Airease 95G2UHV, Installation Instructions Manual

Page 1: ...valent service agency or the gas supplier WARNING Manufactured By Allied Air Enterprises Inc A Lennox International Inc Company 215 Metropolitan Drive West Columbia SC 29170 P 506878 01 P506878 01 Unit Dimensions 2 A95UH2V 95G2UHV Parts Arrangement 3 A95UH2V 95G2UHV Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 Use of Furnace as a Construction Heater 5 General 6 Shipping Bolt Remo...

Page 2: ...ir with optional RAB Return Air Base 3 Bottom return air 4 Return air from both sides 5 Bottom and one side return air 2 Optional External Side Return Air Filter kit is not for use with optional Return Air Base Consider sizing requirements for optional IAQ equipment before cutting side return opening FRONT VIEW SIDE VIEW Model A 17 1 2 A95UH2V 95G2UHV B C in mm in mm in mm 090 12 135 20 533 21 505...

Page 3: ...506878 01 Page 3 of 62 Issue 1139 EXPANDED VIEW Figure 1 ...

Page 4: ... from contact with sharp sheet metal edges Be careful when you handle this equipment CAUTION DANGER OF EXPLOSION DANGER There are circumstances in which odorant used with LP Propane gas can lose its scent In case of a leak LP Propanegaswillsettleclosetothefloorandmaybedifficult to smell An LP Propane leak detector should be installed in all LP applications Use only the type of gas approved for use...

Page 5: ...oling 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 NFPANo 70 The National Electric Code ANSI NFPA No 70 is available from the following address National Fire Protection Association 1 Battery March Park Quinc...

Page 6: ...ndensate drain system These units should not be installed in areas normally subject to freezing temperatures CAUTION 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 Fiberglass wool may also c...

Page 7: ...tu 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 infiltration If the furnace is located in a building of tight construction with weath...

Page 8: ...ugh horizontal ducts each opening shall have a minimum free area of 1 square inch 645 mm per 2 000 Btu 56 kW per 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 ...

Page 9: ...ee 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 WARNING Blower access panel...

Page 10: ...latform with bottom return make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely The furnace is equipped with a removable bottom panel to facilitate installation Markings are provided on both sides of the furnace cabinet for installations that require side return air Cut the furnace cabinet at the maximum dimensions shown o...

Page 11: ...e Upflow Applications Only NOTE Optional side return air filter kits are not for use with return air base 1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air W x H 23 x 11 in 584 x 279 mm The opening can be cut as needed to accommodate plenum ...

Page 12: ...nstalled above finished space fabricate an auxiliary drain pan to be installed under unit Set unit in drain pan as shown in Figure 17 Leave 8 inches for service clearance below unit for condensate trap 3 Provide a service platform in front of unit When installing the unit in a crawl space a proper support platform may be created using cement blocks 4 Route auxiliary drain line so that water draini...

Page 13: ...m 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 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 res...

Page 14: ...BS 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 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 ...

Page 15: ...joint 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 PVCD 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 NOTE Time is critical at this stage Do not allow primer to dry before applying cement DANGER OF EXPLOSION Fumes fro...

Page 16: ...n home make provisions for draining condensate collection from trap and lines Removal of the Furnace from Common Vent In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances the venting system is likely to be too large to properly vent the remaining attached appliances Conduct the following test while each appliance is operating and the othe...

Page 17: ...er draw with the remaining appliance The exhaust vent pipe operates under positive pressure and must be completely sealed to prevent leakage of combustion products into the living space CAUTION Exhaust Piping Route piping to outside of structure Continue with installation following instructions given in piping termination section Do Not discharge exhaust into an existing stack or stack that also s...

Page 18: ...A minimum of 1 4 6 mm drop for each 12 305 mm of horizontal run is mandatory for drainage NOTE Exhaust pipe MUST be glued to furnace exhaust fittings NOTE Exhaust piping should be checked carefully to make sure there are no sages or low spots EXHAUST PIPE Horizontal Application Figure 20 Use the following steps to correctly size vent pipe diameter Table 4 Any approved termination may be added to t...

Page 19: ...sue 1139 Maximum Allowable Intake or Exhaust Vent Length in Feet Table 5 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 ...

Page 20: ...sue 1139 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 Maximum Allowable Intake or Exhaust Vent Length in Feet Table 6 ...

Page 21: ... size use the shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter TYPICAL EXHAUST PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON DIRECT VENT APPLICATIONS RIGHT HAND DISCHARGE SHOWN When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter ...

Page 22: ...ustion Dilution and Ventilation Air section must be followed Figure 24 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 TYPICAL AIR INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT VENT APPLICATIONS RIGHT HAND DISCHARGE SHOWN Figure 23 TYPICAL AIR INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT VENT APPLICATIONS When...

Page 23: ...e 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 Figure 26 Typical Air Intake Pipe Connections Horizontal Non Direct Vent Applications Horizontal Right Hand Air Discharge Application Shown NOTE Debris screen may be positioned straight out preferr...

Page 24: ...t be located within 6 feet 1 8 m of a condensing unit because the condensate can damage the painted coating 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 unconditional area In extremely cold climate areas with temperature below 20 F 6 7 C it is recommended that 3 4 19 mm Armaflex ...

Page 25: ...506878 01 Page 25 of 62 Issue 1139 Figure 27 VENT TERMINATION CLEARANCES FOR NON DIRECT VENT INSTALLATIONS IN THE USA AND CANADA ...

Page 26: ...506878 01 Page 26 of 62 Issue 1139 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATiONS IN THE USA AND CANADA Figure 28 ...

Page 27: ...3 76 mm on roof terminations and 6 152 mm on sidewall terminations 3 On roof terminations the intake piping should terminate straight down using two 90 elbows See Figure 29 4 Exhaust piping must terminate straight out or up as shown Areducer may be required on the exhaust piping at the point where it exits the structure to improve the velocity of exhaust away from the intake piping See Table 7 NOT...

Page 28: ...506878 01 Page 28 of 62 Issue 1139 Figure 31 FIELD SUPPLIED WALL TERMINATION ...

Page 29: ...506878 01 Page 29 of 62 Issue 1139 Figure 32 ...

Page 30: ...506878 01 Page 30 of 62 Issue 1139 Figure 34 FLUSH MOUNT SIDE WALL TERMINATION 51W11 Figure 33 FIELD SUPPLIED WALL TERMINATION ...

Page 31: ... Non Direct Vent Applications 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 30 through 42 show typical terminations 1 Exhaust piping must terminate straight out or up as shown The termination pipe must be sized as listed in Table 7 The specified pipe ...

Page 32: ... but less than 48 Non Direct Vent Field Supplied Wall Termination Extended Non Direct Vent Application Using Existing Chimney NOTE Do not discharge exhaust gases directly into any chimney or vent stack If vertical 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 illustrated In any exterio...

Page 33: ...t maintain a 1 4 downward slope from the furnace to the drain Do not use copper tubing or existing copper condensate lines for drain line CAUTION Condensate Piping This unit is designed for either right or left side exit of condensate piping in upflow applications In horizontal applications the condensate trap must extend below the unit An 8 service clearance is required for the condensate trap Re...

Page 34: ...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 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 Figure 44 CONDENSATE TRAP LOCATIONS Unit shown in upflow position with remote trap Piping from furnace must slope down a minimum of 1 4 per ft toward trap Do not use copper tu...

Page 35: ...506878 01 Page 35 of 62 Issue 1139 Figure 47 TRAP DRAIN ASSEMBLY USING 1 2 PVC or 3 4 PVC ...

Page 36: ...ks Use a leak detecting solution or other preferred means Never use an open flame to test fro gas leaks Check all connections using a commercially available soap solution made specifically for leak detection 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 more than or equal to ...

Page 37: ...506878 01 Page 37 of 62 Issue 1139 Figure 49 NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET HORIZONTALAPPLICATIONS POSSIBLE GAS PIPING CONFIGURATIONS Figure 50 ...

Page 38: ...506878 01 Page 38 of 62 Issue 1139 GAS PIPE CAPACITY FT HR kL HR 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 8 ...

Page 39: ...uit breaker select circuit protection and wire size according to unit nameplate NOTE Unit nameplate states maximum current draw Maximum over current protection allowed is shown in Table 11 2 Holes are on both sides of the furnace cabinet to facilitate wiring 3 Install a separate properly sized disconnect switch near the furnace so that power can be turned off for servicing Figure 51 INTERIOR MAKE ...

Page 40: ...oper 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 RHD Electrical Wiring Risk of electrical shock Disconnect electrical power at the circuit breaker or service panel before making electrical connections Failure to disconnect power supplies can result in property damage personal...

Page 41: ...on Passive Dehumidification For situations where humidity control is a problem a dehumidification feature has been built into the variable speed motor At the start of each cooling cycle the variable speed motor will run at 82 of the rated airflow for 7 5 minutes After 7 5 minutes has elapsed the motor will increase to 100 of the rated airflow Active Dehumidification To achieve additional dehumidif...

Page 42: ...ide of the burner box If tripped check for adequate combustion air before resetting Pressure Switches The pressure switch assembly includes two switches is located in the heating compartment adjacent to the combustion air inducer These switches check for proper combustion air inducer operation before allowing ignition trial The switches are factory set and require no adjustment Temperature Rise Pl...

Page 43: ...ulating blower Cooling The unit is set up at the factory for single stage cooling For two stage cooling operation clip the jumper wire located between the Y to Y2 terminals on the integrated ignition blower control board If the active dehumidification feature is enabled the circulating blower runs at 70 of the selected cooling speed as long as there is a call for dehumidification Single Stage Cool...

Page 44: ... self diagnostic capability If a system problem occurs a fault code is shown by a red LED on the control board The control continuously monitors its own operation and the operation of the system If a failure occurs the LED will indicate the failure code The flash codes are presented in Table 10 Fault Code History Button The control stores the last five fault codes in memory A pushbutton switch is ...

Page 45: ...t the number of times the amber LED flashes Each flash signifies 200 CFM count the flashes and multiply by 200 to determine the actual CFM delivered for example 5 flashes x 200 1000 CFM TYPICAL FIELD WIRING DIAGRAM Figure 55 WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES NOTE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUS...

Page 46: ...506878 01 Page 46 of 62 Issue 1139 TYPICAL WIRING DIAGRAM Figure 56 ...

Page 47: ...loor 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 Placing the furnace into operation This furnace is equipped with an automatic hot surface...

Page 48: ...ove gas valve switch to OFF 5 Replace the upper access panel Failure To Operate 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 g...

Page 49: ...ned Take care to re tighten the 3 32 Hex screw Gas Pressure Adjustment Gas Flow Approximate 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 12 If manifold pressure matches Table 14 and rate is incorrect check gas orifices ...

Page 50: ... NOTE In Canada certification for installations at elevations over 4500 feet 1372 m is the jurisdictiion of local authorities Units may be installed at altitudes up to 10 000 ft above seal level without manifold adjustment Units installed at altitude of 4501 10 000 feet 1373 to 3048 m may require a pressure switch change which can be ordered separately Table 13 lists conversion kit and pressure sw...

Page 51: ...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 52: ...95 810 890 1030 1170 940 1070 1195 1345 830 965 1100 1235 755 840 975 1130 Setting D Setting C Setting B Setting A 860 1060 1215 1365 Norm 810 960 1130 1265 705 840 1005 1140 600 740 840 970 Norm 555 665 770 855 500 600 680 790 Cooling Stage Speed Adjustment Cooling CFM 50 w c Model A95UH2V045B12S Speed Adjustment Cooling Stage Cooling CFM 50 w c 2nd Stage 1st Stage A95UH2V070B12S 1 2 10x9 50 80 2...

Page 53: ... 1005 1070 1130 1335 1165 1250 1315 1520 1075 1140 1195 1405 935 1030 1065 1285 Setting D Setting C Setting B Setting A 1165 1375 1580 1770 Norm 1075 1265 1440 1645 935 1145 1320 1465 840 1005 1155 1315 Norm 780 915 1045 1190 690 835 955 1070 Model Cooling Stage Speed Adjustment Cooling CFM 50 w c A95UH2V090C16S 2nd Stage 1st Stage Temp Rise Heating CFM 50 w c A95UH2V090C16S 3 4 11x11 45 75 30 60 ...

Page 54: ...0 1255 1455 1015 1055 1135 1335 1210 1275 1385 1620 1100 1160 1255 1455 1015 1055 1135 1335 Setting D Setting C Setting B Setting A 1100 1325 1530 1760 Norm 1025 1205 1405 1565 920 1080 1260 1440 810 980 1085 1235 Norm 760 875 1010 1135 695 805 905 1040 A95UH2V110C16S 2nd Stage 1st Stage Temp Rise Heating CFM 50 w c A95UH2V110C16S 3 4 11x11 60 90 35 65 A95UH2V090C20S 2nd Stage 1st Stage Model Moto...

Page 55: ...0 1880 1985 1360 1500 1670 1850 1300 1435 1630 1715 1190 1325 1465 1620 1095 1190 1340 1430 Setting D Setting C Setting B Setting A 1395 1640 1840 2055 Norm 1290 1480 1660 1905 1170 1330 1500 1705 1015 1160 1330 1480 Norm 940 1085 1200 1345 870 965 1110 1225 Model Cooling Stage Speed Adjustment Cooling CFM 50 w c A95UH2V135C20S 2nd Stage 1st Stage Model Motor Size hp Blower Size Temp Rise Heating ...

Page 56: ...install the clean out cap 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 burner access panel 3 Mark all gas valve wires and disconnect them ...

Page 57: ...nd cold end header box 39 Secure burner assembly to vestibule panel using four existing screws Burners are self aligning to center of clam shells 40 Reconnect gas supply line to gas valve 41 Reconnect flame rollout switch wires 42 Reconnect sensor wire and reconnect 2 pin plug from ignitor 43 Reconnect wires to gas valve 44 Replace the blower compartment access panel 45 Refer to instruction on ver...

Page 58: ...ide 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 should be analyzed and compared to the unit specifications Problems detected during the in...

Page 59: ... equivalent service agency or gas supplier Cabinet Parts Upper Access Panel Blower 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 Main Burner Cluster Main Bu...

Page 60: ...506878 01 Page 60 of 62 Issue 1139 Start Up Performance Check List UNIT SET UP ...

Page 61: ...506878 01 Page 61 of 62 Issue 1139 UNIT OPERATION Heating Mode Cooling Mode ...

Page 62: ...imum 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 not ...