Nordyne 072C-16 User manual

Installation Instructions

Do not store or use gasoline

or other flammable vapors

and liquids in the vicinity of

this or any other appliance.

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

FOR YOUR SAFETY

WARNING:

Improper installation,

adjustment, alteration,

service, or maintenance can

cause injury or property

damage. Refer to this

manual. For assistance or

additional information

consult a qualified installer,

service agency, or the gas

supplier.

These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this

appliance. Some local codes require licensed installation/service personnel for this type of equipment. Read all

instructions carefully before starting the installation.

FOR YOUR SAFETY

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.

80+ High Efficiency Upflow/Horizontal and Downflow

with Variable Speed Blower

Residential Gas Furnaces

*RK 80+ Downflow

*RA 80+ Upflow

Table of Contents

Furnace Specifications ....................................................................................................................................................... 4-5

Unit Dimensions and Shipping Weights ....................................................................................................... 4-5

Capacities-Furnace Airflow Data ..................................................................................................................... 6

Safety Information ............................................................................................................................................ 7

Installation Requirements ..................................................................................................................................................... 7

Requirements and Codes ................................................................................................................................ 7

Location............................................................................................................................................................ 7

Clearances to Combustibles ........................................................................................................................... 7

Venting and Combustion Air Requirements ................................................................................................................... 8-13

General ............................................................................................................................................................ 8

Installation in an Unconfined Space ................................................................................................................ 8

Installation in a Confined Space ...................................................................................................................... 8

Horizontal Furnace Installation ........................................................................................................... 10

Air From Inside .................................................................................................................................... 11

Outdoor Air Using Vertical Ducts ........................................................................................................ 12

Air Directly Through an Exterior Wall ................................................................................................. 12

Outdoor Air Using A Crawl Space and Ventilated Attic ...................................................................... 12

Outdoor Air Through Horizontal Ducts ............................................................................................... 12

Venting Requirements .................................................................................................................................................... 13-19

General .......................................................................................................................................................... 13

Category I - Common Venting ....................................................................................................................... 13

Category III - Horizontal Venting .................................................................................................................... 15

Horizontal Venting for Upflow Models ................................................................................................ 15

Horizontal Power Venting ................................................................................................................... 17

Location of Outdoor Terminations ................................................................................................................. 17

Horizontal Installation ......................................................................................................................... 17

Flexible Vent Systems .................................................................................................................................... 19

Circulating Air Supply ..................................................................................................................................................... 19-20

General .......................................................................................................................................................... 19

Return Air ....................................................................................................................................................... 19

Gas Supply and Piping .................................................................................................................................................... 20-22

General .......................................................................................................................................................... 20

Leak Check .................................................................................................................................................... 21

Conversion ..................................................................................................................................................... 21

High-Altitude Application ............................................................................................................................... 21

Natural Gas High Altitude Conversion .......................................................................................................... 22

LP/Propane Gas Sea Level and High Altitude Conversion .......................................................................... 22

Electrical Wiring .............................................................................................................................................................. 22-24

General .......................................................................................................................................................... 22

Line Voltage Wiring ........................................................................................................................................ 23

Low Voltage Wiring ........................................................................................................................................ 24

Start-up & Adjustments ....................................................................................................................................................... 24

General .......................................................................................................................................................... 24

Start-Up Procedures ...................................................................................................................................... 24

Verifying and Adjusting Firing Rate ............................................................................................................... 24

Configuring the Blower .................................................................................................................................. 25

Selecting Airflow ............................................................................................................................................ 25

Verifying and Adjusting Temperature Rise .................................................................................................... 26

Verifying Burner Operation ............................................................................................................................ 27

Verifying Operation of Supply Air Limit Switch .............................................................................................. 27

Description of Components ................................................................................................................................................ 28

Wiring Diagram ..................................................................................................................................................................... 30

Maintenance .................................................................................................................................................................... 29-31

Vent System ................................................................................................................................................... 29

Air Filter(s) ...................................................................................................................................................... 29

Lubrication ..................................................................................................................................................... 29

Blower Compartment ..................................................................................................................................... 29

Heat Exchanger and Burner Maintenance .................................................................................................... 29

Cleaning of Flue Passages ............................................................................................................................ 31

Installation/Performance Checklist .................................................................................................................... Back Cover

Unit Shown in Upflow

Position Rotate 90˚

Clockwise or Counter

Clockwise for Horizontal

Application

23 3/4

19 3/4

3/4

25 1/8

25 1/425 5/8

27 5/8

15 20 1/2

251/4

301/4

FLUE

OUTLET

11/2 X 31/2 Cut-out for

Gas Connection

3/4 3/4

1/4

3/4

7/8 Cut-out for Electric

Connection

11/2 X 31/2 Cut-out for

Gas Connection

7/8 Cut-out for

Electric Connection

Return

Air Opening

(Side)

1 1/4 1 1/4D 23

Return Air Opening

(Bottom)

7/8

FURNACE SPECIFICATIONS - Upflow/Horizontal Models

Figure 1a. Upflow Unit Dimensions

Table 1a. Upflow Furnace Dimensions and Shipping Weights

Furnace Dimensions Shipping

Model Input A B C Flue Outlet Weight D

*RA (Btuh) (in.) (in.) (in.) (in.) (lbs) (IN.)

072C-16 72,000 19 3/4 18 1/4 3 3/4 4 152 17 1/4

096C-12 96,000 19 3/4 18 1/4 3 3/4 4 163 17 1/4

096C-16 96,000 19 3/4 18 1/4 3 3/4 4 163 17 1/4

096C-20 96,000 22 1/2 21 3 3/4 4 174 20

120C-16 120,000 19 3/4 18 1/4 3 3/4 4 174 17 1/4

120C-20 120,000 22 1/2 21 3 3/4 4 182 20

144C-20 144,000 22 1/2 21 4 1/4 5 194 20

FURNACE DIMENSIONS AND

SHIPPING WEIGHTS

FURNACE SPECIFICATIONS - Downflow Models

Figure 1B. Downflow Unit Dimensions

Cut-out for Electric

Connection

Both sides

Cut-out for Gas Connection

1-1/2 x 3-1/2 (both sides)

27 7/8"

3/4"

23 5/8"

19 3/4" 3/4"

3/4"

43"

4" Dia. Vent

Cut - out for

Gas Connection

25"

15 1/2"

27 1/8"

25"

3/4"

(Bottom Opening)

10 1/4"

24 1/2"

19 3/4"

Table 1B. Downflow Furnace Dimensions and Shipping Weights

Model Furnace Shipping

Number Input A B C Weights

*RK (Btuh) inches inches inches (lbs)

060C-12 60,000 14 1/4 12 3/4 5 1/2 134

072C-12 72,000 14 1/4 12 3/4 5 1/2 135

072C-16 72,000 19 3/4 18 1/4 11 147

096C-12 96,000 19 3/4 18 1/4 11 154

096C-16 96,000 19 3/4 18 1/4 11 156

120C-20 120,000 19 3/4 18 1/4 11 182

DOWNFLOW FURNACE MODELS

FURNACE DIMENSIONS AND

SHIPPING WEIGHTS

D ime nsions

CAPACITIES —Furnace Airflow Data

720 900 1056 1200 1350 1500 1656 1800

72,000 59 51 44

90,000 63 55 49 44

96,000 67 59 53 47

108,000 67 59 53 48

120,000 66 59 54 49

126,000 69 62 56 51

144,000 71 64 59

80,000 67 59 52 47

100,000 73 65 59 53 49

120,000 71 64 59

Temperature Rise °F (Recommended settings are Bold)

Nominal Air-Flo

80+%92+%

Switches

Table 2. Heating Airflow Settings

NOTE: 0 = OFF 1 = ON

Nominal A/C and HP

LOW HIGH 1 2 3 4

567

Capacity

500 720 0 0 0 1

550 800 0 0 0 0

610 880 0 0 1 0

650 945 1 0 0 1

72010501000

80011551010

90013050101

1000 1450 0 1 0 0

1060 1530 1 1 0 1

1100 1595 0 1 1 0

1170 1700 1 1 0 0

1290 1870 1 1 1 0

CFM SWITCH NUMBER

2 TON

3.5 TON

4 TON

5 TON

3 TON

2.5 TON

Table 1. Cooling/Heat Pump Airflow Settings

NOTE: 0 = OFF 1 = ON

Notes:

1. Recommended temperature rises are highlighted in bold.

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

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

4. Temperature rises that are shaded grey are for reference only. These conditions are not recommended.

5. For single stage cooling, the indoor blower will operate at the CFM listed in the high column.

SAFETY INFORMATION

1. Use only with type of gas approved for this furnace.

Refer to the furnace rating plate.

2. Install this furnace only in a location and position as

specified on Table 3 of these instructions.

3. Provide adequate combustion and ventilation air to the

furnace space as specified on Pages 11 through 14.

4. Combustion products must be discharged outdoors.

Connect this furnace to an approved vent system only,

as specified on Pages 13 through 14.

5. Never test for gas leaks with an open flame. Use a

commercially available soap solution made specifi-

cally for the detection of leaks to check all connections,

as specified on Page 17 of these instructions.

6. Always install furnace to operate within the furnace’s

intended temperature-rise range with a duct system

which has an external static pressure within the allow-

able range, as specified on Table 2 of these instruc-

tions. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry

air circulated by the furnace to areas outside the space

containing the furnace, the return air shall also be

handled by duct(s) sealed to the furnace casing and

terminating outside the space containing the furnace.

8. A gas-fired furnace for installation in a residential

garage must be installed as specified on Page 6 of

these instructions.

9. The furnace is not to be used for temporary heating of

buildings or structures under construction.

INSTALLATION REQUIREMENTS

Requirements and Codes

This furnace must be installed in accordance with these

instructions, all applicable local building codes, current

revision of the National Fuel Gas Code (ANSI-Z223.1), and

in Canada with the CAN/CGA - B149 installation code. The

current revision of the National Fuel Gas Code is available

from:

American National Standards Institute, Inc.

1430 Broadway

New York, New York 10018

Additional helpful publications are:

NFPA-90A - Installation of

Air Conditioning and Ventilating Systems

NFPA-90B - Warm Air Heating

and Air Conditioning Systems

These publications are available from:

National Fire Protection Association, Inc.

Batterymarch Park

Quincy, Massachusetts 02269

!WARNING:

This furnace is not approved for installation in

mobile homes. Installation in a mobile home

could cause fire, property damage, and/or

personal injury.

Location

Upflow gas furnaces are shipped ready for installation in the

upflow or horizontal right or left positions. The furnace must

be installed on a level surface, located as close to the vent

(or chimney) and as close to the center of the air distribution

system as possible. See Table 1 for overall dimensions

todetermine therequired clearancesin hallways,doorways,

stairs, etc. to allow the furnace to be moved to the

installation point. The furnace must be installed so that all

electricalcomponents areprotected fromwater. The furnace

must be installed upstream from a refrigeration system.

This furnace is not to be used for temporary heating of

buildings or structures under construction.

Clearances to Combustibles

This furnace is Design Certified by CSA International for

the minimum clearances to combustible material listed in

Table 3. Refer to the furnace rating plate, located inside of

the furnace cabinet, for the specific model number and

clearance information.

Access for positioning and servicing the unit must be

considered when locating unit. 24 inches is the minimum

required clearance from the front of the unit for servicing

it. 30 inches is the minimum required clearance from the

front of the unit for positioning it. 36 inches is the

recommended clearance from the front of the unit.

Please note that a panel or door can be located such that

the minimum clearance on the rating plate is satisfied, but

that panel or door must be removable and allow the

appropriate clearance for your installation.

This furnace is certified for use on wood flooring. This

furnace must not be installed directly on carpeting, tile, or

any combustible material other than wood flooring.

A gas-fired furnace installed in a residential garage must be

installed so the burners and the igniter are located not less

than 18 inches (457 mm) above the floor, and the furnace

must be located or protected to avoid physical damage by

vehicles.

3. The following types of installation may require Outdoor

Air for combustion, due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces installed in hobby or craft rooms

• Furnaces installed near chemical storage areas

Exposure to the following substances in the combus-

tion air supply may also require Outdoor Air for

combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

!WARNING:

Furnace installation using methods other than

those described in the following sections must

comply with the National Fuel Gas Code and all

applicable local codes to provide sufficient

combustion air for the furnace.

Installation In An Unconfined Space

An unconfined space is an area including all rooms not

separated by doors with a volume greater than 50 cubic feet

per 1,000 Btuh of the combined input rates of all appliances

which draw combustion air from that space.

For example, a space including a water heater rated at

45,000 Btuh input and a furnace rated at 75,000 Btuh

requires a volume of 6,000 cubic feet [50 x (45 + 75) =

6,000] to be considered unconfined. If the space has an 8

foot ceiling, the floor area of the space must be 750 square

feet (6,000 / 8 = 750). In general, a furnace installed in an

unconfined space will not require outside air for combustion.

However, in “tight” buildings (with weather stripping and

caulk to reduce infiltration), it may be necessary to provide

outside air to ensure adequate combustion and venting,

even though the furnace is located in an unconfined space.

Installation In A Confined Space

A confined space is an area with volume less than 50 cubic

feet per 1,000 Btuh of the combined input rates of all

!WARNING:

Do not place combustible material on or against

the furnace cabinet or within 6 inches of the vent

pipe. Do not place combustible materials,

including gasoline and any other flammable

vapors and liquids, in the vicinity of the furnace.

VENTING AND COMBUSTION

AIR REQUIREMENTS

General

Provisions must be made in the installation of this furnace

toprovide anadequatesupply ofair for combustion. Detailed

instructions for determining the adequacy of an installation

can be found in the current revision of the National Fuel Gas

Code(ANSI Z223.1/ NFPA54) or in applicable local building

codes. Consult local codes for special requirements.

For Canadian installations consult Canadian Installations

Codes and (CAN/CGA B149.1 or .2).If the furnace is

operated with inadequate air for combustion

one of the flame roll-out switches located in the burner

compartment or the vent switch will open, turning off the

gas supply to the burners. These safety devices are

manually reset switches. DO NOT install jumper wires

across these switches to defeat their function. DO NOT

reset a switch without identifying and correcting the fault

condition. If a switch must be replaced, use only the

correct part specified in the Replacement Parts List.

Air openings in the furnace door, warm air registers, and

return air grilles must not be restricted.

!CAUTION:

Combustion air must not be drawn from a

corrosive atmosphere.

To maximize heat exchanger life, the combustion air must

befree ofchemicals whichform corrosiveacidic compounds

in the combustion gases.

Combustion Air Quality

The recommended source of combustion air is to use the

outdoor air supply. However, the use of indoor air in most

applications is acceptable except as follows:

1. If the furnace is installed in a confined space it is

recommended that the necessary combustion air come

from the outdoors by way of attic, crawl space, air duct,

or direct opening.

2. If outdoor combustion air is used, there must be no

exposure to the installations or substances listed in

Item 3 below.

appliancesdrawing combustionairfrom thatspace. Furnace

closets, small equipment rooms and garages are confined

spaces. Furnaces installed in a confined space which

supply heated air to areas outside the space must draw

return air from outside the space and must have the return

air ducts tightly sealed to the furnace. A confined space

must have two openings into the space for combustion

air. One opening must be within 12 inches of the

ceiling, and the other must be within 12 inches of the

floor. The required sizing of these openings is determined

by whether inside or outside air is used to support

combustion, the method by which the air is brought to the

space, and by the total input rate of all appliances in the

space.

Downflow Warning (*RK Models):

The design of the downflow furnace is certified for natural

or propane gas and for installation on non-combustible

flooring. A special combustible floor sub-base is required

when installing on a combustible floor. Failure to install the

sub-base may result in fire, property damage and personal

injury. The special downflow sub-bases are factory sup-

plied 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. How-

ever, the plenum attached to the coil casing must be

installed such that its surfaces are at least 1" from

combustible construction.

CAUTION:

The downflow sub-base must not be installed

directly on carpeting, tile, or any combustible

material other than wood flooring.

A gas-fired furnace installed in a residential garage must be

installed so the burners and the igniter are located not less

than 18 inches (457 mm) above the floor, and the furnace

must be located or protected to avoid physical damage by

vehicles.

!WARNING:

Do not place combustible material on or against

the furnace cabinet or within 6 inches of the

vent pipe. Do not place combustible materials,

including gasoline and any other flammable

vapors and liquids, in the vicinity of the furnace.

Figure 2. Horizontal installation on a Platform

Gas Inlet

Electrical

Supply

Connection

Coil Plenum

Type “B” Vent

Combustible

Platform

Louver Door

Note: Line

Contact is Permissible

Supply Air Plenum Installation

A. Installation on a concrete slab. - *RK

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

Figure 2.

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

B. Installation on a combustible floor. - *RK

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

in Figure 4.

2. Place sub-base for combustible floors over the hole

with its duct collar extended downward. Attach the

supply air plenum to the base in a manner which will

assure 1" clearance to the flooring or other combus-

tible construction. Place furnace on the combustible

base as shown in Figure 6.

3. When a factory or site built cased coil is provided

beneath the furnace the sub-base for combustible

floors is not necessary. However, the plenum at-

tached to the cased coil must be installed such that its

surfaces are at least 1" from the flooring or other

combustible construction.

Horizontal Furnace Installation

This furnace can be installed horizontally in an attic,

basement, crawl space or alcove. It can be suspended

from a ceiling in a basement or utility room in either a right

to left airflow or left to right airflow. (See Figure 2.)

If the furnace is to be suspended from the ceiling, it will be

necessary to use steel straps around each end of the

furnace. These straps should be attached to the furnace

with sheet metal screws and to the rafters with bolts. The

furnace could also be suspended by an angle iron frame

bolted to the rafters.

Table 3. Minimum Clearances to Combustible Material

LEFT

SIDE

BOTTOM

TOP

RIGHT

SIDE

DOWNFLOW APPLICATION

Downflow Furnace Models

* For Downflow furnace installations only,

right side minimum clearance is 0".

** For Downflow furnace installations only,

furnace must be installed on non-

combustible flooring.

*** Allow 24" minimum clearance for servicing.

The recommended clearance is 36".

Vent Connector

Type

Standard Single

Wall Metal Vent

Type B-1 Double

Wall Metal Vent

LEFT SIDE

0" 0"

RIGHT SIDE

5"* 0"

VENT

6" 1"

BACK

0" 0"

BOTTOM

0"** 0"**

TOP

1" 1"

FRONT

4"*** 4"***

UPFLOW/DOWNFLOW INSTALLATION CLEARANCES

LEFT

SIDE

RIGHT

SIDE

Upflow Furnace Models

BOTTOM

UPFLOW APPLICATION

TOP

*** Allow 24" minimum clearance for servicing. The

recommended clearance is 36".

TOP

RIGHT

SIDE

HORIZONTAL APPLICATION

BOTTOM

Vent Connector

Type

Standard Single

Wall Metal Vent

Type B-1 Double

Wall Metal Vent

LEFT SIDE

1" 1"

RIGHT SIDE

0" 0"

VENT

6" 1"

BACK

0" 0"

BOTTOM

0" 0"

TOP

5" 0"

FRONT

4"*** 4"***

HORIZONTAL INSTALLATION CLEARANCES

LEFT

SIDE

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