Nordyne G6RL 90+, G6RC 90+, G6RD 93+ User Manual

Residential Gas Furnaces

Installation Instructions

G6RC Series 90+ Upflow Condensing Furnace G6RD Series 93+ Upflow Condensing Furnace G6RL Series 90+ Downflow Condensing Furnace

G6RC 90+, G6RD 93+ Upflow

G6RL 90+ Downflow

! WARNING:

Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual for assistance. For additional information consult a qualified installer, service agency, or the gas supplier.

! FOR YOUR SAFETY:

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

! FOR YOUR SAFETY:

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.

DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

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
Furnace Airflow Data ..........................................................................................................	6-7
Installation Requirements ..........................................................................................................	8
Supply Air Plenum Installation ..................................................................................................	9
Installation on a Concrete Slab .............................................................................................	9
Installation on a Combustible Floor .......................................................................................	9
Circulating Air Supply ...............................................................................................................	10
Return Air ............................................................................................................................	11
Venting and Combustion Air Requirements ..........................................................................	11
Air Requirements for One-Pipe Installation ........................................................................	13
Installation in An Unconfined Space ...................................................................................	13
Installation in A Confined Space .........................................................................................	13
• Air From Inside ..................................................................................................................	13
• Air Directly Through An Exterior Wall ...............................................................................	14
• Outdoor Air Through Vertical Openings or Ducts .............................................................	14
• Outdoor Air Through Horizontal Openings or Ducts .........................................................	14
Venting Requirements ..............................................................................................................	14
Vent Pipe Material ...............................................................................................................	14
Vent Pipe Length and Diameter ..........................................................................................	14
Vent Pipe Installation ..........................................................................................................	15
Pipe Routing & Support .......................................................................................................	15
Location of Outdoor Terminations .......................................................................................	18
Horizontal Venting ...............................................................................................................	19
Vertical Venting ...................................................................................................................	20
Vent Freezing Protection .....................................................................................................	20
Concentric Vent Termination ...............................................................................................	20
Drainage of Condensate From Furnace .................................................................................	21
Gas Supply and Piping ........................................................................................................	22
Leak Check ..........................................................................................................................	22
Conversion ...........................................................................................................................	23
High Altitude Application .....................................................................................................	23
Natural Gas High Altitude Conversion ................................................................................	23
LP/Propane Gas Sea Level and High Altitude Conversion ................................................	23
Electrical Wiring ........................................................................................................................	24
Line Voltage Wiring .............................................................................................................	24
Low Voltage Wiring .............................................................................................................	25
Start-up and Adjustments .........................................................................................................	25
Start-Up Procedure ..............................................................................................................	26
Verifying and Adjusting Firing Rate .....................................................................................	26
Verifying and Adjusting Temperature Rise .........................................................................	27
Verifying Burner Operation ..................................................................................................	27
Verifying Operation of the Supply Air Limit Switch .............................................................	29
Description of Components .....................................................................................................	29
Maintenance ...............................................................................................................................	31
Combustion Air and Vent System .......................................................................................	31
Air Filter(s) ...........................................................................................................................	31
Lubrication ...........................................................................................................................	31
Condensate Drain Assembly ...............................................................................................	31
Blower Compartment ...........................................................................................................	31
Heat Exchanger and Burner Maintenance ..........................................................................	31
Location of Major Components ...........................................................................................	32
System Operation Information .................................................................................................	31
Sequence of Operation .......................................................................................................	33
Furnace Fails to Operate ....................................................................................................	34
Twinning of Two Furnaces ..................................................................................................	34
Installation/Performance Checklist .........................................................................................	35

4

Dimensions Unit G6RD G6RC, .1 Figure

Upflow G6RC & G6RD Furnaces

3/4" 3/4"

43"

15"

1"

Combustion Air

Inlet 23 1/4"

Exhaust Vent

22 1/2"

19 3/4"

25 1/8"

1 1/2" x 3 1/2" Dia.

Opening for

Gas Connection

7/8" Dia. Electric

Connection

+

Combustion Air Vent

(See Fig. 15 3/4" for sizes)

25 1/4"	33"

20 1/2"

8" Return Air Opening

(Side)

1 1/4"			23"

28"

A

B

C

2 1/4"

3/4"

2" PVC Exhaust Vent

(See Fig. 15 for sizes)

30 1/4"

25 1/4"

Return Air Opening (Bottom)

D

Condensate Drain Outlets

27 5/8"

1 1/2" x 3 1/2" Dia. Opening for

Gas Connection 7/8" Dia. Electric

+Connection

25 5/8"

8"

23" Bottom Return Opening

SPECIFICATIONS FURNACE

	Downflow G6RL Furnace
		Combustion Air Inlet
		24 1/2"
		Exhaust Vent			A
	3/4"	22 1/2"	Exhaust
					B		27 7/8"
			Vent	3/4"		3/4"
			2"
	3/4"					2 1/2"
Figure					C
					C
					L
		24 7/8"				Combusting	24 7/8"
2
						Vent
.
G6RL		7/8" Dia. Electric
	43"					(3" for 80/100	7/8" Dia.
		Connection				2" for 40/60)
							Electric
							Connection
Unit		21 7/8"
		1 1/2" x 3 1/2" Dia.
Dimensions
		Opening for					1 1/2" x 2 1/2"
		Gas Connection					Knockout
							For Gas
							Connection
		21 1/4"	21 1/2"			21 1/2"
			15 1/2"				21 7/8"
		8"			Bottom Supply Air Opening	10 1/4"
					(Side)		19 3/4"
	1"				D
						Condensate
			Condensate				Bottom Opening
						Drain
			Drain			Outlet
			Outlet
5

6

		Heating											External Static Pressure (Inches Water Column)
	Model	Input	Motor	Motor	0.1				0.2			0.3			0.4			0.5			0.6			0.7				0.8
	Number	(Btuh)	High*	HP	1310			-	1260		-	1210		-	1160		45	1100		47	1040		50	980		53	920		56	CAPACITIES
			Speed			CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise
			High*			950		36	920		38	890		39	850		41	800		43	750		46	690		50	630		55
	G6RC040C-08	40,000	Medium	1/5	740			47	710		49	680		51	650		53	600		58	550		63	490		-	430		-
			Low**		620			56	590		59	560		62	520		-	470		-	410		-	350		-	290		-
			High*			1330		-	1280		-	1230		-	1170		-	1120		-	1030		-	940		37	850		41
	G6RC040C-12	40,000	Medium	1/3	1190			-	1160		-	1110		-	1060		-	1010		-	910		38	820		42	720		48
			Low**		830			42	810		43	780		44	760		46	720		48	670		52	610		57	550		63
	G6RC060C-12	60,000	Medium	1/3	1160			45	1120		46	1080		48	1050		49	990		52	940		55	890		58	830		63	—
AirflowFurnace.1 Table																														DataAirflowFurnace
			Med-Low		1440			72	1410		74	1380		75	1320		79	1280		81	1220		85	1150		-	1080		-
			Low**		800			65	780		67	760		68	740		70	710		73	680		-	650		-	620		-
			High*			1490		46	1450		48	1390		50	1310		53	1210		57	1100		63	980		-	830		-
	G6RC080C-12	80,000	Medium	1/3	1230			56	1200		58	1150		60	1080		64	1010		69	910		-	810		-	680		-
			Low**		780			-	750		-	720		-	680		-	630		-	570		-	510		-	440		-
			High*		1840			-	1780		-	1700		41	1630		42	1550		45	1470		47	1380		50	1290		54
	G6RC080C-16	80,000	Med-High	1/2	1600			43	1560		44	1470		47	1400		49	1350		51	1280		54	1210		57	1150		60
			Med-Low**		1380			50	1350		51	1300		53	1250		55	1190		58	1120		62	1040		67	960		-
			Low		1100			-	1050		-	1000		-	950		-	900		-	850		-	800		-	750		-
			High*		1910			45	1860		47	1780		49	1700		51	1620		53	1520		57	1420		61	1310		66
	G6RC100C-16	100,000	Med-High**	1/2	1640			53	1620		53	1540		56	1480		58	1420		61	1340		65	1250		69	1150		75
			Med-Low		1440			60	1410		61	1370		63	1320		66	1270		68	1210		72	1140		-	1060		-
			Low		1230			-	1210		-	1180		-	1140		-	1090		-	1030		-	960		-	880		-
			High*		1860			56	1800		58	1730		60	1650		63	1570		66	1480		70	1380		75	1270		82
	G6RC120C-16	120,000	Med-High**	1/2	1650			63	1610		65	1550		67	1480		70	1410		74	1320		79	1230		84	1120		-
Data			Low		1230			-	1210		-	1180		-	1140		-	1090		-	1030		-	960		-	880		-
			High*		2260			-	2200		-	2140		-	2070		-	1990		-	1910		-	1810		57	1710		61
	G6RC120C-20	120,000	Med-High	3/4	1870			56	1840		56	1790		58	1760		59	1710		61	1660		63	1610		65	1560		67
			Med-Low**		1540			67	1530		68	1510		69	1470		71	1430		73	1370		76	1300		80	1220		85
			Low		1360			-	1330		-	1310		-	1280		-	1250		-	1220		-	1190		-	1150		-
			High*		1050			-	1005		-	960		-	915		-	855		-	800		-	730		48	670		53
	G6RD040C-10	40,000	Medium	1/3	990			-	950		-	905		-	860		-	810		-	760		46	700		50	650		54
			Low**		770			46	740		48	700		50	660		53	625		56	580		61	540		65	500		70
			High*		1175			45	1125		47	1075		49	1030		51	970		54	920		57	860		61	800		66
	G6RD060C-10	60,000	Medium**	1/3	1075			49	1040		51	995		53	950		56	900		59	840		63	790		67	720		73
			Low		800			66	770		69	745		71	710		74	670		-	630		-	580		-	530		-

Data Airflow Furnace .2 Table

	Heating										External Static Pressure (Inches Water Column)
Model	Input	Motor	Motor		0.1		0.2			0.3			0.4			0.5			0.6			0.7				0.8
Number	(Btuh)	Speed	HP	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise	CFM		Rise
		High*		1620		-	1560		45	1490		47	1430		49	1365		52	1300		54	1240		57	1170		60
G6RD080C-14	80,000	Med-High	1/2	1450		49	1400		50	1350		52	1295		54	1240		57	1180		60	1120		63	1060		66
		Med-Low**		1255		56	1225		57	1180		60	1145		61	1105		64	1060		66	1020		69	980		72
		Low		1080		65	1055		67	1030		68	1000		70	960		73	920		-	870		-	820		-
		High*		1620		54	1555		57	1485		59	1425		62	1355		65	1290		68	1220		72	1160		-
G6RD100C-14	100,000	Med-High**	1/2	1430		62	1375		64	1330		66	1265		70	1210		73	1150		-	1080		-	1010		-
		Med-Low		1260		70	1220		72	1170		75	1130		-	1070		-	1010		-	950		-	890		-
		Low		1085		-	1050		-	1015		-	970		-	935		-	890		-	850		-	800		-
		High*		1700		62	1635		65	1565		67	1500		70	1435		74	1370		77	1310		-	1240		-
G6RD120C-14	120,000	Med-High**	1/2	1510		70	1455		73	1405		75	1350		78	1290		-	1230		-	1170		-	1100		-
		Med-Low		1330		79	1280		-	1240		-	1195		-	1145		-	1100		-	1050		-	1000		-
		Low		1140		-	1110		-	1075		-	1040		-	1010		-	980		-	940		-	910		-
		High*		2140		-	2070		-	2010		-	1945		-	1870		56	1800		59	1730		61	1650		64
G6RD120C-19	120,000	Med-High	3/4	1955		-	1900		56	1850		57	1800		59	1740		61	1690		62	1630		65	1570		67
		Med-Low**		1660		64	1620		65	1575		67	1540		69	1495		71	1460		72	1410		75	1370		77
		Low		1450		73	1430		74	1400		75	1360		78	1340		79	1300		81	1270		83	1230		-
		High*		1280		-	1210		-	1180		-	1140		-	1090		-	1070		-	1030		-	990		-
G6RL040C-12	40,000	Medium	1/3	1140		-	1090		-	1060		-	1030		-	980		35	950		36	910		37	870		39
		Low**		875		39	835		41	820		41	805		42	780		43	770		44	760		45	750		45
		High*		1260		40	1190		43	1155		44	1120		45	1075		47	1030		49	980		52	940		54
G6RL060C-12	60,000	Medium	1/3	1120		45	1070		48	1040		49	1010		50	960		53	930		55	890		57	850		60
		Low**		855		59	815		62	800		64	780		65	760		67	730		70	710		-	690		-
		High*		1635		-	1585		-	1525		-	1460		46	1400		48	1330		51	1260		54	1180		57
G6RL080C-16	80,000	Med-High	1/2	1435		47	1395		49	1350		50	1300		52	1255		54	1200		56	1150		59	1090		62
		Med-Low**		1230		55	1200		56	1165		58	1130		60	1090		62	1050		65	1000		68	960		71
		Low		1050		-	1035		-	1010		-	980		-	950		-	910		-	870		-	820		-
		High*		1600		53	1555		54	1500		56	1445		59	1380		61	1310		65	1240		68	1160		73
G6RL100C-16	100,000	Med-High**	1/2	1475		57	1435		59	1385		61	1335		63	1290		66	1240		68	1190		71	1130		75
		Med-Low		1320		-	1290		-	1250		-	1215		-	1170		-	1120		-	1070		-	1020		-
		Low		1150		-	1130		-	1110		-	1075		-	1040		-	1000		-	950		-	890		-

** Factory Set Cooling Speed	NOTES: 1. Airflow rates of 1800 CFM or more require two return air connections. Data is for operation with filter(s).
** Factory Set Heating Speed	2.	Temperature rises in the table are approximate. Actual temperature rises may vary.
- Not Recommended	3.	Temperature rises and airflows for external static pressures greater than 0.5 are for reference only.
		These conditions are not recommended.

7

INSTALLATION REQUIREMENTS

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 (ANSI-Z223.1, NFPA-54). The current revision of the National Fuel Gas Code is available from:

American National Standards Institute, Inc. 1430 Broadway

New York, New York 10018

Canada installations shall comply with CAN/ CGA-B149 installation codes, local plumbing or waste water codes and other applicable codes. 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

! 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.

	Model	Furnace		Dimensions (inches)			Shipping
	Number	Btuh					Weight
			A	B	C	D
							(lbs)
	G6R(C,D)040C	40,000	14 1/4	12 3/4	5 1/8	11 3/4	133
	G6R(C,D)060C	60,000	14 1/4	12 3/4	5 1/8	11 3/4	140
	G6R(C,D)080C	80,000	19 3/4	18 1/4	7 7/8	17 1/4	172
	G6R(C,D)100C	100,000	19 3/4	18 1/4	7 7/8	17 1/4	180
	G6R(C,D)120C	120,000	22 1/2	21	9 1/4	20	204
	G6RL040C	40,000	14 1/4	12 3/4	4 5/8	12 3/4	135
	G6RL060C	60,000	14 1/4	12 3/4	4 5/8	12 3/4	135
	G6RL080C	80,000	19 3/4	18 1/4	10	18 1/4	174
	G6RL100C	100,000	19 3/4	18 1/4	10	18 1/4	185

Table 3. Furnace Dimensions and Shipping Weights

CLEARANCES TO COMBUSTIBLE MATERIALS

This furnace is Designed Certified by AGA/CGA Laboratories for the minimum clearances to combustible material listed in Table 4. See the furnace name plate, located inside the furnace cabinet, for specific model number and clearance information.

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIAL

	Furnace	Cabinet		Minimum Clearances (Inches)
	Input	Width
	(Btuh)	(Inches)	Side	Vent	Back	Top	Front
40,000		14 1/4	0	0	0	1	1*
60,000		14 1/4	0	0	0	1	1*
80,000		14 1/4	0	0	0	1	1*
100,000		19 3/4	0	0	0	1	1*
120,000		22 1/2	0	0	0	1	1*

* 24 inches is the minimum clearance for servicing.

36 inches is the recommended clearance for service.

Table 4. Minimum Clearances to Combustible Materials

8

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 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.

Minimum clearances to combustible materials are listed in Table 4. Access for positioning and servicing must be considered when locating the unit. 24 inches is the minimum required clearance for servicing the unit. 30 inches is the minimum required clearance for positioning the unit. 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. The furnace must be installed on a solid surface and must be level front to back and side to side. This furnace must not be installed directly on carpeting, tile, or any combustible material other than wood flooring.

DOWNFLOW WARNING

(G6RL 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 subbase 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.

A gas-fired furnace installed in a residential garage must be installed so that the bottom of the furnace is located a minimum of 15" from the floor. The furnace must be located or protected to avoid physical damage by vehicles.

HORIZONTAL INSTALLATIONS

The G6RC model furnaces are approved for horizontal installation. Installation Kit #903568 is required for horizontal applications. Follow the installation instructions in the kit for proper conversion. NOTE: The G6RD and G6RL models are NOT approved for horizontal installation.

SUPPLY AIR PLENUM INSTALLATION

A.Installation on a concrete slab - G6RL

1.Construct a hole in the floor per the dimensions in Figure 3.

2.Place the plenum and the furnace as shown in Figure 4.

B.Installation on a combustible floor - G6RL

1.Cut and frame the hole in the floor per the dimensions in Figure 5.

2.Place the 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 ensure 1" clearancetotheflooringorothercombustible material. Place furnace on the combustible base as shown in Figure 6.

3.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 material.

18.75"	13.25"
19.25"	19.25"
Hole in	Hole in
Floor	Floor
G6RL 080/100	G6RL 040/060

Figure 3. Opening for Concrete Slab

9

Concrete	Furnace
Floor
	Sheet
	Metal
	Plenum

Figure 4. Furnace on a Concrete Slab

18.75"	13.25"
19.63"	19.63"
Hole in	Hole in
Floor	Floor
G6RL 080/100	G6RL 040/060

Figure 5. Opening in Wood Floor

Downflow	Furnace	Wood
Sub-base		Floor
	Sheet
	Metal
	Plenum

Figure 6. Furnace on a Wood Floor

CIRCULATING AIR SUPPLY

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).

10

		* Smaller
	18.75"	dimensions for
		G6RL 040/060
	or 13.25"*
		9.25"
				2.0"
	16.75"	28.38"	3 lb density
	or 11.25"*
	1.50"		thick fiberglass	19.63"
		1.58"
			1 inch
	19.75"			3"
	or 14.25"*

Figure 7. Downflow Sub-Base Dimensions

If outside air is utilized as return air to the furnace for ventilation or to improve indoor air quality, the system must be designed so that the return air to the furnace is not less than 50°F (10°C) during heating operation. If a combination of indoor and outdoor air is used, the ducts and damper system 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 airflow over the indoor coil, the coil must be installed downstream (on the outlet side) 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.

! WARNING:

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 conditions including carbon monoxide poisoning that could result in personal injury or death.

All return ductwork must be adequately sealed, all joints must be taped, and the ductwork must be secured to the furnace with sheet metal screws. When return air is provided through the bottom of the furnace, the joint between the furnace and the return air plenum must be sealed.

The floor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps, cracks, or sagging between the furnace and the floor or platform.

Return air and circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert, stove, etc.

Return Air

The return air ductwork may be connected to any or all of the following: left side return, right side return, or bottom return. Tables 1 and 2 show the airflow data for each furnace model.

Where maximum airflow is 1800 CFM or more two openings must be used.

VENTING AND COMBUSTION AIR REQUIREMENTS

NORDYNE condensing furnaces may be installed with outdoor combustion air piped directly to the furnace, or without such special piping. Codes refer to the former as "direct vent" or "two pipe" installation. Installation with air taken from around the furnace is sometimes referred to as "one pipe" installation - i.e. only the vent (exhaust) pipe is provided.

An important consideration in selecting one or two pipe installation is the quality of the combustion air. Indoor air is sometimes contaminated with various household chemicals which can cause severe corrosion in the furnace combustion system. Some common sources of these chemicals are detergents, bleaches, aerosol sprays, and cleaning solvents. Unless indoor air is known to be free of these materials, two pipe installation is recommended.

Provisions must be made for adequate supply of air for combustion and ventilation. For United States installations, the adequacy of air provisions can be determined by consulting the current version of the National Fuel Gas Code (ANSI Z223.1/NPFA-54). For Canadian installations, requirements are specified in the National Standard of Canada (CAN/CGA B149.1 & .2). Consult local codes for special requirements.

NOTE: If the furnace is operated without adequate air for combustion and ventilation, it may not perform properly. Furnace components may be strained by high temperature and could fail prematurely.

! 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.

G6RC/G6RD	Protective Screen
G6RL

Figure 8. Protective Screen for One Pipe Installations

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