Allied 96G2DFE Installation Instructions Manual
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Allied 96G2DFE Installation Instructions Manual

Warm air gas furnace / downflow air
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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.
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
A Lennox International, Inc. Company
215 Metropolitan Drive
West Columbia, SC 29170
507582-04
INSTALLATION INSTRUCTIONS
A96DF2E & 96G2DFE
Warm Air Gas Furnace / Downflow Air
Discharge Direct Vent & Non-Direct Vent
This manual must be left with the homeowner for future reference.
WARNING
CAUTION
Save these instructions for future reference

Table of Contents

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 ...................................................................9
Filters .........................................................................12
Duct System ..............................................................12
Venting Practices .......................................................15
Condensate Piping ....................................................30
Gas Piping .................................................................33
Electrical ....................................................................35
Unit Start-Up ..............................................................46
Other Unit Adjustments..............................................49
Blower Performance ..................................................50
Service.......................................................................52
Planned Service ........................................................53
Repair Parts List ........................................................53
*P507582-04*
Issue 2220
(P) 507582-04
Page 1 of 54

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Summary of Contents for Allied 96G2DFE

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS A96DF2E & 96G2DFE Warm Air Gas Furnace / Downflow Air Discharge Direct Vent & Non-Direct Vent This manual must be left with the homeowner for future reference. 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.

  • Page 2: Unit Dimensions

    Unit Dimensions Model 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 2220 507582-04...

  • Page 3: Parts Arrangement

    Parts Arrangement Figure 1. 507582-04 Issue 2220 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 Use only the type of gas approved for use with this furnace. (or other means to control the flow of air) must adequately Refer to unit nameplate. prevent chilled air from entering the furnace. If the damper is manually operated, it must be equipped to prevent This unit is CSA International certified to ANSI Z21.47 and operation of either the heating or the cooling unit, unless it CSA 2.3 standards.

  • Page 6: General

    CAUTION INSTRUCTIONS VOIDS MANUFACTURER’S EQUIPMENT LIMITED WARRANTY. ALLIED These units should not be installed in areas normally DISCLAIMS ALL LIABILITY IN CONNECTION WITH subject to freezing temperatures. INSTALLER’S FAILURE TO FOLLOW THE ABOVE INSTALLATION INSTRUCTIONS. Page 6 of 54 Issue 2220...

  • Page 7: Combustion, Dilution & Ventilation Air

    Combustion, Dilution & Ventilation Air CAUTION If this unit is installed as a Non-Direct Vent Furnace, follow Do not install the furnace in a corrosive or contaminated the guidelines in this section. atmosphere. Meet all combustion and ventilation air requirements, as well as all local codes. NOTE: In Non-Direct Vent Installations, combustion air is taken from indoors and flue gases are discharged outdoors.
  • Page 8 Air from Inside If the confined space that houses the furnace adjoins a space categorized as unconfined, air can be brought in by providing two permanent openings between the two spaces. Each opening must have a minimum free area of 1 square inch (645 mm²) per 1,000 Btu (.29 kW) per hour of total input rating of all gas-fired equipment in the confined space.

  • Page 9: Installation

    opening required, it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and Roof Terminated grilles will have 60 to 75 percent free area. Louvers and Exhaust Pipe grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.
  • Page 10 Units with 1/2 HP Blower Motor Figure 13. Figure 11. The unit may be installed three ways in downflow applications: on non-combustible flooring, on combustible flooring using an additive base, or on a reverse-flow WARNING cooling coil cabinet. Do not drag the unit across the floor in the downflow position.
  • Page 11 *Front Back Sides 0† Figure 16. Vent After opening is cut, set the combustible flooring base Floor NC‡ into opening. * Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service Check fiberglass strips on the combustible flooring access.

  • Page 12: Filters

    Filters This unit is not equipped with a filter or rack. A field provided filter is required for the unit to operate properly. Table 3 lists recommended filter sizes. A filter must be in place whenever the unit is operating. Furnace Cabinet Width Filter Size 17-1/2”...
  • Page 13 Pipe & Fittings Specifications All pipe, fittings, primer and solvent cement must conform IMPORTANT with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM) standards. The exhaust and intake connections are made of PVC. The solvent shall be free flowing and contain no lumps, Use PVC primer and solvent cement when using PVC undissolved particles or any foreign matter that adversely vent pipe.
  • Page 14 Joint Cementing Procedure Canadian Applications Only All cementing of joints should be done according to the Pipe, fittings, primer and solvent cement used to vent specifications outlined in ASTM D 2855. (exhaust) this appliance must be certified to ULC S636 and supplied by a single manufacturer as part of an approved NOTE: A sheet metal screw may be used to secure the vent (exhaust) system.

  • Page 15: Venting Practices

    Inspect the venting system for proper size and Venting Practices horizontal pitch. Determine that there is no blockage, restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. Close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building.
  • Page 16 In some applications which permit the use of several it exits the termination. different sizes of vent pipe, a combination vent pipe may be used. Contact Allied Air Technical Service for assistance Minimum Vent Pipe Lengths in sizing vent pipe in these applications.
  • Page 17 Maximum Allowable Intake or Exhaust Vent Length (feet) Standard Termination at Elevation 0 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe Number of 90° Model Model Model Model Elbows Used Standard Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 18 Maximum Allowable Intake or Exhaust Vent Length (feet) Concentric Termination at Elevation 0 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe Number of 90° Model Model Model Model Elbows Used Concentric Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 19 Maximum Allowable Exhaust Vent Lengths 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 90° Model Model Model Model Elbows Used NOTE: Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation.
  • Page 20 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 21 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 22 Conditioned Space Exhaust Pipe Pipe Insulation Intake Conditioned Pipe Unconditioned Space Space Figure 27. Insulating Exhaust Pipe in an Unconditioned Space 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...
  • Page 23 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 24 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 25 Details of Intake and Exhaust Piping 3” (76MM) MIN. SIZE PER EXHAUST PIPE Inches (MM) Terminations for Direct Vent Installations TERMINATION SIZE REDUCTION TABLE NOTE: In Direct Vent installations, combustion air is taken UNCONDITIONED from outdoors and flue gases are discharged to outdoors. ATTIC SPACE 8”...
  • Page 26 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 27 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 28 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 closet installations, vertical termination through the roof is preferred. Figure 39 through Figure 42 show typical terminations.
  • Page 29 Exhaust from From To Vent Furnace Furnace Termination To Termination 2” or 3” Sanitary Tee 1/2” PVC Drain Stub Drain Trap Assembly Exhaust from Furnace Rubber Boot (51W18) Drain Plug (15Z70) Drain Trap (assembled) Clamp (51W18 Only) To Termination Figure 43. Kit 51W18 (USA) / 15Z70 (Canada) Parts Identification and Assembly * Kit 51W18 is shown.

  • Page 30: 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 31 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 32 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 33: 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 34 Left Side Piping AUTOMATIC MANUAL (Standard) MAIN SHUT-OFF GAS VALVE MANUAL (with manual VALVE AUTOMATIC MAIN SHUT-OFF shut-off valve) (With 1/8 in. NPT GAS VALVE VALVE Plugged Tap (with manual (With 1/8 in. NPT Shown) shut-off valve) Plugged Tap Shown) GROUND JOINT UNION...

  • Page 35: Electrical

    The unit is equipped with a field makeup box. The makeup Electrical box may be installed on the exterior of the right side of the furnace to facilitate installation. Seal unused openings on left side with plugs removed from right side. Secure ELECTROSTATIC DISCHARGE (ESD) the excess wire to the existing harness to protect it from Precautions and Procedures...
  • Page 36 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 37 Switch 3 Switch 4 (Seconds) Integrated Control DIP Switch Settings A96DF2E & 96G2DFE units are equipped with a two- 90 (Factory) stage integrated control. This control manages ignition timing, heating mode fan off delays and indoor blower speeds based on selections made using the control dip switches and jumpers.
  • Page 38 Figure 56. Wiring Diagram with Resideo/Honeywell Integrated Furnace Control 103132-xx Page 38 of 54 Issue 2220 507582-04...
  • Page 39 120V ACC UNIT HI COOL LOW COOL HIGH HEAT LOW HEAT PARK PRIMARY COMBUSTION AIR (IF USED) BLACK BROWN BLUE YELLOW INDUCER MOTOR DF045-12 LIMIT VALVE DF070-16 BLACK BLUE BROWN YELLOW DF090-16 BLACK BLUE BROWN YELLOW S102 BURNERS DF110-20 BLUE BROWN BLACK YELLOW...
  • Page 40 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 •...
  • Page 41 UTEC TWO-STAGE CONSTANT TORQUE INTEGRATED FURNACE CONTROL Line Voltage Ignitor and Combustion Accessories Humidifier Air Inducer Neutrals ECM DRIVE - 24VAC Line Voltage Flame Sense On Board Links Thermostat Connections 3/16” QUICK CONNECT TERMINALS THERMOSTAT CONNECTIONS HI COOL (24VAC) DS= Dehumidification signal LO COOL (24VAC) W2= Heat demand from 2 nd stage Tstat HI HEAT (24VAC)
  • Page 42 Table 15A. Field Wiring Applications with Conventional Thermostat Page 42 of 54 Issue 2220 507582-04...
  • Page 43 Table 15B. Field Wiring Applications with Conventional Thermostat (Continued) 507582-04 Issue 2220 Page 43 of 54...
  • Page 44 * Connect W1 to W1 ONLY if using defrost tempering kit 67M41 NOTE - Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the integrated control. Table 15C. Field Wiring Applications with Conventional Thermostat (Continued) Page 44 of 54 Issue 2220 507582-04...
  • Page 45 * Connect W1 to W1 ONLY if using defrost tempering kit 67M41 NOTE - Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the integrated control. Table 15D. Field Wiring Applications with Conventional Thermostat (Continued) 507582-04 Issue 2220 Page 45 of 54...

  • Page 46: Unit Start-Up

    Testing for Proper Venting and Sufficient Use the flame of a match or candle to test for spillage of flue gases at the draft hood relief opening after 5 Combustion Air for Non-Direct Vent Applications minutes of main burner operation. If improper venting is observed during any of the WARNING above tests, the venting system must be corrected or...
  • Page 47 BEFORE LIGHTING the unit, smell all around the furnace Wait five minutes to clear out any gas. If you then area for gas. Be sure to smell next to the floor because smell gas, STOP! Immediately call your gas supplier some gas is heavier than air and will settle on the floor.
  • Page 48 Proper Combustion Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of Furnace should operate minimum 15 minutes with correct gas through the meter. (Two revolutions assures a more manifold pressure and gas flow rate before checking accurate time.) Divide by two and compare to time in Table combustion.

  • Page 49: Other Unit Adjustments

    Thermostat Heat Anticipation Other Unit Adjustments Set the heat anticipator setting (if adjustable) according to the amp draw listed on the wiring diagram that is attached to the unit. Primary Limit The primary limit is located on the heating compartment Electrical vestibule panel.

  • Page 50: Blower Performance

    Blower Performance A96DF2E/96G2DFE 045B*12 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.g. 0.00 1395 1290 1190 0.10 1375 1245 1140 0.20 1320 1215 1090 0.30...
  • Page 51 A96DF2E/96G2DFE 110C*20 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.g. 0.00 2285 1990 1805 1685 1480 0.10 2250 1965 1775 1630 1430 0.20...

  • Page 52: 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 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 dangerous operation, serious injury, death or property...

  • 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. Example: A95DF2V045B12S-01. 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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A96df2e045-12070-16090-20110-20

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