Aire-Flo 92AF1UH Installation Instructions Manual

Summary of 92AF1UH

  • Page 1

    Page 1 08/12 *2p0812* 507078−01 *p507078-01* p.O. Box 799900, dallas, tx 75379−9900 installation instructions 92af1uh and 95af1uh warm air gas furnaces upflow/horizontal left and right air discharge this is a safety alert symbol and should never be ignored. When you see this symbol on labels or in m...

  • Page 2

    Page 2 92af1uh and 95af1uh unit dimensions − inches (mm) 2 optional external side return air filter kit is not for use with the optional return air base. 1. Single side return air with transition, to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter. Required to maintain proper ai...

  • Page 3

    Page 3 92af1uh and 951uh gas furnace the 92af1uh and 95af1uh category iv gas furnaces are shipped ready for installation in the upflow or horizon- tal position. Each 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...

  • Page 4

    Page 4 installation locations this furnace is csa international certified for installation clearances to combustible material as listed on the unit nameplate and in the table in figure 9. Accessibility and ser- vice clearances must take precedence over fire protection clearances. Note − for installa...

  • Page 5

    Page 5 d air filters must be installed in the system and must be maintained during construction. D air filters must be replaced upon construction comple- tion. D the input rate and temperature rise must be set per the furnace rating plate. D one hundred percent (100%) outdoor air must be pro- vided ...

  • Page 6

    Page 6 in the absence of local codes concerning air for combus− tion and ventilation, use the guidelines and procedures in this section to install 92af1uh/95af1uh furnaces to ensure efficient and safe operation. You must consider combustion air needs and requirements for exhaust vents and gas piping...

  • Page 7

    Page 7 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 mini- mum free area of 1 square inch per 4,000 btu (645mm 2 per 1.17kw) per hour of total input rating of all equipment in the enc...

  • Page 8

    Page 8 shipping bolt removal units with 1/2 hp blower motor are equipped with three flex- ible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a flexible mounting leg). See figure 7. The bolt an...

  • Page 9

    Page 9 warning improper installation of the furnace can result in per- sonal injury or death. Combustion and flue products must never be allowed to enter the return air system or air in the living space. Use sheet metal screws and joint tape to seal return air system to furnace. In platform installa...

  • Page 10

    Page 10 figure 11 optional return air base (upflow applications only) note− optional side return air filter kits are not for use with return air base. 1 both the unit return air opening and the base return air opening must be covered by a single plenum or iaq cabinet. Minimum unit side return air op...

  • Page 11

    Page 11 left end right end right−hand discharge left−hand discharge top bottom (floor)** bottom (floor)** left end right end air flow air flow air flow air flow horizontal applications installation clearances top 0 front* 0 back 0 ends 0 vent 0 floor 0 ‡ *front clearance in alcove installation must ...

  • Page 12

    Page 12 intake pipe *gas connector service platform *gas connector may be used for canadian installation if accept- able by local authority having jurisdiction. Exhaust pipe figure 16 raised platform return air −− horizontal applications return air may be brought in only through the end of a fur- na...

  • Page 13

    Page 13 caution solvent cements for plastic pipe are flammable liq- uids 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 fire hazard and to minimize breathing of solvent vapors. A...

  • Page 14

    Page 14 table 3 outdoor termination kits usage unit vent pipe dia. (in.) standard concentric outdoor exhaust accelerator (dia. X length) outdoor exhaust accelerator (dia. X length) 2" wall plate kit 3" wall plate kit 2" wall ring kit flush- mount kit 1−1/2" concentric kit 2" concentric kit 3" concen...

  • Page 15

    Page 15 8 − after assembly, wipe excess cement from pipe at end of fitting socket. A properly made joint will show a bead around its entire perimeter. Any gaps may indi- cate an improper assembly due to insufficient sol- vent. 9 − handle joints carefully until completely set. Venting practices figur...

  • Page 16

    Page 16 vent piping guidelines the 92af1uh/95af1uh 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 flue gases are discharged outdoors. In direct vent installations, combustion air is ...

  • Page 17

    Page 17 table 5 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. Standard termination at elevation 0 − 4500’ number of 90° elbows use...

  • Page 18

    Page 18 figure 21 typical exhaust and intake pipe connections in upflow direct or non−direct vent applications transition 2” 2” 2” 3” 2” 2” or do not transition from smaller to larger pipe in horizontal runs of exhaust pipe . Exhaust *2” * when transitioning up in pipe size, use the shortest length ...

  • Page 19

    Page 19 intake piping the 92af1uh/95af1uh furnace may be installed in ei- ther 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 ...

  • Page 20

    Page 20 general guidelines for vent terminations in non-direct vent applications, combustion air is taken from indoors and the flue gases are discharged to the out- doors. The 92af1uh/95af1uh is then classified as a non-direct vent, category iv gas furnace. In direct vent applications, combustion ai...

  • Page 21

    Page 21 figure 25 vent termination clearances for non−direct vent installations in the usa and canada k d e l b c f g a b j a m i h inside corner detail vent terminal air supply inlet area where terminal is not permitted fixed closed operable b fixed closed operable b b a = b = c = d = e = f = g = h...

  • Page 22

    Page 22 figure 26 vent termination clearances for direct vent installations in the usa and canada k d e l b c f g a b j a m i h inside corner detail vent terminal air supply inlet area where terminal is not permitted fixed closed operable b fixed closed operable b b a = b = c = d = e = f = g = h = i...

  • Page 23

    Page 23 details of intake and exhaust piping terminations for direct vent installations note − in direct vent installations, combustion air is tak- en from outdoors and flue gases are discharged to out- doors. Note − flue gas may be slightly acidic and may adversely affect some building materials. I...

  • Page 24

    Page 24 figure 29 c a e d b a b d d b c a c 12" 1 1 2 2 2" (51mm) vent pipe 3" (76mm) vent pipe a − clearance above grade or average snow accumulation b −horizontal separation between intake and exhaust c −minimum from end of exhaust to inlet of intake d −exhaust pipe length e −wall support distance...

  • Page 25

    Page 25 figure 30 field−supplied wall termination or (15f74) wall ring termination kit with intake elbow see venting table 5 for maximum venting lengths with this arrangement. * use wall support every 24" (610 mm). Use two wall supports if extension is greater than 24" (610 mm) but less than 48" (12...

  • Page 26

    Page 26 figure 32 direct vent concentric rooftop termination 71m80, 69m29 or 60l46 (us) 44w92 or 44w93 (canada) minimum above average snow accumulation sheet metal strap (clamp and sheet metal strap must be field installed to support the weight of the termination kit.) flashing (not furnished) clamp...

  • Page 27

    Page 27 figure 37 ÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉ 12” (305 mm) minimum above grade or average snow accumulation 1/2” (13 mm) foam insulation (field − furnished) 5” (127 mm) 5 − 1/2” (140 mm) exhaust air intake air grade 12” (305 mm) intake air exhaust air grade 12” (305 mm) max. ...

  • Page 28

    Page 28 92af1uh/95af1uh direct vent application using existing chimney note − do not discharge exhaust gases directly into any chimney or vent stack. If ver- tical discharge through an existing unused chimney or stack is required, insert piping inside chimney until the pipe open end is above top of ...

  • Page 29

    Page 29 note − do not discharge exhaust gases directly into any chimney or vent stack. If ver- tical discharge through an existing unused chimney or stack is required, insert piping inside chimney until the pipe open end is above top of chimney and terminate as illus- trated. In any exterior portion...

  • Page 30

    Page 30 caution do not use copper tubing or existing copper conden- sate lines for drain line. 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 t...

  • Page 31

    Page 31 important when combining the furnace and evaporator coil drains together, the a/c condensate drain outlet must be vented to relieve pressure in or- der for the furnace pressure switch to operate properly. Figure 48 horizontalfurnace4” min. To 5” max.Above condensatedrain connection) furnacec...

  • Page 32

    Page 32 figure 51 drain trap assembly (furnished) vent drain trap clean out 5 feet maximum coupling 3/4 inch slip x slip (not furnished) 90 ° elbow 3/4 inch pvc (not furnished) 3/4 inch pvc pipe (not furnished) 1/2 inch pvc pipe (not furnished) condensate drain connection in unit drain assembly for ...

  • Page 33

    Page 33 gas piping caution if a flexible 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 flexible connector can then be added between the black iron pipe and the gas supply li...

  • Page 34

    Page 34 ground joint union automatic gas valve (with manual shut−off valve) field provided and installed left−side piping (standard) drip leg manual main shut−off valve right−side piping (alternate) note − black iron pipe only to be routed inside of cabinet bellows grommet plug plug ground joint uni...

  • Page 35

    Page 35 table 8 gas pipe capacity − ft 3 /hr (kl/hr) nominal iron pipe size −inches(mm) internal diameter −inches(mm) length of pipe−feet(m) 10 (3.048) 20 (6.096) 30 (9.144) 40 (12.192) 50 (15.240) 60 (18.288) 70 (21.336) 80 (24.384) 90 (27.432) 100 (30.480) 1/2 (12.7) .622 (17.799) 175 (4.96) 120 (...

  • Page 36

    Page 36 interior make−up box installation figure 56 make−up box right side remove and relocate plug to unused opening on left side the unit is equipped with a field make−up box. The make− up box may be moved to the right side of the furnace to fa- cilitate installation. Seal unused openings on left ...

  • Page 37

    Page 37 typical 92af1uh/95af1uh wiring diagram figure 57.

  • Page 38

    Page 38 figure 58 integrated control (automatic hot surface ignition system) blower off delay jumper terminal designations hum line xfmr eac cool heat park cont neutrals humidifier (120vac) input (120vac) transformer (120vac) indoor air qality accessory air cleaner (120vac) blower − cooling speed (1...

  • Page 39

    Page 39 priming condensate trap the condensate trap should be primed with water prior to start−up to ensure proper condensate drainage. Either pour 10 fl. Oz. (300 ml) of water into the trap, or follow these steps to prime the trap: 1 − follow the lighting instructions to place the unit into op- era...

  • Page 40

    Page 40 gas pressure adjustment gas flow (approximate) table 9 gas meter clocking chart unit seconds for one revolution natural lp 1 cu ft dial 2 cu ft dial 1 cu ft dial 2 cu ft dial −045 80 160 200 400 −070 55 110 136 272 −090 41 82 102 204 −110 33 66 82 164 −135 27 54 68 136 natural−1000 btu/cu ft...

  • Page 41

    Page 41 table 12 lp/propane conversion kit and pressure switch requirements at varying altitudes unit natural to lp/propane high altitude natural burner orifice kit high altitude lp/propane burner orifice kit high altitude pressure switch high altitude pressure switch 92af1uh 95af1uh 0 − 7500 ft (0 ...

  • Page 42

    Page 42 other unit adjustments primary limit . The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no ad- justment. Flame rollout switches (two) these manually reset switches are located on the front of the burner box. Pressure switch the p...

  • Page 43

    Page 43 service warning electrical shock, fire, or explosion hazard. Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous opera- tion, serious injury, death, or property damage. Before se...

  • Page 44

    Page 44 integrated control diagnostic codes diagnostic codes led status description led off no power to control or control harware fault detected. Led on normal operation. 1 flash flame present with gas vavle de−energized. 2 flashes pressure switch closed with combustion air inducer de−energized. 3 ...

  • Page 45

    Page 45 start−up & performance checklist gas supply pressure supply air line voltage gas supply natural gas lp propane gas piping connections tight leak tested supply line pressure w.C.________ 1 intake / exhaust pipe all joints primed and glued terminations installed properly pipes supported conden...

  • Page 46

    Page 46 contractor’s: name_________________________telephone_____________checklist completed____________________ job address_____−________________________________technician’s name___________________________________ 1 heating mode gas manifold pressure w.C._____ combustion sample co 2 % ______ co ppm...

  • Page 47

    Page 47 requirements for commonwealth of massachusetts modifications to nfpa−54, chapter 10 revise nfpa−54 section 10.8.3 to add the following re- quirements: for all side wall, horizontally vented, gas−fueled equipment installed in every dwelling, building or structure used in whole or in part for ...