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Lennox Allied Air 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.
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
Condensate Piping ....................................................30
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
507271-02
INSTALLATION INSTRUCTIONS
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.

Table of Contents

WARNING
Save these instructions for future reference
Gas Piping .................................................................33
Electrical ....................................................................35
Unit Start-Up ..............................................................39
Air for Non-Direct Vent Applications ..........................43
Other Unit Adjustments..............................................44
Service.......................................................................48
Planned Service ........................................................50
Repair Parts List ........................................................50
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Issue 1917
CAUTION
*P507271-02*
(P) 507271-02
Page 1 of 51

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  • Page 1: Table Of Contents

    (or equivalent), service agency or the gas supplier. Manufactured By *P507271-02* Allied Air Enterprises LLC A Lennox International, Inc. Company 215 Metropolitan Drive (P) 507271-02 West Columbia, SC 29170 Save these instructions for future reference...

  • Page 2: Unit Dimensions

    Unit Dimensions Model A95DF1 / A93DF1 95G1DF / 92G1DF 045-12 17-1/2 16-3/8 070-12 090-16 090-20 19-7/8 19-1/2 110-20 Page 2 of 51 Issue 1917 507271-02...

  • Page 3: Parts Arrangement

    Parts Arrangement 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 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 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 the Canadian Electrical Code Part I (CSA Standard C22.1) and other applicable local codes.

  • Page 6: General

    A room thermostat must control the furnace. The use • When the furnace is installed in non-direct vent of fixed jumpers that will provide continuous heating is applications, do not install the furnace where drafts prohibited. might blow directly into it. This could cause improper combustion and unsafe operation.
  • Page 7 of this information has been reprinted with permission from In addition to providing combustion air, fresh outdoor air the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This dilutes contaminants in the indoor air. These contaminants reprinted material is not the complete and official position may include bleaches, adhesives, detergents, solvents of ANSI on the referenced subject, which is represented and other contaminants which can corrode furnace...
  • 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 that are listed on the unit nameplate. Also consider gas WARNING supply connections, electrical supply, vent connection, condensate trap and drain connections, and installation Improper installation of the furnace can result in and service clearances [24 inches (610 mm) at unit front].
  • Page 11 Installation on Non-Combustible Flooring Front to Rear Side to Side Cabinet Catalog See Figure 15 Width Number B cabinet Cut floor opening keeping in mind clearances listed 11M60 18-3/4 (17.5”) on unit rating plate. Also keep in mind gas supply connections, electrical supply, flue and air intake C cabinet 11M61...

  • 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 Pipe & Fittings Specifications Piping and Fittings Specifications All pipe, fittings, primer and solvent cement must conform with American National Standard Institute and the American Schedule 40 PVC (Pipe) D1785 Society for Testing and Materials (ANSI/ASTM) standards. Schedule 40 PVC (Cellular Core Pipe) F891 The solvent shall be free flowing and contain no lumps, undissolved particles or any foreign matter that adversely...
  • 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++ 2-1/2...

  • Page 15: Venting Practices

    Test fit joint and mark depth of fitting on outside of pipe. Venting Practices 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.
  • Page 16 Seal any unused openings in the common venting system. Inspect the venting system for proper size and horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. 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.
  • Page 17 Vent Piping Guidelines Use the following steps to correctly size vent pipe diameter. This gas furnace can be installed as either a Non-Direct Vent or a Direct Vent gas central furnace. NOTE: In non-Direct Vent installations, combustion air is 045, 070, Furnace capacity? taken from indoors and flue gases are discharged outdoors.
  • Page 18 A95DF / 95G1DF and A93DF / 92G1DF Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 10,000 ft 2" Pipe 2-1/2" Pipe 3" Pipe Number of 90° Model Model Model Elbows Used Concentric Termination Elevation 0 - 10,000 ft 2"...
  • Page 19 A95DF / 95G1DF and A93DF / 92G1DF 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 - 4,500 ft 2" Pipe 2-1/2"...
  • Page 20 Figure 24. Typical Intake Pipe Connections (Direct Vent Applications) Intake Piping This furnace may be installed in either direct vent or non- 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.
  • Page 21 Follow the next two steps when installing the unit in Non- Direct Vent applications where combustion air is taken Roof Terminated from indoors and flue gases are discharged outdoors. Exhaust Pipe Use field-provided materials and the factory-provided air intake screen to route the intake piping as shown in Figure 29.
  • Page 22 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 23 VENT TERMINATION CLEARANCES FOR NON-DIRECT VENT INSTALLATIONS IN THE US 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 24 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 (305mm) or 12 in.
  • Page 25 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 26 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 27 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 28 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 29 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 30: 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 31 Figure 49. Evaporator Coil Using a Separate Drain Figure 51. Condensate Trap with Optional Overflow Switch Figure 50. Evaporator Coil Using a Common Drain 507271-02 Issue 1917 Page 31 of 51...
  • Page 32 Figure 52. Trap Drain Assembly Using 1/2” PVC or 3/4” PVC Page 32 of 51 Issue 1917 507271-02...

  • Page 33: 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 34 Figure 54. Gas Pipe Capacity - FT³/HR (kL/HR) Nominal Length of Pipe - feet (m) Internal Iron Pipe Diameter Size - - inches inches (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) (mm) (mm) .622 (12.7) (17.799) (4.96) (3.40) (2.75) (2.32)

  • Page 35: Electrical

    The unit is equipped with a field makeup box on the left Electrical hand side of the cabinet. A field-provided make-up box can be installed on the exterior of the right side of the furnace to facilitate installation. Seal unused openings on left side ELECTROSTATIC DISCHARGE (ESD) with plugs removed from right side.
  • Page 36 Indoor Blower Speeds one amp is connected to this terminal, it is necessary to use an external relay. See Figure 61 for control board When the thermostat is set to “FAN ON”, the indoor configuration. This terminal is energized in the heating blower will run continuously on the heating speed mode when the combustion air inducer is operating.
  • Page 37 Figure 59. Typical Wiring Diagram For A93DF & 92G1DF 507271-02 Issue 1917 Page 37 of 51...
  • Page 38 Figure 60. Typical Wiring Diagram For A95DF & 95G1DF Page 38 of 51 Issue 1917 507271-02...

  • Page 39: Unit Start-Up

    Figure 61. Integrated Control (Automatic Hot Surface Ignition System) Unit Start-Up CAUTION FOR YOUR SAFETY READ BEFORE OPERATING Before attempting perform service maintenance, turn the electrical power to unit OFF at disconnect switch. WARNING BEFORE LIGHTING the unit, smell all around the furnace Do not use this furnace if any part has been underwater.
  • Page 40 Follow the lighting instructions to place the unit into Replace the heating compartment access panel. operation. 10. Turn on all electrical power to the unit. Set the thermostat to initiate a heating demand. 11. Set the thermostat to desired setting. Allow the burners to fire for approximately 3 minutes.
  • Page 41 Gas Pressure Adjustment While waiting for the unit to stabilize, observe the flame. Flame should be stable and should not lift from Gas Flow (Approximate) burner. Natural gas should burn blue. Seconds for One Revolution After allowing unit to stabilize for 5 minutes, record Natural Capacity manifold pressure and compare to value given in...
  • Page 42 Burner Orifice Conversion Kits at Varying Altitudes 0 - 7,500 ft 7,501 - 10,000 ft (0 - 2,286 m) (2,286 - 3,048 m) Capacity High Altitude High Altitude Natural to LP/ LP/Propane to Natural Burner LP/Propane Burner Propane Natural Orifice Kit Orifice Kit 11K50+ 73W80*...

  • Page 43: 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 44: 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 45: Blower Performance A93Df1D / 92G1Df

    Blower Performance A93DF1D / 92G1DF A93DF1D / 92G1DF 045*B12 Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium - High Medium - Low Pressure in. Watts Watts Watts Watts w.g. 0.00 1615 1385 1205 1045 0.10 1605...

  • Page 46: Blower Performance A95Df1D / 95G1Df

    A93DF1D / 92G1DF 110*C20 Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium - High Medium - Low Pressure in. Watts Watts Watts Watts w.g. 0.00 2410 1390 2190 1080 1860 1560 0.10 2405 1385 2180 1070...
  • Page 47 A95DF1D / 92G1DF 070*B12 Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium - High Medium - Low Pressure in. Watts Watts Watts Watts w.g. 0.00 1515 1315 1095 0.10 1490 1300 1075 0.20 1445 1275 1065...

  • Page 48: 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 49 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 50: Planned Service

    Planned Service A service technician should check the following items Problems detected during the inspection may make it during an annual inspection. Power to the unit must be necessary to temporarily shut down the furnace until the shut off for safety. items can be repaired or replaced.
  • Page 51 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...

This manual is also suitable for:

Allied air a93df1dAllied air 92g1df-pAllied air 95g1df-p045-12070-12090-16 ... Show all

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