Allied A95DF1E User manual

508115-01 Issue 2043 Page 1 of 57
SERVICE MANUAL
A95DF1E / 95G1DFE
(P) 508115-01
*P508115-01*
Table of Contents
Technical Specications - A95DF1E............................2
Technical Specications - 95G1DFE ...........................5
Parts Arrangement.......................................................8
Electrical......................................................................9
Placement & Installation............................................23
Joint Cementing Procedure.......................................24
Venting Practices.......................................................25
Vent Piping Guidelines ..............................................26
Condensate Piping ....................................................40
Start-Up .....................................................................44
Heating System Service Checks ...............................45
Typical Operating Characteristics..............................49
Maintenance..............................................................50
Wiring Diagram..........................................................53
Troubleshooting: Heating Sequence of Operation ....54
Troubleshooting: Heating Sequence of Operation
(Continued)................................................................55
Troubleshooting: Cooling Sequence of Operation.....56
Troubleshooting: Continuous Fan / Accessories
Sequence of Operation..............................................57
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

508115-01Issue 2043Page 2 of 57
Technical Specications - A95DF1E
PHYSICAL AND ELECTRICAL DATA
Model Input
(Btuh)
Output
(Btuh)
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.)
Downow
A95DF1E045B12S 44,000 42,000 95.0% 1-1/2 — 3 1/2 120 - 60 - 1 15 6.8 40 131
A95DF1E070B16S 66,000 64,000 95.0% 2-1/2 — 4 1/2 120 - 60 - 1 15 8.4 40 146
A95DF1E090C16S 88,000 85,000 95.0% 2-1/2— 4 1/2 120 - 60 - 1 15 8.4 40 162
A95DF1E110C20S 110,000 106,000 95.0% 3 — 5 1/2 120 - 60 - 1 15 10.9 40 174
Note: For vent length and clearances to combustibles, please reference installation instructions.
MODEL NUMBER GUIDE
Numeric Code
S = Stainless Steel Heat Exchanger
08 = 2 ton add on cooling
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
A = Flagship
95 = 95% Efficiency
UH = Upflow/Horizontal
DF = Downflow
1 = 1 Stage
E = High Efficiency Motor
Heating Input x 1000
A 95 DF 1 E 110 C 20 S - 01

508115-01 Issue 2043 Page 3 of 57
BLOWER PERFORMANCE DATA
Model
Motor
Size
(hp)
Blower
Size
Temp.
Rise
(°F)
Blower
Speed
Heating CFM @ .10" - .80" w.c.
.20 .30 .40 .50 .60 .70 .80
Downow
A95DF1E045B12S 1/2 10 x 8 25 - 55
High 1320 1285 1275 1230 1185 N/A N/A
Med/High 1215 1165 1150 1095 1060 1020 980
Med 1090 1065 1025 985 935 915 860
Med/Low 825 795 750 705 655 590 555
Low 785 735 705 650 605 545 485
A95DF1E070B16S 3/4 11-1/2 x 10 25 - 55
High 1705 1665 1605 1585 1540 N/A N/A
Med/High 1470 1430 1390 1335 1300 1260 1220
Med 1265 1235 1185 1155 1100 1050 1015
Med/Low 1165 1120 1070 1015 970 915 865
Low 895 835 775 690 625 570 520
A95DF1E090C16S 3/4 10 x 10 40 - 70
High 1685 1630 1620 1570 1540 N/A N/A
Med/High 1455 1415 1370 1335 1295 1260 1210
Med 1310 1285 1245 1185 1145 1110 1060
Med/Low 1220 1165 1125 1080 1045 990 940
Low 1080 1035 985 925 875 825 760
A95DF1E110C20S 111 x 11 40 - 70
High 2185 2150 2085 2060 2005 1970 1910
Med/High 1910 1850 1810 1765 1700 1665 1620
Med 1720 1670 1605 1565 1510 1460 1420
Med/Low 1575 1525 1465 1420 1370 1325 1275
Low 1360 1290 1255 1190 1160 1100 1045

508115-01Issue 2043Page 4 of 57
ACCESSORIES
System Accessory Kit Number Description
External Filter Rack
1.841018 1 pack (16 x 25)
1.841039 10 pack (16 x 25)
Natural to LP Kit
11K50 1-Stage - 90
13X57 1-Stage - 90 Low Input [030K BTUH]
Return Air Base
68W62 17.5" B Width
68W63 21.0" C Width
68W64 24.5" D Width
Downow Combustible Flooring Base
11M60 17.5" B Width
11M61 21.0" C Width
11M62 24.5" D Width
Night Service Kit 86W57 Single Stage
Horizontal Suspension Kit 51W10 80% & 90% Kit
Flush Mount Termination
(90% Furnaces Only) (US Only) 51W11 2" & 3" Vent Version
Concentric Vent Kit
(90% Furnaces Only) (US Only)
71M80 1-1/2" Vent Version
69M29 2" Vent Version
60L46 3" Vent Version
Concentric Vent Kit
(90% Furnaces Only) (Canada Only)
44W92 1-1/2" and 2" Vent Version
44W93 3" Vent Version
2-Stage Compressor Kit 85W66 Blower Relay Kit
Twinning Kit 16W72 Constant Torque Gas Furnace Twinning Kit
Note: For vent length and clearances to combustibles, please reference installation instructions.

508115-01 Issue 2043 Page 5 of 57
Technical Specications - 95G1DFE
PHYSICAL AND ELECTRICAL DATA
Model Input
(Btuh)
Output
(Btuh)
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.)
Downow
95G1DF045BE12 44,000 42,000 95.0% 1-1/2 — 3 1/2 120 - 60 - 1 15 6.8 40 131
95G1DF070BE16 66,000 64,000 95.0% 2-1/2 — 4 1/2 120 - 60 - 1 15 8.4 40 144
95G1DF090CE16 88,000 85,000 95.0% 2-1/2 — 4 1/2 120 - 60 - 1 15 8.4 40 160
95G1DF110CE20 110,000 106,000 95.0% 3 — 5 1/2 120 - 60 - 1 15 10.9 40 174
Note: For vent length and clearances to combustibles, please reference installation instructions.
MODEL NUMBER GUIDE
Major Revision
12 = 3 Ton add on cooling
16 = 4 Ton add on cooling
20 = 5 Ton add on cooling
P = PSC
E = High Efficency
V= Variable Speed
B = 17.5” width
C = 21.0” width
95% Efficency
Gas
1 = 1 Stage
UH = Upflow/Horizontal
DF = Downflow
Heating Input x 1000
95 G 1 DF 070 B E 12 -01

508115-01Issue 2043Page 6 of 57
BLOWER PERFORMANCE DATA
Model
Motor
Size
(hp)
Blower
Size
Temp.
Rise
(°F)
Blower
Speed
Heating CFM @ .10" - .80" w.c.
.20 .30 .40 .50 .60 .70 .80
Downow
95G1DF045BE12 1/2 10 x 8 25-55
High 1320 1285 1275 1230 1185 N/A N/A
Med/High 1215 1165 1150 1095 1060 1020 980
Med 1090 1065 1025 985 935 915 860
Med/Low 825 795 750 705 655 590 555
Low 785 735 705 650 605 545 485
95G1DF070BE16 3/4 11-1/2 x 10 25-55
High 1705 1665 1605 1585 1540 N/A N/A
Med/High 1470 1430 1390 1335 1300 1260 1220
Med 1265 1235 1185 1155 1100 1050 1015
Med/Low 1165 1120 1070 1015 970 915 865
Low 895 835 775 690 625 570 520
95G1DF090CE16 3/4 10 x 10 40-70
High 1685 1630 1620 1570 1540 N/A N/A
Med/High 1455 1415 1370 1335 1295 1260 1210
Med 1310 1285 1245 1185 1145 1110 1060
Med/Low 1220 1165 1125 1080 1045 990 940
Low 1080 1035 985 925 875 825 760
95G1DF110CE20 111 x 11 40-70
High 2185 2150 2085 2060 2005 1970 1910
Med/High 1910 1850 1810 1765 1700 1665 1620
Med 1720 1670 1605 1565 1510 1460 1420
Med/Low 1575 1525 1465 1420 1370 1325 1275
Low 1360 1290 1255 1190 1160 1100 1045

508115-01 Issue 2043 Page 7 of 57
ACCESSORIES
System Accessory Kit Number Description
External Filter Rack
1.841018 1 pack (16 x 25)
1.841039 10 pack (16 x 25)
Natural to LP Kit
11K50 1-Stage - 90
11K45 High Altitude 1-Stage
13X57 1-Stage - 90 Low Input [030K BTUH]
Return Air Base
68W62 17.5" B Width
68W63 21.0" C Width
68W64 24.5" D Width
Downow Combustible Flooring Base
11M60 17.5" B Width
11M61 21.0" C Width
Night Service Kit 86W57 Single Stage
Horizontal Suspension Kit 51W10 80% & 90% Kit
Flush Mount Termination
(90% Furnaces Only) (US Only) 51W11 2" & 3" Vent Version
Concentric Vent Kit
(90% Furnaces Only) (US Only)
71M80 1-1/2" Vent Version
69M29 2" Vent Version
60L46 3" Vent Version
Concentric Vent Kit
(90% Furnaces Only) (Canada Only)
44W92 1-1/2" and 2" Vent Version
44W93 3" Vent Version
2-Stage Compressor Kit 85W66 Blower Relay Kit
Twinning Kit 16W72 Constant Torque Gas Furnace Twinning Kit
Note: For vent length and clearances to combustibles, please reference installation instructions.

508115-01Issue 2043Page 8 of 57
Parts Arrangement
Figure 1.
CONTROL BOX
(Includes integrated control,
transformer and door switch)
BAG ASSEMBLY
BLOWER MOTOR
(hidden)
COMBUSTION
AIR INDUCER
BURNER BOX ASSEMBLY
(includes flame sensor, rollout switches and ignitor)
GAS VALVE
BLOWER DECK
HEAT EXCHANGER
COLD END HEADER BOX
PRIMARY LIMIT
BLOWER
ACCESS PANEL
HEATING
ACCESS PANEL
COMPARTMENT
COMPARTMENT

508115-01 Issue 2043 Page 9 of 57
Electrical
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
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
A95DF1E / 95G1DFE unit components are shown in Figure
1. The combustion air inducer, gas valve and burners can
be accessed by removing the outer access panel. The
blower and control box can be accessed by removing the
blower access panel.
Control Box Components (Figure 2)
Unit transformer (T1) and integrated ignition control
(A92) are located in the control box. In addition, a door
interlockswitch (S51) is located in the control box.
Integrated Control
Door Interlock
Switch
Transformer
Circuit Breaker
Figure 2. Control Box
Transformer (T1)
A transformer located in the control box provides power
to the low voltage section of the unit. The transformers on
all models are rated at 40VA with a 120V primary and 24V
secondary.
Door Interlock Switch (S51)
A door interlock switch rated 14A at 120VAC is located
on the control box. The switch is wired in series with line
voltage. When the blower door 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 at 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.
Integrated Ignition Control (A92)
Shock hazard.
Disconnect power before servicing.
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
The hot surface ignition control system consisting of
an integrated control (Figure 3 with control terminal
designations in Table 1 through Table 3), sensor and
ignitor (Figure 5). The integrated control and ignitor work
in combination to ensure furnace ignition and ignitor
durability. The integrated control, controls all major furnace
operations. The integrated control also features a RED
LED for troubleshooting and two accessory terminals rated
at (1) one amp. See Table 4 or Table 5 for troubleshooting
diagnostic codes. The nitride ignitor is made from a non-
porous, high strength proprietary ceramic material that
provides long life and trouble free maintenance.
Pin # Function
1Combustion Air Inducer Line
2Ignitor Line
3Combustion Air Inducer Neutral
4Ignitor Neutral
Table 1. 4-Pin Terminal Designations
Pin # Function
1High Limit Output
2Not Used
3 24V Line
4Not Used
5Rollout Switch Out
624V Neutral
7High Limit Input
8Ground
9 Gas Valve Common
10 Pressure Switch In
11 Rollout Switch In
12 Gas Valve Out
Table 2. 12-Pin Terminal Designations

508115-01Issue 2043Page 10 of 57
1/4” Quick Connect Terminals
120HUM Humidier 120VAC
LINE 120VAC
XFMR Transformer 120VAC
CIRC Indoor Blower 120VAC
EAC Indoor Air Quality Accessory 120VAC
NEUTRALS Common 120VAC
HUM24 Humidier 24VAC
3/16” Quick Connect Terminals
COOL Cooling Tap 24VAC
HEAT Heating Tap 24VAC
FAN Continuous Blower 24VAC
PARK (no power) Park terminal for unused speed taps
FS Flame Sense
24 COM Common 24VAC
Table 3.
The integrated control is equipped with an LED light for troubleshooting. The diagnostic codes are listed in Table 4 or Table
5.
Red LED Flash Code2Diagnostic Codes / Status of Furnace
O󰀨 No power to control or board fault detected
Heartbeat1Control powered - displayed during all modes of operation if no errors are detected
1Reverse Line Voltage Polarity
2Improper Earth Ground
3Burner failed to light, or lost ame during heat demand
4Low Flame Signal - check ame sensor
5Watchguard - burner failed to light, exceeded maximum number of retries or recycles
6Not Used
7Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
8Rollout Switch Open
9 Pressure Switch failed to close or opened during heat demand
10 Watchguard - Pressure Switch opened 5 times during one heat demand
11 Pressure Switch stuck closed prior to activation of combustion air inducer
12 Flame Sensed without gas valve energized
13 Low Line Voltage
1 A ”Heartbeat” is indicated by a ”Slow Flash” - 1 sec on 1 sec o󰀨, repeating
2 Error codes are indicated by a ”Rapid Flash” - the LED ashes X times at 1/2 sec on 1/2 sec o󰀨, remains o󰀨 for 3 sec, then repeats
NOTE: Last 10 error codes are stored in memory including when power is shut o󰀨 to the unit. - To recall, press and release button,
most recent will be displayed rst, LED o󰀨 for 3 sec, then next error code is displayed, etc. To clear error codes, depress and
hold button longer than 5 seconds.
Table 4. -02 Control Diagnostic Codes

508115-01 Issue 2043 Page 11 of 57
Red LED Flash Code2Diagnostic Codes / Status of Furnace
O󰀨 No power to control or board fault detected
Heartbeat1Normal Operation - Idle, Continuous Fan, Cool
Continuous Rapid Flash Call for Heat / Burner Operation
1Reverse Line Voltage Polarity
2Improper Earth Ground
3Burner failed to light, or lost ame during heat demand
4Low Flame Signal - check ame sensor
5Watchguard - burner failed to light, exceeded maximum number of retries or recycles
6Not Used
7Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
8Rollout Switch Open
9 Pressure Switch failed to close or opened during heat demand
10 Watchguard - Pressure Switch opened 5 times during one heat demand
11 Pressure Switch stuck closed prior to activation of combustion air inducer
12 Flame Sensed without gas valve energized
13 Low Line Voltage
1 A ”Heartbeat” is indicated by a ”Slow Flash” - 1 sec on 1 sec o󰀨, repeating
2 Error codes are indicated by a ”Rapid Flash” - the LED ashes X times at 1/2 sec on 1/2 sec o󰀨, remains o󰀨 for 3 sec, then repeats
NOTE: Last 10 error codes are stored in memory including when power is shut o󰀨 to the unit. - To recall, press and release button,
most recent will be displayed rst, LED o󰀨 for 3 sec, then next error code is displayed, etc. To clear error codes, depress and
hold button longer than 5 seconds.
Table 5. -03 Control Diagnostic Codes

508115-01Issue 2043Page 12 of 57
Figure 3. Integrated Control
(Automatic Hot Surface Ignition System)
BLOWER OFF DELAY
RED LED RECALL BUTTON
Electronic Ignition
On a call for heat the integrated control monitors the
combustion air inducer pressure switch. The control board
will not begin the heating cycle if the pressure switch is
closed (by-passed). Once the pressure switch is determined
to be open, the combustion air inducer is energized. When
the di󰀨erential in the pressure switch is great enough, the
pressure switch closes and a 15-second pre-purge begins.
If the pressure switch is not proven within 2-1/2 minutes,
the integrated control goes into Watchguard-Pressure
Switch mode for a 5-minute re-set period.
After the 15-second pre-purge period, the ignitor warms
up for 20 seconds during which the gas valve opens at
19 seconds for a 4-second trial for ignition. The ignitor
remains energized for the rst 3 seconds during the 4
second trial. If ignition is not proved during the 4-second
period, the integrated 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 integrated control goes into Watchguard-
Flame Failure mode. After a 60-minute reset period, the
integrated control will begin the ignition sequence again.
Fan Time Control
Heating Fan On Time
The fan on time of 30 seconds is not adjustable.
Heating Fan O󰀨 Time
Fan o󰀨 time (time that the blower operates after the heat
demand has been satised) can be adjusted by moving
the jumper to a di󰀨erent setting. The unit is shipped with
a factory fan o󰀨 setting of 90 seconds. For customized
comfort, monitor the supply air temperature once the heat
demand is satised. Note the supply air temperature at the
instant the blower is de-energized.
Adjust the fan-o󰀨 delay to achieve a supply air temperature
between 90° - 110° at the instant the blower is de-energized.
(Longer delay times allow for lower air temperature, shorter
delay times allow for higher air temperature). See Figure 4.
Cooling Fan On Time
The fan on time is 2 seconds and is not adjustable.
Cooling Fan O󰀨 Time
The control has a 45 second fan o󰀨 delay after cooling
demand has been met. This delay is factory set and not
adjustable.
Figure 4.
HEAT FAN‐OFF TIME IN SECONDS
To adjust fan-off timing, reposition jumper across pins to
achieve desired setting.
NO JUMPER
60 90
120
180
60 90
120
180
60 90
120
180
60 90
120
180
60 Second
off Time
90 Second
off Time
120 Second
off Time
180 Second
off Time
JUMPER POSITION HEAT OFF
DELAY
PIN 1
PIN 2
PIN 3
PIN 4 PIN 5
60
90
120
180
PIN 2
PIN 3
PIN 4
180
Heating Components
Combustion air inducer (B6), primary limit control (S10),
ignitor, burners, ame rollout switch (S47), gas valve
(GV1), combustion air pressure switch (S18), and heat
exchangers are located in the heating compartment. The
heating compartment can be accessed by removing the
outer access panel.
Ignitor (Figure 5)
A95DF1E / 95G1DFE units use a nitride ignitor made from
a proprietary ceramic material. To check ignitor, measure
its resistance and voltage. A value of 39 to 70 ohms
indicates a good ignitor. Voltage to the ignitor should be
102 - 132VAC. See Figure 9 for resistance and voltage
checks.

508115-01 Issue 2043 Page 13 of 57
Figure 5. Burner Box Assembly
Gas Valve
Burner Box Front
Rollout Switch(s)
Flame Sensor
Ignitor
Burner Assembly
Flame Rollout Switches (Figure 5)
Flame rollout switches S47 are SPST N.C. high temperature
limits located on the left and right of the front buner box
plate. S47 is wired to the burner ignition control A92. When
either of the switches sense ame rollout (indicating a
blockage in the combustion passages), the ame rollout
switch trips, and the ignition control immediately closes
the gas valve. Switch S47 in all A95DF1E / 95G1DFE
units is factory preset to open at 210 F + 12 F (99 C +
6.7 C) on a temperature rise. All ame rollout switches are
manual reset. See ash code 8 in Table 4 or Table 5 for
troubleshooting.
Flame Sensor (Figure 5)
A ame sensor is located on the left side of the burner
support. The sensor is mounted on the front burner box
plate and the tip protrudes into the ame envelope of the
leftmost burner. The sensor can be removed for service
(use steel wool only to clean) without removing any part of
the burners. During operation, ame is sensed by current
passed through the ame and sensing electrode. The
ignition control allows the gas valve to remain open as long
as ame signal is sensed.
NOTE: The A95DF1E / 95G1DFE is polarity sensitive.
Make sure that the furnace is wired correctly and is properly
grounded.
A microamp DC meter is needed to check the ame signal
on the integrated control.
Flame (microamp) signal is an electrical current which
passes from the integrated control to the sensor during
unit operation. Current passes from the sensor through the
ame to ground to complete a safety circuit.
Heat Exchanger (Figure 6)
A95DF1E / 95G1DFE units use an aluminized steel primary
and stainless steel secondary heat exchanger assembly.
Heat is transferred to the air stream from all surfaces of the
heat exchanger. The shape of the heat exchanger ensures
maximum e󰀩ciency.
The combustion air inducer pulls fresh air through the
burner box. This air is mixed with gas in the burners. The
gas / air mixture is then burned at the entrance of each
clamshell. Combustion gases are then pulled through the
primary and secondary heat exchangers and exhausted
out the exhaust vent pipe.

508115-01Issue 2043Page 14 of 57
Primary Limit Control (Figure 6)
Primary limit (S10) used on A95DF1E / 95G1DFE units
is located in the heating vestibule panel. When excess
heat is sensed in the heat exchanger, the limit will open.
Once the limit opens, the furnace control energizes the
supply air blower and de-energizes the gas valve. The
limit automatically resets when unit temperature returns to
normal. The switch is factory set and cannot be adjusted.
For limit replacement remove wires from limit terminals,
remove mounting screws, rotate limit switch 90 degrees
and slowly remove from the vestibule panel. Install
replacement limit with same care. See ash code 7 in
Table 4 or Table 5 for troubleshooting if limit switch opens
during operation.
Figure 6. Primary Limit Location and Heat Exchanger
Install limit face down
Gas Valve (Figure 7)
The A95DF1E / 95G1DFE uses an internally redundant
valve to assure safety shut-o󰀨. If the gas valve must be
replaced, the same type valve must be used.
24VAC terminals and gas control switch are located on top
of the valve. All terminals on the gas valve are connected to
wires from the ignition control. 24V applied to the terminals
opens the valve.
Inlet and outlet pressure taps are located on the valve. A
manifold adjustment screw is also located on the valve. An
LP/Propane changeover kit is available.
Figure 7. Gas Valve
GAS VALVE SHOWN IN ON POSITION
MANIFOLD
PRESSURE
OUTLET
PORT
INLET
PRESSURE
PORT
MANIFOLD PRESSURE
ADJUSTMENT SCREW
(under barbed fitting)
To Measure Flame Signal - Integrated Control:
Use a digital readout meter capable of reading DC
microamps. See Figure 8 for ame signal check.
1. Set the meter to the DC amps scale.
2. Turn o󰀨 supply voltage to control.
3. Remove sensor wire from integrated control.
4. Connect (-) lead to ame sensor wire.
5. Connect (+) lead to Terminal FS on integrated control.
6. Turn supply voltage on and close thermostat contacts
to cycle system.
7. When main burners are in operation for two minutes,
take reading.

508115-01 Issue 2043 Page 15 of 57
Figure 8. Measuring Flame Signal
Flame Signal In Microamps
Normal Low Drop Out
1.50.5 - 1.40.4
(+)
Set Dial to DC MicroAmps
(+)
Multi−Meter
(+) To Control
Sensor Terminal
(−) To Flame
Terminal
Remove Sensor Wire from
Intergrated Control and
Connect Alligator Clip (+)
to Terminal on Control
Flame Sensor
Terminal
Flame Sensor
Wire
Remove Sensor Wire from
Intergrated Control and
Connect Alligator Clip (−)
to Frame Sensor Lead
Intergrated
Control

508115-01Issue 2043Page 16 of 57
Figure 9.
Test 2
Check ignitor for correct resistance.
Seperate the 2-pin jack-plug near the manifold
and check resistance of ignitor at 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.
Integrated Control Detail
Integrated Control Detail
Test 3
Check ignitor for correct voltage
Insert meter probes into terminals 2 and 4 (use small
diameter probes in order not to damage plug).
Check voltage during 20 second ignitor warm up period.
Voltage should read 120 volts +10%. If voltage reads below
these values, check for correct supply voltage to furnace.
Integrated Control Detail
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.

508115-01 Issue 2043 Page 17 of 57
Combustion Air Inducer (B6) & Cold End Header Box
All A95DF1E / 95G1DFE units use a combustion air inducer
to move air through the burners and heat exchanger during
heating operation. The blower uses a shaded pole 120VAC
motor. The motor operates during all heating operation and
is controlled by integrated control A92. Blower operates
continuously while there is a call for heat. The integrated
control will not proceed with the ignition sequence until
combustion air inducer operation is sensed by the proving
switches.
The combustion air inducer is installed on the cold end
header box. The cold end header box is a single piece made
of hard plastic. The box has an internal channel where the
combustion air inducer creates negative pressure at unit
start up. The channel contains an orice used to regulate
ow created by the combustion air inducer. The box has
pressure taps for the combustion air inducer pressure
switch hoses. The pressure switch measures the pressure
across the combustion air inducer orice or di󰀨erence in
the channel and the box. If replacement is necessary the
gaskets used to seal the box to the vestibule panel and the
combustion air inducer to the box, must also be replaced.
Combustion Air Pressure Switch (Figure 10)
A95DF1E / 95G1DFE series units are equipped with a
di󰀨erential pressure switch located on the cold end header
box. The switch monitors across the combustion air inducer
orice to insure proper ow through the heat exchanger.
The switch is a SPST N.O. pressure switch electrically
connected to the integrated control. The purpose of the
switch is to prevent burner operation if the combustion air
inducer is not moving enough air for proper combustion.
Figure 10. Pressure Switch
On start-up, the switch monitors whether the combustion
air inducer is operating. It closes a circuit to the integrated
control when the di󰀨erence in pressure across the
combustion air inducer orice exceeds a non-adjustable
factory setting. If the switch does not successfully sense
the required di󰀨erential, the switch cannot close and the
furnace cannot operate. If the ue or air inlet become
obstructed during operation, the switch senses a loss of
pressure di󰀨erential and opens the circuit to the integrated
control. If the condensate line is blocked, water will back
up into the header box and reduce the pressure di󰀨erential
across the switch. The pressure switch opens if the
di󰀨erential drops below the set point. See Table 6.
Checks of pressure di󰀨erential can aid in troubleshooting.
When measuring the pressure di󰀨erential, readings should
be taken at the pressure switch. See Figure 11 and Table 7.
Lack of di󰀨erential usually indicates problems in the intake
or exhaust piping, but may indicate problems in the heat
exchanger, condensing coil, header boxes, combustion
inducer or other components.
Unit
Altitude (ft.)
0 - 4500 4501 - 7500 7501 - 10000
Set Point “w.c. Set Point “w.c. Set Point “w.c.
045 -0.65” -0.65” -0.60”
070 -0.90” -0.85” -0.65”
090 -0.90” -0.80” -0.65”
110 -0.90” -0.85” -0.65”
NOTE: Set point is factory set and non-adjustable
Table 6.

508115-01Issue 2043Page 18 of 57
Figure 11. Measuring Pressure Di󰀨erential
To Cold End Header Box
Field Provided Tubing
To Pressure Switch
To Cold End Header Box
1 -Remove thermostat demand and allow unit to
cycle off.
2 -Install a tee in the negative (-) line (red and black tubing
or red tubing) and a tee in the positive (+) line (black
tubing) running from the pressure switch to the cold
end header box.
3 - Install a manometer with hose from the negative (-)
side of the manometer to the tee installed in the
negative (-) line and with hose from the positive (+)
side of the manometer to the tee in the positive (+)
line.
NOTE -
tive. However the (+) port reads less negative pressure
than the (-) port.
4 -Operate unit and observe manometer reading.
Readings will change as heat exchanger warms.
a. Take one reading immediately after start‐up.
b. Take a second reading after unit has reached
steady state (approximately 5 minutes). This will be
the pressure differential.
The pressure differential should be greater
than those listed in table 7.
5 -Remove thermostat demand and allow to cycle off.
6 -Remove manometer and tee's. Reinstall combustion
air sensing hoses to the pressure switch.
Black Tubing
(positive +)
Red and Black Tubing
or Red Tubing
(negative -)
“+”
High
“-”
Low

508115-01 Issue 2043 Page 19 of 57
Problem Corrective Action
Pressure switch stuck closed Check that the pressure switch is open without the combustion air inducer
operating. Replace if defective.
Pressure switch does not close due to obstruction in
vent pipe
Check for restricted vent. Remove all blockage.
Check for proper vent sizing. See Table 11 through Table 12.
Pressure switch does not close due to incorrect
routing of the pressure switch tubing
Check that the pressure switch tubing is correctly routed. Correctly route
pressure switch line.
Pressure switch does not close due to obstructions in
the pressure switch line Remove any obstructions from the the pressure switch line and/or taps
Pressure switch tubing damaged Check pressure switch tubing for leaks. Replace damaged tubing if
necessary.
Condensate in pressure switch tubing Check pressure switch tubing for condensate. Remove condensate from
tubing.
Pressure switch does not close due to a low
di󰀨erential pressure across the pressure switch
Check the di󰀨erential pressure across the pressure switch.
Check for restricted inlet vent. Remove all blockage.
Check for proper vent sizing and run length. See Table 11 through Table 12.
Wrong pressure switch installed in the unit, or
pressure switch is out of calibration
Check that the correct pressure switch is installed in the unit. Replace
pressure switch if necessary.
Miswiring of furnace or improper connections at
pressure switch
Check for correct wiring and loose connections. Correct wiring and/or replace
any loose connections.
Pressure switch failure If all the above modes of failure have been checked, the pressure switch
may have failed. Replace pressure switch and determine if unit will operate.
Damaged condensate trap Check trap for any cracks or damage and replace if necessary.
Cold end header box does not drain properly Check that the furnace is set properly with a slight tilt (0 - 1/2”) towards the
front if necessary. See furnace installation instruction.
Air leakage around the combustion air inducer gasket Check gasket and replace if necessary.
Air leakage around the cold end header box gasket Check gasket and replace if necessary.
Damaged cold end header box tubing Check tubing and replace if necessary.
Table 7. Pressure Switch Troubleshooting Guide
Figure 12. Electronic Ignition
DEMAND
CAI
GAS VALVE
15
ON
OFF
38
IGNITOR
34
1
Pre -Purge Ignitor Warm-up Trial for
Ignition Post
Purge
5 SEC80
*Blower on time will be 30 seconds after flame is sensed. Blower off time will depend on “OFF TIME” Setting.
INDOOR BLOWER
Blower “On”*
Delay

508115-01Issue 2043Page 20 of 57
Blower Compartment
Each blower is statically and dynamically balanced as
an assembly before installation in the unit.
IMPORTANT
A95DF1E / 95G1DFE 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. The motor is programmed to provide constant
torque at each of the ve selectable speed taps. Each tap
requires 24 volts to energize.
Input Voltage Requirements
The circuit is designed to be operated with AC voltage. To
enable a tap requires 12 to 33VAC. Expected current draw
will be less than 20mA.
Troubleshooting the Motor
Troubleshooting the motor is an easy process. Follow
steps below.
1. Shut o󰀨 power to unit.
2. Remove input plugs P48 and P49 from motor. See
Figure 16 for troubleshooting procedure.
If correct voltage is present in tests 1 and 2 and motor is
not operating properly, replace motor. The motor is not eld
repairable.
If replacing the indoor blower motor or blower wheel is
necessary, placement is critical. The blower wheel must
be centered in the blower housing as shown in Figure 13.
When replacing the indoor blower motor the set screw
must be aligned and tightened with the motor shaft as
shown in Figure 14.
Secondary Limit Controls
The secondary limit is located in the blower compartment
on the back side of the blower housing. See Figure 15.
When excess heat is sensed in the blower compartment,
the limit will open. If the limit is open, the furnace control
energizes the supply air blower and closes the gas valve.
The limit automatically resets when unit temperature
returns to normal. The secondary limit cannot be adjusted.
Figure 13. Blower Wheel Replacement
Center Blower Wheel
in Blower Housing
Figure 14.
Set Screw
Housing Hub
ALIGN AND TIGHTEN SET SCREW WITH
FLAT SIDE OF MOTOR SHAFT
Motor
Shaft
Figure 15. Secondary Limit Control
Secondary Limits