Users Man PS8 DN
Contents
1. VOZ0 8 Ada CcOO E 561 SEO e C7 ke zaj ZSI 13 IST JSAV Ais 30 ISS A ZSJ ON2. 8 Unitary Products Group i ELECTRICAL 7 i i E 3 i i FABRICATED PARTS 18 BAFFLE FLUE BURNER MAIN GAS BRACKET IGNITOR BRACKET IGNITOR e as 2 e SEN RES CH LS B 035 19922 002 Rev A 0704 S z a a S e MISCELLANEOUS d Z x a PLATE RESTRICTOR COLLAR FLUE HANDLE DOOR GASKET RESTRICTOR PLATE TUBING SILICONE 42 WIRING DIAGRAM WIRING HARNESS NOTE Not Shown Major components and suggested stocking items are shown with shaded item number Unitary Products Group 9 035 19922 002 Rev A 0704 FIELD INSTALLED ACCESSORIES NON ELECTRICAL MODEL NO DESCRIPTION USED WITH P4DN032 064 080 1NP0347 G8T040 080 100 PROPANE LP CONVERSION KIT P4DN48 092 104 1NP0348 G8T060 115 130 1PS0301 1PS0302 1PS0302 s HIGH ALTITUDE PRESSURE SWITCH KIT EN 1PS0311 Does Not Include Orifices 1PS0312 1BR0314 14 1 2 CABINETS 1BR0317 External Bottom Return Filter with High Velocity Filter for Horizontal Applica 17 1 2 CABINETS 1BR0321 tion for Upflow Bottom Return Application 21 CABINETS 1BR0324 24 1 2 CABINETS 1CB0314 14 1 2 CABINETS 1CB0317 17 1 2 CABINETS COMBUSTIBLE FLOOR BASE FOR DOWNFLOW UNITS 1CB0321 21 C
3. USER S INFORMATION MAINTENANCE AND SERVICE MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES MODELS PS8 FC8S FL8S Single Stage Downflow EFFICIENCY RATING CERTIFIED Lait gf Ap P 7 ih 8000 REGISTE This product was manufactured in a plant whose quality system is certified registered as being in conformity with ISO 9001 TABLE OF CONTENTS CONTACT INFORMATION 000 00 cece eee ee eee 1 FURNACE MAINTENANCE GECTION naaa 5 USER S INFORMATION 00c0 cc eee e ence eee eens 1 FURNACE CLEANING SECTION 0 0 00 00 ee eee 5 CAPET orreee aTa a a Gene ot su eeduawneyeueceas 1 B rner MeMmOVal Cleaning ege AE re e eg See 5 INSTRUCTIONS FOR EXAMINING THE FURNACE Cleaning the Heat Exchanger 5 INSTALLATION 0 0 00 0 e cc eee 2 SEQUENCE OF OPERATION 00 0 000 eee eee 6 HOW YOUR GAS FURNACE WORKS 20e0e00 3 Continuous Blower 0 0 00 ee ee 6 START UP AND SHUTDOWN INSTRUCTIONS 3 Intermittent Blower Cooling 6 Read the Instructions Below Before Trying to Start the Furnace 3 Heating CyCo Wee eee ee ee eee 6 Operating Instructions 0 0 cece eee 3 Hot Surface Ignition System 0 0 2 6 To Turn Off the Appliance 00 0 cece eee eee 3 TROUBLESHOOUING EEN 6 FURNACE USER MAINTEN
4. 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 access panel 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 OU ee IN To Turn Off the Appliance 1 Set the thermostat to lowest setting Unitary Products Group 035 19922 002 Rev A 0704 2 Turn off all electric power to the appliance if service is to be per formed 3 Remove burner access panel 4 Move gas control switch to the OFF position See Figure 4 5 Replace burner access panel AWARNING 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 PRESSURE PORT MAIN REGULATOR PRESSURE ADJUSTMENT PORT ON OFF SWITCH Shown in ON position EXTERNAL MANUAL SHUTOFF VALVE TO GAS SUPPLY GROUNDED JOINT UNION MAY BE INSTALLED INSIDE OR OUTSIDE UNIT FIGURE 5 Gas Piping NOTE The spring loaded safety cut off switch
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7. Per sonal Injury and or Property Damage 5 EXAMINE ENTIRE FURNACE CASING SHOWN IN ALL DRAWINGS EXAMINE EXTERNAL VENT PIPE j REMOVE 3 PANEL TO EXAMINE BURNER FLAMES 4 EXAMINE FURNACE CASING EXAMINE RETURN AIR DUCT CONNECTION FIGURE 3 Furnace Examination Checkpoints 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 6 before each heating season Use Figure 3 for visual reference 1 Examine the heat exchanger vent pipe combustion air passes ges vent connectors and chimney to be sure they are clear and free of obstructions 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 Examine the return air duct connections to make sure they are physically sound sealed to the furnace casing and the ducts ter minate outside the space containing the furnace 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 Examine the furnace casing for obvious signs of deterioration Examine the burner flames to make sure they are in good
8. SC Gau SC AAG FE 0091 oz SE e t SION gt 78 Lan 13 gt condao naa SION CSIOND anaLYLMWWOZ gt L Ava SE J5 So g g 118 0002 00 Me HEEN ee ine ys ok Man CMS Conga enaa CION SION 5 Ages wes CATON A78 KOSS op aaa rg a V SN ong Ig 1NIN INY78 gt LASN LH CINVIS CONV Ta COnos gt naqg gt SION C STON fan v I gt 009 080 Na Mie Map d O o JLIHM 1HM gaa g g x579 5 R sy8 amp 39N03 gt MO aad a E S ato Qo SNNVE gt NIVE gt COMMS CNOC gt CNT CHION ons 080 Pa MIND NSS U Syg GJW INNYF gt BE ee MII gt Nat 2soa NON soa WTA JA gaa J34 mg gt 78 SE WII 03W 03A 3 F 39ND Conoa gt Comoe ONAye enag CSION 5 Q CLSSA NSO 7 af ILAYHI AIDA o aa aie A ae See SC ooz ogo 5 0334S IMD D in 5 Jz D S Ee aig naa Conoay NAY aa CATON a ee ae TH 03W 03W 078 aOd LAVHI Jas ma S EE m me m c SOLOW aa i J 18 CIMVH SIUN IH sa CSION SION CIVIS CLVLS YHD CYRI TI CWI CSS8INSD ERR SR Yavd M003 07 ez D09 J ONT 39V IIA fil C bal V a e CLNAWS0SDIIVa 2 WNVAUVIU 7 SES N INNO alla What St GUD a Sot Te al AVHJ wvaJvid NO AJA SIE JJIM Laut 0334S SW FIGURE 8 11 Unitary Products Group Limited Warranty UPG warrants this product to be free from defects in factory workmanship and material under normal use and service and will at its option repair or replace any
9. 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 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 Every time the filters are changed the following items should be visually inspected e Check combustion air and vent pipe for blockage or leakage e Check all components to be sure they are in good condition and that there are no obvious signs of deterioration e Check the drain lines to make sure there are no cracks or leaks e Check for dirt or lint on any surfaces or on components Do not try to clean any of the surfaces or components Cleaning of the fur nace and its components must be done by a qualified service pro fessional 035 19922 002 Rev A 0704 lf during the inspection of your furnace you find any of the following conditions e Excessive amounts of dust and lint on components e Damaged or deteriorated components or surfaces e Leaks or blockage in the vent pipe passages e Water on any surface inside or outside of the furnac
10. 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 e Check combustion air and vent pipe for blockage or leakage e Check all components to be sure they are in good condition and that there are no obvious signs of deterioration e Check the drain lines to make sure there are no cracks or leaks e Check for dirt or lint on any surfaces or on components Do not try to clean any of the surfaces or components Cleaning of the fur nace and its components must be done by a qualified service pro fessional If during the inspection of your furnace you find any of the following conditions e Excessive amounts of dust and lint on components e Damaged or deteriorated components or surfaces e Leaks or blockage in the vent pipe passages e Water on any surface inside or outside of the furnace Do not operate the furnace call a certified dealer servicing contractor to check and or clean your furnace or for more information if you have questions about the operation of your furnace If all components appear to be in good operating condition replace the front panels Turn ON the gas and electrical power supplies to the fur nace and set thermostat to the desired temperature SECTION II SERVICE AND MAINTENANCE MANUAL SAFETY SECTION The following safety rules must be
11. a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire depart ment 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 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
12. adjust ment Refer to the pictorial sketch shown in Figure 2 as a compari son to the actual flame BLUE CONE PORTION OF FLAME SHOULD ENTER HEAT EXCHANGER TUBE FIGURE 2 Burner Flame Drawing 1 EXTERNAL HEAT EXCHANGER INTERNAL VENT COMBUSTION AIR PIPE MUST Ba REMOVE PANEL TO EXAMINE 6 REMOVE PANEL TO EXAMINE BURNER FLAMES 4 EXAMINE FURNACE CASING S EXAMINE RETURN AIR DUCT CONNECTION side or bottom Unitary Products Group HOW YOUR GAS FURNACE WORKS Your furnace is a very easy appliance to take for granted Season after season it sits there in your home keeping you warm and comfortable For this reason you may never have given much thought to the way your furnace operates In order to get the safest and most efficient oper ation from your furnace you should understand how your furnace does its job When you set your thermostat to provide more heat in your home you are starting the heating cycle of the furnace First the inducer motor starts to purge the heat exchanger of any remaining gases Next the hot surface 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 st
13. assem bly to the vestibule panel The surface is also gasketed The assembly including the flue baffle plate rear may be vacuumed or cleaned with hot water if necessary 3 The upper portion of the heat exchanger is now accessible 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 Vacuum loose scale and dirt from each tube 4 Clean Replace all components in reverse order Re gasket all surfaces which required a gasket Reconnect all wiring Reattach vent pipe and gas supply lines before restoring service to furnace Restore electrical power check gas supply piping for leaks and then verify furnace operation A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and danger ous operation Verify proper operation after servicing SEQUENCE OF OPERATION The following describes the sequence of operation of the furnace Refer to Figure 1 for component location Continuous Blower Cooling heating thermostats have a fan switch that has an ON and AUTO position In the ON position the thermostat circuit is completed between terminals R and G The motor will operate on the speed tap selected on the Continuous Fan speed Jumper on the control board HI COOL LO COOL or HEAT pins Intermittent Blower Cooling Cooling heating thermostats have a fan switch that has an ON and AUTO positi
14. followed when servicing the AWARNING ELECTRIC SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous operation serious injury and death or property damage Before servicing disconnect all electrical power to the fur nace When servicing controls label all wires prior to disconnect ing Reconnect wires correctly Verify proper operation after servicing Unitary Products Group 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 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 FURNACE CLEANING SECTION NOTE The cleaning operations listed be
15. 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 faulty hot surface ignitor or burner problem may cause this The furnace will lock out for one hour and then restart Unitary Products Group 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 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 Check that flame probe is not shorted to chassis 10 RED FLASHES Gas valve energized 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 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 c
16. 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 035 19922 002 Rev A 0704 035 19922 002 Rev A 0704 VENT PIPE FLUE COLLAR ELECTRICAL CONTROL JUNCTION BOX BOARD SAFETY SHUTOFF PRESUURE SWITCH SWITCH INDUCED DRAFT ASSEMBLY INDUCED DRAFT MOTOR SILICONE TUBE LIMIT GAS VALVE SWITCH FLAME SENSOR IGNITOR MANIFOLD PIPE FIGURE 1 Component Locations 7 8 9 NEVER Store flammable materials of any kind near your fur nace Gasoline solvents and other volatile liquids should be stored only in approved containers outside your home These materials vaporize easily and are extremely dangerous NEVER Store cleaning materials near your furnace Materials such as bleaches detergents powdered cleansers etc can cause corrosion of the heat exchangers NEVER Use the area around your furnace as a storage area for items which could block the normal flow of air This flow of air is required for ventilation of the various furnace components 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
17. ABINETS 1CB0324 24 1 2 CABINETS 1SR0302 EXTERNAL SIDE FILTER RACK WITH FILTER RACK 6 pack ALL MODELS HIGH PRESSURE SWITCH Input MBH Output MBH 220 e 5 500 gt 5 500 e to10 000 Co o e een O ren Co o a O o O o Coo SI e IT een REPLACEMENT PART CONTACT INFORMATION This is a generic parts list To request a complete parts list refer to the contact information below e Visit our website at www source1parts com for the following information 1 Search for a part or browse the catalog 2 Find a dealer or distributor 3 Customer Service contact information a Click on the Brand Links button b Click on the Customer Service button e You can contact us by mail Just send a written request to York International Consumer Relations 5005 York Drive Norman OK 73069 10 nitary Products Group 035 19922 002 Rev A 0704 WIRING DIAGRAM SECTION IV
18. ANCE eccecceeee 3 FURNACE CONTROL DIAGNOSTICS ao aanananaana annann 6 AW EE 4 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL 7 Removing Fiers a Sege eege D ee E d REPLACEMENT PARTS LIST 0cceee uu enue ueuaaes 8 Ele Gall Cisse gases crew este eras ere ee ee ere 4 REPLACEMENT PART CONTACT INFORMATION 10 Motor Lubrication 0 000 ee ee ee 4 WIRING DIAGRAM 0 00 c eee eee eee 12 SERVICE AND MAINTENANCE MANUAL ceccecs 5 LIMITED WARRANTY 000 c eee e eee ence eee eeaee 12 SAFETY SECTION 00 00 0000 ccc ees 5 CONTACT INFORMATION e Go to website at www york com click on contact then click on contact form and follow the instructions e Contact us by mail York International Consumer Relations 5005 York Drive Norman OK 73069 The manufacturer recommends that the user read all sec tions of this manual and keep the manual for future refer FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or prop erty damage Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other 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
19. OF THE EXPRESS WARRANTY ON THE FACE HEREOF INNO EVENT WHETHER AS A RESULT OF BREACH OF WARRANTY OR CONTRACT TORT INCLUDING NEGLIGENCE STRICT LIABILITY OR OTH ERWISE SHALL UPG BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OF THE EQUIPMENT OR ASSOCIATED EQUIPMENT LOST REVENUES OR PROFITS COST OF SUBSTITUTE EQUIPMENT OR COST OF FUEL OR ELEC TRICITY THE ABOVE LIMITATIONS SHALL INURE TO THE BENEFIT OF UPG S SUPPLIERS AND SUBCONTRACTORS THE ABOVE LIMITATION ON CONSEQUENTIAL DAMAGES SHALL NOT APPLY TO INJURIES TO PERSONS IN THE CASE OF CONSUMER GOODS SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES OR FOR STRICT LIABILITY IN TORT SO THAT THE ABOVE EXCLUSIONS AND LIMITATIONS MAY NOT APPLY TO YOU UPG DOES NOT ASSUME OR AUTHORIZE ANY OTHER PERSON TO ASSUME FOR UPG ANY OTHER LIABILITY FOR THE SALE OF THIS PRODUCT THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE For Owner s Information a E PRODUCT MODEL NO INSTALLATION DATE UNIT SERIAL NO INSTALLING DEALER Subject to change without notice Printed in U S A 035 19922 002 Rev A 0704 Copyright by York International Corp 2004 All rights reserved Supersedes 035 19922 001 Rev A 0404 Unitary 5005 Norman Products York OK Group Drive 73069
20. Y IST HLIM SSISSS NI SI ISS 4 CSV Ave LN A 08 Var U 2 NOILAJDNO2 ST ya 30 S39 310 d INOS SaMSLOW SII 9 0319310 d ATLNSSSHNI Sav SALON 9 NOLIVLNSNIWV 1 004 SSMSLINOCSIG 37 ZSSSINAMOS S SdIdddnS SSMOd Wy X04 SLISNNODSIG 3OIADsd G JV Nc ME JANMOO ZOS aal N3 ASIW NSIG 3al3 LIDD LNAWaIVIdWSe 30 SLNVSOdWOI SLNOL e QSONNOs9 ATaad0dd 38 LSMW SLNSNOdWOI JN 1Y Y SSAIND J30 TIS amd S3LLJAYW SJO INS E AJNO SAGLINONOI Sadd09 X04 JISVLINS SSOLISNNGD E SIIANSS J7 9 3032034 J0 LINA SIHL DNIJIANJS LI 1 dolce SNIOW MV D 3 501 2 LSV471 LV SO SNILVda Salllvadd JL INYAY SanSLIUNOrsig s37 JaAng 304389 SLOSNNOJSIG WW N id SSSMLVASCWSL SSO Y SSLSTSS8 INVANOd XMVIASLYW MII Tou 313 7 Y ONIAVH WWISSLVYW ONISTIM HLIM GSdvIdsa 28 LIN 1I O3iudz2s 1100 7I LMOL N3 NO Ais M SIVIdWSS 29 1I00 i 37 IS e J38 LSMW S3VNaNS SHL HLIM D3I Iddie SY SSIM IYNI I AD JHL D ANY JI e NOILIY JaJa N FISCH vg TINTIN 13 XNY207 S3002 lt 3 3003 ALT aD ne lei 3359 NJIOYNYI 3373 J009 4 XD 0NY 32 gt 3003 29712 NYIOYNYI 8 7 00 13 N33 WWNOTLYN 29712 3003 Y NOTAS AJILNYHI NI S9VIIS IL I SO ONV lt J3N gt 3003 3373 Ten Io Y aad SNIAIM OTIL TW I C3NYHIZYWITI LYLSOW JH1 SALON SJ 10N LVLSOWSSHL 1003 LY EE oio M GER is TSS ZS O WY lt NVHI SadvdnOS 30 SIvqa P 1v3 3X331 Na x Q e ut cavog Dau Ju ek E ih 003 NOILINSI 0 JN LNDI 30 SLLaNUVId YI NS SIVIJ SJO SJLIVINDD j NOILINSI NO SLIVLNOD AVISS AD
21. ation or acts of God tampering altering defacing or removing the product serial number will serve to void this warranty Damages resulting from use of the product in a corrosive atmosphere Damages resulting from inadequacy or interruption of electrical service or fuel supply improper voltage conditions blown fuses or other like damages Cleaning or replacement of filters Damages resulting from failure to properly and regularly clean air and or water side of condenser and evaporator Damages resulting from 1 freezing of condenser water or condensate II inadequate or interrupted water supply Ill use of corrosive water IV fouling or restriction of the water circuit by foreign material or like causes 9 Damages resulting from operation with inadequate supply of air or water 10 Damages resulting from use of components or accessories not approved by UPG vent dampers etc 11 Increase in fuel or electric cost THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABIL ITY AND FITNESS FOR A PARTICULAR PURPOSE SOME STATES DO NOT ALLOW THE DISCLAIMER OF IMPLIED WARRANTY SO THAT THE ABOVE DISCLAIMER MAY NOT APPLY TO YOU SOME STATES ALLOW ONLY A PARTIAL LIMITATION ON IMPLIED WARRANTIES TO LIMIT THE DURATION OF IMPLIED WARRANTIES TO THE DURA TION OF THE EXPRESS WARRANTY IN SUCH STATES THE DURATION OF IMPLIED WARRANTIES IS HEREBY EXPRESSLY LIMITED TO THE DURA TION
22. d 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 3 RED FLASHES This indicates the normally open pressure switch contact did not close after the inducer was energized This could be caused by a number of problems faulty inducer blocked vent pipe bro ken pressure switch hose or faulty pressure switch 4 RED FLASHES This indicates that a primary or auxiliary limit switch has opened its normally closed contacts With this fault code the control will operate the supply air blower and inducer This condition may be caused by dirty filter improperly sized duct system incorrect blower speed setting incorrect firing rate or faulty blower motor 5 RED FLASHES This fault is indicated if the normally closed contacts in the rollout switch opens The rollout control is manually reset If it has opened check for proper combustion air proper inducer operation and primary heat exchanger failure or burner problem Be sure to reset the switch after correcting the failure condition 6 RED FLASHES This indicates that after the unit was operating the pressure switch opened 4 times during the call for heat If the main blower is in a Delay on
23. e 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 Removing Filters Externally Mounted Air Filters The air filter should be located 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 b
24. e 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 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 TABLE 1 Filter Sizes Top Return in Top Return cm R 2 14x 20 2 35 6 x 50 8 35 6 x 50 8 2 2 14x 20 2 35 6 x 50 8 Hr 2 14 x 20 2 35 6 x 50 8 How to Clean your Filter ONLY 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 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
25. llout switches upflow only and the gas valve wires 4 Remove the screws holding the burner assembly to the vestibule panel and remove this assembly Handle the assembly carefully since it contains the igniter which is fragile and easily broken The lower portion of the heat exchanger will now be exposed To clean the burner assembly use a vacuum cleaner or remove the burn ers as outlined in burner cleaning and clean in hot water Upper Heat Exchanger Access 1 Perform steps 1 4 above 2 Disconnect vent piping from the vent motor assembly at the top panel on the furnace upflow only On downflow models the vent pipe is secured to the vent motor outlet with a screw Remove this screw before proceeding 3 Unplug the vent motor wires and ground wire Remove the pres sure switch tubing at the tap on the vent motor housing Unitary Products Group 035 19922 002 Rev A 0704 NOTE It is recommended that replacement gaskets be avail able before removing vent motor 1 Remove six mounting screws that hold the vent motor to the restrictor plate The surface is gasketed and the gasket can be reused if it is carefully removed It is necessary to remove this assembly to gain access to the restrictor plate mounting holes The assembly may be vacuumed if cleaning is necessary If any vent assembly parts are damaged replace with an entire new assembly except for gaskets 2 Remove the perimeter screws attaching the restrictor plate
26. low must be performed only by a qualified service agency 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 Lower Heat Exchanger Access 1 Turn off the electrical power to the unit and turn off gas supply at the shutoff valve 2 Remove the blower and burner compartment access doors Dis connect the gas supply piping at the union to permit removal of the entire burner and gas control assembly from the vestibule panel Use the wrench boss on the gas valve when removing or installing this piping See Figure 4 3 Unplug the igniter from the wire harness Disconnect sensor and rollout switch wires located on top of the air shield Identify and note the location of all leads for ease of reinstallation Also discon nect the wires at the side ro
27. nter purge If during the five recycles the gas supply does not return or the fault condition is not corrected the ignition control will lock out for 60 minutes 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 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 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 any safety control to allow furnace opera tion To do so will allow furnace to operate under poten tially hazardous conditions Do not try to repair controls Replace defective control
28. oling 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 H 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 Calling for Heat E EE Satisfied Seconds 02 17 22 Fan on Delay 30 Seconds THERMOSTAT INDUCER IGNITOR MAIN VALVE HUMIDIFIER ELECTRONIC AIR CLEANER CIRCULATING BLOWER 52 60 90 120 180 SEC LOFF Selectable Fan Off Delay FIGURE 7 Furnace Control Event Schedule Unitary Products Group 035 19922 002 Rev A 0704 SECTION Ill REPLACEMENT PARTS LIST
29. on In the AUTO position the thermostat circuit is completed between terminals R and G when there is a call for cooling The motor will operate on the speed tap wire that is connected to the HI COOL ter minal on the control board When used with two stage cooling units the motor will operate on the speed tap connected to the LO COOL terminal when first stage cooling is operating The motor will operate on the speed tap connected to the HI COOL terminal when second stage cool ing is operating The fan off setting is fixed at 60 seconds for SEER enhancement Heating Cycle When the thermostat switch is set on HEAT and the fan is set on AUTO and there is a call for heat a circuit is completed between terminals R and W of the thermostat When the proper amount of combustion air is being provided the pressure switch will close the ignition control pro vides a 17 Second warm up period the gas valve then opens the gas starts to flow ignition occurs and the flame sensor begins its sensing function The blower motor will energize 30 seconds after the gas valve opens if a flame is detected Normal furnace operation will continue until the thermostat circuit between R and W is opened which causes the ignition system and gas valve to de energize and the burner flames to be extinguished The vent motor will operate for an additional 15 sec onds and the blower motor will operate for the amount of time set by the fan off delay jumper located on the con
30. ondition after 60 minutes Operational faults 6 7 8 will be reset This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction An example would be a low incoming gas supply pressure preventing unit operation When the gas pressure is restored at some point the watchdog would restart the unit and pro vide heat for the house NOTE If a flame is detected the control flashes the LED for 1 8 of a second and then enters a flame stabilization period IGNITION CONTROL P N 031 01973 000 Normal flame sense current is approximately 3 7 microamps DC ua Low flame signal warning starts at 1 5 microamps Low flame signal control lockout point is 0 9 microamps DC ua 035 19922 002 Rev A 0704 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 co
31. ops 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 Donot 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 Set the thermostat to the lowest setting Turn off all electric power to the appliance Remove furnace door 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
32. parts that prove to have such defects according to the terms outlined on this warranty This warranty covers only the equipment described by the Product Model Number and Serial Number listed on the Warranty Registration Card UPG warrants the primary heat exchangers in the product to be free from defects in factory workmanship and material under normal use and service and will at its option repair or furnish a replacement heat exchanger either new or reconditioned that meets the intended fit use and function of the original heat exchanger for any heat exchanger furnished by UPG which proves to have such defects within the duration of warranty coverage Alternatively UPG may at its option extend a replacement allowance to be applied toward the purchase of a new furnace or packaged unit marketed by UPG The exact amount of the allowance will be determined at the discretion of UPG based upon current market conditions but in no case shall this allowance exceed thirty 30 percent of the original consumer purchase price of the furnace excluding such items as ductwork wiring piping and installation costs UPG shall have no responsibility hereunder for installation shipping handling or other charges except as specifically provided herein For your benefit and protection return the Warranty Registration Card to UPG promptly after installation This will initiate the warranty period and allow us to contact you should it become necessary In the absence of a
33. recorded Warranty Registration Card the warranty period will begin upon product shipment from UPG This warranty extends only to the original consumer purchaser and is non transferable For this warranty to apply the product must be installed according to UPG recommendations and specifications and in accordance with all local state and national codes and the product must not be removed from its place of original installation The warranty period for repair or replacement parts provided hereunder shall not extend beyond the warranty period stated on this war ranty HEAT EXCHANGER FURNACE TYPE Residential Applications Non Residential PARTS Original Owner Subsequent Owner Applications pee FCB FLB a w v 5 UPG strongly recommends regular periodic preventative maintenance on this equipment The person most familiar with the equipment in your HVAC system is a UPG dealer The UPG dealer can ensure your maintenance program meets the conditions of the UPG Warranty maximize the efficiency of the equipment and service your unit within the mandated guidelines with regard to unlawful discharge of refrigerants into the atmosphere This warranty applies only to products installed in the United States and Canada EXCLUSIONS This warranty does not cover any 1 Shipping labor or material charges 2 Damages resulting from transportation installation or servicing 3 Damages resulting from accident abuse fire flood alter
34. s 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 sec ond off period SLOW GREEN FLASH Normal operation SLOW AMBER FLASH Normal operation with call for heat RAPID RED FLASH Twinning error incorrect 24V phasing Check twinning wiring RAPID AMBER FLASH Flame sense current is below 1 5 microamps Check and clean flame sensor Check for proper gas flow 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 an
35. trol board See Figure 6 The heating cycle is complete and ready for the start of the next heating cycle 035 19922 002 Rev A 0704 RED LOW SPEED YELLOW MED LOW SPEED BLACK HIGH SPEED BLUE MED HIGH SPEED CONTINUOUS FAN SPEED JUMPER FAN OFF ADJUSTMENT JUMPER FIGURE 6 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 H 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 0 seconds The gas valve will de energize and the control will begin a recycle operation A normal ignition sequence will begin after a 15 sec ond i
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