USER’S INFORMATION,

MAINTENANCE AND
EFFICIENCY
RATING
CERTIFIED

SERVICE MANUAL
ISO 9001

MODELS: PC9
Certified Quality
Management System

(Modulating Downflow/Horizontal With ECM Motor)

TABLE OF CONTENTS
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FURNACE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FURNACE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTRUCTIONS FOR EXAMINING THE FURNACE Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cleaning the Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . .5
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning the Vent / Air Intake System . . . . . . . . . . . . . . . . . . . . . .5
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . 3 NORMAL OPERATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . .5
Read the Instructions Below Before Trying to Start the ADJUSTMENT OF FAN CONTROL SETTINGS . . . . . . . . . . . . . . . .6
Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Delay Taps Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Humidistat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .7
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL . . . . . .7
Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . .10
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . 5 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

CONTACT INFORMATION
• Go to website at www.york.com click on “contact”, then click on “contact form” and follow the instructions.
• Contact us by mail:
York International
Consumer Relations
5005 York Drive
Norman, OK 73069

The manufacturer recommends that the user read all sec- SECTION I: USER’S INFORMATION
tions of this manual and keep the manual for future refer-
SAFETY
ence.
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
FIRE OR EXPLOSION HAZARD - Failure to follow
be examined when installed in an attic or other insulated space or
safety warnings exactly could result in serious injury, when insulation is added to be sure that the insulation material has
death, or property damage. been kept away from the furnace.
— Do not store or use gasoline or other flammable 3. The furnace needs air for combustion in order to operate properly
vapors and liquids in the vicinity of this or any and safely. Do not block or obstruct air openings on the furnace,
other appliance. air openings to the area where the furnace is installed, or spaces
around the furnace.
— WHAT TO DO IF YOU SMELL GAS:
4. Follow the instructions exactly as shown on the OPERATING
• Do not try to light any appliance. INSTRUCTION LABEL or the Start-up and Shutdown Instructions
• Do not touch any electrical switch; do not use any on Page 3 of this manual when lighting the furnace or turning the
phone (including cell phone) in your building. furnace off.

• 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
• Immediately call your gas supplier from a neighbor’s supply.
phone. Follow the gas supplier’s instructions. 6. Do not use this furnace if any part has been under water. A flood-
• If you cannot reach your gas supplier, call the fire damaged furnace is extremely dangerous. Attempts to use the fur-
department. nace can result in fire or explosion. A qualified service agency
should be contacted to inspect the furnace and replace all gas
— Installation and service must be performed by a
controls, control system parts, electrical parts that have been wet
qualified installer, service agency or the gas sup- or the furnace if deemed necessary.
plier.

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INSTRUCTIONS FOR EXAMINING THE FURNACE

VENT PIPE INSTALLATION
It is the owner’s responsibility to ensure that an annual inspection of the
BLOWER CONDENSATE
ACCESS HOSE
entire heating portion of the unit is made by a qualified service agency.
PANEL 1. Examine the heat exchanger, through a field installed access
CONTROL panel located on the supply air plenum. Visually examine the exte-
BOARD rior sections of the vent/combustion air piping and the vent con-
RAIN nectors to be sure that they are physically sound without holes or
TRANSFORMER
GUTTER excessive corrosion.
PRESSURE INDUCER 2. Examine the vent pipe making sure it is firmly in place, that it
SWITCH HOUSING
TUBING slopes slightly upward and is physically sound without holes and
INDUCER all of the connections are secure.
MOTOR
PRESSURE 3. Examine the return-air duct connections to make sure they are
SWITCHES CONDENSATE
DRAIN HOSE physically sound, sealed to the furnace casing, and the ducts ter-
minate outside the space containing the furnace.
GAS CONDENSATE
VALVE TRAP 4. Examine the furnace casing making sure the physical support is
sound without sagging, cracks or gaps. Examine the furnace base
LIMIT
GAS SWITCH
making sure it is physically sound without cracks, gaps or sagging
REFERENCE and has a good seal.
HOSE BURNER BOX
5. Examine the furnace casing for obvious signs of deterioration.
6. Examine the burner flames to make sure they are in good adjust-
FIGURE 1: Component Locations
ment. Refer to the pictorial sketch shown in Figure 2 as a compari-
7. NEVER . . .Store flammable materials of any kind near your fur- son to the actual flame.
nace. Gasoline, solvents, and other volatile liquids should be 7. Examine the furnace as outlined above in steps 1 - 6 before each
stored only in approved containers outside your home. These heating season. Use Figure 3 for visual reference.
materials vaporize easily and are extremely dangerous.
8. NEVER . . .Store cleaning materials near your furnace. Materials MANIFOLD MAIN BURNER
BURNER
such as bleaches, detergents, powdered cleansers, etc., can FLAME
cause corrosion of the heat exchangers.
9. NEVER . . . Use the area around your furnace as a storage area
for items which could block the normal flow of air. This flow of air is
required for ventilation of the various furnace components.
INNER
FLAME
CONES

COMBUSTION
FIRE OR EXPLOSION HAZARD AIR
This furnace is designed and approved for use with Nat- TRANSITION
ural Gas and (LP) Propane Gas ONLY. DO NOT BURN (not shown)
ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE.
Burning any unapproved fuel will result in damage to the
furnace heat exchanger, which could result in Fire, Per- FIGURE 2: Burner Flame Drawing
sonal Injury, and/or Property Damage.

3 EXAMINE RETURN AIR

DUCT CONNECTION

BLOWER DOOR

2 REMOVE
THIS PANEL
TO EXAMINE
VENT PIPE

4 EXAMINE 1 4 EXAMINE
PLACE A FIELD
FURNACE INSTALLED ACCESS FURNACE
CASING 6 REMOVE THIS PANEL LOCATED IN CASING
PANEL TO THE DOWNFLOW
EXAMINE THE PLENUM TO EXAMINE
5 BURNER FLAMES THE HEAT EXCHANGER
EXAMINE BURNER DOOR
CASING FOR 5
EXAMINE CASING
DETERIORATION FOR DETERIORATION

FIGURE 3: Furnace Examination Checkpoints

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HOW YOUR GAS FURNACE WORKS To Turn Off the Appliance:

Your furnace is a very easy appliance to take for granted. Season after 1. Set the thermostat to lowest setting.
season, it sits there in your home, keeping you warm and comfortable. 2. Turn off all electric power to the appliance if service is to be per-
For this reason, you may never have given much thought to the way formed.
your furnace operates. In order to get the safest and most efficient oper-
3. Remove burner access panel.
ation from your furnace, you should understand how your furnace does
4. Move gas control switch to the “OFF” position.
its job.
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- Should overheating occur, or the gas valve fail to shut off,
tributes the warm air throughout the home. The furnace control will vary turn the external manual gas valve in the gas supply line to
the amount of heat and the amount of airflow needed to maintain the the furnace to the “off” position and let the furnace cool off
proper temperature in the home. before shutting off the electrical power supply. Refer to
Figure 5.
START-UP AND SHUTDOWN INSTRUCTIONS
Read the Instructions Below Before Trying to Start the
Furnace

If you do not follow these instructions exactly, a fire or

MAIN
explosion may result causing property damage, personal
REGULATOR
injury, and/or loss of life. ADJUSTMENT

A. This appliance does not have a pilot. It is equipped with an ignition INLET OUTLET
device which automatically lights the burner. Do not try to light the PRESSURE PRESSURE
TAP TAP
burner by hand.
ON/OFF
B. BEFORE OPERATING; smell all around the appliance area for KNOB
gas. Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor. FIGURE 4: Gas Valve - White Rodgers
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 EXTERNAL MANUAL
SHUTOFF VALVE
try to repair it, call a qualified service technician. Force or
attempted repair may result in a fire or explosion. TO GAS TO GAS
D. Do not use this appliance if any part has been under water. Imme- SUPPLY SUPPLY

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.
Operating Instructions:
GROUNDED JOINT UNION
1. STOP! Read the safety information above. DRIP MAY BE INSTALLED
LEG INSIDE OR OUTSIDE UNIT.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance. FIGURE 5: Gas Piping
4. Remove burner door.
MANUAL
5. Move gas control switch to the “OFF” position. Do not force. SHUT-OFF
6. Wait five (5) minutes to clear out any gas. If you then smell gas, VALVE
STOP! Follow “B” in the safety information above. If you don’t DRIP
LEG
smell gas, go to next step. GAS
7. Move gas control switch to the “ON” position. Do not force. PIPE
GAS BURNERS
8. Replace burner door.
9. Turn on all electric power to the appliance. GAS GAS VALVE
PIPE
10. Set thermostat to the desired setting. Burner will light, which may
take 30-60 seconds.
11. After three (3) trials for ignition, if the appliance will not operate fol- DRIP MANUAL
low the instructions, “TO TURN OFF THE APPLIANCE” and call LEG SHUT-OFF VALVE
your service technician or gas supplier.
FIGURE 6: Horizontal Gas Piping
NOTE: The spring-loaded safety cut-off switch, mounted on the blower
deck, behind the indoor fan access panel will automatically cut
off the electrical power supply to the furnace when the blower
panel is removed. As a safety precaution, all electrical power
and the gas supply to the furnace should be turned off before
servicing.

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FURNACE USER MAINTENANCE

FILTER RACK

RACK AND FILTERS SECURED

INSIDE BLOWER SECTION
FOR SHIPMENT
Before proceeding, be sure the area is well ventilated. Turn
the thermostat OFF. If the blower is running, wait until it CASING SIZE DIMENSION FH
stops automatically. Turn OFF the gas and electrical power 14-1/2” 13-1/4”
supplies to the furnace. Check all metal parts and surfaces 17-1/2” 12-1/2”
to be sure they have cooled to room temperature before 21” 11-1/2”
you begin. 24-1/2” 9-3/4”

Blower Care NOTE: FILTER ACCESS THROUGH

DUCKWORK MUST BE PROVIDED
Even with good filters properly in place, blower wheels and motors will FOR REMOVAL AND CLEANING
become dust laden after long months of operation. The entire blower
FILTERS
assembly should be inspected annually. If the motor and wheel are
heavily coated with dust, they can be brushed and cleaned with a vac- FILTER
DUCKWORK RACK
uum cleaner. If the blower cannot be properly cleaned without removing FH
it from the furnace, then this service must be performed by a qualified
service agency.
The blower can be serviced/removed through the blower access panel
on the inside of the furnace. If there is a combustion air pipe installed
inside the furnace, it may have to be removed to access the blower FIGURE 7: Filter Rack Assembly and Attachment
access panel. After the combustion air pipe is removed, it is easy to TABLE 1: Filter Sizes
remove the inside blower access panel by pushing it up, against a
spring, or removing the screws of the access panel. Blower is now Input CFM Cabinet Top Return
ready to be serviced through the opening. BTU/H (kW) (m3/min) Size Filter in(cm)
If the blower has to be removed through the inside blower access panel, 60 (17.6) 1200 (34) B (2) 14 x 20 (36 x 51)
then the top flange, blower door switch and bottom flange will also have 80 (23.4) 1200 (34) B (2) 14 x 20 (36 x 51)
to be removed on some models, On some other models, top and bot-
80 (23.4) 1600 (45) C (2) 14 x 20 (36 x 51)
tom angles will have to be removed to slide the blower out of the fur-
100 (29.3) 1600 (45) C (2) 14 x 20 (36 x 51)
nace.
100 (29.3) 2000 (57) C (2) 14 x 20 (36 x 51)
120 (35.1) 2000 (57) D (2) 14 x 20 (36 x 51)
Externally Mounted Air Filters
Make sure you DO NOT move the clip-on weight on the Some installations may have the air filter in a rack attached to the cas-
indoor fan wheel when cleaning the wheel. This weight is ing of the furnace or placed in the return air duct. You can gain access
used to balance the wheel. Moving the weight will cause to the filter by pulling on the door or unscrewing the retaining screw,
the fan wheel to vibrate. then slide the filter(s) out of its channel. Replace throw away filter(s)
Air Filters with the same size new filter(s). Throw away filter(s) may be replaced
The filters should be checked every 3 months. On new construction, with cleanable filter(s) at this time. Cleanable filter(s) may be cleaned as
check the filters every week for the first four weeks and every three described in the manufacturer instructions or as described below and
weeks after that, especially if the indoor fan is running continuously. then re-installed.
When replacing the filter(s), refer to Table 1 to be sure you install the How to Clean your Filter
right size filter for your furnace. Dirty filters greatly restrict the flow of air
High-velocity filters may be cleaned with a vacuum cleaner or washed
and may cause damage to the moving parts of the furnace. If the filters
with a garden hose. Be sure to shake off excess water and allow filter to
become clogged the heat exchangers and blower motor could overheat
completely dry before re-installing the filter.
resulting in a potentially dangerous situation.
Never operate your furnace without a suitable air filter. To replace the filter after cleaning you must do the following:
1. Slide filter into place.
Removing Filters
Most downflow furnaces have their filters located on the top of the fur- 2. Snap the door on or place the door in position.
nace in an external filter rack. To check filters you should: 3. Make sure the door is secure to the end of the filter rack.
1. Follow the instructions to turn off the appliance before servicing. 4. For filter grilles, place the filter into the grilles, close the grille cover
2. Filters are installed in the return air plenum above the blower and tighten the retaining screw.
assembly. An “A” frame assembly supports the filters. Lift the filter Every time the filters are changed the following items should be visually
slightly and remove for service. inspected:
3. Follow the instructions “HOW TO CLEAN YOUR FURNACE’S FIL- • Check combustion air and vent pipe for blockage or leakage.
TER”. • Check all components to be sure they are in good condition and
4. Reverse the procedure to reinstall filters. that there are no obvious signs of deterioration.
5. Follow the operating instructions to place appliance in operation. • 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.

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If, during the inspection of your furnace, you find any of the following 4. Disconnect wires from flame sensor, rollout switch and HSI igniter.
conditions: Remove igniter carefully, as it is easily broken.
• Excessive amounts of dust and lint on components. 5. Remove the screws that hold the burner box assembly to the vest
• Damaged or deteriorated components or surfaces. panel and remove the assembly.
• Leaks or blockage in the vent pipe passages. 6. Remove burners from the burner assembly.
• Water on any surface inside or outside of the furnace.
7. Burners may be cleaned by rinsing in hot water.
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 8. Reassemble the burners in the reverse order.
questions about the operation of your furnace. Cleaning the Heat Exchanger
If all components appear to be in good operating condition, replace the
1. Turn off the electrical power to the unit.
front panels. Turn ON the gas and electrical power supplies to the fur-
nace, and set thermostat to the desired temperature. 2. Turn off the gas supply at the external manual shut-off valve and
loosen the ground union joint.
Motor Lubrication
The motors in these furnaces are permanently lubricated, and do not 3. Remove the burner door and remove the burner box cover.
require periodic oiling. 4. Disconnect wires from flame sensor, rollout switch and HSI igniter.
Remove igniter carefully, as it is easily broken.
SECTION II: SERVICE AND MAINTENANCE 5. Remove the screws that hold the burner box assembly to the vest
MANUAL panel and remove the assembly.
SAFETY 6. Remove the vent pipe assembly, vent blower and condensate pan.
The following safety rules must be followed when servicing the 7. The heat exchanger is now exposed.
furnace. 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.
ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD 9. Replace all components in reverse order. Reconnect all wiring.
Failure to follow safety warnings exactly could result in
10. Restore electrical power and gas supply to the furnace.
dangerous operation, serious injury, death or property
damage. 11. Check furnace operation.
Improper servicing could result in dangerous operation,
serious injury, and death or property damage.
• Before servicing, disconnect all electrical power to the fur-
nace. Label all wires prior to disconnection when servicing
• When servicing controls, label all wires prior to discon- controls. Wiring errors can cause improper and danger-
necting. Reconnect wires correctly. ous operation. Verify proper operation after servicing.
• Verify proper operation after servicing.
Cleaning the Secondary Heat Exchanger
FURNACE MAINTENANCE
1. Follow steps 1 - 7 under cleaning the Heat Exchanger.
The furnace should be cleaned and adjusted by a certified dealer or
2. Remove the vent piping from the vent blower housing. Disconnect
qualified service contractor once a year or before the start of every the drain lines from the vent blower housing and from the conden-
heating season. The following items must be cleaned and serviced or sate drain pan. Remove the vent blower housing blower and the
replaced if there are signs of deterioration. condensate pan.
1. The vent terminal screen (if applicable). 3. Using a stiff wire brush, remove the loose scale or soot from each
2. The furnace vent and combustion air intake passageways. Should tube.
it be necessary to service the vent/air intake system, the manufac- 4. Vacuum the secondary heat exchanger.
turer recommends this service be conducted by a qualified service 5. Finish the cleaning procedure by following steps 9 - 11 under
agency. The operation of this appliance requires the reassembly cleaning the Heat Exchanger.
and resealing of the vent/air intake system. Cleaning the Vent / Air Intake System
3. The furnace burners, ignitor and flame sensor. Should it be necessary to service the vent / air intake system, the man-
4. The condensate collection and disposal system. If any disassem- ufacturer recommends this service be conducted by a qualified service
bly of components containing flue or vent gases is required, a agency.
qualified service agency must perform the service. The operation of this appliance requires the reassembly and resealing
of the vent / air intake system as specified in the “Combustion Air and
FURNACE CLEANING Vent System” located in the Installation Manual.
NOTE: The cleaning operations listed below must be performed NORMAL OPERATION SEQUENCE
only by a qualified service agency.
The furnace control calculates the optimum firing rate each time the
Burner Removal/Cleaning wall thermostat R and W contacts close or open (at the beginning and
The main burners should be checked periodically for dirt accumulation. at the end of each call for heat) based on information from the thermo-
If cleaning is required, follow this procedure: stat and past demand. UNLIKE CONVENTIONAL SYSTEMS, THE
WALL THERMOSTAT DOES NOT SIMPLY TURN THE FURNACE ON
1. Turn off the electrical power to the unit.
AND OFF. THE FURNACE CONTROL CALCULATES THE DEMAND
2. Turn off the gas supply at the external manual shut-off valve and AND MAY CONTINUE TO FIRE THE FURNACE DURING PORTIONS
loosen the ground union joint. OF THE THERMOSTAT "OFF" CYCLE.
3. Remove the burner door and remove the burner box cover. When the wall thermostat R and W contacts close, indicating a call for
heat, the following sequence occurs:

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1. The inducer is energized and ramps up its speed until airflow is
proven by the pressure switch and by the pressure sensor on the
control board.
2. The hot surface ignitor is energized. CFM
INDICATOR HUMIDIFIER
3. After a 17-20 second igniter heatup, the gas valve opens and the TERMINALS
burners light.
4. When the control senses that flame is present, the circulating CFM

blower starts at low speed. DIAGNOSTIC

LIGHT
5. The furnace fires at 70% of full rate for 30-45 seconds, then drops DELAY COOL ADJUST EAC
TERMINALS
to the minimum (35%) firing rate. R

W
6. The firing rate is automatically adjusted to meet demand, increas- LOW VOLTAGE Y/Y2
ADJUST
Y1
ing gradually to maximum (100%) firing rate if the thermostat is not TERMINALS HUM JUMPER
satisfied within a defined time. G HUMIDISTAT
ERROR C CONNECTED
YES NO
7. When the thermostat R and W contacts open (thermostat is satis- BUTTON AIR RECIRC

fied) the furnace control recalculates the demand and a new firing TEST ERROR
rate. BUTTON TEST

a. If demand exceeds the minimum firing rate, the burners will

continue to fire at a recalculated reduced firing rate, decreas- CONTINUOUS FAN DELAY COOLING
ing if the thermostat remains off for a defined time. SPEED JUMPER JUMPER SPEED JUMPER
b. If demand does not exceed the minimum firing rate, the burn-
ers will shut off immediately. FIGURE 8: Furnace Control Board
8. After the burners shut off, the circulating blower will continue to run Delay Taps Selection
until the temperature sensor detects that the supply air tempera- The set of jumper pins on the control board labeled "DELAY" are used
ture has dropped to the desired level, which should take from 30 to to set the delay profiles for the furnace. These can be chosen so as to
90 seconds. maximize the comfort and sound levels for various regions of the coun-
ADJUSTMENT OF FAN CONTROL SETTINGS try.
Cooling - The airflow delivered by the furnace during cooling operation Tap A is the default profile. It provides a 30-second ramp-up from zero
can be adjusted to match the cooling capacity of the A/C condensing airflow to full capacity and a 30-second ramp-down from full capacity
unit. This is done by moving the COOL and ADJ jumper on the control back to zero airflow. Whenever there is a change in airflow mode, such
board to give the desired airflow. as from low heat to high heat, the motor will take 30 seconds to ramp
from one speed to the other.
The COOL jumper has four positions, which will deliver sufficient airflow Tap B is the humid profile. This profile is best-suited for installations
in cooling mode for the cooling capacities shown in the Table 2. where the humidity is frequently very high during cooling season, such
TABLE 2: Cooling Airflow - A/C Capacity in Tons as in the southern part of the country. On a call for cooling, the blower
will ramp up to 50% of full capacity and will stay there for two minutes,
Cool Jumper Position then will ramp up to 82% of full capacity and will stay there for five min-
Models utes, and then will ramp up to full capacity, where it will stay until the
D C B A
wall thermostat is satisfied. In every case, it will take the motor 30 sec-
60/1200 1-1/2 2 2-1/2 3 onds to ramp from one speed to another.
80/1200 1-1/2 2 2-1/2 3 Tap C is the dry profile. This profile is best suited to parts of the country
80/1600 2-1/2 3 3-1/2 4 where excessive humidity is not generally a problem, where the sum-
mer months are usually dry. On a call for cooling the motor will ramp up
100/1600 2-1/2 3 3-1/2 4
to full capacity and will stay there until the thermostat is satisfied. At the
100/2000 3 3-1/2 4 5 end of the cooling cycle, the blower will ramp down to 50% of full capac-
120/2000 3 3-1/2 4 5 ity where it will stay for 60 seconds. Then it will ramp down to zero. In
every case, it will take the motor 30 seconds to ramp from one speed to
Continuous Fan Operation - The airflow delivered by the furnace dur-
another.
ing continuous fan operation can be adjusted as desired. This is done
my moving the RECIRC jumper on the control board to give the desired Tap D is the normal profile, best suited for most of the country, where
airflow. neither excessive humidity nor extremely dry conditions are the norm.
On a call for cooling, the motor will ramp up to 63% of full capacity and
The jumper has three positions. The "A" position delivers maximum air-
will stay there for 90 seconds, then will ramp up to full capacity. At the
flow, 100% of the blower capacity. Position "B" delivers approximately
end of the cooling cycle, the motor will ramp down to 63% of full capac-
70% of the blower capacity. And Position "C" delivers minimum airflow,
ity and will stay there for 30 seconds, then will ramp down to zero. In
approximately 35% of the blower capacity.
every case, it will take the motor 30 seconds to ramp from one speed to
another.
Humidistat
When a humidistat is installed in the system, the “Humidistat con-
nected?” jumper on the control board should be moved to the “YES”
position. The cooling airflow will then be reduced by 15% whenever the
humidistat indicates high humidity.

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 172988-YUM-A-0106

Hot Surface Ignition System One Red Flash - Flame is present with no power being supplied to gas
valve. This can be caused by a gas valve that is slow to close or that
leaks gas through to the burners.
Two Red Flashes - Stuck closed pressure switch. The control confirms
that the pressure switch contacts are open at the beginning of each
HOT SURFACE IGNITION SYSTEM cycle. This could be caused by a faulty pressure switch or by mis-wiring
Do not attempt to light this furnace by hand (with a of the pressure switch.
match or any other means). There may be a potential Three Red Flashes - Stuck open pressure switch. This indicates that
shock hazard from the components of the hot surface the pressure switch is open when it should be closed. This could be
ignition system. The furnace can only be lit automatically caused by a faulty combustion air blower, blocked vent pipe, blocked air
by its hot surface ignition system. intake pipe, blocked condensate drain, faulty pressure switch hose or a
faulty pressure switch.
TROUBLESHOOTING Four Red Flashes - High limit switch open or 24 volt fuse is open. This
The following visual checks should be made before troubleshooting: may be caused by a dirty air filter, improperly sized duct system, faulty
blower motor, restricted circulating airflow or an open fuse on the con-
1. Check to see that the power to the furnace and the ignition control trol board.
module is ON.
Five Red Flashes - Rollout switch or auxiliary limit switch open. Check
2. The manual shut-off valves in the gas line to the furnace must be the rollout switch on the side of the burner box. It is a manual reset
open. switch. To reset, push the small button in the center of the switch. If it
3. Make sure all wiring connections are secure. cannot be reset or if the switch trips again, contact a qualified service-
4. Review the sequence of operation. Start the system by setting the man. Check the limit switch mounted in the combustion air blower hous-
thermostat above the room temperature. Observe the system’s ing.
response. Then use the troubleshooting section in this manual to Six Red Flashes - Current failure on modulating gas valve.
check the system’s operation.
Seven Red Flashes - Lockout due to no ignition. The control will try
three times for ignition. If flame cannot be established in three tries, the
control will lockout for one hour and then will try again to light. Check
gas supply, ignitor, gas valve, flame sensor.
Never bypass any safety control to allow furnace opera- Eight Red Flashes - Lockout due to too many flame recycles. This
tion. To do so will allow furnace to operate under poten- flash code occurs if flame is lost five times during a single heating cycle.
tially hazardous conditions. This could be caused by a faulty gas valve, low gas pressure, or dirty
flame sensor. The control will lock out for one hour and then will try
Do not try to repair controls. Replace defective controls again.
with UPG Source 1 Parts.
Nine Red Flashes - Reversed line polarity or improper grounding.
Never adjust pressure switch to allow furnace operation. Check polarity of the incoming power to the furnace. Check the ground-
ing of the furnace, including the transformer ground and the L1 and
FURNACE CONTROL DIAGNOSTICS neutral connections.
This furnace has built-in self-diagnostic capability. If a system problem Ten Red Flashes - Unexpected gas flow present. Check gas valve wir-
occurs, a flashing LED shows a fault code. The LED can flash red, ing. If correct, replace gas valve.
green or amber to indicate various conditions. The LED is located on
Eleven Red Flashes - Main blower failure - This flash code occurs
the furnace control board and can be seen through the clear view port
when the main limit opens and fails to reclose within five minutes, indi-
in the lower door of the furnace. To indicate an error condition, the LED
cating that the blower motor or blower wheel has failed.
will turn on for 1/4 second and off for 1/4 second. The pattern will be
repeated the number of times equal to the flash code. For instance, a Twelve Red Flashes - ID plug is not present or not connected properly,
"six flash code" will be indicated by the LED turning on and off six times. check for loose plug or loose wires in plug.
There will be a two second off period between each set of flashes. The Steady On Red - Control fault has been detected or there is 24 volts
flash codes and an indication of their likely causes are listed below: present without 115 volts. Check that there is 24 volts and 115 volts
STEADY OFF - No 24V power to board. Check the 24 volt control cir- being supplied to the board. If so, then the board should be replaced.
cuit fuse on the board. Check the circuit breaker or fuse on the 115 volt
supply power to the furnace. Check that the 24 volt transformer. DIAGNOSTIC FAULT CODE STORAGE AND
One Green Flash - Normal Operation with no call for heat. RETRIEVAL
Two Green Flashes - Indicator for "No error codes in memory". See The control in this furnace is equipped with memory that will store up to
Diagnostic Fault Code Storage and Retrieval section below. five error codes to allow a service technician to diagnose problems
more easily. This memory will be retained even is power to the furnace
Three Green Flashes - Indicator for "Error codes cleared from mem-
ory". See Diagnostic Fault Code Storage and Retrieval section below. is lost. Only a qualified service technician should use this feature.
The control stores up to five separate error codes. If more than five
Rapid Green Flash - Control is in "Factory Speedup" mode. This mode
error codes have occurred since the last reset, only the five most recent
is used only during factory run-testing of the furnace. To stop this mode,
will be retained. The furnace control board has a button, labeled "LAST
cycle power to the furnace off and then back on.
ERROR" that is used to retrieve error codes. This function will only
One Amber Flash - Normal operation with call for cooling. work if there are no active thermostat signals. So any call for heating,
Two Amber Flashes - Normal operation with call for heat. cooling or continuous fan must be terminated before attempting to
retrieve error codes.
Three Amber Flashes - Normal operation, burner is on at end of heat-
ing cycle after wall thermostat has been satisfied. 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
Four Amber Flashes - Heating capacity is reduced due to restriction in with the most recent. There will be a two-second pause between each
the circulating air system. flash code. After the error codes have all been displayed, the LED will
Five Amber Flashes - Heating capacity is reduced due to restriction in resume the normal slow green flash after a five second pause. To
the combustion air or vent system. repeat the series of error codes, push the button again.
Rapid Amber Flash - Low flame sense current. Check for dirty or mis- If there are no error codes in memory, the LED will flash two green
located flame sensor rod. 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.

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 172988-YUM-A-0106

SECTION III: REPLACEMENT PARTS LIST

33
35

7 54
18

13 72 27
71
45 2
11
80
14 69
46 68
19
10
64
5 28

9,37
47
30

15
54
16 18
1
62 59
48
55,56 50 49 57

22 52 2

21
4
23 26 60
25 14

51 31
6
43
44 53

24
20 14
46
63
43 37 6
10 9

29

39 31

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 172988-YUM-A-0106

ITEM DESCRIPTION ITEM DESCRIPTION

MOTOR MISCELLANEOUS
1 MOTOR, DIRECT DRIVE BLOWER 43 PLUG, WINDOW, CLEAR - 1.5”
2 MOTOR, INDUCER ASSY 44 COMBUSTION AIR TRANSITION, 3-WAY
ELECTRICAL 45 TUBING, SILICONE (Gray, .188 ID, 2.83 ft. Req’d)
3* CAPACITOR 46 TUBING, SILICONE (Preformed)
4 SWITCH, LIMIT (INDUCER) 47 TUBING, SILICONE (Gray, .188 ID, 1.25 ft. Req’d)
5 LIMIT, TEMPERATURE (Primary) 48 GASKET, COMBUSTION BLOWER
6 LIMIT, FLAME ROLL-OUT 49 GASKET, CONDENSATE PAN
7 CONTROL, FURNACE MODULE 50 GASKET, UPPER CONDENSATE PAN (2 Req’d)
7A* PLUG, JUMPER 51 GASKET, GAS CONTROLS
8* SENSOR, THERMISTOR 52 GASKET, CONDENSING COIL
9 IGNITER 53 GASKET, COMBUSTION AIR TRANSITION
10 SENSOR, FLAME 54 VENT PIPE 2” X 15.25” LG.
11 SWITCH, PRESSURE 55 GROMMET, MOTOR (3 Req’d)
12* SWITCH, DOOR 56 FERRULE (3 Req’d)
13 TRANSFORMER 57 COMBUSTION BLWR RESTRICTOR
14 VALVE, GAS 58* INSERT, SILICONE
AIR MOVING 59 RESTRICTOR, TUBE
14 HOUSING, BLOWER 60 WASHER, FLAT FIBERGLASS (3 Req’d)
15 WHEEL, BLOWER 61* HARNESS, MAIN WIRING
17* BRACKET, BLOWER (2 Req’d) 62 MOUNT, 1 PC. MOTOR
FABRICATED PARTS 63 ORIFICE, BURNER (Natural #45)
18 PANEL, BLOWER COVER 64 TRAP, CONDENSATE
19 BRACKET, CONDENSATE TRAP 65* WIRING DIAGRAM
20 BURNER, MAIN GAS 66* 45 DEG. STREET ELBOW 2”
21 COIL, CONDENSING 67* DRAIN TUBE, CONDENSATE TRAP
22 SHELF, BLOWER 68 DRAIN TUBE, COMBUSTION BLOWER
23 HEAT EXCHANGER ASS’Y 69 DRAIN TUBE, CONDENSATE PAN
24 MANIFOLD, GAS 70* DRAIN TUBE, STRAIGHT 21” LG.
25 SHIELD, PAN 71 DRAIN TUBE, RAIN GUTTER
26 PAN, CONDENSATE 72 DRAIN HOSE ASSEMBLY
27 PANEL, VEST ACCESS (Upper) 73* DRAIN TUBE, CONDENSATE
28 PANEL, BLOWER ACCESS (Lower) 74* LOCKNUT, CONDUIT (1/2”)
29 WRAPPER, BURNER BOX 75* ADAPTER, INSERT
30 CHANNEL, TOE PLATE 76* BUSHING, THREADED
31 COVER, GAS CONTROL 77* GROMMET, MANIFOLD
32* PANEL, BOTTOM 78* VENT PIPE ASSEMBLY
33 PANEL, TOP 79* DRAIN TUBE, VENT PIPE
34 SUPPORT, BURNER 80 DOOR KNOB (Black)
35 WRAPPER, CABINET (Insulated) 81* SIGHT GLASS, OVAL
36* PLATE, DIFFUSER
37 BRACKET, IGNITER
38* BRACKET, DOOR SWITCH
39 BOTTOM PANEL, BURNER BOX
40
41
42

NOTE: *Not Shown

Major components and suggested stocking items are shown with shaded item number.

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 172988-YUM-A-0106

FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL

MODEL NO. DESCRIPTION USED WITH
1NP0680 PROPANE (LP) CONVERSION KIT WITH GAS VALVE ALL MODELS
1CT0302 CONCENTRIC INTAKE/VENT 2” 60, 80, 100 INPUT MBH
1CT0303 CONCENTRIC INTAKE/VENT 3” 100, 120 MBH
1NK0301 CONDENSATE NEUTRALIZER KIT ALL MODELS
1HT0901 SIDEWALL VENT TERMINATION KIT ALL MODELS
1CB0317 17-1/2” CABINET
1CB0321 COMBUSTIBLE FLOOR BASE 21” CABINET
1CB0324 24-1/2” CABINET
1TK0917 17-1/2” CABINET
1TK0921 COIL TRANSITION KIT 21” CABINET
1TK0924 24-1/2” CABINET

REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:
• Visit our website at www.source1parts.com for the following information:
1. Search for a part or browse the catalog.
2. Find a dealer or distributor.
3. Customer Service contact information.
a. Click on the “Brand Links” button
b. Click on the “Customer Service” button
• You can contact us by mail. Just send a written request to:
York International
Consumer Relations
5005 York Drive
Norman, OK 73069

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 172988-YUM-A-0106

SECTION IV: WIRING DIAGRAM

FIGURE 9: Wiring Diagram

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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 the reverse
side of this warranty.
HEAT EXCHANGER
FURNACE TYPE Residential Applications Non-Residential PARTS
Original Owner Subsequent Owner Applications
90% PC9 Lifetime 20 10 5

UPG strongly recommends regular periodic preventative maintenance on this equipment. The person most familiar with the equipment in your HVAC system is
a UPG dealer. The UPG dealer can ensure your maintenance program meets the conditions of the "UPG Warranty", maximize the efficiency of the equipment,
and service your unit within the mandated guidelines with regard to unlawful discharge of refrigerants into the atmosphere.
This warranty applies only to products installed in the United States and Canada.

EXCLUSIONS
This warranty does not cover any:
1. Shipping, labor, or material charges.
2. Damages resulting from transportation, installation, or servicing.
3. Damages resulting from accident, abuse, fire, flood, alteration, or acts of God (tampering, altering, defacing or removing the product serial number will
serve to void this warranty).
4. Damages resulting from use of the product in a corrosive atmosphere.
5. Damages resulting from inadequacy or interruption of electrical service or fuel supply, improper voltage conditions, blown fuses, or other like damages.
6. Cleaning or replacement of filters.
7. Damages resulting from failure to properly and regularly clean air and/or water side of condenser and evaporator.
8. Damages resulting from: (I) freezing of condenser water or condensate; (II) inadequate or interrupted water supply; (III) use of corrosive water; (IV) fouling
or restriction of the water circuit by foreign material or like causes.
9. Damages resulting from operation with inadequate supply of air or water.
10. Damages resulting from use of components or accessories not approved by UPG (vent dampers, etc.).
11. Increase in fuel or electric cost.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF 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. 172988-YUM-A-0106

Copyright © by Unitary Products Group 2006. All rights reserved. Supersedes: Nothing
Unitary 5005 Norman
Products York OK
Group Drive 73069

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