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Direct Vent (Sealed Combustion) Forced Air Gas Furnaces
M3RL Series 90+ Downflow Condensing Furnace
For installation in:
1. Manufactured Homes
2. Park Models and Manufactured Buildings
3. Modular Homes/Buildings
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death or property damage.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
-WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Leave the building immediately.
• Immediately call yourgas supplierfrom a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
-Installation and service must be performed by a qualified installer, service agency, or the gas supplier
J
BW Models
BWT Models
J
ADVERTISSEMENT:
RISQUE D'INCENDIE OU D'EXPLOSION
Le non=respect des avertissements de securite pourrait entrainer des blessures graves, la mort ou des dommages materiels.
- Ne pas entreposer ni utiliser de I'essence ni d'autres vapeurs ou liquides inflammables dans le voisinage de cet appareil, ni de tout autre appareil.
-QUE FAIRE S'ILYA UNE ODEUR DE GAZ
• Ne pas tenter d'allumer aucun appareil.
• Ne toucher a aucun interrupteur electrique; n'utiliser aucun t61ephone dans le b_timent.
• €:vacuer I'immeuble immediatement.
• Appeler immediatement le fournisseur de gaz en employant le tel6phone d'un voisin. Respecter la lettre les instructions du fournisseur de gaz.
• Si personne ne repond, appeler le service des incendies.
-L'installation et I'entretien doivent Ctre effectues par un installateur qualifie, un organisme de service ou le fournisseur de gaz.
WARNING:
Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply.
Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage.
Refer to this manual.
For assistance or additional information consult a qualified installer, service agency or the gas supplier.
LEAVE THESE INSTRUCTIONS WITH THE HOMEOWNER.
2
TABLE OF CONTENTS
General ......................................................
4
Unit Dimensions ..................................
4
Shipping Weights ................................
4
Furnace Specification ........................
4
Air Flow Data .....................................
4
Owner's information ................................
5 installation Requirements ......................
6
Location ..............................................
8
Clearance ...........................................
8
Circulating Air Supply ..........................
10
Return Air Provisions ............................
10
Air Distribution Systems ......................
11
Duct Connector Selection ....................
11
Duct installation ....................................
12
Venting and Combustion
Air Requirements ..........................
14
Venting Requirements ..........................
14
Vent Table ........................................
15
Vent Pipe Material ............................
16
Vent Pipe Length and Diameter ....... 16
Vent Pipe installation ........................
16
Pipe Routing & Support ....................
16
Location of Outdoor Termination ..... 18
Horizontal Venting ............................
18
Vertical Venting ................................
19
Vent Freezing Protection .................
19
Concentric Vent Termination ........... 20
Drainage of Condensate
From Furnace ................................
20
Gas Supply and Piping .........................
21
Leak Check ......................................
22
High Altitude Derate .........................
22
Pressure Switch ...............................
22
Conversion .............................................
22
Lighting and Adjustment
of the Appliance ............................
24
Electrical Wiring .....................................
24
Line Voltage Wiring ..........................
25
Low Voltage Wiring ..........................
26
Ventilation ...............................................
26
Start-up and Adjustment .....................
26
Start-Up Procedure .........................
26
Shut Down Procedure .....................
27
Verifying and Adjusting Firing Rate.
27
Temperature Rise ............................
27
Verifying and Adjusting
Verifying Burner Operation .............. 28
Verifying Operation of the
Supply Air Limit Switch .................
28
Description of Components ................ 29
Furnace Accessories .............................
29
Maintenance ...........................................
29
Combustion Air and Vent System .... 29
Air Filter(s) .......................................
29
Lubrication ........................................
30
Condensate Drain Assembly ........... 30
Blower Compartment .......................
30
Heat Exchanger and Burner
Maintenance ..................................
30
System Operation Information ............. 30
Sequence of Operation ....................
30
Furnace Fails to Operate .................
31
Component Location ............................
32
Wiring Diagram .......................................
33
Installation/Performance
Checklist .........................................
35
Application
M-Manufactured Home
Furnace Series
Comfort Model
RL - Condensing Downflow
M3RL-060A-A
Heating Capacity input, BTUH (000')
Table 1. Model Identification
W
L
LReturn Air
BlankFront
Configuration
T - Top
Door Color
W - White
G - Gray
Cabinet Dimensions
A - 56"x 19-3/4" x 23-3/4"
B - w/Coil Cavity,
76" x 19-3/4" x 23-3/4"
Electrical Code
A - 1PH, 60 Hz, 120 VAC
3
GENERAL
-19-7/8 --
--3-17/32
COMBUSTION
--1-11/16
EXHAUST
VENT
AIR INTAKE
16
--3-17/32
COMBUSTION
--1-11/16
EXHAUST
VENT
AIR INTAKE
"\
/
SIDE RETURN
/\
KNOCKOUTS
L--- ......_
m
7/3243.
I12
27-25/32
"B" Cabinet
Figure 1.
Furnace Dimensions
"A" Cabinet
_
Top Return Knockouts
Y
Top View
(AW and BW Models)
_
1,000
:
I
_ 12.000
21.000
Top Returrl
(BWT
(
Opening
Models)
21-15/16--
Furnace Model
M3RL 060A AW
M3RL 060A BW*
M3RL 080A AW
M3RL 080A BW*
Shipping
Weight
(Ibs)
150
170
155
175
* May include suffix - T
Table 2.
Shipping Weight
Furnace Specifications / Airflow Data
Furnace rVlodel No.
M3 RL-060
M3 RL-080
Furnace
Input
Btuh
60,000
80,000
Furnace
Output
Btuh
54,000
72,000
Temp.
Rise @ Motor Motor
.3"WC °F HP
35 - 65 1/2
Speed
High*
Med-High
Med-Low
Low**
High*
35 - 65 1/2 Med-High
Med-Low**
Low**
External Static Pressure ( Inches Water Column)
0.1
0.2
0.3
0.4
0.5
CFM
CFM
1660
CFM
1599
CFM
1544
CFM
1474 1410
1512
1340
1467
1304
1416
1261
1363
1217
1304
1158
1176
1660
1142
1599
1108
1544
1025
1474
966
1410
1512
1340
1176
1467
1304
1142
1416
1261
1108
1363
1217
1025
1304
1158
966
Note: Data is for Operation with Filter.
* Factory Wired Cooling Tap
• * Factory Wired Heating Tap
Table 3.
Furnace Specifications/Airflow Data
4
Recommended
A/C
Ton
4
3
2.-1/2
2
4
3
2.-1/2
2
/ WARNING:
Do not use this appliance if any part has been submerged underwater, 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 underwater,
NOTICE TO INSTALLER
Installer is advised to follow carefully all instruc- tions and warnings in this manual to insure maximum performance, safety, and operating efficiency of these appliances.
Improper installation may create hazardous conditions, and will void the appliance warranty.
GENERAL
General Description
The M3 series gas furnaces are listed direct vent (sealed combustion) forced air furnaces for use with both natural and propane gases.
The M3 series is a Category IV and type FSP furnace.
The M3 furnace series has been certified to the ANSI Z21.47/CSA2.3-2001 for use in the United States and Canada and to the
UL307B --1995 for use in the United States.
These furnaces may be installed in:
1. Manufactured Homes.
2. Park Models and Manufactured buildings
3. Modular Homes/Buildings
The following are safety guidelines with references to their specific sections or pages in the manual.
1.
Use only type of gas approved for this furnace.
Refer to the furnace rating plate.
2.
Install this furnace only in location and position as specified in pages 8 - 14 of these instructions.
3.
Provide adequate combustion and ventilation air to the furnace space as specified in pages 13 - 20 of these instructions.
4.
Combustion products must be discharged outdoors, connect this furnace to an approved vent system only, as specified in pages 14-20 of these instructions.
5.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leak to check all connections.
6.
Always install furnace to operate within the furnace's intended temperature rise range with a duct system that has an external static pressure within the allowable range, as specified in page 4 of these instructions. See Table 3 and the furnace rating plate.
7.
When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.
Note: This section only applies to furnaces installed with side or top return air.
8.
A gas4ired furnace for installation in a residential garage must be installed as specified in page 9 of these instructions.
9.
The furnace is not to be used for temporary heat of buildings or structures under construction.
M3 series furnaces are air conditioning ready as shipped. The furnace cooling capacities of the blower motor speed taps are shown in
Table 3. Table 2 lists the shipping weights for the M3 series furnaces.
OWNER INFORMATION
NORDYNE has been involved in the design of products for the manufactured home industry since the first manufactured home or trailer was built.
NORDYNE originated the sealed combustion system, which separates the furnace com= bustion system from the living area of the home, now a standard for the manufactured home industry.
NORDYNE engineers developed the first central 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.
Followthe instructionsinthis bookletcarefully andthis appliancewill providemanyyearsof superiorperformance.
If you wish to coolyour homeautomatically with a centralair conditioningsysteminvestiavailablefromyour heatingand coolingcontractor.Thesesystemsare designedto work bestwith your NORDYNEfurnaceand have beencarefullyengineeredto deliveroptimum performancewhen mated with NORDYNE manufacturedhomefurnaces.
6.
Providing instructional training on how to light and operate the furnace.
7.
Furnace problems caused by installation of an air conditioner, heat pump or other air comfort devices.
8.
Revising installation of the furnace flue assembly.
9.
Adjusting or calibrating of thermostat.
10. Any construction debris which falls into the flue system.
Carefully review these responsibilities with your manufactured housing dealer, service company or gas supplier so there will be no misunderstanding at a later time.
and ventilatingsystemsspecificallydesigned
CAUTION: with your manufacturedhomeretailer,your heating and cooling contractor or your factory8000PhoenixParkway,O'Fallon,MO
63368ifyouarenotabletolocateasourcefor yourarea.
MANUFACTURER WARRANTY,
RESPONSIBILITIES
OWNER'S
It is the sole responsibility of the homeowner to make certain the gas furnace has been correctly set up and converted to the proper fuel (L.P. gas or Natural gas) and adjusted to operate properly. All gas furnaces are manufactured for
Natural gas and must be field converted when using LP. gas.
• Never attempt to alter or modify this furnace or any of its components.
• Never attempt to repair damaged or
inoperable components.
Such action could cause unsafe operation, ex-
plosion, fire and/or asphyxiation.
• If a malfunction has occurred, or if you feel that the furnace is not operating as it should, contact a qualified service agency or gas utility for assistance.
INSTALLATION STANDARDS
A warranty certificate with full details is included with these instructions.
However, NORDYNE will not be responsible for any costs found necessary to correct problems due to improper 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 ductwork in the home found to be faulty.
3.
Correcting wiring problems in the electrical 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.
Installer shall be familiarwith and complywith all codes and regulations applicable to the installation of these heating appliances and related equipment.
In lieu of local codes, the installation shall be in accordance with the current provisions of one or more of the following standards.
a. Federal Manufactured Home Constructions
& Safety Standard (H.U.D.
Title 24, Part
3280.707[a][2]) b. The Standard for Manufactured Home Installations (Manufactured Home Sites, Communities, and Set-Ups) ANSI A225.1
and/or
CAN/CSA-2240 MH Series).
c. American National Standard (ANS1=119.2/
NFPA=501C) for all recreational vehicle installations.
d. American National Standard (ANSI=Z223.1/
NFPA-54) and/or CAN/CGA B149 for all gasfired 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.
6
CE g6nerateurd'air chauddoit Ctre installe conformement auxcodesIocaux.EnI'absencedecodelocal, respecterla normeANSIZ223.,1,instituleNationalFuelGasCodeoulescodesd'installation the side wall horizontal vented gas fueled equipment.
It shall be the responsibility of the property owner to secure the services qualified installation detectors.
licensed of hard professionals wired carbon for of the monoxide
The National Fuel Gas Code is available by writing:
American National Standards Institute, Inc.
1430 Broadway
New York, NY 10018
NFPA publications are available by writing:
National Fire Protection Association
Batterymarch Park
Quincy, ME 02269
IMPORTANT NOTE
INSTALLATION
COMMONWEALTH
MASSACHUSETTS
The
REQUIREMENTS
OF
Commonwealth of
=
Massachusetts requires compliance with regulation 248 CMR
5.00
for installation of the side wall horizontal venting.
The following requirements shall be satisfied.
INSTALLATION OF CARBON
MONOXIDE DETECTORS
At the time of installation of the side wall horizontal vented gas fuel equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed.
In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by
ALL MODELS
Front
Back
Sides
Vent
Top
Duct (Plenum) w/Coil Box w/o Coil Box
(within 3 feet)
CLOSET
Inches
1"
0
0
0
6
0
1/4
ALC OVE
Inches
1"
0
0
0
6
0
1/4
*Note: For 1" clearance, use a fully Iouvered door with at least
400 square inches of free airflow area.
Table 4. Minimum Clearances
In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
In the event that the requirements of this subdivision can not met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
APPROVED CARBON MONOXIDE
DETECTORS
Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
SIGNAGE
A metal or plastic identification plate shall be permanently mounted to the exterior of the building at minimum height of eight feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW.
KEEP CLEAR OF ALL OBSTRUCTIONS."
INSPECTION
The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation inspection, inspector unless, observes upon carbon monoxide detectors and signage installed in accordance with the provisions of 248 CNR
5.08(2)(a) 1 through 4.
Exemptions: The following equipment is exempt frolTl 248 CMR 5.08(2)(a) 1 through 4:
Product approved side wall horizontally vented f_eled equipment installed in room or structure separated from the dwelling, building structure used in whole or in part for residential or purposes.
MANUFACTURERREQUIREMENTS-
GASEQUIPMENTVENTINGSYSTEM
NOT PROVIDED.
When the manufacturer of a Product Approved side wall horizontally equipment does not vented provide the gas fueled parts for venting the flue gases, but identifies" special venting systems", the following requirements shall be satisfied by the manufacturer:
1.
The reference system"
"special instructions included venting shall with the appliance be or
2.
equipment instructions; and
The "special venting systems" shall be Product Approved by the board, and the instructions for that system shall include a part list and detailed installation instructions.
A copy of all installation instructions for all
Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.
LOCATION
The furnace must be installed on a level surface, and as close to the center of the air distribution system as possible.
See Figure 1 for overall dimensions to determine the required clearances in hallways, doorways, stairs, etc.
to allow the furnace to be moved to the instal= lation 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.
This furnace is certified for use on wood floor= ing. The furnace must be installed on a solid surface and must be level front-to-back and
, A Single trunk duct
I
_" Dual trunk duct
B w/crossover connector
Transition duct
C [p w/branches
II
7
[']____[1_
D
II
Figure 2. Non-Platinum
Supply Duct System
II
Top View of Duct
Connector
I I
Figure 4. Connector Dimensions
Use Duct Connector
If "X" (Floor Cavity) is: Model Part Number:
English Metric (mm) Finger Tab Screw Dowr
7/8" 22 901987 904008
2"
4 1/4"
6 1/4"
51
108
150
901988
901989
901990
904009
904010
904011
8 1/4"
10 1/4"
12 1/4"
210
260
311
901991
901992
901993
904012
904013
904014
Table 5. Duct Connector Sizes
FLOOR CAVITY
(depth equal to "X" in Table 5)
Figure 3. Floor Cavity
8
FELT-SEAL
REDUCER _\
SPACERS
(1) FINGER TAB DUCT CONNECTOR ONLY
(2) SCREW DOWN DUCT CONNECTOR ONLY
Figure 5. Duct Connector
,&
X SEE
TABLE 5 side=to=side. This furnace must not be installed directly on carpeting, tile, or any combustible material other than wood flooring.
The furnace may be installed on combustible flooring when installed on a Nordyne duct connector (see
Table 5).
( )OPENING TO DUCT
(1) WITH PLATE (C) REMOVED
OPENING BECOMES
13-1/4" x 13-1/4"
(2) WITH PLATE (C) REMOVED
OPENING BECOMES
13"X 13". WITH REDUCER
IT IS 13"X 10-1/8",
The ductwork within 3 feet of the furnaces without the A/C coil box must be installed such that surfaces are at least 1/4" from combustible materials.
When installed in a residential garage, the fur= nace must be positioned so the burners and the source of the ignition are located no less than
18 inches above the floor and protected from physical damage by vehicles.
HOLE \\\\\ lO"
FLo2
23-1/4"
Figure 6. Closet or Alcove
24
3-1/4
2-1/4
_/////_.REAR
F I 142-_/2 _ 2-3/4'_
WALL OF CLOSET bR_,_co_E_
I
I
i
g
-3/4
14-1/2
17-29/32 u_
--
--
3-19/32
1-3/4
J
_VENT
COMBUSTION AIR INTAKE
_-FUEL LINE ENTRY
2 fl ....
' 1-1/4
ALT FUEL LINE
/ I _
/ !. _
ENTRY /'
_,, _
/
_-
12-7/8
!__q,_
.....
15-1/2 _
FLOOR CUT-OUT
FOR OPTIONAL
COOLING COIL
FOR NON-PLATINUM
SERIES UNITS
I
_ 1-3/4
FURNACE
OUTER DOOR
Figure 7. Floor Cut-Out Dimensions
21-7/16
9
CIRCULATING AiR SUPPLY
z WARNING:
Products of combustion must not be allowed to enter the return air openings of the furnace or the circulating air supply, Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death,
The floor or platform on which the furnace
is mounted must provide sound physical support of the furnace with no gaps, cracks, or sagging between the furnace and the floor or platform,
The circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert, stove, etc,
GENERAL
Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems
(NFPA No. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning
Systems (NFPA No. 90B).
RETURN AIR PROVISIONS
U.S.A. home manufacturers shall comply with all of the following conditions to have acceptable return air systems for closet installed forced air heating appliances: a. Regardless of the location, the return air opening into the closet shall not be less than specified in the appliance's listing.
b. Means shall be provided to prevent 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. Closet installations must use a Iouvered door having a minimum free area of 235 sq. in.
when located 6" from furnace. For clearance between 1" and 6" from furnace, requirements are a Iouvered door with minimum of
235 sq. in. free area, with the openings in closet door directly inline with the Iouvered openings in the furnace door. For 1" clearance from furnace, use a fully Iouvered door with at least 400 sq. in. of free airflow area.
d. The cross-sectional area of the return duct system leading into the closet, when located in the floor or ceiling shall notbe less than 235 square inches.
e. 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 carpeting, boxes and other objects.
f. Materials located in the return duct system must have a flame spread classification of
200 or less. This includes a closet door if the furnace is in a closet.
g. Noncombustible pans having 1" upturned flanges are located beneath openings in a floor duct system.
h. Wiring materials located in the return duct system shall conform to Articles 300-22 of the National Electrical Code (ANSI Cl/
NFPA-70).
i. Gas piping is not run in or through the return duct system.
j.
Test the negative pressure in the closet with the air-circulating fan operating at high speed and the closet closed.
The negative pressure is to be no more negative than minus 0.05 inch water column.
k. For floor return systems, the manufactured home manufacturer shall affix a prominent marking on or near the appliance where it can be easily read when the closet door is open.
The marking shall read:
CAUTION:
HAZARD OF ASPHYXIATION: Do not cover or restrict return air opening,
I. 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.
10
DUCTEDRETURNAIR
M3furnaceswithmodelnumbersendinginAW or BWarefactoryconfiguredfor the returnair to flow throughthe front Iouvereddoor.The
returnairmayalsobeattachedto eithersideor the top of the furnacecabinetusing a field installedkit.RefertoTable10fortheNORDYNE
ductedreturnkitP/Nnumber.Thelocationand
sizeof the sideandtop returnair connections areshownin Figure1.Thefiltersizefortheside
returnairis20"x20"x 1".Fortopreturnthefilter
size is 24" x 16"x 1".
Three typical distribution systems are illus- trated in Figure 2. Location, size, and number of registers should be selected on the basis of best air distribution and floor plan of the home.
DUCT CONNECTOR SELECTION
PLATINUM SERIES a. For Platinum ready construction use the 14" round plenum, p/n: 903896.
NON=PLATINUM SERIES
M3 furnaceswith modelnumbersendingin
BWTarefactoryconfiguredforthe returnairto enterthe top of the furnace.
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.
a.
b.
Determine depth of floor cavity from surface of floor to top of supply air duct
(See Figure 3).
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.
MOUNTING
PLATE
FLOOR
OPENING
REAR WALL
FUEL
LINE
HOLES
SUPPLY AIR DUCT
Figure 8. Mounting Plate
SCREWS
BEND
UNDER
CONNECTOR
DUCT
TABS
OPENING
MOUNTING
PLATE
Finger Tabbed
Duct Connectors
Screw Down
Duct Connectors
Figure 9. Duct Connector Types
Platinum Series
CONNECTION
11
DUCT INSTALLATION
Required floor, ceiling, and roof cut-out openings must be carefully located to avoid misalignment of the furnace (see Figures 6 & 7).
Installation procedures are suggested for typical furnace installations and need not be followed in the exact listed sequence.
CUT OUT FLOOR OPENING & FUEL LINE
HOLE a. Determine center of closet or alcove (Figures 7 & 8).
b. Locate center of the floor opening, measured 10" from the rear wall, and mark cutout measuring approximately 14-1/2" by 14-
1/2" (+ 1") for model duct connector used
(refer to Figures 4 & 5).
c. Locate center of gas line hole, measured 23-
1/4" from the rear wall and 6-5/8" to the left of center of the floor cut=out (See Figure 6) or
5-1/4" to the left of center of the floor cut-out, or for entry through right-side of furnace measured 9" to the right of center of the floor cut-out.
d. Cut out floor opening and one gas line hole.
CUT DUCT OPENING (FINGERTABBED ONLY) a. Place duct connector through the floor opening with bottom tabs resting on top of the supply air duct.
b. 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 1/16" larger than area marked.
INSTALL FURNACE MOUNTING PLATE a. Place mounting plate (supplied within duct connector) at rear of the floor opening (See
Figure 9).
TABS
111--.....
TABS
I/--.....
1.
INSERT DUCT PLENUM
INTO DUCT CUT-OUT.
CONNECTOR 2.
BEND BOTTOM TABS OVER
AND ONTO THE UNDERNEATH
DUCT SERVICE.
Figure 10. Installation of Duct Connector
Duct Connector t-_
12
Duct _ Narrow Duct t)
STEP 1.
Figure 11. Narrow Duct Installation
Fold Back Flap "B"
STEP2.
Cut
Fold Back Flap"B"
"--_
Cut- Out
Area "A"
Cut- Out
Area"A"
Lines "__lt "B"'B" _ Duct
Fold Back Flap"B"
Top of Duct
Fold Back Flap "B"
Bend Duct Connector Tabs Up and Over- (along length of duct)
/ \
STEP 4.
Staple Folded Duct
Flap (typ) to side of Duct
Connector
-k
Duct7
Figure 12. Alternate Installation
/
SLIDE FURNACE
ALL
ONTO
THE WAY
MTG.
BACK
PLATE
Figure 13. "A", "B", & Platinum
Cabinet Furnaces
/
SLIDE
ALL THE
FURNACE
WAY BACK
ONTO MTG PLATE iNSTALLiNG FINGER TABBED DUCT
CONNECTORS a. 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, page 12.
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 sealant, mastic, or tape is used to provide a better seal, it should be approved by applicable national or local codes.
ALTERNATE ATTACHMENT METHODS
Figure 14. "A" Cabinet Furnace on 911969
Coil Cabinet (Non=Platinum Series) iNSTALLiNG PLATINUM
ROUND DUCT CONNECTOR
SERIES 14" a. Place duct connector through the floor opening. (See Figure 9).
b. Secure duct connector to floor.
iNSTALLiNG SCREW DOWN DUCT CON=
NECTOR a. Apply a bead of caulking, mastic, or other approved sealant around bottom side of 1/2" flange and restrictor plate, when applicable.
b. Locate the duct connector over duct and carefully lower screw down duct connector into place.
c. Once duct connector is located on duct, temporarily hold in place while fastening duct connector to the floor using flat head screws or nails. Be sure flanges of duct connector stay in contact with the duct.
d. Screw plenum to duct making sure a seal is made between the duct and the duct connector. Additional screws may be added if required.
e. Cut away along edge of flange allowing the center to drop into the duct. Remove section of duct with caution, as edges will be sharp.
This procedure may also be used to install a furnace duct connector to narrow metal ductwork where insufficient clearance prevents bending of the duct connector tabs at the side(s) of the duct. See Figure 12, page 12.
1. Score and cut the top of 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 (Step 3, Figure 12).
3. At the front=to-back of duct run (Area "A"), bend the duct tabs and secure them directly to the duct.
4. At Area "B", bend the duct tabs up and back over, around the duct connector, (See
Step 3).
5. Fold/form the duct flap against the side of the duct connector and attach as shown, (See
Step 4). Use three (3) staples (minimum) on each duct flap OR, if a 2X block/joist is not provided, use two (2) sheet metal screws
(minimum) on each duct flap. An alternate attachment method is acceptable, as long as the plenum is securely attached.
6. Tape the duct flap edges with an approved tape for a leak-free joint.
iNSTALL FURNACE a. Remove furnace outer door(s) and bottom fuel line knockout.
b. Place furnace onto duct connector and center with floor opening.
13
c. Slideontomountingplate.(Bottomrearslots on furnaceshouldengagewith mounting platetabs.) d. Securefrontwith one(1) fastenerat each corner(SeeFigure13 or 14).
NOTE:Additionalfastenersmay be usedat rear,sidesor throughdoorframe,as desired, to securefurnaceto closetor alcoveframing.
/ WARNING:
Furnace 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 furnace.
VENTING AND COMBUSTION AIR
REQUIREMENTS
/!X CAUTION:
Snow must not be allowed to restrict or block the combustion air intake or vent pipes.
CAUTION:
Do not allow debris to fall into the fur= nace.
This could cause unsafe operation and voids the furnace warranty.
VENTING REQUIREMENTS
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.
/ WARNING:
FURNACE MUST NOT BE COMMON
VENTED WITH OTHER APPLIANCES.
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 components may be properly.
strained
Furnace by temperature and could fail prematurely.
high
/ WARNING:
The combustion air piping must not be blocked or restricted in any manner.
General
This section specifies installation requirements for 2-pipe combustion air piping.
The capacity table provided in this section applies to the maximum equivalent lengths of vent and combustion air intake pipe.
These condensing furnaces are classified as
"Category IV" appliances, which require special venting materials and installation procedures.
Category 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 requirements of Table 6, page 15. to the
The furnace must be vented to the outdoors.
14
APPLICATION
PVC,CPVC or ABS
SCH. 40 Pipe Size
Model M3RL 060
Model M3RL 080
MAXIMUM
DIRECT VENT, DUAL
PIPE LENGTH (ft.)*
Inlet/Outlet
3"
50
50
3"
50
50
*NOTES
1.
2.
3.
Subtract
Two45
3.5 ft. for each additional 3" 90 degree degree elbows are equivalent elbow.
to one 90 degree elbow
4.
5.
One short radius elbow is equivalent elbows.
to two long radius
Do not include termination elbows in calculation of vent length
This table is applicable for elevations from sea level to 400C ft. For higher elevations, decrease vent pipe lengths by 8% pel
1000ft.
of altitude.
6.
Onlythe above pipe materialsare approved for usewith these condensing furnaces.
Table 6. Vent Table
[] VENT TERMINAL (_ AiR SUPPLY INLET [] AREA WHERE TERMINAL IS NOT PERMITTED
A = Clearance above grade, veranda, porch, deck, balcony, or snow accumaulation level
B -- Clearance opened to window or door that may be
Canadian Installations 1
12 inches (30 cm)
6 inches (15 cm) for appliances < 10,000
Btuh (3 kW), 12 inches (30 cm)for appliances > 10,000 Btuh (3 kW) and <
100,00 Btuh (30 kW), 36 inches (91 cm)for appliances >100,00 Btuh (30 kW)
C = Clearance to permanently closed window
D = Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal
E = Clearance to unventilated soffit
F = Clearance to outside corner
G = Clearance to inside corner
H = Clearance to each side of center line
extended above meter/regulator assembly
I = Clearance to service regulator vent outlet
J = Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance
3 feet (91 cm) within a height 15 feet above the meter/regulator assembly
3 feet (1.83 m)
6 inches (15 cm) for appliances < 10,000
Btuh (3 kW), 12 inches (30 cm)for appliances > 10,000 Btuh (3 kW) and <
100,00 Btuh (30 kW), 36 inches (91 cm)for appliances >100,00 Btuh (30 kW)
K = Clearance to a mechanical air supply inlet 6 feet (1.83 m)
7 feet (2.13 m) 1"
US Installations 2
12 inches (30 cm)
6 inches (15 cm) for appliances < 10,000
Btuh (3 kW), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kW) and <
50,000 Btuh (15 kW), 12 inches (30 cm) foi appliances > 50,000 Btuh (15 kW)
6 inches (15 cm)for appliances horizontally appliances
,
< 10,000
Btuh (3 kW), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kW) and <
50,000 Btuh (15 kW), 12 inches (30 cm) foi
> 50,000 Btuh (15 kW)
3 feet (91 cm) above if within 10 feet (3 m)
L -- Clearance above paved sidewalk or paved driveway located on public property
M -- Clearance under veranda, porch deck, or balcony
12 inches (30 cm) $ ,
In accordance
2 In accordance with the current with the current
CSA B149.1
ANSI Z223.1
Natural Gas and Propane
/ NFPA 54 National Fuel
Installation
Gas Code
Code
1" A vent shall not terminate directly above a sidewalk local installation manufacturer's or paved driveway that is located codes, installation and the requirements instructions." between two single family
$ dwellings
Permitted
For and serves only if veranda, clearances not both dwellings.
specified porch, deck, or balcony in ANSI Z223.1
/ NFPA is fully
54 open or CSA on a minimum
B149.1, the of two following sides beneath statement shall the floor.
be included:
"Clearance in accordance with of the gas supplier and the
Figure 15. Vent Termination Clearances for Direct Vent Furnaces
15
/ WARNING:
CARBON MONOXIDE POISONING
HAZARD
1.
Seal any unused openings in the venting system
2.
inspect the venting system for proper size and horizontal pitch, as required in the National Fuel
Gas Code, ANSi Z223.1
or the
CAN/CGA B 149 Installation Codes and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3.
So far as is practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.
4.
Follow the lighting instructions.
Place the appliance being inspected in operation.
thermostat so appliance
Adjust shall operate continuously.
5.
Turn on clothes dryers and any other appliance not connected to the venting system.
Turn on any
exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed.
Do not operate a summer exhaust fan.
6.
Close fireplace dampers.
7.
Test for spillage from draft hood equipped appliance at the draft hood relief opening after 5 minutes of main burner operation.
Use the flame of a match or candle.
8.
If improper venting is observed during any of the above tests, the venting system must be corrected
in accordance with the National
Fuel Gas Code, ANSI Z223.1/NFPA
54and/or CSA B149.1, Natural Gas and Propane Installation Codes.
16
.
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, other their fireplace gas dampers burning previous and any appliance conditions
Material .......................................
Standard
Schedule 40PVC ............................ D1785
PVC-DWV .......................................
D2665
SDR-21 & SDR-26 .......................... D2241
ABS-DWV .......................................
D2661
Schedule 40 ABS ............................
F628
Foam/Cellular Core PVC ................ F891 to of use.
It must not be vented in common with any other appliance, even if that appliance is of the condensing type.
Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to escape through such appliances or vents.
Do not vent the furnace to a fireplace chimney or building chase.
If removing an existing furnace in a venting system, the venting system may not be properly 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 placed in operation, while any other appliances connected to the venting system are not in operation:
Vent Pipe Material
Vent and combustion air pipe and fittings must be one of the following materials and must conform to the indicated ANSI/ASTM standards:
Note: In Canada, vent materials must be certified to the Standard for Type BH Gas Venting
System, ULC $636.
Any certified ULC $636 material must not be interchanged with unlisted or non certified pipes and/or fittings. The plastic components, specified primers and glues of the certified vent system must not be intermixed with any other manufacturer's vent systems or parts.
Cement and primer must conform to ATSM
Standard D2564 for PVC and Standard D2235 forABS.
When joining PVC piping toABS, use an appropriate solvent cement and procedure
Downflow Furnace
Seal/Caulk
Around Pipe -at Building
90 ° E bow \
\
\\
\\
!_
I
',
\"\
\
'<,
_
_
_ _
Coupling // i' r-i
Vent
_!3
9/t 6",_
1 7/8"
See Vent Table 4
Combust on
Air intake Pipe _...
Straps or Other Suitable
Supports at Minimum of
I
I
/
_
"1_
_ _
""
_ p
.i
I
,
_,-_ ._.
i (1_
I
5 ft" Inltervals
/ _\\ i-i ii
\, r-i
I_ _
Top View
MIn
[_J,l_ i
Normal Snow Level
_
_
4,
........
Wal Upward Pitch = 1/4" Per F°°t
Wail Outlet Exhaust Vent
First Support
Furnace
Should
Connection be as Close to as Possible
Combustion Air intake Pipe Furnace
A j
Offset with
Vent for Adequate
Dimensional Clearance
Exhaust
Vent
PVC or
ABS pipe
3"x 2"
Reducer
Figure 16. Horizontal Venting
Support System on Vertical Rise
Below Joints
First support should be as
close to furnace as possible
Intake Pipe
Combustion Air !_
...Vent
Upward Pitch
1/4" per foot
" Combustion Air intake Pipe
®
J-..
per the piping manufacturer's and ASTM Standard D3138.
Figure 17. Vertical Venting recommendation any condensate flows back to the furnace where it can be disposed of through the condensate disposal system.
Vent Pipe Installation
Pipe Routing and Support
Route piping as directly as possible between the furnace and the outdoors and remember that routing affects pipe length limitations per
Table 6. Locate the combustion air intake and the vent exhaust in the same atmospheric pressure zone - i.e. both must exit the building though the same portion of exterior wall or roof.
Vent piping must be sloped upwards not less than 1/4" per foot in the direction from the furnace to the terminal.
This is to ensure that
The quality considered.
CAUTION:
Combustion air must not be drawn from occupied atmosphere, spaces and a corrosive of outdoor intake is not located air must also
Be sure that the combustion be air near a source of solvent
17
fumes or other chemicalswhich can cause corrosionof the furnacecombustionsystem.
.
similar recessed areas, and do not terminate above any public walkways.
Select the point of wall penetration where the minimum 1/4 inch per foot of slope up can be maintained.
itsweightdoesnotbeardownonthefurnace.
Supportsmustbe at intervalsno greaterthan five feet,andat smallerintervalsif necessary to ensurethatthereare no saggingsections to trapwater(SeeFigures16 & 17).
CAUTION:
These condensing furnaces have been certifiedfor installationwith zero clearance
For optimal performance vent furnace through wall which experiences the least exposure to winter winds.
However,it is goodpracticetoallowspacefor conveniencein installationand service.
Horizontal Venting
Vent and combustion air intake terminations must be as shown in Figure 19 unless the concentric vent termination kit is used.
Location of Outdoor Terminations
Vent and combustion air intake terminations must be located to ensure proper furnace operation and to conform to applicable codes.
Figure 15 illustrates necessary distances from the vent termination to windows and building air intakes.
In Canada, the Canadian Fuel
Gas Code takes precedence over these instructions.
Specifically, distance requirements with all minimum 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 18 for alternate method to achieve 12" above snow level.
2.
The minimum distance for a direct vent (2= pipe) installation from any door, openable window, or air gravity inlet is 1 ft. below, 1 ft. horizontally, or 1 ft. above.
3.
The vent termination shall be a minimum of
3 ft. above any forced air inlet within 10 ft.
4.
The vent termination shall be located at least 4 ft. horizontally from any electric meter, gas meter, regulator and any relief equipment.
These distances apply only to U.S. installations. In Canada, the Canadian Fuel Gas Code takes precedence.
5.
Avoid areas where condensate drainage may cause problems by dropping on plant-
ers or patios, etc.
Also ensure that exhaust gases will not impinge on windows or building surfaces, which may be compromised or damaged by condensation.
Do not install the vent terminal such that exhaust is directed into window wells, stairwells, under decks or into alcoves or z WARNING:
Ensure that the combustion air vent and the exhaust vent are configured as shown in Fig.
19.
improper vent termination can cause recirculation of the flue gases. This may result in furnace vibration, in severe cases, the furnace will cycle, due to the intermittent contact between the flame and the flame sensor.
If you note these oscillations occurring, check the vent configuration.
Make sure that the exhaust vent does not have a 90 degree termination.
For horizontal venting, either the Horizontal
Exterior Vent Mounting Kit or the Concentric
Vent Termination Kit may be used (See Table
12).
For Canadian installations please refer to the
Canadian Installation Code (CAN/CGA-B 149.1
or 2) and/or local codes.
The Horizontal Exterior Vent Mounting 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 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 retained on both sides of the wall by
18
VentConfiguration
12"
Minimum
Snow Level.
height above _
Wail ' '_
12" Min.
19" Max.
Support
Outside _
__ _
1,,2"
" __
:__ insulation ol
Equivalent
12"Above
Normally
Expected
Snow
Level
Exhaust Vent
Option B
Mounting
FacepIate Secured
Combustion
Air Inlet
Exhaust Vent
Option C
Exhaust Vent
ion A
_fJ jJ 12" Min, to
Normal Snow Level
,o,o,
Grade
Level red),
Figure 18.
Vent
Alternate
Installation
Horizontal the couplings, and 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 exterior 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 between 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.
A= 12" Above Roof or
Snow Accumulation Level
Elbow
5-Min.
36" Max.
Figure 19.
Exhaust and Combustion Air
Pipe Clearances
4.
Insure the combustion air inlet pipe has a 90 degree termination elbow, and is pointing downward as shown in Figures 19 & 20.
Note that a combustion air intake must be provided with an elbow opening downward.
When the vent pipe must exit an exterior wall close to the grade or expected snow level, a riser should be provided as shown in Figure 18.
Insulation is required to prevent freezing of this section of pipe.
Vertical Venting
For vertical venting, either the configuration shown in Figure 20 or the Concentric Vent
Termination Kit may be used. Vertical venting is one of the shortest routing methods when
.... Exhaust
Plumbing Vent
Roof Boot
(Typ. Both Pipes)
Note: If terminations meet= ing these vertical requirements exceed the maximum height for safe transit, the vent and combustion air intakes may be shipped with the home for assembly on site. The furnace must be labeled to notify the installer/ user not to use the furnace until the vent and combustion air intake terminations are installed.
Figure 20.
Vertical Vent Termination
19
.._.__.__...__-_ Collector Box
Step 1 :
Step 2:
Clamp _iiill
Step 3:
I Burner Box j _ Keep
Floor _ _-'Y"
AIt. Drain
AIt. Drain
Concentric
Figure 21. Furnace with Condensate Drain Trap Assembly piping vents for furnaces.
The M3 furnace operates trouble=free when the furnace is installed with a shorter vent.
• The inlet for the combustion intake pipe must be extended at least one foot above the roofline or snow accumulation level.
• The outlet of the vent must be extended at least
10 inches above the inlet of the combustion air intake pipe.
• The vent as well as the combustion air intake pipe should be located on the same side of the roof. Both pipes must not be closer than 5 inches apart. They should not be separated more than 36 inches.
The roof penetration must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing.
Termination spacing requirements from the roof and from each other must be per Figure 20.
Vent Termination
A concentric vent termination is approved for use with these furnaces (See Table 12).
For proper installation of the concentric vent termination, follow the installation instructions provided with the kit.
NOTE: The condensate drain should tected from freezing when in unheated spaces.
The furnace densate
Do not condensate
The condensate kinked.
is supplied drain trap.
install with an internal
CAUTION: additional drain, traps be proconin the drain may exit through the left side panel, the right side panel, or through the left or right hole on the bottom panel. (See Figure
21). Ensure that the flexible drain hose is not
The condensate should drain from the plastic collector box (location "A", Figure 21) as drop= lets or a small stream. If you notice the furnace has operated for more than 5 minutes without draining or the red status light on the control board is pulsing a 2-blink code follow the steps below.
DRAINAGE OF CONDENSATE
FROM FURNACE
/t WARNING:
The condensate produced by the furnace must be drained, Do not connect a water supply to the drainage hose of the furnace,
1.
Remove the collector box soft tube at location "A", Figure 21 and verify the exit from the collector box is clear of any debris or obstructions.
2.
Replace this tube and verify the fit to the header spout is air tight. Air will be drawn into the header if this connection is not tight.
3.
Check other tube connections along the drain system.
Verify that all are air tight.
NOTE: Industry research studies indicate that when condensate is routed to an active drain,
2O
householddetergents,etc.,bufferitsacidity.If
thedrainis notactivelyusedorifcodesrequire, obtaina neutralizerkit(SeeTable10,page28).
satetubingarerequiredas NORDYNEcannot beheldresponsiblefor water leakagewhich occursdueto loosehoseconnectionsor
NOTE: When pressure testing gas supply lines at pressures greater than 1/2 psig (14 in.
water column), the furnace must be disconnected 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.
GAS SUPPLY AND PIPING
General
This furnace is equipped for bottom, left, or right side gas entry. Typical gas service hookups are shown in Figure 22. When making the gas connection provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace.
Main
All gas piping must be installed in compliance with local codes and utility regulations.
Some local regulations require the installation of a manual main shut=offvalve and ground joint union 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 provisions stated in the Federal Manufactured Home Standard
(H.U.D Title 24, part 280) and the National Fuel
Gas Code (ANSI Z223.1/NFPA-54) or (CAN/
CGA B149) installation codes.
A drip leg should be installed in the vertical pipe run to the unit. Table 11 (page 34) lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.
NOTE: Gas piping must not be run in or through air ducts, gas vents, etc.
Compounds used on threaded joints of gas piping must be resistant to the actions of liquefied petroleum gases.
CAUTION:
Do not use matches, lighters, candies, or other sources of open flame to check for gas leaks.
Control
Board
Burner
Box
Gas
Floor
To Gas
Supply
"J
AIt. Gas
Line Entry
Figure 22.
Typical Gas Piping
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 4,000 feet above sea level for US and Canada. If the elevation for the furnace location is higher than 4,000 feet above sea level, the furnace input must be derated by using the appropriate orifice size listed in
Table 12, page 34.
21
NOTE:The densityof air decreaseswith increasingelevationabovesea level.This retheunitbederatedbyusingsmallergasorifices or lowermanifoldpressure.
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 qualified service personnel, using only factory authorized or approved parts.
The required conversion orifices are supplied with the furnace.
WARNING:
This conversion kit shall be installed by a qualified service agency in accordance
with the manufacturer's instructions and all applicable codes and requirements of the authority having jurisdiction.
If the information in these instructions is not followed or production exactly, of
a fire, carbon explosion monoxide may result causing property damage, personal injury or loss of life.
The qualified service agency is responsible for the proper installation of this kit.The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer's
with the kit. instructions supplied
/!XWARNING:
DO NOT REMOVE OR DEFACE THE
ORIGINAL RATING PLATE.
CAUTION:
Turning Off The Fuel Supply:
1.
Set the room thermostat to "OFF" or its lowest temperature setting.
2.
Turn OFF the main gas supplyto the appliance at the manual valve, outside of the appliance casing.
3.
Remove the control access panel / Iouvered door.
4.
Move the appliance gasvalve lever/knob to the "OFF" position.
5.
Turn OFF the electrical power to the appliance.
Removing 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 ignitor 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 fasteners and remove the burner 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 burner box, lift the burner box upwards and then remove the box from the unit.
Removing The Burner Orifices:
1.
Remove the four (4) fasteners that secure the gas manifold to the burner box, as shown in Figure 25. 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.
The gas supply shall be shut off prior to disconnecting the electrical power, before proceeding with the conversion.
CAUTION:
Caution: orifices.
Do not re-drill
If the orifice the burner size must be changed, use only new orifices.
2.
Carefully remove the burner orifices from the gas manifold, as shown in Figure 25.
22
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 alti=
tude; natural gas or LP gas).
Honeywell
Valve
Figure
PRESSURE
REGULATOR
Regulator
II_1__
23. Convertible
Cap
OTHER
OF CAP
SIDE
Pressure
Converting the Unit to 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 in= stalling at altitudes above 4,000 feet to install the proper orifices, shown in Table
12. When installing the new orifices, DO
NOT use pipe joint compound on the orifice threads.
Screw the orifices into the manifold by hand until snug to eliminate cross threading, then tighten with a wrench.
Before installing an orifice, check the face or side of the orifice for the drill number to ensure that it is the appropriate size.
3.
For the conversion to the alternate fuel, the gas valve regulator cap must be turned over, as shown in Figure 23.
You will unscrew the cap and reinstall for your installation. After reinstalling the cap, you will be able to read "NAT" for the conversion to natural gas or "LP for the conversion to LP gas.
Figure 24. Burner Inspection
Burner
Orifices
\
Gas
Manifold
Flame
Observation
Burner
Box Inlet
Pressure
Tap
Access
Cover
Plate Inlet Gas
Valve
Figure 25.
Typical Installation For Sealed
Burner Box With Access Cover Plate
Reinstalling the 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 burners 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.
Reinstall the burner access cover plate.
6.
Reconnect the ignitor at the 2 position plug.
7.
Reconnect the flame sensor wire to the burner box.
23
Pressure Gauge Installation
NOTE: For natural gas installations, the incom- ing 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 between 11.0" WC and 14.0" WC.
This pressure can be checked at the inlet end of the gas valve using a pressure gauge or U-tube manometer, which must be installed according to the manufacturer's supplied instructions.
LIGHTING AND ADJUSTMENT OF
THEAPPLIANCE
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 appliance.
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 a point above room temperature to begin the heating cycle of the unit.
6.
Check that the unit ignites and operates properly.
Refer to the installation instruc- tions provided with your unit for the normal operating sequence.
7.
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.
Type of Fuel Manifold Pressure in. WC
Natural Gas:
Propane (LP) Gas:
3.5
10.0
Table 7. Manifold Pressure
NOTE: Until all of the air is bled out of the gas line, the hot surface ignitor 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 ignitor will try again to ignite the main burners.
This process may have to be repeated several times before the burners will ignite.
Once the burners are lit, check all gas connections for leaks again with the soap and water solution.
If the solution bubbles there is a gas leak which must be corrected.
Do not use an open flame to check for gas leaks.
Manifold Pressure
The gas valve for the M3 furnace series is equipped with a special conversion pressure regulator cap. The pressure regulator cap is factory set. if the gas valve is converted from natural gas to propane gas or vise versa, the manifold pressure of the gas valve will be set to pressure listed in Table 7.
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 off the power at the disconnect or the main service panel before making any electrical connections,
ELECTRICAL WIRING
General
Electrical connections must be made in accordance with all applicable local codes and ordinances, and with the current revision of the
National Electric Code (ANSI/NFPA 70).
For Canadian installations electrical connections and grounding must be done in accordance with the current Canadian Electrical
Code (CSA C22.1 Part 1) and/or local codes.
If
24
any of the originalwire as suppliedwith the furnacemustbereplaced,it mustbe replaced /!X CAUTION: of 105°C.Referto thefurnacenameplateand
Table8 for electricalrequirements.
Line Voltage Wiring
The linevoltage(115volt)tothe furnacemust be suppliedfrom a dedicatedbranchcircuit containingthe correctfuse or circuitbreaker for the furnace.See Table8. An electrical switchshouldbe readilyaccessiblefromand within sight of the furnace. See the Wiring
Diagramlabelin the furnacefor moredetails.
The furnacecabinetmust have an uninterrupted,unbrokengroundto minimizeinjury shouldan electricalfaultconditionoccur.The
controlsusedin this furnacerequirean earth groundto operateproperly.Acceptablemethodsforgroundingareelectricalwireor conduit approvedforelectricalgroundservice.Do not usegas pipingas an electricalground.
NOTE:Properline voltagepolaritymust be maintainedin orderfor the controlsystemto operatecorrectly.Verifythattheincomingneutral lineis connectedto thewhitewireandthe incoming"hot"line is connectedto the black wireinthefurnacejunctionbox.Thefurnacewill
not operateunless polarityand ground are properlyconnected.See Figure26.
Label all wires prior to disconnection when servicing controls.
Wiring errors can cause improper and dangerous operation,
Verify proper operation after servicing,
Common
Leads
Connect
Neutral _
.....
and/or Humidifier
H....
::ul_l
24 V
_OM _
Timing
Flame Signal TWIN
BIowerOff O
Status
Light (Red) O
Neutrals o
_
> Z/]
_
Humidifier
_
_ _ 3: © x
Ir_nq _ _ _ _ _ o° _- _
IIIIII
tl
II
If
I
11
Tap |
/ I LElectronic Air Tap
(.5A@ 120 VAC)
(.5A@ 120 VAC) _ I These motor speed taps are
L not used for two-stage models
Figure 27.
Blower Speed Tap Location
Furnace
Input
(Btuh)
45,000
80,000
Cabinet
Width
(in.)
19 3/4
19 3/4
Nominal
Electrical
Supply
115-60-1
115-60-1
Maximum
Operating
Voltage
127
127
Minimum
Operating
Voltage
103
103
Maximum
Furnace
Amperes
9.7
9.7
Time-delay fuses or HACR-type circuit breakers are required.
Recommended Thermostat
Thermostat Wire Gauge
24
22
2O
2 - wire
(Heating)
55 ft.
90 ft.
140 ft.
18 225 ft.
Minimum
Wire
Gauge
14
14
Wire Length
4 or 5 wire
(Cooling)
25 ft.
45 ft.
70 ft.
110 ft.
Maximum
Fuse or Circuit
Breaker Amps _
15
15
Table 8.
Electrical Data
Field Supplied
Fused Service
Panel
\
Field Supplied
Disconnect w/in
Sight of Furnace
\
Junction Box (may be int. or ext.
to the furnace).
These connections can be made disconnect in the field at the furnace.
supplied
Wh e (Neu ra) |
...."1
White /, "_
.... I.......... L-_L-_.-_L-:
....._---
[ Ground
Panel Connector
......
__
Field Line Voltage Wiring
Factory Line Voltage Wiring
Figure 26.
Line Voltage Field Wiring
White
Ground
25
/!X ATTENTION:
Lots des operations d'entretien des commandes, _tiqueter tous les flies avant des les d_connecter.
Toute erreur de c,iblage peut _tre une source de danger et de panne.
S'assurer du bon fonctionnement
I'appareil apr_s tout entretien. de
[-I
,, [m__
_ I_
F_[_j
_ Condensing
I C°ndensingunit
Unit control Box oo oo(--1_
Connect m _;-m
R & W __LN. ....
ForI _1
Heating I _m- .....
'-I-
;0 CO=M [_
3 Amp
Fuse i
O_
-i-_1
24==V
:_t®l
_ Flame Only _
Room
Thermostat
.....
TWIN
Signal Light O
Status Light _
(Red)
Low Voltage Wiring
Install the thermostat per the manufacturer's instructions.
The low voltage (24 volt) connec= tions from the thermostat are made at the terminal strip on the control board in the furnace.
See Figure 28 for the proper connections for heating only (two=wire) and heating/cooling
(four=wire) applications.
The recommended minimum wire gauge for thermostat wiring is shown in Table 8 (page 25).
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 components; or
2.
Measure the current flow on the thermostat
R-W circuit after the circulating blower motor has started.
Set the heat anticipator according to the thermostat manufacturer's instructions for heat anticipator settings.
VENTILATION
Ventilation must be provided for homes built to
HUD Manufactured Homes Safety and Construction Standards. This ventilation can be supplied by the VentilAire III or VentilAire IV accessories. See Table 10 on page 34.
Alternate means to pro-vide the ventilation air must meet the requirements of all applicable local and federal codes.
For installation of the VentilAire Ill or IV, follow the instructions provided with the VentilAire kit.
NOTE: The "Y" terminal on the
UTEC control board must be connected to the thermostat for proper cooling mode operation.
FIELD WIRING
Low Voltage
Connections
-i-
C = I
Neutrals
Unused Motor Leads
I_,_1 c'_ _ _'o > _ _ _-
I III I II II
Figure 28.
Low Voltage Field,
Four=wire Heating/Cooling Applications
START=U P AND ADJUSTMENTS
General
Prior to start-up, verify that:
.
The line voltage power leads are securely connected, that the polarity of the connections is correct, and that the furnace is properly grounded.
2.
The thermostat wires (R, W, Y, and G) are securely connected to the correct leads on the terminal strip of the circuit board.
.
The natural gas line service pressure must not exceed 10.0 in. water column (0.36
psig), and must not be less than 4.5 in.
water column (0.16 psig). For LP gas the line service pressure must not exceed 14 in. water column (0.51 psig), and must not be less than 11.0 in. W.C. (0.40 psig).
.
The roll-out and vent safety manual reset switches are closed.
If necessary, press the red button to reset a switch.
See
Figure 26 for location.
DO NOT install a jumper wire across a switch to defeat its function.
If a switch reopens on start=up,
DO NOT reset the switch without identifying and correcting the fault condition which caused the switch to trip.
26
5.
6.
1.
2.
3.
The blower door switch in the line voltage
The gas connections
Start=Up
Close line has been are leak tight.
Procedure
Set the thermostat voltage to the furnace.
Follow the procedures circuit.
purged given on the operating instructions label attached to the furnace.
door is in place, closing the and all to the lowest setting.
the disconnect(s) to provide line
4.
Set the thermostat above room temperature and verify the sequence of operation.
(See the SEQUENCE OF OPERATION.)
.
After the furnace has run for approximately five minutes, set the thermostat below room temperature and verify steps 9 - 11 of the
SEQUENCE OF OPERATION (page 31).
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.
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 / Iouvered door.
.
.
Move the appliance gas valve lever/knob to the "OFF" position.
Turn OFF the electrical power to the appliance.
Verifying Firing Rate
The firing rate must be verified for each installation to prevent over-firing the furnace.
NOTE: The firing rate must not exceed the rate shown on the furnace rating plate. At altitudes above 4000 ft. it must not exceed that on the rating plate less 4% for each
1000 ft.
Use the following procedure to determine the firing rate:
1.
Shut off all other gas fired appliances.
2.
Start the furnace and allow it to run for at least three minutes.
.
.
.
Measure the time (in seconds) required for the gas meter to complete one revolution.
Convert the time per revolution to cubic feet of gas per hour using Table 9. See page 28.
Multiply the gas flow rate in cubic feet per hour bythe 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 = 60 seconds.
* From Table 9 read 60 cubic feet per hour of gas.
* Heating value of the gas (obtained from gas supplier) = 1000 Btu per cubic foot.
* Firing rate = 1000 x 60 = 60,000 Btuh.
6.
See the "High Altitude Derate" section for additional information on firing rate at elevations above 4,000 ft.
The gas valve regulator is set at a nominal value of 3.5 in. water column for use with natural gas.
The manifold pressure must be set at 10.0 in.
water column for use with LP gas.
Verifying and Adjusting Temperature Rise
Verify that the temperature rise through the furnace is within the range specified on the furnace rating plate. Temperature rises outside the specified range could result in premature heat exchanger failure.
Place thermometers in the return and supply air stream as close to the furnace as possible.
The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings.
Adjust all registers and duct dampers to the desired position and run the furnace for fifteen minutes before taking any temperature readings.
The temperature rise is the difference between the supply and return air temperatures.
For typical duct systems, the temperature rise will fall within the range specified on the rating plate with the blower speed at the factory recommended setting, if the temperature rise measured is outside the range specified, it may be necessary to change the blower speed.
Lower blower speeds will increase the temperature rise and higher blower speeds will decrease the temperature rise.
27
TIME FOR
ONE REVOLUTION
(SECONDS)
24
26
28
30
32
44
46
48
50
34
36
38
40
42
58
60
62
52
54
56
64
GAS FLOW RATE (CUBIC FEET PER HOUR)
62
60
58
69
67
64
56
82
78
75
72
106
100
95
90
86
1
150
138
129
120
113
CUBIC FEET PER REVOLUTION
METER
5
750
692
643
600
563
OF
10
1500
1385
1286
1200
1125
529
500
474
450
429
409
391
375
360
1059
1000
947
900
857
818
783
750
720
346
333
321
310
300
290
281
692
667
643
621
600
581
563
TIME FOR
ON E R EVOLUTION
(SECOoNDS)
9O
92
94
96
82
84
86
88
19080
102
104
106
108
110
112
114
116
118
120
Table 9. Gas Flow Rate
32
31
31
33
33
32
30
36
35
35
34
4O
39
38
38
37
CUBIC FEET PER REVOLUTION
1
METER
5
45
44
43
42
41
225
220
214
209
205
OF
10
450
439
429
419
409
200
196
191
188
184
180
176
173
170
400
391
383
375
367
360
353
346
340
167
164
161
158
155
153
150
333
327
321
316
310
305
300
The furnace is equipped with a multispeed motor. Heating and cooling speed selection is made by moving the leads on the integrated control board located in the furnace. The wiring diagram on the furnace and Figure 30 show the speed taps for adjusting motor speed.
If it is desired that the blower operate at the same speed for heating and cooling, tape off the terminal of the unused blower wire. Install the jumper wire, found in the plastic instruction bag, across the HEAT and COOL taps on the control board. Reconnect the desired blower tap to the piggyback quick connect.
The blower control is designed to start the circulating air blower 30 seconds after the gas valve is opened.
The blower control is factory wired to turn the blower motor off 120 seconds 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 27).
Verifying Burner Operation
To verify operation of the burners, remove front door and ensure that the door switch is in the "on" position (see Figure 29). Set the thermostat above room temperature and observe the ignition sequence.
The flame can be observed through the small clear window on the burner box. The burner flame should carry over be= tween all burners. The flames should be blue, without yellow tips. Flames should extend from each burner without lifting, curling, or floating.
28
After verifying ignition, set the thermostat below room temperature and verify that the burner flame extinguishes completely.
Replace the front door.
Verifying Operation of the Supply Air
Limit Switch
To verify operation of the supply air limit switch, make sure that the blower door is in place and that there is power to the furnace.
Completely block the return airflow to the furnace by installing a close-off plate in place of or upstream of the filter(s).
Set the thermostat above room temperature and verify that the Sequence of
Operation is as described in these instructions.
The supply air limit switch should function to turn off the gas valve within approximately five minutes.
The circulating air and combustion blowers should continue to run when the supply
FURNACE ACCESSORY
A/C Coil Box
Kit
Side Return Air Kit
Top Return Air Kit
Sloped Roof VentilAire III Kit
Sloped Roof VentilAire IV Kit
Soffit VentilAire Kit
Concentric Vent Termination Kit
(for horizontal and vertical venting)
Order Number
911969A
904003
904015
914098
914229
917201
904176 (3")
904177 (2")
Horizontal Exterior Vent
Mounting Kit (3" PVC)
Neutralizer Kit - All Models
902375
902377
Table 10.
Accessory Kits
KITS
air limit switchopens.Removethe close-off
MAINTENANCE
opens.Ifthefurnaceoperatesformorethanfive
minuteswith no returnair, setthe thermostat
It is recommended that the furnace be checked yearly. At a minimum, this check should include the following items: the furnace,and replacethe supplyair limit switch.
z: WARNING:
DESCRIPTION OF COMPONENTS
Figure 29 shows the location of each of the functional components described below. If any component of the furnace must be replaced, use only factory authorized replacement parts.
Contact your distributor for the approved replacement parts.
To avoid electricshock, personal injury, or death, turn off the power at the disconnect or the main service panel before performing any maintenance.
z WARNING:
Flame Sensor The flame sensor acts to prove that flame has carried over from the ignitor to the opposite end burner. If no flame is sensed, the furnace will be shut down automatically.
Gas Valve = The gas valve controls the flow of gas to the burners.
When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold.
Pressure Switch = The pressure switch verifies that the inducer is drawing the combustion gases through the heat exchanger.
It also senses a blocked condensate drain condition.
Holes in the vent pipe or heat exchanger can cause products of combustion to enter the occupied space.
Replace the vent pipe or heat exchanger if leaks are found.
Failure to prevent products of combustion from being circulated into the occupied space can crate potentially hazardous conditions, including carbon monoxide poisoning, that could result in personal injury or death.
Deck Limit Switch (Auxiliary Limit) - The deck limit protects the furnace filter temperature from overheating when the motor has malfunctioned.
If the deck switch opens, the power for the furnace will shut down (see Figure
29).
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 obstruction or blockage must be removed prior to operating the furnace.
Air Filter
Supply Air Limit Switch = The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature.
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 construction dust has been removed.
Vent Safety Switch - The vent safety switch shuts the furnace down if the outlet flue gas temperature increases above 145°F.
This switch protects the plastic flue system and the inducer from over-temperature conditions.
/ WARNING'.
Flame Roll-Out Switch - This switch provides flame roll=out protection to the furnace and combustion air inlet pipe.
Never operate the furnace without a filter in place, Dust and lint in the return air can build up on internal components, resulting in loss of efficiency, equipment damage, and possible fire,
29
Lubrication furtheroilingofthe bearingsis requiredforthe lifeofthe motor.
CondensateDrain Assembly
(i.e.avoidkinkinghoses).Alsomakesureall
hoseclampsaretightto avoiddrawingair into the system.
Blower Compartment
The blower compartment should be cleaned monthly during the heating and cooling seasons 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 passageways, 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 in the vicinity of the furnace.
Change or replace the air filters monthly during any period when the circulating blower is operating regularly.
Always replace the doors on the furnace after servicing.
Do not operate the furnace without all doors and covers in place.
Avoid operating the furnace when windows and doors are open.
Be sure that the thermostat is 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 30) 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 (overtemperature limit switch, flame rollout switches and blocked vent switch in series). 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 inducer will continue to run until the switch is closed.
6. The inducer will pre=purge for 30 seconds and then the igniter will start its warm-up as follows:
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 follows: If ignition is successful the warm=up is reduced by 3-seconds on each subsequent
30
call for heat until ignitionfailure occurs.
Uponignitionfailure,the warm-upis increasedby 3-secondson the nexttry. If successful,the timing remainsfixed at this level. In general,wheneverignition failure occurs the warm-up interval is increasedby 3-secondson the next try.
And if successful,it remainsthere.Minimumand maximumwarm-uptime limits are set at 6 and 54-seconds,respectively.
7. Thefurnacecontrolmustproveflamevia theflamesensor5 secondsafterthe gas valveopens.If flameis sensed,all burners are on andthe ignitorcoolsoff. If no flame is sensed,the gas valve closes immediatelyandthe inducercontinuesto run. A secondtrial for ignition(step 6) beginsif no flameis sensed.On the fifth tryforignition,thefurnacecontrolislocked out and the red LED will blink 4 times repetitively. The thermostat must be openedfor at leastten secondsto reset the furnacecontrolaftera lockout.Otherwise,the furnacewill attemptanother ignitionsequencein 1 hour.
8. The furnace control energizesthe circulatingair bloweron the heatingspeed
30 secondsafterthe gasvalvecircuitis energized
.
9.
When the thermostat has been satisfied, gas valve is de-energized.
10. The inducer is de-energized after a 30second postpurge.
11. The furnace control keeps the circulating air blower energized for 120 seconds
(factory set) or 60, 90, or 180 seconds
(field adjustable).
(See Figure 27.)
12. Abnormal conditions: If a limit opens during operation, the inducer and circulating air blower continue to operate. The gas valve is de-energized immediately.
The blowers continue to operate until the limit closes.
When the limit closes the inducer blower is de-energized immediately.
The circulating air blower continues to operate for the specified delay (factory set at 120 seconds).
2.
The furnace control energizes the circulating 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 contactor.
opening the compressor
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 continuous ON position at the thermostat and is then switched to AUTO, the circulating blower will operate for a specified delay
(factory set at 120 seconds).
Furnace Fails to Operate
If the furnace does not operate check the following:
1.
Is the thermostat operating properly?
2.
Is the front door in place?
3.
Is the furnace disconnect closed?
4.
Has the circuit breaker tripped or the control board fuse burned open?
5.
Is the gas turned on?
6.
Are any manual reset switches open?
7.
Is the filter dirty or plugged?
8.
Is the flame sensor coated?
(Remove and clean with emery cloth.)
9.
Is the deck switch open?
If the furnace locks out after 5 attempts for ignition, it will try again every hour if a call for heat remains.
If the inducer and circulating air blowers are operating, and items 1 through 8 have been checked, press the red reset button on the vent safety switch. (See Figure 29.)
If the furnace operates after depressing the reset button, contact a qualified service technician to identify and repair the problem.
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.
If furnace still fails to operate, depress the red reset buttons on the flame roll-out switch.
If the furnace operates after depressing the reset button, contact a qualified service technician to identify and repair the problem.
31
Component Location
1 Door Assembly - Louvered
2 Filter Inside Door
3 Blower Assembly
4 Control Board
5 Pressure Switch
6 Flame Rollout Switch
7 "J" Trap Hard Tube
8 LowVoltageTransformer
9 In Line Drain Assembly
10 Junction Box
11 Vent Safety Switch
Figure 29. M3 DownflowFurnace
12 Ignitor Assembly
13 Burner View Port
14 Main Limit Switch
15 Coil Cabinet Assembly (Optional)
16 Flame Sensor (On Burner Box)
17 Gas Valve
18 Switch, On/Off
19 Blower, Inducer
20 Orifice (In Burner Box)
21 Aux. Limit
22 Burner Box
32
SUPPLY AIR
_s)LIMIT SWITCH
BLUE
FLAME ROLL-OUT
SW_TC H
BLUE
VENT
SAFETY
SWITCH
WHITE (NEUTRAL) .....
BLACK 120V .....
GROUND ....
ROOM THERMOSTAT
'I_ GREEN
WHITE W/BLK
E] TRANSFORMER
STRIPES
STRIPES
,vl[ WHIT ....
BLACK BLK W/WHITE
BLOWER DECK SWtTCH
IITIONER
I
I
I
I m
I
I
I
I
I
I I
I= r
FLAMESENSOR
RED
YELLOW
BROWN
= = i
_]mCWl_A&$
IGNITOR
|l-" i, ,4" :_r_-
Legend
Field Wiring
Factory Wiring:
Low Voltage
High VoJtage
==_._L====
BLACK
BLACK
ORANGE
BLUE
BLACK
2 _
3
4
5
MOTOR
PLUG
FAULT CONDITION
Power On
Limit Circuit Open or External
(Does not apply to Deck Switch,
Load On "W" see below)
Pressure
Pressure
Switch Open with inducer
Switch Closed with inducer
On
On ignition Failure (Check Ground)
115 VAC & Neutral Reversed or no Ground
False Flame or Gas Valve Relay Shorted
Power Off or Deck Limit Open
FAULT CONDiTiON
Low Flame Sensor Signal
Flame Present
STATUS
RED
LIGHT
ON
1 FLASH
2FLASHES
3FLASHES
4 FLASHES
5 FLASHES
Continuous
OFF
FLAME
YELLOW
LIGHT
Continuous
Flash
ON
if any of the original
wire as supplied with the furnace must be replaced, it must be replaced with wiring material having a temperature rating of at least 105 ° C.
Use copper conductors only.
Factory Wired
Heating Speeds
Furnace
input, Btuh
Wire
Color
60,000
80,000
Red
Blue
Figure 30.
Downflow Furnace Wiring Diagram
WD#710240B
33
1
NOMINALBLACK
IRON
PIPE
DIAMETER_
1/2
3/4
1
1/4
10
280
130
520
1,050'
90
190
350
730'
LENGTH OF PIPE BUN (FT)
75
150
285
590
65 i30'
245
500'
760
55
115
215
440
670
50 i05
195
400
610 i
45
95
180
370 i
40
90
170
350
1 1/2 1,600 1,100 890
NOTES
The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace. To determine the cubic feet per hour of gas flow required by the furnace, divide the input rate of the furnace by the heating value (from gas supplier) of the gas.
input To Furnace (Btu/hr)
Cubic Feet Per Hour Required =
Heating Value of Gas (Btu/Cu. Ft.)
Table 11. Black Iron Gas Pipe Capacities
IVlodel
Number
IVl3RL-
060A-A!BW
080A-A!BW
Heating
Input
(Btuh)
Number of
Burners
60,000
80,000
4
5
0 - 2,000 ft
Nat. Gas LP
50
49
57
1.15mm
2,000 ft - 4,000 ft
Nat. Gas LP
50
49
57
1.15mm
Altitude Above Sea Level
4,000 - 6,000 ft
Nat. Gas LP
51
50
58
57
6,000 - 8,000 ft
Nat. Gas LP
51
50
58
57
Table 12. Approximate Orifice Size for Natural and LP Gases
8,000 - 10,000 ft
Nat. Gas LP
52
51
59
58
34
35
iNSTALLER NAME:
CiTY
STATE iNSTALLATiON ADDRESS:
CiTY STATE
UNiT MODEL #
UNiT SERIAL #
Electrical connections tight?
Line voltage polarity correct?
Supply Voltage:
Has the thermostat been calibrated?
is the thermostat level?
is the heat anticipator setting correct_
YES
YES
YES
YES
YES
NO
NO
VOLTS
NO
NO
NO
Minimum clearances
Has the owner's information been reviewed with the homeowner?
YES
I Has the literature package been left near
NO
NORD E
O'Falton, MO
EFFICIENCY
RA_ING
Gas Type: (circle one)
Gas pipe connections leak tested?
Gas Line Pressure: is there adequate fresh air supply for combustion and ventilation?
Installation Altitude:
Deration Percentage:
Furnace Input:
Supply Air Temperature:
Return Air Temperature:
YES
YES
Temperature Rise:
Propane
NO
(in - W.C.)
NO
(FT.)
(%)
(Btuh)
(o F)
(o F)
(o F_
Vent free restrictions?
from
Filter(s) secured in place?
Filter(s) clean?
Flue connections tight?
is there proper draft?
YES
YES
YES
YES
YES
708768C (Replaces 708768B)
IllIIIIIlilllillllllll
without notice or incurring obligations
Printed in U .S.A (03/09)
708768C
NO
NO
NO
NO
NO
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Key Features
- 90%+ AFUE rating for high efficiency
- Variable-speed blower motor for consistent airflow
- Sealed combustion for safety and efficiency
- Direct vent design for ease of installation
- Compact size for easy fit in tight spaces
Related manuals
Frequently Answers and Questions
What is the AFUE rating of the Nordyne M3RL 080A AW?
What type of blower motor does the Nordyne M3RL 080A AW have?
Is the Nordyne M3RL 080A AW a direct vent furnace?
What are the dimensions of the Nordyne M3RL 080A AW?
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