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A95DF, A93DF, 95G1DF & 92G1DF
Warm Air Gas Furnace / Downflow Air Discharge
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
A95/A93/95G1/92G1DF Parts Arrangement ................. 3
A95/A93/95G1/92G1DF 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
*P506725-01*
(P) 506725-01
506725-01
INSTALLATION INSTRUCTIONS
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 ........................................................................ 42
Planned Service .......................................................... 44
Diagnostic Codes ........................................................ 44
Repair Parts List ......................................................... 45
Start Up Checklist ....................................................... 46
A Lennox International, Inc. Company
Issue 1109
WARNING
Manufactured By
Allied Air Enterprises, Inc.
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 48
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Summary of Contents for Allied Air 92G1DF
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS A95DF, A93DF, 95G1DF & 92G1DF 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: Front View
FLOW (838) Supply (19) FRONT VIEW Model Number A95DF/A93DF 95G1DF/92G1DF 045-12 070-12 090-16 110-20 Page 2 of 48 UNIT DIMENSIONS − inches (mm) COMBUSTION AIR INTAKE EXHAUST AIR OUTLET 2−1/16 (52) 1 (25) Front Panel 9/16 (14) 2 (51) Either Side... -
Page 3: A95/A93/95G1/92G1Df Parts Arrangement
PARTS ARRANGEMENT 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 506725-01... -
Page 4: A95/A93/95G1/92G1Df Gas Furnace
Gas Furnace This Category IV gas furnace is shipped ready for installation in the downflow position. The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications. This unit can be installed as either a Direct Vent or a Non-Direct Vent gas central furnace NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors. -
Page 5: Use Of Furnace As A Construction Heater
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 11. Accessibility and service clearances must take precedence over fire protection clearances. NOTE: When furnace is installed on a combustible floor, a downflow combustible flooring base must be installed between the furnace and the floor. -
Page 6: General
To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor. Allied Air Enterprises, Inc. 215 Metropolitan Drive West Columbia, SC 29170 Combustion, Dilution & Ventilation Air If this unit is installed as a Non-Direct Vent Furnace, follow the guidelines in this section. - Page 7 air is brought into the house for combustion, negative pressure (outside pressure is greater than inside pressure) will build to the point that a down draft can occur in the furnace vent pipe or chimney. As a result, combustion gases enter the living space creating a potentially dangerous situation.
- Page 8 Air from Outside If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent openings. One opening shall be within 12” (305 mm) of the top of the enclosure and one within 12” (305 mm) of the bottom.
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Page 9: Setting Equipment
INSTALLATION – Setting Equipment WARNING Do not install the furnace on its front, back or in the horizontal position. See Figure 10. Do no connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death. - Page 10 WARNING Improper installation of the furnace can result in personal injury or death. Combustion and flue products must never be allowed to enter the return air system or air in the living space. Use sheet metal screws and joint tape to seal return air system to furnace.
- Page 11 COMBUSTIBLE FLOORING BASE OPENING SIZE Front to Rear Cabinet Catalog Width Number B Cabinet 11M60 (17.5") C Cabinet 11M61 (21") TABLE 2 FURNACE PROPERLY SIZED FLOOR OPENING FIGURE 13 After opening is cut, set the combustible flooring base into opening. 3.
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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 Filter Size Cabinet Width... - Page 13 PIPE (Dia. X DIA. A93DF Length) (in.) 95G1DF 92G1DF 1−1/2" X 12" 2−1/2 2−1/2 2−1/2 2−1/2 *Requires field−provided and installed 1−1/2" exhaust accelerator. ** Kit 51W11 is provided with a 1−1/2" accelerator which must be used for all 45,000 and 70,000 furnace installations.
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Page 14: Joint Cementing Procedure
Joint Cementing Procedure All cementing of joints should be done according to the specifications outlined in ASTM D 2855. NOTE: A sheet metal screw may be used to secure the intake pipe to the connector, if desired. Use a drill or self tapping screw to make a pilot hole. -
Page 15: Vent Piping Guidelines
Contact Allied Air Technical Service for assistance in sizing vent pipe in these applications. MINIMUM VENT PIPE LENGTHS A95DF, 95G1DF, A93DF, & 92G1DF MODELS 045, 070, 090, 110 *Any approved termination may be added to the minimum length listed. - Page 16 Of 90° Model Elbows Used Page 16 of 48 A95DF / 95G1DF and A93DF / 92G1DF Both Intake and Exhaust must be same pipe size. Standard Termination at Elevation 0 − 10,000 ft. 2−1/2" Pipe Model Concentric Termination 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 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. Guidelines listed in Combustion, Dilution and Ventilation Air section must be followed.
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Page 19: Vent Termination Clearances
FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA VENT TERMINAL Clearance above grade, veranda, porch, deck or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (mm) from the center line of the terminal Clearance to unventilated soffit... - Page 20 FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA VENT TERMINAL Clearance above grade, veranda, porch, deck or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (mm) from the center line of the terminal Clearance to unventilated soffit...
- Page 21 Details of Intake and Exhaust Piping Terminations for Direct Vent Installations NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors. NOTE: Flue gas may be slightly acidic and may adversely affect some building materials. If any vent termination is used and the flue gases may impinge on the building material, a corrosion-resistant shield (minimum 24 inches square) must be used to protect the wall surface.
- Page 22 The exhaust termination tee should be connected to the 2" or 3" PVC flue pipe as shown in the illustration. Do not use an accelerator in applications that include an exhaust termination tee. The accelerator is not required. As required. Flue gas may be acidic and may adversely affect some building materials. If a side wall vent termination is used and flue gases will impinge on the building materials, a corrosion−resistant shield (24 inches square) should be used to protect the wall surface.
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Page 23: Extended Application
FIELD SUPPLIED WALL TERMINATION NOTE − FIELD PROVIDED REDUCER MAY BE 1/2" (13mm) ARMAFLEX REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1/2" (13mm) ARMAFLEX INSULATION IN UNCONDITIONED SPACE (IF REQUIRED) * WALL SUPPORT See venting Table 7 for maximum venting lengths with this arrangement. -
Page 24: Front View
DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada) 1 1/2" (38mm) accelerator provided on 71M80 & 44W92 EXHAUST VENT 12” (305mm) INTAKE Minimum Above Average Snow Accumulation SHEET METAL STRAP (Clamp and sheet metal strap must be field installed to support the weight of the termination kit.) CLAMP... - Page 25 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 is preferred. Figures 34 through 37 show typical terminations. 1.
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Page 26: Condensate Trap Location
Condensate Piping This unit is designed for either right or left side exit of condensate piping in downflow applications. Figure 38 for condensate trap locations. NOTE: If necessary the condensate trap may be installed up to 5” away using PVC pipe from the furnace. Piping from furnace must slope down a minimum of 1/4”... - Page 27 TRAP / DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC OPTIONAL Condensate Drain Connection Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) 90° Street Elbow 1/2 inch PVC (Not Furnished) Condensate Drain Connection In Unit OPTIONAL Drain Piping Drain Assembly for 1/2 inch Drain Pipe 1/2 inch PVC (Not Furnished)
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Page 28: Gas Piping
Gas Piping CAUTION 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 cabinet. The flexible connector can then be added between the black iron pipe and the gas supply line. - Page 29 Left Side Piping (Standard) MANUAL MAIN SHUT−OFF VALVE (With 1/8 in. NPT Plugged Tap Shown) GROUND JOINT UNION DRIP LEG Bellows Grommet Nominal Internal Iron Pipe Size Diameter −Inches(mm) −Inches(mm) (3.048) .622 (12.7) (17.799) (4.96) .824 (19.05) (20.930) (10.19) 1.049 (25.4) (26.645) (19.25)
- Page 30 Removal of the Furnace from Common Vent In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances. Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain connected to the common venting system.
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Page 31: Electrical
Electrical ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures CAUTION Electrostatic discharge can affect electronic components. Take precautions during furnace installation and service to protect the furnace’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the furnace, the control and the technician at the same electrostatic potential. -
Page 32: Typical Field Wiring Diagram
One line voltage “HUM” 1/4” spade terminal is provided on the furnace control board. Any humidifier rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. -
Page 33: Typical Wiring Diagram
TYPICAL WIRING DIAGRAM FIGURE 48 506725-01 Page 33 of 48 Issue 1109... -
Page 34: Unit Start Up
5 AMP FUSE Unit Start-Up FOR YOUR SAFETY READ BEFORE OPERATING WARNING Do not use this furnace if any part has been underwater. A flood-damaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. Immediately call a qualified service technician to inspect the furnace and to replace all gas controls, control system parts, and electrical parts that have been wet or to replace the furnace, if deemed necessary. - Page 35 Priming Condensate Trap The condensate trap should be primed with water prior to start-up to ensure proper condensate drainage. Either pour 10 fl. oz. (300 ml) of water into the trap, or follow these steps to prime the trap: 1. Follow the lighting instructions to place the unit into operation.
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Page 36: Gas Pressure Adjustment
Gas Pressure Adjustment Gas Flow (Approximate) GAS METER CLOCKING CHART Seconds for One Revolution Natural Unit 1 cu ft 2 cu ft Dial Dial −045 −070 −090 −110 −135 Natural−1000 btu/cu ft LP−2500 btu/cu ft TABLE 11 NOTE: To obtain accurate reading, shut off all other gas appliances connected to meter. - Page 37 Burner Orifice Conversion Kits at Varying Altitudes 0 - 7,500 ft (0 - 2,286 m) Natural Unit Size LP/Propane 68W75*† * Conversion requires installation of a gas valve regulator spring which is provided with the gas conversion kit. † LP kit includes low line pressure switch. A93 and 92G1 Pressure Switches at Varying Altitudes Unit 0 - 4,500 ft...
- Page 38 Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
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Page 39: 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 40: Blower Motor Performance
A93DF1D / 92G1DF 045*12B PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External Medium- Static High Pressure High in. w.g. cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1615 650 1385 555 1205 465 1045 390 0.10... - Page 41 A95DF1D / 95G1DF 045*12B PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External Static Medium- High High Pressure in. w.g. cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1615 650 1385 555 1205 465 1045 390 0.10 1605 640 1380 545 1195 455 1035 380 0.20...
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Page 42: Service
Service WARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death, or property damage. Before servicing, disconnect all electrical power to furnace. - Page 43 19. Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting on the support located at the rear of the cabinet. Remove the indoor blower to view this area through the blower opening. 20.
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Page 44: 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 45: 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 Compartment Access Panel Blower Compartment Access Panel... -
Page 46: Unit Setup
Start−Up & Performance Check List GAS SUPPLY Natural Gas Piping Connections Tight Leak Tested INTAKE / EXHAUST PIPE All Joints Primed and Glued Terminations Installed Properly Horizontal Pipes Sloped (if applicable) Condensate Trap Primed / Line Sloped Pipes Supported Heat Cable Installed and Operable (if applicable) Page 46 of 48 UNIT SET UP Furnace:... -
Page 47: Unit Operation
HEATING MODE GAS MANIFOLD PRESSURE “W.C.” ______ COMBUSTION SAMPLE CO ______ INDOOR BLOWER AMPS ______ TEMPERATURE RISE Supply Duct Temperature Return Duct Temperature Temperature Rise TOTAL EXTERNAL STATIC Supply External Static Return External Static Total External Static CONDENSATE LINE Leak Free VENT PIPE Leak Free Combustion CO... -
Page 48: Requirements For Commonwealth Of Massachusetts
REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS Modifications to NFPA-54, Chapter 10 Revise NFPA-54 section 10.8.3 to add the following requirements: For all side wall, horizontally vented, gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above the finished grade in the area of the venting, including but...
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