Nordyne M4RC Installation Instructions Manual Download

Page: 2 / 48

SAFETY INFORMATION .............................................3

REQUIREMENTS AND CODES ..................................4

GENERAL INSTRUCTIONS ........................................5

Manufacturer

Warranty

............................................5

Combustion Air Quality ............................................5

Installation in a Garage ............................................5

Heating

Load

...........................................................6

Clearances to Combustible Materials ......................6

COMBUSTION AIR REQUIREMENTS ........................6

General

Information

.................................................6

Installation in Confi ned Spaces ...............................7

Air From Inside ....................................................7

Outdoor Air from a Crawl Space or

Vented

Attic

.........................................................7

Outdoor Air Using Vertical Ducts ........................7

Outdoor Air Using Horizontal Ducts ....................7

Air Directly Through an Exterior Wall .................8

Alternate Method of Providing air from

Outside

...............................................................8

Installation in Unconfi ned Spaces ...........................8

VENTING REQUIREMENTS ...................................... 10

Vent Pipe Length and Diameter ............................. 10

Vent Pipe Material ................................................. 11

Vent Pipe Installation ............................................. 11

Outdoor Terminations - Horizontal Venting ............ 11

Outdoor Terminations - Vertical Venting ................. 12

Vent Freezing Protection ....................................... 12

Condensate

Disposal

............................................ 13

Concentric Vent Termination .................................. 13

Existing

Installations

.............................................. 13

CIRCULATING AIR REQUIREMENTS ...................... 14

Plenums and Air Ducts .......................................... 14

Return Air Connections ......................................... 14

Supply Air Connections ......................................... 15

Acoustical

Treatments............................................ 15

FURNACE INSTALLATION ....................................... 15

General

Requirements

.......................................... 15

Requirements and Codes ..................................... 15

Upfl ow Furnace Installation .................................. 16

Downfl ow Furnace Installation .............................. 16

Alternate Attachment Method ........................... 18

Bottom Panel Removal .......................................... 19

Alternate Bottom Panel Removal ...................... 19

Pressure Switch Relocation .................................. 19

Inducer Assembly Rotation ...................................20

Direct Vent (2 - Pipe) Applications ......................... 20

Vent and Inducer Assembly Options ..................... 20

Accessories

..........................................................21

Finish

Flange

....................................................21

Rubber

Grommets

............................................21

Inline Drain Assembly .......................................21

PVC TEE, Reducer, and Hose Barbs ...............21

Condensate Drain Lines ...................................22

Filter Retainer Brackets ....................................22

Ventilaire™

Bracket...........................................22

Vent

Couplings

..................................................23

Upfl

Furnaces

...........................................23

Downfl

Furnaces

.......................................23

Alternate Vent Pipe Installation .............................23

GAS SUPPLY AND PIPING .......................................24

Leak Check ..........................................................24

High-Altitude

Application

.......................................24

Conversion to LP/Propane ....................................25

ELECTRICAL WIRING ...............................................29

Low

Voltage

Wiring

................................................29

Line

Voltage

Wiring................................................29

Grounding

.............................................................29

Twinning

................................................................30

START-UP & ADJUSTMENTS ...................................31

Pre-Start

Checklist

................................................31

Start-Up

Procedures

.............................................31

Verifying and Adjusting Input Rate ........................31

Verifying and Adjusting Temperature Rise ............31

Verifying Burner Operation ....................................31

Verifying Operation of the supply Air

Limit

Switch

...........................................................32

OPERATING SEQUENCE .........................................32

Heating

Cycle

........................................................32

Cooling

Cycle

........................................................32

Fan

Mode

..............................................................32

MAINTENANCE .........................................................32

Air Filters ...............................................................33

Blower

Compartment

............................................33

Cleaning of Burners ..............................................33

Heat Exchanger and Burner Maintenance ............33

Lubrication ............................................................33

Vent

System

..........................................................33

DESCRIPTION OF COMPONENTS ..........................34

TROUBLESHOOTING ...............................................34

TABLE OF CONTENTS

Summary of Contents for M4RC

Page 1: ...tarting the installation Return these instructions to the customer s package for future reference GAS FURNACES Installation Instructions 92 1 AFUE PROPOSITION 65 WARNING This product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm WARNING DO NOT DESTROY KEEP IN A SAFE PLACE FOR FUTURE REFERENCE FIRE OR EXPLOSION HAZARD Failure to follow ...

Page 2: ...w Furnace Installation 16 Downflow Furnace Installation 16 Alternate Attachment Method 18 Bottom Panel Removal 19 Alternate Bottom Panel Removal 19 Pressure Switch Relocation 19 Inducer Assembly Rotation 20 Direct Vent 2 Pipe Applications 20 Vent and Inducer Assembly Options 20 Accessories 21 Finish Flange 21 Rubber Grommets 21 Inline Drain Assembly 21 PVC TEE Reducer and Hose Barbs 21 Condensate ...

Page 3: ...rnace Failuretofollowsafety 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 Install this furnace in accordance to the minimum clearances to combustible materials listed in Table 1 page 9 Provide adequate combustion and ventilation air to the furnace space as speci...

Page 4: ... of eight feet away and read Gas Vent Directly Below 2 For direct vent appliances mechanical vent heating appliances or domestic hot water equipment where the bottom of the vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied a A CO detector and alarm shall be placed on each floor level where there are bedrooms The detector shall co...

Page 5: ...source of combustion air is to use outdoor air However the use of indoor air in most applications is acceptable except as listed If the furnace is a single pipe installation and installed in a confined space it is required that the necessary combustion air come from the outdoors by way of attic crawl space air duct or direct opening See pages 6 9 for combustion air requirements Installations in th...

Page 6: ... area with volume less than 50 cubic feet per 1 000 Btuh of the combined input rates of all appliances drawing combustion air from that space COMBUSTION AIR REQUIREMENTS General Information Provisions must be made during the installation of this furnace that provide an adequate supply of air for combustion NORDYNE condensing furnaces must be installed with outdoor combustion air piped directly to ...

Page 7: ...l equipment in the enclosure Alternate Air Inlet Outlet Air Outdoor Air Using Vertical Ducts If combustion air is taken from outdoors through vertical ducts the openings and ducts must have a minimum free area of one square inch per 4 000 Btuh of total appliance input Attics or crawl spaces must connect freely with the outdoors if they are the source of air for combustion and ventilation See Figur...

Page 8: ...wl or attic space that connects with the out of doors 2 The opening must have a minimum free area of 1 sq in per 3 000 Btu per hour of the total input rating of all equipment located in the enclosure 3 The free area must not be less than the sum of all the areas of the vent connectors in the enclosure Installation in Unconfined Spaces An unconfined space is an area including all rooms not separate...

Page 9: ... operate a summer exhaust fan 6 Follow the lighting instructions Place the appliance being inspected into operation Adjust the thermostat so appliance is operating continuously 7 Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle 8 If improper venting is observed during any of the above ...

Page 10: ... their venting and can allow combustion gases to escape through such appliances or vents Do not vent the furnace to a fireplace chimney or building chase Upon completion of the furnace installation carefully inspect the entire flue system both inside and outside the furnace to assure it is properly sealed Leaks in the flue system can result in serious personal injury or death due to exposure of fl...

Page 11: ...at there are no sagging sections that can trap condensate Outdoor Terminations Horizontal Venting Vent and combustion air intake terminations shall be installed as depicted in Figures 6 7 page 12 and in accordance with these instructions Vent termination clearances must be consistent with the NFGC ANSI 2223 1 NFPA 54 and or the CSA B149 1 Natural Gas and Propane Installation Code All minimum clear...

Page 12: ...ing may be installed in an existing chimney which is not in use provided that Both the exhaust vent and air intake run the length of the chimney The top of the chimney is sealed and weatherproofed The termination clearances shown in Figure 9 are maintained No other gas fired or fuel burning equipment is vented through the chimney Vent Freezing Protection When the vent pipe is exposed to temperatur...

Page 13: ...tion Existing Installations When an existing furnace is removed from a vent system serving other appliances the existing vent system may not be sized properly to vent the remaining appliances Example water heater An improperly sized venting systemcanresultintheformationofcondensate leakage or spillage The existing vent system should be checked to make sure it is in compliance with NFGC ANSI Z223 1...

Page 14: ...n air applications When a cooling system is installed which uses the furnace blower to provide airflow over the indoor coil the coil must be installed downstream on the outlet side of the furnace or in parallel with the furnace If a cooling system is installed in parallel with the furnace a damper must be installed to prevent chilled air from entering the furnace and condensing on the heat exchang...

Page 15: ...hlocalcodes for special requirements For best sound performance install all the needed gaskets and grommets around penetrations into the furnace such as for electrical wiring FURNACE INSTALLATION RC series gas furnaces are shipped ready for installation in the upflow position with upflow return air RL series gas furnaces may only be used for downflow operation See Table 1 page 9 for the required c...

Page 16: ...re in place using the provided attachment brackets To install the brackets position one bracket on side of furnace and using the provided self drilling screws secure the bracket to the A C coil box and the furnace Repeat for other side of furnace 5 Position the plenum on top of the coil box and secure together with sheet metal screws The screws must penetrate the sheet metal casing and coil box fl...

Page 17: ...k the cut out area on the supply air duct by tracing around the connector tabs Figure 11 page 16 of the duct connector c Remove the duct connector and cut out the marked area of the supply air duct 1 4 larger the actual cutout drawn d Install the duct connector back in the floor opening with the bottom tabs extending into the supply air duct e Installthemountingplate Figure14 undertheback side of ...

Page 18: ...tthetopofthesupplyairductasindicated in Option 1 or Option 2 Figure 20 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 suppl...

Page 19: ...lide bottom panel 6 out through front of furnace 7 Reinstall the blower assembly 4 in reverse order 6 7 5 1 2 3 4 Figure 22 Bottom Panel Removal Pressure Switch Relocation In some inducer orientations the inducer pressure switch may interfere with gas pipe installation Check the side of the cabinet the gas pipe will enter and determine if the inducer pressure switch needs to be moved If the switch...

Page 20: ... HIGH EAC L1 XFMR HUM 24V L1A NEUTRALS 2 7 8 9 2 FAN 5 2 1 3 6 4 Direct Vent 2 Pipe Applications It is important that Direct Vent 2 pipe systems maintain an airtight flow path from the air inlet to the flue gas outlet The furnace ships from the factory with two holes in the cabinet for the air inlet and flue gas outlet In certain configurations it is necessary to remove and relocate a plastic cap ...

Page 21: ...ecommended you dry fit them first to ensure proper fit and alignment with other vent pipes 1 Install the 1 2 x 1 2 hose barb on the 2 PVC reducer with an adequate amount of approved sealant on the threads Do not over tighten the hose barb 2 Install the tee on the 2 vent pipe that is extending out the side of the cabinet Use appropriate primer and cement to permanently bond the tee to the 2 PVC pip...

Page 22: ...ake care that this drain tube does not sag in the middle Sometimes the lowest point in the vent system is where it connects to the inducer Options 3 6 9 12 If the distance between the exhaust pipe and the cabinet is 6 inches or less one drain at this location is sufficient If the distance is more than 6 inches then another drain will need to be added to the bottom of the tee IMPORTANT NOTE If the ...

Page 23: ... box Upflow Furnaces Combustion air and exhaust vent piping must have removable connections between the furnace flanges and vent pipes when installed vertically in front of the coil box NOTE Both vent pipes must be long enough to clear the height of the coil box when installed This allows for future servicing or maintenance of the coil Position the 2 x 3 neoprene coupling between the top of the 2 ...

Page 24: ...nnected to the furnace This includes connections at the main gas valve emergency shutoff valve and flexible gas connectors if applicable The soap and water solution can be applied on each joint or union using a small paintbrush If any bubbling is observed the connection is not sealed adequately and must be retightened Repeatthetighteningandsoapcheckprocess until bubbling ceases IMPORTANTNOTE Whenp...

Page 25: ...o use the properconversionkitcancausefire explosion propertydamage carbonmonoxidepoisoning personal injury or death This furnace can be converted from factory equipped natural gas to Liquid Propane gas Conversion of this valve requires replacement of the burner orifices on the manifold assembly The orifices required for conversion are supplied with the furnace For altitudes between 0 and 1 999 fee...

Page 26: ...assembly 6 Make sure the center of the orifices are aligned with center of the burners q Secure the manifold assembly 5 to the burner assembly 6 with the four screws 4 removed in step 1 h r Reconnect the gas piping to the gas valve inlet 3 ON OFF IN N A T N A T L P L P Other side of cap Pressure Regulator Cap Manifold Pressure Plug Inlet Pressure Plug ON OFF Knob OR Figure 35 Gas Valve Top View s ...

Page 27: ...ially available soap solution A fire or explosion may result causing property damage personal injury or loss of life Failure to follow the safety warnings exactly could result in serious injury death or property damage a Turn the main gas supply valve on the outside of the furnace to the ON position b Check all gas connections for leaks with a soap and water solution If the solution bubbles there ...

Page 28: ... utilities require Shut Off Valve to be 4 to 5 feet above floor B Inducer assembly omitted for clarity of pipe installation Figure 36 Typical Gas Connections 4 7 5 3 6 UPFLOW MODELS DOWNFLOW MODELS 9 2 See Note B 1 3 See Note B Right Side Entry Left Side Entry Right Side Entry Left Side Entry See Note B See Note B 7 2 9 4 6 1 5 8 4 9 9 4 See Note A See Note A 6 6 5 1 2 3 7 5 3 7 1 2 See Note A See...

Page 29: ... proper cooling mode operation Connect R W For Heating Only 2 ELECTRONIC AIR CLEANER MOTOR SPEED TAPS NOT USED HUMIDIFIER TAP NEUTRAL LEADS 6 3 4 1 7 8 9 5 2 6 3 4 1 FAN IMPORTANTNOTE Settheheatanticipatoraccording to the instructions supplied by the thermostat manufacturer To determine the heat anticipator setting 1 Add the current draw of the system components or 2 Measurethecurrentflowonthether...

Page 30: ...ite Field Line Voltage Wiring Factory Line Voltage Wiring Ground Ground Junction Box may be int or ext to the furnace These connections can be made in the field supplied disconnect at the furnace Ground Furnace Model Number RC RL Furnace Input Btuh Cabinet Width in Nominal Electrical Supply Maximum Operating Voltage Minimum Operating Voltage Maximum Furnace Amperes Minimum Wire Gauge Maximum Fuse ...

Page 31: ...tment door 2 Setthethermostat5degreesaboveroomtemperature and observe the ignition sequence START UP AND ADJUSTMENTS Pre Start Check List Verify the polarity of the connections are correct the line voltage power leads are securely connected and the furnace is properly grounded Verify the thermostat wires R W Y and G are securely connected to the correct leads on the terminal strip of the circuit b...

Page 32: ...goff curling orfloating The flames should be blue without yellow tips 3 After validating the flame change thermostat setting to below room temperature 4 Verify the burner flame is completely extinguished 5 Replace the burner compartment door Verifying Operation of the Supply Air Limit Switch A properly functioning limit switch should turn off the gas valve when the return is blocked time depends o...

Page 33: ... potentially hazardous conditions including carbon monoxide poisoning that could result in personal injury or death Air Filter s WARNING Never operate the furnace without a filter in place Dust and lint can build up on internal components resulting in loss of efficiency equipment damage and possible fire NOTE An air filter is supplied with the furnace as shipped from the factory It is recommended ...

Page 34: ...ressure Switch Open Fault Flash On Open Limit Switch Fault Flash Off Motor Fault On Off Diagnostic Description Yellow LED Low Flame Sensor Signal Continuous Flash Flame Present On Table 7 Control Board Fault Codes DESCRIPTION OF COMPONENTS Thedescriptionsbelowarevariousfunctionalcomponents that affect the operation and shutting down of this furnace Some of these components and their locations are ...

Page 35: ... des foyers 5 Mettre en service les sécheuses et tout autre appareil qui n est pas raccordé à la systéme d évacuation Faire fonctionner à régime maximal tout ventilateur d évacuation tel que les hottes de cuisinière et les ventilateurs de salles de bains Ne pas mettre en service les ventilateurs d été 6 Respecter les instructions d allumage Mettre en service l appareil à l essai Régler le thermost...

Page 36: ...allateur qualifié un organisme de service ou le fournisseur de gazstaller service agency or the gas supplier 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 téléphon...

Page 37: ...om Return Opening Bottom Return Opening RC Upflow Furnace RC Model s Dim A Dim B Dim C 054D 24B 17 15 16 072D 35C 21 19 19 090D 35C 108D 45D 24 22 23 NOTES Dimensions shown in inches A 34 28 10 22 22 2 22 Ø HOLE FOR ELECTRIC 22 25 17 7 16 29 17 22 25 Ø 1 HOLE FOR GAS Ø HOLE FOR THERMOSTAT LEFT SIDE RIGHT SIDE Ø HOLE FOR ELECTRIC CONDENSATE CONDENSATE 25 22 1 X 3 HOLE FOR GAS Ø 3 HOLE FOR VENT PIPE...

Page 38: ... 47 Med Low 1705 45 1675 46 1640 47 1590 48 1555 49 1495 51 1435 53 1340 57 Low 1410 54 1390 55 1365 56 1330 58 1310 59 1275 60 1235 62 1210 63 RC090D 35C Side Return 90 000 High 2240 34 2175 35 2100 37 2040 38 1985 39 1910 40 1825 42 1725 44 Med High 2095 37 2040 38 2000 38 1935 40 1875 41 1825 42 1765 43 1680 46 Med Low 1775 43 1740 44 1705 45 1655 46 1615 47 1555 49 1490 51 1335 57 Low 1465 52 ...

Page 39: ...ion Yellow LED Continuous Flash On Alternating Flash IGNITOR INDUCER FLAME SENSOR C BLOWER LIMIT SWITCH DOOR SWITCH R 4 SPEED MOTOR WHITE RED BLUE ORANGE BLACK BLOWER LIMIT SWITCH GAS VALVE H MH ML L C FLAME ROLLOUT SUPPLY AIR LIMIT PRESSURE SWITCH R C Y G W LOW ML MH HIGH EAC L1 XFMR HUM 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 COM GREEN YELLOW RED 3 AMP FUSE 24V 1 2 3 4 24 V 120 V WHITE BLACK WHITE W BLK S...

Page 40: ... 375 750 104 35 173 346 50 72 360 720 106 34 170 340 52 69 346 692 108 33 167 333 54 67 333 667 110 33 164 327 56 64 321 643 112 32 161 321 58 62 310 621 114 32 158 316 60 60 300 600 116 31 155 310 62 58 290 581 118 31 153 305 64 56 281 563 120 30 150 300 CAPACITY OF BLACK IRON GAS PIPE CU FT PER HOUR FOR NATURAL GAS SPECIFIC GRAVITY 0 60 NOMINAL BLACK IRON PIPE DIAMETER IN LENGTH OF PIPE RUN FT 1...

Page 41: ...HIGH HIGH 10 000 FT LOW LOW HIGH HIGH HIGH HIGH HIGH HIGH HIGH Table 12 Natural Gas Heating Values Table 11 High Altitude Deration Chart for Propane Gas PROPANE GAS ALTITUDE ABOVE SEA LEVEL INPUT BTU 54 000 72 000 90 000 108 000 0 to 1 999 FT 56 56 56 56 ORIFICE SIZE 10 0 10 0 10 0 10 0 MANIFOLD PRESSURE 2 000 to 2 999 FT 56 56 56 56 ORIFICE SIZE 9 0 9 0 9 0 9 0 MANIFOLD PRESSURE 3 000 to 4 999 FT...

Page 42: ... 3 0 3 0 MANIFOLD PRESSURE 9 000 to 9 999 FT 49 49 49 49 ORIFICE SIZE 2 8 2 8 2 8 2 8 MANIFOLD PRESSURE NATURAL GAS LOW HEATING VALUE ALTITUDE ABOVE SEA LEVEL INPUT BTU 54 000 72 000 90 000 108 000 0 to 1 999 FT 47 47 47 47 ORIFICE SIZE 3 5 3 5 3 5 3 5 MANIFOLD PRESSURE 2 000 to 2 999 FT 47 47 47 47 ORIFICE SIZE 3 5 3 5 3 5 3 5 MANIFOLD PRESSURE 3 000 to 3 999 FT 47 47 47 47 ORIFICE SIZE 3 3 3 3 3...

Page 43: ...pply inlet to building or the combustion air inlet to any other appliance 6 inches 15cm for appliances 10 000 Btuh 3kW 6 inches 15cm for appliances 10 000 Btuh 3kW 4 ft 1 2m below or to side of opening 1 ft 300mm above opening 12 inches 30cm for appliances 10 000 Btuh 100 000 Btuh 30kW 9 inches 23cm for appliances 10 000 Btuh 50 000 Btuh 30kW 36 inches 91cm for appliances 100 000 Btuh 30Kw 12 inch...

Page 44: ...se to Furnace as Possible 2 x 3 Neoprene Couplings with 2 Hose Clamps Upward Pitch 1 4 Per Foot Exhaust Vent 5 3 Combustion Air Vent Pipe 7 3 x 90 Elbows 3 x 90 Elbow Exhaust Vent 3 Exhaust Vent Straps or Other Suitable Supports at minimum 5 ft Intervals 3 Combustion Air Vent Pipe 3 Exhaust Vent 3 x 90 Elbows Upward Pitch 1 4 Per Foot Exhaust Vent First Support as Close to Furnace as Possible See ...

Page 45: ...lug X See View C Header Box Drain Inline Drain This drain not needed if X is less than 6 Header Box Drain 1 All drain lines must be trapped with J Trap or field supplied loop 2 Drain line traps may be positioned inside or outside the cabinet 3 PVC Cap is required for options 5 and 6 NOTES Exhaust Vent Exhaust Vent Exhaust Vent Exhaust Vent Inlet Air Exhaust Vent Inlet Air Inlet Air Tubing is route...

Page 46: ... Plug See View F See View E See View F See View E Plug Plug See View D See View D See View L See View M See View M See View L 1 All drain lines must be trapped with J Trap or field supplied loop 2 Drain line traps may be positioned inside or outside the cabinet NOTES Exhaust Vent Exhaust Vent Exhaust Vent Exhaust Vent Exhaust Vent Exhaust Vent Inlet Air Inlet Air Inlet Air PVC TEE Reducer and 1 2 ...

Page 47: ...h 13 Pressure Switch s B C D cabinets only 14 Roll Out Switch s 15 Transformer 9 4 10 12 15 14 2 6 3 7 8 1 11 13 5 Figure 46 Downflow Gas Furnace Components 9 1 2 12 13 12 3 14 6 7 8 11 10 15 4 5 ITEM COMPONENT NAME 1 Blower Assembly 2 Blower Door Switch behind blower panel 3 Burner Assembly 4 Control Board 5 Finish Flange 6 Flame Sensor 7 Gas Manifold 8 Gas Valve 9 Igniter 10 Inducer Assembly 11 ...

Page 48: ...ion and ventilation YES NO Installation Altitude ____________________ FT Deration Percentage ___________________ Furnace Input _______________________ Btuh Supply Air Temperature ________________ F Return Air Temperature ________________ F Temperature Rise ____________________ F VENTING SYSTEM Vent free from restrictions YES NO Filter s secured in place YES NO Filter s clean YES NO Flue connection...

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