International comfort products R80ESN Installation Instructions Manual
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International comfort products R80ESN Installation Instructions Manual

80% single stage, ecm motor category i, 33--1/3 in.
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INSTALLATION INSTRUCTIONS
SAFETY CONSIDERATIONS
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80% Single Stage, ECM Motor
Category I, 33- -1/3 in. Gas Furnace
R80ESN and R80ESL
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(Series A)
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NOTE: Read the entire instruction manual before starting the
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installation.
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Portions of the text and tables are reprinted from current edition
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of NFPA 54/ANSI Z223.1E, with permission of National Fire
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Protection Association, Quincy, MA 02269 and American Gas
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Association, Washington DC 20001. This reprinted material is
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not the complete and official position of the NFPA or ANSI on
the referenced subject, which is represented only by the standard
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in its entirety.
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SAFETY CONSIDERATIONS
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!
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FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
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CARBON MONOXIDE POISONING HAZARD
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Failure to follow this warning could result in dangerous
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operation, serious injury, death, or property damage.
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Improper installation, adjustment, alteration, service,
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maintenance, or use could cause carbon monoxide
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poisoning, explosion, fire, electrical shock, or other
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conditions which may cause personal injury or property
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damage. Consult a qualified service agency, local gas
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supplier, or your distributor or branch for information or
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assistance. The qualified service agency must use only
factory- -authorized and listed kits or accessories when
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modifying this product.
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FURNACE RELIABILITY HAZARD
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Improper installation or misapplication of furnace may
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require excessive servicing or cause premature component
failure.
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Application of this furnace should be indoors with special
attention given to vent sizing and material, gas input rate,
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air temperature rise, unit leveling, and unit sizing.
Use of the AHRI Certified
Mark indicates a
TM
manufacturer's participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
WARNING
CAUTION
441 01 6200 00 3/20/2019

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Summary of Contents for International comfort products R80ESN

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS 80% Single Stage, ECM Motor Category I, 33- -1/3 in. Gas Furnace R80ESN and R80ESL (Series A) SAFETY CONSIDERATIONS ..... . .

  • Page 2: Introduction

    Improper installation, adjustment, alteration, service, 7. When a furnace is installed so that supply ducts carry air maintenance, or use can cause explosion, fire, electrical shock, or circulated by the furnace to areas outside the space con- other conditions which may cause death, personal injury, or taining the furnace, the return air shall also be handled by property damage.
  • Page 3 A190084 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 4 A10269 Fig. 2 - - Clearances to Combustibles Specifications are subject to change without notice. 441 01 6200 00...

  • Page 5: Codes And Standards

    Electrical Connections Current edition of National Electrical Code (NEC) NF- PA 70. Venting Current edition of NFGC NFPA 54 / ANSI Z223.1; Chapters 12 and 13. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE CAUTION FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause A02055 premature furnace component failure.

  • Page 6: Location

    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 OF THE BURNER SECTION,...
  • 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 return- -air duct to PERSONAL INJURY AND/OR PROPERTY prevent pulling air from the burner area and from draft safeguard DAMAGE HAZARD...

  • Page 8: Air For Combustion And Ventilation

    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) ACH* Space Volume (ft. 0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300...
  • Page 9 1 SQ IN. CIRCULATING AIR PER 4000 VENT THROUGH ROOF DUCTS DUCTS BTUH* O UTDOORS 12" MAX (305mm) 12 ″ MAX 12 ″ (305mm) (305mm) 1 SQ IN. VENT 1 SQ IN. PER 2000 THR OUGH PER 1000 BTUH* R OOF BTUH* IN DOOR 1 SQ IN .

  • Page 10: Combination Of Indoor And Outdoor Air

    INSTALLATION Ifan = combined input of all fan- -assisted appliances in Btuh/hr ACH = air changes per hour (ACH shall not exceed 0.60.) UPFLOW INSTALLATION The following requirements apply to the Standard Method and to Bottom Return Air Inlet the Known Air Infiltration Rate Method. These furnaces are shipped with bottom closure panel installed in 1.

  • Page 11: Downflow Installation

    5/ 16  (8mm) (8mm) 5/ 16   (44mm) PLENUM OPENING  (44mm) FLOOR (8mm) OPENING  (8mm) 5/ 16  (44mm) 3/ 4  3/ 4  (44mm) A89014 A96283 Fig. 10 - - Leveling Legs Fig. 11 - - Floor and Plenum Opening Dimensions 4.
  • Page 12 FURNACE APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR OPENING A08556 Fig. 13 - - Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor Table 4 – Opening Dimensions - - In. (mm) FURNACE PLENUM OPENING FLOOR OPENING...

  • Page 13: Horizontal Installation

    HORIZONTAL INSTALLATION Not all horizontal furnaces are approved for side return air connections. (See Fig. 21.) WARNING FILTER ARRANGEMENT WARNING FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD CARBON MONOXIDE AND POISONING Failure to follow this warning could result in personal HAZARD injury, death, and/or property damage.
  • Page 14 Upflow and Horizontal Furnaces Downflow Furnaces Connect supply- -air duct to flanges on furnace supply- -air outlet. Connect supply- -air duct to supply- -air outlet on furnace. Bend Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.) flange inward past 90_ with wide duct pliers.
  • Page 15 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 (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

  • Page 16: Gas Piping

    Return Air Connections WARNING WARNING FIRE OR EXPLOSION HAZARD FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Failure to follow this warning could cause personal injury, death and/or property damage. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector.
  • Page 17 Table 5 – Air Delivery - - CFM (With Filter)* Wire Test Airflow Delivery @ Various External Static Pressures Furnace Lead Function Color Gray Cooling. Do not use for heating. 1230 1190 1155 1120 1080 1045 1010 Yellow Alt Cooling or alt Heating Orange Alt Cooling or alt Heating 0451412...
  • Page 18 Table 6 – Maximum Capacity of Pipe* NOMINAL IRON INTERNAL LENGTH OF PIPE --- FT. (M) PIPE DIAMETER SIZE IN. (mm) In. (mm) 1/2 (13) 0.622 (16) 175 (53) 120 (37) 97 (30) 82 (25) 73 (22) 3/4 (19) 0.824 (21) 360 (110) 250 (76) 200 (61)
  • Page 19 A02163 Fig. 20 - - Downflow Return Air Configurations and Restrictions A02162 Fig. 21 - - Horizontal Return Air Configurations and Restrictions 2” (51mm) Street Elbow A08551 Fig. 22 - - Burner and Manifold 441 01 6200 00 Specifications are subject to change without notice.

  • Page 20: Electrical Connections

    Table 7 – Electrical Data Maximum Operating Voltage* Maximum Wire Volts- Unit Minimum Wire Fuse Range Length Unit Size Hertz- or CKT Ampacity# Size AWG Phase Maximum Minimum feet BKR Amps 0451412 115--- 60--- 1 14.3 0451712 115--- 60--- 1 10.3 0701412 115--- 60--- 1...

  • Page 21: J- -Box Relocation

    or ordinances that might apply. 10. Reattach furnace J- -Box to furnace casing with screws re- moved in Step 4. WARNING 11. Secure field ground wire to J- -Box green ground screw. 12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Fig.

  • Page 22: Accessories

    maintenance could cause this fuse to blow. If fuse replacement is 2. Humidifier (HUM) required, use ONLY a 3- -amp. fuse of identical size. Connect an accessory 24 VAC, 0.5 amp. maximum humidifi- er (if used) to the 1/4- -in male quick- -connect HUM terminal ACCESSORIES and COM- -24V screw terminal on the control board thermo- 1.
  • Page 23 FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 THERMOSTAT FIVE WIRE FIELD-SUPPLIED TERMINALS DISCONNECT THREE-WIRE HEATING-ONLY 208/230- OR BLOWER DOOR SWITCH 460-V THREE PHASE 208/230-V SINGLE PHASE AUXILIARY 115-V FIELD- J-BOX SUPPLIED NOTE 1 DISCONNECT CONDENSING...

  • Page 24: Venting

    VENTING GENERAL VENTING REQUIREMENTS The furnace shall be connected to a listed factory built chimney Follow all safety codes for proper vent sizing and installation or vent, or a clay- -tile lined masonry or concrete chimney. Venting requirements, including local building codes, the current edition into an unlined masonry chimney or concrete chimney is of National Fuel Gas Code ANSI Z223.1/NFPA 54 (NFGC), prohibited.

  • Page 25: Appliance Application Requirements

    Table 9 – Minimum Allowable Input Rating of Space- -Heat- This furnace is permitted to be vented into a clay tile- -lined masonry chimney that is exposed to the outdoors below the roof ing Appliance in Thousands of BTUH per Hour line, provided: INTERNAL AREA OF CHIMNEY 1.
  • Page 26 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211 Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances Crown Rebuild condition: crown. Missing mortar or brick? Is chimney property lined with clay tile liner? Repair Reline...

  • Page 27: Additional Venting Requirements

    NOTE: An accessory flue extension is available to extend from To prevent condensation in the furnace and vent system, the following precautions must be observed: the furnace elbow to outside the furnace casing. See Specification Sheet for accessory listing. If flue extension is used, fasten the 1.
  • Page 28 Caution!! For the following applications, use the minimum vertical vent heights as specified below. For all other applications, follow exclusively the National Fuel Gas Code. MIN. VENT MIN. VERTICAL VENT FURNACE VENT ORIENTATION FURNACE INPUT DIAMETER HEIGHT ORIENTATION (BTUH/HR) IN. (mm)* FT.
  • Page 29 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 Fig. 30 - - Downflow Application- -Vent Elbow Up then Left Fig. 32 - - Downflow Application- -Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following SEE NOTES:1,2,3,4,5,7,8,9...
  • Page 30 SEE NOTES: 1,2,4,7,8,9 on the page following these figures A03214 Fig. 36 - - Horizontal Right Application- -Vent Elbow Right SEE NOTES: 1,2,4,7,8,9 on the page following these figures A03213 Fig. 34 - - Horizontal Left Application- -Vent Elbow Left SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03215...

  • Page 31: Start- -Up, Adjustment, And Safety Check

    SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,7,8,9 A03216 Fig. 39 - - Horizontal Left Application- -Vent Elbow Right A02068 Fig. 40 - - Horizontal Right Application- -Vent Elbow Left VENTING NOTES FOR FIGURES 28 - - 40 1.

  • Page 32: Adjustments

    imately 2 sec). Gas valve and humidifier will not be turned 1. Determine the correct gas input rate. on. (See Fig. 24.) The input rating for altitudes above 2,000 ft. (610 M) must be reduced by 4 percent for each 1,000 ft. (305 M) above WARNING sea level.
  • Page 33 d. Turn gas valve ON/OFF switch to ON. (3.) Return and supply ducts for excessive restrictions causing static pressures greater than 0.50- -In. W.C. e. Manually close blower door switch. c. Adjust air temperature rise by adjusting blower speed. In- f.

  • Page 34: Check Safety Controls

    flow. See Table 5- -Air Delivery- -CFM (With Filter) for lead color identification. Check Safety Controls The flame sensor, gas valve, and pressure switch were all checked in the Start- -up procedure section as part of normal operation. 1. Check Main Limit Switch(es) This control shuts off combustion control system and en- ergizes air- -circulating blower motor, if furnace overheats.
  • Page 35 3. Verify that blower and burner access doors are properly in- THERMOSTAT SUBBASE TERMINALS WITH stalled. THERMOSTAT REMOVED 4. Cycle test furnace with room thermostat. (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.) 5. Check operation of accessories per manufacturer’s instruc- tions.
  • Page 36 Table 12 – Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate A10180 Specifications are subject to change without notice. 441 01 6200 00...
  • Page 37 Table 12 - - Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (CONT) A10180A 441 01 6200 00 Specifications are subject to change without notice.
  • Page 38 Table 13 – Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate A10181 Specifications are subject to change without notice. 441 01 6200 00...
  • Page 39 Table 13- - Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate (CONT) A10181A 441 01 6200 00 Specifications are subject to change without notice.

  • Page 40: 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 service person should inspect the furnace once a year. Failure to follow this warning could result in personal injury or death.

  • Page 41: Care And Maintenance

    A14637 Fig. 44 - - Service Label CARE AND MAINTENANCE WARNING WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in personal injury, death and/or property damage.

  • Page 42: Cleaning And/Or Replacing Air Filter

    maintenance to the accessories as recommended in the ac- 9. If a greasy residue is present on blower wheel, remove cessory instructions. wheel from the blower housing and wash it with an appro- priate degreaser. To remove wheel: CLEANING AND/OR REPLACING AIR FILTER NOTE: Before disassembly, mark blower motor, and blower The air filter arrangement will vary depending on the application.

  • Page 43: Cleaning Heat Exchanger

    c. Perform component self- -test as shown at the bottom of 9. Using field- -provided 25- -caliber rifle cleaning brush, the SERVICE label, located on the front of blower access 36- -in. (914 mm) long, 1/4” (6 mm) diameter steel spring door.

  • Page 44: Sequence Of Operation

    (9.) Install NOx baffles (if removed). WARNING (10.) Reinstall burner assembly. Center burners in cell openings. FIRE OR EXPLOSION HAZARD 10. Remove old sealant from cell panel and collector box flange. Failure to follow this warning could result in personal injury, death and/or property damage.

  • Page 45: Wiring Diagrams

    the furnace control CPU will lock out of Gas- -Heating speed FAN Terminal. Terminal EAC- -1 is energized as mode and operate the inducer motor IDM until flame long as the blower motor BLWM is energized. is no longer proved. During a call for heat, the blower BLWM will stop during igniter warm- -up (17 sec), ignition, and blower- -ON delay e.
  • Page 46 A190026 Fig. 48 - - Wiring Diagram Specifications are subject to change without notice. 441 01 6200 00...
  • Page 47 A190024 441 01 6200 00 Specifications are subject to change without notice.
  • Page 48 A05032 Fig. 49 - - Troubleshooting Guide Specifications are subject to change without notice. 441 01 6200 00...

  • Page 49: Parts Replacement Information Guide

    The qualified installer or service agency must use only facto- ry- -authorized replacement parts, kits, or accessories when modifying this product. Copyright 2019 International Comfort Products Lewisburg, TN 37091 USA 441 01 6200 00 Specifications are subject to change without notice.
  • Page 50 Specifications are subject to change without notice. 441 01 6200 00...

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