Nordyne M3RL 060A BW Installation Instructions Manual
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Direct Vent (SeaHed Combustion) Forced Air Gas Furnaces
M3RL Series 90+ Downfiow Condensing Furnace
For installation in:
I. Manufactured Homes
2. Park Models and Manufactured Buildings
3. Modular Homes/Buildings
WARNING:
FiRE OR EXPLOSION HAZARD
Failure to fol!ow
safety warnings e×actly could result in serious injury, death or property damage.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
-WHAT TO DO mFYOU SMELL GAS o Do not try to light any appliance.
o Do not touch any electrical switch; do not use any phone in your building.
, Leave the building immediately.
o 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.
-installation and service must be performed by a qualified installer, service agency, or the gas supplier.
BW Models
BWT Models
RISQUE D'INCENDmE OU D'EXPLOSmON
Le non-respect des avertissements de s_curit_ pourrait entra_ner des blessutes graves, la mort ou des dommages mat_rieJs.
- Ne pas entreposer ni utiliser de I'essence ni d'autres vapeurs ou liquides inflammables dans Ic voisinage de cet appareil, ni de tout autre apparei
-QUE FAmRE S'IL YA UNE ODEUR DE GAZ o Ne pas tenter d'allumer aucun appareil.
,Ne toucher a aucun interrupteur 61ectdque; n'utiliser aucun t616phone dans le b_timent.
o E_vacuer I'immeuble immCdiatement.
, Appeler immCdiatement le foumisseur de gaz en employant le t616phone d'un voisin. Respecter la lettre les instructions du foumisseur de gaz.
o Si personne ne repond, appeler le service des incendies.
- Uinstallation et I'entretien doivent Ctre effectues par un installateur qualifie, un organisme de service ou le fournisseur de gaz.
WARNING:
Shoumd overheating occur, or the gas suppty fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply.
Improper ment, installation, amteration, adjustservice or maintenance can cause injury or property damage.
Refer to this manual.
For assistance or additional information consult a qualified installer, service agency or the gas supplier.
LEAVE THESE mNSTRUCTmONS WroTHTHE HOMEOWNER.
TABLE OF CONTENTS
Generam ......................................................
4
Unit Dimensions ..................................
4
Shipping Weights ................................
4
Furnace Specification ........................
4
Air Flow Data .....................................
4
Owner's hformation ................................
5
Installation Requirements ......................
6
Location ..............................................
7
Clearance ...........................................
7
Circumating Air Supply ............................
7
Return Air Provisions ..............................
8
Air Distribution Systems ........................
9
Duct Connector Selection ....................
10
Duct Installation ....................................
10
Venting and Combustion
Air Requirements ...........................
13
Venting Requirements ..........................
14
Vent Table ........................................
15
Vent Pipe Material ............................
16
Vent Pipe Length and Diameter ....... 16
Vent Pipe installation ........................
16
Pipe Routing & Support ....................
16
Location of Outdoor Termination ..... 16
Horizontal Venting ............................
18
Vertical Venting ................................
18
Vent Freezing Protection .................
19
Concentric Vent Termination ........... 19
Drainage of Condensate
From Furnace ................................
19
Gas Supply and Piping .........................
20
Leak Check .......................................
21
High Altitude Derate .........................
21
Pressure Switch ..............................
21
Conversion ..............................................
21
Lighting and Adjustment of the Appliance ..............................
23
ElectdcaIWiring ......................................
24
Line Voltage Wiring ...........................
24
Low Voltage Wiring ...........................
26
Ventilation ................................................
26
Start-up and Adjustment ........................
26
Start-Up Procedure ...........................
26
Shut Down Procedure .......................
27
Verifying and Adjusting Firing Rate ... 27
Temperature Rise .............................
27
Verifying and Adjusting
Verifying Burner Operation .............. 28
Verifying Operation of the
Supply Air Limit Switch ................. 28
Description of Components ................ 29
Furnace Accessories .............................
29
Maintenance ...........................................
29
Combustion Air and Vent System .... 29
Air Filter(s) .......................................
29
Lubrication ........................................
30
Condensate Drain Assembly ........... 30
Blower Compartment .......................
30
Heat Exchanger and Burner
Maintenance ..................................
30
System Operation Information ............. 30
Sequence of Operation ....................
30
Furnace Fails to Operate .................
31
Location of Major Components .......... 32
Wiring Diagram .......................................
instaliationlPerformance
CheckJist .........................................
33
35
M3RL060 A - A W
Application
M-Manufactured Home
1
Furnace Series
Comfort Mode!
RL - Condensing Downflow m
Heating Capacity input, BTUH (000')
Tabte 1. Model identification
c°°,,°°,°t,°°
W - White
G - Gray
Cabinet Dimensions
A - 56" x 19-3/4" x 23-3/4"
B - w/Coil Cavity,
76" x 19-3/4" x 23-3/4"
Electricam Code
A - IPH, 60 Hz, 120 VAC
3
2"37116
/32
-I£_7/8 --
® i i
%1#2
317132
COMBUSTION AiR INTAKE
1-1/118
EXHAUST
VENT
24_5/8 --
56!/16
(W/O Coil
18 1#2
KNOCKOUTS
•I-I_r2 fl
(W/C_EBOX}
7_!_
917132 ,
1 19F32
21 157/6 --
Cooling
Coil
Box
1_3/!6
_-24_t4 --
Top Return Knockouts
_J
Figure 1.
Furnace Dimensions
_12.000_
1000
, \
21000
=
©
O
Top Returr_ Opening
(BWT Models)
Furnace Model
M3RL 060A AW
M3RL 060A BW*
M3RL 080A AW
M3RL 080A BW*
* May include suffix - T
Shipping
Weight
(Ibs)
15O
170
155
175
Table 2.
Shipping Weight
Top View
(AW and BW Models)
Furnace Specifications / Airflow Data
Furnace
Model No.
Furnace
Input
Btuh
M3 RL-060 60,000
Furnace
Output
Btuh
54,000
72,000
Temp.
Rise @ Motor
.3"WC °F HP
3565
35 - 65
I/2
I/2
Motor
Speed
High*
Med-High
Med-Low
Low**
High*
Med-High
Med-Low**
Low
External Static Pressure ( Inches Water Column)
0.1
0.2
0.3
0.4
0.5
CFM
1660
1512
1340
1176
1660
1512
1340
1176
CFM
I599
I467
I304
II42
I599
I467
I304
II42
CFM
I544
I416
I261
I108
I544
I416
I261
I108
CFM
1474
1363
1217
1025
1474
1363
1217
1025
CFM
I410
I304
II58
966
I410
I304
II58
966 M3 RL-080
80,000
Note: Data is for Operation with Filter,
* Factory Wired Cooling Tap
** Factory Wired Heating Tap
Table 3.
Furnace SpecificationslAirflow Data
Recommended
A/C
Ton
4
3
2.-I/2
2
4
3
2.-I/2
2
WARNmNG:
Do not use this appmiance if any part has been submerged underwater.
Immediatemy camsa quamified service technician to inspect the appmiance and to repmace any part of the controm system and any gas controm that has been submerged underwater.
NOTICE TO iNSTALLER
Installer is advised to follow carefully all instructions and warnings in this manual to insure maximum performance, safety, and operating efficiency of these appliances.
Improper installation may create hazardous conditions, and will void the appliance warranty.
GENERAL
General Description
The M3 series gas furnaces are listed direct vent (sealed combustion) forced air furnaces for use with both natural and propane gases.
The M3 series is a Category IV and type FSP furnace.
The M3 furnace series has been certified to the ANSi Z21.47/CSA2.%2001 for use in the United States and Canada and to the
UL307B --1995 for use in the United States.
These furnaces may be installed in:
I. Manufactured Homes.
2. Park Models and Manufactured buildings
3. Modular Homes/Buildings
The following are safety guidelines with references to their specific sections or pages in the manual.
I.
Use only type of gas approved for this furnace.
Refer to the furnace rating plate.
2.
Install this furnace only in location and position as specified in pages 7 - 13 of these instructions.
3.
Provide adequate combustion and ventilation air to the furnace space as specified in pages 13 - 20 of these instructions.
4.
Combustion products must be discharged outdoors, connect this furnace to an approved vent system only, as specified in pages 14-19 of these instructions.
5.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leak to check all connections.
6.
Always install furnace to operate within the furnace's intended temperature rise range with a duct system that has an external static pressure within the allowable range, as specified in page 4 of these instructions. See furnace rating plate.
7.
When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.
Note: This section only applies to furnaces installed with side or top return air.
8.
A gas-fired furnace for installation in a residential garage must be installed as specified in page 7 of these instructions.
9.
The furnace is not to be used for temporary heat of buildings or structures under construction.
M3 series furnaces are air conditioning ready as shipped. The furnace cooling capacities of the blower motor speed taps are shown in
Table 3. Table 2 lists the shipping weights for the M3 series furnaces.
OWNER NFORMATION
NORDYNE has been involved in the design of products for the manufactured home industry since the first manufactured home or trailer was built.
NORDYNE originated the sealed combustion system, which separates the furnace combustion system from the living area of the home, now a standard for the manufactured home industry.
NORDYNE engineers developed the first central heating system and the first central air conditioner for manufactured homes.
NORDYNE is dedicated to bringing to its customers the finest heating and cooling comfort possible.
NORDYNE constantly seeks to further refine its products to continuously provide exceptional comfort.
andthis appliancewill providemanyyearsof superiorperformance.
6. Providinginstructionaltrainingon how to lightandoperatethefurnace.
if you wish to cool your homeautomatically witha centralair conditioningsysteminvestigatetheexcellentNORDYNEcoolingsystems availablefromyour heatingand coolingcontractor.Thesesystemsare designedto work best with your NORDYNEfurnaceand have beencarefullyengineeredto deliveroptimum performancewhen mated with NORDYNE manufacturedhomefurnaces.
an air conditioner,heatpumpor otherair comfortdevices.
8. Revisinginstallationof the furnaceflue assembly.
9. Adjustingor calibratingof thermostat.
10.Any constructiondebris which falls into theflue system.
or gas supplierso therewill be no misunderstandingat a latertime.
and ventilatingsystemsspecificallydesigned
CAUTmON'.
with your manufacturedhomeretailer,your heating and cooling contractor or your factory(POBox8809,O'Fallon,MO63366)if youarenotabletolocatea sourceforNORDYNE
WARRANTY,OWNER'S
RESPONSIBILITIES makecertainthegasfurnacehasbeencorrectly
Never attempt to alter or modify this furnace or any of its components.
Never attempt to repair damaged or inoperable components.
Such action could cause unsafe operation, ex-
• plosion, fire and/or asphyxiation.
If a malfunction has occurred, or if you feel that the furnace is not operating as it should, contact a qualified service agency or gas utility for assistance.
or Naturalgas)andadjustedto operateproperly. All gas furnacesare manufacturedfor
Naturalgasandmustbefieldconvertedwhen usingUP.gas.
with theseinstructions.However,NORDYNE essaryto correctproblemsdue to improper improperoperatingprocedureonthepartofthe user, etc.
Somespecificexamplesof servicecallswhich cannotbe includedinwarrantypaymentsare: ofgas.
faulty.
3. Correctingwiringproblemsin theelectrical circuitsupplyingthefurnace.
4. Resettingcircuitbreakers,blownfusesor otherswitches.
5. Correctingproblemsdueto impropergas supplypressuretothefurnace.
iNSTALLATiON STANDARDS
Installer shall be familiar with and comply with all codes and regulations applicable to the installation of these heating appliances and related equipment.
In lieu of local codes, the installation shall be in accordance with the current provisions of one or more of the following standards.
a. Federal Manufactured Home Constructions
& Safety Standard (H.U.D.
Title 24, Part
3280.707[a][2]) b. The Standard for Manufactured Home Installations (Manufactured Home Sites, Communities, and Set-Ups) ANSI A225.1
and/or
CAN/CSA-2240 MH Series).
c. American National Standard (ANS1-119.2/
NFPA-501C) for all recreational vehicle installations.
d. American National Standard (ANSI-Z223.1/
NFPA-54) and/or CAN/CGA B149 for all gasfired furnace models.
e. American National Standard (ANSI-C1iNFPA-
70) and/or CSA 22. I Canadian Electric Code
Part I for all electrical field wiring.
CE gen6rateurd'air chauddoit 6tre installe conformement respecterla normeANSIZ223.,I,instituleNationalFuelGasCodeoulescodesd'installation
CAN/GCA-B149.
bustible material other than wood flooring.
The furnace may be installed on combustible flooring when installed on a Nordyne duct connector (see Table 5).
The NationalFuelGas Codeis availableby writing:
The ductwork within 3 feet of the furnaces without the A/C coil box must be installed such that surfaces are at least I/4" from combustible materials.
AmericanNationalStandardsinstitute,inc.
1430 Broadway
NewYork,NY 10018
NFPApublicationsare availableby writing:
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.
NationalFireProtectionAssociation
CiRCULATiNG AiR SUPPLY
Quincy,ME02269
LOCATION
The furnace must be installed on a level suF face, and as close to the center of the air distribution system as possible.
See Figure I for overall dimensions to determine the required clearances in hallways, doorways, stairs, etc. to allow the furnace to be moved to the installation point. The furnace must be installed so that all electrical components are protected from water.
WARNmNG:
Products of combustion must not be allowed to enter the return air openings of the furnace or the circulating air supply.
Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide personal poisoning that could result in iniury or death.
Minimum clearances to combustible materials are listed in Table 4. Access for positioning and servicing must be considered when locating the unit.
The floor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps, cracks, or sagging between the furnace and the floor or platform.
This furnace is certified for use on wood flooring.
The furnace must be installed on a solid surface and must be level front4o-back and side-to-side.
This furnace must not be installed directly on carpeting, tile, or any com-
ALL MODELS
Front
Back
Sides
Vent
Top
Duct (Plenum) w/Coil Box w/o Coil Box
(within 3 feet)
CLOSET ALCOVE
Inches Inches
1"
0
6
0
0
1"
0
6
0
0
0
1/4
0
1/4
*Note: For 1"clearance, use a fullylouvered door with at least 400 square inches of free airflow area.
Table 4. Minimum Clearances
The circulating be connected air ductwork must not to any other heat producing device such as a fireplace insert, stove, etc.
GENERAL
Plenums and air ducts must be installed in accordance with the Standard for the Installation of Air Conditioning and Ventilating Systems
(NFPA No. 90A) or the Standard for the Installation of Warm Air Heating and Air Conditioning
Systems (NFPA No. 90B).
RETURN AiR PROViSiONS
U.S.A. home manufacturers shall comply with aft of the following conditions to have accept= able return air systems for closet installed forced air heating appliances: a. Regardless of the location, the return air opening into the closet shall not be less than specified in the appliance's listing.
b. Means shall be provided to prevent inadverb ent closure by a flat object placed over the return air opening when it is located in the floor of the closet (versus the vertical front or side wall).
c. Closet installations must use a Iouvered door having a minimum free area of 235 sq.
in. when located 6" from furnace.
For clear= ance between I" and 6" from furnace, requirements are a Iouvered door with minimum of 235 sq. in. free area, with the open= ings in closet door directly inJine with the
Iouvered openings in the furnace door. For
I" clearance from furnace, use a fully Iouvered door with at least 400 sq. in. of free airflow area.
d. The cross-sectional area of the return duct system leading into the closet, when located
in the floor or ceiling shall not be less than 235 square inches.
e. The total free area of openings in the floor or ceifing registers serving the return air duct system must be at least 352 sq. in. At least one register should be located where it is not likely to be covered by carpeting, boxes and other objects.
f. Materials located in the return duct system must have a flame spread classification of
200 or less. This includes a closet door if the furnace is in a closet.
g. Noncombustible pans having I" upturned flanges are located beneath openings in a floor duct system.
h. Wiring materials located in the return duct system shall conform to Articles 300=22 of the National Electrical Code (ANSI CI/
NFPA=70).
, A Single trunk duct
I
/ Dual trunk duct
B w/crossover connector
Transition duct
C pw/branches
U
_
U
Figure 2. Non=Platinum
Supply Duct System
I
I
19"_ I k
10 1/4"
I_13 1/4'_
I
_,
"_
Figure 4.
Top View of Duct
Connector
Use Duct Connector
If "X" (Floor Cavity) is:
English
7/8"
2"
4 1/4"
6 1/4"
8 1/4"
10 1/4"
12 1/4"
Model Part Number:
Metric (mm I Finger Tab Screw Down
22
51
108
150
210
260
311
901987
901988
901989
901990
901991
901992
901993
904008
904009
904010
904011
904012
904013
904014
Table 5. Duct Connectors
Z
FLOOR CAVITY
(depth equal to "X" in Figure 5 and Table 5)
X
I i, "1
I:/ SUPPLY AIR DUCT
/
/
(
Figure 3.
SPACERS
-
(1) FINGER
(2) SCREW m .
E • I • I • I •-
TAB DUCT CONNECTOR
DOWN DUCT CONNECTOR
ONLY
ONLY
Figure 5.
( )OPENING TO DUCT
(1) WITH PLATE
OPENING
(C) REMOVED
BECOMES
13-1/4" x 13-1/4"
(2) WITH PLATE
OPENING
(C) REMOVED
BECOMES
13"X 13" WITH REDUCER
ITIS 13"X 10-1/8"
A
X y
SEE
TABLE 5
ALTFUEL
FUEL
HOLE duct system.
Figure 6. Closet or Alcove i. Gas piping is not run in or through the return j.
Test the negative pressure in the closet with the air-circulating fan operating at high speed and the closet closed. The negative pressure is to be no more negative than minus 0.05 inch water column.
k. For floor return systems, the manufactured home manufacturer shall affix a prominent marking on or near the appliance where it can be easily read when the closet door is open. The marking shall read: tain necessary airflow.
Use NORDYNE's certiduct program to determine proper duct size for AiC.
DUCTED RETURN AIR
M3 furnaces with model numbers ending in AW or BW are factory configured for to flow through the front Iouvered the return air door.
The return air may also be attached to either side or the top of the furnace cabinet using a field installed kit. Refer toTable 12 for the NORDYNE ducted return kit PiN number. The location and size of the side and top return air connections are shown in Figure I. The filter size for the side return air is 20" x 20" x I". For top return the filter size is 24" x 16" x I".
HAZARD OF ASPHY×IATmON: Do not cover or restrict return air opening.
I. Air conditioning systems may require more duct register and open louver area to ob-
M3 furnaces with model numbers ending in
BWT are factory configured for the return air to enter the top of the furnace.
2-1/4
3-I14
21-3/4
14-1/2
1-1/4
ALT FUEL LINE
ENTRY
I
I
FLOOR CUT-OUT
FOR DUCT CONNECTIONS
17-29/32 f
8-19/32
1-3/4
VENT
COMBUSTION AiR INTAKE
FUEL LINE ENTRY
21-7/16
12-7/8
I
15-1/2
FLOOR CUT-OUT
FOR OPTIONAL
COOLING COIL
FOR NON-PLATINUM
SERIES UNITS
1-3/4
OUTER DOOR
Figure 7. Cut-Out Locations
NR DiSTRiBUTiON SYSTEMS
For proper air distribution, the supply duct system must be designed so that the static pressure measured external to the furnace does not exceed the listed static pressure rating shown on the furnace rating plate.
Three typical distribution systems are illustrated in Figure 2. Location, size, and number of registers should be selected on the basis of best air distribution and floor plan of the home.
DUCT CONNECTOR SELECTION
PLATINUM SERES a. For Platinum ready construction use the 14" round plenum, pin: 903896.
NON-PLATINUM SERIES a. Determine depth of floor cavity from surface of floor to top of supply air duct
(See Figure 3).
b. Select appropriate model from Table 5 which matches X-dimension of the floor
I0 cavity.
To maximize air delivery, remove reducer "C" (see Figure 5) to obtain the largest open area that will fit the duct/floor construction.
DUCT iNSTALLATiON
Required floor, ceiling, and roof cut-out openings must be carefully located to avoid misalignment of the furnace (see Figures 6 & 7).
installation procedures are suggested for typical furnace installations and need not be followed in the exact listed sequence.
CUT OUT FLOOR OPENING & FUEL LINE
HOLE a. Determine center of closet or alcove (Figures 7 & 8).
b. Locate center of the floor opening, measured 10" from the rear wall, and mark cutout measuring approximately 14-I/2" by 14-
I/2" (+ I") for model duct connector used
(refer to Figures 4 & 5).
c. Locate center of gas line hole, measured 23-
I/4" from the rear wall and 6-5/8" to the left of center of the floor cut-out (See Figure 6) or
5-I/4"totheleftofcenterofthefloorcut-out, or for entry throughright-sideof furnace measured9"totherightofcenterofthefloor cut-out.
d. Cutoutflooropeningandonegaslinehole.
CUT DUCTOPENING(FINGERTABBED
ONLY) ing with bottomtabs restingon top of the supplyair duct.
rearedgeofflooropening.
c. Markcut-outlocation(tabarea)andremove duct connector.
d. Cutout ductopening1/16"largerthanarea marked.
INSTALLING PLATINUM SERIES 14"
ROUNDDUCT CONNECTOR ing.(SeeFigure9).
b. Secureductconnectorto floor.
INSTALLINGSCREWDOWNDUCTCON-
NECTOR a.Applya beadof caulking,mastic,or other approvedsealantaroundbottomsideof I/2" flangeandrestrictorplate,whenapplicable.
b. Locatethe duct connectorover duct and carefullylowerscrewdownduct connector intoplace.
c. Once duct connectoris locatedon duct,
INSTALLFURNACEMOUNTINGPLATE a. Placemountingplate(suppliedwithinduct connector)at rearof theflooropening(See
Figure9).
or nails.Be sureflangesof ductconnector stayin contactwith the duct.
d. Screwplenumto ductmakingsurea sealis madebetweenthe duct andthe duct con-
MOUNTING REARWALL
FUEL
LINE
HOLES
BEND
UNDER
CONNEC
DUCT
_OR
OPENING
TABS
Figure 8. Mounting Plate
MOUNTING
SCREWS
Finger Tabbed
Duct Connectors
Screw Down
Duct Connectors
Figure 9. Duct Connector
Platinum Series
CONNECTION
11
nector.Additionalscrewsmay be addedif required.
e. Cutawayalongedgeof flangeallowingthe centertodropintotheduct.Removesection
ofductwithcaution,asedgeswill besharp.
attachedtothesidesoftheductbyusingsheet metalscrewsor othersuitablefasteners.(See
Figure11).
INSTALLINGFINGERTABBEDDUCTCON-
NECTORS if sealant,mastic,or tapeis usedto providea betterseal,itshouldbeapprovedbyapplicable nationalor localcodes.
ALTERNATEATTACHMENTMETHODS ingwith bottomtabsextendingthroughthe ductopening.(SeeFigure9) b. Secureduct connectorto floor.
c. Bendbottomtabsunderanduptightlyagainst the supplyair duct (SeeFigure10).
This proceduremay alsobe usedto installa furnace duct connector to narrow metal
NOTE:Theductconnectorisdesignedforuse onducts12"inwidth.Whenusingtheconnec= toron 12"wideducts,theremaybeinsufficient clearanceto bendthe tabsontwosidesof the ductconnector,insuchcasesthetabsmaybe bendingof the duct connectortabs at the side(s)of the duct.(SeeFigure12).
I. Scoreandcutthe top of the metalduct as indicatedin StepI or Step2. WithStep I choice,alsocutoutthemetalfromtheshaded area"A'.
2. Foldthe ductflap "B"up,(SeeStep3).
TABS TABS
DUCT _ DUCT
1. INSERT DUCTPLBNUM CONNECTOR
INTO DUCT CUT-OUT.
2. BEND BOTTOM TABS OVER
AND ONTO THE UNDERNEATH
DUCTBERVtCE.
Figure 10. Installation of Duct Connector
Duct Connector i_
I
12
_) Duct _ Narrow Duct
STEP 1.
Figure 11. Narrow Duct Installation
Fold Back Flap "B"
STEP 2.
Cut
Fold Back Flap"B"
Cut- Out
Cut- Out
Area"A"
Top of Duct
Fold Back Flap "B"
,
Bend Duct Connector Tabs Up and Over- (along length of duct)
,/ \, ,
-Fold Back Flap"B"
Staple Folded Duct
Flap (typ) to side of Duct
Connector
.
// "_k_ !LtC
t
STEP 4.
_L_
Figure 12. Alternate Installation
Duct _--'_
NOTE:Additionalfastenersmay be usedat rear,sidesor throughdoorframe,as desired, to securefurnaceto closetor alcoveframing.
VENTING AND COMBUSTION AiR
CAUTmON'.
Snow must not be allowed to restrict or block the combustion air intake or vent pipes.
Figure 13. "A', "g', & Platinum
Cabinet Furnaces
HOLES
Figure
Coil
,',
• [, '
SECURE
WFH
FURNACE
2 FASTENERS
AT FRONT CORNER
_
HOLES q,
,
'
-
'
,
14. "A" Cabinet
Cabinet
Furnace
(NonoPmatinum
SLIDE FURNACE
ALL THE
ONTO
WAY
MTG
BACK
PLATE on 911969
Series)
3. At the front-to-back of duct run (Area "A'), bend the duct tabs and secure them directly to the duct.
4. At Area "B", bend the duct tabs up and back over, around the duct connector, (See
Step 3).
5. Fold/form the duct flap against the side of the duct connector and attach as shown, (See
Step 4). Use three (3) staples (minimum) on each duct flap OR, if a 2X block/joist is not provided, use two (2) sheet metal screws
(minimum) on each duct flap. An alternate attachment method is acceptable, as long as the plenum is securely attached.
6. Tape the duct flap edges with an approved tape for a leak-free joint.
_NSTALL FURNACE a. Remove furnace outer door(s) and bottom fuel line knockout.
b. Place furnace onto duct connector and center with floor opening.
c. Slide onto mounting plate. (Bottom rear slots on furnace should engage with mounting plate tabs.) d. Secure front with one (1) fastener at each corner (See Figure 13 or 14).
General
NORDYNE condensing furnaces must be installed with outdoor combustion air piped directly to the furnace.
Codes refer to this type of installation as direct vent, or two pipe installation.
Provisions must be made for adequate supply of air for combustion and ventilation.
For
United States installations, the adequacy of air provisions can be determined by consulting the current version of the National Fuel Gas
Code (ANSI Z223.1iNPFA-54).
For Canadian installations, requirements are specified in the
National Standard of Canada (CAN/CGA
B149.1 & .2). Consult local codes for special requirements.
NOTE: If the furnace is operated without adequate air for combustion and ventilation, it may not perform components may be properly.
strained
Furnace by temperature and could fail prematurely.
high
G:
The combustion air piping must not be blocked or restricted in any manner.
WARNmNG:
Furnace other installation than those following
National applicable sufficient sections
Fuel local
Gas combustion must using described codes
Code to methods complywith in and the provide the air for the furnace.
all
13
Do not allow nace.
This could cause unsafe operation and voids the furnace warranty.
VENTING debris to fail
REQUIREMENTS
into the fur-
WARNmNG:
FURNACE MUST NOT BE COMMON
VENTED WiTH OTHER APPLIANCES.
Genera_
This section specifies installation requirements for 2-pipe combustion air piping.
The capacity table provided in this section applies to the maximum equivalent lengths of vent and combustion air intake pipe.
These condensing furnaces are classified as
"Category IV" appliances, which require special venting materials and installation procedures.
Category tV appliances operate with positive vent pressure and therefore require vent systems which are thoroughly sealed.
They also produce combustion condensate, which is slightly acidic and can cause severe corrosion of ordinary venting materials.
Furnace operation can be adversely affected by restrictive vent and combustion air piping. Therefore, vent and combustion air piping lengths must conform completely to the requirements of Table 6.
The furnace must be vented to the outdoors.
WARNmNG:
CARBON MONOXmDE POiSONmNG
HAZARD
1.
Seal any unused openings venting
2.
inspect system the venting system in the for proper size and horizontal as required in the National pitch,
Fuel
Gas Code, ANSI Z223.1
or the
CAN/OGA Bt49 mnstallation Codes and these instructions.
Determine that there is no blockage striction, other leakage, deficiencies corrosion which or reand could cause an unsafe condition.
3.
So far as is practical, close all building all doors doors and windows between the space and in which the appliance(s) to the venting system connected are located and other spaces of the building.
4.
Follow the lighting
Place the appliance instructions.
being inspected thermostat in so operation.
appliance operate continuously.
Adjust shall
5.
Turn on clothes dryers and any other appliance not connected the venting system.
Turn to on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed.
Do not operate a summer exhaust fan.
6.
Close fireplace
7.
Test for spillage dampers.
from draft hood equipped appliance at the draft hood relief opening after 5 minutes of main burner operation.
flame of a match or candle.
Use the
8.
if improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National
Fuel Gas Code, ANSt Z223.1/NFPA
54 a n d/or CSA B I49.1, Natural Gas and Propane Installation
9.
After it has been determined
Codes.
that each appliance venting system when tested return doors, as outlined windows, fans, fireplace dampers other gas burning and appliance any to their previous connected properly conditions to the vents above, exhaust of use.
It must not be vented in common with any other appliance, even if that appliance is of the condensing type.
Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to
14
APPLICATION
PVC,CPVC or ABS
SCH. 40 Pipe Size
Model M3RL 060
Model M3RL 080
MAXIMUM
DIRECT VENT, DUAL
PIPE LENGTH (ft.)*
Inlet/Outlet
3"
50
50
3"
50
50
*NOTES
1.
2.
3
Subtract 3.5 ft. for each additional 3" 90 degree elbow.
Two45degree elbowsare equivalent toone 90degree elbow
One short radius elbow is equivalent to two long radiu,_ elbows.
4.
5
Do not include terrnination elbows incalculation of vent length
This table is applicable for elevations from sea levelto 400( ft. Forhigher elevations, decreasevent pipe lengthsby 8% pe
1000 ft. of altitude
6 Only the above pipe materialsare approved for usewith thes( condensing furnaces.
Tabie 6. Vent Tabie
/
/
/
/
/
/
_J VENT TERMINAL (_ AiR SUPPLY INLET [] AREA WHERE TERMINAL iS NOT PERMITTED
A = Clearance above grade, veranda, porch, deck, or balcony
B = Clearance opened to window or door that may be
Canadian Installations 1
12 inches (30 cm)
US Installations 2
12 inches (30 cm)
6 inches (15 cm)for appliances -< 10,000
Btuh (3 kW), 12 inches (30 cm) for appliances > 10,000 Btuh (3 kW) and -<
100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Btuh (30 kW)
6 inches (15 cm)for appliances -<10,000
Btuh (3 kW), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kW) and -<
50,000 Btuh (15 kW), 12 inches (30 cm) fol appliances > 50,000 Btuh (15 kW)
C = Clearance to permanently closed window
D = Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center tine of the terminal
E = Clearance to unventilated soffit
F = Clearance to outside corner
G = Clearance to inside corner
H = Clearance to each side of center tine extended above meter/regulator assembly
I = Clearance to service regulator vent outlet
J = Clearance to nonmechanicaI air supply inlet to building or the combustion air inlet to any other appliance
K = Clearance to a mechanical air supply inlet
3 feet (91 cm) within a height 15 feet above the meter/regulator assembly
3 feet (1.83 m)
6 inches (15 cm)for appliances -< 10,000
Btuh (3 kW), 12 inches (30 cm)for appliances > 10,000 Btuh (3 kW) and -<
6 inches (15 cm)for appliances -<10,000
Btuh (3 kW), 9 inches (23 cm) for appliances > 10,000 Btuh (3 kW) and -<
100,00 Btuh (30 kW), 36 inches (91 cm) for appliances >100,00 Btuh (30 kW)
50,000 Btuh (15 kW), 12 inches (30 cm) fol appliances > 50,000 Btuh (15 kW)
6 feet (1.83 m) 3 feet (91 cm) above if within 10 feet (3 m) horizontally
L = Clearance above paved sidewatk or paved driveway located on public property
M = Clearance under veranda, porch deck, or balcony
7 feet (2.13 m) 1
12 inches (30 cm) $
In accordance
2 In accordance with the current with the current
CSA B149.1
ANSI Z223.1
Natural Gas and Propane
/ NFPA 54 National Fuel
Installation
Gas Code
Code
1 A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family
_:
* dwellings
Permitted
For and serves both dweltings only if veranda, clearances not specified porch, in deck,
ANSI or balcony
Z223.!
is fully open on a minimum
/ NFPA 54 or CSA B149.1, the of two following sides beneath statement the floor.
shall be included:
"Clearance in accordance with local installation manufacturer's codes, and the requirements installation instructions." of the gas supplier and the
Figure 15. Vent Termination Clearances for Direct Vent Furnaces
15
escapethroughsuchappliancesor vents. Do not ventthefurnaceto a fireplacechimneyor buildingchase.
if removingan existingfurnacein a venting system,theventingsystemmaynotbeproperly sized.Totesttheventsystemwiththeremaining
appliances,followthe test outlinedbelow.
The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in operation:
Combustion occupied atmosphere.
CAUTmON'.
air must not be drawn from spaces and a corrosive
The quality of outdoor air must also be considered.
Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion of the furnace combustion system.
Vent Pipe Material
Vent and combustion air pipe and fittings must be one of the following materials and must conform to the indicated ANSI/ASTM standards:
Piping must be mechanically supported so that its weight does not bear down on the furnace.
Supports must be at intervals no greater than five feet, and at smaller intervals if necessary to ensure that there are no sagging sections to trap water (See Figures 16 & 17).
Material
Schedule 40 PVC
PVC-DWV
SDR-21
& SDR-26
ABS-DWV
Schedule 40 ABS
Foam/Cellular Core PVC
Standard
D1785
D2665
D2241
D2661
F628
F891
These condensing furnaces have been certified for installation with zero clearance between vent piping and combustible surfaces.
However, it is good practice to allow space for convenience in installation and service.
Cement and primer must conform to ATSM
Standard D2564 for PVC and Standard D2235 for ABS. When joining PVC piping to ABS, use an appropriate solvent cement and procedure per the piping manufacturer's recommendation and ASTM Standard D3138.
Location of Outdoor Terminations
Vent and combustion air intake terminations must be located to ensure proper furnace operation and to conform to applicable codes.
Figure 15 illustrates necessary distances from the vent termination to windows and building air intakes.
In Canada, the Canadian Fue!
Gas Code takes precedence instructions.
Specifically, over these all minimum distance requirements with respect to term!nation
of the vent piping listed below.
Vent Pipe Installation
Pipe Routing and Support
Route piping as directly as possible between the furnace and the outdoors and remember that routing affects pipe length limitations per
Table 6. Locate the combustion air intake and the vent exhaust in the same atmospheric pressure zone - i.e. both must exit the building though the same portion of exterior wall or roof.
Vent piping must be sloped upwards not less than 1/4" per foot in the direction from the furnace to the terminal.
This is to ensure that any condensate flows back to the furnace where it can be disposed of through the condensate disposal system.
The following list is a summary of vent terminal location requirements:
I.
The termination must be 12 inches above snow level or grade level whichever is higher. See Figure 18 for alternate method to achieve 12" above snow level.
2.
The minimum distance for a direct vent
(2-pipe) installation from any door, openable window, or air gravity inlet is I ft.
below, 1 ft. horizontally, or 1 ft. above.
3.
The vent termination shall be a minimum of
3 ft. above any forced air inlet within 10 ft.
4.
The vent termination shall be located at least 4 ft. horizontally from any electric meter, gas meter, regulator and any relief equipment.
These distances apply ONLY to U.S. installations, in Canada, the Canadian Fuel Gas Code takes precedence.
16
Downflow Furnace
Seal/Cat_lk
Around Pipe at Building
90 ° Elbow _
\
\
\
\
\
\
\
\
\
I_
f
Normal Snow Level
Vent _ _!3
9/1E"_
÷i 7,8
Combustion Al ,oto,oO,po l i i
Supports at Minimum
5 ft. Intervals
Straps or Other Suitable of
' iq
_ _-_j
Top View
_ ___Z
Offset with
Vent for Adequate
Dirnensiona_ C}eara#ce
Exhaust
Vent
PVC or
ABS pipe
Combustion
Intake Pipe
Air
Figure 16. Horizontal Venting
Support System on Vertical Rise
Below Joints
¢//_ Vent
First support should be as close to furnace es possible
Vent
Upward Pitch t/4" per foot
Figure 17. Vertical Venting
.
Avoid areas where condensate drainage may cause problems by dropping on plant_ ers or patios, etc.
Also ensure that ex_ haust gases will not impinge on windows or building surfaces, which may be com_ promised or damaged by condensation.
Do not install the vent terminal such that exhaust is directed into window wells, stairwells, under decks or into alcoves or similar recessed areas, and do not terminate above any public walkways.
6.
For
Select the point of wall penetration the minimum I/4 inch per foot of slope up can be maintained.
optimal through exposure
CAUTmON'.
performance wall which to winter experiences winds.
vent where furnace the least
17
Horizontal
Vent and combustion must be as shown concentric
Venting air intake terminations in Figure vent termination
19 unless the kit is used.
NG:
Ensure that the combustion the exhaust vent are air vent and configured as shown termination in Fig.
t9.
Improper can cause recirculation vent of the flue gases.
This may result in furnace vibration, in severe cases, the furnace will cycle, due to the intermittent contact between the flame and the flame sensor.
If you note these oscillations occurring, check the vent configuration.
Make sure that the exhaust vent does not have a 90 degree termination.
For horizontal venting, either the Horizontal
Exterior Vent Mounting Kit or the Concentric
Vent Termination Kit may be used (See Table
12).
For Canadian installations please refer to the
Canadian Installation Code (CAN/CGA-B149.1
or 2) and/or local codes.
The HorizontaJ Exterior Vent Mounting Kit consists of two face plates and an insulating gasket to seal the exterior surface.
A hole sized closely to the pipe diameter must first be cut through the wall. A short length of pipe is then cut such that it can penetrate the wall and be held in place by closely fitting standard couplings.
The face plates are retained on both sides of the waJJ by the couplings, and the gasket is retained against the wail by the outer face plate. Face plates must be fastened to the walJ and the outside one must be flashed as appropriate to prevent entry of water.
When the above kits are not used the following steps are required:
I.
Check the hole size cut through the exterior wall. Insure that the hole diameter is less than the diameter of the couplings to be used.
2.
Extend the vent pipe through the wall approximately I" and seal the area between the wall and pipe.
3.
Apply couplings to the vent pipe on the interior and exterior sides of the wall to insure the pipe can not be pushed or pulled through the wall.
4.
Insure the combustion air inlet pipe has a 90 degree termination elbow, and is pointing downward as shown in Figures 19 & 20.
Note that a combustion air intake must be provided with an elbow opening downward.
When the vent pipe must exit an exterior wall close to the grade or expected snow level, a riser should be provided as shown in Figure 18.
Insulation is required to prevent freezing of this section of pipe.
Vertical Venting
For verticaJ venting, either the configuration shown in Figure 20 or the Concentric Vent
Termination Kit may be used. Vertical venting is one of the shortest routing methods when piping vents for furnaces.
The M3 furnace operates trouble-free when the furnace is installed with a shorter vent.
o The inlet for the combustion intake pipe must be extended at least one foot above the roofline or snow accumulation level.
o The outlet of the vent must be extended at least
10 inches above the inlet of the combustion air intake pipe.
, The vent as well as the combustion air intake pipe should be located on the same side of the reel Both pipes must not be closer than 5 inches apart. They should not be separated more than 36 inches.
The roof penetration must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing.
Termination spacing requirements from the roof and from each other must be per Figure 20.
Concentric Vent Terminatien
A concentric vent termination is approved for use with these furnaces (See Table 12).
For proper installation of the concentric vent termination, follow the installation instructions provided with the kit.
18
Exhaust Vent
Vent Configuration
Provide 12" Minimum to height above <7_
Outside
WaEI i
_
\ 12" Min.
Support
_J i_ 1/2"
I
S _ Bnsulation or
, :_ Equivalent
12"Above
NormaHy
Expected
Snow
Level
Figure 18.
A_ternate Horizontam
Vent Installation
Figure 19.
Exhaust and Combustion Air
Pipe Clearances
DRAINAGE OF CONDENSATE
FROM FURNACE
CAUTION'.
Do not install additional condensate drain.
traps in the
NG:
The condensate produced by the furnace must be drained.
Do not connect awater suppmy furnace.
to the drainage hose of the
NOTE: The condensate drain should be protected from freezing when in unheated spaces.
The furnace is supplied with an internal condensate drain trap.
The condensate drain may exit through the left side panel, the right side panel, or through the left or right hole on the bottom panel. (See Figure
21). Ensure that the flexible drain hose is not kinked.
The condensate should drain from the plastic collector box (location A in Figure 21) as 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.
A= 12" Above Roof or
Snow Accumulation Level
Elbow s-Min.
36" l*_ax.
Bxheust
Plumbing
Roof Boot
Vent
(Typ. Both Pipes)
Figure 20.
Vertical Vent Termination
Note: If terminations meeting these vertical requirements exceed the maximum height for safe transit, the vent and combustion air intakes may be shipped with the home for assembly on site. The furnace must be labeled to notify the installer/ user not to use the furnace until the vent and combustion air intake terminations are installed.
19
direction
Figure 21. Furnace with Condensate Drain Trap Assembty
I.
Remove the collector box soft tube at location A in Figure 21 and insure the exit from the collector box is clear of any debris or obstructions.
2.
Replace this tube and insure the fit to the header spout is air tight. Airwill be drawn into the header if this connection is not tight.
3.
Check other tube connections along the drain system, insure that all are air tight.
NOTE: Industry research studies indicate that when condensate is routed to an active drain, household detergents, etc., buffer its acidity. If the drain is not actively used or if codes require, obtain a neutralizer kit (See Table 12). Proper drains and connections to the condensate tub= ing are required as NORDYNE cannot be held responsible for water leakage which occurs due to loose hose connections or improperly sealed drain line pipes.
GAS SUPPLY AND PiPiNG
General
This furnace is equipped for bottom, left, or right side gas entry. Typical gas service hook= ups are shown in Figure 22. When making the gas connection provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace.
All gas piping must be installed in compliance with local codes and utility regulations.
Some local regulations require the installation of a manual main shut=offvalve and ground joint union exter= hal to the furnace. The shut=off valve should be readily accessible for service and/or emer= gency use.
Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut=off. In the absence of local codes, the gas line instal= lation must comply with the provisions stated in the Federal Manufactured Home Standard
(H.U.D Title 24, part 280) and the National Fuel
Gas Code (ANSI Z223.1!NFPA=54) or (CAN/
CGA B149) installation codes.
A drip leg should be installed in the vertical pipe run to the unit. Table 7 lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pres= sure drop in the line.
NOTE: Gas piping must not be run in or through air ducts, gas vents, etc.
Compounds used on threaded joints of gas piping must be resistant to the actions of Iique= fled petroleum gases.
CAUTmON'.
Do not use matches, lighters, candles, or other sources of open flame to check for gas leaks.
NOTE: When pressure testing gas supply lines at pressures greater than I/2 psig (14 in. water column), the furnace must be disconnected from the gas supply piping system to prevent damage to the gas control valve.
2O
Main
CONVERSION
This furnace can be converted from the fac= tory=equipped gas to either natural gas (for LP gas ready models), or LP gas (for natural gas ready models).
Conversions must be made by qualified service personnel, using only factory authorized or approved parts.
The required conversion orifices are supplied with the fur= nace.
\
0/
/ WARNING:
DO NOT REMOVE
ORIGINAL RATING
OR
PLATE.
DEFACE THE
/
/
J
!°
Floor
CAUTION'.
The gas suppmy shammbe shut off prior to disconnecting before proceeding the emectricam power, with the conversion.
To Gas
Supply
Figure 22.
Typical Gas Piping
If the test pressure is less than or equal to I/2 psig (14 in. water column), the furnace must be isolated from the gas supply line by closing the manual shut=off valve.
Leak Check
After the gas piping to the furnace is complete, all connections must be tested for gas leaks. To check for leaks use only a soap and water solu= tion or other approved method.
High Altitude Derate
The nameplate input rating for the furnaces apply for elevations up to 4,000 feet above sea level for US and Canada. If the elevation for the furnace location is higher than 4,000 feet above sea level, the furnace input must be derated by using the appropriate orifice size listed in
Table 8.
NOTE: The density of air decreases with increasing elevation above sea level. This re= duces the quantity of combustion air drawn into the furnace under normal operation and requires the unit be derated by using smaller gas orifices or lower manifold pressure.
To Turn Off Fuel Supply to the Appliance:
I.
Set the room thermostat to "OFF" or its lowest temperature setting.
2.
Turn OFF the main gas supply to the appli= ance at the manual valve, outside of the appliance casing.
3.
Remove the control access panel / Iou= vered door.
4.
Move the appliance gasvalve lever/knob to the "OFF" position.
5.
Turn OFF the electrical power to the appliance.
CAPACITY OF BLACK IRON GAS PIPE (CU. FT, PER HOUR)
FOR NATURAL GAS (SPECIFIC GRAVITY -0.60)
NOMINAL
BLACK IRON
PIPE DIAMETER
(in.)
1/2
3/4
1
1 1/4
1 1/2
10
130
280
520
1050
1600
LENGTH OF PiPE RUN
(feet)
20
90
190
350
30
75
150
285
730 590
1100 890
40
65
130
245
500
760
50
55
115
215
440
670
60
50
105
195
400
610
70
45
95
180
370
560
80
40
90
170
350
530
The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace
To determine the cubicfeet per hourofgas fie _vrequired by the furnace, divide the input rate of the furnace by the heating value of the gas:
Cubic Feet
Per Hour Required
-hputTo Furnace_
Heating Value of Gas (Btu/Cu. Ft.)
Table 7.
Capacity of BJack mron Gas Pipe
(cu.
ft. per hour) for Natural Gas
(specific gravity = .60)
21
To Removethe Burner Assembly:
CAUTmON'.
I.
Followthe instructions"To Turn Off the
FuelSupplyto the Appliance."
2. Disconnecttheflamesensorwirefromthe burnerbox.
3. Disconnectthe ignitorwiresat the 2 pin plug.Thisis a lockingquickconnectand bothsidesof the lowersectionmustbe depressedin orderto be separated.
4. Removethe wiresfrom the terminalsof the gas valve.
5. Disconnectthe rubber pressuretubes fromthe gasvalveandthe burnerbox.
6. Removethe burneraccesscover plate from the burnerbox.
7. Removesupplygas pipingfromthe gas valve.
Caution: orifices.
changed,
Do not re-drill
If the orifice the burner size must be use only new orifices.
Note: The size of the new orifices that will be installed into the unit will depend upon the type of conversion (sea level or Hgh altitude; natural gas or LP gas}.
To Convert the Unit to the Alternate Gas tenersand removethe burnerassembly wereremoved.Notethattheburnerboxmay
havehooksnearthetopandontherightand box,lift the burnerbox upwardsandthen removetheboxfromtheunit.
To Removethe Burner Orifices:
I.
Removethefour(4)fastenersthatsecure the gas manifoldto the burnerbox, as shownin Figure25. Carefullyremovethe gas manifoldassemblyfrom the burner box. Notethatthegasmanifoldassembly consistsofthegasvalve,thegasmanifold, andtheorifices.
gas manifold,as shownin Figure25.
I.
Remove the orifice bag from the manifold of the unit.
2.
Install the appropriate gas burner orifices into the gas manifold.
Remember if installing at altitudes above 4,000 feet to install the proper orifices, shown in Table
8.
When installing the new orifices, DO
NOT use pipe joint compound on the orifice threads.
Screw the orifices into the manifold by hand until snug to eliminate cross threading, then tighten with a wrench.
Before installing an orifice, check the face or side of the orifice for the drill number to ensure that it is the appropriate size.
3.
For the conversion to the alternate fuel, the gas valve regulator cap must be turned over, as shown in Figure 23.
You will unscrew the cap and reinstall for your in= stallation.
After reinstalling the cap, you will be able to read "NAT" for the conversion to natural gas or"LP for the conversion to LP gas.
Furnace
Model Number
M3RL -
060A-A/BW
080A-A/BW
Furnace Rating
Plate Input
(Btuh)
No. of
Burners
60,000
80,000
4
5
Elevation
0 - 2000
Nat
50
49
LP
57
1.15 mm
Elevation
2000-4000
Nat
50
49
LP
57
1.15 mm
Elevation
4000-6000
Nat
51
50
LP
58
57
Elevation
6000-8000
Nat
51
50
LP
58
57
Table 8. Approximate Orifice Size for Natural and LP Gases
Elevation
8000-10000
Nat
52
51
LP
59
58
22
Reinstalling the Burner Assembly:
I.
Reinstal[ the gas manifold assembly to the burner box with the four (4) fasteners, which were removed earlier.
2.
Carefully reinstall the burner box into the unit.
After installing the burner, inspect the alignment of the burners with the heat exchanger tubes.
The center of the burners should be aligned with the center of the tubes.
3.
Reconnect the gas piping to the gas valve.
4.
Reconnectthewirestothegasvalve nals.
termi-
5.
Reconnect the rubber pressure tubes to the gas valve and the burner box. Reinstall the burner access cover plate.
6.
Reconnect the ignitor at the 2 position plug.
7.
Reconnect the flame sensor wire to the burner box.
Pressure Gauge installation
NOTE: For natural gas installations, the incoming gas line pressure at the gas valve inlet must be between 4.5" WC and 10.0" WC.
For
LP gas installations, the incoming gas line pressure at the gas valve inlet must be between
11.0" WC and 14.0" WC. This pressure can be checked at the inlet end of the gas valve using a pressure gauge or U-tube manometer, which must be installed according to the manufacturer's supplied instructions.
LiGHTiNG AND ADJUSTMENT
THE APPLIANCE
OF
Hoooywo,
Valve
PRESSURE
REGULATOR
OTHER SIDE
OF CAP
Figure 23. Convertible Pressure
Regulator Cap
Figure 24. Burner Inspection
I.
Turn ON the gas at the manual valve, outside of the unit.
2.
Check all gas connections for leaks with a soap and water solution.
If the solution bubbles there is a gas leak which must be corrected.
Do NOT use an open flame to check for gas leaks.
3.
Turn ON the electrical power to the appD ance.
4.
Move the gas valve lever/knob to the "ON" position.
The lever/knob must be moved to the end of its range of motion to insure the valve is completely open.
Use only your hand to push in or turn the gas control valve.
Never use tools.
Burner
Box inlet
Pressure
Tap inlet Gas
Valve
Cover
Plate
Figure 25.
Typical Installation For Sealed
Burner Box With Access Cover Plate
5.
Set the room thermostat to a point above room temperature to begin the heating cycle of the unit.
6.
Check that the unit ignites and operates properly.
Refer to the installation instructions provided with your unit for the normal operating sequence.
23
7. Aftertheflameignites,visuallyinspectthe burnerassemblyto ensurethatthe flame isdrawndirectlyintothecenteroftheheat exchangertube,as shownin Figure23.
The end of the flamewill be out of sight aroundthe bend of the heat exchanger tube. Ina properlyadjustedburnerassembly, the flamecolor shouldbe blue with somelightyellowstreaksnearthe outer portionsoftheflame.
CAUTmON'.
To avoid electric shock, personal injury, or death, turn off the power at the disconnect or the main service panel before connections.
making any electrical
ELECTRICAL WIRING
NOTE: Until all of the air is bled out of the gas line, the hot surface ignitor may not ignite the gas.
If the ignition control locks out, turn the thermostat to its lowest setting and wait one minute then turn the thermostat to a point above room temperature and the ignitor will try again to ignite the main burners.
This process may have to be repeated several times before the burners will ignite. Once the burners are lit, check all gas connections for leaks again with the soap and water solution.
If the solution bubbles there is a gas leak which must be corrected.
Do not use an open flame to check for gas leaks.
Manifold Pressure
Genera!
Electrical connections must be made in accoF dance with all applicable local codes and ordinances, and with the current revision of the
National Electric Code (ANSI/NFPA 70).
For Canadian installations electrical connections and grounding must be done in accoF dance with the current Canadian Electrical
Code (CSA C22.1 Part 1) and/or local codes.
If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wire having a minimum temperature rating of I05°C.
Refer to the furnace nameplate and
Table 8 for electrical requirements.
The gas valve for the M3 furnace series is equipped with a special conversion pressure regulator cap. The pressure regulator cap is factory set. If the gas valve is converted from natural gas to propane gas or vise versa, the manifold pressure of the gas valve will be set to pressure listed in Table 9.
Line Voltage Wiring
The line voltage (115 volt) to the furnace must be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace.
See Table 10.
An electrical switch should be readily accessible from and within sight of the furnace.
See the Wiring
Diagram label in the furnace for more details.
Type of Fuel
Natural Gas:
Propane (LP) Gas:
Manifold Pressure
In.WC
3.5
10.0
Table 9. Manifold Pressure
COMPLETING THE CONVERSION
I.
Affix the gas valve conversion label found in the package with the orifices to the unit rating plate.
2.
Run the appliance through a complete cycle to assure proper operation.
The furnace cabinet must have an uninteF rupted, unbroken ground to minimize injury should an electrical fault condition occur. The controls used in this furnace require an earth ground to operate properly.
Acceptable methods for grounding are electrical wire or conduit approved for electrical ground service. Do not use gas piping as an electrical ground.
NOTE: Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify that the incoming neu-
24
tral lineis connectedto thewhitewireandthe incoming"hot"line is connectedto the black wireinthefurnacejunctionbox.Thefurnacewill
not operateunless polarityand groundare properlyconnected.See Figure26.
Low Voltage Wiring install the thermostat per the manufacturer's instructions.
The low voltage (24 volt) connec= tions from the thermostat are made at the terminal strip on the control board in the furnace.
See Figure 28 for the proper connections for heating only (two=wire) and heating/cooling
(four=wire) applications.
The recommended minimum wire gauge for thermostat wiring is shown in Table 10.
Label all wires prior to disconnection when servicing can cause controls.
improper
Wiring errors and dangerous operation.
Verify proper operation after servicing.
c::_::_ C=_] _
©
24 V
_1®1 o1®1
_1®=_
TWIN
Lors des operations commandes, _tiqueter avant des les d_connecter.
d'entretien tousles des files
Toute erreur de c_blage peut danger et de panne.
_tre une source de
S'assurer l'appareil du bon fonctionnement apr_s tout entretien.
de
Furnace
Input
(Btuh)
60,000
80,000
Cabinet
Width
(in.)
19.75
19.75
Nominal
Electrical
Supply
115-60-1
115-60-1
Thermostat Wire Gauge
24
22
20
18
Figure 27.
Blower Speed Tap Location
Maximum Minimum Maximum Minimum
Operating Operating Furnace
Voltage Voltage Amperes
Wire
Gauge
Maximum
Fuse or Circuit
Breaker Amps*
127
127
103
103
9.7
9.7
Recommended
2-wire (heating)
55 ft.
90 ft.
140 ft.
225 ft.
14
14
15
15
Thermostat Wire Length
L
4 or 5-wire (cooling)
25 ft.
45 ft.
70 ft.
1t0 ft.
* Time-delay fuses or HACR-type circuit breakers are required,
Table 10.
Electricam Data
F_/IS
Panel _
WhltB2aNk_tH_rOtl)_
Green_orB_a_rE_ ......
(Ground) _
Black
_.......
_
_ ....
_
Black _
_ .......
Ground / Ground
Field Supplied Disconnect
Within Sight of Furnace
_-]
._Ll_','
_ I
Black
.....
__
Field Line Voltage
Wiring
Factory Line
Voltage Wiring
I
I
=
Ground
Junction Box (may be internal or external to the furnace).
These connections can be made in the field supplied furnace.
disconnect at the
Figure 26.
Line Voltage Field Wiring
25
The thermostatmust not be installedon an outsidewaft or any other locationwhere its operationmaybe adverselyaffected.Adverse
affectsincluderadiantloadingfromfireplaces, sunlight,or lightingfixtures,and convective loadingfrom warm air registersor electrical appliances.
To checkthe heatanticipatorsettingeither:
I.
Addthe currentdrawof the systemcomponents;or
2. Measurethecurrentflowonthethermostat
R-Wcircuitafterthecirculating hasstarted.
NOTB:The "'Y" terminal on the
UTEC control board must be connected to the thermostat for proper cooling mode operation.
!-
Connect
R&W
For
Heating
Only
Room
Thermostat
'
F i
E i
E::::_::_
O
C_=M _
24=V Fuse
3 Amp
Blower Off e_ oo
Timing
TWIN
_::=
Light
(Yellow)
Status Light 0
(Red)
Setthe heatanticipatoraccordingto the thermostat manufacturer'sinstructionsfor heat anticipatorsettings.
I _
C _
Neutrals
Unused Motor Leads u: o m
DD_DDD_
VENTiLATiON
C°"dens'°gun't
Condensing Unit
Figure 28.
Low Voltage Field,
Four=wire Heating/Cooling Applications
Ventilation must be provided for homes built to
HUD Manufactured Homes Safety and Con= struction Standards. This ventilation can be sup= plied by the VentiiAire Ill or VentilAire iV accessories. (See Table 12). Alternate means to pro= vide the ventilation air must meet the requirements of all applicable local and federal codes.
For installation of the VentiiAire Ill or IV, follow the instructions provided with the VentilAire kit.
I.
START-UP AND ADJUSTMENTS
General
Prior to start=up, verify that:
The line voltage power leads are securely connected, that the polarity of the con= nections is correct, and that the furnace is properly grounded.
2.
The thermostat wires (R, W, Y, and G) are securely connected to the correct leads on the terminal strip of the circuit board.
.
The natural gas line service pressure must not exceed 10.0 in. water column (0.36
psig), and must not be less than 4.5 in.
water column (0.16 psig). For LP gas the line service pressure must not exceed 14 in. water column (0.51 psig), and must not be less than 11.0 in. W.C. (0.40 psig).
26
.
The roll-out and vent safety manual reset switches are closed.
If necessary, press the red button to reset a switch.
See
Figure 26 for location.
DO NOT install a jumper wire across a switch to defeat its function.
If a switch reopens on start-up,
DO NOT reset the switch without identifying and correcting the fault condition which caused the switch to trip.
5.
The blower door is in place, closing the door switch in the line voltage circuit.
6.
The gas line has been purged and all connections are leak tight.
Start-Up Procedure
I.
Set the thermostat to the lowest setting.
2.
Close the disconnect(s) to provide line voltage to the furnace.
3.
Follow the procedures given on the operating instructions label attached to the furnace.
4.
Set the thermostat above room temperature and verify the sequence of operation.
(See the SEQUENCE OF OPERATION.)
.
After the furnace has run for approximately five minutes, set the thermostat below room temperature and verify steps 9 - 11 of the
SEQUENCE OF OPERATION.
Shut Down Procedure in the event that the furnace must be shut down, follow this procedure:
I.
Set the room thermostat to "OFF" or its lowest temperature setting.
2.
Turn OFF the main gas supply to the appliance at the manual valve outside of the appliance casing.
3.
Remove the control access panel / Iouvered door.
5.
.
Move the appliance gas valve lever/knob to the "OFF" position.
Turn OFF the electrical power to the appliance.
Verifying Firing Rate
The firing rate must be verified for each installation to prevent over-firing the furnace.
NOTE: The firing rate must not exceed the rate shown on the furnace rating plate. At altitudes above 4000 ft. it must not exceed that on the rating plate mess 4% for each
1000 ft.
Use the following procedure to determine the firing rate:
I.
Shut off all other gas fired appliances.
2.
Start the furnace and allow it to run for at least three minutes.
4.
5.
.
Measure the time (in seconds) required for the gas meter to complete one revolution.
Convert the time per revolution to cubic feet of gas per hour using Table 11.
Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in
Btuh. Example: o Time for I revolution of a gas meter with a I cubic foot dial = 60 seconds.
o From Table 11 read 60 cubic feet per hour of gas.
o Heating value of the gas (obtained from gas supplier) = 1000 Btu per cubic foot.
, Fidng rate = I000 x 60 = 60,000 Btuh.
6.
See the "High Altitude Derate" section for additional information on firing rate at elevations above 4,000 ft.
The gas valve regulator is set at a nominal value of 3.5 in. water column for use with natural gas. The manifold pressure must be set at I 0.0 in.
water column for use with LP gas.
Verifying and Adjusting Temperature Rise
Verify that the temperature rise through the furnace is within the range specified on the furnace rating plate. Temperature rises outside the specified range could result in premature heat exchanger failure.
Place thermometers in the return and supply air stream as close to the furnace as possible.
The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings.
Adjust all registers and duct dampers to the desired position and run the furnace for fifteen minutes before taking any temperature readings.
The temperature rise is the difference between the supply and return air temperatures.
For typical duct systems, the temperature rise will fall within the range specified on the rating plate with the blower speed at the factory recommended setting.
If the temperature rise measured is outside the range specified, it may be necessary to change the blower speed.
Lower blower speeds will increase the temperature rise and higher blower speeds will decrease the temperature rise.
The furnace is equipped with a multispeed motor. Heating and cooling speed selection is made by moving the leads on the integrated control board located in the furnace. The wiring diagram on the furnace and Figure 30 show the speed taps for adjusting motor speed.
If it is desired that the blower operate at the same speed for heating and cooling, tape off the terminal of the unused blower wire. Install the jumper wire, found in the plastic instruction bag, across the HEAT and COOL taps on the control board. Reconnect the desired blower tap to the piggyback quick connect.
The blower control is designed to start the circulating air blower 30 seconds after the gas valve is opened.
The blower control is factory wired to turn the blower motor off 120 seconds
27
TIME FOR
ONE REVOLUTION
(SECONDSI
24
26
28
3O
42
44
46
48
5O
32
34
36
38
4O
52
54
56
58
6O
62
64
GAS FLOW RATE (CUBIC FEET PER HOUR)
86
82
78
75
72
113
106
100
95
90
60
58
56
69
67
64
62
CUBIC FEET PER REVOLUTION OF
METER
1
150
5
750
10
1500
138
129
120
692
643
600
1385
1286
1200
563
529
500
474
450
429
409
391
375
360
346
333
321
310
300
290
281
692
667
643
621
600
581
563
857
818
783
750
720
1125
1059
1000
947
900
TIME FOR
ONE REVOLUTION
J (sEcONDs)
8O
82
84
86
88
9O
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
37
36
35
35
34
41
40
39
38
38
33
33
32
32
31
31
3O
CUBIC FEET PER REVOLUTION OF
1
45
METER
5
225
10
450
44
43
42
220
214
209
439
429
419
205
200
196
191
188
184
180
176
173
170
167
164
161
158
155
153
150
333
327
321
316
310
305
300
367
360
353
346
340
409
400
391
383
375
Table 11.
Gas Flow Rate after the gas valve is dosed. This timing can be changed using the BLOWER OFF timing switch opposite the terminal block on the control board
(See Figure 27).
Verifying Burner Operation
To verify operation of the burners, remove front door and ensure that the door switch is in the "on" position (see Figure 29). Set the thermostat above room temperature and observe the ignition sequence. The flame can be observed through the small clearwindow on the burner box. The burner flame should carry over between all burners. The flames should be blue, without yellow tips. Flames should extend from each burner without lifting, curling, or floating. After verifying ignition, set the thermostat below room temperature and verify that the burner flame extinguishes completely.
Replace the front door.
Verifying Operation of the Supply Air
Limit Switch
To verify operation of the supply air limit switch, make sure that the blower door is in place and that there is power to the furnace.
Completely block the return airflow to the furnace by install=
ing a close=off plate in place of or upstream of the filter(s).
Set the thermostat above room temperature and verify that the Sequence of
Operation is as described in these instructions.
The supply air limit switch should function to turn off the gas valve within approximately five minutes.
The circulating air and combustion blowers should continue to run when the supply air limit switch opens.
Remove the close=off plate immediately after the supply air limit switch opens. If the furnace operates for more than five minutes with no return air, set the thermostat below room temperature, shut off the power to the furnace, and replace the supply air limit switch.
DESCRiPTiON OF COMPONENTS
Figure 29 shows the location of each of the functional components described below. If any component of the furnace must be replaced, use only factory authorized replacement parts.
Contact your distributor for the approved re= placement parts.
Flame Sensor - The flame sensor acts to prove that flame has carried over from the ignitor to the opposite end burner. If no flame is sensed, the furnace will be shut down automati= cally.
28
FURNACE ACCESSORY KtTS
Kit
A/C Coil Box
Side Return Air Kit
Top Return Air Kit
Sloped Roof VentilAire
Sloped Roof VentilAire
Soffit VentilAire Kit
Concentric
Ill Kit
IV Kit
Vent Termination Kit
(for horizontal
Horizontal and vertical
Exterior Vent ventin,q)
Mounting Kit
Neutralizer Kit - All Models
3"PVC
Order Number
911969A
904003
904015
914098
914229
917201
903578
902375
902377
Table 12.
Accessory Kits
Gas Vamve - The gas valve controls the flow of gas to the burners.
When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold.
Pressure Switch - The pressure switch vealties that the inducer is drawing the combustion gases through the heat exchanger.
It alsosenses a blocked condensate drain condition.
Deck Limit Switch (Auxiliary Limit) - The deck limit protects the furnace filter temperature from overheating when the motor has malfunctioned.
If the deck switch opens, the power for the furnace will shut down (see
Figure 29).
Supply Air Limit Switch - The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature.
Vent Safety Switch - The vent safety switch shuts the furnace down if the outlet flue gas temperature increases above 145°F.
This switch protects the plastic flue system and the inducer from over-temperature conditions.
Flame Roll-Out Switch - This switch provides flame roll-out protection to the furnace and combustion air inlet pipe.
MAINTENANCE
It is recommended that the furnace be checked yearly. At a minimum, this check should include the following items:
WARNmNG'.
To avoid electric shock, personal injury, or death, turn off the power disconnect or the main service before performing any maintenance.
at the panel
WARNING:
Holes in the vent pipe or heat exchanger can cause products of combustion to enter the occupied space.
Replace the vent pipe or heat exchanger if leaks are found.
Failure to prevent products combustion from being circulated the occupied space can crate potenof into tially hazardous conditions, carbon monoxide poisoning, including that could result in personal injury or death.
Combustion Air and Vent System
Check the combustion air and vent pipe to ensure that it is not damaged, corroded or blocked by debris.
Any damaged section of vent pipe must be replaced, and any obstruction or blockage must be removed prior to operating the furnace.
Air Filter
An air filter is supplied with the furnace as shipped from the factory.
Filters should be changed or cleaned monthly during the heating season.
New or newly renovated homes may require more frequent changing until the construction dust has been removed.
29
Never operate the furnace without filter Jn pmace. Dust and mintJn the return air can nents, resumtJng equipment buJmd up on Jntemam compo-
Jn moss of efficiency, damage, and possJbme fire.
a
Lubrication
The bearings in the circulating air blower motors are prequbdcated and sealed at the factory. No further oiling of the bearings is required for the life of the motor.
Condensate Drain AssemMy
Be sure the condensate lines are free and open
(i.e. avoid kinking hoses).
Also make sure all hose clamps are tight to avoid drawing air into the system.
Blower Compartment
The blower compartment should be cleaned monthly during the heating and cooling seasons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor.
Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and shortened service life.
Heat Exchanger and Burner Maintenance
The furnace should operate for many years without excessive soot buildup in the flue passageways, however, the flue passageways, the vent system, and the burners should be inspected and cleaned (if required) by a qualified service technician annually to ensure continued safe operation.
Particular attention must be given to identify deterioration from corrosion or other sources.
SYSTEM OPERATION iNFORMATiON
GENERAL
Proper maintenance is most important to achieve the best performance from a furnace.
Follow these instructions for years of safe, trouble free operation.
o Do not place combustible materials on or against the furnace cabinet or the vent pipe.
Do not store gasoline or any other flammable vapors and liquids in the vicinity of the furnace.
Change or replace the air filters monthly during any period when the circulating blower is operating regularly.
Always replace the doors on the furnace after servicing.
Do not operate the furnace without all doors and covers in place.
Avoid operating the furnace when windows and doors are open.
Be sure that the thermostat is propermy installed and is not being affected by drafts or heat from mamps or other appliances.
Sequence of Operation
Operating sequences for the heating, cooling, and fan modes are described below. Refer to the wiring diagrams (Figures 30) and the low voltage field wiring diagram (Figure 26) for more details.
Heating Mode:
I.
On a call for heat the thermostat closes, applying 24 VAC to the W terminal on the control board.
2.
The control board checks for continuity on the 24 VAC limit control circuit (overtemperature limit switch, flame rollout switches and blocked vent switch in series). If an open limit is detected the control board will energize the inducer and the conditioned air blower. All other system functions win be inoperable until the limit circuit closes. While the limit is open, the red LED will pulse at a rate of I blink per unit time.
3.
The furnace control checks for continuity across the pressure switch (24 VAC).
If the pressure switch is closed the heat mode sequence will not continue.
If it remains closed for 10 seconds the red
LED will blink 3 times repetitively until the fault condition clears.
4. The inducer is energized.
5. The pressure switch win close.
If the pressure switch does not close after 10 seconds the fault LED will blink 2 times repetitively and the inducer will continue to run until the switch is closed.
6. The inducer will pre-purge for 30 seconds and then the igniter will start its warm-up as follows:
3O
InitialPowerup:After30secondsofigniter warm-upthegasvalve(24VAC)will then open. The igniter circuitwill stay energized for 3 secondsafter the gas valve opens.
After InitialPowerup: The controlhas a programmedadaptive ignition feature which variesthe warm-upperiodas folcall for heat until ignitionfailure occurs.
Uponignitionfailure,the warm-upis increasedby 3-secondson the nexttry. If successful,thetimingremainsfixedatthis level.Ingeneral,wheneverignitionfailure occursthewarm-upintervalisincreasedby
3-secondsonthe nexttry.Andifsuccessful, it remainsthere.Minimumandmaximumwarm-uptimelimitsareset at6 and
Cooling Mode:
I.
On a call for cooling the thermostat closes, applying 24 VAC to the G and Y terminals on the furnace control.
This closes the compressor contactor.
2.
The furnace control energizes the circulating blower (115 VAC) on the cooling speed.
3.
When the thermostat is satisfied, the G and Y terminals on the control board are de-energized contactor.
opening the compressor
4.
The circulating air blower is de-energized after a 90-second delay.
Fan Mode:
I.
On a callforfan operation, the thermostat applies 24 VAC to the G terminal on the furnace control board.
3.
.
The circulating air blower is energized immediately on the heating speed.
If the furnace is operated in the continuous ON position at the thermostat and is then switched to AUTO, the circulating blower will operate for a specified delay
(factory set at 120 seconds).
7. Thefurnacecontrolmustproveflamevia the flamesensor5 secondsafterthe gas valveopens.If flameis sensed,all burners areon andthe ignitorcoolsoff. If no flame is sensed,the gas valve closes immediatelyandthe inducercontinuesto run. A secondtrial for ignition(step 6) beginsif noflameis sensed.Onthefifth
tryforignition,thefurnacecontrolislocked out and the red LEDwill blink 4 times repetitively. The thermostat must be openedfor at leastten secondsto reset the furnacecontrolaftera lockout. Otherwise,the furnacewill attemptanother ignitionsequencein 1 hour.
8. The furnace control energizesthe circulatingair bloweron the heatingspeed
30 secondsafterthe gasvalvecircuitis energized
.
9. When the thermostat has been satisfied, gas valve is de-energized.
10. The inducer is de-energized after a 30second postpurge.
11. The furnace control keeps the circulating air blower energized for 120 seconds
(factory set) or 60, 90, or 180 seconds
(field adjustable).
(See Figure 27.)
12. Abnormal conditions: If a limit opens during operation, the inducer and circulating air blower continue to operate. The gas valve is de-energized immediately.
The blowers continue to operate until the limit closes.
When the limit closes the inducer blower is de-energized immediately.
The circulating air blower continues to operate for the specified delay (factory set at 120 seconds).
Furnace Fails to Operate
If the furnace does not operate check the following:
I.
Is the thermostat operating properly?
2.
Is the front door in place?
3.
Is the furnace disconnect closed?
4.
Has the circuit breaker tripped or the control board fuse burned open?
5.
Is the gas turned on?
6.
Are any manual reset switches open?
7.
Is the filter dirty or plugged?
8.
Is the flame sensor coated?
(Remove and clean with emery cloth.)
9.
Is the deck switch open?
If the furnace locks out after 5 attempts for ignition, it will try again every hour if a call for heat remains.
If the inducer and circulating air blowers are operating, and items I through 8 have been checked, press the red reset button on the vent safety switch. (See Figure 29.)
If the furnace operates after depressing the reset button, contact a qualified service technician to identify and repair the problem.
If furnace still fails to operate, depress the red reset buttons on the flame roll-out switch.
If the furnace operates after depressing the reset button, contact a qualified service technician to identify and repair the problem.
31
M3 Dewnflow Furnace
32
1 Door Assembly - Louvered
Filter Inside Door
3 Blower Assembly
4 Control Board
5 Pressure Switch
6 Flame Rollout Switch
"J" Trap Hard Tube
8 LowVoltage Transformer
9 In Line Drain Assembly
10 Junction Box
11 Vent Safety Switch
12 Ignitor Assembly
13 BurnerView Port
14 Main Limit Switch
15 Coil Cabinet Assembly (Optional)
16 Flame Sensor (On Burner Box)
17 Gas Valve
18 Switch, On/Off
19 Blower, Inducer
20 Orifice(In BurnerBox)
21 Aux.
Limit
BurnerBox
Figure 29.
Location of Major Components
FAULT CONDmON
Power On
Limit Circuit Open or External
(Does not apply to Deck Switch,
Load On "W" see below)
Pressure
Pressure
Switch
Switch
Open
Closed with with
Inducer
Inducer
On
On
!gn!t!on
Fai!ure
115 VAC & Neutral
(Check Ground)
Reversed or no Ground
False
Power
Flame
Off or Gas or Deck
Valve
Limit
Relay
Open
Shorted
FAULT CONDITION
Low Flame Sensor Signal
Flame Present
STATUS
RED
LUGHT
ON
I FLASH
2 FLASHES
3 FLASHES
4 FLASHES
5 FLASHES
Continuous
OFF
FLAME
YELLOW
LIGHT
Continuous
Flash
ON tf any of the originat wire as supplied with the furnace must be replaced, it must be replaced with wiring materiaJ having a temperature rating of at least 105" C.
Use copper conductors only,
MOTOR
PLUG
Factory Wired
Heating Speeds
Furnace
Input, Btuh
Wire
Cotor
60,000 Red
80,000 Blue
Figure 30.
Downflow Furnace Wiring Diagram
WD#7i0240B
33
34
INSTALLATION/PERFORIVlANCE
LOCATION
INSTALLER
UNIT MODEL NUMBER
CHECK LIST
CITY
CITY
STATE
STATE
UNIT SERIAL NUMBER
Minimum Clearances per Table 3?
Electrical Connections tight?
Line Voltage Polarity correct?
Supply Voltage:
Blower Motor HP:
Volts
Are Flue Connections
Is there Proper Draft?
tight?
Is Vent free from restrictions?
Is the Filter(s) secured in place?
Is the Filter(s) clean?
FUEL TYPE:
Natural Gas LPiPropane
Gas Piping Connections leak-tested?
__
Gas Line Pressure:
(in. water column, with furnace operating)
Manifold Pressure:
(in. water column, with furnace operating)
Is there adequate fresh air supply for combustion and ventilation?
Furnace Input:
Supply Air Temperature:
Return Air Temperature:
Temperature Rise:
Has the Thermostat
Is the Thermostat
Is the Heat Anticipator been calibrated?
level?
Setting correct?
Has the Owner's Information with the home-owner?
been reviewed
(Btuh)
(° F)
(° F)
(° F)
Has the Literature Package been left near the furnace?
35
O'Fallon, MO
NORDYNE
708219D
7082t9D (Replaces 708219C)
Specifications and illustrations subject to change without notice and without incurring obligations.
Printedin
US.A. (04/04)

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