NORDYNE Furnace/Heater, Gas Manual L0612164

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

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Direct Vent (Sealed Combustion) Forced Air Gas Furnaces

M2RC Series 90+ Upflow Condensing Furnace

M2RL Series 90+ Downflow Condensing Furnace

Upflow Model

/ WARNING:

Improper installation, adjustment,

alteration, service, or maintenance

can cause injury or property damage.

Refer to this manual for assistance.

For additional information consult a

qualified installer, service agency, or

the gas supplier.

Do not store or use gasoline or

other flammable vapors and

liquids in the vicinity of this or

any other appliance.

Downflow Model

Do not try to light any appliance.

Do not touch any electrical

switch; do not use any phone in

your building,

Immediately call your gas supplier

from aneighbor's phone. Follow

the gas supplier's instructions.

if you cannot reach your gas

supplier, call the fire department.

Extinguish any open flame.

WARNING: Danger. Only qualified service

personnel shall be used to install and provide

maintenance to this appliance.

TABLE OF CONTENTS

General ...................................................... 3

Unit Dimensions ................................. 3

Furnace Airflow Data ......................... 4

Clearances to Combustible Materials 4

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

Owner's Information ............................... 5

Installation Requirements ...................... 5

Location .............................................. 6

Circulating Air Supply ............................ 6

Return Air Provisions .............................. 7

Air Distribution Systems ........................ 7

Upfiow Furnace Installation .................. 8

Downflow Furnace Installation ............. 8

Venting and Combustion

Air Requirements .......................... 11

Venting Requirements .......................... 11

Vent Table ........................................ 12

Vent Pipe Material ............................ 13

Vent Pipe Length and Diameter....., 13 .........

Vent Pipe Installation ........................ 14

Pipe Routing & Support .................... 14

Horizontal Venting ............................ 17

Vertical Venting ................................ 17

Vent Freezing Protection ................. 18

Drainage of Condensate

From Furnace ................................ 18

Gas Supply and Piping ......................... 19

Leak Check ...................................... 20

High Altitude Derate ......................... 20

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

Lighting and Adjustment

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

Electrical Wiring ..................................... 24

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

Low Voltage Wiring .......................... 25

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

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

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

Shut Down Procedure ..................... 26

Verifying and Adjusting Firing Rate. 26

Verifying and Adjusting

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

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

Verifying Operation of the

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

Description of Components ................ 28

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

Combustion Air and Vent System ... 29

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

Lubdcation ........................................ 29

Condensate Drain Assembly .......... 29

Blower Compartment ....................... 29

Heat Exchanger and Burner

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

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

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

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

Furnace Accessories ............................. 31

Location of Major Components._._ '...... 32

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

Installation/Performance

Checklist ......................................... 34

M 2 RC.- 080 N

IFuel Type

•I_N - Natural Gas Ready

Application

M-Manufactured Home

Furnace Series,

Comfort Model

RC - Condensing Upflow

RL -Condensing Downflow

L-Propane (LP) Gas Read_

Cabinet Width

--B - 19-3/4"

Airflow

16 - 1600 CFM

Electrical Code

A-1PH, 60 Hz, 120 VAC

Heating Capacity

Input, BTUH (000')

Table 1. Model Identification

GENERAL

Upflow Furnace

Cover

Plate

Combusbon Air

Inlet J_l Combustion

23 1'4" -- Airln_et --

1 3/8"

2 t,4" Condensate

4-- Drain Outlet

6 114"

_.: rt

9 n

Bottom Ream

Opening

-- 19 314"_

Exhaust

Vent

A/C Coil Box

--27 5,8"

Gas Connection

Condensata

Drain Outlet

Downflow Furnace

Combust;cm Air Inlet I

'_ i I Exhaul_ ,.

_,-_ : -_,

_l_ 24 718"

1 I/2" T

21 114"_ t5t/2.

°+,,,,o. 1111llt@

,(-_ 19 3/4" _1

Norton Supply Air O_0emng

10_

k_ 8UpldyAk

O_nm.g

(S_ I

Sl/4'

Bottom Supply Atr Open nt

I-3/4-

Combustion

Air Inlet

RetumAirOpenln

-- 27 718"--

, Y

718" Die

Electric

Connection

"_" 11/2. x2 tl2 .

21 1/2"

Figure 1. Unit Dimensions

IMPORTANT:READALL INSTRUCTIONS

CAREFULLYBEFOREBEGINNINGTHE

INSTALLATION.

/ WARNING:

Do not use this product if any part has

been submerged under water.

Immediately call a qualified service

technician to inspect the appliance and

to replace any part of the control system

and any gas control that has been

submerged under water.

ified service technician periodically check allwiring

connections and service unit as required.

The M2 sedes gas furnaces are listed drect vent

(sealed combustion) forced air furnaces (type

FSP) for use with both natural and propane (LP)

gases. The M2 furnace series has been certi-

fied to the UL 307B standard for use in the United

States and to ANSI Z21.47a-CAN/CGA-2.3a-

1995 for use in the United States and Canada.

These furnaces may be installed in:

1. Manufactured Homes

2, Recreational Vehicles, Park Models

3. Manufactured Buildings

/ WARNING:

Should overheating occur, or the gas

fail to shut off, shut offthe manual gas

valve to the appliance before shutting

off the electrical supply.

NOTICE: Leave these instructions withthe home-

owner. Advise unit owner/user to follow the main-

_ter]ance rrecommendations outlined. Have a qual-

4. Modular Homes /Buildings

The M2 furnace is not to be used for the tempo-

rary heating of buildings under construction.

Model Shipping Weight (Ibs)

M2RC - 080A * 16 -B_*) 160

M2RC -1OOA-16 -S(*) 170

M2RL - O60A-16 -B(*) 170

M2RL - 080A -16 - B(*) 170

M2RL -100A - 16 -B(*) 175

A]C Coil Box 20

•Can be N orL

Table 2. Shipping Weights

CAPACITIES --Furnace Airflow Data

Furnace

Furnace input Motor _oto; 0.t

Model No. B_uh Speed HP CFM Rise

High * 1840 *

M2RO-OSO 80,000 Meal-High 1/2 1600 43

Med-Lcw *' 1380 50

Low 1100

High * 1910 -

M2RC-100 100,000 Meal-High "1640 53

Med-Low 1/2 1440 61

Low 1230 -

High * 1620 32

Med High 1450 36

M2RL_60 60,000 Med Low *' 1/2 1255 42

Low 1080 48

High" 1620 43

Med High 1450 49

M2R L-089 8_,000 Med Low _1/2 1255 56

L_ 1080 65

High* 1620 54

Meal High " 1430 62

M2RL-100 100,000 Med Low 112 1260 70

Low 1085

•Factorywired cc_ling speed tap

•* Factory wired heating speed tap

Exkrnal stage Pr,_sure (Inches Water Column}

0.2 0.3 0.4 0.5

CFM I_se CFM Rise CFM Rise CFM Rise

1780 -1700 -1630 -1550 -

1560 44 1470 47 1400 49 1350 51

1350 51 1300 53 1250 55 1190 58

1050 1000 950 900

1860 - 1780 - 1700 - 1620 -

1620 54 1540 57 1480 59 1420 62

1410 62 1370 64 1320 66 1270 70

1210 -1180 - 1140 . 1090 -

1560 33 1490 35 1430 36 1365 38

1400 37 1350 38 1295 40 1240 42

1225 43 1180 44 1145 45 1105 47

1055 49 1030 51 1000 52 960 54

1560 45 1490 47 1430 49 1365 52

1400 50 1350 52 1295 54 1240 57

1225 57 1180 60 1145 61 1105 64

1055 67 1030 68 1000 70 960 73

1555 57 1485 59 1425 62 1355 65

1375 64 1330 66 1265 70 1210 73

1220 72 1170 75 1130 1070

1050 1015 970 935

-NotRecommended

Table 3.

NOTE:Datais for operationwfth filter.

Furnace Airflow Data

CLEARANCES TO COMBUSTIBLE MATERIALS

This furnace is designed for the minimum clearances to combustiblematerial listed in Table 4. Refer

tothe fumace name plate, locatedinside the furnace cabinet,for specificmodel numberand clearance

information. Furnace Cabinet Minimum Clearances (Inches}

Input Width Plenum Ductwork within

(Stuh} flnches_ Side Vent Back Top* Front** Surfac_ 3 fL of Furnace

60,000 19314 O O0 10 0 1/4 1/4

80,000 193/4 O O O 10 O1/4 1/4

100,000 193/4 0 O0 19 0 1/4 , 1/4

* For Downflow model only. Upflow models can be 1".

** 24 inches is the minimum clearance for servicing. 36 inches is the recommended clearance for service.

Table 4. Minimum Clearances to Combustible Materials

NOTICE TO INSTALLER

Installer is advised to follow carefully all in-

structions and warnings in this manual to in-

sure maximum performance, safety, and oper-

ating efficiency of these appliances. Improper

installation may create hazardous conditions,

and will void the appliance warranty.

Manufacturer Warranty, Owner's

Responsibilities

It is the sole responsibility of the homeowner to

make certain the gas furnace has been cor-

rectly installed in the home, converted to the

proper fuel (LP gas or Natural gas), and ad-

justed for proper operation.

OWNER'S INFORMATION

About Your Central Furnace System

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

and is 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.

Awarranty certificate with full details is in-

cluded with this furnace. However, NORDYNE

will not be responsible for any costs found

necessary to correct problems due to im-

proper setup, improper installation, furnace

adjustments, improper operating procedure

on the part of the user, etc.

Some specific examples of service calls which

cannot be included in warranty payments are:

1. Converting the furnace to use another

type of gas.

2. Repairing duct work in the home found to

be faulty.

3. Correcting wiring problems in the electri-

cal circuit supplying the furnace.

4. Resetting circuit breakers, blown fuses

or other switches.

5. Correcting problems due to improper gas

supply pressure to the furnace.

6. Providing instructional training on how to

light and operate the furnace.

7. Correcting any problems caused by in-

stallation of an air conditioner, heat pump

or other air comfort devices.

Follow the instructions in this booklet carefully 8. Revising installation of the furnace flue

and this appliance will provide many years _of ......... assembly: ..............................

superior performance. 9. Adjusting or calibrating of thermostat.

Ifyou wish to cool your home automatically with

a central air conditioning system investigate

the excellent NORDYNE cooling systems avail-

able from your heating and cooling contractor.

These systems are designed to work best with

your NORDYNE furnace and have been care-

fully engineered to deliver optimal performance

when mated with NORDYNE manufactured

home furnaces.

NORDYNE also offers water heaters, fire-

places and ventilating systems specifically

designed for manufactured housing applica-

tions. Ask your manufactured home retailer,

10. Removing any construction debris which-

has fallen into flue system.

Carefully review these responsibilities with

your manufactured housing dealer, service

company, or gas supplier, so that there will be

no misunderstanding at a later time.

INSTALLATION REQUIREMENTS

Requirements and Codes:

The installer must be familiar with and comply

with all local codes and regulations applicable

to the installation of heating appliances and

related equipment. In the absence of local

your heat nn and coolin,_ contractor or your codes, the installation must conform with these

distributor for more information. Write directly instructions and the current provisierfs_'6f_one

to the factory (PO Box 46911, St. Louis, MO or more of the following standards:

63146) if you are unable to locate a source for a. Federal Manufactured Home

NORDYNE manufactured housing products in Constructions & Safety Standard (H.U.D.

your area. Title 24, Part 3280.707[a][2])

b. The Standardfor ManufacturedHome

Installations (Manufactured Home Sites,

Communities, and Set-Ups)ANSI A225.1

and/or CAN/CSA-2240 MH Series).

c. American National Standard (ANSI-

119.2/NFPA-501C) for all recreational

vehicle installations.

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-C1/

NFPA-70) and/or CSA 22.1 Canadian

Electric Code Part 1 for all electrical field

wiring.

CE g6nerateur d'air chaud dolt 6tre insta]l_

conform6ment aux instructions du fabricant et

aux codes Iocaux. En I'absence de code local,

respecter la norme ANSI Z223.,1, institule Na-

tional Fuel Gas Code ou les codes d'installation

CAN/GCA-B 149.

The National Fuel Gas Code is available by

writing:

able and allow the appropriate clearance for

your installation.

This furnace is certified for use on wood

flooring. The furnace must be installed on a

solid surface and must be level front to back

and side to side. This furnace must not be

installed directly on carpeting, tile, or any

combustible material other than wood flooring.

Downflow models can only be installed on

combustible flooring when installed on a

Nordyne plenum base (part numbers 901987

through 901993 - see Table 5). Both the upflow

and downflow models must be installed with

the Nordyne A,'C coil box (part no. 914958).

The plenum attached to the A,'C coil box and

the ductwork within 3 feet of the furnace must

be installed such that surfaces are at least

1/4" from combustible construction.

CIRCULATING AIRSUPPLY

General

Plenums and air ducts must be installed in

AmericanNationaIStandardslnstitute,lnc. 'accordance with the Standard for the

1430 Broadway Installati0n of Air Conditioning and Ventilating

New York, NY 10018 Systems (NFPA No. 90A) or the Standard for

the Installation of Warm Air Heating and Air

NFPA publications are available by writing: Conditioning Systems (NFPA No. 90B).

National Fire Protection Association

Batterymarch Park

Quincy, ME 02269

Location

The furnace must be installed on a level sur-

face, and as close to the center of the air

distribution system as possible. See Figure 1

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 installed

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. 24 inches is the minimum required

clearance for servicing the unit. 30 inches is the

minimum required clearance for positioning the

unit. 36 inches is the recommended clear-

ance from the front of the unit. Please note

that a panel or door can be located such that

the minimum clearance on the rating plate is

satisfied, but that panel or door must be remov-

/ WARNING:

Products of combustion must not be

allowed to enter the return air openings

of the furnace or the circulating airsupply,

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 injury or death.

The floor or platform on which the fumace

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.

RETURN AIR PROVISIONS

Upfiow models draw the return air from the

base of the furnace. A stand or return air duct

must be supplied to the furnace to provide the

required return air.

Downflow models draw the return air from the

top of the furnace. The minimum required

clearance to the top of the furnace is detailed

on the furnace rating plate. Additional clear-

ance may be required depending upon filter

accessibility.

For each application, the U.S.A. home manufac-

turer shall comply with all of the following condi-

tions to have acceptable retum 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

inadvertent 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. The cross-sectional area of the return

duct system leading into the closet shall

not be less than 390 square inches.

d. The total free area of openings in the floor

or ceiling 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

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:

CAUTION:

HAZARD OF ASPHYXIATION: Do not

cover or restrict return air opening.

k. Air conditioning systems may require

more duct, register and open louver area

to obtain necessary airflow. Use

NORDYNE's certiduct program to

determine proper duct size for A/C.

AIR 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 illustrated

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.

A Single trunk duct []

carpeting, boxes and other objects ............................................................

e. Materials located in the return duct

system must have a flame spread

classification of 200 or less. This includes

a-closetdo0r if theefu-rnac_ is"fna-cios_t._

f. Noncombustible panshaving 1"upturned

flanges are located beneath openings in

afloor duct system.

g. Wiring materials located in the return

duct,system shall conform_to Articles ,-

300-22 of the National Electrical Code

(ANSI CI/NFPA-70).

h. Gas piping is not run in or through the

return duct system.

i. 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.

BJ Dual trunk duct _ ]

- _ wlcrossover connector-_- •

U U U

Figure 2. Typical Supply Duct System

FLOOR CAVITY

U(depth equal to "X* in F3gure 5 and Table 5)

tJJJJJJJJJJJJJJJJJJJJJ JJ _JJi_

x-l--- -----.._ il ,l

II)J SuPPLYAiRoucT

-- I_! /k h\l

Figure 3. Floor Cavity Cut-Out 7

If "X"

(Floor cavity) is:

7/8" (22ram)

2" (51ram)

4 1/4" (108ram)

6 1/4" (159rnm)

8 1/4" (210mm)

10 1/4" (260ram)

12 1/4" (311mm)

Use Duct

Connector Model

901987

901988

901989

901990

901991

901992

901993

Table 5. Duct Connectors

1-10li,,

, 1

Figure 4. Top View of Duct Connector

OPENING TO DUCT

WITH pLATE {C) REMOVED

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

OPENING BECOMES

Figure 5. Duct Connector

UPFLOWFURNACE

INSTALLATION

a. Position the furnace on top of the return

air ductwork or return air stand. NOTE:

The ductwork or stand must have an

opening equal to that of the return air

opening of the furnace. Refer to Figure 1

for the proper return air opening size.

Secure the furnace to the floor or base

once it has been properly positioned.

b. Position and secure the A/C coil box to

the top of the furnace. The A/C coil box

can be secured to the furnace using the

provided attachment brackets. These

brackets are designed to attach the

furnace cabinet to the A/C coil box on the

sides. To install these brackets, position

one bracket on the side of the furnace,

so that the locating dimples are in the

groove created by the top of the furnace

cabinet and the bottom of the A/C coil

box. Using the provided self-drilling

screws, secure the bracket to the A/C

coil box and the furnace. Repeat on the

other side of the furnace for the other

bracket.

Attach the plenum from the supply duct

to the flanges of the A/C coil box.

Secure the plenum to the supply

ductwork.

NOTE: Additional fasteners may be used

at rear, sides or through door frame, as

desired, to secure furnace to closet or

alcove framing.

DOWNFLOWFURNACE

INSTALLATION

DUCT CONNECTOR SELECTION FOR

DOWNFLOW MODELS

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, remove

reducer "C" (see Figure 5) to obtain the

largest open area that will fit the duct/

floor construction.

INSTALLATION OF THE DUCT CONNEC-

TOR FOR DOWNFLOW INSTALLATIONS

Required cut-out openings in the floor, ceiling,

roof, and/or walls must be carefully located to

avoid misalignment of the furnace, combustion

air piping, and vent piping (see Figures 14-16).

Installation procedures are suggested for

typical furnace installations and need not be

followed in the exact listed sequence.

CUT OUT FLOOR OPENING FOR

DOWNFLOW MODELS

a. Determine center of closet or alcove

(Figure 7).

b. Locate center of the floor opening, mea-

sured 10" from the rear wall, and mark

cut-out measuring approximately 14-1/

2" by 14-1/2" (+ 1") for model duct

connector used (refer to Figures 6 & 7).

Figure 6. Cut-Out Locations

HOLE

Figure 7. Closet or Alcove Floor Cut-Out

MOUNTING

PLATE REAR WALL

FUEL

1/16TH. LARGER THAN

DUCT CONNECTOR

Figure 8, Mounting Plate

BEND CONNECTOR TABS

UNDER DUCT OPENING

MOUNTING

PLATE

FLOOR

CUTDUCTOPENING

a. Place duct connectorthroughthe floor

Figure 9. Duct Connector

opening with bottom tabs resting on

top of the supply air duct.

Center duct connector and push back

against rear edge of floor opening.

c. Mark cut-out location (tab area) and

remove duct connector.

d. Cut out duct opening 1/4" larger than

area marked.

TABS TABS

-- DUCT _DUCT

1. INSERT DUCT PLENUM CONNECTOR

INTO DUCT CUT-OUT. 2. BEND Bo'n'OM TABS OVER

AND ONTO THE UNDERNEATH

DUCTSER_CE.

Figure 10. Installation of Duct Connector

INSTALL FURNACE MOUNTING PLATE

a. Bend tabs on furnace mounting plate

upwards 90°

b. Place mounting plate (supplied within

duct connector) at rear of the floor

opening (See Figure 8).

INSTALL DUCT CONNECTOR

e. Place duct connector through the floor

opening with bottom tabs extending

through the duct opening. (See Figure 9)

b. Secure duct connector to floor.

c. Bend bottom tabs under and up tightly

against the supply air duct (See Figure

10).

NOTE: The duct connector is designed for

use on ducts 12" in width. When using the

connector on 12" wide ducts, there may be

insufficient clearance to bend the tabs on two

sides of the duct connector. In such cases the

tabs may be attached to the sides of the duct

by using sheet metal screws or other suitable

fasteners. (See Figure 11).

if ial_e is used to provide a better seal, it should

be approved by applicable national orlocal codes.

ALTERNATE ATTACHMENT METHODS

This procedure may also be used to install a

furnace duct connector to narrow metal

ductworkwhere insufficientclearance prevents

bending of the duct connector tabs at the

side(s) of the duct. (See Figure 12).

1. Score and cut the topof the metal duct as

indicated in Step 1 or Step 2. With Step 1

choice, also cut out the metal from the

shaded area "A".

2. Fold the duct flap "B" up, (See Step 3).

3. At the front-to-back of duct run (Area

"A"), bend the duct tabs and secure them

directly to the duct.

Duct Connector "--_

Duct

fNa_ow

Figure 11. Narrow Duct Installation

Duct

STEP 1. STEP 2,

Fold Back Flap "B" Cut Fold _Rap'B"

"' _a "O_A" "B" I

_Fold Back Rap "B. _-- Fold Back Flap'B"

Bend DUCt Connector Tabs Up

and Over- (alonglengthof duct)

Stapk_ Folded Duct

Flap (lypl _0,_ide of Du_

Connector

Duct

STEP 3. S1]EP 4.

Figure 12. Alternate Installation

4. At area"B",bendtheducttabsupand

backover,aroundthe duct connector,

(SeeStep3).

5. Fold/formtheductflapagainstthesideof

theductconnectorand 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.

INSTALL DOWNFLOW FURNACE

a. Prepare the NC coil box as described in

the instructionsprovidedwith the coil box.

b. Place A/C coil box onto duct connector.

c. Slide A/C coil box back until it is firmly

against the mounting plate. Mounting

plate tabs should be bent upwards so as

not to interfere with furnace.

d. Secure front with one (1) fastener at

each corner through front bottom flange

and through the back of the A/C coil box.

e. Position the furnace ontop ofthe A/C coil

box. Ensure that the furnace is properly

positioned on the wrapper.

f. Secure the A/C coil box to the bottom of

the furnace. The A/C coil box can be

secured to the furnace using the provided

attachment brackets. These brackets

are designed to attach the furnace

cabinet to the AJC coil box on the sides.

To install these brackets, position one

bracket on the side of the furnace, so that

the locating dimples are in the groove

created by the bottom of the furnace

cabinet and the top of the A/C coil box.

Using the provided self-drilling screws,

secure the bracket to the A/C coil box

and to the furnace. Repeat on the other

side of the furnace for the other bracket.

NOTE: Additional fasteners may be used at

rear, sides or through door frame, as desired,

to secure furnace to closet or alcove framing.

VENTING AND COMBUSTION AIR

REQUIREMENTS

CAUTION:

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 Z223.1/NPFA-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.

WARNING:

The combustion air piping must not be

blocked or restricted in any manner,

z WARNING:

Fumace installation using methods other

than those described in the following

sections must comply with the National

Fuel Gas Code and all applicable local

codes to provide sufficient combustion

air for the fumace,

VENTING REQUIREMENTS

/t',WARNING:

FURNACE MUST NOT BE COMMON

VENTED WITH OTHER APPLIANCES.

General

This section specifies installation requirements

for 2-pipe combustion air piping. The capacity

table provided in this section applies to the total

sum of vent and combustion air piping lengths.

Thesecondensing furnaces are classified as

"Category IV"appliances, which require special

venting materials and installation procedures.

Category IV 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.

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

escape through such appliances or vents. Do

not vent the furnace to afireplace chimney or

building chase.

If removing an existing furnace in a venting

system, the venting system may not be propedy

sized. To test the vent system with'-the

remaining appliances, follow the test outlined

below.

The following steps shall be followed with each

appliance connected to the venting system place

in operation, while any other appliances con-

nected to the venting system are not in operation:

a. Seal any unused openings in the venting

system.

b. Inspect the venting system for proper

size and horizontal pitch, as required in

the National Fuel Gas Code, ANSI Z223.1

orthe CAN/CGA B149 Installation Codes

and these instructions. Determine that

there is no blockage or restriction,

leakage, corrosion and other deficiencies

which could cause an unsafe condition.

c. In 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.

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.

Close fireplace dampers.

d. Follow the lighting instructions. Place

the appliance being inspected in

operation. Adjust thermostat so appliance

shall operate continuously.

e. Test for draft hood equipped appliance

spillage at the draft hood relief opening

after 5 minutes of main burner operation.

Use the flame of a match or candle.

f. 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.

APPLICATION

PVC, CPVC or ABS

SCH. 40 Pipe Size

Model M2RL 060

Model M2RCIL 080

Model M2RC/L 100

DIRECT VENT, DUAL PIPE LENGTH (ft.)

with 1 long radius elbow on each pipe.*

Inlet/Outlet

3==

3 ID

*NOTES

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

2. Two 45 degree elbows are equivalent to one 90 degree elbow.

3. One short radius elbow is equivalent to two long radius elbows.

4. Do not include termination elbows in calculation of vent length.

5. This table is applicable for elevations from sea level to 2000 ft. For higher elevations,

decrease vent pipe lengths by 8% per 1000 ft. of altitude.

6. Only the above pipe materials are approved for use with these condensing furnaces.

Table 6. Vent Table

g. If improperventingis observedduring

any of the abovetests, the venting

systemmustbe corrected.

Proc6dercommesuit pourchaqueappareil

raccord6ala tuyauterie d'_vacuation et en _tat

normal de fonctionnement; tous les autres

appareils raccordes & la meme tuyautede

d'_vacuation doivent _tre mis hors service:

a. sceller toute ouverture non utilis6e de la

tuyauterie d'evacuation

b. s'assurer que la tuyautede d'6vacuation

pr6sente des dimensions et une pente

horizontale conformes & la norme ANSI

Z223.1, intitul_e National Fuel Gas Code

ou aux codes d'installetion CAN/CGA

B149, ainsi qu'aux pr_sentes

instructions. S'assurer que la tuyauterie

n'est pas bloqu6e, restreinte, corrodee,

qu'elle ne fuit pas et qu'elle ne pr6sente

aucun autre defaut potentiellement

dangereux.

c. dans la mesure du possible, fermertoutes

les pores et fen_tres du b&timent, et

toutes les portes entre la piece o_ se

trouve I'appareil raccorde _,la tuyauterie

d'_vacuation et les autres pieces du

b_timent. Mettre en service les

s6ccheuses et tout autre appareil qui

n'est pas raccord6 _ la tuyauterie

d'_vacuation. Faire fonctionner _ regime

maximal tout ventilateur d'6vacuation,

tel que les hottes de cuisini6re et les

ventilateurs de salles de bains. Ne pas

mettre en service les ventilateurs d'_t_.

Fermer les registres des foyers.

d. respecter les instructions d'allumage.

Mettre en service I'appareil & ressai.

R6gler le thermostat de mani_re &ce que

I'appareil fonctionne sans interruption

e. S'assurer qu'un appareil muni d'un

coupe-tirage ne pr6sente aucune fuite ._

rouverture du coupe-tirage apr_s que ie

bn31eur principal ait fonctionn_ pendant

cinq minutes. Employer la flamme d'une

allumette ou d'une chandelle.

f. Apres avoir d6termin_ que tousles

appareils raccord_s _ la tuyauterie

d'_vacuation evacuent correctment tel

que prescrit ci-dessus, rouvdr les portes

et les fen_tres et remettre les ventilateurs

d'_vacuetion, les registres de foyers et

tout autre appareil fonctionnant au gaz

_,leur etat de fonctionnement initial.

g. Si un appareil n'evacue pas correctement

_, la suite de Pun des essais ci-dessus,

corriger la tuyauterie d'6vacuation.

Vent Pipe Material

Vent and combustion air pipe and fittings must

be one of the following materials and must

conform tothe 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 Length and Diameter

In order for the furnace to operate properly, the

combustion air and vent piping must not be

excessively restrictive. To ensure this use

Table 6, which indicatesthe maximumallowable

piping length for a furnace of specified input

rate, when installed with piping of selected

diameter and number of elbows. This table

applies to the length and number of elbows

for each pipe. To use the table, the furnace

input rate, the centerline lengthand the number

of elbows on each pipe must be known. Choose

the diameter for which the tabulated length is

equal to or greater than required.

Use of the table is illustrated in the following

examples:

Example:

An 80,000 Btuh furnace is to be installed

in a "two-pipe" system with 40 feet of vent

piping. There are four elbows, excluding

those exterior to the building.

Solution:

Consulting Table 6, in the dual pipe length

column for an 80,000 Btuh furnace, the

maximum allowable length for a 3" inlet/

3" outlet is 90 feet with one elbow. Select

3" pipe. For two additional elbows, deduct

3.5 ft. for each elbow, or 7.0 ft. for a

maximum installed vent length of 83 ft.

Condensing furnace combustion products

have very little buoyancy, so Table 6 is to be

used without consideration of any vertical rise

in the piping.

NOTE: Always use the same or larger size

piping for combustion air as is used for the

exhaust vent.

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 size requirements per

the preceding section. 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).

CAUTION:

Combustion air must not be drawn from

a corrosive atmosphere.

_]-he qua!ity of outdoor air must also be

considered. Be sure that the combustion air

intake is not located near asource of solvent

fumes or other chemicals which can cause

corrosion of the furnace combustion system.

Piping must be mechanically supported so that

itsweight does not bear 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 14 & 15).

Figure 16 illustrates vent and combustion air

pipe sizes exiting the furnace. Transition to the

correct pipe size must be done close to the

furnace so that the full length of pipe is of proper

size.

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 forconvenience

in installation and service.

Pipe Couplings at the Furnace

The provided rubber couplings should be in-

stalled in the combustion air (use 3" diameter

coupling) and vent (2" diameter) pipes to allow

for servicing. These couplings are designed to

fit snugly over the pipe and be secured to the

pipes using the provided hose clamps. Use 3"

x 2" flexible coupling at furnace on 2" vent pipe

and on upflow units use 3" diameter coupling

above coil box, as shown in Figures 14 and 15.

Refer to figures 14 and 15 for the proper

installation of these couplings.

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 13 illustrates necessary distances from

the vent termination to windows andbuilding

air intakes. In Canada, the Canadian Fuel

Gas Code takes precedence over these

draft vent

termin_d /

Air Intet

Dite_ Vetlt

terminal -

more than

50,000 Btuh

Figure 13. Vent Termination Clearances

Upflow Furnace

Inlot -- Exhaust _\ I See Vent Table !

=Seal/Cualk

*'_ __ _ :/_aroundpips

5/8"

Combustion

Air Inlet 7\ I

OtfsetwithExhau ! _

Pips for Adequate '

PVC or ABS ' -J

Neopren3e "_apl_nt_ r _ ' [

Straps or other suitable /at buildin

supports at minimum 5foot intervals _ ! /g

; o=,=E,ha°atVent 1="

| Wall _Y_._ MIn,

Exhaust Vent A/C Coil Normal Snow Level _

_,---- - "------ Box

'Flexible 3" x2= reducer to adapt the 2" diameter

vent pips of furnace to the 3" diameter pipe of the vent

--Fuma_

Downflow Furnace

SealiCautk I<

Around Pipe

atSu.dth0 \\ I

Min, i

Normal Snow Level

See Vent Table 4

Straps or Other Suitable

Supports at Minimum of

5 fL intervals

Upward Pitch - 1/4" Per Foot •

Wall Outlet Exhaust Vent

First Support Should he as Close to

Fumace ConnecUon as Possible --

Exhauat Vent

/Exhaust _lnlat

[/// 5/8"

Ii *

: Top View !

rrCombustion Air In_'t

Offset with Exhaust

Pipe for Adequate

Dimensioi_al Clearance

PVC or

ASS pipe

3" diamat_

Neoprene Coupling"

and 2 Clamps

Rax{b •3" x2 reducer to adapt the 2" diameter

vent pipe of furnace to the 3" dLameter pipe of the vent

Figure 14. Horizontal Venting

* These neoprene couplings are field-supplied and can be used if the installation requires

breakable connections inthe piping. Note that a maximum of two couplings per pipe are allowed.

instructions. Specifically, all minimum

distance requirements with respect to

termination of the vent piping listed below.

The following list is a summary of vent terminal

location requirements:

1. The termination must be 12 inches above

snow level or grade level whichever is

higher. See Figure 17 for alternate method

to achieve 12" above snow level.

2. The minimum distance for adirect vent (2-

pipe) installation) from any door,

(openable) window, or air gravity inlet is 1

ft. below, 1 It. 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 Ca-

nadian Fuel Gas Code takes precedence.

5. Avoid areas where condensate drainage

may cause problems by dropping on

planters or patios, etc. Also ensure that

exhaust gases will not impinge on win-

dows or building surfaces, which may be

compromised or damaged by condensa-

tion. 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 1/4 inch per foot of slope up

can be maintained.

Upfiow Furnace

Rubber

Couplinl

Combustion

Air Pipe

3" Coupling

Furnace Front

Box

Fumace \

Support System

on VertJc_atRise

blow Joints

Support System wKh flmt support

as clolm to the furnace as posslbJe

114" per foot

3" diameter

Neoprene Coupling*

w/2 Clamps

Downflow Furnace

Exhaust

Support System

on Vertical Rise

Below Joints

Support System with flint support

as close to the furnace as possible

Upwa_ Pitch

l_'_rFoot

Flexible 3" x2" neducRr

to adapt tha 2" diameter

vent pipe of furnace to

the 3" diameter pipe of

the vent

Figure 15. Vertical Venting

Upflow Furnace Downflow Furnace

Combustion Air Inlet Pipe Collar

Diameter 3" for coupling or reducer

Fureace Top _

2" PVC Exhaust Vent All Models

Combustion Air Inlet

3" PVC on 0801t00 models

Furnace Top

_2" PVC

Exhaust Vent

All Models

Useappropriateadaptorforconnectiontofurnace. Useappropriateadaptorforconnection to furnace.

Figure 16. Furnace Pipe Adaptions

CAUTION:

For optimal performance vent furnace

through wall which experiences the least

exposure to winter winds.

Horizontal Venting

Vent and combustion air intake terminations

must be as shown in Figure 18.

, WARNING:

Ensure thatthe combustion airvent and

the exhaust vent are configured as

shown in Fig. 18. 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 config u ration. Make sure

that the exhaust vent does not have a 90

degree termination.

pipe is then cut such that it can penetrate the

wall and be held in place by closely fitting

standard couplings. The face plates are re-

tained on both sides ofthewall bythe couplings,

end the gasket is retained against the wall by

the outer face plate. Face plates must be

fastened to the wall 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:

1. 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 1" 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 18 & 19.

Note that a combustion air intake must be

provided with an elbow opening downward.

For horizontal venting, one of the following kits

is recommended:

J .. vc.or,zono,J J

Exterior Vent 9023750

Mounting Kit

For Canadian installations please refer to the

Canadian Installation Code (CAN/CGA-B149.1

or 2) and/or local codes.

The kit consists of two face plates and an

insulating gasket to seal the exterior surface.

A hole sized closely to the pipe diameter must

first be cut through the wall. A short length of

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 17.

Insulation is required to prevent freezing of this

section of pipe.

Table 7 describes the maximum length of flue

pipe that can travel through an unconditioned

space or an exterior space. The total vent

length must not exceed the lengths noted on

Table 6.

Vertical Venting

Figure 19 shows the proper installation and

clearances for vertical vent termination. The

Maximum Flue Pipe Length in

Unconditioned and Exterior Spaces

20 45 7O

020 70

-20 10 60

_: = Insulation thickness greater than 3/8 inch, based on an R value

of 3.5 (ft*°F*hr)/(BTU*in)

Table 7. Vent Protection

VentConfigurationto

Provide12"Minimum

height above

Snow LeveE. _. 12" Min,

19" Max.

Out,ide Su po.

wa,, •

_1/2"

_Armaflex

i _ Insulationor

Equivalent

-- 12" Above

Normally

Expected

Snow

Level

ExhaustVent

Op_on B _

Figure 17. Alternate Horizontal

Vent Installation

roof penetration must be properly flashed and

waterproofed witha plumbing roof boot or equiva-

lent flashing. Termination spacing requirements

from the roof and from each other must be per

Figure 19.

Figure 18. Exhaust and Combustion

Air Pipe Clearances

below freezing, i.e., installation within a pre-

existing masonry chimney; the pipe must be

insulated with 1/2 inch thick sponge rubber

insulation, such as an Armaflex-type or equiva-

lent.

Vent and combustion air piping may be in-

stalled in an existing chimney which is not in

use provided that:

a. Both the exhaust vent and air intake run

the length of the chimney.

b. The top of the chimney is sealed and

weatherproofed.

c. The termination clearances shown in

Figure 19 are maintained.

d. No other gas fired appliances are vented

through the chimney.

Vent Freezing Protection

To prevent condensate icing over extended

runs of vent pipe exposed to temperatures

Exhaust

; Vent's.

Combustion

Air

Exhaust

Plumbing Vent

Roof Boot

('ryp, Both Pipes)

iA= 12"AboveRooforSnowAccumulationLevel

Figure t9. Vertical Vent Termination

For extremely cold climates or for conditions of

short furnace cycles (i.e. set back thermostat

conditions) the last three feet of vent pipe can

be reduced one nominal pipe size provided that

the total vent length is at least 15 feet in length

and the vent is sized in accordance with the

venting requirements (Table 4) before this re-

duction isapplied. (Example: 3"to2-1/2") Smaller

vent pipes are less susceptible to freezing, but

must not be excessively restrictive.

Concentric Vent Termination

A concentric vent termination is approved for

use with these furnaces. The kit part number is

listed in Table 13. For proper installation of the

concentric vent termination, follow the installa-

tion instructions provided with that kit.

DRAINAGE OF CONDENSATE FROM

FURNACE

/ WARNING:

The condensate produced by the fumace

m ust be drained. Do not connect a water

supply to the drainage hose of the

furnace.

NOTE: The condensate drain should be pro-

tected from freezing when in unheated spaces.

"HARD" J

Drain Tube

Left

Side

Drain

Route to

floordrain. I Routeto

Im mOR

18.... OR

, Route Io

condensate _ condel_sate

Clamp pump. Ksep _ Clamp pump¸ Keop

(LoosenForStepI) downward "HARD' J (LoosenForSlepI) downward

(RetightanforStep 3) slope. Drain Tube (R(_tightenforStep 3) slope.

Figure 20. Furnace with Condensate Drain Trap Assembly

The condensate drainage system is internal to

the furnace. The drain may exit either the dght

or left side of the furnace cabinet. For a right side

drain, simply extend the tubing out of the 7/8"

hole in the cabinet (See Figure 20).

For a left side drain follow the steps below:

1. Loosen the clamp on the soft exit tube

(see Figure 20.)

2. Rotate the soft exit tube (counter clock-

wise, 180° upflow models; clockwise 90 °

downflow models.)

3. Re-tighten the clamp. MAKE SURE

CLAMP IS TIGHT TO AVOID LEAKAGE

OF CONDENSATE.

4. Route the tubingout ofthe 7/8"hole located

8 inches up fl'om the bottom furnace.

The condensate shouid drain from the plastic

collector box (location A in Figure 20) as droplets

or a small stream. If you notice the furnace has

operated formorethan 5minutes without draining

or the red status light on the control board is

pulsing a 2-blink code follow the steps below.

1. Remove the collector box soft tube at

location A in Figure 20 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 airtight. 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 (usually contains lime-

stone). Proper drains and connections to the

condensate tubing 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 either left or right

side gas entry. Typical gas service hook-ups

are shown in Figure 21. When making the gas

connection provide clearance between the

gas supply line and the entryhole inthe furnace

casing to avoid unwanted noise and/or dam-

age 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-off valve and ground joint-

union external to the furnace. The shut-off

valve should be readily accessible for service

and/or emergency 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 installation must comply with the provi-

sions stated inthe Federal Manufactured Home

Standard (H.UD 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 8 lists gas flow

capacities for standard pipe sizes as a func-

tion of length in typical applications based on

nominal pressure drop in the line.

Typical Left Side Entry -Upflow

Burner Viewport

Roll_ut Limit

°Ourn r °'llll

Some Utilities Assembly

Require Shut- I F _

Off Valve to

be 4 to 5 feet

Above Floor - Ground

/Denotes field-

Automatic Gas Valve /provided and

(wdh manuel shut-off) installed

component.

Typical Right Side Entry -Downflow

Denotes field-

provided and Automatic

installed Gas Valve

components. (with manual

shut-off)

'Ground J<

, UrlioR

Burner Roll-Out Lim_

Assembly _,

Ii .....

int

Some Utilities

1Require Shut-

Off Valve to

be 4 to 5feet

Above Floor

_-Bumer Viewport

Figure 21. Typical Gas Service Connection

NOTE: Gas piping must not be run in or

through air ducts, chimneys, gas vents,

elevator shafts, etc.

water column), the furnace must be discon-

nected from the gas supply piping system to

prevent damage to the gas control valve.

If the test pressure is less than or equal to

1/2 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

solution or other approved method.

High Altitude Derate

The nameplate input rating for the furnaces

apply for elevations up to 2,000 feet (610m)

above sea level. For elevations over 2,000

feet, reduce the input by 4% for each 1,000 feet

above sea level. For example, a furnace ap-

plied at an elevation of 5,000 feet should be

derated by 20%. See Table 9 describing the

correct orifice for derate.

NOTE: For Canadian high altitude (2,000 to

4,500 ft.), simply reduce the gas manifold

pressure to 2.8" WC for natural gas and 8.5"

WC for LP gas without changing the orifices.

NOTE: The density of air decreases with

increasing elevation above sea level. This

reduces 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.

Compounds used on threaded joints of gas

piping must be resistant to the actions of

liquefied petroleum gases.

The main manual gas valve and main power

disconnect to the furnace must be prop-

erly labeled by the installer in case emer-

gency shutdown is required.

CAUTION:

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 1/2 psig (14 in.

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

FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60)

i_OMI MAL LENGTH OF PIPE RUN

BLACK IRON _feet)

PIPE DIAMETER

(in. I10 2D 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

1520 350 285 245 215 195 180 170

1114 1050 730 590 5(0 440 400 370 350

1 1/2 1600 1100 890 7_ 670 610 560 530

T_ecubicfeetperhourlietedinthetableabovemustbegreeterthan

thecubicfeetperhourofgasflowrequiredbythefurnace.

To determine the cubic feet per hour of gas flow required by the

furnace, divide the input rate ofthe furnace bythe heating value ofthe

gas:

Cubic Feet -- InputTo Furnace (Btu/hr)

PerHourRequired HeatingValue ofGas (Btu/Cu, Ft.)

Table 8. Capacity of Black Iron Gas Pipe

(cu. ft. per hour) for Natural Gas

(specific gravity = .60)

CONVERSION

This furnace can be converted from the factory-

equipped gas to either natural gas (for LP gas

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

models). Conversions must be made by quali-

filed service personnel, using only factory autho-

dzed or approved parts. The required conver-

sion orifices are supplied with the furnace.

/ WARNING:

DO NOT REMOVE OR DEFACE THE

ORIGINAL RATING PLATE.

CAUTION:

The gas supply shall be shut off prior to

disconnecting the electrical power,

before proceeding with the conversion.

To Turn Off Fuel Supply to the Appliance:

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

lowest temperature setting.

2. Turn OFF the main gas supply to the

appliance at the manual valve, outside of

the appliance casing.

3. Remove the control access panel /Iou-

vered door.

4. Move the appliance gas valve lever/knob

to the "OFF" position.

5. Turn OFF the electrical power to the

appliance.

To Remove the Burner Assembly:

1. Follow the instructions "To Turn Off the

Fuel Supply to the Appliance."

2. Disconnect the flame sensor wire from

the burner box.

3. Disconnect the igniter wires at the 2 pin

plug. This is a locking quick connect and

both sides of the lower section must be

depressed in order to be separated.

4. Remove the wires from the terminals of

the gas valve.

5. Disconnect the rubber pressure tubes

from the gas valve and the burner box.

6. Remove the burner access cover plate

from the burner box.

7. Remove supply gas piping from the gas

valve.

8. Carefully remove the burner assembly fas-

teners and remove the bumer assembly from

the appliance. Keep the fasteners that were

removed. Note that the burner box may have

hooks near the top and on the right and left

hand sides. To remove this type of bumer

box, lift the burner box upwards and then

remove the box from the unit.

EXAMPLE 1 EXAMPLE 2

Elevation

Type of gas

Furnace model

Odfice as shipped

3,890 feet

Natural

M2RC-100A-16-BN

#45 Ddll

What burner odfices are needed?

The required input for 3890 feet is 84,000

Btuh or 16% less than the sea level rating

of 100,000 Btuh.

See Table 8 for natural gas, find the Furnace

Model Number and follow across the table for

the elevation 2000-4000 column. From the

table, choose a#46 orifice. Install a #46 orifice

in every burner and check the fidng rate per the

VERIFYING AND ADJUSTING FIRING RATE

section. The fidng rate in this example must not

exceed 84,000 Btuh.

Elevation

Type of gas

Furnace model

Orifice in Natural to

LP Conversion Kit

5,500 feet

Propane

M2RC-100A-16-BN

# 55 drill

What burner odfices are needed?

The required input for 5500 feet is 76,000

Btuh or 24% less than the sea level rating

of 100,000 Btuh.

See Table 8 for LP gas, find the Furnace Model

Number and follow across the table for the

elevation 4000-6000 column. From the table,

choose a #56 orifice, install a #56 odfice in

every burner and adjust the manifold pressure

to 10.0 inches water column. The fidng rate in

this example must not exceed 76,000 Btuh.

Furnace Furnace Rating No. of Elevation Elevation Elevation Elevation Elevation

Model Number Plate Input Burners 0 - 2000 2000-4000 4000-6000 6000-6000 8000-10000

M2R(C,L) - (Btuh) Nat LP Nat LP Nat LP Nat LP Nat LP

060A-16-B(* I60tO00 449 56 49 56 50 57 50 57 51 58

080A-16-B(*) 80,000 445 55 46 55 49 56 49 56 50 57

100A-16-B(*) 100,000 5 45 55 46 55 49 56 49 56 50 57

*canbeNorL Table 9. Approximate Orifice Size for Natural and LP Gases

To Remove the Burner Orifices:

1. Remove the four (4) fasteners that secure

the gas manifold to the burner box, as

shown in Figure 24. Carefully remove the

gas manifold assembly from the burner

box. Note that the gas manifold assembly

consists of the gas valve, the gas manifold,

and the orifices.

2. Carefully remove the burner orifices from

the gas manifold, as shown in Figure 24.

Honeywell

Valve

PRESSURE

REGULATOR

OTHER SIDE

OF CAP

CAUTION:

Caution: Do not re-drill the burner odfices.

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 high

altitude; natural gas or LP gas),

To Convert the Unit to the Alternate Gas

1. Remove the orifice bag from the manifold

of the unit.

2. Install the appropriate gas burner orifices

into the gas manifold. Remember if install-

ing in the United States at altitudes above

2,000 feet to install the proper orifices,

shown in Table 6. When installing the new

orifices, DO NOT use pipe joint com-

pound 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 22. You

will unscrew the cap and reinstall for your

installation. After reinstalling the cap, you

will be able to read "NAT" for the conver-

sion to natural gas or "LP for the conver-

sion to LP gas.

Figure 22. Convertible Pressure

Regulator Cap

Figure 23. Burner Inspection

Burner Gas

Orifices Manifold Flame

_t ,_;f_iObservatiOn

Inlet

,Cover

Tap Inlet Gas Plate

Valve

Figure 24. Typical Installation For Sealed

Burner Box With Access Cover Plate

Reinstallingthe Burner Assembly:

1. Reinstall 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. Reconnect the wires to the gas valve

terminals.

5. Reconnect the rubber pressure tubes to

the gas valve and the burner box. Rein-

stall the burner access cover plate.

6. Reconnect the igniter 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

pressure at the gas valve inlet must be be-

tween 11.O"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

1. 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 appli-

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.

5. Set the room thermostat to apoint above

room temperature to begin the heating

cycle of the unit.

Check that the unit ignites and operates

properly. Refer to the installation instruc-

tions provided with your unit for the nor-

mal operating sequence.

After the flame ignites, visually inspect

the burner assembly to ensure that the

flame is drawn directly into the center of

the heat exchanger tube, as shown in

Figure 23. The end of the flame will be out

of sight around the bend of the heat

exchanger tube. In a properly adjusted

burner assembly, the flame color should

be blue with some light yellow streaks

near the outer portions of the flame.

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

line, the hot surface igniter may not ignite the

gas. If the 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 igniter 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.

Adjusting the Manifold Pressure

The manifold pressure can be measured by

installing a pressure gauge or U-tube ma-

nometer to the outlet end of the gas valve as

follows:

1. With a 3/16" Allen wrench, remove the

manifold pressure tap plug located on the

outlet side of the gas valve. Refer to

Figure 3 for more details.

2. A fitting, which has a 1/8" NPT pipe thread

that is compatible with the pressure gauge

or U-tube manometer, must be installed ............

at this point.

3. Install the pressure gauge or U-tube ma-

nometer according to the manufacturer's

supplied instructions.

4. Set the room thermostat to a point above

room temperature to start the furnace.

5. Allow the furnace to operate for three (3)

minutes and then check the manifold

6. pressure.

Table 10 lists the appropriate manifold

pressures for both natural gas and pro-

pane (LP) gas installations, For the type

of fuel and the altitude of your installation,

Natural Propane

Gas (LP)

Manifold Pressure for 0-2000 3.5 10.0

Feet Above Sea Level (In WC)

Table 10. Manifold Pressures for Sea Level

determine the required manifold pres-

sure. For Canadian high altitude installa-

tions, refer to the "High Altitude Derate"

section for more details.

COMPLETING THE CONVERSION

1. 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.

CAUTION:

To avoid electric shock, personal

injury, or death, turn offthe power at

the disconnect or the main service

panel before making any electrical

connections.

ELECTRICAL WIRING

General

Electrical connections must be made in accor-

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 accor-

dance with the current Canadian Electrical

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

If any of the odginal wire as supplied with the

furnace must be replaced, it must be replaced

with wire having a minimum temperature rating

of 105°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 11. 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 uninter-

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.

R&W ""

For .....

Heating .....

Only .....

Room

Thermostat

NOTE:Ttla "_

terminal on the

UTiEC control board

must be connected

to the thermostat

for proper cooling

mode _atlon.

FIELD WIRING

Low Voltage

Connections

A_ Condensing Unit

,,/

Condensing Unit

-- Control Box

[_ Blower Off

3Amp Tlmlng

Fuse T_N

Flame Signal Light

{Yell_ i 0

Status Light

{R,dI •

:_=Neutrals

_Unused Motor Leads

Figure 26. Low Voltage Field,

Four-wire Heating/Cooling Applications

F_/ddS_P pwliied Field Supplied

Panel _Panel Connector

Black_H_ot)J_] Black _Black

ite (Neut-_l_ ____ ___ -_/-hit-e- -______ _-_ _/hite- -

(Ground) _

Ground /Ground

Field Supplied Disconnect

Within Sight of Furnace

..... Field Une Voltage

Black Wiring

Factory Line

White -- Voltage Wiring

round

_Junction Box (may be internal

or external to the furnace). These

connections can be made in the

field supplied disconnect at the

furllace.

Figure 25. Line Voltage Field Wiring

Furnace

Input

(Btuh)

60,000

80,000

100,000

Cabinet Nominal

Width Electrical

(in,) Supply

19.75 115-60-1

19,75 115-60-1

Maximum

Operating

Voltage

127

Minimum

Operating

Voltage

103

Maximum Minimum Maximum

Furnace Wire Fuse or Circuit

Amperes Gauge Breaker Amp_*

9.7 14 15

Thermostat Wire Gauge Recommended Thermostat Wire Length

2-wire {heating) 4 or 5-wire {cooling)

24 55 ft. 25 ft.

22 90 ft. 45 ft,

20 140ft. 70 ft.

18 225 ft, 110ft.

* Time-delayfuses orHACR-typecircuitbreakersare required.

Table 11. Electrical Data

NOTE: Proper line voltage polarity must be

maintained in order for the control system to

operate correctly. Verify that the incoming

neutral line is connected to the white wire and

the incoming "hot" line is connected to the black

wire in the furnace junction box. The furnace

will not operate unless polarity and ground are

properly connected. See Figure 25.

CAUTION:

Label all wires prior to disconnection

when servicing controls. Wiring errors

can cause improper and dangerous

operation.

for heating only (two-wire) and heating/cooling

(four-wire) applications. The recommended

minimum wire gauge for thermostat wiring is

shown in Table 11.

The thermostat must not be installed on an

outside wall or any other location where its

operation may be adversely affected. Adverse

affects include radiant loading from fireplaces,

sunlight, or lighting fixtures, and convective

loading from warm air registers or electrical

appliances.

To check the heat anticipator setting either:

1. Add the current draw of the system com-

ponents; or

Verify proper operation after servicing.

ATTENTION:

Lors des op6rations d'entretien des

commandes, 6tiqueter tous les files

avant des les d6connecter. Toute erreur

de c&blage peut 6tre une source de

danger et de panne.

S'assurer du ben foncUonnement de

rappareil apr_s tout entretien.

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 fur-

nace. See Figure 26 for the proper connections

2. Measure the current flow on the thermo-

stat R-W circuit after the circulating blower

motor has started.

Set the heat anticipator according to the ther-

mostat manufacturer's instructions for heat

anticipator settings.

VentilAire

Bracket

Figure 27. Ventilation Bracket

VENTILATION

Ventilation must be provided for homes built to

HUD Manufactured Homes Safety and Con-

struction Standards. This ventilation can be

supplied by the VentilAire III or VentilAire IV

accessories (see Table 13). Alternate means

to provide the ventilation air must meet the

requirements of all applicable local and federal

codes.

For downfiow models, a bracket is supplied

with the furnaces to allow the use of the VentilAire

III or VentilAire IV accessories. The bracket is

installed on the right hand side at the top of the

cabinet, as shown in Figure 27. The bracket

can be fastened using the self-drilling screws

supplied with the unit.

For upfiow models, the means to provide the

required ventilation must be incorporated into

the upflow furnace base or the return air

ductwork to the furnace.

For installation of the VentilAire III or IV, follow

the instructions provided with the VentilAire kit.

START-UPANDADJUSTMENTS

General

Prior to start-up, verify that:

.The line voltage power leads are securely

connected, that the polarity of the con-

nections is correct, and that the furnace

is properly grounded.

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).

The roll-out and vent safety manual reset

switches are closed. If necessary, press

the red button to reset aswitch. See

Figure 31 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 identi-

fying 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

1. 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.)

5, After the furnace has run for approximately

five minutes, set the thermostatbelow 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:

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

lowest temperature setting.

Turn OFF the main gas supply to the

appliance at the manual valve outside of

the appliance casing.

Remove the control access panel /Iou-

vered door.

4. Move the appliance gas valve lever/knob

to the "OFF" position.

5. Turn OFF the electrical power to the

....._lSpli_+n_:e.

Verifying and Adjusting Firing Rate

The firing rate must be verified for each instal-

lation to prevent over-fldng the furnace.

NOTE: The firing rate must not exceed the

rate shown on the furnace rating plate. At

altitudes above 2000 ft. it must not exceed

that on the rating plate less 4% for each

1000 ft.

Use the following procedure to determine the

firing rate:

1. Shut off all other gas fired appliances.

TIME FOR

ONE REVOLUTION

(SECONDS)

GAS FLOW RATE (CUBIC FEET PER HOUR)

CUBIC FEET PER REVOLUTIONOF

METER

1 5 10

150 750 1500

138 692 1385

129 643 1286

120 600 1200

113 563 1125

106 529 1059

100 500 1000

95 474 947

90 450 900

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

TIME FOR

ONE REVOLUTION

(SECONDS)

100

102

104

106

108

110

112

114

116

118

120

CUBIC FEET PER REVOLUTIONOF

METER

1 5 10

45 225 450

44 220 439

43 214 429

42 209 419

41 205 409

40 200 400

39 196 391

38 191 383

38 188 375

37 184 367

36 180 360

35 176 353

35 173 346

34 170 340

33 167 333

33 164 327

32 161 321

32 158 316

31 155 310

31 153 305

30 150 300

Table 12. Gas Flow Rate

Start the furnace and allow it to run for at

least three minutes.

Measure the time (inseconds) required for

the gas meter to complete one revolution.

Convert the time per revolution to cubic

feet of gas per hour using Table 12.

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:

Time for 1 revolution of a gas meter

with a 1 cubic foot dial = 40 seconds.

From Table 11 read 90 cubic feet per

hour of gas.

Heating value of the gas (obtained

from gas supplier) = 1040 Btu per

cubic foot.

Firing rate = 1040 x 90 = 93,600 Btuh.

Relatively small adjustments to the firing

rate can be made by adjusting the gas

manifold pressure.

See the "High Altitude Derate" section for

additional information on firing rate at

elevations above 2000 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 10.0 in. water column for use with LP gas.

To adjust the manifold pressure, remove the

regulator cap and turn the adjusting screw

clockwise to increase pressure or counter-

clockwise to reduce pressure. Replace the

regulator cap after adjustments are complete.

Verifying and Adjusting Temperature Rise

Verify that the temperature rise through the

furnace is within the range specified on the

furnace rating plate. Temperature rises out-

side the specified range could result in prema-

ture 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

Timing

24 V I

Ra_ Signal

Cornm_

lead8 NeUVldll UnuoedMOlo_

E_c_cnlc I 4 e- ;=

_._ ..... > _--° ._,_

Figure 28. Blower Speed Tap Location

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 28 showthe

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

after the gas valve is closed. This timing can be

changed using the BLOWER OFF timing switch

opposite the terminal block on the control board

(See Figure 28).

Verifying Burner Operation

To verify operation of the burners, make sure

that the blower compartment door is in place

and that there is power to the furnace. Set the

thermostat above room temperature and ob-

serve the ignition sequence. The flame can be

observed through the small clear window 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 veri_ing ignition, set the ther-

mostat below room temperature and verify that

the burner flame extinguishes completely.

Verifying Operation of the Supply Air

Limit Switch

To verify operation of the supply air limit switch,

make surethatthe blower dooris in place and that

there is power to the furnace. Completely block

the retum airflow to the furnace by installinga

close-of[ plate in place of or upstream of the

filter(s). Set the thermostat above room tem-

perature and verify that the Sequence of Opera-

tion 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 imme-

diately 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 31 shows the location of each of the

functional components described below. If

any component of the furnace must be re-

placed, use only factory authorized replace-

ment parts. Contact your distributor for the

approved replacement parts.

Flame Sensor - The flame sensor acts to

prove that flame has carried over from the

igniter to the opposite end burner. If no flame

is sensed, the furnace will be shut down

automatically.

Gas Valve - The gas valve controls the flow

of gas to the burners. When the gas valve is

energized it automatically opens and regu-

lates the gas pressure in the manifold.

Pressure Switch - The pressure switch veri-

fies that the inducer is drawing the combustion

gases through the heat exchanger. It also

senses a blocked condensate drain condition.

Vent Pressure Switch (Downflow models

only) - The vent pressure switch reacts to

blockage in the vent or combustion air piping.

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 160°F, This

switch protects the plastic flue system and the

inducer from over-temperature conditions.

FlameRoll-OutSwitch - This switch pro-

vides flame roll-out protection to the furnace

and combustion air inlet pipe.

MAINTENANCE

It is recommended that the furnace be checked

yearly. At a minimum, this check should include

the following items:

/ WARNING:

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 intothe

occupied space can crate potentially

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(s)

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.

For the upflow model, the air filter is located

underneath the blower in the blower compart-

ment. To remove the filter, first remove the

lower door. Then, slide the filter backwards until

the edge of the filter clears the front flange of the

furnace. Lift the filter up over the flange and then

remove. Reinstall the filter in the reverse man-

ner. Ensure that the filter is centered over the

return opening of the furnace, and is captured

by the fastener at the rear of the furnace.

For the downflow model, the filter is at the top of

the furnace. The filter can be removed by lifting

the filter upwards and out of the opening. Rein-

stall the filter in the reverse manner. Ensure that

the filter is securely held by the braces on either

side of the return air opening.

/t WARNING:

Never operate the furnace without a filter

in place. Dustand lint in the retum aircan

build up on internal components,

resulting in loss of efficiency, equipment

damage, and possible fire.

Lubrication

The bearings in the circulating air blower mo-

tors are pre-lubricated and sealed at the fac-

tory. No further oiling of the bearings is re-

quired for the life of the motor.

Condensate Drain Assembly

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 shortened service life.

Heat Exchanger and Burner Maintenance

The furnace should operate for many years

without excessive soot buildup in the flue

passageways, however, the flue passage-

ways, the vent system, and the burners should

be inspected and cleaned (if required) by a

qualified service technician annually to ensure

continued 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.

Do not place combustible materials on or

against the furnace cabinet or the vent pipe.

Do not store gasoline or any other

flammable vapors and liquids inthe 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 properly

installed and is not being affected by

drafts or heat from lamps or other

appliances.

Sequence of Operation

Operating sequences for the heating, cooling,

and fan modes are described below. Refer to

the wiring diagrams (Figures 31 and 32) and

the low voltage field wiring diagram (Figure 26)

for more details.

Heating Mode:

1. 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

control board will energize the inducer

and the conditioned air blower. All other

system functions will be inoperable until

the limit circuit closes. While the limit is

open, the red LED will pulse at a rate of 1

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 will close. If the

pressure switch does not close after 10

seconds the fault LED will blink 2 times

repetitively and the inducerwill 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:

Initial Power up: After 30 seconds of

igniter warm-up the gas valve (24 VAC)

will then open. The igniter circuit will stay

energized for 3 seconds after the gas

valve opens.

After Initial Power up: The control has a

programmed adaptive ignition feature

which varies the warm-up period as fol-

lows: If ignition is successful the warm-up

is reduced by 3-seconds on each subse-

quent call for heat until ignition failure

occurs. Upon ignition failure, the warm-up

is _ by 3-seconds on the next try.

If successful, the timing remains fixed at

this level. In general, whenever ignition

failure occurs the warm-up interval is

increased by 3-seconds on the next try.

And if successful, it remains there. Mini-

mum and maximum warm-up time limits

are set at 6 and 54-seconds, respec-

tively.

7. The furnace control must prove flame via

the flame sensor 5 seconds after the gas

valve opens. If flame is sensed, all burn-

ers are on and the igniter cools off. If no

flame is sensed, the gas valve closes

immediately and the inducer continues to

run. A second trial for ignition (step 6)

begins if no flame is sensed. On the fifth

try for ignition, the furnace control is locked

out and the red LED will blink 4 times

repetitively. The thermostat must be

opened for at least ten seconds to reset

the furnace control after a lock out. Oth-

erwise, the furnace will attempt another

ignition sequence in 1 hour.

8. The furnace control energizes the circu-

lating air blower on the heating speed 30

seconds after the gas valve circuit is

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.

12.

Thefurnacecontrolkeepsthecirculating

air blowerenergizedfor 120 seconds

(factoryset)or 60, 90,or 180seconds

(fieldadjustable).(SeeFigure28.)

Abnormalconditions:Ifalimitopensduring

operation,the inducerandcirculatingair

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

specified delay (factory set at 120 sec-

onds).

Cooling Mode:

1. 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:

1. On a call for fan operation, the thermostat

applies 24 VAC to the G terminal on the

furnace control board.

2. The circulating air blower is energized

immediately on the heating speed.

3. 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 aspecified delay

(factory set at 120 seconds).

Furnace Fails to Operate

If the furnace does not operate check the

following:

1. Is the thermostat operating properly?

2. Are the blower compartment door(s) 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.)

If the furnace locks out after 5 attempts for

ignition, it will try again every hour ifa call for

heat remains. If the inducer and circulating air

blowers are operating, and items 1 through 8

have been checked, press the red reset but-

ton on the vent safety switch. (See Figure 30.)

If the furnace operates after depressing the

reset button, contact a qualified service tech-

nician to identify and repair the problem.

If furnace continues to not operate, depress

the red reset buttons on the flame roll-out

switch. If the furnace operates after depress-

ing the reset button, contact a qualified service

technician to identify and repair the problem.

FURNACE ACCESSORY KITS

Kit Order Number

Fossil Fuel Kit 914762

A/C Coil Box 914958

Sloped Roof VentilAire IIt Kit 914098

Sloped Roof VentilAire IV Kit 914229

Soffit VentilAire Kit 917201

Concentric Vent Termination Kit 904176 (3 Inch)

for horizontal and vertical venting) 904177 (2 Inch)

Horizontal Exterior Vent

Mounting Kit 2"PVC 902373

3"PVC 902375

Neutralizer Kit - All Models 902377

Table 13. Accessory Kits

1 Manh_old

2 Flame Sensor (Not Shown)

3 Gas Valve

4 Roll-Out Limit Switch (155°F)

5 Pressure Switch

6 Control Board, Integrated

7 Blower Door Switch

8 Vent Safety Limit Switch (160°F)

9 Transformer

10 Limit Switch

11 Blower Assembly

12 Inducer Blower (with gasket)

13 J Trap Hard Tube

14 In-Line Drain Assembly

15 Burner Box Assembly (NaL and LP Gas Ready)

16 Header Outlet Box

17 Cased CoilWrappar

18 Filter (I 8 5/8 x 26 1/2 x 114)(Not Shown)

19 Attachment Bracket

20 Turbulator (NotShown)

21 Coupling Neoprene

22 Orifice, Inducer (Not Shown)

23 Inshot Bumer (Not Shown)

24 Natural and LP Gas Orifice (Not Shown)

25 Igniter (Not Shown)

26 Heat Exchanger Assembly (NotShown)

27 Capacitor Assembly, I0 MFD, 370V (Not Shown)

28 Blower Wheel CCW (Not Shown)

29 Motor - 1/2 HP (4 Speed) (Not Shown)

30 Access Doors, Set (Not Shown)

Upflow Furnace

1Man_oU DownflowFurnace

2 Flame Sensor (Not Shown)

3 Gas Valve

4 Roll-Out Limit Switch (155=F)

5 Pressure Switch

6 Integ rated Control Board

7 Blower Door Switch (Not Shown)

8 Vent Safety Limit Switch (160°F)

9 Transformer

10 Limit Switch

11 BlowerAssembly

12 Inducer Blower (with gasket)

13 JTrap HardTube

14 In-Line Drain Assembly

15 Burner BoxAssembly

16 Header OuUetBox

17 Cased CoilWrapper

18 Filter (18 x 20 x 1) (Not Shown)

19 VenUlAire Bracket

20 Attachment Bracket

21 Turbulator(Not Shown)

22 Auxiliary Limit Switch (120°) (Not Shown)

23 Inducer Orifice (Not Shown)

24 Inehot Bumer (Not Shown)

25 Natural and LP Gas Orifice (Not Shown)

26 Igniter (Not Shown)

27 Heat Exchanger Assembly (No1Shown)

28 Capacitor Assembly, 10 MFD, 370V (Not Shown)

29 Blower Wheel CCW (Not Shown)

30 Motor- 112HP (Net Shown)

31 Access Door (Not Shown)

Figure 30. Location of Major Components

Legend

Field Wiring

Fa_owWidng:

High Voltage _--

LowVoltage --

FAULT CONDITION

Power On

Umlt Circuit Open or External Load On "W"

Pressure Switch Stuck Open

Pressure Switch Stuck Closed

Ignition Failure (Check Ground)

tt5 VAC & Neutral Reversed or .o Ground

False Flame or Gas Valve Relay Shorted

Power Off

FAULT CONDITION

Low Flame Sensor Signal

Flame Present

LIGHT

1 FLASH

2 FLASHES

3 FLASHES

4 FLASH ES

5 FLASHES

Continuous

OFF

FLAME

YELLOW

LIGHT

Continuous

Flash

Ifanyof theoriginalwireas suppliedwith

the fumace mustbe replaced, itmust be

replaced with wiring material having a

temperature rating of at least 105 °C.

Use copper conductorsonly.

WD#710062A

Figure 31. Upflow and Downflow Furnace Wiring Diagram

INSTALLATION/PERFORMANCE 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 __ LP/Propane

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?

IllIIIIIilllIIIlllllfIIIII

708120B

708120B (Replaces 708120A)

Specifications and illusb'ations subject tochange without

notice and without inclJrringobligations, Printed inU.S.A.

O'Fallon,MO NORDYNE (_,o_)

NORDYNE Furnace/Heater, Gas Manual L0612164

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