Table of Contents
Advertisement
Quick Links
INSTALLATION INSTRUCTIONS
97G2DFV
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.
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.
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
508405-01
This manual must be left with the homeowner for future reference.
WARNING
CAUTION
Direct Vent & Non-Direct Vent
Table of Contents
Unit Dimensions ........................................................ 2
Parts Arrangement..................................................... 3
Gas Furnace .............................................................. 4
Shipping and Packing List ......................................... 4
Safety Information ..................................................... 4
General ...................................................................... 6
Combustion, Dilution & Ventilation Air ....................... 7
Installation ............................................................... 10
Filters ....................................................................... 12
Duct System ............................................................ 12
Venting Practices ..................................................... 15
Condensate Piping .................................................. 31
Gas Piping ............................................................... 34
Electrical .................................................................. 36
Air for Non-Direct Vent Applications ........................ 44
Unit Start-Up ............................................................ 45
Blower Performance ................................................ 48
Service..................................................................... 50
Planned Service ...................................................... 52
Repair Parts List ...................................................... 52
*P508405-01*
Issue 2341
Warm Air Gas Furnace
Downflow Air Discharge
(P) 508405-01
Page 1 of 53
Advertisement
Table of Contents
Related Manuals for Lennox 97G2DFV
Summary of Contents for Lennox 97G2DFV
-
Page 1: Table Of Contents
Planned Service ............52 Repair Parts List ............52 Manufactured By *P508405-01* Allied Air Enterprises LLC A Lennox International, Inc. Company 215 Metropolitan Drive (P) 508405-01 West Columbia, SC 29170 508405-01 Issue 2341 Page 1 of 53... -
Page 2: Unit Dimensions
Unit Dimensions 9/16 (14) Flue Condensate Trap Assembly COMBUSTION AIR INTAKE Furnished for external field installation (178) RETURN AIR on either side of unit. OPENING EXHAUST AIR (See installation instructions OUTLET for additional information.) 2-1/16 (52) 9/16 2-1/4 (57) (14) (127) TOP VIEW 27-3/4... -
Page 3: Parts Arrangement
Parts Arrangement Blower Assembly Control Box Access Panel Combustion Air Inducer Gas Valve Burner Box Assembly Figure 1. 508405-01 Issue 2341 Page 3 of 53... -
Page 4: Gas Furnace
Gas Furnace Shipping and Packing List This Category IV gas furnace is shipped ready for Package 1 of 1 contains: installation in the downflow position. 1 - Assembled Gas Unit The furnace is equipped for installation in natural gas 1 - Bag assembly containing the following: applications. - Page 5 be provided according to the current National Fuel Gas Code or CSA-B149 standard. Locations and Clearances This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the table in Figure 14. Accessibility and service clearances must take precedence over fire protection clearances.
-
Page 6: General
A room thermostat must control the furnace. The use General of fixed jumpers that will provide continuous heating is prohibited. These instructions are intended as a general guide and do The input rate and temperature rise must be set per not supersede local codes in any way. -
Page 7: Combustion, Dilution & Ventilation Air
the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This Combustion, Dilution & Ventilation Air reprinted material is not the complete and official position of ANSI on the referenced subject, which is represented If this unit is installed as a Non-Direct Vent Furnace, follow only by the standard in its entirely. - Page 8 It is also permissible to bring air for combustion from a containing the furnace, the return air must be handled by ventilated attic (Figure 9) or ventilated crawl space (Figure ducts which are sealed to the furnace casing and which terminate outside the space containing the furnace.
- Page 9 Ventilation Louvers Inlet Air Roof Terminated (Minimum 12 in. Exhaust Pipe (305mm) above Attic Floor) *Intake Debris Screen (Provided) Furnace * See Maximum Vent Lengths table NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm Figure 7.
-
Page 10: Installation
Installation Setting Equipment WARNING Do not install the furnace on its front, back or in the horizontal position. See Figure 13. Do no 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. - Page 11 * Front Back Figure 15. Sides 0† Vent Installation on Combustible Flooring Floor NC‡ 1. When unit is installed on a combustible floor, a * Front clearance in alcove installation must be 24 in. (610 downflow combustible flooring base must be installed mm).
-
Page 12: Filters
After opening is cut, set the combustible flooring base into opening. Check fiberglass strips on the combustible flooring base to make sure they are properly glued and positioned. Lower supply air plenum into the combustible flooring base until plenum flanges seal against fiberglass strips. - Page 13 furnace is installed. The furnace access panel must always Piping and Fittings Specifications be in place when the furnace is operating and it must not Schedule 40 PVC (Pipe) D1785 allow leaks into the supply air duct system. Schedule 40 PVC (Fittings) D2466 Schedule 40 CPVC (Pipe) F441...
- Page 14 first three feet of vent pipe from the furnace flue collar must 1. Measure and cut vent pipe to desired length. be accessible for inspection. Debur and chamfer end of pipe, removing any ridges or rough edges. If end is not chamfered, edge of pipe Table 5 lists the available exhaust termination kits.
-
Page 15: Venting Practices
Immediately after applying last coat of cement to pipe, and while both inside socket surface and end of pipe WARNING are wet with cement, forcefully insert end of pipe into socket until it bottoms out. Turn PVC pipe 1/4 turn CARBON MONOXIDE POISONING HAZARD during assembly (but not after pipe is fully inserted) to Failure to follow the steps outlined below for each... - Page 16 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 flue gases are discharged outdoors. In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors.
- Page 17 Use the following steps to correctly size vent pipe diameter. 070, 090, Furnace capacity? Standard or Which termination? Concentric? See Table 5 Which needs most Intake or elbows? Exhaust? How many? 1-1/2”, 2”, Desired pipe size? 2-1/2” or 3” What is the altitude? Use Table 7 to find max pipe length.
- Page 18 Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3" Pipe Number of Capacity Capacity Capacity Capacity 90° Elbows Used Standard Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
- Page 19 Maximum Allowable Intake or Exhaust Vent Length in Feet Concentric Termination at Elevation 0 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number of Capacity Capacity Capacity Capacity 90° Elbows Used Concentric Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
- Page 20 Maximum Allowable Exhaust Vent Length Using Ventilated Attic or Crawl Space for Intake Air in Feet Standard Termination at Elevation 0 - 10,000 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number of Capacity Capacity Capacity Capacity 90° Elbows Used NOTE: Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation.
- Page 21 Pipe size determined in table 7. 2” 2” 2” 2” 2” INTAKE EXHAUST TOP VIEW NOTE: 1-1/2” Vent Pipe Diameter Allowed Only on 045/070 Units TRANSITION 3” 1-1/2” *2” 3” TRANSITION TRANSITION *2” *2” *2” * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE: Exhaust pipe and intake pipe must be the same diameter.
- Page 22 Position termination according to location given in Figure 28 or Figure 29. In addition, position termination so it is Roof Terminated free from any obstructions and 12” above the average Exhaust Pipe snow accumulation. At vent termination, care must be taken to maintain protective coatings over building materials (prolonged Inlet Air exposure to exhaust condensate can destroy protective...
- Page 23 Maximum Allowable Exhaust Vent Pipe Length (in ft.) without Insulation in Unconditioned Space for Winter Design Temperatures Unit Input Size Winter Design Temperatures ºF Vent Pipe (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in. 3 in.
- Page 24 VENT TERMINATION CLEARANCES FOR NON-DIRECT VENT INSTALLATIONS IN THE US AND CANADA INSIDE CORNER DETAIL Fixed Operable Fixed Closed Closed Operable AREA WHERE TERMINAL AIR SUPPLY INLET VENT TERMINAL IS NOT PERMITTED US Installations Canadian Installations Clearance above grade, veranda, 12 inches (305mm) or 12 inches (305mm) 12 inches (305mm) or 12 inches (305mm) porch, deck or balcony...
- Page 25 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL Fixed Operable Fixed Closed Closed Operable AREA WHERE TERMINAL AIR SUPPLY INLET VENT TERMINAL IS NOT PERMITTED US Installations Canadian Installations Clearance above grade, veranda, 12 inches (305mm) or 12 inches (305mm) 12 inches (305mm) or 12 inches (305mm) porch, deck or balcony...
- Page 26 Details of Intake and Exhaust Piping NOTE: Care must be taken to avoid recirculation of Terminations for Direct Vent Installations exhaust back into intake pipe. On field supplied terminations, a minimum distance NOTE: In Direct Vent installations, combustion air is taken between the end of the exhaust pipe and the end of from outdoors and flue gases are discharged to outdoors.
- Page 27 If intake and exhaust piping must be run up a side 2” EXTENSION FOR 2” PVC wall to position above snow accumulation or other PIPE1” EXTENSION FOR 3” PVC PIPE obstructions, piping must be supported every 24” (610 mm) as shown in Figure 38. FURNACE EXHAUST When exhaust and intake piping must be run up an...
- Page 28 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT LARGER VENT PIPE SIZE Vent Pipe Vent Pipe TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
- Page 29 Details of Exhaust Piping Terminations for Non- Direct Vent Applications Exhaust pipe may be routed either horizontally through an outside wall or vertically through the roof. In attic or SIZE TERMINATION closet installations, vertical termination through the roof PER EXHAUST PIPE is preferred.
- Page 30 Exhaust through Crawl Space Vent Option All 33” condensing gas furnaces (92%+) are now approved Exhaust from Furnace to be vented down through a crawl space. Ensure a vent To Termination pipe drain kit, 51W18 (USA) or 15Z70 (Canada), is used as directed through the floor joists and into the crawl space.
-
Page 31: Condensate Piping
NOTE: Vinyl tubing may be used for condensate drain. Condensate Piping Tubing must be 1-1/4” OD x 1” ID and should be attached to the drain on the trap using a hose clamp. This unit is designed for either right or left side exit of Figure 48 shows the furnace and evaporator coil condensate piping in downflow applications. - Page 32 Field-Provided Vent From Evaporator Coil (Upflow Furnace 1” Min. to 2” Max. Horizontal Furnace 4” Min. to 5” Max. Field Provided Vent above condensate drain connection) 1” min. 2” max. above condensate drain. Condensate Drain Connection Furnace Condensate Drain Connection Optional Overflow Switch Evaporator Drain Line...
- Page 33 Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 1 (25 mm) Min. Vent 2 (50 mm) Max.
-
Page 34: Gas Piping
Gas Piping IMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petroleum gases. CAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall Leak Check be installed at the gas valve and extend outside the After gas piping is completed, carefully check all field-... - Page 35 Left Side Piping AUTOMATIC MANUAL (Standard) MAIN SHUT-OFF GAS VALVE MANUAL (with manual VALVE AUTOMATIC MAIN SHUT-OFF (With 1/8 in. NPT GAS VALVE shut-off valve) VALVE Plugged Tap (with manual (With 1/8 in. NPT Shown) shut-off valve) Plugged Tap Shown) GROUND JOINT UNION...
-
Page 36: Electrical
The power supply wiring must meet Class I restrictions. Electrical Protected by either a fuse or circuit breaker, select circuit protection and wire size according to unit nameplate. ELECTROSTATIC DISCHARGE (ESD) NOTE: Unit nameplate states maximum current draw. Precautions and Procedures Maximum over current protection allowed is shown in Table 11. - Page 37 Indoor Blower Speeds Electrical Wiring 1. When the thermostat is set to “FAN ON,” the indoor blower will run continuously at approximately 50% WARNING of the second stage cooling speed when there is no cooling or heating demand. See Table 19 for allowable Risk of electrical shock.
- Page 38 Active Dehumidification To achieve additional dehumidification, clip the jumper wire located below the DEHUM terminal on the integrated ignition/blower control board and connect a humidity control that opens on humidity rise to the DEHUM and R terminals. The DEHUM terminal on the control board must be connected to the normally closed contact of the humidity control so that the board senses an open circuit on high humidity.
- Page 39 speed. When the call for continuous fan is satisfied, the lockout. Lockout may be manually reset by removing control immediately ramps down the circulating blower. power from the control for more than 1 second or removing the thermostat call for heat for more than 3 seconds. If during a heating cycle the limit control senses an abnormally high temperature and opens, the control board de-energizes the gas valve and the combustion blower...
- Page 40 A call for 2nd stage cooling from the thermostat closes CFM LED the R to Y2 circuit on the control board. The blower motor On models equipped with a variable speed motor, an amber ramps up to 100% of the selected cooling air flow. When LED is provided on the control board to display CFM.
- Page 41 W1/W2 w1 w2 ***min 100%** W1 - Heat Demand Present 100%* w1 - Heat Demand Satisfied ***min 100%* 100%* W2 - High Heat Demand Present w2 - High Heat Demand Satisfied CALL *Percentage of Low Fire CFM ** Percentage of High Fire CFM *** User-Selected Heat Blower OFF Delay Figure 59.
- Page 42 L1 HOT NEUTRAL 120/1/60 FLAME SENSOR INTERLOCK SWITCH HOT SURFACE IGNITER INDUCED DRAFT BLOWER IND HIGH IND LOW MOTOR HUMIDIFIER AIR CLEANER CHOKE (IF USED) CIRCULATION BLOWER MOTOR 120V TRANSFORMER 2ND STAGE HPS1 LPS1 1ST STAGE GAS VALVE IGNITION CONTROL MOTOR W1 W2 ROLLOUT...
- Page 43 INDUCED DRAFT GAS VALVE HOT SURFACE PRESSURE BLOWER IGNITOR H1 C M SWITCH (HIGH) PINK ROLLOUT ROLLOUT LIMIT BROWN BLUE PRESSURE 2 PIN SWITCH (LOW) CONNECTOR FLAME SENSOR BROWN BLACK GRN/YLW BLACK INTERLOCK SWITCH IGNITION CONTROL 5 PIN CONNECTOR W1 W2 Y2 0 CIRCULATION BLOWER...
-
Page 44: Testing For Proper Venting And Sufficient Combustion Air For Non-Direct Vent Applications
Testing for Proper Venting and Sufficient Combustion Air for Non-Direct Vent Applications Seal any unused openings in the venting system. Visually inspect the venting system for proper size WARNING and horizontal pitch. Determine there is no blockage CARBON MONOXIDE POISONING HAZARD or restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. -
Page 45: Unit Start-Up
Set the thermostat to initiate a heating demand. Unit Start-Up Allow the burners to fire for approximately 3 minutes. Adjust the thermostat to deactivate the heating FOR YOUR SAFETY READ BEFORE OPERATING demand. Wait for the combustion air inducer to stop. Set the thermostat to initiate a heating demand and again WARNING allow the burners to fire for approximately 3 minutes. - Page 46 11. Set the thermostat to desired setting. one turn, connect a piece of 5/16” tubing and connect a manometer to measure supply pressure. NOTE: When unit is initially started, steps 1 through 11 may need to be repeated to purge air from gas line. NOTE: Shut unit off and remove manometer as soon as 12.
- Page 47 High Altitude LP/ Natural to LP/ High Altitude Natural Propane Burner High Altitude Pressure Switch Propane Burner Orifice Kit Orifice Kit Capacity 0 - 7500 ft 7501 - 10000 ft 7501 - 10000 ft 4501 - 7500 ft 7501 - 10000 ft (0 - 2286m) (2286 - 3048m) (2286 - 3048m)
-
Page 48: Blower Performance
Blower Performance Heating CFM @ 0 - 0.8” w.c. Speed Model Temp Rise Adjustment Setting “D” Setting “C” Setting “B” Setting “A” 1110 1305 1430 1700 High Fire Normal 1175 1315 1520 35 - 65 1055 1170 1365 1020 1140 1340 Low Fire Normal... - Page 49 Heating CFM @ 0 - 0.8” w.c. Speed Model Temp Rise Adjustment Setting “D” Setting “C” Setting “B” Setting “A” 1595 1795 1955 2010 High Fire Normal 1450 1615 1795 1865 35 - 65 1290 1460 1610 1680 1165 1305 1465 1547 Low Fire...
-
Page 50: Service
Check amp-draw on the blower motor with the blower Service compartment access panel in place. Motor Nameplate__________Actual__________ WARNING Winterizing and Condensate Trap Care 1. Turn off power to the furnace. ELECTRICAL SHOCK, FIRE, OR EXPLOSION Have a shallow pan ready to empty condensate water. HAZARD. - Page 51 Cleaning the Burner Assembly 16. Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger 1. Turn off electrical and gas power supplies to furnace. assembly to cabinet. Remove two screws from blower Remove upper and lower furnace access panels. rail which secure bottom heat exchanger flange.
-
Page 52: Planned Service
Planned Service A service technician should check the following items Operating performance - Unit must be observed during during an annual inspection. Power to the unit must be operation to monitor proper performance of the unit and shut off for safety. the vent system. - Page 53 Requirements for Commonwealth of Massachusetts Modifications to NFPA-54, Chapter 10 INSPECTION. The state or local gas inspector of the side wall, horizontally vented, gas-fueled equipment Revise NFPA-54 section 10.8.3 to add the following shall not approve the installation unless, upon requirements: inspection, the inspector observes carbon monoxide For all side wall, horizontally vented, gas-fueled equipment...