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Allied A95DF1E Installation Instructions Manual

Warm air gas furnace
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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
A95DF1E & 95G1DFE 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
*P507277-02*
(P) 507277-02
507277-02
INSTALLATION INSTRUCTIONS
A95DF1E & 95G1DFE
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.
CAUTION
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.

TABLE OF CONTENTS

Vent Piping Guidelines .................................................. 15
Gas Piping ..................................................................... 30
Electrical ........................................................................ 33
Unit Start-Up .................................................................. 36
Gas Pressure Adjustment .............................................. 38
High Altitude Information ............................................... 38
Other Unit Adjustments.................................................. 41
Blower Motor Performance ............................................ 42
Service........................................................................... 43
Planned Service ............................................................ 45
Diagnostic Codes .......................................................... 45
Repair Parts List ............................................................ 50
Start-Up & Performance Check List .............................. 51
Issue 1621
WARNING
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 52

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Summary of Contents for Allied A95DF1E

  • Page 1: Table Of Contents

    TABLE OF CONTENTS Unit Dimensions .............. 2 Vent Piping Guidelines ..........15 A95DF1E & 95G1DFE Parts Arrangement...... 3 Gas Piping ..............30 Gas Furnace ..............4 Electrical ................ 33 Shipping and Packing List ..........4 Unit Start-Up ..............

  • Page 2: Unit Dimensions

    (Either Side) 9−1/8 (232) Right 6−9/16 (167) Left 6−1/2 (165) (229) Either Side Supply (19) Supply (19) 19−1/4 (489) (19) FRONT VIEW Model Number A95DF1E/95G1DFE 045-12 17−1/2 16−3/8 070-16 090-16 19−7/8 19−1/2 110-20 Page 2 of 52 Issue 1621 507277-02...

  • Page 3: A95Df1E & 95G1Dfe Parts Arrangement

    Expanded View CONTROL BOX (Includes integrated control, transformer and door switch) BAG ASSEMBLY BLOWER MOTOR (hidden) BLOWER COMPARTMENT ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK HEATING PRIMARY LIMIT COMPARTMENT ACCESS PANEL COLD END HEADER BOX HEAT EXCHANGER GAS VALVE BURNER BOX ASSEMBLY (includes ame sensor, rollout switches and ignitor) Figure 1 507277-02...

  • Page 4: Gas Furnace

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

  • Page 5: Use Of Furnace As Construction Heater

    In Canada, installation must conform with current National In Canada, all electrical wiring and grounding for the unit Standard of Canada CSA-B149 Natural Gas and Propane must be installed according to the current regulations of Installation Codes, local plumbing or waste water codes and the Canadian Electrical Code Part I (CSA Standard C22.1) other applicable local codes.

  • Page 6: General

    • Air filters must be replaced upon construction completion. CAUTION • The input rate and temperature rise must be set per the furnace rating plate. These units should not be installed in areas normally • One hundred percent (100%) outdoor air must be provided subject to freezing temperatures.
  • Page 7 air is brought into the house for combustion, negative If the furnace is located in a building of tight construction pressure (outside pressure is greater than inside pressure) with weather stripping and caulking around the windows will build to the point that a down draft can occur in the and doors, follow the procedures in the “Air from Outside”...
  • Page 8 Air from Outside Equipment in Confined Space - All Air from Outside If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two (All Air Through Ventilated Attic) 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 & 3/4 HP Equipment in Confined Space Blower Motor 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 Front to Rear Side to Side Cabinet Catalog Width Number FURNACE B Cabinet 11M60 18 − 3/4 (17.5") C Cabinet 11M61 22 − 3/4 (21") COOLING COIL Table 2 PROPERLY SIZED FLOOR OPENING PLENUM FURNACE SUPPLY AIR PLENUM PROPERLY...

  • 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 SCHEDULE 40 intake pipe to the connector, if desired. Use a drill or self PVC −...

  • Page 15: Vent Piping Guidelines

    In some applications which permit the use of several different sizes of vent pipe, a combination vent pipe may be IMPORTANT used. Contact Allied Air Technical Service for assistance in sizing vent pipe in these applications. Do not use screens or perforated metal in exhaust or intake terminations.
  • Page 16 A95DF1E / 95G1DFE 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.
  • Page 17 Typical Exhaust Pipe Connections Pipe size determined in Table 7. 2” 2” 2” 2” 2” 3” TRANSITION INTAKE DO NOT transition from smaller EXHAUST *2” to larger pipe size in horizontal TOP VIEW runs of exhaust pipe. * 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.
  • Page 18 Intake Piping Typical Air Intake Pipe Connections This furnace may be installed in either direct vent or non- Non-Direct Vent Applications direct 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.
  • Page 19 Maximum Allowable Exhaust Vent Pipe Length (in ft.) Without Insulation In Unconditioned Space For Winter Design Temperatures Single - Stage High Efficiency Furnace Unit Input Size Winter Design Temperatures Vent Pipe ºF (ºC) Diameter 2 in. 32 to 21 (0 to -6) 2-1/2 in.

  • Page 20: Vent Termination Clearances

    Vent Termination Clearances For Non-Direct Vent Installations in the USA and Canada INSIDE CORNER DETAIL Fixed Operable Fixed Closed Closed Operable AREA WHERE TERMINAL AIR SUPPLY INLET VENT TERMINAL IS NOT PERMITTED US Installations Canadian Installations Clearance above grade, veranda, 12 inches (305mm) or 12 in.
  • Page 21 Vent Termination Clearances For Direct Vent installations in the USA and Canada INSIDE CORNER DETAIL Fixed Operable Fixed Closed Closed Operable AREA WHERE TERMINAL AIR SUPPLY INLET VENT TERMINAL IS NOT PERMITTED US Installations Canadian Installations Clearance above grade, veranda, 12 inches (305 mm) or 12 in.
  • Page 22 Details of Intake and Exhaust Piping Terminations for Direct Vent Roof Termination Kit Direct Vent Installations (15F75 or 44J41) 3"(76mm) MAX. NOTE: In Direct Vent installations, combustion air is taken Inches(mm) SIZE TERMINATION PIPE PER TABLE 8. from outdoors and flue gases are discharged to outdoors. UNCONDITIONED ATTIC SPACE NOTE: Flue gas may be slightly acidic and may adversely...
  • Page 23 Intake Front View of Intake and Exhaust Exhaust Intake Exhaust TABLE 9 2" (51mm) 3" (76mm) Vent Pipe Vent Pipe A − Clearance above grade or average snow 12" (508MM) Min. 12" (508MM) Min. accumulation 12" B −Horizontal 6" (152MM) Min. 6"...
  • Page 24 Field Supplied Wall Termination Field Supplied Wall Termination NOTE − FIELD PROVIDED NOTE − FIELD PROVIDED REDUCER MAY BE 1/2" (13mm) ARMAFLEX REDUCER MAY BE REQUIRED TO ADAPT 1/2" (13mm) ARMAFLEX INSULATION IN UN- REQUIRED TO ADAPT LARGER VENT PIPE SIZE INSULATION IN UN- CONDITIONED SPACE LARGER VENT PIPE SIZE...

  • Page 25: Front View

    Direct Vent Concentric Rooftop Termination Optional Vent Termination for Multiple Unit Installation of Direct Vent Wall Termination Kit 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada) 1 1/2" (38mm) accelerator 12" provided on 71M80 & 44W92 EXHAUST (305mm) EXHAUST VENT 5−1/2"...
  • Page 26 Details of Exhaust Piping Terminations for Non-Direct Non-Direct Vent Field Supplied Wall Termination Vent Applications Extended Exhaust pipe may be routed either horizontally through 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 27 Condensate Piping Condensate Trap and Plug Locations 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”...
  • Page 28 Unit with Evaporator Coil Evaporator Coil Using a Common Drain Figure 40 Figure 41 CAUTION A separate drain line must be run to the drain from the condensate trap to ensure proper drainage and pressure switch operation. DO NOT connect the condensate trap drain into the drain line from the evaporator coil.
  • Page 29 Trap Drain Assembly Using 1/2” PVC or 3/4” PVC Figure 43 507277-02 Issue 1621 Page 29 of 52...

  • Page 30: 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 31 Left Side Piping MANUAL (Standard) AUTOMATIC MAIN SHUT−OFF GAS VALVE MANUAL VALVE AUTOMATIC (with manual Plug MAIN SHUT−OFF (With 1/8 in. NPT shut−o valve) GAS VALVE VALVE Plugged Tap (with manual Plug (With 1/8 in. NPT Shown) shut−o valve) Plugged Tap Shown) GROUND JOINT UNION...
  • Page 32 Removal of the Furnace from Common Vent 3. Close all building doors and windows and all doors In the event that an existing furnace is removed from a between the space in which the appliances remaining venting system commonly run with separate gas appliances, connected to the common venting system are located the venting system is likely to be too large to properly vent and other spaces of the building.

  • Page 33: Electrical

    Electrical The unit is equipped with a field makeup box on the left hand side of the cabinet. A field-provided make-up box can be ELECTROSTATIC DISCHARGE (ESD) installed on the exterior of the right side of the furnace to Precautions and Procedures facilitate installation.
  • Page 34 One line voltage “120 HUM” 1/4” spade terminal is provided Install the room thermostat according to the instructions on the furnace integrated control board. See Figure 51 for provided with the thermostat. See Figure 48 for thermostat integrated control configuration. This terminal is energized designations.
  • Page 35 Typical Wiring Diagram For A95DF1E & 95G1DFE Figure 50 507277-02 Issue 1621 Page 35 of 52...

  • Page 36: Unit Start-Up

    Integrated Control (Automatic Hot Surface Ignition System) Figure 51 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 switch. Do not use this furnace if any part has been underwater. A flood-damaged furnace is extremely dangerous.
  • Page 37 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 38: Gas Pressure Adjustment

    Gas Pressure Adjustment 3. While waiting for the unit to stabilize, observe the flame. Gas Flow (Approximate) Flame should be stable and should not lift from burner. Natural gas should burn blue. 4. After allowing unit to stabilize for 5 minutes, record GAS METER CLOCKING CHART manifold pressure and compare to value given in Seconds for One Revolution...
  • Page 39 Burner Orifice Conversion Kits at Varying Altitudes 0 - 7,500 ft 7,501 - 10,000 ft (0 - 2,286 m) (2,286 - 3048m) Unit Size High Altitude High Altitude LP/ Natural to LP/ LP/Propane to Natural Burner Propane Burner Propane Natural Orifice Kit Orifice Kit 11K50†...
  • Page 40 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 41: Other Unit Adjustments

    Other Unit Adjustments Constant Torque Motor These units are equipped with a constant torque ECM Primary Limit motor. It has a DC motor coupled to an electronic control The primary limit is located on the heating compartment module,both contained in the same motor housing.The vestibule panel.

  • Page 42: Blower Motor Performance

    Blower Data A95DF1E & 95G1DFE A95DF1E / 95G1DFE 045*B12 PERFORMANCE (Less Filter) A95DF1E / 95G1DFE 070*B16 PERFORMANCE (Less Filter) Air Volume / Watts at Different Blower Speeds Air Volume / Watts at Different Blower Speeds Bottom Return Air, Side Return Air with Optional Return...

  • Page 43: 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 44 16. Remove screws along vestibule sides and bottom which Cleaning the Burner Assembly secure vestibule panel and heat exchanger assembly 1. Turn off electrical and gas power supplies to furnace. to cabinet. Remove two screws from blower rail which Remove upper and lower furnace access panels. secure bottom heat exchanger flange.

  • Page 45: 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 46 Troubleshooting: Heating Sequence of Operation Page 46 of 52 Issue 1621 507277-02...
  • Page 47 Troubleshooting: Heating Sequence of Operation (continued) 507277-02 Issue 1621 Page 47 of 52...
  • Page 48 Troubleshooting: Cooling Sequence of Operation Page 48 of 52 Issue 1621 507277-02...
  • Page 49 Troubleshooting: Continuous Fan Sequence of Operation 507277-02 Issue 1621 Page 49 of 52...

  • Page 50: 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: A95DF045P36B-01. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.

  • Page 51: Start-Up & Performance Check List

    Start-Up & Performance Check List UNIT SET UP Furnace: Model Number_______________ Serial Number_________________ SUPPLY Line Voltage GAS SUPPLY LP Propane Gas Natural Gas Piping Connections Tight Leak Tested Flter RETURN AIR Gas Supply Pressure DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated (if necessary) RETURN DUCT Sealed...

  • Page 52: 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 53 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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