Carrier N80ESL Series Installation Instructions Manual Download Page 47

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Specifications are subject to change without notice.

441 01 3400 02

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)

GAS CONTROL GROUP

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

HEAT EXCHANGER GROUP

Heat exchanger cell
Cell panel
Lox NOx baffle (California models only)

INDUCER GROUP

Housing assembly
Pressure switch
Inducer motor
Inducer wheel
Vent elbow assembly
Draft safeguard switch

MODEL

HEATING SIZE

WIDTH

COOLING

AIRFLOW (CFM)

MINOR SERIES

*80ESN

045

----

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.

Summary of Contents for N80ESL Series

Page 1: ...DE 47 NOTE Read the entire instruction manual before starting the installation 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 subje...

Page 2: ... 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 con taining the furnace the return air shall also be handled by duct s sealed to the furnace casing and terminating out side the space containing the furnace See Air Ducts sec tion 8 A gas fired furnace for ...

Page 3: ...ET WIDTH B OUTLET WIDTH C TOP AND BOTTOM FLUE COLLAR D 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 0702116 21 533 19 3 8 492 13 ...

Page 4: ... Z223 1 and the Installation Standards Warm Air Heating and Air Conditioning Systems ANSI NFPA 90B General Installation S 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 Combust...

Page 5: ...e DO NOT move or shuffle your feet do not touch un grounded 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 ungroun ded furnaces 6 Before removing a new control from its container dis charge your body s el...

Page 6: ...rnace 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 WARNING PERSONAL INJURY AND OR PR...

Page 7: ...00 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 Air Changes Hour FIRE HAZARD Failure to follow this warning could result in personal injury death a...

Page 8: ... USTION AIR OPENINGS SHALL BE AT LEAST 3 IN 305mm 305mm 305mm 305mm 305mm 76mm Minimum dimensions of 3 in 76 mm NOTE Use any of the following combinations of openings A B C D D E F G A03174 Fig 7 Air for Combustion Ventilation and Dilution from Outdoors g 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 Fi...

Page 9: ...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 combus tion permanent ventilation and dilution of flue gases However in buildings with unusually tight construction additional air MUST be provided using the methods de scribed in the Outdoor Combustion Air Method section Unusually tight...

Page 10: ...etermine application being installed from Table 4 2 Construct hole in floor per Table 4 and Fig 11 3 Construct plenum to dimensions specified in Table 4 and Fig 11 4 If downflow subbase is used install as shown in Fig 12 If Coil model number END4X ENW4X or Coil Casing model number NAEA is used install as shown in Fig 13 NOTE It is required that the perforated supply air duct flanges be completely ...

Page 11: ...ble Flooring subbase not required 15 7 8 403 19 483 16 1 2 419 19 5 8 498 Downflow Applications on Combustible Flooring subbase required 15 1 8 384 19 483 16 3 4 425 20 5 8 600 Downflow Applications on Combustible Flooring with Cased Coil subbase not required 15 1 2 394 19 483 16 1 2 419 20 508 21 533 Upflow Applications on Combustible or Noncombustible Flooring subbase not required 19 1 2 495 21 ...

Page 12: ...ir 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 21 FILTER ARRANGEMENT CARBON MONOXIDE AND POISONING HAZARD Failure to follow this warning could result in personal inju...

Page 13: ...upply air outlet on furnace Bend flange inward past 90_ with wide duct pliers See Fig 14 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 ca...

Page 14: ...S IN BOTTOM A10131 Fig 16 Horizontal Suspension with Straps 30 IN 762mm MIN WORK AREA 6 MIN TYPE B VENT 17 3 4 22 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 FURNA...

Page 15: ... shall be installed at the furnace gas control valve and extend a minimum of 2 in 51 mm outside the furnace WARNING 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...

Page 16: ...02120 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 ...

Page 17: ...onal 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 sh...

Page 18: ...o change without notice 18 441 01 3400 02 A02163 Fig 20 Downflow Return Air Configurations and Restrictions A02162 Fig 21 Horizontal Return Air Configurations and Restrictions 2 51mm Street Elbow A08551 Fig 22 Burner and Manifold ...

Page 19: ...f 63_F 35_C rise 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 l...

Page 20: ...le 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 as shown in Fig 25 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...

Page 21: ...G COM W C R G Y GND 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 ty...

Page 22: ...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 i...

Page 23: ... 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 stati...

Page 24: ...e between the chimney and the metal liner Exterior Masonry Chimney FAN NAT Installations with Type B Double Wall Vent Connectors NFPA AGA Table 8 Combined Appliance Maximum Input Rating in Thousands of BTUH per Hour 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 ...

Page 25: ...ebris in cleanout Mortar tile metal vent fuel oil residue Is liner and top seal in good condition Is chimney property lined with clay tile liner Crown condition Missing mortar or brick Rebuild crown Yes Yes No No No Reline Yes Repair Yes Yes Yes No No Remove mortar and tile debris Remove metal vent or liner No No No No Yes Yes Suitable Suitable Not Suitable Line chimney with property sized listed ...

Page 26: ...rews The factory supplied vent elbow does NOT count as part of the number of vent connector elbows The vent connector can exit the furnace through one of 5 locations on the casing 1 Attach the single wall vent connector to the furnace vent elbow and fasten the vent connector to the vent elbow with at least two field supplied corrosion resistant sheet metal screws located 180_ apart NOTE An accesso...

Page 27: ...p Fig 35 154 000 132 000 5 127 7 2 1 Horizontal Left Vent Elbow up Fig 37 154 000 132 000 5 127 7 2 1 Horizontal Left Vent elbow right Fig 36 154 000 5 127 7 2 1 Downflow Vent elbow up then left Fig 30 110 000 5 127 10 3 0 Downflow Vent elbow up then right Fig 33 110 000 5 127 10 3 0 NOTE All vent configurations must also meet National Fuel Gas Code venting requirements NFGC 4 in 102 mm inside cas...

Page 28: ...t Elbow Up then Left SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03211 Fig 31 Downflow Application Vent Elbow Up SEE NOTES 1 2 4 5 6 7 8 9 on the page following these figures A03207 Fig 32 Downflow Application Vent Elbow Left then Up SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures A03212 Fig 33 Downflow Application Vent Elbow Up then Right ...

Page 29: ... the page following these figures A03214 Fig 36 Horizontal Right Application Vent Elbow Right SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03215 Fig 37 Horizontal Left Application Vent Elbow Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03219 Fig 38 Horizontal Right Application Vent Elbow Left then Up SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03...

Page 30: ...glasses and gloves when handling parts and servicing furnaces CAUTION 1 Maintain 115 v wiring and ground Improper polarity will result in flashing a status code 10 and no furnace opera tion 2 Make thermostat wire connections at the 24 v terminal block on the furnace control Failure to make proper con nections will result in improper operation See Fig 25 3 Gas supply pressure to the furnace must be...

Page 31: ...rner orifice size in furnace NEVER ASSUME ORIFICE SIZE ALWAYS CHECK AND VERIFY g Replace orifice with correct size if required by Table 10 11 12 and 13 Use only factory supplied orifices See EXAMPLE 1 Table 10 Altitude Derate Multiplier for U S A ALTITUDE FT M PERCENT OF DERATE DERATE MULTIPLIER FACTOR 0 2000 0 610 0 1 00 2001 3000 610 914 8 12 0 90 3001 4000 914 1219 12 16 0 86 4001 5000 1219 152...

Page 32: ...wer speed In crease blower speed to reduce temperature rise Decrease blower speed to increase temperature rise d Turn thermostat down below room temperature and re move blower access door e To change motor speed selection for heating remove blower motor lead from control HEAT terminal See Fig 24 Select desired blower motor speed lead from one of the other terminals and relocate it to the HEAT term...

Page 33: ...the safe shutdown of the furnace during certain blocked vent conditions a Verify vent pipe is cool to the touch b Disconnect power to furnace and remove vent connector from furnace vent elbow c Restore power to furnace and set room thermostat above room temperature d After normal start up allow furnace to operate for 2 min utes then block vent elbow in furnace 80 percent of vent area with a piece ...

Page 34: ... 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 8...

Page 35: ...Specifications are subject to change without notice 35 441 01 3400 02 Table 12 Orifice Size and Manifold Pressure In W C for Gas Input Rate A10180 ...

Page 36: ...Specifications are subject to change without notice 36 441 01 3400 02 Table 12 Orifice Size and Manifold Pressure In W C for Gas Input Rate CONT A10180A ...

Page 37: ...Specifications are subject to change without notice 37 441 01 3400 02 Table 13 Orifice Size And Manifold Pressure In W C For Gas Input Rate A10181 ...

Page 38: ...st be in the OFF position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing WARNING ELECTRICAL OPERATION HAZARD Failure to follow this caution may result in improper furnace operation or failure of furnace Label all wires prior to disconnection when servicing controls Wiring errors ca...

Page 39: ...l CARE AND MAINTENANCE FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Never store anything on near or in contact with the furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning compounds plastic or plastic containers gasoline kerosene ...

Page 40: ... each end of the motor Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove outer door 3 For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door a Disconnect vent connector from furnace vent elbow b Disconnect and remove short piece of vent pipe from within furnace 4 Remove two screws from blower acce...

Page 41: ...rying to clean them thoroughly A heavy build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger Action must be taken to correct the problem If it becomes necessary to clean the heat excha...

Page 42: ...et thermostat above room temperature and check furnace for proper operation 18 Verify blower airflow and speed changes between heating and cooling 19 Check for gas leaks 20 Replace outer access door A91252 Fig 47 Cleaning Heat Exchanger Cell 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 ...

Page 43: ...operating When the thermostat is satisfied the R to G and Y circuits are opened The outdoor unit will stop and the furnace blower motor BLWM will continue oper ating on the COOL speed for an additional 90 sec Cut jumper J2 to reduce the cooling off delay to 5 sec See Fig 24 3 Continuous Blower Mode When the R to G circuit is closed by the thermostat the blower motor BLWM will operate on continuous...

Page 44: ...Specifications are subject to change without notice 44 441 01 3400 02 A190267 Fig 48 Wiring Diagram ...

Page 45: ...Specifications are subject to change without notice 45 441 01 3400 02 A190281 ...

Page 46: ...Specifications are subject to change without notice 46 441 01 3400 02 NOTE NUMBER IN UPPER LEFT HAND CORNER REPRESENTS FLASH CODE A190282 Fig 49 Troubleshooting Guide ...

Page 47: ...sembly Draft safeguard switch MODEL HEATING SIZE WIDTH COOLING AIRFLOW CFM MINOR SERIES 80ESN 045 17 12 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...

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