YORK Furnace/Heater, Gas Manual L0611119
User Manual: YORK YORK Furnace/Heater, Gas Manual YORK Furnace/Heater, Gas Owner's Manual, YORK Furnace/Heater, Gas installation guides
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® % '_i Iso ,;_ _ 9001 Certified Quality Management System TABLE OF CONTENTS CONTACT INFORMATION ................................ USER'S INFORMATION ................................... SAFETY .............................................. INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION ......................................... HOW YOUR GAS FURNACE WORKS ...................... START-UP AND SHUTDOWN INSTRUCTIONS ............... 1 1 1 Read the Instructions Below Before Trying to Start the Furnace.. Operating Instructions: .................................. To Turn Offthe Appliance: ............................... FURNACE USER MAINTENANCE .......................... Blower Care .......................................... Air Filters ............................................ Removing Filters ...................................... Motor Lubrication ...................................... SERVICE AND MAINTENANCE MANUAL ..................... SAFETY SECTION ...................................... FURNACE MAINTENANCE SECTION ....................... 3 3 3 4 4 4 4 5 6 5 5 CONTACT 2 3 3 SEQUENCE OF OPERATION ............................. Continuous Blower ..................................... 5 5 Intermittent Blower - Cooling ............................. Heating Cycle ......................................... Hot Surface Ignition System .............................. FURNACE CLEANING SECTION ........................... 5 5 6 6 Burner Removal/Cleaning ............................... Cleaning the Heat Exchanger ............................ Cleaning the Secondary Heat Exchanger ................... Cleaning the Vent / Air Intake System ...................... TROUBLESHOOTING ................................... FURNACE CONTROL DIAGNOSTICS ....................... DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL REPLACEMENT PARTS LIST .............................. REPLACEMENT PART CONTACT INFORMATION ............. WIRING DIAGRAM ...................................... LIMITED WARRANTY .................................... ...... 6 6 6 6 6 6 7 8 10 11 12 INFORMATION • Go to website at www.york.com • Contact us by mail: click on "contact", then click on "contact form" and follow the instructions. York International Consumer Relations 5006 York Drive Norman, OK 73069 The manufacturer tions of this ence. recommends manual FIRE OR EXPLOSION warnings exactly could erty damage. and keep that the the user manual read for future all secrefer- SECTION h USER'S INFORMATION SAFETY 1. The furnace area must be kept clear and free of combustible rials, gasoline and other flammable vapors and liquids. 2. Insulating materials may be combustible. The furnace must be kept free and clear of insulating materials. The furnace area must be examined when installed in an attic or other insulated space or when insulation is added to be sure that the insulation material has HAZARD - Failure to follow safety result in serious injury, death, or prop- mate- been kept away from the furnace. -- Do not store and liquids ance. -- WHAT or use gasoline in the vicinity or other flammable vapors of this or any other appli- TO DO IF YOU SMELL 3. The furnace needs air for combustion in order to operate properly and safely. Do not block or obstruct air openings on the furnace, air openings to the area where the furnace is installed, or spaces around the furnace. 4. Follow the instructions exactly as shown on the OPERATING INSTRUCTION LABEL or the Start-up and Shutdown Instructions on Page 3 of this manual when lighting the furnace or turning the furnace off. 5. Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply. 6. Do not use this furnace if any part has been under water. A flooddamaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and replace alI gas controls, control system parts, electrical parts that have been wet or the furnace if deemed necessary. GAS: Do not try to light any appliance. Do not touch any electrical switch; do not use any phone (including cell phone) in your building. Leave the building immediately. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you cannot ment. -- reach your gas supplier, call the fire depart- Installation and service must be performed by a qualified installer, service agency or the gas supplier. 167808-UUM-A-1205 167808-UUM-A-1205 INSTRUCTIONS CONDENSATE BLOWER ACCESS-PANEL THE FURNACE 1. Examine the heat exchanger, through a field installed access panel located on the supply air plenum. Visually examine the exterior sections of the vent/combustion air piping and the vent connectors to be sure that they are physically sound without holes or excessive corrosion. 2. Examine the vent pipe making sure it is firmly in place, that it slopes slightly upward and is physically sound without holes and all of the connections are secure. 3. Examine the return-air duct connections to make sure they are physically sound, sealed to the furnace casing, and the ducts terminate outside the space containing the furnace. 4. Examine the furnace casing making sure the physical support is sound without sagging, cracks or gaps. Examine the furnace base making sure it is physically sound without cracks, gaps or sagging and has a good seal. 5. Examine the furnace casing for obvious signs of deterioration. 6. Examine the burner flames to make sure they are in good adjustment. Refer to the pictorial sketch shown in Figure 2 as a comparison to the actual flame. 7. Examine the furnace as outlined above in steps 1 - 6 before each heating season. Use Figure 3 for visual reference. RAIN UTTER -- INDUCER PRESSURE SWITCH TUBING INDUCER MOTOR PRESSURE SWITCHES-_ CONDENSATE DRAIN HOSE _CONDENSATE TRAP GAS -VALVE _LIMIT GAS REFERENCE HOSE _\ BURNER SWITCH BOX FIGURE 1: Component Locations 7. EXAMINING It is the owner% responsibility to ensure that an annual inspection of the entire heating portion of the unit is made by a qualified service agency. CONTROL BOARD-TRANSFORMER FOR INSTALLATION COMBUSTION AIR PIPE NEVER . . .Store flammable materials of any kind near your furnace. Gasoline, solvents, and other volatile liquids should be stored only in approved containers outside your home. materials vaporize easily and are extremely dangerous. These MAIN 8. NEVER...Store cleaning materials near your furnace. Materials such as bleaches, detergents, powdered cleansers, etc., can cause corrosion of the heat exchangers. 9. NEVER... Use the area around your furnace as a storage area for items which could block the normal flow of air. This flow of air is BURNER END OF BURNER MANIFOLD \ \ _ I I _ BURNER I FLAME _ L YELLOW _ required for ventilation of the various furnace components. INNER FLAME CONES (B_ue Flame) FIRE OR EXPLOSION COMBUSTION -_- TRANSITION HAZARD AIR (not shown) This furnace is designed and approved for use with Natural Gas and (LP) Propane Gas ONLY. DO NOT BURN ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE. Burning any unapproved fuel will result in damage to the furnace heat exchanger, which could result in Fire, Personal Injury, and/or Property Damage. FIGURE 2: Burner Flame Drawing 3 EXAMINE RETURN AIR i_y DUCT CONNECTION _" . O BLOWER DOOR L-" " o O o q o 2 REMOVE THIS PANEL TO EXAMINE VENT PIPE [] "© 4 EXAMINE FURNACE CASING 4 EXAMINE 6 REMOVE THIS PANELTO -EXAMINE THE BURNER FLAMES (_) 5 EXAMINE CASING FOR DETERIORATION O FIGURE 3: Furnace Examination 2 ©. b. 1 PLACE A FIELD INSTALLED ACCESS BURNER DOOR1 // PANEL LOCATED IN THE DOWNFLOW PLENUM TO EXAMINE THE HEAT EXCHANGER FURNACE CASING oO 5 EX/_MINECASING FOR DETERIORATION Checkpoints Unitary Products Group 167808-UUM-A-1205 HOW YOUR GAS FURNACE WORKS To Turn Off the Appliance: Your furnace is a very easy appliance to take for granted. Season after season, it sits there in your home, keeping you warm and comfortable. For this reason, you may never have given much thought to the way your furnace operates. In order to get the safest and most efficient operation from your furnace, you should understand how your furnace does its job. When you set your thermostat to provide more heat in your home, you are starting the heating cycle of the furnace. First, the inducer motor starts to purge the heat exchanger of any remaining gases. Next, the hot surface igniter glows and after a warm-up period the gas valve opens and ignition occurs. A short time later, the blower starts and distributes the warm air throughout the home. When the temperature setting on your thermostat is reached, the gas valve closes, the main burners are turned off, and the blower continues to run until the remaining warm air in the system is distributed. When the blower stops, the heating cycle has ended. START-UP AND SHUTDOWN Read the Furnace Instructions Below INSTRUCTIONS Before Trying to Start the _WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, and/or loss of fife. A. B. C. D. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. BEFORE OPERATING; smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. Use only your hand to push the gas control switch to the "on" position. Never use tools. If the switch will not operate by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water. Operating 1. Set the thermostat to lowest setting. 2. Turn off all electric power to the appliance formed. 3. Remove burner access panel. 4. Move gas control switch to the "OFF" position. See Figure 4. 5. Replace burner access panel. Should overheating occur, or the gas valve fail to shut off, turn the external manual gas valve in the gas supply line to the furnace to the "off" position and let the furnace cool off before shutting off the electrical power supply. Refer to Figures 5 & 6. OUTLET PRESSURE [_L PORT _ 1. STOP! Read the safety information 2. Set the thermostat to the lowest setting. above. 3. 4. Turn off all electric power to the appliance. Remove burner door. 5. Move gas control switch to the "OFF" position. Do not force. See Figure 4. 6. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow "B" in the safety information above. If you don't smell gas, go to next step. 4 I I" I 1 BOSS ,NLET/ PRESSURE PORT EXTERNAL MANUAL SHUTOFF VALVE TO GAS SUPPLY TO GAS SUPPLY GROUNDED JOINT UNION MAY BE INSTALLED INSIDE OR OUTSIDE UNIT. FIGURE 5: Downflow Gas Piping MANUAL SHUT-OFF VALVE _DRIP LEG --GAS -- GAS 8. Replace burner door. 9. Turn on all electric power to the appliance. DRIP_UAL 10. Set thermostat to the desired setting. Burner wilI light, which may take 30-60 seconds. LEG 11. After three (3) trials for ignition, if the appliance will not operate follow the instructions, "TO TURN OFF THE APPLIANCE" and call your service technician or gas supplier. Group REGULATOR ADJUSTMENT FIGURE 4: Gas Valve - White Rodgers Move gas control switch to the "ON" position. Do not force. See Figure 4. Products OUTLET _N ON/OFF SWITCH (Shown in ON position) 7. Unitary NT PORT WRENCH J _ DRIP_" LEG Instructions: if service is to be per- SHUT-OFF BURNERS VALVE VALVE FIGURE 6: Horizontal Gas Piping NOTE: The spring-loaded safety cut-off switch, mounted on the blower deck, behind the indoor fan access panel will automatically cut off the electrical power supply to the furnace when the blower panel is removed. As a safety precaution, all electrical power and the gas supply to the furnace should be turned off before servicing. 3 167808-UUM-A-1205 FURNACE USER MAINTENANCE Removing Filters Some downflow furnaces have their filters located on the top of the furnace in an external filter rack. To check filters you should: Before proceeding, be sure the area is well ventilated. Turn the thermostat OFF. If the blower is running, wait until it stops automatically. Turn OFF the gas and electrical power supplies to the furnace. Check all metal parts and surfaces to be sure they have cooled to room temperature before you begin. Blower Care Even with good filters properly in place, blower wheels and motors will become dust laden after long months of operation. The entire blower assembly should be inspected annually. If the motor and wheel are heavily coated with dust, they can be brushed and cleaned with a vacuum cleaner. If the blower cannot be properly cleaned without removing it from the furnace, then this service must be performed by a qualified service agency. The blower can be serviced/removed through the blower access panel on the inside of the furnace. If there is a combustion air pipe installed inside the furnace, it may have to be removed to access the blower access panel. After the combustion air pipe is removed, it is easy to remove the inside blower access panel by removing the screws of the access panel. Blower is now ready to be serviced through the opening. If the blower has to be removed through the inside blower access panel, then the top and bottom angles will have to be removed to slide the blower out of the furnace. Follow the instructions to turn off the appliance 2. Filters are installed in the return air plenum above the blower assembly. An "A" frame assembly supports the filters. Lift the filter slightly and remove for service. 3. Follow the instructions TER". 4. Reverse the procedure to reinstall filters. 5. Follow the operating instructions to place appliance Externally FIL- in operation. Air Filters Some installations may have the air filter in a rack attached to the casing of the furnace or placed in the return air duct. You can gain access to the filter by pulling on the door or unscrewing the retaining screw, then slide the filter(s) out of its channel. Replace throw away filter(s) with the same size new filter(s). Throw away filter(s) may be replaced with cleanabIe filter(s) at this time. Cleanable filter(s) may be cleaned as described in the manufacturer instructions or as described below and then re-installed. How to Clean your Filter High-velocity filters may be cleaned with a vacuum cleaner or washed with a garden hose. Be sure to shake off excess water and allow filter to completely dry before re-installing the filter. To replace the filter after cleaning you must do the following: 2. Snap the door on or place the door in position and tighten the retaining screws, if provided. the clip-on weight on the 3. Make sure the door is secure to the end of the filter rack. indoor fan wheel when cleaning the wheel. This weight is used to balance the wheel. Moving the weight will cause the fan wheel to vibrate. 4. For filter grilles, place the filter into the grilles, close the grille cover and tighten the retaining screw. Filters weeks after that, especially if the indoor fan is running continuously. When replacing the filter(s), refer to Table 1 to be sure you install the right size filter for your furnace. Dirty filters greatly restrict the flow of air and may cause damage to the moving parts of the furnace. If the filters Every time the filters are changed the following items should be visually inspected: • • • • become clogged the heat exchangers and blower motor could overheat resulting in a potentially dangerous situation. Use the following procedure to determine the filter size. 1. Measure the furnace width and use that measurement mine the cabinet width. • • A 14-1/2" wide cabinet is a _'A"cabinet. A 17-1/2" wide cabinet is a _'B"cabinet. • • A 21" wide cabinet is a _'C"cabinet. A 24-1/2" wide cabinet is a _'D"cabinet. Check combustion air and vent pipe for blockage or leakage. Check all components to be sure they are in good condition and that there are no obvious signs of deterioration. Check the drain lines to make sure there are no cracks or leaks. Check for dirt or lint on any surfaces or on components. Do not try to clean any of the surfaces or components. Cleaning of the furnace and its components must be done by a qualified service professional. If, during the inspection conditions: Never operate your furnace without a suitable air filter. 4 "HOW TO CLEAN YOUR FURNACE'S Slide filter into place. The filters should be checked every 3 months. On new construction, check the filters every week for the first four weeks and every three 2. Mounted before servicing. 1. Make sure you DO NOT move Air 1. to deter- After you determine the cabinet size and what return configuration you have, look up the recommended filter size from Table 1. of your furnace, you find any of the following • Excessive amounts of dust and lint on components. • • Damaged or deteriorated components or surfaces. Leaks or blockage in the vent pipe passages. • Water on any surface inside or outside of the furnace. Do not operate the furnace, call a certified dealer / servicing contractor to check and / or clean your furnace, or for more information if you have questions about the operation of your furnace. If all components appear to be in good operating condition, replace the front panels. Turn ON the gas and electrical power supplies to the furnace, and set thermostat to the desired temperature. Unitary Products Group 167808-UUM-A-1205 Motor Lubrication The motors in these furnaces require periodic oiling. Intermittent are permanently lubricated, and do not TABLE 1: Fitter Sizes Input/Output BTU/H (kW) Blower - Cooling Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling. The motor will operate on the speed tap wire that is connected to the HI COOL terminal on the control board. The fan off setting is fixed at 60 seconds for SEER enhancement. CFM Cabinet Top Return Filter (m3/min) Size in (cm) 40/37(1 ! .72/10.84) 1200(34) A (2) 14 x2O (36x 51) Heating 60/55(17.57/16.10) 1200(34) a (2) 14 x20 (36x51) 80/75(23.42/2! .96) 1200(34) a (2) 14 x20 (36x51) 80/75(23.42/2! .96) When the thermostat switch is set on HEAT and the fan is set on AUTO, and there is a call for heat, a circuit is completed between terminals R and W of the thermostat. When the proper amount of combustion air is being provided, the pressure switch will close, the ignition control provides a 17-second warm-up period, the gas valve then opens, the gas starts to flow, ignition occurs and the flame sensor begins its sensing function. The blower motor will energize 30 seconds after the gas valve opens, if a flame is detected. Normal furnace operation will continue until the thermostat circuit between R and W is opened, which causes the ignition system and gas valve to de-energize and the burner flames to be extinguished. The vent motor will operate for 15 seconds and the blower motor will operate for the amount of time set by the fan-off delay jumper located on the control board. See Figure 7. The heating cycle is complete, and ready for the start of the next heating cycle. 1600(45) C (2) 14 x 20 (36 x 51) 100/95(29.28/27.82) 1600(45) C (2) 14 x 20 (36 x 51) 100/95(29.28/27.82) 2000(57) C (2) 14 x 20 (36 x 51) 120/112(35.14/32.80) 2000(57) U (2) 14 x20 (36 x51) SECTION MANUAL SAFETY Ih SERVICE AND MAINTENANCE SECTION The following furnace, safety rules must be followed when servicing the Cycle RED - LOW YELLOW ELECTRIC SHOCK, FIRE OR EXPLOSION SPEED - MED LOW SPEED HAZARD Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous serious injury, and death or property damage. operation, • Before servicing, disconnect nace. • When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly. • Verify proper operation after servicing. FURNACE MAINTENANCE all electrical power to the fur- SECTION The furnace should be cleaned and adjusted by a certified dealer or qualified service contractor once a year or before the start of every heating season. The following items must be cleaned and serviced or replaced if there are signs of deterioration. 1. The vent terminal screen (if applicable). 2. The furnace vent and combustion air intake passageways. Should it be necessary to service the vent!air intake system, the manufacturer recommends this service be conducted by a qualified service agency. The operation of this appliance requires the reassembty and resealing of the vent/air intake system. 3. The furnace burners, ignitor and flame sensor. 4. The condensate collection and disposal system. If any disassembly of components containing flue or vent gases is required, a qualified service agency must perform the service. SEQUENCE OF OPERATION The following describes the sequence of operation of the furnace. Refer to Figure 1 for component location. Continuous Blower Cooling/heating thermostats have a fan switch that has an ON and AUTO position. In the ON position the thermostat circuit is completed between terminals R and G. Unitary Products Group FAN OFF -_ADJUSTMENT JUMPER 0 _ FIGURE 7: Typical Heat/Cool Speed Tap Connections If the flame is not detected within 7 seconds of the gas valve opening, the gas valve is shut off and a retry operation begins. If the flame is lost for 2 seconds during the 10-second stabilization period, the gas valve is shut off and a retry operation begins. During a retry operation, the vent motor starts a 15 second inter-purge and the ignitor warm-up time is extended to 27 seconds. If the flame is established for more than 10 seconds after ignition during a retry, the control will clear the ignition attempt (retry) counter. If three retries occur during a call for heat, the furnace will shut down for one hour. If at the end of the one hour shut down there is a call for heat, the furnace will initiate a normal start cycle. If the problem has not been corrected the furnace will again lockout after three retries. A momentary loss of gas supply, flame blowout, or a faulty flame probe circuit will result in a disruption in the flame and be sensed within 1 second. The gas valve will de-energize and the control will begin a recycle operation. A normal ignition sequence will begin after a 15 second interpurge. If during the five recycles the gas supply does not return, or the fault condition is not corrected the ignition control will lockout for 60 mintues. During burner operation, a momentary loss of power for 50 milliseconds or longer will de-energize the gas valve. When the power is restored, the gas valve will remain de-energized and the ignition sequence will immediately restart. 5 167808-UUM-A-1205 Hot Surface Ignition System _WARNING 3. Using a stiff wire brush, remove the loose scale or soot from each tube. 4. Vacuum the secondary heat exchanger. 5. Finish the cleaning procedure cleaning the Heat Exchanger. HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand (with a match or any other means). There may be a potential shock hazard from the components of the hot surface ignition system. The furnace can only be lit automatically by its hot surface ignition system. FURNACE CLEANING Cleaning steps 9 - !1 under System Should it be necessary to service the vent / air intake system, the manufacturer recommends this service be conducted by a qualified service agency. SECTION NOTE: The cleaning operations listed below must be performed only by a qualified service agency. The operation of this appliance requires the reassembly and resealing of the vent / air intake system as specified in the "Combustion Air and Vent System" located in the Installation Manual. TROUBLESHOOTI NG The following visual checks should be made before troubleshooting: CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Burner the Vent / Air Intake by following Removal/Cleaning The main burners should be checked periodically for dirt accumulation. If cleaning is required, follow this procedure: 1. Check to see that the power to the furnace and the ignition control module is ON. 2. The manual shut-off valves in the gas Iine to the furnace must be open. 3. Make sure all wiring connections 4. Review the sequence of operation. Start the system by setting the thermostat above the room temperature. Observe the system's response. Then use the troubleshooting section in this manual to check the system's operation. are secure. 1. Turn off the electrical power to the unit. 2. Turn off the gas supply at the external loosen the ground union joint. 3. Remove the upper access panel and remove the burner box cover. 4. Disconnect wires from flame sensor, rollout switch and HSl igniter. Remove igniter carefully, as it is easily broken. Never bypass pressure switch to allow furnace operation. To do so will allow furnace to operate under potentially hazardous conditions. 5. Remove the screws that hold the burner box assembly to the vest panel and remove the assembly. Do not try to repair controls. with UPG Source I Parts. 6. Remove burners from the burner assembly. 7. Burners may be cleaned by rinsing in hot water. FURNACE 8. Reassemble The furnace has built-in, self-diagnostic capability. If a system problem occurs, a blinking LED shows a fault code. The LED can flash red, green or amber to indicate various conditions. It is located behind a clear view port in the blower compartment door. Cleaning manual shut-off valve and the Heat Exchanger 1. Turn off the electrical power to the unit. 2. Turn off the gas supply at the external loosen the ground union joint. 3. Remove the upper access panel and remove the burner box cover. 4. Disconnect wires from flame sensor, rollout switch and HSl igniter. Remove igniter carefully, as it is easily broken. 5. Remove the screws that hold the burner box assembly to the vest panel and remove the assembly. manual shut-off valve and 6. Remove the vent pipe assembly, vent blower and condensate 7. The heat exchanger 8. With a long flexible wire brush, clean inside each tube at both the top and bottom. The brush must pass around the rear heat exchanger tubes. Then vacuum loose the scale and dirt from each tube. 10. Restore electrical power and gas supply to the furnace. 11. Check furnace operation. Cleaning pan. is now exposed. Replace all components the Secondary in reverse order. Reconnect all wiring. Heat Exchanger 1. Follow steps 1 - 7 under cleaning the Heat Exchanger. 2. Remove the vent piping from the vent blower housing. Disconnect the drain lines from the vent blower housing and from the condensate drain pan. Remove the vent blower housing blower and the condensate pan. 6 Replace defective controls Never adjust pressure switch to allow furnace operation. the burners in the reverse order. 9. AWARNING CONTROL DIAGNOSTICS The control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED will indicate the failure code. If the failure is internal to the control, the light will stay on continuously. In this case, the entire control should be replaced, as the control is not field repairable. Flash sequence codes 1 through !0 are as follows: LED will turn "on" for 1/4 second and "off' for 1/4 second. This pattern will be repeated the number of times equal to the code. For example, six "on" flashes equals a number 6 fault code. All flash code sequences are broken by a 2 second "off" period. SLOW GREEN FLASH: Normal operation. SLOW AMBER FLASH: Normal operation with call for heat. RAPID RED FLASH: twinning wiring. Twinning error, incorrect 24V phasing. Check RAPID AMBER FLASH: Flame sense current is below 1.5 microamps. Check and clean flame sensor. Check for proper gas flow. 1 RED FLASH: This indicates that flame was sensed when there was not a call for heat. With this fault code the control will turn on both the inducer motor and supply air blower. A gas valve that leaks through or is slow closing would typically cause this fault. 2 RED FLASHES: This indicates that the normally open pressure switch contacts are stuck in the closed position. The control confirms these contacts are open at the beginning of each heat cycle. This would indicate a faulty pressure switch or miswiring. Unitary Products Group 167808-UUM-A-1205 3 RED FLASHES: This indicates the normally open pressure switch contact did not close after the inducer was energized. This could be caused by a number of problems: faulty inducer, blocked vent pipe, broken pressure switch hose or faulty pressure switch. STEADY ON RED: Control failure. Replace control board. 60-MINUTE 4 RED FLASHES: This indicates that a primary or auxiliary limit switch has opened its normally closed contacts. With this fault code the control will operate the supply air blower and inducer. This condition may be caused by: dirty filter, improperly sized duct system, incorrect blower speed setting, incorrect firing rate or faulty blower motor. DIAGNOSTIC RETRIEVAL established. This no-light condition occurred 3 times (2 retries) during the call for heat before locking out. Low gas pressure, faulty gas valve, dirty or faulty flame sensor, faulty hot surface ignitor or burner problem may cause this. Gas flow with no call for heat. Check gas valve and I L ON Ca[[ir_ FAULT CODE STORAGE AND If there are no error codes in memory, the LED will flash two flashes. To clear the memory, push the LAST ERROR button and for more than five seconds. The LED will flash three green flashes the memory has been cleared, then will resume the normal slow flash after a five-second pause. 4 AMBER FLASHES: Y present with no G call. Normally, both Y and G are energized on a call for cooling. If a Y signal is present with no G signal, check to see that the wire from the G terminal on the board to the wall thermostat has not broken or disconnected. Thermostat period. To retrieve the error codes, push the LAST ERROR button. The LED on the control will then flash the error codes that are in memory, starting with the most recent. There will be a two-second pause between each flash code. After the error codes have all been displayed, the LED wilI resume the normal slow green flash after a five second pause. To repeat the series of error codes, push the button again. 11 RED FLASHES: This indicates that a primary or auxiliary limit switch has opened its normally-closed contacts and has remained open for more than five minutes. This condition is usually caused by a failed blower motor or blower wheel. Cycle power (24 VAC) to the contro! to reset the hard lockout condition after correcting the failure condition. 17 control The control stores up to five separate error codes. If more than five error codes have occurred since the last reset, only the five most recent wilI be retained. The furnace control board has a button, labeled "LAST ERROR" that is used to retrieve error codes. This function will only work if there are no active thermostat signals. So any call for heating, cooling or continuous fan must be terminated before attempting to retrieve error codes. 9 RED FLASHES: Indicates reversed line voltage polarity or grounding problem. Both heating and cooling operations will be affected. Check polarity at furnace and branch. Check furnace grounding including the transformer ground. Check that flame probe is not shorted to chassis. :_ This The control in this furnace is equipped with memory that will store up to five error codes to allow a service technician to diagnose problems more easily. This memory will be retained even is power to the furnace is lost. This feature should only be used bv a aualified service technician. 8 RED FLASHES: This fault is indicated if the flame is lost 5 times (4 recycles) during the heating cycle. This could be caused by low gas pressure, dirty or faulty flame sensor or faulty gas valve. The furnace will Iock out for one hour and then restart. 02 LOCKOUT: IGNITION CONTROL (P/N 03!-0!972-000) Normal flame sense current is approximately 3.7 microamps DC (pa) Low flame signal warning starts at 1.5 microamps. Low flame signal control lockout point is 0.9 microamps DC (pa) This fault code indicates that the flame could not be (Seconds} FROM second and then enters a flame stabilization 6 RED FLASHES: This indicates that after the unit was operating, the pressure switch opened 4 times during the call for heat. If the main blower is in a "Delay on" mode it will complete it, and any subsequent delay off period. The furnace wilI Iock out for one hour and then restart. 10 RED FLASHES: gas valve wiring. RESET NOTE: If a flame is detected the control flashes the LED for !/8 of a 5 RED FLASHES: This fault is indicated if the normally closed contacts in the rollout switch opens. The rollout control is manually reset. If it has opened, check for proper combustion air, proper inducer operation, and primary heat exchanger failure or burner problem. Be sure to reset the switch after correcting the failure condition. 7 RED FLASHES: AUTOMATIC includes a "watchdog" type circuit that will reset from a lockout condition after 60 minutes. Operational faults 6,7,8 will be reset. This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction. An example would be a low incoming gas supply pressure preventing unit operation. When the gas pressure is restored, at some point the "watchdog" would restart the unit and provide heat for the house. for Heat _ Thermostat green hold it when green Sat[stied THERMOSTAT INDUCER IGNITOR MAIN VALVE OFF: I iON I HUMIDIFER OFF I ELECTRONIC AIR CLEANER OFF OFF I i CIRCU BLOWER LATIN I G _EF ........................................................................ gEE...... 60, 9o,12o, 18oSEC _gEE Se[ec_able Fan off Delay FIGURE 8: Furnace Control Event Schedule Unitary Products Group 7 167808-UUM-A-1205 SECTION II1: REPLACEMENT PARTS LIST 32 17 J 27 43 11 34 ....... 26 44 _ 56,57_ 22 5 49 42 o 36 6 19j \ 30 65 4t 33 \79 \ 10 28 9,37 45 14 8 23 Unitary Products Group 167808-UUM-A-1205 ITEM I MOTOR ITEM DESCRIPTION 1 MOTOR,DIRECT DRIVE BLOWER 2 MOTOR, NDUCER ASS Y ELECTRICAL CAPACITOR, CAPACITOR, RUN (7.5MFD/370V) RUN (10MFD/370V) DESCRIPTION 41 42 PLUG, WINDOW, CLEAR - 1.5" COMBUSTION AIR TRANSITION 43 TUBING,SILICONE 44 45 TUBING, SILICONE (Preformed) TUBING,SILICONE (Gray, .188 ID, 1.25ft. Req'd) (Gray, .188 ID,2.83 ft. Req'd) 46 GASKET, COMBUSTION BLOWER 4 5 SWITCH, LIMIT (INDUCER) LIMIT, TEMPERATURE (Primary) 47 GASKET, CONDENSATE PAN 48 GASKET,UPPER CONDENSATE PAN (2 Req'd) 6 LIMIT, FLAME ROLL-OUT 49 GASKET, GAS CONTROLS 7 CONTROL, 50 GASKET, 8* 9 FUSE IGNITER 51 GASKET, COMBUSTION AIR TRANSITION 10 11 SENSOR, FLAME SWITCH, PRESSURE 52 53 GASKET, MOUNTING BRKT (Burner Box) COMBUSTION AIR INTAKE ASSEMBLY 12 13 SWITCH, DOOR TRANSFORMER 54 55 VENT PIPE 2" X 15.25" LG. RUBBER SLEEVE 2.5" X 4" LG. 56 GROMMET, MOTOR (3 Req'd) 57 58 FERRULE (3 Req'd) COMBUSTION BLWR RESTRICTOR FURNACE MODULE 14 VALVE, GAS AIR MOVING 15 CONDENSING COIL 59 HOUSING, BLOWER 60 WASHER, FLAT FIBERGLASS (2 61 HANDLE, DOOR (2 Req'd) 62 63 CLAMP, HOSE (2 Req'd) HARNESS, MAIN WIRING 64 MOUNT, ! PC. MOTOR 65 66 67 ORIFICE, BURNER (Natural #45) TRAP, CONDENSATE WIRING DIAGRAM 68 45 DEG STREET ELBOW 2" SHIELD, PAN 69 DRAIN TUBE, CONDENSATE TRAP 25 26 PAN, CONDENSATE PANEL, LOWER ACCESS 70 DRAIN TUBE, COMBUSTION BLOWER 71 DRAIN TUBE, CONDENSATE PAN 27 PANEL, UPPER ACCESS 28 WRAPPER, 72 73 DRAIN TUBE, STRAIGHT 21" LG. DRAIN TUBE, RAIN GUTTER 29 CHANNEL, TOE PLATE 74 DRAIN HOSE ASSEMBLY 30 COVER, GAS CONTROL 3! PANEL, BOTTOM 75 76 LOCKNUT, CONDUIT (!/2") ADAPTER, INSERT 32 PANEL, TOP 77 BUSHING, THREADED 33 SUPPORT, BURNER 78 DRAIN TUBE, VENT PIPE 34 35 WRAPPER, CABINET BRACKET, FILTER 79 BAFFLE, BURNER BOX 36 PLATE, DIFFUSER 80 81 GROMMET, MANIFOLD VENT PIPE ASSEMBLY 37 BRACKET, IGNITER 38 BRACKET, DOOR SWITCH 82 83 DRAIN TUBE, VENT PIPE LOGO/BEZEL PLATE ASSEMBLY 39 BRACKET, DOOR 84 FILTER (20 X 14 X .75) (2 Req'd) 16 WHEEL, BLOWER FABRICATED PARTS 17 PANEL, BLOWER COVER 18 BRACKET, CONDENSATE TRAP 19 20 BURNER, MAIN GAS COIL, CONDENSING 21 SHELF, BLOWER 22 HEAT EXCHANGER 23 MANIFOLD, 24 ASS'Y GAS BURNER BOX Req'd) 40 BOTTOM PANEL, BURNER BOX MISCELLANEOUS NOTE: *Not Shown Major components Unitary Products Group and suggested stocking items are shown with shaded item number 9 167808-UUM-A-1205 FIELD MODEL NO. 1NP0347 1CT0302 1CT0303 1PS0904 1PS0901 1PS0902 1PS0903 1NK0301 1HT0901 1CB0314 1CB0317 1CB0321 1CB0324 1TK0914 1TK0917 1TK0921 1TK0924 1VK0901 1BR0!14 1BR0214 1BR0!17 1BR0217 1BR012! 1BR0221 1BR0124 1BR0224 REPLACEMENT INSTALLED ACCESSORIES - NON-ELECTRICAL DESCRIPTION USED PROPANE (LP) CONVERSION CONCENTRIC INTAKENENT CONCENTRIC INTAKE/VENT WITH ALL MODELS KIT 2" ALL MODELS EXCEPT 120 MBH 3" ALL MODELS SWITCH KIT 60/100/120 40 HIGH ALTITUDE PRESSURE (Does Not Include Orifices) 80/1200 80/1600 CONDENSATE NEUTRALIZER KIT SIDEWALL VENT TERMINATION ALL MODELS KIT ALL MODELS 14-1/2" CABINET COMBUSTIBLE 17-1/2" CABINET FLOOR BASE 21" CABINET 24 !/2" CABINET 14-1/2" CABINET COIL TRANSITION 17-1/2" CABINET KIT 21" CABINET 24 112" CABINET 3-WAY TRANSITION KIT All MODELS BOTTOM RETURN FILTER KIT 1" FILTER BOTTOM 14-1/2" CABINETS RETURN FILTER KIT 1-4" FILTER !4-1/2" CABINETS BOTTOM RETURN FILTER KIT 1" FILTER BOTTOM 17-1/2" CABINETS RETURN FILTER KIT 1-4" FILTER !7-1/2" CABINETS BOTTOM RETURN FILTER KIT 1" FILTER BOTTOM 21" CABINETS RETURN FILTER KIT 1-4" FILTER 21" CABINETS BOTTOM RETURN FILTER KIT 1" FILTER BOTTOM 24-1/2" CABINETS RETURN FILTER KIT 1-4" FILTER 24-1/2" CABINETS PART CONTACT INFORMATION This is a generic parts list. To request a complete parts list, refer to the contact information • Visit our website at www.sourcelparts.com below: for the following information: 1. Search for a part or browse the catalog. 2. Find a dealer or distributor. 3. Customer Service contact information. a. Click on the "Brand Links" button b. Click on the "Customer Service" button • You can contact us by mail. Just send a written request to: York International Consumer Relations 5006 York Drive Norman, OK 73069 10 Unitary Products Group 167808-UUM-A-1205 SECTION IV: WIRING DIAGRAM i z_, w _- B 8 W < w 8_ 8 c_ FIGURE 9: Wiring Diagram Unitary Products Group 11 L imited Warranty UPG warrants this product to be free from defects in factory workmanship and material under normal use and service and will, at its option, This warranty UPG warrants the primary heat exchangers its option, repair or furnish a replacement workmanship and material under normal use and service and will at that meets the intended fit, use and function of the original heat in the product to be free from defects in factory heat exchanger, either new or reconditioned, covers only the equipment repair or replace any parts that prove to have such defects according to the terms outlined on this warranty. Model Number and Serial Number listed on the Warranty Registration Card. described by the Product exchanger for any heat exchanger furnished by UPG which proves to have such defects within the duration of warranty coverage. Alternatively, U PG may, at its option, extend a replacement allowance to be applied toward the purchase of a new furnace or packaged unit marketed by UPG. The exact amount of the allowance will be determined at the discretion of UPG, based upon current market conditions, but in no case shall this allowance exceed thirty (30) percent of the original consumer purchase price of the furnace, excluding such items as ductwork, wiring, piping and installation costs. UPG shall have no responsibility hereunder for installation, shipping, handling or other charges except as specifically provided herein. For your benefit and protection, return the Warranty Registration Card to UPG promptly after installation. contact UPG. you, should it become This warranty extends UPG recommendations necessary. In the absence only to the original and specifications, original installation. The warranty side of this warranty of a recorded Registration Card, This wil! initiate the warranty parts provided TYPE hereunder Residential shall not extend beyond GY9 / GM9 recommends regular periodic preventative maintenance the warranty applies only to products This warranty does not cover any: from installed in the United period stated on the reverse PARTS 10 5 20 10 5 on this equipment. to of Applications The person most familiar with the equipment a UPG dealer. The UPG dealer can ensure your maintenance program meets the conditions of the "UPG Warranty", maximize and service your unit within the mandated guidelines with regard to unlawful discharge of refrigerants into the atmosphere. This warranty and allow us to Lifetime GF9 UPG strongly period upon product shipment HEAT EXCHANGER Applications Non-Residential Original Owner 90% the warranty period wil! begin consumer purchaser and is non-transferable. For this warranty to apply, the product must be installed according and in accordance with all local, state, and national codes; and the product must not be removed from its place period for repair or replacement FURNACE Warranty in your HVAC system is the efficiency of the equipment, States and Canada. EXCLUSIONS 1. 2. Shipping, Damages labor or material charges. resulting from transportation, 3. Damages resulting from accident, serve to void this warranty). 4. 5. Damages Damages 6. 7. Cleaning or replacement of filters. Damages resulting from failure to properly 8. Damages resulting from: (I) freezing of condenser water or condensate; or restriction of the water circuit by foreign material or like causes. 9. Damages 10. 1I. Damages resulting from use of components Increase in fuel or electric cost. resulting resulting resulting THIS WARRANTY ITY AND FITNESS from from installation, or servicing. abuse, fire, flood, alteration, use of the product in a corrosive atmosphere. inadequacy or interruption of electrical service from operation and regularly with inadequate SOME STATES DO NOT ALLOW SOME STATES ALLOW WARRANTY. WARRANTY clean air and/or water supply of air or water. not approved THE DISCLAIMER ONLY A PARTIAL by UPG (vent dampers, WARRANTY, ON IMPLIED IN SUCH STATES, THE DURATION ON THE FACE HEREOF. INCLUDING TO LIMIT THE OF IMPLIED conditions, the product blown fuses, or other serial number will like damages. water supply; (Ill) use of corrosive water; (IV) fouling etc.). SO THAT THE ABOVE WARRANTIES or removing and evaporator. or interrupted OR IMPLIED, defacing voltage side of condenser (ll) inadequate EXPRESSED OF IMPLIED LIMITATION altering, or fuel supply, improper or accessories IS IN LIEU OF ALL OTHER WARRANTIES, FOR A PARTICULAR PURPOSE. TION OF THE EXPRESS TION OF THE EXPRESS or acts of God (tampering, THE IMPLIED DISCLAIMER DURATION WARRANTIES WARRANTIES MAY NOT APPLY OF IMPLIED IS HEREBY OF MERCHANTABIL- TO YOU. WARRANTIES EXPRESSLY LIMITED TO THE DURATO THE DURA- IN NO EVENT, WHETHER AS A RESULT OF BREACH OF WARRANTY OR CONTRACT, TORT (INCLUDING NEGLIGENCE) STRICT LIABILITY OR OTHERWISE, SHALL UPG BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF USE OF THE EQUIPMENT OR ASSOCIATED TRICITY. THE ABOVE LIMITATIONS CONSEQUENTIAL DAMAGES EQUIPMENT, LOST REVENUES OR PROFITS, COST OF SUBSTITUTE EQUIPMENT SHALL INURE TO THE BENEFIT OF UPG'S SUPPLIERS AND SUBCONTRACTORS. SHALL NOT APPLY TO INJURIES TO PERSONS IN THE CASE OF CONSUMER SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL LIABILITY IN TORT, SO THAT THE ABOVE EXCLUSIONS AND LIMITATIONS MAY NOT APPLY TO YOU. UPG DOES NOT ASSUME, THIS WARRANTY GIVES For Owner's Information: OR AUTHORIZE YOU SPECIFIC PRODUCT MODEL. NO. UNIT SERIAL NO. ANY OTHER LEGAL RIGHTS. PERSON TO ASSUME YOU MAY ALSO INSTALLATION INSTALLING FOR UPG, ANY OTHER HAVE OTHER GOODS. OR INCIDENTAL LIABILITY WHICH DAMAGES, OR FOR STRICT FOR THE SALE OF THIS VARY FROM PRODUCT. STATE TO STATE. DATE DEALER Subject to change without notice. Printed in U.S.A. Copyright t-: by Unitary Products Group 2005. All rights reserved. Unitary Products Group RIGHTS OR COST OF FUEL OR ELECTHE ABOVE LIMITATION ON 167808-UUM-A-!205 Supersedes: 127236-UUM-A-0605 5005 York Drive Norman OK 73069
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