Installation Manual

ManualsBrandsStyle Crest ManualsCooling & Air Quality2 ton 14 SEER 95% AFUE 45,000 BTU Revolv AccuCharge Mobile Home Air Conditioner and Gas Furnace System

Single Stage - Direct Vent (Sealed Combustion)

Forced Air

For Installation in:

• Manufactured Homes

• Modular Homes / Buildings

• Park Models, & Manufactured Buildings

MG2R Series Downﬂow Condensing Gas Furnace 95% AFUE

CAUTION

HUD Manufactured Home Construction and

Safety Standards (3280.714) prohibit the use

of noncertiﬁed air conditioning or heat pump

equipment with this furnace. It is strongly

recommended that manufactured housing

air conditioning components from Nortek

Global HVAC be selected to provide a matched

system speciﬁcally designed to meet these

requirements.

The cutting, splicing or modifying of any

internal electrical wiring may void product

warranties and create a hazardous condition.

Failure to comply with these standards could

also provide inadequate heating or cooling

performance and cause structural damage to

a manufactured home.

Please contact your local distributor for help.

A directory of Nortek Global HVAC factory

authorized servicers is located in the furnace

homeowner packet.

Reference: HUD Manufactured Home

Construction and Safety Standards 3280.714.

INSTALLATION INSTRUCTIONS

WARNING AVERTISSEMENT

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 qualiﬁed installer, service agency or the

gas supplier.

• Do not store or use gasoline or other

ﬂammable vapors and liquids in the vicinity

of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not

use any phone in your building.

• 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 ﬁre department.

RISQUE D’INCENDIE OU D’EXPLOSION

• Le non-respect des avertissements de sécurité

pourrait entraîner des blessures graves ou des

dommages matériels.

• L’installation et l’entretien doivent être effectués

par un installateur qualiﬁé, un organisme de

service ou le fournisseur de gaz.

• 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 tenter d’allumer aucun appareil.

• Ne toucher à aucun interrupteur électrique;

n’utiliser aucun téléphone dans le bâtiment.

• Évacuer l’immeuble immédiatement.

• Appeler immédiatement le fournisseur de gaz en

employant le téléphone d’un voisin. Respecter

les instructions du fournisseur de gaz.

• Si personne ne répond, appeler le service des

incendies.

DO NOT DESTROY. PLEASE READ CAREFULLY & KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

NE PAS DÉTRUIRE. VEUILLEZ LIRE ATTENTIVEMENT ET CONSERVER EN UN LIEU SÛR POUR RÉFÉRENCE ULTÉRIEURE.

Front Return

without

Coil Box

Top Return

without

Coil Box

Front Return

with Coil Box

Top Return

with Coil Box

Summary of content (40 pages)

PAGE 1
MG2R Series Downflow Condensing Gas Furnace 95% AFUE INSTALLATION INSTRUCTIONS Single Stage - Direct Vent (Sealed Combustion) Forced Air CAUTION HUD Manufactured Home Construction and Safety Standards (3280.714) prohibit the use of noncertified air conditioning or heat pump equipment with this furnace. It is strongly recommended that manufactured housing air conditioning components from Nortek Global HVAC be selected to provide a matched system specifically designed to meet these requirements.
PAGE 2
TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION...................... 3 GENERAL INFORMATION......................................... 4 Requirements & Codes........................................... 4 Clearances to Combustible Materials...................... 5 Combustion Air Quality............................................ 5 Heating Load........................................................... 5 Condensate Disposal.............................................. 5 COMBUSTION AIR & VENTING REQUIREMENTS .
PAGE 3
IMPORTANT SAFETY INFORMATION INSTALLER: Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. 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.
PAGE 4
GENERAL INFORMATION Requirements & Codes WARNING: This unit must be installed in accordance with instructions outlined in this manual during the installation, service, and operation of this unit. Unqualified individuals should not attempt to interpret these instructions or install this equipment. Failure to follow safety recommendations could result in possible damage to the equipment, serious personal injury or death.
PAGE 5
Clearances to Combustible Materials This furnace is Design Certified in the U.S. and Canada for the minimum clearances to combustible materials. NOTE: The furnace is listed for installation on combustible or non-combustible flooring. However, wood is the only combustible flooring allowed for installation. To obtain furnace base model number and specific clearance information, refer to the furnace rating plate, located inside of the furnace cabinet.
PAGE 6
COMBUSTION AIR & VENTING REQUIREMENTS WARNING: CARBON MONOXIDE POISONING HAZARD 6 AVERTISSEMENT: RISQUE D’EMPOISONNEMENT AU MONOXYDE DE CARBONED Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
PAGE 7
Important Information WARNING: Furnace installation using methods other than those described in the following sections must comply with the National Fuel Gas Code (NFGC) and all applicable local codes. WARNING: 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 flue products, including carbon monoxide.
PAGE 8
MAXIMUM DIRECT VENT, DUAL PIPE LENGTH (FT.) MG2R INPUTS (BTU) INLET / OUTLET 2” DIAMETER INLET / OUTLET 3” DIAMETER 45,000 30 60 60,000 30 60 72,000 30 60 † NOTES: 1. Subtract 2.5 ft. for each additional 2 inch long radius elbow, subtract 5ft for each additional 2” short radiious elbow, subtract 3.5 ft. for each additional 3 inch long radius elbow, and 7 ft. for each additional 3 inch short radius elbow. 2. Two 45 degree elbows are equivalent to one 90 degree elbow. 3.
PAGE 9
in. 18” M ax. 36” M t st ven Exhauon C opti te faceplarews c ng kit Mountito wall with s ) d secure (both pipes t st ven Exhauon A ti p o lbow 90° E t st ven Exhauon B ti op . 8” Minx. a M ” 6 3 ions) ll posit ustion Combinlet air (a um maxim vel in. to le 12” mcted snow expe oth pipes) (b Figure 1. Inlet & Exhaust Pipe Clearances Outdoor Terminations - Vertical Venting 9 in . te 4f t 2 Mechanical draft vent terminal 4 ft No te l ica an ch nt Meaft veal dr min ter 12 in. .
PAGE 10
Vent Freezing Protection these pipes DO NOT reuse this venting system! This recall does not apply to other plastic vent pipes, such as white PVC or CPVC. Check for details on the CPSC website or call their toll-free number (800) 758-3688. CAUTION: When the vent pipe is exposed to temperatures below freezing (i.e., when it passes through unheated spaces, chimneys, etc.) the pipe must be insulated with 1/2 inch thick sponge rubber insulation, Armaflex-type insulation or equivalent.
PAGE 11
Plenums & Air Ducts This unit is designed only for use with a bottom supply duct and must be installed in accordance with the standards of the National Fire Protection Association Standard for Installation of Air Conditioning Systems (NFPA 90A), Standard for Installation of Residence Type Warm Air Heating and Air Conditioning Systems (NFPA 90B), and all applicable local codes.
PAGE 12
exchanges with the living area of the home. A partially louvered door may also be used across the opening. Grilles placed in a side wall require a 6” clearance from the wall to the furnace so that the air may enter the front grille of the furnace. All return air systems, including the floor and ceiling systems, must meet the following conditions: • The return air opening, regardless of its location in the closet, must not be smaller than size specified on unit data label.
PAGE 13
1. Slide the standard 18”x18”x1” filter into the space between the combustion air pipe and the blower assembly. See Figure 7 (page 12). NOTE: Make sure the airflow arrows on the filter point towards the blower assembly. 2. Push the filter to the rear of the furnace cabinet and angle it up over the blower. Make sure the filter is pushed back as far as possible. 3. Position the filter retainer under the filter and insert the stepped ends into the 0.25 holes in the rear of the furnace.
PAGE 14
√ Verify the air delivery of the furnace is adequate to handle the static pressure drop of the coil, filter, and duct work. Locating the Unit • The dimensions of the room or alcove must be able to accommodate the overall size of the unit and required clearances to combustible materials listed in Table 1 (page 5). Access for positioning and servicing must also be considered when locating the unit.
PAGE 15
4. Determine which duct connector to use from the table. 5. Measure and drill gas hole and cut out for cooling coil (if applicable). See Figure 9 or Figure 10. 20" 23 3/4" 21 7/8 FURNACE OUTLINE CEILING CUT-OUTS FOR VENT & COMBUSTION AIR Installing Finger Tabbed Duct Connectors COMBUSTION AIR INLET The standard duct connector is designed for use on ducts 12” in width. Ducts narrower than 12” may not allow sufficient clearances for this type of installation.
PAGE 16
Secure finger tabs to side of air duct with staples or sheet metal screws Finger Tabbed Duct Connector Supply Air Duct Cut out & remove Narrow Duct Bend tabs tightly against supply air duct Figure 13. Narrow Air Ducts - Option 1 Hole for Gas Line od Wo r o Flo Tabs slide into slots in back of furnace Mounting Plate Screw Down Duct Connector ply Sup Duct r i A Figure 14.
PAGE 17
NOTE: Additional fasteners may be used at rear, sides or through door frame, as desired, to secure furnace to closet or alcove framing. SLIDE FURNACE ALL THE WAY BACK ONTO MTG. PLATE Condensate Drainage MTG. PLATE TABS WARNING: The condensate produced by the furnace must be drained. Do not connect a water supply to the drainage hose of the furnace. CAUTION: Do not install additional traps in the condensate drain.
PAGE 18
GAS SUPPLY & PIPING 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 qualified installer, service agency or the gas supplier. • Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance.
PAGE 19
Table 8, (page 34) lists gas flow capacities for standard pipe sizes as a function of length in typical applications based on nominal pressure drop in the line. The furnace is installed with a bottom 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 hookups are shown in Figure 18.
PAGE 20
After changing the orifices, it is required that you measure the gas input rate. This may be accomplished in the usual way, by clocking the gas meter and using the local gas heating value. See Verifying & Adjusting the Input Rate section (page 24). IMPORTANT NOTE: Observe the action of the burners to make sure there is no yellowing, lifting or flashback of the flame. WARNING: Shut off the gas supply at the manual gas shutoff valve, before disconnecting the electrical power.
PAGE 21
11. Read the rating plate affixed to the appliance to determine its rated input (Btu/hr) and the size of the factory installed orifices. IMPORTANT NOTE: Before installing an orifice, check the side or face of the orifice for the drill number to ensure that it is the appropriate size. 12. Install the appropriate LP/Propane gas burner orifices into the gas manifold assembly. NOTE: The orifices are included with the furnace.
PAGE 22
6. Set the room thermostat above room temperature to start the furnace. 7. Allow the furnace to operate for 3 minutes and then check the manifold pressure. Compare the measured value with the value listed in Table 9 (Propane) or Table 11 or Table 12, (page 35) (Natural Gas). Removing the Manometer/Pressure Gauge After the manifold pressure is verified, the Manometer or pressure gauge must be removed from the gas valve. 1. Turn the thermostat to its lowest setting. 2.
PAGE 23
An electrical disconnect must be installed readily accessible from and located within sight of the furnace. See Figure 21 (page 23) or the wiring diagram label inside of the control door. Any other wiring methods must be acceptable to authority having jurisdiction. are wired to the terminal strip on the integrated control in the furnace. Figure 22 (page 24)contains the proper connections for heating only (two-wire) and heating/cooling (four-wire) applications.
PAGE 24
A/C CONDENSING UNIT CONDENSING UNIT CONTROL BOX EXPANSION PORT (MOTOR CONNECTION) 9 6 3 8 5 2 7 4 1 SPEED SELECT STATUS HEAT COOL FAN NOTE: The “Y” terminal on the control board must be connected to the thermostat for proper cooling mode operation.
PAGE 25
Reconnect this wire to the alternate motor plug speed tap. OPERATING SEQUENCE 1. Place thermometers in the return and supply air stream as close to the furnace as possible. IMPORTANT: The thermometer on the supply air side must be shielded from direct radiation from the heat exchanger to avoid false readings. 2. Consult the rating plate for the proper circulating air flow and temperature rise. The operating sequences for the heating, cooling, and fan modes are described below.
PAGE 26
MAINTENANCE Proper maintenance is most important to achieve the best performance from a furnace. Follow these instructions for years of safe, trouble free operation. WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury or property damage. Improper servicing could result in dangerous operation, serious injury, death or property damage. • Before servicing, disconnect all electrical power to furnace.
PAGE 27
10. Inspect the burners for accumulated dust or debris. If necessary carefully clean them with a soft wire brush and a vacuum cleaner. IMPORTANT NOTE: DO NOT damage the igniter while cleaning the burner assembly. 11. Replace all the parts in reverse order that they were removed. 12. Follow the lighting instructions found on the furnace door to return the furnace to operation. Verify proper operation after servicing.
PAGE 28
DESCRIPTION OF COMPONENTS The descriptions below are various functional components that affect the operation and shutting down of this furnace. Some of these components and their locations are shown in Figure 23. If any component of the furnace must be replaced, use only factory authorized replacement parts specified in the Replacement Parts List provided online. Blower Limit Switch: Prevents operation when blower is not operational.
PAGE 29
FIGURES & TABLES Cabinet Dimensions 1 17 3/4 Knockouts (x4) 15 1/2 5 2 1/2 x 5 (Ventilaire) 3 2 2 3/4 2 5/8 2 18 1/2 Knockouts (x4) 3 1/2 (X2) 1 1/2 1/2 1 1/2 18 1/2 2 Knockouts (x4) 18 1/2 18 1/2 20 1/4 17 1/8 2 3/4 56 7/8 (Electric) 1 1/2 X 3 1/2 (Gas or Condensate) 1 1/2 X 3 1/2 (Gas or Condensate) 23 1/2 1 3/16 3 1/2 1 3/16 1 7/8 19 7/8 24 5/8 1 1/2 X 3 1/2 (Gas or Condensate - Typical) 1/2 TYP. 15 21 5/8 TYP. 15 2 3/8 1 1/8 Figure 24.
PAGE 30
1 17 3/4 Knockouts (x4) 15 1/2 5 2 1/2 x 5 (Ventilaire) 3 2 2 3/4 2 5/8 2 18 1/2 Knockouts (x4) 3 1/2 (X2) 1 1/2 1/2 1 1/2 18 1/2 Knockouts (x4) 18 1/2 18 1/2 20 1/4 17 1/8 7/8 (Electric) 55 2 3/4 76 3 1/2 1 7/8 43 1/2 1 1/2 X 3 1/2 (Gas or Condensate) 21 1/4 20 19 7/8 24 5/8 1 1/2 X 3 1/2 (Gas, Condensate, or Linesets - Typical) 15 21 5/8 TYP. 15 2 3/8 1 1/8 Figure 25. Front Return Cabinets (With Coil Box) 30 21.
PAGE 31
17 2 1/2 x 5 (Ventilaire) 3 1/2 (X2) 5 2 18 1/2 Knockouts (x4) 1/2 15 1/2 3 2 2 3/4 2 5/8 1 1/2 1 1/2 18 1/2 2 Knockouts (x4) 18 1/2 18 1/2 2 3/4 56 7/8 (Electric) 1 1/2 X 3 1/2 (Gas or Condensate) 1 1/2 X 3 1/2 (Gas or Condensate) 23 1/2 1 3/16 3 1/2 1 3/16 1 7/8 19 7/8 24 5/8 1 1/2 X 3 1/2 (Gas or Condensate - Typical) 1/2 TYP. 15 21 5/8 TYP. 15 2 3/8 1 1/8 Figure 26.
PAGE 32
17 2 1/2 x 5 (Ventilaire) 3 1/2 (X2) 5 3 2 2 3/4 2 5/8 1 1/2 2 15 1/2 1 1/2 18 1/2 Knockouts (x4) Knockouts (x4) 18 1/2 18 1/2 7/8 (Electric) 18 1/2 2 3/4 55 76 1 1/2 X 3 1/2 (Gas) 1 1/2 X 3 1/2 (Gas) 3 1/2 1 7/8 43 1/2 21 1/4 19 7/8 19 7/8 24 5/8 1 1/2 X 3 1/2 (Gas or Condensate - Typical) 1/2 TYP. 15 21 5/8 TYP. 15 2 3/8 1 1/8 Figure 27. Top Return Cabinets (With Coil Box) 32 21.
PAGE 33
Yellow LED Continuous Flash On GREEN DOOR SWITCH 1 2 BLACK L1A FIELD WIRING LOW VOLTAGE HIGH VOLTAGE BLACK WHITE WHITE 1 4 3 2 5 COM 24V HUM BLACK BLACK 4 5 6 7 8 3 6 120 V 24V YELLOW GREEN RED 1 2 3 4 NOTE: FOR BLOWER WIRING SEE BLOWER TABLE LITERATURE BLUE BLUE BLACK WHITE RED ORANGE BLUE BLK W/ WHITE STRIPES WHITE W/ BLK STRIPES HIGH INDUCER 1 1 2 2 BLACK BLACK 3 AMP FUSE 1 2 3 4 1 2 3 4 9 24 V BLK W/ WHITE STRIPES MH C 1 1 2 2 RED YELLOW YELLOW GREEN FLAM
PAGE 34
Gas Information GAS FLOW RATES (CUBIC FEET PER HOUR) CUBIC FEET PER REVOLUTION OF GAS METER TIME FOR ONE REVOLUTION (SECONDS) 10 12 GAS FLOW RATES (CUBIC FEET PER HOUR) 1 5 10 TIME FOR ONE REVOLUTION (SECONDS) 360 300 1,800 1,500 3,600 3,000 66 68 CUBIC FEET PER REVOLUTION OF GAS METER 1 5 10 55 53 273 265 545 529 14 257 1,286 2,571 70 51 257 514 16 225 1,125 2,250 72 50 250 500 18 200 1,000 2,000 74 49 243 486 20 180 900 1,800 76 47 237 474 22 164 818 1,6
PAGE 35
ORIFICES FOR PROPANE GAS MANIFOLD PRESSURE = 10 IN. W.C. ALTITUDE ABOVE SEA LEVEL 45,000 INPUT (BTU) 60,000 72,000 0 to 1,999 FT 57 55 56 2,000 to 2,999 FT 57 55 56 3,000 to 3,999 FT 57 55 56 4,000 to 4,999 FT 57 56 56 5,000 to 5,999 FT 58 56 56 6,000 to 6,999 FT 59 56 57 7,000 to 7,999 FT 59 56 57 8,000 to 8,999 FT 60 56 57 9,000 to 9,999 FT 61 57 57 Table 9.
PAGE 36
Venting Information VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED CANADIAN INSTALLATIONS A CLEARANCE LOCATION A B Clearance above grade, veranda, porch, deck, balcony, or maximum expected snow level. Clearance to window or door that may be opened.
PAGE 37
Seal/Caulk Around Pipes at Building Straps or Other Suitable Supports at minimum of 5 ft. Intervals Support System on Vertical Rise 90° Elbow See Table 2 for PVC Pipe Lengths (Field Supplied) COMBUSTION AIR 90° Elbow FLUE PIPE See Table 2 for PVC Pipe Lengths (Field Supplied) COMBUSTION AIR FLUE PIPE 90° Elbow Upward Pitch - 1/4” per foot (Flue Pipe) Wall First support placed as close to furnace connection as possible 12” Min. 7” Normal Snow Level Outlet Outlet Must be outside of line.
PAGE 38
PAGE 39
PAGE 40
INSTALLATION CHECKLIST ELECTRICAL SYSTEM 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.