Nordyne M3RL User Manual

Direct Vent (Sealed Combustion) Forced Air Gas Furnaces
Installation Instructions
M3RL Series 90+ Downflow Condensing Furnace
For installation in:
1. Manufactured Homes
2. Park Models and Manufactured Buildings
3. Modular Homes/Buildings
!
W ARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in serious injury, death or property damage.
– Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other appliance.
–WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
– Installation and service must be performed by a
qualified installer, service agency, or the gas sup­plier.
BW Models
!
ADVERTISSEMENT:
RISQUE D’INCENDIE OU D’EXPLOSION
Le non-respect des avertissements de sécurité pourrait entraîner des blessures graves, la mort ou des dommages matériels.
– Ne pas entreposer ni utiliser de l’essence ni
d’autres vapeurs ou liquides inflammables dans le voisinage de cet appareil, ni de tout autre appareil.
–QUE FAIRE S’IL Y A UNE ODEUR DE GAZ
• Ne pas tenter d’allumer aucun appareil.
•Ne toucher à aucun interrupteur électrique; n’utiliser aucun téléphone dans le bâtiment.
• Évacuer l’immeuble immédiatement.
• Appeler immédiatement le fournisseur de gaz en employant le téléphone d’un voisin. Respecter à la lettre les instructions du fournisseur de gaz.
• Si personne ne répond, appeler le service des incendies.
– L’installation et l’entretien doivent être effectués
par un installateur qualifié, un organisme de service ou le fournisseur de gaz.
BWT Models
!
W ARNING:
Should overheating occur, or the gas supply fail to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply.
Improper installation, adjust­ment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier.
LEAVE THESE INSTRUCTIONS WITH THE HOMEOWNER.
2
TABLE OF CONTENTS
General ...................................................... 4
Unit Dimensions .................................. 4
Shipping Weights................................ 4
Furnace Specification ........................ 4
Air Flow Data ..................................... 4
Owner's Information ................................ 5
Installation Requirements...................... 6
Location.............................................. 7
Clearance ........................................... 7
Circulating Air Supply ............................ 7
Return Air Provisions .............................. 8
Air Distribution Systems ........................ 9
Duct Connector Selection.................... 10
Duct Installation .................................... 10
Venting and Combustion
Air Requirements ........................... 13
Venting Requirements .......................... 14
Vent Table ........................................ 1 5
Vent Pipe Material ............................ 16
Vent Pipe Length and Diameter....... 16
Vent Pipe Installation ........................ 16
Pipe Routing & Support .................... 16
Location of Outdoor Termination .....16
Horizontal Venting ............................ 18
Vertical Venting ................................18
Vent Freezing Protection .................19
Concentric Vent Termination ........... 19
Drainage of Condensate
From Furnace ................................ 19
Gas Supply and Piping ......................... 20
Leak Check....................................... 21
High Altitude Derate ......................... 21
Pressure Switch .............................. 21
Conversion .............................................. 21
Lighting and Adjustment
of the Appliance .............................. 23
Electrical Wiring ...................................... 24
Line Voltage Wiring ........................... 24
Low Voltage Wiring ........................... 26
Ventilation ................................................ 26
Start-up and Adjustment ........................ 26
Start-Up Procedure ........................... 26
Shut Down Procedure ....................... 27
Verifying and Adjusting Firing Rate ... 27
Temperature Rise ............................. 27
Verifying and Adjusting
Verifying Burner Operation .............. 28
Verifying Operation of the
Supply Air Limit Switch ................. 28
Description of Components ................ 29
Furnace Accessories............................. 29
Maintenance ........................................... 29
Combustion Air and Vent System....29
Air Filter(s) ....................................... 29
Lubrication........................................ 30
Condensate Drain Assembly ........... 30
Blower Compartment ....................... 30
Heat Exchanger and Burner
Maintenance .................................. 30
System Operation Information............. 30
Sequence of Operation.................... 30
Furnace Fails to Operate ................. 31
Location of Major Components .......... 32
Wiring Diagram ....................................... 33
Installation/Performance
Checklist ......................................... 35
M 3 R L - 060 A - A W
Application
M-Manufactured Home
Furnace Series
Comfort Model
RL - Condensing Downflow
Heating Capacity
Input, BTUH (000’)
Table 1. Model Identification
Return Air Configuration
Blank - Front T - Top
Door Color
W - White G - Gray
Cabinet Dimensions
A - 56" x 19-3/4" x 23-3/4” B - w/Coil Cavity, 76" x 19-3/4" x 23-3/4"
Electrical Code
A - 1PH, 60 Hz, 120 VAC
3
19-7/8
24-5/8
56-1/16
20-9/32
21-17/32
21-29/32
21-15/16
19-3/16
23-7/16
28-15/32
3-17/32
4-11/16
4-11/16
3-17/32
EXHAUST
VENT
17-13/16
COMBUSTION
AIR
INTAKE
21-11/32
7/8 Diameter
1-19/32
1-19/32
EXHAUST VENT
1-11/16
COMBUSTION
AIR
INTAKE
3-17/32
24-3/4
20-1/16
18-1/2
18-1/2
(W/ Coil Box)
75-1/4
SIDE RETURN
KNOCKOUTS
SIDE RETURN
KNOCKOUTS
1-1/2
21-15/16
1-19/32
Cooling
Coil Box
(W/O Coil Box)
GENERAL
(
)
21-11/32
COMBUSTION
17-13/16
EXHAUST
AIR
VENT
INTAKE
19-7/8
3-17/32 COMBUSTION
1-11/16 EXHAUST VENT
AIR
1-1/2
INTAKE
24-5/8
SIDE RETURN
KNOCKOUTS
21-17/32
21-29/32
20-9/32
1-19/32
Top Return Knockouts
7/8 Diameter
23-7/16
3-17/32
4-11/16
56-1/16
28-15/32
Cooling
Coil
(W/O Coil Box)
3-17/32
4-11/16
19-3/16
Box
20-1/16
Figure 1. Furnace Dimensions
12.000
1.000
1.000
18-1/2
SIDE RETURN
KNOCKOUTS
1-19/32
1-19/32
24-3/4
18-1/2
21-15/16
21-15/16
(W/ Coil Box)
75-1/4
21.000
Top View
(AW and BW Models)
Furnace Specifications / Airflow Data
Furnace Furnace Temp. Recommended
Input Output Rise @ A/C
Model No.
Btuh Btuh .3"WC ° F CFM CFM CFM CFM CFM Ton
Top Return Opening
(BWT Models)
Motor HPMotor
Speed
High* 1660 1599 1544 1474 1410 4 Med-High 1512 1467 1416 1363 1304 3
External Static P ressure ( In ches Water Colum n )
Med-Low 1340 1304 1261 1217 1158 2.-1/2
M3 RL-060
M3 RL-080
Note: Data is for Operation with Filter.
60,000 54,000 3 5 - 65 Lo w* * 1176 1142 1 108 1025 966 2
80,000 72,000 35 - 65 Lo w 1176 1142 110 8 1025 966 2
1/2
High* 1660 1599 1544 1474 1410 4 Med-High 1512 1467 1416 1363 1304 3 Med-Low** 1340 1304 1261 1217 1158 2.-1/2
1/2
* Factory Wired Cooling Tap ** Factory Wired Heating Tap
Table 3. Furnace Specifications/Airflow Data
4
0.1 0.2 0.3
Shipping
Weight
Furnace Model
M3RL 060A A W 150 M3RL 060A B W* 170 M3RL 080A A W 155 M3RL 080A B W* 175
* May include suffix - T
Table 2. Shipping Weight
0.4 0.5Furnace
lbs
!
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.
NOTICE TO INSTALLER
Installer is advised to follow carefully all instruc­tions and warnings in this manual to insure maximum performance, safety, and operating efficiency of these appliances. Improper installa­tion may create hazardous conditions, and will void the appliance warranty.
GENERAL
General Description
The M3 series gas furnaces are listed direct vent (sealed combustion) forced air furnaces for use with both natural and propane gases. The M3 series is a Category IV and type FSP furnace. The M3 furnace series has been certified to the ANSI Z21.47/CSA2.3-2001 for use in the United States and Canada and to the UL307B —1995 for use in the United States.
5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leak to check all connections.
6. Always install furnace to operate within the furnace’s intended temperature rise range with a duct system that has an external static pressure within the allowable range, as specified in page 4 of these instruc­tions. See furnace rating plate.
7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space contain­ing the furnace. Note: This section only applies to furnaces installed with side or top return air.
8. A gas-fired furnace for installation in a residential garage must be installed as specified in page 7 of these instructions.
9. The furnace is not to be used for tempo­rary heat of buildings or structures under construction.
M3 series furnaces are air conditioning ready as shipped. The furnace cooling capacities of the blower motor speed taps are shown in Table 3. Table 2 lists the shipping weights for the M3 series furnaces.
These furnaces may be installed in:
1. Manufactured Homes.
2. Park Models and Manufactured buildings
3. Modular Homes/Buildings The following are safety guidelines with refer-
ences to their specific sections or pages in the manual.
1. Use only type of gas approved for this furnace. Refer to the furnace rating plate.
2. Install this furnace only in location and position as specified in pages 7 - 13 of these instructions.
3. Provide adequate combustion and ventila­tion air to the furnace space as specified in pages 13 - 20 of these instructions.
4. Combustion products must be discharged outdoors, connect this furnace to an ap­proved vent system only, as specified in pages 14-19 of these instructions.
OWNER INFORMATION
NORDYNE has been involved in the design of products for the manufactured home industry since the first manufactured home or trailer was built.
NORDYNE originated the sealed combustion system, which separates the furnace com­bustion system from the living area of the home, now a standard for the manufactured home industry.
NORDYNE engineers developed the first cen­tral heating system and the first central air conditioner for manufactured homes.
NORDYNE is dedicated to bringing to its cus­tomers the finest heating and cooling comfort possible. NORDYNE constantly seeks to fur­ther refine its products to continuously provide exceptional comfort.
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Follow the instructions in this booklet carefully and this appliance will provide many years of superior performance.
If you wish to cool your home automatically with a central air conditioning system investi­gate the excellent NORDYNE cooling systems available from your heating and cooling con­tractor. These systems are designed to work best with your NORDYNE furnace and have been carefully engineered to deliver optimum performance when mated with NORDYNE manufactured home furnaces.
NORDYNE also offers water heaters, fireplaces and ventilating systems specifically designed for manufactured housing applications. Check with your manufactured home retailer, your heating and cooling contractor or your distributor for information. Write directly to the factory (PO Box 8809, O’Fallon, MO 63366) if you are not able to locate a source for NORDYNE manufactured housing products in your area.
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.P. gas or Natural gas) and adjusted to operate prop­erly. All gas furnaces are manufactured for Natural gas and must be field converted when using L.P. gas.
A warranty certificate with full details is included with these instructions. However, NORDYNE will not be responsible for any costs found nec­essary to correct problems due to improper setup, improper installation, furnace adjustments, improper operating procedure on the part of the user, etc.
Some specific examples of service calls which cannot be included in warranty payments are:
1. Converting the furnace to use another type
of gas.
2. Repairing duct work in the home found to be
faulty.
3. Correcting wiring problems in the electrical
circuit supplying the furnace.
4. Resetting circuit breakers, blown fuses or
other switches.
5. Correcting problems due to improper gas
supply pressure to the furnace.
6. Providing instructional training on how to light and operate the furnace.
7. Furnace problems caused by installation of an air conditioner, heat pump or other air comfort devices.
8. Revising installation of the furnace flue assembly.
9. Adjusting or calibrating of thermostat.
10. Any construction debris which falls into the flue system.
Carefully review these responsibilities with your manufactured housing dealer, service company or gas supplier so there will be no misunder­standing at a later time.
!
CA UTION:
• Never attempt to alter or modify this
furnace or any of its components.
• Never attempt to repair damaged or
inoperable components. Such action could cause unsafe operation, ex­plosion, fire and/or asphyxiation.
• If a malfunction has occurred, or if
you feel that the furnace is not oper­ating as it should, contact a qualified service agency or gas utility for as­sistance.
INSTALLATION STANDARDS
Installer shall be familiar with and comply with all codes and regulations applicable to the installa­tion of these heating appliances and related equipment. In lieu of local codes, the installation shall be in accordance with the current provi­sions of one or more of the following standards. a. Federal Manufactured Home Constructions
& Safety Standard (H.U.D. Title 24, Part
3280.707[a][2])
b. The Standard for Manufactured Home Instal-
lations (Manufactured Home Sites, Commu­nities, and Set-Ups) ANSI A225.1 and/or CAN/CSA-2240 MH Series).
c. American National Standard (ANSI-119.2/
NFPA-501C) for all recreational vehicle in­stallations.
d. American National Standard (ANSI-Z223.1/
NFPA-54) and/or CAN/CGA B149 for all gas­fired furnace models.
e. American National Standard (ANSI-C1/NFPA-
70) and/or CSA 22.1 Canadian Electric Code Part 1 for all electrical field wiring.
6
CE générateur d'air chaud doit être installé
A
V
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.
The National Fuel Gas Code is available by writing:
bustible material other than wood flooring. The furnace may be installed on combustible floor­ing when installed on a Nordyne duct connec­tor (see Table 5).
The ductwork within 3 feet of the furnaces without the A/C coil box must be installed such that surfaces are at least 1/4" from combustible materials.
American National Standards Institute, Inc. 1430 Broadway New York, NY 10018
NFPA publications are available by writing:
National Fire Protection Association Batterymarch Park Quincy, ME 02269
LOCATION
The furnace must be installed on a level sur­face, and as close to the center of the air distribution system as possible. See Figure 1 for overall dimensions to determine the re­quired clearances in hallways, doorways, stairs, etc. to allow the furnace to be moved to the installation point. The furnace must be in­stalled so that all electrical components are protected from water.
Minimum clearances to combustible materials are listed in Table 4. Access for positioning and servicing must be considered when locating the unit.
This furnace is certified for use on wood flooring. The furnace must be installed on a solid surface and must be level front-to-back and side-to-side. This furnace must not be installed directly on carpeting, tile, or any com-
CLOSETALCOVE
LL MOD ELS Inches Inches
Front 1* 1* Back 0 0 Sides 0 0
ent 0 0 Top 6 6 Duct (Plenum) w/ Coil Box 0 0 w/o Coil Box 1/4 1/4 (within 3 feet)
*Note: For 1” clearance, use a fully louvered door with at least 400 square inches of free airflow area.
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.
CIRCULATING AIR SUPPLY
!
WARNING:
Products of combustion must not be allowed to enter the return air openings of the furnace or the circulating air supply. Failure to prevent products of combustion from being circulated into the living space can create potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death.
The floor or platform on which the furnace is mounted must provide sound physical support of the furnace with no gaps, cracks, or sagging between the furnace and the floor or platform.
The circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert, stove, etc.
GENERAL
Plenums and air ducts must be installed in accordance with the Standard for the Installa­tion of Air Conditioning and Ventilating Systems (NFPA No. 90A) or the Standard for the Instal­lation of Warm Air Heating and Air Conditioning Systems (NFPA No. 90B).
Table 4. Minimum Clearances
7
RETURN AIR PROVISIONS
(mm)
U.S.A. home manufacturers shall comply with all of the following conditions to have accept­able return air systems for closet installed forced air heating appliances: a. Regardless of the location, the return air
opening into the closet shall not be less than specified in the appliance’s listing.
b. Means shall be provided to prevent inadvert-
ent closure by a flat object placed over the return air opening when it is located in the floor of the closet (versus the vertical front or side wall).
c. Closet installations must use a louvered
door having a minimum free area of 235 sq. in. when located 6” from furnace. For clear­ance between 1” and 6” from furnace, re­quirements are a louvered door with mini­mum of 235 sq. in. free area, with the open­ings in closet door directly inline with the louvered openings in the furnace door. For 1” clearance from furnace, use a fully lou­vered door with at least 400 sq. in. of free airflow area.
d. The cross-sectional area of the return duct
system leading into the closet, when located
in the floor or ceiling shall not be less than 235 square inches.
e. The total free area of openings in the floor or
ceiling registers serving the return air duct system must be at least 352 sq. in. At least one register should be located where it is not likely to be covered by carpeting, boxes and other objects.
f. Materials located in the return duct system
must have a flame spread classification of 200 or less. This includes a closet door if the furnace is in a closet.
g. Noncombustible pans having 1" upturned
flanges are located beneath openings in a floor duct system.
h. Wiring materials located in the return duct
system shall conform to Articles 300-22 of the National Electrical Code (ANSI C1/ NFPA-70).
19”
13 1/4"
10 1/4"
T op View
19"
Connector
of Duct
A Single trunk duct
Dual trunk duct
B
w/crossover connector
Transition duct w/branches
C
Figure 2. Non-Platinum
Supply Duct System
If "X " (Fl o or Cavi ty) is: Model P ar t Num b er:
English Metric
10 1/4" 260 901992 904013 12 1/4" 311 901993 904014
FLOOR CAVITY (depth equal to "X" in Figure 5 and Table 5)
x
SUPPLY AIR DUCT
Figure 4.
Use Duct Connecto r
Fin ger Tab Screw Down
7/8" 22 901987 904008
2" 51 901988 904009 4 1/4" 108 901989 904010 6 1/4" 150 901990 904011 8 1/4" 210 901991 904012
Table 5. Duct Connectors
Figure 3.
8
FELT-SEAL(
SPACERS
REDUCER
1
)
(1) FINGER TAB DUCT CONNECTOR ONLY (2) SCREW DOWN DUCT CONNECTOR ONLY
C
Figure 5.
( )OPENING TO DUCT
(1) WITH PLATE (C) REMOVED OPENING BECOMES 13-1/4” x 13-1/4” (2) WITH PLATE (C) REMOVED OPENING BECOMES 13" X 13". WITH REDUCER IT IS 13" X 10-1/8".
SEE
X
TABLE 5
SIDE WALL
ALT. FUEL LINE HOLES
C
L
FUEL LINE HOLE
Figure 6. Closet or Alcove
i. Gas piping is not run in or through the return
duct system.
j. Test the negative pressure in the closet with
the air-circulating fan operating at high speed and the closet closed. The negative pressure is to be no more negative than minus 0.05 inch water column.
k . For floor return systems, the manufactured
home manufacturer shall affix a prominent marking on or near the appliance where it can be easily read when the closet door is open. The marking shall read:
!
CAUTION:
HAZARD OF ASPHYXIATION: Do not cover or restrict return air opening.
l. Air conditioning systems may require more
duct register and open louver area to ob-
REAR WALL
10"
C
FLOOR OPENING
L
23 -1/4"
tain necessary airflow. Use NORDYNE’s certiduct program to determine proper duct size for A/C.
DUCTED RETURN AIR
M3 furnaces with model numbers ending in AW or BW are factory configured for the return air to flow through the front louvered door. The return air may also be attached to either side or the top of the furnace cabinet using a field installed kit. Refer to Table 12 for the NORDYNE ducted return kit P/N number. The location and size of the side and top return air connections are shown in Figure 1. The filter size for the side return air is 20” x 20” x 1”. For top return the filter size is 24” x 16” x 1”.
M3 furnaces with model numbers ending in BWT are factory configured for the return air to enter the top of the furnace.
9
2-1/4
14-1/2
20
14-1/2
2-3/4
REAR WALL OF CLOSET OR ALCOVE
FLOOR CUT-OUT
FOR DUCT CONNECTIONS
FURNACE OUTLINE
17-29/32
23-1/4
21-3/4
˚
1-1/4
ALT FUEL LINE
ENTRY
24
Figure 7. Cut-Out Locations
AIR DISTRIBUTION SYSTEMS
For proper air distribution, the supply duct system must be designed so that the static pressure measured external to the furnace does not exceed the listed static pressure rating shown on the furnace rating plate.
Three typical distribution systems are illus­trated in Figure 2. Location, size, and number of registers should be selected on the basis of best air distribution and floor plan of the home.
21-7/16
10
12-7/8
14-3/4
15-1/2 FLOOR CUT-OUT
FOR OPTIONAL
COOLING COIL
FOR NON-PLATINUM
SERIES UNITS
3-19/32
1-3/4
VENT
COMBUSTION AIR INTAKE
FUEL LINE ENTRY
2
1-3/4
FURNACE
OUTER DOOR
cavity. To maximize air delivery, re­move reducer “C” (see Figure 5) to obtain the largest open area that will fit the duct/floor construction.
DUCT INSTALLATION
Required floor, ceiling, and roof cut-out open­ings must be carefully located to avoid mis­alignment of the furnace (see Figures 6 & 7). Installation procedures are suggested for typi­cal furnace installations and need not be fol­lowed in the exact listed sequence.
DUCT CONNECTOR SELECTION
PLATINUM SERIES
a. For Platinum ready construction use
the 14” round plenum, p/n: 903896.
NON-PLATINUM SERIES
a. Determine depth of floor cavity from
surface of floor to top of supply air duct (See Figure 3).
b. Select appropriate model from Table 5
which matches X-dimension of the floor
10
CUT OUT FLOOR OPENING & FUEL LINE HOLE
a. Determine center of closet or alcove (Fig-
ures 7 & 8).
b. Locate center of the floor opening, mea-
sured 10" from the rear wall, and mark cut­out measuring approximately 14-1/2" by 14­1/2" (± 1”) for model duct connector used (refer to Figures 4 & 5).
c. Locate center of gas line hole, measured 23-
1/4" from the rear wall and 6-5/8" to the left of center of the floor cut-out (See Figure 6) or
REAR W
ALL
SUPPLY AIR DUCT
FUEL LINE HOLES
MOUNTING PLATE
FLOOR OPENING
BEND CONNECTOR TABS UNDER DUCT OPENING
5-1/4" to the left of center of the floor cut-out, or for entry through right-side of furnace measured 9" to the right of center of the floor cut-out.
d. Cut out floor opening and one gas line hole.
INSTALLING PLATINUM SERIES 14” ROUND DUCT CONNECTOR
a. Place duct connector through the floor open-
ing. (See Figure 9).
b. Secure duct connector to floor.
CUT DUCT OPENING (FINGER TABBED ONLY)
a. Place duct connector through the floor open-
ing with bottom tabs resting on top of the supply air duct.
b. Center duct connector and push back against
rear edge of floor opening.
c. Mark cut-out location (tab area) and remove
duct connector.
d. Cut out duct opening 1/16" larger than area
marked.
INSTALL FURNACE MOUNTING PLATE
a. Place mounting plate (supplied within duct
connector) at rear of the floor opening (See Figure 9).
MOUNTING PLATE
FLOOR OPENING
INSTALLING SCREW DOWN DUCT CON­NECTOR
a. Apply a bead of caulking, mastic, or other
approved sealant around bottom side of 1/2” flange and restrictor plate, when applicable.
b. Locate the duct connector over duct and
carefully lower screw down duct connector into place.
c. Once duct connector is located on duct,
temporarily hold in place while fastening duct connector to the floor using flat head screws or nails. Be sure flanges of duct connector stay in contact with the duct.
d. Screw plenum to duct making sure a seal is
made between the duct and the duct con-
REAR WALL
FUEL LINE HOLES
Finger Tabbed
Duct Connectors
SUPPLY AIR DUCT
Figure 8. Mounting Plate
SCREWS
MOUNTING PLATE
FLOOR OPENING
FUEL LINE HOLES
SUPPLY AIR DUCT
Screw Down
Duct Connectors
Figure 9. Duct Connector
PLENUM
MOUNTING PLATE
SCREWS
Platinum Series
FUEL
LINE
HOLES
14” SUPPLY CONNECTION
11
nector. Additional screws may be added if required.
e. Cut away along edge of flange allowing the
center to drop into the duct. Remove section of duct with caution, as edges will be sharp.
INSTALLING FINGER TABBED DUCT CON­NECTORS
a. Place duct connector through the floor open-
ing with bottom tabs extending through the
duct opening. (See Figure 9) b. Secure duct connector to floor. c. Bend bottom tabs under and up tightly against
the supply air duct (See Figure 10). NOTE: The duct connector is designed for use
on ducts 12" in width. When using the connec­tor on 12" wide ducts, there may be insufficient clearance to bend the tabs on two sides of the duct connector. In such cases the tabs may be
TABS TABS
attached to the sides of the duct by using sheet metal screws or other suitable fasteners. (See Figure 11).
If sealant, mastic, or tape is used to provide a better seal, it should be approved by applicable national or local codes.
ALTERNATE ATTACHMENT METHODS
This procedure may also be used to install a furnace duct connector to narrow metal ductwork where insufficient clearance prevents bending of the duct connector tabs at the side(s) of the duct. (See Figure 12).
1. Score and cut the top of the metal duct as indicated in Step 1 or Step 2. With Step 1 choice, also cut out the metal from the shaded area “A”.
2. Fold the duct flap “B” up, (See Step 3).
1. INSERT DUCT PLENUM CONNECTOR INTO DUCT CUT-OUT.
STEP 1.
Fold Back Flap "B"
Cut- Out
Area "A"
Bend Duct Connector Tabs Up
and Over- (along length of duct)
DUCT DUCT
2. BEND BOTTOM TABS OVER AND ONTO THE UNDERNEATH DUCT SERVICE.
Figure 10. Installation of Duct Connector
Duct Connector
Narrow Duct
Duct
Figure 11. Narrow Duct Installation
STEP 2.
Fold Back Flap"B"
Cut
"B"
"A" "A"
"A" "A"
"B"
Fold Back Flap "B"
Cut- Out Area"A"
Top of Duct
Lines Duct
Staple Folded Duct
Flap (typ) to side of Duct
Connector
"B"
"B"
Fold Back Flap"B"
12
STEP 3.
Duct
Duct Flap "B"
Figure 12. Alternate Installation
STEP 4.
Duct
MTG. PLATE TABS
SECURE FURNACE
WITH 2 FASTENERS AT FRONT
CORNER HOLES
SLIDE FURNACE
ALL THE WAY BACK
ONTO MTG. PLATE
NOTE: Additional fasteners may be used at rear, sides or through door frame, as desired, to secure furnace to closet or alcove framing.
VENTING AND COMBUSTION AIR REQUIREMENTS
Knockout Over Holes
S
UPPLY AIR
D
UC
T
Figure 13. “A”, “B”, & Platinum
Cabinet Furnaces
SLIDE FURNACE
ALL THE WAY BACK
ONTO MTG. PLATE
FUEL LINE HOLES
MTG. PLATE TABS
SECURE FURNACE
WITH 2 FASTENERS
AT FRONT CORNER HOLES
SUPPLY AIR DUCT
Figure 14. “A” Cabinet Furnace on 911969
Coil Cabinet (Non-Platinum Series)
3. At the front-to-back of duct run (Area “A”), bend the duct tabs and secure them directly to the duct.
4. At Area “B”, bend the duct tabs up and back over, around the duct connector, (See Step 3).
5. Fold/form the duct flap against the side of the duct connector and attach as shown, (See Step 4). Use three (3) staples (minimum) on each duct flap OR, if a 2X block/joist is not provided, use two (2) sheet metal screws (minimum) on each duct flap. An alternate attachment method is acceptable, as long as the plenum is securely attached.
6. Tape the duct flap edges with an approved tape for a leak-free joint.
!
CAUTION:
Snow must not be allowed to restrict or block the combustion air intake or vent pipes.
General
NORDYNE condensing furnaces must be installed with outdoor combustion air piped directly to the furnace. Codes refer to this type of installation as direct vent, or two pipe installation.
Provisions must be made for adequate supply of air for combustion and ventilation. For United States installations, the adequacy of air provisions can be determined by consulting the current version of the National Fuel Gas Code (ANSI Z223.1/NPFA-54). For Canadian installations, requirements are specified in the National Standard of Canada (CAN/CGA B149.1 & .2). Consult local codes for special requirements.
NOTE: If the furnace is operated without adequate air for combustion and ventilation, it may not perform properly. Furnace components may be strained by high temperature and could fail prematurely.
!
WARNING:
The combustion air piping must not be blocked or restricted in any manner.
INSTALL FURNACE
a. Remove furnace outer door(s) and bottom
fuel line knockout.
b. Place furnace onto duct connector and cen-
ter with floor opening.
c. Slide onto mounting plate. (Bottom rear slots
on furnace should engage with mounting plate tabs.)
d. Secure front with one (1) fastener at each
corner (See Figure 13 or 14).
!
WARNING:
Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code and all applicable local codes to provide sufficient combustion air for the furnace.
13
!
CAUTION:
Do not allow debris to fall into the fur­nace. This could cause unsafe opera­tion and voids the furnace warranty.
VENTING REQUIREMENTS
!
WARNING:
FURNACE MUST NOT BE COMMON VENTED WITH OTHER APPLIANCES.
General
This section specifies installation requirements for 2-pipe combustion air piping. The capacity table provided in this section applies to the maximum equivalent lengths of vent and combustion air intake pipe.
These condensing furnaces are classified as "Category IV" appliances, which require special venting materials and installation procedures. Category IV appliances operate with positive vent pressure and therefore require vent systems which are thoroughly sealed. They also produce combustion condensate, which is slightly acidic and can cause severe corrosion of ordinary venting materials. Furnace operation can be adversely affected by restrictive vent and combustion air piping. Therefore,
piping lengths must conform completely to the requirements of Table 6.
The furnace must be vented to the outdoors.
!
WARNING:
CARBON MONOXIDE POISONING
1. Seal any unused openings in the venting system
2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1 or the CAN/CGA B149 Installation Codes and these instructions. Determine
vent and combustion air
HAZARD
that there is no blockage or re­striction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
3. So far as is practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.
4. Follow the lighting instructions. Place the appliance being inspected in operation. Adjust thermostat so appliance shall operate continuously.
5. Turn on clothes dryers and any other appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they shall operate at maximum speed. Do not operate a summer exhaust fan.
6. Close fireplace dampers.
7. Test for spillage from draft hood equipped appliance at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.
8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the
National
Fuel Gas Code, ANSI Z223.1/NFPA
and/or
54
CSA B149.1, Natural Gas
and Propane Installation Codes.
9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use.
It must not be vented in common with any other appliance, even if that appliance is of the condensing type. Common venting can result in severe corrosion of other appliances or their venting and can allow combustion gases to
14
MAXIMUM
y
g
y
g
y
APPLICATION
PV C,CPVC or ABS
DIRECT VENT, DUAL
PIPE LENGTH (ft.)*
Inlet/Outlet
SCH. 40 P i p e S ize 3" 3"
Model M3RL 060 Model M3RL 080
50 50 50 50
*NOTES
1. Subtract 3.5 ft. for each additional 3" 90 degree elbow.
2. Two 45 degree elbows are equivalent to one 90 degree elbow.
3. One short radius elbow is equivalent to two long radius elbows.
4. Do not include termination elbows in calculation of vent length.
5 . This table is applicable for elevations from sea level to 4000
ft. For higher elevations, decrease vent pipe lengths by 8% per 1000 ft. of altitude.
6. Only the above pipe materials are approved for use with these condensing furnaces.
Table 6. Vent Table
VENT TERMINAL
Clearance above grade, veranda, porch,
A =
deck, or balcony Clearance to window or door that may be
B =
opened
Clearance to perm anent l
C =
Verti c al clearance to ventilat ed soffi t
D =
locat ed above the termi nal wi t hin a horizont al distance of 2 feet (61 cm) f rom the cent er l i ne of t he t erm inal Clearance to unventilat ed soffi t
E =
Clearance to outside corner
F =
Clearance to i ns i de corner
G =
Clearance to each side of center line
H =
extended above meter/re Clearance to servic e regulator vent out let 3 feet (1. 83 m )
I =
Clearance to nonm ec hani cal air supply inlet
J =
to buildi ng or t he c om bus tion air inlet t o any other appliance
Clearance to a m ec hani cal air suppl y inl et 6 f eet (1.83 m) 3 feet (91 c m ) abov e i f wi t hin 10 f eet (3 m)
K =
Clearance above paved sidewalk or pav ed
L =
driveway located on public propert y Clearance under veranda, porc h dec k, or
M =
balcony
1
In accordance with the current CSA B149.1
2
In accordance with the current ANSI Z223.1 / NFPA 54
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family
dwellings and serves both dwellings. ‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor. * For clearances not specified in ANSI Z223.1 / NFPA 54 or CSA B149.1, the following statement shall be included:
“Clearance in accordance with local installation codes, and the requirements of the gas supplier and the
closed window
ulator as sembl
AIR SUPPLY INLET
Canadian I n stal lations
12 inches (30 c m ) 12 inches (30 c m )
6 inches (15 c m ) f or appli ances ≤ 10,000 Btuh (3 k W), 12 i nc hes (30 cm) for applianc es > 10,000 Btuh (3 k W) and ≤ 100,00 Bt uh (30 k W), 36 i nc hes (91 cm) for applianc es > 100, 00 Btuh (30 kW)
3 feet (91 cm) withi n a height 15 feet above the m eter/re
6 inches (15 c m ) f or appli ances ≤ 10,000 Btuh (3 k W), 12 i nc hes (30 cm) for applianc es > 10,000 Btuh (3 k W) and ≤ 100,00 Bt uh (30 k W), 36 i nc hes (91 cm) for applianc es > 100, 00 Btuh (30 kW)
7 feet (2.13 m) †
12 inches (30 c m ) ‡
Natural Gas and Propane Installation Code
manufacturer’s installation instructions.”
National Fuel Gas Code
AREA WHERE TERMINAL IS NOT PERMITTED
1
**
**
** ** **
ulator as sembl
US Installations
6 inc hes (15 cm) for appliances ≤ 10,000 Btuh (3 k W), 9 i nc hes (23 cm) for applianc es > 10, 000 B tuh (3 kW) and ≤ 50,000 Bt uh (15 k W), 12 i nc hes (30 cm) for applianc es > 50, 000 B tuh (15 kW)
6 inc hes (15 cm) for appliances ≤ 10,000 Btuh (3 k W), 9 i nc hes (23 cm) for applianc es > 10, 000 B tuh (3 kW) and ≤ 50,000 Bt uh (15 k W), 12 i nc hes (30 cm) for applianc es > 50, 000 B tuh (15 kW)
horizontally
2
* *
*
*
Figure 15. Vent Termination Clearances for Direct Vent Furnaces
15
escape through such appliances or vents. Do not vent the furnace to a fireplace chimney or building chase.
!
CAUTION:
If removing an existing furnace in a venting system, the venting system may not be properly sized. To test the vent system with the remaining appliances, follow the test outlined below.
The following steps shall be followed with each appliance connected to the venting system placed in operation, while any other appliances connected to the venting system are not in
operation:
Vent Pipe Material
Vent and combustion air pipe and fittings must be one of the following materials and must conform to the indicated ANSI/ASTM standards:
Material Standard
Schedule 40 PVC D1785
PVC-DWV D2665
SDR-21 D2241 & SDR-26 ABS-DWV D2661
Schedule 40 ABS F628
Foam/Cellular Core PVC F891 Cement and primer must conform to ATSM
Standard D2564 for PVC and Standard D2235 for ABS. When joining PVC piping to ABS, use an appropriate solvent cement and procedure per the piping manufacturer's recommendation and ASTM Standard D3138.
Vent Pipe Installation
Pipe Routing and Support
Route piping as directly as possible between the furnace and the outdoors and remember that routing affects pipe length limitations per Table 6. Locate the combustion air intake and the vent exhaust in the same atmospheric pressure zone - i.e. both must exit the building though the same portion of exterior wall or roof. Vent piping must be sloped upwards not less than 1/4" per foot in the direction from the furnace to the terminal. This is to ensure that any condensate flows back to the furnace where it can be disposed of through the condensate disposal system.
Combustion air must not be drawn from occupied spaces and a corrosive atmosphere.
The quality of outdoor air must also be considered. Be sure that the combustion air intake is not located near a source of solvent fumes or other chemicals which can cause corrosion of the furnace combustion system.
Piping must be mechanically supported so that its weight does not bear down on the furnace. Supports must be at intervals no greater than five feet, and at smaller intervals if necessary to ensure that there are no sagging sections to trap water (See Figures 16 & 17).
These condensing furnaces have been certified for installation with zero clearance between vent piping and combustible surfaces. However, it is good practice to allow space for convenience in installation and service.
Location of Outdoor Terminations
Vent and combustion air intake terminations must be located to ensure proper furnace operation and to conform to applicable codes. Figure 15 illustrates necessary distances from the vent termination to windows and building air intakes. In Canada, the Canadian Fuel
Gas Code takes precedence over these instructions. Specifically, all minimum distance requirements with respect to termination of the vent piping listed below.
The following list is a summary of vent terminal location requirements:
1. The termination must be 12 inches above snow level or grade level whichever is higher. See Figure 18 for alternate method to achieve 12" above snow level.
2. The minimum distance for a direct vent (2-pipe) installation from any door, openable window, or air gravity inlet is 1 ft. below, 1 ft. horizontally, or 1 ft. above.
3. The vent termination shall be a minimum of 3 ft. above any forced air inlet within 10 ft.
4. The vent termination shall be located at least 4 ft. horizontally from any electric meter, gas meter, regulator and any relief equipment. These distances apply ONLY to U.S. installations. In Canada, the Cana­dian Fuel Gas Code takes precedence.
16
Downflow Furnace
Seal/Caulk
Around Pipe
at Building
90˚ Elbow
12"
Min.
Normal Snow Level
Combustion
See Vent T able 4
Straps or Other Suitable Supports at Minimum of
Coupling
Upward Pitch - 1/4" Per Foot
Wall
First Support Should be as Close to
Outlet Exhaust Vent
Furnace Connection as Possible
Combustion Air
Intake Pipe
Air Intake Pipe
5 ft. Intervals
Furnace
Figure 16. Horizontal Venting
Vent
3 9/16"
Top View
1 7/8"
3 1/2"
6"
Offset with Vent for Adequate Dimensional Clearance
Exhaust Vent PVC or ABS pipe
3" x 2" Reducer
Support System
on Vertical Rise
Below Joints
Combustion Air Intake Pipe
Vent
Figure 17. Vertical Venting
5. Avoid areas where condensate drainage may cause problems by dropping on plant­ers or patios, etc. Also ensure that ex­haust gases will not impinge on windows or building surfaces, which may be com­promised or damaged by condensation. Do not install the vent terminal such that exhaust is directed into window wells, stairwells, under decks or into alcoves or similar recessed areas, and do not termi­nate above any public walkways.
First support should be as close to furnace as possible
5'
Vent
Upward Pitch
Combustion Air Intake
Pipe
1/4" per foot
6. Select the point of wall penetration where the minimum 1/4 inch per foot of slope up can be maintained.
!
CAUTION:
For optimal performance vent furnace through wall which experiences the least exposure to winter winds.
17
Horizontal Venting
Vent and combustion air intake terminations must be as shown in Figure 19 unless the concentric vent termination kit is used.
!
WARNING:
Ensure that the combustion air vent and the exhaust vent are configured as shown in Fig. 19. Improper vent termination can cause recirculation of the flue gases. This may result in furnace vibration. In severe cases, the furnace will cycle, due to the intermittent contact between the flame and the flame sensor. If you note these oscillations occurring, check the vent configuration. Make sure that the exhaust vent does not have a 90 degree termination.
For horizontal venting, either the Horizontal Exterior Vent Mounting Kit or the Concentric Vent Termination Kit may be used (See Table
12). For Canadian installations please refer to the
Canadian Installation Code (CAN/CGA-B149.1 or 2) and/or local codes.
The Horizontal Exterior Vent Mounting Kit con­sists of two face plates and an insulating gas­ket to seal the exterior surface. A hole sized closely to the pipe diameter must first be cut through the wall. A short length of pipe is then cut such that it can penetrate the wall and be held in place by closely fitting standard cou­plings. The face plates are retained on both sides of the wall by the couplings, and the gasket is retained against the wall by the outer face plate. Face plates must be fastened to the wall and the outside one must be flashed as appropriate to prevent entry of water.
When the above kits are not used the following steps are required:
1. Check the hole size cut through the exte­rior wall. Insure that the hole diameter is less than the diameter of the couplings to be used.
2. Extend the vent pipe through the wall approximately 1" and seal the area be­tween the wall and pipe.
3. Apply couplings to the vent pipe on the interior and exterior sides of the wall to insure the pipe can not be pushed or pulled through the wall.
4. Insure the combustion air inlet pipe has a 90 degree termination elbow, and is pointing downward as shown in Figures 19 & 20.
Note that a combustion air intake must be provided with an elbow opening downward.
When the vent pipe must exit an exterior wall close to the grade or expected snow level, a riser should be provided as shown in Figure 18. Insulation is required to prevent freezing of this section of pipe.
Vertical Venting
For vertical venting, either the configuration shown in Figure 20 or the Concentric Vent Termination Kit may be used. Vertical venting is one of the shortest routing methods when piping vents for furnaces. The M3 furnace operates trouble-free when the furnace is in­stalled with a shorter vent.
•The inlet for the combustion intake pipe must
be extended at least one foot above the roofline or snow accumulation level.
•The outlet of the vent must be extended at least
10 inches above the inlet of the combustion air intake pipe.
•The vent as well as the combustion air intake
pipe should be located on the same side of the roof. Both pipes must not be closer than 5 inches apart. They should not be separated
more than 36 inches. The roof penetration must be properly flashed and waterproofed with a plumbing roof boot or equivalent flashing. Termination spacing re­quirements from the roof and from each other must be per Figure 20.
Concentric Vent Termination
A concentric vent termination is approved for use with these furnaces (See Table 12). For proper installation of the concentric vent termi­nation, follow the installation instructions pro­vided with the kit.
18
Vent Configuration to Provide 12" Minimum height above Snow Level.
Outside Wall
12" Min.
19" Max.
Support
1/2" Armaflex Insulation or Equivalent (if required)
12" Above Normally Expected Snow Level
Exhaust Vent
Option B
Mounting Kit
Faceplate Secured
to Wall with Screws
Combustion
Air Inlet
Exhaust Vent
Option C
7" Min.
12" Min. 36" Max.
12" Min. 36" Max.
12" min.
36" max.
12" Min. to
Normal Snow Level
Exhaust Vent
8" Min.
Exhaust
Inlet
Option A
Grade Level or Normal Snow
Figure 18. Alternate Horizontal
Vent Installation
DRAINAGE OF CONDENSATE FROM FURNACE
!
WARNING:
The condensate produced by the furnace must be drained. Do not connect a water supply to the drainage hose of the furnace.
NOTE: The condensate drain should be pro-
tected from freezing when in unheated spaces. The furnace is supplied with an internal conden-
sate drain trap.
Figure 19. Exhaust and Combustion Air
Pipe Clearances
!
CAUTION:
Do not install additional traps in the condensate drain.
The condensate drain may exit through the left side panel, the right side panel, or through the left or right hole on the bottom panel. (See Figure
21). Ensure that the flexible drain hose is not kinked.
The condensate should drain from the plastic collector box (location A in Figure 21) as drop­lets or a small stream. If you notice the furnace has operated for more than 5 minutes without draining or the red status light on the control board is pulsing a 2-blink code follow the steps below.
A= 12" Above Roof or
Snow Accumulation Level
Elbow
10" Min.
A
5" Min.
36" Max.
Exhaust
Vent
Note: If terminations meet-
ing these vertical require­ments exceed the maximum
Combustion
Air Intake
1"
height for safe transit, the vent and combustion air in­takes may be shipped with the home for assembly on site. The furnace must be labeled to notify the installer/ user not to use the furnace
Exhaust
Plumbing Vent Roof Boot (Typ. Both Pipes)
until the vent and combus­tion air intake terminations are installed.
Figure 20. Vertical Vent Termination
19
A
Collector Box
Burner Box
A
Clamp
Step 1: Loosen Step 2: Rotate to drain direction Step 3: Retighten
“Hard” J Drain T ube
Floor
Alt. Drain
Alt. Drain
Floor Cavity
Alt. Drain
Figure 21. Furnace with Condensate Drain Trap Assembly
1. Remove the collector box soft tube at location A in Figure 21 and insure the exit from the collector box is clear of any debris or obstructions.
2. Replace this tube and insure the fit to the header spout is air tight. Air will be drawn into the header if this connection is not tight.
3. Check other tube connections along the drain system. Insure that all are air tight.
NOTE: Industry research studies indicate that when condensate is routed to an active drain, household detergents, etc., buffer its acidity. If the drain is not actively used or if codes require, obtain a neutralizer kit (See Table 12). Proper drains and connections to the condensate tub­ing are required as NORDYNE cannot be held responsible for water leakage which occurs due to loose hose connections or improperly sealed drain line pipes.
GAS SUPPLY AND PIPING
General
This furnace is equipped for bottom, left, or right side gas entry. Typical gas service hook­ups are shown in Figure 22. When making the gas connection provide clearance between the gas supply line and the entry hole in the furnace casing to avoid unwanted noise and/or damage to the furnace.
Keep Downward Slope
Alt. Drain
readily accessible for service and/or emer­gency use. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut-off. In the absence of local codes, the gas line instal­lation must comply with the provisions stated in the Federal Manufactured Home Standard (H.U.D Title 24, part 280) and the National Fuel Gas Code (ANSI Z223.1/NFPA-54) or (CAN/ CGA B149) installation codes.
A drip leg should be installed in the vertical pipe run to the unit. Table 7 lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pres­sure drop in the line.
NOTE: Gas piping must not be run in or through air ducts, gas vents, etc.
Compounds used on threaded joints of gas piping must be resistant to the actions of lique­fied petroleum gases.
!
CAUTION:
Do not use matches, lighters, candles, or other sources of open flame to check for gas leaks.
All gas piping must be installed in compliance with local codes and utility regulations. Some local regulations require the installation of a manual main shut-off valve and ground joint union exter­nal to the furnace. The shut-off valve should be
20
NOTE: When pressure testing gas supply lines at pressures greater than 1/2 psig (14 in. water column), the furnace must be discon­nected from the gas supply piping system to prevent damage to the gas control valve.
Main Blower
Control Board
CONVERSION
This furnace can be converted from the fac­tory-equipped gas to either natural gas (for LP gas ready models), or LP gas (for natural gas ready models). Conversions must be made by qualified service personnel, using only factory authorized or approved parts. The required conversion orifices are supplied with the fur­nace.
!
WARNING:
Inducer
Burner Box
Gas Valve
Floor
Floor Cavity
Alt. Gas To Gas Supply
Line Entry
Figure 22. Typical Gas Piping
If the test pressure is less than or equal to 1/2 psig (14 in. water column), the furnace must be isolated from the gas supply line by closing the manual shut-off valve.
Leak Check
After the gas piping to the furnace is complete, all connections must be tested for gas leaks. To check for leaks use only a soap and water solu­tion or other approved method.
High Altitude Derate
The nameplate input rating for the furnaces apply for elevations up to 4,000 feet above sea level for US and Canada. If the elevation for the furnace location is higher than 4,000 feet above sea level, the furnace input must be derated by using the appropriate orifice size listed in Table 8.
NOTE: The density of air decreases with in­creasing elevation above sea level. This re­duces the quantity of combustion air drawn into the furnace under normal operation and requires the unit be derated by using smaller gas orifices or lower manifold pressure.
DO NOT REMOVE OR DEFACE THE ORIGINAL RATING PLATE.
!
CAUTION:
The gas supply shall be shut off prior to disconnecting the electrical power, before proceeding with the conversion.
To Turn Off Fuel Supply to the Appliance:
1. Set the room thermostat to “OFF” or its lowest temperature setting.
2. Turn OFF the main gas supply to the appli­ance at the manual valve, outside of the appliance casing.
3. Remove the control access panel / lou­vered door.
4. Move the appliance gas valve lever/knob to the “OFF” position.
5. Turn OFF the electrical power to the appli­ance.
CAPACITY OF BL A CK IRON GAS P IPE ( CU. FT. P ER HOUR)
FOR NAT URAL G AS (SPECIFIC GRAVI TY - 0.6 0 )
NOMINAL LENGTH OF PIPE RUN
BLACK IRON (feet)
PIPE DIAMETER
(in.) 1020304050607080
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 1050 730 590 500 440 400 370 350 1 1/2 1600 1100 890 760 670 610 560 530
The cubic feet per hour listed in the table above must be greater than the cubic feet per hour of gas flow required by the furnace.
To determine the cubic feet per hour of gas flow required by the furnace, divide the input rate of the furnace by the heating value of the gas:
Cubic Feet Input To Furnace (Btu/hr) Per Hour Required Heating Value of Gas (Btu/Cu. Ft.)
Table 7. Capacity of Black Iron Gas Pipe
(cu. ft. per hour) for Natural Gas
=
(specific gravity = .60)
21
To Remove the Burner Assembly:
1. Follow the instructions “To Turn Off the Fuel Supply to the Appliance.”
2. Disconnect the flame sensor wire from the burner box.
3. Disconnect the ignitor wires at the 2 pin plug. This is a locking quick connect and both sides of the lower section must be depressed in order to be separated.
4. Remove the wires from the terminals of the gas valve.
5. Disconnect the rubber pressure tubes from the gas valve and the burner box.
6. Remove the burner access cover plate from the burner box.
7. Remove supply gas piping from the gas valve.
8. Carefully remove the burner assembly fas­teners and remove the burner assembly from the appliance. Keep the fasteners that were removed. Note that the burner box may have hooks near the top and on the right and left hand sides. To remove this type of burner box, lift the burner box upwards and then remove the box from the unit.
To Remove the Burner Orifices:
1. Remove the four (4) fasteners that secure the gas manifold to the burner box, as shown in Figure 25. Carefully remove the gas manifold assembly from the burner box. Note that the gas manifold assembly consists of the gas valve, the gas manifold, and the orifices.
2. Carefully remove the burner orifices from the gas manifold, as shown in Figure 25.
!
CAUTION:
Caution: Do not re-drill the burner orifices. If the orifice size must be changed, use only new orifices.
Note: The size of the new orifices that will be installed into the unit will depend upon the type of conversion (sea level or high altitude; natural gas or LP gas).
To Convert the Unit to the Alternate Gas
1. Remove the orifice bag from the manifold of the unit.
2. Install the appropriate gas burner orifices into the gas manifold. Remember if in­stalling at altitudes above 4,000 feet to install the proper orifices, shown in Table
8. When installing the new orifices, DO NOT use pipe joint compound on the orifice threads. Screw the orifices into the manifold by hand until snug to eliminate cross threading, then tighten with a wrench. Before installing an orifice, check the face or side of the orifice for the drill number to ensure that it is the appropriate size.
3. For the conversion to the alternate fuel, the gas valve regulator cap must be turned over, as shown in Figure 23. You will unscrew the cap and reinstall for your in­stallation. After reinstalling the cap, you will be able to read "NAT" for the conversion to natural gas or "LP for the conversion to LP gas.
Furnace
Model Number
M3RL -
060A-A/BW 60,000 4 50 57 50 57 51 58 51 58 52 59 080A-A/B W 80,000 5 49 1.15 mm 49 1.15 mm 50 57 50 57 51 58
Furnace Rating
Pl at e Input
(Btuh)
No. of
Burners
Elevation
0 - 2000
Nat LP Nat LP Nat LP Nat LP Nat LP
Elevation
2000-4000
Elevation
4000-6000
Elevation
6000-8000
Elevation
8000-10000
Table 8. Approximate Orifice Size for Natural and LP Gases
22
Reinstalling the Burner Assembly:
1. Reinstall the gas manifold assembly to the burner box with the four (4) fasteners, which were removed earlier.
2. Carefully reinstall the burner box into the unit. After installing the burner, inspect the alignment of the burners with the heat exchanger tubes. The center of the burn­ers should be aligned with the center of the tubes.
3. Reconnect the gas piping to the gas valve.
4. Reconnect the wires to the gas valve termi­nals.
5. Reconnect the rubber pressure tubes to the gas valve and the burner box. Reinstall the burner access cover plate.
6. Reconnect the ignitor at the 2 position plug.
7. Reconnect the flame sensor wire to the burner box.
Pressure Gauge Installation
Honeywell V alve
PRESSURE REGULATOR CAP
T
A
N
T
N
A
A
N
T
OR
N
A
T
Figure 23. Convertible Pressure
Regulator Cap
P
L
P
OTHER SIDE OF CAP
M11678
L
NOTE: For natural gas installations, the in­coming gas line pressure at the gas valve inlet must be between 4.5” WC and 10.0” WC. For LP gas installations, the incoming gas line pres­sure at the gas valve inlet must be between
11.0” WC and 14.0” WC. This pressure can be
checked at the inlet end of the gas valve using a pressure gauge or U-tube manometer, which must be installed according to the manufacturer’s supplied instructions.
LIGHTING AND ADJUSTMENT OF THE APPLIANCE
1. Turn ON the gas at the manual valve, outside of the unit.
2. Check all gas connections for leaks with a soap and water solution. If the solution bubbles there is a gas leak which must be corrected. Do NOT use an open flame to check for gas leaks.
3. Turn ON the electrical power to the appli­ance.
4. Move the gas valve lever/knob to the “ON” position. The lever/knob must be moved to the end of its range of motion to insure the valve is completely open. Use only your hand to push in or turn the gas control valve. Never use tools.
Figure 24. Burner Inspection
Burner Box
Burner Orifices
Inlet Pressure Tap
Inlet
Gas Manifold
On/Off Lever
Gas Valve
Flame
Observation
Port
Access
Cover
Plate
Figure 25. Typical Installation For Sealed
Burner Box With Access Cover Plate
5. Set the room thermostat to a point above room temperature to begin the heating cycle of the unit.
6. Check that the unit ignites and operates properly. Refer to the installation instruc­tions provided with your unit for the normal operating sequence.
23
7. After the flame ignites, visually inspect the burner assembly to ensure that the flame is drawn directly into the center of the heat exchanger tube, as shown in Figure 23. The end of the flame will be out of sight around the bend of the heat exchanger tube. In a properly adjusted burner assem­bly, the flame color should be blue with some light yellow streaks near the outer portions of the flame.
!
CAUTION:
To avoid electric shock, personal injury, or death, turn off the power at the disconnect or the main service panel before making any electrical connections.
NOTE: Until all of the air is bled out of the gas
line, the hot surface ignitor may not ignite the gas. If the ignition control locks out, turn the thermostat to its lowest setting and wait one minute then turn the thermostat to a point above room temperature and the ignitor will try again to ignite the main burners. This process may have to be repeated several times before the burners will ignite. Once the burners are lit, check all gas connections for leaks again with the soap and water solution. If the solution bubbles there is a gas leak which must be corrected. Do not use an open flame to check for gas leaks.
Manifold Pressure
The gas valve for the M3 furnace series is equipped with a special conversion pres­sure regulator cap. The pressure regulator cap is factory set. If the gas valve is con­verted from natural gas to propane gas or vise versa, the manifold pressure of the gas valve will be set to pressure listed in Table 9.
Type of Fuel Manifold Pressure
In. WC
ELECTRICAL WIRING
General
Electrical connections must be made in accor­dance with all applicable local codes and ordi­nances, and with the current revision of the National Electric Code (ANSI/NFPA 70).
For Canadian installations electrical connec­tions and grounding must be done in accor­dance with the current Canadian Electrical Code (CSA C22.1 Part 1) and/or local codes. If any of the original wire as supplied with the furnace must be replaced, it must be replaced with wire having a minimum temperature rating of 105°C. Refer to the furnace nameplate and Table 8 for electrical requirements.
Line Voltage Wiring
The line voltage (115 volt) to the furnace must be supplied from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace. See Table 10. An electrical switch should be readily accessible from and within sight of the furnace. See the Wiring Diagram label in the furnace for more details.
Natural Gas: 3.5 Propane (LP) Gas: 10.0
Table 9. Manifold Pressure
COMPLETING THE CONVERSION
1. Affix the gas valve conversion label found in the package with the orifices to the unit rating plate.
2. Run the appliance through a complete cycle to assure proper operation.
24
The furnace cabinet must have an uninter­rupted, unbroken ground to minimize injury should an electrical fault condition occur. The controls used in this furnace require an earth ground to operate properly. Acceptable meth­ods for grounding are electrical wire or conduit approved for electrical ground service. Do not use gas piping as an electrical ground.
NOTE: Proper line voltage polarity must be maintained in order for the control system to operate correctly. Verify that the incoming neu-
g)
g)
tral line is connected to the white wire and the incoming "hot" line is connected to the black wire in the furnace junction box. The furnace will not operate unless polarity and ground are properly connected. See Figure 26.
!
CAUTION:
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
Verify proper operation after servicing.
!
A TTENTION:
Lors des opérations d'entretien des commandes, étiqueter tous les files avant des les déconnecter. Toute erreur de câblage peut être une source de danger et de panne.
S'assurer du bon fonctionnement de l'appareil après tout entretien.
Low Voltage Wiring
Install the thermostat per the manufacturer's instructions. The low voltage (24 volt) connec­tions from the thermostat are made at the terminal strip on the control board in the furnace. See Figure 28 for the proper connections for heating only (two-wire) and heating/cooling (four-wire) applications. The recommended minimum wire gauge for thermostat wiring is shown in Table 10.
90
60
120
Status
COOL
EAC
Electronic Air Tap
(.5A@ 120 VAC)
TWIN
XFMR
180
L1
Common
Leads
Connect
Neutral
Lead of
Electronic
Air Cleaner
and/or Humidifier
Here.
R C Y G W
COM
24 V
3
6
9
2
5
8
1
4
7
EAC
Neutrals
HUM
63 52 41
Humidifier Tap
(.5A@ 120 VAC)
3 Amp Fuse
Unused Motor
Leads
M1M2M3
HUM
Blower Off
Timing
Flame Signal
Light (Yellow)
Light (Red)
HEAT
These motor speed taps are
not used for two-stage models
Figure 27. Blower Speed Tap Location
Furnace Cabinet Nominal Maximum Minimum Maximum Minimum Maximum
Input Width Electrical Operating Operating Furnace Wire Fuse or Circuit
(Btuh) (in.) Supply Voltage Voltage Amperes Gauge Breaker Amps*
60,000 19.75 115-60-1 127 103 9.7 14 15 80,000 19.75 115-60-1 127 103 9.7 14 15
Thermostat Wire Gauge
24 22 20 18
Recommended Thermostat Wire Length
2-wire (heatin
55 ft.
90 ft. 140 ft . 225 ft .
4 or 5-wire (coolin
25 ft. 45 ft. 70 ft.
110 ft .
* Time-delay fuses or HACR-type circuit breakers are required.
Table 10. Electrical Data
Field Supplied Fused Service
White (Neutral)
Green or Bare
Panel
Black (Hot)
(Ground)
Ground
Field Supplied Disconnect Within Sight of Furnace
Field Supplied
Panel Connector
Black White
Ground
Black
White
Field Line Voltage
Black White
Ground
Junction Box (may be internal or external to the furnace). These connections can be made in the field supplied disconnect at the furnace.
Wiring Factory Line
Voltage Wiring
Figure 26. Line Voltage Field Wiring
25
The thermostat must not be installed on an outside wall or any other location where its operation may be adversely affected. Adverse affects include radiant loading from fireplaces, sunlight, or lighting fixtures, and convective loading from warm air registers or electrical appliances.
To check the heat anticipator setting either:
1. Add the current draw of the system com­ponents; or
2. Measure the current flow on the thermostat R-W circuit after the circulating blower motor has started.
Set the heat anticipator according to the ther­mostat manufacturer's instructions for heat anticipator settings.
VENTILATION
A/C Condensing Unit
Condensing Unit
Control Box
R Y G W
Connect
R & W
For
Heating
Only
Room
Thermostat
NOTE: The "Y" terminal on the UTEC control board must be connected to the thermostat for proper cooling mode operation.
FIELD WIRING
Low Voltage Connections
R C Y G W
COM
3 Amp
24 V
3
6
9
2
5
8
1
4
7
EAC
HUM
Neutrals
Unused Motor Leads
HUM
63 52 41
Blower Off
Fuse
Flame Signal Light
Status Light
COOL
M1M2M3
Timing
(Yellow)
(Red)
HEAT
EAC
6090120
TWIN
XFMR
L1
Figure 28. Low Voltage Field,
Four-wire Heating/Cooling Applications
180
Ventilation must be provided for homes built to HUD Manufactured Homes Safety and Con­struction Standards. This ventilation can be sup­plied by the VentilAire III or VentilAire IV acces­sories. (See Table 12). Alternate means to pro­vide the ventilation air must meet the require­ments of all applicable local and federal codes.
For installation of the VentilAire III or IV, follow the instructions provided with the VentilAire kit.
START-UP AND ADJUSTMENTS
General
Prior to start-up, verify that:
1. The line voltage power leads are securely connected, that the polarity of the con­nections is correct, and that the furnace is properly grounded.
2. The thermostat wires (R, W, Y, and G) are securely connected to the correct leads on the terminal strip of the circuit board.
3. The natural gas line service pressure must not exceed 10.0 in. water column (0.36 psig), and must not be less than 4.5 in. water column (0.16 psig). For LP gas the line service pressure must not exceed 14 in. water column (0.51 psig), and must not be less than 11.0 in. W.C. (0.40 psig).
4. The roll-out and vent safety manual reset switches are closed. If necessary, press the red button to reset a switch. See Figure 26 for location. DO NOT install a jumper wire across a switch to defeat its function. If a switch reopens on start-up, DO NOT reset the switch without identify­ing and correcting the fault condition which caused the switch to trip.
5. The blower door is in place, closing the door switch in the line voltage circuit.
6. The gas line has been purged and all connections are leak tight.
Start-Up Procedure
1. Set the thermostat to the lowest setting.
2. Close the disconnect(s) to provide line voltage to the furnace.
3. Follow the procedures given on the oper­ating instructions label attached to the furnace.
4. Set the thermostat above room tempera­ture and verify the sequence of operation. (See the SEQUENCE OF OPERATION.)
26
5. After the furnace has run for approximately five minutes, set the thermostat below room temperature and verify steps 9 - 11 of the
SEQUENCE OF OPERATION.
Shut Down Procedure
In the event that the furnace must be shut down, follow this procedure:
6. See the "High Altitude Derate" section for additional information on firing rate at eleva­tions above 4,000 ft.
The gas valve regulator is set at a nominal value of 3.5 in. water column for use with natural gas. The manifold pressure must be set at 10.0 in. water column for use with LP gas.
1. Set the room thermostat to "OFF" or its lowest temperature setting.
2. Turn OFF the main gas supply to the appli­ance at the manual valve outside of the appliance casing.
3. Remove the control access panel / lou­vered door.
4. Move the appliance gas valve lever/knob to the “OFF” position.
5. Turn OFF the electrical power to the appliance.
Verifying Firing Rate
The firing rate must be verified for each instal­lation to prevent over-firing the furnace.
NOTE: The firing rate must not exceed the rate shown on the furnace rating plate. At altitudes above 4000 ft. it must not exceed that on the rating plate less 4% for each 1000 ft.
Use the following procedure to determine the firing rate:
1. Shut off all other gas fired appliances.
Verifying and Adjusting Temperature Rise
Verify that the temperature rise through the furnace is within the range specified on the fur­nace rating plate. Temperature rises outside the specified range could result in premature heat exchanger failure.
Place thermometers in the return and supply air stream as close to the furnace as possible. The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings. Adjust all registers and duct dampers to the desired position and run the furnace for fifteen minutes before taking any temperature readings. The temperature rise is the difference between the supply and return air temperatures.
For typical duct systems, the temperature rise will fall within the range specified on the rating plate with the blower speed at the factory recommended setting. If the temperature rise measured is outside the range specified, it may be necessary to change the blower speed. Lower blower speeds will increase the tem­perature rise and higher blower speeds will decrease the temperature rise.
2. Start the furnace and allow it to run for at least three minutes.
3. Measure the time (in seconds) required for the gas meter to complete one revolution.
4. Convert the time per revolution to cubic feet of gas per hour using Table 11.
5. Multiply the gas flow rate in cubic feet per hour by the heating value of the gas in Btu per cubic foot to obtain the firing rate in Btuh. Example:
Time for 1 revolution of a gas meter with a 1 cubic foot dial = 60 seconds.
From Table 11 read 60 cubic feet per hour of gas.
Heating value of the gas (obtained from gas supplier) = 1000 Btu per cubic foot.
Firing rate = 1000 x 60 = 60,000 Btuh.
The furnace is equipped with a multispeed motor. Heating and cooling speed selection is made by moving the leads on the integrated control board located in the furnace. The wiring diagram on the furnace and Figure 30 show the speed taps for adjusting motor speed.
If it is desired that the blower operate at the same speed for heating and cooling, tape off the terminal of the unused blower wire. Install the jumper wire, found in the plastic instruction bag, across the HEAT and COOL taps on the control board. Reconnect the desired blower tap to the piggyback quick connect.
The blower control is designed to start the circulating air blower 30 seconds after the gas valve is opened. The blower control is factory wired to turn the blower motor off 120 seconds
27
GAS F L O W RAT E (CUBIC FEET PER HOUR)
TIME FOR TIME FOR
ONE REVOLUTION ONE REVOLUTION
(SECONDS) 1 5 10 (SECONDS) 1 5 10
24 150 750 1500 80 45 225 450 26 138 692 1385 82 44 220 439 28 129 643 1286 84 43 214 429 30 120 600 1200 86 42 209 419 32 113 563 1125 88 41 205 409 34 106 529 1059 90 40 200 400 36 100 500 1000 92 39 196 391 38 95 474 947 94 38 191 383 40 90 450 900 96 38 188 375 42 86 429 857 98 37 184 367 44 82 409 818 100 36 180 360 46 78 391 783 102 35 176 353 48 75 375 750 104 35 173 346 50 72 360 720 106 34 170 340 52 69 346 692 108 33 167 333 54 67 333 667 110 33 164 327 56 64 321 643 112 32 161 321 58 62 310 621 114 32 158 316 60 60 300 600 116 31 155 310 62 58 290 581 118 31 153 305 64 56 281 563 120 30 150 300
CUBIC FEET PER REVOLUTIO N OF
METER
CUBIC FEET PER REVOLUTIO N OF
METER
Table 11. Gas Flow Rate
after the gas valve is closed. This timing can be changed using the BLOWER OFF timing switch opposite the terminal block on the control board (See Figure 27).
Verifying Burner Operation
To verify operation of the burners, remove front door and ensure that the door switch is in the “on” position (see Figure 29). Set the thermostat above room temperature and observe the ignition se­quence. The flame can be observed through the small clear window on the burner box. The burner flame should carry over between all burners. The flames should be blue, without yellow tips. Flames should extend from each burner without lifting, curling, or floating. After verifying ignition, set the thermostat below room temperature and verify that the burner flame extinguishes completely. Replace the front door.
Verifying Operation of the Supply Air Limit Switch
To verify operation of the supply air limit switch, make sure that the blower door is in place and that there is power to the furnace. Completely block the return airflow to the furnace by install­ing a close-off plate in place of or upstream of the filter(s). Set the thermostat above room
temperature and verify that the Sequence of Operation is as described in these instructions. The supply air limit switch should function to turn off the gas valve within approximately five minutes. The circulating air and combustion blowers should continue to run when the supply air limit switch opens. Remove the close-off plate immediately after the supply air limit switch opens. If the furnace operates for more than five minutes with no return air, set the thermostat below room temperature, shut off the power to the furnace, and replace the supply air limit switch.
DESCRIPTION OF COMPONENTS
Figure 29 shows the location of each of the functional components described below. If any component of the furnace must be replaced, use only factory authorized replacement parts. Contact your distributor for the approved re­placement parts.
Flame Sensor – The flame sensor acts to prove that flame has carried over from the ignitor to the opposite end burner. If no flame is sensed, the furnace will be shut down automati­cally.
28
FURNACE ACCESSORY KITS
(
g)
MAINTENANCE
Kit Order Nu mber
A/ C Coil B ox 911969A Side Ret urn A i r Kit 904003 Top Return Air K i t 904015 Sloped Roof VentilAire II I Kit 914098 Sloped Roof VentilAire IV K i t 914229 Sof fit V entilAi re K i t 917201 Concentri c Vent T erm ination Kit
for horiz ont al and vertic al ventin Horizont al E xterior V ent Mounting Kit 3"PVC 902375 Neutralizer Kit - A l l M odel s 902377
Table 12. Accessory Kits
Gas Valve – The gas valve controls the flow of
gas to the burners. When the gas valve is energized it automatically opens and regulates the gas pressure in the manifold.
Pressure Switch – The pressure switch veri­fies that the inducer is drawing the combustion gases through the heat exchanger. It also senses a blocked condensate drain condition.
Deck Limit Switch (Auxiliary Limit) – The deck limit protects the furnace filter tempera­ture from overheating when the motor has malfunctioned. If the deck switch opens, the power for the furnace will shut down (see Figure 29).
Supply Air Limit Switch – The supply air limit switch prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature.
Vent Safety Switch – The vent safety switch shuts the furnace down if the outlet flue gas temperature increases above 145°F. This switch protects the plastic flue system and the inducer from over-temperature conditions.
Flame Roll-Out Switch – This switch pro­vides flame roll-out protection to the furnace and combustion air inlet pipe.
903578
It is recommended that the furnace be checked yearly. At a minimum, this check should include the following items:
!
W ARNING:
To avoid electric shock, personal injury, or death, turn off the power at the disconnect or the main service panel before performing any maintenance.
!
WARNING:
Holes in the vent pipe or heat exchanger can cause products of combustion to enter the occupied space. Replace the vent pipe or heat exchanger if leaks are found. Failure to prevent products of combustion from being circulated into the occupied space can crate poten­tially hazardous conditions, including carbon monoxide poisoning, that could result in personal injury or death.
Combustion Air and Vent System
Check the combustion air and vent pipe to ensure that it is not damaged, corroded or blocked by debris. Any damaged section of vent pipe must be replaced, and any obstruc­tion or blockage must be removed prior to operating the furnace.
Air Filter
An air filter is supplied with the furnace as shipped from the factory. Filters should be changed or cleaned monthly during the heating season. New or newly renovated homes may require more frequent changing until the con­struction dust has been removed.
29
!
WARNING:
Never operate the furnace without a filter in place. Dust and lint in the return air can build up on internal compo­nents, resulting in loss of efficiency, equipment damage, and possible fire.
Lubrication
The bearings in the circulating air blower mo­tors are pre-lubricated and sealed at the fac­tory. No further oiling of the bearings is required for the life of the motor.
Condensate Drain Assembly
Be sure the condensate lines are free and open (i.e. avoid kinking hoses). Also make sure all hose clamps are tight to avoid drawing air into the system.
Blower Compartment
The blower compartment should be cleaned monthly during the heating and cooling sea­sons to remove any dirt and lint that may have accumulated in the compartment or on the blower and motor. Dirt and lint can create excessive loads on the motor resulting in higher than normal operating temperatures and short­ened service life.
Heat Exchanger and Burner Maintenance
The furnace should operate for many years without excessive soot buildup in the flue pas­sageways, however, the flue passageways, the vent system, and the burners should be inspected and cleaned (if required) by a quali­fied service technician annually to ensure con­tinued safe operation. Particular attention must be given to identify deterioration from corrosion or other sources.
SYSTEM OPERATION INFORMATION
GENERAL
Proper maintenance is most important to achieve the best performance from a furnace. Follow these instructions for years of safe, trouble free operation.
Do not place combustible materials on or against the furnace cabinet or the vent pipe.
30
• Do not store gasoline or any other flammable vapors and liquids in the vicinity of the furnace.
• Change or replace the air filters monthly during any period when the circulating blower is operating regularly.
• Always replace the doors on the furnace after servicing. Do not operate the furnace
without all doors and covers in place.
• Avoid operating the furnace when windows and doors are open.
• Be sure that the thermostat is properly installed and is not being affected by drafts or heat from lamps or other appliances.
Sequence of Operation
Operating sequences for the heating, cooling, and fan modes are described below. Refer to the wiring diagrams (Figures 30) and the low voltage field wiring diagram (Figure 26) for more details.
Heating Mode:
1. On a call for heat the thermostat closes, applying 24 VAC to the W terminal on the control board.
2. The control board checks for continuity on the 24 VAC limit control circuit (over­temperature limit switch, flame rollout switches and blocked vent switch in se­ries). If an open limit is detected the con­trol board will energize the inducer and the conditioned air blower. All other sys­tem functions will be inoperable until the limit circuit closes. While the limit is open, the red LED will pulse at a rate of 1 blink per unit time.
3. The furnace control checks for continuity across the pressure switch (24 VAC). If the pressure switch is closed the heat mode sequence will not continue. If it remains closed for 10 seconds the red LED will blink 3 times repetitively until the fault condition clears.
4. The inducer is energized.
5. The pressure switch will close. If the pressure switch does not close after 10 seconds the fault LED will blink 2 times repetitively and the inducer will continue to run until the switch is closed.
6. The inducer will pre-purge for 30 seconds and then the igniter will start its warm-up as follows:
Initial Power up: After 30 seconds of igniter warm-up the gas valve (24 VAC) will then open. The igniter circuit will stay ener­gized for 3 seconds after the gas valve opens. After Initial Power up: The control has a programmed adaptive ignition feature which varies the warm-up period as fol­lows: If ignition is successful the warm-up is reduced by 3-seconds on each subsequent call for heat until ignition failure occurs. Upon ignition failure, the warm-up is in­creased by 3-seconds on the next try. If successful, the timing remains fixed at this level. In general, whenever ignition failure occurs the warm-up interval is increased by 3-seconds on the next try. And if success­ful, it remains there. Minimum and maxi­mum warm-up time limits are set at 6 and 54-seconds, respectively.
7. The furnace control must prove flame via the flame sensor 5 seconds after the gas valve opens. If flame is sensed, all burn­ers are on and the ignitor cools off. If no flame is sensed, the gas valve closes immediately and the inducer continues to run. A second trial for ignition (step 6) begins if no flame is sensed. On the fifth try for ignition, the furnace control is locked out and the red LED will blink 4 times repetitively. The thermostat must be opened for at least ten seconds to reset the furnace control after a lock out. Oth­erwise, the furnace will attempt another ignition sequence in 1 hour.
8. The furnace control energizes the cir­culating air blower on the heating speed 30 seconds after the gas valve circuit is energized .
9. When the thermostat has been satisfied, gas valve is de-energized.
10. The inducer is de-energized after a 30­second postpurge.
11. The furnace control keeps the circulating air blower energized for 120 seconds (factory set) or 60, 90, or 180 seconds (field adjustable). (See Figure 27.)
12. Abnormal conditions: If a limit opens during operation, the inducer and circulating air blower continue to operate. The gas valve is de-energized immediately. The blowers continue to operate until the limit closes. When the limit closes the inducer blower is de-energized immediately. The circulating air blower continues to operate for the speci­fied delay (factory set at 120 seconds).
Cooling Mode:
1. On a call for cooling the thermostat closes, applying 24 VAC to the G and Y terminals on the furnace control. This closes the compressor contactor.
2. The furnace control energizes the circu­lating blower (115 VAC) on the cooling speed.
3. When the thermostat is satisfied, the G and Y terminals on the control board are de-energized opening the compressor contactor.
4. The circulating air blower is de-energized after a 90-second delay.
Fan Mode:
1. On a call for fan operation, the thermostat applies 24 VAC to the G terminal on the furnace control board.
2. The circulating air blower is energized immediately on the heating speed.
3. If the furnace is operated in the continu­ous ON position at the thermostat and is then switched to AUTO, the circulating blower will operate for a specified delay (factory set at 120 seconds).
Furnace Fails to Operate
If the furnace does not operate check the following:
1. Is the thermostat operating properly?
2. Is the front door in place?
3. Is the furnace disconnect closed?
4. Has the circuit breaker tripped or the control board fuse burned open?
5. Is the gas turned on?
6. Are any manual reset switches open?
7. Is the filter dirty or plugged?
8. Is the flame sensor coated? (Remove and clean with emery cloth.)
9. Is the deck switch open?
If the furnace locks out after 5 attempts for ignition, it will try again every hour if a call for heat remains. If the inducer and circulating air blowers are operating, and items 1 through 8 have been checked, press the red reset but­ton on the vent safety switch. (See Figure 29.) If the furnace operates after depressing the reset button, contact a qualified service tech­nician to identify and repair the problem.
If furnace still fails to operate, depress the red reset buttons on the flame roll-out switch. If the furnace operates after depressing the reset button, contact a qualified service tech­nician to identify and repair the problem.
31
M3 Downflow Furnace
3
21
2
18
4
5 19
6
22
7
17
1
8
9
10
11
16
12
13
14
1 Door Assembly - Louvered 2 Filter Inside Door 3 Blower Assembly 4 Control Board 5 Pressure Switch 6 Flame Rollout Switch 7 “J” Trap Hard Tube 8 Low Voltage Transformer 9 In Line Drain Assembly 10 Junction Box 11 Vent Safety Switch
Figure 29. Location of Major Components
32
15
12 Ignitor Assembly 1 3 Burner View Port 14 Main Limit Switch 1 5 Coil Cabinet Assembly (Optional) 1 6 Flame Sensor (On Burner Box) 1 7 Gas Valve 18 Switch, On/Off 19 Blower, Inducer 20 Orifice (In Burner Box) 21 Aux. Limit 22 Burner Box
y
o
l
h
ace
be
be
g
g
a
g
of
atleas
C.
r
ductors
y.
SUPPLY AIR
ORPLUG
d
ace
h
0
0
e
r
ed
ue
SH
S
S
S
S
s
US
GHT
s
GHT
LIMIT SWITCH
(ALL MODELS)
WHITE (NEUTRAL)
BLACK 120V
GROUND
ROOM THERMOSTAT
R Y G
W
AIR CONDITIONER CONDENSING UNIT
C Y
BLUE
FLAME ROLL-OUT
SWITCH
(ALL MODELS)
BLUE
BLUE
BLUE
ORANGE
ORANGE
VENT SAFETY SWITCH
(ALL MODELS)
WHITE
GREEN
WHITE W/ BLK STRIPES
BLK W/ WHITE STRIPES
BLACK
TRANSFORMER
24 V
90
60
PRESSURE
SWITCH
ON/OFF SWITCH
WHITE
120 V
BLACK
180
120
BLACK
BLOWER DECK SWITCH
FLAME SENSOR
GAS
VALVE
RED
YELLOW BROWN
IGNITOR
Legend
Field Wiring
Factory Wiring:
Low Voltage High Voltage
FAULT CONDITION Power On Limit Circuit Open or External Load On "W"
(Does not apply to Deck Switch, see below) Pressure Switch Open with Inducer On
Pressure Switch Closed with Inducer On Ignition Failure (Check Ground)
115 VAC & Neutral Reversed or no Ground
False Flame or Gas Valve Relay Shorted Power Off or Deck Limit Open
FAULT CONDITION Low Flame Sensor Signal
Flame Present
R
INDUCER
2 FLASHE
4 FLASHE
C
TAT
RED
LI
ON
1 FLA
FLASHE
FLASHE
ontinuou
OFF
YELLOW
LI
ontinuou
Flash
ON
BLACK
BLACK BLACK
BLACK
an
thefurn replaced, itmust replaced wirin materialhavin
t
se coppe
n
nl
ftheorigina
wit
must
ratin
RED ORANGE BLUE
BLACK
1 2 3 4
MOT
Factory Wire
Heating Speeds
Furn
Input, Btu
60,00
80,00
3 OR 4 SPEED MOTOR
C
L
WHITE
RED
Wir
R
Bl
MH
ML
ORANGE
olo
H
BLUE
BLACK
WD #710240B
Figure 30. Downflow Furnace Wiring Diagram
33
34
INSTALLATION/PERFORMANCE CHECK LIST
LOCATION ____________________ CITY __________________ STATE ____________ INSTALLER ___________________ CITY __________________ STATE ____________
UNIT MODEL NUMBER________________
Minimum Clearances per Table 3?________ Electrical Connections tight? _____________ Line Voltage Polarity correct? ____________ Supply Voltage: ___________________Volts Blower Motor HP: _____________________
FUEL TYPE: Natural Gas______ LP/Propane _______ Gas Piping Connections leak-tested? _____
Gas Line Pressure: ____________________ (in. water column, with furnace operating) Manifold Pressure: ____________________ (in. water column, with furnace operating) Is there adequate fresh air supply for combustion and ventilation? _____________
Furnace Input: _________________ (Btuh) Supply Air Temperature: __________ (° F) Return Air Temperature: _________ (° F)
UNIT SERIAL NUMBER________________
Are Flue Connections tight? _____________ Is there Proper Draft?__________________ Is Vent free from restrictions? ____________
Is the Filter(s) secured in place? __________ Is the Filter(s) clean? __________________
Has the Thermostat been calibrated? _____ Is the Thermostat level? ________________ Is the Heat Anticipator Setting correct? ____
Has the Owner's Information been reviewed with the home-owner? _________________
Has the Literature Package been left near the furnace? ____________________________
Temperature Rise: ______________ (° F)
35
O’Fallon, MO
¢7082197¤
708219E
708219E (Replaces 708219D)
Specifications and illustrations subject to change without
notice and without incurring obligations. Printed in
U.S.A. (08/06)
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