Nordyne Furnace Repair Manual

The Nordyne Furnace is a high-efficiency heating system designed for residential and light commercial applications. This manual covers installation, operation, maintenance, and troubleshooting procedures for various Nordyne furnace models. Below are key sections for safety, technical specifications, installation guidelines, maintenance procedures, and troubleshooting solutions.

1. Safety Precautions 2. Technical Specifications 3. Installation Guidelines 4. Operation Instructions 5. Maintenance Procedures 6. Control System Overview 7. Electrical Connections 8. Venting Requirements 9. Gas Connection Procedures 10. Troubleshooting Guide 11. Parts Replacement

Safety Precautions

Before performing any service or maintenance, ensure proper safety protocols are followed.

Hazard	Precaution
Electrical Shock	Disconnect power before servicing
Gas Leaks	Check all connections with leak detection solution
High Temperature	Allow furnace to cool before handling components
Carbon Monoxide	Ensure proper ventilation and check heat exchanger
Moving Parts	Disconnect power before accessing blower assembly

Technical Specifications

Input Capacity: 40,000 - 120,000 BTU/H
Efficiency Rating: 80% - 96% AFUE
Voltage Requirements: 120V AC, 60Hz
Gas Type: Natural Gas or LP
Manifold Pressure: 3.5" WC Natural Gas, 10" WC LP
Blower Motor: Multi-speed ECM or PSC
Control System: Integrated furnace controller
Vent Size: 2" - 4" PVC depending on model

Installation Guidelines

Proper installation is critical for safe and efficient operation.

Location Selection: Choose well-ventilated area with adequate clearance
Combustion Air: Ensure sufficient combustion and ventilation air supply
Venting: Install according to local codes and manufacturer specifications
Gas Connection: Use approved pipe and fittings; pressure test all connections
Electrical: Follow NEC guidelines; install proper disconnect switch
Ductwork: Size appropriately for CFM requirements

WARNING! Installation must comply with all local codes and regulations.

Operation Instructions

Understanding normal operation sequences helps identify potential issues.

Thermostat Call: Thermostat initiates heating cycle
Inducer Motor: Draft inducer starts and proves pressure switch
Ignition Sequence: Hot surface igniter or spark ignition activates
Gas Valve: Main gas valve opens; burner ignition occurs
Blower Operation: Blower starts after heat exchanger warm-up period
Cycle Completion: System shuts down when thermostat satisfied

CAUTION! Never bypass safety devices or controls.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

Component	Maintenance Interval	Procedure
Air Filter	Monthly	Clean or replace as needed
Heat Exchanger	Annually	Inspect for cracks or damage
Blower Assembly	Annually	Clean blades and housing
Burners	Annually	Clean and inspect for proper flame
Vent System	Annually	Check for obstructions or damage

Control System Overview

The integrated control board manages all furnace operations and safety functions.

LED Codes: Flashing patterns indicate system status and fault conditions

Safety Controls: Limit switches, pressure switches, rollout switches

Ignition Control: Manages igniter and gas valve sequencing

Blower Control: Regulates blower speed and timing

Electrical Connections

Proper electrical connections are essential for safe operation.

Power Supply: 120V AC dedicated circuit with proper grounding
Thermostat Wiring: Low voltage connections (R, W, G, Y, C)
Safety Switches: Door interlock and high limit connections
Blower Motor: Multi-speed or variable speed configurations
Gas Valve: 24V AC control circuit

Tip: Always verify power is disconnected before making electrical connections.

Venting Requirements

Proper venting is critical for safe combustion and efficient operation.

Material: Use approved PVC or CPVC pipe
Slope: Horizontal runs should slope upward toward termination
Clearances: Maintain required clearances from combustible materials
Termination: Follow manufacturer specifications for location and height
Sealing: Use approved primer and cement for all joints

WARNING! Improper venting can cause carbon monoxide hazards.

Gas Connection Procedures

Gas line installation requires careful attention to detail and safety.

Pipe Sizing: Calculate proper pipe size based on length and BTU
Shut-off Valve: Install approved gas cock within 6 feet of appliance
Drip Leg: Include sediment trap before gas connection
Pressure Test: Test all connections at operating pressure
Leak Check: Use leak detection solution on all joints
Manifold Pressure: Verify and adjust to specified settings

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
No heat	Thermostat, power, gas supply	Check thermostat setting, circuit breaker, gas valve
Short cycling	Dirty filter, limit switch	Replace filter, check airflow, verify limit operation
Blower not running	Motor, capacitor, control board	Check voltage to motor, test capacitor, verify control signals
Ignition failure	Pressure switch, igniter, gas valve	Check venting, test igniter continuity, verify gas pressure
Unusual noises	Blower wheel, inducer motor	Inspect for obstructions, check motor bearings

Parts Replacement

Use only genuine Nordyne replacement parts for optimal performance.

Igniters: Hot surface igniters should be handled carefully
Gas Valves: Replace with identical models and settings
Control Boards: Ensure proper dip switch settings
Blower Motors: Match speed configurations and horsepower
Heat Exchangers: Professional replacement required

Service Support: 1-800-422-4328; www.nordyne.com