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Goodman Mfg GKS9 Installation Instructions Manual

Gas-fired warm air furnace.

 
G
AS
A Blocked Drain Kit (part #0270K00012) is available and MUST BE USED
(Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace)
ATTENTION INSTALLING PERSONNEL
As a professional installer you have an obligation to know the product better than the customer. This includes all safety
Prior to actual installation, thoroughly familiarize yourself with this Instruction Manual. Pay special attention to all safety
warnings. Often during installation or repair it is possible to place yourself in a position which is more hazardous than
Remember, it is your responsibility to install the product safely and to know it well enough to be able to instruct a
Safety is a matter of common sense...a matter of thinking before acting. Most dealers have a list of specific good safety
The precautions listed in this Installation Manual are intended as supplemental to existing practices. However, if there is
a direct conflict between existing practices and the content of this manual, the precautions listed here take precedence.
*NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual.
IO-300M
9/12
©
-F
W
IRED
I
NSTALLATION
This furnace is shipped from the factory as a Dedicated Upflow.
if the furnace is installed Horizontal Left or Horizontal Right.
Installer: Affix all manuals adjacent to the unit.
These furnaces comply with requirements
embodied in the American National Standard
/ National Standard of Canada ANSI
Z21.47·CSA-2.3 Gas Fired Central Furnaces.
RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION.
precautions and related items.
when the unit is in operation.
customer in its safe use.
practices...follow them.
Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com
2006-2008, 2010-2012 Goodman Manufacturing Company, L.P.
GKS9
A
ARM
IR
I
NSTRUCTIONS
F
URNACE

Summary of Contents

  • Page 1

    GKS9 IRED URNACE NSTALLATION NSTRUCTIONS This furnace is shipped from the factory as a Dedicated Upflow. A Blocked Drain Kit (part #0270K00012) is available and MUST BE USED if the furnace is installed Horizontal Left or Horizontal Right. Installer: Affix all manuals adjacent to the unit. (Type FSP CATEGORY IV Direct or Non Direct Vent Air Furnace) These furnaces comply with requirements embodied in the American National Standard...

  • Page 2: Table Of Contents

    Table of Contents I. Component Identification ............................... 5 II. Safety ....................................6 (ESD) P ........................6 LECTROSTATIC ISCHARGE RECAUTIONS III. Product Application ..............................6 IV. Location Requirements & Considerations ........................7 ..................................7 ENERAL ............................8 LEARANCES AND CCESSIBILITY ............................... 8 URNACE USPENSION ...............................

  • Page 3: Table Of Contents

    Table of Contents XIV. Startup Procedure & Adjustment ..........................29 ............................... 29 NTICIPATOR ETTING ............................... 29 RAIN RIMING ................................ 29 URNACE OPERATION ..........................30 UPPLY RESSURE EASUREMENT ....................30 ANIFOLD RESSURE EASUREMENT AND DJUSTMENT ) ......................31 NPUT EASUREMENT ATURAL ................................

  • Page 4

    NSTALLER WARNING Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, F THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED including but not limited to: unit maximum external static pressure, EXACTLY A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY gas pressures, BTU input rating, proper electrical connections, cir-...

  • Page 5: I. Component Identification

    I. COMPONENT IDENTIFICATION Upflow/Horizontal Gas Valve 16 Electrical Connection Inlets (Alternate) Gas Line Entrance (Alternate) 17 Coil Front Cover Drain Port Combustion Air Intake Connection / “Coupling” 18 Drain Line Penetrations Hot Surface Igniter 19 Blower Door Interlock Switch Burners 20 24-Volt Thermostat Connections Rollout Limit 21 Integrated Control Module...

  • Page 6: Ii. Safety, Esd) P Recautions

    II. SAFETY If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. Please adhere to the following warnings and cautions when in- 4. Discharge your body to ground before removing a new stalling, adjusting, altering, servicing, or operating the furnace. control from its container.

  • Page 7: Iv. Location Requirements & Considerations, G Eneral

    NOTE: Do not connect the temporary duct directly to the IV. LOCATION REQUIREMENTS & CONSIDERATIONS furnace. The duct must be sized according to the ENERAL instructions under Section V, Combustion and Ventilation Air Requirements, Section 5.3.3. WARNING • The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned O PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE...

  • Page 8

    cements and glues openings must be within 12 inches of the top; the other opening must be within 12 inches of the bottom of the confined space. In a antistatic fabric softeners for clothes dryers typical construction, the clearance between the door and door frame and masonry acid washing materials is usually adequate to satisfy this ventilation requirement.

  • Page 9

    Corrections must be in accordance with the latest edition of the 3. Smoke from a fireplace will not draw up the chimney. National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1-05 Instal- 4. Flue gases that will not draw up the appliance vent pipe. lation Codes.

  • Page 10

    5.3.3 Equipment Located in Confined Spaces: Chimney or Gas Vent Ventilation louvers (a) All Air from Inside the Building: The confined space shall be pro- (each end of attic) vided with two permanent openings communicating directly with NOTE: The inlet and outlet air openings must each have a free an additional room(s) of sufficient volume so that the combined area of not less than one square...

  • Page 11: Vi. Installation Positions, Vii. Horizontal Applications & Considerations, C Onnection, G Eneral

    5.3.4 Specially Engineered Installations: FURNACE MUST BE LEVEL FROM END TO END ALTERNATE VENT/FLUE The requirements of 5.3.3 shall not necessarily govern when special FURNACE MUST BE LEVEL LOCATION OR SLIGHTLY TILTED FORWARD engineering, approved by the authority having jurisdiction, provides an WITH THE DOORS 0"...

  • Page 12: Ix. Vent/flue Pipe & Combustion Air Pipe, Ga Line Connection

    VIII. PROPANE GAS /HIGH ALTITUDE INSTALLATIONS WARNING OSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION LL CONVERSIONS MUST BE PERFORMED BY A QUALIFIED INSTALLER OR SERVICE AGENCY This furnace is shipped from the factory configured for natural gas at standard altitude.

  • Page 13

    A condensing gas furnace achieves its high level of efficiency by All 90° elbows must be medium radius (1/4 bend DWV) or long extracting almost all of the heat from the products of combustion radius (Long sweep 1/4 bend DWV) types conforming to ASTM and cooling them to the point where condensation takes place.

  • Page 14: M Ethods, Equirements, Onnections, C Onnections

    • A vent termination shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. • The combustion air intake termination of a direct vent application should not terminate in an area which is frequently dusty or dirty.

  • Page 15

    REMOVE WARNING REMOVE PIPE 4 SCREWS DGES OF SHEET METAL HOLES MAY BE SHARP SE GLOVES AS A PRECAUTION WHEN REMOVING HOLE PLUGS REMOVE AND RELOCATE LTERNATE OCATION The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet.

  • Page 16

    TEE (OPTIONAL) Direct Vent (2 - Pipe) and Non-Direct Vent (1 - Pipe) Maximum Allowable Length of Vent/Flue Pipe (1) (2) & Combustion Air Pipe(ft) 12 " Min To Roof Or Highest Anticipated (3) (5) Pipe Number of Elbows Unit Input Snow Level Size (Btu)

  • Page 17

    TEE (OPTIONAL) 12" MIN. VENT/FLUE VENT/FLUE TEE (OPTIONAL) COMBUSTION 90° ELBOW TURNED AIR INTAKE DOWN 12" MIN. 12" MIN. ABOVE HIGHEST ANTICIPATED SCREEN SNOW LEVEL OPTIONAL 12" MIN. TO ROOF OR HIGHEST ANTICIPATED Horizontal Termination (Single Pipe) SNOW LEVEL Above Highest Anticipated Snow Level Vertical Terminations (Dual Pipe) IRECT IPING...

  • Page 18

    NTAKE ERMINATIONS NSTALLATION OF ULTIPLE IRECT URNACES 90° If more than one direct vent furnace is to be installed vertically MEDIUM RADIUS through a common roof top, maintain the same minimum clear- ELBOW ances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.

  • Page 19

    X. CONDENSATE DRAIN LINES & DRAIN TRAP Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning fur- ENERAL nace drain trap installation and drain hose hook ups. A condensing gas furnace achieves its high level of efficiency by •...

  • Page 20

    • If an air conditioning coil is installed with the furnace, a 1. Remove the rubber plug/cap from the front cover drain port common drain may be used. An open tee must be (right or left side, depending on the intended drain trap installed in the drain line, near the cooling coil, to mounting).

  • Page 21

    LTERNATE RAIN ONNECTIONS Cabinet Width Models "X" Length to Cut From Long Upright installations using the alternate vent/flue outlet will require (inches) (kBTU_Tons) End of Hose B “right-side only” drain hoses to be connected as follows. Refer to 045_30 Section IX, Vent/Flue Pipe and Combustion Air Pipe for details on 17 1/2 7 inches alternate vent/flue pipe connection.

  • Page 22

    5. Insert Tube 1 into rubber elbow drain port and secure with a 6. Secure remaining end of Hose B to exposed end of Tube 1 silver hose clamp. Angle tube outward toward front of with a green hose clamp. Route hose to front right down furnace.

  • Page 23: H Arness

    6. Insert approximately one inch of each Tube 2 through left IRING ARNESS side panel grommet hole. Secure tubes to Hose A and The wiring harness is an integral part of this furnace. Field alter- Hose B with a green hose clamps. NOTE: Tube must ation to comply with electrical codes should not be required.

  • Page 24: Wiring

    24 V UMIDIFIER The yellow wire connected to the I.D. Blower pressure switch is powered anytime the pressure switch is closed and provides 24 VAC humidifier control. Remove the yellow wire and connect a field supplied jumper wire with a “piggyback” terminal to the pressure ALTERNATE STANDARD JUNCTION BOX...

  • Page 25

    Refer to the National Fuel Gas Code, ANSI Z223.1, and information Natural Gas Capacity of Pipe provided by the gas supplier to determine the proper orifice size. In Cubic Feet of Gas Per Hour (CFH) Length of Nominal Black Pipe Size A different pressure switch may be required at high altitude regard- Pipe in Feet 1/2"...

  • Page 26: Piping

    • IRECT TANDARD NLET IPING Connect the furnace to the building piping by one of the following methods: When gas piping enters directly to the gas valve through the stan- dard inlet hole, the installer must supply straight pipe with a ground –...

  • Page 27

    A gas detecting warning system is the only reliable way to detect a Sizing Between Single or Second Stage Regulator and Appliance* Maximum Propane Capacities Listed are Based on 1/2" W.C. pressure drop at 11" W.C. setting. propane gas leak. Rust can reduce the level of odorant in propane Capacities in 1,000 BTU/hour.

  • Page 28

    Example: static reading from return duct = -.1" w.c. CUT USING TIN SNIPS static reading from supply duct = .3" w.c. total external static pressure on this system = .4" w.c. PRESS OUT BY HAND NOTE: Both readings may be taken simultaneously and read di- rectly on the manometer if so desired.

  • Page 29: Xiv. Startup Procedure & Adjustment, S Etting

    Refer to Minimum Filter Area tables to determine filter area require- ORIZONTAL NSTALLATIONS ments. Filters must be installed in either the central return register or in the return air duct work. COOLING AIRFLOW REQUIREMENT (CFM) XIV. STARTUP PROCEDURE & ADJUSTMENT 1000 1200 1400...

  • Page 30: A Djustment

    2. Remove the burner compartment door and move the furnace 1. Turn OFF gas to furnace at the manual gas shutoff valve gas valve manual control to the OFF position. external to the furnace. 3. Close the manual gas shutoff valve external to the furnace. 2.

  • Page 31: M Easurement

    NPUT EASUREMENT ATURAL WARNING The gas input rate to the furnace must never be greater than that HIGH VOLTAGE ! specified on the unit rating plate. To measure natural gas input             using the gas meter, use the following procedure. ISCONNECT POWER BEFORE...

  • Page 32: Power Up, Heating Mode, Cooling Mode, Peed

    HEAT EXCHANGER Circulator Blower Speeds RADIATION "LINE OF SIGHT" Medium Low Orange SUPPLY Medium Blue SUPPLY High Black Common/Neutral White RISE = SUPPLY RE TURN XV. NORMAL SEQUENCE OF OPERATION RETURN OWER The normal power up sequence is as follows: RETURN •...

  • Page 33: Fan Only Mode, Xvi. Operational Checks, Burner Flame, Xvii. Safety Circuit Description, G Eneral

    • R and Y thermostat contacts open, completing the call for RIMARY IMIT cool. The primary limit control is located on the partition panel and moni- • tors heat exchanger compartment temperatures. It is a normally- Outdoor fan and compressor are de-energized. closed (electrically), automatic reset, temperature-activated sen- •...

  • Page 34: L Ockout, Chart

    3. Service integrated control module or connecting wiring NNUAL INSPECTION following the discharge process in step 2. Use caution not The furnace should be inspected by a qualified installer, or service to recharge your body with static electricity; (i.e., do not move agency at least once per year.

  • Page 35: B Urners, Xxi. Repair & Replacement Parts

    8. Clean the primary heat exchanger tubes using a wire brush URNERS attached to a length of high grade stainless steel cable, Visually inspect the burner flames periodically during the heating such as drain cleanout cable. Attach a variable speed season.

  • Page 36

    ROUBLESHOOTING HART Associated Associated Symptoms of Abnormal Fault Description(s) Possible Causes Fault Description(s) Possible Causes Corrective Action Operation LED Code LED Code Cautions and Notes • Furnace fails to operate. NONE • No 115 volt power to • Manual disconnect switch •...

  • Page 37

    ROUBLESHOOTING HART Associated Symptoms of Abnormal Fault Description(s) Possible Causes Corrective Action Cautions and Notes Operation LED Code • Circulator blower runs • Primary or auxiliary • Faulty primary or auxiliary • Check primary/auxiliary • Turn power OFF continuously. No furnace limit circuit is open.

  • Page 38: Data.

    BLOWER PERFORMANCE (CFM & Temperature Rise vs. External Static Pressure) EXTERNAL STATIC PRESSURE (Inches Water Column) Tons AC Model Motor at 0.5" Heating Speed Speed As Shipped CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM HIGH 1352 1318...

  • Page 39

    GKS9 WIRING DIAGRAM Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring.

  • Page 40

    PECIAL NSTRUCTIONS FOR RODUCTS NSTALLED IN THE TATE OF ASSACHUSETTS 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line VENT/FLUE with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.

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