. atthe gas control valve. For elevationsup to 2,000 feet, rating plate input

TABLE 6METER TIME

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

HEATING VALUE OF GAS BTU PER CU. FT.METER

900 1000 1040 1100 2500 (LP)INPUT SIZE

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

ONE 1 12 1 20 1 23 1 28 3 20

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

ONE 0 54 1 0 1 3 1 6 2 30

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

ONE 0 44 0 48 0 50 0 53 2 0

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

ONE 0 36 0 40 0 42 0 44 1 40

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

ONE 0 31 0 34 0 36 0 38 1 26

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

ONE 0 27 0 30 0 31 0 33 1 15

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

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

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

ratings apply. For high altitudes(elevations over 2,000 ft.), seeconversion kit index for derating andorifice spud sizes.Checking furnace input is importantto prevent over firing beyond itsdesign-rated input. NEVER SETINPUT ABOVE THAT SHOWN ONTHE RATING PLATE. Use thefollowing table or formula todetermine input rate. Start thefurnace and measure the timerequired to burn one cubic foot ofgas. Prior to checking the furnaceinput, make certain that all other gasappliances are shut off, with theexception of pilot burners. Time themeter with only the furnace inoperation.

SETTING INPUT RATEThe furnace is shipped from thefactory with #50 orifices. They aresized for natural gas having a heatingvalue of 1075 BTU/cu. ft. and aspecific gravity of .60.Since heating values vary geo-graphically, the manifold pressureand/or gas orifice size may need tobe changed to adjust the furnace toits nameplate input. Consult the localgas utility to obtain the yearlyaverage heating value and orificesize required to fire each individualburner at 15,000 BTU/HR.

NOTE: Refer to the National FuelGas Code for high altitude rateadjustment above 2,000 ft.

Sequence if the system doesn’tlight or doesn’t sense flame:1. On a call for heat, the control

runs the inducer for 30 secondsto pre-purge.

2. After the 30-second pre-purge,the spark igniter energizes. Theinducer continues to run.

3. After the spark igniter energizes,the gas valve opens for an 8-second trial for ignition. Theinducer continues and the igniterstays energized.

4. If flame is not sensed within 8seconds after the gas valveopens, the gas valve closes, theigniter de-energizes and:

5. The inducer completes a 10-second post-purge, the inducerstops, and the control verifies thatthe pressure switch has opened.Once the open pressure switch isconfirmed, the control begins thenext ignition cycle by energizingthe inducer for a pre-purge of 30seconds. After the pre-purge, theigniter energizes and the gasvalve opens (inducer continues torun). If no flame is sensed on thesecond attempt, the control goesinto a “self-healing” mode, inwhich the blower and the inducerrun for 3 minutes before anotherignition attempt is made.NOTE: The following appliesonly to units manufacturedbefore third Quarter 2003: Aftera 30-second inter-purge (inducerruns continuously), the igniter isenergized, and the gas valveopens for 8 seconds. If flame isnot sensed in 8 seconds, the gasvalve is closed and the igniter de-energizes. If no flame is sensedon this second attempt, thecontrol goes into a “self-healing”mode, in which the blower andinducer run for 3 minutes beforeanother ignition attempt is made.

6. The control attempts to ignite upto four times (first attemptfollowed by three retries). Afterthe fourth failure to ignite, thecontrol goes into a one-hour“soft-lockout” during which thecontrol will not respond to thethermostat heat call (W). Thelockout can be reset by shuttingoff main power to the furnace forfive seconds, or by turning theheat call (W) from the thermostatoff and then back on.

7. The above sequence will repeatafter a one hour delay. It willcontinue repeating until ignition issuccessful or the call for heat isterminated.

8. To reset the lock out, make andbreak power either at thethermostat or at the unitdisconnect switch for 5 to 10seconds. It then goes throughanother set of trials for ignition.

45

AIR FLOWThe importance of proper air flow over theheat exchanger cannot be overemphasized. One of the most commoncauses of heat exchanger failure isoverheating due to low air flow. An airflow table is located inside the blowerdoor.

TEMPERATURE RISE CHECK

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

1. Insert a thermometer in the supplyair duct as close to the furnace aspossible yet out of a direct line fromthe heat exchanger. See Figure 47.

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

3. Operate the furnace.

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

5. Compare the measured temperaturerise to the approved temperature riserange listed on the furnace nameplate. See Figure 48.

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

THE MEASURED TEMPERATURERISE SHOULD BE AS CLOSE TO THEMIDDLE OF THE STATED RANGE ASPOSSIBLE. FOR EXAMPLE, IF THERISE RANGE IS 40 TO 70 DEGREES,THE MOST IDEAL RISE WOULD BE 55DEGREES (THE MIDDLE OF THE RISERANGE). IN ALL APPLICATIONS, THEINSTALLER MUST ADJUST THETEMPERATURE RISE TO THIS"MIDDLE" POINT AS CLOSELY ASPOSSIBLE. ALSO, THETEMPERATURE RISE SHOULD NEVERBE ABOVE OR FALL BELOW THESTATED RANGE. DOING SO COULDCAUSE DAMAGE TO THE HEATEXCHANGER OR INTERMITTENTOPERATION WHICH COULD CAUSEINJURY OR DEATH AND WILL VOIDTHE MANUFACTURER'S WARRANTYFOR THIS PRODUCT.

FIGURE 47TEMPERATURE RISE MEASUREMENT

FIGURE 48TYPICAL FURNACE NAME PLATE

! WARNING

46

TABLE 7

90 PLUS AIR FLOW PERFORMANCE – (-)GRA & (-)GTA MODELSCFM @ ESPMODEL BLOWER/ SPEED

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

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

(-)GTA-04 11 x 7 / 1/2 LOW 820 790 760 725 690 650 610*M-LO 930 890 850 815 785 750 720M-HI 1150 1120 1090 1045 1002 950 900HIGH 1414 1365 1320 1270 1220 1165 1115

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

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

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

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

(-)GRA-07 12 X 7 1/2 / 3/4 LOW 1105 1095 1080 1050 1030 1010 990M-LO 1290 1275 1260 1220 1195 1170 1140M-HI 1480 1435 1415 1390 1370 1300 1255HIGH 1705 1665 1615 1570 1540 1475 1400

(-)GTA-07 12 X 7 1/2 / 3/4 LOW 1185 1160 1140 1115 1095 1065 1040M-LO 1405 1375 1350 1310 1270 1235 1195M-HI 1595 1560 1525 1480 1440 1380 1325HIGH 1835 1780 1730 1675 1625 1555 1480

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

(-)GTA-09 12 X 11 / 3/4 LOW 1155 1125 1100 1080 1060 1000 940*M-LO 1420 1400 1380 1365 1350 1260 1175M-HI 1605 1575 1550 1560 1570 1480 1390HIGH 2005 1965 1930 1890 1850 1765 1680





* Heating speed for cooling applicationsNOTE: Units tested with filters in place.

47

90 PLUS AIR FLOW PERFORMANCE – (-)GRJ & (-)GTJ MODELSCFM @ ESPMODEL BLOWER/ SPEED

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

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

(-)GTJ-04 11 x 7 / 1/2 LOW 820 790 760 725 690 650 610MED-LO 930 890 850 815 785 750 720MED-HI 1150 1120 1090 1045 1002 950 900HIGH 1414 1365 1320 1270 1220 1165 1115

(-)GRJ-06 11 x 7 / 1/2 LOW 880 845 815 790 760 715 670MED 1060 1025 990 960 925 880 835HIGH 1260 1215 1175 1135 1100 1040 985

(-)GTJ-06 11 x 7 / 1/2 LOW 910 885 860 815 770 725 680MED 1115 1080 1045 1005 965 920 875HIGH 1365 1315 1270 1225 1180 1125 1070

(-)GRJ-07 11 X 7 / 1/2 LOW 880 850 825 785 750 702 655MED 1090 1050 1010 970 925 875 825HIGH 1300 1255 1210 1160 1110 1055 1005

(-)GTJ-07 11 X 7 / 1/2 LOW 890 860 835 790 750 705 660MED 1100 1060 1025 980 940 890 845HIGH 1340 1295 1250 1200 1150 1090 1025

(-)GRJ-07 12 X 7 / 1/2 LOW 1185 1160 1140 1115 1095 1065 1040MED 1405 1375 1350 1310 1270 1235 1195HIGH 1595 1560 1525 1480 1440 1380 1325

(-)GTJ-07 12 X 7 / 1/2 LOW 1105 1095 1080 1050 1030 1010 990MED 1290 1275 1260 1220 1195 1170 1140HIGH 1480 1435 1415 1390 1370 1300 1255

(-)GRJ-07 12 X 7 / 3/4 LOW 1405 1375 1350 1310 1270 1235 1195MED 1595 1560 1525 1480 1440 1380 1325HIGH 1835 1780 1730 1675 1625 1555 1480

(-)GTJ-07 12 X 7 / 3/4 LOW 1290 1275 1260 1220 1195 1170 1140MED 1480 1435 1415 1390 1370 1300 1255HIGH 1705 1665 1615 1570 1540 1475 1400

(-)GRJ-09 12 X 11 / 1/2 LOW 1235 1210 1180 1150 1120 1075 1035MED 1490 1465 1445 1405 1375 1315 1255HIGH 1720 1670 1620 1600 1580 1520 1460

(-)GTJ-09 12 X 11 / 1/2 LOW 1155 1125 1100 1080 1060 1000 940MED 1420 1400 1380 1365 1350 1260 1175HIGH 1605 1575 1550 1560 1570 1480 1395

(-)GRJ-09 12 X 11 / 3/4 LOW 1490 1465 1445 1405 1375 1315 1255MED 1720 1670 1620 1600 1580 1520 1460HIGH 2100 2050 2000 1955 1910 1825 1745

(-)GTJ-09 12 X 11 / 3/24 LOW 1420 1400 1380 1365 1350 1260 1175MED 1605 1575 1550 1560 1570 1480 1395HIGH 2005 1965 1930 1890 1850 1765 1680

(-)GRJ-10 12 X 11 / 1/2 LOW 1230 1205 1180 1155 1130 1090 1050MED 1490 1445 1405 1375 1350 1295 1240HIGH 1710 1665 1620 1580 1540 1475 1410

(-)GTJ-10 12 X 11 / 1/2 LOW 1180 1150 1120 1100 1080 1025 970MED 1460 1425 1390 1375 1360 1280 1200HIGH 1680 1645 1615 1585 1560 1490 1420

(-)GRJ-10 12 X 11 / 3/4 LOW 1490 1445 1405 1375 1350 1295 1240MED 1710 1665 1620 1580 1540 1475 1410HIGH 2010 1955 1900 1855 1810 1710 1610

(-)GTJ-10 12 X 11 / 3/4 LOW 1460 1425 1390 1375 1360 1280 1200MED 1680 1645 1615 1585 1560 1490 1420HIGH 2055 2000 1940 1880 1820 1745 1675

(-)GRJ-12 11 X 10 / 1/2 LOW 1320 1305 1290 1260 1230 1185 1140MED 1610 1580 1555 1515 1475 1415 1355HIGH 1870 1820 1775 1715 1 1590 1520

(-)GTJ-12 11 X 10 / 1/2 LOW 1285 1250 1215 1235 1260 1230 1200MED 1590 1565 1540 1505 1 1425 1375HIGH 1840 1820 1800 1750 1700 1645 1590

(-)GRJ-12 11 X 10 / 3/4 LOW 1610 1580 1555 1515 1475 1415 1355MED 1870 1820 1775 1715 1660 1590 1520HIGH 2115 2050 1990 1945 1900 1795 1690

(-)GTJ-12 11 X 10 / 3/4 LOW 1590 1565 1540 1505 1475 1425 1375MED 1840 1820 1800 1750 1700 1645 1590HIGH 2315 2250 2185 2110 2040 1965 1890

* Heating speed for cooling applicationsNOTE: Units tested with filters in place.

TABLE 8

48

FIGURE 51UT Electronic Controls 1012-925BBLOWER OFF TIMINGS

! WARNING

SETTING BLOWERTIMINGSThe Honeywell and UTELECTRONIC CONTROLS controlboards have three or four quickconnect terminals for connecting themotor speed leads. These are:

1. FAN SPEED — motor runs onthis speed when the thermostatis in the “FAN ON” position.

2. COOL — connect desiredcooling speed.

3. HEAT — connect desiredheating speed.

4. HEAT/COOL (not available onUT Electronic Controls-1028-925control board) — connect desiredspeed when heating and coolingspeed are the same.

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

5. If heating and continuous fanspeed are the same, “piggyback”jumper across “FAN” and “HEAT”terminals.

NOTE: This does not apply to (-)GRJor (-)GTJ models. The heat tapfunctions as the continuous fan tap aswell.

See Figures 49, 50 & 51 forinstructions for setting the blower“OFF” timings.

If cooling speed and fan speed aredesired to be the same, this may beaccomplished by not connecting “Y”to the integrated furnace control.

If desired for cool, fan and heat to allbe the same speed, then “piggyback”jumper “H/C” to “FAN” and do notconnect “Y” to the integrated furnacecontrol. Do not connect anything to“H” or “C.”

GAS FURNACE (DIRECTDRIVE) INSTRUCTIONSFOR CHANGING BLOWERSPEED

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

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

If additional blower speed taps areavailable (leads connected to “M1”and “M2” on the electronic control),speeds may be changed if necessaryto fit requirements of the particularinstallation. Reconnect the unusedmotor leads to “M1” or “M2.” Checkmotor lead color for speeddesignation.

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

IMPORTANT: Always check airtemperature rise after changing theheating speed for any reason.

FIGURE 50UT Electronic Controls 1012-925ABLOWER OFF TIMINGS

OFF TIME SWITCH 1 SWITCH 2

90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON

(TIMER ISRED BLOCKON BOARD)

I335

FIGURE 49UT Electronic Controls 1028-928BLOWER OFF TIMINGS

OFF TIME SWITCH 1 SWITCH 2

90 SEC. OFF ON

120 SEC. OFF OFF

160 SEC. ON OFF

180 SEC. ON ON

TW

INS

ING

LENOTE: SWITCH 3 IS USED FORTWINNING APPLICATIONS.

ON

I402

49

THESE INSTRUCTIONS AREINTENDED AS AN AID TOQUALIFIED SERVICEPERSONNEL FOR PROPERINSTALLATION, ADJUSTMENTAND OPERATION OF THIS UNIT.READ THESE INSTRUCTIONSTHOROUGHLY BEFOREATTEMPTING INSTALLATIONOR OPERATION. FAILURE TOFOLLOW THESE INSTRUCTIONSMAY RESULT IN IMPROPERINSTALLATION, ADJUSTMENT,SERVICE OR MAINTENANCE,POSSIBLY RESULTING IN FIRE,ELECTRICAL SHOCK, CARBONMONOXIDE POISONING,EXPLOSION, PROPERTYDAMAGE, PERSONAL INJURYOR DEATH.

DISCONNECT MAIN ELECTRICALPOWER TO THE UNIT BEFOREATTEMPTING ANY MAINTE-NANCE. FAILURE TO DO SO CANCAUSE ELECTRICAL SHOCKRESULTING IN PERSONALINJURY OR DEATH.

! WARNING

FILTERSNOTE: (-)GRJ and (-)GTJ modelsdo not come from the factory withfilters installed. Filters must befield installed. See Table 9.

Keep the filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air drythoroughly and reinstall.

Keep the filters clean at all times.Vacuum dirt from filter, wash withdetergent and water, air drythoroughly and reinstall.

NOTE: Some filters must be resizedto fit certain units and applications.See Table 10 and Figures 52 and 53.

1. 21” - 90,000 & 105,000 BTUHunits require removal of a3.5-in. segment of filter andframe to get the proper widthfor a side filter.

2. 24.5” - 120,000 BTUH unitrequires removal of a 7" segmentof filter and frame to get theproper width for a side filter.

TABLE 9FILTER SIZES

UPFLOW FILTER SIZES

FURNACE INPUT BOTTOM SIDE QUANTITYWIDTH MBTUH SIZE SIZE

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

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

DOWNFLOW FILTER SIZES

FURNACE INPUT SIZE QUANTITYWIDTH MBTUH

171/2" 45, 60, 75 12" X 20" 221" 90, 105 12" X 20" 2

241/2" 120 14" X 20" 2

MAINTENANCE

FIGURE 52BOTTOM PANEL REMOVAL

JACKET ASSEMBLY

SOLID BOTTOM

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

(2) REQ’D.

JACKET ASSEMBLY

FILTER FILTERROD

SOLID BOTTOM REMOVAL

FILTER & ROD LOCATION

50

FIGURE 53FILTER LOCATIONS

DOWNFLOW

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

CUT-OUT USINGEMBOSSED ANGLES

AS A GU IDE FORPROPER SI ZE

JACKET

JACKET

ANGLE

FILTER RODSUPPORTANGLE

FILTER SUPPORTANGLE(SEE ANGLE DETAIL)

ATTACH WITHSHEET METALSCREWS (2 REQÕD)

ANGLE DETAIL

CUT-OUT AND DRILL DETAILROD & FILTER SUPPORT ANGLE ASSEMBLY

FILTER AND ROD ASSEMBLY

FILTER RODSUPPORTANGLE

FILTERSUPPORTANGLE

FILTER

FILTER ROD

JACKET

I332

I413

UPFLOW

I528

HORIZONTAL

FILTER RODSUPPORTANGLEAE-60520-01

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

FILTERROD45-24095-01

FILTER

FILTERSUPPORTANGLEAE-61883-01

FILTER RODSUPPORTANGLEAE-60520-01

51

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

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

• IMPORTANT: It is recommendedthat at the beginning of the heatingseason, the condensate trap beinspected for debris or blockage. Ablocked condensate trap can causewater to back up into the primaryheat exchanger and lead tonuisance tripping of theovertemperature switches.

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

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

REPLACEMENT PARTSSee sheet enclosed with furnace forreplacement part information.

TROUBLESHOOTINGRefer to Figures 54 and 55 fordetermining cause of unit problems.

WIRING DIAGRAMSFigures 56 through 59 are completewiring diagrams for the furnace andpower sources.

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

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

The blower motor and induced draftblower motor must be cleanedperiodically by a qualified installer,service agency, or the gas supplier toprevent the possibility of overheatingdue to an accumulation of dust anddirt on the windings or on the motorexterior. And, as suggestedelsewhere in these instructions, theair filters should be kept clean. Dirtyfilters can restrict airflow. The motordepends upon sufficient air flowingacross and through it to keep fromoverheating.

SYSTEM OPERATIONINFORMATIONAdvise The Customer

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

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

3. Close doors and windows. Thiswill reduce the heating load onthe system.

4. Avoid excessive use of kitchenexhaust fans.

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

6. Except for the mounting platform,keep all combustible articles 3feet from the furnace and ventsystem.

7. IMPORTANT: Replace allblower doors and compartmentcovers after servicing thefurnace. Do not operate the unitwithout all panels and doorssecurely in place.

8. Explain proper operation of thesystem with constant aircirculation.

ANNUAL INSPECTION• The furnace should operate for

many years without excessive scalebuild-up in the flue passageways.However, it is recommended that aqualified installer, service agency, orthe gas supplier annually inspectthe flue passageways, the ventsystem and the main burners forcontinued safe operation. Payparticular attention to deteriorationfrom corrosion or other sources.

• IMPORTANT: It is recommendedthat at the beginning and atapproximately half way through theheating season, a visual inspectionbe made of the main burner flamesfor the desired flame appearanceby a qualified installer, serviceagency or the gas supplier. If theflames are distorted and/or there isevidence of back pressure, checkthe vent and inlet air system forblockage. If there is carbon andscale in the heat exchanger tubes,the heat exchanger assemblyshould be replaced.

! WARNINGDO NOT OPERATE THE SYSTEMFOR EXTENDED PERIODSWITHOUT FILTERS.A PORTION OF THE DUSTENTRAINED IN THE AIR MAYTEMPORARILY LODGE IN THE AIRDUCT RUNS AND AT THE SUPPLYREGISTERS. ANY RECIRCULATEDDUST PARTICLES WILLBE HEATED AND CHARRED BYCONTACT WITH THE FURNACEHEAT EXCHANGER.THIS RESIDUE WILL SOILCEILINGS, WALLS, DRAPES,CARPETS AND OTHERHOUSEHOLD ARTICLES.

! CAUTION

52

FIGURE 54(-)GRA/(-)GRJ MODELS W/INTEGRATED FURNACE CONTROL (IFC) UT Electronic Controls 1012-925 (115 VAC IGNITER)

53

FIGURE 63(-)GRJ MODELS W/INTEGRATED FURNACE CONTROL (IFC) UT Electronic Controls 1012-925 (115 VAC IGNITER)

54

FIGURE 55(-)GTA/(-)GTJ MODELS W/INTEGRATED FURNACE CONTROL (IFC) UT Electronic Controls 1012-925

CONTINUED ONNEXT PAGE

55

FIGURE 64(-)GTA & (-)GTJ MODELS W/INTEGRATED FURNACE CONTROL (IFC) UT Electronic Controls 1029-927,JOHNSON CONTROLS 6961 DAJ-2401 OR UT Electronic Controls 1012-925

56

FIGURE 56(-)GRA MODELS WITH UT ELECTRONIC CONTROLS 1028-928 & SPARK IGNITION

57

FIGURE 57(-)GTA MODELS WITH UT ELECTRONIC CONTROLS 1028-928 & SPARK IGNITION

58

FIGURE 58(-)GRJ MODELS WITH UT ELECTRONIC CONTROLS 1012-925 CONTROL BOARD & HSI

59

FIGURE 59(-)GTJ MODELS WITH UT ELECTRONIC CONTROLS 1012-925 CONTROL BOARD & HSI

60

NOTESNOTES

CM 1003

Documents

FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH ...pts.myrheem.com/docstore/webdocs/ServiceDocs/histlib/...series furnaces are design-certified by CSA for use with natural and propane gases