Aire-Flo 92AF1DF Installation Instructions Manual Download

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Page 1

02/11

*2P0211*

506721−01

*P506721-01*

P.O. Box 799900, Dallas, TX 75379−9900

INSTALLATION INSTRUCTIONS

92AF1DF and 95AF1DF

Counterflow Warm Air Gas Furnaces

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.

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

CAUTION

As with any mechanical equipment, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.

WARNING

Improper installation, adjustment, alteration, service
or maintenance 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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92AF1DF/95AF1DF Parts Arrangement

. . . . . . . . . . . .

92AF1DF/95AF1DF Gas Furnace

. . . . . . . . . . . . . . . . .

Shipping and Packing List

. . . . . . . . . . . . . . . . . . . . . . . .

Safety Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of Furnace as a Construction Heater

. . . . . . . . . . .

General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion, Dilution and Ventilation Air

. . . . . . . . . . . .

Setting Equipment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pipe and Fittings Specifications

. . . . . . . . . . . . . . . . . . .

Joint Cementing Procedure

. . . . . . . . . . . . . . . . . . . . . . .

Venting Practices

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent Piping Guidelines

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Start Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Measurement

. . . . . . . . . . . . . . . . . . . . . .

Proper Combustion

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Altitude

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing Non Direct Appliances for Proper Air

. . . . . . . .

Other Unit Adjustments

. . . . . . . . . . . . . . . . . . . . . . . . . .

Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planned Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control Diagnostic Codes

. . . . . . . . . . . . . . .

Repair Parts List

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start Up Checklist

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

02/11 Supersedes 01/11

Summary of Contents for 92AF1DF

Page 1: ...s 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 92AF1DF 95AF1DF Parts Arrangement 3 92AF1DF 95AF1DF Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 Use of Furnace as a Construction Heater 5 General 6 Combustion Dilution and Ventilation Air 6 Setting Equipmen...

Page 2: ...05 19 1 4 489 9 1 8 232 Right 6 9 16 167 Left 2 51 Either Side 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 CONDENSATE TRAP CONNECTION 5 127 6 7 16 163 Either Side 9 229 Either Side 2 1 4 57 Either Side Front Panel 3 4 19 Model No A B C in mm in mm in mm 92 95AF1DF045P12B 92 95AF1DF070P12B 17 1 2 446 16 3 8 416 16 406 92AF1DF090P16C 95AF1DF090P20C 92AF1D...

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

Page 4: ...n all LP applications 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 Safety Information WARNING Improper installation adjustment alteration service or maintenance can cause property damage person al injury or loss of life Installation and service must be perf...

Page 5: ...ctric 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 electrical wiring and grounding for the unit must be installed according to the current regulations of the Canadian Electrical Code Part I CSA Standard C22 1 and or local codes FIGURE 3 Heating Unit Installed Parallell to Air Handler Unit AIR H...

Page 6: ...ctly to the furnace Size the temporary duct following these instructions in section for Combustion Dilution and Ventilation Air in a confined space with air from outside The furnace heat exchanger components duct system air filters and evaporator coils must be thoroughly cleaned following final construction clean up All furnace operating conditions including ignition in put rate temperature rise a...

Page 7: ...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 solutions Chlorinated waxes and clean...

Page 8: ... 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 fo...

Page 9: ...ot known for calculating the size opening required it may be assumed that wood louvers will have 20 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 FIGURE 6 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSI...

Page 10: ...inches 610 mm at unit front The unit must be level from side to side Unit may be positioned from level to 1 2 toward the front to aid in draining See figure 9 Allow for clearances to combustible materials as indicated on the unit nameplate Minimum clearances for closet or al cove installations are shown in figure 11 WARNING Blower access panel must be securely in place when blower and burners are ...

Page 11: ...0 mm 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 op tional additive base is installed between the furnace and the com bustible floor FIGURE 11 Installation on Non Combustible Flooring Figure 12 1 Cut floor opening keeping in mind clearance...

Page 12: ...ctions 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 14 COOLING COIL PLENUM PROPERLY SIZED FLOOR OPENING FURNACE Return Air Opening Counterflow Units Return air may...

Page 13: ...glass sealing strips caulking or equivalent seal ing 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 Pipe Fittings Specifications All pipe fittings primer and solvent cement must conform with American National Standard Institute and the Ameri can Society for Testing and Materials ANSI ASTM stan dards...

Page 14: ...roved vent ex haust system In addition the first three feet of vent pipe from the furnace flue collar must be accessible for inspection TABLE 5 OUTDOOR TERMINATION KITS USAGE UNIT VENT PIPE DIA in STANDARD CONCENTRIC Outdoor Exhaust Accelerator Dia X Length Outdoor Exhaust Accelerator Dia X Length 2 Wall Plate Kit 3 Wall Plate Kit 2 Wall Ring Kit Flush Mount Kit 1 1 2 Concentric Kit 2 Concentric K...

Page 15: ...face 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 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 assemb...

Page 16: ...rmitted Table 7 lists the maximum pipe lengths per mitted TABLE 6 MINIMUM VENT PIPE LENGTHS UNIT MIN VENT LENGTH 045 070 090 110 15 ft or 5 ft plus 2 elbows or 10 ft plus 1 elbow Any approved termination may be added to the minimum length listed Regardless of the diameter of pipe used the standard roof and wall terminations described in section Exhaust Piping Terminations should be used Exhaust ve...

Page 17: ...1 n a 85 65 28 112 112 93 93 4 41 26 80 60 23 107 107 88 88 5 36 21 75 55 18 102 102 83 83 6 31 16 70 50 13 97 97 78 78 7 26 11 65 45 n a 92 92 73 73 8 21 n a 60 40 87 87 68 68 9 16 55 35 82 82 63 63 10 11 50 30 77 77 58 58 Concentric Termination Elevation 0 10 000 ft Number Of 90 Elbows 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 48 33 17 n a ...

Page 18: ... 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 21 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 19: ...egory IV gas furnace 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 Code ANSI Z223 1 NFPA 54 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 p...

Page 20: ... 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 a...

Page 21: ...e 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 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 ...

Page 22: ...Size Termination Pipe Size 045 and 070 2 51mm 2 1 2 64mm 3 76mm 1 1 2 38mm 090 2 51mm 110 3 76mm 2 51mm 045 070 and 090 units with the flush mount termination must use the 1 1 2 accelerator supplied with the kit 5 On field supplied terminations for side wall exit ex haust piping may extend a maximum of 12 inches 305mm for 2 PVC and 20 inches 508mm for 3 76mm PVC beyond the outside wall Intake pipi...

Page 23: ...pplications that include an exhaust termination tee The accelerator is not required 2 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 i...

Page 24: ...C A D WALL SUPPORT 1 2 13mm ARMAFLEX INSULATION IN UNCONDITIONED SPACE E EXTENDED APPLICATION A FIGURE 29 FIELD SUPPLIED WALL TERMINATION OR 15F74 WALL RING TERMINATION KIT WITH INTAKE ELBOW 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 suppor...

Page 25: ...tor provided in 71M80 44W92 kits for 045 070 units FIGURE 32 EXHAUST VENT INTAKE AIR 5 1 2 140mm Front View 12 305mm 5 127mm 18 MAX 457mm EXHAUST VENT INTAKE AIR OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT 22G44 44J40 30G28 or 81J20 Inches mm Side View 12 305mm Min above grade or average snow ac cumulation optional intake elbow FIGURE 33 1 2 13mm Fo...

Page 26: ...ipe is less than 12 in 305 mm above snow accumulation or other obstructions field fabricated piping must be installed FIGURE 36 ÉÉÉÉÉÉÉÉÉÉÉÉ 12 305 mm Minimum Above Grade or Average Snow Accumulation 1 2 13 mm FOAM INSULATION Field Furnished 5 127 mm 5 1 2 140 mm EXHAUST AIR INTAKE AIR GRADE 12 305 mm INTAKE AIR EXHAUST AIR GRADE WALL SUPPORT 12 305 mm Minimum Above Grade or Average Snow Accumulat...

Page 27: ...ns 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 veloc ity required to move the exhaust gases away from the building 2 On field supplied terminations for side wall exit ex haust piping may extend a maximum of 12 inches 305mm for 2 PVC and 20 inches 508mm for 3 76mm PVC beyond the outside wa...

Page 28: ...EY Minimum 12 305MM above chimney top plate or average snow accumulation Condensate Piping This unit is designed for either right or left side exit of con densate piping Refer to figure 42 for condensate trap loca tions NOTE If necessary the condensate trap may 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...

Page 29: ...t no 26K69 and 50 ft 15 2m kit no 26K70 FIGURE 43 CONDENSATE TRAP LOCATION shown with right side exit of condensation 5 max to drain Field Provided Vent min 1 Above Condensate Drain 1 min Trap can be installed a maximum of 5 ft from furnace PVC Only Piping from furnace must slope down a minimum of 1 4 per ft toward trap FIGURE 44 92AF1DF 95AF1DF with Evaporator Coil Drain Condensate trap and evapo...

Page 30: ... To Drain 90 Elbow 3 4 inch PVC Not Furnished To Drain 90 Elbow 1 2 inch PVC Not Furnished 1 2 inch PVC Pipe Not Furnished Drain Assembly for 3 4 inch Drain Pipe OPTIONAL Drain Piping OPTIONAL Condensate Drain Connection 90 Street Elbow 1 2 inch PVC Not Furnished Condensate Drain Connection In Unit Adapter 1 2 inch slip X 1 2 inch mpt Not Furnished 1 inch 25mm Minimum Above Top of Condensate Drain...

Page 31: ... 10 feet 2 44 to 3 05m 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 See figure 55 6 In some localities codes may require installation of a manual main shut off valve and union furnished by in staller external to the un...

Page 32: ...1 125 3 54 118 3 34 110 3 11 103 2 92 1 25 4 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 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 ...

Page 33: ...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 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 flam...

Page 34: ... 95AF1DF furnace contains elec tronic components that are polarity sensitive Make sure that the furnace is wired correctly and is properly grounded Generator Use Voltage Requirements The following requirements must be kept in mind when specifying a generator for use with this equipment The furnace requires 120 volts 10 Range 108 volts to 132 volts The furnace operates at 60 Hz 5 Range 57 Hz to 63 ...

Page 35: ... refer to the FM21 installa tion instruction or appropriate dual fuel thermostat in structions 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 92AF1DF 95AF1DF is running in the heat ing mode the indoor blower will run on the heating speed The heat off delay is adjustable w...

Page 36: ...Page 36 TYPICAL 92AF1DF 95AF1DF WIRING DIAGRAM FIGURE 53 ...

Page 37: ...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 CAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at dis connect switch WARNING Danger of explosion Can cause injury or product or property damage Should the gas supply fail to shut off or if over...

Page 38: ...e the upper access panel 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line GAS VALVE SHOWN IN ON POSITION MANIFOLD PRESSURE OUTLET INLET PRESSURE PORT MANIFOLD PRESSURE ADJUSTMENT SCREW FIGURE 55 12 If the appliance will not operate follow the instructions...

Page 39: ...tion instruction for the conversion procedure 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 pres sure 2 Start unit and allow 5 minutes for unit to reach steady state 3 While waiting for the unit to stabilize notice the flame Flame should be stable and should not l...

Page 40: ...ith the re maining 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 ven...

Page 41: ...le 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 furnace operating 3 Check amp draw on the blower motor Motor Nameplate__________Actual__________ HEAT FAN OFF TIME IN SECONDS To adjust fan off timing reposition jumper across pins to achieve desired setting NO JUM...

Page 42: ...er If cleaning the heat exchanger becomes necessary follow the below procedures and refer to figure 1 when disassem bling unit Use papers or protective covering in front of fur nace 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 valv...

Page 43: ...n nections when re establishing supplies 38 Follow lighting instructions to light and operate fur nace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly 39 Replace heating compartment access panel 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 ...

Page 44: ...may make it nec essary 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 in spections 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 pr...

Page 45: ...e agency or gas supplier Cabinet Parts Upper access panel Blower access panel Top Cap Control Panel Parts Transformer Integrated control Door interlock switch Blower Parts Blower wheel Motor Motor mounting frame Motor capacitor Blower housing cutoff plate Heating Parts Flame Sensor Heat exchanger assembly Gas manifold Combustion air inducer Gas valve Main burner cluster Main burner orifices Pressu...

Page 46: ...rly Pipes Supported Condensate Trap Primed Line Sloped Heat Cable Installed and Operable if applicable 2 2 2 1 Horizontal Pipes Sloped if applicable UNIT SET UP Typical 3 4 Flter RETURN AIR Furnace Model Number_______________ Serial Number_________________ 3 DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated if necessary RETURN DUCT Sealed Filter Installed and Clean Grilles Unobstructed 4 VOLTAGE CHECK ...

Page 47: ...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...

Page 48: ... 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...

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Aire-Flo 92AF1DF, Installation Instructions Manual

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