Airease 95G2DFE, Installation Instructions Manual

Page 1: ...r the gas supplier WARNING P 507206 01 P507206 01 This manual must be left with the homeowner for future reference INSTALLATION INSTRUCTIONS A95DF2E 95G2DFE Warm Air Gas Furnace Downflow Air Discharge Direct Vent Non Direct Vent Unit Dimensions 2 A95DF2E 95G2DFE Parts Arrangement 3 A95DF2E 95G2DFE Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 Use of Furnace as a Construction Heate...

Page 2: ...507206 01 Page 2 of 59 Issue 1337 Unit Dimensions inches mm Model A B C A95UH2E 95G2UHE in mm in mm in mm 045 12 17 1 2 446 16 3 8 416 16 406 070 16 090 20 21 533 19 7 8 504 19 1 2 495 110 20 ...

Page 3: ...507206 01 Page 3 of 59 Issue 1337 Figure 1 ...

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

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

Page 6: ... of the condensate drain system NOTE The Commonwealth of Massachusetts stipulates 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 These units should not be installed in areas normally subject to f...

Page 7: ...ection to install these furnaces to ensure efficient and safe operation You must consider combustion air needs and requirements for exhaust vents and gas piping A portion 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 o...

Page 8: ...e total input rating of all equipment in the enclosure See Figure 7 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 p...

Page 9: ...ances 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 11 Shipping Bolt Removal NOTE Units with a 1 2 hp blower motors are equipped with three flexible legs and one rigid leg The rigid leg is equipped with a shipping bolt and a flat white plastic washer...

Page 10: ...ownflow position Floor and furnace flange damage will result Refer to Figure 13 for clearances in downflow applications Figure 13 Downflow Application Installation Clearances CAUTION The furnace and combustible flooring base shall not be installed directly on carpeting tile or other combustible material other than wood flooring Table 1 Non Combustible Floor Opening Size Figure 14 WARNING Improper ...

Page 11: ...r correctly sized opening in floor and installation of cabinet 2 When cooling cabinet is in place set and secure the furnace according to the instructions that are provided with the cooling coil Secure the furnace to the cabinet 3 Seal the cabinet and check for air leaks Return Air Opening Downflow Units Return air may be brought in only through the top opening of a furnace installed in the downfl...

Page 12: ...always be in place when the furnace is operating and it must not allow leaks into the supply air duct system 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 device i e wood fireplace is installed When return air is drawn from a room a negative pressure is created in the room If a gas ...

Page 13: ...nded during cooler weather Metal or plastic strapping may be used as 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 Canadian Applications Only Pipe fittings primer and solvent cement used to vent exhaust this appliance must be certified to ULC S636 and ...

Page 14: ... Do not turn ABS or cellular core pipe NOTE Assembly should be completed within 20 seconds after last application of cement Hammer blows should not be used when inserting pipe 8 After assembly wipe excess cement from pipe at end of fitting socket A properly made joint will show a bead around its entire perimeter Any gaps may indicate an improper defective assembly due to insufficient solvent 9 Han...

Page 15: ...d 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 Resize the common venting system to the minimum vent pipe size determined by usi...

Page 16: ...xhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination Do not use screens or perforated metal in exhaust or intake terminations Doing so will cause freeze ups and may block the terminations IMPORTANT In some applications which permit the use of several different sizes of vent pipe a combination vent pipe may be used Contact Allied Air Technica...

Page 17: ...507206 01 Page 17 of 59 Issue 1337 A95DF2E 95G2DFE Table 7A ...

Page 18: ...507206 01 Page 18 of 59 Issue 1337 A95DF2E 95G2DFE Table 7B ...

Page 19: ...507206 01 Page 19 of 59 Issue 1337 A95DF2E 95G2DFE Table 7C ...

Page 20: ...507206 01 Page 20 of 59 Issue 1337 Typical Exhaust Pipe Connections Figure 22 Figure 23 Typical Intake Pipe Connections Direct Vent Applications ...

Page 21: ...entilated crawlspace Figure 25 or ventilated attic Figure 24 the exhaust vent length must not exceed those listed in Table 7C If 3 diameter pipe is used reduce to 2 diameter pipe to accommodate the debris screen 3 Use a sheet metal screw to secure the intake pipe to the connector if desired General Guidelines for Vent Terminations In Non Direct Vent applications combustion air is taken from indoor...

Page 22: ...rea 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 should 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 ext...

Page 23: ...507206 01 Page 23 of 59 Issue 1337 Figure 26 Vent Termination Clearances For Non Direct Vent Installations in the USA and Canada ...

Page 24: ...507206 01 Page 24 of 59 Issue 1337 Figure 27 Vent Termination Clearances For Direct Vent installations in the USA and Canada ...

Page 25: ...inations are not required to be in the same pressure zone You may exit the intake on one side of the structure and the exhaust on another side Figure 29 You may exit the exhaust out the roof and the intake out the side of the structure Figure 30 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 ...

Page 26: ...obstructions piping must be supported every 24 610 mm as shown in Figures 33 and 34 When exhaust and intake piping must be run up an outside wall the exhaust piping must be terminated with pipe sized per Table 9 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 8 Based on the recommendation of the manufacturer a mul...

Page 27: ...507206 01 Page 27 of 59 Issue 1337 Figure 32 ...

Page 28: ...507206 01 Page 28 of 59 Issue 1337 Figure 33 Field Supplied Wall Termination Figure 34 Field Supplied Wall Termination ...

Page 29: ...ect Vent Concentric Rooftop Termination Figure 36 Direct Vent Concentric Wall Termination Figure 37 Optional Vent Termination for Multiple Unit Installation of Direct Vent Wall Termination Kit Figure 38 Direct Vent Application Using Existing Chimney ...

Page 30: ...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 40 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 41 When exhaust pipin...

Page 31: ...arge flat head screw driver or a 1 2 drive socket extension and remove plug Figure 43 from the cold end header box at the appropriate location on the side of the unit Install provided 3 4 NPT street elbow fitting into cold end header box Use Teflon tape or appropriate pipe dope 3 Install the cap over the clean out opening at the base of the trap Secure with clamp See Figure 48 4 Install drain trap...

Page 32: ...rime trap per procedure outlined in Unit Start Up section Figure 44 Condensate Trap Location shown with right side exit of condensation Figure 45 Evaporator Coil Using a Separate Drain 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 freez...

Page 33: ...a Common Drain When combining the furnace and evaporator coil drains together the A C condensate drain outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly CAUTION Figure 47 Condensate Trap with Optional Overflow Switch ...

Page 34: ...507206 01 Page 34 of 59 Issue 1337 Figure 48 TRAP DRAIN ASSEMBLY USING 1 2 PVC or 3 4 PVC ...

Page 35: ...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 5 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection 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...

Page 36: ...507206 01 Page 36 of 59 Issue 1337 Figure 50 Table 10 ...

Page 37: ...that thermostat wire is long enough to facilitate future removal of blower for service 5 Complete the wiring connections to the equipment Use the provided unit wiring diagram and the field wiring diagram shown in Figure 55 Use 18 gauge wire or larger that is suitable for Class II rating for thermostat connections 6 Electrically ground the unit according to local codes or in the absence of local co...

Page 38: ...mporary power Generator should have a wave form distortion of less than 5 THD Total Harmonic Distortion Electrical Wiring The furnace must be grounded and wired 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 external electrical source is utilized In all instances ...

Page 39: ...o the ON position it will provide a 12 minute delay before secondstage heat is initiated This switch is only activated when the thermostat selector jumper is positioned for SINGLEstage thermostat use Indoor Blower Operation DIP Switch Settings Switches 3 and 4 Heating Mode Blower Off Delay The blower on delay of 30 seconds is not adjustable The blower off delay time that the blower operates after ...

Page 40: ...507206 01 Page 40 of 59 Issue 1337 TYPICAL WIRING DIAGRAM Figure 54 ...

Page 41: ... TO TRANSFORMER GRD TR CHASIS GROUND GRD Y1 THERMOSTAT 1ST STAGE COOL SIGNAL Y2 THERMOSTAT 2ND STAGE COOL SIGNAL O THERMOSTAT SIGNAL TO HEAT PUMP REVERSING VALVE L NOT USED DH NOT USED 3 16 QUICK CONNECT TERMINALS FLAME SENSE SIGNAL HI Cool 24VAC HI HEAT 24VAC LO COOL 24VAC LO HEAT 24VAC PAR PAR COMMON 24VAC 1 4 QUICK CONNECT TERMINALS NEUTRALS 120 NETURAL HUM UNPOWERED NORMALLY OPEN DRY CONTACTS ...

Page 42: ...507206 01 Page 42 of 59 Issue 1337 Field Wiring Applications With Conventional Thermostat Table 15 ...

Page 43: ...507206 01 Page 43 of 59 Issue 1337 Table 15 Field Wiring Applications With Conventional Thermostat Continued ...

Page 44: ...5 Field Wiring Applications With Conventional Thermostat Continued Connect W1 to W1 ONLY if using defrost tempering kit 67M41 NOTE Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the integrated control ...

Page 45: ...5 Field Wiring Applications With Conventional Thermostat Continued Connect W1 to W1 ONLY if using defrost tempering kit 67M41 NOTE Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the integrated control ...

Page 46: ...ose 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 6 Follow the lighting instruction to place the appliance being inspected into operation Adjust thermostat so appliance will operate continuously 7 Use the fl...

Page 47: ...ely 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 57 Unit Start Up FOR YOUR SAFETY READ BEFORE OPERATING 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 ga...

Page 48: ...ted to meter Supply Pressure Measurement A pressure post on the inlet side of the gas valve provides access to the supply pressure Back out the 3 32 Hex screw one turn connect a piece of 5 16 tubing and connect a manometer to measure supply pressure NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to re tighten the 3 32 Hex screw Manifold Pressure ...

Page 49: ...ceed 50 ppm A95DF2E 95G2DFE Gas Manifold Pressure in w g Supply Line Pressure in w g Low Fire Hihh Fire Min Max All Models Natural 1 7 3 5 4 5 10 5 Lp Propane 4 9 10 0 11 0 13 0 Manifold and Supply Line Pressures Altitudes Table 17 A95DF2E 95G2DFE CO2 For Nat CO2 For LP Low Fire High Fire Low Fire High Fire 045 5 6 6 6 7 8 8 8 6 6 7 6 9 1 10 1 070 5 6 6 5 7 3 8 3 6 5 7 5 8 6 9 6 090 5 9 6 9 7 8 8 ...

Page 50: ... the heat demand has been satisfied is 120 seconds and is not adjustible Thermostat Heat Anticipation Set the heat anticipator setting if adjustable according to the amp draw listed on the wiring diagram that is attached to the unit Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace with furnace operating Correct voltage is 120 VAC 10 3 Check amp dra...

Page 51: ...005 745 1700 535 1510 420 1370 355 1160 270 0 70 1970 760 1665 550 1460 440 1325 370 1100 280 0 80 1910 775 1620 560 1420 450 1275 380 1045 295 95DF070 PERFORMANCE Less Filter External Static Pressure in w g Air Volume Watts at Various Blower Speeds High Medium High Medium Medium Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1770 510 1550 340 1355 220 1255 180 1035 115 0 10 1720 5...

Page 52: ...late__________Actual__________ Winterizing and Condensate Trap Care 1 Turn off power to the furnace 2 Have a shallow pan ready to empty condensate water 3 Remove the clean out cap from the condensate trap and empty water Inspect the trap then reinstall the clean out cap Cleaning Heat Exchanger If cleaning the heat exchanger becomes necessary follow the below procedures and refer to Figure 1 when d...

Page 53: ...ners line up in center of burner ports 34 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 35 Reconnect wires to gas valve 36 Replace the blower compartment access panel 37 Refer to instruction on verifying gas and electrical connections when re establishing supplies 38 Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger...

Page 54: ...vide 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 ins...

Page 55: ... equivalent service agency or gas supplier Cabinet Parts Heating Compartment Access Panel Blower Compartment Access Panel Top Cap Control Panel Parts Transformer Integrated Control Board Door Interlock Switch Blower Parts Blower Wheel Motor Motor Mounting Frame Motor Choke Blower Housing Cutoff Plate Heating Parts Flame Sensor Heat Exchanger Assembly Gas Manifold Combustion Air Inducer Gas Valve M...

Page 56: ...507206 01 Page 56 of 59 Issue 1337 Start UP Performance Check List ...

Page 57: ...ly External Static Return External Static Total External Static CONDENSATE LINE 6 Leak Free VENT PIPE 7 Leak Free COOLING MODE INDOOR BLOWER AMPS______ 3 TEMPERATURE DROP Return Duct Temperature Supply Duct Temperature Temperature Drop 4 DRAIN LINE 8 Leak Free THERMOSTAT Adjusted and Programmed Explained Operation to Owner 9 SUPPLY AIR Blower Motor Amps Duct Static Thermostat Gas Manifold Pressure...

Page 58: ... minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall ...