USER’S INFORMATION, EFFICIENCY

MAINTENANCE AND
RATING
CERTIFIED

SERVICE MANUAL This product was manufactured

in a plant whose quality system
is certified/registered as being

MODELS: P*UR / G9T-UP / FG9-UP (Upflow)

in conformity with ISO 9001.

TABLE OF CONTENTS
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTRUCTIONS FOR EXAMINING THE FURNACE Intermittent Blower - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . . 3 Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . 3 FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Read the Instructions Below Before Trying to Start the Furnace . . 3 Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cleaning the Secondary Heat Exchanger . . . . . . . . . . . . . . . . . . .6
FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . . 4 FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .7
SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . . 4 FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL . . . . . .10
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FIELD INSTALLED ACCESSORIES - ELECTRICAL . . . . . . . . . . .10
Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . .10
Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

CONTACT INFORMATION
• Go to website at [Link] 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 safety
be examined when installed in an attic or other insulated space or
warnings exactly could result in serious injury, death, or prop-
when insulation is added to be sure that the insulation material has
erty 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 other and safely. Do not block or obstruct air openings on the furnace,
appliance. air openings to the area where the furnace is installed, or spaces
— WHAT TO DO IF YOU SMELL GAS: around the furnace.

• Do not try to light any appliance. 4. Follow the instructions exactly as shown on the OPERATING
INSTRUCTION LABEL or the Start-up and Shutdown Instructions
• Do not touch any electrical switch; do not use any phone on Page 3 of this manual when lighting the furnace or turning the
(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
• Immediately call your gas supplier from a neighbor’s off the gas valve to the furnace before shutting off the electrical
phone. Follow the gas supplier’s instructions. supply.
• If you cannot reach your gas supplier, call the fire depart- 6. Do not use this furnace if any part has been under water. A flood-
ment. damaged furnace is extremely dangerous. Attempts to use the fur-
— Installation and service must be performed by a quali- nace can result in fire or explosion. A qualified service agency
fied installer, service agency or the gas supplier. 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.

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035-19592-001 Rev. C (0204)

INSTRUCTIONS FOR EXAMINING THE FURNACE

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

FIRE OR EXPLOSION HAZARD

This furnace is designed and approved for use with Nat-
ural Gas and (LP) Propane Gas ONLY. DO NOT BURN INNER FLAME
ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE. MAIN CONES
MANIFOLD BURNER
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.

EXAMINE HEAT EXCHANGER

INTERNAL VENT COMBUSTION
2 EXAMINE EXTERNAL
AIR PIPE. MUST REMOVE PANEL
TO EXAMINE. VENT PIPE
5
EXAMINE ENTIRE
FURNACE CASING
SHOWN IN ALL
DRAWINGS
4
4 EXAMINE
EXAMINE
FURNACE
FURNACE 6
REMOVE PANEL CASING
CASING
TO EXAMINE
BURNER FLAMES

3 3
EXAMINE EXAMINE
RETURN-AIR RETURN-AIR
DUCT CONNECTION DUCT CONNECTION
(SIDE OR BOTTOM)

FIGURE 3: Furnace Examination Checkpoints

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HOW YOUR GAS FURNACE WORKS 10. Set thermostat to the desired setting. Burner will light, which may
take 30-60 seconds.
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. 11. After three (3) trials for ignition, if the appliance will not operate fol-
For this reason, you may never have given much thought to the way low the instructions, “TO TURN OFF THE APPLIANCE” and call
your furnace operates. In order to get the safest and most efficient oper- your service technician or gas supplier.
ation from your furnace, you should understand how your furnace does To Turn Off the Appliance:
its job.
1. Set the thermostat to lowest setting.
When you set your thermostat to provide more heat in your home, you 2. Turn off all electric power to the appliance if service is to be per-
are starting the heating cycle of the furnace. First, the inducer motor formed.
starts to purge the heat exchanger of any remaining gases. Next, the 3. Remove burner access panel.
hot surface ignitor glows and after a warm-up period the gas valve
4. Move gas control switch to the “OFF” position.
opens and ignition occurs. A short time later, the blower starts and dis-
tributes the warm air throughout the home. When the temperature set- 5. Replace burner access panel.
ting on your thermostat is reached, the gas valve closes, the main
burners are turned off, and the blower continues to run until the remain-
ing warm air in the system is distributed. When the blower stops, the
heating cycle has ended. Should overheating occur, or the gas valve fail to shut off,
turn the external manual gas valve in the gas supply line to
START-UP AND SHUTDOWN INSTRUCTIONS the furnace to the “off” position and let the furnace cool off
Read the Instructions Below Before Trying to Start the before shutting off the electrical power supply. Refer to
Furnace Figure 5.

OUTLET
PRESSURE PORT
If you do not follow these instructions exactly, a fire or INLET OUTLET
explosion may result causing property damage, personal
injury, and/or loss of life.
WRENCH
A. This appliance does not have a pilot. It is equipped with an ignition BOSS
device which automatically lights the burner. Do not try to light the INLET MAIN
burner by hand. PRESSURE ON/OFF REGULATOR
PORT ADJUSTMENT
B. BEFORE OPERATING; smell all around the appliance area for SWITCH
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
try to repair it, call a qualified service technician. Force or SHUTOFF VALVE
attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Imme-
TO GAS TO GAS
diately call a qualified service technician to inspect the appliance SUPPLY SUPPLY
and to replace any part of the control system and any gas control,
which has been under water.
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.
GROUND JOINT UNION
4. Remove burner access panel. DROP
MAY BE INSTALLED
5. Move gas control switch to the “OFF” position. Do not force. LEG INSIDE OR OUTSIDE UNIT.

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 FIGURE 5: Gas Piping
smell gas, go to next step. NOTE: The spring-loaded safety cut-off switch, mounted under the
7. Move gas control switch to the “ON” position. Do not force. blower deck will automatically cut off the electrical power supply
8. Replace burner access panel. to the furnace when the blower panel is removed. As a safety
9. Turn on all electric power to the appliance. precaution, all electrical power and the gas supply to the furnace
should be turned off before servicing.

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FURNACE USER MAINTENANCE 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.
Before proceeding, be sure the area is well ventilated. Turn
the thermostat OFF. If the blower is running, wait until it 3. The furnace burners, ignitor and flame sensor.
stops automatically. Turn OFF the gas and electrical power 4. The condensate collection and disposal system. If any disassem-
supplies to the furnace. Check all metal parts and surfaces bly of components containing flue or vent gases is required, a
to be sure they have cooled to room temperature before qualified service agency must perform the service.
you begin.
Air Filters
Every time the filters are changed the following items should be visually The filters should be checked every 3 months. On new construction,
inspected: check the filters every week for the first four weeks and every three
• Check combustion air and vent pipe for blockage or leakage. 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
• Check all components to be sure they are in good condition and
right size filter for your furnace. Dirty filters greatly restrict the flow of air
that there are no obvious signs of deterioration.
and may cause damage to the moving parts of the furnace. If the filters
• Check the drain lines to make sure there are no cracks or leaks. become clogged the heat exchangers and blower motor could overheat
• Check for dirt or lint on any surfaces or on components. Do not try resulting in a potentially dangerous situation.
to clean any of the surfaces or components. Cleaning of the fur-
Never operate your furnace without a suitable air filter.
nace and its components must be done by a qualified service pro-
fessional. Removing Filters
If, during the inspection of your furnace, you find any of the following Internally Mounted Air Filters
conditions: Most upflow furnaces have their filters located on the side or bottom of
• Excessive amounts of dust and lint on components. the furnace in a filter wire retainer located inside the blower compart-
• Damaged or deteriorated components or surfaces. ment. To check filters located in the blower compartment:
• Leaks or blockage in the vent pipe passages. 1. Remove the upper furnace door by lifting up. Pull out bottom of
• Water on any surface inside or outside of the furnace. door and lower from furnace.
2. Remove the blower compartment panel by lifting up.
Do not operate the furnace, call a certified dealer / servicing contractor
3. The filters will be located on the bottom or the one of the sides. To
to check and / or clean your furnace, or for more information if you have
remove bottom-mounted or side mounted filter (s) on all furnaces,
questions about the operation of your furnace.
push the looped end of the filter retainer rod in, and then move
If all components appear to be in good operating condition, replace the away from the filter.
front panels. Turn ON the gas and electrical power supplies to the fur- 4. Reverse the procedure to reinstall filters.
nace, and set thermostat to the desired temperature.
POSITION WIRE RETAINER
SECTION II: SERVICE AND MAINTENANCE (IF PROVIDED) UNDER FLANGE

MANUAL
SAFETY SECTION
The following safety rules must be followed when servicing the IF FILTER
PROVIDED
furnace. CLIPS

RIGHT SIDE
FURNACE
ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD INSTALLATION FRONT
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, Externally Mounted Air Filters
serious injury, and death or property damage.
Some installations may have the air filter in a rack attached to the cas-
• Before servicing, disconnect all electrical power to the fur- ing of the furnace or placed in the return air duct. You can gain access
nace. to the filter by pulling on the door or unscrewing the retaining screw,
• When servicing controls, label all wires prior to discon- then slide the filter(s) out of its channel. Replace throw away filter(s)
necting. Reconnect wires correctly. with the same size new filter(s). Throw away filter(s) may be replaced
• Verify proper operation after servicing. with cleanable filter(s) at this time. Cleanable filter(s) may be cleaned as
described in the manufacturer instructions or as described below and
FURNACE MAINTENANCE SECTION then re-installed.
The furnace should be cleaned and adjusted by a certified dealer or To replace the filter after cleaning you must do the following:
qualified service contractor once a year or before the start of every 1. Slide filter into place.
heating season. The following items must be cleaned and serviced or
2. Snap the door on or place the door in position and tighten the
replaced if there are signs of deterioration.
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.

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TABLE 1: Filter Sizes

Input / Output Cabinet

CFM (cm/m) Side (in) Side (mm) Bottom (in) Bottom (mm)
BTU/H (kW) Size
40/37 (11.71/10.84) 1000 (28.32) 14-1/2” (A) 16 x 25 406 x 635 14 x 25 356 x 635
60/55/ (17.57/16.10) 1000 (28.32) 17-1/2” (B) 16 x 25 406 x 635 16 x 25 406 x 635
80/75/ (23.42/21.96) 1200 (33.98) 17-1/2” (B) 16 x 25 406 x 635 16 x 25 406 x 635
80/75/ (23.42/21.96) 1600 (45.31) 21” (C) 16 x 25 406 x 635 20 x 25 508 x 635
100/95 (29.28/27.82) 1400 (39.64) 21” (C) 16 x 25 406 x 635 20 x 25 508 x 635
100/95 (29.28/27.82) 2000 (56.63) 21” (C) (2) 16 x 25 (2) 406 x 635 20 x 25 508 x 635
120/112/ (35.14/32.80) 2000 (56.63) 24-1/2” (D) (2) 16 x 25 (2) 406 x 635 22 x 25 559 x 635
140/130/ (40.99/38.06) 2000 (56.63) 24-1/2” (D) (2) 16 x 25 (2) 406 x 635 22 x 25 559 x 635
How to Clean your Filter Intermittent Blower - Cooling
High-velocity filters may be cleaned with a vacuum cleaner or washed Cooling/heating thermostats have a fan switch that has an ON and
with a garden hose. Be sure to shake off excess water and allow filter to AUTO position. In the AUTO position the thermostat circuit is completed
completely dry before re-installing the filter. between terminals R and G when there is a call for cooling. The motor
Blower Care 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
Even with good filters properly in place, blower wheels and motors will SEER enhancement.
become dust laden after long months of operation. The entire blower
assembly should be inspected annually. If the motor and wheel are Heating Cycle
heavily coated with dust, they can be brushed and cleaned with a vac- When the thermostat switch is set on HEAT and the fan is set on AUTO,
uum cleaner. If the blower cannot be properly cleaned without removing and there is a call for heat, a circuit is completed between terminals R
it from the furnace, then this service must be performed by a qualified and W of the thermostat. When the proper amount of combustion air is
service agency. 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
Make sure you DO NOT move the clip on weight on the opens, if a flame is detected. Normal furnace operation will continue
indoor fan wheel when cleaning the wheel. This weight is until the thermostat circuit between R and W is opened, which causes
used to balance the wheel. Moving the weight will cause the ignition system and gas valve to de-energize and the burner flames
the fan wheel to vibrate. 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
Motor Lubrication jumper located on the control board. See Figure 7. The heating cycle is
complete, and ready for the start of the next heating cycle.
The motors in these furnaces are permanently lubricated, and do not
require periodic oiling.
RED-LOW SPEED
SEQUENCE OF OPERATION BLU-MEDIUM SPEED MOTOR LEADS
BLK-HIGH SPEED
The following describes the sequence of operation of the furnace. Refer
to Figure 1 for component location.
Continuous Blower BLK
COOL
BLU
Cooling/heating thermostats have a fan switch that has an ON and HEAT
RED
AUTO position. In the ON position the thermostat circuit is completed PARK
between terminals R and G. The motor will operate on the speed tap PARK
LINE
wire that is connected to the cooling terminal on the control board. To
60 XM
obtain a constant air circulation at lower flow rate, change the high-
120

90

speed wire to either the medium speed wire or the low speed wire.
180
FAN OFF
ADJUSTMENT
SWITCHES

FIGURE 7: Typical Heat/Cool Speed Tap Connections

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If the flame is not detected within 2 seconds of the gas valve opening, 6. Remove burners from the burner assembly.
the gas valve is shut off and a retry operation begins. If the flame is lost 7. Remove the upper cover plate at the top of the furnace. Remove
for 2 seconds during the 10-second stabilization period, the gas valve is the internal baffle.
shut off and a retry operation begins. During a retry operation, the vent
8. The upper portion of the heat exchanger is now exposed.
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 9. With a long flexible wire brush, clean inside each tube at both the
seconds after ignition during a retry, the control will clear the ignition top and bottom. The brush must pass around the rear heat
attempt (retry) counter. If three retries occur during a call for heat, the exchanger tubes and then vacuum loose the scale and dirt from
furnace will shut down for one hour. If at the end of the one hour shut each tube.
down there is a call for heat, the furnace will initiate a normal start cycle. 10. Clean - vacuum all burners.
If the problem has not been corrected the furnace will again lockout
11. Replace all components in reverse order. Reconnect all wiring.
after three retries.
12. Restore electrical power and gas supply to the furnace.
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 13. Check furnace operation.
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-
Label all wires prior to disconnection when servicing
out for 60 minutes.
controls. Wiring errors can cause improper and danger-
During burner operation, a momentary loss of power for 50 milliseconds ous operation. Verify proper operation after servicing.
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 Cleaning the Secondary Heat Exchanger
immediately restart.
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
HOT SURFACE IGNITION SYSTEM the secondary heat exchanger.
Do not attempt to light this furnace by hand (with a 3. Using a stiff wire brush, remove the loose scale or soot from each
match or any other means). There may be a potential tube.
shock hazard from the components of the hot surface 4. Vacuum the secondary heat exchanger.
ignition system. The furnace can only be lit automatically
by its hot surface ignition system. 5. Finish the cleaning procedure by following steps 11 thru 13 under
cleaning the Heat Exchanger.
FURNACE CLEANING SECTION
TROUBLESHOOTING
NOTE: The cleaning operations listed below must be performed only by
a qualified service agency. The following visual checks should be made before troubleshooting:
1. Check to see that the power to the furnace and the ignition control
Burner Removal/Cleaning
module is ON.
The main burners should be checked periodically for dirt accumulation.
2. The manual shut-off valves in the gas line to the furnace must be
If cleaning is required, follow this procedure:
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
4. Review the sequence of operation. Start the system by setting the
loosen the ground union joint.
thermostat above the room temperature. Observe the system’s
3. Remove the upper access panel and remove the burner box cover. response. Then use the troubleshooting section in this manual to
4. Disconnect wires from flame sensor, rollout switch and HSI igniter. check the system’s operation.
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
6. Remove burners from the burner assembly.
clear view port in the blower compartment door. DO NOT remove the
7. Burners may be cleaned by rinsing in hot water. furnace blower compartment panel OR turn off furnace power, as either
8. Reassemble the burners in the reverse order. action will clear the control’s memory of the fault.
Cleaning the Heat Exchanger The control continuously monitors its own operation and the operation
1. Turn off the electrical power to the unit. 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
2. Turn off the gas supply at the external manual shut-off valve and this case, the entire control should be replaced, as the control is not
loosen the ground union joint. field repairable.
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
4. Disconnect wires from flame sensor, rollout switch and HSI igniter. one second and “off” for one second. This pattern will be repeated the
Remove igniter carefully, as it is easily broken. number of times equal to the code. For example, six “on” flashes equals
5. Remove the screws that hold the burner box assembly to the vest a number 6 fault code. All flash code sequences are broken by a 2 sec-
panel and remove the assembly. ond “off” period.

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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,
Never bypass pressure switch to allow furnace opera- faulty hot surface ignitor or burner problem may cause this.
tion. To do so will allow furnace to operate under poten- 8 FLASHES: This fault is indicated if the flame is lost 5 times (4 recy-
tially hazardous conditions. cles) during the heating cycle. This could be caused by low gas pres-
Do not try to repair controls. Replace defective controls sure or faulty gas valve.
with UPG Source 1 Parts. 9 FLASHES: Indicates reversed line voltage polarity. Both heating and
Never adjust pressure switch to allow furnace operation. cooling operations will be affected. Check polarity at furnace and
branch.
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 11 FLASHES: This fault will be indicated if the rollout jumper wire con-
both the inducer motor and supply air blower. A gas valve that leaks nection soldered into the board is broken. If this fault occurs the control
through or is slow closing would typically cause this fault. 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
2 FLASHES: This indicates that the normally open pressure switch
is properly grounded.
contacts are stuck in the closed position. The control confirms these
contacts are open at the beginning of each heat cycle. This would indi- STEADY ON: This fault occurs if the gas valve is energized when there
cate a faulty pressure switch or miswiring. 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
3 FLASHES: This indicates the normally open pressure switch contact
point the vent motor de-energizes. This failure is counted as a recycle.
did not close at the beginning of the heat cycle. This could be caused
Check the gas valve and control for proper operation.
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
4 FLASHES: This indicates that a primary or auxiliary limit switch has
after 60 minutes. Operational faults 1,6,7,8 and Steady On will be reset.
opened its normally closed contacts. With this fault code the control will
This provides protection to an unoccupied structure if a temporary con-
operate the supply air blower and inducer. This condition may be
dition exists causing a furnace malfunction. An example would be a low
caused by: dirty filter, improperly sized duct system, incorrect blower
incoming gas supply pressure preventing unit operation. When the gas
speed setting, incorrect firing rate or faulty blower motor.
pressure is restored, at some point the “watchdog” would restart the
5 FLASHES: This fault is indicated if the normally closed contacts in the unit and provide heat for the house.
rollout switch opens. The rollout control is manually reset. If it has
NOTE: If a flame is detected the control flashes the LED for 1/8 of a
opened, check for proper combustion air, proper inducer operation, and
primary heat exchanger failure or burner problem. Be sure to reset the second and then enters a flame stabilization period.
switch after correcting the failure condition. IGNITION CONTROL (P/N 031-01972-001)
6 FLASHES: This indicates that after the unit was operating, the pres- Normal flame sense current is approximately
sure switch opened 4 times during the call for heat. If the main blower is 3.7 microamps DC (µa)
in a “Delay on” mode it will complete it, and any subsequent delay off Low flame signal control lockout point is
period. The vent motor continues to operate until the pressure switch 0.9 microamps DC (µa)
re-closes or a call for heat is removed.

Thermostat Calling for Heat Thermostat Satisfied

(Seconds) 0 2 17 22 52 0

Fan on Delay
30 Seconds

ON
THERMOSTAT
OFF OFF
ON
INDUCER
OFF 15 Sec. OFF
ON Post
Purge
IGNITOR OFF OFF OFF
ON
MAIN VALVE
OFF OFF
ON
HUMIDIFIER
OFF OFF OFF
ELECTRONIC ON
AIR CLEANER
OFF OFF OFF

CIRCULATING ON
BLOWER OFF OFF 60, 90, 120, 180 SEC. OFF
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

34 47
63
31 13
45 23
48
29 5
33 24
9 6
8 20
32 28
43 58
27 4 62 14
2 59 17
10
18
36 37 11
21
38 26
C G R W Y

56 1
HUM
EAC
XFMR

60
44
LINE

16
CIR

HUM

EAC
12 22
49
XFMR

LINE

PARK

PARK

HEAT

COOL

50
7 51
3 15
30 25 52

19 9

13

40, 42
53 9
35
O

24
FF
O
N

29

46
8, 61 27

8 Unitary Products Group

035-19592-001 Rev. C (0204)

ITEM DESCRIPTION ITEM DESCRIPTION

MOTOR 31 COVER, HEAT EXCHANGER
1 MOTOR,DIRECT DRIVE BLOWER 32 PANEL, FRONT (Blower)
2 MOTOR,VENTOR ASS’Y 33 PANEL, FRONT (Burner)
ELECTRICAL 34 PANEL, TOP
CAPACITOR (7.5MFD/370V) 35 SUPPORT, BURNER
3 36 WRAPPER, CABINET
CAPACITOR (10 MFD/370V)
4 CAPACITOR, VENTOR (4MFD/370V) 37 PANEL, VESTIBULE (Lower)
5 CONTROL, HIGH LIMIT 38 PLUG, WINDOW, CLEAR - .875”
6 CONTROL,FLAME ROLL OUT MISCELLANEOUS
7 CONTROL,FURNACE 39* CLIP, FILTER RETAINER(2Req’d)P3U,G9T
7A FUSE 40 COLLAR, AIR INTAKE (Burner Box)
8 IGNITER 41 FILTER, AIR
9 SENSOR, FLAME FILTER SIZE - Refer to Table 1
10 SWITCH, AIR PRESSURE [LP] 42 GASKET, AIR INTAKE
11 SWITCH, DOOR 43 GASKET, COMBUSTION BLOWER
12 TRANSFORMER 44 GASKET, CONDENSATE PAN
13 VALVE, GAS 45 GASKET, BURN BOX TO VEST PANEL
AIR MOVING 46 GROMMET, MANIFOLD SEAL
14 CUTOFF,BLOWER 47 PLUG, WINDOW,CLEAR - 1.5”
15 HOUSING, BLOWER 48 HANDLE, DOOR
16 WHEEL, BLOWER 49 ISOLATOR, TUBE (3 Req’d.)
FABRICATED PARTS 50 ISOLATOR, WASHER (3 Req’d.)
17 BAFFLE, AIR (LH [Link]) 51 ISOLATOR,SLEEVE (3 Req’d.)
18 BAFFLE, AIR (RH [Link]) 52 MOUNT, MOTOR
19 BURNER, MAIN GAS 53 ORIFICE, BURNER (Natural #45)
20 COIL, SECONDARY HEAT EXCHANGER 54
21 DECK, BLOWER (Rear) 55* RETAINER, FILTER
22 DECK, FRONT 56 TRAP, CONDENSATE
23 HEAT EXCHANGER ASS’Y (Primary) 57* WIRING DIAGRAM
24 MANIFOLD, GAS 58 TUBE, DRAIN RAIN GUTTER
25 PAN, BASE 59 TUBE, CONDENSATE DRAIN
26 PAN, CONDENSATE 60 TUBE, DRAIN CONDENSATE TRAP
27 PANEL, BURNER BOX (Bottom) 61 BRACKET, IGNITOR
28 PANEL, BURNER BOX (Front) 62 TUBE, DRAIN CONDENSATE PAN
29 WRAPPER, BURNER BOX 63 PIPE EXHAUST VENT
30 CHANNEL, TOE PLATE

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 - FIELD INSTALLED ACCESSORIES -

NON-ELECTRICAL ELECTRICAL
MODEL NO. DESCRIPTION USED WITH MODEL NO. DESCRIPTION USED WITH
PROPANE (LP) CONVERSION THERMOSTAT- One-stage heat/cool.
1NP0347
KIT ALL MODELS EXCEPT 140 MBH Manual changeover, integral sub-base.
2TH07700124- System Switch: Cool-Off-Heat.
1NP0349 PROPANE (LP) 140 MBH
Fan Switch: Auto-On.
1CT0302 CONCENTRIC INTAKE/VENT 2” ALL P3U MODELS
1CT0303 CONCENTRIC INTAKE/VENT 3” THERMOSTAT- One-stage heat.
HIGH ALTITUDE PRESSURE SWITCH KIT Deluxe 24V with heat only sub-base
1PS0306 does not include fan switch.
(Does Not Include Orifices) 2TH13700424
NOTE: For one-stage cool or
HIGH ALTITUDE PRESSURE SWITCH KIT one-stage heat/cool, must be used
1PS0307
(Does Not Include Orifices) with sub-base 2TB17700424.
HIGH ALTITUDE PRESSURE SWITCH KIT SUBBASE (24V) - One-stage heat/cool. Man-
1PS0308
(Does Not Include Orifices) ual changeover, integral sub-base.
2TB17700424
HIGH ALTITUDE PRESSURE SWITCH KIT System Switch: Cool-Off-Heat.
1PS0309 Fan Switch: Auto-On.
(Does Not Include Orifices)
HIGH ALTITUDE PRESSURE SWITCH KIT THERMOSTAT- One-stage heat/cool.
1PS0310 Programmable changeover, with sub-base.
(Does Not Include Orifices) 2ET07700224
System Switch: Cool-Off-Heat.
EXTERNAL BOTTOM FILTER Fan Switch: Auto-On.
1BR0314
RACK 14-1/2” CABINETS
THERMOSTAT- Heating, One-stage heat, No
1BR0317 17-1/2” CABINETS 6TH13701024 Fan Switch.
1BR0321 21” CABINETS ALL G9T, FG9 MODELS
1BR0324 24-1/2” CABINETS THERMOSTAT- Heating/Cooling,
6TH07700124 One-stage heat/cool.
CONDENSATE NEUTRALIZER
1NK0301 Manual changeover.
KIT ALL MODELS
2CT03700124 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:
• Visit our website at [Link] 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

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 Non-Residential PARTS
Original Owner Subsequent Owner Applications
P*UR / G9T-UP Lifetime 20 10 5
90%
FG9-UP 15 N/A 10 1

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. 035-19592-001 Rev. C (0204)

Copyright © by York International Corp. 2004. All rights reserved. Supersedes: 035-19592-001 Rev. B (1203)
Unitary 5005 Norman
Products York OK
Group Drive 73069