Allied A96DF1E Installation Instructions Manual Download

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508298-01

Page 1 of 55

Issue 2219

INSTALLATION INSTRUCTIONS

A96DF1E

Warm Air Gas Furnace

Downflow Air Discharge

(P) 508298-01

*P508298-01*

Manufactured By

Allied Air Enterprises LLC

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 A96DF1E

Page 1: ...nstallation 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 Informa...

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 Capacity A B C in mm in mm in mm 045 12 070 12 17 1 2 446 16 3 8 416 16 406 090 16 110 20 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: ...t 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 NFPA No 70 is available from the following address National Fire Protection Association 1 Battery March Park Quincy MA 022...

Page 6: ...on direct vent applications do not block the furnace combustion air opening 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 ...

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: ...nstall the furnace on its front back or in the horizontal position See Figure 12 Do no connect the return air ducts to the back of the furnace Doing so will adversely affect the operation of the safety control devices which could result in personal injury or death CAUTION Select a location that allows for the required clearances that are listed on the unit nameplate Also consider gas supply connec...

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: ...dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket Capacity Vent Pipe Dia in Standard Concentric Flush Mount Kit Wall Kit Field Fabricated 1 1 2 inch 2 inch 3 inch 51W11 US 51W12 CA 2 inch 3 inch 71M80 US 4 44W92 CA 69M29 US 4 44W92 CA 60L46 US 4 444W93 CA 22G44 US 4 30G28 CA 44J40 US 4 81J20 CA 045 1 1 1 2 3 YES YES 1 YES 5 YES 2 YES N A N ...

Page 14: ...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 with cement forcefully insert end of pipe into socket until it bottoms out Turn PVC pipe 1 4 turn during assembly but not ...

Page 15: ...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 7D Table 6 lists the minimum vent pipe lengths permitted Table 7A through Table 7D list the maximum pipe lengths permitted Regardless of the diameter of pipe used the standard roof and wall terminations described in sect...

Page 16: ... size 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 7A Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 2 001 10 000 ft Number of 90 Elbows Used 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity 045 070 090 110 045 070 090 110 045 070 090 110 1 35 25 1...

Page 17: ...dditional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation Table 7C Maximum Allowable Intake or Exhaust Vent Length in Feet Concentric Termination at Elevation 2 001 10 000 ft Number of 90 Elbows Used 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Capacity Capacity 045 070 090 110 030 045 070 090 110 030 045 070 090 110 1 35 25 15 ...

Page 18: ... must be included in the total vent length calculation NOTE Contact your local FTC if more than 85ft of venting is needed Table 8A Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet Standard Termination at Elevation 2 001 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Capacity Ca...

Page 19: ...e in horizontal runs of exhaust pipe When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter Figure 22 Typical Intake Pipe Connections Direct Vent Applications 2 Pipe size determined in table 7 2 2 2 2 or TOP VIEW EXHAUST INTAKE TRANSITION 3 2 2 TRANSITION 3 2 2 1 1 2 or TRANSITION NOTE 1 1 2 Vent Pipe Diameter A...

Page 20: ...h the protective screen should always be directed forward or sideways 2 If intake air is drawn from a ventilated attic Figure 25 or ventilated crawlspace Figure 26 the exhaust vent length must not exceed those listed in Table 8A through Table 8B If 3 diameter pipe is used reduce to 2 diameter pipe at the termination point to accommodate the debris screen 3 Use cement to secure the intake pipe to t...

Page 21: ...vent freeze ups Heating cable installation kits are available see unit specification sheets for part numbers Do not use screens or perforated metal in exhaust terminations Doing so will cause freeze ups and may block the terminations IMPORTANT For Canadian Installations Only In accordance to CSA International B149 installation codes the minimum allowed distance between the combustion air intake in...

Page 22: ...n 5 3 12 10 22 19 18 15 2 1 2 in 1 N A 7 N A 15 N A 12 N A 3 in N A N A 2 2 10 10 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 measuring total leng...

Page 23: ... 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 appliances 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 3m horizontally 6 feet 1 8m 7 ...

Page 24: ... 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 feet 2 1m 12 inches 305mm 1 In accordance with the current ANSI Z223 1 NFPA 54 Natural Fue...

Page 25: ... Pipe Size Termination Pipe Size 045 070 2 51 mm 2 1 2 64 mm 3 76 mm 1 1 2 38 mm 090 110 2 51 mm 045 070 and 090 units with the flush mount termination must use the 1 1 2 accelerator supplied with the kit Table 10 Exhaust Pipe Termination Size Reduction 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 3 7...

Page 26: ... 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 27: ...portion of chimney the exhaust vent must be insulated Figure 34 Direct Vent Application Using Existing Chimney Figure 35 Direct Vent Concentric Wall Termination 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada 12 305mm Min above grade or average snow accumulation INTAKE AIR INTAKE AIR INTAKE AIR OUTSIDE WALL GRADE CLAMP Not Furnished FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT DIFFERENT VENT PIPE...

Page 28: ... 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 FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT DIFFERENT VENT PIPE SIZE TO TERMINATION Figure 40 Non Direct Vent Field Supplied Wall Termination Extended SIZE TERMINATION PER EXHAUST PIPE TERMINAT...

Page 29: ...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 30: ...igure 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 section Do Not use copper t...

Page 31: ...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 32: ...508298 01 Page 32 of 55 Issue 2219 Figure 50 Trap Drain Assembly Using 1 2 PVC or 3 4 PVC ...

Page 33: ...nt 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 unit Union must be of the ground joint type Compounds used on threaded joints of gas piping must be resistant to the actions of l...

Page 34: ... 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 35: ...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 36: ...ns 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 Electric Code Part ...

Page 37: ... to 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 Tab...

Page 38: ...508298 01 Page 38 of 55 Issue 2219 045 B12 070 B16 090 C16 110 C20 Figure 57 Typical Wiring Diagram ...

Page 39: ...217 03 Control Red LED Flash Code2 Diagnostic Codes Status of Furnace Off No power to control or control hardware fault detected On Board Fault Detected Fast Heartbeat3 Call for Heat Burner Operation Slow Heartbeat1 Normal Operation Idle Continuous Fan or Cool 1 Flash2 Reverse Line Voltage Polarity or Phasing of 120V power 2 Flashes2 Improper earth ground 3 Flashes2 Burner failed to light or lost ...

Page 40: ...nuous Fan Speed From Indoor Blower Motor 24VAC PARK 3 Terminals For Unused Motor Speed Taps FS Flame Sensor Electrode 120VAC 24V COM Common 24VAC Table 14 Terminal Designations Applicable to 103217 03 and 107163 01 Controls Unit Start Up FOR YOUR SAFETY READ BEFORE OPERATING Do not use this furnace if any part has been underwater A flood damaged furnace is extremely dangerous Attempts to use the f...

Page 41: ...cient water to ensure proper condensate drain 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 See Figure 60 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 e...

Page 42: ... orifices for proper size and restriction Remove temporary gas meter if installed Supply Pressure Measurement A threaded plug on the inlet side of the gas valve provides access to the supply pressure tap Remove the threaded plug install a field provided barbed fitting and connect a manometer to measure supply pressure Replace the threaded plug after measurements have been taken Manifold Pressure M...

Page 43: ... Natural to LP Propane LP Propane to Natural High Altitude Natural Burner Orifice Kit High Altitude LP Propane Burner Orifice Kit All 11K50 73W80 51W01 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 Table 18 Burner Orifice Conversion Kits at Varying Altitudes Capacity 0 4500 ft 0 1 373m 4...

Page 44: ... 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 45: ...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 61 Heat Fan OFF Time in ...

Page 46: ...020 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 1405 540 1255 430 1040 315 910 255 585 160 0 80 1325 515 1215 445 990 320 865 265 525 170 A96DF...

Page 47: ...1500 418 1370 347 1170 264 0 60 1895 749 1625 536 1460 423 1335 358 1110 269 0 70 1830 738 1600 548 1410 438 1280 367 1080 286 0 80 1765 723 1550 564 1370 456 1240 387 1010 290 NOTE All air data is measured external to unit without filter not furnished field provided Allowable Heating Speeds Model Red Yellow Blue Brown Black 045 Allowed Factory Setting Allowed Not Allowed Not Allowed 070 Allowed F...

Page 48: ... 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 Heat Exchanger If cleaning the heat exchanger becomes necessary follow...

Page 49: ...tall burner box assembly in vestibule area 31 Reconnect flame rollout switch wires 32 Reconnect sensor wire and reconnect 2 pin plug from ignitor 33 Secure burner box assembly to vestibule panel using four existing screws Make sure burners line up in center of burner ports 34 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 35 Reconnect 2 wires to gas valve 36 Replace t...

Page 50: ...st be open and unobstructed to provide combustion air Burners Must be inspected for rust dirt or signs of water Vent pipe Must be inspected for signs of water cracked damaged or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Blower access door Must be properly in place and provide a seal between the return air...

Page 51: ...508298 01 Page 51 of 55 Issue 2219 Troubleshooting Heating Sequence of Operation ...

Page 52: ...508298 01 Page 52 of 55 Issue 2219 Troubleshooting Heating Sequence of Operation continued ...

Page 53: ...508298 01 Page 53 of 55 Issue 2219 Troubleshooting Cooling Sequence of Operation ...

Page 54: ...508298 01 Page 54 of 55 Issue 2219 Troubleshooting Continuous Fan Sequence of Operation ...

Page 55: ...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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