Coleman 268897-UUM-B, UGAD, UGAE, UGAF User Manual
USER°S INFORMATION,
MAINTENANCE AND
SERVICE
HIGH EFFiCiENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS_ UGAD / UGAE / UGAF
(S_ngleoS_ag÷ UpHow, 92% AFUE,
Manufactured Housin9 or Modular Home Applications)
ISO 9001
Certified Quality
Management System
CONTACT INFORMATION FOR USA ....................... 1
CONTACT INFORMATION FOR CANADA ................... 1
USER'S INFORMATION ................................... 1
SAFETY .............................................. 1
INSTRUCTIONS FOR EXAMINING THE
FURNACE INSTALLATION ............................... 2
HOW YOUR GAS FURNACE WORKS ...................... 3
START-UP AND SHUTDOWN INSTRUCTIONS ............... 3
Read the Instructions Below Before Trying to Start the Furnace.. 3
Operating Instructions: .................................. 3
To Turn Off the Appliance: ............................... 3
FURNACE USER MAINTENANCE .......................... 3
Air Filters ............................................ 4
Replacing Filters ...................................... 4
How to Clean your Filter ................................ 4
Blower Care .......................................... 4
Motor Lubrication ...................................... 4
SERVICE AND MAINTENANCE MANUAL ..................... 5
TABLE
CONTACT INFORMATION FOR USA
• Contact usby mail:
DISTRIBUTED BY:
StyleCrest
801 W. 37th Street
Building #7
Wichita, Ks 67219
MANUFACTURED BY:
York International
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-
ence.
AWARNING
FIRE OR EXPLOSION HAZARD - Failure to follow
safety warnings exactly could result in serious injury,
death, or property damage.
m 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 (included 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
department.
-- Installation and service must be performed by a
qualified installer, service agency or the gas sup-
plier.
OF CONTENTS
SAFETY SECTION ...................................... 5
FURNACE MAINTENANCE SECTION ....................... 5
FURNACE CLEANING SECTION ........................... 5
Burner Removal/Cleaning ............................... 5
Cleaning the Heat Exchanger ............................ 5
Cleaning the Secondary Heat Exchanger ................... 5
TROUBLESHOOTING ................................... 5
SEQUENCE OF OPERATION ............................. 5
Continuous Blower ..................................... 5
Intermittent Blower - Cooling ............................. 6
Heating Cycle ......................................... 6
Hot Surface Ignition System .............................. 6
FURNACE CONTROL DIAGNOSTICS ....................... 6
DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL ...... 7
REPLACEMENT PARTS LIST .............................. 8
REPLACEMENT PART CONTACT INFORMATION ........... 10
WIRING DIAGRAM ...................................... 11
LIMITED WARRANTY .................................... 12
CONTACT INFORMATION FOR CANADA
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
SECTION h 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 the furnace if deemed necessary.
268897-UUM-B-1108
268897-UUM-B-1108
BURNER
BOX
LIMIT
-- GAS VALVE
PRESSURE
SWITCH
DOOR
SWITCH
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.
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.
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.
PIPE
INDUCER
BLOWER
CONDENSATE
TRAP
CONTROL
BOARD
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, vent/combustion air piping, 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.
3. Examine return connections
For Modular Homes:
a. If the furnace 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.
7. Examine the furnace as outlined above in steps "1 - 6" before each
heating season. Use Figure 3 for visual reference.
COMBUSTIONAIR_ •
INTAKE _1
BURNER
I I FLAME
MA,NFOLDJ
\ I CONES
MAIN BURNER
FIGURE 2: Burner Flame Drawing
1 EXTERNAL HEAT EXCHANGER INTERNAL
VENT COMBUSTION AIR PIPE. MUST
REMOVE PANEL TO EXAMINE. VENT PiPE
5EXAMINE ENTIRE
FURNACE CASING
SHOWNINALL
DRAWINGS
3EXAMINE
RETURN AIR
DUCT
CONNECTION
4 EXAMINE
FURNACE
CASING
O o
o©
[]
o
o
[] o
,,_ , ,,_
BURNERDOOR
6REMOVE
PANEL
TO EXAMINE
BURNER
FLAMES
BLOWER DOOR
FIGURE 3: Furnace ExaminationCheckpoints
2 Johnson Controls Unitary Products
2 EXAMINE EXTERNAL
•. ..;
0 o
o <
°[
oD
Q©
4 EXAMINE
,, FURNACE
CASING
b
q
3
EXAMINE
RETURN AIR
DUCT
CONNECTION
(side or bottom)
268897-UUM-B-1108
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.
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:
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. Remove burner door.
5. Move gas control switch to the "OFF" position. Do not force. See
Figure 4.
6. Wait five (5) minutes to clear out any gas. If you then smell gas,
STOP! Follow "B" in the safety information above. If you don't
smell gas, go to next step.
7. Move gas control switch to the "ON" position. Do not force. See
Figure 4.
8. Replace burner 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.
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 upper access panel.
4. Move gas control switch to the "OFF" position. See Figure 4.
5. Replace burner access panel.
WARNING
Should overheating occur, or the gas valve fail to shut off,
turn the external manual gas valve in the gas supply line to
the furnace to the "off"position and let the furnace cool off
before shutting off the electrical power supply. Refer to
Figure 5.
OUTLET ......... _'1_
ENT PORT
PRES_U::T__.__ _
INLET/
PRESSURE
PORT
FIGURE 4: Convertible Gas Valve
EXTERNAL MANUAL
SHUTOFF VALVE
TOGAS F =[_'_ TOGAS
DRIPI_ PLY
LEG INSIDE OR OUTSIDE UNIT.
FIGURE 5: Gas Piping
NOTE: The spring-loaded safety cut-off switch, mounted under the
blower deck will automatically cut off the electrical power supply
to the furnace when the blower panel is removed. As a safety
precaution, all electrical power and the gas supply to the furnace
should be turned off before servicing.
_IN REGULATOR
ON/OFF SWITCH
(Shown in OFF position)
FURNACE USER MAINTENANCE
AWARNING
Before proceeding, be sure the area is well ventilated. Turn
the thermostat OFF. ff 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.
OUTLET
ADJUSTMENT
Johnson Controls Unitary Products 3
268897-UUM-B-1108
Every time the filters are changed the following items should be visually
inspected:
Check combustion air and vent pipe for blockage or leakage.
Check all components to be sure they are in good condition and
that there are no obvious signs of deterioration.
Check the drain lines to make sure there are no cracks or leaks.
Check for dirt or lint on any surfaces or on components. Do not try
to clean any of the surfaces or components. Cleaning of the fur-
nace and its components must be done by a qualified service pro-
fessional.
If, during the inspection of your furnace, you find any of the following
conditions:
Excessive amounts of dust and lint on components.
Damaged or deteriorated components or surfaces.
Leaks or blockage in the vent pipe passages.
Water on any surface inside or outside of the furnace.
Do not operate the furnace, call a certified dealer / servicing contractor
to check and / or clean your furnace, or for more information if you have
questions about the operation of your furnace.
If all components appear to be in good operating condition, replace the
front panels. Turn ON the gas and electrical power supplies to the fur-
nace, and set thermostat to the desired temperature.
Air Filters
Dirty filters greatly restrict the flow of air and may cause damage to the
moving parts of the furnace. If the filters become clogged the heat
exchangers and blower motor could overheat resulting in a potentially
dangerous situation. The filters should be checked every 3 months. On
new construction, check the filters every week for the first four weeks
and every three weeks after that, especially if the indoor fan is running
continuously. When replacing the filter(s) you must use filters that are
the same size as those recommended in Table 1. Use the following pro-
cedure to determine the filter size. Never operate your furnace without a
suitable air filter.
1. Measure the furnace width and use that measurement to deter-
mine the cabinet width.
• A 17-1/2" wide cabinet is a "B" cabinet.
• A 21" wide cabinet is a "C" 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. If the 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. If the 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.
Replacing Filters
Filters used with this furnace must be installed external to the furnace
casinq 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. 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.
TABLE 1: Filter Sizes
Cabinet Size Side (in) Side (mm) Bottom (in) Bottom (mm)
17-1/2" (B) 16 x 25 406 x 635 16 x 25 406 x 635
21" (C) 16x25 406 x 635 20x25 508 x 635
How to Clean your Filter
High-velocity filters may be cleaned with a vacuum cleaner or washed
with a garden hose. Be sure to shake off excess water and allow filter to
completely dry before re-installing the filter.
Blower Care
Even with good filters properly in place, blower wheels and motors will
become dust laden after long months of operation. The entire blower
assembly should be inspected annually. If the motor and wheel are
heavily coated with dust, they can be brushed and cleaned with a vac-
uum cleaner. If the blower cannot be properly cleaned without removing
it from the furnace, then this service must be performed by a qualified
service agency.
kWARNING
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.
Every time the filters are changed the following items should be visually
inspected:
• Check combustion air and vent pipe for blockage or leakage.
• Check all components to be sure they are in good condition and
that there are no obvious signs of deterioration.
• Check the drain lines to make sure there are no cracks or leaks.
• Check for dirt or lint on any surfaces or on components. Do not try
to clean any of the surfaces or components. Cleaning of the fur-
nace and its components must be done by a qualified service pro-
fessional.
If, during the inspection of your furnace, you find any of the following
conditions:
Excessive amounts of dust and lint on components.
Damaged or deteriorated components or surfaces.
Leaks or blockage in the 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.
4 Johnson Controls Unitary Products
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