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York Furnace
York Furnace
MAINTENANCE AND
EFFICIENCY
RATING
CERTIFIED
SERVICE MANUAL
ISO 9001
MODELS: PC9
Certified Quality
Management System
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.
172988-YUM-A-0106
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.
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
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
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:
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
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.
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
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.