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Nordyne TC060, Installation Instructions Manual

The Nordyne TC060 Installation Instructions Manual is a comprehensive resource for users looking to set up and operate their TC060 HVAC system. This detailed manual, available for free download at 88.208.23.73:8080, provides step-by-step instructions and essential information to ensure a smooth and successful installation process.

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Table of Contents

Furnace Specifications ..................................................................................................................................... 4

Furnace Airflow Data ................................................................................................................................. 6

Safety Information ............................................................................................................................................. 7
Clearances to Combustible Materials .............................................................................................................. 7
Installation Requirements ................................................................................................................................. 7

Location .................................................................................................................................................... 8

Downflow Model Warning .................................................................................................................................. 8
Horizontal Installations ..................................................................................................................................... 8

Conversion of the *TC Upflow Furnace for a Horizontal Right Installation ................................................ 8
Conversion of the *TC Upflow Furnace for a Horizontal Left Installation .................................................. 9

Supply Air Plenum Installation ........................................................................................................................ 10

Installation on a Concrete Slab ................................................................................................................ 10
Installation on a Combustible Floor .......................................................................................................... 10

Circulating Air Supply ..................................................................................................................................... 10

Return Air ................................................................................................................................................. 11

Configuring the Blower .................................................................................................................................... 13

Determining Nominal AC System Capacity ............................................................................................... 13
Selecting the AC Cooling Airflow .............................................................................................................. 13
Selecting the Heating Airflow ................................................................................................................... 13

Venting and Combustion Air Requirements .................................................................................................... 13

Air Requirements for One-Pipe Installation .............................................................................................. 14
Installation in An Unconfined Space ........................................................................................................ 14
Installation in A Confined Space .............................................................................................................. 14
• Air From Inside ....................................................................................................................................... 15
• Air Directly Through An Exterior Wall ..................................................................................................... 15
• Outdoor Air Through Vertical Openings or Ducts ................................................................................... 15
• Outdoor Air Through Horizontal Openings or Ducts ............................................................................... 15

Venting Requirements ...................................................................................................................................... 16

Vent Pipe Material .................................................................................................................................... 20
Vent Pipe Length and Diameter ................................................................................................................ 20
Vent Pipe Installation ............................................................................................................................... 21
Pipe Routing & Support ............................................................................................................................ 21
Location of Outdoor Terminations ............................................................................................................ 22
Horizontal Venting .................................................................................................................................... 22
Vertical Venting ........................................................................................................................................ 24
Vent Freezing Protection .......................................................................................................................... 24
Concentric Vent Termination .................................................................................................................... 24

Drainage of Condensate From Furnace ........................................................................................................... 25
Gas Supply and Piping ..................................................................................................................................... 25

Leak Check .............................................................................................................................................. 2 7
Manifold Pressure Adjustment ................................................................................................................. 27
Conversion ............................................................................................................................................... 28

High Altitude Conversion ................................................................................................................................. 28

High Altitude Application .......................................................................................................................... 28
Pressure Switch Conversion for High Altitude Applications ..................................................................... 28
Natural Gas High Altitude Conversion ...................................................................................................... 28
LP/Propane Gas Sea Level and High Altitude Conversion ....................................................................... 29

Electrical Wiring .............................................................................................................................................. 29

Line Voltage Wiring .................................................................................................................................. 32
Low Voltage Wiring ................................................................................................................................... 32

Start-up and Adjustments ................................................................................................................................ 33

Start-Up Procedure .................................................................................................................................. 34
Verifying and Adjusting Firing Rate .......................................................................................................... 3 4
Configuring the Blower ............................................................................................................................. 3 5
Selecting Heat Airflow .............................................................................................................................. 3 5
Selecting the Cooling/Heat Pump Airflow ................................................................................................. 35
Verifying and Adjusting Temperature Rise ............................................................................................... 35
Verifying Burner Operation ....................................................................................................................... 37
Verifying Operation of the Supply Air Limit Switch ................................................................................... 37

Description of Components .............................................................................................................................. 37
Maintenance ...................................................................................................................................................... 38

Location of Major Components ................................................................................................................. 39
Combustion Air and Vent System ............................................................................................................ 40
Air Filter(s) ............................................................................................................................................... 40
Lubrication ............................................................................................................................................... 40
Condensate Drain Assembly .................................................................................................................... 40
Blower Compartment ................................................................................................................................ 40
Heat Exchanger and Burner Maintenance ................................................................................................ 40

System Operation Information ........................................................................................................................ 40

Sequence of Operation ............................................................................................................................ 40
Furnace Fails to Operate .......................................................................................................................... 42

Installation/Performance Checklist ................................................................................................................. 43

Summary of Contents for TC060

Page 1: ...g Furnace Gas Fired Central Furnaces WARNING Improper installation adjustment al teration service or maintenance can cause injury or property damage Re fer to this manual for assistance For additionalinformationconsultaquali fied installer service agency or the gas supplier FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appli...

Page 2: ...2 ...

Page 3: ...Vent Pipe Installation 21 Pipe Routing Support 21 Location of Outdoor Terminations 22 HorizontalVenting 22 Vertical Venting 24 Vent Freezing Protection 24 ConcentricVentTermination 24 DrainageofCondensateFromFurnace 25 GasSupplyandPiping 25 Leak Check 27 Manifold Pressure Adjustment 27 Conversion 28 HighAltitudeConversion 28 High Altitude Application 28 Pressure Switch Conversion for High Altitude...

Page 4: ...ets A B Combustion Air Vent 3 See Fig 15 for sizes 1 1 2 x 3 1 2 Dia Opening for Gas Connection 3 4 3 4 3 4 22 1 2 Exhaust Vent Combustion Air Inlet 1 1 2 x 3 1 2 Dia Opening for Gas Connection C 2 PVC Exhaust Vent See Fig 15 for sizes 25 5 8 20 1 2 23 7 8 Dia Electric Connection 30 1 4 8 8 1 1 4 1 D 27 5 8 Upflow Horizontal Furnace Models Figure 1 Upflow Horizontal Unit Dimensions See Table 2 ...

Page 5: ...tion A B D 21 7 8 15 1 2 21 1 2 21 7 8 3 4 Bottom Supply Air Opening 24 7 8 Combustion Air Inlet Exhaust Vent C L 1 8 21 1 4 Condensate Drain Outlet Condensate Drain Outlet 7 8 Dia Electric Connection 21 1 2 24 7 8 10 1 4 2 1 2 Combustion Vent 3 for 80 100 2 for 40 60 19 3 4 3 4 Bottom Opening 19 3 4 Downflow Furnace Models Figure 2 Downflow Unit Dimensions See Table 2 ...

Page 6: ...10 880 0 0 1 0 650 945 1 0 0 1 720 1050 1 0 0 0 800 1155 1 0 1 0 900 1305 0 1 0 1 1000 1450 0 1 0 0 1060 1530 1 1 0 1 1100 1595 0 1 1 0 1170 1700 1 1 0 0 1290 1870 1 1 1 0 CFM SWITCH NUMBER 5 TON 4 TON 3 5 TON 3 TON 2 5 TON 2 TON 60 000 42 000 14 1 2 12 3 4 5 1 8 11 3 4 155 TC080 80 000 56 000 19 3 4 18 1 4 7 7 8 17 1 4 195 100 000 70 000 19 3 4 18 1 4 7 7 8 17 1 4 200 120 000 84 000 22 1 2 21 9 1...

Page 7: ...e furnace to areas outside the space containing the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating outside the space containing the furnace 9 A gas fired furnace for installation in a residential garage must be installed as specified on Page 8 of these instructions 10 The furnace is not to be used for temporary heating of buildings or structures...

Page 8: ...d air conditioning coil the sub base is not neces sary 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 garagemustbeinstalledsothatthebottomofthe furnace is located a minimum of 18 from the floor The furnace must be located or protected to avoid physical damage by vehi...

Page 9: ...bing PVC Tee Soft Tubing Looped to Provide a Drain Trap 3 to 2 Reducer Optional Drainage Port is Downard Reducer Bushing Alternative for Horizontal Vent Pressure Switch Pressure Switch Condensate Vinyl Cap Figure 4 90 Upflow Converted for Horizontal Installation Horizontal Left Note To avoid condensate freezing in the drain trap assembly and tubing insulate around the drain trap assembly and all t...

Page 10: ...r site built cased air conditioning coil the sub base is not necessary How ever the plenum attached to the coil casing must be installed such that its surfacesareatleast1 fromcombustible material in Figure 9 CIRCULATINGAIRSUPPLY 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 t...

Page 11: ... shows the airflow data for each furnace model Where maximum airflow is 1800 CFM or more two openings must be used Figure 10 Protective Screen for One Pipe Installations ProtectiveScreen DownflowModels IMPORTANT Thevariablespeedblowerkithasbeen designed to give the installer maxi mumflexibilitytooptimizesystemper formance efficiency and comfort Because there are so many ways to configure the kit i...

Page 12: ...Air Duct must be at least 1 sq in per 4 000 Btuh of total input rating Ducts must extend above attic insulation Air Duct must be at least 1 sq in per 4 000 Btuh of total input rating Ventilation Louvers at each end of attic Attic Insulation 12 Max Total Input Rating Btuh 40 000 60 000 80 000 100 000 120 000 140 000 160 000 Minimum Free Area Each Opening 10 sq in 15 sq in 20 sq in 25 sq in 30 sq in...

Page 13: ...ly compensates for changes in duct static pressure within the limits of the motor VENTINGANDCOMBUSTIONAIR REQUIREMENTS These condensing furnaces may be installed with outdoor combustion air piped directly 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...

Page 14: ...When air for combustion is to be taken from around the furnace a protective screen must be installed over the combustion air intake opening This screen is provided with the furnace instal lation instructions and functions to prevent de bris from entering the combustion system It should be installed on the combustion air intake collarorinletPVC Iffurnacelocationissuchthat thisopeningmightbeunintent...

Page 15: ...r 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...

Page 16: ... 4 per Foot Outlet Exhaust Vent First Support Placed as Close to Furnace Connection as Possible Exhaust Vent Wall Seal Caulk around Pipe at Building 90 Elbow 12 Min Normal Snow Level 7 Straight Neoprene Coupling with 2 Hose Clamps Optional Not Shown 5 8 Inlet Exhaust Combustion Air Inlet Offset with Exhaust Pipe for Adequate Dimensional Clearance PVC or ABS Pipe See Vent Table 4 Straps or Other Su...

Page 17: ...ce as Possible Upward Pitch 1 4 per Foot Furnace Front Straight Neoprene Couplings with 2 Hose Clamps Optional Not Shown Combustion Air Inlet Pipe 3 PVC Furnace Top 2 PVC Exhaust Vent Use 2 to 3 reducer Combustion Air Inlet Pipe Collar Diameter 3 for coupling Furnace Top 2 PVC Exhaust Vent Use 2 to 3 reducer DownflowFurnaces UpflowFurnaces DownflowFurnaces UpflowFurnaces Figure 18 Furnace Pipe Ada...

Page 18: ...ns 1 US Installations 2 A Clearance above grade veranda porch deck or balcony 12 inches 30 cm 12 inches 30 cm B Clearance to window or door that may be opened 6 inches 15 cm for appliances 10 000 Btuh 3 kW 12 inches 30 cm for appliances 10 000 Btuh 3 kW and 100 00 Btuh 30 kW 36 inches 91 cm for appliances 100 00 Btuh 30 kW 6 inches 15 cm for appliances 10 000 Btuh 3 kW 9 inches 23 cm for appliance...

Page 19: ...ck or balcony 12 inches 30 cm 12 inches 30 cm B Clearance to window or door that may be opened 6 inches 15 cm for appliances 10 000 Btuh 3 kW 12 inches 30 cm for appliances 10 000 Btuh 3 kW and 100 00 Btuh 30 kW 36 inches 91 cm for appliances 100 00 Btuh 30 kW 4 feet 1 2 m below or to side of opening 1 foot 300 mm above opening C Clearance to permanently closed window D Vertical clearance to venti...

Page 20: ...nnected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use 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 stan dards Material Standard Schedule 40 PVC D1785 PVC DW...

Page 21: ... 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 quality 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 oth...

Page 22: ...ndow 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 pipeinstallationstherecommended minimum distance from an inside corner formed by two exterior walls is 6 feet but is not required 5 Theventterminationfora1 pipe...

Page 23: ...ng gasket to seal the exterior surface A hole sized closely to the pipe diameter must first be cut through 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 couplings 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 plate Face plates mu...

Page 24: ...s i e set back thermostat conditions the last three 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 4 before this reduction is applied Example 3 to 2 1 2 Smaller vent pipes are less susceptible to freezing but must not be excessively restrictive Concentri...

Page 25: ... MAKE SURE CLAMP IS TIGHT TO AVOID LEAKAGE OF CON DENSATE 4 Route the tubing out of the hole located 8 inches up from the bottom furnace The condensate should drain from the plastic collector box location A in Figure 23 as droplets or a small stream If you notice the furnace has operated for more than 5 minutes without drain ing or the red status light on the control board is pulsing a 2 blink cod...

Page 26: ... emergency shutdown is required CAUTION Donotusematches lighters candles orothersourcesofopenflametocheck for gas leaks Table 7 Manifold Pressure in WC for Natural Gas at Various Altitudes Table 8 Manifold Pressure in WC for LP Propane Gas at Various Altitudes For a Natural Gas Sea Level Heating Value of 800 to 899 Btu cu ft Elevation feet above sea level zero to 1999 2000 to 4999 5000 to 5999 600...

Page 27: ...tap locations on the valve are shown in Figure 24b Manifold pressure would be adjusted below procedure Turnoffgasshutoffvalveoutsidefurnace Install manometer on the gas valve at the outlet pressure tap Turn on the shut off Run furnace at high fire and set manifold pressure Also set manifoldpressurewhilerunningatlowfire refer to Tables 7 and 8 Ensure plug is tight after removing manometer Table 9 N...

Page 28: ... the unit 4 Turn the gas valve knob to the OFF posi tion 5 Shut off the gas to the unit 6 The vent pressure switch will be replaced see Figure 30 This pressure switch is the differential pressure switch between the burner box and the vent assembly If necessary mark the two hoses that attach to the pressure switch 7 Disconnect the electrical leads to the pres sure switch It is not necessary to mark...

Page 29: ... Low Voltage Field Five wire Heating Cooling Applications Figure 26a Two Stage Configuration Legend Field Wiring Factory Wiring Low Voltage High Voltage BROWN AIR CONDITIONER CONDENSING UNIT C Y TWO STAGE ROOM THERMOSTAT R Y G W YELLOW GREEN YELLOW GREY RED BROWN BROWN TO VARIABLE SPEED BLOWER W2 YELLOW BLACK CLOSED END CONNECTOR DO NOT REMOVE HI LO C GAS VALVE YELLOW This kit is for LP propane co...

Page 30: ... Y TWO STAGE ROOM THERMOSTAT R Y G W YELLOW GREEN YELLOW GREY RED BROWN BROWN TO VARIABLE SPEED BLOWER YELLOW BLACK CLOSED END CONNECTOR DO NOT REMOVE HI LO C GAS VALVE YELLOW Legend Field Wiring Factory Wiring Low Voltage High Voltage BROWN AIR CONDITIONER CONDENSING UNIT C Y TWO STAGE ROOM THERMOSTAT R Y G W YELLOW GREEN YELLOW GREY RED BROWN BROWN TO VARIABLE SPEED BLOWER YELLOW BLACK CLOSED EN...

Page 31: ...LLOW CLOSED END CONNECTOR DO NOT REMOVE ODT Legend Field Wiring Factory Wiring Low Voltage High Voltage ODT Open on rise outdoor thermostat YELLOW BLACK BROWN HI LO C GAS VALVE YELLOW BROWN AIR CONDITIONER CONDENSING UNIT C Y ROOM THERMOSTAT R Y G W YELLOW GREEN YELLOW GREY RED BROWN TO VARIABLE SPEED BLOWER YELLOW CLOSED END CONNECTOR DO NOT REMOVE SDT Legend Field Wiring Factory Wiring Low Volta...

Page 32: ...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 Line Voltage Wiring The line voltage 115 volt to the furnace must be supplied from a dedicated branch circuit containing 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 ...

Page 33: ...tivates the fur nacewillstagetohighfireandtheblowerwill operate at a higher speed until the room thermostat is satisfied 6 Two Stage Cooling The furnace is sup plied with the yellow Y1 and blue Y2 connections attached to the control board Connect a field supplied wire from the yellow Y1 to the thermostat and the con densing unit and another wire connected from Y2 on the thermostat to Y2 on the con...

Page 34: ...d for each instal lation to prevent over firing the furnace IMPORTANT NOTE The firing rate must not exceed the rate shown on the furnace rating plate At alti tudes above 2000 feet it must not exceed that on the rating plate less 4 for each 1000 feet Follow the procedure below 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...

Page 35: ...t In some cases the nominal system capac ity is not the same as the nominal capacity of the indoor coil The cooling heat pump airflow is selected by setting switches 1 through 4 on the motor control board located in the blower control panel All airflows for other modes of operation except gas heat are determined by this setting Table 1 shows the airflow values versus the airflow selector switch se...

Page 36: ...STAGE BLOWER DECK LIMIT SWITCH SELECT MODELS ONLY BLUE W W RED R R 13 11 7 5 1 2 3 4 5 6 7 GREY YELLOW BLUE BROWN ORANGE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 POWER FACTOR CORRECTION CHOKE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 VARIABLE SPEED BLOWER MOTOR 1 2 3 4 5 VARIABLE SPEED BLOWER CONTROL BOX NOTES 1 Use copper conductors only 2 If any of the original wire as supplied with the fur...

Page 37: ...V HUM Neutrals 4 1 5 2 6 3 7 8 9 4 5 6 1 2 3 EAC HUM M1 M2 M3 HEAT COOL L1 XFMR Unused Motor Leads EAC Electronic Air Tap 5A 120 VAC Status Light Red Humidifier Tap 5A 120 VAC Connect Neutral Lead of Electronic Air Cleaner and or Humidifier Here Common Leads These motor speed taps are not used for two stage models Figure 29 Blower Speed Tap Location ture and verify that the Sequence of Operation i...

Page 38: ... items WARNING Toavoidelectricshock personalinjury ordeath disconnecttheelectricpower before performing any maintenance WARNING Holesintheventpipeorheatexchanger can cause products of combustion to enter the home Replace the vent pipe or heat exchanger if leaks are found Failure to prevent products of com bustion from being circulated into the livingspacecancreatepotentiallyhaz ardous conditions i...

Page 39: ...tHeaderBox 18 CombustionAir Intake 19 ExhaustVent 20 Choke Upflow HorizontalFurnaceModels 1 Igniter NotShown 2 FlameSensor NotShown 3 Gas Valve 4 FlameRoll outSwitch s 5 CondensatePressureSwitch 6 PressureSwitch 7 ControlBoard 8 BlowerDoor Switch 9 VentSafetySwitch 10 LowVoltage Transformer 11 Supply Air Limit Switch 12 CirculatingAir BlowerAssembly 13 InducedDraft Blower 14 CondensateDrainTube No...

Page 40: ...d lint can create excessive loads on the motor resulting in higher than normal operating temperatures and short ened 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 an...

Page 41: ...fter the gas valve opens If flame is sensed all burners are on and the igniter cools off If no flame is sensed the gas valve closes immedi ately and the inducer continues to run A second trial for ignition step 6 begins if no flame is sensed on the fifth try for ignition the furnace control is locked and the red LED will blink 4 times repetitively The thermostat must be opened for at least ten sec...

Page 42: ...If the furnace locks out after 5 attempts for ignition itwilltryagaineveryhourif acallforheat remains If the inducer and circulating air blow ers are operating and items 1 through 8 have been checked press the red reset button on the vent safety switch See Figure 29 If the furnace operates after depressing the reset button contact a qualified serviceman to identify and repair the problem If the fu...

Page 43: ... operating Manifold Pressure ____________________ in water column with furnace operating Is there adequate fresh air supply for combustion and ventilation _____________ Furnace Input __________________ Btuh Supply Air Temperature ____________ F Return Air Temperature ____________ F Temperature Rise ________________ F Are Flue Connections tight _____________ Is there Proper Draft __________________...

Page 44: ... 708475E 708475A O Fallon MO 708475A Replaces7084750 Specifications and illustrations subject to change without notice and without incurring obligations PrintedinU S A 11 05 ...

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