White Rodgers FC9s Up Thermostat User Manual

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USER’S INFORMATION,  
MAINTENANCE AND  
SERVICE MANUAL  
EFFICIENCY  
RATING  
CERTIFIED  
HIGH EFFICIENCY  
ISO 9001  
Certified Quality  
Management System  
TUBULAR HEAT EXCHANGER SERIES  
MODELS: PS9*UP / FC9S*UP / FL9S*UP  
(Single Stage Upflow)  
TABLE OF CONTENTS  
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
INSTRUCTIONS FOR EXAMINING THE  
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  
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  
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Replacing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
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 property damage.  
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.  
— 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:  
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 try to light any appliance.  
Do not touch any electrical switch; do not use any  
phone (included cell phone) in your building.  
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.  
Leave the building immediately.  
Immediately call your gas supplier from a neighbor’s  
phone. Follow the gas supplier’s instructions.  
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.  
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 sup-  
plier.  
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INSTRUCTIONS FOR EXAMINING THE FURNACE  
INSTALLATION  
It is the owner’s responsibility to ensure that an annual inspection of the  
entire heating portion of the unit is made by a qualified service agency.  
BURNER  
BOX  
VENT PIPE  
GAS VALVE  
LIMIT  
SWITCH  
1. Examine the heat exchanger, vent/combustion air piping, vent  
connectors and chimney to be sure they are clear and free of  
obstructions.  
PRESSURE  
SWITCH  
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.  
DOOR  
SWITCH  
CONDENSATE  
TRAP  
3. Examine the return-air duct connections to make sure they are  
physically sound, sealed to the furnace casing, and the ducts ter-  
minate outside the space containing the furnace.  
CONTROL  
BOARD  
BLOWER  
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.  
FIGURE 1: Component Locations  
5. Examine the furnace casing for obvious signs of deterioration.  
7. NEVER . . .Store flammable materials of any kind near your fur-  
nace. Gasoline, solvents, and other volatile liquids should be  
stored only in approved containers outside your home. These  
materials vaporize easily and are extremely dangerous.  
6. Examine the burner flames to make sure they are in good adjust-  
ment. Refer to the pictorial sketch shown in Figure 2 as a compari-  
son 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.  
8. NEVER . . .Store cleaning materials near your furnace. Materials  
such as bleaches, detergents, powdered cleansers, etc., can  
cause corrosion of the heat exchangers.  
COMBUSTION AIR  
INTAKE  
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.  
BURNER  
FLAME  
FIRE OR EXPLOSION HAZARD  
This furnace is designed and approved for use with Nat-  
ural Gas and (LP) Propane Gas ONLY. DO NOT BURN  
ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE.  
INNER  
FLAME  
CONES  
MAINFOLD  
MAIN  
BURNER  
Burning any unapproved fuel will result in damage to the  
furnace heat exchanger, which could result in Fire, Per-  
sonal Injury, and/or Property Damage.  
FIGURE 2: Burner Flame Drawing  
1
EXTERNAL HEAT EXCHANGER INTERNAL  
VENT COMBUSTION AIR PIPE. MUST  
REMOVE PANEL TO EXAMINE.  
2
EXAMINE EXTERNAL  
VENT PIPE  
EXAMINE ENTIRE  
FURNACE CASING  
SHOWN IN ALL  
DRAWINGS  
5
BURNER DOOR  
6
REMOVE  
PANEL  
TO EXAMINE  
BURNER  
FLAMES  
4
EXAMINE  
FURNACE  
CASING  
4
EXAMINE  
FURNACE  
CASING  
3
3
EXAMINE  
RETURN AIR  
DUCT  
CONNECTION  
(side or bottom)  
EXAMINE  
RETURN AIR  
DUCT  
CONNECTION  
BLOWER DOOR  
FIGURE 3: Furnace Examination Checkpoints  
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HOW YOUR GAS FURNACE WORKS  
To Turn Off the Appliance:  
1. Set the thermostat to lowest setting.  
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.  
2. Turn off all electric power to the appliance if service is to be per-  
formed.  
3. Remove upper access panel.  
4. Move gas control switch to the “OFF” position. See Figure 4.  
5. Replace burner access panel.  
When you set your thermostat to provide more heat in your home, you  
are starting the heating cycle of the furnace. First, the inducer motor  
starts to purge the heat exchanger of any remaining gases. Next, the  
hot surface ignitor glows and after a warm-up period the gas valve  
opens and ignition occurs. A short time later, the blower starts and 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  
Figure 5.  
OUTLET  
VENT PORT  
PRESSURE  
PORT  
START-UP AND SHUTDOWN INSTRUCTIONS  
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)  
FIGURE 4: Gas Valve  
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.  
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.  
GROUNDED JOINT UNION  
MAY BE INSTALLED  
INSIDE OR OUTSIDE UNIT.  
DRIP  
LEG  
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.  
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 should be turned off  
before servicing.  
Operating Instructions:  
1. STOP! Read the safety information above.  
2. Set the thermostat to the lowest setting.  
3. Turn off all electric power to the appliance.  
4. Remove burner door.  
FURNACE USER MAINTENANCE  
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.  
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.  
7. Move gas control switch to the “ON” position. Do not force. See  
Figure 4.  
8. Replace burner door.  
9. Turn on all electric power to the appliance.  
Every time the filters are changed the following items should be visually  
inspected:  
10. Set thermostat to the desired setting. Burner will light, which may  
take 30-60 seconds.  
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.  
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.  
Check the drain lines to make sure there are no cracks or leaks.  
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Check for dirt or lint on any surfaces or on components. Do not try  
a. If the return air filter is on the left or right side of the furnace it  
is a side return  
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.  
b. If the air filter is on the bottom of the furnace then you have a  
bottom return.  
If, during the inspection of your furnace, you find any of the following  
conditions:  
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).  
Excessive amounts of dust and lint on components.  
Damaged or deteriorated components or surfaces.  
Leaks or blockage in the vent pipe passages.  
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).  
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.  
3. 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.  
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 pro-  
cedure to determine the filter size. Never operate your furnace without a  
suitable air filter.  
Some installations may have the air filter in a rack attached to the cas-  
ing of the furnace or placed in the return air duct. If the filter location or  
replacement process is not obvious, contact your installer 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 re-  
installed.  
Externally Mounted Air Filters  
1. Measure the furnace width and use that measurement to deter-  
mine the cabinet width.  
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.  
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. Locate the cabinet size on Table 1 then determine whether you  
have a bottom or side return air duct using the following method.  
TABLE 1: Recommended Filter Sizes  
Nominal CFM  
(m3/min)  
Input/Output  
BTU/H (kW)  
Cabinet  
Size  
Side Return  
Filter in. (cm)  
Bottom Return  
Filter in. (cm)  
40 (11.7)  
60 (17.6)  
80 (23.4)  
80 (23.4)  
100 (29.3)  
120 (35.1)  
135 (39.6)  
1200 (34)  
1200 (34)  
1200 (34)  
2000 (57)  
2000 (57)  
2000 (57)  
2000 (57)  
A
B
B
C
C
D
D
16 x 25 (41 x 64)  
16 x 25 (41 x 64)  
14 x 25 (36 x 64)  
16 x 25 (41 x 64)  
16 x 25 (41 x 64)  
20 x 25 (51 x 64)  
20 x 25 (51 x 64)  
22 x 25 (56 x 64)  
22 x 25 (56 x 64)  
16 x 25 (41 x 64)  
16 x 25 (41 x 64)  
16 x 25 (41 x 64)  
(2) 16 x 25 (2) (41 x 64)  
(2) 16 x 25 (2) (41 x 64)  
NOTES:  
1. Air velocity through throwaway type filters may not exceed 300 feet per minute (91.4 m/min). All velocities over this require the use of high velocity filters.  
2. Air flows above 1800 CFM require either return from two sides or one side plus bottom.  
How to Clean your Filter  
it from the furnace, then this service must be performed by a qualified  
service agency.  
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.  
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.  
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  
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.  
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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.  
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.  
SEQUENCE OF OPERATION  
The following describes the sequence of operation of the furnace. Refer  
to Figure 1 for component location.  
Motor Lubrication  
Continuous Blower  
The motors in these furnaces are permanently lubricated, and do not  
require periodic oiling.  
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).  
SECTION II: SERVICE AND MAINTENANCE  
MANUAL  
SAFETY SECTION  
Intermittent Blower - Cooling  
The following safety rules must be followed when servicing the  
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.  
furnace.  
ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD  
Failure to follow safety warnings exactly could result in  
dangerous operation, serious injury, death or property  
damage.  
Improper servicing could result in dangerous operation,  
serious injury, and death or property damage.  
Before servicing, disconnect all electrical power to the fur-  
nace.  
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 an additional 15 sec-  
onds 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 6. The  
heating cycle is complete, and ready for the start of the next heating  
cycle.  
When servicing controls, label all wires prior to disconnect-  
ing. 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 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.  
TWIN  
CONTINUOUS  
FAN SPEED  
JUMPER  
PARK  
RED-LOW  
PARK  
LO COOL  
HI COOL  
YELLOW-MED. LOW  
BLACK-HI  
FAN OFF  
ADJUSTMENT  
JUMPER  
HEAT  
BLUE-MED. HI  
EAC-H  
L1  
XFMR  
HUM  
FIGURE 6: Furnace Control Board  
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If the flame is not detected within 7 seconds of the gas valve opening,  
the gas valve is shut off and a retry operation begins. If the flame is lost  
for 2 seconds during the 10-second stabilization period, the gas valve is  
shut off and a retry operation begins. During a retry operation, the vent  
motor starts a 15 second inter-purge and the ignitor warm-up time is  
extended to 27 seconds. If the flame is established for more than 10  
seconds after ignition during a retry, the control will clear the ignition  
attempt (retry) counter. If three retries occur during a call for heat, the  
furnace will shut down for one hour. If at the end of the one hour shut  
down there is a call for heat, the furnace will initiate a normal start cycle.  
If the problem has not been corrected the furnace will again lockout  
after three retries.  
FURNACE CONTROL DIAGNOSTICS  
The furnace has built-in, self-diagnostic capability. If a system problem  
occurs, a blinking LED shows a fault code. The LED can flash red,  
green or amber to indicate various conditions. It is located behind a  
clear view port in the blower compartment door.  
The control continuously monitors its own operation and the operation  
of the system. If a failure occurs, the LED will indicate the failure code. If  
the failure is internal to the control, the light will stay on continuously. In  
this case, the entire control should be replaced, as the control is not  
field repairable.  
Flash sequence codes 1 through 10 are as follows: LED will turn “on”  
for 1/4 second and “off” for 1/4 second. This pattern will be repeated the  
number of times equal to the code. For example, six “on” flashes equals  
a number 6 fault code. All flash code sequences are broken by a 2 sec-  
ond “off” period.  
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 1.0  
seconds. The gas valve will de-energize and the control will begin a  
recycle operation. A normal ignition sequence will begin after a 15 sec-  
ond inter-purge. If during the five recycles the gas supply does not  
return, or the fault condition is not corrected the ignition control will lock-  
out for 60 minutes.  
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.  
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.  
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 wir-  
ing.  
Hot Surface Ignition System  
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.  
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.  
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, bro-  
ken pressure switch hose or faulty pressure switch.  
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.  
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.  
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.  
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.  
Never bypass any safety control to allow furnace opera-  
tion. To do so will allow furnace to operate under poten-  
tially hazardous conditions.  
Do not try to repair controls. Replace defective controls  
with UPG Source 1 Parts.  
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.  
Never adjust pressure switch to allow furnace operation.  
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.  
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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.  
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 tech-  
nician.  
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.  
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.  
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 bro-  
ken igniter.  
STEADY ON RED: Control failure. Replace control board.  
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.  
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.  
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.  
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)  
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 7: Furnace Control Event Schedule  
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SECTION III: REPLACEMENT PARTS LIST  
31  
29  
26  
51  
61  
5
10  
39  
40  
13  
24  
69  
12  
62  
2
37  
25  
60  
59  
55  
7
11  
16  
58  
28  
45  
21  
46  
44  
23  
19  
2
20  
48, 50  
53  
14  
15  
4
17  
42  
24  
43  
3
1
18  
6
38 ,41  
54  
29  
27  
36  
37  
22  
47  
9
30  
32  
40  
8
34  
13  
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ITEM DESCRIPTION  
MISCELLANEOUS  
ITEM DESCRIPTION  
MOTOR  
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  
PLUG, WINDOW, CLEAR -1.5”  
CONNECTOR AIR INTAKE 2”  
1
2
MOTOR, DIRECT DRIVE BLOWER  
MOTOR, INDUCER ASSY  
TUBING, SILICONE (Gray, .188 ID, 2 ft. Req’d)  
TUBING, PREFORMED  
ELECTRICAL  
3
4
CAPACITOR, RUN  
GASKET, AIR INTAKE  
SWITCH, LIMIT (INDUCER)  
LIMIT, TEMPERATURE (Primary)  
LIMIT, FLAME ROLL-OUT  
CONTROL, FURNACE MODULE  
IGNITER  
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.  
5
6
7
8
9
SENSOR, FLAME  
10  
11  
12  
13  
SWITCH, PRESSURE  
SWITCH, DOOR  
TRANSFORMER  
FERRULE, MOTOR MOUNT(3 Req’d)  
DOOR KNOB (4 Req’)  
VALVE, GAS  
AIR MOVING  
HARNESS, MAIN WIRING  
MOUNT, 1 PC. MOTOR  
14  
15  
HOUSING, BLOWER  
WHEEL, BLOWER  
ORIFICE, BURNER (Natural #45)  
TRAP, CONDENSATE  
FABRICATED PARTS  
PANEL, BLOCK-OFF  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
WIRING DIAGRAM  
COMBUSTION BLWR RESTRICTOR  
BURNER, MAIN GAS  
COIL, CONDENSING  
SHELF, BLOWER  
BLOWER EXHAUST DRAIN  
DRAIN TUBE, CONDENSATE TRAP  
DRAIN TUBE, COMBUSTION BLOWER  
DRAIN TUBE, CONDENSATE PAN  
VENT TUBE  
HEAT EXCHANGER ASS’Y  
MANIFOLD, GAS  
DRAIN ASSY, DOUBLE GUTTER  
LOCKNUT, CONDUIT (1/2”)  
ADAPTER, INSERT  
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  
BUSHING, THREADED  
WASHER, FLAT FIBERGLASS (2 Req’d)  
2” PVC  
SIGHT GLASS OVAL  
TUBING, SILICONE (Gray, .188 ID, 1.25 ft. Req’d)  
MAGNET, DOOR  
SUPPORT, BURNER  
PLATE, DIFFUSER  
BRACKET, IGNITER  
NOTE: *Not Shown  
Major components and suggested stocking items are shown with shaded item number.  
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TABLE 2: Field Installed Accessories - Non Electrical  
MODEL NO.  
1NP0347  
1CT0302  
1CT0303  
1PS0307  
1PS0309  
1PS0322  
1NK0301  
1HT0901  
1HT0902  
1SF0101  
1SR0200  
1BR0114  
1BR0214  
1BR0117  
1BR0217  
1BR0121  
1BR0221  
1BR0124  
1BR0224  
DESCRIPTION  
USED WITH  
ALL MODELS  
PROPANE (LP) CONVERSION KIT  
CONCENTRIC INTAKE/VENT 2”  
CONCENTRIC INTAKE/VENT 3”  
40, 60, 80, 100 INPUT MBH  
120, 135 MBH  
80, 100 MBH  
HIGH ALTITUDE PRESSURE SWITCH KIT  
(Does Not Include Orifices)  
60, 120 MBH  
40, 135 MBH  
CONDENSATE NEUTRALIZER KIT  
SIDEWALL VENT TERMINATION KIT (3”)  
SIDEWALL VENT TERMINATION KIT (2”)  
EXTERNAL SIDE RETURN FILTER RACK  
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  
ALL MODELS  
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  
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  
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SECTION IV: WIRING DIAGRAM  
FIGURE 8: Wiring Diagram  
Unitary Products Group  
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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 this warranty  
HEAT EXCHANGER  
Residential Applications  
FURNACE TYPE  
90% PS9 / FC9 / FL9  
PARTS  
Non-Residential  
Applications  
Original Owner  
Lifetime  
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.  
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.  
269434-UUM-A-0407  
Copyright © by York International Corp. 2007. All rights reserved.  
Supersedes: 167497-UUM-B-0806  
Unitary  
Products  
Group  
5005  
York  
Drive  
Norman  
OK  
73069  

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