Nordyne G6Rc 90 Users Manual 707931 0 G6 90+ Furnace Ii.p65
G6RL 90+ to the manual 2ed0ecf7-171f-4ed3-80e8-6614f5e344df
2015-02-05
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Residential Gas Furnaces Installation Instructions G6RC Series 90+ Upflow Condensing Furnace G6RD Series 93+ Upflow Condensing Furnace G6RL Series 90+ Downflow Condensing Furnace G6RC 90+, G6RD 93+ Upflow ! WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual for assistance. For additional information consult a qualified installer, service agency, or the gas supplier. G6RL 90+ Downflow ! FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. ! FOR YOUR SAFETY: WHAT TO DO IF YOU SMELL GAS: These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all instructions carefully before starting the installation. DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE. • 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 cannot reach your gas supplier, call the fire department. • Extinguish any open flame. Table of Contents Furnace Specifications ............................................................................................................ 4-5 Furnace Airflow Data .......................................................................................................... 6-7 Installation Requirements .......................................................................................................... 8 Supply Air Plenum Installation .................................................................................................. 9 Installation on a Concrete Slab ............................................................................................. 9 Installation on a Combustible Floor ....................................................................................... 9 Circulating Air Supply ............................................................................................................... 10 Return Air ............................................................................................................................ 11 Venting and Combustion Air Requirements .......................................................................... 11 Air Requirements for One-Pipe Installation ........................................................................ 13 Installation in An Unconfined Space ................................................................................... 13 Installation in A Confined Space ......................................................................................... 13 • Air From Inside .................................................................................................................. 13 • Air Directly Through An Exterior Wall ............................................................................... 14 • Outdoor Air Through Vertical Openings or Ducts ............................................................. 14 • Outdoor Air Through Horizontal Openings or Ducts ......................................................... 14 Venting Requirements .............................................................................................................. 14 Vent Pipe Material ............................................................................................................... 14 Vent Pipe Length and Diameter .......................................................................................... 14 Vent Pipe Installation .......................................................................................................... 15 Pipe Routing & Support ....................................................................................................... 15 Location of Outdoor Terminations ....................................................................................... 18 Horizontal Venting ............................................................................................................... 19 Vertical Venting ................................................................................................................... 20 Vent Freezing Protection ..................................................................................................... 20 Concentric Vent Termination ............................................................................................... 20 Drainage of Condensate From Furnace ................................................................................. 21 Gas Supply and Piping ........................................................................................................ 22 Leak Check .......................................................................................................................... 22 Conversion ........................................................................................................................... 23 High Altitude Application ..................................................................................................... 23 Natural Gas High Altitude Conversion ................................................................................ 23 LP/Propane Gas Sea Level and High Altitude Conversion ................................................ 23 Electrical Wiring ........................................................................................................................ 24 Line Voltage Wiring ............................................................................................................. 24 Low Voltage Wiring ............................................................................................................. 25 Start-up and Adjustments ......................................................................................................... 25 Start-Up Procedure .............................................................................................................. 26 Verifying and Adjusting Firing Rate ..................................................................................... 26 Verifying and Adjusting Temperature Rise ......................................................................... 27 Verifying Burner Operation .................................................................................................. 27 Verifying Operation of the Supply Air Limit Switch ............................................................. 29 Description of Components ..................................................................................................... 29 Maintenance ............................................................................................................................... 31 Combustion Air and Vent System ....................................................................................... 31 Air Filter(s) ........................................................................................................................... 31 Lubrication ........................................................................................................................... 31 Condensate Drain Assembly ............................................................................................... 31 Blower Compartment ........................................................................................................... 31 Heat Exchanger and Burner Maintenance .......................................................................... 31 Location of Major Components ........................................................................................... 32 System Operation Information ................................................................................................. 31 Sequence of Operation ....................................................................................................... 33 Furnace Fails to Operate .................................................................................................... 34 Twinning of Two Furnaces .................................................................................................. 34 Installation/Performance Checklist ......................................................................................... 35 Combustion Air Inlet 23 1/4" A Exhaust Vent 22 1/2" 3/4" B Combustion Air Vent (See Fig. 15 3/4" for sizes) 3/4" 19 3/4" C 2 1/4" Figure 1. G6RC, G6RD Unit Dimensions 27 5/8" 3/4" 2" PVC Exhaust Vent (See Fig. 15 for sizes) 25 1/8" 1 1/2" x 3 1/2" Dia. Opening for Gas Connection 7/8" Dia. Electric Connection 1 1/2" x 3 1/2" Dia. Opening for Gas Connection 7/8" Dia. Electric Connection 43" + + 25 1/4" 25 5/8" 33" 30 1/4" 25 1/4" 20 1/2" 15" 8" Return Air Opening (Side) 1" 1 1/4" 23" 28" Return Air Opening (Bottom) D Condensate Drain Outlets 8" 23" Bottom Return Opening FURNACE SPECIFICATIONS 4 Upflow G6RC & G6RD Furnaces Downflow G6RL Furnace Combustion Air Inlet 24 1/2" 3/4" A Exhaust Vent 22 1/2" Exhaust Vent 2" B 3/4" 27 7/8" 3/4" 2 1/2" 3/4" Figure 2. G6RL Unit Dimensions C CL Combusting Vent (3" for 80/100 2" for 40/60) 24 7/8" 43" 7/8" Dia. Electric Connection 21 7/8" 1 1/2" x 3 1/2" Dia. Opening for Gas Connection 24 7/8" 7/8" Dia. Electric Connection 1 1/2" x 2 1/2" Knockout For Gas Connection 21 1/2" 21 1/4" 21 1/2" 15 1/2" 21 7/8" 8" 10 1/4" Bottom Supply Air Opening (Side) D 19 3/4" 1" Condensate Drain Outlet Condensate Drain Outlet Bottom Opening 5 External Static Pressure (Inches Water Column) 6 Heating Input Motor Motor (Btuh) HP G6RC040C-08 40,000 G6RC040C-12 40,000 G6RC060C-12 60,000 G6RC080C-12 80,000 G6RC080C-16 80,000 G6RC100C-16 100,000 G6RC120C-16 120,000 G6RC120C-20 120,000 G6RD040C-10 40,000 G6RD060C-10 60,000 Speed High* Medium Low** High* Medium Low** High* Medium Low** High* Medium Low** High* Med-High Med-Low** Low High* Med-High** Med-Low Low High* Med-High** Med-Low Low High* Med-High Med-Low** Low High* Medium Low** High* Medium** Low 1/5 1/3 1/3 1/3 1/2 1/2 1/2 3/4 1/3 1/3 0.1 CFM 950 740 620 1330 1190 830 1310 1160 800 1490 1230 780 1840 1600 1380 1100 1910 1640 1440 1230 1860 1650 1440 1230 2260 1870 1540 1360 1050 990 770 1175 1075 800 0.2 Rise 36 47 56 42 45 65 46 56 43 50 45 53 60 56 63 72 56 67 46 45 49 66 CFM 920 710 590 1280 1160 810 1260 1120 780 1450 1200 750 1780 1560 1350 1050 1860 1620 1410 1210 1800 1610 1410 1210 2200 1840 1530 1330 1005 950 740 1125 1040 770 0.3 Rise 38 49 59 43 46 67 48 58 44 51 47 53 61 58 65 74 56 68 48 47 51 69 CFM 890 680 560 1230 1110 780 1210 1080 760 1390 1150 720 1700 1470 1300 1000 1780 1540 1370 1180 1730 1550 1380 1180 2140 1790 1510 1310 960 905 700 1075 995 745 0.4 Rise 39 51 62 44 48 68 50 60 41 47 53 49 56 63 60 67 75 58 69 50 49 53 71 CFM 850 650 520 1170 1060 760 1160 1050 740 1310 1080 680 1630 1400 1250 950 1700 1480 1320 1140 1650 1480 1320 1140 2070 1760 1470 1280 915 860 660 1030 950 710 0.5 Rise 41 53 46 45 49 70 53 64 42 49 55 51 58 66 63 70 79 59 71 53 51 56 74 CFM 800 600 470 1120 1010 720 1100 990 710 1210 1010 630 1550 1350 1190 900 1620 1420 1270 1090 1570 1410 1280 1090 1990 1710 1430 1250 855 810 625 970 900 670 0.6 Rise 43 58 48 47 52 73 57 69 45 51 58 53 61 68 66 74 81 61 73 56 54 59 - CFM 750 550 410 1030 910 670 1040 940 680 1100 910 570 1470 1280 1120 850 1520 1340 1210 1030 1480 1320 1220 1030 1910 1660 1370 1220 800 760 580 920 840 630 0.7 Rise 46 63 38 52 50 55 63 47 54 62 57 65 72 70 79 85 63 76 46 61 57 63 - CFM 690 490 350 940 820 610 980 890 650 980 810 510 1380 1210 1040 800 1420 1250 1140 960 1380 1230 1150 960 1810 1610 1300 1190 730 700 540 860 790 580 0.8 Rise 50 37 42 57 53 58 50 57 67 61 69 75 84 57 65 80 48 50 65 61 67 - CFM 630 430 290 850 720 550 920 830 620 830 680 440 1290 1150 960 750 1310 1150 1060 880 1270 1120 1080 880 1710 1560 1220 1150 670 650 500 800 720 530 Rise 55 41 48 63 56 63 54 60 66 75 82 61 67 85 53 54 70 66 73 - CAPACITIES —Furnace Airflow Data Table 1. Furnace Airflow Data Model Number External Static Pressure (Inches Water Column) Heating Table 2. Furnace Airflow Data Model Input Motor Motor Number (Btuh) HP G6RD080C-14 80,000 G6RD100C-14 100,000 G6RD120C-14 120,000 G6RD120C-19 120,000 G6RL040C-12 40,000 G6RL060C-12 60,000 G6RL080C-16 80,000 G6RL100C-16 100,000 Speed High* Med-High Med-Low** Low High* Med-High** Med-Low Low High* Med-High** Med-Low Low High* Med-High Med-Low** Low High* Medium Low** High* Medium Low** High* Med-High Med-Low** Low High* Med-High** Med-Low Low ** Factory Set Cooling Speed ** Factory Set Heating Speed - Not Recommended 1/2 1/2 1/2 3/4 1/3 1/3 1/2 1/2 0.1 CFM 1620 1450 1255 1080 1620 1430 1260 1085 1700 1510 1330 1140 2140 1955 1660 1450 1280 1140 875 1260 1120 855 1635 1435 1230 1050 1600 1475 1320 1150 0.2 Rise 49 56 65 54 62 70 62 70 79 64 73 39 40 45 59 47 55 53 57 - CFM 1560 1400 1225 1055 1555 1375 1220 1050 1635 1455 1280 1110 2070 1900 1620 1430 1210 1090 835 1190 1070 815 1585 1395 1200 1035 1555 1435 1290 1130 0.3 Rise 45 50 57 67 57 64 72 65 73 56 65 74 41 43 48 62 49 56 54 59 - CFM 1490 1350 1180 1030 1485 1330 1170 1015 1565 1405 1240 1075 2010 1850 1575 1400 1180 1060 820 1155 1040 800 1525 1350 1165 1010 1500 1385 1250 1110 0.4 Rise 47 52 60 68 59 66 75 67 75 57 67 75 41 44 49 64 50 58 56 61 - CFM 1430 1295 1145 1000 1425 1265 1130 970 1500 1350 1195 1040 1945 1800 1540 1360 1140 1030 805 1120 1010 780 1460 1300 1130 980 1445 1335 1215 1075 0.5 Rise 49 54 61 70 62 70 70 78 59 69 78 42 45 50 65 46 52 60 59 63 - CFM 1365 1240 1105 960 1355 1210 1070 935 1435 1290 1145 1010 1870 1740 1495 1340 1090 980 780 1075 960 760 1400 1255 1090 950 1380 1290 1170 1040 0.6 Rise 52 57 64 73 65 73 74 56 61 71 79 35 43 47 53 67 48 54 62 61 66 - CFM 1300 1180 1060 920 1290 1150 1010 890 1370 1230 1100 980 1800 1690 1460 1300 1070 950 770 1030 930 730 1330 1200 1050 910 1310 1240 1120 1000 0.7 Rise 54 60 66 68 77 59 62 72 81 36 44 49 55 70 51 56 65 65 68 - CFM 1240 1120 1020 870 1220 1080 950 850 1310 1170 1050 940 1730 1630 1410 1270 1030 910 760 980 890 710 1260 1150 1000 870 1240 1190 1070 950 0.8 Rise 57 63 69 72 61 65 75 83 37 45 52 57 54 59 68 68 71 - CFM 1170 1060 980 820 1160 1010 890 800 1240 1100 1000 910 1650 1570 1370 1230 990 870 750 940 850 690 1180 1090 960 820 1160 1130 1020 890 NOTES: 1. Airflow rates of 1800 CFM or more require two return air connections. Data is for operation with filter(s). 2. Temperature rises in the table are approximate. Actual temperature rises may vary. 3. Temperature rises and airflows for external static pressures greater than 0.5 are for reference only. These conditions are not recommended. Rise 60 66 72 64 67 77 39 45 54 60 57 62 71 73 75 - 7 • NFPA-90B - Warm Air Heating and Air Conditioning Systems. INSTALLATION REQUIREMENTS Requirements and Codes This furnace must be installed in accordance with these instructions, all applicable local building codes, and the current revision of the National Fuel Gas Code (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. These publications are available from: National Fire Protection Association, Inc. Batterymarch Park Quincy, Massachusetts 02269 ! WARNING: This furnace is not approved for installation in mobile homes. Installation in a mobile home could cause fire, property damage, and/or personal injury. Shipping Weight (lbs) 133 140 172 180 204 135 135 174 185 Dimensions (inches) Model Number Furnace Btuh A B C D G6R(C,D)040C G6R(C,D)060C G6R(C,D)080C G6R(C,D)100C G6R(C,D)120C G6RL040C G6RL060C G6RL080C G6RL100C 40,000 60,000 80,000 100,000 120,000 40,000 60,000 80,000 100,000 14 1/4 14 1/4 19 3/4 19 3/4 22 1/2 14 1/4 14 1/4 19 3/4 19 3/4 12 3/4 12 3/4 18 1/4 18 1/4 21 12 3/4 12 3/4 18 1/4 18 1/4 5 1/8 5 1/8 7 7/8 7 7/8 9 1/4 4 5/8 4 5/8 10 10 11 3/4 11 3/4 17 1/4 17 1/4 20 12 3/4 12 3/4 18 1/4 18 1/4 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 Furnace Input (Btuh) Cabinet Width (Inches) Minimum Clearances (Inches) Side Vent Back Top Front 40,000 60,000 80,000 100,000 120,000 14 1/4 14 1/4 14 1/4 19 3/4 22 1/2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1* 1* 1* 1* 1* * 24 inches is the minimum clearance for servicing. 36 inches is the recommended clearance for service. Table 4. Minimum Clearances to Combustible Materials 8 Location HORIZONTAL INSTALLATIONS The furnace must be installed on a level surface, and as close to the center of the air distribution system as possible. See Table 3 for overall dimensions to determine the required clearances in hallways, doorways, stairs, etc. to allow the furnace to be moved to the installation point. The furnace must be installed so that all electrical 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 clearance 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 satisfied, but that panel or door must be removable and allow the appropriate clearance for your installation. 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 models are NOT approved for horizontal 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 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 combustible floor sub-base is required when installing on a combustible floor. Failure to install the subbase 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 installed on a factory or site-built cased air conditioning 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. 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. Installation on a combustible floor - G6RL 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" clearance to the flooring or other combustible material. Place furnace on the combustible base as shown in Figure 6. 3. When the furnace is installed on a factory or site-built cased air conditioning 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 material. 18.75" 13.25" 19.25" 19.25" Hole in Floor G6RL 080/100 Hole in Floor G6RL 040/060 Figure 3. Opening for Concrete Slab 9 Concrete Floor 18.75" or 13.25"* Furnace * Smaller dimensions for G6RL 040/060 9.25" Sheet Metal Plenum Figure 4. Furnace on a Concrete Slab 16.75" or 11.25"* 28.38" 1.50" 18.75" 13.25" 19.63" Hole in Floor 1.58" 19.63" Hole in Floor 19.75" or 14.25"* 1 inch thick fiberglass 3 lb density 2.0" 19.63" 3" Figure 7. Downflow Sub-Base Dimensions G6RL 080/100 G6RL 040/060 Figure 5. Opening in Wood Floor Downflow Sub-base Furnace Wood Floor Sheet Metal Plenum 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 downstream (on the outlet side) or in parallel with the furnace. Figure 6. Furnace on a Wood Floor CIRCULATING AIR SUPPLY Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B). 10 If a cooling system is installed in parallel with the furnace, a damper must be installed to prevent chilled air from entering the furnace and condensing on the heat exchanger. If a manually operated damper is installed, it must be designed so that operation of the furnace is prevented when the damper is in the cooling position and operation of the cooling system is prevented when the damper is in the heating position. ! WARNING: Products of combustion must not be allowed to enter the 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 conditions including carbon monoxide poisoning that could result in personal injury or death. All return ductwork must be adequately 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 return 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 between 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 fireplace insert, stove, etc. An important consideration in selecting one or two pipe installation is the quality of the combustion air. Indoor air is sometimes contaminated with various household chemicals which can cause severe corrosion in the furnace combustion 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 provisions can be determined by consulting the current version of the National Fuel Gas Code (ANSI Z223.1/NPFA-54). For Canadian installations, requirements are specified in the National Standard of Canada (CAN/CGA B149.1 & .2). Consult local codes for special requirements. NOTE: If the furnace is operated without adequate air for combustion and ventilation, it may not perform properly. Furnace components may be strained by high temperature and could fail prematurely. ! WARNING: Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes to provide sufficient combustion air for the furnace. 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 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 pipe" installation - i.e. only the vent (exhaust) pipe is provided. 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. Each opening to outside must be at least 1 sq. in. per 4000 Btuh of total input rating. --- 12" Max. Vent or Chimney 12" Max Furnace Furnace --- 12" Max. Water Heater 12" Max Water Heater Minimum Total Input Free Area Round Duct Rating (Btuh) (Each Opening) Diameter 40,000 100 sq. in. 12" 60,000 100 sq. in. 12" 80,000 100 sq. in. 12" Figure 9. Equipment in a Confined Space with all Combustion Air drawn from Inside Minimum Total Input Free Area Round Duct Rating (Btuh) (Each Opening) Diameter 40,000 10 sq. in. 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" Figure 10. Equipment in a Confined Space with all Combustion Air drawn from Outdoors through Exterior Wall Ventilation Louvers at each end of attic Vent or Chimney Attic Insulation Vent or Chimney Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. Ducts must extend above attic insulation. Ventilation Louvers (each end of attic) ---- Total Input Rating (Btuh) 40,000 60,000 80,000 100,000 120,000 140,000 160,000 Minimum Free Area Round Duct (Each Opening) Diameter 10 sq. in. 4" 15 sq. in. 5" 20 sq. in. 5" 25 sq. in. 6" 30 sq. in. 6" 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 Water Heater Alternate Air Inlet Inlet Air ,,,,, ,,,,, --- Water Heater Furnace NOTE: Air openings shall each have a free area of not less than one square inch per 4,000 Btuh of the total input rating of all equipment in the enclosure. --- 12" Max Outlet Air --- Furnace Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. 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 Air Duct Furnace Air Duct Air Duct must be at least 1 sq. in. per 2000 Btuh of total input rating. 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 input rates 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 has 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. Water Heater Minimum Total Input Free Area Round Duct Rating (Btuh) (Each Opening) Diameter 40,000 20 sq. in. 5" 60,000 30 sq. in. 6" 80,000 40 sq. in. 7" 100,000 50 sq. in. 8" 120,000 60 sq. in. 9" 140,000 70 sq. in. 10" 160,000 80 sq. in. 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 opening. 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 obstructed, 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 ! CAUTION: "Tight" buildings (with weather stripping and caulk to reduce infiltration), may require special provisions for introduction of outside air to ensure satisfactory combustion and venting, even though the furnace is located in an unconfined space. ! 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 considered confined space installations. Installation In A Confined Space A confined space is one which does not meet the unconfined space volume requirements, and typically involves installation in a small room. All such installations must have specific provisions for introduction of combustion and ventilation air. Codes require that two openings be provided 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 if the building is not "tight" and if the total volume of the furnace space and the space from which air is drawn meets the volume requirements for an unconfined space. In 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 appliances 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.) NORDYNE condensing furnaces are classified as "Category IV" appliances, which require special venting materials and installation procedures. 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 combustion air piping lengths must conform completely to the requirements of Table 5. 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-sectional 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.) The furnace must be vented to the outdoors. It must not be vented in common with any other appliance, even if that appliance is of the condensing 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. 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 square 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.) FURNACE MUST NOT BE COMMON VENTED WITH OTHER APPLIANCES. ! 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 capacity table provided in this section applies to the total of vent and combustion air piping for either type of installation. 14 ! WARNING: 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 Schedule 40 PVC PVC-DWV SDR-21* & SDR-26* ABS-DWV Schedule 40 ABS Standard D1785 D2665 D2241 D2661 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 excessively 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 number 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 diameter for which the tabulated length is equal to or greater than required. Proper use 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 maximum allowable length of 2" is 60 feet with one elbow. Select 2-1/2 or 3" pipe. For three additional 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. APPLICATION PVC,CPVC or ABS SCH. 40 Pipe Size Models G6RC,D,L 040 Models G6RC,D,L 060 & 080 Models G6RC,D,L 100 & 120 SINGLE PIPE LENGTH (ft.) with 1 long radius elbows*. Outlet Outlet 2" 3" 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 quality of outdoor air must also be considered. 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. ! CAUTION: Combustion air must not be drawn from a corrosive atmosphere. DIRECT VENT, DUAL PIPE LENGTH (ft.) with 1 long radius elbows on each pipe.* Inlet/Outlet Inlet/Outlet Inlet/Outlet 2" 2" 3" 2" 3" 3" 80 150 40 40 50 50 90 90 60 150 30 30 35 35 90 90 30 150 15 15 25 25 90 90 *NOTES 1. Subtract 2.5 ft. for each additional 2" elbow and 3.5 ft. for each additional 3" elbow. 2. Two 45 degree elbows are equivalent to one 90 degree elbow. 3. One short radius elbow is equivalent to two long radius elbows 4. Do not include termination elbows in calculation of vent length 5. 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 15 G6RC & G6RD Upflow Furnaces 5/8" Inlet Exhaust See Vent Table 4 Seal/Caulk around Pipe at Building Straps or Other Suitable Supports at Minimum of 5 ft. Intervals Coupling Combustion Offset with Exhaust Pipe for Adequate Dimensional Clearance Upward Pitch - 1/4" per Foot Outlet Exhaust Vent PVC or ABS Pipe First Support Placed as Close to Furnace Connection as Possible 90˚ Elbow 12" Min. 7" Wall Normal Snow Level Exhaust Vent Straight Neoprene Coupling with 2 Hose Clamps* (Optional - Not Shown) G6RL Downflow Furnaces See Vent Table 4 Seal/Caulk around Pipe at Building 90˚ Elbow 12" Min. Normal Snow Level Exhaust Inlet 5/8" Straps or Other Suitable Supports at Minimum of 5 ft. Intervals Coupling Combustion Air Inlet Upward Pitch - 1/4" per Foot Outlet Exhaust Vent First Support Placed as Close to Furnace Wall Connection as Possible Exhaust Vent Offset with Exhaust Pipe for Adequate Dimensional Clearance PVC or ABS Pipe Straight Neoprene Coupling with 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 are allowed. 16 G6RC & G6RD Upflow Furnaces Support System on Vertical Rise Below Joints Support System with first support as close to furnace as Possible Combustion Air Pipe 5' Exhaust Vent Upward Pitch 1/4" per Foot Straight Neoprene Couplings with 2 Hose Clamps* (Optional - Not Shown) Cabinet Furnace Front Support System on Vertical Rise Below Joints G6RL Downflow Furnaces Support System with first support as close to furnace as Possible Exhaust Vent 5' Combustion Air Pipe Straight Neoprene Rubber Couplings with 2 Hose Clamps Upward Pitch 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 & G6RD Upflow Furnaces G6RL Downflow Furnaces Combustion Air Inlet Pipe Collar Diameter 3" for coupling or reducer Furnace Top 2" PVC Exhaust Vent All Models Combustion Air Inlet 2" PVC on G6RL 040/060 models, 3" PVC on G6RL 080/100 models Furnace Top 2" PVC Exhaust Vent All Models Figure 16. Furnace Pipe Adaptions 17 Piping must be mechanically supported so that its weight does not bear on the furnace. Supports must be at intervals no greater than five feet, and at smaller intervals if necessary to ensure that there 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 in the 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- 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 operation 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 requirements 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 level or grade level whichever is higher. See Figure 18 for alternate method to achieve 12" above snow level. 2. The minimum distance for a (1-pipe installation) from any door, (openable) window, or gravity air inlet is 4 ft. below, 4 ft. horizontally, or 1 ft. above. 3. The minimum distance for a direct vent (2pipe) installation) from any door, (openable) window, or air gravity inlet is 1 ft. below, 1 ft. horizontally, or 1 ft. above. 4. For one-pipe installations the recommended minimum distance from an inside corner formed by two exterior walls is 6 feet, but is not required. Direct vent terminal 50,000 Btuh or less Mechanical draft vent terminal Mechanical draft vent terminal 9 in. Less than 10 ft. 12 in. mi n 4 ft. min 4 ft .m in Mechanical draft vent terminal 12 in. 12 in. n mi 3 ft. min. n 12 in. 12 n mi n in i .m Direct vent terminal more than 50,000 Btuh Figure 17. Vent Termination Clearances 18 e ad Gr mi Forced Air Inlet 5. 6. 7. 8. The vent termination for a 1-pipe installation 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 planters or patios, etc. Also ensure that exhaust gases will not impinge on windows or building surfaces, which may be compromised or damaged by condensation. Do not install the vent terminal such that exhaust is directed 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. ! CAUTION: For optimum performance, vent furnace 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. ! WARNING: Ensure that the combustion air vent and the exhaust vent are configured as shown in Figure 19. Improper vent termination can cause recirculation of the flue gases. This may result in furnace vibration. In severe cases, the furnace will cycle due to the intermittent contact between the flame and the flame sensor. If you note oscillations occurring, check the vent configuration. Make sure that the exhaust vent does not have a 90 degree termination. Vent Configuration to Provide 12" Minimum height above Snow Level. Outside Wall Pipe Coupling 12" Min. 19" Max. Support ¢ Q , 1/2" Armaflex Insulation or Equivalent 12" Above Normally Expected Snow Level Figure 18. Alternate Horizontal Vent Installation For horizontal venting, one of the following kits is recommended: Through-the-Wall Exterior Vent Mounting Kit Neutralizer Kit - All Models 2" PVC 3" PVC 9023730 9023750 9023730 9023730 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 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 must be fastened to the wall and the outside one must be flashed as appropriate to prevent entry of water. When the above kits are not used the following steps are required: 1. 2. Check the hole size cut through the exterior wall. Insure that the hole diameter is less than the diameter of the couplings to be used. Extend the vent pipe through the wall approximately 1" and seal the area between the wall and pipe. 19 3. 4. 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. Insure the combustion air inlet pipe (for a 2 pipe installation) has a 90 degree termination 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 clearances for vertical vent termination. The roof penetration must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing. Termination spacing requirements from the roof and from each other must be per Figure 20. Vent and combustion 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. b. The top of the chimney is sealed and weatherproofed. c. The termination clearances shown in Figure 20 are maintained. d. No other 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 equivalent. Insulating pipe is important to avoid condensate icing. For extremely cold climates or for conditions of short furnace cycles (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 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 freezing, 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 concentric vent termination, follow the installation instructions provided with that kit. Exhaust Vent Option B Mounting Kit Faceplate Secured to Wall with Screws Exhaust Vent Option A 18" Min. 36" Max. Combustion Air Inlet Exhaust Vent Option C 8" Min. 18" min. 36" max. 18" Min. 36" Max. 7" Min. 12" Min. to Normal Snow Level Grade Level or Normal Snow Inlet Exhaust Figure 19. Exhaust and Combustion Air Pipe Clearances 20 Elbow Exhaust Vent 1" Combustion Air Intake 18" Min. 36" Max. A A Exhaust Plumbing Vent Roof Boot (Typ. Both Pipes) A= 12" Above Roof or Snow Accumulation Level Figure 20. Vertical Vent Termination DRAINAGE OF CONDENSATE FROM FURNACE 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" hole in the cabinet, see Figure 21. For a left side drain follow the steps below: 1. Loosen the clamp on the soft exit tube (see Figure 21.) 2. Rotate the soft exit tube (counter clockwise, 180° upflow G6RC/RD models; clockwise 90° downflow G6RL models.) G6RC & G6RD A 3. Re-tighten the clamp. MAKE SURE CLAMP IS TIGHT TO AVOID LEAKAGE OF CONDENSATE. Route the tubing out of the 7/8" hole located 8 inches up from the bottom furnace. 4. The condensate should drain from the plastic collector box (location A in Figure 21) as droplets or a small stream. If you notice the furnace has operated for more than 5 minutes without draining or the red status light on the control board is pulsing a 2-blink code follow the steps below. 1. Remove the collector box soft tube at location A in Figure 21 and insure the exit from A G6RL Collector Box Collector Box Left Side Drain Rotate counter clockwise (Step 2) 8" "HARD" J Drain Tube Route to floor drain. ...OR Route to condensate pump. Keep Clamp (Loosen For Step 1) downward (Retighten for Step 3) slope. Left Side Drain Rotate clockwise (Step 2) 8" "HARD" J Drain Tube Clamp (Loosen For Step 1) (Retighten for Step 3) Route to floor drain. ...OR Route to condensate pump. Keep downward slope. Figure 21. Furnace with Condensate Drain Trap Assembly 21 2. 3. the collector box is clear of any debris or obstructions. 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. 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 limestone). 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 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 unit. Table 5 lists 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 liquefied petroleum gases. This furnace is equipped for either left 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. The main manual gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required. 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- Do not use matches, lighters, candles, or other sources of open flame to check for gas leaks. Roll-Out Limit Some Utilities Require ShutOff Valve to be 4 to 5 feet Above Floor Shut-Off Valve with 1/8" NPT Plugged Tap Burner Viewport ! CAUTION: 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 fieldprovided and installed components. Automatic Gas Valve (with manual shut-off) Ground Joint Union Burner Assembly Roll-Out Limit Burner Assembly Ground Joint Union Automatic Gas Valve (with manual shut-off) Denotes fieldprovided and installed components. Figure 22. Typical Gas Service Connection 22 Some Utilities Require ShutOff Valve to be 4 to 5 feet Above Floor Shut-Off Valve with 1/8" NPT Plugged Tap Burner Viewport CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR) FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60) NOMINAL LENGTH OF PIPE RUN BLACK IRON (feet) PIPE DIAMETER (in.) 10 20 30 40 50 60 70 80 1/2 130 90 75 65 55 50 45 40 3/4 280 190 150 130 115 105 95 90 1 520 350 285 245 215 195 180 170 1 1/4 1050 730 590 500 440 400 370 350 1 1/2 1600 1100 890 760 670 610 560 530 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. ! WARNING: This furnace was equipped at the factory for use with natural gas only. A special kit, supplied by the manufacturer, is required to convert the furnace 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 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 & 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 must be 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 5000 ft. above sea level, a # 55 or #56 drill size orifice should be used. After changing the orifices, use Table 8 to 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 kit is for LP/propane conversions in Canada at altitudes between zero and 4500 ft. above sea level. Follow the installation instructions supplied with the kit for proper installation. ! CAUTION: To avoid electric shock, personal injury, or death, turn off the power at the disconnect or the main service panel before making any electrical connections. ELECTRICAL WIRING Electrical connections must be made in accordance with all applicable local codes and ordinances, and with the current revision of the National Electric Code (ANSI/NFPA 70). For Canadian installations electrical connections and grounding must be done in accordance with the current Canadian Electrical Code (CSA C22.1 Part 1) 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 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 in the furnace and Figure 23.) The furnace cabinet must have an uninterrupted, unbroken ground to minimize injury should an electrical fault condition occur. The controls For a Natural Gas Sea Level Heating Value of 800 to 899 Btu/cu.ft. Elevation (feet above sea level) zero to 2000 to 5000 to 6000 to 8000 to 1999 4999 5999 7999 10000 3.5 3.5 3.5 Manifold Pressure Setting (in WC) 3.5 3.0 For a Natural Gas Sea Level Heating Value of 900 to 999 Btu/cu.ft. Elevation (feet above sea level) zero to 2000 to 5000 to 6000 to 8000 to 1999 4999 5999 7999 10000 3.5 3.5 3.5 Manifold Pressure Setting (in WC) 3.2 2.8 For a Natural Gas Sea Level Heating Value of 1,000 to 1,100 Btu/cu.ft. Elevation (feet above sea level) zero to 2000 to 5000 to 6000 to 8000 to 1999 4999 5999 7999 10000 3.5 3.5 Manifold Pressure Setting (in WC) 3.0 2.8 2.5 Table 7. Manifold Pressure (in WC) for Natural Gas at Various Altitudes 0 to 1,999 Manifold Pressure in (WC) for an LP Gas Heating Value of 2,500 Btu/hr. 10.0 Elevation (feet above sea level) 2,000 to 5,000 to 6,000 to 8,000 to 4,999 5,999 7,999 10,000 8.5 10.0 9.0 8.5 Table 8. Manifold Pressure (in WC) for LP/Propane Gas at Various Altitudes 24 Furnace Rating Orifice Drill Size Plate Input (Btu/h) Nat LP 45000 60000 72000 96000 120000 144000 44 45 43 43 43 43 Furnace Rating Orifice Drill Size Plate Input (Btu/h) Nat LP 54 55 54 54 54 54 45000 60000 72000 96000 120000 144000 44 45 43 43 43 43 55 56 55 55 55 55 Table 9. Natural and LP Gas Orifice Sizes for Elevations between zero and 4999 ft. Above Sea Level Table 10. Natural and LP gas Orifice Sizes for Elevations between 5000 and 10,000 ft. Above Sea Level used in this furnace require an earth ground to operate properly. Acceptable methods for grounding are electrical wire or conduit approved for electrical ground service. Do not use gas piping as an electrical ground. nace. See Figure 24 for the 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. NOTE: Proper line voltage polarity must be maintained in order for the 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 polarity and ground are properly connected. See Figure 23. The thermostat must not be installed on an outside wall or any other location where its operation 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. ! CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Add the current draw of the system components; or 2. Measure the current flow on the thermostat R-W circuit after the circulating blower motor has started. Set the heat anticipator according to the thermostat manufacturer's instructions for heat anticipator settings. START-UP AND ADJUSTMENTS Low Voltage Wiring Install the thermostat per the manufacturer's instructions. The low voltage (24 volt) connections from the thermostat are made at the terminal strip on the control board in the furField Supplied Fused Service Panel Black (Hot) White (Neutral) Green or Bare (Ground) Prior to start-up, verify that: 1. The line voltage power leads are securely connected, that the polarity of the connections is correct, and that the furnace is properly grounded. Field Supplied Panel Connector Black White Ground Black White Ground Black White Field Line Voltage Wiring Factory Line Voltage Wiring Ground Field Supplied Disconnect Within Sight of Furnace Figure 23. Line Voltage Field Wiring 25 Furnace Input (Btuh) Cabinet Width (in.) Nominal Electrical Supply 40,000 60,000 80,000 100,000 120,000 14.25 14.25 19.75 19.75 22.50 115-60-1 115-60-1 115-60-1 115-60-1 115-60-1 Maximum Minimum Maximum Operating Operating Furnace Voltage Voltage Amperes 127 127 127 127 127 103 103 103 103 103 12.2 12.2 14.1 14.1 17.3 Minimum Wire Gauge Maximum Fuse or Circuit Breaker Amps* 14 14 14 14 12 15 15 15 15 20 * Time-delay fuses or HACR-type circuit breakers are required. Thermostat Wire Gauge Recommended Thermostat Wire Length 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 A/C Condensing Unit R C R 24 V 3 Amp Fuse Blower Off Timing TWIN Y G 9 6 3 8 5 2 7 4 1 Start-Up Procedure 1. 2. EAC L1 XFMR HEAT M3 M2 M1 HUM Neutrals Unused Motor Leads 6 3 5 2 4 1 Figure 24. Low Voltage Field, Four-wire Heating/Cooling Applications 3. 4. 26 6. Status Light (Red) COOL EAC HUM FIELD WIRING Low Voltage Connections W NOTE: The "Y" terminal on the UTEC control board must be connected to the thermostat. Flame Signal Light (Yellow) G W Room Thermostat 2. 5. Y Connect R&W For Heating Only COM 60 90 120 180 Condensing Unit Control Box 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 correcting the fault condition which caused the switch to trip. The blower door is in place, closing the door switch in the line voltage circuit. The gas line has been purged and all connections are leak tight. 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 3. 4. 5. Set the thermostat to the lowest setting. Close the disconnect(s) to provide line voltage to the furnace. Follow the procedures given on the operating instructions label attached to the furnace. Set the thermostat above room temperature and verify the sequence of operation. (See the SEQUENCE OF OPERATION.) 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 installation 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. 2. Shut off all other gas fired appliances. 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. Convert the 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 ft. The manifold pressure must be set to the appropriate 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 required for your particular installation. To adjust the manifold pressure, remove the regulator cap and turn the adjusting screw clockwise to increase pressure or counterclockwise to reduce pressure. Replace the regulator cap after adjustments are complete. ! 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 position 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 recommended setting. If the temperature rise measured 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 motor. 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 observe the ignition sequence. The flame can be observed through the small clear window on 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 28 GAS FLOW RATE (CU UBIC FEET PER HOUR) TIME FOR ONE REVOLUTION (SECONDS) Table 12. Gas Flow Rate 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 CUBIC FEET PER REVOLUTION OF METER 1 5 10 150 138 129 120 113 106 100 95 90 86 82 78 75 72 69 67 64 62 60 58 56 750 692 643 600 563 529 500 474 450 429 409 391 375 360 346 333 321 310 300 290 281 1500 1385 1286 1200 1125 1059 1000 947 900 857 818 783 750 720 692 667 643 621 600 581 563 TIME FOR ONE REVOLUTION (SECONDS) 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 CUBIC FEET PER REVOLUTION OF METER 1 5 10 45 44 43 42 41 40 39 38 38 37 36 35 35 34 33 33 32 32 31 31 30 225 220 214 209 205 200 196 191 188 184 180 176 173 170 167 164 161 158 155 153 150 450 439 429 419 409 400 391 383 375 367 360 353 346 340 333 327 321 316 310 305 300 Verifying Operation of the Supply Air Limit Switch 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. 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 furnace 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 approximately 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. 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 that the inducer is 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. It 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°F. This switch protects the plastic flue system and the inducer from over-temperature conditions. DESCRIPTION OF COMPONENTS Figure 28 shows the location of each of the functional components described below. If any component of the furnace must be replaced, use only factory authorized replacement parts. See the Replacement Parts List for each component. R COM 3 Amp Fuse Blower Off Timing 60 90 120 180 Flame Roll-Out Switch – This switch provides flame roll-out protection to the furnace and combustion air inlet pipe. 24 V C TWIN Y G Flame Signal Light (Yellow) W Common Leads 6 8 5 2 7 4 1 Neutrals Unused Motor Leads L1 XFMR EAC Cooling Speed Tap HEAT Humidifier Tap (.5A@ 120 VAC) COOL 1 M3 4 M2 3 2 HUM 6 5 M1 EAC HUM Connect Neutral Lead of Electronic Air Cleaner and/or Humidifier Here. Status Light (Red) 3 9 Electronic Air Tap (.5A@ 120 VAC) Heating Speed Tap Figure 25. Blower Speed Tap Location 29 For G6RC, G6RD and G6RL Residential Furnaces BLUE BLUE VENT SAFETY SWITCH (ALL MODELS) BLUE ORANGE FLAME ROLL-OUT SWITCH (ALL MODELS) SUPPLY AIR LIMIT SWITCH (ALL MODELS) BLUE BLOWER DECK SWITCH (SELECT MODELS ONLY) ORANGE BLUE PRESSURE SWITCH WHITE VENT PRESSURE SWITCH (93+ MODELS ONLY) BLACK WHITE (NEUTRAL) BLACK 120V BLOWER DOOR SWITCH GROUND GREEN ROOM THERMOSTAT TRANSFORMER WHITE W/ BLK STRIPES R WHITE Y 120 V 24 V G BLK W/ WHITE STRIPES BLACK W BLACK 180 120 90 60 AIR CONDITIONER CONDENSING UNIT C Y FLAME SENSOR 3 OR 4 SPEED MOTOR RED YELLOW BROWN C H BLUE IGNITOR BLACK Legend Field Wiring Factory Wiring: Low Voltage High Voltage R C BLACK RED BLACK ORANGE BLUE INDUCER BLACK BLACK Power On Limit Circuit Open STATUS RED LIGHT ON 1 FLASH Pressure Switch Stuck Open 2 FLASHES Pressure Switch Stuck Closed 3 FLASHES Ignition Failure (Check Ground) 4 FLASHES 115 VAC & Neutral Reversed or no Ground 5 FLASHES False Flame or Gas Valve Relay Shorted Power Off Continuous OFF FAULT CONDITION Low Flame Sensor Signal FLAME YELLOW LIGHT Continuous Flash ON Flame Present 3 4 5 WHITE FAULT CONDITION 1 2 6 MOTOR PLUG 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 BLACK WHITE RED L VALVE MH ML ORANGE GAS MAINTENANCE It is recommended that the furnace be checked yearly. At a minimum, this check should include the following items. ! WARNING: To avoid electric shock, personal injury, or death, disconnect the electric power before performing any maintenance. ! WARNING: Holes in the vent pipe or heat exchanger 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 combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning 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 blocked by debris. Any damaged section of vent pipe must be replaced, and any obstruction or blockage must be removed prior to operating the furnace. Air Filter(s) ! 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 efficiency, equipment damage, and possible fire. AIR FILTER(S) ARE NOT SUPPLIED WITH THE FURNACE AS SHIPPED 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 adjacent to 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 accumulated in the compartment or on the blower and motor. Dirt and lint can create 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 passageways, however, the flue passageways, the vent system, and the burners should be inspected 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 most important to 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 flammable vapors and liquids in the vicinity of the furnace. 31 G6RC & G6RD Upflow Furnaces 1 Ignitor (Not Shown) 2 Flame Sensor (Not Shown) 3 Gas Valve 4 Flame Roll-out Switch(s) 5 Pressure Switch 6 Vent Pressure Switch (G6RD Only, Not Shown) 7 Control Board 8 Blower Door Switch 9 Vent Safety Switch 10 Low Voltage Transformer 11 Supply Air Limit Switch 12 Circulating Air Blower Assembly13 Induced Draft Blower 14 Condensate Drain Tube 15 In-Line Drain Assembly 16 Burner View Port 17 Front Header Box 18 Combustion Air Intake 19 Exhaust Vent 18 19 4 16 1 2 3 11 10 5 7 13 17 8 9 12 14 19 G6RL Downflow Furnace 1 Ignitor (Not Shown) 2 Flame Sensor (Not Shown) 3 Gas Valve 4 Flame Roll-out Switch(s) 5 Pressure Switch 7 Control Board 8 Blower Door Switch 9 Vent Safety Switch 10 Low Voltage Transformer 11 Supply Air Limit Switch 12 Circulating Air Blower Assembly13 Induced Draft Blower 14 Condensate Drain Tube 15 In-Line Drain Assembly 16 Burner View Port 17 Front Header Box 18 Combustion Air Intake 19 Exhaust Vent 18 10 12 7 8 15 5 13 17 9 14 11 3 2 1 16 4 Figure 28. Location of Major Components 32 15 • 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 windows and doors are open. • Be sure that the thermostat is properly installed and is not being 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. 2. The control board checks for continuity on the 24 VAC limit control circuit (over-temperature 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. 3. 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. 4. The inducer is energized. 5. The pressure switch will close. If the pressure 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. 6. 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. 7. 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 ignition, the furnace control is locked out and the red LED will blink 4 times repetitively. The thermostat 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. 8. The furnace control energizes the circulating air blower on the heating speed 30 seconds after the gas valve circuit is energized . 9. When the thermostat has been satisfied, gas valve is de-energized. 10. The inducer is de-energized after a 30 second postpurge. 11. The furnace control keeps the circulating air blower energized for 120 seconds (factory set) or 60, 90, or 180 seconds (field adjustable). (See Figure 25.) 12. 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 for the specified 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. 2. The furnace control energizes the circulating blower (115 VAC) on the cooling speed. 3. When the thermostat is satisfied, the G and Y terminals on the control board are de-energized opening the compressor contactor. 4. The circulating air blower is de-energized after a 90 second delay. 33 Fan Mode: 1. On a 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 immediately 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 following: 1. Is the thermostat operating properly? 2. Are the blower compartment door(s) in place? 3. Is the furnace disconnect closed? 4. Has the circuit breaker tripped or the control board fuse burned open? 5. Is the gas turned on? 6. Are any manual reset switches open? 7. Is the filter dirty or plugged? 8. Is the flame sensor coated? (Remove and clean with emery cloth.) 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 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, provided 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 connected together for twinning. (See Figure 29.) Thermostat W G Y R R C Y G W Twin Terminal A/C Unit Figure 29. Twinning 34 R C Y G W Twin Terminal INSTALLATION/PERFORMANCE CHECK LIST LOCATION __________________________ CITY ____________________ STATE _____ INSTALLER _________________________ CITY ____________________ STATE _____ UNIT MODEL # _______________________ UNIT SERIAL # ________________________ Minimum Clearances per Table 3? ________ Supply Air Temperature: ____________ (° F) Return Air Temperature: ____________ (° F) Electrical Connections tight? _____________ Line Voltage Polarity correct? ____________ Supply Voltage: ___________________ Volts Blower Motor HP: _____________________ FUEL TYPE: Are Flue Connections tight? _____________ Is there Proper Draft? __________________ Is Vent free from restrictions? ____________ Is the Filter(s) secured in place? __________ 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: __________________ Temperature Rise: ________________ (° F) (Btuh) Is the Filter(s) clean? __________________ Has the Thermostat been calibrated? ______ Is the Thermostat 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 ¢707931*¤ 707931 7079310 (Replaces 7078950) St. Louis, MO Specifications and illustrations subject to change without notice and without incurring obligations. Printed in U.S.A. (9/99)
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