Allied 96G2DF070BV16 Service Manual
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Allied 96G2DF070BV16 Service Manual

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SERVICE MANUAL
96G2DFV Gas Furnace
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 HVAC installer (or
equivalent), service agency or the gas supplier.
As with any mechanical equipment, contact with sharp
sheet metal edges can result in personal injury. Take
care while handling this equipment and wear gloves
and protective clothing.
508193-01
WARNING
CAUTION

Table of Contents

Technical Specifications - 96G2DFV ...........................2
Parts Arrangement.......................................................5
Unit Components .........................................................6
Heating Components .................................................12
Placement and Installation ........................................17
Joint Cementing Procedure .......................................18
Venting Practices .......................................................19
Vent Piping Guidelines ..............................................22
Condensate Piping ....................................................35
Start-Up .....................................................................39
Heating System Service Checks ...............................40
Proper Ground and Voltage .......................................43
Typical Operating Characteristics ..............................44
Maintenance ..............................................................45
Wiring and Sequence of Operation ...........................48
Electric shock hazard.
Can cause injury or death. Before attempting
to perform any service or maintenance,
turn the electrical power to unit OFF at
disconnect switch(es). Unit may have
multiple power supplies.
*P508193-01*
Issue 2117
WARNING
(P) 508193-01
Page 1 of 49

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Summary of Contents for Allied 96G2DF070BV16

  • Page 1: Table Of Contents

    SERVICE MANUAL 96G2DFV Gas Furnace 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. Table of Contents Technical Specifications - 96G2DFV ......2 Parts Arrangement............5 Unit Components ............6 Heating Components ..........12...

  • Page 2: Technical Specifications - 96G2Dfv

    Inlet (ICS) Breaker F.L.A. (V.A.) Weight Input Output* Input Output* Capacity (in.) Phase or Fuse (lbs.) (Btuh) (Btuh) (Btuh) (Btuh) 96G2DF070BV16 43,000 42,000 66,000 64,000 96.0 120-60-1 10.1 96G2DF090CV20 57,000 56,000 88,000 85,000 96.0 120-60-1 12.8 96G2DF110CV20 72,000 70,000 110,000 106,000 96.0...
  • Page 3 1340 1575 1800 35-65 High 1175 1315 1520 1230 1420 1650 Norm Stage Fire 1055 1170 1365 1085 1290 1460 96G2DF070BV16 11x10 1020 1140 1340 1055 1255 25-55 1030 1230 1120 Norm Stage Fire 1085 1395 1555 1695 1825 1335...
  • Page 4 ACCESSORY LIST Catalog Number Description External Filter Rack Kits 1.841018 1 pack (16 x 25) 1.841039 10 pack (16 x 25) Natural to LP Kits 11K48 2-Stage – 90 11K47 High Altitude 2-Stage (>4500') Return Air Base 68W62 17.5" B Width 68W63 21.0"...

  • Page 5: Parts Arrangement

    Parts Arrangement Blower Assembly Control Box Access Panel Combustion Air Inducer Gas Valve Burner Box Assembly Figure 1. 508193-01 Issue 2117 Page 5 of 49...

  • Page 6: Unit Components

    Unit Components WARNING 96G2DFV unit components are shown in Figure 1. The gas Shock hazard. valve, combustion air inducer and burners can be accessed Disconnect power before servicing. Integrated control by removing the access panel. Electrical components are is not field repairable. If control is inoperable, simply in the control box (Figure 2) found in the blower section.
  • Page 7 CFM LED Pin # Function An amber LED is provided on the control board to display Gas Valve Second Stage CFM. To determine what CFM the motor is delivering Second Stage Prove Switch at any time, count the number of times the amber LED flashes.
  • Page 8 Heat Stage Jumper (single stage shown) Air Flow Heat Jumper Taps Cool Taps TERMINAL DESIGNATIONS HUM -Humidifier (120VAC) Line - Input (120VAC) XFMR - Transformer (120VAC) EAC - Indoor Air Accessory (120VAC) Cool - Cool Speed (120VAC) Park 1 - Dead terminal for alternate speed tap Park 2 - Dead terminal for alternate speed tap Figure 3.
  • Page 9 Indoor Blower Motor MOTOR CONTROLLER Figure 5. GenTeq Blower Motor B3 Power Choke STATOR Blower Motor (WINDINGS) (4 and 5 Ton Only) (B3) BEARING Figure 4. OUTPUT SHAFT ROTOR WARNING During blower operation, the ECM motor emits Figure 6. Blower Motor Components energy that may interfere with pacemaker operation.
  • Page 10 Initial Power Up POWER CONTROL When line voltage is applied to B3, there will be a large CONNECTOR J48 CONNECTOR J49 inrush of power lasting less than 1/4 second. This inrush PIN 1 C1 PIN 2 W / W1 charges a bank of DC filter capacitors inside the controller. PIN 3 C2 If the disconnect switch is bounced when the disconnect is PIN 4 - Delay...
  • Page 11 Motor speed is determined by the size of the electrical pulse sent to the motor windings. The longer the pulse, the faster the motor. OUTPUT FROM CONTROLLER TO MOTOR WINDINGS WINDINGS TURNED OFF WINDINGS TURNED ON ON PULSE OFF PULSE The frequency of the pulses to the windings is 20KHz.

  • Page 12: Heating Components

    The pressure switch measures the pressure LPG change over kits are available from Allied Air. Kits differential across the combustion air inducer orifice or include burner orifices and a gas valve.
  • Page 13 Burner Assembly Intake Air Top Cap Sensor Rollout Switch Rollout Switch Ignitor Manifold And Gas Orifices Burner Box Cover Two-Stage Gas Valve Figure 9. Heating Components 508193-01 Issue 2117 Page 13 of 49...
  • Page 14 Test 1 Check ignitor circuit for correct resistance. Remove 4-pin plug from control. Check ohms reading across terminals 1 and 5. Reading should be between 39 and 70 ohms. If value is correct, this is the only test needed. If the reading on the meter is not correct, (0 or infinity) then a second test is needed.
  • Page 15 Combustion Air Inducer Pressure Switch (S18) 96G2DFV series units are equipped with a dual combustion air pressure switch (first and second stage) located on the combustion air inducer orifice bracket. See Figure 11. The switch is connected to the combustion air inducer housing by means of a flexible silicone hose.
  • Page 16 Pressure Switch Check Operate unit and observe manometer reading. Readings will change as heat exchanger warms. To check pressure switch differential, refer to Figure 12 and use the provided fittings and tubing to follow the steps Take one reading immediately after start-up. below.

  • Page 17: Placement And Installation

    Canadian Applications Only - Pipe, fittings, primer and Placement and Installation solvent cement used to vent (exhaust) this appliance must be certified to ULC S636 and supplied by a single All pipe, fittings, primer and solvent cement must conform manufacturer as part of an approved vent (exhaust) with American National Standard Institute and the American system.

  • Page 18: Joint Cementing Procedure

    STANDARD CONCENTRIC Outdoor Outdoor Exhaust Flush 1-1/2” 2” 3” Exhaust VENT PIPE Accelerator Mount Concentric Concentric Concentric Accelerator 96G2DFV DIA. (Dia. X Length) (Dia. X Length) (in.) 71M80 69M29 60L46 1-1/2” X 12” 2” X 12” 51W11 * or 44W93+ +44W92++ +44W92++ 1-1/2...

  • Page 19: Venting Practices

    Removal of the Furnace from Common Vent After assembly, wipe excess cement from pipe at end of fitting socket. A properly made joint will show a bead around its entire perimeter. Any gaps may indicate an WARNING improper assembly due to insufficient solvent. CARBON MONOXIDE POISONING HAZARD Handle joints carefully until completely set.
  • Page 20 Exhaust Piping (Figure 15) Close all building doors and windows and all doors between the space in which the appliances remaining Route piping to outside of structure. Continue with connected to the common venting system are located installation following instructions given in piping termination and other spaces of the building.
  • Page 21 2” 2” Pipe size determined in 2” 2” Table 10A through 10C. 2” TRANSITION 3” *2” 3” *2” TRANSITION *2” INTAKE EXHAUST TOP VIEW * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE −...

  • Page 22: Vent Piping Guidelines

    (305mm) above Attic Floor) Vent Piping Guidelines *Intake Debris Screen (Provided) NOTE: Allied Air has approved the use of DuraVent ® Centrotherm manufactured vent pipe and terminations as Furnace an option to PVC. When using the PolyPro by DuraVent ®...
  • Page 23 In some applications which permit the use of several different sizes of vent pipe, a combination vent pipe may be used. Contact Allied Air Technical Services department for assistance in sizing vent pipe in these applications. NOTE: It is acceptable to use any pipe size which fits...
  • Page 24 Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 4500 ft 1-1/2" Pipe 2" Pipe 2-1/2" Pipe 3" Pipe Number of 90° Model Model Model Model Elbows Used Standard Termination Elevation 4500 - 10,000 ft 1-1/2"...
  • Page 25 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 of 90° Model Model Model Model Elbows Used Concentric Termination Elevation 4,501 - 10,000 ft 1-1/2"...
  • Page 26 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 of 90° Capacity Capacity Capacity Capacity 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 27 Maximum Allowable Exhaust Vent Pipe Length (in ft.) without Insulation in Unconditioned Space for Winter Design Temperatures Unit Input Size Winter Design Vent Pipe Temperatures ºF (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in. 3 in.
  • Page 28 ‡ 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 22. Vent Termination Clearances Direct Vent Installations...
  • Page 29 Details of Intake and Exhaust Piping Intake and exhaust pipes should be placed as close together as possible at termination end (refer to Terminations for Direct Vent Installations illustrations). Maximum separation is 3” (76MM) NOTE: In Direct Vent installations, combustion air is taken on roof terminations and 6”...
  • Page 30 On field-supplied terminations, a minimum distance STRAIGHT-CUT OR between the end of the exhaust pipe and the end of ANGLE-CUT IN DIRECTION OF ROOF SLOPE * the intake pipe without a termination elbow is 8” and a minimum distance of 6” with a termination elbow. See 3”...
  • Page 31 ‡ 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 31. Vent Termination Clearances...
  • Page 32 Details of Exhaust Piping Terminations for Non- STRAIGHT-CUT OR * SIZE TERMINATION PIPE PER EXHAUST Direct Vent Applications ANGLE-CUT IN DIRECTION PIPE TERMINATION SIZE REDUCTION TABLE OF ROOF SLOPE * 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 EXHAUST VENT Minimum 12”...
  • 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 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT Vent Pipe Vent Pipe LARGER VENT PIPE SIZE TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...

  • Page 35: Condensate Piping

    Use a large flat head screw driver or a 1/2” drive Condensate Piping socket extension and remove plug (Figure 38) from the cold end header box at the appropriate location This unit is designed for either right- or left-side exit of on the side of the unit.
  • Page 36 CAUTION Do not use copper tubing or existing copper condensate lines for drain line. If unit will be started immediately upon completion of installation, prime trap per procedure outlined in the Start-Up section. Condensate line must slope downward away from the trap to drain.
  • 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 Optional Condensate Drain Connection Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) 90° Street Elbow 1/2 inch PVC (Not Furnished) Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Condensate Drain Connection In Unit 1 (25 mm) Min. Vent 2 (50 mm) Max.

  • Page 39: Start-Up

    Placing the Furnace into Operation Start-Up 96G2DFV units are equipped with an ignition system. Do NOT attempt to manually light burners on this furnace. Preliminary and Seasonal Checks Each time the thermostat calls for heat, the burners will Inspect electrical wiring, both field and factory installed automatically light The ignitor does not get hot when there for loose connections.

  • Page 40: Heating System Service Checks

    Gas Piping This furnace is equipped with an ignition device which automatically lights the burners. Do not try to light the burners by hand. CAUTION Remove the upper access panel. If a flexible gas connector is required or allowed by Move gas valve switch to OFF.
  • Page 41 When checking piping connections for gas leaks, use Shut unit off and remove manometer as soon as an preferred means. Kitchen detergents can cause harmful accurate reading has been obtained. corrosion on various metals used in gas piping. Use of a Start unit and perform leak check.
  • Page 42 Proper Combustion High Altitude Furnace should operate minimum 15 minutes with correct The manifold pressure, gas orifice and pressure switch manifold pressure and gas flow rate before checking may require adjustment or replacement to ensure proper combustion. Take combustion sample beyond the flue operation at higher altitudes.

  • Page 43: Proper Ground And Voltage

    Proper Ground and Voltage In addition, measure the AC voltage from Line Hot A poorly grounded furnace can contribute to premature ignitor failure. Use the following procedure to check for to Line Neutral (spade terminals) on the integrated control. See Figure 48. This voltage should be in the ground and voltage to the integrated control.

  • Page 44: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 50. Punch a 1/4” diameter hole in supply and return air Blower Operation and Adjustment plenums. Insert manometer hose flush with inside Blower operation is dependent on thermostat control edge of hole or insulation.

  • Page 45: Maintenance

    Maintenance Furnace Cabinet Width Minimum Filter Size 17-1/2” 16 x 25 x 1 (1) 21” WARNING Table 18. ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Exhaust and Air Intake Pipes Failure to follow safety warnings exactly could result in Check the exhaust and air intake pipes and all connections dangerous operation, serious injury, death or property for tightness and to make sure there is no blockage.
  • Page 46 Reinstall screens, reconnect hoses and turn on power 13. Mark and remove wires from pressure switch assembly. to unit. Remove the assembly. Keep tubing attached to pressure switches. 14. Disconnect the plug from the combustion air inducer. Remove two screws which secure combustion air inducer to collector box.
  • Page 47 33. Carefully connect combustion air pressure switch Mark and disconnect sensor wire from the sensor. tubing from pressure switches to proper ports on cold Disconnect wires from flame rollout switches. end header collector box. Disconnect combustion air intake pipe. It may be 34.

  • Page 48: Wiring And Sequence Of Operation

    Wiring and Sequence of Operation 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 49 Sequence of Operation Cooling The unit is set up at the factory for single stage cooling. On a call for heat from the room thermostat, the control For two stage cooling operation, clip the jumper wire board performs a 1 second self check. Upon confirmation located between the Y to Y2 terminals on the integrated that the pressure switch contacts are in an open position, ignition/blower control board.

This manual is also suitable for:

96g2dfv96g2df090cv2096g2df110cv20

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