York International Johnson Controls Y81E Installation Manual

Single-stage standard ecm residential gas furnaces (non-condensing multi-position standard and low nox)

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Installation Manual: Y81E Single-Stage

Standard ECM Residential Gas Furnaces

(Non-condensing Multi-position Standard

and Low NOx)

York International Corp. 5005 York Drive

6100757-UIM-C-1124

Norman, OK 73069

Supersedes: 6100757-UIM-B-0323

www.johnsoncontrols.com

2024-11-22

Johnson Controls Ducted Systems

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Page 1 Installation Manual: Y81E Single-Stage Standard ECM Residential Gas Furnaces (Non-condensing Multi-position Standard and Low NOx) York International Corp. 5005 York Drive 6100757-UIM-C-1124 Norman, OK 73069 Supersedes: 6100757-UIM-B-0323 www.johnsoncontrols.com 2024-11-22 Johnson Controls Ducted Systems...
Page 2 Installation Manual: Y81E Single-Stage Standard ECM Residential Gas Furnaces (Non-condensing Multi- position Standard and Low NOx) Johnson Controls Ducted Systems...
Page 3: Table Of Contents
Contents General................................5 Certification...............................5 DS Solutions App.............................. 5 Safety................................. 5 Safety rules and precautions........................7 Safety requirements..........................9 Combustion air quality and list of contaminants................9 Codes and standards...........................10 For furnaces installed in the Commonwealth of Massachusetts only.......... 11 Inspection............................. 13 Ductwork................................. 14 Ductwork general information......................
Page 4 Twinning and staging............................ 33 Furnace control twinning wiring......................33 Twinning duct system......................... 34 Vent system..............................35 Vent connections..........................35 Category 1 - 450°F maximum vent temperature................36 Venting..............................36 Venting into an existing chimney...................... 37 Fan-assisted combustion system.......................37 Ambient combustion air supply....................... 37 Dampers, louvers and grilles........................
Page 5: General
General These high efficiency, compact units employ induced combustion, reliable hot surface ignition and high heat transfer aluminized steel tubular heat exchangers. The units are factory-shipped for installation in upflow or horizontal applications and may be converted for downflow applications. These furnaces are designed for residential installation in a basement, closet, alcove, attic, recreation room, or garage and are also ideal for commercial applications.
Page 6 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.
Page 7: Safety Rules And Precautions
WARNING • Check that the ground wire is securely connected. Do not connect ground wiring to gas piping, water piping, lighting conductor, or telephone ground wiring. • If a circuit breaker, fuse or safety sensor is frequently activated, i.e. rapid red flashes, shut down the system and contact your service contractor.
Page 8 WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury, death, or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury, or loss of life.
Page 9: Safety Requirements
Safety requirements CAUTION This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes including, but not limited to, building, electrical, and mechanical codes. • Refer to the unit rating plate for the furnace model number and then see for return air plenum dimensions.
Page 10: Codes And Standards
The furnace requires outdoor air for combustion when locating the furnace in any of the following environments: • Buildings with indoor pools • Areas where there is chemical exposure • Commercial buildings • Hobby or craft rooms • Laundry rooms •...
Page 11: Combustion And Ventilation Air
Quincy, MA 02269 or for only the NFGC, contact the American Gas Association, 400 N. Capital, N.W. Washington DC 20001 http://www.NFPA.org • Canada: NSCNGPIC. For a copy, contact: Standard Sales, CSA International 178 Rexdale Boulevard Etobicoke, (Toronto) Ontario, Canada M9W 1RS Combustion and ventilation air •...
Page 12 1. Installation of carbon monoxide detectors - At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed.
Page 13: Inspection
Inspection Immediately after receiving the unit, inspect the unit for possible damage during transit. If damage is evident, perform the following steps: 1. Note the extent of the damage on the carrier’s freight bill. 2. Make a separate request for inspection by the carrier’s agent in writing. Also, before installation, check the unit for any screws or bolts that loosened in transit.
Page 14: Ductwork
Table 1: Unit clearances to combustibles Application Front Rear Left Right Flue Floor or Closet Alcove Attic Line side side bottom contact in. (cm) in. (cm) in. (cm) in. (cm) in. (cm) in. (cm) in. (cm) Upflow 1 (2.5) 1 (2.5) 6 (15.2) Combustible Upflow 1 (2.5)
Page 15: Duct Flanges
air from entering the furnace. If manually operated, equip the damper with means to prevent the furnace or the air conditioner from operating unless the damper is in full heat or cool position. When replacing an existing furnace, if the existing plenum is not the same size as the new furnace then remove the existing plenum and install a new plenum that is the correct size for the new furnace.
Page 16: Ductwork Installation And Supply Plenum Connection - Upflow/Horizontal
Figure 1: Duct attachment Ductwork installation and supply plenum connection - upflow/horizontal Figure 2: Ductwork installation and supply plenum connection - upflow/horizontal To install the ductwork and supply plenum connection in the upflow/horizontal configuration, follow these steps: 1. Attach the supply plenum to the furnace outlet. Use an approved, flexible duct connector on all installations.
Page 17: Floor Base And Ductwork Installation - Downflow
Floor base and ductwork installation - downflow Figure 3: Floor base and ductwork installation - downflow Use a combustible floor base for installations on combustible material or directly on any floors, as shown in Figure 4. Follow the instructions supplied with the combustible floor base accessory. It is possible to replace this combustible floor base with a matching indoor coil, correctly sealed to prevent leaks.
Page 18: Coil Installation
leakage. For details of the coil cabinet dimensions and installation requirements, refer to the installation instructions supplied with the coil cabinet. Attach the indoor coil cabinet to the duct connector and then position the furnace on top of the coil cabinet. Seal the connection to the furnace, coil cabinet, duct connector, and supply air duct to prevent air leakage.
Page 19 Figure 6: Vertical downflow applications with furnaces Figure 7: XAH horizontal right application with furnace Installation Manual: Y81E Single-Stage Standard ECM Residential Gas Furnaces (Non-condensing Multi- position Standard and Low NOx) Johnson Controls Ducted Systems...
Page 20: Downflow Duct Connectors
Figure 8: XAH horizontal left application with furnace Downflow duct connectors All downflow installations must use a suitable duct connector approved by the furnace manufacturer for use with this furnace. The duct connectors are designed to connect to the rectangular duct under the floor and sealed. Refer to the instructions supplied with the duct connector for correct installation.
Page 21: Downflow Application
Downflow application For downflow applications, turn the furnace upside down so the circulating air enters the furnace at the top and exits the furnace at the bottom. Rotate the combustion air inducer 90° as shown in Figure 24. Do not block the combustion air inlet openings. Horizontal application Figure 9: Horizontal application Important: It is possible to install this furnace in a horizontal position on either side as shown...
Page 22: Suspended Furnace Or Crawl Space Installation
Important: During installation, doors must remain on the furnace when moving or lifting. When moving or handling this furnace before installation, always leave the doors on the furnace to provide support and to prevent damage or warping of the cabinet. When lifting the furnace, support the ends of the furnace rather than lifting by the cabinet flanges at the return air openings, bottom or sides, or supply air opening.
Page 23 Figure 12: Dimensions Table 2: Cabinet and duct dimensions Btu/h Nominal Cabinet A (in.) A B (in.) B (cm) C (in.) C (cm) Approximate (kW) size (cm) operating CFM (m weight (lb) input min) 40 (11.7) 1200 (34.0) 14 1/2 36.8 13 3/8 34.0 10.3 26.2...
Page 24: Filters
Filters Filter installation CAUTION All installations must have a filter installed. All filters and mounting provision must be field-supplied. Unauthorized modifications to Johnson Controls products are prohibited as they may create hazards which could result in equipment damage. All applications require the use of a field-installed filter. All filters and mounting provision must be field-supplied.
Page 25: Horizontal Filters
Install the side filter rack following the instructions provided with that accessory. If one or more filters are provided at another location in the return air system, attach the ductwork directly to the furnace side panel. Important: Some accessories such as electronic air cleaners and pleated media may require a larger side opening.
Page 26: Gas Piping Installation
Figure 14: Gas valve Important: Plan the gas supply routing before determining the correct gas pipe entry. Use 90° conventional elbows and short pipe nipples to enter through the cabinet access holes. Gas piping installation You must use correctly sized wrought iron, approved flexible or steel pipe when making gas connections to the unit.
Page 27: Gas Orifice Conversion For Propane (Lp)
CAUTION The gas valve body is a very thin casting that cannot take any external pressure. Never apply a pipe wrench to the body of the gas valve when installing piping. A wrench must be placed on the octagon hub located on the gas inlet side of the valve. Placing a wrench to the body of the gas valve will damage the valve causing improper operation and/or the valve to leak.
Page 28: High Altitude Pressure Switch Conversion
Table 4: Nominal Manifold Pressure Gas heating Manifold pressures Gas heating Manifold pressures (kPa) at halue (in. W.C.) at different value different altitude ranges (m) altitude ranges (ft) (Btu/ft (MJ/m 0–7999 8000– 9000– 0–2437 2438– 2743– 8999 9999 2742 3048 29.8 0.87 0.87...
Page 29: Electric Power
Electric power Electric power connections Field wiring to the unit must be grounded. Electric wires that are field-installed must conform to the temperature limitation for 63°F (35°C) rise wire when installed in accordance with instructions. See Table 5 for specific furnace electrical data. CAUTION Use copper conductors only.
Page 30 Route all power wiring through a conduit connector or other proper bushing that is field- installed into the unit opening and the junction box. In the junction box, there is a black wire, a white wire, and a green ground screw. a.
Page 31: Low Voltage Control Wiring Connections
Low voltage control wiring connections Install the field-supplied thermostat by following the instructions that come with the thermostat. With the thermostat set in the OFF position and the main electrical source disconnected, connect the thermostat wiring from the wiring connections on the thermostat to the terminal block on the control board, as shown in Figure 17 Figure...
Page 32 Figure 18: Standard ECM furnace and multi-stage HP Figure 19: Standard ECM furnace and single-stage AC Figure 20: Standard ECM furnace and premium multi-stage AC Installation Manual: Y81E Single-Stage Standard ECM Residential Gas Furnaces (Non-condensing Multi- position Standard and Low NOx) Johnson Controls Ducted Systems...
Page 33: Accessory Connections
Accessory connections The furnace control allows power-switching control of various accessories. Electronic air cleaner connection Two 1/4 in. (6.4 mm) spade terminals (EAC and EAC-N) for electronic air cleaner connections are located on the control board. The terminals provide 115 VAC (1 A maximum) during circulating blower operation.
Page 34: Twinning Duct System
Figure 21: Wiring using a single-stage thermostat Figure 22: Wiring using a multi-stage thermostat Twinning duct system Twinned furnaces must only be applied on a common duct system. A single air supply plenum must be used for both furnaces and indoor coils. Separate plenums and supply ducts systems cannot be utilized.
Page 35: Vent System
Figure 23: Twinned furnaces CAUTION If a return duct is connected to only one furnace (with a connection between the two furnaces) an imbalance in the airflow will occur and the furnace furthest from the return plenum will overheat. Vent system Vent connections All models are provided with a flue transition that is sized for 4 in.
Page 36: Category 1 - 450°F Maximum Vent Temperature
Figure 24: Combustion air inducer Category 1 - 450°F maximum vent temperature Install the venting system in accordance with Section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code Z223.1/NFPA 54 (latest edition), or Sections 7.2, 7.3 or 7.4 of CSA B149.1, National Gas and Propane Codes (latest edition) or applicable provisions of the local building code and these instructions.
Page 37: Venting Into An Existing Chimney
Venting into an existing chimney For Category I installations, the furnace is connected to a factory-built chimney or vent complying with a recognized standard, or a masonry or concrete chimney lined with a material acceptable to the authority having jurisdiction. Important: Do not vent this furnace into an unlined masonry chimney or concrete chimney.
Page 38 Figure 25: Combustion airflow path through the furnace casing to the burner compartment Figure 26: Combustion airflow path through the furnace casing to the burner compartment WARNING This type of installation requires that the supply air to the appliance(s) be of a sufficient amount to support all of the appliance(s) in the area.
Page 39 WARNING Examine the heat exchanger, vent pipe, combustion air passages, vent connectors, and chimney to be sure they are clear and free of obstructions. Note: Proper orientation on the heat exchanger is for the compressed heat transfer blade portion to be up and away from the burner section, towards the air leaving end of the furnace.
Page 40: Dampers, Louvers And Grilles
Dampers, louvers and grilles The blocking effects of louvers, grilles and screens must be given consideration in calculating free area. If the free area of a specific louver or grille is not known, see Table 6 to estimate free area. Table 6: Estimated free area Wood or metal Wood 20% to 25%...
Page 41 Table 8: Free area Btu/h input rating Minimum free area required for each opening Horizontal duct Vertical duct or opening to Round duct (2,000 Btu/h) outside (4,000 Btu/h) (4,000 Btu/h) 120,000 7 in. (18 cm) 60 in. (387 cm 30 in. (193 cm 130,000 7 in.
Page 42: Ventilated Combustion Air
Ventilated combustion air The ventilated attic space or a crawl space from which the combustion air is taken must comply with the requirements specified in Combustion air source from outdoors in this manual or in Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 (latest edition).
Page 43: Start-Up And Adjustments
WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation: 1.
Page 44: Removing Nox Screens (Lo-Nox Models Only)
When the gas supply is initially connected to the furnace, the gas piping may be full of air. In order to purge this air, loosen the ground union until you detect the odor of gas. When gas is detected, immediately retighten the ground union and check for leaks. Allow 5 min for any gas to dissipate before continuing with the start-up procedure.
Page 45: Calculating The Furnace Input (Natural Gas)
b. After this warm up, the ignition module energizes (opens) the main gas valve. c. Approximately 30 s after a flame is established, the supply air blower starts. Important: Burner ignition may not be satisfactory on first startup due to residual air in the gas line or until gas manifold pressure is adjusted.
Page 46 If the clocked rate does not match the input rate from the unit nameplate, follow the steps in Adjusting the manifold gas pressure and input rate. Repeat Step 2 to Step 5 until the correct input is achieved. CAUTION Ensure to relight any gas appliances that were turned off at the start of this input check. Table 9: Gas rate (cu ft/h) at full input Time for one Size of Test Dial...
Page 47: Adjusting The Manifold Gas Pressure And Input Rate
Table 9: Gas rate (cu ft/h) at full input Time for one Size of Test Dial Time for one Size of Test Dial revolution revolution 1 cu ft 2 cu ft 5 cu ft 1 cu ft 2 cu ft 5 cu ft —...
Page 48 Important: The inlet gas pressure operating range table specifies what the minimum and maximum gas line pressures must be for the furnace to operate safely. The gas line pressure must be a minimum of: 7 in. W.C. (1.74 kPA) for natural gas 11 in.
Page 49: Airflow Settings
6. Once the correct BTU (kW) input has been established, turn the gas valve to OFF and turn the electrical supply switch to OFF; then remove the flexible tubing from the gas valve pressure tap and tighten the pressure tap plug using the 3/32 in. (2.4 mm) hex head wrench. 7.
Page 50 Table 12: Default blower speeds Model number Default blower speeds Heat Cool Continuous fan 100C16 Medium low (2) High (5) Low (1) 100C20 Medium (3) High (5) Low (1) 120C16 Medium low (2) High (5) Low (1) 120C20 High (5) Medium high Low (1) 130D20...
Page 51 delay is factory-set to 120 s. The blower-off setting must be long enough to adequately cool the furnace, but not so long that cold air is blown into the heated space. The blower-off timing can be adjusted by positioning the dip switches as shown in Table 13.
Page 52 Table 14: Blower performance CFM - any position (without filter) Model Speed Airflow data (SCFM) external static pressure (in. W.C.) 060A12 High 1375 1325 1300 1275 1225 1200 1175 1125 Medium High 1125 1075 1050 1025 Medium 1025 Medium Low 080B12 High 1425...
Page 53: Safety Controls
Table 14: Blower performance CFM - any position (without filter) Model Speed Airflow data (SCFM) external static pressure (in. W.C.) 120C16 High 2050 2025 1975 1950 1925 1900 1850 1800 Medium High 1850 1800 1775 1750 1700 1675 1625 1600 Medium 1700 1675...
Page 54: Rollout Switch Controls
This unit is equipped with an electrical interlock switch mounted in the blower compartment. This switch interrupts all power at the unit when the panel covering the blower compartment is removed. Electrical supply to this unit is dependent upon the panel that covers the blower compartment being in place and correctly positioned.
Page 55: Limit Controls
Limit controls There is a high temperature limit control located on the furnace vestibule panel. This is an automatic reset control that provides over temperature protection due to reduced airflow. This may be caused by the following: • A dirty filter •...
Page 56: Hot Surface Ignition System
A momentary loss of gas supply, flame blowout, or a faulty flame probe circuit results in a disruption in the flame and is sensed within 1 s. The gas valve de-energizes and the control begins a recycle operation. A normal ignition sequence begins after a 15 s inter-purge. If during the five recycles the gas supply does not return, or the fault condition is not corrected, the ignition control locks out for 60 min.
Page 57: Troubleshooting
Troubleshooting Make the following visual checks before doing the detailed troubleshooting outlined in the : Check to see that the power to the furnace and the ignition control module is on. Check if the manual shut-off valves in the gas line to the furnace are open. Make sure all wiring connections are secure.
Page 58 3 RED FLASHES: This indicates the pressure switch contacts are open when they should be closed. Check for faulty inducer, blocked vent pipe, broken pressure switch hose, disconnected pressure switch or inducer wires or faulty pressure switch. 4 RED FLASHES: This indicates that the main limit switch has opened its normally closed contacts. The control operates the supply air blower and inducer while the open limit condition exists.
Page 59: Diagnostic Fault Code Storage And Retrieval
SOFT LOCKOUT: This control includes a soft lockout that resets automatically after 1 h. This provides protection to an unoccupied structure if a temporary condition exists causing a furnace malfunction. An example of this is a temporary interruption in gas supply that would prevent the furnace from lighting.
Page 60: Replacement Parts List
Replacement parts list Description Motor MOTOR, DIRECT DRIVE BLOWER BLOWER, COMBUSTION Electrical SWITCH, LIMIT CONTROL, FURNACE IGNITER SENSOR, FLAME SWITCH, PRESSURE SWITCH, DOOR TRANSFORMER VALVE, GAS CONTROL, TEMPERATURE Air moving HOUSING, BLOWER HOUSING, BLOWER with WHEEL WHEEL, BLOWER Fabricated parts BURNER, MAIN GAS BRACKET, IGNITER SHELF, BLOWER...
Page 61: Replacement Part Contact Information
Description FERRULE (Three required) GROMMET (Three required) MOTOR MOUNT TUBING, SILICON DIAGRAM, WIRING KNOB, QUARTER TURN (Four required) This is a generic parts list. To request a complete parts list, refer to the contact information below: Replacement part contact information •...
Page 62: Wiring Diagram
Wiring diagram Installation Manual: Y81E Single-Stage Standard ECM Residential Gas Furnaces (Non-condensing Multi- position Standard and Low NOx) Johnson Controls Ducted Systems...
Page 63: Start-Up Sheet
Start-up sheet Installation Manual: Y81E Single-Stage Standard ECM Residential Gas Furnaces (Non-condensing Multi- position Standard and Low NOx) Johnson Controls Ducted Systems...

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