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Nordyne 80+ AFUE *SA Installation Instructions Manual

Single stage high efficiency gas furnaces
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See also: User's Information Manual
GAS FURNACES

Installation Instructions

Single Stage High Effi ciency Furnaces
*SA Upfl ow/Horizontal Model
WARNING:
• PROPOSITION 65 WARNING: This product
contains chemicals known to the state of
California to cause cancer, birth defects or
other reproductive harm.
• This furnace is not approved for installation
in mobile homes. Installing this furnace in
a mobile home could cause fi re, property
damage, and/or personal injury.
ATTENTION INSTALLERS:
It is your responsibility to know this product better than your
customer. This includes being able to install the product according
to strict safety guidelines and instructing the customer on how to
operate and maintain the equipment for the life of the product.
Safety should always be the deciding factor when installing this
product and using common sense plays an important role as well.
Pay attention to all safety warnings and any other special notes
highlighted in the manual. Improper installation of the furnace
or failure to follow safety warnings could result in serious injury,
death, or property damage.
These instructions are primarily intended to assist qualifi ed
individuals experienced in the proper installation of this appliance.
Some local codes require licensed installation/service personnel
for this type of equipment. Please read all instructions carefully
before starting the installation. Return these instructions to the
customer's package for future reference.
*SK Downfl ow Model
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 qualifi ed installer, service agency or
the gas supplier.
• Do not store or use gasoline or other
fl ammable 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 fi re department.
DO NOT DESTROY THIS MANUAL.
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
80+ AFUE

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Summary of Contents for Nordyne 80+ AFUE *SA

  • Page 1: Installation Instructions

    GAS FURNACES 80+ AFUE Installation Instructions Single Stage High Effi ciency Furnaces *SA Upfl ow/Horizontal Model *SK Downfl ow Model WARNING: WARNING: • PROPOSITION 65 WARNING: This product FIRE OR EXPLOSION HAZARD contains chemicals known to the state of • Failure to follow safety warnings exactly California to cause cancer, birth defects or could result in serious injury or property other reproductive harm.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SAFETY INFORMATION ..........3 FURNACE INSTALLATION ........12 General Requirements ..........12 REQUIREMENTS AND CODES ........4 Upfl ow Installation ..........12 GENERAL INSTRUCTIONS ........4 Side Return Air Inlet .........12 Combustion Air Quality ...........4 Bottom Return Air Inlet ........12 Operation of Furnace During Construction .....5 Horizontal Installation ..........12 Installation in a Garage ...........5 Downfl...

  • Page 3: Safety Information

    MAINTENANCE ............22 SAFETY INFORMATION Safety markings are used frequently throughout this Air Filters ...............22 manual to designate a degree or level of seriousness and Blower Compartment ..........23 should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in Cleaning of Burners ..........23 personal injury or death.

  • Page 4: Requirements And Codes

    REQUIREMENTS and CODES GENERAL INSTRUCTIONS This furnace must be installed in accordance with Combustion Air Quality these instructions, all applicable local building codes CAUTION: and the current revision of the National Fuel Gas Code (NFPA54/ANSI Z223.1) or the Natural Gas and Propane Combustion air must not be drawn from a Installation Code, CAN/CGA B149.1.

  • Page 5: Operation Of Furnace During Construction

    Operation of Furnace During Construction Installation in a Garage CAUTION: WARNING: Failure to follow these instructions will void the Do not place combustible materials on or factory warranty and may signifi cantly reduce against the furnace cabinet or within 6 inches the life or the performance of the furnace, of the vent pipe.
  • Page 6 INSTALLATION CLEARANCES to COMBUSTIBLE MATERIALS For UPFLOW, HORIZONTAL & DOWNFLOW FURNACES Left Side ........0 Inches Vent ..........1 Inch Top ...........0 Inches † Right Side ........0 Inches Back .........0 Inches Front........4 Inches UPFLOW APPLICATION HORIZONTAL APPLICATION DOWNFLOW APPLICATION SIDE SIDE BOTTOM BOTTOM...

  • Page 7: Combustion Air Requirements

    COMBUSTION AIR REQUIREMENTS which supply heated air to areas outside the space must draw return air from outside the space and must have the General Information return air ducts tightly sealed to the furnace. WARNING: The required sizing of these openings is determined by whether inside or outside air is used to support combustion, Furnace installation using methods other than the method by which the air is brought to the space, and...

  • Page 8: Outdoor Air Using Vertical Ducts

    Ventilation louvers at each end of attic Vent or Chimney Vent or Chimney Outlet air duct must be Attic Insulation at least 1 sq. in. per 12" Max 4,000 Btuh of total input rating. Must - - - - - - NOTE: Each extend above attic - - -...

  • Page 9: Alternate Method Of Providing Air From Outside

    VENTING REQUIREMENTS Alternate Method of Providing Air from Outside: If acceptable under local Codes, it is permitted to WARNING: provide outside air using one opening (See NFGC). Upon completion of the furnace installation, Generally, confi ned spaces must have two openings carefully inspect the entire fl...

  • Page 10: Horizontal Venting

    be installed a minimum of every fi ve feet along the vent Horizontal Venting run to ensure no displacement after installation. Under WARNING: no circumstances shall any portion of the vent system extend into or pass through any return air duct, supply air duct, or plenum.

  • Page 11: Circulating Air Requirements

    CIRCULATING AIR REQUIREMENTS must be designed so that the return air supply to the furnace is equal to the return air supply under normal, WARNING: indoor return air applications. • When a cooling system is installed which uses the Do not allow combustion products to enter the furnace blower to provide airfl...

  • Page 12: Side Return Installations

    Side Return Installations FURNACE INSTALLATION To attach the return air duct to the left or right side of *SA series gas furnaces are shipped ready for installation the furnace, punch out the four knockouts from the side in the upfl ow or horizontal right or left positions. Only of the furnace (Figure 17, page 27).

  • Page 13: Downfl Ow Installation

    Downfl ow Installation WARNING: Electrical Supply Connection The furnace must not be installed directly on Gas Inlet carpeting, tile, or any combustible material other Type “B” Vent than wood fl ooring. WARNING: Failure to install the downfl ow sub-base kit may result in fi...

  • Page 14: Bottom Panel Removal

    Alternate Bottom Panel Removal If the bottom panel cannot be removed using the previous instructions, the steps below are an alternate method for Concrete Furnace removing the bottom panel. See Figure 11. Floor 1. Remove the door (1) from the blower compartment . 2.

  • Page 15: Gas Supply And Piping

    GAS SUPPLY AND PIPING pipe connections at the main gas valve, emergency shutoff valve and fl exible gas connectors (if applicable). The soap All gas piping must be installed in compliance with local and water solution can be applied on each joint or union codes and utility regulations.
  • Page 16 UPFLOW MODELS STATUS STATUS Note FLAME FLAME Note BLOWER BLOWER DELAY DELAY Left Side Entry Right Side Entry DOWNFLOW MODELS STATUS STATUS FLAME FLAME BLOWER BLOWER DELAY DELAY Note Note Right Side Entry Left Side Entry ITEM # and COMPONENT (1) Automatic Gas Valve (2) Burner Assembly (3) Dripleg...

  • Page 17: Conversion To Lp/Propane

    with a heating value of more than 1,000 Btu per cubic foot and manifold pressure. When conversion is complete, verify and Table 11 (Low) is for less than 1,000 Btu per cubic the manifold pressure and input rate are correct as listed foot.

  • Page 18: Low Voltage Wiring

    Proper line voltage polarity must be maintained in for heating only (two-wire) and heating/cooling (four-wire) order for the control system to operate correctly. applications. Recommended minimum wire gauge for Verify the incoming neutral line is connected to the thermostat wiring is shown in Table 2. white wire and the incoming “hot”...

  • Page 19: Grounding

    IMPORTANT NOTE: Set the heat anticipator according Twinning to the instructions supplied by the thermostat Single stage G7 furnaces are not supplied with a built- manufacturer. in twinning capability. Other valuable features and enhancements were made to the new control that made it To determine the heat anticipator setting: necessary to remove the twinning capability.

  • Page 20: Start-Up & Adjustments

    START-UP AND ADJUSTMENTS Example: Pre-Start Check List • Time for 1 revolution of a gas meter with a 1 cubic ft dial = 40 seconds. √ erify the polarity of the connections are correct, the line voltage power leads are securely connected and •...

  • Page 21: Verifying Burner Operation

    1. Verify the blower door is securely mounted in place WARNING: and that there is power to the furnace. 2. Block the return airfl ow to the furnace by install- To prevent electric shock, personal injury, or ing a close-off plate in place of or upstream of the death, disconnect the electric power before fi...

  • Page 22: Cooling Cycle

    Cooling Cycle Diagnostic Description Green LED Red LED 1. The thermostat calls for cooling by energizing the Y Control Fault (No Power) terminal with 24VAC. 2. The control energizes the blower in the cooling speed L1/Neutral Polarity Fault Flash Flash and sends 24VAC to the contactor in the condensing 1 Hour Lockout Alternating Flash...

  • Page 23: Blower Compartment

    Filters designed to remove smaller particles such as CAUTION: pollen, may require additional maintenance. Filters for side return and bottom return applications are available Label all wires prior to disconnection when from most local distributors. servicing controls. Wiring errors can cause Blower Compartment improper and dangerous operation.

  • Page 24: Heat Exchanger And Burner Maintenance

    20. Replace all the parts in reverse order that they were DESCRIPTION OF COMPONENTS removed. The descriptions below are various functional components 21. Check gaskets for damage. Replace if needed. that affect the operation and shutting down of this furnace. Some of these components and their locations are shown 22.

  • Page 25: French Translations

    FRENCH TRANSLATIONS The following are French translations of important warning statements found within this manual. AVERTISSEMENT: RISQUE D’EMPOISONNEMENT AU MONOXYDE DE CARBONED Le non-respect des consignes suivantes portant sur chacun des appareils raccordés au système d’évacuation mis en service pourrait entraîner l’empoisennement au monoxyde de carbone ou la mort.
  • Page 26 AVERTISSEMENT: AVERTISSEMENT: RISQUE D’INCENDIE OU D’ EXPLOSION RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE • Le non-respect avertissements OU D’EXPLOSION sécurité pourrait entraîner des blessures Le non-respect des avertissements de sécu- graves, la mort ou des dommages matériels. rité pourrait entraîner un fonctionnement dan- •...

  • Page 27: Figures And Tables

    FIGURES AND TABLES *SA 80+ Upfl ow Furnace *SA Model #’s Dim. “A” Dim. “B” Dim. “C” Dim. “D” -23A † TOP VIEW 14 1/4 10 3/4 12 5/8 12 7/8 -23A † -24B † FRONT 17 1/2 11 3/4 15 7/8 16 1/8 BRACE...

  • Page 28: Airfl Ow Data

    AIRFLOW DATA *SA - UPFLOW / HORIZONTAL GAS FURNACES - 80% AFUE, External Static Pressure (Inches Water Column) Heating Model Motor Input Number Speed (Btuh) Rise Rise Rise Rise Rise Rise Rise Rise High* 1,260 1,205 1,145 1,080 1,025 Med-High Med-Low** High* 1,350...
  • Page 29 *SA - UPFLOW / HORIZONTAL GAS FURNACES - 80% AFUE External Static Pressure (Inches Water Column) Heating Model Motor Input Number Speed (Btuh) Rise Rise Rise Rise Rise Rise Rise Rise High* 1,940 1,860 1,790 1,710 1,625 1,540 1,450 1,355 Med-High** 1,820 1,760...
  • Page 30 *SK - DOWNFLOW GAS FURNACES - 80% AFUE External Static Pressure (Inches Water Column) Heating Model Motor Input Number Speed (Btuh) Rise Rise Rise Rise Rise Rise Rise Rise High* 1,375 1,340 1,300 1,270 1,225 1,175 1,115 1,035 Med-High 1,155 1,130 1,110 1,085...

  • Page 31: Electrical Information

    ELECTRICAL INFORMATION 15-BL-60 (21) HIGH XFMR R C Y G W Figure 18. Wiring Diagram for Upfl ow and Downfl ow Furnaces...

  • Page 32: Gas Information

    GAS INFORMATION GAS FLOW RATES (CUBIC FEET PER HOUR) TIME FOR CUBIC FEET PER REVOLUTION TIME FOR CUBIC FEET PER REVOLUTION ONE REVOLUTION OF GAS METER ONE REVOLUTION OF GAS METER (SECONDS) (SECONDS) 1,800 3,600 1,500 3,000 1,286 2,571 1,125 2,250 1,000 2,000...

  • Page 33: Propane Gas

    PROPANE GAS INPUT (BTU) ALTITUDE ABOVE SEA LEVEL 45,000 54,000 72,000 90,000 108,000 126,000 ORIFICE SIZE 0 to 1,999 FT 10.0 10.0 10.0 10.0 10.0 10.0 MANIFOLD PRESSURE ORIFICE SIZE 2,000 to 2,999 FT MANIFOLD PRESSURE ORIFICE SIZE 3,000 to 4,999 FT MANIFOLD PRESSURE ORIFICE SIZE 5,000 to 5,999 FT...
  • Page 34 NATURAL GAS - HIGH HEATING VALUE INPUT (BTU) ALTITUDE ABOVE SEA LEVEL 45,000 54,000 72,000 90,000 108,000 126,000 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 4,000 to 4,999 FT...

  • Page 35: Location Of Furnace Components

    LOCATION OF FURNACE COMPONENTS COMPONENT NAME ITEM Blower Assembly STATUS Blower Door Switch FLAME BLOWER DELAY Burner Assembly Control Board Flame Sensor Gas Manifold Gas Valve Igniter Inducer Assembly Limit Switch Pressure Switch Roll-Out Switch Transformer Figure 19. Upfl ow/Horizontal Gas Furnace COMPONENT NAME ITEM Blower Assembly...

  • Page 36: Installation/Performance Checklist

    INSTALLATION/PERFORMANCE CHECK LIST ELECTRICAL SYSTEM: INSTALLER NAME: Electrical connections tight? Line voltage polarity correct? CITY _______________ STATE _____________ Supply Voltage: ______________________ VOLTS Has the thermostat been INSTALLATION ADDRESS: calibrated? Is the thermostat level? CITY _______________ STATE _____________ Is the heat anticipator setting correct? UNIT MODEL # GAS SYSTEM:...

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