Allied 96G1DF045BE12 Service Manual
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Allied 96G1DF045BE12 Service Manual

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SERVICE MANUAL
96G1DFE
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.
508176-01
WARNING
CAUTION

Table of Contents

Technical Specifications - 96G1DFE ...........................2
Parts Arrangement.......................................................5
Electrical ......................................................................6
Placement & Installation ............................................19
Joint Cementing Procedure .......................................20
Venting Practices .......................................................21
Vent Piping Guidelines ..............................................22
Condensate Piping ....................................................35
Start-Up .....................................................................39
Heating System Service Checks ...............................40
Typical Operating Characteristics ..............................44
Maintenance ..............................................................45
Wiring Diagram ..........................................................48
(Continued) ................................................................50
Sequence of Operation..............................................52
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.
*P508176-01*
Issue 2112
WARNING
(P) 508176-01
Page 1 of 52

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  • Page 1: Table Of Contents

    SERVICE MANUAL 96G1DFE 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 - 96G1DFE ......2 Parts Arrangement............5 Electrical ..............6 Placement &...

  • Page 2: Technical Specifications - 96G1Dfe

    Trans. Shipping Model Cooling Inlet Delay (Btuh) (Btuh) (ICS) F.L.A. (V.A.) Weight Capacity (in.) Phase Breaker (lbs.) or Fuse 96G1DF045BE12 44,000 42,000 96.0% 3 Ton 120-60-1 96G1DF070BE16 66,000 63,000 96.0% 4 Ton 120-60-1 96G1DF090CE16 88,000 85,000 96.0% 4 Ton 120-60-1 Note: For vent length and clearances to combustibles, please reference installation instructions.

  • Page 3: Blower Performance Data

    BLOWER PERFORMANCE DATA 96G1DFE 045*B12 Performance (Less Filter) Air Volume / Watts at Different Blower Speeds External Bottom Return Air, Side Return Air with Optional Return Air Base, Return Air from Both Sides or Return Air from Static Bottom and One Side. Pressure High Medium-High...
  • 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 1-Stage 17H62 1-Stage - 90 Low Input [030K BTUH] 68W62 17.5"...

  • Page 5: 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 6: 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 7 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 8: Electronic Ignition

    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 9 IGNITOR BURNERS ROLLOUT SWITCHES FRONT BURNER BOX PLATE SENSOR GAS VALVE Figure 5. Burner Box Assembly Flame Rollout Switches (Figure 5) A microamp DC meter is needed to check the flame signal on the integrated control. Flame rollout switches S47 are SPST N.C. high temperature limits located on the left and right of the front buner box Flame (microamp) signal is an electrical current which plate.
  • Page 10 Primary Limit Control (Figure 6) MANIFOLD PRESSURE Primary limit (S10) used on 96G1DFE 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 11 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 12 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 13 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 96G1DFE 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 14 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 15 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 16: Blower Compartment

    Blower Compartment Center Blower Wheel in Blower Housing IMPORTANT Each blower is statically and dynamically balanced as an assembly before installation in the unit. 96G1DFE 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 17 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 18 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 19: 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 20: 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 21: Venting Practices

    After assembly, wipe excess cement from pipe at end REPLACING FURNACE THAT of fitting socket. A properly made joint will show a bead CHIMNEY WAS PART OF A COMMON OR GAS around its entire perimeter. Any gaps may indicate an VENT VENT SYSTEM (Check sizing...

  • Page 22: Vent Piping Guidelines

    Table 10 or Table 11. NOTE: All horizontal runs of exhaust pipe must slope back NOTE: Allied has approved the use of DuraVent ® toward unit. A minimum of 1/4” (6mm) drop for each 12”...
  • Page 23 Maximum Allowable Intake or Exhaust Vent Length in Feet Standard Termination at Elevation 0 − 10,000 ft. 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe Number of Capacity Capacity Capacity Capacity 90° Elbows Used Concentric Termination Elevation 0 − 10,000 ft. 1-1/2”...
  • Page 24 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. 1-1/2” Pipe 2” Pipe 2-1/2” Pipe 3” Pipe Number of Capacity Capacity...
  • Page 25 NOTE: 1-1/2” Vent Pipe Pipe size determined in table 7. Diameter Allowed Only 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 pipe in horizontal runs...
  • Page 26 Intake Piping Intake The 96G1DFE furnace may be installed in either direct Debris vent or non-direct vent applications. In non-direct vent Screen (Provided) applications, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered and guidelines listed in Combustion, Dilution and Ventilation Air section must be followed.
  • Page 27 NOTE: See Table 12 for maximum allowed exhaust pipe length without insulation in unconditioned space during winter design temperatures below 32°F (0°C). If required Roof Terminated Exhaust Pipe exhaust pipe should be insulated with 1/2” (13mm) Armaflex or equivalent. In extreme cold climate areas, 3/4”...
  • Page 28 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 29 ‡ 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 508176-01...
  • Page 30 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 31 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 32 ‡ 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 33 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 34 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 35: Condensate Piping

    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 36 From Evaporator Coil Field Provided Vent 1” min. 2” max. above condensate drain. Trap can be installed a maximum of 5ft. from furnace (*PVC only) Field Provided Vent 1” min. 2” max. above FurnaceCondensate condensate drain. Drain Connection 1” min. Optional 2”...
  • Page 37 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 38 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 39: 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 40: 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 41 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 42: Gas Flow (Approximate)

    Gas Flow (Approximate) NOTE: In Canada, certification installations elevations over 4500 feet (1372 m) is the jurisdiction of Seconds for One Revolution local authorities. Natural Capacity Units may be installed at altitudes up to 10,000 ft. above 1 cu ft 2 cu ft 1 cu ft 2 cu ft...
  • Page 43 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 44: Typical Operating Characteristics

    External Static Pressure Typical Operating Characteristics 1. Tap locations shown in Figure 54. 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 45: Maintenance

    Cabinet Width Filter Size Maintenance 17-1/2” 16 x 25 x 1 (1) 21” Table 20. 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 46 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 47 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 48: Wiring Diagram

    Wiring Diagram Page 48 of 52 Issue 2112 508176-01...

  • Page 49: 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 50: 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 51: 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 52: 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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