Field conversion: downflow with right vent (non-zero clearance)

What is going on

Converts the furnace to downflow with right vent, non-zero clearance. Uses the factory-installed trap, hoses and drain parts as shown. Parts come from the parts bag and conversion kit RXGY-CK. Tools include an electric drill, 1/8" and 3/16" bits, pliers, flat-head screwdriver, 1/4" and 5/16" hex drivers and a tubing cutter. Steps 1 to 5 are shown with the furnace in the as-shipped configuration.

Check in this order

1. Remove the flue transition, transition coupling and elbow. Remove the coupling on the inducer with its elbow.
2. Remove the trap and hoses. Remove the two screws and pull the trap straight out. Retain hose D for later use.
3. Remove the 3-3/8" flush mount plug from the jacket and discard it.
4. Move the 2-3/8" flush mount plug from the jacket to the top plate.
5. Move the 1/2" yellow vinyl cap from the inducer coupling to the inducer coupling as shown on the drawing.
6. Install the 2-5/8" flush plug in the top plate.
7. Move the .403" drain plug in the collector box.
8. Install the 2" pipe grommet.
9. Install the intake coupling in the jacket as shown.
10. Insert the air diffuser into the coupling until the tabs are fully seated. It may fall out at this step, so the installer may fit it after rotating the furnace horizontal.
11. Remove the small mounting bracket and the .403" drain plug and discard them.
12. Install the downflow condensate trap bracket with two screws.
13. Install the .559" drain plug in the condensate trap.
14. Pre-drill two 3/16" holes in the jacket for the condensate trap bracket.
15. Rotate the unit 180 degrees.
16. Tilt the inducer coupling approximately 10-20 degrees so condensate flows downward from the flue venting. Confirm the tilt is toward ground.
17. Install the condensate trap onto the mounting bracket with two screws.
18. Cut the 1/4" vent tube to about 10-1/2" and install it as shown.
19. Install hose D from the inducer coupling to the flue tap in the condensate trap.
20. Install hose E from the collector box to the top of the condensate trap.
21. Pick the right or left drain option. Remove the 7/8" plug from the jacket side and discard it. Drill two 1/8" holes for the condensate drain coupling.
22. Install the condensate drain coupling with two screws. Put the barbed fitting into the vestibule.
23. Left drain remove hose A from the trap and replace it with hose B, reusing the supplied clamp. Cut tube C on the marked lines to the cabinet width. Rotate the rubber hose on tube C so side 1 connects to the PVC and side 2 connects to the drain coupling. Install tube C with a hose clamp.
24. Right drain attach hose A (factory installed) to the condensate drain coupling and clamp it.
25. Verify all hoses are secure and fully seated, all drain ports are plugged, heat tape is installed if required, and hoses are free of kinks.
26. Confirm the hoses slope in the direction of water flow, the clamp is on top of the coupling, the diffuser is installed in the intake coupling, and the unit has forward pitch.

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