Allied 96G1UH030BE08 Service Manual
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Allied 96G1UH030BE08 Service Manual

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SERVICE MANUAL
96G1UHE
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.
508170-01
WARNING
CAUTION

Table of Contents

Technical Specifications - 96G1UHE ...........................2
Parts Arrangement.......................................................6
Electrical ......................................................................7
Placement & Installation ............................................20
Joint Cementing Procedure .......................................21
Venting Practices .......................................................22
Vent Piping Guidelines ..............................................23
Condensate Piping ....................................................39
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.
*P508170-01*
Issue 2110
WARNING
(P) 508170-01
Page 1 of 57

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Summary of Contents for Allied 96G1UH030BE08

  • Page 1: Table Of Contents

    SERVICE MANUAL 96G1UHE 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 - 96G1UHE ......2 Parts Arrangement............6 Electrical ..............7 Placement &...

  • Page 2: Technical Specifications - 96G1Uhe

    Trans. Shipping Model Cooling Inlet Delay (Btuh) (Btuh) (ICS) F.L.A. (V.A.) Weight Capacity (in.) Phase Breaker (lbs.) or Fuse 96G1UH030BE08 30,000 28,000 2 Ton 120-60-1 96G1UH045BE12 44,000 42,000 3 Ton 120-60-1 96G1UH070BE12 66,000 63,000 3 Ton 120-60-1 96G1UH090CE16 88,000 85,000...
  • Page 3 BLOWER PERFORMANCE DATA 96G1UH030BE08 PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure in. w.g. Watts Watts Watts Watts Watts 0.00 1125 1015 0.10 1070 0.20 1035 0.30 1000 0.40 0.50 0.60...
  • Page 4 96G1UH090CE16 PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure in. w.g. Watts Watts Watts Watts Watts 0.00 1765 1535 1410 1315 1155 0.10 1735 1500 1365 1270 1130 0.20 1700 1465 1330 1230...
  • Page 5 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 17H62 1-Stage - 90 Low Input [030K BTUH] 68W62 17.5"...

  • Page 6: Parts Arrangement

    Parts Arrangement Figure 1. Page 6 of 57 Issue 2110 508170-01...

  • Page 7: Electrical

    Circuit Breaker (CB8) Electrical A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer (T1). The breaker is rated at 3A at 32V. If the current ELECTROSTATIC DISCHARGE (ESD) exceeds this limit the breaker will trip and all unit operation Precautions and Procedures will shutdown.
  • Page 8 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 9 Heating Fan Off Time Fan off time (time that the blower operates after the heat demand has been satisfied) can be adjusted by moving the jumper to a different setting. The unit is shipped with a factory fan off setting of 90 seconds. For customized comfort, monitor the supply air temperature once the heat demand is satisfied.
  • Page 10 Burner Assembly Rollout Switch(s) Flame Sensor Ignitor Gas Valve Burner Box Front Figure 5. Burner Box Assembly Flame Rollout Switches (Figure 5) on the integrated control. Flame rollout switches S47 are SPST N.C. high temperature Flame (microamp) signal is an electrical current which limits located on the left and right of the front buner box passes from the integrated control to the sensor during plate.
  • Page 11 Primary Limit Control (Figure 6) MANIFOLD PRESSURE Primary limit (S10) used on 96G1UHE units is located in ADJUSTMENT SCREW the heating vestibule panel. When excess heat is sensed (under barbed fitting) MANIFOLD in the heat exchanger, the limit will open. Once the limit PRESSURE opens, the furnace control energizes the supply air blower OUTLET...
  • Page 12 Flame Signal In Microamps Normal Drop Out 0.5 - 1.4 Flame Sensor Wire Remove sensor from integrated control and connect alligator clip (−) to flame sensor lead. Multi−Meter Intergrated Control Set Dial to DC MicroAmps Flame Sensor Terminal (−) T o Flame Terminal (+) To Control Sensor Terminal...
  • Page 13 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 14 Combustion Air Inducer (B6) & Cold End Header Box On start-up, the switch monitors whether the combustion air inducer is operating. It closes a circuit to the integrated All 96G1UHE units use a combustion air inducer to move control when the difference in pressure across the air through the burners and heat exchanger during heating combustion air inducer orifice exceeds a non-adjustable operation.
  • Page 15 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 16 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 17 Blower Compartment Center Blower Wheel in Blower Housing IMPORTANT Each blower is statically and dynamically balanced as an assembly before installation in the unit. 96G1UHE 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 18 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 19 Testing the Motor (Figure 17) Scale Measurement Range in Words ohms If any motor fails the below tests, the motor is defective two megohms - two million ohms 0 - 2,000,000 and must be replaced. two hundred kil-ohms - 200 K 0 - 200,000 two hundred thousand ohms Using an ohmmeter check the resistance from any...

  • Page 20: Placement & Installation

    Placement & Installation Piping and Fittings Specifications Schedule 40 PVC (Pipe) D1785 Pipe & Fittings Specifications Schedule 40 PVC (Cellular Core Pipe) F891 All pipe, fittings, primer and solvent cement must conform with American National Standard Institute and the American Schedule 40 PVC (Fittings) D2466 Society for Testing and Materials (ANSI/ASTM) standards.

  • Page 21: Joint Cementing Procedure

    STANDARD CONCENTRIC Outdoor Outdoor Exhaust Exhaust Flush Mount 1-1/2" 2" Concentric 3" Concentric VENT Accelerator Accelerator Concentric Kit Capacity PIPE DIA. (Dia. X Length) (Dia. X Length) (in.) 71M80 69M29 60L46 1-1/2" x12" 2" x12" 51W11** +44W92++ +44W92++ 44W93+ 1-1/2 2-1/2"...

  • Page 22: Venting Practices

    Promptly apply solvent cement to end of pipe and REPLACING FURNACE THAT inside socket surface of fitting. Cement should be CHIMNEY WAS PART OF A COMMON OR GAS applied lightly but uniformly to inside of socket. Take VENT VENT SYSTEM (Check sizing care to keep excess cement out of socket.

  • Page 23: Vent Piping Guidelines

    Vent Piping Guidelines NOTE: Allied has approved the use of DuraVent ® Centrotherm manufactured vent pipe and terminations as an option to PVC. When using the PolyPro by DuraVent ® or InnoFlue by Centrotherm venting system the vent ® pipe requirements stated in the unit installation instruction –...
  • Page 24 Use the following steps to correctly size vent pipe diameter. 030, 045, Furnace capacity? 070, 090, Standard or Which termination? Concentric? See Table 8 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 10 through Table 12 to find max...
  • Page 25 96G1UHE Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number Capacity Capacity Capacity Capacity of 90° Elbows Used Standard Termination at Elevation 4,501 - 10,000 ft 1-1/2”...
  • Page 26 96G1UHE Maximum Allowable Intake or Exhaust Vent Length in Feet Concentric Termination at Elevation 0 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number Capacity Capacity Capacity Capacity of 90° Elbows Used Concentric Termination Elevation 4501 - 10,000 ft 1-1/2”...
  • Page 27 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 - 4,500 ft 1-1/2” Pipe 2” Pipe 2-1/2" Pipe 3" Pipe Number Capacity Capacity...
  • Page 28 TYPICAL EXHAUST PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS Pipe size determined in Table 5 2” 2” 2” 2” 3” 2” TRANSITION EXHAUST *2” 030/045/070 Only 1-1/2” DO NOT transition from smaller to larger TRANSITION pipe in horizontal runs 2”...
  • Page 29 Intake Piping Direct Vent applications where combustion air is taken from indoors and flue gases are discharged outdoors. The 96G1UHE furnace may be installed in either direct vent or non-direct vent applications. In non-direct vent 1. Use field-provided materials and the factory-provided applications, when intake air will be drawn into the furnace air intake screen to route the intake piping as shown in from the surrounding space, the indoor air quality must be...
  • Page 30 TYPICAL INTAKE PIPE CONNECTIONS IN HORIZONTAL DIRECT OR NON-DIRECT VENT APPLICATION (RIGHT-HAND DISCHARGE SHOWN) 2” 3” 2” TRANSITION 2” 2” 2” *2” *2” INTAKE * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE: Exhaust pipe and intake pipe must be the same diameter.
  • Page 31 In Direct Vent applications, combustion air is taken from Ventilation Louvers outdoors and the flue gases are discharged to the outdoors. Inlet Air The 96G1UHE is then classified as a direct vent, Category Roof Terminated (Minimum 12 in. Exhaust Pipe IV gas furnace.
  • Page 32 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 Winter Design Vent Pipe Temperatures ºF (ºC) Diameter 1-1/2 in. 32 to 21 2 in. (0 to -6) 2-1/2 in.
  • Page 33 ‡ 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 32. Vent Termination Clearances for Direct Installations 508170-01...
  • Page 34 Details of Intake and Exhaust Piping On field supplied terminations for sidewall exit, exhaust piping may extend a maximum of 12 inches (305 mm) Terminations for Direct Vent Installations for 2” PVC and 20 inches (508 mm) for 3” (76 mm) NOTE: In Direct Vent installations, combustion air is taken PVC beyond the outside wall.
  • Page 35 On field supplied terminations, a minimum distance 1 1/2” (38mm) accelerator between the end of the exhaust pipe and the end of provided on 71M80 & 44W92 EXHAUST kits for -045 and -070 models the intake pipe without a termination elbow is 8” and a VENT minimum distance of 6”...
  • Page 36 ‡ 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 41. Vent Termination Clearances for Non-Direct Installations...
  • Page 37 Details of Exhaust Piping Terminations for Non- STRAIGHT-CUT OR Direct Vent Applications * SIZE TERMINATION PIPE PER EXHAUST 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 38 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 39: Condensate Piping

    above 5” may result in a flooded heat exchanger if the Condensate Piping combined primary drain line were to become restricted. NOTE: In horizontal applications it is recommended to This unit is designed for either right- or left-side exit of install a secondary drain pan underneath the unit and condensate piping in upflow applications.
  • Page 40 If this is not possible, a heat cable kit may be used 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.
  • Page 41 Evaporator drain From Evaporator Coil line required Field Provided Vent 1” min. 2” max. above (Trap at coil is optional) condensate drain. (1” min. to 2” Max.above condensatedrain connection) Condensate FurnaceCondensate Drain Connection Drain Connection Optional Figure 51. Evaporator Coil Using a Common Drain Figure 50.
  • 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

    Start-Up WARNING If you do not follow these instructions exactly, a fire Preliminary and Seasonal Checks or explosion may result causing property damage, Inspect electrical wiring, both field and factory installed personal injury or death. for loose connections. Tighten as required. Check voltage at disconnect switch.

  • Page 45: Heating System Service Checks

    Testing Gas Piping Move gas valve switch to OFF. Replace the access panel. IMPORTANT Failure To Operate In case emergency shutdown is required, turn off the If the unit fails to operate, check the following: main shut-off valve and disconnect the main power to 1.
  • Page 46 Furnace should operate at least 5 minutes before checking Manifold Pressure Measurement gas flow. Determine time in seconds for two revolutions of Follow the steps below and use Figure 57 as a reference. gas through the meter. (Two revolutions assures a more Gas manifold Kit 10L34 provides additional components if accurate time.) Divide by two and compare to time in Table needed.
  • Page 47 Proper Combustion High Altitude Furnace should operate minimum 15 minutes with correct NOTE: In Canada, certification installations manifold pressure and gas flow rate before checking elevations over 4500 feet (1372 m) is the jurisdiction of combustion. Take combustion sample beyond the flue local authorities.
  • Page 48 Proper Ground and Voltage as a function of load indicates a poor or partial ground. Compare the readings to Table 19. If the readings exceed the maximum shown in Table 19, make repairs CAUTION before operating the furnace. In addition, measure the AC voltage from Line Hot Electric Shock Hazard.

  • Page 49: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 60. 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 50: Maintenance

    Filter Size Maintenance Cabinet Width Side Return Bottom Return 17-1/2” 16 x 25 x 1 (1) 16 x 25 x 1 (1) 21” 20 x 25 x 1 (1) WARNING 24-1/2” 16 x 25 x 1 (2) 24 x 25 x 1 (1) ELECTRICAL SHOCK, FIRE, Table 20.
  • Page 51 Winterizing and Condensate Trap Care 10. Disconnect condensate drain line from the cold end header box. 1. Turn off power to the furnace. 11. Disconnect condensate drain tubing from flue collar. Have a shallow pan ready to empty condensate water. Remove screws that secures the flue collar into place.
  • Page 52 Cleaning the Burner Assembly (if needed) 30. Reinstall the cold end header box. 1. Turn off electrical and gas power supplies to furnace. 31. Reinstall the combustion air inducer. Reconnect the Remove upper and lower furnace access panels. plug to the wire harness. Disconnect the wires from the gas valve.

  • Page 53: Wiring Diagram

    Wiring Diagram 508170-01 Issue 2110 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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