Table of Contents
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This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in
manuals, be alert to the potential for personal injury or death.
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Unit Dimensions ............................................................ 2
A80DF & 80G1DF Parts Arrangement .......................... 3
A80DF & 80G1DF Gas Furnace ................................... 4
Shipping and Packing List ............................................ 4
Safety Information ......................................................... 4
Use of Furnace as a Construction Heater .................... 5
General ......................................................................... 6
Combustion, Dilution, Ventilation Air ............................. 6
Setting Equipment ........................................................ 9
Filters .......................................................................... 12
Duct System ................................................................ 12
Venting ........................................................................ 12
Gas Piping .................................................................. 21
*506528-01*
506528-01
INSTALLATION INSTRUCTIONS
A80DF & 80G1DF
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.
CAUTION
TABLE OF CONTENTS
Improper installation, adjustment, alteration, service or
maintenance can cause property damage, personal injury
or loss of life. Installation and service must be performed
by a licensed professional installer (or equivalent), service
agency or the gas supplier.
Electrical ..................................................................... 22
Unit Start-Up ............................................................... 27
Heating Sequence of Operation ................................. 28
Gas Pressure Adjustment ........................................... 28
Control Settings .......................................................... 28
High Altitude ................................................................ 29
Other Unit Adjustments ............................................... 29
Service ........................................................................ 31
Planned Service .......................................................... 34
Control Diagnostic Codes ........................................... 34
Troubleshooting .......................................................... 34
Repair Parts List ......................................................... 35
A Lennox International, Inc. Company
Issue 1035
WARNING
Manufactured By
Allied Air Enterprises, Inc.
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 37
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Summary of Contents for Lennox 80G1DF
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Page 1: Table Of Contents
TABLE OF CONTENTS Unit Dimensions ............2 Electrical ..............22 A80DF & 80G1DF Parts Arrangement ......3 Unit Start-Up ............... 27 A80DF & 80G1DF Gas Furnace ........4 Heating Sequence of Operation ......... 28 Shipping and Packing List ..........4 Gas Pressure Adjustment ........... -
Page 2: Unit Dimensions
A80DF & 80G1DF Unit Dimensions - inches (mm) SIDE VIEW FRONT VIEW Model A801DF/80G1DF 045-08 045-12 13-3/8 14-1/2 4-3/4 070-08 070-12 090-12 17-1/2 16-3/8 6-1/4 090-16 110-12 110-16 19-7/8 19-1/2 110-20 135-20 9-3/4 24-1/2 23-3/8 Page 2 of 37 Issue 1035... -
Page 3: A80Df & 80G1Df Parts Arrangement
A80DF & 80G1DF Expanded View BLOWER ASSEMBLY CONTROL BOX FLUE CHASE INTERNAL FLUE PIPE ASSEMBLY BURNER BOX ASSEMBLY CABINET HEAT EXCHANGER COMBUSTION AIR INDUCER GAS VALVE ACCESS PANEL Figure 1 506528-01 Issue 1035 Page 3 of 37... -
Page 4: A80Df & 80G1Df Gas Furnace
A80DF & 80G1DF Gas Furnace The A80DF & 80G1DF gas furnace is shipped ready for CAUTION installation in the downflow position. As with any mechanical equipment, personal injury can The furnace is equipped for installation in natural gas result from contact with sharp sheet metal edges. Be applications. -
Page 5: Use Of Furnace As A Construction Heater
This furnace may be installed in alcoves, closets, attics, Temperature Rise basements, garages, and utility rooms in the upflow or horizontal position. NOTE: Furnace must be adjusted to obtain a temperature rise within the range specified on the unit nameplate. Failure This furnace design has not been certified for installation in to do so may cause erratic limit operation and may result in mobile homes, recreational vehicles, or outdoors. -
Page 6: General
General Combustion, Dilution & Ventilation Air In the past, there was no problem in bringing in sufficient These instructions are intended as a general guide and do outdoor air for combustion. Infiltration provided all the air not supersede local codes in any way. Consult authorities that was needed. - Page 7 All gas fired appliances require air for the combustion Equipment in Confined Space - All Air From Inside process. If sufficient combustion air is not available, the furnace or other appliances will operate inefficiently and unsafely. Enough air must be provided to meet the needs of all fuelburning appliances and appliances such as exhaust fans which force air out of the house.
- Page 8 When ducts are used, they shall be of the same cross EQUIPMENT IN CONFINED SPACE sectional area as the free area of the openings to which (ALL AIR FROM OUTSIDE) they connect. The minimum dimension of rectangular air ducts shall be no less than 3 inches (75 mm). In calculating free area, the blocking effect of louvers, grilles, or screens must be considered.
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Page 9: Setting Equipment
Setting Equipment Downflow Applications Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or WARNING alcove installations are shown in Figure 8. Do not install the furnace on its front or its back. Do not connect the return air ducts to the back of the furnace. - Page 10 Installation on Non-Combustible Flooring (Figure 11) WARNING 1. Cut floor opening keeping in mind clearances listed on unit rating plate. Also keep in mind gas supply Improper installation of the furnace can result in personal connections, electrical supply, flue and air intake injury or death.
- Page 11 COMBUSTIBLE FLOORING BASE OPENING SIZE Table 2 Figure 13 Return Air Opening - Downflow Units Return air may be brought in only through the top opening of a furnace installed in the downflow position. The following steps should be taken when installing plenum: Figure 12 1.
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Page 12: Filters
Filters Venting This unit is not equipped with a filter or rack. A field provided A 4 inch diameter flue transition is factory installed on the high velocity filter is required for the unit to operate properly. combustion air inducer outlet of all models. A filter must be in place any time the unit is operating. - Page 13 If the existing chimney will not accommodate a listed metal liner, either the chimney must be rebuilt to accommodate WARNING one of these liners or an alternate approved venting method must be found. Asphyxiation hazard. The exhaust vent for this furnace must be securely connected to the furnace flue transitiion Insulation for the flexible vent pipe must be an encapsulated at all times.
- Page 14 Common Venting Using Tile Lined Interior Masonry Chimney and Combined Vent Connector NOTE: Refer to provided venting tables for installations. NOTE: The chimney must be properly sized per provided venting tables or lined with listed metal lining system. Figure 17 DO NOT insulate the space between the liner and the Do not install a manual damper, barometric draft regulator, chimney wall with puffed mica or any other loose granular...
- Page 15 6. The entire length of single wall metal vent connector 13. When the vent connector used for Category I appliances shall be readily accessible for inspection, cleaning, and must be located in or pass through a crawl space, attic replacement. or other areas which may be cold, that portion of the 7.
- Page 16 Capacity of Type B Double Wall Vents with Type B Double Wall Connectors Serving a Single Category I Appliance NOTE: Single appliance venting configureations with zero lateral lengths are assumed to have no elbows in the vent system. For all other vent configurations, the vent system is assumed to have two 90 °...
- Page 17 Capacity of Type B Double Wall Vents with Single Wall Metal Connectors Serving a Single Category I Appliance NOTE: Single appliance venting configureations with zero lateral lengths are assumed to have no elbows in the vent system. For all other vent configurations, the vent system is assumed to have two 90 °...
- Page 18 Vent Connector Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Table 5 Common Vent Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Table 6 Page 18 of 37 Issue 1035...
- Page 19 Vent Connector Capacity Type B Double Wall Vents with Single Wall Metal Connectors Serving Two or More Category I Appliances NOTE: Single appliance venting configureations with zero lateral lengths are assumed to have no elbows in the vent system. For all other vent configurations, the vent system is assumed to have two 90 °...
- Page 20 Removal of the Furnace from Common Vent 3. Close all building doors and windows and all doors In the event that an existing furnace is removed from a between the space in which the appliances remaining venting system commonly run with separate gas appliances, connected to the common venting system are located the venting system is likely to be too large to properly vent and other spaces of the building.
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Page 21: Gas Piping
Gas Piping 4. The piping should be sloped 1/4 inch (6.4 mm) per 15 feet (4.57 m) upward toward the meter from the furnace. The piping must be supported at proper intervals [every CAUTION 8 to 10 feet (2.44 to 3.01 m)] with suitable hangers or straps. -
Page 22: Electrical
NOTE: BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Figure 18 Electrical Leak Check After gas piping is completed, carefully check all piping ELECTROSTATIC DISCHARGE (ESD) connections (factory and field installed) for gas leaks. Use Precautions and Procedures a leak detecting solution or other preferred means. - Page 23 Before connecting the thermostat, check to make sure the INTERIOR MAKE-UP BOX INSTALLATION wires will be long enough for servicing at a later date. Make sure that thermostat wire is long enough to facilitate future removal of blower for service. Complete the wiring connections to the equipment.
- Page 24 Thermostat Install the room thermostat according to the instructions provided with the thermostat. See Figure 22 for thermostat designations. If the furnace is being matched with a heat pump, refer to the FM21 installation instruction or appropriate dual fuel thermostat instructions. Condensing Unit Thermostat Designations (Refer to Specific Thermostat and Outdoor Unit.) * Note: “R”...
- Page 25 Wiring Diagram Figure 23 506528-01 Issue 1035 Page 25 of 37...
- Page 26 Typical Field Wiuring Diagram Figure 24 Integrated Control (Automatic Hot Surface Ignition System) Figure 25 Page 26 of 37 Issue 1035 506528-01...
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Page 27: Unit Start-Up
6. Move switch on gas valve to OFF. Do not force. See Unit Start-UP Figure 26. FOR YOUR SAFETY READ BEFORE LIGHTING UNIT. 7. Wait five minutes to clear out any gas. If you then smell gas, STOP! Immediately call your gas supplier from a neighbor’s phone. -
Page 28: Heating Sequence Of Operation
NOTE: To obtain accurate reading, shut off all other gas Heating Sequence Of Operation (Figure 27) appliances connected to meter. 1. When thermostat calls for heat, combustion air blower starts. Supply Pressure Measurement 2. Combustion air pressure switch proves blower operation. A threaded plug on the inlet side of the gas valve provides Switch is factory set and requires no adjustment. -
Page 29: High Altitude
NOTE: A natural to L.P. propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion procedure. NOTE: For Altitudes of 7501' - 10,000' call Lennox Technical Support Product Applications. Table 12... - Page 30 Thermostat Heat Anticipation NOTE: Termination of any unused motor leads must be Set the heat anticipator setting (if adjustable) according to insulated. the amp draw listed on the wiring diagram that is attached to the unit. 4. Place unused blower speed tap on integrated control “PARK”...
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Page 31: Service
Service WARNING WARNING The blower access panel must be securely in place when the blower and burners are operating. Gas fumes, which ELECTRICAL SHOCK, FIRE, could contain carbon monoxide, can be drawn into living OR EXPLOSION HAZARD. space resulting in personal injury or death. Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. - Page 32 Cleaning the Heat Exchanger and Burners 5. Remove the collector box located behind the combustion air inducer. Be careful with the collector box gasket. If NOTE: Use papers or protective covering in front of the the gasket is damaged, it must be replaced to prevent furnace during cleaning.
- Page 33 9. Remove screws from both sides, top and bottom of Remove 5 Screws If Necessary vestibule panel. (either side of cabinet) 10. Remove heat exchanger. It may be necessary to spread cabinet side to allow more room. If so, remove five screws from the left side or right side of cabinet.
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Page 34: Planned Service
Planned Service FAILURE CODES The following items should be checked during an annual inspection. Power to the unit must be shut off for the service technician’s safety. Fresh air grilles and louvers (on the unit and in the room where the furnace is installed) - Must be open and unobstructed to provide combustion air. -
Page 35: Repair Parts List
Repair Parts List The following repair parts are available through independent Allied Air dealers. When ordering parts, include the complete furnace model number listed on the CSA International nameplate — Example: A801DF045JP24A-01. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier. Heating Parts Cabinet Parts Flame sensor... - Page 36 Start-Up & Performance Check List UNIT SET UP Page 36 of 37 Issue 1035 506528-01...
- Page 37 UNIT OPERATION 506528-01 Issue 1035 Page 37 of 37...