Allied 80G2DFE Service Manual
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Allied 80G2DFE Service Manual

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SERVICE MANUAL
80G2DFE
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 HVAC installer (or
equivalent), service agency or the gas supplier.
As with any mechanical equipment, contact with sharp
sheet metal edges can result in personal injury. Take
care while handling this equipment and wear gloves
and protective clothing.
508189-01
WARNING
CAUTION

Table of Contents

Technical Specifications ..............................................2
Parts Arrangement.......................................................5
Unit Components .........................................................6
Flame Sensor ............................................................16
Gas Valve ..................................................................16
Heating Components .................................................16
Placement and Installation ........................................21
Start-Up .....................................................................21
Heating System Service Checks ...............................22
Typical Operating Characteristics ..............................26
Maintenance ..............................................................27
Wiring and Sequence of Operation ...........................30
Field Wiring and DIP Switch Settings ........................33
Troubleshooting .........................................................37
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.
*P508189-01*
Issue 2116
WARNING
(P) 508189-01
Page 1 of 42

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  • Page 1: Table Of Contents

    SERVICE MANUAL 80G2DFE 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. Table of Contents Technical Specifications ..........2 Parts Arrangement............5...

  • Page 2: Technical Specifications

    Technical Specifications MODEL NUMBER GUIDE 8 0 G 2 U H 1 1 0 C E 1 6 - 0 1 AFUE Major Revision 80 = 80% Efficency Revision Code Nom. CFM x 00 12 = 3 Ton add on cooling Stages 16 = 4 Ton add on cooling 2 = Two Stage...
  • Page 3 BLOWER PERFORMANCE 80G2DF070AE12 Air Volume / Watts at Various Blower Speeds External Static High Medium-High Medium Medium-Low Pressure (Black) (Brown) (Blue) (Yellow) (Red) in. w.g. Watts Watts Watts Watts Watts 0.00 1475 1345 1190 0.10 1440 1325 1165 0.20 1410 1280 1135 0.30...
  • Page 4 ACCESSORIES Accessory Catalog Number Return Air Base Return Air Base 14.5” 68W61 Return Air Base 17.5” 68W62 Return Air Base 21.0” 68W62 High Altitude Pressure Switches 2-Stage 80% UH/DF (4501 - 7500 ft) [045, 070, 090 110] 91W53 2-Stage 80% UH/DF (7501 - 10,000 ft) [045, 070, 090 110] 73W35 High Altitude Orifice Kits (7500 ft+) 2-Stage 80% UH/DF - Natural Gas...

  • Page 5: Parts Arrangement

    Parts Arrangement Top Cap Secondary Limit Indoor Blower Control Box (includes integrated control, transformer and door switch) Internal Flue Pipe Assembly Heat Exchanger Combustion Air Inducer Burner Box Assembly Primary Limit Gas Valve Figure 1. 508189-01 Issue 2116 Page 5 of 42...

  • Page 6: Unit Components

    See Figure 3. your hand and tools to metal prior to handling the control. 80G2DFE unit components are shown in Figure 1. The gas valve, combustion air inducer and burners can be accessed PRESS TO RESET by removing the access panel.
  • Page 7 energized on low (first stage) heat speed. When the Pin # Function differential in the pressure switch is great enough, the Ignitor pressure switch closes and a 15-second pre-purge begins. Combustion Air Inducer High Speed After the 15-second pre-purge period, the ignitor warms Combustion Air Inducer Low Speed up for 20 seconds after which the gas valve opens for a Combustion Air Inducer Neutral...
  • Page 8 24VAC Indoor Ignitor and Combustion Blower Terminals Air Inducer Neutrals Flame Sense S4 DIP Switches Diagnostic Push Button On Board Links 3/16” QUICK CONNECT TERMINALS THERMOSTAT CONNECTIONS (TB1) FLAME SENSE SIGNAL DS = DEHUMIDIFICATION SIGNAL HI COOL 24VAC W2 = HEAT DEMAND FROM 2ND STAGE TSTAT LO COOL 24VAC W1 = HEAT DEMAND FROM 1ST STAGE TSTAT LO HEAT 24VAC...
  • Page 9 2ND STAGE HEAT ON DELAY 7 MIN UPSTAGE THERMOSTAT SELECTION DELAY COOLING BLOWER-OFF DELAY TWO STAGE THERMOSTAT 12 MIN UPSTAGE *45 SECOND DELAY COOL BLOWER 1−STAGE OFF DELAY THERMOSTAT (TIMED STAGING) −SEE SW #2 HSI/CAI 2 SECOND COOL BLOWER HEATING BLOWER−OFF DELAY OFF DELAY 90 SECOND HTG BLOWER...
  • Page 10 Display Action (when button released) No change (idle)* Remain in idle mode Solid “E” Enter diagnostic recal mode Solid “F” Enter flame signal mode * No change implies the display will continue to show whatever is currently being displayed for normal operation (blinking decimal, active error code, heat state, etc.) Table 3.
  • Page 11 Code Diagnostic Codes/Status of Equipment Action Required to Clear and Recover E223 Low pressure switch failed open. Check pressure (inches w.c.) of low pressure switch closing on heat call. Measure operating pressure (inches w.c.). Inspect vent and combustion air inducer for correct operation and restriction. Resumes normal operation after fault is cleared E224 Low pressure switch failed closed.
  • Page 12 Diagnostic LED (Figure 4) Integrated Control DIP Switches The seven-segment diagnostic LED displays operating 80G2DFE units are equipped with a two-stage integrated status, error codes and other information. Table 4 lists control. This control manages ignition timing, heating diagnostic LED codes.
  • Page 13 Onboard Links Indoor Blower Operation DIP Switch Settings Switches 3 and 4 -- Heating Mode Blower-Off Delay -- W914 Dehum The blower-on delay of 30 seconds is not adjustable. The Onboard link W914, is a clippable connection between blower-off delay (time that the blower operates after the terminals R and DS on the integrated control.
  • Page 14 Watchguard for one hour. The switch is factory set and cannot be adjusted. 80G2DFE units are equipped with a constant torque ECM Figure 6. Blower Wheel Replacement motor. It has a DC motor coupled to an electronic control module both contained in the same motor housing.
  • Page 15 Multi−Meter (set to VAC) Multi−Meter (set to VAC) Test 1 Test 3 (if necessary) Turn on power to unit. Check for 120 volts across terminals Check for 120 volts across terminals “L1” and “Neutrals” on “L” and “N” on input plug P48. If voltage is present continue the integrated control.

  • Page 16: Flame Sensor

    Make sure that the furnace is wired correctly and is properly grounded. LPG change over kits are available from Allied. Kits include burner orifices and a gas valve. Flame Sensor...
  • Page 17 Ignitor Burners Rollout Switch Sensor Gas Valve Manifold and Gas Orifices Figure 9. Heating Components 508189-01 Issue 2116 Page 17 of 42...
  • Page 18 Test 1 Check ignitor circuit for correct resistance. Remove 5−pin plug from control. Check ohms reading across terminals 1 and 5. If value is correct, this is the only test needed. If the reading on the meter is not correct, (0 or infinity) then a second test is needed.
  • Page 19 Remove Sensor Wire from Flame Integrated Control and Sensor Connect Alligator Clip (−) to Frame Sensor Lead Flame Sensor Wire Integrated Control Flame Sensor DIGITAL METER Terminal Set dial to measure DC microamps Red Collar Indicates Positive Leads To Flame Terminal Remove Sensor Wire from Integrated Control and...
  • Page 20 Combustion Air Inducer (B6) and Cold End Header Box All 80G2DFE units use a two-speed combustion air inducer to move air through the burners and heat exchanger during 3/16” terminals heating operation. The blower uses a 120VAC motor. The motor operates during all heating operation and is controlled by integrated control control A92.

  • Page 21: Placement And Installation

    12. If the appliance will not operate, follow the instructions “Turning Off Gas to Unit” and call your service The gas valve on the 80G2DFE is equipped with a gas technician or gas supplier. control switch. Use only your hand to move the switch.

  • Page 22: Heating System Service Checks

    MANUAL MAIN SHUT-OFF VALVE All units are C.S.A. design certified without modifications. WILL NOT HOLD TEST PRESSURE IN EXCESS OF 0.5 PSIG (14”W.C.) Refer to the 80G2DFE Operation and Installation Instruction. Gas Piping 1/8 NPT PLUG Gas supply piping should not allow more than 0.5” W.C.
  • Page 23 Manifold gas through the meter. (Two revolutions assures a more pressure for the 80G2DFE can be measured at any time accurate time.) Divide by two and compare to time in Table the gas valve is open and is supplying gas to the unit.
  • Page 24 Manifold Pressure Manifold Pressure Manifold Pressure Supply Line Pressure in. wg. 0 - 4,500 ft. in. wg. 4,501 - 7,500 ft. in. wg. 7,501 - 10,000 ft. in. wg. Capacity Low Fire High Fire Low Fire High Fire Low Fire High Fire Min.
  • Page 25 Proper Ground and Voltage In addition, measure the AC voltage from Line Hot to Line Neutral (spade terminals) on the integrated Furnace must properly grounded proper control. See Figure 15. This voltage should be in the performance. Use the following procedure to check for range of 97 to 132 Vac.

  • Page 26: Typical Operating Characteristics

    OFF position. Seal the hole when the check is complete. Temperature Rise (Figure 16) Temperature rise for 80G2DFE units depends on unit input, EXTERNAL STATIC PRESSURE blower speed, blower horsepower and static pressure as marked on the unit rating plate. The blower speed must be Supply Duct Static set for unit operation within the range of “TEMP.

  • Page 27: Maintenance

    At the beginning of each heating season, and to comply Verify proper operation after servicing. with the Allied Air Limited Warranty, your system should be checked by a licensed professional technician (or At the beginning of each heating season, system should...
  • Page 28 6. Check the cleanliness of blower assembly and 13. Perform a complete combustion analysis during the clean the housing, blower wheel and blower motor if furnace inspection to ensure proper combustion necessary. The blower motors are prelubricated for and operation. Consult Service Literature for proper extended bearing life.
  • Page 29 Cleaning the Heat Exchanger and Burners 16. Reconnect all wires. NOTE: Use papers or protective covering in front of the 17. Reconnect top cap and vent pipe to combustion air furnace during cleaning. inducer outlet. 18. Reconnect gas supply piping. 1.

  • Page 30: Wiring And Sequence Of Operation

    Wiring and Sequence of Operation COMFORT SYNC THERMOSTAT ® 070-12 090-16 Page 30 of 42 Issue 2116 508189-01...
  • Page 31 The two-stage, variable speed integrated control used speed. The control also checks the high fire (second- in 80G2DFE units has an added feature of an internal stage) pressure switch to make sure it is closed. The Watchguard control. The feature serves as an automatic...
  • Page 32 After the 20-second warm-up period has ended, the When the thermostat heating demand is satisfied, the gas valve is energized on low fire (first stage) and combustion air inducer begins a 5-second low speed ignition occurs. At the same time, the control module post-purge.

  • Page 33: Field Wiring And Dip Switch Settings

    Field Wiring and DIP Switch Settings DIP Switch Settings and On-Board Links Thermostat Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options FURNACE OUTDOOR T'STAT TERM. STRIP UNIT 1 Heat / 1 Cool NOTE: Use DIP DO NOT CUT ANY switch 2 to set...
  • Page 34 DIP Switch Settings and On-Board Links Thermostat Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options FURNACE OUTDOOR T'STAT TERM. STRIP UNIT 2 Heat / 2 Cool CUT ON-BOARD LINK W915 2 STAGE COMPR *Not required on all units FURNACE OUTDOOR...
  • Page 35 DIP Switch Settings and On-Board Links Thermostat Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options FURNACE HEAT PUMP TERM. STRIP T'STAT CUT ON-BOARD LINK 67M41* W951 Dual Fuel Single- HEAT Stage Heat Pump PUMP Thermostat w/dual fuel capabilities...
  • Page 36 DIP Switch Settings and On-Board Links Thermostat Wiring Connections DIP Switch 1 On Board Links Must Be Cut To Select System Options FURNACE HEAT PUMP TERM. STRIP T'STAT Dual Fuel Single- 67M41* Stage Heat Pump CUT ON-BOARD LINK Thermostat w/dual W951 fuel capabilities HEAT...

  • Page 37: Troubleshooting

    Troubleshooting Troubleshooting: Heating Sequence of Operation HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. (RESET CONTROL BY CONTROL SELF-CHECK OKAY? TURNING MAIN POWER OFF.) POLARITY REVERSED. POLARITY OKAY? STATUS ERROR CODE 5 + 4.
  • Page 38 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT STATUS LED - HEARTBEAT. (Refer to box A on previous page) GAS VALVE OFF. COMBUSTION AIR INDUCER FIRST-STAGE (LOW FIRE) PRESSURE OFF. INDOOR BLOWER OFF. UNIT WILL RETRY SWITCH CLOSED WITHIN 2.5 MINUTES? AFTER 5-MINUTE WAIT PERIOD.
  • Page 39 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT. STATUS LED -- HEARTBEAT. SEE BOX A. FLAME SIGNAL ABOVE ( 1.40 microamps) LOW FLAME SIGNAL (Does not affect control operation) STATUS ERROR CODE 1 + 2. SINGLE-STAGE THERMOSTAT MODE TWO STAGE THERMOSTAT MODE (DIP SWITCH SET AT “ON”)
  • Page 40 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE OF OPERATION CONTINUED SEE BOX A NORMAL OPERATION. SEE BOX B THERMOSTAT CALLS FOR HEAT. RETURN TO FIRST-STAGE HEAT MODE. FIRST-STAGE CONTINUES UNTIL SECOND- STAGE PRESSURE SWITCH CAN BE PROVEN SECOND-STAGE (HIGH FIRE) HEAT or HEAT DEMAND IS SATISFIED.
  • Page 41 Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION POWER ON SIGNAL POLARITY REVERSED. CONTROL WILL CONTINUE TO CALL FOR COOLING IS POLARITY REVERSED? IN THIS CONDITION. STATUS ERROR CODE 5 + 4. SIGNAL IMPROPER GROUND AT LED. CONTROL WILL CONTINUE TO CALL FOR COOLING IS THERE IN THIS CONDITION.
  • Page 42 Troubleshooting: Continuous Fan Sequence of Operation CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION MANUAL FAN SELECTION MADE AT THERMOSTAT. AFTER 2 SECOND DELAY, INDOOR BLOWER IS ENERGIZED ON CONTINUOUS FAN SPEED. THERMOSTAT CALLS FOR FIRST STAGE COOL. THERMOSTAT CALLS FOR FIRST-STAGE HEAT. INDOOR BLOWER RAMPS TO FIRST STAGE AFTER 45-SECOND DELAY, INDOOR BLOWER COOLING SPEED AFTER A 2-SECOND DELAY.

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