Goodman GKS9 Installation Instructions Manual
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Goodman GKS9 Installation Instructions Manual

Gas-fired warm air furnace
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See also: Technical Manual , Instruction and Installation Manual
G
This furnace is shipped from the factory as a Dedicated Upflow. A "Blocked Drain Kit" is available and MUST
BE USED if the furnace is installed Horizontal Left or Horizontal Right. Check the Serial/Rating Plate on the
(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.
IO-300H
2/10
-F
W
AS
IRED
I
NSTALLATION
furnace for the Kit part number.
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.
*NOTE: Please contact your distributor or our
website for the applicable Specification Sheet
referred to in this manual.
Goodman Manufacturing Company, L.P.
5151 San Felipe, Suite 500, Houston, TX 77056
www.goodmanmfg.com
2006-2008, 2010 Goodman Manufacturing Company, L.P.
©
GKS9
A
ARM
IR
I
NSTRUCTIONS
practices...follow them.
F
URNACE
®
C
US

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  • Page 1 *NOTE: Please contact your distributor or our website for the applicable Specification Sheet referred to in this manual. Goodman Manufacturing Company, L.P. IO-300H 5151 San Felipe, Suite 500, Houston, TX 77056 2/10 www.goodmanmfg.com 2006-2008, 2010 Goodman Manufacturing Company, L.P. ©...

  • 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 XX. Before Leaving an Installation ..........................33 XXI. Repair & Replacement Parts ........................... 33 APPENDIX Troubleshooting Chart ..............................34 GKS9 Wiring Diagram ..............................36 WARNING OODMAN WILL NOT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE...
  • 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: 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: Safety

    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: Location Requirements & Considerations

    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: Clearances And Accessibility

    cements and glues URNACE USPENSION antistatic fabric softeners for clothes dryers If suspending the furnace from rafters or joists, use 3/8" threaded and masonry acid washing materials rod and 2”x2”x1/8” angle iron as shown below. The length of rod • Seal off a non-direct vent furnace if it is installed near an will depend on the application and the clearances necessary.

  • Page 9: Thermostat Location

    If this furnace is to be installed in the same space with other gas If resizing is required on any portion of the venting system, use the appliances, such as a water heater, ensure there is an adequate appropriate table in Appendix G in the latest edition of the National supply of combustion and ventilation air for the other appliances.
  • Page 10 space shall be considered in making this determination. Each open- Chimney or Gas Vent ing shall have a minimum free area of 1 square inch per 1,000 BTU Ventilation louvers (each end of attic) per hour of the total input rating of all gas utilization equipment in NOTE: The inlet and outlet air the confined space, but not less than 100 square inches.

  • Page 11: Installation Positions

    FURNACE MUST BE LEVEL 5. When directly communicating with the outdoors, the single open- FROM END TO END ALTERNATE VENT/FLUE ing shall have a minimum free area of 1 square inch per 3,000 FURNACE MUST BE LEVEL LOCATION OR SLIGHTLY TILTED FORWARD BTU per hour of total input rating of all equipment in the enclo- WITH THE DOORS 0"...

  • Page 12: Alternate Electrical And Gas Line Connections

    change to compensate for the energy content difference between DISCHARGE ALTERNATE FLUE natural and propane gas. PIPE LOCATIONS High altitude installations may require both a pressure switch and an orifice change. These changes are necessary to compensate for the natural reduction in the density of both the gas fuel and the Side Side Return...

  • Page 13: Dual Certification : Non -Direct /Direct Vent

    flue pipe separation, shifting, or sagging during furnace operation. must be insulated with 1/2” thick closed cell foam. Inspect piping for leaks prior to installing insulation. ERTIFICATION IRECT IRECT ERMINATION OCATIONS This furnace is dual certified and may be installed as a non-direct vent (single pipe) or direct vent (dual pipe) appliance.

  • Page 14: Canadian Venting Requirements

    OMBUSTION ANADIAN ENTING EQUIREMENTS IRECT NSTALLATIONS In Canada, venting must conform to the requirements of the cur- On upflow units secure the combustion air intake pipe directly to rent CAN/CSA-B149.1-05 Installation Code. Use only CSA-listed, the air intake coupling. NOTE: Because of probable material con- ULC-S636 compliant two-three-inch diameter PVC or ABS pipe, flicts, do not use other commercially available “no hub connec- solvent cement, and fittings throughout.

  • Page 15: Non -Direct Vent (Single Pipe ) Piping

    FLANGE IRECT INGLE IPING Non-direct vent installations require only a vent/flue pipe. The vent 3.75" pipe can be run horizontally with an exit through the side of the CUT HERE building or run vertically with an exit through the roof of the building. The vent can also be run through an existing unused chimney;...

  • Page 16: Direct Vent (Dual Pipe ) Piping

    tion Air Pipe - Termination Locations for details concerning loca- WALL tion restrictions. A 2 3/8” diameter wall penetration is required for OUTSIDE INSIDE 2” diameter pipe. A 3” diameter hole is required for a 2 1/2” pipe and a 3 1/2” diameter hole is required for 3” diameter pipe. To 90°ELBOW secure the pipe passing through the wall and prohibit damage to TURNED...

  • Page 17: T F I M D V F

    Horizontal terminations should be as shown in the following fig- Direct Vent (Dual Pipe) ure. Refer to Section IX, Vent/Flue Pipe and Combustion Pipe - Maximum Allowable Length of Vent/Flue & Combustion Termination Location for location restrictions. A 2 3/8” diameter Air Intake Pipe (ft) wall penetration is required for 2”...

  • Page 18: Concentric Vent Termination

    extracting almost all of the heat from the products of combustion Vent and cooling them to the point where condensation takes place. The condensate which is generated must be piped to an appropri- ate drain location. In upright installations, the furnace’s drain hoses may exit either 12"...
  • Page 19 mounting). Left side drains 2. Secure Hose A to front cover drain port with a red hose Cut “X” inches from the long end of Hose B and discard. clamp. Route hose to rear side panel grommet hole. Refer to table for appropriate length to cut. Secure remaining hose to Tube 1 with a green hose clamp.
  • Page 20 6. Insert short end of each Tube 2 through side panel grommet a silver hose clamp. Angle tube outward toward front of holes. Secure tubes to Hose A and Hose B with green furnace. hose clamps. Ensure hoses and tubes maintain a 6.

  • Page 21: Horizontal Installations

    ORIZONTAL NSTALLATIONS NOTE: This furnace is shipped from the factory as a Dedicated Upflow. A “Blocked Drain Kit” is available and MUST BE USED if the NOTE: This furnace is shipped from the factory as a Dedicated furnace is installed Horizontal Left or Horizontal Right. Check the Upflow.

  • Page 22: Electrical Connections

    silver hose clamp. Angle tube outward toward front of furnace. Hose B with a green hose clamps. NOTE: Tube must reach bottom of trap. Ensure hoses and tubes maintain a 5. Cut 17 3/4 inches from the long end (end opposite the bend) downward slope for proper drainage and that they are not of Hose B.

  • Page 23: 115 Volt Line Connections

    placement wiring must be copper conductor. 115 V ONNECTIONS Before proceeding with electrical connections, ensure that the sup- ply voltage, frequency, and phase correspond to that specified on ALTERNATE STANDARD JUNCTION BOX JUNCTION BOX the unit rating plate. Power supply to the furnace must be N.E.C. LOCATION LOCATION Class 1, and must comply with all applicable codes.

  • Page 24: General

    gas conversion kit. Taps for measuring the gas supply pressure and manifold pressure are provided on the valve. CAUTION The gas valve has a manual ON/OFF control located on the valve itself. This control may be set only to the “ON” or “OFF” position. O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE Refer to the lighting instructions label or Section XIV, Startup Pro- GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT...
  • Page 25 GAS VALVE MANUAL MANIFOLD BURNERS GROUND JOINT SHUT OFF VALVE PIPE UNION • (UPSTREAM FROM Install a 1/8" NPT pipe plug fitting, accessible for test gage ALTERNATE GROUND JOINT GAS LINE PIPE UNION) LOCATION connection, immediately upstream of the gas supply connection to the furnace.

  • Page 26: Propane Gas Tanks And Piping

    5 to 15 PSIG WARNING First Stage (20 PSIG Max.) Regulator Continuous 11" W.C. O AVOID THE POSSIBILITY OF EXPLOSION OR FIRE NEVER USE A MATCH OR OPEN FLAME TO TEST FOR LEAKS 200 PSIG Second Stage Maximum Regulator Check for leaks using an approved chloride-free soap and water solution, an electronic combustible gas detector, or other approved testing methods.

  • Page 27: Bottom Return Air Opening [Upflow Models ]

    Refer to Minimum Filter Area tables to determine filter area require- OTTOM ETURN PENING PFLOW ODELS ments. The bottom return air opening on upflow models utilizes a “lance and cut” method to remove sheet metal from the duct opening in COOLING AIRFLOW REQUIREMENT (CFM) the base pan.

  • Page 28: Horizontal Installations

    4. Replace the burner compartment door. ORIZONTAL NSTALLATIONS Filters must be installed in either the central return register or in the UPPLY RESSURE EASUREMENT return air duct work. XIV. STARTUP PROCEDURE & ADJUSTMENT CAUTION Furnace must have a 115 VAC power supply properly connected  ...

  • Page 29: Gas Manifold Pressure Measurement And Adjustment

    hose barb fitting into the outlet pressure tap. 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. b. White-Rodgers 36G22 valve: 2. Turn OFF all electrical power to the system. Back inlet pressure test screw (inlet pressure boss) out one turn (counterclockwise, not more than one turn).

  • Page 30: Temperature Rise

    conversion factor (hours to seconds), divided by the number IRCULATOR LOWER PEEDS of seconds per cubic foot. The measured input must not be greater than the input indicated on the unit rating plate. WARNING EXAMPLE: Installation’s gas heating (HTG) value: 1,000 BTU/ft O PREVENT PREMATURE FAILURE OF HEAT EXCHANGER PROPERTY (Obtained from gas supplier)

  • Page 31: Cooling Mode

    extend directly outward from the burners without curling, floating, or • Igniter warm up begins after 15 second prepurge expires. lifting off. Flames must not impinge on the sides of the heat ex- • Gas valve opens at end of igniter warm up period, delivering changer firing tubes.

  • Page 32: Troubleshooting

    XVIII. TROUBLESHOOTING XIX. MAINTENANCE (ESD) P LECTROSTATIC ISCHARGE RECAUTIONS WARNING NOTE: Discharge body’s static electricity before touching unit. An electrostatic discharge can adversely affect electrical components. HIGH VOLTAGE! Use the following precautions during furnace installation and ser- O AVOID PERSONAL INJURY OR DEATH DUE TO vicing to protect the integrated control module from damage.

  • Page 33: Burners

    To remove: brush, such as a gun cleaning brush. 8. Clean the primary heat exchanger tubes using a wire brush 1. Turn OFF electrical power to furnace. attached to a length of high grade stainless steel cable, 2. Remove filter(s) from the central return register or ductwork. such as drain cleanout cable.

  • Page 34: Troubleshooting Chart

    Troubleshooting Chart 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 35 Troubleshooting Chart 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 36: Gks9 Wiring Diagram

    GKS9 WIRING DIAGRAM O E ) S ( ) 4 V C E S R I C L T B WR NU L E Y IM T L W R MPAR U N R O TO 115VAC/ 1 Ø /60 HZ POWER SUPPLY WITH...

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