Direct Vent (Sealed Combustion) Forced Air Gas Furnaces
Installation Instructions
M3RL Series 90+ Downflow Condensing Furnace
Forinstallationin:
1. Manufactured Homes
2. ParkModelsandManufacturedBuildings
3. ModularHomes/Buildings
!
WARNING:
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.
• Leavethebuildingimmediately.
• Immediatelycallyourgassupplierfromaneighbor'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 sup-
plier.
BW Models
BWT 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.
!
WARNING:
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.
– 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.
• Évacuerl’immeubleimmédiatement.
Improper installation, adjust-
ment, 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.
• 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.
LEAVE THESE INSTRUCTIONS WITH THE HOMEOWNER.
Download from Www.Somanuals.com. All Manuals Search And Download.
TABLE OF CONTENTS
General ...................................................... 4
Conversion .............................................. 21
UnitDimensions .................................. 4
Shipping Weights................................ 4
Furnace Specification ........................ 4
Air Flow Data ..................................... 4
LightingandAdjustment
of the Appliance .............................. 23
ElectricalWiring ...................................... 24
LineVoltageWiring ........................... 24
LowVoltageWiring ........................... 26
Owner's Information ................................ 5
Installation Requirements ...................... 6
Location .............................................. 7
Clearance ........................................... 7
Ventilation ................................................ 26
Start-up and Adjustment ........................ 26
Start-UpProcedure ........................... 26
Shut Down Procedure ....................... 27
Verifying and Adjusting Firing Rate ... 27
TemperatureRise ............................. 27
VerifyingandAdjusting
Circulating Air Supply ............................ 7
Return Air Provisions.............................. 8
Air Distribution Systems ........................ 9
Duct Connector Selection .................... 10
Duct Installation .................................... 10
Verifying Burner Operation.............. 28
Verifying Operation of the
Supply Air Limit Switch ................. 28
Venting and Combustion
Description of Components ................ 29
Air Requirements ........................... 13
Furnace Accessories............................. 29
Venting Requirements .......................... 14
Vent Table ........................................ 15
Vent Pipe Material ............................ 16
Vent Pipe Length and Diameter ....... 16
Vent Pipe Installation ........................ 16
Pipe Routing & Support .................... 16
Location of Outdoor Termination ..... 16
Horizontal Venting ............................ 18
Vertical Venting................................ 18
Vent Freezing Protection ................. 19
Concentric Vent Termination ........... 19
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
Drainage of Condensate
From Furnace................................ 19
Location of Major Components .......... 32
Gas Supply and Piping ......................... 20
Leak Check ....................................... 21
High Altitude Derate ......................... 21
Pressure Switch .............................. 21
Wiring Diagram ....................................... 33
Installation/Performance
Checklist ......................................... 35
M 3 R L - 060 A - A W
Return Air Configuration
Blank - Front
T - Top
Application
M-Manufactured Home
Door Color
W - White
G - Gray
Furnace Series
Cabinet Dimensions
A - 56" x 19-3/4" x 23-3/4”
B - w/Coil Cavity,
Comfort Model
RL - Condensing Downflow
76" x 19-3/4" x 23-3/4"
Electrical Code
Heating Capacity
A - 1PH, 60 Hz, 120 VAC
Input, BTUH (000’)
Table 1. Model Identification
3
Download from Www.Somanuals.com. All Manuals Search And Download.
GENERAL
1-1/2
21-11/32
COMBUSTIOON AIR INTAKE
19-7/8
3-17/32
24-5/8
COMBUSTION AIR INTAKE
17-13/16
EXHAUST VENT
1-11/16
EXHAUST
VENT
SIDE RETURN
KNOCKOUTS
SIDE RETURN
KNOCKOUTS
18-1/2
18-1/2
21-17/32
21-29/32
56-1/16
7/8 Diameter
(W/ Coiil Box)
75-1/4
(W/O Coiil Box)
28-15/32
23-7/16
21-15/16
20-9/32
1-19/32
3-17/32
4-11/16
1-19/32
3-17/32
4-11/16
Cooling
Coil
19-3/16
Box
20-1/16
24-3/4
Figure 1. Furnace Dimensions
TopReturnKnockouts
12.000
1.000
Shipping
Weight
(lbs)
Furnace Model
M3RL 060A AW
M3RL 060A BW*
M3RL 080A AW
M3RL 080A BW*
* May include suffix - T
21.000
150
170
155
175
Top View
(AW and BW Models)
Top Return Opening
(BWT Models)
Table 2. Shipping Weight
Furnace Specifications / Airflow Data
Furnace Furnace Temp.
External Static Pressure ( Inches Water Column) Recommended
Furnace
Model No.
Input
Btuh
Output Rise @ Motor Motor
0.1
0.2
0.3
0.4
0.5
A/C
Ton
4
3
2.-1/2
2
4
3
Btuh .3"WC °F HP
Speed
CFM
1660
1512
1340
1176
1660
1512
1340
1176
CFM
1599
1467
1304
1142
1599
1467
1304
1142
CFM
1544
1416
1261
1108
1544
1416
1261
1108
CFM
1474
1363
1217
1025
1474
1363
1217
1025
CFM
1410
1304
1158
966
1410
1304
1158
966
High*
Med-High
Med-Low
M3 RL-060 60,000
54,000 35 - 65
1/2 Low**
High*
Med-High
Med-Low**
2.-1/2
2
M3 RL-080 80,000
72,000 35 - 65
1/2 Low
Note: Data is for Operation with Filter.
Factory Wired Cooling Tap
** Factory Wired Heating Tap
*
Table 3. Furnace Specifications/Airflow Data
4
Download from Www.Somanuals.com. All Manuals Search And Download.
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 instruc-
tions. 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 contain-
ing 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 tempo-
rary heat of buildings or structures under
construction.
!
WARNING:
Do not use this appliance if any part
hasbeensubmergedunderwater. Im-
mediatelycallaqualifiedservicetech-
nician 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 instruc-
tions and warnings in this manual to insure
maximum performance, safety, and operating
efficiencyoftheseappliances.Improperinstalla-
tion 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.
M3 series furnaces are air conditioning ready
as shipped. The furnace cooling capacities of
the blower motor speed taps are shown in
Table 3. Table 2 lists the shipping weights for
the M3 series furnaces.
OWNER INFORMATION
These furnaces may be installed in:
1. Manufactured Homes.
2. Park Models and Manufactured buildings
3. ModularHomes/Buildings
NORDYNE has been involved in the design of
products for the manufactured home industry
since the first manufactured home or trailer
was built.
The following are safety guidelines with refer-
ences to their specific sections or pages in the
manual.
NORDYNE originated the sealed combustion
system, which separates the furnace com-
bustion system from the living area of the
home, now a standard for the manufactured
home industry.
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 ventila-
tion 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 ap-
proved vent system only, as specified in
pages 14-19 of these instructions.
NORDYNE engineers developed the first cen-
tral heating system and the first central air
conditioner for manufactured homes.
NORDYNE is dedicated to bringing to its cus-
tomers the finest heating and cooling comfort
possible. NORDYNE constantly seeks to fur-
ther refine its products to continuously provide
exceptional comfort.
5
Download from Www.Somanuals.com. All Manuals Search And Download.
Follow the instructions in this booklet carefully
and this appliance will provide many years of
superior performance.
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.
If you wish to cool your home automatically
with a central air conditioning system investi-
gate the excellent NORDYNE cooling systems
available from your heating and cooling con-
tractor. 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.
Carefully review these responsibilities with your
manufacturedhousingdealer,servicecompany
or gas supplier so there will be no misunder-
standing at a later time.
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
youarenotabletolocateasourceforNORDYNE
manufactured housing products in your area.
!
CAUTION:
• Never attempt to alter or modify this
furnace or any of its components.
• Never attempt to repair damaged or
inoperablecomponents.Suchaction
could cause unsafe operation, ex-
plosion, fireand/orasphyxiation.
• If a malfunction has occurred, or if
you feel that the furnace is not oper-
atingasitshould,contactaqualified
service agency or gas utility for as-
sistance.
MANUFACTURER WARRANTY, OWNER’S
RESPONSIBILITIES
It is the sole responsibility of the homeowner to
makecertainthegasfurnacehasbeencorrectly
set up and converted to the proper fuel (L.P. gas
or Natural gas) and adjusted to operate prop-
erly. All gas furnaces are manufactured for
Natural gas and must be field converted when
using L.P. gas.
INSTALLATION STANDARDS
Installershallbefamiliarwithandcomplywithall
codes and regulations applicable to the installa-
tion of these heating appliances and related
equipment. In lieu of local codes, the installation
shall be in accordance with the current provi-
sions 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, Commu-
nities, 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 in-
stallations.
d. American National Standard (ANSI-Z223.1/
NFPA-54) and/or CAN/CGA B149 for all gas-
fired furnace models.
A warranty certificate with full details is included
with these instructions. However, NORDYNE
will not be responsible for any costs found nec-
essary to correct problems due to improper
setup,improperinstallation,furnaceadjustments,
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.
e. AmericanNationalStandard(ANSI-C1/NFPA-
70) and/or CSA 22.1 Canadian Electric Code
Part 1 for all electrical field wiring.
5. Correcting problems due to improper gas
supply pressure to the furnace.
6
Download from Www.Somanuals.com. All Manuals Search And Download.
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 Na-
tional Fuel Gas Code ou les codes d'installation
CAN/GCA-B149.
bustible material other than wood flooring. The
furnace may be installed on combustible floor-
ing when installed on a Nordyne duct connec-
tor (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.
The National Fuel Gas Code is available by
writing:
American National Standards Institute, Inc.
1430 Broadway
New York, NY 10018
When installed in a residential garage, the fur-
nace 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.
NFPA publications are available by writing:
National Fire Protection Association
Batterymarch Park
Quincy, ME 02269
CIRCULATING AIR SUPPLY
LOCATION
!
WARNING:
The furnace must be installed on a level sur-
face, and as close to the center of the air
distribution system as possible. See Figure 1
for overall dimensions to determine the re-
quired clearances in hallways, doorways,
stairs, etc. to allow the furnace to be moved to
the installation point. The furnace must be in-
stalled so that all electrical components are
protected from water.
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
hazardousconditionsincludingcarbon
monoxidepoisoningthatcouldresultin
personal injury or death.
Minimum clearances to combustible materials
are listed in Table 4. Access for positioning and
servicing must be considered when locating
the unit.
The floor or platform on which the
furnaceismountedmustprovidesound
physical support of the furnace with no
gaps, cracks, or sagging between the
furnace and the floor or platform.
This furnace is certified for use on wood
flooring. The furnace must be installed on a
solid surface and must be level front-to-back
and side-to-side. This furnace must not be
installed directly on carpeting, tile, or any com-
The circulating air ductwork must not
be connected to any other heat
producing device such as a fireplace
insert, stove, etc.
CLOSET ALCOVE
ALL MODELS
Inches
Inches
Front
Back
Sides
Vent
Top
Duct (Plenum)
w/ Coil Box
1*
0
0
1*
0
0
GENERAL
0
6
0
6
Plenums and air ducts must be installed in
accordance with the Standard for the Installa-
tion of Air Conditioning and Ventilating Systems
(NFPA No. 90A) or the Standard for the Instal-
lation of Warm Air Heating and Air Conditioning
Systems (NFPA No. 90B).
0
1/4
0
1/4
w/o Coil Box
(within 3 feet)
*Note:For1”clearance, useafullylouvereddoorwithat
least400squareinchesoffreeairflowarea.
Table 4. Minimum Clearances
7
Download from Www.Somanuals.com. All Manuals Search And Download.
inthefloororceilingshallnotbelessthan235
square inches.
RETURNAIRPROVISIONS
U.S.A. home manufacturers shall comply with
all of the following conditions to have accept-
able return air systems for closet installed
forced air heating appliances:
a. Regardless of the location, the return air
opening into the closet shall not be less than
specified in the appliance’s listing.
b. Means shall be provided to prevent 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 clear-
ance between 1” and 6” from furnace, re-
quirements are a louvered door with mini-
mum of 235 sq. in. free area, with the open-
ings in closet door directly inline with the
louvered openings in the furnace door. For
1” clearance from furnace, use a fully lou-
vered door with at least 400 sq. in. of free
airflow area.
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”
TopView
13 1/4"
d. The cross-sectional area of the return duct
system leading into the closet, when located
of Duct
10 1/4"
Connector
A Single trunk duct
Figure 4.
Use Duct Connector
If "X" (Floor Cavity) is:
English Metric (mm) Finger Tab Screw Down
Model Part Number:
Dual trunk duct
B
w/crossover connector
7/8"
2"
22
51
901987
901988
901989
901990
901991
901992
901993
904008
904009
904010
904011
904012
904013
904014
4 1/4"
6 1/4"
8 1/4"
10 1/4"
12 1/4"
108
150
210
260
311
Transition duct
w/branches
C
Figure 2. Non-Platinum
Supply Duct System
Table 5. Duct Connectors
FLOOR CAVITY
(depth equal to "X" in Figure 5 and Table 5)
x
SUPPLY AIR DUCT
Figure 3.
8
Download from Www.Somanuals.com. All Manuals Search And Download.
( )OPENING TO DUCT
REDUCER
(1) WITH PLATE (C) REMOVED
OPENING BECOMES
13-1/4” x 13-1/4”
FELT-SEAL(1)
(2) WITH PLATE (C) REMOVED
OPENING BECOMES
13" X 13". WITH REDUCER
IT IS 13" X 10-1/8".
C
SEE
X
TABLE 5
SPACERS
(1) FINGER TAB DUCT CONNECTOR ONLY
(2) SCREW DOWN DUCT CONNECTOR ONLY
Figure 5.
ALT. FUEL
LINE HOLES
10"
C
L
C
L
FLOOR
OPENING
23 -1/4"
FUEL LINE
HOLE
Figure 6. Closet or Alcove
tain necessary airflow. Use NORDYNE’s
certiduct program to determine proper duct
size for A/C.
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:
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
installedkit. RefertoTable12fortheNORDYNE
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”.
!
CAUTION:
HAZARD OF ASPHYXIATION: Do not
cover or restrict return air opening.
M3 furnaces with model numbers ending in
BWT are factory configured for the return air to
enter the top of the furnace.
l. Air conditioning systems may require more
duct register and open louver area to ob-
9
Download from Www.Somanuals.com. All Manuals Search And Download.
20
14-1/2
2-3/4
REAR WALL OF CLOSET OR ALCOVE
2-1/4
FLOOR CUT-OUT
FOR DUCT CONNECTIONS
17-29/32
14-1/2
21-3/4
24
21-7/16
3-19/32
1-3/4
VENT
23-1/4
COMBUSTION AIR INTAKE
FUEL LINE ENTRY
2
10
1-3/4
˚
1-1/4
12-7/8
ALT FUEL LINE
ENTRY
14-3/4
FURNACE
OUTER DOOR
15-1/2
FLOOR CUT-OUT
FOR OPTIONAL
COOLING COIL
FOR NON-PLATINUM
SERIES UNITS
Figure 7. Cut-Out Locations
cavity. To maximize air delivery, re-
move reducer “C” (see Figure 5) to
obtain the largest open area that will fit
the duct/floor construction.
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.
DUCTINSTALLATION
Required floor, ceiling, and roof cut-out open-
ings must be carefully located to avoid mis-
alignment of the furnace (see Figures 6 & 7).
Installation procedures are suggested for typi-
cal furnace installations and need not be fol-
lowed in the exact listed sequence.
Three typical distribution systems are illus-
trated 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.
DUCTCONNECTORSELECTION
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 cut-
out measuring approximately 14-1/2" by 14-
1/2" (± 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
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
INSTALLING PLATINUM SERIES 14”
ROUND DUCT CONNECTOR
a. Place duct connector through the floor open-
ing. (See Figure 9).
d. Cut out floor opening and one gas line hole.
b. Secure duct connector to floor.
CUT DUCT OPENING (FINGER TABBED
ONLY)
INSTALLING SCREW DOWN DUCT CON-
NECTOR
a. Place duct connector through the floor open-
ing with bottom tabs resting on top of the
supply air duct.
b. Centerductconnectorandpushbackagainst
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.
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.
INSTALL FURNACE MOUNTING PLATE
a. Place mounting plate (supplied within duct
connector) at rear of the floor opening (See
Figure 9).
d. Screw plenum to duct making sure a seal is
made between the duct and the duct con-
MOUNTING
PLATE
REAR WALL
FLOOR
OPENING
FUEL
LINE
HOLES
SUPPLY AIR DUCT
Figure 8. Mounting Plate
SCREWS
SCREWS
BEND CONNECTOR TABS
UNDER DUCT OPENING
MOUNTING
PLATE
MOUNTING
PLATE
MOUNTING
PLATE
PLENUM
FLOOR
OPENING
FLOOR
OPENING
FUEL
LINE
HOLES
FUEL
LINE
HOLES
FUEL
LINE
HOLES
SUPPLY AIR DUCT
SUPPLY AIR DUCT
14”SUPPLY
CONNECTION
Screw Down
Finger Tabbed
Duct Connectors
Platinum Series
Duct Connectors
Figure 9. Duct Connector
11
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
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.
INSTALLING FINGER TABBED DUCT CON-
NECTORS
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. Bendbottomtabsunderanduptightlyagainst
the supply air duct (See Figure 10).
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).
NOTE: The duct connector is designed for use
on ducts 12" in width. When using the connec-
tor 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
1. Score and cut the top of the metal duct as
indicated in Step 1 or Step 2. With Step 1
choice,alsocutoutthemetalfromtheshaded
area “A”.
2. Fold the duct flap “B” up, (See Step 3).
TABS
DUCT
TABS
DUCT
1. INSERT DUCT PLENUM CONNECTOR
INTO DUCT CUT-OUT.
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.
STEP 1.
Fold Back Flap "B"
Fold Back Flap"B"
Cut
Lines
Duct
Cut- Out
Area "A"
Cut- Out
Area"A"
"B"
"B"
"B"
"B"
"A"
"A"
"A"
"A"
Top of Duct
Fold Back Flap"B"
Fold Back Flap "B"
Staple Folded Duct
Flap (typ) to side of Duct
Connector
Bend Duct Connector Tabs Up
and Over- (along length of duct)
Duct
Duct
Duct
Flap "B"
STEP 4.
STEP 3.
Figure 12. Alternate Installation
12
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTE: Additional fasteners may be used at
rear, sides or through door frame, as desired,
to secure furnace to closet or alcove framing.
SLIDE FURNACE
ALL THE WAY BACK
ONTO MTG. PLATE
MTG. PLATE TABS
SECURE FURNACE
WITH 2 FASTENERS AT FRONT
CORNER HOLES
VENTINGANDCOMBUSTIONAIR
REQUIREMENTS
!
CAUTION:
Snow must not be allowed to restrict or
block the combustion air intake or vent
pipes.
Figure 13. “A”, “B”, & Platinum
Cabinet Furnaces
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.
SLIDE FURNACE
ALL THE WAY BACK
ONTO MTG. PLATE
MTG. PLATE TABS
SECURE FURNACE
WITH 2 FASTENERS
AT FRONT CORNER HOLES
FUEL
LINE
HOLES
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.
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).
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.
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.
!
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.)
!
WARNING:
Furnace installation using methods
other than those described in the
followingsectionsmustcomplywiththe
National Fuel Gas Code and all
applicable local codes to provide
sufficientcombustionairforthefurnace.
d. Secure front with one (1) fastener at each
corner (See Figure 13 or 14).
13
Download from Www.Somanuals.com. All Manuals Search And Download.
that there is no blockage or re-
striction, leakage, corrosion and
other deficiencies which could
cause an unsafe condition.
!
CAUTION:
Do not allow debris to fall into the fur-
nace. This could cause unsafe opera-
tion and voids the furnace warranty.
3. So far as is practical, close all
building doors and windows and
all doors between the space in
whichtheappliance(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
operatecontinuously.
VENTINGREQUIREMENTS
!
WARNING:
FURNACE MUST NOT BE COMMON
VENTED WITH OTHER APPLIANCES.
5. Turn on clothes dryers and any
other appliance not connected to
the venting system. Turn on any
exhaustfans,suchasrangehoods
and bathroom exhausts, so they
shall operate at maximum speed.
Do not operate a summer exhaust
fan.
General
Thissectionspecifiesinstallationrequirements
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, vent and combustion air
piping lengths must conform completely to the
requirements of Table 6.
6. Close fireplace dampers.
7. Test for spillage from draft hood
equipped appliance at the draft
hoodreliefopeningafter5minutes
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
ventingsystemmustbecorrected
in accordance with the National
FuelGasCode,ANSIZ223.1/NFPA
54and/orCSAB149.1,NaturalGas
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.
The furnace must be vented to the outdoors.
!
WARNING:
CARBON MONOXIDE POISONING
HAZARD
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/CGAB149InstallationCodes
andtheseinstructions. Determine
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
Download from Www.Somanuals.com. All Manuals Search And Download.
*NOTES
1.
2.
3.
Subtract3.5ft.foreachadditional3"90degreeelbow.
MAXIMUM
DIRECT VENT, DUAL
PIPE LENGTH (ft.)*
Two45degreeelbowsareequivalenttoone90degreeelbow.
One short radius elbow is equivalent to two long radius
elbows.
Donotincludeterminationelbowsincalculationofventlength.
Thistableisapplicableforelevationsfromsealevelto4000
ft. Forhigherelevations,decreaseventpipelengthsby8%per
1000ft.ofaltitude.
APPLICATION
Inlet/Outlet
PVC,CPVC or ABS
4.
5.
SCH. 40 Pipe Size
Model M3RL 060
3"
50
50
3"
50
50
Model M3RL 080
6.
Onlytheabovepipematerialsareapprovedforusewiththese
condensingfurnaces.
Table 6. Vent Table
VENT TERMINAL
AIR SUPPLY INLET
AREA WHERE TERMINAL IS NOT PERMITTED
Canadian Installations1
US Installations2
Clearance above grade, veranda, porch,
deck, or balcony
12 inches (30 cm)
12 inches (30 cm)
A =
B =
≤
≤
Clearance to window or door that may be
opened
6 inches (15 cm) for appliances 10,000 6 inches (15 cm) for appliances 10,000
Btuh (3 kW), 12 inches (30 cm) for
appliances > 10,000 Btuh (3 kW) and
Btuh (3 kW), 9 inches (23 cm) for
appliances > 10,000 Btuh (3 kW) and
≤
≤
100,00 Btuh (30 kW), 36 inches (91 cm) for 50,000 Btuh (15 kW), 12 inches (30 cm) for
appliances >100,00 Btuh (30 kW)
appliances > 50,000 Btuh (15 kW)
Clearance to permanently closed window
Vertical clearance to ventilated soffit
located above the terminal within a
horizontal distance of 2 feet (61 cm) from
the center line of the terminal
C =
D =
*
*
*
*
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
Clearance to each side of center line
extended above meter/regulator assembly above the meter/regulator assembly
Clearance to service regulator vent outlet 3 feet (1.83 m)
E =
F =
G =
H =
*
*
*
*
*
*
3 feet (91 cm) within a height 15 feet
*
I =
*
≤
≤
Clearance to nonmechanical air supply inlet 6 inches (15 cm) for appliances 10,000 6 inches (15 cm) for appliances 10,000
J =
to building or the combustion air inlet to any Btuh (3 kW), 12 inches (30 cm) for
Btuh (3 kW), 9 inches (23 cm) for
≤
≤
other appliance
appliances > 10,000 Btuh (3 kW) and
appliances > 10,000 Btuh (3 kW) and
100,00 Btuh (30 kW), 36 inches (91 cm) for 50,000 Btuh (15 kW), 12 inches (30 cm) for
appliances >100,00 Btuh (30 kW)
appliances > 50,000 Btuh (15 kW)
Clearance to a mechanical air supply inlet
6 feet (1.83 m)
3 feet (91 cm) above if within 10 feet (3 m)
horizontally
K =
L =
M =
Clearance above paved sidewalk or paved 7 feet (2.13 m) †
driveway located on public property
*
*
Clearance under veranda, porch deck, or
balcony
12 inches (30 cm) ‡
1
In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code
In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code
A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family
dwellings and serves both dwellings.
2
†
‡
*
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
manufacturer’s installation instructions.”
Figure 15. Vent Termination Clearances for Direct Vent Furnaces
15
Download from Www.Somanuals.com. All Manuals Search And Download.
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,theventingsystemmaynotbeproperly
sized. Totesttheventsystemwiththeremaining
appliances, follow the test outlined below.
Combustionairmustnotbedrawnfrom
occupied spaces and a corrosive
atmosphere.
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
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.
operation:
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).
Vent Pipe Material
Vent and combustion air pipe and fittings must
be one of the following materials and must
conformtotheindicatedANSI/ASTMstandards:
Material
Schedule 40 PVC
PVC-DWV
Standard
D1785
D2665
These condensing furnaces have been
certified for installation with zero clearance
betweenventpipingandcombustiblesurfaces.
However, it is good practice to allow space for
convenience in installation and service.
SDR-21
& SDR-26
ABS-DWV
D2241
D2661
F628
F891
Schedule 40 ABS
Foam/Cellular Core PVC
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.
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
perthepipingmanufacturer'srecommendation
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.
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 Cana-
dian Fuel Gas Code takes precedence.
16
Download from Www.Somanuals.com. All Manuals Search And Download.
Downflow Furnace
3 9/16"
Vent
1 7/8"
Combustion
Air Intake Pipe
See Vent Table 4
Seal/Caulk
Around Pipe
at Building
Straps or Other Suitable
Supports at Minimum of
5 ft. Intervals
Top View
Coupling
90˚ Elbow
Offset with
Vent for Adequate
Dimensional Clearance
Exhaust
Vent
PVC or
ABS pipe
Upward Pitch - 1/4" Per Foot
Outlet Exhaust Vent
12"
Min.
Wall
First Support Should be as Close to
Furnace Connection as Possible
3" x 2"
Combustion Air
Normal Snow Level
Furnace
Reducer
Intake Pipe
Figure 16. Horizontal Venting
Support System
on Vertical Rise
Below Joints
First support should be as
close to furnace as possible
Combustion Air
Intake Pipe
5'
Vent
Vent
Upward Pitch
1/4" per foot
Combustion Air Intake Pipe
Figure 17. Vertical Venting
5. Avoid areas where condensate drainage
may cause problems by dropping on plant-
ers or patios, etc. Also ensure that ex-
haust gases will not impinge on windows
or building surfaces, which may be com-
promised or damaged by condensation.
Do not install the vent terminal such that
exhaust is directed into window wells,
stairwells, under decks or into alcoves or
similar recessed areas, and do not termi-
nate above any public walkways.
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
throughwallwhichexperiencestheleast
exposure to winter winds.
17
Download from Www.Somanuals.com. All Manuals Search And Download.
Horizontal Venting
2. Extend the vent pipe through the wall
approximately 1" and seal the area be-
tween the wall and pipe.
3. Apply couplings to the vent pipe on the
interior and exterior sides of the wall to
insurethepipecannotbepushedorpulled
through the wall.
Vent and combustion air intake terminations
must be as shown in Figure 19 unless the
concentric vent termination kit is used.
!
4. Insure the combustion air inlet pipe has a 90
degree termination elbow, and is pointing
downward as shown in Figures 19 & 20.
WARNING:
Ensurethatthecombustionairventand
the exhaust vent are configured as
shown in Fig. 19. Improper vent
termination can cause recirculation of
thefluegases.Thismayresultinfurnace
vibration. In severe cases, the furnace
willcycle,duetotheintermittentcontact
betweentheflameandtheflamesensor.
Ifyounotetheseoscillationsoccurring,
checktheventconfiguration.Makesure
thattheexhaustventdoesnothavea90
degree termination.
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 in-
stalled with a shorter vent.
For horizontal venting, either the Horizontal
Exterior Vent Mounting Kit or the Concentric
Vent Termination Kit may be used (See Table
12).
• The inlet for the combustion intake pipe must
beextendedatleastonefootabovetheroofline
or snow accumulation level.
• Theoutletoftheventmustbeextendedatleast
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 re-
quirements from the roof and from each other
must be per Figure 20.
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 con-
sists of two face plates and an insulating gas-
ket 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 cou-
plings. 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.
Concentric Vent Termination
A concentric vent termination is approved for
use with these furnaces (See Table 12). For
proper installation of the concentric vent termi-
nation, follow the installation instructions pro-
vided with the kit.
When the above kits are not used the following
steps are required:
1. Check the hole size cut through the exte-
rior wall. Insure that the hole diameter is
less than the diameter of the couplings to
be used.
18
Download from Www.Somanuals.com. All Manuals Search And Download.
Vent Configuration to
Provide 12" Minimum
height above
Exhaust Vent
Option B
Mounting Kit
Faceplate Secured
to Wall with Screws
Snow Level.
Exhaust Vent
Option A
12" Min.
19" Max.
12" Min.
36" Max.
Combustion
Air Inlet
8" Min.
Support
Exhaust Vent
Option C
Outside
Wall
12" Above
Normally
Expected
Snow
12" min.
36" max.
Grade
Level
or Normal
Snow
12" Min.
36" Max.
12" Min. to
7" Min.
1/2"
Armaflex
Normal Snow Level
Level
Exhaust
Inlet
Insulation or
Equivalent
(if required)
Figure 18. Alternate Horizontal
Vent Installation
Figure 19. Exhaust and Combustion Air
Pipe Clearances
DRAINAGEOFCONDENSATE
FROMFURNACE
!
CAUTION:
Do not install additional traps in the
condensate drain.
!
WARNING:
The condensate drain may exit through the left
side panel, the right side panel, or through the
leftorrightholeonthebottompanel.(SeeFigure
21). Ensure that the flexible drain hose is not
kinked.
Thecondensateproducedbythefurnace
mustbedrained.Donotconnectawater
supply to the drainage hose of the
furnace.
NOTE: The condensate drain should be pro-
tected from freezing when in unheated spaces.
The condensate should drain from the plastic
collector box (location A in Figure 21) as drop-
lets 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.
The furnace is supplied with an internal conden-
sate drain trap.
5" Min.
A= 12" Above Roof or
36" Max.
Note: If terminations meet-
ing these vertical require-
Snow Accumulation Level
Exhaust
Vent
Elbow
ments exceed the maximum
height for safe transit, the
vent and combustion air in-
takes may be shipped with
the home for assembly on
site. The furnace must be
labeledtonotifytheinstaller/
user not to use the furnace
Combustion
1"
Air Intake
10" Min.
A
until the vent and combus-
Exhaust
tion air intake terminations
Plumbing Vent
are installed.
Roof Boot
(Typ. Both Pipes)
Figure 20. Vertical Vent Termination
19
Download from Www.Somanuals.com. All Manuals Search And Download.
Collector
Box
A
Clamp
Step 1: Loosen
Step 2: Rotate to drain direction
Step 3: Retighten
Burner
Box
Keep
Downward
Slope
“Hard”
J DrainTube
Floor
Alt. Drain
Alt. Drain
Alt. Drain
Alt. Drain
Figure 21. Furnace with Condensate Drain Trap Assembly
1. Remove the collector box soft tube at
readily accessible for service and/or emer-
gency use. Consult the local utility or gas
supplier for additional requirements regarding
placement of the manual main gas shut-off. In
the absence of local codes, the gas line instal-
lation must comply with the provisions stated in
the Federal Manufactured Home Standard
(H.U.D Title 24, part 280) and the National Fuel
Gas Code (ANSI Z223.1/NFPA-54) or (CAN/
CGA B149) installation codes.
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
headerspoutisairtight.Airwillbedrawninto
the header if this connection is not tight.
3. Check other tube connections along the
drain system. Insure that all are air tight.
NOTE: Industry research studies indicate that
when condensate is routed to an active drain,
household detergents, etc., buffer its acidity. If
the drain is not actively used or if codes require,
obtain a neutralizer kit (See Table 12). Proper
drains and connections to the condensate tub-
ing are required as NORDYNE cannot be held
responsible for water leakage which occurs
due to loose hose connections or improperly
sealed drain line pipes.
A drip leg should be installed in the vertical pipe
run to the unit. Table 7 lists gas flow capacities
for standard pipe sizes as a function of length
in typical applications based on nominal pres-
sure drop in the line.
NOTE: Gas piping must not be run in or through
air ducts, gas vents, etc.
Compounds used on threaded joints of gas
piping must be resistant to the actions of lique-
fied petroleum gases.
GAS SUPPLY AND PIPING
General
This furnace is equipped for bottom, left, or
right side gas entry. Typical gas service hook-
ups are shown in Figure 22. When making the
gas connection provide clearance between the
gas supply line and the entry hole in the furnace
casing to avoid unwanted noise and/or damage
to the furnace.
!
CAUTION:
Do not use matches, lighters, candles,
orothersourcesofopenflametocheck
for gas leaks.
All gas piping must be installed in compliance
with local codes and utility regulations. Some
localregulationsrequiretheinstallationofamanual
mainshut-offvalveandgroundjointunionexter-
nal to the furnace. The shut-off valve should be
NOTE: When pressure testing gas supply
lines at pressures greater than 1/2 psig (14 in.
water column), the furnace must be discon-
nected from the gas supply piping system to
prevent damage to the gas control valve.
20
Download from Www.Somanuals.com. All Manuals Search And Download.
CONVERSION
This furnace can be converted from the fac-
tory-equipped gas to either natural gas (for LP
gas ready models), or LP gas (for natural gas
ready models). Conversions must be made by
qualified service personnel, using only factory
authorized or approved parts. The required
conversion orifices are supplied with the fur-
nace.
Main
Blower
Control
Board
!
WARNING:
DO NOT REMOVE OR DEFACE THE
Inducer
ORIGINAL RATING PLATE.
Burner
Box
Gas
Valve
!
CAUTION:
Floor
The gas supply shall be shut off prior to
disconnecting the electrical power,
beforeproceedingwiththeconversion.
Alt. Gas
Line Entry
To Gas
Supply
To Turn Off Fuel Supply to the Appliance:
Figure 22. Typical Gas Piping
1. Set the room thermostat to “OFF” or its
lowest temperature setting.
2. Turn OFF the main gas supply to the appli-
ance at the manual valve, outside of the
appliancecasing.
3. Remove the control access panel / lou-
vered door.
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.
4. Movetheappliancegasvalvelever/knobto
the “OFF” position.
5. Turn OFF the electrical power to the appli-
ance.
Leak Check
After the gas piping to the furnace is complete,
all connections must be tested for gas leaks. To
check for leaks use only a soap and water solu-
tion or other approved method.
CAPACITY OF BLACK IRON GAS PIPE (CU. FT. PER HOUR)
FOR NATURAL GAS (SPECIFIC GRAVITY - 0.60)
High Altitude Derate
NOMINAL
LENGTH OF PIPE RUN
(feet)
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.
BLACK IRON
PIPE DIAMETER
(in.)
1/2
10
130
20
90
30
75
40
65
50
55
60
50
70
45
95
80
40
90
3/4
280 190 150 130 115 105
1
520 350 285 245 215 195 180 170
1050 730 590 500 440 400 370 350
1600 1100 890 760 670 610 560 530
1 1/4
1 1/2
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.
Todeterminethecubicfeetperhourofgasflowrequiredbythefurnace,
divide the input rate of the furnace by the heating value of the gas:
NOTE: The density of air decreases with in-
creasing elevation above sea level. This re-
duces the quantity of combustion air drawn into
thefurnaceundernormaloperationandrequires
the unit be derated by using smaller gas orifices
or lower manifold pressure.
CubicFeet
PerHourRequired
InputToFurnace(Btu/hr)
HeatingValueofGas(Btu/Cu.Ft.)
=
Table 7. Capacity of Black Iron Gas Pipe
(cu. ft. per hour) for Natural Gas
(specific gravity = .60)
21
Download from Www.Somanuals.com. All Manuals Search And Download.
To Remove the Burner Assembly:
!
CAUTION:
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.
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
typeofconversion(sealevelorhighaltitude;
natural gas or LP gas).
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 fas-
teners 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 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 in-
stalling at altitudes above 4,000 feet to
install the proper orifices, shown in Table
8. When installing the new orifices, DO
NOT use pipe joint compound on the
orifice threads. Screw the orifices into the
manifold by hand until snug to eliminate
cross threading, then tighten with a
wrench. Before installing an orifice, check
the face or side of the orifice for the drill
number to ensure that it is the appropriate
size.
3. For the conversion to the alternate fuel,
the gas valve regulator cap must be turned
over, as shown in Figure 23. You will
unscrew the cap and reinstall for your in-
stallation. Afterreinstallingthecap,youwill
be able to read "NAT" for the conversion to
natural gas or "LP for the conversion to LP
gas.
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. Carefullyremovetheburnerorificesfromthe
gas manifold, as shown in Figure 25.
Furnace Rating
Plate Input
(Btuh)
Elevation
0 - 2000
Elevation
4000-6000
Elevation
6000-8000
Elevation
8000-10000
Elevation
2000-4000
Furnace
Model Number
M3RL -
No. of
Burners
Nat
LP
57
Nat
50
LP
Nat
LP
Nat
LP
Nat
52
LP
59
58
060A-A/BW
080A-A/BW
60,000
80,000
4
5
50
49
57
51
50
58
57
51
50
58
57
1.15 mm
49
1.15 mm
51
Table 8. Approximate Orifice Size for Natural and LP Gases
22
Download from Www.Somanuals.com. All Manuals Search And Download.
Reinstalling the Burner Assembly:
OR
Honeywell
Valve
1. Reinstall the gas manifold assembly to the
burner box with the four (4) fasteners,
which were removed earlier.
OTHER SIDE
OF CAP
PRESSURE
REGULATOR
CAP
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 burn-
ers should be aligned with the center of the
tubes.
M11678
3. Reconnect the gas piping to the gas valve.
4. Reconnectthewirestothegasvalve termi-
nals.
5. Reconnecttherubberpressuretubestothe
gasvalveandtheburnerbox. Reinstallthe
burner access cover plate.
Figure 23. Convertible Pressure
Regulator Cap
6. Reconnect the ignitor at the 2 position
plug.
7. Reconnect the flame sensor wire to the
burner box.
Pressure Gauge Installation
NOTE: For natural gas installations, the in-
coming 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 pres-
sure 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.
Figure 24. Burner Inspection
Burner
Gas
Orifices
Manifold
Flame
Observation
Port
On/Off
Lever
LIGHTINGANDADJUSTMENTOF
THEAPPLIANCE
1. Turn ON the gas at the manual valve,
outside of the unit.
Burner
Box
Inlet
Pressure
Tap
Access
Cover
Plate
Inlet
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.
Gas
Valve
Figure 25. Typical Installation For Sealed
Burner Box With Access Cover Plate
3. Turn ON the electrical power to the appli-
ance.
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 instruc-
tions provided with your unit for the normal
operating sequence.
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.
23
Download from Www.Somanuals.com. All Manuals Search And Download.
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. Inaproperlyadjustedburnerassem-
bly, 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.
ELECTRICAL WIRING
NOTE: Until all of the air is bled out of the gas
line,thehotsurfaceignitormaynotignitethegas.
Iftheignitioncontrollocksout,turnthethermostat
toitslowestsettingandwaitoneminutethenturn
thethermostattoapointaboveroomtemperature
and the ignitor will try again to ignite the main
burners. This process may have to be repeated
severaltimesbeforetheburnerswillignite. 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.
General
Electrical connections must be made in accor-
dance with all applicable local codes and ordi-
nances, and with the current revision of the
National Electric Code (ANSI/NFPA 70).
For Canadian installations electrical connec-
tions and grounding must be done in accor-
dance with the current Canadian Electrical
Code (CSA C22.1 Part 1) and/or local codes. If
any of the original wire as supplied with the
furnace must be replaced, it must be replaced
with wire having a minimum temperature rating
of 105°C. Refer to the furnace nameplate and
Table 8 for electrical requirements.
Manifold Pressure
The gas valve for the M3 furnace series is
equipped with a special conversion pres-
sure regulator cap. The pressure regulator
cap is factory set. If the gas valve is con-
verted from natural gas to propane gas or
vise versa, the manifold pressure of the gas
valve will be set to pressure listed in Table 9.
Line Voltage Wiring
The line voltage (115 volt) to the furnace must
be supplied from a dedicated branch circuit
containing the correct fuse or circuit breaker
for the furnace. See Table 10. An electrical
switch should be readily accessible from and
within sight of the furnace. See the Wiring
Diagram label in the furnace for more details.
Type of Fuel
Manifold Pressure
In. WC
Natural Gas:
Propane (LP) Gas:
3.5
10.0
The furnace cabinet must have an uninter-
rupted, unbroken ground to minimize injury
should an electrical fault condition occur. The
controls used in this furnace require an earth
ground to operate properly. Acceptable meth-
ods for grounding are electrical wire or conduit
approved for electrical ground service. Do not
use gas piping as an electrical ground.
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.
NOTE: Proper line voltage polarity must be
maintained in order for the control system to
operate correctly. Verify that the incoming neu-
24
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
Low Voltage Wiring
Install the thermostat per the manufacturer's
instructions. The low voltage (24 volt) connec-
tions from the thermostat are made at the
terminalstriponthecontrolboardinthefurnace.
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.
!
CAUTION:
Label all wires prior to disconnection
when servicing controls. Wiring errors
can cause improper and dangerous
operation.
3 Amp Fuse
Blower Off
COM
Timing
24 V
TWIN
Verify proper operation after servicing.
Flame Signal
Light (Yellow)
Status
Light (Red)
9
8
7
6
5
4
3
2
1
!
ATTENTION:
Lors des opérations d'entretien des
commandes, étiqueter tous les files
avantdeslesdéconnecter. Touteerreur
de câblage peut être une source de
danger et de panne.
Common
Leads
Neutrals
Unused Motor
Leads
Connect
Neutral
Lead of
6
3
2
1
5
4
Electronic
Air Cleaner
and/or Humidifier
Here.
Electronic Air Tap
(.5A@ 120 VAC)
Humidifier Tap
(.5A@ 120 VAC)
S'assurer du bon fonctionnement de
l'appareil après tout entretien.
These motor speed taps are
not used for two-stage models
Figure 27. Blower Speed Tap Location
Furnace
Input
Cabinet
Width
(in.)
Nominal
Electrical
Supply
Maximum Minimum Maximum Minimum
Maximum
Operating Operating Furnace
Wire
Fuse or Circuit
Breaker Amps*
(Btuh)
Voltage
Voltage
Amperes
Gauge
60,000
80,000
19.75
19.75
115-60-1
115-60-1
127
127
103
103
9.7
9.7
14
14
15
15
Recommended Thermostat Wire Length
Thermostat Wire Gauge
2-wire (heating)
4 or 5-wire (cooling)
24
22
20
18
55 ft.
90 ft.
140 ft.
225 ft.
25 ft.
45 ft.
70 ft.
110 ft.
* Time-delay fuses or HACR-type circuit breakers are required.
Table 10. Electrical Data
Field Supplied
Field Supplied
Fused Service
Panel Connector
Panel
Field Line Voltage
Wiring
Black (Hot)
Black
White
Black
White
Black
White
Factory Line
Voltage Wiring
White (Neutral)
Green or Bare
(Ground)
Ground
Ground
Ground
Junction Box (may be internal
or external to the furnace). These
connections can be made in the
field supplied disconnect at the
furnace.
Field Supplied Disconnect
Within Sight of Furnace
Figure 26. Line Voltage Field Wiring
25
Download from Www.Somanuals.com. All Manuals Search And Download.
A/C Condensing Unit
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.
Condensing Unit
Control Box
Blower Off
Timing
COM
24 V
3 Amp
Fuse
Connect
R & W
For
Heating
Only
TWIN
Flame Signal Light
(Yellow)
To check the heat anticipator setting either:
Status Light
(Red)
Room
Thermostat
9
8
7
6
5
4
3
2
1
1. Add the current draw of the system com-
ponents; or
NOTE:The "Y"
terminal on the
UTEC control board
must be connected
to the thermostat
for proper cooling
mode operation.
2. Measurethecurrentflowonthethermostat
R-Wcircuitafterthecirculatingblowermotor
has started.
Neutrals
Unused Motor Leads
FIELD WIRING
Low Voltage
Connections
6
5
4
3
2
1
Set the heat anticipator according to the ther-
mostat manufacturer's instructions for heat
anticipator settings.
Figure 28. Low Voltage Field,
Four-wire Heating/Cooling Applications
VENTILATION
Ventilation must be provided for homes built to
HUD Manufactured Homes Safety and Con-
structionStandards.Thisventilationcanbesup-
plied by the VentilAire III or VentilAire IV acces-
sories. (See Table 12). Alternate means to pro-
vide the ventilation air must meet the require-
ments of all applicable local and federal codes.
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 identify-
ingandcorrectingthefaultconditionwhich
caused the switch to trip.
For installation of the VentilAire III or IV, follow
the instructions provided with the VentilAire
kit.
5. The blower door is in place, closing the
door switch in the line voltage circuit.
START-UPANDADJUSTMENTS
General
Prior to start-up, verify that:
6. The gas line has been purged and all
connections are leak tight.
1. The line voltage power leads are securely
connected, that the polarity of the con-
nections is correct, and that the furnace
is properly grounded.
Start-Up Procedure
1. Set the thermostat to the lowest setting.
2. Close the disconnect(s) to provide line
voltage to the furnace.
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. Follow the procedures given on the oper-
ating instructions label attached to the
furnace.
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. Set the thermostat above room tempera-
ture and verify the sequence of operation.
(See the SEQUENCE OF OPERATION.)
26
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
6. See the "High Altitude Derate" section for
additionalinformationonfiringrateateleva-
tions 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.Themanifoldpressuremustbesetat10.0in.
water column for use with LP gas.
Shut Down Procedure
In the event that the furnace must be shut down,
follow this procedure:
1. Set the room thermostat to "OFF" or its
lowest temperature setting.
Verifying and Adjusting Temperature Rise
Verify that the temperature rise through the
furnace is within the range specified on the fur-
naceratingplate. Temperaturerisesoutsidethe
specified range could result in premature heat
exchangerfailure.
2. Turn OFF the main gas supply to the appli-
ance at the manual valve outside of the
appliancecasing.
3. Remove the control access panel / lou-
vered door.
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.
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 instal-
lation 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.
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 tem-
perature rise and higher blower speeds will
decrease the temperature rise.
Use the following procedure to determine the
firing rate:
1. Shut off all other gas fired appliances.
2. Start the furnace and allow it to run for at
least three minutes.
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.
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.
Ifitisdesiredthatthebloweroperateatthesame
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.
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.
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
•
Firing rate = 1000 x 60 = 60,000 Btuh.
27
Download from Www.Somanuals.com. All Manuals Search And Download.
GAS FLOW RATE (CUBIC FEET PER HOUR)
CUBIC FEET PER REVOLUTION OF
TIME FOR
ONE REVOLUTION
TIME FOR
ONE REVOLUTION
CUBIC FEET PER REVOLUTION OF
METER
METER
5
(SECONDS)
1
10
(SECONDS)
80
1
5
10
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
64
150
138
129
120
113
106
100
95
90
86
82
78
75
72
69
67
64
62
60
58
750
692
643
600
563
529
500
474
450
429
409
391
375
360
346
333
321
310
300
290
281
1500
1385
1286
1200
1125
1059
1000
947
900
857
818
783
750
720
692
667
643
621
600
581
45
44
43
42
41
40
39
38
38
37
36
35
35
34
33
33
32
32
31
31
30
225
220
214
209
205
200
196
191
188
184
180
176
173
170
167
164
161
158
155
153
150
450
439
429
419
409
400
391
383
375
367
360
353
346
340
333
327
321
316
310
305
300
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
56
563
Table 11. Gas Flow Rate
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
plateimmediatelyafterthesupplyair limitswitch
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.
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).
VerifyingBurnerOperation
To verify operation of the burners, remove front
doorandensurethatthe doorswitchisinthe“on”
position(seeFigure29).Setthethermostatabove
room temperature and observe the ignition se-
quence.Theflamecanbeobserved throughthe
smallclearwindowontheburnerbox.Theburner
flameshouldcarryoverbetweenallburners.The
flamesshouldbeblue,withoutyellowtips.Flames
should extend from each burner without lifting,
curling,orfloating.Afterverifyingignition,setthe
thermostat below room temperature and verify
that the burner flame extinguishes completely.
Replace the front door.
DESCRIPTIONOFCOMPONENTS
Figure 29 shows the location of each of the
functional components described below. If any
component of the furnace must be replaced,
use only factory authorized replacement parts.
Contact your distributor for the approved re-
placement parts.
Verifying Operation of the Supply Air
Limit Switch
To verify operation of the supply air limit switch,
make sure that the blower door is in place and
that there is power to the furnace. Completely
block the return airflow to the furnace by install-
ing a close-off plate in place of or upstream of
the filter(s). Set the thermostat above room
Flame Sensor – The flame sensor acts to
prove that flame has carried over from the
ignitor to the opposite end burner. If no flame is
sensed, the furnace will be shut down automati-
cally.
28
Download from Www.Somanuals.com. All Manuals Search And Download.
MAINTENANCE
FURNACE ACCESSORY KITS
Kit
Order Number
911969A
904003
It is recommended that the furnace be checked
yearly. At a minimum, this check should include
thefollowingitems:
A/C Coil Box
Side Return Air Kit
Top Return Air Kit
904015
Sloped Roof VentilAire III Kit
Sloped Roof VentilAire IV Kit
Soffit VentilAire Kit
Concentric Vent Termination Kit
(for horizontal and vertical venting)
Horizontal Exterior Vent
914098
914229
917201
!
WARNING:
903578
Toavoidelectricshock,personalinjury,
or death, turn off the power at the
disconnect or the main service panel
before performing any maintenance.
Mounting Kit
3"PVC
902375
902377
Neutralizer Kit - All Models
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.
!
WARNING:
Holesintheventpipeorheatexchanger
can cause products of combustion to
enter the occupied space. Replace the
ventpipeorheatexchangerifleaksare
found. Failure to prevent products of
combustion from being circulated into
the occupied space can crate poten-
tially hazardous conditions, including
carbonmonoxidepoisoning,thatcould
result in personal injury or death.
Pressure Switch – The pressure switch veri-
fies that the inducer is drawing the combustion
gasesthroughtheheatexchanger. Italsosenses
a blocked condensate drain condition.
Deck Limit Switch (Auxiliary Limit) – The
deck limit protects the furnace filter tempera-
ture from overheating when the motor has
malfunctioned. If the deck switch opens, the
power for the furnace will shut down (see
Figure 29).
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 obstruc-
tion or blockage must be removed prior to
operating the furnace.
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.
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 con-
struction dust has been removed.
Flame Roll-Out Switch – This switch pro-
vides flame roll-out protection to the furnace
and combustion air inlet pipe.
29
Download from Www.Somanuals.com. All Manuals Search And Download.
• Do not store gasoline or any other
flammable vapors and liquids in the vicinity
of the furnace.
!
WARNING:
Never operate the furnace without a
filterinplace. Dustandlintinthereturn
air can build up on internal compo-
nents, resulting in loss of efficiency,
equipmentdamage, andpossiblefire.
• 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.
Lubrication
The bearings in the circulating air blower mo-
tors are pre-lubricated and sealed at the fac-
tory. No further oiling of the bearings is required
for the life of the motor.
• Avoidoperatingthefurnacewhenwindows
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.
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.
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.
Blower Compartment
The blower compartment should be cleaned
monthly during the heating and cooling sea-
sons 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 short-
ened service life.
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 (over-
temperature limit switch, flame rollout
switches and blocked vent switch in se-
ries). If an open limit is detected the con-
trol board will energize the inducer and
the conditioned air blower. All other sys-
tem 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.
Heat Exchanger and Burner Maintenance
The furnace should operate for many years
without excessive soot buildup in the flue pas-
sageways, however, the flue passageways,
the vent system, and the burners should be
inspected and cleaned (if required) by a quali-
fied service technician annually to ensure con-
tinued safe operation. Particular attention must
be given to identify deterioration from corrosion
or other sources.
SYSTEMOPERATION
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.
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:
• Do not place combustible materials on or
against the furnace cabinet or the vent pipe.
30
Download from Www.Somanuals.com. All Manuals Search And Download.
InitialPowerup:After30secondsofigniter
warm-up the gas valve (24 VAC) will then
open. The igniter circuit will stay ener-
gized for 3 seconds after the gas valve
opens.
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
compressorcontactor.
After Initial Power up: The control has a
programmed adaptive ignition feature
which varies the warm-up period as fol-
lows:Ifignitionissuccessfulthewarm-upis
reducedby3-secondsoneachsubsequent
call for heat until ignition failure occurs.
Upon ignition failure, the warm-up is in-
creased by 3-seconds on the next try. If
successful, the timing remains fixed at this
level. In general, whenever ignition failure
occursthewarm-upintervalisincreasedby
3-seconds on the next try. And if success-
ful, it remains there. Minimum and maxi-
mum warm-up time limits are set at 6 and
54-seconds, respectively.
2. The furnace control energizes the circu-
lating 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 continu-
ous ON position at the thermostat and is
then switched to AUTO, the circulating
blower will operate for a specified delay
(factory set at 120 seconds).
7. The furnace control must prove flame via
the flame sensor 5 seconds after the gas
valve opens. If flame is sensed, all burn-
ers 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
tryforignition, thefurnacecontrolislocked
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. Oth-
erwise, the furnace will attempt another
ignition sequence in 1 hour.
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.)
8. The furnace control energizes the cir-
culating 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.
9. Is the deck switch open?
10. The inducer is de-energized after a 30-
second 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
airblowercontinuestooperateforthespeci-
fied delay (factory set at 120 seconds).
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 but-
ton on the vent safety switch. (See Figure 29.)
If the furnace operates after depressing the
reset button, contact a qualified service tech-
nician 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 tech-
nician to identify and repair the problem.
31
Download from Www.Somanuals.com. All Manuals Search And Download.
M3 Downflow Furnace
3
21
2
8
18
4
9
5
10
19
6
11
16
22
7
12
13
17
14
1
15
1 Door Assembly - Louvered
2 Filter Inside Door
12 Ignitor Assembly
13 Burner View Port
14 Main Limit Switch
3 Blower Assembly
4 ControlBoard
15 Coil Cabinet Assembly (Optional)
16 Flame Sensor (On Burner Box)
17 Gas Valve
5 Pressure Switch
6 Flame Rollout Switch
7 “J” Trap Hard Tube
8 LowVoltageTransformer
9 In Line Drain Assembly
10 Junction Box
18 Switch, On/Off
19 Blower, Inducer
20 Orifice(InBurnerBox)
21 Aux. Limit
11 Vent Safety Switch
22 BurnerBox
Figure 29. Location of Major Components
32
Download from Www.Somanuals.com. All Manuals Search And Download.
BLUE
BLUE
FLAME ROLL-OUT
SWITCH
(ALL MODELS)
VENT
SAFETY
SWITCH
SUPPLY AIR
LIMIT SWITCH
(ALL MODELS)
PRESSURE
SWITCH
(ALL MODELS)
WHITE
BLACK
WHITE (NEUTRAL)
BLACK 120V
GROUND
ON/OFF SWITCH
GREEN
ROOM THERMOSTAT
BLOWER DECK SWITCH
TRANSFORMER
WHITE W/ BLK STRIPES
R
Y
WHITE
120 V
BLACK
24 V
G
BLK W/ WHITE STRIPES
W
AIR CONDITIONER
CONDENSING UNIT
C
Y
FLAME SENSOR
3 OR 4 SPEED MOTOR
RED
YELLOW
BROWN
C
H
MH
ML
GAS
VALVE
L
IGNITOR
BLACK
BLACK
Legend
Field Wiring
Factory Wiring:
RED
1
BLACK
R
C
ORANGE
BLUE
2
3
4
INDUCER
BLACK
BLACK
Low Voltage
5
High Voltage
WHITE
6
MOTOR
PLUG
STATUS
RED
LIGHT
If any of the original
FAULT CONDITION
with
Factory Wired
Heating Speeds
the furnace must be
replaced, it must be
replaced
material having a
rating of
˚ C.
wiring
Furnace
Input, Btuh
Wire
Color
60,000
80,000
Red
at least
Power Off or Deck Limit Open
OFF
Blue
Use copper
conductors
only.
FLAME
YELLOW
LIGHT
FAULT CONDITION
WD#710240B
Figure 30. Downflow Furnace Wiring Diagram
33
Download from Www.Somanuals.com. All Manuals Search And Download.
34
Download from Www.Somanuals.com. All Manuals Search And Download.
INSTALLATION/PERFORMANCE CHECK LIST
LOCATION ____________________ CITY __________________ STATE ____________
INSTALLER ___________________ CITY __________________ STATE ____________
UNIT MODEL NUMBER________________
UNIT SERIAL NUMBER________________
Minimum Clearances per Table 3? ________
Electrical Connections tight? _____________
Line Voltage Polarity correct? ____________
Supply Voltage: ___________________ Volts
Blower Motor HP: _____________________
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? __________________
FUEL TYPE:
Natural Gas ______ LP/Propane _______
Has the Thermostat been calibrated? _____
Is the Thermostat level? ________________
Is the Heat Anticipator Setting correct? ____
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
Has the Owner's Information been reviewed
with the home-owner? _________________
combustion and ventilation? _____________
Has the Literature Package been left near the
furnace? ____________________________
Furnace Input: _________________ (Btuh)
Supply Air Temperature:__________ (° F)
Return Air Temperature: _________ (° F)
Temperature Rise: ______________ (° F)
35
Download from Www.Somanuals.com. All Manuals Search And Download.
¢7082197¤
708219D
708219D(Replaces708219C)
Specificationsandillustrationssubjecttochangewithout
noticeandwithoutincurringobligations. Printedin
U.S.A.(04/04)
O’Fallon, MO
Download from Www.Somanuals.com. All Manuals Search And Download.
|