Unitary products group FC9T-UP Service manual

USER’S INFORMATION,
MAINTENANCE AND
SERVICE MANUAL
EFFICIENCY
RATING
CERTIFIED
HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
ISO 9001
Certified Quality
Management System
MODELS: PT9-UP / FC9T-UP / FL9T-UP
(Two Stage Upflow)
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
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . 5
SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . .5
FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cleaning the Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . .5
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Heating Indoor Fan Off Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Continuous Blower: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .7
DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL . . . . . .8
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . .12
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
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.
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 (included 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.
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.
•
•
272359-UUM-A-0407
272359-UUM-A-0407
INSTRUCTIONS FOR EXAMINING THE FURNACE
INSTALLATION
BURNER
BOX
LIMIT
SWITCH
VENT PIPE
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.
GAS VALVE
1.
Examine the heat exchanger, vent/combustion air piping, vent
connectors and chimney to be sure they are clear and free of
obstructions.
INDUCER
BLOWER
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.
PRESSURE
SWITCH
CONDENSATE
TRAP
DOOR
SWITCH
CONTROL
BOARD
BLOWER
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.
COMBUSTION AIR
INTAKE
BURNER
FLAME
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.
MAINFOLD
2 EXAMINE EXTERNAL
VENT PIPE
BURNER DOOR
4 EXAMINE
FURNACE
CASING
3
INNER
FLAME
CONES
FIGURE 2: Burner Flame Drawing
1 EXTERNAL HEAT EXCHANGER INTERNAL
VENT COMBUSTION AIR PIPE. MUST
REMOVE PANEL TO EXAMINE.
5 EXAMINE ENTIRE
FURNACE CASING
SHOWN IN ALL
DRAWINGS
MAIN
BURNER
EXAMINE
RETURN AIR
DUCT
CONNECTION
6 REMOVE
PANEL
TO EXAMINE
BURNER
FLAMES
4 EXAMINE
FURNACE
CASING
3
BLOWER DOOR
EXAMINE
RETURN AIR
DUCT
CONNECTION
(side or bottom)
FIGURE 3: Furnace Examination Checkpoints
2
Unitary Products Group
272359-UUM-A-0407
HOW YOUR GAS FURNACE WORKS
8.
Replace burner door.
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.
9.
Turn on all electric power to the appliance.
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. When the temperature setting on your thermostat is reached, the gas valve closes, the main
burners are turned off, and the blower continues to run until the remaining warm air in the system is distributed. When the blower stops, the
heating cycle has ended.
To Turn Off 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.
1.
Set the thermostat to lowest setting.
2.
Turn off all electric power to the appliance if service is to be performed.
3.
Remove upper access panel.
4.
Move gas control switch to the “OFF” position. See Figure 4.
5.
Replace burner access panel.
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” 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.
Should overheating occur, or the gas valve fail to shut off,
turn the external manual gas valve in the gas supply line to
the furnace to the “off” position and let the furnace cool off
before shutting off the electrical power supply. Refer to
Figure 5.
OUTLET
WRENCH
BOSS
INLET
PRESSURE
PORT
ON OFF
SWITCH
LOW STAGE REGULATOR
ADJUSTMENT
FIGURE 4: Gas Valve
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.
EXTERNAL MANUAL
SHUTOFF VALVE
TO GAS
SUPPLY
TO GAS
SUPPLY
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. 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.
VENT
PORT
INLET
Operating Instructions:
1.
HIGH STAGE REGULATOR
ADJUSTMENT
OUTLET
PRESSURE
PORT
Move gas control switch to the “ON” position. Do not force. See
Figure 4.
Unitary Products Group
DRIP
LEG
GROUNDED JOINT UNION
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.
FIGURE 5: Gas Piping
NOTE: The spring-loaded safety cut-off switch, mounted under the
blower deck will automatically cut off the electrical power supply
to the furnace when the blower panel is removed. As a safety
precaution, all electrical power and the gas supply to the furnace
3
272359-UUM-A-0407
FURNACE USER MAINTENANCE
Before proceeding, be sure the area is well ventilated. Turn
the thermostat OFF. If the blower is running, wait until it
stops automatically. Turn OFF the gas and electrical power
supplies to the furnace. Check all metal parts and surfaces
to be sure they have cooled to room temperature before
you begin.
Every time the filters are changed the following items should be visually
inspected:
•
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.
B.
If the air filter is on the bottom of the furnace then you have a
bottom return.
C.
If the air filters are on the bottom and the side of the furnace
then you have a bottom and side return. You must replace
both air filters. Table 1 will indicate 2 filters by using brackets
with the number two (2).
D.
If the air filters are on both sides of the furnace then you have
a two sided return. You must replace both air filters. Table 1
will indicate 2 filters by using brackets with the number two
(2).
After you determine the cabinet size and what return configuration
you have, look up the recommended filter size from Table 1.
Replacing Filters
Filters used with this furnace must be installed external to the furnace
casing. DO NOT attempt to install filters inside the furnace cabinet.
•
Damaged or deteriorated components or surfaces.
•
Leaks or blockage in the vent pipe passages.
TABLE 1: Filter Sizes
•
Water on any surface inside or outside of the furnace.
•
Excessive amounts of dust and lint on components.
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.
Air Filters
Dirty filters greatly restrict the flow of air and may cause damage to the
moving parts of the furnace. If the filters become clogged the heat
exchangers and blower motor could overheat resulting in a potentially
dangerous situation. The filters should be checked every 3 months. On
new construction, check the filters every week for the first four weeks
and every three weeks after that, especially if the indoor fan is running
continuously. When replacing the filter(s) you must use filters that are
the same size as those recommended in Table 1. Use the following procedure to determine the filter size. Never operate your furnace without a
suitable air filter.
1.
Measure the furnace width and use that measurement to determine the cabinet width.
•
•
•
•
4
If the return air filter is on the left or right side of the furnace it
is a side return
Some installations may have the air filter in a rack attached to the casing of the furnace or placed in the return air duct. If the filter location or
replacement process is not obvious, contact your installer or service
technician for assistance. 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 reinstalled.
If, during the inspection of your furnace, you find any of the following
conditions:
2.
3.
A.
A 14-1/2” wide cabinet is a “A” cabinet.
A 17-1/2” wide cabinet is a “B” cabinet.
A 21” wide cabinet is a “C” cabinet.
A 24-1/2” wide cabinet is a “D” cabinet.
Locate the cabinet size on Table 1 then determine whether you
have a bottom or side return air duct using the following method.
Cabinet Size
Side (in)
Side (cm)
14-1/2” (A)
16 x 25
40.6 x 63.5
14 x 25
40.6 x 63.5
17-1/2” (B)
16 x 25
40.6 x 63.5
16 x 25
40.6 x 63.5
16 x 25
40.6 x 63.5
20 x 25
50.8 x 63.5
22 x 25
55.9 x 63.5
21” (C)
24-1/2” (D)
(2) 16 x 25* (2) 40.6 x 63.5*
Bottom (in) Bottom (cm)
* Some installations of this model require only one filter.
How to Clean your Filter
High-velocity filters may be cleaned with a vacuum cleaner or washed
with a garden hose. Be sure to shake off excess water and allow filter to
completely dry before re-installing the filter.
Blower Care
Even with good filters properly in place, blower wheels and motors will
become dust laden after long months of operation. The entire blower
assembly should be inspected annually. If the motor and wheel are
heavily coated with dust, they can be brushed and cleaned with a 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.
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.
Unitary Products Group
272359-UUM-A-0407
Motor Lubrication
FURNACE CLEANING SECTION
The motors in these furnaces are permanently lubricated, and do not
require periodic oiling.
NOTE: The cleaning operations listed below must be performed only by
a qualified service agency.
Every time the filters are changed the following items should be visually
inspected:
Burner Removal/Cleaning
•
•
•
•
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.
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.
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.
Cleaning the Heat Exchanger
1.
Turn off the electrical power to the unit.
2.
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.
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.
SECTION II: SERVICE AND MAINTENANCE
MANUAL
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.
SAFETY SECTION
6.
Remove the vent pipe assembly, vent blower and condensate pan.
The following safety rules must be followed when servicing the
furnace.
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.
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 SECTION
The furnace should be cleaned and adjusted by a certified dealer or
qualified service contractor once a year or before the start of every
heating season. The following items must be cleaned and serviced or
replaced if there are signs of deterioration.
1.
The vent terminal.
2.
The furnace vent and combustion air intake passageways. Should
it be necessary to service the vent/air intake system, the 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.
4.
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.
Unitary Products Group
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.
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.
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272359-UUM-A-0407
SEQUENCE OF OPERATION
5.
• The Inducer Motor is de-energized after a 15 second Post Purge
and the Hum terminal is de-energized.
• The ‘Fan Off Delay’ circuit is initiated. The Delay time can be
field set at 60, 90, 120, or 180 seconds. It comes from the factory set at 60 seconds.
• The Heat Low terminal is de-energized; stopping the Blower and
the EAC terminal is de-energized.
1st and 2nd Stage called simultaneously
6.
• The 1st stage call is processed as described in paragraph 1
above.
• Once Flame Rectification is established, 2nd Stage is entered
immediately as described in paragraph 2 above.
1st and 2nd Stage satisfied simultaneously
7.
• Both stages of the Gas Valve are de-energized.
• Flame Rectification is lost.
• The Inducer and Hum relays are de-energized after a 15-second
post purge.
• 30 seconds later the Control shifts the Blower from Heat High to
Heat Low.
• After the Blower-Off Delay Circuit is satisfied, the Blower and
EAC are de-energized.
Manual Fan Operation
8.
• With the thermostat in the Fan On position, a circuit is completed
between R and G of the Control.
• The Heat Low and EAC relays are energized by the Control.
Call for Cooling
9.
• The thermostat closes two circuits R to Y and R to G. Since the
Outdoor Unit is connected to Y and C at the Control, it is energized.
• The Cool and EAC relays are energized by the Control.
• A Blower-Off Delay Timing Circuit is energized by the call on Y.
Cooling call satisfied
The following describes the sequence of operation of the furnace. Refer
to Figure 1 for component location.
1.
Call for 1st stage only
2.
• On a call for 1st stage heat, the thermostat closes a circuit
between R and W1.
• The Microprocessor in the Furnace Control runs a ‘Self Check’.
• The Control checks the Primary Limit, Auxiliary Limit, and Rollout Switches for closed contacts.
• The Control checks that the Low Fire Pressure Switch (1LP) is
open.
• The Inducer Motor is energized on high speed, closing the contacts of 1LP.
• The Control checks that 1LP is closed.
• The Igniter is energized for 17 seconds.
• The Gas Valve is energized on 1st Stage (Low Fire).
• Flame Rectification is recognized within 7 seconds.
• The Inducer is switched to low speed.
• 30 seconds after flame is proven, the ‘Heat Low’ relay is energized providing 120 Volts AC to the Blower Motor.
• At the same time, the EAC and Hum relays are energized, providing 120 Volts AC to the EAC Hot and Hum terminals.
Call for 2nd Stage after 1st Stage is operating
3.
• A call for 2nd Stage can be made by a 2-Stage thermostat, or by
the W2 delay timer on the furnace control.
• The Inducer Motor is shifted to high speed by the control, closing
the contacts of 2LP (The High Fire Pressure Switch.).
• The Control checks that 2LP is closed.
• The Gas Valve is energized on 2nd Stage (High Fire).
• The Control simultaneously de-energizes the Heat Low relay
and energizes the Heat High relay, providing 120 Volts AC to a
different speed of the Blower Motor.
2nd Stage is satisfied, 1st Stage still calling.
4.
• If a Single Stage Thermostat is used, the Furnace will stay on
High Fire until the thermostat is satisfied.
• When the circuit between R and W2 is opened, the Control
switches the Inducer Motor to low speed, causing the contacts of
2LP to open.
• When 2LP opens, 2nd Stage of the Gas Valve is de-energized.
• 30 seconds later, the Control switches the Blower from Heat
High to Heat Low.
1st Stage Satisfied
• The Thermostat opens the circuit between R and W1
• Immediately the Gas Valve is de-energized and Flame Rectification is lost.
6
•
•
•
•
The thermostat opens the R to Y and R to G circuits.
The Outdoor Unit is de-energized.
The 60-second, Blower-Off Delay, timing circuit is initiated.
After 60 seconds, the Cool and EAC relays are de-energized.
Heating Indoor Fan Off Delay
Changing the blower delay jumper on the Integrated Control can
change the indoor fan “OFF” time delay. Refer to Figure 6 for the jumper
settings to obtain the desired fan OFF delay. The blower off delay must
be long enough to adequately cool the furnace, but not so long that cold
air is blown into the living space.
The blower on delay is fixed at 30 seconds and cannot be adjusted.
Unitary Products Group
272359-UUM-A-0407
W1 - W2
DELAY
JUMPER
CONTINUOUS
FAN SPEED
JUMPER
BLOWER DELAY
60
90
120
180
OFF
10 MIN
15 MIN
20 MIN
HI COOL
HI HEAT
W2 DELAY
LO COOL
LO HEAT
Y1 Y/Y2 W/W1 W2
FAN SPEED
REMOTE
SWITCH
FAN OFF
ADJUSTMENT
JUMPER
HI HEAT
LO HEAT
HI COOL
LO COOL
R
EAC-H
BLUE - MED HI
RED - LOW
BLACK - HI
YELLOW - MED LOW
G
XFMR
C
L1
HUM
NEUTRALS
FIGURE 6: Furnace Control Board
Continuous Blower:
FURNACE CONTROL DIAGNOSTICS
The blower will run continuously whenever the wall thermostat fan
switch is in the "ON" position. The furnace blower will run at the speed
selected on the "FAN SPEED" jumpers on the main control board (HI
COOL, LO COOL, HI HEAT or LO HEAT).
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.
Hot Surface Ignition System
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.
HOT SURFACE IGNITION SYSTEM
Do not attempt to light this furnace by hand (with a
match or any other means). There may be a potential
shock hazard from the components of the hot surface
ignition system. The furnace can only be lit automatically
by its hot surface ignition system.
TROUBLESHOOTING
The following visual checks should be made before troubleshooting:
1.
Check to see that the power to the furnace and the ignition control
module is ON.
2.
The manual shut-off valves in the gas line to the furnace must be
open.
3.
Make sure all wiring connections are secure.
4.
Review the sequence of operation. Start the system by setting the
thermostat above the room temperature. Observe the system’s
response. Then use the troubleshooting section in this manual to
check the system’s operation.
Never bypass any safety control to allow furnace 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.
Unitary Products Group
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 second “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.
4 AMBER FLASHES: The control board is recieving a “Y” signal from
the thermostat without a “G” signal, indicating improper thermostat wiring.
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 faulty pressure switch or miswiring.
3 RED FLASHES: This indicates the normally open pressure switch
contact did not close after the inducer was energized. This could be
caused by a number of problems: faulty inducer, blocked vent pipe, broken pressure switch hose or faulty pressure switch.
7
272359-UUM-A-0407
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 out. Low gas pressure, faulty gas valve,
faulty hot surface ignitor or burner problem may cause this. The furnace
will lock out for one hour and then restart.
8 RED FLASHES: This fault is indicated if the flame is lost 5 times (4
recycles) during the heating cycle. This could be caused by low gas
pressure or faulty gas valve. The furnace will lock out for one hour and
then restart.
9 RED FLASHES: Indicates reversed line voltage polarity or grounding
problem. Both heating and cooling operations will be affected. Check
polarity at furnace and branch. Check furnace grounding. Check that
flame probe is not shorted to chassis.
10 RED FLASHES: Gas valve energized with no call for heat. Check
gas valve and gas valve wiring.
11 RED FLASHES: This indicates that a primary or auxiliary limit switch
has opened its normally-closed contacts and has remained open for
more than five minutes. This condition is usually caused by a failed
blower motor or blower wheel.
12 RED FLASHES: This code indicates an open igniter circuit, which
could be caused by a disconnected or loose wire or by a cracked or broken igniter.
STEADY ON RED: Control failure. Replace control board.
60-MINUTE AUTOMATIC RESET FROM LOCKOUT: This control
includes a “watchdog” type circuit that will reset from a lockout 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 provide heat for the house.
NOTE: If a flame is detected the control flashes the LED for 1/8 of a
second and then enters a flame stabilization period.
IGNITION CONTROL
Normal flame sense current is approximately
3.7 microamps DC (µa)
Low flame signal warning starts at 1.5 microamps.
Low flame signal control lockout point is
0.1 microamps DC (µa)
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 if power to the furnace
is lost. This feature should only be used by a qualified service technician.
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.
8
Unitary Products Group
272359-UUM-A-0407
ON
W2 SIGNAL
OFF
ON
HIGH INDUCER
OFF
HIGH STAGE PRESSURE
SWITCH AND 2ND STAGE
MAIN VALVE
CIRCULATOR HIGH
HEAT SPEED
ON
OFF
ON
HIGH
HEAT
OFF
DELAY
30 SEC.
OFF
CALL HIGH HEAT AFTER LOW
HEAT IS ESTABLISHED
2ND STAGE
CLOSED
HIGH LIMIT
OPEN
W1 SIGNAL
ON
OFF
LOW
INDUCER
ON
OFF
LOW STAGE
PRESSURE
SWITCH
CLOSED
OPEN
ON
HSI
OFF
1ST STAGE
MAIN VALVE
FLAME
SENSE
LOW CIRCULATOR
HEAT SPEED
1ST STAGE
ON
OFF
PRESENT
ABSENT
ON
OFF
LOW PRESSURE
SWITCH CLOSE
RECOGNITION
INTERPURGE
60 SEC.
HSI
WARM
UP
17 SEC.
IGNITION
ACTIVATION
PERIOD
4 SEC.
TRIAL FOR
IGNITION
7 SEC.
HSI
WARM
UP
27 SEC.
IGNITION
DEACTIVATION
PERIOD
3 SEC.
HEAT FAN
DELAY ON
30 SEC.
BURN
TIME
POST
PURGE
15 SEC.
HEAT FAN DELAY OFF
SELECTABLE
60,90,120,180 SEC.
NOTE:
1. THIS DIAGRAM SHOWS TWO IGNITION ATTEMPTS
2. TIMING LENGTHS ARE NOT TO SCALE
FIGURE 7: Furnace Control Event Schedule
Unitary Products Group
9
272359-UUM-A-0407
SECTION III: REPLACEMENT PARTS LIST
31
29
26
40
5
13
39
61
10
62
69
2
60
24
51
37
59
11
25
55
12
7
16
58
28
45
21
46
23
44
19
2
20
4
17
42
48, 50
24
14
43
15
3
53
1
18
6
38 ,41
54
36
29
37
27
22
47
9
8
10
30
32
34
40
13
Unitary Products Group
272359-UUM-A-0407
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
NOTE:
DESCRIPTION
MOTOR
MOTOR,DIRECT DRIVE BLOWER
MOTOR, INDUCER ASS’Y
ELECTRICAL
CAPACITOR, RUN
SWITCH, LIMIT (INDUCER)
LIMIT, TEMPERATURE (Primary)
LIMIT, FLAME ROLL-OUT
CONTROL, FURNACE MODULE
IGNITER
SENSOR, FLAME
SWITCH, PRESSURE
SWITCH, DOOR
TRANSFORMER
VALVE, GAS
AIR MOVING
HOUSING, BLOWER
WHEEL, BLOWER
FABRICATED PARTS
PANEL, BLOCK-OFF
COMBUSTION BLWR RESTRICTOR
BURNER, MAIN GAS
COIL, CONDENSING
SHELF, BLOWER
HEAT EXCHANGER ASS’Y
MANIFOLD, GAS
SHIELD, PAN
PAN, CONDENSATE
PANEL, BLOWER ACCESS
ACCESS PANEL, UPPER
WRAPPER, BURNER BOX
CHANNEL, TOE PLATE
COVER, GAS CONTROL
BOTTOM PANEL, BURNER BOX
PANEL, TOP
SUPPORT, BURNER
PLATE, DIFFUSER
BRACKET, IGNITER
ITEM
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
DESCRIPTION
MISCELLANEOUS
PLUG, WINDOW, CLEAR -1.5”
CONNECTOR AIR INTAKE 2”
TUBING, SILICONE (Gray, .188 ID, 2 ft. Req’d)
TUBING, PREFORMED
GASKET, AIR INTAKE
GASKET, COMBUSTION BLOWER
GASKET, CONDENSATE PAN
GASKET, UPPER CONDENSATE PAN
GASKET, GAS CONTROLS
GASKET (COND. COIL/LOWER PAN) (2 Req’d)
GROMMET, MANIFOLD SEAL
GROMMET, MOTOR (3 Req’d)
GROMMET, 1/2” DIA.
FERRULE, MOTOR MOUNT(3 Req’d)
DOOR KNOB (4 Req’d)
HARNESS, MAIN WIRING
MOUNT, 1 PC. MOTOR
ORIFICE, BURNER (Natural #45)
TRAP, CONDENSATE
WIRING DIAGRAM
BLOWER EXHAUST DRAIN
DRAIN TUBE, CONDENSATE TRAP
DRAIN TUBE, COMBUSTION BLOWER
DRAIN TUBE, CONDENSATE PAN
VENT TUBE
DRAIN ASSY, DOUBLE GUTTER
LOCKNUT, CONDUIT (1/2”)
ADAPTER, INSERT
BUSHING, THREADED
WASHER, FLAT FIBERGLASS (2 Req’d)
2” PVC
TUBING, SILICONE (Gray, .188 ID, 1.25 ft. Req’d)
FILTER (.75 x 16 x 25)
FILTER RACK
*Not Shown
Major components and suggested stocking items are shown with shaded item number.
Unitary Products Group
11
272359-UUM-A-0407
TABLE 2: Field Installed Accessories - Non Electrical
MODEL NO.
DESCRIPTION
USED WITH
1NP0347
1CT0302
1CT0303
1HT0901
1HT0902
1PS0501
1PS0502
1PS0503
1PS0505
1PS0506
1NK0301
1SF0101
1SR0302
1SR0200
1BR0114
1BR0214
1BR0117
1BR0217
1BR0121
1BR0221
1BR0124
1BR0224
PROPANE (LP) CONVERSION KIT
CONCENTRIC INTAKE/VENT 2”
CONCENTRIC INTAKE/VENT 3”
SIDEWALL VENT TERMINATION KIT 3”
SIDEWALL VENT TERMINATION KIT 2”
ALL MODELS
40, 60, 80, 100 INPUT MBH
100, 120 MBH
ALL MODELS
ALL MODELS
60 MBH
80/1200 MBH
80/1600, 100/1600, 120 MBH
100/2000 MBH
40 MBH
ALL MODELS
ALL MODELS
ALL MODELS
ALL MODELS
14-1/2” CABINETS
14-1/2” CABINETS
17-1/2” CABINETS
17-1/2” CABINETS
21” CABINETS
21” CABINETS
24-1/2” CABINETS
24-1/2” CABINETS
HIGH ALTITUDE PRESSURE SWITCH KIT
(Does Not Include Orifices)
CONDENSATE NEUTRALIZER KIT
EXTERNAL SIDE FILTER RACK
SIDE RETURN FILTER KIT 1” FILTER
SIDE 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
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
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
12
Unitary Products Group
272359-UUM-A-0407
SECTION IV: WIRING DIAGRAM
FIGURE 8: Wiring Diagram
Unitary Products Group
13
272359-UUM-A-0407
NOTES
14
Unitary Products Group
272359-UUM-A-0407
NOTES
Unitary Products Group
15
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%
PT9 / FC9T / FL9T
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 2007. All rights reserved.
Unitary
Products
Group
272359-UUM-A-0407
Supersedes: 167499-UUM-B-0806
5005
York
Drive
Norman
OK
73069