Owners Manual/Installation InstructionsCMF80-PG Convertible (65, 75, and 90 KBTU/H Inputs),CMF 100-PG (90 KBTU/H Input)CMF80-PO Convertible (65, 75, and 90 KBTU/H Inputs),CMF 100-PO (90 KBTU/H Input)

Counterflow Gas or Oil Heating Appliance

Read all instructions carefully before beginning the installation. Read all labels and tagson the furnace carefully and follow all precautions outlined on those labels and tags.

FOR YOUR SAFETYDo not store or use gasoline or otherflammable vapors and liquids in thevicinity of this or any other appliance.

! WARNING:Improper installation, alteration, ser-vice or maintenance can cause injuryor property damage. Refer to thismanual for assistance or consult aqualified installer, service agency, orthe gas supplier for additional infor-mation.

FOR YOUR SAFETYWHAT TO DO IF YOU

SMELL GAS• Do not try to light any appliance.• Do not touch any electric switch; do not

use any phone in your building.• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’sinstructions.

• If you cannot reach your gas supplier, callthe fire department.

Rated CMF-PG CMF-PO CMF-PG CMF-POBTUH 80 CONV. 80 CONV. 100 100Input 75,000 75,000 90,000 90,000

Output 56,000 60,000 68,000 72,000

GENERALCMF furnaces are high quality, direct ventfurnaces used for manufactured housing, rec-

reational vehicle, and residential† applications.These furnaces are offered in either power gas(designated by PG) or power oil (designated byPO) models. The power gas models are de-signed for operation with either natural or pro-pane (LP) gas.

The CMF series is convertible from power oil topower gas, and vice versa. Furthermore, thefiring rate of the CMF80 Convertible Series canbe changed using a certified NORDYNEconversion kit field-installed by a qualified servicetechnician. Refer to the “Firing Rate Conversion”section later in these instructions for moreinformation on the firing rate change.

These furnaces are certified to the UL307standards (UL 307A for oil models; UL 307B forgas models), and can be installed in a variety ofapplications, as shown in Table 1. This furnaceis not to be used for temporary heating ofbuildings or structures under construction.

! WARNING:This furnace must be installed by a quali-fied installing agency and in accordancewith applicable local codes and ordi-nances that govern this type of equip-ment. Failure to properly install the fur-nace, base assembly, and venting sys-tem as described herein may damage theequipment and/or the home, can create afire or asphyxiation hazard, violates U.S.listing requirements, and will void thewarranty. This furnace is NOT approvedfor installation with split system air con-ditioning. Use a NORDYNE packaged airconditioning system.

2

! WARNING:Do not use this appliance if any part hasbeen submerged under water. Immedi-ately call a qualified service technician toinspect the appliance and to replace anypart of the control system and any gascontrol that has been submerged underwater.

INSTALLATION REQUIREMENTS

Equipment CheckAll units are securely packaged at the time ofshipment and should be carefully inspectedupon arrival for damage. Claims for damages(apparent or concealed), shortage in shipment,or nondelivery should be filed immediately againstthe carrier by the consignee. The carrier isresponsible for making prompt inspection ofdamage and for a thorough investigation ofeach claim. The manufacturer will not acceptclaims for transportation damage.

Requirements and Codes:Installer shall be familiar with and comply with allcodes and regulations and applicable to theinstallation of these heating appliances andrelated equipment.

All manufactured housing installations mustconform with these instructions, all applicablelocal codes, ANSI Z223.1/NFPA 54 (NationalFuel Gas Code), ANSI/NFPA 31 (Installation ofOil Burning Equipment), ANSI/NFPA 70(National Electrical Code), the ManufacturedHome Construction and Safety Standard, Title24 CFR, part 3280, or when this standard is notapplicable, the standard for Manufactured Home

Installations (Manufactured Home Sites,Communities, and Set-ups), ANSI 225.1.

All residential installations (Refer to Table 1)must conform with these instructions, allapplicable local building codes, ANSI Z223.1/NFPA 54 (National Fuel Gas Code), ANSI/NFPA 31 (Installation of Oil-Burning Equipment),ANSI/NFPA70 (National Electrical Code), andNFPA 211 (Chimneys, Fireplaces, Vents, andSolid Fuel-Burning Appliances).

The National Fuel Gas Code is available bywriting:

American National StandardsInstitute, Inc.1430 BroadwayNew York, NY 10018

NFPA publications are available by writing:

National Fire Protection AssociationBatterymarch ParkQuincy, ME 02269

Combustion Air and VentilationRequirementsProvisions for adequate combustion air andventilation air must be in accordance with theANSI Z223.1/NFPA 54, (National Fuel GasCode), ANSI/NFPA 31 (Installation of Oil BurningEquipment), and all applicable local codes.

Depending upon the type of installation (SeeTable 1), the CMF furnace can draw thecombustion air either from outside the home(direct vent) or from the space being conditioned.A direct vent system is one in which the flueproducts are exhausted to and the combustionair is drawn from outside the house. A directvent system can also be referred to as a sealedcombustion system.

Type of Ducted Direct Vent Furnace Flue ProductsInstallation Application System Required Base Used Exhausted By

ManufacturedHousing or Yes Yes

Recreational Vehicle

MA-100 or MA-200 NORDYNE SRJ Roofjack or

Universal Base an Existing Chimney*

CB-200A Cottage NORDYNE SRJ Roofjack or

Base an Existing Chimney*

CB-200A Cottage NORDYNE SRJ Roofjack orBase an Existing Chimney*

†Residential is only defined as a single-story non-manufactured housing installation.

*Refer to the "Venting Requirements" section later in these instructions for more details on properly venting this appliance through an existing chimney.

MA-100 or MA-200Universal Base

NORDYNE SRJRoofjack Only

Yes

No

Yes

YesResidential†

Residential†

Residential†

Yes

No

Table 1

3

For direct vent applications either the combustionair duct provided with the MA Series base kit orthe direct vent kit can be used. The direct ventkit must be ordered separately. Only for aspecial CB-200A cottage base installation canthe CMF draw the combustion air from theconditioned space. The CB-200A cottage basekit must be ordered separately. Refer to thereplacement parts listing provided with thefurnace to order the direct vent kit or the cottagebase kit. Follow the instructions provided withthe kits for proper installation.

When unsure about combustion air supplyavailability, a direct vent system should beused. For small rooms, confined spaces, tightconstruction or similar situations in which thecombustion air requirements of the furnacemight not be met, a direct vent system must beused. The air openings in the door of the unit andthe warm air registers from the ductwork orbase must not be restricted.

Combustion air must not be drawn from acontaminated atmosphere. Excessiveexposure to contaminated combustion air willresult in safety and performance relatedproblems. Some examples of chemicalcontaminants are chlorine, fluorine, and sulfur,which can be found in a wide variety of somecommon commercial and household products.

The installation of the furnace must allow for anadequate supply of combustion air. Thecombustion air opening of the furnace must bedesigned and located to prevent blockage bysnow.

When drawing the combustion air fromunderneath the home, ensure that a vent or ductof at least 18 square inches of free area isprovided from outside. Check to ensure that thecombustion air opening is unobstructed. Whenusing the combustion air duct, ensure that itextends through the floor. When using thedirect vent kit, the combustion air opening mustbe located in the same pressure zone as the flueexit of the roof jack or chimney. Refer to theinstructions provided with the direct vent kit formore information.

Venting Requirements — ManufacturedHousing InstallationsFor all manufactured housing applications, theCMF furnace must be vented using the SRJseries roofjack. The instructions for selectingthe proper roofjack for your installation aredetailed later in these instructions.

Venting Requirements — ResidentialInstallations

! WARNING:This furnace is not to be connected to achimney flue serving a separate appli-ance designed to burn solid fuel.

For residential applications (Refer to Table 1),the CMF furnace may be vented through theSRJ series roofjack or through an existingchimney. If the SRJ roofjack is to be used, thenthe instructions for selecting the proper roofjackfor your installation are detailed later in theseinstructions. If venting through an existingchimney, then the venting system used must bein accordance with these instructions, allapplicable local building codes, ANSI Z223.1/NFPA 54 (National Fuel Gas Code), ANSI/NFPA 31 (Installation of Oil-Burning Equipment),and NFPA 211 (Chimneys, Fireplaces, Vents,and Solid Fuel-Burning Appliances).

! WARNING:When venting through a chimney, checkthe chimney for soot, leaks, obstruc-tions, and proper installation.

The materials used to construct the ventingsystem must be capable of withstandingexposure to temperatures of at least 700 degreesF. The existing chimney servicing this furnacemust be vertical. Horizontal distances to anexisting chimney must be as short as possible,and the connecting pipe must slope upward tothe chimney at not less than a 45 degree angle.The total length of the sloping pipe must notexceed 6 feet. The venting system must haveno obstructions or sharp bends where soot andother foreign matter can accumulate.

If an inspection determines that the chimney isobstructed, the chimney must be cleaned.Furthermore, the connecting flue pipe must becleaned or replaced.

For ONLY a CMF power oil furnace installationvented into an existing chimney, a barometricdamper can be installed at the vent connectionof the furnace to regulate the draft. The barometricdamper must be properly installed per themanufacturer’s instructions. Refer to allapplicable codes to determine whether or not a

4

barometric damper can be used for your CMFpower oil furnace installation. The barometricdamper used must be installed such that airfrom the conditioned space can only enter theflue passageway. Do not use a double actingbarometric damper. All flue pipe joints should befastened with sheet metal screws for rigidity.

The chimney height, required draft, and numberof appliances served by the chimney must bein accordance with all applicable codes. Toprevent down draft, the chimney should extendat least two feet above the peak of the roof.

It is recommended that the furnace flue serveno other appliances. When the chimney servesonly the furnace, the flue area must be sizedaccording to all applicable codes. The minimuminternal area of the flue must be equal to at leastthe area of the furnace flue exit.

When two or more appliances must vent througha common flue, the area of the common flueshould be sized in accordance with all applicablecodes.

When an existing furnace is removed or replacedin a venting system, then the venting systemmay not be properly sized to vent the attachedappliances. The venting system must bechecked to ensure proper venting. Improperlysized venting systems can result in the formationof condensate, leakage, spillage, et cetera.Refer to the ANSI Z223.1/NFPA 54, (NationalFuel Gas Code), and ANSI/NFPA 31( Installationof Oil Burning Equipment) for correcting anyimproperly operating venting system.

The following steps shall be followed with eachappliance connected to the venting systemplaced in operation, while any other appliancesconnected to the venting system are not inoperation:

(a) Seal any unused openings in the ventingsystem.

(b) Inspect the venting system for proper sizeand horizontal pitch, as required in theANSI Z223.1/NFPA 54, (National Fuel GasCode) and ANSI/NFPA 31 (Installation ofOilBurning Equipment), and these instruc-tions. Determinethat there is no blockage or restriction,leakage, corrosionor other deficiencies which could cause anunsafe condition.

(c) In so far as is practical, close all buildingdoors and windows and all doors betweenthe space in which the appliance(s) con-nected to the venting system are locatedand other spaces of the building. Turn onclothes dryers and any appliance not con-nected to the venting system. Turn on anyexhaust fans, such as range hoods andbathroom exhausts, so they shall operateat maximum speed. Do not operate asummer exhaust fan. Close fireplacedampers.

(d) Follow the lighting instructions. Place theappliance being inspected in operation.Adjust thermostat so appliance shall oper-ate continuously.

(e) Test for draft hood equipped appliancespillage at the draft hood relief openingafter 5 minutes of main burner operation.Use the flame of a match or candle.

(f) After it has been determined that eachappliance connected to the venting sys-tem properly vents when tested as out-lined above, return doors, windows,exhaust fans, fireplace dampers and anyother gas burning appliance to their previ-ous conditions of use.

Flashing

BarrelCeiling Plate

VentVentilationKnock-Out

DUCTCONNECTOR

Return AirGrille and Filter

Power SupplyConnection

AccessDoor

Base Pan

Fuel Line

Feeder Duct

CombustionAir Duct

FURNACEASSEMBLY

ROOF JACKASSEMBLY

Combustion AirAdapter (Not Shown)is to be InstalledOver CombustionAir Duct

Figure 1. Typical Furnace Installation forManufactured Housing Applications

5

(g) If improper venting is observed during anyof the above tests, the venting systemmust be corrected.

Unit Location and Clearance to AdjacentMaterial RequirementsThe unit must be installed in a level position. Thefurnace must be installed with the minimumclearances from adjacent materials as stated inTable 2. Additional clearance should be providedto permit servicing of filters, blower, motors,controls, combustion air connections, and ventconnections.

UNIT INSTALLATIONThese instructions are intended for the use ofqualified individuals specially trained andexperienced in installation of this type equipmentand related system components. Installationand service personnel are required by somegoverning bodies to be licensed. Persons notqualified should not attempt to install thisequipment or interpret these instructions.

MA-200 Base InstallationThe MA-200 base is designed for O.E.M. andreplacement installation of the CMF series fur-nace (see Figures 2 and 3). The warm air ductsystem should be designed so the duct staticpressure external to the furnace does notexceed the static pressure listed on the furnacedata label.

Use the base pan to mark the 12-1/8" x 12-1/8" center opening for the feeder duct. When the4" offset feeder duct is used, the floor openingwill be offset 4 inches from the opening in themain duct. If using the combustion air duct,select and knock out the combustion air open-ing to be used. Then mark the 2-1/4" x 7-1/4"opening for the combustion air duct.

Cut the opening for the feeder duct 14-1/8" x 14-1/8" in flooring (cutting opening 1" larger all theway will allow the flanges on the underside of thebase pan to fit in the opening).

If using the combustion air duct, cut the openingfor the duct about 1/8" larger than the markingon the floor. Be sure to cut through all insulationand the bottom board so that the combustion airduct is unobstructed to outside air.

Drill an approximate 1" diameter hole for the fuelline through the floor and bottom board to theoutside. Fuel lines are not supplied with thefurnace. They should be installed to complywith all applicable codes.

Drop transition or offset feeder duct upsidedown through the floor opening and center thetop of the feeder duct in 14-1/8" x 14-1/8" flooropening. Using the feeder duct as a guide, markand cut a 12" x 12" opening in the distributionduct. (See Figure 3)

Insert the feeder tabs into the main duct andbend them over tightly so that the main ductedges are trapped between flanges and tabs.Metal tape may also be used to ensure an airtight connection.

** See Item K in the "Closet Installation ofFurnace" section later in these instruc-tions for clearance less than 6".

Table 2. Minimum Clearancesto Adjacent Materials

Closet AlcoveALL MODELS Installation Installation

Sides 0" 0"Back 0" 0"Front 6"** 18"Top 17" 17"Vent 6" 6"Duct within 3’ from Furnace 1/4" 1/4"Plenum 1" 1"Roof Jack Barrel 0" 0"

Figure 2. MA-200 Base Pan

FRONT

7-1/8 X 2-3/16 Knock-outsCombustion Air

Feeder Duct Opening

FlueLocation

24-1/8

8-3/8

12-1/8

12-1/8

9-1/8

18-1/4

6

Install the base pan around the feeder duct withthe (2) screws through the holes towards therear of the base pan.

Slit the corners of the feeder duct down to thetop of the base pan. While the top of thedistribution duct is pulled up with one hand, benddown each side of the feeder duct tightly to thebase with the other hand. Trim the metal to allowa one inch flange over the top of the base panand seal that flange with the metal tape.

If a “V” or “U”-box crossover system is to beused, see the instructions provided with thecrossover system.

Figure 4. MA-100 Universal Base,Bottom Panel

12-1/8

12-1/8

Feeder DuctOpening

7-1/8 X 2-3/16 Knock-outsCombustion Air

18-1/4

24-1/2

Figure 5. Feeder Duct Installation

Heat Duct Below Joists

Base Feeder Duct

FloorJoists

Cut This Line

Bend OverAlong This Line

1"

Figure 3. Transition and Offset Ducts

Heater Duct Below Joists

Flange

Bend Over Tabs

Base

FloorJoists

Slit 4 CornersBend Down 4 Sides

TRANSITIONDUCT

FloorJoists

Heater Duct Below JoistsBend Over Tabs

Flange

Slit 4 Corners

Base

Bend Down 4 Sides

MA-100 Universal Base InstallationThe MA-100 base is designed primarily forreplacement installation of the CMF series fur-nace where the manufactured home duct sys-tem may be small and restrictive to proper airflow. The MA-100 base provides approxi-mately four (4) inches of additional plenumspace before the discharge air enters the manu-factured home duct system. (See Figures 4and 5)

Use the bottom panel of the base assembly tomark the 12-1/8" x 12-1/8" center opening forthe feeder duct. If using the combustion air duct,select and knock out the combustion air open-ing to be used. Then mark the 2-1/4" x 7-1/4"opening for the combustion air duct.

Cut the opening for the feeder duct 14-1/8" x 14-1/8" in flooring (cutting opening 1" larger all theway around 12-1/8" x 12-1/8" template mark-ing). This will allow the four flanges on theunderside of the panel to fit into the opening.

If using the combustion air duct, cut the openingfor the duct about 1/8" larger than the markingon the floor. Be sure to cut through all insulationand the bottom board so that the combustion airduct is unobstructed to the outside air.

Drill a 1" hole for the fuel line through the floor andbottom board to the outside. Fuel lines are notsupplied with the furnace. They should beinstalled to comply with local codes.

Put the bottom base panel in place (See Figure5). Drop the transition feeder duct upside downthrough the opening and mark a 12" x 12"opening to be cut into the distribution duct.Remove the bottom panel and transition feederduct; then cut the opening into the distributionduct.

7

Damper InstallationAn automatic shut-off damper is available (seereplacement parts list). An automated shut offdamper is required when the home is air con-ditioned by a self-contained unit. This damperis designed to fit in the feeder duct cavity,directly under the furnace. A damper is requiredto prevent chilled air from flowing over thefurnace heat exchanger. For proper installa-tion, refer to the instructions provided with thedamper.

Installation of Furnace onto the MA-200BaseLift the furnace over the base so that the flangeat the back comes to rest on the inside rails ofthe base.

Raise the front of the furnace to clear the gasketon the bottom of the furnace and slide the backuntil the rear flange drops into the channel at therear of the base. Be careful not to damage thecombustion air adapter, if present, while posi-tioning the unit.

Be sure that the furnace is all the way back soas to engage the tabs on the rear flange on thebase.

Open the access door. Fasten the front of thefurnace and the base to the floor with #8 x 1/2"long sheet metal screws.

Using the provided hose clamp, secure theflexible combustion air tubing from the burner tothe combustion air adapter.

Installation of Furnace onto the MA-100BaseTilt the furnace forward and carefully work thefurnace back over the MA-100 Universal base.

Lift the furnace as necessary when positioningthe unit over the base assembly to prevent anydamage to the feeder duct assembly and com-bustion air adapter, if present.

Be sure the furnace is positioned all the way tothe back of the base assembly.

Open the furnace door and fasten the furnaceto the base using #8 x 1/2" long sheet metalscrews.

Install the feeder duct by bending the tabs insidethe heat duct and using the metal tape to insurean airtight connection.

Set the bottom base panel over the feeder duct.Slit the corners of the feeder duct down to thetop of the base. While the top of the distributionduct is pulled up with one hand, bend down eachside of the feeder duct tightly to the base with theother hand. Trim the metal to allow one inchflange over the top of the base and seal thatflange with the metal tape.

Secure the top panel to the floor with two (2)screws through the front flange.

If a “V” or “U”-box crossover system is to beused, see the instructions provided with thecrossover system.

Combustion Air Duct/Pipe InstallationThe CMF furnace must draw the combustion airfrom outside, except for special installations(See Table 1). This can be accomplished eitherby using the 2”X7” rectangular combustion airduct provided in the MA series base kits or usingthe direct vent kit.

When the rectangular combustion air duct is tobe used, install the combustion air duct throughthe selected knockout in the base. For directvent applications, the rear knock-out in thefurnace base cannot be used. After thecombustion air duct has been positioned, installthe combustion air adapter. This adapter willtransition the 2”X7” opening of the combustionair duct to the 2” diameter of the burner flexibletubing. This adapter is included in the MA seriesbase kits. For retrofit applications in which theMA series base is already installed, thecombustion air adapter can be ordered as a kit.Refer to the Replacement Parts List for moredetails on ordering this kit.Secure the adapter with either wood or metalfasteners (field provided), depending upon theparticular installation. Ensure that the gasketfor the adapter is positioned properly beforeinstalling the adapter. Attach the flexible hosefrom the burner to the combustion air adapterusing the provided metal hose clamp.

When the direct vent kit is used, follow theinstructions provided with the kit. Note: Thedirect vent kit should be installed beforepositioning the furnace on the base.

8

Using the provided hose clamp, secure theflexible combustion air tubing from the burner tothe combustion air adapter.

CB-200A Cottage Base InstallationThe CMF can be installed on a CB-200A cottagebase in certain applications, as described earlierin these instructions (See Table 1). Refer to theReplacement Parts List for information onordering this base. For installation, refer to theinstructions that are provided with the CB-200Abase kit.

Closet Installation of the FurnaceReturn air systems for a closet installation of thefurnace may consist of a grille or grilles in acloset door or side wall thatcommunicates with the living area of the home.(See Figure 6) Return air openings should notbe located to draw air directly from a bathroom.Grilles placed in a side wall require a 6" clear-ance from the wall to the furnace so that the airmay enter the front grille of the furnace. Inaddition, all return air systems, including thefloor and ceiling systems, must meet the follow-ing conditions:

A. The return-air opening into the closet,regardless of its location, is to be a mini-mum of 200 square inches.

B. If the return-air opening is located in thefloor of the closet (versus the vertical frontor side wall), the opening is to be providedwith means to prevent its inadvertent clo-sure by a flat object placed over the open-ing.

C. The cross-sectional area of the returnduct system (when located in the floor orceiling of the manufactured home) leadinginto the closet is to be not less than 200square inches.

D. The total free area of the openings in thefloor or the ceiling registers serving thereturn air duct system is to be not less than300 square inches. At least one suchregister is to be located where the likeli-hood of its being covered by carpeting,boxes, and other objects is minimized.

E. Materials located in the return duct systemshall have a flame spread classification of200 or less.

F. Noncombustible pans having one inchupturned flanges are located beneathopenings in a floor return duct system.

G. Hollow spaces used as ducts or plenumsfor environmental air may contain mineral-insulated metal sheathed cable, aluminumsheathed cable, electrical metallic tubing,rigid metal conduit, flexible metal conduitnot to exceed four (4) feet, or metal-cladcables. Wiring materials, fixtures, are tobe suitable for the expected ambienttemperatures to which they will be sub-jected.

H. Gas piping cannot be located in the returnduct system.

I. The negative pressure in the closet mustnot be less than minus 0.05 inches watercolumn with the closet door closed and thefan operating at high speed. A readingbelow minus 0.05" indicates a dirty filter ora restricted return air system.

Figure 6. Closet Installation

9

J. For floor return systems, the manufac-tured housing manufacturer or installershall affix a prominent marking on or nearthe appliance where it is easily read whenthe closet door is open. The marking shallread: “CAUTION, HAZARD OF AS-PHYXIATION. DO NOT COVER ORRESTRICT FLOOR RETURN AIR OPEN-ING.” or equivalent. (This label is suppliedwith the instruction manual in each fur-nace.)

K. For closet installation with less than 6"front clearance, but not less than 1", alouvered door must be used having aminimum 200 square inch free area open-ing directly in line with openings in thefurnace door. A fully louvered door havingthe minimum free area is also permitted if

the front tolerance is not less than 4".Adjust duct registers to obtain a tempera-ture rise within the range specified on thefurnace nameplate.

! WARNING:Failure to comply with the above proce-dure and the following instructions mayresult in fire, asphyxiation or carbonmonoxide poisoning.

SRJ Roof Jack InstallationRefer to Figure 7 to determine SRJ roof jackand appropriate accessories required foryour installation.

Furnace Base Package for O.E.M. and replacement installations . Model No. MA-200

See Replacement Parts List for types of Base Packages offered.

Furnace Base Package for replacement installations ..................... Model No. MA-100

See Replacement Parts List for types of Base Packages offered.

RA-S4

RA-S3

RA-S2.5

4/12

3/12

2-1/2/12

None Flat

SRJ1 & SRJ2 Models are one piece constructionSRJ3, SRJ4, & SRJ5 Models are two piece construction-C Models are two piece construction

OPTIONAL:Raised Inlet Models (-C)RoofJack Adaptor (Use to mount roofjack on pitched roof)Protective Cap (Use when top of roofjack is removed)

Use AdaptorModel No.

When roof pitch is: 1/2 Minimum

FurnaceCMF Series

57"

Add -C for Raised Inlet ModelsExample: SRJ3-34-C

And Ceiling Height is:Add Suffix

For Vent Pipe

7'-28

7'6"-34

8'-40

Ceiling Trim Plates

When Ceiling Cavity is:

Use Roof Jack Model No.

49" to 59"

37" to 48"

SRJ5

25" to 36"

13" to 24"

12" or Less

SRJ4

SRJ3

SRJ2

SRJ1

Adaptor

14" Removable SRJ3, SRJ4, & SRJ525" Removable All -C Models

Figure 7. Selection of Roof Jack and Accessories Chart

10

! WARNING:1. The roof jack and vent pipe as deter-

mined from the chart on in Figure 7must be applied.

2. The indicating line near the bottom ofthe roof jack must extend below thefinished ceiling.

3. The vent pipe must be attached to thefurnace flue collar with the sheet metalscrew provided.

4. DO NOT install any elbows (adjust-able or non-adjustable) or a stackdamper in the venting system.

NOTICE: Accuracy in locating the base panand the roof jack openings with respect to theflue outlet is required to avoid hazardous mis-alignment of the air and vent systems. (SeeFigure 1)

Use only the SRJ series roof jack as specifiedon the furnace label.

Cut an approximate 8-1/4" diameter openingthrough the roof and ceiling directly in line withthe flue connection on the top of the furnace.

A roof jack adaptor is required for use on asloping roof. Center the adaptor opening overthe roof opening, use sealant or caulking underthe adaptor. Use roofing nails or screws onwood construction or sheet metal screws onmetal roofs (caulking, nails or screws not pro-vided).

Insert the vent pipe into the bottom of the roofjack; locking slot, downward, toward the fur-nace. Slide the pipe into the roof jack to a lengththat will allow a convenient reach to the connec-tion at the top of the furnace.

Ease the roof jack assembly through the open-ings. The lower portion of the outer barrel mustextend through the finished ceiling as indicatedon the barrel. Use sealant or caulking on theroof or adaptor to seal under the flashing of theroof jack assembly.

Extend the vent pipe down to engage the lockingslot with the screw in the top of the furnace fluepipe. Turn to lock and tighten the screw. Alljoints and connections should be inspectedbefore start up of the furnace. (See Figures 8& 9)

Fasten the ceiling trim/fire stop plates aroundthe upper barrel with four nails or wood screws(not provided).

NOTE: Model SRJ-3, 4, and 5 roof jackspermit the top section to be removed for transitof the dwelling. If the top is removed, remainingopenings must be sealed from rain, debris, etc.,until the top is replaced. A plastic accessorycap is to be fastened to the lower roof jacksection with the same screws used to mount theroof jack cap assembly. (See Figure 8)

Figure 8. Roof Jack Figure 9. Vent Pipe Installation

VENT PIPE

SLIDE DOWN TOENGAGE SCREW

FLUE PIPEOF FURNACE

TURN TO LOCK-TIGHTEN SCREW

������

����������

��������

Insert Sliding Pipe

Fasten CeilingTrim Plates

Ceiling

Roof

Roof Jack Adaptor

Install With LineBelow Ceiling

Remove three screwsto separate two piecemodels; replace withprotective cap fortransit only

Fasten roof flashing to adaptoror flat roof; apply sealant orcaulking underneath

Fasten adaptor to sloped roof; applysealant or caulkingunderneath

������

11

IMPORTANT: When the top section of theroof jack is removed for transit, a special warn-ing label must be attached adjacent to the fuelline connection of the gas or oil burner. Thespecial warning label is suppled with two pieceroof jack assemblies.

Chimney InstallationWhen venting the CMF through an existingchimney, the materials, sizing, and installationof the chimney must be in accordance with theANSI Z223.1/NFPA 54, (National Fuel GasCode), ANSI/NFPA 31(Installation of Oil Burn-ing Equipment), NFPA 211 (Chimneys, Fire-places, Vents, and Solid Fuel-Burning Appli-ances) and all applicable local codes. Thematerials used must be capable of withstandingexposure to temperatures of at least 700°F .

The CMF power gas units are fan-assisted.

Installation of Ventilaire III or IV AirQuality Package (Accessory)The Ventilaire air quality packages are availableto meet the ventilation requirements as outlined

VENT PIPE

3 FEET MIN.

ROOF JACK ASSY.

ROOF CAP ASSY.

FLEX DUCT

CEILING TRIM COLLAR

CONNECTORDRAW BAND

DRAW BAND

FURNACE

Figure 10. Typical Installation

FURNACE

CAUTIONMAINTAIN 2 1/2" MINIMUM CLEARANCEBETWEEN FLUE PIPE AND FLEX DUCT.FAILURE TO COMPLY WITH THISRESTRICTION COULD CAUSEEQUIPMENT DAMAGE. VENTILAIRE IIIILLUSTRATED OTHER LISTEDVARIATIONS AVAILABLE. CHECK WITHMANUFACTURER.

VentilAire III

VentilAire IV

Figure 11. VentilAire III and IV

12

Table 3. Pipe Length Selection Chart

Type ofPipe

Black IronPipe for 20’ _ 60’ 100’

Natural Gas

Aluminum or

Copper Tubing* 10’ _ 30’ _

for Natural GasAluminum or

Copper Tubing _ 40’ 100’ _for LP Gas

*Copper tubing should be internally tin coated.

1/2" 5/8" 3/4" 1"

Maximum Possible PipeLength Required for Different

Pipe Diameters

in H.U.D. Standard Part 3280.103 (b) (2). Thesepackages introduce outdoor air into the livingspace during furnace blower operation. TheVentilAire IV also serves to exhaust moist and/or hot air from the attic space. See Figures 10and 11 for typical installation. Completeinstallation instructions are supplied with eachair quality package.

FUEL CONNECTIONS

Gas Piping Requirements - PG Series OnlyGas piping should be sized and installed inaccordance with local codes ANSI Z223.1/NFPA 54 (National Fuel Gas Code) and utilityregulations. To install the gas supply piping,connect a separate gas line from the gas meterto the burner with a manual shut-off valveinstalled in the line at the furnace. This valveshould be readily accessible to shut-off the gassupply to the furnace in case of an emergencyshutdown. When installing the gas supply line,always use new clean piping and route the linein such a manner as to be easily accessible.The piping and threading must be free fromcutting burrs and defects. The line must bedurable, substantial, and gas tight. Installing atee fitting with a sediment trap at the bottom ofthe riser to catch any foreign debris in the gassupply line is recommended. An additional mainmanual shut-off valve may be installed in thegas supply line to shut-off the main fuel supply,if desired by the homeowner or required by localcodes.The proper gas supply line size can bedetermined using the gas piping chart, shownin Table 3. Black pipe is the most practical fornatural gas, because of the larger sizes required.Copper tubing with an internal coating of tin isrecommended for use with propane (LP) gasinstallations. Compounds used on the threadedjoints must be resistant to the actions of propane(LP) gases.

Carefully check for gas leaks with a soapsolution or a commercial leak detector fluid.NEVER USE A MATCH OR OPEN FLAME TODETECT A GAS LEAK!

! CAUTION:The furnace and its appliance main gasvalve must be disconnected from the gassupply piping system during any pres-sure testing of that system at test pres-sures in excess of ½ psi (3.5 kPa). Thefurnace must be isolated from the gassupply piping system by closing the equip-ment shut-off valve during any pressuretesting of the gas supply piping system attest pressures equal to or less than ½ psi(3.5 kPa).

Oil Piping Installation — PO Series OnlyThe following procedures are recommendedas good practice. However, requirements oflocal codes and ordinances, H.U.D. Manufac-tured Home and Safety Standards or NationalFire Protection Association must be satisfied,where they apply, for an approved installation.

Use a tank capacity suitable for the applicationwith a weatherproof, capped fill opening and ashielded vent to let in air as fuel is used. The tankmust be clean inside before filling. All water,rust, sediment, and other foreign matter mustbe flushed out.

If a two pipe system is used or if oil is taken fromthe bottom of the tank, a filter is recommended.Furthermore, a manual shut-off valve may beused on a single pipe or two pipe system. Pleasenote that local codes will dictate the specificinstallation requirements.

13

A fuel or tank gauge is recommended for easychecking of the fuel level. Check the gaugereading with a dip stick.

Locate the storage tank conveniently near thehome. For above ground fuel tank installations,the tank may rest three to four inches off theground. Fuel tanks may also be buried ifproperly coated to resist corrosion. For belowground fuel tank installations, the vertical di-mension from the bottom of the tank to the fuelpump must not exceed ten feet. Keep the tankfilled especially in the summer to reduce theaccumulation of condensation.

Fuel Line Hook-Up: One Line SystemThe one line system is highly recommendedwhere vertical lift, from bottom of tank to pump,is not more than eight feet. A single line hookuphas the advantage of costing less and givingquieter operation.

Fuel Line Hook-Up: Two Line SystemUse a two line system only if the vertical liftexceeds 8 feet.

1. Install the oil feed line as outlined in steps1-6 below.

2. Install the oil pump bypass plug in thebottom return port.

3. Run the return line up through the furnacebase to the return port of the pump. Runthe other end of the line to the tank, using3/8" O.D. copper tubing or 1/4" pipe withthe ends capped, and routing the line so itstays clean.

Figure 12. Recommended Tank Hook-Up200 to 300 Gallon Tank

Drain

End of Oil Supply Line3" to 5" AboveBottom Drain

Guide pipe

GaugeVent with

Cap 2" DuplexBushing 2" Fill

3/8" Oil Supply Line

Note: Additional venting maybe required if tank is filled rapidly.

4. Insert the return line through the secondopening in the duplex bushing. If thebottom of the tank is lower than the pumpintake, the tube should be inserted three orfour inches from the tank bottom. If thebottom of the tank is higher than the pumpintake, the return line should extend notmore than 8" inside the tank.

Hook-Up Procedure (See Figure 12)

1. Use 3/8" O.D. copper tubing for the fuelline. Cap the end with tape to keep out dirtwhile the line is being routed.

2. Install duplex bushing for two 3/8" lines inthe top fitting of the tank.

3. Insert one end of the tubing through theduplex bushing until it is three to five inchesfrom the bottom drain. Tighten the bush-ing.

4. Run the line where it will not be subject todamage. Also make bends gradually andavoid kinks which might restrict oil flow.

5. Open the burner access door. Connectthe oil line to the intake port on the pump.Tighten other port plugs on the pump.

6. Be sure the oil line is airtight! Air leaks cancause the pump to lose prime and willcreate other problems such as nozzlefailure, odors, rumbling noise, and falsesafety shut down.

7. Insert the short length of the copper tubelevel with the bottom of the duplex bushing.Tighten the bushing. Form the tube into aninverted “U” to serve as a vent.

How to Eliminate Air LeaksTo eliminate problems caused by air in the oilline, all connections in the oil supply line and allplugs, nuts, and fittings on the pump must beairtight. This includes the nut that covers thepressure adjustment. It is important that thehook-up be done carefully and with a goodflaring tool.

Fuel Oil TypeDo not use fuel oil heavier than Grade No. 2.Grade No. 1 may be used where the oil supplyis subject to low temperatures.

14

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15

DO NOT USE GASOLINE, CRANKCASE OIL,OR ANY OIL CONTAINING GASOLINE.

! WARNING:Failure to keep supply oil clean by variousprocedures described above may causefailure of certain components such as thefuel pump gears, check valve, shaft seal,or burner nozzle which may result in aburner fire.

ELECTRICAL WIRING

GeneralAll electrical wiring must be made in accordancewith these instructions, all local codes, andANSI/NFPA 70 (National Electric Code). Thisfurnace shall be installed so the electricalcomponents are protected from water.

If any of the original wiring supplied with theappliance must be replaced, it must be replacedwith wiring of the same material, gauge, andtemperature rating.

Line Voltage RequirementsBefore proceeding with the electrical connec-tions, make certain that the voltage, frequency,and phase of the supply source are the sameas those specified on the unit rating plate. This

unit must be electrically grounded in accor-dance with local codes, or in the absence oflocal codes, with ANSI/NFPA 70 (National Elec-trical Code).

Use 14-2 Type NM cable with ground or conduitwith single wires. Secure the cable at theappliance using a code approved connector.

Line Voltage ConnectionsBefore connecting the power supply wiring,become familiar with the wiring of this applianceby reviewing the wiring diagram, shown inFigure 13 , or the wiring label located on theinside of the appliance.

1. Open the appliance door to gain access tothe control box.

2. Remove the control box cover.

3. Connect the black wire of the power supplycable to the black wire of the appliance.

4. Connect the white wire of the power supplycable to the white wire of the appliance.

5. Connect the ground wire of the powersupply cable to the green screw located inthe control box of the appliance.

6. Check all electrical connections, whichshould be secure and tight.

CAUTIONDo Not Rotate — Hold

Dial When Setting Pointers

Scaleplate

Limit Stop*Fan OFFIndicator

Fan ONIndicator

Limit Indicator(Factory-Set at 160 F)

50

100150

20

025

0

FAN LIMIT

OFF

ON OFF

Figure 14. Fan and Limit Settings

16

7. Replace the control box cover.

8. Install a disconnect switch (fused or un-fused) between the appliance and theelectrical supply at a convenient locationnear the appliance. This switch should beeasily accessible.

Room Thermostat RequirementsWhen selecting thermostat location, consider-ation must be given to the following:

1. Locate the thermostat approximately fivefeet above the floor in a location accessiblefor wiring and setting, preferably in a livingor adjoining room.

2. Locate on an inside wall.

3. Do not locate where influenced by abnor-mal heat, such as from sunlight, radio,T.V., or lamps.

4. Do not locate where influenced by abnor-mal cold, such as on an outside wall, on awall separating an unheated room,near drafts from stairwells or doors, orclose to windows.

5. Do not locate where air circulation is poor,such as behind open doors, in corners oralcoves, or close to furniture.

The heat anticipator of the thermostat should beadjusted to .4 amps for power oil models, and.9 for power gas direct ignition models.

Room Thermostat Connections

1. Run R and W from the thermostat to theburner compartment.

2. Connect R to one of the low voltageterminals on the burner.

3. Connect W to the other low voltage terminalon the burner.

FAN AND LIMIT CONTROLS

Constant Blower OperationThe button protruding through the cover of thefan and limit control provides either automaticoperation of the blower through the thermostat

or constant blower operation. Pull the button outfor automatic operation. Push the button in forconstant blower operation.

Fan and Limit Settings

! CAUTION:When adjusting the fan setting levers,hold the scaleplate dial to keep it fromturning and straining the sensing ele-ment.

The fan and limit switch has three levers: FANON, FAN OFF, and LIMIT OFF. These leverscontrol the blower operation of the appliance.

The FAN ON lever controls the temperature atwhich the blower energizes. This lever can beadjusted through a range of 15oF above the FANOFF setting to 30 oF below the LIMIT OFFsetting. The recommended factory setting is110 oF.

The FAN OFF lever controls the temperatureat which the blower is to stop to prevent thecirculation of cool air. The recommended factorysetting is 90 oF.

The LIMIT OFF lever is a safety stop. This levershould not be adjusted or tampered with for anyreason. The factory setting is 160 oF.

Figure 15. Direct Ignition Gas Valve

17

Auxiliary LimitThis furnace is equipped with an auxiliary manualreset limit. This limit is designed to function("trip") in the event of a blower motor failure. Ifthe limit trips, reset the limit by firmly pressingthe red button in the center of the limit. The limitis located on the left hand side of the blowerassembly. If the limit will not reset, continues totrip, or the blower does not function, notify yourNORDYNE Distributor or Service PROimmediately.

MAINTENANCE

Air FiltersAir filters should be inspected and cleanedmonthly.

Combustion Air and Venting SystemInspect the combustion air and venting systemat the beginning and end of the heating systemfor deterioration, blockage, or damage. Cleanthe system, if necessary.

LIGHTING AND OPERATINGINSTRUCTIONS FOR CMF PG DIRECTIGNITION GAS BURNERS

For Your Safety Read Before Lighting orOperating.

! WARNING:If you do not follow these instructionsexactly, a fire or explosion may resultcausing property damage, personal in-jury or loss of life.

A. This appliance does not have a pilot. It isequipped with an ignition device whichautomatically lights the burner. Do not tryto light the burner by hand.

B. BEFORE LIGHTING OR OPERATINGsmell all around the appliance area for gas.Be sure to smell next to the floor becausesome gas is heavier than air and will settleon the floor.

WHAT TO DO IF YOU SMELL GAS:• Do not try to light any appliance.• Do not touch any electric switch, do not

use the phone.• Leave the building immediately, then

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

the fire department.

C. Use only your hand to push in and movethe gas control lever. Never use tools. Ifthe lever will not push in by hand, don't tryto repair it, call a qualified service techni-cian. Force or attempted repair may resultin a fire or explosion.

D. Do not use this appliance if any part hasbeen under water. Immediately call aqualified service technician to inspect theappliance and to replace any part of thecontrol system and any gas control whichhas been under water.

E. Should overheating occur, or the gas sup-ply fail to shut off, turn off the manual gasvalve to the appliance.

Operating Instructions for PG DirectIgnition Burner

1. STOP! Read the safety information above.

2. Set the thermostat to OFF or to its lowestsetting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignitiondevice which automatically lights theburner. DO NOT try to light the burner byhand.

5. Turn the latch and open the furnace door.

6. Push in the gas control lever and move toOFF. DO NOT FORCE.

7. Wait ten (10) minutes to clear out any gas.If you then smell gas, STOP! FollowSection B in the safety information above.If you don’t smell gas, go to the next step.

18

8. Move the gas control lever to ON.

9. Close the furnace door and turn the latch.

10. Turn on all electric power to the appliance.

11. Turn the thermostat to ON and set to thedesired setting.

12. If the appliance will not operate after onere-try, follow the instructions in the “ToTurn Off Gas To Appliance” Section belowand call your service technician or gassupplier.

To Turn Off Gas to the Appliance

1. Set the thermostat to OFF or to its lowestsetting.

2. Turn off all electric power to the applianceif service is to be performed.

3. Turn the latch and open the furnace door.

4. Push in the gas control lever and move toOFF. DO NOT FORCE.

5. Close the furnace door and turn the latch.

Checking the Input of the FurnaceRefer to the rating plate on the furnace todetermine the firing rate for your application.Using Table 4, determine the appropriate orificesize for the firing rate and gas being used in yourapplication. Check the burner orifice to ensurethat it is the correct size.

The input of this furnace can be checked usingthe following procedure, which is based onusing a one cubic foot gas meter:

Firing Rate Natural Gas Natural Gas LP Gas LP Gas TimeBurner Input Orifice Time Per Rev.* Orifice Per Rev.**

Designation (BTUH) Number (sec) Number (sec)Gas Gun-65-DI-S 65,000 24 55 43 138Gas Gun-75-DI-S 75,000 20 48 40 120Gas Gun-90-DI-S 90,000 16 40 36 100

* There times are based on natural gas at an average of 1,000 BTU per cubic foot, a burnermanifold pressure of 3.5 in WC, and a meter dial size of 1 cubic foot.

** There times are based on LP gas at an average of 2,500 BTU per cubic foot, a burnermanifold pressure of 3.5 in WC, and a meter dial size of 1 cubic foot.

Table 4. Natural and LP Gas Orifices

1. Shut off all other gas fired appliances,except for any pilots.

2. Start the furnace in heating mode and allowit to run for at least three minutes.

3. Measure the amount of time (in seconds)required for the gas meter to complete onerevolution. Note that one revolution will beequal to one cubic foot of gas.

4. Compare the time measured with theappropriate time listed in Table 4. If the timevaries by more that 5% from the timesshown in the table, then measure the inletand gas valve manifold pressures, usingthe procedure outlined in the “Measuringthe Inlet Supply and Manifold Pressures”section.

5. If both the inlet gas pressure and themanifold pressure are properly set, thencheck the burner orifice to ensure that it isproperly sized. Further gas problemsshould be referred to the local gas supplier.

Measuring the Inlet Gas and ManifoldPressuresFor natural gas installations, the inlet gas linepressure at the gas valve inlet must be between5 in WC and 7 in WC. For LP gas installations,the incoming gas line pressure at the gas valveinlet must be between 11 in WC and 13 in WC.This pressure can be checked at the portlocated on the gas inlet end of the gas valveusing a pressure gauge or U-tube manometer,which must be installed according to themanufacturer’s supplied instructions.

For natural gas installations, the manifoldpressure must be set at 3.5 in WC. For LP gasinstallations, the manifold pressure must be set

19

at 10.0 in WC. This pressure can be checkedat the port located on the gas outlet end of thegas valve using a pressure gauge or U-tubemanometer, which must be installed accordingto the manufacturer’s supplied instructions. Ifthe manifold pressure is not equal to the valvesabove, then it must be adjusted. To adjust themanifold pressure, remove the regulatorconverter from the gas valve, as shown inFigure 16. Then turn the adjusting screwclockwise to increase the pressure orcounterclockwise to reduce the pressure. Oncethe manifold pressure is correctly set, replacethe regulator converter in the same manner asit was removed earlier.

To install a pressure gauge or U-tube manometerin the gas valve:

1. Determine which pressure, the inlet gas ormanifold pressure, you want to measure.

2. With a 3/16” Allen wrench, remove theappropriate tap plug located on the gasvalve. When measuring the inlet gaspressure, remove the tap plug on the inletside of the gas valve. When measuring themanifold pressure, remove the tap plug onthe outlet side of the gas valve.

3. Install a fitting, which has a 1/8” NPT pipethread that is compatible with the pressuregauge or U-tube manometer.

4. Install the pressure gauge or U-tube ma-nometer according to the manufacturer’ssupplied instructions.

5. After measuring the pressure, be sure toremove the pressure gauge or U-tubemanometer from the gas valve and replacethe tap plug. Ensure that the tap plug is tightand not cross-threaded.

Gas Burner ControlsThe gas valve lever can be set to ON or OFF,as shown in Figure 16. When in the ON position,gas flow through the gas valve is allowed whenthe valve is energized electrically. When in theOFF position, gas flow is completely shut off.

Combustion Blower Centrifugal Switch

Figure 16. Natural Gas Configuration

The electric motor for the blower which suppliescombustion air to the burner is equipped with acentrifugal switch wired in series with the burnercontrols. This switch is normally open until thespeed of the blower motor closes it therebypowering the burner controls. The burnercontrols will not function until the blower motoris operating at full speed.

Natural Gas to LP ConversionThis gas fired heating appliance was shippedfrom the factory for use with natural gas. How-ever, the appliance can be converted to be usedwith LP gas. Use the following procedure forgas conversion of the burner.

1. Follow instructions “To Turn Off Gas ToAppliance” earlier in these instructions.

2. Shut off gas supply at meter.

3. Disconnect gas burner electric cord, gaspiping to burner, and thermostat leads.

4. Remove three (3) hexagon nuts holdingburner in place.

5. Disconnect inlet pipe union at burner.

Table 5. Air Shutter Settingfor Different Fuels

Input Natural LP Gas Oil(BTU/H) Gas Setting Setting Setting65,000 3.0 3.0 3.075,000 3.5 3.5 4.090,000 4.0 4.0 3.5

RegulatorConverter

20

6. Disconnect the two wires leading to gascontrol valve.

7. Remove three (3) bolts from U-shapedmanifold plate and orifice assembly.

8. Remove the main orifice and replace it withthe appropriate LP fuel orifice. Refer to therating plate on the furnace to determine thefiring rate for your application. If the firingrate of your furnace has been converted,ensure that the appropriate LP orifice forthe new firing rate is installed. Then, useTable 4 to determine the proper LP orificefor your firing rate.

9. Remove the regulator converter and itsblack cover located on top of the gas valveand invert. (See Figure 16 — For LP, thered ring will be located at the bottom and the“LP” stamping on the converter will appearright side up.)

10. Screw converter back into the regulator,hand tight plus1/8 turn, and replace the black cover ontothe converter top to protect the threads.

11. Reinstall the burner assembly into thefurnace.

12. Reconnect the gas piping and electricalwires to the gas valve.

Figure 17. Oil Pumps

AIR BLEED VALVE

NOZZLEPORT

NOZZLEPORT WEBSTER

SUNTEC

INLET PORT

INLET PORT

INLET PORT

AIR BLEEDVALVE

13. Open the manual shut-off valve and followthe “Operating Instructions” as outlinedpreviously in this manual to put the furnaceinto operation.

Adjusting the BurnerThe air shutter is factory pre-set for installationin a given furnace, as shown in Table 5. Youshould not need to adjust the air shutter settingof the gas gun burner except when convertingthe firing rate of the furnace. For your installation,check to ensure that the air shutter setting iscorrect. It is very important that the combustionair supply be ample without decreasing theefficiency of the burner. An inadequate amountof air can cause carbon monoxide (CO)production. The carbon dioxide (CO2) contentof the flue products should be in the range of8.0% to 9.0% for natural gas and 9.0% to 10.0%for LP gas. The burner should run quietly.For high altitude operation (altitudes greaterthan 2,000 feet), the input should be de-rated by4% for each 1,000 feet above sea level byreducing the orifice size or decreasing themanifold pressure. When decreasing themanifold pressure, the pressure must not beset below 3.2 in WC. If the pressure needs tobe set below 3.2 in WC to achieve the proper de-rate, then change the orifice size and raise themanifold pressure back to 3.5 in WC.

Figure 18. PO Oil Burner Electrode Settings

5/32" GapElectrode

5/16" ABOVE CLNozzle

1/16"

1-1/8" - 65,000 and 75,000 BTU/HR Inputs, FO Head

1-13/32" - 90,000 BTU/HR Input, F3H Head

21

LIGHTING AND OPERATING INSTRUC-TIONS FOR CMF PO OIL BURNERS

Oil burners in this series are factory equippedwith a primary control capable of eitherintermittent or interrupted ignition.

Start-Up Procedure

1. Open all manual shut-off valves in the oilsupply line from the tank to the burner.

2. Turn ON the electrical supply to thefurnace.

3. Set the room thermostat to the desiredtemperature.

Air-Bleed Procedure - Single PipeInstallation

1. Open the door to the furnace.

2. Attach 1/4" I.D. plastic tube over the endof the airbleed valve on the oil pump asshown in Figure 17. Place the other endof the tube in a large container.

3. Pull the door interlock switch out to startthe burner.

4. Turn the airbleed valve open not more than1/2 turn to get a fast flow of oil into thecontainer.

5. To assure continuous operation, use awire to jump terminals T-T (or F-F) on theprimary control while burner is running. Iffurnace is equipped with the HoneywellR7184 primary control, priming oil pumpprocedure is as follows:

a. While the ignition is on, press thereset button for 1/2 second or lessand release the reset button. Thelockout time will be extended to 4minutes.

b. If prime is not established within the4 minutes, the control will lock out.Press the reset button to reset thecontrol and to step “a”.

c. Repeat steps “a” and “b”, if needed,until the pump is fully primed.

6. When oil flow is clear and free of airbubbles, close air-bleed valve and tighten.

(Time to bleed air out will vary dependingon length of oil line, number of bends, etc.)

7. Remove the jumper wire on the primarycontrol.

Oil Burner Shutdown ProcedureSet the room thermostat to “OFF” or itslowest setting.

Flame Adjustment

1. Turn the thermostat to a setting belowroom temperature to start the furnace.

2. Allow the furnace to operate for about ten(10) minutes.

3. Adjust the air shutter setting until 11% CO2with a number zero smoke or less isachieved. Furthermore, the draft over thefire must be at least negative 0.02 in WC.The factory set air shutter settings areshown in Table 5.

Electrode SettingThe electrode setting is carefully set at thefactory. However, during transit, the setting ofthe electrodes may become improper. Beforeattempting to start the oil burner, check thepositioning of the electrodes to ensure that theyare properly positioned, as shown in Figure 18.Improperly adjusted electrodes can result inpoor ignition. Do not permit the electrodes to becloser than ¼” to any grounded surface.

SWITCHING FROM INTERRUPTED TOINTERMITTENT IGNITION CONTROLHoneywell oil primary control can be switchedbetween interrupted and intermittent ignitioncontrol. To switch from interrupted duty (Factoryset) to intermittent duty, remove the ignitor wirefrom the blue control wire. Attach the burnermotor and igniter wire to the orange control wire.Cap and reseal the orange wire. Cap and isolatethe blue control wire. Refer to Figure 13.

FIRING RATE CONVERSION

The rated firing rates of the CMF80 convertiblefurnaces (PO & PG) can be adjusted from thefactory setting of 75,000 BTU/hr. The firing ratecan be changed to either 65,000 BTU/hr or to90,000 BTU/hr using the appropriate certifiedNORDYNE conversion kit installed by aNORDYNE distributor or Service PRO. See theReplacement Parts Listing for the appropriatekit number to order.

22

FURNACE OPERATING SEQUENCE

A. Gas Furnace

1. On a call for heat, the thermostat contactsclose, which applies 24 volts to the “W”terminal.

2. The combustion blower motor energizes.After the motor begins to rotate, thecentrifugal switch, which is located in themotor end cap, closes.

3. A thirty (30) second pre-purge periodbegins, during which the ignition control willinitiate an internal safety start check.

4. Upon passing the safety check, the controlbegins a fifteen (15) second ignitor warm-up period. During this period, the ignitor willwarm to the ignition temperature.

5. The control then applies 24 volts to the gasvalve.

6. The ignitor ignites the gas, and thepresence of flame will be detected usingflame rectification principles.

7. The flame must be detected within a timedtrial ignition period. If the flame is detected,then the ignitor is de-energized. The gasvalve will remain open until the call for heatfrom the thermostat is completed.Conversely, if the flame is not detected,then the control will close the gas valve atthe end of the timed trial ignition period. Thecontrol will then attempt ignition two (2)more times before locking out.

8. The circulating air blower will energizethereafter, when the temperature fanswitch closes.

9. When the thermostat is satisfied, the “W”terminal is de-energized.

10. The gas valve circuit will be de-energized,and the gas valve will close.

11. The circulating air blower will de-energize,when the temperature fan switch opens.

The control will close the gas valve, if thepresence of flame is not or no longer detected.The control will attempt to re-ignite the gas twicebefore locking out. Once in lock-out, the control

can be reset by interrupting the 24 volt power.This can be easily accomplished by setting thethermostat below room temperature for at leastforty five (45) seconds, and then returning it tothe desired setting.

If adjusting the thermostat does not reset theignition control, turn off the power to the appliancefor forty five (45) seconds, and then turn it backon.

NOTE: If the gas control has been replaced orserviced, lighting may not be satisfactory untilair has been purged from the gas line or the gasinput and combustion air have been adjusted.

B. Oil Furnace - Honeywell R7184 Control

1. When a call for heat is initiated, there is a2-6 second delay while the controlperforms a safe start check.

2. The ignition and motor are turned on anda flame should be established within the15-second lockout time.

3. If flame is not sensed within the 15-secondlockout time, the control shuts down onsafety lockout and must be manually reset.If control locks out three times in a row, thecontrol enters restricted lockout. To reset,hold down the reset button for 30 secondsuntil the LED flashes twice.

4. Once flame is established, the ignitionremains on 10 seconds to ensure flamestability. It then turns off. (interruptedignition)

5. The circulating air blower will energizethereafter, the temperature fan switchcloses.

6. The furnace runs until the call for heat issatisfied. Burner is shut down.

7. The circulating air blower will de-energize,when the temperature fan switch opens.

ADJUSTING HEAT DISTRIBUTION

1. Set the room thermostat for the desiredroom temperature.

2. Balance the heat distribution by adjustingthe register openings.

23

SERVICE GUIDE FOR FURNACES WITHPGB POWER BURNER WITH DIRECTIGNITION

! CAUTION:Verify proper operation after servicing.

! IMPORTANT:1. Always disconnect power before ser-

vicing.2. Only persons trained and experienced

in direct ignition systems should ser-vice this equipment.

3. If a condition exists that causes theignition control to go into safetylockout, meter readings must betaken quickly after restart - within trialfor ignition period.

4. Always de-energize the system for atleast 45 seconds before recy-cling for further tests.

5. The ignition control cannot be repaired.If the troubleshooting procedureindicates a malfunction in the con-trol, it must be replaced.

! CAUTION:Label all wires prior to disconnectionwhen servicing controls. Wiring Errorscan cause improper and dangerous op-eration.

A. Burner motor does not run - thermostatcalls for heat.

1. Defective thermostat circuit - bridgeTT connections on burner junctionbox, if burner motor runs, check:

a. Thermostat connectionsb. Thermostat

2. No voltage to burner - plug test lampinto burner plug receptacle, if it doesnot light, check for:

a. Blown fuse, electric supply offb. Door switch not making contactc. Limit switch in open mode

d. Check for clean air filter and properairflow

e. Loose wire connectionsf. Check for tripped manual reset aux-

iliary limit.

3. 120 volts is available to burner - Testlamp does not light. Remove junctionbox cover on burner, check for:

a. Loose wiresb. Defective transformerc. Defective motor

B. Burner motor does not run, no main flame.

1. Defective centrifugal switch

a. Check the operation of centrifugalswitch by removing end bell of theburner motor.

2. Check for gas supply - gas line valveon, control lever on.

3. Check for burner safety lockout. (Re-start burner)

4. Check for 24 volts to ignition control

a. No voltage at purge timer - checkthe centrifugal switch in the com-bustion motor.

b. No voltage to ignition control - checkpurge timer (allow one minute forpurge timer to activate).

c. Check for 120 volts to ignition con-trol. (-Voltmeter at L1 and L2).

C. Ignition control is powered (120v and 24v).Ignitor does not heat up.

1. Remove AMP plug from burner tubereceptacle and check for 120 volts atthe plug during ignition sequence

2. Replace ignition control if 120 volts isnot supplied to AMP plug within 3 min-utes of ignition cycle start.

D. 120 volts is available at AMP plug. Ignitordoes not heat up.

1. Disconnect burner plug from furnacereceptacle.

2. Disconnect AMP plug from burner tubereceptacle and check ignitor circuitthrough receptacle with an ohmmeter.

24

a. Normal ohm reading should be be-tween 40 to 75 ohms.

b. An infinite or zero ohm reading indi-cates a defective ignitor and it mustbe replaced.

3. Check for continuity from ignitor re-ceptacle to burner ground.

4. Check for hairline cracks in ignitor’sinsulating ceramic.

! WARNING:When replacing the ignition control, re-placement control MUST have the safetylockout time. FAILURE TO FOLLOWTHIS WARNING MAY RESULT IN AN EX-PLOSION.

E. Main flame ignites but burner locks out.

1. Ignition control is not properlygrounded.

2. Defective ignition control.

3. Improper gas pressure or burner airadjustment is not allowing flame tocontact ignitor tip for flame provingrectification.

F. 24 volts supplied to gas valve during igni-tion but no main gas flow.

1. Gas valve may be defective. Replaceif necessary.

2. Gas piping may be plugged. Check foradequate gas supply to gas valve atunion.

G. Burner operates, insufficient heat

1. Check the thermostat for proper set-ting and location. The thermostatshould not be located where it will beaffected by another heat source.(Lamps, ovens, sunlight, etc.)

2. Check for clean air filters and properair flow.

3. Check burner for proper gas firingrate.

4. Be sure unit is not undersized for itsthermal load.

5. Check thermostat anticipator. (0.9amps)

H. Burner does not shut off. (Note: Burnerwill stop when the door switch is open. Withthe door open, secure the door switch inthe closed position by depressing theswitch. The means for securing the doorswitch must be removed once this testinghas been completed.

1. Disconnect the thermostat wires fromTT connections on the burner junctionbox. If the burner shuts off, check for:

a. Short circuit in the thermostat wires.

b. Defective thermostat.

I. Burner flame without motor running — gasvalve is stuck in open position — Replacethe control, burner and heat exchangermay need cleaning.

J. Noisy fire — Readjust combustion air toreduce volume of air being drawn into theburner. (Caution — See “Adjusting theBurner” or “Flame Adjustment” sections)

K. High Gas Bills

1. Check the combustion air adjustment.

2. Be sure the proper size orifice is beingused.

3. Be sure the return air filter is clean.

4. Be sure the home is insulated, win-dows and doors fit tightly, and thereare no air leaks in the heating ducts.

5. Check room thermostat to be sure thesetting is not higher than necessary.Low humidity requires higher tempera-tures for comfort. Perhaps humidityshould be increased.

L. Circulation blower will not operate eventhough the burner operates.

1. Turn on the manual blower switch, ifthe blower operates, check the fanswitch.

2. Check the wiring to the motor.

3. Check for a burned out motor.

25

Control Module Status IndicatorA. Gas Furnace

1. One flash - the control is in lock-outbecause the inducer centrifugal switchis or was stuck closed.

2. Two flashes - the control is in lockoutbecause the signal was not receivedby the control that the inducercentrifugal switch had closed withinthe time.

3. Three flashes - the control is in lockoutbecause a failed ignition attempt, a gasvalve error, or a false flame sensedduring the warm up period. A falseflame condition exists when the flamesensor senses a flame without a flamepresent. If a false flame has beensensed, the control will only return tonormal operation after the false flamecondition is no longer present.

4. Four flashes - the control is in lockoutdue to a failure within the control board.

B. Oil FurnaceThe indicator light on the oil primary controlprovides lockout,recycle, and cad cell indications as follows:

1. Flashing ½ second on, ½ second off -system is locked out or in restrictedmode.

2. Flashing 2 seconds on, 2 seconds off- control is in recycle mode.

3. Indicator light is on - cad cell is sensingflame.

4. Indicator light is off - cad cell is notsensing flame.

TROUBLESHOOTING- Honeywell R7184Primary Control

The following service procedures will help youbecome familiar with the R7184 oil primarycontrol. For further service information, pleaserefer to Honeywell R7184 Installation Instruc-tions, 69-1233 and Beckett Technician's QuickReference Guide, RWB 61351.

A. Burner does not start with a call for heat.

1. Check the electrical supply to thefurnace.

2. Be sure the furnace door switch is inthe on position.

3. Check for line voltage at the oil primarycontrol. Thevoltage should be 115 VAC.

4. Check indicator light with burner off, nocall for heat (noflame).

a. If indicator light is on, the cad cellis seeing stray light or the cad cellor controller is defective.

b. If Indicator light is off, go to step 5.

c. If flashing, reset as B 1.

5. Jumper T to T terminals on primarycontrol.

a. If burner starts, check thermostator limit wiringconnections.

b. If burner does not start, turn offpower. Check allwiring connections.

c. If burner does not start, replaceR7184 control.

B. Burner starts, then locks out on safetywith indicator light flashing at ½second on, ½ second off.

1. Reset primary control.

To reset the control from lockout, thebutton needs only to be pressed andreleased. If it is in restricted mode, thebutton should be held in for 30seconds (until the light flashes twice,or until the light stops flashing onearlier models).

Note: Restricted Mode: If the controllocks out three times in a row withouta complete heat cycle betweenattempts, the lockout becomesrestricted mode.

26

Table 6. Cad Cell Resistance when sensing flame

Led Flashes Cad Cell Resistance in Ohms

0 - 400

400 - 800

800 - 1,600

>1600

1

2

3

4

a. If indicator light stops flashing andignition remains off, primary con-trol could be defective. If linevoltage is present at the ignitorterminals, but there is no ignition,the ignitor is probably defective andneeds to be replaced.

b. If indicator light stops flashing, burnerturns on, but control locks out again,check cad cell. If cad cell is Okay,replace primary control.

c. If Indicator light continues to flash at½ second on. ½ second off, verifythat control is not in restricted mode,if restricted mode, reset it. If not inrestricted mode, replace R7184.

d. If indicator light stays off while theflame is on, check cad cell sightingfor view of flame.

e. If burner locks out, check cad cellresistance.

f. If burner keeps running, system isOkay.

g. If indicator light is off, check cadcell assembly after disconnectingline voltage power.

C. Burner will not start, and indicatorlight is flashing at 2 second on, 2second off.

Hold the reset button down for 1-2seconds. If indicator light continues toflash, wait for 60-70 seconds. If it stillcontinues to flash, replace the primarycontrol.

D. To Check Cad Cell Resistance.

Press and release the button during therun mode. The light will flash to indicate thecad cell resistance. For proper burneroperation, it is important that the cad cellresistance reading is not over 1600 Ohms.For cad cell resistance, see Table 6.

¢708062¬¤708062

O’Fallon, MO

708062B (Replaces 708062A)

Specifications and illustrations subject to changewithout notice and without incurring obligations.

Printed in U.S.A. (8/03)

INSTALLER: Please leavethese installation instructionswith the homeowner.

EFFICIENCYRATINGCERTIFIED

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