Nordyne + RC 92+ User manual

Installation Instructions

These instructions are primarily intended

to assist qualiﬁed individuals experienced

in the proper installation of this appliance.

Some local codes require licensed installa-

tion/service personnel for this type of equip-

ment. Read all instructions carefully before

starting the installation.

DO NOT DESTROY. PLEASE READ CARE-

FULLY AND KEEP IN A SAFE PLACE FOR

FUTURE REFERENCE.

*RC 92+ Upﬂow *RL 90+ Downﬂow

*RC 92+ Full Size Upﬂow Condensing Furnace

*RL 90+ Full Size Downﬂow Condensing Furnace

Gas Furnaces

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 vi-

cinity of this or any other appliance.

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

Furnace Airﬂow Data.......................................................................................................... 6-7

Safety Information ....................................................................................................................... 8

Installation Requirements........................................................................................................... 8

Requirements and Codes...................................................................................................... 8

Location................................................................................................................................. 8

Downﬂow Warning................................................................................................................. 9

Horizontal Installations ........................................................................................................ 10

Supply Air Plenum Installation.................................................................................................11

Installation on a Concrete Slab ........................................................................................... 11

Installation on a Combustible Floor ..................................................................................... 11

Circulating Air Supply............................................................................................................... 11

Return Air ............................................................................................................................ 13

Venting and Combustion Air Requirements ........................................................................... 13

Combustion Air Quality........................................................................................................ 15

Air Requirements for One-Pipe Installation ......................................................................... 15

Installation in An Unconﬁned Space.................................................................................... 15

Installation in A Conﬁned Space ......................................................................................... 15

• Air From Inside .................................................................................................................. 16

• Air Directly Through An Exterior Wall................................................................................ 16

• Outdoor Air Through Vertical Openings or Ducts .............................................................. 17

• Outdoor Air Through Horizontal Openings or Ducts.......................................................... 17

Venting Requirements............................................................................................................... 17

Vent Pipe Material ............................................................................................................... 18

Vent Pipe Length and Diameter........................................................................................... 18

Vent Pipe Installation........................................................................................................... 19

Pipe Routing & Support....................................................................................................... 19

Location of Outdoor Terminations........................................................................................ 20

• Horizontal Venting ............................................................................................................ 20

• Vertical Venting.................................................................................................................. 25

• Vent Freezing Protection ................................................................................................... 26

• Concentric and Side Wall Vent Termination....................................................................... 27

Drainage of Condensate From Furnace ................................................................................. 27

Gas Supply and Piping........................................................................................................ 27

Leak Check ......................................................................................................................... 27

Conversion .......................................................................................................................... 27

High Altitude Application ..................................................................................................... 29

Natural Gas High Altitude Conversion................................................................................. 29

LP/Propane Gas Sea Level and High Altitude Conversion.................................................. 29

Electrical Wiring......................................................................................................................... 31

Line Voltage Wiring.............................................................................................................. 31

Low Voltage Wiring .............................................................................................................. 31

Start-up and Adjustments.................................................................................................... 32-34

Start-Up Procedure .............................................................................................................32

Verifying and Adjusting Firing Rate ..................................................................................... 33

Verifying and Adjusting Temperature Rise........................................................................... 34

Verifying Burner Operation .................................................................................................. 34

Verifying Operation of the Supply Air Limit Switch .............................................................. 34

Description of Components ..................................................................................................... 35

Maintenance............................................................................................................................... 35

Combustion Air and Vent System ........................................................................................ 35

Air Filter(s)........................................................................................................................... 35

Lubrication........................................................................................................................... 35

Condensate Drain Assembly ............................................................................................... 35

Blower Compartment........................................................................................................... 35

Heat Exchanger and Burner Maintenance .......................................................................... 34

Location of Major Components ........................................................................................... 37

System Operation Information................................................................................................. 38

Sequence of Operation ....................................................................................................... 38

Furnace Fails to Operate..................................................................................................... 39

Twinning of Two Furnaces ................................................................................................... 39

Installation/Performance Checklist.......................................................................................... 40

FURNACE SPECIFICATIONS

7/8" Dia. Electric

Connection

2 1/4"

23 1/4"

19 3/4"

3/4"

43"

25 1/8"

25 1/4"

23"

28"

15"

25 1/4"

33"

Return Air Opening

(Bottom)

Side Return Bottom Return Opening

Condensate Drain Outlets

A‡

B‡

Combustion Air

Vent 3"

(See Fig. 15

for sizes)

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

Opening for

Gas Connection

3/4" 3/4"

3/4"

22 1/2"

Exhaust Vent

Combustion Air

Inlet

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

Opening for

Gas Connection

‡

2" PVC

Exhaust

Vent

(See Fig. 15

for sizes)

25 5/8"

20 1/2"

23"

7/8" Dia. Electric

Connection

30 1/4"

1 1/4"

1" D

‡

27 5/8"

Upﬂow *RC Furnaces

Figure 1. Upﬂow Unit Dimensions

‡See Table 3

7/8" Dia. Electric

Connection

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

Opening for

Gas Connection

27 7/8"

24 1/2"

22 1/2" 3/4"

3/4"

43"

Exhaust Vent

2" Dia.

1 1/2" x 2 1/2"

Knockout For

Gas Connection

21 7/8"

15 1/2"

21 1/2"

21 7/8"

3/4"

Bottom Supply

Air Opening

24 7/8"

Combustion Air Inlet

Exhaust Vent

21 1/4"

Condensate

Drain Outlet

Condensate

Drain Outlet

7/8" Dia. Electric

Connection

21 1/2"

24 7/8"

10 1/4"

2 1/2"

Combustion

Vent

(3" for 80/100

2" for 40/60)

19 3/4"

3/4"

Bottom Opening

19 3/4"

‡

Downﬂow *RL Furnace

Figure 2. Downﬂow Unit Dimensions

‡See Table 3

Table 1. Furnace Airﬂow Data

CAPACITIES —Furnace Airﬂow Data

NOTES: 1. Airﬂow rates of 1800 CFM or more require two return air connections. Data is for operation with ﬁlter(s).

2. Temperature rises in the table are approximate. Actual temperature rises may vary.

3. Temperature rises and airﬂows for external static pressures greater than 0.5 are for reference only.

These conditions are not recommended.

( ) Can be C or N

** Factory Set Cooling Speed

** Factory Set Heating Speed

- Not Recommended

G6RC UPFLOW FURNACE

Model Heating External Static Pressure (Inches Water Column)

Number Input Motor Motor 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

*RC- (Btuh) Speed HP 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

040( )-08A 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

040( )-12A 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

High* 1310 - 1260 - 1210 - 1160 45 1100 47 1040 50 980 53 920 56

060( )-12A 60,000 Medium** 1/3 1160 45 1120 46 1080 48 1050 49 990 52 940 55 890 58 830 63

Low 800 65 780 67 760 68 740 70 710 73 680 - 650 - 620 -

High* 1775 38 1724 39 1652 40 1583 42 1505 44 1430 46 1343 49 1226 54

080( )-12B 80,000 Med-High** 1/2 1417 47 1385 48 1339 50 1280 52 1224 54 1163 57 1097 61 1013 66

Med-Low 1031 65 987 67 967 69 914 73 882 75 839 - 783 - 692 -

Low 808 - 751 - 717 - 679 - 641 - 595 - 538 - 430 -

High* 1840 - 1780 - 1700 41 1630 42 1550 45 1470 47 1380 50 1290 54

080( )-16B 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 63 1050 66 1000 69 950 - 900 - 850 - 800 - 750 -

High* 2215 30 2155 31 2090 32 2030 33 1975 34 1885 35 1810 37 1730 39

080( )-20B 80,000 Med-High 3/4 2000 33 1970 34 1930 35 1870 36 1820 37 1755 38 1695 39 1625 41

Med-Low 1670 39 1665 40 1660 41 1630 41 1590 42 1535 43 1470 45 1410 47

Low** 1365 48 1360 49 1350 49 1340 50 1305 51 1300 51 1255 53 1225 54

High* 1910 45 1860 47 1780 49 1700 51 1620 53 1520 57 1420 61 1310 66

100( )-16B 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 70 1210 72 1180 73 1140 - 1090 - 1030 - 960 - 880 -

High* 2195 39 2140 40 2065 41 2000 42 1960 44 1860 46 1780 48 1695 50

100( )-20B 100,000 Med-High** 3/4 1975 43 1910 44 1875 45 1845 46 1805 47 1735 50 1670 51 1590 53

Med-Low 1650 51 1615 52 1605 53 1570 54 1540 55 1485 57 1435 59 1370 62

Low 1320 64 1300 65 1280 66 1275 67 1265 67 1250 68 1210 70 1160 73

High* 1860 56 1800 58 1730 60 1650 63 1570 66 1480 70 1380 75 1270 82

120( )-16C 120,000 Med-High** 1/2 1650 63 1610 65 1550 67 1480 70 1410 74 1320 79 1230 84 1120 -

Med-Low 1440 72 1410 74 1380 75 1320 79 1280 81 1220 85 1150 - 1080 -

Low 1230 84 1210 - 1180 - 1140 - 1090 - 1030 - 960 - 880 -

High* 2260 - 2200 - 2140 - 2070 - 1990 - 1910 - 1810 57 1710 61

120( )-20C 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 76 1330 78 1310 79 1280 81 1250 83 1220 85 1190 - 1150 -

Table 2. Furnace Airﬂow Data

CAPACITIES —Furnace Airﬂow Data continued

Model Heating External Static Pressure (Inches Water Column)

Number Input Motor Motor 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

*RL- (Btuh) Speed HP CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

High* 1280 - 1210 - 1180 - 1140 - 1090 - 1070 - 1030 - 990 -

040()-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

060()-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

080()-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

100()-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 -

High* 2085 48 2035 49 1965 51 1910 52 1840 54 1780 56 1715 58 1630 61

120()-20 100,000 Med-High** 3/4 1925 52 1885 53 1835 55 1780 56 1730 58 1675 60 1615 62 1540 65

Med-Low 1720 58 1670 60 1630 61 1610 63 1570 64 1510 66 1465 68 1415 72

Low 1500 66 1495 69 1460 66 1430 70 1400 72 1365 73 1315 - 1265 -

( ) Can be C or N

* Factory Set Cooling Speed

** Factory Set Heating Speed

- Not Recommended

1. Airﬂow rates of 1800 CFM or more require two return air connections.

Data is for operation with ﬁlter(s).

2. Temperature rises in the table are approximate. Actual temperature rises may vary.

3. Temperature rises and airﬂows for external static pressures greater than 0.5 are for reference only.

These conditions are not recommended.

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 4 of these

instructions.

3. Provide adequate combustion and ventila-

tion air to the furnace space as speciﬁed

on Pages 13 through 16.

4. Provide adequate clearances around the

vent air intake terminal(s) as speciﬁed on

Figures 18 through 23 of these instruc-

tions.

5. Combustion products must be discharged

outdoors. Connect this furnace to an ap-

proved vent system only, as speciﬁed on

Pages 16 through 26.

6. 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 28 of these instructions.

7. 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 onTable 2 of these instructions.

See furnace rating plate.

8. 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.

9. A gas-ﬁred furnace for installation in a resi-

dential garage must be installed as speciﬁed

on Page 10 of these instructions.

10. The furnace is not to be used for temporary

heating of buildings or structures under

construction.

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 instal-

lation in mobile homes. Installation in a

mobile home could cause ﬁre,property

damage, and/or personal injury.

IMPORTANT NOTE

The Commonwealth of Massachusetts requires

compliance with regulation 248 CMR 4.00 and

5.00 for installation of through – the – wall vent-

ed gas appliances as follows:

(a) For direct-vent appliances, mechanical-

vent heating appliances or domestic hot

water equipment, where the bottom of the

vent terminal and the air intake is installed

below four feet above grade the following

requirements must be satisﬁed:

1. If there is not one already present,

on each ﬂoor level where there are

bedroom(s), a carbon monoxide detec-

tor and alarm shall be placed in the liv-

ing area outside the bedroom(s). The

carbon monoxide detector shall comply

with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall be

located in the room that houses the ap-

pliance or equipment and shall:

a. Be powered by the same electrical

circuit as the appliance or equipment

such that only one service switch

Table 3. Furnace Dimensions and Shipping Weights

Table 4. Minimum Clearances to Combustible Materials

CLEARANCES TO COMBUSTIBLE MATERIALS

This furnace is Designed Certiﬁed by CSA International for the minimum clearances to combus-

tible material listed in Table 4. See the furnace name plate, located inside the furnace cabinet, for

speciﬁc model number and clearance information.

services both the appliance and the

carbon monoxide detector;

b. Have battery back-up power;

c. Meet ANSI/UL 2034 Standards

and comply with NFPA 720 (2005

Edition);and

d. Have been approved and listed by

a Nationally Recognized Testing

Laboratory as recognized under 527

CMR.

3. A Product-approved vent terminal must

be used, and if applicable, a Product-

approved air intake must be used. In-

stallation shall be in strict compliance

with the manufacturer’s instructions. A

copy of the installation instructions shall

remain with the appliance or equipment

at the completion of the installation.

4. A metal or plastic identiﬁcation plate

shall be mounted at the exterior of the

building, four feet directly above the lo-

cation of vent terminal. The plate shall

be of sufﬁcient size to be easily read

from a distance of eight feet away, and

read “Gas Vent Directly Below”.

Model

Number

Furnace

Btuh

Dimensions (inches) Shipping

Weight

(lbs

)

ABCD

*RC040 40,000 14 1/4 12 3/4 5 1/8 11 3/4 133

*RC060 60,000 14 1/4 12 3/4 5 1/8 11 3/4 140

*RC080 80,000 19 3/4 18 1/4 7 7/8 17 1/4 172

*RC100 100,000 19 3/4 18 1/4 7 7/8 17 1/4 180

*RC120 120,000 22 1/2 21 9 1/4 20 204

*RL040 40,000 14 1/4 12 3/4 4 5/8 12 3/4 135

*RL060 60,000 14 1/4 12 3/4 4 5/8 12 3/4 135

*RL080 80,000 19 3/4 18 1/4 10 18 1/4 174

*RL100 100,000 19 3/4 18 1/4 10 18 1/4 185

*RL120 120,000 22 1/2 21 12 1/2 21 1/8 209

MINIMUM CLEARANCES TO COMBUSTIBLE MATERIAL

Furnace Cabinet Minimum Clearances (Inches)

Input Width

(Btuh) (Inches) Side Vent Back Top Front

40,000 14 1/4 00011*

60,000 14 1/4 00011*

80,000 14 1/4 00011*

100,000 19 3/4 00011*

120,000 22 1/2 00011*

* When installed horizontally, 24 inches is required for servicing.

(b) For direct-vent appliances, mechanical-

vent heating appliances or domestic hot

water equipment where the bottom of the

vent terminal and the air intake is installed

above four feet above grade the following

requirements must be satisﬁed:

1. If there is not one already present,

on each ﬂoor level where there are

bedroom(s), a carbon monoxide detec-

tor and alarm shall be placed in the liv-

ing area outside the bedroom(s). The

carbon monoxide detector shall comply

with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall:

a. Be located in the room that houses

the appliance or equipment;

b. Be either hard-wired or battery pow-

ered or both; and

c. Shall comply with NFPA 720 (2005

Edition).

3. A Product-approved vent terminal must

be used, and if applicable, a Product-

approved air intake must be used. In-

stallation shall be in strict compliance

with the manufacturer’s instructions. A

copy of the installation instructions shall

remain with the appliance or equipment

at the completion of the installation.

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 di-

mensions 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. Twenty four inches is the minimum required

clearance for servicing the unit. Thirty inches is

the minimum required clearance for positioning

the unit. Thirty six 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 satis-

ﬁed, 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

(*RL 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 fac-

tory supplied accessories, part number 902974,

902677, 904108 and 904165. Part #904108 is

an adjustable sub-base kit and it can be used on

all cabinet sizes. 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 ga-

rage must be installed so that the burners and the

ignition source are located a minimum of 18”from

the ﬂoor.The furnace must be located or protected

to avoid physical damage by vehicles.

HORIZONTAL INSTALLATIONS

The upﬂow model furnaces are approved for

horizontal installation. Installation Kit #903568

is available for horizontal applications. The

parts may also be ﬁeld supplied. NOTE: Down-

ﬂow models are NOT approved for horizontal

installation.

CAUTION:

Damage to the product resulting

from failure to follow instructions or

use of unauthorized parts may void

the manufacturer’s product warranty

coverage.

The 90+ upﬂow furnace can be installed hori-

zontally in an attic, basement, crawl space or

alcove.This furnace can be installed horizontally

to the clearances listed in Table 4 on a platform

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