Nordyne 072C-16, 096C-12, 096C-16, 096C-20, 120C-16 Installation Instructions Manual
...
Residential Gas Furnaces
Installation Instructions
80+ High Efficiency Upflow/Horizontal and Downflow
with Variable Speed Blower
*RA 80+ Upflow
!
WARNING:
Improper installation,
adjustment, alteration,
service, or maintenance can
cause injury or property
damage. Refer to this
manual. For assistance or
additional information
consult a qualified installer,
service agency, or the gas
supplier.
DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this
appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all
instructions carefully before starting the installation.
FOR YOUR SAFETY
Do not store or use gasoline
or other flammable vapors
and liquids in the vicinity of
this or any other appliance.
*RK 80+ Downflow
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
Unit Dimensions and Shipping Weights ....................................................................................................... 4-5
Capacities-Furnace Airflow Data ..................................................................................................................... 6
Safety Information ............................................................................................................................................ 7
Installation Requirements ..................................................................................................................................................... 7
Requirements and Codes ................................................................................................................................ 7
Location............................................................................................................................................................ 7
Clearances to Combustibles ........................................................................................................................... 7
Venting and Combustion Air Requirements ................................................................................................................... 8-13
General ............................................................................................................................................................ 8
Installation in an Unconfined Space ................................................................................................................ 8
Installation in a Confined Space ...................................................................................................................... 8
Horizontal Furnace Installation ........................................................................................................... 1 0
Air From Inside .................................................................................................................................... 11
Outdoor Air Using Vertical Ducts ........................................................................................................ 12
Air Directly Through an Exterior Wall ................................................................................................. 1 2
Outdoor Air Using A Crawl Space and Ventilated Attic ...................................................................... 12
Outdoor Air Through Horizontal Ducts ............................................................................................... 12
Venting Requirements .................................................................................................................................................... 13-19
General .......................................................................................................................................................... 13
Category I - Common Venting ....................................................................................................................... 13
Category III - Horizontal Venting .................................................................................................................... 15
Horizontal Venting for Upflow Models ................................................................................................ 15
Horizontal Power Venting ................................................................................................................... 17
Location of Outdoor Terminations ................................................................................................................. 17
Horizontal Installation ......................................................................................................................... 17
Flexible Vent Systems .................................................................................................................................... 1 9
Circulating Air Supply ..................................................................................................................................................... 19-20
General .......................................................................................................................................................... 19
Return Air ....................................................................................................................................................... 19
Gas Supply and Piping .................................................................................................................................................... 20-22
General .......................................................................................................................................................... 20
Leak Check .................................................................................................................................................... 21
Conversion ..................................................................................................................................................... 2 1
High-Altitude Application ............................................................................................................................... 21
Natural Gas High Altitude Conversion .......................................................................................................... 22
LP/Propane Gas Sea Level and High Altitude Conversion .......................................................................... 22
Electrical Wiring .............................................................................................................................................................. 22-24
General .......................................................................................................................................................... 22
Line Voltage Wiring ........................................................................................................................................ 23
Low Voltage Wiring ........................................................................................................................................ 24
Start-up & Adjustments ....................................................................................................................................................... 24
General .......................................................................................................................................................... 24
Start-Up Procedures ...................................................................................................................................... 24
Verifying and Adjusting Firing Rate ............................................................................................................... 24
Configuring the Blower .................................................................................................................................. 25
Selecting Airflow ............................................................................................................................................ 25
Verifying and Adjusting Temperature Rise .................................................................................................... 26
Verifying Burner Operation ............................................................................................................................ 27
Verifying Operation of Supply Air Limit Switch .............................................................................................. 27
Description of Components ................................................................................................................................................ 28
Wiring Diagram ..................................................................................................................................................................... 30
Maintenance .................................................................................................................................................................... 29-31
Vent System ................................................................................................................................................... 29
Air Filter(s) ...................................................................................................................................................... 29
Lubrication ..................................................................................................................................................... 29
Blower Compartment ..................................................................................................................................... 29
Heat Exchanger and Burner Maintenance .................................................................................................... 29
Cleaning of Flue Passages ............................................................................................................................ 31
Installation/Performance Checklist .................................................................................................................... Back Cover
FURNACE SPECIFICATIONS - Upflow/Horizontal Models
3/4
7/8
3/
4
23
3/4
3/
4
19
1/
8
25
1/
1/
2
2
1
X 3
Cut-out for
Gas Connection
7/
8
43
15
1/
4
1
Cut-out for
Electric Connection
25 1/4
Return
Air Opening
(Side)
23
5
27
/8
FLUE
OUTLET
3/4 3/4
33
1/
2
20
1 1/4
A
B
C
Return Air Opening
(Bottom)
30
1 1/4D
Unit Shown in Upflow
Position Rotate 90˚
Clockwise or Counter
Clockwise for Horizontal
Application
1/
2
1
X 3
Gas Connection
7/8 Cut-out for Electric
Connection
1/
4
1/
4
25
1/
2
Cut-out for
5/
8
25
23
Figure 1a. Upflow Unit Dimensions
FURNACE DIMENSIONS AND
SHIPPING WEIGHTS
Furnace Dimensions Shipping
Model Input A B C Flue Outlet Weight D
*RA (Btuh) (in.) (in.) (in.) (in.) (lbs) (IN.)
072C-16 72,000 19 3/4 18 1/4 3 3/4 4 152 17 1/4
096C-12 96,000 19 3/4 18 1/4 3 3/4 4 163 17 1/4
096C-16 96,000 19 3/4 18 1/4 3 3/4 4 163 17 1/4
096C-20 96,000 22 1/2 21 3 3/4 4 174 20
120C-16 120,000 19 3/4 18 1/4 3 3/4 4 174 17 1/4
120C-20 120,000 22 1/2 21 3 3/4 4 182 20
144C-20 144,000 22 1/2 21 4 1/4 5 194 20
Table 1a. Upflow Furnace Dimensions and Shipping Weights
4
FURNACE SPECIFICATIONS - Downflow Models
3/4"
3/4"
23 5/8"
19 3/4"
4" Dia. Vent
3/4"
A
B
C
3/4"
43"
3/4"
24 1/2"
Cut-out for Electric
Connection
Both sides
25"
Cut-out for Gas Connection
1-1/2 x 3-1/2 (both sides)
19 3/4"
(Bottom Opening)
27 7/8"
C
L
27 1/8"
15 1/2"
C
L
B
(Bottom Opening)
10 1/4"
Figure 1B. Downflow Unit Dimensions
DOWNFLOW FURNACE MODELS
25"
Cut - out for
Gas Connection
FURNACE DIMENSIONS AND
Model Furnace Shipping
Number Input A B C Weights
*RK (Btuh) inches inches inches (lbs)
060C-12 60,000 14 1/4 12 3/4 5 1/2 134
072C-12 72,000 14 1/4 12 3/4 5 1/2 135
072C-16 72,000 19 3/4 18 1/4 11 147
096C-12 96,000 19 3/4 18 1/4 11 154
096C-16 96,000 19 3/4 18 1/4 11 156
120C-20 120,000 19 3/4 18 1/4 11 182
Table 1B. Downflow Furnace Dimensions and Shipping Weights
SHIPPING WEIGHTS
Dime nsions
5
CAPACITIES —Furnace Airflow Data
w
CFM SWITCH NUMBER
LOW HIGH 1 2 3 4
500 720 0 0 0 1
550 800 0 0 0 0
610 880 0 0 1 0
650 945 1 0 0 1
72010501000
80011551010
90013050101
1000 1450 0 1 0 0
1060 1530 1 1 0 1
1100 1595 0 1 1 0
1170 1700 1 1 0 0
1290 1870 1 1 1 0
NOTE: 0 = OFF 1 = ON
Table 1. Cooling/Heat Pump Airflow Settings
720 900 1056 1200 1350 1500 1656 1800
7
6
Switches
5
1
0
0
0
0
0
567
Nominal Air-Flo
1
0
1
0
0
1
1
1
0
Nominal A/C and HP
Capacity
2.5 TON
3 TON
3.5 TON
4 TON
5 TON
0
1
0
1
1
1
2 TON
0
1
1
72,000 59
51
90,000 63
96,000 67 59
108,000 67
120,000 66
126,000 69 62
80+% 92+%
144,000 71
80,000 67
100,000 73 65
120,000 71
Temperature Rise °F (Recommended settings are
NOTE: 0 = OFF 1 = ON
Notes:
1. Recommended temperature rises are highlighted in bold.
2. Airflow rates of 1800 CFM or more require two return air connections. Data is for operation with filter(s).
3. Temperature rises in the table are approximate. Actual temperature rises may vary.
4. Temperature rises that are shaded grey are for reference only. These conditions are not recommended.
5. For single stage cooling, the indoor blower will operate at the CFM listed in the high column.
Table 2. Heating Airflow Settings
44
55
59
49 44
53
59
47
53 48
59
52 47
59
54 49
56
64
51
59
53 49
64
Bold
59
)
6
SAFETY INFORMATION
1. Use only with type of gas approved for this furnace.
Refer to the furnace rating plate.
2. Install this furnace only in a location and position as
specified on Table 3 of these instructions.
3. Provide adequate combustion and ventilation air to the
furnace space as specified on Pages 11 through 14.
4. Combustion products must be discharged outdoors.
Connect this furnace to an approved vent system only,
as specified on Pages 13 through 14.
5. Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the detection of leaks to check all connections,
as specified on Page 17 of these instructions.
6. Always install furnace to operate within the furnace’s
intended temperature-rise range with a duct system
which has an external static pressure within the allowable range, as specified on Table 2 of these instructions. See furnace rating plate.
7. When a furnace is installed so that supply ducts carry
air circulated by the furnace to areas outside the space
containing the furnace, the return air shall also be
handled by duct(s) sealed to the furnace casing and
terminating outside the space containing the furnace.
8. A gas-fired furnace for installation in a residential
garage must be installed as specified on Page 6 of
these instructions.
9. The furnace is not to be used for temporary heating of
buildings or structures under construction.
!
WARNING:
This furnace is not approved for installation in
mobile homes. Installation in a mobile home
could cause fire, property damage, and/or
personal injury.
Location
Upflow gas furnaces are shipped ready for installation in the
upflow or horizontal right or left positions. The furnace must
be installed on a level surface, located as close to the vent
(or chimney) and as close to the center of the air distribution
system as possible. See Table 1 for overall dimensions
to determine the required clearances in hallways, doorways,
stairs, etc. to allow the furnace to be moved to the
installation point. The furnace must be installed so that all
electrical components are protected from water. The furnace
must be installed upstream from a refrigeration system.
This furnace is not to be used for temporary heating of
buildings or structures under construction.
Clearances to Combustibles
This furnace is Design Certified by CSA International for
the minimum clearances to combustible material listed in
Table 3. Refer to the furnace rating plate, located inside of
the furnace cabinet, for the specific model number and
clearance information.
INSTALLATION REQUIREMENTS
Requirements and Codes
This furnace must be installed in accordance with these
instructions, all applicable local building codes, current
revision of the National Fuel Gas Code (ANSI-Z223.1), and
in Canada with the CAN/CGA - B149 installation code. The
current revision of the National Fuel Gas Code is available
from:
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018
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
Access for positioning and servicing the unit must be
considered when locating unit. 24 inches is the minimum
required clearance from the front of the unit for servicing
it. 30 inches is the minimum required clearance from the
front of the unit for positioning it. 36 inches is the
recommended clearance from the front of the unit.
Please note that a panel or door can be located such that
the minimum clearance on the rating plate is satisfied, but
that panel or door must be removable and allow the
appropriate clearance for your installation.
This furnace is certified for use on wood flooring. This
furnace must not be installed directly on carpeting, tile, or
any combustible material other than wood flooring.
A gas-fired furnace installed in a residential garage must be
installed so the burners and the igniter are located not less
than 18 inches (457 mm) above the floor, and the furnace
must be located or protected to avoid physical damage by
vehicles.
7
!
WARNING:
Do not place combustible material on or against
the furnace cabinet or within 6 inches of the vent
pipe. Do not place combustible materials,
including gasoline and any other flammable
vapors and liquids, in the vicinity of the furnace.
VENTING AND COMBUSTION
AIR REQUIREMENTS
General
Provisions must be made in the installation of this furnace
to provide an adequate supply of air for combustion. Detailed
instructions for determining the adequacy of an installation
can be found in the current revision of the National Fuel Gas
Code (ANSI Z223.1 / NFPA54) or in applicable local building
codes. Consult local codes for special requirements.
For Canadian installations consult Canadian Installations
Codes and (CAN/CGA B149.1 or .2).If the furnace is
operated with inadequate air for combustion
one of the flame roll-out switches located in the burner
compartment or the vent switch will open, turning off the
gas supply to the burners. These safety devices are
manually reset switches. DO NOT install jumper wires
across these switches to defeat their function. DO NOT
reset a switch without identifying and correcting the fault
condition. If a switch must be replaced, use only the
correct part specified in the Replacement Parts List.
Air openings in the furnace door, warm air registers, and
return air grilles must not be restricted.
3. The following types of installation may require Outdoor
Air for combustion, due to chemical exposures:
• Commercial buildings
• Buildings with indoor pools
• Furnaces installed in laundry rooms
• Furnaces installed in hobby or craft rooms
• Furnaces installed near chemical storage areas
Exposure to the following substances in the combustion air supply may also require Outdoor Air for
combustion:
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine based swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (such as perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cements and glues
• Antistatic fabric softeners for clothes dryers
• Masonry acid washing materials
!
WARNING:
Furnace installation using methods other than
those described in the following sections must
comply with the National Fuel Gas Code and all
applicable local codes to provide sufficient
combustion air for the furnace.
!
CAUTION:
Combustion air must not be drawn from a
corrosive atmosphere.
To maximize heat exchanger life, the combustion air must
be free of chemicals which form corrosive acidic compounds
in the combustion gases.
Combustion Air Quality
The recommended source of combustion air is to use the
outdoor air supply. However, the use of indoor air in most
applications is acceptable except as follows:
1. If the furnace is installed in a confined space it is
recommended that the necessary combustion air come
from the outdoors by way of attic, crawl space, air duct,
or direct opening.
2. If outdoor combustion air is used, there must be no
exposure to the installations or substances listed in
Item 3 below.
8
Installation 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 input 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.
However, in “tight” buildings (with weather stripping and
caulk to reduce infiltration), it may be necessary to provide
outside air to ensure adequate combustion and venting,
even though the furnace is located in an unconfined space.
Installation In A Confined Space
A confined space is an area with volume less than 50 cubic
feet per 1,000 Btuh of the combined input rates of all
appliances drawing combustion air from that space. Furnace
closets, small equipment rooms and garages are confined
spaces. Furnaces installed in a confined space which
supply heated air to areas outside the space must draw
return air from outside the space and must have the return
air ducts tightly sealed to the furnace. A confined space
must have two openings into the space for combustion
air. One opening must be within 12 inches of the
ceiling, and the other must be within 12 inches of the
floor. The required sizing of these openings is determined
by whether inside or outside air is used to support
combustion, the method by which the air is brought to the
space, and by the total input rate of all appliances in the
space.
Downflow Warning (*RK Models):
The design of the downflow furnace is certified for natural
or propane gas and for installation on non-combustible
flooring. A special combustible floor sub-base is required
when installing on a combustible floor. Failure to install the
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 installed on a factory or site-built cased
air conditioning coil, the sub-base is not necessary. However, the plenum attached to the coil casing must be
installed such that its surfaces are at least 1" from
combustible construction.
Supply Air Plenum Installation
A. Installation on a concrete slab. - *RK
1. Construct a hole in the floor per the dimensions in
Figure 2.
2. Place the plenum and the furnace as shown in Figure
3.
B. Installation on a combustible floor. - *RK
1. Cut and frame the hole in the floor per the dimensions
in Figure 4.
2. Place 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
assure 1" clearance to the flooring or other combustible construction. Place furnace on the combustible
base as shown in Figure 6.
3. When a factory or site built cased coil is provided
beneath the furnace the sub-base for combustible
floors is not necessary. However, the plenum attached to the cased coil must be installed such that its
surfaces are at least 1" from the flooring or other
combustible construction.
Horizontal Furnace Installation
This furnace can be installed horizontally in an attic,
basement, crawl space or alcove. It can be suspended
from a ceiling in a basement or utility room in either a right
to left airflow or left to right airflow. (See Figure 2.)
!
CAUTION:
The downflow sub-base must not be installed
directly on carpeting, tile, or any combustible
material other than wood flooring.
A gas-fired furnace installed in a residential garage must be
installed so the burners and the igniter are located not less
than 18 inches (457 mm) above the floor, and the furnace
must be located or protected to avoid physical damage by
vehicles.
!
WARNING:
Do not place combustible material on or against
the furnace cabinet or within 6 inches of the
vent pipe. Do not place combustible materials,
including gasoline and any other flammable
vapors and liquids, in the vicinity of the furnace.
If the furnace is to be suspended from the ceiling, it will be
necessary to use steel straps around each end of the
furnace. These straps should be attached to the furnace
with sheet metal screws and to the rafters with bolts. The
furnace could also be suspended by an angle iron frame
bolted to the rafters.
Note: Line
Contact is Permissible
Type “B” Vent
Coil Plenum
Electrical
Supply
Connection
Figure 2. Horizontal installation on a Platform
Gas Inlet
Combustible
Platform
Louver Door
9
Upflow Furnace Models
LEFT
SIDE
UPFLOW APPLICATION
TOP
RIGHT
SIDE
BOTTOM
HORIZONTAL APPLICATION
TOP
LEFT
SIDE
BOTTOM
HORIZONTAL INSTALLATION CLEARANCES
Vent Connector
Type
LEFT SIDE
RIGHT SIDE
VENT
BACK
BOTTOM
TOP
FRONT
*** Allow 24" minimum clearance for servicing. The
recommended clearance is 36".
Standard Single
Wall Metal Vent
1" 1"
0" 0"
6" 1"
0" 0"
0" 0"
5" 0"
4"*** 4"***
RIGHT
SIDE
Type B-1 Double
Wall Metal Vent
UPFLOW/DOWNFLOW INSTALLATION CL EARANCES
Vent Connector
Type
LEFT SIDE
RIGHT SIDE
VENT
BACK
BOTTOM
TOP
FRONT
Standard Single
Wall Metal Vent
0" 0"
5"* 0"
6" 1"
0" 0"
0"** 0"**
1" 1"
4"*** 4"***
Type B-1 Double
Wall Metal Vent
* For Downflow furnace installations only,
right side minimum clearance is 0".
** For Downflow furnace installations only,
furnace must be installed on noncombustible flooring.
*** Allow 24" minimum clearance for servicing.
The recommended clearance is 36".
Table 3. Minimum Clearances to Combustible Material
Downflow Furnace Models
DOWNFLOW APPLICATION
TOP
LEFT
SIDE
BOTTOM
RIGHT
SIDE
10
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