95G1UH Ducane 92G1 95G1 Upflow Install

User Manual: 95G1UH

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Page Count: 60

507270-03 Page 1 of 60Issue 1621

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.

CAUTION

Manufactured By

Allied Air Enterprises LLC

A Lennox International, Inc. Company

215 Metropolitan Drive

West Columbia, SC 29170

Improper installation, adjustment, alteration, service

or maintenance can cause property damage, personal

injury or loss of life. Installation and service must

be performed by a licensed professional installer (or

equivalent), service agency or the gas supplier.

WARNING

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

A95UH1D,A93UH1D,95G1UH-P & 92G1UH-P

INSTALLATION INSTRUCTIONS

Warm Air Gas Furnace

Upow/Horizontal Left and Right Air Discharge

(P) 507270-03

*P507270-03*

TABLE OF CONTENTS

Unit Dimensions ................................................................ 2

Parts Arrangement............................................................. 3

Gas Furnace ...................................................................... 4

Shipping and Packing List ................................................. 4

Safety Information ............................................................. 4

Use of Furnace as a Construction Heater ......................... 5

General ............................................................................ 6

Combustion, Dilution & Ventilation Air ............................... 6

Setting Equipment ............................................................. 9

Filters .......................................................................... 13

Duct System .................................................................... 13

Pipe & Fittings Specications .......................................... 13

Joint Cementing Procedure ............................................. 15

Venting Practices ............................................................. 16

Vent Piping Guidelines .................................................... 18

Gas Piping ....................................................................... 38

Electrical .......................................................................... 41

Unit Start-Up .................................................................... 44

Gas Pressure Adjustment ................................................ 46

High Altitude Information ................................................. 46

Other Unit Adjustments.................................................... 49

Blower Motor Performance .............................................. 50

Service .......................................................................... 54

Planned Service .............................................................. 56

Diagnostic Codes ............................................................ 56

Repair Parts List .............................................................. 57

Start-Up & Performance Check List ................................ 58

507270-03Page 2 of 60 Issue 1621

A95UH1D, A93UH1D, 95G1UHD & 92G1UHD Unit Dimensions - inches (mm)

1 NOTE - 20C and 20D (5 Ton) size units installed in upow

applications that require air volumes of 1800 cfm (850 L/s) or

greater must have one of the following:

1. Single side return air with transition, to accommodate

20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air lter.

(Required to maintain proper air velocity.)

2. Single side return air with optional “RAB” Return Air

Base.

3. Bottom return air.

4. Return air from both sides.

5. Bottom and one side return air.

See “Blower Performance Tables” for additional information.

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

507270-03 Page 3 of 60Issue 1621

EXPANDED VIEW

Figure 1

507270-03Page 4 of 60 Issue 1621

A95UH1D, A93UH1D, 95G1UH-P & 92G1UH-P Gas

Furnace

The A95UH1D/A93UH1D/95G1UHD & 92G1UHD Category

IV gas furnace is shipped ready for installation in the upow

or horizontal position. The furnace is shipped with the

bottom panel in place. The bottom panel must be removed if

the unit is to be installed in horizontal or upow applications

with bottom return air.

The A95UH1D/A93UH1D/95G1UH-P & 92G1UH-P can

be installed as either a Direct Vent or a Non-Direct Vent

gas central furnace

The furnace is equipped for installation in natural gas

applications. A conversion kit (ordered separately) is

required for use in propane/LP gas applications.

NOTE: In Direct Vent installations, combustion air is taken

from outdoors and ue gases are discharged outdoors.

In Non-Direct Vent installations, combustion air is taken

from indoors and ue gases are discharged outdoors. See

Figures 2 and 3 for applications involving roof termination.

Safety Information

Use only the type of gas approved for use with this furnace.

Refer to unit nameplate.

A95UH1D/A93UH1D/95G1UH-P & 92G1UH-P units are

CSA International certied 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 National Fuel

Gas Code (ANSI Z223.1/NFPA 54). The National Fuel Gas

Code is available from the American National Standards

Institute, Inc., 11 West 42nd Street, New York, NY 10036.

Shipping and Packing List

1 - Assembled Gas Furnace

1 - Bag assembly containing the following:

1 - Snap bushing

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 nd any

damage, immediately contact the last carrier.

Please refer to specication sheets for available accessories

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/Propane gas will settle close to the oor and may be

difcult to smell. An LP/Propane leak detector should

be installed in all LP applications.

As with any mechanical equipment, personal injury can

result from contact with sharp sheet metal edges. Be

careful when you handle this equipment.

CAUTION

Improper installation, adjustment, alteration, service

or maintenance can cause property damage, personal

injury or loss of life. Installation and service must

be performed by a licensed professional installer (or

equivalent), service agency or the gas supplier.

WARNING

Figure 2

Figure 3

507270-03 Page 5 of 60Issue 1621

In Canada, installation must conform with current National

Standard of Canada CSA-B149 Natural Gas and Propane

Installation Codes, local plumbing or waste water codes and

other applicable local codes.

In order to ensure proper unit operation in non-direct vent

applications, combustion and ventilation air supply must be

provided according to the current National Fuel Gas Code

or CSA-B149 standard.

Installation Locations

This furnace is CSA International certied for installation

clearances to combustible material as listed on the unit

nameplate and in the table in Figures13 and 18. Accessibility

and service clearances must take precedence over re

protection clearances.

NOTE: For installation on combustible oors, the furnace

shall not be installed directly on carpeting, tile, or other

combustible material other than wood ooring.

For installation in a residential garage, the furnace must be

installed so that the burner(s) and the ignition source are

located no less than 18 inches (457 mm) above the oor.

The furnace must be located or protected to avoid physical

damage by vehicles. When a furnace is installed in a public

garage, hangar, or other building that has a hazardous

atmosphere, the furnace must be installed according to

recommended good practice requirements and current

National Fuel Gas Code or CSA B149 standards.

Note: Furnace must be adjusted to obtain a temperature

rise within the range specied on the unit nameplate. Failure

to do so may cause erratic limit operation and premature

heat exchanger failure.

This furnace must be installed so that its electrical

components are protected from water.

Installed in Combination with a Cooling Coil

When this furnace is used with cooling units (Figure 4),

it shall be installed in parallel with, or on the upstream

side of, cooling units to avoid condensation in the heating

compartment. With a parallel ow arrangement, a damper

(or other means to control the ow of air) must adequately

prevent chilled air 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 National Electric Code

(ANSI/NFPA No. 70) is available from the following address:

National Fire Protection Association

1 Battery March Park

Quincy, MA 02269

NOTE: This furnace is designed for a minimum continuous

return air temperature of 60°F (16°C) or an intermittent

operation down to 55°F (13°C) dry bulb for cases where a

night setback thermostat is used. Return air temperature

must not exceed 85°F (29°C) dry bulb.

This furnace may be installed in alcoves, closets, attics,

basements, garages, and utility rooms in the upow or

horizontal position.

This furnace design has not been CSA certied for installation

in mobile homes, recreational vehicles, or outdoors.

Use of Furnace as a Construction Heater

These units are not recommended for use as a construction

heater during any phase of construction. Very low return air

temperature, harmful vapors and operation of the unit with

clogged or misplaced lters will damage the unit.

These units may be used for heating of buildings or

structures under construction, if the following conditions

are met:

• The vent system must be permanently installed per

these installation instructions.

• A room thermostat must control the furnace. The use

of xed jumpers that will provide continuous heating is

not allowed.

• The return air duct must be provided and sealed to the

furnace.

• Return air temperature range between 60°F (16°C) and

80°F (27°C) must be maintained.

• Air lters must be installed in the system and must be

maintained during construction.

• Air lters must be replaced upon construction completion.

Figure 4

Heating Unit Installed Parallet to Air Handler Unit

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.

507270-03Page 6 of 60 Issue 1621

• 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 requirements during construction.

Temporary ducting may supply outdoor air to the furnace.

Do not connect duct directly to the furnace. Size the

temporary duct following the instructions in section for

Combustion, Dilution and Ventilation Air in a conned

space with air from outside.

• The furnace heat exchanger, components, duct system,

air lters and evaporator coils must be thoroughly

cleaned following nal construction cleanup.

• All furnace operating conditions (including ignition, input

rate, temperature rise and venting) must be veried

according to these installation instructions.

General

These instructions are intended as a general guide and do

not supersede local codes in any way. Consult authorities

having jurisdiction before installation.

In addition to the requirements outlined previously, the

following general recommendations must be considered

when installing one of these furnaces:

• Place the furnace as close to the center of the air

distribution system as possible. The furnace should

also be located close to the vent termination point.

• When the furnace is installed in non-direct vent

applications, do not install the furnace where drafts

might blow directly into it. This could cause improper

combustion and unsafe operation.

• When the furnace is installed in non-direct vent

applications, do not block the furnace combustion air

opening with clothing, boxes, doors, etc. Air is needed

for proper combustion and safe unit operation.

• When the furnace is installed in an attic or other

insulated space, keep insulation away from the furnace.

• When the furnace is installed in an unconditioned space,

consider provisions required to prevent freezing of

condensate drain system.

Note: The Commonwealth of Massachusetts stipulates

these additional requirements:

• Gas furnaces shall be installed by a licensed plumber

or tter 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

oored.

Combustion, Dilution & Ventilation Air

If this unit is installed as a Non-Direct Vent Furnace,

follow the guidelines in this section.

NOTE: In Non-Direct Vent Installations, combustion air is

taken from indoors and ue gases are discharged outdoors.

In the past, there was no problem in bringing in sufcient

outdoor air for combustion. Inltration provided all the air

that was needed. In today’s homes, tight construction

practices make it necessary to bring in air from outside for

combustion. Take into account that exhaust fans, appliance

vents, chimneys, and replaces force additional air that

could be used for combustion out of the house. Unless

outside

These units should not be installed in areas normally

subject to freezing temperatures.

CAUTION

Insufficient combustion air can cause headaches,

nausea, dizziness or asphyxiation. It will also cause

excess water in the heat exchanger resulting in rusting

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 combustion

air supply:

Permanent wave solutions

Chlorinated waxes and cleaners

Chlorine base swimming pool chemicals

Water softening chemicals

De-icing salts or chemicals

Carbon tetrachloride

Halogen type refrigerants

Cleaning solvents (such as perchloroethylene)

Printing inks, paint removers, varnishes, etc.

Hydrochloric acid

Cements and glues

Antistatic fabric softeners for clothes dryers

Masonry acid washing materials

WARNING

The State of California has determined that this product

may contain or produce a chemical or chemicals, in

very low doses, which may cause serious illness or

death. It may also cause cancer, birth defects or other

repoductive harm.

WARNING

507270-03 Page 7 of 60Issue 1621

Do not install the furnace in a corrosive or contaminated

atmosphere. Meet all combustion and ventilation air

requirements, as well as all local codes.

CAUTION

inltration. If the furnace is located in a building of tight

construction with weather stripping and caulking around

the windows and doors, follow the procedures in the “Air

from Outside” section.

Conned Space

A conned space is an area with a volume less than 50

cubic feet (1.42 m³) per 1,000 Btu (.29 kW) per hour of

the combined input rating of all appliances installed in that

space. This denition includes furnace closets or small

equipment rooms.

When the furnace is installed so that supply ducts carry

air circulated by the furnace to areas outside the space

containing the furnace, the return air must 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 conned 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 for combustion and ventilation can be brought into the

conned space either from inside the building or from

outside.

Air from Inside

If the conned space that houses the furnace adjoins a

space categorized as unconned, air can be brought in by

providing two permanent openings between the two spaces.

Each opening must have a minimum free area of 1 square

inch (645 mm²) per 1,000 Btu (.29 kW) per hour of total

input rating of all gas-red equipment in the conned space.

Each opening must be at least 100 square inches (64516

mm²). One opening shall be within 12 inches (305 mm) of

the top of the enclosure and one opening within 12 inches

(305 mm) of the bottom. See Figure 5.

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 absence of local codes concerning air for combustion

and ventilation, use the guidelines and procedures in this

section to install these furnaces to ensure efcient 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 ofcial position

of ANSI on the referenced subject, which is represented

only by the standard in its entirely.

In Canada, refer to the CSA B149 Installation codes.

All gas-red appliances require air for the combustion

process. If sufcient combustion air is not available, the

furnace or other appliance will operate inefciently and

unsafely. Enough air must be provided to meet the needs of

all fuel-burning appliances and appliances such as exhaust

fans which force air out of the house. When replaces,

exhaust fans, or clothes dryers are used at the same time

as the furnace, much more air is required to ensure proper

combustion and to prevent a down draft. Insufcient air

causes incomplete combustion which can result in carbon

monoxide.

In addition to providing combustion air, fresh outdoor air

dilutes contaminants in the indoor air. These contaminants

may include bleaches, adhesives, detergents, solvents and

other contaminants which can corrode furnace components.

The requirements for providing air for combustion and

ventilation depend largely on whether the furnace is installed

in an unconned or a conned space.

Unconned Space

An unconned space is an area such as a basement or large

equipment room with a volume greater than 50 cubic feet

(1.42 m³) per 1,000 Btu (.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 unconned,

it might be necessary to bring in outdoor air for combustion

if the structure does not provide enough air by

Figure 5

Equipment in Conned Space - All Air From Inside

507270-03Page 8 of 60 Issue 1621

Air from Outside

If air from outside is brought in for combustion and

ventilation, the conned 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 ducts with the outdoors or spaces (crawl or attic) that

freely communicate with the outdoors or indirectly through

vertical ducts. Each opening shall have a minimum free area

of 1 square inch per 4,000 Btu (645 mm² per .59 kW) per

hour of total input rating of all equipment in the enclosure

(See Figures 6 and 7). It is also permissible to bring in air

for combustion from a ventilated attic (Figure 8) or ventilated

crawl space (Figure 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.

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 protective

covering is not 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 xed in the open position or interlocked with the

equipment so that they are opened automatically during

equipment operation.

Figure 6

Equipment in Conned Space - All Air from Outside

(Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)

Figure 7

Equipment in Conned Space - All Air from Outside

(All Air through Ventilated Attic)

Figure 8

Equipment in Conned Space

(Inlet Air from Ventilated Attic & Outlet Air to Outside)

Figure 9

Equipment in Conned Space

(Inlet Air from Ventilated Drawlspace & Outlet Air to Outside)

507270-03 Page 9 of 60Issue 1621

Shipping Bolt Removal

Units with 1/2 hp blower motor are equipped with three

exible legs and one rigid leg. The rigid leg is equipped

with a shipping bolt and a at white plastic washer (rather

than the rubber mounting grommet used with a exible

mounting leg). See Figure 11. 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.

Figure 10

Equipment in Conned Space - All Air from Outside INSTALLATION

Setting Equipment

WARNING

Blower access panel must be securely in place when

blower and burners are operating. Gas fumes, which

could contain carbon monoxide, can be drawn into living

space resulting in personal injury or death.

WARNING

Do not connect the return air ducts to the back of the

furnace. Doing so will adversely affect the operation of

the safety control devices, which could result in personal

injury or death.

Upow Applications

The gas furnaces can be installed as shipped in the upow

position. Refer to Figure 13 for clearances. Select a

location that allows for the required clearances that are

listed on the unit nameplate. Also consider gas supply

connections,

electrical supply, vent connection, condensate trap and

drain connections, and installation and service clearances

[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 12.

Allow for clearances to combustible materials as indicated

on the unit nameplate.

Figure 11

Units with 1/2 HP

Blower Motor

Figure 12

Setting Equipment

Unit must be level side-to-side in all applications.

Tilt the unit slightly (Max. 1/2”) from back to front to aid in the draining of the heat exchanger.

507270-03Page 10 of 60 Issue 1621

WARNING

Improper installation of the furnace can result in

personal injury or death. Combustion and ue products

must never be allowed to enter the return air system

or air in the living space. Use sheet metal screws and

joint tape to seal return air system to furnace.

In platform installations with furnace return, the furnace

should be sealed airtight to the return air plenum. A

door must never be used as a portion of the return air

duct system. The base must provide a stable support

and an airtight seal to the furnace. Allow absolutely no

sagging, cracks, gaps, etc.

For no reason should return and supply air duct systems

ever be connected to or from other heating devices such

as a replace or stove, etc. Fire, explosion, carbon

monoxide poisoning, personal injury and/or property

damage could result.

Return Air Guidlines

Return air can be brought in through the bottom or either

side of the furnace installed in an upow application. If the

furnace is installed on a platform 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 on page 2.

Furnace applications which include side return air and a

condensate trap installed on the same side of the cabinet

(trap can be installed remotely within 5 ft.) require either a

return air base or eld-fabricated transition to accommodate

an optional IAQ accessory taller than 14.5”. See Figure 14.

Figure 13

Installation Clearances

Figure 14

Side Return Air

(with Transition and Filter)

507270-03 Page 11 of 60Issue 1621

Removing the Bottom Panel

Remove the two screws that secure the bottom cap to the

furnace. Pivot the bottom cap down to release the bottom

panel. Once the bottom panel has been removed, reinstall

the bottom cap. See Figure 16.

Horizontal Applications

WARNING

Do not install the furnace on its front or its back. See

Figure 17.

Figure 17

Optional Return Air Base

(Upow Applications Only)

Figure 15

Removing the Bottom Panel

Figure 16

507270-03Page 12 of 60 Issue 1621

Suspended Installation of Horizontal Unit

This furnace may be installed in either an attic or a crawl

space. Either suspend the furnace from roof rafters or oor

joists, as shown in Figure 19, or install the furnace on a

platform, as shown in Figure 20. A horizontal suspension

kit (51W10) may be ordered from your distributor or use

equivalent.

NOTE: When the furnace is installed on a platform or with

the horizontal suspension kit in a crawl space, it must be

elevated enough to avoid water damage, accommodate

drain trap and to allow the evaporator coil to drain.

Platform Installation of Horizontal Unit

1. Select location for unit keeping in mind service and other

necessary clearances. See Figure 18.

2. Construct a raised wooden frame and cover frame with a

plywood sheet. If unit is installed above nished space,

fabricate an auxiliary drain pan to be installed under unit.

Set unit in drain pan as shown in Figure 20. 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 draining from

this outlet will be easily noticed by the homeowner.

5. If necessary, run the condensate line into a condensate

pump to meet drain line slope requirements. The pump

must be rated for use with condensing furnaces. Protect

the condensate discharge line from the pump to the

outside to avoid freezing.

6. Continue with exhaust, condensate and intake piping

installation according to instructions.

Typical Horizontal Application

Figure 19

This furnace can be installed in horizontal applications with

either right or left hand air discharge.

Refer to Figure 18 for clearances in horizontal applications.

NOTE: Heavy-gauge sheet metal straps may be used to

suspend the unit from roof rafters or ceiling joists. When

straps are used to suspend the unit in this way, support

must be provided for both the ends. The straps must not

interfere with the plenum or exhaust piping installation.

Cooling coils and supply and return air plenums must

be supported separately.

Figure 18

Horizontal Application

Installation Clearances

507270-03 Page 13 of 60Issue 1621

Return Air - Horizontal Applications

Return air may be brought in only through the end of a

furnace installed in the horizontal position. The furnace

is equipped with a removable bottom panel to facilitate

installation. See Figure 16.

Filters

This unit is not equipped with a lter or rack. A eld provided

lter is required for the unit to operate properly. Table 1 list

recommended lter sizes.

A lter must be in place whenever the is operating.

Duct System

Use industry approved standards to size and install the

supply and return air duct system. This will result in a quiet

and low-static system that has uniform air distribution.

NOTE: This furnace is not certied for operation in heating

mode (indoor blower operating at selected heating speed)

with an external static pressure which exceeds 0.5 inches

w.c. Operation at these conditions may result in improper

limit operation.

Supply Air Plenum

If the furnace is installed without a cooling coil, a removable

access panel should be installed in the supply air duct. The

access panel should be large enough to permit inspection

(by reected light) of the heat exchanger for leaks after the

furnace is installed. The furnace access panel must 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 replace) 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 ue products can be pulled

back down the vent pipe and into the room. This reverse

ow of the ue gas may result in incomplete combustion

and the formation of carbon monoxide gas. This raw gas or

toxic fumes might then be distributed throughout the house

by the furnace duct system.

Return air can be brought in through the bottom or either

side of the furnace. If a furnace with bottom return air is

installed on a platform, make an airtight seal between the

bottom of the furnace and the platform to ensure that the

unit operates properly and safely. Use berglass sealing

strips, caulking, or equivalent sealing method between the

plenum and the furnace cabinet to ensure a tight seal. If a

lter is installed, size the return air duct to t the lter frame.

Pipe & Fittings Specications

All pipe, ttings, primer and solvent cement must conform

with American National Standard Institute and the American

Society for Testing and Materials (ANSI/ASTM) standards.

The solvent shall be free owing and contain no lumps,

undissolved particles or any foreign matter that adversely

affects the joint strength or chemical resistance of the

cement. The cement shall show no gelation, stratication,

or separation that cannot be removed by stirring. Refer to

Table 2 for approved piping and tting materials.

Table 1

Figure 20

507270-03Page 14 of 60 Issue 1621

Use PVC primer and solvent cement or ABS solvent cement

meeting ASTM specications, refer to Table 2. As an

alternate, use all purpose cement, to bond ABS, PVC, or

CPVC pipe when using ttings and pipe made of the same

materials. Use transition solvent cement when bonding ABS

to either PVC or CPVC.

Low temperature solvent cement is recommended during

cooler weather. Metal or plastic strapping may be used for

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 tting and male end of pipe to depth

of tting socket.

Canadian Applications Only

Pipe, ttings, primer and solvent cement used to vent

(exhaust) this appliance must be certied 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 to bond the pipe to the ue collar, or to bond the 90°

elbow or reducing 90° elbow to the ue collar. In addition,

the rst three feet of vent pipe from the furnace ue collar

must be accessible for inspection.

Solvent cements for plastic pipe are ammable liquids

and should be kept away from all sources of ignition.

Do not use excessive amounts of solvent cement when

making joints. Good ventilation should be maintained to

reduce re hazard and to minimize breathing of solvent

vapors. Avoid contact of cement with skin and eyes.

CAUTION

A95UH1D/A93UH1D/95G1UH-P & 92G1UH-P 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 tting in the

unit.

IMPORTANT

PIPING AND FITTINGS SPECIFICATIONS

Table 2

Schedule 40 PVC (Pipe) D1785

Schedule 40 PVC (Cellular Core Pipe) F891

Schedule 40 PVC (Fittings) D2466

Schedule 40 CPVC (Pipe) F441

Schedule 40 CPVC (Fittings) F438

SDR-21 PVC or SDR-26 PVC (Pipe) D2241

SDR-21 CPVC or SDR-26 CPVC (Pipe) F442

Schedule 40 ABS Cellular Core DWV

(Pipe) F628

Schedule 40 ABS (Pipe) D1527

Schedule 40 ABS (Fittings) D2468

ABS-DWV (Drain Waste & Vent)

(Pipe & Fittings) D2661

PVC-DWV (Drain Waste & Vent)

Pipe & Fittings) D2665

PRIMER & SOLVENT CEMENT ASTM

SPECIFICATION

PVC & CPVC Primer F656

PVC Solvent Cement D2564

CPVC Solvent Cement F493

ABS Solvent Cement D2235

PVC/CPVC/ABS All Purpose Cement For

Fittings & Pipe of the same material

D2564, D2235,

F493

ABS to PVC or CPVC Transition Solvent

Cement D3138

CANADA PIPE & FITTING & SOLVENT

CEMENT MARKING

PVC & CPVC Pipe and Fittings

ULCS636PVC & CPVC Solvent Cement

ABS to PVC or CPVC Transition Cement

POLYPROPYLENE VENTING SYSTEM ULC-S636

PolyPro® by Duravent

InnoFlue® by Centrotherm ULC-S636

507270-03 Page 15 of 60Issue 1621

Joint Cementing Procedure

All cementing of joints should be done according to the

specications 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 tting socket and result in a

leaking joint.

3. Clean and dry surfaces to be joined.

4. Test t joint and mark depth of tting on outside of pipe.

5. Uniformly apply a liberal coat of PVC primer for PVC

or use a clean dry cloth for ABS to clean inside socket

surface of tting and male end of pipe to depth of tting

socket.

NOTE: Time is critical at this stage. Do not allow primer

to dry before applying cement.

NOTE: A sheet metal screw may be used to secure the

intake pipe to the connector, if desired. Use a drill or self

tapping screw to make a pilot hole.

DANGER OF EXPLOSION!

Fumes from PVC glue may ignite during system check.

Allow fumes to dissipate for at least 5 minutes before

placing unit into operation.

DANGER

Table 3

Outdoor Termination Kits Usage

507270-03Page 16 of 60 Issue 1621

6. Promptly apply solvent cement to end of pipe and inside

socket surface of tting. Cement should be applied

lightly but uniformly to inside of socket. Take care to

keep excess cement out of socket. Apply second coat

to end of pipe.

7. Immediately after applying last coat of cement to pipe,

and while both inside socket surface 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

during assembly (but not after pipe is fully inserted) to

distribute cement evenly. 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 tting socket. A properly made joint will show a bead

around its entire perimeter. Any gaps may indicate an

improper defective assembly due to insufcient solvent.

9. Handle joints carefully until completely set.

Venting Practices

Figure 21

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 other appliances (which are not operating) remain

connected to the common venting system. If the venting

system has been installed improperly, you must correct the

system as indicated in the general venting requirements

section.

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 steps shall be followed for each appliance

connected to the venting system being placed into

operation, while all other appliances connected to the

venting system are not in operation.

WARNING

1. Seal any unused openings in the common venting

system.

2. Inspect the venting system for proper size and horizontal

pitch. Determine that there is no blockage, restriction,

leakage, corrosion, or other deciencies which could

cause an unsafe condition.

3. Close all building doors and windows and all doors

between the space in which the appliances remaining

connected to the common venting system are located

and other spaces of the building. Turn ON clothes

dryers 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

operate at maximum speed. Do not operate a summer

exhaust fan. Close replace dampers.

4. Follow the lighting instructions. Turn ON the appliance

that is being inspected. Adjust the thermostat so that

the appliance operates continuously.

507270-03 Page 17 of 60Issue 1621

Exhaust Piping (Figures 25 and 26)

1. In areas where piping penetrates joist or interior walls,

hole must be large enough to allow clearance on all

sides of pipe through center of hole using a hanger.

2. When furnace is installed in a residence where unit is

shut down for an extended period of time, such as a

vacation home, make provisions for draining condensate

collection from trap and lines.

3. Route piping to outside of structure. Continue with

installation following instructions given in piping

termination section.

The exhaust vent pipe operates under positive pressure

and must be completely sealed to prevent leakage of

combustion products into the living space.

CAUTION

Do not discharge exhaust into an existing stack or

stack that also serves another gas appliance. If vertical

discharge through an existing unused stack is required,

insert PVC pipe inside the stack until the end is even

with the top or outlet end of the metal stack.

CAUTION

5. After the main burner has operated for 5 minutes, test

for leaks of ue gases at the draft hood relief opening.

Use the ame of a match or candle.

6. After determining that each appliance connected to

the common venting system is venting properly, (step

3) return all doors, windows, exhaust fans, replace

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 modied to

correct the problems.

Resize the common venting system to the minimum vent

pipe size determined by using the appropriate tables in

Appendix G. (These are in the current standards of the

National Fuel Gas Code ANSI Z223.1.

Figure 22

507270-03Page 18 of 60 Issue 1621

Vent Piping Guidelines

This gas furnace can be installed as either a Non-Direct

Vent or a Direct Vent gas central furnace.

NOTE: In non-Direct Vent installations, combustion air is

taken from indoors and ue gases are discharged outdoors.

In Direct Vent installations, combustion air is taken from

outdoors and ue gases are discharged outdoors.

Intake and exhaust pipe sizing - Size pipe according to

Tables 4 and 5 or 6. Table 4 lists the minimum vent pipe

lengths permitted. Table 5 lists the maximum pipe lengths

permitted for A93UH1D and 92G1UH-P. Table 6 lists

the maximum pipe lengths permitted for A95UH1D and

95G1UH-P.

Regardless of the diameter of pipe used, the standard roof

and wall terminations described in section Exhaust Piping

Terminations should be used. Exhaust vent termination

pipe is sized to optimize the velocity of the exhaust gas as

it exits the termination. Refer to Table 8.

In some applications which permit the use of several

different sizes of vent pipe, a combination vent pipe may be

used. Contact Allied Air Technical Service for assistance in

sizing vent pipe in these applications.

NOTE: It is acceptable to use any pipe size which ts within

the guidelines allowed in Tables 5 and 6.

NOTE: The exhaust collar on all models is sized to

accommodate 2” Schedule 40 vent pipe. In horizontal

applications, transition to exhaust pipe larger than 2” must

be made in vertical runs of the pipe. A 2” elbow must be

added before the pipe is transitioned to any size larger than

2”. This elbow must be added to the elbow count used to

determine acceptable vent lengths. Contact the Application

Department for more information concerning sizing of vent

systems which include multiple pipe sizes.

Do not use screens or perforated metal in exhaust or

intake terminations. Doing so will cause freeze-ups and

may block the terminations.

IMPORTANT

Figure 23

Figure 24

Table 4

507270-03 Page 19 of 60Issue 1621

Table 5A

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.

A93UH1D and 92G1UH-P Maximum Allowable Intake or Exhaust Vent Length in Feet

Table 5B

A93UH1D and 92G1UH-P

507270-03Page 20 of 60 Issue 1621

A95UH1D and 95G1UH-P Maximum Allowable Intake or Exhaust Vent Length in Feet

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.

Table 6A

507270-03 Page 21 of 60Issue 1621

Table 6B

A95UH1D and 95G1UH-P Maximum Allowable Intake or Exhaust Vent Length in Feet

507270-03Page 22 of 60 Issue 1621

Figure 26

Figure 25

507270-03 Page 23 of 60Issue 1621

Intake Piping (Figures 27 through 30)

This gas furnace may be installed in either direct vent

or non-direct vent applications. In non-direct vent

applications, when intake air will be drawn into the furnace

from the surrounding space, the indoor air quality must be

considered and guidelines listed in Combustion, Dilution

and Ventilation Air section must be followed.

Follow the next two steps when installing the unit in Direct

Vent applications, where combustion air is taken from

outdoors and ue gases are discharged outdoors. The

provided air intake screen must not be used in direct

vent applications (outdoors).

Figure 27

Figure 28

507270-03Page 24 of 60 Issue 1621

Follow the next two steps when installing the unit in Non–

Direct Vent applications where combustion air is taken

from indoors and ue gases are discharged outdoors.

1. Use eld-provided materials and the factory-provided

air intake screen to route the intake piping as shown in

Figures 29 or 30. Maintain a minimum clearance of 3”

(76 mm) around the air intake opening. The air intake

opening (with the protective screen) should always be

directed forward or to either side in the upow position,

and either straight out or downward in the horizontal

position.

The air intake piping must not terminate too close

to the ooring or a platform. Ensure that the intake

air inlet will not be obstructed by loose insulation

or other items that may clog the debris screen.

2. Use a sheet metal screw to secure the intake pipe to

the connector, if desired

1. Use transition solvent cement or a sheet metal screw

to secure the intake pipe to the inlet air connector.

2. Route piping to outside of structure. Continue with

installation following instructions given in general guide

lines for piping terminations and in intake and exhaust

piping terminations for direct vent sections. Refer to

Tables 5 and 6 for pipe sizes.

Figure 29

Figure 30

507270-03 Page 25 of 60Issue 1621

General Guidelines for Vent Terminations

In Non–Direct Vent applications, combustion air is taken

from indoors and the ue gases are discharged to the

outdoors. This furnace is then classied as a non–direct

vent, Category IV gas furnace.

In Direct Vent applications, combustion air is taken from

outdoors and the ue gases are discharged to the outdoors.

This furnace is then classied as a direct vent, Category 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 Figures 31

or 32. In addition, position termination so it is free from any

obstructions and 12” above the average snow accumulation.

At vent termination, care must be taken to maintain protective

coatings over building materials (prolonged exposure to

exhaust condensate can destroy protective coatings). It

is recommended that the exhaust outlet not be located

within 6 feet (1.8 m) of a condensing unit because the

condensate can damage the painted coating.

NOTE: See Table 7 for maximum allowed exhaust pipe

length without insulation in unconditiioned space during

winter design temperature is below 32° F (0° C). If required,

exhaust piping should be insulated with 1/2” (13 mm),

Armaex or equivalent. In extremely cold climate areas with

temperature below 20° F (6.7° C) it is recommended that,

3/4” (19 mm) Armaex or equivalent be used. Insulation

on outside runs of exhaust pipe may 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 specic

applications.

NOTE: During extremely cold temperatures, below

approximately 20° F (6.7° C), units with long runs of vent

pipe through unconditioned space, even when insulated,

may form ice in the exhaust termination that prevents the

unit from operating properly. Longer run times of at least 5

minutes will alleviate most icing problems. Also, a heating

cable may be installed on exhaust piping and termination

to prevent freeze-ups. Heating cable installation kits are

available. See unit specication sheets for part numbers.

For Canadian Installations Only:

In accordance to CSA International B149 installation

codes, the minimum allowed distance between the

combustion air intake inlet and the exhaust outlet of

other appliances shall not be less than 12 inches (305

mm).

IMPORTANT

Do not use screens or perforated metal in exhaust

terminations. Doing so will cause freeze-ups and may

block the terminations.

IMPORTANT

Table 7

Maximum Allowable Exhaust Vent Pipe Length (in ft.) Without Insulation

In Unconditioned Space For Winter Design Temperatures Single - Stage High Efciency Furnace

Winter Design Temperatures1

ºF (ºC)

Vent Pipe

Diameter

Unit Input Size

045 070 090 110 135

32 to 21

(0 to -6)

PVC 2PP PVC 2PP PVC 2PP PVC 2PP PVC 2PP

2 in. 18 16 31 28 50 48 30 30 N/A N/A

2-1/2 in. 13 N/A 24 N/A 42 N/A 56 N/A N/A N/A

3 in. 9 9 18 18 35 35 47 47 52 52

20 to 1

(-7 to -17)

2 in. 9 8 18 16 32 29 30 30 N/A N/A

2-1/2 in. 5N/A 13 N/A 24 N/A 34 N/A N/A N/A

3 in. N/A N/A 8 8 19 19 26 26 30 30

0 to -20

(-18 to -29)

2 in. 5 3 12 10 22 19 30 27 N/A N/A

2-1/2 in. N/A N/A 7N/A 15 N/A 22 N/A N/A N/A

3 in. N/A N/A N/A N/A 10 10 16 16 18 18

1 Refer to 99% Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook.

2 Poly-Propylene vent pipe (PP) by Duravent and Centrotherm

NOTE - Concentric terminations are the equivalent of 5’ and should be considered when measuring pipe length.

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 5 or 6.

NOTE - If insulation is required an unconditioned space, it must be located on the pipe closed to the furnace.

507270-03Page 26 of 60 Issue 1621

Figure 31

507270-03 Page 27 of 60Issue 1621

Figure 32

507270-03Page 28 of 60 Issue 1621

Details of Intake and Exhaust Piping Terminations for

Direct Vent Installations

NOTE: In Direct Vent installations, combustion air is taken

from outdoors and ue gases are discharged to outdoors.

NOTE: Flue gas may be slightly acidic and may adversely

affect some building materials. If any vent termination

is used and the ue gases may impinge on the building

material, a corrosion-resistant shield (minimum 24 inches

square) must be used to protect the wall surface. If the

optional tee is used, the protective shield is required.

The shield should be constructed using wood, plastic,

sheet metal or other suitable material. All seams, joints,

cracks, etc. in the affected area should be sealed using an

appropriate sealant. See Figure 37.

Intake and exhaust pipes may be routed either horizontally

through and outside wall or vertically through the roof. In

attic or closet installations, vertical termination through

the roof is preferred. Figures 33 through 43 show typical

terminations.

1. Intake and exhaust terminations 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 34). You may exit the exhaust out the roof

and the intake out the side of the structure (Figure 35).

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

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 33).

4. Exhaust piping must terminate straight out or up as

shown. A reducer 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 8.

NOTE: Care must be taken to avoid recirculation of exhaust

back into intake pipe.

Figure 35

Table 8

Figure 33

Figure 34

507270-03 Page 29 of 60Issue 1621

Figure 36

507270-03Page 30 of 60 Issue 1621

Figure 37

507270-03 Page 31 of 60Issue 1621

5. On eld supplied terminations for sidewall exit, exhaust

piping may extend a maximum of 12 inches (305 mm)

for 2” PVC and 20 inches (508 mm) for 3” (76 mm) PVC

beyond the outside wall. Intake piping should be as

short as possible. See Figures 36 and 38.

6. On eld supplied terminations, a minimum distance

between the end of the exhaust pipe and the end of

the intake pipe without a termination elbow is 8” and a

minimum distance of 6” with a termination elbow. See

Figures 36 and 38.

7. If intake and exhaust piping must be run up a side

wall to position above snow accumulation or other

obstructions, piping must be supported every 24” (610

mm) as shown in Figures 36 and 38. When exhaust

and intake piping must be run up an with pipe sized per

Table 8. 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. A multiple furnace installation may use a group of up to

four terminations assembled together horizontally, as

shown in Figure 42.

Figure 39

Figure 38

507270-03Page 32 of 60 Issue 1621

Details of Exhaust Piping Terminations for 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 44 through 47 show typical terminations.

1. Exhaust piping must terminate straight out or up as

shown. The termination pipe must be sized as listed

in Table 8. The specied pipe size ensures proper

velocity required to move the exhaust gases away from

the building.

2. On eld 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 45.

Figure 42

Figure 41

Figure 40

Figure 43

507270-03 Page 33 of 60Issue 1621

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 46. When exhaust piping must be run up an

outside wall, any reduction in exhaust pipe size must

be done after the nal elbow.

Figure 44

Figure 45

Figure 46

Figure 47

507270-03Page 34 of 60 Issue 1621

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 minimum of 1/4” per ft. toward trap.

1. Determine which side condensate piping will exit the

unit, location of trap, eld-provided ttings and length

of PVC pipe required to reach available drain.

2. Use a large at head screw driver or an 1/2” drive socket

extension and remove plug (Figure 48) from the cold

end header box at the appropriate location on the side

of the unit. Install provided 3/4 NPT street elbow tting

into cold end header box. Use Teon 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 55.

4. Install drain trap using appropriate PVC ttings, glue

all joints. Glue the provided drain trap as shown in

Figure 55. Route the condensate line to an open drain.

Condensate line must 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 upow applications. In horizontal

applications, the condensate trap must extend below the

unit. An 8” service clearance is required for the condensate

trap.

Refer to Figures 48 and 49 for condensate trap locations.

Figure 55 shows trap assembly using 1/2” PVC or 3/4” PVC.

5. Install eld provided vent on trap assembly as shown

in Figures 49 through 54. Trap must extend at least

1” above the furnace condensate drain connection in

upow applications and 4-1/2” above the bottom of the

cabinet in horizontal applications.

6. If unit will be started immediately upon completion of

installation, prime trap per procedure outlined in Unit

Start-Up section.

Figure 48

507270-03 Page 35 of 60Issue 1621

Do not use copper tubing or existing copper condensate

lines for drain line.

CAUTION

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 freezing of condensate

and blockage of 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 50

Unit with Cooling Coil

Figure 49

Condensate Trap Locations

(Unit shown in upow position with remote trap)

Figure 51

Condensate Trap Locations

(Unit shown in horizontal right-hand discharge position)

* Piping from furnace must slope down a minimum of 1/4” per ft. toward trap.

507270-03Page 36 of 60 Issue 1621

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.

IMPORTANT

Figure 52

Condensate Trap with Optional Overow Switch

Figure 53

Evaporator Coil Using a Common Drain

Figure 54

* Piping from furnace must slope down a minimum of 1/4” per ft. toward trap.

Evaporator Coil Using a Common Drain

(Unit shown in horizontal left-hand discharge position)

507270-03 Page 37 of 60Issue 1621

Figure 55

Trap / Drain Assembly Using 1/2” PVC or 3/4” PVC

507270-03Page 38 of 60 Issue 1621

Gas Piping

1. Gas piping may be routed into the unit through either

the left or right hand side. Supply piping enters into the

gas valve from the side of the valve as shown in Figure

57 and 58. Move Bellows grommet to side which gas

line enters. Ensure opposite gas line hole is plugged

with supplied plug.

2. When connecting gas supply, factors such as length

of run, number of ttings and furnace rating must be

considered to avoid excessive pressure drop. Table 10

list recommended pipe sizes for typical applications.

NOTE: Use two wrenches when connecting gas piping

to avoid transferring to the manifold.

3. Gas piping must not run in or through air ducts, clothes

chutes, chimneys or gas vents, dumb waiters or elevator

shafts. Center gas line through piping hole. Gas line

should not touch side of unit. See Figures 57 and 58.

4. Piping should be sloped 1/4 “ per 15 feet (6 mm per 5.6

m) upward toward the gas meter from the furnace. The

piping must be supported at proper intervals, every 8

to 10 feet (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. See

Figure 65.

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

ground joint type.

Leak Check

After gas piping is completed, carefully check all piping

connections (factory and eld installed) for gas leaks. Use

a leak detecting solution or other preferred means.

Never use an open ame to test for gas leaks. Check all

connections using a commercially available soap solution

made specically 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 1/2 psig (3.48 kPa, 14 inches w.c.).

Compounds used on threaded joints of gas piping must

be resistant to the actions of liquied petroleum gases.

IMPORTANT

FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could

result in serious injury, death, or property damage.

Never use an open ame to test for gas leaks. Check

all connections using a commercially available soap

solution made specically for leak detection. Some

soaps used for leak detection are corrosive to certain

metals. Carefully rinse piping thoroughly after leak test

has been completed.

WARNING

If a exible gas connector is required or allowed by the

authority that has jurisdiction, black iron pipe shall be

installed at the gas valve and extend outside the furnace

cabinet. The exible connector can then be added

between the black iron pipe and the gas supply line.

CAUTION

Do not exceed 600 in.-lbs. (50 ft.-lbs.) torque when

attaching the gas piping to the gas valve.

WARNING

When testing pressure of gas lines, gas valve must be

disconnected and isolated. See Figure 56. Gas valves

can be damaged if subjected to pressures greater than

1/2 psig (3.48 kPa).

IMPORTANT

A low inlet pressure switch in LP/propane applications

is recommended.

IMPORTANT

Figure 56

507270-03 Page 39 of 60Issue 1621

Figure 58

Figure 57

507270-03Page 40 of 60 Issue 1621

Table 10

507270-03 Page 41 of 60Issue 1621

Electrical

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and service

to protect the furnace’s electronic controls. Precautions

will help to avoid control exposure to electrostatic

discharge by putting the furnace, the control and the

technician at the same electrostatic potential. Neutralize

electrostatic charge by touching hand and all tools on

an unpainted unit surface, such as the gas valve or

blower deck, before performing any service procedure.

CAUTION

The unit is equipped with a eld makeup box. The makeup

box may be moved to the right side of the furnace to facilitate

installation. Seal unused openings on left side with plugs

removed from right side. Secure the excess wire to the

existing harness to protect it from damage.

Refer to Figure 62 for eld wiring and Figure 63 for schematic

wiring diagram and troubleshooting.

The power supply wiring must meet Class I restrictions.

Protected by either a fuse or circuit breaker, select circuit

protection and wire size according to unit nameplate.

NOTE: Unit nameplate states maximum current draw.

Maximum Over-Current Protection allowed is 15 AMP.

Holes are on both sides of the furnace cabinet to facilitate

wiring.

Install a separate (properly sized) disconnect switch near

the furnace so that power can be turned off for servicing.

Before connecting the thermostat check to make sure the

wires will be long enough for servicing at a later date. Make

sure that thermostat wire is long enough to facilitate future

removal of blower for service.

Complete the wiring connections to the equipment. Use the

provided unit wiring diagram and the eld wiring diagram

shown in Figure 62. Use 18 gauge wire or larger that is

suitable for Class II rating for thermostat connections.

Electrically ground the unit according to local codes or,

in the absence of local codes, according to the current

National Electric Code (ANSI/HFPA No. 70) for the USA

and current Canadian Electric Code Part 1 (CSA standard

C22.1) for Canada. A green ground wire is provided in the

eld makeup box.

NOTE: The gas furnace contains electronic components

that are polarity sensitive. Make sure that the furnace is

wired correctly and is properly grounded.

Accessory Terminals

One line voltage “EAC” 1/4” spade terminal is provided on

the furnace control board. Any accessory 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 an accessory rated at greater than one amp is

connected to this terminal, it is necessary to use an external

relay. See Figure 64 for control board conguration. This

terminal is energized when the indoor blower is operating.

One line voltage “HUM” 1/4” spade terminal is provided on

the furnace control board. Any humidier 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

Figure 59

Figure 60

507270-03Page 42 of 60 Issue 1621

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 furnace is running in the heating mode, the

indoor blower will run on the heating speed.

3. When there is a cooling demand, the indoor blower will

run on the cooling speed.

Generator Use - Voltage Requirements

• The furnace requires 120 volts ± 10% (Range: 108 volts

to 132 volts)

• The furnace operates at 60 Hz ± 5% (Range: 57 Hz to

63 Hz)

• The furnace integrated control requires both proper

polarity and proper ground. Both polarity and proper

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% THD (total harmonic distortion).

terminals. If a humidier rated at greater than one amp

is connected to this terminal, it is necessary to use an

external relay. See Figure 64 for control board conguration.

This terminal is energized in the heating mode when the

combustion air inducer is operating.

Install the room thermostat according to the instructions

provided with the thermostat. See Figure 61 for thermostat

designations. If the furnace is being matched with a

heat pump, refer to the FM21 installation instruction or

appropriate dual fuel thermostat instructions.

Figure 61

Figure 62

507270-03 Page 43 of 60Issue 1621

TYPICAL WIRING DIAGRAM

Figure 63

507270-03Page 44 of 60 Issue 1621

Unit Start-Up

FOR YOUR SAFETY READ BEFORE OPERATING

Before attempting to perform any service or maintenance,

turn the electrical power to unit OFF at disconnect

switch.

CAUTION

BEFORE LIGHTING the unit, smell all around the furnace

area for gas. Be sure to smell next to the oor because

some gas is heavier than air and will settle on the oor.

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 re

or explosion.

Placing the furnace into operation:

This furnace is equipped with an automatic hot surface

ignition system. Do not attempt to manually light burners

on this furnace. Each time the thermostat calls for heat, the

burners will automatically light. The ignitor does not get hot

when there is no call for heat on these units.

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 re or explosion.

Immediately call a qualied service technician to inspect

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.

WARNING

Danger of explosion. Can cause injury or

product or property damage. Should the

gas supply fail to shut off or if overheating

occurs, shut off the gas valve to the

furnace before shutting off the electrical

blower deck, before performing any service

procedure.

WARNING

INTEGRATED CONTROL

(Automatic Hot Surface Ignition System)

Figure 64

507270-03 Page 45 of 60Issue 1621

Priming Condensate Trap

The condensate trap should be primed with water prior to

start-up to ensure proper condensate drainage. Either pour

10 . 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 thermostat to initiate a heating demand.

3. Allow the burners to re for approximately 3 minutes.

4. Adjust the thermostat to deactivate the heating demand.

5. Wait for the combustion air inducer to stop. Set the

thermostat to initiate a heating demand and again allow

the burners to re for approximately 3 minutes.

6. Adjust the thermostat to deactivate the heating demand

and wait for the combustion air inducer to stop. At this

point, the trap should be primed with sufcient water

to ensure proper condensate drain operation.

If you do not follow these instructions exactly, a re

or explosion may result causing property damage,

personal injury or death.

WARNING

Gas Valve Operation (Figure 65)

1. STOP! Read the safety information at the beginning of

this section.

2. Set the thermostat to the lowest setting.

3. Turn OFF all electrical power to the unit.

4. This furnace is equipped with an ignition device which

automatically lights the burners. Do not try to light the

burners by hand.

5. Remove the upper access panel.

6. Move gas valve switch to OFF. See Figure 65.

7. Wait ve minutes to clear out any gas. If you then

smell gas, STOP! Immediately 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 65.

9. Replace the upper access panel.

10. Turn on all electrical power 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.

12. If the appliance will not operate, follow the instructions

“Turning Off Gas to Unit” and call your service technician

or gas supplier.

Turning Off Gas to Unit

1. Set the thermostat to the lowest setting.

2. Turn off all electrical power to the unit if service is to be

performed.

3. Remove the upper access panel.

4. Move 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 lter dirty or plugged? Dirty or plugged lters will

cause the limit control to shut the unit off.

6. Is gas turned on at the meter?

7. Is the manual main shut–off valve open?

8. Is the internal manual shut–off valve open?

9. Is the unit ignition system in lockout? If the unit locks

out again, inspect the unit for blockages.

Heating Sequence Of Operation

1. When thermostat calls for heat, combustion air inducer

starts.

2. Combustion air pressure switch proves blower operation.

Switch is factory set and requires no adjustment.

3. After a 15 second prepurge, the hot surface ignitor

energizes.

4. After a 20 second ignitor warm-up period, the gas valve

solenoid opens. A 4-second “Trial for Ignition” period

begins.

5. Gas is ignited, ame sensor proves the ame, and the

combustion process continues.

6. If ame is not detected after rst ignition trial, the ignition

control will repeat steps 3 and 4 four more times before

locking out the gas valve. The ignition control will then

automatically repeat steps 1 through 6 after 60 minutes.

To interrupt the 60 minute period, move thermostat from

“Heat” to “OFF” then back to “Heat”. Heating sequence

then restarts at step 1.

Figure 65

507270-03Page 46 of 60 Issue 1621

Gas Pressure Adjustment

Gas Flow (Approximate)

Furnace should operate at least 5 minutes before checking

gas ow. 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 11. If manifold pressure matches Table 12 and rate

is incorrect, check gas orices for proper size and restriction.

Remove temporary gas meter if installed.

NOTE: To obtain accurate reading, shut off all other gas

appliances connected to meter.

Supply Pressure Measurement

When testing supply gas pressure, use the 1/8” N.P.T.

plugged tap or pressure post located on the gas valve to

facilitate test gauge connection. See Figure 65. Check gas

line pressure with unit ring at maximum rate. Low pressure

may result in erratic operation or underre. High pressure

can result in permanent damage to gas valve or overre.

On multiple unit installations, each unit should be checked

separately, with and without other units operating. Supply

pressure must fall within range listed in Table 12.

Manifold Pressure Measurement

1. Remove the threaded plug from the outlet side of the gas

valve and install a eld provided barbed tting. Connect

to a manometer to measure manifold pressure.

2. Start unit and allow 5 minutes for unit to reach steady

state.

High Altitude Information

NOTE: In Canada, certication for installations at elevations

over 4500 feet (1371 m) is the jurisdiction of local authorities.

Units may be installed at altitudes up to 10,000 ft. above

sea level. See table 13 for de-rate manifold values. Units

installed at altitude of 7501 - 10,000 feet require an orice

change. Units installed at altitudes of 4,501 - 10,000 feet

(1371 -3048 m) may require a pressure switch change which

can be ordered separately.

Table 14 lists required pressure switch changes and orice

conversion kits at varying altitudes.

The combustion air pressure switches are factory set and

require no adjustment.

Proper Combustion

Furnace should operate minimum 15 minutes with correct

manifold pressure and gas flow rate before checking

combustion. Take combustion sample beyond the ue outlet

and compare to the tables below.

Page 1

10/13

*2P1013*

507280-01

*P507280-01*

TABLE 1

Manifold and Supply Line Pressure 0-10,000ft.

Unit Gas

Manifold Pressure in. wg. Supply Line Pressure

in. w.g.

0 - 10000 ft.

0-4500 ft. 4501-5500 ft. 5501-6500 ft. 6501 - 7500ft. 7501 - 10000ft.

All Sizes

Natural 3.5 3.3 3.2 3.1 3.5 4.5 13.0

LP/propane 10.0 9.4 9.1 8.9 10.0 11.0 13.0

NOTE -

A natural to L.P. propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion

procedure.

TABLE 2

Manifold and Supply Line Pressure 0-10,000ft.

Unit Gas

Manifold Pressure in. wg. Supply Line

Pressure

in. w.g.

0 - 10000 ft.

0-4500 ft. 4501-5500 ft. 5501-6500 ft. 6501 - 7500ft. 7501 - 10000ft.

Low

Fire

High

Fire

Low

Fire

High

Fire

Low

Fire

High

Fire

Low

Fire

High

Fire

Low

Fire

High

Fire Min Max

All

Sizes

Natural 1.7 3.5 1.6 3.3 1.5 3.2 1.5 3.1 1.7 3.5 4.5 13.0

LP/propane 4.9 10.0 4.6 9.4 4.4 9.1 4.3 8.9 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 the changeover kit installation instruction for the conversion

procedure.

Table 12

Table 11

3. While waiting for the unit to stabilize, observe the ame.

Flame should be stable and should not lift from burner.

Natural gas should burn blue.

4. After allowing unit to stabilize for 5 minutes, record

manifold pressure and compare to value given in Table

12.

NOTE: Shut unit off and remove manometer as soon as an

accurate reading has been obtained. Take care to remove

barbed tting and replace threaded plug.

Table 13

Unit CO2% for Nat CO2% for L.P.

All 7.2 - 7.9 8.6 - 9.3

The maximum carbon monoxide reading should not exceed 100 ppm.

507270-03 Page 47 of 60Issue 1621

Table 14

Unit Size 0 - 4500 ft

(0 - 1371m)

4501 - 7500 ft

(1371 - 2286m)

7501 - 10000 ft

(2286 - 3048m)

045 No Change No Change 11J09

070 No Change 11J12 10U93

090 No Change 11J11 10U93

110 No Change 11J12 10U93

135 No Change 11J11 10U93

A95 and 95G1 Pressure Switch Requirements at Varying Altitudes

Pressure switch is factory set. No adjustment necessary. All models use the

factory-installed pressure switch from 0-4500 feet (0-1371 m).

Unit Size 0 - 4500 ft

(0 - 1371m)

4501 - 7500 ft

(1371 - 2286m)

7501 - 10000 ft

(2286 - 3048m)

045

No Change 11J09 11J10

070

090

110

135 No Change 11J11 11U68

A93 and 92G1 Pressure Switch at Varying Altitudes

Pressure switch is factory set. No adjustment necessary. All models use the

factory-installed pressure switch from 0-4500 feet (0-1371 m).

Unit

Size

0 - 7500 ft

(0 - 2286 m) 7501 - 10000 ft

(2286 - 3048 m)

Natural

LP/Propane

Natural

High Altitude

Natural

Burner Orice

Kit

High Altitude

LP/Propane

Burner Orice

Kit

All 11K50+ 73W80* 51W01 11K45+

Burner Orice Conversion Kits at Varying Altitudes

* Conversion requires installation of a gas valve regulator spring which is provided with the

gas conversion Kit.

+ LP Kits include low line pressure switch.

507270-03Page 48 of 60 Issue 1621

Testing for Proper Venting and Sufcient Combustion Air for Non-Direct Vent 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 steps shall be followed for each appliance

connected to the venting system being placed into

operation, while all other appliances connected to the

venting system are not in operation.

WARNING

After the gas furnace has been started, the following test

should be conducted to ensure proper venting and sufcient

combustion air has been provided to the unit as well as to

other gas–red appliances which are separately vented.

If this furnace replaces a Category I furnace which was

commonly vented with another gas appliance, the size of the

existing vent pipe for that gas appliance must be checked.

Without the heat of the original furnace ue products, the

existing vent pipe is probably oversized for the single water

heater or other appliance. The vent should be checked for

proper draw with the remaining 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 sufcient amounts of combustion air, corrections must

be made as outlined in the previous section.

1. Seal any unused openings in the venting system.

2. Visually inspect the venting system for proper size

and horizontal pitch. Determine there is no blockage

or restriction, leakage, corrosion, or other deciencies

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 building.

4. Close replace 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 ame of match or candle to test for spillage

of ue gases at the draft hood relief opening after 5

minutes of main burner operation.

8. If improper venting is observed during any of the above

tests, the venting system must be corrected or sufcient

combustion/makeup air must be provided. The venting

system should be re–sized to approach the minimum

size as determined by using the appropriate tables in

appendix G in the current standards of the National Fuel

Gas Code ANSI-Z223.1/NPFA 54 in the U.S.A., and

the appropriate Natural Gas and Propane appliances

venting sizing tables in the current standard of the

CSA-B149 Natural Gas and Propane Installation Codes

in Canada.

9. After determining that each appliance remaining

connected to the common venting system properly

vents when tested as indicated in step 3, return doors,

windows, exhaust fans, replace dampers and any other

gas burning appliance to their previous condition of use.

507270-03 Page 49 of 60Issue 1621

Other Unit Adjustments

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 (Two)

These manually reset switches are located on the front of

the burner box. These limits are factory set and require no

adjustment.

Pressure Switch

The pressure switch is located in the heating compartment

on the cold end header box. This switch checks for proper

combustion air inducer operation before allowing ignition

trial. The switch is factory set and must not be adjusted.

Temperature Rise

After the furnace has been started and supply and return

air temperatures have been allowed to stabilize, check the

temperature rise. If necessary, adjust the blower speed to

maintain the temperature rise within the range shown on

the unit nameplate. Increase the blower speed to decrease

the temperature. Decrease the blower speed to increase

the temperature rise. Failure to adjust the temperature rise

may cause erratic limit operation.

Fan Control

The fan ON time of 30 seconds is not adjustable. The fan

OFF delay (amount of time that the blower operates after

the heat demand has been satised) may be adjusted by

changing the jumper position across the ve pins on the

integrated control. The unit is shipped with a factory heat

fan OFF setting of 120 seconds. The fan OFF delay affects

comfort and is adjustable to satisfy individual applications.

Adjust the fan OFF delay to achieve a supply air temperature

between 90° and 110° F at the moment that the blower is de-

energized. Longer OFF delay settings provide lower return

air temperatures; shorter settings provide higher return air

temperatures. See Figure 66.

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–draw on the blower motor with the blower

access panel in place.

Motor Nameplate__________Actual__________

Blower Speeds

Follow the steps below to change the blower speeds.

1. Turn off electrical power to furnace.

2. Remove blower access panel.

3. Disconnect existing speed tap at control board speed

terminal.

NOTE: Termination of any unused motor leads must be

insulated.

4. Place unused blower speed tap on integrated control

“PARK” terminal or insulate.

5. Refer to blower speed selection chart on unit wiring

diagram for desired heating or cooling speed. See

Blower performance data beginning on the next page.

6. Connect selected speed tap at control board speed

terminal.

7. Re-secure blower access panel.

8. Turn on electrical power to furnace.

9. Recheck temperature rise.

Electronic Ignition

The integrated control has an added feature of an internal

Watchguard control. The feature serves as an automatic

reset device for integrated control lockout caused by ignition

failure. This type of lockout is usually due to low gas line

pressure. After one hour of continuous thermostat demand

for heat, the Watchguard will break and remake thermostat

demand to the furnace and automatically reset the integrated

control to begin the ignition sequence.

Exhaust and Air Intake Pipe

1. Check exhaust and air intake connections for tightness

and to make sure there is no blockage.

2. Is pressure switch closed? Obstructed exhaust pipe

will cause unit to shut off at pressure switch. Check

termination for blockages.

3. Obstructed pipe or termination may cause rollout

switches to open. Reset manual ame rollout switches

on burner box assembly if necessary.

Figure 66

507270-03Page 50 of 60 Issue 1621

507270-03 Page 51 of 60Issue 1621

507270-03Page 52 of 60 Issue 1621

BLOWER DATA A95UH1D / 95F1UHD

507270-03 Page 53 of 60Issue 1621

507270-03Page 54 of 60 Issue 1621

Service

At the beginning of each heating season, system should be

checked as follows by a qualied 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 securely in place

when the blower and burners are operating. Gas fumes,

which could contain carbon monoxide, can be drawn

into living space resulting in personal injury or death.

WARNING

Filters

All air lters are installed external to the unit. Filters should

be inspected monthly. Clean or replace the lters when

necessary to ensure proper furnace operation. Table 1 lists

recommended lter sizes.

Exhaust and air intake pipes

Check the exhaust and air intake pipes and all connections

for tightness and to make sure there is no blockage.

NOTE: After any heavy snow, ice or frozen fog event the

furnace vent pipes may become restricted. Always check

the vent system and remove any snow or ice that may be

obstructing the plastic intake or exhaust pipes.

ELECTRICAL SHOCK, FIRE,

OR EXPLOSION HAZARD.

WARNING

Failure to follow safety warnings exactly could result in

dangerous operation, serious injury, death or property

damage.

Improper servicing could result in dangerous operation,

serious injury, death, or property damage.

Before servicing, disconnect all electrical power to

furnace.

When servicing controls, label all wires prior to

disconnecting. Take care to reconnect wires correctly.

Verify proper operation after servicing.

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-draw on the blower motor with the blower

access panel in place.

Motor Nameplate__________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

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 from

valve.

4. Remove gas supply line connected to gas valve.

5. Remove sensor wire from ame sensor. Disconnect

2–pin plug from the ignitor.

6. Disconnect wires from ame rollout switches.

7. Remove four burner assembly screws at the vestibule

panel and remove gas valve /manifold and burner box

as a single unit.

8. If necessary, clean burners at this time. Follow

procedures outlined in Burner Cleaning section.

9. Remove the clean-out cap on trap and drain. Replace

cap.

10. Disconnect condensate drain line from the condensate

trap. Remove condensate trap (it may be necessary to

cut drain pipe). Remove the 1/2” NPT tting from the

cold end header box. Disconnect drain tubes from cold

end header collector box.

11. Disconnect condensate drain tubes from ue collar.

Remove screws that secures flue collar in place.

Remove ue collar. It may be necessary to cut the

exiting exhaust pipe for removal of the tting.

12. Loosen two clamps from exible no-hub exhaust collar.

13. Disconnect the 2–pin plug from the combustion air

inducer. Remove screws which secure combustion

air inducer to collector box. Remove combustion air

inducer assembly. Remove ground wire.

14. Mark and disconnect all combustion air pressure tubing

from cold end header collector box.

507270-03 Page 55 of 60Issue 1621

15. Mark and remove wires from pressure switch. Remove

pressure switch. Keep tubing attached to pressure

switch.

16. Remove electrical junction box from the side of the

furnace.

17. Remove blower access panel.

18. Mark and disconnect any remaining wiring to heating

compartment components. Disengage strain relief

bushing and pull wiring and bushing through the hole

in the blower deck.

19. Remove the primary limit from the vestibule panel.

20. Remove top cap screws to allow top cap to be tilted

upward to allow clearance for removing heat exchanger.

21. Remove two screws from the front cabinet ange at

the blower deck. Spread cabinet sides slightly to allow

clearance for removal of heat exchanger.

22. Remove screws along vestibule sides and bottom which

secure vestibule panel and heat exchanger assembly

to cabinet. Remove two screws from blower rails which

secure bottom heat exchanger ange. Remove heat

exchanger from furnace cabinet.

23. Back wash heat exchanger with soapy water solution or

steam. If steam is used it must be below 275°F (135°C).

24. Thoroughly rinse and drain the heat exchanger. Soap

solutions can be corrosive. Take care to rinse entire

assembly.

25. Reinstall heat exchanger into cabinet making sure that

the rear bafe of the heat exchanger assembly is nested

under the support located at the rear of the cabinet.

Remove the indoor blower to view this area through

the blower opening.

26. Re–secure the supporting screws along the vestibule

sides.

27. Reinstall blower assembly and reinstall two screws

through rails.

28. Reinstall cabinet screws on front ange at blower deck.

29. Reinstall screws securing top cap.

30. Reinstall the primary limit on the vestibule panel.

31. Route heating component wiring through hole in blower

deck and reinsert strain relief bushing.

32. Reinstall pressure switch and reconnect pressure switch

wiring.

33. Carefully connect combustion air pressure switch hosing

from pressure switch to proper stubs on cold end header

collector box.

34. Reinstall 1/2” NPT (if removed) in the cold end header

box. Reconnect drain tubing to collector box.

35. Reinstall condensate trap pipe. Reconnect condensate

drain line to the condensate trap.

36. Reinstall electrical junction box.

37. Reinstall the combustion air inducer and exible no hub

connector. Reconnect the 2 pin plug to the wire harness.

38. Reconnect drain tubes between ue collar and 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 ame 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 verifying gas and electrical

connections when reestablishing supplies.

46. Follow lighting instructions to light and operate furnace

for 5 minutes to ensure that heat exchanger is clean

and dry and that furnace is operating properly.

47. Replace heating compartment access panel.

Cleaning the Burner Assembly

1. Turn off gas and electrical power to the furnace. Remove

heating compartment access panel.

2. Disconnect the gas supply line from the gas valve.

3. Disconnect and label wires from gas valve.

4. Disconnect ignitor wiring at 2 circuit plug.

5. Disconnect and label wires from rollout switch.

6. Disconnect and label ame sensor wire.

7. Disconnect and label ground wire from burner/manifold

assembly.

8. Remove four screws that secures burner/manifold

assembly to vestibule. Remove the assembly and

make note not to allow ignitor plate to dislodge from

the assembly.

9. Gently clean the face of the burners using the soft brush

attachment on a vacuum cleaner. Visually inspect the

inside of the burners and crossovers for any blockage

caused by foreign matter. Remove any blockage

10. Reinstall the burner/manifold assembly using the

existing four screws. Burners are self aligning to

center of clam shells.

11. Reconnect ground wire.

12. Reconnect ame sensor wire.

13. Reconnect rollout switch wires.

14. Reconnect ignitor wires.

15. Reconnect gas valve wires.

16. Reconnect gas supply line to gas valve.

17. Refer to instructions on verifying gas and electrical

connections when re-establishing supplies.

18. Follow instructions to place furnace in operation. Run

furnace 5 minutes to ensure burners are clean and

operating correctly.

19. Replace heating compartment access panel.

507270-03Page 56 of 60 Issue 1621

Planned Service

A service technician should check the following items during

an annual inspection. Power 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

unobstructed 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, signs of

water, burnt or damaged wires, or components.

Blower access door - Must be properly in place and

provide 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 specications.

Problems detected during the inspection may make it

necessary 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

inspections 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 production of carbon

monoxide gas.

Diagnostic Codes

507270-03 Page 57 of 60Issue 1621

Repair Parts List

The following repair parts are available through Allied Air dealers. When ordering parts, include the complete furnace model

number listed on the CSA nameplate. All service must be performed by a licensed professional installer (or 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 Capacitor

Blower Housing Cutoff Plate

Heating Parts

Flame Sensor

Heat Exchanger Assembly

Gas Manifold

Combustion Air Inducer

Gas Valve

Main Burner Cluster

Main Burner Orices

Pressure Switch

Ignitor

Primary Limit Control

Flame Rollout Switches

507270-03Page 58 of 60 Issue 1621

Gas Supply Pressure

SUPPLY

AIR

Line Voltage

GAS SUPPLY

Natural Gas LP Propane Gas

Piping Connections Tight

Leak Tested

INTAKE / EXHAUST PIPE

All Joints Primed and Glued

Terminations Installed Properly

Pipes Supported

Condensate Trap Primed / Line Sloped

Heat Cable Installed and Operable (if applicable)

Horizontal Pipes Sloped (if applicable)

UNIT SET UP

Flter

RETURN AIR

Furnace:

Model Number_______________

Serial Number_________________

3DUCT SYSTEM

SUPPLY AIR DUCT

Sealed

Insulated (if necessary)

RETURN DUCT

Sealed

Filter Installed and Clean

Grilles Unobstructed

4VOLTAGE CHECK

Supply Voltage _____

Electrical Connections Tight

Start-Up & Performance Check List

507270-03 Page 59 of 60Issue 1621

Contractor’s: Name_________________________Telephone_____________Checklist Completed____________________

Job Address_____________________________________Technician’s Name___________________________________

HEATING MODE

COMBUSTION SAMPLE CO 2%______ CO PPM_______

INDOOR BLOWER AMPS______

TEMPERATURE RISE

Supply Duct Temperature ________

Return Duct Temperature _ _____

Temperature Rise = ________

TOTAL EXTERNAL STATIC

Supply External Static _______

Return External Static + ______

Total External Static = _______

CONDENSATE LINE

Leak Free

VENT PIPE

Leak Free

COOLING MODE

INDOOR BLOWER AMPS______

TEMPERATURE DROP

Return Duct Temperature _________

Supply Duct Temperature _ _______

Temperature Drop = _________

DRAIN LINE

Leak Free

THERMOSTAT

Adjusted and Programmed

Explained Operation to Owner

SUPPLY

AIR

Blower Motor Amps

Duct Static

Thermostat

Gas Manifold Pressure

Temperatures

RETURN AIR

Combustion CO

UNIT OPERATION

TOTAL EXTERNAL STATIC (dry coil)

Supply External Static _______

Return External Static + ______

Total External Static = _______

507270-03Page 60 of 60 Issue 1621

REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS

Modications to NFPA-54, Chapter 10

Revise NFPA-54 section 10.8.3 to add the following

requirements:

For all side wall, horizontally vented, gas-fueled equipment

installed in every dwelling, building or structure used in whole

or in part for residential purposes, including those owned

or operated by the Commonwealth and where the side wall

exhaust vent termination is less than seven (7) feet above

the nished grade in the area of the venting, including but

not limited to decks and porches, the following requirements

shall be satised:

1. INSTALLATION OF CARBON MONOXIDE

DETECTORS. At the time of installation of the side wall,

horizontally vented, gas-fueled equipment, the installing

plumber or gas tter shall observe that a hard-wired

carbon monoxide detector with an alarm and battery

backup is installed on the oor level where the gas

equipment is to be installed. In addition, the installing

plumber or gas fitter shall observe that a battery-

operated or hard-wired carbon monoxide detector with

an alarm is installed on each additional level of the

dwelling, building or structure served by the side wall,

horizontally vented, gas-fueled equipment. It shall

be the responsibility of the property owner to secure

the services of qualied licensed professionals for the

installation of hard-wired carbon monoxide detectors.

a. In the event that the side wall, horizontally

vented, gas-fueled equipment is installed in a crawl

space or an attic, the hard-wired carbon monoxide

detector with alarm and battery backup may be

installed on the next adjacent oor level.

b. In the event that the requirements of this

subdivision cannot be met at the time

of completion of installation, the owner shall

have a period of thirty ( 3 0 ) d a y s t o

comply with the above requirements;

provided, however, that during said thirty (30) day

period, a battery-operated carbon monoxide

detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS.

Each carbon monoxide detector as required in

accordance with the above provisions shall comply with

NFPA 720 and be ANSI/UL 2034 listed and IAS certied.

3. SIGNAGE. A metal or plastic identication plate shall

be permanently mounted to the exterior of the building at

a 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 not approve the installation unless, upon

inspection, the inspector observes carbon monoxide

detectors and signage installed in accordance with the

provisions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS: The following equipment is exempt from

24 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment

Not Required to Be Vented” in the most current edition

of NFPA 54 as adopted by the Board; and

2. Product Approved side wall, horizontally vented,

gas-fueled equipment installed in a room or structure

separate from the dwelling, building or structure used

in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS -

GAS EQUIPMENT VENTING SYSTEM PROVIDED.

When the manufacturer of Product Approved side wall,

horizontally vented, gas-fueled equipment provides a

venting system design or venting system components with

the equipment, the instructions provided by the manufacturer

for installation of the equipment and the venting system

shall include:

1. Detailed instructions for the installation of the venting

system design or the venting system components: and

2. A complete parts list for the venting system design or

venting system.

MANUFACTURER REQUIREMENTS -

GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of Product Approved sidewall,

horizontally vented, gas-fueled equipment does not provide

the parts for venting the ue gases, but identies “special

venting systems,” the following requirements shall be

satised by the manufacturer:

1. The referenced “special venting system” instructions

shall be included with the appliance or equipment

installation instructions; and

2. The “special venting systems” shall be Product Approved

by the Board, and the instructions for that system shall

include a parts list and detailed installation instructions.

A copy of all installation instructions for all Product

Approved side wall, horizontally vented, gas-fueled

equipment, all venting instructions, all parts lists

for venting instructions, and/or all venting design

instructions shall remain with the appliance or

equipment at the completion of the installation.

95G1UH Ducane 92G1 95G1 Upflow Install

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