Allied A96DS2V Service Manual Download

Page: 1 / 72

508151-01

Issue 2104

Page 1 of 72

SERVICE MANUAL

A96DS2V Gas Furnace

(P) 508151-01

*P508151-01*

Table of Contents

Technical Specifications - A96DS2V

............................2

Parts Arrangement

.......................................................5

Unit Components

.........................................................

Placement and Installation

........................................27

Joint Cementing Procedure

.......................................28

Venting Practices

.......................................................

Vent Piping Guidelines

..............................................32

Condensate Piping

....................................................45

Start-Up

.....................................................................

Heating System Service Checks

...............................50

Proper Ground and Voltage

.......................................53

Typical Operating Characteristics

..............................54

Maintenance

..............................................................55

Wiring and Sequence of Operation

...........................58

Field Wiring Applications with Conventional Thermostat

...................................................................................

Program Unit Capacity Size Modes

...........................

Troubleshooting: Heating Sequence of Operation

....

Troubleshooting: Cooling Sequence of Operation

.....71

Troubleshooting: Continuous Fan Sequence of

Operation

...................................................................72

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.

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.

WARNING

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.

CAUTION

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.

WARNING

Summary of Contents for A96DS2V

Page 1: ...ooting Continuous Fan Sequence of Operation 72 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 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 po...

Page 2: ...96 0 4 1 2 120 60 1 15 10 1 40 136 A96DS2V090C20S 57 000 56 000 88 000 85 000 96 0 5 1 2 120 60 1 20 12 8 40 164 A96DS2V110C20S 72 000 70 000 110 000 106 000 96 0 5 1 2 120 60 1 20 12 8 40 176 Note For vent length and clearances to combustibles please reference installation instructions Outputs shown are High Fire 100 rate Low Fire is 67 of shown output Numeric Code S Stainless Steel Heat Exchange...

Page 3: ...1238 1100 1320 1540 1760 Default 700 850 975 1125 1000 1200 1400 1600 10 630 765 878 1013 900 1080 1260 1440 A96DS2V090C20S Motor Size 1 HP Blwr Size 11 x 11 LOW FIRE HEATING SCFM TEMP RISE 30 60 F HIGH FIRE HEATING SCFM TEMP RISE 40 70 F Adj 18 12 6 Default 6 12 18 24 18 12 6 Default 6 12 18 24 943 1012 1081 1150 1219 1288 1357 1426 1271 1364 1457 1550 1643 1736 1829 1922 FIRST STAGE COOLING SCFM...

Page 4: ...2 17 5 B Width 68W63 21 0 C Width 68W64 24 5 D Width Night Service Kits 89W53 Two stage Horizontal Suspension Kit 51W10 80 90 Kit Flush Mount Termination 90 Furnaces only 51W11 2 3 0 Vent US 51W12 2 3 0 Vent ULC S636 Compliant Canada Concentric Vent Kit 90 Furnaces only 71M80 1 1 2 Vent Version US 44W92 1 1 2 and 2 Vent Version Canada 69M29 2 Vent Version US 60L46 3 Vent Version US 44W93 3 Vent Ve...

Page 5: ...508151 01 Issue 2104 Page 5 of 72 Parts Arrangement Figure 1 BURNER BOX ASSEMBLY GAS VALVE ACCESS PANEL COMBUSTION AIR INDUCER BLOWER ASSEMBLY BAG ASSEMBLY CONTROL BOX ...

Page 6: ... 3 PRESS TO RESET Figure 3 Circuit Breaker CB8 Shock hazard Disconnect power before servicing Integrated control is not field repairable If control is inoperable simply replace entire control Can cause injury or death Unsafe operation will result if repair is attempted WARNING Integrated Control A92 Units are equipped with a variable capacity integrated control This control is used with the Comfor...

Page 7: ... to low fire After the 15 second pre purge period the ignitor warms up for 20 seconds after which the gas valve opens for a 4 second trial for ignition The ignitor remains energized during the trial until flame is sensed If ignition is not proved during the 4 second period the control will try four more times with an inter purge and warm up time between trials of 35 seconds After a total of five t...

Page 8: ...508151 01 Issue 2104 Page 8 of 72 Figure 4 Integrated Control ...

Page 9: ...B OFF 82 100 OFF OPTION C OFF 100 100 OFF OPTION D OFF 100 OFF DEFAULT 10 10 HIGH SPEED MEDIUM HIGH SPEED MEDIUM LOW SPEED LOW SPEED 7 PROTECTIVE PLASTIC FILM ON DIP SWITCHES MAY BE REMOVED FOR EASE IN SETTING OF DIP SW CUT ON BOARD LINK SOLDER TRACE COMPLETELY THROUGH BOTH LAYERS ON THE CONTROL BOARD LINKS CUT IN ERROR INSTALL A JUMPER ON THE APPROPRIATE TERMINALS ON THE TERMINAL STRIP 1 9 10 11 ...

Page 10: ...o access the flame signal mode The integrated control will display the flame current on seven segment LED in in micro amps uA Flame signal mode is exited after any of the following Power is reset Pressing and holding push button until 3 horizontal lines are displayed 10 minutes after entering the flame sense mode Program Unit Capacity Size Mode After the P is selected by releasing the push button ...

Page 11: ...ms System resumes normal operation 5 seconds after fault recovered E115 Low 24V Control will restart if the error recovers 24 Volt Power high Range is 18 to 30 Volts Check and correct voltage Check for additional power robbing equipment connected to system May require installation of larger VA transformer to be installed in furnace air handler Clears after fault recovered E120 Unresponsive device ...

Page 12: ...nstallation instruction Critical Alert Cleared after valid unit code is read following a reset remove thermostat from system while applying power and reprogramming E204 Gas valve mis wired Check gas valve operation and wiring Clears when repaired E205 Gas valve control relay contact shorted Check wiring on control and gas valve If wiring is correct replace control E207 Hot surface igniter sensed o...

Page 13: ...tral to ground to ensure good unit ground Alert clears after current heat call has been completed E274 Soft lockout Exceeded maximum number of recycles Last recycle failed due to the limit circuit opening or limit remained open longer than 3 minutes Shut down system 1 hour soft lockout Check firing rate and air flow Check for blockage Clears when heat call finishes successfully E275 Soft lockout F...

Page 14: ...een R O on integrated control with non communicating outdoor unit dual fuel model required for heat pump application Configuration link R to O needs to be restored Replace link or hardware Applicable in non communicating mode Critical Alert E401 LSOM Compressor long run cycle or low system pressure Compressor ran more that 18 hours to satisfy a single thermostat demand Critical Alert Clears the er...

Page 15: ...ve a supply air temperature between 90 and 110 F at the exact moment that the blower is de energized Longer off delay settings provide lower supply air temperatures shorter settings provide higher supply air temperatures Table 6 provides the blower off timings that will result from different switch settings Blower Off Delay Seconds Switch 3 Switch 4 60 On Off 90 Factory Off Off 120 Off On 180 On O...

Page 16: ...FM 100 CFM COMPRESSOR DEMAND 7 1 2 MIN Ramping Option C Motor runs at 100 until demand is satisfied Once demand is met motor runs at 100 for 45 seconds then ramps down to stop OFF OFF 100 CFM 100 CFM 45 SEC COMPRESSOR DEMAND Ramping Option D Motor runs at 100 until demand is satisfied Once demand is met motor ramps down to stop OFF OFF 100 CFM COMPRESSOR DEMAND Switches 11 12 and 13 Heating Mode B...

Page 17: ...DE operates independent of a Y1 thermostat demand Normal Operation 1 On On On Acceptable 24 VAC High 100 Dehumidification mode begins when humidity is greater than set point Maximum overcool from cooling setpoint is 2 F Dehumidification Call 2 On On On Demand 0 VAC High 70 Dehumidification Call ONLY 1 On On On Demand 0 VAC High 70 Thermostat will keep outdoor unit energized after cooling temperatu...

Page 18: ...ng temperature setpoint has been reached in order to maintain room humidity setpoint Maximum overcool from cooling setpoint is 2 F ROOM THERMOSTAT CALLS FOR FIRST AND SECOND STAGE COOLING BASIC MODE only active on a Y1 thermostat demand Normal Operation 1 On On On On Acceptable 24 VAC High 100 Thermostat energizes 2nd Stage and de energizes D on a call for de humidification Dehumidification Call 2...

Page 19: ...rd link W915 is a clippable connection between terminals Y1 and Y2 on the integrated control W915 must be cut if two stage cooling will be used If the link is not cut the outdoor unit will operate in second stage cooling only Indoor Blower Motor Power Choke 4 and 5 Ton Only Blower Motor B3 Figure 6 During blower operation the ECM motor emits energy that may interfere with pacemaker operation Inter...

Page 20: ...ch when applying power to the unit Motor Start Up When B3 begins start up the motor gently vibrates back and forth for a moment This is normal During this time the electronic controller is determining the exact position of the rotor Once the motor begins turning the controller slowly eases the motor up to speed this is called soft start The motor may take as long as 10 15 seconds to reach full spe...

Page 21: ...r The use of the TECMate PRO isolates the motor from the integrated control Follow the instructions provided with the kit If the motor runs do not replace Figure 8 Blower B3 Harness Connectors MOTOR with INTEGRATED CONTROLLER SHAFT P49 4 Pin P48 5 Pin J48 5 Pin Line Voltage Connector J49 4 Pin Control Connector J48 5 Pin J49 4 Pin MOTOR with INTEGRATED CONTROLLER SHAFT P49 4 Pin P48 5 Pin P48 5 Pi...

Page 22: ...s greater than 20 ohms replace the motor and control module Figure 12 Test B Heating Components Ignitor The ignitor is made of durable silicon nitride Ignitor longevity is enhanced by controlling voltage to the ignitor The integrated control provides 120 volts to the ignitor for a consistent ignition Due to this feature of the control voltage measured with a digital meter will be slightly lower To...

Page 23: ...is precisely matched to the burner input Burners can be removed as a one piece assembly for service If burner assembly has been removed it is critical to align center of each burner to the center of the clamshell when re installing See more detail in Maintenance Gas Valve The valve Figure 47 is internally redundant to assure safety shut off If the gas valve must be replaced the same type valve mus...

Page 24: ...ed to prove inducer operation The combustion air inducer orifice will be different for each model The pressure switch measures the pressure differential across the combustion air inducer orifice When the proving switch opens the furnace control A92 immediately closes the gas valve to prevent burner operation Combustion Air Inducer Pressure Switch A96DS2V series units are equipped with a dual combu...

Page 25: ...the plug Reading should be between 39 and 70 ohms If the reading is correct then the problem is with the wiring between the jack plug and the control If reading is not correct the issue is the ignitor Test 3 Check ignitor for correct voltage Insert meter probes into terminals 1 and 5 use small diameter probes in order not to damage plug Check voltage during 20 second ignitor warm up period Voltage...

Page 26: ...low 1 Remove thermostat demand and allow unit to cycle off 2 Remove the tubing from the negative side red and black or red and positive side black of the pressure switch leave both connected to cold end header box 3 Take the 2 length square tubing and connect to the positive side of the pressure switch Take the 10 length square tubing and tee into the tubing from the positive side of the cold end ...

Page 27: ...t is recommended during cooler weather Metal or plastic strapping may be used for vent pipe hangers Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket Canadian Applications Only Pipe fittings primer and solvent cement used to vent exhaust this appliance must be certified to ...

Page 28: ...e and inside socket surface of fitting Cement should be applied lightly but uniformly to inside of socket Take A96DS2V VENT PIPE DIA in STANDARD CONCENTRIC Outdoor Exhaust Accelerator Dia X Length Outdoor Exhaust Accelerator Dia X Length Flush Mount Kit 1 1 2 Concentric Kit 2 Concentric Kit 3 Concentric Kit 1 1 2 X 12 2 X 12 51W11 71M80 or 44W92 69M29 or 44W92 60L46 or 44W93 045 1 1 1 2 YES YES 2 ...

Page 29: ...places a furnace that was commonly vented with another gas appliance the size of the existing vent pipe for that gas appliance must be checked Without the heat of the original furnace flue prod ucts the existing vent pipe is probably oversized for the single water heater or other appliance The vent should be checked for proper draw with the remaining appliance REPLACING FURNACE THAT WAS PART OF A ...

Page 30: ...d to correct the problem Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in Appendix G These are in the current standards of the National Fuel Gas Code ANSI Z223 1 Exhaust Piping Figure 19 Route piping to outside of structure Continue with installation following instructions given in piping termination section Do not discharge exhaust into ...

Page 31: ...aust vent length must not exceed those listed in Table 20 If 3 diameter pipe is used reduce to 2 diameter pipe to accommodate the debris screen 3 Route piping to outside of structure Continue with installation following instructions given in general guide lines for piping terminations and intake and exhaust piping terminations for direct vent sections Refer to Table 19A through Table 19C for pipe ...

Page 32: ...all elbows inside and outside the home Table 18 lists the minimum vent pipe lengths permitted Table 19A through Table 19C lists the maximum pipe lengths permitted Ventilation Louvers Inlet Air Minimum 12 in 305mm above Attic Floor Roof Terminated Exhaust Pipe Furnace Intake Debris Screen Provided See Maximum Vent Lengths table NOTE The inlet and outlet air openings shall each have a free area of a...

Page 33: ...NOTE Exhaust pipe MUST be glued to furnace exhaust fittings NOTE Exhaust piping should be checked carefully to make sure there are no sags or low spots NOTE If right side venting option is used you must include the elbow at the furnace in the elbow count If transitioning to 3 dia pipe this elbow equates to 20 of equivalent vent length for all models Do not use screens or perforated metal in exhaus...

Page 34: ...8 9 26 11 60 60 38 n a 83 82 63 63 10 21 6 55 55 33 78 77 58 58 Standard Termination Elevation 4500 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model Model Model 45 70 90 110 45 70 90 110 45 70 90 110 45 70 90 110 1 20 15 n a n a 66 51 29 n a 100 100 78 43 123 122 103 103 2 15 10 61 46 24 95 95 73 38 118 117 98 98 3 10 n a 56 41 19 90 90 68 33 113 112 93 93 4 n a 5...

Page 35: ...4 9 18 3 50 50 34 n a 66 66 59 59 10 13 n a 45 45 29 61 61 54 54 Concentric Termination Elevation 4500 10 000 ft Number of 90 Elbows Used 1 1 2 Pipe 2 Pipe 2 1 2 Pipe 3 Pipe Model Model Model Model 45 70 90 110 45 70 90 110 45 70 90 110 45 70 90 110 1 15 10 n a n a 58 43 27 n a 90 90 74 39 106 106 99 99 2 10 n a 53 38 22 85 85 69 34 101 101 94 94 3 n a 48 33 17 80 80 64 29 96 96 89 89 4 43 28 12 7...

Page 36: ...41 24 n a 85 85 63 28 103 102 83 83 2 10 n a 51 36 19 80 80 58 23 98 97 78 78 3 n a 46 31 14 75 75 53 18 93 92 73 73 4 41 26 9 70 70 48 13 88 87 68 68 5 36 21 4 65 65 43 8 83 82 63 63 6 31 16 n a 60 60 38 3 78 77 58 58 7 26 11 55 55 33 n a 73 72 53 53 8 21 6 50 50 28 68 67 48 48 9 16 1 45 45 23 63 62 43 43 10 11 n a 40 40 18 58 57 38 38 NOTE Additional vent pipe and elbows used to terminate the ve...

Page 37: ...intain protective coatings over building materials prolonged exposure to exhaust condensate can destroy protective coatings It is recommended that the exhaust outlet not be located within 6 feet 1 8m of an outdoor AC unit because the condensate can damage the painted coating NOTE See Table 20 for maximum allowed exhaust pipe length without insulation in unconditioned space during winter design tem...

Page 38: ...nimum Design Temperature table provided in the current edition of the ASHRAE Fundamentals Handbook 2 Poly Propylene vent pipe PP by Duravent and Centrotherm 3 Vent length in table is equivalent length Each elbow is equivalent to 5ft of straight pipe and should be included when measuring total length NOTE Concentric terminations are the equivalent of 5 and should be considered when measuring pipe l...

Page 39: ...ches 152mm for appliances 10 000 pliances 10 000 Btuh 3kw and 50 000 pliances 50 000 Btuh 15kw 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 3m horizontally 6 feet 1 8m 7 feet 2 1m 12 inches 305mm 1 In accordance with the current ANSI Z223 1 NFPA 54 N...

Page 40: ... Minimum 12 in 305MM above grade or snow accumulation Figure 28 Exiting Exhaust and Intake Vent no common pressure zone 2 Intake and exhaust pipes should be placed as close together as possible at termination end refer to illustrations Maximum separation is 3 76MM on roof terminations and 6 152MM on side wall terminations NOTE When venting in different pressure zones the maximum separation require...

Page 41: ...ROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 12 305mm INTAKE AIR EXHAUST VENT Figure 31 Direct Vent Concentric Rooftop Termination 71M80 69M29 or 60L46 US 41W92 or 41W93 Canada Figure 32 Direct Vent Application Using Existing Chimney STRAIGHT CUT OR ANGLE CUT IN DIRECTION OF ROOF SLOPE EXHAUST VENT 1 2 13mm WEATHERPROOF INSULATION SHOULDER OF FITTINGS PROVIDE SUPPO...

Page 42: ...e above paved sidewalk or paved driveway located on public property Clearance under veranda porch deck or balcony 12 Equal to or greater than soffit depth 3 feet 9m 12 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 Btuh 3kw 12 inches 305mm for appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances 100 0...

Page 43: ...haust pipe size must be done after the final elbow 4 Distance between exhaust pipe terminations on multiple furnaces must meet local codes UNCONDITIONED ATTIC SPACE 3 76MM OR 2 51MM PVC PROVIDE SUPPORT FOR EXHAUST LINES 12 305MM ABOVE AVE SNOW ACCUMULATION SIZE PER EXHAUST PIPE TERMINATION SIZE REDUCTION TABLE Figure 36 Non Direct Vent Roof Termination Kit 15F75 or 44J41 Figure 37 Non Direct Vent ...

Page 44: ...ance above grade or average snow accumulation B Horizontal separation between intake and exhaust C Minimum from end of exhaust to inlet of intake D Exhaust pipe length E Wall support distance from top of each pipe intake exhaust 12 305 mm Min 12 305 mm Min 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 16 405 mm Max 6 152 mm Max 6 152 mm Min 24 610 mm Max 9 227 mm Min 12 305 mm Min 20 508 m...

Page 45: ... with clamp See Figure 45 and Figure 46 4 Install drain trap using appropriate PVC fittings glue all joints Glue the provided drain trap as shown in Figure 45 and Figure 46 Route the condensate line to an open drain Condensate line must maintain a 1 4 downward slope from the furnace to the drain When combining the furnace and evaporator coil drains together the A C condensate drain outlet must be ...

Page 46: ... should be routed within the conditioned space to avoid freezing of condensate and blockage of drain line If this is not possible a heat cable kit may be used on the condensate trap and line Heating cable kit is available in various lengths 6 ft 1 8m kit no 26K68 24 ft 7 3m kit no 26K69 and 50 ft 15 2m kit no 26K70 Figure 42 Evaporator Coil Using a Separate Drain Figure 43 Evaporator Coil Using a ...

Page 47: ... 2 inch PVC Pipe Not Furnished Drain Assembly for 3 4 inch Drain Pipe Condensate Drain Connection In Unit Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Optional Condensate Drain Connection OptionalDrainPipingFromTrap DrainTrapAssembly Furnished DrainTrap Assembly with 1 2 inch Piping DrainTrap Assembly with 3 4 inch Piping 1 2 inch 3 4 inch 1 25 mm Min 2 50 ...

Page 48: ...ow 1 2 inch PVC To Drain 90 Elbow 1 2 inch PVC Not Furnished 1 2 inch PVC Pipe Not Furnished Drain Assembly for 3 4 inch Drain Pipe 90 Street Elbow 1 2 inch PVC Not Furnished Condensate Drain Connection In Unit Adapter 1 2 inch slip X 1 2 inch mpt Not Furnished Condensate Drain Connection In Unit Vent To Drain Condensate Drain Connection In Unit Drain Trap Assembly with 3 4 inch Piping Vent To Dra...

Page 49: ... replace the valve Do not try to repair it Force or attempted repair may result in a fire or explosion Placing the Furnace into Operation A96DS2V units are equipped with an ignition system Do NOT attempt to manually light burners on this furnace Each time the thermostat calls for heat the burners will automatically light The ignitor does not get hot when there is no call for heat on units with an ...

Page 50: ...o shut the unit off 6 Is gas turned on at the meter 7 Is the manual main shut off valve open 8 Is the internal manual shut off valve open 9 Is the unit ignition system in lockout If the unit locks out again inspect the unit for blockages Heating System Service Checks CSA Certification All units are CSA design certified without modifications Refer to the A96DS2V Installation Instruction Gas Piping ...

Page 51: ... fire adjustment screw 5 Repeat on high fire and compare to value given in Table 24 If necessary make adjustment Figure 47 shows location of high fire adjustment screw 6 Shut unit off and remove manometer as soon as an accurate reading has been obtained 7 Start unit and perform leak check Seal leaks if found The gas valve is factory set and should not require adjustment All gas valves are factory ...

Page 52: ... 13 0 Lp Propane 4 5 10 0 4 2 9 4 4 0 9 1 3 9 8 9 4 5 10 0 11 0 13 0 Table 24 Manifold and Supply Line Pressure 0 10 000 ft Model Natural to LP Propane High Altitude Natural Burner Orifice Kit High Altitude LP Propane Burner Orifice Kit High Altitude Pressure switch 0 7500 ft 0 2286m 7501 10000 ft 2286 3048m 7501 10000 ft 2286 3048m 4501 7500 ft 1371 2286m 7501 10000 ft 2286 3048m 045 11K48 51W01 ...

Page 53: ...or or partial ground Compare the readings to Table 26 If the readings exceed the maximum shown in Table 26 make repairs before operating the furnace 2 In addition measure the AC voltage from Line Hot to Line Neutral spade terminals on the integrated control See Figure 49 This voltage should be in the range of 97 to 132 VAC Furnace Status Measurement VAC Expected Maximum Power On Furnace Idle 0 3 2...

Page 54: ...ly Duct Temperature Return Duct Temperature _ Temperature Rise Figure 50 Temperature Rise External Static Pressure 1 Tap locations shown in Figure 51 2 Punch a 1 4 diameter hole in supply and return air plenums Insert manometer hose flush with inside edge of hole or insulation Seal around the hose with permagum Connect the zero end of the manometer to the discharge supply side of the system On duc...

Page 55: ...ssure drop than standard efficiency glass foam filters If the pressure drop is too great system capacity and performance may be reduced The pressure drop may also cause the limit to trip more frequently during the winter and the indoor coil to freeze in the summer resulting in an increase in the number of service calls Before using any filter with this system check the specifications provided by t...

Page 56: ...om cold end header collector box 11 Mark and remove wires from pressure switch assembly Remove pressure switch assembly Keep tubing attached to pressure switch assembly 12 Disconnect the plug from the combustion air inducer Remove two screws which secure combustion air inducer to collector box Remove combustion air inducer assembly Remove ground wire from vest panel 13 Remove electrical junction b...

Page 57: ...ans Cleaning the Burner Assembly 1 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels 2 Disconnect the 2 pin plug from the gas valve 3 Remove the burner box cover if equipped 4 Disconnect the gas supply line from the gas valve Remove gas valve manifold assembly 5 Loosen clamps and remove combustion air intake flexible connector if equipped 6 Mark and...

Page 58: ...508151 01 Issue 2104 Page 58 of 72 Wiring and Sequence of Operation Figure 53 Wiring Diagram ...

Page 59: ...0 second initial ignitor warm up period begins The combustion air inducer continues to operate at low speed 4 After the 20 second warm up period has ended the gas valve is energized on low fire first stage and ignition occurs At the same time the control module sends a signal to begin an indoor blower 30 second ON delay When the delay ends the indoor blower motor is energized on the low fire heati...

Page 60: ...table to 12 minutes 5 If the heating demand continues beyond the second stage on delay the integrated control energizes the combustion air inducer at high speed The control also checks the high fire second stage pressure switch to make sure it is closed The high fire second stage gas valve is energized and the indoor blower motor is energized for operation at the high fire heating speed 6 When the...

Page 61: ... bundle and attached to the C terminals as shown above NON COMMUNICATING OUTDOOR AIR CONDITIONING UNIT 1 OR 2 STAGE OPTIONAL OUTDOOR AIR SENSOR OPTIONAL DISCHARGE AIR SENSOR OPTIONAL OUTDOOR AIR SENSOR OPTIONAL DISCHARGE AIR SENSOR CLIP ON BOARD LINK W915 Y1 TO Y2 FOR TWO STAGE OPERATION Comfort Sync Wifi Thermostat with A96US2V and Non Communicating Outdoor Unit Comfort Sync Wifi Thermostat Comfo...

Page 62: ...ING NON COMMUNICATING SYSTEM WIRING HUM CONTACT IS CLOSED ANYTIME HUMIDITY DEMAND IS PRESENT NOTE COMFORT SYNC WIFI THERMOSTAT SENSE HUMIDITY CONTROLS HUM CONTACTS TO CYCLE HUMIDIFIER BASED ON DEMAND NO OTHER CONTROL OR HUMIDISTAT REQUIRED OPTIONAL OUTDOOR AIR SENSOR FOR USE WITH HUMIDIFIER IF NOT ALREADY IN THE SYSTEM FOR OTHER FUNCTIONS BUILT INTO ALL COMFORT SYNC OUTDOOR UNITS COMFORT SYNC ENAB...

Page 63: ...IP switch 2 to set sceond stage heat ON delay OFF 7 minutes ON 12 minutes ON CUT ON BOARD LINK W915 2 STAGE COMPR T STAT FURNACE TERM STRIP OUTDOOR UNIT Not required on all units 1 Heat 2 Cool with t stat with dehumidification mode NOTE Use DIP switch 2 to set sceond stage heat ON delay OFF 7 minutes ON 12 minutes ON CUT ON BOARD LINK W915 2 STAGE COMPR CUT ON BOARD LINK W914 DEHUM T STAT FURNACE ...

Page 64: ... W915 2 STAGE COMPR CUT ON BOARD LINK W914 T STAT FURNACE TERM STRIP OUTDOOR UNIT o Not required on all units 2 Heat 1 Cool with t stat with dehumidification mode OFF CUT ON BOARD LINK W914 T STAT FURNACE TERM STRIP OUTDOOR UNIT o Not required on all units 2 Heat 1 Cool OFF DO NOT CUT ANY ON BOARD LINKS T STAT FURNACE TERM STRIP OUTDOOR UNIT Not required on all units NOTE Do NOT make a wire connec...

Page 65: ...E TERM STRIP HEAT PUMP 67M41 Y H L Y2 D B L Y2 T T outdoor sensor Dual Fuel Two Stage Heat Pump Comfort Sync thermostat w dual fuel capabilities Capable of 2 stage gas heat control OFF CUT ON BOARD LINK W951 HEAT PUMP CUT ON BOARD LINK W915 2 STAGE COMPR FURNACE TERM STRIP HEAT PUMP out blue 67M41 H L Y2 D B L Y2 T T outdoor sensor T STAT Y2 NOTE Do NOT make a wire connection between the room ther...

Page 66: ... TERM STRIP HEAT PUMP 67M41 Y H L Y2 D B L Y2 T T outdoor sensor Dual Fuel Two Stage Heat Pump Comfort Sync thermostat w dual fuel capabilities Capable of 2 stage gas heat control with dehumidification mode OFF CUT ON BOARD LINK W914 DEHUM CUT ON BOARD LINK W951 HEAT PUMP CUT ON BOARD LINK W915 2 STAGE COMPR T STAT FURNACE TERM STRIP HEAT PUMP 67M41 H L Y2 D B L Y2 T T outdoor sensor Y2 out blue Y...

Page 67: ...size code If three horizontal bars display the board does not recognize the unit size code The programming function must be repeated FINISHED 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 Yes No Push ...

Page 68: ...URGE HARD LOCKOUT ERROR CODE FLASHES YES YES YES 1 2 1 LOW PRESSURE SWITCH OPENS 1 2 HARD LOCKOUT REQUIRES THERMOSTAT RESET OR CYCLING OF POWER TO RESET THE LOCKOUT 3 IN CASE HIGH SPEED INDUCER IS RUNNING AT THE TIME THE GAS VALVE GETS ENERGIZED 2ND STAGE GAS VALVE IS ENERGIZED INSTEAD OF 1ST STAGE 20 SECONDS AFTER FLAME IS SENSED INDUCER SWITCHES TO LOW SPEED AND GAS VALVE SWITCHES TO 1ST STAGE 1...

Page 69: ...AT YES CALL FOR HEAT SATISFIED INDUCER SWITCHED TO HIGH SPEED SINGLE STAGE THERMOSTAT 2 STAGE THERMOSTAT NO INDUCER SWITCHED TO LOW SPEED 5 MINUTE DELAY ERROR CODE FLASHES HIGH PRESSURE SWITCH CLOSED WITHIN 10 SECONDS 2ND STAGE ON DELAY EXPIRED CALL FOR 2ND STAGE HEAT HIGH FIRE 2 3 1 2 3 1 2 3 YES YES CALL FOR SECOND STAGE HEAT RECOGNITION DELAY 30 SECONDS EXPIRED INDOOR BLOWER ENERGIZED ON HIGH H...

Page 70: ... DE ENERGIZE 2ND STAGE GAS VALVE INDUCER SPEED SWITCHED TO LOW SPEED 1 2 3 1ST STAGE HEAT 1ST STAGE CALL FOR HEAT SATISFIED NO YES GAS VALVE DE ENERGIZED INDUCER OFF AFTER 5 SECOND POST PURGE CALL FOR HEAT SATISFIED FIRST STAGE HEAT SECOND STAGE HEAT INDOOR BLOWER SWITCHED TO LOW HEAT SPEED INDOOR BLOWER OFF AFTER FIELD SELECTABLE OFF DELAY Troubleshooting Heating Sequence of Operation Continued ...

Page 71: ... PROFILE IS SELECTED USING T 1 1 2 2 1 1 1 2 2 DE ENERGIZE 1ST STAGE COOLING CONTACTOR COMPRESSOR FAN 2ND STAGE COOLING REQUEST STILL ACTIVE COOLING REQUEST STILL ACTIVE CALL FOR COOLING WAIT FOR COMPRESSOR TIMED OFF DELAY TO EXPIRE INDOOR BLOWER 2 SECOND ON DELAY YES 1ST STAGE DE ENERGIZE INDOOR BLOWER INDOOR BLOWER LOW COOLING MODE AND HIGH COOLING MODE HAVE SPEC ENERGIZE INDOOR BLOWER LOW COOLI...

Page 72: ...ING 1 1 1 4 YES NO CALL FOR FAN INDOOR BLOWER ON CONTINUOUS FAN SPEED MAINTAIN INDOOR BLOWER AT CONTINUOUS FAN MAINTAIN INDOOR BLOWER AT CONTINUOUS FAN DE ENERGIZE INDOOR BLOWER MAINTAIN INDOOR BLOWER AT CONTINUOUS FAN 1 1 If continuous fan is active unit will light and run at high fire for 60 seconds to improve heat exchanger warm up Troubleshooting Continuous Fan Sequence of Operation ...

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