Installation Guide

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

507324-01 Page 1 of 32Issue 1722

INSTALLATION INSTRUCTIONS

A80UH & 80G1UH

Warm Air Gas Furnace

Upow / Horizontal Left and Right Air Discharge

Save these instructions for future reference

(P) 507324-01

*P507324-01*

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

A80UH & 80G1UH Gas Furnace .................................3

Shipping and Packing List ...........................................3

Safety Information .......................................................3

General ........................................................................4

Combustion, Dilution & Ventilation Air .........................5

Setting Equipment .......................................................7

Filters .........................................................................10

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

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

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

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

Service.......................................................................29

Repair Parts List ........................................................30

Blower Performance ..................................................31

Summary of content (32 pages)

PAGE 1
INSTALLATION INSTRUCTIONS A80UH & 80G1UH Warm Air Gas Furnace Upflow / Horizontal Left and Right 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 A80UH & 80G1UH Gas Furnace..................................
PAGE 2
Unit Dimensions 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 25 (635) D 1. Single side return air with transition, to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter. 2. Single side return air with optional RAB Return Air Base 3. Bottom return air. 4. Return air from both sides. 5. Bottom and one side return air.
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A80UH & 80G1UH Gas Furnace The A80UH & 80G1UH gas furnace is shipped ready for installation in the upflow or horizontal right position (for horizontal left position the combustion air pressure switch must be moved). The furnace is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in horizontal or upflow applications with bottom return air. The furnace is equipped for installation in natural gas applications.
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• The return air duct must be provided and sealed to the furnace. • Return air temperature range between 60°F (16°C) and 80°F (27°C) must be maintained. • Air filters must be installed in the system and must be maintained during construction. • Air filters must be replaced upon construction completion. • The input rate and temperature rise must be set per the furnace rating plate. • One hundred percent (100%) outdoor air must be provided for combustion air requirements during construction.
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• When a furnace is installed in an attic, the passageway to and service area surrounding the equipment shall be floored. The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in an unconfined or a confined space. WARNING WARNING This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm. Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation.
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is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room. Even a small leak around the base of the unit at the platform or at the return air duct connection can cause a potentially dangerous negative pressure condition. Air for combustion and ventilation can be brought into the confined space either from inside the building or from outside.
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Setting Equipment 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. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death. The gas furnace can be installed as shipped in either the upflow position or the horizontal position. Select a location that allows for the required clearances that are listed on the unit nameplate.
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Type of Vent Connector Type C Type B1 Top 1 in. (25 mm) 1 in. (25 mm) *Front 2-1/4 in. (57 mm) 2-1/4 in. (57 mm) Back 0 0 Sides 0† 0 Vent 6 in. (152 mm) 1 in. (25 mm) Floor 0‡ 0‡ Figure 8. Single Side Return Air (with transition and filter) Removing the Bottom Panel Remove the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom panel has been removed, reinstall the bottom cap. See Figure 9.
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Horizontal Applications The furnace can be installed in horizontal applications. Order horizontal suspension kit (51W10) from Allied Air, or use equivalent suspension method. Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in Figure 10. Type of Vent Connector Type C Type B1 Top 0 0 *Front 2-1/4 in. (57 mm) 2-1/4 in. (57 mm) Back 0 0 Ends 2 in. (51 mm) 2 in. (51 mm) Vent 6 in. (152 mm) 1 in.
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WARNING 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 living space. Use screws and joint tape to seal the return air system to the furnace. In platform installations with bottom return air, the furnace should be sealed airtight to the return air plenum. A door must never be used as a portion of the return air duct system.
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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. This will result in a quiet and low static system that has uniform air distribution. NOTE: Do not operate the furnace in the heating mode with an external static pressure that exceeds 0.8 inches w.c.
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• Gas supply piping must be brought into the unit from the right side in order to accommodate the flue pipe. • Disconnect pressure switch hose from barbed fitting on the pressure switch assembly. Remove pressure switch assembly (1 screw) and cut wire tie to free pressure switch wires. Reinstall pressure switch on the other side of orifice plate and reconnect pressure switch hose. • Cut combustion air inducer tubing from 9” to 8” to avoid interference with inducer motor.
PAGE 13
NOTE: Use these instructions as a guide. They do not supersede local codes. This furnace must be vented according to all local codes these installation instructions, and the provided venting tables in these instructions. The venting tables in this manual were extracted from the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) and are provided as a guide for proper vent installation. Proper application, termination, construction and location of vents must conform to local codes having jurisdiction.
PAGE 14
Venting Using a Masonry Chimney The following additional requirements apply when a lined masonry chimney is used to vent this furnace. Masonry chimneys used to vent Category I central furnaces must be either tile lined or lined with a listed metal lining system or dedicated gas vent. Unlined masonry chimneys are prohibited. See Figure 23 and Figure 24 for common venting. A chimney with one or more sides exposed to the outside of the structure is considered to be an exterior chimney.
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If type B1 double wall vent is used inside a chimney, no other appliance can be vented into the chimney. The outer wall of type B1 vent pipe must not be exposed to flue products. A type B1 vent or masonry chimney liner shall 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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14. All venting pipe passing through floors, walls, and ceilings must be installed with the listed clearance to combustible materials and be fire stopped according to local codes. In absence of local codes, refer to NFGC (2223.1 ). 15. No portion of the venting system can extend into, or pass through any circulation air duct or plenum. 16.
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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
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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
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Removal of the Furnace from Common Vent In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain connected to the common venting system.
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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.
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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. Figure 26. CAUTION Some soaps used for leak detection are corrosive to certain metals.
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Electrically ground the unit according to local codes or, in the absence of local codes, according to the current National Electric Code (ANSI/NFPA No. 70). A green ground wire is provided in the field make-up box. NOTE: This furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded. Accessory Terminals One line voltage “ACC” 1/4” spade terminal is provided on the furnace integrated control.
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045-12 070-08 070-12 090-12 090-16 110-12 110-16 110-20 135-20 Figure 31.
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Terminal Designations 120 HUM LINE XFMR EAC Humidifier (120 VAC) Input (120 VAC) 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 all speed taps FLAME NEUTRALS Flame sensor Neutral Terminals (120 VAC) 3 AMP, 32 VAC FUSE HEAT OFF DELAY JUMPER Figure 32.
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Placing the Furnace into Operation Integrated Control Diagnostic Codes LED Status These units are equipped with an automatic ignition system. Do not attempt to manually light burners on these furnaces. Each time the thermostat calls for heat, the burners will automatically light. The ignitor does not get hot when there is no call for heat on units with an automatic ignition system.
PAGE 26
Turning Off Gas to Unit 2. Combustion air pressure switch proves blower operation. Switch is factory set and requires no adjustment. 3. After a 15 second pre-purge, the hot surface ignitor energizes. 4. After a 20 second ignitor warm-up period, the gas valve solenoid opens. A 4 second trial for ignition period begins. Failure to Operate 5. Gas is ignited, flame sensor proves the flame, and the combustion process continues. 1. Is the thermostat calling for heat? 6.
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1 ON OFF Pre-Purge 39 35 15 Ignitor Warm-up Trial for Ignition 80 5 SEC Blower “On” Delay Post Purge Demand CAI Ignitor Gas Valve Indoor Blower Blower on time will be 45 seconds after gas valve is energized. Blower off time will depend on “OFF TIME” Setting. Figure 34. Integrated Ignition Control Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.
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Unit CO2% for Nat CO2% for LP 7.2 - 7.8 7.5 - 9.0 -045 -070 -090 -110 -135 Table 11. High Altitude This furnace is carefully designed for optimal performance under a wide range of operating conditions. To ensure proper operation at higher altitudes, certain adjustments and/or kits may be required. Manifold Pressure Between 2000 and 7500 ft, certain units require manifold pressure adjustments specified in Table 9. Manifold pressure should be measured, and adjusted as required during unit start up.
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Other Unit Adjustments Service 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. These auto reset limits are factory set and require no adjustment. WARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD.
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Filters 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. Table 1 lists recommended filter sizes. Flue and Chimney 1. Check flue pipe, chimney and all connections for tightness and to make sure there is no blockage. 2. Check unit for proper draft. Electrical 1. Check all wiring for loose connections.
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Blower Performance Model 045A12(L) 070A08 070A12(L) Upflow / Horizontal 090B12 090B16(L) 110C12 110C16 110C20(L) 135D20 507324-01 Motor Size (hp) 1/3 (4 spd) 1/5 (3 spd) 1/3 (4 spd) 1/3 (4 spd) 1/2 (4 spd) 1/3 (4 spd) 1/2 (4 spd) 3/4 (4 spd) 3/4 (4 spd) Blower Size 10 x 8 10 x 7 10 x 8 10 x 9 10 x 10 10 x 10 10 x 10 11 x 10 11 x 11 Temp Rise (°F) 15 - 45 40 - 70 30 - 60 35 - 65 30 - 60 45 - 75 30 - 60 30 - 60 30 - 60 CFM @ External Static Pressure - w.c.
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Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 4. Revise NFPA-54 section 10.8.