York Furnace GY8S160E30UH21 User's Manual
Contents
1. Unitary Products Group 2 2442 UUM B 1211 ITEM DESCRIPTION ITEM DESCRIPTION MOTO FABRICATED PARTS 1 MOTOR BELT DRIVEN BLOWER SHIELD SECONDARY AIR MOTOR VENTOR ASS Y BAFFLE FLUE RICAL BURNER MAIN GAS CONTROL HIGH LIMIT 2 Req d BRACKET IGNITER ELEC CONTROL FURNACE FC DECK BLOWER Rear IGNITER PANEL BLOWER MOUNTING SENSOR FLAME HEAT EXCHANGER ASS Y Primary SWITCH AIR PRESSURE 11 MANIFOLD GAS SWITCH DOOR PANEL UPPER ACCESS TRANSFORMER PANEL BASE 0 CONTACTOR PANEL BLOWER ACCESS VALVE GAS PANEL TOP 35 WRAPPER REAR L 36 WRAPPER CABINET LH 13A FUSE WRAPPER CABINET RH 14 RELAY TIME DELAY CHANNEL TOE PLATE AIR MOVING PLUG WINDOW CLEAR 875 5 HOUSING BLOWER BRACKET ROLL OUT SWITCH 16 WHEEL BLOWER SHIELD HEAT CUTOFF BLOWER BEZE LOGO ASSEMBLY SHAFT BLOWER MISCELLANEOUS PULLEY FIXED Blower Wheel2. 727 3919 YNS JYIWLNAWFT1ddANS 713 37 23Qu020vu SNIYG V SIVNUVH NM 405 ASITILAN 3Uu0343Q0 1I3ND IS 8 09 1 V2 802 23AV 3NNOI12NOJ 3183143n0S 30 31 SLIOA O3AV LNVNNOILONOS JNISN 1 30 LYOS SIVW SLIOA 511 YNOd 183ANOO 3S YNFZLOW 31 L NOILd32NOO uf31 YYd 30 539 31044 LNOS SYNFLOW S31 9 J L NOILINOI Q FIOYLNOD 30 3LL9NOVId v1 sns Siv13y 530 S310viNOO NOILINSI NO SLOVLNOD AV 1y NOL IYAT UNOd SONOS S LISSINYNOI 5 EE E MEME E 321A30 ONY ONINIM 01313 38831 N3 3SIW N3I9 3813 1100 1N3W432V1dW3H 30 31NVSOdWO2 31001 y 1134YddY 13 3NISh 1 30 39Y113 321A30 ONY ONIHIM AUOLOVJ 34AI02 38 114 S3113HVW 530 1N3W3103S E 30 1N3WiQHODOVH NO 123NNOO 013153 702 601 4 122 SNIOW 1 1 WOOY NOILDINNOD Ar2 SjunivuidN3l 530 53151539 LNVANOd 23AV 3823 1 19314 30 JYESONSSHE TICCENANSOROSOVE Y vior y 1100 11 1fnOl NO 31ulVd JOVIdWaY 3813 1100 39114 31 IS 2 YNANYOISNYYL LI XMYdIDINAW 13 2 3002 2 LAOZI YNILVINWNDDV N 312VINOO Hi MIO QUAQ EL
3. USER S INFORMATION MAINTENANCE AND SERVICE MANUAL HIGH EFFICIENCY COMMERCIAL BELT DRIVE SERIES MODELS GY8S160E30UH 1 Single Stage Upflow Horizontal AR CERTIFIED www ahridirectory org Residential Furnaces DOE 10 CFR Part 430 AO 2000 REGISGR ISO 9001 Certified Quality Management System TABLE OF CONTENTS CONTACT INFORMATION 1 USER S INFORMATION 53a cR E cC n 1 DAE dU xe E tease 1 INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION 2 HOW YOUR GAS FURNACE WORKS 3 START UP AND SHUTDOWN INSTRUCTIONS 3 Read the Instructions Below Before Trying to Start the Furnace Operating Instructions 3 To Turn Off the 3 FURNACE USER MAINTENANCE 4 Se ETT IE Ett T OT 4 Removing the Air 5 4 Motor Lubrication iaces d jet 5 SERVICE AND MAINTENANCE MANUAL 5 SAFETY SECTION 2 222 lt d0chs0deeneebace 5 FURNACE MAINTENANCE SECTION 5 FURNACE CLEANING SECTION 6 Burner Removal Cleaning
4. 6 Cleaning the Heat Exchanger 6 SEQUENCE OF OPERATION 52 han nrbi eto RR cae 6 Continuous BIOWGF RE RR n RR ORE RO RR ees 6 Intermittent Blower 000 cece es 6 Heating Cycle is iua a oce coc imt bk Rode d de dr cocto OR n 6 Hot Surface Ignition System 7 TROUBLESHOOTING ERR 7 FURNACE CONTROL DIAGNOSTICS 7 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL 8 REPLACEMENT PARTS LIST 9 FIELD INSTALLED ACCESSORIES NON ELECTRICAL 10 REPLACEMENT PART CONTACT INFORMATION 10 WIRING DIAGRAM na age ED EE Sx Ex EU 11 LIMITED WARRANTY urere ma anteri EYE Sd 12 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 tions of this manual and keep the manual for future refer A WARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or prop erty damage Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GA
5. MAIN REGULATOR PRESSURE ADJUSTMENT PORT ON OFF SWITCH Shown in ON position FIGURE 4 Gas Valve White Rodgers EXTERNAL MANUAL SHUTOFF VALVE TO GAS SUPPLY GROUNDED JOINT UNION MAY BE INSTALLED INSIDE OR OUTSIDE UNIT MANUAL SHUT OFF a VALVE DRIP LEG GAS BURNERS GAS VALVE MANUAL LEG SHUT OFF VALVE FIGURE 6 Horizontal 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 2 2442 UUM B 1211 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 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 c
6. 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 Unitary Products Group 2 2442 UUM B 1211 YELLOW MED LOW RED LOW BLACK HI PARK PARK BLUE MED HI A WARNING Never bypass pressure switch 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 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
7. 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 AWARNING Make sure you DO NOT move the clip on weight on the indoor fan wheel when cleaning the wheel This weight Is used to balance the wheel Moving the weight will cause the fan wheel to vibrate 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 AWARNING 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 a
8. MOLOVANUS NI 235 N3IOYNVO 2313 3003 0 NOISS3Hd 30 YNILYLNWWOD 411 HOLIMS 35055309 41 00 13 N30 TWNOILWN 2313 3002 V NO13S N3IINVHO 39V113 LNOL I NO 1V 30 318310NIN 30 1V138 SEIN ee Hee LNVH 1N3W3nfoN 30 YNILYLNWWOD rSOU 1431 dOl HOLIMS LNO 71708 7508 S310N 110 LNVH I1N3W31nOH 30 YNALVLNWNOD 2508 LHOTY 401 HOLIMS LNO 1104 ESOX T 11088 3102 1N3N310ON 30 YNILYLNWWOD ZSO 3015 1H91H HOLIMS LNO 1104 2508 Alo E E LOANNOD AlddNS 3H1M V NISN N3HM SLINSIY 937 GIIM V dl 8 3Honvo 3102 iN3Wi7nON YNALVLNWNOD SON 3015 1431 HOLIMS LNO 1104 150 NOlSS3ud 30 3YIVITIXNY YNFLVLNWWOD ZSI HOLIMS LIWII AuvI TIXOV ZSI AlddfiS 09 1 2VA902 3Vd12NIHd 30 s 31YV1nWWOO 181 HOLIMS LINIT 161 1Y NOllVH3dO NO4 GILVY OSIY S YOLOW H3MO18 ACES 803 dormer LOU IN 234905 3 0n J Nha 2 Q3HI M AHOI2V4J SI LNG AGIT OL 31811N3ANO2 51 YOLOW W4D 000 L JOV4YNS 30 NOILINOI Q 514 Z V 312V1d323H 13 35188 ES Ed cul KALRGMOHNI JUV NOILINSI Q 31081NOO 30 FLLINOVId v1 UNS 518 P V 312V1d323H 9 35188 ZS Zd Quvo8 1OH1NOD JOVNUNS NO 137905 v ONId v eS ed NOILINDI Q 31041N02 30 3LLINOYId V1 H S 514 ZI V 310V1d323N 35184 18 14 TOYLNOD FDVNUNS NO 137205 P ONId Nid ZI 15 14 53119915 YJMOd VIV 403 SI23NNOOSIQ 30IAOHd S JONVHD 3ovJunS 30 NOILIN9I NOI u31IN9I J VAYNS LOH NOI Q30NnONO A1H3dONd 38 LSNW SIN3NOdWOO LN3W3OV1d3H
9. STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance Remove furnace door Move gas control switch to the OFF position Do not force See Figure 4 6 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above If you don t smell gas go to next step 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 oO xm em Ie Unitary Products Group 2 2442 UUM B 1211 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 OUTLET PRESSURE PORT
10. 11V 7 249 30 JdYdNOS AD 579 AD KINO SYOLINGNOD N3ddOO FIGVLINS SUOLO3NNOO NOLONOPSI1G 30 YNFLVLNWNOD SQ HOLIMS 1293NNOODSIQ 50 Q 601 3 122 15937 1Y 30 ONILVY 3unlVH3dW3l V ONIAVH 1VIN3IVA NINIM HLIM Q32v1d3H 38 LSAW LI Q32V1d3H 304393431 38 ISAW 32vNunj 3Hl HLIM 03179915 SV 3HIM 1VNIOINO 3HL 30 31 Z 0 53002 ALID YO 1v201 2 WO QNV 232 3002 2313 NVIQVNVO 8 NYD WO QNV 234 3002 2313 IYNOILYN Y H3d ONIHIM 01313 11 SALON nig AV13H N3WIL NO AW1 d no JONVUO YOSNIS JONVAO m 29 389802 ada 06 97 319819 5 183A 3ATVA SVO reer N3349 Nys JLYNYJ11Y SY9 o e NYE AN M18 18 m zs NONG an ONV 18 31 1HM GND 7 AW 15K 134 NOTTIA LOH 118 3417 39108 aay 2vA0 2 902 e b 178 OVASII OL 0318 178 2 YOLOW 3181183ANO2 3119 5 5 YOLOW YON y18 C 5 43 L QNV y2v18 5 4 10H 53101 335 a 30 31081802 cm 39V113 5165 30 3009 3oviuns LOH ES LHM wig 1081N02 3ovNun4 THM A3 TAIM LHM 418 NEUTRALS zn amp al amp RD S d P oe a ve LINN SIHL 9NIOIAN3S LNYAY Sun3aloNOfSI YA ofo NEO ous 18 380438 SLOINNODSIG 71 N3dO 2508 ESOX 1 MS O N 8004 ad NOLLNVD va vg OO INIT aie IS d 41g VAS I 1508 7508
11. INIWACYOOOVYE 30 JWWVYOVIG WVadVIC NOLLDANNOD 08 1198 _ JOLON 43018 E 9 ONY I 5310 335 7 SWVYOVIG ONINIM 07313 140 95 YOLOVLNOD m 2 2 m 20 cjxs 4 m P c 4 n b o o o o o Ei E o o m o m o o ES Z de di ANO LER ty yolon YN zi L QNV Ya dH 2 1 1 S310N 33S 09 1 0 2 802 S 11 09 1 11 09 1 0 2 802 AlddNS JYIM A1ddNS HU3MOd AlddNS u3MOd LVLSOWYSHL 1002 1V3H oro ato aio D Jii S1 251 NY 1V3H 440 lan 7 1002 ano 7908 ISON 2508 2508 KYTIN JAIWA SVO A O77 SE OW 235 Ave VAOV LI Tad ASI Lr Av138 YOLOW YOLNGA m u314101NnH M do x TR 431310INDnH ova H oa 3V3 NS YOLOWLNOD ad Ny TVH 8 1002 1V3H 1005 1 S3LON 335 N Or ISa 09 1 S11 A1ddN pi d 11 13 3AWVHO5VIQ iagram D iring W FIGURE 12 11 Unitary Products Group Limited Warranty UPG warrants this product to be free from defects in factory workmanship and material under
12. repairable Flash sequence codes 1 through 11 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 Verify that current is greater than 1 5 microamps at flame current test pad 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 2 2442 UUM B 1211 3 RED FLASHES This indicates the normally open pressure switch contact did not close af
13. s mounted externally to the cabinet on either both sides of the cabinet one side and the bottom of the cabinet or the bottom of the cabinet only DO NOT place the air filter s on the inside of the blower compartment on this furnace The air filter s must be place in the externally mounted air filter hardware Follow the instruc tions below to remove and replace the air filter s 1 Before removing the air filters follow the instructions To turn off the Appliance on page 3 2 Remove the cover on the front of the filter box by removing the retaining screw or knob that secures the cover to the box The external filter box will be located on the bottom of the furnace cab inet Refer to Figure 7 for upflow filter box locations or Figure 8 for horizontal filter box locations 3 Use your fingers to grab the outside edge of the filter and remove the filter s from the filter box 4 Ifthe filter s are permanent cleanable filter s follow the instruc tions on how to clean your filter or you may replace the throwaway filter with permanent cleanable filter s at this time Refer to Table 1 for the recommended air filter size 5 Install the filter s The filter s should fit in the entire filter track If the filter does not fit inside the entire filter track then the filter you have is the wrong size Refer to Table 1 for the recommended filter size 6 Reinstall the filter box access cover 7 Follow the Operating Instructions on pa
14. shutting off the electrical supply 6 Do not use this furnace if any part has been under water flood damaged furnace is extremely dangerous Attempts to use the fur nace can result in fire or explosion A qualified service agency 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 2442 UUM B 1211 2 2442 UUM B 1211 VENT PIPE FLUE COLLAR ELECTRICAL JUNCTION BOX INDUCED DRAFT ASSEMBLY INDUCED DRAFT MOTOR GAS VALVE LIMIT SWITCH IGNITOR MANIFOLD PIPE SAFETY SHUTOFF SWITCH CONTROL BOARD BLOWER SHAFT PRESUURE SWITCH SILICONE TUBE Am cid i SENSOR D 7 LI m MOTOR PULLEY FAN BELT FAN PULLEY BLOWER HOUSING Pri Ld E ES 4 Cle FIGURE 1 Component Locations 7 6 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 bleaches 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 t
15. O 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 Od OD OT P PRODUCT MODEL NO INSTALLATION DATE UNIT SERIAL NO INSTALLING DEALER Subject to change without notice Published in U S A 272442 UUM B 121 1 Copyright 2011 by Johnson Controls Inc All rights reserved Supersedes 272442 UUM A 0407 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069
16. ORIFICE BURNER Natural 43 SPACER PLATE RESTRICTOR BEARING BALL 2 Req d COLLAR FLUE 22 BELT BLOWER HANDLE DOOR PULLEY VARIABLE Motor GASKET RESTRICTOR PLATE SPIDER BLOWER TUBING RUBBER SPRING DOOR 2 Req d BRACKET MOUNT MOTOR DIAGRAM WIRING COLLAR SHAFT S27 KEYSTOCK 1 1 4 LG SHIELD INDUCER HARNESS MAIN WIRING s ala NOTE Not Shown Major components and suggested stocking items are shown with shaded item number FIELD INSTALLED ACCESSORIES NON ELECTRICAL MODEL NO DESCRIPTION 1NP0349 PROPANE LP CONVERSION KIT 1BR0432 FILTER FRAME KIT BOTTOM 1SR0402 FILTER FRAME KIT SIDE 1PS0301 HIGH ALTITUDE PRESSURE SWITCH 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 10 0 Uniar Products Group 2 2442 UUM B 1211 WIRING DIAGRAM SECTION IV 9001 212
17. Reassemble the burners in the reverse order Cleaning the Heat Exchanger Lower Heat Exchanger Access 1 Turn off the electrical power to the unit and turn off gas supply at the shutoff valve 2 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 wires 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 4 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 1 Perform steps 1 4 above 2 Disconnect vent piping from the vent motor assembly at the top panel on the furnace upflow only On downflow models the vent pipe is secured to the vent motor outlet with a screw Remove this screw before proceeding Unplug the ven
18. S Do not try to light any appliance Do not touch any electrical switch do not use any phone including cell phone in your building Leave the building immediately Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire depart ment Installation and service must be performed by a quali fied installer service agency or the gas supplier SECTION I USER S INFORMATION SAFETY 1 The furnace area must be kept clear and free of combustible mate rials gasoline and other flammable vapors and liquids 2 Insulating materials may be combustible The furnace must be kept free and clear of insulating materials The furnace area must be examined when installed in an attic or other insulated space or when insulation is added to be sure that the insulation material has been kept away from the furnace 3 The furnace needs air for combustion in order to operate properly and safely Do not block or obstruct air openings on the furnace air openings to the area where the furnace is installed or spaces around the furnace 4 Follow the instructions exactly as shown on the OPERATING INSTRUCTION LABEL or the Start up and Shutdown Instructions on Page 3 of this manual when lighting the furnace or turning the furnace off 5 Should the gas supply fail to shut off or if overheating occurs shut off the gas valve to the furnace before
19. at a circuit is completed between terminals R and W of the thermostat When the proper amount of combustion air is being provided the pressure switch will close the ignition control pro vides a 17 second warm up period the gas valve then opens the gas starts to flow ignition occurs and the flame sensor begins its sensing function The blower motor will energize 30 seconds after the gas valve opens if a flame is detected Normal furnace operation will continue until the thermostat circuit between R and W is opened which causes the ignition system and gas valve to de energize and the burner flames to be extinguished The vent motor will operate for 15 seconds and the blower motor will operate for the amount of time set by the fan off delay jumper located on the control board See Figure 10 The heating cycle is complete and ready for the start of the next heating cycle Unitary Products Group FAN OFF ADJUSTMENT JUMPER DOOO OOO FIGURE 10 Furnace Control Board If the flame is not detected within 7 seconds of the gas valve opening the gas valve is shut off and a retry operation begins If the flame is lost for 2 seconds during the 10 second stabilization period the gas valve is shut off and a retry operation begins During a retry operation the vent motor starts a 15 second inter purge and the igniter warm up time is extended to 27 seconds If the flame is established for more than 10 seconds after ignition during a
20. ccurs 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 15 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 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 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 1
21. ent 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 WARRANTIES IS HEREBY EXPRESSLY LIMITED T
22. furnace without a suitable air filter 1 Determine whether you have a bottom or side return air duct using the following method a If the return air filter is on the left or right side of the furnace it is a side return b Ifthe air filter is on the bottom of the furnace then you have a bottom return C If the air filters are on the bottom and the side of the furnace then you have a bottom and side return You must replace both air filters Table 1 will indicate 2 filters by using brackets with the number two 2 d Ifthe air filters are on both sides of the furnace then you have a two sided return You must replace both air filters Table 1 will indicate 2 filters by using brackets with the number two 2 2 After you determine the cabinet size and what return configuration you have look up the recommended filter size from Table 1 Removing the Air Filters A WARNING Turn off ALL electrical power to the furnace when conduct ing any service or inspection procedure Furnace may have isolated electrical supplies one providing power to the Circulating Blower 230V or 115V and another supply ing the control circuit 115V which controls the Circulat ing Blower The spring loaded safety cutoff switch mounted to the blower deck DOES NOT interrupt all electri cal potential in the blower compartment when the blower access panel is removed Externally Bottom Mounted Air Filters This furnace has the filter
23. g 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 Continuous Blower Cooling heating thermostats have a fan switch that has an ON and AUTO position In the ON position the thermostat circuit is completed between terminals R and G The motor will operate on the speed tap wire that is connected to the cooling terminal on the control board Intermittent Blower Cooling heating thermostats have a fan switch that has an ON and AUTO position In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling and termi nals R and W when there is a call for heating The integrated control will energize the delay ON timer relay which is a non adjustable fan on delay timer The delay on timer relay will energize the indoor fan motor relay after the delay ON time has expired The indoor fan motor will be turned off after the delay OFF time on the integrated control has expired The delay OFF time is adjustable by changing the jumper pin setting on the integrated control Refer to Figure 10 for the location of the fan off adjustment jumper The fan off setting is fixed at 60 seconds for SEER enhancement Heating Cycle When the thermostat switch is set on HEAT and the fan is set on AUTO and there is a call for he
24. ge 3 to place the furnace back in service FILTER RACK RETURN AIR PLATFORM FIGURE 7 Bottom Return Filter Rack XS R OOOO SSN tete Oo NE UN AN D s D 5 S X WV NO FIGURE 8 Bottom Return Filter Rack in the Horizontal Position Unitary Products Group Externally Side Mounted Air Filters 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 in How to Clean Your Filter This furnace has the filter s mounted externally to the cabinet on either both sides of the cabinet one side and the bottom of the cabinet or the bottom of the cabinet only DO NOT place the air filter s on the inside of the blower compartment on this furnace The air filter s must be placed in the externally mounted air filter hardware Follow the instructions below to remove and replace the air filter s 1 Before removing the air filters follow the instructions To Turn Off the Appliance on page 3 2 Remove the cover on the front of the filter box by removing the retaining screw or knob that secures the cover to the box The external filter box may be located on one side or both sides of the furnace cabinet Refer to Figure 9 for filter box locations 3 Use your fingers to grab the outside edge of t
25. he filter and remove the filter s from the filter box 4 Ifthe filter s are permanent cleanable filter s follow the instruc tions on how to clean your filter or you may replace the throwaway filter with permanent cleanable filter s at this time Refer to Table 1 for the recommended air filter size 5 Install the filter s The filter s should fit in the entire filter track If the filter does not fit inside the entire filter track then the filter you have is the wrong size Refer to Table 1 for the recommended filter size 6 Reinstall the filter box access cover 7 Follow the Operating Instructions on page to place the furnace back in service FIGURE 9 Side Return Filter Rack in the Horizontal Position TABLE 1 Air Filter Size Side Return Bottom End Return 16 x 25 41 x 63 5 2 16 x 29 2 41 x 74 Return air duct s may consist of either a bottom return only or a bottom return and one side return A single side return or a dual side return IS NOT ALLOWED An Accessory External Side Filter Rack and an Accessory External Bottom Filter Rack are available Refer to the accessories section at the back of these instructions for the Filter Rack part numbers Unitary Products Group 272442 UUM B 1211 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
26. he 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 5 EXAMINE ENTIRE FURNACE CASING SHOWN IN ALL DRAWINGS EXAMINE EXTERNAL VENT PIPE REMOVE PANEL TO EXAMINE BURNER FLAMES 4 EXAMINE FURNACE CASING EXAMINE RETURN AIR DUCT CONNECTION FIGURE 3 Furnace Examination Checkpoints 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 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 vent connectors and chimney to be sure they are clear and free of obstructions 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 ter minate outside the space containing the furnace Examine the f
27. lean 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 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
28. 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 dirty or faulty flame sensor 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 flow 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 Cycle power 24 VAC to the control to reset the hard lockout condition after correcting the failure condition 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 temp
29. nd 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 furnace burners igniter and flame sensor 2 2442 UUM B 1211 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 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 upper access panel 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 h
30. 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 installation This will initiate the warranty period and all
31. orary 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 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 fla
32. ow 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 this warranty HEAT EXCHANGER FURNACE TYPE Residential Applications Non Residential PARTS Original Owner Subsequent Owner Applications 0 N GY8S 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 accid
33. retry the control will clear the ignition attempt retry counter If three retries occur during a call for heat the furnace will shut down for one hour If at the end of the one hour shut down there is a call for heat the furnace will initiate a normal start cycle If the problem has not been corrected the furnace will again lockout after three retries A momentary loss of gas supply flame blowout or a faulty flame probe circuit will result in a disruption in the flame and be sensed within 1 0 seconds The gas valve will de energize and the control will begin a recycle operation A normal ignition sequence will begin after a 15 sec ond inter purge If during the five recycles the gas supply does not return or the fault condition is not corrected the ignition control will lock out for 60 minutes During burner operation a momentary loss of power for 50 milliseconds or longer will de energize the gas valve When the power is restored the gas valve will remain de energized and the ignition sequence will immediately restart Hot Surface Ignition System A WARNING 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
34. sh 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 Thermostat Calling for Heat IP Satisfied Seconds Fan on Delay 30 Seconds THERMOSTAT INDUCER IGNITOR MAIN VALVE HUMIDIFIER ELECTRONIC AIR CLEANER CIRCULATING BLOWER FIGURE 11 Furnace Control Event Schedule 60 90 120 180 SEC LOFF Selectable Fan Off Delay Unitary Products Group 2 2442 UUM B 1211 REPLACEMENT PARTS LIST SECTION III
35. t motor wires and ground wire Remove the pres sure switch tubing at the top on the vent motor housing NOTE It is recommended that replacement gaskets be available before removing vent motor 1 Remove six mounting screws that hold the vent motor to the restrictor plate The surface is gasketed and the gasket can be reused if it is 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 any vent assembly parts are damaged replace with an entire new assembly except for gaskets 2 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 3 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 4 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 Wirin
36. ter 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 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 and cycle power 24 VAC to the control after correcting the fail ure 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 dirty or faulty flame sensor faulty hot surface ignitor or burner problem
37. urnace 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 BLUE CONE PORTION OF FLAME SHOULD ENTER HEAT EXCHANGER TUBE FIGURE 2 Burner Flame Drawing L 1 EXTERNAL HEAT EXCHANGER INTERNAL VENT COMBUSTION AIR PIPE MUST REMOVE PANEL TO EXAMINE 6 REMOVE PANEL TO EXAMINE BURNER FLAMES 4 EXAMINE FURNACE CASING EXAMINE RETURN AIR DUCT CONNECTION side or bottom 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 o
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