Armstrong G1D80BR Installation Instructions Manual Download | Manualshive

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# 45465K005

Page 1

INSTALLATION INSTRUCTIONS

This furnace is not approved for installation in
a mobile home. Do not install this furnace in a
mobile home. Installation in a mobile home
could result in actions that could cause prop-
erty damage, personal injury, or death.

WARNING

Manufactured By

A.A.C.

A Lennox International Inc. Company

421 Monroe Street

Bellevue, OH 44811

TABLE OF CONTENTS

SAFETY ................................................. 2

INSTALLATION....................................... 3

START-UP ............................................ 19

OPERATION ........................................ 20

MAINTENANCE ................................... 25

CONTROL DIAGNOSTICS .................. 26

REPAIR PARTS .................................... 27

WIRING DIAGRAMS ............................ 28

Do not store combustible materials, including
gasoline and other flammable vapors and
liquids, near the furnace, vent pipe, or warm air
ducts. The homeowner should be cautioned that
the furnace area must not be used as a broom
closet or for any other storage purposes. Such
uses may result in actions that could cause
property damage, personal injury, or death.

WARNING

Improper installation, adjustment, alteration, service, or maintenance can cause injury or
property damage. Refer to this manual. For assistance or additional information, consult
a qualified installer, service agency, or the gas supplier.

WARNING

The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of the
National Fire Protection Association; the National Fuel Gas Code, ANSI Z223.1/NFPA No. 54 (latest edition) and
the National Electrical Code, ANSI/NFPA No. 70 (latest edition) in the United States; CSA B149.1 (latest edition)
Natural Gas and Propane Installation Codes and the Canadian Electrical Code Part 1, CSA 22.1 (latest edition)
in Canada; and any state or provincial laws, local ordinances (including plumbing or wastewater codes), or local
gas utility requirements. Local authorities having jurisdiction should be consulted before installation is made.
Such applicable regulations or requirements take precedence over the general instructions in this manual.

IMPORTANT

Save these instructions for future reference

G1D80BT, G1D80BR, G2D80CT, & G2D80CR

80% Gas Furnace

with System Sentry™ Control System

*45465K005*

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Summary of Contents for G1D80BR

Page 1: ... alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier WARNING The installation of the furnace wiring warm air ducts venting etc must conform to the requirements of the National Fire Protection Association the National Fuel Gas Code ANSI Z223 1 NFPA No 54 l...

Page 2: ...lways install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in Temperature Rise on page 23 of these instructions See furnace rating plate 7 When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnac...

Page 3: ...pping damage If damage is found it should be noted on the carrier s freight bill Damage claims should be filed with the carrier immediately Claims of shortages should be filed with the seller within 5 days Check the rating plate for correct model number type of gas and input Clearances All servicing and cleaning of the furnace can be performed from the front If installed in a closet or utility roo...

Page 4: ...perature range between 60 F and 80 F 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 construc tion Temporary ductin...

Page 5: ... Gas Vent Openings Furnace Equipment in Confined Space All Air From Inside Confined Space Installation Air from Outside Structure If air from outside is brought in for combustion the confined space shall be provided with two permanent openings One opening shall be within 12 of the ceiling and one opening within 12 of the floor Several methods can be used to bring the outside air in through these o...

Page 6: ...ene Printing inks paint removers varnishes etc Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials Chlorinated laundry products Hydrochloric acid Venting This furnace has a fan assisted combustion system designed for vertical venting into a suitable chimney or listed gas vent and is classified as a Category I furnace negative vent as shipped from the fac...

Page 7: ...such as local and national codes The venting system should be designed in accordance with the FAN columns in the venting tables in the latest editions of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 1 Natural Gas and Propane Installation Codes For installations using inside air for combustion the inlet air restrictor plate supplied must be installed in the air inlet pipe as shown...

Page 8: ... r a e l C D e h t e v o b a d e t a c o l t i f f o s d e t a l i t n e v o t e c n a r a e l c l a c i t r e V e h t m o r f m c 1 6 t e e f 2 f o e c n a t s i d l a t n o z i r o h a n i h t i w l a n i m r e t l a n i m r e t e h t f o e n i l r e t n e c E t i f f o s d e t a l i t n e v n u o t e c n a r a e l C F r e n r o c e d i s t u o o t e c n a r a e l C G r e n r o c e d i s n i o t...

Page 9: ...l C D e h t e v o b a d e t a c o l t i f f o s d e t a l i t n e v o t e c n a r a e l c l a c i t r e V e h t m o r f m c 1 6 t e e f 2 f o e c n a t s i d l a t n o z i r o h a n i h t i w l a n i m r e t l a n i m r e t e h t f o e n i l r e t n e c E t i f f o s d e t a l i t n e v n u o t e c n a r a e l C F r e n r o c e d i s t u o o t e c n a r a e l C G r e n r o c e d i s n i o t e c n ...

Page 10: ... 13 7 Extend the vent connector into the chimney so that it is flush with the inside of the flue liner Seal the joint between the pipe and the liner 8 Masonry chimneys serving fireplaces cannot be used for venting purposes unless the fireplace opening is permanently sealed 9 A vent connector serving this appliance must not be connected into any portion of mechanical draft systems operating under p...

Page 11: ...ved Vent System Equivalent vent length PVC ABS single wall galvanized or single wall stainless steel pipe see Table 1 This configuration is for informational purposes and might not exactly reflect your installation Some modifications may be required to accommodate the unit location inlet pipe and building structure The inlet pipe must be free from any obstructions and anticipated snow fall since a...

Page 12: ...furnace to areas outside the space containing the furnace the return air shall be handled by a duct or ducts sealed to the furnace casing Joist and Insulation Soffit Vents Gas Water Heater Gas Furnace Gable Vent 12 Min Attic Must Be Well Ventilated Note Optional Attic Inlet Air Figure 15 and terminated outside the space containing the furnace A return air duct system is recommended If the unit is ...

Page 13: ...ting system must be corrected in accordance with the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition and or the CSA B149 1 Natural Gas and Propane Installa tion Codes 9 After it has been determined that each appliance remaining connected to the venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas fired burning a...

Page 14: ...following instructions and Figure 18 1 Cut a hole in the floor sized to provide 1 clearance between all four sides of the duct and the edge of the flooring The four angles on the base assembly should recess into the floor joists and the base should rest on all four outside flanges 2 Construct duct connections with 1 to 1 3 4 right angle flanges and long enough to extend below the floor joists 3 Dr...

Page 15: ...ce desig nated by an L in the model number such as G1D80BT100D20CL 1A to propane the NOx inserts must be removed Failure to remove the inserts can create a situation where carbon monoxide is produced which may lead to asphyxiation WARNING Any conversion of a natural gas unit to pro pane gas must be done by qualified personnel using a conversion kit available from the manufacturer following the ins...

Page 16: ...d Provide a drip leg on the outside of the furnace A manual shutoff valve shall be installed in the gas line outside the unit 5 above the floor or in accordance with any local codes A test gauge connection must be installed with a 1 8 NPT plugged tapping immediately upstream of the shutoff valve see Figure 22 The furnace must be isolated from the gas supply piping system by closing the individual ...

Page 17: ...n see Figure 23 to desired setting 5 minutes or 10 minutes The furnace will start on 1st stage heat and stay at 1st stage heat for the duration of the selected time before switching to 2nd stage heat W1 on the control board must be connected to W1 on the thermostat Humidifier Terminals are provided on the integrated ignition blower control board for connection to a 120 volt humidifier The HUM term...

Page 18: ... Figure 25 NOTE If a single stage thermostat is used move the automatic heat staging jumper pin see Figure 23 on page 17 from the NONE position to either the 5 or 10 minute setting Connect rest of wiring as shown in Figure 24 or Figure 25 except in this single stage stat configuration the W2 must remain open only W1 should be connected If the red LED on the control board flashes a 9 flash fault co...

Page 19: ...nder water IMPORTANT Refer to the Lighting Instruction label on the furnace for instructions on operating the specific controls used on your unit Be sure the manual gas control has been in the OFF position for at least 5 minutes before starting the unit Do not attempt to manually light the burners CAUTION If you do not follow these instructions exactly a fire or explosion may result causing prop e...

Page 20: ...stat energizes the R Y circuit of the control board After a 1 second cooling on delay the control energizes the cooling fan speed If the fan is already energized it remains running and does not de energize for the 1 second cooling fan on delay The call for cooling has priority over continuous fan operation while a call for heating has priority over both a call for cooling or continuous fan Ignitio...

Page 21: ... flow Inadequate air flow resulting from excessive venting system restriction or a failed combustion blower will cause the switch to remain open G2D80CR and G2D80CT models have two pressure switches Rollout Switch The rollout switch is a normally closed switch that opens when abnormal temperatures exist in the burner area This can be caused by a restricted heat exchanger causing main burner flame ...

Page 22: ...gas input procedure on G1D80BR and G1D80BT models see For Natural Gas on next page G2D80CR and G2D80CT Models G2D80CR and G2D80CT units are equipped for rated input at manifold pressures of 1 7 W C 1st stage and 3 5 W C 2nd stage for natural gas When these model furnaces have been converted for use with propane gas the manifold pressures are 4 9 W C 1st stage and 10 0 W C 2nd stage To measure inle...

Page 23: ... pres sures are within the allowable ranges specified above for the gas being used Be sure to replace the inlet and outlet pressure tap plugs after testing and or adjusting gas input The furnace rate must be within 2 of the appliance rating input CAUTION For Natural Gas Check the furnace rate by observing the gas meter when available making sure all other gas appliances are turned off The test han...

Page 24: ... t f U T B 3 d l o f i n a M e r u s s e r P e r i F w o L C W n i d l o f i n a M e r u s s e r P e r i F h g i H C W n i 0 0 0 2 8 4 9 0 7 1 0 5 3 8 7 2 2 0 9 4 0 0 0 1 6 6 6 9 0 0 0 0 3 4 1 9 0 7 1 0 5 3 6 9 1 2 0 9 4 0 0 0 1 9 9 4 9 0 0 0 0 4 1 8 8 0 7 1 0 5 3 6 1 1 2 0 9 4 0 0 0 1 2 3 3 9 0 0 0 5 4 5 6 8 0 7 1 0 5 3 7 7 0 2 0 9 4 0 0 0 1 9 4 2 9 0 0 0 0 5 9 4 8 1 6 1 9 2 3 9 3 0 2 1 6 4 1 4 9...

Page 25: ...should be cleaned regularly It is important to keep the air filters clean as dirty filters can restrict airflow and the blower and induced draft motors depend upon sufficient air flowing across and through them to keep from overheating Lubrication The blower motor and induced draft motor are pre lubricated by the manufacturer and do not require further lubricating attention However the motors shou...

Page 26: ...ilure Codes Red LED G1D80BR and G1D80BT Models Table 5 D E L s u t a t S n o i t p i r c s e D t l u a F f f O D E L l o r t n o c r o l o r t n o c o t r e w o p o N d e t c e t e d t l u a f e r a w d r a h n O D E L n o i t a r e p o l a m r o N h s a l F 1 f f o e v l a v s a g h t i w t n e s e r p e m a l F s e h s a l F 2 f f o r e c u d n i h t i w d e s o l c h c t i w s e r u s s e r P s...

Page 27: ...nversion Kit G1D80BR and G1D80BT models ALPKT582 Natural Gas to Propane Conversion Kit G2D80CR and G2D80CT models ANGKT557 Propane to Natural Gas Conversion Kit G1D80BR and G1D80BT models ANGKT556 Propane to Natural Gas Conversion Kit G2D80CR and G2D80CT models AMB20A Single Side External Filter AFILT524 Side Return Filter Kit upflow models AFILT525 Return Filter Kit counterflow models AFILT529 Bo...

Page 28: ...C HUM THERMOSTAT SUB BASE HEAT ANTICIPATOR 60 AMP CONDENSER CIRCULATION BLOWER INTERLOCK SWITCH INDUCED DRAFT BLOWER AUX LIMIT LOW VOLTAGE FIELD LOW VOLTAGE FACTORY LINE VOLTAGE FIELD LINE VOLTAGE FACTORY FAULT CODE HISTORY BUTTON SEE NOTE 1 VLT PRESSURE SWITCH IF USED S1 P1 S2 P2 1 HISTORY BUTTON TO DISPLAY FAULT CODES TO ERASE CODES PRESS AND HOLD BUTTON IN FOR MORE THAN 5 SECONDS PRESS AND RELE...

Page 29: ... 45465K005 Page 29 Figure 30 G1D80BT G1D80BR Schematic Diagram P N 45198 006 ...

Page 30: ...CTORY LINE VOLTAGE FIELD LINE VOLTAGE FACTORY SW1 FAULT CODE HISTORY BUTTON SEE NOTE 1 AUTOMATIC HEAT STAGING JUMPER BLOWER OFF DELAY TIMING 180 120 90 60 C NOTES 3 PROPER POLARITY MUST BE OBSERVED FOR FIELD LINE VOLTAGE SUPPLY IGNITION CONTROL WILL LOCK OUT IF POLARITY IS REVERSED 1 PRESS AND RELEASE FAULT CODE HISTORY BUTTON TO DISPLAY FAULT CODES TO ERASE CODES PRESS AND HOLD BUTTON IN FOR MORE...

Page 31: ... 45465K005 Page 31 Figure 32 G2D80CT G2D80CR Wiring Schematic P N 45604 005 ...

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