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Summary of Contents for Nordyne G6 Series
- Page 1 G6 Series 80+ Mid Efficiency Upflow Horizontal/ Downflow Models Service Manual...
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Page 3: Table Of Contents
TABLE OF CONTENTS 1. Introduction .............. 2 7. Component Parts ........... 19 Model Identification Code ......... 5 Line Voltage ............19 Serial Number Identification Code ......5 Supply Voltage ............20 Furnace Specifications ......... 5, 6 Trouble Shooting Sequence ........21 Clearances to Combustibles ........ -
Page 4: Introduction
INTRODUCTION This service manual is designed to be used in conjunction with the installation manual provided with each furnace. This furnace represents the very latest in mid efficiency gas furnace technology. Consequently, certain controls within the furnace consist of highly sophisticated electronic components which are not user serviceable. - Page 5 FURNACE SPECIFICATIONS - Upflow G6RA Models Unit Shown in Upflow Position 3/ 4 Rotate 90 Clockwise or Counter Clockwise FLUE OUTLET for Horizontal Application 3/ 4 1/ 8 Cut-out for 1/ 2 1/ 2 Gas Connection 1/ 2 1/ 2 Cut-out for Gas Connection 7/ 8...
- Page 6 FURNACE SPECIFICATIONS - Downflow G6RK Models 3/4" 23 5/8" 3/4" 4" Dia. Vent 19 3/4" 3/4" 3/4" 24 1/2" Cut-out for Electric Connection 43" Both sides 25" 25" Cut-out for Gas Connection Cut - out for 1-1/2 x 3-1/2 (both sides) 27 1/8"...
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Page 7: Model Identification Code
MODEL IDENTIFICATION CODE Nominal CFM Airflow @ 0.5" WC 08 = 800 16 = 1600 12 = 1200 20 = 2000 Design Series C = U.S. / Canada Residential N = NOx U.S. A = 80+ AFUE Upflow/ Heating Input - Btuh Horizontal 040 = 40,000 080 =... -
Page 8: Clearances To Combustibles
Clearances to Combustibles Downflow Warning (G6RK Models): The design of the downflow furnace is certified for natural or This furnace is Design Certified by A.G.A. Laboratories, and propane gas and for installation on non-combustible flooring. approved by Canadian Gas Association (CGA) for the minimum A special combustible floor sub-base is required when clearances to combustible material listed in Table 2. -
Page 9: Circulating Air Supply
A clearance of at least 36 inches from the front of the furnace If a cooling system is installed in parallel with the furnace, a is recommended to allow for servicing and maintenance. damper must be installed to prevent chilled air from entering Where accessibility clearances are greater than the the furnace and condensing on the heat exchanger. -
Page 10: Airflow Data
CAPACITIES —Furnace Airflow Data Upflow Furnace Airflow Data G6RA External Static Pressure (Inches Water Column) Furnace Motor Motor Model No. Speed Rise Rise Rise Rise Rise High * 1000 045C-08 Medium Low ** High * 1380 1350 1310 1260 1210 060C-12 Medium 1220... -
Page 11: Venting And Combustion Air Requirements
For example, a space including a water heater rated at 45,000 VENTING AND COMBUSTION Btuh input and a furnace rated at 75,000 Btuh requires a AIR REQUIREMENTS volume of 6,000 cubic feet [50 x (45 + 75) = 6,000] to be General considered unconfined. -
Page 12: Air From Inside
If the furnace is to be suspended from the ceiling, it will be Vent or necessary to use steel straps around each end of the Openings to Chimney adjacent space. furnace. These straps should be attached to the furnace with Each opening must be at least 100 sq. -
Page 13: Air Directly Through An Exterior Wall
If the unit is installed in an area with an exhaust fan, provide sufficient ventilation to prevent negative pressures from Ventilation Louvers at Vent or each end of attic occurring in the room. Chimney Outlet Air Duct must be at least The combustion air openings must not be restricted in any 1 sq. -
Page 14: Category I Common Venting
VENTING REQUIREMENTS (e) Test for draft hood equipped appliance spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle. General This furnace must be vented in compliance with, the current (f) After it has been determined that each appliance connected revision of the National Fuel Gas Code (ANSI-Z223.1/NFPA54), to the venting system properly vents when tested as outlined... -
Page 15: Category Iii Horizontal Venting
The venting system should be designed to have the minimum Horizontal Venting For G6RA Models: number of elbows or turns. All horizontal runs shall be sloped upwards from the furnace at 1/4 inch per running foot NOTE: An optional horizontal vent kit will be required. See of vent. -
Page 16: For G6Rk
By-pass the vent switch, located on blower compartment door, by removing both wires from the switch. Remove wire terminals, strip wires and tie Collector Pressure Bleed Tube Switch Switch Switch Switch Bleed Tube Orifice Limit Flame Vent Roll-Out Limit Wire Nut Blue Figure 10. -
Page 17: Through-The-Wall Power Venting
All horizontal sections must have a slope toward the CAUTION: drain tee of not less than 1/4" per foot to prevent the collection of condensate at any location other than at Do not drill holes through the vent pipe or the tee. -
Page 18: Location Of Outdoor Termination
Flexible Vent Systems Use Wall Thimble at Vent Points WARNING: Termination Tee The entire vent system must be sealed with Support a high temperature sealant which will withstand temperatures 450°F. Recommended sealants: Dow Corning Sealant 736 RTV; GE 106 RTV; High Tech Ind., High TEMP RED. -
Page 19: Flexible Vent Systems
General Outer Overlapping Inside Proper maintenance is most important to achieve the best Shield 6 " Dia. Combustible Wall performance from a furnace. Follow these instructions for Wall Thimble (Inner Half) years of safe, trouble free operation. Wall Thimble Outer Half 3"... -
Page 20: Cooling Mode
Twinning of Two Furnaces energized for 120 second (factory set) or 60, 90, or 180 The control board on a G6 series furnace is capable of being seconds (field adjustable). (See Figure 21.) twinned to another G6 furnace. The thermostat wires and the 12. -
Page 21: Component Parts
Thermostat W G Y R Twin Twin Terminal Terminal Unit Figure 18. Twinning G6RA G6RK 8 Vent Assembly (G6RA) 1 Ignitor 13 Blower Assembly 9 Vent Switch 14 Inducer 2 Flame Sensor 10 Low Voltage 15 Combustion Tube 3 Gas Valve Transformer w/insulation (G6RK) 4 Roll-Out Switch(s) -
Page 22: Line Voltage
Line Voltage Wiring (See Figure 15) wire and the incoming "hot" line is connected to the black wire in the furnace junction box. The G6 series The line voltage (115 volt) to the furnace must be supplied furnaces will not operate unless polarity and ground are from a dedicated circuit containing the correct fuse or circuit properly connected. -
Page 23: Trouble Shooting Sequence
Troubleshooting Flow Chart Use in conjunction with time sequence and wiring diagrams that follow. Call for heat, Check for voltage Inducer starts Circuit board 3 blinks t-stat closes R-W at inducer molex plug Replace Pressure switch Replace Inducer Check for red light Check fuse on 24 Volt, C to W Board... -
Page 24: Utec Control Board Sequence
Figure 21. UTEC Control Sequence 22 G6RA, G6RK Service Manual... -
Page 25: Wiring Diagram - G6Ra Upflow
For G6RA Residential Furnaces BLUE BLUE BLUE BLUE BLUE FLAME FLAME SUPLY AIR PRESSURE VENT FLAME BLOWER VENT ROLL-OUT ROLL-OUT LIMIT SWITCH DECK PRESSURE SWITCH ROLL-OUT SAFETY SWITCH SWITCH SWITCH SWITCH SWITCH (G6RD Only) SWITCH (optional) (optional) (optional) WHITE BLACK JUNCTION WHITE (NEUTRAL) BLACK 120V... -
Page 26: Wiring Diagram - G6Rk Downflow
For G6RK Residential Furnaces BLUE BLUE BLUE BLUE SUPPLY AIR VENT BLOWER FLAME PRESSURE LIMIT SAFETY DECK ROLL-OUT SWITCH SWITCH SWITCH SWITCH SWITCH WHITE BLACK WHITE (NEUTRAL) BLACK 120V BLOWER DOOR SWITCH GROUND GREEN ROOM THERMOSTAT TRANSFORMER WHITE W/ BLK STRIPES WHITE 24 V 120 V... -
Page 27: Polarity And Ground
Figure 24. Polarity and Ground Polarity and Ground Check-out procedure (using ohm meter). The G6 furnace will not operate if loss of ground occurs. 1. Turn off incoming power supply. Every effort should be made at the installation to provide a 2. -
Page 28: Low Voltage Wiring
Check-out procedure: A/C Condensing Unit 1. Using a volt/ohmmeter on at least 115 vac scale. 2. Measure the voltage on the control board terminals Condensing Unit "XFMR" & "NEUTRAL". Control Box 3. If voltage is 115 vac measure the voltage at terminals marked "24 vac"... - Page 29 A. 90 second delay blower "off" time in cooling mode. D. Humidifier & Electronic Cleaner Tap - Both taps are rated B. Low Voltage Fuse - an over-current, short circuit safety at 1 amp and have an output voltage of 120 VAC. All device designed to protect the control board in the event humidifiers and electronic air cleaners should be installed of a low voltage short or over-current.
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Page 30: High Limit Controls
Fault Status of Fault Condition of Flashes Furnace Clearing ------- No Fault LED on Normal Main Blower & Induced Draft Motor running Limit Circuit closes Limit Circuit open Induced Draft Pressure Switch Pressure Switch closes Motor running stuck open Pressure Switch stuck closed Unit does not operate Pressure Switch opens... -
Page 31: Main Air Limit Control
Main Air Limit Control (See Figure 35) Vent Limit Control (See Figure 35A) The main limit control is an automatic reset type. It reacts to The function of the vent limit switch is to sense the heat from abnormally high air temperatures in the heat exchanger area. the flue gas in the event the vent system becomes blocked If the main limit opens, the gas valve is de-energized and the or restricted. -
Page 32: Roll Out Limit Control
Roll Out Limit Control (See Figure 36) The function of a roll out switch is to sense any flames backing out of the heat exchanger tubes. They are normally closed and are manually reset. Check-out Procedure: 1. Shut off power supply to furnace. 2. - Page 33 Exchanger Air Flow through Heat Exchangers Vent Burner Compartment Combustion Figure 40. Settings Open Close Application Nordyne Part # Switch Type -0.55 -0.75 80+ upflow 632212 atm.-single port (NO) -0.55 -0.75 80+ downflow 632212 atm.-single port (NO) *G6RD vent pressure switch is normally closed Table 7.
- Page 34 Check-out Procedure: 2. Connect a Differential Pressure Gauge or Inclined 1. Remove orange wires from pressure switch. Place a tee Manometer to tee. in the hose connecting pressure switch to the inducer 3. Start induce draft motor. housing. 4. Negative pressure created by the induced draft motor must be greater than 0.75"...
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Page 35: Hot Surface Ignitor
3/16" in front of the burners. Its function is to ignite fuel at the appropriate time in the sequence. The hot surface ignitor used by NORDYNE is manufactured by CARBORUNDUM. NOTE: Special care should be taken when handling the ignitor. -
Page 36: Gas Valve
Gas Valve (See Figure 45.) Check-out Procedure 1. By using a volt meter on a 24 volt scale, position the The G6 series furnaces use Honeywell valve VR8205A2008. probes at the gas valves. Gas valves are 24 vac operated. There are ports on the 2. -
Page 37: Flame Sensor
Flame Sensor (See Figure 48.) The flame sensor is located in front of the first burner. After the burners are ignited, flame is proven through the flame sensor by flame rectification. The sensor is an alloy consisting of aluminum, chromium, and iron. This alloy is commonly known as Kanthal D. -
Page 38: Blower Performance
FLUE GAS TEMPERATURE Proper Airflow - Checking Temperature Rise. (See page 7.) The G6 series furnaces flue gas temperature range is A temperature rise may be taken across the furnace by between 300°F and 325°F Make a small hole in vent pipe, as checking the temperature of the supply duct and subtracting close to furnace as possible. -
Page 39: Gas Conversion And High Altitude
CAUTION: G6RA&K Typical Left Side Entry Manifold Do not re-drill the burner orifices. If the orifice size must be changed, use only new orifices. GAS CONVERSION AND HIGH ALTITUDE DERATE Burner Assembly High Altitude Derate The nameplate input rating for the furnaces apply for elevations up to 2,000 feet (610m) above sea level. - Page 40 Follow the procedure below to determine the firing rate. 6. Relatively small adjustments to the firing rate can be made by adjusting the gas manifold pressure. 1. Shut off all other gas fired appliances. 7. See High Altitude Derate for advice on gas orifice size for 2.
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Page 41: Accessories
P/N 902995 and high altitudes P/N 902996. Electronic Air Cleaner (Figure 56) NORDYNE offers an Electronic Air Cleaner for installation on all G6 series furnaces. These units are powered from the furnace's integrated control board. Figure 56. Electronic Air Cleaner... -
Page 42: Vent Kit Bleed Tube Chart
VENT KIT #903196 BLEED TUBE CHART WHITE CLEAR G6RA 072C-16 G6RA144C-20 G6RA 060C-12 G6RA 096C-20 G6RA 144N-20 G6RA 072C-12 G6RA 072N-16 G6RA 144C-20-H G6RA 096C-16 G6RA 096N-20 G6RA 144E-20 G6RA 120C-16 G6RA 072C-16-H G6RA 120C-20 G6RA 096C-20-H G6RA 060N-12 G6RA 072N-12 G6RA 096N-16 G6RA 120N-16 G6RA 120N-20... - Page 43 Typical meters used to service furnaces. A. Differential Pressure Gauge B. Volt-Ohm Meter C. Gas Pressure Gauge D. Incline Manometer...
- Page 44 407A-0298 Specifications and illustrations subject to change without notice and without incurring obligations. St. Louis, MO Printed in U.S.A. (12/97)
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