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Nordyne AND M5S Furnace User Manual

1. To Gas Valve On Auto Switch or Burner Heating Models Only Figure 24 Control Panel All Models Verifying Anticipator Setting Afterthe furnace is installed check the thermostat anticipator against the nominal setting of 0 4 1 Connect the milliamp meter in series with one of the gas valve s low voltage terminals 2 Energize the gas valve 3 Read the value of the milliamps 4 Adjust the heat anticipator of the thermostat to the value on the milliamp meter If the heat anticipator is set too high the furnace may delay turning on If set too low the furnace may cycle frequently and not provide comfort to the homeowner Recommended T STAT Wire Thermostat Length Unit to T STAT Wire Gauge 2 Wire 5 Wire Table 6 Thermostat Wire Gauge M1 M5 A C Ready Furnace Red White IN White Green N Green Yellow WW Figure 25 Thermostat Wiring For A C Ready Models Grounding A WARNING To minimize personal injury the furnace cabinet must have an uninterrupted or unbroken electrical ground The controls used in this furnace require an earth ground to operate properly Acceptable methods include electrical wire or conduit approved for ground service Do not use gas piping as an electrical ground Grey FUEL SUPPLY AND PIPING A WARNING All piping must conform with local building codes or in the absence ofloc
2. Movida SNISNOH HOLIMS 3dO NO w Ww ed e 9 501 95 peoejdai eq jsnui e2uerdde y se s s m eurBuo y Aue Xn Vv uoneuuojur 2 104 o2euunj 295 jsnui Buruoou h SALON 060 220 HDL peonpuj INVSOVIG Figure 41 Standing Pilot with Induced Draft Furnace M1GH 077 090 Models 35 g pue p Jeduunf y uo 9 10 p JEUuIUlJ9 JOY 3A1VA SVD Burjooo pue ui peeds je uni OL 310 wzaiHd NZ ay uonoejes 2 V 01 AIG2L 0 speeds ASEL eoejdei 020 85 LIN 37 peeds pad ea2ejda1 2 9 Xog 1VOIH123 13 AOWNYNA 0801014 008 009101 MAYOS ovis 35NVHO aariddns YAINYOASNWHYL HO LIMS vig NV gt a gt v 39 9 e
3. ania 7 wo v 10 zm Ip 12 2 qai AN SNITOOS ONILWSH HOLO3NNOO sy ed ania 2 501 asn peoejdei eq y se y jo Aue 2 ania E UNN 104 ees 00 peziiejod eq 1snui SILON SIPPOW 020 990 9 g OLN Ape y 4 sey WVdSVId ONIHIM Figure 42 Gas Atmospheric Furnace A C Ready M1GB 056 070 Models 36 OVOLOLZ seoejdeg 00 90 OLSLOLZ HOLIMS y ejg Aq paoejdas eBue1Q BuneeH 060 89LIN Aq pea2ejde4 270 I9LN samojg 0 2 V OL 9 1 paj2euuo peeds IH esiweuyo speedg 5 sun 060 89LIW 9JIM Xog 1V2141233 AAIVA wa AS VI 5 3 0553 SNISNOH YOLDANNOD NOILSNEWOD BE GN DNS P _ M SNIMO
4. 19 STARTUP amp ADJUSTMENTS 20 Lighting Instructions Pilot Models 20 How to Shut Off Gas Pilot Models 21 Operating Instructions Direct Ignition 21 How to Shut Off Gas Direct Ignition 22 Operating Instructions Oil Gun 22 Operating Instructions Gas Gun 22 How to Shut Off Gas Gas Gun 22 Burner Adjustments 22 Gas Pressure 22 ilie digi re 22 Combustion Air 23 23 Oil 23 Electrode Setting Oil Gun 23 Switching Honeywell R7184 Ignition from Interrupted to Intermittent 23 OPERATING SEQUENCE 24 Standing Pilot us 24 Standing Pilot w Induced Draft Blower 24 M1 Models Direct 24 Oil Gun 24 Gas Gun 24 FURNACE CONTROLS amp FUNCTIONS 25 Furnace On Off Switch 25 Limit Control essen 25 GaS tine ni 25 Roll Out Switch M1G 25 Oil Burner Primary Control 25 Summer Cooling B C D Series 25 TROUBLESHOOTING 26 Standing Pilot Models
5. VINLIN 101 pouinboa si 18MoJ q e Ji aq jsnui SNLVLS LHOI1l IOHINOO 3A1VA SV9 Av 071313 YOLINSI a 9 WEIN peddeuM peddeuM jonuog eu eu p1eog peddeuM peddeJM H peog 040 950 eu eu 105009 q 9 INLIN peddeJuM peddeiM fH peddeuM 1 peog H preog peddeJM paddeyy Jonuo2 410 020 an n N i lonuo 1990 VINLIN vi 93M enig xoelg 94M M ams Yow TOTAN Nvo 5 IW T ova IH dai g H9IH SISPOIN IIV INLIN 3HnsSsaHd HOLIMS 1VOIH123 3 39VN3d 295 Wann n SLHOIT A MOTT3A _ d e HOLIMS 33O NO i ana HOTH Xn v Apees o y 9
6. 26 Direct Ignition Models 26 Oil Gun 5 27 OPTIONAL ACCESSORIES 28 MAINTENANCE eese 30 Homeowner Information 30 Installer Information Information 30 FIGURE amp TABLES 31 Table 10 Furnace Specifications 31 Table 11 Orifice Sizes High 32 Table 12 Blower Speed Selection 32 Gas Information 33 Table 13 Gas Flow Rates 33 Table 14 Gas Pipe Capacities 33 34 Fig 39 Gas Furnace 056 070 34 Fig 41 Standing Pilot 077 090 35 Fig 42 Gas w ac 056 070 36 Fig 43 Standing Pilot w ac 077 090 37 Fig 44 Gas Only M1M Models 38 Fig 45 Gas amp Oil M5S 39 Installation Checklist 40 SAFETY INFORMATION Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored WARNING indicates a potentially hazardous situation that if not avoided could result in personal injury or death CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage A WARNING The safety informat
7. Resetting circuit breakers blown fuses or other switches Correcting problems due to improper gas supply pressure to the furnace Providing instructional training on how to light and operate the furnace Furnace problems caused by installation of an air conditioner heat pump or other air comfort devices e Adding a Roof Jack extension because of unusual wind and or snow conditions Revising installation of the furnace flue assembly Roof Jack Adjusting or calibrating of thermostat Any construction debris which falls into flue system Minimum Clearances This heating appliance must be installed with clearances not less than the minimums listed in Table 1 This furnace must be installed with ample clearance for easy access to the air filter blower assembly burner assembly controls and vent connections See Figures 1 3 page 6 The dimensions of the room or alcove must be able to accommodate the overall size of the furnace and the installation clearances listed in Table 1 and in Figure 4 page 6 Alcove installations minimum 18 clearance at front of furnace shall be provided for future servicing A removable access panel should be installed between top of the furnace door frame and the ceiling Closet installations must use a louvered door having a minimum free area of 235 sq in when located 6 from furnace or 390 sq in for 5 ton ready 1 5 furnaces For special clearance between 1 6 req
8. ooeuun uoniuD 529 jue eAinbe s 40 ed onsejdouueu 5 801 esn eq jsnw eouerdde y se eui jo Aue uoneuuojur 104 ees 10109 jsnw SALON Figure 44 Gas Direct Ignition Furnace Heating amp A C Ready M1M Models 38 6060 H9IH vu IULII 2 06660 LZ SNIHIM 91913 ON3931 310V1d323H 995 IATA TI HUM Linva MOTTA 3IIHM INT JUHM 7 AdIHLS ILIHM M DV 18 a MOTTSA ovi bl TOULNOD A AUVINIYd SON JUHM Oow 97804 YO J31ndOW mMm Ta 90119 38lM USTIVISNIA 3HHAVA 330 icu quw ab WOM j YJWYOJSNYYL YINYN4 TIO US CLE WALI sli JAIM duoo ann 3AIVASVO gt 3718 3uIM 9NIS 8N sanna p ama 378 825 ANNOYD 3LIHM qas 31ON 335 M JHM in
9. second off For Beckett 7505 control the red LED will flash 1 Reset primary control To reset the control from soft lockout the button needs only to be pressed and released If the R7184 control is in restricted mode press and hold the button for 45 seconds until the LED flashes once If the 7505 control is in restricted mode press and hold the button in for 15 seconds until the red turns off and the yellow LED turns on NOTE Restricted Lockout If the control locks out three times in a row without a complete heat cycle between attempts the lockout becomes a restricted hard lockout 2 1 the LED indicator stops flashing and the ignition remains off the primary control could be defective If line voltage is present at the igniter terminals and there is no ignition the igniter is likely defective and needs to be replaced 3 If the stops flashing burner turns on but the control locks out again check the cad cell If 27 the cad cell is operational replace the primary control 4 f the LED continues to flash at the interval listed above verify that the control is not in restricted mode If in restricted mode reset it If not in restricted mode replace the control 5 If the LED indicator for R7184 control green LED for 7505 control stays off while the flame is on check the cad cell sighting for view of the flame 6 If the burner locks out check the cad cell resistance See Table 8 7 the b
10. 4 Verify the thermocouple millivoltage reading is not between 18 30 mv the gas valve electromagnet may be defective Replace the gas valve if necessary 5 Verify the pilot shield is in place 6 Check for gas leaks page 18 7 Check the flue assembly for air leaks 8 See lighting procedures pages 20 22 Main Flame Is Not Burning Properly 1 Check the manifold gas pressure 2 Check for the correct main burner orifice See furnace nameplate for specifications 3 Check the flue for any blockages or loose connections 4 Check the combustion air passages for blockage 26 High Gas Bills a Verify the proper orifices are being used b Check the return air system Is it clear and free of blockage c Check the furnace filter Is it clean or need replacing d Verify the home is insulated windows and doors fit tightly and there are no leaks in the heating duct system e Check the room thermostat Is the setting higher than necessary Low humidity requires higher temperatures for the same level of comfort Check for proper humidity level in the home Direct Ignition Furnaces Including Gas Gun M1B Series see Table 9 page 29 Burner Motor won t Run T stat Calls for Heat 1 Check the electrical supply to the furnace 2 Verify the furnace furnace On Off switch is in the ON position 3 Defective thermostat circuit white and red thermostat low voltage leads M1 M5M M1 M5B models If the burner
11. m 5 7 HOIN ang Xv S OL WALI 7 M 5NIHSh8 n H x2e q 01 pa12auuoo si paads sj pow 19470 UO paesu s m jeduunf ogo S g LW pue v S g LW siepoui uo 5NIHSh8 s1o32npuoo esf 9 juejeAinbe sy 10 ed 5 50 asn pe e dai aq NND Sv5 quajeainba 10 5 501 asn 3snuu 22uerdde y se au jo Aue pa2ejdau 51 y parjddns asm ay Aue lt uoneuuojulr je u2e e 104 a euunj 295 uonpe es 5 LL 9 qe1 0 Jajay speeds buneaH 5 v pezuejod aq ysn SALON ZH 09 ojBuis HOA OZL 5 SSIN 8 SLIN INVHSOVIG SONISBIA 39 Figure 45 Gas and Oil Furnaces A C Ready M1B amp M5S 066 086 Models INSTALLATION PERFORMANCE CHECK LIST INSTALLER NAME ELECTRICAL SYSTEM Electrical connections tight Line voltage polarity correct YES CITY STATE INSTALLATION ADDRESS Has the thermostat been calibrated CITY Is the thermostat level UNIT MODEL I
12. Evap Coil Setting 2 1 2 Ton 0600 HH L hM H 066 070 077 M1 M5 C Models and for use with Blower Kit No 903413 1 2 Hp 4 Speed Heating Cooling Speed Evap Coil Speed 2 1 2 Ton amp 3 Ton 3 1 2 Ton Setting 077 086 090 056 066 070 Cooling Speed Evap Coil Heating Speed 2 1 2 amp 3 3 1 2 amp 4 Setting Table 12 A C Blower Speed Selection Chart 32 GAS INFORMATION GAS FLOW RATES GAS FLOW RATES TIME FOR CUBIC FEET PER CUBIC FEET PER TIME FOR REVOLUTION REVOLUTION ONE REVOLUTION OF GAS METER ONE REVOLUTION OF GAS METER SECONDS _ n SECONDS T 10 e ss 273 s mr LU San ea Ee 26 188 1385 e2 44 220 430 so 12 600 1200 8 42 209 419 34 106 529 EK 059 O 90 ____ 40 200 400 Seen 98 ____ 37 184 367 1 Seas 1 6 60 300 600 Table 13 Gas Flow Rates Cubic Feet per Hour CAPACITY OF BLACK IRON GAS PIPE CU FT PER HOUR FOR NATURAL GAS SPECIFIC GRAVITY 0 60 NOMINAL BLACK IRON LENGTH OF PIPE RUN FT PIPE DIAMETER IN 10 20 30 40 50 60 70 80 245 Pt 1 600 1100 890 760 670 610 Input To Furnace Btu hr Cubic Feet Per Hour Required Heating Value of Gas Btu Cu Ft NOTE The cubic feet per hour listed in the table above must
13. The dimensions of the room or alcove must be able to accommodate the overall size of the furnace and the installation clearances outlined on page 2 and Figures 1 4 page 6 The furnace shall be appropriately connected to the supply and return air distribution system as shownin Figures 14 amp 15 page 11 1 Removefurnace outer door s and bottom fuel line knockout 2 Place furnace onto duct connector and center with floor opening 3 Slide onto mounting plate Bottom rear slots onfurnace should engage with mounting plate tabs 4 Secure front with one 1 fastener at each corner Figures 14 or 15 NOTE Additional fasteners may be used at rear sides or through door frame as desired to secure furnace to closet or alcove framing SCREWS a MOUNTING CONNECTOR CONNECTION SLIDE FURNACE ALL THE WAY BACK ONTO MTG PLATE 4 SECURE FURNACE ITH 2 FASTENERS FRONT CORNER HOLES ll i Knockout Over Holes I i SUPPLY AIR DUCT nz Figure 14 A amp B Cabinet Furnaces SLIDE FURNACE BACK AGAINST MTG PLATE SUPPLY AIR DUCT o WITH 2 FASTENERS AT FRONT CORNER HOLES Figure 15 A Cabinet Furnace on Coil Cabinet ROOF JACK SLANT DECK FLASHING PITCHED ROOF en Y X SEE TABLE 5 CEILING D za CAVITY X OS Roof tt Opening CEILING 4 Flue Pipe Y lt Combustion Air P
14. W C On Off Fan Switch Control Panel Alt Fuel Line Entry Figure 26 Typical Gas Piping For L P gas pressure to the gas valve must be more than 11 W C but not more than 13 W C Pressure is reduced to 10 W C by the pressure regulator in the gas valve N CAUTION Furnace conversion must be per formed by a qualified technician Improper conversion can cause unsafe operation explosion fire and or asphyxiation Cil Tank and Piping Installation The following procedures are recommended as good practice However requirements of local codes and ordinances H U D Manufactured Home and Safety Standards or National Fire Protection Association must be satisfied where they apply for an approved installation Useatankcapacity suitable forthe application with a weatherproof capped fill opening and a shielded vent to let in air as fuel is used The inside of the tank must be clean before filling All water rust sediment and debris must be flushed out A fuel or tank gauge Figure 27 is recom mended for easy checking of the fuel level Check the gauge reading with a dipstick Locate the storage tank conveniently near the home If the fuel tank is installed above ground the tank may rest 3 to 4 inches off the ground Fuel tanks may also be buried if properly coatedto resist corrosion The vertical dimension from the b
15. be greater than the cubic feet per hour of gas flow required by the furnace To determine the cubic feet per hour of gas flow required by the furnace divide the input rate of the furnace by the heating value from gas supplier of the gas Table 14 Capacity of Black Iron Gas Pipe cu ft per hour for Natural Gas w Specific Gravity 0 60 33 WIRING DIAGRAMS 66 20 v489 04 seoe dey 8188207 HOLIMS LN3A 18589 ASLL HOLIMS OLNV NO 020 980 HOLIN se2euun4 seg HJTIVISNI aariddns W3WHOJSNVH L HOLIMS NV43 asnd ve p wn xnv dV2 ONISNOH HOLIMS SLIM AHOSS322V 7 TIVNOILdO 33O NO NOWWOD TD w d s 40 ed 2 2 80 95 peoejdai aq jsnui y perjiddns se y Aue Z uoneuuojur je2129 a 104 995 0 pezuejod eq jsnui SALON NVYSVIC Figure 40 Gas Atmospheric Furnace M1GH 056 070 Models 34 66 20 HOLIMS 888820 seoejdeu um OLNVINO NY4 28880 1VOIH 12313 H21IMS e lt 5 4
16. but may be used if allowed by local jurisdiction Only new flexible connectors may be used DO NOT reuse old flexible gas connectors Adriplegshould be installed in the vertical pipe run to the unit Figure 36 All piping shall be black iron pipe or equivalently sized steel tubing Internally tinned copper tubing may be used for gas supply systems 16 Fuel line installations other than typical installations shown in Figures 26 and 27 page 17 must comply with the fuel piping 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 Optional fuel inlet lines are available for all gas furnace models to permit the addition of 1 2 shut off valve above the floor NOTE Shut off valve must be designed and listed for use with liquid petroleum L P gas The gas supply to your home will either be Natural Gas or L P bottle gas Your furnace is factory equipped to operate on Natural Gas If your gas supply is L P bottle gas you must contact a qualified serviceman or gas supplier to convert the furnace Instructions for gas conversion are listed on page 18 Factory installed orifice sizes are listed in Table 10 page 31 For natural gas operation the furnace is designed for 7 W C inlet pressure Pressure is reduced to 3 1 2 W C by the pressure regulator in the gas valve The maximum inlet pressure for the valve is 13
17. dI wmaw wma ON epon peeg quio2 10 59 oNeoguo 1ndino indui eoeuin4 kai Table 10 M1 M5 Furnace Specifications Factory Settings E we poe 05 BE NA Ee nm O E l Doy NEN E T lt eo s X X X X X X X X X X X X 31 FURNACE ORIFICE SIZE AND SEA MODEL OUTPUT CAPACITY VEL Orifice Size Nat Gas MI ME C Orifice Size LP Output MBTUH M1M M1G Orifice Size Nat Gas 070 Orifice Size LP Output MBTUH Orifice Size Nat Gas M1M 077 Orifice Size LP A gt ois rv sre she lt efs Output MBTUH niL nd 5 o g c5 gt 5 5 5 JO 5 5 5 02 A A oo gt Fo O 5 o gt P9 5 C2 o 5 to w T E AR D A N 5 35 gt 5 5 o RIMIS to alyl leleislalylslaly lale w P S AR wo o gt 5 45 02 5 5 C2 co N A co
18. einsseJd pjojiueui eonpei 009 7 01 000 2 ueipeue 104 ze 21 ees uBiH 4 9 01 4 9919 JexeeJg 10 esn 4 Ud ZHOO9 SHOA 02 jddng 4 Wes 9 eo uss 6 o eo uos ss 99 90 OM OL SPD 0 M G G SPH e 0 Bumes euuoN e ILA 0 7 09 SHOA PNOO e V 908 980 OSSIN ejBuy Jeuang has TT V V e t V V 8l 980 sl 980 98 990 OGL 990 v e x eo 2 o x x __ 9 az v m x __ e o 2 2zoonw m gt o fie z z 2osmww v m gt x vw zs w m ecole v 2 v m x ___ eo e 9 9 e9soom Le _ Sv 6c 99 __ 9 2 22 06 __ tw 25 22 22080 __ cv ve 25 _ 05 suo pag omu
19. light any appliance Failure to follow safety warnings Donottouchanyelectricalswitch exactly could result in serious do not use any phone in your injury or property damage building Installation and service must be performed by a qualified installer service agency or the gas supplier Do not store or use gasoline or other flammable vapors and Leave the building immediately Immediately call your gas supplier from a neighbors phone Follow the gas suppliers instructions e If you cannot reach your gas in the vicinity of this or supplier call the fire department any other appliance DO NOT DESTROY PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE SAFETY 3 REQUIREMENTS amp CODES 3 GENERAL INFORMATION 5 Warranty Information 5 Minimum Clearances 5 Applications 6 Unit LOCAU 6 CIRCULATING AIR REQUIREMENTS 7 Return Air Connections 7 Supply Air Connections 7 FURNACE INSTALLATION 8 General 8 Requirements amp Codes 8 Locating amp Cutting Duct Openings 8 Standard Duct Connector Installation 9 A
20. pipe assembly NOTE Make sure inside flue pipe attaches over inner flue pipe and outer Roof Jack pipe fits over outer pipe 7 Secure in place using three 3 10 1 2 sheet metal screws removed in step 5 Do not use the same holes which secured the rain cap in place 8 Remove and discard venting system warning tags A WARNING Failure to properly secure the flue pipe to the furnace may result in fire explosion or asphyxiation when operating the furnace 4 UPPER ROOF JACK CROWN SCREWS bia L misc WEATHER CAP FLASHING OUTER PIPE COMPLETED ASSEMBLY TO FURNACE Figure 23 Roof Jack Crown INNER FLUE PIPE FLUE ASSEMBLY 14 ELECTRICAL INFORMATION A WARNING To avoid electric shock personal injury or death turn off the electric power at the disconnect or the main service panel before making any electrical connections Electrical connections must be in compliance with all applicable local codes with the current revision of the National Electric Code ANSI NFPA 70 For Canadian installations the electrical connections and grounding shall comply with the current Canadian Electrical Code CSA C22 1 and or local codes Line Voltage Wiring It is recommended that 115VAC line voltage be supplied to the furnace from a dedicated branch circuit containing the correct fuse or circuit breaker for the furnace See Table 10 page 31 IMPORTANT NOTE An electrica
21. the furnace Gas Control Lever Pilot Position PILOT BRACKET Figure 31 Lighting The Furnace 12 Setthethermostat modeto HEAT ora desired temperature setting and then ON A WARNING Close the hinged fire door If door is left open or spring is broken it may allow products of combustion intothe living space by thefurnace blower resulting in possible asphyxiation 13 Replace the furnace door NOTE In the event of any flashback or explosion immediately shut off the furnace and call your service technician A WARNING Should overheating occur or the gas supply fails to shut off shut off the manual gas valvetothe furnace before shutting off the electrical supply AVERTISSEMENT En case de temp rature excessive ou sail est impossible de cooper l alimentation en gaz fermer le robinet manuel d alimentation en gaz du g n rateur d sir chaud avant de cooper l alimentation lectrique How to Shut Off Gas Standing Pilot 1 Set the thermostat to the lowest setting 2 Turn off all electric power to the appliance at the breaker or fuse box 3 Remove the furnace door 4 Push in the gas control lever and move to the left to the OFF position DO NOT FORCE 5 Replace the furnace door Operating Instructions for Direct Ignition Models M1M Directignition furnaces do not have a pilot Ignition is accomplished by a silicon carbide hot surface ignitor A control modu
22. valve for proper operation replace if necessary and inspect heat exchanger Check for 115 volts to the combustion blower motor replace if necessary f no power to combustion blower then check wiring and control module replace if necessary Circulation Air Blower Will Not Operate Even Though The Burner Does Operate Check thermostat G connection Check wiring to motor Check for a defective motor Oil Gun Honeywell R7184 or Beckett 7505 Controls Only M5S Series Burner does not start with a call for heat Check the electrical supply to furnace Verify the furnace door switch is in the ON position Check for line voltage 115 VAC at the oil primary control Check indicator LED with burner off no call for heat no flame See Table 9 page 29 If green LED indicator is on the cad cell is seeing stray light or the cad cell of controller is defective LED indicator is off go immediately to step 5 f LED indicator is flashing red or green on Beckett 7505 control refer to the next step 1 below Reset primary control Jumper T to T terminals on primary control f burner starts check thermostat or limit wiring connections fburnerdoes notstart turn off power Check all wiring connections f burner does not start replace primary control Burner starts and then locks out on safety with Honeywell R7184 LED indicator flashing Ye second on
23. AGAINST SUPPLY AIR DUCT SUPPLY AIR DUCT 2 Figure 10 Duct Connector Tabs Alternate Attachment Method The standard duct connector is designed for use on ducts 12 in width However if there is insufficient clearance to bend the duct connector tabs this alternate attachment method may be used 1 Score and cut the top of the supply air duct as indicated in Option 1 or Option 2 Figure 11 With Option 1 choice cut out the metal from the shaded area 2 Fold the two flaps Options 1 or 2 up to form the opening for the duct connector 3 Install the duct connector with the bottom tabs extending into the supply air duct 4 Bend the tabs on the bottom of the duct connector upwards and as tight as possible against the supply air duct Figure 12 5 Form the flaps Options 1 or 2 up against the duct connector as tight as possible 6 Securethe ductconnectorflapsto the supply air duct with staples 3 minimum or if a 2x block joist is not provided use sheet metal screws 2 minimum NOTE The duct connector tabs may be attached to the air duct with sheet metal screws or other suitable fasteners as long as the duct connector and the air duct are securely attached 7 Seal all connections with industrial grade sealing tape or liquid sealant NOTE Requirements for sealing ductwork vary from region to region Consult with local codes for requirements specific to your ar
24. All connections inside the home must be made below the ceiling NOTE Ifthe roof jack crown is covered or blocked with snow the furnace will not operate properly F S AW T 1523 0 2 4 A S 23 F S AW T 2135 0 2 4 A S F S AW T 2747 0 2 4 A S F S AW T 3563 0 2 4 A S F S AW T 5195 0 2 4 A S S AW T 27 47 2 S FLUE STEEL TYPE A ALUMINIZED S STAINLESS A S A S A S A S A S F FLAT FLASHING S SLANT FLASHING MIN ADJ LENGTH AW ALL WEATHER L FLASHING PITCH 12 RISE O FLAT 2 2 5 12 4 442 L ADJ LENGTH TYPE BLANK NON TRANSIT T TRANSIT MODE Table 4 Roof Jack Assemblies 11 4 ROOF JACK SLANT DECK FLASHING PITCHED ROOF X SEE TABLE 6 CEILING CAVITY CEILING ROOF OPENING CEILING OPENING Figure 17 Example of Flat Jack with Flashing ROOF JACK WITH 2 V2 12 SLANT FLASHING 2122 SLANT DECK 5 12 ROOF SLOPE Figure 18 Example of 212 12 Slant Jack with Flashing If the home is located in regions where snow accumulation exceeds 7 HUD snowload zones use an external roof jack extension p n 901937 Extensions are optional accessories and may be purchased through your NORDYNE distributor Locating and Cutting Roof amp Ceiling Openings DO NOT ALLOW DEBRIS TO FALL INTO THE FURNACE THIS COULD CAUSE UNSAFE OPERATION AND VOIDS THE FURNACE WARRANTY Use the top cap that comes with the furn
25. Downflow Direct Vent Sealed Combustion Forced Air Gas amp Oil Furnaces Installation Instructions For installation in Series M1B MG 1 amp MBS Manufactured Homes e Recreational Vehicles Park Models amp Manufactured Buildings Modular Homes Buildings ATTENTION INSTALLERS Itis your responsibility to know this product better than your customer This includes being able to install the product according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for the life of the product Safety should always be the deciding factor when installing this product and using common sense plays an important role as well Pay attention to all safety warnings and any other special notes highlighted in the manual Improper installation ofthe furnace or failure to follow safety warnings could result in serious injury death or property damage MI TA These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installation service personnel for this type of equipment Please read all instructions carefully before starting the installation Return these instructions to the customer s package for future reference WARNING WHAT TO DO IF YOU SMELL GAS FIRE OR EXPLOSION HAZARD e Do not try to
26. N A N N ER AJN mI AJN M1M 090 Orifice Size LP _____ M1G 090 Orifice Size LP _____ 1 066 Orifice Size LP_ 52 A v 2 9 e 2 9 5 5 co 00 0 Ro 5 5 5 9 6 2 ae e co R EN e AB oo A m AJIN lt SES BIO NIO JO o N N Ajo co 6 8 6 A AK 2 39 20 21 22 23 24 26 M1B 086 Orifice Size LP 8 Output MBTUH 68 2 62 0 60 3 57 9 55 6 53 4 51 2 49 2 47 2 45 3 NOTES For Canadian high altitude 2 000 4 500 reduce gas manifold pressure to 3 0 W C natural gas and 9 W C for LP gas Includes 4 Input Reduction for Each 1 000 Feet These specs do not apply to oil furnace installations Reference Sources ANSI 2233 1 8 54 National Fuel Gas Code N O o Output MBTUH 88 ho 8 Nyi SISI Orifice Size Nat Gas M1G 077 Orifice Size LP Table 11 Equivalent Orifice Sizes for High Altitude Installations M1 M5 B Models and for use with Blower Kit No 903773 1 4 Hp 3 Speed Heating Speed Cooling Speed
27. NADA CAN CGA B149 1 and 2 M00 National Standard of Canada NSCNGPIC GENERAL INFORMATION Manufacturer Warranty Owner s Responsibilities It is the sole responsibility of the homeowner to make certain the gas furnace has been correctly set up and converted to the proper fuel L P gas or Natural gas and adjusted to operate properly All gasfurnaces are manufacturedfor Natural gas and must be field converted when using L P gas A CAUTION DoNotalter or modify this furnace or any of its components Never attempt to repair damaged or inoperable components This may cause unsafe operation ex plosion fire and or asphyxiation f furnace malfunctions or does not operate properly contact a qualified service agency or gas utility for assistance A warranty certificate with full details is included with these instructions However NORDYNE will not be responsible for any costs found necessary to correct problems due to improper setup improperinstallation furnace adjustments improper operating procedure on the part of the user etc Carefully review these responsibilities with your manufactured housing dealer service company or gas supplier Some specific examples of service calls which cannot be included in warranty payments are Converting the furnace to use another type of gas Repairing duct work in the home found to be faulty Correcting wiring problems in the electrical circuit supplying the furnace
28. OD ONILVAH ASNVYO J3 TIVISNI aariddns 3snd VE 060 220 Ce 2 Apeay a v se2euun YeIG Burpuejs 5 HOLO3NNOO juejeninbe sil 40 ed onsejdouueu L 2 801 esn peoejdeJ eq 1snuu eui peiddns se y jo Aue J e94199Je 104 jaqe eoeuinj eeg 10109 pezuejod eq snw SALON As E32 41 Figure 43 Standing Pilot with Induced Draft Furnace A C Ready M1G B C D 077 090 Models 37 WZSLOLZ seoeldes ACSLOLL jeu amp ig euie 4 jeufig eure 4 xeon 4 poog M J9 O g 060 220 ou 10 pesje ei e1jneu ILA GLL pejrej 1n03203 Jo s YMS ensseJg uo uedo 51 YAMS einsseJd uedo s quur 440 peeis 4 1emod NO peeis MO 1 MOTI3A seuse 8 Seuse J y seuse seuse 2 use use J pidey 440 peeis NO peeis jenueui y uonoejes OL AQEL 0 speeds Buneay 9 060 pue
29. ace packaging or alternate protector to prevent debris from falling into the furnace before the final roof jack connection is made ROOF JACK SERIES IF ROOF PITCH IS 2 in 12 2 1 2 in 12 1 Locate center of Roof Jack opening measure 13 1 2 from the rear wall of closet or alcove along the center line of furnace and floor opening See Figure 19 2 Cut ceiling and roof holes as follows Ceiling 8 3 4 222 mm diameter Roof 9 3 8 238 mm diameter A IMPORTANT Refer to the installation instructions provided with optional air conditioning packages when installing furnaces with optional cooling coil cabinet or with optional C series indoor coils 20 10 54 gt REAR WALL OF CLOSET OR ALCOVE 3 73 CEILING CUT OUT FOR FLUE AND ROOF JACK FURNACE OUTLINE FURNACE OUTER DOOR Figure 19 Cut Out Dimensions for Flue amp Roof Jack SLANT DECK X FACTOR FLASHING NUMBER IS 903893 2 5 12 2 1 8 903893 2 5 12 2 1 2 F Series 3 in 12 903894 3 12 2 7 8 3 1 2 in 12 903894 3 12 3 1 4 4 in 12 4 1 2 in 12 5 in 12 5 1 2 in 12 6 in 12 6 1 2 in 12 5 Series 2 5 12 Pitch only 903895 4 12 3 5 8 903895 2 5 12 2 1 8 903895 2 5 12 2 1 2 903894 3 12 2 7 8 903894 3 12 3 1 4 3 5 8 903895 4 12 Optional Deck Flashings for Flat and 2 5 12 Pitch Roof J
30. acks 4 12 Pitch Roof Jacks not applicable 12 Table 5 Slant Deck Flashings Installing The Roof Jack 1 Apply caulking compound on underside of roof flashing to form a continuous strip at least 3 8 wide around the underside of the perimeter of the flashing See Figures 20 or 21 2 Connect Roof Jack Assembly to the furnace Inserttelescoping Roof Jack Assembly through the opening cut on the roof 3 Connect flue pipe to flue collar of furnace See Figure 22 4 Connect combustion air pipe to furnace collar with sheet metal screw See Figure 22 NOTE It is recommended that the connection of the combustion air pipe to the furnace be made before the flashing is secured to the roof to maintain alignment of roof jack and furnace connections NOTE For replacement furnaces be sure the inner flue pipe connects over the furnace vent collar DO NOT use a smaller diameter inner flue pipe which could slide inside the furnace vent collar and restrict the flow of furnace flue products 5 Attach Roof Flashing If necessary shift roof flashing slightly in the roof opening so that assembly is in alignment with furnace NOTE If flashing is mounted on 12 degree angle it may be necessary to adjust the angle to match the roof pitch 1 12 4 12 maximum 6 Press down firmly on roof flashing over caulking to make the seal with roof water tight 7 Secure flashing with appropriate fasteners NOTE For added protection against
31. al codes with the most recent edition of the National Fuel Gas Code ANSI Z223 1 or CAN CGA B149 1 or 2 Failure to follow all safety warnings could result in serious injury death or property damage This furnace may be installed with left or right side gas entry When connecting the gas supply 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 Typical gas service hookup for this furnace is shown in Figure 26 Table 14 page 37 lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line IMPORTANT NOTES Some local regulations require the installation of a manual main shut off valve and ground joint union external to the furnace Figure 36 The shut off valve should be readily accessible for service and or emergency use Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut off Gas piping must never run in or through air ducts chimneys gas vents or elevator shafts Compoundsusedonthreaded joints of gas piping must be resistant to the actions of liquefied petroleum gases The main gas valve and main power disconnecttothe furnace must be properly labeled by the installer in case emergency shutdown is required Flexible gas connectors are not recom mended for this furnace
32. aled to the furnace casing and terminating outside the space containing the furnace See page 14 WARNING Do not use this appliance if any part has been submerged under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been submerged underwater Notice to Installer Installer is advised to carefully follow all instructions and warnings in this manualto insure maximum performance safety and operating efficiency of these appliances Improper installation may create hazardous conditions and will void the appliance warranty 7 WARNING PROPOSITION 65 WARNING This productcontains chemicals known to the state of California to cause cancer birth defects other reproductive harm REQUIREMENTS AND CODES This furnace mustbe installed in accordance with these instructions all applicable local building codes and the current revision of the National Fuel Gas Code NFPA54 ANSI Z223 1 or the Natural Gas and Propane Installation Code CAN CGA B149 1 CE g n rateur d air chaud doit tre install conform ment aux instructions du fabricant et aux codes locaux En l absence de code local respecter la norme ANSI Z223 1 institul National Fuel Gas Code ou les codes d installation CAN GCA B149 The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 00 and 5 00 for installatio
33. by vehicles A 56 Model w o Coil Cabinet B Model w Coil Cabinet Y Figure 4 Overall Dimensions CIRCULATING AIR REQUIREMENTS A WARNING Do notallow combustion products to enter the circulating air supply Failure to prevent the circulation of combustion products into the living space cancreate potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death All return ductwork must be secured tothefurnace with sheet metal screws For installations in confined spaces all return ductwork must be adequately sealed The joint between the furnace and the return air plenum must be air tight The surface that the furnace is mounted on must provide sound physical support of the furnace with no gaps cracks or sagging between the furnace and the floor or platform Return air and circulating air ductwork must not be connected to any other heat producing device such as a fireplace insert stove etc This may result in fire explosion carbon monoxide poisoning personal injury or property damage Return Air Connections U S A home manufacturers shall comply with all of the following conditions to have acceptable return air systems for closet installed forced air heating appliances The return air opening into the closet shall not belessthan specified inthe appliance s listing The cross sectional area
34. ce furnace On Off switch is in the ON position 3 Check for proper thermostat operation 4 Check for broken or open thermostat wires 5 Verify the insulation located on the inside of the front panel is glued securely around the fan switch and the limit switch 6 Shut off the electrical supply to the furnace and remove the electrical box cover 7 Check for a defective transformer or blown fuse 8 Check electrical circuit for proper grounding polarity and make sure the electrical connections are tight 9 Checkthe limit switches Did they fail to close 10 Replace the electrical box cover and restore electrical power to the furnace Turn the furnace On Off switch to ON and raise the thermostat setting above room temperature 11 Check for 24 VAC at the gas valve Replace the valve if the pilot is established and it does not open when powered with 24 volts Powered 24 VAC Gas Valve No Main Flame 1 Verify the manual shut off valve is OFF 2 Check the pilot flame It must be established 3 Check the gas valve control lever It must be in the ON position 4 Check incoming gas pressure 5 Replace the gas valve if the main burner does not come on under the above conditions Pilot Will Not Light or Goes Out 1 Check the incoming gas pressure 2 Check for the proper pilot orifice See specifications on the furnace nameplate 3 Check for proper pilot flame adjustment See Burner Adjustment section page 22
35. ch heating season Call your serviceman to e Remove the air circulator and clean all dust and lint from the unit with a stiff bristle brush Inspect the combustion chamber blower compartment flue collar and Roof Jack Check the gas valve if applicable and fuel line connections for leaks Make any adjustments necessary for good operation 30 WARNING Use of furnace or air conditioning components that are not included inthe certification ofthis appliance may create a hazard invalidate the certification and in many states make installations illegal Listed NORDYNE air conditioning components are specified on the furnace label Additional Oil Furnace Maintenance In addition to the preceding the following should be performed by a qualified service contractor at least once each season for oil fired furnaces Replace the oil nozzle with the type nozzle specified for your furnace Clean adjust and replace if necessary the spark electrodes Reset the nozzle drawer assembly to factory specifications Cleanthe inside ofthe furnace heat exchanger and replace the combustion liner if necessary Clean or replace the oil filter element at the oil tank Adjust the burner for top efficiency and check to make sure all fittings are leak tight Check for Ice Here Figure 39 Roof Jack FIGURES amp TABLES seb d7 10 8 01 pue enjeu DM 0 01
36. ckout time will be extended to 4 minutes 2 If prime is not established within the 4 minutes the control will lock out Press the reset button to reset the control 3 Repeat steps 1 amp 2 if needed until the oil pump is fully primed Priming furnaces equipped with the Beckett 7505 primary control 1 After the burner starts press and hold the reset button until the yellow LED turns on 15 seconds This indicates that the button has been held long enough 2 Release the reset button The yellow LED will turn off and the burner will start up again 3 At burner start up click the reset button while the igniter is still on This transitions the control 18 to a dedicated pump prime mode during which the motor igniter and valve are powered for 4 minutes The yellow LED will be on NOTE If prime is not established during the four minute pump prime mode repeat step 3 until the oil pump is fully primed 4 When oil flow is clear and free of air bubbles close air bleed valve and tighten Time to bleed air out will vary depending on length of oil line number of bends etc Fuel Oil Type Do not use fuel oil heavier than Grade No 2 Grade No 1 may be used where the oil supply is subject to low temperatures DO NOT USE GASOLINE CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE WARNING Failure to keep supply of oil clean by various procedures described above may cause failure of certain components suc
37. ckwise for more air Gently tighten the lock nuts after completing the adjustment For bestresults use instrumentto measure between 8 9 CO after the combustion air has been adjusted Note Do not over tighten the lock nuts This may damage the plastic air shutter Oil Gun Only Itis recommended that the CO and Smoke levels be measured for maximum performance CO readings should be 10 1196 for 66 000 BTUH furnaces and 12 13 for 86 000 BTUH furnaces The Smoke should be NO 0 on the Bacharach Scale and 0 to 0 02 negative draft over fire Electrode Setting Oil Gun Only Poor ignition of the oil spray may result if the electrodes are not adjusted as shown in Figure 34 Do not permit any electrodes to be grounded to any surface Switching Ignition Control between Interrupted and Intermittent Duty Oil Gun Only Honeywell and Beckett oil primary controls can be switched between interrupted and intermittent ignition control To switch from interrupted duty Factory set to intermittent duty remove the blue wire from the quick connect terminal Attach the burner motor and igniter wire to the burner motor orange control terminal by splicing or adding tab adapters Seal and isolate any bare wires m 5 32 GAP _P i ELECTRODE 5 16 ABOVE CL NOZZLE 0 146 gt Figure 34 Oil Gun electrode Position 23 OPERATING SEQUENCE Standing Pilot 1 On a call for heat the t
38. coils compressor and vertical discharge fan This type of unit connects with the existing home air duct system an optional close off damper is required with the furnace Split system unit with vertical discharge for quiet operation connects with NORDYNE cooling coil furnace optional coil cavity required with model furnaces MAINTENANCE Homeowner Information On some closet installations the return air opening to the furnace may be on the floor in the door in the side wall of the closet or any combination of these The upper grille on the front of the furnace admits return air to the blower Return air must be provided back to the circulating blower in order to provide air distribution See Figure 38 Filters Atleast twice each season more often in dusty areas remove and clean the air filters with a vacuum or with warm water and soap Reinstall when dry Also clean dust and lint around furnace and in the furnace vestibule During extremely cold weather ice may form on the furnace roof jack Figure 39 Small amounts of ice forming on the roof jack will present no problems to proper furnace operation Excessive ice formation could restrict the combustion air supply to the burner causing inefficient burner operation If excessive ice has formed on the air inlet or exhaust portions of the roof jack it must be carefully removed Installer Information All furnaces need periodic service at the beginning of ea
39. cutout drawn This will allow some clearance when installing the duct connector 4 Measure from the top of the floor down to the top of the supply air duct to obtain the depth of the floor cavity NOTE The depth of the floor cavity shown as X in Figure 9 page 9 will determine the correct duct connector 5 Determine which duct connector to use from Table 3 page 9 6 Measure and drill gas hole and cut out for cooling coil if applicable See Figures 6 or 7 page 9 20 14 1 2 FLOOR OPENING gt REAR WALL OF CLOSET OR ALCOVE 5 T 2 1 4 SUPPLY AIR DUCT CAVITY Figure 9 Floor Cavity 3 Duct Connector tror FLOOR CUT OUT FOR STANDARD DUCT CONNECTORS FURNACE OUTLINE 21 3 4 K 14 1 2 CUT OUT FOR OPTIONAL COOLING COIL ALT FUEL LINE u ENTRY 1 1 4 Dia 2 FURNACE OUTER DOOR Figure 6 Cut Out Dimensions for Standard Duct Connectors Table 3 Duct Connector Sizes 20 Standard Duct Connector Installation 0 The standard duct connector is designed for use on ducts 12 in width However ducts narrower than 12 may not allow sufficient clearances for this type of installation For an alternate installation method see page 10 gt _ gt REAR WALL OF CLOSET OR ALCOVE gt 8 CUTOUT FOR 1 Center the duc
40. d call your service technician GAS CONTROL KNOB Figure 32 Direct Ignition Gas Valve Honeywell Gas Control Lever Figure 33 Direct Ignition Gas Valve Robertshaw 21 How to Shut Off Gas Direct Ignition 1 Set the thermostat to the lowest setting 2 Turn off all electric power to the appliance before servicing unit 3 Set the furnace On Off Switch to OFF Honeywell Figure 32 Turn gas control knob clockwise to OFF Robertshaw Figure 33 Push the gas control lever to OFF For oil shut off all valves 4 Replace the furnace door Operating Instructions for Oil Gun Furnaces If your furnace model number begins with 55 the furnace is equipped with an ignition device which automatically lights the burner Do not try to light this furnace manually 1 Open all valves in the oil line 2 Verify the fire door is closed 3 Set the furnace On Off switch to ON 4 Set the thermostat to the desired setting NOTE 5 oil gun furnaces may be converted to gas guninthefield by usingthe proper conversion kit listed in the RPL Operating Instructions for Gas Gun Models If your furnace model number begins with M1B the furnace does not have a pilot Ignition is accomplished by a silicon carbide hot surface ignitor A control module takes care of all lighting and timing functions There are no external relays or timing devices Do try to light this furnace by hand The control module is no
41. e visible just above the pilot bracket when viewed through the observation door The same pilot orifice is used with both natural and LP gas Combustion Air In order for the flame to burn efficiently it must receive adequate combustion air The amount of combustion air required varies according to altitude actual B T U content of the fuel gas pressure conversion to another gas and other factors The burner flame should be observed and any necessary adjustments made before the furnace is placed into service See Table 7 for Factory Air settings N CAUTION Combustion air adjustment must be made only by a qualified tech nician Improper air adjustment may cause unsafe operation ex plosion and or fire asphyxiation elf the input to the furnace is too great because of excessive gas pressure wrong size nozzle or orifice high altitude etc the burner flame will be sooty and can produce carbon monoxide which could result in unsafe operation explosion and or fire or asphyxiation Model NatGas LPGas Table 7 Factory Combustion Air Settings Gas Gun Combustion air box adjustment is made to the main burner by loosening the two lock nuts on the plastic air shutter located on the left side of the burnerblower housing Air shutteradjustment line is located on the same side of the blower housing Turn the plastic shutter to a smaller number counter clockwise for less airto larger number clo
42. ea OPTION 1 Remove OPTION 2 this Fl Cut Here P Supply _ a Cut Here 7 Air Duct Cut Here Fold Flap o o x S iL 3 o Fold Flap ens Fold Flap Here 1 Cut Here Cut Here Figure 11 Narrow Air Duct Openings 10 Duct connector tabs AN Narrow Duct Duct Flap Staples or sheet metal screws OM ON Narrow Duct Duct Connector Sheet metal s screws Narrow Duct Figure 12 Narrow Ducts Round Duct Connector Installation 1 Apply a bead of caulking mastic or other approved sealant around bottom side of connector 2 Install and center the duct connector in the floor opening 3 Install the mounting plate under the back side of the duct connector See Figure 13 page 11 NOTE Align the screw holes in both components 4 Secure the duct connector and the mounting plate to the wood floor with appropriate size screws 5 Connectthe round supply duct to the underside of the duct connector and secure them with field supplied sheet metal screws 6 Seal all connections with industrial grade sealing tape or liquid sealant NOTE Requirements for sealing ductwork vary from region to region Consult with local codes for requirements specific to your area Installing The Furnace Sides and back of the furnace may be enclosed by wall framing such as in a closet or alcove
43. flashes The control is in lockout because the signal was not received by the control that the inducer centrifugal switch had closed within the time The control is in lockout because a failed ignition attempt a gas valve error or a false flame sensed during the warm up period If false flame has been sensed the control will return to normal operation and repeat ignition sequence when the false flame is not present Four flashes The control is in lockout due to a failure within the control board Control Module Status Indicator M5S Series The LED indicator s on the oil primary control provides lockout recycle and cad cell indications Three flashes Honeywell R7184 Control Green LED maicator Suus Om Gmiesrsseenglame MbefamsoraeyAy Lockout Restricted Lockout Beckett 7505 Control LED Indicator Color On Continuously Flashing Restricted hard lockout Soft lockout Cad cell is sensing flame could be flame or stray light Pump prime mode or reset button currently held for 15 sec Table 9 Control Module Status Indicators 29 OPTIONAL ADD ON AIR CONDITIONING Whether split system or single package an energy saving NORDYNE Air Conditioner is available that has been designed specifically for manufactured housing applications and can best handle your home comfort needs Ask your dealer or contractor about NORDYNE add on central air conditioning systems Single package unit includes cooling
44. furnaces are a 100 shut off type and will fail safe if for some reason the gas is turned off The valve is a step open type for M1G models and slow open for M1M and M1B models which means it opens to a low fire position and aftera few seconds steps open to high fire Roll Out Switch M1G 056 amp 070 Thefurnaceis protected by a manual reset safety Switch located on the bottom left hand side of the combustion pipe Cil Burner Primary Control The primary control for oil gun furnaces starts the burner monitors a safe operating cycle and shuts the burner off atthe end of a heating cycle The control uses a light sensing transducer to determine if fuel ignition has been successfully attained If ignition is not attained by the end of the safety ignition timing period the control shuts the burner off and enters lock out See Figure 35 Summer Cooling B C amp D Series Your furnace is A C ready equipped with A C relay and transformer The unit is equipped to use a 4 wire thermostat When using a 5 wire thermostat RC and RH should be jumped see instructions included with thermostat Upper Limit Switch Lower Limit Switch d o Furnace ce On Off e Switch Fan Control Cil Burner Control Figure 35 Furnace Controls Oil Furnace 25 TROUBLESHOOTING Standing Pilot Models Main Burner Does Not Ignite 1 Check the electrical supply to the furnace 2 Verify the furna
45. h as the fuel pump gears check valve shaft seal or burner nozzle which may result in a burner fire Conversion to Propane LP Gas This gas fired heating appliance was shipped from the factory for use with natural gas However the appliance can be converted for use with LP gas Use the following procedure for gas conversion of the burner See Table Atmospheric and Direct Ignition Furnaces 1 Follow the instructions How to Shut Off Gas on pages 21 or 22 2 Disconnect the gas pipe union and the electrical wires connected to the gas valve 3 Remove the pilot tube and thermocouple from the gas valve M1G 4 Remove the gas valve assembly a Remove screw s from gas valve bracket Gas valve and spud may be removed Orifice is located at the end of the spud M1G or M1M or remove three 3 bolts from U shaped manifold plate and orifice assembly M1B 5 Replace the main orifice with the L P gas orifice supplied in the envelope located by the gas valve Verify the orifice size matches the nameplate or Table 10 page 31 NOTE It is not necessary to convert the pilot orifice 6 For Honeywell gas valves with the regulator converter Figure 28 page 19 a Unscrew the pressure regulator cap and check for the letters NAT or LP b Invert the cap and tighten until snug 7 For Robertshaw gas valves with the regulator converter Figure 29 a Remove the black cover and unscrew the converter located on top of t
46. he gas valve b Invert the converter for LP the red ring will belocatedatthe bottom andthe LP stamping on the converter will appear right side up c Screw converter back into the regulator hand tight plus 1 8 turn Replace the black cover on the converter top to protect the threads 8 Reassemble the burner assembly into the furnace 9 Reconnect the gas piping and electrical wires to the gas valve 10 Open the manual shut off valve and follow the Lighting and Operating instructions on page 22 High Altitude Conversion High altitude conversion with this furnace depends on the installation altitude and the heating value of the gas The installation of this furnace at altitudes above 2 000 feet must meet the requirements of the National Fuel Gas Code or local jurisdiction In Canada the requirements for high altitude are different and governed by CGA B149 1 Please consult your local code authority A WARNING The reduction of input rating nec essary for high altitude installation may only be accomplished with factory supplied orifices Do not attempt to drill out orifices in the field Improperly drilled orifices may cause fire explosion carbon monoxide poisoning personal injury or death This furnace is shipped from the factory with orifices and gas regulator settings for natural gas operation at sea level altitudes At 2000 feet the NFGC requires that this appliance be derated 496 for each 1000 feet of alt
47. hermostat contacts close supplying 24 VAC to the gas valve When energized the valve steps open at a reduced flow and opens fully within 14 seconds 2 When the call for heat is satisfied the thermostat contacts open shutting off gas flow Standing Pilot w Induced Draft Blowers 1 On call for heat the thermostat contacts close supplying 24 VAC to the relay 2 Therelay contacts close and the induced draft motor energizes 3 When the inducer starts the air pressure switch closes at 0 20W C differential pressure and energizes the gas valve The valve steps open at a reduced flow and opens fully after approximately 14 seconds 4 When the call for heat is satisfied the thermostat contacts open the gas valve shuts offgasflow and the induced draftblower stops M1M Models with Direct Ignition 1 On call for heat the thermostat contacts close supplying 24 VAC between terminals C and W of the control module 2 When the inducer starts the air pressure switch closes at 0 20 W C differential pressure and energizes the gas valve 3 Aftera 45 second purge the ignitoris energized for a 30 second warm up period After warm up the gas valve opens NOTE The time for ignition is approximately 6 seconds after which the gas valve either remains open if flame is sensed or closes if flame is not sensed 5 If flame is not sensed the sequence repeats four more times before a lockout occurs To reset wait 30 seconds and
48. hes once Beckett 7505 Hold down reset button for 15 seconds until the red LED turns off and the yellow LED turns on A WARNING If furnace still doesn t light turn the furnace off as described above and call your technician In the event of flashback or explosion immediately shut off furnace and call your service technician 4 After flame is established the ignition remains on for 10 seconds to ensure flame stability It then turns off 5 The circulating air blower will energize after the temperature fan switch closes 6 The furnace runs until the call for heat is satisfied 7 The circulating air blower will de energize when the temperature fan switch opens Gas Gun Models 1 On a call for heat the furnace control begins anignition sequence which lasts approximately 45 seconds 2 After this sequence the control module tests to see if flame is sensed If it has the furnace continues to heat until the thermostat is satisfied 3 If the burner has not lit the ignition sequence is repeated a maximum of two more times If flame is not sensed after three attempts the control enters Lockout and no further attempts to light the burner will occur If Lockout occurs contact a qualified service technician for assistance 4 When call for heat is satisfied the thermostat contacts open and the gas valve shuts off gas flow A WARNING Should overheating occur or the gas supply fails to shut off s
49. hut off the manual gas valvetothe furnace before shutting off the electrical supply AVERTISSEMENT En case de temp rature excessive ou sail est impossible de cooper l alimentation en gaz fermer le robinet manuel d alimentation en gaz du g n rateur d sir chaud avant de cooper l alimentation lectrique FURNACE CONTROLS amp FUNCTIONS Furnace On Off Switch This switch turns electrical power to the furnace on and off The switch must be set in the ON position for the furnace to operate For M1G models in warm weather there is a possibility ofthe blower turning on periodically or operating continuously due to a heat buildup within the furnace by a combination of warm weather and heat from the pilot This is normal operation as long as there is power to the furnace and the furnace On Off switch is in the ON position If blower operation is not desired the furnace On Off switch may be set in the OFF position to cut the electrical powertothefurnace See Figure 35 Limit Control Thisfurnaceis protected by two high temperature safety limit switches The auxiliary upper limit Switch and the high temperature lower limit Switch are automatic reset types If either limit trips the burner will shut off If either limit switch trips off again soon after resetting set the furnace furnace On Off switch to the OFF position and call your authorized serviceman See Figure 35 Gas Valve The gas valves for the gas
50. ion listed below must be followed during the installation service and operation of this furnace Failure to follow safety recommendations could result in possible damage to the equipment serious personal injury or death Use only with type of gas approved for this furnace Refer to the furnace rating plate nstall this furnace in accordance to the minimum clearances to combustible materials listed in Table 1 page 5 Provide adequate combustion airtothe furnace space as specified on page 23 Combustion products must be discharged outdoors Connectthis furnace to an approved vent system as specified on pages 13 14 Never test for gas leaks with an open flame Use a commercially available soap solution to check all connections page 18 This furnace is designed to operate with a maximum external pressure rise of 0 5 inches of water column Consult Table 8 page 38 and the rating plate for the proper circulating air flow and temperature rise NOTE It is important that the duct system be designed to handle the desired flow rate and external pressure rise An improperly designed ductsystem can resultin nuisance shutdowns and comfort or noise issues This furnace may not be used for temporary heating of buildings or structures under construction When supply ducts carry air circulated by the furnace to areas outside the space containing the furnace the return air shall also be handled by duct s se
51. ipe Furnace Figure 16 Ceiling Cavity Depth ROOF JACK INSTALLATION Required ceiling and roof cut out openings see Figure 11 must be carefully located to avoid misalignment of the furnace and Roof Jack Note Install only Roof Jack Assemblies listed in Table 4 on this heating appliance Roof Jack Selection 1 Determine depth of ceiling cavity from center of roof opening to center of ceiling opening See Dimension in Figure 16 2 Determine ceiling height and subtract height of furnace See Dimension B in Figure 16 3 Add dimensions A B and X from Table 5 and Figure 18 if slant deck flashing is used The total length of A B X must be within the minimum and maximum range of one of the Roof Jacks listed in Table 4 Application Notes FAW FAWT SAW and SAWT Series Roof Jacks with a 5 diameter inner vent pipe may be used with all models of M1 Series gas and M5 Series oil furnaces F Flat Flashing flexes from 0 12 to 1 12 roof slope See Figure 17 page 12 S Slant Flashing 2 5 12 Slope flexes from 1 12 to 4 12 roof slope 4 12 flexes from 3 12 to 5 12 See Figure 18 Stainless steel roof jacks are available 1 5 furnaces may be used with roof jacks as tall as 170 except M1M 056 amp M1B 066 models which are limited to 120 An internal roof jack extension p n 901935 10 p n 903107 18 can be used to increase roof jack height
52. itude For example the input needs to be reduced 8 at 2 000 feet 12 at 3 000 feet and etc This deration is in reference to the input rate and gas heating value at sea level See Table 12 page 32 voee PRESSURE REGULATOR CAP OTHER SIDE OF CAP LP Gas Configuration Black Cover Natural Gas Configuration Figure 29 Robertshaw Gas Valve Flue Gas Sampling It may be necessary to take flue gas sampling from oil and gas furnaces M5S and M1B Series Models in order to check the performance after furnace installation A flue gas sample may be taken from the heat exchanger which is located behind the hole of the top front of blower compartment 1 Turn off all electric power to the appliance 2 Remove the black plastic cap located above the blower Do not discard cap 3 Drill a hole through the top of the blower compartment NOTE Hole diameter should be same size as sampling tube 4 Insert sampling tube through the drilled hole and into the heat exchanger 5 After a complete check and adjustment of furnace performance seal the drilled hole with a screw larger than the hole NOTE Seal the screw threads with silicon sealant rated at least 500 F 6 Plug the outside hole with the plastic cap removed in step 3 19 STARTUP AND ADJUSTMENTS PLEASE READ ALL SAFETY INFORMATION BEFORE LIGHTING THE FURNACE A WARNING FIRE OR EXPLOSION HAZARD WHAT TO DO IF YOU SMELL GAS Do n
53. k bottom If the bottom of the tank is higher than the pump intake the return line should extend not more than 8 inside the tank Fuel line Hook Up 1 Use a 3 8 O D copper tubing for the fuel line NOTE Cap the end with tape to keep out dirt while the line is being routed 2 Install duplex bushing for two 3 8 lines in the top fitting of the tank See Figure 27 3 Insertone end of the tubing through the duplex bushing until it is three to five inches from the bottom drain Tighten the bushing 4 Route the line where it will not incur any damage Make bends gradual and avoid kinks which might restrict oil flow Cordset Bypass Solenoid Valve Pressure Adjustment Eo Nozzle Port 3 16 Flare Fitting Bleed amp Gauge Port Inlet Port 1 4 NPTF Return Port Install 1 6 Bypass Pipe Plug for 2 pipe System Only On Off Fan Use 5 32 Allen Wrench Switch If fuel pump fails to lift oil check for air leaks and tighten all fuel fittings Re prime fuel pump by injecting fuel oil into optional top return port Replace return r Oil Gun port plug and repeat priming procedure Burner Figure 27 Typical Oil Piping for Above Ground Single Line Supply 17 5 Open the furnace door and connectthe oil line to the intake port on the pump Tighten other port plugs on the pump NOTE Verify the oil line is airtight Air leaks can cause the pump to lose pri
54. l disconnect mustbe installed readily accessible from and located within sight of the furnace Refer to the wiring diagram inside the control box cover or Figures 40 45 pages 34 39 for the wiring of your particular unit Any other wiring methods must be acceptable to authority having jurisdiction N CAUTION Label all wires prior to disconnection whenservicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing IMPORTANT NOTE Proper line voltage polarity must be maintained in order for the control system to operate correctly Verify the incoming neutral line is connected to the white wire and the incoming hot line is connected to the black wire The furnace will not operate unless the polarity and ground are properly connected as shown in Figure 25 Route all electrical wiring to the left side of the furnace For installation of A Cabinet furnaces allow sufficient slack in the wiring if an optional cooling coil cabinet is added at a later time Use of copper conductors is recommended Connecting Power Supply Wires 1 Remove the furnace control panel cover 2 Route wires 115 VAC through the strain relief on the left side of the furnace control box see Figure 24 3 Connect the hot wire to the black pigtail lead and the neutral wire to the white pigtail lead Secure all connections with suitable wire nuts 4 Connect the ground wire to the gr
55. le takes care of all timing functions After lighting the control module uses the ignitor as a flame sensor shutting off gas should the flame go out There are no external relays or timing devices Do try to light this furnace by hand The control module is not field serviceable 1 Set the thermostat to the lowest setting 2 Turn off all electric power to the appliance 3 Remove the furnace door and turn off the gas valve Honeywell push in and turn the gas control knob clockwise to OFF Figure 32 Robertshaw push the gas control lever to the OFF position Figure 33 Do not force 4 Wait ten 10 minutes to clear out any gas If you smell gas STOP and follow the Safety Information on page 19 If you do not smell gas proceed to next step 5 5 Set the thermostat MODE the ON position 6 Turn the gas valve ON e Honeywell push in and turn gas control knob counter clockwise to ON Figure 32 Robertshaw push the gas control lever to the ON position Figure 33 Do not force 7 Replace the furnace door 8 Turn on all electric power to the appliance 9 Change the thermostat mode to HEAT and the temperature selector to a desired temperature level The igniter should light in approximately 75 seconds If the appliance will not operate see How To Shut Off Gas Direct Ignition and call your service technician or gas supplier NOTE Inthe eventof any flashback or explosion immediately shut off the furnace an
56. leaks coat theflashing plate and fasteners with approved roofing compound Installation of Transit Mode Venting System Manufactured Home Factory 1 Furnace must be installed in accordance to furnace installation manual 2 Select appropriate Roof Jack from Table 4 page 11 3 Roof Jack less upper Roof Jack crown with weather capto be installed as described under Install Roof Jack NOTE Upper Roof Jack crown to be stored in a prominent location inside manufactured home until on site installation Secure roof jack with appropriate fasteners after connecting to Caulk under roof flashing to prevent water leakage Optional 2 piece ceiling ring 902521 Secure lower roof jack section with no 10 S M screws Optional Slant Deck Flashing E m Secure flashing with appropriate fasteners Ceiling Caulk under roof flashing to prevent water leakage Figure 21 Pitched Roof Connect outer flue shield Inner flue pipe zee Vent Collar Mtg Fiange Figure 22 Combustion Air Pipe Connection 13 4 The four warning tags supplied must be installed as follows To weather cap Tofuelline connection point Gas orfurnace burner Cil To furnace flame observation door Gas or Oil To furnace wall thermostat 5 Transit mode weather cap to be removed and upper Roof Jack crown installed See Figure 24 Do Not Discard screws 6 Place upper Roof Jack crown on to the flue
57. ll be of sufficient size easily read from a distance of eight feet away and read Gas Vent Directly Below For direct vent appliances mechanical vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied a A CO detector and alarm shall be placed on each floor level where there are bedrooms The detector shall comply with NFPA 720 2005 Edition and be mounted in the living area outside the bedroom s b The CO detector shall Be located in the room that houses the appliance or equipment Behard wired battery poweredorboth Shall comply with 720 2005 Edition C A product approved vent terminal must be used and if applicable a product approved air intake must be used Installation shall be in strict compliance with the manufacturers instructions A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation The information listed below is for reference purposes only and does not necessarily have jurisdiction over local or state codes Always consult with local authorities before installing any gas appliance Combustion and Ventilation Air US National Fuel Gas Code NFGC Air for Combustion and Ventilation CANADA Natural Gas and Propane Instal lation Codes NSCNGPIC Venting Sy
58. lternate Attachment Method 10 Round Duct Connector Installation 10 Installing the Furnace 10 ROOF JACK INSTALLATION 11 Roof Jack Selection 11 Application 11 Locating amp Cutting Roof Openings 12 Installing the Roof 13 Installation of Transit Mode Vent System 13 Manufactured Home Factory 13 ELECTRICAL INFORMATION 14 Line Voltage Wiring 14 Connecting Power Supply Wires 15 Low Voltage Wiring 15 Connecting Thermostat Wires 15 Verifying Anticipator Setting 15 Grounding a aein aeea 15 FUEL SUPPLY AND PIPING 16 Oil Tank amp Piping Istallation 17 One Line System 17 Two Line 17 Fuel Line Hook Up 17 Leak Check 18 Priming Honeywell R7184 18 Priming Beckett 7505 18 Fuel Oil Type 18 Conversion to Propane Gas 18 Atmospheric amp Direct Ignition 18 High Altitude Conversion 19 Flue Gas Sampling
59. me and will create other problems such as nozzle failure odors rumbling noise and false safety shutdown 6 Insert the short length of the copper tube level with the bottom of the duplex bushing Form the tube into an inverted U to serve as a vent Leak Check To eliminate problems caused by air in the oil line all connections in the oil supply line and all plugs nuts and fittings on the pump must be airtight NOTE This includes the nut that covers the pressure adjustment It is important that the hook up be done carefully and with a good flaring tool Prepare the burner for priming by attaching a clear plastic hose over the bleed port fitting and fully opening the pump bleed port Use a suitable container to collect purged oil To ensure continuous operation use a wire to jumpterminals T T or F F on the primary control while burner is running After the piping to the furnace is complete all connections must be tested for leakage This includes pipe connections atthe main gas valve emergency shutoff valve and each joint or union The soap and water solution can be applied using a small paintbrush If any bubbling is observed theconnectionis notsealed adequately and must be retightened Repeat the tightening and soap check process until bubbling ceases Priming furnaces equipped with Honeywell 87184 primary control 1 While the ignition is on press for 1 2 second or less and release the reset button The lo
60. motor or combustion fan runs check Thermostat connections Thermostat 4 No voltage to control module determine if 24 volts or 120 volts is available to the control module If voltage is not available check for Blown fuse defective transformer circuit breaker no electrical supply Limit switch open Loose connections Combustion Blower Runs No Flame 1 Defective centrifugal switch M1B Model Check the operation of centrifugal switch by removing end bell of the burner motor Clean contacts of motor fthecontacts are closed replace the motor 2 Defective pressure switch M1M amp M1G 077 090 Models check air tube and electrical connections 3 Burner in purge mode allow 75 seconds for flame establishing period 4 Check for proper electrical connections at purge timer control box or gas valve 5 Check for gas supply gas line valve on control lever on Control Module is Powered Ignitor won t Heat Up 1 Disconnectignitorleads at AMP receptacle and check for 120 volts at the plug during ignition sequence 2 Replace ignition control if 120 volts is not available at AMP plug during ignition sequence 120 Is Available At AMP Plug Ignitor Does Not Heat Up 1 Disconnect power to the furnace 2 Disconnect AMP plug to the ignitor and check ignitor resistance with an ohm meter Set on RX1 scale Normal reading should be 40 75 ohms f above or bel
61. n of through the wall vented gas appliances as follows 1 For direct vent appliances mechanical vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied a A carbon monoxide CO detector and alarm shall be placed on each floor level where there are bedrooms The detector shall comply with NFPA 720 2005 Edition and be mounted in the living area outside the bedroom s CO detector shall be located in the room that houses the appliance or equipment and shall Be powered by the same electrical circuit as the appliance or equipment Only one service switch shall power the appliance and the CO detector Have battery back up power Meet ANSI UL 2034 Standards and comply with NFPA 720 2005 Edition and Approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR A Product approved vent terminal must be used and if applicable a product approved air intake must be used Installation shall be in strict compliance with the manufacturers instructions A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation d Ametalorplastic identification plate shall be mounted at the exterior of the building 4 feet directly above the location of vent terminal The plate sha
62. nt sealed combustion downflow heating appliances for manufactured mobile homes recreational vehicles and for use in residential modular commercial construction The furnace must be located so that venting can be properly achieved Air conditioning may be added to structures with M1 M5 series furnaces using air conditioning or conventional units This Installation Instruction manual includes special requirements for incorporation of air conditioning equipmenttothe M1 M5 series of furnaces See Tabel 12 page 32 Multi speed blower assemblies shown in Table 2 have been certified for field installation in M1 M5 Series furnaces Unit Location The furnace shall be appropriately located to the supply and return air distribution system See Page 7 Sides and back of the furnace may be enclosed by wall framing See Minimum Clearances page 2 and Figures 1 3 The furnace installation is only intended for freeairreturn through the furnace door louvers DO NOT connect a ducted return air system directly to the furnace Improper installation may create a hazard and damage equipment as well as void all warranties Furnace may be installed on combustible flooring when using NORDYNE Duct Connectors See pages 9 amp 10 When installed in a residential garage the furnace must be positioned so the burners and the source of the ignition are located no less than 18 inches above the floor and protected from physical damage
63. of the return duct system leading into the closet when located in the floor or ceiling shall not be less than 235 square inches or 390 square inches for 5 ton ready M1 M5 Furnaces N CAUTION HAZARD OF ASPHYXIATION Do not cover or restrict return air opening Means shall be provided that prevent inadvertent closure of flat objects placed over the return air opening located in the floor of the closet versus the vertical front or side wall The total free area of openings in the floor or ceiling registers serving the return air duct System must be at least 235 sq in At least one register should be located where it is not likely to be covered by carpeting boxes and other objects Materials located in the return duct system must have a flame spread classification of 200 or less This includes a closet door if the furnace is in a closet Noncombustible pans having 1 upturned flanges are located beneath openings in a floor duct system Wiring materials located in the return duct system shall conform to Articles 300 22 of the National Electrical Code ANSI C 1 NFPA 70 Gas piping is not run in or through the return duct system N CAUTION HAZARD OF ASPHYXIATION Negative pressure inside the closet with closet door closed and the furnace blower operating on high speed shall be no more negative than minus 0 05 inch water column Test the negative pressure in the closet with the air circulating fan o
64. ons Standing Pilot Models 1 Set the thermostat to the lowest setting 2 Turn off all electric power to the appliance 3 Remove the furnace door 4 Push in and move the gas control lever to the OFF positon Figure 30 DO NOT FORCE 5 Wait 10 minutes to clear out any gas If you smell gas STOP and read the Safety Information If you don t smell gas proceed to step 6 6 Find pilot follow metal pilot tube from gas control valve Open hinged fire observation door The pilot is found at the end of the pilot tube just left of the pilot shield Figure 31 7 Lightly depress the gas control lever and move it to the ON position Release and move the lever to the PILOT position 8 Move the control lever to SET and hold Immediately light the pilot with a match Continue to hold the control lever for about one 1 minute after the pilot is lit NOTE The pilot flame is adjustable by turning the adjustment screw located on the gas valve with a small screwdriver See Figure 29 9 Release the lever and it will spring back to the PILOT position NOTE Pilot should remain lit If it goes out repeat steps 4 through 8 above If the lever does not spring back when released immediately call your service technician or gas supplier If the pilot will not stay lit after several tries move the gas control lever to OFF and call your service technician or gas supplier 10 Move the gas control lever to ON 11 Turn on all electric power to
65. ot try to light any appliance Do nottouch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier fromaneighbors phone Followthe gas suppliers instructions f you cannot reach your gas supplier call the fire department A WARNING Before placing the furnace in service it must be checked to ensure it is equipped for the type ofgas being used The burner flame must be observed and adjusted if necessary Failure to observe this caution may result in unsafe operation explosion and or fire or asphyxiation See the Gas Supply and Combustion Air sections The first lighting of the furnace after any home setup must be performed by a qualified service technician If this appliance has a pilot that must be lit by hand follow these instructions exactly BEFORE LIGHTING Smell all around the furnace for gas and next to the floor Some gas is heavier than air and may settle on the floor Use only your hand to push in the gas control lever Never use tools Ifthe lever will not push in by hand don ttry to repairit Force orattempted repair may result in a fire or explosion Call a qualified service technician Do not use this furnace if any part has been under water Immediately call a service technicianto inspectthe furnace andto replace any part of the gas valve or control system which has been under water 20 Lighting Instructi
66. ottom of the fuel tank to the fuel pump must not exceed 10 feet Keep the tank filled especially in the summer to reduce the accumulation of condensation 3 8 Oil Supply Line Oil Vent with cap 2 Duplex Top of Tank End of Oil Supply Line 3 to 5 Above Bottom Drain Alternate Fuel Line NOTE Additional venting may be required if tank is filled rapidly X Cy Inlet Port Es NPTF 4 Flue Gas c Furnace _ 7 Sampling gt fe lt n Hole 9 IK One Line System The one line system is highly recommended where vertical lift from bottom of tank to pump is less than eight feet Figure 27 A single line hookup has the advantage of lower cost and quieter operation Two Line System If a two pipe system is used or if oil is taken from the bottom of the tank a filter is recommended A two line system should only be used if vertical lift exceeds 8 feet 1 Install the oil feed line as outlined in steps 1 6 below 2 Install the oil pump bypass plug in the bottom return port 3 Route the return line up through the furnace base to the return port of the pump Route the other end of the line to the tank using 3 8 O D copper tubing or 1 4 pipe with the ends capped 4 nsert the return line through the second opening in the duplex bushing If the bottom of the tank is lower than the pump intake the tube should be inserted three or four inches from the tan
67. ounding Screw 5 Reinstall the control panel cover and secure with the original mounting screws Low Voltage Wiring The thermostat must be installed according to the instructions supplied by the thermostat manufacturer Low voltage connections 24 VAC from the thermostat are wired to the terminal strip on the integrated control in the furnace NOTE The thermostat must not be installed on an outside wall or any other location where its operation may be adversely affected by radiant heat from fireplaces sunlight or lighting fixtures and convective heat from warm air registers or electrical appliances The nominal anticipator setting is 0 4 Refer to the thermostat literature for additional information Five conductor thermostat wire is recommended for 24 volt low voltage circuit 2 wire is required for furnace only 5 wire for heating and optional cooling systems Refer to table 6 for thermostat wire information Connecting Thermostat Wires 1 Insert 24 volt wires through the plastic grommet just above the control panel 2 Connect the thermostat wires to the furnace low voltage pigtails see Figure 25 3 Connect low voltage circuit to the wall thermostat 4 A hole may be made in the furnace cabinet to ease thermostat wiring Make sure that the wiring is protected from the sharp edge of the added hole Thermostat Wires AC Furnace Control Box To combustion Blower or Flame Roll out Switch
68. ow this rating at room tem perature change ignitor 3 Check for continuity from ignitor receptacle to burner Main Flame Ignites Burner Locks Out Ignition control is not properly grounded Defective ignition control Improper polarity of 120 volt power supply Ignitor has hairline crack Improper gas pressure or burner air adjustment is not allowing flame to contact ignitor tip for flame rectification Misaligned ignitor does not allow flame to contact ignitor tip for flame rectification Burner Short Cycling Thermostat Calls for Heat Limit Switches Closed Check for polarity Check ground Check flue Check combustion air Check gas pressure Check orifice Checkthe position of ignitor a normal reading should be 40 75 ohms 24 Volts Supplied To Gas Valve During Ignition No Main Gas Flow Gas valve may be defective Replace if necessary Gas piping may be plugged Check for adequate gas supply to gas valve at union Burner Operates Insufficient Heat Check thermostat for proper setting and location Thermostat should not be located where it will be affected by another heatsource Check for clean filter and proper air flow Check burner for proper gas firing rate Be sure unit is not undersized for its thermal load Check thermostat anticipator The nominal setting is 0 4 Burner Flame Without Motor Running Gas valve stuck open check gas
69. perating at high speed andthe closetclosed The negative pressure is to be no more negative than minus 0 05 inch water column Air conditioning systems may require more duct register and open louver area to ob tain necessary airflow Use NORDYNE s certiduct program to determine proper duct size for A C Supply Air Connections For proper air distribution the supply duct system must be designed so that the static pressure measured external to the furnace does not exceed the listed static pressure rating shown on the furnace rating plate N Location size and number of registers should be selected on the basis of best air distribution and floor plan of the home The supply air must be delivered to the heated space by duct s secured to the furnace casing running full size and without interruption Three typical distribution systems are shown in Figure 5 The location size and number of registers should be selected on the basis of best air distribution and floor plan of the home A Single trunk duct B Dual trunk duct a w crossover connector Transition duct w branches Figure 5 Typical Supply Duct System FURNACE INSTALLATION NOTE These Installation procedures are suggested for typical furnace installations Since all installations are different from each other the sequence of instr
70. s the heat anticipator setting YES correct UNIT SERIAL Minimum clearances per GAS SYSTEM 2 Table 1 page 5 Gas Type circle one Propane Has the owner s information been reviewed with the Gas pipe connections leak YES NO home owner tested ME orature YES NO Gas Line Pressure in W C been left near the furnace Is there adequate fresh air supply for combustion and ventilation Installation Altitude FT We Encourage Deration Percentage 96 Professionalism J Furnace Input Btuh Supply Air Temperature F Through Technician o Listed US Certification by NATE Return Air Temperature CF Temperature Rise F Vent free from restrictions Filter s secured in place 231 Q ENCE Flue connections tight Is there proper draft NORDYNE 709123A Replaces 7091230 Specifications amp illustrations COMPLETE COMFORT GENUINE VALUE subject to change without notice or incurring obligations O Fallon MO 709123A Printed in U S A 04 10
71. stems and Air Supply for Appliances Duct Systems e USand CANADA Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigeration and Air Conditioning Engineers ASHRAE Fundamentals Hand book Electrical Connections US National Electrical Code NEC ANSI NFPA 70 CANADA Canadian Electrical Code CSA C22 1 Gas Piping and Gas Pipe Pressure Testing US NFGC and National Plumbing Codes CANADA NSCNGPIC General Installation US Current edition of the NFGC and the 90B For copies contact the National Fire Protection Association Inc Batterymarch Park Quincy MA 02269 or American Gas Association 400 N Capitol N W Washington DC 20001 or www NFPA org CANADA NSCNGPIC For a copy contact Standard Sales CSA International 178 Rexdale Boulevard Etobicoke Toronto Ontario M9W 1R3 Canada Safety e US NFGC 54 1999 ANSI 2223 1 and the Installation Standards Warm Air Heating andAir Conditioning Systems ANSI NFPA 90B Federal Manufactured Home Constructions amp Safety Standard H U D Title 24 Part 3280 707 a 2 The Standard for Manufactured Home Installations Manufactured Home Sites Communities and Set Ups ANSI A225 1 and or CAN CSA 2240 MH Series American National Standard ANSI 119 2 NFPA 501C for all recreational vehicle installations e CA
72. t field serviceable 1 Before operation smell for gas all around the furnace especially near the floor because some gases are heavier than air and will settle on the floor If you detect gas STOP and follow all the safety instructions 2 Set the thermostat to the lowest setting 3 Turn off all electric power to the appliance 4 Turn off the gas valve Honeywell push in the gas control knob and turn clockwise to OFF Figure 32 Robertshaw push the gas control lever to OFF Figure 33 The lever cannot be placed in the off position unless it is pushed in slightly DO NOT FORCE 5 Wait ten minutes to clear out any gas you smell gas STOP and follow the safety information If gas is not detected proceed to the next step 6 Set the furnace On Off switch to the ON position Honeywell turn knob on gas control counter clockwise to ON Robertshaw push the gas control lever to ON 22 7 Turn electric power to the appliance ON 8 Set the thermostat to HEAT and or the desired temperature setting The furnace should light in approximately 45 seconds If the appliance will not operate follow the instructions How to Shut Off Gas Direct Ignition Furnace page 21 and call your service technician or gas supplier In the event of any flashback or explosion immediately shut off the furnace and call your service technician How to Shut Off Gas Oil amp Gas Gun 1 Set the thermostat to the lowes
73. t connector in the floor opening 5 i qu TA DIAMETER with bottom tabs resting on top of the supply gt C air duct tasas 2 Mark the cut out area on the supply air duct by e SUT OUTFOR tracing around the connector tabs Figure 8 of the ER PENES uu duct connector 13 44 L D 3 Remove the duct connector and cut out the ALT FUEL LINE FUEL 2 3 4 gt 1 1 4 Dia LINE marked area of the supply air duct 1 4 larger 17 8 FOUTER the actual cutout drawn 2 7 8 DOOR 4 Install the duct connector back in the floor opening with the bottom tabs extending into the supply air duct 5 Install the mounting plate Figure 8 under the back side of the duct connector Align the screw holes in both components Bandiabs 6 Secure the duct connector and the mounting ome B up 90 plate to the wood floor with appropriate size 4 screws 7 Bend the connector tabs on the bottom of the duct connector upwards and as tight as possible against the supply air duct 8 Bend both tabs on the mounting plate up 90 See Figure 10 page 10 9 Seal all connections with industrial grade sealing tape or liquid sealant Figure 7 Cut Out Dimensions for Round Duct Connectors NOTE Requirements for sealing ductwork vary from region to region Consult with local codes for requirements specific to your area Figure 8 Standard Duct Connector In stalled DUCT CONNECTOR BEND TABS TIGHTLY
74. t setting 2 Turn off all electric power to the appliance at the breaker or fuse box 3 Set the thermostat MODE switch to OFF 4 Turn the gas valve OFF Honeywell push in and turn the gas control knob clockwise to the OFF position Figure 32 Robertshaw push the gas control lever to the OFF position Figure 33 5 Replace the furnace door NOTE M1B gas gun furnaces may be converted to oil gun in the field by using the proper conversion kit listed in the RPL Burner Adjustments Burnersettings are made atthe factory However these settings may change during shipping handling and installation The following items should be checked and readjusted if necessary Gas Pressure The gas pressure can be checked with a manometer at the pressure tap located on the side of the gas valve The gas valve pressure regulator can be adjusted by removing the regulator selector stack and turning the slotted insert located directly under the selector stack The regulator selector stack must be secured in place before each pressure reading is taken Natural gas manifold pressure should be 3 5 W C and L P gas manifold pressure should be 10 W C Replace the gas pressure tap plug on the gas valve Pilot Flame Standing Pilot Only The pilot flame can be adjusted by turning the pilot adjustment screw located on top of the gas valve See Figure 30 page 20 The pilot flame height should be between 3 4 and 1 The flame tip should b
75. tes independently of the furnace the thermostat system must have an interlock to prevent the furnace and air conditioner from operating at the same time This interlock system usually contains either a Heat Cool switch which must be turned to one of the positions to activate heat or cool operation or a positive OFF switch on the cooling thermostat The furnace must also be equipped with an automatic damper to prevent cold air from being discharged up around the heat exchanger NORDYNE p n 901996 for furnaces without coil cavity or p n 901083 with coil cavity See Figure 36 or 37 Cold air may cause condensation inside the heat exchanger which can rust and lead to early failure Figure 37 Damper without Coil Cavity Control Module Status Indicators M1M Series Red LED Indicator Steady ON Steady OFF Rapid flash One flash Two flashes Control OK No power False flame or internal control fault Limit switch is open Pressure switch is open Three flashes Pressure switch is stuck closed Four flashes Lockout due to failed ignition Five flashes L1 neutral reversed or L1 voltage not present on L1 Flame Status A Yellow LED labeled Flame is provided to indicate flame status When flame is sensed the flame LED is lit If flame sense is weak yellow LED will flash Control Module Status Indicator M1B The control is in lock out because the inducer centrifugal switch is or One flash was stuck closed Two
76. then interrupt the 24 VAC power by turning the room thermostat below room temperature then returning it to the original set point 6 If flame does not establish on the 5th attempt initialfire 4 re tries the control de energizes the gas valve the red LED flashes 4 times and the furnace locks out heat operation for 1 hour See Table 9 page 29 If a flame is present the control energizes the main blower on heat speed 30 seconds after the gas valve opens 8 When call for heat is satisfied the thermostat contacts open the gas valve shuts off gas flow and the combustion blower remains on for a 30 second post purge period 9 The main blower is de energized after a 120 second blower off delay N 24 Oil Gun Furnace with Honeywell R7184 Beckett 7505 Control M5S Models 1 When a call for heat is initiated there is a 2 to 6 second delay while the control performs a safe start check 2 The ignition and motor are turned on and a flame should establish within a 15 second lockout time NOTE Burner will prepurge for 15 seconds if equipped with Honeywell R7184B or Beckett 7505B Control 3 flame is not sensed within the 15 second lockout time the control shuts down on safety lockout and must be manually reset by pushing the reset button on the control If control locks over three times in a row the control enters restricted lockout To reset Honeywell R7184 Hold down the reset button for 45 seconds until the LED flas
77. uctions may differ from the actual installation Only qualified HVAC technicians should install this furnace General Information e The furnace mustbe leveled atinstallation and attached to a properly installed duct system Do not use the back of the furnace for return air See page 7 for circulating requirements The furnace must be installed so that all electrical components are protected from water The dimensions of the room or alcove must be able to accommodate the overall size of the furnace and the installation clearances listed in Table 1 and Figure 3 page 6 The furnace must be installed upstream from a refrigeration system The plenum attached to the A C coil box and ductwork within 3 ft of the furnace must be installed so that surfaces are at least 1 4 from combustible construction The cabinet plug must always be used to close the hole in the side ofthe furnace when rotating the inducer M1 M5 models must be installed with the Nordyne A C coil box which are listed according to the cabinet size of the furnace B cabinet 920169 C cabinet 920171 and D cabinet 920172 The M1 Series gas and 5 Series oil furnace is certified for use on wood flooring or supports but must be installed on top of a duct connector This factory supplied accessory must be installed in the floor cavity and attached to the supply air duct before the furnace is installed Requirements and Codes Installer m
78. uirements are a louvered door with a minimum of 250 sq in free area with the openings in the closet door in line with the louvered openings in the furnace door A fully louvered closet door may be used See Circulating Air Requirements page 7 ALL MODELS CLOSET ALCOVE Se 1 Bak v Sides o Roof Jack Too v Bottom of Duct BCabnet o A Cabinet w coil box A Cabinet Table 1 Minimum Clearances 6 152 mm Top Clearance f Removable access panel should be installed above furnace door frame to access roof jack Clearance to Furnace WAN 18 457 mm ag Nearest Wall or Partition AAI N a Provide min 235 6 152 mm Sq in 1516 cm Top Clearance K open free area in 1 front or side wall Ka In closet door located at top center or bottom Provide 250 Sq in 1613 cm open free area in front or side wall Z or in closet door a fully louvered door may Clearance be used to Furnace n 4 2 Figure 3 Special 1 Clearance Blower Motor Assembly Blower Wheel A C Capacity Tons 903773 2 224 3 903413 2 2 5 3 amp 4 903890 2 210 3 4 amp 5 Table 2 Blower Assemblies Applications M1 Series gas and M5 Series oil furnaces are listed direct ve
79. urner stays running the system is operational 8 If the LED indicator for R7184 control green LED for 7505 control is off check the cad cell assembly after disconnecting the line voltage Burner will not start and the LED indicator is flashing at 2 seconds on 2 seconds off for 87184 or the green LED is flashing for 7505 Hold the reset button down for 1 2 seconds If LED indicator continues to flash wait for 60 70 seconds If it still continues to flash replace the primary control Honeywell R7184 control To check cad cell resistance press and release the button during the run mode with the igniter off The LED will flash to indicate the cad cell resistance For proper burner operation it is important that the cad cell resistance is under 1600 Ohms For cad cell resistance see Table 8 Beckett 7505 control To check cad cell resistance unplug the cad cell leads yellow wires fromthe control Measure the resistance with a meter in the conventional way when a flame is present For proper burner operation it is important that the cad cell resistance is under 1 600 Ohms LED Flashes Ohms Cad Cell Resistance 0 400 400 800 800 1600 4 gt 1600 Table 8 Cad Cell Resistance when sensing flame 28 OPTIONAL ACCESSORIES Necessary when the Furnace is Used with Some Central Air Conditioners If an air conditioner is installed that does not use the furnace blower for air distribution and opera
80. ust be familiar with and comply with all codes and regulations applicable to the installation of these heating appliances and related equipment In the absence of local codes the installation must be in accordance with the current provisions of one or more of the following standards Federal Manufactured Home Constructions amp Safety Standard H U D Title 24 Part 3280 707 a 2 American National Standard ANSI 119 2 NFPA 501C for all recreational vehicle installations American National Standard ANSI Z223 1 NFPA 54 and or CAN CSA B149 for all gas fired furnace models American National Standard ANSI Z95 1 NFPA 31 and or CSA B139 for all oil fired furnace models American National Standard ANSI C1 NFPA 70 and or CSA 22 1 Canadian Electric Code Part 1 for all electrical field wiring Units have been researched under standards UL 307A amp B UL727 1999 ANSI Z21 47b CSA 2 3b 2008 and CSA B140 10 Locating and Cutting Duct Openings Floorcut outs andfuelline holes mustbe carefully located to avoid misalignment of the furnace and vent piping To locate standard ducts see Figure 6 page 9 For round ducts see Figure 7 1 Measure 10 from the rear wall or alcove and mark the centerline of the cut out on the floor 2 Using the centerline as a starting point draw the rest of the duct cut out to the dimensions shown in Figures 6 or 7 3 Cut out the floor opening 1 16 larger than the actual

Nordyne AND M5S Furnace User Manual

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