Nortek SA Series User manual

GAS FURNACES SINGLE STAGE,TWO-STAGE, & MODULATING FURNACES
USER’S MANUAL
NON-CONDENSING GAS FURNACES CONDENSING GAS FURNACES
80+ AFUE 92.1% AFUE 95% - 97% AFUE
*SA Upflow / Horizontal
Furnaces
*SC Upflow / Horizontal
Furnaces
*SD, *TC, *MQ Upflow /
Horizontal Furnaces
*SK Downflow
Furnaces
*SL Downflow
Furnaces
*SM & *TL Downflow
Furnaces
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qualiedinstaller,serviceagencyorthegas
supplier.
•Donotstoreorusegasolineorother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
redepartment.
DO NOT DESTROY. PLEASE READ CAREFULLY & KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

2

3
TABLE OF CONTENTS
IMPORTANT SAFETY INFORMATION................................................................................... 4
GAS SUPPLY & PIPING .................................................................................................................................... 4
VENTING SYSTEM............................................................................................................................................ 4
CLEARANCES TO COMBUSTIBLES ................................................................................................................ 5
SOURCES OF CORROSION............................................................................................................................. 5
FILTER ............................................................................................................................................................... 5
FLOOD DAMAGE............................................................................................................................................... 5
IMPORTANT SAFETY INFORMATION................................................................................... 5
ABOUT THE FURNACE.......................................................................................................... 6
INTRODUCTION ................................................................................................................................................ 6
CATEGORY I (NON-CONDENSING) FURNACES .........................................................................................6
CATEGORY IV (CONDENSING) FURNACES................................................................................................6
FILTER ............................................................................................................................................................... 6
THERMOSTAT................................................................................................................................................... 6
FURNACE LOCATION....................................................................................................................................... 6
COMPONENT LOCATIONS FOR NON-CONDENSING TYPE FURNACES .................................................... 7
COMPONENT LOCATIONS FOR CONDENSING TYPE FURNACES ............................................................. 8
STARTUP & SHUTDOWN....................................................................................................... 10
STARTING THE FURNACE............................................................................................................................... 10
SHUTTING DOWN THE FURNACE .................................................................................................................. 10
TROUBLESHOOTING............................................................................................................. 10
MAINTENANCE & INSPECTION ............................................................................................ 11
FURNACE & AIR DUCTS .................................................................................................................................. 11
VENTING SYSTEM............................................................................................................................................ 11
BLOWER & FILTER ........................................................................................................................................... 11
BURNER OPERATION ...................................................................................................................................... 11
NEW CONSTRUCTION ..................................................................................................................................... 11

4
IMPORTANT NOTE
Ifthegassupplyfailstoshutofforifoverheating
occurs,shutoffthegasvalvetothefurnacebefore
shuttingofftheelectricalsupply!
WARNING:
The furnace was shipped from the factory
equippedtooperateonnaturalgas.Conversion
to LP/propane gas must be performed by a
licensed HVAC technician using a factory
suppliedconversionkit.Failuretousetheproper
conversionkitcancausere,explosion,property
damage,carbonmonoxidepoisoning,personal
injury,ordeath.
WARNING:
All gas piping and shutoff valves must be
installed in compliance with local codes and
utilityregulationsbylicensedinstallers.DONOT
attempttomodify,ortapintoexistinggaslines
yourself.Fireorexplosionmayresultcausing
propertydamage,personalinjuryorlossoflife.
Failuretofollowthesafetywarningsexactlycould
resultinseriousinjury,deathorpropertydamage.
VENTINGSYSTEM
WARNING:
Itisimperativetomaintainproperoperationofthe
ventingsystem,includingthemasonrychimney
(ifapplicable).Insufcientventingcouldcreate
theproductionofexcessiveamountsofCarbon
Monoxide(CO)-acolorless,odorlessgasthatis
producedduringincompletecombustionofany
fuel.Itcancausedeathwithoutwarning.Carbon
monoxidepoisoningcancauseu-likesymptoms
andalsodizziness,fatigue,headaches,nausea,
andirregularbreathing.
If you suspect that you are experiencing CO
poisoning,getfreshairimmediately.Leavethe
homeandcallforassistancefromaneighbor’s
home.
 
      

        



      

WARNING
  
CAUTION


WARNING:
The safety information listed below must be
followed during the installation, service, and
operationofthisfurnace.Failuretofollowsafety
recommendations could result in possible
damage to the equipment, serious personal
injury,ordeath.
WARNING:
PROPOSITION 65 WARNING: This product
contains chemicals known to the state of
Californiatocausecancer,birthdefectsorother
reproductiveharm.
WARNING:
Thisfurnaceisnotapprovedforinstallationin
mobilehomes.Installingthisfurnaceinamobile
homecouldcausere,propertydamage,and/or
personalinjury.
GAS SUPPLY & PIPING
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redepartment.
Installation and service must be performed by a
qualiedinstaller,serviceagencyorthegassupplier.
Thisfurnacedoesnothaveapilot.

DO NOT
IMPORTANT SAFETY INFORMATION

5
CAUTION:
This furnace requires unrestricted airow for
combustion and ventilation. For proper and
safeoperation,itisextremelyimportantthatthe
furnacereceivesanunobstructedowofclean,
freshairtoproperlyburnthefuelgas.Ifthisow
ofairisrestricted,thepartiallyburnedcombustion
gasesmaycreatedangerousamountsofcarbon
monoxidethatcancausepersonalinjuryordeath.
 




           







        
    
        
    
       
       


CLEARANCES TO COMBUSTIBLES
WARNING:
Donotplacecombustiblematerialsonoragainst
thefurnacecabinetorwithin6inchesofthevent
pipe.Furnaceareamustbekeptclearandfree
of combustible materials, gasoline and other
ammablevaporsandliquids.Areorexplosion
mayresultcausingpropertydamage,personal
injuryorlossoflife.Failuretofollowthesafety
warningsexactlycouldresultinseriousinjury,
deathorpropertydamage.



   


SOURCES OF CORROSION




Donotstorethesechemicalsnearthefurnace:
 
 
 
 
 
 
 
 
 
 
 
 
 
FILTER
WARNING:
Neveroperatethefurnacewithoutalterinplace.
Accumulating dust in the return air can build
uponinternalcomponents,resultinginlossof
efciency,equipmentdamage,andpossiblere.



FLOOD DAMAGE
WARNING:
Donotusethisfurnaceifanyparthasbeenunder
water. A ood damaged furnace is extremely
dangerous.Attemptstousethefurnacecanresult
inreorexplosion.Aqualied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.
IMPORTANT SAFETY INFORMATION

6
INTRODUCTION

       

       


      




       
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.









Therearenouserserviceableparts.Allrepairs
mustbeperformedbyalicensedHVACtechnician.
CategoryI(Non-Condensing)Furnaces





CategoryIV(Condensing)Furnaces


    



      





 


 


Ifcondensatefreezesinthelines,thiswill
causethecondensatedrainswitchtoshutdown
thefurnace.OnlyalicensedHVACtechniciancan
resetthisswitch.
FILTER
WARNING:
Neveroperatethefurnacewithoutalterinplace.
Accumulating dust in the return air can build
uponinternalcomponents,resultinginlossof
efciency,equipmentdamage,andpossiblere.
 Air lter(s) are not supplied with the furnace as
shippedfromthefactory.



 



        
      


 
Donotoperatethe
furnacewithoutalldoorsandcoversinplace.
THERMOSTAT



          


         

NOTE:

        
      

        


FURNACE LOCATION





ABOUT THE FURNACE

7
COMPONENT LOCATIONS FOR NON-CONDENSING TYPE FURNACES
SingleStageModels
2-StageModels
Blower
Door
Switch Burner
Assembly
Flame Sensor
Gas
Manifold
Gas Valve
Igniter
Inducer
Assembly
Pressure
Switch
Roll-Out
Switch
Transformer
Blower
Assembly
Furnace
Control
Board
Main Air
Limit Switch
Combustion Tube
Gas
Manifold
Gas Valve
Inducer
Assembly
Pressure
Switch
Transformer
Blower Assembly
(behind blower panel)
Burner
AssemblyFlame
Sensor
Roll-Out
Switch
Igniter
Main Air
Limit Switch
Blower
Door Switch
(behind blower panel)
*SA 80+ Upflow / Horizontal Gas Furnace
*SK 80+ Downflow Gas Furnace
Furnace
Control
Board
1 2 3 45 6 7 8
Motor Choke
(C & D cabinets only)
Motor Control
Board
Motor
Control Box
Blower
Door
Switch Burner
Assembly
Flame Sensor
Gas Manifold
Gas Valve
Igniter
Inducer
Assembly
Pressure
Switch
Roll-Out Switch
Transformer
Blower
Assembly
Furnace
Control Board
Main Air
Limit Switch
1 2 3 45 6 7 8
Furnace
Control
Board
Combustion Tube
Gas Manifold
Gas Valve
Inducer
Assembly
Pressure
Switches
Transformer
Burner
AssemblyFlame
Sensor
Roll-Out
Switch
Igniter
Main Air
Limit Switch
Blower
Door Switch
(behind blower panel)
Motor Choke
(C & D cabinets only)
Motor
Control
Board
Blower Assembly
(behind blower panel)
*TA 80+ Upflow / Horizontal Gas Furnace
*TK 80+ Downflow Gas Furnace

8
COMPONENT LOCATIONS FOR CONDENSING TYPE FURNACES
SingleStageModels
Blower
Assembly
Blower Door
Switch
Burner
Assembly
Furnace
Control
Board
Finish
Flange
Flame
Sensor
Gas
Manifold
Gas
Valve
Igniter
Inducer
Assembly
Main Air
Limit Switch
Inducer
Pressure Switch
Condensate
Pressure Switch
(‘B’, ‘C’, & ‘D’ cabinets only)
Roll-Out
Switch
Transformer
Inducer
Limit Switch
Finish
Flange
Blower Door
Switch
(behind blower panel)
Burner
Assembly Flame
Sensor
Gas Manifold
Gas Valve
Igniter
Inducer
Assembly
Inducer
Pressure
Switch
Vent Limit
Switch
Furnace
Control
Board
Main Air
Limit Switch
Transformer
Roll-Out
Switch
*SC 92.1% Upflow / Horizontal Gas Furnace
*SL 92.1% Downflow Gas Furnace
Blower Assembly
(behind blower panel)
Burner
Assembly
Finish
Flange
Flame
Sensor
Igniter
Roll-Out
Switch
Gas Valve
Furnace
Control Board
Condensate
Pressure
Switch
Transformer
Blower
Assembly
Blower
Door Switch
Inducer
Assembly
Inducer Pressure
Switch
Inducer
Limit Switch
Main Air
Limit Switch
Burner
Assembly
Flame
Sensor
Roll-Out
Switch
Finish
Flange
Blower Door Switch
(behind blower panel)
Gas
Manifold
Gas Valve
Igniter
Inducer
Assembly
Inducer
Limit Switch
Furnace
Control
Board
Pressure
Switch
Transformer
Blower Assembly
(behind blower panel)
*SD 95.0% Upflow / Horizontal Gas Furnace
*SM 95.0% Downflow Gas Furnace
Gas
Manifold


Two-StageModels
AIR FLOW
1 2 3 45 6 7 8
Burner
Assembly
Finish
Flange
Igniter
Roll-Out
Switch
Gas Valve
Furnace
Control Board
Condensate
Pressure
Switches
Transformer
Motor
Control
Board
Blower
Assembly
Motor Choke
(C & D cabinets only)
Blower Door
Switch
Inducer
Assembly
Inducer
Pressure
Switches
Motor
Control Box
Inducer
Limit Switch
Main Air
Limit Switch
Burner
Assembly
Flame
Sensor
Roll-Out
Switch
Finish
Flange
Blower Assembly
(behind blower panel)
Blower
Door Switch
(behind blower panel)
Motor Choke
(C & D cabinets only)
Gas
Manifold
Gas Valve
Igniter
Inducer
Assembly
Inducer Limit
Switch Main Air
Limit Switch
Furnace
Control
Board
Motor
Control
Board
Pressure
Switches
Transformer
FLOWAIR
*TC 95.1% Upflow / Horizontal Gas Furnace
*TL 95.1% + Downflow Gas Furnace
Flame
Sensor Gas
Manifold
Burner
Assembly
Finish
Flange
Roll-Out
Switch
Transformer
Motor
Control
Board
Blower
Assembly
Flame
Sensor
Motor Choke
(C & D cabinets only) Motor
Control
Box
Blower Door
Switch
Inducer
Assembly
Pressure
Switches
Inducer
Limit Switch
Furnace
Control Board
Igniter
Gas Valve
Gas
Manifold
Main Air
Limit Switch
*MQ 97.1% Upflow / Horizontal Gas Furnace

10
STARTING THE FURNACE
 
 
 
 
 
 
 

 

 
 
 
 
 

 
SHUTTING DOWN THE FURNACE


OFF THE GAS VALVE TO THE FURNACE BEFORE
TURNING OFF THE ELECTRICAL SERVICE.
NOTE:







 
 
 
 
 
 
Ifthefurnacefailstooperatecheckthefollowing:
 
 
 

 
 
        

Figure1.GasValves
SINGLE STAGE VALVE
MODULATING VALVE
TWO - STAGE VALVE
STARTUP & SHUTDOWN
TROUBLESHOOTING