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Lennox Allied Air A96UH2E 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.
As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges. Be
careful when you handle this equipment.
Unit Dimensions ............................................................2
Parts Arrangement.........................................................3
A96UH2E Gas Furnace .................................................4
Shipping and Packing List .............................................4
Safety Information .........................................................4
General ..........................................................................6
Combustion, Dilution & Ventilation Air ...........................7
Installation ...................................................................10
Filters ...........................................................................14
Duct System ................................................................14
Manufactured By
Allied Air Enterprises LLC
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
507581-04
INSTALLATION INSTRUCTIONS
A96UH2E
Warm Air Gas Furnace
Upflow/Horizontal Left Air Discharge
Direct Vent & Non-Direct Vent
This manual must be left with the homeowner for future reference.
CAUTION

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Save these instructions for future reference
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.
Venting.........................................................................16
Condensate Piping ......................................................34
Gas Piping ...................................................................38
Electrical ......................................................................41
Blower Performance ....................................................50
Unit Start-Up ................................................................53
Other Unit Adjustments................................................56
Service.........................................................................56
Planned Service ..........................................................58
Repair Parts List ..........................................................59
*P507581-04*
Issue 2128
WARNING
(P) 507581-04
Page 1 of 60

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  • Page 1: Table Of Contents

    Planned Service ............58 Duct System ..............14 Repair Parts List ............59 Manufactured By *P507581-04* Allied Air Enterprises LLC A Lennox International, Inc. Company 215 Metropolitan Drive (P) 507581-04 West Columbia, SC 29170 Save these instructions for future reference 507581-04 Issue 2128...

  • Page 2: Unit Dimensions

    Unit Dimensions 1 NOTE - 20 C/D (5 Ton) size units installed in upflow applications EXHAUST AIR 3−3/8 that require air volumes of 1800 cfm (850 L/s) or greater must OUTLET (86) have one of the following: Single side return air with transition, to accommodate 20 x 25 2 (51) x 1 in.

  • Page 3: Parts Arrangement

    Parts Arrangement Figure 1. 507581-04 Issue 2128 Page 3 of 60...

  • Page 4: A96Uh2E Gas Furnace

    A96UH2E Gas Furnace Shipping and Packing List The A96UH2E Category IV gas furnace is shipped ready 1 - Assembled Gas Furnace for installation in the upflow or horizontal position. The 1 - Bag assembly containing the following: furnace is shipped with the bottom panel in place. The 1 - Snap bushing bottom panel must be removed if the unit is to be installed 1 - Snap Plug...
  • Page 5 Building Codes When installed, this furnace must be electrically grounded according to local codes. In addition, in the United States, In the USA, installation of gas furnaces must conform with installation must conform with the current National local building codes. In the absence of local codes, units Electric Code, ANSI/NFPA No.

  • Page 6: General

    Use of Furnace as a Construction Heater NOTWITHSTANDING THE FOREGOING, INSTALLER IS RESPONSIBLE FOR CONFIRMING THAT THE USE Units may be used for heating of buildings or structures OF CONSTRUCTION HEAT IS CONSISTENT WITH under construction, if the following conditions are met to THE POLICIES AND CODES OF ALL REGULATING ensure proper operation.

  • Page 7: Combustion, Dilution & Ventilation Air

    of this information has been reprinted with permission from Combustion, Dilution & Ventilation Air the National Fuel Gas Code (ANSI-Z223.1/NFPA 54). This reprinted material is not the complete and official position If this unit is installed as a Non-Direct Vent Furnace, follow of ANSI on the referenced subject, which is represented the guidelines in this section.
  • Page 8 When the furnace is installed so that supply ducts carry a minimum free area of 1 square inch per 4,000 Btu (645 air circulated by the furnace to areas outside the space mm² per .59 kW) per hour of the total input rating of all containing the furnace, the return air must be handled by equipment in the enclosure (See Figure 6 and Figure 7).
  • Page 9 Roof Terminated Exhaust Pipe Inlet Air (Minimum 12 in.(305mm) Ventilation Furnace Above crawl Louvers space floor) (Crawl space) Coupling or *Intake Debris Screen Provided) 3 in. to 2 in. Transition (Field Provided) Figure 8. Equipment in Confined Space - All Air from * See Maximum Vent Lengths table Outside NOTE-The inlet and outlet air openings shall each have a free area...

  • Page 10: Installation

    Installation Units with 1/2 HP Blower Motor Setting Equipment WARNING Do not connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of Figure 11. the safety control devices, which could result in personal injury or death.
  • Page 11 Return Air Guidelines Return air can be brought in through the bottom or either WARNING side of the furnace installed in an upflow application. If the furnace is installed on a platform with bottom return, make Improper installation of the furnace can result in an airtight seal between the bottom of the furnace and the personal injury or death.
  • Page 12 FURNACE FRONT 23 (584) IF BASE 3−1/4 Overall IS USED (83) (Maximum) Minimum WITHOUT 11 (279) IAQ CABINET, INDOOR AIR A SINGLE Maximum 22−7/16 QUALITY Unit side return air RETURN AIR 14 (356) (570) CABINET Opening PLENUM Overall MUST AIR FLOW (Maximum) COVER BOTH UNIT AND...
  • Page 13 platform, as shown in Figure 20. A horizontal suspension Right-Hand Discharge kit (51W10) may be ordered from your distributor or use equivalent. Left End Right End NOTE: Heavy-gauge sheet metal straps may be used to Flow Flow 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.

  • Page 14: Filters

    Return Air - Horizontal Applications Return air can be brought in through the bottom or either side of the furnace. If a furnace with bottom return air is Return air may be brought in only through the end of a installed on a platform, make an airtight seal between the furnace installed in the horizontal position.
  • Page 15 Piping and Fittings Specifications IMPORTANT Schedule 40 PVC (Pipe) D1785 A96UH2E exhaust and intake connections are made Schedule 40 PVC (Cellular Core Pipe) F891 of PVC. Use PVC primer and solvent cement when using PVC vent pipe. When using ABS vent pipe, use Schedule 40 PVC (Fittings) D2466 transitional solvent cement to make connections to the...

  • Page 16: Venting

    STANDARD CONCENTRIC Outdoor Outdoor Flush 1-1/2" 2" 3" Vent Pipe Exhaust Exhaust Mount Concentric Concentric Concentric Model Dia. Accelerator Accelerator (in.) (Dia. X Length) (Dia. X Length) 71M80 or 69M29 or 60L46 or 1-1/2" x12" 2" x12" 51W11 +44W92++ +44W92++ 44W93+ 1-1/2 2-1/2"...
  • Page 17 WARNING 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:...
  • Page 18 Regardless of the diameter of pipe used, the standard roof Use the following steps to correctly size vent pipe diameter. 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 030, 045, it exits the termination.
  • Page 19 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 Model Model Model Model of 90° Elbows Used Standard Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 20 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 Model Model Model Model of 90° Elbows Used Concentric Termination Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 21 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 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number Model Model...
  • Page 22 TYPICAL EXHAUST PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS Pipe size determined in Table 5 2” 2” 2” 2” 3” 2” TRANSITION EXHAUST *2” 030/045/070 Only 1-1/2” DO NOT transition from smaller to larger TRANSITION pipe in horizontal runs 2”...
  • Page 23 Intake Piping See Figure 27 through Figure 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 the Combustion, Dilution &...
  • Page 24 The air intake piping must not terminate too close to TYPICAL AIR INTAKE PIPE CONNECTIONS the flooring or a platform. Ensure that the intake air UPFLOW NON-DIRECT VENT APPLICATIONS inlet will not be obstructed by loose insulation or other items that may clog the debris screen. Intake Debris If intake air is drawn from a ventilated attic (Figure...
  • Page 25 Roof Terminated Exhaust Pipe Conditioned Space Inlet Air (Minimum Exhaust 12 in.(305mm) Ventilation Pipe Furnace Above crawl Louvers Pipe Insulation space floor) (Crawl space) Intake Conditioned Pipe Unconditioned Space Space Coupling or Figure 33. Insulating Exhaust Pipe in an *Intake Debris Screen Provided) 3 in.
  • Page 26 General Guidelines for Vent Terminations NOTE: See Table 6 for maximum allowed exhaust pipe length without insulation in unconditioned space during In Non–Direct Vent applications, combustion air is taken winter design temperature below 32° F (0° C). If required, from indoors and the flue gases are discharged to the exhaust pipe should be insulated with 1/2”...
  • Page 27 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 in.
  • Page 28 Details of Intake and Exhaust Piping On field supplied terminations, a minimum distance between the end of the exhaust pipe and the end of Terminations for Direct Vent Installations the intake pipe without a termination elbow is 8” and a NOTE: In Direct Vent installations, combustion air is taken minimum distance of 6”...
  • Page 29 FIELD-PROVIDED 1-1/2” (38mm) accelerator REDUCER MAY BE REQUIRED provided on 71M80 & 44W92 TO ADAPT DIFFERENT VENT kits for -045 and -070 models PIPE SIZE TO TERMINATION OUTSIDE INTAKE WALL EXHAUST EXHAUST VENT VENT 12” (305mm) Min. INTAKE INTAKE CLAMP above grade or (Not Furnished) average snow...
  • Page 30 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 in.
  • Page 31 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 SIZE TERMINATION is preferred. Figure 44 through Figure 47 show typical PER EXHAUST PIPE terminations.
  • Page 32 Consult the vent tables for vent lengths and approved materials. Exhaust from Furnace To Termination From To Vent Furnace Termination 2” or 3” Sanitary Tee 1/2” PVC Drain Stub Exhaust from Furnace Drain Trap Assembly Rubber Boot (51W18) Drain Plug (15Z70) To Termination Drain Trap (assembled)
  • Page 33 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 34: Condensate Piping

    Condensate Piping CAUTION This unit is designed for either right or left side exit of Do not use copper tubing or existing copper condensate condensate piping in upflow applications. In horizontal lines for drain line. applications, the condensate trap must extend below the unit.
  • Page 35 *Piping from furnace must slope down a minimum of 1/4” per ft. toward trap. Figure 53. Condensate Trap Locations (Unit shown in upflow position with remote trap) Figure 54. Unit with Evaporator Coil IMPORTANT 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 36 *Piping from furnace must slope down a minimum of 1/4” per ft. toward trap. Figure 55. Evaporator Coil Using a Common Drain (Unit shown in horizontal right hand discharge position) Figure 56. Condensate Trap with Optional Overflow Figure 57. Evaporator Coil Using a Common Drain Switch *Piping from furnace must slope down a minimum of 1/4”...
  • Page 37 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 38: 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 39 Upflow Application Upflow Application Left Side Piping Right Side Piping (Standard) (Alternate) MANUAL MAIN SHUT-OFF VALVE MANUAL MAIN SHUT-OFF VALVE GROUND GROUND JOINT JOINT UNION UNION DRIP LEG Gas Valve Gas Valve FIELD PROVIDED AND INSTALLED DRIP LEG NOTE - BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Figure 61.
  • Page 40 Gas Pipe Capacity - FT³/HR (kL/HR) Nominal Length or Pipe - feet (m) Internal Iron Pipe Diameter Size - - inches inches (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480) (mm) (mm) .622 (12.7) (17.799) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87)

  • Page 41: Electrical

    The unit is equipped with a field makeup box. The makeup Electrical box may be moved to the right side of the furnace to facilitate installation. Seal unused openings on left side ELECTROSTATIC DISCHARGE (ESD) with plugs removed from right side. Secure the excess wire to the existing harness to protect it from damage.
  • Page 42 Electrical Wiring An unpowered, normally open (dry) set of contacts with a 1/4” spade terminal “HUM” are provided for humidifier connections and may be connected to 24V or 120V. WARNING Any humidifier rated up to one amp can be connected to these terminals.
  • Page 43 3/16” QUICK CONNECT TERMINALS THERMOSTAT CONNECTIONS (TB1) FLAME SENSE SIGNAL DS = DEHUMIDIFICATION SIGNAL HI Cool 24VAC W2 = HEAT DEMAND FROM 2ND STAGE T/STAT HI HEAT 24VAC W1 = HEAT DEMAND FROM 1ST STAGE T/STAT LO COOL 24VAC R = CLASS 2 VOLTAGE TO THERMOSTAT LO HEAT 24VAC G = MANUAL FAN FROM THERMOSTAT C = THERMOSTAT SIGNAL GROUND CONNECTED TO...
  • Page 44 Integrated Control DIP Switch Settings Indoor Blower Operation DIP Switch Settings -- Switches 3 and 4 -- Heating Mode Blower-Off Delay A96UH2E units are equipped with a two-stage integrated -- The blower-on delay of 30 seconds is not adjustable. control. This control manages ignition timing, heating The blower-off delay (time that the blower operates after mode fan off delays and indoor blower speeds based on the heating demand has been satisfied) can be adjusted...
  • Page 45 Field Wiring Applications With Conventional Thermostat DIP Switch Settings and On-Board Links DIP Switch 1 On Board Links Must Be Cut To Select Thermostat Thermostat Wiring Connections System Options Heating Stages 1 Heat / 1 Cool FURNACE OUTDOOR T'STAT TERM. STRIP UNIT NOTE - Use DIP switch 2 to set...
  • Page 46 Field Wiring Applications with Conventional Thermostat (Continued) DIP Switch Settings and On-Board Links DIP Switch 1 On Board Links Must Be Cut To Select Thermostat Thermostat Wiring Connections System Options Heating Stages 2 Heat / 2 Cool FURNACE OUTDOOR T'STAT TERM.
  • Page 47 Field Wiring Applications with Conventional Thermostat (Continued) DIP Switch Settings and On-Board Links DIP Switch 1 Thermostat On Board Links Must Be Cut To Select Wiring Connections Thermostat Heating System Options Stages Dual Fuel L7724U FURNACE HEAT PUMP T'STAT TERM. STRIP Single Stage Heat Pump CUT ON-BOARD LINK...
  • Page 48 Field Wiring Applications with Conventional Thermostat (Continued) DIP Switch Settings and On-Board Links DIP Switch 1 Wiring Connections Thermostat On Board Links Must Be Cut To Select Thermostat Heating System Options Stages Dual Fuel FURNACE L7742U HEAT PUMP TERM. STRIP T'STAT Single Stage Heat Pump...
  • Page 49 Figure 66. 507581-04 Issue 2128 Page 49 of 60...

  • Page 50: Blower Performance

    Blower Performance A96UH2E030B08 Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure in. w.g. Watts Watts Watts Watts Watts 0.00 1025 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 A96UH2E045B12 Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static...
  • Page 51 A96UH2E070B12 Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure in. w.g. Watts Watts Watts Watts Watts 0.00 1380 1305 1190 0.10 1360 1270 1180 0.20 1310 1250 1130 0.30 1275 1205 1100 0.40...
  • Page 52 Page 52 of 60 Issue 2128 507581-04...

  • Page 53: Unit Start-Up

    Allowable Heating Speeds Low Fire Heating Speeds High Fire Heating Speeds Model Yellow Blue Brown Black Yellow Blue Brown Black Factory Factory A96UH2E030B08S Allowed Allowed Allowed Allowed Allowed Setting Allowed Allowed Allowed Setting Factory Factory A96UH2E045B12S Allowed Allowed Allowed Allowed Setting Allowed Allowed...
  • Page 54 Turn OFF all electrical power to the unit. Turning Off Gas to Unit Set the thermostat to the lowest setting. This furnace is equipped with an ignition device which automatically lights the burners. Do not try to light the Turn off all electrical power to the unit if service is to burners by hand.
  • Page 55 If flame is not detected after first ignition trial, the For proper furnace operation the minimum gas supply ignition control will repeat steps 3 and 4 four more pressure is 4.5” w.c and the maximum gas supply pressure times before locking out the gas valve. The ignition is 10.5”...

  • Page 56: Other Unit Adjustments

    kit and pressure switch requirements at varying altitudes. Is pressure switch closed? Obstructed exhaust pipe The combustion air pressure switch is factory-set and will cause unit to shut off at pressure switch. Check requires no adjustment. termination for blockages. Obstructed pipe or termination may cause rollout switches to open.
  • Page 57 Electrical 15. Mark and remove wires from pressure switch. Remove pressure switch. Keep tubing attached to pressure Check all wiring for loose connections. switch. Check for the correct voltage at the furnace (furnace 16. Remove electrical junction box from the side of the operating).

  • Page 58: Planned Service

    36. Reinstall electrical junction box. Disconnect and label wires from rollout switch. 37. Reinstall the combustion air inducer and flexible no Disconnect and label flame sensor wire. hub connector. Reconnect the 2 pin plug to the wire Disconnect and label ground wire from burner/manifold harness.

  • Page 59: 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. Cabinet Parts Heating Parts •...
  • Page 60 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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