York PC9 User's Manual
Contents
1. R DO CFM lo be DO INDICATOR 4 HUMIDIFIER 14 TERMINALS 1 ot 6 CFM o l DIAGNOSTIC LIGHT C EAC JUST o in BJR O lw PRES LOW VOLTAGE tyne 000000 ADJUST TERMINALS 8 o JUMPER Ole numbistar ERROR MB c CONECTED o BUTTON 550 He pem o TEST Bon BUTTON gt 0 TEST o o CONTINUOUS FAN DELAY COOLING SPEED JUMPER JUMPER SPEED JUMPER FIGURE 8 Furnace Control Board Delay Taps Selection The set of jumper pins on the control board labeled 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 30 second ramp up from zero airflow to full capacity and a 30 second ramp down from full capacity back to zero airflow Whenever there is a change in airflow mode such as from low heat to high heat the motor will take 30 seconds to ramp from one speed to the other Tap B is the humid profile This profile is best suited for installations where the humidity is frequently very high during cooling season such as in the southern part of the country On a call for cooling the blower will ramp up to 50 of full capacity and will stay there for two minutes then will ramp up to 82 of full capacity and will stay there for five min utes and then will ramp up to2. USER S INFORMATION MAINTENANCE AND SERVICE MANUAL MODELS PC9 Modulating Downflow Horizontal With ECM Motor EFFICIENCY RATING CERTIFIED ENERGY STAR TIEN j K gt 000 REGIS N ISO 9001 Certified Quality Management System TABLE OF CONTENTS CONTACT INFORMATION 0000 cece eee eee eee 1 FURNACE MAINTENANCE 2 00000 cece eee eee 5 USER S INFORMATION 2000ce cee eeceeeesecaees 1 FURNACE CLEANING coi cc ka cies crac ad 5 SAFE a al dite domes 1 Burner Removal Cleaning 000 00 cece e eee eee 5 INSTRUCTIONS FOR EXAMINING THE FURNACE Cleaning the Heat Exchanger 000000 eee eee 5 INSTALLATION cc oaa aaa LLL LL cece LLL LLL Laaa 2 Cleaning the Secondary Heat Exchanger 5 HOW YOUR GAS FURNACE WORKS 2 ceccecceee 3 Cleaning the Vent Air Intake System 0000 5 START UP AND SHUTDOWN INSTRUCTIONS 3 NORMAL OPERATION SEQUENCE 00 0000s 5 Read the Instructions Below Before Trying to Start the ADJUSTMENT OF FAN CONTROL SETTINGS 5 6 Furat a ar fort cdo na eh ne ah at ete oie ae ama ae 3 Delay Taps Selection aia a aba 6 Operating Instructions 00 0 0 ccc cece eee eee eee aes 3 Humidistat oeste vedanta Heated nies 6 To Turn Off the Appliance 2 0 0 2c ccc cece eee ee 3 Hot Surface Ignition System 0 6 eee eee 7 FURNACE USER MAINTENANCE 0 000000 000s
3. 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 172988 YUM A 0106 SECTION Ill REPLACEMENT PARTS LIST 8 Unitary Products Group 172988 YUM A 0106 ITEM DESCRIPTION ITEM DESCRIPTION MOTOR MISCELLANEOUS 1 MOTOR DIRECT DRIVE BLOWER 2 MOTOR INDUCER ASSY ELECTRICAL 3 CAPACITOR 4 SWITCH LIMIT INDUCER 5 LIMIT TEMPERATURE Primary 6 LIMIT FLAME ROLL OUT 7 CONTROL FURNACE MODULE 7A PLUG JUMPER 8 SENSOR THERMISTOR 9 IGNITER 10 SENSOR FLAME 11 SWITCH PRESSURE 12 SWITCH DOOR 13 TRANSFORMER 14 VALVE GAS AIR MOVING 14 HOUSING BLOWER 15 WHEEL BLOWER 17 BRACKET BLOWER 2 Req d FABRICATED PARTS 43 PLUG WINDOW CLEAR 1 5 44 COMBUSTION AIR TRANSITION 3 WAY 45 TUBING SILICONE Gray 188 ID 2 83 ft Req d 46 TUBING SILICONE Preformed 47 TUBING SILICONE Gray 188 ID 1 25 ft Req d 48 GASKET COMBUSTION BLOWER 49 GASKET CONDENSATE PAN 50 GASKET UPPER CONDENSATE PAN 2 Req d 5
4. 4 Examine the furnace casing making sure the physical support is LIMIT sound without sagging cracks or gaps Examine the furnace base GAS SWITCH making sure it is physically sound without cracks gaps or sagging REFERENCE and has a good seal HOSE BURNER BOX 5 Examine the furnace casing for obvious signs of deterioration E 6 Examine the burner flames to make sure they are in good adjust FIGURE T Component Locati ns ment Refer to the pictorial sketch shown in Figure 2 as a compari 7 NEVER Store flammable materials of any kind near your fur son to the actual flame nace Gasoline solvents and other volatile liquids should be 7 Examine the furnace as outlined above in steps 1 6 before each stored only in approved containers outside your home These heating season Use Figure 3 for visual reference materials vaporize easily and are extremely dangerous 8 NEVER Store cleaning materials near your furnace Materials MANIFOLD MAIN BURNER BURNER such as bleaches detergents powdered cleansers etc can FLAME 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 el gt required for ventilation of the various furnace components INNER FLAME AWARNING CONES FIRE OR EXPLOSION HAZARD oo This furnace is designed and approved for use with Nat TRANSITION not shown ural Gas and LP Propane Gas ONLY DO NO
5. 4 TROUBLESHOOTING 1 0 2 1 e eee eee 7 Blower Care sg Se aca neha A ries ech a a el een 4 FURNACE CONTROL DIAGNOSTICS e arya eras ae Tey Sete 7 Air Filters oc ccc ccc cece a aaa LL LLL LLL LaLa 4 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL 7 Removing Filters nnana c ccc eee eect nee 4 REPLACEMENT PARTS LIST 00c cece cece eens 8 Motor Lubrication 0 0 ccc eee eee 5 REPLACEMENT PART CONTACT INFORMATION 10 SERVICE AND MAINTENANCE MANUAL 5 WIRING DIAGRAM 00 0c cece cece teeta 11 SAFETY aco Hi aaa wowed aha des anda 5 LIMITED WARRANTY 0000 c cece cece eee e nee eeeaeee 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 AWARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property 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 GAS e Do nottry to light any appliance Do not touch any electrical switch do not use any phone including cell phone in your buildi
6. full capacity where it will stay until the wall thermostat is satisfied In every case it will take the motor 30 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 In every case it will take the motor 30 seconds to ramp from one speed to another Tap D is the normal profile best suited for most of the country where neither excessive humidity nor extremely dry conditions are the norm On a call for cooling the motor will ramp up to 63 of full capacity and will stay there for 90 seconds then will ramp up to full capacity At the end of the cooling cycle the motor will ramp down to 63 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 30 seconds to ramp from one speed to another Humidistat When a humidistat is installed in the system the Humidistat con nected jumper on the control board should be moved to the YES position The cooling airflow will then be reduced by 15 whenever the humidistat indicates high humidity Uni
7. should be visually inspected Check combustion air and vent pipe for blockage or leakage e Check all components to be sure they are in good condition and that there are no obvious signs of deterioration Check the drain lines to make sure there are no cracks or leaks 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 Unitary Products Group 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 Motor Lubrication The motors in these furnaces are permanently lubricated and do not require periodic oiling SECTION Il SERVICE AND MAINTENANCE MANUAL SAFETY The following safety rules must be followed when servicing the AWARNING ELECTRIC SHOCK FIRE OR E
8. 1 GASKET GAS CONTROLS 52 GASKET CONDENSING COIL 53 GASKET COMBUSTION AIR TRANSITION 54 VENT PIPE 2 X 15 25 LG 55 GROMMET MOTOR 3 Reqd 56 FERRULE 3 Req d 57 COMBUSTION BLWR RESTRICTOR 58 INSERT SILICONE 59 RESTRICTOR TUBE 60 WASHER FLAT FIBERGLASS 3 Req d 61 HARNESS MAIN WIRING 62 MOUNT 1 PC MOTOR 63 ORIFICE BURNER Natural 45 64 TRAP CONDENSATE 65 WIRING DIAGRAM 66 45 DEG STREET ELBOW 2 67 DRAIN TUBE CONDENSATE TRAP 68 DRAIN TUBE COMBUSTION BLOWER 69 DRAIN TUBE CONDENSATE PAN 70 DRAIN TUBE STRAIGHT 21 LG 71 DRAIN TUBE RAIN GUTTER 72 DRAIN HOSE ASSEMBLY 73 DRAIN TUBE CONDENSATE 74 LOCKNUT CONDUIT 1 2 75 ADAPTER INSERT 76 BUSHING THREADED 77 GROMMET MANIFOLD 78 VENT PIPE ASSEMBLY 79 DRAIN TUBE VENT PIPE 80 DOOR KNOB Black 81 SIGHT GLASS OVAL 18 PANEL BLOWER COVER 19 BRACKET CONDENSATE TRAP 20 BURNER MAIN GAS 21 COIL CONDENSING 22 SHELF BLOWER 23 HEAT EXCHANGER ASS Y 24 MANIFOLD GAS 25 SHIELD PAN 26 PAN CONDENSATE 27 PANEL VEST ACCESS Upper 28 PANEL BLOWER ACCESS Lower 29 WRAPPER BURNER BOX 30 CHANNEL TOE PLATE 31 COVER GAS CONTROL 32 PANEL BOTTOM 33 PANEL TOP 34 SUPPORT BURNER 35 WRAPPER CABINET Insulated 36 PLATE DIFFUSER 37 BRACKET IGNITER 38 BRACKET DOOR SWITCH 39 BO
9. IN REGULATOR ADJUSTMENT C INLET gt l OUTLET PRESSURE PRESSURE TAP TAP ON OFF KNOB FIGURE 4 Gas Valve White Rodgers EXTERNAL MANUAL SHUTOFF VALVE TO GAS i TO GAS SUPPLY SUPPLY N Z GROUNDED JOINT UNION MAY BE INSTALLED LEG INSIDE OR OUTSIDE UNIT FIGURE 5 Gas Piping MANUAL SHUT OFF _ VALVE lng DRIP ERE LEG PIPE GAS BURNERS GAS VALVE GAS_ PIPE LEG SHUT OFF VALVE DRIP y x MANUAL FIGURE 6 Horizontal Gas Piping NOTE The spring loaded safety cut off switch mounted on the blower deck behind the indoor fan access panel will automatically cut off the electrical power supply to the furnace when the blower panel is removed As a safety precaution all electrical power and the gas supply to the furnace should be turned off before servicing 172988 YUM A 0106 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 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 a
10. NGER FURNACE TYPE Residential Applications Non Residential PARTS Original Owner Subsequent Owner Applications 90 PC9 Lifetime 20 10 5 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 I freezing of condenser water or condensate II inadequate or interr
11. O 18 GN now a Cee LLAI T uaan T2908 E m i eos yamo gu OY Bee z pe n378 me 48 gas 31937144n0s ame O N 31804 30 NY i 30 un3L0N o0 0 BION ma EO3LYLAWAOO L_BION IOA 09 1 SI NOTLVINBNIW _ 4 q V9AS11_30_3N917 MS ON OOO x y T BION 335 09 1 SI1 ATddNs H3m04 39113 na BNIT SVASI 8 0 A 1a LYSANO INZASIVABON O 4N37N09 30 3009 S ig HA ose YaMONEG d33dS 318VIHVA Say AN JA SNES VIO ue 20 ELVA HOD 1 uo NA 1M3N VIAS 3 A _ _ _ HOLIMS 8000 AS O N i L ININ OVASI uanuoasnval va or ONILVYINGOW SOVNYN4 ZINOH NMOG 06 INV89vIO y300Y7 zj FIGURE 9 Wiring Diagram 11 Unitary Products Group 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 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 defe
12. SHNI SUV SHOLOM 9 v A o o SAITdANS Y3MOA TIY HOW SLIANNOISIO 3OTAOHA S MN SIH mia O3ONNOY9 ATHSdOd 38 LSNW SLNSNOdNOD IN3N3OWld38 TWV LINN SIHL NIJIAYIS LN3N308093V8 30 JNWYY VIQ Hi Lol O KINO SHOLONGNOD Y3dd03 HO4 3TBVLINS SHOLOSNNOD S 34038 SLOSNNOISIO Ty N3dO ae ss ea Y ONIAVH E o N NVH9IVIO NOTLOSNNOO jan veo E Ol 38 1SMN SOVNYNS JHL HLIM GST lddNS SY SYIM IvNI9TWO SHL 30 ANY 31 2 NOILNVI 3009 ALIO YO 14907 9 E fA 740 0NV 939 3009 9313 NviavNvo 8 po ba 7SO ONY SBN 300 5373 TWNOILWN Y 836 ONIMIM 07314 TV 1 HSLSTNGSHL PATO o 10 BEERZESS S3LON AT YU o ami 0 e Bes 85598 Bo nH M E NOTLOSNNOD 1V1S 1 NOWNOD IVISOMWHL NOOY o PAS El HOSNSS dtd er STOHINOI pine NW dou INY O H3NOTLIONOD HIV OL D 3NV379 TT Tynan L0H E Y SIV LZ pee eee eee eee O v vaa vaq 3 Que BAA Sv9 we ly RS ai g T e P HOLINOI 3 dz 20009540000 o do DTO ITO avu LHM LHM 2508 15084 zs Y A esos sou 257 FE 157 Fi 0 LHM LHN aao todo t omo io O O E Sat t 33S AbZ YOLON 78 a 78 LINO mi Ln Ze nu 10H Ne OTTO YO LN3A na ol 9 157 woo AOZI r e Sate h JJA T EE 7 31 4IGINNH Maua H NOI b a oe ae a 3 HANAH 4 40 0 4 so O LNZ a cond G BAWA AREG gt EZ NR Ny awa Bet nazas rad a oe EEE poe ok Me O sree a e WS lee ie pS ici TiTe Jf rn E eee Aa S OO tp aaa bhana LM neg mue cc A ONILWINCON 7 LM TON a ashe SAC canas y T 10 7 MO 18 AH
13. SUMER 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 So o e For Owner s Information PRODUCT MODEL NO INSTALLATION DATE UNIT SERIAL NO INSTALLING DEALER Subject to change without notice Printed in U S A 172988 YUM A 0106 Copyright by Unitary Products Group 2006 All rights reserved Supersedes Nothing Unitary 5005 Norman Products York OK Group Drive 73069
14. T 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 FIGURE 2 Burner Flame Drawing 3 EXAMINE RETURN AIR ee DUCT CONNECTION O 4 EXAMINE FURNACE CASING 5 EXAMINE CASING FOR o o DETERIORATION O BLOWER DOOR 6 REMOVE THIS PANELTO EXAMINE THE BURNER FLAMES 2 REMOVE THIS PANEL o TO EXAMINE VENT PIPE O ER PLACE A FIELD o 4 EXAMINE INSTALLED ACCESS W _ FURNACE PANEL LOCATED IN CASING _ _ gt THE DOWNFLOW _ PLENUM TO EXAMINE 50 BURNER DOON THE HEAT EXCHANGER E A EXAMINE CASING FOR DETERIORATION FIGURE 3 Furnace Examination Checkpoints 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 exch
15. TTOM PANEL BURNER BOX 40 41 42 NOTE Not Shown Major components and suggested stocking items are shown with shaded item number Unitary Products Group i 172988 YUM A 0106 FIELD INSTALLED ACCESSORIES NON ELECTRICAL MODEL NO DESCRIPTION USED WITH 1NP0680 PROPANE LP CONVERSION KIT WITH GAS VALVE ALL MODELS 1CT0302 CONCENTRIC INTAKE VENT 2 60 80 100 INPUT MBH 1CT0303 CONCENTRIC INTAKE VENT 3 100 120 MBH 1NK0301 CONDENSATE NEUTRALIZER KIT ALL MODELS 1HT0901 SIDEWALL VENT TERMINATION KIT ALL MODELS 1CB0317 17 1 2 CABINET 1CB0321 COMBUSTIBLE FLOOR BASE 21 CABINET 1CB0324 24 1 2 CABINET 1TKO917 17 1 2 CABINET 1TK0921 COIL TRANSITION KIT 21 CABINET 1TK0924 24 1 2 CABINET 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 itary Products Group 172988 YUM A 0106 WIRING DIAGRAM SECTION IV rr SII3UVAdY 13 B3LIN
16. VHO 30 39Y114 STI38VddV 13 3NISM 1 30 39113 YAO HN3NHOASNVEL 11 S30130 ONY ONIMIM 01314 S301A30 ONY ONTYIM AYOLOVS VAOY H3NHOASNVEL NOILdS9NO9 EN31 EVA 30 S39 3LOWd INOS SHNSLOW S37 NOLIVINANI TW YNOd SENILINOFSIO S31 ZASSINYNOS 9010 W 0MN 1662L1 9 Bee or En ii si lone pcm 34431 N3 SSIW N31 3813 1100 IN3N30WIdA38 30 ALNVSOdNOD SLNOL peros 30 envio 2308 forms aro Toa 2508 BUAINO 30 14 UNO S3LIZUVN S30 ANS AN3W37NOY 30 YNSLVLNWNOD 1508 HOLIMS LNO 7108 ISON Mi i hi z hoppia SUNLVSJIN3L SJO Y Y3LSIS3Y INVANOS XAVIS3LVA N JJAY 381347 NOILONGNI G YNSLON NY 3LINIT 30 YN3LVIMAMOD 257 HOLIMS LIMIT Y3OMONI 257 1700 11 INdL N3 nO 3181V3 N3 39Y1dH38 3813 1100 304114 JT ts 3014835 37 23AyY 3030084 30 SWdIONIYd SLIWIT 30 YNSLVLNWNOD 157 HOLIMS LINIT AYWNIdd 157 XAVdIDINNN 13 XNY207 S3009 9 a 3ONVHO SOv4uNS 30 NOILIN I NOT B3LINOT 3Ov4uNS LOH NOT 70 13 939 _N3IOVNVO 9373 3009 8 INVAY SYNSLONOPSIO S31 Z3SYANO ZY 30 Bavanos AS INWA SY9 AO M0 13 N30 IVNOILVN 5373 3009 Y NO73S Y3ILNVHO N3 39714 LMOL I NOLONOPSIO 30 HNALYLNWWOD SO HOLIMS LI3NNOISIA SO S3LON NOILN 935d 30N3931 N3931 OBLOBLOUd ATLNSY
17. XPLOSION 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 e Before servicing disconnect all electrical power to the fur nace e When servicing controls label all wires prior to discon necting Reconnect wires correctly e Verify proper operation after servicing FURNACE MAINTENANCE The furnace should be cleaned and adjusted by a certified dealer or qualified service contractor once a year or before the start of every heating season The following items must be cleaned and serviced or replaced if there are signs of deterioration 1 The vent terminal screen if applicable 2 The furnace vent and combustion air intake passageways Should it be necessary to service the vent air intake system the 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 3 The furnace burners ignitor and flame sensor 4 The condensate collection and disposal system If any disassem bly of components containing flue or vent gases is required a qualified service agency must perform the service FURNACE CLEANING NOTE The cleaning operations listed below must be performed only by a qualified service agency Burner Removal Cleaning The main
18. anger 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 The furnace control will vary the amount of heat and the amount of airflow needed to maintain the proper temperature in the home START UP AND SHUTDOWN INSTRUCTIONS Read the Instructions Below Before Trying to Start the Furnace AWARNING 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 In
19. burners should be checked periodically for dirt accumulation If cleaning is required follow this procedure 1 Turn off the electrical power to the unit 2 Turn off the gas supply at the external manual shut off valve and loosen the ground union joint 3 Remove the burner door and remove the burner box cover Unitary Products Group 172988 YUM A 0106 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 Reassemble the burners in the reverse order Cleaning the Heat Exchanger 1 Turn off the electrical power to the unit 2 Turn off the gas supply at the external manual shut off valve and loosen the ground union joint 3 Remove the burner door and remove the burner box cover 4 Disconnect wires from flame sensor rollout switch and HSI igniter Remove igniter carefully as it is easily broken 5 Remove the screws that hold the burner box assembly to the vest panel and remove the assembly 6 Remove the vent pipe assembly vent blower and condensate pan The heat exchanger is now exposed 8 With a long flexible wire brush clean inside each tube at both the top and bottom The brush must pass around the rear heat exchanger tubes The
20. ced due to restriction in the circulating air system Five Amber Flashes Heating capacity is reduced due to restriction in the combustion air or vent system Rapid Amber Flash Low flame sense current Check for dirty or mis located flame sensor rod Unitary Products Group 172988 YUM A 0106 One Red Flash Flame is present with no power being supplied to gas valve This can be caused by a gas valve that is slow to close or that leaks gas through to the burners Two Red Flashes Stuck closed pressure switch The control confirms that the pressure switch contacts are open at the beginning of each cycle This could be caused by a faulty pressure switch or by mis wiring of the pressure switch Three Red Flashes Stuck open pressure switch This indicates that the pressure switch is open when it should be closed This could be caused by a faulty combustion air blower blocked vent pipe blocked air intake pipe blocked condensate drain faulty pressure switch hose or a faulty pressure switch Four Red Flashes High limit switch open or 24 volt fuse is open This may be caused by a dirty air filter improperly sized duct system faulty blower motor restricted circulating airflow or an open fuse on the con trol board Five Red Flashes Rollout switch or auxiliary limit switch open Check the rollout switch on the side of the burner box It is a manual reset switch To reset push the small button in the center of the switch If i
21. cts 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 reverse side of this warranty HEAT EXCHA
22. ged 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 172988 YUM A 0106 172988 YUM A 0106 TRANSFORMER VENT PIPE BLOWER ACCESS PANEL CONTROL BOARD CONDENSATE HOSE RAIN GUTTER INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION It is the owner s responsibility to ensure that an annual inspection of the entire heating portion of the unit is made by a qualified service agency 1 Examine the heat exchanger through a field installed access panel located on the supply air plenum Visually examine the exte rior sections of the vent combustion air piping and the vent con nectors to be sure that they are physically sound without holes or excessive corrosion irda MUSINE 2 Examine the vent pipe making sure it is firmly in place that it TUBING slopes slightly upward and is physically sound without holes and ces all of the connections are secure as CONDENSATE 3 Examine the return air duct connections to make sure they are DRAIN HOSE physically sound sealed to the furnace casing and the ducts ter SAs minate outside the space containing the furnace VALVE id
23. he beginning and at the end of each call for heat based on information from the thermo stat and past demand UNLIKE CONVENTIONAL SYSTEMS THE WALL THERMOSTAT DOES NOT SIMPLY TURN THE FURNACE ON AND OFF THE FURNACE CONTROL CALCULATES THE DEMAND AND MAY CONTINUE TO FIRE THE FURNACE DURING PORTIONS OF THE THERMOSTAT OFF CYCLE When the wall thermostat R and W contacts close indicating a call for heat the following sequence occurs 172988 YUM A 0106 1 The inducer is energized and ramps up its speed until airflow is proven by the pressure switch and by the pressure sensor on the control board 2 The hot surface ignitor is energized 3 After a 17 20 second igniter heatup the gas valve opens and the burners light 4 When the control senses that flame is present the circulating blower starts at low speed 5 The furnace fires at 70 of full rate for 30 45 seconds then drops to the minimum 35 firing rate 6 The firing rate is automatically adjusted to meet demand increas ing gradually to maximum 100 firing rate if the thermostat is not satisfied within a defined time 7 When the thermostat R and W contacts open thermostat is satis fied the furnace control recalculates the demand and a new firing rate a If demand exceeds the minimum firing rate the burners will continue to fire at a recalculated reduced firing rate decreas ing if the thermostat remains off for a defined time b If demand does not exceed t
24. he minimum firing rate the burn ers will shut off immediately 8 After the burners shut off the circulating blower will continue to run until the temperature sensor detects that the supply air tempera ture has dropped to the desired level which should take from 30 to 90 seconds ADJ USTMENT OF FAN CONTROL SETTINGS Cooling The airflow delivered by the furnace during cooling operation can be adjusted to match the cooling capacity of the A C condensing unit This is done by moving the COOL and ADJ jumper on the control board to give the desired airflow The COOL jumper has four positions which will deliver sufficient airflow in cooling mode for the cooling capacities shown in the Table 2 TABLE 2 Cooling Airflow A C Capacity in Tons Cool Jumper Position Models D C B A 60 1200 1 1 2 2 2 1 2 3 80 1200 1 1 2 2 2 1 2 3 80 1600 2 1 2 3 3 1 2 4 100 1600 2 1 2 3 3 1 2 4 100 2000 3 3 1 2 4 5 120 2000 3 3 1 2 4 5 Continuous Fan Operation The airflow delivered by the furnace dur ing continuous fan operation can be adjusted as desired This is done my moving the RECIRC jumper on the control board to give the desired airflow The jumper has three positions The A position delivers maximum air flow 100 of the blower capacity Position B delivers approximately 70 of the blower capacity And Position C delivers minimum airflow approximately 35 of the blower capacity
25. in Size Filter in cm 60 17 6 1200 34 B 2 14x 20 36 x 51 80 23 4 1200 34 B 2 14x 20 36 x 51 80 23 4 1600 45 C 2 14 x 20 36 x 51 100 29 3 1600 45 C 2 14 x 20 36 x 51 100 29 3 2000 57 C 2 14 x 20 36 x 51 120 35 1 2000 57 D 2 14 x 20 36 x 51 Externally Mounted Air Filters Some installations may have the air filter in a rack attached to the cas ing of the furnace or placed in the return air duct You can gain access to the filter by pulling on the door or unscrewing the retaining screw then slide the filter s out of its channel Replace throw away filter s with the same size new filter s Throw away filter s may be replaced with cleanable filter s at this time Cleanable filter s may be cleaned as described in the manufacturer instructions or as described below and then re installed How to Clean your Filter High velocity filters may be cleaned with a vacuum cleaner or washed with a garden hose Be sure to shake off excess water and allow filter to completely dry before re installing the filter To replace the filter after cleaning you must do the following 1 Slide filter into place 2 Snap the door on or place the door in position 3 Make sure the door is secure to the end of the filter rack 4 For filter grilles place the filter into the grilles close the grille cover and tighten the retaining screw Every time the filters are changed the following items
26. lter s refer to Table 1 to be sure you install the right size filter for your furnace Dirty filters greatly restrict the flow of air and may cause damage to the moving parts of the furnace If the filters become clogged the heat exchangers and blower motor could overheat resulting in a potentially dangerous situation Never operate your furnace without a suitable air filter Removing Filters Most downflow furnaces have their filters located on the top of the fur nace in an external filter rack To check filters you should 1 Follow the instructions to turn off the appliance before servicing 2 Filters are installed in the return air plenum above the blower assembly An A frame assembly supports the filters Lift the filter slightly and remove for service 3 Follow the instructions HOW TO CLEAN YOUR FURNACESS FIL TER 4 Reverse the procedure to reinstall filters 5 Follow the operating instructions to place appliance in operation FILTER RACK RACK AND FILTERS SECURED INSIDE BLOWER SECTION FOR SHIPMENT CASING SIZE DIMENSION FH 14 1 2 13 1 4 17 1 2 12 1 2 21 11 1 2 24 1 2 9 3 4 NOTE FILTER ACCESS THROUGH DUCKWORK MUST BE PROVIDED FOR REMOVAL AND CLEANING A FILTERS DUCKWORK HA we FH c FIGURE 7 Filter Rack Assembly and Attachment TABLE 1 Filter Sizes Input CFM Cabinet Top Return BTU H kW m3 m
27. n through the clear view port in the lower door of the furnace To indicate an error condition the LED will turn on for 1 4 second and off for 1 4 second The pattern will be repeated the number of times equal to the flash code For instance a six flash code will be indicated by the LED turning on and off six times There will be a two second off period between each set of flashes The flash codes and an indication of their likely causes are listed below STEADY OFF No 24V power to board Check the 24 volt control cir cuit fuse on the board Check the circuit breaker or fuse on the 115 volt supply power to the furnace Check that the 24 volt transformer One Green Flash Normal Operation with no call for heat Two Green Flashes Indicator for No error codes in memory See Diagnostic Fault Code Storage and Retrieval section below Three Green Flashes Indicator for Error codes cleared from mem ory See Diagnostic Fault Code Storage and Retrieval section below Rapid Green Flash Control is in Factory Speedup mode This mode is used only during factory run testing of the furnace To stop this mode cycle power to the furnace off and then back on One Amber Flash Normal operation with call for cooling Two Amber Flashes Normal operation with call for heat Three Amber Flashes Normal operation burner is on at end of heat ing cycle after wall thermostat has been satisfied Four Amber Flashes Heating capacity is redu
28. n vacuum loose the scale and dirt from each tube 9 Replace all components in reverse order Reconnect all wiring 10 Restore electrical power and gas supply to the furnace 11 Check furnace operation A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and danger ous operation Verify proper operation after servicing Cleaning the Secondary Heat Exchanger 1 Follow steps 1 7 under cleaning the Heat Exchanger 2 Remove the vent piping from the vent blower housing Disconnect the drain lines from the vent blower housing and from the conden sate drain pan Remove the vent blower housing blower and the condensate pan 3 Using a stiff wire brush remove the loose scale or soot from each tube 4 Vacuum the secondary heat exchanger 5 Finish the cleaning procedure by following steps 9 11 under cleaning the Heat Exchanger Cleaning the Vent Air Intake System Should it be necessary to service the vent air intake system the man ufacturer recommends this service be conducted by a qualified service agency The operation of this appliance requires the reassembly and resealing of the vent air intake system as specified in the Combustion Air and Vent System located in the Installation Manual NORMAL OPERATION SEQUENCE The furnace control calculates the optimum firing rate each time the wall thermostat R and W contacts close or open at t
29. ng e 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 department Installation and service must be performed by a qualified installer service agency or the gas sup plier 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 shutting off the electrical supply 6 Do not use this furnace if any part has been under water A flood dama
30. nnually If the motor and wheel are heavily coated with dust they can be brushed and cleaned with a vac uum cleaner If the blower cannot be properly cleaned without removing it from the furnace then this service must be performed by a qualified service agency The blower can be serviced removed through the blower access panel on the inside of the furnace If there is a combustion air pipe installed inside the furnace it may have to be removed to access the blower access panel After the combustion air pipe is removed it is easy to remove the inside blower access panel by pushing it up against a spring or removing the screws of the access panel Blower is now ready to be serviced through the opening If the blower has to be removed through the inside blower access panel then the top flange blower door switch and bottom flange will also have to be removed on some models On some other models top and bot tom angles will have to be removed to slide the blower out of the fur nace 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 Air Filters The filters should be checked every 3 months On new construction check the filters every week for the first four weeks and every three weeks after that especially if the indoor fan is running continuously When replacing the fi
31. structions STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance Remove burner door Move gas control switch to the OFF position Do not force Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above If you don t smell gas go to next step Move gas control switch to the ON position Do not force Replace burner door 9 Turn on all electric power to the appliance 10 Set thermostat to the desired setting Burner will light which may take 30 60 seconds 11 After three 3 trials for ignition if the appliance will not operate fol low the instructions TO TURN OFF THE APPLIANCE and call your service technician or gas supplier 9 021002 oN Unitary Products Group 172988 YUM A 0106 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 Move gas control switch to the OFF position 5 Replace burner access panel Should overheating occur or the gas valve fail to shut off turn the external manual gas valve in the gas supply line to the furnace to the off position and let the furnace cool off before shutting off the electrical power supply Refer to Figure 5 gt MA
32. t cannot be reset or if the switch trips again contact a qualified service man Check the limit switch mounted in the combustion air blower hous ing Six Red Flashes Current failure on modulating gas valve Seven Red Flashes Lockout due to no ignition The control will try three times for ignition If flame cannot be established in three tries the control will lockout for one hour and then will try again to light Check gas supply ignitor gas valve flame sensor Eight Red Flashes Lockout due to too many flame recycles This flash code occurs if flame is lost five times during a single heating cycle This could be caused by a faulty gas valve low gas pressure or dirty flame sensor The control will lock out for one hour and then will try again Nine Red Flashes Reversed line polarity or improper grounding Check polarity of the incoming power to the furnace Check the ground ing of the furnace including the transformer ground and the L1 and neutral connections Ten Red Flashes Unexpected gas flow present Check gas valve wir ing If correct replace gas valve Eleven Red Flashes Main blower failure This flash code occurs when the main limit opens and fails to reclose within five minutes indi cating that the blower motor or blower wheel has failed Twelve Red Flashes ID plug is not present or not connected properly check for loose plug or loose wires in plug Steady On Red Control fault has been detected or
33. tary Products Group Hot Surface Ignition System HOT SURFACE IGNITION SYSTEM Do not attempt to light this furnace by hand with a match or any other means There may be a potential shock hazard from the components of the hot surface ignition system The furnace can only be lit automatically by its hot surface ignition system TROUBLESHOOTING The following visual checks should be made before troubleshooting 1 Check to see that the power to the furnace and the ignition control module is ON 2 The manual shut off 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 AWARNING Never bypass any safety control to allow furnace opera tion To do so will allow furnace to operate under poten tially hazardous conditions Do not try to repair controls Replace defective controls with UPG Source 1 Parts Never adjust pressure switch to allow furnace operation FURNACE CONTROL DIAGNOSTICS This furnace has built in self diagnostic capability If a system problem occurs a flashing LED shows a fault code The LED can flash red green or amber to indicate various conditions The LED is located on the furnace control board and can be see
34. there is 24 volts present without 115 volts Check that there is 24 volts and 115 volts being supplied to the board If so then the board should be replaced 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 is power to the furnace is lost Only a qualified service technician should use this feature The control stores up to five separate error codes If more than five error codes have occurred since the last reset only the five most recent will be retained The furnace control board has a button labeled LAST ERROR that is used to retrieve error codes This function will only work if there are no active thermostat signals So any call for heating cooling or continuous fan must be terminated before attempting to retrieve error codes To retrieve the error codes push the LAST ERROR button The LED on the control will then flash the error codes that are in memory starting with the most recent There will be a two second pause between each flash code After the error codes have all been displayed the LED will resume the normal slow green flash after a five second pause To repeat the series of error codes push the button again If there are no error codes in memory the LED will flash two green flashes To clear the memory push the LAST ERROR button and hold it
35. upted 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 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 CON
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