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INSTALLATION INSTRUCTIONS
FOR UPFLOW, UPFLOW/HORIZONTAL,
AND DOWNFLOW INDUCED DRAFT GAS FURNACES
80PJ AND 80LJ SERIES
PROPOSITION 65: THIS PRODUCT CONTAINS CHEMICALS,
INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF
CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER
REPRODUCTIVE HARM.
92-24161-31-07
SUPERSEDES 92-24161-31-06
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Table of Contents
Related Manuals for Iceco 80LJ SERIES
Summary of Contents for Iceco 80LJ SERIES
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Page 1: Installation Instructions
INSTALLATION INSTRUCTIONS FOR UPFLOW, UPFLOW/HORIZONTAL, AND DOWNFLOW INDUCED DRAFT GAS FURNACES 80PJ AND 80LJ SERIES PROPOSITION 65: THIS PRODUCT CONTAINS CHEMICALS, INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. 92-24161-31-07... -
Page 2: Installation Checklist
Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction is sometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Make copies of the checklist and complete one for every Low Profile Furnace service call for your records. INSTALLATION CHECKLIST (Refer to this manual for specifics.) GAS SUPPLY... -
Page 3: Table Of Contents
IMPORTANT: All ICECO products CONTENTS meet current Federal OSHA Guidelines for safety. California Proposition 65 Safety Precautions ....................4 warnings are required for certain products, which are not covered by the Installation Check List ....................2 OSHA standards. General Information....................5 California's Proposition 65 requires warnings for products sold in California Location Requirements and Considerations ............5... -
Page 4: Safety Information
SAFETY INFORMATION WARNING WARNING WARNING NEVER TEST FOR GAS LEAKS WHEN THIS FURNACE IS USE ONLY WITH TYPE OF GAS WITH AN OPEN FLAME. USE A INSTALLED IN A RESIDENTIAL APPROVED FOR THIS FURNACE. COMMERCIALLY AVAILABLE GARAGE, IT MUST BE INSTALLED REFER TO THE FURNACE RATING SOAP SOLUTION MADE SO THE BURNERS AND IGNITION... -
Page 5: General Information
GENERAL INFORMATION The 80PJ and 80LJ series furnaces are and .2 Installation Codes for gas These publications are available from: design certified by CSA for use with burning appliances), and the National Fire Protection Association, natural and propane gases as follows: requirements or codes of the local utility Inc. - Page 6 FIGURE 2 UPFLOW AND UPFLOW/HORIZONTAL DIMENSIONS...
- Page 7 FIGURE 3 DOWNFLOW DIMENSIONS...
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Page 8: Site Selection
CLEARANCE – NUMBER) BE IN PLACE WHEN THE PLACEMENT OF COMBUSTIBLE FURNACE IS INSTALLED WITH SIDE MATERIALS ON, AGAINST OR ACCESSIBILITY OR REAR AIR RETURN DUCTS. AROUND THE FURNACE JACKET The design of forced air furnaces with FAILURE TO INSTALL A BASE PLATE CAN CAUSE AN EXPLOSION OR COULD CAUSE PRODUCTS OF FIRE RESULTING IN PROPERTY... -
Page 9: Horizontal Units
AND THE RETURN AIR PLENUM. b. If summer air conditioning is WARNING desired, position the indoor coil on THE RETURN AIR PLENUM MUST A SOLID METAL BASE PLATE, (SEE the bottom of the unit. Insure that BE PERMANENTLY ENCLOSED. TABLE 1) MUST BE IN PLACE no air can bypass this coil. -
Page 10: Combustion And Ventilation Air
COMBUSTION AIR FIGURE 5 REQUIREMENTS HORIZONTAL RETURN AIR DUCT IMPORTANT: Air for combustion and (LEFT-HAND AIRFLOW POSITION SHOWN) ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage. The following types of installation may require OUTDOOR AIR for combustion, due to chemical... - Page 11 Combustion air must be free of acid FIGURE 7 forming chemicals; such as sulphur, AIR FROM ATTIC/CRAWL SPACE fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products.
- Page 12 B: Method 1 B: Method 2 Provide two permanent openings, One permanent opening, located within IMPORTANT: If the furnace is in a one located within 12 inches of the 12 inches of the top of the enclosure, location with an exhaust fan, there top and one located within 12 shall be permitted where the must be sufficient ventilation to prevent...
- Page 13 VENTING FIGURE 9 ATTACHING TO DRAFT INDUCER COLLAR GENERAL INFORMATION VENT PIPE The furnace must be vented in ADAPTER CONNECTOR* accordance with these instructions, National Fuel Gas Code, ANSI Z223.1 and/or the Natural Gas Installation Code, CSA-B149.1 & .2 and requirements or codes of the local utility or other authority having jurisdiction.
- Page 14 “B-1” VERTICAL VENTING FIGURE 10 TYPICAL VENTING WITH “B-1” VENT Type “B-1” vents must be installed in accordance with the terms of their listings and the vent manufacturer’s instructions. “B-1” vents must be supported and spaced in accordance with their listings and the manufacturer’s instructions.
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Page 15: Power Vent Systems
HORIZONTAL VENTING EXISTING VENT SYSTEMS appliances remaining connected to the common venting system are IMPORTANT RETROFIT SPECIAL VENT SYSTEMS (SVS) located. Turn on clothes dryers and VENTING INSTRUCTIONS any appliance not connected to the IMPORTANT: It is THE FURNACE common venting system. Turn on MANUFACTURER’s position now that If this furnace is a replacement any exhaust fans, such as range... -
Page 16: Gas Supply And Piping
GAS SUPPLY AND PIPING GAS SUPPLY FIGURE 12 GAS PIPING INSTALLATION WARNING UPFLOW & DOWNFLOW THIS FURNACE IS EQUIPPED AT THE FACTORY FOR USE ON MANUAL GAS VALVE UNION (IN CLOSED POSITION) NATURAL GAS ONLY. CONVERSION TO LP GAS REQUIRES A SPECIAL GAS VALVE KIT SUPPLIED BY THE DISTRIBUTOR OR MANUFACTURER. -
Page 17: Gas Pressure
GAS PRESSURE LP CONVERSION NOx MODELS IMPORTANT: The maximum gas NOTE: For installation, see specific LP When converting furnaces equipped supply pressure to the furnace should kit installation instructions. with NOx inserts to LP gas, remove the be 10.5” w.c. for natural gas and 13” NOx insert assemblies. -
Page 18: Setting Gas Pressure
SETTING GAS PRESSURE FIGURE 13 The maximum gas supply pressure to TYPICAL HOSE CONNECTION TO LINE PRESSURE TAP the furnace should be 10.5” w.c. natural gas, or 13” w.c. LP gas. The minimum supply gas pressure to the gas valve should be 5" w.c. natural gas or 11"... - Page 19 ADJUSTING OR CHECKING TO CHANGE ORIFICE SPUDS: ORIFICE ORDERING 1. Shut off the manual main gas valve INFORMATION FURNACE INPUT and remove the gas manifold. Orifice sizes are selected by adding the CAUTION 2. Replace the orifice spuds. 2-digit drill size required in the orifice ELEVATIONS ABOVE 2000 FT 3.
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Page 20: Electrical Wiring
ELECTRICAL WIRING FIGURE 14 ISOLATION RELAY WARNING TURN OFF ELECTRIC POWER AT THE FUSE BOX OR SERVICE PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. ALSO, THE GROUND CONNECTION MUST BE COMPLETED BEFORE MAKING LINE VOLTAGE CONNECTIONS. FAILURE TO DO SO CAN RESULT IN ELECTRICAL SHOCK, SEVERE PERSONAL INJURY OR DEATH. -
Page 21: Accessories
UT ELECTRONIC CONTROLS FIGURE 15 1028-928 CONTROL BOARD LINE VOLTAGE CONNECTIONS 1. Single Stage Operation UT ELECTRONIC CONTROLS 1028-928 CONTROL BOARDS (See Figure 16) a. Control board "ONE" is on furnace connected to the thermostat. b. The 24 VAC supply to both control boards must be in phase I677 with each other. - Page 22 FIGURE 16 UT Electronic Controls 1028-928 CONTROL BOARD, TWINNING CONNECTION -- SINGLE STAGE OPERATION I400 a099201...
- Page 23 FIGURE 17 UTEC 1028-928 CONTROL BOARD, TWINNING CONNECTION -- TWO-STAGE OPERATION a099301...
- Page 24 80+ HIGH ALTITUDE NOTE: Factory installed orifices are From Table F.4 of National Fuel Gas calculated and sized based on a sea Code Handbook, 2002 INSTRUCTIONS level Natural Gas heating value of 1075 Orifice required at 5000 ft. elevation BTU per cubic ft. (4% de-rate per thousand ft.): #42 CAUTION Orifice required at 8000 ft.
- Page 26 Part # 62-22175-60 pressure at the orifice, which differs from IMPORTANT: Actual input rates must Example 2: ICECO products that use 10" of water be measured onsite with manifold 1.15mm drill size orifice required column at the orifice. This difference pressure adjustment to ensure that an Part # 62-22175-91.
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Page 27: Start-Up Procedures
START-UP PROCEDURE LIGHTING INSTRUCTIONS 4. If flame is not sensed during the WARNING 8th second after the gas valve This appliance is equipped with either a SHOULD OVERHEATING OCCUR OR opens, the gas valve closes, and direct spark ignition device or a hot THE GAS SUPPLY FAIL TO SHUT the igniter de-energizes. - Page 28 1. Each time the thermostat contacts attempt, the control goes into a FIGURE 18 close, the induced draft blower “self-healing” mode, in which the UT Electronic Controls 1028-928 (inducer) begins a prepurge cycle. blower and inducer run for 3 minutes before another ignition BLOWER OFF TIMINGS 2.
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Page 29: Air Flow
GAS FURNACE (DIRECT FIGURE 21 DRIVE) INSTRUCTIONS FOR TEMPERATURE RISE MEASUREMENT CHANGING BLOWER SPEED WARNING DISCONNECT THE ELECTRICAL SUPPLY TO THE FURNACE BEFORE ATTEMPTING TO CHANGE THE BLOWER SPEED. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. - Page 30 BLOWER PERFORMANCE DATA – 80PJ UPFLOW/HORIZONTAL MODELS BLOWER PERFORMANCE DATA – 80LJ DOWNFLOW MODELS ONLY...
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Page 31: Safety Features
3. Operate the furnace. restrictions in the duct system, or by adding more supply or return air duct. If 4. When the thermometer in the the measured temperature rise is below supply air duct stops rising the approved range, the air flow is too (approximately five minutes), much. - Page 32 LUBRICATION FIGURE 23 The indoor blower motor and induced DOWNFLOW BLOWER REMOVAL draft motor are prelubricated by the motor manufacturer and do not require further attention. The motors must be cleaned periodically by a qualified installer, service agency, or the gas supplier to prevent the possibility of overheating due to an accumulation of dust and dirt on the windings or on the motor...
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Page 33: Maintenance
MAINTENANCE FIGURE 24 RESIZING FILTERS & FRAME WARNING DISCONNECT MAIN ELECTRICAL POWER TO THE UNIT BEFORE ATTEMPTING ANY MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. FILTERS NOTE: 80PJ and 80LJ models are not factory equipped with filters. - Page 34 FIGURE 26 FILTER RETAINING ROD (SIDE RETURN) FILTER 45-24095-01 FILTER ROD SUPPORT ANGLE AE-60520-01 FILTER SUPPORT ANGLE AE-61883-01 FILTER ROD SUPPORT ANGLE AE-60520-01 FILTER SUPPORT ANGLE (SEE ANGLE DETAIL) AE-61883-01 FIGURE 27 DOWNFLOW FILTER INSTALLATION...
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Page 35: Troubleshooting
important that the airflow is not reduced • IMPORTANT: It is also WARNING to maximize system performance and recommended that at the beginning life. Always verify that the systems of the heating season, the flame COMBUSTIBLE MATERIAL MUST airflow is not impaired by the filtering sensor on hot surface ignition NOT BE PLACED ON OR AGAINST system that has been installed, by... -
Page 36: Troubleshooting Guide
FIGURE 28 TROUBLESHOOTING FLOWCHART INTEGRATED FURNACE CONTROL (IFC) WARNING TROUBLESHOOTING GUIDE HAZARDOUS VOLTAGE DISCONNECT POWER BEFORE SERVICING. NOTE: Most failures are not due to the IFC. Double check all other LINE VOLTAGE SERVICE MUST BE BY A TRAINED, QUALIFIED possibilities, including the ground connection, before replacing the IFC. CONNECTIONS SERVICE TECHNICIAN. - Page 37 FIGURE 29 FOR MODELS WITH UT ELECTRONIC CONTROLS 1028-928 INTEGRATED FURNACE CONTROL AND DIRECT SPARK IGNITION...
- Page 38 FIGURE 30 FOR MODELS WITH UT ELECTRONIC CONTROLS 1012-925 OR INVENSYS CLIMATE CONTROLS ICC-H1MC7-01 INTEGRATED FURNACE CONTROL AND HOT SURFACE IGNITION...
- Page 40 MANUFACTURED BY ICECO ® 5600 OLD GREENWOOD ROAD, FORT SMITH, ARKANSAS, 72908 CM 0604...