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Iceco 90RJ Series Installation Instructions Manual

Upflow & downflow/horizontal high efficiency condensing gas furnaces
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INSTALLATION INSTRUCTIONS
FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH
EFFICIENCY CONDENSING GAS FURNACES
90RJ AND 90TJ SERIES
U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all
applications, and their installation should be in accordance with the manufacturer's
recommendations and/or local laws, rules, regulations, or customs.
92-24161-32-10
SUPERSEDES 92-24161-32-09

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  • Page 1: Safety Precautions

    INSTALLATION INSTRUCTIONS FOR UPFLOW & DOWNFLOW/HORIZONTAL HIGH EFFICIENCY CONDENSING GAS FURNACES 90RJ AND 90TJ SERIES U.L. recognized fuel gas and CO (carbon monoxide) detectors are recommended in all applications, and their installation should be in accordance with the manufacturer’s recommendations and/or local laws, rules, regulations, or customs. 92-24161-32-10 SUPERSEDES 92-24161-32-09...

  • Page 2: Installation Check List

    INSTALLATION CHECK LIST REFER TO INSTALLATION INSTRUCTIONS GAS SUPPLY TERMINATIONS – DIRECT VENT Adequate pipe size VERTICAL Correct supply pressure (during furnace operation) Intake – 12" min. above roof/snow level Manifold pressure Correct relationship – exhaust to intake No gas leaks HORIZONTAL/VERTICAL –...

  • Page 3: Table Of Contents

    IMPORTANT: All ICECO products CONTENTS meet current Federal OSHA Guidelines for safety. California Proposition 65 Safety Precautions ....................1 warnings are required for certain products, which are not covered by the Installation Check List ....................2 OSHA standards. General Information....................4 California's Proposition 65 requires warnings for products sold in California Safety Information ....................5...

  • Page 4: General Information

    GENERAL INFORMATION The 90RJ and 90TJ series furnaces CSA-INTERNATIONAL Install this furnace in accordance with are design-certified by CSA for use the American National Standard 8501 East Pleasant Valley Road with natural and propane gases as Cleveland, Ohio 44131-5575 Z223.1 – latest edition entitled follows: “National Fuel Gas Code”...

  • Page 5: Safety Information

    SAFETY INFORMATION WARNING WARNING WARNING NEVER TEST FOR GAS LEAKS WHEN THIS FURNACE IS USE ONLY WITH TYPE OF GAS WITH AN OPEN FLAME. USE A APPROVED FOR THIS FURNACE. INSTALLED IN A RESIDENTIAL REFER TO THE FURNACE RATING COMMERCIALLY AVAILABLE GARAGE, IT MUST BE INSTALLED PLATE.
  • Page 6 WARNING NOTICE DUCT LEAKS CAN CREATE AN IN COMPLIANCE WITH UNBALANCED SYSTEM AND RECOGNIZED CODES, IT IS DRAW POLLUTANTS SUCH AS RECOMMENDED THAT AN DIRT, DUST, FUMES AND ODORS AUXILIARY DRAIN PAN BE INTO THE HOME CAUSING INSTALLED UNDER ALL PROPERTY DAMAGE.

  • Page 7: Location Requirements And Considerations

    LOCATION REQUIREMENTS AND CONSIDERATIONS GENERAL INFORMATION FIGURE 3 IMPORTANT INFORMATION MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES ABOUT EFFICIENCY AND INDOOR AIR QUALITY Central cooling and heating equipment is only as efficient as the duct system that carries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality, it is important to have the proper balance between the air...
  • Page 8 1. IMPORTANT: If installing the 3. IMPORTANT: Install the furnace WARNING unit over a finished ceiling or level. If it is not level, condensate DO NOT USE THIS FURNACE living area, be certain to install an cannot drain properly, possibly DURING CONSTRUCTION IF AIR auxiliary condensate drain pan causing furnace shut down.
  • Page 9 c. The heat tape should be FIGURE 5 rated at 5 or 6 watts per foot HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS at 120V. IMPORTANT: Support this unit PIPE when installed. Since this furnace is suitable for attic or crawl space installation, it may be installed on combustible wood flooring or by INTAKE...
  • Page 10 FIGURE 6 CLEARANCE TO COMBUSTIBLES, UPFLOW UNITS I392...
  • Page 11 FIGURE 7 CLEARANCE TO COMBUSTIBLES, DOWNFLOW UNITS I393...
  • Page 12 FIGURE 8 CLEARANCE TO COMBUSTIBLES, HORIZONTAL UNITS I520...

  • Page 13: Ducting

    DUCTING UPFLOW UNITS 5. If summer air conditioning is desired, position the indoor coil 1. Position the unit to minimize long Proper air flow is required for the on the top of the unit. Insure that runs of duct or runs of duct with correct operation of this furnace.

  • Page 14: Venting And Combustion Air Piping

    4. Connect the furnace to the 4. Connect the return air ducting to 5. Be sure to have adequate supply air plenum. the return air opening at the right space for the unit filter. end of the unit. Make the 5.
  • Page 15 The following steps should be space containing the appliances is in CEMENTING JOINTS followed with each appliance a building with tight construction Properly seal all joints in the PVC remaining connected to the original (contemporary construction), outside vent using the following materials and common vent system.

  • Page 16: Combustion And Ventilation Air

    COMBUSTION AND VENTILATION AIR NON-DIRECT FURNACE INSTALLATIONS • Cleaning solvents (such as BTUH Minimum Sq. Feet Typical Room Size Input With 8' Ceiling With 8' Ceiling perchloroethylene) 45,000 14' x 20' OR 16' x 18' • Printing inks, paint removers, WARNING 60,000 15' x 25' OR 19' x 20'...
  • Page 17 BTUH Free Area FIGURE 11 Input Each Opening AIR FROM HEATED SPACE 45,000 100 square inches 60,000 100 square inches 75,000 100 square inches 90,000 100 square inches 105,000 105 square inches 120,000 120 square inches NOTE: EACH OPENING SHALL B.
  • Page 18 Method 2 CONNECTION TO BTUH Free Area Round Pipe (Not Shown) Input Each Opening Size FURNACE One permanent opening, located 45,000 15.00 square inches 4" within 12 inches of the top of the IMPORTANT: When indoor 60,000 16.67 square inches 5"...

  • Page 19: Vent Pipe Installation

    VENT PIPE INSTALLATION NON-DIRECT VENT TABLE 1 FOR NON-DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION INSTALLATION PROVIDED FROM INDOORS GUIDELINES MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE PIPE IMPORTANT: Failure to correctly follow all venting guidelines may NUMBERS OF ELBOWS result in erratic furnace operation, 45°...
  • Page 20 “rub-a-tex” insulation may also be INSTALLATION CAN CAUSE 7. Avoid areas where dripping used as long as there is no heat STRUCTURAL OR EXTERIOR condensate may cause problems, tape applied to the vent pipe. For FINISH DAMAGE TO THE such as above planters, patios, or horizontal runs where water may BUILDING.
  • Page 21 FIGURE 17 OTHER THAN DIRECT VENT TERMINAL CLEARANCES...
  • Page 22 DIRECT VENT TABLE 2 INSTALLATIONS FOR DIRECT VENT APPLICATIONS - AIR FOR COMBUSTION PROVIDED FROM OUTDOORS WARNING MAXIMUM ALLOWABLE LENGTH IN FEET OF EACH EXHAUST PIPE AND INTAKE AIR PIPE READ AND FOLLOW ALL INSTRUCTIONS IN THIS SECTION. NUMBER OF ELBOWS VENT TERMINATION FAILURE TO PROPERLY VENT 45°...
  • Page 23 COMBUSTION AIR FOR STANDARD HORIZONTAL Refer to Table 2 for proper TERMINATIONS application. This must DIRECT VENT be reduced to 1” or 1 “ the last INSTALLATIONS COMBUSTION AIR PIPING 12 inches for models with inputs of THE COMBUSTION AIR SYSTEM When 3-in.
  • Page 24 • Insulate the entire length of vent FIGURE 18 pipe, between the elbow where the ALTERNATE HORIZONTAL DIRECT VENT TERMINATION pipe exits the wall and the elbow EXHAUST VENT where the termination is made, with " PVC FOR MODELS WITH 120,000 BTU INPUT (KIT NO.
  • Page 25 CONCENTRIC TERMINATIONS VERTICAL/HORIZONTAL CONCENTRIC VENT KIT NO. RXGY-E03 This kit is for vertical/horizontal intake air/vent runs and may be installed through roofs and sidewalls. One 5” diameter hole is required for the installation. See Figure 19 for the general layout. Complete installation instructions are included with the kit.
  • Page 26 FIGURE 20 STANDARD VERTICAL DIRECT VENTING 3" UPFLOW MODEL SHOWN (TYPICAL FOR DOWNFLOW MODELS) EXHAUST MAX. VENT COMBUSTION AIR PIPE 12" 3" MAX. MIN. SEPARATION 12” 12" MIN. 3" EXHAUST MAX. VENT EXHAUST COMBUSTION AIR COMBUSTION TERMINATION PIPE AIR PIPE 12"...
  • Page 27 FIGURE 22 DIRECT VENT TERMINAL CLEARANCES...
  • Page 28 LOCATION REQUIREMENTS In addition to the minimum surfaces, unless a rust-resistant clearances listed above, the vent sheet metal or plastic backing HORIZONTAL DIRECT VENTS location should also be governed plate behind vent. See Figure 23. by the following guidelines. 5. Do not locate too close to shrubs CAUTION 1.
  • Page 29 FIGURE 24 FIGURE 25 TWO FURNACE VENTING THROUGH ROOF TWO FURNACE VENTING THROUGH WALL TWO-PIPE VENTING TWO-PIPE VENTING EXHAUST VENT MODELS 06-07 TO BE REDUCED TO 1-1/2” PVC LAST 12”. 3” MINIMUM 24” MAXIMUM 3” MINIMUM 24” MAXIMUM CONCENTRIC VENTING CONCENTRIC VENTING 8”...
  • Page 30 RXGY-G02 SIDE WALL VENT NOTE: Install the vent and air intake NOTE: The vent illustration in Figure piping into the vent plate openings. 27 can be used for Non-direct vent This termination for horizontal venting Seal all gaps between the pipes and terminations also.
  • Page 31 CONNECTING TO FURNACE FIGURE 28 UPFLOW COMBUSTION AIR AND VENT PIPE CONNECTION IMPORTANT: Clean and debur all pipe cuts. The shavings must not be allowed to block the exhaust, inlet or condensate drain pipes. COMBUSTION “O” RING AIR ADAPTER TOP PLATE NOTE: UPFLOW FURNACE WHEN COMBUSTION AIR INLET IS IN...

  • Page 32: Condensate Drain/Neutralizer

    CONDENSATE DRAIN/NEUTRALIZER GENERAL INFORMATION drain is present, install a riser which is CONDENSATE OVERFLOW: With a a minimum of 10 ⁄ ”. If the furnace is ⁄ inch riser installed above the tee, installed in an attic, crawlspace or other a blocked drain will result in overflow CAUTION area where freezing temperatures may...
  • Page 33 REVERSING THE TRAP Remove the plug from the 2” alternate IMPORTANT: Do not connect into a drain hole (see Figure 33) and common drain line with an air replace it with the 2” rubber grommet UPFLOW UNITS conditioner evaporator coil drain supplied in the RXGY- H01 downflow located above the furnace.

  • Page 34: Converting Downflow To Horizontal

    CONVERTING DOWNFLOW TO HORIZONTAL 8. Attach the gasket ➇ onto the trap CONDENSATE DRAIN 12. IMPORTANT: There are two assembly so that the gasket options when choosing a height FOR HORIZONTAL holes on the gasket line up with for the condensate riser: INSTALLATION the holes on the trap assembly.

  • Page 36: Gas Supply And Piping

    GAS SUPPLY AND PIPING GAS SUPPLY FIGURE 37 GAS PIPING INSTALLATION UPFLOW WARNING THIS FURNACE IS EQUIPPED AT GROMMET THE FACTORY FOR USE ON MAIN GAS NATURAL GAS ONLY. NOTE: WHEN GAS LINE VALVE TOP VIEW OF GAS LINE AND VALVE IS IN OPT.
  • Page 37 Install a ground joint union inside TABLE 3 the cabinet to easily remove the NATURAL GAS PIPE CAPACITY TABLE (CU. FT./HR.) control valve assembly. Install a manual shut-off valve in the gas Capacity of gas pipe of different diameters and lengths in cu. ft. per hr. with pressure drop of 0.3 in. and specific line outside the furnace casing.
  • Page 38 LP CONVERSION FIGURE 40 TYPICAL LP KIT CONTENTS NOTE: See Page 38 for Canadian High-Altitude Derate IMPORTANT: LP gas from trucks used to transport liquid-based fertilizers can contain chemicals that will damage the furnace. Verify that your gas supplier does not use the same trucks to transport materials other than LP.
  • Page 39 SETTING GAS PRESSURE The maximum gas supply pressure Supply Gas Pressure Measure- 6. Replace the pressure tap plug to the furnace should be 10.5" w.c. ment. A line pressure tap is on the before turning on the gas. natural gas, or 13" w.c. LP gas. The input side of the gas valve.
  • Page 40 FIGURE 42 MANIFOLD PRESSURE READING FIGURE 43 UPFLOW GROUNDING CONNECTIONS LOW VOLTAGE TERMINALS JUNCTION CONDENSATE TRAP MOUNTING PLATE BLOWER COMPARTMENT CONTROL IS GROUNDED WHEN ATTACHED TO BLOWER I409-3...

  • Page 41: Electrical Wiring

    ELECTRICAL WIRING sense flame if L1 and L2 are reversed. integrated furnace control. The low See Figure 44. voltage wiring should be sized as shown. Make all electrical connections in WARNING accordance with the latest edition of the NOTE: Do not use 24 volt control National Electrical Code ANSI/NFPA70 wiring smaller than No.

  • Page 42: Accessories

    fireplace, sun rays, lamps, televisions, FURNACE TWINNING UT ELECTRONIC CONTROLS radios or air streams from registers. 1028-928 CONTROL BOARD INSTALLATIONS Refer to instructions packed with the 1. Single Stage Operation thermostat for “heater” selection or Twinning operation of two furnaces, (See Figure 44) adjustment.
  • Page 43 FIGURE 46 UT Electronic Controls 1028-928 CONTROL BOARD, TWINNING CONNECTION -- SINGLE STAGE OPERATION Control Board 1 Control Board 2...
  • Page 44 FIGURE 47 UT ELECTRONIC CONTROLS 1028-928 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION Control Board 1 Control Board 2...

  • Page 45: High Altitude Instructions

    90+ HIGH ALTITUDE NATURAL GAS The following are examples of orifice sizing using the National Fuel Gas INSTRUCTIONS CAUTION Code Appendix F. For a simplified estimation of orifice size based on INSTALLATION OF THIS FURNACE 90RJ/90TJ HIGH ALTITUDE heating value and elevation, use AT ALTITUDES ABOVE 2000 FT (610 Tables 5 and 6.
  • Page 47 LP GAS AT HIGH ALTITUDE ORIFICE ORDERING INFORMATION The information in Table 8 is based Orifice sizes are selected by adding the on a heating value of 1000 BTU per ELEVATIONS 2-digit drill size required in the orifice cubic feet of natural gas, and 2500 part number.

  • Page 48: Start-Up Procedures

    START-UP PROCEDURES This furnace is equipped with a direct induced draft blower operates for the second igniter warm-up period, the gas valve opens and the control ignition device. Each time the room complete heating cycle. looks for a flame signal for up to 8 thermostat calls for heat, the ignitor 4.
  • Page 49 Sequence if the system doesn’t light or doesn’t sense flame: 1. On a call for heat, the control runs the inducer for 30 seconds TABLE 9 to pre-purge. METER TIME 2. After the 30-second pre-purge, the spark igniter energizes. The METER TIME IN MINUTES AND SECONDS FOR NORMAL INPUT RATING OF FURNACES inducer continues to run.

  • Page 50: Air Flow

    AIR FLOW THE MOST IDEAL RISE WOULD BE FIGURE 49 55 DEGREES (THE MIDDLE OF TEMPERATURE RISE MEASUREMENT THE RISE RANGE). IN ALL The importance of proper air flow over APPLICATIONS, THE INSTALLER the heat exchanger cannot be over MUST ADJUST THE emphasized.
  • Page 51 TABLE 10 90 PLUS AIR FLOW PERFORMANCE – 90RJ & 90TJ MODELS CFM @ ESP MODEL BLOWER/ SPEED MOTOR HP 90RJ04 11 x 7 / MED-LO MED-HI 1140 1110 1085 1045 1010 HIGH 1360 1320 1280 1235 1195 1140 1080 90TJ04 11 x 7 / MED-LO...
  • Page 52 SETTING BLOWER GAS FURNACE (DIRECT FIGURE 51 TIMINGS DRIVE) INSTRUCTIONS UT Electronic Controls 1028-928 BLOWER OFF TIMINGS FOR CHANGING BLOWER The Honeywell UT ELECTRONIC SPEED CONTROLS and Invensys Climate Controls IFC’S (Integrated Furnace Controls) have three or four quick WARNING connect terminals for connecting the DISCONNECT THE ELECTRICAL motor speed leads.

  • Page 53: Maintenance

    MAINTENANCE TABLE 12 FILTER SIZES WARNING UPFLOW FILTER SIZES FURNACE INPUT BOTTOM SIDE QUANTITY THESE INSTRUCTIONS ARE WIDTH MBTUH SIZE SIZE INTENDED AS AN AID TO " 45, 60, 75 " X 25" " X 25" QUALIFIED SERVICE 21" 90, 105 "...
  • Page 54 FIGURE 55 FILTER LOCATIONS UPFLOW JACKET JACKET ANGLE DRILL (2) JACKET 3/16" DIA. HOLES ANGLE DETAIL ATTACH WITH SHEET METAL 8.000 SCREWS (2 REQÕD) 4.875 FILTER ROD FILTER ROD SUPPORT SUPPORT ANGLE ANGLE AE-60520-01 1.531 FILTER SUPPORT FILTER SUPPORT ANGLE ANGLE (SEE ANGLE DETAIL) (SEE ANGLE DETAIL)

  • Page 55: Wiring Diagrams

    4. Avoid excessive use of kitchen CAUTION WARNING exhaust fans. DO NOT OPERATE THE SYSTEM HOLES IN THE VENT PIPE OR 5. Do not permit the heat generated FOR EXTENDED PERIODS HEAT EXCHANGER CAN CAUSE by television, lamps or radios to WITHOUT FILTERS.

  • Page 56: Troubleshooting

    FIGURE 56 90RJ MODELS W/INTEGRATED FURNACE CONTROL (IFC) UT Electronic Controls 1012-925 (115 VAC IGNITER) INTEGRATED FURNACE CONTROL (IFC) WARNING TROUBLESHOOTING GUIDE HAZARDOUS VOLTAGE DISCONNECT POWER BEFORE SERVICING. NOTE: Most failures are not due to the IFC. Double check all other LINE VOLTAGE SERVICE MUST BE BY A TRAINED, QUALIFIED possibilities, including the ground connection, before replacing the IFC.
  • Page 57 FIGURE 57 90RJ MODELS WITH UT ELECTRONIC CONTROLS 1012-925 OR INVENSYS CLIMATE CONTROLS ICC-H1MC7-01 CONTROL BOARD & HSI...
  • Page 58 FIGURE 58 90RJ MODELS WITH UT ELECTRONIC CONTROLS 1012-925 OR INVENSYS CLIMATE CONTROLS ICC-H1MC7-01 CONTROL BOARD & HSI...
  • Page 60 MANUFACTURED BY ICECO ® 5600 OLD GREENWOOD ROAD, FORT SMITH, ARKANSAS, 72908 CM 0607...

This manual is also suitable for:

90tj series

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