York GF9 Marine Heating System User Manual
Contents
1. USER S INFORMATION MAINTENANCE AND SERVICE MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES MODELS GF9 GM9 GY9 Single Stage Downflow Horizontal _ et Ae Ki Ze V 9000 REGISTR ISO 9001 Certified Quality Management System ENERGY STAR TABLE OF CONTENTS CONTACTINFORMATION 000 ee eee eee ee eee 1 SEQUENCE OF OPERATION A rege ge date ke ate ed 5 USER S INFORMATION 1 Continuous Blower 0ccc cece eeceeeeeeeeeeaes 5 SAFETY LLL LLL LLL bebe e LLL LL 1 Intermittent Blower Cooling 5 INSTRUCTIONS FOR EXAMINING THE FURNACE aere E a a ESENE 5 INSTALLATION bereede Gro 2 Hot Surface Ignition System 0 6 eee eee eee eee 6 HOW YOUR GAS FURNACE WORKS 3 FURNACE CLEANING GECTION 00000 eee 6 START UP AND SHUTDOWN INSTRUCTIONS 3 Burner Removal Cleaning 6 Read the Instructions Below Before Trying to Start the Furnace 3 Cleaning the Heat Exchanger 6 Operating Instructions 0000 00 cece cece eee 3 Cleaning the Secondary Heat Exchanger 6 To Turn Off the Appliance 0 cece eee ee eee 3 Cleaning the Vent Air Intake System 08 6 FURNACE USER MAINTENANCE 22 22 4 TROUBLESHOOTING s 5c0 00s nine de cua dew devine sewaweees 6 SET 42. iagram D iring W FIGURE 9 11 Unitary Products Group Subject to change without notice Printed in U S A Copyright by Unitary Products Group 2005 All rights reserved Unitary Products Group 5005 York Drive 168106 PUM A 1205 Supersedes 165458 PUM A 0905 Norman OK 73069
3. Do not store OF Use Gasollne or other lammable vapors 3 The furnace needs air for combustion in order to operate proper and liquids in the vicinity of this or any other appli l l p E and safely Do not block or obstruct air openings on the furnace ance oY air openings to the area where the furnace is installed or spaces WHAT TO DO IF YOU SMELL GAS around the furnace Do not try to light any appliance 4 Follow the instructions exactly as shown on the OPERATING Do not touch any electrical switch do not use any phone INSTRUCTION LABEL or the Start up and Shutdown Instructions including cell phone in your building on Page 3 of this manual when lighting the furnace or turning the furnace off Leave the building immediately 5 Should the gas supply fail to shut off or if overheating occurs shut Immediately call your gas supplier from a neighbor s off the gas valve to the furnace before shutting off the electrical phone Follow the gas supplier s instructions supply If you cannot reach your gas supplier call the fire depart 6 Do not use this furnace if any part has been under water A flood ment damaged furnace is extremely dangerous Attempts to use the fur Installation and service must be performed by a quali nace can result in fire or explosion A qualified service agency fied installer service agency or the gas supplier should be contacted to inspect the furnace and replace all gas controls control
4. TO GAS SUPPLY TO GAS SUPPLY NS a GROUNDED JOINT UNION MAY BE INSTALLED LEG INSIDE OR OUTSIDE UNIT MANUAL SHUT OFF a LEG GAS BURNERS GAS VALVE 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 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 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 The blower can be serviced removed through the blower access panel on the inside of t
5. i ELECTRICAL CAPACITOR RUN 7 5MFD 370V CAPACITOR RUN 10MFD 370V FUSE o enen 12 SWITCH DOOR WHEEL BLOWER FABRICATED PARTS PANEL BLOWER COVER BRACKET CONDENSATE TRAP COIL CONDENSING SHELF BLOWER HEAT EXCHANGER ASS Y MANIFOLD GAS SHIELD PAN PAN CONDENSATE PANEL UPPER ACCESS WRAPPER BURNER BOX CHANNEL TOE PLATE PANEL BOTTOM PANEL TOP BRACKET FILTER PLATE DIFFUSER RR Not Shown 168106 PUM A 1205 ITEM DESCRIPTION PLUG WINDOW CLEAR 1 5 PLUG WINDOW CLEAR 15 a7 GASKET UPPER CONDENSATE PAN 2 Req d GASKET GAS CONTROLS GASKET CONDENSING COIL GASKET COMBUSTION AIR TRANSITION GASKET MOUNTING BRKT Burner Box COMBUSTION AIR INTAKE ASSEMBLY VENT PIPE 2 X 15 25 LG GROMMET MOTOR 3 Req d FERRULE 3 Req d COMBUSTION BLWR RESTRICTOR 59 o O WASHER FLAT FIBERGLASS 2 Req d HANDLE DOOR 2 Req d MOUNT 1 PC MOTOR 66 TRAP CONDENSATE WIRING DIAGRAM 45 DEG STREET ELBOW 2 45 DEG STREET ELBOW 69 DRAIN TUBE CONDENSATE TRAP DRAIN HOSE ASSEMBLY LOCKNUT CONDUIT 1 2 BUSHING THREADED DRAIN TUBE VENT PIPE BAFFLE BURNER BOX 50 GROMMET MANIFOLD VENT PIPE ASSEMBLY DRAIN TUBE VENT PIPE LOGO BEZEL PLATE ASSEMBLY FILTER 20 X 14 X 75 2 Reqd Major components and suggested stocking items are shown with shaded item number Fees Unitary Products Group 168106 PUM A 1205 10 FIELD INSTALLED ACCESSORIES
6. 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 Turnon 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 oe eS Unitary Products Group 168106 PUM A 1205 To Turn Off the Appliance 1 Set the thermostat to lowest setting 2 Turn off all electric power to the appliance if service is to be per formed 3 Remove 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 amp 6 OUTLET PRESSURE PORT VENT PORT OUTLET MAIN REGULATOR PRESSURE ADJUSTMENT PORT ON OFF SWITCH Shown in ON position FIGURE 4 Gas Valve White Rodgers EXTERNAL MANUAL SHUTOFF VALVE
7. NOILINOLG JTOHLNOO 20 2200 YI HS Sld v Y FIOVLdSISY 13 204 2S 2d GHVOG TOYLNOD NOILINSI NO L3 90S OH Nid 2S 2d 29 Lem SOVNUNS JHL HLIM Ode SY 201 MII IHL 4O ANY JI 2 NOILINSL G JTOYLNO9 20 SLLSNDVId YI HS Sld ZI Y ATOVIdaISY 13 Zeng IS Id GYVOG OYLNOD NOILINOI NO L u20e ONId NId ZI IS Id S3009 ALIQ 40 7Y207 2 EE ee ee ee eee ae Lou ES 5069 a aN Yad ONIMIM 0734 rg 340439 SLOSNNOISIG Tv NIJO ZV9 30 AdvdnoS A9 JAVA SVD AD NOLONOPSIC 20 YNSLVLNWNOD SO HOLINS LOSNNOOSIO sa SJ LON NOTLAVS JON4394 1I aN394 1 Antenn Le lena i LVLSOWYSHL 7009 1Y3H SONVHO V40 SYYSL N3 SONVYO NO 349431 N3 RM 9 H M ZAZA IA oto oto AN 23 oe Tl 1893A NYO O00000 Zug 20 ISI zer o Wy 4NVHO Sarina ae Daer S3dYdNOS 30 SIv7134 1Y3H EON EEN N I NNYg NYE 5 4 IS Z d OLO OXA P 440 N3399 Nd g auuaL Na dT d e CH CATS IN NI woo ASII G aio aio NOU Naa E 2SOY ISOH ONV 1g ONY em e oe T JLIHM LHM 34431 NA ee annver NAVE ATYA SV Kaf 33S Atz XION 19 39NOY 034 Ger JAVA Gg OLN NOTTS a F nana ma A ett d NO KRIS Snow 1434 ONY8 LHM CO vaot LI ve V RER ER NO ONT LHM EA e Oe n308 ER ee E ONY78 LHM woo Td A NOILINSI G AWTS ER ma i i SIV 134 YSLINSI JION JION Q CH unre WOR vg XION vg NAW TSA ol egene NOI 2 ION vg NS LONGNI G AW RFT AR TONS vi 30 S0YLNOo YOLON SIv 134 SONJA SIICHT N XION vg JOHLNOJ en ao CH LA E TION yE D naa ng YION vg RER
8. 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 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
9. system parts electrical parts that have been wet or the furnace if deemed necessary 168106 PUM A 1205 168106 PUM A 1205 COMBUSTION AIR PIPE BLOWER ACCESS PANEL CONTROL BOARD VENT PIPE CONDENSATE HOSE TRANSFORMER INDUCER HOUSING INDUCER MOTOR CONDENSATE DRAIN HOSE PRESSURE SWITCH TUBING PRESSURE SWITCHES CONDENSATE GAS TRAP LIMIT GAS SWITCH REFERENCE HOSE BURNER BOX 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 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 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 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 saggi
10. ETS 21 CABINETS 24 1 2 CABINETS 24 1 2 CABINETS Unitary Products Group 168106 PUM A 1205 WIRING DIAGRAM SECTION IV UNO ON i NOILINSLO JJ04LNO9 30 SLLENOWId V1 HE Sien SIO S3LdviNoo NOTLINSI NO SLOVLNOD Aen AOTEA NOO HNA Taya Aa ere ee eee at del y Aau ER STISuVdd 13 YSILNVHO 30 EI S391430 ONY ONIYIM DI ET NGS E Sa ZASSINUNOA a Ee E EECH EES INY SONTUM ELE 2021 NI 3SIW N31 3413 1100 LNAW3OVIdN3Y 30 JLNVSOdNOD 3LNOL
11. 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 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 01972 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 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
12. FURNACE CONTROL DANI 6 PUES een 4 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL 7 Removing Filters oes 2ccc wdedaeckeus dE ENN NEEN 4 REPLACEMENT PARTS LIST e 8 Motor Lubrication 5 REPLACEMENT PART CONTACT INFORMATION 10 SERVICE AND MAINTENANCE MANUAL 5 WIRING DIAGRAM 000 eee 11 SAFETY SECTION A eer ee a lara ate SE ab alae deeg 5 LIMITED WARRANTY 000 0c cece cece ee ees 12 FURNACE MAINTENANCE GECTION anaana 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 SECTION I USER S INFORMATION tions of this manual and keep the manual for future refer SAFETY ence 1 The furnace area must be kept clear and free of combustible mate rials gasoline and other flammable vapors and liquids AWARNING 2 Insulating materials may be combustible The furnace must be FIRE OR EXPLOSION HAZARD Failure to follow safety kept free and clear of insulating materials The furnace area must warnings exactly could result in serious injury death or prop be examined when installed in an attic or other insulated space or erty damage when insulation is added to be sure that the insulation material has been kept away from the furnace
13. HSLLNVHO 30 1NINIOY090YY O NOILOSNNOD 13143 O SEMIN cad ET S0 ENAN a NaS LOVH HYd 27914 30 LVISOWHSHL NO INAWSGHODOVY AvZ V7 1V LSOWYSH WOOH NOILOSNNOD AZ V7 E EE ANE EA SC E ILINSA a IV INOZINOH vue HMANYOSSNVYL LI vue H3NHOSSNVYL LI XAVAIDINNN 13 am 3000 9 406 ASIVNYNO J SISILNAGI LNAWSNNOILINOS 30 Hl UI YOLIOVdVO NOY OUI NO 1L3 949 N3IGVNYS 9373 3009 9 NOILWSNSGNO9 NOISSSYd 30 YNALVLNWNOD aZ BLVSNSGNO9 HOLIMS SYNSSSYd dZ N0 13 N39 TWNOILWN 93713 3009 Y NOVAS YAILNVHD N3 202 LNOL AYNA rg 20 3LIOG LONGNI NOISSSYd 20 YNALVLNWWOD dI HOLNSA XO HMH HOLIMS JHNSSIYd dl SALON FIgIsnj co asnj c WVLNOZIYOH MO T4ANMOG 06 11080 3109 LNAWS1INOY 20 YNALVLNWNOD 00 SGIS LHOIY HOLIMS LNO 104 2S0uY 31231044 ATLNSYSHNI 3HY SHOLOW 9 JHONY 2107 LNSNSINOY 20 YNALVINWNOD SOY AQIS 1437 HOLIMS LNO 71704 IS0Y Jean Y3MOd TY 404 SLOSNNOISIG ZCIAOud S NOILONGNILG Hl NV JLINIT 20 YNSLYLNWNOD ze HOLIMS UNI YSONGNI zer E uaau ag ENN INENOJNOA NENAGH ady EEN FOIANSS 31 OAV 4303004d 30 AWdIONIYd 3LIWIT 20 YNALVLNNNOD 1S7 HOLIMS LIWIT AYVNIYd 157 1NYAY SYNSLONOPSIG S37 ZIYANO NOILONGNLG YNALON NY Sid Z Y 3IVIddISH 13 ASIYd tS vd HOLON MSONGNI LV L u70e OTM Nid Z S td AINO SET Ek BOS ES E E 96601 40122 LSV31 LY 40 ONILVY JYNLYYIJNIL NOILAVOSYd JONYHO 209 HIE 20 NOILINDLG Sld Z Y J10Y1d30JY 13 ISIUd S ed HOLINDI J YJHNS LOH LY LaMOOS X Odd Nid Z S d Y ONIAVH WIM LYW ONIMIM LLIN Owi 3a SAW LI ONE
14. J 30NYH3 27 gt J YN3 INOI 4 Goo 30 NOILINSI ONY um WOH E E as EN Y YTM Y3LIN9I mz AYdyNOd dud SWNV 14 YA 4IQINNH J 9 Se 3Ov4uNS LOH j ON aj 0 eumgs Elan SL tl eee 30 Hl oO eS A O IO I c S CC H LAAN VOASI l S a0 advanos SE 9303 381714 LN VASII ONY70 LHM ANWA Ge YOSNSS 21 4 A 9373 au O 722 VOASII 20 3N9I7 ANN TSA Z l 3v3 V3 YION N319g MII OVASII STON 18 Or Nnua NU Ta 34431 N3 3v3 S amp a dog 0002 ozi ON 3140d 30 Ge SION vg ang St QS EA HION oooz ooi YNILYLNNWNOI L Ova j up LO Am LVBH em 7 ng wg WS ON 8000 9 A A EE oto HMO 18 000 LV3H den SN ee 009 ool Dua N3 44 HION Jeep h nio 1000 naa HION INZN ONV18 LNIN LHM GE i Nayt EEN IA Ae sva ang yaa 9931 Bee INDOO NY Sve SOnOW M0 T0 E SS 20 YNILON o x e CH 09 YION ENNEN Con nue Nua EREECHEN GE aa fie ots SLON YIOA O9 I SII NOILYLNINITIY A n 2g A us _ __ _ 310 143A NUS MOT 024 uNOd ILAYHI HIOA NNHe Mun ze 3L0N 33S 09 I SI ATddNS HIMOd N3 18 HION oos 090 o o CR Das LAVH GaW GaN N3 19g 033dS Y34078 OMIG 20 EI VN noa GAINI 3IY3744N0S YNSLON IH 03W703N N8 X04 LYVHO 33S LYSANO LNSWSTVWYON ON Ye YOLON Y3M078 o g ____ 3l d 20 YNILYLNNNOJ DER 009 N39 LNdNI LAVH UION IH y78 H LIMS YOOd MS O N 3 EEGEN 1N3N30Y4099YY Sl WAVHSVIG SYIV IN SE WNVYOVIG IA VI i3 LYVHO Q33dS HAMO jd VI NOILOANNOO WYYSVIC 4 y
15. NON ELECTRICAL 1BR0224 MODEL NO 1NP0347 1CT0302 1CT0303 1PS0904 1PS0901 1PS0902 1PS0903 1NK0301 1HT0901 1CB0314 1CB0317 1CB0321 1CB0324 1TKO0914 1TK0917 1TK0921 1TK0924 1VK0901 1BR0114 1BR0214 1BR0117 1BR0217 1BR0121 1BR0221 1BR0124 DESCRIPTION PROPANE LP CONVERSION KIT CONCENTRIC INTAKE VENT 2 CONCENTRIC INTAKE VENT 3 HIGH ALTITUDE PRESSURE SWITCH KIT Does Not Include Orifices CONDENSATE NEUTRALIZER KIT SIDEWALL VENT TERMINATION KIT COMBUSTIBLE FLOOR BASE COIL TRANSITION KIT BOTTOM RETURN FILTER KIT 1 FILTER BOTTOM RETURN FILTER KIT 1 4 FILTER BOTTOM RETURN FILTER KIT 1 FILTER BOTTOM RETURN FILTER KIT 1 4 FILTER BOTTOM RETURN FILTER KIT 1 FILTER BOTTOM RETURN FILTER KIT 1 4 FILTER 3 WAY TRANSITION KIT 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 2 3 Search for a part or browse the catalog Find a dealer or distributor 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 14 1 2 CABINETS 14 1 2 CABINETS 17 1 2 CABINETS 17 1 2 CABINETS 21 CABIN
16. O o BEERE ume 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 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 60 min tues During burner operation a momentary loss of power for 50 milliseconds or longer will de energize the gas valve When the pow
17. TION FIGURE 3 Furnace Examination Checkpoints 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 BLOWER DOOR L KH 2 REMOVE THIS PANEL TO EXAMINE VENT PIPE FIGURE 2 Burner Flame Drawing TBLACE AFIELD INSTALLED ACCESS PANEL LOCATED IN THE DOWNFLOW PLENUM TO EXAMINE THE HEAT EXCHANGER YELLOW SSS TIPS INNER FLAME CONES Blue Flame COMBUSTION AIR TRANSITION not shown 4 EXAMINE FURNACE CASING o0 9 EXAMINE CASING FOR DETERIORATION 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 igniter 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 turn
18. alled 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 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 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 certif
19. 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 kr Thermostat Calling for Heat T Satisfied Seconds 02 17 22 52 0 Fan on Delay 30 Seconds THERMOSTAT INDUCER IGNITOR MAIN VALVE HUMIDIFIER ELECTRONIC AIR CLEANER CIRCULATING BLOWER 60 90 120 180 SEC Selectable Fan Off Delay FIGURE 8 Furnace Control Event Schedule Unitary Products Group 7 168106 PUM A 1205 SECTION III REPLACEMENT PARTS LIST 2 ei A SOE wy E Sg EA Ken e A Fuk re de roS a TD J ear Ze E U ON LAR l ech 48 C a 14 PR Ee 5 d ao Ben o f 6 8 Unitary Products Group NOTE MOTO
20. eat Exchanger Cleaning the Vent Air Intake System Should it be necessary to service the vent air intake system the man ufacturer 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 AWARNING Never bypass pressure switch 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 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 blinking LED shows a fault code The LED can flash red green or amber to indicate various conditions It is located
21. ed 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 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 burner door Move gas control switch to the OFF position
22. er is restored the gas valve will remain de energized and the ignition sequence will immediately restart 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 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 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 b
23. faulty pressure switch or miswiring Unitary Products Group 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 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 ou
24. h e A 14 1 2 wide cabinet is a A cabinet e A 17 1 2 wide cabinet is a B cabinet e A 21 wide cabinet is a C cabinet e 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 fur nace 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 FIL TER 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 cas ing 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 inst
25. 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 ter minal 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 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 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 RED LOW SPEED YELLOW MED LOW SPEED BLACK HIGH SPEED BLUE MED HIGH SPEED FAN OFF ADJUSTMENT JUMPER OO
26. he 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 deter mine the cabinet widt
27. ied 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 Unitary Products Group Motor Lubrication The motors in these furnaces are permanently lubricated and do not require periodic oiling TABLE 1 Filter Sizes Input Output CFM Cabinet BTU H kW m min Size 40 37 11 72 10 84 1200 34 60 55 17 57 16 10 1200 34 OB 80751234212190 120084 B 214x20 86x51 80 75 23 42 21 96 1600 45 2 14 x 20 36 x 51 ODP Top Return Filter in cm 14 x 20 36 x 51 36 x 51 2 2 14 x 20 100 95 29 28 27 82 2000 57 2 14 x 20 36 x 51 120 112 35 14 32 80 2000 57 SECTION II SERVICE AND MAINTENANCE MANUAL SAFETY SECTION The following safety rules must be followed when servicing the 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 nect
28. ing Reconnect wires correctly Verify proper operation after servicing 100 95 29 28 27 82 1600 45 2 14 x 20 36 x 51 82 2 14 x 20 36 x 51 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 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 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 Unitary Products Group 168106 PUM A 1205 Intermittent Blower Cooling Cooling heating thermostats
29. ng and has a good seal 5 Examine the furnace casing for obvious signs of deterioration 6 Examine the burner flames to make sure they are in good adjust ment Refer to the pictorial sketch shown in Figure 2 as a compari FIGURE 1 Component Locations 7 NEVER Store flammable materials of any kind near your fur 7 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 son to the actual flame Examine the furnace as outlined above in steps 1 6 before each heating season Use Figure 3 for visual reference END OF BURNER MAIN BURNER MANIFOLD BURNER FLAME cause corrosion of the heat exchangers 9 NEVER required for ventilation of the various furnace components AWARNING 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 3 EXAMINE RETURN AIR DUCT CONNECTION 4 EXAMINE FURNACE CASING 6 REMOVE THIS PANEL TO EXAMINE THE BURNER FLAMES 9 EXAMINE CASING FOR DETERIORA
30. t 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 sig nal check to see that the wire from the G terminal on the board to the wall thermostat has not broken or disconnected 168106 PUM A 1205 STEADY ON RED Control failure Replace control board 60 MINUTE AUTOMATIC RESET
31. urners 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 conden sate 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 H
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