Nordyne G6RL 90+ manual

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 C[...]

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Table of Contents Furnace Specifications ......................................................................................................... ... 4-5 Furnace Airflow Data .......................................................................................................... 6 -7 Installation Requirements ....................................[...]

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&q[...]

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[...]

6 Table 1. Furnace Airflow Data CAPACITIES —Furnace Airflow Data E xter nal S tatic P r e ssur e (Inche s W ate r Col umn) 0.1 0.2 0 .3 0.4 0.5 0.6 0.7 0.8 C FM R ise C FM R ise CF M R ise CF M Rise CF M Rise CF M Rise CFM Rise CFM R ise 950 36 9 20 38 890 3 9 8 50 41 80 0 43 75 0 46 690 50 630 55 740 47 7 10 49 680 5 1 6 50 53 60 0 58 55 0 63 49[...]

7 Table 2. Furnace Airflow Data Heat ing Model Input M ot or Motor Numbe r (Btuh) S pee d HP Hi g h* G 6R D080 C- 1 4 80,0 00 Med- H igh 1/2 Med- L ow** Low Hi g h* G 6R D100 C- 1 4 100, 000 Med- H i g h** 1/2 Med- L ow Low Hi g h* G 6R D120 C- 1 4 120, 000 Med- H i g h** 1/2 Med- L ow Low Hi g h* G 6R D120 C- 1 9 120, 000 Med- H igh 3/4 Med- L ow*[...]

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 mater[...]

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 electr[...]

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&[...]

11 ! W ARNING: 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 [...]

12 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[...]

13 T otal 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[...]

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 Throug[...]

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 t[...]

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 V ent T able 4 Straps or Other Suitable Supports at Minimum of 5 ft. Inter v als Upward Pitc h - 1/4" per Foot Outlet Exhaust V ent First Support Placed as Close to Furnace[...]

17 Combustion Air Pipe Exhaust V ent Cabinet 5' Support System on V er tical Rise Belo w Joints Support System with first support as close to furnace as P ossible Upward Pitc h 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 Ri[...]

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 supporte[...]

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 Co[...]

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[...]

21 Combustion Air Intake Elbow Exhaust V ent Exhaust Plumbing V ent Roof Boot (T yp. 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 r[...]

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 V alv e to be 4 to 5 feet Abov e Floor Denotes field- provided and installed components. Shut-Off V alv e with 1/ 8" NPT Pl[...]

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 [...]

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 [...]

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 inco[...]

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. wat[...]

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 tempera[...]

28 Table 12. Gas Flow Rate TIM E FO R ONE R EVOLU TI ON (SEC O N D S ) 1 5 1 0 24 150 750 150 0 26 138 692 138 5 28 129 643 128 6 30 120 600 120 0 32 113 563 112 5 34 106 529 105 9 36 100 500 100 0 38 95 474 9 47 40 90 450 9 00 42 86 429 8 57 44 82 409 8 18 46 78 391 7 83 48 75 375 7 50 50 72 360 7 20 52 69 346 6 92 54 67 333 6 67 56 64 321 6 43 58[...]

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 temp[...]

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[...]

31 MAINTENANCE It is recommended that the furnace be checked yearly. At a minimum, this check should include the following items. ! W ARNING: To avoid electric shock, personal in- jury, or death, disconnect the electric power before performing any mainte- nance. ! W ARNING: Holes in the vent pipe or heat ex- changer can cause products of com- busti[...]

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 I[...]

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 pr[...]

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 [...]

35 INSTALLATION/PERFORMANCE CHECK LIST LOCATION __________________________ CITY ____________________ STATE _____ INSTALLER _________________________ CITY ____________________ STATE _____ UNIT MODEL # _______________________ UNIT SERIAL # ________________________ Minimum Clearances per Table 3? ________ Electrical Connections tight? _____________ Li[...]

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[...]