Nordyne G6Rc 90 Users Manual 707931 0 G6 90+ Furnace Ii.p65

G6RL 90+ to the manual 2ed0ecf7-171f-4ed3-80e8-6614f5e344df

: Nordyne Nordyne-G6Rc-90-Users-Manual-404100 nordyne-g6rc-90-users-manual-404100 nordyne pdf

Open the PDF directly: View PDF .
Page Count: 36

Installation Instructions

These instructions are primarily intended to

assist qualified individuals experienced in

the proper installation of this appliance.

Some local codes require licensed installa-

tion/service personnel for this type of equip-

ment. Read all instructions carefully before

starting the installation.

DO NOT DESTROY. PLEASE READ CARE-

FULLY AND KEEP IN A SAFE PLACE FOR

FUTURE REFERENCE.

G6RC 90+, G6RD 93+ Upflow G6RL 90+ Downflow

G6RC Series 90+ Upflow Condensing Furnace

G6RD Series 93+ Upflow Condensing Furnace

G6RL Series 90+ Downflow Condensing Furnace

Residential Gas Furnaces

! WARNING:

Improper installation, adjustment, al-

teration, service, or maintenance can

cause injury or property damage. Re-

fer to this manual for assistance. For

additional information consult a quali-

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 appliance.

! FOR YOUR SAFETY:

WHAT TO DO IF YOU SMELL GAS:

• 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

4

FURNACE SPECIFICATIONS

7/8" Dia. Electric

Connection

2 1/4"

23 1/4"

19 3/4"

3/4"

43"

25 1/8"

25 1/4"

23"

28"

15"

25 1/4"

33"

Return Air Opening

(Bottom)

Return Air Opening

(Side)

Bottom Return Opening

Condensate Drain Outlets

A

B

Combustion Air

Vent

(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 G6RC & G6RD Furnaces

Figure 1. G6RC, G6RD Unit Dimensions

5

3/4" 3/4"

2 1/2"

Combusting

Vent

(3" for 80/100

2" for 40/60)

L

C

A

C

D

B

Condensate

Drain

Outlet

Condensate

Drain

Outlet

7/8" Dia.

Electric

Connection

1 1/2" x 2 1/2"

Knockout

For Gas

Connection

Bottom Opening

27 7/8"

19 3/4"

7/8" Dia. Electric

Connection

24 1/2"

3/4"

43"

21 7/8"

21 1/2"

15 1/2" 21 1/2"

10 1/4"

Bottom Supply Air Opening

(Side)

Exhaust

Vent

2"

1 1/2" x 3 1/2" Dia.

Opening for

Gas Connection

3/4"

22 1/2"

Exhaust Vent

Combustion Air Inlet

24 7/8" 24 7/8"

21 7/8"

21 1/4"

8"

1"

Downflow G6RL Furnace

Figure 2. G6RL Unit Dimensions

6

Table 1. Furnace Airflow Data

CAPACITIES —Furnace Airflow Data

External Static Pressure (Inches Water Column)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

950 36 920 38 890 39 850 41 800 43 750 46 690 50 630 55

740 47 710 49 680 51 650 53 600 58 550 63 490 - 430 -

620 56 590 59 560 62 520 - 470 - 410 - 350 - 290 -

1330 - 1280 - 1230 -

1170

- 1120 - 1030 - 940 37 850 41

1190 - 1160 - 1110 -

1060

- 1010 - 910 38 820 42 720 48

830 42 810 43 780 44 760 46 720 48 670 52 610 57 550 63

1310 - 1260 - 1210 -

1160

45 1100 47 1040 50 980 53 920 56

1160 45 1120 46 1080 48

1050

49 990 52 940 55 890 58 830 63

800 65 780 67 760 68 740 70 710 73 680 - 650 - 620 -

1490 46 1450 48 1390 50

1310

53 1210 57 1100 63 980 - 830 -

1230 56 1200 58 1150 60

1080

64 1010 69 910 - 810 - 680 -

780 - 750 - 720 - 680 - 630 - 570 - 510 - 440 -

1840 - 1780 - 1700 41

1630

42 1550 45 1470 47 1380 50 1290 54

1600 43 1560 44 1470 47

1400

49 1350 51 1280 54 1210 57 1150 60

1380 50 1350 51 1300 53

1250

55 1190 58 1120 62 1040 67 960 -

1100 - 1050 - 1000 - 950 - 900 - 850 - 800 - 750 -

1910 45 1860 47 1780 49

1700

51 1620 53 1520 57 1420 61 1310 66

1640 53 1620 53 1540 56

1480

58 1420 61 1340 65 1250 69 1150 75

1440 60 1410 61 1370 63

1320

66 1270 68 1210 72 1140 - 1060 -

1230 - 1210 - 1180 -

1140

- 1090 - 1030 - 960 - 880 -

1860 56 1800 58 1730 60

1650

63 1570 66 1480 70 1380 75 1270 82

1650 63 1610 65 1550 67

1480

70 1410 74 1320 79 1230 84 1120 -

1440 72 1410 74 1380 75

1320

79 1280 81 1220 85 1150 - 1080 -

1230 - 1210 - 1180 -

1140

- 1090 - 1030 - 960 - 880 -

2260 - 2200 - 2140 -

2070

- 1990 - 1910 - 1810 57 1710 61

1870 56 1840 56 1790 58

1760

59 1710 61 1660 63 1610 65 1560 67

1540 67 1530 68 1510 69

1470

71 1430 73 1370 76 1300 80 1220 85

1360 - 1330 - 1310 -

1280

- 1250 - 1220 - 1190 - 1150 -

1050 - 1005 - 960 - 915 - 855 - 800 - 730 48 670 53

990 - 950 - 905 - 860 - 810 - 760 46 700 50 650 54

770 46 740 48 700 50 660 53 625 56 580 61 540 65 500 70

1175 45 1125 47 1075 49

1030

51 970 54 920 57 860 61 800 66

1075 49 1040 51 995 53 950 56 900 59 840 63 790 67 720 73

800 66 770 69 745 71 710 74 670 - 630 - 580 - 530 -

Heating

Model Input Motor Motor

Number (Btuh) Speed HP

Hi

g

h*

G6RC040C-08

40,000 Medium 1/5

Low**

Hi

g

h*

G6RC040C-12

40,000 Medium 1/3

Low**

Hi

g

h*

G6RC060C-12

60,000 Medium 1/3

Low**

Hi

g

h*

G6RC080C-12

80,000 Medium 1/3

Low**

Hi

g

h*

G6RC080C-16

80,000

Med-High

1/2

Med-Low**

Low

Hi

g

h*

G6RC100C-16

100,000 Med-Hi

g

h** 1/2

Med-Low

Low

Hi

g

h*

G6RC120C-16

120,000 Med-Hi

g

h** 1/2

Med-Low

Low

Hi

g

h*

G6RC120C-20

120,000

Med-High

3/4

Med-Low**

Low

Hi

g

h*

G6RD040C-10

40,000 Medium 1/3

Low**

Hi

g

h*

G6RD060C-10

60,000 Medium** 1/3

Low

7

Table 2. Furnace Airflow Data

Heating

Model Input Motor Motor

Number (Btuh) Speed HP

Hi

g

h*

G6RD080C-14 80,000

Med-High

1/2

Med-Low**

Low

Hi

g

h*

G6RD100C-14 100,000 Med-Hi

g

h** 1/2

Med-Low

Low

Hi

g

h*

G6RD120C-14 120,000 Med-Hi

g

h** 1/2

Med-Low

Low

Hi

g

h*

G6RD120C-19 120,000

Med-High

3/4

Med-Low**

Low

External Static Pressure (Inches Water Column)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

1620 - 1560 45 1490 47

1430

49 1365 52 1300 54 1240 57 1170 60

1450 49 1400 50 1350 52

1295

54 1240 57 1180 60 1120 63 1060 66

1255 56 1225 57 1180 60

1145

61 1105 64 1060 66 1020 69 980 72

1080 65 1055 67 1030 68

1000

70 960 73 920 - 870 - 820 -

1620 54 1555 57 1485 59

1425

62 1355 65 1290 68 1220 72 1160 -

1430 62 1375 64 1330 66

1265

70 1210 73 1150 - 1080 - 1010 -

1260 70 1220 72 1170 75

1130

- 1070 - 1010 - 950 - 890 -

1085 - 1050 - 1015 - 970 - 935 - 890 - 850 - 800 -

1700 62 1635 65 1565 67

1500

70 1435 74 1370 77 1310 - 1240 -

1510 70 1455 73 1405 75

1350

78 1290 - 1230 - 1170 - 1100 -

1330 79 1280 - 1240 -

1195

- 1145 - 1100 - 1050 - 1000 -

1140 - 1110 - 1075 -

1040

- 1010 - 980 - 940 - 910 -

2140 - 2070 - 2010 -

1945

- 1870 56 1800 59 1730 61 1650 64

1955 - 1900 56 1850 57

1800

59 1740 61 1690 62 1630 65 1570 67

1660 64 1620 65 1575 67

1540

69 1495 71 1460 72 1410 75 1370 77

1450 73 1430 74 1400 75

1360

78 1340 79 1300 81 1270 83 1230 -

1280 - 1210 - 1180 - 1140 - 1090 - 1070 - 1030 - 990 -

1140 - 1090 - 1060 - 1030 - 980 35 950 36 910 37 870 39

875 39 835 41 820 41 805 42 780 43 770 44 760 45 750 45

1260 40 1190 43 1155 44 1120 45 1075 47 1030 49 980 52 940 54

1120 45 1070 48 1040 49 1010 50 960 53 930 55 890 57 850 60

855 59 815 62 800 64 780 65 760 67 730 70 710 - 690 -

1635 - 1585 - 1525 - 1460 46 1400 48 1330 51 1260 54 1180 57

1435 47 1395 49 1350 50 1300 52 1255 54 1200 56 1150 59 1090 62

1230 55 1200 56 1165 58 1130 60 1090 62 1050 65 1000 68 960 71

1050 - 1035 - 1010 - 980 - 950 - 910 - 870 - 820 -

1600 53 1555 54 1500 56 1445 59 1380 61 1310 65 1240 68 1160 73

1475 57 1435 59 1385 61 1335 63 1290 66 1240 68 1190 71 1130 75

1320 - 1290 - 1250 - 1215 - 1170 - 1120 - 1070 - 1020 -

1150 - 1130 - 1110 - 1075 - 1040 - 1000 - 950 - 890 -

High*

G6RL040C-12 40,000 Medium 1/3

Low**

High*

G6RL060C-12 60,000 Medium 1/3

Low**

High*

G6RL080C-16 80,000 Med-High 1/2

Med-Low**

Low

High*

G6RL100C-16 100,000 Med-High** 1/2

Med-Low

Low

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.

** Factory Set Cooling Speed

** Factory Set Heating Speed

- Not Recommended

8

Table 3. Furnace Dimensions and Shipping Weights

Table 4. Minimum Clearances to Combustible Materials

* 24 inches is the minimum clearance for servicing.

36 inches is the recommended clearance for service.

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 Cabinet Minimum Clearances (Inches)

Input Width

(Btuh) (Inches) Side Vent Back Top Front

40,000 14 1/4 0 0 0 1 1*

60,000 14 1/4 0 0 0 1 1*

80,000 14 1/4 0 0 0 1 1*

100,000 19 3/4 0 0 0 1 1*

120,000 22 1/2 0 0 0 1 1*

INSTALLATION REQUIREMENTS

Requirements and Codes

This furnace must be installed in accordance

with these instructions, all applicable local build-

ing codes, and the current revision of the Na-

tional Fuel Gas Code (ANSI-Z223.1, NFPA-54).

The current revision of the National Fuel Gas

Code is available from:

American National Standards Institute, Inc.

1430 Broadway

New York, New York 10018

Canada installations shall comply with CAN/

CGA-B149 installation codes, local plumbing or

waste water codes and other applicable codes.

Additional helpful publications are:

• NFPA-90A - Installation of Air Conditioning

and Ventilating Systems.

• NFPA-90B - Warm Air Heating and Air

Conditioning Systems.

These publications are available from:

National Fire Protection Association, Inc.

Batterymarch Park

Quincy, Massachusetts 02269

! WARNING:

This furnace is not approved for in-

stallation in mobile homes. Installa-

tion in a mobile home could cause

fire, property damage, and/or personal

injury.

G6R(C,D)040C 40,000 14 1/4 12 3/4 5 1/8 11 3/4 133

G6R(C,D)060C 60,000 14 1/4 12 3/4 5 1/8 11 3/4 140

G6R(C,D)080C 80,000 19 3/4 18 1/4 7 7/8 17 1/4 172

G6R(C,D)100C 100,000 19 3/4 18 1/4 7 7/8 17 1/4 180

G6R(C,D)120C 120,000 22 1/2 21 9 1/4 20 204

G6RL040C 40,000 14 1/4 12 3/4 4 5/8 12 3/4 135

G6RL060C 60,000 14 1/4 12 3/4 4 5/8 12 3/4 135

G6RL080C 80,000 19 3/4 18 1/4 10 18 1/4 174

G6RL100C 100,000 19 3/4 18 1/4 10 18 1/4 185

AB

Dimensions (inches)

Furnace

Btuh CD

Shipping

Weight

(

lbs

)

Model

Number

9

Location

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 clear-

ances in hallways, doorways, stairs, etc. to allow

the furnace to be moved to the installation point.

The furnace must be installed so that all electri-

cal components are protected from water.

Minimum clearances to combustible materials

are listed in Table 4. Access for positioning and

servicing must be considered when locating the

unit. 24 inches is the minimum required clear-

ance for servicing the unit. 30 inches is the

minimum required clearance for positioning the

unit. 36 inches is the recommended clearance

from the front of the unit. Please note that a

panel or door can be located such that the

minimum clearance on the rating plate is satis-

fied, but that panel or door must be removable

and allow the appropriate clearance for your

installation.

This furnace is certified for use on wood flooring.

The furnace must be installed on a solid surface

and must be level front to back and side to side.

This furnace must not be installed directly on

carpeting, tile, or any combustible material other

than wood flooring.

DOWNFLOW WARNING

(G6RL Models):

The design of the downflow furnace is certified

for natural or propane gas and for installation on

non-combustible flooring. A special combus-

tible floor sub-base is required when installing

on a combustible floor. Failure to install the sub-

base may result in fire, property damage and

personal injury. The special downflow sub-bases

are factory supplied accessories, part numbers

902677 and 902974. When the furnace is in-

stalled on a factory or site-built cased air condi-

tioning coil, the sub-base is not necessary.

However, the plenum attached to the coil casing

must be installed such that its surfaces are at

least 1" from combustible construction.

A gas-fired furnace installed in a residential

garage must be installed so that the bottom of

the furnace is located a minimum of 15" from the

floor. The furnace must be located or protected

to avoid physical damage by vehicles.

HORIZONTAL INSTALLATIONS

The G6RC model furnaces are approved for

horizontal installation. Installation Kit #903568

is required for horizontal applications. Follow

the installation instructions in the kit for proper

conversion. NOTE: The G6RD and G6RL mod-

els are NOT approved for horizontal installation.

SUPPLY AIR PLENUM INSTALLATION

A. Installation on a concrete slab - G6RL

1. Construct a hole in the floor per the

dimensions in Figure 3.

2. Place the plenum and the furnace as

shown in Figure 4.

B. 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.

Hole in

Floor

19.25"

18.75"

Hole in

Floor

19.25"

13.25"

G6RL 080/100 G6RL 040/060

Figure 3. Opening for Concrete Slab

10

19.63"

18.75"

19.63"

13.25"

Hole in

Floor Hole in

Floor

Downflow Wood

Sub-base Floor

Furnace

Sheet

Metal

Plenum

Figure 5. Opening in Wood Floor

G6RL 080/100 G6RL 040/060

Figure 6. Furnace on a Wood Floor

1 inch thick fiberglass 3 lb density

28.38"

9.25"

19.63"

3"

19.75"

or 14.25"*

2.0"

1.58"

1.50"

16.75"

or 11.25"*

18.75"

or 13.25"*

Concrete

Floor Furnace

Sheet

Metal

Plenum

Figure 4. Furnace on a Concrete Slab

CIRCULATING AIR SUPPLY

Plenums and air ducts must be installed in

accordance with the Standard for the Installa-

tion of Air Conditioning and Ventilating Systems

(NFPA No. 90A) or the Standard for the Installa-

tion of Warm Air Heating and Air Conditioning

Systems (NFPA No. 90B).

* Smaller

dimensions for

G6RL 040/060

Figure 7. Downflow Sub-Base Dimensions

If outside air is utilized as return air to the furnace

for ventilation or to improve indoor air quality, the

system must be designed so that the return air to

the furnace is not less than 50°F (10°C) during

heating operation. If a combination of indoor and

outdoor air is used, the ducts and damper system

must be designed so that the return air supply to

the furnace is equal to the return air supply under

normal, indoor return air applications.

When a cooling system is installed which uses

the furnace blower to provide airflow over the

indoor coil, the coil must be installed down-

stream (on the outlet side) or in parallel with the

furnace.

If a cooling system is installed in parallel with the

furnace, a damper must be installed to prevent

chilled air from entering the furnace and con-

densing on the heat exchanger. If a manually

operated damper is installed, it must be de-

signed so that operation of the furnace is pre-

vented when the damper is in the cooling posi-

tion and operation of the cooling system is

prevented when the damper is in the heating

position.

11

! 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 con-

ditions including carbon monoxide

poisoning that could result in per-

sonal injury or death.

All return ductwork must be ad-

equately sealed, all joints must be

taped, and the ductwork must be

secured to the furnace with sheet metal

screws. When return air is provided

through the bottom of the furnace, the

joint between the furnace and the re-

turn air plenum must be sealed.

The floor or platform on which the

furnace is mounted must provide

sound physical support of the furnace

with no gaps, cracks, or sagging be-

tween the furnace and the floor or

platform.

Return air and circulating air ductwork

must not be connected to any other

heat producing device such as a fire-

place insert, stove, etc.

Return Air

The return air ductwork may be connected to

any or all of the following: left side return, right

side return, or bottom return. Tables 1 and 2

show the airflow data for each furnace model.

Where maximum airflow is 1800 CFM or

more two openings must be used.

VENTING AND COMBUSTION AIR

REQUIREMENTS

NORDYNE condensing furnaces may be in-

stalled with outdoor combustion air piped di-

rectly to the furnace, or without such special

piping. Codes refer to the former as "direct vent"

or "two pipe" installation. Installation with air

taken from around the furnace is sometimes

referred to as "one pipe" installation - i.e. only

the vent (exhaust) pipe is provided. Figure 8. Protective Screen for One Pipe

Installations

Protective Screen

G6RC/G6RD

G6RL

An important consideration in selecting one or

two pipe installation is the quality of the combus-

tion air. Indoor air is sometimes contaminated

with various household chemicals which can

cause severe corrosion in the furnace combus-

tion system. Some common sources of these

chemicals are detergents, bleaches, aerosol

sprays, and cleaning solvents. Unless indoor air

is known to be free of these materials, two pipe

installation is recommended.

Provisions must be made for adequate supply of

air for combustion and ventilation. For United

States installations, the adequacy of air provi-

sions can be determined by consulting the cur-

rent version of the National Fuel Gas Code

(ANSI Z223.1/NPFA-54). For Canadian installa-

tions, requirements are specified in the National

Standard of Canada (CAN/CGA B149.1 & .2).

Consult local codes for special requirements.

NOTE: If the furnace is operated without ad-

equate air for combustion and ventilation, it may

not perform properly. Furnace components may

be strained by high temperature and could fail

prematurely.

! WARNING:

Furnace installation using methods

other than those described in the fol-

lowing sections must comply with the

National Fuel Gas Code and all appli-

cable local codes to provide sufficient

combustion air for the furnace.

12

Each opening

to outside must

be at least

1 sq. in. per

4000 Btuh of

total input

rating.

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.

35 sq. in.

40 sq. in.

Round Duct

Diameter

4"

5"

5"

6"

6"

7"

8"

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Furnace

Water Heater

Vent or

Chimney

12"

Max

Figure 11. Equipment in a Confined Space

with all Combustion Air drawn from

Outdoors through Vertical Ducts – from

Ventilated Attic

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.

35 sq. in.

40 sq. in.

Round Duct

Diameter

4"

5"

5"

6"

6"

7"

8"

Furnace

Water Heater

Vent or

Chimney

Figure 10. Equipment in a Confined Space

with all Combustion Air drawn from

Outdoors through Exterior Wall

Water

Heater

Vent or

Chimney

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Furnace

Ventilation Louvers For

Unheated Crawl Space

-

-

-

-

-

-

-

-

-

Inlet Air

Ventilation Louvers

(each end of attic)

NOTE: Air open-

ings shall each

have a free area

of not less than

one square inch

per 4,000 Btuh of

the total input rat-

ing of all equipment

in the enclosure.

-

-

-

-

-

-

-

-

-

Alternate

Air Inlet

Outlet

Air

Total Input

Rating (Btuh)

40,000

60,000

80,000

Round Duct

Diameter

12"

12"

12"

Minimum

Free Area

(Each Opening)

100 sq. in.

100 sq. in.

1

00

sq

. in.

Furnace

12" Max.

12" Max.

Water Heater

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.

Figure 9. Equipment in a Confined Space

with all Combustion Air drawn from Inside

Figure 12. Equipment in a Confined Space

with all Combustion Air drawn from

Outdoors through Ventilated Crawl Space

and Ventilated Attic

13

Total Input

Rating (Btuh)

40,000

60,000

80,000

100,000

120,000

140,000

160,000

Minimum

Free Area

(Each Opening)

20 sq. in.

30 sq. in.

40 sq. in.

50 sq. in.

60 sq. in.

70 sq. in.

80 sq. in.

Round Duct

Diameter

5"

6"

7"

8"

9"

10"

10"

Furnace

Water Heater

Air Duct

must be

at least

1 sq. in.

per 2000

Btuh of

total input

rating.

Vent or

Chimney

Air Duct

Air Duct

Figure 13. Equipment in a Confined Space

with all Combustion Air Drawn from the

Outside through Horizontal Ducts

Air Requirements For One-Pipe

Installation

When air for combustion is to be taken from

around the furnace, a protective screen must be

installed over the combustion air intake open-

ing. This screen is provided with the furnace

installation instructions and functions to prevent

debris from entering the combustion system. It

should be installed on the combustion air intake

collar or inlet PVC. If furnace location is such

that this opening might be unintentionally ob-

structed, a 3" PVC elbow should be installed on

the collar, and the screen placed inside the inlet

of the elbow. See Figure 8.

Installation In An Unconfined Space

! CAUTION:

"Tight" buildings (with weather strip-

ping and caulk to reduce infiltration),

may require special provisions for in-

troduction of outside air to ensure

satisfactory combustion and venting,

even though the furnace is located in

an unconfined space.

An unconfined space is an area including all

rooms not separated by doors with a volume

greater than 50 cubic feet per 1,000 Btuh of the

combined 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.

! WARNING:

Furnaces installed with combustion

air drawn from a heated space which

includes exhaust fans, fireplaces, or

other devices that may produce a

negative pressure should be consid-

ered confined space installations.

Installation In A Confined Space

A confined 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 pro-

vided for this - one with bottom edge within 12"

of the floor and one with top edge within 12" of

the ceiling.

The size and other criteria for these

openings must be per the following sections.

Combustion air openings must not be restricted

in any manner.

Furnaces installed in a confined space which

supply circulating air to areas outside of the

space must draw return air from outside the

space and must have return air ducts tightly

sealed to the furnace.

Air From Inside

Air for combustion and ventilation may be taken

from inside the building through an interior wall

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

14

inches of free area. See Figure 9. For example,

if the combined input rate of all appliances is less

than or equal to 100,000 Btuh,

each

opening

must have a free area of at least 100 square

inches. If the combined input rate of all appli-

ances is 120,000 Btuh,

each

opening must have

a free area of at least 120 square inches.

Air Directly Through An Exterior Wall

If combustion air is provided directly through an

exterior wall, the two openings must

each

have

free area of at least one square inch per 4000

Btuh of

total

appliance input. (See Figure 10.)

Outdoor Air Through Vertical Openings or Ducts

If combustion air is provided through vertical

ducts or openings to attics or crawl spaces, the

two openings must each have free area of at

least one square inch per 4000 Btuh of total

appliance input. Ducts must have cross-sec-

tional areas at least as large as the free area of

their respective openings to the furnace space.

Attics or crawl spaces must communicate freely

with the outdoors if they are the source of air for

combustion and ventilation. (See Figures 11

and 12.)

Outdoor Air Through Horizontal

Openings or Ducts

If combustion air is taken from outdoors through

horizontal ducts, the openings must

each

have

free area of at least one 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.)

! CAUTION:

Do not supply combustion air from an

attic space that is equipped with power

ventilation or any other device that

may produce a negative pressure.

VENTING REQUIREMENTS

This section specifies installation requirements

for vent and "2-pipe" combustion air piping. For

"one pipe" installations, install vent piping per

this section and provide air for combustion and

ventilation per the previous section. The capac-

ity table provided in this section applies to the

total of vent and combustion air piping for either

type of installation.

NORDYNE condensing furnaces are classified

as "Category IV" appliances, which require spe-

cial venting materials and installation proce-

dures. Category IV appliances operate with

positive vent pressure and therefore require

vent systems which are thoroughly sealed. They

also produce combustion condensate, which is

slightly acidic and can cause severe corrosion of

ordinary venting materials. Furnace operation

can be adversely affected by restrictive vent and

combustion air piping. Therefore,

vent and com-

bustion air piping lengths must conform com-

pletely to the requirements of Table 5.

The furnace must be vented to the outdoors. It

must not be vented in common with any other

appliance, even if that appliance is of the con-

densing type. Common venting can result in

severe corrosion of other appliances or their

venting and can allow combustion gases to

escape through such appliances or vents. Do

not vent the furnace to a fireplace chimney or

building chase.

! WARNING:

FURNACE MUST NOT BE COMMON

VENTED WITH OTHER APPLIANCES.

Vent Pipe Material

Vent and combustion air pipe and fittings must

be one of the following materials and must

conform to the indicated ANSI/ASTM standards:

Material Standard

Schedule 40 PVC D1785

PVC-DWV D2665

SDR-21* D2241

& SDR-26*

ABS-DWV D2661

Schedule 40 ABS F628

Cement and primer must conform to ATSM

Standard D2564 for PVC and Standard D2235

for ABS. When joining PVC piping to ABS, use

PVC solvent cement. (See procedure specified

in ASTM Standard D3138.)

Vent Pipe Length and Diameter

In order for the furnace to operate properly, the

combustion air and vent piping must not be exces-

sively restrictive. To ensure this use Table 5, which

indicates the maximum allowable piping length for

a furnace of specified input rate, when installed

15

with piping of selected diameter and number of

elbows. This table applies to the length and num-

ber of elbows for each pipe. To use the table, the

furnace input rate, the centerline length and the

number of elbows on each pipe must be known.

Choose the 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 maxi-

mum allowable length of 2" is 60 feet with one

elbow. Select 2-1/2 or 3" pipe. For three addi-

tional elbows, deduct 2.5 ft. for each elbow, or

7.5 ft. for a maximum installed vent length of

52.5 ft.

Condensing furnace combustion products have

very little buoyancy, so Table 5 is to be used

without consideration of any vertical rise in the

piping.

NOTE: Always use the same or larger size

piping for combustion air as is used for the

exhaust vent.

Vent Pipe Installation

Pipe Routing and Support

Route piping as directly as possible between the

furnace and the outdoors and remember that

routing affects pipe size requirements per the

preceding section. If a two pipe system is used,

locate the combustion air intake and the vent

exhaust in the same atmospheric pressure zone

- i.e. both must exit the building though the same

portion of exterior wall or roof. Vent piping must

be sloped upwards not less than 1/4" per foot in

the direction from the furnace to the terminal.

This is to ensure that any condensate flows back

to the furnace (where it can be disposed of

through the condensate disposal system).

The 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

other chemicals which can cause corrosion of

the furnace combustion system.

!

CAUTION:

Combustion air must not be drawn

from a corrosive atmosphere.

*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

APPLICATION SINGLE PIPE LENGTH (ft.) DIRECT VENT, DUAL PIPE LENGTH (ft.)

with 1 long radius elbows*. with 1 long radius elbows on each pipe.*

PVC,CPVC or ABS Outlet Outlet Inlet/Outlet Inlet/Outlet Inlet/Outlet

SCH. 40 Pipe Size 2" 3" 2" 2" 3" 2" 3" 3"

Models

G6RC,D,L 80 150 40 40 50 50 90 90

040

Models

G6RC,D,L 60 150 30 30 35 35 90 90

060 & 080

Models

G6RC,D,L 30 150 15 15 25 25 90 90

100 & 120

16

G6RL Downflow Furnaces

G6RC & G6RD Upflow Furnaces

5/8" Inlet Exhaust

Combustion

Offset with

Exhaust Pipe

for Adequate

Dimensional

Clearance

PVC or

ABS Pipe

See Vent Table 4

Straps or Other Suitable

Supports at Minimum of 5 ft. Intervals

Upward Pitch - 1/4" per Foot

Outlet Exhaust Vent

First Support Placed

as Close to Furnace

Connection as Possible

Exhaust Vent

Wall

Coupling

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 Suitable

Supports at Minimum of 5 ft. Intervals

Upward Pitch - 1/4" per Foot

Outlet Exhaust Vent

First Support Placed

as Close to Furnace

Connection as Possible

Exhaust Vent

Wall

Coupling

Seal/Caulk

around Pipe

at Building

90˚ Elbow

12" Min.

Normal Snow Level 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.

17

Combustion

Air Pipe

Exhaust

Vent

Cabinet

5'

Support System on

Vertical Rise Below Joints

Support System with

first support as close

to furnace as Possible

Upward Pitch

1/4" per Foot

Furnace Front

Straight Neoprene

Rubber Couplings

with 2 Hose Clamps

Combustion

Air Pipe Exhaust

Vent

Cabinet

5'

Support System on

Vertical Rise Below Joints

Support System with

first support as close

to furnace as Possible

Upward Pitch

1/4" per Foot

Furnace Front

Straight Neoprene

Couplings with

2 Hose Clamps*

(Optional - Not

Shown)

Combustion Air Inlet

2" PVC on G6RL 040/060 models,

3" PVC on G6RL 080/100 models

2" PVC

Exhaust Vent

All Models

Furnace Top

Combustion Air Inlet Pipe Collar

Diameter 3" for coupling or reducer

Furnace Top

2" PVC

Exhaust Vent

All Models

G6RL Downflow Furnaces

G6RC & G6RD Upflow

Furnaces

G6RL Downflow Furnaces

G6RC & G6RD Upflow

Furnaces

Figure 16. Furnace Pipe Adaptions

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.

18

4 ft. min

12 in. min

12 in. min

12 in. min

9 in.

4 ft. min

12 in. min

12 in. min

Mechanical

draft vent

terminal

Direct vent

terminal

50,000 Btuh

or less

Forced

Air Inlet

Direct vent

terminal -

more than

50,000 Btuh

Mechanical

draft vent

terminal

Mechanical

draft vent

terminal

Grade

Less

than 10 ft.

3 ft. min.

Piping must be mechanically supported so that

its weight does not bear on the furnace. Sup-

ports must be at intervals no greater than five

feet, and at smaller intervals if necessary to

ensure 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-

Figure 17. Vent Termination Clearances

tween vent piping and combustible surfaces.

However, it is good practice to allow space for

convenience in installation and service.

Location of Outdoor Terminations

Vent and combustion air intake terminations

must be located to ensure proper furnace opera-

tion and to conform to applicable codes. Figure

16 illustrates necessary distances from the vent

termination to windows and building air intakes.

In Canada, the Canadian Fuel Gas Code

takes precedence over these instructions.

Specifically, all minimum distance require-

ments with respect to termination of the vent

piping listed below (items 1 through 8).

The following list is a summary of vent terminal

location requirements:

1. The termination must be 12 inches above

snow 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 instal-

lation) from any door, (openable) window,

or gravity air inlet is 4 ft. below, 4 ft. horizon-

tally, or 1 ft. above.

3. The minimum distance for a direct vent (2-

pipe) installation) from any door, (openable)

window, or air gravity inlet is 1 ft. below, 1 ft.

horizontally, or 1 ft. above.

4. For one-pipe installations the recommended

minimum distance from an inside corner

formed by two exterior walls is 6 feet, but is

not required.

19

5. The vent termination for a 1-pipe installa-

tion shall be a minimum of 3 ft. above any

forced air inlet within 10 ft.

6. 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.

7. Avoid areas where condensate drainage

may cause problems by dropping on plant-

ers or patios, etc. Also ensure that exhaust

gases will not impinge on windows or build-

ing surfaces, which may be compromised

or damaged by condensation. Do not install

the vent terminal such that exhaust is di-

rected into window wells, stairwells, under

decks or into alcoves or similar recessed

areas, and do not terminate above any

public walkways.

8. 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 fur-

nace through wall which experiences

the least exposure to winter winds.

Horizontal Venting

Vent and combustion air intake terminations

must be as shown in Figure 19.

! 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 fur-

nace vibration. In severe cases, the

furnace will cycle due to the intermit-

tent contact between the flame and the

flame sensor. If you note oscillations

occurring, check the vent configura-

tion. Make sure that the exhaust vent

does not have a 90 degree termination.

Figure 18. Alternate Horizontal Vent

Installation

Outside

Wall

Support

Pipe

Coupling

Vent Configuration to

Provide 12" Minimum

height above

Snow Level.

1/2"

Armaflex

Insulation or

Equivalent

12" Above

Normally

Expected

Snow

Level

12" Min.

19" Max.

For horizontal venting, one of the following kits

is recommended:

2" PVC 3" PVC

Through-the-Wall

Exterior Vent

Mountin

g

Kit

9023730 9023750

Neutralizer Kit - All

Models 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 cou-

plings. The face plates are retained on both

sides of the wall by the couplings, and the gasket

is retained against the wall by the outer face

plate. Face plates must be fastened to the wall

and the outside one must be flashed as appro-

priate to prevent entry of water.

When the above kits are not used the following

steps are required:

1. 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.

2. Extend the vent pipe through the wall ap-

proximately 1" and seal the area between

the wall and pipe.

20

3. Apply couplings to the vent pipe on the

interior and exterior sides of the wall to

insure the pipe can not be pushed or pulled

through the wall.

4. Insure the combustion air inlet pipe (for a 2

pipe installation) has a 90 degree termina-

tion elbow as shown in Figures 19 and 20.

Note that a combustion air intake must be

provided with an elbow opening downward.

The screen provided with the furnace must be

installed in the elbow to prevent entry of debris

or creatures.

When the vent pipe must exit an exterior wall

close to the grade or expected snow level, a riser

should be provided as shown in Figure 18.

Insulation is required to prevent freezing of this

section of pipe.

Vertical Venting

Figure 20 shows the proper installation and clear-

ances for vertical vent termination. The roof penetra-

tion must be properly flashed and waterproofed with

a plumbing roof boot or equivalent flashing. Termi-

nation spacing requirements from the roof and from

each other must be per Figure 20.

Vent and combustion 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 equiva-

lent. Insulating pipe is important to avoid con-

densate icing.

For extremely cold climates or for conditions of

short furnace cycles (i.e. set back thermostat

conditions) the 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 freez-

ing, but must not be excessively restrictive.

Concentric Vent Termination

A concentric vent termination is approved for

use with these furnaces. The kit part number is

903578. For proper installation of the concentric

vent termination, follow the installation instruc-

tions provided with that kit.

36" max.

18" min.

Exhaust Vent

Option B

Exhaust Vent

Option A

Exhaust Vent

Option C

Mounting Kit

Faceplate Secured

to Wall with Screws

18" Min.

36" Max.

7" Min.

8" Min.

12" Min. to

Normal Snow Level

Combustion

Air Inlet

Grade

Level

or Normal

Snow

Inlet Exhaust

18" Min.

36" Max.

Figure 19. Exhaust and Combustion Air Pipe Clearances

21

Combustion

Air

Intake

Elbow

Exhaust

Vent

Exhaust

Plumbing Vent Roof Boot

(Typ. Both Pipes)

A

1"

18" Min.

36" Max.

A

Figure 20. Vertical Vent Termination

A= 12" Above Roof or Snow Accumulation Level

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.)

8"

Left Side

Drain

"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.

Collector Box

A

Rotate counter

clockwise (Step 2)

8"

Left

Side

Drain

"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.

Collector Box

A

Rotate clockwise

(Step 2)

G6RLG6RC & G6RD

3. Re-tighten the clamp. MAKE SURE CLAMP

IS TIGHT TO AVOID LEAKAGE OF CON-

DENSATE.

4. Route the tubing out of the 7/8" hole located

8 inches up from the bottom furnace.

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 drain-

ing 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 loca-

tion A in Figure 21 and insure the exit from

Figure 21. Furnace with Condensate Drain Trap Assembly

22

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.

Some Utilities

Require Shut-

Off Valve to

be 4 to 5 feet

Above Floor

Denotes field-

provided and

installed

components.

Shut-Off Valve

with 1/8" NPT

Plugged Tap

Burner Viewport

Roll-Out Limit

Automatic Gas Valve

(with manual shut-off)

Burner

Assembly

Ground

Joint

Union

the collector box is clear of any debris or

obstructions.

2. Replace this tube and insure the fit to the

header spout is air tight. Air will be drawn

into the header if this connection is not tight.

3. Check other tube connections along the

drain system. Insure that all are air tight.

NOTE: Industry research studies indicate that

when condensate is routed to an active drain,

household detergents, etc., buffer its acidity. If

the drain is not actively used or if codes require,

obtain a neutralizer kit (usually contains lime-

stone). Proper drains and connections to the

condensate tubing are required as NORDYNE

cannot be held responsible for water leakage

which occurs due to loose hose connections or

improperly sealed drain line pipes.

GAS SUPPLY AND PIPING

This furnace is equipped for either 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.

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-

Figure 22. Typical Gas Service Connection

Some Utilities

Require Shut-

Off Valve to

be 4 to 5 feet

Above Floor

Denotes field-

provided and

installed

components.

Shut-Off Valve

with 1/8" NPT

Plugged Tap

Burner Viewport

Automatic

Gas Valve

(with manual

shut-off)

Burner

Assembly

Ground Joint

Union

Roll-Out Limit

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 lique-

fied petroleum gases.

The main manual gas valve and main power

disconnect to the furnace must be properly

labeled by the installer in case emergency shut-

down is required.

! CAUTION:

Do not use matches, lighters, candles,

or other sources of open flame to

check for gas leaks.

23

Table 6. Capacity of Black Iron Gas Pipe (cu. ft. per hour)

for Natural Gas (specific gravity = .60)

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.)

NOMINAL LENGTH OF PIPE RUN

BLACK IRON (feet)

PIPE DIAMETER

(in.) 1020304050607080

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

CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR)

FOR NATURAL GAS

(

SPECIFIC GRAVITY - 0.60

)

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 fac-

tory for use with natural gas only. A

special kit, supplied by the manufac-

turer, is required to convert the fur-

nace to operate on LP/propane gas.

Failure to use the proper conversion

kit can cause fire, explosion, property

damage, carbon monoxide poisoning,

personal injury, or death.

Conversion

Conversion of this furnace to use LP/propane

gas must be made 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.

24

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 in-

jury, or death, turn off the power at the

disconnect or the main service panel

before making any electrical connec-

tions.

ELECTRICAL WIRING

Electrical connections must be made in accor-

dance with all applicable local codes and ordi-

nances, and with the current revision of the

National Electric Code (ANSI/NFPA 70).

For Canadian installations electrical connec-

tions and grounding must be done in accor-

dance with the current Canadian Electrical Code

(CSA C22.1 Part 1) 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 con-

taining the correct fuse or circuit breaker for the

furnace. See Table 11. An electrical switch

should be readily accessible from and within

sight of the furnace. (See the Wiring Diagram

label in the furnace and Figure 23.)

The furnace cabinet must have an uninterrupted,

unbroken ground to minimize injury should an

electrical fault condition occur. The controls

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

Elevation (feet above sea level)

0 to 2,000 to 5,000 to 6,000 to 8,000 to

1,999 4,999 5,999 7,999 10,000

10.0 8.5 10.0 9.0 8.5

Manifold Pressure in (WC)

for an LP Gas Heating

Value of 2,500 Btu/hr.

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

6000 to

7999

8000 to

10000

Manifold Pressure Setting (in WC) 3.5 3.5 3.5 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

1999

2000 to

4999

5000 to

5999

6000 to

7999

8000 to

10000

Manifold Pressure Setting (in WC) 3.5 3.5 3.5 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

1999

2000 to

4999

5000 to

5999

6000 to

7999

8000 to

10000

Manifold Pressure Setting (in WC) 3.5 3.5 3.0 2.8 2.5

25

used in this furnace require an earth ground to

operate properly. Acceptable methods for

grounding are electrical wire or conduit ap-

proved for electrical ground service. Do not use

gas piping as an electrical ground.

NOTE: Proper line voltage polarity must be

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 po-

larity and ground are properly connected.

See Figure 23.

! CAUTION:

Label all wires prior to disconnection

when servicing controls. Wiring er-

rors can cause improper and danger-

ous operation. Verify proper opera-

tion after servicing.

Low Voltage Wiring

Install the thermostat per the manufacturer's

instructions. The low voltage (24 volt) connec-

tions from the thermostat are made at the

terminal strip on the control board in the fur-

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.

The thermostat must not be installed on an

outside wall or any other location where its opera-

tion may be adversely affected. Adverse affects

include radiant loading from fireplaces, sunlight,

or lighting fixtures, and convective loading from

warm air registers or electrical appliances.

To check the heat anticipator setting either:

1. Add the current draw of the system compo-

nents; or

2. Measure the current flow on the thermostat

R-W circuit after the circulating blower mo-

tor has started.

Set the heat anticipator according to the thermo-

stat manufacturer's instructions for heat antici-

pator settings.

START-UP AND ADJUSTMENTS

Prior to start-up, verify that:

1. The line voltage power leads are securely

connected, that the polarity of the connec-

tions is correct, and that the furnace is

properly grounded.

Field Supplied Disconnect

Within Sight of Furnace

Field Supplied

Panel Connector

Field Supplied

Fused Service

Panel

Black (Hot)

White (Neutral)

Green or Bare

(Ground)

Black

White

Black

White

Black

White

Field Line Voltage

Wiring

Factory Line

Voltage Wiring

Ground Ground Ground

Figure 23. Line Voltage Field Wiring

Table 9. Natural and LP Gas Orifice Sizes

for Elevations between zero and

4999 ft. Above Sea Level

Furnace Rating

Plate Input (Btu/h) Nat LP

45000 44 54

60000 45 55

72000 43 54

96000 43 54

120000 43 54

144000 43 54

Orifice Drill Size

Furnace Ratin

g

Plate Input (Btu/h) Nat LP

45000 44 55

60000 45 56

72000 43 55

96000 43 55

120000 43 55

144000 43 55

Orifice Drill Size

Table 10. Natural and LP gas Orifice Sizes

for Elevations between 5000 and 10,000 ft.

Above Sea Level

26

2. The thermostat wires (R, W, Y, and G) are

securely connected to the correct leads on

the terminal strip of the circuit board.

3. 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).

4. The roll-out and vent safety manual reset

switches are closed. If necessary, press the

red button to reset a switch. See Figure 28

* Time-delay fuses or HACR-type circuit breakers are required.

Table 11. Electrical Data

for location. DO NOT install a jumper wire

across a switch to defeat its function. If a

switch reopens on start-up, DO NOT reset

the switch without identifying and correct-

ing the fault condition which caused the

switch to trip.

5. The blower door is in place, closing the door

switch in the line voltage circuit.

6. The gas line has been purged and all con-

nections are leak tight.

Start-Up Procedure

1. Set the thermostat to the lowest setting.

2. Close the disconnect(s) to provide line volt-

age to the furnace.

3. Follow the procedures given on the operat-

ing instructions label attached to the furnace.

4. Set the thermostat above room tempera-

ture and verify the sequence of operation.

(See the SEQUENCE OF OPERATION.)

5. After the furnace has run for approximately

five minutes, set the thermostat below room

temperature and verify steps (9) through

(11) of the SEQUENCE OF OPERATION.

Verifying and Adjusting

Firing Rate

The firing rate must be verified for each installa-

tion to prevent over-firing the furnace.

NOTE: The firing rate must not exceed the rate

shown on the furnace rating plate. At altitudes

above 2000 ft. the firing rate must be adjusted as

described in the high altitude section.

Figure 24. Low Voltage Field,

Four-wire Heating/Cooling Applications

R C Y G W

A/C Condensing Unit

Condensing Unit

Control Box

Room

Thermostat

Flame Signal Light

(Yellow)

Status Light

(Red)

60

90

120

180

Blower Off

Timing

TWIN

3 Amp

Fuse

COM

24 V

HUM

Neutrals

Low Voltage

Connections 41

52

63

7

8

9

4

5

6

1

2

3

EAC

HUM

M1

M2

M3

COOL

HEAT

L1

XFMR

Unused Motor Leads

EAC

R Y G W

Connect

R & W

For

Heating

Only

FIELD WIRING

NOTE: The "Y"

terminal on the

UTEC control board

must be connected

to the thermostat.

Furnace Cabinet Nominal Maximum Minimum Maximum Minimum Maximum

Input Width Electrical Operating Operating Furnace Wire Fuse or Circuit

(Btuh) (in.) Supply Voltage Voltage Amperes Gauge Breaker Amps*

40,000 14.25 115-60-1 127 103 12.2 14 15

60,000 14.25 115-60-1 127 103 12.2 14 15

80,000 19.75 115-60-1 127 103 14.1 14 15

100,000 19.75 115-60-1 127 103 14.1 14 15

120,000 22.50 115-60-1 127 103 17.3 12 20

Thermostat Recommended Thermostat

Wire Wire Length

Gauge 2-wire 4 or 5-wire

(heating) (cooling)

24 55 ft. 25 ft.

22 90 ft. 45 ft.

20 140 ft. 70 ft.

18 225 ft. 110 ft.

27

thermometer on the supply air side must be

shielded from direct radiation from the heat

exchanger to avoid false readings. Adjust all

registers and duct dampers to the desired posi-

tion and run the furnace for fifteen minutes

before taking any temperature readings. The

temperature rise is the difference between the

supply and return air temperatures.

For typical duct systems, the temperature rise

will fall within the range specified on the rating

plate with the blower speed at the factory recom-

mended setting. If the temperature rise mea-

sured is outside the range specified, it may be

necessary to change the blower speed. Lower

blower speeds will increase the temperature rise

and higher blower speeds will decrease the

temperature rise.

The furnace is equipped with a multispeed mo-

tor. Heating and cooling speed selection is made

by moving the leads on the integrated control

board located in the furnace. The wiring diagram

on the furnace and Figures 25, 26 and 27 show

the speed taps for adjusting motor speed.

If it is desired that the blower operate at the

same speed for heating and cooling, tape off the

terminal of the unused blower wire. Install the

jumper wire, found in the plastic instruction bag,

across the HEAT and COOL taps on the control

board. Reconnect the desired blower tap to the

piggyback quick connect.

The blower control is designed to start the

circulating air blower 30 seconds after the gas

valve is opened. The blower control is factory

wired to turn the blower motor off 120 seconds

after the gas valve is closed. This timing can be

changed using the BLOWER OFF timing switch

opposite the terminal block on the control board.

(See Figure 25.)

Verifying Burner Operation

To verify operation of the burners, make sure

that the blower compartment door is in place and

that there is power to the furnace. Set the

thermostat above room temperature and ob-

serve the ignition sequence. The flame can be

observed through the small clear window on 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.

Use the following procedure to determine the

firing rate:

1. Shut off all other gas fired appliances.

2. Start the furnace and allow it to run for at

least three minutes.

3. Measure the time (in seconds) required for

the gas meter to complete one revolution.

4. 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 appro-

priate value for your installation. Refer to either

Table 7 for natural gas or Table 8 for LP/propane

gas to verify the manifold pressure setting re-

quired for your particular installation. To adjust

the manifold pressure, remove the regulator cap

and turn the adjusting screw clockwise to in-

crease pressure or counterclockwise to reduce

pressure. Replace the regulator cap after adjust-

ments are complete.

! 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

28

Table 12. Gas Flow Rate

TIME FOR

ONE REVOLUTION

(SECONDS) 1 5 10

24 150 750 1500

26 138 692 1385

28 129 643 1286

30 120 600 1200

32 113 563 1125

34 106 529 1059

36 100 500 1000

38 95 474 947

40 90 450 900

42 86 429 857

44 82 409 818

46 78 391 783

48 75 375 750

50 72 360 720

52 69 346 692

54 67 333 667

56 64 321 643

58 62 310 621

60 60 300 600

62 58 290 581

64 56 281 563

GAS FLOW RATE (C

U

CUBIC FEET PER REVOLUTION OF

METER

TIME FOR

ONE REVOLUTION

(SECONDS) 1 5 10

80 45 225 450

82 44 220 439

84 43 214 429

86 42 209 419

88 41 205 409

90 40 200 400

92 39 196 391

94 38 191 383

96 38 188 375

98 37 184 367

100 36 180 360

102 35 176 353

104 35 173 346

106 34 170 340

108 33 167 333

110 33 164 327

112 32 161 321

114 32 158 316

116 31 155 310

118 31 153 305

120 30 150 300

U

BIC FEET PER HOUR)

CUBIC FEET PER REVOLUTION OF

METER

29

Verifying Operation of the Supply

Air Limit Switch

To verify operation of the supply air limit

switch, make sure that the blower door is in

place and that there is power to the furnace.

Completely block the return airflow to the fur-

nace by installing a close-off plate in place of or

upstream of the filter(s). Set the thermostat

above room temperature and verify that the

Sequence of Operation is as described in these

instructions. The supply air limit switch should

function to turn off the gas valve within approxi-

mately five minutes. The circulating air and

combustion blowers should continue to run

when the supply air limit switch opens. Remove

the close-off plate immediately after the supply

air limit switch opens. If the furnace operates

for more than five minutes with no return air, set

the thermostat below room temperature, shut

off the power to the furnace, and replace the

supply air limit switch.

DESCRIPTION OF COMPONENTS

Figure 28 shows the location of each of the

functional components described below. If

any component of the furnace must be re-

placed, use only factory authorized replace-

ment parts. See the Replacement Parts List

for each component.

R C Y G W

Flame Signal

Light (Yellow)

60

90

120

180

TWIN

3 Amp Fuse

COM

24 V

HUM

Neutrals

41

52

63

7

8

9

4

5

6

1

2

3

EAC

HUM

M1

M2

M3

COOL

HEAT

L1

XFMR

Unused Motor

Leads

EAC

Electronic Air Tap

(.5A@ 120 VAC)

Status

Light (Red)

Heating Speed Tap

Cooling

Speed Tap

Humidifier Tap

(.5A@ 120 VAC)

Connect

Neutral

Lead of

Electronic

Air Cleaner

and/or Humidifier

Here.

Common

Leads

Blower Off

Timing

Figure 25. Blower Speed Tap Location

Flame Sensor – The flame sensor acts to prove

that flame has carried over from the ignitor to the

opposite end burner. If no flame is sensed, the

furnace will be shut down automatically.

Gas Valve – The gas valve controls the flow of

gas to the burners. When the gas valve is

energized it automatically opens and regulates

the gas pressure in the manifold.

Pressure Switch – The pressure switch verifies

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.

Flame Roll-Out Switch – This switch provides

flame roll-out protection to the furnace and

combustion air inlet pipe.

30

For G6RC, G6RD and G6RL Residential Furnaces

Figure 26. G6RC, G6RD and G6RL Integrated Control Board System Diagram

IGNITOR

INDUCER

GAS

VALVE

SUPPLY AIR

LIMIT SWITCH

(ALL MODELS)

VENT

SAFETY

SWITCH

(ALL MODELS)

TRANSFORMER

FLAME SENSOR

C

GREEN

BLACK

WHITE

BLUE BLUE

24 V 120 V

ORANGE

BLUE

BLUE

YELLOW

BROWN

RED

BLACK

WHITE

ORANGE

BLUE

BLACK

ORANGE

BLACK

RED

AIR CONDITIONER

CONDENSING UNIT

BLACK

BLACK

BLOWER DOOR

SWITCH

R

WHITE

BLACK

WHITE W/ BLK STRIPES

BLK W/ WHITE STRIPES

WHITE (NEUTRAL)

BLACK 120V

GROUND

ROOM THERMOSTAT

3 OR 4 SPEED MOTOR

H

MH

ML

L

C

WHITE

RED

ORANGE

BLUE

BLACK

MOTOR

PLUG

1

2

3

4

5

6

BLACK

BLUE

FLAME ROLL-OUT

SWITCH

(ALL MODELS)

VENT

PRESSURE SWITCH

(93+ MODELS ONLY)

PRESSURE

SWITCH

R

Y

G

W

C

Y

180

120

90

60

THESE WIRES ARE

NOT PRESENT

ON 3 SPEED

MODELS

BLOWER

DECK SWITCH

(SELECT MODELS

ONLY)

Legend

Field Wiring

Factory Wiring:

Low Voltage

High Voltage

Power On

Limit Circuit Open

Pressure Switch Stuck Open

Pressure Switch Stuck Closed

Ignition Failure (Check Ground)

115 VAC & Neutral Reversed or no Ground

False Flame or Gas Valve Relay Shorted

ON

1 FLASH

2 FLASHES

3 FLASHES

4 FLASHES

5 FLASHES

Continuous

STATUS

RED

LIGHT

FAULT CONDITION

Power Off

Low Flame Sensor Signal

Flame Present

Continuous

Flash

OFF

ON

FLAME

YELLOW

LIGHT

FAULT CONDITION

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.

31

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 in-

jury, or death, disconnect the electric

power before performing any mainte-

nance.

! WARNING:

Holes in the vent pipe or heat ex-

changer can cause products of com-

bustion to enter the home. Replace

the vent pipe or heat exchanger if

leaks are found. Failure to prevent

products of combustion from being

circulated into the living space can

create potentially hazardous condi-

tions including carbon monoxide poi-

soning that could result in personal

injury or death.

Combustion Air and Vent System

Check the combustion air and vent pipe to

ensure that it is not damaged, corroded or

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 effi-

ciency, equipment damage, and pos-

sible 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 accu-

mulated 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 pas-

sageways, however, the flue passageways, the

vent system, and the burners should be in-

spected and cleaned (if required) by a qualified

serviceman annually to ensure continued safe

operation. Particular attention must be given to

identify deterioration from corrosion or other

sources.

SYSTEM OPERATION

INFORMATION

Proper maintenance is 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 flam-

mable vapors and liquids in the vicinity of

the furnace.

32

Figure 28. Location of Major Components

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 Assembly-

13 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

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 Assembly-

13 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

12

3

4

9

10 11

12

17

19

5

7

8

13

14

15

16

18

G6RL Downflow Furnace

1

2

3

4

9

10

11

12

17

19

5

7

8

13

14

15

16

18

33

• Change or replace the air filters monthly

during any period when the circulating

blower is operating regularly.

• Always replace the doors on the furnace

after servicing. Do not operate the furnace

without all doors and covers in place.

• Avoid operating the furnace when win-

dows and doors are open.

• Be sure that the thermostat is properly

installed 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-tem-

perature limit switch, flame rollout switches

and blocked vent switch in series). If an

open limit is detected the control board will

energize the inducer and the conditioned

air blower. All other system functions will be

inoperable until the limit circuit closes. While

the limit is open, the red LED will pulse at

a rate of 1 blink per unit time.

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 pres-

sure switch does not close after 10 seconds

the fault LED will blink 2 times repetitively

and the inducer will continue to run until the

switch is closed.

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 ther-

mostat must be opened for at least ten

seconds to reset the furnace control after a

lock out. Otherwise, the furnace will attempt

another ignition sequence in 1 hour.

8. The furnace control energizes the circulat-

ing air blower on the heating speed 30

seconds after the gas valve circuit is ener-

gized .

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 adjust-

able). (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 speci-

fied delay (factory set at 120 seconds).

Cooling Mode:

1. On a call for cooling the thermostat closes,

applying 24 VAC to the G and Y terminals

on the furnace control. This closes the

compressor contactor.

2. The furnace control energizes the circulat-

ing 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 con-

tactor.

4. The circulating air blower is de-energized

after a 90 second delay.

34

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 im-

mediately on the heating speed.

3. If the furnace is operated in the continuous

ON position at the thermostat and is then

switched to AUTO, the circulating blower

will operate for a specified delay (factory set

at 120 seconds).

Furnace Fails to Operate

If the furnace does not operate check the follow-

ing:

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, pro-

vided the circuit boards are both UTEC type. If

using UTEC control boards, leave the fuses

installed on each board. The thermostat wires

and the 1/4 inch quick-connect terminals marked

"TWIN" on the furnace controls must be con-

nected together for twinning. (See Figure 29.)

Figure 29. Twinning

W G Y R

Thermostat

A/C

Unit

Twin

Terminal

Twin

Terminal

R

C

Y

G

W

R

C

Y

G

W

35

INSTALLATION/PERFORMANCE CHECK LIST

LOCATION __________________________ CITY ____________________ STATE _____

INSTALLER _________________________ CITY ____________________ STATE _____

UNIT MODEL # _______________________ UNIT SERIAL # ________________________

Minimum Clearances per Table 3? ________

Electrical Connections tight?_____________

Line Voltage Polarity correct? ____________

Supply Voltage: ___________________ Volts

Blower Motor HP: _____________________

FUEL TYPE:

Natural Gas _______ LP/Propane ________

Gas Piping Connections leak-tested? ______

Gas Line Pressure: ____________________

(in. water column, with furnace operating)

Manifold Pressure: ____________________

(in. water column, with furnace operating)

Is there adequate fresh air supply for

combustion and ventilation? _____________

Furnace Input: __________________ (Btuh)

Supply Air Temperature: ____________ (° F)

Return Air Temperature: ____________ (° F)

Temperature Rise: ________________ (° F)

Are Flue Connections tight? _____________

Is there Proper Draft? __________________

Is Vent free from restrictions? ____________

Is the Filter(s) secured in place? __________

Is the Filter(s) clean? __________________

Has the Thermostat been calibrated? ______

Is the 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? ____________________________

St. Louis, MO

7079310 (Replaces 7078950)

Specifications and illustrations subject to change

without notice and without incurring obligations.

Printed in U.S.A. (9/99)

¢707931*¤

707931