Iceco 80LJ, 80PJ Installation Instructions Manual

92-24161-31-07

SUPERSEDES 92-24161-31-06

INSTALLATION INSTRUCTIONS

FOR UPFLOW, UPFLOW/HORIZONTAL, AND DOWNFLOW INDUCED DRAFT GAS FURNACES

80PJ AND 80LJ SERIES

PROPOSITION 65: THIS PRODUCT CONTAINS CHEMICALS, INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.

Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction is sometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Make copies of the checklist and complete one for every Low Profile Furnace service call for your records.

INST ALLATION CHECKLIST

(Refer to this manual for specifics.) GAS SUPPLY

Adequate pipe size No gas leaks

Proper supply and manifold gas pressure (check with an accurate U-tube manometer with the furnace and all other gas appliances operating.)

ELECTRICAL

Correct thermostat and subbase Thermostat model Subbase model

Correct thermostat mode and setting Correct line supply voltage Correct power supply polarity is required with electronic ignition Correct furnace ground to electrical panel DC microamp (µA) flame signal (hot surface ignition units) Correct control voltage Measure and set heat anticipator amperage Air conditioning low voltage wires connected to terminals “Y” “C” - not with wire nuts

VENTING

Correct vent pipe diameter and length (according to CSA tables) Vent connection size

Correct venting material (according to CSA tables) Correct lining for masonry chimneys Adequate clearance from combustibles Proper negative pressure reading in the vent

Vent pipe secured to induced draft blower housing

COMBUSTION AIR

Proper source of combustion air

Correct combustion air opening size

FURNACE INSTALLATION

Adequate clearance from combustibles Adequate clearance for service Proper air temperature rise (See furnace rating plate)

External static pressure inches w.c.

Correct filter(s) Correct cooling coil or accessories (if equipped)

Adequate supply and return air ducting Return Air Duct Size Supply Air Duct Size

Air ducts sealed to prevent leakage

IMPORTANT: to insure proper installation and operation of this product, completely read all instructions prior to attempting to assemble, install, operate, maintain or repair this product. upon unpacking of THE furnace, inspect all parts for damage prior to installation and start-up.

CONTENTS

Safety Precautions...................................................................................................4

Installation Check List ..............................................................................................2

General Information..................................................................................................5

Location Requirements and Considerations............................................................5

Combustion and Ventilation Air..............................................................................10

Vent Pipe Installation..............................................................................................13

Gas Supply and Piping...........................................................................................16

Electrical Wiring......................................................................................................20

Accessories............................................................................................................21

Furnace Twinning...................................................................................................21

High Altitude Installations.......................................................................................24

Start-Up Procedures...............................................................................................27

Air Flow...................................................................................................................29

Safety Features......................................................................................................32

Maintenance...........................................................................................................34

Troubleshooting......................................................................................................37

Wiring Diagrams.....................................................................................................38

IMPORTANT: All ICECO products meet current Federal OSHA Guidelines for safety. California Proposition 65 warnings are required for certain products, which are not covered by the OSHA standards.

California's Proposition 65 requires warnings for products sold in California that contain, or produce, any of over 600 listed chemicals known to the State of California to cause cancer or birth defects such as fiberglass insulation, lead in brass, and combustion products from natural gas.

All “new equipment” shipped for sale in California will have labels stating that the product contains and/or produces Proposition 65 chemicals. Although we have not changed our processes, having the same label on all our products facilitates manufacturing and shipping. We cannot always know “when, or if” products will be sold in the California market.

You may receive inquiries from customers about chemicals found in, or produced by, some of our heating and air-conditioning equipment, or found in natural gas used with some of our products. Listed below are those chemicals and substances commonly associated with similar equipment in our industry and other manufacturers.

• Glass Wool (Fiberglass) Insulation

• Carbon Monoxide (CO)

• Formaldehyde

• Benzene More details are available at the

Websites for OSHA (Occupational Safety and Health Administration), at www.osha.gov

and the State of California's OEHHA (Office of Environmental Health Hazard Assessment), at www.oehha.org. Consumer education is important since the chemicals and substances on the list are found in our daily lives. Most consumers are aware that products present safety and health risks, when improperly used, handled and maintained.

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 GAS SUPPLY AND PIPING SECTION OF THESE INSTRUCTIONS.

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 DUCTING SECTION OF THESE INSTRUCTIONS. SEE ALSO FURNACE RATING PLATE.

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.

WHEN THIS FURNACE IS INSTALLED IN A RESIDENTIAL GARAGE, IT MUST BE INSTALLED SO THE BURNERS AND IGNITION SOURCE ARE LOCATED NO LESS THAN 18 INCHES ABOVE THE FLOOR. THIS IS TO REDUCE THE RISK OF IGNITING FLAMMABLE VAPORS WHICH MAY BE PRESENT IN A GARAGE. ALSO, THE FURNACE MUST BE LOCATED OR PROTECTED TO AVOID PHYSICAL DAMAGE BY VEHICLES. FAILURE TO FOLLOW THESE WARNINGS CAN CAUSE A FIRE OR EXPLOSION, RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

USE OF THIS FURNACE IS ALLOWED DURING CONSTRUCTION IF THE FOLLOWING TEMPORARY INSTALLATION REQUIREMENTS ARE MET. INSTALLATION MUST COMPLY WITH ALL INSTALLATION INSTRUCTIONS INCLUDING:

• PROPER VENT INSTALLATION;

• FURNACE OPERATING UNDER THERMOSTATIC CONTROL;

• RETURN AIR DUCT SEALED TO THE FURNACE;

• AIR FILTERS IN PLACE;

• SET FURNACE INPUT RATE AND TEMPERATURE RISE PER RATING PLATE MARKING;

• MEANS FOR PROVIDING OUTDOOR AIR REQUIRED FOR COMBUSTION;

• RETURN AIR TEMPERATURE MAINTAINED BETWEEN 55°F (13°C) AND 80°F (27°C); AND

• CLEAN FURNACE, DUCT WORK AND COMPONENTS UPON SUBSTANTIAL COMPLETION OF THE CONSTRUCTION PROCESS, AND VERIFY FURNACE OPERATING CONDITIONS INCLUDING IGNITION, INPUT RATE, TEMPERATURE RISE AND VENTING, ACCORDING TO THE INSTRUCTIONS.

WARNING

SAFETY INFORMATION

WARNING

DO NOT OPERATE THE SYSTEM FOR EXTENDED PERIODS WITHOUT FILTERS. A PORTION OF THE DUST ENTRAINED IN THE AIR MAY TEMPORARILY LODGE IN THE AIR DUCT RUNS AND AT THE SUPPLY REGISTERS. ANY CIRCULATED DUST PARTICLES WILL BE HEATED AND CHARRED BY CONTACT WITH THE FURNACE HEAT EXCHANGER. THIS SOOTY RESIDUE WILL SOIL CEILINGS, WALLS, DRAPES, CARPETS AND OTHER HOUSEHOLD ARTICLES. SOOT DAMAGE MAY ALSO RESULT WITH, OR WITHOUT, FILTERS IN PLACE, WHEN CERTAIN TYPES OF CANDLES ARE BURNED, OR CANDLEWICKS ARE LEFT UNTRIMMED.

COMBUSTION PRODUCTS MUST BE DISCHARGED OUTDOORS. CONNECT THIS FURNACE TO AN APPROVED VENT SYSTEM ONLY, AS SPECIFIED IN VENT PIPE INSTALLATION SECTION OF THESE INSTRUCTIONS.

PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE FURNACE SPACE AS SPECIFIED IN THE COMBUSTION AND VENTILATION AIR SECTION OF THESE INSTRUCTIONS.

INSTALL THIS FURNACE ONLY IN A LOCATION AND POSITION AS SPECIFIED IN THE LOCATION REQUIREMENTS AND CONSIDERATIONS SECTION OF THESE INSTRUCTIONS. PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR TO THE FURNACE SPACE AS SPECIFIED IN THE VENTING SECTION OF THESE INSTRUCTIONS.

USE ONLY WITH TYPE OF GAS APPROVED FOR THIS FURNACE. REFER TO THE FURNACE RATING PLATE.

GENERAL INFORMATION

DO NOT USE THIS FURNACE DURING CONSTRUCTION IF AIR LADEN CORROSIVE COMPOUNDS ARE PRESENT SUCH AS CHLORINE AND FLUORINE. OTHERWISE, PROVISIONS MUST BE TAKEN TO PROVIDE CLEAN, UNCONTAMINATED COMBUSTION AND VENTILATION AIR TO THE FURNACE. FURNACE COMBUSTION AND VENTILATION AIR CONTAMINATED WITH THESE COMPOUNDS FORMS ACIDS DURING COMBUSTION WHICH CORRODES THE HEAT EXCHANGER AND COMPONENT PARTS. SOME OF THESE CONTAMINANTS ARE FOUND IN, BUT NOT LIMITED TO, PANELING, DRY WALL, ADHESIVES, PAINTS, STAINES, VARNISHES, SEALERS, AND MASONRY CLEANING MATERIALS.

1. NOTE: This furnace is shipped with heat exchanger support brackets installed under the back of the heat exchanger. These may be removed before installation, but it is not required.

LOCATION

THIS FURNACE IS NOT APPROVED FOR INSTALLATION IN A MOBILE HOME. DO NOT INSTALL THIS FURNACE IN A MOBILE HOME. INSTALLATION IN A MOBILE HOME COULD CAUSE FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

2. IMPORTANT: This furnace is not approved or recommended for installation on its back, with access doors facing upwards.

3. This furnace is suitable for installation in buildings constructed on-site. This heating unit should be centralized with respect to the heat distribution system as much as practicable.

4. NOTE: These furnaces are approved for installation in attics, as well as alcoves, utility rooms, closets and crawlspaces.

5. IMPORTANT: Support this unit when installed. For attic or crawl space installation, horizontal furnaces may be installed on combustible wood flooring or by using support brackets. See Figure

6. IMPORTANT: If installing in a utility room, be sure the door is wide enough to:

a. allow the largest part of the

furnace to pass; or

b. allow any other appliance (such

as a water heater) to pass.

The 80PJ and 80LJ series furnaces are design certified by CSA for use with natural and propane gases as follows:

As a Category I furnace, it may be vented vertically with type B-1 vent pipe and also may be common vented as described in these instructions.

This furnace should be installed in accordance with the American National Standard Z223.1 - latest edition booklet entitled “National Fuel Gas Code” (NFPA 54) (in Canada, CSA B149.1

and .2 Installation Codes for gas burning appliances), and the requirements or codes of the local utility or other authority having jurisdiction including local plumbing or waste water codes.

Additional helpful publications available from the “National Fire Protection Association” are: NFPA-90A – Installation of Air Conditioning and Ventilating Systems 1985 or latest edition. NFPA-90B – Warm Air Heating and Air Conditioning Systems 1984.

These publications are available from:

National Fire Protection Association,

Inc. Batterymarch Park Quincy, MA 02269

CSA-INTERNATIONAL 178 Rexdale Blvd. Etobicoke (Toronto), Ontario Canada M9W, 1R3

GENERAL INFORMATION

LOCATION REQUIREMENTS AND CONSIDERATIONS

WARNING

FIGURE 1

HORIZONTAL FURNACE INSTALLED W/SUPPORT BRACKETS

EXHAUST VENT

GAS PIPE

ELECTRICAL CONDUIT

ST-A0799-01

CAUTION

REDUCED CLEARANCE (IN.)

Model A B C D E

Left Right

Back Top Front Vent

Ship.

Side Side Wgts.

05 14 12

/32 10

/8 ➀ 11

/2 04➁ 01 36➂ 85 lbs.

07 17

/2 16

/32 12

/8 ➀ 15 0 3➁ 01 36➂ 105 lbs.

10(A) 17

/2 16

/32 12

/8 ➀ 15 0 3➁ 01 36➂ 115 lbs.

10(B) 21 19

/32 13

/8 ➀ 18

/2 00 0136➂ 120 lbs.

12 24

/2 23

/32 15

/8 ➀ 22 0 0 0 1 3 6➂ 140 lbs.

15 24

/2 23

/32 15

/8 ➀ 22 0 0 0 1 3 6➂ 150 lbs.

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)

UPFLOW AND UPFLOW/HORIZONTAL MODELS

TOP

LEFT SIDE

FRONT

RIGHT SIDE

BOTTOM

/16

/32

/16

/8 DIA.

/32

GAS CONNECTION

ELECTRICAL CONNECTION

OPTIONAL RETURN AIR CUTOUT

(EITHER SIDE) FOR USE WITH

EXTERNAL SIDE FILTER FRAME

LOW VOLTAGE

➀ May require 3” to 4” or 3” or 5” adapter.

➁ May be 0” with type B vent.

➂ May be 1” with type B vent.

FIGURE 2

UPFLOW AND UPFLOW/HORIZONTAL DIMENSIONS

IMPORTANT: This furnace is not approved or recommended for

installation on its back, with access doors facing upwards.

SUPPLY

AIR

RETURN

AIR

AIRFLOW

FIGURE 3

DOWNFLOW DIMENSIONS

REDUCED CLEARANCE (IN.)

Model A B C D E

Left Right

Back Top Front Vent

Ship.

Side Side Wgts.

05 14 12

/32 10

/8 ➀ 13

/8 04➁ 0136➂ 85 lbs.

07 17

/32

/8 ➀ 16

03➁ 0136➂ 105 lbs.

10(A) 17

/2 16

/32 12

/8 ➀ 16

/8 03➁ 0136➂ 115 lbs.

10(B) 21 19

/32 13

/8 ➀ 20

/8 00 0 166➂ 120 lbs.

12 24

2 23

32 15

➀ 23

8 00 0136➂ 140 lbs.

15 24

/2 23

/32 15

/8 ➀ 23

/8 00 0 136➂ 150 lbs.

TOP

BOTTOM

B D

LOW VOLTAGE

GAS CONNECTION

ELECTRIC CONNECTION

/16

/8 DIA.

➀ May require 3” to 4” or 3” or 5” adapter.

➁ May be 0” with type B vent.

➂ May be 1” with type B vent.

CLEARANCE TO COMBUSTIBLE MATERIAL (INCHES)

DOWNFLOW MODELS

NOTE: IN DOWNFLOW CONFIGURATION, OPTIONAL AIR CUTOUT IS NOT PERMITTED.

SUPPLY

AIR

RETURN

AIR

AIRFLOW

CLEARANCE – ACCESSIBILITY

The design of forced air furnaces with input ratings as listed in the tables on the following pages are certified by CSA for the clearances to combustible materials shown in inches.

See name/rating plate and clearance label for specific model number and clearance information.

Service clearance of at least 24 inches is recommended in front of all furnaces.

ACCESSIBILITY CLEARANCES, WHERE GREATER, MUST TAKE PRECEDENCE OVER FIRE PROTECTION CLEARANCES.

UPFLOW AND HORIZONTAL FURNACES MUST NOT BE INSTALLED DIRECTLY ON CARPETING, TILE OR OTHER COMBUSTIBLE MATERIAL OTHER THAN WOOD FLOORING. INSTALLATION ON A COMBUSTIBLE MATERIAL CAN RESULT IN FIRE CAUSING PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.

DOWNFLOW UNIT DESIGN IS CERTIFIED FOR INSTALLATION ON NON-COMBUSTIBLE FLOOR. A SPECIAL COMBUSTIBLE FLOOR SUB-BASE IS REQUIRED WHEN INSTALLING ON A COMBUSTIBLE FLOOR. FAILURE TO INSTALL THE SUB-BASE MAY RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THIS SPECIAL BASE IS OFFERED AS AN ACCESSORY FROM THE FACTORY. SEE THE CLEARANCE LABEL LOCATED INSIDE THE FURNACE FOR THE APPROPRIATE MODEL NUMBER.

THE SPECIAL BASE IS NOT REQUIRED WHEN THE FURNACE IS INSTALLED ON TOP OF AN AIR CONDITIONING PLENUM.

A gas-fired furnace for installation in a residential garage must be installed so that the burner(s) and the ignition source are located not less than 18” above the floor and the furnace is located or protected to avoid physical damage by vehicles.

UPFLOW UNIT DESIGN REQUIRES A SOLID METAL BASE PLATE (SEE TABLE 1 OR FURNACE CLEARANCE LABEL FOR PART

PLACEMENT OF COMBUSTIBLE MATERIALS ON, AGAINST OR AROUND THE FURNACE JACKET CAN CAUSE AN EXPLOSION OR FIRE RESULTING IN PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THE FURNACE OWNER SHOULD BE CAUTIONED THAT THE FURNACE AREA MUST NOT BE USED AS A BROOM CLOSET OR FOR ANY OTHER STORAGE PURPOSES.

DUCTING

Proper air flow is required for the correct operation of this furnace. Too little air flow can cause erratic operation and can damage the heat exchanger. The duct system must carry the correct amount of air for heating and cooling. Position the unit minimize long runs or runs with many turns and elbows.

Size the ducts according to acceptable industry standards and methods. The total static pressure drop (including evaporator coil, if used) of the entire system should not exceed 0.5” w.c. Be sure to have adequate space for unit filter.

IMPORTANT: Some high efficiency filters have a greater than normal resistance to air flow. This can adversely affect furnace operation. BE SURE TO CHECK AIR FLOW if using any filter other than the factoryprovided filter.

NOTE: DO NOT take return air from bathrooms, kitchens, furnace rooms, garages, utility or laundry rooms, or cold areas.

IMPORTANT: When using outside air, design and adjust the system to maintain a return air temperature above 50°F during the heating season.

NEVER ALLOW PRODUCTS OF COMBUSTION OR THE FLUE PRODUCTS TO ENTER THE RETURN AIR DUCTWORK, OR THE CIRCULATING AIR SUPPLY. ALL RETURN DUCTWORK MUST BE ADEQUATELY SEALED AND SECURED TO THE FURNACE WITH SHEET METAL SCREWS, AND JOINTS TAPED. WHEN A FURNACE IS MOUNTED ON A PLATFORM, WITH RETURN THROUGH THE BOTTOM, IT MUST BE SEALED AIRTIGHT BETWEEN THE FURNACE

NUMBER) BE IN PLACE WHEN THE FURNACE IS INSTALLED WITH SIDE OR REAR AIR RETURN DUCTS. FAILURE TO INSTALL A BASE PLATE COULD CAUSE PRODUCTS OF COMBUSTION TO BE CIRCULATED INTO THE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING.

SITE SELECTION

1. Select a site in the building near the center of the proposed, or existing, duct system.

2. Give consideration to the vent system piping when selecting the furnace location. Be sure the venting system can travel from the furnace to the termination with minimal length and elbows.

3. Locate the furnace near the existing gas piping. Or, if running a new gas line, locate the furnace to minimize the length and elbows in the gas piping.

4. Locate the furnace to maintain proper clearance to combustibles as shown in Figures 2 & 3.

WHEN COILS ARE USED WITH AIR HANDLERS OR FURNACES AND INSTALLED ABOVE A FINISHED CEILING OR LIVING AREA, IT IS RECOMMENDED THAT AN AUXILIARY SHEET METAL CONDENSATE DRAIN PAN BE FABRICATED AND INSTALLED UNDER ENTIRE UNIT. FAILURE TO DO SO CAN RESULT IN PROPERTY DAMAGE.

COMBUSTIBLE MATERIAL MUST NOT BE PLACED ON OR AGAINST THE FURNACE JACKET OR WITHIN THE SPECIFIED CLEARANCES OF THE VENT PIPE. THE AREA AROUND THE FURNACE MUST BE KEPT CLEAR AND FREE OF ALL COMBUSTIBLE MATERIALS INCLUDING GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.

CAUTION

WARNING

TABLE 1

FURNACE BASE BASE

WIDTH

PLATE NO. PLATE SIZE

14” RXGB-D14 11

/8” x 239/16”

/2” RXGB-D17 151/8” x 239/16”

21” RXGB-D21 18

/8” x 239/16”

/2” RXGB-D24 255/8” x 239/16”

AND THE RETURN AIR PLENUM. THE RETURN AIR PLENUM MUST BE PERMANENTLY ENCLOSED. NEVER USE A DOOR AS A PART OF THE RETURN AIR PLENUM. THE FLOOR OR PLATFORM MUST PROVIDE SOUND PHYSICAL SUPPORT OF THE FURNACE, WITHOUT SAGGING, CRACKS, GAPS, ETC., AROUND THE BASE AS TO PROVIDE A SEAL BETWEEN THE SUPPORT AND THE BASE.

FAILURE TO PREVENT PRODUCTS OF COMBUSTION FROM BEING CIRCULATED INTO THE LIVING SPACE CAN CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

DO NOT, UNDER ANY CIRCUMSTANCES, CONNECT RETURN OR SUPPLY DUCTWORK TO OR FROM ANY OTHER HEAT PRODUCING DEVICE SUCH AS A FIREPLACE INSERT, STOVE, ETC. DOING SO MAY RESULT IN FIRE, CARBON MONOXIDE POISONING, EXPLOSION, PERSONAL INJURY OR PROPERTY DAMAGE.

BLOWER AND BURNERS MUST NEVER BE OPERATED WITHOUT THE BLOWER DOOR IN PLACE. THIS IS TO PREVENT DRAWING GAS FUMES (WHICH COULD CONTAIN HAZARDOUS CARBON MONOXIDE) INTO THE HOME THAT COULD RESULT IN PERSONAL INJURY OR DEATH.

UPFLOW UNITS

1. Set furnace in place and connect the return duct or return air cabinet to unit. Make the connection air-tight to prevent entraining combustion gases from any adjacent fuelburning appliances. Unit return air may be connected on the sides or bottom of the return air compartment.

a. Openings in the side must be cut

out the full width of the knockouts on the unit. If using side return air,

THE BOTTOM base plate must be installed.

NOTE: Where the maximum

airflow is 1800 CFM or more, both sides or the bottom must be used for return air.

b. If using bottom return air, place

furnace over return air plenum and seal furnace bottom to return air plenum.

A SOLID METAL BASE PLATE, (SEE TABLE 1) MUST BE IN PLACE WHEN THE FURNACE IS INSTALLED WITH SIDE OR REAR AIR RETURN DUCTS. FAILURE TO INSTALL A BASE PLATE COULD CAUSE PRODUCTS OF COMBUSTION TO BE CIRCULATED INTO THE LIVING SPACE AND CREATE POTENTIALLY HAZARDOUS CONDITIONS, INCLUDING CARBON MONOXIDE POISONING OR DEATH.

2. If summer air conditioning is desired, position the indoor coil on the top of the unit. Insure that no air can bypass this coil.

3. Connect the supply air plenum to the furnace plenum opening.

DOWNFLOW UNITS

THE DOWNFLOW FURNACE DESIGN IS CERTIFIED FOR INSTALLATION ON A NONCOMBUSTIBLE FLOOR. IF INSTALLED ON A COMBUSTIBLE FLOOR, USE THE SPECIAL BASE SPECIFIED ON THE FURNACE CLEARANCE LABEL. FAILURE TO INSTALL THE SPECIAL BASE MAY RESULT IN FIRE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. THIS SPECIAL BASE IS SHIPPED FROM THE FACTORY AS AN ACCESSORY.

1. Position the unit over the supply air plenum and connect.

a. If installing on a combustible floor

and not using an evaporator coil box, install the special

combustible floor base. See Figure 4.

b. If summer air conditioning is

desired, position the indoor coil on the bottom of the unit. Insure that no air can bypass this coil.

2. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

HORIZONTAL UNITS

1. Unit can be mounted left or right side airflow configuration.

2. Position the unit on adequate supports or by using support brackets (see Figure 1) and connect supply plenum.

3. If summer air conditioning is desired, position the indoor coil on the supply air side of the unit. Insure that no air can bypass this coil.

4. Secure the four angle brackets shipped with the unit to the return air opening. See Figure 5. Connect the return air ducting to the return air opening at the top of the unit. Make the connection air tight to prevent entraining combustion gases from an adjacent fuel-burning appliance.

NOTE: Do not block furnace access with support rods. Maintain clearances recommended in Figure 2. Allow enough space for proper service, maintenance or replacement of the heat exchanger and blower assembly.

FIGURE 4

COMBUSTIBLE FLOOR BASE

WARNING

THIS FURNACE AND ANY OTHER FUEL-BURNING APPLIANCE MUST BE PROVIDED WITH ENOUGH FRESH AIR FOR PROPER COMBUSTION AND VENTILATION OF THE FLUE GASES. MOST HOMES WILL REQUIRE THAT OUTSIDE AIR BE SUPPLIED INTO THE FURNACE AREA. FAILURE TO DO SO CAN CAUSE DEATH FROM CARBON MONOXIDE POISONING.

Adequate facilities for providing air for combustion and ventilation must be provided in accordance with section

5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI, Z223.1 latest edition or CSA B149.1 and .2 or, applicable provisions for the local building codes, and not obstructed so as to prevent the flow of air to the furnace.

OVERTEMPERATURE SAFETY SWITCHES

This furnace is equipped with safety switches in the burner compartment to protect against overtemperature conditions caused by inadequate combustion air supply. The switches are located just above the burners on the furnace center panel on upflow and downflow models and also on each side of the burners on upflow/horizontal and horizontal “only” models, and must be manually reset if tripped. DO NOT jumper this switch. If this switch should trip, a qualified furnace installer, service agency or the

FIGURE 5

HORIZONTAL RETURN AIR DUCT

FIGURE 6

AIR FROM HEATED SPACE

gas supplier should be called to check and/or correct for adequate combustion air supply. If this unit is mounted in a closet, the door must be closed when making this check of the installation.

DO NOT reset the overtemperature switch without taking corrective action to assure that an adequate supply of combustion air is maintained under all conditions of operation.

Replace this switch only with the identical replacement part.

COMBUSTION AIR REQUIREMENTS

IMPORTANT: Air for combustion and ventilation must not come from a corrosive atmosphere. Any failure due to corrosive elements in the atmosphere is excluded from warranty coverage.

The following types of installation may require OUTDOOR AIR for combustion, due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Furnaces installed in laundry rooms

• Furnaces in hobby or craft rooms

• Furnaces installed near chemical

storage areas.

Exposure to the following substances in the combustion air supply may also require OUTDOOR AIR 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

COMBUSTION AND VENTILATION AIR

WARNING

FOUR ANGLE BRACKETS ARE SHIPPED WITH EACH UNIT THAT CAN BE INSTALLED HORIZONTALLY. THESE BRACKETS MAY BE USED TO SECURE THE RETURN AIR DUCT TO A HORIZONTAL UNIT.

(LEFT-HAND AIRFLOW POSITION SHOWN)

AIRFLOW

Combustion air must be free of acid forming chemicals; such as sulphur, fluorine and chlorine. These elements are found in aerosol sprays, detergents, bleaches, cleaning solvents, air fresheners, paint and varnish removers, refrigerants and many other commercial and household products. Vapors from these products when burned in a gas flame form acid compounds. The acid compounds increase the dew point temperature of the flue products and are highly corrosive after they condense.

ALL FURNACE INSTALLATIONS MUST COMPLY WITH THE NATIONAL FUEL GAS CODE AND LOCAL CODES TO PROVIDE ADEQUATE COMBUSTION AND VENTILATION AIR FOR THE FURNACE. FAILURE TO DO SO CAN CREATE HAZARDOUS CONDITIONS RESULTING IN PROPERTY DAMAGE, BODILY INJURY OR DEATH FROM SMOKE, FIRE OR CARBON MONOXIDE.

Combustion air requirements are determined by whether the furnace is in an open (unconfined) area or in a confined space such as a closet or small room.

EXAMPLE 1. FURNACE LOCATED IN AN UNCONFINED SPACE

Using indoor air for combustion.

An unconfined space must have at least 50 cubic feet for each 1,000 BTUH of the total input for all appliances in the space. Here are a few examples of the room sizes required for different inputs. The sizes are based on 8 foot ceilings.

BTUH Minimum Sq. Feet Typical Room Size

Input

With 8' Ceiling With 8' Ceiling

50,000 312 14*x24* or 18*x18*

75,000 469 15*x31* or 20*x24* 100,000 625 20*x31* or 25*x25* 125,000 833 23*x34* or 26*x30* 150,000 938 25*x38* or 30*x31*

If the open space containing the furnace is in a building with tight construction (contemporary construction), outside air may still be required for the furnace to operate and vent properly. Outside air openings should be sized the same as for a confined space.

FIGURE 7

AIR FROM ATTIC/CRAWL SPACE

EXAMPLE 2. FURNACE LOCATED IN A CONFINED SPACE

A confined space (any space smaller than shown above as “unconfined”) must have openings into the space which are located in accordance with the requirements set forth in the following subsections A and B. Size the openings by how they are connected to the heated area or to the outside, and by the input of all appliances in the space.

If confined space is within a building with tight construction, combustion air must be taken from outdoors or area freely communicating with the outdoors.

A. USING INDOOR AIR FOR

COMBUSTION (FIGURE 6)

IMPORTANT: Air should not be taken from a heated space with a fireplace, exhaust fan or other device that may produce a negative pressure.

If combustion air is taken from the heated area, the openings must each

have at least 100 square inches of free area. Each opening must have at least one square inch of free area for each 1,000 Btuh of total input in the space. Here are some examples of typical openings required.

Btuh Free Area

Input Each Opening

100,000 100 Square Inches 150,000 150 Square Inches

B. USING OUTDOOR AIR FOR

COMBUSTION (FIGURE 7) IMPORTANT: Never take

combustion air from an attic space that is equipped with power ventilation.

The confined space must communicate with the outdoors according to Methods 1 and 2. The minimum air opening dimension shall not be less than 3 inches. When using ducts, they shall be of the same cross-sectional area as the free area of the openings to which they connect.

WARNING

IMPORTANT: If the furnace is in a location with an exhaust fan, there must be sufficient ventilation to prevent the exhaust fan from creating a negative pressure in the room.

Combustion air openings must NOT BE RESTRICTED in any manner.

CONSULT LOCAL CODES FOR SPECIAL REQUIREMENTS.

Air opening in the furnace casing front, return air grilles, and warm air registers must not be obstructed.

B: Method 1 Provide two permanent openings,

one located within 12 inches of the top and one located within 12 inches of the bottom of the enclosure. Each opening shall communicate directly, or by ducts, with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

a. Where directly communicating

with the outdoors or where communicating to the outdoors through VERTICAL DUCTS, each opening shall have a minimum free area of 1 square inch for each 4000 BTUH of total appliance input rating in the enclosure (see Figure 7). Here are typical duct sizes:

b. Where communicating with

outdoors through HORIZONTAL DUCTS, each opening shall have a minimum free area of 1 square inch for each 2000 BTUH of total input rating for all equipment in the enclosure (see Figure 8). Here are typical duct sizes:

FIGURE 8

OUTSIDE AIR USING A HORIZONTAL INLET & OUTLET

B: Method 2 One permanent opening, located within

12 inches of the top of the enclosure, shall be permitted where the equipment has clearances of at least 1 inch from the sides and back and 6 inches from the front of the appliance. The opening shall directly communicate with the outdoors or communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors and have a minimum free area of:

a. One square inch for each 3000

BTUH of the total input rating of all equipment located in the enclosure,

AND

b. Not less than the sum of the areas of

all vent connectors in the confined space.

VERTICAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round Input Each Opening Pipe Size

50,000 12.50 sq. inches 4”

75,000 18.75 sq. inches 5” 100,000 25.00 sq. inches 6” 125,000 31.25 sq. inches 7” 150,000 37.50 sq. inches 7”

HORIZONTAL OUTDOOR AIR OPENING DIMENSIONS

BTUH Free Area Round

Input Each Opening Pipe Size

50,000 25.00 sq. inches 6”

75,000 37.50 sq. inches 7” 100,000 50.00 sq. inches 8” 125,000 62.50 sq. inches 9” 150,000 75.00 sq. inches 10”

+ 28 hidden pages

Iceco 80LJ, 80PJ Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual