White Rodgers Furnace FG9 User Manual

USER’S INFORMATION,  
MAINTENANCE AND  
SERVICE MANUAL  
EFFICIENCY  
RATING  
CERTIFIED  
This product was manufactured  
in a plant whose quality system  
is certified/registered as being  
in conformity with ISO 9001.  
MODELS: P*UR / G9T-UP / FG9-UP (Upflow)  
TABLE OF CONTENTS  
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1  
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
INSTRUCTIONS FOR EXAMINING THE FURNACE  
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Intermittent Blower - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5  
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
Cleaning the Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . .6  
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6  
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .7  
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8  
FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL . . . . . .10  
FIELD INSTALLED ACCESSORIES - ELECTRICAL . . . . . . . . . . .10  
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . .10  
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12  
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . . 3  
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . 3  
Read the Instructions Below Before Trying to Start the Furnace . . 3  
Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . 4  
SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . 4  
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 prop-  
erty damage.  
Do not store or use gasoline or other flammable  
vapors and liquids in the vicinity of this or any other  
appliance.  
3. The furnace needs air for combustion in order to operate properly  
and safely. Do not block or obstruct air openings on the furnace,  
air openings to the area where the furnace is installed, or spaces  
around the furnace.  
WHAT TO DO IF YOU SMELL GAS:  
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  
(including cell phone) in your building.  
Leave the building immediately.  
5. Should the gas supply fail to shut off or if overheating occurs, shut  
off the gas valve to the furnace before shutting off the electrical  
supply.  
Immediately call your gas supplier from a neighbor’s  
phone. Follow the gas supplier’s instructions.  
If you cannot reach your gas supplier, call the fire depart-  
ment.  
6. Do not use this furnace if any part has been under water. A flood-  
damaged furnace is extremely dangerous. Attempts to use the fur-  
nace can result in fire or explosion. A qualified service agency  
should be contacted to inspect the furnace and replace all gas  
controls, control system parts, electrical parts that have been wet  
or the furnace if deemed necessary.  
Installation and service must be performed by a quali-  
fied installer, service agency or the gas supplier.  
035-19592-001 Rev. C (0204)  
 
035-19592-001 Rev. C (0204)  
10. Set thermostat to the desired setting. Burner will light, which may  
take 30-60 seconds.  
HOW YOUR GAS FURNACE WORKS  
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.  
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.  
To Turn Off the Appliance:  
1. Set the thermostat to lowest setting.  
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.  
2. Turn off all electric power to the appliance if service is to be per-  
formed.  
3. Remove burner access panel.  
4. Move gas control switch to the “OFF” position.  
5. Replace burner access panel.  
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.  
START-UP AND SHUTDOWN INSTRUCTIONS  
Read the Instructions Below Before Trying to Start the  
Furnace  
OUTLET  
PRESSURE PORT  
If you do not follow these instructions exactly, a fire or  
explosion may result causing property damage, personal  
injury, and/or loss of life.  
INLET  
OUTLET  
WRENCH  
BOSS  
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.  
INLET  
PRESSURE  
PORT  
MAIN  
REGULATOR  
ADJUSTMENT  
ON/OFF  
SWITCH  
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.  
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  
try to repair it, call a qualified service technician. Force or  
attempted repair may result in a fire or explosion.  
EXTERNAL MANUAL  
SHUTOFF VALVE  
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.  
TO GAS  
SUPPLY  
TO GAS  
SUPPLY  
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 access panel.  
GROUND JOINT UNION  
MAY BE INSTALLED  
INSIDE OR OUTSIDE UNIT.  
DROP  
LEG  
5. Move gas control switch to the “OFF” position. Do not force.  
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.  
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.  
7. Move gas control switch to the “ON” position. Do not force.  
8. Replace burner access panel.  
9. Turn on all electric power to the appliance.  
Unitary Products Group  
3
 
035-19592-001 Rev. C (0204)  
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.  
FURNACE USER MAINTENANCE  
Before proceeding, be sure the area is well ventilated. Turn  
the thermostat OFF. If the blower is running, wait until it  
stops automatically. Turn OFF the gas and electrical power  
supplies to the furnace. Check all metal parts and surfaces  
to be sure they have cooled to room temperature before  
you begin.  
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.  
Air Filters  
Every time the filters are changed the following items should be visually  
inspected:  
The filters should be checked every 3 months. On new construction,  
check the filters every week for the first four weeks and every three  
weeks after that, especially if the indoor fan is running continuously.  
When replacing the filter(s), refer to Table 1 to be sure you install the  
right size filter for your furnace. Dirty filters greatly restrict the flow of air  
and may cause damage to the moving parts of the furnace. If the filters  
become clogged the heat exchangers and blower motor could overheat  
resulting in a potentially dangerous situation.  
Check combustion air and vent pipe for blockage or leakage.  
Check all components to be sure they are in good condition and  
that there are no obvious signs of deterioration.  
Check the drain lines to make sure there are no cracks or leaks.  
Check for dirt or lint on any surfaces or on components. Do not try  
to clean any of the surfaces or components. Cleaning of the fur-  
nace and its components must be done by a qualified service pro-  
fessional.  
Never operate your furnace without a suitable air filter.  
Removing Filters  
Internally Mounted Air Filters  
If, during the inspection of your furnace, you find any of the following  
conditions:  
Most upflow furnaces have their filters located on the side or bottom of  
the furnace in a filter wire retainer located inside the blower compart-  
ment. To check filters located in the blower compartment:  
Excessive amounts of dust and lint on components.  
Damaged or deteriorated components or surfaces.  
Leaks or blockage in the vent pipe passages.  
1. Remove the upper furnace door by lifting up. Pull out bottom of  
door and lower from furnace.  
Water on any surface inside or outside of the furnace.  
2. Remove the blower compartment panel by lifting up.  
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.  
3. The filters will be located on the bottom or the one of the sides. To  
remove bottom-mounted or side mounted filter (s) on all furnaces,  
push the looped end of the filter retainer rod in, and then move  
away from the filter.  
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.  
4. Reverse the procedure to reinstall filters.  
POSITION WIRE RETAINER  
(IF PROVIDED) UNDER FLANGE  
SECTION II: SERVICE AND MAINTENANCE  
MANUAL  
SAFETY SECTION  
The following safety rules must be followed when servicing the  
furnace.  
IF FILTER  
PROVIDED  
CLIPS  
RIGHT SIDE  
FURNACE  
INSTALLATION  
FRONT  
ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD  
SHOWN  
Failure to follow safety warnings exactly could result in  
dangerous operation, serious injury, death or property  
damage.  
FIGURE 6: Upflow Internal Filter Retainer  
Improper servicing could result in dangerous operation,  
serious injury, and death or property damage.  
Externally Mounted Air Filters  
Some installations may have the air filter in a rack attached to the cas-  
ing of the furnace or placed in the return air duct. You can gain access  
to the filter by pulling on the door or unscrewing the retaining screw,  
then slide the filter(s) out of its channel. Replace throw away filter(s)  
with the same size new filter(s). Throw away filter(s) may be replaced  
with cleanable filter(s) at this time. Cleanable filter(s) may be cleaned as  
described in the manufacturer instructions or as described below and  
then re-installed.  
Before servicing, disconnect all electrical power to the fur-  
nace.  
When servicing controls, label all wires prior to discon-  
necting. 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.  
To replace the filter after cleaning you must do the following:  
1. Slide filter into place.  
2. Snap the door on or place the door in position and tighten the  
retaining screws, if provided.  
1. The vent terminal screen (if applicable).  
3. Make sure the door is secure to the end of the filter rack.  
4
Unitary Products Group  
 
035-19592-001 Rev. C (0204)  
TABLE 1: Filter Sizes  
Input / Output  
BTU/H (kW)  
Cabinet  
Size  
CFM (cm/m)  
Side (in)  
Side (mm)  
Bottom (in)  
Bottom (mm)  
40/37 (11.71/10.84)  
60/55/ (17.57/16.10)  
80/75/ (23.42/21.96)  
80/75/ (23.42/21.96)  
100/95 (29.28/27.82)  
100/95 (29.28/27.82)  
120/112/ (35.14/32.80)  
140/130/ (40.99/38.06)  
1000 (28.32)  
1000 (28.32)  
1200 (33.98)  
1600 (45.31)  
1400 (39.64)  
2000 (56.63)  
2000 (56.63)  
2000 (56.63)  
14-1/2” (A)  
17-1/2” (B)  
17-1/2” (B)  
21” (C)  
16 x 25  
16 x 25  
406 x 635  
406 x 635  
14 x 25  
16 x 25  
16 x 25  
20 x 25  
20 x 25  
20 x 25  
22 x 25  
22 x 25  
356 x 635  
406 x 635  
406 x 635  
508 x 635  
508 x 635  
508 x 635  
559 x 635  
559 x 635  
16 x 25  
406 x 635  
16 x 25  
406 x 635  
21” (C)  
16 x 25  
406 x 635  
21” (C)  
(2) 16 x 25  
(2) 16 x 25  
(2) 16 x 25  
(2) 406 x 635  
(2) 406 x 635  
(2) 406 x 635  
24-1/2” (D)  
24-1/2” (D)  
How to Clean your Filter  
Intermittent Blower - Cooling  
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.  
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 cooling termi-  
nal on the control board. The fan off setting is fixed at 60 seconds for  
SEER enhancement.  
Blower Care  
Even with good filters properly in place, blower wheels and motors will  
become dust laden after long months of operation. The entire blower  
assembly should be inspected annually. If the motor and wheel are  
heavily coated with dust, they can be brushed and cleaned with a vac-  
uum cleaner. If the blower cannot be properly cleaned without removing  
it from the furnace, then this service must be performed by a qualified  
service agency.  
Heating Cycle  
When the thermostat switch is set on HEAT and the fan is set on AUTO,  
and there is a call for heat, a circuit is completed between terminals R  
and W of the thermostat. When the proper amount of combustion air is  
being provided, the pressure switch will close, the ignition control pro-  
vides a 17-second warm-up period, the gas valve then opens, the gas  
starts to flow, ignition occurs and the flame sensor begins its sensing  
function. The blower motor will energize 30 seconds after the gas valve  
opens, if a flame is detected. Normal furnace operation will continue  
until the thermostat circuit between R and W is opened, which causes  
the ignition system and gas valve to de-energize and the burner flames  
to be extinguished. The vent motor will operate for 15 seconds and the  
blower motor will operate for the amount of time set by the fan-off delay  
jumper located on the control board. See Figure 7. The heating cycle is  
complete, and ready for the start of the next heating cycle.  
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.  
Motor Lubrication  
The motors in these furnaces are permanently lubricated, and do not  
require periodic oiling.  
RED-LOW SPEED  
MOTOR LEADS  
BLU-MEDIUM SPEED  
BLK-HIGH SPEED  
SEQUENCE OF OPERATION  
The following describes the sequence of operation of the furnace. Refer  
to Figure 1 for component location.  
BLK  
BLU  
RED  
Continuous Blower  
COOL  
HEAT  
PARK  
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  
wire that is connected to the cooling terminal on the control board. To  
obtain a constant air circulation at lower flow rate, change the high-  
speed wire to either the medium speed wire or the low speed wire.  
PARK  
LINE  
60  
XM  
180  
FAN OFF  
ADJUSTMENT  
SWITCHES  
FIGURE 7: Typical Heat/Cool Speed Tap Connections  
Unitary Products Group  
5
 
035-19592-001 Rev. C (0204)  
If the flame is not detected within 2 seconds of the gas valve opening,  
the gas valve is shut off and a retry operation begins. If the flame is lost  
for 2 seconds during the 10-second stabilization period, the gas valve is  
shut off and a retry operation begins. During a retry operation, the vent  
motor starts a 15 second inter-purge and the ignitor warm-up time is  
extended to 27 seconds. If the flame is established for more than 10  
seconds after ignition during a retry, the control will clear the ignition  
attempt (retry) counter. If three retries occur during a call for heat, the  
furnace will shut down for one hour. If at the end of the one hour shut  
down there is a call for heat, the furnace will initiate a normal start cycle.  
If the problem has not been corrected the furnace will again lockout  
after three retries.  
6. Remove burners from the burner assembly.  
7. Remove the upper cover plate at the top of the furnace. Remove  
the internal baffle.  
8. The upper portion of the heat exchanger is now exposed.  
9. 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 and then vacuum loose the scale and dirt from  
each tube.  
10. Clean - vacuum all burners.  
11. Replace all components in reverse order. Reconnect all wiring.  
12. Restore electrical power and gas supply to the furnace.  
13. Check furnace operation.  
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.  
Label all wires prior to disconnection when servicing  
controls. Wiring errors can cause improper and danger-  
ous operation. Verify proper operation after servicing.  
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.  
Cleaning the Secondary Heat Exchanger  
1. Follow steps 1 - 8 under cleaning the Heat Exchanger.  
Hot Surface Ignition System  
2. Remove the vent piping from the vent blower housing. Disconnect  
the drain lines from the vent blower housing and from the conden-  
sate drain pan. Remove the vent blower housing blower and the  
condensate pan. The turbulators can then be gently removed from  
the secondary heat exchanger.  
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.  
3. Using a stiff wire brush, remove the loose scale or soot from each  
tube.  
4. Vacuum the secondary heat exchanger.  
5. Finish the cleaning procedure by following steps 11 thru 13 under  
cleaning the Heat Exchanger.  
FURNACE CLEANING SECTION  
NOTE: The cleaning operations listed below must be performed only by  
TROUBLESHOOTING  
The following visual checks should be made before troubleshooting:  
a qualified service agency.  
1. Check to see that the power to the furnace and the ignition control  
module is ON.  
Burner Removal/Cleaning  
The main burners should be checked periodically for dirt accumulation.  
If cleaning is required, follow this procedure:  
2. The manual shut-off valves in the gas line to the furnace must be  
open.  
1. Turn off the electrical power to the unit.  
3. Make sure all wiring connections are secure.  
2. Turn off the gas supply at the external manual shut-off valve and  
loosen the ground union joint.  
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.  
3. Remove the upper access panel and remove the burner box cover.  
4. Disconnect wires from flame sensor, rollout switch and HSI igniter.  
Remove igniter carefully, as it is easily broken.  
FURNACE CONTROL DIAGNOSTICS  
5. Remove the screws that hold the burner box assembly to the vest  
panel and remove the assembly.  
The furnace has built-in, self-diagnostic capability. If a system problem  
occurs, a blinking red LED shows a fault code. It is located behind a  
clear view port in the blower compartment door. DO NOT remove the  
furnace blower compartment panel OR turn off furnace power, as either  
action will clear the control’s memory of the fault.  
6. Remove burners from the burner assembly.  
7. Burners may be cleaned by rinsing in hot water.  
8. Reassemble the burners in the reverse order.  
Cleaning the Heat Exchanger  
The control continuously monitors its own operation and the operation  
of the system. If a failure occurs, the LED will indicate the failure code. If  
the failure is internal to the control, the light will stay on continuously. In  
this case, the entire control should be replaced, as the control is not  
field repairable.  
1. Turn off the electrical power to the unit.  
2. Turn off the gas supply at the external manual shut-off valve and  
loosen the ground union joint.  
3. Remove the upper access panel and remove the burner box cover.  
Flash sequence codes 1 through 11 are as follows: LED will turn “on” for  
one second and “off” for one 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.  
4. Disconnect wires from flame sensor, rollout switch and HSI igniter.  
Remove igniter carefully, as it is easily broken.  
5. Remove the screws that hold the burner box assembly to the vest  
panel and remove the assembly.  
6
Unitary Products Group  
 
035-19592-001 Rev. C (0204)  
7 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.  
Never bypass pressure switch to allow furnace opera-  
tion. To do so will allow furnace to operate under poten-  
tially hazardous conditions.  
8 FLASHES: This fault is indicated if the flame is lost 5 times (4 recy-  
cles) during the heating cycle. This could be caused by low gas pres-  
sure or faulty gas valve.  
Do not try to repair controls. Replace defective controls  
with UPG Source 1 Parts.  
9 FLASHES: Indicates reversed line voltage polarity. Both heating and  
cooling operations will be affected. Check polarity at furnace and  
branch.  
Never adjust pressure switch to allow furnace operation.  
CONTINUOUS 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.  
11 FLASHES: This fault will be indicated if the rollout jumper wire con-  
nection soldered into the board is broken. If this fault occurs the control  
will have to be replaced. This fault may also occur in installations where  
an improper ground is present. Prior to replacing control, verify that unit  
is properly grounded.  
2 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 indi-  
cate a faulty pressure switch or miswiring.  
STEADY ON: This fault occurs if the gas valve is energized when there  
is no call for heat. If this happens the vent motor is energized and will  
remain energized for 5 seconds or until the fault clears itself at which  
point the vent motor de-energizes. This failure is counted as a recycle.  
Check the gas valve and control for proper operation.  
3 FLASHES: This indicates the normally open pressure switch contact  
did not close at the beginning of the heat cycle. This could be caused  
by a number of problems faulty inducer, blocked vent pipe, broken pres-  
sure switch hose or faulty pressure switch.  
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 1,6,7,8 and Steady On will be reset.  
This provides protection to an unoccupied structure if a temporary con-  
dition exists causing a furnace malfunction. An example would be a low  
incoming gas supply pressure preventing unit operation. When the gas  
pressure is restored, at some point the “watchdog” would restart the  
unit and provide heat for the house.  
4 FLASHES: This indicates that a primary or auxiliary limit switch has  
opened its normally closed contacts. With this fault code the control will  
operate the supply air blower and inducer. This condition may be  
caused by: dirty filter, improperly sized duct system, incorrect blower  
speed setting, incorrect firing rate or faulty blower motor.  
5 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.  
NOTE: If a flame is detected the control flashes the LED for 1/8 of a  
second and then enters a flame stabilization period.  
IGNITION CONTROL (P/N 031-01972-001)  
Normal flame sense current is approximately  
3.7 microamps DC (µa)  
Low flame signal control lockout point is  
0.9 microamps DC (µa)  
6 FLASHES: This indicates that after the unit was operating, the pres-  
sure 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 vent motor continues to operate until the pressure switch  
re-closes or a call for heat is removed.  
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 8: Furnace Control Event Schedule  
Unitary Products Group  
7
 
035-19592-001 Rev. C (0204)  
SECTION III: REPLACEMENT PARTS LIST  
47  
34  
63  
13  
31  
48  
23  
45  
5
29  
33  
24  
9
6
20  
14  
8
28  
43  
4
32  
58  
62  
59  
27  
10  
2
17  
18  
11  
37  
36  
21  
C
G
R
W
Y
56  
60  
12  
38  
26  
44  
M
U H  
1
C A  
E
R
M F  
X
E
N
I
L
R
I
C
16  
M U H  
22  
C A  
E
R
M F  
X
E
N
I
L
K R A  
P
K R A  
P
49  
50  
51  
T
A
E
H
L
O O C  
7
15  
3
52  
25  
30  
9
19  
13  
40, 42  
53  
9
35  
24  
29  
6
46  
27  
8, 61  
8
Unitary Products Group  
 
035-19592-001 Rev. C (0204)  
ITEM  
31  
DESCRIPTION  
COVER, HEAT EXCHANGER  
PANEL, FRONT (Blower)  
PANEL, FRONT (Burner)  
PANEL, TOP  
ITEM  
DESCRIPTION  
MOTOR  
32  
1
2
MOTOR,DIRECT DRIVE BLOWER  
MOTOR,VENTOR ASS’Y  
33  
34  
ELECTRICAL  
35  
SUPPORT, BURNER  
CAPACITOR (7.5MFD/370V)  
CAPACITOR (10 MFD/370V)  
CAPACITOR, VENTOR  
3
36  
WRAPPER, CABINET  
37  
PANEL, VESTIBULE (Lower)  
PLUG, WINDOW, CLEAR - .875”  
4
5
(4MFD/370V)  
38  
CONTROL, HIGH LIMIT  
CONTROL,FLAME ROLL OUT  
CONTROL,FURNACE  
FUSE  
MISCELLANEOUS  
6
39*  
40  
CLIP, FILTER RETAINER(2Req’d)P3U,G9T  
7
COLLAR, AIR INTAKE (Burner Box)  
FILTER, AIR  
7A  
8
41  
IGNITER  
FILTER SIZE - Refer to Table 1  
GASKET, AIR INTAKE  
9
SENSOR, FLAME  
SWITCH, AIR PRESSURE [LP]  
SWITCH, DOOR  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
10  
11  
12  
13  
GASKET, COMBUSTION BLOWER  
GASKET, CONDENSATE PAN  
GASKET, BURN BOX TO VEST PANEL  
GROMMET, MANIFOLD SEAL  
PLUG, WINDOW,CLEAR - 1.5”  
HANDLE, DOOR  
TRANSFORMER  
VALVE, GAS  
AIR MOVING  
14  
15  
16  
CUTOFF,BLOWER  
HOUSING, BLOWER  
WHEEL, BLOWER  
ISOLATOR, TUBE (3 Req’d.)  
ISOLATOR, WASHER (3 Req’d.)  
ISOLATOR,SLEEVE (3 Req’d.)  
MOUNT, MOTOR  
FABRICATED PARTS  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
BAFFLE, AIR (LH Recoup.Coil)  
BAFFLE, AIR (RH Recoup.Coil)  
BURNER, MAIN GAS  
ORIFICE, BURNER (Natural #45)  
COIL, SECONDARY HEAT EXCHANGER  
DECK, BLOWER (Rear)  
DECK, FRONT  
55* RETAINER, FILTER  
56 TRAP, CONDENSATE  
57* WIRING DIAGRAM  
HEAT EXCHANGER ASS’Y (Primary)  
MANIFOLD, GAS  
58  
59  
60  
61  
62  
63  
TUBE, DRAIN RAIN GUTTER  
TUBE, CONDENSATE DRAIN  
TUBE, DRAIN CONDENSATE TRAP  
BRACKET, IGNITOR  
PAN, BASE  
PAN, CONDENSATE  
PANEL, BURNER BOX (Bottom)  
PANEL, BURNER BOX (Front)  
WRAPPER, BURNER BOX  
CHANNEL, TOE PLATE  
TUBE, DRAIN CONDENSATE PAN  
PIPE EXHAUST VENT  
NOTE: *Not Shown  
New replacement parts shown in bold face type at the first printing of parts list dated 11/02.  
Major components and suggested stocking items are shown with shaded item number.  
Unitary Products Group  
9
 
035-19592-001 Rev. C (0204)  
FIELD INSTALLED ACCESSORIES -  
NON-ELECTRICAL  
FIELD INSTALLED ACCESSORIES -  
ELECTRICAL  
MODEL NO.  
DESCRIPTION USED WITH  
MODEL NO.  
DESCRIPTION USED WITH  
PROPANE (LP) CONVERSION  
KIT ALL MODELS EXCEPT 140 MBH  
THERMOSTAT- One-stage heat/cool.  
Manual changeover, integral sub-base.  
System Switch: Cool-Off-Heat.  
Fan Switch: Auto-On.  
1NP0347  
2TH07700124-  
1NP0349  
1CT0302  
1CT0303  
PROPANE (LP) 140 MBH  
CONCENTRIC INTAKE/VENT 2”  
CONCENTRIC INTAKE/VENT 3”  
ALL P3U MODELS  
THERMOSTAT- One-stage heat.  
Deluxe 24V with heat only sub-base  
does not include fan switch.  
NOTE: For one-stage cool or  
one-stage heat/cool, must be used  
with sub-base 2TB17700424.  
HIGH ALTITUDE PRESSURE SWITCH KIT  
(Does Not Include Orifices)  
1PS0306  
1PS0307  
1PS0308  
1PS0309  
1PS0310  
1BR0314  
2TH13700424  
2TB17700424  
HIGH ALTITUDE PRESSURE SWITCH KIT  
(Does Not Include Orifices)  
HIGH ALTITUDE PRESSURE SWITCH KIT  
(Does Not Include Orifices)  
SUBBASE (24V) - One-stage heat/cool. Man-  
ual changeover, integral sub-base.  
System Switch: Cool-Off-Heat.  
Fan Switch: Auto-On.  
HIGH ALTITUDE PRESSURE SWITCH KIT  
(Does Not Include Orifices)  
THERMOSTAT- One-stage heat/cool.  
Programmable changeover, with sub-base.  
System Switch: Cool-Off-Heat.  
HIGH ALTITUDE PRESSURE SWITCH KIT  
(Does Not Include Orifices)  
2ET07700224  
6TH13701024  
EXTERNAL BOTTOM FILTER  
RACK 14-1/2” CABINETS  
Fan Switch: Auto-On.  
THERMOSTAT- Heating, One-stage heat, No  
Fan Switch.  
1BR0317  
1BR0321  
1BR0324  
17-1/2” CABINETS  
21” CABINETS  
ALL G9T, FG9 MODELS  
THERMOSTAT- Heating/Cooling,  
One-stage heat/cool.  
24-1/2” CABINETS  
6TH07700124  
2CT03700124  
CONDENSATE NEUTRALIZER  
KIT ALL MODELS  
Manual changeover.  
1NK0301  
TWINNING CONTROL ALL MODELS  
REPLACEMENT PART CONTACT INFORMATION  
This is a generic parts list. To request a complete parts list, refer to the contact information below:  
1. Search for a part or browse the catalog.  
2. Find a dealer or distributor.  
3. Customer Service contact information.  
a. Click on the “Brand Links” button  
b. Click on the “Customer Service” button  
You can contact us by mail. Just send a written request to:  
York International  
Consumer Relations  
5005 York Drive  
Norman, OK 73069  
10  
Unitary Products Group  
 
035-19592-001 Rev. C (0204)  
SECTION IV: WIRING DIAGRAM  
FIGURE 9: Wiring Diagram  
Unitary Products Group  
11  
 
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 the reverse side of this warranty. This warranty covers only the equipment  
described by the Product Model Number and Serial Number listed on the Warranty Registration Card.  
UPG warrants the primary heat exchangers in the product to be free from defects in factory workmanship and material under normal use and service and will at  
its option, repair or furnish a replacement heat exchanger, either new or reconditioned, that meets the intended fit, use and function of the original heat  
exchanger for any heat exchanger furnished by UPG which proves to have such defects within the duration of warranty coverage. Alternatively, UPG may, at its  
option, extend a replacement allowance to be applied toward the purchase of a new furnace or packaged unit marketed by UPG. The exact amount of the  
allowance will be determined at the discretion of UPG, based upon current market conditions, but in no case shall this allowance exceed thirty (30) percent of  
the original consumer purchase price of the furnace, excluding such items as ductwork, wiring, piping and installation costs. UPG shall have no responsibility  
hereunder for installation, shipping, handling or other charges except as specifically provided herein.  
For your benefit and protection, return the Warranty Registration Card to UPG promptly after installation. This will initiate the warranty period and allow us to  
contact you, should it become necessary. In the absence of a recorded Warranty Registration Card, the warranty period will begin upon product shipment from  
UPG.  
This warranty extends only to the original consumer purchaser and is non-transferable. For this warranty to apply, the product must be installed according to  
UPG recommendations and specifications, and in accordance with all local, state, and national codes; and the product must not be removed from its place of  
original installation. The warranty period for repair or replacement parts provided hereunder shall not extend beyond the warranty period stated on the reverse  
side of this warranty.  
HEAT EXCHANGER  
FURNACE TYPE  
Residential Applications  
Original Owner Subsequent Owner  
PARTS  
Non-Residential  
Applications  
Lifetime  
15  
20  
10  
10  
5
1
P*UR / G9T-UP  
FG9-UP  
90%  
N/A  
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.  
035-19592-001 Rev. C (0204)  
Copyright © by York International Corp. 2004. All rights reserved.  
Supersedes: 035-19592-001 Rev. B (1203)  
Unitary  
Products  
Group  
5005  
York  
Drive  
Norman  
OK  
73069  
 

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