Nordyne G5R Furnace Manual

The Nordyne G5R is a high-efficiency gas furnace designed for residential heating applications. This furnace features advanced combustion technology, multiple heating stages, variable-speed blower motor, electronic ignition system, built-in diagnostic controls, safety shut-off features, and compatibility with various thermostat systems. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Thermostat 7. Operation 8. Maintenance 9. Safety Features 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Gas valve, heat exchanger, blower assembly, control board, igniter, flame sensor, pressure switches, venting system.

Feature	Description
Gas valve	Regulates gas flow to burners
Heat exchanger	Stainless steel primary and secondary
Blower assembly	Variable-speed ECM motor
Control board	Microprocessor-based with diagnostic LEDs
Igniter	Hot surface ignition system
Flame sensor	Detects burner flame presence
Pressure switches	Verify proper venting operation
Venting system	PVC pipe compatible
Thermostat connections	Standard 24VAC terminals
Safety shut-off	Automatic gas valve closure on fault

Installation

Unpack and inspect contents. Install in approved location with proper clearances.

Position furnace: Level installation with proper combustion air supply.
Connect gas supply: Use approved black iron pipe with sediment trap.
Connect electrical: 120VAC power supply with proper grounding.
Install venting: PVC pipe system with proper slope and termination.
Connect thermostat: Standard 5-wire or 8-wire thermostat cable.

WARNING! Gas furnaces must be installed by qualified HVAC technician. Ensure proper ventilation and gas leak testing.

First-Time Setup

Power on furnace; follow startup sequence.

Verify gas supply: Ensure gas valve is open and no leaks present.
Check electrical: Confirm proper voltage at unit.
Test operation: Set thermostat to heat mode above room temperature.
Monitor ignition: Observe proper burner ignition sequence.
Check airflow: Verify proper air delivery through registers.

CAUTION! Initial startup must be performed by qualified technician. Monitor for proper combustion.

Specifications

Heating Capacity: 40,000 - 120,000 BTU/hr (multiple models)
Efficiency: Up to 96% AFUE
Gas Type: Natural gas or LP (with conversion kit)
Electrical: 120VAC, 60Hz, 15A circuit
Blower Motor: Variable-speed ECM
Stages: Single or two-stage heating
Venting: PVC pipe (2" or 3")
Dimensions: Varies by model (typically 21"W x 21"D x 40"H)
Warranty: Limited lifetime heat exchanger, 10-year parts

Controls and Settings

Access control board via front panel. LED diagnostic lights indicate system status.

Control Board: Power switch, diagnostic LEDs, dip switch settings, terminal connections.

Settings: Heating stages (single/two-stage), blower speeds (cooling/heating), fan on/off delays, thermostat type (conventional/heat pump). Diagnostic codes: Flash patterns indicate specific faults (pressure switch, igniter, flame sensor, limit switch).

Connecting Thermostat

Standard 24VAC thermostat connections: R (power), W (heat), Y (cool), G (fan), C (common).

Turn off power to furnace before wiring.
Match thermostat wires to control board terminals.
Use proper gauge thermostat wire (18-22 AWG).
Program thermostat for furnace type (gas/conventional).

Tip: Ensure power is off and verify connections with multimeter.

Operation

Normal heating cycle operation.

Thermostat call: Thermostat calls for heat when temperature drops below setpoint.
Inducer motor: Draft inducer starts to clear combustion chamber.
Pressure switch: Verifies proper draft before ignition.
Ignition: Hot surface igniter glows, gas valve opens.
Flame detection: Flame sensor confirms burner ignition.
Blower operation: Blower starts after heat exchanger warms up.
Cycle completion: System shuts down when thermostat satisfied.

WARNING! Do not attempt to override safety controls. Unusual odors or sounds require immediate shutdown.

Maintenance

Annual maintenance required for optimal performance and safety.

Replace air filter: Monthly during heating season.
Clean burners: Remove and clean burner assembly annually.
Inspect heat exchanger: Check for cracks or corrosion.
Clean flame sensor: Light sanding to remove buildup.
Check venting: Ensure proper slope and no obstructions.
Lubricate blower: If required (most ECM motors are sealed).

CAUTION! Always turn off power and gas supply before maintenance. Use qualified technician for complex tasks.

Safety Features

Multiple safety systems protect against hazardous conditions.

Flame rollout switches: Detect burner flame outside combustion chamber
High limit switches: Prevent overheating of heat exchanger
Pressure switches: Verify proper venting operation
Flame sensor: Confirms burner ignition within trial period
Gas valve: Automatic shut-off on safety system activation

Regulatory Information

ANSI Z21.47: Certified for gas-fired central furnaces. UL 1995: Standard for heating and cooling equipment. CSA International: Certified for US and Canadian markets. For technical support, contact Nordyne at 1-800-422-4328 or visit www.nordyne.com. Installation must comply with local building codes and utility requirements.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power/thermostat	Check circuit breaker; verify thermostat settings; ensure door switch engaged.
No heat	Gas supply/ignition	Verify gas valve open; check for ignition lockout; inspect flame sensor.
Short cycling	Airflow/limit switch	Replace dirty filter; check blocked vents; verify proper blower operation.
Blower won't stop	Thermostat/fan switch	Check thermostat fan setting; verify fan limit control operation.
Unusual noises	Mechanical issues	Inspect blower wheel; check motor bearings; verify proper gas pressure.

Reset: Power cycle unit to clear temporary lockouts.

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