Nordyne G6RC 90+ 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.

G6RC 90+, G6RD 93+ Upflow G6RL 90+ Downflow

G6RC Series 90+ Upflow Condensing Furnace

G6RD Series 93+ Upflow Condensing Furnace

G6RL Series 90+ Downflow Condensing Furnace

Residential Gas Furnaces

!WARNING:

Improper installation, adjustment, al-

teration, service, or maintenance can

cause injury or property damage. Re-

fer to this manual for assistance. For

additionalinformationconsultaquali-

fied 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:

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Donottouchanyelectricalswitch;do

not use any phone in your building.

• Immediately call your gas supplier

from a neighbor's phone. Follow the

gas supplier's instructions.

• Ifyoucannotreachyourgassupplier,

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

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)

Return Air Opening

(Side)

Bottom Return Opening

Condensate Drain Outlets

Combustion Air

Vent

(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 G6RC & G6RD Furnaces

Figure 1. G6RC, G6RD Unit Dimensions

3/4" 3/4"

2 1/2"

Combusting

Vent

(3" for 80/100

2" for 40/60)

Condensate

Drain

Outlet

Condensate

Drain

Outlet

7/8" Dia.

Electric

Connection

1 1/2" x 2 1/2"

Knockout

For Gas

Connection

Bottom Opening

27 7/8"

19 3/4"

7/8" Dia. Electric

Connection

24 1/2"

3/4"

43"

21 7/8"

21 1/2"

15 1/2" 21 1/2"

10 1/4"

Bottom Supply Air Opening

(Side)

Exhaust

Vent

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

Opening for

Gas Connection

3/4"

22 1/2"

Exhaust Vent

Combustion Air Inlet

24 7/8" 24 7/8"

21 7/8"

21 1/4"

Downflow G6RL Furnace

Figure 2. G6RL Unit Dimensions

6Table 1. Furnace Airflow Data

CAPACITIES —Furnace Airflow Data

External Static Pressure (Inches WaterColumn)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

950 36 920 38 890 39 850 41 800 43 750 46 690 50 630 55

740 47 710 49 680 51 650 53 600 58 550 63 490 - 430 -

620 56 590 59 560 62 520 - 470 - 410 - 350 - 290 -

1330 - 1280 - 1230 -

1170

- 1120 - 1030 - 940 37 850 41

1190 - 1160 - 1110 -

1060

- 1010 - 910 38 820 42 720 48

830 42 810 43 780 44 760 46 720 48 670 52 610 57 550 63

1310 - 1260 - 1210 -

1160

45 1100 47 1040 50 980 53 920 56

1160 45 1120 46 1080 48

1050

49 990 52 940 55 890 58 830 63

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

1490 46 1450 48 1390 50

1310

53 1210 57 1100 63 980 - 830 -

1230 56 1200 58 1150 60

1080

64 1010 69 910 - 810 - 680 -

780 - 750 - 720 - 680 - 630 - 570 - 510 - 440 -

1840 - 1780 - 1700 41

1630

42 1550 45 1470 47 1380 50 1290 54

1600 43 1560 44 1470 47

1400

49 1350 51 1280 54 1210 57 1150 60

1380 50 1350 51 1300 53

1250

55 1190 58 1120 62 1040 67 960 -

1100 - 1050 - 1000 - 950 - 900 - 850 - 800 - 750 -

1910 45 1860 47 1780 49

1700

51 1620 53 1520 57 1420 61 1310 66

1640 53 1620 53 1540 56

1480

58 1420 61 1340 65 1250 69 1150 75

1440 60 1410 61 1370 63

1320

66 1270 68 1210 72 1140 - 1060 -

1230 - 1210 - 1180 -

1140

- 1090 - 1030 - 960 - 880 -

1860 56 1800 58 1730 60

1650

63 1570 66 1480 70 1380 75 1270 82

1650 63 1610 65 1550 67

1480

70 1410 74 1320 79 1230 84 1120 -

1440 72 1410 74 1380 75

1320

79 1280 81 1220 85 1150 - 1080 -

1230 - 1210 - 1180 -

1140

- 1090 - 1030 - 960 - 880 -

2260 - 2200 - 2140 -

2070

- 1990 - 1910 - 1810 57 1710 61

1870 56 1840 56 1790 58

1760

59 1710 61 1660 63 1610 65 1560 67

1540 67 1530 68 1510 69

1470

71 1430 73 1370 76 1300 80 1220 85

1360 - 1330 - 1310 -

1280

- 1250 - 1220 - 1190 - 1150 -

1050 - 1005 - 960 - 915 - 855 - 800 - 730 48 670 53

990 - 950 - 905 - 860 - 810 - 760 46 700 50 650 54

770 46 740 48 700 50 660 53 625 56 580 61 540 65 500 70

1175 45 1125 47 1075 49

1030

51 970 54 920 57 860 61 800 66

1075 49 1040 51 995 53 950 56 900 59 840 63 790 67 720 73

800 66 770 69 745 71 710 74 670 - 630 - 580 - 530 -

Heating

Model Input Motor Motor

Number (Btuh) Speed HP

G6RC040C-08

40,000 Medium 1/5

Low**

G6RC040C-12

40,000 Medium 1/3

Low**

G6RC060C-12

60,000 Medium 1/3

Low**

G6RC080C-12

80,000 Medium 1/3

Low**

G6RC080C-16

80,000

Med-High

1/2

Med-Low**

Low

G6RC100C-16

100,000 Med-Hi

h** 1/2

Med-Low

Low

G6RC120C-16

120,000 Med-Hi

h** 1/2

Med-Low

Low

G6RC120C-20

120,000

Med-High

3/4

Med-Low**

Low

G6RD040C-10

40,000 Medium 1/3

Low**

G6RD060C-10

60,000 Medium** 1/3

Low

Table 2. Furnace Airflow Data

Heating

Model Input Motor Motor

Number (Btuh) Speed HP

G6RD080C-14 80,000

Med-High

1/2

Med-Low**

Low

G6RD100C-14 100,000 Med-Hi

h** 1/2

Med-Low

Low

G6RD120C-14 120,000 Med-Hi

h** 1/2

Med-Low

Low

G6RD120C-19 120,000

Med-High

3/4

Med-Low**

Low

External Static Pressure (Inches WaterColumn)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

1620 - 1560 45 1490 47

1430

49 1365 52 1300 54 1240 57 1170 60

1450 49 1400 50 1350 52

1295

54 1240 57 1180 60 1120 63 1060 66

1255 56 1225 57 1180 60

1145

61 1105 64 1060 66 1020 69 980 72

1080 65 1055 67 1030 68

1000

70 960 73 920 - 870 - 820 -

1620 54 1555 57 1485 59

1425

62 1355 65 1290 68 1220 72 1160 -

1430 62 1375 64 1330 66

1265

70 1210 73 1150 - 1080 - 1010 -

1260 70 1220 72 1170 75

1130

- 1070 - 1010 - 950 - 890 -

1085 - 1050 - 1015 - 970 - 935 - 890 - 850 - 800 -

1700 62 1635 65 1565 67

1500

70 1435 74 1370 77 1310 - 1240 -

1510 70 1455 73 1405 75

1350

78 1290 - 1230 - 1170 - 1100 -

1330 79 1280 - 1240 -

1195

- 1145 - 1100 - 1050 - 1000 -

1140 - 1110 - 1075 -

1040

- 1010 - 980 - 940 - 910 -

2140 - 2070 - 2010 -

1945

- 1870 56 1800 59 1730 61 1650 64

1955 - 1900 56 1850 57

1800

59 1740 61 1690 62 1630 65 1570 67

1660 64 1620 65 1575 67

1540

69 1495 71 1460 72 1410 75 1370 77

1450 73 1430 74 1400 75

1360

78 1340 79 1300 81 1270 83 1230 -

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

1140 - 1090 - 1060 - 1030 - 980 35 950 36 910 37 870 39

875 39 835 41 820 41 805 42 780 43 770 44 760 45 750 45

1260 40 1190 43 1155 44 1120 45 1075 47 1030 49 980 52 940 54

1120 45 1070 48 1040 49 1010 50 960 53 930 55 890 57 850 60

855 59 815 62 800 64 780 65 760 67 730 70 710 - 690 -

1635 - 1585 - 1525 - 1460 46 1400 48 1330 51 1260 54 1180 57

1435 47 1395 49 1350 50 1300 52 1255 54 1200 56 1150 59 1090 62

1230 55 1200 56 1165 58 1130 60 1090 62 1050 65 1000 68 960 71

1050 - 1035 - 1010 - 980 - 950 - 910 - 870 - 820 -

1600 53 1555 54 1500 56 1445 59 1380 61 1310 65 1240 68 1160 73

1475 57 1435 59 1385 61 1335 63 1290 66 1240 68 1190 71 1130 75

1320 - 1290 - 1250 - 1215 - 1170 - 1120 - 1070 - 1020 -

1150 - 1130 - 1110 - 1075 - 1040 - 1000 - 950 - 890 -

High*

G6RL040C-12 40,000 Medium 1/3

Low**

High*

G6RL060C-12 60,000 Medium 1/3

Low**

High*

G6RL080C-16 80,000 Med-High 1/2

Med-Low**

Low

High*

G6RL100C-16 100,000 Med-High** 1/2

Med-Low

Low

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.

** Factory Set Cooling Speed

** Factory Set Heating Speed

- Not Recommended

Table 3. Furnace Dimensions and Shipping Weights

Table 4. Minimum Clearances to Combustible Materials

* 24 inches is the minimum clearance for servicing.

36 inches is the recommended clearance for service.

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*

INSTALLATION REQUIREMENTS

Requirements and Codes

This furnace must be installed in accordance

withtheseinstructions,allapplicablelocalbuild-

ing codes, and the current revision of the Na-

tionalFuelGasCode(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-B149installation 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 in-

stallation in mobile homes. Installa-

tion in a mobile home could cause

fire,propertydamage,and/orpersonal

injury.

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

Dimensions (inches)

Furnace

Btuh CD

Shipping

Weight

(

lbs

)

Model

Number

Location

Thefurnacemustbeinstalledonalevelsurface,

and as close to the center of the air distribution

system as possible. See Table 3 for overall

dimensions to determine the required clear-

ancesinhallways,doorways,stairs,etc.toallow

thefurnaceto bemovedtothe installationpoint.

The furnace must be installed so that all electri-

cal 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 clear-

ance 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 satis-

fied, but that panel or door must be removable

and allow the appropriate clearance for your

installation.

Thisfurnaceiscertifiedforuseonwoodflooring.

Thefurnace mustbe installedona solidsurface

and must be level front to back and side to side.

This furnace must not be installed directly on

carpeting,tile,oranycombustiblematerialother

than wood flooring.

DOWNFLOW WARNING

(G6RL Models):

The design of the downflow furnace is certified

fornaturalor propanegasandfor installationon

non-combustible flooring. A special combus-

tible floor sub-base is required when installing

onacombustiblefloor. Failuretoinstallthesub-

base may result in fire, property damage and

personalinjury.Thespecialdownflowsub-bases

are factory supplied accessories, part numbers

902677 and 902974. When the furnace is in-

stalled on a factory or site-built cased air condi-

tioning coil, the sub-base is not necessary.

However,theplenumattachedtothecoilcasing

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

thefurnaceislocatedaminimumof15"fromthe

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 mod-

elsareNOTapprovedforhorizontalinstallation.

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. Installationonacombustiblefloor-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.Attachthesupplyairplenumto

the base in a manner which will ensure 1"

clearancetotheflooringorothercombustible

material.Placefurnaceonthecombustible

base as shown in Figure 6.

3. Whenthefurnaceisinstalledonafactory

or site-built cased air conditioning coil,

thesub-baseisnotnecessary.However,

the plenum attached to the coil casing

must be installed such that its surfaces

areatleast1"fromcombustiblematerial.

Hole in

Floor

19.25"

18.75"

Hole in

Floor

19.25"

13.25"

G6RL 080/100 G6RL 040/060

Figure 3. Opening for Concrete Slab

19.63"

18.75"

19.63"

13.25"

Hole in

Floor Hole in

Floor

Downflow Wood

Sub-base Floor

Furnace

Sheet

Metal

Plenum

Figure 5. Opening in Wood Floor

G6RL 080/100 G6RL 040/060

Figure 6. Furnace on a Wood Floor

1 inch thick fiberglass 3 lb density

28.38"

9.25"

19.63"

19.75"

or 14.25"*

2.0"

1.58"

1.50"

16.75"

or 11.25"*

18.75"

or 13.25"*

Concrete

Floor Furnace

Sheet

Metal

Plenum

Figure 4. Furnace on a Concrete Slab

CIRCULATING AIR SUPPLY

Plenums and air ducts must be installed in

accordance with the Standard for the Installa-

tionof AirConditioning andVentilating Systems

(NFPANo.90A) ortheStandard fortheInstalla-

tion of Warm Air Heating and Air Conditioning

Systems (NFPA No. 90B).

* Smaller

dimensions for

G6RL 040/060

Figure 7. Downflow Sub-Base Dimensions

Ifoutside airisutilized asreturn airtothe furnace

forventilation or toimprove indoor airquality, the

systemmust be designedso thatthe return airto

the furnace is not less than 50°F (10°C) during

heating operation. If a combination of indoor and

outdoorairisused,theductsanddampersystem

must be designed so that the return air supply to

thefurnaceis equaltothereturn airsupplyunder

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 down-

stream (on the outlet side) or in parallel with the

furnace.

Ifacoolingsystemisinstalledinparallelwiththe

furnace, a damper must be installed to prevent

chilled air from entering the furnace and con-

densing on the heat exchanger. If a manually

operated damper is installed, it must be de-

signed so that operation of the furnace is pre-

vented when the damper is in the cooling posi-

tion and operation of the cooling system is

prevented when the damper is in the heating

position.

This manual suits for next models

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