Allied Air Enterprises Furnace 92G1DF User Manual

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.

WARNING

CAUTION

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.

As with any mechanical equipment, personal injury can

result from contact with sharp sheet metal edges. Be

careful when you handle this equipment.

TABLE OF CONTENTS

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

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

Manufactured By

Allied Air Enterprises, Inc.

A Lennox International, Inc. Company

215 Metropolitan Drive

*P506725-01*

(P) 506725-01

West Columbia, SC 29170

506725-01

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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

ACCESS

COLD END HEADER BOX

HEAT EXCHANGER

PANEL

GAS VALVE

BURNER BOX ASSEMBLY

(includes ﬂame sensor, rollout switches and ignitor)

FIGURE 1

506725-01

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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

applications. Aconversion kit (ordered separately) is required

for use in propane/LP gas applications.

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.

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. In

Non-Direct Vent installations, combustion air is taken from

indoors and flue gases are discharged outdoors. See Figure

2 for applications involving roof termination.

CAUTION

As with any mechanical equipment, personal injury can

result from contact with sharp sheet metal edges. Be

careful when you handle this equipment.

DANGER

DANGER OF EXPLOSION!

There are circumstances in which odorant used with LP/

Propane gas can lose its scent. In case of a leak, LP/

Propane gas will settle close to the floor and may be difficult

to smell. An LP/Propane leak detector should be installed

in all LP applications.

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.

FIGURE 2

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 the current National Fuel Gas

Code (ANSI Z223.1/NFPA54). The National Fuel Gas Code

is available from the American National Standards

Institute, Inc., 11 West 42nd Street, New York, NY 10036.

Shipping and Packing List

Package 1 of 1 contains:

1 - Assembled Gas Unit

1 - Bag assembly containing the following:

3 - Wire nuts

1 - Snap bushing

1 - Snap Plug

1 - Wire tie

1 - Condensate trap

In Canada, installation must conform with current National

Standard of Canada CSA-B149 Natural Gas and Propane

Installation Codes, local plumbing or waste water codes and

other applicable local codes.

1 - Condensate trap cap

1 - Condensate trap clamp

1 - 2” diameter debris screen

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.

Check equipment for shipping damage. If you find any

damage, immediately contact the last carrier.

Please refer to specification sheets for available accessories.

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506725-01

Locations and Clearances

Heating Unit Installed Parallell to Air Handler Unit

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.

AIR HANDLER

GAS UNIT

For installation in a residential garage, the furnace must be

installed so that the burner(s) and the ignition source are

located no less than 18 inches (457 mm) above the floor.

The furnace must be located or protected to avoid physical

damage by vehicles. When a furnace is installed in a public

garage, hangar, or other building that has a hazardous

atmosphere, the furnace must be installed according to

recommended good practice requirements and current

National Fuel Gas Code or CSA B149 standards.

Dampers

(open during cooling

operation only)

Dampers

(open during heating

operation only)

FIGURE 3

Note: Furnace must be adjusted to obtain a temperature

rise within the range specified on the unit nameplate. Failure

to do so may cause erratic limit operation and premature

heat exchanger failure.

NOTE: This furnace is designed for a minimum continuous

return air temperature of 60°F (16°C) or an intermittent

operation down to 55°F (13°C) dry bulb for cases where a

night setback thermostat is used. Return air temperature

must not exceed 85°F (29°C) dry bulb.

This gas furnace must be installed so that its electrical

components are protected from water.

This gas furnace may be installed in alcoves, closets, attics,

basements, garages, and utility rooms.

Installed in Combination with a Cooling Coil

When this furnace is used with cooling units (Figure 3), it

shall be installed in parallel with, or on the upstream side of,

cooling units to avoid condensation in the heating

compartment. With a parallel flow arrangement, a damper

(or other means to control the flow of air) must adequately

prevent chilled air 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.

This furnace design has NOT been CSA certified for

installation in mobile homes, recreational vehicles, or

outdoors.

Never use an open flame to test for gas leaks. Check all

connections using a commercially available soap solution

made specifically for leak detection.

Use of Furnace as Construction Heater

These units are not recommended for use as a construction

heater during any phase of construction. Very low return air

temperature, harmful vapors and operation of the unit with

clogged or misplaced filters will damage the unit.

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/NFPANo. 70. The National Electric Code (ANSI/

NFPA No. 70) is available from the following address:

These units may be used for heating of buildings or structures

under construction, if the following conditions are met:

National Fire Protection Association

1 Battery March Park

Quincy, MA 02269

•

The vent system must be permanently installed per these

installation instructions.

•

Aroom thermostat must control the furnace. The use of

fixed jumpers that will provide continuous heating is not

allowed.

The return air duct must be provided and sealed to the

furnace.

Return air temperature range between 60°F (16°C) and

80°F (27°C) must be maintained.

Air filters must be installed in the system and must be

maintained during construction.

In Canada, all electrical wiring and grounding for the unit

must be installed according to the current regulations of the

Canadian Electrical Code Part I (CSAStandard C22.1) and/

or local codes.

•

506725-01

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•

Air filters must be replaced upon construction completion.

The input rate and temperature rise must be set per the

furnace rating plate.

WARNING

•

One hundred percent (100%) outdoor air must be provided

for combustion air requirements during construction.

Temporary ducting may supply outdoor air to the furnace.

Do not connect duct directly to the furnace. Size the

temporary duct following the instructions in section for

Combustion, Dilution and Ventilation Air in a confined

space with air from outside.

Product Contains Fiberglass Wool.

Disturbing the insulation in this product during

installation, maintenance, or repair will expose you to

fiberglass wool. Breathing this may cause lung cancer.

(Fiberglass wool is known to the State of California to

cause cancer.)

•

The furnace heat exchanger, components, duct system,

air filters and evaporator coils must be thoroughly

cleaned following final construction cleanup.

All furnace operating conditions (including ignition, input

rate, temperature rise and venting) must be verified

according to these installation instructions.

Fiberglass wool may also cause respiratory, skin, and

eye irritation.

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

General

These instructions are intended as a general guide and do

not supersede local codes in any way. Consult authorities

having jurisdiction before installation.

Combustion, Dilution & Ventilation Air

If this unit is installed as a Non-Direct Vent Furnace,

follow the guidelines in this section.

In addition to the requirements outlined previously, the

following general recommendations must be considered

when installing one of these furnaces:

NOTE: In Non-Direct Vent Installations, combustion air is

taken from indoors and flue gases are discharged outdoors.

•

Place the furnace as close to the center of the air

distribution system as possible. The furnace should also

be located close to the vent termination point.

When the furnace is installed in non-direct vent

applications, do not install the furnace where drafts might

blow directly into it. This could cause improper

combustion and unsafe operation.

When the furnace is installed in a non-direct vent

applications, do not block the furnace combustion air

opening with clothing, boxes, doors, etc. Air is needed

for proper combustion and safe unit operation.

When the furnace is installed in an attic or other insulated

space, keep insulation away from the furnace.

When the furnace is installed in an unconditioned space,

consider provisions required to prevent freezing of the

condensate drain system.

WARNING

Insufficient combustion air can cause headaches,

nausea, dizziness or asphyxiation. It will also cause

excess water in the heat exchanger resulting in rusting

and premature heat exchanger failure. Excessive

exposure to contaminated combustion air will result in

safety and performance related problems. Avoid

exposure to the following substances in the combustion

air supply:

•

Permanent wave solutions

Chlorinated waxes and cleaners

Chlorine base swimming pool chemicals

Water softening chemicals

De-icing salts or chemicals

Carbon tetrachloride

Halogen type refrigerants

NOTE: The Commonwealth of Massachusetts stipulates

Cleaning solvents (such as perchloroethylene)

Printing inks, paint removers, varnishes, etc.

Hydrochloric acid

Cements and glues

Antistatic fabric softeners for clothes dryers

Masonry acid washing materials

these 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.

In the past, there was no problem in bringing in sufficient

outdoor air for combustion. Infiltration provided all the air

that was needed. In today’s homes, tight construction

practices make it necessary to bring in air from outside for

combustion. Take into account that exhaust fans, appliance

vents, chimneys, and fireplaces force additional air that could

be used for combustion out of the house. Unless outside

CAUTION

These units should not be installed in areas normally

subject to freezing temperatures.

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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.

infiltration. If the furnace is located in a building of tight

construction with weather stripping and caulking around the

windows and doors, follow the procedures in the “Air from

Outside” section.

Confined Space

In the absence of local codes concerning air for combustion

and ventilation, use the guidelines and procedures in this

section to install these furnaces to ensure efficient and safe

operation. You must consider combustion air needs and

requirements for exhaust vents and gas piping. Aportion of

this information has been reprinted with permission from

the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This

reprinted material is not the complete and official position of

ANSI on the referenced subject, which is represented only

by the standard in its entirely.

A confined space is an area with a volume less than 50

cubic feet (1.42 m³) per 1,000 Btu (.29 kW) per hour of the

combined input rating of all appliances installed in that space.

This definition includes furnace closets or small equipment

rooms.

When the furnace is installed so that supply ducts carry air

circulated by the furnace to areas outside the space

containing the furnace, the return air must be handled by

ducts which are sealed to the furnace casing and which

terminate outside the space containing the furnace. This is

especially important when the furnace is mounted on a

platform in a confined space such as a closet or small

equipment room. Even a small leak around the base 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.

In Canada, refer to the CSA B149 Installation codes.

CAUTION

Do not install the furnace in a corrosive or contaminated

atmosphere. Meet all combustion and ventilation air

requirements, as well as all local codes.

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 permanent openings between the two spaces. Each

opening must have a minimum free area of 1 square inch

(645 mm²) per 1,000 Btu (.29 kW) per hour of total input

rating of all gas-fired equipment in the confined space. Each

opening must be at least 100 square inches (64516 mm²).

One opening shall be within 12 inches (305 mm) of the top

of the enclosure and one opening within 12 inches (305 mm)

of the bottom. See Figure 4.

All gas-fired appliances require air for the combustion

process. If sufficient combustion air is not available, the

furnace or other appliance will operate inefficiently and

unsafely. Enough air must be provided to meet the needs

of all fuel-burning appliances and appliances such as exhaust

fans which force air out of the house. When fireplaces,

exhaust fans, or clothes dryers are used at the same time

as the furnace, much more air is required to ensure proper

combustion and to prevent a down draft. Insufficient air

causes incomplete combustion which can result in carbon

monoxide.

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM INSIDE

In addition to providing combustion air, fresh outdoor air

dilutes contaminants in the indoor air. These contaminants

may include bleaches, adhesives, detergents, solvents and

other contaminants which can corrode furnace components.

ROOF TERMINATED

EXHAUST PIPE

The requirements for providing air for combustion and

ventilation depend largely on whether the furnace is installed

in an unconfined or a confined space.

OPENINGS

(To Adjacent

Unconﬁned

Space)

Unconfined Space

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

FURNACE

An unconfined space is an area such as a basement or

large equipment room with a volume greater than 50 cubic

feet (1.42 m³) per 1,000 Btu (.29 kW) per hour of the

combined input rating of all appliances installed in that space.

This space also includes adjacent rooms which are not

separated by a door. Though an area may appear to be

unconfined, it might be necessary to bring in outdoor air for

combustion if the structure does not provide enough air by

NOTE− Each opening shall have a free area of at least one square inch

per 1,000 Btu (645 mm per .29 kW) per hour of the total input rating of

all equipment in the enclosure, but not less than 100 square inches

(64516 mm ).

FIGURE 4

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to 25 percent free area and metal louvers and grilles will

have 60 to 75 percent free area. Louvers and grilles must

be fixed in the open position or interlocked with the equipment

so that they are opened automatically during equipment

operation.

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. These openings must communicate directly or by

ducts with the outdoors or spaces (crawl or attic) that freely

communicate with the outdoors or indirectly through vertical

ducts. Each opening shall have a minimum free area of 1

square inch per 4,000 Btu (645 mm² per .59 kW) per total

input rating of all equipment in the enclosure (See Figure 5).

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

ROOF TERMINATED

EXHAUST PIPE

VENTILATION LOUVERS

(Each end of attic)

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE

(Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)

OUTLET

AIR

VENTILATION LOUVERS

(Each end of attic)

ROOF TERMINATED

EXHAUST PIPE

INLET AIR

(Ends 12" above

bottom)

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

FURNACE

OUTLET

AIR

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

FURNACE

NOTE−The inlet and outlet air openings shall each have a free area of

VENTILATION

LOUVERS

(For unheated

crawl space)

at least one square inch per 4,000 Btu (645 mm per 1.17 kW) per hour

INLET

AIR

of the total input rating of all equipment in the enclosure.

FIGURE 6

NOTE−The inlet and outlet air openings shall each have a free area

of at least one square inch per 4,000 Btu (645 mm per 1.17 kW) per

hour of the total input rating of all equipment in the enclosure.

FIGURE 5

If air from outside is brought in for combustion and ventilation,

the confined space must have two permanent openings. One

opening shall be within 12 inches (305 mm) of the top of the

enclosure and one opening within 12 inches (305 mm) of

the bottom. These openings must communicate directly or

by ducts with the outdoors or spaces (crawl or attic) that

freely communicate with the outdoors or indirectly through

vertical ducts. Each opening shall have a minimum free

area of 1 square inch (645 mm²) per 4,000 Btu (1.17 kW)

per hour of total input rating of all equipment in the enclosure.

See figures 5 and 6. When communicating with the outdoors

through horizontal ducts, each opening shall have a minimum

free area of 1 square inch (645 mm²) per 2,000 Btu (.56

kW) per total input rating of all equipment in the enclosure.

See Figure 7.

EQUIPMENT IN CONFINED SPACE −

ALL AIR FROM OUTSIDE

ROOF TERMINATED

EXHAUST PIPE

OUTLET AIR

FURNACE

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

INLET AIR

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 the design and free area of protective

covering is not known for calculating the size opening

required, it may be assumed that wood louvers will have 20

NOTE−Each air duct opening shall have a free area of at least one

square inch per 2,000 Btu (645 mm per .59 kW) per hour of the total

input rating of all equipment in the enclosure. If the equipment room

is located against an outside wall and the air openings communi-

cate directly with the outdoors, each opening shall have a free area

of at least 1 square inch per 4,000 Btu (645 mm per 1.17 kW) per

hour of the total input rating of all other equipment in the enclosure.

FIGURE 7

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506725-01

INSTALLATION – Setting Equipment

NOTE: These units may be equipped with a shipping pad

under the blower housing. Remove the shipping pad prior

to operation.

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.

Allow for clearances to combustible materials as indicated

on the unit nameplate. Minimum clearances for closet or

alcove installations are shown in Figure 11.

Select a location that allows for the required clearances that

are listed on the unit nameplate. Also consider gas supply

connections, electrical supply, vent connection, condensate

trap and drain connections, and installation and service

clearances [24 inches (610 mm) at unit front]. The 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 9.

WARNING

Blower access panel must be securely in place when

blower and burners are operating. Gas fumes, which

could contain carbon monoxide, can be drawn into living

space resulting in personal injury or death.

Shipping Bolt Removal

SETTING EQUIPMENT

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 used with a flexible

mounting leg). See Figure 8. The bolt and washer must

be removed before the furnace is placed into operation.

After the bolt and washer have been removed, the rigid leg

will not touch the blower housing.

AIR FLOW

UNITS WITH 1/2 HP BLOWER MOTOR

1/2"

max.

RIGID LEG

(remove shipping bolt and washer)

FRONT VIEW

SIDE VIEW

Unit must be level side−to−side. Unit may be positioned

from level to 1/2" toward the front to aid in draining.

FIGURE 9

FIGURE 8

Figure 10

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Installation on Non-Combustible Flooring (Figure 12)

1. Cut floor opening keeping in mind clearances listed on

unit rating plate. Also keep in mind gas supply

connections, electrical supply, flue and air intake

connections and sufficient installation and servicing

clearances. See Table 1 for correct floor opening size.

2. Flange warm air plenum and lower the plenum into the

opening.

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.

3. Set the unit over the plenum and seal the plenum to the

unit.

4. Ensure that the seal is adequate.

In platform installations with furnace return, the furnace

should be sealed airtight to the return air plenum. A

door must never be used as a portion of the return air

duct system. The base must provide a stable support

and an airtight seal to the furnace. Allow absolutely no

sagging, cracks, gaps, etc.

NON−COMBUSTIBLE FLOOR OPENING SIZE

Front to Rear

Side to Side

For no reason should return and supply air duct systems

ever be connected to or from other heating devices such

as a fireplace or stove, etc. Fire, explosion, carbon

monoxide poisoning, personal injury and/or property

damage could result.

Cabinet Width

in.

422

511

B Cabinet (17.5")

C Cabinet (21")

19 − 3/4

502

16 − 5/8

20−1/8

NOTE: Floor opening dimensions listed are 1/4 inch (6 mm) larger than

the unit opening. See dimension drawing on page 2.

The unit may be installed three ways in downflow applica-

tions: on non-combustible flooring, on combustible flooring

using an additive base, or on a reverse-flow cooling coil

cabinet. Do not drag the unit across the floor in the

downflow position. Floor and furnace flange damage

will result.

TABLE 1

Refer to Figure 11 for clearances in downflow applica-

tions.

FURNACE

Downflow Application Installation Clearances

Top

PROPERLY

SIZED FLOOR

OPENING

SUPPLY AIR

PLENUM

Left Side

Right Side

FIGURE 12

Bottom

Installation on Combustible Flooring (Figure 13)

1. When unit is installed on a combustible floor, a downflow

combustible flooring base must be installed between the

furnace and the floor. The base must be ordered

separately. See Table 2 for opening size to cut in floor.

Top

*Front

Back

Sides

Vent

0†

CAUTION

Floor

NC ‡

The furnace and combustible flooring base shall not be

installed directly on carpeting, tile, or other combustible

material other than wood flooring.

*Front clearance in alcove installation must be 24 in. (610 mm).

Maintain a minimum of 24 in. (610 mm) for front service access.

†Allow proper clearances to accommodate condensate trap.

‡The furnace may be installed on a combustible wood ﬂoor if an optional

additive base is installed between the furnace and the combustible ﬂoor.

FIGURE 11

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506725-01

COMBUSTIBLE FLOORING BASE OPENING SIZE

Front to Rear

Side to Side

Cabinet

Width

Catalog

Number

in.

559

in.

FURNACE

B Cabinet

(17.5")

11M60

11M61

18 − 3/4

476

578

C Cabinet

(21")

559

22 − 3/4

COOLING COIL

PLENUM

TABLE 2

PROPERLY

SIZED FLOOR

OPENING

FURNACE

SUPPLY AIR

PLENUM

PROPERLY

SIZED FLOOR

OPENING

COMBUSTIBLE

FLOORING BASE

FIGURE 14

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 taken when installing plenum:

1. Bottom edge of plenum should be flanged with a

hemmed edge (See Figure 15 or 16).

2. Sealing strips should be used to ensure an airtight seal

between the cabinet and the plenum.

3. In all cases, plenum should be secured to top of furnace

using sheet metal screws.

4. Make certain that an adequate seal is made.

FIGURE 13

2. After opening is cut, set the combustible flooring base

into opening.

3. Check fiberglass strips on the combustible flooring base

to make sure they are properly glued and positioned.

4. Lower supply air plenum into the combustible flooring

base until plenum flanges seal against fiberglass strips.

er opening is

PLENUM

(Field Provided)

NOTE: Be careful not to damage fiberglass strips. Check

for a tight seal.

SECURE FROM

OUTSIDE CABINET

5. Set the furnace over the plenum.

6. Ensure that the seal between the furnace and plenum

is adequate.

CABINET

SEALING STRIP

SIDE PANEL

(Field Provided)

Side View

Installation on Cooling Coil Cabinet (Figure 14)

FIGURE 15

NOTE: Downflow combustible flooring kit is not used.

PLENUM

(Field Provided)

SEALING STRIP

1. Refer to reverse-flow coil installation instructions for

correctly sized opening in floor and installation of

cabinet.

(Field Provided)

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.

CABINET

SIDE PANEL

SECURE FROM

INSIDE CABINET

Side View

FIGURE 16

506725-01

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Filters

Pipe & Fittings Specifications

This unit is not equipped with a filter or rack. Afield provided

filter is required for the unit to operate properly. Table 3 lists

recommended filter sizes.

All pipe, fittings, primer and solvent cement must conform

withAmerican National Standard Institute and theAmerican

Society for Testing and Materials (ANSI/ASTM) standards.

The solvent shall be free flowing and contain no lumps,

undissolved particles or any foreign matter that adversely

affects the joint strength or chemical resistance of the

cement. The cement shall show no gelation, stratification,

or separation that cannot be removed by stirring. Refer to

Table 4 below for approved piping and fitting materials.

A filter must be in place whenever the unit is operating.

Furnace

Filter Size

Cabinet Width

17−1/2"

21"

16 x 25 x 1 (1)

TABLE 3

CAUTION

Duct System

Use industry-approved standards to size and install the

supply and return air duct system. This will result in a quiet

and low-static system that has uniform air distribution.

Solvent cements for plastic pipe are flammable liquids

and should be kept away from all sources of ignition.

Do not use excessive amounts of solvent cement when

making joints. Good ventilation should be maintained

to reduce fire hazard and to minimize breathing of

solvent vapors. Avoid contact of cement with skin and

eyes.

NOTE: This furnace is not certified for operation in heating

mode (indoor blower operating at selected heating speed)

with an external static pressure which exceeds 0.5 inches

w.c. Operation at these conditions may result in improper

limit operation.

Supply Air Plenum

PIPING AND FITTINGS SPECIFICATIONS

If the fumace is installed without a cooling coil, a removable

access panel should be installed in the supply air duct. The

access panel should be large enough to permit inspection

(by reflected light) of the heat exchanger for leaks after the

furnace is installed. The furnace access panel must always

be in place when the furnace is operating and it must not

allow leaks into the supply air duct system.

Schedule 40 PVC (Pipe)

D1785

F891

Schedule 40 PVC (Cellular Core Pipe)

Schedule 40 PVC (Fittings)

D2466

F441

Schedule 40 CPVC (Pipe)

Schedule 40 CPVC (Fittings)

SDR−21 PVC or SDR−26 PVC (Pipe)

SDR−21 CPVC or SDR−26 CPVC (Pipe)

Schedule 40 ABS Cellular Core DWV (Pipe)

Schedule 40 ABS (Pipe)

F438

D2241

F442

F628

Return Air Plenum

D1527

D2468

Schedule 40 ABS (Fittings)

NOTE: Return air must not be drawn from a room where

this furnace, or any other gas-fueled appliance (i.e.,

water heater), or carbon monoxide-producing device

(i.e., wood fireplace) is installed.

ABS−DWV (Drain Waste & Vent)

(Pipe & Fittings)

D2661

D2665

PVC−DWV (Drain Waste & Vent)

Pipe & Fittings)

ASTM

SPECIFICATION

PRIMER & SOLVENT CEMENT

When return air is drawn from a room, a negative pressure

is created in the room. If a gas appliance is operating in a

room with negative pressure, the flue 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.

PVC & CPVC Primer

PVC Solvent Cement

CPVC Solvent Cement

ABS Solvent Cement

F656

D2564

F493

D2235

PVC/CPVC/ABS All Purpose Cement For

Fittings & Pipe of the same material

D2564, D2235, F493

D3138

ABS to PVC or CPVC Transition Solvent

Cement

CANADA PIPE & FITTING & SOLVENT

CEMENT

Use fiberglass sealing strips, caulking, or equivalent sealing

method between the plenum and the furnace cabinet to

ensure a tight seal. If a filter is installed, size the return air

duct to fit the filter frame.

MARKING

PVC & CPVC Pipe and Fittings

PVC & CPVC Solvent Cement

ULCS636

ABS to PVC or CPVC Transition Cement

TABLE 4

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vent pipe hangers. 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.

IMPORTANT

The exhaust and intake connections are made of PVC.

Use PVC primer and solvent cement when using PVC

vent pipe. When using ABS vent pipe, use transitional

solvent cement to make connections to the PVC fitting in

the unit.

Canadian Applications Only

Pipe, fittings, primer and solvent cement used to vent

(exhaust) this appliance must be certified to ULC S636 and

supplied by a single manufacturer as part of an approved

vent (exhaust) system. When bonding the vent system to

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.

Use PVC primer and solvent cement orABS solvent cement

meeting ASTM specifications, refer to Table 4. As an

alternate, use all purpose cement, to bond ABS, PVC, or

CPVC pipe when using fittings and pipe made of the same

materials. Use transition solvent cement when bondingABS

to either PVC or CPVC.

Table 5 Lists the available exhaust termination kits. All vent

terminations are PVC.

Low temperature solvent cement is recommended during

cooler weather. Metal or plastic strapping may be used as

OUTDOOR TERMINATION KITS USAGE

STANDARD

CONCENTRIC

Outdoor

Exhaust

Accelerator

(Dia. X

Length)

Outdoor

Flush-

Mount

Kit

1−1/2"

Concentric Concentric Concentric

Exhaust

Accelerator

(Dia. X

VENT

PIPE

DIA.

(in.)

A95DF

A93DF

95G1DF

92G1DF

Kit

Length)

60L46

44W93

71M80

44W92

69M29

44W92

1−1/2" X 12"

2" X 12"

51W11**

YES

2−1/2

045

2−1/2

070

090

110

YES

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.

†† The 44W92 Concentric kit is provided with a 1-1/2” accelerator which must be installed on the exhaust outlet when

this kit is used with the 45,000 and 70,000 furnaces.

TABLE 5

506725-01

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Joint Cementing Procedure

All cementing of joints should be done according to the

specifications outlined in ASTM D 2855.

Venting Practices

Piping Suspension Guidelines

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.

SCHEDULE 40

PVC − 5’

all other pipe* − 3’

DANGER

* See Table 4 for allowable pipe.

DANGER OF EXPLOSION!

NOTE: Isolate piping at the point where it exits the outside wall or

roof in order to prevent transmission of vibration to the structure.

Fumes from PVC glue may ignite during system check.

Allow fumes to dissipate for at least 5 minutes before

placing unit into operation.

Wall Thickness Guidelines

24" maximum

3/4" minimum

1. Measure and cut vent pipe to desired length.

2. Debur and chamfer end of pipe, removing any ridges or

rough edges. If end is not chamfered, edge of pipe

may remove cement from fitting socket and result in a

leaking joint.

Wall

inside

outside

3. Clean and dry surfaces to be joined.

4. Test fit joint and mark depth of fitting on outside of pipe.

5. 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.

6. Promptly apply solvent cement to end of pipe and inside

socket surface of fitting. Cement should be applied

lightly but uniformly to inside of socket. Take care to

keep excess cement out of socket. Apply second coat

to end of pipe.

insulation

(if required)

FIGURE 17

REPLACING FURNACE THAT

WAS PART OF A COMMON

VENT SYSTEM

CHIMNEY

OR GAS

VENT

(Check sizing

for remaining

appliance)

NOTE: Time is critical at this stage. Do Not allow Primer to

dry before applying cement.

7. Immediately after applying last coat of cement to pipe,

and while both inside socket surface 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.

FURNACE

WATER

HEATER

(Removed from

from common

vent system)

OPENINGS

(To Adjacent

Room)

NOTE: Assembly should be completed within 20 seconds

after last application of cement. Hammer blows should not

be used when inserting pipe.

If this gas furnace replaces a furnace which was

commonly vented with another gas appliance,

the size of the existing vent pipe for that gas ap-

pliance must be checked. Without the heat of the

original furnace ﬂue products, the existing vent pipe

is probably oversized for the single water heater or

other appliance. The vent should be checked for

proper draw with the remaining appliance.

8. After assembly, wipe excess cement from pipe at end

of fitting socket. A properly made join will show a bead

around its entire perimeter. Any gaps may indicate an

improper defective assembly due to insufficient solvent.

9. Handle joints carefully until completely set.

FIGURE 18

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506725-01

1. In areas where piping penetrates joist or interior walls,

hole must be large enough to allow clearance 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.

Use the following steps to correctly size vent pipe diameter.

045, 070,

090, 110

Furnace capacity?

Exhaust Piping (Figure 20)

Route piping to outside of structure. Continue with

installation following instructions given in piping termination

section.

Standard or

Concentric?

See Table 5

Which termination?

CAUTION

Do not discharge exhaust into an existing stack or stack

that also serves another gas appliance. If vertical

discharge through an existing unused stack is required,

insert PVC pipe inside the stack until the end is even

with the top or outlet end of the metal stack.

Which needs

most elbows?

Intake or

exhaust

CAUTION

The exhaust vent pipe operates under positive pressure

and must be completely sealed to prevent leakage of

combustion products into the living space.

How many?

Vent Piping Guidelines

2", 2 1/2"

or 3"

Desired pipe size?

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

taken from indoors and flue gases are discharged outdoors.

In Direct Vent installations, combustion air is taken from

outdoors and flue gases are discharged outdoors.

What is the altitude?

Intake and exhaust pipe sizing - Size pipe according toTables

6 and 7. Table 6 lists the minimum vent pipe lengths

permitted. Table 7 lists the maximum pipe lengths permitted.

Use Table 7 to ﬁnd

max intake or exhaust

pipe length.

Regardless of the diameter of pipe used, the standard roof

and wall terminations described in section Exhaust Piping

Terminations should be used. Exhaust vent termination pipe

is sized to optimize the velocity of the exhaust gas as it exits

the termination.

FIGURE 19

In some applications which permit the use of several different

sizes of vent pipe, a combination vent pipe may be used.

Contact Allied Air Technical Service for assistance in sizing

vent pipe in these applications.

MINIMUM VENT PIPE LENGTHS

IMPORTANT

A95DF, 95G1DF, A93DF, & 92G1DF

MIN. VENT LENGTH*

MODELS

Do not use screens or perforated metal in exhaust or

intake terminations. Doing so will cause freeze-ups and

may block the terminations.

15 ft. or

5 ft plus 2 elbows or

10 ft plus 1 elbow

045, 070, 090, 110

*Any approved termination may be added to the minimum length listed.

TABLE 6

506725-01

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A95DF / 95G1DF and A93DF / 92G1DF

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.

2" Pipe

Model

2−1/2" Pipe

Model

3" Pipe

Model

Number

Of 90°

Elbows

Used

045

070

090

110

045

100

070

090

110

045

127

122

117

112

107

102

070

127

122

117

112

107

102

090

108

103

110

108

103

n/a

Concentric Termination Elevation 0 − 10,000 ft.

2" Pipe

Model

2−1/2" Pipe

Model

3" Pipe

Model

Number

Of 90°

Elbows

Used

045

n/a

070

090

110

045

070

090

110

045

111

106

101

070

111

106

101

090

104

110

104

n/a

TABLE 7

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TYPICAL EXHAUST PIPE CONNECTIONS

Pipe size determined in Table 7.

2”

3”

TRANSITION

*2”

INTAKE

EXHAUST

DO NOT transition from smaller

to larger pipe size in horizontal

runs of exhaust pipe.

TOP VIEW

* 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.

FIGURE 20

TYPICAL INTAKE PIPE CONNECTIONS (DIRECT VENT APPLICATIONS)

2”

Pipe size determined in Table 7.

2”

TRANSITION

3”

*2”

TRANSITION

*2”

INTAKE

EXHAUST

TOP VIEW

* When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible.

NOTE: Intake pipe and exhaust pipe must be the same diameter.

FIGURE 21

506725-01

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Intake Piping

General Guidelines for Vent Terminations

In Non-Direct Vent applications, combustion air is taken from

indoors and the flue gases are discharged to the outdoors.

This unit is then classified as a non-direct vent, Category IV

gas furnace.

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 VentilationAir

section must be followed.

In Direct Vent applications, combustion air is taken from

outdoors and the flue gases are discharged to the outdoors.

This unit is then classified as a direct vent, Category IV gas

furnace.

Follow the next two steps when installing the unit in Direct

Vent applications, where combustion air is taken from

outdoors and flue gases are discharged outdoors. The

provided air intake screen must not be used in direct

vent applications (outdoors).

1. Use cement or a sheet metal screw to secure the intake

pipe to the inlet air connector.

2. Route piping to outside of structure. Continue with

installation following instructions given in general guide

lines for piping terminations and intake and exhaust

piping terminations for direct vent sections. Refer to

Table 7 for pipe sizes.

In both Non-Direct Vent and Direct Vent applications, the

vent termination is limited by local building codes. In the

absence of local codes, refer to the current National Fuel

Gas CodeANSI Z223-1/NFPA54 in U.S.A., and current CSA-

B149 Natural Gas and Propane Installation Codes in Canada

for details.

Position termination according to location given in Figure 23

or 24. In addition, position termination so it is free from any

obstructions and 12" above the average snow accumulation.

At vent termination, care must be taken to maintain protective

coatings over building materials (prolonged exposure to

exhaust condensate can destroy protective coatings). It is

recommended that the exhaust outlet not be located within

6 feet (1.8 m) of a condensing unit because the condensate

can damage the painted coating.

TYPICAL AIR INTAKE PIPE CONNECTIONS

NON−DIRECT VENT APPLICATIONS

AIR

INTAKE

SCREEN

(Provided)

NOTE: If winter design temperature is below 32° F (0° C), it is

recommended that the exhaust piping be insulated with 1/2" (13

mm), Armaflex or equivalent when run through an unconditioned

area. In extremely cold climate areas with temperature below 20°

F (6.7° C) it is recommended that 3/4" (19 mm) Armaflex or

equivalent be used. Insulation on outside runs of exhaust pipe

may be painted or wrapped to protect insulation from deterioration

in accordance with the insulation manufacturers recommendation.

Exhaust pipe insulation may not be necessary in some specific

applications.

NOTE: During extremely cold temperatures, below approximately

20° F (6° C), units with long runs of vent pipe through unconditioned

space, even when insulated, may form ice in the exhaust

termination that prevents the unit from operating properly. Longer

run times of at least 5 minutes will alleviate most icing problems.

Also, a heating cable may be installed on exhaust piping and

termination to prevent freeze-ups. Heating cable installation kits

are available, see unit specification sheets for part numbers.

NOTE: Air intake screen and elbow may be rotated, so that

screen may be positioned to face forward or to either side.

FIGURE 22

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.

1. Use field-provided materials and the factory-provided

air intake screen to route the intake piping as shown in

Figure 23. 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.

IMPORTANT

Do not use screens or perforated metal in exhaust

terminations. Doing so will cause freeze-ups and may

block the terminations.

IMPORTANT

For Canadian Installations Only:

In accordance to CSA International B149 installation

codes, the minimum allowed distance between the

combustion air intake inlet and the exhaust outlet of

other appliances shall not be less than 12 inches (305

mm).

2. Use a sheet metal screw to secure the intake pipe to

the connector, if desired.

Page 18 of 48

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VENT TERMINATION CLEARANCES

FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA

INSIDE CORNER

DETAIL

Fixed

Closed

Operable

Fixed

Closed

Operable

AREA WHERE TERMINAL

IS NOT PERMITTED

AIR SUPPLY INLET

US Installations

VENT TERMINAL

Canadian Installations

A =

Clearance above grade, veranda,

porch, deck or balcony

12 inches (305mm) or 12 in. 305mm)

above average snow accumulation.

12 inches (305mm) or 12 in. 305mm)

above average snow accumulation.

B =

Clearance to window or

door that may be opened

6 inches (152mm) for appliances <10,000

Btuh (3kw), 12 inches (305mm) for

appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m)

for appliances > 100,000 Btuh (30kw)

4 feet (1.2 m) below or to side of opening;

1 foot (30 cm) above opening

C =

D =

Clearance to permanently

closed window

* 12"

Vertical clearance to ventilated soﬃt

* Equal to or greater than soﬃt depth.

located above the terminal within a

horizontal distance of 2 feet (mm)

from the center line of the terminal

* Equal to or greater than soﬃt depth.

E =

F =

G =

Clearance to unventilated soﬃt

Clearance to outside corner

* Equal to or greater than soﬃt depth.

* No minimum to outside corner

Clearance to inside corner

H = Clearance to each side of center line ex-

tended above meter / regulator assembly

3 feet (.9m) within a height 15 feet (4.5m)

above the meter / regulator assembly

3 feet (.9m) within a height 15 feet (4.5m)

above the meter / regulator assembly

I =

Clearance to service regulator

vent outlet

3 feet (.9m)

* 3 feet (.9m)

J =

Clearance to non−mechanical air

supply inlet to building or the com-

bustion air inlet to any other ap-

pliance

6 inches (152mm) for appliances <10,000

Btuh (3kw), 12 inches (305mm) for

appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m)

for appliances > 100,000 Btuh (30kw)

4 feet (1.2 m) below or to side of opening;

1 foot (30 cm) above opening

K =

L =

Clearance to mechanical air sup-

ply inlet

3 feet (.9m) above if within 10 feet

(3m) horizontally

6 feet (1.8m)

Clearance above paved sidewalk or

paved driveway located on public property

M =

Clearance under veranda, porch,

deck or balcony

In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code

*For clearances not speciﬁed in ANSI Z223.1/NFPA 54 or CSA B149.1,

clearance will be in accordance with local installation codes and the re-

quirements of the gas supplier and these installation instructions."

In accordance with the current CSA B149.1, N

atural Gas and Pr opane Inst allation Code

between two single family dwellings and serves both dwellings.

sides beneath the ﬂoor. Lennox recommends avoiding this location if possible.

FIGURE 23

506725-01

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VENT TERMINATION CLEARANCES

FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA

INSIDE CORNER

DETAIL

Fixed

Closed

Operable

Fixed

Closed

Operable

AREA WHERE TERMINAL

IS NOT PERMITTED

AIR SUPPLY INLET

US Installations

VENT TERMINAL

Canadian Installations

A =

Clearance above grade, veranda,

porch, deck or balcony

12 inches (305mm) or 12 in. 305mm)

above average snow accumulation.

12 inches (305mm) or 12 in. 305mm)

above average snow accumulation.

B =

Clearance to window or

door that may be opened

6 inches (152mm) for appliances <10,000

Btuh (3kw), 9 inches (mm) for appliances

> 10,000 Btuh (3kw) and <50,000 Btuh

(15 kw), 12 inches (305mm) for ap-

pliances > 50,000 Btuh (15kw)

6 inches (152mm) for appliances <10,000

Btuh (3kw), 12 inches (305mm) for

appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m)

for appliances > 100,000 Btuh (30kw)

* 12"

C =

D =

Clearance to permanently

closed window

* 12"

Vertical clearance to ventilated soﬃt

* Equal to or greater than soﬃt depth

located above the terminal within a

horizontal distance of 2 feet (mm)

from the center line of the terminal

* Equal to or greater than soﬃt depth

E =

F =

G =

Clearance to unventilated soﬃt

Clearance to outside corner

Clearance to inside corner

* No minimum to outside corner

H = Clearance to each side of center line ex-

tended above meter / regulator assembly

3 feet (.9m) within a height 15 feet (4.5m)

above the meter / regulator assembly

3 feet (.9m) within a height 15 feet (4.5m)

above the meter / regulator assembly

I =

Clearance to service regulator

vent outlet

3 feet (.9m)

* 3 feet (.9m)

J =

Clearance to non−mechanical air

supply inlet to building or the com-

bustion air inlet to any other ap-

pliance

6 inches (152mm) for appliances <10,000

Btuh (3kw), 9 inches (mm) for appliances

> 10,000 Btuh (3kw) and <50,000 Btuh

(15 kw), 12 inches (305mm) for ap-

pliances > 50,000 Btuh (15kw)

6 inches (152mm) for appliances <10,000

Btuh (3kw), 12 inches (305mm) for

appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m)

for appliances > 100,000 Btuh (30kw)

K =

L =

Clearance to mechanical air sup-

ply inlet

Clearance above paved sidewalk or

paved driveway located on public property

3 feet (.9m) above if within 10 feet

(3m) horizontally

6 feet (1.8m)

* 7 feet (2.1m)

M =

Clearance under veranda, porch,

deck or balcony

In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code

*For clearances not speciﬁed in ANSI Z223.1/NFPA 54 or CSA

B149.1, clear-

ance will be in accordance with local installation c odes and the requirements

of the gas supplier and these installation instructions."

In accordance with the current CSA B149.1, Natura

l Gas and Prop ane Installation Code

between two single family dwellings and serves both dwellings.

sides beneath the ﬂoor. Lennox recommends avoiding this location if possible.

FIGURE 24

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506725-01

Details of Intake and Exhaust Piping Terminations for

Direct Vent Installations

DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

3"(76mm) MAX.

SIZE TERMINATION

PIPE PER TABLE 8.

Inches(mm)

NOTE: In Direct Vent installations, combustion air is taken

from outdoors and flue gases are discharged to outdoors.

UNCONDITIONED

ATTIC SPACE

8" (203mm) MIN

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. If the

optional tee is used, the protective shield is required. The

shield should be constructed using wood, plastic, sheet metal

or other suitable material. All seams, joints, cracks, etc. in

the affected area should be sealed using an appropriate

sealant. See Figure 27.

1/2" (13mm) FOAM

INSULATION IN

12" (305mm) ABOVE

AVERAGE SNOW

ACCUMULATION

UNCONDITIONED

(IF REQUIRED)

SPACE

3" (76mm) OR

2" (51mm) PVC

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES

Intake and exhaust pipes 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 25 through 33 show typical

terminations.

FIGURE 25

FLUSH−MOUNT SIDE WALL TERMINATION

51W11

2" EXTENSION

FOR 2" PVC PIPE

1" EXTENSION

FOR 3" PVC PIPE

1. Exhaust and intake exits must be in same pressure zone.

Do not exit one through the roof and one on the side.

Also, do not exit the intake on one side and the exhaust

on another side of the house or structure.

2. Intake 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 25).

4. Exhaust piping must terminate straight out or up as

shown. Areducer may be required on the exhaust piping

at the point where it exits the structure to improve the

velocity of exhaust away from the intake piping. See

Table 8.

FURNACE

EXHAUST

PIPE

4’’

FURNACE

INTAKE PIPE

GLUE EXHAUST

END FLUSH INTO

TERMINATION

FLAT SIDE

1−1/2" ACCELERATOR

(all −45, −070 and −090 units)

FIGURE 26

EXHAUST PIPE TERMINATION SIZE REDUCTION

6. On field supplied terminations, a minimum distance

between the end of the exhaust pipe and the end of the

intake pipe without a termination elbow is 8" and a

minimum distance of 6" with a termination elbow. See

Figures 28 and 29.

7. If intake and exhaust piping must be run up a side wall

to position above snow accumulation or other

obstructions, piping must be supported every 24" (610

mm) as shown in Figures 28 and 29.

Termination

MODEL

Exhaust Pipe Size

Pipe Size

1−1/2" (38mm)

2" (51mm)

2" (51mm), 2−1/2" (64mm),

3" (76mm)

*045 and *070

*090

3" (76mm)

110

TABLE 8

*045, 070and090unitswiththe ﬂush−mounttermination

must use the 1−1/2"accelerator supplied with the kit.

5. On field supplied terminations for side wall exit, exhaust

piping may extend a maximum of 12 inches (305 mm)

for 2" PVC and 20 inches (508 mm) for 3" (76 mm) PVC

beyond the outside wall. Intake piping should be as

short as possible. See Figures 28 and 29.

When exhaust and intake piping must be run up an

outside wall, the exhaust piping must be terminated with

pipe sized per Table 8. The intake piping may be

equipped with a 90° elbow turndown. Using turndown

will add 5 feet (1.5 m) to the equivalent length of the

pipe.

NOTE: Care must be taken to avoid recirculation of exhaust

back into intake pipe.

8. Based on the recommendation of the manufacturer, a

multiple furnace installation may use a group of up to

four terminations assembled together horizontally, as

shown in Figure 32.

506725-01

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Intake

Front View of

Intake and Exhaust

Exhaust

Intake

Exhaust

TABLE 9

2" (51mm)

Vent Pipe

3" (76mm)

Vent Pipe

A− Clearance above

grade or average snow

accumulation

12" (508MM) Min.

12"

B −Horizontal

separation between

intake and exhaust

6" (152MM) Min.

24" (610 MM) Max

6" (152MM) Min.

24" (610 MM) Max

9" (227MM) Min.

C −Minimum from

end of exhaust to

inlet of intake

9" (227MM) Min.

12" (305MM) Min.

16" (405 MM) Max.

12" (305MM) Min.

20" (508MM) Max.

D−Exhaust pipe length

E −Wall support distance

from top of each pipe

(intake/exhaust)

6" (152MM) Max.

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. If optional tee is used, the protective shield is recom-

mended. The shield should be constructed using wood, sheet metal or other suitable material. All seams, joints,

cracks, etc. in aﬀected area, should be sealed using an appropriate sealant.

Exhaust pipe 45° elbow can be rotated to the side away from the combustion air inlet to direct exhaust away

from adjacent property. The exhaust must never be directed toward the combustion air inlet.

FIGURE 27

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FIELD SUPPLIED WALL TERMINATION

NOTE − FIELD PROVIDED

REDUCER MAY BE

REQUIRED TO ADAPT

LARGER VENT PIPE SIZE

TO TERMINATION

NOTE − FIELD PROVIDED

REDUCER MAY BE

REQUIRED TO ADAPT

LARGER VENT PIPE SIZE

TO TERMINATION

1/2" (13mm) ARMAFLEX

INSULATION IN UN-

CONDITIONED SPACE

(IF REQUIRED)

INSULATION IN UN-

CONDITIONED SPACE

(IF REQUIRED)

SIZE TERMINATION

PER TABLE 8

SIZE TERMINATION

PER TABLE 8

STRAIGHT

APPPLICATION

1/2" (13mm) ARMAFLEX INSULATION

IN UNCONDITIONED SPACE (IF REQUIRED)

1/2" (13mm) ARMAFLEX INSULATION

IN UNCONDITIONED SPACE (IF REQUIRED)

* WALL

SUPPORT

* WALL

SUPPORT

EXTENDED

APPLICATION

EXTENDED

APPLICATION

See venting Table 7 for maximum venting lengths with this

arrangement.

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 each pipe

(intake and exhaust)

* 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 each pipe

(intake and exhaust)

2" (51mm)

Vent Pipe

3" (76mm)

Vent Pipe

2" (51mm)

Vent Pipe

3" (76mm)

Vent Pipe

A−Minimum clearance

above grade or average

snow accumulation

A−Minimum clearance

above grade or average

snow accumulation

12" (508MM)

6" (152MM)

8" (203MM)

12" (508MM)

6" (152MM)

8" (203MM)

B −Maximum horizontal

separation between

intake and exhaust

C −Minimum from

end of exhaust to

inlet of intake

B −Maximum horizontal

separation between

intake and exhaust

6" (152MM)

C −Minimum from

end of exhaust to

inlet of intake

6" (152MM)

20" (508MM)

6" (152MM)

12" (305MM)

6" (152MM)

D−Maximum exhaust

pipe length

12" (305MM)

6" (152MM)

20" (508MM)

6" (152MM)

pipe length

E −Maximum wall support

distance from top of each

pipe (intake/exhaust)

E −Maximum wall support

distance from top of each

pipe (intake/exhaust)

FIGURE 29

FIGURE 28

506725-01

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DIRECT VENT CONCENTRIC ROOFTOP TERMINATION

71M80, 69M29 or 60L46 (US)

OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT

INSTALLATION OF DIRECT VENT WALL TERMINATION KIT

44W92 or 44W93 (Canada)

1 1/2" (38mm) accelerator

provided on 71M80 & 44W92

12"

EXHAUST

VENT

(305mm)

EXHAUST

VENT

5−1/2"

(140mm)

(127mm)

INTAKE

AIR

FLASHING

(Not Furnished)

12” (305mm)

Minimum

INTAKE

AIR

18" MAX.

(457mm)

Front View

Above Average

Snow

EXHAUST VENT

Accumulation

12" (305mm) Min.

above grade or

average snow

accumulation.

Inches (mm)

INTAKE

AIR

SHEET METAL STRAP

(Clamp and sheet metal strap

must be field installed to support

the weight of the termination kit.)

optional intake elbow

CLAMP

Side View

FIGURE 32

FIELD−PROVIDED

REDUCER MAY BE REQUIRED

TO ADAPT LARGER VENT

PIPE SIZE TO TERMINATION

FIGURE 30

DIRECT VENT CONCENTRIC WALL TERMINATION

71M80, 69M29 or 60L46 (US)

DIRECT VENT APPLICATION

USING EXISTING CHIMNEY

44W92 or 44W93 (Canada)

STRAIGHT−CUT OR

FIELD−PROVIDED

REDUCER MAY BE REQUIRED

1−1/2" (38mm) accelerator

provided on 71M80 & 44W92

ANGLE−CUT IN DIRECTION

OF ROOF SLOPE *

3"−8"

(76mm−203mm)

TO ADAPT LARGER VENT

PIPE SIZE TO TERMINATION

EXHAUST VENT

1/2" (13mm)

WEATHERPROOF

INSULATION

8" − 12"

(203mm − 305mm)

OUTSIDE

WALL

INTAKE

AIR

EXHAUST

VENT

EXHAUST

VENT

SHOULDER OF FITTINGS

PROVIDE SUPPORT

Minimum 12" (305MM)

above chimney top

plate or average snow

accumulation

INTAKE PIPE

INSULATION (optional)

OF PIPE ON TOP PLATE

SHEET

METAL TOP

PLATE

ALTERNATE

INTAKE PIPE

12" (305mm) Min.

INTAKE

AIR

CLAMP

(Not Furnished)

above grade or

average snow

accumulation.

AIR

3" − 8"

(76mm−

203mm)

INSULATE

TO FORM

SEAL

EXTERIOR

PORTION OF

CHIMNEY

GRADE

FIGURE 31

*SIZE TERMINATION

PIPE PER TABLE 6.

NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If ver-

tical discharge through an existing unused chimney or stack is required, insert piping

inside chimney until the pipe open end is above top of chimney and terminate as illus-

trated. In any exterior portion of chimney, the exhaust vent must be insulated.

FIGURE 33

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506725-01

Details of Exhaust Piping Terminations for Non-Direct

VentApplications

NON−DIRECT VENT FIELD SUPPLIED WALL

TERMINATION EXTENDED

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.

12" (305mm) MAX. for 2" (51mm)

20" (508mm) MAX. for 3" (76mm)

UNCONDITIONED

SPACE

6" (152mm)

Max

SIZE TER-

MINATION

PIPE PER

TABLE 8.

1. Exhaust piping must terminate straight out or up as

shown. The termination pipe must be sized as listed in

Table 8. The specified pipe size ensures proper velocity

required to move the exhaust gases away from the

building.

2. On field supplied terminations for side wall exit, exhaust

piping may extend a maximum of 12 inches (305 mm)

for 2” PVC and 20” (508 mm) for 3” (76 mm) PVC beyond

the outside wall. See Figure 35.

*WALL SUPPORT

OUTSIDE WALL

FIELD−PROVIDED

REDUCER MAY BE

REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE TO

TERMINATION

12" (305mm)

ABOVE GRADE OR

AVERAGE SNOW

ACCUMULATION

1/2" (13mm) FOAM

INSULATION IN

3. If exhaust piping must be run up a sidewall to position

above snow accumulation or other obstructions, piping

must be supported every 24” (610 mm) as shown in

Figure 36. When exhaust piping must be run up an

outside wall, any reduction in exhaust pipe size must be

done after the final elbow.

UNCONDITIONED

SPACE (IF REQUIRED)

1/2" (13mm) FOAM

INSULATION (IF REQUIRED)

*Use wall support every 24" (610). Use two supports if extension is

greater than 24" but less than 48".

FIGURE 36

NON−DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

SIZE TERMINATION

PIPE PER TABLE 8.

NON−DIRECT VENT APPLICATION

USING EXISTING CHIMNEY

12" (305mm)

ABOVE AVE.

SNOW

ACCUMULATION

STRAIGHT−CUT OR

SIZE TERMINATION

PIPE PER TABLE 8.

ANGLE−CUT IN DIRECTION

1/2" (13mm) FOAM

INSULATION IF REQUIRED

OF ROOF SLOPE

EXHAUST VENT

1/2" (13mm)

WEATHERPROOF

Minimum 12" (305MM)

3" (76mm) OR

2" (51mm) PVC

INSULATION (IF REQUIRED)

UNCONDITIONED

ATTIC SPACE

above chimney top

plate or average snow

SHOULDER OF FITTINGS

accumulation

PROVIDE SUPPORT

FOR EXHAUST LINES

OF PIPE ON TOP PLATE

SHEET

METAL TOP

PLATE

INSULATE

TO FORM

SEAL

FIGURE 34

EXTERIOR

PORTION OF

CHIMNEY

NON−DIRECT VENT FIELD SUPPLIED WALL TERMINATION

NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If ver-

tical discharge through an existing unused chimney or stack is required, insert piping

inside chimney until the pipe open end is above top of chimney and terminate as illus-

trated. In any exterior portion of chimney, the exhaust vent must be insulated.

12" (305mm) MAX. for 2" (51mm)

20" (508mm) MAX. for 3" (76mm)

1/2" (13mm) ARMAFLEX

INSULATION IN

UNCONDITIONED SPACE (IF REQUIRED)

1/2" (13mm)

ARMAFLEX

FIGURE 37

FIELD−PROVIDED

REDUCER MAY

INSULATION

(IF REQUIRED)

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

PVC REDUCER

12" MIN.

(305mm)

Above Grade or

average snow

accumulation

SIZE TERMINATION

PIPE PER TABLE 8.

FIGURE 35

506725-01

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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.

Condensate line must slope downward away from the trap

to drain. If drain level is above condensate trap, condensate

pump must be used. Condensate drain line should be routed

within the conditioned space to avoid freezing of condensate

and blockage of drain line. If this is not possible, a heat

cable kit may be used on the condensate trap and line.

Heating cable kit is available in various lengths:

Refer to

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” per ft. toward

trap.

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.

1. Determine which side condensate piping will exit the

unit, location of trap, field-provided fittings and length of

PVC pipe required to reach available drain.

CONDENSATE TRAP LOCATION

(shown with right side exit of condensation)

2. Remove plug (Figure 38) from the cold end header box

at the appropriate location on the side of the unit. Install

field-provided 1/2 NPT male fitting into cold end header

box. Use Teflon tape or appropriate pipe dope.

Field Provided Vent

min. 1" Above

Condensate Drain

3. Install the cap over the clean out opening at the base of

the trap. Secure with clamp. See Figure 41.

4. Install drain trap using appropriate PVC fittings, glue all

Trap can be installed a

maximum of 5 ft. from furnace.

(*PVC Only)

joints.

Glue the provided drain trap as shown in

1" min.

Figure 41. Route the condensate line to an open drain.

Condensate line must maintain a 1/4” downward slope

from the furnace to the drain.

5’ max.

CAUTION

to drain

Do Not use copper tubing or existing copper condensate

lines for drain line.

*Piping from furnace must slope down a minimum of

1/4" per ft. toward trap.

5. If unit will be started immediately upon completion of

installation, prime trap per procedure outlined in Unit

Start-Up section.

FIGURE 39

UNIT WITH EVAPORATOR COIL

CONDENSATE TRAP AND PLUG LOCATIONS

Condensate trap and

evaporator coil must drain

separately as shown.

Field−Provided Vent

Trap

(same on

right side)

Plug

1−1/2 in.

(same on left

Drain

side)

FIGURE 40

CAUTION

A separate drain line must be run to the drain from the

condensate trap to ensure proper drainage and pressure

switch operation. DO NOT connect the condensate trap

drain into the drain line from the evaporator coil.

FIGURE 38

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506725-01

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)

Condensate Drain

Connection In Unit

1/2 inch mpt (Not Furnished)

Vent

90° Street Elbow

1 (25) Minimum

1/2 inch PVC

5 Feet

Maximum

(Not Furnished)

Above Top of Condensate Drain

Connection In Unit

90° Elbow 1/2 inch PVC

Condensate Drain

Connection In Unit

(Not Furnished)

1/2 inch PVC Pipe

(Not Furnished)

1/2 inch PVC Pipe

(Not Furnished)

OPTIONAL Drain Piping

Drain Assembly for 1/2 inch Drain Pipe

Coupling 1/2 inch slip X slip

(Not Furnished)

1/2 inch PVC Pipe

(Not Furnished)

Drain Trap

Assembly

(Furnished)

1/2 inch PVC

90° Elbow

(Not Furnished)

1/2 inch PVC

(Not Furnished)

Drain

Drain Assembly for 3/4 inch Drain Pipe

Drain Trap

Clean Out

90° Elbow

3/4 inch PVC

(Not Furnished)

3/4 inch PVC

(Not Furnished)

Drain

Coupling 3/4 inch slip X slip

(Not Furnished)

Drain Trap Assembly with 3/4 inch Piping

Drain Trap Assembly with 1/2 inch Piping

1 inch (25mm) Minimum Above Top of

Condensate Drain Connection In Unit

1 inch (25mm) Minimum Above Top of

Condensate Drain Connection In Unit

Vent

Drain Trap Assembly

(Furnished)

Vent

3/4 inch

Piping

Condensate Drain

Connection In Unit

Condensate Drain

Connection In Unit

(178)

Drain

FIGURE 41

506725-01

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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 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.

Leak Check

After gas piping is completed, carefully check all piping

connections (factory and field installed) for gas leaks. Use

a leak detecting solution or other preferred means.

The furnace must be isolated from the gas supply system

by closing its individual manual shut off valve during any

pressure testing of the gas supply system at pressures

greater than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).

WARNING

Do Not exceed 600 in. lbs. (50 ft. lbs.) torque when

attaching the gas piping to the gas valve.

MANUAL MAIN SHUT−OFF

FURNACE

VALVE WILL NOT HOLD

1. Gas piping may be routed into the unit through either

the left or right hand side. Supply piping enters into

the gas valve from the side of the valve as shown in

Figure 43. Move bellows grommet to side of the cabinet

which the gas line enters. Ensure opposite gas line

entrance is plugged with supplied plug.

NORMAL TEST PRESSURE

ISOLATE

1/8" N.P.T. PLUGGED TAP

GAS VALVE

CAP

FIGURE 42

IMPORTANT

A low inlet pressure switch in LP/propane applications

is recommended.

IMPORTANT

When testing pressure of gas lines, gas valve must be

disconnected and isolated. (See Figure 42.) Gas

Valves can be damaged if subjected to pressures

greater than 1/2 psig (3.48 kPa).

2. When connecting gas supply, factors such as length of

run, number of fittings and furnace rating must be

considered to avoid excessive pressure drop. Table 10

lists recommended pipe sizes for typical applications.

NOTE: Use two wrenches when connecting gas piping to

avoid transferring torque to the manifold.

WARNING

3. Gas piping must not run in or through air ducts, clothes

chutes, chimneys or gas vents, dumb waiters or elevator

shafts. Center gas line through piping hole. Gas line

should not touch side of unit. See Figures 43.

4. Piping should be sloped 1/4 inch per 15 feet (6 mm per

5.6 m) upward toward the gas meter from the furnace.

The piping must be supported at proper intervals, every

8 to 10 feet (2.44 to 3.05 m), using suitable hangers or

straps. Install a drip leg in vertical pipe runs to serve as

a trap for sediment or condensate.

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result

in serious injury, death, or property damage. Never use

an open flame to test for gas leaks. Check all

connections using a commercially available soap

solution made specifically for leak detection. Some

soaps used for leak detection are corrosive to certain

metals. Carefully rinse piping thoroughly after leak test

has been completed.

5. A1/8" N.P.T. plugged tap or pressure post is located on

the gas valve to facilitate test gauge connection. See

Figure 50.

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.

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506725-01

Left Side Piping

(Standard)

MANUAL

MAIN SHUT−OFF

VALVE

(With 1/8 in. NPT

Plugged Tap

Shown)

AUTOMATIC

GAS VALVE

(with manual

shut−oﬀ valve)

MANUAL

MAIN SHUT−OFF

VALVE

(With 1/8 in. NPT

Plugged Tap Shown)

AUTOMATIC

GAS VALVE

(with manual

shut−oﬀ valve)

Plug

GROUND

JOINT

UNION

GROUND

JOINT

UNION

DRIP LEG

Right Side Piping

(Alternate)

FIELD

PROVIDED

AND INSTALLED

DRIP LEG

Bellows Grommet

NOTE − BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET

FIGURE 43

GAS PIPE CAPACITY − FT /HR (kL/HR)

Length of Pipe−Feet(m)

Nominal

Iron Pipe Size

−Inches(mm)

Internal

Diameter

(3.048)

(9.144)

(12.192)

(15.240)

(18.288)

(21.336)

(24.384)

(27.432)

100

(30.480)

−Inches(mm)

(6.096)

1/2

(12.7)

.622

(17.799)

175

(4.96)

120

(3.40)

(2.75)

(2.32)

(2.07)

(1.87)

(1.73)

(1.61)

(1.50)

(1.42)

3/4

(19.05)

.824

(20.930)

360

(10.19)

250

(7.08)

200

(5.66)

170

(4.81)

151

(4.28)

138

(3.91)

125

(3.54)

118

(3.34)

110

(3.11)

103

(2.92)

1.049

(26.645)

680

(19.25)

465

(13.17)

375

(10.62)

320

(9.06)

285

(8.07)

260

(7.36)

240

(6.80)

220

(6.23)

205

(5.80)

195

(5.52)

(25.4)

1−1/4

(31.75)

1.380

(35.052)

1400

(39.64)

950

(26.90)

770

(21.80)

660

(18.69)

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)

460

(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)

2.067

(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)

(50.8)

2−1/2

(63.5)

2.469

(67.713)

6300

(178.39)

4350

(123.17)

3520

(99.67)

3000

(84.95)

2650

(75.04)

2400

(67.96)

2250

(63.71)

2050

(58.05)

1950

(55.22)

1850

(52.38)

3.068

(77.927)

11000

(311.48)

7700

(218.03)

6250

(176.98)

5300

(150.07)

4750

(134.50)

4300

(121.76)

3900

(110.43)

3700

(104.77)

3450

(97.69)

3250

(92.03)

(76.2)

4.026

(102.260)

23000

(651.27)

15800

(447.39)

12800

(362.44)

10900

(308.64)

9700

(274.67)

8800

(249.18)

8100

(229.36)

7500

(212.37)

7200

(203.88)

6700

(189.72)

(101.6)

NOTE − Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 speciﬁc gravity gas.

TABLE 10

506725-01

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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.

3. 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. Turn ON clothes dryers

and any appliances not connected to the common

venting system. Turn ON any exhaust fans, such as

range hoods and bathroom exhausts, so they will

operate at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers.

Conduct the following test while each appliance is operating

and the other appliances (which are not operating) remain

connected to the common venting system. If the venting

system has been installed improperly, you must correct the

system as indicated in the general venting requirements

section.

4. Follow the lighting instructions. Turn ON the appliance

that is being inspected. Adjust the thermostat so that

the appliance operates continuously.

5. After the main burner has operated 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 the preceding

tests, the common venting system must be modified to

correct the problems.

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.

The following steps shall be followed for each appliance

connected to the venting system being placed into

operation, while all other appliances connected to the

venting system are not in operation.

Resize the common venting system to the minimum vent

pipe size determined by using the appropriate tables in

Appendix G. These are in the current standards of the

National Fuel Gas Code ANSI Z223.1.

1. Seal any unused openings in the common venting

system.

2. 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.

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506725-01

Electrical

ELECTROSTATIC DISCHARGE (ESD)

The unit is equipped with a field makeup box on the left

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 with

plugs removed from right side. Secure the excess wire to

the existing harness to protect it from damage.

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. Neutralize electrostatic charge by touching

hand and all tools on an unpainted unit surface, such as

the gas valve or blower deck, before performing any

service procedure.

Refer to Figure 47 for field wiring and Figure 48 for schematic

wiring diagram and troubleshooting.

The power supply wiring must meet Class I restrictions.

Protected by either a fuse or circuit breaker, select circuit

protection and wire size according to unit nameplate.

NOTE: Unit nameplate states maximum current draw.

Maximum Over-Current Protection allowed is 15 AMP.

Holes are on both sides of the furnace cabinet to facilitate

wiring.

INTERIOR MAKE−UP BOX

Install a separate (properly sized) disconnect switch near

the furnace so that power can be turned off for servicing.

(FACTORY− INSTALLED LEFT SIDE)

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.

MAKE−UP

BOX INSIDE

Left side

CABINET

Complete the wiring connections to the equipment. Use the

provided unit wiring diagram and the field wiring diagram

shown in Figure 47. Use 18 gauge wire or larger that is

suitable for Class II rating for thermostat connections.

Electrically ground the unit according to local codes or, in

the absence of local codes, according to the current National

Electric Code (ANSI/HFPA No. 70) for the USA and current

Canadian Electric Code Part 1 (CSA standard C22.1) for

Canada. Agreen ground wire is provided in the field makeup

box.

FIGURE 44

EXTERIOR MAKE−UP BOX

(FIELD PROVIDED RIGHT SIDE)

NOTE: The gas furnace contains electronic components

that are polarity sensitive. Make sure that the furnace is

wired correctly and is properly grounded.

MAKE−UP

BOX

OUTSIDE

CABINET

Accessory Terminals

One line voltage “EAC” 1/4” spade terminal is provided on

the furnace control board. Any accessory 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. If an accessory rated at greater than one amp is

connected to this terminal, it is necessary to use an external

relay. See Figure 49 for control board configuration. This

terminal is energized when the indoor blower is operating.

Right Side

FIGURE 45

506725-01

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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. If a humidifier rated at greater than one amp is

connected to this terminal, it is necessary to use an external

relay. See Figure 49 for control board configuration. This

terminal is energized in the heating mode when the

combustion air inducer is operating.

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 requirements must be kept in mind when

specifying a generator for use with this equipment:

Install the room thermostat according to the instructions

provided with the thermostat. See Figure 46 for thermostat

designations. If the furnace is being matched with a heat

pump, refer to the FM21 installation instruction or appropriate

dual fuel thermostat instructions.

•

The furnace requires 120 volts ± 10% (Range: 108 volts

to 132 volts).

The furnace operates at 60 Hz ± 5% (Range: 57 Hz to

63 Hz).

The furnace integrated control requires both polarity and

proper ground. Both polarity and proper grounding

should be checked before attempting to operate the

furnace on either permanent or temporary power.

Generator should have a wave form distortion of less

than 5% THD (total harmonic distortion).

FURNACE and CONDENSING UNIT

THERMOSTAT DESIGNATIONS

(Refer to speciﬁc thermostat and outdoor unit.)

Thermostat

Furnace

Condensing

Unit

•

*CONDENSING

POWER

HEAT

CONDENSING

COOLING

INDOOR BLOWER

COMMON

FIGURE 46

TYPICAL FIELD WIRING DIAGRAM

IGNITOR

FIGURE 47

Issue 1109

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506725-01

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TYPICAL WIRING DIAGRAM

FIGURE 48

506725-01

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INTEGRATED CONTROL

(Automatic Hot Surface Ignition System)

HEAT BLOWER

OFF DELAY JUMPER

DIAGNOSTIC CODE

RECALL BUTTON

TERMINAL DESIGNATIONS

Humidifier (120 VAC)

Input (120 VAC)

HUM

XFMR

5 AMP

FUSE

Transformer (120 VAC)

Blower - Continuous Fan (120 VAC)

Electronic Air Cleaner (120 VAC)

Blower - Cooling Speed (120 VAC)

CONT

EAC

COOL

HEAT

PARK

Blower - Heating Speed (120 VAC)

Dead terminals to park alternate spd taps

NEUTRALS Neutral terminals (120 VAC)

FIGURE 49

Unit Start-Up

FOR YOUR SAFETY READ BEFORE OPERATING

CAUTION

Before attempting to perform any service or

maintenance, turn the electrical power to unit OFF at

disconnect switch.

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.

BEFORE LIGHTING the unit, smell all around the furnace

area for gas. Be sure to smell next to the floor because

some 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.

WARNING

Danger of explosion. Can cause injury

or product or property damage. Should

the gas supply fail to shut off or if

overheating occurs, shut off the gas

valve to the furnace before shutting off

the electrical blower deck, before

performing any service procedure.

Placing the furnace into operation:

This furnace is equipped with an automatic hot surface

ignition system. Do not attempt to manually light burners on

this furnace. Each time the thermostat calls for heat, the

burners will automatically light. The ignitor does not get hot

when there is no call for heat on these units.

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506725-01

Priming Condensate Trap

9. Replace the heating compartment access panel.

10. Turn on all electrical power to the unit.

11. Set the thermostat to desired setting.

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.

NOTE: When unit is initially started, steps 1 through 11

may need to be repeated to purge air from gas line.

2. Set the thermostat to initiate a heating demand.

3. Allow the burners to fire for approximately 3 minutes.

4. Adjust the thermostat to deactivate the heating demand.

5. Wait for the combustion air inducer to stop. Set the

thermostat to initiate a heating demand and again allow

the burners to fire for approximately 3 minutes.

6. Adjust the thermostat to deactivate the heating demand

and wait for the combustion air inducer to stop. At this

point, the trap should be primed with sufficient water to

ensure proper condensate drain operation.

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

performed.

3. Remove the heating compartment access panel.

4. Move gas valve switch to OFF.

5. Replace the heating compartment access panel.

WARNING

Failure To Operate

If you do not follow these instructions exactly, a fire or

explosion may result causing property damage, personal

injury or death.

If the unit fails to operate, check the following:

1. Is the thermostat calling for heat?

2. Are access panels securely in place?

3. Is the main disconnect switch closed?

4. Is there a blown fuse or tripped breaker?

5. Is the filter dirty or plugged? Dirty or plugged filters will

cause the limit control to shut the unit off.

6. Is gas turned on at the meter?

Gas Valve Operation (Figure 50)

1. STOP! Read the safety information at the beginning of

this section.

2. Set the thermostat to the lowest setting.

3. Turn OFF all electrical power to the unit.

4. This furnace is equipped with an ignition device which

automatically lights the burners. Do not try to light the

burners by hand.

7. Is the manual main shut–off valve open?

8. Is the internal manual shut–off valve open?

9. Is the unit ignition system in lockout? If the unit locks

out again, inspect the unit for blockages.

5. Remove the heating compartment access panel.

6. Move gas valve switch to OFF. See Figure 50.

7. Wait five minutes to clear out any gas. If you then smell

gas, STOP! Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions. If you do not smell gas go to next step.

8. Move gas valve switch to ON. See Figure 50.

Heating Sequence Of Operation

1. When thermostat calls for heat, combustion air inducer

starts.

2. Combustion air pressure switch proves blower

operation. Switch is factory set and requires no

adjustment.

3. After a 15 second prepurge, the hot surface ignitor

energizes.

4. After a 20 second ignitor warm-up period, the gas valve

solenoid opens. A 4-second “Trial for Ignition” period

begins.

5. Gas is ignited, flame sensor proves the flame, and the

combustion process continues.

6. If flame is not detected after first ignition trial, the ignition

control will repeat steps 3 and 4 four more times before

locking out the gas valve. The ignition control will then

automatically repeat steps 1 through 6 after 60 minutes.

To interrupt the 60 minute lockout period, move

thermostat from “Heat” to “OFF” then back to “Heat”.

Heating sequence then restarts at step 1.

GAS VALVE SHOWN IN ON POSITION

MANIFOLD

PRESSURE

ADJUSTMENT

SCREW

MANIFOLD

PRESSURE

OUTLET

(UNDER CAP)

INLET

PRESSURE

PORT

FIGURE 50

506725-01

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Gas Pressure Adjustment

Gas Flow (Approximate)

Supply Line and Manifold Pressure (inches w.c.)

Manifold

GAS METER CLOCKING CHART

Seconds for One Revolution

Unit

Fuel

Line Pressure

Pressure

All

Nat. Gas

L.P. Gas

3.5

4.5 − 10.5

Natural

Unit

1 cu ft

2 cu ft

Dial

1 cu ft

Dial

200

136

102

2 cu ft

DIAL

10.0

11.0 − 13.0

Dial

TABLE 12

−045

−070

−090

−110

−135

160

110

400

272

204

164

136

NOTE:A natural to L.P. propane gas changeover kit is necessary

to convert this unit. Refer to the changeover kit installation

instruction for the conversion procedure.

Natural−1000 btu/cu ft

LP−2500 btu/cu ft

TABLE 11

Proper Combustion

NOTE: To obtain accurate reading, shut off all other gas

Furnace 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 50 ppm.

appliances connected to meter.

Furnace should operate at least 5 minutes before checking

gas flow. Determine time in seconds for two revolutions of

gas through the meter. (Two revolutions assures a more

accurate time.) Divide by two and compare to time in

Table 11. If manifold pressure matches Table 12 and rate

is incorrect, check gas orifices for proper size and restriction.

Remove temporary gas meter if installed.

CO %

For L.P.

Unit

For Nat

All

7.2 − 7.9

8.6 − 9.3

Supply Pressure Measurement

A threaded plug on the inlet side of the gas valve provides

access to the supply pressure tap. Remove the threaded

plug, install a field-provided barbed fitting and connect a

manometer to measure supply pressure. Replace the

threaded plug after measurements have been taken.

The maximum carbon monoxide reading should not exceed 50 ppm.

TABLE 13

High Altitude Information

Manifold Pressure Measurement

1. Remove the threaded plug from the outlet side of the

gas valve and install a field provided barbed fitting.

Connect to a manometer to measure manifold pressure.

2. Start unit and allow 5 minutes for unit to reach steady

state.

3. While waiting for the unit to stabilize, observe the flame.

Flame should be stable and should not lift from burner.

Natural gas should burn blue.

NOTE: In Canada, certification for installations at elevations

over 4500 feet (1372 m) is the jurisdiction of local authorities.

The furnace requires no manifold pressure adjustments for

operation at altitudes up to 10,000 feet (3048 m) above sea

level. Units installed at altitudes of 4501 - 10,000 feet (1373

to 3048 m) require a pressure switch change which can be

ordered separately. Table 14 lists conversion kit and

pressure switch requirements at varying altitudes.

4. After allowing unit to stabilize for 5 minutes, record

manifold pressure and compare to value given in

Table 12.

The combustion air pressure switch is factory-set and

requires no adjustment.

NOTE: Shut unit off and remove manometer as soon as

an accurate reading has been obtained. Take care to remove

barbed fitting and replace threaded plug.

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506725-01

Burner Orifice Conversion Kits at Varying Altitudes

0 - 7,500 ft

(0 - 2,286 m)

7,501 - 10,000 ft

(2,286 - 3,038 m)

High Altitude

LP/Propane

Burner Orifice

Kit

Natural

LP/Propane

Natural

Burner Orifice

Kit

Unit

Size

LP/Propane

Natural

All

68W75*†

73W80*

51W01

68W70*†

* 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

4,501 - 7,500 ft 7,501 - 10,000 ft

(0 - 1,373 m)

(1,373 - 2,286 m)

(2,286 - 3,038 m)

Size

All

No Change

74W91

Pressure switch is factory set. No adjustment necessary.

All models use the factory installed pressure switch from 0 - 7,500 feet.

A95 and 95G1 Pressure Switches at Varying Altitudes

Unit

0 - 4,500 ft

4,501 - 7,500 ft 7,501 - 10,000 ft

(0 - 1,373 m)

(1,373 - 2,286 m)

(2,286 - 3,038 m)

Size

045

070

090

110

135

No Change

77W43

74W90

73W22

77W42

77W43

77W42

Pressure switch is factory set. No adjustment necessary.

All models use the factory installed pressure switch from 0 - 4,500 feet.

TABLE 14

506725-01

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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

appliance will operate continuously.

WARNING

7. Use the flame of a match or candle to test for spillage

of flue gases at the draft hood relief opening after 5

minutes of main burner operation.

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.

8. If improper venting is observed during any of the above

tests, the venting system must be corrected or sufficient

combustion/makeup air must be provided. The venting

system should be resized to approach the minimum

size as determined by using the appropriate tables in

appendix G in the current standards of the National Fuel

Gas Code ANSI-Z223.1/NPFA 54 in the U.S.A., and

the appropriate Natural Gas and Propane appliances

venting sizing tables in the current standard of the CSA-

B149 Natural Gas and Propane Installation Codes in

Canada.

9. After determining that each appliance remaining

connected to the common venting system properly

vents when tested as indicated in step 3, return doors,

windows, exhaust fans, fireplace dampers and any other

gas burning appliance to their previous condition of use.

The following steps shall be followed for each appliance

connected to the venting system being placed into

operation, while all other appliances connected to the

venting system are not in operation.

After the gas furnace has been started, the following test

should be conducted to ensure proper venting and sufficient

combustion air has been provided to the unit as well as to

other gas fired appliances which are separately vented.

If this furnace replaces a Category I furnace which was

commonly vented with another gas appliance, the size of

the existing vent pipe for that gas appliance must be

checked. Without the heat of the original furnace flue

products, the existing vent pipe is probably oversized for

the single water heater or other appliance. The vent should

be checked for proper draw with the remaining appliance.

The test should be conducted while all appliances (both in

operation and those not in operation) are connected to the

venting system being tested. If the venting system has been

installed improperly, or if provisions have not been made

for sufficient amounts of combustion air, corrections must

be made as outlined in the previous section.

1. Seal any unused openings in the venting system.

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 building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliances not

connected to the venting system. Turn on any exhaust

fans, such as range hoods and bathroom exhausts, so

they will operate at maximum speed. Do not operate

a summer exhaust fan.

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506725-01

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

vestibule panel. This limit is factory set and requires no

adjustment.

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.

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.

Motor Nameplate__________Actual__________

Pressure Switch

The pressure switch is located in the heating compartment

on the cold end header box. This switch checks for proper

combustion air inducer operation before allowing ignition

trial. The switch is factory set and must not be adjusted.

Blower Speeds

Follow the steps below to change the blower speeds.

1. Turn off electrical power to furnace.

2. Remove blower compartment access panel.

3. Disconnect existing speed tap at control board speed

terminal.

Temperature Rise

After the furnace has been started and supply and return

air temperatures have been allowed to stabilize, check the

temperature rise. If necessary, adjust the blower speed to

maintain the temperature rise within the range shown on

the unit nameplate. Increase the blower speed to decrease

the the temperature. Decrease the blower speed to increase

the temperature rise. Failure to adjust the temperature rise

may cause erratic limit operation.

NOTE: Termination of any unused motor leads must be

insulated.

4. Place unused blower speed tap on integrated control

“PARK” terminal or insulate.

5. Refer to blower speed selection chart on unit wiring

diagram for desired heating or cooling speed. See

Blower performance data beginning on the next page.

6. Connect selected speed tap at control board speed

terminal.

7. Re-secure blower access panel.

8. Turn on electrical power to furnace.

9. Recheck temperature rise.

Fan Control

The fan ON time of 30 seconds is not adjustable. The fan

OFF delay (amount of time that the blower operates after

the heat demand has been satisfied) may be adjusted by

changing the jumper position across the five pins on the

integrated control. The unit is shipped with a factory heat

fan OFF setting of 120 seconds. The fan OFF delay affects

comfort and is adjustable to satisfy individual applications.

Adjust the fan OFF delay to achieve a supply air temperature

between 90° and 110° F at the moment that the blower is

de-energized. Longer OFF delay settings provide lower

return air temperatures; shorter settings provide higher

return air temperatures. See Figure 51.

Electronic Ignition

The integrated control has an added feature of an internal

Watchguard control. The feature serves as an automatic

reset device for integrated control lockout caused by ignition

failure. This type of lockout is usually due to low gas line

pressure. After one hour of continuous thermostat demand

for heat, the Watchguard will break and remake thermostat

demand to the furnace and automatically reset the integrated

control to begin the ignition sequence.

HEAT FAN-OFF TIME IN SECONDS

Exhaust and Air Intake Pipe

1. Check exhaust and air intake connections for tightness

and to make sure there is no blockage.

2. Is pressure switch closed? Obstructed exhaust pipe

will cause unit to shut off at pressure switch. Check

termination for blockages.

NO JUMPER

To adjust fan−oﬀ timing, reposition jumper across pins to

achieve desired setting.

60 Second

oﬀ Time

90 Second

oﬀ Time

120 Second

oﬀ Time

180 Second

oﬀ Time

3. Obstructed pipe or termination may cause rollout

switches to open. Reset manual flame rollout switches

on burner box assembly if necessary.

FIGURE 51

506725-01

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BLOWER DATA A93DF1D / 92G1DF

A93DF1D / 92G1DF 045*12B PERFORMANCE (Less Filter)

A93DF1D / 92G1DF 090*16C PERFORMANCE (Less Filter)

Air Volume / Watts at Various Blower Speeds

External

Static

Medium-

High

Medium-

Low

Medium-

High

Medium-

Low

Static

Pressure

in. w.g.

High

Low

High

Low

Pressure

in. w.g.

cfm Watts cfm Watts cfm Watts cfm Watts

1615 650 1385 555 1205 465 1045 390

1605 640 1375 545 1195 455 1035 380

1500 620 1340 525 1165 445 1015 370

1450 590 1290 490 1125 420 975 365

1350 560 1235 480 1090 405 920 345

1300 545 1170 450 1035 380 875 335

1195 500 1095 425 990 365 840 320

1140 485 1020 400 895 345 780 300

1025 450 920 370 840 330 695 275

945 435 800 335 700 295 605 250

cfm Watts cfm Watts cfm Watts cfm Watts

2145 900 1865 740 1545 635 1295 530

2135 890 1855 730 1540 625 1290 520

2065 845 1815 710 1525 600 1285 500

2010 825 1760 685 1510 580 1275 485

1930 775 1705 630 1495 575 1235 455

1845 740 1645 610 1450 530 1215 450

1745 700 1525 550 1380 505 1185 430

1620 650 1460 535 1315 480 1110 405

1450 585 1340 505 1220 445 1020 375

1320 555 1130 450 1010 385 920 345

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

A93DF1D / 92G1DF 070*12B PERFORMANCE (Less Filter)

A93DF1D / 92G1DF 110*20C PERFORMANCE (Less Filter)

Air Volume / Watts at Various Blower Speeds

External

Air Volume / Watts at Various Blower Speeds

External

Medium-

High

Medium-

Low

Medium-

High

Medium-

Low

Static

Pressure

in. w.g.

Static

Pressure

in. w.g.

High

Low

High

Low

cfm Watts cfm Watts cfm Watts cfm Watts

1505 660 1310 570 1090 455 940 390

1480 625 1295 550 1070 435 935 365

1405 585 1255 515 1055 425 930 350

1355 580 1225 475 1045 405 900 330

1305 540 1165 470 1010 385 890 325

1270 525 1110 425 975 370 835 305

1175 500 1080 415 925 345 815 290

1105 460 1000 395 855 320 745 270

1040 440 925 365 790 300 670 250

920 400 825 335 680 270 560 225

cfm Watts cfm Watts cfm Watts cfm Watts

2410 1390 2190 1080 1860 910 1560 735

2405 1385 2180 1070 1855 905 1555 730

2285 1345 2120 1030 1850 865 1540 720

2220 1315 2015 1005 1770 840 1535 705

2185 1295 1950 955 1750 815 1530 685

2045 1240 1830 925 1680 790 1500 660

1965 1220 1710 890 1575 755 1445 640

1820 1165 1610 850 1495 720 1370 615

1625 1155 1510 820 1400 695 1315 595

1455 1110 1390 790 1350 660 1210 565

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

NOTES: All air data is measured external to unit without filter (not furnished - field provided)

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BLOWER DATA A95DF1D / 95G1DF

A95DF1D / 95G1DF 045*12B PERFORMANCE (Less Filter)

A95DF1D / 95G1DF 090*20C PERFORMANCE (Less Filter)

Air Volume / Watts at Various Blower Speeds

External

Static

Medium-

High

Medium-

Low

Medium-

High

Medium-

Low

Static

Pressure

in. w.g.

High

Low

High

Low

Pressure

in. w.g.

cfm Watts cfm Watts cfm Watts cfm Watts

1615 650 1385 555 1205 465 1045 390

1605 640 1380 545 1195 455 1035 380

1500 620 1345 525 1165 445 1015 370

1450 590 1290 490 1125 420 975 365

1350 560 1235 480 1090 405 920 345

1300 545 1170 450 1035 380 880 330

1195 500 1095 425 990 365 840 320

1140 480 1020 395 895 345 780 300

1025 450 920 370 840 330 695 270

945 430 800 335 700 290 605 250

cfm Watts cfm Watts cfm Watts cfm Watts

2305 1255 2145 950 1900 810 1515 670

2295 1240 2135 940 1885 795 1500 665

2200 1220 2085 915 1865 775 1525 655

2160 1210 1990 875 1830 755 1545 640

2055 1170 1935 865 1790 725 1530 620

1970 1130 1855 835 1705 700 1500 600

1890 1105 1765 805 1635 675 1495 580

1775 1075 1680 785 1565 655 1430 560

1690 1050 1590 760 1485 630 1370 540

1580 1010 1485 735 1405 610 1270 510

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

A95DF1D / 95G1DF 070*12B PERFORMANCE (Less Filter)

A95DF1D /95G1DF 110*20C PERFORMANCE (Less Filter)

Air Volume / Watts at Various Blower Speeds

External

Air Volume / Watts at Various Blower Speeds

External

Medium-

High

Medium-

Low

Medium-

High

Medium-

Low

Static

Pressure

in. w.g.

Static

Pressure

in. w.g.

High

Low

High

Low

cfm Watts cfm Watts cfm Watts cfm Watts

1515 620 1315 545 1095 465 910 390

1490 585 1300 525 1075 445 890 375

1445 555 1275 500 1065 425 910 360

1380 520 1240 470 1060 400 900 340

1315 495 1190 440 1020 385 875 325

1270 470 1145 420 995 355 870 310

1155 435 1075 390 940 330 820 300

1075 415 1000 355 875 310 765 270

975 380 900 325 800 285 715 250

900 365 800 300 675 255 615 225

cfm Watts cfm Watts cfm Watts cfm Watts

2375 1250 2205 915 1975 785 1630 640

2365 1235 2195 905 1960 775 1625 635

2275 1200 2125 890 1950 760 1635 625

2200 1180 2060 880 1900 735 1620 610

2115 1150 1995 850 1845 710 1620 600

2040 1115 1940 835 1795 695 1585 580

1955 1090 1855 810 1745 670 1540 565

1860 1070 1730 765 1640 650 1515 550

1735 1030 1620 740 1590 620 1415 535

1640 1010 1535 715 1480 600 1330 510

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

NOTES: All air data is measured external to unit without filter (not furnished - field provided)

506725-01

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Service

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.

WARNING

ELECTRICAL SHOCK, FIRE,

OR EXPLOSION HAZARD.

Failure to follow safety warnings exactly could result in

dangerous operation, serious injury, death or property

damage.

Cleaning Heat Exchanger

If cleaning the heat exchanger becomes necessary, follow

the below procedures and refer to Figure 1 when

disassembling unit. Use papers or protective covering in

front of furnace while removing heat exchanger assembly.

1. Turn off electrical and gas supplies to the furnace.

2. Remove the furnace access panels.

3. Disconnect the 2 wires from the gas valve.

4. Remove gas supply line connected to gas valve.

Remove gas valve/manifold assembly.

Improper servicing could result in dangerous operation,

serious injury, death, or property damage.

Before servicing, disconnect all electrical power to

furnace.

When servicing controls, label all wires prior to

disconnecting. Take care to reconnect wires correctly.

Verify proper operation after servicing.

5. Remove sensor wire from sensor. Disconnect 2 pin

plug from the ignitor.

6. Disconnect wires from flame rollout switches.

7. Loosen clamps at vent elbow. Disconnect condensate

drain tubing from flue collar and remove the vent elbow.

8. Remove four burner box screws at the vestibule panel

and remove burner box. Set burner box assembly aside.

At the beginning of each heating season, system should be

checked as follows by a qualified service technician:

Blower

Check the blower wheel for debris and clean if necessary.

The blower motors are prelubricated for extended bearing

life. No further lubrication is needed.

NOTE: If necessary, clean burners at this time. Follow

procedures outlined in Burner Cleaning section.

9. Mark and disconnect all combustion air pressure tubing

from cold end header collector box.

10. Mark and remove wires from pressure switches.

Remove pressure switches. Keep tubing attached to

pressure switches.

11. Disconnect the plug from the combustion air inducer.

Remove two screws which secure combustion air

inducer to collector box. Remove combustion air inducer

assembly. Remove ground wire from vest panel.

12. Remove electrical junction box from the side of the

furnace.

13. Mark and disconnect any remaining wiring to heating

compartment components. Disengage strain relief

bushing and pull wiring and bushing through the hole in

the blower deck.

14. Remove the primary limit from the vestibule panel.

15. Remove two screws from the front cabinet flange at the

blower deck. Spread cabinet sides slightly to allow

clearance for removal of heat exchanger.

16. Remove screws along vestibule sides and bottom which

secure vestibule panel and heat exchanger assembly

to cabinet. Remove two screws from blower rail which

secure bottom heat exchanger flange. Remove heat

exchanger from furnace cabinet.

17. Back wash heat exchanger with soapy water solution or

steam. If steam is used it must be below 275°F (135°C).

18. Thoroughly rinse and drain the heat exchanger. Soap

solutions can be corrosive. Take care to rinse entire

assembly.

WARNING

The blower access panel must be securely in place when

the blower and burners are operating. Gas fumes, which

could contain carbon monoxide, can be drawn into living

space resulting in personal injury or death.

Filters

All air filters are installed external to the unit. Filters should

be inspected monthly. Clean or replace the filters when

necessary to ensure proper furnace operation. Table 3 lists

recommended filter sizes.

Exhaust and air intake pipes

Check the exhaust and air intake pipes and all connections

for tightness and to make sure there is no blockage.

NOTE: After any heavy snow, ice or frozen fog event the

furnace vent pipes may become restricted. Always check

the vent system and remove any snow or ice that may be

obstructing the plastic intake or exhaust pipes.

Electrical

1. Check all wiring for loose connections.

2. Check for the correct voltage at the furnace (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__________

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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.

Cleaning the Burner Assembly

1. Turn off electrical and gas power supplies to furnace.

Remove upper and lower furnace access panels.

2. Disconnect the 2 pin plug from the gas valve.

3. Remove the burner box cover.

20. Resecure the supporting screws along the vestibule

sides and bottom to the cabinet. Reinstall blower and

mounting screws.

21. Reinstall cabinet screws on front flange at blower deck.

22. Reinstall the primary limit on the vestibule panel.

23. Route heating component wiring through hole in blower

deck and reinsert strain relief bushing.

4. Disconnect the gas supply line from the gas valve.

Remove gas valve/manifold assembly.

5. Mark and disconnect sensor wire from the sensor.

Disconnect 2 pin plug from the ignitor at the burner box.

6. Remove four screws which secure burner box assembly

to vest panel. Remove burner box from the unit.

7. Use the soft brush attachment on a vacuum cleaner to

gently clean the face of the burners. Visually inspect

the inside of the burners and crossovers for any blockage

caused by foreign matter. Remove any blockage.

8. Reconnect the sensor wire and reconnect the 2 pin plug

to the ignitor wiring harness.

24. Reinstall electrical junction box.

25. Reinstall the combustion air inducer. Reconnect the

combustion air inducer to the wire harness.

26. Reinstall pressure switches and reconnect pressure

switch wiring.

27. Carefully connect combustion air pressure switch hosing

from pressure switches to proper stubs on cold end

header collector box.

9. Reinstall the burner box assembly using the existing four

screws. Make sure that the burners line up in the

center of the burner ports.

10. Reinstall the gas valve manifold assembly. Reconnect

the gas supply line to the gas valve. Reinstall the burner

box cover.

28. Reinstall condensate trap.

29. Reconnect exhaust piping and exhaust drain tubing.

30. Reinstall burner box assembly in vestibule area.

31. Reconnect flame rollout switch wires.

11. Reconnect 2 pin plug to gas valve.

32. Reconnect sensor wire and reconnect 2 pin plug from

ignitor.

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.

12. Replace the blower compartment access panel.

13. Refer to instruction on verifying gas and electrical

connections when re-establishing supplies.

14. Follow lighting instructions to light and operate furnace

for 5 minutes to ensure that heat exchanger is clean

and dry and that furnace is operating properly.

15. Replace heating compartment access panel.

36. Replace the blower compartment access panel.

37. Refer to instruction on verifying gas and electrical

connections when re-establishing supplies.

38. Follow lighting instructions to light and operate furnace

for 5 minutes to ensure that heat exchanger is clean

and dry and that furnace is operating properly.

39. Replace heating compartment access panel.

506725-01

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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.

Burners - Must be inspected for rust, dirt, or signs of water.

Vent pipe - Must be inspected for signs of water, cracked,

damaged or sagging pipe, or disconnected joints.

Unit appearance - Must be inspected for rust, dirt, signs of

water, burnt or damaged wires, or components.

Blower access door - Must be properly in place and provide

a seal 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 may make it

necessary to temporarily shut down the furnace until the

items can be repaired or replaced.

Instruct the homeowners to pay attention to their

furnace. Situations can arise between annual furnace

inspections that may result in unsafe operation. For

instance, items innocently stored next to the furnace may

obstruct the combustion air supply. This could cause

incomplete combustion and the production of carbon

monoxide gas.

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506725-01

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 CSAnameplate. 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

Blower Compartment Access Panel

Top Cap

Flame Sensor

Heat Exchanger Assembly

Gas Manifold

Combustion Air Inducer

Gas Valve

Main Burner Cluster

Main Burner Orifices

Control Panel Parts

Transformer

Integrated Control Board

Door Interlock Switch

Pressure Switch

Ignitor

Primary Limit Control

Blower Parts

Blower Wheel

Flame Rollout Switches

Motor

Motor Mounting Frame

Motor Capacitor

Blower Housing Cutoff Plate

506725-01

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Start−Up & Performance Check List

UNIT SET UP

Furnace:

Model Number_______________

Serial Number_________________

SUPPLY

AIR

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

INTAKE / EXHAUST PIPE

Sealed

All Joints Primed and Glued

Filter Installed and Clean

Terminations Installed Properly

Grilles Unobstructed

Horizontal Pipes Sloped (if applicable)

Condensate Trap Primed / Line Sloped

VOLTAGE CHECK

Supply Voltage _____

Electrical Connections Tight

Pipes Supported

Heat Cable Installed and Operable (if applicable)

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UNIT OPERATION

HEATING MODE

COOLING MODE

GAS MANIFOLD PRESSURE “W.C.” ______

INDOOR BLOWER AMPS ______

COMBUSTION SAMPLE CO ______%

CO _____ PPM

TEMPERATURE DROP

______

Return Duct Temperature

Supply Duct Temperature

INDOOR BLOWER AMPS ______

______

Temperature Drop

TEMPERATURE RISE

TOTAL EXTERNAL STATIC (dry coil)

Supply Duct Temperature _{_}

______

Supply External Static

Return External Static

Total External Static

DRAIN LINE

Return Duct Temperature

Temperature Rise

______

TOTAL EXTERNAL STATIC

Supply External Static

Return External Static

______

Leak Free

Total External Static

CONDENSATE LINE

Leak Free

______

THERMOSTAT

Adjusted and Programmed

Explained Operation to Owner

VENT PIPE

Leak Free

Combustion CO

SUPPLY

AIR

Thermostat

Temperatures

Gas Manifold Pressure

Blower Motor Amps

Duct Static

RETURN AIR

Contractor’s: Name______________________________________Telephone________________Checklist Completed____________________

Job Address_______________________________________________________Technician’s Name___________________________________

506725-01

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REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS

4. INSPECTION. The state or local gas inspector of the

Modifications to NFPA-54, Chapter 10

Revise NFPA-54 section 10.8.3 to add the following

requirements:

side wall, horizontally vented, gas-fueled equipment shall

not approve the installation unless, upon inspection, the

inspector observes carbon monoxide detectors and

signage installed in accordance with the provisions of

248 CMR 5.08(2)(a) 1 through 4.

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

not limited to decks and porches, the following requirements

shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE

DETECTORS. At the time of installation of the side wall,

horizontally vented, gas-fueled equipment, the installing

plumber or gas fitter shall observe that a hard wired

carbon monoxide detector with an alarm and battery

backup is installed on the floor level where the gas

equipment is to be installed. In addition, the installing

plumber or gas fitter shall observe that a battery operated

or hard wired carbon monoxide detector with an alarm

is installed on each additional level of the dwelling,

building or structure served by the side wall, horizontally

vented, gas fueled equipment. It shall be the

responsibility of the property owner to secure the

services of qualified licensed professionals for the

installation of hard wired carbon monoxide detectors.

a. In the event that the side wall, horizontally vented,

gas fueled equipment is installed in a crawl space

or an attic, the hard wired carbon monoxide detector

with alarm and battery backup may be installed on

the next adjacent floor level.

EXEMPTIONS: The following equipment is exempt from

24 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment

Not Required to Be Vented” in the most current edition

of NFPA 54 as adopted by the Board; and

2. Product Approved side wall, horizontally vented, gas

fueled equipment installed in a room or structure

separate from the dwelling, building or structure used in

whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS -

GAS EQUIPMENT VENTING SYSTEM PROVIDED.

When the manufacturer of Product Approved side wall,

horizontally vented, gas fueled equipment provides a venting

system design or venting system components with the

equipment, the instructions provided by the manufacturer

for installation of the equipment and the venting system shall

include:

1. Detailed instructions for the installation of the venting

system design or the venting system components: and

2. A complete parts list for the venting system design or

venting system.

MANUFACTURER REQUIREMENTS -

b. In the event that the requirements of this subdivision

cannot be met at the time of completion of

GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of Product Approved sidewall,

horizontally vented, gas fueled equipment does not provide

the parts for venting the flue gases, but identifies “special

venting systems,” the following requirements shall be

satisfied by the manufacturer:

1. The referenced “special venting system” instructions

shall be included with the appliance or equipment

installation instructions; and

2. The “special venting systems” shall be Product

Approved by the Board, and the instructions for that

system shall include a parts list and detailed installation

instructions.

A copy of all installation instructions for all Product

Approved side wall, horizontally vented, gas fueled

equipment, all venting instructions, all parts lists for

venting instructions, and/or all venting design

instructions shall remain with the appliance or

equipment at the completion of the installation.

installation, the owner shall have a period of thirty

(30) days to comply with the above requirements;

provided, however, that during said thirty (30) day

period, a battery operated carbon monoxide

detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS.

Each carbon monoxide detector as required in

accordance with the above provisions shall comply with

NFPA720 and beANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall

be permanently mounted to the exterior of the building

at a 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.”

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506725-01

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