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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
215 Metropolitan Drive
West Columbia, SC 29170
507868-02
INSTALLATION INSTRUCTIONS
A93DF1E & 92G1DFE
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
Condensate Piping ....................................................29
Gas Piping .................................................................32
Electrical ....................................................................34
Unit Start-Up ..............................................................37
Air for Non-Direct Vent Applications ..........................41
Other Unit Adjustments..............................................42
Blower Performance ..................................................43
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.
*P507868-02*
Issue 2128
CAUTION
(P) 507868-02
Page 1 of 48
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Summary of Contents for Allied Air A93DF1E
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS A93DF1E & 92G1DFE 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 Capacity 045-B12 17-1/2 16-3/8 070-B12 090-C16 19-7/8 19-1/2 Page 2 of 48 Issue 2128 507868-02... -
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. 507868-02 Issue 2128 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.
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Page 6: General
Supply and Return air ducts must be provided and • When the furnace is installed in a non-direct vent sealed to the furnace. Return air must be terminated applications, do not block the furnace combustion air outside of the space where furnace is installed. opening with clothing, boxes, doors, etc. - 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.
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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 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.
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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 B (17.5”) - 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...
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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 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 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" Pipe Number of 90° Capacity Capacity Capacity...
- Page 19 TYPICAL INTAKE PIPE CONNECTIONS Pipe size determined in Table 11A and Table 11B. 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 Terminations for Direct Vent Installations exhaust back into intake pipe. 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 1-1/2” (38mm) accelerator REDUCER MAY BE REQUIRED 2” EXTENSION FOR 2” PVC provided on 71M80 & 44W92 TO ADAPT DIFFERENT VENT PIPE1” EXTENSION FOR 3” kits for -045 and -070 models PIPE SIZE TO TERMINATION PVC PIPE OUTSIDE INTAKE WALL FURNACE EXHAUST...
- 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 closet installations, vertical termination through the roof SIZE TERMINATION 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.
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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 2128 507868-02...
- Page 31 Figure 52. Trap Drain Assembly Using 1/2” PVC or 3/4” PVC 507868-02 Issue 2128 Page 31 of 48...
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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 field-... - 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...
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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 2128 507868-02...
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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 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*...
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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
Other Unit Adjustments Primary Limit The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no adjustment. Flame Rollout Switches (Two) These manually reset switches are located on the front of the burner box. These limits are factory set and require no adjustment. -
Page 43: Blower Performance
Blower Performance 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 1330 1215 1070 0.40... -
Page 44: Service
Allowable Heating Speeds Model Yellow Blue Brown Black 045-12 Allowed Factory Setting Allowed Allowed Not Allowed 070-12 Not Allowed Allowed Factory Setting Allowed Not Allowed 090-16 Not Allowed Allowed Factory Setting Allowed Not Allowed Table 15. Allowable Circulation Speeds Model Yellow Blue Brown... - Page 45 Cleaning Heat Exchanger 18. Thoroughly rinse and drain the heat exchanger. Soap solutions can be corrosive. Take care to rinse entire If cleaning the heat exchanger becomes necessary, assembly. follow the below procedures and refer to Figure 1 when disassembling unit. Use papers or protective covering in 19.
- Page 46 Cleaning the Burner Assembly Reconnect the sensor wire and reconnect the 2 pin plug to the ignitor wiring harness. 1. Turn off electrical and gas power supplies to furnace. Remove upper and lower furnace access panels. Reinstall the burner box assembly using the existing four screws.
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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...