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White Rodgers FC9S Maintenance and Service Guide

1. USER S INFORMATION MAINTENANCE AND SERVICE MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES MODELS PS9 FC9S FL9S Single Stage Downflow Horizontal X So aD 2000 REGISTRA ISO 9001 Certified Quality Management System ENERGY STAR MMII TABLE OF CONTENTS CONTACT INFORMATION 1 FURNACE MAINTENANCE GECTION aaan 5 USER S INFORMATION x x x x x ooo 1 SEQUENCE OF OPERATION o 5 e Oe GENEE 1 Continuous BIOWET EE 5 INSTRUCTIONS FOR EXAMINING THE Intermittent Blower Cooling 000 c cece eens 5 FURNACE INSTALLATION 0000c cece eee eee eee 2 Heating Cycle L L eee eee ee 5 HOW YOUR GAS FURNACE WORKS 3 Hot Surface Ignition System 02s 6 START UP AND SHUTDOWN INSTRUCTIONS 3 FURNACE CLEANING SECTION S D Read the Instructions Below Before Trying to Start the Burner Removal Cleaning a ba A 6 Furnace gege geet Seege eg esa 3 Cleaning the Heat Exchanger L L L L L eee eee D Operating Instructions 000cc cece eee eee 3 Cleaning the Secondary Heat Exchanger 6 To Turn Off the Appliance eee eee ee 3 Cleaning the Vent Air Intake System L L o 6 FURNACE USER MAINTENANCE 222k 4 TROUBLESHOOTING 22cexucecveceyaeett see beeen seen eae 6 EECH 4 FURNACE CO
2. 3 RED FLASHES This indicates the normally open pressure switch contact did not close after the inducer was energized This could be caused by a number of problems faulty inducer blocked vent pipe bro ken pressure switch hose or faulty pressure switch 4 RED FLASHES This indicates that a primary or auxiliary limit switch has opened its normally closed contacts With this fault code the control will operate the supply air blower and inducer This condition may be caused by dirty filter improperly sized duct system incorrect blower speed setting incorrect firing rate or faulty blower motor 5 RED FLASHES This fault is indicated if the normally closed contacts in the rollout switch opens The rollout control is manually reset If it has opened check for proper combustion air proper inducer operation and primary heat exchanger failure or burner problem Be sure to reset the switch after correcting the failure condition 6 RED FLASHES This indicates that after the unit was operating the pressure switch opened 4 times during the call for heat If the main blower is in a Delay on mode it will complete it and any subsequent delay off period The furnace will lock out for one hour and then restart 7 RED FLASHES This fault code indicates that the flame could not be established This no light condition occurred 3 times 2 retries during the call for heat before locking out Low gas pressure faulty gas valve dirty or faulty flame sens
3. FIL TER 4 Reverse the procedure to reinstall filters 5 Follow the operating instructions to place appliance in operation FILTER RACK _ factory supplied with some furnaces RACK AND FILTERS SECURED INSIDE BLOWER SECTION FOR SHIPMENT CASING SIZE DIMENSION FH 14 1 2 13 1 4 12 1 2 11 1 2 9 3 4 NOTE FILTER ACCESS THROUGH DUCTWORK MUST BE PROVIDED BRANCH FOR REMOVAL AND CLEANING DUCTS FILTERS ess FILTER DUCTWORK RACK S CROSS SECTION A A with Plenum and filters FIGURE 7 Filter Rack Assembly and Attachment 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 i
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5. e A 17 1 2 wide cabinet is a B cabinet e A 21 wide cabinet is a C cabinet e A 24 1 2 wide cabinet is a D cabinet 2 Locate the cabinet size on Table 1 then 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 3 After you determine the cabinet size and what return configuration you have look up the recommended filter size from Table 1 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
6. or continuous fan must be terminated before attempting to retrieve error codes To retrieve the error codes push the LAST ERROR button The LED on the control will then flash the error codes that are in memory starting with the most recent There will be a two second pause between each flash code After the error codes have all been displayed the LED will resume the normal slow green flash after a five second pause To repeat the series of error codes push the button again If there are no error codes in memory the LED will flash two green flashes To clear the memory push the LAST ERROR button and hold it for more than five seconds The LED will flash three green flashes when the memory has been cleared then will resume the normal slow green flash after a five second pause ON Thermostat Calling for Heat Satisfied Seconds 02 17 22 Fan on Delay 30 Seconds THERMOSTAT INDUCER IGNITOR MAIN VALVE HUMIDIFIER CIRCULATING BLOWER FIGURE 9 Furnace Control Event Schedule Unitary Products Group 0 ELECTRONIC AIR CLEANER E e 60 90 120 180 SEC LOFF Selectable Fan Off Delay REPLACEMENT PARTS LIST 127237 UUM A 0605 SECTION III N H TL L S y LP VAS H R COD F ID p lt Ve as NL E U AIT L L A Ve E Lei i CU V N LAA WA A Y WA N Ph L GO I o o H SCH A W i T AL Sa G Q A Tag AV ESP cI SoG E A
7. 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 TABLE 1 Filter Sizes Input Output CFM Cabinet BTU H kW m min Size Top Return Filter in cm 40 37 11 72 10 84 1200 34 2 14 x 20 36 x 51 60 55 17 57 16 10 1200 34 B E 80 75 23 42 21 96 120034 B 14x20 86x51 120 112 35 14 32 80 2000 57 D 2 14x20 36 x 51 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 discon necting Reconnect wires correctly Verify proper operation after servicing FURNACE MAINTENANCE SECTION The furnace should be cleaned and adjusted by a certified dealer or qualified service contractor once a year or before the start of every heating season The following items must be cleaned and serviced or replaced if there are signs of deterioration 1 The vent terminal screen if applicable 2 The
8. the LO COOL terminal when first stage cooling is operating The motor will operate on the speed tap connected to the HI COOL terminal when second stage cool ing is operating 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 heat a circuit is completed between terminals R and W of the thermostat When the proper amount of combustion air is being provided the pressure switch will close the ignition control 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 8 The heating cycle is complete and ready for the start of the next heating cycle RED LOW SPEED YELLOW MED LOW SPEED BLACK HIGH SPEED BLUE MED HIGH SPEED CONTINUOUS FAN SPEED JUMPER FAN OFF ADJUSTMENT JUMPER QOQ gt PEREREL FIGURE 8 Typical Heat Cool Speed Tap C
9. the furnace if deemed necessary 127237 UUM A 0605 127237 UUM A 0605 TRANSFORMER VENT PIPE CONDENSATE BLOWER HOSE ACCESS PANEL CONTROL BOARD RAIN GUTTER INDUCER HOUSING INDUCER MOTOR PRESSURE 3 CONDENSATE SWITCHES E E DRAIN HOSE B TFT A Y PRESSURE SWITCH TUBING A Je a A y y ET Cy TT CONDENSATE GAS TRAP VALVE lt LIMIT GAS gt wenn SWITCH REFERENCE IC HOSE BURNER BOX FIGURE 1 Component Locations 7 NEVER Store flammable materials of any kind near your fur nace Gasoline solvents and other volatile liquids should be stored only in approved containers outside your home These materials vaporize easily and are extremely dangerous NEVER Store cleaning materials near your furnace Materials such as 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 the various furnace components AWARNING FIRE OR EXPLOSION HAZARD This furnace is designed and approved for use with Nat ural Gas and LP Propane Gas ONLY DO NOT BURN ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE Burning any unapproved fuel will result in damage to the furnace heat exchanger which could result in Fire Per sonal Injury and or Property Damage 3 EXAMINE RET
10. AS 2 LAVH VA 39314 30 1WISONS3H1 NO IN3NI0DEODIVE Av2 J LVLSONYSHL WOOY NOILOSNNOD Av2 VY nds e eise gian E ae do EE ILINSA a IV LNOZIMOH JLJILN3QI LNSWSNNOILONOS 30 Hl e YOLIIVIVI NAY GSISILNSQI e ion T OL Na no amira EE E oa soria Tee F VAO HNSNHOISNVHL LI VAO YANYOISNVHL LI XAVAIDINAW 13 XNVI07 3009 0 06 3SIVN8NO 4 31311N301 LNSWSNNOILONOS 30 EN3LIDVAVI OUI HOLIOVAVI NOY OUI M0 13 939 N3IOYNVI 9313 3009 8 NOILYSNJQNOO NOISSSYd 20 YNILYLNWWOO d 1VSN3ONO9 HOLIMS 38NSS YS dZ M0 13 N39 IVNOLLVN 9313 3009 Y NOTES S3LLNVHO N3 39V14 LMOL 3D WN J YNSINYA 30 31108 L9MONI NOISS3Yd 30 HNALYLNWWOO al YOLN3A X08 YSNYNG HOLIMS 38NSS3YA YI S3 LON a JNAISNA c 3sn4 c IV ELNOZIYOH MO IINMOO 06 11080 3109 LNAWAINOY 30 YNALVLAWNOD GO 3018 1H9l8 HOLIMS LNO 17704 200 031931084 ATLNSYSHNI 38HV SHOLON 9 3HONV9 3109 IN3N37N08 30 YNSLVLNWNOD ISOY 301S 1337 HOLIMS 1MO T04 Ier E tod Tv uo IGT auna e NOLLONGNLG EN3 OWN NY ALINIT 30 EN3LVINWANOI ze HOLIMS LIMIT Y3IMONI zen io Puso Bar liado oa sy 3OIAY3S 371 D3AV Y30300Yd 30 JWdIONINd SLINIT 30 YNSLVLNWNOD 1S7 HOLIMS LINIT AVISA 1S7 INVAV SHMALONOPSIO S37 Z3YANO NOLLOMONI O NILON AV Sid 2 Y 371DVIA3D3Y 13 ASIA S vd HOLON YSONONI LY 1 29905 INMI Nid Z S vd R KE eg Ger Ge S NOLLNYOJHd 20ngu2 30W 48NS 30 NOLLIN9LO Sld ZY 379V1d3038 13 ISIHd S d YOLINOI 3OVJWNS LOH LW Le gt gnd Nid Z S d o EE ea F NOILINSLO STOMLNOD 30 3113NOWld YI UNS Sld Y Y J0Y1d30J
11. 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 INNO 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 eT ee SS PRODUCT MODEL NO INSTALLATION DATE UNIT SERIAL NO INSTALLING DEALER Subject to change without notice Print
12. NTROL DIAGNOSTICS o0ooococococcooooo 6 an 4 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL 7 Removing HE 4 REPLACEMENT PARTS LIST x x x x x x eee eee eee 8 Motor Lubrication sh sore tude rre ras 5 REPLACEMENT PART CONTACT INFORMATION 10 SERVICE AND MAINTENANCE MANUAL sx x x x x x eee 5 WIRING DIAGRAM aere eege KEE E eg 11 SAFE FOTON sv pee es std staba does pees 5 LIMITED WARRANTY GE 12 CONTACT INFORMATION e Goto website at www york com click on contact then click on contact form and follow the instructions e 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 prop erty damage Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appli ance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone including cell phone in your building Leave the building immediately Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire depart ment Installation and servic
13. OLD BURNER BURNER FLAME YELLOW TIPS INNER FLAME CONES Blue Flame COMBUSTION AIR TRANSITION not shown FIGURE 2 Burner Flame Drawing BLOWER DOOR O 2 REMOVE H THIS PANEL o TO EXAMINE g Q 4 EXAMINE a FURNACE CASING 6 REMOVE THIS O PANEL TO EXAMINE THE VENT PIPE PLACE AFIELD g 4 EXAMINE INSTALLED ACCESS Jo FURNACE PANEL LOCATED IN Wi CASING THE DOWNFLOW PLENUM TO EXAMINE 5 EXAMINE S BURNER FLAMES BURNER DOOR THE HEAT EXCHANGER CASING FOR DETERIORATION O FIGURE 3 Furnace Examination Checkpoints EXAMINE CASING FOR DETERIORATION 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 igniter glows and after a warm up period the gas valve opens and ignition occurs A short time later the blower starts and dis tributes the warm air throughout the home When the temperature set ting on your thermostat is reached th
14. OSANNOD NY QOVY IO D20UY iagram D iring W FIGURE 10 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 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 install
15. URN AIR a DUCT CONNECTION INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION It is the owner s responsibility to ensure that an annual inspection of the entire heating portion of the unit is made by a qualified service agency 1 Examine the heat exchanger through a field installed access panel located on the supply air plenum Visually examine the exte rior sections of the vent combustion air piping and the vent con nectors to be sure that they are physically sound without holes or excessive corrosion 2 Examine the vent pipe making sure it is firmly in place that it slopes slightly upward and is physically sound without holes and all of the connections are secure 3 Examine the return air duct connections to make sure they are physically sound sealed to the furnace casing and the ducts ter minate outside the space containing the furnace 4 Examine the furnace casing making sure the physical support is sound without sagging cracks or gaps Examine the furnace base making sure it is physically sound without cracks gaps or sagging and has a good seal 5 Examine the furnace casing for obvious signs of deterioration 6 Examine the burner flames to make sure they are in good adjust ment Refer to the pictorial sketch shown in Figure 2 as a compari son to the actual flame 7 Examine the furnace as outlined above in steps 1 6 before each heating season Use Figure 3 for visual reference MAIN BURNER END OF MANIF
16. USTION BLWR RESTRICTOR 46 TUBING SILICONE Preformed RETAINER SQUARE RESTRICTOR TUBE ofS HARNESS MAIN WIRING MOUNT 1 PC MOTOR pp ORIFICE BURNER Natural 45 TRAP CONDENSATE WIRING DIAGRAM 45 DEG STREET ELBOW 2 DRAIN HOSE ASSEMBLY DRAIN TUBE CONDENSATE ADAPTER INSERT BUSHING THREADED FILTER AIR 2 Req d 20 x 14 x 75 BAFFLE BURNER BOX GROMMET MANIFOLD 83 DRAIN TUBE VENT PIPE DOOR KNOB Black RETAINER DOOR KNOB NUT SELF THREADING SIGHT GLASS OVAL Not Shown Major components and suggested stocking items are shown with shaded item number Unitary Products Group 127237 UUM A 0605 FIELD INSTALLED ACCESSORIES NON ELECTRICAL MODEL NO DESCRIPTION USED WITH PROPANE LP CONVERSION KIT HIGH ALTITUDE PRESSURE SWITCH KIT Does Not Include Orifices TT COIL TRANSITION KIT eren AI MODELS 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 e You can contact us by mail Just send a written request to York International Consumer Relations 5005 York Drive Norman OK 73069 TD nitar Products Grou
17. Y 13 ASIA ZS Zd devOg IOHLNOJ NOILINSI NO 1 39906 IMA Nid 25 Zd 398 LSAW 30VN8NJ 201 HLIM d3Tedns SV 38IM IVNISIVO JHL 30 ANY 31 2 NOILINOIG JIONLNOD 30 3LL3NOWId YI nS Sld ZI Y 319VId3038 13 3SIHA IS Id GYVOG TOYLNOD NOILINOI NO 129205 gnd Nid ZI IS Id S3009 ALI YO 79207 9 EN ENE aa o E NOL S n ee 707 ONY GE 3000 a NON hj 3d ONIMIM 01313 TW I 34038 SLOSNNOOSIO Ty NadO Zeg 30 3dvdNOS A9 JAVA SVD A9 Ee NOLONOFSIO 30 YNSLVLNWNOD SO HOLIMS LOSNNOOSIG SO SJ DN NOILNY ON393 1 ON393 INVHO VWITO LWISONY3HL i LVISONYSHL 009 LV3H S9NVEO veo 38831 N3 APA SONVYO NYO oe 190021 N3 o o 3udunod 3ugenod ON ano lean nao 000000 zv9 30 ST ze Ka 3NVHO TET dud G S3dvdNOS 30 sivi38 LW3H EOS Ee 5 Ny9 Nnga NYE lo Ch 15719 39831 N3 mL OXG o 330 N3389 NHS By CNS W112 NnNyg NU INS 009 NMOHG NYG Wo2 ASII O n9 aio a o a e ME kt 2500 1508 on 9NV8 TONY 79 S aio SAV138 SLIHM 1HM Ee J35 AYE YION VC e 39no8 GSE Se 3NWVA SV9 Ge OLNW Cho a ON 33S Mp2 NO anos Tano 183A nana nqa INVI8 LHM Ge ba VAO puro rad O Y aay b s _ eT vuO NYO e A r ERD JS E TS eon kon rel LHM woo Hd agit NOTLINOI G A nae ID i oo l Sa SIV 13y j YJLIN I 4 HION HION YION Yg 3NNVF 734 Sly STVNENOS ES NOI NOV Tg yg S SION WIG N LONGNI G ENER ava 1m TO M EEN SIv138 HOLN3A S9V1I4 Nd YION 478 cer D JOY1LN03 SOVNYNS nana ma O XION y8 7 3O0nvHo 30w38ns al 4ION 4718 dl HUT
18. Y BE INSTALLED INSIDE OR OUTSIDE UNIT MANUAL SHUT OFF _ VALVE LEG GAS BURNERS GAS VALVE MANUAL SHUT OFF VALVE FIGURE 6 Horizontal Gas Piping NOTE The spring loaded safety cut off switch mounted on the blower deck behind the indoor fan access panel will automatically cut off the electrical power supply to the furnace when the blower panel is removed As a safety precaution all electrical power and the gas supply to the furnace should be turned off before servicing 127237 UUM A 0605 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 annually If the motor and wheel are heavily coated with dust they can be brushed and cleaned with a vac uum cleaner If the blower cannot be properly cleaned without removing it from the furnace then this service must be performed by a qualified service agency The blower can be serviced removed through the blower access panel on the inside of the furnace If there is a combustion air pipe installed insid
19. ain de energized and the ignition sequence will immediately restart 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 FURNACE CLEANING SECTION NOTE The cleaning operations listed below must be performed only by a qualified service agency 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 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 Reassemble the burners in the reverse order Cleaning the Heat Exchanger 1 Tu
20. ation 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 EXCHANGER FURNACE TYPE Residential Applications Non Residential PARTS Original Owner Applications SCHEER 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 product
21. bee gt m AS y g U y ie H Qa Mr e A ow HN GJ c a AFA 7 a c AE NOA E A BN MA r A 6 91 2 xg ES 4 T SS ete T C c Pe U N ES S C Mil D H L L A OT LS U Rea lO Z ss Gn dp z l q H ES YA B AD g o 5 JNE E g A E 2 e of if L L e l S TR ITS d O L Q d l V e S i LR TIE A N NS p wg x al U b Wei I N ES 7 gt s NF Es 7 E U e e N uy dile S ay e L a Sea G Se 7 FH i Tey 3 z d R V ks l Get Is 2 c Gs Qi Ce Y SGL Mess K MS CA SL IHi Q LO W Jinn i AL Pb e JA st st ID HEITE Ot OY 4 d LZ _e V Unitary Products Group NOTE ITEM DESCRIPTION RICAL MOTO RR ELEC C d Wu VING BURNER MAIN GAS COIL CONDENSING SHELF BLOWER 22 HEAT EXCHANGER ASS Y MANIFOLD GAS SHIELD PAN PANEL BLOWER ACCESS WRAPPER BURNER BOX CHANNEL TOE PLATE PANEL BOTTOM WRAPPER CABINET BRACKET FILTER PLATE DIFFUSER BRACKET DOOR SWITCH BRACKET DOOR BOTTOM PANEL BURNER BOX TOP MOUNTING BRACKET BOTTOM MOUNTING BRACKET gt 0 D O i j O1 127237 UUM A 0605 ITEM DESCRIPTION MISCELLANEOUS PLUG WINDOW CLEAR 1 5 A4 COMBUSTION AIR TRANSITION 3 WAY 45 TUBING SILICONE Gray 188 ID 2 83 ft req d 4 44 45 46 54 VENT PIPE 2 X 15 25 LG GROMMET MOTOR 3 Req d FERRULE 3 Req d COMB
22. 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 dont smell gas go to next step 7 Move gas control switch to the ON position Do not force 8 Replace burner door 9 Turn on all electric power to the appliance 10 Set thermostat to the desired setting Burner will light which may take 30 60 seconds 11 After three 3 trials for ignition if the appliance will not operate fol low the instructions TO TURN OFF THE APPLIANCE and call your service technician or gas supplier O PU E I s Unitary Products Group 127237 UUM A 0605 To Turn Off the Appliance 1 Get 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 5 Replace burner access panel Should overheating occur or the gas valve fail to shut off turn the external manual gas valve in the gas supply line to the furnace to the off position and let the furnace cool off before shutting off the electrical power supply Refer to Figures 5 amp 6 OUTLET PRESSURE PORT VENT PORT BOSS INLET PRESSURE PORT MAIN REGULATOR ON OFF SWITCH SEH Shown in ON position EXTERNAL MANUAL SHUTOFF VALVE N Y j GROUNDED JOINT UNION MA
23. e gas valve closes the main burners are turned off and the blower continues to run until the remain ing warm air in the system is distributed When the blower stops the heating cycle has ended START UP AND SHUTDOWN INSTRUCTIONS Read the Instructions Below Before Trying to Start the Furnace 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 Instructions STOP Read the safety information above Set the thermostat to the lowest setting Turn off all electric power to the appliance Remove burner
24. e 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 shutting off the electrical supply 6 Do not use this furnace if any part has been under water A 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
25. e the furnace it may have to be removed to access the blower access panel After the combustion air pipe is removed it is easy to remove the inside blower access panel by removing the screws of the access panel Blower is now ready to be serviced through the opening If the blower has to be removed through the inside blower access panel then the top and bottom angles will have to be removed to slide the blower out of the furnace 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 filter s refer to Table 1 to be sure you install the right size filter for your furnace Dirty filters greatly restrict the flow of air and may cause damage to the moving parts of the furnace If the filters become clogged the heat exchangers and blower motor could overheat resulting in a potentially dangerous situation Never operate your furnace without a suitable air filter Use the following procedure to determine the filter size 1 Measure the furnace width and use that measurement to deter mine the cabinet width e A 14 1 2 wide cabinet is a A cabinet
26. ed in U S A 127237 UUM A 0605 Copyright by Unitary Products Group 2005 All rights reserved Supersedes 104449 UUM A 1204 Unitary 5005 Norman Products York OK Group Drive 73069
27. 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 Unitary Products Group 127237 UUM A 0605 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 selected on the Continuous Fan Speed Jumper on the control board HI COOL LO COOL or HEAT pins Intermittent Blower Cooling Cooling heating thermostats have a fan switch that has an ON and AUTO position In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling The motor will operate on the speed tap wire that is connected to the HI COOL ter minal on the control board When used with two stage cooling units the motor will operate on the speed tap connected to
28. hat will reset from a lockout condition after 60 minutes Operational faults 6 7 8 will be reset This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction An example would be a low incoming gas supply pressure preventing unit operation When the gas pressure is restored at some point the watchdog would restart the unit and pro vide heat for the house NOTE If a flame is detected the control flashes the LED for 1 8 of a second and then enters a flame stabilization period IGNITION CONTROL P N 031 01972 000 Normal flame sense current is approximately 3 7 microamps DC ua Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 9 microamps DC ua DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL The control in this furnace is equipped with memory that will store up to five error codes to allow a service technician to diagnose problems more easily This memory will be retained even is 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
29. ld 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 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 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 c
30. nto place 2 Snap the door on or place the door in position and tighten the retaining screws if provided 3 Make sure the door is secure to the end of the filter rack 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 should be visually inspected e 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 e Check the drain lines to make sure there are no cracks or leaks e Check for dirt or lint on any surfaces or on components Do not try to clean any of the surfaces or components Cleaning of the fur nace and its components must be done by a qualified service pro fessional Unitary Products Group If during the inspection of your furnace you find any of the following conditions e Excessive amounts of dust and lint on components e Damaged or deteriorated components or surfaces e Leaks or blockage in the vent pipe passages e 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
31. onnections If the flame is not detected within 2 seconds of the gas valve opening the gas valve is shut off and a retry operation begins If the flame is lost for 2 seconds during the 10 second stabilization period the gas valve is shut off and a retry operation begins During a retry operation the vent motor starts a 15 second inter purge and the ignitor warm up time is extended to 27 seconds If the flame is established for more than 10 seconds after ignition during a retry the control will clear the ignition attempt retry counter If three retries occur during a call for heat the furnace will shut down for one hour If at the end of the one hour shut down there is a call for heat the furnace will initiate a normal start cycle If the problem has not been corrected the furnace will again lockout after three retries 127237 UUM A 0605 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 sec ond The gas valve will de energize and the control will begin a recycle operation A normal ignition sequence will begin after a 15 second inter purge If during the five recycles the gas supply does not return or the fault condition is not corrected the ignition control will lockout for one hour 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 rem
32. ontrol continuously monitors its own operation and the operation of the system If a failure occurs the LED will indicate the failure code If the failure is internal to the control the light will stay on continuously In this case the entire control should be replaced as the control is not field repairable Flash sequence codes 1 through 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 Unitary Products Group 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
33. or faulty hot surface ignitor or burner problem may cause this 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 including the transformer ground 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 127237 UUM A 0605 4 AMBER FLASHES Y present with no G call Normally both Y and G are energized on a call for cooling If a Y signal is present with no G sig nal check to see that the wire from the G terminal on the board to the wall thermostat has not broken or disconnected STEADY ON RED Control failure Replace control board 60 MINUTE AUTOMATIC RESET FROM LOCKOUT This control includes a watchdog type circuit t
34. p 127237 UUM A 0605 WIRING DIAGRAM SECTION IV i de vO8 IOYLNOO S 7 NOLLIN LO 371081NO9 30 SLLSNOVId YI Ens SivI38 s30 saLowino9 NOILINOI NO SLOWINOD aviau IF SE OO AN MTS 2021 Y A38 100 1y661 S 0 E E SJ13HYddY 13 YSILNVHO 30 29914 S331430 ONY 9NIBIM 01313 l L S Na AAA EE N SCENE EE 38831 N3 3SIN N3IG 3813 1100 INN 30 3INVSO4WOJ 3LNOL HSILNVHO 30 IN3N308099V8 O NOILOSNNOD 01914 O Rau AC MA HNA SAL LJUVA S30 INANI IN
35. rn 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 the vent pipe assembly vent blower and condensate pan 7 The heat exchanger is now exposed 8 With a long flexible wire brush clean inside each tube at both the top and bottom The brush must pass around the rear heat exchanger tubes Then vacuum loose the scale and dirt from each tube 9 Replace all components in reverse order Reconnect all wiring 10 Restore electrical power and gas supply to the furnace 11 Check furnace operation 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 Shou
36. s installed in the United States and Canada EXCLUSIONS This warranty does not cover any 1 Shipping labor or material charges 2 Damages resulting from transportation installation or servicing 3 Damages resulting from accident abuse fire flood alteration or acts of God tampering altering defacing or removing the product serial number will serve to void this warranty Damages resulting from use of the product in a corrosive atmosphere Damages resulting from inadequacy or interruption of electrical service or fuel supply improper voltage conditions blown fuses or other like damages Cleaning or replacement of filters Damages resulting from failure to properly and regularly clean air and or water side of condenser and evaporator Damages resulting from 1 freezing of condenser water or condensate II inadequate or interrupted water supply Ill 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

White Rodgers FC9S Maintenance and Service Guide

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