Allied 045-12 Installation Instructions Manual Download

Page: 1 / 54

507582-04

Page 1 of 54

Issue 2220

INSTALLATION INSTRUCTIONS

A96DF2E & 96G2DFE

Warm Air Gas Furnace / Downflow Air

Discharge Direct Vent & Non-Direct Vent

Save these instructions for future reference

(P) 507582-04

*P507582-04*

Manufactured By

Allied Air Enterprises LLC

A Lennox International, Inc. Company

215 Metropolitan Drive

West Columbia, SC 29170

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.

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

As with any mechanical equipment, personal injury can

result from contact with sharp sheet metal edges. Be

careful when you handle this equipment.

CAUTION

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

Summary of Contents for 045-12

Page 1: ...on 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 As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment CAUTION Table...

Page 2: ...507582 04 Page 2 of 54 Issue 2220 Model A B C in mm in mm in mm 045 12 17 1 2 446 16 3 8 416 16 406 070 16 090 20 21 533 19 7 8 504 19 1 2 495 110 20 Unit Dimensions ...

Page 3: ...507582 04 Page 3 of 54 Issue 2220 Figure 1 Parts Arrangement ...

Page 4: ...ing 1 Snap bushing 1 Snap Plug 1 Wire tie 1 Condensate trap 1 Condensate trap cap 1 Condensate trap clamp 1 2 diameter debris screen 1 3 4 Threaded street elbow Check equipment for shipping damage If you find any damage immediately contact the last carrier Please refer to specification sheets for available accessories Safety Information Improper installation adjustment alteration service or mainte...

Page 5: ...al Fuel Gas Code or CSA B149 standards NOTE Furnace must be adjusted to obtain a temperature rise within the range specified on the unit nameplate Failure to do so may cause erratic limit operation and premature heat exchanger failure This gas furnace must be installed so that its electrical components are protected from water Installed in Combination with a Cooling Coil When this furnace is used ...

Page 6: ...INSTRUCTIONS FAILURE TO FOLLOW THE ABOVE INSTALLATION INSTRUCTIONS VOIDS THE MANUFACTURER S EQUIPMENT LIMITED WARRANTY ALLIED AIR DISCLAIMS ALL LIABILITY IN CONNECTION WITH INSTALLER S FAILURE TO FOLLOW THE ABOVE INSTALLATION INSTRUCTIONS General These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installatio...

Page 7: ...quirements as well as all local codes CAUTION In the absence of local codes concerning air for combustion and ventilation use the guidelines and procedures in this section to install these furnaces to ensure efficient and safe operation You must consider combustion air needs and requirements for exhaust vents and gas piping A portion of this information has been reprinted with permission from the ...

Page 8: ...nicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors or indirectly through vertical ducts Each opening shall have a minimum free area of 1 square inch per 4 000 Btu 645 mm per 59 kW per hour of the total input rating of all equipment in the enclosure See Figure 6 and Figure 7 It is also permissible to bring air for combustion from a venti...

Page 9: ...d in an application with combustion air coming in from a space serviced by an exhaust fan power exhaust fan or other device which may create a negative pressure in the space take care when sizing the inlet air opening The inlet air opening must be sized to accommodate the maximum volume of exhaust air as well as the maximum volume of combustion air required for all gas appliances serviced by this ...

Page 10: ...xide can be drawn into living space resulting in personal injury or death WARNING Figure 12 Setting Equipment Figure 13 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 cooling coil cabinet Do not drag the unit across the floor in the downflow position Floor and furnace flange damage will r...

Page 11: ...Table 2 Combustible Flooring Base Opening Size Cabinet Width Catalog Number Front to Rear Side to Side in mm in mm B 17 5 11M60 22 559 18 3 4 476 C 21 11M61 22 559 22 3 4 578 Figure 16 2 After opening is cut set the combustible flooring base into opening 3 Check fiberglass strips on the combustible flooring base to make sure they are properly glued and positioned 4 Lower supply air plenum into the...

Page 12: ...ternal static pressure which exceeds 0 8 inches w c Operation at these conditions may result in improper limit operation Supply Air Plenum If the furnace is installed without a cooling coil a removable access panel should be installed in the supply air duct The access panel should be large enough to permit inspection by reflected light of the heat exchanger for leaks after the furnace is installed...

Page 13: ...S to either PVC or CPVC Low temperature solvent cement is recommended during cooler weather Metal or plastic strapping may be used as vent pipe hangers Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket Model VENT PIPE DIA in STANDARD CONCENTRIC Outdoor Exhaust Accelerator D...

Page 14: ...lined in ASTM D 2855 NOTE A sheet metal screw may be used to secure the intake pipe to the connector if desired Use a drill or self tapping screw to make a pilot hole DANGER OF EXPLOSION Fumes from PVC glue may ignite during system check Allow fumes to dissipate for at least 5 minutes before placing unit into operation DANGER 1 Measure and cut vent pipe to desired length 2 Debur and chamfer end of...

Page 15: ...ge restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 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 Turn ON clothes dryers and any appliances not connected to the common venting system Turn ON any exhaust fans such as ...

Page 16: ...ations combustion air is taken from outdoors and flue gases are discharged outdoors Intake and exhaust pipe sizing Size pipe according to Table 6 and Table 7A through Table 7C Table 6 lists the minimum vent pipe lengths permitted Table 7A through Table 7C list the maximum pipe lengths permitted Regardless of the diameter of pipe used the standard roof and wall terminations described in section Exh...

Page 17: ... 26 11 60 60 38 n a 83 82 63 63 10 21 6 55 55 33 78 77 58 58 Standard Termination at Elevation 4 501 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model Model Model 45 70 90 110 45 70 90 110 45 70 90 110 45 70 90 110 1 20 15 n a n a 66 51 29 n a 100 100 78 43 123 122 103 103 2 15 10 61 46 24 95 95 73 38 118 117 98 98 3 10 n a 56 41 19 90 90 68 33 113 112 93 93 4 n a ...

Page 18: ...1 64 64 9 18 50 50 34 66 66 59 59 10 13 45 45 29 61 61 54 54 Concentric Termination at Elevation 4 501 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model Model Model 45 70 90 110 45 70 90 110 45 70 90 110 45 70 90 110 1 15 10 n a n a 58 43 27 n a 90 90 74 39 106 106 99 99 2 10 n a 53 38 22 85 85 69 34 101 101 94 94 3 n a 48 33 17 80 80 64 29 96 96 89 89 4 43 28 12 7...

Page 19: ...33 n a 73 72 53 53 8 21 6 50 50 28 68 67 48 48 9 16 1 45 45 23 63 62 43 43 10 11 n a 40 40 18 58 57 38 38 NOTE Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation Table 7C Figure 23 Typical Exhaust Pipe Connections Pipe size determined in table 7 2 TOP VIEW EXHAUST INTAKE 2 2 2 2 or TRANSITION 3 2 2 1 1 2 or TR...

Page 20: ... given in general guide lines for piping terminations and intake and exhaust piping terminations for direct vent sections Refer to Table 7A through Table 7C for pipe sizes Follow the next two steps when installing the unit in Non Direct Vent applications where combustion air is taken from indoors and flue gases are discharged outdoors 1 Use field provided materials and the factory provided air int...

Page 21: ...e 28 or Figure 29 In addition position termination so it is free from any obstructions 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 8 m of a condensing unit beca...

Page 22: ...0 to 20 18 to 29 1 1 2 in 8 N A 13 N A N A N A N A N A 2 in 6 4 12 10 19 16 18 15 2 1 2 in N A N A 7 N A 13 N A 12 N A 3 in N A N A N A N A 8 8 7 7 1 Refer to 99 Minimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook 2 Poly Propylene vent pipe PP by Duravent and Centrotherm 3 Vent length in table is equivalent length Each elbow is equivalent to 5ft of ...

Page 23: ...ly inlet Clearance above paved sidewalk or paved driveway located on public property Clearance under veranda porch deck or balcony 12 Equal to or greater than soffit depth 3 feet 9m 12 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for...

Page 24: ...m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 pliances 10 000 Btuh 3kw and 50 000 pliances 50 000 Btuh 15kw 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 3m horizontally 6 feet 1 8m 7 ...

Page 25: ...ake and exhaust pipes should be placed as close together as possible at termination end refer to illustrations Minimum separation is 3 76 mm on roof terminations and 6 152 mm on side wall terminations 3 On roof terminations the intake piping should terminate straight down using two 90 elbows See Figure 30 4 Exhaust piping must terminate straight out or up as shown A reducer may be required on the ...

Page 26: ...Y BE REQUIRED TO ADAPT DIFFERENT VENT PIPE SIZE TO TERMINATION 1 1 2 38mm accelerator provided on 71M80 44W92 kits for 045 and 070 models 12 305mm INTAKE AIR EXHAUST VENT Figure 35 Direct Vent Concentric Wall Termination 71M80 69M29 OR 60L46 US 41W92 or 41W93 Canada 12 305mm Min above grade or average snow accumulation INTAKE AIR INTAKE AIR INTAKE AIR OUTSIDE WALL GRADE CLAMP Not Furnished FIELD P...

Page 27: ... 3 76MM Vent Pipe A Clearance above grade or average snow accumulation B Horizontal separation between intake and exhaust C Minimum from end of exhaust to inlet of intake D Exhaust pipe length E Wall support distance from top of each pipe intake exhaust 12 305 mm Min 12 305 mm Min 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 16 405 mm Max 6 152 mm Max 6 152 mm Min 24 610 mm Max 9 227 mm M...

Page 28: ...mm PVC beyond the outside wall See Figure 40 3 If exhaust piping must be run up a sidewall to position above snow accumulation or other obstructions piping must be supported every 24 610 mm as shown in Figure 41 When exhaust piping must be run up an outside wall any reduction in exhaust pipe size must be done after the final elbow Figure 39 Non Direct Vent Roof Termination Kit Figure 40 Non Direct...

Page 29: ...on Kit 51W18 is shown Figure 44 Crawl Space Vent Pipe Drain Trap Assembled Incorrectly Figure 45 Upflow or Downflow Furnace with Exhaust through Crawl Space KIT 51W18 USA Basement Floor To Termination 1 2 PVC to Code Approved Drain 24 max Downflow Furnace Exhaust KIT 15Z70 Canada Kit 51W18 is shown NOTE Upflow furnaces exhaust from the left side All dimensions shown are typical for upflow or downf...

Page 30: ...ensate line must maintain a 1 4 downward slope from the furnace to the drain Do Not use copper tubing or existing copper condensate lines for drain line CAUTION Figure 46 Condensate Trap and Plug Locations 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 5 Figure 48 shows the furnace and evaporator ...

Page 31: ...bining 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 CAUTION Figure 49 Evaporator Coil Using a Common Drain Figure 50 Condensate Trap with Optional Overflow Switch ...

Page 32: ...rnished Drain Assembly for 3 4 inch Drain Pipe Condensate Drain Connection In Unit Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Optional Condensate Drain Connection OptionalDrainPipingFromTrap DrainTrapAssembly Furnished DrainTrap Assembly with 1 2 inch Piping DrainTrap Assembly with 3 4 inch Piping 1 2 inch 3 4 inch 1 25 mm Min 2 50 mm Max Above Top Of Con...

Page 33: ...diment or condensate 5 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection 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 type Compounds used on threaded joints of gas piping must be resistant to the actions of liquified p...

Page 34: ...54 118 3 34 110 3 11 103 2 92 1 25 4 1 049 26 645 680 19 25 465 13 17 375 10 62 320 9 06 285 8 07 260 7 36 240 6 80 220 6 23 205 5 80 195 5 52 1 1 4 31 75 1 380 35 052 1400 39 64 950 26 90 770 21 80 660 18 69 580 16 42 530 15 01 490 13 87 460 13 03 430 12 18 400 11 33 1 1 2 38 1 1 610 40 894 2100 59 46 460 41 34 1180 33 41 990 28 03 900 25 48 810 22 94 750 21 24 690 19 54 650 18 41 620 17 56 2 50 ...

Page 35: ...e 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 Table 11 Model Maximum Over Current Protection Amps 045B12 070B16 15 090C20 110C20 20 4 Before connecting the thermostat check to make sure the wires will be long enough for servicing at a later date Make sure that thermost...

Page 36: ... should be checked before attempting to operate the furnace on either permanent or temporary power Generator should have a wave form distortion of less than 5 THD Total Harmonic Distortion Electrical Wiring Risk of electrical shock Disconnect electrical power at the circuit breaker or service panel before making electrical connections Failure to disconnect power supplies can result in property dam...

Page 37: ...n delay when a single stage thermostat is being used The switch is factory set in the OFF position which provides a 7 minute delay before second stage heat is initiated If the switch is toggled to the ON position it will provide a 12 minute delay before second stage heat is initiated This switch is only activated when the thermostat selector jumper is positioned for single stage thermostat use Ind...

Page 38: ...507582 04 Page 38 of 54 Issue 2220 Figure 56 Wiring Diagram with Resideo Honeywell Integrated Furnace Control 103132 xx ...

Page 39: ... A92 CONTROL BOARD WHEN USED FOR DUAL FUEL APPLICATIONS RATING INSULATION THICKNESS AND TERMINATION K1 K4 K7 K8 8 8 HI W914 W915 M M 1 2 3 4 5 6 7 L1 J3 NEUTRALS J2 65 AMP 43 AMP WHITE RODGERS VALVE NOTE SEE INSTALLATION INSTRUCTIONS FOR PROCEDURE TO SET CORRECT BLOWER SPEED FOR SPECIFIC COOLING TONNAGE BEING APPLIED AND HEATING TEMPERATURE RISE DESIRED TYPICAL SYSTEM SHOWN FOR 2 HEAT 2 COOL WITH ...

Page 40: ...D GRD Y1 THERMOSTAT 1ST STAGE COOL SIGNAL Y2 THERMOSTAT 2ND STAGE COOL SIGNAL O THERMOSTAT SIGNAL TO HEAT PUMP REVERSING VALVE L NOT USED DH NOT USED 3 16 QUICK CONNECT TERMINALS FLAME SENSE SIGNAL HI Cool 24VAC HI HEAT 24VAC LO COOL 24VAC LO HEAT 24VAC PAR PAR COMMON 24VAC 1 4 QUICK CONNECT TERMINALS NEUTRALS 120 NEUTRAL HUM UNPOWERED NORMALLY OPEN DRY CONTACTS LI 120 VAC INPUT TO CONTROL ACC 120...

Page 41: ...ry contacts ACC one 120VAC output terminal for optional accessory L1 three 120VAC line terminals Neutrals five 120VAC neutral terminals THERMOSTAT CONNECTIONS DS Dehumidification signal W2 Heat demand from 2nd stage Tstat W1 Heat demand from 1st stage Tstat white R Class 2 voltage to thermostat G Manual fan from Tstat green C Tstat signal ground connected to transformer Ground TR Chassis ground GR...

Page 42: ...507582 04 Page 42 of 54 Issue 2220 Table 15A Field Wiring Applications with Conventional Thermostat ...

Page 43: ...507582 04 Page 43 of 54 Issue 2220 Table 15B Field Wiring Applications with Conventional Thermostat Continued ...

Page 44: ...C Field Wiring Applications with Conventional Thermostat Continued 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 ...

Page 45: ...D Field Wiring Applications with Conventional Thermostat Continued 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 ...

Page 46: ...ces of the building 4 Close fireplace dampers 5 Turn on clothes dryers and any appliances not connected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instruction to place the appliance being inspected into operation Adjust thermostat so appliance will operate c...

Page 47: ...rain operation If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death WARNING Gas Valve Operation 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest setting 3 Turn OFF all electrical power to the unit 4 This furnace is equipped with an ignition device which automatically lig...

Page 48: ...ifold pressure 2 Start unit and allow 5 minutes for unit to reach steady state 3 While waiting for the unit to stabilize observe the flame Flame should be stable and should not lift from burner Natural gas should burn blue 4 After allowing unit to stabilize for 5 minutes record manifold pressure and compare to value given in Table 18 NOTE Shut unit off and remove manometer as soon as an accurate r...

Page 49: ...ble 20 for allowable heating speeds Increase the blower speed to decrease the temperature Decrease the blower speed to increase the temperature rise Failure to adjust the temperature rise may cause erratic limit operation Blower Control The blower ON time of 30 seconds is not adjustable The blower OFF delay amount of time that the blower operates after the heat demand has been satisfied is 120 sec...

Page 50: ...atts 0 00 1770 510 1550 340 1355 220 1255 180 1035 115 0 10 1720 520 1510 355 1315 230 1200 185 980 105 0 20 1705 535 1470 365 1265 245 1165 195 895 110 0 30 1665 540 1430 380 1235 250 1120 205 835 120 0 40 1605 555 1390 395 1185 260 1070 210 775 130 0 50 1585 565 1335 400 1155 275 1015 225 690 140 0 60 1540 565 1300 410 1100 290 970 235 625 145 0 70 N A N A 1260 420 1050 295 915 245 570 150 0 80 ...

Page 51: ...ng Speeds Model Low Fire Heating Speeds High Fire Heating Speeds Red Yellow Blue Brown Black Red Yellow Blue Brown Black 045 Allowed Factory Setting Not Allowed Not Allowed Not Allowed Not Allowed Allowed Factory Setting Allowed Allowed 070 Allowed Factory Setting Allowed Not Allowed Not Allowed Not Allowed Allowed Allowed Factory Setting Allowed 090 Allowed Factory Setting Allowed Not Allowed Not...

Page 52: ... 120 VAC 10 3 Check amp draw on the blower motor with the blower compartment access panel in place Motor Nameplate____________Actual____________ Winterizing and Condensate Trap Care 1 Turn off power to the furnace 2 Have a shallow pan ready to empty condensate water 3 Remove the clean out cap from the condensate trap and empty water Inspect the trap then reinstall the clean out cap Cleaning the Bu...

Page 53: ...ng the inspection may make it necessary to temporarily shut down the furnace until the items can be repaired or replaced Instruct the homeowners to pay attention to their furnace Situations can arise between annual furnace inspections that may result in unsafe operation For instance items innocently stored next to the furnace may obstruct the combustion air supply This could cause incomplete combu...

Page 54: ...nimum 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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