AHRI F80CSU Installation Instructions Manual Download

Page: 44 / 44

Specifications are subject to change without notice.

441 01 4200 01

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP

Outer door
Blower door
Top filler plate
Bottom filler plate
Bottom enclosure

ELECTRICAL GROUP

Control bracket
Junction box
Limit switch(es)
Circuit board
Door switch
Transformer
Wiring harness 115v
Wiring harness 24v

BLOWER GROUP

Blower housing
Blower cutoff
Blower motor
Blower wheel
Grommet
Power choke (where used)
Auxiliary limit switches

GAS CONTROL GROUP

Burner assembly
Orifice
Flame sensor
Hot surface ignitor
Gas valve
Manual reset limit switches
Burner support assembly

HEAT EXCHANGER GROUP

Heat exchanger cell
Cell panel

INDUCER GROUP

Housing assembly
Transducer
Inducer motor
Inducer wheel
Vent elbow assembly

MODEL

HEATING SIZE

WIDTH

COOLING SIZE

MAJOR

SERIES

MINOR

SERIES

F/G80CSU

060

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or the classified section of your local telephone directory under the “Heating

Equipment“ or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name, or contact:

International Comfort Products

Consumer Relations Department

P.O. Box 128

Lewisburg, TN 37091, USA

931--270--4100

Have available the product/model number and the serial number located on the unit rating plate to ensure correct replacement parts.

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death. Consult a

qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency must use only facto-

ry--authorized replacement parts, kits, or accessories when modifying this product.

Lewisburg, TN 37091 USA

Summary of Contents for F80CSU

Page 1: ...NG 23 START UP ADJUSTMENT AND SAFETY CHECK 25 GENERAL 25 START UP PROCEDURES 25 ADJUSTMENTS 25 FURNACE SETUP SWITCHES 26 AIR DELIVERY CFM 30 COOLING OR CONTINUOUS AIRFLOW 32 CHECK SAFETY CONTROLS 32 CHECKLIST 33 SERVICE AND MAINTENANCE PROCEDURES 35 ELECTRICAL CONTROLS AND WIRING 35 CARE AND MAINTENANCE 36 COMPONENT TEST 36 CLEANING AND OR REPLACING AIR FILTER 37 BLOWER MOTOR AND WHEEL 37 FLAME SE...

Page 2: ...he 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 s...

Page 3: ...H IN MM OUTLET WIDTH IN MM TOP FLUE COLLAR ONLY IN MM BOTTOM WIDTH IN MM VENT CONNECTION SIZE IN MM SHIP WT LB KG 0401712 17 1 2 445 15 7 8 403 11 9 16 294 16 406 4 102 119 54 0601716 17 1 2 445 15 7 8 403 11 9 16 294 16 406 4 102 124 56 0802120 21 533 19 3 8 492 13 5 16 338 19 1 2 495 4 102 144 65 1002120 21 533 19 3 8 492 13 5 16 338 19 1 2 495 4 102 154 70 ...

Page 4: ...rrent edition of NFGC NFPA 54 ANSI Z223 1 Chapters 12 and 13 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE 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 ...

Page 5: ...minated 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 requireme...

Page 6: ...0 13043 5 127 15 9678 5 127 80 000 40 25807 7 178 27 17391 6 152 20 12904 5 127 100 000 50 32258 8 203 34 21739 7 178 25 16130 6 152 EXAMPLE Determining Free Area FURNACE WATER HEATER TOTAL INPUT 100 000 30 000 130 000 divided by 4 000 32 5 Sq In for each two Vertical Ducts or Openings 60 000 40 000 100 000 divided by 3 000 33 3 Sq In for each Single Duct or Opening 80 000 30 000 110 000 divided b...

Page 7: ...STION AIR STAN DARD 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 7 illustrates how to provide TWO OUTDOOR OPENINGS one inle...

Page 8: ...ot 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 no...

Page 9: ...eturn 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 10 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...

Page 10: ...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 Table 4 Opening Dimensions In mm FURNACE CASING WIDTH APPLICATION PLENUM OPENING FLOOR OPENING A B C D 17 1 2 445 Upflow Applications on Combustible or Noncombustible Flooring subbase not required 16 406 21 5 8 549 16 5 8 422 22 ...

Page 11: ...ns supplied with the external filter rack for assembly and installation options 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 Cond...

Page 12: ...h supply side air duct humidifier or other accessories All accessories MUST be connected to duct external to furnace casing A190346 Fig 14 Duct Flanges 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...

Page 13: ...bottom inlet as shown in Fig 19 DO NOT cut into casing sides left or right Side opening is permitted for only upflow and most horizontal furnaces See Fig 19 Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace 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 ...

Page 14: ... 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 Refer to Table 5 for recommended gas pipe sizing Risers must be used to connect to furnace and ...

Page 15: ...Operating Voltage Range Maximum Unit Amps Unit Ampacity Minimum Wire Size AWG Maximum Wire Length ft Maximum Fuse or CKT BKR Amps Maximum Minimum 0401712 115 60 1 127 104 11 4 12 6 14 29 15 0601716 115 60 1 127 104 11 4 12 6 14 29 15 0802120 115 60 1 127 104 17 8 18 9 12 30 20 1002120 115 60 1 127 104 17 8 18 9 12 30 20 Permissible limits of the voltage range at which the unit operates satisfactor...

Page 16: ...ed in Step 1 5 Route J Box wires within furnace away from sharp edges rotating parts and hot surfaces ELECTRICAL CONNECTION TO J BOX Electrical Box on Furnace Casing Side 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 ...

Page 17: ...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 us ing 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 23 2 Humidi...

Page 18: ...LT 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 OR 460 VOLT THREE PHASE 208 230 VOLT SINGLE PHASE WHT BLK WHT BLK W W1 W2 Y Y2 G NOTES 1 2 3 A95236 Fig 24 Heating and Cooling Applicat...

Page 19: ...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 HUM connection is 24 VAC and is energized when the blower turns on during a call for heat 6 When connecting ...

Page 20: ... 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 minim...

Page 21: ...r VENT HEIGHT FT M INTERNAL AREA OF CHIMNEY IN2 MM2 12 7741 19 12258 28 18064 38 24516 6 1 8 74 119 178 257 8 2 4 80 130 193 279 10 3 0 84 138 207 299 15 4 5 NR 152 233 334 20 6 0 NR NR 250 368 30 9 1 NR NR NR 404 APPLIANCE APPLICATION REQUIREMENTS Appliance operation has a significant impact on the performance of the venting system If the appliances are sized installed adjusted and operated prope...

Page 22: ...Specifications are subject to change without notice 22 441 01 4200 01 A180242 Fig 29 Chimney Inspection Chart ...

Page 23: ...onnector as shown in Fig 30 33 3 Determine the correct location of the knockout to be re moved 4 Use a hammer and screwdriver to strike a sharp blow be tween the tie points and work the slug back and forth until the slug breaks free 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 clothi...

Page 24: ...or is required refer to Note 1 above 3 Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace except when factory authorized Downflow Vent Guard Kit is used in the downflow position See Specification Sheet for accessory listing 4 Type B vent where required refer to Note 1 above 5 Four inch single wall 26 ga min vent must be used inside fur...

Page 25: ...re Component test feature will not operate if any thermostat signal is present at the control Refer to service label attached to furnace or See Fig 36 Component test sequence is as follows a Inducer motor turns on at 50 duty cycle for 15 secs then stays on for the entire test b Hot surface ignitor is energized for 15 sec then off c Blower motor operates for 15 sec d After component test is complet...

Page 26: ...Specifications are subject to change without notice 26 441 01 4200 01 Table 10 Furnace Setup Switch Description A190351 ...

Page 27: ...Specifications are subject to change without notice 27 441 01 4200 01 A190347 Fig 36 Service Label ...

Page 28: ... connected and pro ceed to next step NOTE If orifice hole appears damaged or it is suspected to have been redrilled check orifice hole with a numbered drill bit of correct size Never redrill an orifice A burr free and properly sized orifice hole is essential for proper flame characteristics 5 Verify natural gas input rate by clocking meter NOTE Gas valve regulator adjustment cap must be in place f...

Page 29: ...stat from subbase or from wall 2 Connect an amp meter as shown in Fig 39 across the R and W subbase terminals or R and W wires at wall R Y W G 10 TURNS THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER EXAMPLE 5 0 AMPS ON AMMETER 10 TURNS AROUND JAWS 0 5 AMPS FOR THERMOSTAT ANTICIPATOR SETTING FROM UNIT 24 V CONTROL TERMINALS Fig...

Page 30: ...efault OFF OFF OFF 530 545 545 535 505 495 485 See Note 4 Continuous Fan Airflow SW3 OFF OFF ON 530 545 545 535 505 495 485 See Note 4 OFF ON OFF 715 705 730 730 735 735 740 725 720 695 OFF ON ON 870 910 925 925 935 935 925 915 910 900 ON OFF OFF 1100 1090 1080 1110 1120 1120 1110 1110 1100 1095 ON OFF ON 1100 1090 1080 1110 1120 1120 1110 1110 1100 1095 ON ON OFF 1100 1090 1080 1110 1120 1120 111...

Page 31: ... 3 SW3 2 SW3 1 Low Clg Default OFF OFF OFF 1785 1800 1805 1830 1830 1845 1855 1860 1850 1840 Cooling Airflow SW2 Low Cooling Airflow SW3 OFF OFF ON 635 630 See Note 4 OFF ON OFF 785 820 865 See Note 4 OFF ON ON 1040 1045 1070 1085 1130 See Note 4 ON OFF OFF 1205 1220 1245 1280 1290 1295 1290 1280 See Note 4 ON OFF ON 1380 1425 1445 1465 1480 1475 1490 1485 1455 1460 ON ON OFF 1785 1800 1805 1830 1...

Page 32: ...3 Switch positions are also shown on furnace wiring diagram Fig 40 Cooling A C or Continuous Fan Airflow Selection Chart Check Safety Controls 1 Check Main Limit Switch es This control shuts off combustion control system and en ergizes air circulating blower motor if furnace overheats By using this method to check limit control it can be es tablished that limit is functioning properly and will ope...

Page 33: ...0 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367 Table 14 Gas Valve Outlet Pres...

Page 34: ... 2 2 875 1 9 1 9 2 0 2 1 5400 900 1 8 1 8 1 9 2 0 1646 925 1 8 1 8 1 8 1 9 950 1 8 1 8 1 8 1 8 975 1 8 1 8 1 8 1 8 1000 1 8 1 8 1 8 1 8 Table 16 Gas Valve Outlet Pressure for Gas Heat Values at Altitude 80 000 Tabulated Data Based on 80 000 BTUH Input for 0 ft 0 m to 5400 ft 1646 M above sea level ALTITUDE RANGE AVG GAS SPECIFIC GRAVITY OF NATURAL GAS HEAT VALUE 0 58 0 60 0 62 0 64 AT ALTITUDE Gas...

Page 35: ...ace once a year FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury death and or property damage The ability to properly perform maintenance on this equipment requires certain knowledge mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the Us...

Page 36: ...all blower access door and replace outer door or refer to the SERVICE label on the front of the blower access door for more informa tion Component Self Test Component Test can ONLY be initiated by performing the following 1 Remove outer access door 2 Remove blower access door 3 Remove the wire from the R terminal of the control board 4 Turn Setup Switch SW 1 6 ON 5 Manually close blower access doo...

Page 37: ...ded BLOWER MOTOR AND WHEEL ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Blower access door switch opens 115 v power to control No component operation can occur unless switch is closed Caution must be taken when manually closing this switch for service purposes WARNING NOTE The blower wheel should not be dropped or bent as balance will be affected ...

Page 38: ...HAZARD Failure to follow this warning could result in personal injury death and or property damage Turn off the gas and electrical supplies to the furnace and install lockout tag before performing any maintenance or service Follow the operating instructions on the label attached to the furnace WARNING Refer to Fig 41 1 Disconnect power at external disconnect fuse or circuit breaker 2 Turn off gas ...

Page 39: ...tem 9 can usually be purchased at local hardware stores a Remove metal screw fitting from wire brush to allow in sertion into cable b Insert the twisted wire end of brush into end of spring cable and crimp tight with crimping tool or crimp by striking with ball peen hammer TIGHTNESS IS VERY IMPORTANT A180230 Fig 41 Ignitor Position 1 Attach variable speed reversible drill to the end of spring cabl...

Page 40: ... 15 second prepurge period If the transducer fails to reach target pressure the inducer motor IDM will remain running until tar get pressure is maintained After the transducer maintains pressure target the furnace control CPU will begin a 15 second prepurge period and continue to run the inducer motor IDM at that pressure b Ignitor Warm Up At the end of the prepurge period the Hot Surface Ignitor ...

Page 41: ...rue on board CF continuous fan selection as shown in Fig 40 b High cooling When the R to G and Y Y2 circuit is closed and there is a demand for dehumidification the furnace blower motor BLWM will drop the blower airflow to 86 percent of cooling airflow Cooling air flow is based on the A C air conditioning selection shown in Fig 40 c Cooling off delay When the call for cooling is satisfied and ther...

Page 42: ...LWM will operate at continuous blower airflow 7 Component test The furnace features a component test system to help diag nose a system problem in the case of a component failure To initiate the component test procedure ensure that there are no thermostat inputs to the control and all time delays have expired Turn on setup switch SW1 6 See Fig 23 NOTE The component test feature will not operate if ...

Page 43: ...Specifications are subject to change without notice 43 441 01 4200 01 A190249 Fig 43 Wiring Diagram ...

Page 44: ...E MAJOR SERIES MINOR SERIES F G80CSU 060 17 16 A 1 TO OBTAIN INFORMATION ON PARTS Consult your installing dealer or the classified section of your local telephone directory under the Heating Equipment or Air Conditioning Contractors and Systems headings for dealer listing by brand name or contact International Comfort Products Consumer Relations Department P O Box 128 Lewisburg TN 37091 USA 931 27...

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