Allied A96UH1E Installation Instructions Manual
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Allied A96UH1E Installation Instructions Manual

Warm air gas furnace upflow/horizontal left and right air discharge
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Upflow/Horizontal Left and Right 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.
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
215 Metropolitan Drive
West Columbia, SC 29170
508297-01
INSTALLATION INSTRUCTIONS
Warm Air Gas Furnace
This manual must be left with the homeowner for future reference.
WARNING
CAUTION
A96UH1E
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 .........................................................................13
Duct System ..............................................................13
Venting Practices .......................................................16
Condensate Piping ....................................................34
Gas Piping .................................................................38
Electrical ....................................................................41
Unit Start-Up ..............................................................45
Air for Non-Direct Vent Applications ..........................49
Other Unit Adjustments..............................................50
Blower Performance ..................................................51
Service.......................................................................54
Planned Service ........................................................56
Repair Parts List ........................................................56
Issue 2219

Table of Contents

*P508297-01*
(P) 508297-01
Page 1 of 57

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Summary of Contents for Allied A96UH1E

  • Page 1: Table Of Contents

    Be Service...............54 careful when you handle this equipment. Planned Service ............56 Repair Parts List ............56 Manufactured By *P508297-01* Allied Air Enterprises LLC 215 Metropolitan Drive (P) 508297-01 West Columbia, SC 29170 508297-01 Issue 2219 Page 1 of 57...

  • Page 2: Unit Dimensions

    Unit Dimensions NOTE - C*20 and D*20 (5 Ton) size units installed in upflow applications that require air volumes of 1800 cfm (850 L/s) or greater Top View must have one of the following: Single side return air with transition, to accommodate 20 x 25 x 1 Exhaust Air in.

  • Page 3: Parts Arrangement

    Parts Arrangement TOP CAP BURNER BOX ASSEMBLY HEAT EXCHANGER ASSEMBLY GAS VALVE FLUE COLLAR COMBUSTION AIR INDUCER CABINET BLOWER ASSEMBLY COMBUSTION AIR PRESSURE PROVE SWITCH CONTROL BOX COLD END HEADER BOX Figure 1. 508297-01 Issue 2219 Page 3 of 57...

  • Page 4: Gas Furnace

    1 - Snap bushing in horizontal or upflow applications with bottom return air. 1 - Snap Plug The A96UH1E can be installed as either a Direct Vent or a 1 - Wire tie Non-Direct Vent gas central furnace. 1 - Condensate trap...
  • Page 5 In order to ensure proper unit operation in non-direct vent applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standard. Installation Locations This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the table in Figure 13 and Figure 18.

  • 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 If this unit is installed as a Non-Direct Vent Furnace, follow INSTALLATION INSTRUCTIONS. the guidelines in this section.
  • Page 7 The requirements for providing air for combustion and ventilation depend largely on whether the furnace is WARNING installed in an unconfined or a confined space. Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause Unconfined Space excess water in the heat exchanger resulting in rusting An unconfined space is an area such as a basement and premature heat exchanger failure.
  • 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 Figure 8.

  • Page 9: Installation

    Shipping Bolt Removal Units with 1/2 hp & 3/4 hp blower motor are equipped WARNING with three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic If this unit is being installed in an application with washer (rather than the rubber mounting grommet used combustion air coming in from a space serviced by an with a flexible mounting leg).
  • Page 10 Tilt the unit slightly (Max. 1/2”) from back to front to aid in the draining of the heat exchanger. Unit must be level side-to-side in all applications. Figure 12. Setting Equipment WARNING Improper installation of the furnace can result in personal injury or death.
  • Page 11 Return Air Guidelines Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the 20” X 25” X 1” furnace is installed on a platform with bottom return, make (508mm X 635mm X 25mm) an airtight seal between the bottom of the furnace and the Air Filter...
  • Page 12 Right-Hand Discharge Left End Right End Flow Flow Bottom (Floor)** Left-Hand Discharge Left End Right End Flow Flow Bottom (Floor)** Figure 16. Removing the Bottom Panel Top/Plenum 1 in. (25 mm) Removing the Bottom Panel * Front Remove the two screws that secure the bottom cap to the Back furnace.

  • Page 13: Filters

    NOTE: Heavy-gauge sheet metal straps may be used to Filters 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. The straps must not This unit is not equipped with a filter or rack.
  • Page 14 D2665 Pipe & Fittings) ASTM PRIMER & SOLVENT CEMENT IMPORTANT SPECIFICATION A96UH1E exhaust and intake connections are made PVC & CPVC Primer F656 of PVC. Use PVC primer and solvent cement when PVC Solvent Cement D2564 using PVC vent pipe. When using ABS vent pipe, use...
  • Page 15 Standard Concentric Flush Mount Kit Wall Kit 1-1/2 inch 2 inch 3 inch Vent Pipe Dia. Field (in.) 2 inch 3 inch Fabricated 71M80 (US) 69M29 (US) 60L46 (US) 51W11 (US) 44W92 44W92 444W93 22G44 (US) 44J40 (US) 51W12 (CA) (CA) (CA) (CA)

  • Page 16: Venting Practices

    Promptly apply solvent cement to end of pipe and Conduct the following test while each appliance is operating inside socket surface of fitting. Cement should be and the other appliances (which are not operating) remain applied lightly but uniformly to inside of socket. Take connected to the common venting system.
  • Page 17 Contact Allied Air Technical Service for assistance is probably oversized for the single water heater or in sizing vent pipe in these applications.
  • Page 18 IMPORTANT Do not use screens or perforated metal in exhaust or 030, 045, Furnace capacity? 070, 090, intake terminations. Doing so will cause freeze-ups and 110, 135 may block the terminations. Capacity Min. Vent Length* 15 ft or 5 ft plus 2 elbows or Standard or 030, 045, 070, 090, 110, 135 Which termination?
  • Page 19 Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 2,000 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number Capacity Capacity Capacity Capacity of 90° Elbows 030/ 030/ 030/ 030 045 070 090 110 135 070 090 110 135 070 090 110 135 070 090 110 135...
  • Page 20 Maximum Allowable Intake or Exhaust Vent Length in Feet Concentric Termination at Elevation 0 - 2,000 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number Capacity Capacity Capacity Capacity of 90° Elbows 030/ 030/ 030/ 030 045 070 090 110 135 070 090 110 135 070 090 110 135 070 090 110 135...
  • 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 - 2,000 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number Capacity Capacity...
  • 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 pipe in horizontal runs TRANSITION of exhaust pipe.
  • Page 23 TYPICAL INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS 2” 3” Pipe size determined in Table 5 TRANSITION INTAKE *2” 2” 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 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 NOTE: See Table 6A through Table 6B for maximum allowed exhaust pipe length without insulation in unconditioned space during winter design temperatures Roof Terminated Exhaust Pipe below 32°F (0°C). If required exhaust pipe should be insulated with 1/2” (13 mm) Armaflex or equivalent. In extreme cold climate areas, 3/4”...
  • Page 26 Maximum Allowable Exhaust Vent Pipe Length (in ft.) without Insulation in Unconditioned Space For Winter Design Temperatures Single - Stage High Efficiency Furnace Winter Design Unit Input Size Vent Pipe Temperatures Diameter ºF (ºC) 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in.
  • Page 27 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 in.
  • Page 28 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 29 Details of Intake and Exhaust Piping 3” (76MM) MIN. SIZE PER EXHAUST PIPE Inches (MM) Terminations for Direct Vent Installations TERMINATION SIZE NOTE: In Direct Vent installations, combustion air is taken REDUCTION TABLE from outdoors and flue gases are discharged to outdoors. UNCONDITIONED ATTIC SPACE 8”...
  • Page 30 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 31 On field supplied terminations, a minimum distance 1 1/2” (38mm) accelerator between the end of the exhaust pipe and the end of provided on 71M80 & 44W92 EXHAUST kits for -045 and -070 models the intake pipe without a termination elbow is 8” and a VENT minimum distance of 6”...
  • Page 32 Details of Exhaust Piping Terminations for Non- If exhaust piping must be run up a sidewall to position above snow accumulation or other obstructions, piping Direct Vent Applications must be supported every 24” (610 mm) as shown in Exhaust pipes may be routed either horizontally through Figure 47.
  • Page 33 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 34: Condensate Piping

    Figure 55 and Figure 56 show the furnace and Condensate Piping evaporator coil using a separate drain. If necessary the condensate line from the furnace and evaporator This unit is designed for either right or left side exit of coil can drain together. See Figure 57 and Figure 58. condensate piping in upflow applications.
  • 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. Condensate Trap with Optional Overflow Switch WARNING 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. Condensate Trap Locations Figure 56. Unit with Cooling Coil Using Separate Figure 57. Evaporator Coil Using a Common Drain Drain Piping from furnace and evaporator coil must slope down a minimum 1/4” per ft. toward trap. Figure 58.
  • Page 37 Figure 59. Trap / Drain Assembly Using 1/2” PVC or 3/4” PVC 508297-01 Issue 2219 Page 37 of 57...

  • 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 AUTOMATIC Left Side Piping Right Side Piping GAS VALVE (Standard) (with manual (Alternate) shut-off valve) 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...
  • Page 40 Gas Pipe Capacity - FT³/HR (kL/HR) Nominal Length of 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 with plugs removed from right side. Secure the excess wire ELECTROSTATIC DISCHARGE (ESD) to the existing harness to protect it from damage.
  • Page 42 external relay. See Figure 68 or Figure 69for control board Install the room thermostat according to the instructions configuration. This terminal is energized in the heating provided with the thermostat. See Figure 65 for thermostat mode when the combustion air inducer is operating. designations.
  • Page 43 030*B08 045*B12 070*B12 090*C16 110*C20 135*D20 Figure 67. Typical Wiring Diagram 508297-01 Issue 2219 Page 43 of 57...
  • Page 44 Red LED Flash Code Diagnostic Codes / Status of Furnace 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 Improper earth ground 3 Flashes...

  • Page 45: Unit Start-Up

    1/4” Quick Connect Terminal Designations 120V HUM Power for Humidifier (120VAC) LINE Incoming Power Line (120VAC) XFMR Transformer Primary (120VAC) CIRC Indoor Blower Motor (120VAC) Electronic Air Cleaner (120VAC) HUM24 Power For Humidifier (24VAC) NEUTRALS (5) Neutral 3/16” Quick Connect Terminal Designations Cool Speed From Indoor Blower Motor COOL (24VAC)
  • Page 46 Set the thermostat to the lowest setting. Turn OFF all electrical power to the unit. CAUTION This furnace is equipped with an ignition device which Before attempting perform service automatically lights the burners. Do not try to light the maintenance, turn the electrical power to unit OFF at burners by hand.
  • Page 47 Is the filter dirty or plugged? Dirty or plugged filters will Supply Pressure Measurement cause the limit control to shut the unit off. When testing supply gas pressure, use the 1/8” N.P.T. Is gas turned on at the meter? plugged tap or pressure post located on the gas valve to facilitate test gauge connection.
  • Page 48 Manifold and Supply Line Pressure 0-10,000 ft. Manifold Pressure in. w.g. Supply Line Pressure Capacity in. w.g. 0-10,000 ft. 0-4500 ft. 4501-5500 ft. 5501-6500 ft. 6501-7500 ft. 7501-10000 ft. Natural 13.0 All Sizes LP / 10.0 10.0 11.0 13.0 Propane NOTE: A natural to LP propane gas changeover kit is necessary to convert this unit.

  • Page 49: 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 50: Other Unit Adjustments

    SW2-1 SW2-2 Other Unit Adjustments Primary Limit The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no adjustment. * Factory setting Table 18. Blower Delay Select Flame Rollout Switches (Two) These manually reset switches are located on the front of the burner box.

  • Page 51: Blower Performance

    Disconnect existing speed tap at control board speed Re-secure blower access panel. terminal. Turn on electrical power to furnace. NOTE: Termination of any unused motor leads must Recheck temperature rise. be insulated. Place unused blower speed tap on integrated control Electronic Ignition “PARK”...
  • Page 52 A96UH1E070B12 Performance (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium - High Medium Medium - Low Pressure Watts Watts Watts Watts Watts in. w.c. 0.00 1445 1315 1215 0.10 1445 1275 1170 0.20 1415 1240 1125 0.30...
  • Page 53 A96UH1E135D20 Performance (Less Filter) Air Volume / Watts at Various Blower Speeds External Bottom Return Air, Side Return Air with Optional Return Air Base, Return Air from Single Side Return Air - Air volumes in bold require field fabricated transition to Static Both Sides or Return Air from Bottom and One Side.

  • Page 54: Service

    Winterizing and Condensate Trap Care Service 1. Turn off power to the furnace. Have a shallow pan ready to empty condensate water. Remove the clean out cap from the condensate trap WARNING and empty water. Inspect the trap then reinstall the clean out cap.
  • Page 55 19. Remove the primary limit from the vestibule panel. 41. Reconnect flame rollout switch wires. 20. Remove top cap screws to allow top cap to be 42. Reconnect sensor wire and reconnect 2 pin plug from tilted upward to allow clearance for removing heat ignitor.

  • Page 56: 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 57 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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