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AHRI F80CSU Installation Instructions Manual

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INSTALLATION INSTRUCTIONS
Communicating, 80% AFUE Gas Furnace
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4- -Way Multipoise, Ultra Low NOx
F80CSU, G80CSU
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Approved for installations up to 5,400 feet (1646 meters)
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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
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the referenced subject, which is represented only by the standard
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Summary of Contents for AHRI F80CSU

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS 4- -Way Multipoise, Ultra Low NOx Communicating, 80% AFUE Gas Furnace F80CSU, G80CSU SAFETY CONSIDERATIONS ......

  • Page 2: Safety Considerations

    SAFETY CONSIDERATIONS 1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate. 2. Install this furnace only in a location and position as WARNING specified in the “Location” section of these instructions. 3. Provide adequate combustion and ventilation air to the FIRE, EXPLOSION, ELECTRICAL SHOCK, AND furnace space as specified in “Air for Combustion and Ventilation”...
  • Page 3 A180207 Fig. 1 - - Dimensional Drawing Table 1 – Dimensions VENT VENT CABINET TOP FLUE CONNECTION WIDTH OUTLET WIDTH COLLAR ONLY BOTTOM WIDTH SIZE* SHIP WT FURNACE SIZE IN. (MM) IN. (MM) IN. (MM) IN. (MM) IN. (MM) (LB / KG) 17- -1/2 (445) 15- -7/8 (403) 11- -9/16 (294)

  • Page 4: Codes And Standards

    Duct Systems Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contract- ors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Condition- ing Engineers (ASHRAE) 2005 Fundamentals Hand- book Chapter 35 or 2004 HVAC Systems and Equip- ment Handbook Chapters 9 and 16.

  • Page 5: 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 6 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 inches above the floor. (See Fig. 5) The furnace must be located or protected to avoid damage by vehicles.

  • Page 7: Safety Considerations

    a. One opening MUST commence within 12- -in. (300 mm) CAUTION of the ceiling and the second opening MUST commence within 12- -in. (300 mm) of the floor. b. Size openings and ducts per Fig. 7 and Table 2. FURNACE CORROSION HAZARD Failure to follow this caution may result in furnace damage.
  • Page 8 WARNING = 21ft Volume other 1000 Btu/hr Other CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in death and/or A04002 personal injury. 2. For fan- -assisted appliances such as this furnace: Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases.

  • Page 9: Installation

    b. Outdoor opening size reduction Factor is 1 minus the 4. Adjust outside nut to provide desired height, and tighten Ratio in a. above. inside nut to secure arrangement. c. Minimum size of Outdoor openings shall be the size 5. Reinstall bottom closure panel if removed. required in Outdoor Combustion Air Method above 5/ 16 ...

  • Page 10: Horizontal Installation

    4. Reinstall bottom filler panel and screws FURNACE APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE FLOORING PLENUM OPENING SHEET METAL PLENUM FLOOR OPENING FLOOR OPENING A96283 A08556 Fig. 11 - - Floor and Plenum Opening Dimensions Fig. 13 - - Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor FURNACE HORIZONTAL INSTALLATION...

  • Page 11: Air Ducts

    Suspended Furnace Support There are no provisions for an internal filter rack in these furnaces. The furnace may be supported under each end with threaded rod, A field- -supplied accessory external filter is required. angle iron or metal plumber’s strap as shown. (See Fig. 15 and 16) Secure angle iron to bottom of furnace as shown.
  • Page 12 flange temporarily while the remaining attachment and sealing of the coil are performed. Downflow Furnaces Connect supply- -air duct to supply- -air outlet on furnace. Bend flange inward past 90_ with wide duct pliers. (See Fig. 14) The supply- -air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing (when used).
  • Page 13 A180240 Fig. 17 - - Typical Attic Installation Return Air Connections WARNING FIRE HAZARD Failure to follow this warning could cause personal injury, death and/or property damage. Never connect return- -air ducts to the back of the furnace. Follow instructions below Downflow Furnaces The return- -air duct must be connected to return- -air opening (bottom inlet) as shown in Fig.

  • Page 14: Gas Piping

    CAUTION FURNACE OVERHEAT HAZARD Failure to follow this caution may result in property damage. Connect gas pipe to gas valve using a backup wrench to avoid damaging gas controls and burner misalignment. WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage.

  • Page 15: Electrical Connections

    If pressure exceeds 0.5 psig (14- -In. W.C.), gas supply pipe must be disconnected from furnace and capped before and during SUPPLY supply pipe pressure test. If test pressure is equal to or less than MANUAL 0.5 psig (14- -In. W.C.), turn off electric shutoff switch located on SHUTOFF furnace gas control valve and accessible manual equipment VALVE...

  • Page 16: 115- -V Wiring

    5. Route J- -Box wires within furnace away from sharp edges, WARNING rotating parts and hot surfaces. ELECTRICAL CONNECTION TO J- -BOX ELECTRICAL SHOCK AND FIRE HAZARD Electrical Box on Furnace Casing Side Failure to follow this warning could result in personal WARNING injury, death, or property damage.

  • Page 17: 24- -V Wiring

    24- -V WIRING Make field 24- -v connections at the 24- -v terminal strip. (See Fig. 24) Connect terminal Y as shown in Fig. 43 for proper cooling operation. Use only AWG No. 18, color- -coded, copper thermostat wire. The 24- -v circuit contains an automotive- -type, 3- -amp. fuse located on the control.
  • Page 18 FIELD 24-VOLT WIRING FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING NOTE 2 1-STAGE THERMOSTAT FIVE FIELD-SUPPLIED TERMINALS WIRE FUSED DISCONNECT THREE-WIRE 208/230- OR HEATING- 460-VOLT ONLY THREE PHASE 208/230- W/W1 VOLT NOTE 1 SINGLE Y/Y2 115-VOLT FIELD- JUNCTION PHASE SUPPLIED...
  • Page 19 A190374 Fig. 27 - - 1- -Speed Variable Furnace with Single- -Speed Heat A190375 Pump (Dual Fuel) Fig. 28 - - 1- -Speed Variable Furnace with Two- -Speed Heat Pump (Dual Fuel) NOTES FOR FIGURES 25 - - 28 1. Refer to outdoor equipment Installation Instructions for additional information and setup procedure. 2.

  • Page 20: Venting

    VENTING GENERAL VENTING REQUIREMENTS Follow all safety codes for proper vent sizing and installation The furnace shall be connected to a listed factory built chimney requirements, including local building codes, the current edition or vent, or a clay- -tile lined masonry or concrete chimney. Venting of National Fuel Gas Code ANSI Z223.1/NFPA 54 (NFGC), into an unlined masonry chimney or concrete chimney is Parts 12 and 13, the local building codes, and furnace and vent...

  • Page 21: Appliance Application Requirements

    Table 7 – Minimum Allowable Input Rating of Table 8 – Combined Appliance Maximum Input Rating in Space- -Heating Appliance in Thousands of BTUH per Hour Thousands of BTUH per Hour INTERNAL AREA OF CHIMNEY INTERNAL AREA OF CHIMNEY VENT HEIGHT .
  • Page 22 A180242 Fig. 29 - - Chimney Inspection Chart Specifications are subject to change without notice. 441 01 4200 01...

  • Page 23: Additional Venting Requirements

    ADDITIONAL VENTING REQUIREMENTS CAUTION A 4” (101 mm) round vent elbow is supplied with the furnace. A 5- -inch (127 mm) or 6- - inch (152 mm) vent connector may be CUT HAZARD required some model furnaces. field- -supplied 4- -inch- -to- -5- -inch (101 - - 127 mm) or 4- -inch- -to- -6- -inch (101 - - Failure to follow this caution may result in personal injury.
  • Page 24 SEE NOTES: 1,2,4,7,8,9 on the page following these figures A03213 Fig. 32 - - Horizontal Left Application- -Vent Elbow Left SEE NOTES: 1,2,4,5,6,7,8,9 on the page following these figures A03207 Fig. 35 - - Downflow Application- -Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03215...

  • Page 25: Start- -Up, Adjustment, And Safety Check

    START- - UP, ADJUSTMENT, AND SAFETY Refer to service label attached to furnace or See Fig. 36. CHECK Component test sequence is as follows: General a. Inducer motor turns on at 50% duty cycle for 15 secs, then stays on for the entire test. WARNING b.

  • Page 26: Furnace Setup Switches

    Table 10 – Furnace Setup Switch Description A190351 Specifications are subject to change without notice. 441 01 4200 01...
  • Page 27 A190347 Fig. 36 - - Service Label 441 01 4200 01 Specifications are subject to change without notice.
  • Page 28 2. Determine the correct outlet gas pressure adjustment. h. Install regulator seal cap. a. Obtain average yearly gas heat value (at installed altitude) i. Leave manometer or similar device connected and pro- from local gas supplier. ceed to next step. b.
  • Page 29 e. To increase heating airflow, set Comfort/Efficiency CAUTION SW1- -4 on furnace control to OFF = Efficiency. f. Repeat steps a through e. g. When correct input rate and temperature rise is achieved, FURNACE OVERHEATING HAZARD turn gas valve ON/OFF switch to OFF. Failure to follow this caution may result in reduced furnace h.

  • Page 30: Air Delivery - - Cfm

    9. Set Airflow for Continuous Fan/Low Speed Cooling cooling unit. Adjust the continuous fan CFM to match the Airflow The ECM blower motor can be adjusted for airflow required for low speed cooling. Select the required continuous fan speeds different than heating or cooling fan airflow from Fig.
  • Page 31 Air Delivery - - CFM continued (with Filter)* (SW1--- 5 and SW4--- 3 set to OFF, except as indicated. See notes 1 and 2) 0802120 Clg/CF Switch settings External Static Pressure (ESP) Size: Clg Switches SW2--- 3 SW2--- 2 SW2--- 1 Clg Default: 1905 1920...

  • Page 32: Cooling Or Continuous Airflow

    BASED ON 350 CFM/TON (SETUP SWITCH SW1---5 OFF, SW4---3 OFF) SETUP SWITCH SW2 OR SW3 POSITIONS Model Size 3T-040 1050 1225 1400 1400 4T-060 1050 1225 1400 1400 5T-080 1050 1225 1400 1750 2100 5T-100 1050 1225 1400 1750 2100 BASED ON 400 CFM/TON (SETUP SWITCH SW1---5 ON, SW4---3 OFF) SETUP SWITCH SW2 OR SW3 POSITIONS Model Size...

  • Page 33: Checklist

    Checklist Table 14 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude - - 40,000 1. Put away tools and instruments. Clean up debris. 2. Verify that switches SW1- -1 and SW1- -6 are OFF and oth- Tabulated Data Based on 40,000 BTUH Input for 0-ft (0 M) to er setup switches are set as desired.
  • Page 34 Table 15 – Gas Valve Outlet Pressure for Gas Heat Values at Table 16 – Gas Valve Outlet Pressure for Gas Heat Values at Altitude - - 60,000 Altitude - - 80,000 Tabulated Data Based on 60,000 BTUH Input for 0-ft (0m) to Tabulated Data Based on 80,000 BTUH Input, for 0-ft (0-m) to 5400-ft (1646-M) above sea level...

  • Page 35: Service And Maintenance Procedures

    Table 17 – Gas Valve Outlet Pressure for Gas Heat Values at must be performed by trained service personnel. A qualified service person should inspect the furnace once a year. Altitude - - 100,000 WARNING (Tabulated Data Based on 100,000 BTUH Input, for 0-ft (0-m) to 5400-ft (1646-M) above sea level) SPECIFIC GRAVITY OF FIRE, INJURY, OR DEATH HAZARD...

  • Page 36: Care And Maintenance

    NOTE: If the polarity is not correct, the STATUS LED on the must be taken when manually closing this switch for service purposes. control will flash status code 10 and prevent the furnace from heating. The control system also requires an earth ground for WARNING proper operation of the control and flame- -sensing electrode.

  • Page 37: Cleaning And/Or Replacing Air Filter

    BLOWER MOTOR AND WHEEL WARNING WARNING ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal ELECTRICAL SHOCK HAZARD injury, death or property damage. Failure to follow this warning could result in personal injury Turn off the gas and electrical supplies to the unit and install or death.

  • Page 38: Flame Sensor Cleaning And Servicing

    13. Reinstall two screws securing blower assembly to blower WARNING deck. CAUTION ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury, UNIT DAMAGE HAZARD death, and/or property damage. Turn off the gas and electrical supplies to the furnace and Failure to follow this caution may result in shortened heat install lockout tag before performing any maintenance or exchanger life.

  • Page 39: Cleaning Heat Exchanger

    CLEANING HEAT EXCHANGER The following steps should be performed by a qualified service agency: NOTE: If the heat exchangers get a heavy accumulation of soot and carbon, they should be replaced rather than trying to clean them thoroughly. A heavy build- -up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of gas valve outlet pressure, insufficient or poor quality combustion air, incorrect size or damaged orifice(s),...

  • Page 40: Sequence Of Operation

    d. Gas valve control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot- -surface ignitor HSI, and gas valve GV. e. Hot surface ignitor 1. Heating with Single- -Stage Thermostat f. Flame- -sensing electrode See Fig. 25 - - 28 for thermostat connections g.
  • Page 41 ing on selection at blower- -OFF delay switches). The furnace blower motor BLWM will drop the blower furnace control CPU is factory- -set for a 120- -second airflow to 86 percent of cooling airflow. Cooling air- blower- -OFF delay. flow is based on the A/C (air conditioning) selection shown in Fig.

  • Page 42: Wiring Diagrams

    seconds, if no other function requires blower motor NOTE: The component test feature will not operate if the control BLWM operation. is receiving any thermostat signals or until all time delays have expired. 6. Heat pump The component test sequence is as follows: See Fig.
  • Page 43 A190249 Fig. 43 - - Wiring Diagram 441 01 4200 01 Specifications are subject to change without notice.

  • Page 44: Parts Replacement Information Guide

    PARTS REPLACEMENT INFORMATION GUIDE CASING GROUP GAS CONTROL GROUP Outer door Burner assembly Blower door Orifice Top filler plate Flame sensor Bottom filler plate Hot surface ignitor Bottom enclosure Gas valve ELECTRICAL GROUP Manual reset limit switches Burner support assembly Control bracket HEAT EXCHANGER GROUP Junction box...

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G80csu

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