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Allied Air A80DS2V Installation Instructions Manual

Warm air gas furnace variable speed downflow air discharge
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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.
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
A80DS2V Parts Arrangement ....................................... 3
A80DS2V Gas Furnace ................................................ 4
Shipping and Packing List ............................................ 4
Safety Information ......................................................... 4
General ......................................................................... 6
Combustion, Dilution, Ventilation Air ............................. 6
Setting Equipment ...................................................... 10
Filters .......................................................................... 11
Duct System ................................................................ 11
Venting ........................................................................ 12
Gas Piping .................................................................. 19
Electrical ..................................................................... 21
Thermostat .................................................................. 22
*P506892-01*
(P) 506892-01
506892-01
INSTALLATION INSTRUCTIONS
A80DS2V
Warm Air Gas Furnace Variable Speed
Downflow Air Discharge
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

System Wiring ............................................................. 24
Wiring Diagram ........................................................... 30
Intergrated Control Board ........................................... 32
Blower Data ................................................................. 38
Unit Start-Up ............................................................... 40
Gas Pressure Adjustment ........................................... 41
Proper Combustion ..................................................... 41
High Altitude ................................................................ 42
Other Unit Adjustments ............................................... 43
Heating Sequence of Operation ................................. 43
Service ........................................................................ 45
Planned Service .......................................................... 48
Repair Parts List ......................................................... 48
Diagnostic Codes ........................................................ 49
Issue 1251
NOTICE
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 64

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  • Page 1: Table Of Contents

    TABLE OF CONTENTS System Wiring ............. 24 Unit Dimensions ............2 Wiring Diagram ............30 A80DS2V Parts Arrangement ........3 Intergrated Control Board ........... 32 A80DS2V Gas Furnace ..........4 Blower Data ..............38 Shipping and Packing List ..........4 Unit Start-Up ...............

  • Page 2: Unit Dimensions

    A80DS2V Unit Dimensions - inches (mm) TOP VIEW FRONT VIEW SIDE VIEW Model A80DS2V 14-1/2 13-3/8 070-12 4-3/4 090-16 17-1/2 16-3/8 6-1/4 110-20 19-7/8 19-1/2 Page 2 of 64 Issue 1251 506892-01...

  • Page 3: A80Ds2V Parts Arrangement

    EXPANDED VIEW Figure 1 506892-01 Issue 1251 Page 3 of 64...

  • Page 4: A80Ds2V Gas Furnace

    A80DS2V Gas Furnace The A80DS2V gas furnace is shipped with a two stage, CAUTION variable speed control. The control is compatible with: As with any mechanical equipment, personal injury can Comfort Sync™ communicating thermostats result from contact with sharp sheet metal edges. Be Conventional non-communicating thermostats careful when you handle this equipment.

  • 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 Allied Air does not recommend the use of these units as a installed in parallel with, or on the upstream side of, cooling construction heater during any phase of construction.

  • 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 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 (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.
  • Page 9 Downflow Installation Downflow unit installs in three ways: on non-combustible CAUTION flooring, on combustible flooring using a downflow combustible flooring base, or on a reverse flow cooling The furnace and downflow combustible flooring base cabinet. Do not drag the unit across the floor. shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.

  • Page 10: Setting Equipment

    Setting Equipment WARNING Do not install the furnace on its front, back or in the horizontal position. See Figure 13. Do not connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death.

  • Page 11: Filters

    Figure 13 Downflow Application Allow for clearances to combustible materials as indicated WARNING on the unit nameplate. Minimum clearances for closet or alcove installations are shown in Figure 14 Improper installation of the furnace can result in personal injury or death. Combustion and flue products must never be allowed to enter the return air system or the Downflow Application Installation Clearances living space.

  • Page 12: Venting

    NOTE: Do not operate the furnace in the heating mode Refer to the tables and the venting information contained in with an external static pressure that exceeds 0.8 inches w.c. these instructions to properly size and install the venting Higher external static pressures may cause erratic limit system.
  • Page 13 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 16 Venting Using a Masonry Chimney Insulation for the flexible vent pipe must be an encapsulated The following additional requirements apply when a lined...
  • Page 14 Never connect a Category I appliance to a chimney that is servicing a solid fuel appliance. If a fireplace chimney flue is used to vent this appliance, the fireplace opening must be permanently sealed. A type B 1 or listed chimney lining system that passes through an unused masonry chimney flue is not considered to be exposed to the outdoors.
  • Page 15 8. The common vent diameter must always be at least as 21. When connecting this appliance to an existing dedicated large as the largest vent connector diameter. or common venting system, you must inspect the venting 19. In no case, shall the vent connector be sized more than system’s general condition and look for signs of two consecutive table size diameters over the size of corrosion.
  • Page 16 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 17 Vent Connector Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Table 7 Common Vent Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Table 8 506892-01 Issue 1251...
  • Page 18 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 19: Gas Piping

    Removal of the Furnace from Common Vent 7. If a venting problem is found during any of the preceding In the event that an existing furnace is removed from a tests, the common venting system must be modified to venting system commonly run with separate gas appliances, correct the problem.
  • Page 20 Gas Pipe Capacity - ft³/hr (m³/hr) Note: Capacity given in cubic feet (m³) of gas per hour and based on 0.60 specific gravity gas. Table 11 NOTE: BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Figure 18 Page 20 of 64 Issue 1251 506892-01...

  • Page 21: 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 22: Thermostat

    Non-Communicating In non-communication applications this furnace is designed to operate in a SINGLE-STAGE mode or TWO-STAGE mode using a convention thermostat. Table 12 For optimal performance in non-communicating applications, use a high quality electronic digital thermostat or any other with adjustable settings for 1st stage / 2nd 4.
  • Page 23 Generator Use - Voltage Requirements The following requirements must kept in mind when specifying a generator use with this equipment: The furnace requires 120 volts (Range: 102 volts to • volts). The furnace operates at 60 Hz ± (Range: 57 Hz to •...

  • Page 24: System Wiring

    Figure 22 Page 24 of 64 Issue 1251 506892-01...
  • Page 25 Optional Accessories for use with any Comfort Sync System Figure 23 506892-01 Issue 1251 Page 25 of 64...
  • Page 26 Field Wiring Applications with Conventional Thermostat * Not required on all units. Table 13A Page 26 of 64 Issue 1251 506892-01...
  • Page 27 Field Wiring Applications with Conventional Thermostat (continued) * Not required on all units. Table 13B 506892-01 Issue 1251 Page 27 of 64...
  • Page 28 Field Wiring Applications with Conventional Thermostat (continued) Table 13C Page 28 of 64 Issue 1251 506892-01...
  • Page 29 Field Wiring Applications with Conventional Thermostat (continued) Table 13D 506892-01 Issue 1251 Page 29 of 64...

  • Page 30: Wiring Diagram

    A80DS2V Schematic Wiring Diagram Figure 24 Page 30 of 64 Issue 1251 506892-01...
  • Page 31 Typical A80DS2V Field Wiring Diagram Figure 25 506892-01 Issue 1251 Page 31 of 64...

  • Page 32: Intergrated Control Board

    Integrated Control Figure 26 Page 32 of 64 Issue 1251 506892-01...
  • Page 33 Integrated Control DIP Switch Settings - Conventional blower OFF delay to achieve a supply air temperature Thermostat (non-communicating) between 90° and 110°F at the exact moment that the blower is de-energized. Longer OFF delay settings provide lower This furnace is equipped with a two-stage, variable speed supply air temperatures;...
  • Page 34 Cooling Mode Blower Speed Ramping Ramping Option D 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. •...
  • Page 35 Refer to Table 19 for operation sequence in applications including A80DS2V, a thermostat which Error Code Recall Mode features humidity control and a single- speed outdoor Unit.

  • Page 36: Operating Sequence

    OPERATING SEQUENCE 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 S E Q U E N C E T herm ostat D em and R elative H um idity...
  • Page 37 OPERATING SEQUENCE 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 S E Q U E N C E T herm ostat D em and R elative H um idity...

  • Page 38: Blower Data

    B L O W E R D AT A A8 0 DS 2 V 0 7 0 A1 2 B L O W E R P E R F O R M AN AC E (le s s filte r) 0 th ro u g h 0 .8 in .
  • Page 39 B L O W E R D AT A A8 0 DS 2 V 1 1 0 C 2 0 B L O W E R P E R F O R M AN AC E (le s s filte r) 0 th ro u g h 0 .8 in .

  • Page 40: Unit Start-Up

    START-UP Gas Valve Operation (Figures 27 and 28) 1. STOP! Read the safety information at the beginning of For Your Safety, Read Before Operating this section. 2. Set the thermostat to the lowest setting. 3. Turn OFF all electrical power to the unit. WARNING 4.

  • Page 41: Gas Pressure Adjustment

    Turning Off Gas to Unit Supply Pressure Measurement 1. Set the thermostat to the lowest setting. White Rodgers Valve: 2. Turn off all electrical power to the unit if service is to be An inlet post located on the gas valve provides access to performed.

  • Page 42: High Altitude

    OPERATION High Altitude The manifold pressure, gas orifice and pressure switch may WARNING require adjustment or replacement to ensure proper For safety, shut unit OFF and remove manometer as operation at higher altitudes. See Table 22 through 25 for soon as an accurate reading has been obtained. Take manifold pressures, pressure switch and gas conversion kits care to replace pressure tap plug.

  • Page 43: Other Unit Adjustments

    OTHER UNIT ADJUSTMENTS Applications Using a Two-Stage Thermostat A-Heating Sequence - Control Thermostat Selection DIP Primary and Secondary Limits switch in “Two Stage” Position (Factory Setting) 1. On a call for heat, thermostat first stage contacts close The primary limit is located on the heating compartment sending a signal to the integrated control.
  • Page 44 Application Using a Single 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 - Integrated Control Thermostat ignition occurs. At the same time, the control module Selection DIP switch 1 ON in “Single-Stage”...

  • Page 45: Service

    SERVICE Flue And Chimney 1. Check flue pipe, chimney and all connections for tightness and to make sure there is no blockage. WARNING 2. Check unit for proper draft. ELECTRICAL SHOCK, FIRE, Electrical OR EXPLOSION HAZARD. 1. Check all wiring for loose connections. 2.
  • Page 46 Cleaning the Heat Exchanger and Burners 6. Disconnect gas supply piping. Remove the screw securing the burner box cover and remove cover. NOTE: Use papers or protective covering in front of the Remove the four screws securing the burner manifold furnace during cleaning.
  • Page 47 22. If a leak is detected, shut gas and electricity off and NOx Inserts repair leak. 23. Repeat steps 21 and 23 until no leaks are detected. 24. Replace access panel. Remove five screws if necessary (either side of cabinet) Figure 32 11.

  • Page 48: Planned Service

    Planned Service The following items should be checked during an annual inspecation. Power to the unit must 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 49: Diagnostic Codes

    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 50 Integrated Control Diagnostic Codes Page 50 of 64 Issue 1251 506892-01...
  • Page 51 Integrated Control Diagnostic Codes (continued) 506892-01 Issue 1251 Page 51 of 64...
  • Page 52 Integrated Control Diagnostic Codes (continued) Page 52 of 64 Issue 1251 506892-01...
  • Page 53 Integrated Control Diagnostic Codes (continued) 506892-01 Issue 1251 Page 53 of 64...
  • Page 54 Integrated Control Diagnostic Codes (continued) Page 54 of 64 Issue 1251 506892-01...
  • Page 55 Program Unit Capacity / Size Mode 506892-01 Issue 1251 Page 55 of 64...
  • Page 56 Troubleshooting: Heating Sequence of Operation Page 56 of 64 Issue 1251 506892-01...
  • Page 57 Troubleshooting: Heat Sequence of Operation (continued) 506892-01 Issue 1251 Page 57 of 64...
  • Page 58 Troubleshooting: Heat Sequence of Operation (continued) Page 58 of 64 Issue 1251 506892-01...
  • Page 59 Troubleshooting: Heat Sequence of Operation (continued) 506892-01 Issue 1251 Page 59 of 64...
  • Page 60 Troubleshooting: Continuous Fan Sequence of Operation Page 60 of 64 Issue 1251 506892-01...
  • Page 61 Start-Up & Performance Check List UNIT SET UP 506892-01 Issue 1251 Page 61 of 64...
  • Page 62 Start-Up & Performance Check List - continued Page 62 of 64 Issue 1251 506892-01...
  • Page 63 REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS Modifications to NFPA-54, Chapter 10 4. INSPECTION. The state or local gas inspector of the Revise NFPA-54 section 10.8.3 to add the following side wall, horizontally vented, gas-fueled equipment requirements: shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide For all side wall, horizontally vented, gas-fueled equipment detectors and signage installed in accordance with the...

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