User's Information Manual
Residential Gas Furnaces
FOR YOUR SAFETY
— Do not store or use gasoline or other
flammable 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.
• 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.
— Installation and service must be
performed by a qualified installer,
service agency, or the gas supplier.
— 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
• Ne pas tenter d’allumer aucun appareil.
• Ne toucher à aucun interrupteur
électrique; n’utiliser aucun téléphone
dans le bâtiment.
• Appeler immédiatement le
fournisseur de gaz en employant le
téléphone d’un voisin. Respecter à
la lettre les instructions du
fournisseur de gaz.
• Si personne ne répond, appeler le
service des incendies.
— L’installation et l’entretien doivent être
effectués par un installateur qualifié,
un organisme de service ou le
fournisseur de gaz.
IMPORTANT
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 the recommendations
given. If the suggestions do not 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.
!
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety precautions exactly could
result in serious injury, death or property damage.
!
AVERTISSEMENT:
RISQUE D’INCENDIE OU
D’EXPLOSION
Le non-respect des consignes de sécurité pourrait
entraîner des blessures graves, la mort ou des
dommages matériels.
2
3
1 Ignitor
2 Flame Sensor
(Not Shown)
3 Gas Valve
4 Flame Roll-out
Switch(s)
5 Pressure Switch
6 Control Board
7 Blower Door
Switch(s)
8 Exhaust Adapter
9 Low Voltage
Transformer
10 Burner Assembly
11 Supply Air Limit
Switch
12 Blower Assembly
13 Induced Draft
Blower
14 Vent Transition
1 Ignitor
2 Flame Sensor
3 Gas Valve
4 Flame Roll-out
Switch(s)
5 Pressure Switch
6 Control Board
7 Blower Door
Switch
80+ AFUE
2
5
7
6
3
10
4
1
11
8
12
14
13
9
8 Vent Assembly
(Upflow Only)
9 Vent Switch
10 Low Voltage
Transformer
11 Burner Assembly
12 Supply Air Limit
Switch
13 Blower Assembly
14 Induced Draft
Blower
15 Combustion Tube
w/insulation
(Downflow Only)
16 Vent Transition
Assembly
(Downflow Only)
Upflow/Horizontal Furnace
Upflow/Horizontal Furnace
5
2
9
3
4
1
6
7
13
15
10
12
14
16
11
Downflow Furnace
Figure 1. Furnace Parts Identified
13
6
5
9
7
4
12
11
10
1
3
14
8
80+ AFUE
4
90+ AFUE
1 Ignitor (Not Shown)
2 Flame Sensor (Not Shown)
3 Gas Valve
4 Flame Roll-out Switch(s)
5 Pressure Switch
7 Control Board
8 Blower Door Switch
9 Vent Safety Switch
10 Low Voltage
Transformer
11 Supply AIr Limit
Switch
12 Circulating Air
Blower Assembly
13 Induced Draft
Blower
14 Condensate Drain
Tube
15 In-Line Drain
Assembly
16 Burner View Port
17 Front Header Box
18 Combustion Air
Intake
19 Exhaust Vent
Upflow/Horizontal Full Size
Condensing Furnaces
Downflow Condensing Furnace
10
7
8
13
5
9
14
11
3
1
4
16
2
17
15
12
18
19
Figure 2. Furnace Parts Identified
4
1
7
8
9
13
5
19
18
17
2
10
15
11
16
3
6
12
14
Upflow/Horizontal Compact
Condensing Furnaces
14
4
8
9
5
19
18
17
10
15
13
16
3
7
12
5
90+ AFUE Two - Stage Models
Figure 3. Furnace Parts Identified
Upflow/Horizontal Furnace Models
20
5
7
3
8
18
9
17
12
16
14
10
17
5
3
12
10
14
9
8
11
20
19
7
16
18
1 Ignitor (Not Shown)
2 Flame Sensor (Not
Shown)
3 Primary Gas Valve
4 Secondary Gas Valve
5 Flame Roll-out Switch(s)
6 Pressure Switch
7 Vent Pressure Switch
8 Control Board
9 Blower Door Switch
Downflow Furnace Models
10 Vent Safety Switch
11 Low Voltage
Transformer
12 Supply Air Limit Switch
13 Circulating Air Blower
Assembly (Not Shown
on Downflow Model)
14 Induced Draft Blower
15 Condensate Drain
Tube
16 In-Line Drain
Assembly
17 Burner View Port
18 Front Header Box
19 Combustion Air
Intake (Not Shown
on Upflow Model))
20 Exhaust Vent
(Not Shown on
Downflow Model)
4
6
6
11
13
15
4
15
6
1 Ignitor
2 Flame Sensor
3 Gas Valve
4 Flame Roll-out
Switch(s)
5 Pressure Switch
6 Control Board
7 Blower Door
Switch
8 Vent Assembly
9 Low Voltage
Transformer
10 Burner Assembly
11 Supply Air Limit
Switch
12 Blower Assembly
13 Induced Draft
Blower
Upflow/Horizontal Furnace
80+ AFUE Two - Stage Models
2
5
7
6
3
9
4
1
10
11
13
12
8
Figure 4. Furnace Parts Identified
7
GENERAL INFORMATION
This furnace has been designed and built to
provide many years of safe and dependable
home comfort, providing it is properly installed
and maintained. With regular maintenance, this
furnace will operate satisfactorily year after year.
Abuse, improper use, and/or improper mainte-
nance 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
furnace.
A regular service and maintenance schedule
should be established to insure efficient and
safe operation of the furnace. See Section 5 for
maintenance procedures and schedules.
Devices attached to the flue or vent for the
purpose of reducing heat loss up the chim-
ney have not been tested and have not
been included in the design certification
of this furnace. We, the manufacturer, can
not and will not be responsible for injury
1. Safety Information
The furnace area and the vicinity of any other
gas appliance 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. Some insulation materials may be
combustible.
For proper and safe operation, the furnace
needs air for combustion and ventilation. Do not
block or obstruct air openings on the furnace, or
any air openings where the furnace may be
installed, including any surrounding spaces.
Should the gas supply fail to shut off or if
overheating occurs, shut off gas valve to the
furnace before shutting off electrical supply.
Do not use this furnace if any part has been
under water. A flood-damaged furnace is
extremely dangerous. Attemps to use the
furnace can result in fire or explosion. A qualified
service agency should be contacted to inspect
the furnace and to replace all gas controls,
control system parts, electrical parts that have
been wet or the furnace if deemed necessary.
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. 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.
For 90+ Models: 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 Figures 2 and 3). 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.
For 80+ Models: If the furnace is operated with
inadequate combustion air supply, the flame roll-
out control switch located above the burners may
open, turning off the gas supply to the burners.
The flame roll-out control is a manually resettable
device (See Figure 1 and 4). DO NOT install a
jumper wire across this switch to defeat its function.
DO NOT reset the control without identifying and
correcting the fault condition which caused the
control to trip. 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.
8
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 chemicals 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. These duct(s) must be full size
and without interruption in the spaces outside of
where 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.
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, explosion, personal
injury, carbon monoxide poisoning, or property
damage.
Use a type high velocity air filter in the return air
duct to maintain a clean heat exchanger.
!
WARNING:
Failure to prevent products of com-
bustion from being circulated into the
living space can create potentially
hazardous conditions including car-
bon monoxide poisoning that could
result in personal injury or death.
4. Vent System
The furnace must always be connected to an
approved vent pipe to carry the furnace
combustion products outdoors. At the beginning
and end of each heating season, inspect the
outdoor vent terminal closely with a flashlight to
determine if any of the conditions listed under
the following warning exist.
MAINTENANCE ITEM BEGINNING OF END OF EACH
EACH HEATING SEASON HEATING SEASON MONTHLY
VERIFY FURNACE AREA IS FREE
OF COMBUSTIBLE MATERIALS
XXX
VERIFY COMBUSTION AND VENTILATION
AIR IS NOT RESTRICTED
XXX
VERIFY NO SIGNS OF PHYSICAL
DETERIORATION OF THE FURNACE
XXX
VERIFY NO OBSTRUCTIONS OR
RESTRICTIONS IN VENT OR CHIMNEY
XX
VERIFY NO HOLES OR CRACKS IN VENT PIPE
XX
VERIFY NO CORROSION IN VENT PIPE
XX
VERIFY THAT HORIZONTAL VENT PIPES
SLOPE UPWARDS AWAY FROM FURNACE
XX
VERIFY BURNER FLAME
X
CLEAN OR REPLACE FILTER(S)
X
CLEAN BLOWER COMPARTMENT
X
CLEAN BURNER ASSEMBLY
X
FRE
QU
EN
C
Y
O
F MAINTENAN
C
E
Table 1. Maintenance Table
9
5. Maintenance
Proper maintenance is most important to achieve
the best performance from this furnace and
should be performed by a qualified service
technician. Follow the maintenance schedule
(see Table 1) and the following instructions 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.
• Change or replace the air filters monthly
during any period when the circulating
blower is operating regularly.
• Always replace the doors on the furnace
after servicing or cleaning/changing the
filters. Do not operate the furnace
without all doors and covers in place,
except to check burner operation.
• Avoid operating the furnace when
windows and doors are open.
• Be sure that the thermostat is properly
installed and is not being affected by
drafts or heat from lamps or other
appliances.
Air Filter(s) — Air filter(s) are not supplied with
the furnace as shipped from the factory. The
installer must provide a high velocity filter and
rack in the return air duct adjacent to the furnace,
or in a return air grille to the furnace. The filter(s)
must be removed and cleaned monthly during the
heating season to ensure proper furnace
operation. New or newly renovated homes may
require more frequent changing until the
construction dust has been removed.
!
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.
Always replace the door(s) on the furnace after
servicing or cleaning/changing the filters. Do not
operate the furnace without the door(s) in place.
Lubrication — The bearings in the circulating
air blower motors used in these furnaces are
pre-lubricated and sealed at the factory. No
further oiling of the bearings is required for the
life of the motor.
Blower Compartment — The blower
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 top door
from the furnace and visually inspect the burner
through the view hole to make sure that the
flame is drawn into the center of the heat
exchanger tube (See Figure 5). In a properly
adjusted burner assembly, the flame bends
down and to the right at the end of the heat
exchanger tube, 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 burner
vestibule are at high temperatures
while the burners are operating. Use
caution to avoid personal injury.
Figure 5. Burner Inspection
Burner
Flame
Manifold
10
!
WARNING:
Do not operate your furnace if you
find any of the following conditions.
Such conditions may allow toxic
fumes to escape into your home:
• Obstructions or restrictions in
the vent pipe and/or chimney.
• Holes or cracks in the vent pipe.
• Visible corrosion in the vent pipe.
• Horizontal vent pipes that do not
slope upward.
If any of the above conditions are found
in the vent pipe, call a qualified service
technician to install new vent pipe.
For upflow and downflow low NOx models
only: Burner Maintenance, If the second or
eighth character of the model number is an “N”
the furnace has factory installed NOx reduction
inserts. The inserts reduce the NOx emissions
of the furnace. The NOx reduction inserts are
located in the first pass of the top portion of the
heat exchanger. When the burners are
operating, the flame should extend through the
center of the NOx reduction inserts. The flame
color should be blue, however some light yellow
streaks may occur on the outer portions of the
flame.
Inspect the burners, mounting brackets, and all
other parts in the vestibule for signs of
deterioration. The burner vestibule should be
vacuumed clean and inspected annually.
!
CAUTION:
Do not strike any of the internal
electrical components while
vacuuming.
6. Operating Instructions
READ THE SAFETY INFORMATION ON
THE FOLLOWING PAGE 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 température excessive, ou
s’il est impossible de couper
l’alimentation en gaz, fermer le robinet
manuel d’alimentation en gaz du
générateur d’air chaud avant de
couper l’alimentation électrique.
These furnaces are equipped with roll-out limit
switch(s), a vent safety switch, and a pressure
switch (See Figures 1, 2, 3 and 4). The pressure
switch verifies that the flame is receiving
combustion air. If the flame is not drawn into the
heat exchanger tube, the roll out limit switch or
flame sensor, will shut the furnace down.
The vent safety switch shuts the furnace down
if the vent becomes blocked or restricted.
Furnace Fails To Operate — If the furnace
does not operate, check the following:
1) Is the thermostat operating properly?
2) Are the blower door(s) 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 filter dirty or plugged?
11
If the combustion and circulating air blowers are
operating, and items 1 through 6 have been
checked without identifying the cause of the
problem, press the red reset buttons on the vent
safety and the roll out limit switches. (See
Figures 1, 2, 3 and 4).
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.
The Manufacturer warrants the furnace to be free from defects in material or workmanship for the
warranty period. However, the Manufacturer will not be responsible for 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 distributor.
IMPORTANT: If the furnace operates after
depressing the 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 identify
and repair the problem.
7082880 (Replaces 7082220)
Specifications and illustrations subject to change
without notice and without incurring obligations.
Printed in U.S.A. (08/03)
¢708288T¤
7082880
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dans d''autres langues
- English: Broan KG6T(A,K) User manual
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