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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
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
*P507327-01*
(P) 507327-01
507327-01
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.
Duct System ................................................................12
Venting.........................................................................12
Gas Piping ...................................................................20
Electrical ......................................................................22
Wiring Diagrams ..........................................................24
Unit Start-Up ................................................................27
Other Unit Adjustments................................................29
Service.........................................................................31
Repair Parts List ..........................................................34
A Lennox International, Inc. Company
Issue 1809
WARNING
Manufactured By
Allied Air Enterprises LLC
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 34
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Summary of Contents for Lennox Allied Air A80DF
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Page 1: Table Of Contents
Combustion, Dilution & Ventilation Air ......6 Service.................31 Setting Equipment ............9 Repair Parts List ............34 Filters ................12 Manufactured By *P507327-01* Allied Air Enterprises LLC A Lennox International, Inc. Company 215 Metropolitan Drive (P) 507327-01 West Columbia, SC 29170 507327-01 Issue 1809 Page 1 of 34... -
Page 2: Unit Dimensions
Unit Dimensions Return Air Opening SIDE VIEW FRONT VIEW Model Number A80DF/ 80G1DF 045-08 045-12 14-1/2 13-3/8 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 24-1/2 23-3/8 9-3/4 Page 2 of 34 Issue 1809 507327-01... -
Page 3: Parts Arrangement
Parts Arrangement BLOWER ASSEMBLY CONTROL BOX FLUE CHASE INTERNAL FLUE PIPE ASSEMBLY BURNER BOX ASSEMBLY CABINET HEAT EXCHANGER COMBUSTION AIR INDUCER GAS VALVE ROLLOUT LOCATED INSIDE BURNER BOX ACCESS PANEL Figure 1 507327-01 Issue 1809 Page 3 of 34... -
Page 4: A80Df / 80G1Df Gas Furnace
A80DF / 80G1DF Gas Furnace CAUTION The A80DF / 80G1DF gas furnace is shipped ready for As with any mechanical equipment, personal injury can installation in the downflow position. result from contact with sharp sheet metal edges. Be careful when you handle this equipment. The furnace is equipped for installation in natural gas applications. -
Page 5: Use Of Furnace As A Construction Heater
Installed in Combination with a Cooling Coil Use of Furnace as a Construction Heater When this furnace is used with cooling units, it shall be installed in parallel with, or on the upstream side of, cooling These units are not recommended for construction heating units to avoid condensation in the heating compartment. -
Page 6: General
General Combustion, Dilution & Ventilation Air These instructions are intended as a general guide and do In the past, there was no problem in bringing in sufficient not supersede local codes in any way. Consult authorities outdoor air for combustion. Infiltration provided all the air having jurisdiction before installation. - Page 7 All gas fired appliances require air for the combustion process. If sufficient combustion air is not available, the furnace or other appliances will operate inefficiently and dangerously. Enough air must be provided to meet the needs of all fuel-burning 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 sectional area as the free area of the openings to which 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
Downflow Applications Setting Equipment Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in Figure 8. WARNING 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 Return Air Installation on Non-Combustible Flooring Return air must be brought in through the top of the furnace See Figure 11 installed in an downflow application. Cut floor opening keeping in mind clearances listed on unit rating plate. Also keep in mind gas supply connections, electrical supply, flue and air intake WARNING connections and sufficient installation and servicing...
- Page 11 Front to Cabinet Catalog Side to Side Rear Width Number B Cabinet 11M60 18-3/4 (17.5”) C Cabinet 11M61 22-3/4 (21”) Table 2. Combustible Flooring Base Opening Size 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.
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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 An exterior masonry chimney that is not tile lined must be lined with B 1 vent or a listed insulated flexible metal vent. An exterior tile lined chimney that is sealed and capped may be lined with a listed uninsulated flexible metal vent. If the existing chimney will not accommodate a listed metal liner, either the chimney must be rebuilt to accommodate one of these liners or an alternate approved venting...
- Page 14 The minimum vent capacity determined by the sizing tables must be less than the low fire input rating and IMPORTANT the maximum vent capacity must be greater than the high fire input rating. SINGLE appliance venting of a fan assisted furnace into a tile lined masonry chimney (interior or outside wall) is Single appliance vents - If the vertical vent or tile prohibited.
- Page 15 11. A vent connector shall be supported without any dips Conduct the following test while each appliance is operating or sags and shall slope a minimum of 1/4 inch (6.4 and the other appliances (which are not operating) remain mm) per linear foot (305 mm) of connector, back connected to the common venting system.
- Page 16 Capacity of Type B Double Wall Vents with Type B Double Wall Connectors Serving a Single Category I Appliance Vent and Connector Diameter - D (inches) 3 inch 4 inch 5 inch 6 inch Height H Lateral L (feet) (feet) Appliance Input Rating in Thousands of Btu per Hour NOTE: Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system.
- Page 17 Capacity of Type B Double Wall Vents with Single Wall Metal Connectors Serving a Single Category I Appliance Vent and Connector Diameter - D (inches) 3 inch 4 inch 5 inch 6 inch Height H Lateral L (feet) (feet) Appliance Input Rating in Thousands of Btu per Hour NOTE: Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system.
- Page 18 Vent Connector Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Vent and Connector Diameter - D (inches) Vent Connector 3 inch 4 inch 5 inch 6 inch Height H Rise R Appliance Input Rating in Thousands of Btu per Hour (feet)
- Page 19 Vent Connector Capacity Type B Double Wall Vents with Single Wall Metal Connectors Serving Two or More Category I Appliances Vent and Connector Diameter - D (inches) Vent 3 inch 4 inch 5 inch 6 inch Lateral L Height H (feet) Appliance Input Rating in Thousands of Btu per Hour (feet)
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Page 20: Gas Piping
Leak Check Gas Piping After gas piping is completed, carefully check all piping connections (factory and field installed) for gas leaks. Use a leak detecting solution or other preferred means. CAUTION NOTE: If emergency shutoff is necessary, shut off the main manual gas valve and disconnect the main power to the If a flexible gas connector is required or allowed by furnace. - Page 21 Gas Pipe Capacity - ft³/hr (m³/hr) Nominal Length of Pipe - feet (m) Internal Iron Pipe Diameter Size inches inches (mm) (mm) (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) .622 (12.7) (17.799) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61)
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Page 22: Electrical
Electrical ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures CAUTION Electrostatic discharge can affect electronic components. Take precautions during furnace installation and service to protect the furnace’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the furnace, the control and the technician at the same electrostatic potential. - Page 23 Accessory Terminals Thermostat One line voltage “EAC” 1/4” spade terminal is provided on Install the room thermostat according to the instructions the furnace integrated control. See Figure 26 for integrated provided with the thermostat. See Figure 23 for thermostat control configuration. This terminal is energized when the designations.
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Page 24: Wiring Diagrams
Wiring Diagrams Figure 24 Page 24 of 34 Issue 1809 507327-01... - Page 25 BURNERS S47 FLAME S47 FLAME ROLLOUT ROLLOUT FLAME IGNITOR SWITCH SWITCH SENSOR J159 P159 120V ACC COMBUSTION AIR INDUCER MOTOR S10 PRIMA- RY GAS LIMIT S145 LOW GAS PRESSURE GAS VALVE SWITCH COMBUSTION AIR PROVING SWITCH TRANSFORMER 10 11 DOOR INTERLOCK J156 (J1)
- Page 26 3 AMP, 32 VAC FUSE [RED] [GREEN] HEAT OFF DELAY JUMPER Terminal Designations Humidifier (120 VAC) LINE Input (120 VAC) XFMR Transformer (120 VAC) Electronic Air Cleaner (120 VAC) COOL Blower - Cooling Speed (120 VAC) HEAT Blower - Heating Speed (120 VAC) PARK Dead terminals to park alternate speed taps FLAME...
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Page 27: Unit Start-Up
Set the thermostat to the lowest setting. Unit Start-Up Turn off all electrical power to the unit. This furnace is equipped with an ignition device which FOR YOUR SAFETY, READ BEFORE LIGHTING UNIT automatically lights the burners. Do not try to light the burners by hand. - Page 28 Gas Pressure Adjustment Is the filter dirty or plugged? Dirty or plugged filters will cause the limit control to shut the unit off. Gas Flow (Approximate) Is gas turned on at the meter? Seconds for One Revolution Is the manual main shut-off valve open? Natural Capacity Is the internal manual shut-off valve open?
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Page 29: Other Unit Adjustments
Manifold Pressure Measurement Pressure Switch Remove the threaded plug from the outlet side of The pressure switch is located in the heating compartment the gas valve and install a field provided barbed adjacent to the combustion air inducer. The switch checks fitting. - Page 30 Page 30 of 34 Issue 1809 507327-01...
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Page 31: Service
Thermostat Heat Anticipation Service Set the heat anticipator setting (if adjustable) according to the amp draw listed on the wiring diagram that is attached to the unit. WARNING NOTE: Do not secure the electrical conduit directly to the air ducts or structure. ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. - Page 32 Cleaning the Heat Exchanger and Burners Remove screws securing burner box and remove burner box. NOTE: Use papers or protective covering in front of the NOx units only - Remove screw securing NOx insert. furnace during cleaning. Remove NOx insert. See Figure 31. Turn off both electrical and gas power supplies to Remove screws from both sides, top and bottom of furnace.
- Page 33 16. Reinstall collector box and combustion air assembly. 18. Reconnect all wires. Reinstall all screws to the collector box and combustion 19. Reconnect top cap and vent pipe to combustion air air inducer. Failure to replace all screws may cause inducer outlet.
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Page 34: Repair Parts List
Combustion gases - Flue products must be analyzed and LED Status Fault Description compared to the unit specifications. No power to control or control hardware LED Off Problems detected during the inspection may make it fault detected necessary to temporarily shut down the furnace until the LED On Normal operation items can be repaired or replaced.