Allied A96US2V User manual

508148-01 Issue 2128 Page 1 of 75

SERVICE MANUAL

A96US2V Gas Furnace

(P) 508148-01

*P508148-01*

Table of Contents

Technical Specications - A96US2V............................2

Parts Arrangement.......................................................6

Unit Components.........................................................7

Placement and Installation ........................................28

Joint Cementing Procedure.......................................29

Venting Practices.......................................................30

Vent Piping Guidelines ..............................................34

Condensate Piping ....................................................47

Start-Up .....................................................................52

Heating System Service Checks ...............................53

Proper Ground and Voltage.......................................56

Typical Operating Characteristics..............................57

Maintenance..............................................................58

Wiring and Sequence of Operation ...........................61

Field Wiring Applications with Conventional Thermostat

...................................................................................66

Program Unit Capacity Size Modes...........................70

Troubleshooting: Heating Sequence of Operation ....71

Troubleshooting: Cooling Sequence of Operation.....74

Troubleshooting: Continuous Fan Sequence of

Operation...................................................................75

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

508148-01Issue 2128Page 2 of 75

Technical Specications - A96US2V

MODEL NUMBER GUIDE

PHYSICAL AND ELECTRICAL DATA

Model

1st Stage 2nd Stage AFUE

(ICS)

Nominal

Cooling

Capacity

Gas

Inlet

(in.)

Volts/

Hz/

Phase

Max. Time

Delay

Breaker

or Fuse

Nominal

F.L.A.

Trans.

(V.A.)

Approx.

Shipping

Weight

(lbs.)

Input

(Btuh)

Output*

(Btuh)

Input

(Btuh)

Output*

(Btuh)

UPFLOW/HORIZONTAL

A96US2V045B12S 29,000 28,000 44,000 42,000 96.0 31/2 120-60-1 15 7.7 40 130

A96US2V070B12S 43,000 41,000 66,000 62,000 96.0 31/2 120-60-1 15 7.7 40 138

A96US2V090C12S 57,000 55,000 88,000 84,000 96.0 31/2 120-60-1 15 7.7 40 154

A96US2V090C16S 57,000 55,000 88,000 85,000 96.0 41/2 120-60-1 15 10.1 40 165

A96US2V090C20S 57,000 55,000 88,000 85,000 96.0 51/2 120-60-1 20 12.8 40 166

A96US2V110C16S 72,000 70,000 110,000 105,000 96.0 41/2 120-60-1 15 10.1 40 173

A96US2V110C20S 72,000 70,000 110,000 106,000 96.0 51/2 120-60-1 20 12.8 40 174

A96US2V135D20S 88,000 84,000 132,000 126,000 96.0 51/2 120-60-1 20 12.8 40 188

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 Exchanger

12 = 3 Ton add on cooling

16 = 4 Ton add on cooling

20 = 5 Ton add on cooling

B = 17.5 Width

C = 21.0 Width

D = 24.5 Width

Heating Input x 1000

A = Flagship

96 = 96% Efficiency

U = Upflow/Horizontal

D = Downflow

S = Communicating

2 = 2 Stage

V = Variable Speed

A 96 U S 2 V 110 C 16 S - 01

508148-01 Issue 2128 Page 3 of 75

BLOWER PERFORMANCE DATA

A96US2V045B12S

Motor Size: 1/2 HP

Blwr Size: 10 x 9

LOW FIRE HEATING - SCFM

[TEMP RISE: 20 - 50 F°]*

HIGH FIRE HEATING - SCFM

[TEMP RISE: 35 - 65 F°]*

Adj. -18% -12% -6% Default +6% +12% +18% +24% -18% -12% -6% Default +6% +12% +18% +24%

595 638 682 725 769 812 856 899 738 792 846 900 954 1008 1062 1116

FIRST STAGE COOLING - SCFM SECOND STAGE COOLING - SCFM

Speed Low Med Low Med High High Low Med Low Med High High

+10% 605 743 853 963 880 1045 1210 1375

Default 550 675 775 875 800 950 1100 1250

-10% 495 608 698 788 720 855 990 1125

A96US2V070B12S

Motor Size: 1/2 HP

Blwr Size: 10 x 9

LOW FIRE HEATING - SCFM

[TEMP RISE: 25 - 55 F°]*

HIGH FIRE HEATING - SCFM

[TEMP RISE: 50 - 80 F°]*

Adj. -18% -12% -6% Default +6% +12% +18% +24% -18% -12% -6% Default +6% +12% +18% +24%

718 770 823 875 928 980 1033 1085 800 858 917 975 1034 1092 1151 1209

FIRST STAGE COOLING - SCFM SECOND STAGE COOLING - SCFM

Speed Low Med Low Med High High Low Med Low Med High High

+10% 605 743 853 963 880 1045 1210 1375

Default 550 675 775 875 800 950 1100 1250

-10% 495 608 698 788 720 855 990 1125

A96US2V090C12S

Motor Size: 1/2 HP

Blwr Size: 10 x 9

LOW FIRE HEATING - SCFM

[TEMP RISE: 30 - 60 F°]*

HIGH FIRE HEATING - SCFM

[TEMP RISE: 60 - 90 F°]*

Adj. -18% -12% -6% Default +6% +12% +18% +24% -18% -12% -6% Default +6% +12% +18% +24%

800 858 917 975 1034 1092 1151 1209 861 924 987 1050 1113 1176 1239 1302

FIRST STAGE COOLING - SCFM SECOND STAGE COOLING - SCFM

Speed Low Med Low Med High High Low Med Low Med High High

+10% 605 743 853 963 880 1045 1210 1375

Default 550 675 775 875 800 950 1100 1250

-10% 495 608 698 788 720 855 990 1125

A96US2V090C16S

Motor Size: 3/4 HP

Blwr Size: 11 x 11

LOW FIRE HEATING - SCFM

[TEMP RISE: 30 - 60 F°]*

HIGH FIRE HEATING - SCFM

[TEMP RISE: 45 - 75 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 1046 1122 1199 1275 1352 1428 1505 1581

FIRST STAGE COOLING - SCFM SECOND STAGE COOLING - SCFM

Speed Low Med Low Med High High Low Med Low Med High High

+10% 770 935 1073 1238 1100 1320 1540 1760

Default 700 850 975 1125 1000 1200 1400 1600

-10% 630 765 878 1013 900 1080 1260 1440

A96US2V090C20S

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 SECOND STAGE COOLING - SCFM

Speed Low Med Low Med High High Low Med Low Med High High

+10% 935 1073 1238 1403 1320 1540 1760 2008

Default 850 975 1125 1275 1200 1400 1600 1825

-10% 765 878 1013 1148 1080 1260 1440 1643

* @ .10” - .80” w.c.

508148-01Issue 2128Page 4 of 75

A96US2V110C16S

Motor Size: 3/4 HP

Blwr Size: 11 x 11

LOW FIRE HEATING - SCFM

[TEMP RISE: 35 - 65 F°]*

HIGH FIRE HEATING - SCFM

[TEMP RISE: 60 - 90 F°]*

Adj. -18% -12% -6% Default +6% +12% +18% +24% -18% -12% -6% Default +6% +12% +18% +24%

1005 1078 1152 1225 1299 1372 1446 1519 1066 1144 1222 1300 1378 1456 1534 1612

FIRST STAGE COOLING - SCFM SECOND STAGE COOLING - SCFM

Speed Low Med Low Med High High Low Med Low Med High High

+10% 770 935 1073 1238 1100 1320 1540 1760

Default 700 850 975 1125 1000 1200 1400 1600

-10% 630 765 878 1013 900 1080 1260 1440

A96US2V110C20S

Motor Size: 1 HP

Blwr Size: 11 x 11

LOW FIRE HEATING - SCFM

[TEMP RISE: 35 - 65 F°]*

HIGH FIRE HEATING - SCFM

[TEMP RISE: 45 - 75 F°]*

Adj. -18% -12% -6% Default +6% +12% +18% +24% -18% -12% -6% Default +6% +12% +18% +24%

1005 1078 1152 1225 1299 1372 1446 1519 1333 1430 1528 1625 1723 1820 1918 2015

FIRST STAGE COOLING - SCFM SECOND STAGE COOLING - SCFM

Speed Low Med Low Med High High Low Med Low Med High High

+10% 935 1073 1238 1403 1320 1540 1760 2008

Default 850 975 1125 1275 1200 1400 1600 1825

-10% 765 878 1013 1148 1080 1260 1440 1643

A96US2V135D20S

Motor Size: 1 HP

Blwr Size: 11 x 11

LOW FIRE HEATING - SCFM

[TEMP RISE: 40 - 70 F°]*

HIGH FIRE HEATING - SCFM

[TEMP RISE: 55 - 85 F°]*

Adj. -18% -12% -6% Default +6% +12% +18% +24% -18% -12% -6% Default +6% +12% +18% +24%

1128 1210 1293 1375 1458 1540 1623 1705 1374 1474 1575 1675 1776 1876 1977 2077

FIRST STAGE COOLING - SCFM SECOND STAGE COOLING - SCFM

Speed Low Med Low Med High High Low Med Low Med High High

+10% 935 1073 1238 1403 1320 1540 1760 2008

Default 850 975 1125 1275 1200 1400 1600 1825

-10% 765 878 1013 1148 1080 1260 1440 1643

* @ .10” - .80” w.c.

508148-01 Issue 2128 Page 5 of 75

ACCESSORY LIST

Catalog Number Description

Comfort Sync Wi-Fi Thermostat

1.841197 Comfort Sync Wi-Fi Thermostat

External Filter Rack Kits

1.841018 1 pack (16 x 25)

1.841039 10 pack (16 x 25)

Natural to LP Kits

11K48 2-Stage – 90

11K47 High Altitude (> 7500')

Return Air Base

68W62 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 Version (Canada)

For vent length and clearances to combustibles, please reference installation instructions.

508148-01Issue 2128Page 6 of 75

Parts Arrangement

Figure 1.

508148-01 Issue 2128 Page 7 of 75

Unit Components

A96US2V unit components are shown in Figure 1.

The gas valve, combustion air inducer and burners can

be accessed by removing the access panel. Electrical

components are in the control box (Figure 2) found in the

blower compartment.

A96US2V units are factory-equipped with a bottom return

air panel in place. The panel is designed to be eld removed

as required for bottom air return. Markings are provided for

side return air and may be cut out in the eld.

Electrostatic discharge can a󰀨ect

electronic components. Take

precautions to neutralize electrostatic

charge by touching your hand and

tools to metal prior to handling the

control.

CAUTION

Control Box

Control Transformer (T1)

A transformer located in the control box provides power

to the low voltage section of the unit. Transformers on all

models are rated 40VA with a 120V primary and a 24V

secondary.

Transformer

Integrated Control

Interlock Switch

Circuit Breaker

Figure 2. Control Box

Door Interlock Switch (S51)

A door interlock switch rated 14A at 125VAC is wired in

series with line voltage. When the inner blower access

panel is removed the unit will shut down.

Circuit Breaker (CB8)

A 24V circuit breaker is also located in the control box. The

switch provides overcurrent protection to the transformer

(T1). The breaker is rated 3A at 32V. If the current exceeds

this limit the breaker will trip and all unit operation will

shutdown. The breaker can be manually reset by pressing

the button on the face. See Figure 3.

PRESS TO RESET

Figure 3. Circuit Breaker CB8

Shock hazard.

Disconnect power before servicing. Integrated control

is not eld 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 Comfort Sync®

thermostat as part of a communicating comfort system.

The control can also operate with a non-communicating

conventional single or two-stage thermostat. The system

consists of an ignition / blower control (Figure 4 and Figure

5) with control pin designations (Table 1 through Table 3)

and an ignitor. The control and ignitor work in combination

to ensure furnace ignition and ignitor durability. The

control provides gas ignition, safety checks and indoor

blower control with two-stage gas heating. The furnace

combustion air inducer, gas valve and indoor blower are

controlled in response to various system inputs such as

thermostat signal, pressure and limit switch signal and

ame signal. The control features a seven-segment LED

display, indicating furnace status (including indoor blower)

and error codes. The LED ashes in single digits. For

example, using Table 5 under CODE, an “E” followed by

“2” followed by “5” followed by “0”, the limit switch circuit

is open. The control also has two unpowered (dry) 1/4”

contacts for a humidier and a 120 volt accessory terminal.

Both rated at (1) one amp each.

508148-01Issue 2128Page 8 of 75

Pin # Function

1Ignitor

2 Combustion Air Inducer High Speed

3Combustion Air Inducer Low Speed

4Combustion Air Inducer Neutral

5Ignitor Neutral

Table 1. Control 5-Pin Terminal Designation

Pin # Function

1Gas Valve Second Stage

2 Second Stage Prove Switch

3Rollout Switch In

4Ground

524V Hot

6 Primary Limit In

7Gas Valve First Stage

8Gas Valve Common

9 24V Neutral

10 Ground

11 Rollout Switch Out

12 First Stage Prove Switch

Table 2. Control 12-Pin Terminal Designation

Pin # Function

1Data Input From Motor

2 Common

3Not Used

4Data Output To Motor

55 Volt Bias Supply

6 Not Used

Table 3. Control 6-Pin Terminal Designation

Electronic Ignition

At the beginning of the heat cycle the integrated control

monitors the rst stage and second stage combustion air

inducer prove switch. The control will not begin the heating

cycle if the rst stage prove switch is closed (by-passed).

Likewise the integrated control will not begin the second

stage heating cycle if the second stage prove switch is

closed, and will remain in rst stage heat. However, if the

second stage prove switch closes during the rst stage

heat pre-purge, the control will allow second stage heat.

Once the rst stage prove switch is determined to be open,

the combustion air inducer is energized on low (rst stage)

heat speed. When the di󰀨erential in the prove switch is

great enough, the prove switch closes and a 15-second

pre-purge begins.

NOTE: During abnormal conditions such as low supply

voltage or low outdoor temperatures and the low re

pressure switch does not close, the combustion air inducer

will switch to high re. After a 15 second pre-purge the

high re pressure switch will close and the unit will begin

operation on high re. After 10 to 20 seconds of high re

operation the unit will switch to low re

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 ame 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 ve trials for ignition (including

the initial trial), the control goes into Watchguard-Flame

Failure mode. After a 60-minute reset period, the control

will begin the ignition sequence again.

Two Stage Operation / Thermostat Selection

DIP Switch

The control can be utilized in two modes: SINGLE-STAGE

thermostat or TWO-STAGE thermostat. The thermostat

selection is made using a DIP switch and must be positioned

for the particular application. DIP switch 1, labeled T”STAT

HEAT STAGE is factory-set in the OFF position for use

with a two-stage thermostat. Move the DIP switch to ON

for use with a single stage thermostat.

While in the single-stage thermostat mode, the burners will

always re on rst-stage heat. The combustion air inducer

will operate on low speed and indoor blower will operate on

low heat speed. The unit will switch to second stage heat

after a “recognition period”. DIP switch 2, labeled SECOND

STAGE DELAY, is factory set in the OFF position for a 7

minute recognition period. The switch can be moved to the

ON position for a 12 minute recognition period, after which

time the unit will switch to secondstage heat. While in the

two-stage thermostat mode, the burners will re on rst-

stage heat. The combustion air inducer will operate on low

speed and indoor blower will operate on low heat speed.

The unit will switch to second-stage heat on call from

the indoor thermostat. If there is a simultaneous call for

rst and second stage heat, the unit will re an rst stage

heat and switch to second stage heat after 30 seconds of

operation. See Sequence of Operation ow charts in the

back of this manual for more detail.

508148-01 Issue 2128 Page 9 of 75

Figure 4. Integrated Control

508148-01Issue 2128Page 10 of 75

HEATING BLOWER−OFF DELAY

60 SECOND

HTG BLOWER

OFF DELAY

120 SECOND

HTG BLOWER

OFF DELAY

180 SECOND

HTG BLOWER

OFF DELAY

FLAME

HSI/CAI

2ND STAGE HEAT ON DELAY

7 MIN

UPSTAGE

DELAY

12 MIN

UPSTAGE

DELAY

COOLING MODE BLOWER RAMPING

CLG BLOWER SPEED ADJUSTMENT

COOLING MODE BLOWER SPEED

W915

2 STAGE

COMPR

1−STG COMPRESSOR

2−STAGE

COMPRESSOR LINK

(JUMPERS Y1 to Y2)

W915

DO NOT CUT

2−STG COMPRESSOR

HEAT PUMP LINK

(JUMPERS R to O)

W951

DEHUMIDIFICATION−

HARMONY LINK

(JUMPERS R to DS)

W914

W915

2 STAGE

COMPR

CUT LINK

A/C UNIT

DO NOT CUT

HEAT PUMP UNIT

CUT LINK

W951

HEAT

PUMP

W951

HEAT

PUMP

W914

DEHUM

ZONING

NO SIGNATURESTAT

W/ DS CONNECTION

DO NOT CUT

ZONING

SIGNATURESTAT W/

DS CONNECTION

CUT LINK

W914

DEHUM

ON−BOARD LINK

OPTION SELECTION

1234567

123567

NEUTRALS

ACC

HUM

P79

110

312

4 7

W915

2 STAGE

COMPR

W951

HEAT

PUMP

W914

DEHUM

HARMONY

CUT FOR

OPTION

SELECTION

OUTDOOR

SENSOR

DISCHARGE

AIR SENSOR

123456

10 12

91113

W1W2 GY2 Y1 CC DH LODSR

OPTION A

OFF−50%−82%−

100%−50%−OFF

OPTION 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

−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

90 SECOND

HTG BLOWER

OFF DELAY

*1234567

1234567

THERMOSTAT SELECTION

1−STAGE

THERMOSTAT

(TIMED STAGING)

−SEE SW #2

TWO STAGE

THERMOSTAT

1234567

−BLOWER ON DELAY − 30 SEC. FIXED

1234567

10 11

12 13

10 11

12 14 15

10 11

12 14 15

10 11

12 14 15

10 11

12 13

10 11

12 14 15

10 11

12 14 15

10 11

12 14 15

HEATING MODE BLOWER SPEED

1234567

10 11

12 13

10 11

12 14 15

10 11

12 14 15

10 11

12 14 15

FACTORY

DEFAULT

+ 24%

+ 18%

+ 12%

+ 6%

− 6%

− 12%

− 18%

14 15

INCREASE AIR HTG CFM

DECREASE AIR HTG CFM

SENSE

RI+ I− CR

I+ I− C

OUTDOOR EQUIPMENT

I+ I−

INDOOR EQUIPMENT

IGN

CAI2

CAI1

S4S3

* FACTORY DEFAULT

DIAGNOSTIC

LED

DIAGNOSTIC

PUSH BUTTON

Figure 5. Integrated Control Conguration Guide

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