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92-24161-36-26SUPERSEDES 92-24161-36-25

INSTALLATION INSTRUCTIONSFOR UPFLOW AND DOWNFLOW/HORIZONTALHIGH EFFICIENCY CONDENSING TWO-STAGEGAS FURNACESRGRK-12ERAJS, RGRL, AND RGTK SERIES

ISO 9001:2008

U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in allapplications, and their installation should be in accordance with the manufacturer’srecommendations and/or local laws, rules, regulations, or customs.

INSTALLATION CHECK LISTREFER TO INSTALLATION INSTRUCTIONS

GAS SUPPLY

______ Adequate pipe size

______ Correct supply pressure (during furnace operation)

______ Manifold pressure

______ No gas leaks

______ L.P. Kit Number (if applicable)

ELECTRICAL

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

______ Polarity observed

______ Furnace properly grounded

______ Adequate wire size

FURNACE INSTALLATION

______ Adequate clearance to combustibles

______ Adequate clearance for service (at front)

DUCT STATIC PRESSURE

______ in. w.c. on heating speed

______ in. w.c. on cooling speed

______ Air temperature rise

CONDENSATE LINE

______ Trap filled with water

______ Vented

______ Sloped toward drain

______ Condensate drain line hoses connectedand clamped

______ Freeze protection (if necessary)

VENTING – DIRECT VENT

______ in. diameter – intake pipe

______ in. diameter – exhaust pipe

______ ft. of pipe – intake air

______ no. of elbows – intake air

______ ft. of pipe – exhaust pipe

______ no. of elbows – exhaust pipe

______ Exhaust Vent Temperature

TERMINATIONS – DIRECT VENT

VERTICAL

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

______ Correct relationship – exhaust to intake

HORIZONTAL/VERTICAL – CONCENTRIC ((-)XGY-E03A)

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

______ Intake “Y” rotated above center

______ Exhaust sloped toward furnace

HORIZONTAL – STANDARD ((-)XGY-D02, -D03) – US((-)XGY-D02A, (-)XGY-D03A) – CANADA


______ 12" min. above grade/snow level

HORIZONTAL – ALTERNATE((-)XGY-D02, -D03 OR -D04) – US((-)XGY-D02A, -D03A, -D04A) – CANADA


______ Above anticipated snow level

VENTING – NON-DIRECT VENT

______ in. diameter – exhaust pipe

______ ft. of pipe – exhaust

______ no. of elbows

TERMINATION – NON-DIRECT VENT

VERTICAL

______ 12" min. above roof/snow level

HORIZONTAL – STANDARD

______ 12" min. above grade/snow level

HORIZONTAL – ALTERNATE

______ Above anticipated snow level

_____________________________ Model Number

_____________________________ Serial Number

_____________________________ Date of Installation

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CONTENTS

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

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

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

Safety Information ....................................................................................................6

Location Requirements and Considerations ............................................................8

Ducting ...................................................................................................................13

Venting and Combustion Air Piping .......................................................................15

Combustion and Ventilation Air ..............................................................................17

Vent Pipe Installation..............................................................................................20

Condensate Drain/Neutralizer ................................................................................33

Gas Supply and Piping...........................................................................................37

Electrical Wiring......................................................................................................42

Accessories ............................................................................................................43

Furnace Twinning...................................................................................................44

High Altitude Installations .......................................................................................48

Start-Up Procedures...............................................................................................51

Air Flow...................................................................................................................54

Maintenance...........................................................................................................57

Troubleshooting......................................................................................................59

Wiring Diagrams.....................................................................................................62

IMPORTANT: All manufacturerproducts meet current Federal OSHAGuidelines for safety. CaliforniaProposition 65 warnings are requiredfor certain products, which are notcovered by the OSHA standards.

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

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

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

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

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

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

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

2. As direct vent central forced airfurnaces with all combustion airsupplied directly to the furnaceburners through a special air intakesystem outlined in theseinstructions.Install this furnace inaccordance with the AmericanNational Standard Z223.1 – latestedition entitled “National Fuel GasCode” (NFPA54) and requirementsor codes of the local utilities orother authorities having jurisdiction.This is available from the following:National Fire Protection Association, Inc.Batterymarch ParkQuincy, MA 02269CSA-INTERNATIONAL8501 East Pleasant Valley RoadCleveland, Ohio 44131-5575

GENERAL INFORMATION

FIGURE 1UPFLOW FURNACE COMPONENTS

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

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

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

(DOWNFLOW/HORIZONTAL UNITS ONLY)

NOTE: A PARTS BAG IS INCLUDED WITH THE FURNACE. IF A NEWPARTS BAG NEEDS TO BE ORDERED, USE THE FOLLOWING PARTNUMBERS: AS-100717-01 FOR (-)GRL-45, (-)GRL-60, (-)GRK-75, (-)GRL-90 AND (-)GRK-105 AS-100717-02 FOR (-)GRK-120

DOWNFLOW/HORIZONTAL FURNACE COMPONENTS

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

AIRFLOW

9

8

4

17

1125

10

18

5

19

20

21

2

3 15 12 23 22

71

14613

AIRFLOW

Install units in Canada in accordancewith CSA-B149, local installationcodes and authorities havingjurisdiction. CSA-B149 is availablefrom:CSA-INTERNATIONAL178 Rexdale Blvd.Toronto, OntarioCanada M9W, 1R3NOTE: It is our recommendation thatany HVAC equipment which weresubject to flooding be replaced toavoid any risk of property damage,personal injury or death. Also, ourposition that the immersion by floodwaters compromises any HVACproducts thus voiding this warranty.NOTE:Models having option code 320added at the end of the model numberdesignation are shipped factory readyfor a horizontal only installation. Thedrain trap for downflow installation isnot included in the parts bag for theseappliances.

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IMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCE WITH THE CSAINTERNATIONAL (CSA)CERTIFICATION OR THESEINSTRUCTIONS, CAN RESULT INUNSATISFACTORY OPERATIONAND/OR DANGEROUS CONDI-TIONS AND ARE NOT COVERED BYTHE UNIT WARRANTY.

IN COMPLIANCE WITHRECOGNIZED CODES, IT ISRECOMMENDED THAT ANAUXILIARY DRAIN PAN BEINSTALLED UNDER ALLEVAPORATOR COILS OR UNITSCONTAINING EVAPORATOR COILSTHAT ARE LOCATED IN ANY AREAOF A STRUCTURE WHERE DAMAGETO THE BUILDING OR BUILDINGCONTENTS MAY OCCUR AS ARESULT OF AN OVERFLOW OF THECOIL DRAIN PAN OR A STOPPAGEIN THE PRIMARY CONDENSATEDRAIN PIPING. SEE ACCESSORIESSECTION OF THESE INSTRUCTIONSFOR AUXILIARY HORIZONTALOVERFLOW PAN INFORMATION(MODEL (-)XBM).

RECEIVINGImmediately upon receipt, all cartonsand contents should be inspected fortransit damage. Units with damagedcartons should be opened immediately.If damage is found, it should be notedon the delivery papers, and a damageclaim filed with the last carrier. • After unit has been delivered to jobsite, remove carton taking care not todamage unit.

• Check the unit rating plate for unitsize, electric heat, coil, voltage,phase, etc. to be sure equipment

NOTICE

IMPORTANT INFORMATIONABOUT EFFICIENCY ANDINDOOR AIR QUALITYCentral cooling and heating equipmentis only as efficient as the duct systemthat carries the cooled or heated air. Tomaintain efficiency, comfort and goodindoor air quality, it is important to havethe proper balance between the airbeing supplied to each room and the airreturning to the cooling and heatingequipment.

Proper balance and sealing of the ductsystem improves the efficiency of theheating and air conditioning systemand improves the indoor air quality ofthe home by reducing the amount ofairborne pollutants that enter homesfrom spaces where the ductwork and /or equipment is located. Themanufacturer and the U.S.Environmental Protection Agency’sEnergy Star Program recommend thatcentral duct systems be checked by aqualified contractor for proper balanceand sealing.

DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM AND DRAWPOLLUTANTS SUCH AS DIRT,DUST, FUMES AND ODORS INTOTHE HOME CAUSING PROPERTYDAMAGE. FUMES AND ODORSFROM TOXIC, VOLATILE ORFLAMMABLE CHEMICALS, ASWELL AS AUTOMOBILE EXHAUSTAND CARBON MONOXIDE (CO),CAN BE DRAWN INTO THE LIVINGSPACE THROUGH LEAKING DUCTSAND UNBALANCED DUCTSYSTEMS CAUSING PERSONALINJURY OR DEATH (SEE FIGURE 2). • IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUST BESEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDING CARBONMONOXIDE FROM MIGRATINGINTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCH ASWATER HEATERS OR BOILERS -ALL JOINTS, SEAMS, ANDOPENINGS IN THE EQUIPMENTAND DUCT MUST ALSO BESEALED TO PREVENTDEPRESSURIZATION OF THESPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDINGCARBON MONOXIDE INTO THELIVING SPACE.

NOTICE

WARNING!

matches what is required for thejob specification.

• Read the entire instructions beforestarting the installation.

• Some building codes require extracabinet insulation and gasketingwhen unit is installed in atticapplications.

• If installed in an unconditionedspace, apply caulking around thepower wires, control wires,refrigerant tubing and condensateline where they enter the cabinet.Seal the power wires on the insidewhere they exit conduit opening.Caulking is required to prevent airleakage into and condensate fromforming inside the unit, control box,and on electrical controls.

• Install the unit in such a way as toallow necessary access to thecoil/filter rack and blower/controlcompartment.

• Install the unit in a level position toensure proper condensatedrainage. Make sure unit is level inboth directions within 1/8”.

• Install the unit in accordance withany local code which may applyand the national codes. Latesteditions are available from:“National Fire ProtectionAssociation, Inc., BatterymarchPark, Quincy, MA 02269.” Thesepublications are:

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

• NFPA90A Installation of AirConditioning and VentilatingSystems.

• NFPA90B Installation of warm airheating and air conditioningsystems.

• The equipment has beenevaluated in accordance with theCode of Federal Regulations,Chapter XX, Part 3280.

FIGURE 2MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

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

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

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

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

THE FURNACE MAY BE USEDFOR HEATING OF BUILDINGS ORSTRUCTURES UNDERCONSTRUCTION.

INSTALLATION MUST COMPLYWITH ALL INSTALLATIONINSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDERTHERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TOTHE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATEAND TEMPERATURE RISE PERRATING PLATE MARKING;

• MEANS FOR PROVIDINGOUTDOOR AIR REQUIRED FORCOMBUSTION;

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

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

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

! WARNING

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! WARNING

SAFETY INFORMATION

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

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

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

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

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

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

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DUCT LEAKS CAN CREATE ANUNBALANCED SYSTEM AND DRAWPOLLUTANTS SUCH AS DIRT, DUST,FUMES AND ODORS INTO THEHOME CAUSING PROPERTYDAMAGE. FUMES AND ODORSFROM TOXIC, VOLATILE ORFLAMMABLE CHEMICALS, AS WELLAS AUTOMOBILE EXHAUST ANDCARBON MONOXIDE (CO), CAN BEDRAWN INTO THE LIVING SPACETHROUGH LEAKING DUCTS ANDUNBALANCED DUCT SYSTEMSCAUSING PERSONAL INJURY ORDEATH (SEE FIGURE 2). • IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INGARAGES OR OFF-GARAGESTORAGE AREAS - ALL JOINTS,SEAMS, AND OPENINGS IN THEEQUIPMENT AND DUCT MUST BESEALED TO LIMIT THEMIGRATION OF TOXIC FUMESAND ODORS INCLUDING CARBONMONOXIDE FROM MIGRATINGINTO THE LIVING SPACE.

• IF AIR-MOVING EQUIPMENT ORDUCTWORK IS LOCATED INSPACES CONTAINING FUELBURNING APPLIANCES SUCH ASWATER HEATERS OR BOILERS -ALL JOINTS, SEAMS, ANDOPENINGS IN THE EQUIPMENTAND DUCT MUST ALSO BESEALED TO PREVENTDEPRESSURIZATION OF THESPACE AND POSSIBLEMIGRATION OF COMBUSTIONBYPRODUCTS INCLUDINGCARBON MONOXIDE INTO THELIVING SPACE.

IN COMPLIANCE WITH RECOGNIZEDCODES, IT IS RECOMMENDED THATAN AUXILIARY DRAIN PAN BEINSTALLED UNDER ALLEVAPORATOR COILS OR UNITSCONTAINING EVAPORATOR COILSTHAT ARE LOCATED IN ANY AREAOF A STRUCTURE WHERE DAMAGETO THE BUILDING OR BUILDINGCONTENTS MAY OCCUR AS ARESULT OF AN OVERFLOW OF THECOIL DRAIN PAN OR A STOPPAGEIN THE PRIMARY CONDENSATEDRAIN PIPING. SEE ACCESSORIESSECTION OF THESE INSTRUCTIONSFOR AUXILIARY HORIZONTALOVERFLOW PAN INFORMATION(MODEL (-)XBM).

! WARNING

NOTICEIMPROPER INSTALLATION, ORINSTALLATION NOT MADE INACCORDANCE WITH THE CSAINTERNATIONAL (CSA)CERTIFICATION OR THESEINSTRUCTIONS, CAN RESULT INUNSATISFACTORY OPERATIONAND/OR DANGEROUS CONDI-TIONSAND ARE NOT COVERED BY THEUNIT WARRANTY.

NOTICE

IMPORTANT!THE COMMONWEALTH OFMASSACHUSETTS REQUIRESCOMPLIANCE WITH REGULATION248 CMR 4.00 AND 5.00 FORINSTALLATION OF THROUGH-THE-WALL VENTED GAS APPLIANCES ASFOLLOWS:(a) For all side wall horizontally ventedgas fueled equipment installed in everydwelling, building or structure used inwhole or in part for residential purposes,including those owned or operated bythe Commonwealth and where the sidewall exhaust vent termination is less thanseven (7) feet above finished grade inthe area of the venting, including but notlimited to decks and porches, thefollowing requirements shall be satisfied:1. INSTALLATION OF CARBONMONOXIDE DETECTORS. At the timeof installation of the side wall horizontalvented gas fueled equipment, theinstalling plumber or gasfitter shallobserve that a hard wired carbonmonoxide detector with an alarm andbattery back-up is installed on the floorlevel where the gas equipment is to beinstalled. In addition, the installingplumber or gasfitter shall observe that abattery operated or hard wired carbonmonoxide detector with an alarm isinstalled on each additional level of thedwelling, building or structure served bythe side wall horizontal vented gasfueled equipment. It shall be theresponsibility of the property owner tosecure the services of qualified licensedprofessionals for the installation of hardwired carbon monoxide detectors.a. In the event that the side wallhorizontally vented gas fueled equipmentis installed in a crawl space or an attic,the hard wired carbon monoxide detectorwith alarm and battery back-up may beinstalled on the next adjacent floor level.b. In the event that the requirements ofthis subdivision can not be met at thetime of completion of installation, theowner shall have a period of thirty (30)days to comply with the aboverequirements; provided, however, thatduring said thirty (30) day period, abattery operated carbon monoxidedetector with an alarm shall be installed.2. APPROVED CARBON MONOXIDEDETECTORS. Each carbon monoxidedetector as required in accordance withthe above provisions shall comply withNFPA 720 and be ANSI/UL 2034 listedand IAS certified.3. SIGNAGE. A metal or plasticidentification plate shall be permanentlymounted to the exterior of the building ata minimum height of eight (8) feet abovegrade directly in line with the exhaustvent terminal for the horizontally ventedgas fueled heating appliance orequipment. The sign shall read, in printsize no less than one-half (1/2) inch insize, “GAS VENT DIRECTLY BELOW.KEEP CLEAR OF ALLOBSTRUCTIONS”.

4. INSPECTION. The state or localgas inspector of the side wallhorizontally vented gas fueledequipment shall not approve theinstallation unless, upon inspection,the inspector observes carbonmonoxide detectors and signageinstalled in accordance with theprovisions of 248 CMR 5.08(2)(a) 1through 4.(b) EXEMPTIONS: The followingequipment is exempt from 248 CMR5.08(2)(a)1 through 4:1. The equipment listed in Chapter 10entitled “Equipment Not Required ToBe Vented” in the most current editionof NFPA 54 as adopted by the Board;and2. Product Approved side wallhorizontally vented gas fueledequipment installed in a room orstructure separate from the dwelling,building or structure used in whole orin part for residential purposes.(c) MANUFACTURERREQUIREMENTS – GASEQUIPMENT VENTING SYSTEMPROVIDED. When the manufacturerof Product Approved side wallhorizontally vented gas equipmentprovides a venting system design orventing system components with theequipment, the instructions providedby the manufacturer for installation ofthe equipment and the ventingsystem shall include:1. Detailed instructions for theinstallation of the venting systemdesign or the venting systemcomponents; and2. A complete parts list for the ventingsystem design or venting system.(d) MANUFACTURERREQUIREMENTS – GASEQUIPMENT VENTING SYSTEMNOT PROVIDED. When themanufacturer of a Product Approvedside wall horizontally vented gasfueled equipment does not providethe parts for venting the flue gases,but identifies “special ventingsystems”, the following requirementsshall be satisfied by the manufacturer:1. The referenced “special ventingsystem” instructions shall be includedwith the appliance or equipmentinstallation instructions; and2. The “special venting systems” shallbe Product Approved by the Board,and the instructions for that systemshall include a parts list and detailedinstallation instructions.(e) A copy of all installationinstructions for all Product Approvedside wall horizontally vented gasfueled equipment, all ventinginstructions, all parts lists for ventinginstructions, and/or all venting designinstructions shall remain with theappliance or equipment at thecompletion of the installation.

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FIGURE 3HORIZONTAL FURNACE W/HEAT TAPE ON CONDENSATE TRAP

GENERAL INFORMATION

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

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

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

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

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

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

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

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

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

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

! WARNING

! WARNING

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

a. The heat tape must be ULlisted.

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

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

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

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

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

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

c. allow service clearance

LOCATION REQUIREMENTS AND CONSIDERATIONS

I526

DRAINPIPE

HEATTAPE

TRAP

AIRFLOW

9

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

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

CLEARANCE -ACCESSIBILITYThe design of forced air furnaces withinput ratings as listed in the tableunder Figure 5 are certified by CSA-International for the clearances tocombustible materials shown ininches.

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

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

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

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

! WARNING

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

SITE SELECTION1. Select a site in the building near

the center of the proposed, orexisting, duct system.

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

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

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

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

! WARNING

CAUTION!

! WARNING

FIGURE 4HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

GASPIPE

TRAP

EXHAUSTFAN

ELECTRICALCONDUIT

INTAKEVENT

I522

AIRFLOW

NOTE: Do not block furnace access with support rods. Maintain clearances recommended in Figure7. Allow enough space for proper service maintenance or replacement of the heat exchanger andblower assembly.

10

FIGURE 5CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS

I392

UPF

LOW M

ODELS

MINIM

UM CLEAR

ANCE

(IN.)

LEFT

RIGHT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0417

1 /2

1611/32

155 /8

215

1325/32

00

01

2*0

111

0617

1 /2

1611/32

155 /8

215

1325/32

00

01

2*0

117

07A

171 /2

1611/32

155 /8

215

1325/32

00

01

2*0

123

07B

2119

27/32

191 /8

218

1 /2

179 /32

00

01

2*0

145

0921

1927/32

191 /8

218

1 /2

179 /32

00

01

2*0

148

1021

1927/32

191 /8

218

1 /2

179 /32

00

01

2*0

152

1224

1 /2

2311/32

225 /8

222

2025/32

00

01

2*0

160

*A service clearance of a

t least 24 inches is re

commended in front o

f all furnaces.

SUPPLY

AIR

RETURN

AIR

AIRFLOW

OPTIONAL RETURN AIR

CUTOUT (EITHER SIDE)*

*BOTH SIDES FOR 1800 CFM

OPTIONAL

RETURN

AIR CUTOUT

(EITHER SIDE)*

I392.DGN

2 DIA. KNOCKOUT

ALT. GAS CONNECTION

267 ⁄16

275 ⁄8

2 DIA.

GAS CONNECTION

11

FIGURE 6CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS

I393

DOWNFLOW M

ODELS

MINIM

UM CLEAR

ANCE

(IN.)

LEFT

RIGHT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0617

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

0117

07A

171 ⁄2

1611⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

0123

07B

2119

27/32

193 /16

218

1 /2

179 /32

00

01

2*0

123

0921

1927⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

148

1021

1927⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

152

1224

1 ⁄223

11⁄32

225 ⁄8

223

5 ⁄820

7 ⁄80

00

12*

0160




f all furnaces.

NOTE:IN DOWNFLOW CONFIGURATION, RETURN AIR CUTOUT IS NOT PERMITTED.

AIRFLOW

SUPPLY

AIR

RETURN

AIR

A103501.DGN

2 DIA.

ALT. GAS CONNECTION

2513⁄16

43⁄8

2 DIA.

GAS

CONNECTION

12

FIGURE 7CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS

I520

HORIZONTA

L MODELS

MINIM

UM CLEAR

ANCE

(IN.)

LEFT

RIGHT

SHIP

MODEL

AB

CD

EF

SIDE

SIDE

BACK

TOP

FRONT

VENT

WGT

S

0617

1 ⁄216

11⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

0117

07A

171 ⁄2

1611⁄32

155 ⁄8

216

5 ⁄813

7 ⁄80

00

12*

0123

07B

2119

27⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

123

0921

1927⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

148

1021

1927⁄32

193 ⁄1

62

201 ⁄8

173 ⁄8

00

01

2*0

152

1224

1 ⁄223

11⁄32

225 ⁄8

223

5 ⁄820

7 ⁄80

00

12*

0160




f all furnaces.

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

Horizontal left-hand airflow only.

IMPORTANT: This furnace is not approved or recommended for

installation on its back, with access doors facing upwards.

AIRFLOW

DRAIN TRAP LOCATION

SUPPLY

AIR

RETURN AIR

A103601.DGN

2 DIA.

GAS

CONNECTION

2 DIA.

ALT. GAS

CONNECTION

43⁄8

2513⁄16

1313

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

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

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

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

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

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

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

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

UPFLOW UNITS1. Position the unit to minimize long

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

2. Open the return air compartment.

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

a. Cut an opening in the side. Theopening should be cut the fullwidth and height of the knockoutson the unit. See Figure 8.

NOTE: Where the maximum air flowis 1800 CFM or more, both sides or 1side and the bottom must be used forreturn air.

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

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

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

NOTE: DO NOT use a rear airreturn.

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

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

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

! WARNING

FIGURE 8UPFLOW CUTOUT AND DRILL INFORMATION

JACKET

DRILL (2)3/16" DIA.HOLES

8.000

4.875

1.531

! WARNING

14

DOWNFLOW UNITS1. Position the unit to minimize long

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

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

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

4. Connect the furnace to thesupply air plenum.

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

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

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

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

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

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

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

3. Connect the furnace to the supplyair plenum.

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

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

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

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

! WARNING

FIGURE 9NON-COMBUSTIBLE FLOOR BASE

TABLE 1NON-COMBUSTIBLE FLOOR BASES

Floor Base SizeNo. Cabinet

(-)XGC-B17 17

(-)XGC-B21 21

(-)XGC-B24 24

15

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).

IN CANADA, PRODUCTSCERTIFIED FOR INSTALLATIONAND INTENDED TO BE VENTEDWITH PLASTIC VENT SYSTEMS(PVC, CPVC) MUST USE VENTSYSTEMS THAT ARE CERTIFIEDTO THE STANDARD FOR TYPE BHGAS VENTING SYSTEMS, ULCS636.THE COMPONENTS OF THECERTIFIED MATERIAL MUST NOTBE INTERCHANGED WITH OTHERVENT SYSTEMS OR UNLISTEDPIPE/FITTINGS.PLASTIC COMPONENTS ANDSPECIFIED PRIMERS AND GLUESOF THE CERTIFIED SYSTEM MUSTBE FROM A SINGLE SYSTEMMANUFACTURER AND NOTINTERMIXED WITH OTHERSYSTEM MANUFACTURER’SPARTS.NOTE: INLET AIR PIPING IS NOTCONSIDERED TO BE A PART OFTHE “VENTING SYSTEM”. THE

REQUIREMENT THAT VENTMATERIAL BE CERTIFIED TO ULCS636 DOES NOT APPLY TO INLETAIR PIPING. VENT TERMINATIONSAND CONCENTRIC TERMINATIONSMUST BE APPROVED BY THEMANUFACTURER AND CERTIFIEDULC-636.

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

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

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

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

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

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

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

REPLACE THESE SWITCHESONLY WITH THE IDENTICALREPLACEMENT PART.

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

openings in the common ventingsystem.

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

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

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

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

VENTING AND COMBUSTION AIR PIPING

! WARNING

! WARNING

! WARNING

16

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

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

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

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

JOINING PIPE AND FITTINGS

PVC SOLVENT CEMENTS ANDPRIMERS ARE HIGHLYFLAMMABLE. PROVIDEADEQUATE VENTILATION AND DONOT ASSEMBLE NEAR HEATSOURCE OR AN OPEN FLAME. DONOT SMOKE. AVOID SKIN OR EYECONTACT. OBSERVE ALLCAUTIONS AND WARNINGSPRINTED ON MATERIALCONTAINERS. FAILURE TOFOLLOW THESE GUIDELINESMAY RESULT IN FIRE, EXPLOSIONOR ASPHYXIATION CAUSINGPERSONAL INJURY OR DEATH.All pipe, fittings, solvent cement,primers and procedures mustconform to American NationalStandard Institute and AmericanSociety for Testing and Materials(ANSI/ASTM) standards as shownbelow:

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.

! WARNING

PIPE & FITTING MATERIAL ASTMSPECIFICATION

Schedule 40 PVC (Pipe) D1785

Schedule 40 PVC (Cellular Core Pipe) F891

Schedule 40 PVC (Fittings) D2466

SDR-21PVC (Pipe) D2241

SDR-26 PVC (Pipe) D2241

Schedule 40 ABS Cellular Core DWV (Pipe) F628

Schedule 40 ABS (Pipe) D1527

Schedule 40 ABS (Fittings) D2468

ABS-DWV (Drain Waste & Vent)(Pipe & Fittings) D2661

PVC-DWV (Drain Waste & Vent)(Pipe & Fittings) D2665

17

NON-DIRECTFURNACE INSTALLATIONS

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

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

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

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

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

• 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 forclothes dryers

• Masonry curing and acid washingmaterials

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

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

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

EXAMPLE 1:FURNACE LOCATED IN ANUNCONFINED SPACE

Using indoor air for combustion.

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

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

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

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

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

90,000 563 20’ x 28’ OR 24’ x 24’

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

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

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

EXAMPLE 2:FURNACE LOCATED IN ACONFINED SPACE

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

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

A. USING INDOOR AIR FORCOMBUSTION

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

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

COMBUSTION AND VENTILATION AIR

! WARNING

! WARNING

18

BTUH Free AreaInput Each Opening

45,000 100 square inches






B. USING OUTDOOR AIR FORCOMBUSTION

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

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

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

a. Where directly communicatingwith the outdoors or where

communicating to the outdoorsthrough vertical ducts as shown inFigure 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 (see 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 OFNOT LESS THAN ONESQUARE INCH PER 1,000BTU PER H0UR OF THETOTAL INPUT RATING OFALL EQUIPMENT IN THEENCLOSURE, BUT NOTLESS THAN 100 SQUAREINCHES.

GASWATERHEATER

FURNACE

GASWATERHEATER

GASWATERHEATER

FURNACE FURNACE

12" MAX.12"MAX.

1 SQ. INCH PER4000 BTUH INLET AIR

OUTLET AIR 1 SQ. INCHPER 2000 BTUH

INLET AIR 1 SQ. INCHPER 2000 BTUH

1 SQ. INCH PER4000 BTUHOUTLET AIR

OPTIONAL 1 SQ. INCH PER 4000 BTUH INLET AIR

VENTILATEDATTIC GABLE ORSOFFIT VENTS

GABLEVENTOUTLET AIR

IN ATTICMUST BEABOVEINSULATION

19

FIGURE 13COMBUSTION AIR FITTING

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

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








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

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

Combustion air openings must not berestricted in any manner.

CONSULT LOCAL CODES FORSPECIAL REQUIREMENTS.

CONNECTION TOFURNACEIMPORTANT:When indoorcombustion air is used, the inlet airopening at the furnace must beprotected from accidental blockage.(See Figure 13).

UPFLOW

DOWNFLOW/HORIZONTAL

2" PVCDOUBLEELBOW

TOPOPTION

EXHAUST

2" PVC ELBOW

SIDEOPTION

2" PVCDOUBLEELBOW*

COMBUSTION AIREXHAUST

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

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

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

I337I336

PREDRILL FOR SCREWS.

20

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 long-sweep, 2-in.PVC elbows and 2-in. PVC pipe, attaching the tee so it is 12 inches from the wall.

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

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

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

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

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

6. The minimum vent pipe length is5 feet.

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

8. Vent cannot be ran underground.

FIGURE 14TEE TERMINAL – FOR STANDARDHORIZONTAL NON-DIRECTINSTALLATION

VENT

12" 12" MIN. ABOVEGRADE OR

SNOW LEVEL

NUMBERS OF ELBOWS45° OR 90°

Medium / Long Radius ONLY

1-2 3-4 5-6

2”Standard 60 55 50

45,000Alternate 55 50 45


Alternate 25 20 1560,000

3”Standard 120 120 115

Alternate 120 120 110

3”Standard 45 40 NA

75,000Alternate 45 45 NA


90,000Alternate 60 50 45

105,000 3”Standard 45 40 NA

Alternate 45 45 NA

120,000 3”Standard 70 65 55

Alternate 40 30 25

NOTES:1. *N.A. - NOT APPLICABLE.2. MAXIMUM OF 6 ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FORALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.

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

FURNACEINPUT

VENT PIPE INSTALLATION

PIPESIZE

TERMINATION

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

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

NUMBERS OF ELBOWS45° OR 90°


1-2 3-4 5-6


Alternate 30 25 2060,000

3”Standard 120 120 120

Alternate 110 105 100

3”Standard 120 120 120

75,000Alternate 100 95 85

90,000 3”Standard 110 105 95

Alternate 50 40 35

105,000 3”Standard 65 60 55

Alternate 50 40 35

120,000 3”Standard 40 35 30

Alternate 40 35 30

NOTES:1. *N.R. - NOT RECOMMENDED.2. MAXIMUM OF 6 - 90 DEGREE ELBOWS MAY BE USED. DO NOT COUNT ELBOWS REQUIRED FORALTERNATE TERMINATION. USE ONLY MEDIUM OR LONG SWEEP ELBOWS.

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

FURNACEINPUT

PIPESIZE

TERMINATION

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

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

21

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

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

Vertical through-the-roof installations donot require a vent termination. Use 2-in.PVC pipe extending a minimum of 12inches above the anticipated level ofsnow accumulation. See exhaust piperequirements, Figure 19. When 3-in.vent pipe is used from furnace to theroof, reduce it to 2 inches beforepenetrating the roof. A maximum of 18inches of 2-in. pipe may be used belowthe roof. Maximum exposed vent lengthabove the roof line is 30”. Total 2” ventlength is a maximum of 48”.

Horizontal vent terminations require a2-in. PVC tee positioned 12 inches fromthe outside wall. See exhaust piperequirements, Figure 29. 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 long-sweepradius bend, 2-in. PVC elbows and alength of 2-in. PVC pipe so that theelbows are on 24-in. centers.

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

NON-DIRECT VENT TERMINATIONLOCATION REQUIREMENTS

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

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

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

! CAUTION

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

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

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

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

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

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

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

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

FIGURE 15ALTERNATE HORIZONTAL TERMINATION FOR NON-DIRECT VENTINSTALLATIONS

NOT APPLICABLE FOR:(-)GRL-07EYBGS MODEL(-)GRL-07EMAES MODEL(-)GRL-10EZAJS MODEL

12"

FROM

24"MAX.

PIPESUPPORTSTRAP

OUTSIDEWALL

I198

22

FIGURE 16OTHER THAN DIRECT VENT TERMINAL CLEARANCES

Nat

ural

Gas

and

Pro

pan

e In

stal

latio

n C

od

eN

atio

nal F

uel G

as C

od

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

23

DIRECT VENTINSTALLATIONS

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

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

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

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

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

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

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

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

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

! WARNING

Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/GXGY-G02 65 60 5545,000 2”

Alternate RXGY-D02/RXGY-D02A 55 50 45

Standard/Concentric RXGY-D02/RXGY-D02A/RXGY-E03A/RXGY-G02 40 35 302”

Alternate RXGY-D02/RXGY-D02A 40 35 3060,000

3”Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 120 120 120


Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 40 NA75,000 3”

Alternate RXGY-D03/RXGY-D03A 50 40 NA

Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 110 105 9590,000 3”


Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 50 40 NA105,000 3”

Alternate RXGY-D03/RXGY-D03A 50 40 NA



FURNACEINPUT

PIPESIZE

TERMINATION VENT TERMINATIONKIT RECOMMENDED

2 4 6

NUMBER OF ELBOWS45 or 90 Degrees


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

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

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

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

FURNACEINPUT

PIPESIZE

TERMINATION VENT TERMINATIONKIT RECOMMENDED

1 - 2 3 - 4 5 - 6

NUMBER OF ELBOWS22.5, 45 or 90 Degrees


NOTES:1. N.A. - NOT APPLICABLE2. 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/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.5. USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATETHRU-THE-WALL VENTING.

6. USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.7. KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.8. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.(A*) = 171⁄2” CABINET (B*) = 21” CABINET


Alternate RXGY-D02/RXGY-D02A 30 25 2060,000





Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-D03A/RXGY-G02 110 105 9590,000 3”

Alternate RXGY-D03/RXGH-D03A 50 40 35

Standard/Concentric RXGY-D03/RXGY-D03A/RXGH-E03A/RXGY-G02 65 60 55105,000 3”


Standard/Concentric RXGY-D03/RXGY-D03A/RXGY-E03A/RXGY-G02 40 35 30

120,000 3” Alternate RXGY-D03/RXGY-D03A 40 35 30


NOTES:1. N.A. - NOT APPLICABLE2. 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/RXGY-E03A IS FOR THRU-THE-ROOF OR THRU-THE-WALL VENTING.5. USE KITS RXGY-DO2/D02A (2"), RXGY-G02 (2"), OR RXGY-D03/D03A (3") FOR STANDARD OR ALTERNATETHRU-THE-WALL VENTING.

6. USE KITS RXGY-D04/D04A FOR ALTERNATE VENTING OF 120,000 BTUH UNITS WITH LONG RUNS.7. KIT NUMBERS CONTAINING SUFFIX “A” ARE APPROVED FOR INSTALLATION IN CANADA.8. NO SCREENS MAY BE USED TO COVER COMBUSTION AIR AND EXHAUST.(A*) = 171⁄2” CABINET (B*) = 21” CABINET

24

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: (-)XGY-D02/D02A, (-)XGY-D03/D03A, (-)XGY-D04/D04A, or (-)XGY-E03A.

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

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

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

STANDARD TERMINATIONSSTANDARD VERTICALTERMINATIONS

COMBUSTION AIR PIPING

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

prevent entry of rain. See Figure 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.

IMPORTANT: To ensure properfurnace operation, the supplied vanemust be installed in the verticalposition with PVC solvent as shown inFigure 20, 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 (-)XGY-E03/E03A, must have a drain teeassembly and trap installed as closeto the furnace as possible. This is todrain any water that may be in thecombustion air pipe to prevent it fromentering the furnace combustionchamber.

These parts are included in kits (-)XGY-D02/D02A (for 2-in. pipe), (-)XGY-D03/D03A (for 3-in. pipe) and(-)XGY-D04/D04A (special for the120,000 BTU furnace installed withthe alternate horizontal termination).Attach the trap to the bottom of thetee with PVC solvent. Connect theother end to a suitable drain, as to thedownstream of a condensate trap onthe 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 air

termination. 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 4 for properapplication. This mustbe reduced to 11/2“ the last12 inches for models with inputs of45,000 through 75,000 BTUH.See Figure 19.

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 A.

The combustion air and exhaustterminations must be at least 12inches above grade and must beoriented with respect to each other asshown in Figure 20, Detail B. Refer tosection on alternate venting optionswhen higher snow levels areanticipated.

ALTERNATETERMINATIONSALTERNATE HORIZONTALDIRECT VENT TERMINATIONS

(-)XGY-D02/D02A, -D03/D03A AND -D04/D04A

The combustion air and exhaustterminations may be raised amaximum of 24 inches above thewall penetration to maintain therequired 12 inch clearance abovegrade or snow level. See Figure 17.Size the pipe length according toTable 4 and Table 5.

Review the following guidelines:

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

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

length (above the roof line) is 30”.

25

FIGURE 17ALTERNATE HORIZONTAL DIRECT VENT TERMINATION

SEE DETAIL A

24” MAX.

PIPESUPPORTSTRAP

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

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

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

INTAKE VENT21/2" PVC FOR MODELS WITH120,000 BTU INPUT.2" PVC ELBOWS AND RISERMODELS WITH INPUTS OF 45,000THRU 105,000 BTU.USE KIT NO. (-)XGY-D02/D02A WHEN 2"PIPE IS USED BETWEEN FURNACE ANDOUTSIDE WALL. USE KIT NO. (-)XGY-D03/D03A WHEN 3" PIPE IS USED.

I339

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

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

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

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

The 45,000 BTUH unit only uses kit (-)XGY-D02/D02A. The 60,000 BTUHand 75,000 BTUH downflow onlyunits may use kits (-)XGY-D02/D02Aor (-)XGY-D03/D03A depending onpipe lengths and number of elbows.Use kit (-)XGY-D03/D03A with 90,000BTUH downflow through 120,000BTUH units or upflow 90,000 or120,000. The (-)XGY-D04/D04A kitonly applies to the 120,000 BTUHunit using an alternate terminationand excessively long runs. SeeTable 4.

The following are parts lists for the (-)XGY-D02/D02A, (-)XGY-D03/D03Aand (-)XGY-D04/D04A alternatehorizontal direct vent termination kits:

(-)XGY-D02/D02A1. 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

(-)XGY-D03/D03A1. 3-in. tee with reducer assembly2. 1⁄2-in. PVC 6-in. dia. trap3. PVC vane4. 2-in. PVC elbow5. PVC strap6. vent template

(-)XGY-D04/D04A1. 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 strap10. vent template

NOTE: The (-)XGY-D04/D04A kit onlyapplies to the 120,000 BTUH unitusing an alternate termination andexcessively long runs.

3”

4”EXHAUST VANE

INTAKE OPTIONALINTAKE

DETAIL BEXHAUST / INTAKE RELATIONSHIP

DETAIL AEXHAUST VENT FOR

MODELS WITHINPUT OF 45,000 THRU

75,000 BTU

DETAIL CCOMBUSTION AIRTERMINATION

4" FROMWALL

12"FROMWALL

1-1/2"PIPE

12" FROMWALL

(-)XGY-D02A1. 2” Tee assembly w/1⁄2” drain

connection2. 1⁄2” PVC-5” diameter trap3. Wind deflector vane4. Vent template


connection2. 1⁄2” PVC-5” diameter trap3. Wind deflector vane4. Vent Template


connection2. 1⁄2” PVC-6” diameter trap3. Wind deflector vane4. Vent template

26

FIGURE 18CONCENTRIC VENT KIT NO. (-)XGY-E03A

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. (-)XGY-E03A

This kit is for vertical/horizontalintake air/vent runs and may beinstalled through roofs or sidewalls.One 5” diameter hole is required forthe installation. See Figure 18 forthe general layout. Completeinstallation instructions are includedwith the kit.

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

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

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

NOTE: The following IPEX brandconcentric termination (System 636)may be purchased in the field andused in place of factory supplied kits:

3” Concentric Kit – Item # 196006

27

FIGURE 19STANDARD VERTICAL DIRECT VENTING

FIGURE 20STANDARD HORIZONTAL DIRECT VENTING

I407

3" MAX.SEPARATION

36" MAX. COMBUSTION AIRPIPE

12" MIN.SEPARATION

12" MIN. ABOVEROOF LEVELROOF LINEEXHAUST PIPE

COMBUSTION AIR PIPE

SUPPLY AIR

RETURN AIR

EXHAUST VENT

3"MAX.

EXHAUSTVENT

ROOF LINE

COMBUSTIONAIR PIPE

12"MIN.

12"MIN.

ANTICIPATEDSNOW LEVEL

COMBUSTIONAIR PIPE

3"MAX.EXHAUST

VENT

12"MIN.

12"MIN.

3"

MAX.

12" MIN

. 12" MIN

. ABOVE

ANTICIPA

TED SN

OW LEVEL

NOTES:

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

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

3 SUPPORT VERTICAL PIPE EVERY 6FEET.4 EXHAUST TERMINATION - TERMINATETHE LAST 12 INCHES WITH 2” PVC PIPE

ON 90,000 AND 120,000 BTUH MODELS.REDUCE AND TERMINATE THE LAST12 INCHES WITH 11/2” PVC PIPE ON45,000 THROUGH 75,000 BTUHMODELS. SEE DETAIL A.

5 30” MAXIMUM EXPOSED VENTLENGTH.6 THE COMBUSTION AIR PIPE MUSTTERMINATE IN THE SAME PRESSURE

ZONE AS THE EXHAUST PIPE.

7 NO SCREENS MAY BE USED TOCOVER COMBUSTION AIR ANDEXHAUST.

PITCHED ROOF INSTALLATIONS

NOTES:

1 SUPPORT HORIZONTAL PIPEEVERY FOUR FEET.2 WHEN 3 IN. PIPE IS USED REDUCE TO 2 IN.BEFORE PENETRATING OUTSIDE WALL.3 18 IN. MAXIMUM. 2 IN. DIAMETER PIPE MAYBE USED INSIDE THE WALL.4 DETAIL “A” - EXHAUST TERMINATIONTERMINATE THE LAST 12 INCHES WITH 2”

PVC PIPE ON 90,000 AND 120,000 BTUHMODELS. REDUCE AND TERMINATE THELAST 12 INCHES WITH 11/2” PVC PIPE ON45,000 THROUGH 75,000 BTUH MODELS.

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

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

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

8 NO SCREENS MAY BE USED TO COVERCOMBUSTION AIR AND EXHAUST.9 NO ELBOWS CAN BE INSTALLED ATTERMINATION.

3”

12”

4”

4”

SEE DETAIL A

VANE 2” PVCCOUPLING

12” MIN. ABOVEGRADE LEVEL 5

SEE DETAIL B

2” OR 3” TEEW/DRAIN TRAP

RETURN AIR

TRAP

SUPPLY AIR

EXHAUST PIPE

COMBUSTION AIR PIPE

CONNECTTO DRAIN

12�

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