Installation Guide

ManualsBrandsROYALTON ManualsForced Air Furnaces44,000 BTU 80% AFUE Single-Stage Upflow/Horizntal Forced Air Natural Gas Furnace with ECM Blower Motor

507332-01 Page 1 of 35Issue 1723

INSTALLATION INSTRUCTIONS

A80DF1E & 80G1DFE

Warm Air Gas Furnace

Downow Air Discharge

Save these instructions for future reference

(P) 507332-01

*P507332-01*

Manufactured By

Allied Air Enterprises LLC

A Lennox International, Inc. Company

215 Metropolitan Drive

West Columbia, SC 29170

This manual must be left with the homeowner for future reference.

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.

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.

WARNING

As with any mechanical equipment, personal injury can

result from contact with sharp sheet metal edges. Be

careful when you handle this equipment.

CAUTION

Table of Contents

Unit Dimensions ..........................................................2

Parts Arrangement.......................................................3

A80DF1E & 80G1DFE Gas Furnace ...........................4

Shipping and Packing List ...........................................4

Safety Information .......................................................4

General ........................................................................6

Combustion, Dilution & Ventilation Air .........................6

Setting Equipment .......................................................8

Filters .........................................................................11

Duct System ..............................................................11

Gas Piping .................................................................19

Electrical ....................................................................21

Unit Start-Up ..............................................................25

Blower Performance ..................................................29

Service.......................................................................30

Planned Service ........................................................32

Repair Parts List ........................................................34

Summary of content (35 pages)

PAGE 1
INSTALLATION INSTRUCTIONS A80DF1E & 80G1DFE Warm Air Gas Furnace Downflow Air Discharge This manual must be left with the homeowner for future reference. 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. Table of Contents Unit Dimensions...........................................................2 Parts Arrangement.......................................................
PAGE 2
Unit Dimensions FRONT VIEW A80DF1E / 80G1DFE Capacity SIDE VIEW A B C D in. mm in. mm in. mm in.
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Parts Arrangement BLOWER ASSEMBLY CONTROL BOX FLUE CHASE INTERNAL FLUE PIPE ASSEMBLY BURNER BOX ASSEMBLY CABINET HEAT EXCHANGER COMBUSTION AIR INDUCER GAS VALVE ACCESS PANEL ROLLOUT LOCATED INSIDE BURNER BOX Figure 1.
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A80DF1E & 80G1DFE Gas Furnace Safety Information The A80DF1E & 80G1DFE gas furnace is shipped ready for installation in the downflow position. WARNING The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications. DANGER OF EXPLOSION! There are circumstances in which odorant used with LP/Propane gas can lose its scent.
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Temperature Rise NOTE: Furnace must be adjusted to obtain a temperature rise within the range specified on the unit nameplate. Failure to do so may cause erratic limit operation and may result in premature heat exchanger failure. This furnace must be installed so that its electrical components are protected from water.
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General These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation. In addition to the requirements outlined previously, the following general recommendations must be considered when installing one of these furnaces: • Place the furnace as close to the center of the air distribution system as possible. The furnace should also be located close to the chimney or vent termination point.
PAGE 7
The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in an unconfined or a confined space. Unconfined Space An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space. This space also includes adjacent rooms which are not separated by a door.
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NOTE: Each air duct opening shall have a free area of at least one square inch per 2,000 Btu (645 mm² per .59 kW) per hour of the total input rating of all equipment in the enclosure. If the equipment room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of at least 1 square inch per 4,000 Btu (645 mm² per 1.17 kW) per hour of the total input rating of all other equipment in the enclosure.
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Units with 1/2 HP & 3/4 HP Blower Motor Figure 9. Figure 7. Return Air Downflow Applications Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in Figure 8. Return air must be brought in through the top of the furnace installed in an downflow application. WARNING Improper installation of the furnace can result in personal injury or death.
PAGE 10
Front to Rear Side to Side in. mm in. mm 19-3/4 502 16-5/8 422 20-1/8 511 Cabinet Width B Cabinet (17.5”) C Cabinet (21”) NOTE: Floor opening dimensions listed are 1/4 in. (6 mm) larger than the unit opening. See dimension drawing on Page 2. Table 1. Non-Combustible Floor Opening Size Figure 11. 2. After opening is cut, set the combustible flooring base into opening. 3. Check fiberglass strips on the combustible flooring base to make sure they are properly glued and positioned. 4.
PAGE 11
Filters This unit is not equipped with a filter or rack. A field provided high velocity filter is required for the unit to operate properly. A filter must be in place any time the unit is operating. 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.
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one self drilling screw through the front and one through each side of the vent pipe and collar. See Figure 15. IMPORTANT Install the first vent connector elbow at a minimum of six inches (152 mm) from the furnace vent outlet. See Figure 15. The unit will not vent properly with the flue transition pointed down in the 6 o’clock position. The combustion air inducer may be rotated clockwise or counterclockwise by 90° to allow for top or side vent discharge in all applications.
PAGE 13
DO NOT insulate the space between the liner and the chimney wall with puffed mica or any other loose granular insulating material. terminate above the roof surface with a listed cap or a listed roof assembly according to the terms of their respective listings and the vent manufacturer’s instructions.
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determine the minimum vent capacity and the vent connector diameter to determine the maximum vent capacity. The flow area of the vertical vent, however, shall not exceed 7 times the flow area of the listed appliance categorized vent area, drafthood outlet area or flue collar area unless designed according to approved engineering methods. 5.
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Capacity of Type B Double Wall Vents with Type B Double Wall Connectors Serving a Single Category I Appliance Height H (feet) 6 8 10 15 20 30 Lateral L (feet) Vent and Connector Diameter - D (inches) 3 inch 4 inch 5 inch 6 inch Appliance Input Rating in Thousands of Btu per Hour MIN MAX MIN MAX MIN MAX MIN MAX 0 0 78 0 152 0 251 0 375 2 13 51 18 97 27 157 32 232 4 21 49 30 94 39 153 50 227 6 25 46 36 91 47 149 59 223 0 0 84 0 165 0 276 0 415 2
PAGE 16
Capacity of Type B Double Wall Vents with Single Wall Metal Connectors Serving a Single Category I Appliance Height H (feet) Lateral L (feet) 0 6 8 10 15 20 30 Vent and Connector Diameter - D (inches) 3 inch 4 inch 5 inch 6 inch Appliance Input Rating in Thousands of Btu per Hour MIN MAX MIN MAX MIN MAX MIN MAX 38 77 59 151 85 243 126 373 2 39 51 60 96 85 158 123 231 4 NR NR 74 92 102 152 146 225 6 NR NR 83 89 114 147 163 220 0 37 83 68 164 83 273
PAGE 17
Vent Connector Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Vent Height H (feet) Connector Rise R (feet) 6 8 10 15 20 30 Vent and Connector Diameter - D (inches) 3 inch 4 inch 5 inch 6 inch Appliance Input Rating in Thousands of Btu per Hour MIN MAX MIN MAX MIN MAX MIN MAX 1 22 37 35 66 46 106 58 164 2 23 41 37 75 48 121 60 183 3 24 44 38 81 49 132 62 199 1 22 40 35 72 49 114 64 176 2 2
PAGE 18
Vent Connector Capacity Type B Double Wall Vents with Single Wall Metal Connectors Serving Two or More Category I Appliances Vent Height H (feet) Connector Rise R (feet) 6 8 10 15 20 30 Vent and Connector Diameter - D (inches) 3 inch 4 inch 5 inch 6 inch Appliance Input Rating in Thousands of Btu per Hour MIN MAX MIN MAX MIN MAX MIN MAX 1 NR NR NR NR NR NR NR NR 2 NR NR NR NR NR NR 168 182 3 NR NR NR NR 121 131 175 198 1 NR NR NR NR NR NR NR NR 2 NR
PAGE 19
Removal of the Furnace from Common Vent Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in Appendix G. (These are in the current standards of the National Fuel Gas Code ANSI 2223.1. Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain connected to the common venting system.
PAGE 20
Gas Pipe Capacity - FT³/HR (kL/HR) Nominal Iron Pipe Size inches (mm) Internal Diameter - inches (mm) Length of Pipe - feet (m) 10 (3.048) 20 (6.096) 30 (9.144) 1/2 (12.7) .622 (17.799) 175 (4.96) 120 (3.40) 97 (2.75) 82 (2.32) 73 (2.07) 66 (1.87) 61 (1.73) 57 (1.61) 53 (1.50) 50 (1.42) 3/4 (19.05) .824 (20.930) 360 (10.19) 250 (7.08) 200 (5.66) 170 (4.81) 151 (4.28) 138 (3.91) 125 (3.54) 118 (3.34) 110 (3.11) 103 (2.92) 1 (25.4) 1.049 (26.645) 680 (19.25) 465 (13.
PAGE 21
Leak Check 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. NOTE: If emergency shutoff is necessary, shut off the main manual gas valve and disconnect the main power to the furnace. The installer should properly label these devices. ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures CAUTION Electrostatic discharge can affect electronic components.
PAGE 22
Refer to Figure 23 for schematic wiring diagram and troubleshooting and Figure 24 for field wiring. The power supply wiring must meet Class I restrictions. Protected by either a fuse or circuit breaker, select circuit protection and wire size according to unit nameplate. connected to ground or the “C” terminal. See Figure 25 for control board configuration. This terminal is energized in the heating mode when the combustion air inducer is operating.
PAGE 23
Figure 23.
PAGE 24
Figure 24.
PAGE 25
Unit Start-Up FOR YOUR SAFETY READ BEFORE LIGHTING UNIT WARNING Do not use this furnace if any part have been underwater. Immediately call a licensed professional service technician (or equivalent) to inspect the furnace and to replace any part of the control system and any gas control which has been underwater. 2. Set the thermostat to the lowest setting. 3. Turn off all electrical power to the unit. 4. This furnace is equipped with an ignition device which automatically lights the burners.
PAGE 26
Gas Pressure Adjustment 6. Is gas turned on at the meter? 7. Is the manual main shut-off valve open? 8. Is the internal manual shut-off valve open? 9. Is the unit ignition system in lock out? If the unit locks out again, call the service technician to inspect the unit for blockages. Gas Flow (Approximate) Gas Meter Clocking Chart Seconds for One Revolution Natural Capacity 10. Is pressure switch closed? Obstructed flue will cause unit to shut off at pressure switch.
PAGE 27
3. While waiting for the unit to stabilize, observe the flame. Flame should be stable and should not lift from burner. Natural gas should burn blue. 4. After allowing unit to stabilize for 5 minutes, record manifold pressure and compare to value given in Table 13. Other Unit Adjustments Primary and Secondary Limits The primary limit is located on the heating compartment vestibule panel. The secondary limits (if equipped) are located in the blower compartment, attached to the back side of the blower.
PAGE 28
Thermostat Heat Anticipation Set the heat anticipator setting (if adjustable) according to the amp draw listed on the wiring diagram that is attached to the unit. IMPORTANT For Safety, shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to replace pressure tap plug. NOTE: Do not secure the electrical conduit directly to the air ducts or structure. Fan Control The fan on time of 45 seconds is not adjustable.
PAGE 29
Blower Performance A80DF1E / 80G1DFE 045*A12 Performance (Less Filter) External Static Pressure in. w.c. Air Volume / Watts at Various Blower Speeds cfm watts cfm 0.00 1430 285 0.10 1400 285 0.20 1375 300 High Medium-High Medium Medium-Low watts cfm watts cfm watts 1215 180 1035 120 995 1175 185 995 130 885 1145 200 950 140 840 110 Low cfm watts 110 930 100 100 850 90 725 85 0.30 1335 315 1120 210 915 145 790 115 665 95 0.
PAGE 30
A80DF1E / 80G1DFE 110*C20 Performance (Less Filter) External Static Pressure in. w.c. Air Volume / Watts at Various Blower Speeds cfm watts cfm watts cfm watts cfm watts cfm watts 0.00 2410 625 2095 405 1875 295 1700 225 1635 180 0.10 2385 630 2100 410 1830 310 1610 240 1505 190 0.20 2325 650 2010 440 1760 330 1570 255 1375 195 0.30 2280 675 1940 460 1705 340 1500 260 1320 210 0.40 2235 690 1895 475 1635 365 1440 285 1265 225 0.
PAGE 31
7. Remove screws securing burner box and remove burner box. 8. NOX units only - Remove screw securing NOX insert. Remove NOX insert. See Figure 29. 9. Remove screws from both sides, top and bottom of vestibule panel. 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. See Figure 31. 16. Reinstall collector box and combustion air assembly.
PAGE 32
Planned Service 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. Burners - Must be inspected for rust, dirt, or signs of water. Vent pipe - Must be inspected for signs of water, damaged or sagging pipe, or disconnected joints.
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-02 Integrated Control LED Codes Red LED Flash Code Diagnostic Codes / Status of Furnace LED Off Heartbeat No power to control or control hardware fault detected Control powered - displayed during all modes of operation if no errors are detected 1 1 Flash 1 Reverse line voltage polarity 2 Flashes Improper earth ground 3 Flashes Burner failed to light, or lost flame during heat demand 4 Flashes Low flame signal - check flame sensor 5 Flashes Watchguard - burner failed to light, exceeded maximu
PAGE 34
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.
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Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 4. Revise NFPA-54 section 10.8.