Nordyne M3RL Series User manual

Installation Instructions

M3RLSeries 90+DownflowCondensingFurnace

Direct Vent (Sealed Combustion) Forced Air Gas Furnaces

LEAVE THESE INSTRUCTIONS WITH THE HOMEOWNER.

!WARNING:

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could

result in serious injury, death or property

damage.

!ADVERTISSEMENT:

RISQUE D’INCENDIE OU D’EXPLOSION

Lenon-respectdesavertissementsdesécurité

pourrait entraîner des blessures graves, la

mort ou des dommages matériels.

– Donotstoreorusegasolineorotherflammable

vapors and liquids in the vicinity of this or any other

appliance.

–WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any

phoneinyourbuilding.

• Leavethebuildingimmediately.

• Immediatelycallyourgassupplierfromaneighbor's

phone.Followthegassupplier'sinstructions.

• If you cannot reach your gas supplier, call the fire

department.

– Installation and service must be performed by a

qualified installer, service agency, or the gas sup-

plier.

– Ne pas entreposer ni utiliser de l’essence ni

d’autres vapeurs ou liquides inflammables dans le

voisinage de cet appareil, ni de tout autre appareil.

–QUE FAIRE S’IL Y A UNE ODEUR DE GAZ

• Ne pas tenter d’allumer aucun appareil.

•Ne toucher à aucun interrupteur électrique;

n’utiliser aucun téléphone dans le bâtiment.

• Évacuerl’immeubleimmédiatement.

• Appeler immédiatement le fournisseur de gaz en

employant le téléphone d’un voisin. Respecter à

la lettre les instructions du fournisseur de gaz.

• Si personne ne répond, appeler le service des

incendies.

– L’installation et l’entretien doivent être effectués

par un installateur qualifié, un organisme de

service ou le fournisseur de gaz.

Forinstallationin:

1. Manufactured Homes

2. ParkModelsandManufacturedBuildings

3. ModularHomes/Buildings

!WARNING:

Should overheating occur, or the

gas supply fail to shut off, shut

off the manual gas valve to the

appliance before shutting off the

electrical supply.

Improper installation, adjust-

ment, alteration, service or

maintenance can cause injury

or property damage. Refer to

this manual. For assistance or

additional information consult

a qualified installer, service

agency or the gas supplier.

BW Models

BWT Models

Application

M-Manufactured Home

Furnace Series

Comfort Model

RL - Condensing Downflow

M 3 R L - 060 A - A W

Door Color

W - White

G - Gray

Cabinet Dimensions

A - 56" x 19-3/4" x 23-3/4”

B - w/Coil Cavity,

76" x 19-3/4" x 23-3/4"

Electrical Code

A - 1PH, 60 Hz, 120 VAC

Conversion .............................................. 21

LightingandAdjustment

oftheAppliance .............................. 23

ElectricalWiring ...................................... 24

LineVoltageWiring ........................... 24

LowVoltageWiring ........................... 26

Ventilation ................................................ 26

Start-upandAdjustment ........................ 26

Start-UpProcedure ........................... 26

ShutDownProcedure ....................... 27

VerifyingandAdjustingFiringRate ... 27

TemperatureRise ............................. 27

VerifyingandAdjusting

Verifying Burner Operation.............. 28

Verifying Operation of the

Supply Air Limit Switch ................. 28

Description of Components ................ 29

Furnace Accessories............................. 29

Maintenance ........................................... 29

Combustion Air and Vent System.... 29

Air Filter(s) ....................................... 29

Lubrication........................................ 30

Condensate Drain Assembly ........... 30

Blower Compartment ....................... 30

Heat Exchanger and Burner

Maintenance .................................. 30

System Operation Information............. 30

Sequence of Operation.................... 30

Furnace Fails to Operate ................. 31

Location of Major Components .......... 32

Wiring Diagram ....................................... 33

Installation/Performance

Checklist ......................................... 35

General ...................................................... 4

UnitDimensions .................................. 4

Shipping Weights................................ 4

Furnace Specification ........................ 4

Air Flow Data ..................................... 4

Owner's Information ................................ 5

Installation Requirements...................... 6

Location.............................................. 7

Clearance ........................................... 7

Circulating Air Supply ............................ 7

Return Air Provisions.............................. 8

Air Distribution Systems ........................ 9

Duct Connector Selection.................... 10

Duct Installation .................................... 10

Venting and Combustion

Air Requirements ........................... 13

Venting Requirements .......................... 14

Vent Table ........................................ 15

Vent Pipe Material ............................ 16

Vent Pipe Length and Diameter....... 16

Vent Pipe Installation ........................ 16

Pipe Routing & Support .................... 16

Location of Outdoor Termination ..... 16

Horizontal Venting ............................ 18

Vertical Venting................................ 18

Vent Freezing Protection ................. 19

Concentric Vent Termination ........... 19

Drainage of Condensate

From Furnace................................ 19

Gas Supply and Piping ......................... 20

Leak Check....................................... 21

High Altitude Derate ......................... 21

Pressure Switch .............................. 21

TABLE OF CONTENTS

Table 1. Model Identification

Return Air Configuration

Blank - Front

T - Top

Heating Capacity

Input, BTUH (000’)

19-7/8

24-5/8

56-1/16

20-9/32

21-17/32

21-29/32

21-15/16

19-3/16

23-7/16

28-15/32

3-17/32

4-11/16

3-17/32

EXHAUST

VENT

17-13/16

COMBUSTION

AIR

INTAKE

21-11/32

7/8 Diameter

1-19/32

EXHAUST

VENT

1-11/16

COMBUSTION

AIR

INTAKE

3-17/32

24-3/4

20-1/16

18-1/2

(W/ Coil Box)

75-1/4

SIDE RETURN

KNOCKOUTS

SIDE RETURN

KNOCKOUTS

1-1/2

21-15/16

1-19/32

Cooling

Coil

Box

(W/O Coil Box)

Table 2. Shipping Weight

Table 3. Furnace Specifications/Airflow Data

GENERAL

Note: Data is for Operation with Filter.

* Factory Wired Cooling Tap

** Factory Wired Heating Tap

Furnace Specifications / Airflow Data

Furnace Furnace Temp. Recommended

Input Output Rise @ A/C

Btuh Btuh .3"WC °F CFM CFM CFM CFM CFM Ton

High* 1660 1599 1544 1474 1410 4

Med-High 1512 1467 1416 1363 1304 3

Med-Low 1340 1304 1261 1217 1158 2.-1/2

60,000 54,000 35 - 65 Low** 1176 1142 1108 1025 966 2

High* 1660 1599 1544 1474 1410 4

Med-High 1512 1467 1416 1363 1304 3

Med-Low** 1340 1304 1261 1217 1158 2.-1/2

80,000 72,000 35 - 65 Low 1176 1142 1108 1025 966 2

0.4 0.5Furnace

Model No. Motor

HP Motor

Speed

External Static Pressure ( Inches Water Column)

0.1 0.2 0.3

M3 RL-060

M3 RL-080

1/2

TopReturnKnockouts Figure 1. Furnace Dimensions

Top Return Opening

(BWT Models)

*May includesuffix -T

Furnace Model

Shipping

Weight

(

lbs

)

M3RL 060A AW 150

M3RL 060A BW* 170

M3RL 080A AW 155

M3RL 080A BW* 175

Top View

(AW and BW Models)

1.000

21.000

12.000

!WARNING:

Do not use this appliance if any part

hasbeensubmergedunderwater.Im-

mediatelycallaqualifiedservicetech-

nician to inspect the appliance and to

replaceanypartofthecontrolsystem

and any gas control that has been

submerged underwater.

NOTICE TO INSTALLER

Installerisadvisedto follow carefullyallinstruc-

tions and warnings in this manual to insure

maximum performance, safety, and operating

efficiencyoftheseappliances.Improperinstalla-

tion may create hazardous conditions, and will

void the appliance warranty.

GENERAL

General Description

The M3 series gas furnaces are listed direct

vent (sealed combustion) forced air furnaces

for use with both natural and propane gases.

The M3 series is a Category IV and type FSP

furnace. The M3 furnace series has been

certified to the ANSI Z21.47/CSA2.3-2001 for

use in the United States and Canada and to the

UL307B —1995 for use in the United States.

These furnaces may be installed in:

1. Manufactured Homes.

2. Park Models and Manufactured buildings

3. ModularHomes/Buildings

The following are safety guidelines with refer-

ences to their specific sections or pages in the

manual.

1. Use only type of gas approved for this

furnace. Refer to the furnace rating plate.

2. Install this furnace only in location and

position as specified in pages 7 - 13 of

these instructions.

3. Provide adequate combustion and ventila-

tion air to the furnace space as specified in

pages 13 - 20 of these instructions.

4. Combustion products must be discharged

outdoors, connect this furnace to an ap-

proved vent system only, as specified in

pages 14-19 of these instructions.

5. Never test for gas leaks with an open

flame. Use a commercially available soap

solution made specifically for the detection

of leak to check all connections.

6. Always install furnace to operate within the

furnace’s intended temperature rise range

with a duct system that has an external

static pressure within the allowable range,

as specified in page 4 of these instruc-

tions. See furnace rating plate.

7. When a furnace is installed so that supply

ducts carry air circulated by the furnace to

areas outside the space containing the

furnace,thereturnairshallalsobehandled

by duct(s) sealed to the furnace casing

and terminating outside the space contain-

ing the furnace. Note: This section only

applies to furnaces installed with side or

top return air.

8. A gas-fired furnace for installation in a

residential garage must be installed as

specified in page 7 of these instructions.

9. The furnace is not to be used for tempo-

rary heat of buildings or structures under

construction.

M3 series furnaces are air conditioning ready

as shipped. The furnace cooling capacities of

the blower motor speed taps are shown in

Table 3. Table 2 lists the shipping weights for

the M3 series furnaces.

OWNER INFORMATION

NORDYNE has been involved in the design of

products for the manufactured home industry

since the first manufactured home or trailer

was built.

NORDYNE originated the sealed combustion

system, which separates the furnace com-

bustion system from the living area of the

home, now a standard for the manufactured

home industry.

NORDYNE engineers developed the first cen-

tral heating system and the first central air

conditioner for manufactured homes.

NORDYNE is dedicated to bringing to its cus-

tomers the finest heating and cooling comfort

possible. NORDYNE constantly seeks to fur-

ther refine its products to continuously provide

exceptional comfort.

Follow the instructions in this booklet carefully

and this appliance will provide many years of

superior performance.

If you wish to cool your home automatically

with a central air conditioning system investi-

gate the excellent NORDYNE cooling systems

available from your heating and cooling con-

tractor. These systems are designed to work

best with your NORDYNE furnace and have

been carefully engineered to deliver optimum

performance when mated with NORDYNE

manufactured home furnaces.

NORDYNE also offers water heaters, fireplaces

and ventilating systems specifically designed

for manufactured housing applications. Check

with your manufactured home retailer, your

heating and cooling contractor or your

distributor for information. Write directly to the

factory (PO Box 8809, O’Fallon, MO 63366) if

youarenotabletolocateasourceforNORDYNE

manufactured housing products in your area.

MANUFACTURER WARRANTY, OWNER’S

RESPONSIBILITIES

It is the sole responsibility of the homeowner to

makecertainthegasfurnacehasbeencorrectly

setupandconvertedtotheproperfuel(L.P.gas

or Natural gas) and adjusted to operate prop-

erly. All gas furnaces are manufactured for

Natural gas and must be field converted when

using L.P. gas.

Awarrantycertificatewithfulldetailsisincluded

with these instructions. However, NORDYNE

will not be responsible for any costs found nec-

essary to correct problems due to improper

setup,improperinstallation,furnaceadjustments,

improperoperatingprocedureonthepart of the

user, etc.

Some specific examples of service calls which

cannot be included in warranty payments are:

1. Converting the furnace to use another type

of gas.

2. Repairingductworkinthehomefoundtobe

faulty.

3. Correcting wiring problems in the electrical

circuit supplying the furnace.

4. Resetting circuit breakers, blown fuses or

other switches.

5. Correcting problems due to improper gas

supply pressure to the furnace.

6. Providing instructional training on how to

light and operate the furnace.

7. Furnace problems caused by installation of

an air conditioner, heat pump or other air

comfort devices.

8. Revising installation of the furnace flue

assembly.

9. Adjusting or calibrating of thermostat.

10. Any construction debris which falls into

the flue system.

Carefullyreviewtheseresponsibilitieswithyour

manufacturedhousingdealer,servicecompany

or gas supplier so there will be no misunder-

standing at a later time.

!CAUTION:

• Never attempttoalterormodifythis

furnace or any of its components.

• Never attempt to repair damaged or

inoperablecomponents.Suchaction

could cause unsafe operation, ex-

plosion,fireand/orasphyxiation.

• If a malfunction has occurred, or if

you feel that the furnace is not oper-

atingasitshould,contactaqualified

service agency or gas utility for as-

sistance.

INSTALLATION STANDARDS

Installershallbefamiliarwithandcomplywithall

codesandregulationsapplicabletotheinstalla-

tion of these heating appliances and related

equipment.Inlieuoflocalcodes,theinstallation

shall be in accordance with the current provi-

sions of one or more of the following standards.

a. Federal Manufactured Home Constructions

& Safety Standard (H.U.D. Title 24, Part

3280.707[a][2])

b. TheStandardforManufacturedHomeInstal-

lations (Manufactured Home Sites, Commu-

nities, and Set-Ups) ANSI A225.1 and/or

CAN/CSA-2240 MH Series).

c. American National Standard (ANSI-119.2/

NFPA-501C) for all recreational vehicle in-

stallations.

d. American National Standard (ANSI-Z223.1/

NFPA-54)and/orCAN/CGAB149forallgas-

fired furnace models.

e. AmericanNationalStandard(ANSI-C1/NFPA-

70)and/orCSA22.1CanadianElectricCode

Part 1 for all electrical field wiring.

CE générateur d'air chaud doit être installé

conformément aux instructions du fabricant et

aux codes locaux. En l'absence de code local,

respecter la norme ANSI Z223.,1, institulé Na-

tionalFuelGas Codeoules codesd'installation

CAN/GCA-B149.

The National Fuel Gas Code is available by

writing:

American National Standards Institute, Inc.

1430 Broadway

New York, NY 10018

NFPA publications are available by writing:

National Fire Protection Association

Batterymarch Park

Quincy, ME 02269

LOCATION

The furnace must be installed on a level sur-

face, and as close to the center of the air

distribution system as possible. See Figure 1

for overall dimensions to determine the re-

quired clearances in hallways, doorways,

stairs, etc. to allow the furnace to be moved to

the installation point. The furnace must be in-

stalled so that all electrical components are

protected from water.

Minimum clearances to combustible materials

arelistedinTable4. Accessforpositioningand

servicing must be considered when locating

the unit.

This furnace is certified for use on wood

flooring. The furnace must be installed on a

solid surface and must be level front-to-back

and side-to-side. This furnace must not be

installed directly on carpeting, tile, or any com-

Table 4. Minimum Clearances

*Note:For1”clearance,useafullylouvereddoorwithat

least400squareinchesoffreeairflowarea.

CLOSET

LCOVE

LL MODELS Inches Inches

Front 1* 1*

Back 0 0

Sides 0 0

ent 0 0

Top 6 6

Duct (Plenum)

w/ Coil Box 0 0

w/o Coil Box 1/4 1/4

(within 3 feet)

bustible material other than wood flooring. The

furnace may be installed on combustible floor-

ing when installed on a Nordyne duct connec-

tor (see Table 5).

The ductwork within 3 feet of the furnaces

without the A/C coil box must be installed such

that surfaces are at least 1/4" from combustible

materials.

When installed in a residential garage, the fur-

nacemustbe positioned sotheburners and the

source of the ignition are located no less than

18 inches above the floor and protected from

physical damage by vehicles.

CIRCULATING AIR SUPPLY

!WARNING:

Products of combustion must not be

allowedtoenterthereturnairopenings

of the furnace or the circulating air

supply. Failure to prevent products of

combustion from being circulated into

the living space can create potentially

hazardousconditionsincludingcarbon

monoxidepoisoningthatcouldresultin

personal injury or death.

The floor or platform on which the

furnaceismountedmustprovidesound

physical support of the furnace with no

gaps, cracks, or sagging between the

furnace and the floor or platform.

The circulating air ductwork must not

be connected to any other heat

producing device such as a fireplace

insert, stove, etc.

GENERAL

Plenums and air ducts must be installed in

accordance with the Standard for the Installa-

tionofAirConditioningandVentilatingSystems

(NFPA No. 90A) or the Standard for the Instal-

lationofWarmAirHeatingandAirConditioning

Systems (NFPA No. 90B).

Figure 4.

Figure 3.

13 1/4"

10 1/4"

19”

19"

TopView

ofDuct

Connector

SUPPLY AIR DUCT

FLOOR CAVITY

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

RETURNAIRPROVISIONS

U.S.A. home manufacturers shall comply with

all of the following conditions to have accept-

able return air systems for closet installed

forced air heating appliances:

a. Regardless of the location, the return air

opening into the closet shall not be less than

specified in the appliance’s listing.

b. Means shall be provided to prevent inadvert-

ent closure by a flat object placed over the

return air opening when it is located in the

floor of the closet (versus the vertical front

or side wall).

c. Closet installations must use a louvered

door having a minimum free area of 235 sq.

in. when located 6” from furnace. For clear-

ance between 1” and 6” from furnace, re-

quirements are a louvered door with mini-

mum of 235 sq. in. free area, with the open-

ings in closet door directly inline with the

louvered openings in the furnace door. For

1” clearance from furnace, use a fully lou-

vered door with at least 400 sq. in. of free

airflow area.

d. The cross-sectional area of the return duct

system leading into the closet, when located

Figure 2. Non-Platinum

Supply Duct System

A Single trunk duct

BDual trunk duct

w/crossover connector

CTransition duct

w/branches

Table 5. Duct Connectors

Use Duct Connector

If "X" (Floor Cavity) is: Model Part Number:

English Metric

(

)

Finger Tab Screw Down

7/8" 22 901987 904008

2" 51 901988 904009

4 1/4" 108 901989 904010

6 1/4" 150 901990 904011

8 1/4" 210 901991 904012

10 1/4" 260 901992 904013

12 1/4" 311 901993 904014

inthefloororceilingshallnotbelessthan235

square inches.

e. The total free area of openings in the floor or

ceiling registers serving the return air duct

system must be at least 352 sq. in. At least

one register should be located where it is not

likely to be covered by carpeting, boxes and

other objects.

f. Materials located in the return duct system

must have a flame spread classification of

200 or less. This includes a closet door if the

furnace is in a closet.

g. Noncombustible pans having 1" upturned

flanges are located beneath openings in a

floor duct system.

h. Wiring materials located in the return duct

system shall conform to Articles 300-22 of

the National Electrical Code (ANSI C1/

NFPA-70).

Figure 6. Closet or Alcove

10"

23 -1/4"

FLOOR

OPENING

ALT. FUEL

LINE HOLES

SIDE WALL

REAR WALL

FUEL LINE

HOLE

Figure 5.

XSEE

TABLE 5

REDUCER

FELT-SEAL(1)

SPACERS

( )OPENING TO DUCT

(1) WITH PLATE (C) REMOVED

OPENING BECOMES

13-1/4” x 13-1/4”

(2) WITH PLATE (C) REMOVED

OPENING BECOMES

13" X 13". WITH REDUCER

IT IS 13" X 10-1/8".

(1) FINGER TAB DUCT CONNECTOR ONLY

(2) SCREW DOWN DUCT CONNECTOR ONLY

i. Gas piping is not run in or through the return

duct system.

j. Test the negative pressure in the closet with

theair-circulatingfanoperatingathighspeed

and the closet closed. The negative

pressure is to be no more negative than

minus 0.05 inch water column.

k. For floor return systems, the manufactured

home manufacturer shall affix a prominent

marking on or near the appliance where it

can be easily read when the closet door is

open. The marking shall read:

CAUTION:

HAZARD OF ASPHYXIATION: Do not

cover or restrict return air opening.

l. Air conditioning systems may require more

duct register and open louver area to ob-

tain necessary airflow. Use NORDYNE’s

certiduct program to determine proper duct

size for A/C.

DUCTED RETURN AIR

M3furnaces with model numbers ending in AW

or BW are factory configured for the return air

to flow through the front louvered door. The

return air may also be attached to either side or

the top of the furnace cabinet using a field

installedkit. RefertoTable12fortheNORDYNE

ducted return kit P/N number. The location and

size of the side and top return air connections

areshowninFigure1.Thefiltersizefortheside

return air is 20” x 20” x 1”. For top return the

filter size is 24” x 16” x 1”.

M3 furnaces with model numbers ending in

BWT are factory configured for the return air to

enter the top of the furnace.

Figure 7. Cut-Out Locations

2-3/4

1-3/4

17-29/32

21-7/16

1-3/4

3-19/32

14-1/2

2-1/4

23-1/4

12-7/814-3/4

24 21-3/4

15-1/2

ALT FUEL LINE

ENTRY

1-1/4

VENT

FUEL LINE ENTRY

FURNACE

OUTER DOOR

FLOOR CUT-OUT

FOR DUCT CONNECTIONS

FLOOR CUT-OUT

FOR OPTIONAL

COOLING COIL

FOR NON-PLATINUM

SERIES UNITS

FURNACE OUTLINE

REAR WALL OF CLOSET OR ALCOVE

COMBUSTION AIR INTAKE

AIRDISTRIBUTIONSYSTEMS

For proper air distribution, the supply duct

system must be designed so that the static

pressure measured external to the furnace

does not exceed the listed static pressure

rating shown on the furnace rating plate.

Three typical distribution systems are illus-

trated in Figure 2. Location, size, and number

of registers should be selected on the basis of

best air distribution and floor plan of the home.

DUCTCONNECTORSELECTION

PLATINUM SERIES

a. For Platinum ready construction use

the 14” round plenum, p/n: 903896.

NON-PLATINUM SERIES

a. Determine depth of floor cavity from

surface of floor to top of supply air duct

(See Figure 3).

b. Select appropriate model from Table 5

whichmatchesX-dimensionofthefloor

cavity. To maximize air delivery, re-

move reducer “C” (see Figure 5) to

obtain the largest open area that will fit

the duct/floor construction.

DUCTINSTALLATION

Required floor, ceiling, and roof cut-out open-

ings must be carefully located to avoid mis-

alignment of the furnace (see Figures 6 & 7).

Installation procedures are suggested for typi-

cal furnace installations and need not be fol-

lowed in the exact listed sequence.

CUT OUT FLOOR OPENING & FUEL LINE

HOLE

a. Determine center of closet or alcove (Fig-

ures 7 & 8).

b. Locate center of the floor opening, mea-

sured 10" from the rear wall, and mark cut-

out measuring approximately 14-1/2" by 14-

1/2" (± 1”) for model duct connector used

(refer to Figures 4 & 5).

c. Locate center of gas line hole, measured 23-

1/4"fromtherearwalland 6-5/8" to the leftof

center of the floor cut-out (See Figure 6) or

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