SERVICE TIPS Unitary Products Group 5005 York Drive Norman, OK 73069 877-874-7378

DATE: September 2, 2009 ST-045-09 TO: All York Branches and Distributors All York Service Managers All Field Service Supervisors SUBJECT: UTEC Integrated Furnace Control (IFC) Boards on All Single and Two Stage Gas Furnaces In August 2009 (W0H9 furnace serial number prefix) we phased in the new UTEC control board on all single and two stage residential furnaces. These boards are basically a drop in replacement for current production models. The new boards may be larger than some previous boards which may require drilling mounting holes to apply in older products. Instructions with a drilling template will be provided with each repair part board. Single stage PSC motor boards are 4 ½” X 5 ⅞”, Single stage X13 motor boards are 4 ⅞” X 7”, Two stage PSC motor boards are 5” X 8” and Two stage ECM motor boards are 5 ¼” X 8”. Please Note: Single Stage Heat with PSC Motor Board Will Not Have ‘CONT FAN SPEED’ Selection and will are designed for Single Stage Cooling only, no Y2. For CONT FAN SPEED and Two Stage Cooling Use Existing W/R Emerson board P/N S1-3310916700 - - While Limited Supplies Last - -. Installation of a switching relay, such as S1-S90-370, will otherwise be required for two stages of cooling, refer to Figure 1. Single stage Heat and Cool with PSC motor board SAP# (on the board) 539617 Source 1# S1-33102956000, refer to Figure 2. Board is capable of “Twining”. Single stage Heat and Cool with X13 ECM motor board SAP# 542760 Source 1# S1-03102951001, refer to Figure 3. Note: Blower speed is #1 = Hi and #5 = Lo. You can not twin ECM motors. Two stage Heat and Cool with PSC motor board SAP# 542767 Source 1# S1-33102954000, refer to Figure 4. Two Stage board is capable of “Twining”. Two stage Heat and Cool with Variable Speed ECM motor board SAP# 542766 Source 1# S1-33102955000, refer to Figure 5. You can not twin ECM motors. General Replacement Information: Refer to the electrical wire diagram of the furnace being serviced for circuit connections specific to that model. The Service Tip Letter on “Basic Electrical Checks” (ST-065-08) is great for general troubleshooting. Save time and money by referring to Service Tip Letter on “Twinning Furnaces” (ST-031-08) for valuable information and troubleshooting. Please copy and distribute the “Fault Code Sheets” at the back of this service letter.

Fig 1: Switching Relay Drawing For Two Stage Cooling With Single Stage Cooling Board

Fig 2: Single Stage Heat/Cool PSC Motor Board SAP# 539617 Order S1-33102956000 Note: Can Be Twinned; Twinning Terminal near The Low Voltage Terminal Block

Fig 3: Single Stage Heat/Cool X13 ECM Motor Board SAP# 542760 Order S1-03102951001 Note: Blower output terminals are marked “24 VAC Motor” for the X13; Do Not Twin

Fig 4: Two Stage Heat/Cool PSC Motor Board SAP# 542767 Order S1-33102954000 Note: Can Be Twinned; Twinning Terminal in Top Left Corner

Fig 5: Two Stage Heat/Cool Variable Speed ECM Motor Board SAP# 542766 Order S1-33102955000 Note: Can Not Be Twinned When replacing a Two Stage Board with separate CFM board to the new Single combination board shown in Fig 5 a new 16 wire, 16 pin to 16 pin motor connector cable will be required; S1-02541130000. Set CFM Selectors (ADJ, COOL, DELAY and HEAT) on the new board the same as the replaced CFM Board. Modulating furnaces are not affected by this change. Ron Butcher Robert Cabrera

Ron Butcher Robert Cabrera Field Service Supervisor Director of Heating Engineering

16 Pin ECM Cable

New UTEC IFC Boards

Fault Code LED Flashes -

Single Stage PSC & X13 ECM Motors

Two Stage PSC Motor

Two Stage Variable Speed

ECM Motor

Some Difference From Last Boards

539617 / S1-33102956000

542760/ S1-03102951001

542767 / S1-33102954000

542766 / S1-33102955000

Steady Off No Power To Board, Control Failure

Green Heart Beat Normal Operation, No Call For Heat, No Active Errors

Amber Heat Beat Normal- Call For Heat Normal Operation With Call For Heat / First Stage On 2 Stage

2 Amber Flash N/A Normal Operation With Call For Second Stage Heat

3 Amber Flash N/A W2 Present With No W1

4 Amber Flash Y Present With No G Call Rapid Amber

Flash Low Flame Sense Current

Solid LED, Of Any Color Control Fault Detected

Rapid Flash Red Incorrect 24 vac Phasing/Twinning Error Do Not Twin X-13 ECM Motors

Do Not Twin ECM Motors

1 Flash Red * Flame Sensed With Gas Valve Off

2 Flash Red * Pressure Switch Stuck Closed

3 Flash Red * Pressure Switch Open 1st-Stage Pressure Switch Open

3 Double Red * N/A 2nd-stage Pressure Switch Stuck Open

4 Flash Red * Open High Limit Switch

5 Flash Red * ## Open Rollout

6 Flash Red * # Pressure Switch Cycle Lockout

7 Flash Red * # One Hour Lockout (Retries)

8 Flash Red * # Lockout (Recycles), Flame Dropouts

9 Flash Red Grounding Or Reversed Polarity, Transformer Leads Reversed

10 Flash Red * Gas Valve Energized With No Call For Heat

11 Flash Red * ## Limit Switch Open More Than 5 Minutes – Blower Failure

12 Flash Red Open HIS

* = Stored In Error Code Array; # = One Hour Soft Lockout; ## = Hard Lockout

Fault Code Retrieval: To retrieve fault codes, push and release the “LAST ERROR” button for more than 1/5 second and less than 5 seconds. The LED will flash up to five stored fault codes, beginning with the most recent. If there are no fault codes in memory, the LED will flash two green flashes. The control will flash the most recent error first and the oldest error last (last in first out). There shall be 2 seconds between codes. Solid LED error codes will not be displayed.

Fault Code Reset: To clear the fault code memory, push and hold the “LAST ERROR” button for at least five seconds. The LED will flash three green flashes when the memory has been cleared.

Last Generation W/R Emerson IFC Boards

Single Stage Two Stage PSC Motor

Two Stage ECM Motor Variable Speed

Fault Code/Flashes

265901 & S1-33109167000/265902 S1-33109168000/265903 S1-33109169000/265904

Steady Off No Power To Board, Fault Codes Possible With Blown On-Board Fuse Green Heart Beat Normal Operation No Call For Heat

1 Amber Flash Normal Operation With Call For Heat, First Stage On 2 Stage 2 Amber Flash N/A Normal Operation With Call For Second Stage Heat 3 Amber Flash N/A W2 Present With No W1 4 Amber Flash Y Present With No G Call Rapid Amber

Flash Low Flame Sense Current Solid LED Red Solid Internal GV Error, Micro, And Frequency Check

Rapid Flash Red Rapid Twinning Error, Incorrect 24v Phasing 1 Flash Red * Flame Sensed When No Flame Should Be Present 2 Flash Red * Pressure Switch Stuck Closed/ Inducer Error 3 Flash Red * 1st-Stage Pressure Switch Stuck Open/ Inducer Error

3 Double Red * N/A 2nd-stage Pressure Switch Stuck Open/ Inducer Error 4 Flash Red * Open Limit Switch

5 Flash Red * ## Open Rollout/Open Fuse Detect 6 Flash Red * # Pressure Switch Cycle Lockout 7 Flash Red * # External Lockout (Retries) 8 Flash Red * # External Lockout (Recycles)

9 Flash Red Grounding Or Reversed Polarity, Transformer Leads Reversed 10 Flash Red * Gas Flow With No Call For Heat

11 Flash Red * ## Limit Switch Open More Than 5 Minutes – Blower Failure 12 Flash Red Ignitor Failure

* = Stored In Error Code Array; # = One Hour Soft Lockout; ## = Hard Lockout

Fault Code Retrieval: To retrieve fault codes, push and release the “LAST ERROR” button for more than 1/5 second and less than 5 seconds. The LED will flash up to five stored fault codes, beginning with the most recent. If there are no fault codes in memory, the LED will flash two green flashes. The control will flash the most recent error first and the oldest error last (last in first out). There shall be 2 seconds between codes. Solid LED error codes will not be displayed. Fault Code Reset: To clear the fault code memory, push and hold the “LAST ERROR” button for at least five seconds. The LED will flash three green flashes when the memory has been cleared.