Nortek SL Series Installation Instructions Manual
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Nortek SL Series Installation Instructions Manual

Single stage condensing gas furnaces
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Single Stage Condensing Gas Furnaces
INSTALLATION INSTRUCTIONS
*SC (92.1%AFUE)
Upflow / Horizontal Furnace
• Failure to follow safety warnings exactly could result in serious injury, death 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.
• 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 fire department.
DO NOT DESTROY. PLEASE READ CAREFULLY & KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
*SD (95.0% AFUE)
Upflow / Horizontal Furnace
WARNING
FIRE OR EXPLOSION HAZARD
WHAT TO DO IF YOU SMELL GAS
92.1% Through 95.0% AFUE
*SL (92.1% AFUE) &
*SM (95.0% AFUE)
Downflow Furnace

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  • Page 1 Single Stage Condensing Gas Furnaces 92.1% Through 95.0% AFUE INSTALLATION INSTRUCTIONS *SC (92.1%AFUE) *SL (92.1% AFUE) & *SM (95.0% AFUE) Upflow / Horizontal Furnace Downflow Furnace *SD (95.0% AFUE) Upflow / Horizontal Furnace WARNING FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could result in serious injury, death or property damage.

  • Page 2: Table Of Contents

    LOW Heating Value ........38 Acoustical Treatments ............14 Table 12. Vent Termination Clearances ....... 39 FURNACE INSTALLATION ..........14 *SC & *SL Series General Requirements ............. 14 Figure 38. Horizontal & Vertical Venting ...... 40 Upflow Furnaces .............. 14 Figure 39.

  • Page 3: Important Safety Information

    IMPORTANT SAFETY INFORMATION kerosene, cigarette lighter fluid, dry cleaning fluids, paint thinners, or other volatile fluids. INSTALLER: Please read all instructions before servicing • The installer should become familiar with the units wiring this equipment. Pay attention to all safety warnings and diagram before making any electrical connections to the any other special notes highlighted in the manual.

  • Page 4: Combustion Air Quality

    1. For direct-vent appliances, mechanical-vent heating The information listed below is for reference purposes only appliances or domestic hot water equipment, where the and does not necessarily have jurisdiction over local or state bottom of the vent terminal and the air intake is installed codes.

  • Page 5: Heating Load

    • Exposure to the following substances in the combustion CLEARANCES TO COMBUSTIBLE MATERIALS air supply may require outdoor air for combustion: UPFLOW DOWNFLOW Permanent wave solutions APPLICATIONS APPLICATIONS Chlorinated waxes and cleaners Chlorine based swimming pool chemicals BACK BACK HORIZONTAL Water softening chemicals APPLICATIONS De-icing salts or chemicals...

  • Page 6: Combustion Air & Venting Requirements

    Construction checklist. result in carbon monoxide poisoning or death. — Email copy of completed Use of Furnace During Construction checklist to warranty@nortek.com The following steps shall be followed with — Leave original completed Use of Furnace During each individual appliance connected to the Construction checklist with furnace.

  • Page 7: Direct Vent Furnaces

    IMPORTANT INFORMATION: CAUTION: • This furnace must be vented in compliance with the current revision of the National Fuel Gas Code Exhaust fans, clothes dryers, fireplaces and (ANSI-Z223.1/NFPA54). Instructions for determining the other appliances that force air from the house adequacy of an installation can be found in the current revision of the NFGC (ANSI Z223.1 / NFPA54).

  • Page 8: Outdoor Air From A Crawl Space Or Vented Attic

    Outdoor Air Using Vertical Ducts EXAMPLE If combustion air is taken from outdoors through vertical If the combined input rate of all appliances is less than or ducts, the openings and ducts must have a minimum free equal to 100,000 Btuh, each opening must have a free area of one square inch per 4,000 Btuh of total appliance area of at least 100 in .

  • Page 9: Air Directly Through An Exterior Wall

    Conventional Vent Systems - Unconfined Air Directly Through An Exterior Wall If combustion air is provided directly through an exterior Spaces wall, the two openings must each have free area of at least An unconfined space is an area including all rooms not one square inch per 4,000 Btuh of total appliance input.

  • Page 10: Vent Pipe Material

    Vent Pipe Material indicates the maximum allowable pipe Table 1 (page 10) length for a furnace of known input rate, when installed with Vent and combustion air pipe and fittings must be one of piping of selected diameter and number of elbows. To use the following materials in the list and must conform to the the table, the furnace input rate, the centerline length and indicated ANSI/ASTM standards.

  • Page 11: Outdoor Terminations - Horizontal Venting

    • Route piping as direct as possible between the furnace and the outdoors. Horizontal piping from inducer to the flue pipe must be sloped 1/4” per foot to ensure condensate flows towards the drain tee or PVC trap. Longer vent runs require larger pipe diameters. Refer to the Inducer &...

  • Page 12: Outdoor Terminations - Vertical Venting

    19" Max. MAXIMUM FLUE PIPE LENGTH (FEET) WINTER DESIGN IN UNCONDITIONED & EXTERIOR SPACES (See Note) TEMPERATURE 12" Above WITHOUT INSULATION WITH INSULATION* Maximum Expected Support Snow Level 1/2" Outside *NOTE: Insulation thickness greater than 3/8 inch, based on an R value Armaflex Wall of 3.5 (ft x F x hr) / (BTU x in.)

  • Page 13: Circulating Air Requirements

    For Installations where there is limited clearance for the • When a cooling system is installed which uses the J-Trap (such as an attic where it may be installed between furnace blower to provide airflow over the indoor coil, the ceiling joists), either side of the J-Trap can be shortened to coil must be installed downstream (on the outlet side) of a minimum of 3 Inches.

  • Page 14: Downflow Furnaces

    FURNACE INSTALLATION Downflow Furnaces • To attach the return air duct to the furnace, bend the *SC & *SD series gas furnaces offer a wide range of flanges on the furnace upward 90° with wide duct pliers. installation options, including installation in the upflow or for furnace flange locations.

  • Page 15: Downflow Furnaces

    Downflow Furnaces Two-pipe installation shown WARNING: Flue pipe vented to outside Wood or The furnace must not be installed directly on non-combustible carpeting, tile, or any combustible material other platform than wood flooring. Coil Plenum WARNING: Condensate Combustion Air Drain Lines Failure to install the downflow sub-base kit may result in fire, property damage or personal injury.

  • Page 16: Inducer Assembly Rotation

    6. Remove the cabinet plug from side of furnace and reinstall Inducer Assembly Rotation in hole on opposite side of cabinet. 7. Install in-line drain assembly and tubing. WARNING: 8. Install all condensate drain lines. For *SC & *SL series, refer to , or Figure 38 Figure 39...

  • Page 17: Finish Flange

    ALTERNATE PRIMARY Figure 14. Pressure Switch Tubing LOCATION LOCATION for *SC038 Furnaces Only Figure 17. Alternate Pressure Switch Location FRONT Finish FRONT lettering must be Flange located near front of furnace Flange Gasket Hole for Hole for Inlet Flue Air Vent Pipe Vent Pipe Figure 15.

  • Page 18: Pvc Components

    INSTALLATION OF PVC COMPONENTS ø 2 1/4” Rubber Grommet (TYPICAL ORIENTATION) (see note) 2” PVC Pipe from Inline Drain Assembly (Not Included) 2” PVC Tee PVC TRAP Not Included in *SC & *SL Models 1/2” Tubing (Field Supplied) Drain Line Attached 1/2”...

  • Page 19: Optional Pvc Pipe Installation

    The J-trap may need to be Blower rotated to the side that matches your setup. Assembly For *SC & *SL series, see Figure 39 (page 41) Figure Bottom Panel , &...

  • Page 20: Gas Supply & Piping

    • Gas piping must never run in or through air ducts, chimneys, gas vents, or elevator shafts. • Compounds used on threaded joints of gas piping Screws must be resistant to the actions of LP propane gas. Blower • The main gas valve and main power disconnect to the Door Deck furnace must be properly labeled by the installer in...

  • Page 21: Converting From Natural Gas To Lp / Propane

    After changing the regulator pressure or the orifices, it is WARNING: required that you measure the gas input rate. This may be accomplished in the usual way, by clocking the gas meter The reduction of input rating necessary for high and using the local gas heating value.
  • Page 22 *SC SERIES Burner Burner Assembly Assembly Manifold Manifold Valve Valve Note “A” Note “A” Shut-Off Pipe Shut-Off Pipe Valve Nipple Valve Nipple Note “B” Note “B” Plug Elbow Drip Leg Drip Leg Elbow Ground Ground Joint Joint Union Union Right Side Entry Left Side Entry *SD SERIES Burner...
  • Page 23 *SL SERIES Note “A” Note “A” Shut-Off Shut-Off Elbow Valve Elbow Note “B” Note “B” Valve Plug Drip Leg Drip Leg Pipe Pipe Nipple Ground Ground Nipple Joint Joint Union Union Valve Valve Right Side Entry Left Side Entry Burner...

  • Page 24: Electrical Wiring

    ELECTRICAL WIRING Line Voltage Wiring It is recommended that the line voltage (115 VAC) to the WARNING: furnace be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace as listed Table 5 (page 24) ELECTRICAL SHOCK, FIRE OR The installer should become familiar with the units wiring EXPLOSION HAZARD...

  • Page 25: Thermostat / Low Voltage Connections

    Field Supplied Field Supplied Fused Service Disconnect within Field Supplied Field Line Voltage Wiring Panel Sight of Furnace Panel Connector Factory Line Voltage Wiring Black Black (Hot) Black Black White (Neutral) White White White Green or Bare (Ground) Ground Ground Ground Junction Box (may be int.

  • Page 26: One Stage Heating

    • Both furnaces must have a common return duct and SINGLE STAGE HEATING (WITH TWINNING) common supply plenum. • Both furnaces must be the same phase and on the same UNIT THERMOSTAT RELAY leg of power. • Furnaces equipped with variable speed iSEER™ motors may not be twinned under any circumstances.

  • Page 27: Start-Up & Adjustments

    START-UP & ADJUSTMENTS Capscrew Pre-Start Check List √ Verify the polarity of the connections are correct, the line voltage power leads are securely connected and the furnace is properly grounded. √ Verify the thermostat wires (R, W, Y, & G) are securely connected to the correct leads on the terminal strip of the circuit board.

  • Page 28: Verifying Burner Operation

    Fault Conditions from the factory pre-wired for 4 blower speeds. There is a fifth alternate speed available on the motor. To utilize the alternate There is a green and a red LED (labeled “Status”) on the speed, remove the wire at the motor plug of the desired speed to motor control board to provide system faults as described be changed (H, MH, ML, L).

  • Page 29: Maintenance

    MAINTENANCE for component location. 1. Shut off gas supply to the furnace at the meter or at a WARNING: manual valve in the supply piping. 2. Turn off all power to the furnace and set the thermostat to it’s lowest setting. ELECTRICAL SHOCK, FIRE OR 3.

  • Page 30: Figures & Tables

    FIGURES & TABLES TOP VIEW BOTTOM VIEW *SL & *SM DOWNFLOW FURNACES MODEL #’S DIM. -A- DIM. -B- DIM. -C- Front Brace 054D-T24B1 17 1/2 15 7/8 16 1/8 072D-T24B1 072D-T35C1 19 3/8 19 5/8 090D-T35C1 NOTE: Dimensions shown in inches. Combustion Flue 7 1/2...
  • Page 31 TOP VIEW BOTTOM VIEW *SC UPFLOW / HORIZONTAL FURNACES Front Brace MODEL #’S DIM. -A- DIM. -B- DIM. -C- 038D-T23A1 14 1/4 12 5/8 12 7/8 054D-T24B1 17 1/2 15 7/8 16 1/8 Bottom 072D-T24B1 Panel 072D-T35C1 19 3/8 19 5/8 Flue 090D-T35C1 Combustion...
  • Page 32 Electrical Information HIGH XFMR R C Y G W Figure 34. Nordyne/UTEC Wiring Diagram...
  • Page 33 Electrical Information EAC-H 120V HUM-H CIRC-H XFRM-H LINE-H Figure 35. Emerson Wiring Diagram...
  • Page 34 LADDER DIAGRAM Single Stage Furnaces DOOR SWITCH NEUTRAL NEUTRAL BLOWER CHOKE MOTOR (SOME MODELS) FLAME SENSOR P1-7 NEUTRAL ELECTRONIC AIR CLEANER P2-3 P2-6 HOT SURFACE IGNITOR NEUTRAL HUMIDIFIER P2-1 P2-4 INDUCER NEUTRAL XFORMER 120 VAC See Note TRANSFORMER 24 VAC TO MOTOR 3A FUSE RELAYS...
  • Page 35 LADDER DIAGRAM Single Stage Furnaces DOOR SWITCH NEUTRAL NEUTRAL BLOWER CHOKE MOTOR (SOME MODELS) FLAME SENSOR P1-2 NEUTRAL ELECTRONIC AIR CLEANER P2-1 NEUTRAL HOT SURFACE IGNITOR NEUTRAL HUMIDIFIER P2-2 NEUTRAL INDUCER NEUTRAL XFORMER 120 VAC See Note TRANSFORMER 24 VAC P1-3 TO MOTOR 3A FUSE...
  • Page 36 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) ALTITUDE ABOVE 38,000 38,000 SEA LEVEL 54,000 72,000 90,000 108,000 118,000 120,000 (SC MODELS) (SD MODELS) ORIFICE SIZE 0 to 1,999 FT 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 MANIFOLD PRESSURE ORIFICE SIZE 2,000 to 2,999 FT MANIFOLD PRESSURE...
  • Page 38 HIGH ALTITUDE DERATION – NATURAL GAS WITH HIGH HEATING VALUE INPUT (BTU) ALTITUDE ABOVE 38,000 38,000 SEA LEVEL 54,000 72,000 90,000 108,000 118,000 120,000 (SC MODELS) (SD MODELS) 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...
  • Page 39 Venting Information VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED CANADIAN INSTALLATIONS US INSTALLATIONS CLEARANCE LOCATION DIRECT VENT (2-PIPE) & 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 40: Sc & *Sl Series

    *SC & *SL Series HORIZONTAL VENTING w/ 2-Pipes Straps or other suitable supports Wall (Upflow Furnace Shown) at minimum 5 ft. intervals (both pipes) Seal / caulk around pipes First support as close at wall to furnace as possible 90° Elbows 90°...

  • Page 41: (*Sc Series)

    *SC SERIES UPFLOW - 1 PIPE OPTIONS Rubber COMBUSTION COMBUSTION Grommet COMBUSTION Plug Plug NOTE 5 NOTE 5 Rubber Grommet OPTION 1 OPTION 3 OPTION 2 Rubber Grommet PVC Trap See VIEW C for drain line positions See VIEW A for drain line positions See VIEW B for drain line positions VIEW -A- VIEW -B-...
  • Page 42 *SC SERIES HORIZONTAL RIGHT - 1 PIPE OPTIONS Rubber See VIEW D for See VIEW E for Grommet Plug drain line positions drain line positions NOTE 5 Plug COMBUSTION COMBUSTION OPTION OPTION Plug Plug VIEW -D- VIEW -E- VIEW -F- VIEW -G- Inline Drain Field Supplied...
  • Page 43 *SC SERIES HORIZONTAL RIGHT - 2 PIPE OPTIONS Rubber See VIEW H for See VIEW I for Plug Grommet drain line positions drain line positions NOTE 5 Plug COMBUSTION AIR COMBUSTION AIR OPTION OPTION Flange Flange Plug Plug VIEW -I- VIEW -K- VIEW -H- VIEW -J-...

  • Page 44: (*Sl Series)

    Option NOTE 5 NOTE 5 Rubber Grommet Trap Rubber Grommet See VIEW L for drain line positions See VIEW M for drain line positions See VIEW N for drain line positions Figure 42. Venting Options for Downflow Installations (*SL Series)

  • Page 45: Sd & *Sm Series

    *SD & *SM Series HORIZONTAL VENTING w/ 2-Pipes (Upflow Furnace Shown) Straps or Other Suitable Seal/Caulk Supports at minimum of 5 ft. Intervals Around Pipes at Building 90° 90° Elbow Elbow COMBUSTION AIR 90° Elbow Upward Pitch - 1/4” per foot 12”...
  • Page 46 *SD SERIES UPFLOW - 1 PIPE OPTIONS COMBUSTION COMBUSTION NOTE 5 PVC Tee PVC Trap NOTE 5 PVC Tee Rubber Grommet OPTION 21 OPTION 22 PVC Trap Rubber Grommet See VIEW O for drain line positions See VIEW P for drain line positions VIEW -O- VIEW -P- Field Supplied...
  • Page 47 *SD SERIES HORIZONTAL RIGHT - 1 PIPE OPTION *SD SERIES HORIZONTAL LEFT - 1 PIPE OPTION Rubber Rubber Option Option Grommet Grommet COMBUSTION COMBUSTION See VIEW R for See VIEW Q for Plug Plug drain line positions drain line positions Inline Drain (Factory Supplied) See NOTE 3...
  • Page 48 *SM SERIES DOWNFLOW - 1 PIPE OPTIONS COMBUSTION COMBUSTION Rubber COMBUSTION Grommet Option Option Option NOTE 5 PVC Tee NOTE 5 PVC Trap PVC Tee Rubber Grommet PVC Trap Rubber Grommet See VIEW S for drain line positions See VIEW T for drain line positions See VIEW U for drain line positions VIEW -U- Inline Drain...

  • Page 49: Troubleshooting

    TROUBLESHOOTING RED LED ERROR/CONDITION FLASH If the furnace fails to operate check the following: • Is the thermostat operating properly? System Lockout (Retries Exceeded) • Are the blower compartment door(s) in place? Pressure Switch Stuck Closed • Is the furnace disconnect closed? Pressure Switch Stuck Open •...

  • Page 50: Furnace Components

    FURNACE COMPONENTS The descriptions below are various functional components that affect the operation and shutting down of this furnace. Some of these components and their locations are shown . If any Figure 47 (page 51) Figure 48 (page 52) component of the furnace must be replaced, use only factory authorized replacement parts specified in the Replacement Parts List provided online.
  • Page 51 UPFLOW / HORIZONTAL FURNACE (*SC SERIES) Finish Flange Igniter Flame Roll-Out Burner Sensor Switch Assembly Gas Manifold Control Board Gas Valve Main Air Limit Switch Vent Limit Switch Pressure Switch - Condensate Inducer Assembly (‘B’, ‘C’, & ‘D’ Pressure Switch cabinets only) (Inducer) Transformer...
  • Page 52 DOWNFLOW FURNACE (*SL SERIES) Finish Blower Flange Assembly Control Board Blower Door Switch Transformer (behind blower panel) Vent Limit Switch Inducer Assembly Pressure Switch Main Air Limit Switch Gas Valve Gas Manifold Igniter Burner Roll-Out Flame Assembly Switch Sensor DOWNFLOW FURNACE...

  • Page 56: Installation Checklist

    Vent free from restrictions? Filter(s) secured in place? Filter(s) clean? Flue connections tight? Is there proper draft? Specifications & illustrations subject to change without notice or incurring obligations (04/22). 10415940 O’Fallon, MO, © Nortek Global HVAC LLC 2022. All Rights Reserved. (Replaces 10348800)

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