Nordyne G5RC User's Manual
Contents
1. Willard Scott Burner Inlet Burner Box Combustion View Port Assembly Air Collar Exhaust Vent Roll Out Limit Control Flame Hot Surface Sensor Ignitor Pressure Automatic i Gas Valve past i nline Drain Over Temperature Assembly Limit Control Combustion Integrated Air Blower Control Board Assembly Front i Header Box TOT Bein c Motor Box Vent Safety Condensate 5 Switch Drain Lines Door Switch Circulating Air Blower Motor Circulating Air Blower Assembly GENERAL INFORMATION This furnace has been designed and built to provide many years of safe and dependable home comfort pro viding itis properly installed and main tained With regular main tenance this furnace will operate satisfactorily year after year Abuse improperuse and or improper maintenance can shorten the life of the furnace and create hazards for you Please read this manual carefully to familiarize yourself with operation maintenance and safety procedures for this fur nace Figure 1 Furnace Parts Identified A regular service and maintenance schedule should be established to insure efficient and safe operation of the furnace See Section 5 for main tenance procedures and schedules Devices attachedto the flue or vent for the purpose of reducing heat loss up the chimney including field installed draft inducers have not been tested and have not been incl2. ARR T Voir la Figure Attendre cinq 5 minutes pour s assurer de la dissipation du gaz En cas d odeur ARR TER LE PROC D Suivre les instruc tions ci dessus Section B En l absence de toute odeur de gaz avancer l tape suivante 8 Pousser l g rement le levier et le d placer vers la droite pour l amener sur ON MARCHE Voir la Figure 9 Remettre en place la porte volets d a ration de la chaudi re 10 Rebrancher l appareil sur le r seau lectrique 11 Ajuster le thermostat la position d sir e 12 Si l appareil ne fonctionne pas suivre les Directives d arr t ci dessous et appeler le technicien de service DIRECTIVES D ARR T Mettre le thermostat la position minimale D brancher l appareil en pr vision de la r paration Retirer la porte volets d a ration de la chaudi re Pousser l g rement le levier et le d placer vers la gauche pour l amener sur OFF ARR T Ne pas forcer Voir la Figure Remettre en place la porte volets d a ration de la chaudi re MANUFACTURER WARRANTY OWNER RESPONSIBILITIES It is the sole responsibility of the homeowner to make certain the gas furnace has been correctly set up and adjusted to operate properly NORDYNE warrants the furnace to be free from defects in material or workmanship for a period of one year A warranty certificate with full details isincluded with the furnace However NORDYNE will not be responsible fo
3. ser s Information Manual High Efficiency Upflow Induced Draft Gas Furnace Model G5RC Condensing Furnace FOR YOUR SAFETY WARNING If the inform his manual is no n ry or SU rah yay hike eret et PASE id Donotstoreoruse gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building Immediately call you gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department e Extinguish any open flame installation and service must be performed by aqualified installer service agency orthe gas supplier ADVERTISSEMENT Quiconque ne respecte pas fa lettre le instructions dans le pr sent manuel risque de d clencher un incendie ou une explosion trainant des dommages mat riels des l sions orelles ou la perte de vies humaines Ne pas entreposer ni utiliser de l essence ni d autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ni de tout autre appareil QUE FAIRE S UL Y A UNE ODEUR DE GAZ e Ne pas tenter d allumer aucun appareil e Ne toucher aucun interrupteur lectrique n utiliser aucun t l phone dans le b timent e Appeler imm diatement le fournisseur de gaz en employant le t l
4. and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label Setthe thermostat to lowest setting Turn off all electrical power to the appliance The appliance s ignition device automatically lights the burner Do not try to light burner by hand Remove louvered door of furnace Push lever in slightly and move left to OFF See Figure Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B inabove information If you don t smell gas go to next step 8 Push lever in slightly and move to ON See Figure 9 Replace louvered door 10 Turn on all electrical power to LEVER a LEVIER the appliance 11 Set the thermostat to a desired setting 12 lf the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician FIGURE TO TURN OFF GAS TO APPLIANCE Set the thermostat to the lowest setting Turn off all electrical power to the appliance if service is to be performed Remove louvered door of furnace Push lever in on gas valve slightly and move to the left to OFF Do not use force See Figure Replace louvered door of furnace A Cet appareil m nager n a pas de veilleuse Il est dot d un syst me d allumage automatiqu
5. compartment should be cleaned monthly during the heating and cooling seasons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor Build up of dirt and lint on the blower and motor can create excessive loads on the motor resulting in higher than normal operating temperatures and possible shortened service life Burner Maintenance Check the burner flames at the start of every heating season Set the thermostat to a temperature setting above the room temperature Remove the louvered door to the furnace and visually inspect the burner through EVERY SIX MONTHLY MONTHS VERIFY COMBUSTION AND VENTILATION AIR IS NOT RESTRICTED VERIFY NO SIGNS OF PHYSICAL DETERIORIZATION OF THE FURNACE VERIFY NO OBSTRUCTIONS OR RESTRICTIONS IN VENT OR CHIMNEY VERIFY NO HOLES OR CRACKS IN VENT PIPE Xx VERIFY NO CORROSION IN VENT PIPE VERIFY THAT HORIZONTAL VENT PIPES SLOPE UPWARDS AWAY FROM FURNACE VERIFY BURNER FLAME CLEAN OR REPLACE FILTER S CLEAN BLOWER COMPARTMENT F CLEAN BURNER VESTIBULE 4 NORDYNE manufacturer of Intertherm and Miller products the view hole to make sure that the flame is drawn into the center of the heat exchanger tube See Figure 3 In a properly adjusted burner assembly the flame bends down and to the right at the end of the heat exchanger tub
6. control which has been under water Familiarize yourself with the controls that shut off the gas and electrical power to the furnace If the furnace is to be shut down for an extended period of time turn off both the gas and electrical power For your safety always turn off both the gas and electrical power before performing service or maintenance on the furnace 2 Combustion Air Supply A furnace needs an adequate supply of combustion and ventilation air for proper and safe operation This furnace is a direct vent furnace and therefore requires outside air for combustion Follow the installation instructions included with the furnace to properly vent air to the combustion air inlet and exhaust the products of combustion to the outside from the exhaust vent If the furnace is operated with a restricted combustion air supply the pressure switch will open turning off the gas supply to the burners See Figure 1 DO NOT install a jumper wire across this switch to defeat its function If this switch must be replaced use only the replacement part specified in the Replacement Parts List Air openings in warm air registers and return air grilles must not be restricted CAUTION Combustion air must not be drawn from a corrosive atmosphere To maximize heat exchanger life the combustion air must be free of chemicals which form corrosive acidic compounds in the combustion gases Some examples of these c
7. phone d un voisin Respecter la lettre les instructions du fournisseur de gaz e Si personne ne r pond appeler le service des incendies L installationetl entretien doivent tre effectu s par un installateur qualifi un organisme de NORDYNE Manufacturer of AITEDTLCDRE Iu cnincnim and R48 LER products Take it from me Willard Scott America s Weatherman Follow these inStructions and you ll get really great comfort from your NORDYNE equipment SEEN EFFICIENCY RATING CERTIFIED ama SEAT service ou le fournisseur de gaz IMPORTAN Read this owner information thoroughly before attempting to operate or maintain this furnace to become familiar with the capabilities and use of your heating appliance Keep this with literature on other appliances where you have easy access to it in the future If a problem occurs check the instructions and follow recommendations given If these suggestions don t eliminate your problem call your NORDYNE Servicing Contractor Service PRO Any additions changes or conversions required in order for the appliance to satisfactorily meet the application needs must be made by a qualified installer service agency or the gas supplier using factory specified and approved parts Identification of parts you need to know about in order to secure optimum performance from this appliance
8. 2 632252 632252 632252 632252 9 LIMIT SWITCH 150 F 626418 LIMIT SWITCH 165 F 626390 LIMIT SWITCH 195 F 626419 LIMIT SWITCH 175 626424 626424 LIMIT SWITCH 210 626425 10 _ BLOWER INDUCER with gasket 902655 902655 902655 902655 902655 ORIFICE INDUCER 1 DIA 151885 NA ORIFICE INDUCER 1 25 DIA a ORIFICE INDUCER 1 50 DIA 151886 ORIFICE INDUCER 1 63 DIA 151884 COUPLING NEOPRENE 668916 668916 668916 668916 668916 668916 IN LINE DRAIN ASSEMBLY 371890 371890 371890 371890 371890 371890 BOX HEADER OUTLET PLUS SEALANT 902383 90 388 902384 o2384 902385 902385 SWITCH DOOR 632205 632205 632205 632205 632205 632205 TRAP ASSEMBLY 477600 477600 477600 477600 477600 VENT SAFETY LIMIT SWITCH 626389 626389 626389 626389 626389 626389 ROLL OUT LIMIT SWITCH 626422 626422 626422 626422 626422 626422 NORDYNE manufacturer of Intertherm and Miller products 9
9. e Ne pas essayer d allumer le br leur manuellement B AVANT L USAGE Attention une possible odeur de gaz surtout au niveau du plancher o les gaz les plus lourds ont la tendance de se concentrer EN CAS D ODEUR DE GAZ e Ne mettre en marche aucun appareil lectrique Netoucher aucun commutateur lectrique ne pas employer le t l phone Quitter le b timent imm diatement et avertir la compagnie du gaz en utili sant le t l phone d un voisin A d faut de la compagnie du gaz avertir le service des pompiers Tourner le robinet gaz levier Ne jamais employer d outils En levier de difficult ne pas essayer de le r parer vous m me Appeler un sp cialiste Forcer ou tenter de r parer le robinet peut entrainer une explosion ou un incendie l est d conseill d utiliser cet appareil en contact prolong avec l eau Faire inspecter ou remplacer toute commande par un technicien qualifi si un des syst mes de contr le du gaz s est trouv sous l eau MODE D EMPLOI ATTENTION Lire d abord la liste des mesures de s curit ci dessus Mettre le thermostat la position minimale Couper le courant lectrique qui m ne l appareil Cet appareil m nager tant dot d un systeme d allumage automatique ne pas essayer d allumer le br leur manuellement Retirer la porte volets d a ration de la chaudi re Pousser l g rement le levier et le d placer vers la gauche pour l amener sur OFF
10. e and the end of the flame will be out of sight around the bend The flame color should be blue however some light yellow streaks may occur on the outer portions of the flame CAUTION some components in the rner vestibule are at high temperatures while the burners are operating Use caution to avoid personal injury Drain Trap Inspection Burner Maintenance NOx The efficient operation of this furnace causes the condensation of water from the flue gases This conden sation collects in the front header box and will drain from the left side into the trap assembly See installation instructions for installation of trap and condensate drain Prior to operating furnace the trap MUST be filled with water This provides consistent drainage and assures smooth furnace operation Verify that all drain lines are tight and secure Burner 6 Operating Instructions FOR YOUR SAFETY READ PAGE 6 BEFORE OPERATING WARNING Should overheating occur or the gas supply fail to shut off shut off the manual gas valve to the furnace before shutting off the electrical supply ADVERTISSEMENT En cas de temp rature excessive ous ilestimpossible de couper l alimentation en gaz fermer le robinet manuel d alimentation en gaz du g n rateur d air chaud avant de couperl alimentation lectrique Thisfurnaceis equipped with a roll out limit vent safety switch and a pressure Switch See F
11. explosion personal injury carbon monoxide poisoning or property damage 4 Vent System The furnace must always be connected to an approved vent pipe to carry combustion products outdoors Atthe beginning and end of each heating season inspect the outdoor vent terminal closely with a flashlight WARNING Do not operate your furnace if you find any of the following conditions since toxic fumes can escape into your home Obstructions or restrictions inthe vent pipe and or chimney Holes in the vent pipe Cracks in the vent pipa Visible corrosion in the vent pipe Horizontal vent pipes that do not slope upward If any ofthe above conditions are found in the vent pipe call a qualified service technician to install new vent pipe 5 Maintenance Propermaintenance is mostimportant to achieve the best performance from a furnace and should be performed by a qualified service technician Follow the maintenance schedule in the table and the instructions below for years of safe trouble free operation Do not place combustible materials on or against the furnace cabinet Do not store gasoline or any other flammable vapors and liquids in the vicinity of the furnace Annually inspect the furnace ductwork and vent system for signs of physical deterioration e Changeorreplacethe airfilters monthly during any period when the circulating blower is operating regularly Always replace the d
12. fy and repair the problem FOR YOUR SAFETY READ BEFORE OPERATING POUR VOTRE SECURITE LIRE AVANT L EMPLOI WARNING If you do not follow these in structions exactly a fire or explosion may result causing property damage personal injury or loss of life ATTENTION L inobservation de ces instructions peut entra ner un incendie ou une explosion pouvant causer des dammages votre propri t votre personne ou la mort A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor 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 can t reach your gas supplier call the fire department Use only your hand to push in or turn the gas control lever Never use tools If the lever will not push in or move by hand do not try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Don t use this appliance if any part has been under water Immediately call a service technician to inspect the appliance
13. hemicals are chlorine fluorine and sulphur Some common sources of these chemicals are detergents bleaches aerosol sprays cleaning solvents and a wide variety of commercial and household products 3 Return Air Supply In applications where the supply ducts carry heated air to areas outside the space in which the furnace is installed the return air must be delivered to the furnace by duct s sealed to the furnace casing running full size and without interruption to the outside of space in which the furnace is installed The return air duct connection s must be physically sound and sealed to the furnace casing to prevent products of combustion from entering the living space Use a cleanable type high velocity air filter in the return air duct to maintain a clean heat exchanger WARNING Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death NORDYNE manufacturer of Intertherm and Miller products The floor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps cracks or sagging between the furnace and floor or platform The return air and circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert stove etc Doing so may result in fire
14. igure 1 The pressure Switch acts to verify that the burner flame is being drawn into the heat exchanger tubes If the burner flame is not being drawn into the heat exchanger tubes the roll out limit Switch or flame sensor will open and shudown the unit Figure 2 Burner Inspection NORDYNE manufacturer of Intertherm and Miller products The vent safety switch acts to shut the furnace down in the event of an overtemperature condition to protect the PVC flue system and inducer blower Furnace Fails To Operate If the furnace does not operate check the following 1 IS the thermostat operating properly 2 Is the blower door in place 3 Is the furnace disconnect closed 4 Has the circuit breaker tripped or fuse blown 5 Is the gas turned on 6 Is the manual shut off valve open 7 Is the filter dirty or plugged 8 Is the trap filled with water 9 Does the pressure switch close when the combustion air blower comes on If the combustion and circulating air blowers are operating and items 1 through 8 have been checked without identifying the cause of the problem press the red reset button on the vent safety limit and on the roll out limit Switch See Figure 1 IMPORTANT f the furnace operates after depressingthe reset button on the vent limit or roll out limit it is an indication of a potentially serious problem in the installation Contact a qualified serviceman to identi
15. oors on the furnace after servicing or cleaning changing the filters Do not operate the furnace without all doors and covers in place Avoid operating the furnace when windows and doors are open Besure that the thermostat is properly installed and is not beingaffected by drafts or heat from lamps or other appliances MAINTENANCE ITEM Air Filter s The installer should provide a filter rack for a high velocity type cleanable filter in the return air duct adjacent to the furnace Filters should be cleaned or changed monthly during the heating season New or newly renovated homes may require more frequent changing until the construction dust has been removed Alwaysreplacethe door on the furnace after servicing or the unit Do not operate the furnace without the door in place y WARNING Never operate the furnace without a filter in place Dust and lint in the return air can build up on the internal components resulting in a loss of efficiency equipment damage and possible fire risk FREQUENC BEGINNING OF EACH HEATING SEASON VERIFY FURNACE AREA IS FREE OF COMBUSTIBLE MATERIALS OF MAINTENANCE END OF EACH HEATING SEASON Lubrication The bearings in the circulating air blower motors used in these furnaces are pre lubricated and sealed atthe factory No further oiling of the bearings is required for the life of the motor Blower Compartment The blower
16. own ra not shown of Intertherm and Miller products NORDYNE manufacturer Residential Condensing Furnace Model G5RC ITEM ina mae MODEL AND PART NUMBERS DESCRIPTION G5RC 040 GSRC 060 G5RC 080 G5RC 100 G5RC 120 16 GSRC 120 20 CABINET BOTTOM 372671 372671 372672 372672 372673 372673 DOOR ACCESS GREY 902656 902656 902657 3 TRANSFORMER 621486 621486 621486 621486 621486 621486 4 BLOWER ASSEMBLY 902191 900131 902344 Dues me Je MOTOR 1 3 H P 902127 902127 x 4B BLOWER WHEEL 667037 667037 667207 667207 667207 667227 CAPACITOR 620273 620273 620233 620233 4 moror mount ewm 5 HEAT EXCHANGER ASSEMBLY 493821 493822 493823 493824 493825 493825 6 INTEGRATED CONTROL BOARD 902378 902378 902378 902378 902378 902378 r BURNER BOX ASSEMBLY 493870 493880 493890 493900 493810 493910 GAS VALVE 624506 624506 624506 624506 624506 7B IGNITOR 902661 902661 902661 902661 902661 7C FLAME SENSOR 632143 632143 632143 632143 632143 7D ORIFICE NATURAL GAS 44 660796 660796 660796 660796 660796 660796 7E BURNER 660812 660812 660812 660812 660812 660812 NOTE If furnace has a 632200 8 PRESSURE SWITCH Switch replace with same part no 632252 63225
17. r any costs found necessary to correct problems due to improper set up improper installation furnace adjustments improper operating procedure on the part of the user etc Some specific examples of service calls which cannot be included in warranty payments are 1 Repairing duct work in the home found to be faulty 2 Correcting wiring problems in the electrical circuit supplying the furnace 3 Re setting circuit breakers or other switches 4 Correction of problems due to improper gas supply pressure to the furnace 5 Providing instructional training on how to light and operate the furnace 6 Furnace problems caused by installation of an air conditioner heat pump or other air comfort devices 7 Revising installation of the vent assembly 8 Adjusting or calibrating of the thermostat Carefully review these responsibilities with your dealer service company or gas supplier so there will be no misunderstanding at a later time Read Your Warranty Please read your limited warranty completely It contains valuable information about your furnace If you have any questions about the warranty information contact your NORDYNE distributor LL NORDYNE manufacturer of Intertherm and Miller products 2 Door Not Shown a 20e PE er TE se 44 QU cH DH All ro 2 WES ER WE WI i d d d d b bb amp Trap Assembly not sh
18. uded in the design certification of this furnace We the manufac turer can not and will not be re sponsible for injury or damage caused by the use of such un tested and or uncertified devices accessories or components Be sure that the thermostat is prop erly installed and is not being af fected by drafts or heat from lamps or other appliances A WARNING To avoid possible equipment dam age fire or death the following instructions must be observed regarding furnace location com bustion air requirements and operation procedures NORDYNE manufacturer of Intertherm and Miller products rr 1 Furnace Location The furnace area and the vicinity of any other gas appliances must be kept clear and free of combustible materials gasoline and other flammable vapors and liquids Do not store or use flammable items such as paint varnish or strippers in the vicinity of the furnace Do not use the furnace closet or area next to the furnace as a storage area This area must be kept clear clean and free of lint The furnace must also be kept clear of loose or exposed insulation materials Examine the furnace area when the furnace is installed or when insulation is added since some insulation materials may be combustible Do notuse this furnace if any parthas been under water Immediately call a qualified service technician to inspect the furnace and to replace any part of the control system and any gas
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