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INSTALLATION INSTRUCTIONS
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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
installation.
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Portions of the text and tables are reprinted from current edition
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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in its entirety.
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SAFETY CONSIDERATIONS
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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
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
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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
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failure.
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Application of this furnace should be indoors with special
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attention given to vent sizing and material, gas input rate,
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air temperature rise, unit leveling, and unit sizing.
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Improper
installation,
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maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
WARNING
CAUTION
adjustment,
alteration,
441 01 6200 02 7/13/2019
service,
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Related Manuals for Carrier R80ESN
Summary of Contents for Carrier R80ESN
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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: Safety Considerations
property damage. Consult a qualified installer, service agency, or taining the furnace, the return air shall also be handled by your distributor or branch for information or assistance. The duct(s) sealed to the furnace casing and terminating out- qualified installer or agency must use factory- -authorized kits or side the space containing the furnace. - 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.
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Page 4: Codes And Standards
A10269 Fig. 2 - - Clearances to Combustibles having jurisdiction. In the United States, follow all codes and standards for the following: Safety USA: Current edition of National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B General Installation Current edition of the NFGC and the NFPA 90B. -
Page 5: Acoustical Lining And Fibrous Glass Duct
Acoustical Lining and Fibrous Glass Duct 1. Disconnect all power to the furnace. Multiple disconnects maybe required. DO NOT TOUCH THE CONTROL OR Current edition of SMACNA and NFPA 90B as tested ANY WIRE CONNECTED TO THE CONTROL PRIOR by UL Standard 181 for Class I Rigid Air Ducts DISCHARGING YOUR BODY’S... - Page 6 WARNING WARNING CARBON MONOXIDE POISONING HAZARD FIRE HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in personal injury or death, and unit component damage. injury, death, and/or property damage. Corrosive or contaminated air may cause failure of parts When the furnace is installed in a residential garage, the containing flue gas, which could leak into the living space.
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Page 7: Air For Combustion And Ventilation
Table 2 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO OPENINGS OR VERTICAL TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING DUCTS (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) (1 SQ. IN./4,000 BTUH) FURNACE (1,100 SQ. -
Page 8: Outdoor Combustion Air Method
g. TWO HORIZONTAL DUCTS require 1 square inch of U.S. installations: Section 9.3 of the current edition of free area per 2,000 Btuh (1,100 mm /kW) of combined NFGC NFPA54/ANSI Z223.1, Air for Combustion input for all gas appliances in the space per Fig. 7 and and Ventilation, and applicable provisions of the local Table 2. -
Page 9: Installation
2. The air infiltration rate is not known to be less than 0.40 a. Walls and ceilings exposed to the outdoors have a con- air changes per hour (ACH). tinuous, sealed vapor barrier. Openings are gasketed or sealed and The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be: b. -
Page 10: Downflow Installation
38 mm) (max) corrosion- -resistant machine bolts, washers and Bottom Return Air Inlet nuts. These furnaces are shipped with bottom closure panel installed in NOTE: Bottom closure must be used when leveling legs are bottom return- -air opening. Remove and discard this panel when used. - Page 11 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...
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Page 12: 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 13 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 14 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).
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Page 15: 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, If local codes allow the use of a flexible gas appliance death and/or property damage. - Page 16 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 17 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 18 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 Specifications are subject to change without notice. 441 01 6200 02...
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Page 19: Electrical Connections
Table 7 – Electrical Data Maximum Operating Voltage* Maximum Wire Volts- Unit Minimum Wire Fuse Range Length Hertz- Unit Size Ampacity# Size AWG or CKT Phase Maximum Minimum feet BKR Amps 0451412 115--- 60--- 1 14.3 0451712 115--- 60--- 1 10.3 0701412 115--- 60--- 1... -
Page 20: 24- -V Wiring
2. Cut wire tie on loop in furnace wires attached to J- -box. 2. Route BX cable into 7/8- -inch diameter hole in J- -Box. 3. Move J- -Box to desired location. 3. Secure BX cable to J- -Box bracket with connectors ap- 4. - Page 21 A190023 Fig. 24 - - Furnace Control 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...
- Page 22 A190085 Fig. 26 - - Thermostat Wiring Diagrams NOTES FOR THERMOSTAT WIRING DIAGRAMS 1. Refer to outdoor equipment Installation Instructions for additional information and setup procedure. 2. Outdoor Air Temperature Sensor must be attached in all dual fuel application. 3. Refer to ICP thermostat Installation Instructions for additional information and setup procedure. 4.
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Page 23: 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 24: Appliance Application Requirements
This furnace is permitted to be vented into a clay tile- -lined Table 9 – Minimum Allowable Input Rating of Space- -Heat- 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 25 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...
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Page 26: Additional Venting Requirements
To prevent condensation in the furnace and vent system, the NOTE: An accessory flue extension is available to extend from 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 27 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 28 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 29 SEE NOTES: 1,2,4,7,8,9 on the page SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures following these figures A03213 Fig. 34 - - Horizontal Left Application- -Vent Elbow Left A03219 Fig. 38 - - Horizontal Right Application- -Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures...
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Page 30: Start- -Up, Adjustment, And Safety Check
VENTING NOTES FOR FIGURES 28 - - 40 1. For common vent, vent connector sizing and vent material: United States- -- -use the NFGC. 2. Immediately increase to 5- -inch (127 mm) or 6- -inch (152 mm) vent connector outside furnace casing when 5- -inch (127 mm) vent connector is required, refer to Note 1 above. -
Page 31: Adjustments
g. Reconnect R lead to furnace control board, release blower g. Replace orifice with correct size if required by Table 10, door switch and re- -install blower door. 11, 12 and 13. Use only factory- -supplied orifices. See EXAMPLE 1. 4. - Page 32 e. Multiply gas rate (cu ft./hr) by heating value (Btuh/cu ft.) j. Reinstall manifold pressure tap plug in gas valve. to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input.
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Page 33: Check Safety Controls
6. Set thermostat heat anticipator. h. Re- -install vent connector. NOTE: a. Mechanical thermostat - - Set thermostat heat anticipator Should switch remain open longer than 3 minutes, to match the amp. draw of the electrical components in furnace control board will lockout the furnace for 3 hours. To 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 12 – Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate A10180 441 01 6200 02 Specifications are subject to change without notice.
- Page 36 Table 12 - - Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (CONT) A10180A Specifications are subject to change without notice. 441 01 6200 02...
- Page 37 Table 13 – Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate A10181 441 01 6200 02 Specifications are subject to change without notice.
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Page 38: Service And Maintenance Procedures
Table 13- - Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate (CONT) A10181A SERVICE AND MAINTENANCE CAUTION PROCEDURES Untrained personnel can perform basic maintenance functions ELECTRICAL OPERATION HAZARD such as cleaning and replacing air filters. All other operations Failure to follow this caution may result in improper must be performed by trained service personnel. -
Page 39: Care And Maintenance
The electrical ground and polarity for 115- -v wiring must be See Fig. 49 for a brief Troubleshooting Guide. properly maintained. Refer to Fig. 25 for field wiring information For Controls With an Amber LED and to Fig. 48 for furnace wiring information. The stored status code will not be erased from the control NOTE: If the polarity is not correct, the STATUS LED on the memory, if 115- - or 24- -v power is interrupted. -
Page 40: Cleaning And/Or Replacing Air Filter
BLOWER MOTOR AND WHEEL WARNING WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in personal injury injury, death and/or property damage. or death. Never operate unit without a filter or with filter access door Blower access door switch opens 115- -v power to control. -
Page 41: Cleaning Heat Exchanger
Loosen set screw on blower wheel and reposition if neces- 20. Cycle furnace through one complete heating and cooling sary. cycle. Verify the furnace temperature rise as shown in “Adjustments” Section. Adjust temperature rise as shown 12. Spin the blower wheel by hand to verify that the wheel in “Adjustments”... - Page 42 ing with ball- -peen hammer. TIGHTNESS IS VERY IM- NOTE: A releasing agent such as cooking spray or equivalent PORTANT. (must not contain corn or canola oil, aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant 9/32” (G.E.
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Page 43: Sequence Of Operation
green/yellow wire routed to gas valve and manifold bracket tor and HUM (115- -v) humidifier terminal. The blower motor BLWM and air cleaner terminal EAC 1 will screw. remain energized for 90, 120, 150, or 180 seconds Using the schematic diagram, follow the sequence of operation (depending on the HEAT- -OFF delay selection). -
Page 44: Troubleshooting
Troubleshooting each question and follow the appropriate arrow to the next item. The Guide will help to identify the problem or failed component. Refer to the service label. (See Fig. 44.) The Troubleshooting After replacing any component, verify correct operation Guide (See Fig. - Page 45 A190024 441 01 6200 02 Specifications are subject to change without notice.
- Page 46 A05032 Fig. 49 - - Troubleshooting Guide Specifications are subject to change without notice. 441 01 6200 02...
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Page 47: Parts Replacement Information Guide
WIDTH MINOR SERIES AIRFLOW (CFM) R80ESN - -- - TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the “Heating Equipment“ or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name, or contact:... - Page 48 Copyright 2019 International Comfort Products Lewisburg, TN 37091 USA Specifications are subject to change without notice. 441 01 6200 02...
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