Nordyne 80+ AFUE Two, Installation Instructions Manual

Page 1: ... reference GAS FURNACES Single Stage High Efficiency Furnaces Installation Instructions SA Upflow Horizontal Model SK Downflow Model 80 AFUE DO NOT DESTROY THIS MANUAL KEEP IN A SAFE PLACE FOR FUTURE REFERENCE FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage Installation and service must be performed by a qualified installer servi...

Page 2: ...1 Downflow Furnaces 11 Return Air Connections 11 Upflow Horizontal Furnaces 11 Side Return Installations 12 Bottom Return Installations 12 Downflow Furnaces 12 Acoustical Treatments 12 FURNACE INSTALLATION 12 General Requirements 12 Upflow Installation 12 Side Return Air Inlet 12 Bottom Return Air Inlet 12 Horizontal Installation 12 Downflow Installation 13 Installation on a Concrete Slab 13 Botto...

Page 3: ...g the installation service and operationofthisfurnace Failuretofollowsafety recommendations could result in possible damage to the equipment serious personal injury or death Use only with type of gas approved for this furnace Refer to the furnace rating plate Install this furnace only in a location and position as specified in Table 1 page 6 Provide adequate combustion and ventilation air to the f...

Page 4: ...oride Halogen type refrigerants Cleaning solvents perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners Masonry acid washing materials Additional codes listed below are for reference purposes only and do not necessarily have jurisdiction over local or state codes Always consult with local authorities before installing any gas a...

Page 5: ...g construction on furnaces Proof of this submittal shall be available for the final inspection of the furnace prior to occupancy This furnace is designed to operate with return air temperatures in ranges normally found in occupied residences including setbacks Minimum continuous return temperature must not be below 60 F 15 C Occasionally a temporary return temperature of 55 F 12 C is acceptable Ho...

Page 6: ...uctions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously 7 Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above tests the venting system must be corrected in accordance ...

Page 7: ...r from that space Furnaceclosets smallequipmentroomsandgaragesare confined spaces Furnaces installed in a confined space which supply heated air to areas outside the space must draw return air from outside the space and must have the return air ducts tightly sealed to the furnace The required sizing of these openings is determined by whetherinsideoroutsideairisusedtosupportcombustion the method by...

Page 8: ...ior Wall 12 Max 12 Max Furnace NOTE Each opening to outside must be at least 1 sq in per 4 000 Btuh of total input rating Vent or Chimney Water Heater See Note Total Input Rating Btuh Minimum Free Area Each Opening Round Duct Diameter 40 000 10 sq In 4 inches 60 000 15 sq In 5 inches 80 000 20 sq In 5 inches 100 000 25 sq In 6 inches 120 000 30 sq In 6 inches 140 000 35 sq In 7 inches 160 000 40 s...

Page 9: ... of the furnace installation carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed Leaks in the flue system can result in serious personal injury or death due to exposure of flue products including carbon monoxide This furnace must be vented in compliance with the current revision of the National Fuel Gas Code ANSI Z223 1 NFPA54 and the instru...

Page 10: ...result in the formation of condensate leakage or spillage The existing vent system should also be checked to make sure it remains in compliance with NFGC If it isn t the vent system must be brought into compliance before installing the furnace Horizontal Venting WARNING Horizontal vent systems must be sealed with a high temperature sealant that can withstand temperaturesof450 F Recommendedsealants...

Page 11: ... 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 downstream on the outlet side of the furnace or in ...

Page 12: ...the four knockouts from the side of the furnace Figure 17 page 27 Using sharp metal cutters cut an opening between all four knockouts to expose the blower assembly Position the return air duct over the opening in the side and secure together with sheet metal screws The screws must penetrate the duct and furnace casing WARNING The solid base of the furnace must be in place when the furnace is insta...

Page 13: ...ing in concrete floor SK MODEL NUMBERS Dimension A Dimension B 054 23A 13 1 4 19 1 4 072 24B 16 5 8 19 1 4 090 24B 16 5 8 19 1 4 108 35C 20 1 8 19 1 4 126 45D 23 5 8 19 1 4 Dimensions shown in Inches Figure 8 Cutout Dimensions Downflow Installation WARNING The furnace must not be installed directly on carpeting tile oranycombustiblematerialother than wood flooring WARNING Failure to install the do...

Page 14: ...f the furnace cabinet outwards while sliding the bottom panel 2 out through the front of the furnace 7 Reassemble the furnace in reverse order Concrete Floor Furnace Sheet Metal Plenum Figure 9 Furnace on a Concrete Slab Bottom Panel Removal Thestepslistedbelowdescribehowtoremovethebottom panel from the furnace See Figure 10 1 Remove the door 1 from the blower compartment 2 Disconnect the blower m...

Page 15: ... pipeconnectionsatthemaingasvalve emergencyshutoff valve and flexible gas connectors if applicable The soap and water solution can be applied on each joint or union using a small paintbrush If any bubbling is observed the connection is not sealed adequately and must be retightened Repeatthetighteningandsoapcheckprocess until bubbling ceases IMPORTANTNOTE Whenpressuretestinggassupply lines at press...

Page 16: ... Y G W STATUS FLAME 180 COOL HEAT 120 90 60 BLOWER OFF DELAY LOW ML MH HIGH EAC L1 XFMR HUM 24V L1A 5 NEUTRALS 2 6 3 4 1 7 8 9 5 2 6 3 4 1 FAN 8 3 5 See Note R C Y G W STATUS FLAME 180 COOL HEAT 120 90 60 BLOWER OFF DELAY LOW ML MH HIGH EAC L1 XFMR HUM 24V L1A 5 NEUTRALS 2 6 3 4 1 7 8 9 5 2 6 3 4 1 FAN R C Y G W STATUS FLAME 180 COOL HEAT 120 90 60 BLOWER OFF DELAY LOW ML MH HIGH EAC L1 XFMR HUM 2...

Page 17: ...above 2 000 ft refer to Table 8 page 33 to determine the correct orifice size andmanifoldpressure Whenconversioniscomplete verify the manifold pressure and input rate are correct as listed in the Tables Approved conversion kits are listed below The United States LP Propane Gas Sea Level and High Altitude Conversion Kit P N 904914 is for LP propane conversion in the United States at altitudes betwe...

Page 18: ...trip on the integrated control in the furnace See Figure 14 page 19 for proper connections Furnace Model Number SA SK Furnace Input Btuh Cabinet Width in Nominal Electrical Supply Maximum Operating Voltage Minimum Operating Voltage Maximum Furnace Amperes Minimum Wire Gauge Maximum Fuse or Circuit Breaker Ampsσ 045 23A 45 000 14 1 4 115 60 1 127 103 6 3 14 15 054 23A 54 000 14 1 4 115 60 1 127 103...

Page 19: ...t necessary to remove the twinning capability All standard two stagefurnacesequippedwiththefixedspeediSEER motor include a twinning terminal on the blower control board However if both single stage G7 furnaces are upgraded to the fixed speed iSEER blower the twin terminal on the blower control boards Figure 15 may be used to twin the single stage furnaces only if the following criteria are met Bot...

Page 20: ...TANT NOTE The input rate must not exceed therateshownonthefurnaceratingplate Ataltitudes above 2 000 feet it must not exceed that on the rating plate less 4 for each 1 000 feet The input rate must be verified for each installation to prevent over firing of the furnace To determine the exact input rate perform the following procedures 1 Shut off all other gas fired appliances 2 Start the furnace an...

Page 21: ... blocked The circulating air and combustion blowers should continue to run when the limit switch opens 1 Verify the blower door is securely mounted in place and that there is power to the furnace 2 Block the return airflow to the furnace by install ing a close off plate in place of or upstream of the filter s 3 Set the thermostat above room temperature and observe the Operating Sequence 4 Removeth...

Page 22: ...ame Roll out Switches and reset if necessary See Figure 19 or 20 for component location If the furnace operates when the Flame Rollout Switch is reset contact a qualified service technician to identify and repair the problem Diagnostic Description Green LED Red LED Control Fault No Power Off Off L1 Neutral Polarity Fault Flash Flash 1 Hour Lockout Alternating Flash Normal Operation On On Pressure ...

Page 23: ...o the furnace and set the thermostat to the lowest temperature setting 3 Remove the blower door from the furnace 4 Turn the gas control switch to the OFF position CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation 5 Disconnectthewiresfromthegasvalve flamesensor inducer flame roll out switch limit switch pressure switch an...

Page 24: ...sor will shut the furnace down Supply Air Limit Switch The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature 20 Replace all the parts in reverse order that they were removed 21 Check gaskets for damage Replace if needed 22 Follow the lighting instructions found on the furnace door to return the furnace to operation ...

Page 25: ...oyers 5 Mettre en service les sécheuses et tout autre appareil qui n est pas raccordé à la systéme d évacuation Faire fonctionner à régime maximal tout ventilateur d évacuation tel que les hottes de cuisinière et les ventilateurs de salles de bains Ne pas mettre en service les ventilateurs d été 6 Respecter les instructions d allumage Mettre en service l appareil à l essai Régler le thermostat de ...

Page 26: ...allateur qualifié un organisme de service ou le fournisseur de gazstaller service agency or the gas supplier Ne pas entreposer ni utiliser de l essence ni d autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ni de tout autre appareil QUE FAIRE S IL Y A UNE ODEUR DE GAZ Ne pas tenter d allumer aucun appareil Ne toucher à aucun interrupteur électrique n utiliser aucun téléphon...

Page 27: ... 1 2 15 1 4 22 7 8 23 1 8 NOTES C Standard Models N 80 Low NOx Models Dimensions shown in Inches Figure 17 Furnace Dimensions SK Model s Dim A Dim B Dim C Dim D 054 23A 14 1 4 10 3 4 12 5 8 12 7 8 072 24B 17 1 2 11 3 4 15 7 8 16 1 8 090 24B 108 35C 21 14 19 3 8 19 5 8 126 45D 24 1 2 15 1 4 22 7 8 23 1 8 NOTES C Standard Models N 80 Low NOx Models Dimensions shown in Inches A 18 5 8 D C 7 34 1 2 22...

Page 28: ...85 32 1 645 32 1 590 34 1 550 34 1 485 36 1 415 38 Med High 1 400 38 1 360 39 1 340 40 1 310 41 1 275 42 1 245 43 1 190 45 1 125 47 Med Low 1 235 43 1 215 44 1 180 45 1 155 46 1 130 47 1 100 48 1 060 50 1 005 53 Low 975 55 940 57 930 57 890 60 865 62 840 63 810 66 775 69 SA090 24B Bottom Return 90 000 High 1 610 41 1 575 42 1 530 44 1 485 45 1 440 46 1 385 48 1 340 50 1 275 52 Med High 1 295 51 1 ...

Page 29: ...75 68 SA108 35C Side Return 108 000 High 2 295 35 2 235 36 2 180 37 2 110 38 2 050 39 1 975 41 1 900 42 1 810 44 Med High 2 130 38 2 075 39 2 035 39 1 970 41 1 915 42 1 845 43 1 765 45 1 675 48 Med Low 1 770 45 1 750 46 1 710 47 1 675 48 1 630 49 1 585 50 1 520 53 1 430 56 Low 1 445 55 1 425 56 1 410 57 1 375 58 1 350 59 1 320 61 1 275 63 1 225 65 SA108 35C Side Bottom or 2 Sides 108 000 High 2 31...

Page 30: ...0 52 1 255 53 1 230 54 1 200 56 1 150 58 Med Low 1 180 56 1 165 57 1 150 58 1 135 59 1 115 60 1 090 61 1 060 63 1 010 66 Low 940 71 925 72 900 74 880 76 850 78 825 81 795 84 760 88 SK108 35C 108 000 High 2 395 33 2 335 34 2 285 35 2 230 36 2 200 36 2 140 37 2 080 38 2 000 40 Med High 2 190 37 2 135 37 2 115 38 2 080 38 2 030 39 1 975 41 1 915 42 1 810 44 Med Low 1 785 45 1 770 45 1 740 46 1 725 46...

Page 31: ...tion Yellow LED Continuous Flash On Alternating Flash IGNITOR INDUCER FLAME SENSOR C BLOWER LIMIT SWITCH DOOR SWITCH R 4 SPEED MOTOR WHITE RED BLUE ORANGE BLACK BLOWER LIMIT SWITCH GAS VALVE H MH ML L C FLAME ROLLOUT SUPPLY AIR LIMIT PRESSURE SWITCH R C Y G W LOW ML MH HIGH EAC L1 XFMR HUM 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 COM GREEN YELLOW RED 3 AMP FUSE 24V 1 2 3 4 24 V 120 V WHITE BLACK WHITE W BLK ...

Page 32: ...73 346 50 72 360 720 106 34 170 340 52 69 346 692 108 33 167 333 54 67 333 667 110 33 164 327 56 64 321 643 112 32 161 321 58 62 310 621 114 32 158 316 60 60 300 600 116 31 155 310 62 58 290 581 118 31 153 305 64 56 281 563 120 30 150 300 Table 6 Gas Flow Rates CAPACITY OF BLACK IRON GAS PIPE CU FT PER HOUR FOR NATURAL GAS SPECIFIC GRAVITY 0 60 NOMINAL BLACK IRON PIPE DIAMETER IN LENGTH OF PIPE RU...

Page 33: ...H HIGH HIGH Table 9 Natural Gas Heating Values Table 8 High Altitude Deration Chart for Propane Gas PROPANE GAS ALTITUDE ABOVE SEA LEVEL INPUT BTU 45 000 54 000 72 000 90 000 108 000 126 000 0 to 1 999 FT 57 56 56 56 56 56 ORIFICE SIZE 10 0 10 0 10 0 10 0 10 0 10 0 MANIFOLD PRESSURE 2 000 to 2 999 FT 57 56 56 56 56 56 ORIFICE SIZE 9 0 9 0 9 0 9 0 9 0 9 0 MANIFOLD PRESSURE 3 000 to 4 999 FT 57 56 5...

Page 34: ...OLD PRESSURE 9 000 to 9 999 FT 51 49 49 49 49 49 ORIFICE SIZE 2 6 2 8 2 8 2 8 2 8 2 8 MANIFOLD PRESSURE Table 11 High Altitude Deration Chart for Natural Gas Low Heating Value NATURAL GAS LOW HEATING VALUE ALTITUDE ABOVE SEA LEVEL INPUT BTU 45 000 54 000 72 000 90 000 108 000 126 000 0 to 1 999 FT 49 47 47 47 47 47 ORIFICE SIZE 3 5 3 5 3 5 3 5 3 5 3 5 MANIFOLD PRESSURE 2 000 to 2 999 FT 49 47 47 4...

Page 35: ...HIGH EAC L1 XFMR HUM 24V L1A 5 NEUTRALS 2 6 3 4 1 7 8 9 5 2 6 3 4 1 FAN 8 4 7 3 11 1 9 10 13 12 2 5 6 ITEM COMPONENT NAME 1 Blower Assembly 2 Blower Door Switch behind blower panel 3 Burner Assembly 4 Combustion Tube 5 Control Board 6 Flame Sensor 7 Gas Manifold 8 Gas Valve 9 Igniter 10 Inducer Assembly 11 Limit Switch 12 Pressure Switch 13 Roll Out Switch 14 Transformer Figure 20 Downflow Gas Fur...

Page 36: ... for combustion and ventilation YES NO Installation Altitude ____________________ FT Deration Percentage ___________________ Furnace Input _______________________ Btuh Supply Air Temperature ________________ F Return Air Temperature ________________ F Temperature Rise ____________________ F VENTING SYSTEM Vent free from restrictions YES NO Filter s secured in place YES NO Filter s clean YES NO Flu...