Allied 96G1DFE Installation Instructions Manual Download

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507769-04

Page 1 of 53

Issue 1927

INSTALLATION INSTRUCTIONS

96G1DFE

Warm Air Gas Furnace

Downflow Air Discharge

Save these instructions for future reference

(P) 507769-04

*P507769-04*

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

..........................................................

Parts Arrangement

.......................................................

Gas Furnace

................................................................

Shipping and Packing List ...........................................

Safety Information

.......................................................

General

........................................................................

Combustion, Dilution & Ventilation Air

.........................

Installation

...................................................................

Filters

.........................................................................

Duct System

..............................................................

Venting Practices

.......................................................

Condensate Piping

....................................................

Gas Piping

.................................................................

Electrical

....................................................................

Unit Start-Up

..............................................................

Testing for Proper Venting and Sufficient Combustion

Air for Non-Direct Vent Applications

..........................

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

Blower Performance Data

.........................................

Service

.......................................................................

Planned Service

........................................................

Repair Parts List

........................................................

Summary of Contents for 96G1DFE

Page 1: ...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 Sh...

Page 2: ... 9 1 8 232 Right 6 9 16 167 Left 2 51 Either Side 3 4 19 B Supply Air 9 16 14 9 16 14 9 16 14 19 7 16 494 CONDENSATE TRAP CONNECTION 5 127 6 1 2 165 Either Side 2 1 4 57 Either Side 1 25 Front Panel 705 AIR FLOW 33 838 C 3 4 19 3 4 19 FRONT VIEW Supply Air 9 16 14 9 229 Unit Dimensions 96G1DFE Capacity A B C in mm in mm in mm 045 12 070 16 17 1 2 446 16 3 8 416 16 406 090 16 21 533 19 7 8 504 19 1...

Page 3: ...and door switch BAG ASSEMBLY BLOWER MOTOR hidden COMBUSTION AIR INDUCER BURNER BOX ASSEMBLY includes flame sensor rollout switches and ignitor GAS VALVE BLOWER DECK HEAT EXCHANGER COLD END HEADER BOX PRIMARY LIMIT BLOWER ACCESS PANEL HEATING ACCESS PANEL COMPARTMENT COMPARTMENT Parts Arrangement ...

Page 4: ...the Gas Piping section for relevant diagrams 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 DANGER OF EXPLOSION There are circumstances in which odorant used with LP Propane gas can lose its scent In case of a leak LP Propane gas will settle close to the floor and may ...

Page 5: ...must be electrically grounded according to local codes In addition in the United States installation must conform with the current National Electric Code ANSI NFPA No 70 The National Electric Code ANSI NFPA No 70 is available from the following address National Fire Protection Association 1 Battery March Park Quincy MA 02269 In Canada all electrical wiring and grounding for the unit must be instal...

Page 6: ...with clothing boxes doors etc Air is needed for proper combustion and safe unit operation When the furnace is installed in an attic or other insulated space keep insulation away from the furnace When the furnace is installed in an unconditioned space consider provisions required to prevent freezing of the condensate drain system NOTE The Commonwealth of Massachusetts stipulates these additional re...

Page 7: ... the combined input rating of all appliances installed in that space This space also includes adjacent rooms which are not separated by a door Though an area may appear to be unconfined it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration Do not install the furnace in a corrosive or contaminated atmosphere Meet all combustion and...

Page 8: ...g shall have a minimum free area of 1 square inch 645 mm per 2 000 Btu 56 kW per hour of the total input rating of all equipment in the enclosure See Figure 7 When ducts are used they shall be of the same cross sectional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be no less than 3 inches 75 mm In calculating free area the blocki...

Page 9: ...nections electrical supply vent connection condensate trap and drain connections and installation and service clearances 24 inches 610 mm at unit front The unit must be level from side to side Tilt the unit slightly maximum 1 2 in from level from back to front to aid in the draining of the heat exchanger See Figure 11 Shipping Bolt Removal Units with a 1 2 hp 3 4 hp blower motors are equipped with...

Page 10: ...applications Top Bottom Left Side Right Side Top 0 Front 0 Back 0 Sides 0 Vent 0 Floor NC Front clearance in alcove installation must be 24 in 610 mm Maintain a minimum of 24 in 610 mm for front service access Allow proper clearances to accommodate condensate trap Thefurnacemaybeinstalledonacombustiblewoodfloorifanoptional additive base is installed between the furnace and the combustible floor Fi...

Page 11: ...o the combustible flooring base until plenum flanges seal against fiberglass strips NOTE Be careful not to damage fiberglass strips Check for a tight seal 5 Set the furnace over the plenum 6 Ensure that the seal between the furnace and plenum is adequate Installation on Cooling Coil Cabinet See Figure 16 NOTE Downflow combustible flooring kit is not used 1 Refer to reverse flow coil installation i...

Page 12: ... appliance i e water heater or carbon monoxide producing device i e wood fireplace is installed When return air is drawn from a room a negative pressure is created in the room If a gas appliance is operating in a room with negative pressure the flue products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete combustion and the formati...

Page 13: ...itional solvent cement to make connections to the PVC fitting in the unit IMPORTANT Canadian Applications Only Pipe fittings primer and solvent cement used to vent exhaust this appliance must be certified to ULC S636 and supplied by a single manufacturer as part of an approved vent exhaust system When bonding the vent system to the furnace use ULC S636 approved One Step Transition Cement to bond t...

Page 14: ...ipe 1 4 turn during assembly but not after pipe is fully inserted to distribute cement evenly Do not turn ABS or cellular core pipe NOTE Assembly should be completed within 20 seconds after last application of cement Hammer blows should not be used when inserting pipe 8 After assembly wipe excess cement from pipe at end of fitting socket A properly made joint will show a bead around its entire per...

Page 15: ...ged outdoors Intake and exhaust pipe sizing Size pipe according to Table 6 and Table 7 Table 6 lists the minimum vent pipe lengths permitted Table 7 lists the maximum pipe lengths permitted Regardless of the diameter of pipe used the standard roof and wall terminations described in section Exhaust Piping Terminations should be used Exhaust vent termination pipe is sized to optimize the velocity of...

Page 16: ...7 78 8 26 11 65 45 n a 92 92 73 9 21 n a 60 40 87 87 68 10 16 55 35 82 82 63 Concentric Termination Elevation 0 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity Capacity 045 070 090 045 070 090 045 070 090 045 070 090 1 10 10 n a 53 38 22 90 70 39 111 111 104 2 n a n a 48 33 17 85 65 34 106 106 99 3 43 28 12 80 60 29 101 101 94 4 38 23 n a 75 55 24 ...

Page 17: ...haust 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 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity Capacity 045 070 090 045 070 090 045 070 090 045 070 090 1 10 10 n a 61 46 24 100 80 43 127 127 108 2 n a n a 56 41 19 95 75 38 122 122 103...

Page 18: ... the inlet air connector 2 Route piping to outside of structure Continue with installation following instructions given in general guide lines for piping terminations and intake and exhaust piping terminations for direct vent sections Refer to Table 7 for pipe sizes Follow the next steps when installing the unit in Non Direct Vent applications where combustion air is taken from indoors and flue ga...

Page 19: ...igure 27 or Figure 28 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 ...

Page 20: ...18 16 32 29 2 1 2 in 5 N A 13 N A 24 N A 3 in N A N A 8 8 19 19 0 to 20 18 to 29 1 1 2 in 10 N A 15 N A N A N A 2 in 5 3 12 10 22 19 2 1 2 in N A N A 7 N A 15 N A 3 in N A N A N A N A 10 10 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 ...

Page 21: ...nlet 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 app...

Page 22: ...ithin 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 fee...

Page 23: ...e Termination Size Reduction 96G1DFE Capacity Exhaust Pipe Size Termination Pipe Size 045 and 070 2 51 mm 2 1 2 64 mm 3 76 mm 1 1 2 38 mm 090 2 51 mm 045 070 and 090 units with the flush mount termination must use the 1 1 2 accelerator supplied with the kit 5 On field supplied terminations for side wall exit exhaust piping may extend a maximum of 12 inches 305 mm for 2 PVC and 20 inches 508 mm for...

Page 24: ... 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 Min 12 305 mm Min 20 508 mm Max 6 15...

Page 25: ...xterior portion of chimney the exhaust vent must be insulated Figure 34 Direct Vent Application Using Existing Chimney Figure 35 Direct Vent Concentric Wall Termination 12 305mm Min above grade or average snow accumulation 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada INTAKE AIR INTAKE AIR INTAKE AIR OUTSIDE WALL GRADE CLAMP Not Furnished FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT...

Page 26: ...ion Kit 15F75 or 44J41 UNCONDITIONED ATTIC SPACE 3 76MM OR 2 51MM PVC PROVIDE SUPPORT FOR EXHAUST LINES 12 305MM ABOVE AVE SNOW ACCUMULATION SIZE PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE Figure 39 Non Direct Vent Field Supplied Wall Termination SIZE TERMINATION PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE Figure 40 Non Direct Vent Field Supplied Wall Termination Extended SIZE TERMINA...

Page 27: ...Termination Drain Trap assembled Figure 42 Kit 51W18 USA 15Z70 Canada Parts Identification and Assembly Exhaust from Furnace To Termination Exhaust from Furnace To Termination Kit 51W18 is shown Figure 43 Crawl Space Vent Pipe Drain Trap Assembled Incorrectly Figure 44 Upflow or Downflow Furnace with Exhaust through Crawl Space KIT 51W18 USA Basement Floor To Termination 1 2 PVC to Code Approved D...

Page 28: ...trap Secure with clamp See Figure 50 4 Install drain trap using appropriate PVC fittings glue all joints Glue the provided drain trap as shown in Figure 50 Route the condensate line to an open drain Condensate line must maintain a 1 4 downward slope from the furnace to the drain 5 If unit will be started immediately upon completion of installation prime trap per procedure outlined in Unit Start Up...

Page 29: ...n DO NOT connect the condensate trap drain into the drain line from the evaporator coil CAUTION When combining 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 IMPORTANT Figure 48 Evaporator Coil Using a Common Drain Figure 49 Condensate Trap with Optional Overflow Switch ...

Page 30: ...507769 04 Page 30 of 53 Issue 1927 Figure 50 Trap Drain Assembly Using 1 2 PVC or 3 4 PVC ...

Page 31: ...10 feet 2 44 to 3 05 m using suitable hangers or straps Install a drip leg in vertical pipe runs to serve as a trap for sediment 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 See Figure 51 6 In some localities codes may require installation of a manual main shut off valve and union furnished by installer external to the uni...

Page 32: ... 4 28 138 3 91 125 3 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 ...

Page 33: ...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 range hoods and bathroo...

Page 34: ...ng connections to the equipment Use the provided unit wiring diagram and the field wiring diagram shown in Figure 56 Use 18 gauge wire or larger that is suitable for Class II rating for thermostat connections Electrically ground the unit according to local codes or in the absence of local codes according to the current National Electric Code ANSI HFPA No 70 for the USA and current Canadian Electri...

Page 35: ... the instructions provided with the thermostat See Figure 55 for thermostat designations If the furnace is being matched with a heat pump refer to the FM21 installation instruction or appropriate dual fuel thermostat instructions Indoor Blower Speeds 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 ...

Page 36: ...507769 04 Page 36 of 53 Issue 1927 Figure 57 Typical Wiring Diagram ...

Page 37: ...WARNING Danger of explosion Can cause injury or product or property damage Should the gas supply fail to shut off or if overheating occurs shut off the gas valve to the furnace before shutting off the electrical blower deck before performing any service procedure WARNING Before attempting to perform any service or maintenance turn the electrical power to unit OFF at disconnect switch CAUTION BEFOR...

Page 38: ...s valve switch to ON See Figure 59 9 Replace the heating compartment access panel 10 Turn on all electrical power to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 12 If the appliance will not operate follow the instructions Turning Off Gas to Unit and call your service technician or gas su...

Page 39: ...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 14 NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to remove barbed fitting and re...

Page 40: ... 11K45 Conversion requires installation of a gas valve regulator spring which is provided with the gas conversion kit LP kits include low line pressure switch 96G1 Pressure Switch Requirements at Varying Altitudes 96G1DFE Capacity 0 4500 ft 0 1 373m 4501 7500 ft 1371 2286m 7501 10000 ft 2286 3048m 045 No Change No Change 11J09 070 No Change 17V95 11U67 090 No Change 11U70 10U93 Pressure switch is ...

Page 41: ... 2 Visually inspect the venting system for proper size and horizontal pitch Determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 To the extent that it is practical close all building doors and windows and all doors between the space in which the appliances connected to the venting system are located and other spaces of the bu...

Page 42: ...ol module both contained in the same motor housing The motor is programmed to provide constant torque at each of the five selectable speeds The motor has five speed taps Each tap requires 24 volts to energize Thermostat Heat Anticipation Set the heat anticipator setting if adjustable according to the amp draw listed on the wiring diagram that is attached to the unit Figure 60 Heat Fan OFF Time in ...

Page 43: ...atts cfm watts cfm watts 0 00 1720 510 1545 355 1340 235 1240 190 1020 95 0 10 1700 530 1505 360 1310 245 1195 200 955 110 0 20 1675 545 1465 370 1275 255 1155 205 895 115 0 30 1640 555 1420 380 1230 270 1120 215 835 125 0 40 1600 565 1380 395 1180 280 1060 225 785 135 0 50 1560 570 1340 400 1140 290 1015 235 715 145 0 60 1500 565 1300 420 1095 305 965 245 640 150 0 70 N A N A 1255 430 1040 315 91...

Page 44: ...lting in personal injury or death WARNING Filters All air filters are installed external to the unit Filters should be inspected monthly Clean or replace the filters when necessary to ensure proper furnace operation Table 3 lists recommended filter sizes Exhaust and Air Intake Pipes Check the exhaust and air intake pipes and all connections for tightness and to make sure there is no blockage NOTE ...

Page 45: ...s used it must be below 275 F 135 C 18 Thoroughly rinse and drain the heat exchanger Soap solutions can be corrosive Take care to rinse entire assembly 19 Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting on the support located at the rear of the cabinet Remove the indoor blower to view this area through the blower opening 20 Resecure ...

Page 46: ...e 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 combustion and the production of carbon monoxide gas 6 Remove four screws which secure burner box assembly to vest panel Remove burner bo...

Page 47: ...e limit switch open longer than 3 minutes 8 Flashes Rollout switch open 9 Flashes Pressure switch failed to close or opened during heat demand 10 Flashes Watchguard Pressure switch opened 5 times during one heat demand 11 Flashes Pressure switch stuck closed prior to activation of combustion air inducer 12 Flashes Flame sensed without gas valve energized 13 Flashes Low line voltage 1 A heartbeat i...

Page 48: ...507769 04 Page 48 of 53 Issue 1927 Troubleshooting Heating Sequence of Operation ...

Page 49: ...507769 04 Page 49 of 53 Issue 1927 Troubleshooting Heating Sequence of Operation continued ...

Page 50: ...507769 04 Page 50 of 53 Issue 1927 Troubleshooting Cooling Sequence of Operation ...

Page 51: ...507769 04 Page 51 of 53 Issue 1927 Troubleshooting Continuous Fan Sequence of Operation ...

Page 52: ...quivalent service agency or gas supplier Cabinet Parts Upper Access Panel Blower Access Panel Top Cap Control Panel Parts Transformer Integrated Control Board Door Interlock Switch Blower Parts Blower Wheel Motor Motor Mounting Frame Motor Capacitor Blower Housing Cutoff Plate Heating Parts Flame Sensor Heat Exchanger Assembly Gas Manifold Combustion Air Inducer Gas Valve Main Burner Cluster Main ...

Page 53: ...m 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 app...

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