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GAS FURNACES
Installation Instructions
Two-Stage Condensing Furnaces With Fixed and Variable Speed Blowers
*TC 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.
*TL 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
neighbors phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call
the fi re department.
DO NOT DESTROY.
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
95.1% AFUE
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Summary of Contents for Nordyne TC Upflow/Horizontal
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Page 1: Installation Instructions
GAS FURNACES 95.1% AFUE Installation Instructions Two-Stage Condensing Furnaces With Fixed and Variable Speed Blowers *TC Upfl ow/Horizontal Model *TL Downfl ow Model WARNING: WARNING: • PROPOSITION 65 WARNING: This product FIRE OR EXPLOSION HAZARD contains chemicals known to the state of •... -
Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY INFORMATION ..........4 Upfl ow/Horizontal Furnaces ......15 REQUIREMENTS AND CODES ........4 Side Return Installations ......15 GENERAL INSTRUCTIONS ........5 Bottom Return Installations ......15 Combustion Air Quality ..........5 Downfl ow Furnaces ..........15 Operation of Furnace During Construction ....5 Acoustical Treatments ..........15 Heating Load ............6 FURNACE INSTALLATION ........16 Installation in a Garage ..........6... - Page 3 Autostaging for Single Stage Thermostats .....24 Gas Information .............38 Autostaging for Two-Stage Thermostats ....25 Table 11 - Gas Flow Rates .........38 Dehumidifi cation Options ........25 Table 12 - Gas Pipe Capacities ......38 Line Voltage Wiring ..........25 Table 13 - High Altitude Deration Chart for Low Voltage Wiring ..........25 Propane Gas ........39 Grounding ...............25...
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Page 4: Safety Information
REQUIREMENTS and CODES SAFETY INFORMATION This furnace must be installed in accordance with Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and these instructions, all applicable local building codes should not be ignored. WARNING indicates a potentially and the current revision of the National Fuel Gas Code hazardous situation that if not avoided, could result in (NFPA54/ANSI Z223.1) or the Natural Gas and Propane... -
Page 5: General Instructions
b.) The (CO) detector shall: GENERAL INSTRUCTIONS • Be located in the room that houses the appliance Combustion Air Quality or equipment; • Be hard-wired or battery powered or both. CAUTION: • Shall comply with NFPA 720 (2005 Edition). c.) A product-approved vent terminal must be used, and Combustion air must not be drawn from a if applicable, a product-approved air intake must be corrosive atmosphere. -
Page 6: Heating Load
Operating gas furnaces in construction environments can For installations above 2,000 ft., the furnace should have cause a variety of problems with the furnace. Proper use a sea level input rating large enough that it will meet the of commercial portable space heating equipment during heating load after deration for altitude. - Page 7 INSTALLATION CLEARANCES to COMBUSTIBLE MATERIALS For UPFLOW, HORIZONTAL & DOWNFLOW FURNACES Left Side ........0 Inches Vent ..........1 Inch Top ...........1 Inches † Right Side ........0 Inches Back .........0 Inches Front........4 Inches UPFLOW APPLICATION HORIZONTAL APPLICATION DOWNFLOW APPLICATION SIDE SIDE BOTTOM BOTTOM...
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Page 8: Combustion Air Requirements
COMBUSTION AIR REQUIREMENTS the fl ame roll-out switch will open, turning off the gas supply to the burners. This safety device is a manually General Information reset switch. DO NOT install jumper wires across these switches to defeat their function or reset a WARNING: switch without identifying and correcting the fault condition. -
Page 9: Outdoor Air From A Crawl Space Or Vented Attic
Ventilation Louvers at each end of attic Air Duct must be Vent or at least 1 sq. in. Vent or Chimney per 4,000 Btuh of Chimney Attic total input rating. Insulation NOTES: 12” Max. Ducts must Each opening must be extend above at least 100 sq. -
Page 10: Air Directly Through An Exterior Wall
Air Directly Through an Exterior Wall Conventional Furnaces - Unconfi ned Spaces If combustion air is provided directly through an exterior An unconfi ned space is an area including all rooms not wall, the two openings must each have free area of at separated by doors with a volume greater than 50 cubic least one square inch per 4,000 Btuh of total appliance feet per 1,000 Btuh of the combined input rates of all... -
Page 11: Vent Pipe Material
This section specifi es installation requirements for Material ........Standard Conventional (1-pipe) and Direct Vent (2-pipe) piping. For Schedule 40PVC ......D1785 1- pipe installations, install vent piping as described in PVC-DWV ........D2665 this section and provide air for combustion and ventilation SDR-21 &... -
Page 12: Vent Pipe Installation
of selected diameter and number of elbows. To use the on either side of the exterior wall (Figure 36). These table, the furnace input rate, the centerline length and the couplings may be required by local code. number of elbows on each pipe must be known. •... -
Page 13: Outdoor Terminations - Vertical Venting
to U.S. installations. In Canada, CSA B149.1, takes Outdoor Terminations - Vertical Venting precedence over these instructions. Termination spacing requirements from the roof and from • Do not install the vent terminal such that exhaust is each other are shown in Figure 9. The roof penetration directed into window wells, stairwells, under decks must be properly fl... -
Page 14: Condensate Disposal
• For extremely cold climates or for conditions of short CIRCULATING AIR REQUIREMENTS furnace cycles (i.e. set back thermostat conditions) the WARNING: last 18 inches of vent pipe can be reduced. It is acceptable 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, the vent Do not allow combustion products to enter the length is within the parameters specifi... -
Page 15: Supply Air Connections
system must be designed so that the return air supply the blower assembly. Position the return air duct over to the furnace is equal to the return air supply under the opening in the side and secure together with sheet normal, indoor return air applications. -
Page 16: Furnace Installation
FURNACE INSTALLATION Downfl ow Installation *TC series gas furnaces offer a wide range of installation WARNING: options, including installation in the upfl ow or horizontal positions with either right, left, or upfl ow return air. The The furnace must not be installed directly on *TL series gas furnaces may only be installed as a down carpeting, tile, or any combustible material other fl... -
Page 17: Horizontal Installation
Concrete Furnace Floor Sheet Nuts (x2) Metal Plenum Bolt Washer Threaded Lockwasher Figure 11. Furnace on a Concrete Slab Horizontal Installation Nuts (x2) WARNING: Figure 13. *TC Horizontally Suspended The furnace must not be installed directly on in Attic or Crawl Space carpeting, tile, or any combustible material other than wood fl... -
Page 18: Alternate Bottom Panel Removal
5. Remove all screws (5) securing bottom panel (6) to Conventional (1 Pipe) bottom of furnace and front brace (7). Horiz. Horiz. Vent Upfl ow Downfl ow Right Left 6. Lift up and slide bottom panel (6) out through front of furnace. -
Page 19: Accessories
6. Secure the inducer assembly (2) to the header box (6) rubber grommet should be installed in the 1 5/8” hole by reinstalling the four screws (5) and the extra screw prior to running the gas pipe into the cabinet. No sealants provided in the parts package. -
Page 20: Condensate Drain Lines
(page 34) for hole location The condensate drain should drain lines on the outside of the residence be wrapped be connected to the barbed end. Attach 1” PVC drain with an industry approved insulation or material line to the threaded end. allowed by local code. - Page 21 UPFLOW MODELS Note “A” Note “A” Note “B” Note “B” Left Side Entry Right Side Entry DOWNFLOW MODELS Note “A” Note “A” Note “B” Note “B” Left Side Entry Right Side Entry ITEM # and COMPONENT (1) Automatic Gas Valve (2) Burner Assembly (3) Dripleg (w/ manual shut-off)
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Page 22: High-Altitude Application
After the gas piping to the furnace is complete, all heating value of more than 1,000 Btu per cubic foot and connections must be tested for gas leaks. This includes Table 16 (LOW) is for less than 1,000 Btu per cubic foot. pipe connections at the main gas valve, emergency shutoff To determine which table to use: valve and fl... -
Page 23: Electrical Wiring
• The Canadian LP/Propane Gas Sea Level and High Fixed Speed Blower Applications Altitude Conversion Kit (P/N 904915) is for LP/propane NOTE: This section applies only to furnaces with model conversions in Canada at altitudes between zero and numbers suffi xed with two numbers, followed by a letter, 4,500 ft. -
Page 24: Wiring Confi Gurations
Wiring Confi gurations Two-Stage AC and Two-Stage Thermostat (Fig. 23) Depending on the type of air conditioning unit and This option uses the full two stage heating capability of thermostat used, both blower applications utilize three the furnace with a two stage outdoor unit: basic wiring confi... -
Page 25: Autostaging For Two-Stage Thermostats
Autostaging for Two-Stage Thermostats IMPORTANT NOTE: An electrical disconnect must be The Autostage setting on the furnace control board (Figure installed readily accessible from and located within 31) is disabled when shipped from the factory. This feature sight of the furnace. See Figure 25 (page 26) or the will be not used when paired with a two-stage thermostat. -
Page 26: Twinning
Furnace Cabinet Nominal Maximum Minimum Maximum Minimum Maximum Input Width Electrical Operating Operating Furnace Wire Fuse or Circuit (Btuh) (in.) Supply Voltage Voltage Amperes Gauge Breaker Amps** 60,000 ½ 115-60-1 80,000 115-60-1 100,000 115-60-1 ½ 120,000 115-60-1 12.5 ** Time-delay fuses or HACR-type circuit breakers are required. Recommended Thermostat Wire Length Thermostat Wire Gauge 2 - wire... -
Page 27: Start-Up & Adjustments
START-UP AND ADJUSTMENTS Multiply the gas fl ow rate in cubic feet per hr by the heating value of the gas in Btu per cubic ft to obtain Pre-Start Check List the input rate in Btuh. See example. √ Verify the polarity of the connections are correct, the line voltage power leads are securely connected and Example: the furnace is properly grounded. -
Page 28: Verifying And Adjusting Temperature Rise
Verifying and Adjusting Temperature Rise Block the return airfl ow to the furnace by installing Confi rm the temperature rise through the furnace is a close-off plate in place of or upstream of the within the limits specifi ed on the furnace rating plate. Any fi... -
Page 29: Cooling Cycle
12. The circulating air blower will continue to run for the Fan Mode selected Blower Off Delay(P5). This may be 60, 90, • When the thermostat energizes the G terminal for or 120 seconds depending on the Jumper setting on continuous fan (without calling for heat or cooling), the the Furnace Control Board. -
Page 30: Description Of Components
DESCRIPTION OF COMPONENTS MAINTENANCE The descriptions below are various functional components WARNING: that affect the operation and shutting down of this furnace. Some of these components and their locations are shown These maintenance instructions are primarily in Figures 40 and 41 (page 51). If any component of the furnace must be replaced, use only factory authorized intended to assist qualified technicians replacement parts specifi... -
Page 31: Cleaning Of Burners
Heat Exchanger and Burner Maintenance Cleaning of Burners If the burners must be cleaned, follow the steps below and The furnace should operate for many years without soot see Figure 40 or 41 (page 51) for component location. buildup in the fl ue passageways, however, the fl ue, vent system, and burners should be inspected and cleaned 1. -
Page 32: 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 33 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 sécurité graves, la mort ou des dommages matériels. pourrait entraîner un fonctionnement dangereux •...
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Page 34: Figures And Tables
FIGURES AND TABLES *TC 95.1% Upfl ow/Horizontal Furnace Upfl ow/Horz. Dim. Dim. Dim. TOP VIEW Cabinets “A” “B” “C” ‘B’ Cabinet 17 ½ 15 ⅞ 16 ⅛ FRONT ‘C’ Cabinet 19 ⅜ 19 ⅝ BRACE ‘D’ Cabinet 24 ½ 22 ⅞ 23 ⅛... -
Page 35: Airfl Ow Data
AIRFLOW DATA *TC/TL FURNACES WITH FIXED SPEED BLOWERS External Static Pressure (in.W.C.) Motor Switch Settings Model Heating Input (0 = OFF, 1 = ON) Number (Btuh) Rise Rise Rise Rise Rise Rise Rise Rise 1,055 1,015 1,135 1,095 1,055 1,010 1,185 1,145 1,105... - Page 36 *TC/TL FURNACES WITH VARIABLE SPEED BLOWERS Switch Settings For Heat *TC/TL-060D-*B (0 = OFF, 1 = ON) Input (BTU) 60,000 Temp Rise (°F) 1,000 1,100 1,200 “B” CABINET 1,300 1,400 1,500 1,600 1,700 Switch Settings For Heat *TC/TL-080D-*C *TC/TL-100D-*C (0 = OFF, 1 = ON) Input (BTU) 80,000 Input (BTU) 100,000 Temp Rise (°F)
- Page 37 *TC/TL FURNACES WITH VARIABLE SPEED BLOWERS “B” CABINET Switch Settings (0 = OFF, 1 = ON) Nominal A/C and HP HEAT COOL Capacity HIGH 1,000 1,060 1,120 1,180 1,240 1,300 1,360 1,420 1,020 1,480 1,065 1,540 1,105 1,600 *TC/TL FURNACES WITH VARIABLE SPEED BLOWERS *TC/TL FURNACES WITH VARIABLE SPEED BLOWERS “C”...
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Page 38: Gas Information
GAS INFORMATION GAS FLOW RATES (CUBIC FEET PER HOUR) CUBIC FEET PER CUBIC FEET PER TIME FOR ONE TIME FOR ONE REVOLUTION REVOLUTION REVOLUTION REVOLUTION OF GAS METER 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 39: Propane Gas
PROPANE GAS INPUT (BTU) and STAGE ALTITUDE ABOVE SEA 60,000 80,000 100,000 120,000 LEVEL 1st 2nd 1st 2nd 1st 2nd 1st 2nd 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... - Page 40 NATURAL GAS - HIGH HEATING VALUE INPUT (BTU) and STAGE ALTITUDE 60,000 80,000 100,000 120,000 ABOVE SEA LEVEL 2nd 1st 2nd 1st 2nd 1st 2nd 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...
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Page 41: 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 29. Two-Stage Fixed Speed Motor Control Board STATUS LIGHTS L2-OUT L2-IN W_OUT Y/Y2_OUT L1-IN Y1_OUT... - Page 42 COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 32. Wiring Diagram for Two-Stage, Fixed Speed Upfl ow Furnaces...
- Page 43 COOL HEAT FAN SPEED BLACK BLACK LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 33. Wiring Diagram for Two-Stage, Fixed Speed Downfl ow Furnaces...
- Page 44 COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 34. Wiring Diagram for Two-Stage, Variable Speed Upfl ow Furnaces...
- Page 45 COOL HEAT FAN SPEED LINE- N LINE- N XMFR-N LINE LINE XMFR Figure 35. Wiring Diagram for Two-Stage, Variable Speed Downfl ow Furnaces...
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Page 46: 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, balcony, or 12 inches (30cm) 12 inches (30cm) 12 inches (30cm) -
Page 47: Figure 36 - Horizontal And Vertical Venting
HORIZONTAL VENTING Straps or Other Suitable Supports at minimum of 5 ft. Intervals Seal/Caulk (2-Pipe Shown) Around Pipes at Building 90° Elbow 90° Elbow Combustion Air 90° Elbow Upward Pitch - 1/4” per foot 12” Min. 7” Outlet Exhaust Vent Straight Neoprene Coupling with 2 Hose Clamps* (Optional) First Support Placed... - Page 48 1 Pipe Upflow Option Option PVC TEE and Reducer PVC TEE and Reducer Drain Line Attached to 3/4 x 1/2 Hose Barb See View -A- See View -B- (This drain not needed if “X” is less than 6”.) View -B- VIEW -B- VIEW -A- Header...
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Page 49: Figure 38 - Horizontal Options
1 Pipe Horizontal Option Option See View -C- Inlet Air Inlet Air Plug Plug See View -D- See View -C- See View -D- Inline Drain VIEW -C- VIEW -D- Header Box Inline Drain Drain Header Box Drain All drain lines must be trapped with J-Trap or field supplied loop. 2 Pipe Horizontal Option Option... - Page 50 1 Pipe Downflow Option Option Option See Table 2 for 2” PVC Pipe Length (Field Supplied) PVC TEE and Reducer View -F- PVC TEE and Reducer Drain Line Attached to 1/2 x 1/2 See View -E- See View -G- Hose Barb Drain Line Attached to 1/2 x 1/2 Hose Barb VIEW -E-...
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Page 51: Location Of Furnace Components
LOCATION OF FURNACE COMPONENTS ITEM COMPONENT NAME Blower Assembly Blower Door Switch Burner Assembly Finish Flange Flame Roll-Out Switch Flame Sensor Furnace Control Board Gas Manifold Gas Valve Igniter Inducer Assembly Inducer Limit Switch Inline Drain Assembly Motor Choke (C and D cabinets only) Motor Control Board Motor Control Box Pressure Switches... -
Page 52: 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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