GKS9 GAS-FIRED WARM AIR FURNACE INSTALLATION INSTRUCTIONS 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 / National Standard of Canada ANSI Z21.47·CSA-2.
Table of Contents I. Component Identification ............................................................................................................................................... 5 II. Safety .............................................................................................................................................................................. 6 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS ..........................................................................................
Table of Contents XIV. Startup Procedure & Adjustment ............................................................................................................................. 29 HEAT ANTICIPATOR SETTING ............................................................................................................................................... 29 DRAIN TRAP PRIMING ..........................................................................................................................................
TO THE INSTALLER WARNING Before installing this unit, please read this manual thoroughly to familiarize yourself with specific items which must be adhered to, including but not limited to: unit maximum external static pressure, gas pressures, BTU input rating, proper electrical connections, circulating air temperature rise, minimum or maximum CFM, and motor speed connections.
I.
If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace. Return any old or new controls to their containers before touching any ungrounded object. II. SAFETY Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace.
• • NOTE: Do not connect the temporary duct directly to the furnace. The duct must be sized according to the instructions under Section V, Combustion and Ventilation Air Requirements, Section 5.3.3. The furnace heat exchanger, components, duct system, air filters and evaporator coils are thoroughly cleaned following final construction clean up. All furnace operating conditions (including ignition, input rate, temperature rise and venting) are verified according to these installation instructions. IV.
• • • • 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 typical construction, the clearance between the door and door frame is usually adequate to satisfy this ventilation requirement. cements and glues antistatic fabric softeners for clothes dryers and masonry acid washing materials Seal off a non-direct vent furnace if it is installed near an area frequently contaminated by any of the above substances.
3. Smoke from a fireplace will not draw up the chimney. 4. Flue gases that will not draw up the appliance vent pipe. If this furnace is to be installed in the same space with other gas appliances, such as a water heater, ensure there is an adequate supply of combustion and ventilation air for the other appliances. Refer to the latest edition of the National Fuel Gas Code ANSI Z223.1 (Section 5.3), or CSA B149.1-05 Installation Codes (Sections 7.2, 7.3, or 7.
5.3.3 Equipment Located in Confined Spaces: Chimney or Gas Vent Ventilation louvers (each end of attic) (a) All Air from Inside the Building: The confined space shall be provided with two permanent openings communicating directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an unconfined space. The total input of all gas utilization equipment installed in the combined space shall be considered in making this determination.
FURNACE MUST BE LEVEL 5.3.4 Specially Engineered Installations: FROM END TO END ALTERNATE VENT/FLUE The requirements of 5.3.3 shall not necessarily govern when special engineering, approved by the authority having jurisdiction, provides an adequate supply of air for combustion, ventilation, and dilution of flue gases. FURNACE MUST BE LEVEL LOCATION OR SLIGHTLY TILTED FORWARD WITH THE DOORS 0" - 3/4" BELOW THE BACK PANEL 5.3.5 Louvers and Grilles: 4 3/4" MINIMUM In calculating free area in 5.3.
VIII. PROPANE GAS /HIGH ALTITUDE INSTALLATIONS WARNING POSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF THE CORRECT CONVERSION KITS ARE NOT INSTALLED. THE APPROPRIATE KITS MUST BE APPLIED TO ENSURE SAFE AND PROPER FURNACE OPERATION. ALL 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.
A condensing gas furnace achieves its high level of efficiency by extracting almost all of the heat from the products of combustion and cooling them to the point where condensation takes place. Because of the relatively low flue gas temperature and water condensation requirements, PVC pipe is used as venting material.
• • 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.
3 REMOVE PIPE WARNING EDGES OF SHEET METAL HOLES MAY BE SHARP. PRECAUTION WHEN REMOVING HOLE PLUGS. 1 REMOVE 4 SCREWS USE GLOVES AS A 5 REMOVE AND RELOCATE ALTERNATE VENT/FLUE LOCATION The alternate vent/flue location is the large hole directly in line with the induced draft blower outlet. To use the alternate vent/flue location refer to the following steps, the “Vent/Flue Pipe Cuts” figure, and the “Alternate Vent/Flue Location” figure. 1.
TEE (OPTIONAL) Direct Vent (2 - Pipe) and Non-Direct Vent (1 - Pipe) 6 Maximum Allowable Length of Vent/Flue Pipe & Combustion Air Pipe(ft) (1) (2) Pipe Unit Input Size (4) (Btu) (in.
TEE (OPTIONAL) 12" MIN. VENT/FLUE VENT/FLUE TEE (OPTIONAL) or 90° ELBOW TURNED DOWN COMBUSTION AIR INTAKE 12" MIN. 12" MIN. ABOVE HIGHEST ANTICIPATED SNOW LEVEL SCREEN OPTIONAL 12" MIN. TO ROOF OR HIGHEST ANTICIPATED SNOW LEVEL Horizontal Termination (Single Pipe) Above Highest Anticipated Snow Level Vertical Terminations (Dual Pipe) DIRECT VENT (DUAL PIPE) PIPING Direct vent installations require both a combustion air intake and a vent/flue pipe.
VENT/INTAKE TERMINATIONS FOR INSTALLATION OF MULTIPLE DIRECT VENT FURNACES 90° MEDIUM RADIUS ELBOW 24" MAX If more than one direct vent furnace is to be installed vertically through a common roof top, maintain the same minimum clearances between the exhaust vent and air intake terminations of adjacent units as with the exhaust vent and air intake terminations of a single unit.
Follow the bullets listed below when installing the drain system. Refer to the following sections for specific details concerning furnace drain trap installation and drain hose hook ups. • The drain trap supplied with the furnace must be used. • The drain line between furnace and drain location must be constructed of 3/4” PVC. • The drain line between furnace and drain location must maintain a 1/4 inch per foot downward slope toward the drain.
• If an air conditioning coil is installed with the furnace, a common drain may be used. An open tee must be installed in the drain line, near the cooling coil, to relieve positive air pressure from the coil’s plenum. This is necessary to prohibit any interference with the function of the furnace’s drain trap. 1. Remove the rubber plug/cap from the front cover drain port (right or left side, depending on the intended drain trap mounting). 2. Secure Hose A to front cover drain port with a red hose clamp.
Cabinet Width (inches) 17 1/2 21 24 1/2 Models (kBTU_Tons) ALTERNATE VENT/FLUE DRAIN HOSE CONNECTIONS "X" Length to Cut From Long End of Hose B 045_30 7 inches 070_30 070_40 3 1/2 inches 090_40 090_50 None 115_50 6. Insert short end of each Tube 2 through side panel grommet holes. Secure tubes to Hose A and Hose B with green hose clamps. Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding.
5. Insert Tube 1 into rubber elbow drain port and secure with a silver hose clamp. Angle tube outward toward front of furnace. 6. Cut 17 7/8 inches from the long end of Hose B and discard. 7. Secure remaining end of Hose B to exposed end of Tube 1 with a green hose clamp. Route hose toward right side panel grommet holes. 8. Insert short end of one Tube 2 through rear right side panel grommet drain hole. Secure tube to Hose A with a green hose clamp. 9.
6. Insert approximately one inch of each Tube 2 through left side panel grommet hole. Secure tubes to Hose A and Hose B with a green hose clamps. NOTE: Tube must reach bottom of trap. Ensure hoses and tubes maintain a downward slope for proper drainage and that they are not kinked or binding. WIRING HARNESS 7. A “Blocked Drain Kit” MUST be installed for left side down installations. The kit includes a front cover pressure switch that must be used to protect against a blocked drain condition.
VOLT HUMIDIFIER * * * * ALTERNATE JUNCTION BOX LOCATION * * * STANDARD JUNCTION BOX LOCATION 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 switch terminal.
Refer to the National Fuel Gas Code, ANSI Z223.1, and information provided by the gas supplier to determine the proper orifice size. A different pressure switch may be required at high altitude regardless of the BTU/ft3 content of the fuel used. Contact your distributor for a tabular listing of appropriate altitude ranges and corresponding manufacturer’s pressure switch kits.
• Connect the furnace to the building piping by one of the following methods: – – Rigid metallic pipe and fittings. Semi-rigid metallic tubing and metallic fittings. Aluminum alloy tubing must not be used in exterior locations. In order to seal the grommet cabinet penetration, rigid pipe must be used to reach the outside of the cabinet. A semi-rigid connector to the gas piping may be used from there. • Use listed gas appliance connectors in accordance with their instructions.
A gas detecting warning system is the only reliable way to detect a propane gas leak. Rust can reduce the level of odorant in propane gas. Do not rely on your sense of smell. Contact a local propane gas supplier about installing a gas detecting warning system. If the presence of gas is suspected, follow the instructions on Page 4 of this manual. All propane gas equipment must conform to the safety standards of the National Board of Fire Underwriters, NBFU Manual 58.
Example: static reading from return duct = -.1" w.c. static reading from supply duct = .3" w.c. total external static pressure on this system = .4" w.c. CUT USING TIN SNIPS PRESS OUT BY HAND NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace, the readings must also include theses components, as shown in the following drawing. 4.
Refer to Minimum Filter Area tables to determine filter area requirements. COOLING AIRFLOW REQUIREMENT (CFM) Input__Airflow 600 800 1000 1200 1400 1600 Filters must be installed in either the central return register or in the return air duct work. XIV.
2. Remove the burner compartment door and move the furnace gas valve manual control to the OFF position. 3. Close the manual gas shutoff valve external to the furnace. 4. Replace the burner compartment door. 1. Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace. 2. Turn OFF all electrical power to the system. 3. Inlet pressure tap connections: a. Honeywell VR8215 Valve: Remove the inlet pressure boss plug. Install an 1/8” NPT hose barb fitting into the outlet pressure tap. b.
GAS INPUT RATE MEASUREMENT (NATURAL GAS ONLY) WARNING The gas input rate to the furnace must never be greater than that specified on the unit rating plate. To measure natural gas input using the gas meter, use the following procedure. HIGH VOLTAGE ! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE , PERSONAL INJURY OR DEATH. This valve is shipped from the factory with the regulator preset (see control label).
HEAT EXCHANGER RADIATION "LINE OF SIGHT" Circulator Blower Speeds Low Red Medium Low Orange Medium Blue High Black Common/Neutral White SUPPLY AIR T SUPPLY RISE = TSUPPLY - T RE TURN XV. NORMAL SEQUENCE OF OPERATION T RETURN POWER UP The normal power up sequence is as follows: • 115 VAC power applied to furnace. RETURN AIR Temperature Rise Measurement 3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise.
• R and Y thermostat contacts open, completing the call for cool. • • Outdoor fan and compressor are de-energized. • Furnace awaits next call from thermostat. PRIMARY LIMIT The primary limit control is located on the partition panel and monitors heat exchanger compartment temperatures. It is a normallyclosed (electrically), automatic reset, temperature-activated sensor. The limit guards against the overheating as a result of insufficient conditioned air passing over the heat exchanger.
3. Service integrated control module or connecting wiring following the discharge process in step 2. Use caution not to recharge your body with static electricity; (i.e., do not move or shuffle your feet, do not touch ungrounded objects, etc.). If you come in contact with an ungrounded object, repeat step 2 before touching control or wires. 4. Discharge your body to ground before removing a new control from its container. Follow steps 1 through 3 if installing the control on a furnace.
BURNERS Visually inspect the burner flames periodically during the heating season. Turn on the furnace at the thermostat and allow several minutes for flames to stabilize, since any dislodged dust will alter the flames normal appearance. Flames should be stable, quiet, soft, and blue (dust may cause orange tips but they must not be yellow). They should extend directly outward from the burners without curling, floating, or lifting off. Flames must not impinge on the sides of the heat exchanger firing tubes.
TROUBLESHOOTING CHART Symptoms of Abnormal Operation Associated LED Code22 • Furnace fails to operate. • Integrated control module diagnostic LED provides no signal. NONE • LED is Steady On. ON Fault Description(s) Possible Causes Corrective Action Cautions and Notes • No 115 volt power to • Manual disconnect switch furnace, or no 24 volt OFF, door switch open, or power to integrated 24 volt wires improperly control module. connected or loose.
TROUBLESHOOTING CHART Symptoms of Abnormal Operation Associated LED Code2 Fault Description(s) Possible Causes Corrective Action Cautions and Notes • Circulator blower runs continuously. No furnace 4 operation. • Integrated control 4 FLASHES module diagnostic LED is flashing FOUR (4) flashes. • Primary or auxiliary limit circuit is open. • Faulty primary or auxiliary limit switch. • Insufficient conditioned air over the heat exchanger.
BLOWER PERFORMANCE (CFM & Temperature Rise vs. External Static Pressure) ( 1. 2. 3. 4. 5. 6 7. EXTERNAL STATIC PRESSURE (Inches Water Column) Tons AC Model ) Heating Speed As Shipped Motor Speed at 0.5" ESP 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM HIGH 3.0 1352 --- 1318 --- 1260 --- 1202 --- 1128 --- 1044 955 853 GKS90453BX* MED 2.5 1214 --- 1172 --- 1123 --- 1064 --- 1012 --- 938 859 741 (LOW) MED-LO 2.
GKS9 WIRING DIAGRAM BLOWER COMPARTMENT DOOR SWITCH (OPEN WHEN DOOR OPEN) 24 VAC HUMIDIFIER INTEGRATED CONTROL MODULE HUMIDIFIER TR (6) GND GND (8) C2 MVC (9) C G R BK 1 5 4 9 8 7 12 11 10 24V THERMOSTAT CONNECTIONS 2 C ID BLOWER PRESSURE SWITCH OPTIONAL FRONT COVER PRESSURE SWITCH BK 3 6 M1 MV(12) C W Y FUSE G PS (10) NO C PSO (4) TO MICRO Y HLI (7) W HLO (1) R RO2 (11) RO1 (5) TH (3) HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT.
SPECIAL INSTRUCTIONS FOR PRODUCTS INSTALLED IN THE STATE OF MASSACHUSETTS 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 with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. 4. INSPECTION.
