MAYTAG MG2R Single Stage Condensing Gas Furnace User Manual

MAYTAG MG2R Single-Stage Condensing Gas Furnace

Product Information

The MG2R Downflow and MG2S Downflow are condensing gas furnaces with a single- stage and two-stage operation, respectively. Both models have an Annual Fuel Utilization Efficiency (AFUE) rating of 95% or higher. These furnaces are designed for use in manufactured homes, recreational vehicles, park models, and manufactured buildings.

User’s Manual

Please read this user manual thoroughly before operating or maintaining the furnace. Familiarize yourself with the capabilities and use of the appliance. Pay close attention to all safety warnings and special notes highlighted in the manual. Keep this manual easily accessible for future reference. If you encounter any problems, refer to the instructions and follow the recommendations provided. If the issue persists, contact your servicing contractor. It is important to note that only licensed installation and service personnel should handle the installation and servicing of this equipment. Some local codes may require licensed professionals to handle the installation and service of this type of equipment. Improper service, adjustment, or maintenance can result in dangerous conditions such as explosion, fire, electrical shock, or personal injury.

Important Safety Information

This manual contains important safety information, and safety markings are used throughout to indicate the level of seriousness. Please take these warnings seriously and do not ignore them.

WARNING: This indicates a potentially hazardous situation that could result in personal injury or death if not avoided.

CAUTION: This indicates a potentially hazardous situation that may result in minor or moderate injury or property damage if not avoided.

Flood Damage

WARNING: Do not use the furnace if any part has been under water due to flood damage. Using a flood-damaged furnace can lead to fire or explosion. Contact a qualified service agency to inspect the furnace and replace any wet gas controls, control system parts, electrical parts, or the furnace itself if necessary. Installation and service should be performed by a qualified installer, service agency, or the gas supplier.

Gas Piping and Shutoff Valves

WARNING: All gas piping and shutoff valves must be installed in compliance with local codes and utility regulations by licensed installers. Do not attempt to modify or tap into existing gas lines yourself. Failure to follow these safety warnings exactly may result in serious injury, death, or property damage.

Extended Shutdown

WARNING: If the furnace needs to be shut down for an extended period of time, turn off both the gas and electrical power. Always turn off both the gas and electrical power before performing any service or maintenance on the furnace. Refer to the shut-down instructions on page 7 if the gas supply to the unit must be shut off.

For Furnaces Installed in: Manufactured Homes, Recreational Vehicles, Park Models, & Manufactured Buildings

IMPORTANT! Please read all information in this manual thoroughly and become familiar with the capabilities and use of your appliance before attempting to operate or maintain this unit. Pay attention to all safety warnings and any other special notes highlighted in the manual.
Keep this literature where you have easy access to it in the future. If a problem occurs, check the instructions and follow the recommendations given. If these suggestions don’t eliminate your problem, call your servicing contractor. Under no circumstances should the appliance owner attempt to install and/or service this equipment.
Some local codes require licensed installation/service personnel for this type of equipment. Improper service, adjustment, or maintenance may cause an explosion, fire, electrical shock or other hazardous conditions which may result in personal injury or property damage.

Front Return without Coil Box Front Return with Coil Box

Top Return with Coil Box

Top Return without Coil Box

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.

• 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 neighbor’s phone. Follow the gas suppliers’ instructions.

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

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

IMPORTANT SAFETY INFORMATION

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. CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

WARNING:
To avoid possible equipment damage, fire, or personal injury, the following instructions must be observed regarding unit maintenance and operational procedures.

• To achieve optimum performance and minimize equipment failure, it is recommended that periodic maintenance be performed on this unit. The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools. Please consult your dealer for maintenance information and availability of maintenance contracts.
• The area around the gas furnace (Figure 1, (page 4)) and the vicinity of any other gas appliances must be kept clear and free  of combustible materials, gasoline, and other flammable vaporsand liquids. Do not store or use flammable items such as paint, varnish, or strippers in the vicinity of the unit.
• Do not use the area around the unit as a storage area. This area must be kept clean and clear of loose or exposed insulation materials. Examine the unit’s area when it is installed or when insulation is added, since some insulation materials may be combustible.

FLOOD DAMAGE

WARNING:
Do not use this furnace if any part has been underwater. A flood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and to replace all gas controls, control system parts, electrical parts that have been wet or the furnace if deemed necessary.

• Familiarize yourself with the controls that shut off the gas and electrical power to the unit.

IMPORTANT NOTE
If the unit needs to be shut down for an extended period of time, turn off both the gas and electrical power. For your  safety always turn off both the gas and electrical power before performing service or maintenance on the furnace. If the gas supply to the unit must be shut off, refer to the shutdown instructions on page 7.

GAS SUPPLY & PIPING
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 neighbor’s phone. Follow the gas suppliers’ instructions.
• If you cannot reach your gas supplier, call the fire department.

Installation and service must be performed by a qualified installer, service agency or gas supplier.

WARNING:
All gas piping and shutoff valves must be installed in compliance with local codes and utility regulations by licensed installers. DO NOT attempt to modify, or tap into existing gas lines yourself. Fire or explosion may result causing property damage, personal injury or loss of life. Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

WARNING:
The furnace was shipped from the factory equipped to operate on natural gas. Conversion to LP/propane gas must be performed by a licensed HVAC technician using a factory-supplied conversion kit. Failure to use the proper conversion kit can cause fire, explosion, property damage, carbon monoxide poisoning, personal injury, or death.

This furnace does not have a pilot. It is equipped with an ignition device that automatically lights the burner. DO NOT light the burner by hand.

IMPORTANT NOTE
Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply!

VENTING SYSTEM
WARNING:
CARBON-MONOXIDE POISONING HAZARD
Failure to folow instructions could result in severe personal injury or death due to carbon monoxide poisoning if combustion products infiltrate into the building.
Check that all openings in the outside wall around the vent (and air intake) pipe(s) are sealed to prevent infiltration of combustion products into the building. Check that furnace vent (and air intake) terminal(s) are not obstructed in any way during all seasons.

WARNING:
It is extremely important that the furnace receives an unobstructed flow of clean, fresh air to properly burn the fuel gas. If this flow of air is restricted, the partially burned combustion gases may create dangerous amounts of carbon monoxide – a colorless, odorless gas that is a deadly poison that can cause personal injury or death. This could create the production of excessive amounts of Carbon Monoxide – a colorless, odorless gas that is a deadly poison that could result in serious personal injury or death.
Do not block any openings that are supplying fresh air to the room or closet in which the furnace is located. Your furnace obtains its air through a pipe to the outdoors, do not allow the inlet of the pipe to become blocked.

• For proper and safe operation, this furnace requires unrestricted airflow for combustion and ventilation. Do not block or obstruct air openings on the furnace, air openings around the furnace area or the spacings around the furnace.
• Air openings on the top or front of the furnace and openings in closet doors or walls must never be restricted. If the furnace is operated without adequate air for combustion, the flame roll-out switch will open, turning off the gas supply to the burners. This indicates that a serious problem with the burners has occurred and must be corrected immediately. Only a licensed HVAC technician can reset this switch.
• Your furnace and its venting system should be inspected annually by a licensed HVAC technician. The filter should be inspected at least once a month. See the Maintenance Information on page 6.
• Before you remodel a room near the furnace, consult with a local code official or the National Fuel Gas Code to make sure you will be in compliance with supplying adequate air for combustion. By erecting new walls, it is sometimes possible to inadvertently restrict the furnace’s air supply. You can find more information about supplying combustion air in the NFGC, which is available at many libraries.

CLEARANCES TO COMBUSTIBLES

WARNING:
Do not place combustible materials on or against the furnace cabinet or vent pipe. The area around the furnace must be kept clear and free of combustible materials, gasoline and other flammable vapors and  liquids. A fire or explosion may result causing propertydamage, personal injury or loss of life. Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

The furnace is designed to have certain clearances to combustible items such as wood, paper, etc. Some types of insulation are combustible. If your furnace is installed in an attic, near unfinished walls, or in other insulated space, keep area surrounding the furnace free of insulating material. See Figure 1 below.

CLEARANCES TO COMBUSTIBLE MATERIALS

Sides………………….. 0 Inches Front…………………….1 Inch
Top………………………6 Inches Rear……………………. 0 Inches
Vent……………………. 0 Inches

Minimum Clearances

SHUTTING DOWN THE FURNACE
If you need to shut down your furnace for service or maintenance, shut off the gas valve to the furnace before shutting off the electrical service. Remove the door panel from the front of the furnace and turn the gas valve OFF. See Figure 2, (page 7). Additional instructions for shutting down the furnace can be found on page 7. If your installation has a manual gas shutoff valve on the gas supply pipe, shut this off, then shut off the electricity to the furnace.

GENERAL INFORMATION

ABOUT THE FURNACE
• This furnace has been tested for capacity and efficiency in accordance with AHRI Standards and will provide many years of safe and dependable comfort, providing it is properly installed and maintained. With regular maintenance, this unit will operate satisfactorily year after year. Abuse, improper use, and/or improper maintenance can shorten the life of the appliance and create unsafe hazards.
• This furnace is designed to fulfill the requirements of being classified as a Category IV furnace. This classification is related to the furnace’s Annual Fuel Utilization Efficiency (AFUE) rating, the percentage of fuel that is converted into usable heating energy.
• Category IV furnaces typically have an AFUE rating over 90% and are mainly vented through plastic PVC pipe.

AIR FILTERS
WARNING:
Never operate the furnace without a filter in place. Accumulating dust in the return air can build up on internal components, resulting in loss of efficiency, equipment damage, and possible fire.

• An air filter is supplied with the furnace as shipped from the factory.
• The furnace should always have a clean filter. If the filter becomes dirty, it should be cleaned or replaced. The filter is installed over the return air grille of the door inside the furnace cabinet.
• New or newly renovated homes may require more frequent changing or cleaning until the construction dust has minimized. Filters designed to remove smaller particles such as pollen, may require additional maintenance.

THERMOSTAT

• Single-stage gas furnaces (MG2R series) are designed to be controlled by a conventional single-stage thermostat. Two-stage gas furnaces (MG2S series) will perform best with a conventional two-stage thermostat. However, it is possible to control the MG2S furnace with a single-stage thermostat. Consult with your installer about which type is best for your installation. Both thermostats are commonly available at your local building supply store.
• The thermostat’s wiring must comply with the current provisions of the NEC (ANSI/NFPA 70) and with applicable local codes having jurisdiction. Thermostat connections should be made according to the instructions supplied with the thermostat and the indoor equipment.
• The thermostat should be mounted about 5 feet above the floor on an inside wall and not on an outside wall or other location where its operation may be adversely affected by radiant heat from fireplaces, sunlight, or lighting fixtures, and convective heat from warm air registers or electrical appliances.
• Thermostat styles vary. Please refer to the thermostat manufacturer’s User Manual for detailed programming instructions.

FURNACE IN A SMALL ROOM OR CLOSET
If a furnace is installed in a relatively small utility room or closet, the installation needs openings in the walls or door to let return air  in. Make sure that these openings remain unobstructed. Do notmodify these openings in any way without consulting a licensed HVAC technician.

SOURCES OF CORROSION
It is known that certain common household chemicals can cause heat exchanger corrosion if the vapors are pulled into the furnace’s burners The following is a list of chemicals that should not be used or stored near the furnace.
Do not store these chemicals near the furnace:

• Gasoline/Kerosene
• Permanent wave solutions
• Chlorinated waxes and cleaners
• Chlorine-based swimming pool chemicals
• Water softening chemicals
• De-icing salts or chemicals
• Carbon tetrachloride
• Halogen type refrigerants
• Cleaning solvents (perchloroethylene)
• Printing inks, paint removers, varnishes, etc.
• Hydrochloric acid
• Cement and glues
• Antistatic fabric softeners
• Masonry acid-washing materials

WARRANTY INFORMATION
A warranty certificate with full details is included with the equipment. Carefully review these responsibilities with your dealer or service company. The manufacturer will not be responsible for any costs found necessary to correct problems due to improper setup, improper installation, adjustments, improper operating procedure on the part of the user, Some specific examples of service calls which are not included in the limited warranty are:

• Correcting wiring problems in the electrical circuit supplying the equipment.
• Resetting circuit breakers or other switches.
• Adjusting or calibrating of thermostat.

MAINTENANCE INFORMATION

Proper maintenance is important to achieve optimum performance from the furnace. This equipment should be inspected annually by a licensed HVAC technician. Table 1, (page 7) contains suggested inspections and frequency of maintenance. Routine maintenance should include the following:

BLOWER & FILTER

• Never operate the furnace without a filter in place. Dust and lint can build up on internal components, resulting in loss of efficiency, equipment damage, and possible fire.
• Keep air filters cleaned. Filters should be changed or cleaned monthly during the heating/cooling season. Clean or replace filter to maintain proper airflow and achieve maximum efficiency. Newly built or renovated homes may require more frequent changing until the construction dust has minimized. Filters designed to remove smaller particles such as pollen, may require additional maintenance.
• It is recommended that the blower compartment be cleaned of dirt or lint that may have accumulated in the compartment or on the blower and motor as part of the annual inspection.

CONDENSATE DRAINAGE

• This furnace produces liquid condensate which is slightly acidic. The vent pipe must be sloped upwards away from the furnace to properly drain the water back into the condensate disposal system.
• Condensate drain tubes must maintain a downward slope to ensure proper drainage. Periodically inspect the condensate drain tube for proper drainage. Also, do not place heavy objects on the tubing that restricts the flow of condensate.

FURNACE & AIR DUCTS

• Homeowners should perform frequent visual inspections of the furnace for obvious signs of deterioration. The furnace should be sound without sagging, cracks gaps, etc around the base. The return air duct connection(s) is secured and sealed to the furnace cabinet and terminates outside the area containing the furnace.Any signs of damage or loose connections should be repaired by a qualified HVAC technician.
• Furniture and drapery should be arranged so that the supply air registers and return grilles are not obstructed.

VENTING SYSTEM
• For proper and safe operation, the furnace needs air for combustion and ventilation. Do Not block or obstruct air openings on the furnace, or any air openings where the furnace may be installed, including any surrounding spaces.
• Direct vent furnaces pull combustion air from the outdoors and vent combustion products back outside. Combustion air coming from the outside needs to be clean of chemicals that can cause corrosion, such as pool chlorinating products.
• Vent pipe must slope upwards and be physically sound without holes or corrosion. Any corroded section of vent pipe must be replaced, and any obstruction or blockage must be removed by a licensed HVAC technician.
• Flue passageways, the vent system, and the burners should be inspected and cleaned (if required) by a licensed HVAC technician annually to ensure continued safe operation.

TROUBLESHOOTING

the furnace fails to operate check the following:

1. Is the thermostat setting correct?
2. Is the On / OFF switch (inside the blower compartment) turned on? See Figure 3, (page 8).
3. Is the circuit breaker tripped?
4. Is the gas turned on at the manual shutoff?
5. Is the filter dirty or clogged?

If the furnace still doesn’t operate, contact a licensed HVAC technician.

MAINTENANCE ITEM

| FREQUENCY OF MAINTENANCE
---|---
BEGINNING OF EACH HEATING SEASON| END OF EACH HEATING SEASON|

MONTHLY

Verify furnace area is free of combustible materials| X| X| X
Verify combustion and ventilation air is not restricted| X| X| X
Verify no signs of physical deterioration of the furnace| X| X| X
Verify no obstructions or restrictions in vent or chimney| X| X|
Verify no holes or cracks in vent pipe| X| X|
Verify no corrosion in vent pipe| X| X|
Verify the horizontal vent pipes slope upwards away from the furnace| X| X|
Clean or replace filter(s)|  |  | X
MAINTENANCE ITEMS BELOW SHOULD BE PERFOMED BY QUALIFIED SERVICE PERSON.
Verify burner flame| X|  |
Clean blower compartment| X|  |
Clean burner assembly| X|  |
Clean condensate collection & disposal system (if applicable)| X|  |

Table 1. Maintenance Table

STARTUP & SHUTDOWN

STARTING THE FURNACE

1. Make sure the filter is clean and properly installed.

2. Make sure the vent system is properly installed.

3. Set the thermostat to the lowest setting.

4. Close the manual gas valve outside the furnace.

5. Turn off all electric to the furnace.

6. Remove the door from the burner compartment.

7. Set the gas valve ON/OFF knob / switch to the OFF position.
   See Figure 2 for gas valve type and knob / switch location.

8. Wait 5 minutes. If there is any smell of gas, see WHAT TO DO
   IF YOU SMELL GAS on page 1.

9. Set the gas valve ON/OFF knob to the ON position.

10. Turn on all electric to the furnace, including the ON/ OFF switch.

11. Open the manual gas valve.

12. Turn the thermostat back up to force ignition.

13. Observe operation, including burners. If burners fail to ignite, call a licensed HVAC technician.

14. Replace the door on the burner compartment

SHUTTING DOWN THE FURNACE

If you need to shut down your furnace for service or maintenance, follow these steps:

1. Set the thermostat to the lowest setting.

2. Close the manual gas valve outside the furnace.

3. Turn electric to the furnace off.

4. Open the door to the burner compartment.

5. Set the gas valve ON/OFF knob / switch to the OFF position.
   See Figure 2 for gas valve type and knob / switch location.

6. Set the ON / OFF switch to off.

7. Replace the door on the burner Compartment.

FURNACE COMPONENTS

The furnace components shown in Figure 3 will help identify and locate various parts of the furnace. The component you need to familiarize yourself with is the gas valve. You will use this to turn the furnace on and off. There are no user serviceable parts. All repairs must be done by a licensed HVAC technician .

Specifications & illustrations subject to change without notice or incurring obligations (02/22). O’Fallon, MO, © Nortek Global HVAC LLC 2022. All Rights Reserved.

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