Portions of the text and tables are reprinted from NFPA 54 /ANSI Z223.1−2012, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washing-

ton, DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI, on the referenced subject, which is represented only by the standard in its entirety.

Printed in U.S.A.

80% Single Stage, ECM Motor

Category I, Gas Furnace

Safety Labeling and Signal Words

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R8MXL

Signal Words in Manuals

The signal word WARNING is used throughout this manual in

the following manner:

The signal word CAUTION is used throughout this manual in

the following manner:

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures

or product labels.

Safety−alert symbol

When you see this symbol on the unit and in instructions or manu-

als, be alert to the potential for personal injury.

PERSONAL INJURY, AND/OR PROPERTY

DAMAGE HAZARD

Failure to carefully read and follow this warning could

result in equipment malfunction, property damage,

personal injury and/or death.

Installation or repairs made by unqualified persons

could result in equipment malfunction, property

damage, personal injury and/or death.

The information contained in this manual is intended for

use by a qualified service technician familiar with safety

procedures and equipped with proper tools and test

instruments.

Installation must conform with local building codes and

with the Natural Fuel Gas Code (NFCG) NFPA

54/ANSI Z223.1

INSTALLER: Affix these instructions on or adjacent to the furnace.

CONSUMER: Retain these instructions for future reference.

WARNING

CAUTION

Use of the AHRI Certified TM Mark indic-

ates a manufacturer's participation in the

program. For verification of certification for

individual products, go to www.ahridirect-

ory.org .

WARNING

441 01 6100 01 2/18/2015

Table of Contents

Summary of Contents for International comfort products R8MXL

Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS 80% Single Stage, ECM Motor Category I, Gas Furnace R8MXL These instructions must be read and understood completely before attempting installation. Safety Labeling and Signal Words DANGER, WARNING, CAUTION, and NOTE Signal Words in Manuals The signal words DANGER, WARNING, CAUTION, and NOTE...
Page 2 Figure 1 − Dimensional Drawing NOTES: 1. Two additional 7/8−in. (22 mm) diameter holes are located in the top plate. 2. Minimum return−air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a.
Page 3: Safety Considerations
SAFETY CONSIDERATIONS CAUTION WARNING CUT HAZARD Failure to follow this caution may result in personal FIRE, EXPLOSION, ELECTRICAL SHOCK, AND injury. CARBON MONOXIDE POISONING HAZARD Sheet metal parts may have sharp edges or burrs. Failure to follow this warning could result in dangerous Use care and wear appropriate protective clothing, operation, serious injury, death, or property damage.
Page 4: Codes And Standards
INTRODUCTION (16_C)db or intermittent operation down to 55_F (13_C) db such as when used with a night setback thermostat. R8MXN 4−way multipoise Category I fan−assisted furnace is Return−air temperature must not exceed 80_F (27_C) db. CSA design−certified. A Category I fan−assisted furnace is Failure to follow these return−air temperature limits may affect an appliance equipped with an integral mechanical means to reliability of heat exchangers, motors, and controls.
Page 5: Combustion And Ventilation Air
ELECTROSTATIC DISCHARGE (ESD) Figure 3 − Return Air Temperature PRECAUTIONS PROCEDURE CAUTION 80_F/27_C FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure. Electrostatic discharge affect electronic components. Follow Electrostatic Discharge Precautions Procedure listed below during furnace installation and servicing to protect the furnace 60_F/16_C electronic control.
Page 6: Location
Figure 4 − Multipoise Orientations THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE...
Page 7 All fuel−burning equipment must be supplied with air for fuel CAUTION combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the PERSONAL INJURY AND/OR PROPERTY return−air duct to prevent pulling air from the burner area and DAMAGE HAZARD from draft safeguard opening.
Page 8: Location Relative To Cooling Equipment
Table 3 – Minimum Space volumes for 100% combustion, Ventilation, and Dilution from Indoors OTHER THAN FAN−ASSISTED TOTAL FAN−ASSISTED TOTAL (1,000’S BTUH GAS INPUT RATE (1,000’S BTUH GAS INPUT RATE) Space Volume (ft. 0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 0.50...
Page 9 c. TWO HORIZONTAL DUCTS require 1 square inch of WARNING free area per 2,000 Btuh (1,100 mm /kW) of combined input for all gas appliances in the space per Figure 7 and Table 2. CARBON MONOXIDE POISONING HAZARD d. TWO OPENINGS OR VERTICAL DUCTS require 1 Failure to follow this warning could result in death square inch of free area per 4,000 Btuh (550 mm /kW)
Page 10 of air openings shall be at least 3 in. (80 mm). (See 2. Outdoor openings shall be located as required in the Figure 8) Outdoor Combustion Air Method mentioned previ- ously and, c. Combining space on different floor levels. The volumes of spaces on different floor levels shall be 3.
Page 11 2. For each leg, install nut on bolt and then install bolt and Figure 11 − Floor and Plenum Opening Dimensions nut in hole. (Install flat washer if desired.) 3. Install another nut on other side of furnace base. (In- stall flat washer if desired.) Figure 10 −...
Page 12: Opening Dimensions
Table 4 – Opening Dimensions − In. (mm) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications on Combustible or Noncombustible Flooring 12−11/16 21−5/8 13−5/16 22−1/4 (subbase not required) (322) (549) (338) (565) Downflow Applications on Noncombustible Flooring 12−9/16 13−3/16 19−5/8 (subbase not required)
Page 13: Air Ducts
2. Rotate bottom filler panel downward to release holding NOTE: Flexible connections should be used between tabs. ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be 3. Remove bottom closure panel. insulated and sealed to enhance system performance. When 4.
Page 14 Figure 14 − Duct Flanges UPFLOW DOWNFLOW HORIZONTAL 90 90 120 120 120 A02020 Figure 15 − Horizontal Unit Suspension " (6mm) THREADED ROD 4 REQ. OUTER DOOR A S SEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x "...
Page 15 Figure 16 − Horizontal Suspension with Straps METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES. METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS...
Page 16: Gas Piping
furnace casing as shown in Figure 20 and Figure 22. Bypass Refer to Table 6 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all humidifier may be attached into unused return air side of the gas piping with appropriate straps, hangers, etc.
Page 17 Table 5 – Air Delivery − CFM (With Filter)* Test Airflow Delivery @ Various External Static Pressures WIRE- (in. w.c.) LEAD UNIT SIZE SPEED COLOR Gray 1230 1190 1155 1120 1080 1045 1010 Yellow Orange 0451412 Blue −− Gray 1185 1140 1095 1055...
Page 18 Figure 20 − Upflow Return Air Configurations and Restrictions 5 TONS AND GREATER * * 2000 CFM AND GREATER AT .6 ESP HI COOLING SPEED Figure 21 − Downflow Return Air Configurations and Restrictions 5 TONS AND GREATER * * 2000 CFM AND GREATER AT .6 ESP HI COOLING SPEED Figure 22 −...
Page 19: Electrical Connections
Table 7 – Electrical Data Operating Voltage* Range Volts− Minimum Maximum Maximum FURNACE Maxi- Mini- Hertz− Maximum Unit Wire Size Wire Length‡ Fuse or CKT MODEL Phase Unit Amps Ampacity# ft (m) BKR† Amps 0451412 115-60-1 14.0 47.0 (14.3) 15.0 0701712 115-60-1 14.0...
Page 20 NOTE: The J−Box cover need not be removed from the Figure 23 − Relocating J−Box J−Box in order to move the J−Box. Do NOT remove green ground screw inside J−Box. 2. Cut wire tie on loop in furnace wires attached to J−box. FACTORY INSTALLED 3.
Page 21 POWER CORD INSTALLATION IN FURNACE J−BOX ACCESSORIES NOTE: Power cords must be able to handle the electrical 1. Electronic Air Cleaner (EAC) requirements listed in Table 7. Refer to power cord Connect an accessory Electronic Air Cleaner (if used) manufacturer’s listings. using 1/4−in female quick connect terminals to the two 1.
Page 22 Figure 25 − Furnace Control HEAT J2 JUMPER OFF DELAY TWINNING AND/OR COMPONENT TEST TERMINAL 24 V THERMOSTAT TERMINALS HUMIDIFIER TERMINAL 3 AMP FUSE (24 VAC 0.5 AMP MAX) TRANSFORMER 24 VAC CONNECTIONS SEC 2 SEC 1 LED OPERATION & DIAGNOSTIC LIGHT LOW VOLTAGE MAIN HARNESS CONNECTOR...
Page 23: Venting
VENTING GENERAL VENTING REQUIREMENTS The furnace shall be connected to a listed factory built Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National chimney or vent, or a clay−tile lined masonry or concrete Fuel Gas Code ANSI Z223.1−2012/NFPA 54−2012 (NFGC), chimney.
Page 24 4. The input rating of each space heating appliance is can cause low vent gas temperature and potential for greater than the minimum input rating given in Table 9 condensation problems. for the local 99% Winter Design Temperature. Chim- 4. Set the thermostat heat anticipator or cycle rate to re- neys having internal areas greater than 38 square duce short cycling.
Page 25 ADDITIONAL VENTING REQUIREMENTS is used, fasten the flue extension to the vent elbow with at least two field−supplied, corrosion−resistant, sheet metal A 4” (101 mm) round vent elbow is supplied with the furnace. screws located 180_ apart. Fasten the vent connector to the A 5−inch (127 mm) or 6−...
Page 26 Figure 27 − Chimney Inspection Chart 441 01 6100 01 Specifications are subject to change without notice.
Page 27 The horizontal portion of the venting system shall slope CAUTION upwards not less than 1/4−in. per linear ft. (21 mm/M) from the furnace to the vent and shall be rigidly supported every 5 ft. (2 M) or less with metal hangers or straps to ensure there BURN HAZARD is no movement after installation.
Page 28 Figure 30 − Downflow Application−Vent Elbow Up then Figure 32 − Downflow Application−Vent Elbow Left then Left SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,6,7,8,9 on the page following these figures A03210 A03207 Figure 31 − Downflow Application−Vent Elbow Up Figure 33 −...
Page 29 Figure 34 − Horizontal Left Application−Vent Elbow Left Figure 38 − Horizontal Right Application−Vent Elbow Left then Up SEE NOTES: 1,2,4,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,7,8,9 on the page A03213 Figure 35 − Horizontal Left Application−Vent Elbow Right following these figures then Up A03219...
Page 30: Start−Up, Adjustment, And Safety Check
Step 2 —Start−Up Procedures 5. Four−inch single−wall (26 ga. min.) vent must be used inside furnace casing and when the Downflow Vent Guard Kit is used external to the furnace. WARNING 6. Accessory Downflow Vent Guard Kit, required in downflow installations with lower vent configuration. FIRE AND EXPLOSION HAZARD 7.
Page 31 Step 3 —Adjustments Table 10 – Altitude Derate Multiplier for U.S.A. WARNING ALTITUDE PERCENT DERATE (FT. / M) MULTIPLIER DERATE FACTOR* FIRE HAZARD 0–2000 (0−610) 1.00 Failure to follow this warning could result in injury, 2001–3000 (610−914) 8–12 0.90 death and/or property damage. 3001–4000 (914−1219) 12–16 0.86...
Page 32 If clocked rate does not match required input from Step 1, Figure 41 − Gas Control Valve increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct input is achieved. Reinstall regulator seal cap on gas valve.
Page 33 6. Set thermostat heat anticipator. h. Re−install vent connector. a. Mechanical thermostat − Set thermostat heat anticip- NOTE: Should switch remain open longer than 3 minutes, ator to match the amp. draw of the electrical compon- furnace control board will lockout the furnace for 3 hours. To ents in the R−W circuit.
Page 34 Table 11 – Gas Rate (Cu Ft./Hr.) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 REVOLUTION FOR 1 REVOLUTION 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. Cu Ft. 1800 1636 1500...
Page 35 Table 13 – Orifice Size* and Manifold Pressure (in. w.c.) for Gas Input Rate A10180 441 01 6100 01 Specifications are subject to change without notice.
Page 36 Table 13 − Orifice Size* and Manifold Pressure (in. w.c.) for Gas Input Rate (CONT) A10180A 441 01 6100 01 Specifications are subject to change without notice.
Page 37 Table 14 – Orifice Size* And Manifold Pressure (in. w.c.) For Gas Input Rate A10181 441 01 6100 01 Specifications are subject to change without notice.
Page 38 Table 14− Orifice Size* And Manifold Pressure (in. w.c.) For Gas Input Rate (CONT) A10181A Figure 44 − Service Label 441 01 6100 01 Specifications are subject to change without notice.
Page 39: Service And Maintenance Procedures
SERVICE AND MAINTENANCE ELECTRICAL CONTROLS AND WIRING PROCEDURES WARNING Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations ELECTRICAL OPERATION HAZARD must be performed by trained service personnel. A qualified ser- Failure to follow this warning could result in personal vice person should inspect the furnace once a year.
Page 40 For continuing high performance and to minimize possible BLOWER MOTOR AND WHEEL equipment failure, periodic maintenance must be performed WARNING on this equipment. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract. ELECTRICAL SHOCK HAZARD WARNING Failure to follow this warning could result in personal injury or death.
Page 41 10. Reassemble motor and blower by reversing steps 11f 20. Cycle furnace through one complete heating and cool- through 11a, finishing with 11a. Be sure to reattach ing cycle. Verify the furnace temperature rise as shown ground wire to the blower housing. in “Adjustments”...
Page 42: Sequence Of Operation
Figure 45 − Igniter Position−Side View sealant are required. DO NOT substitute any other type of RTV sealant. 12. Apply new sealant to flange of collector box and attach to cell panel using existing screws, making sure all screws are secure. 13.
Page 43 Follow the sequence of operation through the different and de−energizing the humidifier terminal HUM. modes. Read and follow the wiring diagram very carefully. The inducer motor IDM will remain energized for a 5−second post−purge period. The blower motor NOTE: If a power interruption occurs during a call for heat BLWM and air cleaner terminal EAC−1 will remain (W), the control will start a 90−sec blower−only ON period two energized for 90, 120, 150, or 180 seconds (de-...
Page 44: Wiring Diagram
Figure 48 − Wiring Diagram 441 01 6100 01 Specifications are subject to change without notice.
Page 45: Troubleshooting Guide
Figure 49 − Troubleshooting Guide 441 01 6100 01 Specifications are subject to change without notice.
Page 46 441 01 6100 01 Specifications are subject to change without notice.
Page 47 The qualified installer or service agency must use only factory−authorized replacement parts, kits, or accessories when modifying this product. Specifications are subject to change without notice. 441 01 6100 01 Copyright 2015 International Comfort Products Lewisburg, TN 37091 USA...

International comfort products R8MXL Installation Instructions Manual

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