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Allied 95G2DFV 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
507052-05
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
95G2DFV
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 1922
CAUTION
*P507052-05*
(P) 507052-05
Page 1 of 54

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  • Page 1: Table Of Contents

    (or careful when you handle this equipment. equivalent), service agency or the gas supplier. Manufactured By *P507052-05* Allied Air Enterprises LLC A Lennox International, Inc. Company 215 Metropolitan Drive (P) 507052-05 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 54 Issue 1922 507052-05...

  • Page 3: Parts Arrangement

    Parts Arrangement Blower Assembly Control Box Access Panel Combustion Air Inducer Gas Valve Burner Box Assembly Figure 1. 507052-05 Issue 1922 Page 3 of 54...

  • 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 10).
  • 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 per 1.17kW) per hour of the total input of all equipment in the 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

    during assembly (but not after pipe is fully inserted) to distribute cement evenly. Do not turn ABS or cellular WARNING core pipe. CARBON MONOXIDE POISONING HAZARD NOTE: Assembly should be completed within 20 seconds after last application of cement. Hammer Failure to follow the steps outlined below for each blows should not be used when inserting pipe.
  • 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. 045, 070, Furnace capacity? 090, 110 Standard or Which termination? Concentric? See Table 5 Which needs most Intake or elbows? Exhaust? How many? 2”, 2-1/2” Desired pipe size? or 3” What is the altitude? Use Table 7 to find max pipe length.
  • Page 18 95G2DFV 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 Capacity Capacity Capacity Capacity of 90° Elbows Used Standard Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 19 95G2DFV 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 Capacity Capacity Capacity Capacity of 90° Elbows Used Concentric Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 20 95G2DFV 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 Capacity Capacity Capacity Capacity of 90°...
  • Page 21 Figure 24. Typical Intake Pipe Connections (Direct Vent Applications) Intake Piping If intake air is drawn from a ventilated crawl space (Figure 26) or ventilated attic (Figure 25) the exhaust This furnace may be installed in either direct vent or non- vent length must not exceed those listed in Table 7C.
  • 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 2 in. 32 to 21 (0 to -6) 2-1/2 in. 3 in. 2 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 exhaust back into intake pipe. Terminations for Direct Vent Installations NOTE: In Direct Vent installations, combustion air is taken 3” (76MM) MIN. from outdoors and flue gases are discharged to outdoors. SIZE PER EXHAUST PIPE Inches (MM) TERMINATION SIZE...
  • Page 27 Figure 33. Flush Mount Side Wall Termination On field supplied terminations, a minimum distance between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8” and a minimum distance of 6” with a termination elbow. See Figure 38.
  • Page 28 Figure 36. Optional Vent Termination for Multiple Unit Installation of Direct Vent Wall Termination Kit Figure 34. Direct Vent Concentric Rooftop Termination Figure 35. Direct Vent Concentric Wall Termination Figure 37. Direct Vent Application Using Existing Chimney Page 28 of 54 Issue 1922 507052-05...
  • Page 29 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 30 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 31 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 32: 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 33 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 34 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 35: 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 36 Left Side Piping MANUAL AUTOMATIC (Standard) GAS VALVE MAIN SHUT-OFF MANUAL VALVE AUTOMATIC (with manual MAIN SHUT-OFF shut-off valve) (With 1/8 in. NPT GAS VALVE VALVE (with manual Plugged Tap (With 1/8 in. NPT Shown) shut-off valve) Plugged Tap Shown) GROUND JOINT UNION...

  • Page 37: 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 38 (95G2DFV). To activate this option, move the jumper pin (see Figure 56) to desired setting (5 minutes or 10 •...
  • Page 39 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 40 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 41 5 seconds before releasing. High Heat State LED On 95G2DFV models, a green LED is provided on the control board to indicate high heat state (see Table 13). 507052-05...
  • Page 42 Figure 58. Typical Field Wiring Diagram Page 42 of 54 Issue 1922 507052-05...
  • Page 43 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 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” 1015 1210 High Fire Normal 1070 35 - 65 1000 1110 Low Fire Normal 1055 20 - 50 95G2DF045BV12 Cooling CFM @ 0 - 0.8”...
  • Page 49 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 50 Allowable Heating Speeds Model Number Speed Adjust Setting "D" Setting "C" Setting "B" Setting "A" +10% Allowed Allowed Allowed Not Allowed 95G2DF045BV12 Norm Allowed Allowed Factory Setting Not Allowed -10% Allowed Allowed Allowed Not Allowed +10% Allowed Allowed Allowed Allowed 95G2DF070BV16 Norm Allowed...

  • Page 51: 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 HAZARD. Have a shallow pan ready to empty condensate water. Remove the clean out cap from the condensate trap Failure to follow safety warnings exactly could result in and empty water.
  • Page 52 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 53: 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 54 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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