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Allied 96G2DFV Installation Instructions Manual

Warm air gas furnace / downflow air discharge direct vent & non-direct vent
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Warm Air Gas Furnace / Downflow Air Discharge
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.
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
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.
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
507962-01
INSTALLATION INSTRUCTIONS
Direct Vent & Non-Direct Vent
This manual must be left with the homeowner for future reference.

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WARNING
Save these instructions for future reference
96G2DFV
Condensate Piping ....................................................32
Gas Piping .................................................................35
Electrical ....................................................................37
Air for Non-Direct Vent Applications ..........................44
Unit Start-Up ..............................................................45
Blower Performance ..................................................48
Service.......................................................................51
Planned Service ........................................................53
Repair Parts List ........................................................53
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Issue 2149
CAUTION
*P507962-01*
(P) 507962-01
Page 1 of 53

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Summary of Contents for Allied 96G2DFV

  • Page 1: Table Of Contents

    (or careful when you handle this equipment. equivalent), service agency or the gas supplier. Manufactured By *P507962-01* Allied Air Enterprises LLC A Lennox International, Inc. Company 215 Metropolitan Drive (P) 507962-01 West Columbia, SC 29170...

  • Page 2: Unit Dimensions

    Unit Dimensions Capacity 045-12 17-1/2 16-3/8 070-16 090-20 19-7/8 19-1/2 110-20 Page 2 of 53 Issue 2149 507962-01...

  • Page 3: Parts Arrangement

    Parts Arrangement Blower Assembly Control Box Access Panel Combustion Air Inducer Gas Valve Burner Box Assembly Figure 1. 507962-01 Issue 2149 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

    VOIDS MANUFACTURER’S or fitter only. EQUIPMENT LIMITED WARRANTY. ALLIED DISCLAIMS ALL LIABILITY IN CONNECTION WITH • The gas cock must be “T handle” type. INSTALLER’S FAILURE TO FOLLOW THE ABOVE • When a furnace is installed in an attic, the passageway INSTALLATION INSTRUCTIONS.

  • 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 (Cellular Core Pipe) F891 Schedule 40 PVC (Fittings) D2466...
  • Page 14 vent (exhaust) system. When bonding the vent system to 1. Measure and cut vent pipe to desired length. the furnace, use ULC S636 approved One-Step Transition Debur and chamfer end of pipe, removing any ridges Cement to bond the pipe to the flue collar. In addition, the or rough edges.

  • 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 When furnace is installed in a residence where unit be used. Contact Allied Air Technical Service for assistance is shut down for an extended period of time, such in sizing vent pipe in these applications.
  • 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 96G2DFV 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 96G2DFV 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 96G2DFV 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...
  • 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 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Allied Air recommends avoiding this location if possible. Figure 28. Vent Termination Clearances...
  • Page 25 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Allied Air recommends avoiding this location if possible. Figure 29. Vent Termination Clearances For Direct Vent installations in the USA and Canada...
  • 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 to be vented down through a crawl space. Ensure a vent Furnace pipe drain kit, 51W18 (USA) or 15Z70 (Canada), is used as To Termination 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 Figure 48. Evaporator Coil Using a Separate Drain Figure 50. Condensate Trap with Optional Overflow Switch CAUTION 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.
  • 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 (96G2DFV). To activate this option, move the jumper pin (see Figure 56) to desired setting (5 minutes or 10 •...
  • Page 38 Electronic Air Cleaner LED on the control board flashes. Each flash signifies 100 CFM; count the flashes and multiply by 100 to determine Terminals are provided on the integrated ignition/blower the actual CFM delivered (for example: 10 flashes x 100 = control board for connection of a 120-volt electronic air 1000 CFM).
  • Page 39 Sequence of Operation Cooling Heating The unit is set up at the factory for single stage cooling. For two stage cooling operation, clip the jumper wire located On a call for heat from the room thermostat, the control between the Y to Y2 terminals on the integrated ignition/ board performs a 1 second self check.
  • Page 40 5 seconds before releasing. High Heat State LED On 96G2DFV models, a green LED is provided on the control board to indicate high heat state (see Table 13). Page 40 of 53...
  • Page 41 Figure 58. Typical Field Wiring Diagram 507962-01 Issue 2149 Page 41 of 53...
  • Page 42 NOTES: PRESS AND RELEASE FAULT CODE HISTORY BUTTON TO DISPLAY FAULT CODES. TO ERASE CODES, PRESS AND HOLD BUTTON IN FOR MORE THAN 5 SECONDS IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED, IT MUST BE REPLACED WITH WIRING MATERIAL HAVING A TEMP.

  • Page 43: 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 44: 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 45 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 46 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 47: Blower Performance

    Blower Performance Heating CFM @ 0 - 0.8” w.c. Speed Model Temp Rise Adjustment Setting “D” Setting “C” Setting “B” Setting “A” 1015 1210 High Fire Normal 1070 35 - 65 1000 1110 Low Fire Normal 1055 20 - 50 96G2DF045BV12 Cooling CFM @ 0 - 0.8”...
  • Page 48 Heating CFM @ 0 - 0.8” w.c. Speed Model Temp Rise Adjustment Setting “D” Setting “C” Setting “B” Setting “A” 1395 1555 1695 1825 High Fire Normal 1275 1395 1585 1670 35 - 65 1145 1265 1405 1525 1130 1230 1365 1475 Low Fire...
  • Page 49 Allowable Heating Speeds Model Number Speed Adjust Setting "D" Setting "C" Setting "B" Setting "A" +10% Allowed Allowed Allowed Not Allowed 96G2DF045BV12 Norm Allowed Allowed Factory Setting Not Allowed -10% Allowed Allowed Allowed Not Allowed +10% Allowed Allowed Allowed Allowed 96G2DF070BV16 Norm Allowed...

  • 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

    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.
  • 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...

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