Page 1
USER’S INFORMATION,
MAINTENANCE AND
SERVICE MANUAL
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS: GF9/GM9/GY9
(Single Stage Downflow/Horizontal)
EFFICIENCY
RATING
CERTIFIED
ISO 9001
Certified Quality
Management System
TABLE OF CONTENTS
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . .4
Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . .5
SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . .5
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Intermittent Blower - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Cleaning the Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . .6
Cleaning the Vent / Air Intake System . . . . . . . . . . . . . . . . . . . . . .6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
• Go to website at www.york.com click on “contact”, then click on “contact form” and follow the instructions.
• Contact us by mail:
York International
Consumer Relations
5005 York Drive
Norman, OK 73069
The manufacturer recommends that the user read all 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 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 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 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 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.
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168106-PUM-A-1205
COMBUSTION
AIR PIPE
BLOWER
ACCESS
PANEL
CONTROL
BOARD
TRANSFORMER
PRESSURE
SWITCH
TUBING
PRESSURE
SWITCHES
GAS
VALV E
GAS
REFERENCE
HOSE
BURNER BOX
FIGURE 1: Component Locations
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.
VENT PIPE
CONDENSATE
HOSE
RAIN
GUTTER
INDUCER
HOUSING
INDUCER
MOTOR
CONDENSATE
DRAIN HOSE
CONDENSATE
TRAP
LIMIT
SWITCH
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 exterior sections of the vent/combustion air piping and the vent connectors 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 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 2 as a comparison 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.
MANIFOLD
MAIN BURNER
END OF
BURNER
BURNER
FLAME
YELLOW
TIPS
INNER FLAME
CONES
(Blue Flame)
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.
3
EXAMINE RETURN AIR
DUCT CONNECTION
4
EXAMINE
FURNACE
CASING
5
EXAMINE CASING
FOR DETERIORATION
6
REMOVE THIS
PANEL TO
EXAMINE THE
BURNER FLAMES
FIGURE 3: Furnace Examination Checkpoints
FIGURE 2: Burner Flame Drawing
BLOWER DOOR
2
REMOVE
THIS PANEL
TO EXAMINE
VENT PIPE
BURNER DOOR
1
PLACE A FIELD
INSTALLED ACCESS
PANEL LOCATED IN
THE DOWNFLOW
PLENUM TO EXAMINE
THE HEAT EXCHANGER
COMBUSTION AIR
TRANSITION
(not shown)
4
EXAMINE
FURNACE
CASING
5
EXAMINE CASING
FOR DETERIORATION
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168106-PUM-A-1205
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 igniter 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.
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.
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 follow 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 performed.
3. Remove burner access panel.
4. Move gas control switch to the “OFF” position. See Figure 4.
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 & 6.
OUTLET
PRESSURE
PORT
INLET
WRENCH
BOSS
INLET
PRESSURE
PORT
ON/OFF SWITCH
(Shown in ON position)
OFF
ON
FIGURE 4: Gas Valve - White Rodgers
EXTERNAL MANUAL
SHUTOFF VALVE
TO GAS
SUPPLY
GROUNDED JOINT UNION
DRIP
LEG
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.
FIGURE 5: Downflow Gas Piping
MANUAL
SHUT-OFF
VALV E
GAS
PIPE
GAS
PIPE
DRIP
LEG
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.
VENT PORT
OUTLET
MAIN REGULATOR
ADJUSTMENT
TO GAS
SUPPLY
DRIP
LEG
GAS BURNERS
GAS VALVE
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168106-PUM-A-1205
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 vacuum cleaner. If the blower cannot be properly cleaned without removing
it from the furnace, then this service must be performed by a qualified
service agency.
The blower can be serviced/removed through the blower access panel
on the inside of the furnace. If there is a combustion air pipe installed
inside the furnace, it may have to be removed to access the blower
access panel. After the combustion air pipe is removed, it is easy to
remove the inside blower access panel by 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.
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 determine the cabinet width.
• A 14-1/2” wide cabinet is a “A” cabinet.
• A 17-1/2” wide cabinet is a “B” cabinet.
• A 21” wide cabinet is a “C” cabinet.
• A 24-1/2” wide cabinet is a “D” cabinet.
2. After you determine the cabinet size and what return configuration
you have, look up the recommended filter size from Table 1.
Removing Filters
Some downflow furnaces have their filters located on the top of the furnace 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 FURNACE’S FILTER”.
4. Reverse the procedure to reinstall filters.
5. Follow the operating instructions to place appliance in operation.
Externally Mounted Air Filters
Some installations may have the air filter in a rack attached to the casing of the furnace or placed in the return air duct. You can gain access
to the filter by pulling on the door or unscrewing the retaining screw,
then slide the filter(s) out of its channel. Replace throw away filter(s)
with the same size new filter(s). Throw away filter(s) may be replaced
with cleanable filter(s) at this time. Cleanable filter(s) may be cleaned as
described in the manufacturer instructions or as described below and
then re-installed.
How to Clean your Filter
High-velocity filters may be cleaned with a vacuum cleaner or washed
with a garden hose. Be sure to shake off excess water and allow filter to
completely dry before re-installing the filter.
To replace the filter after cleaning you must do the following:
1. Slide filter into place.
2. Snap the door on or place the door in position 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:
• 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 / 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 furnace, and set thermostat to the desired temperature.
4 Unitary Products Group
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168106-PUM-A-1205
RED - LOW SPEED
YELLOW - MED. LOW SPEED
BLACK - HIGH SPEED
BLUE -MED. HIGH SPEED
NEUTRALS
HI COOL
HEAT
EAC
L1
XFMR
HUM
PARK
PARK
Y/Y2
W
R
G
C
FAN OFF
ADJUSTMENT
JUMPER
Motor Lubrication
The motors in these furnaces are permanently lubricated, and do not
require periodic oiling.
TABLE 1:
Filter Sizes
Input/Output
BTU/H (kW)
(m
CFM
3
/min)
Cabinet
Size
Top Return Filter
in (cm)
40/37(11.72/10.84) 1200(34) A (2) 14 x 20 (36 x 51)
60/55(17.57/16.10) 1200 (34) B (2) 14 x 20 (36 x 51)
80/75(23.42/21.96) 1200 (34) B (2) 14 x 20 (36 x 51)
80/75(23.42/21.96) 1600 (45) C (2) 14 x 20 (36 x 51)
100/95(29.28/27.82) 1600 (45) C (2) 14 x 20 (36 x 51)
100/95(29.28/27.82) 2000 (57) C (2) 14 x 20 (36 x 51)
120/112(35.14/32.80) 2000 (57) D (2) 14 x 20 (36 x 51)
SECTION II: SERVICE AND MAIN TENANCE
MANUAL
SAFETY SECTION
The following safety rules must be followed when servicing th e
furnace.
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 furnace.
• When servicing controls, label all wires prior to disconnecting. 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 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.
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.
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 terminal on the control board. 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 provides 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 7. The heating cycle is
complete, and ready for the start of the next heating cycle.
FIGURE 7: Typical Heat/Cool Speed Tap Connections
If the flame is not detected within 7 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.
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 second. The gas valve will de-energize and the control will begin a recycle
operation. A normal ignition sequence will begin after a 15 second interpurge. If during the five recycles the gas supply does not return, or the
fault condition is not corrected the ignition control will lockout for 60 mintues.
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 remain de-energized and the ignition sequence will
immediately restart.
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168106-PUM-A-1205
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.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous 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. 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 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 condensate drain pan. Remove the vent blower housing blower and the
condensate pan.
3. Using a stiff wire brush, remove the loose scale or soot from each
tube.
4. Vacuum the secondary heat exchanger.
5. Finish the cleaning procedure by following steps 9 - 11 under
cleaning the Heat Exchanger.
Cleaning the Vent / Air Intake System
Should it be necessary to service the vent / air intake system, the 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 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.
Never bypass pressure switch to allow furnace operation. To do so will allow furnace to operate under potentially hazardous conditions.
Do not try to repair controls. Replace defective con trols
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 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 second “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.
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.
6 Unitary Products Group
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168106-PUM-A-1205
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, broken 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 sensor, 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.
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 signal, 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 that 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 provide 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 (µa)
Low flame signal warning starts at 1.5 microamps.
Low flame signal control lockout point is
0.9 microamps DC (µa)
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
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.
Thermostat Satisfied
0
OFF
15 Sec.
Post
Purge
OFF
OFF
60, 90, 120, 180 SEC.
Selectable Fan Off Delay
OFF
OFF
OFF
OFF
(Seconds)
THERMOSTAT
INDUCER
IGNITOR
MAIN VALVE
HUMIDIFIER
ELECTRONIC
AIR CLEANER
CIRCULATING
BLOWER
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Thermostat Calling for Heat
0
2
17 22
ON
ON
ON
ON
Fan on Delay
30 Seconds
OFF
OFF
OFF
OFF
52
ON
ON
ON
FIGURE 8: Furnace Control Event Schedule
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168106-PUM-A-1205
SECTION III: REPLACEMENT PARTS LIST
53
13
7
43
43
11
34
44
56,57
64
16
1
15
31
35
10
14
32
29
37
54
74
71
18
66
70
5
9
17
27
2
17
54
50
47
59
24
46
58
61
26
71
19
6
9, 37
21
20
22
30
2
4
36
49
42
25
48
6
51
60
14
5
28
30
41
6
42
65
A
79
10
33
41
28
40
45
A
14
44
23
8 Unitary Products Group
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168106-PUM-A-1205
ITEM DESCRIPTION
MOTOR
1MOTOR,DIRECT DRIVE BLOWER
2 MOTOR, INDUCER ASS’Y
ELECTRICAL
CAPACITOR, RUN (7.5MFD/370V)
3
CAPACITOR, RUN (10MFD/370V)
4 SWITCH, LIMIT (INDUCER)
LIMIT, TEMPERATURE (Primary)
5
6 LIMIT, FLAME ROLL-OUT
7 CONTROL, FURNACE MODULE
8* FUSE
9IGNITER
10 SENSOR, FLAME
11 SWITCH, PRESSURE
12 SWITCH, DOOR
13 TRANSFORMER
14 VALVE, GAS
AIR MOVING
15 HOUSING, BLOWER
16 WHEEL, BLOWER
FABRICATED PARTS
17 PANEL, BLOWER COVER
BRACKET, CONDENSATE TRAP
18
19 BURNER, MAIN GAS
20 COIL, CONDENSING
21 SHELF, BLOWER
22 HEAT EXCHANGER ASS’Y
23 MANIFOLD, GAS
24 SHIELD, PAN
25 PAN, CONDENSATE
26 PANEL, LOWER ACCESS
27 PANEL, UPPER ACCESS
28 WRAPPER, BURNER BOX
29 CHANNEL, TOE PLATE
30 COVER, GAS CONTROL
31 PANEL, BOTTOM
32 PANEL, TOP
33 SUPPORT, BURNER
34 WRAPPER, CABINET
35 BRACKET, FILTER
36 PLATE, DIFFUSER
37 BRACKET, IGNITER
38 BRACKET, DOOR SWITCH
39 BRACKET, DOOR
40 BOTTOM PANEL, BURNER BOX
MISCELLANEOUS
ITEM DESCRIPTION
41 PLUG, WINDOW, CLEAR - 1.5”
42 COMBUSTION AIR TRANSITION
TUBING, SILICONE (Gray, .188 ID, 2.83 ft. Req’d)
43
44 TUBING, SILICONE (Preformed)
TUBING, SILICONE (Gray, .188 ID, 1.25 ft. Req’d)
45
46 GASKET, COMBUSTION BLOWER
47 GASKET, CONDENSATE PAN
GASKET, UPPER CONDENSATE PAN (2 Req’d)
48
49 GASKET, GAS CONTROLS
50 GASKET,
GASKET, COMBUSTION AIR TRANSITION
51
CONDENSING COIL
52 GASKET, MOUNTING BRKT (Burner Box)
53 COMBUSTION AIR INTAKE ASSEMBLY
54 VENT PIPE 2” X 15.25” LG.
55 RUBBER SLEEVE 2.5” X 4” LG.
56 GROMMET, MOTOR (3 Req’d)
57 FERRULE (3 Req’d)
COMBUSTION BLWR RESTRICTOR
58
59
WASHER, FLAT FIBERGLASS (2 Req’d)
60
61 HANDLE, DOOR (2 Req’d)
62 CLAMP, HOSE (2 Req’d)
63 HARNESS, MAIN WIRING
64 MOUNT, 1 PC. MOTOR
65 ORIFICE, BURNER
(Natural #45)
66 TRAP, CONDENSATE
67 WIRING DIAGRAM
68 45 DEG STREET ELBOW 2”
69 DRAIN TUBE, CONDENSATE TRAP
70 DRAIN TUBE, COMBUSTION BLOWER
71 DRAIN TUBE,
CONDENSATE PAN
72 DRAIN TUBE, STRAIGHT 21” LG.
73 DRAIN TUBE, RAIN GUTTER
74 DRAIN HOSE ASSEMBLY
75 LOCKNUT, CONDUIT (1/2”)
76 ADAPTER, INSERT
77 BUSHING, THREADED
78 DRAIN TUBE, VENT PIPE
79 BAFFLE, BURNER BOX
80 GROMMET, MANIFOLD
81 VENT PIPE ASSEMBLY
82 DRAIN TUBE, VENT PIPE
83 LOGO/BEZEL PLATE ASSEMBLY
84 FILTER (20 X 14 X .75) (2 Req’d)
NOTE: *Not Shown
Major components and suggested stocking items are shown with shaded item number.
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168106-PUM-A-1205
MODEL NO. DESCRIPTION USED WITH
1NP0347 PROPANE (LP) CONVERSION KIT ALL MODELS
1CT0302 CONCENTRIC INTAKE/VENT 2” ALL MODELS EXCEPT 120 MBH
1CT0303 CONCENTRIC INTAKE/VENT 3” ALL MODELS
1PS0904
1PS0901 60/100/120
1PS0902 80/1200
1PS0903 80/1600
1NK0301 CONDENSATE NEUTRALIZER KIT ALL MODELS
1HT0901 SIDEWALL VENT TERMINATION KIT ALL MODELS
1CB0314
1CB0317 17-1/2” CABINET
1CB0321 21” CABINET
1CB0324 24 1/2” CABINET
1TK0914
1TK0917 17-1/2” CABINET
1TK0921 21” CABINET
1TK0924 24 1/2” CABINET
1VK0901 3-WAY TRANSITION KIT All MODELS
1BR0114 BOTTOM RETURN FILTER KIT 1” FILTER 14-1/2” CABINETS
1BR0214 BOTTOM RETURN FILTER KIT 1-4” FILTER 14-1/2” CABINETS
1BR0117 BOTTOM RETURN FILTER KIT 1” FILTER 17-1/2” CABINETS
1BR0217 BOTTOM RETURN FILTER KIT 1-4” FILTER 17-1/2” CABINETS
1BR0121 BOTTOM RETURN FILTER KIT 1” FILTER 21” CABINETS
1BR0221 BOTTOM RETURN FILTER KIT 1-4” FILTER 21” CABINETS
1BR0124 BOTTOM RETURN FILTER KIT 1” FILTER 24-1/2” CABINETS
1BR0224 BOTTOM RETURN FILTER KIT 1-4” FILTER 24-1/2” CABINETS
FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL
40
HIGH ALTITUDE PRESSURE SWITCH KIT
(Does Not Include Orifices)
14-1/2” CABINET
COMBUSTIBLE FLOOR BASE
14-1/2” CABINET
COIL TRANSITION KIT
REPLACEMENT PART CONTACT INFORMATION
This is a generic parts list. To request a complete parts list, refer to the contact information below:
• Visit our website at www.source1parts.com for the following information:
1. Search for a part or browse the catalog.
2. Find a dealer or distributor.
3. Customer Service contact information.
a. Click on the “Brand Links” button
b. Click on the “Customer Service” button
• You can contact us by mail. Just send a written request to:
York International
Consumer Relations
5005 York Drive
Norman, OK 73069
10 Unitary Products Group
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SECTION IV: WIRING DIAGRAM
168106-PUM-A-1205
FIGURE 9: Wiring Diagram
Unitary Products Group 11
Page 12
Subject to change without notice. Printed in U.S.A. 168106-PUM-A-1205
Copyright © by Unitary Products Group 2005. All rights reserved. Supersedes: 165458-PUM-A-0905
Unitary 5005 Norman
Products York OK
Group Drive 73069
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