Allied A80US2V Service Manual
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Allied A80US2V Service Manual

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SERVICE MANUAL
A80US2V Gas Furnace
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.
508155-01
WARNING
CAUTION

Table of Contents

Technical Specifications - A80US2V............................2
Parts Arrangement.......................................................5
Unit Components .........................................................6
Placement and Installation ........................................27
Start-Up .....................................................................27
Heating System Service Checks ...............................28
Typical Operating Characteristics ..............................31
Maintenance ..............................................................32
Wiring and Sequence of Operation ...........................35
...................................................................................40
Program Unit Capacity Size Modes...........................44
Operation ...................................................................49
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.
*P508155-01*
Issue 2108
WARNING
(P) 508155-01
Page 1 of 49

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Summary of Contents for Allied A80US2V

  • 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 - A80US2V......2 Parts Arrangement............5 Unit Components ............6 Placement and Installation ........27...

  • Page 2: Technical Specifications - A80Us2V

    Technical Specifications - A80US2V MODEL NUMBER GUIDE A 8 0 U S 2 V 11 0 C 2 0 L - 0 1 A = Flagship Major Revision Code Numeric Code AFUE 80 = 80% Efficency Option Code L = Low NOx...
  • Page 3 BLOWER PERFORMANCE DATA Heating Cooling Motor CFM @ 0" - 0.8" w.c. Blower Low Fire High Fire Size Size Cooling Speed (hp) Rise CFM @ Rise CFM @ Stage Adjustment Speed Speed High 0" - 0.5" 0" - 0.5" Range Range Med Low Med High Adjustment...
  • Page 4 ACCESSORY LIST Catalog Number Description External Filter Rack Kits 1.841018 1 pack (16 x 25) 1.841039 10 pack (16 x 25) Natural to LP Kits 11K48 Two-Stage (0 - 7500 ft.) 11K47 Two-Stage (>7500 ft.) Return Air Base 68W61 Return Air Base 14.5 Inch, A Width 68W62 Return Air Base 17.5 Inch, B Width 68W63...

  • Page 5: Parts Arrangement

    Parts Arrangement Heat Exchanger Combustion Air Inducer Combustion Air Inducer Pressure Switch Rollout Located Valve Inside Burner Box Cabinet Burner Box Control Box (Includes Integrated Control, and Transformer) Burner Access Panel Blower Access Blower Assembly Panel Figure 1. Expanded View Page 5 of 49 508155-01 Issue 2108...

  • Page 6: Unit Components

    A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer A80US2V unit components are shown in Figure 1. (T1). The breaker is rated 3A at 32V. If the current exceeds The gas valve, combustion air inducer and burners can this limit the breaker will trip and all unit operation will be accessed by removing the access panel.
  • Page 7 NOTE: During abnormal conditions such as low supply Pin # Function voltage or low outdoor temperatures and the low fire Ignitor pressure switch does not close, the combustion air inducer Combustion Air Inducer High Speed will switch to high fire. After a 15 second pre-purge the Combustion Air Inducer Low Speed high fire pressure switch will close and the unit will begin operation on high fire.
  • Page 8 Figure 4. Integrated Control Page 8 of 49 Issue 2108 508155-01...
  • Page 9 CLG BLOWER SPEED ADJUSTMENT 2ND STAGE HEAT ON DELAY DEFAULT 7 MIN CONTINUOUS FAN MODE BLOWER SPEED UPSTAGE THERMOSTAT SELECTION DELAY + 10% MEDIUM−LOW SPEED TWO STAGE (38%) THERMOSTAT 12 MIN UPSTAGE − 10% MEDIUM−HIGH DELAY SPEED 1−STAGE (70%) THERMOSTAT (TIMED STAGING) −SEE SW #2 SPEED...
  • Page 10 Display Action (when button released) No change (idle)* Remain in idle mode Solid “E” Enter diagnostic recall mode Solid “D” Discharge air installed Solid “F” Enter flame signal mode Solid “P” (variable speed only) Program unit capacity/size unit (Unit Code) * 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 4.
  • Page 11 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover Idle mode (Decimal blinks at 1 Hertz - 0.5 • seconds ON, 0.5 seconds OFF). Cubic feet per minute (cfm) setting for indoor blower (1 second ON, 0.5 seconds OFF) / cfm setting for current mode displayed.
  • Page 12 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E180 Outdoor air temperature sensor failure. Only Compare outdoor sensor resistance to temperature resistance charts shown if shorted or out of range (Communicating in unit installation instructions. Replace sensor pack if necessary. At systems only) beginning of (any) configuration, furnace or air handler control will sense outdoor air and discharge air temperature sensor(s) If detected (reading...
  • Page 13 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E240 Low flame current - Run mode- Refer to Check micro-amperes of flame sensor using control diagnostics or field troubleshooting installed mode. Clean or replace sensor. Measure voltage of neutral to ground to ensure good unit ground.
  • Page 14 Code Diagnostic Codes / Status of Equipment Action Required to Clear and Recover E311 Heat rate reduced to match indoor blower airflow. Warning Only. Furnace blower in cutback mode due to restricted airflow. Reduce firing rate every 60 seconds to match available CFM. Check filter and duct system.
  • Page 15 NOTE: All Comfort Sync settings are set at the Comfort Indoor Blower Operation DIP Switch Settings Sync Wi-Fi thermostat. See Comfort Sync installation Switches 5 and 6 -- Cooling Mode Blower Speed -- instruction. In Comfort Sync communication system all The unit is shipped from the factory with the dip switches DIP switch and clippable link settings are ignored.
  • Page 16 Switches 11, 12 and 13 -- Heating Mode Blower Speed Ramping Option A (Factory Selection) -- The switches are factory set to the OFF position which • Motor runs at 50% for 30 seconds. provides factory default heat speed. Refer to Table 10 for •...
  • Page 17 * Dehumidification blower speed is 70% of COOL speed for all units. ** In Precision mode, thermostat will maintain room temperature up to 2°F (1.2°C) cooler than room setting. Table 11. A80US2V, Non-Communicating Thermostat with Humidity Control Feature and Single-Speed Outdoor Unit...
  • Page 18 • With Heat Pump - Cut W914 (R to DS) and W951 (R to O) on control *Normal operation first stage cooling blower speed is 70% COOL speed. **Dehumidification blower speed is reduced to 70% of COOL. Table 12. A80US2V, Non-Communicating Thermostat with Humidity Control Feature and Two-Speed Outdoor Unit Page 18 of 49...
  • Page 19 IMPORTANT Earlier ECM motors used on other Allied Air furnace models are not interchangeable with motors used on the A80US2V furnace line. A solid-state controller is permanently attached to the motor.
  • Page 20 The cfm remains relatively stable over a broad range of static pressure. Since the blower constantly adjusts rpm to A choke coil is used on A80US2V 4 and 5 ton units maintain a specified cfm, motor rpm is not rated. Hence, equipped with 1 hp motors.
  • Page 21 Using test jumpers, apply 24V to pins 3 and 4 on P49 P48 5 Pin on the motor. P49 4 Pin NOTE: Do not apply 24V to pins 2 and 4 on P49. Doing SHAFT so will cause permanent damage to the motor. Motor should run at 75%.
  • Page 22 Figure 10. value should be 39 to 70. See Figure 14 for ignitor location and Figure 13 for ignitor check out. TEST A NOTE: The A80US2V furnace contains electronic Measure the resistance between each of the three motor leads (3-pin plug) and the unpainted part of the end shield.
  • Page 23 Test 1 Remove 5-pin plug from control Check ohms reading across terminals 1and 5 Ohm value should be between 39 - 70. Meter (set to ohms) Integrated control detail Test 2 Seperate the 2-pin jack plug near the manifold and check resistance of the ignitor. If the reading is correct, then then there is a problem with the wiring between the jack plug and control.
  • Page 24 Each burner uses an orifice LPG change over kits are available from Allied. Kits include that is precisely matched to the burner input. Burners can burner orifices and a gas valve.
  • Page 25 Combustion Air Inducer Prove Switch The primary limit (S10) is located in the heating vestibule A80US2V series units are equipped with a dual combustion panel. When excess heat is sensed in the heat exchanger, air proving switch (first and second stage) located on the the limit will open.
  • Page 26 Multiple Venting The A80US2V furnace can vent in multiple positions. See IMPORTANT Figure 16. The combustion air pressure switch must be moved for horizontal discharge air left position. The make up box may be removed and the combustion air inducer may be rotated clockwise or counterclockwise 90°...

  • Page 27: Placement And Installation

    Failure to Operate Shock and burn hazard. If the unit fails to operate, check the following: A80US2V units are equipped with a hot surface ignition 1. Is the thermostat calling for heat? system. Do not attempt to light manually. Are access panels securely in place?

  • Page 28: Heating System Service Checks

    Do not over torque (800 in-lbs) or under torque (350 regulator adjustment. Manifold pressure for the A80US2V in-lbs) when attaching the gas piping to the gas valve. can be measured at any time the gas valve is open and is supplying gas to the unit.
  • Page 29 Proper Gas Flow (Approximate) High Altitude Furnace should operate at least 5 minutes before checking The manifold pressure, gas orifice and pressure switch gas flow. Determine time in seconds for two revolutions of may require adjustment or replacement to ensure proper gas through the meter.
  • Page 30 Manifold Manifold Manifold Supply Line Orifice Size Pressure in w.g. Pressure in w.g. Pressure in w.g. Orifice Size Pressure in w.g. Unit 0 - 4500 ft. 4501 - 7500 ft. 7501 - 10,000 ft. 7501 ft. - 0 - 7500 ft. Input 10,000 ft.

  • Page 31: Typical Operating Characteristics

    Temperature Rise more than 1.0” W.C. Temperature rise for A80US2V units depends on unit input, Seal the hole when the check is complete. blower speed, blower horsepower and static pressure as marked on the unit rating plate.

  • Page 32: Maintenance

    At the beginning of each heating season, and to comply necessary . The blower motors are prelubricated for with the Allied Air Limited Warranty, your system should extended bearing life. No further lubrication is needed. be checked by a licensed professional technician (or...
  • Page 33 Clock gas meter to ensure that the unit is operating 14. Reinstall heat exchanger in vestibule. (Replace the at the specified firing rate. Check the supply pressure five screws in the cabinet from step 10 if removed). and the manifold pressure. On two-stage gas furnaces 15.
  • Page 34 Figure 23. A80US2V Burner, C.A.I. Assembly, and Heat Exchanger Removal Page 34 of 49 Issue 2108 508155-01...

  • Page 35: Wiring And Sequence Of Operation

    Wiring and Sequence of Operation Figure 24. A80US2V Schematic Wiring Schematic Page 35 of 49 508155-01 Issue 2108...
  • Page 36 NOTE: If the low fire pressure switch does not close the combustion air inducer will switch to high fire. After WARNING a 15 second pre-purge the high fire pressure switch will close and the unit will begin operation on high fire. Electric Shock Hazard.
  • Page 37 Applications Using a Single-Stage After the pre-purge is complete, a 20-second initial ignitor warm-up period begins. The combustion air Thermostat inducer continues to operate at low speed. B - Heating Sequence -- Integrated Control Thermostat After the 20-second warm-up period has ended, the Selection DIP Switch 1 ON in “Single-Stage”...
  • Page 38 Comfort Sync Wifi Thermostat with A96US2V Comfort Sync Wifi Thermostat with A96US2V and Comfort Sync-enabled Outdoor Unit and Non-Communicating Outdoor Unit Comfort Sync Wifi Thermostat Comfort Sync Wifi Thermostat Comfort Sync-enabled A96US2V Indoor Furnace Comfort Sync-enabled A96US2V Indoor Furnace Comfort Sync-enabled Outdoor Air Conditioner or Heat Pump Non-Communicating Outdoor Air Conditioner COMFORT SYNC...
  • Page 39 NOTE: COMFORT SYNC WIFI THERMOSTAT SENSE HUMIDITY & CONTROLS HUM CONTACTS TO CYCLE HUMIDIFIER BASED ON 120V CONNECTIONS DEMAND. NO OTHER CONTROL OR HUMIDISTAT REQUIRED. “HUM” CONTACT IS OPTIONAL OUTDOOR AIR SENSOR FOR USE WITH HUMIDIFIER CLOSED ANYTIME (IF NOT ALREADY IN THE SYSTEM FOR OTHER FUNCTIONS. HUMIDITY DEMAND IS PRESENT BUILT INTO ALL COMFORT SYNC OUTDOOR UNITS).

  • Page 40: Field Wiring Applications With Conventional Thermostat

    ON - 12 minutes *Not required on all units NOTE - Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the A80US2V integrated control. Table 21. Field Wiring for Non-Communicating Thermostat Applications...
  • Page 41 2 Heat / 1 Cool *Not required on all units NOTE - Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the A80US2V integrated control. Table 21. Field Wiring for Non-Communicating Thermostat Applications...
  • Page 42 NOTE - Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the A80US2V integrated control. Table 21. Field Wiring for Non-Communicating Thermostat Applications Page 42 of 49...
  • Page 43 NOTE - Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the A80US2V integrated control. Table 21. Field Wiring for Non-Communicating Thermostat Applications Page 43 of 49...

  • Page 44: Program Unit Capacity Size Modes

    Program Unit Capacity Size Modes Power-Up - Number displayed by integrated control represents unit size code (furnace model and capacity). If three horizontal bars are displayed followed by continuous E203, furnace control does not recognize unit size code. Configure per the following: Turn room thermostat to OFF.

  • Page 45: Troubleshooting: Heating Sequence Of Operation

    Troubleshooting: Heating Sequence of Operation CALL FOR FIRST-STAGE HEAT CALL FOR 1ST STAGE HEAT (LOW FIRE) INDOOR BLOWER OFF AFTER HEAT FAN OFF DELAY (LOW HEAT SPEED) INDOOR LIMIT BLOWER OFF HIGH ERROR SWITCH INDOOR WATCHGUARD − AFTER HEAT FAN LIMIT SWITCH CODE CLOSED WITHIN 3...
  • Page 46 Troubleshooting: Heating Sequence of Operation (Continued) CALL FOR SECOND-STAGE HEAT CALL FOR 2ND STAGE HEAT (HIGH FIRE) SINGLE STAGE 2 STAGE THERMOSTAT THERMOSTAT 2ND STAGE RECOGNITION DELAY ON DELAY (30 SECONDS) EXPIRED? EXPIRED? ONLY FOR 1ST REQUEST FOR 2ND STAGE HEAT INDUCER SWITCHED TO HIGH SPEED HIGH...
  • Page 47 Troubleshooting: Heating Sequence of Operation (Continued) CALL FOR HEAT SATISFIED FIRST-STAGE HEAT SECOND-STAGE HEAT RUN MODE: 1ST OR 2ND STAGE CALL FOR HEAT. ALL INPUTS MONITORED (LIMIT, PRESSURE, CALL FOR HEAT/COOL, FLAME LEVEL) 2ND STAGE HEAT 2ND STAGE CALL FOR HEAT SATISFIED? DE−ENERGIZE 2ND STAGE GAS VALVE...

  • Page 48: Troubleshooting: Cooling Sequence Of Operation

    Troubleshooting: Cooling Sequence of Operation CALL FOR COOLING 1ST STAGE COOLING REQUEST RECEIVED WAIT FOR COMPRESSOR TIMED OFF DELAY TO EXPIRE ENERGIZE 1ST STAGE COOLING CONTACTOR (COMPRESSOR & FAN) INDOOR BLOWER 2 SECOND ON DELAY ENERGIZE INDOOR BLOWER (LOW COOLING MODE) MAINTAIN INDOOR BLOWER (LOW COOLING MODE)

  • Page 49: Troubleshooting: Continuous Fan Sequence Of Operation

    Troubleshooting: Continuous Fan Sequence of Operation CALL FOR FAN CALL FOR FAN INDOOR BLOWER ON CONTINUOUS FAN SPEED CALL FOR FAN MAINTAIN INDOOR BLOWER AT REMOVED? CONTINUOUS FAN REQUEST MAINTAIN INDOOR FOR COOLING GO TO CALL FOR COOLING BLOWER AT RECEIVED? CONTINUOUS FAN MAINTAIN INDOOR...

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