Allied 92G1DF-P Installation Instructions Manual Download

Page: 1 / 52

507271-02

Page 1 of 52

Issue 1621

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.

CAUTION

Manufactured By

Allied Air Enterprises LLC

A Lennox International, Inc. Company

215 Metropolitan Drive

West Columbia, SC 29170

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.

WARNING

(P) 507271-02

*P507271-02*

INSTALLATION INSTRUCTIONS

A95DF1D, A93DF1D, 95G1DF-P & 92G1DF-P

Warm Air Gas Furnace

Downflow Air Discharge

This manual must be left with the homeowner for future reference.

TABLE OF CONTENTS

Unit Dimensions ................................................................ 2

Parts Arrangement............................................................. 3

Gas Furnace ...................................................................... 4

Shipping and Packing List ................................................. 4

Safety Information ............................................................. 4

Use of Furnace as Construction Heater ............................ 5

General .............................................................................. 6

Combustion, Dilution & Ventilation Air ............................... 6

Setting Equipment ............................................................. 9

Filters ............................................................................... 12

Duct System .................................................................... 12

Pipe & Fittings Specifications

.......................................... 12

Joint Cementing Procedure ............................................. 14

Venting Practices ............................................................. 14

Vent Piping Guidelines .................................................... 16

Gas Piping ....................................................................... 32

Electrical .......................................................................... 34

Unit Start-Up .................................................................... 38

Gas Pressure Adjustment ................................................ 40

High Altitude Information ................................................. 40

Other Unit Adjustments.................................................... 43

Blower Motor Performance .............................................. 44

Service............................................................................. 46

Planned Service .............................................................. 48

Diagnostic Codes ............................................................ 48

Repair Parts List .............................................................. 49

Start-Up & Performance Check List ................................ 50

Summary of Contents for 92G1DF-P

Page 1: ...ler or equivalent service agency or the gas supplier WARNING P 507271 02 P507271 02 INSTALLATION INSTRUCTIONS A95DF1D A93DF1D 95G1DF P 92G1DF P Warm Air Gas Furnace Downflow Air Discharge This manual must be left with the homeowner for future reference TABLE OF CONTENTS Unit Dimensions 2 Parts Arrangement 3 Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 Use of Furnace as Constructi...

Page 2: ...07271 02 Page 2 of 52 Issue 1621 Unit Dimensions inches mm Model A95DF1 A93DF1 95G1DF 92G1DF A B C in mm in mm in mm 045 12 070 12 17 1 2 446 16 3 8 416 16 406 090 16 110 20 21 533 19 7 8 504 19 1 2 495 ...

Page 3: ...rol transformer and door switch BAG ASSEMBLY BLOWER MOTOR hidden BLOWER ACCESS PANEL HEATING ACCESS PANEL COMBUSTION AIR INDUCER BURNER BOX ASSEMBLY includes flame sensor rollout switches and ignitor GAS VALVE BLOWER DECK HEAT EXCHANGER COLD END HEADER BOX PRIMARY LIMIT COMPARTMENT COMPARTMENT ...

Page 4: ...o specification sheets for available accessories Figure 2A Safety Information Use only the type of gas approved for use with this furnace Refer to unit nameplate This unit is CSA International certified to ANSI Z21 47 and CSA 2 3 standards Building Codes In the USA installation of gas furnaces must conform with local building codes In the absence of local codes units must be installed according to...

Page 5: ...ir from entering the furnace If the damper is manually operated it must be equipped to prevent operation of either the heating or the cooling unit unless it is in the full HEAT or COOL setting When installed this furnace must be electrically grounded according to local codes In addition in the United States installation must conform with the current National Electric Code ANSI NFPA No 70 The Natio...

Page 6: ...hese additional requirements Gas furnaces shall be installed by a licensed plumber or fitter only The gas cock must be T handle type When a furnace is installed in an attic the passageway to and service area surrounding the equipment shall be floored Combustion Dilution Ventilation Air If this unit is installed as a Non Direct Vent Furnace follow the guidelines in this section NOTE In Non Direct V...

Page 7: ... of the unit at the platform or at the return air duct connection can cause a potentially dangerous negative pressure condition Air for combustion and ventilation can be brought into the confined space either from inside the building or from outside Air from Inside If the confined space that houses the furnace adjoins a space categorized as unconfined air can be brought in by providing two permane...

Page 8: ...000 Btu 56 kW per hour of the total input rating of all equipment in the enclosure See Figure 9 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be no less than 3 inches 75 mm In calculating free area the blocking effect of louvers grilles or screens must be considered If t...

Page 9: ...unit must be level from side to side Tilt the unit slightly maximum 1 2 in from level from back to front to aid in the draining of the heat exchanger See Figure 11 Shipping Bolt Removal NOTE Units with a 1 2 hp blower motors are equipped with three flexible legs and one rigid leg The rigid leg is equipped with a shipping bolt and a flat white plastic washer rather than the rubber mounting grommet ...

Page 10: ...nace flange damage will result Refer to Figure 13 for clearances in downflow appli cations Figure 13 Downflow Application Installation Clearances CAUTION The furnace and combustible flooring base shall not be installed directly on carpeting tile or other combustible material other than wood flooring Table 1 Non Combustible Floor Opening Size Figure 14 SUPPLY AIR PLENUM PROPERLY SIZED FLOOR OPENING...

Page 11: ...ation of cabinet 2 When cooling cabinet is in place set and secure the furnace according to the instructions that are provided with the cooling coil Secure the furnace to the cabinet 3 Seal the cabinet and check for air leaks Return Air Opening Downflow Units Return air may be brought in only through the top opening of a furnace installed in the downflow position The following steps should be take...

Page 12: ...e products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas This toxic gas might then be distributed throughout the house by the furnace duct system Use fiberglass sealing strips caulking or equivalent sealing method between the plenum and the furnace cabinet to ensure a tight seal...

Page 13: ...o the furnace use ULC S636 approved One Step Transition Cement to bond the pipe to the flue collar In addition the first three feet of vent pipe from the furnace flue collar must be accessible for inspection Table 5 Lists the available exhaust termination kits All vent terminations are PVC Table 5 Outdoor Termination Kits Usage A95DF1E A93DF1E 95G1DFE 92G1DFE VENT PIPE DIA in STANDARD CONCENTRIC O...

Page 14: ...ce and end of pipe are wet with cement forcefully insert end of pipe into socket until it bottoms out Turn PVC pipe 1 4 turn during assembly but not after pipe is fully inserted to distribute cement evenly Do not turn ABS or cellular core pipe NOTE Assembly should be completed within 20 seconds after last application of cement Hammer blows should not be used when inserting pipe 8 After assembly wi...

Page 15: ...rated for 5 minutes test for leaks of flue gases at the draft hood relief opening Use the flame of a match or candle 6 After determining that each appliance connected to the common venting system is venting properly step 3 return all doors windows exhaust fans fireplace dampers and any other gas burning appliances to their previous mode of operation 7 If a venting problem is found during any of th...

Page 16: ...rance on all sides of pipe through center of hole using a hanger 2 When furnace is installed in a residence where unit is shut down for an extended period of time such as a vacation home make provisions for draining condensate collection trap and lines Exhaust Piping Figure 22 Route piping to outside of structure Continue with installation following instructions given in piping termination section...

Page 17: ...507271 02 Page 17 of 52 Issue 1621 A95DF 95G1DF and A93DF 92G1DF Table 7 ...

Page 18: ...507271 02 Page 18 of 52 Issue 1621 A95DF 95G1DF and A93DF 92G1DF Table 8 ...

Page 19: ...507271 02 Page 19 of 52 Issue 1621 Typical Exhaust Pipe Connections Figure 22 Figure 23 Typical Intake Pipe Connections Direct Vent Applications ...

Page 20: ... materials and the factory provided air intake screen to route the intake piping as shown in Figure 27 Maintain a minimum clearance of 3 76 mm around the air intake opening The air intake opening with the protective screen should always be directed forward or sideways 2 If intake air is drawn from a ventilated attic Figure 25 or ventilated crawlspace Figure 26 the exhaust vent length must not exce...

Page 21: ...appliances shall not be less than 12 inches 305 mm IMPORTANT NOTE See Table 9 for maximum allowed exhaust pipe length without insulation in unconditioned space during winter design termperatures below 32 F 0 C If required exhaust pipe should be insulated with 1 2 13 mm Armaflex or equivalent In extremely cold climate areas 3 4 19 mm Araflex or equivalent may be necessary Insulation on outside runs...

Page 22: ...507271 02 Page 22 of 52 Issue 1621 Figure 27 Vent Termination Clearances For Non Direct Vent Installations in the USA and Canada ...

Page 23: ...507271 02 Page 23 of 52 Issue 1621 Figure 28 Vent Termination Clearances For Direct Vent installations in the USA and Canada ...

Page 24: ...and exhaust pipes should be placed as close together as possible at termination end refer to illustrations Maximum separation is 3 76 mm on roof terminations and 6 152 mm on side wall terminations 3 On roof terminations the intake piping should terminate straight down using two 90 elbows See Figure 29 4 Exhaust piping must terminate straight out or up as shown Areducer may be required on the exhau...

Page 25: ...MM Min 6 152MM Min 24 610 MM Max 9 227MM Min 12 305MM Min 16 405 MM Max 6 152MM Max 6 152MM Min 24 610 MM Max 9 227MM Min 12 305MM Min 20 508MM Max 6 152MM Max TABLE 10 1 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 2 As requi...

Page 26: ... A D WALL SUPPORT 1 2 13mm ARMAFLEX INSULATION IN UNCONDITIONED SPACE IF REQUIRED E EXTENDED APPLICATION A IF REQUIRED Figure 35 Field Supplied Wall Termination See venting Table 7 for maximum venting lengths with this arrangement Use wall support every 24 610 mm Use two wall supports if extension is greater than 24 610 mm but less than 48 1219 mm NOTE One wall support must be 6 152 mm from top of...

Page 27: ...ect Vent Concentric Rooftop Termination Figure 37 Direct Vent Concentric Wall Termination Figure 38 Optional Vent Termination for Multiple Unit Installation of Direct Vent Wall Termination Kit Figure 39 Direct Vent Application Using Existing Chimney ...

Page 28: ... 10 FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 12 MIN 305mm Above Grade or average snow accumulation 12 305mm MAX for 2 51mm 20 508mm MAX for 3 76mm IF REQUIRED Non Direct Vent Field Supplied Wall Termination Extended Figure 42 12 305mm ABOVE GRADE OR AVERAGE SNOW ACCUMULATION UNCONDITIONED SPACE 1 2 13mm FOAM INSULATION IF REQUIRED 1 2 13mm FOAM INSULATIO...

Page 29: ...rovided 3 4 NPT street elbow fitting into cold end header box Use Teflon tape or appropriate pipe dope 3 Install the cap over the clean out opening at the base of the trap Secure with clamp See Figure 49 4 Install drain trap using appropriate PVC fittings glue all joints Glue the provided drain trap as shown in Figure 49 Route the condensate line to an open drain Condensate line must maintain a 1 ...

Page 30: ...ed on the condensate trap and line Heating cable kit is available in various lengths 6 ft 1 8 m kit no 26K68 24 ft 7 3 m kit no 26K69 and 50 ft 15 2 m kit no 26K70 Do Not use copper tubing or existing copper condensate lines for drain line CAUTION Figure 46 Evaporator Coil Using a Separate Drain Figure 45 Condensate Trap Location shown with right side exit of condensation Figure 47 Evaporator Coil...

Page 31: ...507271 02 Page 31 of 52 Issue 1621 Figure 49 Trap Drain Assembly Using 1 2 PVC or 3 4 PVC ...

Page 32: ...ertical pipe runs to serve as a trap for sediment or condensate 5 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection See Figure 59 6 In some localities codes may require installation of a manual main shut off valve and union furnished by installer external to the unit Union must be of the ground joint type Leak Check After gas piping is complet...

Page 33: ...69 580 16 42 530 15 01 490 13 87 460 13 03 430 12 18 400 11 33 1 1 2 38 1 1 610 40 894 2100 59 46 1460 41 34 1180 33 41 990 28 03 900 25 48 810 22 94 750 21 24 690 19 54 650 18 41 620 17 56 2 50 8 2 067 52 502 3950 111 85 2750 77 87 2200 62 30 1900 53 80 1680 47 57 1520 43 04 1400 39 64 1300 36 81 1220 34 55 1150 32 56 2 1 2 63 5 2 469 67 713 6300 178 39 4350 123 17 3520 99 67 3000 84 95 2650 75 0...

Page 34: ...stall a separate properly sized disconnect switch near the furnace so that power can be turned off for servicing Before connecting the thermostat check to make sure the wires will be long enough for servicing at a later date Make sure that thermostat wire is long enough to facilitate future removal of blower for service Complete the wiring connections to the equipment Use the provided unit wiring ...

Page 35: ...tions Indoor Blower Speeds 1 When the thermostat is set to FAN ON the indoor blower will run continuously on the heating speed when there is no cooling or heating demand 2 When the furnace is running in the heating mode the indoor blower will run on the heating speed 3 When there is a cooling demand the indoor blower will run on the cooling speed Generator Use Voltage Requirements The following re...

Page 36: ...507271 02 Page 36 of 52 Issue 1621 Figure 56 Typical Wiring Diagram For A93DF 92G1DF ...

Page 37: ...507271 02 Page 37 of 52 Issue 1621 Typical Wiring Diagram Figure 57 For A95DF 95G1DF ...

Page 38: ...ome gas is heavier than air and will settle on the floor The gas valve on the unit is equipped with a gas control switch lever Use only your hand to move switch Never use tools If the switch will not move by hand do not try to repair it Force or attempted repair may result in a fire or explosion Placing the furnace into operation This furnace is equipped with an automatic hot surface ignition syst...

Page 39: ...ostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 12 If the appliance will not operate follow the instructions Turning Off Gas to Unit and call your service technician or gas supplier Turning Off Gas to Unit 1 Set the thermostat to the lowest setting 2 Turn off all electrical power to the unit if service is to be perf...

Page 40: ...urnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking combustion Take combustion sample beyond the flue outlet and compare to the tables below The maximum carbon monoxide reading should not exceed 100 ppm High Altitude Information NOTE In Canada certification for installations at elevations over 4500 feet 1371 m is the jurisdiction of local autho...

Page 41: ...1 7500 ft 1371 2286m 7501 10000 ft 2286 3048m All No Change No Change 93W88 A93 and 92G1 Pressure Switch at Varying Altitudes Pressure switch is factory set No adjustment necessary All models use the factory installed pressure switch from 0 7500 feet 0 2286 m Unit Size 0 7500 ft 0 2286 m 7501 10000 ft 2286 3048 m Natural to LP Propane LP Propane to Natural High Altitude Natural Burner Orifice Kit ...

Page 42: ... 2 Visually inspect the venting system for proper size and horizontal pitch Determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 To the extent that it is practical close all building doors and windows and all doors between the space in which the appliances connected to the venting system are located and other spaces of the bu...

Page 43: ...at anticipator setting if adjustable according to the amp draw listed on the wiring diagram that is attached to the unit Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace with furnace operating Correct voltage is 120 VAC 10 3 Check amp draw on the blower motor with the blower compartment access panel in place Motor Nameplate__________Actual_________...

Page 44: ...0 295 605 250 0 90 1320 555 1130 450 1010 385 920 345 A93DF1D 92G1DF 070 12B PERFORMANCE Less Filter A93DF1D 92G1DF 110 20C PERFORMANCE Less Filter External Static Pressure in w g Air Volume Watts at Various Blower Speeds External Static Pressure in w g Air Volume Watts at Various Blower Speeds High Medium High Medium Low Low High Medium High Medium Low Low cfm Watts cfm Watts cfm Watts cfm Watts ...

Page 45: ...335 700 290 605 250 0 90 1580 1010 1485 735 1405 610 1270 510 A95DF1D 92G1DF 070 12B PERFORMANCE Less Filter A95DF1D 95G1DF 110 20C PERFORMANCE Less Filter External S t a t i c Pressure in w g Air Volume Watts at Various Blower Speeds External S t a t i c Pressure in w g Air Volume Watts at Various Blower Speeds High Medium High Medium Low Low High Medium High Medium Low Low cfm Watts cfm Watts cf...

Page 46: ...0 3 Check amp draw on the blower motor with the blower compartment access panel in place Motor Nameplate__________Actual__________ Winterizing and Condensate Trap Care 1 Turn off power to the furnace 2 Have a shallow pan ready to empty condensate water 3 Remove the clean out cap from the condensate trap and empty water Inspect the trap then reinstall the clean out cap Cleaning Heat Exchanger If cl...

Page 47: ... 33 Secure burner box assembly to vestibule panel using four existing screws Make sure burners line up in center of burner ports 34 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 35 Reconnect 2 wires to gas valve 36 Replace the blower compartment access panel 37 Refer to instruction on verifying gas and electrical connections when re establishing supplies 38 Follow li...

Page 48: ...al between the return air and the room where the furnace is installed Return air duct Must be properly attached and provide an air seal to the unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications Problems detected during the inspection m...

Page 49: ...uivalent service agency or gas supplier Cabinet Parts Heating Compartment Access Panel Blower Compartment Access Panel Top Cap Control Panel Parts Transformer Integrated Control Board Door Interlock Switch Blower Parts Blower Wheel Motor Motor Mounting Frame Motor Capacitor Blower Housing Cutoff Plate Heating Parts Flame Sensor Heat Exchanger Assembly Gas Manifold Combustion Air Inducer Gas Valve ...

Page 50: ...507271 02 Page 50 of 52 Issue 1621 Start Up Performance Check List ...

Page 51: ...ly External Static Return External Static Total External Static CONDENSATE LINE 6 Leak Free VENT PIPE 7 Leak Free COOLING MODE INDOOR BLOWER AMPS______ 3 TEMPERATURE DROP Return Duct Temperature Supply Duct Temperature Temperature Drop 4 DRAIN LINE 8 Leak Free THERMOSTAT Adjusted and Programmed Explained Operation to Owner 9 SUPPLY AIR Blower Motor Amps Duct Static Thermostat Gas Manifold Pressure...

Page 52: ... minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall ...

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