White Rodgers Furnace FC9S User Manual

USER’S INFORMATION,  
MAINTENANCE AND  
SERVICE MANUAL  
EFFICIENCY  
RATING  
CERTIFIED  
ISO 9001  
Certified Quality  
Management System  
HIGH EFFICIENCY  
TUBULAR HEAT EXCHANGER SERIES  
MODELS: PS9 / FC9S / FL9S  
(Single Stage 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 SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . .5  
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Intermittent Blower - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Cleaning the Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . .6  
Cleaning the Vent / Air Intake System . . . . . . . . . . . . . . . . . . . . . .6  
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .6  
DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL . . . . . .7  
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . .10  
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11  
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
CONTACT INFORMATION  
Contact us by mail:  
York International  
Consumer Relations  
5005 York Drive  
Norman, OK 73069  
The manufacturer recommends that the user read all sec-  
tions of this manual and keep the manual for future refer-  
ence.  
SECTION I: USER’S INFORMATION  
SAFETY  
1. The furnace area must be kept clear and free of combustible mate-  
rials, gasoline and other flammable vapors and liquids.  
2. Insulating materials may be combustible. The furnace must be  
kept free and clear of insulating materials. The furnace area must  
be examined when installed in an attic or other insulated space or  
when insulation is added to be sure that the insulation material has  
been kept away from the furnace.  
FIRE OR EXPLOSION HAZARD - Failure to follow safety  
warnings exactly could result in serious injury, death, or prop-  
erty damage.  
— Do not store or use gasoline or other flammable vapors  
and liquids in the vicinity of this or any other appli-  
ance.  
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.  
— WHAT TO DO IF YOU SMELL GAS:  
Do not try to light any appliance.  
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.  
Do not touch any electrical switch; do not use any phone  
(including cell phone) in your building.  
Leave the building immediately.  
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.  
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 depart-  
ment.  
6. Do not use this furnace if any part has been under water. A flood-  
damaged furnace is extremely dangerous. Attempts to use the fur-  
nace can result in fire or explosion. A qualified service agency  
should be contacted to inspect the furnace and replace all gas  
controls, control system parts, electrical parts that have been wet  
or the furnace if deemed necessary.  
— Installation and service must be performed by a quali-  
fied installer, service agency or the gas supplier.  
127237-UUM-A-0605  
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
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 oper-  
ation 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 per-  
formed.  
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 igniter glows and after a warm-up period the gas valve  
opens and ignition occurs. A short time later, the blower starts and dis-  
tributes the warm air throughout the home. When the temperature set-  
ting on your thermostat is reached, the gas valve closes, the main  
burners are 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.  
Should overheating occur, or the gas valve fail to shut off,  
turn the external manual gas valve in the gas supply line to  
the furnace to the “off” position and let the furnace cool off  
before shutting off the electrical power supply. Refer to  
Figures 5 & 6.  
START-UP AND SHUTDOWN INSTRUCTIONS  
OUTLET  
PRESSURE  
PORT  
VENT PORT  
Read the Instructions Below Before Trying to Start the  
Furnace  
INLET  
OUTLET  
WRENCH  
BOSS  
INLET  
PRESSURE  
PORT  
MAIN REGULATOR  
ADJUSTMENT  
If you do not follow these instructions exactly, a fire or  
explosion may result causing property damage, personal  
injury, and/or loss of life.  
ON/OFF SWITCH  
(Shown in ON position)  
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.  
FIGURE 4: Gas Valve - White Rodgers  
EXTERNAL MANUAL  
SHUTOFF VALVE  
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.  
TO GAS  
SUPPLY  
TO GAS  
SUPPLY  
C. Use only your hand to push the gas control switch to the “on” posi-  
tion. Never use tools. If the switch will not operate by hand, don’t  
try to repair it, call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
D. Do not use this appliance if any part has been under water. Imme-  
diately call a qualified service technician to inspect the appliance  
and to replace any part of the control system and any gas control,  
which has been under water.  
GROUNDED JOINT UNION  
MAY BE INSTALLED  
INSIDE OR OUTSIDE UNIT.  
DRIP  
LEG  
Operating Instructions:  
FIGURE 5: Gas Piping  
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.  
MANUAL  
SHUT-OFF  
VALVE  
DRIP  
LEG  
GAS  
PIPE  
5. Move gas control switch to the “OFF” position. Do not force.  
GAS BURNERS  
GAS VALVE  
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.  
GAS  
PIPE  
7. Move gas control switch to the “ON” position. Do not force.  
8. Replace burner door.  
MANUAL  
SHUT-OFF VALVE  
DRIP  
LEG  
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.  
FIGURE 6: Horizontal Gas Piping  
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.  
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.  
Unitary Products Group  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
3. After you determine the cabinet size and what return configuration  
you have, look up the recommended filter size from Table 1.  
FURNACE USER MAINTENANCE  
Removing Filters  
Most downflow furnaces have their filters located on the top of the fur-  
nace in an external filter rack. To check filters you should:  
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.  
1. Follow the instructions to turn off the appliance before servicing.  
2. Filters are installed in the return air plenum above the blower  
assembly. An “A” frame assembly supports the filters. Lift the filter  
slightly and remove for service.  
3. Follow the instructions “HOW TO CLEAN YOUR FURNACE’S FIL-  
TER”.  
Blower Care  
Even with good filters properly in place, blower wheels and motors will  
become dust laden after long months of operation. The entire blower  
assembly should be inspected annually. If the motor and wheel are  
heavily coated with dust, they can be brushed and cleaned with a vac-  
uum cleaner. If the blower cannot be properly cleaned without removing  
it from the furnace, then this service must be performed by a qualified  
service agency.  
4. Reverse the procedure to reinstall filters.  
5. Follow the operating instructions to place appliance in operation.  
FILTER RACK  
(factory supplied with some furnaces)  
RACK AND FILTERS SECURED  
INSIDE BLOWER SECTION  
FOR SHIPMENT  
CASING SIZE DIMENSION FH  
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 removing the screws of the  
access panel. Blower is now ready to be serviced through the opening.  
If the blower has to be removed through the inside blower access panel,  
then the top and bottom angles will have to be removed to slide the  
blower out of the furnace.  
14-1/2”  
17-1/2”  
21”  
13-1/4”  
12-1/2”  
11-1/2”  
9-3/4”  
24-1/2”  
NOTE: FILTER ACCESS THROUGH  
DUCTWORK MUST BE PROVIDED  
FOR REMOVAL AND CLEANING  
BRANCH  
DUCTS  
FILTERS  
FILTER  
RACK  
DUCTWORK  
FH  
CROSS SECTION A-A  
(with Plenum and filters)  
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.  
FIGURE 7: Filter Rack Assembly and Attachment  
Externally Mounted Air Filters  
Some installations may have the air filter in a rack attached to the cas-  
ing of the furnace or placed in the return air duct. You can gain access  
to the filter by pulling on the door or unscrewing the retaining screw,  
then slide the filter(s) out of its channel. Replace throw away filter(s)  
with the same size new filter(s). Throw away filter(s) may be replaced  
with cleanable filter(s) at this time. Cleanable filter(s) may be cleaned as  
described in the manufacturer instructions or as described below and  
then re-installed.  
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.  
How to Clean your Filter  
Never operate your furnace without a suitable air filter.  
Use the following procedure to determine the filter size.  
1. Measure the furnace width and use that measurement to deter-  
mine the cabinet width.  
High-velocity filters may be cleaned with a vacuum cleaner or washed  
with a garden hose. Be sure to shake off excess water and allow filter to  
completely dry before re-installing the filter.  
To replace the filter after cleaning you must do the following:  
1. Slide filter into place.  
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.  
2. Snap the door on or place the door in position and tighten the  
retaining screws, if provided.  
3. Make sure the door is secure to the end of the filter rack.  
2. Locate the cabinet size on Table 1 then determine whether you  
have a bottom or side return air duct using the following method.  
a. If the return air filter is on the left or right side of the furnace it  
is a side return  
4. For filter grilles, place the filter into the grilles, close the grille cover  
and tighten the retaining screw.  
Every time the filters are changed the following items should be visually  
inspected:  
b. If the air filter is on the bottom of the furnace then you have a  
bottom return.  
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.  
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).  
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 fur-  
nace and its components must be done by a qualified service pro-  
fessional.  
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).  
4
Unitary Products Group  
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
If, during the inspection of your furnace, you find any of the following  
conditions:  
SEQUENCE OF OPERATION  
The following describes the sequence of operation of the furnace. Refer  
to Figure 1 for component location.  
Excessive amounts of dust and lint on components.  
Damaged or deteriorated components or surfaces.  
Leaks or blockage in the vent pipe passages.  
Continuous Blower  
Cooling/heating thermostats have a fan switch that has an ON and  
AUTO position. In the ON position the thermostat circuit is completed  
between terminals R and G. The motor will operate on the speed tap  
selected on the Continuous Fan Speed Jumper on the control board (HI  
COOL, LO COOL, or HEAT pins).  
Water on any surface inside or outside of the furnace.  
Do not operate the furnace, call a certified dealer / servicing contractor  
to check and / or clean your furnace, or for more information if you have  
questions about the operation of your furnace.  
If all components appear to be in good operating condition, replace the  
front panels. Turn ON the gas and electrical power supplies to the fur-  
nace, and set thermostat to the desired temperature.  
Intermittent Blower - Cooling  
Cooling/heating thermostats have a fan switch that has an ON and  
AUTO position. In the AUTO position the thermostat circuit is completed  
between terminals R and G when there is a call for cooling. The motor  
will operate on the speed tap wire that is connected to the HI COOL ter-  
minal on the control board. When used with two-stage cooling units, the  
motor will operate on the speed tap connected to the LO COOL terminal  
when first stage cooling is operating. The motor will operate on the  
speed tap connected to the HI COOL terminal when second stage cool-  
ing is operating. The fan off setting is fixed at 60 seconds for SEER  
enhancement.  
Motor Lubrication  
The motors in these furnaces are permanently lubricated, and do not  
require periodic oiling.  
TABLE 1: Filter Sizes  
CFM  
Input / Output  
BTU/H (kW)  
Cabinet  
Size  
Top Return  
Filter in(cm)  
(m3/min)  
1200 (34)  
1200 (34)  
1200 (34)  
1600 (45)  
1600 (45)  
2000 (57)  
40/37 (11.72/10.84)  
60/55 (17.57/16.10)  
80/75 (23.42/21.96)  
80/75 (23.42/21.96)  
100/95 (29.28/27.82)  
100/95 (29.28/27.82)  
A
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)  
(2) 14 x 20 (36 x 51)  
Heating Cycle  
When the thermostat switch is set on HEAT and the fan is set on AUTO,  
and there is a call for heat, a circuit is completed between terminals R  
and W of the thermostat. When the proper amount of combustion air is  
being provided, the pressure switch will close, the ignition control pro-  
vides a 17-second warm-up period, the gas valve then opens, the gas  
starts to flow, ignition occurs and the flame sensor begins its sensing  
function. The blower motor will energize 30 seconds after the gas valve  
opens, if a flame is detected. Normal furnace operation will continue  
until the thermostat circuit between R and W is opened, which causes  
the ignition system and gas valve to de-energize and the burner flames  
to be extinguished. The vent motor will operate for 15 seconds and the  
blower motor will operate for the amount of time set by the fan-off delay  
jumper located on the control board. See Figure 8. The heating cycle is  
complete, and ready for the start of the next heating cycle.  
120/112 (35.14/32.80) 2000 (57)  
SECTION II: SERVICE AND MAINTENANCE  
MANUAL  
SAFETY SECTION  
The following safety rules must be followed when servicing the  
furnace.  
ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD  
Failure to follow safety warnings exactly could result in  
dangerous operation, serious injury, death or property  
damage.  
RED - LOW SPEED  
YELLOW - MED. LOW SPEED  
BLACK - HIGH SPEED  
BLUE -MED. HIGH SPEED  
Improper servicing could result in dangerous operation,  
serious injury, and death or property damage.  
NEUTRALS  
Before servicing, disconnect all electrical power to the fur-  
nace.  
When servicing controls, label all wires prior to discon-  
necting. Reconnect wires correctly.  
CONTINUOUS  
FAN SPEED  
JUMPER  
Verify proper operation after servicing.  
FAN OFF  
ADJUSTMENT  
JUMPER  
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.  
FIGURE 8: Typical Heat/Cool Speed Tap Connections  
1. The vent terminal screen (if applicable).  
If the flame is not detected within 2 seconds of the gas valve opening,  
the gas valve is shut off and a retry operation begins. If the flame is lost  
for 2 seconds during the 10-second stabilization period, the gas valve is  
shut off and a retry operation begins. During a retry operation, the vent  
motor starts a 15 second inter-purge and the ignitor warm-up time is  
extended to 27 seconds. If the flame is established for more than 10  
seconds after ignition during a retry, the control will clear the ignition  
attempt (retry) counter. If three retries occur during a call for heat, the  
furnace will shut down for one hour. If at the end of the one hour shut  
down there is a call for heat, the furnace will initiate a normal start cycle.  
If the problem has not been corrected the furnace will again lockout  
after three retries.  
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.  
Unitary Products Group  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
A momentary loss of gas supply, flame blowout, or a faulty flame probe  
circuit will result in a disruption in the flame and be sensed within 1 sec-  
ond. The gas valve will de-energize and the control will begin a recycle  
operation. A normal ignition sequence will begin after a 15 second inter-  
purge. If during the five recycles the gas supply does not return, or the  
fault condition is not corrected the ignition control will lockout for one  
hour.  
10. Restore electrical power and gas supply to the furnace.  
11. Check furnace operation.  
Cleaning the Secondary Heat Exchanger  
1. Follow steps 1 - 7 under cleaning the Heat Exchanger.  
2. Remove the vent piping from the vent blower housing. Disconnect  
the drain lines from the vent blower housing and from the conden-  
sate drain pan. Remove the vent blower housing blower and the  
condensate pan.  
During burner operation, a momentary loss of power for 50 milliseconds  
or longer will de-energize the gas valve. When the power is restored,  
the gas valve will remain de-energized and the ignition sequence will  
immediately restart.  
3. Using a stiff wire brush, remove the loose scale or soot from each  
tube.  
4. Vacuum the secondary heat exchanger.  
Hot Surface Ignition System  
5. Finish the cleaning procedure by following steps 9 - 11 under  
cleaning the Heat Exchanger.  
Cleaning the Vent / Air Intake System  
HOT SURFACE IGNITION SYSTEM  
Should it be necessary to service the vent / air intake system, the man-  
ufacturer recommends this service be conducted by a qualified service  
agency.  
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.  
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.  
FURNACE CLEANING SECTION  
NOTE: The cleaning operations listed below must be performed only by  
TROUBLESHOOTING  
The following visual checks should be made before troubleshooting:  
a qualified service agency.  
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.  
Label all wires prior to disconnection when servicing  
controls. Wiring errors can cause improper and danger-  
ous operation. Verify proper operation after servicing.  
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.  
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.  
Never bypass pressure switch to allow furnace opera-  
tion. To do so will allow furnace to operate under poten-  
tially hazardous conditions.  
3. Remove the upper access panel and remove the burner box cover.  
Do not try to repair controls. Replace defective controls  
with UPG Source 1 Parts.  
4. Disconnect wires from flame sensor, rollout switch and HSI igniter.  
Remove igniter carefully, as it is easily broken.  
Never adjust pressure switch to allow furnace operation.  
5. Remove the screws that hold the burner box assembly to the vest  
panel and remove the assembly.  
FURNACE CONTROL DIAGNOSTICS  
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.  
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.  
Cleaning the Heat Exchanger  
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.  
1. Turn off the electrical power to the unit.  
2. Turn off the gas supply at the external manual shut-off valve and  
loosen the ground union joint.  
3. Remove the upper access panel and remove the burner box cover.  
4. Disconnect wires from flame sensor, rollout switch and HSI igniter.  
Remove igniter carefully, as it is easily broken.  
Flash sequence codes 1 through 11 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.  
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.  
SLOW GREEN FLASH: Normal operation.  
SLOW AMBER FLASH: Normal operation with call for heat.  
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.  
RAPID RED FLASH: Twinning error, incorrect 24V phasing. Check  
twinning wiring.  
RAPID AMBER FLASH: Flame sense current is below 1.5 microamps.  
9. Replace all components in reverse order. Reconnect all wiring.  
Check and clean flame sensor. Check for proper gas flow.  
6
Unitary Products Group  
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
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.  
4 AMBER FLASHES: Y present with no G call. Normally, both Y and G  
are energized on a call for cooling. If a Y signal is present with no G sig-  
nal, check to see that the wire from the G terminal on the board to the  
wall thermostat has not broken or disconnected.  
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.  
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 pro-  
vide heat for the house.  
3 RED FLASHES: This indicates the normally open pressure switch  
contact did not close after the inducer was energized. This could be  
caused by a number of problems: faulty inducer, blocked vent pipe, bro-  
ken pressure switch hose or faulty pressure switch.  
4 RED FLASHES: This indicates that a primary or auxiliary limit switch  
has opened its normally closed contacts. With this fault code the control  
will operate the supply air blower and inducer. This condition may be  
caused by: dirty filter, improperly sized duct system, incorrect blower  
speed setting, incorrect firing rate or faulty blower motor.  
NOTE: If a flame is detected the control flashes the LED for 1/8 of a  
second and then enters a flame stabilization period.  
IGNITION CONTROL (P/N 031-01972-000)  
Normal flame sense current is approximately  
3.7 microamps DC (µa)  
Low flame signal warning starts at 1.5 microamps.  
Low flame signal control lockout point is  
0.9 microamps DC (µa)  
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.  
DIAGNOSTIC FAULT CODE STORAGE AND  
RETRIEVAL  
The control in this furnace is equipped with memory that will store up to  
five error codes to allow a service technician to diagnose problems  
more easily. This memory will be retained even is power to the furnace  
is lost. This feature should only be used by a qualified service tech-  
nician.  
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,  
dirty or faulty flame sensor, faulty hot surface ignitor or burner problem  
may cause this.  
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.  
8 RED FLASHES: This fault is indicated if the flame is lost 5 times (4  
recycles) during the heating cycle. This could be caused by low gas  
pressure, dirty or faulty flame sensor or faulty gas valve. The furnace  
will lock out for one hour and then restart.  
9 RED FLASHES: Indicates reversed line voltage polarity or grounding  
problem. Both heating and cooling operations will be affected. Check  
polarity at furnace and branch. Check furnace grounding including the  
transformer ground. Check that flame probe is not shorted to chassis.  
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.  
10 RED FLASHES: Gas flow with no call for heat. Check gas valve and  
gas valve wiring.  
11 RED FLASHES: This indicates that a primary or auxiliary limit switch  
has opened its normally-closed contacts and has remained open for  
more than five minutes. This condition is usually caused by a failed  
blower motor or blower wheel. Cycle power (24 VAC) to the control to  
reset the hard lockout condition after correcting the failure condition.  
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.  
Thermostat Satisfied  
Thermostat Calling for Heat  
(Seconds)  
0
2
17  
22  
52  
0
Fan on Delay  
30 Seconds  
ON  
ON  
ON  
THERMOSTAT  
INDUCER  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
OFF  
15 Sec.  
Post  
Purge  
IGNITOR  
OFF  
ON  
MAIN VALVE  
OFF  
ON  
HUMIDIFIER  
OFF  
OFF  
OFF  
OFF  
ELECTRONIC  
AIR CLEANER  
ON  
ON  
OFF  
OFF  
CIRCULATING  
BLOWER  
60, 90, 120, 180 SEC.  
Selectable Fan Off Delay  
FIGURE 9: Furnace Control Event Schedule  
Unitary Products Group  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
SECTION III: REPLACEMENT PARTS LIST  
35  
32  
17  
7
26  
55  
74  
13  
45  
85  
75  
2
34  
88  
27  
72  
18  
41  
42  
71  
67  
11  
5
14  
10  
9, 37  
46  
29  
15  
16  
17  
56  
74  
1
52  
54  
48  
65  
58  
49  
24  
56,57  
2
4
21  
20  
62  
25  
50  
14  
22  
5
28  
51  
6
30  
44  
43  
53  
14  
47  
6
28  
23  
44  
66  
19  
10  
30  
9,37  
36  
43  
46  
33  
40  
82  
8
Unitary Products Group  
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
ITEM  
DESCRIPTION  
ITEM  
DESCRIPTION  
MISCELLANEOUS  
MOTOR  
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  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
PLUG, WINDOW, CLEAR - 1.5”  
1
2
MOTOR,DIRECT DRIVE BLOWER  
MOTOR, INDUCER ASS’Y  
COMBUSTION AIR TRANSITION, 3-WAY  
TUBING, SILICONE (Gray, .188 ID, 2.83 ft. req’d)  
TUBING, SILICONE (Preformed)  
ELECTRICAL  
3
4
CAPACITOR, RUN  
TUBING, SILICONE (Gray, .188 ID, 1.25 ft. req’d)  
GASKET, COMBUSTION BLOWER  
GASKET, CONDENSATE PAN  
SWITCH, LIMIT (INDUCER)  
LIMIT, TEMPERATURE (Primary)  
LIMIT, FLAME ROLL-OUT  
CONTROL, FURNACE MODULE  
FUSE  
5
6
GASKET, UPPER CONDENSATE PAN (2 Req’d)  
GASKET, GAS CONTROLS  
7
8
GASKET, CONDENSING COIL  
9
IGNITER  
GASKET, COMBUSTION AIR TRANSITION  
10  
11  
12  
13  
14  
SENSOR, FLAME  
SWITCH, PRESSURE  
SWITCH, DOOR  
VENT PIPE 2” X 15.25” LG.  
GROMMET, MOTOR (3 Req’d)  
FERRULE (3 Req’d)  
TRANSFORMER  
VALVE, GAS  
COMBUSTION BLWR RESTRICTOR  
AIR MOVING  
15  
16  
HOUSING, BLOWER  
WHEEL, BLOWER  
RETAINER, SQUARE  
RESTRICTOR, TUBE  
FABRICATED PARTS  
PANEL, BLOWER COVER  
WASHER, FLAT FIBERGLASS (2 Req’d)  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
BRACKET, CONDENSATE TRAP  
BURNER, MAIN GAS  
COIL, CONDENSING  
SHELF, BLOWER  
HARNESS, MAIN WIRING  
MOUNT, 1 PC. MOTOR  
ORIFICE, BURNER (Natural #45)  
TRAP, CONDENSATE  
HEAT EXCHANGER ASS’Y  
MANIFOLD, GAS  
WIRING DIAGRAM  
45 DEG. STREET ELBOW 2”  
DRAIN TUBE, CONDENSATE TRAP  
DRAIN TUBE, COMBUSTION BLOWER  
DRAIN TUBE, CONDENSATE PAN  
DRAIN TUBE, STRAIGHT 21” LG.  
DRAIN TUBE, RAIN GUTTER  
DRAIN HOSE ASSEMBLY  
DRAIN TUBE, CONDENSATE  
LOCKNUT, CONDUIT (1/2”)  
ADAPTER, INSERT  
SHIELD, PAN  
PAN, CONDENSATE  
PANEL, VEST ACCESS  
PANEL, BLOWER ACCESS  
WRAPPER, BURNER BOX  
CHANNEL, TOE PLATE  
COVER, GAS CONTROL  
PANEL, BOTTOM  
PANEL, TOP  
SUPPORT, BURNER  
WRAPPER, CABINET  
BRACKET, FILTER  
BUSHING, THREADED  
FILTER, AIR (2 Req’d) (20 x 14 x .75)  
BAFFLE, BURNER BOX  
PLATE, DIFFUSER  
GROMMET, MANIFOLD  
BRACKET, IGNITER  
BRACKET, DOOR SWITCH  
BRACKET, DOOR  
DRAIN TUBE, VENT PIPE  
DOOR KNOB (Black)  
BOTTOM PANEL, BURNER BOX  
TOP MOUNTING BRACKET  
BOTTOM MOUNTING BRACKET  
RETAINER, DOOR KNOB  
NUT, SELF-THREADING  
SIGHT GLASS, OVAL  
NOTE: *Not Shown  
Major components and suggested stocking items are shown with shaded item number.  
Unitary Products Group  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL  
DESCRIPTION  
MODEL NO.  
1NP0347  
1CT0302  
1CT0303  
1PS0904  
1PS0901  
1PS0902  
1PS0903  
1NK0301  
1HT0901  
1CB0314  
1CB0317  
1CB0321  
1CB0324  
1TK0914  
1TK0917  
1TK0921  
1TK0924  
1VK0901  
USED WITH  
PROPANE (LP) CONVERSION KIT  
ALL MODELS  
CONCENTRIC INTAKE/VENT 2”  
CONCENTRIC INTAKE/VENT 3”  
ALL MODELS EXCEPT 120 MBH  
ALL MODELS  
40  
60/100/120  
HIGH ALTITUDE PRESSURE SWITCH KIT  
(Does Not Include Orifices)  
80/1200  
80/1600  
CONDENSATE NEUTRALIZER KIT  
SIDEWALL VENT TERMINATION KIT  
ALL MODELS  
ALL MODELS  
14-1/2” CABINET  
17-1/2” CABINET  
21” CABINET  
24 1/2” CABINET  
14-1/2” CABINET  
17-1/2” CABINET  
21” CABINET  
24 1/2” CABINET  
All MODELS  
COMBUSTIBLE FLOOR BASE  
COIL TRANSITION KIT  
3-WAY TRANSITION KIT  
REPLACEMENT PART CONTACT INFORMATION  
This is a generic parts list. To request a complete parts list, refer to the contact information below:  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
127237-UUM-A-0605  
SECTION IV: WIRING DIAGRAM  
FIGURE 10: Wiring Diagram  
Unitary Products Group  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
FURNACE TYPE  
Residential Applications  
Original Owner  
Lifetime  
PARTS  
Non-Residential  
Applications  
10  
5
90% PS9 / FC9S / FL9S  
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.  
2.  
3.  
Shipping, labor, or material charges.  
Damages resulting from transportation, installation, or servicing.  
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.  
5.  
6.  
7.  
8.  
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; (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 MERCHANTABIL-  
ITY AND FITNESS FOR A PARTICULAR PURPOSE.  
SOME STATES DO NOT ALLOW THE DISCLAIMER OF IMPLIED WARRANTY, SO THAT THE ABOVE DISCLAIMER MAY NOT APPLY TO YOU.  
SOME STATES ALLOW ONLY A PARTIAL LIMITATION ON IMPLIED WARRANTIES 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.  
IN NO 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:  
PRODUCT MODEL. NO. ____________________ INSTALLATION DATE ______________________________  
UNIT SERIAL NO. _________________________ INSTALLING DEALER ______________________________  
Subject to change without notice. Printed in U.S.A.  
127237-UUM-A-0605  
Copyright © by Unitary Products Group 2005. All rights reserved.  
Supersedes: 104449-UUM-A-1204  
Unitary  
Products  
Group  
5005  
York  
Drive  
Norman  
OK  
73069  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Westinghouse Microwave Oven WCM11100SSB User Manual
Whirlpool Double Oven 379 User Manual
Whirlpool Flat Panel Television XVT3D424SV User Manual
White Rodgers Gas Heater F92 1011 User Manual
Windmere Iron I 210 User Manual
Xerox Printer 120 MX User Manual
Yamaha DVD Player 127 User Manual
Yamaha Network Router F50D User Manual
Zanussi Washer ZWC 1300W User Manual
Zebra Technologies Car Video System AM16629 1 User Manual