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Lennox A96DFMV Installation Instructions Manual

Warm air gas furnace downflow air discharge
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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
Gas Furnace ................................................................. 4
Shipping and Packing List ............................................ 4
Safety Information ......................................................... 4
General ......................................................................... 6
Setting Equipment ........................................................ 6
Filters ............................................................................ 9
Duct System .................................................................. 9
Pipe and Fittings Specifications .................................. 10
Joint Cementing Procedure ........................................ 11
Venting Practices ........................................................ 12
Vent Piping Guidelines ................................................ 12
Gas Piping .................................................................. 20
*506552-01*
506552-01
INSTALLATION INSTRUCTIONS
A96DFMV
Warm Air Gas Furnace
Downflow Air Discharge
This manual must be left with the homeowner for future reference.
CAUTION

TABLE OF CONTENTS

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.
Electrical ..................................................................... 22
Integrated Control ....................................................... 29
Blower Motor Performance ......................................... 30
Unit Start Up ................................................................ 35
Gas Pressure Measurement ....................................... 36
High Altitude Information ............................................. 36
Proper Combustion ..................................................... 36
Other Unit Adjustments ............................................... 37
Heating Sequence of Operation ................................. 38
Service ........................................................................ 40
Planned Service .......................................................... 42
Integrated Control Diagnostic Codes .......................... 43
Configuring Unit Size Codes ....................................... 44
Troubleshooting .......................................................... 45
Repair Parts List ......................................................... 51
Allied Air Enterprises, Inc.
A Lennox International, Inc. Company
Issue 1034
WARNING
Manufactured By
215 Metropolitan Drive
West Columbia, SC 29170
Page 1 of 52

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  • Page 1: Table Of Contents

    Vent Piping Guidelines ..........12 Troubleshooting ............45 Gas Piping ..............20 Repair Parts List ............51 Manufactured By *506552-01* Allied Air Enterprises, Inc. A Lennox International, Inc. Company 215 Metropolitan Drive West Columbia, SC 29170 506552-01 Issue 1034 Page 1 of 52...

  • Page 2: Unit Dimensions

    Unit Dimensions - inches (mm) SIDE VIEW FRONT VIEW Model Number A96DFMV070B12S 17-1/2 16-3/8 7-5/8 A96DFMV090C12S A96DFMV090C16S 19-1/2 9-3/8 19-7/8 A96DFMV090C20S A96DFMV110C20S Page 2 of 52 Issue 1034 506552-01...

  • Page 3: Parts Arrangement

    A96DFMV Exploded View Figure 1 506552-01 Issue 1034 Page 3 of 52...

  • Page 4: Gas Furnace

    A96DFMV Gas Furnace Safety Information The A96DFMV Category IV gas furnace is equipped with a variable capacity, varable speed integrated control. Each DANGER A96DFMV is shipped ready for installation in the Downflow air discharge position. DANGER OF EXPLOSION! The furnace is equipped for installation in natural gas There are circumstances in which odorant used with LP/ applications only.

  • Page 5: Use Of Furnace As A Construction Heater

    CAUTION This A96DFMV furnace must be installed so that its electrical Do Not set thermostat below 60° F (16° C) in heating components are protected from water. mode. Setting thermostat below 60° F (16° C) reduces Installed in Combination with a Cooling Coil the number of heating cycles.

  • Page 6: General

    • Air filters must be replaced upon construction completion. In addition to the requirements outlined previously, the • The input rate and temperature rise must be set per the following general recommendations should be considered furnace rating plate. when installing one of these furnaces: •...
  • Page 7 NOTE: The 1/2 hp blower motor used in this unit is equipped The unit may be installed three ways in downflow with three flexible legs and one rigid leg. The rigid leg is applications: on non-combustible flooring, on combustible equipped with a shipping bolt and a flat white plastic washer flooring using a base, or on a reverse flow cooling coil (rather than the rubber mounting grommet used with a flexible cabinet.
  • Page 8 Non- Combustible Floor Opening Size NOTE: Floor opening dimensions listed are 1/4 inch (6 mm) larger than the unit opening. See dimension drawing on page 2. Table 1 Figure 9 2. After opening is cut, set combustible flooring base into opening.

  • Page 9: Filters

    Figure 12 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 size. Figure 10 A filter must be in place whenever the unit is operating. Return Air Opening - Downflow Units Return air may be brought in only through the top opening of a furnace installed in the downflow position.

  • Page 10: Pipe And Fittings Specifications

    Pipe & Fittings Specifications CAUTION All pipe, fittings, primer and solvent cement must conform with American National Standard Institute and the American Solvent cements for plastic pipe are flammable liquids Society for Testing and Materials (ANSI/ASTM) standards. and should be kept away from all sources of ignition. The solvent shall be free flowing and contain no lumps, Do not use excessive amounts of solvent cement when undissolved particles or any foreign matter that adversely...

  • Page 11: Joint Cementing Procedure

    Outdoor Termination Kits Usage * Requires field provided and instal/ed 1-1/2" exhaust accelerator. ** Kit 51W11 includes a 1-1/2" accelerator which must be used for all 2" and 2-1/2" PVC installations. † Termination kits 44W92, 44W93, 30G28 and 81J20 approved for use in Canadian installations. ††...

  • Page 12: Venting Practices

    Venting Practices 1. In areas where piping penetrates joists or interior walls, hole must be large enough to allow clearance on all sides Piping Suspension Guidelines of pipe through center of hole using a hanger. 2. When furnace is installed in a residence where unit is shut down for an extended period of time, such as a vacation home, make provisions for draining condensate collection trap and lines.
  • Page 13 NOTE: The exhaust collar on all models is sized to accommodate 2" Schedule 40 vent pipe. Contact the Technical Services Department for more information concerning sizing of vent systems which include multiple pipe sizes. NOTE: All horizontal runs of exhaust pipe must slope back toward unit.
  • Page 14 MAXIMUM ALLOWABLE VENT LENGTH Table 7 Page 14 of 52 Issue 1034 506552-01...
  • Page 15 TYPICAL EXHAUST PIPE CONNECTIONS AND CONDENSATE TRAP INSTALLATION Figure 16 TYPICAL AIR INTAKE PIPE CONNECTIONS Figure 17 506552-01 Issue 1034 Page 15 of 52...
  • Page 16 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA Figure 18 Page 16 of 52 Issue 1034 506552-01...
  • Page 17 Details of Intake and Exhaust Piping Terminations for Direct Vent Installations FIELD SUPPLIED WALL TERMINATION NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors. Intake and exhaust pipes may be routed either horizontally through and outside wall or vertically through the roof.
  • Page 18 EXHAUST PIPE TERMINATION SIZE REDUCTION FIELD SUPPLIED WALL TERMINATION Table 8 5. On field supplied terminations for sidewall exit, exhaust piping may extend a maximum of 12 inches (305 mm) for 2” PVC and 20 inches (508 mm) for 3” (76 mm) PVC beyond the outside wall.
  • Page 19 3. Install drain trap using appropriate PVC fittings, glue all DIRECT VENT APPLICATION joints. Glue the provided drain trap as shown in Figure USING EXISTING CHIMNEY 26. Route the condensate line to an open drain. 4. If unit will be started immediately upon completion of installation, prime trap per procedure outlined in Unit Start-Up section.

  • Page 20: Gas Piping

    4. Piping should be sloped 1/4 inch per 15 feet (6mm per CAUTION 5.6m) upward toward the gas meter from the furnace. The piping must be supported at proper intervals, every A separate drain line must be run to the drain from the 8 to 10 feet (2.44 to 3.05m), using suitable hangers or condensate trap.
  • Page 21 NOTE: BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Figure 29 Removal of the Furnace from Common Vent 3. Close all building doors and windows and all doors between the space in which the appliances remaining In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances, connected to the common venting system are located the venting system is likely to be too large to properly vent...

  • Page 22: Electrical

    GAS PIPE CAPACITY - FT³/HR (kL/HR) Table 9 Electrical EXTERIOR MAKE-UP BOX ELECTROSTATIC DISCHARGE (ESD) (FIELD INSTALLED RIGHT SIDE) Precautions and Procedures CAUTION Electrostatic discharge can affect electronic components. Take precautions during furnace installation and service to protect the furnace’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the furnace, the control and the technician at the same electrostatic potential.
  • Page 23 NOTE: Unit nameplate states maximum current draw. See 10. Install the room thermostat according to the instructions table for maximum over current protection. provided with the thermostat. See Table 11 for thermostat connections. If the furnace is being matched with a heat pump, refer to the instruction packaged with the dual fuel thermostat.
  • Page 24 • Generator Use - Voltage Requirements The furnace integrated control requires both polarity and The following requirements must be kept in mind when proper ground. Both polarity and proper grounding specifying a generator for use with this equipment: should be checked before attempting to operate the furnace on either permanent or temporary power.
  • Page 25 Field Wiring Connections for Non-Communicating Thermostat Applications * “R” required on some units. Table 11 506552-01 Issue 1034 Page 25 of 52...
  • Page 26 Field Wiring Connections for Non-Communicating Thermostat Applications (Continued) * “R” required on some units. Table 11 Page 26 of 52 Issue 1034 506552-01...
  • Page 27 Low Voltage Field Wiring Single Stage 2 Stage Table 11 506552-01 Issue 1034 Page 27 of 52...
  • Page 28 TYPICAL WIRING DIAGRAM Figure 33 Page 28 of 52 Issue 1034 506552-01...

  • Page 29: Integrated Control

    INTEGRATED CONTROL Figure 34 506552-01 Issue 1034 Page 29 of 52...

  • Page 30: Blower Motor Performance

    THERMOSTAT SELECTION SWITCH SETTINGS Table 12 The blower OFF delay affects comfort and is adjustable to The units are equipped with an integrated control. This satisfy individual applications. Adjust the blower OFF delay control manages ignition timing, combustion air inducer speed, heating mode fan off delays and indoor blower speeds to achieve a supply air temperature between 90°...
  • Page 31 Switches 8 and 9 - Cooling Mode Blower Speed- Cooling Mode Blower Speed Ramping The unit is shipped from the factory with the DIP switches positioned for high speed (4) indoor blower motor operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings.
  • Page 32 Switches 14 through 19 - Heating Mode Blower Speed Diagnostic LED (Figure 34) These switches are factory set at the OFF position which The seven segment diagnostic LED displays operating provides 100% of normal speed during HIGH HEAT demand, status, target airflow, error codes and other information. The 70% of normal speed during MIDRANGE HEAT demand table on page 43 lists diagnostic LED codes.
  • Page 33 COOLING OPERATING SEQUENCE A96DFMV and Single Stage Outdoor Unit Table 19 506552-01 Issue 1034 Page 33 of 52...
  • Page 34 COOLING OPERATING SEQUENCE A96DFMV and Two Stage Outdoor Unit Table 20 Page 34 of 52 Issue 1034 506552-01...

  • Page 35: Unit Start Up

    Unit Start Up BEFORE PLACING THE UNIT INTO OPERATION Smell all around the furnace area for gas. Be sure to smell FOR YOUR SAFETY READ BEFORE OPERATING next to the floor because some gas is heavier than air and will settle on the floor. WARNING The gas valve on these units are equipped with a gas control switch.

  • Page 36: Gas Pressure Measurement

    9. Replace the access panel. NOTE: To obtain accurate reading, shut off all other gas 10. Turn on all electrical power to the unit. appliances connected to meter. 11. Set the thermostat to desired setting. Supply Pressure Measurement NOTE: When unit is initially started, steps 1 through 11 A threaded plug on the inlet side of the gas valve provides may need to be repeated to purge air from gas line.

  • Page 37: Other Unit Adjustments

    Conversion Kit Requirements and Manifold Test Pressures NOTE: The values given in table are measurements only. The gas valve should not be adjusted. Table 24 Pressure Switches (Two) Manifold Pressure Measurement To correctly measure manifold pressure, the differential The pressure switches are located on the cold end header pressure between the positive gas manifold and the negative box.

  • Page 38: Heating Sequence Of Operation

    Heating Sequence of Operation 6. At the end of the recognition delay and on all subsequent The integrated control initiates a pressure switch calibration calls for heat in the same heating cycle, the intergrated at the initial unit start-up on a call for heat. The ignition control energizes the combustion air inducer at high control will also initiate a calibration any time main power is speed.
  • Page 39 5. If second-stage heat is required, the thermostat second 2. Once the control receives a signal that the low fire stage heat contacts close and send a signal to the pressure switch has closed, the combustion air inducer integrated control. The integrated control either begins a 15 second prepurge at the ignition speed.

  • Page 40: Service

    Service 3. Check amp-draw on the blower motor. Motor Nameplate_____________ Actual___________ WARNING Winterizing and Condensate Trap Care 1. Turn off power to the unit. ELECTRICAL SHOCK, FIRE, 2. Have a shallow pan ready to empty condensate water. OR EXPLOSION HAZARD. 3.
  • Page 41 18. Remove screws along vestibule sides and bottom which 39. Reconnect 2 pin plug to gas valve. secure vestibule panel and heat exchanger assembly 40. Replace the blower compartment access panel. to cabinet. Remove two screws from blower rail which 41.

  • Page 42: Planned Service

    Planned Service Return air duct - Must be properly attached and provide an air seal to the unit. A service technician should check the following items during an annual inspection. Power to the unit must be shut off for Operating performance - Unit must be observed during the service technician's safety.

  • Page 43: Integrated Control Diagnostic Codes

    Integrated Control Diagnostic Codes Press the diagnostic push button and hold it to cycle through a menu of options. Every five seconds a new menu item will be displayed. Release the button when the desired mode is displayed. When a solid "P" is displayed, the furnace capacity/ size is programmed. When the solid "E"...

  • Page 44: Configuring Unit Size Codes

    CONFIGURING UNIT SIZE CODE Page 44 of 52 Issue 1034 506552-01...

  • Page 45: Troubleshooting

    Troubleshooting: Heating Sequence of Operation IGNITION AND CALL FOR LOW FIRE WITH TWO STAGE THERMOSTAT 506552-01 Issue 1034 Page 45 of 52...
  • Page 46 Troubleshooting: Heating Sequence of Operation (Continued) CALL FOR HIGH FIRE WITH TWO STGE THERMOSTAT Page 46 of 52 Issue 1034 506552-01...
  • Page 47 Troubleshooting: Heating Sequence of Operation (Continued) CALL FOR HEAT SATISFIED 506552-01 Issue 1034 Page 47 of 52...
  • Page 48 Troubleshooting : Heating Sequence of Operation (continued) IGNITION AND CALL FOR HEAT WITH SINGLE STAGE THERMOSTAT Page 48 of 52 Issue 1034 506552-01...
  • Page 49 Troubleshooting : Cooling Sequence of Operation CALL FOR COOLING 506552-01 Issue 1034 Page 49 of 52...
  • Page 50 Troubleshooting : Continuous Fan Sequence of Operation Continuous Low Speed Indoor Blower Sequence of Operation Page 50 of 52 Issue 1034 506552-01...

  • Page 51: Repair Parts List

    REPAIR PARTS LIST The following repair parts are available through Allied Air distributors. When ordering parts, include the complete furnace model number listed on the nameplate. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier. Cabinet Parts Heating Parts Outer Access Panel...
  • Page 52 REQUIREMENTS for COMMONWEALTH of MASSACHUSETTS Modifications to NFPA-54, Chapter 10 INSPECTION. The state or local gas inspector of the Revise NFPA-54 section 10.8.3 to add the following side wall, horizontally vented, gas-fueled equipment requirements: shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide For all side wall, horizontally vented, gas-fueled equipment detectors and signage installed in accordance with the...

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