Nordyne RC 92+ manual

Installation Instructions These instructions are primarily intended to assist qualifi ed individuals experienced in the proper installation of this appliance. Some local codes require licensed installa- tion/service personnel f or this type of equip- ment. Read all instructions carefull y before starting the installation. DO NO T DESTR O Y . PLEAS[...]

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3 T able of Contents Furnace Specifi cations ............................................................................................................ 4-5 Fur nace Airfl ow Data .......................................................................................................... 6-7 Safety Inf ormation ....................................[...]

4 FURNA CE SPECIFICA TIONS 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) Side Return Bottom Return Opening Condensate Drain Outlets A ‡ B ‡ Combustion Air Vent 3" (See Fig. 15 for sizes) 1 1[...]

5 7/8" Dia. Electric Connection 1 1/2" x 3 1/2" Dia. Opening for Gas Connection 27 7/8" 24 1/2" 22 1/2" 3/4" C 3/4" 3/4" 43" Exhaust Vent 2" Dia. 1 1/2" x 2 1/2" Knockout For Gas Connection A B D 21 7/8" 15 1/2" 21 1/2" 21 7/8" 3/4" Bottom Supply Air Opening 2[...]

6 T able 1. Furnace Airfl ow Data CAP A CITIES —Furnace Airfl ow Data NO TES: 1. Airfl ow rates of 1800 CFM or more require tw o retur n air connections. Data is f or operation with fi lter(s). 2. T emperature rises in the table are appro ximate. Actual temperature rises may v ar y . 3. T emperature rises and airfl ows f or external static p[...]

7 T able 2. Furnace Airfl ow Data CAP A CITIES —Furnace Airfl ow Data continued Model Heating External Static Pressure (Inches Water Column) Number Input Motor Motor 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 *RL- (Btuh) Speed HP CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise High* 1280 - 1210 - 1180 - 1140 - 1090 - 1070 - 1030 - [...]

8 SAFETY INFORMA TION 1. Use only with type of gas appro ved f or this fur nace. Ref er to the fur nace rating plate. 2. Install this fur nace only in a location and position as specifi ed on T able 4 of these instructions. 3. Provide adequate combustion and v entila- tion air to the fur nace space as specifi ed on P ages 13 through 16. 4. Pro vi[...]

9 T able 3. Furnace Dimensions and Shipping Weights T able 4. Minimum Clearances to Combustib le Materials CLEARANCES T O COMBUSTIBLE MA TERIALS This fur nace is Designed Cer tifi ed by CSA International for the minimum clear ances to combus- tible material listed in T able 4. See the fur nace name plate, located inside the furnace cabinet, for sp[...]

10 (b) F or direct-vent appliances , mechanical- v ent heating appliances or domestic hot water equipment where the bottom of the v ent ter minal and the air intak e is installed abov e four f eet abov e grade the f ollowing requirements must be satisfi ed: 1. If there is not one already present, on each fl oor lev el where there are bedroom(s), [...]

11 Figure 3. 90+ Upfl ow Con verted for Horizontal Installation (Horizontal Right) 5/8" Vinyl Cap 1/4" Vinyl Cap Drain T rap 1/2" Vinyl Cap Soft T ubing PVC T ee Soft T ubing Looped to Provide a Drain T rap 3" to 2" Reducer (Optional) PVC Reducer Bushing Pressure Switch Grey T ubing Soft T ubing 1/4" Vinyl Cap Grey T [...]

12 NO TE: T o av oid condensate freezing in the drain trap assemb ly and tubing, insulate around the drain trap assemb ly and all tubing located in unconditioned space. NO TE: When con verting the fur nace, to horizontal left, ensure that the drainage por t on the in-line drain assemb ly is downward as shown in Figure 4. If the in-line drain assemb[...]

13 Return Air The retur n air ductwork ma y be connected to any or all of the f ollowing: left side retur n, right side retur n, or bottom return. T ables 1 and 2 sho w the airfl ow data f or each fur nace model. Where maximum airfl o w is 1800 CFM or more two openings must be used. VENTING AND COMBUSTION AIR REQUIREMENTS NORD YNE condensing fur [...]

14 T otal Input Rating (Btuh) 40,000 60,000 80,000 100,000 120,000 140,000 160,000 Round Duct Diameter 12" 12" 12" 12" 13" 14" 15" Minimum Free Area (Each Opening) 100 sq. in. 100 sq. in. 100 sq. in. 100 sq. in. 120 sq. in. 140 sq. in. 160 sq. in. Furnace 12" Max. 12" Max. Water Heater Vent or Chimney Ea[...]

15 Each opening to outside must be at least 1 sq. in. per 4000 Btuh of total input rating. 12" Max T otal 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&qu[...]

16 Comb ustion Air Quality The recommended source of combustion air is to use the outdoor air supply . Howe v er , the use of indoor air in most applications is acceptable e xcept as follows: 1. If the fur nace is installed in a confi ned space it is recommended that the necessar y combustion air come from the outdoors b y wa y of attic, cra wl sp[...]

17 The size and other criteria for these openings must be per the f ollowing sections. Combustion air openings m ust not be restr icted in any manner . Fur naces installed in a confi ned space which supply circulating air to areas outside of the space must dra w retur n air from outside the space and must ha ve return air ducts tightly sealed to t[...]

18 ! W ARNING: CARBON MONO XIDE POISONING HAZARD 1. Seal any un used openings in the vent- ing system 2. Inspect the venting system f or proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1 or the CAN/CGA B149 Instal- lation Codes and these instructions. Determine that there is no bloc kage or restriction, leakag[...]

19 Figure 16. Horizontal V enting * These neoprene couplings are fi eld-supplied and can be used if the installation requires breakable connections in the pipin g. Note that a maximum of two couplings per pipe are allo wed. Upfl ow Furnaces Downfl ow Furnaces **NO TES 1. Subtract 2.5 ft. for each additional 2” long radius elbow , 5 ft. for eac[...]

20 equiv alent vent length is less than the maxim um allow able vent length. Returning to our example , we consult T able 5 and determine that for an 80,000 Btu/h fur nace the maximum v ent length f or 2” diameter piping is 60 f eet or f or 3” diameter piping is 150 f eet. Note that the maximum vent length giv en in T ab le 5 includes one long [...]

21 Combustion Air Pipe Exhaust V ent Cabinet 5' Support System on V er tical Rise Below Joints Support System with first support as close to furnace as P ossible Upward Pitch 1/4" per Foot Furnace Front Straight Neoprene Rubber Couplings with 2 Hose Clamps* Combustion Air Pipe Exhaust V ent Cabinet 5' Support System on V er tical Ris[...]

22 ! W ARNING: Ensure that the combustion air vent and the exhaust vent are confi gured as shown in Figure 19 and 20. Improper vent termination can cause recir- culation of the fl ue gases. This may result in furnace vibration. In severe cases, the furnace will cyc le due to the intermittent contact between the fl ame and the fl ame sensor . If[...]

23 VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED 1 In accordance with the current CSA B149.1 Natur al Gas and Propane Installation Code 2 In accordance with the current ANSI Z223.1 / NFP A 54 National Fuel Gas Code † A vent shall not terminate directly above a sidewalk or pa ved drivew ay that is located between two single f[...]

24 VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED 1 In accordance with the current CSA B149.1 Natur al Gas and Propane Installation Code 2 In accordance with the current ANSI Z223.1 / NFP A 54 National Fuel Gas Code † A vent shall not terminate directly above a sidewalk or pa ved drivew ay that is located between two single f[...]

25 Outside Wa ll Support V ent Configuration to Pro vide 12" Minimum height above Snow Level. 1/2" Armaflex Insulation or Equivalent (If Required) 12" Above Normally Expected Snow Level 12" Min. 19" Max. 4. Insure the combustion air inlet pipe (f or a 2 pipe installation) has a 90 degree termination elbow as sho wn in Figur[...]

26 V ent and combustion air piping ma y be installed in an e xisting chimney which is not in use pro- vided that: a. Both the e xhaust vent and air intak e r un the length of the chimney . b . The top of the chimne y is sealed and weatherproofed. c. The ter mination clearances shown in Figure 23 are maintained. d. No other gas fi red or fuel-burni[...]

27 Concentric V ent T er mination Concentric vent termination kits are approv ed f or use with these fur naces. The kit par t numbers are 904176 (3 inch) and 904177 (2 inch). For proper installation of the concentric vent termina- tion, f ollow the installation instructions provided with that kit. Side W all V ent Kit This side wall v ent kit is ap[...]

28 NO TE: Industr y research studies indicate that when condensate is routed to an activ e drain, household detergents, etc., b uffer its acidity . If the drain is not activ ely used or if codes require, obtain a neutraliz er kit (usually contains lime- stone). Proper drains and connections to the condensate tubing are required as NORD YNE cannot b[...]

29 T able 7. Capacity of Black Iron Gas Pipe (cu. ft. per hour) for Natural Gas (specifi c gravity = .60) The cubic f eet per hour listed in the table abov e must be greater than the cubic f eet per hour of gas fl ow required by the furnace. T o determine the cubic feet per hour of gas fl ow required b y the fur nace, divide the input r ate of t[...]

30 Con version Conv ersion of this fur nace to use LP/propane gas must be made b y qualifi ed ser vice person- nel, using only appro ved par ts. High Altitude Application High altitude application with this fur nace can be fi eld performed by a simple adjustment of manif old pressure, and if necessar y changing the orifi ces. The changes require[...]

31 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 Junction Box (may be internal or external to the furnace). These conn[...]

32 T o check the heat anticipator setting either : 1. Add the current draw of the system compo- nents; or 2. Measure the current fl ow on the thermostat R-W circuit after the circulating blo wer motor has star ted. Set the heat anticipator according to the ther- mostat manuf acturer’ s instr uctions f or heat anticipator settings. ST AR T -UP AN[...]

33 6. Adjustments to the fi r ing rate can be made by adjusting the gas manif old pressure. See the High Altitude Application section f or additional information of fi r ing rate at ele vations abov e 2000 ft. The manif old pressure must be set to the ap- propriate value f or your installation. Refer to either T able 8 f or natural gas or T able [...]

34 T able 13. Gas Flow Rate control board. Reconnect the desired blow er tap to the piggyback quic k connect. The blo wer control is designed to star t the circulating air blo wer 30 seconds after the gas v alve is opened. The blow er control is f actor y wired to tur n the b low er motor off 120 seconds after the gas v alve is closed. This timing [...]

35 through the heat e xchanger . It also senses a bloc ked condensate drain condition. V ent Pressure Switch – The vent pressure s witch reacts to blockage in the v ent or combus- tion air piping. Supply Air Limit Switc h – The supply air limit s witch prev ents the air temperature leaving the fur nace from e xceeding the maximum outlet air tem[...]

36 IGNITOR INDUCER GAS VALVE SUPPLY AIR LIMIT SWITCH (ALL MODELS) VENT SAFETY SWITCH (SELECT MODELS ONLY) 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[...]

37 Figure 30. Location of Major Components 1 Igniter (Not Shown) 2 Flame Sensor (Not Shown) 3 Gas V alve 4 Flame Roll-out Switch(s) 5 Pressure Switch 7 Control Board 8 Blower Door Switch 9 V ent Safety Switch 10 Low V oltage T ransformer 11 Supply Air Limit Switch 12 Circulating Air Blower Assembly- 13 Induced Draft Blower 14 Condensate Drain T ube[...]

38 to remov e any dir t and lint that ma y hav e ac- cumulated in the compar tment or on the blo wer and motor . Dir t and lint can create e xcessive loads on the motor resulting in higher than nor mal operating temper atures and shor tened ser vice lif e. Heat Exchanger and Burner Maintenance The fur nace should operate f or many y ears without e [...]

39 A second trial for ignition (step 6) begins if no fl ame is sensed. On the fi fth try for ignition, the fur nace control is loc ked out and the red LED will blink 4 times repetitiv ely . The ther mostat must be opened f or at least ten seconds to reset the fur nace control after a lock out. Otherwise, the furnace will attempt another ignition [...]

INST ALLA TION/PERFORMANCE CHECK LIST LOCA TION ____________________________ CITY _____________________ ST A TE _______ INST ALLER ___________________________ CITY _____________________ ST A TE _______ UNIT MODEL # ________________________ UNIT SERIAL # __________________________ Minimum Clearances per T able 3? _________ Electrical Connections tig[...]