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Allied 96G1DFE Installation Instructions Manual

Warm air gas furnace
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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 .........................6
Installation ...................................................................9
Filters .........................................................................12
Duct System ..............................................................12
Venting Practices .......................................................14
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
507769-04
INSTALLATION INSTRUCTIONS
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.

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WARNING
Save these instructions for future reference
96G1DFE
Condensate Piping ....................................................28
Gas Piping .................................................................31
Electrical ....................................................................34
Unit Start-Up ..............................................................37
Air for Non-Direct Vent Applications ..........................41
Other Unit Adjustments..............................................42
Blower Performance Data .........................................43
Service.......................................................................44
Planned Service ........................................................46
Repair Parts List ........................................................52
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Issue 1927
CAUTION
*P507769-04*
(P) 507769-04
Page 1 of 53

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Summary of Contents for Allied 96G1DFE

  • Page 1: Table Of Contents

    (or careful when you handle this equipment. equivalent), service agency or the gas supplier. Manufactured By *P507769-04* Allied Air Enterprises LLC A Lennox International, Inc. Company 215 Metropolitan Drive (P) 507769-04 West Columbia, SC 29170...

  • Page 2: Unit Dimensions

    (Either Side) (Either Side) 9−1/8 (232) Right 6−9/16 (167) Left 6−1/2 (165) (229) Either Side Supply (19) Supply (19) 19−1/4 (489) (19) FRONT VIEW 96G1DFE Capacity 045-12 17-1/2 16-3/8 070-16 090-16 19-7/8 19-1/2 Page 2 of 53 Issue 1927 507769-04...

  • Page 3: Parts Arrangement

    Parts Arrangement CONTROL BOX (Includes integrated control, transformer and door switch) BAG ASSEMBLY BLOWER MOTOR (hidden) BLOWER COMPARTMENT ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK HEATING PRIMARY LIMIT COMPARTMENT ACCESS PANEL COLD END HEADER BOX HEAT EXCHANGER GAS VALVE BURNER BOX ASSEMBLY (includes flame sensor, rollout switches and ignitor) Figure 1.

  • Page 4: Gas Furnace

    Gas Furnace Shipping and Packing List This Category IV gas furnace is shipped ready for 1 - Assembled Gas Unit installation in the downflow position. 1 - Bag assembly containing the following: 1 - Snap bushing The furnace is equipped for installation in natural gas applications.
  • Page 5 In order to ensure proper unit operation in non-direct vent Heating Unit Installed Parallell to Air Handler Unit applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standard. Locations and Clearances AIR HANDLER GAS UNIT This furnace is CSA International certified for installation...

  • Page 6: General

    INSTRUCTIONS VOIDS MANUFACTURER’S EQUIPMENT LIMITED WARRANTY. ALLIED Combustion, Dilution & Ventilation Air DISCLAIMS ALL LIABILITY IN CONNECTION WITH INSTALLER’S FAILURE TO FOLLOW THE ABOVE INSTALLATION INSTRUCTIONS. If this unit is installed as a Non-Direct Vent Furnace, follow the guidelines in this section.
  • Page 7 not separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air WARNING for combustion if the structure does not provide enough air by infiltration. Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation.
  • Page 8 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 hour of the total input rating of all equipment in the enclosure. See ROOF TERMINATED EXHAUST PIPE Figure 7.

  • Page 9: Installation

    Installation Setting Equipment CAUTION Do not install the furnace on its front, back or in the horizontal position. See Figure 12. 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 10 AIR FLOW AIR FLOW AIR FLOW Left Side Right Side 1/2" max. SIDE VIEW FRONT VIEW SIDE VIEW Unit must be level side−to−side. Unit may be positioned Bottom from level to 1/2" toward the front to aid in draining. Figure 11. Setting Equipment *Front *Front Back...
  • Page 11 Check fiberglass strips on the combustible flooring base to make sure they are properly glued and FURNACE positioned. Lower supply air plenum into the combustible flooring base until plenum flanges seal against fiberglass strips. PROPERLY SIZED FLOOR SUPPLY AIR NOTE: Be careful not to damage fiberglass strips. OPENING PLENUM Check for a tight seal.

  • Page 12: Filters

    Return Air Plenum PLENUM NOTE: Return air must not be drawn from a room where SECURE FROM (Field Provided) OUTSIDE CABINET this furnace, or any other gas-fueled appliance (i.e., water heater), or carbon monoxide-producing device (i.e., wood fireplace) is installed. CABINET When return air is drawn from a room, a negative pressure SEALING STRIP...
  • Page 13 Standard Concentric Outdoor Exhaust Outdoor Exhaust 1-1/2” 2” 3” Flush-Mount Vent Pipe Accelerator Accelerator Concentric Concentric Concentric 96G1DFE Dia. (Dia. x Length) (Dia. x Length) Capacity (in.) 71M80 69M29 60L46 1-1/2” x 12” 2” x 12” 51W11** †44W92†† †44W92†† 44W93†...

  • Page 14: Venting Practices

    Joint Cementing Procedure Venting Practices All cementing of joints should be done according to the specifications outlined in ASTM D 2855. SCHEDULE 40 NOTE: A sheet metal screw may be used to secure the PVC − 5’ intake pipe to the connector, if desired. Use a drill or self all other pipe* −...
  • Page 15 In some applications which permit the use of several What is the altitude? 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. Use Table 7 to find 96G1DFE Min.
  • Page 16 Maximum Allowable Intake or Exhaust Vent Length 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 Concentric Termination Elevation 0 − 10,000 ft. 1-1/2”...
  • Page 17 Maximum Allowable Exhaust Vent Lengths with Furnace Installed in a Closet or Basement 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...
  • Page 18 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 19 General Guidelines for Vent Terminations In Non-Direct Vent applications, combustion air is taken from indoors and the flue gases are discharged to the outdoors. This unit is then classified as a non-direct vent, Category IV gas furnace. In Direct Vent applications, combustion air is taken from outdoors and the flue gases are discharged to the outdoors.
  • Page 20 IMPORTANT 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). Maximum Allowable Exhaust Vent Pipe Length (in ft.) without Insulation in Unconditioned Space for Winter Design Temperatures Single - Stage High Efficiency Furnace Unit Input Size...
  • Page 21 ‡ 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 27. Vent Termination Clearances...
  • Page 22 ‡ 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 For Direct Vent installations in the USA and Canada...
  • Page 23 Figure 30. Flush Mount Side Wall Termination piping. See Table 10. On field supplied terminations, a minimum distance 96G1DFE Termination Pipe between the end of the exhaust pipe and the end of Exhaust Pipe Size...
  • Page 24 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 25 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada) FIELD−PROVIDED 1−1/2" (38mm) accelerator REDUCER MAY BE REQUIRED provided on 71M80 & 44W92 TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION OUTSIDE INTAKE WALL EXHAUST Inlet Air EXHAUST VENT Minimum 12 in. VENT Exhaust Furnace...
  • Page 26 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 27 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 28: Condensate Piping

    Condensate Piping This unit is designed for either right or left side exit of condensate piping in downflow applications. Refer to Figure 45 for condensate trap locations. NOTE: If necessary the condensate trap may be installed up to 5” away using PVC pipe from the furnace. Piping from furnace must slope down a minimum of 1/4”...
  • Page 29 Figure 47. Unit with Evaporator Coil Figure 48. Evaporator Coil Using a Common Drain CAUTION A separate drain line must be run to the drain from the condensate trap to ensure proper drainage and pressure switch operation. DO NOT connect the condensate trap drain into the drain line from the evaporator coil.
  • Page 30 Figure 50. Trap Drain Assembly Using 1/2” PVC or 3/4” PVC Page 30 of 53 Issue 1927 507769-04...

  • Page 31: 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 piping...
  • Page 32 Left Side Piping MANUAL (Standard) AUTOMATIC MAIN SHUT−OFF GAS VALVE MANUAL VALVE AUTOMATIC (with manual Plug MAIN SHUT−OFF (With 1/8 in. NPT GAS VALVE shut−o valve) VALVE Plugged Tap (with manual Plug (With 1/8 in. NPT Shown) shut−o valve) Plugged Tap Shown) GROUND JOINT UNION...
  • Page 33 Removal of the Furnace from Common Vent Seal any unused openings in the common venting system. In the event that an existing furnace is removed from a venting system commonly run with separate gas Inspect the venting system for proper size and appliances, the venting system is likely to be too large to horizontal pitch.

  • Page 34: 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. Maximum Over-Current Protection allowed is 15 AMP. Precautions and Procedures Holes are on both sides of the furnace cabinet to facilitate wiring.
  • Page 35 Indoor Blower Speeds mode when the combustion air inducer is operating and the pressure switch is closed. Any humidifier rated up to When the thermostat is set to “FAN ON”, the indoor 0.5 amp can be connected to this terminal with the ground blower will run continuously on the fan speed when leg of the circuit connected to ground or the “C”...
  • Page 36 Figure 57. Typical Wiring Diagram Page 36 of 53 Issue 1927 507769-04...

  • Page 37: Unit Start-Up

    Terminal Designations 120 HUM Humidifier (120 VAC) LINE Input (120 VAC) XFMR Transformer (120 VAC) CIRC Indoor Blower (120 VAC) Electronic Air Cleaner (120 VAC) COOL Blower - Cooling Speed (24 VAC) HEAT Blower - Heating Speed (24 VAC) Blower - Fan Speed (24 VAC) PARK Dead terminals to park all speed taps NEUTRALS...
  • Page 38 Priming Condensate Trap Gas Valve Shown In “ON’ Position The condensate trap should be primed with water prior to start-up to ensure proper condensate drainage. Either MANIFOLD MANIFOLD pour 10 fl. oz. (300 ml) of water into the trap, or follow PRESSURE PRESSURE these steps to prime the trap:...
  • Page 39 Take care to remove barbed fitting and replace threaded plug. Gas Meter Clocking Chart Seconds for One Revolution Proper Combustion 96G1DFE Natural Furnace should operate minimum 15 minutes with correct Capacity 1 cu ft 2 cu ft...
  • Page 40 Burner Orifice Conversion Kits at Varying Altitudes 0 - 7,500 ft 7,501 - 10,000 ft (0 - 2,286 m) (2,286 - 3048m) 96G1DFE High Altitude High Altitude LP/ Capacity Natural to LP/ LP/Propane to Natural Burner Propane Burner Propane Natural...

  • Page 41: 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 42: Other Unit Adjustments

    Other Unit Adjustments Primary Limit The primary limit is located on the heating compartment NO JUMPER vestibule panel. This limit is factory set and requires no To adjust fan−o timing, reposition jumper across pins to adjustment. achieve desired setting. 60 Second 90 Second 120 Second 180 Second...

  • Page 43: Blower Performance Data

    Blower Performance Data 96G1DFE 045*B12 Performance (Less Filter) Air Volume / Watts at Different Blower Speeds External Bottom Return Air, Side Return Air with Optional Return Air Base, Return Air from Both Sides or Return Air from Static Bottom and One Side.

  • Page 44: Service

    Allowable Heating Speeds Model Yellow Blue Brown Black 96G1DF045BE12 Allowed Factory Setting Allowed Not Allowed Not Allowed 96G1DF070BE16 Allowed Factory Setting Allowed Not Allowed Not Allowed 96G1DF090CE16 Allowed Factory Setting Allowed Allowed Not Allowed Table 16. Allowable Circulation Speeds Model Yellow Blue Brown...
  • Page 45 Cleaning Heat Exchanger 19. Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly If cleaning the heat exchanger becomes necessary, are resting on the support located at the rear of the follow the below procedures and refer to Figure 1 when cabinet.

  • Page 46: Planned Service

    Remove four screws which secure burner box 10. Reinstall the gas valve manifold assembly. Reconnect assembly to vest panel. Remove burner box from the the gas supply line to the gas valve. Reinstall the unit. burner box cover. Use the soft brush attachment on a vacuum cleaner 11.
  • Page 47 -03 Integrated Control LED Codes Red LED Flash Code Diagnostic Codes / Status of Furnace LED Off No power to control or control hardware fault detected Heartbeat Normal operation - idle, continuous fan, cool Continuous Rapid Flash Call for heat / burner operation 1 Flash Reverse line voltage polarity 2 Flashes...
  • Page 48 Troubleshooting: Heating Sequence of Operation Page 48 of 53 Issue 1927 507769-04...
  • Page 49 Troubleshooting: Heating Sequence of Operation (continued) 507769-04 Issue 1927 Page 49 of 53...
  • Page 50 Troubleshooting: Cooling Sequence of Operation Page 50 of 53 Issue 1927 507769-04...
  • Page 51 Troubleshooting: Continuous Fan Sequence of Operation 507769-04 Issue 1927 Page 51 of 53...

  • Page 52: Repair Parts List

    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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