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York GF9S*DH Installation Manual

High efficiency tubular heat exchanger series 40 - 120 mbh input (11.72 - 35.17 kw) input
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INSTALLATION MANUAL

HIGH EFFICIENCY
TUBULAR HEAT EXCHANGER SERIES
MODELS: GY9S*DH / GM9S*DH / GF9S*DH
(Single Stage Downflow/Horizontal)
40 - 120 MBH INPUT
(11.72 - 35.17 KW) INPUT
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transition Kit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Return Filter Grill and Return Duct Installation . . . . . . . . . . . . . . . . . . . 8
Typical Attic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Downflow Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Horizontal Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Thermostat Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . 13
Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 14
Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Downflow/Horizontal Vent Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 18
Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Termination Configuration - 2 Pipe Horizontal . . . . . . . . . . . . . . . . . . 18
Crawl Space Termination Configuration - 2Pipe . . . . . . . . . . . . . . . . 19
Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . 5
Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cabinet and Duct Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maximum Equivalent Pipe Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Equivalent Length of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Elbow Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION I: SAFETY
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words DANGER,
WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if not
avoided, will result in death or serious injury.
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. It is also used to
alert against unsafe practices and hazards involving only property dam-
age.
LIST OF SECTIONS
TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .14
CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .31
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
LIST OF FIGURES
Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .21
Attic Combustion Air Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Condensate Drain Internal Hose Routing . . . . . . . . . . . . . . . . . . . . . .22
Downflow Condensate Drain Hose Configuration . . . . . . . . . . . . . . .23
(Option 1 - Front of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
(Option 1 - Front of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
(Option 2 - Back of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
(Option 2 - Back of Casing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Pressure Switch Tubing Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Furnace Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
LIST OF TABLES
(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Free Area - Outdoor Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Condensate Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or mainte-
nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con-
tractor, installer or service agency.
This product must be installed in strict compliance with the installa-
tion instructions and any applicable local, state, and national codes
including, but not limited to building, electrical, and mechanical
codes.
EFFICIENCY
RATING
CERTIFIED
ISO 9001
Certified Quality
Management System

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  • Page 1: Table Of Contents

    INSTALLATION MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES MODELS: GY9S*DH / GM9S*DH / GF9S*DH (Single Stage Downflow/Horizontal) 40 - 120 MBH INPUT (11.72 - 35.17 KW) INPUT SAFETY ..........1 DUCTWORK .

  • Page 2: Safety

    268890-UIM-B-0607 SPECIFIC SAFETY RULES AND PRECAUTIONS Only Natural gas or Propane (LP) gas are approved for use with this furnace. Refer to the furnace rating plate or Section IV of these instructions. Install this furnace only in a location and position as specified in SECTION I of these instructions.
  • Page 3 The furnace area must not be used as a broom closet or for any other storage purposes, as a fire hazard may be created. Never store items such as the following on, near or in contact with the fur- nace. 1.

  • Page 4: Ductwork

    268890-UIM-B-0607 Downflow/Horizontal furnaces for installation on combustible floor- ing only when installed on the accessory combustible floor base on wood flooring only and shall not be installed directly on carpeting, tile or other combustible material. Check the rating plate and power supply to be sure that the electri- cal characteristics match.

  • Page 5: Minimum Duct Sizing For Proper Airflow

    Use the Example below to help you in calculating the duct area to deter- mine whether the ducts have sufficient area so that the furnace oper- ates at the specified external static pressure and within the air temperature rise specified on the nameplate. The following are general duct sizing guidelines that may not serve to requirements of every application.

  • Page 6: Transition Kit Assembly

    268890-UIM-B-0607 Downflow Air Conditioning Coil Cabinet The Cooling Coil Cabinet can be used in place of the combustible floor base for downflow installations on combustible materials. The furnace should be installed with the cooling coil cabinet specifically intended for downflow applications. The cooling coil cabinet must be secured to the floor.

  • Page 7: Filters

    T-STAT WIRING 7/8” K.O. HORIZONTAL CONDENSATE DRAIN OPENING 1-3/4” HORIZONTAL CONDENSATE DRAIN OPENING 2” JUNCTION BOX HOLE 7/8” GAS PIPE ENTRY 1-1/2” CONDENSATE DRAIN HOLE 7/8” SIDE PIPING HOLE 3-3/8” 28-1/2 LEFT SIDE 1-1/4 FIGURE 3: Dimensions TABLE 4: Cabinet and Duct Dimensions BTUH (kW) Input/Output 40/37 (11.7/10.8)

  • Page 8: Return Filter Grill And Return Duct Installation

    268890-UIM-B-0607 Downflow Filters Downflow furnaces typically are installed with the filters located above the furnace, extending into the return air plenum or duct. Any branch duct (rectangular or round duct) attached to the plenum must attach to the vertical plenum above the filter height. Filters(s) may be located in the duct system external to the furnace using an external duct filter box attached to the furnace plenum or at the end of the duct in a return filter grille(s).

  • Page 9: Gas Piping

    ANGLE IRON BRACKET 1” MAX. BETWEEN ROD & FURNACE 6” MIN. BETWEEN ROD & FURNACE FIGURE 6: Typical Suspended Furnace / Crawl Space Installation In any application where temperatures below freezing are possible, see “BELOW FREEZING LOCATIONS”. SECTION IV: GAS PIPING GAS SAFETY An overpressure protection device, such as a pressure regulator, must be installed in the gas piping system upstream of the furnace...

  • Page 10: Electrical Power

    268890-UIM-B-0607 TABLE 6: Nominal Manifold Pressure Manifold Pressures (in wc) 0-7999 1000 1050 1100 2500 (LP) PROPANE AND HIGH ALTITUDE CONVERSION KITS It is very important to choose the correct kit and/or gas orifices for the altitude and the type of gas for which the furnace is being installed. Only use natural gas in furnaces designed for natural gas.

  • Page 11: Electrical Wiring

    SUPPLY VOLTAGE CONNECTIONS IMPORTANT: The power connection leads and wiring box may be relo- cated to the left side of the furnace. Remove the screws and cut wire tie holding excess wiring. Reposition on the left side of the furnace and fas- ten using holes provided.

  • Page 12: Thermostat Chart

    268890-UIM-B-0607 FIGURE 11: Thermostat Chart Unitary Products Group...

  • Page 13: Accessory Connections

    ACCESSORY CONNECTIONS The furnace control will allow power-switching control of various acces- sories. Refer to Figure 12, for connection details. HUM. HOT 115 VOLT HUMIDIFER EAC HOT 115 VOLT ELECTRONIC AIR CLEANER FIGURE 12: Accessory Connections ELECTRONIC AIR CLEANER CONNECTION Two 1/4”...

  • Page 14: Single Stage Twinning Wiring Diagram

    268890-UIM-B-0607 Single-Wire Twinning Instructions Connect the control wiring as shown in the Figure 14. Connect the low voltage wiring from the wall thermostat to the ter- minal strip on the control board of Furnace #1. Connect a wire from the TWIN terminal of Furnace #1 to the TWIN terminal of Furnace #2.

  • Page 15: Maximum Equivalent Pipe Length

    This furnace may not be common vented with any other appliance, since it requires separate, properly sized air intake and vent lines. The furnace shall not be connected to any type of B, BW or L vent or vent connector, and not connected to any portion of a factory- built or masonry chimney The furnace shall not be connected to a chimney flue serving a sep- arate appliance designed to burn solid fuel.

  • Page 16: Dimensions

    268890-UIM-B-0607 STANDARD ELBOW LONG (SWEEP) ELBOW FIGURE 16: Dimensions TABLE 10: Elbow Dimensions Elbow "A" Dimension 2" Standard 2-5/16" 3" Standard 3-1/16" 2" Sweep 3-1/4" 3" Sweep 4-1/16" Dimensions are those required in Standard ASTM D-3311. NOTE: Sidewall vent terminal may be used for sidewall vent termina- tions.

  • Page 17: Home Layout

    VENT CLEARANCES FIXED CLOSED FIGURE 17: Home Layout Direct Vent Terminal Clearances A. Clearance above grade, veranda, porch, deck, or balcony B. Clearance to window or door that may be opened C. Clearance to permanently closed window D. Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (61 cm) from the center line of the terminal E.

  • Page 18: Downflow/Horizontal Vent Assembly

    268890-UIM-B-0607 VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations. Horizontal vent system. This vent system can be installed com- pletely horizontal or combinations of horizontal, vertical, or offset using elbows. Vertical vent system. This vent system can be installed completely vertical or a combination of horizontal, vertical, or offset using elbows.

  • Page 19: Crawl Space Termination Configuration - 2Pipe

    VENT DRAIN FIGURE 22: Crawl Space Termination Configuration - 2Pipe VERTICAL VENT APPLICATIONS AND TERMINATION Roof mounted vertical terminals may be field fabricated. Standard PVC/ SRD fittings may be used. If installing a vertical venting system through any unconditioned space such as an attic or crawl space it must be insulated.

  • Page 20: Combustion Airflow Path Through The Furnace Casing To The Burner

    268890-UIM-B-0607 The combustion air intake pipe should be located either through the wall (horizontal or side vent) or through the roof (vertical vent). Care should be taken to locate side vented systems where trees or shrubs will not block or restrict supply air from entering the terminal. Also, the terminal assembly should be located as far as possible from a swimming pool or a location where swimming pool chemicals might be stored.

  • Page 21: Outside And Ambient Combustion Air

    GABLE VENT VENT VENTILATED ATTIC OPTIONAL TOP ABOVE INLET (a) INSULATION OUTLET SOFFIT AIR (a) VENT WATER HEATER VENTILATED CRAWL SPACE 5. A square or rectangular shaped duct shall only be used when the required free area of the supply opening is 9 in (58.06 cm ) or larger.

  • Page 22: Condensate Piping

    268890-UIM-B-0607 12” MINIMUM BETWEEN BOTTOM OF BELOW AND ANY MATERIAL 12” MIN. FIGURE 28: Attic Combustion Air Termination Specially Engineered Installations The above requirements shall be permitted to be waived where special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation and dilution of flue gases.

  • Page 23: Downflow Condensate Drain Hose Configuration

    FIGURE 30: Downflow Condensate Drain Hose Configuration Horizontal Left Air Flow (Inducer Low) - Refer to Figures 31 & 32 Remove all the condensate hoses inside the furnace, leaving the 3/8" barbed nipple and hose # 4, both factory installed, in the rain gutter.

  • Page 24: Horizontal Left Condensate Drain Hose Configuration

    268890-UIM-B-0607 FIGURE 31: Horizontal Left Condensate Drain Hose Configuration Unitary Products Group...

  • Page 25: Horizontal Left Condensate Drain Hose Configuration

    268890-UIM-B-0607 FIGURE 32: Horizontal Left Condensate Drain Hose Configuration Unitary Products Group...
  • Page 26 268890-UIM-B-0607 Horizontal Right Air Flow (Inducer High) Refer to Figures 33-36 Installation with condensate trap bracket (Front of casing): Refer to Figure 33 & 34 Remove the 2" knockout on the casing side, away from the inducer motor. Remove all the condensate hoses inside the furnace, including the 3/8"...

  • Page 27: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front Of Casing)

    268890-UIM-B-0607 FIGURE 33: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front of Casing) Unitary Products Group...

  • Page 28: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front Of Casing)

    268890-UIM-B-0607 FIGURE 34: Horizontal Right Condensate Drain Hose Configuration (Option 1 - Front of Casing) Unitary Products Group...

  • Page 29: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back Of Casing)

    268890-UIM-B-0607 FIGURE 35: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back of Casing) Unitary Products Group...

  • Page 30: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back Of Casing)

    268890-UIM-B-0607 FIGURE 36: Horizontal Right Condensate Drain Hose Configuration (Option 2 - Back of Casing) Unitary Products Group...

  • Page 31: Safety Controls

    CONDENSATE DRAIN TERMINATION DO NOT terminate condensate drain in a chimney, or where the drain line may freeze. The line must terminate at an inside drain to prevent freezing of the condensate and possible property damage. DO NOT trap the drain line at any other location than at the condensate drain trap supplied with the furnace.

  • Page 32: Natural Gas

    268890-UIM-B-0607 There is an accessory kit (1PK0601) available from Source 1, which has the following items: • 1 - 12” (30 cm) length x 1/8” (0.3 cm) diameter tubing • 2 – pieces of 4” (10 cm) length x 1/8” (0.3 cm) diameter tubing •...
  • Page 33 In the USA use the following formula to calculate the furnace input. For natural gas multiply the heat content of the gas BTU/SCF or Default 1030 BTU/SCF (38.4 MJ/m the gas meter, times a barometric pressure and temperature correction factor of 0.960; times 3600, then divided by the time (In seconds) it took to measure 2 cubic ft.

  • Page 34: Gas Valve

    268890-UIM-B-0607 Be sure to relight any gas appliances that were turned off at the start of this input check. TABLE 16: Inlet Gas Pressure Range INLET GAS PRESSURE RANGE Natural Gas Minimum 4.5” W.C. (1.12 kPa) Maximum 10.5” W.C. (2.61 kPa) IMPORTANT: The inlet gas pressure operating range table specifies what the minimum and maximum gas line presures must be for the fur- nace to operate safely.

  • Page 35: Reading Gas Pressure

    WITH BURNER BOX COVER IN PLACE FITTING VALVE BURNER BOX PRESSURE REFERENCE HOSE U-TUBE MANOMETER FIGURE 39: Reading Gas Pressure ADJUSTMENT OF TEMPERATURE RISE The temperature rise, or temperature difference between the return air and the supply (heated) air from the furnace, must be within the range shown on the furnace rating plate and within the application limitations shown in Table 7 “ELECTRICAL AND PERFORMANCE DATA”.
  • Page 36 268890-UIM-B-0607 FURNACE CONTROL DIAGNOSTICS The furnace has built-in, self-diagnostic capability. If a system problem occurs, a blinking LED shows a fault code. The LED can flash red, green or amber to indicate various conditions. It is located behind a clear view port in the blower compartment door. The control continuously monitors its own operation and the operation of the system.

  • Page 37: Blower Performance Cfm

    TABLE 18: Blower Performance CFM MODELS Airflow with Top Return - without Filters (CFM) Input/ Speed External Static Pressure, Inches W.C. Airflow/ Cabinet High 1635 1590 1535 1480 1415 1340 1280 1185 Med-High 1179 1170 1160 1140 40/1200/A Med-Low 969 High 1687 1652 1631 1595 1557 1511 1456 1382 1313 1211 Med-High 1193...
  • Page 38 268890-UIM-B-0607 APPLYING FILTER PRESSURE DROP TO DETERMINE SYSTEM AIRFLOW To determine the approximate airflow of the unit with a filter in place, fol- low the steps below: Select the filter type. Determine the External System Static Pressure (ESP) without the filter.

  • Page 39: Wiring Diagram

    268890-UIM-B-0607 SECTION XI: WIRING DIAGRAM FIGURE 41: Wiring Diagram Unitary Products Group...
  • Page 40 Subject to change without notice. Printed in U.S.A. Copyright © by York International Corp. 2007. All rights reserved. Unitary Product Group NOTES 5005 York Drive 268890-UIM-B-0607 Supersedes: 268890-UIM-A-0407 Norman 73069...

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