INSTALLATION INSTRUCTIONS A95DF2E & 95G2DFE Warm Air Gas Furnace / Downflow Air Discharge Direct Vent & Non-Direct Vent 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 WARNING As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges.
Unit Dimensions Model A95UH2E/95G2UHE 045-12 070-16 090-20 110-20 Page 2 of 53 A B C in. mm in. mm in.
Parts Arrangement Figure 1.
Gas Furnace Shipping and Packing List This Category IV gas furnace is shipped ready for installation in the downflow position. Package 1 of 1 contains: The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in LP/propane gas applications. 1 - Bag assembly containing the following: 1 - Assembled Gas Unit 1 - Snap bushing 1 - Snap Plug This unit can be installed as either a Direct Vent or a Non-Direct Vent gas central furnace.
Use only the type of gas approved for use with this furnace. Refer to unit nameplate. This unit is CSA International certified to ANSI Z21.47 and CSA 2.3 standards. Building Codes In the USA, installation of gas furnaces must conform with local building codes. In the absence of local codes, units must be installed according to the current National Fuel Gas Code (ANSI Z223.1/NFPA 54). The National Fuel Gas Code is available from the American National Standards Institute, Inc.
Use of Furnace as Construction Heater General WARNING These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation. Gas furnaces manufactured on or after May 1, 2017, are not permitted to be used in Canada for heating of buildings or structures under construction. The following statement only applies to the US.
Combustion, Dilution & Ventilation Air If this unit is installed as a Non-Direct Vent Furnace, follow the guidelines in this section. NOTE: In Non-Direct Vent Installations, combustion air is taken from indoors and flue gases are discharged outdoors. the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This reprinted material is not the complete and official position of ANSI on the referenced subject, which is represented only by the standard in its entirely.
When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air must be handled by ducts which are sealed to the furnace casing and which terminate outside the space containing the furnace. This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room.
Roof Terminated Exhaust Pipe Ventilation Louvers (Crawl space) Inlet Air (Minimum 12 in.(305mm) Above crawl space floor) Furnace Coupling or 3 in. to 2 in. Transition (Field Provided) Figure 7. Equipment in Confined Space - All Air from Outside (All Air Through Ventilated Attic) *Intake Debris Screen Provided) * See Maximum Vent Lengths table NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm2 per 1.
Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in Figure 14. Units with 1/2 HP Blower Motor Figure 11. WARNING Blower access panel must be securely in place when blower and burners are operating. Gas fumes, which could contain carbon monoxide, can be drawn into living space resulting in personal injury or death. WARNING Improper installation of the furnace can result in personal injury or death.
Installation on Non-Combustible Flooring 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.
Return Air Opening - Downflow Units Return air may be brought in only through the top opening of a furnace installed in the downflow position. The following steps should be taken when installing plenum: 1. Bottom edge of plenum should be flanged with a hemmed edge (See Figure 18 or Figure 19). 2. Sealing strips should be used to ensure an airtight seal between the cabinet and the plenum. 3. In all cases, plenum should be secured to top of furnace using sheet metal screws. 4.
PVC, or CPVC pipe when using fittings and pipe made of the same materials. Use transition solvent cement when bonding ABS to either PVC or CPVC. CAUTION Solvent cements for plastic pipe are flammable liquids and should be kept away from all sources of ignition. Do not use excessive amounts of solvent cement when making joints. Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors. Avoid contact of cement with skin and eyes.
Joint Cementing Procedure Piping and Fittings Specifications Schedule 40 PVC (Pipe) Schedule 40 PVC (Cellular Core Pipe) Schedule 40 PVC (Fittings) Schedule 40 CPVC (Pipe) Schedule 40 CPVC (Fittings) SDR-21 PVC or SDR-26 PVC (Pipe) SDR-21 CPVC or SDR-26 CPVC (Pipe) Schedule 40 ABS Cellular Core DWV (Pipe) Schedule 40 ABS (Pipe) Schedule 40 ABS (Fittings) ABS-DWV (Drain Waste & Vent) (Pipe & Fittings) PVC-DWV (Drain Waste & Vent) (Pipe & Fittings) Primer & Solvent Cement PVC & CPVC Primer PVC Solvent Cement
restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. Venting Practices 3. Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn ON clothes dryers and any appliances not connected to the common venting system. Turn ON any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed.
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.
Maximum Allowable Intake or Exhaust Vent Length (feet) Standard Termination at Elevation 0 - 4,500 ft Number of 90° Elbows Used 2” Pipe 2-1/2” Pipe 3” Pipe Modal Model Model 45 70 90 110 45 70 90 110 45 70 90 110 1 66 51 29 9 100 100 78 43 123 122 103 103 2 61 46 24 95 95 73 38 118 117 98 98 3 56 41 19 90 90 68 33 113 112 93 93 4 51 36 14 85 85 63 28 108 107 88 88 5 46 31 9 80 80 58 23 103 102 83 83 6 41 26 75 75 53 18 98
Maximum Allowable Intake or Exhaust Vent Length (feet) Concentric Termination at Elevation 0 - 4,500 ft Number of 90° Elbows Used 2” Pipe 2-1/2” Pipe 3” Pipe Modal Model Model 45 70 90 110 45 70 90 110 45 70 90 110 1 58 43 27 7 90 90 74 39 106 106 99 99 2 53 38 22 85 85 69 34 101 101 94 94 3 48 33 17 80 80 64 29 96 96 89 89 4 43 28 12 75 75 59 24 91 91 84 84 5 38 23 7 70 70 54 19 86 86 79 79 6 33 18 65 65 49 14 81 81 74
Maximum Allowable Exhaust Vent Lengths Using Ventilated Attic or Crawl Space for Intake Air in Feet Standard Termination at Elevation 0 - 10,000 ft Number of 90° Elbows Used 2” Pipe 2-1/2” Pipe 3” Pipe Model Model Model 45 70 90 1 56 41 2 51 3 45 70 90 110 45 70 90 110 24 85 85 63 28 103 102 83 83 36 19 80 80 58 23 98 97 78 78 46 31 14 75 75 53 18 93 92 73 73 4 41 26 9 70 70 48 13 88 87 68 68 5 36 21 4 65 65 43 8 83 82 63 63 6 31
Figure 23. Typical Exhaust Pipe Connections Figure 24.
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.
At vent termination, care must be taken to maintain protective coatings over building materials (prolonged exposure to exhaust condensate can destroy protective coatings). It is recommended that the exhaust outlet not be located within 6 feet (1.8 m) of a condensing unit because the condensate can damage the painted coating. runs of exhaust pipe should be painted or wrapped to protect insulation from deterioration in accordance with the insulation manufacturers recommendation.
VENT TERMINATION CLEARANCES FOR NON-DIRECT VENT INSTALLATIONS IN THE US AND CANADA INSIDE CORNER DETAIL G H A D E B L Fixed Closed Operable F B B C B K AREA WHERE TERMINAL IS NOT PERMITTED AIR SUPPLY INLET VENT TERMINAL M J A B I Fixed Closed Operable US Installations1 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 ter
VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL G H A D E B L Fixed Closed Operable F B B C Operable B A B M K J AREA WHERE TERMINAL IS NOT PERMITTED AIR SUPPLY INLET VENT TERMINAL I Fixed Closed US Installations1 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
Details of Intake and Exhaust Piping Terminations for Direct Vent Installations 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. If any vent termination is used and the flue gases may impinge on the building material, a corrosion-resistant shield (minimum 24 inches square) must be used to protect the wall surface.
Figure 33. Flush Mount Side Wall Termination Figure 35. Direct Vent Concentric Wall Termination 6. On field supplied terminations, a minimum distance between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8” and a minimum distance of 6” with a termination elbow. See Figure 38. 7. If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported every 24” (610 mm) as shown in Figure 38.
FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 2” (51mm) 3” (76mm) Vent Pipe Vent Pipe D D B C1 A B Intake Elbow C2 A STRAIGHT APPPLICATION * WALL SUPPORT D E D E B B A C1 EXTENDED APPLICATION A C2 A− Minimum clearance above grade or average snow accumulation 12” (305 mm) 12” (305 mm) B− Maximum horizontal separation between intake and exhaust 6” (152 mm) 6” (152 mm) C1 -Minimum from end of exhaust t
Details of Exhaust Piping Terminations for NonDirect 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. Figure 39 through Figure 42 show typical terminations. 1. Exhaust piping must terminate straight out or up as shown. The termination pipe must be sized as listed in Table 9.
Exhaust through Crawl Space Vent Option All 33” condensing gas furnaces (92%+) are now approved to be vented down through a crawl space. Ensure a vent pipe drain kit, 51W18 (USA) or 15Z70 (Canada), is used as directed through the floor joists and into the crawl space. See the following figures. Exhaust from Furnace To Termination Consult the vent tables for vent lengths and approved materials.
Condensate Piping This unit is designed for either right or left side exit of condensate piping in downflow applications. Refer to Figure 46 for condensate trap locations. NOTE: Vinyl tubing may be used for condensate drain. Tubing must be 1-1/4” OD x 1” ID and should be attached to the drain on the trap using a hose clamp. 5. NOTE: If necessary the condensate trap may be installed up to 5 feet away using PVC pipe from the furnace. Piping from furnace must slope down a minimum of 1/4” per ft. toward trap.
Figure 49. Evaporator Coil Using a Common Drain Figure 48. Evaporator Coil Using a Separate Drain CAUTION Do Not use copper tubing or existing copper condensate lines for drain line. CAUTION When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly. Figure 50.
Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 90° Street Elbow 3/4 inch PVC ( furnished) 1 (25 mm) Min. 2 (50 mm) Max.
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 has 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.
Figure 53. Gas Pipe Capacity - FT³/HR (kL/HR) Nominal Iron Pipe Size inches (mm) Internal Diameter - inches (mm) Length or Pipe - feet (m) 10 20 30 (3.048) (6.096) (9.144) 40 50 60 70 80 90 100 (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) 1/2 .622 175 120 97 82 73 66 61 57 53 50 (12.7) (17.799) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42) 3/4 .824 360 250 200 170 151 138 125 118 110 103 (19.05) (20.930) (10.
1. Electrical ELECTROSTATIC DISCHARGE (ESD) The power supply wiring must meet Class I restrictions. Protected by either a fuse or circuit breaker, select circuit protection and wire size according to unit nameplate. NOTE: Unit nameplate states maximum current draw. Maximum over current protection allowed is shown in Table 11. Precautions and Procedures CAUTION Electrostatic discharge can affect electronic components.
9. Install the room thermostat according to the instructions provided with the thermostat. If the furnace is being matched with a heat pump, refer to the instruction packaged with the dual fuel thermostat. Indoor Blower Speeds 1. When the thermostat is set to “FAN ON,” the indoor blower will run continuously on the field selectable fan speed (“LOW HEAT” is default) when there is no cooling or heating demand. 2.
Thermostat Install a room thermostat according to the instructions furnished with it. Select a location on an inside wall that is not subject to drafts, direct sunshine, or other heat sources. The initial heat anticipator setting should be equal to the total current draw of the control circuit. Low voltage thermostat connections are to be made to the integrated ignition/blower control board as indicated on the wiring diagram.
Figure 56.
3/16” QUICK CONNECT TERMINALS • FLAME SENSE SIGNAL THERMOSTAT CONNECTIONS (TB1) • DS = DEHUMIDIFICATION SIGNAL • HI Cool 24VAC • W2 = HEAT DEMAND FROM 2ND STAGE T/STAT • HI HEAT 24VAC • W1 = HEAT DEMAND FROM 1ST STAGE T/STAT • LO COOL 24VAC • R = CLASS 2 VOLTAGE TO THERMOSTAT • LO HEAT 24VAC • G = MANUAL FAN FROM THERMOSTAT • PAR • • PAR C = THERMOSTAT SIGNAL GROUND CONNECTED TO TRANSFORMER GRD (TR) & CHASSIS GROUND (GRD) • COMMON 24VAC • Y1 = THERMOSTAT 1ST STAGE COOL SIGNAL •
Table 15A.
Table 15B.
* Connect W1 to W1 ONLY if using defrost tempering kit 67M41 NOTE: Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the integrated control. Table 15C.
* Connect W1 to W1 ONLY if using defrost tempering kit 67M41 NOTE: Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the integrated control. Table 15D.
Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications 3. To the extent that it is practical, close all building doors and windows and all doors between the space in which the appliances connected to the venting system are located and other spaces of the building. 4. Close fireplace dampers. 5. Turn on clothes dryers and any appliances not connected to the venting system.
Unit Start-Up FOR YOUR SAFETY READ BEFORE OPERATING WARNING Do not use this furnace if any part has been underwater. A flood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. Immediately call a qualified service technician to inspect the furnace and to replace all gas controls, control system parts, and electrical parts that have been wet or to replace the furnace, if deemed necessary. 1. Follow the lighting instructions to place the unit into operation.
11. Set the thermostat to desired setting. Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time in Table 16. If manifold pressure matches Table 17 and rate is incorrect, check gas orifices for proper size and restriction. Remove temporary gas meter if installed.
Proper Combustion Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking combustion. Take combustion sample beyond the flue outlet and compare to the table below. The maximum carbon monoxide reading should not exceed 100 ppm. A95DF2E CO2 % For Nat CO2 % For LP 95G2DFE Low Fire High Fire Low Fire High Fire 045 5.6 - 6.6 7.8 - 8.8 6.6 - 7.6 9.1 - 10.1 070 5.6 - 6.5 7.3 - 8.3 6.5 - 7.5 8.6 - 9.6 090 5.9 - 6.9 7.8 - 8.8 6.9 - 7.9 9.
Electrical Exhaust and Air Intake Pipe 1. Check all wiring for loose connections. 2. Check for the correct voltage at the furnace (with furnace operating). Correct voltage is 120 VAC ± 10%. 3. Check amp–draw on the blower motor with the blower compartment access panel in place. Motor Nameplate____________Actual____________ 1. Check exhaust and air intake connections for tightness and to make sure there is no blockage. 2.
95DF070 Performance (Less Filter) External Static Pressure in. w.g. Air Volume / Watts at Various Blower Speeds cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1770 510 1550 340 1355 220 1255 180 1035 115 0.10 1720 520 1510 355 1315 230 1200 185 980 105 0.20 1705 535 1470 365 1265 245 1165 195 895 110 0.30 1665 540 1430 380 1235 250 1120 205 835 120 0.40 1605 555 1390 395 1185 260 1070 210 775 130 0.
Electrical Service WARNING 1. Check all wiring for loose connections. 2. Check for the correct voltage at the furnace (furnace operating). Correct voltage is 120 VAC ± 10%. 3. Check amp-draw on the blower motor with the blower compartment access panel in place. ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Motor Nameplate____________Actual____________ Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage.
13. Mark and disconnect any remaining wiring to heating compartment components. Disengage strain relief bushing and pull wiring and bushing through the hole in the blower deck. 14. Remove the primary limit from the vestibule panel. 15. Remove two screws from the front cabinet flange at the blower deck. Spread cabinet sides slightly to allow clearance for removal of heat exchanger. 16. Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger assembly to cabinet.
Planned Service A service technician should check the following items during an annual inspection. Power to the unit must be shut off for 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. 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.
Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 4. Revise NFPA-54 section 10.8.
