Coleman 33, MG9S User's Information Manual

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USER'S INFORMATION MANUAL

MODELS:

33" Multi-position Gas Furnaces (Manufactured Housing or Modular Home Applications)

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TABLE OF CONTENTS

SAFETY 1 Removing Filters For Manufactured (Mobile) Home INSTRUCTIONS FOR EXAMINING THE And Modular Home Installations Without A Return FURNACE INSTALLATION 2 Air Duct System And Plenum 4

START-UP AND SHUTDOWN INSTRUCTIONS 2 BLOWER CARE .4

HOW YOUR GAS FURNACE WORKS 3 MOTOR LUBRICATION 5

OPERATING INSTRUCTIONS 3 SERVICE INFORMATION 5

TO TURN OFF THE APPLIANCE 3 TROUBLESHOOTING PROBLEMS 5

FURNACE MAINTENANCE - USER INFORMATION 4 FURNACE CONTROL DIAGNOSTICS 5

EXTERNAL AIR FILTERS 4 FURNACE MAINTENANCE - DEALERICONTACTOR 5

How to Clean your Filter 4 REPLACEMENT PARTS LIST 5

Removing Filters For Manufactured (Mobile) Home And Modular WIRING DIAGRAM 5

Home Installations Using A Return Air Duct System And Plenum 4 LIMITED WARRANTY 6

CONTACT INFORMATION FOR USA

DISTRIBUTED BY: StyleCrest 801 W. 37th Street Building #7 Wichita, Ks 67219

We recommend that the user read all sections of this

manual and keep the manual for future reference.

Manufacturer:

Johnson Controls Unitary Products

rAWARNINGl

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:

Do not try to light any appliance.

Do not touch any electrical switch; do not use any phone (includ- ing cell phone) in your building.

Leave the building immediately.

Immediately call your gas supplier from a neighbor's phone. Fol- low 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 supplier.

SECTION I: SAFETY

IAI

Understand and pay particular attention to the signal words DANGER,

WARNING, or CAUTION.

DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious injurv.

This is a safety alert symbol. When you see this symbol on

~_ !abels or in manuals, be alert to the potential for personal

mjury,

CONTACT INFORMATION FOR CANADA

Go to website at www.york.com click on "contact", then click on

"contact form" and follow the instructions.

Johnson Controls Unitary Products

Consumer Relations

5005 York Drive

Norman, OK 73069

WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injurv.

CAUTION indicates a potentially hazardous situation, which, if not avoided may result in minor or moderate injurv. It is also used to alert against unsafe practices and hazards involving only property dam-

age.

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 on the furnace or the "START-UP AND

SHUTDOWN INSTRUCTIONS" section of this manual when light-

ing 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 the furnace if deemed necessary.

420706-UUM-A-1008

420706-UU M-A-1 008

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.

8. NEVER ... Store cleaning materials near your furnace. Materials such as bleaches, detergents, powdered cleansers, etc., can cause corrosion of the heat exchangers.

9. NEVER ... Use the area around your furnace as a storage area for items which could block the normal flow of air. This flow of air is required for ventilation of the various furnace components.

~WARNIN~

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-

sonallnjury, and/or Property Damage.

SECTION II: INSTRUCTIONS FOR EXAMINING THE FURNACE

INSTALLATION

It is the owner's responsibility to ensure that an annual inspection of the

entire heating portion of the unit is made by a qualified service agency.

Examine the furnace as outlined below in steps "1 - 8" before each

heating season. Use Figure 1 for visual reference.

3. Examine return connections

For Modular Homes:

a. If the fumace has a return air duct, examine the return air

duct connections to make sure they are physically sound, sealed to the furnace casing, and the ducts terminate out- side the space containing the furnace.

b. If the furnace does not have a return air duct, examine the

return air filter rack connections to make sure they are phys- ically sound, sealed to the furnace casing.

For Manufactured (Mobile) Homes:

a. Examine the return air filter rack connections to make sure

they are physically sound, sealed to the furnace casing.

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.

Manifold Pipe

Ignitor

Gas Valve

Electrical

Junction Box

Silicone Tube

Safety

Door Switch

Transformer

Blower

FIGURE 1: Component Location - 95% Single Stage Models

1. Examine the heat exchanger, vent pipe, combustion air passages, vent connectors and chimney to be sure they are clear and free of

obstructions.

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.

Rollout Safety Switch

Flame Sensor

Limit Switch

Vent Pipe

Pressure Switch

Manifold Draft Assembly

Condensate Pan

Control Board

Capacitor

BLUE CONE PORTION OF FLAME SHOULD ENTER HEAT EXCHANGER TUBE

FIGURE 2: Burner Flame Drawing (Upflow Configuration Shown)

7. Examine and replace external air filters as needed to make sure they are not blocked, and proper airflow is provided to the furnace.

8. Examine any installed accessories or system components such as evaporator coils to insure proper operation, drainage of conden- sate, and that there is no water leakage or damage to the furnace

or any components.

SECTION III: START-UP AND SHUTDOWN

INSTRUCTIONS

Read the Instructions Below Before Trying to Start the Furnace!

~VVARNIN

If you do not follow these instructions exactly,afire or explosion may result causing property damage, personal injury, and/or loss

life.

Johnson Controls Unitary Products

420706-UUM-A-1008

HOW YOUR GAS FURNACE WORKS

Your furnace is a very easy appliance to take for granted. Season after season, it sits there in your home, keeping you warm and comfortable.

For this reason, you may never have given much thought to the way your furnace operates. In order to get the safest and most efficient oper- ation from your furnace, you should understand how your furnace does

its job.

When you set your thermostat to provide more heat in your home, you are starting the heating cycle of the furnace. First, the inducer motor starts to purge the heat exchanger of any remaining gases. Next, the

hot surface ignitor glows and after a warm-up period the gas valve opens and ignition occurs. A short time later, the blower starts and dis-

tributes the warm air throughout the home. When the temperature set- ting on your thermostat is reached, the gas valve closes, the main

burners are turned off, and the blower continues to run until the remain-

ing warm air in the system is distributed. When the blower stops, the

heating cycle has ended.

1. 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.

2. 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.

3. 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.

4. 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.

7. Move gas control switch to the "ON" position. Do not force. See Figure 3.

8. Replace furnace burner access panel/door.

9. Tum 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.

TO TURN OFF THE APPLIANCE

1. Set the thermostat to lowest setting in heating mode.

2. Tum off all electric power to the appliance if service is to be per-

formed.

3. Remove furnace burner access panel/door.

4. Move gas control switch to the "OFF" position. See Figure 3.

5. Replace furnace burner access panel/door.

LAWARNING!

Should overheating occur, or the gas valve fail to shut turn the external manual gas valve in the gas supply line to the furnace to the "off" position and let the furnace cool

before shutting

OUTLET PRESSURE PORT

INLET --.

off

the electrical power supply.

VENT PORT

off,

off

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above for your protection.

2. Set the thermostat to the lowest setting in the heat mode.

3. Turn off all electric power to the appliance.

4. Remove furnace burner access panel/door.

5. Move gas control switch to the "OFF" position. Do not force. See

Figure 3.

6. Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow "B" in the safety information above. If you don't smell gas, go to next step.

To Gas

To Gas Supply

Ground Union

Supply

Ground Union

Gas Valve

Gas Pipe

Upflow

Configuration

WRENCH BOSS /

INLET/ PRESSURE PORT

FIGURE 3: Single Stage Gas Valve

Ground Union

Gas Pipe

ON/OFF SWITCH (Shown in ON position)

Downflow

Configuration

Ground

Union

Gas Valve

FIGURE 4: Upflow/Downflow Gas Piping

Johnson Controls Unitary Products

420706-U U M-A-1 008

SECTION IV: FURNACE MAINTENANCE· USER INFORMATION

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

you begin.

EXTERNAL AIR FILTERS

Filters used with this furnace must be installed external to the furnace casing. DO NOT attempt to install filters inside the furnace cabinet.

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. If the filter location or replacement process is not obvious, contact your installer or service

technician for assistance.

Every time the external air filters are changed the following items should

be visually inspected:

• Check combustion air and vent pipe for blockage or leakage.

• Check for dirt or lint on any surfaces or on components. Do not try

If during the inspection of your furnace, you find any of the following

conditions:

• Damaged or deteriorated components or surfaces.

Do not operate the furnace, call a certified dealer or servicing contractor

to check 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 furnace access panels/doors. Tum ON the gas and electrical power supplies to the furnace, and set thermostat to the desired temperature.

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.

Replace throwaway filter(s) with the same size new filter(s). Throw

away filter(s) may be replaced with cleanable filter(s) at this time.

Removing Filters For Manufactured (Mobile) Home And

Modular Home Installations Using A Return Air Duct Sys-

tem And Plenum

Modular Home downflow furnaces requiring a return duct system by

Local, State, or Regional Codes will have the filters located on the top of

the furnace in an external filter rack located inside the return air plenum

as shown in Figure 5. To check, clean or replace the air filters you

should:

1. Follow the instructions to turn off the appliance before servicing.

2. Filters that are installed in the return air plenum above the blower

the furnace. Check all metal parts and surfaces

be sure they have cooledtoroom temperature before

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.

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.

Excessive amounts of dust and lint on components.

Leaks or blockage in the vent pipe passages. Water on any surface inside or outside of the furnace.

assembly and are located in an "V" frame assembly that supports

the filters as shown in Figure 5.

3. To remove the filters you must remove the screws that are secur- ing the access panels on the return air plenum and remove the

access panels.

4. Lift the filters lightly and remove them.

5. If the filters are the throwaway type you must replace the filters with filters that are the same size as the filters you removed. If you want to replace the throwaway air filters with permanent washable

filters you can do so at this time.

6. If the filters are washable, follow the instructions "HOW TO CLEAN YOUR FURNACE'S FILTER".

7. To reinstall the air filters reverse steps 1 - 6 above.

8. To place the furnace back in operation follow the operating instruc-

tions to place appliance in operation.

Removing Filters For Manufactured (Mobile) Home And

Modular Home Installations Without A Return Air Duct Sys-

tem And Plenum

Manufactured (Mobile) Home downflow furnaces and modular home furnaces not requiring a return duct system by Local, State, or Regional codes will have the filters located on the top of the furnace in an exter-

nal filter rack. To check, clean or replace the air filters you should:

1. Follow the instructions to turn off the appliance before servicing

2. Filters that are installed on the top of the furnace above the blower assembly and are located in an "A" frame assembly that supports

the filters as shown in Figure 5.

3. To remove the filters just slide them out of the assembly. You may have to bend the filters to slide them around the combustion air

and the vent pipes.

4. If the filters are the throwaway type you must replace the filters with filters that are the same size as the filters you removed. If you want to replace the throwaway air filters with permanent washable

filters you can do so at this time.

5. If the filters are washable, follow the instructions "HOW TO CLEAN

YOUR FILTER".

6. To reinstall the air filters reverse steps 1 - 4 above.

7. To place the furnace back in operation follow the operating instruc-

tions to place appliance in operation.

FIGURE 5: Mobile Home Filter Frame

BLOWER CARE

Even with good filters property in place, blower wheels and motors will become dust laden after months of operation. The entire blower assem- bly should be inspected annually. This service must be performed by a

qualified service agency.

NOTE: The spring-loaded safety cut-off switch, mounted at the blower deck will automatically cut off the electrical power supply to the furnace when the furnace blower access panel/door is removed. As a safety precaution, all electrical power and the gas supply to the furnace should be turned off before servicing.

Johnson Controls Unitary Products

Make sure you DO NOT move the clip on weight on the indoor fan wheel when cleaning the wheel. This weight is used to balance the wheel. Moving the weight will cause the fan wheel to vibrate.

MOTOR LUBRICATION

The motors in these furnaces are permanently lubricated, and do not

require periodic oiling.

SECTION V: SERVICE INFORMATION

TROUBLESHOOTING PROBLEMS

If your furnace is not operating correctly, the following visual checks should be made before contacting your local contractor, dealer, or ser- vice provider.

1. Check that electrical power to the furnace is turned on.

2. Check that the manual gas shut-off valve in the gas piping supply is turned to the ON position. Refer to Figure 3.

3. Check that the ON/OFF switch on the gas valve is turned to the ON position. Refer to Figure 3.

4. Check that the furnace blower access panel/door is correctly posi-

tioned. The electrical power supply will be cut off if this door is

removed.

FURNACE CONTROL DIAGNOSTICS

The furnace has built-in, self-diagnostic capability. If a system problem occurs, a blinking LED shows a fault code. The LED can flash red, green or amber to indicate various conditions. It is located behind a clear view port in the blower compartment door.

The control continuously monitors its own operation and the operation of the system. If a failure occurs, the LED will indicate the failure code. If the failure is internal to the control, the light will stay on continuously. In this case, the entire control should be replaced, as the control is not field repairable.

Flash sequence codes 1 through 10 are as follows: LED will turn "on" for 1/4 second and "off" for 1/4 second. This pattern will be repeated the number of times equal to the code. For example, six "on" flashes equals a number 6 fault code. All flash code sequences are broken by a 2 sec- ond "off" period.

420706-UUM-A-1008

SLOW GREEN FLASH: Normal operation.

DOUBLE AMBER FLASH: Normal heating operation - Modulating Fur- nace Models Only

SLOW AMBER FLASH: Normal operation with call for heat.

RAPID RED FLASHES: There is a problem with the operation of this

furnace. Contact your local dealer, contractor or service provider.

FURNACE MAINTENANCE - DEALERICONTACTOR

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.

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.

5. Heat exchanger assembly.

6. Induced draft motor assembly.

REPLACEMENT PARTS LIST

All components, assemblies, accessories, and replacement parts for this furnace are available through qualified service agencies. It is not recommended that the user purchase, install, or replace any compo- nents of this furnace. Contact your local contactor, dealer, or service provider for additional information.

WIRING DIAGRAM

The unit wiring diagram may be found on the inside of one of the access panels on the furnace. It is intended for reference only. If service is required, contact your local contactor, dealer, or service provider.

Johnson Controls Unitary Products

Limited Warranty

Manufactured Housing Furnace

UPG warrants this product to be free from defects in factory workmanship and material under normal use and service and will replace parts that prove to have

such defects according to the terms outlined below.

FURNACE MODELS

Furnace Model

MG9S

'Thermostat labor coverage for 30 days only, no trip allowance.

The warranty period for any replacement heat exchanger or part provided here under shall not extend beyond the warranty period stated above. The heat

exchanger warranty is on a parts only basis: no labor, freight or other service charges are allowed.

The warranty period will begin on the purchase date of the residence when the product is installed as original equipment, or the installation date when installed

in a residence previously purchased by the consumer. Return the Warranty Registration Card to UPG promptly after product installation or purchase for your benefit and protection. The warranty period will begin upon product shipment from UPG in the absence of a recorded Warranty Registration Card.

This warranty applies to the original consumer/purchaser and any subsequent purchaser. The warranty does not apply if the furnace is removed from the orig- inal residence, or if the residence has been moved from the original location where the furnace was placed in service.

This warranty applies only to products installed: (1) in the United States of America or Canada; (2) in accordance with UPG recommendations and specifica- tions outlined in the Installation Manual provided with the product; (3) in accordance with all national, state/provincial, and local codes; and (4) in the original

residence.

1. Shipping/freight, or material charges.

2. Damages resulting from transportation, mishandling, improper application, installation or servicing.

3. Damages resulting from accident, abuse, fire, flood, or other acts of nature.

4. Use of the product in a corrosive atmosphere.

5. Alteration, tampering, defacing or removing the product serial number will serve to void the warranty.

6. Damages resulting from inadequacy or interruption of electrical service, improper energy supply, blown fuses, improper wiring external to the

unit or other like damages.

7. Damages resulting from the use of components not approved by UPG

8. This warranty does not cover consequential damages, incidental damages or incidental expenses including damages to property.

9. Damages caused by failure to perform normal or routine maintenance as set out in the operation and service instructions.

10. Cleaning, replacement of filters, or any other routine maintenance as set out in the User's Information, Maintenance and Service Manual.

11. Replacement or cleaning of nozzles or orifices.

12. Fuses either internal or external to the product.

13. Excessive fuel or electricity consumption.

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, OR LIMIT THE DURATION OF IMPLIED WARRANTIES TO THE DURATION OF THE EXPRESS WARRANTY. IN SUCH STATES, THE DURATION OF IMPLIED WARRANTIES IS HEREBY EXPRESSLY LIMITED TO THE DURATION OF THE EXPRESS WARRANTY ON THE FACE HEREOF. IN NO EVENT, WHETHER AS A RESULT OF BREACH OF WARRANTY OR CON- TRACT TORT (INCLUDING NEGLIGENCE) STRICT LIABILITY OR OTHERWISE, SHALL UPG BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSE- QUENTIAL DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF USE OF THE EQUIPMENT OR ASSOCIATED EQUIPMENT, LOST REVENUES OR PROFITS, COST OF SUBSTITUTE EQUIPMENT. THIS WARRANTY DOES NOT COVER CONSEQUENTIAL DAMAGES. THE ABOVE LIMITATIONS SHALL INURE TO THE BENEFIT OF UPG 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 PERSON TO ASSUME FOR UPG ANY 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.

Consult the Authorized Service Center list packed with the furnace installed in the manufactured home or contact your installing or servicing dealer.

Or, look in the Yellow Pages of the telephone book under Mobile Homes-or Manufactured Housing-Repair and Service for the name and telephone number of the nearest authorized manufactured housing service center. If local authorized service cannot be obtained, or you are unable to contact your installing dealer,

contact the authorized distributor in your area. If there is no distributor in your area, and you cannot obtain proper service under the terms of the warranty, please write: Unitary Products Group (UPG) Customer Relations Department, PO Box 19014, Wichita, KS 67204-9014.

Heat Exchanger

15 years

Exclusions

TO OBTAIN WARRANTY SERVICE

I I

Parts Coverage

2 years

Labor and Trip Coverage"

I I

2 years

420706-UU M-A-1 008 Supersedes: Nothing

Johnson Controls Unitary Products

5005 York Drive

Norman, OK 73069

Coleman 33, MG9S User's Information Manual

Specifications and Main Features

Frequently Asked Questions

User Manual