Comfortmaker F80ctl Guide

Installation, Start–Up, Operating and

Service and Maintenance Instructions

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Table 1 – Minimum Free Area Required for Each Combustion Air

opening of Duct to Outdoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Table 2 – Minimum Space Volumes for 100% Combustion, Ventila-

tion, and Dilution from Indoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table 3 – Opening Dimensions - In. (mm). . . . . . . . . . . . . . . . . . . . 10

AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

GAS PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 4 – Maximum Capacity of Pipe . . . . . . . . . . . . . . . . . . . . . . . 14

ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 5 – Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Table 6 – Minimum Allowable Input Rating of

Space-Heating Appliance in Thousands of Btuh per Hour. . . . . . . . 21

Table 7 – Combined Appliance Maximum Input Rating

in Thousands of Btuh per Hour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 8 – Recommended Minimum Vent Height Per Furnace and Vent

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

START-UP, ADJUSTMENT, AND SAFETY CHECK . . . . . . . . . . . 25

Table 9 – Altitude Derate Multiplier for U.S.A.. . . . . . . . . . . . . . . . 26

Table 10 – Gas Rate (CU ft./hr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table 11 – Blower Off Delay Setup Switch . . . . . . . . . . . . . . . . . . . 28

Table 12 – Cooling Airflow Adjustments from 1.5 to 6 Tons . . . . . 29

Table 13 – Air Delivery - CFM (With Filter). . . . . . . . . . . . . . . . . . 30

Table 14 – Furnace Setup Switch Description . . . . . . . . . . . . . . . . . 34

Table 15 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input

Rate (Tabulated Data Based on 22,000 Btuh High-Heat/14,500 Btuh

for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft. (305 M)

Above Sea Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table 16 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input

Rate (Tabulated Data Based on 21,000 Btuh High-Heat/14,500 Btuh

for Low-Heat Per Burner, Derated 4 Percent for Each 1000 Ft. (305 M)

Above Sea level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

SERVICE AND MAINTENANCE PROCEDURES. . . . . . . . . . . . . . 37

Table 17 – Filter Size Information - In. (mm) . . . . . . . . . . . . . . . . . 39

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . . . . . . . 48

EXAMPLE OF MODEL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Most states in the USA an jurisdictions in Canada have laws that require

the use of Carbon Monoxide (CO) alarms with fuel burning products.

Examples of fuel burning products are furnaces, boilers, space heaters,

generators, water heaters, stoves/ranges, clothes dryers, fireplaces,

incinerators, automobiles, and other internal combustion engines. Even

if there are no laws in your jurisdiction requiring a CO Alarm, it’s highly

recommended that whenever any fuel burning product is used in or

around the home or business that the dwelling be equipped with a CO

Alarm(s). The Consumer Product Safety Commission recommends the

use of CO Alarm(s). The CO Alarm(s) must be installed, operated, and

maintained according to the CO Alarm manufacturer’s instructions. For

more information about Carbon Monoxide, local laws, or to purchase a

CO Alarm online, please visit the following website.

https://www.kidde.com.

A200115

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1E, with permission of National Fire Protection Association, Quincy, MA

02269 and American Gas Association, Washington 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.

F80CTL & G80CTL

80% AFUE, Two-Stage, Variable–Speed

4–Way Multipoise Gas Furnace

(Series A)

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury and/or

death.

Carbon Monoxide (CO) is a colorless, odorless, and tasteless poisonous

gas that can be fatal when inhaled. Follow all installation, maintenance,

and service instructions. See additional information below regarding

the installation of a CO Alarm.

Use of the AHRI Certified TM Mark indicates

a manufacturer’s participation in the program.

For verification of certification for individual

products, go to www.ahridirectory.org .

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

A190045

Fig. 1 – Dimensional Drawing

FURNACE SIZE

CABINET WIDTH

OUTLET WIDTH

TOP AND

BOTTOM FLUE

COLLAR

BOTTOM

INLET WIDTH

VENT

CONNECTION

SIZE

SHIP WT.

LB (KG)

0451712 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 118 (53.5)

0701412 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 118 (53.5)

0701716 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 126 (57.1)

0702120 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 147 (66.7)

0901716 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 134 (60.8)

0902120 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 153 (69.4)

1102120 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 156 (70.7)

1352422 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102)*

*. 135 size furnace require a 5 or 6-in. (127 or 152 mm) vent. Use a vent adapter between furnace and vent stack. See Installation Instructions for complete installation

requirements.

169 (76.6)

U.S. ECCN: Not Subject to Regulation (N.S.R.)

SD5523-4 REV. B

NOTE: ALL DIMENSIONS IN INCH (MM)

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

SAFETY CONSIDERATIONS

Installing and servicing heating equipment can be hazardous due to gas

and electrical components. Only trained and qualified personnel should

install, repair, or service heating equipment. Untrained personnel can

perform basic maintenance functions such as cleaning and replacing air

filters. All other operations must be performed by trained service

personnel. When working on heating equipment, observe precautions in

literature, on tags, and on labels attached to or shipped with furnace and

other safety precautions that may apply.

These instructions cover minimum requirements and conform to existing

national standards and safety codes. In some instances, these instructions

exceed certain local codes and ordinances, especially those that may not

have kept up with changing residential construction practices. We

require these instructions as a minimum for a safe installation.

Wear safety glasses, protective clothing and work gloves. Have fire

extinguisher available during start-up and adjustment procedures and

service calls.

This is the safety-alert symbol . When you see this symbol on the

furnace and in instructions or manuals, be alert to the potential for

personal injury.

Understand the signal words DANGER, WARNING, and CAUTION.

These words are used with the safety-alert symbol. DANGER identifies

the most serious hazards which will result in severe personal injury or

death. WARNING signifies a hazard which could result in personal

injury or death. CAUTION is used to identify hazards which may result

in minor personal injury or product and property damage. NOTE is used

to highlight suggestions which will result in enhanced installation,

reliability, or operation.

The following additional safety considerations should be followed for

gas furnaces:

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 specified in the

“Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace

space as specified in “Air for Combustion and Ventilation” section.

4. Combustion products must be discharged outdoors. Connect this

furnace to an approved vent system only, as specified in the

“Venting” section of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially

available soap solution made specifically for the detection of leaks

to check all connections, as specified in the “Gas Piping” section.

6. Always install furnace to operate within the furnace’s intended

temperature-rise range with a duct system which has an external

static pressure within the allowable range, as specified in the

“Start-Up, Adjustments, and Safety Check” section. See furnace

rating plate.

7. When a furnace is installed so that supply ducts carry air circulated

by the furnace to areas outside the space containing the furnace, the

return air shall also be handled by duct(s) sealed to the furnace

casing and terminating outside the space containing the furnace.

See “Air Ducts” section.

8. A gas-fired furnace for installation in a residential garage must be

installed as specified in the warning box in the “Location” section.

9. The furnace may be used for construction heat provided that the

furnace installation and operation complies with the first

CAUTION in the LOCATION section of these instructions.

10. These Multipoise Gas-Fired Furnaces are CSA (formerly A.G.A.

and C.G.A.) design-certified for use with natural and propane gases

(see furnace rating plate) and for installation in alcoves, attics,

basements, closets, utility rooms, crawlspaces, and garages. The

furnace is factory-shipped for use with natural gas. A CSA (A.G.A.

and C.G.A.) listed accessory gas conversion kit is required to

convert furnace for use with propane gas.

11. See Fig. 2 for required clearances to combustible construction.

12. Maintain a 1-in. (25 mm) clearance from combustible materials to

supply air ductwork for a distance of 36 in. (914 mm) horizontally

from the furnace. See NFPA 90B or local code for further

requirements.

13. These furnaces SHALL NOT be installed directly on carpeting, tile,

or any other combustible material other than wood flooring. In

downflow installations, factory accessory floor base MUST be used

when installed on combustible materials and wood flooring. Special

base is not required when this furnace is installed on manufacturer’s

Coil Assembly Part No. END4X, ENW4X or coil casing model

number NAEA. See Fig. 2 for clearance to combustible

construction information.

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation,

personal injury, death, or property damage.

Improper installation, adjustment, alteration, service, maintenance, or

use can cause carbon monoxide poisoning, explosion, fire, electrical

shock, or other conditions which may cause personal injury or property

damage. Consult a qualified service agency, local gas supplier, or your

distributor or branch for information or assistance. The qualified

service agency must use only factory-authorized and listed kits or

accessories when modifying this product.

CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

Application of this furnace should be indoors with special attention

given to vent sizing and material, gas input rate, air temperature rise,

unit leveling, and unit sizing.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear

appropriate protective clothing, safety glasses and gloves when

handling parts, and servicing furnaces.

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

INTRODUCTION

A10269

Fig. 2 – Clearances to Combustibles

The 4-way multipoise Category I fan-assisted furnace is CSA (formerly

A.G.A. and C.G.A.) design-certified. A Category I fan-assisted furnace is

an appliance equipped with an integral mechanical means to either draw

or force products of combustion through the combustion chamber and/or

heat exchanger. The furnace is factory-shipped for use with natural gas.

This furnace is not approved for installation in mobile homes,

recreational vehicles, or outdoors.

This furnace is designed for minimum continuous return-air temperature

of 60°F (15°C) db or intermittent operation down to 55°F (13°C)db such

as when used with a night setback thermostat. Return-air temperature

must not exceed 80°F (27°C) db. Failure to follow these return-air

temperature limits may affect reliability of heat exchangers, motors, and

controls, see Fig. 3.

For accessory installation details, refer to the applicable instruction

literature.

NOTE: Remove all shipping brackets and materials before operating the

furnace.

A06745

Fig. 3 – Return Air Temperature

A02054

Fig. 4 – Prohibit Installation on Back

A93044

Fig. 5 – Installation in a Garage

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these

instructions. The installation must comply with regulations of the

serving gas supplier, local building, heating, plumbing, and other codes.

In absence of local codes, the installation must comply with the national

codes listed below and all authorities having jurisdiction.

In the United States, follow all codes and standards for the following:

Safety

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. For copies, contact the

National Fire Protection Association Inc., Batterymarch Park, Quincy,

MA 02269; (www.NFPA.org) or for only the NFGC, contact the

American Gas Association, 400 N. Capitol Street, N.W., Washington,

DC 20001 (www.AGA.org.).

Combustion and Ventilation Air

Section 9.3 NFPA 54/ANSI Z223.1, Air for Combustion and Ventilation.

WARNING

FIRE HAZARD

Failure to follow this warning could result in personal injury, death

and/or property damage.

Do not install the furnace on its back or hang furnace with control

compartment facing downward. Safety control operation will be

adversely affected. Never connect return-air ducts to the back of the

furnace, see Fig. 4.

80 / 27 C

/ 16 C

WARNING

FIRE, INJURY OR DEATH 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 in. (457 mm) above the

floor. The furnace must be located or protected to avoid damage by

vehicles. When the furnace is installed in a public garage, airplane

hangar, or other building having a hazardous atmosphere, the furnace

must be installed in accordance with the NFPA 54/ANSI Z223.1, see

Fig. 5.

18-IN. (457.2 mm)

MINIMUM TO BURNERS

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Duct Systems

Air Conditioning Contractors Association (ACCA) Manual D, Sheet

Metal and Air Conditioning Contractors National Association

(SMACNA), or American Society of Heating, Refrigeration, and Air

Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook

Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters

9 and 16.

Acoustical Lining and Fibrous Glass Duct

Current edition of SMACNA and NFPA 90B as tested by UL Standard

181 for Class I Rigid Air Ducts.

Gas Piping and Gas Pipe Pressure Testing

NFPA 54/ANSI Z223.1; Chapters 5, 6, and 7 and National Plumbing

Codes.

Electrical Connections

National Electrical Code (NEC) ANSI/NFPA70.

Venting

NFPA 54/ANSI Z223.1; Chapters 12 and 13.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

1. Disconnect all power to the furnace. Multiple disconnects may be

required. DO NOT TOUCH THE CONTROL OR ANY WIRE

CONNECTED TO THE CONTROL PRIOR TO DISCHARGING

YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the furnace

chassis which is close to the control. Tools held in a person’s hand

during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control

or connecting wires as long as you do nothing to recharge your

body with static electricity (for example; DO NOT move or shuffle

your feet, do not touch ungrounded objects, etc.).

4. If you touch ungrounded objects (and recharge your body with

static electricity), firmly touch a clean, unpainted metal surface of

the furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded)

furnaces.

6. Before removing a new control from its container, discharge your

body’s electrostatic charge to ground to protect the control from

damage. If the control is to be installed in a furnace, follow items 1

through 4 before bringing the control or yourself in contact with the

furnace. Put all used and new controls into containers before

touching ungrounded objects.

7. An ESD service kit (available from commercial sources) may also

be used to prevent ESD damage. LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration. Some

assembly and modifications are required when used in any of four

applications, see in Fig. 6.

CAUTION

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in unit component damage.

Electrostatic discharge can affect electronic components. Take

precautions during furnace installation and servicing to protect the

furnace electronic control. Precautions will prevent electrostatic

discharges from personnel and hand tools which are held during the

procedure. These precautions will help to avoid exposing the control to

electrostatic discharge by putting the furnace, the control, and the

person at the same electrostatic potential.

CAUTION

PERSONAL INJURY AND/OR PROPERTY

DAMAGE HAZARD

Improper use or installation of this furnace may result in premature

furnace component failure. This gas furnace may be used for heating

buildings under construction provided that:

– The furnace is permanently installed with all electrical wiring, piping,

venting and ducting installed according to these installation

instructions. A return air duct is provided, sealed to the furnace casing,

and terminated outside the space containing the furnace. This prevents

a negative pressure condition as created by the circulating air blower,

causing a flame rollout and/or drawing combustion products into the

structure.

– The furnace is controlled by a thermostat. It may not be “hot wired”

to provide heat continuously to the structure without thermostatic

control.

– Clean outside air is provided for combustion. This is to minimize the

corrosive effects of adhesives, sealers and other construction materials.

It also prevents the entrainment of drywall dust into combustion air,

which can cause fouling and plugging of furnace components.

– The temperature of the return air to the furnace is maintained between

55°F (13°C) and 80°F (27°C), with no evening setback or shutdown.

The use of the furnace while the structure is under construction is

deemed to be intermittent operation per our installation instructions.

– The air temperature rise is within the rated rise range on the furnace

rating plate, and the gas input rate has been set to the nameplate value.

– The filters used to clean the circulating air during the construction

process must be either changed or thoroughly cleaned prior to

occupancy.

– The furnace, ductwork and filters are cleaned as necessary to remove

drywall dust and construction debris from all HVAC system

components after construction is completed.

– Verify proper furnace operating conditions including ignition, gas

input rate, air temperature rise, and venting according to these

installation instructions.

WARNING

CARBON MONOXIDE POISONING / COMPONENT

DAMAGE HAZARD

Failure to follow this warning could result in personal injury or death

and unit component damage.

Corrosive or contaminated air may cause failure of parts containing flue

gas, which could leak into the living space. Air for combustion must not

be contaminated by halogen compounds, which include fluoride,

chloride, bromide, and iodide. These elements can corrode heat

exchangers and shorten furnace life. Air contaminants are found in

aerosol sprays, detergents, bleaches, cleaning solvents, salts, air

fresheners, and other household products. Do not install furnace in a

corrosive or contaminated atmosphere. Make sure all combustion and

circulating air requirements are met, in addition to all local codes and

ordinances.

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

A02097

Fig. 6 – Multipoise Orientations

NOTE: For high-altitude installations, the high-altitude conversion kit

MUST be installed at or above 5500 ft. (1676 M) above sea level. Obtain

high-altitude conversion kit from your area authorized distributor.

This furnace must:

• be installed so the electrical components are protected from water.

• not be installed directly on any combustible material other than

wood flooring (refer to SAFETY CONSIDERATIONS).

• be located close to the chimney or vent and attached to an air

distribution system. Refer to Air Ducts section.

• be provided ample space for servicing and cleaning. Always

comply with minimum fire protection clearances shown on the

furnace clearance to combustible construction label.

The following types of furnace installations may require OUTDOOR

AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas

If air is exposed to the following substances, it should not be used for

combustion air, and outdoor air may be required for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel

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 prevent pulling air from the

burner area and from draft safeguard opening.

AIR FOR COMBUSTION AND VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be

provided in accordance with:

• U.S. Installations: Section 9.3 of the NFPA 54/ANSI Z223.1, Air

for Combustion and Ventilation and applicable provisions of the

local building codes.

The requirements for combustion and ventilation air depend upon

whether or not the furnace is located in a space having a volume of at

least 50 cubic feet per 1,000 Btuh input rating for all gas appliances

installed in the space.

• Spaces having less than 50 cubic feet per 1,000 Btuh require the

OUTDOOR COMBUSTION AIR METHOD.

• Spaces having at least 50 cubic feet per 1,000 Btuh may use the

INDOOR COMBUSTION AIR, STANDARD or KNOWN AIR

INFILTRATION METHOD.

Minimum dimensions of 3-in. (76 mm).

NOTE: Use any of the following combinations of openings:

A & B C & D D & E F & G

A03174

Fig. 7 – Air for Combustion, Ventilation, and Dilution for Outdoors

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion,

ventilation, and dilution of flue gases using permanent horizontal or

vertical duct(s) or opening(s) directly communicating with the

outdoors or spaces that freely communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS,

one inlet and one outlet combustion and ventilation air opening, to

the outdoors.

a. One opening MUST commence within 12 in. (300 mm) of the

ceiling and the second opening MUST commence within 12 in.

(300 mm) of the floor.

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage.

Air for combustion must not be contaminated by halogen compounds,

which include fluoride, chloride, bromide, and iodide. These elements

can corrode heat exchangers and shorten furnace life. Air contaminants

are found in aerosol sprays, detergents, bleaches, cleaning solvents,

salts, air fresheners, and other household products.

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT. WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

The operation of exhaust fans, kitchen ventilation fans, clothes dryers,

attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE

CONDITION at the furnace. Make-up air MUST be provided for the

ventilation devices, in addition to that required by the furnace. Refer to

the Carbon Monoxide Poisoning Hazard warning in the venting section

of these instructions to determine if an adequate amount of make-up air

is available.

1 SQ IN.

PER

4000

BTUH*

DUCTS

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

CIRCULATING

AIR DUCTS

VENT

THROUGH

ROOF

1 SQ IN.

PER 4000

BTUH*

DUCT

OUTDOORS

CIRCULATING AIR DUCTS

1 SQ IN.

PER 2000

BTUH*

1 SQ IN.

PER 2000

BTUH*

DUCTS

OUTDOORS

12″MAX

12″

MAX

12″

MAX

OUTDOORS

1 SQ IN.

PER

4000

BTUH*

CLEARANCE IN FRONT

OF COMBUSTION AIR

OPENINGS SHALL BE

AT LEAST 3 IN.

(305mm)

(76mm)

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

b. Size openings and ducts per Fig. 7 and Table 1.

c. TWO HORIZONTAL DUCTS require 1 sq. in. (645 sq. mm) of

free area per 2,000 Btuh (1,100 mm2/kW) of combined input for

all gas appliances in the space per Fig. 7 and Table 1.

d. TWO OPENINGS OR VERTICAL DUCTS require 1 sq. in.

(645 sq. mm) of free area per 4,000 Btuh (550 mm2/kW) for

combined input of all gas appliances in the space per Fig. 7 and

Table 1.

3. ONE OUTDOOR OPENING requires:

a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh (734 mm2/kW)

for combined input of all gas appliances in the space per Table 1

and

b. Not less than the sum of the areas of all vent connectors in the

space.

NP = Not Permitted

The opening shall commence within 12 in. (300 mm) of the ceiling.

Appliances in the space shall have clearances of at least 1 in. (25 mm)

from the sides and back and 6 in. (150 mm) from the front. The opening

shall directly communicate with the outdoors or shall communicate

through a vertical or horizontal duct to the outdoors or spaces (crawl or

attic) that freely communicate with the outdoors.

•Indoor Combustion Air© NFPA & AGA

•Standard and Known-Air-Infiltration Rate Methods

•Indoor air is permitted for combustion, ventilation, and dilution, if

the Standard or Known-Air-Infiltration Method is used. The Standard Method:

Use the Standard Method if:

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of

the maximum input ratings for all gas appliances installed in the

space and

2. The air infiltration rate is not known to be less than 0.40 air changes

per hour (ACH).

Table 1 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors

FURNACE

INPUT

(BTUH)

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

Free Area of Opening and

Duct

Sq. In. (Sq. mm)

Round Duct Dia.

In. (mm)

Free Area of Opening and

Duct

Sq. In. (Sq. mm)

Round Duct Dia.

In. (mm)

Free Area of Opening and

Duct

Sq. In. (Sq. mm)

Round Duct Dia.

In. (mm)

44,000 22 (14194) 6 (152) 14.7 (9484) 5 (127) 11 (7096) 4 (102)

66,000 33 (21290) 7 (178) 22 (14193) 6 (152) 16.5 (10645) 5 (127)

88,000 44 (28387) 8 (203) 29.3 (18903) 7 (178) 22 (14193) 6 (152)

110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 (17742) 6 (152)

132,000 66 (42580) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)

EXAMPLES: DETERMINING FREE AREA

FURNACE WATER HEATER TOTAL INPUT

110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening

88,000 + 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

Table 2 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

ACH

30 40 50 44 66 88 110 132 154

Space Volume Ft3 (M3)

0.60 1,050

(29.7)

1,400

(39.6)

1,750

(49.5)

1,100

(31.1)

1,650

(46.7)

2,200

(62.2)

2,750

(77.8)

3,300

(93.4)

3,850

(109.0)

0.50 1,260

(35.6)

1,680

(47.5)

2,100

(59.4)

1,320

(37.3)

1,980

(56.0)

2,640

(74.7)

3,300

(93.4)

3,960

(112.1)

4,620

(130.8)

0.40 1,575

(44.5)

2,100

(59.4)

2,625

(74.3)

1,650

(46.7)

2,475

(70.0)

3,300

(93.4)

4,125

(116.8)

4,950

(140.1)

5,775

(163.5)

0.30 2,100

(59.4)

2,800

(79.2)

3,500

(99.1)

2,200

(62.2)

3,300

(93.4)

4,400

(124.5)

5,500

(155.7)

6,600

(186.8)

7,700

(218.0)

0.20 3,150

(89.1)

4,200

(118.9)

5,250

(148.6)

3,300

(93.4)

4,950

(140.1)

6,600

(186.8)

8,250

(233.6)

9,900

(280.3)

11,550

(327.0)

0.10 6,300

(178.3)

8,400

(237.8)

10,500

(297.3)

6,600

(186.8)

9,900

(280.3)

13,200

(373.7)

16,500

(467.2)

19,800

(560.6)

23,100

(654.1)

0.00 NP NP NP NP NP NP NP NP NP

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Many homes require air to be supplied from outdoors for furnace

combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in accordance

with this instruction manual.

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Use the Known Air Infiltration Rate Method if the infiltration rate is

known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum

required volume of the space varies with the number of ACH and shall

be determined per Table 2 or Equations 1 and 2. Determine the minimum

required volume for each appliance in the space and add the volumes

together to get the total minimum required volume for the space.

Table 2 - Minimum Space Volumes were determined by using the

following equations from the National Fuel Gas Code ANSI

Z223.1/NFPA 54, 9.3.2.2:

1. For other than fan-assisted appliances, such as a draft

hood-equipped water heater, use the following equation:

A04002

2. For fan-assisted appliances such as this furnace, use the following

equation:

A04003

If the following is applied to either equation:

Iother = combined input of all other than fan-assisted appliances in

Btuh/hr

Ifan = combined input of all fan-assisted appliances in Btuh/hr

ACH = air changes per hour (ACH shall not exceed 0.60.)

* Minimum opening size is 100 sq in. (64516 sq. mm) with minimum dimensions of 3 in.

(76 mm)

† Minimum of 3 in. (76 mm) when type-B1 vent is used.

A03175

Fig. 8 – Air for Combustion, Ventilation, and Dilution from Indoors

Then the following requirements apply to both the Standard Method

and to the Known Air Infiltration Rate Method:

1. Adjoining rooms can be considered part of a space if:

a. There are no closeable doors between rooms.

b. Combining spaces on same floor level. Each opening shall have

free area of at least 1 in.2/1,000 Btuh (2,000 mm2/kW) of the

total input rating of all gas appliances in the space, but not less

than 100 in.2 (0.06 m2). One opening shall commence within 12

in. (300 mm) of the ceiling and the second opening shall

commence within 12 in. (300 mm) of the floor. The minimum

dimension of air openings shall be at least 3 in. (80 mm), see

Fig. 8.

c. Combining space on different floor levels. The volumes of

spaces on different floor levels shall be considered as

communicating spaces if connected by one or more permanent

openings in doors or floors having free area of at least 2

in.2/1,000 Btuh (4,400 mm2/kW) of total input rating of all gas

appliances

2. An attic or crawlspace may be considered a space that freely

communicates with the outdoors provided there are adequate

permanent ventilation openings directly to outdoors having free

area of at least 1-in.2/4,000 Btuh of total input rating for all gas

appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration

should be adequate to provide air for combustion, permanent

ventilation and dilution of flue gases. However, in buildings with

unusually tight construction, additional air MUST be provided

using the methods described in the Outdoor Combustion Air

Method section.

4. Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a continuous,

sealed vapor barrier. Openings are gasketed or sealed and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include joints

around window and door frames, between sole plates and floors,

between wall-ceiling joints, between wall panels, at penetrations

for plumbing, electrical and gas lines, etc.

Combination of Indoor and Outdoor Air

1. Indoor openings shall comply with the Indoor Combustion Air

Method below and,

2. Outdoor openings shall be located as required in the Outdoor

Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided by

required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the Ratio in a.

above.

c. Minimum size of Outdoor openings shall be the size required in

Outdoor Combustion Air Method above multiplied by reduction

Factor in b. above. The minimum dimension of air openings shall

be not less than 3 in. (80 mm).

INSTALLATION

UPFLOW INSTALLATION

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom

return-air opening. Remove and discard this panel when bottom return

air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom filler

panel, see Fig. 9.

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

A10273

Fig. 9 – Removing Bottom Closure Panel

Volume Other =21ft3

ACH

I other

1000 Btu/hr

Volume Fan =15ft3

ACH

I fan

1000 Btu/hr

CIRCULATING AIR

DUCTS

6" MIN

(FRONT)Ü

CIRCULATING AIR DUCTS

VENT THROUGH ROOF

1 SQ IN.

PER 1000

BTUH* IN DOOR

ORWALL

12" MAX

1 SQ IN.

PER 1000

BTUH* IN DOOR

ORWALL

12" MAX

UNCONFINED

SPACE

INTERIOR

HEATED

SPACE

CLEARANCE IN FRONT OF COMBUSTION AIR

OPENINGS SHALL BE AT LEAST3 IN.

(305mm)

(152mm)

(305mm)

Bottom

Closure Panel

Bottom Filler Panel

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom

return-air opening. This panel MUST be in place when only side return

air is used.

NOTE: Side return-air openings can be used in UPFLOW and most

HORIZONTAL configurations. Do not use side return-air openings in

DOWNFLOW configuration.

DOWNFLOW INSTALLATION

NOTE: For downflow applications, this furnace is approved for use on

combustible flooring when any one of the following accessories are

used:

•Downflow combustible factory-approved floor subbase

•Coil model numbers EAM4X, EDM4X, EMA4X, END4X or ENW4X

•Coil casing model number NAEA

1. Determine application being installed from Table 3.

2. Construct hole in floor, see Table 3 and Fig. 10.

3. Construct plenum to dimensions specified, see Table 3 and Fig. 10.

4. If downflow subbase is used, install as, see Fig. 11. If coil model

numbers END4X, ENW4X or coil casing model number NAEA are

used, install as, see Fig. 12.

NOTE: It is recommended that the perforated supply-air duct flanges be

completely folded over or removed from furnace when installing the

furnace on a factory-supplied cased coil or coil box. To remove the

supply-air duct flange, use wide duct pliers or hand seamers to bend

flange back and forth until it breaks off. Be careful of sharp edges. Refer

to Duct Flanges (Fig. 17) in the “Air Ducts” section.

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom

return-air opening. Remove and discard this panel when bottom return

air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom filler

panel, Fig. 9.

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

A96283

Fig. 10 – Floor and Plenum Opening Dimensions

A96285

Fig. 11 – Furnace, Plenum, and Subbase Installed on a Combustible

Floor

A08556

Fig. 12 – Furnace, Plenum, and Coil Assembly or Coil Box Installed

on a Combustible Floor

HORIZONTAL INSTALLATION

The furnace can be installed horizontally in an attic or crawlspace on

either the left-hand (LH) or right-hand (RH) side. The furnace can be

hung from floor joists, rafters or trusses or installed on a

non-combustible platform, blocks, bricks or pad.

Suspended Furnace Support

The furnace may be supported under each end with threaded rod, angle

iron or metal plumber’s strap as shown, see Fig. 14 and Fig. 15. Secure

angle iron to bottom of furnace as shown. Heavy-gauge sheet metal

straps (plumber’s straps) may be used to suspend the furnace from each

bottom corner. To prevent screws from pulling out, use 2 #8 x in. screws

into the side and 2 #8 x in. screws in the bottom of the furnace casing for

each strap, see Fig. 14 and Fig. 15.

If the screws are attached to ONLY the furnace sides and not the bottom,

the straps must be vertical against the furnace sides and not pull away

from the furnace sides, so that the strap attachment screws are not in

tension (are loaded in shear) for reliable support.

Platform Furnace Support

Construct working platform at location where all required furnace

clearances are met, see Fig. 2 and Fig. 13. For furnaces with 1-in. (25

mm) clearance requirement on side, set furnace on non-combustible

blocks, bricks or angle iron. For crawlspace installations, if the furnace

is not suspended from the floor joists, the ground underneath furnace

must be level and the furnace set in blocks or bricks.

PLENUM

OPENING

FLOOR

OPENING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

APPROVED

COIL ASSEMBLY

COIL BOX

FURNACE

SHEET METAL

PLENUM

FLOOR

OPENING

COMBUSTIBLE

FLOORING

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Roll-Out Protection

Provide a minimum 17-3/4-in. X 22-in. (451 X 559 mm) piece of sheet

metal for flame roll-out protection in front of burner area for furnaces

closer than 12-in. (305 mm) above the combustible deck or suspended

furnaces closer than 12-in. (305 mm) to joists. The sheet metal MUST

extend underneath the furnace casing by 1-in. (25 mm) with the door

removed.

The bottom closure panel on furnaces of widths 17-1/2-in. (445 mm) and

larger may be used for flame roll-out protection when bottom of furnace

is used for return air connection. See Fig. 13 for proper orientation of

roll-out shield.

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom

return-air opening. Remove and discard this panel when bottom return

air is used. To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove two screws holding bottom filler

panel, see Fig. 9.

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

A10164

Fig. 13 – Typical Attic Installation

Side Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom

return-air opening. This panel MUST be in place when side return air

inlet(s) are used without a bottom return air inlet.

Not all horizontal furnaces are approved for side return air connections,

see Fig. 20.

Table 3 – Opening Dimensions - In. (mm)

FURNACE

CASING

WIDTH

IN. (mm)

APPLICATION

PLENUM OPENING FLOOR OPENING

A B C D

14–3/16

(360)

Upflow Applications on Combustible or Noncombustible

Flooring (subbase not required)

12-11/16

(322)

21-5/8

(549)

13-5/16

(338)

22-1/4

(565)

Downflow Applications on Noncombustible Flooring

(subbase not required)

12-9/16

(319)

(483)

13-3/16

(335)

19-5/8

(498)

Downflow applications on Combustible Flooring

(subbase required)

11-13/16

(284)

(483)

13-7/16

(341)

20-5/8

(600)

Downflow Applications on Combustible Flooring with coil assembly or coil

box (subbase not required)

12-5/16

(319)

(483)

13-5/16

(338)

(508)

17–1/2

(445)

Upflow Applications on Combustible or Noncombustible

Flooring (subbase not required)

(406)

21-5/8

(549)

16-5/8

(422)

22-1/4

(565)

Downflow Applications on Noncombustible Flooring

(subbase not required)

15-7/8

(403)

(483)

16-1/2

(419)

19-5/8

(498)

Downflow Applications on Combustible Flooring

(subbase required)

15-1/8

(384)

(483)

16-3/4

(425)

20-5/8

(600)

Downflow Applications on Combustible Flooring with coil assembly or coil

box (subbase not required)

15-1/2

(394)

(483)

16-1/2

(419)

(508)

(533)

Upflow Applications on Combustible or Noncombustible

Flooring (subbase not required)

19-1/2

(495)

21-5/8

(549)

20-1/8

(511)

22-1/4

(565)

Downflow Applications on Noncombustible Flooring

(subbase not required)

19-3/8

(492)

(483)

(508)

19-5/8

(498)

Downflow Applications on Combustible Flooring

(subbase required)

18-5/8

(473)

(483)

20-1/4

(514)

20-5/8

(600)

Downflow Applications on Combustible Flooring with coil assembly or coil

box (subbase not required)

(483)

(508)

24-1/2

(622)

Upflow Applications on Combustible or Noncombustible

Flooring (subbase not required)

(584)

21-1/8

(537)

23-5/8

(600)

22-1/4

(565)

Downflow Applications on Noncombustible Flooring

(subbase not required)

22-7/8

(581)

(483)

23-1/2

(597)

19-5/8

(498)

Downflow Applications on Combustible Flooring

(subbase required)

22-1/8

(562)

(483)

23-3/4

(603)

20-5/8

(600)

Downflow Applications on Combustible Flooring with coil assembly or coil

box (subbase not required)

22-1/2

(572)

(483)

23-1/2

(597)

(508)

30-IN. (762mm)

MIN WORK AREA

6″ MIN*

TYPE-B

VENT

17 3/4

″

SHEET

METAL

SEDIMENT

TRAP

EQUIPMENT MANUAL

SHUT-OFF GAS VALVE

LINE CONTACT ONLY PERMISSIBLE BETWEEN

LINES FORMED BY INTERSECTIONS OF

THE TOP AND TWO SIDES OF THE FURNACE

JACKET AND BUILDING JOISTS,

STUDS, OR FRAMING.

GAS

ENTRY

17 3/4

″

(451mm)

OVERALL

4 3/4

″

(121mm)

UNDER DOOR

1″

(25mm)

UNDER FURNACE

EXTEND OUT 12″

(305mm)

FROM FACE OF DOOR

* WHEN USED WITH

SINGLE WALL VENT

CONNECTIONS

UNION

(152mm)

(451mm)

(559mm)

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

A10130

Fig. 14 – Horizontal Unit Suspension

A10131

Fig. 15 – Horizontal Suspension with Straps

FILTER ARRANGEMENT

There are no provisions for an internal filter rack in these furnaces. A

field-supplied accessory external filter rack is required.

Refer to the instructions supplied with the external filter rack for

assembly and installation options.

Leveling Legs (If Desired)

In upflow position with side return inlet(s), leveling legs may be used,

see Fig. 16. Install field-supplied, 5/16 X 1-1/2 in. (8 X 38 mm) (max)

corrosion-resistant machine bolts, washers and nuts.

A89014

Fig. 16 – Leveling Legs

NOTE: Bottom closure must be used when leveling legs are used. It

may be necessary to remove and reinstall bottom closure panel to install

leveling legs. To remove bottom closure panel, see Item 1 in “Bottom

Return Air Inlet” section in Step 1 above.

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom

corner of furnace, see Fig. 16.

2. For each leg, install nut on bolt and then install bolt with nut in

hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer

if desired.)

4. Adjust outside nut to provide desired height, and tighten inside nut

to secure arrangement.

5. Reinstall bottom closure panel if removed.

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the downstream

side of the unit to avoid condensation in the heat exchangers. When

installed parallel with the furnace, dampers or other flow control must

prevent chilled air from entering the furnace. If the dampers are

manually operated, they must be equipped with means to prevent

operation of either unit unless the damper is in the full-heat or full-cool

position.

AIR DUCTS

GENERAL REQUIREMENTS

The duct system should be designed and sized according to accepted

national standards such as those published by: Air Conditioning

Contractors Association (ACCA), Sheet Metal and Air Conditioning

Contractors National Association (SMACNA) or American Society of

Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or

consult The Air Systems Design Guidelines reference tables available

from your local distributor. The duct system should be sized to handle

the required system design CFM at the design external static pressure.

The furnace airflow rates are provided in Table 13-Air Delivery-CFM

(With Filter). When a furnace is installed so that the supply ducts carry

air circulated by the furnace to areas outside the space containing the

WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE

POISONING HAZARD

Failure to follow this warning could result in personal injury, death, or

property damage.

Do not install the furnace on its back or hang furnace with control

compartment facing downward. Safety control operation will be

adversely affected. Never connect return-air ducts to the back of the

furnace.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, or death.

Never operate a furnace without a filter or with filter access door

removed.

1/4" (6mm) THREADED ROD

4 REQ.

SECURE ANGLE

IRON TO BOTTOM

OF FURNACE WITH

3 #8 x3/4" (19mm) SCREWS

TYPICAL FOR 2 SUPPORTS

1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm)

ANGLE IRON OR UNI-STRUT MAY BE USED

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS

REQ. PER ROD

8" (203mm) MIN

FOR DOOR REMOVAL

OUTER DOOR

ASSEMBLY

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).

(44mm)

(8mm)

(44mm)

(8mm)

(44mm)

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

furnace, the return air shall also be handled by duct(s) sealed to the

furnace casing and terminating outside the space containing the furnace.

Secure ductwork with proper fasteners for type of ductwork used. Seal

supply- and return-duct connections to furnace with code approved tape

or duct sealer.

NOTE: Flexible connections should be used between ductwork and

furnace to prevent transmission of vibration.

Ductwork passing through unconditioned space should be insulated to

enhance system performance. When air conditioning is used, a vapor

barrier is recommended.

Maintain a 1-in. (25 mm) clearance from combustible materials to

supply air ductwork for a distance of 36-in. (914 mm) horizontally from

the furnace. See NFPA 90B or local code for further requirements

Ductwork Acoustical Treatment

NOTE: Metal duct systems that do not have a 90 degree elbow and 10

ft. (3 M) of main duct to the first branch take-off may require internal

acoustical lining. As an alternative, fibrous ductwork may be used if

constructed and installed in accordance with the latest edition of

SMACNA construction standard on fibrous glass ducts. Both acoustical

lining and fibrous ductwork shall comply with NFPA 90B as tested by

UL Standard 181 for Class 1 Rigid air ducts.

SUPPLY AIR CONNECTIONS

For a furnace not equipped with a cooling coil, the outlet duct shall be

provided with a removable access panel. This opening shall be

accessible when the furnace is installed and shall be of such a size that

the heat exchanger can be viewed for possible openings using light

assistance or a probe can be inserted for sampling the air stream. The

cover attachment shall prevent leaks.

Upflow and Horizontal Furnaces

Connect supply-air duct to flanges on furnace supply-air outlet. Bend

flange upward to 90° with wide duct pliers, see Fig. 17. The supply-air

duct must be connected to ONLY the furnace supply-outlet-air duct

flanges or air conditioning coil casing (when used). DO NOT cut main

furnace casing side to attach supply air duct, humidifier, or other

accessories. All accessories MUST be connected to duct external to

furnace main casing.

NOTE: For horizontal applications, the top most flange may be bent

past 90° to allow the evaporator coil to hang on the 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. 17. The supply-air duct

must be connected to ONLY the furnace supply outlet or air conditioning

coil casing (when used). When installed on combustible material,

supply-air duct must be connected to ONLY the factory-approved

accessory subbase, or a factory-approved air conditioning coil casing.

DO NOT cut main furnace casing to attach supply side air duct,

humidifier, or other accessories. All accessories MUST be connected to

duct external to furnace casing.

RETURN AIR CONNECTIONS

A190346

Fig. 17 – Duct Flanges

Downflow Furnaces

The return-air duct must be connected to return-air opening bottom inlet,

see Fig. 1. DO NOT cut into casing sides (left or right). Side opening is

permitted for only upflow and certain horizontal furnaces. Bypass

humidifier connections should be made at ductwork or coil casing sides

exterior to furnace, see Fig. 18.

Upflow and Horizontal Furnaces

The return-air duct must be connected to bottom, sides (left or right), or a

combination of bottom and side(s) of main furnace casing, see Fig. 1.

Bypass humidifier may be attached into unused return air side of the

furnace casing, see Fig. 19 and Fig. 20. Not all horizontal furnace

models are approved for side return air connections, see Fig. 20.

WARNING

FIRE HAZARD

A 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.

UPFLOW/

HORIZONTAL DOWNFLOW

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

A02163

Fig. 18 – Downflow Return Air Configurations and Restrictions

A02075

Fig. 19 – Upflow Return Air Configurations and Restrictions

A02162

Fig. 20 – Horizontal Return Air Configurations and Restrictions

DOWNFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

GAS PIPING

Gas piping must be installed in accordance with national and local

codes. Refer to current edition of NFGC in the U.S.

Installations must be made in accordance with all authorities having

jurisdiction. If possible, the gas supply line should be a separate line

running directly from meter to furnace.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber

or gas fitter.

2. When flexible connectors are used, the maximum length shall not

exceed 36 in. (915 mm).

3. When lever handle type manual equipment shutoff valves are used,

they shall be T-handle valves.

4. The use of copper tubing for gas piping is NOT approved by the

state of Massachusetts.

Refer to Table 4 for recommended gas pipe sizing. Risers must be used

to connect to furnace and to meter. Support all gas piping with

appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft.

(1.8 M). Joint compound (pipe dope) should be applied sparingly and

only to male threads of joints. Pipe dope must be resistant to the action

of propane gas.

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14-In. W.C.) or less and a pressure

drop of 0.5-In. W.C. (based on a 0.60 specific gravity gas). Ref: Table 6 and 9.2 NFGC.

An accessible manual equipment shutoff valve MUST be installed

external to furnace casing and within 6 ft. (1.8 M) of furnace. A 1/8-in.

(3 mm) NPT plugged tapping, accessible for test gauge connection,

MUST be installed immediately upstream of gas supply connection to

furnace and downstream of manual equipment shutoff valve.

NOTE: The furnace gas control valve inlet pressure tap connection is

suitable to use as test gauge connection providing test pressure DOES

NOT exceed maximum 0.5 psig (14-In. W.C.) stated on gas control

valve, see Fig. 21.

Some installations require gas entry on right side of furnace (as viewed

in upflow), see Fig. 22.

A04167

Fig. 21 – Redundant Automatic Gas Control Valve

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death,

and/or property damage.

Never purge a gas line into a combustion chamber. Never test for gas

leaks with an open flame. Use a commercially available soap solution

made specifically for the detection of leaks to check all connections. A

fire or explosion may result causing property damage, personal injury

or loss of life.

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death,

and/or property damage.

Use proper length of pipe to avoid stress on gas control manifold and

gas valve.

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death,

and/or property damage.

Gas valve inlet and/or inlet pipe must remain capped until gas supply

line is permanently installed to protect the valve from moisture and

debris. Also, install a sediment trap in the gas supply piping at the inlet

to the gas valve.

Table 4 – Maximum Capacity of Pipe

NOMINAL

IRON PIPE

SIZE

IN. (MM)

INTERNAL

DIA.

IN. (MM)

LENGTH OF PIPE - FT (M)

(3.0)

(6.0)

(9.1)

(12.1)

(15.2)

1/2 (12.7) 0.622(158) 175 120 97 82 73

3/4 (19.0) 0.824 (20.9) 360 250 200 170 151

1 ( 25.4) 1.049 (26.6) 680 465 375 320 285

1-1/4 (31.8) 1.380 (35.0) 1400 950 770 660 580

1-1/2 (38.1) 1.610 (40.9) 2100 1460 1180 990 900

WARNING

FIRE OR EXPLOSION HAZARD

A failure to follow this warning could result in 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. Do not use a connector which has

previously served another gas appliance. Black iron pipe shall be

installed at the furnace gas control valve and extend a minimum of 2-in.

(51 mm) outside the furnace.

CAUTION

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace damage.

Connect gas pipe to furnace using a backup wrench to avoid damaging

gas controls and burner misalignment.

REGULATOR COVER SCREW

PLASTIC ADJUST SCREW

LOW STAGE

GAS PRESSURE

REGULATOR ADJUSTMENT

MANIFOLD

PRESSURE TAP

INLET

PRESSURE TAP

ON/OFF SWITCH

REGULATOR SPRING

HIGH STAGE GAS

PRESSURE REGULATOR

ADJUSTMENT

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

A08551

Fig. 22 – Burner and Manifold

Install a sediment trap in riser leading to furnace, see Fig. 23. Connect a

capped nipple into lower end of tee. Capped nipple should extend below

level of furnace gas controls. Place a ground joint union between furnace

gas control valve and exterior manual equipment gas shutoff valve.

A 1/8-in. (3 mm) NPT plugged tapping, accessible for test gauge

connection, MUST be installed immediately upstream of gas supply

connection to furnace and downstream of manual equipment shutoff

valve.

A02035

Fig. 23 – Typical Gas Pipe Arrangement

Piping should be pressure and leak tested in accordance with the current

addition of the NFGC in the United States, local, and national plumbing

and gas codes before the furnace has been connected. After all

connections have been made, purge lines and check for leakage at

furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14-In. W.C.), gas supply pipe must be

disconnected from furnace and capped before and during supply pipe

pressure test. If test pressure is equal to or less than 0.5 psig (14-In.

W.C.), turn off electric shutoff switch located on furnace gas control

valve and accessible manual equipment shutoff valve before and during

supply pipe pressure test. After all connections have been made, purge

lines and check for leakage at furnace prior to operating furnace.

The gas supply pressure shall be within the maximum and minimum

inlet supply pressures marked on the rating plate with the furnace

burners ON and OFF.

ELECTRICAL CONNECTIONS

See Fig. 24 for field wiring diagram showing typical field 115-v wiring.

Check all factory and field electrical connections for tightness.

Field-supplied wiring shall conform with the limitations of 63°F (33°C)

rise.

2” (51mm)

Street Elbow

UNION

SEDIMENT

TRAP

MANUAL

SHUTOFF

VALVE

(REQUIRED)

GAS

SUPPLY

WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings could result in dangerous operation,

serious injury, death or property damage.

Improper servicing could result in dangerous operation, serious injury,

death or property damage.

- Before servicing, disconnect all electrical power to furnace.

- When servicing controls, label all wires prior to disconnection.

Reconnect wires correctly.

- Verify proper operation after servicing.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower access panel door switch opens 115-v power to control. No

component operation can occur. Do not bypass or close switch with

panel removed.

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or

property damage.

The cabinet MUST have an uninterrupted or unbroken ground

according to NEC NFPA 70 or local codes to minimize personal injury

if an electrical fault should occur. This may consist of electrical wire,

conduit approved for electrical ground or a listed, grounded power cord

(where permitted by local code) when installed in accordance with

existing electrical codes. Refer to the power cord manufacturer’s

ratings for proper wire gauge. Do not use gas piping as an electrical

ground.

CAUTION

FURNACE MAY NOT OPERATE HAZARD

Failure to follow this caution may result in intermittent furnace

operation.

Furnace control must be grounded for proper operation or else control

will lock out. Control must remain grounded through green/yellow wire

routed to gas valve and manifold bracket screw.

WARNING

FIRE HAZARD

Failure to follow this warning could result in personal injury, death, or

property damage.

Do not connect aluminum wire between disconnect switch and furnace.

Use only copper wire, see Fig. 25.

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

A95236

Fig. 24 – Field Wiring Diagram

A190279

Fig. 25 – Field-Supplied External

Electrical Box on Furnace Casing

115-V Wiring

Verify that the voltage, frequency, and phase correspond to that specified

on unit rating plate. Also, check to be sure that service provided by

utility is sufficient to handle load imposed by this equipment. Refer to

rating plate or Table 5 for equipment electrical specifications.

U.S. Installations: Make all electrical connections in accordance with

National Electrical Code (NEC) NFPA 70 and any local codes or

ordinances that might apply.

Use a separate, fused branch electrical circuit with a properly sized fuse

or circuit breaker for this furnace. See Table 5 for wire size and fuse

specifications. A readily accessible means of electrical disconnect must

be located within sight of the furnace.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity

is incorrect, control LED status indicator light will flash status code 10

and furnace will NOT operate.

J-BOX RELOCATION

NOTE: If factory location of J-Box is acceptable, go to next section

(ELECTRICAL CONNECTION to J-Box).

NOTE: On 14-in. (356 mm) wide casing models, the J-Box shall not be

relocated to other side of furnace casing when the vent pipe is routed

within the casing.

1. Remove and save two screws holding J-Box, see Fig. 26.

NOTE: The J-Box cover need not be removed from the J-Box in order

to move the J-Box. Do NOT remove green ground screw inside J-Box,

see Fig. 26.

2. Cut wire tie on loop in furnace wires attached to J-Box.

3. Move J-Box to desired location.

4. Fasten J-Box to casing with the two screws removed in Step 1.

5. Route J-Box wires within furnace away from sharp edges, rotating

parts and hot surfaces.

Table 5 – Electrical Data

FURNACE

SIZE

VOLTS-

HERTZ-

PHASE

OPERATING

VOLTAGE RANGE*

*. Permissible limits of the voltage range at which the unit operates satisfactorily.

MAX.

UNIT

AMPS

UNIT

AMPACITY†

†. Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier, etc.) full load

amps.

MAX. WIRE LENGTH

- FT (M)‡

‡. Length shown is as measured 1 way along wire path between furnace and service panel for maximum 2 percent voltage drop.

MAX. FUSE OR CKT

BKR AMPS **

**. Time-delay type is recommended.

MIN. WIRE

GAUGE

Max. Min.

0451712 115-60-1 127 104 9.0 12.0 30 (9.4) 15 14

0701412 115-60-1 127 104 9.0 12.0 30 (9.4) 15 14

0701716 115-60-1 127 104 9.0 13.0 28 (8.7) 15 14

0702120 115-60-1 127 104 14.1 18.4 31 (9.5) 20 12

0901716 115-60-1 127 104 9.6 12.63 29 (9.0) 15 14

0902120 115-60-1 127 104 14.7 19.0 30 (9.2) 20 12

1102120 115-60-1 127 104 15.0 19.3 29 (9.1) 20 12

1352422 115-60-1 127 104 15.0 19.3 29 (9.1) 20 12

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

JUNCTION

BOX CONTROL

BOX

24-VOLT

TERMINAL

BLOCK

THREE-WIRE

HEATING-

ONLY

FIVE

WIRE

NOTE 2

NOTE 1

1-STAGE

THERMOSTAT

TERMINALS

FIELD-SUPPLIED

FUSED DISCONNECT

CONDENSING

UNIT

FURNACE

COM

WCY RG

GND

FIELD 24-VOLT WIRING

FIELD 115-, 208/230-, 460-VOLT WIRING

FACTORY 24-VOLT WIRING

FACTORY 115-VOLT WIRING

Connect Y/Y2-terminal as shown for proper operation.

Some thermostats require a "C" terminal connection as shown.

If any of the original wire, as supplied, must be replaced, use

same type or equivalent wire.

208/230- O

460-VOLT

THREE

PHASE

208/230-

VOLT

SINGLE

PHASE

BLK

WHT

BLK

W/W1

Y/Y2

NOTES: 1.

COPPER

WIRE ONLY

ELECTRIC

DISCONNECT

SWITCH

ALUMINUM

WIRE

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

A10291

Fig. 26 – Relocating J-Box

Electrical Connection to J-Box

Electrical Box on Furnace Casing Side

A190278

Fig. 27 – Field-Supplied Electrical Box on Furnace Casing

1. Select and remove a hole knockout in the casing where the

electrical box is to be installed.

NOTE: Check that duct on side of furnace will not interfere with

installed electrical box.

2. Remove the desired electrical box hole knockout and position the

hole in the electrical box over the hole in the furnace casing.

3. Fasten the electrical box to casing by driving two field-supplied

screws from inside electrical box into casing steel.

4. Remove and save two screws holding J-Box, see Fig. 26.

5. Pull furnace power wires out of 1/2-in. (12 mm) diameter hole in

J-Box. Do not loosen wires from strain-relief wire-tie on outside of

J-Box.

6. Route furnace power wires through holes in casing and electrical

box and into electrical box.

7. Pull field power wires into electrical box.

8. Remove cover from furnace J-Box.

9. Route field ground wire through holes in electrical box and casing,

and into furnace J-Box.

10. Reattach furnace J-Box to furnace casing with screws removed in

Step 4.

11. Secure field ground wire to J-Box green ground screw.

12. Complete electrical box wiring and installation. Connect line

voltage leads, see Fig. 27. Use best practices (NEC in U.S. for wire

bushings, strain relief, etc.

13. Reinstall cover to J-Box. Do not pinch wires between cover and

bracket.

Power Cord Installation in Furnace J-Box

NOTE: Power cords must be able to handle the electrical requirements

listed in Table 5. Refer to power cord manufacturer’s listings.

1. Remove cover from J-Box.

2. Route listed power cord through 7/8-in. (22 mm) diameter hole in

J-Box.

3. Secure power cord to J-Box bracket with a strain relief bushing or a

connector approved for the type of cord used.

4. Secure field ground wire to green ground screw on J-Box bracket.

5. Connect line voltage leads, see Fig. 24.

6. Reinstall cover to J-Box. Do not pinch wires between cover and

bracket.

BX Cable Installation in Furnace J-Box

1. Remove cover from J-Box.

2. Route BX cable into 7/8-in. (22 mm) diameter hole in J-Box.

3. Secure BX cable to J-Box bracket with connectors approved for the

type of cable used.

4. Secure field ground wire to green ground screw on J-Box bracket.

5. Connect line voltage leads, see Fig. 24.

6. Reinstall cover to J-Box. Do not pinch wires between cover and

bracket.

24-V Wiring

Make field 24-v connections at the 24-v terminal strip, see Fig. 24 -

Fig. 32. Connect terminal Y/Y2 as shown in Fig. 28 - Fig. 31 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. Any direct shorts during installation, service, or maintenance

could cause this fuse to blow. If fuse replacement is required, use ONLY

a 3-amp. fuse of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC)

Connect an accessory Electronic Air Cleaner (if used) using 1/4-in

female quick connect terminals to the two male 1/4-in

quick-connect terminals on the control board marked EAC-1 and

EAC-2. The terminals are rated for 115VAC, 1.0 amps maximum

and are energized during blower motor operation, see Fig. 32.

2. Humidifier (HUM)

Connect an accessory 24 VAC, 0.5 amp. maximum humidifier

(if used) to the 1/4-in male quick-connect HUM terminal and

COM-24V screw terminal on the control board thermostat strip.

The HUM terminal is energized when blower is energized in

heating, see Fig. 32.

NOTE: DO NOT connect furnace control HUM terminal to HUM

(humidifier) terminal on Thermostat, Zone Controller or similar device.

See Thermostat, Zone Controller, thermostat, or controller

manufacturer’s instructions for proper connection.

WARNING

FIRE OR ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, death, or

property damage.

If field-supplied manual disconnect switch is to be mounted on furnace

casing side, select a location where a drill or fastener cannot damage

electrical or gas components.

FactoryFactory

InstalledInstalled

AlternateAlternate

LocationLocation

GROUND

NEUTRAL

INE VOLTAGE

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

L09F025

Fig. 28 – Variable Furnace with Single-Speed Air Conditioner

L09F026

Fig. 29 – Variable Furnace with Two-Speed Air Conditioner

L09F026

Fig. 30 – Variable Furnace with Single-Speed Heat Pump

(Dual Fuel)

L09F028

Fig. 31 – Variable Furnace with Two-Speed Heat Pump

(Dual Fuel)

NOTES FOR FIGURE 28 - FIGURE 31

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 applications.

3. Refer to ICP thermostat Installation Instructions for additional information and setup procedure.

4. When using a Humidity Sensing Thermostat, set DEHUMIDIFY OPTIONS to H DE-ENRGZD FOR DEHUM.

5. Optional connection. If wire is connected SW1-2 on VS furnace control should be set in ON position to allow

ICP Thermostat to control the furnace staging.

6. HUM connection is 24 VAC and is energized when the blower turns on during a call for heat.

7. When connecting 115 VAC to humidifier use a separate 115 VAC supply.

8. When using a humidifier on a HP installation connect humidifier to

hot water.

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

A190154

Fig. 32 – Variable Speed Furnace Control for ECM Blower Motor

VENTING

The furnace shall be connected to a listed factory built chimney or vent,

or a clay-tile lined masonry or concrete chimney. Venting into an unlined

masonry chimney or concrete chimney is prohibited.

When an existing Category I furnace is removed or replaced, the original

venting system, may no longer be sized to properly vent the attached

appliances. An improperly sized Category I venting system could cause

the formation of condensate in the furnace and vent, leakage of

condensate and combustion products, and spillage of combustion

products into the living space.

Vent system or vent connectors may need to be resized. Vent systems or

vent connectors must be sized to approach minimum size as determined

using appropriate table found in the current edition of NFGC.

GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation

requirements, including local building codes, the National Fuel Gas

Code NFPA 54/ANSI Z223.1 (NFGC), Parts 12 and 13 in the United

States, the local building codes, and furnace and vent manufacturers’

instructions.

These furnaces are design-certified as Category I furnaces in accordance

with ANSI Z21.47/CSA 2.3 and operate with a non-positive vent static

pressure to minimize the potential for vent gas leakage. Category I

furnaces operate with a flue loss not less than 17 percent to minimize the

potential for condensation in the venting system. These furnaces are

approved for common venting and multistory venting with other fan

assisted or draft hood equipped appliances in accordance with the

NFGC, the local building codes, and furnace and vent manufacturers’

instructions. The following information and warning must be considered

in addition to the requirements defined in the NFGC.

1. If a vent (common or dedicated) becomes blocked, the furnace will

be shut off by the draft safeguard switch located on the vent elbow.

2. Two-stage furnaces require Type B vent connectors outside the

casing in all configurations. Single wall vent connector may be

used inside the furnace casing with the transition to Type B vent

outside the furnace casing. Size the connector so that the FAN-Min

vent connector capacity is equal to or lower than the low fire rate of

the furnace and the FAN-Max vent connector capacity is equal to or

higher than the furnace high fire rate.

3. Do not vent this Category I furnace into a single wall dedicated or

common vent. The dedicated or common vent is considered to be

the vertical portion of the vent system that terminates outdoors.

4. Vent connectors serving Category I furnaces shall not be connected

into any portion of a mechanical draft system operating under

positive pressure.

5. Do not vent this appliance with any solid fuel burning appliance.

6. Category I furnaces must be vented vertically or nearly vertically

unless equipped with a listed mechanical venter. See SIDEWALL

VENTING section.

7. Do not vent this appliance into an unlined masonry chimney. (Refer

to Chimney Inspection Chart, Fig. 33.

24-V THERMOSTAT

TERMINALS

PL2 – HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

115-VAC (L2) NEUTRAL

CONNECTIONS 115-VAC (L1) LINE

VOLTAGE CONNECTIONS

EAC-1 TERMINAL

(

115-VAC 1.0 AMP MAX.

)

PL1 – LOW VOLTAGE MAIN

HARNESS CONNECTOR

TRANSFORMER 24-VAC

CONNECTIONS

3-AMP FUSE

STATUS AND COMM

LED LIGHTS

SW1 SETUP

SWITCHES AND

BLOWER OFF-

DELAY

MODEL PLUG

CONNECTOR

COMMUNICATION

CONNECTOR

AIR CONDITIONING (A/C) &

CONTINUOUS FAN (CF)

AIRFLOW SETUP SWITCHES

OUTDOOR

AIR TEMP

CONNECTOR

HUMIDIFIER

TERMINAL (24-VAC

0.5 AMP MAX.)

FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

SOFTWARE

VERSION

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or death.

Do not bypass the draft safeguard switch, as an unsafe condition could

exist which must be corrected.

F80CTL & G80CTL: Installation, Start–Up, Operating and Service and Maintenance Instructions

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Masonry Chimney Requirement

NOTE: These furnaces are CSA design-certified for use in exterior

tile-lined masonry chimneys with a factory accessory Chimney Adapter

Kit. Refer to the furnace rating plate for correct kit usage. The Chimney

Adapter Kits are for use with ONLY furnaces having a Chimney Adapter

Kit number marked on the furnace rating plate.

If a clay tile-lined masonry chimney is being used and it is exposed to

the outdoors below the roof line, relining might be required. Chimneys

shall conform to the Standard for Chimneys, Fireplaces, Vents, and Solid

Fuel Burning Appliances ANSI/NFPA 211 in the United States and must

be in good condition.

U.S.A. – Refer to Sections 13.1.8 and 13.2.20 of the NFPA 54/ANSI

Z223.1 or the authority having jurisdiction to determine whether relining

is required. If relining is required, use a properly sized listed metal liner,

Type-B vent, or a listed alternative venting design.

NOTE: See the NFPA 54/ANSI Z223.1 13.1.9 and 13.2.20 regarding

alternative venting design and the exception, which cover installations

such as our Chimney Adapter Kits which are listed for use with these

furnaces. See Specification Sheet for accessory listing.

A10133

Fig. 33 – Chimney Inspection Chart

The Chimney Adapter Kit is a listed alternative venting system for these

furnaces. See the kit instructions for complete details.

This furnace is permitted to be vented into a clay tile-lined masonry

chimney that is exposed to the outdoors below the roof line, provided:

1. Vent connector is Type-B double-wall, and

2. This furnace is common vented with at least 1 draft hood equipped

appliance, and

3. The combined appliance input rating is less than the maximum

capacity given in Table 6, and

4. The input rating of each space heating appliance is greater than the

minimum input rating given in Table 6 for the local 99% Winter

Design Temperature. Chimneys having internal areas greater than

38 sq. in. (24516 sq. mm) require furnace input ratings greater than

the input ratings of these furnaces. See footnote at bottom of

Table 6, and

5. The authority having jurisdiction approves.

If all of these conditions cannot be met, an alternative venting design

shall be used, such as the listed chimney adapter kit with a furnace listed

for use with the kit, a listed chimney-lining system, or a Type-B common

vent.

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected

to the venting system being placed into operation could result in carbon

monoxide poisoning or death.

The following steps shall be followed for each appliance connected to

the venting system being placed into operation, while all other

appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as

required in the National Fuel Gas Code, NFPA 54/ANSI Z223.1

and these instructions. Determine that there is no blockage or

restriction, leakage, corrosion and other deficiencies, which could

cause an unsafe condition.

3. As far as practical, close all building doors and windows and all

doors between the space in which the appliance(s) connected to

the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the

venting system. Turn on any exhaust fans, such as range hoods and

bathroom exhausts, so they are operating at maximum speed. Do

not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being

inspected into operation. Adjust the thermostat so appliance is

operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft

hood relief opening after 5 minutes of main burner operation. Use

the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the

venting system must be corrected in accordance with the National

Fuel Gas Code, NFPA 54/ANSI Z223.1.

9. After it has been determined that each appliance connected to the

venting system properly vents when tested as outlined above,

return doors, windows, exhaust fans, fireplace dampers and any

other gas-fired burning appliance to their previous conditions of

use.

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

Consult

Par t C of

chimney adapter venting

instructions for

application

suitability

Is chimney

lined with properly

sized, listed liner or

Type-B vent?

Is chimney

to be dedicated to

a single

furnace?

Chimney

exposed to

outdoors below

roof line?

Repair

liner or top seal

or reline chimney as

necessary.

Mortar

or tile

debris?

Clay

tile misalignment,

missing sections,

gaps?

Debris

in cleanout?

Mortar, tile, metal vent,

fuel oil residue?

liner and top

seal in good

condition?

Is chimney

property lined with

clay tile liner?

Crown

condition:

Missing mortar

or brick?

Rebuild

crown.

Ye s

No Reline

Ye s Repair

Ye s

Remove mortar

and tile debris

Remove metal vent

or liner.

Ye s

Suitable

Not Suitable

Line chimney with property

sized, listed flexible metal

liner or Type-B vent per

NFGC Vent

Sizing Tables and liner or

vent manufacturer’s

Installation instructions.

Install chimney

adapter per

instructions.

Chimney is

acceptable for use.

Install chimney

adapter per

instructions.

Consult

Par t B of

chimney adapter venting

instructions for

application

suitability.

Ye s

Not Suitable

Condensate

drainage at bottom

of chimney?

Ye s

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