Nordyne TC Upflow/Horizontal Installation Instructions Manual Download Page 2

Page: 2 / 52

SAFETY INFORMATION .............................................4

REQUIREMENTS AND CODES ..................................4

GENERAL INSTRUCTIONS ........................................5

Combustion Air Quality .............................................5

Operation of Furnace During Construction ...............5

Heating

Load

............................................................6

Installation in a Garage ............................................6

Clearances to Combustible Materials .......................6

COMBUSTION AIR REQUIREMENTS ........................8

General

Information

.................................................8

Direct

Vent

Furnaces

................................................8

Conventional Furnaces - Confi ned Spaces ..............8

Air From Inside .....................................................8

Outdoor Air from a Crawl Space or

Vented

Attic...........................................................8

Outdoor Air Using Vertical Ducts ..........................9

Outdoor Air Using Horizontal Ducts ......................9

Air Directly Through an Exterior Wall .................. 10

Alternate Method of Providing Air from

Outside

............................................................... 10

Conventional Furnaces - Unconfi ned Spaces ........ 10

VENTING REQUIREMENTS ...................................... 10

Vent Pipe Material .................................................. 11

Vent Pipe Length and Diameter ............................. 11

Vent Pipe Installation .............................................. 12

Outdoor Terminations - Horizontal Venting ............. 12

Outdoor Terminations - Vertical Venting ................. 13

Vent Freezing Protection ........................................ 13

Condensate

Disposal

............................................. 14

Existing

Installations

............................................... 14

CIRCULATING AIR REQUIREMENTS ...................... 14

Plenums and Air Ducts ........................................... 14

Supply Air Connections .......................................... 15

Upfl

ow/Horizontal

Furnaces

............................... 15

Downfl

Furnaces

............................................ 15

Return Air Connections .......................................... 15

Upfl

ow/Horizontal

Furnaces

..............................15

Side Return Installations ..............................15

Bottom Return Installations ..........................15

Downfl ow Furnaces ............................................15

Acoustical

Treatments

............................................15

FURNACE INSTALLATION .......................................16

General

Requirements

...........................................16

Direct Vent (2 - Pipe) Applications ..........................16

Upfl

Installation

..................................................16

Side Return Air Inlet ...........................................16

Bottom Return Air Inlet .......................................16

Downfl

Installation

..............................................16

Installation on a Concrete Slab ..........................16

Horizontal

Installation

.............................................17

Bottom Panel Removal ...........................................17

Alternate Bottom Panel Removal .......................18

Vent and Inducer Assembly Options ......................18

Inducer Assembly Rotation ....................................18

Accessories

............................................................19

Finish

Flange

......................................................19

Rubber

Grommets

..............................................19

PVC Tee, Reducer, & Hose Barb ........................19

Condensate Drain Lines .....................................20

GAS SUPPLY AND PIPING .......................................20

Leak

Check

...........................................................20

High-Altitude

Application

........................................22

Conversion to LP/Propane .....................................22

ELECTRICAL WIRING ...............................................23

Fixed Speed Blower Applications ..........................23

Variable Speed Blower Applications ......................23

Wiring

Confi

gurations

............................................24

Single Stage AC and Single Stage Heat
Thermostat

.........................................................24

Single Stage AC and Two - Stage Heat

Thermostat

.........................................................24

Two - Stage AC and Two - Stage Heat

Thermostat

.........................................................24

TABLE OF CONTENTS

Summary of Contents for TC Upflow/Horizontal

Page 1: ...ad all instructions carefully before starting the installation Return these instructions to the customer s package for future reference PROPOSITION 65 WARNING This product contains chemicals known to...

Page 2: ...and Air Ducts 14 Supply Air Connections 15 Upflow Horizontal Furnaces 15 Downflow Furnaces 15 Return Air Connections 15 Upflow Horizontal Furnaces 15 Side Return Installations 15 Bottom Return Instal...

Page 3: ...37 Gas Information 38 Table 11 Gas Flow Rates 38 Table 12 Gas Pipe Capacities 38 Table 13 High Altitude Deration Chart for Propane Gas 39 Table 14 Natural Gas Heating Values 39 Table 15 High Altitude...

Page 4: ...tor and alarm shall be placed on each floor level where there are bedrooms The detector shall comply with NFPA 720 2005 Edition and be mounted in the living area outside the bedroom s SAFETY INFORMATI...

Page 5: ...NFPA 54 1999 ANSI Z223 1 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B CANADA CAN CGA B149 1 and 2 M00 National Standard of Canada NSCNGPIC GENERAL INSTRUC...

Page 6: ...ds available from Air Conditioning Contractors of America Manual J American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering methods Excessive oversizing o...

Page 7: ...ctions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously 7 Test for spillage from draft hood equipped appliances at the draft hood relief...

Page 8: ...d If the furnace is operated without adequate air for combustion the flame roll out switch will open turning off the gas supply to the burners This safety device is a manually reset switch DO NOT inst...

Page 9: ...freely exchange with the outdoors Figure 2 Outdoor Air Using Vertical Ducts If combustion air is taken from outdoors through vertical ducts the openings and ducts must have a minimum free area of one...

Page 10: ...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 a...

Page 11: ...hly sealed They also produce liquid condensate which is slightly acidic and can cause severe corrosion of ordinary venting materials Furnace operation can be adversely affected by restrictive vent and...

Page 12: ...ressure zone This means both pipes must exit the building through the same portion of exterior wall or roof as shown in Figures 6 9 pages 12 13 and Figure 36 page 47 Pipingmustbemechanicallysupporteds...

Page 13: ...kit When the vent pipe must exit an exterior wall close to the grade or expected snow level where it is not possible to obtain clearances shown in Figure 6 a riser may be provided as shown in Figure...

Page 14: ...DO NOT reuse this venting system This recall does not apply to other plastic vent pipes such as white PVC or CPVC Check for details on the CPSC website or call their toll free number 800 758 3688 CIR...

Page 15: ...left or right return air NOTE Do not use the back of the furnace for return air Side Return Installations To attach the return air duct to the left or right side of the furnace punchoutthefourknockout...

Page 16: ...rances needed to move the furnace to its installation point hallways doorways stairs etc The furnace must be installed so that all electrical components are protected from water The furnace must be in...

Page 17: ...together with nuts Figure 12 TC Horizontal installation on a Platform Exhaust Pipe Vented to Outside Combustible Platform Coil Plenum Combustion Air Condensate Drain Lines Must Be Trapped With J Trap...

Page 18: ...et to the blower deck 5 4 Remove all screws 6 securing the furnace cabinet to the bottom panel 2 5 Remove the screw 7 securing the bottom corner of the furnace cabinet to the front brace 3 6 Carefully...

Page 19: ...sealants are required The 3 4 rubber grommet is used if venting out the left side of the cabinet and the drain tube is routed through the blower deck Remove the plastic plug from the hole and install...

Page 20: ...outed out the left or right side of the furnace but must maintain a downward slope to ensure proper condensate drainage The J trap may need to be rotated to the side that matches your setup in Figures...

Page 21: ...ire Shut Off Valve to be 4 to 5 feet above floor NOTE B Inducer assembly omitted for clarity of pipe installation Figure 20 Typical Gas Connections 6 4 2 UPFLOW MODELS DOWNFLOW MODELS 1 See Note B See...

Page 22: ...the residence s gas meter as the local value For added flexibility two tables have been provided for natural gas installations with high or low heating values at sea level Tables 15 and 16 page 40 co...

Page 23: ...ction applies only to furnaces with model numbers suffixed with two numbers followed by a letter such as 35C or 45D If your model has suffix VA VB VC or VD please consult the Variable Speed Blower App...

Page 24: ...mostat Y and Y1 to the furnace control board s Y Y2 and Y1 terminal s Field supplied wires should also connect the Y Y2 and Y1 signals to the outdoor unit s Y and Y1 terminals Connect terminal C to th...

Page 25: ...CFM for 10 minutes after a call for cooling IMPORTANT NOTE An electrical disconnect must be installed readily accessible from and located within sight of the furnace See Figure 25 page 26 or the wiri...

Page 26: ...or Bare Ground Black White Black White Black White Field Line Voltage Wiring Factory Line Voltage Wiring Ground Ground Junction Box may be int or ext to the furnace These connections can be made in th...

Page 27: ...ee page 28 5 After 5 minutes of operation set the thermostat below room temperature and verify steps 11 12 of the Operating Sequence Verifying and Adjusting Input Rate IMPORTANT NOTE The input rate mu...

Page 28: ...Check the blower door and verify that it is securely mounted in place and that there is power to the furnace OPERATING SEQUENCE The operating sequences for the heating cooling and fan modes are descri...

Page 29: ...ator coil clean and free of debris If applicable Are all the LED s on the furnace and motor control boards constantly ON If not refer to Tables 6 7 to determine fault condition IMPORTANT NOTE The furn...

Page 30: ...res and shortened service life It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual in...

Page 31: ...they were removed 12 Follow the lighting instructions found on the furnace door to return the furnace to operation Verify proper operation after servicing Heat Exchanger and Burner Maintenance The fu...

Page 32: ...registres des foyers 5 Mettre en service les s cheuses et tout autre appareil qui n est pas raccord la syst me d vacuation Faire fonctionner r gime maximal tout ventilateur d vacuation tel que les ho...

Page 33: ...stallateur qualifi un organisme de service ou le fournisseur de gazstaller service agency or the gas supplier Ne pas entreposer ni utiliser de l essence ni d autres vapeurs ou liquides inflammables da...

Page 34: ...B Dim C B Cabinet 17 15 16 C Cabinet 21 19 19 D Cabinet 24 22 23 NOTES Dimensions shown in inches 19 B TOP VIEW 3 7 1 2 FLUE INLET AIR FLANGES 34 1 2 28 16 1 2 10 1 4 22 1 4 24 1 8 2 3 4 22 1 2 7 8 H...

Page 35: ...0 1 0 1 525 58 1 450 61 1 375 64 1 300 68 1 225 72 1 150 76 1 075 82 1 000 88 1 0 1 0 1 620 54 1 540 57 1 465 60 1 390 63 1 315 67 1 240 71 1 165 76 1 090 81 0 1 1 0 1 695 52 1 620 54 1 545 57 1 465 6...

Page 36: ...52 1 345 65 1 0 0 1 460 48 1 460 60 1 0 1 1 575 45 1 575 56 1 1 0 1 690 42 1 690 52 1 1 1 1 805 39 1 805 49 D CABINET Switch Settings For Heat 0 OFF 1 ON TC TL 120D D Input BTU 120 000 1 2 3 4 CFM Te...

Page 37: ...ON CFM Nominal A C and HP Capacity HEAT COOL HEAT COOL 1 4 5 6 7 8 LOW HIGH 1 4 5 6 7 8 LOW HIGH 0 0 0 0 705 1 025 2 5 TON 0 0 0 0 965 1 400 3 5 TON 0 0 0 1 750 1 090 3 TON 0 0 0 1 995 1 440 4 TON 0 0...

Page 38: ...176 353 48 75 375 750 104 35 173 346 50 72 360 720 106 34 170 340 52 69 346 692 108 33 167 333 54 67 333 667 110 33 164 327 56 64 321 643 112 32 161 321 58 62 310 621 114 32 158 316 60 60 300 600 116...

Page 39: ...Heating Values Table 13 High Altitude Deration Chart for Propane Gas PROPANE GAS ALTITUDE ABOVE SEA LEVEL INPUT BTU and STAGE 60 000 80 000 100 000 120 000 1st 2nd 1st 2nd 1st 2nd 1st 2nd 0 to 1 999 F...

Page 40: ...PRESSURE 9 000 to 9 999 FT 48 48 48 48 ORIFICE SIZE 1 7 2 8 1 7 2 8 1 7 2 8 1 7 2 8 MANIFOLD PRESSURE Table 16 High Altitude Deration Chart for Natural Gas Low heating Value NATURAL GAS LOW HEATING V...

Page 41: ..._IN H_OUT L2 OUT L2 IN L1 IN L1 OUT Y1_OUT Y Y2_OUT W_OUT C EXPANSION PORT R RED GREEN NOT FOR FIELD USE CONNECTION TO FURNACE CONTROL BOARD CONNECTION TO IQ THERMOSTAT IF APPLICABLE MOTOR WIRING HARN...

Page 42: ...REEN BROWN BROWN YELLOW VIOLET VIOLET VIOLET ORANGE ORANGE ORANGE VENT LIMIT ON SELECT MODELS BLACK 120V WHITE NEUTRAL GROUND 710916 CONDENSATE ON SELECT MODELS Refer to the Installation Instructions...

Page 43: ...END 0409 LOW VOLTAGE HIGH VOLTAGE BLUE BLUE BLUE BLUE BLACK BLACK 120V WHITE BLACK BLACK BLACK BLACK BLACK BLACK WHITE WHITE NEUTRAL BLACK WHITE WHITE RED RED GREEN GROUND GREEN BROWN BROWN YELLOW VIO...

Page 44: ...AL GROUND CONDENSATE ON SELECT MODELS BLACK VIOLET For 80 and 90 2 Stage Variable Speed Upflow Furnaces WIRING DIAGRAM 7109180 FIELD WIRING LEGEND LOW VOLTAGE HIGH VOLTAGE Refer to the Installation In...

Page 45: ...t Flash Off Low Flame Sensor Signal Flame Present Diagnostic Description FAULT CONDITIONS Diagnostic Description Yellow LED Continuous Flash On Alternating Flash Motor Fault On Off 0409 FLAME ROLL OUT...

Page 46: ...lator vent outlet 3 feet 1 83m J Clearance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 6 inches 15cm for appliances 10 000 Btuh 3kW 6 inches 15cm...

Page 47: ...Optional 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 Wall Normal Snow...

Page 48: ...ion 1 Header Box Drain Inline Drain Tubing is routed thru the blower deck and side of cabinet X See View B This drain not needed if X is less than 6 Drain Line Attached to 3 4 x 1 2 Hose Barb PVC TEE...

Page 49: ...ption 7 Option 8 All drain lines must be trapped with J Trap or field supplied loop Inline Drain Header Box Drain Header Box Drain VIEW C VIEW D See View C See View C See View D See View D See View D...

Page 50: ...side the cabinet NOTES X Inline Drain This drain not needed if X is less than 6 X Exhaust Vent Exhaust Vent Exhaust Vent Exhaust Vent Inlet Air Inlet Air Option 12 See Table 2 for 2 PVC Pipe Length Fi...

Page 51: ...Transformer Figure 40 Upflow Horizontal Gas Furnace Components 9 2 10 3 6 5 17 11 12 14 8 16 4 13 AIR FLOW 7 18 1 15 17 ITEM COMPONENT NAME 1 Blower Assembly 2 Blower Door Switch behind blower panel 3...

Page 52: ...or combustion and ventilation YES NO Installation Altitude ____________________ FT Deration Percentage ___________________ Furnace Input _______________________ Btuh Supply Air Temperature ___________...

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