York International PM9*DH Service manual

USER’S INFORMATION,
MAINTENANCE AND
SERVICE MANUAL
EFFICIENCY
RATING
CERTIFIED
ISO 9001
Certified Quality
Management System
MODELS: PM9*DH, FC9M*DH, FL9M*DH
(Modulating Downflow/Horizontal)
TABLE OF CONTENTS
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTRUCTIONS FOR EXAMINING THE
FURNACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . . 3
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . 3
Read the Instructions Below Before Trying
to Start the Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . 5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FURNACE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FURNACE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cleaning the Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . .6
Cleaning the Vent / Air Intake System . . . . . . . . . . . . . . . . . . . . . .6
NORMAL OPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . .6
ADJUSTMENT OF FAN CONTROL SETTINGS . . . . . . . . . . . . . . . .6
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .7
DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL . . . . . .7
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . .10
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
CONTACT INFORMATION
•
•
Go to website at www.york.com click on “contact”, then click on “contact form” and follow the instructions.
Contact us by mail:
York International
Consumer Relations
5005 York Drive
Norman, OK 73069
The manufacturer recommends that the user read all sections of this manual and keep the manual for future reference.
SECTION I: USER’S INFORMATION
SAFETY
1.
The furnace area must be kept clear and free of combustible materials, gasoline and other flammable vapors and liquids.
2.
Insulating materials may be combustible. The furnace must be
kept free and clear of insulating materials. The furnace area must
be examined when installed in an attic or other insulated space or
when insulation is added to be sure that the insulation material has
been kept away from the furnace.
3.
The furnace needs air for combustion in order to operate properly
and safely. Do not block or obstruct air openings on the furnace,
air openings to the area where the furnace is installed, or spaces
around the furnace.
4.
Follow the instructions exactly as shown on the OPERATING
INSTRUCTION LABEL or the Start-up and Shutdown Instructions
on Page 3 of this manual when lighting the furnace or turning the
furnace off.
5.
Should the gas supply fail to shut off or if overheating occurs, shut
off the gas valve to the furnace before shutting off the electrical
supply.
6.
Do not use this furnace if any part has been under water. A flooddamaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency
should be contacted to inspect the furnace and replace all gas
controls, control system parts, electrical parts that have been wet
or the furnace if deemed necessary.
FIRE OR EXPLOSION HAZARD - Failure to follow
safety warnings exactly could result in serious injury,
death, or property damage.
— Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
— WHAT TO DO IF YOU SMELL GAS:
•
•
•
•
•
Do not try to light any appliance.
Do not touch any electrical switch; do not use any
phone (including cell phone) in your building.
Leave the building immediately.
Immediately call your gas supplier from a neighbor’s
phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire
department.
— Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
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INSTRUCTIONS FOR EXAMINING THE FURNACE
INSTALLATION
VENT PIPE
BLOWER
ACCESS
PANEL
CONDENSATE
HOSE
It is the owner’s responsibility to ensure that an annual inspection of the
entire heating portion of the unit is made by a qualified service agency.
1.
Examine the heat exchanger, through a field installed access
panel located on the supply air plenum. Visually examine the exterior sections of the vent/combustion air piping and the vent connectors to be sure that they are physically sound without holes or
excessive corrosion.
2.
Examine the vent pipe making sure it is firmly in place, that it
slopes slightly upward and is physically sound without holes and
all of the connections are secure.
3.
Examine the return-air duct connections to make sure they are
physically sound, sealed to the furnace casing, and the ducts terminate outside the space containing the furnace.
4.
Examine the furnace casing making sure the physical support is
sound without sagging, cracks or gaps. Examine the furnace base
making sure it is physically sound without cracks, gaps or sagging
and has a good seal.
5.
Examine the furnace casing for obvious signs of deterioration.
6.
Examine the burner flames to make sure they are in good adjustment. Refer to the pictorial sketch shown in Figure 2 as a comparison to the actual flame.
7.
Examine the furnace as outlined above in steps 1 - 6 before each
heating season. Use Figure 3 for visual reference.
CONTROL
BOARD
RAIN
GUTTER
INDUCER
HOUSING
TRANSFORMER
PRESSURE
SWITCH
TUBING
INDUCER
MOTOR
PRESSURE
SWITCHES
CONDENSATE
DRAIN HOSE
GAS
VALVE
CONDENSATE
TRAP
LIMIT
SWITCH
GAS
REFERENCE
HOSE
BURNER BOX
FIGURE 1: Component Locations
7.
NEVER . . .Store flammable materials of any kind near your furnace. Gasoline, solvents, and other volatile liquids should be
stored only in approved containers outside your home. These
materials vaporize easily and are extremely dangerous.
8.
NEVER . . .Store cleaning materials near your furnace. Materials
such as bleaches, detergents, powdered cleansers, etc., can
cause corrosion of the heat exchangers.
9.
NEVER . . . Use the area around your furnace as a storage area
for items which could block the normal flow of air. This flow of air is
required for ventilation of the various furnace components.
MANIFOLD
MAIN BURNER
BURNER
FLAME
INNER
FLAME
CONES
COMBUSTION
AIR
TRANSITION
(not shown)
FIRE OR EXPLOSION HAZARD
This furnace is designed and approved for use with Natural Gas and (LP) Propane Gas ONLY. DO NOT BURN
ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE.
Burning any unapproved fuel will result in damage to the
furnace heat exchanger, which could result in Fire, Personal Injury, and/or Property Damage.
FIGURE 2: Burner Flame Drawing
3 EXAMINE RETURN AIR
DUCT CONNECTION
BLOWER DOOR
2 REMOVE
THIS PANEL
TO EXAMINE
VENT PIPE
4 EXAMINE
FURNACE
CASING
5
EXAMINE
CASING FOR
DETERIORATION
1
6 REMOVE THIS
PANEL TO
EXAMINE THE
BURNER FLAMES
BURNER DOOR
4 EXAMINE
FURNACE
CASING
PLACE A FIELD
INSTALLED ACCESS
PANEL LOCATED IN
THE DOWNFLOW
PLENUM TO EXAMINE
THE HEAT EXCHANGER
5
EXAMINE CASING
FOR DETERIORATION
FIGURE 3: Furnace Examination Checkpoints
2
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HOW YOUR GAS FURNACE WORKS
To Turn Off the Appliance:
Your furnace is a very easy appliance to take for granted. Season after
season, it sits there in your home, keeping you warm and comfortable.
For this reason, you may never have given much thought to the way
your furnace operates. In order to get the safest and most efficient operation from your furnace, you should understand how your furnace does
its job.
1.
Set the thermostat to lowest setting.
2.
Turn off all electric power to the appliance if service is to be performed.
3.
Remove burner access panel.
4.
Move gas control switch to the “OFF” position.
5.
Replace burner access panel.
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 distributes the warm air throughout the home. The furnace control will vary
the amount of heat and the amount of airflow needed to maintain the
proper temperature in the home.
START-UP AND SHUTDOWN INSTRUCTIONS
Read the Instructions Below Before Trying to Start the
Furnace
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.
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” 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.
MAIN
REGULATOR
ADJUSTMENT
INLET
PRESSURE
TAP
OUTLET
PRESSURE
TAP
ON/OFF
KNOB
FIGURE 4: Gas Valve - White Rodgers
EXTERNAL MANUAL
SHUTOFF VALVE
Operating Instructions:
1.
STOP! Read the safety information above.
2.
Set the thermostat to the lowest setting.
3.
Turn off all electric power to the appliance.
4.
Remove burner door.
5.
Move gas control switch to the “OFF” position. Do not force.
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.
8.
Replace burner door.
9.
Turn on all electric power to the appliance.
10. Set thermostat to the desired setting. Burner will light, which may
take 30-60 seconds.
11. After three (3) trials for ignition, if the appliance will not operate follow the instructions, “TO TURN OFF THE APPLIANCE” and call
your service technician or gas supplier.
TO GAS
SUPPLY
TO GAS
SUPPLY
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.
GROUNDED JOINT UNION
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.
DRIP
LEG
FIGURE 5: Gas Piping
MANUAL
SHUT-OFF
VALVE
GAS
PIPE
DRIP
LEG
GAS BURNERS
GAS
PIPE
DRIP
LEG
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.
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FURNACE USER MAINTENANCE
FILTER RACK
RACK AND FILTERS SECURED
INSIDE BLOWER SECTION
FOR SHIPMENT
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.
CASING SIZE
14-1/2”
17-1/2”
21”
24-1/2”
Blower Care
NOTE: FILTER ACCESS THROUGH
DUCKWORK MUST BE PROVIDED
FOR REMOVAL AND CLEANING
Even with good filters properly in place, blower wheels and motors will
become dust laden after long months of operation. The entire blower
assembly should be inspected annually. If the motor and wheel are
heavily coated with dust, they can be brushed and cleaned with a vacuum cleaner. If the blower cannot be properly cleaned without removing
it from the furnace, then this service must be performed by a qualified
service agency.
The blower can be serviced/removed through the blower access panel
on the inside of the furnace. If there is a combustion air pipe installed
inside the furnace, it may have to be removed to access the blower
access panel. After the combustion air pipe is removed, it is easy to
remove the inside blower access panel by pushing it up, against a
spring, or removing the screws of the access panel. Blower is now
ready to be serviced through the opening.
FILTERS
DUCKWORK
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.
FILTER
RACK
FH
FIGURE 7: Filter Rack Assembly and Attachment
TABLE 1: Filter Sizes
If the blower has to be removed through the inside blower access panel,
then the top flange, blower door switch and bottom flange will also have
to be removed on some models, On some other models, 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.
DIMENSION FH
13-1/4”
12-1/2”
11-1/2”
9-3/4”
CFM
Input
BTU/H (kW)
(m3/min)
Cabinet
Size
Top Return
Filter in(cm)
60 (17.6)
80 (23.4)
80 (23.4)
100 (29.3)
100 (29.3)
120 (35.1)
1200 (34)
1200 (34)
1600 (45)
1600 (45)
2000 (57)
2000 (57)
B
B
C
C
C
D
(2) 14 x 20 (36 x 51)
(2) 14 x 20 (36 x 51)
(2) 14 x 20 (36 x 51)
(2) 14 x 20 (36 x 51)
(2) 14 x 20 (36 x 51)
(2) 14 x 20 (36 x 51)
Externally Mounted Air Filters
Some installations may have the air filter in a rack attached to the casing of the furnace or placed in the return air duct. You can gain access
to the filter by pulling on the door or unscrewing the retaining screw,
then slide the filter(s) out of its channel. Replace throw away filter(s)
with the same size new filter(s). Throw away filter(s) may be replaced
with cleanable filter(s) at this time. Cleanable filter(s) may be cleaned as
described in the manufacturer instructions or as described below and
then re-installed.
How to Clean your Filter
High-velocity filters may be cleaned with a vacuum cleaner or washed
with a garden hose. Be sure to shake off excess water and allow filter to
completely dry before re-installing the filter.
To replace the filter after cleaning you must do the following:
Removing Filters
1.
Slide filter into place.
Most downflow furnaces have their filters located on the top of the furnace in an external filter rack. To check filters you should:
2.
Snap the door on or place the door in position and tighten the
retaining screws, if provided.
1.
Follow the instructions to turn off the appliance before servicing.
3.
Make sure the door is secure to the end of the filter rack.
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.
4.
For filter grilles, place the filter into the grilles, close the grille cover
and tighten the retaining screw.
3.
Follow the instructions “HOW TO CLEAN YOUR FURNACE’S FILTER”.
4.
Reverse the procedure to reinstall filters.
5.
Follow the operating instructions to place appliance in operation.
4
Every time the filters are changed the following items should be visually
inspected:
• Check combustion air and vent pipe for blockage or leakage.
• Check all components to be sure they are in good condition and
that there are no obvious signs of deterioration.
• Check the drain lines to make sure there are no cracks or leaks.
• Check for dirt or lint on any surfaces or on components. Do not try
to clean any of the surfaces or components. Cleaning of the furnace and its components must be done by a qualified service professional.
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If, during the inspection of your furnace, you find any of the following
conditions:
• Excessive amounts of dust and lint on components.
• Damaged or deteriorated components or surfaces.
• Leaks or blockage in the vent pipe passages.
• Water on any surface inside or outside of the furnace.
Do not operate the furnace, call a certified dealer / servicing contractor
to check and / or clean your furnace, or for more information if you have
questions about the operation of your furnace.
If all components appear to be in good operating condition, replace the
front panels. Turn ON the gas and electrical power supplies to the furnace, and set thermostat to the desired temperature.
Motor Lubrication
The motors in these furnaces are permanently lubricated, and do not
require periodic oiling.
SECTION II: SERVICE AND MAINTENANCE
MANUAL
4.
FURNACE CLEANING
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 burner door and remove the burner box cover.
4.
Disconnect wires from flame sensor, rollout switch and HSI igniter.
Remove igniter carefully, as it is easily broken.
5.
Remove the screws that hold the burner box assembly to the vest
panel and remove the assembly.
6.
Remove burners from the burner assembly.
7.
Burners may be cleaned by rinsing in hot water.
8.
Reassemble the burners in the reverse order.
SAFETY
The following safety rules must be followed when servicing the
furnace.
The condensate collection and disposal system. If any disassembly of components containing flue or vent gases is required, a
qualified service agency must perform the service.
Cleaning the Heat Exchanger
ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in
dangerous operation, serious injury, death or property
damage.
Improper servicing could result in dangerous operation,
serious injury, and death or property damage.
• Before servicing, disconnect all electrical power to the furnace.
• When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.
• Verify proper operation after servicing.
FURNACE MAINTENANCE
The furnace should be cleaned and adjusted by a certified dealer or
qualified service contractor once a year or before the start of every
heating season. The following items must be cleaned and serviced or
replaced if there are signs of deterioration.
1. The vent terminal screen (if applicable).
2. The furnace vent and combustion air intake passageways. Should
it be necessary to service the vent/air intake system, the manufacturer recommends this service be conducted by a qualified service
agency. The operation of this appliance requires the reassembly
and resealing of the vent/air intake system.
3.
The furnace burners, ignitor and flame sensor.
Unitary Products Group
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 burner door 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.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
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Cleaning the Secondary Heat Exchanger
1.
Follow steps 1 - 7 under cleaning the Heat Exchanger.
2.
Remove the vent piping from the vent blower housing. Disconnect
the drain lines from the vent blower housing and from the condensate drain pan. Remove the vent blower housing blower and the
condensate pan.
3.
Using a stiff wire brush, remove the loose scale or soot from each
tube.
4.
Vacuum the secondary heat exchanger.
5.
Finish the cleaning procedure by following steps 9 - 11 under
cleaning the Heat Exchanger.
Do not move the motor wires to different positions on the
furnace control board!
The jumper has four positions, which will deliver sufficient airflow in
cooling mode for the cooling capacities shown in the table below. The
CFM delivery on each jumper position is shown in Table 2.
TABLE 2: Cooling Airflow - A/C Capacity in Tons
Jumper Position
Models
D
C
B
A
60/1200
1-1/2
2
2-1/2
3
80/1200
1-1/2
2
2-1/2
3
Cleaning the Vent / Air Intake System
80/1600
2-1/2
3
3-1/2
4
Should it be necessary to service the vent / air intake system, the manufacturer recommends this service be conducted by a qualified service
agency.
100/1600
2-1/2
3
3-1/2
4
100/2000
3
3-1/2
4
5
120/2000
3
3-1/2
4
5
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.
NORMAL OPERATION SEQUENCE
The furnace control calculates the optimum firing rate each time the wall
thermostat R and W contacts close or open (at the beginning and at the
end of each call for heat) based on information from the thermostat and
past demand. UNLIKE CONVENTIONAL SYSTEMS, THE WALL
THERMOSTAT DOES NOT SIMPLY TURN THE FURNACE ON AND
OFF. THE FURNACE CONTROL CALCULATES THE DEMAND AND
MAY CONTINUE TO FIRE THE FURNACE DURING PORTIONS OF
THE THERMOSTAT "OFF" CYCLE.
When the wall thermostat R and W contacts close, indicating a call for
heat, the following sequence occurs:
1.
The inducer is energized and ramps up its speed until airflow is
proven by the pressure switch and by the pressure sensor on the
control board.
Continuous Fan Operation - The airflow delivered by the furnace during continuous fan operation can be adjusted as desired. This is done
my moving the FAN jumper on the control board to give the desired airflow.
Do not move the motor wires to different positions on the
furnace control board!
The jumper has three positions. The "A" position delivers maximum airflow, 100% of the blower capacity. Position "B" delivers approximately
70% of the blower capacity. And Position "C" delivers minimum airflow,
approximately 40% of the blower capacity.
A
LOW VOLTAGE
TERMINALS
B
C
DIAGNOSTIC
LIGHT
BLOWER
D’AUX
2.
The hot surface ignitor is energized.
3.
After a 17-20 second igniter heatup, the gas valve opens and the
burners light.
4.
When the control senses that flame is present, the circulating
blower starts at low speed.
5.
The furnace fires at 70% of full rate for 30-45 seconds, then drops
to the minimum (35%) firing rate.
6.
7.
8.
The firing rate is automatically adjusted to meet demand, increasing gradually to maximum (100%) firing rate if the thermostat is not
satisfied within a defined time.
When the thermostat R and W contacts open (thermostat is satisfied) the furnace control recalculates the demand and a new firing
rate.
a.
If demand exceeds the minimum firing rate, the burners will
continue to fire at a recalculated reduced firing rate, decreasing if the thermostat remains off for a defined time.
b.
If demand does not exceed the minimum firing rate, the burners will shut off immediately.
After the burners shut off, the circulating blower will continue to run
until the temperature sensor detects that the supply air temperature has dropped to the desired level, which should take from 30 to
90 seconds.
ADJUSTMENT OF FAN CONTROL SETTINGS
HUMIDIFIER
TERMINALS
TEST
BUTTON
TEST
LAST ERROR
BUTTON
CONTINUOUS
FAN SPEED
JUMPER
ERROR
EAC
TERMINALS
COOLING
SPEED JUMPER
FIGURE 8: Furnace Control Board
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.
Cooling - The airflow delivered by the furnace during cooling operation
can be adjusted to match the cooling capacity of the A/C condensing
unit. This is done by moving the COOL jumper on the control board to
give the desired airflow.
6
Unitary Products Group
158334-UUM-C-0606
TROUBLESHOOTING
The following visual checks should be made before troubleshooting:
1.
Check to see that the power to the furnace and the ignition control
module is ON.
2.
The manual shut-off valves in the gas line to the furnace must be
open.
3.
Make sure all wiring connections are secure.
4.
Review the sequence of operation. Start the system by setting the
thermostat above the room temperature. Observe the system’s
response. Then use the troubleshooting section in this manual to
check the system’s operation.
Never bypass any safety control to allow furnace 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
This furnace has built-in self-diagnostic capability. If a system problem
occurs, a flashing LED shows a fault code. The LED can flash red,
green or amber to indicate various conditions. The LED is located on
the furnace control board and can be seen through the clear view port
in the lower door of the furnace. To indicate an error condition, the LED
will turn on for 1/4 second and off for 1/4 second. The pattern will be
repeated the number of times equal to the flash code. For instance, a
"six flash code" will be indicated by the LED turning on and off six times.
There will be a two second off period between each set of flashes. The
flash codes and an indication of their likely causes are listed below:
Three Red Flashes - Stuck open pressure switch. This indicates that
the pressure switch is open when it should be closed. This could be
caused by a faulty combustion air blower, blocked vent pipe, blocked air
intake pipe, blocked condensate drain, faulty pressure switch hose or a
faulty pressure switch.
Four Red Flashes - High limit switch open or 24 volt fuse is open. This
may be caused by a dirty air filter, improperly sized duct system, faulty
blower motor, restricted circulating airflow or an open fuse on the control board.
Five Red Flashes - Rollout switch, auxiliary limit switch or condensate
pressure switch open. Check the rollout switch on the side of the burner
box. It is a manual reset switch. To reset, push the small button in the
center of the switch. If it cannot be reset or if the switch trips again, contact a qualified serviceman. Check the limit switch mounted in the combustion air blower housing. Check the condensate switch mounted on
the vestibule panel.
Six Red Flashes - Current failure on modulating gas valve.
Seven Red Flashes - Lockout due to no ignition. The control will try
three times for ignition. If flame cannot be established in three tries, the
control will lockout for one hour and then will try again to light. Check
gas supply, ignitor, gas valve, flame sensor.
Eight Red Flashes - Lockout due to too many flame recycles. This
flash code occurs if flame is lost five times during a single heating cycle.
This could be caused by a faulty gas valve, low gas pressure, or dirty
flame sensor. The control will lock out for one hour and then will try
again.
Nine Red Flashes - Reversed line polarity or improper grounding.
Check polarity of the incoming power to the furnace. Check the grounding of the furnace, including the transformer ground and the L1 and
neutral connections.
Ten Red Flashes - Gas valve circuit shorted. Check gas valve wiring. If
correct, replace gas valve.
STEADY OFF - No 24V power to board. Check the 24 volt control circuit fuse on the board. Check the circuit breaker or fuse on the 115 volt
supply power to the furnace. Check that the 24 volt transformer.
Eleven Red Flashes - Main blower failure - This flash code occurs
when the main limit opens and fails to reclose within five minutes, indicating that the blower motor or blower wheel has failed.
One Green Flash - Normal Operation with no call for heat.
Twelve Red Flashes - ID plug is not present or not connected properly,
check for loose plug or loose wires in plug.
Two Green Flashes - Indicator for "No error codes in memory". See
Diagnostic Fault Code Storage and Retrieval section below.
Three Green Flashes - Indicator for "Error codes cleared from memory". See Diagnostic Fault Code Storage and Retrieval section below.
Steady On Red - Control fault has been detected or there is 24 volts
present without 115 volts. Check that there is 24 volts and 115 volts
being supplied to the board. If so, then the board should be replaced.
Rapid Green Flash - Control is in "Factory Speedup" mode. This mode
is used only during factory run-testing of the furnace. To stop this mode,
cycle power to the furnace off and then back on.
DIAGNOSTIC FAULT CODE STORAGE AND
RETRIEVAL
One Amber Flash - Normal operation with call for cooling.
Two Amber Flashes - Normal operation with call for heat.
Three Amber flashes - Normal operation, burner is on at end of heating cycle after wall thermostat has been satisfied.
Four Amber Flashes - Heating capacity is reduced due to restriction in
the circulating air system. Check for dirty filter or closed registers.
Five Amber Flashes - Heating capacity is reduced due to restriction in
the combustion air or vent system. Check for blocked vent/air pipe or
clogged condensate drain. Above 4,000 feet altitude, this may also indicate automatic, normal derating for altitude.
Rapid Amber Flash - Low flame sense current. Check for dirty or mislocated flame sensor rod.
One Red Flash - Flame is present with no power being supplied to gas
valve. This can be caused by a gas valve that is slow to close or that
leaks gas through to the burners.
Two Red Flashes - Stuck closed pressure switch. The control confirms
that the pressure switch contacts are open at the beginning of each
cycle. This could be caused by a faulty pressure switch or by mis-wiring
of the pressure switch.
Unitary Products Group
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. Only a qualified service technician should use this feature.
The control stores up to five separate error codes. If more than five
error codes have occurred since the last reset, only the five most recent
will be retained. The furnace control board has a button, labeled "LAST
ERROR" that is used to retrieve error codes. This function will only
work if there are no active thermostat signals. So any call for heating,
cooling or continuous fan must be terminated before attempting to
retrieve error codes.
To retrieve the error codes, push the LAST ERROR button. The LED on
the control will then flash the error codes that are in memory, starting
with the most recent. There will be a two-second pause between each
flash code. After the error codes have all been displayed, the LED will
resume the normal slow green flash after a five second pause. To
repeat the series of error codes, push the button again.
If there are no error codes in memory, the LED will flash two green
flashes. To clear the memory, push the LAST ERROR button and hold it
for more than five seconds. The LED will flash three green flashes
when the memory has been cleared, then will resume the normal slow
green flash after a five-second pause.
7
158334-UUM-C-0606
SECTION III: REPLACEMENT PARTS LIST
33
35
54
7
18
13
72
45
71
2
27
11
80
69
68
19
64
14
46
10
28
5
9,37
47
30
15
54
16
18
1
59
62
48
57
50 49
55,56
22
52
2
21
4
23
26
14
25
60
5
31
51
6
43
44
53
24
20
14
46
63
43
10
37
6
9
29
39
8
31
Unitary Products Group
158334-UUM-C-0606
ITEM
DESCRIPTION
MOTOR
1
MOTOR, DIRECT DRIVE BLOWER
2
MOTOR, INDUCER ASSY
ELECTRICAL
3*
CAPACITOR
4
SWITCH, LIMIT (INDUCER)
5
LIMIT, TEMPERATURE (Primary)
6
LIMIT, FLAME ROLL-OUT
7
CONTROL, FURNACE MODULE
7A* PLUG, JUMPER
8*
SENSOR, THERMISTOR
9
IGNITER
10
SENSOR, FLAME
11
SWITCH, PRESSURE
12*
SWITCH, DOOR
13
TRANSFORMER
14
VALVE, GAS
AIR MOVING
14
HOUSING, BLOWER
15
WHEEL, BLOWER
17* BRACKET, BLOWER (2 Req’d)
FABRICATED PARTS
18
PANEL, BLOWER COVER
19
BRACKET, CONDENSATE TRAP
20
BURNER, MAIN GAS
21
COIL, CONDENSING
22
SHELF, BLOWER
23
HEAT EXCHANGER ASS’Y
24
MANIFOLD, GAS
25
SHIELD, PAN
26
PAN, CONDENSATE
27
PANEL, VEST ACCESS (Upper)
28
PANEL, BLOWER ACCESS (Lower)
29
WRAPPER, BURNER BOX
30
CHANNEL, TOE PLATE
31
COVER, GAS CONTROL
32*
PANEL, BOTTOM
33
PANEL, TOP
34
SUPPORT, BURNER
35
WRAPPER, CABINET (Insulated)
36* PLATE, DIFFUSER
37
BRACKET, IGNITER
38* BRACKET, DOOR SWITCH
39
BOTTOM PANEL, BURNER BOX
40
41
42
NOTE:
ITEM
DESCRIPTION
MISCELLANEOUS
43
PLUG, WINDOW, CLEAR - 1.5”
44
COMBUSTION AIR TRANSITION, 3-WAY
TUBING, SILICONE (Gray, .188 ID, 2.83 ft. Req’d)
45
46
TUBING, SILICONE (Preformed)
TUBING, SILICONE (Gray, .188 ID, 1.25 ft. Req’d)
47
48
GASKET, COMBUSTION BLOWER
49
GASKET, CONDENSATE PAN
GASKET, UPPER CONDENSATE PAN (2 Req’d)
50
51
GASKET, GAS CONTROLS
52
GASKET, CONDENSING COIL
GASKET, COMBUSTION AIR TRANSITION
53
54
VENT PIPE 2” X 15.25” LG.
55
GROMMET, MOTOR (3 Req’d)
56
FERRULE (3 Req’d)
57
COMBUSTION BLWR RESTRICTOR
58* INSERT, SILICONE
59
RESTRICTOR, TUBE
WASHER, FLAT FIBERGLASS (3 Req’d)
60
61* HARNESS, MAIN WIRING
62
MOUNT, 1 PC. MOTOR
63
ORIFICE, BURNER (Natural #45)
64
TRAP, CONDENSATE
65* WIRING DIAGRAM
66* 45 DEG. STREET ELBOW 2”
67* DRAIN TUBE, CONDENSATE TRAP
68
DRAIN TUBE, COMBUSTION BLOWER
69
DRAIN TUBE, CONDENSATE PAN
70* DRAIN TUBE, STRAIGHT 21” LG.
71
DRAIN TUBE, RAIN GUTTER
72
DRAIN HOSE ASSEMBLY
73* DRAIN TUBE, CONDENSATE
74* LOCKNUT, CONDUIT (1/2”)
75* ADAPTER, INSERT
76* BUSHING, THREADED
77* GROMMET, MANIFOLD
78* VENT PIPE ASSEMBLY
79* DRAIN TUBE, VENT PIPE
80
DOOR KNOB (Black)
81* SIGHT GLASS, OVAL
*Not Shown
Major components and suggested stocking items are shown with shaded item number.
Unitary Products Group
9
158334-UUM-C-0606
MODEL NO.
FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL
DESCRIPTION
USED WITH
1NP0680
PROPANE (LP) CONVERSION KIT
ALL MODELS
1CT0302
CONCENTRIC INTAKE/VENT 2”
60, 80, 100 INPUT MBH
1CT0303
CONCENTRIC INTAKE/VENT 3”
100, 120 MBH
1NK0301
CONDENSATE NEUTRALIZER KIT
ALL MODELS
1HT0901
SIDEWALL VENT TERMINATION KIT
1CB0317
1CB0321
ALL MODELS
17-1/2” CABINET
COMBUSTIBLE FLOOR BASE
1CB0324
1TK0917
1TK0921
21” CABINET
24-1/2” CABINET
17-1/2” CABINET
COIL TRANSITION KIT
1TK0924
21” CABINET
24-1/2” CABINET
REPLACEMENT PART CONTACT INFORMATION
This is a generic parts list. To request a complete parts list, refer to the contact information below:
• Visit our website at www.source1parts.com for the following information:
1. Search for a part or browse the catalog.
2. Find a dealer or distributor.
3. Customer Service contact information.
a. Click on the “Brand Links” button
b. Click on the “Customer Service” button
• You can contact us by mail. Just send a written request to:
York International
Consumer Relations
5005 York Drive
Norman, OK 73069
10
Unitary Products Group
158334-UUM-C-0606
SECTION IV: WIRING DIAGRAM
FIGURE 9: Wiring Diagram
Unitary Products Group
11
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 responsibility
hereunder for installation, shipping, handling or other charges except as specifically provided herein.
For your benefit and protection, return the Warranty Registration Card to UPG promptly after installation. This will initiate the warranty period and allow us to
contact you, should it become necessary. In the absence of a 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 the reverse
side of this warranty.
HEAT EXCHANGER
Residential Applications
FURNACE TYPE
90%
PM9*DH, FC9M*DH, FL9M*DH
Original Owner
Lifetime
Non-Residential
Applications
PARTS
Subsequent Owner
20
10
5
UPG strongly recommends regular periodic preventative maintenance on this equipment. The person most familiar with the equipment in your HVAC system is
a UPG dealer. The UPG dealer can ensure your maintenance program meets the conditions of the "UPG Warranty", maximize the efficiency of the equipment,
and service your unit within the mandated guidelines with regard to unlawful discharge of refrigerants into the atmosphere.
This warranty applies only to products installed in the United States and Canada.
EXCLUSIONS
This warranty does not cover any:
1.
Shipping, labor, or material charges.
2.
Damages resulting from transportation, installation, or servicing.
3.
Damages resulting from accident, abuse, fire, flood, alteration, or acts of God (tampering, altering, defacing or removing the product serial number will
serve to void this warranty).
4.
Damages resulting from use of the product in a corrosive atmosphere.
5.
Damages resulting from inadequacy or interruption of electrical service or fuel supply, improper voltage conditions, blown fuses, or other like damages.
6.
Cleaning or replacement of filters.
7.
Damages resulting from failure to properly and regularly clean air and/or water side of condenser and evaporator.
8.
Damages resulting from: (I) freezing of condenser water or condensate; (II) inadequate or interrupted water supply; (III) 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 MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
SOME STATES DO NOT ALLOW THE DISCLAIMER OF IMPLIED WARRANTY, SO THAT THE ABOVE DISCLAIMER MAY NOT APPLY TO YOU.
SOME STATES ALLOW ONLY A PARTIAL LIMITATION ON IMPLIED WARRANTIES TO LIMIT THE DURATION OF IMPLIED WARRANTIES TO THE 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 CONTRACT, TORT (INCLUDING NEGLIGENCE) STRICT LIABILITY OR OTHERWISE, 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 ELECTRICITY. 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:
PRODUCT MODEL. NO. ____________________ INSTALLATION DATE ______________________________
UNIT SERIAL NO. _________________________ INSTALLING DEALER ______________________________
Subject to change without notice. Printed in U.S.A.
Copyright © by Unitary Products Group 2006. All rights reserved.
Unitary
Products
Group
158334-UUM-C-0606
Supersedes: 158334-YUM-B-0406
5005
York
Drive
Norman
OK
73069