Ingersoll-Rand A801X026AM2SAA, Service Facts

Page 1: ...that are attached to the equipment June 2019 A A8 80 01 1X X S SF F 1 1A A E EN N Upflow Downflow Horizontal Left Right Gas Fired Single Stage Induced Draft Furnaces with High Efficiency Motor U Up pf fl lo ow w D Do ow wn nf fl lo ow w H Ho or ri iz zo on nt ta al l R Ri ig gh ht t L Le ef ft t Single Stage A801X026AM2SAA A801X040AM3SAA A801X040BM2SAA A801X060BM3SAA A801X060BM4SAA A801X080BM4SAA ...

Page 2: ... t i in n s se er ri io ou us s i in nj ju ur ry y d de ea at th h o or r p pr ro op pe er rt ty y d da am ma ag ge e N Ne ev ve er r t te es st t f fo or r g ga as s l le ea ak ks s w wi it th h a an n o op pe en n f fl la am me e U Us se e a a c co om mm me er rc ci ia al ll ly y a av va ai il la ab bl le e s so oa ap p s so ol lu ut ti io on n m ma ad de e s sp pe ec ci if fi ic ca al ll ly y f...

Page 3: ...do oo or r s sw wi it tc ch h o or r p pa an ne el l l lo oo op p b by y a an ny y p pe er rm ma an ne en nt t m me ea an ns s W WA AR RN NI IN NG G E EL LE EC CT TR RI IC CA AL L S SH HO OC CK K H HA AZ ZA AR RD D F Fa ai il lu ur re e t to o f fo ol ll lo ow w t th hi is s W Wa ar rn ni in ng g c co ou ul ld d r re es su ul lt t i in n p pr ro op pe er rt ty y d da am ma ag ge e s se ev ve er re...

Page 4: ... or r d de ea at th h D Do o n no ot t i in ns st ta al ll l t th he e f fi il lt te er r i in n t th he e r re et tu ur rn n d du uc ct t d di ir re ec ct tl ly y a ab bo ov ve e t th he e f fu ur rn na ac ce e i in n h ho or ri iz zo on nt ta al l a ap pp pl li ic ca at ti io on ns s I In ns st ta al ll l t th he e f fi il lt te er r r re em mo ot te el ly y W WA AR RN NI IN NG G S SA AF FE ET T...

Page 5: ...ow w t th hi is s C Ca au ut ti io on n c co ou ul ld d r re es su ul lt t i in n p pr ro op pe er rt ty y d da am ma ag ge e o or r p pe er rs so on na al l i in nj ju ur ry y I It t i is s r re ec co om mm me en nd de ed d t th ha at t a an n e ex xt te er rn na al l o ov ve er rf fl lo ow w d dr ra ai in n p pa an n b be e i in ns st ta al ll le ed d i in n a al ll l a ap pp pl li ic ca at ti i...

Page 6: ... be et tw we ee en n t th he e s sp pa ac ce e i in n w wh hi ic ch h t th he e a ap pp pl li ia an nc ce e s s c co on nn ne ec ct te ed d t to o t th he e v ve en nt ti in ng g s sy ys st te em m a ar re e l lo oc ca at te ed d A Al ls so o c cl lo os se e f fi ir re ep pl la ac ce e d da am mp pe er rs s T Tu ur rn n o on n c cl lo ot th he es s d dr ry ye er rs s a an nd d a an ny y a ap pp pl...

Page 7: ... Velocity High Vel No Size Thk 1 14x25 1 in 1 14x25 1 in 1 16x25 1 in VENT PIPE DIAMETER Min in e 4 Round 4 Round 4 Round HEAT EXCHANGER Type Aluminized Steel Aluminized Steel Aluminized Steel Gauge Fired 20 20 20 ORIFICES Main Nat Gas Qty Drill Size 2 51 2 45 2 45 GAS VALVE Redundant Single Stage Redundant Single Stage Redundant Single Stage PILOT SAFETY DEVICE Type 120 V SiNi Igniter 120 V SiNi ...

Page 8: ...16x25 1 in 1 16x25 1 in VENT PIPE DIAMETER Min in e 4 Round 4 Round 4 Round HEAT EXCHANGER Type Aluminized Steel Aluminized Steel Aluminized Steel Gauge Fired 20 20 20 ORIFICES Main Nat Gas Qty Drill Size 3 45 3 45 4 45 GAS VALVE Redundant Single Stage Redundant Single Stage Redundant Single Stage PILOT SAFETY DEVICE Type 120 V SiNi Igniter 120 V SiNi Igniter 120 V SiNi Igniter BURNERS QTY 3 3 4 P...

Page 9: ...1 20x25 1 in 1 24x25 1 in VENT PIPE DIAMETER Min in e 4 Round 4 Round 4 Round HEAT EXCHANGER Type Aluminized Steel Aluminized Steel Aluminized Steel Gauge Fired 20 20 20 ORIFICES Main Nat Gas Qty Drill Size 4 45 5 45 6 45 GAS VALVE Redundant Single Stage Redundant Single Stage Redundant Single Stage PILOT SAFETY DEVICE Type 120 V SiNi Igniter 120 V SiNi Igniter 120 V SiNi Igniter BURNERS QTY 4 5 6...

Page 10: ...current use a VOM set to DC volts 1VDC 1 micro amp Flame current will vary depending on the type of meter used Typical flame current ranges from 0 75 3 0 micro amps 0 75 3 VDC 8 Once the flame sense has been established a timer on the IFC starts and the indoor blower will energize after the blower Heat On Delay has completed The seven segment LED for example will alternately read Xt Gas heating tP...

Page 11: ...ectric power supply To clean burners remove burner bottom plate 2 screws and bottom burner bracket 2 screws Twist burner towards slot lift and push forward away from orifice Remove burners Alternate method Remove manifold assembly bottom burner plate and bottom burner bracket Remove burners N No ot te e Be careful NOT to break igniter when removing burners Clean burners with brush and or vacuum cl...

Page 12: ...ACCEPTABLE RANGE IS 0 75 3 MICROAMPS A801X 1 Stage Inducer with CTM Blower Motor INTERNAL THERMAL PROTECTION FP FLAME PROBE IGN HOT SURFACE IGNITER FRS FLAME ROLLOUT SWITCH PS PRESSURE SWITCH RAF REVERSE AIR FLOW GROUND FUSE LC LINE CHOKE ELECTRICAL RATING INPUT 24VAC 60 HZ TNS SEC CURRENT 450MA MV LOAD MV OUTPUT 1 5A 24 VAC IND OUTPUT 2 2 FLA 3 5 LRA 120 VAC IGN OUTPUT 2 0 A 120 VAC CIRC BLOWER O...

Page 13: ...atic Pressure in W C Model Tap 0 1 0 3 0 5 0 7 0 9 A801X040AM3SAA 1 580 34 2 716 471 226 3 743 533 323 113 4 929 742 556 370 183 5 988 831 675 518 361 6 1112 975 839 702 566 7 1174 1046 917 788 659 8 1280 1164 1049 933 817 9 1558 1475 1392 1309 1226 Furnace Airflow CFM Vs External Static Pressure in W C Model Tap 0 1 0 3 0 5 0 7 0 9 A801X040BM2SAA 1 582 2 815 546 277 8 3 872 639 406 172 4 1001 809...

Page 14: ...1 0 3 0 5 0 7 0 9 A801X060BM4SAA 1 707 225 2 870 617 363 110 3 1073 895 716 538 360 4 1264 1126 988 850 713 5 1384 1260 1137 1013 890 6 1422 1304 1186 1069 951 7 1555 1452 1348 1244 1141 8 1658 1559 1460 1361 1262 9 2047 1971 1895 1818 1743 Furnace Airflow CFM Vs External Static Pressure in W C Model Tap 0 1 0 3 0 5 0 7 0 9 A801X080BM4SAA 1 633 297 2 957 800 719 428 213 3 1220 1080 940 800 660 4 1...

Page 15: ...0 7 0 9 A801X100CM5SAA 1 918 438 2 1183 950 716 483 249 3 1709 1546 1383 1220 1057 4 1771 1676 1581 1486 1391 5 1931 1793 1656 1518 1380 6 2028 1898 1768 1638 1508 7 2177 2057 1938 1818 1699 8 2351 2246 2141 2036 1931 9 2609 2522 2434 2347 2260 Furnace Airflow CFM Vs External Static Pressure in W C Model Tap 0 1 0 3 0 5 0 7 0 9 A801X120DM5SAA 1 857 416 2 1282 1043 804 565 326 3 1596 1426 1255 1085...

Page 16: ...000 2100 2200 2300 2400 A801X026AM2SAA 48 39 32 A801X040AM3SAA 59 49 42 37 33 30 27 A801X040BM2SAA 59 49 42 37 33 30 27 A801X060BM3SAA 56 49 44 40 37 34 32 A801X060BM4SAA 56 49 44 40 37 34 32 A801X080BM4SAA 59 54 49 46 42 40 37 35 33 A801X080CM4SAA 59 54 49 46 42 40 37 35 33 A801X100CM5SAA 57 53 49 46 44 41 39 37 35 34 32 31 A801X120DM5SAA 59 56 52 49 47 44 42 40 39 37 ...

Page 17: ... key and then depress the OPTION key to the desired setting Then momentarily depress the MENU key again to save the change 180 C1 7 C1 1 C1 2 C1 3 C1 4 HtP Heating Speed Tap H1 5 H1 1 01 H1 2 H1 6 H1 3 Example Single Stage SELECTING GAS HEAT FAN SPEEDS Airflow can be adjusted while the unit is running Scroll to the HTP menu and momentarily push the OPTION key Tap 5 is the default setting for all m...

Page 18: ...enu key then push the op on key The LED will flash three mes then begin the test To exit the test mode momentarily push the Menu key cycle power to the furnace or make a valid thermostat call for capacity or fan Sequence of Run Test Mode Turns the inducer on in 1st stage for 30 seconds Not applicable Turns the ignitor on for 10 seconds Turns the circula ng blower on 1st stage compressor speed for ...

Page 19: ...sing and wheel removed from view for clarity Furnace Model Dimension A inches A026 3 5 3 1 2 A040 3 75 3 3 4 B040 3 5 3 1 2 B060 3 ton 3 75 3 3 4 B060 4 ton 4 25 4 1 4 B080 4 25 4 1 4 2 375 A Blower housing and wheel removed from view for clarity Furnace Model Dimension A inches C080 4 125 4 1 8 C100 4 125 4 1 8 D120 4 125 4 1 8 ...

Page 20: ...rty damage including death Troubleshoo ng Flowchart Index IFC Component Layout Ge ng Started Error Codes E2 1 Retries Exceeded flame never sensed E2 2 Recycles Exceeded loss of flame a er being sensed E3 1 Shorted Pressure Switch E3 2 Open Pressure Switch E04 Open Thermal Limit E04 Flame Rollout E05 Flame Detected should not be present E6 1 Reversed Polarity High Voltage E6 2 Faulty Ground E6 3 Ig...

Page 21: ...U and OPTION Select Buttons 5 Amp Fuse Flame Current FP HLI W R G B C Y Y1 Inducer Igniter Connector IGN N IND N IND H IGN H MV GND TH MVC HLO PS1 TR ILI 6 Pin CTM Motor Connector Tap 1 Low Speed Tap 2 Tap 3 Tap 4 Tap 5 High Speed Common 6 Pin CTM Connector A801X IFC Component Layout T Tr ro ou ub bl le es sh ho oo ot ti in ng g ...

Page 22: ... VAC measured at transformer NO Is 120 VAC measured between Line and Neutral at the IFC NO Is 120 VAC measured between Line and Neutral at J box NO Verify Panel Loop is connected YES Repair high voltage NO Is 24 VAC measured at transformer YES Replace Xfmr NO YES Is 24 VAC measured at TH and TR at IFC Repair wiring NO Replace IFC YES YES E01 Fault Code DEFINITION Internal Failure of the Control Bo...

Page 23: ...gas pressure connector Is inlet gas pressure above 13 8 WC or less than nameplate minimum NO Correct inlet gas pressure Maximum pressure is 13 8 WC Check opera on YES There are two flame sense pads located on the IFC marked FP To measure flame current use a VOM set to DC volts Flame current will vary depending on the type of meter used Typical flame current ranges from 0 75 3 0 micro amps 0 75 3 0...

Page 24: ...lectrical power to furnace Connect manometer to manifold pressure connector NO YES NO Disconnect electrical power to furnace Connect manometer to inlet gas pressure connector Cycle power to furnace and call for 1st stage heat Is minimum outlet gas manifold pressure maintained Correct incoming gas supply pressure NO YES Possible Causes Dirty Sensor Dirty burners Poor grounding Sensor loca on Wire c...

Page 25: ...itch is closed when it should be open In most cases the pressure switch is not the problem If winds are in excess of 15mph a 90 degree elbow may be required to inhibit the switch from closing NOTE Verify pressure switch wiring and tube rou ng are correct 3 1 Fault Code Cycle power to the furnace and call for heat NO Replace pressure switch Verify wiring If correct replace IFC YES T Tr ro ou ub bl ...

Page 26: ...e switch wiring and tube rou ng are correct Note 2 Measured pressure is nega ve greater than refers to magnitude only 3 2 Fault Code NO Cycle power to the furnace and call for 1st stage heat NO Possible Causes Verify PS hose s is connected and that flue piping has no obstruc on NO NO Is 120VAC measured from RD to WH on the inducer motor within 60 seconds of the W1 call Replace inducer assembly YES...

Page 27: ...O Increase blower off delay YES DEFINITION Limit switches are safety devices that will open when an abnormal high temperature has been sensed REMOVE ALL JUMPER WIRING TO SWITCHES Under no circumstances shall these switches be le jumpered when not troubleshoo ng Verify filters and blower wheels are clean Make sure any temperature measuring devices thermocouples dial thermometers used to es mate lim...

Page 28: ...n comes on do flames stay consistent Replace heat exchanger Check opera on NO Replace Roll out switch Check opera on YES DEFINITION Limit switches are safety devices that will open when an abnormal high temperature has been sensed REMOVE ALL JUMPER WIRING TO SWITCHES Under no circumstances shall these switches be le jumpered when not troubleshoo ng YES Are all burner flames directed into heat exch...

Page 29: ...ode and Installa on Instruc ons YES NO Disconnect power to unit Turn off gas supply Remove gas valve 05 Fault Code Is flame current measured across FS pads YES Is flame seen with no call for heat YES Replace IFC NO NO Possible Causes Flame sense wire shorted to ground Flame sensor is grounded NO There are two flame sense pads located on the IFC marked FP To measure flame current use a VOM set to D...

Page 30: ...l and ground problem Furnace must be on a dedicated circuit YES 6 1 Fault Code DEFINITION Ground Fault Incoming or chassis ground connec on is not sensed Connect volt meter to black incoming and chassis ground at burner box Does meter read 120 vac Disconnect incoming electrical power to furnace NO Correct earth ground Check opera on Check correct all ground connec ons within furnace for con nuity ...

Page 31: ...ctors are ght Disconnect igniter and check resistance Is resistance reading between 37 70 ohms at 75F NO Replace ignitor Check opera on YES 6 3 Fault Code Igniter is good Does igniter glow Make a call for heat Igniter is good Replace IFC igniter relay has failed YES YES YES YES Is 120 VAC measured between IGN H and IGN N Replace IFC igniter relay has failed NO Disconnect electrical power to the fu...

Page 32: ...present when it should not be present Is 24 VAC nominal voltage present between Red lead at gas valve connec on to chassis ground Turn Comfort Control to OFF posi on Correct wiring Check opera on YES Replace IFC NO 7 1 Fault Code T Tr ro ou ub bl le es sh ho oo ot ti in ng g ...

Page 33: ...orrectly See figure YES YES Correct flame sensor loca on NO Flame sensor is good Check wiring and or connec ons NO 08 Fault Code Make a call for hea ng 442 REF 1 470 REF Flame Sensor 385 REF 585 REF 1 586 REF 239 REF There are two flame sense pads located on the IFC marked FP To measure flame current use a VOM set to DC volts Flame current will vary depending on the type of meter used Typical flam...

Page 34: ...C measured across the fuse terminals Replace fuse Is fuse fully seated into connector NO Properly seat the fuse NO Replace IFC YES Start unit and measure amp draw on transformer 24VAC red wire Is amp draw less than 5 amps Correct low voltage wiring NO Turn on each accessory if installed and measure amp draw If amp draw exceeds fuse ra ng correct wiring associated with that accessory YES T Tr ro ou...

Page 35: ...is unit is limited to TAP 1 only No field adjustment can be made If troubleshoo ng other speed taps use the method as outlined below using the voltages listed for the tap number being used A801X CTM Output Voltage BK W2 W1 R G B C Y2 Y1 O 6 Pin CTM Motor Connector Tap 1 Low Speed Tap 2 Tap 3 Tap 4 Tap 5 High Speed Common 6 Pin CTM Connector 3 2 1 C 5 4 CONTROL CONNECTION POWER CONNECTION L G N 3 2...

Page 36: ...A EN Part List Igniter Flame Sensor In shot Burner s Gas Valve Inducer Assembly Blower Motor Blower Wheel IFC Integrated Furnace Control Pressure Switch es Main Thermal Limit Roll Out Switch es Reverse Air Switch es ...

Page 37: ...A801X SF 1A EN 37 N No ot te es s ...

Page 38: ...38 A801X SF 1A EN N No ot te es s ...

Page 39: ...A801X SF 1A EN 39 N No ot te es s ...

Page 40: ...transport and protect food and perishables and increase industrial productivity and efficiency We are a global business committed to a world of sustainable progress and enduring results ingersollrand com Ingersoll Rand has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice We are committed to using environmentally ...