Nortek KG7TL Installation Instructions Manual
Two-stage condensing gas furnaces with fixed & variable speed blowers 95.0% afue
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Two-Stage Condensing gas Furnaces With Fixed & Variable Speed Blowers
INSTALLATION INSTRUCTIONS
• 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.
• 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.
*TC Upflow / Horizontal Furnace
WARNING
FIRE OR EXPLOSION HAZARD
WHAT TO DO IF YOU SMELL GAS
95.0% AFUE
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Summary of Contents for Nortek KG7TL
- Page 1 Two-Stage Condensing gas Furnaces With Fixed & Variable Speed Blowers 95.0% AFUE 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.
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Page 2: Table Of Contents
TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION ......3 Autostaging for Single Stage Thermostats ......23 Autostaging for Two-Stage Thermostats ......23 REQUIREMENTS & CODES ..........3 Blower Speed Configuration ..........23 Combustion Air Quality ............4 Fixed Speed Blower Applications ........23 Heating Load ..............5 Variable Speed Blower Applications ......23 Installation in a Garage ............5 Dehumidification Options ..........23 Clearances to Combustible Materials ......5... -
Page 3: Important Safety Information
IMPORTANT SAFETY INFORMATION prior to performing the installation and operational checkout of the equipment. INSTALLER: Please read all instructions before servicing • Use caution when handling this appliance or removing this equipment. Pay attention to all safety warnings and any components. -
Page 4: Combustion Air Quality
The information listed below is for reference purposes only • A gas-fired furnace for installation in a residential garage and does not necessarily have jurisdiction over local or state must be installed as specified on page 5 codes. Always consult with local authorities before installing •... -
Page 5: Heating Load
• Exposure to the following substances in the combustion Clearances to Combustible Materials air supply may require outdoor air for combustion: This furnace is Design Certified in the U.S. and Canada by Permanent wave solutions CSA International for the minimum clearances to combustible Chlorinated waxes and cleaners materials. -
Page 6: Combustion Air & Venting Requirements
COMBUSTION AIR & VENTING IMPORTANT INFORMATION: • This furnace must be vented in compliance with REQUIREMENTS the current revision of the National Fuel Gas Code (ANSI-Z223.1/NFPA54). Instructions for determining WARNING: the adequacy of an installation can be found in the current revision of the NFGC (ANSI Z223.1 / NFPA54). -
Page 7: Direct Vent Systems
CAUTION: EXAMPLE If the combined input rate of all appliances is less than or equal to 100,000 Btuh, each opening must have a free Exhaust fans, clothes dryers, fireplaces and area of at least 100 in . If the combined input rate of all other appliances that force air from the house appliances is 120,000 Btuh, each opening must have a to the outdoors can create a negative pressure... -
Page 8: Outdoor Air Using Vertical Ducts
Outdoor Air Using Vertical Ducts If combustion air is taken from outdoors through vertical ducts, the openings and ducts must have a minimum free area of one square inch per 4,000 Btuh of total appliance Vent or input. See Figure 4 Chimney Air Duct Ventilation Louvers... -
Page 9: Conventional Vent Systems - Unconfined Spaces
Conventional Vent Systems - Unconfined section ( ). The length of vent and combustion air page 6 piping for either type of installation are shown in Table 1 Spaces An unconfined space is an area including all rooms not Category IV appliances operate with positive vent pressure separated by doors with a volume greater than 50 cubic feet and therefore require vent systems which are thoroughly per 1,000 Btuh of the combined input rates of all appliances... -
Page 10: Vent Pipe Length & Diameter
Vent Pipe Length & Diameter In order for the furnace to operate properly, the combustion air and vent piping must not be excessively restrictive. • The venting system should be designed to have the minimum number of elbows or turns. •... -
Page 11: Outdoor Terminations - Horizontal Venting
• If venting horizontally, a side wall vent kit is available Plumbing Vent Roof Boot according to the pipe diameter size of the installation. For (Both Pipes) 2 inch pipe use side wall vent kit #904617, and for 3 inch Elbows on the combustion air pipe use kit #904347. -
Page 12: Existing Installations
18 inches of vent pipe can be reduced. It is acceptable CIRCULATING AIR REQUIREMENTS to reduce from 3” to 2-1/2”, 3” to 2”, or 2” to 1-1/2” if the total vent length is at least 15 feet in length and the vent WARNING: length is within the parameters specified in . -
Page 13: Return Air Connections
damper is in the cooling position and operation of the • Side Return Installations: To attach the return air duct cooling system is prevented when the damper is in the to the left or right side of the furnace, punch out the 4 heating position. -
Page 14: Furnace Installation
FURNACE INSTALLATION If the furnace will be suspended from the ceiling, assemble a support frame ( Figure 12 ) using slotted iron channel and full *TC series gas furnaces offer a wide range of installation threaded rod. Fasten the frame together with nuts, washers, options, including installation in the upflow or horizontal and lockwashers. -
Page 15: Inducer & Venting Options
Inducer & Venting Options Inducer Assembly Rotation To increase installation flexibility, the inducer assembly can be rotated to 2 different positions (‘B’, ‘C’, & ‘D’ width cabinets WARNING: only). Each variation has slightly different requirements with regard to condensate disposal and, in some cases, the need Inducer rotation must be completed before to seal the furnace cabinet. -
Page 16: Accessories
Accessories PVC Components The components in & are included in the Figure 14 Figure 15 IMPORTANT NOTES: extra parts bag supplied with the purchase of *TC furnaces. • Before permanently installing these components, it is Depending on your particular installation, some of these recommended you dry-fit them first to ensure proper components are optional and may not be used. -
Page 17: Alternate Orientation
EXCEPTIONS AND CLARIFICATIONS TO THE 3. Install the 1/2” x 1/2” hose barb on the 2” PVC reducer. NOTE: Do not over tighten! Use an adequate amount of GENERAL RULES: Teflon tape on the threads. Do not use liquid sealants. •... -
Page 18: Gas Supply & Piping
GAS SUPPLY & PIPING WARNING: Door Screws Wiring Harness FIRE OR EXPLOSION HAZARD • Failure to follow safety warnings exactly could result in serious injury or property damage. • Installation and service must be performed Screws by a qualified installer, service agency or the gas supplier. -
Page 19: Leak Check
Leak Check Burner Assembly Manifold Automatic Gas Valvle WARNING: (w/ Manual Shut-Off) FIRE OR EXPLOSION HAZARD Note “A” Failure to follow safety warnings exactly could result in serious injury or property damage. Shut-Off Pipe Valve Note “B” Nipple Never test for gas leaks with an open flame. Elbow Plug Dripleg... -
Page 20: Converting From Natural Gas To Lp / Propane
specifies the heating value at the residence’s gas meter Converting from Natural Gas to LP / Propane as the “local value”. WARNING: For added flexibility, two tables have been provided for natural gas installations with high or low heating values at The furnace was shipped from the factory sea level. -
Page 21: Electrical Wiring
ELECTRICAL WIRING IMPORTANT NOTE: • If replacing any of the original wires supplied with the furnace, the replacement wire must be copper WARNING: wiring and have a temperature rating of at least 105°F (40°C). For electrical specifications, refer to the furnace ELECTRICAL SHOCK, FIRE OR nameplate or Table 4... -
Page 22: Grounding
NEC (ANSI/NFPA 70) and with applicable local codes having jurisdiction. • Nortek no longer supports twinning of two stage furnaces. Please contact your furnace distributor for details. • The thermostat must be installed according to the instructions supplied by the thermostat manufacturer. -
Page 23: Autostaging For Single Stage Thermostats
Autostaging for Single Stage Thermostats Variable Speed Blower Applications The Autostaging feature makes it possible to use a single stage thermostat and still receive some of the benefits of 2-stage CAUTION: furnace operation. If Autostage is enabled, the furnace will drop to LOW fire after initially starting in HIGH fire. -
Page 24: Start-Up & Adjustments
above 2,000 feet, it must not exceed that on the rating plate MOTOR less 4% for each 1,000 feet. To determine the exact input CONTROL BOARD HUMIDISTAT rate, perform the following procedures: DHUM DHUM 1. Shut off all other gas fired appliances. 2. -
Page 25: Verifying Burner Operation
Verifying Operation of the Supply Air Limit 2-STAGE GAS VALVES Switch Lo Input HI Input Adjusting A properly functioning limit switch should turn off the gas Adjusting Screw valve when the return is blocked (time depends on how well Screw the return air is blocked). -
Page 26: Cooling Cycle
Cooling Cycle Air Filter(s) - Air filter(s) are not supplied with the furnace 1. The thermostat calls for cooling by energizing the Y / Y2 as shipped from the factory. The installer must provide a or Y1 terminal with 24VAC. high velocity filter and rack for a filter in the return air duct adjacent to the furnace, or in a return air grill to the furnace. -
Page 27: Figures & Tables
12. Follow the lighting instructions found on the furnace door WARNING: to return the furnace to operation. Verify proper operation after servicing. Holes in the vent pipe or heat exchanger can Heat Exchanger & Burner Maintenance - The furnace cause combustion products to enter the home. should operate for many years without soot buildup in the Replace the vent pipe or heat exchanger if leaks flue passageways, however, the flue, vent system, and... -
Page 28: 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 29 HIGH ALTITUDE DERATION – PROPANE GAS INPUT (BTU) & STAGE ALTITUDE ABOVE 38,000 60,000 80,000 100,000 120,000 SEA LEVEL ORIFICE SIZE 0 to 1,999 FT 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...
- Page 30 HIGH ALTITUDE DERATION – NATURAL GAS WITH HIGH HEATING VALUE INPUT (BTU) & STAGE ALTITUDE ABOVE 38,000 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...
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Page 31: 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 27. Two-Stage Fixed Speed Motor Control Board STATUS LIGHTS L2-IN L2-OUT W_OUT Y/Y2_OUT L1-IN Y1_OUT... - Page 32 COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 30. Wiring Diagram for Two-Stage, Fixed Speed Upflow Furnaces...
- Page 33 COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 31. Wiring Diagram for Two-Stage, Variable Speed Upflow Furnaces...
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Page 34: Venting Information
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 35 HORIZONTAL VENTING w/ 2-PIPES Straps or other suitable supports (’A’ WIDTH CABINETS ONLY) Wall at minimum 5 ft. intervals (both pipes) Seal / caulk around pipes First support as close at wall to furnace as possible 90° Elbows 90° Elbow COMBUSTION AIR VENT PIPE Flue Pipe must slope FLUE PIPE...
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Page 36: (B, C, & D Width Cabinets)
HORIZONTAL VENTING W/ 2-PIPES Straps or Other Suitable Seal/Caulk Supports at minimum of 5 ft. Intervals (B, C, & D WIDTH CABINETS) Around Pipes at Building 90° 90° Elbow Elbow COMBUSTION AIR 90° Elbow Upward Pitch - 1/4” per foot 12”... - Page 37 UPFLOW - 2 PIPE OPTION UPFLOW - 1 PIPE OPTION (‘A’ WIDTH CABINETS ONLY) (‘A’ WIDTH CABINETS ONLY) Rubber Rubber Grommet Grommet See VIEW A for drain line positions OPTION 2 OPTION 1 VIEW -A- NOTES: 1. See Accessories section (page 15) for optional PVC Tee configurations and drainage options.
- Page 38 UPFLOW - 1 PIPE OPTIONS (B, C, & D WIDTH CABINETS ONLY) COMBUSTION COMBUSTION NOTE 3 PVC Tee PVC Trap NOTE 3 PVC Tee Rubber Grommet OPTION 4 OPTION 3 PVC Trap Rubber Grommet See VIEW B for drain line positions See VIEW C for drain line positions VIEW -B- VIEW -C-...
- Page 39 HORIZONTAL RIGHT - 1 PIPE OPTION HORIZONTAL LEFT - 1 PIPE OPTION (’A’ WIDTH CABINETS ONLY) (’A’ WIDTH CABINETS ONLY) Rubber Grommet FLUE PIPE OPTION OPTION COMBUSTION AIR COMBUSTION AIR FLUE PIPE Rubber See VIEW E for See VIEW D for Grommet drain line positions drain line positions...
- Page 40 HORIZONTAL RIGHT - 1 PIPE OPTION HORIZONTAL LEFT - 1 PIPE OPTION (B, C, & D WIDTH CABINETS ONLY) (B, C, & D WIDTH CABINETS ONLY) Rubber Rubber OPTION OPTION Grommet Grommet COMBUSTION AIR FLOW COMBUSTION See VIEW G for See VIEW F for Plug Plug...
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Page 41: Troubleshooting
TROUBLESHOOTING • If the furnace still doesn’t operate, check the Flame Roll- out Switches ( Figure 38 ) and reset if necessary. If the furnace fails to operate check the following: • If the furnace operates when the Flame Rollout Switch is •... - Page 42 UPFLOW / HORIZONTAL FURNACE (*TC SERIES) 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 &...
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Page 44: Installation Checklist
G A S - F I R E D L I S T E D Specifications & illustrations subject to change without notice or incurring obligations (11/20). 10348770 O’Fallon, MO, © Nortek Global HVAC LLC 2020. All Rights Reserved. (Replaces 1025890A)
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