Nordyne VG7TC-FS Installation Instructions Manual

Two-stage condensing gas furnaces with fixed & variable speed blowers
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Two-Stage Condensing gas Furnaces With Fixed & Variable Speed Blowers
INSTALLATION INSTRUCTIONS
*TC Upflow / Horizontal Furnace
WARNING:
FIRE OR EXPLOSION HAZARD
• Failure to follow safety warnings exactly could
result in serious injury or property damage.
• Installation and service must be performed
by a qualified installer, service agency or the
gas supplier.
• Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
DO NOT DESTROY THIS MANUAL. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
*TL Downflow Furnace
AVERTISSEMENT
RISQUE D'INCENDIE OU D' EXPLOSION
• Le non-respect des avertissements de
sécurité pourrait entraîner des blessures
graves, la mort ou des dommages matériels.
• L'installation et l'entretien doivent être
effectués par un installateur qualifié, un
organisme de service ou le fournisseur de
gazstaller, service agency or the gas supplier.
• Ne pas entreposer ni utiliser de l'essence ni
d'autres vapeurs ou liquides inflammables
dans le voisinage de cet appareil, ni de tout
autre appareil.
QUE FAIRE S'IL Y A UNE ODEUR DE GAZ
• Ne pas tenter d'allumer aucun appareil.
• Ne toucher à aucun interrupteur électrique;
n'utiliser aucun téléphone dans le bâtiment.
• Évacuer l'immeuble immédiatement.
• Appeler immédiatement le fournisseur de
gaz en employant le téléphone d'un voisin.
Respecter à la lettre les instructions du
fournisseur de gaz.
• Si personne ne répond, appeler le service des
incendies.
95.0% AFUE

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Summary of Contents for Nordyne VG7TC-FS

  • Page 1 Two-Stage Condensing gas Furnaces With Fixed & Variable Speed Blowers 95.0% AFUE INSTALLATION INSTRUCTIONS *TC Upflow / Horizontal Furnace *TL Downflow Furnace WARNING: AVERTISSEMENT RISQUE D’INCENDIE OU D’ EXPLOSION FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could •...
  • Page 2: Table Of Contents

    TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION ....3 ELECTRICAL WIRING..........24 Line Voltage Wiring ..........24 REQUIREMENTS & CODES ........4 Grounding .............. 25 Combustion Air Quality .......... 5 Thermostat / Low Voltage Connections ....25 Heating Load ............5 Single Stage AC &...
  • Page 3: Important Safety Information

    Figure 33. Wiring Diagram for Two-Stage, Fixed WARNING: Speed Downflow Furnaces ....41 Figure 34. Wiring Diagram for Two-Stage, Variable Improper installation, service, adjustment, Speed Upflow Furnaces ...... 42 or maintenance may cause explosion, fire, Figure 35. Wiring Diagram for Two-Stage, Variable electrical shock or other hazardous conditions Speed Downflow Furnaces ....
  • Page 4: Requirements & Codes

    REQUIREMENTS & CODES 1. 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 WARNING: below four feet above grade the following requirements must be satisfied: The safety information listed below must be followed during the installation, service, and a.) A carbon monoxide (CO) detector and alarm shall...
  • Page 5: Combustion Air Quality

    • Installations in these locations may require outdoor air The information listed below is for reference purposes only for combustion, due to chemical exposures: and does not necessarily have jurisdiction over local or state Commercial buildings codes. Always consult with local authorities before installing any gas appliance.
  • Page 6: Operation Of Furnace During Construction

    Operation of Furnace During Construction WARNING: CAUTION: Do not place combustible material on or against the furnace cabinet or within 6 inches of the Failure to follow these instructions will void the vent pipe. Do not place combustible materials, factory warranty and may significantly reduce including gasoline or any other flammable the life or the performance of the furnace, and/ vapors and liquids,in the vicinity of the furnace.
  • Page 7: Combustion Air & Venting Requirements

    COMBUSTION AIR & VENTING REQUIREMENTS AVERTISSEMENT: WARNING: RISQUE D’EMPOISONNEMENT AU CARBON MONOXIDE POISONING HAZARD MONOXYDE DE CARBONED Failure to follow the steps outlined below for each appliance connected to the venting Le non-respect des consignes suivantes portant sur chacun des appareils raccordés au système system being placed into operation could d’évacuation mis en service pourrait entraîner result in carbon monoxide poisoning or death.
  • Page 8: Direct Vent Systems

    IMPORTANT INFORMATION Another important consideration when selecting one or • This furnace must be vented in compliance with two pipe installation is the quality of the Indoor air which can sometimes be contaminated with various household the current revision of the National Fuel Gas Code chemicals .
  • Page 9: Air From Inside

    by the total input rate of all appliances in the space. In all cases, the minimum dimension of any combustion air Vent or Chimney opening is 3 inches. Ventilation Louvers Air From Inside (each end of attic) If combustion air is taken from the heated space, the two Outlet openings must each have a free area of at least one square NOTE: Air openings shall...
  • Page 10: Alternate Method Of Providing Air From Outside

    Alternate Method of Providing Air from Out- side: If acceptable under local Codes, it is permitted to provide Vent or outside air using one opening (See NFGC). Generally, Chimney confined spaces must have 2 openings in the space for combustion air. One opening must be within 12 inches of Air Duct Water the ceiling, and the other must be within 12 inches of the...
  • Page 11: Vent Pipe Material

    Category IV appliances operate with positive vent pressure Vent Pipe Length & Diameter and therefore require vent systems which are thoroughly In order for the furnace to operate properly, the combustion sealed. They also produce liquid condensate, which is air and vent piping must not be excessively restrictive. slightly acidic and can cause severe corrosion of ordinary •...
  • Page 12: Vent Pipe Installation

    Vent Pipe Installation Outdoor Terminations - Horizontal Venting • Vent and combustion air intake terminations shall be installed as depicted in Figure 7 & Figure 8 and in CAUTION: accordance with these instructions: • Vent termination clearances must be consistent with the Combustion air must not be drawn from a NFGC, ANSI 2223.1/NFPA 54 and/or the CSA B149.1, corrosive atmosphere.
  • Page 13: Outdoor Terminations - Vertical Venting

    • For optimal performance, vent the furnace through a Outdoor Terminations - Vertical Venting wall that experiences the least exposure to winter winds. Termination spacing requirements from the roof and from • The vent termination shall be located at least 3 ft. each other are shown in Figure 10 (page 13).
  • Page 14: Existing Installations

    CIRCULATING AIR REQUIREMENTS Maximum Flue Pipe Length (FEET) Winter Design in Unconditioned & Exterior Spaces WARNING: Temperature Without Insulation With Insulation* Do not allow combustion products to enter the circulating air supply. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous *NOTE: Insulation thickness greater than 3/8 inch, based on an R value of 3.5 (ft x F x hr) / (BTU x in.)
  • Page 15: Return Air Connections

    60° F (15° C) during operation. If a combination of indoor Using sharp metal cutters, cut an opening between all 4 knockouts to expose the blower assembly. Position and outdoor air is used, the ducts and damper system the return air duct over the opening and secure to the must be designed so that the return air supply to the side with sheet metal screws.
  • Page 16: Furnace Installation

    FURNACE INSTALLATION If installing the furnace in an attic, it is required that a drip pan be placed under the furnace. If the installation is on *TC series gas furnaces offer a wide range of installation a combustible platform (Figure 11), it is recommended options, including installation in the upflow or horizontal that the drip pan extend at least 12 inches past the top...
  • Page 17: Downflow Furnaces

    Downflow Furnaces Opening in concrete floor WARNING: “A” The furnace must not be installed directly on carpeting,tile,or any combustible material other “B” than wood flooring. Cabinet Size Dim. “A” Dim. “B” WARNING: 16 5/8 19 1/4 20 1/8 19 1/4 Failure to install the downflow sub-base kit may 23 5/8 19 1/4...
  • Page 18: Pressure Switch Tubing

    CAUTION: It is good practice to label all wires prior to disconnection. Wiring errors can cause improper and dangerous operation. 1. Disconnect the electrical harness from the inducer assembly. 2. Remove the inducer assembly ground wire from the blower deck or door. 3.
  • Page 19: Pvc Components

    The 3/4” rubber grommet is used if venting out the left Alternate Orientation side of the cabinet and the drain tube is routed through 1. Install the 2” PVC Tee horizontally on the 2” vent pipe that the blower deck. Remove the plastic plug from the hole is extending out the side of the cabinet.
  • Page 20: Condensate Drain Lines

    Condensate Drain Lines 5. Remove all screws (5) securing bottom panel (6) to bottom of furnace and front brace (7). IMPORTANT NOTE If the furnace is installed in an area where temperatures 6. Lift up and slide bottom panel (6) out through front of fall below freezing, special precautions must be made furnace.
  • Page 21: Gas Supply & Piping

    GAS SUPPLY & PIPING All gas piping must be installed in compliance with local codes and utility regulations. In the absence of local codes the gas line installation must comply with the latest edition WARNING: of the National Fuel Gas Code (ANSI Z223.1) or (CAN/ CGA B149.1 or .2) Installation Codes.
  • Page 22 UPFLOW MODELS Note “A” Note “A” Note “B” Note “B” Left Side Entry Right Side Entry DOWNFLOW MODELS Note “A” Note “A” Note “B” Note “B” Right Side Entry Left Side Entry COMPONENTS: (1) Automatic Gas Valve (2) Burner Assembly (3) Dripleg (w/ manual shut-off) (4) Elbow...
  • Page 23: High Altitude Application (Natural Gas Only)

    1. The chemical mixture of the gas varies from region to WARNING: region and is expressed as the “sea level heating value”. 2. The heating value varies by altitude. For this reason, FIRE OR EXPLOSION HAZARD particularly in high altitude areas, the local gas utility Failure to follow safety warnings exactly could usually specifies the heating value at the residence’s result in serious injury or property damage.
  • Page 24: Electrical Wiring

    ELECTRICAL WIRING Conversion to LP / Propane is detailed in the installation instructions provided with the conversion kit. Generally, this will require the replacement of the burner orifices and WARNING: the spring assembly in the pressure regulator. Approved conversion kits are listed below: ELECTRICAL SHOCK,FIRE OR EXPLOSION •...
  • Page 25: Grounding

    105°F (40°C). For electrical specifications, refer to • NORDYNE no longer supports twinning of two stage the furnace nameplate or Table furnaces. Please contact your furnace distributor for details.
  • Page 26: Single Stage Ac & Single Stage Thermostat

    Low voltage connections (24 VAC) from the thermostat are wired to the terminal strip on the integrated control in the furnace. Recommended minimum wire gauge for thermostat wiring is shown in Table 5 (page 25). • The thermostat should be mounted about 5 feet above HIGH EFFICIENCY BLOWER MOTOR the floor on an inside wall.
  • Page 27: Autostaging For Two-Stage Thermostats

    NOTE: If the autostage jumper is in the ON position and should be set so that the DEHUM output should be high a W1 demand is present when power is applied to the (positive) when dehumidification is needed. See also furnace, the first heat cycle will run in second stage heat Dehumidification Options section.
  • Page 28: Start-Up & Adjustments

    • If a humidistat is not available, it is an acceptable option At altitudes above 2,000 feet, it must not exceed that on to connect the R & DEHUM via a field supplied normally the rating plate less 4% for each 1,000 feet. To determine 27).
  • Page 29: Verifying Burner Operation

    Verifying Burner Operation 2-STAGE GAS VALVES Lo Input CAUTION: HI Input Adjusting Screw Adjusting Screw The door over the burners may only be open for inspection purposes only.The door must be Manifold pressure installed during unattended operation. 1. Remove the burner compartment door. 2.
  • Page 30: Operating Sequence

    OPERATING SEQUENCE Fan Mode • When the thermostat energizes the G terminal for The operating sequences for the heating, cooling, and fan continuous fan (without calling for heat or cooling), the modes are described below. Refer to the field and furnace indoor fan is energized on the selected FAN speed.
  • Page 31 Proper maintenance is most important to achieve the best CAUTION: performance from a furnace. Follow these instructions for years of safe, trouble free operation. To prevent damage to the unit or internal • These maintenance instructions are primarily intended components, it is recommended that two to assist qualified technicians experienced in the proper wrenches be used when loosening or tightening maintenance and operation of this appliance.
  • Page 32: Figures & Tables

    FIGURES & TABLES TOP VIEW BOTTOM VIEW *TC 95.1% Upflow / Horizontal Furnace Front Brace Cabinet Dim. Dim. Dim. Size “A” “B” “C” ‘B’ Cabinet 17 1/2 15 7/8 16 1/8 Bottom ‘C’ Cabinet 19 3/8 19 5/8 Panel ‘D’ Cabinet 24 1/2 22 7/8 23 1/8...
  • Page 33: Airflow Data

    Airflow Data *TC / TL FURNACES WITH FIXED SPEED BLOWERS Model Number External Static Pressure (in.W.C.) Motor Switch Settings & (0 = OFF, 1 = ON) Heating Input (Btuh) CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise —...
  • Page 34 *TC / TL FURNACES WITH VARIABLE SPEED BLOWERS Switch Settings for Heat *TC / TL - 060D - VB (0 = OFF, 1 = ON) Input (BTU) 60,000 Temp Rise (° F) 1,000 1,100 “B” CABINET 1,200 1,300 1,400 1,500 1,600 —...
  • Page 35 *TC / *TL FURNACES WITH VARIABLE SPEED BLOWERS “B” CABINET Switch Settings (0 = OFF, 1 = ON) Nominal A/C & HP Capacity HEAT COOL LOW HIGH 1,000 1,060 1,120 1,180 1,240 1,300 1,360 1,420 1 1,020 1,480 0 1,065 1,540 1 1,105 1,600 “C”...
  • Page 36: Gas Information

    Gas Information GAS FLOW RATES GAS FLOW RATES (CUBIC FEET PER HOUR) (CUBIC FEET PER HOUR) CUBIC FEET PER CUBIC FEET PER TIME FOR TIME FOR REVOLUTION OF GAS METER REVOLUTION OF GAS METER ONE REVOLUTION ONE REVOLUTION (SECONDS) (SECONDS) 1,800 3,600 1,500...
  • Page 37 HIGH ALTITUDE DERATION – PROPANE GAS INPUT (BTU) & STAGE ALTITUDE ABOVE SEA 60,000 80,000 100,000 120,000 LEVEL 1st 2nd 1st 2nd 1st 2nd 1st 2nd ORIFICE SIZE 0 to 1,999 FT 10.0 10.0 10.0 10.0 MANIFOLD PRESSURE ORIFICE SIZE 2,000 to 2,999 FT MANIFOLD PRESSURE ORIFICE SIZE...
  • Page 38 HIGH ALTITUDE DERATION – NATURAL GAS WITH HIGH HEATING VALUE INPUT (BTU) & STAGE ALTITUDE ABOVE 60,000 80,000 100,000 120,000 SEA LEVEL ORIFICE SIZE 0 to 1,999 FT MANIFOLD PRESSURE ORIFICE SIZE 2,000 to 2,999 FT MANIFOLD PRESSURE ORIFICE SIZE 3,000 to 3,999 FT MANIFOLD PRESSURE ORIFICE SIZE...
  • Page 39: Electrical Information

    Electrical Information NOT USED EXPANSION PORT CONNECTION TO FURNACE CONTROL BOARD MOTOR WIRE HARNESS FAN SPEED 1 2 3 4 5 6 7 8 COOL HEAT STATUS Figure 29. Two-Stage Fixed Speed Motor Control Board STATUS LIGHTS L2-OUT L2-IN W_OUT Y/Y2_OUT L1-IN Y1_OUT...
  • Page 40 COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 32. Wiring Diagram for Two-Stage, Fixed Speed Upflow Furnaces...
  • Page 41 COOL HEAT FAN SPEED BLACK BLACK LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 33. Wiring Diagram for Two-Stage, Fixed Speed Downflow Furnaces...
  • Page 42 COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 34. Wiring Diagram for Two-Stage, Variable Speed Upflow Furnaces...
  • Page 43 COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 35. Wiring Diagram for Two-Stage, Variable Speed Downflow Furnaces...
  • Page 44 Venting Information VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED CANADIAN INSTALLATIONS US INSTALLATIONS Direct Vent (2-pipe) & Clearance Location Direct Vent Conventional Vent Conventional Vent (1-pipe) (2-pipe) Furnaces (1-pipe) Furnaces Furnaces Clearance above grade, veranda, porch, deck, 12 inches (30cm) 12 inches (30cm) 12 inches (30cm)
  • Page 45 HORIZONTAL VENTING Straps or Other Suitable Seal/Caulk Supports at minimum of 5 ft. Intervals (2-Pipe Shown) Around Pipes at Building 90° 90° Elbow Elbow COMBUSTION AIR 90° Elbow Upward Pitch - 1/4” per foot 12” Min. 7” Table 1 for 2” PVC pipe (Flue Pipe) lengths (field supplied) First support placed as close...
  • Page 46 UPFLOW - 1 PIPE OPTIONS COMBUSTION COMBUSTION NOTE 5 PVC Tee PVC Trap NOTE 5 PVC Tee Rubber Grommet OPTION 1 PVC Trap OPTION 2 Rubber Grommet See VIEW A for drain line positions See VIEW B for drain line positions VIEW -A- VIEW -B- Drain Line Attached...
  • Page 47 HORIZONTAL RIGHT - 1 PIPE OPTION HORIZONTAL LEFT - 1 PIPE OPTION Rubber Rubber Option Option Grommet Grommet COMBUSTION AIR FLOW COMBUSTION See VIEW D for See VIEW C for Plug Plug drain line positions drain line positions Inline Drain (Factory Supplied) See NOTE 3 VIEW -C-...
  • Page 48 DOWNFLOW - 1 PIPE OPTIONS COMBUSTION COMBUSTION Rubber COMBUSTION Grommet Option Option Option NOTE 5 PVC Tee PVC Trap NOTE 5 PVC Tee Rubber Grommet PVC Trap Rubber Grommet See VIEW E for drain line positions See VIEW F for drain line positions See VIEW G for drain line positions Inline Drain VIEW -F-...
  • Page 49 TROUBLESHOOTING Diagnostic Description Green LED Red LED If the furnace fails to operate check the following: Control Fault (No Power) • Is the thermostat operating properly? L1/Neutral Polarity Fault Flash Flash • Are the blower compartment door(s) in place? 1 Hour Lockout Alternating Flash •...
  • Page 50 Finish Flange Roll-Out Burner Flame Switch Assembly Sensor Pressure Switches Igniter (Inducer) Gas Valve Furnace Control Board Main Air Limit Switch Inducer Limit Switch Pressure Switches Inducer Assembly (Condensate) Transformer Blower Door Switch Motor Control Box Motor Choke (C & D cabinets only) Motor Control Board Blower Assembly Upflow / Horizontal Furnace...
  • Page 52 INSTALLATION / PERFORMANCE CHECK LIST ATTENTION INSTALLERS: ELECTRICAL SYSTEM It is your responsibility to know this product better than your customer. Electrical connections tight? This includes being able to install the product according to strict Line voltage polarity correct? safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product.

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