Nordyne M5S, M1B User Manual
Downfl ow, Direct Vent (Sealed Combustion)
Forced Air Gas & Oil Furnaces
Installation Instructions
Series M1B, M1G, M1M & M5S
For installation in:
• Manufactured Homes
• Recreational Vehicles, Park Models, &
Manufactured Buildings
• Modular Homes/Buildings
ATTENTION INSTALLERS:
It is your responsi b il i ty to k no w th i s pro du ct
better than your customer. This includes
being able to install the product according
to strict safety guidelines and instructing the
customer on how to operate and maintain the
equipment for the life of the product. Safety
should always be the deciding factor when
installing this product and using common
sense plays an important role as well. Pay
attenti on to all safety warni ngs and any other
special notes highlighted in the manual.
Improper installation of the furnace or failure
to follow safety warnings could result in
serious injury, death, or property damage.
These instructions are primarily intended
to assist qualifi ed individuals experienced
in the proper installation of this appliance.
Some local codes require licensed
installation/service personnel for this type
of equipment. Please read all instructions
carefully before starting the installation.
Return these instructions to the customer’s
package for future reference.
!
WARNING:
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
FIRE OR EXPLOSION HAZARD
• Failure to follow safety warnings
exactly could result in serious
injury or property damage.
• Installation and service must
be performed by a qualified
installer, service agency or the
gas supplier.
from a neighbors phone. Follow
the gas suppliers instructions.
• If you cannot reach your gas
supplier, call the fi re department
DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
• Do not store or use gasoline
or other fl ammable 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 INFORMATION .....................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 Specifi cations ........31
Table 11 - Orifi ce Sizes - High Alt. ........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
2
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 qualifi ed
service technician to inspect the
appliance and to replace any part
of the control system and any gas
control that has been submerged
underwater.
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 per
or death
• 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 air to the furnace
space as specifi ed on page 23.
• Combustion products must be discharged
outdoors. Connect this furnace to an approved
vent system, as specifi ed on pages 13 - 14.
• Never test for gas leaks with an open fl ame.
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 fl ow and temperature rise.
NOTE: It is important that the duct system be
designed to handle the desired fl ow rate and
external pressure rise. An improper ly 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.
.
sonal injury
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.
WARNING:
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, all applicable local building
codes and the current revision of the National
Fuel Gas Code (NFPA54/ANSI Z223.1) or the
Natural Gas and Propane Installation Code,
CAN/CGA B149.1.
CE générateur d’air chaud doit être installé
conformément aux instructions du fabricant
et aux codes locaux. En l’absence de code
local, respecter la norme ANSI Z223.,1,
institulé National Fuel Gas Code ou les codes
d’installation CAN/GCA-B149.
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, mechanicalvent heating appliances or domestic hot
water equipment, where the bottom of the
vent terminal and the air intake is installed
below four feet above grade the following
requirements must be satisfi ed:
3
a.) A carbon monoxide (CO) detector and
alarm shall be placed on each fl oor
level where there are bedrooms. The
detector shall comply with NFPA 720
(2005 Edition) and be mounted in the
living area outside the bedroom(s).
b.) A (CO) detector shall be located in
the room that houses the appliance or
equipment and shall:
• Be powered by the same electrical
circuit as the appliance or equipment.
Only one service switch shall power
the appliance and the (CO) detector;
• Have battery back-up power;
• Meet ANSI/UL 2034 Standards
and comply with NFPA 720 (2005
Edition); and Approved and listed
by a Nationally Recognized Testing
Laboratory as recognized under 527
CMR.
c.) A Product-approved vent terminal must
be used, and if applicable, a productapproved air intake must be used.
Installation shall be in strict compliance
with the manufacturer’s instructions. A
copy of the installation instructions shall
remain with the appliance or equipment
at the completion of the installation.
d.) A metal or plastic identifi cation plate shall
be mounted at the exterior of the building,
4 feet directly above the location of vent
terminal. The plate shall be of suffi cient
size, easily read from a distance of eight
feet away, and read “Gas Vent Directly
Below”.
2. For direct-vent appliances, mechanical
vent heating appliances or domestic hot
water equipment where the bottom of the
vent terminal and the air intake is installed
above four feet above grade the following
requirements must be satisfi ed:
a.) A (CO) detector and alarm shall be
placed on each fl oor level where there
are bedrooms. The detector shall comply
with NFPA 720 (2005 Edition) and be
mounted in the living area outside the
bedroom(s).
b.) The (CO) detector shall:
• Be located in the room that houses
the appliance or equipment;
• Be hard-wired, batter y powered or both.
• Shall comply with NFPA 720 (2005
Edition).
c.) A product-approved vent terminal must
be used, and if applicable, a productapproved 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 Installation Codes (NSCNGPIC), Venting Systems
and Air Supply for Appliances
Duct Systems
• US and CANADA: Air Conditioning Contractors
Association (ACCA) Manual D, Sheet Metal
and Air Conditioning Contractors National
Association (SMACNA), or American Society
of Heating, Refrigeration, and Air Conditioning
Engineers (ASHRAE) Fundamentals Handbook
Electrical Connections
• US: National Electrical Code (NEC) ANSI/
NFPA 70
• CANADA: Canadian Electrical Code CSA
C22.1
Gas Piping 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) NFPA 54–1999/ANSI Z223.1 and
the Installation Standards, Warm Air Heating
and Air Conditioning Systems ANSI/NFPA 90B.
• Federal Manufactured Home Constructions
& Safety Standard (H.U.D. Title 24, Part
3280.707[a][2])
• The Standard for Manufactured Home
Installations (Manufactured Home Sites,
Communities, and Set-Ups) ANSI A225.1 and/
or CAN/CSA-2240 MH Series).
4
• American National Standard (ANSI-119.2/
NFPA-501C) for all recreational vehicle
installations.
• CANADA: CAN/CGA-B149.1 and .2–M00
National Standard of Canada. (NSCNGPIC)
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.P. gas
or Natural gas) and adjusted to operate properly.
All gas furnaces are manufactured for Natural gas
and must be fi eld converted when using L.P. gas.
CAUTION:
• Do Not alter or modify this furnace
or any of its components.
• Never attempt to repair damaged
or inoperable components. This
may cause unsafe operation, explosion, fi re and/or asphyxiation.
• If furnace malfunctions or does
not operate properly, contact a
qualifi ed service agency or gas
utility for assistance.
A warranty certifi cate 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 specifi c examples
of service calls which cannot be included in
warranty payments are:
• Converting the furnace to use another type of
gas.
• Repairing duct work in the home found to be
faulty.
• Correcting wiring problems in the electrical
circuit supplying the furnace.
• Resetting circuit breakers, blown fuses or other
switches.
• Correcting problems due to improper gas
supply pressure to the furnace.
• Providing instructional training on how to light
and operate the furnace.
• Furnace problems caused by installation of an
air conditioner, heat pump or other air comfort
devices.
• Adding a Roof Jack extension because of
unusual wind and/or snow conditions.
• Revising installation of the furnace flue
assembly (Roof Jack).
• Adjusting or calibrating of thermostat.
• Any construction debris which falls into fl ue
system.
Minimum Clearances
This heating appliance must be installed with
clearances not less than the minimums listed
in Table 1. This furnace must be installed with
ample clearance for easy access to the air fi lter,
blower assembly, bur ner assembly, controls, and
vent connections. See Figures 1 - 3 (page 6).
• The dimensions of the room or alcove must be
able to accommodate the overall size of the
furnace and the installation clearances listed
in Table 1 and in Figure 4 (page 6).
• Alcove installations: minimum 18” clearance
at front of furnace shall be provided for future
servicing. A removable access panel should
be installed between top of the furnace door
frame and the ceiling.
• Closet installations must use a louvered door
having a minimum free area of 235 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 louvered
door with a minimum of 250 sq. in. free area,
with the openings in the closet door in line with
the louvered openings in the furnace door. A
fully louvered closet door may be used. See
Circulating Air Requirements (page 7).
ALL MODELS CLOSET ALCOVE
Front 6” 18”
Back 0” 0”
Sides 0” 0”
Roof Jack 0” 0”
To p 6 ” 6 ”
Top and Sides of Duct 0” 0”
Bottom of Duct
B Cabinet 0” 0”
A Cabinet
(w/ coil box)
A Cabinet
(w/o coil box)
Table 1. Minimum Clearances
0” 0”
1/4” 1/4”
5
6" (152 mm)
Top Clearance
0" Side
Clearance
to Furnace
Cabinet
6" (152 mm)
Top Clearance
0" Side
Clearance
to Furnace
Cabinet
6" (152 mm)
Top Clearance
0" Side
Clearance
to Furnace
Cabinet
Removable access
panel should be
installed above
furnace door frame
to access roof jack
18"
(457 mm)
Figure 1. Alcove Installation
Provide min. 235
sq. in. (1516 cm )
open free area in
front or side wall
6"
(152 mm)
CLOSET DOOR
Figure 2. Closet Installation
Provide min. 250
sq. in. (1613 cm )
open free area in
front or side wall
1"
(25 mm)
Nearest
Wall or
Partition
2
or
In closet
door
located
at top,
center
or bottom
2
or
in closet
door
a fully
louvered
door may
be used
Applications
M1 Series gas and M5 Series oil furnaces are
listed direct vent (sealed combustion), downfl ow
heating appliances for manufactured (mobile)
homes, recreational vehicles, and for use in
residential/modular/commercial construction.
The furnace must be located so that venting can
be properly achieved.
Air conditioning may be added to structures with
M1/M5 series furnaces using air conditioning or
conventional units. This Installation Instruction
manual includes special requirements for
incorporation of air conditioning equipment to the
M1/M5 series of furnaces. See Tabel 12 (page 32).
Multi-speed blower assemblies shown in Table
2, have been certifi ed for fi eld installation in M1/
M5 Series furnaces.
Unit Location
• The furnace shall be appropriately located to
the supply and return air distribution system
(See Page 7). Sides and back of the furnace
may be enclosed by wall 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 fl oor and protected
from physical damage by vehicles.
CLOSET DOOR
Figure 3. Special 1” Clearance
Blower / Motor
Part
No.
Assembly
Blower
Wheel
Motor
(Hp)
A/C Capacity
(Tons)
903773 10 x 8 1/4 2, 2½ & 3
903413 11 x 8 1/2 2, 2½, 3 & 4
903890 11 x 8 3/4 2, 2½, 3, 4 & 5
Table 2. Blower Assemblies
6
“A”- 56"
“A” Model
w/o Coil
Cabinet
“B” Model
w/Coil
Cabinet
“B”- 76"
23 3/4"
19 3/4"
Figure 4. Overall Dimensions
CIRCULATING AIR REQUIREMENTS
WARNING:
Do not allow combustion products
to enter the circulating air supply.
Failure to prevent the circulation
of combustion products into the
living space can create potentially
hazardous conditions including
carbon monoxide poisoning that
could result in personal injury or
death.
All return ductwork must be secured
to the furnace with sheet metal screws.
For installations in confi ned spaces,
all return ductwork must be adequately
sealed. The joint between the furnace
and the return air plenum must be
air tight.
The surface that the furnace is
mounted on must provide sound
physical support of the furnace with
no gaps, cracks or sagging between
the furnace and the fl oor or platform.
Return air and circulating air ductwork
must not be connected to any other
heat producing device such as a
fireplace insert, stove, etc. This
may result in fi re, explosion, carbon
monoxide poisoning, personal injury,
or property damage.
Return Air Connections
U.S.A. home manufacturers shall comply with
all of the following conditions to have acceptable
return air systems for closet installed forced air
heating appliances:
• The return air opening into the closet shall not
be less than specifi ed in the appliance’s listing.
• The cross-sectional area of the return duct
system leading into the closet, when located
in the fl oor or ceiling shall not be less than 235
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 shall be provided that prevent
inadvertent closure of fl at objects placed over
the return air opening located in the fl oor of the
closet (versus the vertical front or side wall).
• The total free area of openings in the fl oor or
ceiling registers serving the return air duct
system must be at least 235 sq. in. At least
one register should be located where it is not
likely to be covered by carpeting, boxes and
other objects.
• Materials located in the return duct system
must have a fl ame spread classifi cation of
200 or less. This includes a closet door if the
furnace is in a closet.
• Noncombustible pans having 1” upturned
fl anges are located beneath openings in a
fl oor duct system.
• Wiring materials located in the return duct
system shall conform to Articles 300-22 of the
National Electrical Code (ANSI C1/NFPA-70).
• Gas piping is not run in or through the return
duct system.
CAUTION:
HAZARD OF ASPHYXIATION:
Negative pressure inside the
closet, with closet door closed
and the furnace blower operating
on high speed, shall be no more
negative than minus 0.05 inch
water column.
• Test the negative pressure in the closet with
the 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.
• Air conditioning systems may require more
duct register and open louver area to obtain necessary airflow. Use NORDYNE’s
certiduct program to determine proper duct
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.
7
Location, size, and number of registers should
A Single trunk duct
B
Dual trunk duct
w/crossover connector
C
Transition duct
w/branches
be selected on the basis of best air distribution
and fl oor plan of the home. The supply air must
be delivered to the heated space by duct(s)
secured to the furnace casing, running full
size and without interruption.
• The M1 Series gas and M5 Series oil furnace
is certifi ed for use on wood fl ooring or supports,
but must be installed on top of a duct connector.
This factory supplied accessory must be
installed in the fl oor cavity and attached to the
supply air duct before the furnace is installed.
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 fl oor plan of the home.
Figure 5. Typical Supply Duct System
FURNACE INSTALLATION
NOTE: These Installation procedures are
suggested for typical furnace installations.
Since all installations are different from each
other, the sequence of instructions may differ
from the actual installation. Only qualifi ed HVAC
technicians should install this furnace.
General Information
• The furnace must be leveled at installation and
attached to a properly installed duct system. Do
not use the back of the furnace for return
air. See page 7 for circulating requirements.
• The furnace must be installed so that all
electrical components are protected from
water.
• The dimensions of the room or alcove must be
able to accommodate the overall size of the
furnace and the installation clearances listed
in Table 1 and Figure 3 (page 6)
• The furnace must be installed upstream from
a refrigeration system.
• The 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 in the 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.
8
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. In the absence of local codes,
the installation must be in accordance with the
current provisions of one or more of the following
standards.
• Federal Manufactured Home Constructions
& Safety Standard (H.U.D. Title 24, Part
3280.707[a][2])
• American National Standard (ANSI-119.2/
NFPA-501C) for all recreational vehicle
installations.
• American National Standard (ANSI-Z223.1/
NFPA-54) and/or CAN/CSA B149 for all gasfi red furnace models.
• American National Standard (ANSI-Z95.1/
NFPA-31) and/or CSA B139 for all oil-fi red
furnace models.
• American National Standard (ANSI-C1/NFPA-
70) and/or CSA 22.1 Canadian Electric Code
Part 1 for all electrical fi eld wiring.
• Units have been researched under standards
UL 307A & B, UL727-1999, ANSI Z21.47b/
CSA 2.3b-2008, and CSA B140.10.
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 fl oor.
2. Using the centerline as a starting point, draw
the rest of the duct cut-out to the dimensions
shown in Figures 6 or 7.
3. Cut out the fl oor opening 1/16” larger than
the actual cutout drawn. This will allow some
clearance when installing the duct connector.
4. Measure from the top of the fl oor down to the
top of the supply air duct to obtain the depth of
the fl oor cavity. NOTE: The depth of the fl oor
cavity shown as “X” in Figure 9 (page 9) will
determine the correct duct connector.
5. Determine which duct connector to use from
Table 3 (page 9).
Measure and drill gas hole. and cut out for cooling
6.
coil (if applicable). See Figures 6 or 7 (page 9).
20"
14 1/2"
C
L
REAR WALL OF CLOSET OR ALCOVE
2 1/4"
FLOOR CUT-OUT
24"
21 3/4"
14 1/2"
23 1/4"
C
L
1 3/4"
3/4"
1 7/8"
FOR STANDARD
DUCT CONNECTORS
FURNACE OUTLINE
C
C
L
L
2 7/8"
CUT-OUT FOR
OPTIONAL
COOLING COIL
ALT FUEL-LINE
ENTRY 1 1/4" Dia.
1 3/4"
C
L
FURNACE
OUTER
DOOR
Figure 6. Cut-Out Dimensions for
Standard Duct Connectors
2 3/4"
10"
C
L
3/4"
FUEL
LINE
“X”
FLOOR
CAVITY
FLOOR OPENING
SUPPLY AIR DUCT
Figure 9. Floor Cavity
If Floor Cavity
“X” is:
7/8” / (22) 901987A 904008
C
L
2"
2” / (51) 901988A 904009
4-1/4” / (108) 901989A 904010
6-1/4” / (159) 901990A 904011
8-1/4” / (210) 901991A 904012
10-1/4” / (260) 901992A 904013
12-1/4” / (311) 901993A 904014
Note: Dimensions shown as Inches / (Millimeter)
Duct Connector
Type & Part Number
Standard Duct Round Duct
Table 3. Duct Connector Sizes
20"
C
L
10"
REAR WALL OF CLOSET OR ALCOVE
FLOOR
CUT-OUT FOR
24"
C
L
23 1/4"
21 3/4"
1 3/4"
3/4"
1 7/8"
2 7/8"
ROUND DUCT
(14 1/4” DIAMETER)
FURNACE OUTLINE
CUT-OUT FOR
C
C
L
L
COOLING COIL
ALT FUEL-LINE
ENTRY 1 1/4" Dia.
OPTIONAL
C
L
FURNACE
C
L
OUTER
DOOR
1 3/4"
Figure 7. Cut-Out Dimensions for
Round Duct Connectors
Hole for
Gas Line
Duct
Connector
Wood Floor
Connector
Tabs
Supply
Air Duct
Mounting Plate
10"
C
L
3/4"
FUEL
2"
LINE
Bend tabs
up 90°
Standard Duct Connector Installation
The standard duct connector is designed for use
on ducts 12” in width. However ducts narrower
than 12” may not allow suffi cient clearances
for this type of installation. For an alternate
installation method, see page 10.
1. Center the duct connector in the fl oor opening
with bottom tabs resting on top of the supply
air duct.
Mark the cut-out area on the supply air duct by
2.
tracing around the 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 fl oor
opening with the bottom tabs extending into
the supply air duct.
5. Install the mounting plate (Figure 8) under
the back side of the duct connector. Align the
screw holes in both components.
6. Secure the duct connector and the mounting
plate to the wood fl oor with appropriate size
screws.
7. Bend the connector tabs on the bottom of
the duct connector upwards and as tight as
possible against the supply air duct.
8. Bend both tabs 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 specifi c to your area.
9
DUCT CONNECTOR
SUPPLY
AIR DUCT
Duct connector tabs
Narrow
Duct
Duct
Flap
Staples or sheet metal screws
Narrow
Duct
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
insuffi cient clearance to bend the duct connector
tabs, this alternate attachment method may be
used.
1. Score and cut the top of the supply air duct as
indicated in Option 1 or Option 2 (Figure 11).
With Option 1 choice, cut out the metal from
the shaded area.
2. Fold the two fl aps (Options 1 or 2) up to form
the opening for the duct connector.
3. Install the duct connector with the bottom tabs
extending into the supply air duct.
4. Bend the tabs on the bottom of the duct
connector upwards and as tight as possible
against the supply air duct (Figure 12).
5. Form the fl aps (Options 1 or 2) up against the
duct connector as tight as possible.
6. Secure the duct connector fl aps to the supply air
duct with staples (3 minimum) or if a 2x block/
joist is not provided, use sheet metal screws
(2 minimum). NOTE: The duct connector tabs
may be attached to the air duct with sheet
metal screws or other suitable fasteners as
long as the duct connector and the air duct
are securely attached.
7. Seal all connections with industrial grade
sealing tape or liquid sealant.
NOTE: Requirements for sealing ductwork
vary from region to region. Consult with local
codes for requirements specifi c to your area.
Duct
Sheet metal
screws
Connector
Narrow
Duct
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
fl oor 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 fl oor with appropriate size
screws.
5. Connect the round supply duct to the underside
of the duct connector and secure them with
fi eld supplied sheet metal screws.
6. Seal all connections with industrial grade
sealing tape or liquid sealant.
NOTE: Requirements for sealing ductwork
vary from region to region. Consult with local
codes for requirements specifi c to your area.
Installing The Furnace
Sides and back of the furnace may be enclosed
by wall framing such as in a closet or alcove. The
dimensions of the room or alcove must be able
to accommodate the overall size of the furnace
and the installation clearances outlined on page
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 OPTION 2
Remove
this
Cut Here
Cut Here
Cut Here
Cut Here
Fold Flap Here
Remove
this
Flap
Flap
Cut Here
Cut Here
Supply
Air Duct
Fold Flap Here
Fold Flap Here
Figure 11. Narrow Air Duct Openings
10
Cut Here
Cut Here
Cut Here
Fold Flap Here
1. Remove furnace outer door(s) and bottom fuel
line knockout.
2. Place furnace onto duct connector and center
with fl oor opening.
3. Slide onto mounting plate. (Bottom rear slots
on furnace should engage with mounting plate
tabs.)
4. Secure front with one (1) fastener at each
corner (Figures 14 or 15).
NOTE: Additional fasteners may be used at rear,
sides or through door frame, as desired, to secure
furnace to closet or alcove framing.
DUCT
CONNECTOR
SCREWS
MOUNTING
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.
FUEL
LINE
HOLES
14” SUPPLY
CONNECTION
Figure 13. Round Duct Connector Installed
MTG. PLATE TABS
SECURE FURNACE
WITH 2 FASTENERS AT FRONT
CORNER HOLES
Knockout Over Holes
SUPPLY AIR DUCT
SLIDE FURNACE
ALL THE WAY BACK
ONTO MTG. PLATE
Figure 14. “A” & “B” Cabinet Furnaces
SLIDE FURNACE
BACK AGAINST
MTG. PLATE
MTG. PLATE TABS
SECURE FURNACE
WITH 2 FASTENERS
AT FRONT CORNER HOLES
FUEL LINE HOLES
SUPPLY
AIR DUCT
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 fl ashing 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.
F = Flat Flashing: fl exes from 0/12 to 1/12 roof
slope. See Figure 17 (page 12).
S = Slant Flashing: 2.5/12 Slope fl exes from
1/12 to 4/12 roof slope, 4/12 fl exes from
3/12 to 5/12. See Figure 18.
• Stainless steel roof jacks are available.
• M1/M5 furnaces may be used with roof jacks
as tall as 170” (except M1M 056 & M1B 066
models, which are limited to 120”). An internal
roof jack extension (p/n 901935 - 10”, p/n
903107 - 18”) can be used to increase roof
jack height. All connections inside the home
must be made below the ceiling.
Figure 15. “A” Cabinet Furnace on Coil
Cabinet
ROOF JACK
SLANT DECK
PITCHED
ROOF
CEILING
CAVITY
CEILING
“A”
“B”
Furnace
FLASHING
"X" (SEE TABLE 5)
Roof
Opening
Flue Pipe
Combustion Air Pipe
56" or 76"
Figure 16. Ceiling Cavity Depth
NOTE: If the roof jack crown is covered or blocked
with snow, the furnace will not operate properly.
MODEL NUMBER
(F,S)AW(T)1523-(0,2,4)(A,S) 15” - 23”
(F,S)AW(T)2135-(0,2,4)(A,S) 21” - 35”
(F,S)AW(T)2747-(0,2,4)(A,S) 27” - 47”
(F,S)AW(T)3563-(0,2,4)(A,S) 35” - 63”
(F,S)AW(T)5195-(0,2,4)(A,S) 51” - 95”
SSAW
F = FLAT FLASHING
S = SLANT FLASHING
AW= ALL WEATHER
TYPE:
BLANK = NON-TRANSIT
T= TRANSIT MODE
APPROX. LENGTH
BELOW FLASHING
47 - 2
T
27
MIN. ADJ.
LENGTH
MAX. ADJ.
LENGTH
FLUE STEEL TYPE
A= ALUMINIZED
S=STAINLESS
FLASHING
PITCH/12" RISE
0=FLAT
2=2.5/12
4=4/12
Table 4. Roof Jack Assemblies
11
1. Locate center of Roof Jack opening, measure
CEILING
CUT-OUT FOR
FLUE AND
ROOF JACK
C
L
C
L
24"
20"
13 1/2"
REAR WALL OF CLOSET OR ALCOVE
10"
FURNACE
OUTER
DOOR
FURNACE OUTLINE
13 1/2” from the rear wall of closet or alcove
along the center line of furnace and fl oor
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
IMPORTANT:
Figure 17. Example of Flat Jack
with Flashing
Figure 18. Example of 2½/12 Slant 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 into the fur nace before
the fi nal roof jack connection is made
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.
Figure 19. Cut-Out Dimensions for
Flue & Roof Jack
12
ROOF JACK SERIES IF ROOF PITCH IS:
SLANT DECK
FLASHING NUMBER
“X” FACTOR
IS:
2” in 12” 903893 (2.5/12) 2-1/8”
2-1/2” in 12” 903893 (2.5/12) 2-1/2”
“F Series
3” in 12” 903894 (3/12) 2-7/8”
3-1/2” in 12” 903894 (3/12) 3-1/4”
4” in 12” 903895 (4/12) 3-5/8”
4-1/2” in 12” 903895 (2.5/12) 2-1/8”
5” in 12” 903895 (2.5/12) 2-1/2”
“S” Series (2.5 / 12
Pitch only)
Optional Deck Flashings for Flat and 2.5/12 Pitch Roof Jacks. 4/12 Pitch Roof Jacks not applicable.
5-1/2” in 12” 903894 (3/12) 2-7/8”
6” in 12” 903894 (3/12) 3-1/4”
6-1/2” in 12” 903895 (4/12) 3-5/8”
Table 5. Slant Deck Flashings
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