Nordyne M1MB 077, M1MB 070, M1MC 077, M1MB 090, M1MC 090 Installation Instructions Manual

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Page 1

INSTALLATION INSTRUCTIONS

Downﬂ ow, Direct Vent (Sealed Combustion) Forced Air Gas & Oil Furnaces

Series M1B, M1M & M5S

For installation in:

• Manufactured Homes

• Recreational Vehicles, Park Models, & Manufactured Buildings

• Modular Homes / Buildings

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 qualiﬁ ed installer, service agency or the gas supplier.

• Do not store or use gasoline or other

ﬂ ammable 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 ﬁ re 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 qualiﬁ é, 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 inﬂ ammables 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.

Page 2

TABLE OF CONTENTS

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

REQUIREMENTS & CODES .......................................3

GENERAL INFORMATION ..........................................5

Manufacturer Warranty .............................................5

Minimum Clearances ............................................... 5

Applications .............................................................5

Unit Location ............................................................5

CIRCULATING AIR REQUIREMENTS ........................7

Return Air Connections ...........................................7

Supply Air Connections ............................................7

FURNACE INSTALLATION .........................................8

General Information ..................................................8

Locating & Cutting Duct Openings ..........................8

Standard Duct Connector Installation ....................... 8

Alternate Attachment Method ................................. 9

Round Duct Connector Installation ......................... 10

Installing the Furnace ............................................. 10

ROOF JACK INSTALLATION .................................... 11

Roof Jack Selection ................................................ 11

Application Notes ....................................................11

Locating & Cutting Roof Openings ......................... 12

Installing the Roof Jack ........................................... 13

Installation of Transit-Mode Vent System ................ 13

ELECTRICAL INFORMATION ................................... 14

Line Voltage Wiring ................................................. 14

Connecting Power Supply Wires .......................... 14

Low Voltage Wiring ................................................. 15

Connecting Thermostat Wires .............................. 15

Verifying Anticipator Setting ................................. 15

Grounding ...............................................................15

FUEL SUPPLY & PIPING .......................................... 16

Leak Check ............................................................ 17

Oil Tank & Piping Istallation .................................... 17

One-Line System ..................................................18

Two-Line System .................................................. 18

Fuel Line Hook Up ................................................. 18

Fuel Line Bleeding ................................................. 18

Priming Honeywell R7184 ................................... 19

Priming Beckett 7505 .......................................... 19

Fuel Oil Type .......................................................... 19

Conversion to Propane Gas .................................. 19

Atmospheric & Direct Ignition .............................. 19

High Altitude Conversion ....................................... 19

Flue Gas Sampling ................................................ 20

STARTUP & ADJUSTMENTS ...................................21

Operating Instructions - Direct Ignition (M1M) ....... 22

How to Shut Off Gas - Direct Ignition ................... 22

Operating Instructions - Oil Gun (M5S) .................. 22

Operating Instructions - Gas Gun (M1B) ................ 22

How to Shut Off Gas - Gas Gun ........................... 23

Verifying & Adjusting Temperature Rise ................. 23

Burner Adjustments ................................................ 23

Gas Pressure ....................................................... 23

Combustion Air ....................................................... 23

Gas Gun ............................................................... 24

Oil Gun .................................................................24

Electrode Setting - Oil Gun ..................................... 24

Switching Honeywell (R7184) Ignition from

Interrupted to Intermittent ....................................... 24

OPERATING SEQUENCE .........................................24

Direct Ignition Furnaces (M1M Models).................. 24

Oil Gun Furnaces (M5S Models) ............................ 24

Gas Gun Furnaces (M1B Models) .......................... 24

FURNACE CONTROLS & FUNCTIONS ................... 25

Furnace On / Off Switch ......................................... 25

Limit Control ........................................................... 25

Gas Valve................................................................25

Oil Burner Primary Control ..................................... 25

Summer Cooling - B,C,D Series ............................. 25

TROUBLESHOOTING ...............................................26

Direct Ignition & Gas Gun (M1M & M1B Models) ... 26

Oil Gun Models (M5S Models) ...............................27

OPTIONAL ACCESSORIES ...................................... 28

Optional Add-On Air Conditioning .........................29

MAINTENANCE ......................................................... 29

Homeowner Information ........................................ 29

Installer Information Information ............................ 29

Additional Oil Furnace Maintenance ................... 29

FIGURE & TABLES .................................................... 30

Table 10 - M1 / M5 Furnace Speciﬁ cations ..........30

Table 11 - Oriﬁ ce Sizes - High Altitude. ................ 31

Table 12 - A/C Blower Speed Selection ................ 31

Gas Information ...................................................... 32

Table 13 - Gas Flow Rates ................................... 32

Table 14 - Gas Pipe Capacities ............................ 32

Electrical Information .............................................. 33

Fig. 38 - Gas Only (M1M Models) ........................ 33

Fig. 39 - Gas & Oil (M1B & M5S) ......................... 34

INSTALLATION CHECKLIST .................................... 36

Page 3

IMPORTANT SAFETY INFORMATION

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.

WARNING:

Do not use this appliance if any part has been submerged under water. Immediately call a qualiﬁ ed service technician to inspect the appliance and to replace any part of the control system and any gas control that has been submerged underwater.

WARNING:

The safety information listed below must be followed during the installation, service, and operation of this furnace. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death.

WARNING:

FIRE AND EXPLOSION HAZARD

Can result in serious injury or death.

Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance. Storage of or use of gasoline or other ﬂ ammable vapors or liquids in the vicinity of this or any appliance can result in serious injury or death.

AVERTISSEMENT:

RISQUE D’INCENDIE ET D’EXPLOSION

Risque de blessures graves ou de mort.

Ne pas entreposer ni utiliser de l’essence ni d’autres vapeurs ou liquides inﬂ ammables dans le voisinage de cet appareil, ni de tout autre appareil. Le fait d’entreposer ou d’utiliser de l’essence ou d’autres liquides ou vapeurs inﬂ ammables à proximité de cet appareil ou de tout autre appareil peut causer des blessures graves ou la mort.

REQUIREMENTS & CODES

• 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.

• CE générateur d’air chaud doit être installé conformément aux instructions du fabricant et aux codes locaux. En l’absence de code local, respecter la norme ANSI Z223.,1, institulé National Fuel Gas Code ou les codes d’installation CAN/GCA-B149.

• Use only with type of gas approved for this furnace. Refer to the furnace rating plate.

• Install this furnace in accordance to the minimum clearances to combustible materials listed in Table 1 (page 6).

• Provide adequate combustion and ventilation air to the furnace space as speciﬁ ed on page 23. Do not block or obstruct air openings on the furnace, air openings to the area where the furnace is installed, or the space around the furnace.

• Combustion products must be discharged outdoors. Connect this furnace to an approved vent system, as speciﬁ ed on pages 11 - 14.

• Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution to check all connections (page 17).

• This furnace is designed to operate with a maximum external pressure rise of 0.5 inches of water column. Consult Table 12 (page 31) and the rating plate for the proper circulating air ﬂ ow and temperature rise.

NOTE: It is important that the duct system be designed

to handle the desired ﬂ ow rate and external pressure rise. An improperly designed duct system can result in nuisance shutdowns, and comfort or noise issues.

• When 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. See pages 8 - 10.

• This furnace may 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:

Page 4

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 satisﬁ ed: a.) A carbon monoxide (CO) detector and alarm

shall be placed on each ﬂ oor 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 identiﬁ cation plate shall be

mounted at the exterior of the building, 4 feet directly above the location of vent terminal. The plate shall be of sufﬁ cient 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 satisﬁ ed: a.) A (CO) detector and alarm shall be placed on each

ﬂ oor 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,

Additional information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes. Always consult with local authorities before installing any gas appliance.

Combustion & Ventilation Air

• US: National Fuel Gas Code (NFGC), Air for Combustion and Ventilation

• CANADA: Natural Gas and Propane Installation Codes (NSCNGPIC), Venting Systems and Air Supply for Appliances

Duct Systems

• US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) Fundamentals Handbook

Electrical Connections

• US: National Electrical Code (NEC) ANSI/NFPA 70

• CANADA: Canadian Electrical Code CSA C22.1

Gas Piping & Gas Pipe Pressure Testing

• US: NFGC and National Plumbing Codes

• CANADA: NSCNGPIC

General Installation

• US: Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or American Gas Association, 400 N. Capitol, N.W., Washington DC 20001 or www.NFPA.org

• CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W 1R3 Canada

Safety

• US: (NFGC) NFPA 54–1999/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/ NFPA 90B.

• Federal Manufactured Home Constructions & Safety Standard (H.U.D. Title 24, Part 3280.707[a][2])

• The Standard for Manufactured Home Installations (Manufactured Home Sites, Communities, and Set-Ups) ANSI A225.1 and/or CAN/ CSA-2240 MH Series).

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

• CANADA: CAN/CGA-B149.1 and .2–M00 National Standard of Canada. (NSCNGPIC)

Page 5

GENERAL INFORMATION

CAUTION:

• Do Not alter or modify this furnace or any of its components.

• Never attempt to repair damaged or inoperable components. This may cause unsafe operation, explosion, ﬁ re and/or asphyxiation.

• If furnace malfunctions or does not operate properly, contact a qualiﬁ ed service agency or gas utility for assistance.

Manufacturer Warranty - Owner’s Responsibilities

A warranty certiﬁ cate with full details is included with these instructions. Carefully review these responsibilities with your manufactured housing dealer, service company or gas supplier. It is the sole responsibility of the homeowner to make certain the gas furnace has been correctly set up and converted to the proper fuel (L.P. gas or Natural gas) and adjusted to operate properly. All gas furnaces are manufactured for Natural gas and must be ﬁ eld converted when using L.P. gas.

NORDYNE will not be responsible for any costs found necessary to correct problems due to improper setup, improper installation, furnace adjustments, improper operating procedure on the part of the user, etc. Some speciﬁ c examples of service calls which cannot be included in warranty payments are:

• Converting the furnace to use another type of gas.

• Repairing duct work in the home found to be faulty.

• Correcting wiring problems in the electrical circuit supplying the furnace.

• Resetting circuit breakers, blown fuses or other switches.

• Correcting problems due to improper gas supply pressure to the furnace.

• Providing instructional training on how to light and operate the furnace.

• Furnace problems caused by installation of an air conditioner, heat pump or other air comfort devices.

• Adding a Roof Jack extension because of unusual wind and/or snow conditions.

• Revising installation of the furnace ﬂ ue assembly (Roof Jack).

• Adjusting or calibrating of thermostat.

• Any construction debris which falls into ﬂ ue system.

Minimum Clearances

This heating appliance must be installed with clearances not less than the minimums listed in Table 1. This furnace must be installed with ample clearance for easy access to the air ﬁ lter, blower assembly, burner assembly, controls, and vent connections. See Figures 1 - 3 (page 6).

• The dimensions of the room or alcove must be able to accommodate the overall size of the furnace and the installation clearances listed in Table 1 and in Figure 4 (page 6).

• Alcove installations: minimum 18” clearance at front of furnace shall be provided for future servicing. A removable access panel should be installed between top of the furnace door frame and the ceiling.

• Closet installations must use a louvered door having a minimum free area of 235 in2 when located 6” from furnace or 390 in2 for 5 ton ready M1/M5 furnaces. For special clearance between 1” - 6”, requirements are a louvered door with a minimum of 250 in2 free area, with the openings in the closet door in line with the louvered openings in the furnace door. A fully louvered closet door may be used. See Circulating Air Requirements (page 7).

• The furnace must be kept free and clear of insulating material. Examine the furnace area when the furnace is installed or when insulation is added. Insulating material may be combustible.

Applications

M1 Series gas and M5 Series oil furnaces are listed direct vent (sealed combustion), downﬂ ow heating appliances for manufactured (mobile) homes, recreational vehicles, and for use in residential/modular/commercial construction. The furnace must be located so that venting can be properly achieved.

Air conditioning may be added to structures with M1/M5 series furnaces using air conditioning or conventional units. This Installation Instruction manual includes special requirements for incorporation of air conditioning equipment to the M1/M5 series of furnaces. See Table 12 (page 31).

Multi-speed blower assemblies shown in Table 2 (page 6), have been certiﬁ ed for ﬁ eld installation in M1/M5 Series furnaces.

Unit Location

• The furnace shall be appropriately located to the supply and return air distribution system (page 7). Sides and back of the furnace may be enclosed by wall framing. See Minimum Clearances and Figures 1- 3 (page 6).

• The fur nace installation is only intended for free air return through the furnace door louvers. DO NOT connect a ducted return air system directly to the furnace. Improper installation may create a hazard and damage equipment, as well as void all warranties.

• Furnace may be installed on combustible ﬂ ooring when using NORDYNE Duct Connectors. See pages 8 - 10.

• 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 ﬂ oor and protected from physical damage by vehicles.

Page 6

6" (152 mm)

Top Clearance

0" Side Clearance to Furnace Cabinet

Figure 1. Alcove Installation

Removable access panel should be installed above furnace door frame to access roof jack

18"

(457 mm)

Nearest Wall or Partition

ALL MODELS CLOSET ALCOVE

Front 6” 18”

Back 0” 0”

Sides 0” 0”

Roof Jack 0” 0”

To p 6 ” 6 ”

Top and Sides of Duct 0” 0”

Bottom of Duct

B Cabinet 0” 0”

A Cabinet (w/ coil box) 0” 0”

A Cabinet (w/o coil box) 1/4” 1/4”

Table 1. Minimum Clearances

6" (152 mm)

Top Clearance

0" Side Clearance to Furnace Cabinet

6" (152 mm)

Top Clearance

0" Side Clearance to Furnace Cabinet

Provide min. 235 sq. in. (1516 cm ) open free area in front or side wall

(152 mm)

CLOSET DOOR

Figure 2. Closet Installation

Provide min. 250 sq. in. (1613 cm ) open free area in front or side wall

(25 mm)

or In closet

door located at top, center or bottom

or in closet door

a fully louvered door may be used

“A”- 56"

“A” Model

w/o Coil

Cabinet

“B”- 76"

“B” Model

w/Coil

Cabinet

23 3/4"

19 3/4"

Figure 4. Overall Dimensions

Part

No.

903773 10 x 8 1/4 2, 2½ & 3 903413 11 x 8 1/2 2, 2½, 3 & 4 903890 11 x 8 3/4 2, 2½, 3, 4 & 5

Blower / Motor Assembly

Blower Wheel Motor (Hp)

A/C Capacity

(Tons)

Table 2. Blower Assemblies

CLOSET DOOR

Figure 3. Special 1” Clearance

Page 7

CIRCULATING AIR REQUIREMENTS

A Single trunk duct

Dual trunk duct w/crossover connector

Transition duct w/branches

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 poison-

ing that could result in personal injury or death. All return ductwork must be secured to

the furnace with sheet metal screws. For installations in conﬁ ned spaces, all return ductwork must be adequately sealed. The joint between the furnace and the return air 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 ﬂ oor or platform. Return air and circulating air ductwork must

not be connected to any other heat producing device such as a ﬁ replace insert, stove, etc. This may result in ﬁ re, explosion, carbon monoxide

poisoning, personal injury, or property damage.

Return Air Connections

U.S.A. home manufacturers shall comply with all of the following conditions to have acceptable return air systems for closet installed forced air heating appliances:

• The return air opening into the closet shall not be less than speciﬁ ed in the appliance’s listing.

• The cross-sectional area of the return duct system leading into the closet, when located in the ﬂ oor or ceiling shall not be less than 235 in2 (or 390 in2 for 5 ton ready M1/M5 Furnaces).

• Noncombustible pans having 1” upturned ﬂ anges are located beneath openings in a ﬂ oor duct system.

• Wiring materials located in the return duct system shall conform to Articles 300-22 of the National Electrical Code (ANSI C1/NFPA-70).

• Gas piping is not run in or through the return duct system.

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 is to be no more negative than minus 0.05 inch water column.

• Air conditioning systems may require more duct register and open louver area to obtain necessary airﬂ ow. Use NORDYNE’s certiduct program to determine proper duct sizes for air conditioning.

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 rating shown on the furnace rating plate.

Location, size, and number of registers should be selected on the basis of best air distribution and ﬂ oor plan of the home. The supply air must be delivered to the heated

space by duct(s) secured to the furnace casing, running full size and without interruption. Three typical

distribution systems are shown in Figure 5

HAZARD OF ASPHYXIATION: Do not cover or restrict return air opening.

• Means shall be provided that prevent inadvertent closure of ﬂ at objects placed over the return air opening located in the ﬂ oor of the closet (versus the vertical front or side wall).

• The total free area of openings in the ﬂ oor or ceiling registers serving the return air duct system must be at least 235 in2. At least one register should be located where it is not likely to be covered by carpeting, boxes and other objects.

• Materials located in the return duct system must have a ﬂ ame spread classiﬁ cation of 200 or less. This includes a closet door if the furnace is in a closet.

CAUTION:

Figure 5. Typical Supply Duct System

Page 8

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 qualiﬁ ed 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-ﬁ red furnace models.

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

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

• Units have been researched under standards UL 307A & B, UL727-1999, ANSI Z21.47b/CSA 2.3b-2008, and CSA B140.10.

General Information

• The furnace must be leveled at installation and attached to a properly installed duct system. Do not use the back of the furnace for return air. See page 7 for circulating requirements.

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

• The dimensions of the room or alcove must be able to accommodate the overall size of the furnace and the installation clearances listed in Table 1 and Figure 3 (page 6)

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

• The M1 Series gas and M5 Series oil furnace is certiﬁ ed for use on wood ﬂ ooring or supports, but must be installed on top of a duct connector. This factory supplied accessory must be installed in the ﬂ oor cavity and attached to the supply air duct before the furnace is installed.

Locating & Cutting Duct Openings

Floor cut-outs and fuel line holes must be carefully located to avoid misalignment of the furnace, and vent piping. To locate standard ducts see Figure 6 (page 9). For round ducts, see Figure 7.

1. Measure 10” from the rear wall or alcove and mark the centerline of the cut-out on the ﬂ oor.

2. Using the centerline as a starting point, draw the rest of the duct cut-out to the dimensions shown in Figures 6 or 7.

3. Cut out the ﬂ oor opening 1/16” larger than the actual cutout drawn. This will allow some clearance when installing the duct connector.

4. Measure from the top of the ﬂ oor down to the top of the supply air duct to obtain the depth of the ﬂ oor cavity. NOTE: The depth of the ﬂ oor cavity shown as “X” in Figure 9 (page 9) will determine the correct duct connector.

5. Determine which duct connector to use from Table 3 (page 9).

6. Measure and drill gas hole and cut out for cooling coil (if applicable). See Figures 6 or 7.

Standard Duct Connector Installation

The standard duct connector is designed for use on ducts 12” in width. However ducts narrower than 12” may not allow sufﬁ cient clearances for this type of installation. For an alternate installation method, see page 9.

1. Center the duct connector in the ﬂ oor 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 8, page 9) of the duct connector.

3. Remove the duct connector and cut out the marked area of the supply air duct 1/4” larger the actual cutout drawn.

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

5. Install the mounting plate (Figure 8) 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 ﬂ oor with appropriate size screws.

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

8. Bend both tabs up 90° on the mounting plate. See Figure 10 (page 10)

9. 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 speciﬁ c to your area.

Page 9

20"

14 1/2"

REAR WALL OF CLOSET OR ALCOVE

2 3/4"

2 1/4"

10"

FLOOR CUT-OUT

24"

21 3/4"

23 1/4"

1 3/4"

3/4"

FOR STANDARD

DUCT CONNECTORS

14 1/2"

FURNACE OUTLINE

CUT-OUT FOR

OPTIONAL

COOLING COIL

ALT FUEL-LINE

ENTRY 1 1/4" Dia.

1 7/8"

2 7/8"

1 3/4"

FURNACE

OUTER

DOOR

FUEL

LINE

3/4"

Figure 6. Cut-Out Dimensions for

Standard Duct Connectors

20"

10"

REAR WALL OF CLOSET OR ALCOVE

“X”

FLOOR OPENING

SUPPLY AIR DUCT

FLOOR CAVITY

Figure 9. Floor Cavity

If Floor Cavity

“X” is:

Standard Duct Round Duct

7/8” / (22) 901987A 904008

2” / (51) 901988A 904009

4-1/4” / (108) 901989A 904010

6-1/4” / (159) 901990A 904011

8-1/4” / (210) 901991A 904012

10-1/4” / (260) 901992A 904013

12-1/4” / (311) 901993A 904014

NOTE: Dimensions shown as Inches / (Millimeter)

Duct Connector

Type & Part Number

Table 3. Duct Connector Sizes

FLOOR

CUT-OUT FOR

24"

23 1/4"

21 3/4"

1 3/4"

3/4"

1 7/8"

ROUND DUCT

(14 1/4” DIAMETER)

FURNACE OUTLINE

CUT-OUT FOR

COOLING COIL

ENTRY 1 1/4" Dia.

2 7/8"

OPTIONAL

ALT FUEL-LINE

FURNACE

OUTER

DOOR

Figure 7. Cut-Out Dimensions for

Round Duct Connectors

Hole for

Gas Line

Duct

Connector

Wood Floor

Connector

Tabs

Supply

Air Duct

Mounting Plate

10"

1 3/4"

3/4"

FUEL

LINE

Bend tabs

up 90°

Alternate Attachment Method

The standard duct connector is designed for use on ducts 12” in width. However if there is insufﬁ cient clearance to bend the duct connector tabs, this alternate attachment method may be used.

1. Score and cut the top of the supply air duct as indicated in Option 1 or Option 2 (Figure 11, page 10). With Option 1 choice, cut out the metal from the shaded area.

2. Fold the two ﬂ aps (Options 1 or 2) up to form the opening for the duct connector.

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 supply air duct (Figure 12, page 10).

5. Form the ﬂ aps (Options 1 or 2) up against the duct connector as tight as possible.

6. Secure the duct connector ﬂ aps 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.

Figure 8. Standard Duct Connector Installed

NOTE: Requirements for sealing ductwork vary

from region to region. Consult with local codes for requirements speciﬁ c to your area.

Page 10

DUCT CONNECTOR

MTG. PLATE TABS

SLIDE FURNACE

ALL THE WAY BACK

ONTO MTG. PLATE

SUPPLY AIR DUCT

Knockout Over Holes

SECURE FURNACE

WITH 2 FASTENERS AT FRONT

CORNER HOLES

BEND TABS TIGHTLY

AGAINST SUPPLY AIR DUCT

Figure 10. Duct Connector Tabs

OPTION 1 OPTION 2

Remove

this

Cut Here

Fold Flap Here

Cut Here

Remove

this

Flap

Cut Here

Supply

Air Duct

Fold Flap Here

Cut Here

SUPPLY

AIR DUCT

Fold Flap Here

Round Duct Connector Installation

1. Apply a bead of caulking, mastic, or other approved sealant around bottom side of connector.

2. Install and center the duct connector in the ﬂ oor opening.

3. Install the mounting plate under the back side of the duct connector. See Figure 13. NOTE: Align the screw holes in both components.

4. Secure the duct connector and the mounting plate to the wood ﬂ oor with appropriate size screws.

5. Connect the round supply duct to the underside of the duct connector and secure them with ﬁ eld supplied sheet metal screws.

6. 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 speciﬁ c to your area.

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 14 & 15 (page 11).

Figure 11. Narrow Air Duct Openings

Duct connector tabs

Narrow

Duct

Duct Flap

Sheet metal

screws

Staples or sheet metal screws

Duct

Connector

Narrow

Duct

Figure 12. Narrow Ducts

SCREWS

DUCT

CONNECTOR

14” SUPPLY CONNECTION

Figure 13. Round Duct Connector Installed

Narrow

Duct

MOUNTING

PLATE

FUEL LINE

HOLES

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

2. Place furnace onto duct connector and center with ﬂ oor 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 14 or 15).

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

Figure 14. “A” & “B” Cabinet Furnaces

Page 11

SLIDE FURNACE

BACK AGAINST

MTG. PLATE

MTG. PLATE TABS

SECURE FURNACE

WITH 2 FASTENERS

AT FRONT CORNER HOLES

FUEL LINE HOLES

SUPPLY

AIR DUCT

Figure 15. “A” Cabinet Furnace on Coil Cabinet

ROOF JACK INSTALLATION

Required ceiling and roof cut-out openings must be carefully located to avoid misalignment of the furnace and Roof Jack. NOTE: Install only Roof Jack Assemblies listed in Table 4 on this heating appliance.

Roof Jack Selection

1. Determine depth of ceiling cavity from center of roof opening to center of ceiling opening (Dimension [A] in Figure 16).

2. Determine ceiling height and subtract height of furnace (Dimension [B] in Figure 16).

3. Add dimensions [A] + [B] (and [X] from Table 5 & Figure 16, page 12 if slant deck ﬂ ashing is used). The total length of [A] + [B] + [X] must be within the minimum and maximum range of the Roof Jack listed in Table 4.

ROOF JACK

SLANT DECK

PITCHED

ROOF

CEILING

CAVITY

CEILING

“A”

“B”

Furnace

FLASHING

"X" (SEE TABLE 5)

Roof

Opening

Flue Pipe

Combustion Air Pipe

56" or 76"

Figure 16. Ceiling Cavity Depth

MODEL NUMBER

(F,S)AW(T)1523-(0,2,4)(A,S) 15” - 23”

(F,S)AW(T)2135-(0,2,4)(A,S) 21” - 35”

(F,S)AW(T)2747-(0,2,4)(A,S) 27” - 47”

(F,S)AW(T)3563-(0,2,4)(A,S) 35” - 63”

(F,S)AW(T)5195-(0,2,4)(A,S) 51” - 95”

SSAW

F = FLAT FLASHING

S = SLANT FLASHING

AW= ALL WEATHER

TYPE:

BLANK = NON-TRANSIT

T= TRANSIT MODE

APPROX. LENGTH

BELOW FLASHING

47 - 2

MIN. ADJ. LENGTH

MAX. ADJ. LENGTH

FLUE STEEL TYPE A= ALUMINIZED S=STAINLESS

FLASHING PITCH/12" RISE 0=FLAT 2=2.5/12 4=4/12

Application Notes

• FAW, FAWT, SAW and SAWT Series Roof Jacks with a 5” diameter inner vent pipe may be used with all models of M1 Series gas and M5 Series oil furnaces.

F = Flat Flashing: ﬂ exes from 0/12 to 1/12 roof slope.

See Figure 17 (page 12).

S = Slant Flashing: 2.5/12 Slope ﬂ exes from 1/12 to

4/12 roof slope, 4/12 ﬂ exes from 3/12 to 5/12. See Figure 18.

• Stainless steel roof jacks are available.

• M1/M5 furnaces may be used with roof jacks as tall as 170” (except M1M 056 & M1B 066 models, which are limited to 120”). An internal roof jack extension (p/n 901935 - 10”, p/n 903107 - 18”) can be used to increase roof jack height. All connections inside the home must be made below the ceiling.

• This furnace must never be connected to a chimney ﬂ ue servicing a ﬁ replace or other appliance designed to burn solid fuel.

NOTE: If the roof jack crown is covered or blocked with snow, the furnace will not operate properly. If the home is located in regions where snow accumulation exceeds 7” (HUD snowload zones) use an external roof jack extension (p/n 901937). Extensions are optional accessories and may be purchased through your NORDYNE distributor.

See Table 5

Table 4. Roof Jack Assemblies

Figure 17. Example of Flat Jack with Flashing

Page 12

Figure 18. Example of 2½ / 12 Slant Jack

CEILING

CUT-OUT FOR

FLUE AND

ROOF JACK

24"

20"

13 1/2"

REAR WALL OF CLOSET OR ALCOVE

10"

FURNACE

OUTER

DOOR

FURNACE OUTLINE

with Flashing

ROOF JACK

SERIES

“F Series

“S” Series

(2.5 / 12 Pitch only)

Optional deck ﬂ ashings for ﬂ at and 2.5/12 pitch roof jacks. 4/12 pitch roof jacks not applicable.

Table 5. Slant Deck Flashings

Locating & Cutting Roof/Ceiling Openings

Do not allow debris to fall into the furnace. This could cause unsafe operation and void the furnace warranty. Use the top cap that comes with the furnace packaging (or alternate protector) to prevent debris from falling into the furnace before the ﬁ nal roof jack connection is made

NOTE: Refer to the installation instructions provided

with optional air conditioning packages when installing furnaces with optional cooling coil cabinet or with optional C* series indoor coils.

1. Locate center of Roof Jack opening, measure 13 1/2”

2. Cut ceiling and roof holes:

from the rear wall of closet or alcove along the center line of furnace and ﬂ oor opening. See Figure 19.

• Ceiling = 8 3/4” (222 mm) diameter

• Roof = 9 3/8” (238 mm) diameter

IF ROOF

PITCH IS:

2” in 12” 903893 (2.5/12) 2-1/8”

2-1/2” in 12” 903893 (2.5/12) 2-1/2”

3” in 12” 903894 (3/12) 2-7/8”

3-1/2” in 12” 903894 (3/12) 3-1/4”

4” in 12” 903895 (4/12) 3-5/8”

4-1/2” in 12” 903895 (2.5/12) 2-1/8”

5” in 12” 903895 (2.5/12) 2-1/2”

5-1/2” in 12” 903894 (3/12) 2-7/8”

6” in 12” 903894 (3/12) 3-1/4”

6-1/2” in 12” 903895 (4/12) 3-5/8”

SLANT DECK

FLASHING

NUMBER

FACTOR

IMPORTANT:

“X”

IS:

Figure 19. Cut-Out Dimensions for

Flue & Roof Jack

Installing The Roof Jack

1. Apply caulking compound on underside of roof ﬂ ashing to form a continuous strip at least 3/8” wide around the underside of the perimeter of the ﬂ ashing. See Figures 20 or 21 (page13).

2. Connect Roof Jack Assembly to the furnace. Insert telescoping Roof Jack Assembly through the opening cut on the roof.

3. Connect ﬂ ue pipe to ﬂ ue collar of furnace. See Figure 22 (page 13).

4. Connect combustion air pipe to furnace collar with sheet metal screw (See Figure 22).

NOTES:

• It is recommended that the connection of the combustion air pipe to the furnace be made before the ﬂ ashing is secured to the roof to maintain alignment of roof jack and furnace connections.

• For replacement furnaces, be sure the inner ﬂ ue pipe connects over the furnace vent collar. DO NOT use a

smaller diameter inner ﬂ ue pipe which could slide inside the furnace vent collar and restrict the ﬂ ow of furnace ﬂ ue products.

5. Attach Roof Flashing. If necessary, shift roof ﬂ ashing slightly in the roof opening so that assembly is in alignment with furnace.

NOTE: If ﬂ ashing is mounted on 12 degree angle, it

may be necessary to adjust the angle to match the roof pitch; (1/12 - 4/12 maximum).

6. Press down ﬁ rmly on roof ﬂ ashing (over caulking) to make the seal with roof water tight.

7. Secure ﬂ ashing with appropriate fasteners. added protection against leaks, coat the ﬂ ashing plate and fasteners with approved rooﬁ ng compound.

NOTE: For

Page 13

Secure roof jack with

SCREWS

COMPLETED ASSEMBLY

TO FURNACE

UPPER ROOF

JACK (CROWN)

INNER FLUE PIPE

FLUE ASSEMBLY

OUTER PIPE

FLASHING

WEATHER CAP

appropriate fasteners

after connecting to

furnace

Caulk under roof

flashing to prevent

water leakage

Optional 2-piece ceiling

ring #902521

Secure lower roof

jack section with

no. 10 S.M. screws

Caulk under roof

ashing to prevent

water leakage

Figure 20. Flat Roof

Upper Roof Jack Section

Ceiling

Figure 21. Pitched Roof

Ceiling

Optional Slant Deck Flashing

Secure ashing

with appropriate

fasteners

Roof

Figure 23. Roof Jack Crown

Installation of Transit-Mode Venting System (Manufactured Home Factory)

1. Furnace must be installed in accordance to furnace installation manual.

2. Select appropriate Roof Jack from Table 4 (page 11).

3. Roof Jack (less upper Roof Jack crown), with weather cap to be installed as described under Install Roof Jack.

NOTE: Upper Roof Jack crown to be stored in a prominent location inside manufactured home until on-site installation.

4. The four warning tags supplied must be installed as follows:

• To weather cap

• To fuel line connection point (Gas) or furnace burner

(Oil)

• To furnace ﬂ ame observation door (Gas or Oil)

• To furnace wall thermostat

5. Transit-mode weather cap to be removed and upper Roof Jack crown installed (See Figure 23). Do Not Discard screws.

6. Place upper Roof Jack (crown) on the ﬂ ue pipe assembly.

Figure 22. Combustion Air Pipe Connection

NOTE: Make sure inside ﬂ ue pipe attaches over inner

ﬂ ue pipe and outer Roof Jack pipe ﬁ ts over outer pipe.

7. Secure in place using three (3), #10, 1/2” sheet metal screws removed in step 5. Do not use the same holes which secured the rain cap in place.

8. Remove and discard venting system warning tags.

WARNING:

Failure to properly secure the ﬂ ue pipe to the furnace may result in ﬁ re, explosion or asphyxiation when operating the furnace.

Page 14

On-Off Switch

Blower

Plug

Powe r

Entry

On-Auto Switch

(Heating Models Only)

Thermostat Wires

Furnace

Control Box

To combustion

Blower or Flame

Roll-out Switch

To Gas Valve

or Burner

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.

• 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).

Figure 24. Control Panel (All Models)

ELECTRICAL INFORMATION

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 furnace.

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

• 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 ﬁ ls avant de les débrancher. S’assurer de les raccorder correctement.

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

Line Voltage Wiring

It is recommended that 115VAC line voltage be supplied to the furnace from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace.

IMPORTANT NOTE: An electrical disconnect must be installed readily accessible from and located within sight of the furnace. Refer to the wiring diagram inside the control box cover or Figures 38 & 39 (pages 33 & 34) for the wiring of your particular unit. Any other wiring methods must be acceptable to authority having jurisdiction.

CAUTION:

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

IMPORTANT NOTE: 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 25.

Route all electrical wiring to the left side of the furnace (See Figure 24). For installation of “A” Cabinet furnaces, allow sufﬁ cient slack in the wiring if an optional cooling coil cabinet is added at a later time. Use of copper conductors

is recommended.

Connecting Power Supply Wires

1. Remove the furnace control panel cover.

2. Route wires (115 VAC) through the strain relief on the left side of the furnace control box (Figure 24).

3. Connect the hot wire to the black pigtail lead, and the neutral wire to the white pigtail lead. Secure all connections with suitable wire nuts.

4. Connect the ground wire to the grounding screw.

5. Reinstall the control panel cover and secure with the original mounting screws.

Page 15

Low Voltage Wiring

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.

NOTE: The thermostat must not be installed on an outside wall or any other location where its operation may be adversely affected by radiant heat from ﬁ replaces, sunlight, or lighting ﬁ xtures, and convective heat from warm air registers or electrical appliances. The nominal anticipator setting is 0.4. (Refer to the thermostat literature for additional information.)

Five-conductor thermostat wire is recommended for 24 volt low-voltage circuit (2-wire is required for furnace only; 5-wire for heating and optional cooling systems). Refer to Table 6 for thermostat wire information.

Connecting Thermostat Wires

1. Insert 24 volt wires through the plastic grommet just above the control panel.

2. Connect the thermostat wires to the fur nace low voltage pigtails (see Figure 25).

3. Connect low-voltage circuit to the wall thermostat.

4. A hole may be made in the furnace cabinet to ease thermostat wiring. Make sure that the wiring is protected from the sharp edge of the added hole.

Verifying Anticipator Setting

After the furnace is installed, check the thermostat anticipator against the nominal setting of 0.4.

1. Connect the milliamp meter in series with one of the gas valve’s low voltage terminals.

2. Energize the gas valve.

3. Read the value of the milliamps.

4. Adjust the heat anticipator of the thermostat to the value on the milliamp meter. If the heat anticipator is set too high, the furnace may delay turning on. If set too low, the furnace may cycle frequently and not provide comfort to the homeowner.

Grounding

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!

Thermostat

Figure 25. Thermostat Wiring For

Thermostat

Wire Gauge

24 55 25

22 90 45

20 140 70

18 225 110

Red

White

Green

Yellow

A/C Ready Models

Recommended T’STAT Wire

Length (Unit to T’STAT)

2-Wire

(Heating)

M1/M5 A/C

Ready Furnace

Red

White

Green

Grey

5-Wire

(Heating/Cooling)

Table 6. Thermostat Wire Gauge

Page 16

FUEL SUPPLY & PIPING

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 qualiﬁ ed installer, service agency or the gas supplier.

• Do not store or use gasoline or other ﬂ ammable 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 ﬁ re 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 qualiﬁ é, 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 inﬂ ammables 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.

WARNING:

All piping must conform with local building codes, or in the absence of local codes, with the most recent edition of the National Fuel Gas Code ANSI Z223.1 or (CAN/CGA B149.1 or .2). Failure to follow all safety warnings could result in serious injury, death or property damage.

This furnace may be installed with left, right, or 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 service hookup for this furnace is shown in Figure 26 (page 17). Table 14 (page 37) lists gas ﬂ ow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line.

IMPORTANT NOTES:

• Some local regulations require the installation of a manual main shut-off valve and ground joint union external to the furnace (Figure 27, page 18). The shutoff 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 -liqueﬁ ed petroleum gases.

• 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 furnace but may be used if allowed by local jurisdiction. Only new ﬂ exible connectors may be used. DO NOT reuse old ﬂ exible gas connectors.

• A drip leg is recommended for a vertical run to the unit.

• All piping shall be black iron pipe, or equivalently sized steel tubing. Internally tinned copper tubing may be used for gas supply systems.

• Fuel line installations other than typical installations shown in Figures 26 (page 17) & 27 (page 18) must comply with the fuel piping 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).

• Shut-off valve must be designed and listed for use with liquid petroleum (L.P. gas).

• A 1/8” NPT plugged tappings for test gauge connection are present on the gas valve. See Figure 28 for locations

Page 17

NOTE: Optional fuel inlet lines are available for all gas furnace models to permit the addition of a 1/2” F.P.T. shut-off valve above the ﬂ oor.

The gas supply to your home will either be Natural Gas or L.P. (bottle gas). Your furnace is factory equipped to operate on Natural Gas. If your gas supply is L.P. (bottle gas), you must contact a qualiﬁ ed serviceman or gas supplier to convert the furnace. Instructions for gas conversion are listed on page 19. Factory installed oriﬁ ce sizes are listed in Table 10 (page 30).

For natural gas operation, the furnace is designed for 7” W.C. inlet pressure. Pressure is reduced to 3 1/2” W.C. by the pressure regulator in the gas valve. The maximum inlet pressure for the valve is 7” W.C and the minimum inlet pressure is 4.5” W.C.

For L.P. gas, pressure to the gas valve must be more than 11” W.C. but not more than 13” W.C. Pressure is reduced to 10” W.C. by the pressure regulator in the gas valve.

Leak Check

WARNING:

FIRE OR EXPLOSION HAZARD

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

Never test for gas leaks with an open ﬂ ame. Use a commercially available soap solution made speciﬁ cally for the detection of leaks to check all connections. A ﬁ re 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 ﬂ amme nue por vériﬁ er la présence des fuites de gaz. Pour la vériﬁ cation de tous les joints, utiliser plutôt une solution savonneuse commerciale fabriquée spéciﬁ quement pur la détection des fuites de gaz. Un incendie ou une explosion peut entraîner des dommages matériels, des blessures ou la mort.

On-Off-Fan

Switch

Control

Panel

To Gas

Supply

Floor

Floor Cavity

Figure 26. Typical Gas Piping

Alt. Fuel

Line Entry

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 ﬂ exible 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.

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.

Oil Tank & Piping Installation

The following procedures are recommended as good practice. However, requirements of local codes and ordinances, H.U.D. Manufactured Home and Safety Standards or National Fire Protection Association must be satisﬁ ed, where they apply, for an approved installation.

• Use a tank capacity suitable for the application with a weatherproof, capped ﬁ ll opening and a shielded vent to let in air as fuel is used.

Page 18

Vent with cap

Gauge

End of Oil Supply Line 3" to 5" Above Bottom Drain

3/8" Oil Supply Line

Guide

Pipe

NOTE: Additional venting may be required if tank is filled rapidly.

Cordset

Pressure Adjustment

Becket

INLET

USE ONLY WITH VALVE ON DELAY

A2EA-6520

4 GPH 100-150 PSI 3450 RPM

NO. 2 & LIGHTER FUEL

3 GPH 150-200 PSI 3450 RPM

NO. 2 FUEL

INLET

BY-PASS

Made by Suntec

Exclusively for Beckett

If fuel pump fails to lift oil, check for air leaks and tighten all fuel fittings. Reprime fuel pump by injecting fuel oil into optional (top) return port. Replace return port plug and repeat priming procedure.

Inlet Port

1/4 NPTF

Bleed & Gauge Port

Return Port - Install 1/6” Bypass Pipe

Plug for 2-pipe System Only.

(Use 5/32” Allen Wrench)

2" Duplex Bushing

2" Fill

Drain

Top of Tank

Shut-off

Valve

Optional Fuel Filter

8 ft.

Alternate Fuel Line

Entry

Furnace

Control Panel

Oil

Bypass Solenoid Valve

Nozzle Port

3/16 Flare Fitting

Flue Gas Sampling

Hole

On-Off-Fan

Switch

Oil-Gun Burner

Floor

Floor Cavity

Inlet Port

1/4 NPTF

Figure 27. Typical Oil Piping for Above Ground (Single-Line) Supply

Screw

• The inside of the tank must be clean before ﬁ lling. All water, rust, sediment, and debris must be ﬂ ushed out.

• A fuel or tank gauge (Figure 27) is recommended for easy checking of the fuel level. Check the gauge reading with a dipstick.

• Locate the storage tank conveniently near the home. If the fuel tank is installed above ground, the tank may rest 3 to 4 inches off the ground. Fuel tanks may also be buried if properly coated to resist corrosion. The vertical dimension from the bottom of the fuel tank to the fuel pump must not exceed 10 feet.

• Keep the tank ﬁ lled, especially in the summer to reduce the accumulation of condensation.

One-Line System

The One-Line System is highly recommended where vertical lift, from bottom of tank to pump, is less than 8 feet (Figure 27). A single line hookup has the advantage of lower cost and quieter operation.

Two-Line System

If a Two-Line system is used or if oil is taken from the bottom of the tank, a ﬁ lter is recommended. A Two-Line system should only be used if vertical lift exceeds 8 feet.

1. Install the oil feed line as outlined in steps 1 - 6 below.

2. Install the oil pump bypass plug in the bottom return port.

3. Route the return line up through the furnace base to the return port of the pump. Route the other end of the line to the tank, using 3/8” O.D. copper tubing or 1/4” pipe with the ends capped.

4. Insert the return line through the second opening in the duplex bushing. If the bottom of the tank is lower than the pump intake, the tube should be inserted three or four inches from the tank bottom. If the bottom of the tank is higher than the pump intake, the return line should extend not more than 8” inside the tank.

Fuel line Hook-Up

1. Use a 3/8” O.D. copper tubing for the fuel line.

NOTE: Cap the end with tape to keep out dirt while the line is being routed.

2. Install duplex bushing for two 3/8” lines in the top ﬁ tting of the tank. See Figure 27.

3. Inser t one end of the tubing through the duplex bushing until it is three to ﬁ ve inches from the bottom drain. Tighten the bushing.

4. Route the line where it will not incur any damage. Make bends gradual and avoid kinks which might restrict oil ﬂ o w .

5. Open the furnace door and connect the oil line to the intake port on the pump. Tighten other port plugs on the pump. NOTE: Verify the oil line is airtight! Air leaks can cause the pump to lose prime and will create other problems such as nozzle failure, odors, rumbling noise, and false safety shutdown.

6. Insert the short length of the copper tube level with the bottom of the duplex bushing. Form the tube into an inverted “U” to serve as a vent.

Fuel Line Bleeding

To eliminate problems caused by air in the oil line, all connections in the oil supply line and all plugs, nuts, and ﬁ ttings on the pump must be airtight. NOTE: This includes the nut that covers the pressure adjustment. It is important that the hook-up be done carefully and with a good ﬂ aring tool.

Prepare the burner for priming by attaching a clear plastic hose over the bleed port ﬁ tting and fully opening the pump bleed port. Use a suitable container to collect purged oil.

To ensure continuous operation, use a wire to jump terminals T-T (or F-F) on the primary control while burner is running.

Page 19

Priming furnaces equipped with Honeywell R7184 primary control:

1. While the ignition is on, press for 1/2 second (or less), and release the reset button. The lockout time will be extended to 4 minutes.

2. If prime is not established within the 4 minutes, the control will lock out. Press the reset button to reset the control.

3. Repeat steps 1 & 2 (if needed) until the oil pump is fully primed.

Priming furnaces equipped with Beckett 7505 primary control:

1. After the burner starts, press and hold the reset button until the yellow LED turns on (15 seconds). This indicates that the button has been held long enough.

2. Release the reset button. The yellow LED will turn off and the burner will start up again.

3. At burner star t up, click the reset button while the igniter is still on. This transitions the control to a dedicated pump prime mode, during which the motor, igniter and valve are powered for 4 minutes. The yellow LED will be on. NOTE: If prime is not established during the four minute pump prime mode, repeat step 3 until the oil pump is fully primed.

4. When oil ﬂ ow is clear and free of air bubbles, close air-bleed valve and tighten. NOTE: Air bleed out time will varies depending on length of oil line, number of bends, etc.

Fuel Oil Type

WARNING:

Do not use gasoline, crankcase oil, or any oil containing gasline. Failure to keep supply of oil clean by various procedures described above may cause failure of certain components such as the fuel pump gears, check valve, shaft seal, or burner nozzle which may result in a burner ﬁ re.

Do not use fuel oil heavier than Grade No. 2. In areas where the oil supply is subject to low temperatures, Grade No. 1 may be used.

Conversion to Propane (LP) Gas

can be converted for use with LP gas. Use the following procedure for gas conversion of the burner.

Atmospheric & Direct Ignition Furnaces

1. Follow the instructions “How to Shut Off Gas” (page

22).

2. Disconnect the gas pipe union and the electrical wires connected to the gas valve.

3. Remove the gas valve assembly: a. Remove screw(s) from gas valve bracket. Gas valve

and spud may be removed. Oriﬁ ce is located at the end of the spud (M1M Models)

b. Remove three (3) bolts from U-shaped manifold plate

and oriﬁ ce assembly (M1B Models).

5. Replace the main or iﬁ ce with the L.P. gas oriﬁ ce supplied in the envelope located by the gas valve. Verify the oriﬁ ce size matches the nameplate or Table 10 (page

31).

6. For Honeywell gas valves with the regulator converter: a. Unscrew the pressure regulator cap and check for

the letters NAT or LP. See Figure 28, page 20.

b. Invert the cap and tighten until snug.

7. For Robertshaw gas valves with the regulator converter: a. Remove the black cover and unscrew the converter

located on top of the gas valve. See Figure 29.

b. Invert the converter. For LP, the red ring will be located

at the bottom and the LP stamping on the converter will appear right side up.

c. Screw converter back into the regulator, hand tight

plus 1/8 turn. Replace the black cover on the converter top to protect the threads.

8. Reassemble the burner assembly into the furnace.

9. Reconnect the gas piping and electrical wires to the gas valve.

10. Open the manual shut-off valve and follow the Lighting

and Operating instructions on page 22.

High Altitude Conversion

High altitude conversion with this furnace depends on the installation altitude and the heating value of the gas. The installation of this furnace at altitudes above 2,000 feet must meet the requirements of the National Fuel Gas Code or local jurisdiction. In Canada, the requirements for high altitude are different and governed by CGA B149.1. Please consult your local code authority.

CAUTION:

Furnace conversion must be performed by a qualiﬁ ed technician. Improper conversion can cause unsafe operation, explosion, ﬁ re and/or asphyxiation.

This gas ﬁ red heating appliance was shipped from the factory for use with natural gas. However, the appliance

WARNING:

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

Page 20

REGULATOR

INLET PRESSURE

TAP (1/8 NPT)

LP Gas

Configuration

Black Cover

Natural Gas

Configuration

PRESSURE

CAP

OTHER SIDE

M11678

OF CAP

OUTLET PRESSURE

Figure 28. Honeywell Gas Valve

Red

TAP (1/8 NPT)

This furnace is shipped from the factory with oriﬁ ces 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 and etc. This deration is in reference to the input rate and gas heating value at sea level. See Table 11 (page 31).

Flue Gas Sampling

It may be necessary to take ﬂ ue gas sampling from oil and gas furnaces (M5S and M1B Series Models) in order to check the performance after furnace installation. A ﬂ ue gas sample may be taken from the heat exchanger, which is located behind the hole of the top-front of blower compartment.

1. Turn off all electric power to the appliance.

2. Remove the black plastic cap located above the blower. Do not discard cap.

3. Drill a hole through the top of the blower compartment. NOTE: Hole diameter should be same size as sampling tube.

4. Insert sampling tube through the drilled hole and into the heat exchanger.

5. After a complete check and adjustment of furnace performance, seal the drilled hole with a screw larger than the hole. NOTE: Seal the screw threads with silicon sealant - rated at least 500° F.

6. Plug the outside hole with the plastic cap removed in step 3.

Figure 29. Robertshaw Gas Valve

Page 21

STARTUP & ADJUSTMENTS

PLEASE READ ALL SAFETY INFORMATION BEFORE LIGHTING THE FURNACE

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 qualiﬁ ed installer, service agency or the gas supplier.

• Do not store or use gasoline or other ﬂ ammable 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 ﬁ re department.

WARNING:

Before placing the furnace in service, it must be checked to ensure it is equipped for the type of gas being used. The burner ﬂ ame must be observed and adjusted if necessary. Failure to observe this caution may result in unsafe operation, explosion and/or ﬁ re, or asphyxiation. See the Gas Supply and Combustion Air sections.

• The ﬁ rst lighting of the furnace after any home setup must be performed by a qualiﬁ ed service technician.

• BEFORE LIGHTING: Smell all around the furnace for gas and next to the ﬂ oor. Some gas is heavier than air and may settle on the ﬂ oor.

• Use only your hand to push in the gas control lever. Never use tools. If the lever will not push in by hand, don’t try to repair it. Force or attempted repair may result in a ﬁ re or explosion. Call a qualiﬁ ed service technician.

• Do not use this furnace if any part has been under water. Immediately call a service technician to inspect the furnace and to replace any part of the gas valve or control system which has been under water.

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 qualiﬁ é, 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 inﬂ ammables 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.

WARNING:

Close the hinged ﬁ re door. If door is left open or spring is broken it may allow products of combustion into the living space by the furnace blower, resulting in possible asphyxiation.

WARNING:

Should overheating occur, or the gas supply fails to shut off, shut off the manual gas valve to the furnace before shutting off the electrical supply.

AVERTISSEMENT:

En case de température excessive, ou sail est impossible de cooper l’alimentation en gaz, fermer le robinet manuel d’alimentation en gaz du générateur d’sir chaud avant de cooper l’alimentation électrique.

Page 22

Operating Instructions for Direct Ignition

GAS CONTROL KNOB

Furnaces (M1M Models)

Direct ignition furnaces do not have a pilot. Ignition is accomplished by a silicon carbide hot surface ignitor. A control module takes care of all timing functions. After lighting, the control module uses the ignitor as a ﬂ ame sensor, shutting off gas should the ﬂ ame go out. There are no external relays or timing devices. Do not try to

light this furnace by hand. The control module is not ﬁ eld serviceable.

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance.

3. Remove the furnace door and turn off the gas valve:

• Honeywell: push in and turn the gas control knob

clockwise to OFF (Figure 30)

• Robertshaw: push the gas control lever to the OFF position (Figure 31). Do not force!

4. Wait ten (10) minutes to clear out any gas. If you smell

gas, STOP! and follow the Safety Information on page

19. If you do not smell gas, proceed to next step 5.

5. Set the thermostat MODE the ON position.

6. Turn the gas valve ON:

• Honeywell: push in and turn gas control knob counterclockwise to ON (Figure 30).

• Robertshaw: push the gas control lever to the ON position (Figure 31). Do not force!

7. Replace the furnace door.

8. Turn on all electric power to the appliance.

9. Change the thermostat mode to HEAT and the

temperature selector to a desired temperature level. The igniter should light in approximately 75 seconds. If the appliance will not operate, see “How To Shut Off Gas - Direct Ignition” and call your service technician or gas supplier.

NOTE: In the event of any ﬂ ashback or explosion, immediately shut off the furnace and call your service technician.

How to Shut Off Gas - Direct Ignition

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance before servicing unit.

3. Set the furnace On-Off Switch to OFF.

• Honeywell (Figure 30): Turn gas control knob clockwise

to OFF, Robertshaw (Figure 31): Push the gas control lever to OFF.

• For oil, shut off all valves.

4. Replace the furnace door.

Operating Instructions for Oil Gun Furnaces (M5S Models)

If your furnace model number begins with M5S*, the furnace is equipped with an ignition device which automatically lights the burner. Do not try to light this

furnace manually.

1. Open all valves in the oil line.

2. Verify the ﬁ re door is closed.

3. Set the furnace On-Off switch to ON.

4. Set the thermostat to the desired setting. NOTE: M5 oil gun furnaces may be converted to gas gun

in the ﬁ eld by using the proper conversion kit listed in the Replacement Parts List.

Operating Instructions for Gas Gun Furnaces (M1B Models)

If your furnace model number begins with M1B, the furnace does not have a pilot. Ignition is accomplished by a silicon carbide hot surface ignitor. A control module takes care of all lighting and timing functions. There are no external relays or timing devices. Do not try to light this furnace

by hand. The control module is not ﬁ eld serviceable.

1. Before operation, smell for gas all around the furnace, especially near the ﬂ oor because some gases are heavier than air and will settle on the ﬂ oor. If you detect gas, STOP and follow all the safety instructions.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

4. Turn off the gas valve:

• Honeywell: push in the gas control knob and turn

clockwise to OFF (Figure 30).

• Robertshaw: push the gas control lever to OFF (Figure

31).The lever cannot be placed in the off position unless it is pushed in slightly. DO NOT FORCE!

Figure 30. Direct Ignition Gas Valve - Honeywell

Gas Control Lever

Figure 31. Direct Ignition Gas Valve - Robertshaw

Page 23

5. Wait ten minutes to clear out any gas. If you smell gas, STOP! and follow the safety information. If gas is not detected, proceed to the next step.

6. Set the furnace On-Off switch to the ON position.

• Honeywell: turn knob on gas control counter clockwise

to ON.

• Robertshaw: push the gas control lever to ON.

7. Turn electric power to the appliance ON.

8. Set the thermostat to HEAT and/or the desired temperature setting. The furnace should light in approximately 45 seconds. If the appliance will not operate, follow the instructions “How to Shut Off Gas Direct Ignition Furnace” (page 22) and call your service technician or gas supplier.

In the event of any ﬂ ashback or explosion, immediately shut off the furnace and call your service technician.

How to Shut Off Gas - Oil & Gas Gun

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance at the breaker or fuse box.

3. Set the thermostat MODE switch to OFF.

4. Turn the gas valve OFF:

• Honeywell: push in and turn the gas control knob

clockwise to the OFF position (Figure 30).

• Robertshaw: push the gas control lever to the OFF

position (Figure 31).

5. Replace the furnace door.

NOTE: M1B gas gun furnaces may be converted to oil gun in the ﬁ eld by using the proper conversion kit listed in the Replacement Parts List available online.

Verifying & Adjusting Temperature Rise

Conﬁ rm the temperature rise through the furnace is within the limits speciﬁ ed on the furnace rating plate. Any temperature rise outside the speciﬁ ed limits could result in premature failure of the heat exchanger.

1. Place thermometers in the return and supply air stream as close to the furnace as possible. To avoid false readings, the thermometer on the supply air side must be shielded from direct radiation from the heat exchanger.

2. Adjust all registers and duct dampers to the desired position and run the furnace for 10 to 15 minutes in high ﬁ re 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 limits speciﬁ ed on the rating plate with the blower speed at the factory recommended setting. If the measured temperature rise is outside the speciﬁ ed limits, it may be necessary to change the speed of the blower. NOTE: Lowering the blower speed increases the temperature rise and a higher blower speed will decrease the temperature rise.

The furnace is equipped with a multi-speed motor. Refer to the furnace wiring diagram (Figures 38 & 39, pages 33 & 34) for blower speed selection.

Burner Adjustments

Burner settings are made at the factory. However, these settings may change during shipping, handling, and installation. The following items should be checked and readjusted if necessary.

Gas Pressure

The gas pressure can be checked with a manometer at the pressure tap (Figure 28, page 20) located on the top of the gas valve. The gas valve pressure regulator can be adjusted by removing the regulator selector stack and turning the slotted insert located directly under the selector stack. The regulator selector stack must be secured in place before each pressure reading is taken. Natural gas manifold pressure should be 3.5” W.C. and L.P. gas manifold pressure should be 10” W.C. Replace the gas pressure tap plug on the gas valve.

Combustion Air

CAUTION:

• Combustion air adjustment must be made only by a qualiﬁ ed technician. Improper air adjustment may cause unsafe operation, explosion and/or ﬁ re asphyxiation.

• If the input to the furnace is too great because of excessive gas pressure, wrong size nozzle or oriﬁ ce, high altitude, etc., the burner ﬂ ame will be sooty and can produce carbon monoxide, which could result in unsafe operation, explosion and/or ﬁ re or asphyxiation.

In order for the ﬂ ame to burn efﬁ ciently, it must receive adequate combustion air. The amount of combustion air required varies according to altitude, actual B.T.U. content of the fuel, gas pressure, conversion to another gas and other factors. The burner ﬂ ame should be observed and any necessary adjustments made before the furnace is placed into service. See Table 7 for Factory Air settings.

Model Nat. Gas LP Gas Oil

66,000 3.5 3.5 3.5

86,000 5.3 6 5

Table 7. Factory Combustion Air Settings

Page 24

Gas Gun (M1B Models)

Combustion air box adjustment is made to the main burner by loosening the two lock nuts on the plastic air shutter, located on the left side of the burner blower housing. Air shutter adjustment line is located on the same side of the blower housing. Turn the plastic shutter to a smaller number (counter clockwise) for less air to a larger number (clockwise) for more air. Gently tighten the lock nuts after completing the adjustment. For best results, use instrument to measure between 8 - 9% CO

, after the combustion air

has been adjusted. NOTE: Do not over-tighten the lock nuts. This may damage the plastic air shutter.

Oil Gun Only (M5S Models)

It is recommended that the CO2 and Smoke levels be measured for maximum performance. CO2 readings should be 10 - 11% for 66,000 BTUH furnaces and 12 - 13% for 86,000 BTUH furnaces. The Smoke should be N0. 0 on the Bacharach Scale, and 0 to 0.02 negative draft over ﬁ re.

Electrode Setting (Oil Gun Only)

Poor ignition of the oil spray may result if the electrodes are not adjusted as shown in Figure 32. Do not permit any electrodes to be grounded to any surface.

Switching Ignition Control between Interrupted and Intermittent Duty (Oil Gun Only)

Honeywell and Beckett oil primar y controls can be switched between interrupted and intermittent ignition control. To switch from interrupted duty (Factory set) to intermittent duty, remove the blue wire from the quick-connect terminal. Attach the burner motor and igniter wire to the burner motor (orange) control terminal by splicing or adding tab adapters. Seal and isolate any bare wires.

5/32” GAP

5/16” ABOVE CL

0-1/16”

1 1/8”

ELECTRODE

NOZZLE

OPERATING SEQUENCE

Direct Ignition Furnaces (M1M Models)

1. On a call for heat, the thermostat contacts close,

supplying 24 VAC between terminals C and W of the control module.

2. When the inducer starts, the air pressure switch closes at -0.20 W.C. differential pressure and energizes the gas valve.

3. After a 45 second purge, the ignitor is energized for a 30 second warm-up period. After warm up, the gas valve opens. NOTE: The time for ignition is approximately 6 seconds, after which the gas valve either remains open if ﬂ ame is sensed, or closes if ﬂ ame is not sensed.

5. If ﬂ ame is not sensed, the sequence repeats four more times before a lockout occurs. To reset, wait 30 seconds and then interrupt the 24 VAC power by turning the room thermostat below room temperature, then returning it to the original set point.

6. If ﬂ ame does not establish on the 5th attempt (initial ﬁ re + 4 re-tries), the control de-energizes the gas valve, the red LED ﬂ ashes 4 times, and the furnace locks out heat operation for 1 hour. See Table 9 (page 28).

7. If a ﬂ ame is present, the control energizes the main blower on heat speed 30 seconds after the gas valve opens.

8. When call for heat is satisﬁ ed the thermostat contacts open, the gas valve shuts off gas ﬂ ow and the combustion blower remains on for a 30 second postpurge period.

9. The main blower is de-energized after a 120 second blower off delay.

Oil Gun Furnaces (M5S Models)

With Honeywell R7184 / Beckett 7505 Control

1. When a call for heat is initiated, there is a 2 to 6 second delay while the control performs a safe start check.

2. The ignition and motor are turned on and a ﬂ ame should establish within a 15-second lockout time. NOTE: Burner will prepurge for 15 seconds if equipped with Honeywell R7184B or Beckett 7505B Control.

3. If ﬂ ame is not sensed within the 15-second lockout time, the control shuts down on safety lockout and must be manually reset by pushing the reset button on the control. If control locks over three times in a row, the control enters restricted lockout. To reset Honeywell R7184: Hold down the reset button for 45 seconds until the LED ﬂ ashes once. Beckett 7505: Hold down reset button for 15 seconds until the red LED turns off and the yellow LED turns on.

WARNING:

If furnace still doesn’t light, turn the furnace off as described above and call your technician. In the event of ﬂ ashback or explosion, immediately shut off furnace and call your service technician.

Figure 32. Oil Gun electrode Position

Page 25

4. After ﬂ ame is established, the ignition remains on for 10 seconds to ensure ﬂ ame stability. It then turns off.

5. The circulating air blower will energize after the temperature fan switch closes.

6. The furnace runs until the call for heat is satisﬁ ed.

7. The circulating air blower will de-energize when the temperature fan switch opens.

Gas Gun Furnaces (M1B Models)

1. On a call for heat, the furnace control begins an ignition sequence which lasts approximately 45 seconds.

2. After this sequence, the control module tests to see if ﬂ ame is sensed. If it has, the furnace continues to heat until the thermostat is satisﬁ ed.

3. If the burner has not lit, the ignition sequence is repeated a maximum of two more times. If ﬂ ame is not sensed after three attempts, the control enters Lockout and no further attempts to light the burner will occur. If Lockout occurs, contact a qualiﬁ ed service technician for assistance.

4. When call for heat is satisﬁ ed, the thermostat contacts open and the gas valve shuts off gas ﬂ ow.

WARNING:

Should overheating occur, or the gas supply fails to shut off, shut off the manual gas valve to the furnace before shutting off the electrical supply.

AVERTISSEMENT:

FURNACE CONTROLS & FUNCTIONS

Furnace On / Off Switch

This switch turns electrical power to the furnace on and off. The switch must be set in the ON position for the furnace to operate. If blower operation is not desired, the furnace On-Off switch may be set in the OFF position to cut the electrical power to the furnace. See Figure 33.

Gas Valve

The gas valves for the gas furnaces are a 100% shut-off type and will fail safe, if for some reason the gas is turned off. The valve is a “slow-open” for M1M and M1B models which means it opens to a low-ﬁ re position, and after a few seconds, “steps-open” to high-ﬁ re.

Oil Burner Primary Control

The primary control for oil gun furnaces starts the burner, monitors a safe operating cycle, and shuts the burner off at the end of a heating cycle. The control uses a light sensing transducer to determine if fuel ignition has been successfully attained. If ignition is not attained by the end of the safety ignition timing period, the control shuts the burner off and enters “lock-out.” See Figure 33.

Summer Cooling - (B, C, & D Series)

Your furnace is A/C ready, equipped with A/C relay and transformer. The unit is equipped to use a 4-wire thermostat. When using a 5-wire thermostat, RC and RH should be jumped (see instructions included with thermostat).

Upper

Limit

Switch

Furnace

On-Off

Switch

Oil

Pump

Lower

Limit

Switch

Fan

Control

Oil

Burner

Control

Limit Control

This furnace is protected by two high temperature safety limit switches. The auxiliary (upper) limit switch and the high temperature (lower) limit switch are automatic reset types. If either limit trips, the burner will shut off. If either limit switch trips off again soon after resetting, set the furnace furnace On-Off switch to the OFF position and call your authorized serviceman. See Figure 33.

Figure 33. Furnace Controls - Oil Furnace

Page 26

TROUBLESHOOTING

Direct Ignition Furnaces (M1M Models) & Gas Gun Furnaces (M1B Models)

High Gas Bills

a. Verify the proper oriﬁ ce is being used. b. Check the return air system. Is it clear and free of

blockage?

c. Check the furnace ﬁ lter. Is it clean or need replacing? d. Verify the home is insulated, windows and doors ﬁ t

tightly, and there are no leaks in the heating duct system.

e. Check the room thermostat. Is the setting higher than

necessary? Low humidity requires higher temperatures for the same level of comfort. Check for proper humidity level in the home.

Burner Motor won’t Run - T-stat Calls for Heat

1. Check the electrical supply to the furnace.

2. Verify the furnace furnace On-Off switch is in the ON position.

3. Defective thermostat circuit - white and red thermostat low voltage leads (M1/M5M, M1/M5B models). If the burner motor or combustion fan runs, check:

• Thermostat connections

• Thermostat

4. No voltage to control module - determine if 24 volts (or 120 volts) is available to the control module. If voltage is not available check for:

• Blown fuse, defective transformer, circuit breaker, no electrical supply.

• Limit switch open.

• Loose connections.

Combustion Blower Runs - No Flame

1. Defective centrifugal switch (M1B Model).

• Check the operation of centrifugal switch by removing end bell of the burner motor.

• Clean contacts of motor.

• If the contacts are closed, replace the motor.

2. Defective pressure switch (M1M - 077 & 090 Models)

- check air tube and electrical connections.

3. Burner in purge mode - allow 75 seconds for ﬂ ame establishing period.

4. Check for proper electrical connections at purge timer, control box, or gas valve.

5. Check for gas supply - gas line valve on, control lever on.

120 VAC Is Available At AMP Plug Ignitor Does Not Heat Up

1. Disconnect power to the furnace.

2. Disconnect AMP plug to the ignitor, and check ignitor resistance with an ohm meter. Set on RX1 scale.

• Normal reading should be 40 - 75 ohms.

• If above or below this rating at room temperature

change ignitor.

3. Check for continuity from ignitor receptacle to burner.

Control Module is Powered - Ignitor won’t Heat Up

1. Disconnect ignitor leads at AMP receptacle and check for 120 volts at the plug during ignition sequence.

2. Replace ignition control if 120 volts is not available at AMP plug during ignition sequence.

Main Flame Ignites - Burner Locks Out

• Ignition control is not properly grounded.

• Defective ignition control.

• Improper polarity of 120 volt power supply.

• Ignitor has hairline crack.

• Improper gas pressure or burner air adjustment is not allowing ﬂ ame to contact ignitor tip for ﬂ ame rectiﬁ cation.

• Misaligned ignitor does not allow ﬂ ame to contact ignitor tip for ﬂ ame rectiﬁ cation.

Burner Short Cycling - Thermostat Calls for Heat, Limit Switches Closed

• Check for polarity.

• Check ground.

• Check ﬂ ue.

• Check combustion air.

• Check gas pressure.

• Check oriﬁ ce.

• Check the position of ignitor, a normal reading should be 40-75 ohms.

24 Volts Supplied To Gas Valve During Ignition

- No Main Gas Flow

• Gas valve may be defective. Replace if necessary.

• Gas piping may be plugged. Check for adequate gas supply to gas valve at union.

Burner Operates - Insufﬁ cient Heat

• Check thermostat for proper setting and location. Thermostat should not be located where it will be affected by another heat source.

• Check for clean ﬁ lter and proper air ﬂ ow.

• Check burner for proper gas ﬁ ring rate.

• Be sure unit is not undersized for its thermal load.

• Check thermostat anticipator. The nominal setting is

0.4.

Burner Flame Without Motor Running

• Gas valve stuck open, check gas valve for proper operation (replace if necessary) and inspect heat exchanger.

• Check for 115 volts to the combustion blower motor; replace if necessary.

• If no power to combustion blower then check wiring and control module; replace if necessary.

Circulation Air Blower Will Not Operate Even Though The Burner Does Operate

• Check thermostat G connection.

• Check wiring to motor.

• Check for a defective motor.

Page 27

Oil Gun - Honeywell R7184 or Beckett 7505 Controls Only - M5S Series.

Burner does not start with a call for heat

• Check the electrical supply to furnace.

• Verify the furnace door switch is in the ON position.

• Check for line voltage (115 VAC) at the oil primary control.

• Check indicator LED with burner off, no call for heat (no ﬂ ame). See Table 9 (page 28).

- If green LED indicator is on, the cad cell is seeing stray light or the cad cell of controller is defective.

- If green LED indicator is off, go immediately to step

- If LED indicator is ﬂ ashing (red or green on Beckett 7505 control), refer to the next step 1 below - Reset primary control.

• Jumper T to T terminals on primary control.

- If burner starts, check thermostat or limit wiring connections.

- If burner does not start, turn off power. Check all wiring connections.

- If burner does not start, replace primary control.

Burner starts & then locks out on safety with Honeywell R7184 LED indicator ﬂ ashing ½ second on, ½ second off. For Beckett 7505 control, the red LED will ﬂ ash

1. Reset primary control: To reset the control from (soft) lockout, the button needs only to be pressed and released. If the R7184 control is in restricted mode, press and hold the button for 45 seconds - until the LED ﬂ ashes once. If the 7505 control is in restricted mode, press and hold the button in for 15 seconds until the red turns off and the yellow LED turns on.

7. If the burner stays running, the system is operational.

8. If the (LED indicator for R7184 control; green LED for 7505 control) is off, check the cad cell assembly after disconnecting the line voltage.

Burner will not start and the LED indicator is ﬂ ashing at 2 seconds on, 2 seconds off for R7184 (or green LED is ﬂ ashing for 7505)

• Hold the reset button down for 1 - 2 seconds. If LED indicator continues to ﬂ ash, wait for 60 - 70 seconds. If it still continues to ﬂ ash, replace the primary control.

• Honeywell R7184 control: To check cad cell resistance, press and release the button during the run mode, with the igniter off. The LED will ﬂ ash to indicate the cad cell resistance. For proper burner operation, it is important that the cad cell resistance is under 1600 Ohms. For cad cell resistance, see Table 8.

• Beckett 7505 control: To check cad cell resistance, unplug the cad cell leads (yellow wires) from the control. Measure the resistance with a meter in the conventional way (when a ﬂ ame is present). For proper burner operation, it is important that the cad cell resistance is under 1,600 Ohms.

LED Flashes (Ohms) Cad Cell Resistance

1 0-400

2 400-800

3 800-1600

4 >1600

Table 8. Cad Cell Resistance when

sensing ﬂ ame

NOTE: Restricted Lockout: If the control locks out three

times in a row without a complete heat cycle between attempts, the lockout becomes a restricted (hard) lockout.

2. If the LED indicator stops ﬂ ashing and the ignition remains off, the primary control could be defective. If line voltage is present at the igniter terminals, and there is no ignition, the igniter is likely defective and needs to be replaced.

3. If the stops ﬂ ashing, burner turns on, but the control locks out again, check the cad cell. If the cad cell is operational, replace the primary control.

4. If the LED continues to ﬂ ash at the interval listed above, verify that the control is not in restricted mode. If in restricted mode, reset it. If not in restricted mode, replace the control.

5. If the (LED indicator for R7184 control; green LED for 7505 control) stays off while the ﬂ ame is on, check the cad cell sighting for view of the ﬂ ame.

6. If the burner locks out, check the cad cell resistance (See Table 8).

Page 28

CONTROL MODULE STATUS INDICATORS - M1M SERIES

Red LED Indicator Status

Steady ON Control OK

Steady OFF No power

Rapid ﬂ ash False ﬂ ame or internal control fault

One ﬂ ash Limit switch is open

Two ﬂ ashes Pressure switch is open

Three ﬂ ashes Pressure switch is stuck closed

Four ﬂ ashes Lockout due to failed ignition

Five ﬂ ashes

Flame Status - A Yellow LED labeled “Flame” is provided to indicate ﬂ ame status. When ﬂ ame is sensed, the ﬂ ame LED is lit. If ﬂ ame sense is weak, yellow LED will ﬂ ash.

CONTROL MODULE STATUS INDICATOR - M1B

Red LED Indicator Status

One ﬂ ash

Two ﬂ ashes

Three ﬂ ashes

Four ﬂ ashes

L1 neutral reversed or L1 voltage not present on L1

The control is in lock-out because the inducer centrifugal switch is or was stuck closed.

The control is in lockout because the signal was not received by the control that the inducer centrifugal switch had closed within the time.

The control is in lockout because a failed ignition attempt, a gas valve error, or a false ﬂ ame sensed during the warm up period. If false ﬂ ame has been sensed, the control will return to normal operation, and repeat ignition sequence when the false ﬂ ame is not present.

The control is in lockout due to a failure within the control board

OPTIONAL ACCESSORIES

Necessary when the Furnace is Used with Some Central Air Conditioners

If an air conditioner is installed that does not use the furnace blower for air distribution and operates independently of the furnace, the thermostat system must have an interlock to prevent the furnace and air conditioner from operating at the same time. This interlock system usually contains either a “Heat-Cool” switch which must be turned to one of the positions to activate heat or cool operation, or a positive “OFF” switch on the cooling thermostat.

The furnace must also be equipped with an automatic damper to prevent cold air from being discharged up around the heat exchanger (NORDYNE p/n 901996 for furnaces without coil cavity, or p/n 901083 with coil cavity). See Figure 34 or 35. Cold air may cause condensation inside the heat exchanger which can rust and lead to early failure.

Control Module Status Indicator -

M5S Series Honeywell R7184 Control

Green LED

Indicator

Off Cad cell is not sensing ﬂ ame

Flashing - 1/2 sec. on, 1/2 sec. off

Flashing - 2 sec. on, 2 sec. off

LED Indicator

Color

Red

Green

Yellow

Cad cell is sensing ﬂ ame (could be ﬂ ame or stray light)

Lockout / Restricted Lockout

Recycle

Beckett 7505 Control

On Continuously Flashing

Restricted (hard) lockout

Cad cell is sensing ﬂ ame - (could be ﬂ ame or stray light)

Pump prime mode or reset button currently held for 15+ sec.

Status

Soft lockout

Recycle

N/A

Table 9. Control Module Status Indicators

Figure 34. Coil Cavity Damper

Figure 35. Damper without Coil Cavity

Page 29

Optional Add-On Air Conditioning

Check for Ice Here

Whether split system or single package, an energysaving NORDYNE Air Conditioner is available that has been designed speciﬁ cally for manufactured housing applications and can best handle your home comfort needs. Ask your dealer or contractor about NORDYNE add-on central air conditioning systems.

Single package unit includes cooling coils, compressor, and vertical discharge fan. This type of unit connects with the existing home air duct system (an optional close-off damper is required with the furnace).

Split system unit with vertical discharge for quiet operation connects with NORDYNE cooling coil furnace (optional coil cavity required with “A” model furnaces).

MAINTENANCE

Homeowner Information

• On some closet installations, the return air opening to the furnace may be on the ﬂ oor, in the door, in the side wall of the closet, or any combination of these. The upper grille on the front of the furnace admits return air to the blower. Return air must be provided back to the circulating blower in order to provide air distribution. See Figure 36.

• Filters - At least twice each season (more often in dusty areas) remove and clean the air ﬁ lters with a vacuum or with warm water and soap. Reinstall when dry. Also clean dust and lint around furnace and in the furnace vestibule.

• During extremely cold weather, ice may form on the furnace roof jack (Figure 37). Small amounts of ice forming on the roof jack will present no problems to proper furnace operation. Excessive ice formation could restrict the combustion air supply to the burner, causing inefﬁ cient burner operation. If excessive ice has formed on the air inlet or exhaust portions of the roof jack, it must be carefully removed.

WARNING:

Use of furnace or air conditioning components that are not included in the certiﬁ cation of this appliance may create a hazard, invalidate the certiﬁ cation, and in many states, make installations illegal. Listed NORDYNE air conditioning components are speciﬁ ed on the furnace label.

Additional Oil Furnace Maintenance

In addition to the preceding, the following should be performed by a qualiﬁ ed service contractor at least once each season for oil-ﬁ red furnaces:

• Replace the oil nozzle with the type nozzle speciﬁ ed for your furnace.

• Clean, adjust and replace if necessary the spark electrodes.

• Reset the nozzle/drawer assembly to factory speciﬁ cations.

• Clean the inside of the furnace heat exchanger and replace the combustion liner if necessary.

• Clean or replace the oil ﬁ lter element at the oil tank.

• Adjust the burner for top efﬁ ciency and check to make sure all ﬁ ttings are leak-tight.

Installer Information

All furnaces need periodic service at the beginning of each heating season. Call your qualiﬁ ed service contractor for these items:

• Remove the air circulator and clean all dust and lint from the unit with a stiff bristle brush.

• Inspect the combustion chamber blower compartment, ﬂ ue collar and Roof Jack.

• Check the gas valve (if applicable) and fuel line connections for leaks.

• Make any adjustments necessary for good operation.

Figure 36. Periodic Cleaning

Figure 37. Roof Jack

Page 30

FIGURES & TABLES

Furnace

Model No

M1MB 056 56 46 29 45 0.3 x x 1/4 3

M1MC 056 56 46 29 45 0.3 x x 1/2 4

M1MB 070 70 57 24 42 0.3 x x 1/4 3

M1MC 070 70 57 24 42 0.3 x x 1/2 4

M1MB 077 77 62 21 40 0.3 x x 1/4 3

M1MC 077 77 62 21 40 0.3 x x 1/2 4

M1MB 090 90 72 17 36 0.3 x x 1/4 3

M1MC 090 90 72 17 36 0.3 x x 1/2 4

M1BB 066 66 53 26 43 0.3 x x 1/4 3

M1BC 066 66 53 26 43 0.3 x x 1/2 4

M1BB 086 86 68 18 37 0.3 x x 1/4 3

M1BC 086 86 68 18 37 0.3 x x 1/2 4

M5SB 066 66 56 0.3 .50 Gph x

M5SC 066 66 56 0.3 .50 Gph x 1/2 4

M5SB 086 86 73 0.3 .65 Gph x

M5SC 086 86 73 0.3 .65 Gph x 1/2 4

NOTES:

Input

MBtu/h

• Electrical Supply - 120 volts, 60HZ, 1 Ph. Fuse or Breaker - 15 amps

• Temperature Rise - 45° F to 75° F

• High Altitude - See Table 11 (page 32). For Canadian Altitudes

(2,000’ to 4,500’), reduce the gas manifold pressure to 3.0” W.C.

for natural gas and to 8” W.C. for LP gas.

Output MBtu/h

Oriﬁ ce No

Nat. LP

E.S.P. In WC

Oil

Nozzle

Ignitor

Direct

• Thermostat Circuit - 24 volts, 60HZ, 30 vac

• Normal Anticipator Setting - 0.4

• Manifold Pressure - Natural Gas: 3.5” w.c.

LP Gas: 10” w.c.

Comb.

Blower

Burner Model:

AF-10

Spray Angle:

80° A

MotorHpA/C Ready

1/4 3

Tons

Table 10. M1/M5 Furnace Speciﬁ cations - Factory Settings

Page 31

FURNACE

MODELS

M1M - 056

M1M - 070

M1M - 077

M1M - 090

M1B - 066

M1B - 086

ORIFICE SIZE &

OUTPUT CAPACITY

Oriﬁ ce Size - Nat. Gas 29 29 30 30 30 30 31 31 31 32

Oriﬁ ce Size - LP 45 46 47 47 47 48 48 49 49 50

Output - MBTUH 45.4 41.8 40.1 38.5 37.0 35.5 34.1 32.7 31.4 30.2

Oriﬁ ce Size - Nat. Gas 24 25 26 27 27 28 28 29 29 30

Oriﬁ ce Size - LP 42 42 43 43 43 44 44 45 46 47

Output - MBTUH 56.7 52.3 50.2 48.2 46.2 44.4 42.6 40.9 39.3 37.7

Oriﬁ ce Size - Nat. Gas 21 23 23 24 25 26 27 28 28 29

Oriﬁ ce Size - LP 40 41 42 42 42 43 43 44 44 45

Output - MBTUH 61.7 56.9 54.6 52.4 50.3 48.3 46.4 44.5 42.7 41.0

Oriﬁ ce Size - Nat. Gas 17 18 19 19 20 21 22 23 24 26

Oriﬁ ce Size - LP 36 37 38 38 39 40 41 41 42 43

Output - MBTUH 71.7 66.1 63.5 60.9 58.5 56.1 53.9 51.7 49.7 47.7

Oriﬁ ce Size - Nat. Gas 26 27 28 28 28 29 29 30 30 30

Oriﬁ ce Size - LP 43 44 44 44 45 45 46 47 47 48

Output - MBTUH 52.6 48.5 46.6 44.7 42.9 41.2 39.6 38.0 36.5 35.0

Oriﬁ ce Size - Nat. Gas 18 19 19 20 21 22 23 24 26 27

Oriﬁ ce Size - LP 37 38 39 39 40 41 42 42 43 43

Output - MBTUH 68.2 62.9 60.3 57.9 55.6 53.4 51.2 49.2 47.2 45.3

SEA

LEVEL

2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000

ALTITUDE - FEET

NOTES: For Canadian high altitude (2,000 - 4,500’), reduce gas manifold pressure to 3.0” W.C. for natural gas and 9” W.C. for LP gas.

(Includes 4% Input Reduction for Each 1,000 Feet). These specs do not apply to oil furnace installations. Reference Sources: ANSI Z233.1 &

NFPA 54, National Fuel Gas Code.

Table 11. Equivalent Oriﬁ ce Sizes for High Altitude Installations

M1/M5*B Models & for use with Blower Kit No. 903773 1/4 Hp 3 Speed

Furance Input

086, 090 H L M H

066, 070, 077 M L M H

56 L L M H

Heating Speed

Setting

2 Ton 2-1/2 Ton 3 Ton

Cooling Speed/ Evap Coil

M1/M5*C Models & for use with Blower Kit No. 903413 1/2 Hp 4 Speed

Furance Input

077, 086, 090 ML L ML MH H

056, 066, 070 L L ML MH H

Heating

Speed

Setting

2 Ton 2-1/2 Ton & 3 Ton 3-1/2 Ton 4 Ton

Cooling Speed/ Evap Coil

M1/M5*D Models & for use with Blower Kit No. 903890 3/4 Hp 4 Speed

Furance Input

077, 086, 090 ML L ML MH H

056, 066, 070 L L ML MH H

Heating

Speed

Setting

2 Ton 2-1/2 Ton & 3 Ton 3-1/2 Ton & 4 Ton 5 Ton

Cooling Speed/ Evap Coil

Table 12. A/C Blower Speed Selection Chart

Page 32

GAS INFORMATION

TIME FOR

ONE REVOLUTION

(SECONDS)

10 360 1,800 3,600 12 300 1,500 3,000

14 257 1,286 2,571

16 225 1,125 2,250

18 200 1,000 2,000

20 180 900 1,800

22 164 818 1,636

24 150 750 1,500

26 138 692 1,385

28 129 643 1,286

30 120 600 1,200

32 113 563 1,125

34 106 529 1,059

36 100 500 1,000

38 95 474 947

40 90 450 900

42 86 429 857

44 82 409 818

46 78 391 783

48 75 375 750

50 72 360 720

52 69 346 692

54 67 333 667

56 64 321 643

58 62 310 621

60 60 300 600

62 58 290 581 64 56 281 563

GAS FLOW RATES

CUBIC FEET PER

REVOLUTION OF GAS METER 15 10

GAS FLOW RATES

TIME FOR

ONE REVOLUTION

(SECONDS)

66 55 273 545 68 53 265 529

70 51 257 514

72 50 250 500

74 49 243 486

76 47 237 474

78 46 231 462

80 45 225 450

82 44 220 439

84 43 214 429

86 42 209 419

88 41 205 409

90 40 200 400

92 39 196 391

94 38 191 383

96 38 188 375

98 37 184 367

100 36 180 360

102 35 176 353

104 35 173 346

106 34 170 340

108 33 167 333

110 33 164 327

112 32 161 321

114 32 158 316

116 31 155 310

118 31 153 305 120 30 150 300

CUBIC FEET PER

REVOLUTION OF GAS METER

15 10

Table 13. Gas Flow Rates (Cubic Feet per Hour)

GAS PIPE CAPACITIES

Nominal Pipe

Diameter (IN.)

1/2 130 90 75 65 55 50 45 40

3/4 280 190 150 130 115 105 95 90

1 520 350 285 245 215 195 180 170

1 1/4 1,050 730 590 500 440 400 370 350

1 1/2 1,600 1,100 890 760 670 610

10 20 30 40 50 60 70 80

Cubic Feet Per Hour Required =

Length of Pipe Run (Feet)

Input To Furnace (Btu/hr)

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

NOTE: The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas ﬂ ow required by the furnace. To determine the cubic feet per hour of gas ﬂ ow required by the furnace, divide the input rate of the furnace by the heating value (from gas supplier) of the gas.

Table 14. Capacity of Black Iron Gas Pipe (cu. ft. per hour)

for Natural Gas w/ Speciﬁ c Gravity = 0.60

Page 33

SUPPLIED

BY INSTALLER

ELECTRICAL INFORMATION

Control

Board "H"

Black Blu e Orange

Wire #2 Wire # 3 Wir e #4

MOTOR

4 SPEED

BLOWER

MOTOR

3 SPEED

BLOWER

654321

WHITE

ORANGE (MED. LO)

BLUE (MED. HI) BLACK (HIGH)

RED (LO)

654321

WHITE

RED (LO)

BLUE (MED. HI)

BLACK (HIGH)

Blowe r Wire Conne ctions

Wire #1

Furnace

Tie Tie Ti e

Red

Model

M1MA 056/

Tie Control Tie Control

M1MB

Wrapped Board "C" Wrapped Board "H"

056

Wrapped Wrapped Wrapped

070/077/090

AUX. LIMIT

HI-LIMIT

WHITE

GREEN

RED

GRAY

BLUE

Gas Direct Ignition Furnace,

Heating & A/C Ready, M1M All Models.

654321

SPEED

MOTOR

SINGLE

BLOWER

GREEN

BLACK

See Table

CONNECTOR

HOUSING CAP

TIE

WIRE

COMBUSTION FAN

BLACK

TRANS-

FORMER

GROUND

24V

COM

Tie Tie Control Control

M1MB

Wrapped Wrapped Board "H" Board "C"

070/077

24 V

SCREW

C W G R

123

456

789

115 V

L1 N

CONTROL

Tie Control Tie Tie

Wrapped Board "H" Wrapped Wrapped

M1MB

BLACK

LIGHTS

BLACK

ORANGE

See Table

Control Tie Tie Control

M1M(C,D)

PRESSURE

SWITCH

ORANGE

NEU

Board "H" Wrapped Wrapped Board "C"

056/070

RED

WHITE

BLACK

WHITE

Tie Tie Ti e Con trol

Blower Wire Table

Wrapped Wrapped Wrapped Board "H"

077/090

M1M(C,D)

CONTROL LIGHT STATUS

FURNACE ELECTRICAL BOX

Jumper must be removed if

BLACK

710152C 8/10

(Replaces 710152B)

langiS emalF kaeWgniknilBrewop oNFFO ydaetS

langiS emalF dooGNO ydaetSKO lortnoCNO ydaetS

WOLLEYDER

Rapid Flash False flame or internal control fault Steady OFF No Flame Signal

1 Flash Limit switch is open

2 Flashes Pressure switch is open with inducer on

3 Flashes Pressure switch is closed with inducer off

4 Flashes Lockout due to failed ignition

5 Flashes 115 vac & neutral reversed or no ground

converting to a multispeed blower.

Jumper is required for M1MA

models and M1MB 090

A/C & Heating Speeds: Refer to

Table 12, A/C Blower Selection

in the manual

GAS VALVE

ON/OFF

SWITCH

coding. (See furnace data label for electrical

information.)

appliance) must be replaced, use 105˚C Thermoplastic

NOTES

WIRING DIAGRAM

1. Incoming power must be polarized. Observe color

type wire or its equivalent.

2. If any of the original wires (as supplied with the

BLACK

YELLOW YELLOW

GROUND SCREW

NEUTRAL

Figure 38. Gas Direct Ignition Furnace, Heating & A/C Ready - All M1M Models

IGNITOR

LEGENDS

115V: FIELD 115V:

24V: FIELD 24V:

Page 34

BLACK

BUSHING

Single Phase / 60 Hz

GAS GUN BURNER

BUSHING

TERMINAL HOUSING

IGNITER

BLACK

BLACK BLACK

IND

BLACK

HSI

WHITE

HSIG

L2WPSI

MODULE

CONTROL

RED

BLACK

RED

FSI

RED

BUSHING

GRAY

GREEN

PSO

FSG

FROM "W"

BUSHING

TERMINAL

GROUND SCREW

BURNER ELECTRICAL BOX

BLUE

WIRE (BLUE)

FROM "C"

WIRE (GRAY)

LINE CORD

GAS VALVE

MOTOR

BURNER

MODULE

IGNITION

WHITE

ORANGE

BLUE W/WHITE STRIPE

IGNITER

MOTOR

7505B

R7184B

PRIMARY

OIL GUN BURNER

FROM 'R' WIRE (RED)

FROM 'W' WIRE (BLUE)

LINE CORD

VALVE

BLACK

BLACK W/WHITE STRIPE

WHITE

VIOLET

VALVE

CONTROL

CAD

CELL

YELLOW

CAD

CELL

0810

710999A

(Replaces 7109990)

¢710999e¤

AUX. LIMIT

120 Volt

105˚C wire or equivalent.

4. A/C Heating Speeds: Refer to Table 12, A/C Blower Selection

5. If any of the original wire supplied with the appliance is replaced,

use

6. Use copper conductors only.

7. Flash Codes: Refer to Table 9, Control Module Status Indicators.

4 SPEED

3 SPEED

RGW

MOTOR

BLOWER

MOTOR

BLOWER

BLUE

WHITE

ORANGE (MED LO)

BLUE (MED. HI)

BLACK (HIGH)

2 1

RED (LO)

WHITE

543

RED (LO) BLUE (MEDHI)

BLACK (HI)

SWITCH

ON/OFF

ERI

E IT

WHITE

RED

BLUE

WHITE GREEN RED GRAY

CONNECTOR

HOUSING CAP

GREEN

ORANGE

BLACK

A/C

BLOWER

RELAY

(SEE NOTE 3) RED

FAN

SWITCH

HI-LIMIT

3A FUSE

GRAY

BLACK

RED

GRAY

GREEN

24 V

115 V

L1 N

TRANSFORMER

BLACK

BY INSTALLER

SUPPLIED

WHITE

RED

GRAY

BLACK

ORANGE

BLACK

WHITE

ELECTRICAL BOX

FURNACE

SCREW

GROUND

BUSHING

CRW

TO BURNER CONTROL

RECEPTACLE

LEGEND:

WIRING DIAGRAM

NOTES:

1. Incoming power must be polarized. Observe color coding.

(See furnace data label for electrical information.)

2. If any of the original wires (as supplied with the appliance) must

be replaced, use 105˚C Thermoplastic type wire or its equivalent.

3. On models M1(B,S)A and M1/M5(B,S)086 jumper wire is installed.

M1B & M5S Furnace Series

On all other models, cooling speed is connected to black wire.

NEUTRAL

Figure 39. Gas and Oil Furnaces, A/C Ready - M1B & M5S (066, 086) Models

FIELD WIRING

LOW VOLTAGE

HIGH VOLTAGE

Page 35

Page 36

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 qualiﬁ ed 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.

INSTALLER NAME:

CITY: STATE:

INSTALLATION ADDRESS:

CITY: STATE:

ELECTRICAL SYSTEM:

Electrical connections tight? YES NO

Line voltage polarity correct? YES NO

Supply Voltage: ________________________________ VOLTS

Has the thermostat been calibrated? YES NO

Is the thermostat level? YES NO

Is the heat anticipator setting correct? YES NO

GAS SYSTEM:

Gas Type: (circle one)

Gas pipe connections leak tested? YES NO

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

Installation Altitude: ______________________________ (FT.)

Deration Percentage: ______________________________ (%)

Natural

Gas

Propane

UNIT MODEL #

UNIT SERIAL #

Minimum clearances per Table 1 (page 6)?

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

Has the literature package been left near the furnace?

YES NO

WARNING:

PROPOSITION 65 WARNING: This product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

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 & ventilation?

Vent free from restrictions? YES NO

Filter(s) secured in place? YES NO

Filter(s) clean? YES NO

Flue connections tight? YES NO

Is there proper draft? YES NO

YES NO

Speciﬁ cations & illustrations subject to change without notice or incurring obligations. O’ Fallon, MO | Printed in U.S.A. (10/10)

¢709243%¤

7092430 (Replaces 709123A)