USER’S INFORMATION
ISO 9001
Certified Quality
Management System
EFFICIENCY
RATING
CERTIFIED
MANUAL
MODELS: (Export Only)
All Residential Multi-position Gas Furnaces
(33” Models)
TABLE OF CONTENTS
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTRUCTIONS FOR EXAMINING THE
FURNACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . .3
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . .3
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
TO TURN OFF THE APPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FURNACE MAINTENANCE - USER INFORMATION . . . . . . . . . . . . 3
EXTERNAL AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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:
Johnson Controls Unitary Products
Consumer Relations
5005 York Drive
Norman, OK 73069
How to Clean your Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BLOWER CARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
MOTOR LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
TROUBLESHOOTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . .4
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .4
FURNACE MAINTENANCE - DEALER/CONTACTOR . . . . . . . . . . .4
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
We recommend that the user read all sections of this
manual and keep the manual for future reference.
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 (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 department.
— Installation and service must be performed by a qualified
installer, service agency or the gas supplier.
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
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 injury
WARNING indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or mo derate injury.
alert against unsafe practices and hazards involving only property damage.
.
.
It is also used to
1. The furnace area must be kept clear and free of combustible materials, 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 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 flooddamaged furnace is extremely dangerous. Attempts to use the furnace 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.
7. NEVER . . .Store flammable materials of any kind near your furnace. 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.
435337-XUM-A-0209
435337-XUM-A-0209
Blue Cone Portion of Flame Should
Enter Heat Exchanger Tube
Vent Pipe
Pressure
Switch
Silicone
Tube
Rollout
Safety Switch
Gas Valve
Flame
Sensor
Induced Draft
Assembly
Induced
Draft Motor
Limit Switch
Ignitor
Manifold
Pipe
Safety
Door Switch
Control
Board
Flue
Collar
Electrical
Junction Box
Blower
Transformer
Capacitor
Vent Pipe
Pressure
Switch
Manifold
Pipe
Rollout
Safety Switch
Gas Valve
Flame Sensor
Manifold Draft
Assembly
Limit Switch
Ignitor
Safety
Door Switch
Control
Board
Electrical
Junction Box
Blower
Transformer
Capacitor
Condensate
Pan
Silicone Tube
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, Personal Injury, 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 Figures 2 - 3 for visual reference.
1. Examine the heat exchanger, vent pipe, combustion air passages,
vent connectors and chimney to be sure they are clear and free of
obstructions.
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 terminate 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 adjustment. Refer to the pictorial sketch shown in Figure 1 as a comparison to the actual flame.
FIGURE 1: 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 condensate, and that there is no water leakage or damage to the furnace
or any components.
FIGURE 2: Component Location - 80% Single Stage Models FIGURE 3: Component Location - 95% Single Stage Models
2 Johnson Controls Unitary Products
435337-XUM-A-0209
Inlet
Wrench
Boss
Inlet
Pressure
Port
ON
OFF
On/Off Switch
(Shown in ON position)
Main Regulator
Adjustment
Outlet
Outlet
Pressure
Port
Vent Port
External Manual
Shutoff Valve
To Gas
Supply
To Gas
Supply
Grounded Joint Union
may be Installed
Inside or Outside Unit.
Drip Leg
SECTION III: START-UP AND SHUTDOWN
INSTRUCTIONS
Read the Instructions Below Before Trying to Start the
Furnace!
If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal
injury, and/or loss of life.
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 operation 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 distributes the warm air throughout the home. When the temperature setting on your thermostat is reached, the gas valve closes, the main
burners are turned off, and the blower continues to run until the remaining 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” position. 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. Immediately 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 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 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 furnace burner access panel/door.
9. Turn on all electric power to the appliance.
10. Set thermostat to the desired setting. Burner will light, which may
11. After three (3) trials for ignition, if the appliance will not operate fol-
Johnson Controls Unitary Products 3
take 30-60 seconds.
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. Turn off all electric power to the appliance if service is to be performed.
3. Remove furnace burner access panel/door.
4. Move gas control switch to the “OFF” position. See Figure 4.
5. Replace furnace burner access panel/door.
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.
FIGURE 4: Single Stage Gas Valve
FIGURE 5: Gas Piping
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 to the furnace. Check all metal parts and surfaces
to be sure they have cooled to room temperature before
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 casing 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 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 furnace and its components must be done by a qualified service professional.
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 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. Turn 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 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.
BLOWER CARE
Even with good filters properly in place, blower wheels and motors will
become dust laden after months of operation. The entire blower assembly 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.
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.
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 5.
3. Check that the ON/OFF switch on the gas valve is turned to the
ON position. Refer to Figure 4.
4. Check that the furnace blower access panel/door is correctly positioned. The electrical power supply will be cut off if this door is
removed.
FURNACE CONTROL DIAGNOSTICS
The electronic furnace control supplied on this furnace is e quipp ed with
a diagnostic light which flashes when there is a service problem with the
furnace. The number of times the light flashes indicates the location of
the problem, as listed below:
One flash - Ignition failure -- Check for proper gas flow and gas pressure, gas valve operation and flame sensor operation. Check for proper
location of ignitor.
Two flashes - Pressure switch stuck closed. Check for shorted wires,
bad pressure switch.
Three flashes - Pressure switch failed to close -- Check vent blower,
pressure switch, vent blockage, disconnected pressure hose.
Four flashes - Limit switch open -- Check for open limit switch, open
rollout switch, loose connections in limit circuit.
Five flashes - False flame sense -- Check for stuck open gas valve.
Six flashes - Reversed polarity -- Check polarity.
FURNACE MAINTENANCE - DEALER/CONTACTOR
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 manufacturer 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 disassembly 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 components of this furnace. Contact your local contactor, dealer, or service
provider for additional information.
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 service provider.
Subject to change without notice. Printed in U.S.A. 435337-XUM-A-0209
Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: Nothing
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 Unitar y Products
5005 York Drive
Norman, OK 73069
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