Allied 96G2DFV Installation Instructions Manual Download

Page: 1 / 53

507962-01

Page 1 of 53

Issue 2149

INSTALLATION INSTRUCTIONS

96G2DFV

Warm Air Gas Furnace / Downflow Air Discharge

Direct Vent & Non-Direct Vent

Save these instructions for future reference

(P) 507962-01

*P507962-01*

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

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

Testing for Proper Venting and Sufficient Combustion

Air for Non-Direct Vent Applications

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

Unit Start-Up

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

Blower Performance

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

Service

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

Planned Service

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

Repair Parts List

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

Summary of Contents for 96G2DFV

Page 1: ...intenance 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 A...

Page 2: ...507962 01 Page 2 of 53 Issue 2149 Unit Dimensions 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 20 110 20 21 533 19 7 8 504 19 1 2 495 ...

Page 3: ...507962 01 Page 3 of 53 Issue 2149 Parts Arrangement Figure 1 Access Panel Combustion Air Inducer Burner Box Assembly Gas Valve Control Box Blower Assembly ...

Page 4: ... 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 be difficult to smell An LP propane leak detector should be installed in all LP applica...

Page 5: ...rnace If the damper is manually operated it must be equipped to prevent operation of either the heating or the cooling unit unless it is in the full HEAT or COOL setting When installed this furnace 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 ...

Page 6: ...ALLER IS RESPONSIBLE FOR CONFIRMING THAT THE USE OF CONSTRUCTION HEAT IS CONSISTENT WITH THE POLICIES AND CODES OF ALL REGULATING ENTITIES ALL SUCH POLICIES AND CODES MUST BE ADHERED TO General These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation In addition to the requirements outlined previously...

Page 7: ...This reprinted material is not the complete and official position of ANSI on the referenced subject which is represented only by the standard in its entirely In Canada refer to the CSA B149 Installation codes Do not install the furnace in a corrosive or contaminated atmosphere Meet all combustion and ventilation air requirements as well as all local codes CAUTION All gas fired appliances require a...

Page 8: ...m of the top of the enclosure and one within 12 305 mm of the bottom These openings must communicate 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 enclo...

Page 9: ...ted Exhaust Pipe Furnace Intake Debris Screen Provided See Maximum Vent Lengths table NOTE The inlet and outlet air openings shall each have a free area of at least one square inch per 4 000 Btu 645mm2 per 1 17kW per hour of the total input rating of all equipment in the enclosure Figure 9 Equipment in Confined Space Inlet Air from Ventilated Attic and Outlet Air to Outside Roof Terminated Exhaust...

Page 10: ...t nameplate Minimum clearances for closet or alcove installations are shown in Figure 14 Figure 11 Units with 1 2 HP Blower Motor Blower access panel must be securely in place when blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal injury or death WARNING Figure 12 Setting Equipment Figure 13 Improper installation of ...

Page 11: ...um into the opening 3 Set the unit over the plenum and seal the plenum to the unit 4 Ensure that the seal is adequate Table 1 Non Combustible Floor Opening Size Cabinet Width Front to Rear Side to Side in mm in mm B cabinet 17 5 19 3 4 502 16 5 8 422 C cabinet 21 20 1 8 511 NOTE Floor opening dimensions listed are 1 4 in 6 mm larger than the unit opening See dimension drawing on Page 2 Figure 15 I...

Page 12: ...glass strips on the combustible flooring base to make sure they are properly glued and positioned 4 Lower supply air plenum into 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 Co...

Page 13: ...cement with skin and eyes CAUTION The exhaust and intake connections are made of PVC Use PVC primer and solvent cement when using PVC vent pipe When using ABS vent pipe use transitional solvent cement to make connections to the PVC fitting in the unit IMPORTANT Table 4 Piping and Fittings Specifications Schedule 40 PVC Pipe D1785 Schedule 40 PVC Cellular Core Pipe F891 Schedule 40 PVC Fittings D24...

Page 14: ...romptly apply solvent cement to 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 Capacity VENT PIPE DIA in STANDARD CONCENTRIC Outdoor Exhaust Accelerator Dia X Length ...

Page 15: ...ning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation WARNING 1 Seal any unused openings in the common venting system 2 Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage cor...

Page 16: ...t Vent gas central furnace NOTE In non Direct Vent installations combustion air is taken from indoors and flue gases are discharged outdoors In Direct Vent installations 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 7...

Page 17: ...size vent pipe diameter Figure 22 070 090 110 Standard or Concentric See Table 5 Intake or Exhaust 1 1 2 2 2 1 2 or 3 Furnace capacity 1 Which termination 2 Which needs most elbows 3 How many 4 Desired pipe size 5 What is the altitude 6 Use Table 7 to find max pipe length 7 ...

Page 18: ...8 16 65 43 8 87 68 68 9 11 60 38 n a 82 63 63 10 6 55 33 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 Capacity Capacity Capacity Capacity 070 090 110 070 090 110 070 090 110 070 090 110 1 15 n a n a 51 29 n a 100 78 43 122 103 103 2 10 46 24 95 73 38 117 98 98 3 n a 41 19 90 68 33 112 93 93 4 36 14 85 63 28 107 88 88 5 31 9...

Page 19: ...69 69 8 n a 55 39 n a 71 64 64 9 50 34 66 59 59 10 45 29 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 Capacity Capacity Capacity Capacity 070 090 110 070 090 110 070 090 110 070 090 110 1 n a n a n a 43 27 n a 90 74 39 106 99 99 2 38 22 85 69 34 101 94 94 3 33 17 80 64 29 96 89 89 4 28 12 75 59 24 91 84 84 5 23 7 70 54 19...

Page 20: ... be the same diameter 96G2DFV Maximum Allowable Exhaust Vent Length 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 070 090 110 070 090 110 070 090 110 070 090 110 1 n a n a n a 41 24 n a 85 63 28 102 83 83 2 36 19 80 58 23 97 78 78 3 31 14 75 ...

Page 21: ...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 Use the following 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 intake...

Page 22: ...re 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 bec...

Page 23: ...9 1 1 2 in 13 N A N A N A N A N A 2 in 12 10 19 16 18 15 2 1 2 in 7 N A 13 N A 12 N A 3 in 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 straight pipe and should be included when...

Page 24: ...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 25: ...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 26: ... 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 exhaust piping at the point where it exits the structure to improve the velocity of exhaust away from the intake piping See Table 9 Table 9 Exhaust Pipe Termination Size Reduction Capacity Exhaust Pipe Size Termination Pipe Size 045 and 070 2 51 mm 2 1 2 64 ...

Page 27: ...ake piping must be run up an outside wall the exhaust piping must be terminated with pipe sized per Table 9 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 8 Based on the recommendation of the manufacturer a multiple furnace installation may use a group of up to four terminations assembled together horizontally as...

Page 28: ...e 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 6 152 mm Max D C 12 ...

Page 29: ... ACCUMULATION SIZE PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE Figure 40 Non Direct Vent Field Supplied Wall Termination SIZE TERMINATION PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT DIFFERENT VENT PIPE SIZE TO TERMINATION Figure 41 Non Direct Vent Field Supplied Wall Termination Extended SIZE TERMINATION PER EXHAUST PIPE TERMINATION SIZE ...

Page 30: ...Termination Drain Trap assembled Figure 43 Kit 51W18 USA 15Z70 Canada Parts Identification and Assembly Exhaust from Furnace To Termination Exhaust from Furnace To Termination 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 D...

Page 31: ...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 Plug same on left side Trap same on right side 1 1 2 in 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 ...

Page 32: ...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 33: ...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 34: ...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 35: ...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 36: ...ty 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 thermostat wire is long enough to facilitate future removal of blower for service 5 Complete the wiring connections to the equipment Use the provided unit wiring diagram and the field wiring diagra...

Page 37: ...erature limitation for Type T wire 63 F 35 C rise Connect a sufficiently sized wire with ground to the furnace s line voltage connections and ground wire Refer to the furnace rating plate for electrical characteristics to be used in sizing field supply wiring and overcurrent protection The line voltage supply should be routed through a readily accessible disconnect located within sight of the furn...

Page 38: ... is a call for dehumidification Both the passive and active dehumidification methods described above can be utilized on the same furnace Circulating Airflow Adjustments Cooling Mode The units are factory set for the highest airflow for each model Adjustments can be made to the cooling airflow by repositioning the jumper plug marked COOL A B C D see Figure 57 To determine what CFM the motor is deli...

Page 39: ...fan closes the R to G circuit and the circulating blower motor runs at 50 of the selected cooling CFM until switched off When the call for fan is turned OFF the control de energizes the circulating blower Cooling The unit is set up at the factory for single stage cooling For two stage cooling operation clip the jumper wire located between the Y to Y2 terminals on the integrated ignition blower con...

Page 40: ...e code The flash codes are presented in Table 12 Fault Code History Button The control stores the last five fault codes in memory A push button switch is located on the control When the push button switch is pressed and released the control flashes the stored fault codes The most recent fault code is flashed first the oldest fault code is flashed last To clear the fault code history press and hold...

Page 41: ...507962 01 Page 41 of 53 Issue 2149 Figure 58 Typical Field Wiring Diagram ...

Page 42: ...NG MATERIAL HAVING A TEMP RATING OF AT LEAST 90 c 3 PROPER POLARITY MUST BE OBSERVED FOR FIELD LINE VOLTAGE SUPPLY IGNITION CONTROL WILL LOCK OUT IF POLARITY IS REVERSED 4 FOR TEMPORARY SERVICE REPLACEMENT OF CIRCULATING BLOWER MOTOR WITH PSC MOTOR CONNECT DESIRED SPEED TAP TO EAC TERMINAL AND NEUTRAL TAP TO NEUTRAL TERMINAL ON IGNITION CONTROL 5 DO NOT CONNECT C COMMON CONNECTION BETWEEN INDOOR U...

Page 43: ... 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 44: ... Priming Condensate Trap The condensate trap should be primed with water prior to start up to ensure proper condensate drainage Either pour 10 fl oz 300 ml of water into the trap or follow these steps to prime the trap 1 Follow the lighting instructions to place the unit into operation 2 Set the thermostat to initiate a heating demand 3 Allow the burners to fire for approximately 3 minutes 4 Adjus...

Page 45: ...ck gas orifices for proper size and restriction Remove temporary gas meter if installed NOTE To obtain accurate reading shut off all other gas appliances connected to meter Supply Pressure Measurement A pressure post on the inlet side of the gas valve provides access to the supply pressure Back out the 3 32 Hex screw one turn connect a piece of 5 16 tubing and connect a manometer to measure supply...

Page 46: ...efore allowing ignition trial The switch is factory set and must not be adjusted Temperature Rise After the furnace has been started and supply and return air temperatures have been allowed to stabilize check the temperature rise If necessary adjust the blower speed to maintain the temperature rise within the range shown on the unit nameplate See Table 18 for allowable heating speeds Increase the ...

Page 47: ...0 1210 1360 Normal 805 965 1105 1250 735 865 1000 1130 1st Stage 640 755 850 975 Normal 580 695 780 880 545 645 720 795 Model Temp Rise Speed Adjustment Heating CFM 0 0 8 w c Setting D Setting C Setting B Setting A 96G2DF070BV16 High Fire 35 65 1110 1305 1430 1700 Normal 995 1175 1315 1520 880 1055 1170 1365 Low Fire 25 55 860 1020 1140 1340 Normal 795 910 1030 1230 680 825 910 1085 Cooling Stage ...

Page 48: ...ormal 1225 1450 1630 1830 1120 1270 1450 1660 1st Stage 955 1115 1265 1450 Normal 855 1005 1150 1285 750 890 1060 1170 Model Temp Rise Speed Adjustment Heating CFM 0 0 8 w c Setting D Setting C Setting B Setting A 96G2DF110CV20 High Fire 35 65 1595 1795 1955 2140 Normal 1450 1615 1795 1975 1290 1460 1610 1795 Low Fire 25 55 1165 1305 1465 1625 Normal 1055 1185 1315 1475 930 1070 1180 1320 Cooling ...

Page 49: ... Allowed Allowed Allowed Allowed Norm Allowed Allowed Factory Setting Allowed 10 Allowed Allowed Allowed Allowed 96G2DF090CV20 10 Allowed Allowed Allowed Allowed Norm Allowed Allowed Factory Setting Allowed 10 Allowed Allowed Allowed Allowed 96G2DF110CV20 10 Allowed Allowed Allowed Allowed Norm Allowed Allowed Factory Setting Allowed 10 Allowed Allowed Allowed Allowed Table 18 Allowable Circulatio...

Page 50: ...late__________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 Heat Exchanger If cleaning the heat exchanger becomes necessary follow the below procedures and refer to Figure 1 when d...

Page 51: ...ners line up in center of burner ports 34 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 35 Reconnect wires to gas valve 36 Replace the blower compartment access panel 37 Refer to instruction on verifying gas and electrical connections when re establishing supplies 38 Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger...

Page 52: ...detected during 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 inc...

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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