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General

Service Bulletin
Integrated Furnace Control Diode Error
ADX-R, AUX-R, ADY-R, AUY-R, TDX-R, TUX-R,
TDY-R, TUY-R Two Stage 90+ Gas Furnaces
ORDER No: FURN-SVB14A-EN

DATE: August 17, 2004

Introduction
The purpose of this bulletin is to inform the field of an error in the production of the
Integrated Furnace Controls (IFCs) used in the furnace models in the table below.
The action described in this bulletin is not being taken to address a safety concern.
However, failure to perform the corrective action described in this bulletin may result in
No Heat complaints, frozen or burst water pipes, etc.. This is a mandatory rework.

NOTICE: Warnings and Cautions appear at appropriate sections


throughout this bulletin. Read these carefully.

WARNING: Indicates a potentially hazardous situation which,


if not avoided, could result in death or serious injury.

CAUTION: Indicates a potentially hazardous situation which,


if not avoided, may result in minor or moderate injury.
CAUTION: May also be used to alert reader to a situation that could
result in equipment or property-only damage.
WARNING
Service checks and diagnostic procedures described in this bulletin are
intended to be performed by trained, qualified personnel. Some checks may be
required to be performed with voltage present and the hazard of moving parts
also exists in these situations. Failure to follow warnings and cautions in this
bulletin may result in personal injury or death.

2004 American Standard Inc. All Rights Reserved

Trane

Trane

(CNT03778)

(CNT03777)

American
Standard

American
Standard

(CNT03778)

(CNT03777)

TDX060R936W3

TDY060R9V3W4

ADX060R936W3

ADY060R9V3W4

TDX080R942W3

TDY080R9V3W4

ADX080R942W3

ADY080R9V3W4

TDX100R948W3

TDY100R9V4W4

ADX100R948W3

ADY100R9V4W4

TDX120R960W3

TDY120R9V5W4

ADX120R960W3

ADY120R9V5W4

TUX060R936W3

TUY060R9V3W4

AUX060R936W3

AUY060R9V3W4

TUX080R942W3

TUY080R9V3W4

AUX080R942W3

AUY080R9V3W4

TUX100R948W3

TUY100R9V4W4

AUX100R948W3

AUY100R9V4W4

TUX120R960W3

TUY120R9V5W4

AUX120R960W3

AUY120R9V5W4

Discussion
The error is a wrong part on the IFC which causes a failure of the draft inducer power
supply circuitry. The IFC will fail to energize the draft inducer, resulting in a 3 flash
(Pressure Switch Circuit) error and No Heat. Some of the reports of failures have
been at unit start up. The R27 resistor at the top of the IFC may be burned open
visibly.
The error is limited to IFC date codes of 0424 through 0433 (White Rodgers date code
is 4 digits 04=2004, 24= fiscal week 24 the 2nd week of June). The date code is
found on a label on the lower, left corner near the 12 pin polarized plug (See Fig. 1)
These IFCs were used in furnaces produced between serial number date code
ranges of 424****** through 433******.

FIGURE 1

0424

Date Code Label

D342062P01

FURN-SVB14A-EN

Factory Corrective Action


The production of these furnaces was temporarily halted on Thursday August 12,
2004 as soon as we learned of the problem. Arrangements were made to return all
affected Integrated Furnace Controls to White Rodgers and get new inventory with
which to rework and build new furnaces. Inspection / rework of units in the Trenton, NJ
warehouse and new furnace production began on Monday August 16th, 2004.
Reworked units will be identified with a 2 inch, square light green dot above the
model and serial number label on the carton.
Furnaces with serial numbers beginning with 434****** date codes (and later) do not
have this error.

Field Corrective Action


Installed Units

WARNING
Hazardous Voltage!
Disconnect all electric power, including remote disconnects before servicing.
Follow proper lockout/tagout procedures to ensure the power can not be
inadvertently energized. Failure to disconnect power before servicing could
result in death or serious injury.
All affected furnaces with 424****** to 433****** serial number date code range which
are already installed must have the IFC date code checked immediately. The IFC
must be replaced if the IFC date code is 0424 through 0433.
Also, a thorough functional start up should be performed after replacing the IFC,
checking all modes of operation. Check low-fire and high-fire heating operation and
ensure proper input rates, airflow and temperature rise.
Field Warehouse Inventory
Furnaces with 428****** through 433****** date codes in IWD and DSO inventory are
to be returned for factory rework.
Furnaces with 424****** and 427****** date codes may be unboxed and inspected for
the IFC date code using the following guidelines:

FURN-SVB14A-EN

Record the unit model and serial number


Cut the band on the carton bottom flap on upflow models. Cut the top flap band on
downflow models.
On upflow models, raise the carton sleeve up until the blower access panel can be
opened and check the IFC date code
On downflow models, an inspection mirror and flashlight can be used to check the
IFC date code by inserting the mirror through the combustion air piping opening in
the top panel of the furnace.
If the IFC is not a 0424 through 0433 date code, the furnace may be sold and
installed. Record the IFC date code, then mark the furnace as good and return it
to free supply. (DSOs : Contact Inventory Service @ TNDC to get the furnaces
released)
If the IFC date code is 0424 through 0433 date code, re-box and re-band the
furnace for factory return. Please do not use tape.
3

Dealer Inventory
Dealers who have inventory for return should make arrangements through their local
Distributor or Trane Dealer Sales Office. If a dealer has a furnace which falls in these
date ranges with a bad IFC in it, they may install the furnace if the job requires it for
building commission, real estate closings or medical necessity as long as the local
Dealer Support Specialist or Field Service Representative approves it. The DSS or
FSR must first ensure the dealer understands what is required to change the IFC and
how to test the system after installation.

Parts
All of the CNT03777 (ADY / AUY / TDY / TUY furnaces) and CNT03778 (ADX-R /
AUX-R / TDX-R / TUX-R furnaces) in the National Parts Distribution Center in
Memphis, TN have been checked and purged. All known service parts in field
inventory and in factory inventory should be good.
Parts changed out in the field are on mandatory return to the supplier for quality
analysis and therefor must be returned to the local parts center or distributor. Please
use the replacement part box for return and indicate the original furnace model and
serial number on the outside of the box.
Parts Centers and Distributors please include a copy of the warranty claim with the
part.

Questions
Contact your local Dealer Support Specialist or Field Service Representative with
questions regarding this Service Bulletin.

Literature Order Number

FURN-SVB14A-EN

File Number

SV-UN- FURN-SVB14A-EN -080504

Supersedes

New

Stocking Location

Electronic Only

Trane and American Standard have a policy of continuous product data and product improvement
and reserve the right to change design and specifications without notice. Only qualified technicians
should perform the installation and servicing of equipment referred to in this bulletin.

FURN-SVB14A-EN