INSTALLATION INSTRUCTIONS SAFETY INFORMATION KIT SUPPLIED PARTS

INSTALLATION INSTRUCTIONS SAFETY INFORMATION KIT SUPPLIED PARTS
HEAT EXCHANGER CONDENSATE DRAIN AND VENT KIT
INSTALLATION INSTRUCTIONS
FOR R8HE / PPG3HE SERIES, GROUND MOUNT, CONDENSING STYLE GAS / ELECTRIC PACKAGE UNITS
SAFETY INFORMATION
IMPORTANT: Please read all instructions before
installing the kit. Pay attention to all safety warnings and
any other special notes highlighted in the manual. Safety
markings are used frequently throughout this manual to
designate a degree or level of seriousness and should not
be ignored. WARNING indicates a potentially hazardous
situation that if not avoided, could result in personal injury
or death. CAUTION indicates a potentially hazardous
situation that if not avoided, may result in minor or moderate
injury or property damage.
WARNING:
ELECTRICAL SHOCK, FIRE OR
EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury or property damage.
Improper servicing could result in dangerous
operation, serious injury, death or property
damage.
• Before servicing, disconnect all electrical power
to the equipment.
• When servicing controls, label all wires prior
to disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.
The installer performing this work assumes all responsibility
when installing this kit. These instructions are primarily
intended to assist qualified individuals experienced in the
proper installation of these components. Some local codes
require licensed installation/service personnel for this type
of equipment. Safety should always be the deciding factor
when installing this product and using common sense
plays an important role as well. Improper installation of
the components or failure to follow safety warnings could
result in serious injury, death, or property damage. After
completing the installation, return these instructions to the
Homeowner’s Package for owner-user’s future reference.
ABOUT THE KIT
This accessory kit is for use with 2-5 Ton 95% condensing
style package gas/electric unit ground mount installations
for proper heat exchanger condensate disposal and
venting. Table 1 is a detailed listing of the components
in the Heat Exchanger Condensate Drain and Vent Kit.
Please check the contents of the kit with that of the parts
listing, and familiarize yourself with each component.
KIT SUPPLIED PARTS
ITEM #
DESCRIPTION
QTY
1
2” PVC x 90 Degree Elbow & 1/4” Mesh Screen
1
2
2” PVC x 10” Pipe
1
3
2” PVC Tee
1
4
2” x 1/2” PVC Reducer Bushing
1
5
1/2” Barb x 1/2” NPTF
1
6
Spring Hose Clamp
1
7
1/2” ID x 36” Drain Hose
1
8
Horizontal Vent Support Bracket & U-Bolt
1
9
1/4-20 Nuts
4
Self Drilling Screws (Not shown)
2
Wire Tie (Not shown)
1
3 Ft. Flexible Insulation (Not Shown)
1
1
9
2
8
3
4
6
5
7
FIELD SUPPLIED PARTS
• 2” PVC pipe x Length. (Length is approximately 16”
+ Regional Frost Line Depth for unit on standard
2’ concrete pad). NOTE: For a trench style drain
installation (page 3) you will also need 4”x36” (min.)
corrugated flexible pipe w/ drain holes, a 2”x4”
PVC reducer, 4” corrugated piping connection,
2”x90 degree. PVC elbow, and 4” filtration sleeve
or permeable barrier material.
• 40-80 Lb. Rock or chat, (Limestone rock or lime
pellets if required by local code for neutralizing the
condensate when disposing into the ground).
• PVC Solvent Cleaner and Pipe Cement.
Table 1. Parts List
VENT PIPE & DRAIN HOSE ASSEMBLY
1.Connect the horizontal 13.25” x 2” PVC pipe (supplied
with the unit) to the inducer motor rubber coupler
and secure using 3” hose clamp provided. NOTE: A
horizontal pipe length up to 18” is approved if pit location
circumstances require it to be further from the unit and
pad. A new support bracket or adaptor piece will have
to be field created to ensure the vent assembly does
not rotate.
2.Clean & glue the 2” x ½” reducer bushing into the Tee.
3.Install the ½” hose connector to the reducer bushing.
4.Place the 2” PVC Tee onto the end of the horizontal pipe. DO NOT CEMENT THE TEE ON AT THIS TIME.
Drop a plumb line from the bottom of the ½” drain fitting
to the ground to locate the starting point of the pit or
trench.
VERTICAL DRAIN PIT METHOD
NOTE TO INSTALLER
READ THIS BEFORE YOU DIG!
Before you begin digging the pit for the condensate
drain line assembly, you may need to call to find out
where underground electric, gas, or other utilities
are located. Some state laws require that a locate
request be placed at least three (3) working days
prior to any digging projects. The utilities should
respond to your request by marking the approximate
location of their utilities or notifying you that they
have no utilities in your dig site area. After confirming
utility response, you can then proceed with your
excavation avoiding damages.
IMPORTANT NOTE: The flue condensate of this unit
is slightly acidic and some local codes may require
a neutralizing treatment when disposing directly into
the ground. Check state or local code requirements
for application of this equipment and if necessary
substitute limestone rock, chat, or lime pellets to
the pit to neutralize the condensate instead of using
basic rock or chat.
Preparing the pit
After pit location has been determined, the condensate
drain pit must be prepared for installation of the vertical
2” PVC vent pipe and insulated drain hose assembly. If
desired, remove any sod and top soil prior to digging for
later use at end of installation.
Vertical pit should be approximately 12”-14” in diameter
(or larger) for installation of the rock base and vertical
piping system to allow for proper drainage with a depth of
4”-6” below the regional frost line if possible. See Figure 1.
Percolation Test (Optional)
A simple percolation test (not required) can be performed
to aide in determining if the diameter and depth for the pit
is suitable. It will allow you to simply observe how quickly
a known volume of water dissipates into the subsoil of a
drilled hole of known surface area. In general, sandy soil
will absorb more water than soil with a high concentration
of clay or where the water table is close to the surface.
2
FURNACE HX SIZE
UNIT CONDENSATE DISPOSAL RATE
STEADY STATE
3 Tube – 60 KBTU
0.35 GPH
4 Tube – 80 KBTU
5 Tube – 100 KBTU
0.45 GPH
0.55 GPH
Table 2. Condensate Disposal Rate
1.Using Table 2, identify the approximate volume of water
being produced for the equipment being installed.
2.Pour a volume (V) of water large enough into the hole
capable of measuring the height.
(V) = (X) x Steady state Disposal Rate.
Example: For 5-Tube (100,000 BTU), if X=4 then
water volume (V) = 4 x 0.55 GPH = 2.20 Gallons.
3.Immediately measure the water level depth at the start
of the test (Y1Start) and then again after one hour
(Y2Final).
NOTE: The pit water level height change should be
greater than or equal to the disposal rate height change
or you may want to widen or deepen the hole if possible.
Pit Water Level Height Change = (Y1Start)-(Y2Final)
should be greater than or equal to Disposal Rate Height
Change= (Y1Start)/(X).
Vertical Drain Pipe Installation
1.After the pit has been dug out, pour the rock or chat
base to a level approximately 2” below the frost line.
Mix in 50% of the limestone rock, chat, or lime pellets
(if required by code) with the initial rock base.
2.Measure the distance between the top of the rock base
and bottom of ½” drain fitting.
3.Cut the field supplied 2” PVC pipe to the measured
length.
4.Cut the drain hose and insulation to the measured length
less 3” so the drain cannot become blocked.
5.Connect vinyl drain tube to the ½” barbed drain
connection at bottom of 2” PVC Tee and secure with
spring hose clamp.
6.Install flexible insulation over the entire length of drain
tube and cut away any excess, then secure at the top
with wire tie provided.
7.Place the 2” PVC pipe into the pit and work the drain
hose assembly into the pipe until the entire length is
inside and the PVC pipe is vertical.
8.Glue or use two 1/2” long screws (field supplied) to
secure the 2” PVC Tee to the unit horizontal vent pipe. See Joint A in Figure 1. NOTE: Fastening the Tee to
the horizontal vent pipe with 1/2” screws will make
disassembly easier for future cleaning or inspection of
the drain / vent system.
9.While holding the 2” pipe completely vertical and
centered to the drain tee, slowly backfill the pit around
the outside of the pipe. NOTE: Use the remaining rock
or chat until above the frost line then use remaining
backfill materials from the excavation area.
10.Continue to backfill the hole until 1”-2” above grade level,
then grade away to keep rain water from collecting in
the pit area as the ground settles over time. Add any
remaining top soil & sod back to pit location if desired.
11.Proceed to Completing the Vent section on page 3.
HORIZONTAL DRAIN TRENCH METHOD
(ALTERNATE DRAIN CONSTRUCTION)
If the surrounding area does not allow the digging of
a pit due to rock, dense clay soil, etc., the drain may
be applied in a shallower horizontal trench as long as
regional conditions allow. This type of application is not
recommended for areas where temperatures are below
200 F for extended periods of time but is also dependent
on the final depth of the trench if the frost line cannot be
reached. The unit will operate longer and more frequently
during colder weather to help keep the trench from freezing.
NOTE TO INSTALLER
READ THIS BEFORE YOU DIG!
Before you begin digging the trench for the
condensate drain line assembly, you may need to
call to find out where underground electric, gas, or
other utilities are located. Some state laws require
that a locate request be placed at least three (3)
working days prior to any digging projects. The
utilities should respond to your request by marking
the approximate location of their utilities or notifying
you that they have no utilities in your dig site area.
After confirming utility response, you can then
proceed with your excavation avoiding damages.
IMPORTANT NOTE: The flue condensate of this unit
is slightly acidic and some local codes may require
a neutralizing treatment when disposing directly into
the ground. Check state or local code requirements
for application of this equipment and if necessary
substitute limestone rock, chat, or lime pellets to
the pit to neutralize the condensate instead of using
basic rock or chat.
Preparing the Trench
Start the trench where the 2” vertical pipe can be installed
vertically into the trench and centered under the vent
tee. The horizontal trench should be approximately 8”10” wide x 30”-36” long with a minimum depth of 12”-14”
(or deeper) when possible to allow for proper drainage
and minimize chance of freeze up. The trench shoud be
directed away from the unit and home with an approximate
1” / 12” slope. To determine if the length and width for the
trench is suitable, refer to the optional percolation test
section on page 2.
Horizontal Drain Pipe Installation
1.After the trench has been dug out, lay in a 3”-4” rock
or chat base the full length of the trench with a slight
slope of 1/4”-1/2”/ per foot. Mix in 50% of the limestone
rock, chat, or lime pellets (if required by code) with the
initial rock base.
2.Clean and cement the field supplied 2” x 90 degree
elbow and 2” x 4” reducer assembly together.
3.Measure and cut a length of 2” PVC that extends vertically
from the bottom of the ¾” drain fitting at the bottom of
the tee to the 2” elbow/reducer assembly resting on the
rock base as shown in Figure 2.
4.Cut the 3/4” vinyl drain hose and flexible insulation to
the same length as the 2” vertical PVC pipe.
5.Secure the elbow/reducer assembly to one end of the
4” drain pipe.
6.Cut the 4” corrugated flexible drain pipe with drain holes
to a length extending to the end of the trench.
7.Connect vinyl drain tube to the ½” barbed drain
connection at bottom of 2” PVC Tee and secure with
spring hose clamp.
8.Install flexible insulation over the entire length of drain
tube and cut away any excess, then secure at the top
with wire tie provided.
9.Cement the 2” PVC pipe into the elbow/reducer assembly.
10.Work the drain hose assembly into the pipe until the
entire length is inside and the PVC pipe is vertical.
11.Glue or use two 1/2” long screws (field supplied) to
secure the 2” PVC Tee to the unit horizontal vent pipe. See Joint A in Figure 2. NOTE: Fastening the Tee to
the horizontal vent pipe with 1/2” screws will make
disassembly easier for future cleaning or inspection
of the drain / vent system.
12.Prior to backfilling install the 4” flexible pipe filtration
sleeve over the drain pipe or lay the permeable barrier
material down over the length of pipe in the trench.
13.While holding the 2” pipe completely vertical and
centered to the drain tee, slowly backfill the trench
over the full length of the pipe. Use any remaining
rock or chat until the entire length of 4” drain pipe is
covered then use remaining backfill materials from the
excavation area.
14.Continue to backfill the hole until 1”-2” above grade
level and then grade away to keep rain water from
collecting in the trench area as the ground settles over
time. Add any remaining top soil and sod back to pit
location if needed.
COMPLETING THE VENT INSTALLATION
1.Mark a pencil line up from the centerline of the unit vent
exit hole for aligning and attaching the vent support
bracket.
2.Holding bracket on pencil line at desired height (for
securing to the 10” vent pipe), secure the support bracket
to the unit with two self drilling screws provided in kit.
3.Carefully insert the 1/4” mesh screen into the elbow
and make sure it is firmly in place.
4.Cement the 2” x 90 degree PVC elbow (opposite end
with 1/4” mesh screen) and 10” pipe together.
5.Cement or mechanically fasten the assembly (with 1/2”
long screws) into the top of the tee. Verify the outlet is
perpendicular to the unit. See Joint B in Figure 1 and
Figure 2.
NOTE: Fastening the 10” pipe to the Tee with 1/2”
screws will make disassembly easier for future cleaning
or inspection of the drain / vent system.
6.Install the 2-1/2” U-Bolt to support bracket using nuts
(provided in kit) to secure the vent assembly to the unit.
3
JOINTS A & B CAN BE MECHANICALLY FASTENED
USING STANDARD 1/2” LONG SCREWS. THIS WILL
MAKE DISASSEMBLY EASIER FOR FUTURE CLEANING
OR INSPECTION OF THE VENT AND DRAIN SYSTEM.
JOINT B
JOINT A
DRAIN HOSE
& INSULATION
2” PAD
OUTER 2” PVC PIPE
(FIELD SUPPIED)
GRADE LEVEL
GRADE LEVEL
BACK
FILL
FROST
LINE
DRAIN HOSE TO END
OF 2” PVC CLEARANCE
ROCK/DIRT
MIXTURE
3"
4" - 6" OR DEEPER
ROCK BASE
12" - 14"
OR GREATER
2" - 3" ROCK BASE
BELOW 2” PVC PIPE
Figure 1. Condensate Disposal Using A Vertical Drainage Pit
JOINTS A & B CAN BE MECHANICALLY FASTENED
USING STANDARD 1/2” LONG SCREWS. THIS WILL
MAKE DISASSEMBLY EASIER FOR FUTURE CLEANING
OR INSPECTION OF THE VENT AND DRAIN SYSTEM.
JOINT A
JOINT B
2” PAD
CLOSE OFF END OF 4” PIPE
WITH PLASTIC CAP, END OF
FILTRATION SLEEVE, OR
PERMEABLE BARRIER MATERIAL.
GRADE LEVEL
GRADE LEVEL
2" - 4"
BACK FILL
NOTE: SLOPE 1” / 12” IF POSSIBLE FOR TRENCH AND 1/4” - 1/2” / 12” FOR 4” PIPE.
3"
ROCK
4" PIPE
DRAIN
ROCK BASE (SEE NOTE)
3"
30" - 36"
OR GREATER
Figure 2. Condensate Disposal Using A Horizontal Drainage Trench
Specifications & illustrations subject to change
without notice or incurring obligations (10/13).
7096700 (NEW)
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