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Allied A95DF1E Service Manual

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SERVICE MANUAL
A95DF1E / 95G1DFE
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.
508115-01
WARNING
CAUTION

Table of Contents

Technical Specifications - A95DF1E ............................2
Technical Specifications - 95G1DFE ...........................5
Parts Arrangement.......................................................8
Electrical ......................................................................9
Placement & Installation ............................................23
Joint Cementing Procedure .......................................24
Venting Practices .......................................................25
Vent Piping Guidelines ..............................................26
Condensate Piping ....................................................40
Start-Up .....................................................................44
Heating System Service Checks ...............................45
Typical Operating Characteristics ..............................49
Maintenance ..............................................................50
Wiring Diagram ..........................................................53
(Continued) ................................................................55
Sequence of Operation..............................................57
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.
*P508115-01*
Issue 2043
WARNING
(P) 508115-01
Page 1 of 57

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Summary of Contents for Allied A95DF1E

  • 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 - A95DF1E ......2 Technical Specifications - 95G1DFE ......5 Parts Arrangement............8 Electrical ..............9...

  • Page 2: Technical Specifications - A95Df1E

    Technical Specifications - A95DF1E MODEL NUMBER GUIDE A 95 DF 1 E 110 C 20 S - 01 A = Flagship Numeric Code 95 = 95% Efficiency S = Stainless Steel Heat Exchanger UH = Upflow/Horizontal 08 = 2 ton add on cooling...
  • Page 3 BLOWER PERFORMANCE DATA Motor Temp. Heating CFM @ .10" - .80" w.c. Blower Blower Model Size Rise Size Speed (hp) (°F) High 1320 1285 1275 1230 1185 Med/High 1215 1165 1150 1095 1060 1020 A95DF1E045B12S 10 x 8 25 - 55 1090 1065 1025...
  • 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 13X57 1-Stage - 90 Low Input [030K BTUH] 68W62 17.5" B Width Return Air Base 68W63 21.0"...

  • Page 5: Technical Specifications - 95G1Dfe

    Technical Specifications - 95G1DFE MODEL NUMBER GUIDE 9 5 G 1 D F 0 7 0 B E 1 2 - 0 1 95% Efficency Major Revision 12 = 3 Ton add on cooling 16 = 4 Ton add on cooling 1 = 1 Stage 20 = 5 Ton add on cooling UH = Upflow/Horizontal...
  • Page 6 BLOWER PERFORMANCE DATA Motor Temp. Heating CFM @ .10" - .80" w.c. Blower Blower Model Size Rise Size Speed (hp) (°F) High 1320 1285 1275 1230 1185 Med/High 1215 1165 1150 1095 1060 1020 95G1DF045BE12 10 x 8 25-55 1090 1065 1025 Med/Low...
  • 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 1-Stage 13X57 1-Stage - 90 Low Input [030K BTUH] 68W62 17.5"...

  • Page 8: Parts Arrangement

    Parts Arrangement CONTROL BOX (Includes integrated control, transformer and door switch) BAG ASSEMBLY BLOWER MOTOR (hidden) BLOWER COMPARTMENT ACCESS PANEL COMBUSTION AIR INDUCER BLOWER DECK HEATING PRIMARY LIMIT COMPARTMENT ACCESS PANEL COLD END HEADER BOX HEAT EXCHANGER GAS VALVE BURNER BOX ASSEMBLY (includes flame sensor, rollout switches and ignitor) Figure 1.

  • Page 9: Electrical

    Control is not field repairable. If control is A95DF1E / 95G1DFE unit components are shown in Figure inoperable, simply replace entire control. 1. The combustion air inducer, gas valve and burners can Can cause injury or death. Unsafe be accessed by removing the outer access panel.
  • 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 Fan Time Control Ignitor (Figure 5) Heating Fan On Time A95DF1E / 95G1DFE units use a nitride ignitor made from The fan on time of 30 seconds is not adjustable. a proprietary ceramic material. To check ignitor, measure its resistance and voltage. A value of 39 to 70 ohms indicates a good ignitor.
  • Page 13 Switch S47 in all A95DF1E / 95G1DFE Heat Exchanger (Figure 6) units is factory preset to open at 210 F + 12 F (99 C + A95DF1E / 95G1DFE units use an aluminized steel primary 6.7 C) on a temperature rise.
  • Page 14 Primary Limit Control (Figure 6) MANIFOLD PRESSURE Primary limit (S10) used on A95DF1E / 95G1DFE units ADJUSTMENT SCREW is located in the heating vestibule panel. When excess (under barbed fitting) MANIFOLD heat is sensed in the heat exchanger, the limit will open.
  • Page 15 Flame Signal In Microamps Normal Drop Out 0.5 - 1.4 Flame Sensor Terminal Remove Sensor Wire from Intergrated Control and Intergrated Connect Alligator Clip (−) Control to Frame Sensor Lead Remove Sensor Wire from Intergrated Control and Connect Alligator Clip (+) to Terminal on Control Multi−Meter Flame Sensor...
  • Page 16 Test 1 Check ignitor circuit for correct resistance. Remove 4-pin plug from control. Check ohms reading across terminals 2 and 4. Reading should be between 39 and 70 ohms. 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 17 On start-up, the switch monitors whether the combustion air inducer is operating. It closes a circuit to the integrated All A95DF1E / 95G1DFE units use a combustion air inducer control when the difference in pressure across the to move air through the burners and heat exchanger during combustion air inducer orifice exceeds a non-adjustable heating operation.
  • Page 18 Black Tubing (positive +) Red and Black Tubing or Red Tubing (negative -) To Cold End Header Box To Cold End Header Box Field Provided Tubing To Pressure Switch “+” High “-” 1 - Remove thermostat demand and allow unit to 4 - Operate unit and observe manometer reading.
  • Page 19 Problem Corrective Action Check that the pressure switch is open without the combustion air inducer Pressure switch stuck closed operating. Replace if defective. Check for restricted vent. Remove all blockage. Pressure switch does not close due to obstruction in vent pipe Check for proper vent sizing.
  • Page 20 Each blower is statically and dynamically balanced as an assembly before installation in the unit. A95DF1E / 95G1DFE 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 21 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 22 Testing the Motor (Figure 17) Motor Module Installation If any motor fails the below tests, do not install the new All replacement motor control modules look similar; control module. The motor is defective and it also must be however, each module is designed for a specific motor replaced.

  • Page 23: Placement & Installation

    SPECIFICATION PVC & CPVC Primer F656 IMPORTANT PVC Solvent Cement D2564 A95DF1E / 95G1DFE exhaust and intake connections CPVC Solvent Cement F493 are made of PVC. Use PVC primer and solvent cement ABS Solvent Cement D2235 when using PVC vent pipe. When using ABS vent pipe,...

  • Page 24: Joint Cementing Procedure

    Standard Concentric Outdoor Exhaust Outdoor Exhaust 1-1/2” 2” 3” Flush-Mount Vent Pipe Accelerator Accelerator Concentric Concentric Concentric Capacity Dia. (Dia. x Length) (Dia. x Length) (in.) 71M80 69M29 60L46 1-1/2” x 12” 2” x 12” 51W11** †44W92†† †44W92†† 44W93† 1-1/2 2-1/2 1-1/2 2-1/2...

  • Page 25: Venting Practices

    during assembly (but not after pipe is fully inserted) to REPLACING FURNACE THAT distribute cement evenly. DO NOT turn ABS or cellular CHIMNEY WAS PART OF A COMMON OR GAS core pipe. VENT VENT SYSTEM (Check sizing for water NOTE: Assembly should be completed within 20 heater only) seconds after last application of cement.

  • Page 26: Vent Piping Guidelines

    Table 13. The A95DF1E / 95G1DFE can be installed as either a Non-Direct Vent or a Direct Vent gas central furnace. NOTE: In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors.
  • Page 27 Use the following steps to correctly size vent pipe diameter. 045, 070, Furnace capacity? 090, 110 Standard or Which termination? Concentric? See Table 9 Which needs most Intake or elbows? Exhaust? How many? 1-1/2”, 2”, Desired pipe size? 2-1/2” or 3” What is the altitude? Use Table 11 through Table 12 to find max...
  • Page 28 Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 − 10,000 ft. Number 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe of 90° Capacity Capacity Capacity Capacity Elbows Used Concentric Termination Elevation 0 − 10,000 ft. Number 1-1/2”...
  • Page 29 Maximum Allowable Exhaust Vent Lengths with Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space for Intake Air in Feet Standard Termination at Elevation 0 − 10,000 ft. Number 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe of 90°...
  • Page 30 NOTE: 1-1/2” Vent Pipe Pipe size determined in Table 11 Diameter Allowed Only or Table 12. on 045/070 Units 2” 2” 2” 2” 3” 1-1/2” 2” TRANSITION TRANSITION *2” *2” INTAKE DO NOT transition DO NOT transition EXHAUST from smaller to larger from larger to smaller TOP VIEW pipe in horizontal runs...
  • Page 31 Intake Piping Intake The A95DF1E / 95G1DFE furnace may be installed in Debris either direct vent or non-direct vent applications. In Screen (Provided) non-direct vent applications, when intake air will be drawn into the furnace from the surrounding space, the indoor...
  • Page 32 In Non-Direct Vent applications, combustion air is taken from indoors and the flue gases are discharged to the outdoors. The A95DF1E / 95G1DFE is then classified as a non-direct vent, Category IV gas furnace. In Direct Vent applications, combustion air is taken from outdoors and the flue gases are discharged to the outdoors.
  • Page 33 Maximum Allowable Exhaust Vent Pipe Length (in ft.) without Insulation in Unconditioned Space For Winter Design Temperatures Single - Stage High Efficiency Furnace Unit Input Size Vent Pipe Winter Design Temperatures ºF (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in.
  • Page 34 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Allied Air recommends avoiding this location if possible. Figure 28. Vent Termination Clearances for Direct Installations Page 34 of 57...
  • Page 35 Details of Intake and Exhaust Piping 3” (76MM) MIN. SIZE PER EXHAUST PIPE Inches (MM) Terminations for Direct Vent Installations TERMINATION SIZE NOTE: In Direct Vent installations, combustion air is taken REDUCTION TABLE from outdoors and flue gases are discharged to outdoors. UNCONDITIONED ATTIC SPACE 8”...
  • Page 36 If intake and exhaust piping must be run up a side 1 1/2” (38mm) accelerator wall to position above snow accumulation or other provided on 71M80 & 44W92 EXHAUST kits for -045 and -070 models obstructions, piping must be supported. At least one VENT bracket must be used within 6”...
  • Page 37 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Allied Air recommends avoiding this location if possible. Figure 37. Vent Termination Clearances for Non-Direct Installations...
  • Page 38 Details of Exhaust Piping Terminations for Non- STRAIGHT-CUT OR * SIZE TERMINATION PIPE PER EXHAUST Direct Vent Applications ANGLE-CUT IN DIRECTION PIPE TERMINATION SIZE REDUCTION TABLE OF ROOF SLOPE * Exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof EXHAUST VENT Minimum 12”...
  • Page 39 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT LARGER VENT PIPE SIZE Vent Pipe Vent Pipe TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...

  • Page 40: Condensate Piping

    Condensate Piping This unit is designed for either right- or left-side exit of condensate piping. Refer to Figure 41 for condensate trap locations. Trap NOTE: If necessary the condensate trap may be installed (same on up to 5 feet away from the furnace. Piping from furnace right side) must slope down a minimum of 1/4”...
  • Page 41 If this is not possible, a heat cable kit may be used Optional on the condensate trap and line. Heating cable kit is available from Allied in various lengths; 6 ft. (1.8m) - kit no. 26K68 and 24 ft. (7.3m) - kit no. 26K69. Trap can be installed a maximum of 5ft.
  • Page 42 Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 1 (25 mm) Min. Vent 2 (50 mm) Max.
  • Page 43 Optional Condensate Drain Connection Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) 90° Street Elbow 1/2 inch PVC (Not Furnished) Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Condensate Drain Connection In Unit 1 (25 mm) Min. Vent 2 (50 mm) Max.

  • Page 44: Start-Up

    Remove the access panel. Move gas valve switch to OFF. See Figure 49. The gas valve on the A95DF1E / 95G1DFE is equipped Wait five minutes to clear out any gas. If you then with a gas control switch. Use only your hand to move the smell gas, STOP! Immediately call your gas supplier switch.

  • Page 45: Heating System Service Checks

    All units are C.S.A. design certified without modifications. preferred means. Kitchen detergents can cause harmful corrosion on various metals used in gas piping. Use of a Refer to the A95DF1E / 95G1DFE Operation and specialty Gas Leak Detector is strongly recommended. Installation Instruction.
  • Page 46 Tee into the gas valve regulator vent hose and connect to test gauge negative “-”. IMPORTANT Start unit and let run for 5 minutes to allow for steady For safety, connect a shut-off valve between the state conditions. manometer and the gas tap to permit shut off of gas After allowing unit to stabilize for 5 minutes, record pressure to the manometer.
  • Page 47 Gas Flow (Approximate) High Altitude NOTE: In Canada, certification installations Seconds for One Revolution elevations over 4500 feet (1372 m) is the jurisdiction of Natural Capacity local authorities. 1 cu ft 2 cu ft 1 cu ft 2 cu ft Dial Dial Dial...
  • Page 48 Proper Ground and Voltage 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 CAUTION before operating the furnace. In addition, measure the AC voltage from Line Hot Electric Shock Hazard.

  • Page 49: Typical Operating Characteristics

    OFF position. Seal the hole when the check is complete. Temperature Rise (Figure 53) EXTERNAL STATIC PRESSURE Temperature rise for A95DF1E / 95G1DFE units depends Supply Duct Static on unit input, blower speed, blower horsepower and static Return Duct Static + pressure as marked on the unit rating plate.

  • Page 50: Maintenance

    Cabinet Width Filter Size Maintenance 17-1/2” 16 x 25 x 1 (1) 21” Table 21. WARNING ELECTRICAL SHOCK, FIRE, Exhaust and Air Intake Pipes OR EXPLOSION HAZARD. Check the exhaust and air intake pipes and all connections Failure to follow safety warnings exactly could result in for tightness and to make sure there is no blockage.
  • Page 51 Winterizing and Condensate Trap Care Remove four burner box screws at the vestibule panel and remove burner box. Set burner box assembly 1. Turn off power to the furnace. aside. Have a shallow pan ready to empty condensate water. NOTE: If necessary, clean burners at this time. Follow Remove the clean out cap from the condensate trap procedures outlined in Burner Cleaning section.
  • Page 52 Cleaning the Burner Assembly (if needed) 26. Route heating component wiring through hole in blower deck and reinsert strain relief bushing. Turn off electrical and gas power supplies to furnace. Remove upper and lower furnace access panels. 27. Reinstall electrical junction box. Disconnect the 2-pin plug from the gas valve.

  • Page 53: Wiring Diagram

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

  • Page 54: 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 55: 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 56: 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 57: 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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