York Thermostat FC8V*DH User's Manual
Contents
1. D c C Products Group ITEM DESCRIPTION A ELECTRICAL 2 0 3 AIR MOVING 16 HOUSING BLOWER 16 PANEL FILLER WRAP WHEEL BLOWER FABRICATED PARTS BAFFLE FLUE BURNER MAIN GAS DECK BLOWER Rear DECK FRONT HEAT EXCHANGER ASS Y Primary MANIFOLD GAS PANEL FRONT Lower Magnet E PANEL FRONT Upper Magnet PANEL TOP WRAPPER INSULATED N N N NEM EE EM L9 NOTE Not Shown 2 1015 UUM A 0407 ITEM DESCRIPTION MISCELLANEOUS L 34 ORIFICE BURNER Natural 45 HOUSING FLUE MOTOR MOUNT MAGNET DOOR Major components and suggested stocking items are shown with shaded item number _ Not applicable to specified model Unitary Products Group 11 2 1015 UUM A 0407 TABLE 2 Field Installed Accessories Non Electrical MODEL NO DESCRIPTION USED WITH 1NP0347 PROPANE LP CONVERSION KIT ALL MODELS 1PS0313 HIGH ALTITUDE PRESSURE SWITCH KIT 57 80 100 MBH Does Not Include Orifices COMBUSTIBLE FLOOR BASE FOR DOWNFLOW UNITS REPLACEMENT PART CONTACT INFORMATION This is a generic parts list To request a complete parts list refer to the contact information below Visit2. USER S INFORMATION MAINTENANCE AND SERVICE MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES MODELS PV8 DH FL8V DH FC8V DH LL8V DH LC8V DH Variable Speed Downflow Horizontal Low NOx AS 9000 REGIST ISO 9001 Certified Quality Management System TABLE OF CONTENTS CONTACT INFORMATION 1 FURNACE CLEANING SECTION 5 USER S INFORMATION 1 Burner Removal Cleaning 5 SAFETY ei ee 1 Cleaning the Heat Exchanger 5 INSTRUCTIONS FOR EXAMINING THE SEQUENCE OF OPERATION iiis mer RR ERR 5 FURNACE INSTALLATION 2 CONTROL BOARD 6 HOW YOUR GAS FURNACE WORKS 3 HEATING AIRFLOW 6 START UP AND SHUTDOWN INSTRUCTIONS 3 ADJUSTMENT OF FAN CONTROL SETTINGS 6 Read the Instructions Below Before Trying to Start the Furnace Heating Indoor Fan Off Delay isis ren 6 Operating 5 3 Continuous Blower Operation 7 To Turn Off the 3 Delay Tap Selection
3. 7 FURNACE USER MAINTENANCE 3 A ges 7 Air PANGS qM ERIAmS Iq Pu kun a 326520582 E 4 Hot Surface Ignition 7 Removing Filters _ 4 TROUBLESHOOTING rents eret Rom t 7 BOWS Cole aac sors d PR E e Edd dE ERE dns f anr t 4 FURNACE CONTROL DIAGNOSTICS 7 Motor Lubrication 4 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL 8 SERVICE AND MAINTENANCE MANUAL 4 REPLACEMENT PARTS LIST 10 SAFETY SECTION 4 WIRING DIAGRAM a 13 FURNACE MAINTENANCE SECTION 4 LIMITED WARRANTY 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 SAFETY ence 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 furnac
4. SV8 MOT LAWH HOIH dd 110 W119 1009 olny C A0 VH2 1V3H NG canaivor grainy 9 u3MO 8 O A INO S 1300W y 3183144008 Wi 0002 0091 ia 30 un310W 1 310N 8IOA 09 1 G11 NOILVIN3WI 1V sa HOLIMS Y000 310N 33 09 1 Alddf S YIMOd ERO MS O N 1Y3 NO LN3W31IVNHON O N 318ViuVA 3SS31IA V 13 uVd 331 1N3A S39V1S c V 08 3SIVNuDOJ 4AIVNUNA 5 WISVIWHVA ADV LS OML 2508 30 YNALVLNWWOD 3dlVIN3N313 3WAVHOVIG INVHDVIG WWXGGV I iagram D iring W FIGURE 8 13 Unitary Products Group 2 1015 UUM A 0407 NOTES dd o itary Products Group 2 1015 UUM A 0407 NOTES Unitary Products Group 15 Limited 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 repair or replace any parts that prove to have such defects according to the terms outlined on the reverse side of 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 excha
5. 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 A WARNING 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 on 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 Do not 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 1 STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance Remove burner access panel Move gas control switch to the OFF position D
6. 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 WARRANTIES 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 STATE
7. for gaskets Remove the perimeter screws attaching the restrictor plate assem bly to the vestibule panel The surface is also gasketed The assembly including the flue baffle plate rear may be vacuumed or cleaned with hot water if necessary The upper portion of the heat exchanger is now accessible 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 Vacuum loose scale and dirt from each tube Unitary Products Group 2 1015 UUM A 0407 Clean Replace all components in reverse order Re gasket all surfaces which required a gasket Reconnect all wiring Reattach vent pipe and gas supply lines before restoring service to furnace Restore electrical power check gas supply piping for leaks and then verify 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 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 t
8. furnace heat exchanger which could result in Fire Per FIGURE 2 Burner Flame Drawing sonal Injury and or Property Damage 3 5 EXAMINE ENTIRE EXAMINE EXTERNAL EXAMINE FURNACE CASING RETURN AIR MODE DUCT E 3 EXAMINE CONNECTION RETURN AIR DUCT CONNECTION 1 EXTERNAL HEAT A ERAMINE EXAMINE EXCHANGER 6 FURNACE INTERNAL Y REMOVE CASING VENT COMBUSTION i AIR PIPE MUST REMOVE PANEL REMOVE PANEL TO TO EXAMINE BURNER EXAMINE BURNER FLAMES FLAMES 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 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 ignitor 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
9. 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 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 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 tim
10. 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 jo Unity Products Group 2 1015 UUM A 0407 WIRING DIAGRAM SECTION IV L0I10 V QMhn Sv80 c 39v1S XN SNO 3NOSYOTI 440 NOILISOd N3 34H13 1100 Z3S1711N SNOA 3NOSYOTI IV13Q 30 31Y3LNN NOI1d39N09 438031 YVd 30 NOLIVINGWI1V 1 YNOd 3uH31 N3 3SIN N3lIG8 3813 1100 LN3W3 AYAIND 30 114 Siunivud3dWw3l 530 V 93151535 LNVAN 1100 1 LAOL N3 NO 31YLVd 32V XNVdIDINAW 13 XNVIOT S3009 9 00 13 232 N3IOVNVO 2313 3009 8 n0 13 N3O IVNOILVN 2313 3009 V NO 980 6 prvi 1 x18 coe LHM 2 NYG 11 ve 318 038 21 938 v LHM 1 LHM S Tak 00 ADS 00 9 NYS GI L 418 134 91 x18 8 85 89 g 95 94 NUD JOO C lo 318 oo 38831 N3 oo QNO 3193144008 YNFLOW vS vd 34431 N3 QNO NYS 39V 1YNS 30 NOILINO9I Y311N91 39V 14NS LOH lt ININ VOASITI LAIN OVASII V2ASII 30 3N917 INIT OVASII AINO 1300N W4D 0002 0091 30 v LVLSOWYSH
11. 30 SALIVLINOD Sli3HVddV 13 H3IINVHO 30 397113 S7113YVd dV 13 I3NISN 7 30 J9V1I4 8311NVHO2 30 1N3W304Y099VY8 32314 30 LVLSOWYFHL NG LNAWAGHODIVE Ave VAO YNAWYOISNVUL NOISS3Uud 30 YNALVLAWWOD NG 39viS 30 NOISS3Hd YNFLVINWWOD 39v1S ujIW3uUd 3791SN4 113 L 9 1N3A3103S 1N3N310O8 30 YNILVLNWWOI 1135 L 9 S 11040 LAVH 1139 G 2 381N32 LAWH 1N3W31008 30 YN3LVLNWWOI 11040 3102 LNAWFINOY 30 YNALVINWWOD 9 3100 IN3W310O8 30 YNALVLAWWOD divdioNINd 31IWI1 30 YNALVLAWWOD NOILIN91 0 30 V YAS SALLVd 91 3111 00 13 35194 314Y37144NOS 30 YNALOW 31 YAS Silivd S V ATTINOG 13 IS1Yd 314Y371411NOS YI 30 YNALOW 37 YNOd 514 91 V 3 9V1d392389 13 ASlud 3dVdNOS V1 unS 5311 4 V 3111 00 13 ASlud YNILINONIT YNALOW NV S3iivd V 3111 00 13 35194 39V1YNS 30 NOILIIN9I GO Sid V 31927143939 13 3S1Yd NOILINOSI QG FIOYLNOD 30 3113NOV7Id v YNS 514 S Y 379VLd393Y 13 JSl d NOILINO9I Q JIOYLNOD 30 3113NOV7Id YI YNS 514 21 V 312V1d323U8 13 3S1Yd JONWHD 39V1YNS 30 NOILIINOI ZV9 30 idvdnos NOLONOFSIG 30 YNALVLAWWOD 30N3931 wo d n m IOS Nue Ed LHM Et FUE 134 T 39008 038 e me ovaa 18 Canny 39V1I4 AG YNAINOD 40 3002 3131999 ATM TAIM YOSNIS 3Wv14 391 Y3S 31 DAV 032044 30 INVAV SYNFLINOFSIG 531 ZIYANO
12. L NN 23511110 V1 30 39VLNOd 31 8 S39V1S 2 V LVLSOWYSHL NN IN V 30 SIVNYVH 31 Z3 31N3 L 39 310Uud INOS SufilON S3 9 SYNALONOFSIG 531 Z3SSINHnOJ S 2V1dN389 30 JLNVSOdWOD 31001 P YNOd SALLIYWW 530 LINIWI7NIS E 702 601 4 122 SNION Od XNVIYALVW NN 23AV 3414 1 dN3H 3413 1100 39V114 3 IS e 135 YSILNVHD N3 39 113 LNOL 310N 38831 N3 Nu9 ano I gt Nug Iud ASII C O N 31u0d YNILVLAWWOD MS O N 5000 dd LNAWIGYOOOVYE 30 JWWVYOVIG WVadVIC NOLLOAUNNOD Nug LVLSOWYSHL 39V1S V 5 N3HM NOILISOd 440 NI 38 LSAW YAdWNAF YAWIL 8 LVLSOWYSHL JOVLS V 9 5 NAHM SS3NUVH YAWIL AV13Q FHL 3AOW3U Q312310Hd ATLNAYSHNI SYOLOW 53119405 11V HOJ SLOANNODSIG 3QIAOYd 9 ATYAdOUd 38 LSNW SIN3NOdWOO IN3W3OV Id3H 117 KINO SYOLONGNOD u3ddOO JIGVLINS SHOLO3NNOO 002 601 4 lee LSV41 LV 30 ONILVY JFYNLVYAdWAL V ONIAVH TWIYSLVW 9NINIM HLIM G39V1d9u 38 ISDN 11 d3ovi1diH 38 LSNW 39VNYN4 JHL HLIM 0317ddNS SV 3H8IM 1VNIOINHO JHL 40 dl e 3002 ALID YO 1V201 2 80 QNV 232 3009 9413 NVIQVNVO 8 7YO ONV 23N 3009 2313 IVNOILVN V 83d 9NTYIM 01313 717V C SALON 3 1 V1 30 31081NO2 TOYLNOD 39VNYN4 VOASII 30 3NOIT 3N17 OVASII 18 JONVSSINd 30 YNALIVA undlVWHOJSNVHI NOI1IN91 Q 31O0H1NOO 30 3113NOV71d V YNS SIV13H 5
13. NOIInv23Nd LINA 5 9NIOIAH3S 380438 S123NNOOSIQ 11v NidO TWdlONIYd NOLLNVD dd YIWYOISNVYL YOLIVI YIMOd QuVOS8 1ONINOO 39VNYN4 NO SIOVINOO AVTIIY pisces 321 30 QNV ONIMNIM 01313 321 3Q QNV ONIYIM AYOLIVG NOILO3NNOO 01314 zZ 1V1SONS3HI WOOY NOIIO3NNOO Arc EN VAO 4u3AHOJSNVUL 39V1S QNO23S HOLIMS 3YNSSIYd dll 39V1S 18913 HOLIMS 3YNSSIYd 3513 v 504 AINO 1132 L 9 9 1431 401 HOLIMS LNO 1104 1135 L G LHOIY dOL 509 1149 8 2 JIGGIW dOl HOLIMS LNO 1104 2SOu 301S LHOIY HOLIMS LNO 1104 1SOY 3415 1331 HOLIMS LNO 1104 1S1 HOLIMS LINIT 6S 6d QuvO8 TOYLNOD 39VNYN4 NO 13719205 9 ON Id Nid 91 8S 8d YOLOW YAMOT1E NO 131205 O Td Nid S 9S 9d YOLOW YO4 13208 ON 1d Nid 9 SS Sd 3AlVA NO 137205 Ofld Nid vS td YOLOW YSDNGNI LV 137205 ON Id Nid ES Ed YOLINS 39V43480S LOH LV 131205 Of ld Nid 2S 2d QuvOg 70YLN09 39VNYN4 NO 13710205 9NTId S IS Id TOYLNOD 39VNYN4 NO 139208 9 1 Nid Z N9I YOLIN9I 39V14YNS LOH JAVA SVO sa HOLIMS L23NNOOSIQ 339331 3 OND CNADAT 39V1S 3W32 39VLS QN 39V1S 31 39V1S 151 VAOV LI wo 4 agit N91 YNJLOW 12010NI Q YNILVII4101WNH WOH k O Y314101WNH 15343 381713 s X l 12313 381113 2313 381113 YOLOW 1002 z lv3H CL 3nv82 1 1V3H 0 SIV13U AV13H H3L1lN9I
14. S 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 OON or gs PRODUCT MODEL NO INSTALLATION DATE UNIT SERIAL NO INSTALLING DEALER Subject to change without notice Printed in U S A 271015 UUM A 0407 Copyright O by York International Corp 2007 All rights reserved Supersedes 167354 UUM B 0806 Unitary 5005 Norman Products York OK Group Drive 73069
15. SED U U I LOW INDUCER EN OFF m I l LOW STAGE CLOSED PRESSURE I SWITCH OPEN i I l I ON I I HSI OFF j 1 l l l 1ST STAGE ON MAIN VALVE OFF i I I 1 1 PRESENT 7 a FLAME j l ABSENT E ON d aj LOW CIRCULATOR r EN I i HEAT SPEED OPE J 1 I I I I I I HIGH LIMIT OPEN l l l W1 SIGNAL Bn x l OFF l l I l HSI l HEAT FAN BURN I WARM PURGE WARM DELAY ON I I UP 60SEC UP 30SEC I i LOW PRESSURE 17 SEC 27 SEC X 1ST STAGE SWITCH CLOSE POST I RECOGNITION 3 eiio Aic I DEACTIVATION PERIOD I IGNITION l 3 SEC SEG ON TRAITOR SEEEN or IGNITION 4 SEC 7 SEC 60 90 120 180 SEC NOTE 1 THIS DIAGRAM SHOWS TWO IGNITION ATTEMPTS 2 TIMING LENGTHS ARE NOT TO SCALE FIGURE 7 Furnace Control Event Schedule Unitary Products Group 9 2 1015 UUM A 0407 SECTION III REPLACEMENT PARTS LIST 29 IE x OCI Rx INA WEE
16. SHUTOFF VALVE TO GAS SUPPLY GROUNDED JOINT UNION MAY BE INSTALLED INSIDE OR OUTSIDE UNIT FIGURE 5 Gas Piping NOTE The spring loaded safety cut off switch mounted under the blower deck 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 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 electrical power supplies to the furnace Check all metal parts and surfaces to be sure they have cooled to room temperature before you begin 2 1015 UUM A 0407 Every time the filters are changed the following items should be visually inspected Check 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 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 Damaged or deteriorated components or surfaces Leaks or blockage in the
17. ace 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 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 the retaining screws if provided 3 Make sure the door is secure to the end of the filter rack TABLE 1 Filter Sizes Top Return in 2 14 x 20 35 6 x 50 8 Cabinet Size Top Return cm 8 35 6 x 50 8 x0 8356x508 2 35 6 x 50 8 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 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 A WARNING Make sure you DO NOT move the clip on weight on the indoor fan wheel when cleaning the wheel Thi
18. d 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 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 1596 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 Unitary Products Group 2 1015 UUM A 0407 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 valves 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 Never bypass any safety control to allow furnace opera tion To do so will allow furnac
19. e containing the furnace SENSOR I d MANIFOLD 4 Examine the furnace casing making sure the physical support is PIPE sound without sagging cracks or gaps Examine the furnace base making sure it is physically sound without cracks gaps or sagging FIGURE 1 Component Locations and has a good seal 7 NEVER Store flammable materials of any kind near your fur 5 Examine the furnace casing for obvious signs of deterioration nace Gasoline solvents and other volatile liquids should be 6 Examine the burner flames to make sure they are in good adjust stored only in approved containers outside your home These ment Refer to the pictorial sketch shown in Figure 2 as a compari materials vaporize easily and are extremely dangerous son to the actual flame 8 NEVER Store cleaning materials near your furnace Materials SNE ONE PORTO such as bleaches detergents powdered cleansers etc can ENTER HEAT EXCHANGER TUBE 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 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
20. e delay Refer to Figure 6 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 CONTINUOUS FAN SPEED JUMPER BLOWER OFF DELAY JUMPER DEHUMIDISTAT JUMPER LOW VOLTAGE TERMINALS COOLING PROFILE JUMPER 3 8 v 8 v VX WHO O XD AVO BLOWER SPEED JUMPERS FIGURE 6 Furnace Control Board 6 Unitary Products Group 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 5096 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 furnace 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
21. e must be FIRE OR EXPLOSION HAZARD Failure to follow safety kept free and clear of insulating materials The furnace area must warnings exactly could result in serious injury death or prop i examined ance su AN ANG Or oter dul erty damage when insulation is added to be sure that the insulation material has been kept away from the furnace Do not store or use gasoline or other flammable 3 vapors and liquids in the vicinity of this or any other and safely Do not block or obstruct air openings on the furnace appliance air openings to the area where the furnace is installed or spaces WHAT TO DO IF YOU SMELL GAS around the furnace 4 Follow the instructions exactly as shown on the OPERATING Do not try to light any appliance y y 9 y app INSTRUCTION LABEL or the Start up and Shutdown Instructions on Page 3 of this manual when lighting the furnace or turning the furnace off The furnace needs air for combustion in order to operate properly Do not touch any electrical switch do not use any phone including cell phone in your building Leave ie building 5 Should the gas supply fail to shut off or if overheating occurs shut Immediately call your gas supplier from a neighbor s off the gas valve to the furnace before shutting off the electrical phone Follow the gas supplier s instructions supply If you cannot reach your gas supplier call the fire depart 6 Do not use this furnace if any part has be
22. e 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 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 on 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 recievi
23. en under water A flood ment damaged furnace is extremely dangerous Attempts to use the fur Installation and service must be performed by a quali nace can result in fire or explosion A qualified service agency fied installer service agency or the gas supplier should be contacted to inspect the furnace and replace all gas controls control system parts electrical parts that have been wet or the furnace if deemed necessary 2 1015 UUM A 0407 2 1015 UUM A 0407 INSTRUCTIONS FOR EXAMINING THE FURNACE SERT PIPE bug INSTALLATION COLLAR It is the owner s responsibility to ensure that an annual inspection of the F Fr Asas entire heating portion of the unit is made by a qualified service agency CONTROL JUNCTION BOX Examine the furnace as outlined below in steps 1 6 before each heating season Use Figure 3 for visual reference 1 Examine the heat exchanger vent pipe combustion air passages zzi L N vent connectors and chimney to be sure they are clear and free of SWITCH obstructions SILICONE LA J RA 2 Examine the vent pipe making sure it is firmly in place that it TUBE INBUGE BRAS slopes slightly upward and is physically sound without holes and all of the connections are secure LIMIT 3 Examine the return air duct connections to make sure they are GAS VALVE SWITCH physically sound sealed to the furnace casing and the ducts ter FLAME _ 2 E minate outside the spac
24. everse side of this warranty HEAT EXCHANGER FURNACE TYPE Residential Applications Non Residential PARTS 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 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 11 inadequate or interrupted water supply IIl use of
25. he 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 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 Valve 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
26. ires located on top of the air shield Identify and note the location of all leads for ease of reinstallation Also discon nect the wires at the side rollout switches upflow only and the gas valve wires Remove the screws holding the burner assembly to the vestibule panel and remove this assembly Handle the assembly carefully since it contains the igniter which is fragile and easily broken The lower portion of the heat exchanger will now be exposed To clean the burner assembly use a vacuum cleaner or remove the burn ers as outlined in burner cleaning and clean in hot water Upper Heat Exchanger Access l 2 Perform steps 1 4 above Disconnect vent piping from the vent motor assembly at the top panel on the furnace upflow only On downflow models the vent pipe is attached to the vent motor outlet Remove this screw before proceeding Unplug the vent motor wires and ground wire Remove the pres sure switch tubing at the tap on the vent motor housing NOTE It is recommended that replacement gaskets be available before removing vent motor 4 Remove six mounting screws that hold the vent motor to the restrictor plate The surface is gasketed and gasket can be reused if itis carefully removed It is necessary to remove this assembly to gain access to the restrictor plate mounting holes The assembly may be vacuumed if cleaning is necessary If any vent assembly parts are damaged replace with an entire new assembly except
27. is de energized 90 seconds later the Control switches the Blower from Heat High to Heat Low 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 2 1015 UUM A 0407 5 1stand 2nd Stage called simultaneously The 1st stage call is processed as described in paragraph 1 above 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 Rectification is lost The Inducer and Hum relays are de energized after a 15 second The blower CFM for heating can be modified by changing the jumper pin position on the taps selection marked HEAT The taps selection pins 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 wil
28. l pro vide the highest CFM and D will provide the lowest CFM The taps selection marked DELAY are used for cooling only The recommended post purge settings for these jumper pins are listed in Delay taps selection later the Control shifts the Blower from Heat High to HEATING AIRFLOW 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 Heat Low and EAC relays are energized by the Control 8 Call for Cooling 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 e 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 After 60 seconds the Cool and EAC relays are de energized 10 Two stage cooling This furnace is equipped to handle a two stage AC unit The wall thermostat will energize the Y1 circuit for low cooling and the Y2 circuit for high cooling 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
29. ng 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 2 1015 UUM A 0407 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 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 primar
30. nger 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 installation 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 r
31. o not force See Figure 4 6 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 See Figure 4 8 Replace burner access panel 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 QU gt 2 Iu Unitary Products Group 2 1015 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 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 Figure 5 HIGH STAGE REGULATOR ADJUSTMENT OUTLET PRESSURE F An ew WERK NI WA PRESSURE Q PORT ON OFF SWITCH LOW STAGE REGULATOR ADJUSTMENT FIGURE 4 Gas Valve EXTERNAL MANUAL
32. res 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 flashes when the memory has been cleared then will resume the normal slow green flash after a five second pause Unitary Products Group 2 1015 UUM A 0407 ON W2 SIGNAL OFF ON HIGH INDUCER OFF HIGH STAGE PRESSURE gw I SWITCH AND 2ND STAGE MAIN VALVE OFF ON CIRCULATOR HIGH HIGH HEAT SPEED OFF l HEAT A OFF I CALL HIGH HEAT AFTER LOW 1 I HEAT IS ESTABLISHED 2ND STAGE CLO
33. s weight is used to balance the wheel Moving the weight will cause the fan wheel to vibrate Motor Lubrication The motors in these furnaces are permanently lubricated and do not require periodic oiling SECTION II SERVICE AND MAINTENANCE MANUAL SAFETY SECTION The following safety rules must be followed when servicing the A WARNING 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 disconnect ing 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 s
34. tion 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 Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 1 microamps DC pa 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 sto
35. 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 Air Filters 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 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 you must use filters that are the same size as those recommended in Table 1 use the following pro cedure to determine the filter size Never operate your furnace without a suitable air filter Removing Filters 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 Repl
36. 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 5096 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 seconds 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 6396 of full capacity and will stay there for 90 seconds then will ramp up to full capacity At the en
37. y 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 problem 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 condi
38. ystem 3 furnace burners ignitor and flame sensor Unitary Products Group FURNACE CLEANING SECTION NOTE The cleaning operations listed below must be performed only by a qualified service agency Burner Removal Cleaning The main burners should be checked periodically for dirt accumulation If cleaning is required follow this procedure 1 2 6 7 8 Turn off the electrical power to the unit Turn off the gas supply at the external manual shut off valve and loosen the ground union joint Remove the upper access panel and remove the burner box cover Disconnect wires from flame sensor rollout switch and HSI igniter Remove igniter carefully as it is easily broken Remove the screws that hold the burner box assembly to the vest panel and remove the assembly Remove burners from the burner assembly Burners may be cleaned by rinsing in hot water Reassemble the burners in the reverse order Cleaning the Heat Exchanger Lower Heat Exchanger Access 1 2 Turn off the electrical power to the unit and turn off gas supply at the shutoff valve Remove the blower and burner compartment access doors Dis connect the gas supply piping at the union to permit removal of the entire burner and gas control assembly from the vestibule panel Use the wrench boss on the gas valve when removing or installing this piping See Figure 4 Unplug the igniter from the wire harness Disconnect sensor and rollout switch w
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