Lennox A80US2V Installation Instructions Manual
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Lennox A80US2V Installation Instructions Manual

Lennox A80US2V Installation Instructions Manual

Warm air gas furnace upflow / horizontal left and right air discharge
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Upflow / Horizontal Left and Right Air Discharge
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.
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.
Unit Dimensions .............................................................2
A80US2V Parts Arrangement .........................................3
A80US2V Gas Furnace ..................................................4
Shipping and Packing List ..............................................4
.......................................................4
Combustion, Dilution, Ventilation Air...............................6
Setting Equipment ..........................................................9
12
Duct System .................................................................12
Gas Piping ....................................................................23
*P506891-01*
(P) 506891-01
506891-01
INSTALLATION INSTRUCTIONS
A80US2V
Warm Air Gas Furnace
This manual must be left with the homeowner for future reference.
CAUTION
WARNING
A thermostat is not included and must be ordered
separately.
• A Comfort Sync™ thermostat must be used in
communicating applications.
• In non-communicating applications, a traditional
non-communication thermostat may be used.
In all cases, setup is critical to ensure proper system
operation.
Field wiring for both communicating and non-
communicating applications is illustrated in these
instructions.

TABLE OF CONTENTS

Electrical .......................................................................25
Thermostat ...................................................................27
Unit Start-Up .................................................................30
High Altitude .................................................................32
Gas Pressure Adjustment .............................................33
Sequence of Operation.................................................33
Other Unit Adjustments.................................................33
Maintenance .................................................................36
Repair Parts List ...........................................................40
Wiring Diagram .............................................................41
Wiring Schematic..........................................................42
Start Up & Performance Check List..............................43
.....................................................................................................
Issue 1606
NOTICE
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 65

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  • Page 1: Table Of Contents

    TABLE OF CONTENTS Unit Dimensions .............2 Electrical ...............25 A80US2V Parts Arrangement .........3 Thermostat ..............27 A80US2V Gas Furnace ..........4 Unit Start-Up ..............30 Shipping and Packing List ..........4 High Altitude ..............32 Safety Information ............4...

  • Page 2: Front View

    A80US2V Unit Dimensions - inches (mm) 1. NOTE - 20C and 20D size units installed in upflow applications that require air volumes of 1800 cfm (850 L/s) or greater must have one of the following: 1. Single side return air with transition to accommodate 20 x 25 x 1in.

  • Page 3: Expanded View

    EXPANDED VIEW HEAT EXCHANGER COMBUSTION AIR INDUCER COMBUSTION AIR INDUCER PRESSURE SWITCH GAS VALVE ROLLOUT SWITCH CABINET BURNER BOX CONTROL BOX (INCLUDES INTEGRATED CONTROL, AND TRANSFORMER) BURNER ACCESS PANEL BLOWER BLOWER ASSEMBLY ACCESS PANEL Figure 1 506891-01 Issue 1606 Page 3 of 65...

  • Page 4: A80Us2V Gas Furnace

    A80US2V Gas Furnace The A80US2V gas furnace is shipped ready for installation in CAUTION the upflow or horizontal position (left or right). The furnace is shipped with the bottom panel in place. The bottom panel As with any mechanical equipment, personal injury can must be removed if the unit is to be installed in a horizontal result from contact with sharp sheet metal edges.

  • Page 5: Use Of Furnace As A Construction Heater

    Temperature Rise This furnace may be installed in alcoves, closets, attics, basements, garages, and utility rooms in the upflow or NOTE: Furnace must be adjusted to obtain a temperature horizontal position. rise (high and low fire) within the range(s) specified on the This furnace design has not been certified for installation unit nameplate.

  • 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 that not supersede local codes in any way. Consult authorities was needed.

  • Page 7: Unconfined Space

    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 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 EQUIPMENT IN CONFINED SPACE sectional area as the free area of the openings to which they (ALL AIR FROM OUTSIDE) 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.

  • Page 9: Setting Equipment

    Setting Equipment Upflow Applications Allow for clearances to combustible materials as indicated WARNING on the unit nameplate. Minimum clearances for closet or 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 Return Air - Upflow Applications Return air can be brought in through the bottom or either Single Side Return Air side of the furnace installed in an upflow application. If the (with transition and filter) furnace is installed on a platform with bottom return, make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely.
  • Page 11 Removing the Bottom Panel Horizontal Applications The furnace can be installed in horizontal applications. Remove the two screws that secure the bottom cap to the Order horizontal suspension kit (51W10) from Allied Air, or furnace. Pivot the bottom cap down to release the bottom use equivalent suspension method.

  • Page 12: Filters

    Horizontal Application Unit installed on Platform Table 1 Duct System Use industry approved standards (such as those published by Air Conditioning Contractors of America or American Society of Heating, Refrigerating and Air Conditioning Engineers) to size and install the supply and return air duct system.

  • Page 13: Venting

    Venting If necessary reposition the combustion air inducer, pressure A 4 inch diameter flue transition is factory installed on the switch and/or make-up box as needed per the following combustion air inducer outlet of all models. Figure 16 steps. See Figures 16 through 22. shows the combustion air inducer as shipped from 1.

  • Page 14: Horizontal Position

    Horizontal Position HORIZONTAL LEFT POSITION HORIZONTAL RIGHT POSITION Top Vent discharge Top Vent Discharge • Disconnect pressure switch hose from barbed fitting on the pressure • Remove make-up box assembly (2 screws) and cut wire tie to free make- switch assembly. Remove pressure switch assembly (1 screw) and up box wires.
  • Page 15 These series units are classified as fan assisted Category Use self drilling sheet metal screws or a mechanical fastener I furnaces when vertically vented according to the latest to firmly secure the vent pipe to the round collar of the flue edition of National Fuel Gas Code (NFPA 54 / ANSI Z223.1) transition.
  • Page 16 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 25 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 17 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 or replacement.
  • Page 18 Capacity of Type B Double Wall Vents with Type B Double Wall Connectors Serving a Single Category I Appliance NOTE: Single appliance venting configurations 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 19 Capacity of Type B Double Wall Vents with Single Wall Metal Connectors Serving a Single Category I Appliance NOTE: Single appliance venting configurations 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 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 20 of 65 Issue 1606...
  • Page 21 Vent Connector Capacity Type B Double Wall Vents with Single Wall Metal Connectors Serving Two or More Category I Appliances NOTE: Single appliance venting configurations 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 22 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.

  • Page 23: 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 24 NOTE: BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Figure 26 Horizontal Applications Possible Gas Piping Configurations NOTE: BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Figure 27 Page 24 of 65 Issue 1606 506891-01...

  • Page 25: Electrical

    Leak Check The unit is equipped with a field make-up box on the left After gas piping is completed, carefully check all piping hand side of the cabinet. The make-up box may be moved connections (factory and field installed) for gas leaks. Use to the right side of the furnace to facilitate installation.

  • Page 26: Electrical Wiring

    3. When there is a cooling demand, the indoor blower will run on the cooling speed designated by the positions of DIP switches (A, B, C, D) of the COOL jumper plug. Generator Use - Voltage Requirements The following requirements must be kept in mind when Table 10 specifying a generator for use with this equipment: •...
  • Page 27 Figure 31 506891-01 Issue 1606 Page 27 of 65...
  • Page 28 Optional Accessories for use with any ConfortSync® System Figure 32 Page 28 of 65 Issue 1606 506891-01...
  • Page 29 A80US2V Field Wiring Applications with Conventional Thermostat * Not required on all units. Table 11A 506891-01 Issue 1606 Page 29 of 65...
  • Page 30 A80US2V Field Wiring Applications with Conventional Thermostat (continued) * Not required on all units. Table 11B Page 30 of 65 Issue 1606 506891-01...
  • Page 31 A80US2V Field Wiring Applications with Conventional Thermostat (continued) * Connect W1 to W1 ONLY if using defrost tempering kit 67M41 NOTE: Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the A80 inte- grated control.
  • Page 32 A80US2V Field Wiring Applications with Conventional Thermostat (continued) * Connect W1 to W1 ONLY if using defrost tempering kit 67M41 NOTE: Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the A80 inte- grated control.
  • Page 33 A80US2V Schematic Wiring Diagram Figure 33 506891-01 Issue 1606 Page 33 of 65...
  • Page 34 Typical A80US2V Field Wiring Diagram Figure 34 Page 34 of 65 Issue 1606 506891-01...
  • Page 35 Integrated Control Figure 35 506891-01 Issue 1606 Page 35 of 65...

  • Page 36: Thermostat

    Integrated Control DIP Switch Settings - Conventional between 90° and 110°F at the exact moment that the blower Thermostat (non-communicating) is de-energized. Longer OFF delay blower OFF delay to achieve a supply air temperature between 90° and 110°F at A95US2V units are equipped with a two-stage, variable the exact moment that the blower is de-energized.
  • Page 37 Ramping Option 0 Cooling Mode Blower Speed Ramping • Motor runs at 100% until demand is satisfied. R am p in g O p tio n S w itch 9 S w itch 10 • Once demand is met, motor ramps down to stop. A (F actory) O ff...
  • Page 38 Refer to Table 18 for operation button is released. sequence in applications including A80US2V, a thermostat which fetures humidity control and a single- speed outdoor Error Code Recall Mode Unit.

  • Page 39: Operating Sequence

    OPERATING SEQUENCE A80US2V, Non-Communicating Thermostat with Humidity Control Feature and Single-Speed Outdoor Unit O P E R A T IN G S Y S T E M D E M A N D S Y S T E M R E S P O N S E...
  • Page 40 OPERATING SEQUENCE A80US2V, Non-Communicating Thermostat with Humidity Control Feature and Two-Speed Outdoor Unit O P E R A T IN G S Y S T E M D E M A N D S Y S T E M R E S P O N S E...
  • Page 41 START-UP WARNING For Your Safety, Read Before Operating If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. WARNING Do not use this furnace if any part has been under Gas Valve Operation (Figures 36 and 37) water.

  • Page 42: Gas Pressure Adjustment

    12. If the appliance will not operate, follow the instructions Supply Line Pressure “Turning Off Gas to Unit” and call your service technician A threaded plug on the inlet side of the gas valve provides or gas supplier. access to the supply pressure tap. Turning Off Gas to Unit White Rodgers Valve: An inlet post located on the gas valve provides access to...

  • Page 43: High Altitude

    OPERATION High Altitude The manifold pressure, gas orifice and pressure switch WARNING may require adjustment or replacement to ensure proper For safety, shut unit OFF and remove manometer as operation at higher altitudes. See Table 23 through 26 for soon as an accurate reading has been obtained. Take manifold pressures, pressure switch and gas conversion care to replace pressure tap plug.

  • Page 44: Sequence Of Operation

    OTHER UNIT ADJUSTMENTS Applications Using a Two-Stage Thermostat A-Heating Sequence - Control Thermostat Selection Primary and Secondary Limits DIP switch in “Two Stage” Position (Factory Settling) The primary limit is located on the heating compartment 1. On a call for heat, thermostat first stage contacts vestibule panel.
  • Page 45 Application Using a Two Stage Thermostat After the 20-second warm-up period has ended, the gas valve is energized on low fire (first stage) and B - Heating Sequence - Control Thermostat Selection ignition occurs. At the same time, the control module DIP switch in “Variable Capacity”...
  • Page 46 8. NOX units only - Remove screw securing NOX insert. Filters All A80US2V filters are installed external to the unit. Filters should be inspected monthly. Clean or replace the filters when necessary to ensure that the furnace operates properly. Replacement filters must be rated for high velocity airflow.
  • Page 47 A80US2V Burner, Combustion Air Inducer Assembly & Heat Exchanger Removal Figure 40 9. Remove screws from both sides, top and bottom of 13. To clean the combustion air inducer visually inspect vestibule panel. and using a wire brush clean where necessary. Use 10.
  • Page 48 18. Reconnect all wires. 19. Reconnect top cap and vent pipe to combustion air A80US2V NOX Inserts inducer outlet. 20. Reconnect gas supply piping. 21. Turn on power and gas supply to unit. 22. Set thermostat and check for proper operation.

  • Page 49: Repair Parts List

    Planned Service The following items should be checked during an annual inspecation. Power to the unit nmust be shut OFF for the service technician’s safety. Operating performance - Unit must be observed during Fresh air grilles and louvers (on the unit and in the room operation to monitor proper performance of the unit and where the furnace is installed) - Must be open and the vent system.

  • Page 50: Integrated Control Diagnostic Modes

    Integrated Control Diagnostic Modes D isplay A ction (w hen button release d) N o chang e (idle)* R em ain in idle m od e S olid "E" E nter diagn ostic recall m ode S olid "D" D ischarge A ir Installed S olid "F"...
  • Page 51 Integrated Control Diagnostic Codes C ode D iagnostic C odes/S tatus of E quipm ent A ction R equired to C lear and R ecover D evice com m unication problem - N o other devices on R S B U S (C om m u - E quipm ent is unable to com m unicate Indicates nication...
  • Page 52 Integrated Control Diagnostic Codes (continued) C orrupted control param eters (V erify configuration of system C om m uni- R econfigure the system . R eplace control if heating cating only. or cooling is not availab O nly applicable in the com m unicating m ode, not in...
  • Page 53 Integrated Control Diagnostic Codes (continued) C ode D iagnostic C odes/S tatus of E quipm ent A ction R equired to C lear and R ecover Low pressure sw itch failed open C heck pressure (inches w .c.) of low pressure sw itch closing on heat call.
  • Page 54 Integrated Control Diagnostic Codes (continued) E 272 S oft lockout - E xceeded m axim um num ber of recycles. Last recycle due C heck operation of low pressure sw itch to see if it is to the pressure sw itch opening. stuck closed on heat call.
  • Page 55 Integrated Control Diagnostic Codes (continued) C ode D iagnostic C odes/S tatus of E quipm ent A ction R equired to C lear and R ecover E 312 R estricted air flow in cooling or continuous fan m ode is low than cfm W arning O nly.
  • Page 56 Integrated Control Diagnostic Codes (continued) LS O M - C om pressor open start circuit. R equired am ount of current is not passing through E406 S tart current transform C lears the error after cur- rent is sensed in S T A R T sensor, or after pow er re- set.
  • Page 57 Program Unit Capacity / Size Mode 506891-01 Issue 1606 Page 57 of 65...

  • Page 58: Troubleshooting: Heating Sequence Of Operation

    Troubleshooting: Heating Sequence of Operation Page 58 of 65 Issue 1606 506891-01...
  • Page 59 Troubleshooting: Heat Sequence of Operation (continued) 506891-01 Issue 1606 Page 59 of 65...
  • Page 60 Troubleshooting: Heat Sequence of Operation (continued) Page 60 of 65 Issue 1606 506891-01...
  • Page 61 Troubleshooting: Heat Sequence of Operation (continued) 506891-01 Issue 1606 Page 61 of 65...
  • Page 62 Troubleshooting: Continuous Fan Sequence of Operation Page 62 of 65 Issue 1606 506891-01...

  • Page 63: Start Up & Performance Check List

    Start-Up & Performance Check List 506891-01 Issue 1606 Page 63 of 65...

  • Page 64: Unit Operation

    UNIT OPERATION Page 64 of 65 Issue 1606 506891-01...

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