Nordyne M1MC090, M1MC056, M1MC070, M1MC077, M1MB090 Installation Guide
...
Downflow, Direct Vent (Sealed Combustion)
Forced Air Gas & Oil Furnaces
For installation in:
Series M1 B, lVllG, M1M & M5S
, Manufactured Homes
, Recreational Vehicles, Park Models, &
Manufactured Buildings
, Modular Homes/Buildings
ATTENTION INSTALLERS:
It is your responsibility to know this product
better than your customer. This includes
being able to install the product according
tostrict safety guidelines and instructing the
customer on howtooperate and maintain the
equipment for the life of the product. Safety
should always be the deciding factor when
installing this product and using common
sense plays an important role as well. Pay
attention to all safety warnings and any other
special notes highlighted in the manual.
Improper installation of the furnace or failure
to follow safety warnings could result in
serious injury, death, or property damage.
These instructions are primarily intended
to assist qualified individuals experienced
in the proper installation of this appliance.
Some local codes require licensed
installation/service personnel for this type
of equipment. Please read all instructions
carefully before starting the installation.
Return these instructions to the customer's
package for future reference.
WHATTO DO IFYOU SMELL GAS FIRE OR EXPLOSION HAZARD
• Do not try to light any appliance.
,, Do nottouch anyelectrical switch;
do not use any phone in your
building.
• Leave the building immediately.
• Immediately call your gas supplier
,, Failure to follow safety warnings
exactly could result in serious
injury or property damage.
• Installation and service must
be performed by a qualified
installer, service agency or the
gas supplier.
from a neighbors phone. Follow
the gas suppliers instructions.
• If you cannot reach your gas
supplier, call the fire department
• Do not store or use gasoline
or other flammable vapors and
liquids in the vicinity of this or
any other appliance.
SAFETY iNFORMATiON .............................. 3
REQUIREMENTS & CODES ........................ 3
GENERAL INFORMATION ........................... 5
Warranty information ................................ 5
Minimum Clearances ............................... 5
Applications ............................................. 6
Unit Location ............................................ 6
CIRCULATING AiR REQUIREMENTS ......... 7
Return Air Connections ........................... 7
Supply Air Connections ............................ 7
Operating instructions - Oil Gun .............. 22
Operating Instructions - Gas Gun ............ 22
How to Shut Off Gas- Gas Gun ........... 22
Burner Adjustments ................................. 22
Gas Pressure ....................................... 22
Pilot Flame ........................................... 22
Combustion Air ........................................ 23
Gas Gun ............................................... 23
Oil Gun ................................................. 23
Electrode Setting - Oil Gun ...................... 23
Switching Honeywell (R7184) Ignition from
interrupted to intermittent ........................ 23
FURNACE iNSTALLATION .......................... 8
General information .................................. 8
Requirements & Codes ............................ 8
Locating & Cutting Duct Openings .......... 8
Standard Duct Connector Installation ....... 9
Alternate Attachment Method ............... 10
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
Manufactured Home Factory ................. 13
ELECTRICAL iN FORMATION ..................... 14
Line Voltage Wiring .................................. 14
Connecting Power Supply Wires ........... 15
Low Voltage Wiring .................................. 15
Connecting Thermostat Wires ............... 15
Verifying Anticipator Setting .................. 15
Grounding ................................................ 15
FUEL SUPPLY AND PiPiNG ....................... 16
Oil Tank & Piping Istallation ..................... 17
One Line System .................................. 17
Two Line System ................................... 17
Fuel Line Hook Up .................................. 17
Leak Check ............................................. 18
Priming Honeywell R7184 ...................... 18
Priming Beckett 7505 .............................. 18
Fuel Oil Type ........................................... 18
Conversion to Propane Gas ................... 18
Atmospheric & Direct ignition .............. 18
High Altitude Conversion ........................ 19
Flue Gas Sampling ................................. 19
STARTUP & ADJUSTMENTS ..................... 20
Lighting instructions - Pilot Models .......... 20
How to Shut Off Gas - Pilot Models ...... 21
Operating Instructions - Direct Ignition ...21
How to Shut Off Gas - Direct Ignition ...22
OPERATING SEQUENCE ........................... 24
Standing Pilot .......................................... 24
Standing Pilot w/Induced Draft Blower ...24
M1 Models - Direct Ignition ...................... 24
Oil Gun Models ........................................ 24
Gas Gun Models ...................................... 24
FURNACE CONTROLS & FUNCTIONS ..... 25
Furnace On-Off Switch ............................ 25
Limit Control ............................................ 25
Gas Valve ................................................. 25
Roll Out Switch - M1G ............................. 25
Oil Burner Primary Control ...................... 25
Summer Cooling - B,C,D Series .............. 25
TROUBLESHOOTING ................................. 26
Standing Pilot Models .............................. 26
Direct ignition Models .............................. 26
Oil Gun Models ........................................ 27
OPTIONAL ACCESSORIES ........................ 28
MAINTENANCE ........................................... 30
Homeowner information .......................... 30
installer information information .............. 30
FIGURE & TABLES ...................................... 31
Table 10 - Furnace Specifications ........ 31
Table 11 - Orifice Sizes - High AIt ......... 32
Table 12- Blower Speed Selection ....... 32
Gas Information ....................................... 33
Table 13 - Gas Flow Rates ................... 33
Table 14 - Gas Pipe Capacities ............ 33
Wiring Diagrams ...................................... 34
Fig. 39 - Gas Furnace - 056, 070 ......... 34
Fig. 41 - Standing Pilot - 077, 090 ........ 35
Fig. 42 - Gas Furn. w/ac 056, 070 ........ 36
Fig. 43 - Standing Pilot. w/ac 077, 090.37
Fig. 44 - Gas Only (M1M Models) ........ 38
Fig. 45 - Gas & Oil (M1B & M5S) ......... 39
Installation Checklist ................................ 40
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:
WARNING:
Do not use this appliance if any
part has been submerged under
water. Immediately call a qualified
service technician to inspect the
appliance and to replace any part
of the control system and any gas
control that has been submerged
underwater.
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.
o 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 5).
Provide adequate combustion airtothe furnace
space as specified on page 23.
Combustion products must be discharged
outdoors. Connect this furnace to an approved
vent system, as specified on pages 13 - 14.
Never test for gas leaks with an open flame.
Use a commercially available soap solution to
check all connections (page 18).
This furnace is designed to operate with a
maximum external pressure rise of 0.5 inches
of water column. Consult Table 8 (page 38),
and the rating plate for the proper circulating
air flow and temperature rise.
NOTE: It is important that the duct system be
designed to handle the desired flow rate and
external pressure rise.An improperly designed
duct system can result in nuisance shutdowns,
and comfort or noise issues.
This furnace may not be used for temporary
heating of buildings or structures under
construction.
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 page 14.
Notice to installer
Installer is advised to carefully follow all
instructions and warnings in this manual to insure
maximum performance, safety, and operating
efficiency of these appliances. Improper
installation may create hazardous conditions,
and will void the appliance warranty.
PROPOSITION 65 WARNING"
This product contains chemicals
known to the state of California
to cause cancer, birth defects or
other reproductive harm.
REQUIREMENTS AND CODES
This furnace must be installed in accordance with
these instructions, ale 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 generateur d'air chaud doit 6tre installe
conformement aux instructions du fabricant
et aux codes Iocaux. En Fabsence de code
local, respecter la norme ANSI Z223.,1,
institule National Fuel Gas Code ou les codes
d'installation CAN/GCA-B149.
The Commonwealth of Massachusetts requires
compliance with regulation 248 CMR 4.00 and
5.00 for installation of through-the-wall vented
gas appliances as follows:
1. For direct-vent appliances, mechanical-
vent heating appliances or domestic hot
water equipment, where the bottom of the
vent terminal and the air intake is installed
below four feet above grade the following
requirements must be satisfied:
a.) Acarbonmonoxide(CO)detectorand
alarmshall be placedon eachfloor
levelwherethereare bedrooms.The
detectorshallcomplywith NFPA720
(2005Edition)andbe mountedin the
livingareaoutsidethebedroom(s).
b.) A (CO) detectorshall be locatedin
theroomthathousestheapplianceor
equipmentandshall:
. 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 ANSl/UL 2034 Standards
and comply with NFPA 720 (2005
Edition); and Approved and listed
by a Nationally Recognized Testing
Laboratory as recognized under 527
CMR.
c.) A Product-approved vent terminal must
be used, and if applicable, a product-
approved air intake must be used.
Installation shall be in strict compliance
with the manufacturer's instructions. A
copy of the installation instructions shall
remain with the appliance or equipment
at the completion of the installation.
d.) A metal or plastic identification plate shall
be mounted at the exterior of the building,
4 feet directly above the location of vent
terminal. The plate shall be of sufficient
size, easily read from a distance of eight
feet away, and read "Gas Vent Directly
Below".
2. For
direct-vent appliances, mechanical
vent heating appliances or domestic hot
water equipment where the bottom of the
vent terminal and the air intake is installed
above four feet above grade the following
requirements must be satisfied:
a.) A (CO) detector and alarm shall be
placed on each floor level where there
are bedrooms.The detector shall comply
with NFPA 720 (2005 Edition) and be
mounted in the living area outside the
bedroom(s).
b.) The (CO) detector shall:
. Be located in the room that houses
the appliance or equipment;
. Be hard-wired, batterypowered or both.
. Shall comply with NFPA 720 (2005
Edition).
c.) A product-approved vent terminal must
be used, and if applicable, a product-
approved air intake must be used.
Installation shall be in strict compliance
with the manufacturer's instructions. A
copy of the installation instructions shall
remain with the appliance or equipment
at the completion of the installation.
The 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 and Ventilation Air
. US: National Fuel Gas Code (NFGC), Air for
Combustion and Ventilation
. CANADA: Natural Gas and Propane Instal-
lation 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 Hand-
book
Electrical Connections
" US: National Electrical Code (NEC) ANSI/
NFPA 7O
. CANADA: Canadian Electrical Code CSA
C22.1
Gas Piping and 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) NFPA54-1999/ANSI Z223.1 and
the Installation Standards, Warm Air Heating
and Air Conditioning SystemsANSI/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).
, AmericanNationalStandard(ANS1-119.2/
NFPA-501C)for all recreationalvehicle
installations.
, CANADA:CAN/CGA-B149.1and .2-M00
National Standard of Canada. (NSCNGPIC)
GENERAL iNFORMATiON
Manufacturer Warranty - Owner's
Responsibilities
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.R gas
or Natural gas) and adjusted to operate properly.
All gas furnaces are manufactured for Natural gas
and must be field converted when using L.R gas.
CAUTION:
• Do Not alter or modifythisfurnace
or any of its components.
• Never attempt to repair damaged
or inoperable components. This
may cause unsafe operation, ex=
plosion, fire and/or asphyxiation.
,, If furnace malfunctions or does
not operate properly, contact a
qualified service agency or gas
utility for assistance.
A warranty certificate with full details is included
with these instructions. However, NORDYNE
will not be responsible for any costs found
necessary to correct problems due to improper
setup, improper installation, furnace adjustments,
improper operating procedure on the part of the
user, etc. Carefully review these responsibilities
with your manufactured housing dealer, service
company or gas supplier. Some specific 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 flue
assembly (Roof Jack).
Adjusting or calibrating of thermostat.
Any construction debris which falls into flue
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 filter,
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 Iouvered door
having a minimum free area of 235 sq. in. when
located 6" from furnace or 390 sq. in. for 5 ton
ready M1/M5 furnaces. For special clearance
between 1"and 6", requirements are a Iouvered
door with a minimum of 250 sq. in. free area,
with the openings in the closet door in line with
the Iouvered openings in the furnace door. A
fully Iouvered closet door may be used. See
Circulating Air Requirements (page 7).
ALL MODELS CLOSET ALCOVE
Front 6" 18"
Back 0" 0"
Sides 0" 0"
Roof Jack 0" 0"
Top 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 1/4" 1/4"
(w/o coil box)
Table 1. Minimum Clearances
6"
Top Clearance
Removable access
0" Side
Clearance
to Furnace
Cabinet
panel should be
installed above
furnace door frame
to access roof jack
- -_.,, Nearest
i, Wall or
Figure 1. Alcove installation
6"
Top Clearance
, I In closet
i located
F at top,
0" Side center
Clearar or bottom
to
Provide min. 235
in. (1516 cm 2)
open free area in
front or side wall
CLOSET DOOR
Figure 2. Closet Installation
6" (152 mm) sq. in. (1613 cm 2)
Top Clearance -_._/ (( open free area in
__--_ /i' front or side wall
/ - !r<_
_ door
_t a fully
, I Iouvered
0" Side door may
Clearance be used
to Furnace
Cabinet
------_ Provide min. 250
Partition
door
or
in closet
Applications
M1 Series gas and M5 Series oil furnaces are
listed direct vent (sealed combustion), downflow
heating appliances for manufactured (mobile)
homes, recreational vehicles, and for use in
residentia!/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 airconditioning equipment to the
M1/M5 serJesof fumaces. See Tabel 12 (page 32).
Multi-speed blower assemblies shown in Table
2, have been certified for field installation in M1/
M5 Series furnaces.
Unit Location
, The furnace shall be appropriately located to
the supply and return air distribution system
(See Page 7). Sides and back of the furnace
may be enclosed bywall framing. See Minimum
Clearances (page 2) and Figures 1- 3.
, The furnace 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
flooring when using NORDYNE Duct
Connectors. See pages 9 & 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 floor and protected
from physical damage by vehicles.
Figure 3. Special 1" Clearance
Blower / Motor
Part
No.
Assembly
Blower Motor
Wheel (Hp)
903773
903413
903890
10x 8 1/4
11 x8 1/2
11 x 8 3/4
Table 2. Blower Assemblies
:iOSET DOOR
NC Capacity
(Tons)
2, 21/2& 3
2, 21/2,3 & 4
2, 21/2,3, 4&._5
"A"-s6'i
..........l¸-
w/o Coil
"A" Model _
Cabinet "B'= 76"
"B" Model j _a
w/Coil
Cabinet
Figure 4. Overall Dimensions
CIRCULATING AIR REQUIREMENTS
WARNING:
Donot allow combustion products
to enter the circulating air supply.
Failure to prevent the circulation
of combustion products into the
living space can create potentially
hazardous conditions including
carbon monoxide poisoning that
could result in personal injury or
death.
All return ductwork must be secured
to the furnace withsheet metal screws.
For installations in confined spaces,
all return ductwork mustbe 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 floor or platform.
Returnairandcirculatingairductwork
must not be connected to any other
heat producing device such as a
fireplace insert, stove, etc. This
may result in fire, explosion, carbon
monoxidepoisoning,personalinjury,
or propertydamage.
Return Air Connections
U.S.A. home manufacturers sha!l 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 specified in the appliance's listing.
, The cross-sectional area of the return duct
system leading into the closet, when located
in the floor or ceiling shall not be less than 235
square inches (or 390 square inches for 5 ton
ready M1/M5 Furnaces).
CAUTION'.
HAZARD OF ASPHYXIATION: Do not
cover or restrict return air opening.
, Means sha!l be provided that prevent
inadvertent c!osure of fiat objects p!aced over
the return air opening !ocated in the floor of the
c!oset (versus the vertical front or side wa!!).
, The total free area of openings in the floor or
cei!ing registers serving the return air duct
system must be at beast 235 sq. in. At beast
one register shou!d be !ocated where it is not
!ikely to be covered by carpeting, boxes and
other objects.
, Materia!s !ocated in the return duct system
must have a flame spread c!assification of
200 or less. This inc!udes a closet door if the
furnace is in a c!oset.
, Noncombustib!e pans having 1" upturned
flanges are located beneath openings in a
floor duct system.
, Wiring materials located in the return duct
system shah conform to Artic!es 300-22 of the
National Electrica! 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 air-circu!ating 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 !ouver area to ob-
tain necessary airflow. Use NORDYNE's
certiduct program to determine proper duct
size for A/C.
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,andnumberofregistersshould
beselectedonthebasisofbestairdistribution
andfloorplanofthehome.Thesupplyairmust
bedeliveredtotheheatedspaceby duct(s)
secured to the furnace casing, running full
size and without interruption.
, The M1 Series gas and M5 Series oil furnace
iscertified for use on wood flooring or supports,
but must be installed on top of aduct connector.
This factory supplied accessory must be
installed in the floor cavity and attached to the
supply air duct before the furnace is installed.
Three typical distribution systems are shown
in Figure 5. The location, size, and number of
registers should be selected on the basis of
best air distribution and floor plan of the home.
A Single trunk duct
_" Dual trunk duct
B w/crossover connector
Transition duct
I C []_ w/branches _
I
J
Figure 5. Typical Supply Duct System
FURNACE INSTALLATION
NOTE: These Installation procedures are
suggested for typical furnace installations.
Since a!! installations are different from each
other, the sequence of instructions may differ
from the actual installation. Only qualified HVAC
technicians should install this furnace.
General Information
, The furnace must be leveled at installation and
attached to aproperly 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 plenum attached to the A/C coil box and
ductwork within 3 ft. of the furnace must be
installed so that surfaces are at least 1/4" from
combustible construction.
, The cabinet plug must always be used to close
the hole inthe side of the furnace when rotating
the inducer.
, M1/M5 models must be installed with the Nordyne
A/C coil box which are listed according to the
cabinet size of the furnace: "B" cabinet - 920169,
"C" cabinet - 920171, and"D" cabinet- 920172.
Requirements and Codes
Installer must be familiar with and comply with
all codes and regulations applicable to the
installation of these heating appliances and
related equipment, inthe absence of local codes,
the installation must be in accordance with the
current provisions of one or more of the following
standards.
, Federal Manufactured Home Constructions
& Safety Standard (H.U.D. Title 24, Part
3280.707[a][2])
, American National Standard (ANSI-119.2/
NFPA-501C) for all recreational vehicle
installations.
, American National Standard (ANSI-Z223.1/
NFPA-54) and/or CAN/CSA B149 for all gas-
fired furnace models.
, American National Standard (ANSI-Z95.1/
NFPA-31) and/or CSA B139 for all oil-fired
furnace models.
, American National Standard (ANSI-C1/NFPA-
70) and/or CSA 22.1 Canadian Electric Code
Part 1 for all electrical field wiring.
, Units have been researched under standards
UL 307A & B, UL727-1999, ANSI Z21.47b/
CSA 2.%-2008, and CSA B140.10.
Locating and 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 floor.
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 floor 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 floor down to the
top of the supply air duct to obtain the depth of
the floor cavity. NOTE: The depth of the floor
cavity shown as "X" in 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 (page 9).
14 1/2"_ 2 3/4"
201" _
±
_J_/_ FLOOR OPENING !._'
"X" _ _,/,I
FLOOR
CAVITY
Figure 9. Floor Cavity
C'_ J Z CUT-OUTFOR 1 3/4"
I _ I CL ¢'- / OPTIONAL ¢_ /
1 3/4"_i: : ::_ :A:L; :F; ELIL,; E _ _'
3/4"_ _ ENTRY 1 1/4" Dia, \\ LINE
17/8"_ _ FURNACE
2 7/8"_ _ DOOR
Figure 6. Cut=Out Dimensions for
Standard Duct Connectors
Figure 7. Cut=Out Dimensions for
Round Duct Connectors
Hole for
Gas Line
Mounting Plate
Duct
Connecto
if Floor Cavity
"X" is:
7/8"/(22)
2"/(51)
4-1/4" / (108)
6-1/4"/(159)
8-1/4" / (210)
10-1/4" / (260)
12-1/4"/(311)
Note: Dimensions shown as Inches / (Millimeter_
Duct Connector
Type & Part Number
Standard Duct
901987A
901988A
901989A
901990A
901991A
901992A
901993A
Round Duct
904008
904009
904010
904011
904012
904013
904014
Table 3. Duct Connector Sizes
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 sufficient clearances
for this type of installation. For an alternate
installation method, see page 10.
1. Center the duct connector in the floor opening
with bottom tabs resting on top of the supply
air duct.
2. Mark the cut-out area on the supply air duct by
tracing aroundthe connector tabs (Figure 8)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 floor
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 floor 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 on the mounting plate up 90 °.
See Figure 10, (page 10)
9. Seal all connections with industrial grade
sealing tape or liquid sealant.
Figure 8. Standard Duct Connector In-
stalled
NOTE: Requirements for sealing ductwork
vary from region to region. Consult with local
codes for requirements specific to your area.
Duct connector tabs Staples or sheet metal screws
, ,/ \, , / \
\ /
BEND TABS TIGHTLY
AGAINST SUPPLY AIR DUCT
Figure 10. Duct Connector Tabs
Alternate Attachment Method
The standard duct connector is designed for
use on ducts 12" in width. However if there is
insufficient 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).
With Option 1 choice, cut out the metal from
the shaded area.
2. Fold the two flaps (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).
5. Form the flaps (Options 1 or 2) up against the
duct connector as tight as possible.
6. Secure the duct connector flaps to the supply air
duct with staples (3 minimum) or if a 2x block/
joist is not provided, use sheet metal screws
(2 minimum). NOTE: The duct connector tabs
may be attached to the air duct with sheet
metal screws or other suitable fasteners as
long as the duct connector and the air duct
are securely attached.
7. Seal all connections with industrial grade
sealing tape or liquid sealant.
NOTE: Requirements for sealing ductwork
vary from region to region. Consult with local
codes for requirements specific to your area.
!_t ]_ _]_
r q
F"arrowq
I Ductj
hConnector_
Sheetscrewsmetal_ _-_ _
Figure 12. Narrow Ducts
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
floor opening.
3. Install the mounting plate under the back side
of the duct connector. See Figure 13 (page 11).
NOTE: Align the screw holes in both
components.
4. Secure the duct connector and the mounting
plate to the wood floor with appropriate size
screws.
5. Connect the round supply duct to the underside
of the duct connector and secure them with
field supplied sheet metal screws.
&Seal all connections with industrial grade
sealing tape or liquid sealant.
NOTE: Requirements for sealing ductwork
vary from region to region. Consult with local
codes for requirements specific to your area.
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
2 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).
OPTION 1
Rernove
this
Flap _ Supply _ Cut Here
i _;'t _ !"% J_ _: J _
i Air Duct
E
I Cut Here
LE
Remove
this
Flap
E E
--_ __ Cut Here
,,o ,,o
Figure 11. Narrow Air Duct Openings
10
OPTION 2
i ¢
1. Remove furnace outer door(s) and bottom fuel
line knockout.
2. Place furnace onto duct connector and center
with floor opening.
3. Slide onto mounting plate. (Bottom rear slots
on furnace should engage with mounting plate
tabs.)
4. Secure front with one (1) fastener at each
corner (Figures 14 or 15).
NOTE: Additional fasteners may be used at rear,
sides or through door frame, as desired, tosecure
furnace to closet or alcove framing.
SCREWS MOUNTING
DUCT _' :_ PLATE
CONNECTOR i i
CONNECTION
Figure 13. Round Duct Connector Installed
SLIDE FURNACE
ALL THE WAY BACK
ONTO MTG. PLATE
/
//
/
ROOF JACK iNSTALLATION
Required ceiling and roof cut-out openings (see
Figure 11) 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.
(See Dimension "A" in Figure 16.)
2. Determine ceiling height and subtract height
of furnace. (See Dimension "B" in Figure 16.)
3. Add dimensions A + B (and X from Table 5
and Figure 18 if slant deck flashing is used).
The total length of (A + B + X) must be within
the minimum and maximum range of one of
the Roof Jacks listed in Table 4.
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.
Figure 14. "A" & "B" Cabinet Furnaces
Figure 15. "A" Cabinet Furnace on Coil
Cabinet
"_- ROOF JACK
PITCHED j
_ SLANT DECK
ROOF
f i II"x"(SEETABLE5)
CEILING ,_, ,_-- I_
--ILIN _ ,_--Combustion Air Pipe
lii'--P'uePipe
Furnace 66"or76"
FLASHING
F = Flat Flashing: flexes from 0/12 to 1/12 roof
slope. See Figure 17 (page 12).
S = Slant Flashing: 2.5/12 Slope flexes from
1/12 to 4/12 roof slope, 4/12 flexes from
3/12 to 5/12. See Figure 18.
o
Stainless steel roof jacks are available.
o
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.
NOTE: If the roof jack crown iscovered or blocked
with snow, the furnace will not operate properly.
MODEL NUMBER
(ES)AW(T)1523-(0,2,4)(A,S)
(ES)AW(T)2135-(0,2,4)(A,S)
(F,S)AW(T)2747-(0,2,4)(A,S)
(F,S)AW(T)3563-(0,2,4)(A,S)
(F,S)AW(T)5195-(0,2,4)(A,S)
S AW T 27
APPROX. LENGTH
BELOW FLASHING
15"-23"
21"- 35"
27"- 47"
35"- 63"
51"- 95"
47 - 2 S
T T U T T T 2F'UESTEELTYPE
F = FLAT FLASHING _ I I I I I A= ALUMINIZED
S=SLANTFLASHING/ WIN.ADJ./ S=STAINLESS
AW= ALL WEATHER / / _ FLASHING
TYPE: / / 4=4/12
BLANK = NON-TRANSIT _ /
T= TRANSIT MODE " '
LENGTR /
/ / PITCH/12"RISE
/ / 0=FLAT
/ / 2=2,5/12
L MAX ADJ
LENGTH
Figure 16. Ceiling Cavity Depth
Table 4. Roof Jack Assemblies
11
1. Locate centerof Roof Jackopening, measure
13 1/2" from the rear wall of closet or alcove
along the center line of furnace and floor
opening. See Figure 19.
2. Cut ceiling and roof holes as follows:
, Ceiling = 8 3/4" (222 mm) diameter
Roof = 9 3/8" (238 mm) diameter
CEiLiNG OPENING
Figure 17. Example of Fiat Jack
with Flashing
0
Figure 18. Example of 21/2112Slant Jack
with Flashing
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.
Locating and Cutting Roof & Ceiling Openings
DO NOT ALLOW DEBRIS TO FALL INTO THE
FURNACE. THIS COULD CAUSE UNSAFE
OPERATION AND VOIDS THE FURNACE
WARRANTY. Use the top cap that comes with
the furnace packaging (or alternate protector) to
prevent debris from falling intothe furnace before
the final roof jack connection is made
IMPORTANT:
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.
0 _=
/ CUT-OUT FOR _ +
_ FLUE AND ) ¢'-
LL \ ROOF JACK /
FURNACE
7 OUTER
DOOR
Figure 19. Cut-Out Dimensions for
Flue & Roof Jack
ROOF JACK SERIES
"F Series
"S" Series (2.5 / 12
Pitch only)
Optional Deck Flashings for Flat and
12
IF ROOF PITCH IS:
2"in 12"
2-1/2" in 12"
3"in 12"
3-1/2" in 12"
4"in 12"
4-1/2" in 12"
5"in 12"
5-1/2" in 12"
6"in 12"
6-1/2" in 12"
2.5/12 Pitch Roof Jacks. 4/12
Table 5. Slant Deck Flashings
SLANT DECK
FLASHING NUMBER
903893 (2.5/12)
903893 (2.5/12)
903894 (3/12)
903894 (3/12)
903895 (4/12)
903895 (2.5/12)
903895 (2.5/12)
903894 (3/12)
903894 (3/12)
903895 (4/12)
Pitch Roof Jacks not applicable.
"X" FACTOR
IS:
2-1/8"
2-1/2"
2-7/8"
3-1/4"
3-5/8"
2-1/8"
2-1/2"
2-7/8"
3-1/4"
3-5/8"
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