Nordyne Furnace M3RL User Manual

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.

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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

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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

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

2.-1/2

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

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

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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.

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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.

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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

Front

Back

Sides

Vent

Top

Duct (Plenum)

w/ Coil Box

GENERAL

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).

1/4

w/o Coil Box

(within 3 feet)

*Note:For1”clearance, useafullylouvereddoorwithat

least400squareinchesoffreeairflowarea.

Table 4. Minimum Clearances

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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

w/crossover connector

7/8"

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

Figure 2. Non-Platinum

Supply Duct System

Table 5. Duct Connectors

FLOOR CAVITY

(depth equal to "X" in Figure 5 and Table 5)

SUPPLY AIR DUCT

Figure 3.

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( )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".

SEE

TABLE 5

SPACERS

(1) FINGER TAB DUCT CONNECTOR ONLY

(2) SCREW DOWN DUCT CONNECTOR ONLY

Figure 5.

ALT. FUEL

LINE HOLES

10"

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-

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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

21-7/16

3-19/32

1-3/4

VENT

23-1/4

COMBUSTION AIR INTAKE

FUEL LINE ENTRY

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

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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

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

14”SUPPLY

CONNECTION

Screw Down

Finger Tabbed

Duct Connectors

Platinum Series

Duct Connectors

Figure 9. Duct Connector

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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"

"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

Flap "B"

STEP 4.

STEP 3.

Figure 12. Alternate Installation

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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).

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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

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*NOTES

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

SCH. 40 Pipe Size

Model M3RL 060

Model M3RL 080

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)

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

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) ‡

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.

†

‡

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

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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.

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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

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.

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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.

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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

Air Intake

10" Min.

until the vent and combus-

Exhaust

tion air intake terminations

Plumbing Vent

are installed.

Roof Boot

(Typ. Both Pipes)

Figure 20. Vertical Vent Termination

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Collector

Box

Clamp

Step 1: Loosen

Step 2: Rotate to drain direction

Step 3: Retighten

Burner

Box

Keep

Downward

Slope

“Hard”

J DrainTube

Floor

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.

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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

130

3/4

280 190 150 130 115 105

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)

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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

060A-A/BW

080A-A/BW

60,000

80,000

1.15 mm

Table 8. Approximate Orifice Size for Natural and LP Gases

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Reinstalling the Burner Assembly:

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.

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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-

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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)

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

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

Amperes

Gauge

60,000

80,000

19.75

115-60-1

127

103

9.7

Recommended Thermostat Wire Length

Thermostat Wire Gauge

2-wire (heating)

4 or 5-wire (cooling)

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

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

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

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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

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

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.)

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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.

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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

(SECONDS)

150

138

129

120

113

106

100

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

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

100

102

104

106

108

110

112

114

116

118

120

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.

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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.

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• 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.

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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.

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M3 Downflow Furnace

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

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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

WHITE

120 V

BLACK

24 V

BLK W/ WHITE STRIPES

AIR CONDITIONER

CONDENSING UNIT

FLAME SENSOR

3 OR 4 SPEED MOTOR

RED

YELLOW

BROWN

GAS

VALVE

IGNITOR

BLACK

Legend

Field Wiring

Factory Wiring:

RED

BLACK

ORANGE

BLUE

INDUCER

BLACK

Low Voltage

High Voltage

WHITE

MOTOR

PLUG

STATUS

RED

LIGHT

If any of the original

FAULT CONDITION

Power On

with

Factory Wired

Heating Speeds

the furnace must be

replaced, it must be

Limit Circuit Open or External Load On "W"

(Does not apply to Deck Switch, see below)

1 FLASH

replaced

material having a

rating of

˚ C.

wiring

Furnace

Input, Btuh

Wire

Color

Pressure Switch Open with Inducer On

Pressure Switch Closed with Inducer On

Ignition Failure (Check Ground)

2 FLASHES

3 FLASHES

4 FLASHES

60,000

80,000

Red

115 VAC & Neutral Reversed or no Ground 5 FLASHES

at least

False Flame or Gas Valve Relay Shorted

Power Off or Deck Limit Open

Continuous

OFF

Blue

Use copper

conductors

only.

FLAME

YELLOW

LIGHT

FAULT CONDITION

Low Flame Sensor Signal

Continuous

Flash

Flame Present

WD#710240B

Figure 30. Downflow Furnace Wiring Diagram

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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)

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¢7082197¤

708219E

708219E(Replaces708219D)

Specificationsandillustrationssubjecttochangewithout

noticeandwithoutincurringobligations. Printedin

U.S.A.(08/06)

O’Fallon, MO

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