INSTALLATION INSTRUCTIONS A95DF, A93DF, 95G1DF & 92G1DF Warm Air Gas Furnace / Downflow 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. WARNING CAUTION Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
UNIT DIMENSIONS − inches (mm) 9/16 (14) COMBUSTION AIR INTAKE Return Air Opening B EXHAUST AIR OUTLET 2−1/16 (52) 5 (127) 9/16 (14) 2−1/4 (57) TOP VIEW 27−3/4 (705) 1 (25) Front Panel AIR 19−7/16 (494) 9/16 (14) FLOW ELECTRICAL INLET (Either Side) 33 (838) 2 (51) Either Side CONDENSATE TRAP CONNECTION (Either Side) GAS PIPING INLET (Either Side) 9−1/8 (232) Right 6−9/16 (167) Left 3/4 (19) C Supply 6−1/2 (165) Either Side 3/4 (19) Air Model Number A95DF/A93DF 95G1DF/92G1DF 9 (229)
PARTS ARRANGEMENT CONTROL BOX (Includes integrated control, transformer and door switch) BAG ASSEMBLY BLOWER MOTOR (hidden) BLOWER COMPARTMENT ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK PRIMARY LIMIT HEATING COMPARTMENT ACCESS PANEL COLD END HEADER BOX HEAT EXCHANGER GAS VALVE BURNER BOX ASSEMBLY (includes flame sensor, rollout switches and ignitor) FIGURE 1 506725-01 Issue 1109 Page 3 of 48
Gas Furnace This Category IV gas furnace is shipped ready for installation in the downflow position. Safety Information WARNING The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
Locations and Clearances This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the table in Figure 11. Accessibility and service clearances must take precedence over fire protection clearances. Heating Unit Installed Parallell to Air Handler Unit NOTE: When furnace is installed on a combustible floor, a downflow combustible flooring base must be installed between the furnace and the floor.
• • • • • 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. Temporary ducting may supply outdoor air to the furnace. Do not connect duct directly to the furnace. Size the temporary duct following the instructions in section for Combustion, Dilution and Ventilation Air in a confined space with air from outside.
air is brought into the house for combustion, negative pressure (outside pressure is greater than inside pressure) will build to the point that a down draft can occur in the furnace vent pipe or chimney. As a result, combustion gases enter the living space creating a potentially dangerous situation. In the absence of local codes concerning air for combustion and ventilation, use the guidelines and procedures in this section to install these furnaces to ensure efficient and safe operation.
Air from Outside If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent openings. One opening shall be within 12” (305 mm) of the top of the enclosure and one within 12” (305 mm) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts.
INSTALLATION – Setting Equipment NOTE: These units may be equipped with a shipping pad under the blower housing. Remove the shipping pad prior to operation. WARNING Do not install the furnace on its front, back or in the horizontal position. See Figure 10. Do no 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.
Installation on Non-Combustible Flooring (Figure 12) 1. Cut floor opening keeping in mind clearances listed on unit rating plate. Also keep in mind gas supply connections, electrical supply, flue and air intake connections and sufficient installation and servicing clearances. See Table 1 for correct floor opening size. 2. Flange warm air plenum and lower the plenum into the opening. 3. Set the unit over the plenum and seal the plenum to the unit. 4. Ensure that the seal is adequate.
COMBUSTIBLE FLOORING BASE OPENING SIZE Cabinet Width Catalog Number B Cabinet (17.5") C Cabinet (21") Front to Rear Side to Side in. mm in. mm 11M60 22 559 18 − 3/4 476 11M61 22 559 22 − 3/4 578 FURNACE COOLING COIL TABLE 2 PROPERLY SIZED FLOOR OPENING PLENUM FURNACE SUPPLY AIR PLENUM PROPERLY SIZED FLOOR OPENING COMBUSTIBLE FLOORING BASE FIGURE 14 FIGURE 13 2. After opening is cut, set the combustible flooring base into opening. 3.
Filters This unit is not equipped with a filter or rack. A field provided filter is required for the unit to operate properly. Table 3 lists recommended filter sizes. A filter must be in place whenever the unit is operating. Furnace Cabinet Width Filter Size 17−1/2" 16 x 25 x 1 (1) Pipe & Fittings Specifications All pipe, fittings, primer and solvent cement must conform with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM) standards.
vent pipe hangers. Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket. IMPORTANT The exhaust and intake connections are made of PVC. Use PVC primer and solvent cement when using PVC vent pipe. When using ABS vent pipe, use transitional solvent cement to make connections to the PVC fitting in the unit.
Joint Cementing Procedure All cementing of joints should be done according to the specifications outlined in ASTM D 2855. Venting Practices Piping Suspension Guidelines NOTE: A sheet metal screw may be used to secure the intake pipe to the connector, if desired. Use a drill or self tapping screw to make a pilot hole. SCHEDULE 40 PVC − 5’ all other pipe* − 3’ DANGER * See Table 4 for allowable pipe.
1. In areas where piping penetrates joist or interior walls, hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger. 2. When furnace is installed in a residence where unit is shut down for an extended period of time, such as a vacation home, make provisions for draining condensate collection trap and lines. Use the following steps to correctly size vent pipe diameter. Exhaust Piping (Figure 20) Route piping to outside of structure.
A95DF / 95G1DF and A93DF / 92G1DF Maximum Allowable Intake or Exhaust Vent Length in Feet *Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size. Standard Termination at Elevation 0 − 10,000 ft.
TYPICAL EXHAUST PIPE CONNECTIONS Pipe size determined in Table 7. 2” 2” 2” 2” 2” or 3” TRANSITION *2” DO NOT transition from smaller to larger pipe size in horizontal runs of exhaust pipe. INTAKE EXHAUST TOP VIEW * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE: Exhaust pipe and intake pipe must be the same diameter. FIGURE 20 TYPICAL INTAKE PIPE CONNECTIONS (DIRECT VENT APPLICATIONS) Pipe size determined in Table 7.
Intake Piping This furnace may be installed in either direct vent or nondirect vent applications. In non-direct vent applications, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered. Guidelines listed in Combustion, Dilution and Ventilation Air section must be followed. Follow the next two steps when installing the unit in Direct Vent applications, where combustion air is taken from outdoors and flue gases are discharged outdoors.
VENT TERMINATION CLEARANCES FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL G H A D E B L Fixed Closed Operable Fixed Closed Operable F B B C I M B K J A B AREA WHERE TERMINAL IS NOT PERMITTED AIR SUPPLY INLET VENT TERMINAL US Installations A= Clearance above grade, veranda, porch, deck or balcony B= Clearance to window or door that may be opened C= Clearance to permanently closed window D= Vertical clearance to ventilated soffit located above the term
VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL G H A D E B L I Fixed Closed Operable Fixed Closed Operable F B B C M B K J A B US Installations A= Clearance above grade, veranda, porch, deck or balcony B= Clearance to window or door that may be opened C= Clearance to permanently closed window D= Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (mm) from the center line of t
Details of Intake and Exhaust Piping Terminations for Direct Vent Installations DIRECT VENT ROOF TERMINATION KIT (15F75 or 44J41) Inches(mm) NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors. NOTE: Flue gas may be slightly acidic and may adversely affect some building materials.
B B D D C Intake C 3 1 Front View of Intake and Exhaust A Exhaust A 2 Intake Exhaust D TABLE 9 1 E 2" (51mm) Vent Pipe B A − Clearance above grade or average snow accumulation 12" C 2 A B −Horizontal separation between intake and exhaust C −Minimum from end of exhaust to inlet of intake D−Exhaust pipe length E −Wall support distance from top of each pipe (intake/exhaust) 3" (76mm) Vent Pipe 12" (508MM) Min. 12" (508MM) Min. 6" (152MM) Min. 24" (610 MM) Max 6" (152MM) Min.
FIELD SUPPLIED WALL TERMINATION FIELD SUPPLIED WALL TERMINATION NOTE − FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION NOTE − FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1/2" (13mm) ARMAFLEX INSULATION IN UNCONDITIONED SPACE (IF REQUIRED) 1/2" (13mm) ARMAFLEX INSULATION IN UNCONDITIONED SPACE (IF REQUIRED) SIZE TERMINATION PER TABLE 8 SIZE TERMINATION PER TABLE 8 D D B C B STRAIGHT APPPLICATION A A 1/2" (13mm) ARMAF
DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada) OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT 1 1/2" (38mm) accelerator provided on 71M80 & 44W92 EXHAUST VENT 12” (305mm) INTAKE AIR Minimum Above Average Snow Accumulation EXHAUST VENT 12" (305mm) 5−1/2" (140mm) 5" (127mm) INTAKE AIR FLASHING (Not Furnished) 18" MAX.
Details of Exhaust Piping Terminations for Non-Direct Vent Applications Exhaust pipe may be routed either horizontally through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof is preferred. Figures 34 through 37 show typical terminations. 1. Exhaust piping must terminate straight out or up as shown. The termination pipe must be sized as listed in Table 8.
Condensate Piping This unit is designed for either right or left side exit of condensate piping in downflow applications. Refer to Figure 38 for condensate trap locations. NOTE: If necessary the condensate trap may be installed up to 5” away using PVC pipe from the furnace. Piping from furnace must slope down a minimum of 1/4” per ft. toward trap. Condensate line must slope downward away from the trap to drain. If drain level is above condensate trap, condensate pump must be used.
TRAP / DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC OPTIONAL Condensate Drain Connection Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Vent 90° Street Elbow 1/2 inch PVC (Not Furnished) 1 (25) Minimum Condensate Drain Connection In Unit 5 Feet Maximum Above Top of Condensate Drain Connection In Unit 90° Elbow 1/2 inch PVC (Not Furnished) Condensate Drain Connection In Unit OPTIONAL Drain Piping 1/2 inch PVC Pipe (Not Furnished) 1/2 inch PV
Gas Piping IMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petroleum gases. CAUTION If a flexible gas connector is required or allowed by the authority that thas jurisdiction, black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet. The flexible connector can then be added between the black iron pipe and the gas supply line.
Left Side Piping (Standard) MANUAL MAIN SHUT−OFF VALVE (With 1/8 in. NPT Plugged Tap Shown) AUTOMATIC GAS VALVE (with manual shut−off valve) MANUAL MAIN SHUT−OFF VALVE (With 1/8 in.
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.
Electrical ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures CAUTION Electrostatic discharge can affect electronic components. Take precautions during furnace installation and service to protect the furnace’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the furnace, the control and the technician at the same electrostatic potential.
One line voltage “HUM” 1/4” spade terminal is provided on the furnace control board. Any humidifier rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. If a humidifier rated at greater than one amp is connected to this terminal, it is necessary to use an external relay. See Figure 49 for control board configuration. This terminal is energized in the heating mode when the combustion air inducer is operating.
TYPICAL WIRING DIAGRAM FIGURE 48 506725-01 Issue 1109 Page 33 of 48
INTEGRATED CONTROL (Automatic Hot Surface Ignition System) DIAGNOSTIC CODE RECALL BUTTON HEAT BLOWER OFF DELAY JUMPER TERMINAL DESIGNATIONS Humidifier (120 VAC) HUM Input (120 VAC) L1 Transformer (120 VAC) XFMR Blower - Continuous Fan (120 VAC) CONT Electronic Air Cleaner (120 VAC) EAC Blower - Cooling Speed (120 VAC) COOL Blower - Heating Speed (120 VAC) HEAT Dead terminals to park alternate spd taps PARK NEUTRALS Neutral terminals (120 VAC) 5 AMP FUSE FIGURE 49 Unit Start-Up FOR YOUR SAFETY READ BEF
Priming Condensate Trap The condensate trap should be primed with water prior to start-up to ensure proper condensate drainage. Either pour 10 fl. oz. (300 ml) of water into the trap, or follow these steps to prime the trap: 1. Follow the lighting instructions to place the unit into operation. 2. Set the thermostat to initiate a heating demand. 3. Allow the burners to fire for approximately 3 minutes. 4. Adjust the thermostat to deactivate the heating demand. 5. Wait for the combustion air inducer to stop.
Gas Pressure Adjustment Gas Flow (Approximate) GAS METER CLOCKING CHART Seconds for One Revolution Natural LP Unit 1 cu ft 2 cu ft 1 cu ft 2 cu ft Dial Dial Dial DIAL −045 80 160 200 400 −070 55 110 136 272 −090 41 82 102 204 −110 33 66 82 164 −135 27 54 68 136 Natural−1000 btu/cu ft Supply Line and Manifold Pressure (inches w.c.) Unit Fuel Manifold Pressure Line Pressure All Nat. Gas 3.5 4.5 − 10.5 All L.P. Gas 10.0 11.0 − 13.0 TABLE 12 NOTE: A natural to L.P.
Burner Orifice Conversion Kits at Varying Altitudes 0 - 7,500 ft (0 - 2,286 m) 7,501 - 10,000 ft (2,286 - 3,038 m) Unit Size Natural to LP/Propane LP/Propane to Natural High Altitude Natural Burner Orifice Kit High Altitude LP/Propane Burner Orifice Kit All 68W75*† 73W80* 51W01 68W70*† * Conversion requires installation of a gas valve regulator spring which is provided with the gas conversion kit. † LP kit includes low line pressure switch.
Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation.
Other Unit Adjustments Primary Limit The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no adjustment. Flame Rollout Switches (Two) These manually reset switches are located on the front of the burner box. These limits are factory set and require no adjustment. Pressure Switch The pressure switch is located in the heating compartment on the cold end header box.
BLOWER DATA A93DF1D / 92G1DF A93DF1D / 92G1DF 045*12B PERFORMANCE (Less Filter) External Static Pressure in. w.g. Air Volume / Watts at Various Blower Speeds High MediumHigh MediumLow Low cfm Watts cfm Watts cfm Watts cfm Watts A93DF1D / 92G1DF 090*16C PERFORMANCE (Less Filter) External Static Pressure in. w.g. Air Volume / Watts at Various Blower Speeds High MediumHigh MediumLow Low cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1615 650 1385 555 1205 465 1045 390 0.
BLOWER DATA A95DF1D / 95G1DF A95DF1D / 95G1DF 045*12B PERFORMANCE (Less Filter) External Static Pressure in. w.g. Air Volume / Watts at Various Blower Speeds High MediumHigh MediumLow Low cfm Watts cfm Watts cfm Watts cfm Watts A95DF1D / 95G1DF 090*20C PERFORMANCE (Less Filter) External Static Pressure in. w.g. High MediumHigh MediumLow Low cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1615 650 1385 555 1205 465 1045 390 0.10 1605 640 1380 545 1195 455 1035 380 0.
Winterizing and Condensate Trap Care 1. Turn off power to the furnace. 2. Have a shallow pan ready to empty condensate water. 3. Remove the clean out cap from the condensate trap and empty water. Inspect the trap then reinstall the clean out cap. Service WARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage.
19. Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting on the support located at the rear of the cabinet. Remove the indoor blower to view this area through the blower opening. 20. Resecure the supporting screws along the vestibule sides and bottom to the cabinet. Reinstall blower and mounting screws. 21. Reinstall cabinet screws on front flange at blower deck. 22. Reinstall the primary limit on the vestibule panel. 23.
Planned Service A service technician should check the following items during an annual inspection. Power to the unit must be shut off for safety. DIAGNOSTIC CODES 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. Burners - Must be inspected for rust, dirt, or signs of water. Vent pipe - Must be inspected for signs of water, cracked, damaged or sagging pipe, or disconnected joints.
REPAIR PARTS LIST The following repair parts are available through Allied Air dealers. When ordering parts, include the complete furnace model number listed on the CSA nameplate. Example: A93DF045P36B-01. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.
Start−Up & Performance Check List UNIT SET UP Furnace: Model Number_______________ Serial Number_________________ Line Voltage SUPPLY AIR 2 4 1 GAS SUPPLY LP Propane Gas Natural Gas 3 Piping Connections Tight Leak Tested Flter 2 RETURN AIR 1 Gas Supply Pressure 3 1 DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated (if necessary) 2 RETURN DUCT INTAKE / EXHAUST PIPE Sealed All Joints Primed and Glued Filter Installed and Clean Terminations Installed Properly Grilles Unobstructed Horizontal Pip
UNIT OPERATION HEATING MODE COOLING MODE 1 GAS MANIFOLD PRESSURE “W.C.
REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS Modifications to NFPA-54, Chapter 10 Revise NFPA-54 section 10.8.