NORDYNE Furnace/Heater, Gas Manual L0523341

M3RL Series L0523341

User Manual: NORDYNE NORDYNE Furnace/Heater, Gas Manual NORDYNE Furnace/Heater, Gas Owner's Manual, NORDYNE Furnace/Heater, Gas installation guides

Open the PDF directly: View PDF .
Page Count: 36

Direct Vent (SeaHed Combustion) Forced Air Gas Furnaces

M3RL Series 90+ Downfiow Condensing Furnace

For installation in:

I. Manufactured Homes

2. Park Models and Manufactured Buildings

3. Modular Homes/Buildings

WARNING:

FiRE OR EXPLOSION HAZARD

Failure to fol!ow safety warnings e×actly could

result in serious injury, death or property

damage.

- Do not store or use gasoline or other flammable

vapors and liquids in the vicinity of this or any other

appliance.

-WHAT TO DO mFYOU SMELL GAS

oDo not try to light any appliance.

oDo not touch any electrical switch; do not use any

phone in your building.

, Leave the building immediately.

oImmediately 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.

-installation and service must be performed by a

qualified installer, service agency, or the gas sup-

plier.

RISQUE D'INCENDmE OU D'EXPLOSmON

Le non-respect des avertissements de s_curit_

pourrait entra_ner des blessutes graves, la

mort ou des dommages mat_rieJs.

- Ne pas entreposer ni utiliser de I'essence ni

d'autres vapeurs ou liquides inflammables dans Ic

voisinage de cet appareil, ni de tout autre apparei

-QUE FAmRE S'IL YA UNE ODEUR DE GAZ

oNe pas tenter d'allumer aucun appareil.

,Ne toucher a aucun interrupteur 61ectdque;

n'utiliser aucun t616phone dans le b_timent.

oE_vacuerI'immeuble immCdiatement.

, Appeler immCdiatement le foumisseur de gaz en

employant le t616phone d'un voisin. Respecter

la lettre les instructions du foumisseur de gaz.

oSi personne ne repond, appeler le service des

incendies.

- Uinstallation et I'entretien doivent Ctre effectues

par un installateur qualifie, un organisme de

service ou le fournisseur de gaz.

BW Models

BWT Models

WARNING:

Shoumd overheating occur, or the

gas suppty fail to shut off, shut

off the manual gas valve to the

appliance before shutting off the

electrical supply.

Improper installation, adjust-

ment, amteration, service or

maintenance can cause injury

or property damage. Refer to

this manual. For assistance or

additional information consult

a qualified installer, service

agency or the gas supplier.

LEAVE THESE mNSTRUCTmONS WroTHTHE HOMEOWNER.

TABLE OF CONTENTS

Generam ...................................................... 4

Unit Dimensions .................................. 4

Shipping Weights ................................ 4

Furnace Specification ........................ 4

Air Flow Data ..................................... 4

Owner's hformation ................................ 5

Installation Requirements ...................... 6

Location .............................................. 7

Clearance ........................................... 7

Circumating Air Supply ............................ 7

Return Air Provisions .............................. 8

Air Distribution Systems ........................ 9

Duct Connector Selection .................... 10

Duct Installation .................................... 10

Venting and Combustion

Air Requirements ........................... 13

Venting Requirements .......................... 14

Vent Table ........................................ 15

Vent Pipe Material ............................ 16

Vent Pipe Length and Diameter ....... 16

Vent Pipe installation ........................ 16

Pipe Routing & Support .................... 16

Location of Outdoor Termination ..... 16

Horizontal Venting ............................ 18

Vertical Venting ................................ 18

Vent Freezing Protection ................. 19

Concentric Vent Termination ........... 19

Drainage of Condensate

From Furnace ................................ 19

Gas Supply and Piping ......................... 20

Leak Check ....................................... 21

High Altitude Derate ......................... 21

Pressure Switch .............................. 21

Conversion .............................................. 21

Lighting and Adjustment

of the Appliance .............................. 23

ElectdcaIWiring ...................................... 24

Line Voltage Wiring ........................... 24

Low Voltage Wiring ........................... 26

Ventilation ................................................ 26

Start-up and Adjustment ........................ 26

Start-Up Procedure ........................... 26

Shut Down Procedure ....................... 27

Verifying and Adjusting Firing Rate ... 27

Temperature Rise ............................. 27

Verifying and Adjusting

Verifying Burner Operation .............. 28

Verifying Operation of the

Supply Air Limit Switch ................. 28

Description of Components ................ 29

Furnace Accessories ............................. 29

Maintenance ........................................... 29

Combustion Air and Vent System .... 29

Air Filter(s) ....................................... 29

Lubrication ........................................ 30

Condensate Drain Assembly ........... 30

Blower Compartment ....................... 30

Heat Exchanger and Burner

Maintenance .................................. 30

System Operation Information ............. 30

Sequence of Operation .................... 30

Furnace Fails to Operate ................. 31

Location of Major Components .......... 32

Wiring Diagram ....................................... 33

instaliationlPerformance

CheckJist ......................................... 35

M3RL-

Application 1

M-Manufactured Home

Furnace Series

Comfort Mode! m

RL - Condensing Downflow

Heating Capacity

input, BTUH (000')

060 A -A W

c°°,,°°,°t,°°

W - White

G - Gray

Cabinet Dimensions

A - 56" x 19-3/4" x 23-3/4"

B - w/Coil Cavity,

76" x 19-3/4" x 23-3/4"

Electricam Code

A - IPH, 60 Hz, 120 VAC

Tabte 1. Model identification

3

2"37116

-- I£_7/8 --

®

/32

Cooling

Coil

Box

i i

%1#2

317132

COMBUSTION AiR INTAKE

1-1/118

EXHAUST

VENT

18 1#2

56!/16

(W/O CoilBo_)

917132 ,

1_3/!6

24_5/8 --

KNOCKOUTS

•I-- I_r2 fl

21 157/6 --

1 19F32

_-- 24_t4 --

(W/C_EBOX}

7_!_

Top Return Knockouts

_J

, \

Top View

(AW and BW Models)

Figure 1. Furnace Dimensions

_12.000_

1000

21000

O

=©

Top Returr_ Opening

(BWT Models)

Furnace Model

M3RL 060A AW

M3RL 060A BW*

M3RL 080A AW

M3RL 080A BW*

* May include suffix - T

Table 2.

Shipping

Weight

(Ibs)

15O

170

155

175

Shipping Weight

Furnace Specifications /Airflow Data

Furnace Furnace Temp.

Furnace Input Output Rise @ Motor

Model No. Btuh Btuh .3"WC °F HP

M3 RL-060 60,000 54,000 35- 65 I/2

M3 RL-080

Note:

80,000 72,000 35 - 65 I/2

External Static Pressure ( Inches Water Column) Recommended

Motor 0.1 0.2 0.3 0.4 0.5 A/C

Speed CFM CFM CFM CFM CFM Ton

High* 1660 I599 I544 1474 I410 4

Med-High 1512 I467 I416 1363 I304 3

Med-Low 1340 I304 I261 1217 II58 2.-I/2

Low** 1176 II42 I108 1025 966 2

High* 1660 I599 I544 1474 I410 4

Med-High 1512 I467 I416 1363 I304 3

Med-Low** 1340 I304 I261 1217 II58 2.-I/2

Low 1176 II42 I108 1025 966 2

Data is for Operation with Filter,

* Factory Wired Cooling Tap

** Factory Wired Heating Tap

Table 3. Furnace SpecificationslAirflow Data

WARNmNG:

Do not use this appmiance if any part

has been submerged underwater. Im-

mediatemy camsa quamified service tech-

nician to inspect the appmiance and to

repmace any part of the controm system

and any gas controm that has been

submerged underwater.

NOTICE TO iNSTALLER

Installer is advised to follow carefully all instruc-

tions and warnings in this manual to insure

maximum performance, safety, and operating

efficiency of these appliances. Improper installa-

tion may create hazardous conditions, and will

void the appliance warranty.

GENERAL

General Description

The M3 series gas furnaces are listed direct

vent (sealed combustion) forced air furnaces

for use with both natural and propane gases.

The M3 series is a Category IV and type FSP

furnace. The M3 furnace series has been

certified to the ANSi Z21.47/CSA2.%2001 for

use in the United States and Canada and to the

UL307B --1995 for use in the United States.

These furnaces may be installed in:

I. Manufactured Homes.

2. Park Models and Manufactured buildings

3. Modular Homes/Buildings

The following are safety guidelines with refer-

ences to their specific sections or pages in the

manual.

I. Use only type of gas approved for this

furnace. Refer to the furnace rating plate.

2. Install this furnace only in location and

position as specified in pages 7 - 13 of

these instructions.

3. Provide adequate combustion and ventila-

tion air to the furnace space as specified in

pages 13 - 20 of these instructions.

4. Combustion products must be discharged

outdoors, connect this furnace to an ap-

proved vent system only, as specified in

pages 14-19 of these instructions.

5. Never test for gas leaks with an open

flame. Use a commercially available soap

solution made specifically for the detection

of leak to check all connections.

6. Always install furnace to operate within the

furnace's intended temperature rise range

with a duct system that has an external

static pressure within the allowable range,

as specified in page 4 of these instruc-

tions. See furnace rating plate.

7. When a furnace is installed so that supply

ducts carry air circulated by the furnace to

areas outside the space containing the

furnace, the return air shall also be handled

by duct(s) sealed to the furnace casing

and terminating outside the space contain-

ing the furnace. Note: This section only

applies to furnaces installed with side or

top return air.

8. A gas-fired furnace for installation in a

residential garage must be installed as

specified in page 7 of these instructions.

9. The furnace is not to be used for tempo-

rary heat of buildings or structures under

construction.

M3 series furnaces are air conditioning ready

as shipped. The furnace cooling capacities of

the blower motor speed taps are shown in

Table 3. Table 2 lists the shipping weights for

the M3 series furnaces.

OWNER NFORMATION

NORDYNE has been involved in the design of

products for the manufactured home industry

since the first manufactured home or trailer

was built.

NORDYNE originated the sealed combustion

system, which separates the furnace com-

bustion system from the living area of the

home, now a standard for the manufactured

home industry.

NORDYNE engineers developed the first cen-

tral heating system and the first central air

conditioner for manufactured homes.

NORDYNE is dedicated to bringing to its cus-

tomers the finest heating and cooling comfort

possible. NORDYNE constantly seeks to fur-

ther refine its products to continuously provide

exceptional comfort.

Followtheinstructionsinthisbookletcarefully

andthisappliancewillprovidemanyyearsof

superiorperformance.

if youwish to cool yourhomeautomatically

witha centralair conditioningsysteminvesti-

gatetheexcellentNORDYNEcoolingsystems

availablefromyour heatingand coolingcon-

tractor.Thesesystemsare designedto work

bestwithyour NORDYNEfurnaceand have

beencarefullyengineeredto deliveroptimum

performancewhen mated with NORDYNE

manufacturedhomefurnaces.

NORDYNEalsoofferswaterheaters,fireplaces

and ventilatingsystemsspecificallydesigned

for manufacturedhousingapplications.Check

with your manufacturedhomeretailer,your

heating and cooling contractor or your

distributorfor information.Writedirectlyto the

factory(POBox8809,O'Fallon,MO63366)if

youarenotabletolocateasourceforNORDYNE

manufacturedhousingproductsin yourarea.

MANUFACTURERWARRANTY,OWNER'S

RESPONSIBILITIES

it isthesoleresponsibilityofthehomeownerto

makecertainthegasfurnacehasbeencorrectly

setupandconvertedtotheproperfuel(UP.gas

or Naturalgas)andadjustedto operateprop-

erly. All gas furnacesare manufacturedfor

Naturalgasandmustbefieldconvertedwhen

usingUP.gas.

Awarrantycertificatewithfulldetailsisincluded

withtheseinstructions.However,NORDYNE

willnotberesponsibleforanycostsfoundnec-

essaryto correctproblemsdue to improper

setup,improperinstallation,furnaceadjustments,

improperoperatingprocedureonthepartofthe

user,etc.

Somespecificexamplesof servicecallswhich

cannotbeincludedinwarrantypaymentsare:

I. Convertingthefurnacetouseanothertype

ofgas.

2. Repairingductworkinthehomefoundtobe

faulty.

3. Correctingwiringproblemsintheelectrical

circuitsupplyingthefurnace.

4. Resettingcircuitbreakers,blownfusesor

otherswitches.

5. Correctingproblemsdueto impropergas

supplypressuretothefurnace.

6. Providinginstructionaltrainingon how to

lightandoperatethefurnace.

7. Furnaceproblemscausedbyinstallationof

anair conditioner,heatpumpor otherair

comfortdevices.

8. Revisinginstallationof the furnaceflue

assembly.

9. Adjustingor calibratingof thermostat.

10.Any constructiondebriswhich falls into

thefluesystem.

Carefullyreviewtheseresponsibilitieswithyour

manufacturedhousingdealer,servicecompany

or gassupplierso therewill beno misunder-

standingat alatertime.

CAUTmON'.

Never attempt to alter or modify this

furnace or any of its components.

Never attempt to repair damaged or

inoperable components. Such action

could cause unsafe operation, ex-

plosion, fire and/or asphyxiation.

• If a malfunction has occurred, or if

you feel that the furnace is not oper-

ating as it should, contact a qualified

service agency or gas utility for as-

sistance.

iNSTALLATiON STANDARDS

Installer shall be familiar with and comply with all

codes and regulations applicable to the installa-

tion of these heating appliances and related

equipment. In lieu of local codes, the installation

shall be in accordance with the current provi-

sions of one or more of the following standards.

a. Federal Manufactured Home Constructions

& Safety Standard (H.U.D. Title 24, Part

3280.707[a][2])

b. The Standard for Manufactured Home Instal-

lations (Manufactured Home Sites, Commu-

nities, and Set-Ups) ANSI A225.1 and/or

CAN/CSA-2240 MH Series).

c. American National Standard (ANS1-119.2/

NFPA-501C) for all recreational vehicle in-

stallations.

d. American National Standard (ANSI-Z223.1/

NFPA-54) and/or CAN/CGA B149 for all gas-

fired furnace models.

e. American National Standard (ANSI-C1iNFPA-

70) and/or CSA 22. I Canadian Electric Code

Part I for all electrical field wiring.

CE gen6rateurd'air chauddoit 6tre installe

conformementauxinstructionsdufabricantet

auxcodesIocaux.EnI'absencedecodelocal,

respecterlanormeANSIZ223.,I,instituleNa-

tionalFuelGasCodeoulescodesd'installation

CAN/GCA-B149.

The NationalFuelGas Codeis availableby

writing:

AmericanNationalStandardsinstitute,inc.

1430 Broadway

NewYork,NY10018

NFPApublicationsareavailablebywriting:

NationalFireProtectionAssociation

BatterymarchPark

Quincy,ME02269

LOCATION

The furnace must be installed on a level suF

face, and as close to the center of the air

distribution system as possible. See Figure I

for overall dimensions to determine the re-

quired clearances in hallways, doorways,

stairs, etc. to allow the furnace to be moved to

the installation point. The furnace must be in-

stalled so that all electrical components are

protected from water.

Minimum clearances to combustible materials

are listed in Table 4. Access for positioning and

servicing must be considered when locating

the unit.

This furnace is certified for use on wood

flooring. The furnace must be installed on a

solid surface and must be level front4o-back

and side-to-side. This furnace must not be

installed directly on carpeting, tile, or any com-

CLOSET ALCOVE

ALL MODELS Inches Inches

Front

Back

Sides

Vent

Top

Duct (Plenum)

w/Coil Box

w/o Coil Box

(within 3 feet)

1" 1"

0 0

0 0

0 0

6 6

0 0

1/4 1/4

*Note: For 1"clearance, use a fullylouvered door with at

least 400 square inches of free airflow area.

Table 4. Minimum Clearances

bustible material other than wood flooring. The

furnace may be installed on combustible floor-

ing when installed on a Nordyne duct connec-

tor (see Table 5).

The ductwork within 3 feet of the furnaces

without the A/C coil box must be installed such

that surfaces are at least I/4" from combustible

materials.

When installed in a residential garage, the fur-

nace must be positioned so the burners and the

source of the ignition are located no less than

18 inches above the floor and protected from

physical damage by vehicles.

CiRCULATiNG AiR SUPPLY

WARNmNG:

Products of combustion must not be

allowed to enter the return air openings

of the furnace or the circulating air

supply. 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 iniury or death.

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 the floor or platform.

The circulating air ductwork must not

be connected to any other heat

producing device such as a fireplace

insert, stove, etc.

GENERAL

Plenums and air ducts must be installed in

accordance with the Standard for the Installa-

tion of Air Conditioning and Ventilating Systems

(NFPA No. 90A) or the Standard for the Instal-

lation of Warm Air Heating and Air Conditioning

Systems (NFPA No. 90B).

RETURN AiR PROViSiONS

U.S.A. home manufacturers shall comply with

aft of the following conditions to have accept=

able return air systems for closet installed

forced air heating appliances:

a. Regardless of the location, the return air

opening into the closet shall not be less than

specified in the appliance's listing.

b. Means shall be provided to prevent inadverb

ent closure by a flat object placed over the

return air opening when it is located in the

floor of the closet (versus the vertical front

or side wall).

c. Closet installations must use a Iouvered

door having a minimum free area of 235 sq.

in. when located 6" from furnace. For clear=

ance between I" and 6" from furnace, re-

quirements are a Iouvered door with mini-

mum of 235 sq. in. free area, with the open=

ings in closet door directly inJine with the

Iouvered openings in the furnace door. For

I" clearance from furnace, use a fully Iou-

vered door with at least 400 sq. in. of free

airflow area.

d. The cross-sectional area of the return duct

system leading into the closet, when located

ASingle trunk duct

,

/Dual trunk duct

B w/crossover connector

I

I

I

Transition duct

C pw/branches _

U U

Figure 2. Non=Platinum

Supply Duct System

inthe floor or ceiling shall not be less than 235

square inches.

e. The total free area of openings in the floor or

ceifing registers serving the return air duct

system must be at least 352 sq. in. At least

one register should be located where it is not

likely to be covered by carpeting, boxes and

other objects.

f. Materials located in the return duct system

must have a flame spread classification of

200 or less. This includes a closet door if the

furnace is in a closet.

g. Noncombustible pans having I" upturned

flanges are located beneath openings in a

floor duct system.

h. Wiring materials located in the return duct

system shall conform to Articles 300=22 of

the National Electrical Code (ANSI CI/

NFPA=70).

19"_ I

I_13 1/4'_

10 1/4"

I

k

Top View

_, of Duct

"_ Connector

Figure 4.

Use Duct Connector

If "X" (Floor Cavity) is: Model Part Number:

English Metric (mm I Finger Tab Screw Down

7/8" 22 901987 904008

2" 51 901988 904009

4 1/4" 108 901989 904010

6 1/4" 150 901990 904011

8 1/4" 210 901991 904012

10 1/4" 260 901992 904013

12 1/4" 311 901993 904014

Table 5. Duct Connectors

FLOOR CAVITY

Z(depth equal to "X" in Figure 5 and Table 5)

X i, "1

I I:/ SUPPLY AIR DUCT

/

/(

Figure 3.

( )OPENING TO DUCT

(1) WITH PLATE (C) REMOVED

OPENING BECOMES

13-1/4" x 13-1/4"

(2) WITH PLATE (C) REMOVED

OPENING BECOMES

13"X 13" WITH REDUCER

ITIS 13"X 10-1/8"

SPACERS -m . E • I • I • I •-

(1) FINGER TAB DUCT CONNECTOR ONLY

(2) SCREW DOWN DUCT CONNECTOR ONLY

A

X SEE

y TABLE 5

Figure 5.

ALTFUEL

FUEL

HOLE

Figure 6. Closet or Alcove

i. Gas piping is not run in or through the return

duct system.

j. Test the negative pressure in the closet with

the air-circulating fan operating at high speed

and the closet closed. The negative

pressure is to be no more negative than

minus 0.05 inch water column.

k. For floor return systems, the manufactured

home manufacturer shall affix a prominent

marking on or near the appliance where it

can be easily read when the closet door is

open. The marking shall read:

HAZARD OF ASPHY×IATmON: Do not

cover or restrict return air opening.

I. Air conditioning systems may require more

duct register and open louver area to ob-

tain necessary airflow. Use NORDYNE's

certiduct program to determine proper duct

size for AiC.

DUCTED RETURN AIR

M3 furnaces with model numbers ending in AW

or BW are factory configured for the return air

to flow through the front Iouvered door. The

return air may also be attached to either side or

the top of the furnace cabinet using a field

installed kit. Refer toTable 12 for the NORDYNE

ducted return kit PiN number. The location and

size of the side and top return air connections

are shown in Figure I. The filter size for the side

return air is 20" x 20" x I". For top return the

filter size is 24" x 16" x I".

M3 furnaces with model numbers ending in

BWT are factory configured for the return air to

enter the top of the furnace.

2-1/4

14-1/2

21-3/4

3-I14

1-1/4

ALT FUEL LINE

ENTRY

I

I

FLOOR CUT-OUT

FOR DUCT CONNECTIONS

I

12-7/8

15-1/2

FLOOR CUT-OUT

FOR OPTIONAL

COOLING COIL

FOR NON-PLATINUM

SERIES UNITS

8-19/32

1-3/4

f VENT

COMBUSTION AiR INTAKE

FUEL LINE ENTRY

1-3/4

OUTER DOOR

17-29/32

21-7/16

Figure 7. Cut-Out Locations

NR DiSTRiBUTiON SYSTEMS

For proper air distribution, the supply duct

system must be designed so that the static

pressure measured external to the furnace

does not exceed the listed static pressure

rating shown on the furnace rating plate.

Three typical distribution systems are illus-

trated in Figure 2. Location, size, and number

of registers should be selected on the basis of

best air distribution and floor plan of the home.

DUCT CONNECTOR SELECTION

PLATINUM SERES

a. For Platinum ready construction use

the 14" round plenum, pin: 903896.

I0

NON-PLATINUM SERIES

a. Determine depth of floor cavity from

surface of floor to top of supply air duct

(See Figure 3).

b. Select appropriate model from Table 5

which matches X-dimension of the floor

cavity. To maximize air delivery, re-

move reducer "C" (see Figure 5) to

obtain the largest open area that will fit

the duct/floor construction.

DUCT iNSTALLATiON

Required floor, ceiling, and roof cut-out open-

ings must be carefully located to avoid mis-

alignment of the furnace (see Figures 6 & 7).

installation procedures are suggested for typi-

cal furnace installations and need not be fol-

lowed in the exact listed sequence.

CUT OUT FLOOR OPENING & FUEL LINE

HOLE

a. Determine center of closet or alcove (Fig-

ures 7 & 8).

b. Locate center of the floor opening, mea-

sured 10" from the rear wall, and mark cut-

out measuring approximately 14-I/2" by 14-

I/2" (+ I") for model duct connector used

(refer to Figures 4 & 5).

c. Locate center of gas line hole, measured 23-

I/4" from the rear wall and 6-5/8" to the left of

center of the floor cut-out (See Figure 6) or

5-I/4"totheleftofcenterofthefloorcut-out,

or for entrythroughright-sideof furnace

measured9"totherightofcenterofthefloor

cut-out.

d. Cutoutflooropeningandonegaslinehole.

CUT DUCTOPENING(FINGERTABBED

ONLY)

a. Placeductconnectorthroughtheflooropen-

ing withbottomtabsrestingon top of the

supplyairduct.

b. Centerductconnectorandpushbackagainst

rearedgeofflooropening.

c. Markcut-outlocation(tabarea)andremove

duct connector.

d. Cutoutductopening1/16"largerthanarea

marked.

INSTALLFURNACEMOUNTINGPLATE

a. Placemountingplate(suppliedwithinduct

connector)at rearof theflooropening(See

Figure9).

INSTALLING PLATINUM SERIES 14"

ROUNDDUCTCONNECTOR

a. Placeductconnectorthroughtheflooropen-

ing.(SeeFigure9).

b. Secureductconnectorto floor.

INSTALLINGSCREWDOWNDUCTCON-

NECTOR

a.Applya beadof caulking,mastic,or other

approvedsealantaroundbottomsideof I/2"

flangeandrestrictorplate,whenapplicable.

b. Locatethe duct connectoroverduct and

carefullylowerscrewdownductconnector

intoplace.

c. Onceduct connectoris locatedon duct,

temporarilyholdinplacewhilefasteningduct

connectorto thefloorusingflatheadscrews

or nails.Besureflangesof ductconnector

stayincontactwiththeduct.

d. Screwplenumto ductmakingsureasealis

madebetweenthe ductandtheduct con-

MOUNTING REARWALL

FUEL

LINE

HOLES

Figure 8. MountingPlate

BEND CONNEC _OR TABS

UNDER DUCT OPENING

Finger Tabbed

Duct Connectors

Screw Down

Duct Connectors

MOUNTING

SCREWS

CONNECTION

Platinum Series

Figure 9. Duct Connector

11

nector.Additionalscrewsmaybe addedif

required.

e. Cutawayalongedgeof flangeallowingthe

centertodropintotheduct.Removesection

ofductwithcaution,asedgeswillbesharp.

INSTALLINGFINGERTABBEDDUCTCON-

NECTORS

a. Placeductconnectorthroughtheflooropen-

ingwithbottomtabsextendingthroughthe

ductopening.(SeeFigure9)

b. Secureductconnectorto floor.

c. Bendbottomtabsunderanduptightlyagainst

thesupplyair duct(SeeFigure10).

NOTE:Theductconnectorisdesignedforuse

onducts12"inwidth.Whenusingtheconnec=

toron12"wideducts,theremaybeinsufficient

clearanceto bendthetabsontwosidesof the

ductconnector,insuchcasesthetabsmaybe

attachedtothesidesoftheductbyusingsheet

metalscrewsor othersuitablefasteners.(See

Figure11).

if sealant,mastic,ortapeisusedto providea

betterseal,itshouldbeapprovedbyapplicable

nationalor localcodes.

ALTERNATEATTACHMENTMETHODS

Thisproceduremayalsobeusedto installa

furnace duct connector to narrow metal

ductworkwhereinsufficientclearanceprevents

bendingof the duct connectortabs at the

side(s)of theduct.(SeeFigure12).

I. Scoreandcutthetopof themetalductas

indicatedin StepI or Step2. WithStepI

choice,alsocutoutthemetalfromtheshaded

area"A'.

2. Foldtheductflap"B"up,(SeeStep3).

12

STEP 1.

TABS TABS

DUCT _ DUCT

1. INSERT DUCTPLBNUM CONNECTOR 2. BEND BOTTOM TABS OVER

INTO DUCT CUT-OUT. AND ONTO THE UNDERNEATH

DUCTBERVtCE.

Figure 10. Installation of Duct Connector

Duct Connector i_

I

_) Duct

Figure 11. Narrow Duct Installation

_ Narrow Duct

Fold Back Flap "B"

Cut- Out Cut- Out

Area"A"

Top of Duct

Fold Back Flap "B"

STEP 2.

Fold Back Flap"B"

Cut

-- Fold Back Flap"B"

Bend Duct Connector Tabs Up

and Over- (along length of duct)

, ,/ \, ,

// "_k_ !LtC t

Staple Folded Duct

Flap (typ) to side of Duct

Connector .

_L_ Duct _--'_

STEP 4.

Figure 12. Alternate Installation

NOTE:Additionalfastenersmaybe usedat

rear,sidesor throughdoorframe,asdesired,

to securefurnaceto closetor alcoveframing.

VENTING AND COMBUSTION AiR

Figure 13. "A', "g', & Platinum

Cabinet Furnaces

SLIDE FURNACE

ALL THE WAY BACK

ONTO MTG PLATE

SECURE FURNACE _ q, -

•[, ' WFH 2 FASTENERS , ,

,', AT FRONT CORNER HOLES ' '

HOLES

Figure 14. "A" Cabinet Furnace on 911969

Coil Cabinet (NonoPmatinum Series)

3. At the front-to-back of duct run (Area "A'),

bend the duct tabs and secure them directly

to the duct.

4. At Area "B", bend the duct tabs up and back

over, around the duct connector, (See

Step 3).

5. Fold/form the duct flap against the side of the

duct connector and attach as shown, (See

Step 4). Use three (3) staples (minimum) on

each duct flap OR, if a 2X block/joist is not

provided, use two (2) sheet metal screws

(minimum) on each duct flap. An alternate

attachment method is acceptable, as long

as the plenum is securely attached.

6. Tape the duct flap edges with an approved

tape for a leak-free joint.

_NSTALL FURNACE

a. Remove furnace outer door(s) and bottom

fuel line knockout.

b. Place furnace onto duct connector and cen-

ter with floor opening.

c. Slide onto mounting plate. (Bottom rear slots

on furnace should engage with mounting

plate tabs.)

d. Secure front with one (1) fastener at each

corner (See Figure 13 or 14).

CAUTmON'.

Snow must not be allowed to restrict or

block the combustion air intake or vent

pipes.

General

NORDYNE condensing furnaces must be

installed with outdoor combustion air piped

directly to the furnace. Codes refer to this

type of installation as direct vent, or two pipe

installation.

Provisions must be made for adequate supply

of air for combustion and ventilation. For

United States installations, the adequacy of

air provisions can be determined by consulting

the current version of the National Fuel Gas

Code (ANSI Z223.1iNPFA-54). For Canadian

installations, requirements are specified in the

National Standard of Canada (CAN/CGA

B149.1 & .2). Consult local codes for special

requirements.

NOTE: If the furnace is operated without

adequate air for combustion and ventilation, it

may not perform properly. Furnace

components may be strained by high

temperature and could fail prematurely.

G:

The combustion air piping must not be

blocked or restricted in any manner.

WARNmNG:

Furnace installation using methods

other than those described in the

following sections must complywith the

National Fuel Gas Code and all

applicable local codes to provide

sufficient combustion air for the furnace.

13

Do not allow debris to fail into the fur-

nace. This could cause unsafe opera-

tion and voids the furnace warranty.

VENTING REQUIREMENTS

WARNmNG:

FURNACE MUST NOT BE COMMON

VENTED WiTH OTHER APPLIANCES.

Genera_

This section specifies installation requirements

for 2-pipe combustion air piping. The capacity

table provided in this section applies to the

maximum equivalent lengths of vent and

combustion air intake pipe.

These condensing furnaces are classified as

"Category IV" appliances, which require

special venting materials and installation

procedures. Category tV appliances operate

with positive vent pressure and therefore

require vent systems which are thoroughly

sealed. They also produce combustion

condensate, which is slightly acidic and can

cause severe corrosion of ordinary venting

materials. Furnace operation can be adversely

affected by restrictive vent and combustion

air piping. Therefore, vent and combustion air

piping lengths must conform completely to the

requirements of Table 6.

The furnace must be vented to the outdoors.

WARNmNG:

CARBON MONOXmDE POiSONmNG

HAZARD

1. Seal any unused openings in the

venting system

2. inspect the venting system for

proper size and horizontal pitch,

as required in the National Fuel

Gas Code, ANSI Z223.1 or the

CAN/OGA Bt49 mnstallation Codes

and these instructions. Determine

that there is no blockage or re-

striction, leakage, corrosion and

other deficiencies which could

cause an unsafe condition.

3. So far as is practical, close all

building doors and windows and

all doors between the space in

which the appliance(s) connected

to the venting system are located

and other spaces of the building.

4. Follow the lighting instructions.

Place the appliance being

inspected in operation. Adjust

thermostat so appliance shall

operate continuously.

5. Turn on clothes dryers and any

other appliance not connected to

the venting system. Turn on any

exhaust fans, such as range hoods

and bathroom exhausts, so they

shall operate at maximum speed.

Do not operate a summer exhaust

fan.

6. Close fireplace dampers.

7. Test for spillage from draft hood

equipped appliance at the draft

hood relief opening after 5 minutes

of main burner operation. Use the

flame of a match or candle.

8. if improper venting is observed

during any of the above tests, the

venting system must be corrected

in accordance with the National

Fuel Gas Code, ANSt Z223.1/NFPA

54 an d/or CSA B I49.1, Natural Gas

and Propane Installation Codes.

9. After it has been determined that

each appliance connected to the

venting system properly vents

when tested as outlined above,

return doors, windows, exhaust

fans, fireplace dampers and any

other gas burning appliance to

their previous conditions of use.

It must not be vented in common with any

other appliance, even if that appliance is of the

condensing type. Common venting can result

in severe corrosion of other appliances or their

venting and can allow combustion gases to

14

APPLICATION

PVC,CPVC or ABS

SCH. 40 Pipe Size

Model M3RL 060

Model M3RL 080

MAXIMUM

DIRECT VENT, DUAL

PIPE LENGTH (ft.)*

Inlet/Outlet

3" 3"

50 50

50 50

*NOTES

1. Subtract 3.5 ft. for each additional 3" 90 degree elbow.

2. Two45degree elbowsare equivalent toone 90degree elbow

3 One short radius elbow is equivalent to two long radiu,_

elbows.

4. Do not include terrnination elbows incalculation of vent length

5 This table is applicable for elevations from sea levelto 400(

ft. Forhigher elevations, decreasevent pipe lengthsby 8% pe

1000 ft. of altitude

6 Only the above pipematerialsare approved for usewith thes(

condensing furnaces.

Tabie 6. Vent Tabie

/

/

/

/

/

/

_J VENT TERMINAL (_ AiR SUPPLY INLET [] AREA WHERE TERMINAL iS NOT PERMITTED

A = Clearance above grade, veranda, porch,

deck, or balcony

B = Clearance to window or door that may be

opened

C = Clearance to permanently closed window

D=Vertical clearance to ventilated soffit

located above the terminal within a

horizontal distance of 2 feet (61 cm) from

the center tine of the terminal

E = Clearance to unventilated soffit

F = Clearance to outside corner

G = Clearance to inside corner

H = Clearance to each side of center tine

extended above meter/regulator assembly

I = Clearance to service regulator vent outlet

J = Clearance to nonmechanicaI air supply inlet

to building or the combustion air inlet to any

other appliance

Canadian Installations 1

12 inches (30 cm)

K = Clearance to a mechanical air supply inlet

L = Clearance above paved sidewatk or paved 7 feet (2.13 m) 1

driveway located on public property

M= Clearance under veranda, porch deck, or 12 inches (30 cm) $

balcony

6 inches (15 cm)for appliances -< 10,000

Btuh (3 kW), 12 inches (30 cm) for

appliances > 10,000 Btuh (3 kW) and -<

100,00 Btuh (30 kW), 36 inches (91 cm) for

appliances >100,00 Btuh (30 kW)

3 feet (91 cm) within a height 15 feet

above the meter/regulator assembly

3 feet (1.83 m)

6 inches (15 cm)for appliances -< 10,000

Btuh (3 kW), 12 inches (30 cm)for

appliances > 10,000 Btuh (3 kW) and -<

100,00 Btuh (30 kW), 36 inches (91 cm) for

appliances >100,00 Btuh (30 kW)

6 feet (1.83 m)

US Installations 2

12 inches (30 cm)

6 inches (15 cm)for appliances -<10,000

Btuh (3 kW), 9 inches (23 cm) for

appliances > 10,000 Btuh (3 kW) and -<

50,000 Btuh (15 kW), 12 inches (30 cm) fol

appliances > 50,000 Btuh (15 kW)

6 inches (15 cm)for appliances -<10,000

Btuh (3 kW), 9 inches (23 cm) for

appliances > 10,000 Btuh (3 kW) and -<

50,000 Btuh (15 kW), 12 inches (30 cm) fol

appliances > 50,000 Btuh (15 kW)

3 feet (91 cm) above if within 10 feet (3 m)

horizontally

In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code

2 In accordance with the current ANSI Z223.1 /NFPA 54 National Fuel Gas Code

1 A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family

dwellings and serves both dweltings

_: Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.! /NFPA 54 or CSA B149.1, the following statement shall be included:

"Clearance in accordance with local installation codes, and the requirements of the gas supplier and the

manufacturer's installation instructions."

Figure 15. Vent Termination Clearances for Direct Vent Furnaces

15

escapethroughsuchappliancesorvents. Do

notventthefurnaceto afireplacechimneyor

buildingchase.

if removingan existingfurnacein a venting

system,theventingsystemmaynotbeproperly

sized.Totesttheventsystemwiththeremaining

appliances,followthetestoutlinedbelow.

CAUTmON'.

Combustion air must not be drawn from

occupied spaces and a corrosive

atmosphere.

The following steps shall be followed with each

appliance connected to the venting system

placed in operation, while any other appliances

connected to the venting system are not in

operation:

The quality of outdoor air must also be

considered. Be sure that the combustion air

intake is not located near a source of solvent

fumes or other chemicals which can cause

corrosion of the furnace combustion system.

Vent Pipe Material

Vent and combustion air pipe and fittings must

be one of the following materials and must

conform to the indicated ANSI/ASTM standards:

Material Standard

Schedule 40 PVC D1785

PVC-DWV D2665

SDR-21 D2241

& SDR-26

ABS-DWV D2661

Schedule 40 ABS F628

Foam/Cellular Core PVC F891

Cement and primer must conform to ATSM

Standard D2564 for PVC and Standard D2235

for ABS. When joining PVC piping to ABS, use

an appropriate solvent cement and procedure

per the piping manufacturer's recommendation

and ASTM Standard D3138.

Vent Pipe Installation

Pipe Routing and Support

Route piping as directly as possible between

the furnace and the outdoors and remember

that routing affects pipe length limitations per

Table 6. Locate the combustion air intake and

the vent exhaust in the same atmospheric

pressure zone - i.e. both must exit the building

though the same portion of exterior wall or

roof. Vent piping must be sloped upwards not

less than 1/4" per foot in the direction from the

furnace to the terminal. This is to ensure that

any condensate flows back to the furnace

where it can be disposed of through the

condensate disposal system.

Piping must be mechanically supported so that

its weight does not bear down on the furnace.

Supports must be at intervals no greater than

five feet, and at smaller intervals if necessary

to ensure that there are no sagging sections

to trap water (See Figures 16 & 17).

These condensing furnaces have been

certified for installation with zero clearance

between vent piping and combustible surfaces.

However, it is good practice to allow space for

convenience in installation and service.

Location of Outdoor Terminations

Vent and combustion air intake terminations

must be located to ensure proper furnace

operation and to conform to applicable codes.

Figure 15 illustrates necessary distances from

the vent termination to windows and building

air intakes. In Canada, the Canadian Fue!

Gas Code takes precedence over these

instructions. Specifically, all minimum

distance requirements with respect to

term!nation of the vent piping listed below.

The following list is a summary of vent terminal

location requirements:

I. The termination must be 12 inches above

snow level or grade level whichever is

higher. See Figure 18 for alternate method

to achieve 12" above snow level.

2. The minimum distance for a direct vent

(2-pipe) installation from any door,

openable window, or air gravity inlet is I ft.

below, 1 ft. horizontally, or 1 ft. above.

3. The vent termination shall be a minimum of

3 ft. above any forced air inlet within 10 ft.

4. The vent termination shall be located at

least 4 ft. horizontally from any electric

meter, gas meter, regulator and any relief

equipment. These distances apply ONLY

to U.S. installations, in Canada, the Cana-

dian Fuel Gas Code takes precedence.

16

Downflow Furnace

Seal/Cat_lk I_

Around Pipe

at Building \\\\\\

90 ° Elbow _ \

\\

f

Normal Snow Level

Vent _ _!3 9/1E"_

÷i 7,8

Combustion

Al ,oto,oO,po l i i

Straps or Other Suitable _ __-_j ___Z

Supports at Minimum of

5 ft. Intervals

' Top View

iq

Combustion Air

Intake Pipe

Offset with

Vent for Adequate

Dirnensiona_ C}eara#ce

Exhaust

Vent

PVC or

ABS pipe

Figure 16. Horizontal Venting

Support System

on Vertical Rise

Below Joints

¢//_ Vent

First support should be as

close to furnace es possible

Vent

Upward Pitch

t/4" per foot

.

Figure 17. Vertical Venting

Avoid areas where condensate drainage

may cause problems by dropping on plant_

ers or patios, etc. Also ensure that ex_

haust gases will not impinge on windows

or building surfaces, which may be com_

promised or damaged by condensation.

Do not install the vent terminal such that

exhaust is directed into window wells,

stairwells, under decks or into alcoves or

similar recessed areas, and do not termi-

nate above any public walkways.

6. Select the point of wall penetration where

the minimum I/4 inch per foot of slope up

can be maintained.

CAUTmON'.

For optimal performance vent furnace

through wall which experiences the least

exposure to winter winds.

17

Horizontal Venting

Vent and combustion air intake terminations

must be as shown in Figure 19 unless the

concentric vent termination kit is used.

NG:

Ensure that the combustion air vent and

the exhaust vent are configured as

shown in Fig. t9. Improper vent

termination can cause recirculation of

the flue gases. This may result in furnace

vibration, in severe cases, the furnace

will cycle, due to the intermittent contact

between the flame and the flame sensor.

If you note these oscillations occurring,

check the vent configuration. Make sure

that the exhaust vent does not have a 90

degree termination.

For horizontal venting, either the Horizontal

Exterior Vent Mounting Kit or the Concentric

Vent Termination Kit may be used (See Table

12).

For Canadian installations please refer to the

Canadian Installation Code (CAN/CGA-B149.1

or 2) and/or local codes.

The HorizontaJ Exterior Vent Mounting Kit con-

sists of two face plates and an insulating gas-

ket to seal the exterior surface. A hole sized

closely to the pipe diameter must first be cut

through the wall. A short length of pipe is then

cut such that it can penetrate the wall and be

held in place by closely fitting standard cou-

plings. The face plates are retained on both

sides of the waJJ by the couplings, and the

gasket is retained against the wail by the outer

face plate. Face plates must be fastened to the

walJ and the outside one must be flashed as

appropriate to prevent entry of water.

When the above kits are not used the following

steps are required:

I. Check the hole size cut through the exte-

rior wall. Insure that the hole diameter is

less than the diameter of the couplings to

be used.

2. Extend the vent pipe through the wall

approximately I" and seal the area be-

tween the wall and pipe.

3. Apply couplings to the vent pipe on the

interior and exterior sides of the wall to

insure the pipe can not be pushed or pulled

through the wall.

4. Insure the combustion air inlet pipe has a 90

degree termination elbow, and is pointing

downward as shown in Figures 19 & 20.

Note that a combustion air intake must be

provided with an elbow opening downward.

When the vent pipe must exit an exterior wall

close to the grade or expected snow level, a

riser should be provided as shown in Figure 18.

Insulation is required to prevent freezing of this

section of pipe.

Vertical Venting

For verticaJ venting, either the configuration

shown in Figure 20 or the Concentric Vent

Termination Kit may be used. Vertical venting is

one of the shortest routing methods when

piping vents for furnaces. The M3 furnace

operates trouble-free when the furnace is in-

stalled with a shorter vent.

oThe inlet for the combustion intake pipe must

be extended at least one foot above the roofline

or snow accumulation level.

oThe outlet of the vent must be extended at least

10 inches above the inlet of the combustion air

intake pipe.

, The vent as well as the combustion air intake

pipe should be located on the same side of the

reel Both pipes must not be closer than 5

inches apart. They should not be separated

more than 36 inches.

The roof penetration must be properly flashed

and waterproofed with a plumbing roof boot or

equivalent flashing. Termination spacing re-

quirements from the roof and from each other

must be per Figure 20.

Concentric Vent Terminatien

A concentric vent termination is approved for

use with these furnaces (See Table 12). For

proper installation of the concentric vent termi-

nation, follow the installation instructions pro-

vided with the kit.

18

Vent Configuration to

Provide 12" Minimum

height above <7_

Snow Level. \ 12" Min.

I 19" Nax.

i

Outside _ Support

WaEI _J

i_ 1/2"

// /_ Armaflex

f/ 4

S _ Bnsulationor

,:_ Equivalent

'_..............................._ (if required)

12"Above

NormaHy

Expected

Snow

Level

Figure 18. A_ternate Horizontam

Vent Installation

DRAINAGE OF CONDENSATE

FROM FURNACE

NG:

The condensate produced by the furnace

must be drained. Do not connect awater

suppmy to the drainage hose of the

furnace.

NOTE: The condensate drain should be pro-

tected from freezing when in unheated spaces.

The furnace is supplied with an internal conden-

sate drain trap.

Exhaust Vent

Figure 19. Exhaust and Combustion Air

Pipe Clearances

CAUTION'.

Do not install additional traps in the

condensate drain.

The condensate drain may exit through the left

side panel, the right side panel, or through the

left or right hole on the bottom panel. (See Figure

21). Ensure that the flexible drain hose is not

kinked.

The condensate should drain from the plastic

collector box (location A in Figure 21) as drop-

lets or a small stream. If you notice the furnace

has operated for more than 5 minutes without

draining or the red status light on the control

board is pulsing a 2-blink code follow the steps

below.

A= 12" Above Roof or s-Min.

36" l*_ax.

Snow Accumulation Level

Elbow

Bxheust

Plumbing Vent

Roof Boot

(Typ. Both Pipes)

Note: If terminations meet-

ing these vertical require-

ments exceed the maximum

height for safe transit, the

vent and combustion air in-

takes may be shipped with

the home for assembly on

site. The furnace must be

labeled to notify the installer/

user not to use the furnace

until the vent and combus-

tion air intake terminations

are installed.

Figure 20. Vertical Vent Termination

19

direction

Figure 21. Furnace with Condensate Drain Trap Assembty

I. Remove the collector box soft tube at

location A in Figure 21 and insure the exit

from the collector box is clear of any

debris or obstructions.

2. Replace this tube and insure the fit to the

header spout is air tight. Airwill be drawn into

the header if this connection is not tight.

3. Check other tube connections along the

drain system, insure that all are air tight.

NOTE: Industry research studies indicate that

when condensate is routed to an active drain,

household detergents, etc., buffer its acidity. If

the drain is not actively used or if codes require,

obtain a neutralizer kit (See Table 12). Proper

drains and connections to the condensate tub=

ing are required as NORDYNE cannot be held

responsible for water leakage which occurs

due to loose hose connections or improperly

sealed drain line pipes.

GAS SUPPLY AND PiPiNG

General

This furnace is equipped for bottom, left, or

right side gas entry. Typical gas service hook=

ups are shown in Figure 22. When making the

gas connection provide clearance between the

gas supply line and the entry hole in the furnace

casing to avoid unwanted noise and/or damage

to the furnace.

All gas piping must be installed in compliance

with local codes and utility regulations. Some

local regulations require the installation of a manual

main shut=offvalve and ground joint union exter=

hal to the furnace. The shut=off valve should be

readily accessible for service and/or emer=

gency use. Consult the local utility or gas

supplier for additional requirements regarding

placement of the manual main gas shut=off. In

the absence of local codes, the gas line instal=

lation must comply with the provisions stated in

the Federal Manufactured Home Standard

(H.U.D Title 24, part 280) and the National Fuel

Gas Code (ANSI Z223.1!NFPA=54) or (CAN/

CGA B149) installation codes.

A drip leg should be installed in the vertical pipe

run to the unit. Table 7 lists gas flow capacities

for standard pipe sizes as a function of length

in typical applications based on nominal pres=

sure drop in the line.

NOTE: Gas piping must not be run inor through

air ducts, gas vents, etc.

Compounds used on threaded joints of gas

piping must be resistant to the actions of Iique=

fled petroleum gases.

CAUTmON'.

Do not use matches, lighters, candles,

or other sources of open flame to check

for gas leaks.

NOTE: When pressure testing gas supply

lines at pressures greater than I/2 psig (14 in.

water column), the furnace must be discon-

nected from the gas supply piping system to

prevent damage to the gas control valve.

2O

Main

Floor

To Gas

Supply

0/

/

\

/

/

J

!°

CONVERSION

This furnace can be converted from the fac=

tory=equipped gas to either natural gas (for LP

gas ready models), or LP gas (for natural gas

ready models). Conversions must be made by

qualified service personnel, using only factory

authorized or approved parts. The required

conversion orifices are supplied with the fur=

nace.

WARNING:

DO NOT REMOVE OR DEFACE THE

ORIGINAL RATING PLATE.

CAUTION'.

The gas suppmy shammbe shut off prior to

disconnecting the emectricam power,

before proceeding with the conversion.

To Turn Off Fuel Supply to the Appliance:

Figure 22. Typical Gas Piping

If the test pressure is less than or equal to I/2

psig (14 in. water column), the furnace must be

isolated from the gas supply line by closing the

manual shut=off valve.

Leak Check

After the gas piping to the furnace is complete,

all connections must be tested for gas leaks. To

check for leaks use only a soap and water solu=

tion or other approved method.

High Altitude Derate

The nameplate input rating for the furnaces

apply for elevations up to 4,000 feet above sea

level for US and Canada. If the elevation for the

furnace location is higher than 4,000 feet above

sea level, the furnace input must be derated by

using the appropriate orifice size listed in

Table 8.

NOTE: The density of air decreases with in-

creasing elevation above sea level. This re=

duces the quantity of combustion air drawn into

the furnace under normal operation and requires

the unit be derated by using smaller gas orifices

or lower manifold pressure.

I. Set the room thermostat to "OFF" or its

lowest temperature setting.

2. Turn OFF the main gas supply to the appli=

ance at the manual valve, outside of the

appliance casing.

3. Remove the control access panel /Iou=

vered door.

4. Move the appliance gasvalve lever/knob to

the "OFF" position.

5. Turn OFF the electrical power to the appli-

ance.

CAPACITY OF BLACK IRON GAS PIPE (CU. FT, PER HOUR)

FOR NATURAL GAS (SPECIFIC GRAVITY -0.60)

LENGTH OF PiPE RUN

(feet)

NOMINAL

BLACK IRON

PIPE DIAMETER

(in.) 10 20 30 40 50 60 70 80

1/2 130 90 75 65 55 50 45 40

3/4 280 190 150 130 115 105 95 90

1 520 350 285 245 215 195 180 170

1 1/4 1050 730 590 500 440 400 370 350

1 1/2 1600 1100 890 760 670 610 560 530

The cubic feet per hour listed in the table above must be greater than

the cubic feet per hour of gas flow required by the furnace

\

To determine the cubicfeet per hourofgas fie _vrequired by the furnace,

divide the input rate of the furnace by the heating value of the gas:

Cubic Feet -- hputTo Furnace_

Per Hour Required Heating Value of Gas (Btu/Cu. Ft.)

Table 7. Capacity of BJack mron Gas Pipe

(cu. ft. per hour) for Natural Gas

(specific gravity = .60)

21

To Removethe Burner Assembly:

I. Followthe instructions"To Turn Off the

FuelSupplyto theAppliance."

2. Disconnecttheflamesensorwirefromthe

burnerbox.

3. Disconnecttheignitorwiresat the 2 pin

plug.Thisis a lockingquickconnectand

bothsidesof the lowersectionmustbe

depressedin orderto be separated.

4. Removethewiresfrom the terminalsof

the gasvalve.

5. Disconnectthe rubber pressuretubes

fromthe gasvalveandthe burnerbox.

6. Removethe burneraccesscoverplate

from the burnerbox.

7. Removesupplygaspipingfromthe gas

valve.

8. Carefullyremovetheburnerassemblyfas-

tenersand removethe burnerassembly

fromtheappliance.Keepthefastenersthat

wereremoved.Notethattheburnerboxmay

havehooksnearthetopandontherightand

lefthandsides.Toremovethistypeofburner

box,lift theburnerboxupwardsandthen

removetheboxfromtheunit.

To Removethe Burner Orifices:

I. Removethefour(4)fastenersthatsecure

the gas manifoldto the burnerbox, as

showninFigure25. Carefullyremovethe

gas manifoldassemblyfrom the burner

box. Notethatthegasmanifoldassembly

consistsofthegasvalve,thegasmanifold,

andtheorifices.

2. Carefullyremovetheburnerorificesfromthe

gasmanifold,asshowninFigure25.

CAUTmON'.

Caution: Do not re-drill the burner

orifices. If the orifice size must be

changed, use only new orifices.

Note: The size of the new orifices that will be

installed into the unit will depend upon the

type of conversion (sea level or Hgh altitude;

natural gas or LP gas}.

To Convert the Unit to the Alternate Gas

I. Remove the orifice bag from the manifold

of the unit.

2. Install the appropriate gas burner orifices

into the gas manifold. Remember if in-

stalling at altitudes above 4,000 feet to

install the proper orifices, shown in Table

8. When installing the new orifices, DO

NOT use pipe joint compound on the

orifice threads. Screw the orifices into the

manifold by hand until snug to eliminate

cross threading, then tighten with a

wrench. Before installing an orifice, check

the face or side of the orifice for the drill

number to ensure that it is the appropriate

size.

3. For the conversion to the alternate fuel,

the gas valve regulator cap must be turned

over, as shown in Figure 23. You will

unscrew the cap and reinstall for your in=

stallation. After reinstalling the cap, you will

be able to read "NAT" for the conversion to

natural gas or"LP for the conversion to LP

gas.

Furnace

Model Number

M3RL -

Furnace Rating Elevation

Plate Input No. of 0- 2000

(Btuh) Burners

Elevation

4000-6000

Elevation

2000-4000

Nat LP

50 57

49 1.15 mm

Elevation

6000-8000

Elevation

8000-10000

Nat LP Nat LP Nat LP Nat LP

060A-A/BW 60,000 4 50 57 51 58 51 58 52 59

080A-A/BW 80,000 5 49 1.15 mm 50 57 50 57 51 58

Table 8. Approximate Orifice Size for Natural and LP Gases

22

Reinstalling the Burner Assembly:

I. Reinstal[ the gas manifold assembly to the

burner box with the four (4) fasteners,

which were removed earlier.

2. Carefully reinstall the burner box into the

unit. After installing the burner, inspect

the alignment of the burners with the heat

exchanger tubes. The center of the burn-

ers should be aligned with the center of the

tubes.

3. Reconnect the gas piping to the gas valve.

4. Reconnectthewirestothegasvalve termi-

nals.

5. Reconnect the rubber pressure tubes to the

gas valve and the burner box. Reinstall the

burner access cover plate.

6. Reconnect the ignitor at the 2 position

plug.

7. Reconnect the flame sensor wire to the

burner box.

Pressure Gauge installation

NOTE: For natural gas installations, the in-

coming gas line pressure at the gas valve inlet

must be between 4.5" WC and 10.0" WC. For

LP gas installations, the incoming gas line pres-

sure at the gas valve inlet must be between

11.0" WC and 14.0" WC. This pressure can be

checked at the inlet end of the gas valve using

a pressure gauge or U-tube manometer, which

must be installed according to the

manufacturer's supplied instructions.

LiGHTiNG AND ADJUSTMENT OF

THE APPLIANCE

I. Turn ON the gas at the manual valve,

outside of the unit.

2. Check all gas connections for leaks with

a soap and water solution. If the solution

bubbles there is a gas leak which must be

corrected. Do NOT use an open flame to

check for gas leaks.

3. Turn ON the electrical power to the appD

ance.

4. Move the gas valve lever/knob to the "ON"

position. The lever/knob must be moved

to the end of its range of motion to insure

the valve is completely open. Use only

your hand to push in or turn the gas control

valve. Never use tools.

Hoooywo,

Valve

PRESSURE OTHER SIDE

OF CAP

REGULATOR

Figure 23. Convertible Pressure

Regulator Cap

Figure 24. Burner Inspection

Burner inlet

Box Pressure Cover

Tap inlet Gas Plate

Valve

Figure 25. Typical Installation For Sealed

Burner Box With Access Cover Plate

5. Set the room thermostat to a point above

room temperature to begin the heating

cycle of the unit.

6. Check that the unit ignites and operates

properly. Refer to the installation instruc-

tions provided with your unit for the normal

operating sequence.

23

7. Aftertheflameignites,visuallyinspectthe

burnerassemblyto ensurethattheflame

isdrawndirectlyintothecenteroftheheat

exchangertube,as shownin Figure23.

Theend of theflamewill beout of sight

aroundthe bendof the heatexchanger

tube.Inaproperlyadjustedburnerassem-

bly,the flamecolor shouldbe bluewith

somelightyellowstreaksnearthe outer

portionsoftheflame.

CAUTmON'.

To avoid electric shock, personal

injury, or death, turn off the power at

the disconnect or the main service

panel before making any electrical

connections.

NOTE: Until all of the air is bled out of the gas

line, the hot surface ignitor may not ignite the gas.

Ifthe ignition control locks out, turn the thermostat

to its lowest setting and wait one minute then turn

the thermostat to a point above room temperature

and the ignitor will try again to ignite the main

burners. This process may have to be repeated

several times before the burners will ignite. Once

the burners are lit, check all gas connections for

leaks again with the soap and water solution. If

the solution bubbles there is a gas leak which

must be corrected. Do not use an open flame to

check for gas leaks.

Manifold Pressure

The gas valve for the M3 furnace series is

equipped with a special conversion pres-

sure regulator cap. The pressure regulator

cap is factory set. If the gas valve is con-

verted from natural gas to propane gas or

vise versa, the manifold pressure of the gas

valve will be set to pressure listed in Table 9.

Type of Fuel Manifold Pressure

In.WC

Natural Gas: 3.5

Propane (LP) Gas: 10.0

Table 9. Manifold Pressure

COMPLETING THE CONVERSION

I. Affix the gas valve conversion label found

in the package with the orifices to the unit

rating plate.

2. Run the appliance through a complete

cycle to assure proper operation.

ELECTRICAL WIRING

Genera!

Electrical connections must be made in accoF

dance with all applicable local codes and ordi-

nances, and with the current revision of the

National Electric Code (ANSI/NFPA 70).

For Canadian installations electrical connec-

tions and grounding must be done in accoF

dance with the current Canadian Electrical

Code (CSA C22.1 Part 1) and/or local codes. If

any of the original wire as supplied with the

furnace must be replaced, it must be replaced

with wire having a minimum temperature rating

of I05°C. Refer to the furnace nameplate and

Table 8 for electrical requirements.

Line Voltage Wiring

The line voltage (115 volt) to the furnace must

be supplied from a dedicated branch circuit

containing the correct fuse or circuit breaker

for the furnace. See Table 10. An electrical

switch should be readily accessible from and

within sight of the furnace. See the Wiring

Diagram label in the furnace for more details.

The furnace cabinet must have an uninteF

rupted, unbroken ground to minimize injury

should an electrical fault condition occur. The

controls used in this furnace require an earth

ground to operate properly. Acceptable meth-

ods for grounding are electrical wire or conduit

approved for electrical ground service. Do not

use gas piping as an electrical ground.

NOTE: Proper line voltage polarity must be

maintained in order for the control system to

operate correctly. Verify that the incoming neu-

24

trallineis connectedto thewhitewireandthe

incoming"hot"lineis connectedto the black

wireinthefurnacejunctionbox.Thefurnacewill

not operateunlesspolarityand groundare

properlyconnected.SeeFigure26.

Label all wires prior to disconnection

when servicing controls. Wiring errors

can cause improper and dangerous

operation.

Verify proper operation after servicing.

Low Voltage Wiring

install the thermostat per the manufacturer's

instructions. The low voltage (24 volt) connec=

tions from the thermostat are made at the

terminal strip on the control board in the furnace.

See Figure 28 for the proper connections for

heating only (two=wire) and heating/cooling

(four=wire) applications. The recommended

minimum wire gauge for thermostat wiring is

shown in Table 10.

Lors des operations d'entretien des

commandes, _tiqueter tousles files

avant des les d_connecter. Toute erreur

de c_blage peut _tre une source de

danger et de panne.

S'assurer du bon fonctionnement de

l'appareil apr_s tout entretien.

c::_::_ C=_] _ BowerOff

Til/mg

24 V

©TWIN

_1®1

o1®1

_1®=_

Figure 27. Blower Speed Tap Location

Furnace Cabinet Nominal Maximum Minimum Maximum Minimum Maximum

Input Width Electrical Operating Operating Furnace Wire Fuse or Circuit

(Btuh) (in.) Supply Voltage Voltage Amperes Gauge Breaker Amps*

60,000 19.75 115-60-1 127 103 9.7 14 15

80,000 19.75 115-60-1 127 103 9.7 14 15

Thermostat Wire Gauge Recommended Thermostat Wire Length

2-wire (heating) L4or 5-wire (cooling)

55 ft. 25 ft.

90 ft. 45 ft.

140 ft. 70 ft.

225 ft. 1t0 ft.

24

22

20

18

* Time-delay fuses or HACR-type circuit breakers are required,

Table 10. Electricam Data

F_/IS ;PerPvliiedepaFnieel'd Snupp/iteodr

Panel _

WhltB2aNk_tH_rOtl)_ Black _Black _ _-] Black

Green_orB_a_rE_...... _....... _ .... _ ....... ._Ll_',' I

(Ground) _ _ _ I I =

Ground /Ground

Field Supplied Disconnect

Within Sight of Furnace

..... Field Line Voltage

Wiring

__ Factory Line

Voltage Wiring

Ground

Junction Box (may be internal

or external to the furnace). These

connections can be made in the

field supplied disconnect at the

furnace.

Figure 26. Line Voltage Field Wiring 25

The thermostatmust not be installedon an

outsidewaft or any other locationwhereits

operationmaybeadverselyaffected.Adverse

affectsincluderadiantloadingfromfireplaces,

sunlight,or lightingfixtures,and convective

loadingfrom warmair registersor electrical

appliances.

To checktheheatanticipatorsettingeither:

I. Addthe currentdrawof thesystemcom-

ponents;or

2. Measurethecurrentflowonthethermostat

R-Wcircuitafterthecirculatingblowermotor

hasstarted.

Settheheatanticipatoraccordingto thether-

mostat manufacturer'sinstructionsfor heat

anticipatorsettings.

VENTiLATiON

C°"dens'°gun't

!- Condensing Unit

F i

E i

Connect '

R&W

For

Heating

Only

Room

Thermostat

NOTB:The "'Y"

terminal on the

UTEC control board

must be connected

to the thermostat

for proper cooling

mode operation.

oo

E::::_::_ C_=M _Blower Off e_

3 Amp Timing

24=V Fuse

OTWIN

F,ameBignalLight0

(Yellow)

_::= Status Light 0

(Red)

I _ Neutrals

C _ Unused Motor Leads

u: o m

DD_DDD_

Figure 28. Low Voltage Field,

Four=wire Heating/Cooling Applications

Ventilation must be provided for homes built to

HUD Manufactured Homes Safety and Con=

struction Standards. This ventilation can be sup=

plied by the VentiiAire Ill or VentilAire iV acces-

sories. (See Table 12). Alternate means to pro=

vide the ventilation air must meet the require-

ments of all applicable local and federal codes.

For installation of the VentiiAire Ill or IV, follow

the instructions provided with the VentilAire

kit.

START-UP AND ADJUSTMENTS

General

Prior to start=up, verify that:

I. The line voltage power leads are securely

connected, that the polarity of the con=

nections is correct, and that the furnace

is properly grounded.

2. The thermostat wires (R, W, Y, and G) are

securely connected to the correct leads

on the terminal strip of the circuit board.

.The natural gas line service pressure must

not exceed 10.0 in. water column (0.36

psig), and must not be less than 4.5 in.

water column (0.16 psig). For LP gas the

line service pressure must not exceed 14

in. water column (0.51 psig), and must not

be less than 11.0 in. W.C. (0.40 psig).

26

.The roll-out and vent safety manual reset

switches are closed. If necessary, press

the red button to reset a switch. See

Figure 26 for location. DO NOT install a

jumper wire across a switch to defeat its

function. If a switch reopens on start-up,

DO NOT reset the switch without identify-

ing and correcting the fault condition which

caused the switch to trip.

5. The blower door is in place, closing the

door switch in the line voltage circuit.

6. The gas line has been purged and all

connections are leak tight.

Start-Up Procedure

I. Set the thermostat to the lowest setting.

2. Close the disconnect(s) to provide line

voltage to the furnace.

3. Follow the procedures given on the oper-

ating instructions label attached to the

furnace.

4. Set the thermostat above room tempera-

ture and verify the sequence of operation.

(See the SEQUENCE OF OPERATION.)

.After the furnace has run for approximately

five minutes, set the thermostat below room

temperature and verify steps 9 - 11 of the

SEQUENCE OF OPERATION.

Shut Down Procedure

in the event that the furnace must be shut down,

follow this procedure:

I. Set the room thermostat to "OFF" or its

lowest temperature setting.

2. Turn OFF the main gas supply to the appli-

ance at the manual valve outside of the

appliance casing.

3. Remove the control access panel /Iou-

vered door.

.

5.

Move the appliance gas valve lever/knob

to the "OFF" position.

Turn OFF the electrical power to the

appliance.

Verifying Firing Rate

The firing rate must be verified for each instal-

lation to prevent over-firing the furnace.

NOTE: The firing rate must not exceed the

rate shown on the furnace rating plate. At

altitudes above 4000 ft. it must not exceed

that on the rating plate mess 4% for each

1000 ft.

Use the following procedure to determine the

firing rate:

I. Shut off all other gas fired appliances.

2. Start the furnace and allow it to run for at

least three minutes.

.

4.

5.

Measure the time (in seconds) required for

the gas meter to complete one revolution.

Convert the time per revolution to cubic

feet of gas per hour using Table 11.

Multiply the gas flow rate in cubic feet per

hour by the heating value of the gas in Btu

per cubic foot to obtain the firing rate in

Btuh. Example:

o Time for I revolution of a gas meter

with a I cubic foot dial = 60 seconds.

o From Table 11 read 60 cubic feet per

hour of gas.

o Heating value of the gas (obtained

from gas supplier) = 1000 Btu per

cubic foot.

, Fidng rate = I000 x 60 = 60,000 Btuh.

6. See the "High Altitude Derate" section for

additional information on firing rate at eleva-

tions above 4,000 ft.

The gas valve regulator is set at a nominal

value of 3.5 in. water column for use with natural

gas. The manifold pressure must be set at I 0.0 in.

water column for use with LP gas.

Verifying and Adjusting Temperature Rise

Verify that the temperature rise through the

furnace is within the range specified on the fur-

nace rating plate. Temperature rises outside the

specified range could result in premature heat

exchanger failure.

Place thermometers in the return and supply

air stream as close to the furnace as possible.

The thermometer on the supply air side must

be shielded from direct radiation from the heat

exchanger to avoid false readings. Adjust all

registers and duct dampers to the desired

position and run the furnace for fifteen minutes

before taking any temperature readings. The

temperature rise is the difference between the

supply and return air temperatures.

For typical duct systems, the temperature rise

will fall within the range specified on the rating

plate with the blower speed at the factory

recommended setting. If the temperature rise

measured is outside the range specified, it may

be necessary to change the blower speed.

Lower blower speeds will increase the tem-

perature rise and higher blower speeds will

decrease the temperature rise.

The furnace is equipped with a multispeed

motor. Heating and cooling speed selection is

made by moving the leads on the integrated

control board located in the furnace. The wiring

diagram on the furnace and Figure 30 show the

speed taps for adjusting motor speed.

If it is desired that the blower operate at the same

speed for heating and cooling, tape off the

terminal of the unused blower wire. Install the

jumper wire, found in the plastic instruction bag,

across the HEAT and COOL taps on the control

board. Reconnect the desired blower tap to the

piggyback quick connect.

The blower control is designed to start the

circulating air blower 30 seconds after the gas

valve is opened. The blower control is factory

wired to turn the blower motor off 120 seconds

27

TIME FOR

ONE REVOLUTION

(SECONDSI

24

26

28

3O

32

34

36

38

4O

42

44

46

48

5O

52

54

56

58

6O

62

64

1

150

138

129

120

113

106

100

95

90

GAS FLOW RATE (CUBIC FEET PER HOUR)

CUBIC FEET PER REVOLUTION OF TIME FOR

ONE REVOLUTION

J(sEcONDs)

8O

82

84

86

88

9O

92

94

96

98

100

102

104

106

108

110

112

114

116

118

120

METER

5 10

750 1500

692 1385

643 1286

600 1200

563 1125

529 1059

500 1000

474 947

450 900

86 429 857

82 409 818

78 391 783

75 375 750

72 360 720

69 346 692

67 333 667

64 321 643

62 310 621

60 300 600

58 290 581

56 281 563

CUBIC FEET PER REVOLUTION OF

METER

1

45

44

43

42

41

40

39

38

38

37

36

35

35

34

33

33

32

32

31

31

3O

5 10

225 450

220 439

214 429

209 419

205 409

200 400

196 391

191 383

188 375

184 367

180 360

176 353

173 346

170 340

167 333

164 327

161 321

158 316

155 310

153 305

150 300

Table 11. Gas Flow Rate

after the gas valve is dosed. This timing can be

changed using the BLOWER OFF timing switch

opposite the terminal block on the control board

(See Figure 27).

Verifying Burner Operation

To verify operation of the burners, remove front

door and ensure that the door switch is in the "on"

position (see Figure 29). Set the thermostat above

room temperature and observe the ignition se-

quence. The flame can be observed through the

small clearwindow on the burner box. The burner

flame should carry over between all burners. The

flames should be blue, without yellow tips. Flames

should extend from each burner without lifting,

curling, or floating. After verifying ignition, set the

thermostat below room temperature and verify

that the burner flame extinguishes completely.

Replace the front door.

Verifying Operation of the Supply Air

Limit Switch

To verify operation of the supply air limit switch,

make sure that the blower door is in place and

that there is power to the furnace. Completely

block the return airflow to the furnace by install=

ing a close=off plate in place of or upstream of

the filter(s). Set the thermostat above room

temperature and verify that the Sequence of

Operation is as described in these instructions.

The supply air limit switch should function to

turn off the gas valve within approximately five

minutes. The circulating air and combustion

blowers should continue to run when the supply

air limit switch opens. Remove the close=off

plate immediately after the supply air limit switch

opens. If the furnace operates for more than five

minutes with no return air, set the thermostat

below room temperature, shut off the power to

the furnace, and replace the supply air limit

switch.

DESCRiPTiON OF COMPONENTS

Figure 29 shows the location of each of the

functional components described below. If any

component of the furnace must be replaced,

use only factory authorized replacement parts.

Contact your distributor for the approved re=

placement parts.

Flame Sensor - The flame sensor acts to

prove that flame has carried over from the

ignitor to the opposite end burner. If no flame is

sensed, the furnace will be shut down automati=

cally.

28

FURNACE ACCESSORY KtTS MAINTENANCE

Kit

A/C Coil Box

Side Return Air Kit

Top Return Air Kit

Sloped Roof VentilAire Ill Kit

Sloped Roof VentilAire IV Kit

Soffit VentilAire Kit

Concentric Vent Termination Kit

(for horizontal and vertical ventin,q)

Horizontal Exterior Vent

Mounting Kit 3"PVC

Neutralizer Kit - All Models

Order Number

911969A

904003

904015

914098

914229

917201

903578

902375

902377

Table 12. Accessory Kits

Gas Vamve - The gas valve controls the flow of

gas to the burners. When the gas valve is

energized it automatically opens and regulates

the gas pressure in the manifold.

Pressure Switch - The pressure switch veal-

ties that the inducer is drawing the combustion

gases through the heat exchanger. It alsosenses

a blocked condensate drain condition.

Deck Limit Switch (Auxiliary Limit) - The

deck limit protects the furnace filter tempera-

ture from overheating when the motor has

malfunctioned. If the deck switch opens, the

power for the furnace will shut down (see

Figure 29).

Supply Air Limit Switch - The supply air limit

switch prevents the air temperature leaving the

furnace from exceeding the maximum outlet air

temperature.

Vent Safety Switch - The vent safety switch

shuts the furnace down if the outlet flue gas

temperature increases above 145°F. This

switch protects the plastic flue system and the

inducer from over-temperature conditions.

Flame Roll-Out Switch - This switch pro-

vides flame roll-out protection to the furnace

and combustion air inlet pipe.

It is recommended that the furnace be checked

yearly. At a minimum, this check should include

the following items:

WARNmNG'.

To avoid electric shock, personal injury,

or death, turn off the power at the

disconnect or the main service panel

before performing any maintenance.

WARNING:

Holes in the vent pipe or heat exchanger

can cause products of combustion to

enter the occupied space. Replace the

vent pipe or heat exchanger if leaks are

found. Failure to prevent products of

combustion from being circulated into

the occupied space can crate poten-

tially hazardous conditions, including

carbon monoxide poisoning, that could

result in personal injury or death.

Combustion Air and Vent System

Check the combustion air and vent pipe to

ensure that it is not damaged, corroded or

blocked by debris. Any damaged section of

vent pipe must be replaced, and any obstruc-

tion or blockage must be removed prior to

operating the furnace.

Air Filter

An air filter is supplied with the furnace as

shipped from the factory. Filters should be

changed or cleaned monthly during the heating

season. New or newly renovated homes may

require more frequent changing until the con-

struction dust has been removed.

29

Never operate the furnace without a

filter Jn pmace. Dust and mintJn the return

air can buJmd up on Jntemam compo-

nents, resumtJng Jn moss of efficiency,

equipment damage, and possJbme fire.

Lubrication

The bearings in the circulating air blower mo-

tors are prequbdcated and sealed at the fac-

tory. No further oiling of the bearings is required

for the life of the motor.

Condensate Drain AssemMy

Be sure the condensate lines are free and open

(i.e. avoid kinking hoses). Also make sure all

hose clamps are tight to avoid drawing air into

the system.

Blower Compartment

The blower compartment should be cleaned

monthly during the heating and cooling sea-

sons to remove any dirt and lint that may have

accumulated in the compartment or on the

blower and motor. Dirt and lint can create

excessive loads on the motor resulting in higher

than normal operating temperatures and short-

ened service life.

Heat Exchanger and Burner Maintenance

The furnace should operate for many years

without excessive soot buildup in the flue pas-

sageways, however, the flue passageways,

the vent system, and the burners should be

inspected and cleaned (if required) by a quali-

fied service technician annually to ensure con-

tinued safe operation. Particular attention must

be given to identify deterioration from corrosion

or other sources.

SYSTEM OPERATION

iNFORMATiON

GENERAL

Proper maintenance is most important to

achieve the best performance from a

furnace. Follow these instructions for years

of safe, trouble free operation.

o Do not place combustible materials on or

against the furnace cabinet or the vent pipe.

3O

Do not store gasoline or any other

flammable vapors and liquids in the vicinity

of the furnace.

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. Do not operate the furnace

without all doors and covers in place.

Avoid operating the furnace when windows

and doors are open.

Be sure that the thermostat is propermy

installed and is not being affected by

drafts or heat from mamps or other

appliances.

Sequence of Operation

Operating sequences for the heating, cooling,

and fan modes are described below. Refer to

the wiring diagrams (Figures 30) and the low

voltage field wiring diagram (Figure 26) for

more details.

Heating Mode:

I. On a call for heat the thermostat closes,

applying 24 VAC to the W terminal on the

control board.

2. The control board checks for continuity

on the 24 VAC limit control circuit (over-

temperature limit switch, flame rollout

switches and blocked vent switch in se-

ries). If an open limit is detected the con-

trol board will energize the inducer and

the conditioned air blower. All other sys-

tem functions win be inoperable until the

limit circuit closes. While the limit is open,

the red LED will pulse at a rate of I blink

per unit time.

3. The furnace control checks for continuity

across the pressure switch (24 VAC). If

the pressure switch is closed the heat

mode sequence will not continue. If it

remains closed for 10 seconds the red

LED will blink 3 times repetitively until the

fault condition clears.

4. The inducer is energized.

5. The pressure switch win close. If the

pressure switch does not close after 10

seconds the fault LED will blink 2 times

repetitively and the inducer will continue

to run until the switch is closed.

6. The inducer will pre-purge for 30 seconds

and then the igniter will start its warm-up

as follows:

InitialPowerup:After30secondsofigniter

warm-upthegasvalve(24VAC)willthen

open. The ignitercircuitwill stay ener-

gizedfor 3 secondsafter the gasvalve

opens.

AfterInitialPowerup: Thecontrolhasa

programmedadaptiveignition feature

whichvariesthe warm-upperiodas fol-

lows:Ifignitionissuccessfulthewarm-upis

reducedby3-secondsoneachsubsequent

call for heatuntil ignitionfailureoccurs.

Uponignitionfailure,the warm-upis in-

creasedby 3-secondson the nexttry. If

successful,thetimingremainsfixedatthis

level.Ingeneral,wheneverignitionfailure

occursthewarm-upintervalisincreasedby

3-secondsonthenexttry.Andifsuccess-

ful, it remainsthere.Minimumandmaxi-

mumwarm-uptimelimitsareset at6and

54-seconds,respectively.

7. Thefurnacecontrolmustproveflamevia

theflamesensor5 secondsafterthegas

valveopens.Ifflameis sensed,all burn-

ers areon andtheignitorcoolsoff. If no

flame is sensed,the gas valve closes

immediatelyandtheinducercontinuesto

run. A secondtrial for ignition(step6)

beginsif noflameis sensed.Onthefifth

tryforignition,thefurnacecontrolislocked

out and the red LEDwill blink4 times

repetitively. The thermostat must be

openedfor at leastten secondsto reset

the furnacecontrolaftera lockout. Oth-

erwise,the furnacewill attemptanother

ignitionsequencein 1hour.

8. The furnace control energizesthe cir-

culatingair blowerontheheatingspeed

30secondsafterthe gasvalvecircuitis

energized.

9. When the thermostat has been satisfied,

gas valve is de-energized.

10. The inducer is de-energized after a 30-

second postpurge.

11. The furnace control keeps the circulating

air blower energized for 120 seconds

(factory set) or 60, 90, or 180 seconds

(field adjustable). (See Figure 27.)

12. Abnormal conditions: If a limit opens during

operation, the inducer and circulating air

blower continue to operate. The gas valve

is de-energized immediately. The blowers

continue to operate until the limit closes.

When the limit closes the inducer blower is

de-energized immediately. The circulating

air blower continues to operate for the speci-

fied delay (factory set at 120 seconds).

Cooling Mode:

I. On a call for cooling the thermostat closes,

applying 24 VAC to the G and Y terminals

on the furnace control. This closes the

compressor contactor.

2. The furnace control energizes the circu-

lating blower (115 VAC) on the cooling

speed.

3. When the thermostat is satisfied, the G

and Y terminals on the control board are

de-energized opening the compressor

contactor.

4. The circulating air blower is de-energized

after a 90-second delay.

Fan Mode:

I. On a callforfan

.

3.

operation, the thermostat

applies 24 VAC to the G terminal on the

furnace control board.

The circulating air blower is energized

immediately on the heating speed.

If the furnace is operated in the continu-

ous ON position at the thermostat and is

then switched to AUTO, the circulating

blower will operate for a specified delay

(factory set at 120 seconds).

Furnace Fails to Operate

If the furnace does not operate check the

following:

I. Is the thermostat operating properly?

2. Is the front door in place?

3. Is the furnace disconnect closed?

4. Has the circuit breaker tripped or the

control board fuse burned open?

5. Is the gas turned on?

6. Are any manual reset switches open?

7. Is the filter dirty or plugged?

8. Is the flame sensor coated? (Remove

and clean with emery cloth.)

9. Is the deck switch open?

If the furnace locks out after 5 attempts for

ignition, it will try again every hour if a call for

heat remains. If the inducer and circulating air

blowers are operating, and items I through 8

have been checked, press the red reset but-

ton on the vent safety switch. (See Figure 29.)

If the furnace operates after depressing the

reset button, contact a qualified service tech-

nician to identify and repair the problem.

If furnace still fails to operate, depress the red

reset buttons on the flame roll-out switch. If

the furnace operates after depressing the

reset button, contact a qualified service tech-

nician to identify and repair the problem.

31

M3 Dewnflow Furnace

1 Door Assembly -Louvered

Filter Inside Door

3 Blower Assembly

4 Control Board

5 Pressure Switch

6 Flame Rollout Switch

"J" Trap Hard Tube

8 LowVoltage Transformer

9 In Line Drain Assembly

10 Junction Box

11 Vent Safety Switch

12 Ignitor Assembly

13 BurnerView Port

14 Main Limit Switch

15 Coil Cabinet Assembly (Optional)

16 Flame Sensor (On Burner Box)

17 Gas Valve

18 Switch, On/Off

19 Blower, Inducer

20 Orifice(In BurnerBox)

21 Aux. Limit

BurnerBox

Figure 29. Location of Major Components

32

FAULT CONDmON

Power On

Limit Circuit Open or External Load On "W"

(Does not apply to Deck Switch, see below)

Pressure Switch Open with Inducer On

Pressure Switch Closed with Inducer On

!gn!t!on Fai!ure (Check Ground)

115 VAC & Neutral Reversed or no Ground

False Flame or Gas Valve Relay Shorted

Power Off or Deck Limit Open

FAULT CONDITION

Low Flame Sensor Signal

Flame Present

STATUS

RED

LUGHT

ON

I FLASH

2 FLASHES

3 FLASHES

4 FLASHES

5 FLASHES

Continuous

OFF

FLAME

YELLOW

LIGHT

Continuous

Flash

ON

tf any of the originat

wire as supplied with

the furnace must be

replaced, it must be

replaced with wiring

materiaJ having a

temperature rating of

at least 105" C.

Use copper

conductors

only,

MOTOR

PLUG

Factory Wired

Heating Speeds

Furnace Wire

Input, Btuh Cotor

60,000 Red

80,000 Blue

WD#7i0240B

Figure 30. Downflow Furnace Wiring Diagram

33

34

INSTALLATION/PERFORIVlANCE CHECK LIST

LOCATION CITY STATE

INSTALLER CITY STATE

UNIT MODEL NUMBER UNIT SERIAL NUMBER

Minimum Clearances per Table 3?

Electrical Connections tight?

Line Voltage Polarity correct?

Supply Voltage:

Blower Motor HP:

Volts

FUEL TYPE:

Natural Gas LPiPropane

Gas Piping Connections leak-tested? __

Gas Line Pressure:

(in. water column, with furnace operating)

Manifold Pressure:

(in. water column, with furnace operating)

Is there adequate fresh air supply for

combustion and ventilation?

Furnace Input:

Supply Air Temperature:

Return Air Temperature:

Temperature Rise:

(Btuh)

(° F)

(° F)

(° F)

Are Flue Connections tight?

Is there Proper Draft?

Is Vent free from restrictions?

Is the Filter(s) secured in place?

Is the Filter(s) clean?

Has the Thermostat been calibrated?

Is the Thermostat level?

Is the Heat Anticipator Setting correct?

Has the Owner's Information been reviewed

with the home-owner?

Has the Literature Package been left near the

furnace?

35

O'Fallon, MO NORDYNE

708219D

7082t9D (Replaces 708219C)

Specifications and illustrations subject to change without

notice and without incurring obligations. Printedin

US.A. (04/04)