USER`S INFORMATION, MAINTENANCE AND SERVICE MANUAL
Contents
1. 23AV 3813 7 V 9NIAVH IVIXSLVW ONISIM HLIM 5 38 15 11 32V ld38 1100 11 1701 N3 3IalVd gov ddW3a 3813 1100 0 114 STIS Z 38 LSMW 5 3Hl HLIM 03174615 SV WNISIBD JHL 40 ANY 2122 XIIVd JINIW 13 XAYDI 22 au 1 tI 13 242 N3IQVNVJ 2313 8 A0 0NY C332 NVICVNVJ 8 gt 0 19 NAD TWNOLLWN 3973 Y NITBS B3IINVHO NJ I ZADNY IIN 3373 WNDILVN V i d DNIJIA 01314 TY SALON SALON Do cava aoaunog G 1 NDILINSI 0 31galND3 119 0 7 v7 ans SIVTS8 S30 S312Y1ND2 ud rr NOTLINSI NO SI2OYINUI2 AYJ T S3avan s 30 v S I38Vddv 2i 33IAB3S 37 23 a3 033 0ad 3d ANVAY 5 12 5 0 37 Z3eAnu NOTLAVOAUd ASTVNUNOd 08 AJAL dKV ID2 08 LINN SNTITASAS 302439 SLISNNOISTO 77 N3d0 NOTLAVO CJDWHJAVWITJ LV LSOWASHL gt iviSOWSSH1 700371v34 bkm o o 6 ANVHID 151 a O 1v3l i 25 O220 13 M3IINVHO 30 S331430 ONY SNIBIM 07914 eL NAD o c1 SOME2. ITEM DESCRIPTION ITEM DESCRIPTION 1 Heat Exchanger Assembly 20 Burner 3 Req d 2 Gasket Vent Blower 21 Door 3 Blower Vent 22 Casing Bottom Cap 4 Tube Pressure 15 23 Plate Logo Bezel 5 Switch Pressure 24 Transition 4 6 Rod Sensor 25 Clip Door Latch 2 per pkg 7 Ignitor 26 Gasket Package 8 Switch Limit open 155 deg 27 Spacer Ferrule 3 Req d 9 Switch Door 28 Switch Roll Out 3 Req d 10 Control Integrated 29 Thermostat Heat Cool 11 Harness Wire 30 Control Box Assembly Ref Only 12 Transformer 40VA 31 Blower Assembly 13 Capacitor 10MFD 370V 32 Burner Assembly Ref Only 14 Wheel Blower 33 Air Box Assembly Ref Only 15 Motor Blower 34 Strain Relief Bushing 16 Mount 1 PC Motor 35 Manifold Gas 17 Motor Mounts Rubber 3 Req d 36 Diagram Wiring 18 Valve Gas 37 Housing Blower Orifice Gas Natural 0 2 000 Ft 38 Wrapper Casing Orifice Gas LP 0 2 000 Ft 19 Orifice Gas Natural High Altitude 2 000 5 000 Ft Orifice Gas Natural High Altitude 5 000 7 000 Ft Orifice Gas LP High Altitude 2 000 7 000 Ft NOTE Not Shown Major components and suggested stocking items are shown with shaded item number FIELD INSTALLED ACCESSORIES NON ELECTRICAL Field Installed Accessories Non Electrical Model No Description USED WITH 1 0805 PROPANE LP CONVERSION KIT 50 7512 1 0806 PROPANE LP CON
3. 7 To Turn Off the 3 FURNACE CONTROL DIAGNOSTICS 7 FURNACE USER MAINTENANCE 4 FIELD INSTALLED ACCESSORIES NON ELECTRICAL 10 Air Filters 4 REPLACEMENT PART CONTACT INFORMATION 10 Removing Filters 4 WIRING DIAGRAM 11 Blower Care casis xc ApURERRA ERES 5 LIMITED WARRANTY 12 Motor Eubricatlon 5 CONTACT INFORMATION FOR USA Contact us by mail DISTRIBUTED BY MANUFACTURED BY StyleCrest York International 801 W 37th Street 5005 York Drive Building 7 Norman OK 73069 Wichita Ks 67219 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 Donottry 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
4. USER S INFORMATION MAINTENANCE AND SERVICE MANUAL HIGH EFFICIENCY CLAM TUBE HEAT EXCHANGER SERIES MODELS UGAE Single Stage Upflow Only 990 REGISTRE ISO 9001 Certified Quality Management System EFFICIENCY RATING CERTIFIED TABLE OF CONTENTS USER S INFORMATION 1 SERVICE AND MAINTENANCE MANUAL 5 SAFETY iceberg pap RR ERA QR E PAGE 1 SAFETY SECTION tease tae br dees 5 CONTACT INFORMATION 1 1 FURNACE MAINTENANCE 5 DESCRIPTION 75 MBH INPUT 8 2 FURNACE CLEANING SECTION 5 INSTRUCTIONS FOR EXAMINING THE Burner Removal Cleaning 5 FURNACE INSTALLATION 2 Cleaning the Heat Exchanger 6 HOW YOUR GAS FURNACE WORKS 3 SEQUENCE OF OPERATION 6 START UP AND SHUTDOWN INSTRUCTIONS 3 Continuous Blower 6 Read the Instructions Below Before Trying to Heating Cycle dcos nsasdexe meae bt been dues 6 Start the F rn ce bese oeste On 3 Hot Surface Ignition 7 Operating 3 TROUBLESHOOTING
5. 75 MBH INPUT MODELS This furnace can be installed in the upflow position Figure 1 shows a typical model in the upflow position The furnace is equipped with an induced draft vent blower and atmospheric burners Combustion air is taken through roof jack and drawn into the burners through the louvers in the front panel Flue gas is drawn from the heat exchanger by the vent blower and discharged through the inside flue pipe to the outside atmosphere This is a forced air furnace The furnace circulating air blower draws cool air from the house passes it over the hot furnace heat exchanger and circulates the warmed air through the ductwork to the house The furnace is equipped with the controls necessary for proper opera tion The various components referred to in this manual and on the fur nace rating plate are identified in Figure 2 ROOF JACK VENT BLOWER GAS VALVE LIMIT SWITCH PRESSURE GAS VALVE SWITCH _ REGULATOR GAS SHUT OFF HOT SURFACE VALVE IGNITOR MANIFOLD MANIFOLD SCREWS SCREWS BLOWER DOOR BURNER BOX SWITCH BLOWER BEHIND PANEL b e FURNACE S 4 LPA CONTROL FIGURE 1 Component Locations INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION It is the owner s responsibility to ensure that an annual inspection of the entire hea
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7. STIJ VedV 13 1 30 S321A30 ONY ONIMIM AMDIOV2 ONS 4 AUD B3I1NVE2 30 IN34304022V8 O 1123 03 07318 T H a 323Id 30 LVLSOWASHL MO LN3ASUSDUD2VBS Ave V iviSOWaSHL NDII23NNUO Ave VY W 2 SIJIINGUI LN2WSNNOTLINO4 30 112 6 2 AOLTIvdvI NNS USIJIINGU SVO BISWBUJSNVSL LI ASWADASNVAL LI ae LNAWANNOTIONO4 30 aNalTov 281 BULTOVdvA NNA aT TAANA AAAS 2 amp Dy D E anggas 30 31IUB 1272NI NOISSSBd 30 afalvi HOLIMS Sasso dl e StS Se 318ISI4 3sn4 ce CNOTILINST JWAIINISd 3LIWIT 90 SMSLVLNWAOD 157 HJLIMS LIWIT ABVaI d 151 e siv ise 4 NDILJUONI O AMSLOW Sid Z Y 37DV1d3238 13 35184 AQLOW ASINONI Ly 192005 8 NId Z 5 NOL L FOMVHI 3OvJerIs 30 NOTLINDIG Sid Z V 3 DV1d32d8 19 SSIBd ES Ed MULINDI 8294805 LOH ly 192005 3 IMI NIS Z ES Ed I30ONI UO NUILINDI U GTUBINUJ 3C 31130EVJd V7 ANS Slid v V 9 3sIBd 25 24 JEBINUIJ NDILINSI NO 192005 IMa NIS v 25 24 4 sive i NOILINSI O 271DaINDZ2 30 3 13nBvJd v AMS Sid ZI v 370 3234 3SI d IS ld ADBINDJ NDILINSI NO 190005 94d ZI 15 4 L 3OTWH2 2 8 30 NOILINOI B31INDI 3OVdNOS LOH NOI ESSE EN CBTISLNO2JIGIWDH O AWTS WOH LONONI O gt 51 Zv5 30 3dvdnDs Ag SVO AD e Da Janavo 7 j ATH NOLINOPSIOG 20 AMSLVL
8. 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 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 D 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 Unitary Products Group 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 burner 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 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 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 tec
9. installed as original equipment or the installation date when installed in a residence previously purchased by the consumer Return the Warranty Registration Card to UPG promptly after product installation or purchase for your benefit and protection The warranty period will begin upon product shipment from UPG in the absence of a recorded Warranty Registration Card This warranty applies to the original consumer purchaser and any subsequent purchaser The warranty does not apply if the furnace is removed from the orig inal residence or if the residence has been moved from the original location where the furnace was placed in service This warranty applies only to products installed 1 in the United States of America or Canada 2 in accordance with UPG recommendations and specifica tions outlined in the Installation Manual provided with the product 3 in accordance with all national state provincial and local codes and 4 in the original residence Exclusions Shipping freight labor or material charges Damages resulting from transportation mishandling improper application installation or servicing Damages resulting from accident abuse fire flood or other acts of nature Use of the product in a corrosive atmosphere Alteration tampering defacing or removing the product serial number will serve to void the warranty Damages resulting from inadequacy or interruption of electrical service improper energy supply blown fuses improper
10. 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 CONTACT INFORMATION FOR CANADA Go to website at www york com click on contact then click on contact form and follow the instructions Contact us by mail York International Consumer Relations 5005 York Drive Norman OK 73069 SECTION 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 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 4 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 g
11. wiring external to the unit or other like damages 7 Damages resulting from the use of components not approved by UPG 8 This warranty does not cover consequential damages incidental damages or incidental expenses including damages to property 9 Damages caused by failure to perform normal or routine maintenance as set out in the operation and service instructions 10 Cleaning replacement of filters or any other routine maintenance as set out in the User s Information Maintenance and Service Manual 11 Replacement or cleaning of nozzles or orifices 12 Fuses either internal or external to the product 13 Excessive fuel or electricity consumption THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABIL ITY AND FITNESS FOR A PARTICULAR PURPOSE SOME STATES DO NOT ALLOW THE DISCLAIMER OF IMPLIED WARRANTY SO THAT THE ABOVE DISCLAIMER MAY NOT APPLY TO YOU SOME STATES ALLOW ONLY A PARTIAL LIMITATION ON IMPLIED WARRANTIES OR LIMIT THE DURATION OF IMPLIED WARRANTIES TO THE DURATION OF THE EXPRESS WARRANTY IN SUCH STATES THE DURATION OF IMPLIED WARRANTIES IS HEREBY EXPRESSLY LIMITED TO THE DURATION OF THE EXPRESS WARRANTY ON THE FACE HEREOF IN NO EVENT WHETHER AS A RESULT OF BREACH OF WARRANTY OR CON TRACT TORT INCLUDING NEGLIGENCE STRICT LIABILITY OR OTHERWISE SHALL UPG BE LIABLE FOR SPECIAL INCIDENTAL OR CONSE QUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE OF THE E
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13. QUIPMENT OR ASSOCIATED EQUIPMENT LOST REVENUES OR PROFITS COST OF SUBSTITUTE EQUIPMENT THIS WARRANTY DOES NOT COVER CONSEQUENTIAL DAMAGES THE ABOVE LIMITATIONS SHALL INURE TO THE BENEFIT OF UPG SUPPLIERS AND SUBCONTRACTORS THE ABOVE LIMITATION ON CONSEQUENTIAL DAMAGES SHALL NOT APPLY TO INJURIES TO PERSONS IN THE CASE OF CONSUMER GOODS SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES OR FOR STRICT LIABILITY IN TORT SO THAT THE ABOVE EXCLUSIONS AND LIMITATIONS MAY NOT APPLY TO YOU UPG DOES NOT ASSUME OR AUTHORIZE ANY PERSON TO ASSUME FOR UPG ANY LIABILITY FOR THE SALE OF THIS PRODUCT THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE TO OBTAIN WARRANTY SERVICE For Coleman Vexar Consult the Authorized Service Center list packed with furnace installed in the manufactured home Ne For Evcon and Red T brands Contact your installing servicing dealer For all brands Look in the Yellow Pages of the telephone book under Mobile Homes Repair and Service for the name and telephone number of the nearest authorized manufactured housing service center If local authorized service cannot be obtained or you are unable to contact your installing contractor contact the authorized distributor in your area If there is no distributor in your area and you cannot obtain proper service under the terms of the warranty please wri
14. VERSION KIT 7516 10016 1LN0802 LOW NOX KIT ALL MODELS 1FF0110 FILTER FRAME KIT 50 7512 1FF0112 FILTER FRAME KIT 7516 10016 1HA0802 HIGH ALTITUDE INSTRUCTION PACKET DOES NOT INCLUDE ORIFICES ALL MODELS 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 itary Products Group 98619 035 20010 001 Rev B 1205 WIRING DIAGRAM SECTION III CPOPO V Ada 100 2310026 6 0 NDILdS2ND2 ANITI avd 30 S3O 31DBd INOS SAMSLOW 551 8 CS12HIDBd Sav SBDIDW G NDLIVINSWITV 7 Bd SAMSLINOSIO S31 ZASSINAMOS 6 S3ITddIs B3HDd 11 SLOSNNOISIO SOIADd S 3aa31 SSIW 38 3 1100 IN3W32VdW38 30 SINWSOdWOI 21001 O30NND 9 38 LSMW S N3NUdADO INGWGOVlH38 DY 2 3SA1NI 30 114 afl d S3lldavW S30 IN3W3 IBS ANO SAOLINGNOS addd2 A04 31871175 SallJ3NND3 3 01 3 122 SNIOW lv d 2 5012 3 122 1SV3 1Y 40 UNIIV SBllvaddw3l SdefiivaddW3l 530 33151538
15. ally hazardous conditions Do not try to repair controls Replace defective controls with UPG Source 1 Parts Never adjust pressure switch to allow furnace operation 1 lhernostat Calling for Heat T Thermostat Satisfied gt 02 17 2 52 0 seconds Fon on Deloy 30 Seconds N 1 1 i THERMOSTAT UE v UFF i i 5 Sec FF DF fF E 1 Purge OFF ON 1 main vave E FF ON i HMIDIFIER OFF FF FF IN i ELECTRONIC aene U ul FF CIRCULATING ue bci BLOWER FF 60 90 120 180 SEC FF Selectoble Fon Off Deloy FIGURE 9 Furnace Event Control Schedule Unitary Products Group REPLACEMENT PARTS LIST 98619 035 20010 001 Rev B 1205 N X lt gt X Y 31 1727 5 Blower l 13 Assembly 18 14 30 Control Box Assembly Unitary Products Group 98619 035 20010 001 Rev B 1205
16. as valve to the furnace before shutting off the electrical supply 6 Do not use this furnace if any part has been under water A flood damaged furnace is extremely dangerous Attempts to use the fur nace can result in fire or explosion A qualified service agency should be contacted to inspect the furnace and replace all gas controls control system parts electrical parts that have been wet or the furnace if deemed necessary 98619 035 20010 001 Rev B 1205 98619 035 20010 001 Rev B 1205 7 NEVER Store flammable materials of any kind near your fur nace Gasoline solvents and other volatile liquids should be stored only in approved containers outside your home These materials vaporize easily and are extremely dangerous 8 NEVER Store cleaning materials near your furnace Materials such as bleaches detergents powdered cleansers etc can cause corrosion of the heat exchangers 9 NEVER Use the area around your furnace as a storage area for items which could block the normal flow of air This flow of air is required for ventilation of the various furnace components A WARNING FIRE OR EXPLOSION HAZARD This furnace is designed and approved for use with Nat ural Gas and LP Propane Gas ONLY DO NOT BURN ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE Burning any unapproved fuel will result in damage to the furnace heat exchanger which could result in Fire Per sonal Injury and or Property Damage DESCRIPTION
17. cally 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 Check combustion air and exterior roof jack vent pipe for block age or leakage 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 Excessive amounts of dust and lint on components Damaged or deteriorated components or surfaces Leaks or blockage in the vent pipe passages Water on any surface inside or outside of the furnace Do not operate the furnace call a certified dealer servicing contractor to check and or clean your furnace or for more information if you have questions about the operation of your furnace If all components appear to be in good operating condition replace the front panels Turn ON the gas and electrical power supplies to the fur nace and set thermostat to the desired temperature Air Filters Dirty fi
18. ce then call a qualified service agency Only a qualified service agency can perform this service Unitary Products Group Motor Lubrication The motors in these furnaces are permanently lubricated and do not require periodic oiling SECTION II SERVICE AND MAINTENANCE MANUAL SAFETY SECTION This section has been designed to assist a qualified service agency in performing service and maintenance on this appliance The homeown ers and or end user must never attempt to perform any service or main tenance on the appliance especially when it involves the removal or adjustment of any parts and or components The following safety rules must be 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 discon necting 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 dete
19. could be caused by low gas pressure or faulty gas valve 9 FLASH Indicates reversed line voltage polarity Both heating and cooling operations will be affected Check polarity at furnace and branch 11 FLASH This fault will be indicated if the rollout jumper wire connec tion soldered into the board is broken If this fault occurs the control will have to be replaced STEADY ON This fault occurs if the gas valve is energized when there is no call for heat If this happens the ventor is energized and will remain energized for 5 seconds or until the fault clears itself at which point the ventor de energizes This failure is counted as a recycle Check the gas valve and control for proper operation 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 1 6 7 8 and Steady On will be reset This provides protection to an unoccupied structure if a temporary con dition 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 Never jump pressure switch to allow furnace opera tion To do so will allow furnace to operate under potenti
20. easy appliance to take for granted Season after season it sits there in your home keeping you warm and comfortable For this reason you may never have given much thought to the way your furnace operates In order to get the safest and most efficient oper ation from your furnace you should understand how your furnace does its job When you set your thermostat to provide more heat in your home you are starting the heating cycle of the furnace First the inducer motor starts to purge the heat exchanger of any remaining gases Next the hot surface ignitor glows and after a warm up period the gas valve opens and ignition occurs A short time later the blower starts and dis tributes the warm air throughout the home When the temperature set ting on your thermostat is reached the gas valve closes the main burners are turned off and the blower continues to run until the remain ing warm air in the system is distributed When the blower stops the heating cycle has ended START UP AND SHUTDOWN INSTRUCTIONS Read the Instructions Below Before Trying to Start the Furnace A WARNING 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
21. ess 1 Perform steps 1 4 in cleaning the heat exchanger 2 Unplug the vent motor wires and ground wire Remove the pres sure switch tubing at the tap on the vent motor housing 3 Disconnect vent piping from the vent motor assembly 4 Remove the screws that secure the vent motor assembly to the flue box and remove the vent motor assembly The surface is also gasketed so be extra careful not to tear the gasket 5 Remove the screws from the flue box that secure the flue box to the vestibule panel and remove the flue box The surface is also gasketed so be extra careful not to tear the gasket 6 The upper portion of the heat exchanger is now accessible With a long flexible wire brush clean inside of each heat exchanger at both the top and bottom The brush must pass around the rear heat exchanger to remove any soot and scale Vacuum loose soot scale and dirt from each heat exchanger 7 After cleaning is complete 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 pip ing for leaks and then verify furnace operation A CAUTION Label all wires prior to disconnection when servicing con trols Wiring errors can cause improper and dangerous operation Verify proper operation after servicing SEQUENCE OF OPERATION Continuous Blower On c
22. hnician or gas supplier To Turn Off the Appliance 1 Setthe thermostat to lowest setting 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 a RON 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 98619 035 20010 001 Rev B 1205 OUTLET PRESSURE PORT BOSS LJ lt gt INLET MAIN REGULATOR PRESSURE ADJUSTMENT PORT ON OFF SWITCH Shown in OFF position FIGURE 4 Gas Valve EXTERNAL MANUAL SHUTOFF VALVE GROUNDED JOINT UNION DRIP MAY BE INSTALLED LEG INSIDE OR OUTSIDE UNIT FIGURE 5 Gas Piping NOTE The spring loaded safety cut off switch mounted behind the blower 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 FURNACE USER MAINTENANCE AWARNING Before proceeding be sure the area is well ventilated Turn the thermostat OFF If the blower is running wait until it stops automati
23. itors 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 11 are as follows LED will turn on for one second and off for one 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 IGNITION CONTROL Normal flame sense current is approximately 3 7 microamps DC va Low flame signal control lockout point is 0 9 microamps DC va 1 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 This fault would typically be caused by a gas valve that leaks through or is slow closing 2 FLASH This indicates that the normally open pressure switch con tacts are stuck in the closed position The control confirms these con tacts are open at the beginning of each heat cycle This would indicate a faulty pressure switch or mis wiring 3 FLASH This indicates the normally open pressure switch contact did not close at the beginning of the heat cycle This could be caused by a number of problems faulty inducer blocked vent pipe bro
24. ken pressure Switch hose or faulty pressure switch 4 FLASH 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 FLASH 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 pri mary heat exchanger failure or burner problem Be sure to reset the Switch after correcting the failure condition 6 FLASH 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 ventor continues to operate until the pressure switch re closes or a call for heat is removed 98619 035 20010 001 Rev B 1205 7 FLASH This fault code indicates that the flame could not be estab lished This no light condition occurred 3 times 3 retries during the call for heat before locking out This may be caused by low gas pressure faulty gas valve faulty hot surface ignitor or burner problem 8 FLASH This fault is indicated if the flame is lost 5 times 5 recycles during the heating cycle This
25. l result in a disruption in the flame and be sensed within 0 8 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 inter 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 A WARNING 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 haz ard from the components of the hot surface ignition sys tem 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 manual shut off valves in the gas line to the furnace must be open 3 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 syste
26. lters 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 procedure to determine the filter size Never operate your furnace without a suitable air filter 1 Locate the cabinet size on Table 1 then determine whether you have a bottom side or top return using the following method a Ifthe return air filters are on the left or right side of the fur nace it is a side return Refer to Figure 6 b Ifthe air filter is on the bottom of the furnace then you have bottom return Refer to Figure 7 c Ifthe air filters are on the bottom and the side of the furnace then you have a bottom and side return You must replace both air filters Brackets with the number two 2 before the fil ter size requires 2 filters Refer to Figures 6 and 7 d Ifthe air filters are on both sides of the furnace then you have a 2 sided return You must replace both air filters 2 After you determine the cabinet size and what return configuration you have look up the rec
27. m s operation 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 sec ond The gas valve will de energize and the control will begin a recycle operation A normal ignition sequence will begin after a 15 second inter purge If during the five recycles the gas supply does not return or the fault condition is not corrected the ignition control will lockout for one hour 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 Unitary Products Group 98619 035 20010 001 Rev B 1205 A WARNING 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 controls 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 fault code is shown by a blinking red LED It is located behind a clear view port in the blower compartment door DO NOT remove the furnace blower compartment panel OR turn off furnace power as either action will clear the control s memory of the fault The control continuously mon
28. mine the furnace casing for obvious signs of deterioration 6 Examine the burner flames to make sure the burners look like they are operating properly The burner flames for natural gas should appear blue with a few yellow tips The burner flames for propane gas should appear blue with moderate yellow tips The flame should appear cylindrical in shape and should extend from the end of the burner into the heat exchanger 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 e BLUE CONE PORTION OF FLAME SHOULD ENTER HEAT EXCHANGER TUBE NO FIGURE 2 Burner Flame Drawing Unitary Products Group 98619 035 20010 001 Rev B 1205 5 EXAMINE ENTIRE 1 EXTERNAL HEAT EXCHANGER INTERNAL EXAMINE EXTERNAL FURNACE CASING VENT COMBUSTIONAIRPIBE MUST ROOF JACK SHOWN IN ALL SE WINGS REMOVE PANEL TO EXAMINE 6 REMOVE REMOVE 4 EXAMINE 4 EXAMINE PANEL PANEL FURNACE FURNACE TO EXAMINE TO EXAMINE CASING CASING BURNER BURNER FLAMES FLAMES 3 3 EXAMINE EXAMINE RETURN AIR RETURN AIR DUCT DUCT CONNECTION CONNECTION FIGURE 3 Furnace Examination Checkpoints Upflow HOW YOUR GAS FURNACE WORKS Your furnace is a very
29. 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 a wrench on the wrench boss on the gas valve when remov ing or installing this piping Refer to 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 rollout 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 With a long flexible wire brush clean inside of each heat exchanger at both the top and bottom The brush must pass around the rear heat exchanger to remove any soot and scale Vacuum loose soot scale and dirt from each heat exchanger 5 After cleaning is complete 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 pip ing for leaks and then verify furnace operation Upper Heat Exchanger Acc
30. ommended filter size from Table 1 You must replace the air filters with the same size as recommended Removing Filters Externally Mounted Air Filters The air filter is in a rack that is attached to the casing of the furnace or placed in the return air duct Figures 6 and 7 indicate possible external air filter box locations Seeseees AIR FILTER AIR FIRER PACK RACK ACCESS ACCESS DOOR FURNACE DOOR m y AIR FLOW SS ssese LEFT SIDE RIGHT SIDE FILTER RACK FILTER RACK FIGURE 6 External Air Filter Rack Left amp Right Side Position Unitary Products Group ESESESEBESESESES FURNACE AIR FILTER RACK BOTTOM FILTER ACCESS DOOR AIR FLOW t FIGURE 7 External Air Filter Rack Bottom Position To remove the filter you must do the following DUCT 1 Before proceeding be sure the area is well ventilated Follow instruction To turn off the appliance Check all metal parts and surfaces to be sure they have cooled to room temperature before you begin 2 Remove the door by removing the retaining screw s if provided 3 Remove the air filter by pulling on it The air filter will slide out of the rack 4 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 instruction
31. ooling heating thermostats with fan switch when the fan switch is set in the ON position a circuit is completed between terminals R and G of the thermostat The blower motor is energized through the cool fan terminal on the ignition control module Intermittent Blower Cooling On cooling heating thermostats with fan switch when the fan switch is set in the auto position and the thermostat calls for cooling a circuit is completed between the R Y and G terminals The motor is energized through the cool fan terminal and runs on the selected speed The fan off setting is fixed at 60 seconds for SEER enhancement Heating Cycle When the system switch is set on HEAT and the fan is set on AUTO and the room thermostat calls for heat a circuit is completed between terminals R and W of the thermostat When the proper amount of com bustion air is being provided a pressure switch activates the ignition control The ignition control provides a 17 second warm up period The gas valve then opens for 10 seconds As the gas starts to flow and ignition occurs the flame sensor begins its sensing function If a flame is detected during the 10 second flame sta bilization period the circulating blower will energize 30 seconds after the gas valve opens 20 seconds after the flame stabilization period ends Normal furnace operation will continue until the thermostat circuit between R and W is opened When the thermostat circuit opens the ignition cont
32. rioration 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 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 furnace burners ignitor and flame sensor FURNACE CLEANING SECTION NOTE The cleaning operations listed below 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 98619 035 20010 001 Rev B 1205 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 Rinsing in hot water may clean burners 8 Reassemble in the reverse order Cleaning the Heat Exchanger NOTE It is recommended that replacement gaskets be available before removing vent motor Lower Heat Exchanger Access 1 Turn off the electrical power to the unit and turn
33. rol is de energized When the ignition control is de ener gized the gas flow stops and the burner flames are extinguished The ventor continues to operate for 15 seconds after the gas flow stops FAN OFF ADJUSTMENT SWITCHES FIGURE 8 Typical Heat Cool Speed Tap Connections The blower motor continues to operate for the amount of time set by the fan off delay Jumper located on the ignition control board Figure 16 The heating cycle is complete and the furnace is ready for the start of the next heating cycle Unitary Products Group If the flame is not detected within 2 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 ventor 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 wil
34. s or as described in these instructions To replace the filter after cleaning you must do the following 5 Slide filter into place If the filter has been cleaned make sure it is dry before re installing it 6 Replace the door or cover panel and tighten the retaining screws if provided 7 Make sure the door is secure to the end of the filter rack and Sealed to prevent leaks 8 Follow the Operating Instructions to place the furnace back in operation TABLE 1 Filter Sizes 98619 035 20010 001 Rev B 1205 A WARNING 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 Cabinet Side Return Bottom End Return Size in cm in em 25x16 64 x 41 24x15 61 x 38 How to Clean your Filter High velocity filters may be cleaned with a vacuum cleaner or washed with a garden hose Be sure to shake off excess water and allow filter to completely dry before re installing the filter Blower Care Even with good filters properly in place blower wheels and motors will become dust laden after long months of operation The entire blower assembly should be inspected annually If the motor and wheel are heavily coated with dust they can be brushed and cleaned with a vac uum cleaner If the blower cannot be properly cleaned without removing it from the furna
35. te Unitary Products Group UPG Customer Relations Department PO Box 19014 Wichita KS 67204 9014 Subject to change without notice Printed in U S A 98619 035 20010 001 Rev B 1205 Copyright by York International Corp 2005 All rights reserved Supersedes 035 20010 001 Rev A 0704 Unitary 5005 Norman Products York OK Group Drive 73069
36. ting 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 Figures 2 and 3 for visual reference 1 Examine the heat exchanger through a field installed access panel located on the supply air plenum Visually examine the exte rior sections of the vent combustion air piping and the vent con nectors 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 return connections For Modular Homes a If the furnace has a return air duct examine the return air duct connections to make sure they are physically sound sealed to the furnace casing and the ducts terminate out side the space containing the furnace b If the furnace does not have a return air duct examine the return air filter rack connections to make sure they are phys ically sound sealed to the furnace casing For Manufactured Mobile Homes a Examine the return air filter rack connections to make sure they are physically sound sealed to the furnace casing 4 Examine the furnace casing making sure the physical support is sound without sagging cracks or gaps Examine the furnace base making sure it is physically sound without cracks gaps or sagging and has a good seal Exa
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