When you saw the spark in the old breaker, that's the point where your problem was most likely going to be.
Check with the people that installed the AC unit and MAKE SURE that the breaker you bought is the right one for that job.
Most likely, THEY saw an "80" already there and figured it was good enough to handle the load, never taking into account that age and wear will surely rear its ugly heads at the least convenient time for you...down the the road.
Just check to be sure EVERYTHING in that circuit is still functional and won't take the place down or burn the place up...