Unbranded M7RL Installation Instruction

INSTALLATION INSTRUCTIONS

M7RL Series Downflow Condensing Gas Furnace

Direct Vent (Sealed Combustion) Forced Air

95.1% AFUE

For Installation in:

• Manufactured Homes

• Modular Homes / Buildings

• Park Models, & Manufactured

Buildings

CAUTION:

HUD Manufactured Home Construction and

Safety Standards (3280.714) prohibit the use of noncertified air conditioning or heat pump equipment with this furnace. It is strongly recommended that NORDYNE manufactured housing air conditioning components

(Intertherm or Miller brands) be selected to provide a matched system specifically designed to meet these requirements.

The cutting, splicing or modifying of any internal electrical wiring may void product warranties and create a hazardous condition.

Failure to comply with these standards could also provide inadequate heating or cooling performance and cause structural damage to a manufactured home.

Please contact your local Intertherm or Miller distributor for help. A directory of NORDYNE factory authorized service is located in the furnace homeowner packet.

Reference: HUD Manufactured Home

Construction and Safety Standards 3280.714.

WARNING:

FIRE OR EXPLOSION HAZARD

• Failure to follow safety warnings exactly could result in serious injury or property damage.

• Installation and service must be performed by 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.

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 your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

AVERTISSEMENT:

RISQUE D’INCENDIE OU D’ EXPLOSION

• Le non-respect des avertissements de sécurité pourrait entraîner des blessures graves, la mort ou des dommages matériels.

• L’installation et l’entretien doivent être effectués par un installateur qualifié, un organisme de service ou le fournisseur de gazstaller, service agency or the gas supplier.

• Ne pas entreposer ni utiliser de l’essence ni d’autres vapeurs ou liquides inflammables dans le voisinage de cet appareil, ni de tout autre appareil.

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

• Ne pas tenter d’allumer aucun appareil.

• Ne toucher à aucun interrupteur électrique; n’utiliser aucun téléphone dans le bâtiment.

• Évacuer l’immeuble immédiatement.

• Appeler immédiatement le fournisseur de gaz en employant le téléphone d’un voisin.

Respecter à la lettre les instructions du fournisseur de gaz.

• Si personne ne répond, appeler le service des incendies.

DO NOT DESTROY THIS MANUAL. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

2

TABLE OF CONTENTS

IMPORTANT SAFETY INFORMATION .......................3

GENERAL INFORMATION ..........................................4

Requirements & Codes ............................................

4

Clearances to Combustible Materials .......................

5

Combustion Air Quality .............................................

5

Heating Load ............................................................

5

Condensate Disposal ...............................................

5

COMBUSTION AIR & VENTING REQUIREMENTS ....6

Important Information ...............................................

7

Category IV Appliances ............................................

7

Direct Vent Installation ..............................................

7

Vent Pipe Length & Diameter .................................

7

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

8

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

8

Outdoor Terminations - Horizontal Venting .............

8

Outdoor Terminations - Vertical Venting .................

9

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

10

Existing Installations .............................................

10

Ventilaire III or IV Air Quality Package ...................

10

CIRCULATING AIR REQUIREMENTS ...................... 11

Plenums & Air Ducts ..............................................

11

Supply Air Connections ..........................................

11

Return Air Connections ..........................................

11

Closet & Alcove Installations ..................................

12

Furnace Filter .........................................................

12

Dampers .................................................................

13

Acoustical Treatments ............................................

13

FURNACE INSTALLATION ....................................... 14

About the Furnace ..................................................

14

Before You Install this Furnace ...............................

14

Locating the Unit ....................................................

14

Locating & Cutting Floor Openings ......................

15

Locating & Cutting Ceiling Openings ....................

15

Installing Finger Tabbed Duct Connectors .............

15

Narrow Duct Attachment - Option 1......................

16

Narrow Duct Attachment - Option 2......................

16

Installing Screw-Down Duct Connectors ................

17

Installing Round Duct Connectors ..........................

17

Installing the Furnace .............................................

17

Condensate Drainage ............................................

17

GAS SUPPLY & PIPING ............................................ 18

Leak Check ...........................................................

19

High-Altitude Application ........................................

20

Converting to LP / Propane Gas ............................

20

Removing the Burner Orifices ..............................

21

Gas Pressure Adjustment ......................................

21

Measuring the Supply Gas Pressure ....................

21

Lighting & Adjustment of the Appliance ................

22

Measuring the Manifold Pressure .........................

22

Adjusting the Manifold Pressure ...........................

22

Removing the Manometer / Pressure Gauge ......

22

Completing the Conversion ....................................

22

ELECTRICAL WIRING ............................................... 23

Line Voltage Wiring ................................................ 23

Thermostat / Low Voltage Connections .................

23

Heat Anticipator ....................................................

24

Grounding ...............................................................

24

START-UP & ADJUSTMENTS

................................... 25

Pre-Start Checklist .................................................

25

Start-Up Procedures ..............................................

25

Verifying & Adjusting Input Rate .............................

25

Verifying & Adjusting Temperature Rise .................

25

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

26

Verifying Operation of the Supply Air

Limit Switch ............................................................

26

OPERATING SEQUENCE ......................................... 27

Heating Cycle .........................................................

27

Cooling Cycle .........................................................

27

Fan Mode ...............................................................

27

MAINTENANCE ......................................................... 27

Air Filters ................................................................

28

Blower Compartment ..............................................

28

Cleaning of Burners ................................................

28

Vent System ........................................................... 28

Heat Exchanger & Burner Maintenance .................

28

Lubrication ..............................................................

28

TROUBLESHOOTING ............................................... 29

DESCRIPTION OF COMPONENTS .......................... 29

FIGURES & TABLES ................................................. 30

Furnace Dimensions...............................................

30

Figure 24 - A Cabinet Models (Short)...................

30

Figure 25 - B Cabinet Models (Tall) ......................

31

Figure 26 - B Cabinet Models (Top Return Air) ....

32

Wiring Diagram .......................................................

33

Figure 27 - M7RL Wiring Diagram ........................

33

Gas Information ......................................................

34

Table 8 - Gas Flow Rates .....................................

34

Table 9 - Gas Pipe Capacities ..............................

34

Table 10 - High Altitude Deration Chart for

Propane Gas .......................................

35

Table 11 - Natural Gas Heating Values .................

35


Nat. Gas - High Heating Values ...........

35


Nat. Gas - Low Heating Values ............

35

Venting Information ................................................

36

Table 14 - Vent Termination Clearances ...............

36

Figure 28 - Horizontal & Vertical Venting ..............

37

INSTALLATION / PERFORMANCE CHECKLIST ..... 40

IMPORTANT SAFETY INFORMATION

INSTALLER: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored.

WARNING

indicates a potentially hazardous situation that if not avoided, could result in personal injury or death.

CAUTION

indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

• To minimize equipment failure or personal injury, it is essential that only qualified individuals install, service, or maintain this equipment. If you do not posses mechanical skills or tools, call your local dealer for assistance.

• Follow all precautions in the literature, on tags, and on labels provided with the equipment. Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment.

• Use caution when handling this appliance or removing components. Personal injury can occur from sharp metal edges present in all sheet metal constructed equipment.

• Do not store any of the following on, or in contact with, the unit: Rags, brooms, vacuum cleaners, or other cleaning tools, spray or aerosol cans, soap powders, bleaches, waxes, cleaning compounds, plastics or plastic containers, paper bags or other paper products, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, paint thinners, or other volatile fluids.

• Installation of equipment may require brazing operations.

Installer must comply with safety codes and wear appropriate safety equipment (safety glasses, work gloves, fire extinguisher, etc.) when performing brazing operations.

• The installer should become familiar with the units wiring diagram before making any electrical connections to the unit. See the unit wiring label or Figure 27 (page 33).

• Always reinstall the doors on the indoor blower after servicing or cleaning/changing the filters. Do not operate the indoor blower without all doors and covers in place.

WARNING:

The safety information listed in this manual must be followed during the installation, service, and operation of this unit. Unqualified individuals should not attempt to interpret these instructions or install this equipment. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death.

WARNING:

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow safety warnings exactly could result in serious injury or property damage.

Improper servicing could result in dangerous operation, serious injury, death or property damage.

• Before servicing, disconnect all electrical power to the indoor blower.

• When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

WARNING:











WARNING:

Improper installation, service, adjustment, or maintenance may cause explosion, fire, electrical shock or other hazardous conditions which may result in personal injury or property damage. Unless otherwise noted in these instructions, only factory authorized kits or accessories may be used with this product.

WARNING:

Unless otherwise noted in these instructions, only factory authorized kits or accessories may be used with or when modifying this product.

3

4

GENERAL INFORMATION

Requirements & Codes

WARNING:

This unit must be installed in accordance with instructions outlined in this manual during the installation, service, and operation of this unit. Unqualified individuals should not attempt to interpret these instructions or install this equipment. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death..

• The installer must comply with all local codes and regulations which govern the installation of this type of equipment. Local codes and regulations take precedence over any recommendations contained in these instructions. Consult local building codes and the

National Electrical Code (ANSI CI) for special installation requirements.

• All electrical wiring must be completed in accordance with local, state and national codes and regulations and with the National Electric Code (ANSI/NFPA 70) or in Canada the Canadian Electric Code Part 1 CSA

C.22.1.

• This furnace must be installed in accordance with these instructions, all applicable local building codes and the current revision of the National Fuel Gas Code

(NFPA54/ANSI Z223.1) or the Natural Gas and Propane

Installation Code, CAN/CGA B149.1.

• Use only with type of gas approved for this furnace.

Refer to the furnace rating plate.

• Install this furnace only in a location and position as specified on page 5.

• Provide adequate combustion and ventilation air to the furnace space as specified on pages 6 - 7.

• Provide adequate clearances around the vent air intake terminal as specified in Figures 1 - 4 (page 9).

• Combustion products must be discharged outdoors.

Connect this furnace to an approved vent system only, as specified on pages 7 - 10.

• Never test for gas leaks with an open flame. Use a commercially available soap solution to check all connections. See pages 18 - 19.

• This furnace is designed to operate with a maximum external pressure rise of 0.3 inches of water column.

Consult Table 6 (page 26) and the rating plate for the proper circulating air flow and temperature rise. It is important that the duct system be designed to provide the correct flow rates and external pressure rise. An improperly designed duct system can result in nuisance shutdowns, and comfort or noise issues.

• This furnace must not be used for temporary heating of buildings or structures under construction.

• The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of through – the – wall vented gas appliances as follows:

1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: a.) A carbon monoxide (CO) detector and alarm shall be placed on each floor level where there are bedrooms.

The detector shall comply with NFPA 720 (2005

Edition) and be mounted in the living area outside the bedroom(s).

b.) A (CO) detector shall be located in the room that houses the appliance or equipment and shall:

• Be powered by the same electrical circuit as the appliance or equipment. Only one service switch shall power the appliance and the (CO) detector;

• Have battery back-up power;

• Meet ANSI/UL 2034 Standards and comply with

NFPA 720 (2005 Edition); and Approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR.

c.) A Product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

d.) A metal or plastic identification plate shall be mounted at the exterior of the building, 4 feet directly above the location of vent terminal. The plate shall be of sufficient size, easily read from a distance of eight feet away, and read “Gas Vent Directly Below”.

2. For direct-vent appliances, mechanical vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied: a.) A (CO) detector and alarm shall be placed on each floor level where there are bedrooms. The detector shall comply with NFPA 720 (2005 Edition) and be mounted in the living area outside the bedroom(s).

b.) The (CO) detector shall:

• Be located in the room that houses the appliance or equipment;

• Be hard-wired, battery powered or both.

• Shall comply with NFPA 720 (2005 Edition).

c.) A product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.

Clearances to Combustible Materials

This furnace is Design Certified in the U.S. and Canada by CSA International for the minimum clearances to combustible materials.

NOTE:

The furnace is listed for installation on combustible or non-combustible flooring.

However, wood is the only combustible flooring allowed for installation. To obtain furnace base model number and specific clearance information, refer to the furnace rating plate, located inside of the furnace cabinet.

Access for positioning and servicing the unit must be considered when locating unit. The need to provide clearance for access to panels or doors may require clearance distances over and above the requirements.

Allow 18 inches minimum clearance from the front of the unit. However 36 inches is strongly recommended.

See Table 1 for minimum clearance requirements.

LEFT

SIDE

INSTALLATION CLEARANCES

Front *

Rear

Sides

Top

Duct w/in 3ft of furnace

Vent

Plenum Without Coil Box

Plenum With Coil Box

REAR

RIGHT

SIDE

CLOSET

1"

0"

0"

6"

1/4"

0”

1"

0”

LEFT

SIDE

REAR

ALCOVE

1"

0"

0"

6"

1/4"

0”

1"

0”

RIGHT

SIDE

The ductwork should be appropriately sized to the capacity of the furnace to ensure its proper airflow rating. For installations above 2,000 ft., the furnace should have a sea level input rating large enough that it will meet the heating load after deration for altitude.

Combustion Air Quality

CAUTION:

Combustion air must not be drawn from a corrosive atmosphere.

To maximize heat exchanger life, the combustion air must be free of chemicals that can form corrosive acidic compounds in the combustion gases. The required source of combustion air is to use outdoor air.

Exposure to the following substances in the combustion air supply will result in safety and performance related problems. The list below contains examples of chemical containments found in a wide variety of common commercial household products:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon Tetrachloride

• Halogen type refrigerants

• Cleaning solvents (perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric Acid

• Cements and glues

• Antistatic fabric softeners

• Masonry acid washing materials

FRONT

VENT

SHORT A-SIZE CABINET & TALL B-SIZE CABINET

FRONT

VENT

TALL B-SIZE CABINET WITH TOP AIR RETURN

NOTES:

Alcove Installations - Allow 18 in. minimum clearance from front of unit to nearest wall or partition for servicing.

Closet installations - Require a return air grill installed in the door or a partially louvered door across the opening for proper air circulation. For clearances 6” or greater, the closet must have an open free area of

235 in

2

minimum. For special clearances between 1” &

6”, requirements are a louvered door with a minimum of 250 in

2

(1613 cm

2

) free area. For 1” clearance from furnace, use a fully louvered door with at least 400 in 2 of free airflow area. A fully louvered closet door is strongly recommended for all installation types.

Heating Load

This furnace should be sized to provide the design heating load requirement. Heating load estimates can be made using approved methods available from Air Conditioning

Contractors of America (Manual J); American Society of

Heating, Refrigerating, and Air Conditioning Engineers; or other approved engineering methods.

Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely.

Condensate Disposal

The method for disposing of condensate varies according to local codes. Consult your local code or authority having jurisdiction. Neutralizer kit P/N 902377 is available for use with this furnace.

Please follow the instructions provided with the kit.

Table 1. Minimum Clearance Requirements

5

6

COMBUSTION AIR & VENTING REQUIREMENTS

WARNING:

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed with each individual appliance connected to the venting system being placed in operation, while all other appliances connected to the venting system are not in operation:

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/NFPA 54 or the CSA

B149.1, Natural Gas and Propane 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. As far as 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. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation.

Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances 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 54 and/or CSA

B149.1, Natural Gas and Propane Installation

Codes.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

AVERTISSEMENT:

RISQUE D’EMPOISONNEMENT AU

MONOXYDE DE CARBONED

Le non-respect des consignes suivantes portant sur chacun des appareils raccordés au système d’évacuation mis en service pourrait entraîner l’empoisennement au monoxyde de carbone ou la mort. Les consignes suivantes doivent être observées pour chaque appareil raccordé au système d’évacuation mis en service si les autres appareils raccordés au système ne sont pas en service:

1. Sceller toute ouverture non utilisée de la systéme d’évacuation;

2. S’assurer que la systéme d’évacuation présente des dimensions et une pente horizontale conformes à la norme ANSI Z223.1/NFPA

54, intitulée National Fuel Gas Code ou aux codes d’installation CSA-B149.1, ainsi qu’aux présentes instructions. S’assurer que la systéme d’évacuation n’est pas bloquée, restreinte, corrodée, qu’elle ne fuit pas et qu’elle ne présente aucun autre défaut potentiellement dangereux;

3. Dans la mesure du possible, fermer toutes les portes et fenêtres du bâtiment, et toutes les portes entre la pièce où se trouve l’appareil raccordé à la systéme d’évacuation et les autres pièces du bâtiment.

4. Fermer les registres des foyers;

5. Mettre en service les sécheuses et tout autre appareil qui n’est pas raccordé à la systéme d’évacuation. Faire fonctionner à régime maximal tout ventilateur d’évacuation, tel que les hottes de cuisinière et les ventilateurs de salles de bains.

Ne pas mettre en service les ventilateurs d’été.

6. Respecter les instructions d’allumage. Mettre en service l’appareil à l’essai. Régler le thermostat de manière à ce que l’appareil fonctionne sans interruption;

7. Vérifier s’il y a débordement à l’orifice d’évacuation du coupe tirage des appareils dotés d’un coupe tirage 5 minutes après l’allumage du brûleur principal. Utiliser la flamme d’une allumette ou d’une chandelle.

8. Si l’on constate, au cours de l’un des essais qui précèdent, que l’évacuation est déficiente, corriger le système d’évacuation conformément

à la norm ANSI Z223.1/NFPA 54, National Fuel

Gas Code, et (ou) aux codes d’installation CSA

B149.1.

9. Après avoir déterminé que tous les appareils raccordés à la systéme d’évacuation évacuent correctement tel que prescrit ci-dessus, rouvrir les portes et les fenêtres et remettre les ventilateurs d’évacuation, les registres de foyers et tout autre appareil fonctionnant au gaz à leur

état de fonctionnement initial.

Important Information

WARNING:

Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code (NFGC) and all applicable local codes.

WARNING:

Upon completion of the furnace installation, carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed. Leaks in the flue system can result in serious personal injury or death due to exposure of flue products, including carbon monoxide.

WARNING:

This furnace must not be vented with other appliances, even if that appliance is of the condensing type. This includes water heaters of any efficiency. 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.

• This furnace must be vented in compliance with the current revision of the National Fuel Gas Code

(ANSI-Z223.1/NFPA54). Instructions for determining the adequacy of combustion air for an installation can be found in the current revision of the NFGC

(ANSI Z223.1 / NFPA54).

Consult local codes for special requirements

. These requirements are for

US installations as found in the NFGC.

• The requirements in Canada (B149.1) are structured differently. In Canada, venting shall conform to the requirements of the current (CAN/CGA B149.1 or .2) installation codes.

Consult local codes for special requirements.

Category IV Appliances

This furnace is classified as a Category IV appliance, which requires special venting materials and installation procedures. Category IV appliances operate with positive vent pressure and requires thoroughly sealed vent systems.

They also produce liquid 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.

Direct Vent Installation

This condensing furnace is certified for installation as a

Direct Vent (2-pipe) appliance. Direct Vent (2-pipe) furnaces draw combustion air directly from the outdoors and then vent the combustion products back outside, isolating the entire system from the indoor space. It is important to make sure that the whole system is sealed and clearances to combustibles are maintained regardless of the installation being in a confined or unconfined space. This section specifies installation requirements for Direct Vent (2-pipe) piping. Table 2 (page 8) contains the length of vent and combustion air piping for this type of installation.

Provisions must be made during the installation of this furnace that provide an adequate supply of fresh air for combustion and ventilation. The combustion air from the outside needs to be clear of chemicals that can cause corrosion. The inlet pipe should not be placed near corrosive chemicals such as those listed on page 5.

Air openings on top of the furnace and openings in closet doors or walls must never be restricted. If the furnace is operated without adequate air for combustion, the flame roll-out switch will open, turning off the gas supply to the burners.

NOTE

:

This safety device is a manually reset switch.

DO NOT install jumper wires across these switches to defeat their function or reset a switch without identifying and correcting the fault condition.

If a switch must be replaced, use only the correct sized part specified in the Replacement Parts List provided online.

Vent Pipe Length & Diameter

For proper furnace operation, the combustion air and vent piping must not be excessively restrictive.

• The venting system should be designed to have the minimum number of elbows or turns.

• All horizontal runs must slope upwards from the furnace at 1/4 inch minimum per running foot of vent.

• Transition to the final vent diameter should be done as close to the furnace outlet as practical.

• Always use the same size or a larger pipe for combustion air that is used for the exhaust vent.

Table 2 (page 8) indicates the maximum allowable pipe length for a furnace of known input rate, when installed with piping of selected diameter and number of elbows. To use the table, the furnace input rate, the centerline length and the number of elbows on each pipe must be known.

When estimating the length of vent runs, consideration must be made to the effect of elbows and other fittings.

This is conveniently handled using the idea of “equivalent length”. This means the fittings are assigned a linear length that accounts for the pressure drop they will cause. For example: a 3” diameter, long radius elbow is worth the equivalent of 3.5 feet of linear run.

The equivalent lenghts of tees and various elbows are listed in Table 2. Measure the linear length of your vent run and then add in the equivalent length of each fitting. The

7

8

Maximum Direct Vent, Dual Pipe Length (FT.)

M7RL INPUTS

(BTU)

45,000

60,000

72,000

INLET / OUTLET

2” Diameter

30

30

30

INLET / OUTLET

3” Diameter

60

60

60

†

NOTES:

1. Subtract 2.5 ft. for each additional 2 inch long radius elbow, subtract

5ft for each additional 2” short radiious elbow, subtract 3.5 ft. for each additional 3 inch long radius elbow, and 7 ft. for each additional

3 inch short radius elbow.

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

3. This table applies for elevations from sea level to 2,000 ft. For higher elevations, decrease pipe lengths by 8% per 1,000 ft of altitude.

Table 2. Vent Pipe Lengths

total length, including the equivalent fitting lengths, must be less than the maximum length specified in the table.

Condensing furnace combustion products have very little buoyancy, so Table 2 is to be used without consideration of any vertical rise in the piping.

Vent Pipe Material

Vent and combustion air pipe and fittings must be one of the following materials in the list and must conform to the indicated ANSI/ASTM standards. Cement must conform to ASTM Standard D2564 for PVC and Standard D2235 for ABS. PVC primer must meet standard ASTM F656.

When joining PVC piping to ABS, use PVC solvent cement.

(See procedure specified in ASTM Standard D3138).

In Canada, all plastic vent pipes and fittings including any cement, cleaners, or primers must be certified as a system to ULC S636. However this requirement does not apply to piping internal to the furnace.

Materials

SCHEDULE 40PVC ............................................... D1785

PVC-DWV .............................................................. D2665

SDR-21 & SDR-26 ................................................. D2241

ABS-DWV .............................................................. D2661

SCHEDULE 40 ABS .............................................. F628

FOAM / CELLULAR CORE PVC ........................... F891

Vent Pipe Installation

CAUTION:

Standards

Combustion air must not be drawn from a corrosive atmosphere.

This furnace has been certified for installation with zero clearance between vent piping and combustible surfaces.

However, it is good practice to allow space for convenience in installation and service.

• In the absence of local codes, the location of any combustion air inlet relative to any vent terminal must be at least 8 inches. This includes installations involving more than one furnace.

• The quality of outdoor air must also be considered. Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion of the furnace combustion system.

(See page 5 for a sample list of substances).

• Route piping as direct as possible between the furnace and the outdoors. Longer vent runs require larger diameters. Vent piping must be sloped upwards 1/4” per foot in the direction from the furnace to the terminal.

This ensures that any condensate flows back to the condensate disposal system.

• When a Direct Vent (2-pipe) system is used, the combustion air intake and the vent exhaust must be located in the same atmospheric pressure zone. This means both pipes must exit the building through the same portion of exterior wall or roof as shown in Figure

28, page 37.

• Piping must be mechanically supported so that its weight does not bear on the furnace. Pipe supports must be installed a minimum of every five feet along the vent run to ensure no displacement after installation.

Supports may be at shorter intervals if necessary to ensure that there are no sagging sections that can trap condensate. It is recommended to install couplings along the vent pipe, on either side of the exterior wall

(Figure 28). Couplings may be required by local code.

• If breakable connections are required in the combustion air inlet pipe (if present) and exhaust vent piping, then straight neoprene couplings for 3” piping with hose clamps can be used. These couplings can be ordered through your local furnace distributor. To install a coupling:

1. Slide the rubber coupling over the end of the pipe that is attached to the furnace and secure it with one of the hose clamps.

2. Slide the other end of the rubber coupling onto the other pipe from the vent.

3. Secure the coupling with the second hose clamp, ensuring that the connection is tight and leak free.

Outdoor Terminations - Horizontal Venting

• Vent and combustion air intake terminations shall be installed as shown in Figures 1 & 2 (page 9) and in accordance with these instructions:

• Vent termination clearances must be consistent with the

NFGC, ANSI 2223.1/NFPA 54 and/or the CSA B149.1,

Natural Gas and Propane Installation Code. Table 12

(page 33) lists the necessary distances from the vent termination to windows and building air intakes.

• Vent and combustion air intake terminations must be located to ensure proper furnace operation and conformance to applicable codes. A vent terminal must be located at least 3 feet above any forced air inlet located within 10 feet. This does not apply to the combustion air inlet of a direct vent (two pipe) appliance.

In Canada, CSA B149.1 takes precedence over these instructions. See Table 14 (page 36).

• All minimum clearances (Figure 2) must be maintained to protect building materials from degradation by flue gases.

18” Min.

36” Max.

aceplate all with scre ws

Exhaust v ent option C

Exhaust v option A ent

Exhaust v option B ent 90° Elbo w

Comb ustion air inlet

12” min.

to maximum expected sno

(both pipes)

8” Min.

36” Max.

(all positions)

Figure 1. Inlet & Exhaust Pipe Clearances

Direct v or less

9 in.

Note 2

4 ft

4 ft

Mechanical draft vent terminal

Note 2

NOTES:

1. All dimensions shown are

minimum requirements.

2. Exterior vent terminations must

be located at least 12” above the

maximum expected snow level.

Mechanical draft v ter

Mechanical draft v ent ter minal

3 ft.

12 in.

12 in.

Less than

10 ft.

Forced air inlet

Note 2

Direct vent terminal - more than 50,000 Btuh

Figure 2. Vent Locations

Support

19" Max.

(See Note)

12" Above

Maximum

Expected

Snow Level

Outside

Wall

1/2"

Armaflex

Insulation or

Equivalent

(if required)

NOTE:

Vent Configuration to Provide

12" Minimum height above Snow Level.

Figure 3. Alternate Horizontal Vent Installation

• For optimal performance, vent the furnace through a wall that experiences the least exposure to winter winds.

• The vent termination shall be located at least 3 ft. horizontally from any electric meter, gas meter, regulator and any relief equipment. These distances apply ONLY to U.S. installations. In Canada, CSA B149.1 takes precedence over these instructions.

• 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 terminate above any public walkways.

• If venting horizontally, side wall vent kits are available according to the pipe diameter size of the installation.

For 3 inch pipe, use kit #904347. Faceplate kit #902375 is also available for 3 inch horizontal venting.

Please follow the instructions provided with the kits.

• Concentric vent termination kits are available for use with these furnaces. For 3 inch pipe use kit # 904953.

Please follow the instructions provided with the kit.

• When the vent pipe must exit an exterior wall close to the grade or expected snow level where it is not possible to obtain clearances shown in Figure 1, a riser may be provided as shown in Figure 3. Insulation is required to prevent freezing of this section of pipe. See Table 3

(page 10) for vent freezing protection.

Outdoor Terminations - Vertical Venting

Termination spacing requirements from the roof and from each other are shown in Figure 4. The roof penetration must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing. Vent and combustion air piping may be installed in an existing chimney which is not in use provided that:

• Both the exhaust vent and air intake run the length of the chimney.

• The top of the chimney is sealed and weatherproofed.

• The termination clearances shown in Figure 4 are maintained.

• No other gas fired or fuel-burning equipment is vented through the chimney.

Elbows on the combustion air inlet must be positioned pointing

away from the exhaust vent.

12” Above Maximum

Expected Snow Level

(Both pipes)

Plumbing Vent Roof Boot

(Both Pipes)

8" Min.

36" Max.

Figure 4. Vertical Vent Termination

9

10

Vent Freezing Protection

CAUTION:

When the vent pipe is exposed to temperatures below freezing (i.e., when it passes through unheated spaces, chimneys, etc.) the pipe must be insulated with 1/2 inch thick sponge rubber insulation, Armaflex-type insulation or equivalent. Insulating pipe is important to avoid condensate icing.

• Table 3 lists 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 in the table. For Canadian installations, please refer to the Canadian Installation Code (CAN/

CGA-B149.1 or 2) and/or local codes.

• For extremely cold climates or for conditions of short furnace cycles (i.e. set back thermostat conditions) the last 18 inches of vent pipe can be reduced. It is acceptable to reduce from 3” to 2-1/2” or, 3” to 2” if the total vent length is at least 15 feet in length, and the vent length is within the parameters specified in Table

2 (page 8). The restriction should be counted as 3 equivalent feet. Smaller vent pipes are less susceptible to freezing, but must not be excessively restrictive. .

• To prevent debris or creatures from entering the combustion system, a protective screen may be installed over the combustion air intake opening. The screens hole size must be large enough to prevent air restriction.

Existing Installations

When an existing furnace is removed from a vent system serving other appliances, the existing vent system may not be sized properly to vent the remaining appliances

(example: water heater). An improperly sized venting system can result in the formation of condensate, leakage, or spillage. The existing vent system should be checked to make sure it is in compliance with NFGC and must be brought into compliance before installing the furnace.

NOTE:

If replacing an existing furnace, it is possible you will encounter an existing plastic venting system that is subject to a Consumer Product Safety Commission recall. The pipes involved in the recall are High Temperature Plastic

Vent (HTPV).

If your venting system contains these pipes DO NOT reuse this venting system!

This recall does not apply to other plastic vent pipes, such as white

PVC or CPVC. Check for details on the CPSC website or call their toll-free number (800) 758-3688.

Ventilaire III or IV Air Quality Package

The Ventilaire air quality accessory packages are available to meet the ventilation requirements as outlined in H.U.D.

Standard Part 3280.103 (b) (2). These packages introduce outdoor air into the living space during furnace blower operation. The VentilAire IV also serves to exhaust moist and/or hot air from the attic space. See Figure 5 for typical installation. Complete installation instructions are supplied with each air quality package.

VentilAire III

Winter Design

Temperature

Maximum Flue Pipe Length (FEET)

in Unconditioned & Exterior Spaces

Without Insulation With Insulation*

20

0

-20

45

20

10

70

70

60

*NOTE:

Insulation thickness greater than 3/8 inch, based on an

R value of 3.5 (ft x F x hr) / (BTU x in.)

Table 3. Vent Protection

VentilAire IV

Figure 5. VentilAire III & IV

CIRCULATING AIR REQUIREMENTS

WARNING:

Do not allow combustion products to enter the circulating air supply. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

All supply ducts must be secured to the furnace with sheet metal screws and adequately sealed.

When supply air is provided through the bottom of the unit, the joint between the furnace and the plenum must be air tight.

The surface that the furnace is mounted on must provide sound physical support of the furnace with no gaps, cracks or sagging between the furnace and the floor or platform.

Supply air ducts must not be connected to any other heat producing device such as a fireplace insert, stove, etc. This may result in fire, explosion, carbon monoxide poisoning, personal injury, or property damage.

Plenums & Air Ducts

This unit is designed only for use with a bottom supply duct and must be installed in accordance with the standards of the National Fire Protection Association

Standard for Installation of Air Conditioning Systems

(NFPA 90A), Standard for Installation of Residence Type

Warm Air Heating and Air Conditioning Systems (NFPA

90B), and all applicable local codes. NFPA publications are available by writing to: National Fire Protection

Association, Batterymarch Park, Quincy, ME 02269 or go to www.NFPA.org on the web.

• Design the air ducts according to methods described by the Air Conditioning Contractors of America (ACCA).

• Air ducts must be aluminum, tin plate, galvanized sheet steel, or other approved materials for outlet or return air ducts. Snap-Lock or Pittsburgh-Lock seams are preferred. All other types of seams must be made tight to prevent leakage.

• It is good practice to seal all connections and joints with industrial grade sealing tape or liquid sealant.

Requirements for sealing ducts vary from region to region. Consult with local codes for requirements specific to your area.

• Gas piping must not run in or through any of the air duct system.

• Hollow spaces used as ducts or plenums for environmental air may contain mineral-insulated metal sheathed cable, aluminum sheathed cable, electrical metallic tubing, rigid metal conduit, flexible metal conduit (not to exceed 4 ft), or metal-clad cables. Wiring materials, fixtures, are to be suitable for the expected ambient temperatures to which they will be subjected.

Wiring materials located in the return duct system shall conform to Articles 300-22 of the National Electrical

Code (ANSI C1/NFPA-70).

• All duct work passing through unconditioned space must be properly insulated to minimize duct losses and prevent condensation. Use insulation with an outer vapor barrier. Refer to local codes for insulation material requirements

• 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 sizes for air conditioning.

• Noncombustible pans having one inch upturned flanges are located beneath openings in a floor return duct system.

Supply Air Connections

• 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 shown on the furnace rating plate. The supply air must be delivered to the heated space by duct(s) secured to the furnace casing, running full length and without interruption.

• Duct system must be designed so that no supply registers are located in duct system directly below the furnace.

• Location, size, and number of registers should be selected on the basis of best air distribution and floor plan of the home. Three typical distribution systems are shown in Figure 6

A Single trunk duct

B

Dual trunk duct w/crossover connector

C

Transition duct

w/branches

Figure 6. Typical Supply Duct Systems

Return Air Connections

• M7 furnaces with model numbers ending in AW or BW are factory configured for the return air to flow through the front louvered door. The return air may also be attached to either side of the furnace cabinet using a field installed kit (PN 904003). The location and size of the side and top return air connections are shown in Figures 24 & 25 (pages 30 & 31). The filter size for the side return air is 20” x 20” x 1”.

• Model numbers ending in BWT are factory configured for the return air to enter the top of the furnace. See

Figure 26 (page 32).

NOTE:

For top return installations,

11

12 an external or in-wall filter mount can be used. The factory installed filter should be removed and the return duct should be sized to provide adequate airflow.

• For floor return systems, the manufactured housing manufacturer or installer shall affix a prominent marking on or near the appliance where it is easily read when the closet door is open. The marking shall read:

CAUTION, HAZARD OF ASPHYXIATION. DO NOT

COVER OR RESTRICT FLOOR RETURN AIR

OPENING.

• Return air openings should not be located to draw air directly from a bathroom.

• Materials located in the return duct system shall have a flame spread classification of 200 or less.

• The total free area of the openings in the floor or the ceiling registers serving the return air duct system must not be not less than 352 in

2

(2,270 cm

2

). At least one register should be located where it is not likely to be covered by carpeting, boxes and other objects.

Closet & Alcove Installations

WARNING:

Failure to comply with the the following instructions may result in fire, asphyxiation or carbon monoxide poisoning.

For proper air circulation, closet installations require a return air grill installed in the door or side wall that exchanges with the living area of the home. A partially louvered door may also be used across the opening. Grilles placed in a side wall require a 6” clearance from the wall to the furnace so that the air may enter the front grille of the furnace. All return air systems, including the floor and ceiling systems, must meet the following conditions:

• The return air opening, regardless of its location in the closet, must not be smaller than size specified on unit data label. If located in the floor, the opening must be provided with a means of preventing its inadvertent closure by flat object(s) placed over the opening.

• The cross-sectional area of the return duct system (in floor or ceiling) leading into the closet must not be less than 235 in

2

(1,516 cm

2

).

CAUTION:

HAZARD OF ASPHYXIATION: Negative pressure inside the closet, with closet door closed and the furnace blower operating on high speed, shall be no more negative than minus 0.05 inch water column.

• Test the negative pressure in the closet with the aircirculating fan operating at high speed and the closet closed. The negative pressure in the closet must not be less than minus 0.05 inches water column with the closet door closed and the fan operating at high speed.

The negative pressure is to be no more negative than minus 0.05” water column as this indicates a dirty filter or a restricted return air system.

• For closet installation with less than 6” front clearance, but not less than 1”, a louvered door must be used having a minimum 250 in

2

(1,613 cm

2

) free area opening directly in line with openings in the furnace door. For

1” clearance from furnace, use a fully louvered door with at least 400 in

2

(2,580 cm

2

) of free airflow area.

Furnace Filter

WARNING:

Never operate the furnace without a filter in place. Accumulating dust in the return air can build up on internal components, resulting in loss of efficiency, equipment damage, and possible fire.

• M7RL furnaces with AW or BW suffixes are supplied with a single reusable air filter when shipped from the factory. Accessing the filter does not require tools and can be easily removed from the inside of the access door. The filter is secured to the door with a retaining bracket.

• M7RLfurnaces with BWT suffixes are shipped with a non-reusable single 18”x18”x1” air filter from the factory.

Accessing the filter does not require tools and can be easily removed from inside the blower compartment.

The filter is secured with a U-shaped retaining bracket.

It is recommended that the filter be cleaned or replaced monthly. Newly built or recently renovated homes may require more frequent changing until the construction dust has minimized.

1. Slide the standard 18”x18”x1” filter (NORDYNE P/N

669779) into the space bewteen the combustion air pipe and the blower assembly. See Figure 7 (page

13).

NOTE:

Make sure the airflow arrows on the filter point towards the blower assembly.

2. Push the filter to the rear of the furnace cabinet and angle it up over the blower. Make sure the filter is pushed back as far as possible.

3. Position the filter retainer under the filter and insert the stepped ends into the 0.25 holes in the rear of the furnace.

NOTE:

The stepped ends should be facing upwards in the holes.

4. Evenly align the filter over the opening in the top of the furnace cabinet and position the other end of filter retainer up over the flange in the furnace’s top panel.

NOTE:

To properly secure the filter, make sure the filter retainer is properly positioned in the top panel of the furnace. There should be no visible air gaps. The retainer may slide left or right slightly, but must not have any movement between the front and rear. See Figure 7.

Align the filter over the opening and secure with filter retainer

Blower

Assembly

Insert filter between blower assembly & combustion air pipe

Filter

Blower

Assembly ustion Air Pipe

Angle the filter into place above the blower assembly

Filter

Blower

Assembly

Figure 7. Filter Installation

• Replacement filters are available at most local retailers.

Inspect filters frequently and replace when necessary with filter of same dimensional size. Filters designed to remove smaller particles such as pollen, may require additional maintenance.

Dampers

An automated shut off damper is required when the home is air conditioned by a self-contained unit. A damper is required to prevent chilled air from flowing over the furnace heat exchanger. This damper is designed to fit in the feeder duct cavity, directly under the furnace. For proper installation, refer to the instructions provided with the damper. See replacement parts list provided online.

Acoustical Treatments

Damping ducts, flexible vibration isolators, or pleated media-style filters on the return air inlet of the furnace may be used to reduce the transmission of equipment noise eminating from the furnace. These treatments can produce a quieter installation, particularly in the heated space. However, they can increase the pressure drop in the duct system. Care must be taken to maintain the proper maximum pressure rise across the furnace, temperature rise and flow rate. This may mean increasing the duct size and/or reducing the blower speed. These treatments must be constructed and installed in accordance with NFPA and

SMACNA construction standards. Consult with local codes for special requirements. For best sound performance, install all the needed gaskets and grommets around penetrations into the furnace, such as for electrical wiring.

13

14

FURNACE INSTALLATION

NOTE:

These Installation procedures are suggested for typical furnace installations. Since each installation is different, the sequence of instructions may differ from the actual installation. Only qualified HVAC technicians should install this furnace.

The installer must be familiar with and comply with all codes and regulations applicable to the installation of these heating appliances and related equipment. In the absence of local codes, the installation must be in accordance with the current provisions of one or more of the following standards.

• Federal Manufactured Home Constructions & Safety

Standard (H.U.D. Title 24, Part 3280.707[a][2])

• American National Standard (ANSI-119.2/NFPA-501C) for all recreational vehicle installations.

• American National Standard (ANSI-Z223.1/NFPA-54) and/or CAN/CSA B149 for all gas-fired furnace models.

• American National Standard (ANSI-Z95.1/NFPA-31) and/or CSA B139 for all oil-fired furnace models.

• American National Standard (ANSI-C1/NFPA-70) and/ or CSA 22.1 Canadian Electric Code Part 1 for all electrical field wiring.

• Units have been researched under standards UL 307A

& B, UL727-1999, ANSI Z21.47b/CSA 2.3b-2008, and

CSA B140.10.

About The Furnace

The M7RL furnace is designed only for indoor installations and can be readily connected to the high static duct system of a home. Units are approved for single/multistory residential or mobile/modular/manufactured structures in freestanding/closet/alcove downflow only configurations.

This appliance will provide many years of safe and dependable comfort, providing it is properly installed and maintained. Abuse, improper use, and/or improper maintenance can shorten the life of the appliance and create unsafe hazards. Please read all instructions before installing the unit.

Approved installation, operation, and maintenance of this appliance must be in accordance with the listed specifications contained in these instructions and other documents supplied with the furnace and/or optional air conditioning equipment. Unless it is noted differently in this manual, only use factory authorized kits and accessories on this appliance. Refer to local authorities having jurisdiction for further information.

and provided with circuit protection in accordance with local building codes. If there is any question concerning the power supply, contact the local power company.

√

Verify the air delivery of the furnace is adequate to handle the static pressure drop of the coil, filter, and duct work.

Locating the Unit

• The dimensions of the room or alcove must be able to accommodate the overall size of the unit and required clearances to combustible materials listed in Table 1

(page 5). Access for positioning and servicing must also be considered when locating the unit. To determine the required clearances needed for installation and combustible materials, refer to Figures 24 - 26 (pages

30 - 32) for overall dimensions.

• The furnace must be installed on a solid surface and must be level front-to-back and side-to-side at installation. The surface that the furnace is mounted on must provide sound physical support of the unit.

• The furnace should be installed as close to the center of the air distribution system as possible and attached to a properly installed duct system.

Do not use the back of the furnace for return air.

See pages 11 - 12 for circulating requirements.

• The furnace must be installed so that all electrical components are protected from water.

• The plenum attached to the A/C coil box and ductwork within 3 ft. of the furnace must be installed so that surfaces are at least 1/4” from combustible construction.

• When installed in a residential garage, the furnace 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.

• This furnace is certified for use on wood flooring or supports, but must not be installed directly on carpeting, tile, or any combustible material other than wood flooring.

NOTE:

The furnace may be installed on combustible flooring when installed on a Nordyne duct connector

(Figure 8). This factory supplied accessory must be installed in the floor cavity and attached to the supply air duct before the downflow furnace is installed.

• The furnace must be installed upstream from a refrigeration system.

FELT-SEAL

REDUCER

(See Notes)

Before You Install this Furnace

√

This equipment is securely packaged at the time of shipment and upon arrival should be carefully inspected for damage prior to installing the equipment at the job site. Claims for damage (apparent or concealed) should be filed immediately with the carrier.

√

Check the electrical supply and verify the power supply is adequate for unit operation. The system must be wired

FIBERGLASS

INSULATION

DUCT CONNECTOR TABS

NOTES:

With reducer installed: Opening to duct is 10-1/4” x 13-1/4”.

With reducer removed: Opening to duct is 13-1/4” x 13-1/4”.

Figure 8. Duct Connector

SPACERS

FLOOR OPENING

“X”

SUPPLY AIR DUCT

FLOOR

CAVITY

If Floor Cavity

(“X”) is:

Duct Connector

Type & Part Number

7/8” (22)

2” (51)

4-1/4” (108)

6-1/4” (159)

8-1/4” (210)

10-1/4” (260)

12-1/4” (311)

Finger Tab

901987A

901988A

901989A

901990A

901991A

901992A

901993A

Screw Down

904008

NOTE:

Dimensions shown as Inches (Millimeter)

Table 4. Duct Connector Sizes

904009

904010

904011

904012

904013

904014

2 1/4

20"

REAR WALL OF CLOSET OR ALCOVE

2 3/4

Floor Cut-Out for

Duct Connector

16 3/4

21 5/8

TYP.

14 1/2”

CL

1 1/2 TYP.

Furnace Door

1/2 TYP.

Optional floor cutouts for gas, condensate, or AC linesets

(3 1/2 x 1 1/2 - 2 places)

Figure 9. Floor Cutout Dimensions

20"

REAR WALL OF CLOSET OR ALCOVE

CEILING CUT-OUTS FOR

VENT & COMBUSTION AIR

EXHAUST

VENT

COMBUSTION

AIR INLET

Locating & Cutting Floor Openings

IMPORTANT NOTE: Cut-outs in the floor, must be carefully located to avoid misalignment of the furnace.

To locate standard ducts, see Figure 9. For round ducts, see Figure 10.

1. Measure from the rear wall or alcove and mark the centerline of the cut-out on the floor. Using the centerline as a starting point, draw the rest of the duct cut-out to the dimensions shown in Figure 9.

2. Cut out the floor opening to within 1” of the actual cutout drawn.

3. Measure from the top of the floor down to the top of the supply air duct to obtain the depth of the floor cavity.

NOTE:

The depth of the floor cavity shown as “X” in

Table 4 will determine the correct duct connector.

4. Determine which duct connector to use from the table.

6. Measure and drill gas hole and cut out for cooling coil

(if applicable). See Figures 9 or 10.

Locating & Cutting Ceiling Openings

IMPORTANT NOTE: Cut-outs in the ceiling and roof must be carefully located to avoid misalignment of the furnace, combustion air piping, and vent piping.

See Figure 9.

1. Measure from the rear wall or alcove and mark the centerlines of both cut-outs in the ceiling.

2. Using the centerlines as a starting point, draw the rest of the cut-outs to the dimensions shown in Figure 10.

3. Cut out the ceiling openings.

Installing Finger Tabbed Duct Connectors

The standard duct connector is designed for use on ducts

12” in width. However ducts narrower than 12” may not allow sufficient clearances for this type of installation. For an alternate installation method, see page 16.

1. Center the duct connector in the floor opening with bottom tabs resting on top of the supply air duct.

2. Mark the cut-out area on the supply air duct by tracing around the connector tabs (Figure 11, page 16) of the duct connector.

3. Remove the duct connector and cut out the marked area of the supply air duct 1/16” larger the actual cutout drawn.

4. Install the duct connector back in the floor opening with the bottom tabs extending into the supply air duct.

5. Install the mounting plate (Figure 11) under the back side of the duct connector. Align the screw holes in both components.

6. Secure the duct connector and the mounting plate to the wood floor with appropriate size screws.

2 1/2

2 3/4

FURNACE

OUTER

DOOR

Figure 10. Ceiling Cut-Out Dimensions

15

16

7. Bend the connector tabs on the bottom of the duct connector upwards and as tight as possible against the supply air duct. See Figure 12 (page 16).

8. Seal all connections with industrial grade sealing tape or liquid sealant.

NOTE:

Requirements for sealing ductwork vary from region to region. Consult with local codes for requirements specific to your area.

Narrow Duct Attachment - Option 1

Thes alternate attachment methods may be used to install a furnace duct connector to narrow metal ductwork if insufficient clearances prevent the bending of the duct connector tabs at the side of the duct.

1. Select Option A or Option B in Figure 12 and cut the top of the supply air duct. Remove metal flaps from the duct (shaded area) if Option A is selected.

2. Fold the duct flaps up to form an opening for the duct connector (applies to Options A or B).

3. Install the duct connector with the bottom tabs extending into the supply air duct.

4. Bend the tabs on the bottom of the duct connector upwards and as tight as possible against the removed ends of the supply air duct.

5. Form the duct flaps up against the side of the duct connector as tight as possible. See Figure 12.

6. Secure the duct connector flaps to the supply air duct with staples (3 minimum) or if a 2x block/joist is not provided, use sheet metal screws (2 minimum).

NOTE:

The duct connector tabs may be attached to the air duct with sheet metal screws or other suitable fasteners as long as the duct connector and the air duct are securely attached.

7. Seal all connections with industrial grade sealing tape or liquid sealant.

NOTE:


Narrow Duct Attachment - Option 2

Thes alternate attachment methods may be used to install a furnace duct connector to narrow metal ductwork if insufficient clearances prevent the bending of the duct connector tabs at the side of the duct.

1. Cut and remove the top of the supply air duct as shown in Figure 13.

2. Install the duct connector with the bottom tabs extending into the supply air duct.

3. Bend the tabs on the bottom of the duct connector upwards and as tight as possible against the supply air duct (Figure 13).

4. Secure the duct connector tabs to the supply air duct with staples (3 minimum) or sheet metal screws (2 minimum).

Hole for

Gas Line

Connector

Tabs

Cutting

Option A

Wood Floor

Fold duct flap here

Cut Here

Cut Here

Cut Here

Cut Here

Fold duct flap here

Supply

Air Duct

Narrow

Duct

Fold duct flaps into duct connector

Fold Flap Here

Secure Flaps with Staples or sheet metal screws

Cutting

Option B

Cut Here

Supply

Air Duct

Narrow

Duct

Fold Flap Here

Figure 12. Narrow Air Ducts - Option 1

Supply Air Duct

Cut out & remove

Secure finger tabs to side of air duct with staples

or sheet metal screws

Finger Tabbed

Duct Connector

Narrow

Duct

Bend tabs tightly against supply air duct

Figure 13. Narrow Ducts - Option 2

Hole for

Gas Line

Supply

Air Duct

Tabs slide into slots in back of furnace

Wood Floor

Mounting

Plate

Duct

Connector

Supply

Air Duct

Supply

Air Duct

Duct Connector

Bend tabs tightly against supply air duct

Figure 11. Finger Tabbed Duct Connector

Finger Tabs


Mounting

Plate

Screw Down

Duct Connector

Figure 14. Screw-Down Duct Connector

Installing Screw-Down Duct Connectors

1. Apply a bead of caulking, mastic, or other approved sealant around bottom side of 1/2” flange and restrictor plate (when applicable).

2. Locate the screw down duct connector over the duct and carefully lower it into place.

3. Secure the duct connector to the floor using flat head screws or nails.

NOTE:

Make sure the duct connector flanges stay in contact with the duct.

4. Secure the plenum to the duct using sheet metal screws making sure a tight seal is made between the duct and the duct connector.

NOTE:

Additional screws may be added if required.

5. Cut away along edge of flange allowing the center to drop into the duct.

NOTE:

Remove section of duct with caution, as edges will be sharp.

Round Duct Connector Installation

1. Install and center the duct connector in the floor opening.

2. Install the mounting plate (Figure 15, page 17) under the back side of the duct connector.

NOTE:

Make sure the screw holes are aligned in both components.

3. Using appropriate size screws, secure the duct connector and the mounting plate to the wood floor.

4. Connect the round supply duct to the underside of the duct connector and secure them with field supplied sheet metal screws or appropriate clamps.

5. Seal all connections with industrial grade sealing tape or liquid sealant as required.

NOTE:


Installing the Furnace

Sides and back of the furnace may be enclosed by wall framing such as in a closet or alcove. The dimensions of the room or alcove must be able to accommodate the overall size of the furnace and the installation clearances outlined on page 5 and Figures 1 - 4 (page 6). The furnace shall be appropriately connected to the supply and return air distribution system as shown in Figures 24 - 26 (pages

30 - 32).

1. Remove furnace outer door(s) and bottom fuel line knockout.

2. Place furnace onto duct connector and center with floor opening.

3. Slide onto mounting plate. (Bottom rear slots on furnace should engage with mounting plate tabs.)

4. Secure front with one (1) fastener at each corner

(Figures 15 or 16).

NOTE:

Additional fasteners may be used at rear, sides or through door frame, as desired, to secure furnace to closet or alcove framing.

Condensate Drainage

CAUTION:

Do not install additional traps in the condensate drain.


Mounting

Plate

WARNING:

The condensate produced by the furnace must be drained. Do not connect a water supply to the drainage hose of the furnace.

Optional Hole for Gas Line

14” Round

Duct Connector

Optional Hole for Gas Line

Figure 15. Round Duct Connector

•

If the furnace is installed in an area where temperatures fall below freezing, special precautions must be made for insulating condensate drain lines that drain to the outdoors. If condensate freezes in the lines, this will cause improper operation or damage to the furnace. It is recommended that all drain lines on the outside of the residence be wrapped with an industry approved insulation or material allowed by local code.

• Before routing the drain tube out of the furnace, loosen the tube clamp and turn the tube so the preset 90° turn faces the intended direction of exit from the cabinet. Do not route the drain tube without rotating the tube first.

This will kink the tube and prevent condensate from draining.

• Care should be taken to route the drain line away from the burner box. Drain lines resting on the burner box can become kinked or collapsed due to the heat from the burner box.

• The condensate drain may exit through the left or right slots in the bottom of the furnace(Figure 16). Make sure the flexible drain hose is not kinked.

17

• The condensate should drain from the plastic collector box as droplets 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.

1. Remove the collector box soft tube (Figure 17) 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.

MTG. PLATE TABS

SECURE FURNACE WITH

2 FASTENERS IN FRONT

Knockout Over Holes

SUPPLY AIR DUCT

SLIDE FURNACE

ALL THE WAY BACK

ONTO MTG. PLATE

GAS SUPPLY & PIPING

WARNING:











18

Figure 16. Cabinet Furnace on Supply Air Duct

Inline

Drain

Optional Exits for

Condensate Drain Lines

Short A Cabinet

Optional Exits for

Condensate Drain Lines

Collector

Box Drain

B Cabinets

Tall & Top Return Air Type

AVERTISSEMENT :

RISQUE D’INCENDIE OU D’ EXPLOSION

• Le non-respect des avertissements de sécurité pourrait entraîner des blessures graves, la mort ou des dommages matériels.

• L’installation et l’entretien doivent être effectués par un installateur qualifié, un organisme de service ou le fournisseur de gazstaller, service agency or the gas supplier.

• Ne pas entreposer ni utiliser de l’essence ni d’autres vapeurs ou liquides inflammables dans le voisinage de cet appareil, ni de tout autre appareil.

QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

• Ne pas tenter d’allumer aucun appareil.

• Ne toucher à aucun interrupteur électrique; n’utiliser aucun téléphone dans le bâtiment.

• Évacuer l’immeuble immédiatement.

• Appeler immédiatement le fournisseur de gaz en employant le téléphone d’un voisin. Respecter à la lettre les instructions du fournisseur de gaz.

• Si personne ne répond, appeler le service des incendies.

Figure 17. Condensate Drainage

•

All gas piping must be installed in compliance with local codes and utility regulations. In the absence of local codes the gas line installation must comply with the latest edition of the Federal Manufactured

Home Constructions & Safety Standard (H.U.D. Title

24, Part 3280.707[a][2]), National Fuel Gas Code

(ANSI Z223.1) or (CAN/CGA B149.1 or .2) Installation

Codes.

• Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace as shown in Figure 18

(page 18). 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.

• Gas piping must never run in or through air ducts, chimneys, gas vents, or elevator shafts.

• Compounds used on threaded joints of gas piping must be resistant to the actions of LP propane gas.

• The main gas valve and main power disconnect to the furnace must be properly labeled by the installer in case emergency shutdown is required.

• Flexible gas connectors are not recommended for this type of furnace but may be used if allowed by local jurisdiction. Only new flexible connectors may be used. Do not use a connector which has previously serviced another gas appliance.

• A drip leg should be installed in the vertical pipe run to the unit if not entering the furnace through the floor.

Table 9 (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.

Leak Check

WARNING:



Never test for gas leaks with an open flame.

Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

AVERTISSEMENT :

RISQUE D’INDENDIE OU D’EXPLOSION

Le non-respect des avertissements de sécurité pourrait d’entraîner des blessures graves, la mort ou des dommages matériels.

Ne jamais utiliser une flamme nue por vérifier la présence des fuites de gaz. Pour la vérification de tous les joints, utiliser plutôt une solution savonneuse commerciale fabriquée spécifiquement pur la détection des fuites de gaz. Un incendie ou une explosion peut entraîner des dommages matériels, des blessures ou la mort.

The furnace is installed with a bottom gas entry. When connecting the gas supply, 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.

Typical gas hookups are shown in Figure 18.

After the gas piping to the furnace is complete, all connections must be tested for gas leaks. This includes pipe connections at the main gas valve, emergency shutoff valve and flexible gas connectors (if applicable). The soap and water solution can be applied on each joint or union using a small paintbrush. If any bubbling is observed, the connection is not sealed adequately and must be retightened. Repeat the tightening and soap check process until bubbling ceases.

A Cabinet (Short)

B Cabinets

(Tall & Top Return Air Type)

Elbows

Elbows

Gas Valve

4

Alternate Fuel

Line Entrance

IMPORTANT NOTE: When pressure testing gas supply lines at pressures greater than 1/2 psig (14 inch W.C.), the gas supply piping system must be disconnected from the furnace to prevent damage to the gas control valve. If the test pressure is less than or equal to 1/2 psig (14 inch W.C.), close the manual shut-off valve.

Gas Valve

Shut-Off

Valve

Alternate Fuel

Line Entrance

Shut-Off

Valve

Alternate Fuel

Line Entrance

Figure 18. Typical Gas Connections

19

20

High Altitude Application

High altitude conversion with this furnace depends on the installation altitude and the heating value of the gas.

Installation of this furnace at altitudes above 2,000 feet shall be in accordance with local codes, or in the absence of local codes, the National Fuel Gas Code, ANSI Z223.1/

NFPA 54 or National Standard of Canada, Natural Gas &

Propane Installation Code CGA B149.1. Please consult your local code authority.

meter and using the local gas heating value. See Verifying

& Adjusting the Input Rate section (page 25).

IMPORTANT NOTE: Observe the action of the burners to make sure there is no yellowing, lifting or flashback of the flame.

Installation Example

Elevation:

.................................................. 5,000 feet

Type of Gas:

........................................... Natural Gas

Local Heating Value of Gas:

..............................

750

WARNING:

The reduction of input rating necessary for high altitude installation may only be accomplished with factory supplied orifices. Do not attempt to drill out orifices in the field. Improperly drilled orifices may cause fire, explosion, carbon monoxide poisoning, personal injury or death.

The furnaces are shipped from the factory with orifices and gas regulator settings for natural gas operation at sea level altitudes. At 2000 feet, the NFGC requires that this appliance be derated 4% for each 1000 feet of altitude.

For example, the input needs to be reduced 8% at 2,000 feet, 12% at 3,000 feet, etc. This deration is in reference to the input rate and gas heating value at sea level.

To derate the furnace requires knowing the heating value of the gas at the installation site. Heating values at particular job sites vary for two reasons:

1. The chemical mixture of the gas varies across regions and is expressed as the sea level heating value.

2. The heating value varies by altitude. For this reason, especially in high altitude areas, the local gas utility specifies the heating value at the residence’s gas meter as the local value.

For added flexibility, two tables have been provided for natural gas installations with high or low heating values at sea level. Tables 12 & 13 (page 35) contain the manifold pressure and orifice sizes to use at various altitudes.

Table 12 (HIGH) is for natural gas installations with a heating value of more than 1,000 Btu per cubic foot and

Table 13 (LOW) is for less than 1,000 Btu per cubic foot.

To determine which table to use:

1. Consult the local utility for the local heating value at your installation site.

2. From Table 11 (page 35), find your local heating value as supplied by the utility company. Follow down the column and stop at your altitude level.

3. If your sea level heating value is HIGH, use Table 12 or if it’s LOW, use Table 13. See example.

After changing the regulator pressure or the orifices, it is required that you measure the gas input rate. This may be accomplished in the usual way, by clocking the gas

From Table 11, find 750 and follow down the column, stop at the 5,000 feet row. The heating value listed is

LOW. Table 13 will be used to determine orifice size and manifold pressure.

Regulator Cap

Adjusting Screw

On / Off Knob

Manifold

Pressure Tap

Terminal

Connectors

AT N

AT

OR

L

P

P

L

OTHER SIDE

OF CAP

Figure 19. Gas Valve

Converting to LP/Propane Gas at Altitudes between 0 & 10,000 FT.

WARNING:

Inlet

Pressure

Tap

The furnace was shipped from the factory equipped to operate on natural gas. Conversion to LP / Propane gas must be performed by qualified service personnel using a factory supplied conversion kit. Failure to use the proper conversion kit can cause fire, explosion, property damage, carbon monoxide poisoning, personal injury, or death.

Converting single stage valves to LP/Propane requires the replacement of the burner orifices and flipping the regulator cap to the side marked LP. The end facing up should now read LP. See Figure 19.

Table 10 (page 35), provides the manifold pressure for altitudes above 2,000 feet.

WARNING:

Shut off the gas supply at the manual gas shutoff valve, before disconnecting the electrical power.

A fire or explosion may result causing property damage, personal injury or loss of life. Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

Burner Box

Gas Valve

(X4)

Burner Box

Door

Orifice

(X4)

Gas Manifold

Figure 20. Orifice Removal

(X6)

WARNING:

To avoid electric shock, personal injury, or death, turn off the electric power at the disconnect or the main service panel before making any electrical connections.

12. Install the appropriate LP/Propane gas burner orifices into the gas manifold assembly.

NOTE:

The orifices are included with the furnace.

To prevent cross threading, hand tighten the orifices into the gas manifold assembly until snug, then tighten with a wrench.

13. Unscrew the gas valve pressure regulator cap marked

NAT. Invert the cap so LP faces up. Reinstall the cap and tighten until snug. Make sure LP is visible after conversion.

WARNING:

The reduction of input rating necessary for high altitude installation may only be accomplished with factory supplied orifices. Do not attempt to drill out orifices in the field. Improperly drilled orifices may cause fire, explosion, carbon monoxide poisoning, personal injury or death.

Removing The Burner Orifices

1. Set the thermostat to the OFF position, or its lowest temperature setting.

2. Shut OFF the gas supply at the manual shutoff valve located outside of the appliance.

3. Turn off all electrical power to the appliance.

4. Remove the door from the burner box by removing 6 screws.

5. Turn the gas valve ON/OFF knob to the OFF position.

See Figure 19.

6. Remove the wires from the terminals of the gas valve.

7. Remove the supply gas piping from the gas valve inlet.

8. Carefully remove four screws securing the gas manifold assembly to the burner assembly. See Figure 20.

9. Set the screws aside and remove the gas manifold assembly from the appliance.

10. Carefully remove the burner orifices from the gas manifold assembly.

11. Read the rating plate affixed to the appliance to determine its rated input (Btu/hr) and the size of the factory installed orifices.

IMPORTANT: Before installing an orifice, check the side or face of the orifice for the drill number to ensure that it is the appropriate size.

WARNING:

Do not use Teflon tape or pipe joint compound on the orifice threads. The hole in the orifice may become blocked and cause fire, explosion, property damage, carbon monoxide poisoning, personal injury, or death.

14. Reinstall the gas manifold assembly to the burner assembly with the 4 screws, that were removed earlier.

NOTE:

It is important that the center of the orifices are aligned with the center of the burners.

15. Reinstall the burner box door with the 6 screws that were removed earlier in step 4.

16. Reconnect the gas piping to the gas valve inlet.

17. Reconnect the wires to the gas valve terminals.

Gas Pressure Adjustment

Measuring the Supply Gas Pressure

1. Turn OFF the gas supply at the manual valve located on the outside of the unit.

2. Using a 3/16” Allen wrench, remove the plug from the inlet pressure tap (INLET side of gas valve). See Figure

19 (page 20).

3. Install an 1/8” NPT pipe thread fitting, that is compatible with a Manometer or similar pressure gauge.

4. Connect the Manometer or pressure gauge to the Inlet

Pressure Tap.

5. Turn ON the main gas supply at the manual valve.

6. Check and adjust the incoming gas line pressure to

11.0-14.0 inches Water Column for LP/Propane gas.

7. Turn OFF the gas supply at the manual valve.

8. Disconnect the Manometer or pressure gauge.

21

22

9. Remove the NPT fitting and reinstall the INLET pressure tap plug. Hand tighten the plug first to prevent crossthreading. Tighten with 3/16 Allen wrench.

Lighting & Adjustment of the Appliance

WARNING:



Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

1. Turn ON the manual gas valve, located on the outside of the unit to the ON position.

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.

3. Turn on the electrical power to the appliance.

4. Turn the gas valve ON/OFF knob to the ON position.

See Figure 19 (page 20).

5. Set the thermostat to a point above room temperature to begin the heating cycle of the furnace.

6. Check that the furnace ignites and operates properly.

Refer to the installation instructions provided with the unit for the normal operating sequence.

7. After ignition, visually inspect the burner assembly to ensure that the flame is drawn directly into the center 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:

The igniter may not ignite the gas until all air is bled from the gas line. 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. After the burners are lit, check all gas connections for leaks again with the soap and water solution.

Measuring the Manifold Pressure

The manifold pressure must be measured by installing a pressure gauge (Manometer, Magnehelic Meter, etc.) to the outlet end of the gas valve as follows:

1. Turn off all electrical power to the appliance.

2. Shut OFF the gas supply at the manual shutoff valve located outside of the appliance.

3. Using a 3/16” Allen wrench, remove the manifold pressure tap plug located on the outlet side of the gas valve. See Figure 19 (page 20).

4. Install an 1/8” NPT pipe thread fitting, that is compatible with a Manometer or similar pressure gauge.

5. Connect the Manometer or pressure gauge to the manifold pressure tap.

6. Set the room thermostat above room temperature to start the furnace.

7. Allow the furnace to operate for 3 minutes and then check the manifold pressure. Compare the measured value with the value listed in Table 10 (Propane) or Tables 12 or 13 (Natural Gas) on page 35. If the manifold pressure is not set to the appropriate pressure, then it must be adjusted.

Adjusting the Manifold Pressure

1. Single stage gas valve: Remove the regulator cap from the top of the gas valve. See Figure 19 (page 20).

2. Using a screwdriver, slowly turn the adjustment screw till the appropriate manifold pressure is displayed on the pressure guage.

NOTE:

Turning the screw clockwise increases the pressure, turning the screw counter-clockwise decreases the pressure. To prevent the screw from backing all the way out from the valve, turn the screw slowly.

3. Replace and tighten the regulator cap over the adjustment screw.

Removing the Manometer/Pressure Gauge

After the manifold pressure is properly adjusted, the

Manometer or pressure gauge must be removed from the gas valve.

1. Turn the thermostat to its lowest setting.

2. Turn OFF the main gas supply to the unit at the manual shut-off valve, which is located outside of the unit.

3. Turn OFF all of the electrical power supplies to the unit.

4. Remove the pressure gauge adapter from the gas valve and replace it with the 1/8” NPT manifold pressure plug that had been removed earlier.

NOTE:

Make sure the plug is tight and not cross-threaded.

5. Turn ON the electrical power to the unit.

6. Turn ON the main gas supply to the unit at the manual shut-off valve.

Completing the Conversion

WARNING:

Do not alter or remove the original rating plate from the furnace.

1. Affix the LP label from the orifice package to the rating plate.

2. Reinstall the appliance door.

3. Run the appliance through 3 complete cycles to assure proper operation.

ELECTRICAL WIRING

WARNING:


HAZARD



• Before servicing, disconnect all electrical power to furnace.


• Verify proper operation after servicing.”

AVERTISSEMENT :

RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE

OU D’EXPLOSION

Le non-respect des avertissements de sécurité pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages matériels.

Un entretein incorrect pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages matériels

• Couper toute alimentation électrique au générateur d’air chaud avant de prodéder aux travaux d’entretein.

• Au moment de l’entretien des commandes,

étiquetez tous les fils avant de les débrancher.

S’assurer de les raccorder correctement.

• S’assurer que l’appareil fonctionne adéquatement aprés l’entretien.

Line Voltage Wiring

• Electrical connections must be in compliance with all applicable local codes with the current revision of the

National Electric Code (ANSI/NFPA 70).

• For Canadian installations the electrical connections and grounding shall comply with the current Canadian

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

• It is recommended that the line voltage (115 VAC) to the furnace be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace as listed in Table 5 (page 24).

IMPORTANT NOTES:

If replacing any of the original wires supplied with the furnace, the replacement wire must be copper wiring and have a temperature rating of at least 105°F

(40°C). For electrical specifications, refer to the furnace nameplate or Table 5.

An electrical disconnect must be installed readily accessible from and located within sight of the furnace.

See Figure 21 (page 24) or the wiring diagram label inside of the control door. Any other wiring methods must be acceptable to authority having jurisdiction.

Proper line voltage polarity must be maintained in order for the control system to operate correctly.

Verify the incoming neutral line is connected to the white wire and the incoming HOT line is connected to the black wire. The furnace will not operate unless the polarity and ground are properly connected as shown in Figure 21.

Thermostat / Low Voltage Connections

• The furnace is designed to be controlled by a 24 VAC thermostat. The thermostat’s wiring must comply with the current provisions of the NEC (ANSI/NFPA 70) and with applicable local codes having jurisdiction.

• The thermostat must be installed according to the instructions supplied by the thermostat manufacturer.

Low voltage connections (24 VAC) from the thermostat are wired to the terminal strip on the integrated control in the furnace. Figure 22 (page 24) contains the proper connections for heating only (two-wire) and heating/ cooling (four-wire) applications. Recommended minimum wire gauge for thermostat wiring is shown in Table 5 (page 24).

• The thermostat should be mounted about 5 feet above the floor on an inside wall. DO NOT install the thermostat on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces, sunlight, or lighting fixtures, and convective heat from warm air registers or electrical appliances. Refer to the thermostat manufacturer’s instruction sheet for detailed mounting information.

23

24

Furnace

Model

Number

M7RL-

045A

060A

072A

Furnace

Input

(Btuh)

45,000

60,000

72,000

Cabinet

Width

(in.)

19 7/8

19 7/8

19 7/8

Nominal

Electrical

Supply

Maximum

Operating

Voltage

Minimum

Operating

Voltage

Maximum

Furnace

Amperes

Minimum

Wire

Gauge

Maximum

Fuse or Circuit

Breaker Amps*

115-60-1

115-60-1

115-60-1

127

127

127

103

103

103

11.0

11.0

10.4

14

14

14

20

20

20

Minimum

Circuit

Ampacity 1

13.1

13.1

12.4

Mamimum

Overcurrent

Protection 2

21.7

21.7

20.4

NOTE:

Minimum wire gauge and maximum fuse/circuit breaker amperage are based on MCA

1

and MOP

2

calculations. This furnace is approved for installation with a 15 or 20 amp fuse/circuit breaker however wiring sizing must adhere to current version of the NEC and/or applicable local codes depending upon the overcurrent protection.

Recommended Thermostat Wire Length

Thermostat Wire Gauge

2 - wire - Heating

24

22

20

18

55 ft.

90 ft.

140 ft.

225 ft.

*

Time-delay fuses or circuit breakers are required.

4 or 5 wire - Cooling

25 ft.

45 ft.

70 ft.

110 ft.

Table 5. Wire Length & Voltage Specifications

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 in the field supplied disconnect at the furnace.

Black (Hot)

White (Neutral)

Green or Bare

(Ground)

Black

White

Ground

Field Line Voltage Wiring

Factory Line Voltage Wiring

Black

White

Ground

Field Supplied

Panel Connector

Black

White

Ground

ROOM

THERMOSTAT

Connect

R & W

For Heating

Only

NOTE: The “Y” terminal on the control board must be connected to the thermostat for proper cooling mode operation.

FIELD WIRING

LOW VOLTAGE

CONNECTION

R

C

Y

G

W

A/C CONDENSING UNIT

3 AMP

FUSE

Figure 21. Line Voltage Field Wiring

CONDENSING UNIT

CONTROL BOX

EXPANSION PORT

(MOTOR CONNECTION)

SPEED

SELECT

STATUS

FLAME

RED

GREEN

YELLOW

Heat Anticipator

Set the heat anticipator according to the instructions supplied by the thermostat manufacturer.

To determine the heat anticipator setting:

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.

Grounding

9

8

7

6 3

5

2

4 1

BLOWER

OFF

DELAY

180

120

90

60

6 3

5

2

4 1

NEUTRAL LEADS

MOTOR SPEED TAPS

(NOT USED)

ELECTRONIC AIR CLEANER

HUMIDIFIER TAP

Figure 22. Low Voltage Field, Four-wire

Heating/Cooling Applications

WARNING:

To minimize personal injury, the furnace cabinet must have an uninterrupted or unbroken electrical ground. The controls used in this furnace require an earth ground to operate properly. Acceptable methods include electrical wire or conduit approved for ground service.

Do not use gas piping as an electrical ground!

START-UP & ADJUSTMENTS

Pre-Start Check List

√

Verify the polarity of the connections are correct, the line voltage power leads are securely connected and the furnace is properly grounded.

√

Verify the thermostat wires (

R

,

W

,

Y

, &

G

) are securely connected to the correct leads on the terminal strip of the circuit board.

√

Verify the gas line service pressure does not exceed

10.0 inches of W.C., and is not less than 4.5 inches W.C. for natural gas. For LP gas the line service pressure must not exceed 14 in. W.C., and must not be less than

11.0 in. W.C.

√

Verify the roll-out and vent switches are closed. If necessary, press the red button to reset a switch.

DO

NOT install a jumper wire across a switch to defeat its function.

If a switch reopens on startup, DO NOT reset the switch without identifying and correcting the fault condition.

√

Verify the blower door is in place, closing the door switch in the line voltage circuit.

√

Verify the gas line has been purged and all connections are leak free.

Start-up Procedures

Do not perform these steps until all of the checks in the previous steps have been completed:

1. Set the thermostat to the lowest setting.

2. Turn off all electrical power to the furnace.

3. Follow the Operating Instructions on the label attached to the furnace.

4. Set the thermostat above room temperature and verify the Operating Sequence (page 27).

5. After 5 minutes of operation, set the thermostat below room temperature and verify steps 9 - 10 of the Operating

Sequence.

Verifying & Adjusting Input Rate

The input rate must be verified for each installation to prevent over-firing of the furnace.

NOTE:

The input rate must not exceed the rate shown on the furnace rating plate.

At altitudes above 2,000 feet, it must not exceed that on the rating plate less 4% for each 1,000 feet. To determine the exact input rate, perform the following procedures:

1. Shut off all other gas fired appliances.

2. Start the furnace and run it for at least 3 minutes.

3. Measure the time (in seconds) required for the gas meter to complete one revolution.

4. Convert the time per revolution to cubic feet of gas per hour using Table 8 (page 34).

5. Multiply the gas flow rate in cubic ft per hr by the heating value of the gas in Btu per cubic ft to obtain the input rate in Btuh. See example above.

6. The manifold pressure must be set to the appropriate value for each installation by a qualified installer, service agency or the gas supplier.

Example

:

• Time for 1 revolution of a gas meter with a 1 cubic ft dial = 40 seconds.

• From Table 8 read 90 cubic ft gas per hr.

• Local heating value of the gas (obtained from gas supplier) = 1,040 Btu per cubic ft.

• Input rate = 1,040 x 90 = 93,600 Btuh.

WARNING:

Do not attempt to drill the gas orifices. Use only factory supplied orifices. Improperly drilled orifices may cause fire, explosion, carbon monoxide poisoning, personal injury or death.

a.) Obtain the manifold pressure setting required for this installation by referring to Table 10 for Propane or Tables 12 or 13 (page 35) for Natural Gas.

b.) Remove the regulator capscrew from the INLET side of the regulator. See Figure 19, page 20.

c.) Slowly turn the adjustment screw inside the regulator to obtain the appropriate manifold pressure.

NOTE: Turning the screw clockwise increases the pressure and turning the screw counter-clockwise decreases the pressure. To prevent backing the screw all the way out from the valve, turn the screw slowly.

d.) Replace and tighten the regulator capscrew over the adjustment screw.

Verifying & Adjusting Temperature Rise

After installation of the furnace, confirm the temperature rise of the furnace is within the limits specified on the rating plate. Any temperature rise outside the specified limits could result in premature failure of the heat exchanger.

For typical duct systems, the temperature rise will fall within the limits specified on the rating plate with the blower speed at the factory recommended setting. If the measured temperature rise is outside the specified limits, it may be necessary to change the speed of the blower.

NOTE:

Lowering the blower speed will increase the temperature rise and a higher blower speed will decrease the temperature rise.

The furnace is equipped with a multi-speed motor. Heating and cooling speed selection is made by moving the switch on the integrated control located in the furnace.

1. Place thermometers in the return and supply air stream as close to the furnace as possible.

IMPORTANT: The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings.

2. Consult Table 6 (page 26) and the rating plate for the proper circulating air flow and temperature rise.

25

26

NOTE:

This furnace is designed to operate with a maximum external pressure rise of 0.3 inches of water column. It is important that the duct system be designed to provide the correct flow rates and external pressure rise. An improperly designed duct system can result in nuisance shutdowns, and comfort or noise issues.

3. Adjust all registers and duct dampers to the desired position and run the furnace for 10 to 15 minutes before taking any temperature readings. The temperature rise is the difference between the supply and return air temperatures.

Verifying Burner Operation

CAUTION:

The door over the burners may only be open for inspection purposes only. The door must be installed during unattended operation.

Verifying Operation of the Supply Air Limit

Switch

NOTE:

A properly functioning limit switch should turn off the gas valve when the return is blocked (time depends on how well the return air is blocked). The circulating air and combustion blowers should continue to run when the limit switch opens

.

1. Verify the blower door is securely mounted in place and that there is power to the furnace.

2. Block the return airflow to the furnace by installing a close-off plate in place of or upstream of the filter(s).

3. Set the thermostat above room temperature and observe the Operating Sequence.

4. Remove the close-off immediately after the limit switch opens. If the furnace continues to operate with no return air, set the thermostat below room temperature, shut off power to the furnace, and replace the limit switch.

1. Set the thermostat above room temperature and observe the ignition sequence.

NOTE:

The burner flame should carry over immediately between all burners without lifting off, curling, or floating. The flames should be blue, without yellow tips.

2. After validating the flame, change thermostat setting to below room temperature.

3. Verify the burner flame is completely extinguished.

4. Replace the burner compartment door.

Model Number &

Heating Input (BTUH)

M7RL 045

45,000

M7RL 060

60,000

M7RL 072

72,000

Motor Speed 0.1

External Static Pressure (Inches Water Column)

0.2

0.3

0.4

0.5

CFM Rise CFM Rise CFM Rise CFM Rise CFM Rise

HIGH*

MED HIGH

MED LOW

LOW**

1580

1355

1185

25

29

33

1530

1330

1165

26

30

34

1485

1300

1140

27

30

35

1435

1265

1100

28

31

36

1380

1220

1065

29

32

37

910 44 890 45 865 46 835 47 810 49

HIGH*

1580 33 1530 35 1485 36 1435 37 1380 38

MED HIGH**

1355 39 1330 40 1300 41 1265 42 1220 43

MED LOW

LOW

1185

910

45

58

1165

890

45

59

1140

865

46

61

1100

835

48

63

1065

810

50

65

HIGH*

1555 41 1505 42 1460 43 1405 45 1350 47

MED HIGH**

1490 43 1450 44 1405 45 1355 47 1310 48

MED LOW

LOW

1005

900

63

70

975

875

65

72

950

845

67

75

925

810

69

78

875

775

72

82

Recommended

A/C Ton

4

3

2 1/2

2

4

3

2 1/2

2

4

3

2 1/2

2

NOTES:

* Factory Set Cooling Speed

** Factory Set Heating Speed

1. Temperature rises (°F) in the table are approximate. Actual temperature rises may vary.

2. Temperature rises shaded in gray are for reference only. These conditions are not recommended.

3. Airflow performance is with a filter.

Table 6. Maximum Airflow & Temperature Rises (° F)

OPERATING SEQUENCE

The operating sequences for the heating, cooling, and fan modes are described below. Refer to the field and furnace wiring diagrams: (Figure 22, page 24) and (Figure

27 page 33).

MAINTENANCE

Proper maintenance is most important to achieve the best performance from a furnace. Follow these instructions for years of safe, trouble free operation.

Heating Cycle

1. The thermostat calls for heat by energizing the

W

terminal with 24VAC.

2. The control verifies the pressure switch is open.

3. If the pressure switch is open, the control energizes the inducer and waits for the pressure switch to close. The pressure switch must close within 10 seconds.

4. The control runs the inducer for a 30 second pre-purge.

5. The control energizes the Hot Surface Igniter (HSI) output for the appropriate warm-up time limit.

6. The control energizes the main gas valve for 3 seconds.

7. If the flame proved and ignites the gas, the control deenergizes the HSI. The gas valve and inducer remains energized. The control goes to blower on delay.

8. If flame is present, the control energizes the blower on the selected HEAT speed 30 seconds after the gas valve opened. The gas valve and inducer remain energized.

9. When the thermostat demand for heat is satisfied, the control de-energizes the gas valve. The Inducer output remains on for a 30 second post-purge period.

10. Blower off timing begins when the thermostat is satisfied. The control will operate at the selected HEAT speed of 60, 90, 120, or 180 seconds. If the blower off delay jumper is not present, the fan should still operate for 120 seconds at the selected HEAT speed.

The Indoor blower motor is de-energized after a blower off delay as selected by the movable jumper.

Cooling Cycle

1. The thermostat calls for cooling by energizing the

Y

terminal with 24VAC.

2. The control energizes the blower in cooling speed and sends 24VAC to the contactor in the condensing unit

3. When the thermostat removes the call for cooling, the contactor in the outdoor condensing unit is de-energized and the control continues to run the fan for a period of

60 seconds.

WARNING:


HAZARD



• Before servicing, disconnect all electrical power to furnace.


• Verify proper operation after servicing.”

AVERTISSEMENT :

RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE

OU D’EXPLOSION

Le non-respect des avertissements de sécurité pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages matériels.

Un entretein incorrect pourrait entraîner un fonctionnement dangereux de l’appareil, des blessures graves, la mort ou des dommages matériels

• Couper toute alimentation électrique au générateur d’air chaud avant de prodéder aux travaux d’entretein.

• Au moment de l’entretien des commandes,

étiquetez tous les fils avant de les débrancher. S’assurer de les raccorder correctement.

• S’assurer que l’appareil fonctionne adéquatement aprés l’entretien.

Fan Mode

• When the thermostat energizes the

G

terminal for continuous fan (without calling for heat or cooling), the indoor fan is energized on the selected FAN speed.

• If a call for cooling occurs during continuous fan, the blower will switch over to the selected COOL speed.

• If the

W

terminal receives a call for heat during continuous fan, the blower will de energize.

• A call for fan is ignored while in lockout.

• These maintenance instructions are primarily intended to assist qualified technicians experienced in the proper maintenance and operation of this appliance.

• Always close the door on the furnace after servicing or cleaning/changing the filters.

Do not operate the furnace without the door closed.

• Verify the thermostat is properly installed and will not be affected by drafts or heat from lamps or other appliances.

27

28

• To achieve the best performance and minimize equipment failure it is recommended that a yearly maintenance checkup be performed. At a minimum, this check should include the following items:

Air Filter(s)

WARNING:

Never operate the furnace without a filter in place. Dust and lint can build up on internal components, resulting in loss of efficiency, equipment damage, and possible fire.

An air filter is supplied with the furnace as shipped from the factory. Filters should be changed or cleaned monthly during the heating season. Newly built or renovated homes may require more frequent changing until the construction dust has minimized.

Filters designed to remove smaller particles such as pollen, may require additional maintenance.

6. Remove the piping between the gas valve and the ground-joint union. (If applicable).

7. Remove 6 screws securing the burner box door. See


8. Remove 4 screws securing the manifold assembly to the burner box.

9. Remove 4 screws from the corners of the box and carefully remove the burner assembly from the furnace.

IMPORTANT: DO NOT damage the igniter while removing the burner assembly.

10. Inspect the burners for accumulated dust or debris.

If necessary carefully clean them with a soft wire brush and a vacuum cleaner.

IMPORTANT: DO NOT damage the igniter while cleaning the burner assembly.

11. Replace all the parts in reverse order that they were removed.

12. Follow the lighting instructions found on the furnace door to return the furnace to operation. Verify proper operation after servicing.

Vent System

Blower Compartment

Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life. It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection.

Cleaning of Burners

If the burners must be cleaned, follow steps 1-12. See

Figure 23 (page 29) for component location.

1. Shut off gas supply to the furnace at the meter or at a manual valve in the supply piping.

2. Turn off all power to the furnace and set the thermostat to it’s lowest setting.

3. Turn the gas control knob to the OFF position. See


4. Disconnect the wires from the gas valve, igniter, flame sensor, and flame rollout switch.

CAUTION:

To prevent damage to the unit or internal components, it is recommended that two wrenches be used when loosening or tightening nuts. Do not over tighten!

5. Using two wrenches, separate the ground-joint union in the gas supply piping at the furnace.

WARNING:

Holes in the vent pipe or heat exchanger can cause combustion products to enter the home.

Replace the vent pipe or heat exchanger if leaks are found. Failure to prevent the circulation of combustion products into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.

Check the inlet pipe (if applicable) and outlet pipe to ensure they are not 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.

Heat Exchanger & Burner Maintenance

The furnace should operate for many years without soot buildup in the flue passageways, however, the flue, vent system, and burners should be inspected and cleaned

(if required) by a qualified service technician annually to ensure continued safe operation. Pay attention to any deterioration from corrosion or other sources.

Lubrication

The bearings in the blower motor and inducer blower used in these furnaces are pre-lubricated and sealed by the manufacturer. No further oiling of the bearings is required for the life of the motor.

TROUBLESHOOTING

If the furnace fails to operate check the following:

• Is the thermostat operating properly?

• Are the blower compartment door(s) in place?

• Is the furnace disconnect closed?

• Has the circuit breaker tripped or the control board fuse burned open?

• Is the gas turned on?

• Are any manual reset switches open?

• Is the filter dirty or plugged?

• Is the flame sensor coated? (Remove and clean with steel wool.

(Do not use emery cloth or sandpaper!)

• Is there blockage in the condensate drain switch? Also verify that there is no double trapping of condensate.

• Is the secondary heat exchanger free of debris and clogs?

• Is evaporator coil clean and free of debris (If applicable).

• Are all the LED’s on the furnace control board constantly

ON? If not, refer to Table 7 or the wiring diagram (Figure

27, page 33) to determine fault condition.

IMPORTANT NOTE: The furnace will lock out after 5 failed attempts for ignition and will try again every hour if the call for heat remains.

• If the inducer blower is operating, and items above have been verified, check the blower limit switch and reset if necessary. See Figure 23 for component location.

• If the furnace operates when the Blower Limit Switch is reset, contact a qualified service technician to identify and repair the problem.

• If the furnace still doesn’t operate, check the flame roll-out switch and reset if necessary.

• If the furnace operates when the flame rollout switch is reset, contact a qualified service technician to identify and repair the problem.

DESCRIPTION OF COMPONENTS

The descriptions below are various functional components that affect the operation and shutting down of this furnace.

Some of these components and their locations are shown in Figure 23. If any component of the furnace must be replaced, use only factory authorized replacement parts specified in the Replacement Parts List provided online.

Blower Limit Switch:

Prevents operation when blower is not operational.

Flame Sensor:

Verifies when a flame has carried over from the igniter to the opposite end burner. If no flame is detected, the furnace will shut down within 4 seconds.

Flame Roll-Out Switch:

Verifies that the burner flames are drawn into the heat exchanger tubes. If the burner flames are not properly drawn into the heat exchanger, the flame roll-out switch will close the gas valve and initiate the shutdown cycle.

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.

Inducer Assembly:

Vents products of combustion to the outside.

Pressure Switch:

Verifies that the inducer is drawing the combustion gases through the heat exchanger. The pressure switch prevents furnace operation with excessive flue/condensate blockage or improper inducer operation.

Main Air Limit Switch:

Prevents the air temperature leaving the furnace from exceeding the maximum allowable outlet air temperature.

Diagnostic Description Green LED Red LED

Control Fault (No Power)

L1/Neutral Polarity Fault

1 Hour Lockout

Normal Operation

Pressure Switch Closed Fault

Pressure Switch Open Fault

Open Limit Switch Fault

Off

Flash

Off

Flash

Alternating Flash

On On

On Flash

Flash

Flash

On

Off

Diagnostic Description

Low Flame Sensor Signal

Flame Present

Yellow LED

Continuous Flash

On

Table 7. Control Board Fault Conditions

Exhaust Vent Pipe

Blower Switch

Control Board

Inline Drain

Assembly

Limit Switch

Gas Valve

Igniter

Blower Assembly

Inducer Assembly

Combustion Air Pipe

24V Transformer

Main Air Limit Switch

Flame Sensor

Roll-Out Switch

Gas Manifold &

Burner Assembly

M7RL B Cabinet Shown

Figure 23. Furnace Components

29

30

FIGURES & TABLES

1

Furnace Dimensions

17 3/4

15 1/2

Knockouts (x4)

2 1/2 x 5

(Ventilaire)

5

2

2 5/8

2 3/4

3

3 1/2

(X2)

2

18 1/2

18 1/2

Knockouts (x4)

1/2

1 1/2

20 1/4

17 1/8

2 3/4

7/8

(Electric)

1 1/2 X 3 1/2

(Gas or Condensate)

23 1/2

1 3/16

3 1/2

24 5/8

56

19 7/8

1 1/2 X 3 1/2

(Gas or Condensate - Typical)

1/2 TYP.

15

21 5/8

TYP.

15

2 3/8

1 1/8

Figure 24. A-Size Cabinet Models (Short)

1 1/2

18 1/2

Knockouts (x4)

2

18 1/2

1 3/16

1 1/2 X 3 1/2

(Gas or Condensate)

1 7/8

1

17 3/4

15 1/2

Knockouts (x4)

2 1/2 x 5

(Ventilaire)

5

2

2 5/8

2 3/4

3

3 1/2

(X2)

2

18 1/2

18 1/2

Knockouts (x4)

1/2

1 1/2

20 1/4

7/8

(Electric)

2 3/4

17 1/8

55

76

3 1/2

43 1/2

1 1/2 X 3 1/2

(Gas or Condensate)

21 1/4

24 5/8

20

19 7/8

1 1/2 X 3 1/2

(Gas, Condensate, or Linesets - Typical)

15

21 5/8

TYP.

15

2 3/8

1 1/8

Figure 25. B-Size Cabinet (Tall) Models

1 1/2

18 1/2

18 1/2

Knockouts (x4)

2

1 7/8

21.250

1 1/2 X 3 1/2

(Gas or Condensate)

31

32

17

3 1/2

(X2)

5

2

2 5/8

2 1/2 x 5

(Ventilaire)

15 1/2

2 3/4

3

2 18 1/2

Knockouts (x4)

1 1/2

18 1/2

1 1/2

18 1/2

18 1/2

Knockouts (x4)

2

7/8

(Electric)

1 1/2 X 3 1/2

(Gas)

24 5/8

2 3/4

55

76

3 1/2

43 1/2

21 1/4

19 7/8

19 7/8

1 1/2 X 3 1/2

(Gas or Condensate - Typical)

1/2 TYP.

15

15

2 3/8

1 1/8

21 5/8

TYP.

Figure 26. B-Size Cabinet (w/ Top Return Air) Models

1 7/8

1 1/2 X 3 1/2

(Gas)

21.250

WIRING DIAGRAM

BLUE

BLUE

TO OUTDOOR UNIT

W

RX

TX

COM

C

R

R C Y G W

L1A

LOW

ML

MH

HIGH

EAC

L1

XFMR

HUM

K BLAC

WHITE

NEUTRALS

BLACK

BLACK

BLUE

BLUE

Figure 27. M7RL Wiring Diagram

33

34

GAS INFORMATION

50

52

54

44

46

48

56

58

60

62

64

38

40

42

32

34

36

22

24

26

28

30

16

18

20

10

12

14

TIME FOR

ONE REVOLUTION

(SECONDS)

GAS FLOW RATES

72

69

67

82

78

75

64

62

113

106

100

95

90

86

60

58

56

164

150

138

129

120

360

300

257

225

200

180

CUBIC FEET PER

REVOLUTION OF GAS METER

1

818

783

750

720

692

667

643

621

10

1,500

1,385

1,286

1,200

1,125

1,059

1,000

3,600

3,000

2,571

2,250

2,000

1,800

1,636

947

900

857

600

581

563

409

391

375

360

346

333

321

310

300

290

281

563

529

500

474

450

429

5

1,800

1,500

1,286

1,125

1,000

900

818

750

692

643

600

100

102

104

106

108

110

112

114

94

96

98

88

90

92

116

118

120

78

80

82

84

86

72

74

76

66

68

70

TIME FOR

ONE REVOLUTION

(SECONDS)

GAS FLOW RATES

CUBIC FEET PER

REVOLUTION OF GAS METER

1 5 10

34

33

33

36

35

35

32

32

31

31

30

38

38

37

41

40

39

46

45

44

43

42

50

49

47

55

53

51

180

176

173

170

167

164

161

158

205

200

196

191

188

184

155

153

150

231

225

220

214

209

273

265

257

250

243

237

360

353

346

340

333

327

321

316

409

400

391

383

375

367

310

305

300

462

450

439

429

419

545

529

514

500

486

474

Table 8. Gas Flow Rates (Cubic Feet per Hour)

Nominal Pipe

Diameter (IN.)

1/2

3/4

1

1 1/4

1 1/2

10

130

280

520

1,050

1,600

20

90

190

350

730

1,100

GAS PIPE CAPACITIES

30

75

150

285

590

890

Length of Pipe Run (Feet)

40 50

65

130

55

115

245

500

760

215

440

670

60

50

105

195

400

610

Cubic Feet Per Hour Required =

Input To Furnace (Btu/hr)

Heating Value of Gas (Btu/Cu. Ft.)

70

45

95

180

370

80

40

90

170

350

NOTE:

The cubic feet per hour listed 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.

Table 9. Capacity of Black Iron Gas Pipe (cu. ft. per hour) for Natural Gas w/ Specific Gravity = 0.60

Furnace

Model

M7RL

Furnace

Input

(Btuh)

045A

060A

072A

45,000

60,000

72,000

0 to 1,999 2,000 to 2,999

ALTITUDE ABOVE SEA LEVEL (FEET)

3,000 to 4,999 5,000 to 5,999 6,000 to 7,999 8,000 to 10,000

Orifice

Size

Manifold

Pressure

Orifice

Size

57

55

56

10.0

10.0

10.0

57

55

56

Manifold

Pressure

Orifice

Size

9.0

9.0

9.0

57

55

56

Manifold

Pressure

Orifice

Size

8.5

8.5

8.5

59

56

57

Manifold

Pressure

Orifice

Size

Manifold

Pressure

Orifice

Size

Manifold

Pressure

10.0

10.0

10.0

59

56

57

9.0

9.0

9.0

59

56

57

8.5

8.5

8.5

Table 10. High Altitude Deration Chart for Propane Gas

LOCAL HEATING VALUES FOR NATURAL GAS

ALTITUDE ABOVE

SEA LEVEL

2,000 FT

3,000 FT

4,000 FT

5,000 FT

6,000 FT

7,000 FT

8,000 FT

9,000 FT

10,000 FT

BTU PER CUBIC FOOT

650 700 750 800 850 900 950 1,000 1,050

LOW LOW LOW LOW LOW LOW

HIGH HIGH HIGH

LOW LOW LOW LOW LOW LOW

HIGH HIGH HIGH

LOW LOW LOW LOW LOW

HIGH HIGH HIGH HIGH

LOW LOW LOW LOW LOW

HIGH HIGH HIGH HIGH

LOW LOW LOW LOW

HIGH HIGH HIGH HIGH HIGH

LOW LOW LOW LOW

HIGH HIGH HIGH HIGH HIGH

LOW LOW LOW

HIGH HIGH HIGH HIGH HIGH HIGH

LOW LOW LOW

HIGH HIGH HIGH HIGH HIGH HIGH

LOW LOW

HIGH HIGH HIGH HIGH HIGH HIGH HIGH

Table 11. Natural Gas Heating Values

NATURAL GAS with

HIGH HEATING VALUE

ALTITUDE ABOVE

SEA LEVEL

0 to 1,999 FT

2,000 to 2,999 FT

3,000 to 3,999 FT

4,000 to 4,999 FT

5,000 to 5,999 FT

6,000 to 6,999 FT

7,000 to 7,999 FT

8,000 to 8,999 FT

9,000 to 9,999 FT

51

3.0

51

2.8

51

2.6

49

2.5

51

3.3

INPUT (BTU)

45,000 60,000 72,000

49

2.8

49

2.6

49

3.5

49

2.9

45

3.5

45

3.3

45

3.1

45

2.9

47

3.0

47

2.8

47

3.5

47

3.2

48

3.3

48

3.0

48

2.8

45

2.8

48

3.5

49

3.3

49

3.0

49

2.8

47

2.7

49

3.5

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

Table 12. High Altitude Deration Chart for Natural

Gas - High Heating Value

NATURAL GAS with

LOW HEATING VALUE

ALTITUDE ABOVE

SEA LEVEL

0 to 1,999 FT

2,000 to 2,999 FT

3,000 to 3,999 FT

4,000 to 4,999 FT

5,000 to 5,999 FT

6,000 to 6,999 FT

7,000 to 7,999 FT

8,000 to 8,999 FT

9,000 to 9,999 FT

INPUT (BTU)

45,000 60,000 72,000

51

3.5

51

3.1

51

2.9

49

2.7

49

2.6

49

3.1

49

2.9

49

3.5

49

3.5

48

3.5

48

3.3

48

3.1

45

3.1

45

2.9

45

3.4

45

3.2

45

3.5

45

3.5

49

3.4

49

3.2

49

2.9

47

2.9

47

2.8

47

3.3

47

3.1

47

3.5

47

3.5

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

ORIFICE SIZE

MANIFOLD PRESSURE

Table 13. High Altitude Deration Chart for Natural

Gas - Low Heating Value

35

VENTING INFORMATION

36

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

A

B

C

D

Clearance Location

CANADIAN INSTALLATIONS a

Direct Vent (2-pipe) &

Conventional Vent (1-pipe)

Furnaces

Clearance above grade, veranda, porch, deck, balcony, or maximum expected snow level.

12 inches (30cm)

Clearance to window or door that may be opened.

Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61cm) from the center line of the terminal.

6 inches (15cm) for appliances

< 10,000 Btuh (3kW)


10,000 Btuh - 100,000 Btuh (30kW)


> 100,000 Btuh (30Kw)

*

*

US INSTALLATIONS b

Direct Vent

(2-pipe) Furnaces

12 inches (30cm)


< 10,000 Btuh (3kW)


10,000 Btuh - 50,000 Btuh (30kW)


> 50,000 Btuh (30Kw)

*

*

Conventional Vent

(1-pipe) Furnaces

12 inches (30cm)

4 ft. (1.2m) below or to side of opening;

1 ft. (300mm) above opening

*

*

E

F

G

H

J

K

I

Clearance to unventilated soffit.

Clearance to outside corner.

Clearance to inside corner.

Clearance to each side of center line extended above meter/regulator assembly.

Clearance to service regulator vent outlet.

Clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance.

Clearance to mechanical air supply inlet.

*

*

*

3 feet (91cm) within a height 15 feet above the meter/regulator assembly

3 feet (1.83m)


< 10,000 Btuh (3kW)


10,000 Btuh - 100,000 Btuh (30kW)


> 100,000 Btuh (30Kw)

6 feet (1.83m)

*

*

*

*

*


< 10,000 Btuh (3kW)


10,000 Btuh - 50,000 Btuh (30kW)


> 50,000 Btuh (30Kw)

3 feet (91cm) above if within

10 feet (3m) horizontally

*

*

*

*

*

4 ft. (1.2m) below or to side of opening;

1 ft. (300mm) above opening

3 ft. (91cm) above if within

10 feet (3m) horizontally

L

Clearance above paved sidewalk or driveway located on public property.

Clearance under veranda, porch, deck, or balcony.

7 feet (2.13m)

c *

7 ft. (2.13m)

M

12 inches (30cm)

d * *

NOTES:

a

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

In accordance with the current ANSI Z223.1 / NFPA 54 Natural Fuel Gas Code c

A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

d

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

*

For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA B149.1, the following statement shall be included: “Clearance in accordance with local installation codes, and the requirements of the gas supplier and the manufacturers installation instructions.” / “Dégagement conforme aux codes d’installation locaux, aux exigences du fournisseur de gaz et aux instructions d’installation du fabricant”.

Table 14. Vent Termination Clearances

VERTICAL VENTING

Support System on

Vertical Rise

See Table 2 for

PVC Pipe Lengths

(Field Supplied)

90°

Elbow

90° Elbow

See Table 2 for

PVC Pipe Lengths

(Field Supplied)

HORIZONTAL VENTING

Straps or Other Suitable

Supports at minimum of 5 ft. Intervals

Upward Pitch - 1/4” per foot

(Flue Pipe)

Wall

First support placed as close to furnace connection as possible

Seal/Caulk

Around Pipes at Building

90°

Elbow

12” Min.

7”

Normal

Snow Level

M7RL B Cabinet Shown

Figure 28. Horizontal & Vertical Venting

37

38

39

INSTALLATION / PERFORMANCE CHECK LIST

ATTENTION INSTALLERS:

It is your responsibility to know this product better than your customer.

This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product. Safety should always be the deciding factor when installing this product and using common sense plays an important role as well. Pay attention to all safety warnings and any other special notes highlighted in the manual. Improper installation of the furnace or failure to follow safety warnings could result in serious injury, death, or property damage.

These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/service personnel for this type of equipment. Please read all instructions carefully before starting the installation. Return these instructions to the customer’s package for future reference.

ELECTRICAL SYSTEM:

Electrical connections tight?

Line voltage polarity correct?

YES

YES

NO

NO

Supply Voltage: ________________________________ VOLTS

Has the thermostat been calibrated?

YES

NO

Is the thermostat level?

Is the heat anticipator setting correct?

YES

YES

NO

NO

Gas Type: (circle one)

GAS SYSTEM:

Natural

Gas

Propane

Gas pipe connections leak tested?

YES

NO

INSTALLER NAME:

CITY:

INSTALLATION ADDRESS:

CITY:

UNIT MODEL #

UNIT SERIAL #

Minimum clearances per Table 1

(page 5)?

Has the owner’s information been reviewed with the home-owner?

Has the literature package been left near the furnace?

STATE:

STATE:

YES

YES

YES

WARNING:

NO

NO

NO

PROPOSITION 65 WARNING: This product contains chemicals known to the state of

California to cause cancer, birth defects or other reproductive harm.

Gas Line Pressure: ____________________________ (in - W.C.)

Installation Altitude: ______________________________ (FT.)

Deration Percentage: ______________________________ (%)

Furnace Input: _________________________________ (Btuh)

Supply Air Temperature: __________________________ (° F)

Return Air Temperature: __________________________ (° F)

Temperature Rise: _______________________________ (° F)

COMBUSTION AIR & VENTING SYSTEM:

Is there adequate fresh air supply for combustion and ventilation?

Vent free from restrictions?

Filter(s) secured in place?

Filter(s) clean?

Flue connections tight?

Is there proper draft?

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

Specifications & illustrations subject to change without notice or incurring obligations.

O’ Fallon, MO | Printed in U.S.A. (02/12)

7093750

(Replaces 709264A)

No results