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Allied A93DF1E 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.
Unit Dimensions ..........................................................2
Parts Arrangement.......................................................3
Gas Furnace ................................................................4
Shipping and Packing List ...........................................4
Safety Information .......................................................4
General ........................................................................6
Combustion, Dilution & Ventilation Air .........................6
Installation ...................................................................9
Filters .........................................................................12
Duct System ..............................................................12
Venting Practices .......................................................15
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.
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
507868-01
INSTALLATION INSTRUCTIONS
A93DF1E & 92G1DFE
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.

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WARNING
Save these instructions for future reference
Condensate Piping ....................................................29
Gas Piping .................................................................32
Electrical ....................................................................34
Unit Start-Up ..............................................................37
Air for Non-Direct Vent Applications ..........................41
Other Unit Adjustments..............................................42
Service.......................................................................44
Planned Service ........................................................47
Repair Parts List ........................................................47
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Issue 1912
CAUTION
*P507868-01*
(P) 507868-01
Page 1 of 48

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  • Page 1: Table Of Contents

    Testing for Proper Venting and Sufficient Combustion General ................6 Air for Non-Direct Vent Applications ......41 Combustion, Dilution & Ventilation Air ......6 Other Unit Adjustments..........42 Installation ..............9 Blower Performance A93DF1E / 92G1DFE....43 Filters .................12 Service...............44 Duct System ..............12 Planned Service ............47 Venting Practices ............15 Repair Parts List ............47...

  • Page 2: Unit Dimensions

    Unit Dimensions Model A93DF1E / 92G1DFE 045-12 17-1/2 16-3/8 070-12 090-16 19-7/8 19-1/2 Page 2 of 48 Issue 1912 507868-01...

  • Page 3: Parts Arrangement

    Parts Arrangement Bag Assemblies Blower Assembly Control Box (includes integrated control, transformer and door switch) Cabinet Blower Deck Blower Access Panel Heat Exchanger Cold End Header Box Heating Combustion Compartment Air Inducer Access Panel Gas Valve Burner Box Assembly Figure 1. 507868-01 Issue 1912 Page 3 of 48...

  • Page 4: Gas Furnace

    Gas Furnace Shipping and Packing List This Category IV gas furnace is shipped ready for Package 1 of 1 contains: installation in the downflow position. 1 - Assembled Gas Unit The furnace is equipped for installation in natural gas 1 - Bag assembly containing the following: applications.
  • Page 5 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. 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 14.

  • Page 6: General

    INSTRUCTIONS VOIDS MANUFACTURER’S EQUIPMENT LIMITED WARRANTY. ALLIED DISCLAIMS ALL LIABILITY IN CONNECTION WITH Combustion, Dilution & Ventilation Air INSTALLER’S FAILURE TO FOLLOW THE ABOVE INSTALLATION INSTRUCTIONS. If this unit is installed as a Non-Direct Vent Furnace, follow the guidelines in this section.
  • Page 7 the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This In addition to providing combustion air, fresh outdoor air reprinted material is not the complete and official position dilutes contaminants in the indoor air. These contaminants of ANSI on the referenced subject, which is represented may include bleaches, adhesives, detergents, solvents only by the standard in its entirely.
  • Page 8 Air from Outside When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 If air from outside is brought in for combustion and square inch (645 mm²) per 2,000 Btu (.56 kW) per hour of ventilation, the confined space shall be provided with two the total input rating of all equipment in the enclosure.

  • Page 9: Installation

    Roof Terminated Exhaust Pipe Inlet Air Minimum 12 in. (305mm) Ventilation Furnace above Crawl Louvers (Crawl Space) Space Floor Coupling or *Intake Debris Screen Provided 3 in. to 2 in. Transition (Field Provided) * See Maximum Vent Lengths table NOTE: The inlet and outlet air openings shall each have a free area Figure 10.
  • Page 10 Select a location that allows for the required clearances Refer to Figure 14 for clearances in downflow applications. that are listed on the unit nameplate. Also consider gas supply connections, electrical supply, vent connection, condensate trap and drain connections, and installation WARNING and service clearances [24 inches (610 mm) at unit front].
  • Page 11 Installation on Non-Combustible Flooring Lower supply air plenum into the combustible flooring base until plenum flanges seal against fiberglass See Figure 15 strips. Cut floor opening keeping in mind clearances listed NOTE: Be careful not to damage fiberglass strips. on unit rating plate. Also keep in mind gas supply Check for a tight seal.

  • Page 12: Filters

    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”...
  • Page 13 Piping and Fittings Specifications CAUTION Schedule 40 PVC (Pipe) D1785 Solvent cements for plastic pipe are flammable liquids Schedule 40 PVC (Cellular Core Pipe) F891 and should be kept away from all sources of ignition. Schedule 40 PVC (Fittings) D2466 Do not use excessive amounts of solvent cement when making joints.
  • Page 14 STANDARD CONCENTRIC Outdoor Outdoor Exhaust 1-1/2” 2” 3” Exhaust Flush Accelerator Concentric Concentric Concentric VENT Accelerator Mount Kit Capacity PIPE DIA. (Dia. X Length) (Dia. X Length) (in.) 71M80 69M29 60L46 1-1/2” X 12” 2” X 12” 51W11 ** or 44W93+ +44W92++ +44W92++ 1-1/2...

  • Page 15: Venting Practices

    Close all building doors and windows and all doors Venting Practices 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.
  • Page 16 In some applications which permit the use of several different sizes of vent pipe, a combination vent pipe may Use Table 7 to find max pipe length. be used. Contact Allied Air Technical Service for assistance in sizing vent pipe in these applications. Capacity Min. Vent Length* Figure 22.
  • Page 17 A93DF1E / 92G1DFE Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 10,000 ft 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe Number of 90° Model Model Model Model Elbows Used Concentric Termination Elevation 0 - 10,000 ft 1-1/2"...
  • Page 18 A93DF1E / 92G1DFE Maximum Allowable Exhaust Vent Length with Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space for Intake in Feet Standard Termination at Elevation 0 - 10,000 ft 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3"...
  • Page 19 TYPICAL INTAKE PIPE CONNECTIONS Pipe size determined in table 7. 2” 2” 2” 2” 2” INTAKE EXHAUST TOP VIEW TRANSITION 3” 1-1/2” *2” 3” TRANSITION TRANSITION *2” **2” *2” * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. ** When transitioning down in pipe size, use at least 1 foot of 2"...
  • Page 20 Follow the next two steps when installing the unit in Non- Direct Vent applications where combustion air is taken from indoors and flue gases are discharged outdoors. Roof Terminated Exhaust Pipe Use field-provided materials and the factory-provided air intake screen to route the intake piping as shown in Figure 29.
  • Page 21 exhaust pipe should be insulated with 1/2” (13 mm) Armaflex or equivalent. In extremely cold climate areas, 3/4” (19 mm) Armaflex or equivalent may be necessary. Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insulation from deterioration. Exhaust pipe insulation may not be necessary in some specific applications.
  • Page 22 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Allied Air recommends avoiding this location if possible. Figure 29. Vent Termination Clearances for Non-Direct Vent Installations...
  • Page 23 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Allied Air recommends avoiding this location if possible. Figure 30. Vent Termination Clearances for Direct Vent Installations...
  • Page 24 Details of Intake and Exhaust Piping NOTE: Care must be taken to avoid recirculation of exhaust back into intake pipe. Terminations for Direct Vent Installations NOTE: In Direct Vent installations, combustion air is taken On field supplied terminations, a minimum distance from outdoors and flue gases are discharged to outdoors.
  • Page 25 FIELD-PROVIDED 2” EXTENSION FOR 2” PVC PIPE REDUCER MAY BE REQUIRED 1-1/2” (38mm) accelerator 1” EXTENSION FOR 3” PVC PIPE TO ADAPT LARGER VENT provided on 71M80 & 44W92 PIPE SIZE TO TERMINATION kits for -45 and -70 units OUTSIDE INTAKE WALL FURNACE...
  • Page 26 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT LARGER VENT PIPE SIZE Vent Pipe Vent Pipe TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
  • Page 27 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 SIZE TERMINATION closet installations, vertical termination through the roof PER EXHAUST PIPE is preferred.
  • Page 28 Exhaust through Crawl Space Vent Option All 33” condensing gas furnaces (92%+) are now approved Exhaust from to be vented down through a crawl space. Ensure a vent Furnace pipe drain kit, 51W18 (USA) or 15Z70 (Canada), is used as To Termination directed through the floor joists and into the crawl space.

  • Page 29: Condensate Piping

    Figure 49 shows the furnace and evaporator coil Condensate Piping using a separate drain. If necessary, the condensate line from the furnace and evaporator coil can drain This unit is designed for either right or left side exit of together. See Figure 50. The field provided vent must condensate piping in downflow applications.
  • Page 30 Figure 49. Evaporator Coil Using a Separate Drain Figure 51. Condensate Trap with Optional Overflow Switch Figure 50. Evaporator Coil Using a Common Drain Page 30 of 48 Issue 1912 507868-01...
  • Page 31 Figure 52. Trap Drain Assembly Using 1/2” PVC or 3/4” PVC 507868-01 Issue 1912 Page 31 of 48...

  • Page 32: Gas Piping

    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 Leak Check be installed at the gas valve and extend outside the After gas piping is completed, carefully check all piping...
  • Page 33 Left Side Piping MANUAL AUTOMATIC (Standard) GAS VALVE MAIN SHUT-OFF MANUAL VALVE AUTOMATIC (with manual MAIN SHUT-OFF shut-off valve) (With 1/8 in. NPT GAS VALVE VALVE Plugged Tap (with manual (With 1/8 in. NPT Shown) shut-off valve) Plugged Tap Shown) GROUND JOINT UNION...

  • Page 34: Electrical

    Refer to Figure 58 for field wiring and Figure 59 for Electrical schematic wiring diagram and troubleshooting. The power supply wiring must meet Class I restrictions. ELECTROSTATIC DISCHARGE (ESD) Protected by either a fuse or circuit breaker, select circuit Precautions and Procedures protection and wire size according to unit nameplate.
  • Page 35 Indoor Blower Speeds mode when the combustion air inducer is operating and the pressure switch is closed. Any humidifier rated up to When the thermostat is set to “FAN ON”, the indoor 0.5 amp can be connected to this terminal with the ground blower will run continuously on the heating speed leg of the circuit connected to ground or the “C”...
  • Page 36 Figure 59. Typical Wiring Diagram Page 36 of 48 Issue 1912 507868-01...

  • Page 37: Unit Start-Up

    Terminal Designations 120 HUM Humidifier (120 VAC) LINE Input (120 VAC) XFMR Transformer (120 VAC) CIRC Indoor Blower (120 VAC) Electronic Air Cleaner (120 VAC) COOL Blower - Cooling Speed (24 VAC) HEAT Blower - Heating Speed (24 VAC) Blower - Fan Speed (24 VAC) PARK Dead terminals to park all speed taps NEUTRALS...
  • Page 38 Priming Condensate Trap Wait five minutes to clear out any gas. If you then smell gas, STOP! Immediately call your gas supplier The condensate trap should be primed with water prior from a neighbor’s phone. Follow the gas supplier’s to start-up to ensure proper condensate drainage. Either instructions.
  • Page 39 If flame is not detected after first ignition trial, the Start unit and allow 5 minutes for unit to reach steady ignition control will repeat steps 3 and 4 four more state. times before locking out the gas valve. The ignition While waiting for the unit to stabilize, observe the control will then automatically repeat steps 1 through flame.
  • Page 40 * Conversion requires installation of a gas valve regulator spring which is provided with the gas conversion Kit. + LP Kits include low line pressure switch. A93DF1E / 92G1DFE Pressure Switch at Varying Altitudes 0 - 4500 ft 4501 - 7500 ft...

  • Page 41: Testing For Proper Venting And Sufficient Combustion Air For Non-Direct Vent Applications

    Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications Seal any unused openings in the venting system. Visually inspect the venting system for proper size WARNING and horizontal pitch. Determine there is no blockage CARBON MONOXIDE POISONING HAZARD or restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition.

  • Page 42: Other Unit Adjustments

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

  • Page 43: Blower Performance A93Df1E / 92G1Dfe

    Blower Performance A93DF1E / 92G1DFE A93DF1E045B12A / 92G1DF045BE12 Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure Watts Watts Watts Watts Watts in. w.g. 0.10 1395 1270 1145 0.20 1365 1245 1105 0.30...

  • Page 44: Service

    Check amp-draw on the blower motor with the blower Service compartment access panel in place. Motor Nameplate____________ Actual____________ WARNING Winterizing and Condensate Trap Care 1. Turn off power to the furnace. ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Have a shallow pan ready to empty condensate water. Failure to follow safety warnings exactly could result in Remove the clean out cap from the condensate trap and empty water.
  • Page 45 Cleaning the Burner Assembly 16. Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger 1. Turn off electrical and gas power supplies to furnace. assembly to cabinet. Remove two screws from blower Remove upper and lower furnace access panels. rail which secure bottom heat exchanger flange.
  • Page 46 Integrated Control LED Codes Red LED Flash Code Diagnostic Codes / Status of Furnace LED Off No power to control or control hardware fault detected Heartbeat Normal operation - idle, continuous fan, cool Continuous Rapid Flash Call for heat / burner operation 1 Flash Reverse line voltage polarity 2 Flashes...

  • Page 47: Planned Service

    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. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.
  • Page 48 Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 INSPECTION. The state or local gas inspector of the 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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