Allied A96DF1EK Installation Instructions Manual

Warm air gas furnace downflow air discharge direct vent & non-direct vent

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INSTALLATION INSTRUCTIONS

A96DF1EK & 96G1DFEK

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.

This furnance is equipped with an ignition control factory

enabled for use with Allied A2L refrigerant systems.

Disabling the refrigerant detection functionality on A2L

system is prohibited by safety codes. Refer to furnace

installation instructions for non-A2L and non-Allied

refrigerant system setup.

Allied Air Enterprises LLC

215 Metropolitan Drive

West Columbia, SC 29170

Page 1 of 57

This manual must be left with the homeowner for future reference.

WARNING

CAUTION

WARNING

Manufactured By

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 .........................................................................12

Duct System ..............................................................12

Venting Practices .......................................................15

Condensate Piping ....................................................31

Gas Piping .................................................................34

Electrical ....................................................................37

Ignition control............................................................40

Twinning.....................................................................45

Low GWP application.................................................46

Unit Start-Up ..............................................................49

Testing for Proper Venting and Sufficient Combustion

Air for Non-Direct Vent Applications ..........................52

Other Unit Adjustments..............................................53

Blower Performance Data .........................................54

Service.......................................................................54

Planned Service ........................................................56

Repair Parts List ........................................................56

Issue 2504

Warm Air Gas Furnace

Downflow Air Discharge

Direct Vent & Non-Direct Vent

Table of Contents

*P508619-01*

(P) 508619-01

508619-01

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Summary of Contents for Allied A96DF1EK

Page 1 WARNING Air for Non-Direct Vent Applications ......52 This furnance is equipped with an ignition control factory Other Unit Adjustments..........53 enabled for use with Allied A2L refrigerant systems. Blower Performance Data .........54 Disabling the refrigerant detection functionality on A2L Service...............54 system is prohibited by safety codes. Refer to furnace Planned Service ............56...
Page 2 Unit Dimensions 9/16 (14) COMBUSTION AIR INTAKE Return Air Opening EXHAUST AIR OUTLET 2−1/16 (52) 9/16 2−1/4 (14) (57) (127) TOP VIEW 1 (25) 27−3/4 Front Panel (705) 19−7/16 9/16 9/16 (494) (14) (14) FLOW ELECTRICAL INLET (Either Side) (838) 2 (51) Either Side CONDENSATE...
Page 3 Parts Arrangement CONTROL BOX (Includes integrated control, transformer and door switch) BAG ASSEMBLY BLOWER MOTOR (hidden) BLOWER COMPARTMENT ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK HEATING PRIMARY LIMIT COMPARTMENT ACCESS PANEL COLD END HEADER BOX HEAT EXCHANGER GAS VALVE BURNER BOX ASSEMBLY (includes flame sensor, rollout switches and ignitor) Figure 2.
Page 4 Gas Furnace Shipping and Packing List This Category IV gas furnace is shipped ready for 1 - Assembled Gas Unit installation in the downflow position. 1 - Bag assembly containing the following: 1 - Snap bushing The furnace is equipped for installation in natural gas applications.
Page 5 In order to ensure proper unit operation in non-direct vent Heating Unit Installed Parallell to Air Handler Unit applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standard. Locations and Clearances AIR HANDLER GAS UNIT This furnace is CSA International certified for installation...
Page 6 If this unit is installed as a Non-Direct Vent Furnace, follow EQUIPMENT LIMITED WARRANTY. ALLIED the guidelines in this section. DISCLAIMS ALL LIABILITY IN CONNECTION WITH NOTE: In Non-Direct Vent Installations, combustion air is INSTALLER’S FAILURE TO FOLLOW THE ABOVE taken from indoors and flue gases are discharged outdoors.
Page 7 not separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air WARNING for combustion if the structure does not provide enough air by infiltration. Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation.
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 ROOF TERMINATED EXHAUST PIPE Figure 7.
Page 9 Installation Ventilation Louvers Inlet Air Roof Terminated (Minimum 12 in. Exhaust Pipe (305mm) above Setting Equipment Attic Floor) *Intake Debris CAUTION Screen (Provided) Do not install the furnace on its front, back or in the horizontal position. See Figure 11. Do no connect the Furnace return air ducts to the back of the furnace.
Page 10 Front Back Horizontal NOTE - Do not install the furnace on its front, back or in the horizontal position Figure 11. Refer to Figure 13 for clearances in downflow applications. AIR FLOW AIR FLOW AIR FLOW Left Side Right Side 1/2"...
Page 11 Set the unit over the plenum and seal the plenum to the unit. FURNACE Ensure that the seal is adequate. Front to Rear Side to Side SUPPLY AIR Cabinet Width PLENUM PROPERLY COMBUSTIBLE B (17.5”) 19-3/4 16-5/8 SIZED FLOOR FLOORING BASE OPENING C (21”) 19-3/4...
Page 12 When cooling cabinet is in place, set and secure the Duct System furnace according to the instructions that are provided with the cooling coil. Secure the furnace to the cabinet. Use industry-approved standards to size and install the Seal the cabinet and check for air leaks. supply and return air duct system.
Page 13 Low temperature solvent cement is recommended during cooler weather. Metal or plastic strapping may be used as CAUTION vent pipe hangers. Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean Solvent cements for plastic pipe are flammable liquids inside socket surface of fitting and male end of pipe to and should be kept away from all sources of ignition.
Page 14 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 15 NOTE: Assembly should be completed within 20 REPLACING FURNACE THAT seconds after last application of cement. Hammer WAS PART OF A COMMON blows should not be used when inserting pipe. CHIMNEY VENT SYSTEM OR GAS VENT After assembly, wipe excess cement from pipe at end (Check sizing for remaining of fitting socket.
Page 16 Exhaust? 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 Service for assistance in sizing vent pipe in these applications. Capacity Min. Vent Length* How many? 15 ft.
Page 17 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 of Capacity Capacity Capacity Capacity 90° Elbows Used NOTE - Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size.
Page 18 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 of Capacity Capacity Capacity Capacity 90° Elbows Used NOTE - Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size.
Page 19 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 of Capacity Capacity...
Page 20 NOTE: 1-1/2” Vent Pipe Pipe size determined in table 7A/7B/7C/7D. Diameter Allowed Only on 045/070 Units 2” 2” 2” 2” 3” 1-1/2” 2” TRANSITION TRANSITION *2” *2” INTAKE DO NOT transition DO NOT transition EXHAUST from smaller to larger from larger to smaller TOP VIEW pipe in horizontal runs pipe in horizontal runs...
Page 21 Intake Piping Intake This furnace may be installed in either direct vent or non- Debris direct vent applications. In non-direct vent applications, Screen (Provided) when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered.
Page 22 At vent termination, care must be taken to maintain protective coatings over building materials (prolonged Roof Terminated exposure to exhaust condensate can destroy protective Exhaust Pipe coatings). It is recommended that the exhaust outlet not be located within 6 feet (1.8 m) of a condensing unit because the condensate can damage the painted coating.
Page 23 Maximum Allowable Exhaust Vent Pipe Length (in ft.) without Insulation in Unconditioned Space for Winter Design Temperatures Single - Stage High Efficiency Furnace Unit Input Size Winter Design Temperatures Vent Pipe ºF (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in.
Page 24 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 inches (305mm) 12 inches (305mm) or 12 inches (305mm) porch, deck or balcony...
Page 25 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 inches (305mm) 12 inches (305mm) or 12 inches (305mm) porch, deck or balcony...
Page 26 Details of Intake and Exhaust Piping 51W11 Terminations for Direct Vent Installations 2" EXTENSION NOTE: In Direct Vent installations, combustion air is taken FOR 2" PVC PIPE 1" EXTENSION from outdoors and flue gases are discharged to outdoors. FOR 3" PVC PIPE NOTE: Flue gas may be slightly acidic and may adversely FURNACE affect some building materials.
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 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada) FIELD−PROVIDED 1−1/2" (38mm) accelerator REDUCER MAY BE REQUIRED provided on 71M80 & 44W92 TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION OUTSIDE INTAKE WALL EXHAUST Inlet Air EXHAUST VENT Minimum 12 in. VENT Exhaust Furnace...
Page 29 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 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 EXHAUST VENT Minimum 12”...
Page 30 Exhaust through Crawl Space Vent Option Figure 40.Kit 51W18 (USA) / 15Z70 (Canada) Parts Identification and Assembly All 33” condensing gas furnaces (92%+) are now approved to be vented down through a crawl space. Ensure a vent pipe drain kit, 51W18 (USA) or 15Z70 (Canada), is used as Exhaust from directed through the floor joists and into the crawl space.
Page 31 Condensate Piping This unit is designed for either right or left side exit of condensate piping in downflow applications. Refer to Figure 43 for condensate trap locations. Trap NOTE: If necessary the condensate trap may be installed (same on up to 5” away using PVC pipe from the furnace. Piping right side) from furnace must slope down a minimum of 1/4”...
Page 32 Field Provided Vent Field Provided Vent 1” min. 2” max. above 1” min. 2” max. above condensate drain. condensate drain. Condensate Drain Condensate Drain Connection Connection Evaporator Drain Line (vent required) Evaporator Drain Line Drain (vent required) Figure 45. Unit with Cooling Coil Using Separate Drain Figure 46.
Page 33 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 34 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 35 Left Side Piping MANUAL (Standard) AUTOMATIC MAIN SHUT−OFF GAS VALVE MANUAL VALVE AUTOMATIC (with manual Plug MAIN SHUT−OFF (With 1/8 in. NPT GAS VALVE shut−o valve) VALVE Plugged Tap (with manual Plug (With 1/8 in. NPT Shown) shut−o valve) Plugged Tap Shown) GROUND JOINT UNION...
Page 36 Removal of the Furnace from Common Vent Seal any unused openings in the common venting system. In the event that an existing furnace is removed from a venting system commonly run with separate gas Inspect the venting system for proper size and appliances, the venting system is likely to be too large to horizontal pitch.
Page 37 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. Maximum Over-Current Protection allowed is 15 AMP. Precautions and Procedures Holes are on both sides of the furnace cabinet to facilitate wiring.
Page 38 Generator Use - Voltage Requirements The following requirements must be kept in mind when specifying a generator for use with this equipment: • The furnace requires 120 volts ± 10% (Range: 108 volts to 132 volts). • The furnace operates at 60 Hz ± 5% (Range: 57 Hz to 63 Hz).
Page 39 OUTDOOR UNIT BLOWER SPEED CHART FACTORY CONNECTED SPEED TAPS UNIT COOL HEAT PARK BLACK YELLOW BROWN,BLUE 045B(E)12K BLACK YELLOW BROWN,BLUE 070B(E)16K POWER CHOKE 090C(E)16K BLACK BLUE BROWN, YELLOW INDOOR 110C(E)20K BLACK BLUE, YELLOW BROWN BLOWER MOTOR BLOWER SPEED SELECTION ZONE ALARM BLUE SPEED TAPS...
Page 40 Integrated Control DIP Switch Settings heat fan-off delay (amount of time that the blower oper- A96DF1EK & 96G1DFEK units are equipped with a sin- ates after the heat demand has been satisfied) may be gle-stage integrated control. This control manages igni-...
Page 41 On Board Links Must NOT Be Cut To Select Thermostat Wiring Connections AC ON System Options Heat / Cool FURNACE OUTDOOR T'STAT TERM. STRIP UNIT DO NOT CUT ANY ON-BOARD LINKS Figure 55 On Board Links Must Be Cut To Select Wiring Connections Thermostat Heat Pump Options...
Page 42 Single Stage, Constant Torque, Non-Communicating 107792-01 Figure 57 TABLE 12 TABLE 13 1/4” QUICK CONNECT TERMINALS THERMOSTAT INPUT TERMINALS HEAT 120V HUM POWER FOR HUMIDIFIER (120 VAC COMMON GROUND LINE INCOMING POWER LINE (120 VAC) 24V AC XFMR TRANSFORMER PRIMARY (120 VAC) CIRC INDOOR BLOWER MOTOR (120 VAC) COOL...
Page 43 IGNITION CONTROL DIAGNOSTIC CODES DIAGNOSTIC CODES / STATUS OF FURNACE CODE IDLE MODE (DECIMALBLINKS AT 1 HERTZ -- 0.5 SECONDS ON, 0.5 SECONDS OFF INDOOR BLOWER OPERATION: CONTINUOUS FAN MODE (COSTANT TORQUE ONLY) INDOOR BLOWER OPERATION: FOLLOWED BY CFM SETTING FOR INDOOR BLOWER (1 SECOND ON, 0.5 SECOND OFF) / CFM SETTING FOR MODE DISPLAYED (VARIALBE SPEED ONLY) COOLING STAGE (1 SECOND ON, 0.5 SECOND OFF) 1 OR 2 DISPLAYED / PAUSE / REPEAT CODES.
Page 44 1 - When the thermostat is set to “FAN ON,” the indoor blower will run continuously on the fan speed when there is no cooling or heating demand. See table 15 for allowable circulation speeds. 2 - When the A96DF1EK & 96G1DFEK is running in the heating mode, the indoor blower will run on the heating speed. See table 16 for allowable heating speeds.
Page 45 The 24 VAC secondary of the two systems must be in Twinning Two A96DF1EK & 96G1DFEK Furnaces phase. All thermostat connections are made to one control The control board in this furnace is equipped with a provi- only. See diagram below.
Page 46 Low GWP Application WARNING For use with Allied approved evaporator coil and LGWP sensors only. Use original manufacturer recommended LGWP sensors if using non-Allied approved evaporator coil. Figure 59 CONNECTING THE FURNACE CONTROL BOARD SENSOR. TABLE 17 See Figure 60 and follow steps below: DIP Switch Settings 1 - Route sensor wire #1 through provided grommet.
Page 47 FURNACE CONTROL BOARD LOW GWP MODES OF The furnace control board activates the blower (high speed). The blower purges refrigerant from the OPERATION cabinet, plenum, and ductwork. The modes of operation for the furnace control board are 3. After the furnace control board determines the Initializing, Normal, Leak Detected, and Fault.
Page 48 LGWP TEST BUTTON FUNCTIONALITY External Alarm (For applications with external alarms wired directly to the The furnace control board is equipped with a Test/Reset furnace control board) push button. The Test button can be used to perform sev- The furnace control board triggers the external alarm sys- eral functions, depending on the mode of operation of the tem when it enters Leak Detected mode.
Page 49 Follow the lighting instructions to place the unit into Unit Start-Up operation. Set the thermostat to initiate a heating demand. FOR YOUR SAFETY READ BEFORE OPERATING Allow the burners to fire for approximately 3 minutes. Adjust the thermostat to deactivate the heating demand.
Page 50 If flame is not detected after first ignition trial, the Gas Valve Shown In “ON’ Position ignition control will repeat steps 3 and 4 four more times before locking out the gas valve. The ignition MANIFOLD MANIFOLD control will then automatically repeat steps 1 through PRESSURE PRESSURE 6 after 60 minutes.
Page 51 NOTE: Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to remove barbed fitting and replace threaded plug. Proper Combustion Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking combustion. Take combustion sample beyond the flue outlet and compare to the tables below.
Page 52 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 53 Check amp–draw on the blower motor with the blower Other Unit Adjustments compartment access panel in place. Motor Nameplate____________ Actual____________ Primary Limit The primary limit is located on the heating compartment Blower Speeds vestibule panel. This limit is factory set and requires no Follow the steps below to change the blower speeds.
Page 54 Blower Performance NOTE: Please refer to the Product Specifications for airflow/blower data. Electrical Service Check all wiring for loose connections. Check for the correct voltage at the furnace (furnace operating). Correct voltage is 120 VAC ± 10%. WARNING Check amp-draw on the blower motor with the blower compartment access panel in place.
Page 55 13. Mark and disconnect any remaining wiring to heating 35. Reconnect 2 wires to gas valve. compartment components. Disengage strain relief 36. Replace the blower compartment access panel. bushing and pull wiring and bushing through the hole 37. Refer to instruction on verifying gas and electrical in the blower deck.
Page 56 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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