York YPLCC Operating instructions
Contents
1. USER S INFORMATION CERTIFIED MANUAL MODELS All Residential Multi position Gas Furnaces 33 Models 4 i a S000 REGISTER ISO 9001 Certified Quality Management System TABLE OF CONTENTS SAFETY aweewe side tedden ceeds vie victins tu eeeeew eee ee we 1 How to Clean your Filter 0 0 00 cece eee 4 CONTACT INFORMATION 0 000 eee eee enn a 1 BLOWER CARE sana ecue teed ie dee weet woos seer eee oes 4 INSTRUCTIONS FOR EXAMINING THE FURNACE MOTOR LUBRICATION 2 000s 4 INSTALLATION s 66 6 00 pa REAREA RERE ee eens 2 SERVICE INFORMATION 2000 cece eee 5 START UP AND SHUTDOWN INSTRUCTIONS 3 TROUBLESHOOTING PROBLEMS 0005 5 HOW YOUR GAS FURNACE WORKS 000005 3 FURNACE CONTROL DIAGNOSTICS 220005 5 OPERATING INSTRUCTIONS 20020000 0 eee 3 FURNACE MAINTENANCE DEALER CONTACTOR 5 TO TURN OFF THE APPLIANCE 002200005 3 REPLACEMENT PARTS LIST 0000 0c eee eeeee 5 FURNACE MAINTENANCE USER INFORMATION 4 WIRING DIAGRAM 0 0 ee ees 5 EXTERNAL AIR FILTERS cc LLL LLL LLL LLL 4 LIMITED WARRANTY 22605 c00Sie0s0s5 essen eee a tin eeoaed 6 CONTACT INFORMATION e Go to website at www york com click on2. the pictorial sketch shown in Figure 5 as a compar ison to the actual flame Blue Cone Portion of Flame Should Enter Heat Exchanger Tube FIGURE 5 Burner Flame Drawing Upflow Configuration Shown 7 Examine and replace external air filters as needed to make sure they are not blocked and proper airflow is provided to the furnace 8 Examine any installed accessories or system components such as evaporator coils to insure proper operation drainage of conden sate and that there is no water leakage or damage to the furnace or any components Johnson Controls Unitary Products 356486 UUM D 0608 Rollout Safety Switch Flame Sensor Gas Valve Manifold i Ignitor Limit Switch Behind gas valve Vent Pipe Draft Inducer Assembly ZAN 9 Te Electrical Junction Box Pressure Switch Condensate Pan 2a a YAS LO RS x v Alp Ls ry ii Safety Door Switch Control Board ECM MOT SECTION lll START UP AND SHUTDOWN INSTRUCTIONS Read the Instructions Below Before Trying to Start the Furnace AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury and or loss of life HOW YOUR GAS FURNACE WORKS Your furnace is a very easy appliance to take for granted Season after season it sits there in your home keeping you warm and comfortable For this reason you may never have given much th
3. D RED FLASHES There is a problem with the operation of this furnace Contact your local dealer contractor or service provider FURNACE MAINTENANCE DEALER CONTACTOR The furnace should be cleaned and adjusted by a certified dealer or qualified service contractor once a year or before the start of every heating season The following items must be cleaned and serviced or replaced if there are signs of deterioration 1 The vent terminal 2 The furnace vent and combustion air intake passageways Should it be necessary to service the vent air intake system the 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 5 Heat exchanger assembly 6 Induced draft motor assembly REPLACEMENT PARTS LIST All components assemblies accessories and replacement parts for this furnace are available through qualified service agencies It is not recommended that the user purchase install or replace any compo nents of this furnace Contact your local contactor dealer or service provider for additional information WIRING DIAGRAM The unit wiring diagram may be found on the inside of on
4. ER 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 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 oe oS PRODUCT MODEL NO INSTALLATION DATE UNIT SERIAL NO INSTALLING DEALER Subject to change without notice Pri
5. burner access panel door ga e MND 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 Outlet Pressure Port Inlet gt Wrench Boss Inlet Pressure Adjustment Port On Off Switch Shown in ON position Main Regulator Adjustment Inlet Outlet Pressure Pressure Tap Tap FIGURE 7 Modulating Gas Valve External Manual Shutoff Valve Ba an i Grounded Joint Union L may be Installed Inside or Outside Unit Drip Leg FIGURE 8 Gas Piping SECTION IV FURNACE MAINTENANCE USER INFORMATION AWARNING Before proceeding be sure the area is well ventilated Turn the thermostat OFF If the blower is running wait until it stops automatically Turn OFF the gas and electrical power supplies to the furnace Check all metal parts and surfaces to be sure they have cooled to room temperature before you begin EXTERNAL AIR FILTERS Filters used with this furnace must be installed external to the furnace casing DO NOT attempt to install filters inside the furnace cabinet Some installations may have the air filter in a rack attached to the cas ing of the furnace or placed in the return air duct If the filter location or replacement process is not obvious contact your installer o
6. contact then click on contact form and follow the instructions e Contact us by mail Johnson Controls Unitary Products Consumer Relations 5005 York Drive Norman OK 73069 We recommend that the user read all sections of this manual and keep the manual for future reference FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property damage Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone includ ing cell phone in your building Leave the building immediately Immediately call your gas supplier from a neighbor s phone Fol low the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier SECTION I SAFETY This is a safety alert symbol When you see this symbol on A labels or in manuals be alert to the potential for personal injury Understand and pay particular attention to the signal words DANGER WARNING or CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not a
7. cy 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 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 356486 UUM D 0608 356486 UUM D 0608 FIRE OR EXPLOSION HAZARD AWARNING 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 Silicone Tube Induced Draft Motor Pressure Switch Limit Switch Electrical Junction Box Sensor Safety Door Switch Blower Transformer Vent Pipe Flue Collar Induced Draft Assembly Ignitor Gas Valve Rollout Safety Switch Manifold Pipe Control Boar
8. d Capacitor FIGURE 1 Component Location 80 Single Stage Models Silicone Tube Induced Draft Motor Pressure Sensor Limit Switch Electrical Junction Box Sensor Safety Door Switch ADAA we Flue Collar Pressure Switch Induced Draft Assembly Gas Valve Ignitor Rollout Safety Switch Manifold Pipe Control Board Capacitor SECTION Il INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION It is the owner s responsibility to ensure that an annual inspection of the entire heating portion of the unit is made by a qualified service agency Examine the furnace as outlined below in steps 1 8 before each heating season Use Figures 1 4 for visual reference Manifold Rollout lt Safety Switch Flame Sensor Limit Switch Ignitor Gas Valve Vent Pipe Electrical WAL Pressure EE ee Junction Box LEWA 70 Switch a Manifold Draft Silicone Tube SS Assembly i i Condensate Safety _ Pan Door Switch Control Board Transformer Capacitor pa FIGURE 2 Component Location 95 Single Stage Models Flue Sheek Ne AOOO Wee Induced p ee Pressure Draft Motor No a Switch Ita A T Pressi i A HY Induced Draft po e W A VAa Assembly Sensor i te A Limit Switch i o EEn Gas Valve a a oon Ignitor Electrical fl X aE NN EES L Junction Box q Rollout O i Safety Switch Flame Sensor Safety Door Switc
9. e of the access panels on the furnace It is intended for reference only If service is required contact your local contactor dealer or service provider 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 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 r
10. e re installing the filter Replace throw away filter s with the same size new filter s Throw away filter s may be replaced with cleanable filter s at this time Johnson Controls Unitary Products BLOWER CARE Even with good filters properly in place blower wheels and motors will become dust laden after months of operation The entire blower assem bly should be inspected annually This service must be performed by a qualified service agency NOTE The spring loaded safety cut off switch mounted at the blower deck will automatically cut off the electrical power supply to the furnace when the furnace blower access panel door is removed As a safety precaution all electrical power and the gas supply to the furnace should be turned off before servicing AWARNING Make sure you DO NOT move the clip on weight on the indoor fan wheel when cleaning the wheel This weight Is used to balance the wheel Moving the weight will cause the fan wheel to vibrate MOTOR LUBRICATION The motors in these furnaces are permanently lubricated and do not require periodic oiling SECTION V SERVICE INFORMATION TROUBLESHOOTING PROBLEMS If your furnace is not operating correctly the following visual checks should be made before contacting your local contractor dealer or ser vice provider 1 Check that electrical power to the furnace is turned on 2 Check that the manual gas shut off valve in the gas piping supply is t
11. esponsibility 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 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 warranty HEAT EXCHANGER TM8M TMLM YM8M YMLM CM8M CMLM LM8M LMLM amp TP8C TPLC YP8C YPLC CP8C CPLC LP8C LPLC 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 prod
12. h Blower Manifold Pipe Control Board Capacitor Transformer Transformer PSC MOTOR ECM MOTOR FIGURE 3 Component Location 80 Modulating Models 2 Johnson Controls Unitary Products Rollout Safety Switch Flame Sensor Gas Valve Manifold e l MPi lgnitor T O ei Limit Switch i te ANY oer Behind gas valve if Electrical k e Junction Box Vent Pipe Draft Inducer Assembly Pressure Switch Condensate Safety i aE i Pan Door Switch Ofa Silicone Tube Control Board Capacitor FIGURE 4 Component Location 97 Modulating Models 1 Examine the heat exchanger vent pipe combustion air passages vent connectors and chimney to be sure they are clear and free of obstructions 2 Examine the vent pipe making sure it is firmly in place that it slopes slightly upward and is physically sound without holes and all of the connections are secure 3 Examine the return air duct connections to make sure they are physically sound sealed to the furnace casing and the ducts 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 sagging and has a good seal 5 Examine the furnace casing for obvious signs of deterioration 6 Examine the burner flames to make sure they are in good adjust ment Refer to
13. nted in U S A 356486 UUM D 0608 Copyright 2008 by Johnson Controls Inc All rights reserved Supersedes 356486 UUM C 0508 Johnson Controls Unitary Products 5005 York Drive Norman OK 73069
14. ought 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 1 This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 2 BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor 3 Use only your hand to push the gas control switch to the on 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 4 Do not use this appliance if any part has been unde
15. r service technician for assistance Every time the external air 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 or servicing contractor to check or clean your furnace or for more information if you have questions about the operation of your furnace If all components appear to be in good operating condition replace the furnace access panels doors Turn ON the gas and electrical power supplies to the furnace and set thermostat to the desired temperature How to Clean your Filter High velocity filters may be cleaned with a vacuum cleaner or washed with a garden hose Be sure to shake off excess water and allow filter to completely dry befor
16. r 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 356486 UUM D 0608 OPERATING INSTRUCTIONS 1 STOP Read the safety information above for your protection Set the thermostat to the lowest setting in the heat mode Turn off all electric power to the appliance Remove furnace burner access panel door Move gas control switch to the OFF position Do not force See Figures 6 amp 7 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 Figures 6 amp 7 8 Replace furnace burner access panel 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 TO TURN OFF THE APPLIANCE 1 Set the thermostat to lowest setting in heating mode 2 Turn off all electric power to the appliance if service is to be per formed 3 Remove furnace burner access panel door 4 Move gas control switch to the OFF position See Figures 6 amp 7 5 Replace furnace
17. ucts 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 alteration 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 I 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 DISCLAIM
18. urned to the ON position Refer to Figure 8 3 Check that the ON OFF switch on the gas valve is turned to the ON position Refer to Figures 6 amp 7 4 Check that the furnace blower access panel door is correctly posi tioned The electrical power supply will be cut off if this door is removed 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 Johnson Controls Unitary Products 356486 UUM D 0608 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 DOUBLE AMBER FLASH Normal heating operation Modulating Fur nace Models Only SLOW AMBER FLASH Normal operation with call for heat RAPI
19. voided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It is also used to alert against unsafe practices and hazards involving only property dam age The furnace area must be kept clear and free of combustible mate rials gasoline and other flammable vapors and liquids 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 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 Follow the instructions exactly as shown on the OPERATING INSTRUCTION LABEL on the furnace or the START UP AND SHUTDOWN INSTRUCTIONS section of this manual when light ing the furnace or turning the furnace off 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 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 agen
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