Nordyne M4RC Upflow Installation Instructions Manual
92.1% afue single stage condensing gas furnaces
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GAS FURNACES
Installation Instructions
Single Stage Condensing Gas Furnaces
M4RC Upfl ow Furnace
WARNING:
PROPOSITION 65 WARNING: This product
contains chemicals known to the state of
California to cause cancer, birth defects or
other reproductive harm.
ATTENTION INSTALLERS:
It is 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 of the furnace or failure to
follow safety warnings could result in serious injury, death,
or property damage.
These instructions are primarily intended to assist qualifi ed
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
M4RL Downfl ow Furnace
WARNING:
FIRE OR EXPLOSION HAZARD
• Failure to follow safety warnings exactly
could result in serious injury or property
damage.
• Installation and service must be performed
by a qualifi ed installer, service agency or
the gas supplier.
• Do not store or use gasoline or other
fl ammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbors phone. Follow the gas suppliers
instructions.
• If you cannot reach your gas supplier, call
the fi re department.
DO NOT DESTROY.
KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
92.1% AFUE
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Table of Contents
Related Manuals for Nordyne M4RC Upflow
Summary of Contents for Nordyne M4RC Upflow
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Page 1: Installation Instructions
GAS FURNACES 92.1% AFUE Installation Instructions Single Stage Condensing Gas Furnaces M4RL Downfl ow Furnace M4RC Upfl ow Furnace WARNING: WARNING: PROPOSITION 65 WARNING: This product FIRE OR EXPLOSION HAZARD contains chemicals known to the state of • Failure to follow safety warnings exactly California to cause cancer, birth defects or could result in serious injury or property other reproductive harm. -
Page 2: Table Of Contents
TABLE OF CONTENTS Direct Vent (2 - Pipe) Applications ......20 SAFETY INFORMATION ..........3 Vent and Inducer Assembly Options ..... 20 REQUIREMENTS AND CODES ........4 Accessories ............21 GENERAL INSTRUCTIONS ........5 Finish Flange ............21 Manufacturer Warranty ..........5 Rubber Grommets ..........21 Combustion Air Quality ..........5 Inline Drain Assembly ........21 Installation in a Garage ..........5 PVC TEE, Reducer, and Hose Barbs ....21... -
Page 3: Safety Information
FRENCH TRANSLATIONS ........35 SAFETY INFORMATION Safety markings are used frequently throughout this FIGURES AND TABLES ..........37 manual to designate a degree or level of seriousness and Figure 40 - Furnace Dimensions .......37 should not be ignored. WARNING indicates a potentially Table 8 - Blower Performance Chart ....38 hazardous situation that if not avoided, could result in personal injury or death. -
Page 4: Requirements And Codes
REQUIREMENTS and CODES a.) A (CO) detector and alarm shall be placed on each fl oor level where there are bedrooms. The This furnace must be installed in accordance with detector shall comply with NFPA 720 (2005 Edition) these instructions, all applicable local building codes and be mounted in the living area outside the and the current revision of the National Fuel Gas Code bedroom(s). -
Page 5: General Instructions
Commercial buildings A warranty certifi cate with full details is included with this Buildings with indoor pools furnace. However, NORDYNE will not be responsible for any Furnaces installed in laundry rooms costs found necessary to correct problems due to improper... -
Page 6: Heating Load
Provisions must be made during the installation of this furnace that provide an adequate supply of air for Exhaust fans, clothes dryers, fi replaces and combustion. NORDYNE condensing furnaces must be other appliances that force air from the house installed with outdoor combustion air piped directly to to the outdoors can create a negative pressure the furnace. -
Page 7: Installation In Confi Ned Spaces
Furnace closets, small equipment rooms and garages are confi ned spaces. Furnaces installed in a confi ned space Vent or Chimney which supply heated air to areas outside the space must Ventilation Louvers draw return air from outside the space and must have the (each end of attic) return air ducts tightly sealed to the furnace. -
Page 8: Air Directly Through An Exterior Wall
Alternate Method of Providing Air from Outside: If acceptable under local Codes, it is permitted to provide outside air using one opening (See NFGC). Vent or Chimney Generally, confi ned spaces must have two openings in the space for combustion air. One opening must be within Air Duct 12 inches of the ceiling, and the other must be within Water... - Page 9 INSTALLATION CLEARANCES to COMBUSTIBLE MATERIALS For UPFLOW, HORIZONTAL & DOWNFLOW FURNACES Left Side ........0 Inches Vent ..........1 Inch Top ...........1 Inches † Right Side ........0 Inches Back .........0 Inches Front........4 Inches DOWNFLOW APPLICATION UPFLOW APPLICATION BOTTOM BOTTOM † Allow 30 in.
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Page 10: Venting Requirements
VENTING REQUIREMENTS can cause severe corrosion of ordinary venting materials. Furnace operation can be adversely affected by restrictive WARNING: vent and combustion air piping. Vent Pipe Length and Diameter This furnace must not be vented with other In order for the furnace to operate properly, the combustion appliances, even if that appliance is of the air and vent piping must not be excessively restrictive. -
Page 11: Vent Pipe Material
Condensing furnace combustion products have very little Outdoor Terminations - Horizontal Venting buoyancy, so Table 2 is to be used without consideration Vent and combustion air intake terminations shall be of any vertical rise in the piping. installed as depicted in Figures 6 - 7 (page 12) and in accordance with these instructions: Vent Pipe Material •... -
Page 12: Outdoor Terminations - Vertical Venting
• For optimal performance, vent the furnace through a wall Mounting Kit that experiences the least exposure to winter winds. Faceplate Secured to Wall with Screws • Termination kits consist of two face plates and an Typical Both Pipes insulating gasket to seal the exterior surface. Combustion •... -
Page 13: Condensate Disposal
Proper drains and connections to the be longer than 18 inches. Smaller vent pipes are less condensate tubing are required as NORDYNE cannot be susceptible to freezing, but must not be excessively held responsible for water leakage which occurs due to restrictive. -
Page 14: Circulating Air Requirements
CIRCULATING AIR REQUIREMENTS to the furnace is equal to the return air supply under normal, indoor return air applications. WARNING: • When a cooling system is installed which uses the furnace blower to provide airfl ow over the indoor coil, the coil must be installed downstream (on the outlet Do not allow combustion products to enter the side) of the furnace or in parallel with the furnace. -
Page 15: Supply Air Connections
• Upfl ow and downfl ow models must be installed with A Single trunk duct 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. -
Page 16: Upfl Ow Furnace Installation
• American National Standard (ANSI-Z223.1/NFPA-54) WARNING: and/or CAN/CGA B149 for all gas-fi red furnace models. • American National Standard (ANSI-C1/NFPA-70) and/ The furnace must not be installed directly on or CSA 22.1 Canadian Electric Code Part 1 for all carpeting, tile, or any combustible material other electrical fi... - Page 17 IMPORTANT NOTE: Cut-outs in the fl oor, ceiling, roof, walls and/or ductwork must be carefully located to REAR WALL OF CLOSET OR ALCOVE avoid misalignment of the furnace, combustion air piping, and vent piping. Floor Cut-Out for 10” 1. Determine the depth of the fl oor cavity: Duct Connector a.
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Page 18: Alternate Attachment Method
3. Prepare the A/C coil box for installation: a. Remove two screws (Figure 17) from the sides of the A/C coil box. b. Install the close-off plate on the bottom of the of the coil box. c. Align the screw holes in the close off plate and the coil box. -
Page 19: Bottom Panel Removal
5. Remove the screw (7) securing the bottom corner of the Staples or sheet metal screws Duct connector tabs furnace cabinet to the front brace (3). 6. Carefully spread the bottom corner of the furnace cabinet outwards while sliding the bottom panel (2) out through the front of the furnace. -
Page 20: Inducer Assembly Rotation
Inducer Assembly Rotation Direct Vent (2-Pipe) Applications It is important that Direct Vent (2-pipe) systems maintain WARNING: an airtight fl ow path from the air inlet to the fl ue gas outlet. The furnace ships from the factory with two holes in the Inducer rotation must be completed before cabinet for the air inlet and fl... -
Page 21: Finish Flange
Finish Flange (Figure 26) ø 2 1/4” Rubber The fi nish fl ange must be installed to vent the combustion Grommet air pipe through the top of the furnace. NOTE: For proper installation, it is important that the pipe and screw holes in the fi... -
Page 22: Condensate Drain Lines
Condensate Drain Lines (Figs. 42 - 43, pages 45 - 46) The placement of the condensate drain lines will depend on the confi guration selected in Table 5 (page 20). The drain lines can be routed out the left or right side of the furnace, but must maintain a downward slope to ensure Exhaust Air proper condensate drainage. -
Page 23: Vent Couplings
(914098) or VentilAire™ IV (914229) fresh air supply Downfl ow Furnaces system. Alternate means for providing ventilation air Since there is no coil box above the furnace, both 3” vent must meet the requirements of all applicable local and pipes can be run vertically for the entire length of the federal codes. -
Page 24: Gas Supply And Piping
GAS SUPPLY AND PIPING All gas pipe connections must be tested for gas leaks after they’ve been connected to the furnace. This includes WARNING: connections at the main gas valve, emergency shutoff valve and fl exible gas connectors (if applicable). The soap All gas piping must conform with local building and water solution can be applied on each joint or union codes, or in the absence of local codes, with... -
Page 25: Conversion To Lp/Propane
pressure and orifi ce sizes to use at various altitudes. Table See Table 11 (page 41) to determine the correct orifi ce 13 (HIGH) is for natural gas installations with a heating size and manifold pressure to use at different altitudes. value of more than 1,000 Btu per cubic foot and Table WARNING: 14 (LOW) is for less than 1,000 Btu per cubic foot. - Page 26 h. Remove four screws (4) securing the gas manifold s. Reconnect the wires to the gas valve terminals (2). assembly (5) to the burner assembly (6). 2. Measure the Supply Gas Pressure: i. Set aside the screws (4) and remove the gas manifold IMPORTANT NOTE: To obtain an accurate pressure assembly (5) from the burner assembly.
- Page 27 3. Measure / Adjust the Manifold Pressure: b. Check all gas connections for leaks with a soap and water solution. If the solution bubbles there is a gas The manifold pressure must be measured by installing a leak which must be corrected. pressure gauge (Manometer, Magnehelic Meter, etc.) to the outlet end of the gas valve.
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Page 28: Burner Assembly
UPFLOW MODELS Note “A” Note “A” Note “B” Note “B” Left Side Entry Right Side Entry DOWNFLOW MODELS Note “A” Note “A” Note “B” Note “B” Left Side Entry Right Side Entry ITEM # COMPONENT ITEM # COMPONENT ITEM # COMPONENT 8”... -
Page 29: Electrical Wiring
ELECTRICAL WIRING IMPORTANT NOTE: Set the heat anticipator according to the instructions supplied by the thermostat WARNING: manufacturer. To determine the heat anticipator setting: To avoid electric shock, personal injury, or death, turn off the electric power at the disconnect 1. -
Page 30: Twinning
Furnace Furnace Cabinet Nominal Maximum Minimum Maximum Minimum Maximum Model Number Input Width Electrical Operating Operating Furnace Wire Fuse or Circuit *RC/*RL (Btuh) (in.) Supply Voltage Voltage Amperes Gauge Breaker Amps** ½ 054D-24B 54,000 115-60-1 10.0 072D-35C 72,000 115-60-1 090D-35C 90,000 115-60-1 15.6... -
Page 31: Start-Up & Adjustments
START-UP AND ADJUSTMENTS 5. Multiply the gas fl ow rate in cubic ft per hr by the heating value of the gas in Btu per cubic ft to obtain Pre-Start Check List the input rate in Btuh. See example. Verify the polarity of the connections are correct, the 6. -
Page 32: Verifying Operation Of The Supply Air Limit Switch
NOTE: The fl ame should carry over immediately 10. Blower off timing begins when the thermostat is between all burners without lifting off, curling, or fl oating. satisfi ed. The control will operate at the selected HEAT The fl ames should be blue, without yellow tips. speed of 60, 90, 120, or 180 seconds. -
Page 33: Air Filters
Air Filter(s) 3. Remove the burner door from the furnace. 4. Turn the gas control switch to the OFF position. WARNING: 5. Disconnect the wires from the gas valve, igniter, fl ame sensor, and fl ame rollout switch. Never operate the furnace without a fi lter in 6. -
Page 34: Description Of Components
DESCRIPTION OF COMPONENTS TROUBLESHOOTING The descriptions below are various functional components If the furnace fails to operate check the following: that affect the operation and shutting down of this furnace. • Is the thermostat operating properly? Some of these components and their locations are shown •... -
Page 35: French Translations
FRENCH TRANSLATIONS The following are French translations of important warning statements found within this manual. AVERTISSEMENT: RISQUE D’EMPOISONNEMENT AU MONOXYDE DE CARBONED Le non-respect des consignes suivantes portant sur chacun des appareils raccordés au système d’évacuation mis en service pourrait entraîner l’empoisennement au monoxyde de carbone ou la mort. - Page 36 AVERTISSEMENT: AVERTISSEMENT: RISQUE D’INCENDIE OU D’ EXPLOSION RISQUE DE CHOC ÉLECTRIQUE, D’INCENDIE • Le non-respect avertissements OU D’EXPLOSION sécurité pourrait entraîner des blessures Le non-respect des avertissements de sécurité graves, la mort ou des dommages matériels. pourrait entraîner un fonctionnement dangereux •...
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Page 37: Figures And Tables
FIGURES AND TABLES *RC Upfl ow Furnace Bottom Dim. Dim. Dim. Return TOP VIEW Opening Model #’s “A” “B” “C” 054D-24B ⅞ ⅛ ½ FRONT BRACE 072D-35C ⅜ ⅝ 090D-35C FLANGES ½ ½ ⅞ ⅛ 108D-45D BOTTOM Bottom PANEL Return NOTES: 3”... -
Page 38: Airflow Data
AIRFLOW DATA External Static Pressure (Inches Water Column) Heating Model Motor Input Number Speed (Btuh) Rise Rise Rise Rise Rise Rise Rise Rise High* 1550 1520 1485 1450 1410 1360 1300 1255 Med-High 1250 1220 1200 1170 1140 1105 1065 1010 54,000 Med-Low**... -
Page 39: Electrical Information
ELECTRICAL INFORMATION 15-BL-60 (21) HIGH XFMR R C Y G W Figure 41. Wiring Diagram for Upfl ow and Downfl ow Models... -
Page 40: Gas Information
GAS INFORMATION GAS FLOW RATES (CUBIC FEET PER HOUR) TIME FOR CUBIC FEET PER REVOLUTION TIME FOR CUBIC FEET PER REVOLUTION ONE REVOLUTION OF GAS METER ONE REVOLUTION OF GAS METER (SECONDS) (SECONDS) 1,800 3,600 1,500 3,000 12,86 2,571 1,125 2,250 1,000 2,000... -
Page 41: Propane Gas
PROPANE GAS INPUT (BTU) ALTITUDE ABOVE SEA LEVEL 54,000 72,000 90,000 108,000 ORIFICE SIZE 0 to 1,999 FT 10.0 10.0 10.0 10.0 MANIFOLD PRESSURE ORIFICE SIZE 2,000 to 2,999 FT MANIFOLD PRESSURE ORIFICE SIZE 3,000 to 4,999 FT MANIFOLD PRESSURE ORIFICE SIZE 5,000 to 5,999 FT 10.0... - Page 42 NATURAL GAS - HIGH HEATING VALUE INPUT (BTU) ALTITUDE ABOVE SEA LEVEL 54,000 72,000 90,000 108,000 ORIFICE SIZE 0 to 1,999 FT MANIFOLD PRESSURE ORIFICE SIZE 2,000 to 2,999 FT MANIFOLD PRESSURE ORIFICE SIZE 3,000 to 3,999 FT MANIFOLD PRESSURE ORIFICE SIZE 4,000 to 4,999 FT MANIFOLD PRESSURE...
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Page 43: Venting Information
VENTING INFORMATION VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED CANADIAN INSTALLATIONS US INSTALLATIONS Direct Vent (2-pipe) & Clearance Location Direct Vent Conventional Vent Conventional Vent (1-pipe) (2-pipe) Furnaces (1-pipe) Furnaces Furnaces Clearance above grade, veranda, porch, deck, balcony, or 12 inches (30cm) 12 inches (30cm) 12 inches (30cm) -
Page 44: Figure 42 - Horizontal And Vertical Venting
HORIZONTAL VENTING (2-Pipe Shown) First Support as Close Straps or Other Suitable to Furnace as Possible Supports at minimum Seal / Caulk 5 ft. Intervals 3” x 90° Elbows Around Pipes at Wall 3” x 90° Elbow Upward Pitch 1/4” Per Foot (Exhaust Vent) 3”... - Page 45 1 Pipe Upflow See View Option Option Option Plug Plug See View -A- See View -B- See View -C- Inline VIEW -A- VIEW -B- VIEW -C- Header Drain Box Drain Inline Drain Header Box Drain Header Box Drain Tubing is routed NOTES: thru the blower deck Inline Drain...
- Page 46 1 Pipe Downflow Option Option Option PVC TEE, Reducer, and 1/2” X1/2” View -L- View -M- Hose Barb See View -E- See View -D- See View -F- VIEW -D- VIEW -E- VIEW -F- Inline Header Box Drain Header Box Drain Drain Header Inline...
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Page 47: Location Of Furnace Components
LOCATION OF FURNACE COMPONENTS COMPONENT NAME ITEM Blower Assembly Blower Door Switch Burner Assembly Control Board Finish Flange Flame Sensor Gas Manifold Gas Valve Igniter Inducer Assembly Limit Switch Main Air Limit Switch Pressure Switch(s) (‘B’, ‘C’, & ‘D’ cabinets only) Roll-Out Switch(s) Transformer Figure 45. -
Page 48: Installation/Performance Checklist
INSTALLATION/PERFORMANCE CHECK LIST ELECTRICAL SYSTEM: INSTALLER NAME: Electrical connections tight? Line voltage polarity correct? CITY _______________ STATE _____________ Supply Voltage: ______________________ VOLTS Has the thermostat been INSTALLATION ADDRESS: calibrated? Is the thermostat level? CITY _______________ STATE _____________ Is the heat anticipator setting correct? UNIT MODEL # GAS SYSTEM:...