International comfort products R80esl Guide

R80ESN/R80ESL(Series A): 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.

Installation, Start–Up, Operating and

Service and Maintenance Instructions

NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CODES AND STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCE-

DURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

AIR FOR COMBUSTION AND VENTILATION . . . . . . . . . . . . 5

Table 1 – Minimum Free Area Required for Each Combustion Air

Opening or Duct to Outdoors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

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

UPFLOW INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DOWNFLOW INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 8

Table 3 – Opening Dimensions - In. (mm) . . . . . . . . . . . . . . . . . . 9

HORIZONTAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 9

LOCATION RELATIVE TO COOLING EQUIPMENT . . . . . . 10

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

GENERAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SUPPLY AIR CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 11

Table 4 – Air Delivery - CFM (With Filter)* . . . . . . . . . . . . . . . 12

Table 5 – Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

Table 6 – Maximum Capacity of Pipe* . . . . . . . . . . . . . . . . . . . . 15

ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 7 – Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

J-BOX RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

NOTES FOR THERMOSTAT WIRING DIAGRAMS . . . . . . . 20

VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GENERAL VENTING REQUIREMENTS . . . . . . . . . . . . . . . . 20

Table 8 – Combined Appliance Maximum Input Rating

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

Table 9 – Minimum Allowable Input Rating of Space-Heating Appli-

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

EXTERIOR MASONRY CHIMNEY FAN + NAT

INSTALLATIONS WITH TYPE-B DOUBLE-WALL

VENT CONNECTORS ©NFPA & AGA . . . . . . . . . . . . . . . . . . 22

VENTING NOTES FOR Fig. 31 - Fig. 43 . . . . . . . . . . . . . . . . . 25

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

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Table 10 – Altitude Derate Multiplier for U.S.A. . . . . . . . . . . . . 27

Table 11 – Orifice Size* and Manifold Pressure (In. W.C.) for Gas In-

put Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Table 12 – Orifice Size* And Manifold Pressure (In. W.C.) For Gas

Input Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Table 13 – Gas Rate (Cu Ft./Hr.). . . . . . . . . . . . . . . . . . . . . . . . . 29

SERVICE AND MAINTENANCE PROCEDURES. . . . . . . . . . . . 30

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ELECTRICAL CONTROLS AND WIRING . . . . . . . . . . . . . . . 31

CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CLEANING AND/OR REPLACING AIR FILTER. . . . . . . . . . 32

Table 14 – Filter Size Information (In. / mm) . . . . . . . . . . . . . . . 32

BLOWER MOTOR AND WHEEL. . . . . . . . . . . . . . . . . . . . . . . 32

CLEANING HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . 33

SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . . . . . 39

CASING GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

ELECTRICAL GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

BLOWER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

GAS CONTROL GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

HEAT EXCHANGER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . 39

INDUCER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Portions of the text and tables are reprinted from current edition of 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.

R80ESN/R80ESL(Series A)

Single Stage, Multi-Speed ECM,

Non–Condensing Gas Furnace

Input Capacities: 45,000 Thru 155,000 Btuh

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.

R80ESN/R80ESL(Series A): 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

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

use can cause explosion, fire, electrical shock, or other conditions which

may cause death, personal injury, or property damage. Consult a

qualified installer, service agency, or your distributor or branch for

information or assistance. The qualified installer or agency must use

factory-authorized kits or accessories when modifying this product.

Refer to the individual instructions packaged with the kits or accessories

when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and

work gloves. Have a fire extinguisher available. Read these instructions

thoroughly and follow all warnings or cautions include in literature and

attached to the unit. Consult local building codes, the current editions of

the current edition of National Fuel Gas Code (NFGC) NFPA 54/ANSI

Z223.1 and the current edition of National Electrical Code (NEC) NFPA

70.

Recognize safety information. This is the safety-alert symbol . When

you see this symbol on the unit 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 hazards which could result in personal

injury or death. CAUTION is used to identify unsafe practices 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 listed

accessory gas conversion kit is required to convert furnace for use

with propane gas.

11. See Fig. 1 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 inches (914 mm)

horizontally from the furnace. See current edition of 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 model numbers END4X, ENW4X or coil casing model number

NAEA is used. See Fig. 1 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,

serious injury, death, or property damage.

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

use could 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.

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND

CARBON MONOXIDE POINSING HAZARD

Failure to follow this warning could result in dangerous operation,

personal injury, death, or property damage.

Furnaces shall NOT be twinned (i.e. tandem or staged operation) unless

approved in factory technical specifications literature for the furnace. A

factory authorized, field-supplied Twinning Kit MUST be used.

Consult furnace pre-sale literature for specific models approved for

twinning and the correct twinning kit. Twinned furnaces must be

installed on both a common supply AND a common return duct system

as shown in the Twinning Kit Installation Instructions. Only two

furnaces can be twinned on a common supply and return duct system

using a factory authorized twinning kit.

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may require

excessive servicing or cause premature component failure.

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.

R80ESN/R80ESL(Series A): 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. 1 – Clearances to Combustibles

This 4-way multipoise Category I fan-assisted furnace is CSA

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 (16°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. 2).

For accessory installation details, refer to the applicable instruction

literature.

NOTE: Remove all shipping brackets and materials before operating the

furnace.

A02055

Fig. 2 – Return Air Temperature

A02054

Fig. 3 – Prohibit Installation on Back

A93044

Fig. 4 – 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

USA: Current edition of National Fuel Gas Code (NFGC) NFPA

54/ANSI Z223.1 and the Installation Standards, Warm Air Heating and

Air Conditioning Systems ANSI/NFPA 90B.

Min 60ºF / 16ºC

Max 85ºF/ 29ºC

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. 3).

WARNING

FIRE HAZARD

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

and/or property damage.

When the furnace is installed in a residential garage, the burners and

ignition sources must be located at least 18 inches above the floor. 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 NFGC (see Fig. 4).

18-IN. (457.2 mm)

MINIMUM TO BURNERS

R80ESN/R80ESL(Series A): 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.

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

Current edition of NFGC NFPA54/ANSI Z223.1 Section 9.3, Air for

Combustion and Ventilation.

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) 2005 Fundamentals Handbook

Chapter 35 or 2004 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

Current edition of NFGC NFPA54/ANSI Z223.1; chapters 5, 6, 7, and 8

and National Plumbing Codes.

Electrical Connections

Current edition of National Electrical Code (NEC) NFPA 70.

Venting

Current edition of NFGC NFPA 54 / ANSI Z223.1; Chapters 12 and 13.

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

1. Disconnect all power to the furnace. Multiple disconnects maybe

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. 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.

CAUTION

FURNACE RELIABILITY HAZARD

Improper installation or service of furnace may cause premature

furnace component failure.

Electrostatic discharge can affect electronic components. Follow the

Electrostatic Discharge Precautions Procedure listed below 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 cause 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 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.

R80ESN/R80ESL(Series A): 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.

LOCATION

GENERAL

This multipoise furnace is shipped in packaged configuration. Some

assembly and modifications are required when used in any of the four

applications (see Fig. 5).

A02097

Fig. 5 – Multipoise Orientations

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 for upflow applications. Downflow installations

require use of a factory-approved floor base or coil assembly when

installed on combustible materials or wood flooring (refer to

SAFETY CONSIDERATIONS).

• be located as 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 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 current edition of NFGC

NFPA54/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.

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. 6 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.

b. Size openings and ducts per Fig. 6 and Table 1.

c. TWO HORIZONTAL DUCTS require 1 square inch of free area

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

appliances in the space per Fig. 6 and Table 1.

d. TWO OPENINGS OR VERTICAL DUCTS require 1 square

inch of free area per 4,000 Btuh (550 mm2/kW) for combined

input of all gas appliances in the space per Fig. 6 and Table 1.

3. ONE OUTDOOR OPENING requires:

a. 1 square inch of free area per 3,000 Btuh (734 mm2/kW) for

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

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.

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.

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

Carbon Monoxide Poisoning Hazard warning in venting section of

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

available.

R80ESN/R80ESL(Series A): 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. Not less than the sum of the areas of all vent connectors in the

space.

*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. 6 – Air for Combustion, Ventilation,

and Dilution for Outdoors

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

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

from the sides and back and 6” (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).

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 current edition of National Fuel Gas Code

ANSI Z223.1/NFPA 54:

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

hood-equipped water heater:

A04002

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)

WARNING

CARBON MONOXIDE POISONING HAZARD

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

injury.

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.

Table 1 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

FURNACE

INPUT (BTUH)

TWO HORIZONTAL DUCTS

(1 SQ. IN./2,000 BTUH)

(1,100 SQ. MM/KW)

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH)

(734 SQ. MM/KW)

TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./4,000 BTUH)

(550 SQ. MM/KW)

Free Area of Opening

and Duct

(sq. in. / sq. mm)

Round Duct Diameter

(in./mm)

Free Area of Opening

and Duct

(sq. In. / sq. mm)

Round Duct Diameter

(in. / mm)

Free Area of

Opening and Duct

(sq. In. / sq. mm)

Round Duct Diameter

(In./mm)

44,000 22 (14193) 6 (152) 14.7 (9484) 5 (127) 11 (7097) 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 (42581) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178)

154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)

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

Volume Other =21ft3

ACH

I other

1000 Btu/hr

R80ESN/R80ESL(Series A): 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.

2. For fan-assisted appliances such as this furnace:

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.)

The following requirements apply to 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”

(300 mm) of the ceiling and the second opening shall commence

within 12” (300 mm) of the floor. The minimum dimension of air

openings shall be at least 3 in. (80 mm) (see Fig. 7).

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.

*Air Changes/Hour

*Minimum opening size is 100 in.2 with minimum dimensions of 3 in. (76 mm).

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

A03175

Fig. 7 – Air for Combustion, Ventilation, and Dilution from Indoors

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).

Volume Fan =15ft3

ACH

I fan

1000 Btu/hr

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

ACH*

OTHER THAN FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

30 40 50 44 66 88 110 132

Space Volume (ft.3)

0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300

0.50 1,260 1,680 2,100 1,320 1,980 2,640 3,300 3,960

0.40 1,575 2,100 2,625 1,650 2,475 3,300 4,125 4,950

0.30 2,100 2,800 3,500 2,200 3,300 4,400 5,500 6,600

0.20 3,150 4,200 5,250 3,300 4,950 6,600 8,250 9,900

0.10 6,300 8,400 10,500 6,600 9,900 13,200 16,500 19,800

0.00 NP NP NP NP NP NP NP NP

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

)

R80ESN/R80ESL(Series A): 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.

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 two screws holding bottom filler

panel (see Fig. 8).

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

A10273

Fig. 8 – Removing Bottom Closure Panel

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 3 accessories are

used:

• Downflow combustible floor subbase

• Cased Coil numbers END4X, ENW4X

• Coil casing model number NAEA

1. Determine application being installed from Table 3.

2. Construct hole in floor (see Table 3 and Fig. 9).

3. Construct plenum to dimensions specified (see Table 3 and Fig. 9).

4. If downflow subbase is used, install as shown (see Fig. 10). If Coil

model number END4X, ENW4X or Coil Casing model number

NAEA is used, install as shown (see Fig. 11).

NOTE: It is required 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. 16) 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 two screws holding bottom filler

panel (see Fig. 8).

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws

A96283

Fig. 9 – Floor and Plenum Opening Dimensions

A96285

Fig. 10 – Furnace, Plenum, and Subbase Installed on a

Combustible Floor

A08556

Fig. 11 – Furnace, Plenum, and Coil Assembly or

Coil Box Installed on a Combustible Floor

Bottom

Closure Panel

Bottom Filler Panel

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

R80ESN/R80ESL(Series A): 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.

HORIZONTAL INSTALLATION

The furnace can be installed horizontally in an attic or crawl space 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.

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. 8).

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

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws. Side Return Air Inlet

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) is used without a bottom return air inlet.

Not all horizontal furnaces are approved for side return air connections

(see Fig. 20).

FILTER ARRANGEMENT

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

A field-supplied accessory external filter is required.

Refer to the instructions supplied with the external filter rack for

assembly and installation options.

Table 3 – Opening Dimensions - In. (mm)

FURNACE

CASING

WIDTH

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 Cased Coil

(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 Cased Coil

(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 Cased Coil

(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 Cased Coil

(subbase not required)

22-1/2

(572)

(483)

23-1/2

(597)

(508)

WARNING

FIRE, EXPLOSION, AND CARBON MONOXIDE

POISONING 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. WARNING

CARBON MONOXIDE AND 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.

R80ESN/R80ESL(Series A): 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.

Leveling Legs (If Desired)

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

(see Fig. 12). Install field-supplied, 5/16 x 1-1/2 in. (8 x 38 mm) (max)

corrosion-resistant machine bolts, washers and nuts.

A89014

Fig. 12 – 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.

To install leveling legs:

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

corner of furnace (see Fig. 12).

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

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 3/4-in. (19

mm) screws into the side and 2 #8 x 3/4-in. (19 mm) 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. 1 and Fig. 13). For furnaces with 1-in. (25

mm) clearance requirement on side, set furnace on noncombustible

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

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

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

A10164

Fig. 13 – Typical Attic Installation

A10130

Fig. 14 – Horizontal Unit Suspension

A10131

Fig. 15 – Horizontal Suspension with Straps

(44mm)

(8mm)

(44mm)

(8mm)

(44mm)

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)

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).

R80ESN/R80ESL(Series A): 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 mm x 559 mm) piece of

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

furnaces closer than 12 inches (305 mm) above the combustible deck or

suspended furnaces closer than 12 inches (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.

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 4-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 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 and sealed 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 airstream. 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. 16). 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 degrees 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. 16). 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. 16 – Duct Flanges

Downflow Furnaces

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

(see Fig. 17). DO NOT cut into casing sides (left or right). Side opening

is permitted for only upflow and most horizontal furnaces (see Fig. 18).

Bypass humidifier connections should be made at ductwork or coil

casing sides exterior to furnace.

CAUTION

FIRE HAZARD

Failure to follow this warning could cause personal injury, death and/or

property damage.

Never connect return-air ducts to the back of the furnace. Follow

instructions below.

UPFLOW/

HORIZONTAL DOWNFLOW

R80ESN/R80ESL(Series A): 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.

Table 4 – Air Delivery - CFM (With Filter)*

Furnace Wire Lead

Color Function Test Airflow Delivery @ Various External Static Pressures

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0451412

Gray Cooling. Do not use for heating. 1230 1190 1155 1120 1080 1045 1010 975 935 895

Yellow Alt Cooling or alt Heating 980 945 920 890 855 815 770 735 690 645

Orange Alt Cooling or alt Heating 770 720 685 640 600 560 520 475 430 385

Blue Heating or alt Cooling 710 660 620 580 540 490 455 415 375 335

Red Alt Cooling. Do not use for heating. 600 540 500 455 415 385 345 305 235 -

0451712

Gray Cooling. Do not use for heating. 1370 1335 1295 1255 1215 1175 1135 1095 1055 1020

Yellow Alt Cooling or alt Heating 1130 1085 1040 995 955 910 865 825 780 730

Orange Alt Cooling or alt Heating 930 885 835 795 745 700 655 600 545 495

Blue Heating or alt Cooling 760 720 670 625 580 515 460 410 355 300

Red Alt Cooling. Do not use for heating. 610 500 445 375 320 260 200 135 - -

0701412

Gray Cooling. Do not use for heating. 1205 1170 1143 1105 1070 1035 1000 960 925 885

Blue Heating or alt Cooling 1095 1060 1030 995 960 925 885 840 800 735

Yellow Alt Cooling or alt Heating 920 880 845 805 765 730 685 620 560 510

Orange Alt Cooling. Do not use for heating. 715 650 610 575 520 465 410 380 305 245

Red Alt Cooling. Do not use for heating. 635 490 445 375 315 270 205 230 190 140

0701712

Gray Cooling. Do not use for heating. 1185 1140 1095 1055 1005 960 915 865 820 780

Yellow Alt Cooling or alt Heating 1000 940 895 850 800 750 695 650 600 555

Blue Heating or alt Cooling 990 935 895 845 790 740 690 640 590 535

Orange Alt Cooling or alt Heating 855 775 720 660 605 560 495 435 385 335

Red Alt Cooling. Do not use for heating. 860 685 515 445 385 340 275 205 - -

0701716

Gray Cooling. Do not use for heating. 1650 1615 1580 1545 1515 1480 1445 1415 1380 1350

Yellow Alt Cooling. Do not use for heating 1405 1365 1325 1285 1250 1215 1175 1140 1100 1065

Orange Alt Cooling or alt Heating 1255 1215 1175 1130 1090 1090 1010 970 930 895

Blue Heating or alt Cooling 1185 1140 1095 1050 1005 1005 920 880 840 800

Red Alt Cooling. Do not use for heating. 1100 1050 1005 960 915 915 825 785 740 700

0702116

Gray Cooling. Do not use for heating. 1735 1685 1640 1595 1545 1495 1450 1405 1360 1310

Yellow Alt Cooling or alt Heating 1480 1435 1395 1340 1290 1240 1190 1135 1085 1030

Blue Heating or alt Cooling 1315 1275 1225 1180 1135 1085 1030 975 915 860

Orange Alt Cooling or alt Heating 1135 1080 1030 985 935 885 835 770 705 645

Red Alt Cooling. Do not use for heating. 980 930 875 820 775 715 665 595 530 455

0901714

Gray Cooling. Do not use for heating. 1355 1320 1285 1245 1210 1165 1125 1080 1025 815

Yellow Alt Cooling or alt Heating 1295 1255 1220 1185 1140 1100 1055 1005 955 815

Blue Heating or alt Cooling 1220 1185 1150 1105 1065 1025 975 915 840 740

Orange Alt Cooling or alt Heating 1030 985 940 900 845 790 715 655 590 535

Red Alt Cooling. Do not use for heating. 945 905 855 800 750 670 600 540 490 435

0902116

Gray Cooling. Do not use for heating. 1625 1580 1535 1490 1445 1395 1340 1260 1135 995

Yellow Alt Cooling or alt Heating 1425 1380 1335 1290 1235 1185 1125 1075 1020 640

Blue Heating or alt Cooling 1440 1395 1350 1305 1255 1200 1145 1090 1040 950

Orange Alt Cooling or alt Heating 1260 1210 1160 1105 1050 990 935 880 820 755

Red Alt Cooling. Do not use for heating. 1095 1040 980 905 845 780 720 650 585 520

0902120

Gray Cooling. Do not use for heating. 2180 2130 2080 2030 1980 1925 1870 1805 1745 1680

Yellow Alt Cooling or alt Heating 1900 1845 1795 1740 1685 1635 1570 1500 1435 1375

Blue Heating or alt Cooling 1685 1620 1565 1505 1455 1385 1320 1260 1200 1140

Orange Alt Cooling or alt Heating 1390 1315 1240 1175 1095 1030 970 900 825 760

Red Alt Cooling. Do not use for heating. 1240 1155 1075 990 915 835 765 690 615 555

0902420

Gray Cooling. Do not use for heating. 2190 2135 2075 2015 1960 1900 1835 1775 1705 1630

Yellow Alt Cooling or alt Heating 1870 1810 1745 1685 1625 1565 1495 1420 1345 1280

Blue Heating or alt Cooling 1580 1510 1445 1385 1320 1240 1175 1115 1050 970

Orange Alt Cooling or alt Heating 1305 1220 1160 1075 1000 930 865 770 690 610

Red Alt Cooling. Do not use for heating. 1210 1075 1000 915 845 765 675 595 515 425

1102120

Gray Cooling. Do not use for heating. 2255 2205 2150 2100 2040 1985 1920 1835 1735 1615

Blue Heating or alt Cooling 1945 1890 1830 1770 1715 1655 1600 1545 1480 1430

Yellow Alt Cooling or alt Heating 1600 1525 1465 1400 1335 1275 1210 1150 1080 1015

Orange Alt Cooling. Do not use for heating. 1420 1340 1280 1200 1140 1065 1005 925 865 790

Red Alt Cooling. Do not use for heating. 1280 1205 1140 1055 990 910 840 760 695 630

R80ESN/R80ESL(Series A): 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.

1. A filter is required for each return-air inlet. Airflow performance included 3/4-in. (19 mm) washable filter (see accessory list). To determine airflow performance without this filter, assume an

additional 0.1 In. W.C. available external static pressure.

2. Adjust the blower speed tabs as necessary for the proper air temperature rise for each installation.

3. -- Indicates unstable operating conditions.

4. If the same motor speed tap is needed for heating and cooling, a Jumper Wire accessory kit is available. (See Specification sheet for the current Jumper Wire accessory part number). See

Function column for applicable limitations.

A190084

NOTES:

1. Two additional 7/8-in. (22 mm) diameter holes are located in the top plate.

2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.

a. For 800 CFM-16-in. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.

b. For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle.

c. For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) rectangle.

d. For airflow requirements above 1800 CFM, see Air Delivery table in Specification Sheet literature for specific use of single side inlets. The use of both side inlets, a combination of 1

side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

Fig. 17 – Dimensional Drawing

1102420

Gray Cooling. Do not use for heating. 2250 2190 2130 2070 2005 1950 1885 1820 1755 1685

Blue Heating or alt Cooling 1995 1930 1865 1800 1740 1670 1605 1535 1465 1400

Yellow Alt Cooling or alt Heating 1540 1460 1385 1305 1235 1165 1095 1035 955 890

Orange Alt Cooling. Do not use for heating. 1345 1195 1135 1055 980 920 845 770 695 620

Red Alt Cooling. Do not use for heating. 1335 1075 965 890 820 735 660 580 505 440

1352420

Gray Cooling. Do not use for heating. 2065 2005 1940 1875 1810 1740 1670 1600 1530 1470

Blue Heating or alt Cooling 1825 1760 1695 1630 1560 1490 1420 1350 1275 1205

Yellow Alt Cooling or alt Heating 1760 1690 1625 1555 1485 1415 1345 1275 1200 1130

Orange Alt Cooling. Do not use for heating. 1620 1550 1480 1405 1335 1260 1195 1130 1065 995

Red Alt Cooling. Do not use for heating. 1325 1260 1185 1100 1025 955 885 805 735 670

Table 4 – Air Delivery - CFM (With Filter)* (Continued)

Furnace Wire Lead

Color Function Test Airflow Delivery @ Various External Static Pressures

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

33 1/3

[845.9]

R80ESN/R80ESL(Series A): 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.

*135 size furnace requires 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.

Upflow 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. 19

and Fig. 20). Bypass humidifier may be attached into unused return air

side of the furnace casing (see Fig. 19 and Fig. 20). Not all horizontal

furnaces are approved for side return air connections (see Fig. 20).

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

GAS PIPING

Gas piping must be installed in accordance with national and local

codes. Refer to current edition of NFGC.

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

inches (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.

Table 5 – Dimensions

Unit Size

CABINET WIDTH

OUTLET WIDTH

TOP AND

BOTTOM FLUE

COLLAR

BOTTOM

INLET WIDTH

VENT

CONNECTION

SIZE

SHIP WT. LB.

(KG)

0451412 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 104 (47)

0451712 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 119 (54)

0701412 14-3/16 (360) 12-9/16 (319) 9-5/16 (237) 12-11/16 (322) 4 (102) 114 (52)

0701712 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 120 (54)

0701716 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 126 (57)

0702116 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 142 (64)

0901714 17-1/2 (445) 15-7/8 (403) 11-9/16 (294) 16 (406) 4 (102) 131 (49)

0902116 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 137 (62)

0902120 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 140 (64)

0902420 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102) 146 (66)

1102120 21 (533) 19-3/8 (492) 13-5/16 (338) 19-1/2 (495) 4 (102) 146 (66)

1102420 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102) 161 (73)

1352420 24-1/2 (622) 22-7/8 (581) 15-1/16 (383) 23 (584) 4 (102) 167 (76)

DOWNFLOW RETURN AIR CONFIGURATIONS AND RESTRICTIONS

R80ESN/R80ESL(Series A): 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.

Refer to Table 6 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.

(2 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 natural 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: Chapter 6 current

edition of ANSI Z223/NFPA 54.

An accessible manual equipment shutoff valve MUST be installed

external to furnace casing and within 6 ft. (2 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).

A06666

Fig. 21 – Gas Control Valve

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

in upflow.) (See Fig. 22).

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.

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.

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

gas valve.

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 6 – Maximum Capacity of Pipe*

NOMINAL

IRON

PIPE

INTERNAL

DIAMETER LENGTH OF PIPE - FT. (M)

SIZE IN.

(mm) In. (mm) 10 20 30 40 50

1/2 (13) 0.622 (16) 175 (53) 120 (37) 97 (30) 82 (25) 73 (22)

3/4 (19) 0.824 (21) 360 (110) 250 (76) 200 (61) 170 (52) 151 (46)

1 (25) 1.049 (27) 680 (207) 465 (142) 375 (114) 320 (98) 285 (87)

1-1/4 (32) 1.380 (35) 1400 (427) 950 (290) 770 (235) 660 (201) 580 (177)

1-1/2 (38) 1.610 (41) 2100 (640) 1460 (445) 1180 (360) 990 (301) 900 (274)

WARNING

FIRE OR EXPLOSION HAZARD

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 OVERHEAT HAZARD

Failure to follow this caution may result in property damage.

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

controls and burner misalignment.

2” (51mm)

Street Elbow

R80ESN/R80ESL(Series A): 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.

A02035

Fig. 23 – Typical Gas Pipe Arrangement

Piping should be pressure and leak tested in accordance with 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 (35°C)

rise.

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 7 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 7 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 rapidly and

furnace will NOT operate.

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.

UNION

SEDIMENT

TRAP

MANUAL

SHUTOFF

VALVE

(REQUIRED)

GAS

SUPPLY

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 current edition of 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

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.

R80ESN/R80ESL(Series A): 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.

A190079

Fig. 24 – Heating and Cooling Application Wiring Diagram with 1-Stage Thermostat

A190279

Fig. 25 – Field-Supplied External Electrical Box on Furnace Casing

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

# 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.

† Time-delay type is recommended.

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

115-V FIELD-

SUPPLIED

DISCONNECT

AUXILIARY

J-BOX

24-V

TERMINAL

BLOCK

THREE-WIRE

HEATING-ONLY

FIVE WIRE

NOTE 1

NOTE 2

FIELD-SUPPLIED

DISCONNECT

CONDENSING

UNIT

TWO

WIRE

FURNACE

COM

WCR GY

GND

FIELD 24-V WIRING

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

FACTORY 24-V WIRING

FACTORY 115-V WIRING

208/230- OR

460-V

THREE

PHASE

208/230-V

SINGLE

PHASE

BLOWER DOOR SWITCH

WHT

BLK

WHT

BLK

NOTES: Connect Y-terminal in furnace as shown for proper blower 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.

GND

THERMOSTAT

TERMINALS

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).

COPPER

WIRE ONLY

ELECTRIC

DISCONNECT

SWITCH

ALUMINUM

WIRE

Table 7 – Electrical Data

Unit Size Volts-

Hertz- Phase

Operating Voltage* Range Unit

Ampacity#

Minimum Wire

Size AWG

Maximum Wire

Length‡

Maximum

Fuse

or CKT

BKR Amps†

Maximum Minimum feet m

0451412 115-60-1 127 104 7.8 14 47 14.3 15

0451712 115-60-1 127 104 10.3 14 36 11 15

0701412 115-60-1 127 104 7.8 14 47 14.3 15

0701712 115-60-1 127 104 7.8 14 47 14.3 15

0701716 115-60-1 127 104 14.3 14 25 7.6 15

0702116 115-60-1 127 104 13.3 14 27 8.2 15

0901714 115-60-1 127 104 11 14 33 10.1 15

0902116 115-60-1 127 104 11 14 33 10.1 15

0902120 115-60-1 127 104 16.9 12 34 10.4 20

0902420 115-60-1 127 104 13.5 14 27 8.2 15

1102120 115-60-1 127 104 17.4 12 33 10.1 20

1102420 115-60-1 127 104 14 14 26 7.9 15

1352420 115-60-1 127 104 14 14 26 7.9 15

R80ESN/R80ESL(Series A): 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.

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.

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 two screws removed in Step 1.

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

parts and hot surfaces.

A10291

Fig. 26 – Relocating J-Box

Electrical Connection to J-Box

Electrical Box on Furnace Casing Side

1. Refer to Fig. 27 when installing an electrical box.

2. 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.

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

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

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

screws from inside electrical box into casing steel.

A190278

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

5. Remove and save two screws holding J-Box.

6. 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.

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

box and into electrical box.

8. Pull field power wires into electrical box.

9. Remove cover from furnace J-Box.

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

and into furnace J-Box.

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

Step 4.

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

13. Complete electrical box wiring and installation. Connect line

voltage leads (see Fig. 24). Use best practices (NEC in U.S. for

wire bushings, strain relief, etc.)

14. 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 7. 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-inch 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. 20).

Connect terminal Y for proper cooling operation (see Fig. 28). Use only

AWG No. 18, color-coded, copper thermostat wire.

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

LINE VOLTAGE

R80ESN/R80ESL(Series A): 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.

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 115 VAC, 1.0 amps maximum

and are energized during blower motor operation (see Fig. 28).

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 the pressure switch closes

during a call for heat (see Fig. 28).

NOTE: DO NOT connect furnace control HUM terminal to HUM

(humidifier) terminal on humidity sensing thermostat, zone controller or

similar device. See humidity sensing thermostat, zone controller,

thermostat, or controller manufacturer’s instructions for proper

connection.

A190023

Fig. 28 – Furnace Control

A190085

Fig. 29 – Thermostat Wiring Diagrams

24-V THERMOSTAT

TERMINALS

PL2 –(115VAC) HOT SURFACE IGNITER &

INDUCER MOTOR 115V SUPPLY CONNECTOR

115-VAC (L2) NEUTRAL

CONNECTIONS

115-VAC (BL-1) BLOWER MOTOR LINE

VOLTAGE CONNECTION

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

PL1 –LOW VOLTAGE MAIN HARNESS

CONNECTOR

TRANSFORMER 24-VAC

CONNECTIONS

3-AMP FUSE

STATUS LED LIGHT

HEAT OFF-DELAY

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

BOARD PART NUMBER

LOCATION

COOLING SPEED

TAP

HEATING SPEED

TAP

PR-1

115-VAC (PR-1) TRANSFORMER

PRIMARY

J2 DEFEAT

JUMPER

TEST/TWIN

HEAT OFF-DELAY

JUMPER SELECT

PLT -FACTORY RUN TEST PORT

PRODUCTION USE ONLY

BL-1

115-VAC (L1) LINE VOLTAGE

CONNECTION

FAN SPEED TAP

Single-Stage Furnace with Single-Speed Air Conditioner Single-Stage Furnace with Single-Speed Heat Pump

THERMOSTAT

See notes 1 and 4

See notes 1 and 3

R80ESN/R80ESL(Series A): 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.

NOTES FOR THERMOSTAT WIRING DIAGRAMS

1. Refer to outdoor equipment Installation Instructions for additional

information and setup procedure.

2. Outdoor Air Temperature Sensor must be attached in all dual fuel

application.

3. Refer to ICP thermostat Installation Instructions for additional

information and setup procedure.

4. HUM 24VAC terminal is 24 VAC and is energized when the low

pressure switch closes during a call for heat.

5. When connecting 115 VAC to humidifier use a separate 115 VAC

supply.

6. When using a humidifier on a HP installation, connect humidifier to

hot water.

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 NFGC.

GENERAL VENTING REQUIREMENTS

Follow all safety codes for proper vent sizing and installation

requirements, including local building codes, the current edition of

National Fuel Gas Code ANSI Z223.1/NFPA 54 (NFGC), Parts 12 and

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

instructions.

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

with current edition of 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. 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.

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

into any portion of a mechanical draft system operating under

positive pressure.

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

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

unless equipped with a listed power venter.

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

to Chimney Inspection Chart, Fig. 30).

A10133

Fig. 30 – Chimney Inspection Chart

MASONRY CHIMNEY REQUIREMENTS

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 numbers 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 current edition of ANSI/NFPA 211 and must

be in good condition.

U.S.A.— Refer to Sections 13.1.8 and 13.2.20 of the current edition of NFGC

NFPA54/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 current edition of NFPA54/ANSI Z223.1, 13.1.8 and

13.2.20 regarding alternative venting design and the Exception, which

cover installations such as the Chimney Adapter Kits, which are listed

for use with these furnaces. See Specification Sheet for accessory

listing.

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

Part 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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