Allied 92G1DF manual

506725-01 Page 1 of 48 Issue 1 109 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. As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment. CAU[...]

506725-01 Page 2 of 48 Issue 1 109 UNIT DIMENSIONS − inches (mm) EXHAUST AIR OUTLET COMBUSTION AIR INT AKE 2−1/16 (52) GAS PIPING INLET (Either Side) ELECTRICAL INLET (Either Side) Return Air Opening W E I V E D I S TOP VIEW 27−3/4 19−1/4 (489) 9−1/8 (232) Right 6−9/16 (167) Left 2 (51) Either Side 3/4 (19) B Supply Air 9/16 (14) 9/16 ([...]

506725-01 Page 3 of 48 Issue 1 109 PARTS ARRANGEMENT FIGURE 1 CONTROL BOX (Includes integrated control, transformer and door switch) BAG ASSEMBL Y BLOWER MOTOR (hidden) BLOWER ACCESS P ANEL HEATING ACCESS P ANEL COMBUSTION AIR INDUCER BURNER BOX ASSEMBL Y (includes ame sensor , rollout switches and ignitor) GAS V AL VE BLOWER DECK HEA T EXCHANGE[...]

506725-01 Page 4 of 48 Issue 1 109 Gas Furnace This Category IV gas furnace is shipped ready for installation in the downflow position. The furnace is equipped for installation in natural gas applications. A conversion kit (ordered sep arately) is required for use in propane/LP gas applications. This unit can be installed as either a Direct V ent o[...]

506725-01 Page 5 of 48 Issue 1 109 Locations and Clearances This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the table in Figure 1 1. Accessibility and service clearances must take precedence over fire protection clearances. NOTE: When furnace is inst alled on a c[...]

506725-01 Page 6 of 48 Issue 1 109 • Air filters must be replaced upon construction completion. • The input rate and temperature rise must be set per the furnace rating plate. • One hundred percent (100%) outdoor air must be provided for combustion air requirement s during construction. T emporary ducting may supply outdoor air to the furnace[...]

506725-01 Page 7 of 48 Issue 1 109 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. In the absenc[...]

506725-01 Page 8 of 48 Issue 1 109 Air from Out side If air from out side 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 d[...]

506725-01 Page 9 of 48 Issue 1 109 INST ALLA TION – Setting Equipment Shipping Bolt Removal NOTE: Unit s 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). Se[...]

506725-01 Page 10 of 48 Issue 1 109 W ARNING 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 t ape to seal return air system to furnace. In platform installations with furnace re[...]

506725-01 Page 11 of 48 Issue 1 109 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[...]

506725-01 Page 12 of 48 Issue 1 109 Filters This unit is not equipped with a filter or rack. A field provided filter is required for the unit to operate properly . T able 3 list s recommended filter sizes. A filter must be in place whenever the unit is operating. CAUTION Solvent cements for plastic pipe are flammable liquids and should be kept away[...]

506725-01 Page 13 of 48 Issue 1 109 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. IMPORT ANT Use PVC primer and solvent cement or ABS solvent cement meeting ASTM specificatio[...]

506725-01 Page 14 of 48 Issue 1 109 Joint Cementing Procedure All cementing of joint s should be done according to the specifications outlined in ASTM D 2855. 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 sock[...]

506725-01 Page 15 of 48 Issue 1 109 V ent Piping Guidelines This gas furnace can be installed as either a Non-Direct V ent or a Direct V ent gas central furnace. NOTE: In non-Direct V ent installations, combustion air is taken from indoors and flue gases are discharged outdoors. In Direct Vent inst allations, combustion air is taken from outdoors a[...]

506725-01 Page 16 of 48 Issue 1 109 T ABLE 7 Maximum Allowable Intake or Exhaust V ent Length in Feet *Siz e intake and exhaus t pipe length separately . Values in table are for Intake OR Ex haust, not combined total. Both Intake an d Exhaus t must be same pipe size. St andard T ermination at Elevation 0 − 10,000 ft. Number Of 90° Elbows Used 2&[...]

506725-01 Page 17 of 48 Issue 1 109 FIGURE 21 TYPICAL INT AKE PIPE CONNECTIONS (DIRECT VENT APPLICATIONS) 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 mus[...]

506725-01 Page 18 of 48 Issue 1 109 Int ake Piping This furnace may be installed in either direct vent or non- direct vent applications. In non-direct vent applications, when int ake air will be drawn into the furnace from the surrounding sp ace, the indoor air quality must be considered. Guidelines listed in Combustion, Dilution and V entilation A[...]

506725-01 Page 19 of 48 Issue 1 109 FIGURE 23 VENT TERMINA TION CLEARANCES FOR NON−DIRECT VENT INST ALLA TIONS IN THE USA AND CANADA K D E L B C F G A B J A M I H INSIDE CORNER DET AIL VENT TERMINAL AIR SUPPL Y INLET AREA WHERE TERMINAL IS NOT PERMITTED Fixed Closed Operable B Fixed Closed Operable B B A = B = C = D = E = F = G = H = I = J = K = [...]

506725-01 Page 20 of 48 Issue 1 109 FIGURE 24 VENT TERMINA TION CLEARANCES FOR DIRECT VENT INST ALLA TIONS IN THE USA AND CANADA K D E L B C F G A B J A M I H INSIDE CORNER DET AIL VENT TERMINAL AIR SUPPL Y INLET AREA WHERE TERMINAL IS NOT PERMITTED Fixed Closed Operable B Fixed Closed Operable B B A = B = C = D = E = F = G = H = I = J = K = L = M [...]

506725-01 Page 21 of 48 Issue 1 109 Details of Int ake and Exhaust Piping T erminations for Direct V ent Inst allations NOTE: In Direct V ent installations, combustion air is t aken from outdoors and flue gases are discharged to outdoors. NOTE: Flue gas may be slightly acidic and may adversely affect some building materials. If any vent termination[...]

506725-01 Page 22 of 48 Issue 1 109 FIGURE 27 C A E D B A B D D B C A C 12" 1 1 2 2 2" (51mm) V ent Pipe 3" (76mm) V ent Pipe A − Clearance above grade or average snow accumulation B −Horizontal separation between intake and exhaust C −Minimum from end of exhaust to inlet of intake D −Exhaust pipe length E −Wall support dis[...]

506725-01 Page 23 of 48 Issue 1 109 FIGURE 28 FIELD SUPPLIED W ALL TERMINA TION 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) f[...]

506725-01 Page 24 of 48 Issue 1 109 FIGURE 30 DIRECT VENT CONCENTRIC ROOFTOP TERMINA TION 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada) Minimum Above Average Snow Accumulation SHEET MET AL STRAP (Clamp and sheet metal strap must be field installed to support the weight of the termination kit.) FLASHING (Not Furnished) CLAMP FIELD−PROVIDED RE[...]

506725-01 Page 25 of 48 Issue 1 109 Details of Exhaust Piping T erminations for Non-Direct V ent Applications 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. 1.[...]

506725-01 Page 26 of 48 Issue 1 109 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 downflow applications. Refer to Figure 38 for condensate trap locations. NOTE: If necessary the condensate trap may be installed u[...]

506725-01 Page 27 of 48 Issue 1 109 FIGURE 41 Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Drain T rap Assembly (Furnished) Ve n t Drain T rap Clean Out 5 Feet Maximum Coupling 1/2 inch slip X slip (Not Furnished) 90 ° Elbow 1/2 inch PVC (Not Furnished) 1/2 inch PVC Pipe (Not Furnished) 1/2 inch PVC Pipe (Not Furnished) 1 (25) Minimum Abov[...]

506725-01 Page 28 of 48 Issue 1 109 Gas Piping 1. Gas piping may be routed into the unit through either the lef t 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 suppl[...]

506725-01 Page 29 of 48 Issue 1 109 GROUND JOINT UNION AUTOMA TIC GAS V AL VE (with manual shut−o valve) FIELD PROVIDED AND INST ALLED GROUND JOINT UNION Left Side Piping (St andard) Right Side Piping (Alternate) AUTOMA TIC GAS V ALVE (with manual shut−o valve) DRIP LEG DRIP LEG MANUAL MAIN SHUT−OFF VA LV E (With 1/8 in. NPT Plugged T a[...]

506725-01 Page 30 of 48 Issue 1 109 Removal of the Furnace from Common V ent 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 a[...]

506725-01 Page 31 of 48 Issue 1 109 Electrical ELECTROST A TIC DISCHARGE (ESD) Precautions and Procedures Electrostatic discharge can af fect electronic components. T ake precautions during furnace installation and service to protect the furnace’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by p[...]

506725-01 Page 32 of 48 Issue 1 109 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 t[...]

506725-01 Page 33 of 48 Issue 1 109 TYPICAL WIRING DIAGRAM FIGURE 48[...]

506725-01 Page 34 of 48 Issue 1 109 Unit St art-Up FOR YOUR SAFETY READ BEFORE OPERA TING 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[...]

506725-01 Page 35 of 48 Issue 1 109 Priming Condensate T rap 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. 2. Set the thermos[...]

506725-01 Page 36 of 48 Issue 1 109 Gas Pressure Adjustment Gas Flow (Approximate) NOTE: T o obt ain accurate reading, shut off all other gas 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 . (T wo revolutions assures a more a[...]

506725-01 Page 37 of 48 Issue 1 109 Nat ur a l to LP / P ropane LP / P ropane to Nat u ra l H i g h Al titu d e Nat u ra l B urner Orifi c e Kit H ig h Altitu d e LP / P ro pa n e Bu r n e r O r if ice Kit A l l 68W 75*† 73W 80 * 51W 01 6 8W 70* † * Conv ers i on r e qui res i ns t al l at ion of a gas v al v e regul at or s pri ng w hi c h i s[...]

506725-01 Page 38 of 48 Issue 1 109 T esting for Proper V enting and Sufficient Combustion Air for Non-Direct V ent Applications 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 [...]

506725-01 Page 39 of 48 Issue 1 109 Other Unit Adjustment s Primary Limit The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no adjustment. Flame Rollout Switches (T wo) These manually reset switches are located on the front of the burner box. These limits are factory set and require no a[...]

506725-01 Page 40 of 48 Issue 1 109 BL O WE R D A T A A93DF1D / 92G1DF A93DF1D / 92G1DF 070*12B PERFORMANCE (Less Filter) External Static Pressure in. w .g. Air V olume / Watts at V arious Blower Speeds High Medium- High Medium- Low Low cfm W atts cfm Watts cfm W atts cfm Watts 0.00 1505 660 1310 570 1090 455 940 390 0.10 1480 625 1295 550 1070 435[...]

506725-01 Page 41 of 48 Issue 1 109 BL OWE R DA T A A95DF1D / 95G1DF A95DF1D / 95G1DF 070*12B PERFORMANCE (Less Filter) External Static Pressure in. w .g. Air V olume / Watts at V arious Blower Speeds High Medium- High Medium- Low Low cfm W atts cfm Watts cfm W atts cfm Watts 0.00 1515 620 1315 545 1095 465 910 390 0.10 1490 585 1300 525 1075 445 8[...]

506725-01 Page 42 of 48 Issue 1 109 Service 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. The blower access panel must be[...]

506725-01 Page 43 of 48 Issue 1 109 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. 20 . Resecure the supporting screws along the vestibule sides and bottom to[...]

506725-01 Page 44 of 48 Issue 1 109 Planned Service A service technician should check the following items during an annual inspection. Power to the unit must be shut of f 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 [...]

506725-01 Page 45 of 48 Issue 1 109 REP AIR P ARTS LIST The following repair part s are available through Allied Air dealers. When ordering part s, include the complete furnace model number listed on the CSA nameplate. Example: A93DF045P36B-01. All service must be performed by a licensed professional installer (or equivalent), service agency , or g[...]

506725-01 Page 46 of 48 Issue 1 109 St art−Up & Performance Check List Gas Supply Pressure SUPPL Y AIR Line V oltage GAS SUPPL Y Natural Gas LP Prop ane Gas Piping Connections Tight Leak T ested 1 INT AKE / EXHAUST PIPE All Joints Primed and Glued T erminations Installed Properly Pipes Supported Condensate T rap Primed / Line Sloped Heat Cabl[...]

506725-01 Page 47 of 48 Issue 1 109 Contractor’s: Name______________________________________T elephone_ _______________Checklist Completed____________________ Job Address_______________________________________________________T echnician’s Name___________________________________ 1 HEA TING MODE COMBUSTION SAMPLE CO 2 % ______ C O _____ P PM 2 IN[...]

506725-01 Page 48 of 48 Issue 1 109 REQUIREMENTS for COMMONWEAL TH of MASSACHUSETTS Modifications to NFP A-54, Chapter 10 Revise NFP A-54 section 10.8.3 to add the following requirement s: For all side wall, horizont ally vented, gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purpose[...]