Allied 80G1UH manual

506526-01 Page 1 of 39 Issue 1031 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. CAUT[...]

506526-01 Page 2 of 39 Issue 1031 Model A 368 14-1/2 A801UH/80G1UH B C in. mm in. mm in. mm 340 13-3/8 330 13 090-12 135-20 533 21 504 19-7/8 495 19-1/2 622 24-1/2 546 23-3/8 584 23 D in. mm 248 9-3/4 203 8 121 4-3/4 070-08 090-16 110-16 110-20 070-12 045-12 045-08 110-12 446 17-1/2 416 16-3/8 406 16 159 6-1/4 A80UH & 80G1UH Unit Dimensions - i[...]

506526-01 Page 3 of 39 Issue 1031 A80UH & 80G1UH Expanded V iew Figure 1[...]

506526-01 Page 4 of 39 Issue 1031 A80UH & 80G1UH Gas Furnace The A80UH & 80G1UH gas furnace is shipped ready for installation in the up flow 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 [...]

506526-01 Page 5 of 39 Issue 1031 T emperature Rise NOTE: Furnace must be adjusted to obt ain 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 it s electrical components are protected from[...]

506526-01 Page 6 of 39 Issue 1031 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: [...]

506526-01 Page 7 of 39 Issue 1031 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 unsafely . Enough air must be provided to meet the needs of all fuel burning appliances and appliances such as exhaust fans which force air o[...]

506526-01 Page 8 of 39 Issue 1031 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 rect angular 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. If the[...]

506526-01 Page 9 of 39 Issue 1031 The gas furnace can be installed as shipped in either the upflow position or the horizont al position. Select a location that allows for the required clearances that are listed on the unit nameplate. Also consider gas supply connections, electrical supply , vent connection, and installation and service clearances [[...]

506526-01 Page 10 of 39 Issue 1031 Return Air - Upflow Applications Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the 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 operat[...]

506526-01 Page 11 of 39 Issue 1031 Figure 1 1 Removing the Bottom Panel 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 p anel has been removed, reinstall the bottom cap. See Figure 1 1. Horizontal Application Inst allatioin clearances [...]

506526-01 Page 12 of 39 Issue 1031 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 . T able 1 lists recommended filter sizes. A filter must be in place any time the unit is operating. Duct System Use industry approved standards (such as those published by Ai[...]

506526-01 Page 13 of 39 Issue 1031 V enting A 4 inch diameter flue transition is factory installed on the combustion air inducer outlet of all models. Figure 16 shows the combustion air inducer as shipped from the factory . Mounting Screws Location Figure 15 UPFLOW POSITION T op V ent Discharge Figure 16 The unit will not vent properly with the flu[...]

506526-01 Page 14 of 39 Issue 1031 Horizontal Position HORIZONT AL LEFT POSITION T op V ent discharge Figure 19 • 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 pla[...]

506526-01 Page 15 of 39 Issue 1031 Once the venting system is installed, attach the “Disconnected V ent” warning sticker to a visible area of the plenum near the vent pipe. See Figure 23. The warning sticker is provided in the bag assembly . Order kit 66W04 for additional stickers. IMPORT ANT These series units are classified as fan assisted Ca[...]

506526-01 Page 16 of 39 Issue 1031 DO NOT insulate the space between the liner and the chimney wall with puffed mica or any other loose granular insulating material. SINGLE appliance venting of a fan assisted furnace into a tile lined masonry chimney (interior or outside wall) is prohibited. The chimney must first be lined with either type B1 vent [...]

506526-01 Page 17 of 39 Issue 1031 6. The entire length of single wall metal vent connector shall be readily accessible for inspection, cleaning, and replacement. 7. Single appliance venting configurations with zero lateral lengths (T ables 3 and 4) are assumed to have no elbows in the vent system. For all other vent configurations, the vent system[...]

506526-01 Page 18 of 39 Issue 1031 Cap acity of T ype B Double W all V ents with T ype B Double Wall Connectors Serving a Single Category I Appliance T able 3 NOTE: Single appliance venting configureations 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 hav[...]

506526-01 Page 19 of 39 Issue 1031 Capacity of T ype B Double Wall V ents with Single Wall Metal Connectors Serving a Single Category I Appliance T able 4 NOTE: Single appliance venting configureations 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 tw[...]

506526-01 Page 20 of 39 Issue 1031 V ent Connector Capacity T ype B Double Wall V ents with Type B Double W all Connectors Serving Two or More Category I Appliances Common V ent Capacity T ype B Double Wall V ents with Type B Double W all Connectors Serving Two or More Category I Appliances T able 5 T able 6[...]

506526-01 Page 21 of 39 Issue 1031 V ent Connector Capacity T ype B Double Wall V ents with Single Wall Metal Connectors Serving T wo or More Category I Appliances T able 7 Common V ent Capacity T ype B Double W all Vent s with Single W all Metal Connectors Serving T wo or more Category I Appliances T able 8 NOTE: Single appliance venting configure[...]

506526-01 Page 22 of 39 Issue 1031 Removal of the Furnace from Common V ent 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 an[...]

506526-01 Page 23 of 39 Issue 1031 Gas Supply 1 . This unit is shipped standard for left or right side installation of gas piping (or top entry in horizont al applica-tions). Connect the gas supply to the piping assembly . 2. When connecting the gas supply piping, consider factors such as length of run, number of fittings, and furnace rating to avo[...]

506526-01 Page 24 of 39 Issue 1031 Horizontal Applications Possible Gas Piping Configurations NOTE: BLACK IRON PIPE ONL Y TO BE ROUTED INSIDE OF CABINET Figure 27 NOTE: BLACK IRON PIPE ONL Y TO BE ROUTED INSIDE OF CABINET Figure 26[...]

506526-01 Page 25 of 39 Issue 1031 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 instal[...]

506526-01 Page 26 of 39 Issue 1031 Before connecting the thermostat, check to make sure the wires will be long enough for servicing at a later date. Make sure that thermostat wire is long enough to facilitate future removal of blower for service. Complete the wiring connections to the equipment. Use the provided unit wiring diagram and the field wi[...]

506526-01 Page 27 of 39 Issue 1031 Wiring Diagram Figure 32[...]

506526-01 Page 28 of 39 Issue 1031 T ypical Field Wiring Diagram Figure 33 Figure 34 Integrated Control (Automatic Hot Surface Ignition System)[...]

506526-01 Page 29 of 39 Issue 1031 BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor . The gas valve on this unit will be equipped with a gas control switch. Use only your hand to move the switch. Never use tools. If the switch will not t[...]

506526-01 Page 30 of 39 Issue 1031 Heating Sequence Of Operation (Figure 36) 1. When thermostat calls for heat, combustion air blower start s. 2. Combustion air pressure switch proves blower operation. Switch is factory set and requires no adjustment. 3. After a 15 second prepurge, the hot surface ignitor energizes. 4. After a 20 second ignitor war[...]

506526-01 Page 31 of 39 Issue 1031 High Altitude The manifold pressure may require adjustment to ensure proper combustion at higher altitudes. Refer to T able 12 for manifold pressure and pressure switch change. Other Unit Adjustments Primary and Secondary Limit s The primary limit is located on the heating compartment vestibule panel. The secondar[...]

506526-01 Page 32 of 39 Issue 1031 Thermost at Heat Anticip ation Set the heat anticipator setting (if adjustable) according to the amp draw listed on the wiring diagram that is attached to the unit. NOTE: Do not secure the electrical conduit directly to the air ducts or structure. Electrical 1. Check all wiring for loose connections. 2. Check for [...]

506526-01 Page 33 of 39 Issue 1031 At the beginning of each heating season, a qualified technician should check the system as follows: Blower Check the blower wheel for debris and clean if necessary . The blower motors are prelubricated for extended bearing life. No further lubrication is needed. Filters Filters are installed external to the unit. [...]

506526-01 Page 34 of 39 Issue 1031 Cleaning the Heat Exchanger and Burners NOTE: Use papers or protective covering in front of the furnace during cleaning. 1 . Turn of f both electrical and gas power supplies to furnace. 2. Remove flue pipe and top cap (some applications top cap can remain) from the unit. 3. Label the wires from gas valve, rollout [...]

506526-01 Page 35 of 39 Issue 1031 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 40. 1 1. Backwash using steam. Begin from the bumer opening on each clam.[...]

506526-01 Page 36 of 39 Issue 1031 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 . Burner[...]

506526-01 Page 37 of 39 Issue 1031 Cabinet Parts Upper access panel Blower panel T op cap Control Panel Parts T ransformer Integrated control Door interlock switch Circuit breaker Blower Part s Blower wheel Blower housing Motor Motor mounting frame Motor capacitor Blower housing cutoff plate REP AIR P ARTS LIST The following repair p arts are avail[...]

506526-01 Page 38 of 39 Issue 1031 ST ART -UP & PERFORMANCE CHECK LIST UNIT SET UP[...]

506526-01 Page 39 of 39 Issue 1031 UNIT OPERA TION[...]