Nordyne 80+ AFUE *SA Installation Instructions Manual

GAS FURNACES

Installation Instructions

Single Stage High Efﬁ ciency Furnaces

80+ AFUE

*SA Upﬂ ow/Horizontal Model *SK Downﬂ ow Model

WARNING:

• PROPOSITION 65 WARNING: This product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

• This furnace is not approved for installation in mobile homes. Installing this furnace in a mobile home could cause ﬁ re, property damage, and/or personal injury.

ATTENTION INSTALLERS:

It is your responsibility to know this product better than your customer. This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product. Safety should always be the deciding factor when installing this product and using common sense plays an important role as well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the furnace or failure to follow safety warnings could result in serious injury, death, or property damage.

These instructions are primarily intended to assist qualiﬁ ed individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Please read all instructions carefully before starting the installation. Return these instructions to the customer’s package for future reference.

WARNING:

FIRE OR EXPLOSION HAZARD

• Failure to follow safety warnings exactly could result in serious injury or property damage.

• Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier.

• Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

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.

• Leave the building immediately.

• 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 ﬁ re department.

DO NOT DESTROY THIS MANUAL.

KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

TABLE OF CONTENTS

SAFETY INFORMATION .............................................3

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

GENERAL INSTRUCTIONS ........................................4

Combustion Air Quality ...........................................4

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

Installation in a Garage ...........................................5

Heating Load ...........................................................5

Clearances to Combustible Materials .....................5

COMBUSTION AIR REQUIREMENTS ........................7

General Information ................................................7

Installation in a Conﬁ ned Space ..............................7

Air From Inside ...................................................7

Outdoor Air Using a Crawl Space or

Vented Attic ........................................................ 7

Outdoor Air Using Vertical Ducts ........................8

Outdoor Air Using Horizontal Ducts ...................8

FURNACE INSTALLATION .......................................12

General Requirements ..........................................12

Upﬂ ow Installation .................................................12

Side Return Air Inlet .........................................12

Bottom Return Air Inlet .....................................12

Horizontal Installation ............................................12

Downﬂ ow Installation ............................................13

Installation on a Concrete Slab ........................13

Bottom Panel Removal ..........................................14

Alternate Bottom Panel Removal .....................14

GAS SUPPLY AND PIPING .......................................15

Leak Check ...........................................................15

High-Altitude Application .......................................15

Conversion to LP/Propane ....................................17

ELECTRICAL WIRING ...............................................17

Line Voltage Wiring ................................................17

Air Directly Through an Exterior Wall .................8

Alternate Method of Providing Air from

Outside ...............................................................9

Installation in an Unconﬁ ned Space ........................ 9

VENTING REQUIREMENTS ........................................9

Category I Venting ...................................................9

Horizontal Venting .................................................. 10

Flexible Vent Systems ............................................ 10

CIRCULATING AIR REQUIREMENTS ......................11

Plenums and Air Ducts ..........................................11

Supply Air Connections .........................................11

Upﬂ ow/Horizontal Furnaces ..............................11

Downﬂ ow Furnaces ...........................................11

Return Air Connections .........................................11

Upﬂ ow/Horizontal Furnaces .............................. 11

Side Return Installations ................................. 12

Bottom Return Installations ............................ 12

Low Voltage Wiring ................................................18

Grounding ..............................................................19

Twinning .................................................................19

START-UP & ADJUSTMENTS ...................................20

Pre-Start Checklist ................................................20

Start-Up Procedures ..............................................20

Verifying and Adjusting Input Rate ........................20

Verifying and Adjusting Temperature Rise .............20

Verifying Burner Operation ....................................21

Verify Operation of the Supply Air

Limit Switch ...........................................................21

OPERATING SEQUENCE .........................................21

Heating Cycle ........................................................21

Cooling Cycle ........................................................22

Fan Mode ..............................................................22

TROUBLESHOOTING ...............................................22

Downﬂ ow Furnaces ........................................... 12

Acoustical Treatments............................................ 12

MAINTENANCE .........................................................22

Air Filters ...............................................................22

Blower Compartment ............................................23

Cleaning of Burners ..............................................23

Cleaning of Flue Passages ...................................23

Heat Exchanger and Burner Maintenance ............24

SAFETY INFORMATION

Safety markings are used frequently throughout this

manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death. CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

Lubrication ............................................................24

Vent System ..........................................................24

DESCRIPTION OF COMPONENTS ..........................24

FRENCH TRANSLATIONS ........................................25

FIGURES AND TABLES ............................................27

Figure 17 - Furnace Dimensions ......................27

Airﬂ ow Data ...........................................................28

Table 4 - Upﬂ ow/Horizontal Gas Furnaces .......28

Table 5 - Downﬂ ow Gas Furnaces ....................30

Electrical Information.............................................31

Figure 18 - Wiring Diagram ..............................31

Gas Information .....................................................32

Table 6 - Gas Flow Rates.................................32

Table 7 - Gas Pipe Capacities .........................32

Table 8 - High Altitude Deration Chart for

Propane Gas .....................................33

Table 9 - Natural Gas Heating Values ..............33

Table 10 - High Altitude Deration Chart for

Nat. Gas - High Heating Values .......34

Table 11 - High Altitude Deration Chart for

Nat. Gas - Low Heating Values........34

Location of Furnace Components .........................35

Figure 19 - Upﬂ ow/Horizontal Gas Furnace

Components ..................................35

Figure 20 - Downﬂ ow Gas Furnace

Components ..................................35

INSTALLATION/PERFORMANCE CHECKLIST .......36

WARNING:

The safety information listed below must be followed during the installation, service, and operation of this furnace. Failure to follow safety recommendations could result in possible damage to the equipment, serious per

injury or death

• Use only with type of gas approved for this furnace. Refer to the furnace rating plate.

• Install this furnace only in a location and position as speciﬁ ed in Table 1 (page 6).

• Provide adequate combustion and ventilation air to the furnace space as speciﬁ ed on pages 7 - 9.

• Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as speciﬁ ed on pages 9 - 10.

• Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution to check all connections. See page 15.

• This furnace is designed to operate with a maximum external pressure rise of 0.5 inches of water column. Consult Tables 4 - 5 (pages 28 - 30), and the rating plate for the proper circulating air ﬂ ow and temperature rise. It is important that the duct system be designed to handle the desired ﬂ ow rate and temperature rise. An improperly designed duct system can result in nuisance shutdowns, and comfort or noise issues.

• When 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. See page 11.

• This furnace may be used for temporary heating of buildings or structures under construction. See the guidelines listed on page 5.

• A gas-ﬁ red furnace for installation in a residential garage must be installed as speciﬁ ed on page 5.

sonal

REQUIREMENTS and CODES This furnace must be installed in accordance with

these instructions, all applicable local building codes and the current revision of the National Fuel Gas Code (NFPA54/ANSI Z223.1) or the Natural Gas and Propane Installation Code, CAN/CGA B149.1.

GENERAL INSTRUCTIONS Combustion Air Quality

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

Additional codes listed below are for reference purposes only and do not necessarily have jurisdiction over local or state codes. Always consult with local authorities before installing any gas appliance.

Combustion and Ventilation Air

• US: National Fuel Gas Code (NFGC), Air for Combustion and Ventilation

• CANADA: Natural Gas and Propane Installation Codes (NSCNGPIC), Venting Systems and Air Supply for Appliances

Duct Systems

• US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) Fundamentals Handbook

Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70

• CANADA: Canadian Electrical Code CSA C22.1

Gas Piping and Gas Pipe Pressure Testing

• US: NFGC and National Plumbing Codes

• CANADA: NSCNGPIC

General Installation

• US: Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or American Gas Association, 400 N. Capitol, N.W., Washington DC 20001 or www.NFPA.org

• CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada

To maximize heat exchanger life, the combustion air must be free of chemicals that can form corrosive acidic compounds in the combustion gases. The recommended source of combustion air is to use outdoor air. However, the use of indoor air in most applications is acceptable except as listed:

• If the furnace is installed in a conﬁ ned space, it is required that the necessary combustion air come from the outdoors by way of attic, crawl space, air duct, or direct opening. For Installations in conﬁ ned spaces, see pages 7 - 8 for combustion air requirements.

• Installations in these locations 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 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 (perchloroethylene) Printing inks, paint removers, varnishes, etc. Hydrochloric acid Cements and glues Antistatic fabric softeners Masonry acid washing materials

Safety

• US: (NFGC) 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)

Operation of Furnace During Construction

Installation in a Garage

CAUTION:

Failure to follow these instructions will void the factory warranty and may signiﬁ cantly reduce the life or the performance of the furnace, and/or result in other unsafe conditions. It is the responsibility of the installing contractor to insure these provisions are met.

Operating gas furnaces in construction environments can cause a variety of problems with the furnace. Proper use of commercial portable space heating equipment during construction is recommended. This gas furnace may be used during construction if it is not in violation of any applicable codes and the following criteria are met:

• The installation must meet all applicable codes. The furnace must be permanently installed according to the instructions with the furnace including electrical supply, gas supply, duct work and venting. The furnace must be controlled by a thermostat properly installed according to the instructions supplied with the furnace and thermostat. The installation must include a properly installed ﬁ lter in the return air system with no by-pass air. The ﬁ lter must be inspected frequently and replaced when necessary.

• Combustion air must be supplied from outside the structure and located such that dust and gases from construction activity are not introduced into the combustion system.

• Provisions must be made to insure that condensate does not freeze in the furnace or condensate drain lines during operation and during idle times; for example, overnight if turned off. (Condensing furnaces only)

• Before occupying the structure: The ﬁ lter must be replaced or cleaned, the duct work must be inspected and cleaned of any construction debris, and the furnace must be cleaned and/or repaired if found to be dirty, damaged, or malfunctioning in any way by a qualiﬁ ed HVAC technician. The furnace shall be inspected and approved by applicable local authority even if this requires redundant inspections.

• Serial numbers for furnaces used during construction must be submitted in writing (fax and email also acceptable). This information will be used to track the long-term affects of the use during construction on furnaces. Proof of this submittal shall be available for the ﬁ nal inspection of the furnace prior to occupancy.

• This furnace is designed to operate with return air temperatures in ranges normally found in occupied residences, including setbacks. Minimum continuous return temperature must not be below 60° F (15° C). Occasionally a temporary return temperature of 55° F (12° C) is acceptable. However, operation with a return temperature below 55° F (12° C) is not allowed.

WARNING:

Do not place combustible materials on or against the furnace cabinet or within 6 inches of the vent pipe. Do not place combustible materials, including gasoline or any other ﬂ ammable vapors and liquids, in the vicinity of the furnace.

This gas-ﬁ red furnace may be installed in a residential garage with the provision that the burners and igniter are located no less than 18 inches (457mm) above the ﬂ oor. The furnace must be located or protected to prevent physical damage by vehicles.

Heating Load

The furnace should be sized to provide the design heating load requirement. Heating load estimates can be made using approved methods 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 of the furnace could cause the furnace and/or vent to fail prematurely.

The ductwork should be appropriately sized to the capacity of the furnace to ensure its proper airﬂ ow rating. For installations above 2,000 ft., the furnace should have a sea level input rating large enough that it will meet the heating load after deration for altitude.

Clearances to Combustible Materials

This furnace is Design Certiﬁ ed in the U.S. and Canada by CSA International for the minimum clearances to combustible materials listed in Table 1 (page 6). To obtain model number and speciﬁ c clearance information, refer to the furnace rating plate, located inside of the furnace cabinet.

Access for positioning and servicing the unit must be considered when locating unit. The need to provide clearance for access to panels or doors may require clearance distances over and above the requirements.

Allow 24 inches minimum clearance from the front of the unit. However 36 inches is strongly recommended.

INSTALLATION CLEARANCES to COMBUSTIBLE MATERIALS

For UPFLOW, HORIZONTAL & DOWNFLOW FURNACES

Left Side ...................................0 Inches Vent ............................................. 1 Inch Top ...........................................0 Inches

Right Side ................................0 Inches Back .........................................0 Inches Front.......................................4 Inches

UPFLOW APPLICATION

TOP

HORIZONTAL APPLICATION

SIDE

DOWNFLOW APPLICATION

TOP

†

TOP

LEFT SIDE

BOTTOM

†

Allow 24 in. minimum clearance for servicing. Recommended clearance is 36 in.

NOTE: The furnace is listed for installation on combustible or non-combustible ﬂ ooring. However, wood is the only combustible ﬂ ooring allowed for installation. Downﬂ ow models must use the appropriate subase kit when installing over a wood ﬂ oor

RIGHT SIDE

SIDE

Table 1. Minimum Clearances to Combustible Materials

WARNING:

BOTTOM

LEFT SIDE

BOTTOM

RIGHT SIDE

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system

being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National

Fuel Gas Code, ANSI Z223. 1/NFPA 54 or the CSA B149.1, Natural Gas and Propane Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage,

corrosion and other deﬁ ciencies which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close ﬁ replace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. 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 opening after 5 minutes of main burner operation. Use the ﬂ ame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Codes.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, ﬁ replace dampers and any other gas-ﬁ red burning appliance to their previous conditions of use.

COMBUSTION AIR REQUIREMENTS General Information

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.

WARNING:

Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code (NFGC) and all applicable local codes.

• Instructions for determining the adequacy of combustion air for an installation can be found in the current revision of the NFGC (ANSI Z223.1 / NFPA54). Consult local codes for special requirements. These requirements are for US installations as found in the NFGC.

• The requirements in Canada (B149.1) are structured differently. Consult with B149.1 and local code ofﬁ cials for Canadian installations.

Provisions must be made during the installation of this furnace that provide an adequate supply of air for combustion.

CAUTION:

Exhaust fans, clothes dryers, ﬁ replaces and other appliances that force air from the house to the outdoors can create a negative pressure inside the house, resulting in improper furnace operation or unsafe conditions such as ﬂ ame roll out. It is imperative that sufﬁ cient air exchange with the outdoors is provided to prevent depressurization. Additional information about how to test for negative pressure problems can be found in the NFGC.

NOTE: Air openings on top of the furnace and openings in

closet doors or walls must never be restricted. If the furnace is operated without adequate air for combustion, the ﬂ ame roll-out switch will open, turning off the gas supply to the burners. This safety device is a manually reset switch.

DO NOT install jumper wires across these switches to defeat their function or reset a switch without identifying and correcting the fault condition.

If a switch must be replaced, use only the correct sized part speciﬁ ed in the Replacement Parts List provided online.

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. In all cases, the minimum dimension of any combustion air opening is 3 inches.

Air From Inside

If combustion air is taken from the heated space, the two openings must each have a free area of at least one square inch per 1,000 Btuh of total input of all appliances in the conﬁ ned space, but not less than 100 square inches of free area (Figure 1). See example.

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 appliances is 120,000 Btuh, each opening must have a free area of at least 120 square inches.

Vent or

Chimney

NOTES: Each opening must be at least 100 sq. in. or 1 sq. in. per 1,000 Btuh of total input rating, whichever is greater.

Openings must start at no more than 12 inches from the top and bottom of the enclosure.

Water Heater

Total Input Rating

(Btuh)

40,000 100 sq. In 12 inches 60,000 100 sq. In 12 inches

80,000 100 sq. In 12 inches 100,000 100 sq. In 12 inches 120,000 120 sq. In 13 inches 140,000 140 sq. In 14 inches 160,000 160 sq. In 15 inches

Minimum Free Area

(Each Opening)

12" Max.

Furnace

See Notes

12” Max.

See

Notes

Round Duct

Diameter

Installation In A Conﬁ ned Space

A conﬁ ned 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 conﬁ ned spaces. Furnaces installed in a conﬁ ned space

Figure 1. Combustion Air Drawn from Inside

Outdoor Air from a Crawl Space or Vented Attic When the openings can freely exchange air with the outdoors, each opening shall have a minimum free area of 1 square inch per 4,000 Btuh of total appliance input. The openings shall exchange directly, or by ducts, with the outdoor spaces (crawl or attic) that freely exchange with the outdoors (Figure 2, page 8).

Ventilation louvers

Vent or

Chimney

Attic Insulation

at each end of attic

Outlet air duct must be at least 1 sq. in. per 4,000 Btuh of total input rating. Must

Water Heater

Furnace

extend above attic insulation

Inlet air duct must be at least 1 sq. in. per 4,000 Btuh of total input rating.

Crawl Space

Ventilated Louvers for unheated crawl space

Figure 2. Combustion Air Drawn from a Crawl

Space or Vented Attic

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 square inch per 4,000 Btuh of total appliance input. In installations drawing combustion air from a ventilated attic, both air ducts must extend above the attic insulation (Figure 3).

Vent or

Chimney

12" Max

See

Note

12" Max

Total Input Rating

(Btuh)

Water Heater

Air Duct

Furnace

Air Duct

Minimum Free Area

(Each Opening)

NOTE: Each

opening to outside must be at least 1 sq. in. per 2,000 Btuh of total

input rating.

Round Duct

Diameter

40,000 10 sq. In 5 inches

60,000 15 sq. In 6 inches

80,000 20 sq. In 7 inches 100,000 25 sq. In 8 inches 120,000 30 sq. In 9 inches 140,000 35 sq. In 10 inches 160,000 40 sq. In 10 inches

Figure 4. Combustion Air Drawn from Outside

Through Horizontal Ducts

Ventilation Louvers at each end of attic

Vent or Chimney

Water Heater

Attic

Insulation

Furnace

Outlet Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating.

Inlet and Outlet Ducts must extend above attic insulation.

Inlet Air Duct must be at least 1 sq. in. per 4,000 Btuh of total input rating.

12" Max

Total Input Rating

(Btuh)

Minimum Free Area

(Each Opening)

Round Duct

Diameter

40,000 100 sq. In 12 inches 60,000 100 sq. In 12 inches

80,000 100 sq. In 12 inches 100,000 100 sq. In 12 inches 120,000 120 sq. In 13 inches 140,000 140 sq. In 14 inches 160,000 160 sq. In 15 inches

Figure 3. Combustion Air Drawn from Outside

Through Vertical Ducts

Outdoor Air Using Horizontal Ducts If combustion air is taken from outdoors through horizontal ducts, the openings and ducts must have a minimum free area of one square inch per 2,000 Btuh of total appliance input (Figure 4).

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 4,000 Btuh of total appliance input (Figure 5).

Vent or

12" Max

See Note

12" Max

Total Input Rating

(Btuh)

40,000 10 sq. In 4 inches 60,000 15 sq. In 5 inches

80,000 20 sq. In 5 inches 100,000 25 sq. In 6 inches 120,000 30 sq. In 6 inches 140,000 35 sq. In 7 inches 160,000 40 sq. In 8 inches

Chimney

Furnace

Water Heater

Minimum Free Area

(Each Opening)

NOTE: Each opening

to outside must be at least 1 sq. in. per 4,000 Btuh of total input rating.

Round Duct

Diameter

Figure 5. Combustion Air Drawn from Outside

Through an Exterior Wall

Alternate Method of Providing Air from Outside: If acceptable under local Codes, it is permitted to provide outside air using one opening (See NFGC).

Generally, conﬁ ned spaces must have two openings in 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 ﬂ oor. However, an alternative method recently adopted by the NFGC uses one opening within 12 inches of the top of the space. This method may be used if it is acceptable to the local codes.

The following conditions must be met:

1. The opening must start within 12” of the top of the structure and connect with the out of doors through vertical or horizontal ducts or be ducted to a crawl or attic space that connects with the out of doors.

2. The opening must have a minimum free area of 1 sq. in. per 3,000 Btu per hour of the total input rating of all equipment located in the enclosure.

3. The free area must not be less than the sum of all the areas of the vent connectors in the enclosure.

Installation In An Unconﬁ ned Space

An unconﬁ ned 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.

In general, a furnace installed in an unconﬁ ned space will not require outside air for combustion. However, in homes built for energy efﬁ ciency (low air change rates), it may be necessary to provide outside air to ensure adequate combustion and venting, even though the furnace is located in an unconﬁ ned space. See example.

Example:

A space with 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 unconﬁ ned. If the space has an 8 foot ceiling, the ﬂ oor area of the space must be 750 square feet (6,000 / 8 = 750).

VENTING REQUIREMENTS

WARNING:

Upon completion of the furnace installation, carefully inspect the entire ﬂ ue system both inside and outside the furnace to assure it is properly sealed. Leaks in the ﬂ ue system can result in serious personal injury or death due to exposure of ﬂ ue products, including carbon monoxide.

• This furnace must be vented in compliance with the current revision of the National Fuel Gas Code (ANSI-Z223.1/NFPA54) and the instructions provided below. Consult local codes for special

requirements.

• In Canada, venting shall conform to the requirements of the current (CAN/CGA B149.1 or .2) installation codes.

Consult local codes for special requirements.

Category I Venting

This furnace is listed as a Category I vented appliance. Category I furnaces generally operate with a slight negative pressure (draft) and must be vented vertically or near vertical. Additionally it is important to guard against excessive condensation.

• Category I furnace installations must be connected to a factory built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction.

WARNING:

Venting into an unlined masonry chimney or concrete chimney is prohibited. This may result in improper draft and excess condensation forming in the chimney.

• This furnace may be vented with a dedicated venting system or common vented with other Category I appliances. The vent system dimensions and material must conform to the NFGC or local Codes. Generally, this means using Type B vent pipe or a lined masonry chimney. When consulting the vent sizing tables in the NFGC, the MAX capacity of the vent must be greater than the furnaces high ﬁ re rate. The MIN capacity must be lower than the low ﬁ re rate. If the venting system is inappropriate for the furnace, the venting system will need to be modiﬁ ed to comply with NFGC or local codes. The minimum diameter of any vent pipe is 4

inches.

• The venting system should be designed to have the minimum number of elbows or turns. All horizontal runs shall slope upwards from the furnace at ¼ inch per running foot of vent. Supports for the vent pipe must

be installed a minimum of every ﬁ ve feet along the vent run to ensure no displacement after installation. Under no circumstances shall any portion of the vent system extend into or pass through any return air duct, supply air duct, or plenum.

• Single wall vent connectors may be used under the limited capacity ranges found in the vent sizing tables. It is recommended that Type B double wall vent be used for the connector whenever possible. An existing masonry chimney should be inspected and relined if necessary.

• In the U.S., this furnace must never be vented to a chimney or ﬂ ue that services a ﬁ replace or other appliance designed to burn solid fuel. If the furnace vent is to be connected to a chimney serving a ﬁ replace, the ﬁ replace must be sealed off from the chimney. In Canada, common venting with a ﬁ replace is permitted. Consult B149.1 and your local code authority.

• Single wall metal vertical vents shall not be used for Category I venting. The furnace vent, if metal, may be insulated if local codes allow. Any part of the vent system, metal vent only, not exposed to weather, but which are exposed to temperatures below 35° F (1°C) must be insulated to prevent condensation. All vent insulation shall be foil backed ﬁ berglass of one inch minimum thickness.

• Sheet metal fasteners should be used to secure the vent pipe to the furnace ﬂ ue. However, the NFGC states that alternative vent products may be attached according to the vent manufacturers instructions.

• When an existing furnace is removed from a vent system serving other appliances, the existing vent system may no longer be sized to properly vent the remaining appliances. An improperly sized venting system can result in the formation of condensate, leakage, or spillage. The existing vent system should also be checked to make sure it remains in compliance with NFGC. If it isn’t, the vent system must be brought into compliance before installing the furnace.

Horizontal Venting

WARNING:

Horizontal vent systems must be sealed with a high temperature sealant that can withstand temperatures of 450° F. Recommended sealants: Dow Corning Sealant 736 RTV; GE 106 RTV; High Tech Ind., High TEMP RED.

This furnace is not approved for horizontal venting without the use of an add-on power venter. Power venters establish negative pressure in the vent piping and the furnace operates as if connected to a Category I vertical vent. The power venter is only for use when exhausting through an exterior wall.

The power venter must be installed according to the instructions provided by the power venter manufacturer and applicable requirements of local codes. For Canadian installations please refer to the Canadian Installation Code (CAN/CGA-B149.1 or 2) and/or local codes.

The outlet of the vent must be at least 12 inches above the highest expected snow accumulation.

Flexible Vent Systems

Flexible venting systems are approved for use providing they are listed for the application and meet all local Code requirements. These systems are primarily used to line existing masonry chimneys. They must be sized to the application according to the sizing tables in the National Fuel Gas Code, including the required 20% reduction in maximum capacity.

Flexible venting systems are permitted to be used as the vent connector. However, great care must be taken to ensure that there are no sags in the venting system which could accumulate condensate. The ﬂ exible vent system must be supported at no more than 5 foot intervals and maintain a minimum slope of ¼ inch per foot of horizontal run.

CIRCULATING AIR REQUIREMENTS

WARNING:

Do not allow combustion products to enter the circulating air supply. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

All return ductwork must be secured to the furnace with sheet metal screws. For installations in conﬁ ned spaces, all return ductwork must be adequately sealed. When return air is provided through the bottom of the furnace, the joint between the furnace and the return air plenum must be air tight.

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 airﬂ ow over the indoor coil, the coil must be installed downstream (on the outlet side) of the furnace 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 condensing on the heat exchanger. If a manually operated damper is installed, it must be designed so that operation of the furnace is prevented when the damper is in the cooling position and operation of the cooling system is prevented when the damper is in the heating position.

• It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant. Requirements for sealing ductwork vary from region to region. Consult with local codes for requirements speciﬁ c to your area.

The surface that the furnace is mounted on must provide sound physical support of the furnace with no gaps, cracks or sagging between the furnace and the ﬂ oor or platform.

Return air and circulating air ductwork must not be connected to any other heat producing device such as a ﬁ replace insert, stove, etc. This may result in ﬁ re, explosion, carbon monoxide poisoning, personal injury, or property damage.

Plenums and Air Ducts

• Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B).

• Tables 4 - 5 (pages 28 - 30) contain the maximum airﬂ ow and temperature rise data for each furnace input rate. If the maximum airﬂ ow is 1,600 CFM or more, it is recommended that two openings be used for return air on upﬂ ow furnaces. Downﬂ ow furnaces can only use one return opening.

• It is recommended that the outlet duct contain a removable access panel. The opening should be accessible when the furnace is installed in service and shall be of a size that smoke or reﬂ ected light may be observed inside the casing to indicate the presence of leaks in the heat exchanger. The cover for the opening shall be attached in such a manner as to prevent leaks.

• If outside air is used as return air to the furnace for ventilation or to improve indoor air quality, the system must be designed so that the return air is not less than 60° F (15° C) during operation. If a combination of indoor and outdoor air is used, the ducts and damper system

Supply Air Connections

The supply air must be delivered to the heated space by duct(s) secured to the furnace casing, running full size and without interruption.

Upﬂ ow and Horizontal Furnaces To attach the supply air duct to the furnace, bend the furnace ﬂ anges (Figure 17, page 27) upward 90° with a pair of wide duct pliers. Position the duct on top of the furnace and secure together with sheet metal screws. The screws must penetrate the sheet metal casing and furnace ﬂ ange. Tape or seal all seams if required by local code.

Downﬂ ow Furnaces To attach the supply air duct to the downﬂ ow furnace, position the furnace over the duct and secure together with sheet metal screws. The screws must penetrate the duct and furnace casing.

Return Air Connections

In applications where the supply ducts carry heated air to areas outside the space where the furnace is installed, the return air must be delivered to the furnace by duct(s) secured to the furnace casing, running full size and without interruption.

Upﬂ ow and Horizontal Furnaces For upﬂ ow installations, the return air ductwork may be connected to the left side, right side, or bottom. The bottom panel (Figure 17) must be installed for left or right return air. NOTE: Do not use the back of the furnace

for return air.

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Nordyne 80+ AFUE *SA Installation Instructions Manual

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