Allied 92G1DFE, Service Manual

Page 1: ...quence of Operation 56 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 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 ...

Page 2: ...120 60 1 15 6 8 40 131 A93DF1E070B12A 66000 63000 93 0 1 5 3 1 2 120 60 1 15 6 8 40 135 A93DF1E090C16A 88000 84000 93 0 2 5 4 1 2 120 60 1 15 8 4 40 153 Note For vent length and clearances to combustibles please reference installation instructions A 93 D F 1 E 070 B 12 A 01 A Flagship 93 93 Efficiency UH Upflow Horizontal DF Downflow 1 1 Stage E High Efficiency Constant Torque Motor Revision A Alu...

Page 3: ... 795 740 700 660 615 585 545 Low 695 640 575 530 485 445 390 335 A93DF1E070B12A 1 2 10 x 8 40 70 High 1380 1345 1325 1295 1260 1235 1185 NA Med High 1265 1240 1215 1175 1135 1105 1080 1040 Med 1140 1090 1060 1025 985 955 910 865 Med Low 860 810 770 710 670 620 585 540 Low 700 645 590 530 490 440 395 340 A93DF1E090C16A 3 4 10 x 10 45 75 High 1695 1680 1640 1605 1575 1550 1490 NA Med High 1495 1445 ...

Page 4: ... C Width Downflow Combustible Flooring Base 11M60 17 5 B Width 11M61 21 0 C Width Night Service Kit 84W48 Single Stage Horizontal Suspension Kit 51W10 80 90 Kit Flush Mount Termination 90 Furnaces Only US Only 51W11 2 3 Vent Version Concentric Vent Kit 90 Furnaces Only US Only 71M80 1 1 2 Vent Version 69M29 2 Vent Version 60L46 3 Vent Version 2 Stage Compressor Kit 85W66 Blower Relay Kit Twinning ...

Page 5: ... 2 120 60 1 15 6 8 40 123 5 92G1DF045BE12 66000 63000 92 1 1 5 3 1 2 120 60 1 15 6 8 40 129 5 92G1DF070BE16 88000 84000 92 1 2 5 4 1 2 120 60 1 15 8 4 40 152 0 Note For vent length and clearances to combustibles please reference installation instructions MODEL NUMBER GUIDE Major Revision 12 3 Ton add on cooling 16 4 Ton add on cooling 20 5 Ton add on cooling E High Efficiency B 17 5 width C 21 0 w...

Page 6: ...5 795 740 700 660 615 585 545 Low 695 640 575 530 485 445 390 335 92G1DF045BE12 1 2 10 x 8 40 70 High 1380 1345 1325 1295 1260 1235 1185 NA Med High 1265 1240 1215 1175 1135 1105 1080 1040 Med 1140 1090 1060 1025 985 955 910 865 Med Low 860 810 770 710 670 620 585 540 Low 700 645 590 530 490 440 395 340 92G1DF070BE16 3 4 10 x 10 45 75 High 1695 1680 1640 1605 1575 1550 1490 NA Med High 1495 1445 1...

Page 7: ... C Width Downflow Combustible Flooring Base 11M60 17 5 B Width 11M61 21 0 C Width Night Service Kit 18F15 Single Stage Horizontal Suspension Kit 51W10 80 90 Kit Flush Mount Termination 90 Furnaces Only US Only 51W11 2 3 Vent Version Concentric Vent Kit 90 Furnaces Only US Only 71M80 1 1 2 Vent Version 69M29 2 Vent Version 60L46 3 Vent Version 2 Stage Compressor Kit 85W66 Blower Relay Kit Twinning ...

Page 8: ...Assembly Gas Valve Heating Compartment Access Panel Blower Access Panel Cold End Header Box Control Box includes integrated control transformer and door switch Blower Assembly Bag Assemblies Cabinet Blower Deck Heat Exchanger Combustion Air Inducer E X H A U S T IN T A K E ...

Page 9: ...on 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 Integrated Ignition Control A92 Shock hazard Disconnect power before servicing Control is not field repairable If control is inoperable simply replace entire control Can cause inj...

Page 10: ...g heat demand 4 Low Flame Signal check flame sensor 5 Watchguard burner failed to light exceeded maximum number of retries or recycles 6 Not Used 7 Primary or Secondary Limit Open or Watchguard Mode Limit Switch Open longer than 3 minutes 8 Rollout Switch Open 9 Pressure Switch failed to close or opened during heat demand 10 Watchguard Pressure Switch opened 5 times during one heat demand 11 Press...

Page 11: ... Open 9 Pressure Switch failed to close or opened during heat demand 10 Watchguard Pressure Switch opened 5 times during one heat demand 11 Pressure Switch stuck closed prior to activation of combustion air inducer 12 Flame Sensed without gas valve energized 13 Low Line Voltage 1 A Heartbeat is indicated by a Slow Flash 1 sec on 1 sec off repeating 2 Error codes are indicated by a Rapid Flash the ...

Page 12: ...as been satisfied can be adjusted by moving the jumper to a different setting The unit is shipped with a factory fan off setting of 90 seconds For customized comfort monitor the supply air temperature once the heat demand is satisfied Note the supply air temperature at the instant the blower is de energized Adjust the fan off delay to achieve a supply air temperature between 90 110 at the instant ...

Page 13: ... clean without removing any part of the burners During operation flame is sensed by current passed through the flame and sensing electrode The ignition control allows the gas valve to remain open as long as flame signal is sensed NOTE The A93DF1E 92G1DFE is polarity sensitive Make sure that the furnace is wired correctly and is properly grounded A microamp DC meter is needed to check the flame sig...

Page 14: ...alve to assure safety shut off If the gas valve must be replaced the same type valve must be used 24VAC terminals and gas control switch are located on top of the valve All terminals on the gas valve are connected to wires from the ignition control 24V applied to the terminals opens the valve Inlet and outlet pressure taps are located on the valve A manifold adjustment screw is also located on the...

Page 15: ... Set Dial to DC MicroAmps Multi Meter To Control Sensor T erminal T o Flame Terminal Remove Sensor Wire from Intergrated Control and Connect Alligator Clip to Terminal on Control Flame Sensor Terminal Flame Sensor Wire Remove Sensor Wire from Intergrated Control and Connect Alligator Clip to Frame Sensor Lead Intergrated Control ...

Page 16: ... 3 Check ignitor for correct voltage Insert meter probes into terminals 2 and 4 use small diameter probes in order not to damage plug Check voltage during 20 second ignitor warm up period Voltage should read 120 volts 10 If voltage reads below these values check for correct supply voltage to furnace Integrated Control Detail Test 1 Check ignitor circuit for correct resistance Remove 4 pin plug fro...

Page 17: ...he switch monitors across the combustion air inducer orifice to insure proper flow through the heat exchanger The switch is a SPST N O pressure switch electrically connected to the integrated control The purpose of the switch is to prevent burner operation if the combustion air inducer is not moving enough air for proper combustion Figure 10 Pressure Switch On start up the switch monitors whether ...

Page 18: ...ine and with hose from the positive side of the manometer to the tee in the positive line NOTE tive However the port reads less negative pressure than the port 4 Operate unit and observe manometer reading Readings will change as heat exchanger warms a Take one reading immediately after start up b Take a second reading after unit has reached steady state approximately 5 minutes This will be the pre...

Page 19: ...A through Table 11B Wrong pressure switch installed in the unit or pressure switch is out of calibration Check that the correct pressure switch is installed in the unit Replace pressure switch if necessary Miswiring of furnace or improper connections at pressure switch Check for correct wiring and loose connections Correct wiring and or replace any loose connections Pressure switch failure If all ...

Page 20: ...e is present in tests 1 and 2 and motor is not operating properly replace motor The motor is not field repairable If replacing the indoor blower motor or blower wheel is necessary placement is critical The blower wheel must be centered in the blower housing as shown in Figure 13 When replacing the indoor blower motor the set screw must be aligned and tightened with the motor shaft as shown in Figu...

Page 21: ...g P49 If 24 volts is not present problem may be up stream of plug P49 Proceed to test 4 Multi Meter set to VAC 12 0 12 0 24 Multi Meter set to VAC problem is with the harness If voltage is not present problem may be may be with the integrated control Check for 120 volts across terminals CIRC and Neutrals on the integrated control If voltage is present problem is with the harness If voltage is not ...

Page 22: ... 20 000 2 K two kilo ohms two thousand ohms 0 2 000 200 two hundred ohms 0 200 Motor Module Installation All replacement motor control modules look similar however each module is designed for a specific motor size It is very important to make sure that you are using the correct replacement motor control module USE OF THE WRONG MOTOR CONTROL MODULE MAY RESULT IN UNEXPECTED UNIT OPERATION 1 Verify e...

Page 23: ... or CPVC Low temperature solvent cement is recommended during cooler weather Metal or plastic strapping may be used for 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 NOTE Canadian Applications Only Pipe fittings primer and solvent cement used to vent e...

Page 24: ...ocket Take care to keep excess cement out of socket Apply second coat to end of pipe 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 after pipe is fully inserted to distribute cement evenly DO NOT turn ABS or...

Page 25: ...cation home make provisions for draining condensate collection trap and lines Figure 20 CHIMNEY OR GAS VENT Check sizing for water heater only FURNACE Replaced by EL195 WATER HEATER OPENINGS To Adjacent Room If the furnace replaces a furnace which was commonly vented with another gas appliance appliance must be checked Without the heat of the original furnace flue products the existing vent pipe i...

Page 26: ...dard roof and wall terminations described in section Exhaust Piping Terminations should be used Exhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination Refer to Table 13 In some applications which permit the use of several different sizes of vent pipe a combination vent pipe may be used Contact Allied Technical Services Department for assistan...

Page 27: ...78 8 26 11 60 45 n a 92 92 73 9 21 n a 55 40 87 87 68 10 16 50 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 Model Model Model Model 045 070 090 045 070 090 045 070 090 045 070 090 1 15 10 n a 53 38 22 90 70 39 111 111 104 2 10 n a 48 33 17 85 65 34 106 106 99 3 n a 43 28 12 80 60 29 101 101 94 4 38 23 n a 75 55 24 96 96 89 5 ...

Page 28: ...y Capacity Capacity 045 070 090 045 070 090 045 070 090 045 070 090 1 15 10 n a 51 36 14 85 100 28 107 107 88 2 10 n a 46 31 9 80 95 23 102 102 83 3 n a 41 26 4 75 90 18 97 97 78 4 36 21 n a 70 85 13 92 92 73 5 31 16 65 80 8 87 87 68 6 26 11 60 75 n a 82 82 63 7 21 6 55 70 77 77 58 8 16 n a 50 65 72 72 53 9 11 45 60 67 67 48 10 6 40 55 62 62 43 NOTE Additional vent pipe and elbows used to terminat...

Page 29: ...pipe EXHAUST When transitioning up in pipe size use the shortest length of 2 PVC pipe possible When transitioning down in pipe size use at least 1 foot of 2 PVC pipe NOTE Exhaust pipe and intake pipe must be the same diameter Figure 23 Typical Intake Pipe Connections Direct Vent Applications TYPICAL INTAKE PIPE CONNECTIONS 2 Pipe size determined in Table 11A and Table 11B 2 2 2 2 or TOP VIEW EXHAU...

Page 30: ...ir intake opening with 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 11B If 3 diameter pipe is used reduce to 2 diameter pipe at the termination point to accommodate the debris screen 3 Use a sheet metal screw to secure th...

Page 31: ...odes in Canada for details Position termination according to location given in Figure 28 or Figure 37 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 ...

Page 32: ...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 NOTE Concentric terminations are the equivalent of 5 and should be considered when measuring pipe length NOTE Maximum uninsulated vent lengths listed may include the termination vent pipe ext...

Page 33: ...ches 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 feet 2 1m 12 inches 305mm 1 In accordance with the current ANSI Z223 1 NFPA 54 N...

Page 34: ...ld terminate straight down using two 90 elbows see Figure 29 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 13 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 ...

Page 35: ...EET METAL STRAP Clamp and sheet metal strap must be field installed to support the weight of the termination kit FLASHING Not Furnished CLAMP FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER 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 ...

Page 36: ... 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 appliances 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 3m horizontally 6 fe...

Page 37: ...exhaust pipe size must be done after the final elbow 4 Distance between exhaust pipe terminations on multiple furnaces must meet local codes Figure 38 Non Direct Vent Roof Termination 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 Ven...

Page 38: ...ance 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 Min 12 305 mm Min 20 508 m...

Page 39: ... shown in Figure 47 or Figure 48 Route the condensate line to an open drain Condensate line must maintain a 1 4 downward slope from the furnace to the drain 5 Figure 45 shows the furnace and evaporator coil using a separate drain If necessary the condensate line from the furnace and evaporator coil can drain together See Figure 46 The field provided vent must be a minimum 1 to a maximum 2 length a...

Page 40: ...bove condensate drain Figure 44 Condensate Trap with Optional Overflow Switch Figure 45 Unit with Cooling Coil Using Separate Drain Drain Field Provided Vent 1 min 2 max above condensate drain Condensate Drain Connection Evaporator Drain Line vent required When combining the furnace and evaporator coil drains together the A C condensate drain outlet must be vented to relieve pressure in order for ...

Page 41: ... 2 inch PVC Pipe Not Furnished 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 ...

Page 42: ...ow 1 2 inch PVC To Drain 90 Elbow 1 2 inch PVC Not Furnished 1 2 inch PVC Pipe Not Furnished Drain Assembly for 3 4 inch Drain Pipe 90 Street Elbow 1 2 inch PVC Not Furnished Condensate Drain Connection In Unit Adapter 1 2 inch slip X 1 2 inch mpt Not Furnished Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Drain Trap Assembly with 3 4 inch Piping Vent To Dra...

Page 43: ...tivate the heating demand 5 Wait for the combustion air inducer to stop Set the thermostat to initiate a heating demand and again allow the burners to fire for approximately 3 minutes 6 Adjust the thermostat to deactivate the heating demand and again wait for the combustion air inducer to stop At this point the trap should be primed with sufficient water to ensure proper condensate drain operation...

Page 44: ...sed on gas piping threaded joints should be resistant to action of liquefied petroleum gases 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 and isolated Gas valves can be damaged if ...

Page 45: ...cated on unit gas valve GV1 Checks of manifold pressure are made as verification of proper regulator adjustment 1 Connect the test gauge positive side to manifold pressure tap on gas valve 2 Tee into the gas valve regulator vent hose and connect to test gauge negative 3 Start unit and let run for 5 minutes to allow for steady state conditions 4 After allowing unit to stabilize for 5 minutes record...

Page 46: ...ation instruction for the conversion procedure Table 16 Supply Line and Manifold Pressure at All Altitudes inches w c for 1 Through 3 Units Capacity Gas Manifold Pressure in w g Supply Line Pressure in w g 0 10 000 ft 0 4500 ft 4501 5500 ft 5501 6500 ft 6501 7500 ft 7501 10000 ft All Sizes Natural 3 5 3 3 3 2 3 1 3 5 4 5 13 0 LP Propane 10 0 9 4 9 1 8 9 10 0 11 0 13 0 NOTE A natural to LP propane ...

Page 47: ...n in the voltage between Line Neutral and C as a function of load indicates a poor or partial ground Compare the readings to Table 20 If the readings exceed the maximum shown in Table 20 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 52 This voltage should be in the range of 97 to 132...

Page 48: ...ply 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 the manometer to the discharge supply side of the system On ducted systems connect the other end of manometer to the return duct as above 3 With only the blower motor running and the evaporator coil dry observe the manometer reading Adjust blower ...

Page 49: ...c pressure drop than standard efficiency glass foam filters If the pressure drop is too great system capacity and performance may be reduced The pressure 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...

Page 50: ...sure switch assembly 12 Disconnect the plug from the combustion air inducer Remove two screws which secure combustion air inducer to collector box Remove combustion air inducer assembly Remove ground wire from vest panel 13 Remove electrical junction box from the side of the furnace 14 Disconnect condensate line from cold end header box Remove cold end header box 15 Loosen clamps on exhaust and ai...

Page 51: ...ng the Burner Assembly if needed 1 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels 2 Disconnect the 2 pin plug from the gas valve 3 Remove the burner box cover if equipped 4 Disconnect the gas supply line from the gas valve Remove gas valve manifold assembly 5 Loosen clamps and remove combustion air intake flexible connector if equipped 6 Mark and...

Page 52: ...508134 01 Issue 2045 Page 52 of 56 Wiring Diagram ...

Page 53: ...GIZED GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED FLASHES CODE 11 PRESSURE SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY Sequence holds until pressure switch opens or thermostat resets control NO NO YES YES IS VOLTAGE ABOVE 70 VOLTS LED FLASHES CODE 13 LOW LINE VOLTAGE CONTROL WILL NOT RESPOND TO A CALL FOR HEATING UNTIL VOLTAGE ...

Page 54: ...FF WITH DELAY IS 60 MINUTE RESET PERIOD COMPLETE YES 4 SECONDS YES HAS CONTROL RESET IGNITION SEQUENCE FOUR TIMES FLAME SIGNAL 1 5 MICROAMPS OR GREATER YES YES YES ROLLOUT SWITCH CLOSED LED FLASHES CODE 8 ROLLOUT SWITCH OPEN GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF ON ...

Page 55: ...ONITORED CONTINUOUSLY IS ROLLOUT SWITCH CLOSED LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED COMPRESSOR OFF THERMOSTAT OPENS SYSTEM FAN AND EAC TERM OFF WITH 45 SECOND DELAY NO NO LED FLASHES CODE 8 ROLLOUT SWITCH OPEN GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER O...

Page 56: ...G THERMOSTAT OPENS SYSTEM FAN SWITCHED TO COOL SPEED EAC TERM REMAINS ON THERMOSTAT OPENS MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT FAN SPEED EAC TERM ENERGIZED NO YES YES NO SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30 SECOND DELAY EAC AND HUM TERMINALS REMAIN ON SYSTEM FAN CONTINUES FAN SPEED WITHOUT INTERRUPTION EAC TERMINAL REMAIN ON HUM TERMINALS ARE ENERGIZED WI...