Aire-Flo 95AF2DF045V12B, Installation Instructions Manual

Page 1: ...enance can cause property damage person al injury or loss of life Installation and service must be performed by a licensed professional installer or equivalent service agency or the gas supplier TABLE OF CONTENTS Unit Dimensions 2 Parts Arrangement 3 95AF2DFV Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 Use of Furnace as a Construction Heater 5 General 6 Combustion Dilution Venti...

Page 2: ... 1 25 2 1 16 52 ELECTRICAL INLET Either Side ELECTRICAL INLET Either Side 2 1 16 52 RETURN AIR OPENING FRONT VIEW SIDE VIEW TOP VIEW A B C 3 4 19 27 3 4 705 19 1 4 489 33 838 3 4 19 B Supply Air Supply Air 9 16 14 9 16 14 9 16 14 9 16 14 19 7 16 494 3 4 19 2 1 4 57 3 4 19 Front Panel mm in A B C Model No in mm in mm 17 1 2 446 16 3 8 416 16 406 21 533 19 7 8 505 19 1 2 495 95AF2DF090V20C 95AF2DF11...

Page 3: ...SEMBLY includes sensor rollout switches and ignitor GAS VALVE COLD END HEADER BOX PRIMARY LIMIT COMBUSTION AIR INDUCER PRESSURE SWITCH CONTROL BOX Includes integrated control transformer and door switch BAG ASSEMBLY shipping location VARIABLE SPEED MOTOR hidden BLOWER DECK DuralokPlusTM HEAT EXCHANGER ASSEMBLY ...

Page 4: ... 1 Snap plug 1 Wire tie 1 Condensate trap 1 Condensate trap cap 1 Condensate trap clamp 1 2 diameter debris screen 1 3 4 Threaded street elbow Check equipment for shipping damage If you find any damage immediately contact the last carrier The following items may also be ordered separately 1 Thermostat 1 LP Propane changeover kit 1 Return air base kit 1 Horizontal suspension kit 1 High altitude pre...

Page 5: ... HEAT or COOL setting When installed this furnace must be electrically grounded according to local codes In addition in the United States installation must conform with the current National Electric Code ANSI NFPA No 70 The National Electric Code ANSI NFPA No 70 is available from the following ad dress National Fire Protection Association 1 Battery March Park Quincy MA 02269 In Canada all electric...

Page 6: ...RNING Insufficient combustion air can cause headaches nausea dizziness or asphyxiation It will also cause excess water in the heat exchanger resulting in rust ing 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 com bustion air supply Permanent wave solutio...

Page 7: ...t 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 pres...

Page 8: ...e 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 en closure See figures 6 and 9 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 10 FIGURE 8 NOTE The inlet...

Page 9: ...h a shipping bolt and a flat white plastic washer rather than the rubber mounting grommet used with a flexible mounting leg See figure 11 The bolt and washer must be re moved before the furnace is placed into operation Af ter the bolt and washer have been removed the rigid leg will not touch the blower housing FIGURE 11 RIGID LEG Remove shipping bolt and washer 95AF2 Furnaces with 1 2 HP Blower Mo...

Page 10: ...LOW UNIT FRONT 1 2 max AIR FLOW UNIT FRONT Unit must be level side to side Unit may be positioned from level to 1 2 toward the front to aid in draining SIDE VIEW FIGURE 13 Front NOTE Do not install the furnace on its front back or in the horizontal position Back Horizontal ...

Page 11: ...Maintain a minimum of 24 in 610 mm for front service access Allow proper clearances to accommodate condensate trap and vent pipe installation 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 14 Installation on Non Combustible Flooring Figure 15 1 Cut floor opening keeping in mind clearances liste...

Page 12: ...tructions for correctly sized opening in floor and installation of cabi net 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 FIGURE 17 COOLING COIL PLENUM PROPERLY SIZED FLOOR OPENING FURNACE Return Air Opening Downflow Units Return air may...

Page 13: ...talled in the supply air duct The access panel should be large enough to permit inspection of the heat exchanger The furnace access panel must al ways be in place when the furnace is operating and it must not allow leaks Return Air Plenum 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 de vice i e wood...

Page 14: ...PE FITTING SOLVENT CEMENT MARKING PVC CPVC Pipe and Fittings ULCS636 PVC CPVC Solvent Cement ABS to PVC or CPVC Transition Cement IMPORTANT 95AF2DFV 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 con nections to the PVC fittings in the unit Use PVC primer and solvent cement o...

Page 15: ...110 2 YES YES YES 5YES YES YES 2 1 2 YES YES 5YES YES YES 3 YES YES 5YES YES YES NOTE Standard Terminations do not include any vent pipe or elbows external to the structure Any vent pipe or elbows external to the structure must be included in total vent length calculations See vent length tables Kits must be properly installed according to kit instructions 1Requires field provided outdoor 1 1 2 ex...

Page 16: ...wet with cement forcefully insert end of pipe into socket until it bottoms out Turn PVC pipe 1 4 turn dur ing assembly but not after pipe is fully inserted to dis tribute cement evenly DO NOT turn ABS or cellular core pipe NOTE Assembly should be completed within 20 sec onds after last application of cement Hammer blows should not be used when inserting pipe 8 After assembly wipe excess cement fro...

Page 17: ...m are located and other spaces of the building Turn on clothes dry ers 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 oper ate at maximum speed Do not operate a summer ex haust fan Close fireplace dampers 4 Follow the lighting instructions Turn on the appliance that is being inspected Adjust the thermost...

Page 18: ...y be used Contact Lennox Application Department for assis tance in sizing vent pipe in these applications IMPORTANT Do not use screens or perforated metal in exhaust or intake terminations Doing so will cause freeze ups and may block the terminations NOTE It is acceptable to use any pipe size which fits within the guidelines allowed in table 7 NOTE All horizontal runs of exhaust pipe must slope ba...

Page 19: ...38 118 117 98 98 3 56 41 19 90 90 68 33 113 112 93 93 4 51 36 14 85 85 63 28 108 107 88 88 5 46 31 9 80 80 58 23 103 102 83 83 6 41 26 4 75 75 53 18 98 97 78 78 7 36 21 n a 70 70 48 13 93 92 73 73 8 31 16 65 65 43 8 88 87 68 68 9 26 11 60 60 38 3 83 82 63 63 10 21 6 55 55 33 n a 78 77 58 58 Concentric Termination at Elevation 0 4500 ft Number Of 90 Elbows Used 2 Pipe 2 1 2 Pipe 3 Pipe Model Model ...

Page 20: ...at Elevation 0 10 000 ft Number Of 90 El bows Used 2 Pipe 2 1 2 Pipe 3 Pipe Model Model Model 045 070 090 110 045 070 090 110 045 070 090 110 1 56 41 19 n a 85 85 63 28 103 102 83 83 2 51 36 14 80 80 58 23 98 97 78 78 3 46 31 9 75 75 53 18 93 92 73 73 4 41 26 4 70 70 48 13 88 87 68 68 5 36 21 n a 65 65 43 8 81 82 63 63 6 31 16 60 60 38 3 78 77 58 58 7 26 11 55 55 33 n a 73 72 53 53 8 21 6 50 50 28...

Page 21: ... 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 2 FIGURE 24 TYPICAL INTAKE PIPE CONNECTIONS 2 2 TRANSITION 2 3 TRANSITION 3 Pipe size determined in table 7 2 2 or TOP VIEW EXHAUST INTAKE When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Intake pipe and exhaust pipe must be...

Page 22: ...alled in an application with combustion air coming in from a space serviced by an exhaust fan power exhaust fan or other device which may create a negative pressure in the space take care when sizing the inlet air opening The in let air opening must be sized to accommodate the maximum volume of exhausted air as well as the maximum volume of combustion air required for all gas appliances serviced b...

Page 23: ... Z223 1 NFPA 54 in U S A and current CSA B149 Natural Gas and Propane Installation Codes in Can ada for details Position termination according to location given in figure 29 or 30 In addition position termination so it is free from any obstructions and 12 above the average snow accumula tion At vent termination care must be taken to maintain protective coatings over building materials prolonged ex...

Page 24: ...to 29 2 in 8 12 18 22 N A 2 1 2 in 6 8 12 16 N A 3 in 2 6 10 12 15 1Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook NOTE Maximum uninsulated vent lengths listed may include the termination vent pipe exterior to the structure and cannot exceed 5 linear feet or the maximum allowable intake or exhaust vent length listed in table 7 or 8 ...

Page 25: ...ly inlet Clearance above paved sidewalk or paved driveway located on public property Clearance under veranda porch deck or balcony 12 Equal to or greater than soffit depth 3 feet 9m 12 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 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...

Page 26: ...ove paved sidewalk or paved driveway located on public property Clearance under veranda porch deck or balcony 12 7 feet 2 1m 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 Btuh 3kw 9 inches 228mm for ap pliances 10 000 Btuh 3kw and 50 000 Btuh 15 kw 12 inches 305mm for ap pliances 50 000 Btuh 15kw 6 inches 152mm for applianc...

Page 27: ... NOT apply 3 On roof terminations the intake piping should termi nate straight down using two 90 elbows See figure 31 4 Exhaust piping must terminate straight out or up as shown A reducer may be required on the exhaust pip ing at the point where it exits the structure to improve the velocity of exhaust away from the intake piping See table 10 TABLE 10 EXHAUST PIPE TERMINATION SIZE REDUCTION 95AF2D...

Page 28: ...hown in figure 34 to prevent any movement in any direction When exhaust and intake piping must be run up an outside wall the exhaust piping must be terminated with pipe sized per table 10 The intake piping may be equipped with a 90 elbow turndown Using turndown will add 5 feet 1 5m to the equivalent length of the pipe 8 A multiple furnace installation may use a group of up to four terminations ass...

Page 29: ...ntake exhaust 12 305 mm Min 12 305 mm Min 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 16 405 mm Max 6 152 mm Max 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 20 508 mm Max 6 152 mm Max Intake Elbow WALL SUPPORT B A D E B D E A ALTERNATE TERMINATIONS TEE FORTY FIVE DEGREE ELBOWS ONLY D C 12 1 2 E B A 1 The exhaust termination tee should be connected to the 2 or 3 PVC flue pipe as...

Page 30: ...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 39 3 8 76mm 203mm 3 8 76mm 203mm STRAIGHT CUT OR ANGLE CUT IN...

Page 31: ...y be installed up to 5 away from the furnace Use PVC pipe to connect trap to furnace condensate outlet Piping from furnace must slope down a minimum of 1 4 per ft toward trap FIGURE 42 CONDENSATE TRAP AND PLUG LOCATIONS Trap same on right side Plug same on left side 1 1 2 in 1 Determine which side condensate piping will exit the unit location of trap field provided fittings and length of PVC pipe ...

Page 32: ...AP LOCATION shown with right side exit of condensation 5 max to drain 1 min 2 max Trap can be installed a maxi mum of 5ft from furnace PVC only Field Provided Vent 1 min 2 max above condensate drain Piping from furnace must slope down a minimum of 1 4 per ft toward trap FIGURE 45 95AF2DFV with Evaporator Coil Using a Separate Drain Drain Field Provided Vent 1 min 2 max above condensate drain Conde...

Page 33: ...Drain Connection In Unit Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Optional Condensate Drain Connection OptionalDrainPipingFromTrap DrainTrapAssembly Furnished DrainTrap Assembly with 1 2 inch Piping DrainTrap Assembly with 3 4 inch Piping 1 2 inch 3 4 inch 1 25 mm Min 2 50 mm Max Above Top Of Condensate Drain Connection In Unit 1 25 mm Min 2 50 mm Max A...

Page 34: ...ap for sediment or condensate 5 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection See figure 57 6 In some localities codes may require installation of a manual main shut off valve and union furnished by in staller external to the unit Union must be of the ground joint type IMPORTANT Compounds used on threaded joints of gas piping must be resis...

Page 35: ... 336 80 24 384 90 27 432 100 30 480 1 2 12 7 622 17 799 172 4 87 118 3 34 95 2 69 81 2 29 72 2 03 65 1 84 60 1 69 56 1 58 52 1 47 50 1 42 3 4 19 05 824 20 930 360 10 19 247 7 00 199 5 63 170 4 81 151 4 28 137 3 87 126 3 56 117 3 31 110 3 11 104 2 94 1 25 4 1 049 26 645 678 19 19 466 13 19 374 10 59 320 9 06 284 8 04 257 7 27 237 6 71 220 6 23 207 5 86 195 5 52 1 1 4 31 75 1 380 35 052 1350 38 22 9...

Page 36: ...20C 20 Holes are on both sides of the furnace cabinet to facili tate wiring Install a separate properly sized disconnect switch near the furnace so that power can be turned off for servicing Before connecting the thermostat or the power wiring check to make sure the wires will be long enough for servicing at a later date Remove the blower access panel to check the length of the wire Complete the w...

Page 37: ...ired in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA No 70 latest edition and or CSA C22 1 Electrical Code latest edition if an ex ternal electrical source is utilized In all instances other than wiring for the thermostat the wiring to be done and any replacement of wire shall con form with the temperature limitation for Type T wire 635F ...

Page 38: ...ise to the DEHUM and R termi nals The DEHUM terminal on the control board must be connected to the normally closed contact of the humidity control so that the board senses an open circuit on high hu midity In this setup the variable speed motor will operate at a 30 reduction in the normal cooling airflow rate when there is a call for dehumidification Circulating Airflow Adjustments Cooling Mode Th...

Page 39: ...Page 39 95AF2DFV Schematic Wiring Diagram FIGURE 55 ...

Page 40: ...mper ature Observe system response Then use the information provided in this section to check the system operation The furnace has a built in self diagnostic capability If a system problem occurs a fault code is shown by ared LED on the control The control continuously monitors its own operation and the operation of the system If a failure oc curs the LED will indicate the failure code The flash c...

Page 41: ...lace the unit into op eration 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 de mand 5 Wait for the combustion air inducer to stop Set the thermostat to initiate a heating demand and again al low the burners to fire for approximately 3 minutes 6 Adjust the thermostat to deactivate the heati...

Page 42: ...ng 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 15 If manifold pressure matches table 17 and rate is incor rect check gas orifices for proper size and restriction Re move temporary gas meter if installed NOTE To obtain accurate reading shut off all other gas appliances connect...

Page 43: ...ying altitudes The combustion air pressure switch is factory set and re quires no adjustment TABLE 17 Manifold and Supply Line Pressure 0 10 000ft 95AF2 Unit Gas Manifold Pressure in wg Supply Line Pressure in w g Low Fire High Fire Min Max All Sizes Natural 1 7 3 5 4 5 10 5 LP propane 4 9 10 0 11 0 13 0 NOTE A natural to L P propane gas changeover kit is necessary to convert this unit Refer to th...

Page 44: ...ually inspect the venting system for proper size and horizontal pitch Determine there is no blockage or re striction 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 buildin...

Page 45: ...rgizes on 1st stage and burn ers ignite 45 seconds after the control confirms ignition has occurred the control drops the combustion blower to low speed The circulating blower ramps up to 50 of 1st stage heat speed and operates at that speed for one minute including ramp up time then at 75 of 1st stage heat speed for an additional minute After that the circulating blower oper ates at full 1st stag...

Page 46: ... to the neutral terminal on the ignition control refer to the furnace wiring diagram The ignition control will control the motor s operation including a nominal 20 second on delay with a call for heat and a nominal 180 second off delay when the thermostat is satisfied It will also operate the motor on a call for cooling with no on or off delays Verify that the unit is operating at the desired spee...

Page 47: ...imit from the vestibule panel 18 Remove two screws from the front cabinet flange at the blower deck Spread cabinet sides slightly to allow clearance for removal of heat exchanger 19 Remove screws along vestibule sides which secure vestibule panel and heat exchanger assembly to cabi net Remove two screws from blower rail which secure top heat exchanger flange Remove heat exchanger from furnace cabi...

Page 48: ...r 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 unob structed 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 sign...

Page 49: ...Pipes Sup ported Condensate Trap Primed Line Sloped Heat Cable Installed and Operable if applicable 2 2 2 1 Horizontal Pipes Sloped if applicable UNIT SET UP Upflow Furnace shown in Typical Set Up 3 4 Flter RETURN AIR Furnace Model Number_______________ Serial Number_________________ 3 DUCT SYS TEM SUPPLY AIR DUCT Sealed Insulated if necessary RETURN DUCT Sealed Filter Installed and Clean Grilles ...

Page 50: ...ATIC 5 Supply External Static _______ Return External Static ______ Total External Static _______ CONDENSATE LINE 6 Leak Free VENT PIPE 7 Leak Free COOLING MODE INDOOR BLOWER AMPS______ 3 TEMPERATURE DROP Return Duct Temperature _________ Supply Duct Temperature _ _______ Temperature Drop _________ 4 DRAIN LINE 8 Leak Free THERMOSTAT Adjusted and Programmed Explained Operation to Own er 9 SUPPLY A...

Page 51: ... eight 8 feet above grade di rectly in line with the exhaust vent terminal for the hori zontally 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 DIRECT LY BELOW KEEP CLEAR OF ALL OBSTRUC TIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve th...

Page 52: ...st pipe exits the structure is not required in direct or non direct vent applications in the Province of Ontario In these applica tions the vent should be oriented such that the exhaust plume is unobjectionable If the installation requires more separation between the flue gases and the building struc ture a reducer may be installed on the exhaust pipe to in crease the flue gas velocity ...