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GAS FURNACES
Installation Instructions
G7XC Series - Single Stage Condensing Furnace
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.
Upfl ow/Horizontal Model
• 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.
• 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
neighbors phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call
the fi re department.
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
WARNING:
FIRE OR EXPLOSION HAZARD
WHAT TO DO IF YOU SMELL GAS
DO NOT DESTROY.
92.1% AFUE
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Table of Contents
Related Manuals for Nordyne G7XC Series
Summary of Contents for Nordyne G7XC Series
- Page 1 GAS FURNACES 92.1% AFUE Installation Instructions G7XC Series - Single Stage Condensing Furnace Upfl ow/Horizontal 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...
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Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION ..........3 Inducer Assembly Rotation ........13 Vent and Inducer Assembly Options .....14 REQUIREMENTS AND CODES ........3 Accessories ............14 Finish Flange .............14 GENERAL INSTRUCTIONS ........4 Rubber Grommets ..........14 Combustion Air Quality ..........4 PVC Tee, Reducer, & Hose Barbs ......15 Clearances to Combustible Materials ......4 Condensate Drain Lines ........15 Installation in a Garage ..........4... -
Page 3: Safety Information
SAFETY INFORMATION Safety markings are used frequently throughout this FIGURES AND TABLES ..........25 manual to designate a degree or level of seriousness and Figure 25 - Furnace Dimensions .......25 should not be ignored. WARNING indicates a potentially Airfl ow Data............26 hazardous situation that if not avoided, could result in Table 8 - Upfl... -
Page 4: General Instructions
GENERAL INSTRUCTIONS Installation in a Garage Combustion Air Quality WARNING: CAUTION: Do not place combustible material on or against the furnace cabinet or within 6 inches Combustion air must not be drawn from a of the vent pipe. Do not place combustible corrosive atmosphere. - Page 5 UPFLOW/HORIZONTAL INSTALLATION CLEARANCES* UPFLOW APPLICATION Left Side ....0 Inches Back ......0 Inches Right Side ..... 0 Inches Top ........ 1 Inch Vent ......1 Inch Front......4 Inches SIDE Allow 24 in. minimum clearance for servicing. Recommended clearance is 36 in. BOTTOM NOTE: This furnace is listed for installation on combustible or non-combustible fl...
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Page 6: Conventional Furnaces - Confi Ned Spaces
• Air openings on top of the furnace and in closet doors or walls must never be restricted. If the furnace is operated without adequate air for combustion, the fl ame roll-out Vent or switch will open, turning off the gas supply to the burners. Chimney This safety device is a manually reset switch. -
Page 7: Outdoor Air Using Horizontal Ducts
Air Directly Through An Exterior Wall Ventilation Louvers If combustion air is provided directly through an exterior at each end of attic wall, the two openings must each have free area of at Air Duct must be Vent or least one square inch per 4,000 Btuh of total appliance at least 1 sq. -
Page 8: Direct Vent Furnaces
Direct Vent Furnaces This section specifies installation requirements for Direct Vent (2-pipe) furnaces pull combustion air directly Conventional (1-pipe) and Direct Vent (2-pipe) piping. For from the outdoors and then vent the combustion products 1- pipe installations, install vent piping per this section back outside, isolating the entire system from the indoor and provide air for combustion and ventilation per the space. -
Page 9: Outdoor Terminations - Horizontal Venting
• The quality of outdoor air must also be considered. Be SINGLE VENT PIPE DUAL VENT PIPE sure that the combustion air intake is not located near with 1 long with 1 long radius FURNACE radius elbow* elbow on each pipe* a source of solvent fumes or other chemicals which can MODELS cause corrosion of the furnace combustion system. -
Page 10: Outdoor Terminations - Vertical Venting
Vent Freezing Protection Vent Configuration to • When the vent pipe is exposed to temperatures below Provide 12" Minimum height above freezing (i.e., when it passes through unheated spaces, Snow Level. 12" Min. chimneys, etc.) the pipe must be insulated with 1/2 inch 19"... -
Page 11: Circulating Air Requirements
CIRCULATING AIR REQUIREMENTS must be installed downstream (on the outlet side) of the furnace or in parallel with the furnace. WARNING: • If a cooling system is installed in parallel with the furnace, a damper must be installed to prevent chilled air Do not allow combustion products to enter the from entering the furnace and condensing on the heat •... -
Page 12: Furnace Installation
Bottom Return Air Inlet If the bottom of the furnace is being used as a return air G7XC series gas furnaces are shipped ready for installation inlet, the bottom panel must be removed prior to installation. in the upfl ow or horizontal right or left positions. Access See Bottom Panel Removal (page 13). -
Page 13: Bottom Panel Removal
Bottom Panel Removal The steps listed below describe how to remove the bottom panel from the furnace. See Figure 12. 1. Remove the door (1) from the blower compartment. 2. Disconnect the blower motor wiring harness (2) from the control board. 3. -
Page 14: Vent And Inducer Assembly Options
Accessories The components below are included in the extra parts bag that is supplied with the purchase of your furnace. Depending on your particular installation, some of these STATUS components are optional and may not be used. Please FLAME BLOWER DELAY refer to the descriptions and accompanying fi... -
Page 15: Pvc Tee, Reducer, & Hose Barbs
1. Install the 1/2” x 1/2” hose barb on the 2” PVC reducer. Do not over tighten! NOTE: Use an adequate amount of Tefl on tape on the threads. Do not use liquid sealants. 2. Install the reducer on one end of the PVC tee. Use appropriate primer and cement to permanently bond the reducer and tee together. -
Page 16: Optional Pvc Pipe Installation
GAS SUPPLY AND PIPING Optional PVC Pipe Installation (Figure 18) All gas piping must be installed in compliance with local When running the 2” PVC pipe out through the top codes and utility regulations. In the absence of local codes of the *SC upfl... -
Page 17: High-Altitude Application
IMPORTANT NOTE: When pressure testing gas supply be reduced 8% at 2,000 feet, 12% at 3,000 feet, etc. This lines at pressures greater than 1/2 psig (14 inch W.C.), deration is in reference to the input rate and gas heating the gas supply piping system must be disconnected value at sea level. -
Page 18: Conversion To Lp/Propane
When deration is completed, it is required that you ELECTRICAL WIRING measure the gas input rate. This may be accomplished Electrical connections must be in compliance with all in the usual way, by clocking the gas meter and using applicable local codes. For electrical requirements, refer the local gas heating value. -
Page 19: Twinning
Furnace Furnace Cabinet Nominal Maximum Minimum Maximum Minimum Maximum Model Input Width Electrical Operating Operating Furnace Wire Fuse or Circuit Number (Btu/hr) (in.) Supply Voltage Voltage Amperes Gauge Breaker Amps** G7XC ½ 046E-24B 46,000 230-50-1 ½ 061E-24B 61,000 230-50-1 076E-35C 76,000 230-50-1 ½... -
Page 20: Grounding
Grounding 1. Shut off all other gas fi red appliances. 2. Start the furnace and run it for at least 3 minutes. WARNING: 3. Measure the time (in seconds) required for the gas meter to complete one revolution. To minimize personal injury, the furnace cabinet 4. -
Page 21: Verifying And Adjusting Temperature Rise
Verifying and Adjusting Temperature Rise Verifying Burner Operation Confi rm the temperature rise through the furnace is CAUTION: within the limits specifi ed on the furnace rating plate. Any temperature rise outside the specifi ed limits could result The door over the burners may only be open in premature failure of the heat exchanger. -
Page 22: Operating Sequence
OPERATING SEQUENCE MAINTENANCE The operating sequences for the heating, cooling, and fan WARNING: modes are described below. Refer to the fi eld and furnace wiring diagrams (Figure 15, page 16), (Figure 16, page These maintenance instructions are primarily 17) and (Figure 23, page 29). intended to assist qualified technicians Heating Cycle experienced in the proper maintenance and... -
Page 23: Blower Compartment
3. Remove the burner door from the furnace. The bearings in the blower motor and inducer blower used in these furnaces are pre-lubricated and sealed by the 4. Turn the gas control switch to the OFF position. manufacturer. No further oiling of the bearings is required for the life of the motor. -
Page 24: Troubleshooting
TROUBLESHOOTING If the furnace fails to operate check the following: Green Diagnostic Description • Is the thermostat operating properly? • Are the blower compartment door(s) in place? Control Fault (No Power) • Is the furnace disconnect closed? L1/Neutral Polarity Fault Flash Flash •... -
Page 25: Figures And Tables
FIGURES AND TABLES *XC 92.1% Upfl ow/Horizontal Furnace Dim. Dim. Dim. Model #’s “A” “B” “C” 046E-24B TOP VIEW 17 ½ 15 ⅞ 16 ⅛ FRONT BRACE 061E-24B 076E-35C 19 ⅜ 19 ⅝ FLANGES 102E-45D 24 ½ 22 ⅞ 23 ⅛ BOTTOM ½... -
Page 26: Airfl Ow Data
AIRFLOW DATA G7XC UPFLOW / HORIZONTAL GAS FURNACES - 92.1% AFUE External Static Pressure (in.w.c.) Motor Switch Heating Model Setting Input Number (Btuh) 1/5 2/6 3/7 4/8 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise 0 0 0 0 1 0 0 0 0 1 0 0... - Page 27 G7XC UPFLOW / HORIZONTAL GAS FURNACES - 92.1% AFUE External Static Pressure (in.w.c.) Motor Switch Heating Model Setting Input Number (Btuh) 1/5 2/6 3/7 4/8 CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise 0 0 0 0 1,125 1,040 1 0 0 0 1,205...
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Page 28: 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 12,86 2,571 1,125 2,250 1,000 2,000... -
Page 29: Natural Gas
NATURAL GAS INPUT (BTU) ALTITUDE ABOVE SEA LEVEL 46,000 61,000 76,000 102,000 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 3,000 to 4,999 FT MANIFOLD PRESSURE ORIFICE SIZE 5,000 to 5,999 FT 10.0... -
Page 30: Electrical Information
ELECTRICAL INFORMATION COOL HEAT FAN SPEED HIGH HEAT COOL XFMR R C Y G W Figure 26. Wiring Diagram for Upfl ow/Horizontal Furnaces... -
Page 31: Venting Information
VENTING INFORMATION 1 Pipe Upflow See View Option Option Option See View -A- Drain Line See View -B- See View -C- Attached to (Tubing is routed thru the 3/4 x 1/2 Hose Barb blower deck and side of cabinet.) VIEW -A- VIEW -B- VIEW -C- Header... - Page 32 Horizontal Right - 1 Pipe Option Plug Option See View -D- PVC TEE and Reducer Inlet Air Inlet Drain Line Attached to 3/4 x 1/2 Hose Barb Plug Plug See View -E- See View -D- See View -E- Inline Drain VIEW -E- VIEW -F- VIEW -G-...
- Page 33 Horizontal Right - 2 Pipe Plug Option Option PVC TEE See View -H- and Reducer Inlet Air Inlet Air Drain Line Attached to 3/4 x 1/2 Plug Plug Hose Barb See View -H- See View -I- See View -I- Inline Drain VIEW -J- VIEW -K-...
- Page 34 HORIZONTAL VENTING Straps or Other Suitable Supports (2-Pipe Shown) at minimum 5 ft. Intervals Seal / Caulk First Support as Close Around Pipes to Furnace as Possible at Wall 90° Elbows 90° Elbow Upward Pitch 1/4” Per Foot (Exhaust Vent) 12”...
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Page 35: Location Of Furnace Components
LOCATION OF FURNACE COMPONENTS COMPONENT NAME ITEM Blower Assembly Blower Door Switch Burner Assembly Control Board Finish Flanges Flame Sensor Gas Manifold Gas Valve Igniter Inducer Assembly Limit Switch Main Air Limit Switch Motor Control Board Pressure Switch(s) (‘B’, ‘C’, & ‘D’ cabinets only) Roll-Out Switch(s) Transformer Figure 31. -
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 INSTALLATION ADDRESS: Has the thermostat been calibrated? Is the thermostat level? CITY _______________ STATE _____________ Is the heat anticipator setting correct? UNIT MODEL # GAS SYSTEM:...