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Allied A97USMV, Installation Instructions Manual

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506887-01

Page 1 of 78

Issue 1213

As with any mechanical equipment, personal injury can
result from contact with sharp sheet metal edges.  Be
careful when you handle this equipment.

  CAUTION

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.

  WARNING

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.

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

INSTALLATION INSTRUCTIONS

A97USMV

Warm Air Gas Furnace

Upflow/Horizontal Left and Right Air Discharge

* P 5 0 6 8 8 7 - 0 1 *

(P)   506887-01

Manufactured By

Allied Air Enterprises, Inc.

A Lennox International, Inc. Company

215 Metropolitan Drive

West Columbia, SC 29170

Unit Dimensions ..................................................................................... 2
Parts Arrangement ................................................................................. 3
Gas Furnace .......................................................................................... 4
Shipping and Packing List ...................................................................... 4
Safety Information .................................................................................. 4
Use of Furnace as a Construction Heater .............................................. 5
General .................................................................................................. 6
Setting Equipment .................................................................................. 6
Filters .................................................................................................... 11
Duct System .......................................................................................... 11
Pipe and Fittings Specifications ............................................................ 12
Joint Cementing Procedure .................................................................. 13
Venting Practices ................................................................................. 14
Vent Piping Guidelines .......................................................................... 15
Gas Piping ............................................................................................. 29

TABLE OF CONTENTS

Electrical ............................................................................................... 32
Integrated Control ................................................................................. 41
Blower Motor Performance .................................................................... 46
Unit Start Up ......................................................................................... 57
Gas Pressure Measurement ................................................................. 58
High Altitude Information ...................................................................... 59
Proper Combustion ............................................................................... 59
Other Unit Adjustments ........................................................................ 61
Heating Sequence of Operation ............................................................ 62
Service .................................................................................................. 64
Planned Service .................................................................................... 66
Integrated Control Diagnostic Codes .................................................... 67
Configuring Unit Size Codes ................................................................. 70
Troubleshooting ..................................................................................... 71

Repair Parts List ................................................................................... 77

A thermostat is not included and must be ordered
separately.

•

A Comfort Sync

TM

 thermostat must be used in

communicating applications.

•

In non-communicating applications, a traditional non-
communication thermostat may be used.

In all cases, setup is critical to ensure proper system
operation.

Field wiring for both communicating and non-
communicating applications is illustrated in these
instructions.

NOTICE

Summary of Contents for A97USMV

Page 1: ...lumbia SC 29170 Unit Dimensions 2 Parts Arrangement 3 Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 Use of Furnace as a Construction Heater 5 General 6 Setting Equipment 6 Filters 11 Duct System 11 Pipe and Fittings Specifications 12 Joint Cementing Procedure 13 Venting Practices 14 Vent Piping Guidelines 15 Gas Piping 29 TABLE OF CONTENTS Electrical 32 Integrated Control 41 Blowe...

Page 2: ...rn Air Base 3 Bottom return air 4 Return air from both sides 5 Bottom and one side return air See Blower Performance Tables for additional information Optional External Side Return Air Filter Kit is not for use with the optional RAB Return Air Base FRONT VIEW SIDE VIEW Model Number A 446 17 1 2 A97USMV070B12S B C in mm in mm in mm 416 16 3 8 406 16 A97USMV090C12S A97USMV090C16S A97USMV090C20S A97U...

Page 3: ...506887 01 Page 3 of 78 Issue 1213 A97USMV Exploded View Figure 1 ...

Page 4: ...ith LP Propane gas can lose its scent In case of a leak LP Propanegaswillsettleclosetothefloorandmaybedifficult to smell An LP Propane leak detector should be installed in all LP applications Use only the type of gas approved for use with this furnace Refer to unit nameplate Building Codes In the USA installation of gas furnaces must conform with local building codes In the absence of local codes ...

Page 5: ...ts are not recommended for use as a construction heater during any phase of construction Very low return air temperature harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit These units may be used for heating of buildings or structures under construction if the following conditions are met The vent system must be permanently installed per these installat...

Page 6: ... not supersede local codes in any way Consult authorities having jurisdiction before installation In addition to the requirements outlined previously the following general recommendations should be considered when installing one of these furnaces Place the furnace as close to the center of the air distribution system as possible The furnace should also be located close to the vent termination poin...

Page 7: ...PMENT Figure 5 UNIT MUST BE LEVEL SIDE TO SIDE IN ALL APPLICATIONS FOR PROPER OPERATION A SLIGHT TILT TOWARD THE DRAIN IS RECOMMENDED FOR PROPER DRAINAGE TILT THE UNIT SLIGHTLY MAX 1 2 FROM BACK TO FRONT TO AID IN THE DRAINING OF THE HEAT EXCHANGER ...

Page 8: ...5 See Figure 6 Optional Return Air Base Upflow Applications Only NOTE Optional side return air filter kits are not for use with return air base 1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air W x H 23 x 11 in 584 x 279 mm The opening can b...

Page 9: ...plenum A door must never be used as a portion of the return air duct system The base must provide a stable support and an airtight seal to the furnace Allow absolutely no sagging cracks gaps etc For no reason should return and supply air duct systems ever be connected to or from other heating devices such as a fireplace or stove etc Fire explosion carbon monoxide poisoning personal injury and or p...

Page 10: ...cessary clearances See Figure 11 2 Construct a raised wooden frame and cover frame with a plywood sheet If unit is installed above finished space fabricate an auxiliary drain pan to be installed under unit Set unit in drain pan as shown in Figure 13 Leave 8 inches for service clearance below unit for condensate trap unless trap is installed remotely 3 Provide a service platform in front of unit Wh...

Page 11: ...ion by reflected light of the heat exchanger for leaks after the furnace is installed If present this access panel must always be in place when the furnace is operating and it must not allow leaks into or from the supply air duct system Return Air Plenum Return air must not be drawn from a room where this furnace or any other gas fueled appliance i e water heater or carbon monoxide producing devic...

Page 12: ...ll sources of ignition Do not use excessive amounts of solvent cement when making joints Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors Avoid contact of cement with skin and eyes Use PVC primer and solvent cement orABS solvent cement meeting ASTM specifications refer to Table 2 As an alternate use all purpose cement to bond ABS PVC or CPVC p...

Page 13: ... end of pipe and inside socket surface of fitting Cement should be applied lightly but uniformly to inside of socket Take care to keep excess cement out of socket Apply second coat to end of pipe NOTE Time is critical at this stage Do not allow primer to dry before applying cement 7 Immediately after applying last coat of cement to pipe and while both inside socket surface and end of pipe are wet ...

Page 14: ...ough to allow clearance on all sides 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 from trap and lines The exhaust vent pipe operates under positive pressure and must be completely sealed to prevent leakage of combustion produc...

Page 15: ...ey will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Follow the lighting instructions Turn ON the appliance that is being inspected Adjust the thermostat so that the appliance operates continuously 5 After the main burner has operated for 5 minutes test for leaks of flue gases at the draft hood relief opening Use the flame of a match or candle 6 After dete...

Page 16: ...506887 01 Page 16 of 78 Issue 1213 Figure 17 ...

Page 17: ...16 65 18 nla 87 68 43 39 2 1 2 P ipe n a n a 2 1 2 P ipe 070 090 34 29 24 19 9 Concentric T erm ination at E levation 0 7 500 ft N u m b er O f 2 P ipe 3 P ipe 9 0 E lb o w s M o d el M o d e l M o d e l U s e d 110 135 0 7 0 0 9 0 11 0 13 5 0 7 0 0 9 0 1 1 0 1 3 5 1 78 62 125 84 34 141 134 109 100 2 73 57 120 79 29 136 129 104 95 3 68 52 115 74 24 131 124 99 90 4 63 47 110 69 19 126 119 94 85 5 5...

Page 18: ...PLICATIONS Figure 18 Figure 19 TYPICAL EXHAUSTAND INTAKE PIPE CONNECTIONS IN HORIZONTAL APPLICATIONS RIGHT HAND DISCHARGE SHOWN When transitioning up in pipe size use the shortest length of 2 PVC pipe possible When transitioning up in pipe size use the shortest length of 2 PVC pipe possible ...

Page 19: ...506887 01 Page 19 of 78 Issue 1213 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATiONS IN THE USA AND CANADA Figure 20 ...

Page 20: ...ructions and 12 above the average snow accumulation At vent termination care must be taken to maintain protective coatings over building materials prolonged exposure to exhaust condensate can destroy protective coatings It is recommended that the exhaust outlet not be located within 6 feet 1 8m of a condensing unit because the condensate can damage the painted coating NOTE See Table 6 for maximum ...

Page 21: ...be in the same pressure zone You may exit the intake on one side of the structure and the exhaust on another side Figure 20 You may exit the exhaust out the roof and the intake out the side of the structure Figure 21 2 Intake and exhaust pipes should be placed as close together as possible at termination end refer to illustrations Maximum separation is 3 76 mm on roof terminations and 6 152 mm on ...

Page 22: ...ON OR See venting Table 5 for maximum venting lengths with this arrangement Use wall support every 24 610 mm Use two wall supports if extension is greater than 24 610 mm but less than 48 1219 mm NOTE One wall support must be 6 152 mm from top of each pipe Figure 24 ...

Page 23: ...addition close coupled wall termination must be extended for use in this application See Figures 22 and 23 When exhaust and intake piping must be run up an with pipe sized per Table 7 The intake piping may be equipped with a 90 elbow turndown Using turndown will add 5 feet 1 5 m to the equivalent length of the pipe DIRECTVENTCONCENTRICROOFTOPTERMINATION 71M80 69M29 or 60L46 US 44W92 or 44W93 Canad...

Page 24: ...506887 01 Page 24 of 78 Issue 1213 DIRECTVENTCONCENTRICWALTERMINATION 71M80 69M29 OR 60L46 US 44W92 or 44W93 Canada Figure 27 Figure 28 FLUSH MOUNTSIDEWALLTERMINATION 51W11 Figure 29 ...

Page 25: ...ns it is recommended to install a secondary drain pan underneath the unit and trap assembly NOTE Vinyl tubing may be used for condensate drain Tubing must be 1 1 4 OD X 1 ID and should be attached to the drain on the trap using a hose clamp 6 If unit will be started immediately upon completion of installation prime trap per procedure outlined in Unit Start Up section Condensate line must slope dow...

Page 26: ... run to the drain from the condensate trap DO NOT connect the condensate trap drain into the drain line from the evaporator coil CAUTION Evaporator Coil Using A Separate Drain Figure 34 A97USMV With Evaporator Coil Using a Separate Drain Figure 33 Figure 32 Furnace ...

Page 27: ...outlet must be vented to relieve pressure in order for the furnace pressure switch to operate properly IMPORTANT Figure 36 Evaporator Coil using a Common Drain Figure 35 Condensate Trap with Optional Overflow Switch Evaporator Coil using a Common Drain Unit shown in Horizontal Left Hand Discharge Position Figure 37 Furnace ...

Page 28: ...506887 01 Page 28 of 78 Issue 1213 Trap Drain Assembly using 1 2 PVC or 3 4 PVC Figure 38 ...

Page 29: ...d outside the furnace cabinet The flexible connector can then be added between the black iron pipe and the gas supply line CAUTION Do not exceed 600 in lbs 50 ft lbs torque when attaching the gas piping to the gas valve WARNING 6 In some localities codes may require installation of a manual main shut off valve and union furnished by installer external to the unit Union must be of the ground joint ...

Page 30: ...e 30 of 78 Issue 1213 Figure 36 NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET Horizontal Applications Possible Gas Piping Configurations Figure 37 NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET ...

Page 31: ...506887 01 Page 31 of 78 Issue 1213 GAS PIPE CAPACITY FT HR kL HR NOTE Capacity given in cubic feet of gas per hour kilo liters of gas per hour and based on 0 60 specific gravity gas Table 7 1 ...

Page 32: ...ate states maximum current draw See table for maximum over current protection 2 Holes are on both sides of the furnace cabinet to facilitate wiring 3 Install a separate properly sized disconnect switch near the furnace so that power can be turned off for servicing 4 Before connecting the thermostat check to make sure the wires will be long enough for servicing at a later date Make sure that the th...

Page 33: ...differentials and adjustable stage timers The following is a two stage thermostat setup for optimal variable rate capacity mode First heat stage differential set to 1 2 to 1 F second heat stage differential set to 1 2 or 1 F second heat stage upstage timer disabled or set to maximum 1 hr minimum NOTE When the furnace is used with a Comfort SyncTM thermostat proper indoor blower speed selections ar...

Page 34: ...506887 01 Page 34 of 78 Issue 1213 Typical A97USMV Field Wiring Diagram for Standard Non Communicating Thermostat Figure 44 ...

Page 35: ...506887 01 Page 35 of 78 Issue 1213 ...

Page 36: ...506887 01 Page 36 of 78 Issue 1213 Figure 46 ...

Page 37: ...utes ON Intact Intact Intact S1 T STAT CONTROL TERM STRIP OUTDOOR UNIT 1 Heat 2 Cool NOTE Use DIP switch 3 to set second stage heat ON delay OFF 7 minutes ON 12 m inutes ON Cut Intact Intact S1 T STAT CONTROL TERM STRIP OUTDOOR UNIT 1 Heat 2 Cool with t stat with dehum idification m ode NOTE Use DIP switch 3 to set second stage heat ON delay OFF 7 minutes ON 12 m inutes ON Cut Cut Intact S1 T STAT...

Page 38: ... Harm ony III W 951 O to R Heat Pum ps 2 Heat 2 Cool OFF Cut Intact Intact S1 T STAT CONTROL TERM STRIP OUTDOOR UNIT 2 Heat 2 Cool with t stat with dehum idification m ode OFF Cut Cut Intact S1 T STAT CONTROL TERM STRIP OUTDOOR UNIT 2 Heat 1 Cool OFF Intact Intact Intact S1 T STAT CONTROL TERM STRIP OUTDOOR UNIT Table 12B Field Wiring for Non Communicating Applications continued R required on some...

Page 39: ...506887 01 Page 39 of 78 Issue 1213 ...

Page 40: ...506887 01 Page 40 of 78 Issue 1213 Typical A97USMV Wiring Diagram Figure 47 ...

Page 41: ...506887 01 Page 41 of 78 Issue 1213 Integrated Control Figure 48 ...

Page 42: ...506887 01 Page 42 of 78 Issue 1213 Low Voltage Field Wiring Table 14 2 Stage Single Stage ...

Page 43: ...tat is used the integrated control can be used to energize second stage heat after either 7 minutes or 12 minutes of first stage heat operation See Table 12 Switches 4 and 5 Blower Off Delay The blower On delay of 30 seconds is not adjustable The blower Off delay time that the blower operates after the heating demand has been satisfied can be adjusted by moving switches 4 and 5 on the integrated c...

Page 44: ... Speed Ramping Blower speed ramping may be used to enhance dehumidification performance The switches are factory set at option A which has the greatest effect on blower motor performance Table 19 provides the cooling mode blower speed ramping options that will result from different switch settings The cooling mode blower speed ramping options are detailed below NOTE The OFF portion of the selected...

Page 45: ...to enable the Error Code Recall mode and the Field Test mode Press the button and hold it to cycle through a menu of options Every five seconds a new menu item will be displayed When the button is released the displayed item will be selected Once all items in the menu have been displayed the menu resumes from the beginning until the button is released Error Code Recall Mode Select E from the menu ...

Page 46: ...506887 01 Page 46 of 78 Issue 1213 BLOWER DATA ...

Page 47: ...506887 01 Page 47 of 78 Issue 1213 BLOWER DATA ...

Page 48: ...506887 01 Page 48 of 78 Issue 1213 BLOWER DATA ...

Page 49: ...506887 01 Page 49 of 78 Issue 1213 BLOWER DATA ...

Page 50: ...506887 01 Page 50 of 78 Issue 1213 BLOWER DATA ...

Page 51: ...506887 01 Page 51 of 78 Issue 1213 BLOWER DATA ...

Page 52: ...506887 01 Page 52 of 78 Issue 1213 BLOWER DATA ...

Page 53: ...506887 01 Page 53 of 78 Issue 1213 BLOWER DATA ...

Page 54: ...506887 01 Page 54 of 78 Issue 1213 BLOWER DATA ...

Page 55: ...506887 01 Page 55 of 78 Issue 1213 TABLE 22 ...

Page 56: ...506887 01 Page 56 of 78 Issue 1213 TABLE 23 ...

Page 57: ...as is heavier than air and will settle on the floor The gas valve on these units are equipped with a gas control switch Use only your hand to move the control switch Never use tools If the switch will not move by hand do not try to repair it Force or attempted repair may result in a fire or explosion Placing the Furnace into Operation These units are equipped with an automatic ignition system Do n...

Page 58: ...osed 4 Is there a blown fuse 5 Is the filter dirty or plugged Dirty or plugged filters will cause the limit conrol to shut the unit off 6 Is gas turned on at the meter 7 Is the manual main shut Off valve open 8 Is the gas valve turned on 9 Is the unit ignition system in lock out If the unit locks out again inspect the unit for blockages 10 Is blower harness connected to ignition control Furnace wi...

Page 59: ...old pressures at all altitudes The combustion air pressure switch is factory set and requires no adjustment High Fire Table 22 Table 24 Table 23 Proper Combustion Furnace should operate a minimum of 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 The maximum carbon monoxide reading ...

Page 60: ...506887 01 Page 60 of 78 Issue 1213 Figure 50 ...

Page 61: ... blockages 3 Reset manual flame rollout switches on burner box cover Temperature Rise After the furnace has been started and supply and return air temperatures have been allowed to stabilize check the temperature rise with the unit operating at 100 percent firing rate If necessary adjust the blower speed to maintain the temperture rise within the range shown on the unit nameplate Increase the blow...

Page 62: ...ntegrated control initiates a 30 second stage recognition delay 6 At the end of the recognition delay and on all subsequent calls for heat in the same heating cycle the intergrated control energizes the combustion air inducer at high speed The control also checks the high fire pressure switch to make sure it is closed As the inducer speed is increased to high the indoor blower motor is adjusted to...

Page 63: ...nducer is energized at the ignition speed which is approximately the same as the inducer speed at 70 percent firing rate 2 Once the control receives a signal that the low fire pressure switch has closed the combustion air inducer begins a 15 second prepurge at the ignition speed 3 After the prepurge is complete a 20 second initial ignitor warm up period begins The combustion air inducer continues ...

Page 64: ...y condensate water 3 Remove the drain cap from the condensate trap and empty water Inspect the trap then reinstall the drain cap Cleaning Heat Exchanger If cleaning the heat exchanger becomes necessary follow the below procedures and refer to Figure 1 when disassembling unit Use papers or protective covering in front of furnace while removing heat exchanger assembly 1 Turn off electrical and gas s...

Page 65: ...panel using four existing screws Make sure burners line up in center of burner ports 37 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 38 Reinstall burner box cover 39 Reconnect 2 pin plug to gas valve 40 Replace the blower compartment access panel 41 Refer to instruction on verifying gas and electrical connections when re establishing supplies 42 Follow lighting inst...

Page 66: ... be properly in place and provide a seal between the return air and the room where the furnace is installed Return air duct Must be properly attached and provide an air seal to the unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications Pro...

Page 67: ...e can be programmed When the solid E is displayed the control enters the Error Code Recall mode Error Code Recall mode menu options No change displaying error history remains in Error Code Recall mode solid exits Error Code Recall mode and solid c clears the error history Must press button while flashing c is displayed to clear error codes When the solid is displayed the control enters the Field T...

Page 68: ...506887 01 Page 68 of 78 Issue 1213 ...

Page 69: ...506887 01 Page 69 of 78 Issue 1213 ...

Page 70: ...506887 01 Page 70 of 78 Issue 1213 ...

Page 71: ...506887 01 Page 71 of 78 Issue 1213 Troubleshooting Heating Sequence of Operation Ignition and Call for Low Fire With Two Stage Thermostat ...

Page 72: ...506887 01 Page 72 of 78 Issue 1213 Troubleshooting Heating Sequence of Operation continued Call for High Fire With Two Stage Thermostat ...

Page 73: ...506887 01 Page 73 of 78 Issue 1213 Troubleshooting Heating Sequence of Operation continued Call for Heat Satisfied ...

Page 74: ...506887 01 Page 74 of 78 Issue 1213 Troubleshooting Heating Sequence of Operation continued Ignition and Call for Heat with Single Stage Thermostat ...

Page 75: ...506887 01 Page 75 of 78 Issue 1213 Troubleshooting Cooling Sequence of Operation Call for Cooling ...

Page 76: ...506887 01 Page 76 of 78 Issue 1213 Troubleshooting Continuous Fan Sequence of Operation Continuous Low Speed Indoor Blower Sequence of Operation ...

Page 77: ...agency or gas supplier Cabinet Parts Heating Compartment Access Panel Blower Access Panel Top Cap Control Panel Parts Transformer Integrated Control Board Door Interlock Switch Circuit Breaker Blower Parts Blower Wheel Motor Motor Mounting Frame Blower Housing Cut Off Plate Power Choke 1 HP only Heating Parts Flame Sensor Heat Exchanger Assembly Gas Manifold Combustion Air Inducer Gas Valve Main B...

Page 78: ...imum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not ...

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