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Allied A95DF1D Installation Instructions Manual

Warm air gas furnace
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A95DF1D, A93DF1D, 95G1DF-P & 92G1DF-P
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.
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Unit Dimensions ................................................................ 2
Parts Arrangement............................................................. 3
Gas Furnace ...................................................................... 4
Shipping and Packing List ................................................. 4
Safety Information ............................................................. 4
Use of Furnace as Construction Heater ............................ 5
General .............................................................................. 6
Combustion, Dilution & Ventilation Air ............................... 6
Setting Equipment ............................................................. 9
Filters ............................................................................... 12
Duct System .................................................................... 12
Pipe & Fittings Specifications .......................................... 12
Joint Cementing Procedure ............................................. 14
Venting Practices ............................................................. 14
*P507271-02*
(P) 507271-02
507271-02
INSTALLATION INSTRUCTIONS
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.
CAUTION

TABLE OF CONTENTS

Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal
injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
Vent Piping Guidelines .................................................... 16
Gas Piping ....................................................................... 32
Electrical .......................................................................... 34
Unit Start-Up .................................................................... 38
Gas Pressure Adjustment ................................................ 40
High Altitude Information ................................................. 40
Other Unit Adjustments.................................................... 43
Blower Motor Performance .............................................. 44
Service............................................................................. 46
Planned Service .............................................................. 48
Diagnostic Codes ............................................................ 48
Repair Parts List .............................................................. 49
Start-Up & Performance Check List ................................ 50
A Lennox International, Inc. Company
Issue 1621
WARNING
Manufactured By
Allied Air Enterprises LLC
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 52

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Summary of Contents for Allied A95DF1D

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS A95DF1D, A93DF1D, 95G1DF-P & 92G1DF-P 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.

  • Page 2: Unit Dimensions

    Unit Dimensions - inches (mm) Model A95DF1/A93DF1 95G1DF/92G1DF 045-12 17−1/2 16−3/8 070-12 090-16 19−7/8 19−1/2 110-20 Page 2 of 52 Issue 1621 507271-02...

  • Page 3: Parts Arrangement

    Expanded View BAG ASSEMBLY CONTROL BOX (Includes integrated control, transformer and door switch) BLOWER MOTOR (hidden) BLOWER COMPARTMENT ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK HEAT EXCHANGER PRIMARY HEATING LIMIT COMPARTMENT COLD END ACCESS PANEL HEADER BOX GAS VALVE BURNER BOX ASSEMBLY (includes flame sensor, rollout switches and ignitor)

  • Page 4: Gas Furnace

    Gas Furnace Shipping and Packing List This Category IV gas furnace is shipped ready for installation Package 1 of 1 contains: in the downflow position. 1 - Assembled Gas Unit 1 - Bag assembly containing the following: The furnace is equipped for installation in natural gas 1 - Snap bushing applications.

  • Page 5: Use Of Furnace As Construction Heater

    In Canada, installation must conform with current National Standard of Canada CSA-B149 Natural Gas and Propane Installation Codes, local plumbing or waste water codes and other applicable local codes. In order to ensure proper unit operation in non-direct vent applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standard.

  • Page 6: General

    • Air filters must be replaced upon construction completion. • The input rate and temperature rise must be set per the WARNING furnace rating plate. • One hundred percent (100%) outdoor air must be provided The State of California has determined that this product may contain or produce a chemical or chemicals, in very for combustion air requirements during construction.
  • Page 7 furnace vent pipe or chimney. As a result, combustion infiltration. If the furnace is located in a building of tight gases enter the living space creating a potentially dangerous construction with weather stripping and caulking around situation. the windows and doors, follow the procedures in the “Air from Outside”...
  • Page 8 Air from Outside Equipment in Confined Space If air from outside is brought in for combustion and (Inlet Air fron Ventilated Attic & Outlet Air to Outside) 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”...

  • Page 9: Setting Equipment

    Units with 1/2 HP Blower Motor Equipment in Confined Space - all Air from Outside Figure 10 NOTE: These units may be equipped with a shipping pad under the blower housing. Remove the shipping pad prior to operation. Allow for clearances to combustible materials as indicated on the unit nameplate.
  • Page 10 Installation on Non-Combustible Flooring (Figure 14) WARNING 1. Cut floor opening keeping in mind clearances listed on unit rating plate. Also keep in mind gas supply Improper installation of the furnace can result in connections, electrical supply, flue and air intake personal injury or death.
  • Page 11 Combustible Flooring Base Opening Size Table 2 FURNACE SUPPLY AIR PLENUM PROPERLY COMBUSTIBLE SIZED FLOOR Figure 16 FLOORING BASE OPENING COMBUSTIBLE FLOORING Return Air Opening - Downflow Units Return air may be brought in only through the top opening of a furnace installed in the downflow position.

  • Page 12: Filters

    Filters Pipe & Fittings Specifications This unit is not equipped with a filter or rack. A field provided All pipe, fittings, primer and solvent cement must conform filter is required for the unit to operate properly. Table 3 lists with American National Standard Institute and the American recommended filter sizes.
  • Page 13 vent pipe hangers. Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean IMPORTANT inside socket surface of fitting and male end of pipe to depth of fitting socket. The exhaust and intake connections are made of PVC. Use PVC primer and solvent cement when using PVC Canadian Applications Only vent pipe.

  • Page 14: Joint Cementing Procedure

    Joint Cementing Procedure Venting Practices All cementing of joints should be done according to the specifications outlined in ASTM D 2855. 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.
  • Page 15 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.

  • Page 16: Vent Piping Guidelines

    In some applications which permit the use of several different sizes of vent pipe, a combination vent pipe may be used. Contact Allied Air Technical Service for assistance in sizing IMPORTANT vent pipe in these applications.
  • Page 17 A95DF / 95G1DF and A93DF / 92G1DF Table 7 507271-02 Issue 1621 Page 17 of 52...
  • Page 18 A95DF / 95G1DF and A93DF / 92G1DF Table 8 Page 18 of 52 Issue 1621 507271-02...
  • Page 19 Typical Exhaust Pipe Connections Figure 22 Typical Intake Pipe Connections (Direct Vent Applications) Figure 23 507271-02 Issue 1621 Page 19 of 52...
  • Page 20 Intake Piping 3. Use a sheet metal screw to secure the intake pipe to This furnace may be installed in either direct vent or non- the connector, if desired. direct vent applications. In non-direct vent applications, when intake air will be drawn into the furnace from the CAUTION surrounding space, the indoor air quality must be considered.
  • Page 21 General Guidelines for Vent Terminations NOTE: See Table 9 for maximum allowed exhaust pipe length In Non-Direct Vent applications, combustion air is taken from without insulation in unconditioned space during winter design termperatures below 32°F (0°C). If required exhaust pipe should indoors and the flue gases are discharged to the outdoors.
  • Page 22 Vent Termination Clearances For Non-Direct Vent Installations in the USA and Canada Figure 27 Page 22 of 52 Issue 1621 507271-02...
  • Page 23 Vent Termination Clearances For Direct Vent installations in the USA and Canada Figure 28 507271-02 Issue 1621 Page 23 of 52...
  • Page 24 Details of Intake and Exhaust Piping Terminations for 6. On field supplied terminations, a minimum distance Direct Vent Installations between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8” and a NOTE: In Direct Vent installations, combustion air is taken minimum distance of 6”...
  • Page 25 7. If intake and exhaust piping must be run up a side wall to Flush Mount Side Wall Termination position above snow accumulation or other obstructions, piping must be supported every 24” (610 mm) as shown in Figures 34 and 35. When exhaust and intake piping must be run up an outside wall, the exhaust piping must be terminated with pipe sized per Table 10.
  • Page 26 Field Supplied Wall Termination Field Supplied Wall Termination NOTE − FIELD PROVIDED NOTE − FIELD PROVIDED REDUCER MAY BE REDUCER MAY BE 1/2" (13mm) ARMAFLEX 1/2" (13mm) ARMAFLEX REQUIRED TO ADAPT REQUIRED TO ADAPT INSULATION IN UN- INSULATION IN UN- LARGER VENT PIPE SIZE LARGER VENT PIPE SIZE CONDITIONED SPACE...
  • Page 27 Direct Vent Concentric Rooftop Termination Optional Vent Termination for Multiple Unit Installation of Direct Vent Wall Termination Kit Figure 38 Figure 36 Direct Vent Application Using Existing Chimney Direct Vent Concentric Wall Termination Figure 37 Figure 39 507271-02 Issue 1621 Page 27 of 52...
  • Page 28 Details of Exhaust Piping Terminations for Non-Direct Vent Applications Non-Direct Vent Field Supplied Wall Termination Exhaust pipe may be routed either horizontally through Extended an outside wall or vertically through the roof. In attic or 12" (305mm) MAX. for 2" (51mm) closet installations, vertical termination through the roof is 20"...
  • Page 29 Condensate Piping 5. Figure 46 shows the furnace and evaporator coil using This unit is designed for either right or left side exit of a separate drain. If necessary, the condensate line from condensate piping in downflow applications. Refer to Figure the furnace and evaporator coil can drain together.
  • Page 30 6. If unit will be started immediately upon completion of installation, prime trap per procedure outlined in Unit CAUTION Start-Up section. Do Not use copper tubing or existing copper condensate lines for drain line. Condensate line must slope downward away from the trap to drain.
  • Page 31 Trap Drain Assembly Using 1/2” PVC or 3/4” PVC Figure 49 507271-02 Issue 1621 Page 31 of 52...

  • Page 32: Gas Piping

    Gas Piping IMPORTANT Compounds used on threaded joints of gas piping must CAUTION be resistant to the actions of liquified petroleum gases. 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 Leak Check cabinet.
  • Page 33 Figure 51 GAS PIPE CAPACITY − FT /HR (kL/HR) Length of Pipe−Feet(m) Nominal Internal Iron Pipe Size Diameter Inches(mm) Inches(mm) (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) .622 (12.7) (17.799) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42)

  • Page 34: Electrical

    Electrical The unit is equipped with a field makeup box on the left hand ELECTROSTATIC DISCHARGE (ESD) side of the cabinet. A field-provided make-up box can be Precautions and Procedures installed on the exterior of the right side of the furnace to facilitate installation.
  • Page 35 Indoor Blower Speeds One line voltage “HUM” 1/4” spade terminal is provided on the furnace control board. Any humidifier rated up to one 1. When the thermostat is set to “FAN ON”, the indoor amp can be connected to this terminal with the neutral leg blower will run continuously on the heating speed when of the circuit being connected to one of the provided neutral there is no cooling or heating demand.
  • Page 36 Typical Wiring Diagram For A93DF & 92G1DF Figure 56 Page 36 of 52 Issue 1621 507271-02...
  • Page 37 Typical Wiring Diagram For A95DF, 95G1DF Figure 57 507271-02 Issue 1621 Page 37 of 52...

  • Page 38: Unit Start-Up

    Integrated Control (Automatic Hot Surface Ignition System) Figure 58 Unit Start-Up FOR YOUR SAFETY READ BEFORE OPERATING CAUTION WARNING Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect Do not use this furnace if any part has been underwater. switch.
  • Page 39 Priming Condensate Trap 9. Replace the heating compartment access panel. The condensate trap should be primed with water prior to 10. Turn on all electrical power to the unit. start-up to ensure proper condensate drainage. Either pour 11. Set the thermostat to desired setting. 10 fl.

  • Page 40: Gas Pressure Adjustment

    Gas Pressure Adjustment Gas Flow (Approximate) NOTE: Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to remove barbed fitting and replace threaded plug. Proper Combustion Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking combustion.
  • Page 41 Burner Orifice Conversion Kits at Varying Altitudes 0 - 7500 ft 7501 - 10000 ft (0 - 2286 m) (2286 - 3048 m) Unit High Altitude High Altitude Natural LP/Propane Size Natural LP/Propane Burner Orifice Burner Orifice LP/Propane Natural 11K50+ 73W80* 51W01 11K45+...
  • Page 42 Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications 6. Follow the lighting instruction to place the appliance being inspected into operation. Adjust thermostat so WARNING appliance will operate continuously. 7. Use the flame of a match or candle to test for spillage CARBON MONOXIDE POISONING HAZARD of flue gases at the draft hood relief opening after 5 Failure to follow the steps outlined below for each...

  • Page 43: Other Unit Adjustments

    Other Unit Adjustments Thermostat Heat Anticipation Set the heat anticipator setting (if adjustable) according to Primary Limit the amp draw listed on the wiring diagram that is attached The primary limit is located on the heating compartment to the unit. vestibule panel.

  • Page 44: Blower Motor Performance

    BLOWER DATA A93DF1D / 92G1DF A93DF1D / 92G1DF 045*12B PERFORMANCE (Less Filter) A93DF1D / 92G1DF 090*16C PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds Air Volume / Watts at Various Blower Speeds External External Static Static High Medium - High Medium - Low High...
  • Page 45 BLOWER DATA A95DF1D / 95G1DF A95DF1D / 95G1DF 045*12B PERFORMANCE (Less Filter) A95DF1D / 95G1DF 090*20C PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds External Air Volume / Watts at Various Blower Speeds S t a t i c...

  • Page 46: Service

    Service Electrical 1. Check all wiring for loose connections. WARNING 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 ELECTRICAL SHOCK, FIRE, compartment access panel in place.
  • Page 47 14. Remove the primary limit from the vestibule panel. Cleaning the Burner Assembly 15. Remove two screws from the front cabinet flange at 1. Turn off electrical and gas power supplies to furnace. the blower deck. Spread cabinet sides slightly to allow Remove upper and lower furnace access panels.

  • Page 48: Planned Service

    Planned Service Diagnostic Codes 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.

  • Page 49: Repair Parts List

    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: A93DF1D045B36-01. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.

  • Page 50: Start-Up & Performance Check List

    Start-Up & Performance Check List Page 50 of 52 Issue 1621 507271-02...

  • Page 51: Issue

    UNIT OPERATION HEATING MODE COOLING MODE GAS MANIFOLD PRESSURE “W.C.” ______ INDOOR BLOWER AMPS ______ COMBUSTION SAMPLE CO CO _____ PPM TEMPERATURE DROP ______ ______ Return Duct Temperature INDOOR BLOWER AMPS ______ ______ Supply Duct Temperature ______ Temperature Drop TEMPERATURE RISE TOTAL EXTERNAL STATIC (dry coil) Supply Duct Temperature ______...
  • Page 52 REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS 4. INSPECTION. The state or local gas inspector of the Modifications to NFPA-54, Chapter 10 side wall, horizontally vented, gas-fueled equipment Revise NFPA-54 section 10.8.3 to add the following shall not approve the installation unless, upon requirements: inspection, the inspector observes carbon monoxide For all side wall, horizontally vented, gas fueled equipment...

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