Allied 95G1DFE, Service Manual

Page 1: ...quence of Operation 57 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: ...4 1 2 120 60 1 15 8 4 40 146 A95DF1E090C16S 88 000 85 000 95 0 2 1 2 4 1 2 120 60 1 15 8 4 40 162 A95DF1E110C20S 110 000 106 000 95 0 3 5 1 2 120 60 1 15 10 9 40 174 Note For vent length and clearances to combustibles please reference installation instructions MODEL NUMBER GUIDE Numeric Code S Stainless Steel Heat Exchanger 08 2 ton add on cooling 12 3 Ton add on cooling 16 4 Ton add on cooling 20...

Page 3: ...5 1585 1540 N A N A Med High 1470 1430 1390 1335 1300 1260 1220 Med 1265 1235 1185 1155 1100 1050 1015 Med Low 1165 1120 1070 1015 970 915 865 Low 895 835 775 690 625 570 520 A95DF1E090C16S 3 4 10 x 10 40 70 High 1685 1630 1620 1570 1540 N A N A Med High 1455 1415 1370 1335 1295 1260 1210 Med 1310 1285 1245 1185 1145 1110 1060 Med Low 1220 1165 1125 1080 1045 990 940 Low 1080 1035 985 925 875 825 ...

Page 4: ...2 24 5 D Width Night Service Kit 86W57 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 Concentric Vent Kit 90 Furnaces Only Canada Only 44W92 1 1 2 and 2 Vent Version 44W93 3 Vent Version 2 Stage Compressor Ki...

Page 5: ... 000 64 000 95 0 2 1 2 4 1 2 120 60 1 15 8 4 40 144 95G1DF090CE16 88 000 85 000 95 0 2 1 2 4 1 2 120 60 1 15 8 4 40 160 95G1DF110CE20 110 000 106 000 95 0 3 5 1 2 120 60 1 15 10 9 40 174 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 P PSC E High...

Page 6: ...5 1585 1540 N A N A Med High 1470 1430 1390 1335 1300 1260 1220 Med 1265 1235 1185 1155 1100 1050 1015 Med Low 1165 1120 1070 1015 970 915 865 Low 895 835 775 690 625 570 520 95G1DF090CE16 3 4 10 x 10 40 70 High 1685 1630 1620 1570 1540 N A N A Med High 1455 1415 1370 1335 1295 1260 1210 Med 1310 1285 1245 1185 1145 1110 1060 Med Low 1220 1165 1125 1080 1045 990 940 Low 1080 1035 985 925 875 825 7...

Page 7: ... 11M61 21 0 C Width Night Service Kit 86W57 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 Concentric Vent Kit 90 Furnaces Only Canada Only 44W92 1 1 2 and 2 Vent Version 44W93 3 Vent Version 2 Stage Compress...

Page 8: ...ntrol transformer 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 ...

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: ...y to 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 A95DF1E 95G1DFE 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...

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: ...cer 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 the combustion air inducer is operating It closes...

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: ... through Table 12 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 th...

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: ...t 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 Capacity Vent Pipe Dia in Standard Concentric Outdoor Exhaust Accelerator Dia x Length Outdoor Exhaust Accelerator Dia x Length Flush Mount Kit 1 1 2 Concentric Kit 2 Concentric Kit 3 Concentric Kit 1 1 2 x 12 2 x 12 51W1...

Page 25: ...n a residence where unit is shut down for an extended period of time such as a vacation 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 checke...

Page 26: ...and outside the home Table 10 lists the minimum vent pipe lengths permitted Table 11 through Table 12 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 the exhaust gas as it exits the termination Re...

Page 27: ...045 070 090 110 Standard or Concentric See Table 9 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 11 through Table 12 to find max pipe length 7 Figure 21 Vent Pipe Diameter Sizing ...

Page 28: ... 11 65 45 n a 92 92 73 73 9 21 n a 60 40 87 87 68 68 10 16 55 35 82 82 63 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 045 070 090 110 045 070 090 110 045 070 090 110 045 070 090 110 1 15 10 n a n a 53 38 22 n a 90 70 39 n a 111 111 104 104 2 10 n a 48 33 17 85 65 34 106 106 99 99 3 n a 43 28 12 80 ...

Page 29: ... 070 090 110 045 070 090 110 045 070 090 110 1 15 10 n a n a 61 46 24 n a 100 80 43 n a 127 127 108 108 2 10 n a 56 41 19 95 75 38 122 122 103 103 3 n a 51 36 14 90 70 33 117 117 98 98 4 46 31 n a 85 65 28 112 112 93 93 5 41 26 80 60 23 107 107 88 88 6 36 21 75 55 18 102 102 83 83 7 31 16 70 50 13 97 97 78 78 8 26 11 65 45 n a 92 92 73 73 9 21 n a 60 40 87 87 68 68 10 16 55 35 82 82 63 63 NOTE Add...

Page 30: ...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 23 Typical Intake Pipe Connections Direct Vent Applications 2 Pipe size determined in Table 11 or Table 12 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 Pi...

Page 31: ... 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 12 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 the i...

Page 32: ...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 33: ...0 10 16 16 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 length NOTE Maximum uninsulated vent lengths listed may include the termination...

Page 34: ...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 35: ...should 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 14 Capacity Exhaust Pipe Size Termination Pipe Size 045 070 2 51mm 21 2 64mm 3 76mm 1 1 2 38mm 90 2 51mm 110 045...

Page 36: ...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 37: ... 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 38: ...EDUCTION TABLE 3 If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions piping must be supported every 24 inches 610mm When exhaust piping must be run up an outside wall any reduction in exhaust pipe size must be done after the final elbow 4 Distance between exhaust pipe terminations on multiple furnaces must meet local codes Figure 39 Non Direct Ven...

Page 39: ...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 40: ...ld end header box drain plugs are factory installed Check the unused plug for tightness to prevent leakage 3 Install the cap over the clean out opening at the base of the trap Secure with clamp See Figure 47 or Figure 48 4 Install drain trap using appropriate PVC fittings glue all joints Glue the provided drain trap as shown in Figure 47 or Figure 48 Route the condensate line to an open drain Cond...

Page 41: ...1 min 2 max Trap can be installed a maximum of 5ft from furnace PVC only Field Provided Vent 1 min 2 max above condensate drain Piping from furnace must slope down a minimum 1 4 per ft toward trap Figure 44 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 FurnaceCondensate DrainC...

Page 42: ... 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 43: ...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 44: ...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 45: ...ould 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 subjected to more than 0 5 psig 14 W...

Page 46: ...nometer as soon as an accurate reading has been obtained Take care to remove barbed fitting and replace threaded plug 6 Start unit and perform leak check Seal leaks if found 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 ...

Page 47: ... 000 feet require an orifice change Units installed at altitudes of 4501 10 000 feet 1373 to 3048 m require a pressure switch change which can be ordered separately Table 15 lists conversion kit and pressure switch requirements at varying altitudes The combustion air pressure switch is factory set and requires no adjustment Capacity 0 7 500 ft 0 2 286m 7 501 10 000 ft 2 286 3 048 m Natural to LP P...

Page 48: ...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 49: ...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 50: ... static 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 pr...

Page 51: ...r collector box 11 Mark and remove wires from pressure switch assembly Remove pressure switch assembly Keep tubing attached to pressure 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 ...

Page 52: ...ter leak test has been completed Do not use matches candles flame or other sources of ignition to check for gas leaks CAUTION Cleaning 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...

Page 53: ...508115 01 Issue 2043 Page 53 of 57 Wiring Diagram ...

Page 54: ...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 55: ...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 56: ...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 57: ...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...