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Armstrong 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
A95DF1E & 95G1DFE Gas Furnace ................................. 4
Shipping and Packing List ............................................... 4
Safety Information .......................................................... 4
Use of Furnace as a Construction Heater ....................... 5
General .......................................................................... 6
Combustion, Dilution, Ventilation Air ................................. 6
Setting Equipment ........................................................... 9
Filters ........................................................................... 12
Duct System ................................................................. 12
Pipe and Fittings Specifications ..................................... 12
Joint Cementing Procedure ............................................ 14
Venting Practices .......................................................... 14
*P506845-01*
(P) 506845-01
506845-01
INSTALLATION INSTRUCTIONS
A95DF1E & 95G1DFE
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 ................................................ 15
Gas Piping .................................................................. 28
Electrical ..................................................................... 31
Unit Start Up ................................................................ 34
Gas Pressure Adjustment ........................................... 36
High Altitude Information ............................................. 36
Other Unit Adjustments ............................................... 39
Blower Motor Performance ......................................... 40
Service ........................................................................ 41
Planned Service ........................................................... 43
Diagnostic Codes .......................................................... 43
Repair Parts List ........................................................... 44
Start Up Checklist .......................................................... 45
A Lennox International, Inc. Company
Issue 1132
WARNING
Manufactured By
Allied Air Enterprises, Inc.
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 47

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  • Page 1: Table Of Contents

    TABLE OF CONTENTS Unit Dimensions ............2 Vent Piping Guidelines ..........15 A95DF1E & 95G1DFE Parts Arrangement ......3 Gas Piping ..............28 A95DF1E & 95G1DFE Gas Furnace ......... 4 Electrical ..............31 Shipping and Packing List ..........4 Unit Start Up ..............

  • Page 2: Unit Dimensions

    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 16−3/8 070-12 090-16 19−7/8 19−1/2 110-20 Page 2 of 47 Issue 1132 506845-01...

  • 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 PRIMARY LIMIT HEATING COMPARTMENT COLD END HEADER BOX ACCESS HEAT EXCHANGER PANEL GAS VALVE BURNER BOX ASSEMBLY (includes flame sensor, rollout switches and ignitor) Figure 1 506845-01...

  • Page 4: A95Df1E & 95G1Dfe Gas Furnace

    Gas Furnace Safety Information This Category IV gas furnace is shipped ready for installation in the downflow position. WARNING The furnace is equipped for installation in natural gas Improper installation, adjustment, alteration, service or applications. A conversion kit (ordered separately) is required maintenance can cause property damage, personal injury for use in propane/LP gas applications.

  • Page 5: Use Of Furnace As A Construction Heater

    Locations and Clearances This furnace is CSA International certified for installation Heating Unit Installed Parallell to Air Handler Unit clearances to combustible material as listed on the unit nameplate and in the table in Figure 11. Accessibility and service clearances must take precedence over fire protection clearances.

  • 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 Product Contains Fiberglass Wool. for combustion air requirements during construction. Temporary ducting may supply outdoor air to the furnace.
  • Page 7 air is brought into the house for combustion, negative infiltration. If the furnace is located in a building of tight pressure (outside pressure is greater than inside pressure) construction with weather stripping and caulking around the will build to the point that a down draft can occur in the furnace windows and doors, follow the procedures in the “Air from vent pipe or chimney.
  • Page 8 to 25 percent free area and metal louvers and grilles will Air from Outside have 60 to 75 percent free area. Louvers and grilles must If air from outside is brought in for combustion and ventilation, be fixed in the open position or interlocked with the equipment the confined space shall be provided with two permanent so that they are opened automatically during equipment openings.

  • Page 9: Setting Equipment

    INSTALLATION – Setting Equipment NOTE: These units may be equipped with a shipping pad under the blower housing. Remove the shipping pad prior WARNING to operation. Do not install the furnace on its front, back or in the Allow for clearances to combustible materials as indicated horizontal position.
  • Page 10 Installation on Non-Combustible Flooring (Figure 12) 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 personal connections, electrical supply, flue and air intake 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 Outdoor Exhaust Exhaust Flush- 2" 3" 1−1/2" VENT Mount Concentric Concentric Accelerator Accelerator Concentric PIPE (Dia. X (Dia. X A95DF1E DIA. Length) Length) 95G1DFE (in.) 60L46 71M80 69M29 1−1/2" X 12" 2" X 12" 51W11** 44W92 44W92 44W93 2−1/2 2−1/2 2−1/2...

  • 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

    Do not use screens or perforated metal in exhaust or MINIMUM VENT PIPE LENGTHS intake terminations. Doing so will cause freeze-ups and A95DF1E & 95G1DFE MIN. VENT LENGTH* may block the terminations. MODELS 15 ft. or...
  • 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 EXHAUST DO NOT transition from smaller *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 General Guidelines for Vent Terminations This furnace may be installed in either direct vent or non- In Non-Direct Vent applications, combustion air is taken from direct vent applications. In non-direct vent applications, indoors and the flue gases are discharged to the outdoors. when intake air will be drawn into the furnace from the This unit is then classified as a non-direct vent, Category IV surrounding space, the indoor air quality must be considered.
  • Page 19 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 20 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 21 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 22 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 23 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 24 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 25 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 closet 12" (305mm) MAX. for 2" (51mm) installations, vertical termination through the roof is preferred.
  • Page 26 Condensate line must slope downward away from the trap Condensate Piping to drain. If drain level is above condensate trap, condensate This unit is designed for either right or left side exit of pump must be used. Condensate drain line should be routed condensate piping in downflow applications.
  • Page 27 Trap Drain Assembly Using 1/2” PVC or 3/4” PVC OPTIONAL Condensate Drain Connection Adapter 1/2 inch slip X Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Condensate Drain 1/2 inch mpt (Not Furnished) Connection In Unit Vent 90 Street Elbow 1 (25) Minimum 1/2 inch PVC 5 Feet...

  • Page 28: 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 29 Left Side Piping MANUAL AUTOMATIC (Standard) MAIN SHUT−OFF GAS VALVE MANUAL VALVE AUTOMATIC (with manual MAIN SHUT−OFF Plug (With 1/8 in. NPT shut−off valve) GAS VALVE VALVE Plugged Tap (with manual Plug (With 1/8 in. NPT Shown) shut−off valve) Plugged Tap Shown) GROUND JOINT UNION...
  • Page 30 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 31: Electrical

    Electrical The unit is equipped with a field makeup box on the left ELECTROSTATIC DISCHARGE (ESD) hand side of the cabinet. A field-provided make-up box can Precautions and Procedures be installed on the exterior of the right side of the furnace to facilitate installation.
  • Page 32 One line voltage “HUM” 1/4” spade terminal is provided on the heating mode when the combustion air inducer is the furnace control board. Any humidifier rated up to one operating. amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral Install the room thermostat according to the instructions terminals.
  • Page 33 Typical Wiring Diagram For A95DF1E & 95G1DFE Figure 48 506845-01 Page 33 of 47 Issue 1132...

  • Page 34: Unit Start Up

    Integrated Control (Automatic Hot Surface Ignition System) Figure 49 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 Do not use this furnace if any part has been disconnect switch.
  • Page 35 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 36: Gas Pressure Adjustment

    Gas Pressure Adjustment Gas Flow (Approximate) Supply Line and Manifold Pressure (inches w.c.) Manifold Unit Fuel Line Pressure GAS METER CLOCKING CHART Pressure Seconds for One Revolution Nat. Gas 4.5 − 10.5 Natural Unit 1 cu ft 2 cu ft 1 cu ft 2 cu ft L.P.
  • Page 37 Table 14 506845-01 Page 37 of 47 Issue 1132...
  • Page 38 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 39: 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 motor vestibule panel.

  • Page 40: Blower Motor Performance

    Blower Data A95DF1E & 95G1DFE A95DF1E / 95G1DFE 045*12B PERFORMANCE (Less Filter) A95DF1E / 95G1DFE 070*12B 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 41: 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%. ELECTRICAL SHOCK, FIRE, 3. Check amp-draw on the blower motor with the blower OR EXPLOSION HAZARD.
  • Page 42 16. Remove screws along vestibule sides and bottom Cleaning the Burner Assembly 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 43: 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 44: 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: A93DF045P36B-01. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier. Cabinet Parts Heating Parts Heating Compartment Access Panel...

  • Page 45: Start Up Checklist

    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 46 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 47 REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS Modifications to NFPA-54, Chapter 10 - 4. INSPECTION. The state or local gas inspector of the Revise NFPA-54 section 10.8.3 to add the following side wall, horizontally vented, gas-fueled equipment requirements: shall not approve the installation unless, upon For all side wall, horizontally vented, gas fueled equipment inspection, the inspector observes carbon monoxide installed in every dwelling, building or structure used in whole...

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