USER`S INFORMATION, MAINTENANCE AND SERVICE MANUAL
Contents
1. USER S INFORMATION MAINTENANCE AND SERVICE MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES MODELS PV9 DH FC9V DH FL9V DH Two Stage Variable Speed Downflow Horizontal zs ND a 000 cs Ye ISO 9001 Certified Quality Management System TABLE OF CONTENTS CONTACT INFORMATION 1 Burner Removal Cleaning 5 USER S INFORMATION 1 Cleaning the Heat Exchanger 5 SAFETY 1 Cleaning the Secondary Heat Exchanger 5 INSTRUCTIONS FOR EXAMINING THE Cleaning the Vent Air Intake System 5 FURNACE INSTALLATION 2 SEQUENCE OF OPERATION 5 HOW YOUR GAS FURNACE WORKS 3 CONTROL BOARD 6 START UP AND SHUTDOWN INSTRUCTIONS 3 HEATING AIRFLOW 6 Read the Instructions Below Before Trying to Start the Furnace 3 ADJUSTMENT OF FAN CONTROL SETTINGS 6 Operating Instructions 3 Heating Indoor Fan Off 6 To Turn Off the Appliance2. flashes equals a number 6 fault code All flash code sequences are broken by a 2 sec ond off period SLOW GREEN FLASH Normal operation SLOW AMBER FLASH Normal operation with call for heat RAPID RED FLASH Twinning error incorrect 24V phasing Check twinning wiring RAPID AMBER FLASH Flame sense current is below 1 5 microamps Check and clean flame sensor Check for proper gas flow 4 AMBER FLASHES The control board is recieving a Y signal from the thermostat without a G signal indicating improper thermostat wir ing 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 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 bro ken pressure switch hose or faulty pressure switch 4 RED FLASHES This indicates that a primary or auxiliary limit switch has opened its normally closed contacts With this fault code the
3. 9NINIM AYOLOVS XMVdIDINAW 13 XnV201 3002 2 VAOV UNAWYOASNVYL LI VAOP YAWYOISNVYL LI 00 13 232 N3IQVNV2 2313 3002 8 AS i 134 NOISS343d 30 YNILVLNWWOD NG NOIIVSN3ONOO 30 LINGOYd dIE VIVSN3QNOD HOLIMS 3uhSS3Hd dIE nO 13 N32 1VNOILVN 2313 3009 V FNO 3S Y3ILNVHD N3 39 113 LNOL 1 NOISS38d 30 YNFLVLNWWOD NG 3971 3W31X03g jovis QNO93S HOLIAS JYNSSIYd 412 310N RN qq NOISS3 d 30 YNFLVLNWWOD NG JOVLS H3IW3Hd 411 OV 1S L5413 H2LIMS JYNSSJYd 41 am JHONY9 3102 1N34310ON 30 YNFLVINWWOD 2509 301 1331 HOLIMS LNO 1104 ZSO Q3123108d A1IN3H3HNI SHOLON 9 TUE 11040 3102 IN3W31n0N 30 YNALVLNWNOD 15089 3QIS 1H913 HOLIMS LNO 1108 ISO 53119415 H3MOd 11V S123NNOOSIQ 3Q0lAONd S y2v18 419 E EN Bois m HOLIMS LIWIT 83ODQON 251 Q30NhONO A1N3dONd 38 1 SLNANOdWOD IN3W3OV1d3N 11 P HOLIMS LIWII AYYWIYd 181 39115 Nd 4031002 3680 16002 2 35 3 AINO SYOLONGNOD HU3ddO2 JIGVLINS SYOLOINNOD NOILINSI G 310H1NOO 30 FLLINOVId v1 UNS 14 91 V 3120V14323J 13 3SlUd 65 64 duvod 3681805 3avMdAd NO I34OOS v 8nd Kid 9 58 64 3153133005 v1 30 Nn310N 31 YNOd Sld S V 310V1d303H 13 ASIYd 85 84 4 COSOI dale 1SV31 LV 40 ONILVY 3uf llvu3dN3l C D TALM A O A O Ge ae seu YOLOW Ju3MO 18 NO 137905 Y ONId Nid S 85 84 V ONIAVH lVI831VW ONIYIM HLIM Q3ov1d3H 38 ISDN LI 030V1d3U A I 3 YOLOW Y3MO1G WJ YIMOTG NO 137205 9
4. 3 Continuous Blower Operation 7 FURNACE USER MAINTENANCE 4 Delay Tap Selection 7 Blower Care 4 Humidistat 7 Air FINES e dece tore was wa ote 4 Hot Surface Ignition System 7 Removing Filters 4 TROUBLESHOOTING ebay queen pe cee 7 Motor Lubrication 4 FURNACE CONTROL DIAGNOSTICS 8 SERVICE AND MAINTENANCE MANUAL 5 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL 8 SAFETY SECTION 5 REPLACEMENT PARTS LIST 9 FURNACE MAINTENANCE SECTION 5 WIRING DIAGRAM 12 FURNACE CLEANING SECTION 5 LIMITED WARRANTY IRI RH eee 16 CONTACT INFORMATION Go to website at www york com click on contact then click on contact form and follow the instructions Contact us by mail York International Consumer Relations 5005 York Drive Norman OK 73069 The manufacturer recommends that the user read all sec SECTION I USER S INFORMATION tions of this manual and keep the manual for future refer
5. nize an adjustment The fixed blower on delay and adjustable blower off delay will function as described in the OPERATION AND MAINTE NANCE Section in the Users Information Manual ADJ USTMENT OF FAN CONTROL SETTINGS Heating Indoor Fan Off Delay Changing the blower delay jumper on the Furnace Control Board can change the indoor fan OFF time delay Refer to Figure 7 for the jumper settings to obtain the desired fan OFF delay The blower off delay must be long enough to adequately cool the furnace but not so long that cold air is blown into the living space The blower on delay is fixed at 30 seconds and cannot be adjusted Unitary Products Group 271042 UUM A 0407 CONTINUOUS Leal FAN SPEED DELAY HI HEAT BLOWER DEHUMIDISTAT JUMPER oe JUMPER JUMPER LOW VOLTAGE TERMINALS sla 1v34 009 AVTO 3 8 v 3 8 v VX WHO O O 8 rav DO OO DD OO FIGURE 7 Furnace Control Board Continuous Blower Operation The blower will run continuously whenever the wall thermostat fan switch is in the ON position The furnace blower will run at the speed selected on the FAN SPEED jumpers on the main control board HI COOL LO COOL HI HEAT or LO HEAT When the jumper is in the VS G position the blower will run at 50 of the high cool speed Delay Tap Selection The set of jumper pins on the control board labelled DELAY are used to set the delay profiles for the f
6. 3 Damages resulting from accident abuse fire flood alteration or acts of God tampering altering defacing or removing the product serial number will serve to void this warranty Damages resulting from use of the product in a corrosive atmosphere Damages resulting from inadequacy or interruption of electrical service or fuel supply improper voltage conditions blown fuses or other like damages Cleaning or replacement of filters Damages resulting from failure to properly and regularly clean air and or water side of condenser and evaporator Damages resulting from 1 freezing of condenser water or condensate II inadequate or interrupted water supply III use of corrosive water IV fouling or restriction of the water circuit by foreign material or like causes 9 Damages resulting from operation with inadequate supply of air or water 10 Damages resulting from use of components or accessories not approved by UPG vent dampers etc 11 Increase in fuel or electric cost THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABIL ITY AND FITNESS FOR A PARTICULAR PURPOSE SOME STATES DO NOT ALLOW THE DISCLAIMER OF IMPLIED WARRANTY SO THAT THE ABOVE DISCLAIMER MAY NOT APPLY TO YOU SOME STATES ALLOW ONLY A PARTIAL LIMITATION ON IMPLIED WARRANTIES TO LIMIT THE DURATION OF IMPLIED WARRANTIES TO THE DURA TION OF THE EXPRESS WARRANTY IN SUCH STATES THE DURATION OF IMPLIED WARRANTI
7. ISON 51 dll 19 Sv8 MO vS vd TET Mix __ 51 NYO F ma CNET w 0 Q anion i ae G L Wie LJ m 0 3S1 VN300J Uf031V21 3I O1WRHO 30 31081NOO2 8313IgIunH ES d _ 1081N02 32vNun4 40NVHD 39 uns F LHM 2 30 _NOILINSD SEG B JAWA SV9 3 381113 u311N9 32V38nS LOH THAT 3 con 321AN3S 31 O3AV HU30320Nd ININ OYASII mm TH SYNIL NOFSIA S31 Z3HADO Na z N 3N11 VASI I waa Ud O N 318HOd 30 un31V1nNNO2 LINN SIHL ONIDIAYAS 103N LHM MS O N 8000 380338 SI23NNOOSIQ 11 N3dO NOLLI VD 3183134008 0002 0091 30 310 I 310N 09 1 11 NOILVLNIWI TV ZA 310N 33S 09 1 GI1 AlddNS u3MOd 318VIHVA JSSJLIA V 13 SAVE 31 gVd JATILNAA 539715 Z V JSIYNYNOJ 06 IN3W31VWHON O N 3184 30 YNFLVINWWOD d HOLIMS 38000 NS 0 N 1N3W3Q8O02V8 30 3WAV39V10 XOVNUOM dAAdS WISVPIIVA H9V LIS OA L AO LINA Od 06 38IVINJWi13 3WWVUDVIQ INVNDVIG NOLLOANNOD INVUDVIG AAAdAV I c AINO 1300W Fm Wao 0002 0091 iagram D iring W FIGURE 8 Unitary Products Group 12 271042 UUM A 0407 NOTES Unitary Products Group 13 271042 UUM A 0407 NOTES o Uniar Products Group 271042 UUM A 0407 NOTES Unitary Products Group 15 Limited Warranty UPG warrants this product to be free
8. NO USED WITH PROPANE LP CONVERSION HIGH ALTITUDE PRESSURE SWITCH KIT Does Not Include Orifices COMBUSTIBLE FLOOR BASE COIL TRANSITION KIT REPLACEMENT PART CONTACT INFORMATION This is a generic parts list To request a complete parts list refer to the contact information below e Visit our website at www source1parts com 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 5005 York Drive Norman OK 73069 Unitary Products Group UM 271042 UUM A 0407 WIRING DIAGRAM SECTION IV LOIO V GMN O OILe 39NYUO NOLIVIN3WI1V 1 YNOd 312 10 S31 Z3SSINUNOS G 34431 N3 351 N3I8 3813 1100 LN3WFDVIdW9Y 30 FLNVSOdWOD 31001 f 119504 dud 3UAI02 30 114 YNOd S31138VW S30 1N3W31n3S FR J NYSSINd 30 2 35 NG YNALVWHOASNVYL dd YINYOJSNYYL YOLIV4 H3MOd dd 709 601 dalee SNION 0 NANYA mE s3univHu3dW3l 30 V 831SIS38 LNVANOd XNYIYILYW 23AV 3813 1 n ee NE 391A30 9NINIM 071313 1100 1 1001 N3 nO 3 UlVd 32V7dW3H 3813 1100 397113 JT IS Z DER mi OR 321A30
9. 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 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 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 will lock out for one hour and then restart 7 RED FLASHES This fault code indicates that the flame could not be established This no light condition occurred 3 times 2 retries during the call for heat before locking out Low gas pressure faulty gas valve faulty hot surface ignitor or burner problem may cause this The furnace will lock out for one hour and then restart 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 or faulty gas valve The furnace will lock out for one hour and then restart 9 RED FLASHES Indicates reversed line voltage polarity or grounding proble
10. intake system as specified in the Combustion Air and Vent System located in the Installation Manual SEQUENCE OF OPERATION The following describes the sequence of operation of the furnace Refer to Figure 1 for component location 1 Call for 1st stage only On a call for 1st stage heat the thermostat closes a circuit between R and W1 The Microprocessor in the Furnace Control runs a Self Check The Control checks the Primary Limit Auxiliary Limit and Roll out Switches for closed contacts The Control checks that the Low Fire Pressure Switch 1LP is open The Inducer Motor is energized on high speed closing the con tacts of 1LP The Control checks that 1LP is closed The Igniter is energized for 17 seconds The Gas Valve is energized on 1st Stage Low Fire Flame Rectification is recognized within 7 seconds The Inducer is switched to low speed 30 seconds after flame is proven the Heat Low relay is ener gized providing 120 Volts AC to the Blower Motor At the same time the EAC and Hum relays are energized pro viding 120 Volts AC to the EAC Hot and Hum terminals 271042 UUM A 0407 2 Call for 2nd Stage after 1st Stage is operating A call for 2nd Stage can be made by a 2 Stage thermostat or by the W2 delay timer on the furnace control The Inducer Motor is shifted to high speed by the control closing the contacts of 2LP The High Fire Pressure Switch The Control checks that 2LP is closed The Gas V
11. 114 91 95 94 39 1 JOVNUNS JHL HLIM 031719915 SV 3YIM lVNI918O FHL jO ANY jl Z 3dvd OS v1 UNS NY Sid Y 312V1d3238 13 35189 65 84 JAYA swa NO LAOS DNA Mid SS Sd S 3009 ALI X 19303 OM NOILONGNI G YN3LOW Sld V 312V143938 13 35199 vS vd 1 YFONGNI NO 137205 9 14 Nid FS rd WO QNV 232 3002 2313 NVIQVNVO 8 _ JONVHD JOV4YNS 30 NOILINOSI Q Sid Z V 312V1d3238 13 3SlHd 4 NOLINOI 3Ovi4uns OH NO L3N20S Ond Nid Z eS ee uO QNv 23N 3002 23713 TVNOIIVN V N3d ONIUIM 01314 11 1 LVLSONN3HL MOON i e NOILINO Q 310 LNOD 30 31L3NOWId YI UNS Sid S V 310V1d3238 13 35189 ZS Zd 10NINO2 JJYNYNA NO 137208 9NId Nid 25 24 SrLLON mm ONI1VJH JOYIS 2 NOILINO9I Q 310H1NOO 30 3113n0v1d UNS 14 ZI V 312V143234 13 3SlUd 15 14 quvom 1ONINOO 33vNand NO 133908 9014 Nid 2 IS ld JONVHD JOV4YNS 30 NOILINO NOI YJLIN9I 32vJ3NDS LOH NOI ZY9 30 3dVdNOS AD JAIWA SV9 AD S108 1NO2 NOLONOPSIG 30 YNFLVINWWOD 80 HOLIMS 123NNO2S Q SQ YINOILIGNOD HIV OL 980 6 p18 1 x18 con SPI 10N 391 GNHDWI NH8 11 we 318 CAF aay 20 09 r 34H31 N3 3A1VA SV9 Na 39V1S ONZ 1HM 0 LHM S 38H31 N3 k c nes nig JIVSN3GNOD 39 18 181 CGI 4WWV14 Y F 418 734 91 wig 8 99 9d wr 30 513142 QTO QIQ oo Nag YOSNIS 3WY1j 85 84 OO NUD 43019 C we oo 03H D 3183143nOS YNILON
12. 3 Remove burner access panel 4 Move gas control switch to the OFF position 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 Figure 5 HIGH STAGE REGULATOR AD TMENT OUTLET O PN QE t THRO PRESSURE iL VENT PORT 2 i d 2 OUTLET 4 PRESSURE _ __ PORT LOW STAGE REGULATOR ADJUSTMENT ON OFF SWITCH FIGURE 4 Gas Valve EXTERNAL MANUAL SHUTOFF VALVE N 2 i GROUNDED JOINT UNION MAY BE INSTALLED INSIDE OR OUTSIDE UNIT MANUAL SHUT OFF a VALVE LEG GAS BURNERS GAS VALVE MANUAL SHUT OFF 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 271042 UUM A 0407 FURNACE USER MAINTENANCE 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
13. 5 microamps Low flame signal control lockout point is 0 1 microamps DC ua DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL 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 if power to the furnace is lost This feature should only be used by a qualified service tech nician 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 will 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 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 will resume the normal slow green flash after a five second pause To repeat the series of error codes push the button again If there are no error codes in memory the LED will flash two green flashes To clear the memory push the LAST ERROR button and hold it for more than five seconds The LED will flash three green flashe
14. ES IS HEREBY EXPRESSLY LIMITED TO THE DURA TION OF THE EXPRESS WARRANTY ON THE FACE HEREOF IN NO EVENT WHETHER AS A RESULT OF BREACH OF WARRANTY OR CONTRACT TORT INCLUDING NEGLIGENCE STRICT LIABILITY OR OTH ERWISE SHALL UPG BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OF THE EQUIPMENT OR ASSOCIATED EQUIPMENT LOST REVENUES OR PROFITS COST OF SUBSTITUTE EQUIPMENT OR COST OF FUEL OR ELEC TRICITY THE ABOVE LIMITATIONS SHALL INURE TO THE BENEFIT OF UPG S SUPPLIERS AND SUBCONTRACTORS THE ABOVE LIMITATION ON CONSEQUENTIAL DAMAGES SHALL NOT APPLY TO INJURIES TO PERSONS IN THE CASE OF CONSUMER GOODS SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES OR FOR STRICT LIABILITY IN TORT SO THAT THE ABOVE EXCLUSIONS AND LIMITATIONS MAY NOT APPLY TO YOU UPG DOES NOT ASSUME OR AUTHORIZE ANY OTHER PERSON TO ASSUME FOR UPG ANY OTHER LIABILITY FOR THE SALE OF THIS PRODUCT THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE For Owner s Information oS Oe PRODUCT MODEL NO INSTALLATION DATE UNIT SERIAL NO INSTALLING DEALER Subject to change without notice Printed in U S A 271042 UUM A 0407 Copyright by York International Corp 2007 All rights reserved Supersedes 167812 UUM B 0706 Unitary 5005 Norman Products York OK Group Drive 73069
15. alve is energized on 2nd Stage High Fire The Control simultaneously de energizes the Heat Low relay and energizes the Heat High relay providing 120 Volts AC to a different speed of the Blower Motor 2nd Stage is satisfied 1st Stage still calling If a Single Stage Thermostat is used the Furnace will stay on High Fire until the thermostat is satisfied When the circuit between R and W2 is opened the Control switches the Inducer Motor to low speed causing the contacts of 2LP to open When 2LP opens 2nd Stage of the Gas Valve is de energized 30 seconds later the Control switches the Blower from Heat High to Heat Low 4 1st Stage Satisfied The Thermostat opens the circuit between R and W1 Immediately the Gas Valve is de energized and Flame Rectifica tion is lost The Inducer Motor is de energized after a 15 second Post Purge and the Hum terminal is de energized The Fan Off Delay circuit is initiated The Delay time can be field set at 60 90 120 or 180 seconds It comes from the fac tory set at 60 seconds The Heat Low terminal is de energized stopping the Blower and the EAC terminal is de energized 5 1st and 2nd Stage called simultaneously The 1st stage call is processed as described in paragraph 1 above e Once Flame Rectification is established 2nd Stage is entered immediately as described in paragraph 2 above 6 stand 2nd Stage satisfied simultaneously Both stages of the Gas Valve are de energized Flame Recti
16. assem bly of components containing flue or vent gases is required a qualified service agency must perform the service FURNACE CLEANING SECTION NOTE The cleaning operations listed below must be performed only by a qualified service agency e Burner Removal Cleaning The main burners should be checked periodically for dirt accumulation If cleaning is required follow this procedure 1 Turn off the electrical power to the unit 2 Turn off the gas supply at the external manual shut off valve and loosen the ground union joint 3 Remove the burner door and remove the burner box cover 4 Disconnect wires from flame sensor rollout switch and HSI 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 6 Remove burners from the burner assembly 7 Burners may be cleaned by rinsing in hot water 8 M HReassemble the burners in the reverse order Cleaning the Heat Exchanger 1 Turn off the electrical power to the unit 2 Turn off the gas supply at the external manual shut off valve and loosen the ground union joint 3 Remove the burner door and remove the burner box cover 4 Disconnect wires from flame sensor rollout switch and HSI igniter Remove igniter carefully as it is easily broken Unitary Products Group 2 1042 UUM A 0407 5 Remove the screws that hold the burner box assembly to the vest panel and
17. conds and any ramp down to a lower speed or off will take 60 seconds Tap D is the normal profile best suited for most of the country where neither excessive humidity nor extremely dry conditions are the norm On a call for cooling the motor will ramp up to 63 of full capacity and will stay there for 90 seconds then will ramp up to full capacity At the end of the cooling cycle the motor will ramp down to 639 of full capac ity and will stay there for 30 seconds then will ramp down to zero In every case it will take the motor 15 seconds to ramp from one speed to another Unitary Products Group OFF DELAY JUMPER COOLING PROFILE JUMPER BLOWER SPEED JUMPERS Humidistat When a humidistat is installed in the system the Humidistat Installed jumper on the CFM board should be moved to the YES position The cooling CFM will then be reduced by 15 whenever the humidistat indi cates high humidity Hot Surface Ignition System 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 TROUBLESHOOTING The following visual checks should be made before troubleshooting 1 Check to see that the power to the furnace and the ignition control module is ON 2 The manual shut off valve
18. e retaining screws if provided 3 Make sure the door is secure to the end of the filter rack 4 Forfilter grilles place the filter into the grilles close the grille cover and tighten the retaining screw Every time the filters are changed the following items should be visually inspected 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 e Check the drain lines to make sure there are no cracks or leaks e 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 fur nace and its components must be done by a qualified service pro fessional If during the inspection of your furnace you find any of the following conditions Excessive amounts of dust and lint on components e 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 fur nace and set thermostat to the desired temperature Motor Lubrication The motors i
19. 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 vac uum 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 pushing it up against a spring or 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 flange blower door switch and bottom flange will also have to be removed on some models On some other models top and bot tom angles will have to be removed to slide the blower out of the fur A WARNING Make sure you DO NOT move the clip on weight on the indoor fan wheel when cleaning the wheel This weight is used to ba
20. ence SAFETY 1 The furnace area must be kept clear and free of combustible mate rials gasoline and other flammable vapors and liquids A WARNING 2 Insulating materials may be combustible The furnace must be FIRE OR EXPLOSION HAZARD Failure to follow kept free and clear of insulating materials The furnace area must a be examined when installed in an attic or other insulated space or safety warnings exactly could result in serious injury when insulation is added to be sure that the insulation material has death or property damage been kept away from the furnace Do not store or use gasoline or other flammable 3 The furnace needs air for combustion in order to operate properly vapors and liquids in the vicinity of this or any and safely Do not block or obstruct air openings on the furnace other appliance air openings to the area where the furnace is installed or spaces WHAT TO DO IF YOU SMELL GAS around the furnace Donottry to light any appliance 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 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 5 Sho
21. fication is lost The Inducer and Hum relays are de energized after a 15 second post purge 30 seconds later the Control shifts the Blower from Heat High to Heat Low After the Blower Off Delay Circuit is satisfied the Blower and EAC are de energized 7 Manual Fan Operation With the thermostat in the Fan On position a circuit is completed between R and G of the Control The blower motor and EAC terminal are energized by the Con trol 8 Call for Cooling e The thermostat closes two circuits R to Y and R to G Since the Outdoor Unit is connected to Y and C at the Control it is ener gized The Cool and EAC relays are energized by the Control A Blower Off Delay Timing Circuit is energized by the call on Y 9 Cooling call satisfied The thermostat opens the R to Y and R to G circuits The Outdoor Unit is de energized The 60 second Blower Off Delay timing circuit is initiated e After 60 seconds the Cool and EAC relays are de energized CONTROL BOARD Variable speed motors will adjust the motor speed in order to maintain the indoor fan CFM The control board is used to control the blower speed thus the CFM when the unit is operating in the heating or cooling modes The blower CFM for cooling can be modified by changing the jumper pin position on the taps selection marked COOL and ADJ The blower CFM for heating can be modified by changing the jumper pin position on the taps selection marked HEAT The taps selection pins
22. from defects in factory workmanship and material under normal use and service and will at its option repair or replace any parts that prove to have such defects according to the terms outlined on this warranty This warranty covers only the equipment described by the Product Model Number and Serial Number listed on the Warranty Registration Card UPG warrants the primary heat exchangers in the product to be free from defects in factory workmanship and material under normal use and service and will at its option repair or furnish a replacement heat exchanger either new or reconditioned that meets the intended fit use and function of the original heat exchanger for any heat exchanger furnished by UPG which proves to have such defects within the duration of warranty coverage Alternatively UPG 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 insta
23. ghtly and remove for service 3 Follow the instructions HOW TO CLEAN YOUR FURNACE S FIL TER 4 Reverse the procedure to reinstall filters 5 Follow the operating instructions to place appliance in operation TABLE 1 Filter Sizes Input CFM BTU H kW Cabinet m3 min Size Top Return Filter in cm 60 17 6 1200 34 B 2 14 20 36 x 51 agra 1200 4 2 14x 20 6x51 80 23 4 1600 45 2 14 x 20 36 x 51 100 29 3 2000 57 C __ 120 851 2000 57 D 14x 20 86x51 Externally Mounted Air Filters Some installations may have the air filter in a rack attached to the cas ing 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 cleanable 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 1 Slide filter into place 2 Snap the door on or place the door in position and tighten th
24. have been preset at the factory to provide the maximum CFM Air Flow Data table in the installation manual list the recommended jumper pin settings If a lesser CFM is required for a specific HVAC system the taps selec tion pins can be moved to the B C or D positions Pin A will pro vide the highest CFM and D will provide the lowest CFM The taps selection marked DELAY are used for cooling only The recommended settings for these jumper pins are listed in Delay taps selection HEATING AIRFLOW The heating airflow has been preset at the factory to provide maximum CFM If a lesser CFM is required for a specific HVAC system the JUMPER on the HEAT selection pins on the control board may be moved to tap B or D HEAT Taps Selection on the control board Pin Position A will provide the highest CFM Pin Position B and C are the medium and medium low CFM settings Pin Position D will provide the lowest CFM Refer to Air Flow Data table in the installation manual for the proper HEAT Taps Selection for the model furnace you are installing NOTE When changing jumper positions make sure that the jumper is pushed all the way on the pins If the jumper is not making good contact or is left off completely the blower will operate as if the jumper were in the A position NOTE Power to the blower must be removed for at least 4 seconds after a heat or cool tap selection change in order for the motor to recog
25. hes detergents powdered cleansers etc can cause corrosion of the heat exchangers 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 required for ventilation of the various furnace components A WARNING FIRE OR EXPLOSION HAZARD This furnace is designed and approved for use with Nat ural 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 Per sonal Injury and or Property Damage 3 EXAMINE RETURN AIR m DUCT CONNECTION INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION It is the owner s responsibility to ensure that an annual inspection of the entire heating portion of the unit is made by a qualified service agency 1 Examine the heat exchanger through a field installed access panel located on the supply air plenum Visually examine the exte rior sections of the vent combustion air piping and the vent con nectors to be sure that they are physically sound without holes or excessive corrosion 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 Examine the return air duct connections to make sure they are physically sound sealed to the furnace casing and the ducts
26. lance the wheel Moving the weight will cause the fan wheel to vibrate Air Filters The filters should be checked every 3 months On new construction check the filters every week for the first four weeks and every three 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 become clogged the heat exchangers and blower motor could overheat resulting in a potentially dangerous situation Never operate your furnace without a suitable air filter Use the following procedure to determine the filter size 1 Measure the furnace width and use that measurement to deter mine the cabinet width e 17 1 2 wide cabinet is a B cabinet A21 wide cabinet is a C cabinet A 24 1 2 wide cabinet is a D cabinet 2 After you determine the cabinet size and what return configuration you have look up the recommended filter size from Table 1 Removing Filters Some downflow furnaces have their filters located on the top of the fur nace in an external filter rack To check filters you should 1 Follow the instructions to turn off the appliance before servicing 2 Filters are installed in the return air plenum above the blower assembly An A frame assembly supports the filters Lift the filter sli
27. llation This will initiate the warranty period and allow us to contact you should it become necessary In the absence of a recorded Warranty Registration Card the warranty period will begin upon product shipment from UPG This warranty extends only to the original consumer purchaser and is non transferable For this warranty to apply the product must be installed according to UPG recommendations and specifications and in accordance with all local state and national codes and the product must not be removed from its place of original installation The warranty period for repair or replacement parts provided hereunder shall not extend beyond the warranty period stated on the reverse side of this warranty HEAT EXCHANGER FURNACE TYPE Residential Applications Non Residential PARTS Applications UPG strongly recommends regular periodic preventative maintenance on this equipment The person most familiar with the equipment in your HVAC system is a UPG dealer The UPG dealer can ensure your maintenance program meets the conditions of the UPG Warranty maximize the efficiency of the equipment and service your unit within the mandated guidelines with regard to unlawful discharge of refrigerants into the atmosphere This warranty applies only to products installed in the United States and Canada EXCLUSIONS This warranty does not cover any 1 Shipping labor or material charges 2 Damages resulting from transportation installation or servicing
28. m Both heating and cooling operations will be affected Check polarity at furnace and branch Check furnace grounding Check that flame probe is not shorted to chassis 10 RED FLASHES Gas valve energized with no call for heat Check gas valve and gas valve wiring 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 12 RED FLASHES This code indicates an open igniter circuit which could be caused by a disconnected or loose wire or by a cracked or bro ken igniter STEADY ON RED Control failure Replace control board 60 MINUTE AUTOMATIC RESET FROM LOCKOUT This control 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 pro vide heat for the house NOTE If a flame is detected the control flashes the LED for 1 8 of a second and then enters a flame stabilization period IGNITION CONTROL Normal flame sense current is approximately 3 7 microamps DC ua Low flame signal warning starts at 1
29. n posi tion 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 D Donot use this appliance if any part has been under water Imme diately 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 Instructions STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance Remove burner door Move gas control switch to the OFF position Do not force Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow in the safety information above If you don t smell gas go to next step 7 Move gas control switch to the ON position Do not force 8 Replace burner door 9 Turn on all electric power to the appliance 10 Set thermostat to the desired setting Burner will light which may take 30 60 seconds 11 After three 3 trials for ignition if the appliance will not operate fol low the instructions TO TURN OFF THE APPLIANCE and call your service technician or gas supplier m e Unitary Products Group 2 1042 UUM A 0407 To Turn Off the Appliance 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be per formed
30. n these furnaces are permanently lubricated and do not require periodic oiling Unitary Products Group SECTIONII SERVICEANDMAINTENANCE MANUAL SAFETY SECTION The following safety rules must be followed when servicing the ELECTRIC SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous operation serious injury and death or property damage Before servicing disconnect all electrical power to the fur nace When servicing controls label all wires prior to discon necting Reconnect wires correctly Verify proper operation after servicing FURNACE MAINTENANCE 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 furnace vent and combustion air intake passageways Should it be necessary to service the vent air intake system the manufac turer recommends this service be conducted by a qualified service agency The operation of this appliance requires the reassembly and resealing of the vent air intake system The furnace burners ignitor and flame sensor 4 The condensate collection and disposal system If any dis
31. remove the assembly 6 Remove the vent pipe assembly vent blower and condensate pan 7 The heat exchanger is now exposed 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 9 Replace all components in reverse order Reconnect all wiring 10 Restore electrical power and gas supply to the furnace 11 Check furnace operation A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and danger ous operation Verify proper operation after servicing Cleaning the Secondary 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 conden sate drain pan Remove the vent blower housing blower and the condensate pan 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 by following steps 9 11 under cleaning the Heat Exchanger Cleaning the Vent Air Intake System Should it be necessary to service the vent air intake system the man ufacturer recommends this service be conducted by a qualified service agency The operation of this appliance requires the reassembly and resealing of the vent air
32. s in the gas line to the furnace must be open 3 Make sure all wiring connections are secure 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 A WARNING Never bypass any safety control to allow furnace opera tion To do so will allow furnace to operate under poten tially hazardous conditions Do not try to repair controls Replace defective controls with UPG Source 1 Parts Never adjust pressure switch to allow furnace operation 271042 UUM A 0407 FURNACE CONTROL DIAGNOSTICS 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 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 10 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
33. s when the memory has been cleared then will resume the normal slow green flash after a five second pause Unitary Products Group 271042 UUM A 0407 SECTION III REPLACEMENT PARTS LIST Po Al V 5m 5 cE o o o gt 4 Unitary Products Group 9 271042 UUM A 0407 MOTOR A B ELECTRICAL 2 3 T3A FABRICATED PARTS MOUNT MOTOR COIL CONDENSING MANIFOLD GAS DOOR VEST ACCESS Upper Magnet DOOR BLOWER ACCESS Lower Magnet CHANNEL TOE PLATE PANEL TOP 28 PLATE DIFFUSER COVER GAS CONTROL WRAPPER BURNER BOX 31 BRACKET IGNITER PAN SHIELD PANEL BLOWER ACCESS BRACKET BLOWER MTG 2 Req d C NOTE Not Shown 10 Major components and suggested stocking items are shown with shaded item number ITEM aj NNNM 8 _ _ FF r MISCELLANEOUS 49 PAN CONDENSATE TUBE DRAIN CONDENSATE PAN TUBE DRAIN COMBUSTION BLWR TUBE VENT PIPE TUBE STRAIGHT DRAIN 21 TUBE RAIN GUTTER DRAIN 66 TUBE CONDENSTE TRAP DRAIN PIPE VENT ASSEMBLY 68 TRANSITION 3 WAY 45 DEG ELBOW VENT PIPE 15 25 LG BUSHING INSERT ADAPTER LOCKNUT 1 2 DOOR KNOB BLACK 4 Req d Magnet SIGHT GLASS OVAL TUBE RESTRICTOR MAGNET DOOR 4 Req d HARNESS MOTOR WIRING 16 Pin Unitary Products Group 271042 UUM A 0407 TABLE 2 Field Installed Accessories Non Electrical MODEL
34. ter minate outside the space containing the furnace 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 Examine the furnace casing for obvious signs of deterioration Examine the burner flames to make sure they are in good adjust ment Refer to the pictorial sketch shown in Figure 2 as a compari son to the actual flame Examine the furnace as outlined above in steps 1 6 before each heating season Use Figure 3 for visual reference MANIFOLD MAIN BURNER BURNER FLAME INNER FLAME CONES COMBUSTION AIR TRANSITION not shown FIGURE 2 Burner Flame Drawing BLOWER DOOR 2 REMOVE THIS PANEL D TO EXAMINE u O VENT PIPE 4 EXAMINE 1PLACE A FIELD FURNACE INSTALLED ACCESS CASING PANEL LOCATED IN THE DOWNFLOW PLENUM TO EXAMINE THE HEAT EXCHANGER 4 EXAMINE FURNACE 6 REMOVE THIS CASING O PANEL TO EXAMINE THE 9 BURNER FLAMES EXAMINE 9 CASING FOR DETERIORATION DOOR CASING FOR DETERIORATION FIGURE 3 Furnace Examination Checkpoints 2 Unitary Products Group HOW YOUR GAS FURNACE WORKS 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
35. uld 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 If you cannot reach your gas supplier call the fire 6 Do not use this furnace if any part has been under water A flood department damaged lurnace is extremely dangerous Attempts to use the fur Installation and service must be performed by a nace can result in fire or explosion A qualified service agency qualified installer service agency or the gas sup should be contacted to inspect the furnace and replace all gas plier controls control system parts electrical parts that have been wet or the furnace if deemed necessary 271042 UUM A 0407 271042 UUM A 0407 CONDENSATE BLOWER HOSE ACCESS PANEL CONTROL BOARD PFC CHOKE RAIN GUTTER INDUCER HOUSING INDUCER MOTOR CONDENSATE DRAIN HOSE TRANSFORMER PRESSURE SWITCH TUBING PRESSURE SWITCHES GAS e CONDENSATE VALVE Pu TRAP Cr S VE ces MESI m 4 D 9 a Q LIMIT ea SWITCH GAS REFERENCE HOSE BURNER BOX FIGURE 1 Component Locations 7 NEVER Store flammable materials of any kind near your fur nace Gasoline solvents and other volatile liquids should be stored only in approved containers outside your home These materials vaporize easily and are extremely dangerous NEVER Store cleaning materials near your furnace Materials such as bleac
36. urnace These can be chosen so as to maximize the comfort and sound levels for various regions of the coun try Tap A is the default profile It provides a 15 second ramp up from zero airflow to full capacity and a 15 second ramp down from full capacity back to zero airflow Whenever there is a change in airflow mode such as from low heat to high heat the motor will take 15 seconds to ramp from one speed to the other Tap B is the humid profile This profile is best suited for installations where the humidity is frequently very high during cooling season such as in the southern part of the country On a call for cooling the blower will ramp up to 50 of full capacity and will stay there for two minutes then will ramp up to 82 of full capacity and will stay there for five min utes and then will ramp up to full capacity where it will stay until the wall thermostat is satisfied In every case it will take the motor 15 sec onds to ramp from one speed to another Tap C is the dry profile This profile is best suited to parts of the country where excessive humidity is not generally a problem where the sum mer months are usually dry On a call for cooling the motor will ramp up to full capacity and will stay there until the thermostat is satisfied At the end of the cooling cycle the blower will ramp down to 50 of full capac ity where it will stay for 60 seconds Then it will ramp down to zero Any ramp up to a higher speed will take 30 se
37. way your furnace operates In order to get the safest and most efficient oper ation 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 dis tributes the warm air throughout the home When the temperature set ting on your thermostat is reached the gas valve closes the main burners are turned off and the blower continues to run until the remain ing warm air in the system is distributed When the blower stops the heating cycle has ended START UP AND SHUTDOWN INSTRUCTIONS Read the Instructions Below Before Trying to Start the Furnace If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury and or loss of life A 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 B 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 C Use only your hand to push the gas control switch to the o
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