Nordyne G6RC 90+ Furnace User Manual
Contents
1. 15 Pipe Routing amp SUpport qasa 15 Location of Outdoor Terminations 18 ERE 19 Vertical Ventilig uuu u Em 20 Vent Freezing Protection HG UIS OU HERE ES 20 Concentric Vent 20 Drainage of Condensate From Furnace u u u 21 Gas Supply PIPING 22 Leak ca 22 DNE E 23 High Altitude Application seen nemen nennen 23 Natural Gas High Altitude Conversion essen 23 LP Propane Gas Sea Level and High Altitude Conversion 23 El ctrica Wiring ioc 24 Line Voltage WINING ua aaa eare eee ade E SENESE 24 OW Voltage iaaa uuu isuu e EEE RENEK 25 Start up and Adjustmehts uuu U U U L U Q 25 Start Up ad de ef o 26 Verifying and Adjusting Firing Rate uy unn u uuu titan eren na 26 Verifying and Adjusting Temperature Rise a 27 Verifying Burner Operation eene nnne 27 Verifying Operation of the Supply Air Limit Switch a 29 Descriptio2. Figure 16 Furnace Pipe Adaptions Piping must be mechanically supported so that its weight does not bear on the furnace Sup ports must be at intervals no greater than five feet and at smaller intervals if necessary to ensure thatthere are no sagging sections to trap water See Figures 14 and 15 Figure 16 illustrates vent and combustion air pipe sizes exiting the furnace Transition to the correct pipe size must be done close to the furnace so that the full length of pipe is of proper size Straight neoprene couplings are supplied with the downflow furnaces only These couplings are to be installed in the combustion air inlet if present and exhaust vent piping at the furnace as shown in Figures 13 and 14 For an upflow furnace installation if breakable connections are required inthe combustion air inlet if present and exhaust vent piping then straight neoprene couplings for 2 or 3 piping with hose clamps can be used These couplings can be ordered through your local furnace distributor To install a coupling slide the rubber coupling over the end of the pipe that is attached to the furnace and secure it with one of the hose clamps Then slide the other end of the rubber coupling onto the other pipe from the vent and secure the coupling with the second hose clamp Ensure that the connection is tight and leak free NORDYNE condensing furnaces have been certified for installation with zero clearance be D
3. DESCRIPTION OF COMPONENTS Figure 28 shows the location of each of the functional components described below If any component of the furnace must be re placed use only factory authorized replace ment parts See the Replacement Parts List for each component 24 V Common Leads Neutrals Connect Neutral Lead of Electronic Air Cleaner and or Humidifier Here Humidifier Tap 5A 120 VAC Speed Tap Flame Sensor The flame sensor acts to prove that flame has carried over from the ignitor to the opposite end burner If no flame is sensed the furnace will be shut down automatically Gas Valve The gas valve controls the flow of gas to the burners When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold Pressure Switch The pressure switch verifies thatthe induceris drawing the combustion gases through the heat exchanger It also senses a blocked condensate drain condition Vent Pressure Switch G6RD Only The vent pressure switch reacts to blockage in the vent or combustion air piping lt is utilized in G6RD furnaces only Supply Air Limit Switch The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature Vent Safety Switch The vent safety switch shuts the furnace down if the outlet flue gas temperature increases above 160 This switch protects the plastic flu
4. Furnace Input Btuh Minimum Clearances Inches 24 inches is the minimum clearance for servicing 36 inches is the recommended clearance for service Table 4 Minimum Clearances to Combustible Materials Location The furnace mustbe installed on alevel surface and as close to the center of the air distribution system as possible See Table 3 for overall dimensions to determine the required clear ances in hallways doorways stairs etc to allow the furnace to be moved to the installation point The furnace must be installed so that all electri cal components are protected from water Minimum clearances to combustible materials are listed in Table 4 Access for positioning and servicing must be considered when locating the unit 24 inches is the minimum required clear ance for servicing the unit 30 inches is the minimum required clearance for positioning the unit 36 inches is the recommended clearance from the front of the unit Please note that a panel or door can be located such that the minimum clearance on the rating plate is satis fied but that panel or door must be removable and allow the appropriate clearance for your installation This furnace is certified for use on wood flooring The furnace must be installed on a solid surface and must be level front to back and side to side This furnace must not be installed directly on carpeting tile or any combustible material other than wood flooring DOWNFLOW
5. Water Heater Minimum Total Input Free Area Rating Btuh Each Opening 40 000 100 sq in 60 000 100 sq in 80 000 100 sa in Figure 9 Equipment in a Confined Space with all Combustion Air drawn from Inside 12 Max Round Duct Diameter Ventilation Louvers at each end of attic Vent or gt Chimney Air Duct must be at least 1 sq in per 4 000 Btuh of total input rating Ducts must extend above Attic InsulationZ attic insulation Air Duct must be L at least 1 sq in Furnace per 4 000 Btuh of 72 total input rating 12 Max 4 Water Heater Minimum Free Area Round Duct Total Input Each Opening Diameter 10 sq in 4 Rating Btuh 40 000 60 000 80 000 100 000 120 000 140 000 160 000 15 sq in 20 sq in 5 25 sq in 6 30 sq in 35 sq in 7 40 sq in 8 Figure 11 Equipment in a Confined Space with all Combustion Air drawn from Outdoors through Vertical Ducts from Ventilated Attic 12 Vent Each opening Chimney to outside must be at least 1 sq in per 4000 Btuh of total input rating Furnace 1 Water Heater Minimum Total Input Free Area Round Duct
6. tactor The circulating air blower is de energized after a 90 second delay 33 Fan Mode 1 Ona call for fan operation the thermostat applies 24 VAC to the G terminal on the furnace control board 2 The circulating air blower is energized im mediately on the heating speed 3 If the furnace is operated in the continuous ON position at the thermostat and is then switched to AUTO the circulating blower will operate for a specified delay factory set at 120 seconds Furnace Fails to Operate If the furnace does not operate check the follow ing Is the thermostat operating properly 2 Are the blower compartment door s in place Is the furnace disconnect closed Has the circuit breaker tripped or the control board fuse burned open Is the gas turned on Are any manual reset switches open Is the filter dirty or plugged Is the flame sensor coated Remove and clean with emery cloth Bo ON Q Qu Thermostat WGYR 502020 If the furnace locks out after 5 attempts for ignition it will try again every hour if a call for heat remains If the inducer and circulating air blowers are operating and items 1 through 8 have been checked press the red reset button on the vent safety switch See Figure 28 If the furnace operates after depressing the reset button contact a qualified serviceman to identify and repair the problem If the furnace continues to not operate depress the red reset buttons on
7. A White E G Ground Field Supplied Disconnect Within Sight of Furnace Figure 23 Line Voltage Field Wiring 25 Furnace Cabinet Nominal Maximum Minimum Maximum Minimum Maximum Input Width Electrical Operating Operating Furnace Wire Fuse or Circuit Btuh in Supply Voltage Voltage Amperes Gauge Breaker Amps 40 000 14 25 115 60 1 127 103 12 2 14 15 60 000 14 25 115 60 1 127 103 12 2 14 15 80 000 19 75 115 60 1 127 103 14 1 14 15 100 000 19 75 115 60 1 127 103 14 1 14 15 120 000 22 50 115 60 1 127 103 17 3 12 20 Time delay fuses or HA CR type circuit breakers are required Thermostat Recommended Thermostat Wire Wire Length Gauge 2 wire 4 or 5 wire heating cooling 24 55 ft 25 ft 22 90 ft 45 ft 20 140 ft 70 ft 18 225 ft 110 ft Table 11 Electrical Data Condensing Unit Condensing Unit Control Box Blower Off 258 Timing f for location DO NOT install a jumper wire across a switch to defeat its function If a switch reopens on start up DO NOT reset the switch without identifying and correct ing the fault condition which caused the switch to trip Connect R amp W For Heating Only Thermostat NOTE The Y terminal on the UTEC control board must be connected
8. Rating Btuh Each Opening Diameter 10 sq 4 60 000 15 sq in 5 80 000 20 sq in 5 100 000 25 sq in 6 120 000 30 sq in 6 140 000 35 sq in 7 160 000 40 sq in 8 2 Figure 10 Equipment Confined Space with all Combustion Air drawn from Outdoors through Exterior Wall Vent or Chimney Ventilation Louvers each end of attic I unn Outlet NOTE Air open Air ings shall each have a free area of not less than one square inch per 4 000 Btuh of the total input rat ing of all equipment in the enclosure Water Furnace Heater Alternate Air Inlet Inlet Air ILI T im Ventilation Louvers For Unheated Crawl Space Figure 12 Equipment in a Confined Space with all Combustion Air drawn from Outdoors through Ventilated Crawl Space and Ventilated Attic Vent or Chimney X Air Duct must be at least 1 sq in per 2000 Btuh of total input rating Air Duct Furnace Air Duct k Water Heater Minimum Total Input Free Area Round Duct Rating Btuh Each Opening Diameter 40 000 20 sq in 5 60 000 80 000 100 000 120 000 140 000 160 000 30 sq in 6 40 sq in 7 50 sq in 8 60 sq in 9 70 sq in 10 80 sq i
9. Speed External Static Pressure Inches Water Column G6RC040C 08 40 000 High Medium Low G6RC040C 12 40 000 High Medium Low G6RC060C 12 60 000 High Medium Low G6RC080C 12 G6RC080C 16 G6RC100C 16 80 000 80 000 100 000 High Medium Low High Med High Med Low Low G6RC120C 16 G6RC120C 20 120 000 120 000 High Med High Med Low Low High Med High Med Low Low G6RD040C 10 40 000 High Medium Low G6RDO060C 10 60 000 High Medium Low 1175 1075 800 1125 1040 770 1075 995 745 1030 950 710 eoeun4 SAILIOVdVO eed eoeuinJ 72 Heating External Static Pressure Inches Water Column Model Input Motor Motor o2 os oa 0 5 0 6 0 7 0 8 Number Btuh Speed HP me cru nue mim e CM re Rie High 1620 G6RD080C 14 80 000 Med High 1 2 1450 Med Low 1255 Low 1080 High 1620 G6RD100C 14 100 000 Med High 1 2 1430 Med Low 1260 Low 1085 High 1700 G6RD120C 14 120 000 Med High 1 2 1510 Med Low 1330 Low 1140 High 2140 G6RD120C 19 120 000 Med High 3 4 1955 Med Low 1660 Low 1450 High 1280 1210 1180 1140 G6RL040C 12 40 000 Medium 1 8 1140 1090 1060 1030 L
10. ANSI Z223 1 NFPA 54 The current revision of the National Fuel Gas Code is available from American National Standards Institute Inc 1430 Broadway New York New York 10018 Canada installations shall comply with CAN CGA B149 installation codes local plumbing or waste water codes and other applicable codes Additional helpful publications are NFPA 90A Installation of Air Conditioning and Ventilating Systems NFPA 90B Warm Air Heating and Air Conditioning Systems These publications are available from National Fire Protection Association Inc Batterymarch Park Quincy Massachusetts 02269 N WARNING This furnace is not approved for in stallation in mobile homes Installa tion in a mobile home could cause fire property damage and or personal injury Model Furnace Dimensions inches Shipping Number Btuh A ed G6R C D 040C G6R C D 060C G6R C D 080C G6R C D 100C G6R C D 120C 120 000 22 1 2 21 9 1 4 20 G6RLO40C G6RLO60C G6RLO80C G6RL100C Table 3 Furnace Dimensions and Shipping Weights CLEARANCES TO COMBUSTIBLE MATERIALS This furnace is Designed Certified by AGA CGA Laboratories for the minimum clearances to combustible material listed in Table 4 See the furnace name plate located inside the furnace cabinet for specific model number and clearance information MINIMUM CLEARANCES TO COMBUSTIBLE MATERIAL Cabinet Width Inches
11. OPERATION 5 After the furnace has run for approximately five minutes set the thermostat below room temperature and verify steps 9 through 11 of the SEQUENCE OF OPERATION Verifying and Adjusting Firing Rate The firing rate must be verified for each installa tion to prevent over firing the furnace NOTE The firing rate must not exceed the rate shown on the furnace rating plate At altitudes above 2000 ft the firing rate must be adjusted as described in the high altitude section Use the following procedure to determine the firing rate 1 Shut off all other gas fired appliances 2 Start the furnace and allow it to run for at least three minutes 3 Measure the time in seconds required for the gas meter to complete one revolution 4 QConvertthe time per revolution to cubic feet of gas per hour using Table 12 5 Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in Btuh Example Time for 1 revolution of a gas meter with a 1 cubic foot dial 40 seconds From Table 9 read 90 cubic feet per hour of gas Heating value of the gas obtained from gas supplier 1040 Btu per cubic foot Firing rate 1040 x 90 93 600 Btuh 6 Adjustments to the firing rate can be made by adjusting the gas manifold pressure See the High Altitude Application section for additional information of firing rate at elevations above 2000
12. are allowed 16 G6RC amp G6RD Upflow Support System on Furnaces Vertical Rise Below Joints Support System with first support as close to furnace as Possible Combustion Exhaust Air Pipe Vent i l j Straight Neoprene gt i Upward Pitch N Couplings with 1 4 per Foot 4 2 Hose Clamps Optional Not Shown lt Cabinet Furnace Front G6RL Downtflow Furnaces Support System on Vertical Rise Below Joints Support System with first support as close to furnace as Possible Exhaust Vent Combustion Air Pipe E straight Neoprene gt Rubber Couplings Upward Pitch with 2 Hose Clamps 1 4 per Foot Cabinet Furnace Front Figure 15 Vertical Venting These couplings are field supplied and can be used if the installation requires breakable connections in the piping Note that a maximum of two couplings per pipe are allowed G6RC amp G6RD Upflow G6RL Downflow Furnaces Furnaces Combustion Air Inlet Combustion Air Inlet Pipe Collar 2 PVC on G6RL 040 060 models Diameter 3 for coupling or reducer 3 PVC on G6RL 080 100 models Furnace Top Furnace Top 2 PVC Q Q 2 PVC O Exhaust Vent Exhaust Vent All Models All Models
13. be ad equately sealed all joints must be taped and the ductwork must be secured to the furnace with sheet metal screws When return air is provided through the bottom of the furnace the joint between the furnace and the re turn air plenum must be sealed The floor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps cracks or sagging be tween the furnace and the floor or platform Return air and circulating air ductwork must not be connected to any other heat producing device such as a fire place insert stove etc Return Air The return air ductwork may be connected to any or all of the following left side return right side return or bottom return Tables 1 and 2 show the airflow data for each furnace model Where maximum airflow is 1800 CFM or more two openings must be used VENTING AND COMBUSTION AIR REQUIREMENTS NORDYNE condensing furnaces may be in stalled with outdoor combustion air piped di rectly to the furnace or without such special piping Codes refer to the former as direct vent or two pipe installation Installation with air taken from around the furnace is sometimes referred to as one pipe installation i e only the vent exhaust pipe is provided An important consideration in selecting one or two pipe installation is the quality of the combus tion air Indoor air is sometimes contaminated with various household chemicals whic
14. excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life Heat Exchanger and Burner Maintenance The furnace should operate for many years without excessive soot buildup in the flue pas sageways however the flue passageways the vent system and the burners should be in spected and cleaned if required by a qualified serviceman annually to ensure continued safe operation Particular attention must be given to identify deterioration from corrosion or other sources SYSTEM OPERATION INFORMATION Proper maintenance is mostimportantto achieve the best performance from a furnace Follow these instructions for years of safe trouble free operation Do not place combustible materials on or against the furnace cabinet or the vent pipe Do not store gasoline or any other flam mable vapors and liquids in the vicinity of the furnace 31 G6RC amp G6RD Upflow Furnaces 1 Ignitor Not Shown Flame Sensor Not Shown Gas Valve Flame Roll out Switch s Pressure Switch Vent Pressure Switch G6RD Only Not Shown Control Board Blower Door Switch Vent Safety Switch Low Voltage Transformer Supply Air Limit Switch Circulating Air Blower Assembly Induced Draft Blower Condensate Drain Tube In Line Drain Assembly Burner View Port Front Header Box Combustion Air Intak
15. if that appliance is of the con densing type Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to escape through such appliances or vents Do not vent the furnace to a fireplace chimney or building chase N WARNING FURNACE MUST NOT BE COMMON VENTED WITH OTHER APPLIANCES Vent Pipe Material Vent and combustion air pipe and fittings must be one of the following materials and must conform to the indicated ANSI ASTM standards Material Standard Schedule 40 PVC D1785 PVC DWV D2665 SDR 21 D2241 amp SDR 26 ABS DWV D2661 Schedule 40 ABS F628 Cement and primer must conform to ATSM Standard D2564 for PVC and Standard D2235 for ABS When joining PVC piping to ABS use PVC solvent cement See procedure specified in ASTM Standard D3138 Vent Pipe Length and Diameter In order for the furnace to operate properly the combustion air and vent piping must not be exces sively restrictive To ensure this use Table 5 which indicates the maximum allowable piping length for a furnace of specified input rate when installed with piping of selected diameter and number of elbows This table applies to the length and num ber of elbows for each pipe To use the table the furnace input rate the centerline length and the number of elbows on each pipe must be known Choose the diameterfor which the tabulated length is equal to or greater than required Proper use
16. of the table is illustrated by the following example Example An 80 000 Btuh furnace is to be installed in a one pipe system with 40 feet of vent piping There are four elbows including those exterior to the building Solution Consulting Table 5 in the single pipe length column for an 80 000 Btuh furnace the maxi mum allowable length of 2 is 60 feet with one elbow Select 2 1 2 or 3 pipe For three addi tional elbows deduct 2 5 ft for each elbow or 7 5 ft for a maximum installed vent length of 52 5 ft Condensing furnace combustion products have very little buoyancy so Table 5 is to be used without consideration of any vertical rise in the piping NOTE Always use the same or larger size piping for combustion air as is used for the exhaust vent Vent Pipe Installation Pipe Routing and Support Route piping as directly as possible between the furnace and the outdoors and remember that routing affects pipe size requirements per the preceding section If a two pipe system is used locate the combustion air intake and the vent exhaust in the same atmospheric pressure zone i e both must exit the building though the same portion of exterior wall or roof Vent piping must be sloped upwards not less than 1 4 per foot in the direction from the furnace to the terminal This is to ensure that any condensate flows back to the furnace where it can be disposed of through the condensate disposal system The qualit
17. to the thermostat LOL o Room WNH OVA FIELD WIRING Low Voltage Connections H Neutrals TWIN Flame Signal Light Yellow Status Light Red e Unused Motor Leads OG zli The blower door is in place closing the door switch in the line voltage circuit The gas line has been purged and all con nections are leak tight Start Up Procedure Set the thermostat to the lowest setting Close the disconnect s to provide line volt age to the furnace Follow the procedures given on the operat ing instructions label attached to the furnace 8 DO 5 Figure 24 Low Voltage Field Four wire Heating Cooling Applications The thermostat wires R W Y and G are securely connected to the correct leads on the terminal strip of the circuit board The gas line service pressure does not exceed 10 0 in water column 0 36 psig and is not less than 4 5 in water column 0 16 psig for natural gas For LP gas the line service pressure must not exceed 14 in water column 0 51 psig and must not be less than 11 0 in W C 0 40 psig The roll out and vent safety manual reset switches are closed If necessary press the red button to reset a switch See Figure 28 26 4 Set the thermostat above room tempera ture and verify the sequence of operation See the SEQUENCE OF
18. 0 ft above sea level a 55 or 56 drill size orifice should be used After changing the orifices use Table8to determine the appropriate manifold pressure for your installation 23 Conversion to LP propane sea level and high altitude is detailed in the installation instructions provided with the conversion kit Approved conversion kits are listed below United States LP Propane Gas Sea Level and High Altitude Conversion Kit P N 903616 This kit is for LP propane conversion in the United States at altitudes between zero and 10 000 ft above sea level Follow the installation instructions supplied with the kit for proper installation Canadian LP Propane Gas Sea Level and High Altitude Conversion Kit P N 903617 This kitis for LP propane conversions in Canada ataltitudes between zero and 4500 ft above sea level Followthe installation instructions supplied with the kit for proper installation N CAUTION To avoid electric shock personal in jury or death turn off the power at the disconnect or the main service panel before making any electrical connec tions ELECTRICAL WIRING Electrical connections must be made in accor dance with all applicable local codes and ordi nances and with the current revision of the National Electric Code ANSI NFPA 70 For Canadian installations electrical connec tions and grounding must be done in accor dance with the current Canadian Electrical Code CSA C22 1 Part 1
19. 60 1 2 65 55 50 3 4 130 115 105 1 245 215 195 11 4 500 440 400 The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace To determine the cubic feet per hour of gas flow required by the furnace divide the input rate of the furnace by the heating value of the gas Cubic Feet Per Hour Required Input To Furnace Btu hr Heating Value of Gas Btu Cu Ft Table 6 Capacity of Black Iron Gas Pipe cu ft per hour for Natural Gas specific gravity 60 NOTE When pressure testing gas supply lines at pressures greater than 1 2 psig 14 in water column the furnace must be disconnected from the gas supply piping system to prevent damage to the gas control valve If the test pressure is less than or equal to 1 2 psig 14 in water column the furnace must be isolated from the gas supply line by closing the manual shut off valve N WARNING This furnace was equipped at the fac tory for use with natural gas only A special kit supplied by the manufac turer is required to convert the fur nace to operate on LP propane gas Failure to use the proper conversion kit can cause fire explosion property damage carbon monoxide poisoning personal injury or death Conversion Conversion of this furnace to use LP propane gas must be made
20. Residential Gas Furnaces Installation Instructions G6RC Series 90 Upflow Condensing Furnace G6RD Series 93 Upflow Condensing Furnace G6RL Series 90 Downflow Condensing Furnace 1 G6RC 90 G6RD 93 Upflow N WARNING Improper installation adjustment al teration service or maintenance can cause injury or property damage Re fer to this manual for assistance For additionalinformation consulta quali fied installer service agency or the gas supplier These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installa tion service personnel for this type of equip ment Read all instructions caretully before starting the installation DO NOT DESTROY PLEASE READ CARE FULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE G6RL 90 Downflow N FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance N FOR YOUR SAFETY WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannotreach your ga
21. WARNING G6RL Models The design of the downflow furnace is certified for natural or propane gas and for installation on non combustible flooring A special combus tible floor sub base is required when installing on a combustible floor Failure to install the sub base may result in fire property damage and personal injury The special downflow sub bases are factory supplied accessories part numbers 902677 and 902974 When the furnace is in stalled on a factory or site built cased air condi tioning coil the sub base is not necessary However the plenum attached to the coil casing must be installed such that its surfaces are at least 1 from combustible construction A gas fired furnace installed in a residential garage must be installed so that the bottom of the furnace is located a minimum of 15 from the floor The furnace must be located or protected to avoid physical damage by vehicles HORIZONTAL INSTALLATIONS The G6RC model furnaces are approved for horizontal installation Installation Kit 903568 is required for horizontal applications Follow the installation instructions in the kit for proper conversion NOTE The G6RD and G6RL mod els are NOT approved for horizontal installation SUPPLY AIR PLENUM INSTALLATION A Installation on a concrete slab G6RL 1 Construct a hole in the floor per the dimensions in Figure 3 2 Place the plenum and the furnace as shown in Figure 4 B Installationonacombustible f
22. air piping may be installed in an existing chimney which is not in use provided that a Both the exhaust vent and air intake run the length of the chimney Exhaust Vent Option B Mounting Kit Faceplate Secured to Wall with Screws Combustion Air Inlet Exhaust Vent Option C b The top of the chimney is sealed and weatherproofed c The termination clearances shown in Figure 20 are maintained d Noother gas fired appliances are vented through the chimney Vent Freezing Protection When the vent pipe is exposed to temperatures below freezing i e when it passes through unheated spaces chimneys etc the pipe must be insulated with 1 2 inch thick sponge rubber insulation Armaflex type insulation or equiva lent Insulating pipe is important to avoid con densate icing For extremely cold climates or for conditions of short furnace cycles i e set back thermostat conditions the lastthree feet of vent pipe can be reduced one nominal pipe size provided that the total vent length is at least 15 feet in length and the vent is sized in accordance with the venting requirements Table 5 before this reduction is applied Example 3 to 2 1 2 or 2 to 1 1 2 Smaller vent pipes are less susceptible to freez ing but must not be excessively restrictive Concentric Vent Termination A concentric vent termination is approved for use with these furnaces The kit part number is 903578 For proper installation of the conce
23. and or local codes If any of the original wire as supplied with the furnace must be replaced it must be replaced with wire having a minimum temperature rating of 105 C Refer to the furnace nameplate and Table 11 for electrical requirements Line Voltage Wiring The line voltage 115 volt to the furnace mustbe supplied from a dedicated branch circuit con taining the correct fuse or circuit breaker for the furnace See Table 11 An electrical switch should be readily accessible from and within sight of the furnace See the Wiring Diagram label in the furnace and Figure 23 Thefurnace cabinet must have an uninterrupted unbroken ground to minimize injury should an electrical fault condition occur The controls zero to 1999 Manifold Pressure Setting in WC For a Natural Gas Sea Level Heating For a Natural Gas Sea Level Heating Value of 800 to 899 Btu cu ft Elevation feet above sea level 2000 to 5000 to 6000 to 4999 5999 7999 8000 to 10000 Value of 900 to 999 Btu cu ft Elevation feet above sea level zero to 1999 Manifold Pressure Setting in WC For a Natural Gas Sea Level Heating 2000 to 5000 to 6000 to 4999 5999 7999 8000 to 10000 Value of 1 000 to 1 100 Btu cu ft Elevation feet above sea level zero to 1999 Manifold Pressure Setting in WC 2000 to 5000 to 6000 to 4999 5999 7999 3 5 3 0 8000 to 10000 Table 7 Manifold Pressure in WC for Natura
24. as an 8 foot ceiling the floor area of the space must be 750 square feet 6 000 8 750 In general a furnace installed in an unconfined space will not require outside air for combustion N WARNING Furnaces installed with combustion air drawn from a heated space which includes exhaust fans fireplaces or other devices that may produce a negative pressure should be consid ered confined space installations Installation In A Confined Space A confined spaceis one which does not meetthe unconfined space volume requirements and typically involves installation ina small room All such installations must have specific provisions for introduction of combustion and ventilation air Codes require that two openings be pro vided for this one with bottom edge within 12 of the floor and one with top edge within 12 of the ceiling The size and other criteria for these openings must be per the following sections Combustion air openings must not be restricted in any manner Furnaces installed in a confined space which supply circulating air to areas outside of the space must draw return air from outside the space and must have return air ducts tightly sealed to the furnace Air From Inside Air for combustion and ventilation may be taken from inside the building through an interior wall ifthe building is not tight and ifthe total volume of the furnace space and the space from which air is drawn meets the volume requiremen
25. by qualified service personnel using only approved parts High Altitude Application High altitude application with this furnace can be field performed by a simple adjustment of manifold pressure and if necessary changing the orifices The changes required depend on the installation altitude and the heating value of the gas The gas heating value based on sea level can be obtained from your local gas utility The heating value of gas at high altitude is always lower than the sea level heating value The heating values used in Tables 7 amp 8 are based on sea level values Natural Gas High Altitude Conversion All factory shipped furnaces are ready to operate between zero and 4999 ft above sea level For higher altitudes between 5000 and 10 000 ft above sea level conversion can be achieved simply by adjusting the furnace manifold pressure as shown in Table 7 LP Propane Gas Sea Level and High Altitude Conversion Conversion of this furnace to utilize LP propane gas mustbe made by qualified service personnel using factory authorized or approved parts Conversion to LP propane gas can be accomplished by first replacing the natural gas orifices with the appropriate LP propane orifices shown in Table 9 or 10 Note for installations between zero and 5000 ft above sea level a 54 or 55 drill size orifice should be used depending upon the rated firing rate of the unit see Table 9 or 10 However for installations above 500
26. e Exhaust Vent Ignitor Not Shown Flame Sensor Not Shown Gas Valve Flame Roll out Switch s Pressure Switch Control Board Blower Door Switch Vent Safety Switch Low Voltage Transformer Supply Air Limit Switch Circulating Air Blower Assembly Induced Draft Blower Condensate Drain Tube In Line Drain Assembly Burner View Port Front Header Box Combustion Air Intake Exhaust Vent Figure 28 Location of Major Components 32 Change or replace the air filters monthly during any period when the circulating blower is operating regularly Always replace the doors on the furnace after servicing Do not operate the furnace without all doors and covers in place Avoid operating the furnace when win dows and doors are open Be sure that the thermostat is properly installed andis notbeing affected by drafts or heat from lamps or other appliances Sequence of Operation Operating sequences for the heating cooling and fan modes are described below Refer to the wiring diagrams Figures 26 and 27 and the low voltage field wiring diagram Figure 24 Heating Mode 1 On a call for heat the thermostat closes applying 24 VAC to the W terminal on the control board The control board checks for continuity on the 24 VAC limit control circuit ov
27. e 21 and insure the exit from G6RC amp G6RD n Collector Box Collector Bg Rotate counter Rotate clockwise clockwise Step 2 Route to 2 Step 2 Route to UU l pc floor drain floor drain OR Left Side Drain L Zd 8 1 Route to condensate nnd u Clam pump Keep Clamp pump Keep HARD J ForStep1 downward ARD e Loosen For Step 1 downward Route to Drain Tube Retighten for Step 3 Slope Retighten for Step 3 slope Figure 21 Furnace with Condensate Drain Trap Assembly 21 the collector box is clear of any debris or obstructions 2 Replace this tube and insure the fit to the header spout is air tight Air will be drawn into the header if this connection is not tight 3 Check other tube connections along the drain system Insure that all are air tight NOTE Industry research studies indicate that when condensate is routed to an active drain household detergents etc buffer its acidity If the drain is not actively used or if codes require obtain a neutralizer kit usually contains lime stone Proper drains and connections to the condensate tubing are required as NORDYNE cannot be held responsible for water leakage which occurs due to loose hose connections or improperly sealed drain line pipes GAS SUPPLY AND PIPING This furnace is equipped for either le
28. e system and the inducer from over temperature conditions Flame Roll Out Switch This switch provides flame roll out protection to the furnace and combustion air inlet pipe Oeo E Blower Off 22022 Timing TWIN Flame Signal Light Yellow O Status Light Red Motor Leads Electronic Air Tap Cooling 5A 120 VAC Heating Speed Tap Figure 25 Blower Speed Tap Location 29 For G6RC G6RD and G6RL Residential Furnaces N BLUE s BLUE BLUE BLOWER SUPPLY AIR FLAME ROLL OUT DECK SWITCH LIMIT SWITCH SELECT MODELS ALL MODELS ONLY SWITCH ALL MODELS VENT PRESSURE SWI VENT SAFETY ITCH PRESSURE SWITCH SWITCH 93 MODELS ONLY ALL MODELS WHITE NEUTRAL BLACK 120V GROUND ROOM THERMOSTAT BLOWER DOOR SWITCH TRANSFORMER WHITE W BLK STRIPES 24V IBLK W WHITE STRIPES AIR CONDITIONER CONDENSING UNIT Taw rur SLOWER OFF g FLAME SENSOR YELLOW 3 4 SPEED MOTOR BROWN IGNITOR Field Wiring Factory Wiring Low Voltage High Voltage STATUS RED FAULT CONDITION LIGHT Power On ON Limit Circuit Open 1 FLASH Pressure Switch Stuck Open 2 FLASHES Press
29. emperature rise mea sured is outside the range specified it may be necessary to change the blower speed Lower blower speeds will increase the temperature rise and higher blower speeds will decrease the temperature rise The furnace is equipped with a multispeed mo tor Heating and cooling speed selection is made by moving the leads on the integrated control board located in the furnace The wiring diagram on the furnace and Figures 25 26 and 27 show the speed taps for adjusting motor speed If it is desired that the blower operate at the same speed for heating and cooling tape off the terminal of the unused blower wire Install the jumper wire found in the plastic instruction bag across the HEAT and COOL taps on the control board Reconnect the desired blower tap to the piggyback quick connect The blower control is designed to start the circulating air blower 30 seconds after the gas valve is opened The blower control is factory wired to turn the blower motor off 120 seconds after the gas valve is closed This timing can be changed using the BLOWER OFF timing switch opposite the terminal block on the control board See Figure 25 Verifying Burner Operation To verify operation of the burners make sure that the blower compartment door is in place and that there is power to the furnace Set the thermostat above room temperature and ob serve the ignition sequence The flame can be observed through the small clear window on
30. er tem perature limit switch flame rollout switches and blocked vent switch in series If an open limit is detected the control board will energize the inducer and the conditioned air blower All other system functions will be inoperable until the limit circuit closes While the limit is open the red LED will pulse at a rate of 1 blink per unit time The furnace control checks for continuity across the pressure switch 24 VAC If the pressure switch is closed the heat mode sequence will not continue If it remains closed for 10 seconds the red LED will blink 3 times repetitively until the fault condition clears The inducer is energized The pressure switch will close If the pres sure switch does not close after 10 seconds the fault LED will blink 2 times repetitively and the inducer will continue to run until the switch is closed The inducer will pre purge for 30 seconds and then the ignitor will start its warm up After 30 seconds of ignitor warm up the gas valve 24 VAC will open The ignitor circuit stays energized for 6 seconds after the gas valve opens T 10 11 12 The furnace control must prove flame via the flame sensor six seconds after the gas valve opens If flame is sensed all burners are on and the ignitor cools off If no flame is sensed the gas valve closes immediately and the inducer continues to run A second trial for ignition step 6 begins if no flame is sensed On the fifth try for ig
31. ft The manifold pressure must be set to the appro priate value for your installation Refer to either Table 7 for natural gas or Table 8 for LP propane gas to verify the manifold pressure setting re quired for your particular installation To adjust the manifold pressure remove the regulator cap and turn the adjusting screw clockwise to in crease pressure or counterclockwise to reduce pressure Replace the regulator cap after adjust ments are complete N CAUTION Do not re drill the burner orifices If the orifice size must be changed use only new orifices Verifying and Adjusting Temperature Rise Verify that the temperature rise through the furnace is within the range specified on the furnace rating plate Temperature rises outside the specified range could result in premature heat exchanger failure Place thermometers in the return and supply air stream as close to the furnace as possible The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings Adjust all registers and duct dampers to the desired posi tion and run the furnace for fifteen minutes before taking any temperature readings The temperature rise is the difference between the supply and return air temperatures For typical duct systems the temperature rise will fall within the range specified on the rating plate with the blower speed at the factory recom mended setting If the t
32. ft or right side gas entry Typical gas service hook ups are shown in Figure 22 When making the gas connection provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and or damage to the furnace All gas piping must be installed in compliance with local codes and utility regulations Some local regulations require the installation of a manual main shut off valve and ground joint union external to the furnace The shut off valve should be readily accessible for service and or emergency use Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut off In the absence of local codes the gas line installa Burner Viewport Roll Out Limit s S Nos Ve 4 Burner Some Utilities Assembly Require Shut Off Valve to be 4 to 5 feet LJ Above Floor A N Denotes field provided and installed components Shut Off Valve with 1 8 NPT Plugged Tap Automatic Gas Valve with manual shut off tion must comply with the latest edition of the National Fuel Gas Code ANSI Z223 1 or CAN CGA B149 installation codes A 1 8 NPT plugged tap must be installed in the gas line to the unit for use when measuring the gas supply pressure The plug should be readily accessible for service use A drip leg should be installed in the vertical pipe run to the uni
33. h can cause severe corrosion in the furnace combus tion system Some common sources of these chemicals are detergents bleaches aerosol sprays and cleaning solvents Unless indoor air is known to be free of these materials two pipe installation is recommended Provisions must be made for adequate supply of air for combustion and ventilation For United States installations the adequacy of air provi sions can be determined by consulting the cur rent version of the National Fuel Gas Code ANSI Z223 1 NPFA 54 For Canadian installa tions requirements are specified in the National Standard of Canada CAN CGA B149 1 amp 2 Consult local codes for special requirements NOTE If the furnace is operated without ad equate air for combustion and ventilation it may not perform properly Furnace components may be strained by high temperature and could fail prematurely N WARNING Furnace installation using methods other than those described in the fol lowing sections must comply with the National Fuel Gas Code and all appli cable local codes to provide sufficient combustion air for the furnace G6RC G6RD Protective Screen G6RL Figure 8 Protective Screen for One Pipe Installations 11 Vent or Chimney Each opening must be at least 100 sq in or 1 sq in per 1000 Btuh of total input rating whichever is greater See minimum area per table Furnace
34. imensions If outside air is utilized as return air to the furnace for ventilation or to improve indoor air quality the system must be designed so that the return air to the furnace is not less than 50 F 10 C during heating operation If a combination of indoor and outdoor air is used the ducts and damper system must be designed so that the return air supply to the furnace is equal to the return air supply under normal indoor return air applications When a cooling system is installed which uses the furnace blower to provide airflow over the indoor coil the coil must be installed down stream on the outlet side or in parallel with the furnace If a cooling systemis installed in parallel with the furnace a damper must be installed to prevent chilled air from entering the furnace and con densing on the heat exchanger If a manually operated damper is installed it must be de signed so that operation of the furnace is pre vented when the damper is in the cooling posi tion and operation of the cooling system is prevented when the damper is in the heating position N WARNING Products of combustion must not be allowedtoenterthe return air ductwork or the circulating air supply Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous con ditions including carbon monoxide poisoning that could result in per sonal injury or death All return ductwork must
35. irect vent terminal 50 000 Btuh or less Mechanical draft vent terminal tween vent piping and combustible surfaces However it is good practice to allow space for convenience in installation and service Location of Outdoor Terminations Vent and combustion air intake terminations must be located to ensure proper furnace opera tion and to conform to applicable codes Figure 16 illustrates necessary distances from the vent termination to windows and building air intakes In Canada the Canadian Fuel Gas Code takes precedence over these instructions Specifically all minimum distance require ments with respect to termination of the vent piping listed below items 1 through 8 The following list is a summary of vent terminal location requirements 1 The termination must be 12 inches above snow levelorgrade level whichever is higher See Figure 18 for alternate method to achieve 12 above snow level 2 The minimum distance for a 1 pipe instal lation from any door openable window or gravity air inlet is 4 ft below 4 ft horizon tally or 1 ft above 3 The minimum distance for a direct vent 2 pipe installation from any door openable window or air gravity inlet is 1 ft below 1 ft horizontally or 1 ft above 4 Forone pipeinstallations the recommended minimum distance from an inside corner formed by two exterior walls is 6 feet but is not required Mechanical draft vent terminal Mechanica
36. l draft vent terminal Less than 10 ft Forced Air Inlet lt tae Direct vent terminal more than 50 000 Btuh Figure 17 Vent Termination Clearances e The vent termination for a 1 pipe installa tion shall be a minimum of 3 ft above any forced air inlet within 10 ft The vent termination shall be located at least 4 ft horizontally from any electric meter gas meter regulator and any relief equipment These distances apply ONLY to U S installations In Canada the Canadian Fuel Gas Code takes precedence Avoid areas where condensate drainage may cause problems by dropping on plant ers or patios etc Also ensure that exhaust gases will not impinge on windows or build ing surfaces which may be compromised or damaged by condensation Do not install the vent terminal such that exhaust is di rected into window wells stairwells under decks or into alcoves or similar recessed areas and do not terminate above any public walkways Select the point of wall penetration where the minimum 1 4 inch per foot of slope up can be maintained N CAUTION For optimum performance vent fur nace through wall which experiences the least exposure to winter winds Horizontal Venting Vent and combustion air intake terminations must be as shown in Figure 19 N WARNING Ensure that the combustion air vent andthe exhaust vent are configured as shown in Figure 19 Improper ven
37. l Gas at Various Altitudes Elevation feet above sea level Manifold Pressure in WC for an LP Gas Heating Value of 2 500 Btu hr Table 8 Manifold Pressure in WC for LP Propane Gas at Various Altitudes 24 Plate Input Btu h Nat LP 45000 44 54 60000 45 55 72000 43 54 96000 43 54 120000 43 54 144000 43 54 Table 9 Natural and LP Gas Orifice Sizes for Elevations between zero and 4999 ft Above Sea Level used in this furnace require an earth ground to operate properly Acceptable methods for grounding are electrical wire or conduit ap proved for electrical ground service Do not use gas piping as an electrical ground NOTE Proper line voltage polarity must be maintainedin order forthe control system to operate correctly Verify that the incoming neutral line is connected to the white wire and the incoming hot line is connected to the black wire in the furnace junction box These furnaces will not operate unless po larity and ground are properly connected See Figure 23 N CAUTION Label all wires prior to disconnection when servicing controls Wiring er rors can cause improper and danger ous operation Verify proper opera tion after servicing Low Voltage Wiring Install the thermostat per the manufacturer s instructions The low voltage 24 volt connec tions from the thermostat are made at the terminal strip on the control board in the fur Field Supplied F
38. loor GGRL 1 Cut and frame the hole in the floor per the dimensions in Figure 5 2 Place the sub base for combustible floors over the hole with its duct collar extended downward Attach the supply air plenum to the base in a manner which will ensure 1 clearancetotheflooringorothercombustible material Place furnace on the combustible base as shown in Figure 6 3 Whenthefurnaceisinstalled on afactory or site built cased air conditioning coil the sub baseis not necessary However the plenum attached to the coil casing must be installed such that its surfaces are atleast 1 from combustible material G6RL 080 100 Figure 3 Opening for Concrete Slab G6RL 040 060 Concrete Floor Furnace L 1 Sheet Metal Plenum Figure 4 Furnace on a Concrete Slab G6RL 080 100 G6RL 040 060 Figure 5 Opening in Wood Floor Downflow Sub base Furnace Metal Plenum Figure 6 Furnace on a Wood Floor CIRCULATING AIR SUPPLY Plenums and air ducts must be installed in accordance with the Standard for the Installa tion of Air Conditioning and Ventilating Systems NFPA No 90A or the Standard for the Installa tion of Warm Air Heating and Air Conditioning Systems NFPA No 90B Smaller dimensions for G6RL 040 060 18 75 or 13 25 16 75 or 11 25 gt o c 2 e o o i o 2 x 2 lt lt o 19 75 or 14 25 Figure 7 Downflow Sub Base D
39. n 10 Figure 13 Equipment in a Confined Space with all Combustion Air Drawn from the Outside through Horizontal Ducts Air Requirements For One Pipe Installation When air for combustion is to be taken from around the furnace a protective screen must be installed over the combustion air intake open ing This screen is provided with the furnace installation instructions and functions to prevent debris from entering the combustion system It should be installed on the combustion air intake collar or inlet PVC If furnace location is such that this opening might be unintentionally ob structed a 3 PVC elbow should be installed on the collar and the screen placed inside the inlet of the elbow See Figure 8 Installation In An Unconfined Space N CAUTION Tight buildings with weather strip ping and caulk to reduce infiltration may require special provisions for in troduction of outside air to ensure satisfactory combustion and venting even though the furnace is located in an unconfined space An unconfined space is an area including all rooms not separated by doors with a volume greater than 50 cubic feet per 1 000 Btuh of the combined inputrates of all appliances which draw combustion air from that space For example a space including a water heater rated at 45 000 Btuh and a furnace rated at 75 000 Btuh requires a volume of 6 000 cubic feet 50 x 45 75 6 000 to be considered unconfined If the space h
40. n Air Opening 9 L Side Upflow G6RC amp G6RD Furnaces Combustion Air Vent See Fig 15 3 4 for sizes lt 23 28 lt C gt lt 2 1 4 lt 3 4 lt LLL 2 PVC Exhaust Vent See Fig 15 for sizes Return Air Opening Bottom lt D 27 5 8 1 1 2 x 31 2 Dia Opening for Gas Connection 7 8 Dia Electric Connection 25 5 8 Condensate Drain Outlets ottom Return Opening SNOILVOI3JI93dS 39VNHf suoisueuiq HUN 1899 72 inBid Downflow G6RL Furnace Combustion Air Inlet lt 241 2 gt Exhaust Vent lt 22 1 2 gt lt 24 7 8 gt 7 8 Dia Electric Connection So o 4 217 8 1 1 2 x 3 1 2 Dia Opening for Gas Connection lt 21 1 4 Exhaust Vent 2 Y Y Condensate Drain Outlet 3 4 Bottom Supply Air Opening Side D 3 r 2 1 2 Combusting Vent 3 for 80 100 2 for 40 60 Condensate Drain Outlet 27 7 8 24 7 8 7 8 Dia Electric Connection 1 1 2 x 2 1 2 Knockout For Gas Connection 0 lt 278 gt lt 193 4 Bottom Opening eed eoeuinJ Model Number Heating Input Btuh Motor
41. n of Components UU uuu u llu uu USgSSGI sassa arraia iaaea ndun 29 ooi ade cce Pe re A aed eu eui oaa du mass oe ceu 31 Combustion Air and Vent 31 hsc 31 Lubricalionis eH DEP 31 Condensate Drain Assembly cccecccceeececeeeeeeeeeeeeseaeesesaeeeeeaeeescaeeeseeeesceeeeseeeeeseeeesaees 31 Blower Compartment E 31 Heat Exchanger and Burner Maintenance 31 Location of Major Components L nennen nnn 32 System Operation Information u uu u u u u 31 Sequence of Operation 33 F rnace Fails to Operate uuu ddeau 34 TWINING Ot TWO FUrtlaces Dn eie Eod E Lure ee EEEE 34 Installation Performance Checklist nnn nnn 35 suoisueuiq GH95 9499 1 e1n614 Combustion Air Inlet lt 23 1 4 Exhaust Vent lt 221 2 lt 3 4 25 1 8 1 1 2 x 3 1 2 Dia Opening for Gas Connection _ 7 8 Dia Electric nos 25 1 4 E 8 Retur
42. nition the furnace control is locked out and the red LED will blink 4 times repetitively The ther mostat must be opened for at least ten seconds to reset the furnace control after a lock out Otherwise the furnace will attempt another ignition sequence in 1 hour The furnace control energizes the circulat ing air blower on the heating speed 30 seconds after the gas valve circuit is ener gized When the thermostat has been satisfied gas valve is de energized The inducer is de energized after a 30 second postpurge The furnace control keeps the circulating air blower energized for 120 seconds factory Set or 60 90 or 180 seconds field adjust able See Figure 25 Abnormal conditions If a limit opens during operation the inducer and circulating air blower continue to operate The gas valve is de energized immediately The blowers continue to operate until the limit closes When the limit closes the inducer blower is de energized immediately The circulating air blower continues to operate forthe speci fied delay factory set at 120 seconds Cooling Mode 1 On a call for cooling the thermostat closes applying 24 VAC to the G and Y terminals on the furnace control This closes the compressor contactor The furnace control energizes the circulat ing blower 115 VAC on the cooling speed When the thermostat is satisfied the G and Y terminals on the control board are de energized opening the compressor con
43. ntric vent termination follow the installation instruc tions provided with that kit Exhaust Vent Option A or Normal 12 Min to Snow Normal Snow Level Inlet Exhaust Figure 19 Exhaust and Combustion Air Pipe Clearances 20 Exhaust Elbow Combustion Air Intake Exhaust Plumbing Vent Roof Boot Typ Both Pipes Az 12 Above Roof or Snow Accumulation Level Figure 20 Vertical Vent Termination DRAINAGE OF CONDENSATE 3 Re tightenthe clamp MAKE SURE CLAMP FROM FURNACE IS TIGHT TO AVOID LEAKAGE OF CON DENSATE The condensate drainage system is internal to the furnace The drain may exit either the right or left side of the furnace cabinet For a right side drain simply extend the tubing out of the 7 8 4 Route the tubing out of the 7 8 hole located 8 inches up from the bottom furnace hole in the cabinet see Figure 21 The condensate should drain from the plastic collector box location A in Figure 21 as droplets For a left side drain follow the steps below or a small stream If you notice the furnace has 1 Loosenthe clamp on the soft exit tube see operated for more than 5 minutes without drain Figure 21 ing or the red status light on the control board is 2 Rotate the soft exit tube counter clockwise RESI ee DIMER a Iie DEION 180 upflow G6RC RD models clockwise 90 downflow G6RL models 1 Remove the collector box soft tube at loca tion A in Figur
44. ocked by debris Any damaged section of vent pipe must be replaced and any obstruction or blockage mustbe removed prior to operating the furnace Air Filter s N WARNING Never operate the furnace without a filter in place Dust and lint in the return air can build up on internal components resulting in loss of effi ciency equipment damage and pos sible fire AIRFILTER S ARE NOT SUPPLIED WITH THE FURNACE ASSHIPPED FROM THE FACTORY FILTERS FOR SIDE RETURN AND BOTTOM RETURN APPLICATIONS ARE AVAILABLE FROM NORDYNE DISTRIBUTORS The installer should provide a filter rack for a high velocity type filter in the return air duct adjacentto the furnace Filters should be changed or cleaned monthly during the heating season New or newly renovated homes may require more frequent changing until the construction dust has been removed Lubrication The bearings in the circulating air blower motors are pre lubricated and sealed at the factory No further oiling of the bearings is required for the life of the motor Condensate Drain Assembly Be sure the condensate lines are free and open i e avoid kinking hoses Also make sure all hose clamps are tight to avoid drawing air into the system Blower Compartment The blower compartment should be cleaned monthly during the heating and cooling seasons to remove any dirt and lint that may have accu mulated in the compartment or on the blower and motor Dirt and lint can create
45. ow 875 835 820 805 High 1260 40 1190 43 1155 44 1120 45 1075 47 1030 49 980 52 940 54 G6RLO60C 12 60 000 Medium 1 3 1120 45 1070 48 1040 49 1010 50 960 53 930 55 890 57 850 60 Low 855 59 815 62 800 64 780 65 760 67 730 70 710 690 High 1635 1585 1525 1460 46 1400 48 1330 51 1260 54 1180 57 G6RLO80C 16 80 000 Med High 1 2 1435 47 1395 49 1350 50 1300 52 1255 54 1200 56 1150 59 1090 62 Med Low 1230 55 1200 56 1165 58 1130 60 1090 62 1050 65 1000 68 960 71 Low 1050 1035 1010 980 i 950 910 870 820 2 High 1600 53 1555 54 1500 56 1445 59 1380 61 1310 65 1240 68 1160 73 G6RL100C 16 100 000 Med High 1 2 1475 57 1435 59 1385 61 1335 63 1290 66 1240 68 1190 71 1130 75 Med Low 1320 1290 1250 2 1215 1170 1120 1070 1020 Low 1150 1130 1110 1075 1040 E 1000 950 890 Factory Set Cooling Speed NOTES 1 Airflow rates of 1800 CFM or more require two return air connections Data is for operation with filter s Factory Set Heating Speed 2 Temperature rises in the table are approximate Actual temperature rises may vary Not Recommended 3 Temperature rises and airflows for external static pressures greater than 0 5 are for reference only These conditions are not recommended INSTALLATION REQUIREMENTS Requirements and Codes This furnace must be installed in accordance with these instructions all applicable local build ing codes and the current revision of the Na tional Fuel Gas Code
46. quare inch per 2000 Btuh of total appliance input Ducts must have cross sectional area at least as large as the free area of their respective openings to the furnace space See Figure 13 N CAUTION Do not supply combustion air from an attic space that is equipped with power ventilation or any other device that may produce a negative pressure VENTING REQUIREMENTS This section specifies installation requirements for vent and 2 pipe combustion air piping For one pipe installations install vent piping per this section and provide air for combustion and ventilation per the previous section The capac ity table provided in this section applies to the total of vent and combustion air piping for either type of installation 14 NORDYNE condensing furnaces are classified as Category IV appliances which require spe cial venting materials and installation proce dures Category IV appliances operate with positive vent pressure and therefore require vent systems which are thoroughly sealed They also produce combustion condensate which is slightly acidic and can cause severe corrosion of ordinary venting materials Furnace operation can be adversely affected by restrictive vent and combustion air piping Therefore vent and com bustion air piping lengths must conform com pletely to the requirements of Table 5 The furnace must be vented to the outdoors It must not be vented in common with any other appliance even
47. r Suitable around Pipe Supports at Minimum of 5 ft Intervals 2 at Building A Combustion 90 Elbow Offset with NI d X Y Exhaust Pipe for Adequate z i Dimensional i Y Clearance Upward Pitch 1 4 per Foot 12 Min I Outlet Exhaust Vent PVCor gt ABS Pipe First Support Placed as Close to Furnace Wall Connection as Possible Normal Snow Level T Exhaust Vent Straight Neoprene Coupling with 2 Hose Clamps Optional Not Shown G6RL Downflow Furnaces Exhaust See Vent Table 4 Seal Caulk i around Pipe Straps or Other Suitable Y at Building Supports at Minimum ot 5 ft Intervals D 90 Elbow 7 N U Combustion Air Inlet 5 g Inlet x Offset with Exhaust ii Pipe for Adequate E E Dimensional N Upward Pitch 1 4 per Foot lt gt 12 Min Outlet Exhaust Vent Clearance First Support Placed 443 e Wall as Close to Furnace p Connection as Possible l iraidh Neoprene Normal Snow Level Exhaust Vent 2 Hose Clamps Figure 14 Horizontal Venting These couplings are field supplied and can be used if the installation requires breakable connections in the piping Note that a maximum of two couplings per pipe
48. s supplier call the fire department Extinguish any open flame Table of Contents Furnace Specifications u l U i uuu Dn snae Das sss usu assasssssssa sassa 4 5 Furnace Airflow 6 7 Installation Requirements LLULLU LIL u aa aca acd dau annu kd 8 Supply Air Plenum Installation ccena Uu lulu name nn tn cuanta uses c adora asa e uin cra 9 Installation on a Concrete 9 Installation on a Combustible Floor n 9 Circulating Air Supply uu L LI 10 11 Venting and Combustion Air Requirements 0 2 2 11 Air Requirements for One Pipe Installation 2 13 Installation in An Unconfined 5 13 Installation in A Confined 5 13 miden 13 Air Directly Through An Exterior Wall enne 14 e Outdoor Air Through Vertical Openings or 14 e Outdoor Air Through Horizontal Openings or 14 Venting Requirements 14 Vent RIDEMA 14 Ment Pipe Length and Diameter eco oti rr erri eh ote eerta 14 Vent Pipe Installation ua
49. t Table 5lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line NOTE Gas piping must not be run in or through air ducts chimneys gas vents elevator shafts etc Compounds used on threaded joints of gas piping must be resistant to the actions of lique fied petroleum gases The main manual gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shut down is required N CAUTION Do notuse matches lighters candles or other sources of open flame to check for gas leaks Leak Check After the gas piping to the furnace is complete all connections must be tested for gas leaks To check for leaks use only a soap and water solution or other approved method Denotes field provided and installed components gU Automatic Gas Valve with manual r shut off Ground Joint N V Union Some Utilities EON i y Require Shut i Off Valve to Burner Out Limit be 4 to 5 feet Assembly N Above Floor Valve with 1 8 NPT ka Plugged Tap Burner Viewport Figure 22 Typical Gas Service Connection 22 CAPACITY OF BLACK IRON GAS PIPE CU FT PER HOUR FOR NATURAL GAS SPECIFIC GRAVITY 0 60 NOMINAL BLACK IRON LENGTH OF PIPE RUN feet PIPE DIAMETER in 40 50
50. t termination can cause recirculation of the flue gases This may result in fur nace vibration In severe cases the furnace will cycle due to the intermit tent contact between the flame and the flame sensor If you note oscillations occurring check the vent configura tion Make sure that the exhaust vent does not have a 90 degree termination Vent Configuration to Provide 12 Minimum height above X Snow Level 12 Min 19 Max Support Outside _ gt Wall 12 Above Normally Expected Snow Level Armaflex i Insulation or 79 Equivalent Coupling ei Figure 18 Alternate Horizontal Vent Installation For horizontal venting one of the following kits is recommended 2 PVC 3 PVC Through the Wall Exterior Vent 9023730 9023750 Mounting Kit Neutralizer Kit All 9023730 9023730 Models For Canadian installations please refer to the Canadian Installation Code CAN CGA B149 1 or 2 and or local codes The kit consists of two face plates and an insulating gasket to sealthe exterior surface A hole sized closely to the pipe diameter must first be cutthrough the wall A short length of pipe is then cut such that it can penetrate the wall and be held in place by closely fitting standard cou plings The face plates are retained on both sides of the wall by the couplings and the gasket is retained against the wall by the outer face pla
51. t level Is the Heat Anticipator Setting correct Has the Owner s Information been reviewed with the home owner Has the Literature Package been left near the furnace 35 FFFICITMGY CERTIFIED ama 707931 7079310 Replaces 7078950 Specifications and illustrations subject to change without notice and without incurring obligations St Louis MO NORDYNE Printed in U S A 9 99
52. te Face plates must be fastened to the wall and the outside one must be flashed as appro priate to prevent entry of water When the above kits are not used the following steps are required 1 Checkthe hole size cut through the exterior wall Insure that the hole diameter is less than the diameter of the couplings to be used 2 Extend the vent pipe through the wall ap proximately 1 and seal the area between the wall and pipe 3 Apply couplings to the vent pipe on the interior and exterior sides of the wall to insure the pipe can not be pushed or pulled through the wall 4 Insure the combustion air inlet pipe for a 2 pipe installation has a 90 degree termina tion elbow as shown in Figures 19 and 20 Note that a combustion air intake must be provided with an elbow opening downward The screen provided with the furnace must be installed in the elbow to prevent entry of debris or creatures When the vent pipe must exit an exterior wall close to the grade or expected snow level a riser should be provided as shown in Figure 18 Insulation is required to prevent freezing of this section of pipe Vertical Venting Figure 20 shows the proper installation and clear ancesfor vertical venttermination The roof penetra tion must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing Termi nation spacing requirements from the roof and from each other must be per Figure 20 Vent and combustion
53. the burner box The burner flame should carry over between all burners The flames should be blue without yellow tips Flames should extend from each burner without lifting curling or floating After verifying ignition set the thermostat below room temperature and verify that the burner flame extinguishes completely 27 8c yey 520 ZI TIME FOR ONE REVOLUTION SECONDS GAS FLOW RATE CUBIC FEET PER HOUR CUBIC FEET PER REVOLUTION OF TIME FOR ONE REVOLUTION SECONDS CUBIC FEET PER REVOLUTION OF METER Verifying Operation of the Supply Air Limit Switch To verify operation of the supply air limit switch make sure that the blower door is in place and that there is power to the furnace Completely block the return airflow to the fur nace by installing a close off plate in place of or upstream of the filter s Set the thermostat above room temperature and verify that the Sequence of Operation is as described in these instructions The supply air limit switch should function to turn off the gas valve within approxi mately five minutes The circulating air and combustion blowers should continue to run when the supply air limit switch opens Remove the close off plate immediately after the supply air limit switch opens If the furnace operates for more than five minutes with no return air set the thermostat below room temperature shut off the power to the furnace and replace the supply air limit switch
54. the flame rollout switches See Figure 28 If the furnace operates after depressing the reset buttons contact a qualified servicemen to identify and repair the problem Twinning of Two Furnaces The control board on these furnaces is capable of being twinned to another G6 furnace pro vided the circuit boards are both UTEC type If using UTEC control boards leave the fuses installed on each board The thermostat wires and the 1 4 inch quick connect terminals marked TWIN on the furnace controls must be con nected together for twinning See Figure 29 Twin Terminal Figure 29 Twinning 34 INSTALLATION PERFORMANCE CHECK LIST LOCATION INSTALLER UNIT MODEL Minimum Clearances per Table 3 Electrical Connections tight Line Voltage Polarity correct Supply Voltage Volts Blower Motor HP FUEL TYPE Natural Gas LP Propane Gas Piping Connections leak tested Gas Line Pressure in water column with furnace operating Manifold Pressure in water column with furnace operating Is there adequate fresh air supply for combustion and ventilation Furnace Input Btuh CITY STATE _ CITY STATE _ UNIT SERIAL Supply Air Temperature F Return Air Temperature F Temperature Rise F Are Flue Connections tight Is there Proper Draft Is Vent free from restrictions Is the Filter s secured in place Is the Filter s clean Has the Thermostat been calibrated Is the Thermosta
55. ts for an unconfined space n such cases the two openings in the wall must each have free area of at least one square inch per 1000 Btuh of total appliance input but not less than 100 square 13 inches of free area See Figure 9 For example if the combined input rate of all appliances is less than or equal to 100 000 Btuh each opening must have a free area of at least 100 square inches If the combined input rate of all appli ances is 120 000 Btuh each opening must have a free area of at least 120 square inches Air Directly Through An Exterior Wall If combustion air is provided directly through an exterior wall the two openings must each have free area of at least one square inch per 4000 Btuh of total appliance input See Figure 10 Outdoor Air Through Vertical Openings or Ducts If combustion air is provided through vertical ducts or openings to attics or crawl spaces the two openings must each have free area of at least one square inch per 4000 Btuh of total appliance input Ducts must have cross sec tional areas at least as large as the free area of their respective openings to the furnace space Attics or crawl spaces must communicate freely with the outdoors if they are the source of air for combustion and ventilation See Figures 11 and 12 Outdoor Air Through Horizontal Openings or Ducts If combustion air is taken from outdoors through horizontal ducts the openings must each have free area of at least one s
56. ure Switch Stuck Closed 3 FLASHES Ignition Failure Check Ground 4 FLASHES 115 VAC amp Neutral Reversed or no Ground 5 FLASHES False Flame or Gas Valve Relay Shorted Continuous Power Off OFF FLAME YELLOW FAULT CONDITION LIGHT Low Flame Sensor Signal Continuous Flash Flame Present ON INDUCER ORANGE BLUE BLACK THESE WIRES ARE NOT PRESENT ON 3 SPEED MODELS If any of the original wire as supplied with the furnace must be replaced it must be replaced with wiring material having a temperature rating of at least 105 C Figure 26 G6RC G6RD and G6RL Integrated Control Board System Diagram 30 MAINTENANCE It is recommended that the furnace be checked yearly Ata minimum this check should include the following items N WARNING To avoid electric shock personal in jury or death disconnect the electric power before performing any mainte nance N WARNING Holes in the vent pipe or heat ex changer can cause products of com bustion to enter the home Replace the vent pipe or heat exchanger if leaks are found Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous condi tions including carbon monoxide poi soning that could result in personal injury or death Combustion Air and Vent System Check the combustion air and vent pipe to ensure that it is not damaged corroded or bl
57. used Service Panel u Black Hot Field Supplied Panel Connector Ground Ground Plate Input Btu h Nat LP 45000 44 55 60000 45 56 72000 43 55 96000 43 55 120000 43 55 144000 43 55 Table 10 Natural and LP gas Orifice Sizes for Elevations between 5000 and 10 000 ft Above Sea Level nace See Figure 24 forthe proper connections for heating only two wire and heating cooling four wire applications The recommended minimum wire gauge for thermostat wiring is shown in Table 11 The thermostat must not be installed on an outside wall or any other location where its opera tion may be adversely affected Adverse affects include radiant loading from fireplaces sunlight or lighting fixtures and convective loading from warm air registers or electrical appliances To check the heat anticipator setting either 1 Addthe current draw of the system compo nents or 2 Measure the current flow on the thermostat R W circuit after the circulating blower mo tor has started Setthe heat anticipator according to the thermo stat manufacturer s instructions for heat antici pator settings START UP AND ADJUSTMENTS Prior to start up verify that 1 The line voltage power leads are securely connected that the polarity of the connec tions is correct and that the furnace is properly grounded Field Line Voltage Wiring Factory Line Voltage Wiring Black
58. y of outdoor air must also be consid ered Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion of the furnace combustion system N CAUTION Combustion air must not be drawn from a corrosive atmosphere APPLICATION SINGLE PIPE LENGTH ft DIRECT VENT DUAL PIPE LENGTH ft with 1 long radius elbows with 1 long radius elbows on each pipe PVC CPVC or ABS Outlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet SCH 40 Pipe Size 2 3 2 2 3 2 3 3 Models G6RC D L 80 150 40 40 50 50 90 90 040 Models G6RC D L 60 150 30 30 35 35 90 90 060 amp 080 Models G6RC D L 30 150 15 15 25 25 90 90 100 amp 120 NOTES Subtract 2 5 for each additional 2 elbow 3 5 ft for each additional 3 elbow Two 45 degree elbows are equivalent to one 90 degree elbow One short radius elbow is equivalent to two long radius elbows Do not include termination elbows in calculation of vent length This table is applicable for elevations from sea level to 2000 ft For higher elevations decrease vent pipe lengths by 8 per 1000 ft of altitude 6 Only the above pipe materials are approved for use with G6 Condensing Furnaces Table 5 Vent Table G6RC amp G6RD Upflow Furnaces 5 8 Inlet Exhaust See Vent Table 4 gt Seal Caulk t5 Straps or Othe
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