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  5. Installation Instructions Manual

Iceco 80LJ SERIES Installation Instructions Manual

Manual is about: UPFLOW, UPFLOW/HORIZONTAL, AND DOWNFLOW INDUCED DRAFT GAS FURNACES

Summary of 80LJ SERIES

  • Page 1

    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 o...

  • Page 2

    2 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 pr...

  • Page 3

    3 3 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 sa...

  • Page 4: Safety Information

    4 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 temper...

  • Page 5: General Information

    5 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 con...

  • Page 6

    6 reduced clearance (in.) model a b c d e left right back top front vent ship. Side side wgts. 05 14 12 27 / 32 10 3 / 8 ➀ 11 1 / 2 04 ➁ 01 3 6 ➂ 85 lbs. 07 17 1 / 2 16 11 / 32 12 1 / 8 ➀ 15 0 3 ➁ 01 3 6 ➂ 105 lbs. 10(a) 17 1 / 2 16 11 / 32 12 1 / 8 ➀ 15 0 3 ➁ 01 3 6 ➂ 115 lbs. 10(b) 21 19 27 / 32 1...

  • Page 7

    7 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 27 / 32 10 3 / 8 ➀ 13 1 / 8 04 ➁ 01 3 6 ➂ 85 lbs. 07 17 1 / 2 16 11 / 32 12 1 / 8 ➀ 16 5 / 8 03 ➁ 01 3 6 ➂ 105 lbs. 10(a) 17 1 / 2 16 11 / 32 12 1 / 8 ➀ 16 5 / 8 03 ➁ ...

  • Page 8

    8 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 informat...

  • Page 9

    9 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 suppor...

  • Page 10

    10 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 f...

  • Page 11

    11 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 fro...

  • Page 12

    12 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...

  • Page 13: Venting

    13 general information the furnace must be vented in accordance with these instructions, national fuel gas code, ansi z223.1 and/or the natural gas installation code, csa-b149.1 & .2 and requirements or codes of the local utility or other authority having jurisdiction. Devices attached to the flue o...

  • Page 14

    14 “b-1” vertical venting type “b-1” vents must be installed in accordance with the terms of their listings and the vent manufacturer’s instructions. “b-1” vents must be supported and spaced in accordance with their listings and the manufacturer’s instructions. All vents must be supported to maintai...

  • Page 15

    15 existing vent systems important retrofit venting instructions if this furnace is a replacement installation, always inspect the existing vent system to be sure there are no obstructions, blockages, or signs of corrosion. When the existing furnace is removed from a venting system serving other app...

  • Page 16: Gas Supply and Piping

    16 figure 12 gas piping installation upflow & downflow gas supply and piping gas supply this furnace is equipped at the factory for use on natural gas only. Conversion to lp gas requires a special kit supplied by the distributor or manufacturer. Mailing addresses are listed on the furnace rating pla...

  • Page 17

    17 gas pressure important: the maximum gas supply pressure to the furnace should be 10.5” w.C. For natural gas and 13” w.C. For lp gas. Natural gas supply pressure should operate between 5" to 10.5 ” w.C. Lp gas supply pressure should be 11 ” to 13 ” w.C. This pressure must be maintained with all ot...

  • Page 18

    18 table 3 lp gas pipe capacity table (cu. Ft./hr.) setting gas pressure the maximum gas supply pressure to the furnace should be 10.5 ” w.C. Natural gas, or 13 ” w.C. Lp gas. The minimum supply gas pressure to the gas valve should be 5" w.C. Natural gas or 11" w.C. Lp gas. A properly calibrated man...

  • Page 19

    Table 4 19 adjusting or checking furnace input elevations above 2000 ft require that the furnace input rating be adjusted and that the size of the burner orifices be re-calculated based on elevation and gas heating value. The burner orifices may (or may not) need to be changed. See the section title...

  • Page 20: Electrical Wiring

    20 electrical wiring turn off electric power at the fuse box or service panel before making any electrical connections. Also, the ground connection must be completed before making line voltage connections. Failure to do so can result in electrical shock, severe personal injury or death. Important: t...

  • Page 21

    21 field installed option accessories electronic air cleaner 1. Electronic air cleaner line voltage power can be supplied from the screw terminal “eac” and a line voltage neutral screw terminal on the control board. See figure 15. Note: for 80pj and 80lj units spade terms only are provided for e.A.C...

  • Page 22

    22 i400 figure 16 ut electronic controls 1028-928 control board, twinning connection -- single stage operation a099201.

  • Page 23

    23 figure 17 utec 1028-928 control board, twinning connection -- two-stage operation a099301.

  • Page 24

    24 80+ high altitude instructions the national fuel gas code (nfgc) guidelines should be followed when converting these furnaces for high altitude operation. Elevations above 2000 ft require that the furnace input rating be adjusted and that the size of the burner orifices be re-calculated based on ...

  • Page 25

    25 table 6 supplemental orifice size chart 80 plus only models with 25,000 btu's per burner. Do not use this chart for any 90 plus model. Natural gas quick reference chart for orifice selection, at 3.5" w.C. And approximate final firing rates sea level orifice size sea level cubic foot at 3.5" w.C. ...

  • Page 26

    26 lp gas lp gas is a manufactured gas that has consistent heating value across most regions. The nfgc guidelines are used with the following exception: the recommended lp gas high altitude orifice selections differ slightly in that the nfgc lp orifice chart, as they are not accurate for iceco produ...

  • Page 27: Start-Up Procedure

    27 lighting instructions this appliance is equipped with either a direct spark ignition device or a hot surface silicon carbide ignition device. This device lights the main burners each time the room thermostat (closes) calls for heat. See lighting instructions on the furnace. To start furnace 1. Be...

  • Page 28

    28 figure 19 ut electronic controls 1012-925a and invensys climate controls icc-h1mc7 blower off timings off time switch 1 switch 2 90 sec. Off on 120 sec. Off off 160 sec. On off 180 sec. On on (timer is red block on board) i335 1. Each time the thermostat contacts close, the induced draft blower (...

  • Page 29: Air Flow

    29 air flow the importance of proper air flow over the heat exchanger cannot be over emphasized. It is important that each duct system be sized and installed for the specific application by properly applying the appropriate industry accepted standard. If less than minimum standards are applied, the ...

  • Page 30

    30 blower performance data – 80lj downflow models only blower performance data – 80pj upflow/horizontal models.

  • Page 31: Safety Features

    31 safety features limit control the high limit cut-off temperature is set at the factory and cannot be adjusted. The temperature setting prevents the air temperature leaving the furnace from exceeding the maximum outlet air temperature, which, if exceeded, will shut the furnace down. There are seve...

  • Page 32

    32 lubrication the indoor blower motor and induced draft motor are prelubricated by the motor manufacturer and do not require further attention. The motors must be cleaned periodically by a qualified installer, service agency, or the gas supplier to prevent the possibility of overheating due to an a...

  • Page 33: Maintenance

    33 figure 25 bottom return disconnect main electrical power to the unit before attempting any maintenance. Failure to do so can cause electrical shock resulting in severe personal injury or death. Filters note: 80pj and 80lj models are not factory equipped with filters. Filters must be field install...

  • Page 34

    34 figure 26 filter retaining rod (side return) figure 27 downflow filter installation filter rod 45-24095-01 filter rod support angle ae-60520-01 filter support angle (see angle detail) ae-61883-01 filter rod support angle ae-60520-01 filter support angle ae-61883-01.

  • Page 35

    35 important that the airflow is not reduced to maximize system performance and life. Always verify that the systems airflow is not impaired by the filtering system that has been installed, by performing a temperature rise and temperature drop test. Keep the air filters clean at all times. Vacuum di...

  • Page 36

    36 figure 28 troubleshooting flowchart go to e warning integrated furnace control (ifc) troubleshooting guide hazardous voltage line voltage connections disconnect power before servicing. Service must be by a trained, qualified service technician. Note: most failures are not due to the ifc. Double c...

  • Page 37

    37 figure 29 for models with ut electronic controls 1028-928 integrated furnace control and direct spark ignition.

  • Page 38

    38 figure 30 for models with ut electronic controls 1012-925 or invensys climate controls icc-h1mc7-01 integrated furnace control and hot surface ignition.

  • Page 39

    39.

  • Page 40

    40 cm 0604 manufactured by iceco ® 5600 old greenwood road, fort smith, arkansas, 72908.