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Allied A80DF1E Service Manual

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SERVICE MANUAL
A80DF1E / 80G1DFE
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.
WARNING
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.
CAUTION
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.
508142-01

Table of Contents

Technical Specifications - A80DF1E ............................2
Technical Specifications - 80G1DFE ...........................5
Parts Arrangement.......................................................8
Unit Components .........................................................9
Placement & Installation ............................................20
Start-Up .....................................................................20
Heating System Service Checks ...............................21
Typical Operating Characteristics ..............................25
Maintenance ..............................................................26
Wiring Diagram ..........................................................29
(Continued) ................................................................31
Sequence of Operation..............................................33
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.
*P508142-01*
Issue 2047
WARNING
(P) 508142-01
Page 1 of 33

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Summary of Contents for Allied A80DF1E

  • 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 - A80DF1E ......2 Technical Specifications - 80G1DFE ......5 Parts Arrangement............8 Unit Components ............9...

  • Page 2: Technical Specifications - A80Df1E

    Technical Specifications - A80DF1E MODEL NUMBER GUIDE A 80 D F 1 E 110 C 20 01 A = Flagship Numeric Code 80 = 80% Efficiency 12 = 3 Ton add on cooling 16 = 4 Ton add on cooling...
  • Page 3 BLOWER PERFORMANCE DATA CFM @ External Static Pressure - " w.c. Motor Temp Blower Blower Model Size Rise Size Speed (hp) (°F) 0.20 0.30 0.40 0.50 0.60 0.70 0.80 High 1375 1335 1320 1275 1245 1215 1175 Med/High 1145 1120 1075 1045 1000...
  • Page 4 ACCESSORIES System Accessory Kit Number Description 1.841018 1 pack (16 x 25) External Filter Rack 1.841039 10 pack (16 x 25) 11K50 1-Stage - 90 Natural to LP Kit 11K45 High Altitude (>7500') 68W61 14.5" A Width 68W62 17.5" B Width Return Air Base 68W63 21.0"...

  • Page 5: Technical Specifications - 80G1Dfe

    Technical Specifications - 80G1DFE MODEL NUMBER GUIDE 8 0 G 1 D F 1 1 0 C E 2 0 ( L ) - 0 1 AFUE Rev Code Revision 80 = 80% Efficency L = Low Nox G = Gas Nom.
  • Page 6 BLOWER PERFORMANCE DATA Motor Temp CFM @ External Static Pressure - " w.c. Blower Blower Model Size Rise Size Speed (hp) (°F) 0.20 0.30 0.40 0.50 0.60 0.70 0.80 High 1375 1335 1320 1275 1245 1215 1175 Med/High 1145 1120 1075 1045 1000...
  • Page 7 ACCESSORIES System Accessory Kit Number Description 1.841018 1 pack (16 x 25) External Filter Rack 1.841039 10 pack (16 x 25) 11K50 1-Stage - 90 Natural to LP Kit 11K45 High Altitude (>7500') 68W61 14.5" A Width 68W62 17.5" B Width Return Air Base 68W63 21.0"...

  • Page 8: Parts Arrangement

    Parts Arrangement BLOWER ASSEMBLY CONTROL BOX FLUE CHASE INTERNAL FLUE PIPE ASSEMBLY BURNER BOX ASSEMBLY CABINET HEAT EXCHANGER COMBUSTION AIR INDUCER GAS VALVE ROLLOUT LOCATED INSIDE BURNER BOX ACCESS PANEL Figure 1. Page 8 of 33 Issue 2047 508142-01...

  • Page 9: Unit Components

    A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer A80DF1E / 80G1DFE unit components are shown in (T1). The breaker is rated at 3A at 32V. If the current Figure 1. The gas valve, combustion air inducer and...
  • Page 10 1/4” Quick Connect Terminals 120HUM Humidifier 120VAC LINE 120VAC XFMR Transformer 120VAC CIRC Indoor Blower 120VAC Indoor Air Quality Accessory 120VAC NEUTRALS Common 120VAC HUM24 Humidifier 24VAC 3/16” Quick Connect Terminals COOL Cooling Tap 24VAC HEAT Heating Tap 24VAC Continuous Blower 24VAC PARK (no power) Park terminal for unused speed taps Flame Sense...
  • Page 11 Red LED Flash Code Diagnostic Codes / Status of Furnace No power to control or board fault detected Heartbeat Normal Operation - Idle, Continuous Fan, Cool Continuous Rapid Flash Call for Heat / Burner Operation Reverse Line Voltage Polarity Improper Earth Ground Burner failed to light, or lost flame during heat demand Low Flame Signal - check flame sensor Watchguard - burner failed to light, exceeded maximum number of retries or recycles...
  • Page 12 an inter purge and warm-up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the integrated control goes into Watchguard- Flame Failure mode. After a 60-minute reset period, the integrated control will begin the ignition sequence again. Fan Time Control Heating Fan On Time The fan on time of 30 seconds is not adjustable.
  • Page 13 Flame Sensor (Figure 6) checks. A flame sensor is located on the left side of the burner NOTE: The A80DF1E / 80G1DFE furnace contains support. The sensor is mounted on the flame rollout plate electronic components that are polarity sensitive. Make and the tip protrudes into the flame envelope of the left- most burner.
  • Page 14 24V applied to the terminals Primary Limit Control energizes the valve. The primary limit on A80DF1E / 80G1DFE units is located in the heating vestibule panel under the combustion air Inlet and outlet pressure taps are located on the valve. A inducer.
  • Page 15 Remove Sensor Wire from Flame Integrated Control and Sensor Connect Alligator Clip (−) to Flame Sensor Lead Flame Sensor Wire DIGITAL METER Set dial to measure dc microamps Integrated Control Red Collar Indicates Positive Lead Flame Sensor Terminal (-) To flame sensor (+) To Control...
  • Page 16 Test 1 Check ignitor circuit for correct resistance. Remove 4-pin plug from control. Check ohms reading across terminals 2 and 4. If value is correct (39 to 70 ohms), 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 17 On start-up, the switch senses that the combustion air inducer is operating. It closes a circuit to the integrated All A80DF1E / 80G1DFE units use a combustion air inducer control when pressure inside the combustion air inducer to move air through the burners and heat exchanger during decreases to a certain set point.
  • Page 18 Each blower is statically and dynamically balanced as an assembly before installation in the unit. A80DF1E / 80G1DFE 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 19 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 “CIRC” and “Neutrals” “L” and “N” on input plug P48. If voltage is present continue on the integrated control.

  • Page 20: Placement & Installation

    WARNING WRONG MOTOR CONTROL MODULE MAY RESULT IN UNEXPECTED UNIT OPERATION. Shock and burn hazard. A80DF1E / 80G1DFE units are equipped with a hot surface ignition system. Do not attempt to light manually. Page 20 of 33 Issue 2047 508142-01...

  • Page 21: Heating System Service Checks

    Gas Valve Operation (Figure 16) Extended Period Shutdown 1. STOP! Read the safety information at the beginning Turn off thermostat or set to “UNOCCUPIED” mode. of this section. Close all gas valves (both internal and external to unit) to guarantee no gas leaks into combustion chamber. Turn Set the thermostat to the lowest setting.
  • Page 22 gas valve and install a field-provided barbed fitting. Connect to a test gauge to measure supply pressure. MANUAL MAIN SHUT-OFF VALVE Start unit and allow 5 minutes for unit to reach steady state. WILL NOT HOLD TEST PRESSURE IN EXCESS OF 0.5 PSIG (14”W.C.) After allowing unit to stabilize for 5 minutes, record supply pressure and compare to value given in Table Manifold Pressure Measurement...
  • Page 23 508142-01 Issue 2047 Page 23 of 33...
  • Page 24 Proper Ground and Voltage In addition, measure the AC voltage from Line Hot to Line Neutral (spade terminals) on the integrated A poorly grounded furnace can contribute to premature control. See Figure 18. This voltage should be in the ignitor failure. Use the following procedure to check for range of 97 to 132 VAC ground and voltage to the integrated control.

  • Page 25: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 20. Punch a 1/4” diameter hole in supply and return air Blower Operation and Adjustment plenums. Insert manometer hose flush with inside edge of hole or insulation. Seal around the hose with NOTE: The following is a generalized procedure and does permagum.

  • Page 26: Maintenance

    At the beginning of each heating season, and to comply Check the condition and cleanliness of burners and with the Allied Limited Warranty, your system should heat exchanger and clean if necessary. be checked by a licensed professional technician (or...
  • Page 27 Clock gas meter to ensure that the unit is operating damage and replace if necessary. at the specified firing rate. Check the supply pressure 14. Reinstall burner box, manifold assembly and burner and the manifold pressure. On two-stage gas furnaces box cover.
  • Page 28 gasket orifice plate orifice plate gasket gasket flue chase internal flue pipe internal flue pipe combustion air inducer combustion air inducer ignitor collector box collector box rollout switch heat exchanger heat exchanger pressure switch pressure switch sensor retention rings burners burners manifold and gas valve manifold and gas valve...

  • Page 29: Wiring Diagram

    Wiring Diagram Figure 23. 508142-01 Issue 2047 Page 29 of 33...

  • Page 30: Troubleshooting: Heating Sequence Of Operation

    Troubleshooting: Heating Sequence of Operation HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF-CHECK OKAY? LED SLOW FLASH (RESET CONTROL BY TURNING MAIN POWER OFF.) LED FLASHES CODE 1 - POLARITY IS POLARITY CORRECT? REVERSED.

  • Page 31: Troubleshooting: Heating Sequence Of Operation (Continued)

    Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE CONTINUED 15 SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. LED FLASHES CODE 13 - LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IS VOLTAGE ABOVE 70 VOLTS? IGNITOR WARM UP -- 20 SECONDS. 75 VOLTS, HEATING SEQUENCE RESTARTS.

  • Page 32: Troubleshooting: Cooling Sequence Of Operation

    Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION POWER ON IGNITION CONTROL MAIN POWER ON. LED FLASHES STEADY - CIRCUIT BOARD FAILURE CONTROL SELF DIAGNOSTIC CHECK. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. IS CONTROL OPERATING NORMALLY? INDOOR BLOWER OFF WITH NORMAL DELAY. INTERRUPT MAIN POWER TO RESET CONTROL.

  • Page 33: Troubleshooting: Continuous Fan / Accessories Sequence Of Operation

    Troubleshooting: Continuous Fan / Accessories Sequence of Operation CONTINUOUS FAN / ACCESSORIES SEQUENCE OF OPERATION LED: SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE. MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERMINAL IS ENERGIZED. THERMOSTAT CALLS FOR HEAT (W).

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