# 45464G003 Page 1

INSTALLATION INSTRUCTIONSG1N80AU, GIN80AR, GIN80AT, CG80UA, CG80RA, & CG80TA

80% Gas-Fired Furnace

Manufactured ByA.A.C.

A Lennox International Company421 Monroe Street

Bellevue, OH 44811

TABLE OF CONTENTS

SAFETY ................................................. 2

INSTALLATION....................................... 2

START-UP ............................................ 13

OPERATION ........................................ 14

MAINTENANCE ................................... 16

REPAIR PARTS .................................... 17

CONTROL SYSTEM DIAGNOSTICS .. 18

WIRING DIAGRAMS ............................ 19

Do not store combustible materials, includinggasoline and other flammable vapors andliquids, near the furnace, vent pipe, or warmair ducts. The homeowner should be cau-tioned that the furnace area must not beused as a broom closet or for any otherstorage purposes. Such uses may result inactions that could cause property damage,personal injury, or death.

WARNING

This furnace is not approved for installation ina mobile home. Do not install this furnace in amobile home. Installation in a mobile homecould result in actions that could cause prop-erty damage, personal injury, or death.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause injuryor property damage. Refer to this manual. For assistance or additional information,consult a qualified installer, service agency, or the gas supplier.

WARNING

The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of theNational Fire Protection Association; the National Fuel Gas Code, ANSI Z223.1/NFPA No. 54 (latest edition)and the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States; CSA B149.1(latest edition) Natural Gas and Propane Installation Codes and the Canadian Electrical Code Part 1, CSA22.1 (latest edition) in Canada; and any state or provincial laws, local ordinances (including plumbing orwastewater codes), or local gas utility requirements. Local authorities having jurisdiction should be con-sulted before installation is made. Such applicable regulations or requirements take precedence over thegeneral instructions in this manual.

IMPORTANT

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INSTALLATION

These instructions must be placed on or near thefurnace in a conspicuous place.

This furnace is design certified by CSA International as aCategory I furnace using air from inside the structure forcombustion. The combustion system is fan-assisted, whichmeans it is equipped with an integral mechanical means todraw products of combustion through the heat exchanger.

G1N80AT and CG80TA models may be installed as upflowor horizontal furnaces. G1N80AR and CG80RA modelsmay be installed as counterflow (downflow) or horizontalfurnaces. When installed horizontally, the installer mustinstall a sheet metal screw to retain the upper door asshown in Figure 1.

G1N80AU and CG80UA models must be installed only asupflow furnaces.

Never install any furnace on its back.

Horizontal Installations

Locate Screw Here When HorizontalInstallation is Airflow Right to Left

Return

Supply

Locate Screw Here When HorizontalInstallation is Airflow Left to Right

G1N80AR/CG80RA Models

ReturnSupply

Locate Screw Here When HorizontalInstallation is Airflow Left to Right

Locate Screw Here When HorizontalInstallation is Airflow Right to Left

G1N80AT/CG80TA Models

Figure 1

IMPORTANT SAFETY INFORMATIONThe following is a list of safety rules and precautionsthat must be followed when installing this furnace.

1. Use only with the type of gas approved for thisfurnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and position asspecified in the Location section on page 3 ofthese instructions.

3. Provide adequate combustion and ventilation air tothe furnace space as specified in the Combustionand Ventilation Air section beginning on page 4 ofthese instructions.

4. Combustion products must be discharged outdoors.Connect this furnace to an approved vent systemonly, as specified in Venting beginning on page 6 ofthese instructions.

5. Never test for gas leaks with an open flame. Use acommercially available soap solution made specifi-cally for the detection of leaks to check all connec-tions, as specified in Gas Supply and Pipingbeginning on page 11 of these instructions.

6. Always install furnace to operate within the furnace’sintended temperature-rise range with a duct system

which has an external static pressure within theallowable range, as specified in Temperature Riseon page 16 of these instructions. See furnace ratingplate.

7. When a furnace is installed so that the supply ductscarry air circulated by the furnace to areas outsidethe space containing the furnace, the return air shallalso be handled by duct(s) sealed to the furnacecasing and terminating outside the space containingthe furnace. See Circulating Air Supply on page 9of these instructions.

8. A gas-fired furnace for installation in a residentialgarage must be installed as specified in the Loca-tion section on page 3 of these instructions.

9. The furnace is not to be used for temporary heating ofbuildings or structures under construction as specifiedon page 4 of these instructions.

In the State of Massachusetts:

This product must be installed by a licensed Plumberor Gas Fitter. When flexible connectors are used, themaximum length shall not exceed 36". When lever-type gas shutoffs are used, they shall be T-handletype.

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Inspection of Shipment

This furnace is shipped in one package, completelyassembled and wired. The thermostat is shipped in aseparate carton when ordered.

Upon receipt of equipment, carefully inspect it for possibleshipping damage. If damage is found, it should be noted onthe carrier’s freight bill. Damage claims should be filed withthe carrier immediately. Claims of shortages should befiled with the seller within 5 days.

Check the rating plate for correct model number, type ofgas, and input.

Clearances

All servicing and cleaning of the furnace can be performedfrom the front. If installed in a closet or utility room, provide18" clearance in front for service if the door to the room isnot in line with the front of the furnace.

All models are suitable for installation at reduced clear-ances to combustibles as noted in the tables in Figure 2.Where servicing clearances are greater than clearances tocombustibles, servicing clearances take precedence.

G1N80AU, G1N80AT, CG80UA, and CG80TA models, andhorizontally installed G1N80AR and CG80RA models maybe installed on wood flooring, but shall not be installeddirectly on carpeting, tile, or other combustible materialother than wood flooring.

G1N80AR and CG80RA models installed as counterflow(downflow) units may be installed on combustible flooringprovided a special combustible floor base is used. (Referto the Counterflow/Downflow Installations sectionbeginning on page 9 for more information on using thespecial base assembly.)

Location

All models are suitable for closet or utility room installation.The furnace must be installed so that electrical compo-nents are protected from water.

The furnace is suitable for installation in buildings con-structed on-site. The furnace should be centralized inrespect to the heat distribution system as much aspracticable. When installed in a utility room, the doorshould be wide enough to allow the largest part of thefurnace to enter, or permit the replacement of anotherappliance, such as a water heater.

A gas-fired furnace for installation in a residential garagemust be installed so the burner(s) and the ignition sourceare located not less than 18" above the floor. The furnaceis to be located or protected to avoid physical damage byvehicles.

G1N80AR, G1N80AT, CG80RA, and CG80TA modelsinstalled in the horizontal position are approved for atticinstallations. If the furnace is to be installed in an atticor other insulated space, it must be kept free andclear of insulating materials. When a furnace isinstalled in conjunction with an evaporator coil in anattic or above a finished ceiling where condensateoverflow could result in property damage, a drainpan should be provided under the units as specifiedby most local building codes.

Figure 2

Minimum Clearances to Combustibles(all measurements in inches)

Upflow and Counterflow Installations

Horizontal Installations(G1N80AR and CG80RA models)

1 May be 2" when Type B-1 vent pipe is used.2 May be 1" when Type B-1 vent pipe is used.3 Where values greater than 0 are shown, may be 0”

when Type B-1 vent pipe is used.

Horizontal Installations(G1N80AT and CG80TA models)

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Unconfined Space

An unconfined space is defined as “a space whosevolume is more than 50 cubic feet per 1000 BTU per hourof the combined input rating of all appliances installed inthat space.” When a furnace is installed in an unconfinedspace in a building, it can be assumed that the infiltrationwill be sufficient to supply the required air. If the furnace isinstalled in a ventilated attic or crawl space, it is assumedthat the infiltration is sufficient to supply the required air.

However, in a building of unusually tight construction,additional outdoor air should be provided.

Confined Space

A confined space is defined as “a space whose volume isless than 50 cubic feet per 1000 BTU per hour of thecombined input rating of all appliances installed in thatspace.”

Confined Space Installation/Air from Inside Structure

If the furnace is installed in a confined space within thebuilding and combustion air is taken from a heated space,the combustion air and ventilating air must enter and leavethe space through two permanent openings of equal area.One opening shall be located within 12" of the ceiling andthe other within 12" of the floor, each having a free area of1 square inch per 1000 BTU/HR of total input rating of allappliances within the space and not less than 100 squareinches each (see Figure 3).

Confined Space Installation/Air from Outside Structure

If air from outside is brought in for combustion, the confinedspace shall be provided with two permanent openings. Oneopening shall be within 12" of the ceiling and one openingwithin 12" of the floor. Several methods can be used to bringthe outside air in through these openings. The openingsshall open directly or by ducts with the outdoors, throughspaces (crawl space or attic) that freely open to the out-doors, or indirectly through vertical ducts (see Figures 4 and5). If any of these methods are used, each opening shallhave a free area of 1 square inch per 4000 BTU/HR of thetotal input rating of all appliances within the enclosure.

Do not use the furnace as a heater in abuilding under construction. The furnace canbe severely damaged due to the abnormalenvironment caused by construction. Chlo-rides from sources such as paint, stain, orvarnish; tile and counter cements; adhesives;and foam insulation are abundant in a struc-ture under construction and can be highlycorrosive. Low return air temperature cancause condensation in the furnace and otherdamage that can shorten the life of the unit.

CAUTION

G1N80AR, G1N80AT, CG80RA, and CG80TA models maybe installed as suspended units in the horizontal position.These furnaces are not designed for direct attachment ofsuspension rods to the furnace casing.

The suspending means must be field fabricated, andshould consist of two “cradles” made by attaching two rodsto a length of angle iron or suitable gage steel. Locate thecradles so that they are as close as possible to the endsof the furnace (this will provide access for removal ofmajor components such as the blower assembly). Provideenough clearance between the suspension rods and thefurnace to allow removal of access panels.

Combustion and Ventilation Air

Adequate provisions for combustion air and ventilation offurnace must be made. Refer to Section 5.3, “Air forCombustion and Ventilation,” of the National Fuel GasCode, ANSI Z223.1/NFPA54 (latest edition), Sections 7.2,7.3, or 7.4 of CSA B149.1 Natural Gas and PropaneInstallation Codes (latest editions), or applicable provi-sions of the local building codes.

Air openings in the front of the furnace mustbe kept free of obstructions. Any obstructionmay cause improper operation that can resultin a fire hazard or carbon monoxide injury.

WARNINGFigure 3

Note: Each opening shall have a free area of at least one squareinch per 1000 BTU per hour of the total input rating of allequipment in the enclosure, but not less than 100 squareinches.

WaterHeater

Chimney orGas Vent

Openings

Furnace

Equipment in Confined SpaceAll Air From Inside

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Figure 4

Equipment in Confined SpaceAll Air from Outside

(Inlet Air from Crawl Space andOutlet Air to Ventilated Attic)

Chimney orGas Vent

Ventilation Louvers(Each end of attic)

WaterHeater

Furnace

OutletAir

InletAirVentilation

Louvers(For unheatedcrawl space)

Note: The inlet and outlet air opening shall each have a free area ofat least one square inch per 4000 BTU per hour of the totalinput rating of all equipment in the enclosure.

Figure 6

Equipment in Confined SpaceAll Air from Outside

(All Air Through Horizontal Ducts)

Chimney orGas Vent

Furnace

Water Heater

Outlet Air

Inlet Air

Note: Each air duct opening shall have a free area of at least onesquare inch per 2000 BTU per hour of the total input rating ofall equipment in the enclosure. If the equipment room islocated against an outside wall and the air openings communi-cate directly with the outdoors, each opening shall have a freearea of at least one square inch per 4000 BTU per hour of thetotal input rating of all other equipment in the enclosure.

Figure 5

Chimney orGas Vent

Ventilation Louvers(Each end of attic)

Inlet Air(Ends 12”

above bottom)

Outlet Air

WaterHeater

Furnace

Equipment in Confined SpaceAll Air from Outside

(All Air Through Ventilated Attic)

Note: The inlet and outlet air opening shall each have a free area ofat least one square inch per 4000 BTU per hour of the totalinput rating of all equipment in the enclosure.

Another option is to use horizontal combustion ducts (seeFigure 6). If horizontal combustion ducts are run, 1 squareinch per 2000 BTU/HR is required.

Contaminated Combustion Air

Excessive exposure to contaminated combustion air willresult in safety and performance related problems. Therecommended source of combustion air is outdoor air.However, the use of indoor air in most applications isacceptable if the following guidelines are followed:

1. If the furnace is installed in a confined space, it isrecommended that the necessary combustion air

come from the outdoors by way of an attic, crawlspace, air duct, or direct opening.

2. If indoor combustion air is used, there must be noexposure to the substances listed in item 5.

3. All provisions for indoor combustion air must meet therequirements for combustion air indicated in theNational Fuel Gas Code, ANSI Z223.1/NFPA 54 (latestedition), and/or any applicable local codes. In Canada,see CSA B149.1, Natural Gas and Propane Installa-tion Codes (latest edition).

4. The following types of installation may require out-door air for combustion, due to chemical exposures:

• Commercial buildings• Buildings with indoor pools• Furnaces installed in laundry rooms• Furnaces installed in hobby or craft rooms• Furnaces installed near chemical storage areas

5. Exposure to the following substances in the combustionair supply may also require outdoor air for combustion:

• Permanent wave solutions• Chlorinated waxes and cleaners• Chlorine-based swimming pool chemicals• Water softening chemicals• Deicing salts or chemicals• Carbon tetrachloride• Halogen-type refrigerants• Cleaning solvents (such as perchloroethylene)

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Less Than10 Ft.(2540 mm)

2 Ft. (810 mm)Min.

Ridge

3 Ft.(914 mm)

Min.

Vent Through Roof

Figure 7

For 100K, 125K, and 150K BTUH input models,the minimum vent connector diameter is 5". Thetransition from 4" diameter flue outlet to 5"diameter pipe must be made at the flue outlet.

IMPORTANT

• Printing inks, paint removers, varnishes, etc.• Cements and glues• Antistatic fabric softeners for clothes dryers• Masonry acid washing materials• Chlorinated laundry products• Hydrochloric acid

Venting

This furnace has a fan-assisted combustion systemdesigned for vertical venting into a suitable chimney orlisted gas vent, and is classified as a Category I furnaceas shipped from the factory.

If this furnace is used to replace an existing furnace,it is possible that the existing venting system is notsuitable for venting this furnace. Furthermore, theexisting venting system may have to be modified toproperly vent any other gas appliance, such as a waterheater, that remains connected to it. Carefully read theVertical Venting, Sidewall Venting, and Existing VentSystems sections that follow to determine proper ventingpractices for the installation.

Installation shall be in accordance with Parts 7 and 11 ofthe National Fuel Gas Code, ANSI Z223.1/NFPA 54 (latestedition) and/or Section 7 and Appendix B of the CSAB149.1, Natural Gas and Propane Installation Codes(latest edition); local building codes; vent manufacturerinstructions; and these instructions.

Vertical Venting

Category I furnaces must be vented vertically or nearlyvertically. Common venting and multistory venting arepermitted when done in accordance with applicable codes,such as local and national codes.

The venting system should be designed in accordance withthe “FAN” columns in the venting tables in the latest editionsof the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or theCSA B149.1, Natural Gas and Propane Installation Codes.

1. Consult local building codes for installation require-ments.

2. The vent connector should be as short as possible withthe least number of elbows and angles to do the job.

3. It is recommended a minimum of 26 gauge galvanizedflue pipe be used. Use of single-wall vent pipe for the

vent connector is permissible only in conditionedspace. Use Doublewall Type B vent pipe throughunconditioned space such as attics and crawlspaces. The vent material used should be in accor-dance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (latest edition) or the CSA B149.1, NaturalGas and Propane Installation Codes and local codes.Fan-assisted combustion system Category I furnacesshall not be vented into single wall metal vents.

4. The vent connector must have an upward slope towardthe chimney on all horizontal runs of at least 1/4" perfoot of horizontal run and should be supported by asheet metal strap. The vent pipe connection must besecured to the induced draft blower outlet. A singlescrew is sufficient. On G1N80AR and CG80RA models,a hole in the door hook will allow access to the bloweroutlet without removing the door hook.

5. A factory-built chimney must extend 3' above thehighest point where it passes through a roof of abuilding and at least 2' higher than any portion of abuilding within a horizontal distance of 10' (seeFigure 7).

6. All vents passing through floors, ceilings, and wallsmust be firestopped according to the requirements ofthe National Fuel Gas Code (see Figure 8).

7. The furnace shall be connected to a factory-builtchimney or vent complying with a recognized stan-dard, or a masonry or concrete chimney lined with alining material acceptable to the authority with jurisdic-tion. Venting into an unlined chimney or a singlewall metal vent is prohibited in all cases. A linedchimney may be used if a draft hood equippedappliance, such as a water heater, is connected tothe same flue (see Figures 9 and 10).

8. Extend the vent connector into the chimney so that itis flush with the inside of the flue liner. Seal the jointbetween the pipe and the liner.

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Figure 8

26 Gauge GalvanizedFirestop on Top ofFramed Opening

Flue Pipe

Pipe Collar(Firestop) Flue Pipe

Floor1” 1”

Thimble

Flue Pipe

CombustibleWall

Vent Through Ceiling

Vent Through Floor

Vent Through Wall

Liner

MasonryChimney

Cleanout

Masonry Chimney Venting

Figure 9

Factory-BuiltChimney

Cleanout

Factory-Built Chimney Venting

Figure 10

9. Masonry chimneys serving fireplaces cannot be usedfor venting purposes unless the fireplace opening ispermanently sealed.

10. A vent connector serving this appliance must not beconnected into any portion of mechanical draft sys-tems operating under positive pressure.

11. The vent pipe must not be connected to a chimneyflue serving a solid fuel appliance.

12. A manual damper, barometric draft regulator, or fluerestrictor must not be installed between the furnaceand the chimney.

13. Where local experience indicates that condensate maybe a problem, the vent shall be constructed to prevent

condensation from entering the combustion blower.Provision shall be made to drain off the condensate(see Figures 9 and 10).

14. All unused chimney openings should be closed.

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15. All vent pipe run through unconditioned areas oroutside shall be constructed of factory-built chimneysections (see Figure 10 on page 7).

16. Multistory venting is allowed as permitted by theNational Fuel Gas Code or local codes.

17. Install all vents in accordance with the ventmanufacturer’s instructions. For unlisted material,install in accordance with the National Fuel Gas Code.

18. Vent terminals must be installed in accordance withthe vent terminals listing or in accordance with theNational Fuel Gas Code, ANSI Z223.1/NFPA 54 (latestedition) or the CSA B149.1, Natural Gas and PropaneInstallation Codes, and local codes.

Sidewall Venting

This furnace can be sidewall (horizontally) vented with alisted sidewall venter, such as Field Controls Model SWG-4HD with CK-43 Control Kit, or Tjernlund Model GPAK-JT.Category I venting classification is maintained when ventedin this manner. The furnace, power venter and control kit(where applicable) must be installed in accordance with theirinstallation instructions and all applicable codes.

The following limitations also apply to the two previouslymentioned venters.

Vent pipe diameter: 4"Minimum vent pipe length: 4'Maximum vent pipe length: 25'*Maximum number of 90° elbows: 4

* When fewer than four elbows are used, maximum ventpipe length can be increased by 5' per unused elbow.

For Canadian installations, only the Field Controlsventer and control kit mentioned above are autho-rized by CSA for use with this furnace.

Existing Venting Systems

When an existing Category I furnace is removed or replaced,the original venting system may no longer be sized toproperly vent the attached appliances. An improperly sizedventing system can result in spillage of flue products into theliving space, the formation of condensate, leakage, etc. Seethe WARNING box in the next column for proper testprocedure.

Circulating Air Supply

When the furnace is installed so that the supply ductscarry air circulated by the furnace to areas outside thespace containing the furnace, the return air shall behandled by a duct or ducts sealed to the furnace casingand terminated outside the space containing the furnace.

Failure to follow the steps outlined below for eachappliance connected to the venting system beingplaced into operation could result in carbon monox-ide poisoning or death.

The following steps shall be followed for eachappliance connected to the venting system beingplaced into operation, while all other appliancesconnected to the common venting system are not inoperation:

1. Seal any unused openings in the common ventingsystem.

2. Visually inspect the venting system for propersize and horizontal pitch, as required in theNational Fuel Gas Code, ANSI Z223.1/NFPA 54(latest edition) or the CSA B149.1, Natural Gasand Propane Installation Codes and theseinstructions. Determine that there is no blockageor restriction, leakage, corrosion, or other defi-ciencies which could cause an unsafe condition.

3. As far as practical, close all building doors andwindows between the space in which theappliance(s) connected to the venting system arelocated and other spaces in the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance notconnected to the venting system. Turn on anyexhaust fans, such as range hoods and bathroomexhausts, so they are operating at maximumspeed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the unitbeing inspected in operation. Adjust the thermo-stat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appli-ances at the draft hood relief opening after 5minutes of main burner operation. Use the flameof a match or candle.

8. If improper venting is observed during any of theabove tests, the venting system must be cor-rected in accordance with the National Fuel GasCode, ANSI Z223.1/NFPA 54 (latest edition) and/or the CSA B149.1, Natural Gas and PropaneInstallation Codes.

9. After it has been determined that each applianceremaining connected to the venting systemproperly vents when tested as outlined above,return doors, windows, exhaust fans, fireplacedampers, and any other gas-fired burning appli-ance to their previous conditions of use.

CARBON MONOXIDE POISONING HAZARD

WARNING

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When an air conditioning unit is used in conjunc-tion with the furnace, the evaporator coil must beinstalled in the discharge (supply) air. Do notinstall an evaporator coil in the return air; exces-sive condensation will occur within the furnace.

CAUTION

When installing a CAM coil in a horizontal position with ahorizontal gas furnace, always keep the open end of the A-coil facing the supply air outlet of the furnace (blow intothe open end of the A-coil). The A-coil should point awayfrom the supply air outlet of the furnace (see Figure 11).

If a cooling coil is not installed with the furnace, then aremovable access panel should be provided in the supplyplenum for purposes of inspecting the heat exchanger.This opening shall be accessible when the furnace isinstalled, and shall be of such size that the heat exchanger

can be viewed for possible openings using light assistanceor a probe can be inserted for sampling the air stream. Thecover for the opening shall be leaktight.

Upflow Installations

G1N80AU, G1N80AT, CG80UA, and CG80TA seriesfurnaces can be installed as upflow units with either a sideor bottom air return. For units that do not include a sidereturn filter rack, kit #AFILT524 can be used. Bottom filterkit #AFILT529 can be used with all G1N80AU, G1N80AT,CG80UA, and CG80TA series furnaces.

For side return installation, a full-size return air openingmust be cut in the side panel. A starter hole and cornerembossments are provided in each side (see Figure 13 inthe Filters section on page 10).

When side return is desired on a furnace withan open bottom, the bottom must be sealedwith a piece of sheet metal large enough tocover the entire opening. Failure to connect areturn air duct to the bottom, or to enclosethe bottom when side return is desired, mayresult in combustion products being drawninto the circulating air stream which couldresult in asphyxiation.

WARNING

To provide sufficient filter area for installations requiringmore than 1600 CFM nominal air delivery, return air willhave to be brought through both sides of the furnace,through one side and the bottom, or optional filter rackAFILTHA7 may be used.

Horizontal Installations

G1N80AR, G1N80AT, CG80RA, and GCH80TA seriesfurnaces can be horizontally installed for airflow right to leftor left to right. These furnaces are to be installed so thatthe burner and blower access panels are in a verticalplane; they are NOT to be installed such that these panelsare in a horizontal plane (see Figure 1 on page 2). Neverinstall any furnace on its back.

Counterflow (Downflow) Installations

G1N80AR and CG80RA furnaces may be installeddirectly on the supply plenum or coil cabinet if the furnaceis installed on a non-combustible floor.

For installations on combustible flooring, a special basemust be ordered and used. (See the Accessories sectionon page 17 for more information.) To install the specialbase, follow the instructions provided on page 10.

A return air duct system is recommended. If the unit isinstalled in a confined space or closet, a return connectionmust be run, full size, to a location outside the closet. Theair duct in the closet must be tight to prevent any entranceof air from the closet into the circulating air.

If there is no complete return air duct system, the return airconnection must be sealed to the furnace casing and runfull size to a location outside the utility room or spacehousing the furnace to prevent a negative pressure on theventing system.

Figure 11

Correct Positioning of CAM Coil in theHorizontal Position with a Gas Furnace

ReturnSupply

Incorrect

ReturnSupply

Correct

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Model AFILTHA7 external filter frame accessory isavailable for single side return air connection ininstallations requiring more than 1600 CFM nominalair delivery.

G1N80AT, CG80TA, G1N80AR, and CG80RA Models

Filters are not supplied with G1N80AT, CG80TA, G1N80AR,or CG80RA series furnaces since filters are commonlylocated behind a return grille for ease of servicing. It is theinstaller’s responsibility to install properly sized filters inaccordance with Table 1.

If filters are needed at the furnace only, use the followingkits:

• AFILT524 for side return on upflow installations.

• AFILT529 for bottom return on upflow installations orhorizontal installations of G1N80AT or CG80TA furnaces.

• AFILT525 for counterflow installations of G1N80AR orCG80RA furnaces.

Other filter accessories are also available from the manufac-turer including a full line of indoor air quality products. Forinformation on these products, contact the local distributor.

Figure 12

Combustible Floor Installation(Counterflow Models Only)

1. Cut a hole in the floor, sized to provide 1" clearancebetween all four sides of the duct and the edge of theflooring (see Figure 12). The four angles on the baseassembly should recess into the floor joists and thebase should rest on all four outside flanges.

2. Construct duct connections with 1" to 1-3/4" rightangle flanges, and long enough to extend below thefloor joists.

3. Drop the duct connections through the top of the baseassembly with the right angle flanges in good contactwith the glass tape on top of the base assembly.

4. Carefully position the furnace over the right angle ductflanges.

Filters

Filters are not supplied with CG80UA, CG80TA, orCG80RA series furnaces.

G1N80AU Models

A filter rack and washable 16" x 25" x 1/2" filter aresupplied with each G1N80AU furnace. (Models designedfor more than 1600 CFM nominal air delivery include two

of each.) The filter rack is to be installed between thereturn air duct and the side of furnace. Refer to Figure 13and the following instructions to install the filter rack:

1. Using the corner embossments as a guide, mark andcut a full-size opening in the side panel(s).

2. Using the filter rack as a template, mark and drill four7/64" diameter screw holes in the side panel(s).

3. With the filter access opening toward the front of thefurnace, use sheet metal screws to fasten the rack(s)to the side panel(s).

4. Install the filter(s) in the rack(s), mesh side of filtertowards furnace.

1"

CombustibleFlooring

WovenGlass Tape

BaseAssembly

Duct

Furnace

Outlet Duct(Drops Into Base

Assembly)

Woven Glass Tape(Between Flangesof Outlet Duct andBase Assembly)

Combustible FloorBase Assembly

Figure 13

Filter Rack Mounting Hole

Screw

Filter RackCorner EmbossmentsFront of Cabinet

Filter Rack Installation

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Gas Supply and Piping

Refer to the furnace rating plate to make sure the furnaceis equipped to burn the gas supplied (natural or propane).

To remove the NOx inserts, first take out the burners. After

removing the burners, remove the screw holding eachinsert and pull the insert from the combustion chamber(see Figure 15). The screws must be re-installed in thevest panel after the inserts are removed.

When converting a low NOx furnace (desig-nated by an “L” in the model number, such asG1N80AU100D20CL-1A) to propane, theNOx inserts must be removed. Failure toremove the inserts can create a situationwhere carbon monoxide is produced whichmay lead to asphyxiation.

WARNING

Any conversion of a natural gas unit to pro-pane gas must be done by qualified person-nel using a conversion kit available from themanufacturer, following the instructions in theconversion kit. If done improperly, overfiring ofthe burners and improper burner operationcan result. This can create carbon monoxidewhich could cause asphyxiation.

WARNING

NOx Insert Location

Figure 15

NO Inserts(If Used)

x

CombustionChamber

Figure 14

Upflow Model Filter Location

BOTTOM RETURN

FilterBase

Side

SIDE RETURN

R/A Duct

Filter RackFilter - Slides in from Front of Unit

Table 1

Minimum Filter Requirements

1. The Airflow Descriptor is the two digits followingthe “D” in the model number.

2. Areas and dimensions shown for permanent filtersare based on filters rated at 600 feet per minuteface velocity.

3. Typical filter sizes are shown; however, anycombination of filters whose area equals orexceeds the minimum area shown is satisfactory.

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# 45464G003Page 12

After gas piping is complete, carefully check all pipingconnections (factory and field) for gas leaks. Use a leakdetecting solution or other preferred means. Some soapsused for leak detection are corrosive to certainmetals. Carefully rinse piping thoroughly after leakdetection has been completed.

Electrical WiringManualGas Valve

Union

Tee

Drip Leg

Cap

1/8" NPTPluggedTapping

Gas Connection

HorizontalInstallation

Figure 16

ManualGas Valve

Union

Tee

Drip Leg

Cap

1/8" NPTPluggedTapping

Upflow/CounterflowInstallation

Gas supply piping should be installed in accordance withlocal codes and the regulations of the utility. Piping must beof adequate size to prevent undue pressure drop. Consultthe local utility or gas supplier for complete details on specialrequirements for sizing gas piping.

If local codes allow the use of a flexible gas applianceconnector, always use a new listed connector. Do not usea connector which has previously serviced another gasappliance.

Pipe connections must be tight, and a non-hardening pipecompound resistant to liquefied petroleum gases shouldbe used.

Connect the gas pipe to the furnace controls providing aground joint union as close to the controls as is possible tofacilitate removal of controls and manifold. Provide a dripleg on the outside of the furnace. A manual shutoff valveshall be installed in the gas line, outside the unit, 5' abovethe floor, or in accordance with any local codes. A testgauge connection must be installed with a 1/8" NPTplugged tapping immediately upstream of the shutoff valve(see Figure 16).

The furnace must be isolated from the gas supply pipingsystem by closing the individual manual shutoff valveduring any pressure testing of the gas supply pipingsystem at test pressure equal to or less than 1/2 psig(3.5 kPa) or 14" W.C. If the piping system is to be tested atpressures in excess of 1/2 psig (3.5 kPa), the furnace andits appliance main gas valve must be disconnected fromthe gas supply piping system.

Risk of electrical shock. Disconnect electricalpower at the circuit breaker or service panelbefore making electrical connections. Failureto disconnect power supplies can result inproperty damage, personal injury, or death.

WARNING

The gas valve supplied with this furnace israted at 1/2 psig maximum. Any higher pres-sure may rupture the pressure regulator dia-phragm and may cause overfiring of the burnersand improper burner operation. The overfiringmay result in the creation of carbon monoxidewhich could cause asphyxiation.

WARNING

Failure to follow the safety warnings exactlycould result in serious injury, death, or prop-erty damage.

Never test for gas leaks with an open flame.Use a commercially available soap solutionmade specifically for the detection of leaks tocheck all connections. A fire or explosion mayresult causing property damage, personalinjury, or loss of life.

WARNINGFIRE OR EXPLOSION HAZARD

# 45464G003 Page 13

Electronic Air Cleaner (Not Available on All Models)

Terminals are provided on the blower control board forconnection of a 120-volt electronic air cleaner. The “EAC”terminal is energized whenever the thermostat calls forheat, cooling, or continuous blower. Refer to the furnacewiring diagram for specific connection information.

Twinning

The blower control board is designed to permit “twinning”of furnaces (two furnaces connected to a common supplyand return air system, and controlled by one thermostat).An accessory kit must be ordered from the manufacturer.Specific wiring and operating instructions are includedwith the kit.

Each furnace must have its own dedicated vent system.

The furnace must be grounded and wired in accordancewith local codes or, in the absence of local codes, with theNational Electrical Code ANSI/NFPA No. 70 (latest edition)and/or CSA C22.1 Electrical Code (latest edition) if anexternal electrical source is utilized.

In all instances, other than wiring for the thermostat, thewiring to be done and any replacement of wire shallconform with the temperature limitation for Type T wire –63°F (35°C) rise.

Connect a sufficiently sized wire with ground to the furnace’sline voltage connections and ground lug. Refer to thefurnace rating plate for electrical characteristics to be usedin sizing field supply wiring and over-current protection.

The line voltage supply should be routed through areadily accessible disconnect located within sight of thefurnace. A junction box on the furnace side panel isprovided for line voltage connections. Refer to the furnacewiring diagram for specific connection information.

Proper polarity of the supply connections (�HOT�and �NEUTRAL�) must be observed to ensure thatsafety controls provide the protection intended.

A connection to the ground lug and actual earth ground(typically a ground stake or buried steel pipe) must bemaintained for proper operation.

Thermostat

Install a room thermostat according to the instructionsfurnished with it. Select a location on an inside wall that isnot subject to drafts, direct sunshine, or other heatsources. The initial heat anticipator setting should be equalto the total current draw of the control circuit.

Low voltage thermostat connections are to be made to theblower control board as indicated on the wiring diagram.

Continuous Blower Operation

If continuous blower operation on low speed is desired,connect the low speed motor tap to the “CONT” terminalon the blower control board (refer to the furnace wiringdiagram.) The blower will operate on low speed whenevermain power is connected to the furnace, except when itoperates on heating or cooling speed during thermostatcall for heat or cooling. This constant air terminal isintended for low speed only. If a motor is wired for ahigher speed, the increased amp draw could cause theboard control to fail and void the warranty.

Humidifier

Terminals are provided on the blower control board forconnection to a 120-volt humidifier. The “HUM” terminal isenergized whenever the thermostat calls for heat. Refer tofurnace wiring diagram for specific connection information.

START-UP

Lighting Instructions

For Your Safety, Read Before Operating

These furnaces are equipped with an ignition devicewhich automatically lights the burner. Do not try to lightthe burner by hand.

Before operating, smell all around the appliance area forgas. Be sure to smell next to the floor because some gasis heavier than air and will settle on the floor.

What to do if you smell gas:

• Do not try to light any appliances.• Extinguish any open flame.• Do not touch any electric switch; do not use any

phone in your building.• Immediately call your gas supplier from a neighbor’s

phone. Follow the gas supplier’s instructions.• If you cannot reach your gas supplier, call the fire

department.

Do not use this furnace if any part has been under water.Immediately call a qualified service technician to inspectthe furnace and to replace any part of the control systemand gas control which has been under water.

IMPORTANT: Refer to the Lighting Instruction label onthe furnace for instructions on operating the specificcontrols used on your unit.

If you do not follow these instructions exactly,a fire or explosion may result causing prop-erty damage, personal injury, or loss of life.

WARNING

# 45464G003Page 14

Sequence of Operation

Heating

A call for heat from the thermostat closes R to W on theblower control board, which begins the ignition sequence.The induced draft blower output energizes. The pressureswitch senses normal combustion air flow and closes. Aftera 15-second pre-purge, the control energizes the hotsurface igniter. After an igniter warm-up period, the maingas valve energizes. Upon main burner ignition, the circulat-ing air blower energizes following a 30-second delay.

When the call for heat is satisfied, R to W opens and thegas to the burners shuts off. The control turns off theinducer after a 5-second post-purge delay and the heatingspeed blower output turns off following the blower “off”delay. G1N80AU, G1N80AR, and G1N80AT modelsfeature user-selectable blower “off” delay times (60, 90,120, and 150 seconds). CG80UA, CG80RA, and CG80TAmodels have a fixed blower “off” delay of 90 seconds(one-time adjustable to 150 seconds – see wiring diagramon page 19).

In the event the limit control senses an abnormally hightemperature and opens, the ignition control de-energizes,and the combustion blower and circulating air blowerheating speed continue to energize.

Fan On

A call for fan from the thermostat closes R to G on thecontrol board. The control waits for a 1-second thermostatdebounce delay before responding by energizing the heatspeed blower. When the call for fan is turned off, thecontrol de-energizes the heating speed blower after a60-second delay.

Cooling

A call for cooling from the thermostat closes R to Y and Rto G on the blower control board. The control waits for a1-second thermostat debounce delay before energizingthe cool speed blower. When the call for cooling is satis-fied, the control de-energizes the cooling speed blowerafter a 60-second delay.

Controls

Following is a description of the operation of some of thecontrols used in this furnace. All models use one of eachcontrol, except as noted.

Pressure Switch

The pressure switch is a normally open switch thatmonitors combustion air flow. Inadequate air flow resulting

OPERATION

1. Set the room thermostat to lowest setting.

2. Remove burner access door.

3. Move the gas control switch to the “ON” position. Useonly your hand to turn the gas control switch; neveruse tools. If the switch will not turn by hand, don’t tryto repair it; call a qualified service technician. Force orattempted repair may result in a fire or explosion.

4. Replace the burner access door.

5. Turn on the electrical power to the furnace.

6. Set the room thermostat to a point above roomtemperature to light the main burners. After theburners have ignited, set the room thermostat todesired temperature.

To Shut Down Furnace:

1. Set the room thermostat to the lowest setting.

2. Turn off all electric power to the furnace.

3. Remove burner access door.

4. Shut off the gas by moving the gas control switch tothe “OFF” position.

5. Replace the burner access door.

Be sure the manual gas control has been inthe “OFF” position for at least 5 minutesbefore starting the unit. Do not attempt tomanually light the burners.

CAUTION

Should overheating occur or the gas supplyfail to shut off, shut off the manual gas valveto the appliance before shutting off the elec-trical supply.

WARNING

To Start Furnace:

# 45464G003 Page 15

from excessive venting system restriction or a failedcombustion blower will cause the switch to remain open.

Rollout Switch

The rollout switch is a normally closed switch that openswhen abnormal temperatures exist in the burner area. Thiscan be caused by a restricted heat exchanger causingmain burner flame to “roll out” into the vestibule area orburner box.

This switch must be manually reset by pushing the buttonon top to restore furnace operation. G1N80AR, G1N80AT,CG80RA, and CG80TA series units incorporate two rolloutswitches.

Primary Limit Control

This is a normally closed control that opens if abnormallyhigh circulating air temperatures occur. It is an automaticreset control.

Auxiliary Limit Control

This is a normally closed control, located on the circulat-ing air blower housing, that opens under abnormal“reverse air flow” conditions that could occur in acounterflow or horizontal installation if the circulating airblower fails. It is an automatic reset control.

G1N80AU and CG80UA models do not include an auxil-iary limit control.

Interlock (Blower Door) Switch

When the blower door is removed, the interlock switchbreaks the power supply to the burner controls and blowermotor. The switch operation must be checked to confirm itis operating correctly.

Blower Control Board

The blower control board operates the circulating airblower, the combustion blower and any accessoriesconnected to it. G1N80AU, G1N80AR, and G1N80ATmodels feature user-selectable blower “off” delay times(60, 90, 120, and 150 seconds) that are factory set toprovide a 120-second blower “off” delay on heating.CG80UA, CG80RA, and CG80TA models have a fixedblower “off” delay of 90 seconds (one-time adjustable to150 seconds – see wiring diagram on page 19).

Refer to the furnace wiring diagram while using thefollowing procedure to change motor speed:

1. Turn off electrical power to the unit.

2. Connect the desired speed tap for cooling on theblower control board.

3. For heating speed, check the temperature rise and, ifnecessary, adjust the blower speed tap to maintaintemperature rise within the range shown on thefurnace rating plate.

If you want to use the same speed tap for bothheating and cooling, install a piggyback terminal onthe speed tap using a short jumper. Wire 1/4" quickconnect terminals on both ends to jumper the HEATand COOL speed on the blower control board.

4. The remaining speed taps must be connected todummy terminals M1 and M2 on the blower controlboard.

Checking and Adjusting Gas Input

The minimum permissible gas supply pressure for thepurpose of input adjustment is 5" W.C. for natural gas and11" W.C. for propane gas. This furnace requires conversionfor use with propane (see Accessories section on page 17for correct kit). The maximum inlet gas supply pressure is10.5" W.C. for natural gas and 13" W.C. for propane.

Gas input must never exceed the value shown on thefurnace rating plate. This furnace is equipped for ratedinput at manifold pressures of 3.5" W.C. for natural gasand 10.0" W.C. for propane gas.

The manifold pressure can be measured by removing thepipe plug in the downstream side of the gas valve andconnecting a water manometer or gauge.

To adjust the regulator, turn the adjusting screw on theregulator clockwise to increase pressure and input;counterclockwise to decrease pressure and input.

The heating value of your gas can be obtained from yourlocal utility company.

For Propane Gas: The only check for the furnace rate is toproperly adjust the manifold pressure using a manometerand the information provided in Tables 2 and 3 on page 16.

x 3600 x= Cubic Feet Per RevolutionBTU/HR INPUT # Seconds Per Revolution

HeatingValue

For Natural Gas: Check the furnace rate by observing thegas meter, when available, making sure all other gasappliances are turned off. The test hand on the metershould be timed for at least one revolution. Note thenumber of seconds for one revolution.

The furnace rate must be within +/– 2% ofthe appliance rating input.

CAUTION

# 45464G003Page 16

MAINTENANCE

Typical manifold set point for installations at altitudes from0 to 4500 feet above sea level is 10.0" W.C.

Temperature Rise

Check the temperature rise and, if necessary, adjustblower speed to maintain temperature rise within therange shown on the unit rating plate.

High Altitude

In both the United States and Canada, this furnace isapproved for operation at altitudes from 0 to 4500 feetabove sea level without any required modifications. From4500 to 7500 feet, the gas manifold pressure needs to beadjusted according to the information shown in Table 2 (formodels G1N80AU150 and CG80UA150, see Table 3). Toadjust the manifold pressure, refer to previous sectionChecking and Adjusting Gas Input. For installationsabove 7500 feet, call Technical Service at 1-800-448-5872ext. 2610 for assistance.

Failure to follow the safety warnings exactlycould result in dangerous operation, seriousinjury, death, or property damage.

Improper servicing could result in dangerousoperation, serious injury, death, or propertydamage.

• Before servicing, disconnect all electricalpower to furnace.

• When servicing controls, label all wires priorto disconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

WARNING

ELECTRICAL SHOCK, FIRE,OR EXPLOSION HAZARD

Table 2

Manifold Pressure vs. Altitude

* Consult local utility for actual heating value.

Furnace Input = Input Factor x Nameplate Input

Above 7500 feet, call Technical Services at 1-800-448-5872 ext. 2610.

Table 3

Manifold Pressure vs. Altitude(G1N80AU150 and CG80UA150 only)

* Consult local utility for actual heating value.

Furnace Input = Input Factor x 148,000

Above 7500 feet, call Technical Services at 1-800-448-5872 ext. 2610.

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# 45464G003 Page 17

It is recommended that this furnace be inspected by aqualified service technician at the beginning of eachheating season.

Filters

Filters should be checked at least every 6 weeks. Dispos-able filters should be replaced when dirty, and permanentfilters should be cleaned regularly. It is important to keep theair filters clean, as dirty filters can restrict airflow and theblower and induced draft motors depend upon sufficient airflowing across and through them to keep from overheating.

Main Burners

Light the burners and allow to operate for a few minutes toestablish normal burning conditions. Observe the mainburner flames. Compare this observation to Figure 16 todetermine if proper flame adjustment is present. Flameshould be predominantly blue in color and strong in appear-ance. Check that all burners are lit, and that the flame doesnot impinge on the sides of the heat exchanger.

Distorted flame or yellow tipping of the natural gas mainburner flame, or long yellow tips on propane, may becaused by lint accumulation or dirt inside the burner orburner ports, at the air inlet between the burner andmanifold pipe, or obstructions over the main burner orifice.

Use a soft brush or vacuum to clean the affected areas.

REPAIR PARTS

Lubrication

The blower motor and induced draft motor are pre-lubricated by the manufacturer and do not require furtherlubricating attention. However, the motors should becleaned periodically to prevent the possibility of overheat-ing due to an accumulation of dust and dirt on the wind-ings or on the motor exterior.

The following repair parts are available from the localdistributor. When ordering parts, include the completefurnace model number and serial number which areprinted on the rating plate located on the furnace.

Control Group

TransformerHigh limit controlAuxiliary limit (if used)Gas valve/ignition controlBlower control boardFlame sensorPressure switchBlower door interlock switchCombustion blower assemblyFlame rollout protector switchHot surface igniter

Heat Exchanger Group

Heat exchangerFlue box coverCombustion blower transition

Blower Group

Blower housing assemblyBlower wheelBlower mountBlower motor mountBlower motor capacitor

Burner Group

Gas manifoldMain burner orificesMain burners

Accessories

ALPKT572 Natural Gas to Propane Conversion KitANGKT555 Propane to Natural Gas Conversion KitAFILTHA7 Single Side Filter Frame KitAFILT524 Side Return Filter Kit (Upflow Models)AFILT525 Return Filter Kit (Counterflow Models)AFILT529 Bottom Return Filter KitATWIN578 Twinning KitABASE511 Combustible Floor Base (14.5" cabinets)ABASE512 Combustible Floor Base (17.5" cabinets)ABASE568 Combustible Floor Base (21.0" cabinets)ABASE569 Combustible Floor Base (24.5" cabinets)

Typical Flame Appearance(Main Burners)

Figure 17

HeatExchanger

BurnerFlame

(Blue Only)

Burner

GasManifold

# 45464G003Page 18

CONTROL SYSTEM DIAGNOSTICS Start the system by setting the thermostat above the roomtemperature. Observe the system’s response. Then usethe information provided in this section to check thesystem’s operation.

The furnace has a built-in, self-diagnostic capability. If asystem problem occurs, a fault code is shown by an LEDon the gas valve. Do not remove the blower compart-ment door or turn off the power to the furnace sinceeither action will clear the control�s memory of thefault.

The control continuously monitors its own operation andthe operation of the system. If a failure occurs, the LEDwill indicate the failure code. The flash codes are pre-sented in Table 4.

Troubleshooting

The following visual checks should be made beforetroubleshooting:

1. Check to see that the power to the furnace and theblower control board is on.

2. The manual shutoff valves in the gas line to thefurnace must be open.

3. Make sure all wiring connections are secure.

4. Review the Sequence of Operation (see page 14).

Failure Codes

Table 4

Note 1: The 6 + X designation indicates a combination of flash codes. Six flashes shows the control is in soft lock-out, followed by X flashes to indicate the reason the control went into soft lockout. When the 6 + X code isflashed, the control will attempt a new ignition sequence after 1 hour (if the call for heat is still present). Resetof the thermostat will initiate a new ignition sequence immediately.

Note 2: Any combination of five “abnormal events” during a single call for heat will result in a soft lockout. An abnor-mal event is an occurrence of any of the following: flame sense failure during run, airflow proving circuit openduring run, or limit circuit open during run. The flash code will indicate which was the last abnormal event thatput the system into the soft lockout state (see above).

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# 45464G003 Page 19

Connection DiagramGas-Fired Furnace w/Honeywell �Smart Valve II� Ignition System

Figure 18

# 45464G003Page 20

Figure 19

Wiring SchematicGas-Fired Furnace w/Honeywell �Smart Valve II� Ignition System