Allied 80G2DFE, Service Manual

Page 1: ... in manuals be alert to the potential for personal injury or death Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electrical power to unit OFF at disconnect switch es Unit may have multiple power supplies WARNING As with any mechanical equipment contact with sharp sheet metal edges can result in personal injury Take care while handl...

Page 2: ... 1 40 1 2 123 80G2DF090BE16 88 000 69 000 57 000 46 000 80 0 4 1 2 120 60 1 15 8 2 40 3 4 142 Note For vent length and clearances to combustibles please reference installation instructions Note Filters and provisions for mounting are not furnished and must be field provided Major Revision Revision Code Nom CFM x 00 12 3 Ton add on cooling 16 4 Ton add on cooling 20 5 Ton add on cooling Blower Driv...

Page 3: ...2 0 70 1405 482 1235 365 1075 295 990 259 840 209 0 80 1160 369 1025 308 925 268 780 217 BLOWER PERFORMANCE 80G2DF070AE12 External Static Pressure in w g Air Volume Watts at Various Blower Speeds High Black Medium High Brown Medium Blue Medium Low Yellow Low Red cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1475 346 1345 269 1190 192 970 109 785 71 0 10 1440 355 1325 276 1165 198 935 114 ...

Page 4: ...01 2 Stage 80 UH DF Propane Gas 11K47 Natural to LP Kits 2 Stage 80 UH DF 0 7500 ft 11K48 2 Stage 80 UH DF 7501 10 000 ft 11K47 LP to Natural Kits 2 Stage 80 UH DF 77W10 Downflow Specific Air Filters 14 5 51W06 17 5 51W07 Downflow Combustible Flooring Base 14 5 11M59 17 5 11M60 Night Service Kits 2 Stage 22J94 Horizontal Suspension Kit 80 90 51W10 External Filter Rack Kits 1 pack 16 x 25 1 841018 ...

Page 5: ...ts Arrangement Figure 1 Control Box includes integrated control transformer and door switch Secondary Limit Internal Flue Pipe Assembly Gas Valve Burner Box Assembly Combustion Air Inducer Indoor Blower Heat Exchanger Primary Limit Top Cap ...

Page 6: ...overcurrent protection to the transformer T1 The breaker is rated at 3A at 32V If the current exceeds this limit the breaker will trip and all unit operation will shutdown The breaker can be manually reset by pressing the button on the face See Figure 3 Figure 3 Circuit Breaker CB8 PRESS TO RESET Integrated Ignition Control A92 Shock hazard Disconnect power before servicing Control is not field re...

Page 7: ... purge and warm up time between trials of 35 seconds After a total of five trials for ignition including the initial trial the control goes into Watchguard Flame Failure mode After a 60 minute reset period the control will begin the ignition sequence again NOTE During abnormal conditions such as low supply voltage or low outdoor temperatures and the low fire pressure switch does not close the comb...

Page 8: ...UICK CONNECT TERMINALS NEUTRALS 120 VAC NEUTRAL HUM UNPOWERED NORMALLY OPEN DRY CONTACTS LI 120VAC INPUT TO CONTROL ACC 120VAC OUTPUT TO OPTIONAL ACCESSORY THERMOSTAT CONNECTIONS TB1 DS DEHUMIDIFICATION SIGNAL W2 HEAT DEMAND FROM 2ND STAGE TSTAT W1 HEAT DEMAND FROM 1ST STAGE TSTAT R CLASS 2 VOLTAGE TO TSTAT G MANUAL FAN FROM TSTAT C TSTAT SIGNAL GROUND CONNECTED TO TRANSFORMER GRD TR CHASSIS GROUN...

Page 9: ...5 2 STAGE COMPR W951 HEAT PUMP W914 DEHUM CUT FOR OPTION SELECTION 1 2 3 4 5 6 ON W1W2 G Y2 Y1 C C DH L O DS R W1 W2 G Y2 Y1 C C R L DH 7 1 ON ON ON ON 90 SECOND HTG BLOWER OFF DELAY 1 2 3 4 5 6 7 ON 1 2 3 4 5 6 7 ON THERMOSTAT SELECTION 1 STAGE THERMOSTAT TIMED STAGING SEE SW 2 TWO STAGE THERMOSTAT 1 2 3 4 5 6 7 1 2 3 4 5 6 7 ON ON BLOWER ON DELAY 30 SEC FIXED 1 2 3 4 5 6 7 ON SENSE IGN CAI2 CAI1...

Page 10: ...ncy problems System resumes normal operation 5 seconds after fault recovered E115 Low 24V Control will restart if the error recovers 24 Volt Power Low Range is 18 to 30 volts Check and correct voltage Check for additional power robbing equipment connected to system May require installation of larger VA transformer to be installed in furnace air handler Clears after fault recovered E117 Poor ground...

Page 11: ...sure good unit ground Alert clears after current heat call has been completed E241 Flame sensed out of sequence Flame still present Shut off gas Check for gas valve leak Replace if necessary Alert clears when fault is recovered E250 Limit switch circuit open Check for proper firing rate on furnace Ensure there is no blockage in heater Check for proper air flow If limit not closed within 3 minutes ...

Page 12: ...re displayed 10 minutes after entering the flame sense mode Integrated Control DIP Switches Integrated Control DIP Switches 80G2DFE units are equipped with a two stage integrated control This control manages ignition timing heating mode fan off delays and indoor blower speeds based on selections made using the control dip switches and jumpers The control includes an internal watchguard feature whi...

Page 13: ...gs Switches 6 and 7 Continuous Fan Mode Continuous fan speed can be controlled by changing DIP switch positions Table 7 provides DIP switch settings for continuous fan mode Continuous Fan Mode Switch 6 Switch 7 Low Heat Speed Factory Off Off Low Cool Speed Off On High Heat Speed On Off High Cool Speed On On Table 7 Continuous Fan Mode Settings Onboard Links W914 Dehum Onboard link W914 is a clippa...

Page 14: ...ant torque at each of the five selectable speed taps Each tap requires 24 volts to energize Input Voltage Requirements The circuit is designed to be operated with AC voltage To enable a tap requires 12 to 33VAC Expected current draw will be less than 20mA Troubleshooting the Motor Troubleshooting the motor is an easy process Follow steps below 1 Shut off power to unit 2 Remove input plugs P48 and ...

Page 15: ...t 3 Check for 120 volts across terminals L1 and Neutrals on the integrated control If voltage is present problem is with the harness If voltage is not present problem may be may be with the integrated control Switch thermostat to CONTINUOUS FAN MODE Check for 24 volts across terminal C on input plug P48 and speed tap used for continuous fan 1 2 3 4 or 5 on input plug P49 If 24 volts is not present...

Page 16: ...e valve must be used 24VAC terminals and gas control knob are located on the valve A wire harness connects the terminals from the gas valve to the electronic ignition control 24V applied to the terminals energizes the valve Inlet and outlet pressure taps are located on the valve A regulator adjustment screw is located on the valve LPG change over kits are available from Allied Kits include burner ...

Page 17: ...508189 01 Issue 2116 Page 17 of 42 Figure 9 Heating Components Ignitor Burners Sensor Gas Valve Manifold and Gas Orifices Rollout Switch ...

Page 18: ...o furnace Meter set to AC volts Test 2 Check ignitor for correct resistance Seperate the 2 pin jack plug near the manifold and check resistance of ignitor at the plug Reading should be between 39 and 70 ohms If the reading is correct then the problem is with the wiring between the jack plug and the control If reading is not correct the issue is the ignitor Meter set to ohms Test 1 Check ignitor ci...

Page 19: ...L METER Red Collar Indicates Positive Leads To Control Sensor Terminal Flame Sensor Flame Sensor Wire Integrated Control Remove Sensor Wire from Integrated Control and Connect Alligator Clip to Frame Sensor Lead Flame Sensor Terminal Remove Sensor Wire from Integrated Control and Connect Alligator Clip to Terminal on Control ...

Page 20: ...re Switch S18 Figure 12 80G2DFE series units are equipped with a dual combustion air pressure switch first and second stage located on the CEHB The switch is connected to the cold end header box by means of flexible silicone hoses It monitors negative differential pressure across the cold end header box orifice The switches are a single pole single throw pressure switches electrically connected to...

Page 21: ...lve switch to OFF See Figure 13 7 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you do not smell gas go to next step 8 Move gas valve switch to ON See Figure 13 Figure 13 Gas Valve GAS VALVE SHOWN IN ON POSITION INLET PRESSURE POST HIGH FIRE ADJUSTMENT SCREW under cap MANIFOLD P...

Page 22: ...as supply line CAUTION Do not over torque 800 in lbs or under torque 350 in lbs when attaching the gas piping to the gas valve WARNING Testing Gas Piping In case emergency shutdown is required turn off the main shut off valve and disconnect the main power to unit These controls should be properly labeled by the installer IMPORTANT When pressure testing gas lines the gas valve must be disconnected ...

Page 23: ...eaks if found Gas Flow Approximate Furnace should operate at least 5 minutes before checking gas flow Determine time in seconds for two revolutions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in Table 10 If manifold pressure matches Table 12 and rate is incorrect check gas orifices for proper size and restriction Remove temporary gas mete...

Page 24: ...r kit is necessary to convert this unit Refer to the changeover kit installation instruction for the conversion procedure NOTE Units may be installed at altitudes up to 4500 ft above sea level without modifications Table 12 Manifold Pressure and Line Pressure at Various Altitudes Capacity High Altitude Pressure Switch Kit High Altitude Natural Gas Oririce Kit Natural to LP Propane Kit LP Propane t...

Page 25: ... of load indicates a poor or partial ground Compare the readings to Table 14 If the readings exceed the maximum shown in Table 14 make repairs before operating the furnace 2 In addition measure the AC voltage from Line Hot to Line Neutral spade terminals on the integrated control See Figure 15 This voltage should be in the range of 97 to 132 Vac Furnace Status Measurement VAC Expected Maximum Powe...

Page 26: ...sted on the unit rating plate Figure 16 TEMPERATURE RISE Return Supply Temperatures Supply Duct Temperature Return Duct Temperature _ Temperature Rise External Static Pressure 1 Tap locations shown in Figure 17 2 Punch a 1 4 diameter hole in supply and return air plenums Insert manometer hose flush with inside edge of hole or insulation Seal around the hose with permagum Connect the zero end of th...

Page 27: ...ssure drop may also cause the limit to trip more frequently during the winter and the indoor coil to freeze in the summer resulting in an increase in the number of service calls Before using any filter with this system check the specifications provided by the filter manufacturer IMPORTANT Furnace Cabinet Width Return Air Filter Size in A 14 1 2 14 x 25 x 1 B 17 1 2 16 x 25 x 1 Table 15 Exhaust and...

Page 28: ...to ensure proper combustion and operation Consult Service Literature for proper combustion values 14 Verify operation of CO detectors and replace batteries as required Perform a general system test Turn on the furnace to check operating functions such as the start up and shut off operation 1 Check the operation of the ignition system inspect and clean flame sensor Check microamps before and after ...

Page 29: ... F 11 To clean burners run a vacuum cleaner with a soft brush attachment over the face of burners Visually inspect inside the burners and crossovers for any blockage caused by foreign matter Remove any blockage Figure 18 shows burner detail 12 To clean the combustion air inducer visually inspect and using a wire brush clean where necessary Use compressed air to clean off debris and any rust 13 Rei...

Page 30: ...508189 01 Issue 2116 Page 30 of 42 Wiring and Sequence of Operation 070 12 090 16 COMFORT SYNC THERMOSTAT ...

Page 31: ...d send a signal to the integrated control The integrated control initiates a 30 second second stage recognition delay 6 At the end of the recognition delay the integrated control energizes the combustion air inducer at high speed The control also checks the high fire second stage pressure switch to make sure it is closed The high fire second stage gas valve is energized and the indoor blower motor...

Page 32: ...r begins a 5 second low speed post purge The field selected indoor blower off delay begins The indoor blower operates at the low fire heating speed 7 When the combustion air post purge period is complete the inducer and the HUM contacts are deenergized The indoor blower is de energized at the end of the off delay as well as the 120 ACC terminals Figure 20 Heating Operation with Two Stage Thermosta...

Page 33: ...itch 2 to set sceond stage heat ON delay OFF 7 minutes ON 12 minutes ON CUT ON BOARD LINK W915 2 STAGE COMPR T STAT FURNACE TERM STRIP OUTDOOR UNIT Not required on all units 1 Heat 2 Cool with t stat with dehumidification mode NOTE Use DIP switch 2 to set sceond stage heat ON delay OFF 7 minutes ON 12 minutes ON CUT ON BOARD LINK W915 2 STAGE COMPR CUT ON BOARD LINK W914 DEHUM T STAT FURNACE TERM ...

Page 34: ...LINK W915 2 STAGE COMPR CUT ON BOARD LINK W914 T STAT FURNACE TERM STRIP OUTDOOR UNIT o Not required on all units 2 Heat 1 Cool with t stat with dehumidification mode OFF CUT ON BOARD LINK W914 T STAT FURNACE TERM STRIP OUTDOOR UNIT o Not required on all units 2 Heat 1 Cool OFF DO NOT CUT ANY ON BOARD LINKS T STAT FURNACE TERM STRIP OUTDOOR UNIT Not required on all units NOTE Do NOT make a wire co...

Page 35: ...RNACE TERM STRIP HEAT PUMP 67M41 Y H L Y2 D B L Y2 T T outdoor sensor Dual Fuel Two Stage Heat Pump Thermostat w dual fuel capabilities Capable of 2 stage gas heat control OFF CUT ON BOARD LINK W951 HEAT PUMP CUT ON BOARD LINK W915 2 STAGE COMPR FURNACE TERM STRIP HEAT PUMP out blue 67M41 H L Y2 D B L Y2 T T outdoor sensor T STAT Y2 NOTE Do NOT make a wire connection between the room thermostat L ...

Page 36: ...NACE TERM STRIP HEAT PUMP 67M41 Y H L Y2 D B L Y2 T T outdoor sensor Dual Fuel Two Stage Heat Pump Thermostat w dual fuel capabilities Capable of 2 stage gas heat control with dehumidification mode OFF CUT ON BOARD LINK W914 DEHUM CUT ON BOARD LINK W951 HEAT PUMP CUT ON BOARD LINK W915 2 STAGE COMPR T STAT FURNACE TERM STRIP HEAT PUMP 67M41 H L Y2 D B L Y2 T T outdoor sensor Y2 out blue Y2 NOTE Do...

Page 37: ...S INTERRUPTED OR T STAT IS CYCLED OFF ON FOR 3 SEC MINIMUM NO YES FIRST LOW STAGE PRESSURE SWITCH CONTACTS OPEN NO GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF CONTROL REMAINS UNTIL PRESSURE SWITCH IS DETECTED OPEN STATUS ERROR CODE 2 4 YES GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF CONTROL WILL NOT ATTEMPT SECOND STAGE OPERATION DURING THIS HEAT DEMAND FIRST STAGE OP...

Page 38: ...N WITHIN 4 SECONDS AFTER GAS VALVE OPENS 0 19 microamps GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF STATUS LED HEARTBEAT HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND YES THERMOSTAT CALLS FOR HEAT STATUS LED HEARTBEAT Refer to box A on previous page YES FLAME PRESENT NO HAS CONTROL RESET IGNITION SEQUENCE FOUR 4 TIMES WATCHGUARD MODE STATUS ...

Page 39: ...TES NO YES FIRST STAGE HEAT DEMAND SATISFIED GAS VALVE OFF COMBUSTION AIR INDUCER OFF FOLLOWING POST PURGE INDOOR BLOWER OFF WITH DELAY STATUS LED PULSE YES SECOND STAGE HEAT DEMAND SECOND STAGE HEAT DEMAND REQUIRED NO SECOND STAGE PRESSURE SWITCH CLOSED ABNORMAL FLASH CODE NOTE IF SECOND STAGE PRESSURE SWITCH WAS ORIGINALLY FOUND CLOSED ABNORMAL CODE WILL FLASH SECOND STAGE PRESSURE SWITCH CLOSED...

Page 40: ...GE THERMOSTAT MODE DIP SWITCH SET AT SINGLE YES YES FIRST AND SECOND STAGE HEAT DEMAND SATISFIED SIMULTANEOUSLY STATUS LED HEARTBEAT YES GAS VALVE OFF COMBUSTION AIR INDUCER OFF AFTER 5 SECOND LOW SPEED POST PURGE PERIOD INDOOR BLOWER OFF DELAY INITIATED ON LOW HEAT SPEED STATUS LED HEARTBEAT DEMAND FOR HEAT SATISFIED POWER ON STAND BY STATUS LED PULSE YES SECOND STAGE HEAT DEMAND SATISFIED STATUS...

Page 41: ...NSER FAN ENERGIZED NO IS THERE PROPER GROUND YES NO INDOOR BLOWER ENERGIZED ON FIRST STAGE COOL SPEED AFTER 2 SECOND DELAY FIRST STAGE DEMAND FOR COOL SATISFIED NO THERMOSTAT CALLS FOR SECOND STAGE COOL COMPRESSOR AND CONDENSER FAN DE ENERGIZED INDOOR BLOWER DE ENEGIZED YES INDOOR BLOWER RAMPS UP TO SECOND STAGE COOL SPEED SECOND STAGE DEMAND FOR COOL SATISFIED YES UNIT RETURNS TO FIRST STAGE COOL...

Page 42: ...WER SWITCHES TO LOW HEAT SPEED FIRST STAGE HEAT DEMAND SATISFIED YES NO THERMOSTAT CALLS FOR SECOND STAGE HEAT YES INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED AFTER 30 SECOND RECOGNITION PERIOD SECOND STAGE HEAT DEMAND SATISFIED YES YES INDOOR BLOWER RAMPS DOWN TO LOW HEAT SPEED INDOOR BLOWER RAMPS TO FIRST STAGE COOLING SPEED AFTER A 2 SECOND DELAY FIRST STAGE COOL DEMAND SATISFIED YES NO SECOND ST...