Allied A80UH2E Service Manual
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Allied A80UH2E Service Manual

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SERVICE MANUAL
A80UH2E / 80G2UHE
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.
508187-01
WARNING
CAUTION

Table of Contents

Technical Specifications - A80UH2E ...........................2
Technical Specifications - 80G2UHE ...........................7
Parts Arrangement.....................................................12
Unit Components .......................................................13
Flame Sensor ............................................................23
Gas Valve ..................................................................23
Heating Components .................................................23
Placement and Installation ........................................29
Start-Up .....................................................................29
Heating System Service Checks ...............................30
Typical Operating Characteristics ..............................34
Maintenance ..............................................................35
Wiring and Sequence of Operation ...........................39
Field Wiring and DIP Switch Settings ........................42
Troubleshooting .........................................................46
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.
*P508187-01*
Issue 2116
WARNING
(P) 508187-01
Page 1 of 51

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Summary of Contents for Allied A80UH2E

  • Page 1: Table Of Contents

    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 - A80UH2E ......2 Technical Specifications - 80G2UHE ......7 Parts Arrangement.............12 Unit Components ............13...

  • Page 2: Technical Specifications - A80Uh2E

    Technical Specifications - A80UH2E MODEL NUMBER GUIDE A 8 0 U H 2 E 11 0 C 2 0 0 1 Major Revision Flagship Revision Code AFUE Nom. CFM x 00 80 = 80% Efficency 12 = 3 Ton add on cooling...
  • Page 3 BLOWER PERFORMANCE A80UH2E045A12 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 1500 1220 1050 0.10 1485 1200 1025 0.20 1460 1170 0.30 1420...
  • Page 4 A80UH2E090B16 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 1800 1555 1425 1370 1240 0.10 1765 1525 1390 1320 1190 0.20 1725 1485...
  • Page 5 508187-01 Issue 2116 Page 5 of 51...
  • Page 6 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 7: Technical Specifications - 80G2Uhe

    Technical Specifications - 80G2UHE 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 8 BLOWER PERFORMANCE 80G2UH045AE12 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 1500 1220 1050 0.10 1485 1200 1025 0.20 1460 1170 0.30 1420...
  • Page 9 80G2UH090BE16 / 80G2UH090BE16L 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 1800 1555 1425 1370 1240 0.10 1765 1525 1390 1320 1190 0.20...
  • Page 10 Page 10 of 51 Issue 2116 508187-01...
  • Page 11 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 12: Parts Arrangement

    Parts Arrangement Make Up Box Heat Exchanger Combustion Air Inducer Combustion Air Pressure Switch Gas Valve and Manifold Assembly Collector Box Indoor Blower and Motor Assembly (installed in cabinet) Limit Switch (under collector box) Constant Torque Indoor Blower Motor (removed from cabinet) Two-Stage Integrated Control Figure 1.

  • Page 13: Unit Components

    Electrical components are in the control box (Figure 2) found in the blower section. A80UH2E / 80G2UHE(L) units are factory equipped with Figure 3. Circuit Breaker (CB8) a bottom return air panel in place. The panel is designed to be field removed as required for bottom air return.
  • Page 14 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 15 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 16 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 17 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 18 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 19 Diagnostic LED (Figure 4) Integrated Control DIP Switches The seven-segment diagnostic LED displays operating A80UH2E / 80G2UHE(L) units are equipped with a two- status, error codes and other information. Table 4 lists stage integrated control. This control manages ignition diagnostic LED codes.
  • Page 20 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 21 Each blower is statically and dynamically balanced as an assembly before installation in the unit. A80UH2E / 80G2UHE(L) units are equipped with a constant torque ECM motor. It has a DC motor coupled to an electronic control module both contained in the same motor housing.
  • Page 22 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 23: Flame Sensor

    Make sure that the furnace is wired correctly and is properly LPG change over kits are available from Allied. Kits include grounded. burner orifices and a gas valve.
  • Page 24 Ignitor Burners Rollout Switches Sensor Gas Valve Gas Orifices Figure 9. Heating Components Page 24 of 51 Issue 2116 508187-01...
  • Page 25 Test 1 Checking resistance of ignitor circuit Remove 5-pin plug from integrated control. Check Ohms reading across terminal 1 and 5. Reading should be between 39 and 70 ohms. If value is correct, this is the only test needed. If the meter reading is not correct (”0”...
  • Page 26 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 27 Combustion Air Inducer (B6) and Cold End Header Box All A80UH2E / 80G2UHE(L) units use a two-speed combustion air inducer to move air through the burners 3/16” terminals and heat exchanger during heating operation. The blower uses a 120VAC motor. The motor operates during all heating operation and is controlled by integrated control control A92.
  • Page 28 Multiple Venting The A80UH2E / 80G2UHE(L) furnace can vent in multiple IMPORTANT positions. See Figure 13. The combustion air pressure switch must be moved for The make up box may be removed and the combustion air horizontal discharge air left position.

  • Page 29: 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 A80UH2E / 80G2UHE(L) is equipped technician or gas supplier. with a gas control switch. Use only your hand to move the switch.

  • Page 30: 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 A80UH2E / 80G2UHE(L) Operation and Installation Instruction. Gas Piping 1/8 NPT PLUG Gas supply piping should not allow more than 0.5” W.C.
  • Page 31 Manifold gas through the meter. (Two revolutions assures a more pressure for the A80UH2E / 80G2UHE(L) can be measured accurate time.) Divide by two and compare to time in Table at any time the gas valve is open and is supplying gas to 10.
  • Page 32 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 33 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 16. This voltage should be in the performance. Use the following procedure to check for range of 97 to 132 Vac.

  • Page 34: Typical Operating Characteristics

    OFF position. Seal the hole when the check is complete. Temperature Rise (Figure 17) Temperature rise for A80UH2E / 80G2UHE(L) units EXTERNAL STATIC PRESSURE depends on unit input, blower speed, blower horsepower and static pressure as marked on the unit rating plate.

  • Page 35: Maintenance

    Verify proper operation after servicing. At the beginning of each heating season, and to comply with the Allied Air Limited Warranty, your system should At the beginning of each heating season, system should be checked by a licensed professional technician (or...
  • Page 36 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 37 Cleaning the Heat Exchanger and Burners 17. Reinstall burner box, manifold assembly and burner box cover. NOTE: Use papers or protective covering in front of the furnace during cleaning. 18. Reconnect all wires. 19. Reconnect top cap and vent pipe to combustion air 1.
  • Page 38 Figure 21. Remove 5 screws if necessary (either side of cabinet) Page 38 of 51 Issue 2116 508187-01...

  • Page 39: Wiring And Sequence Of Operation

    Wiring and Sequence of Operation COMFORT SYNC ® THERMOSTAT 045-12 070-12 090-12 090-16 110-16 110-20 508187-01 Issue 2116 Page 39 of 51...
  • Page 40 The two-stage, variable speed integrated control used in speed. The control also checks the high fire (second- A80UH2E / 80G2UHE(L) units has an added feature of stage) pressure switch to make sure it is closed. The an internal Watchguard control. The feature serves as an...
  • Page 41 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 42: 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 43 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 44 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 45 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 46: 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 47 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 48 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 49 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 50 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 51 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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