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Gas Fired Central Furnaces
Installation Instructions
*TC Series 92+ Upflow/Horizontal Two-Stage Condensing Furnace
*TL Series 90+ Downflow Two-Stage Condensing Furnace
*TC 92+ Upflow/Horizontal
WARNING:
!
Improper installation, adjustment, al-
teration, service, or maintenance can
cause injury or property damage. Re-
fer to this manual for assistance. For
additional information consult a quali-
fied installer, service agency, or the
gas supplier.
These instructions are primarily intended
to assist qualified individuals experienced
in the proper installation of this appliance.
Some local codes require licensed installa-
tion/service personnel for this type of equip-
ment. Read all instructions carefully before
starting the installation.
DO NOT DESTROY. PLEASE READ CARE-
FULLY AND KEEP IN A SAFE PLACE FOR
FUTURE REFERENCE.
*TL 90+ Downflow
! FOR YOUR SAFETY:
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
! FOR YOUR SAFETY:
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.
• Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
• If you cannot reach your gas supplier,
call the fire department.
• Extinguish any open flame.
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Summary of Contents for Nordyne TC060
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Page 1: Installation Instructions
Gas Fired Central Furnaces Installation Instructions *TC Series 92+ Upflow/Horizontal Two-Stage Condensing Furnace *TL Series 90+ Downflow Two-Stage Condensing Furnace *TC 92+ Upflow/Horizontal *TL 90+ Downflow ! FOR YOUR SAFETY: WARNING: Do not store or use gasoline or other Improper installation, adjustment, al- flammable vapors and liquids in the teration, service, or maintenance can vicinity of this or any other appliance. -
Page 3: Table Of Contents
Table of Contents Furnace Specifications ............................. 4 Furnace Airflow Data ..........................6 Safety Information ............................. 7 Clearances to Combustible Materials ......................7 Installation Requirements ..........................7 Location ..............................8 Downflow Model Warning ..........................8 Horizontal Installations ............................. 8 Conversion of the *TC Upflow Furnace for a Horizontal Right Installation ..........8 Conversion of the *TC Upflow Furnace for a Horizontal Left Installation .......... -
Page 4: Furnace Specifications
FURNACE SPECIFICATIONS Figure 1. Upflow/Horizontal Unit Dimensions... - Page 5 Figure 2. Downflow Unit Dimensions...
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Page 6: Furnace Airflow Data
Table 1c. Heating Airflow Settings Shipping Low Fire High Fire Dimensions (inches) Model Weight Furnace Furnace Number (lbs) Input Btuh *TC060 60,000 42,000 14 1/2 12 3/4 5 1/8 11 3/4 *TC080 80,000 56,000 19 3/4 18 1/4 7 7/8... -
Page 7: Safety Information
SAFETY INFORMATION terminating outside the space containing the furnace. A gas-fired furnace for installation in a Use only with type of gas approved for this residential garage must be installed as furnace. Refer to the furnace rating plate. specified on Page 8 of these instructions. Install this furnace only in a location and 10. -
Page 8: Location
A gas-fired furnace installed in a residential WARNING: garage must be installed so that the bottom of the furnace is located a minimum of 18" from the floor. The furnace must be located or protected This furnace is not approved for instal- to avoid physical damage by vehicles. -
Page 9: Conversion Of The *Tc Upflow Furnace For A Horizontal Left Installation
corresponding pressure tap on the oppo- Note: To avoid condensate freezing in the site of the header box. drain trap assembly and tubing, insulate around 5. Place the gray tubing that was removed, the drain trap assembly and all tubing located to the corresponding pressure tap on the in unconditioned space. -
Page 10: Supply Air Plenum Installation
*Larger dimension for TL110 18.75" or 13.25 or 21.50 2.0" 16.75" 28.38" or *19.50" MODEL *TL 060 13.25” 19.25” 1.50" *TL 080/100 18.75” 19.25” 19.63" *TL 120 21.50” 19.25” Figure 5. Opening for Concrete Slab 1.58" 3" 19.75" or 14.25 or 22.50"* Figure 9. -
Page 11: Return Air
If outside air is utilized as return air to the furnace for ventilation or to improve indoor air quality, the IMPORTANT: system must be designed so that the return air to the furnace is not less than 50°F (10°C) during The variable speed blower kit has been heating operation. - Page 12 Vent or Each opening must Chimney be at least 100 sq. in. or 1 sq. in. per 1000 Btuh of total input Vent or rating, whichever is Chimney greater. See minimum area per table. - - - - - - 12"...
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Page 13: Configuring The Blower
Selecting the Heating Airflow Vent or The heating airflow is selected by setting Chimney switches 5 and 6 on the motor control board located in the blower control panel. Note that switch 7 is not used for heating or cooling in these furnaces. -
Page 14: Air Requirements For One-Pipe Installation
Air Requirements For One-Pipe WARNING: Installation When air for combustion is to be taken from Furnace installation using methods around the furnace, a protective screen must be other than those described in the fol- installed over the combustion air intake opening. lowing sections must comply with the This screen is provided with the furnace instal- National Fuel Gas Code and all appli-... -
Page 15: Air From Inside
typically involves installation in a small room. All inches. If the combined input rate of all appli- ances is 120,000 Btuh, each opening must have such installations must have specific provisions for introduction of combustion and ventilation a free area of at least 120 square inches. air. -
Page 16: Venting Requirements
VENTING REQUIREMENTS CAUTION: This section specifies installation requirements for vent and "2-pipe" combustion air piping. For Do not supply combustion air from an "one pipe" installations, install vent piping per attic space that is equipped with power this section and provide air for combustion and ventilation or any other device that ventilation per the previous section. -
Page 17: Downflow Furnaces
Upflow Furnaces Support System on Vertical Rise Below Joints Support System with first support as close to furnace as Possible Combustion Exhaust Air Pipe Vent Upward Pitch Straight Neoprene 1/4" per Foot Couplings with 2 Hose Clamps* (Optional - Not Shown) Cabinet Furnace Front... - Page 18 These condensing furnaces are classified as of ordinary venting materials. Furnace opera- "Category IV" appliances, which require special tion can be adversely affected by restrictive venting materials and installation procedures. vent and combustion air piping. Therefore, vent Category IV appliances operate with positive and combustion air piping lengths must conform completely to the requirements of Table 4.
- Page 19 appliance, even if that appliance is of the con- densing type. Common venting can result in WARNING: severe corrosion of other appliances or their venting and can allow combustion gases to FURNACE MUST NOT BE COMMON escape through such appliances or vents. Do VENTED WITH OTHER APPLIANCES.
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Page 20: Vent Pipe Material
Vent Pipe Material WARNING: Vent and combustion air pipe and fittings must be one of the following materials and must CARBON MONOXIDE POISONING conform to the indicated ANSI/ASTM stan- HAZARD dards: 1. Seal any unused openings in the Material Standard venting system Schedule 40 PVC D1785... -
Page 21: Vent Pipe Installation
Proper use of the table is illustrated by the flows back to the furnace (where it can be following example: disposed of through the condensate disposal system). Example: A 110,000 Btu/h furnace is to be installed in a The quality of outdoor air must also be consid- "one-pipe"... -
Page 22: Location Of Outdoor Terminations
These condensing furnaces have been certi- The minimum distance for a (1-pipe instal- fied for installation with zero clearance between lation) from any door, (openable) window, vent piping and combustible surfaces. How- or gravity air inlet is 4 ft. below, 4 ft. horizon- ever, it is good practice to allow space for tally, or 1 ft. - Page 23 For Canadian installations please refer to the Canadian Installation Code (CAN/CGA-B149.1 Exhaust Vent or 2) and/or local codes. Elbow 1" The kit consists of two face plates and an Combustion 18" Min. insulating gasket to seal the exterior surface. A Intake 36"...
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Page 24: Vertical Venting
Maximum Flue Pipe Length in Unconditioned and Exterior Spaces Winter Design Without Insulation With Insulation Termperature ( (feet) (feet) ‡ = Insulation thickness greater than 3/8 inch, based on an R value of 3.5 (ft*°F*hr)/(BTU*in) Table 5. Vent Protection Table 5 describes the maximum length of flue Vent Freezing Protection pipe that can travel through an unconditioned When the vent pipe is exposed to temperatures... -
Page 25: Drainage Of Condensate From Furnace
Figure 23. For a drains and connections to the condensate tub- left side drain follow the steps below: ing are required as NORDYNE cannot be held responsible for water leakage which occurs Loosen the clamp on the soft exit tube (see due to loose hose connections or improperly Figure 23.) - Page 26 should be readily accessible for service and/or NOTE: Gas piping must not be run in or through emergency use. Consult the local utility or gas air ducts, chimneys, gas vents, elevator shafts, supplier for additional requirements regarding etc. placement of the manual main gas shut-off. In Compounds used on threaded joints of gas the absence of local codes the gas line installa- piping must be resistant to the actions of lique-...
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Page 27: Leak Check
Furnace Orifice Orifice Furnace Rating Orifice Orifice High Fire Rating Drill Size Drill Size Plate Input Drill Size Drill Size Plate Input (Btu/h) (Btu/h) 60,000 60,000 80,000 80,000 100,000 100,000 120,000 120,000 Table 9. Natural and LP Gas Orifice Sizes Table 10. -
Page 28: Conversion
3. Remove the access door(s) from the front Conversion of the unit. Conversion of this furnace to use LP/propane 4. Turn the gas valve knob to the OFF posi- gas must be made by qualified service tion. personnel, using only approved parts. 5. -
Page 29: Lp/Propane Gas Sea Level And High Altitude Conversion
This kit is for LP/propane conversions in Canada above sea level), conversion can be achieved at altitudes between zero and 4500 ft. above sea simply by adjusting the furnace manifold level. Follow the installation instructions supplied pressure as shown in Table 7. with the kit for proper installation. - Page 30 Low Voltage Field, Five-wire Heating/Cooling Applications - continued TWO STAGE ROOM THERMOSTAT CLOSED END AIR CONDITIONER CONNECTOR CONDENSING UNIT DO NOT REMOVE! BROWN YELLOW/ BLACK VARIABLE GREY SPEED YELLOW BLOWER GREEN YELLOW Legend YELLOW Field Wiring BROWN Factory Wiring: Low Voltage High Voltage GAS VALVE Figure 26b.
- Page 31 Low Voltage Field, Five-wire Heating/Cooling Applications - continued ROOM THERMOSTAT CLOSED END AIR CONDITIONER CONNECTOR CONDENSING UNIT DO NOT REMOVE! BROWN YELLOW/ BLACK VARIABLE GREY SPEED YELLOW BLOWER GREEN YELLOW Legend Field Wiring YELLOW YELLOW Factory Wiring: BROWN Low Voltage High Voltage ODT: Open on rise GAS VALVE...
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Page 32: Line Voltage Wiring
Line Voltage Wiring NOTE: The following procedure describes how to connect the furnace for a two-stage application. The line voltage (115 volt) to the furnace must be supplied from a dedicated branch circuit Low Voltage Wiring containing the correct fuse or circuit breaker for the furnace. -
Page 33: Start-Up And Adjustments
Install the thermostat per the manufacturer's feature and the furnace operates on high instructions. The low voltage (24 volt) connec- fire only. All of the burners will operate on a call for heat and the variable speed blower tions from the thermostat are made at the will operate higher... -
Page 34: Start-Up Procedure
The thermostat wires (R, W, Y, and G) are Follow the procedure below to determine the securely connected to the correct leads on firing rate. the terminal strip of the circuit board. Shut off all other gas fired appliances. The gas line service pressure does not exceed 10.0 in. -
Page 35: Configuring The Blower
must be known. The nominal system capacity WARNING: is ALWAYS the nominal capacity of the outdoor unit. In some cases the nominal system capac- To avoid electric shock, personal in- ity is not the same as the nominal capacity of the indoor coil. - Page 36 For Upflow and Downflow Residential Furnaces WD# 710525A Figure 28. Upflow and Downflow Wiring Diagram...
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Page 37: Verifying Burner Operation
3 Amp Fuse 24 V Flame Signal Light (Yellow) Status Light (Red) Common Leads Neutrals Unused Motor Leads Connect Neutral Lead of Electronic Air Cleaner and/or Humidifier Here. Electronic Air Tap (.5A@ 120 VAC) Humidifier Tap (.5A@ 120 VAC) These motor speed taps are not used for two-stage models Figure 29. -
Page 38: Maintenance
Primary Gas Valve – The gas valve controls the MAINTENANCE flow of gas to all of the burners. When the gas It is recommended that the furnace be checked valve is energized it automatically opens and yearly. At a minimum, this check should include regulates the gas pressure in the manifold. -
Page 39: Location Of Major Components
Upflow/Horizontal Furnace Models 1 Igniter (Not Shown) 2 Flame Sensor (Not Shown) 3 Gas Valve 4 Flame Roll-out Switch(s) 5 Condensate Pressure Switch 6 Pressure Switch 7 Control Board 8 Blower Door Switch 9 Vent Safety Switch 10 Low Voltage Transformer 11 Supply Air Limit Switch... -
Page 40: Combustion Air And Vent System
Heat Exchanger and Burner Maintenance Combustion Air and Vent System The furnace should operate for many years Check the combustion air and vent pipe to ensure without excessive soot buildup in the flue pas- that it is not damaged, corroded or blocked by sageways, however, the flue passageways, the debris. - Page 41 the furnace control is locked and the red perature limit switch, flame rollout switches LED will blink 4 times repetitively. The and blocked vent switch in series). If an thermostat must be opened for at least ten open limit is detected the control board will seconds to reset the furnace control after energize the inducer blower.
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Page 42: Furnace Fails To Operate
Furnace Fails to Operate If the furnace does not operate check the following: 1. Is the thermostat operating properly? 2. Are the blower compartment door(s) in place? 3. Is the furnace disconnect closed? 4. Has the circuit breaker tripped or the con- trol board fuse burned open? 5. -
Page 43: Installation/Performance Checklist
INSTALLATION/PERFORMANCE CHECK LIST LOCATION __________________________ CITY ____________________ STATE _____ INSTALLER _________________________ CITY ____________________ STATE _____ UNIT MODEL # ______________________ UNIT SERIAL # ________________________ Minimum Clearances per Table 3? _______ Supply Air Temperature: ____________ (° F) Return Air Temperature: ____________ (° F) Electrical Connections tight? _____________ Temperature Rise: ________________ (°... - Page 44 ¢708475E¤ 708475A 708475A (Replaces 7084750) Specifications and illustrations subject to change without notice and without incurring obligations. O’Fallon, MO Printed in U.S.A. (11/05)
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