Installation manual

ManualsBrandsYork ManualsFurnace92% GY 9 (Upflow)

035-17736-003 Rev. A (0504)

HIGH EFFICIENCY

TUBULAR HEAT EXCHANGER SERIES

MODELS: 92% GF9 / GM9 / GY9 (Upflow)

60 - 120 MBH INPUT

(17.6 - 35.1 KW) INPUT

INSTALLATION MANUAL

EFFICIENCY

RATING

CERTIFIED

This product was manufactured

in a plant whose quality system

is certified/registered as being

in conformity with ISO 9001.

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.

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.

TABLE OF CONTENTS

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TWINNING AND STAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

COMBUSTION AIR AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . .10

CONDENSATE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

START-UP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .18

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

LIST OF FIGURES

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Furnace Base Rectangular Blockoff Panel . . . . . . . . . . . . . . . . . . . . . 5

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Line Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Heating and Cooling Thermostat Connections . . . . . . . . . . . . . . . . . . 8

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Typical Twinned Furnace Application . . . . . . . . . . . . . . . . . . . . . . . . . 9

Single Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 10

Two-Stage Twinning Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 10

Home Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Termination Configuration - 1 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Termination Configuration - 2 Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Termination Configuration - 2 Pipe Basement . . . . . . . . . . . . . . . . . .13

Double Horizontal Sealed Combustion Air and Vent Termination . . .14

Double Vertical Sealed Combustion Air and Vent Termination . . . . .14

External Horizontal Vent Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Sealed Combustion Air Intake Connection and Vent Connection . . .14

Combustion Airflow Path Through The Furnace Casing to the

Burner Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Outside and Ambient Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . .16

Attic and Crawl Space Combustion Air Termination . . . . . . . . . . . . . .17

Condensate Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Pressure Switch Tube Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Reading Gas Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Typical Heat/Cool Speed Tap Connections . . . . . . . . . . . . . . . . . . . .21

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

LIST OF TABLES

Unit Clearances to Combustibles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Minimum Duct Sizing For Proper Airflow . . . . . . . . . . . . . . . . . . . . . . . 4

Round Duct Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Filter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

High Altitude Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical and Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Combustion Air Intake and Vent Connection Size at Furnace

(All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Combustion Air Supply and Vent Piping . . . . . . . . . . . . . . . . . . . . . . .11

Estimated Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Free Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Unconfined Space Minimum Area in Square Inch . . . . . . . . . . . . . . .15

Inlet Gas Pressure Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Nominal Manifold Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Blower Performance CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Filter Performance - Pressure Drop Inches W.C. and (kPa) . . . . . . . .22

Summary of content (24 pages)

PAGE 1
INSTALLATION MANUAL HIGH EFFICIENCY TUBULAR HEAT EXCHANGER SERIES EFFICIENCY RATING CERTIFIED MODELS: 92% GF9 / GM9 / GY9 (Upflow) 60 - 120 MBH INPUT (17.6 - 35.1 KW) INPUT This product was manufactured in a plant whose quality system is certified/registered as being in conformity with ISO 9001. TABLE OF CONTENTS SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 2
035-17736-003 Rev. A (0504) SPECIFIC SAFETY RULES AND PRECAUTIONS 1. 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. 2. Install this furnace only in a location and position as specified in SECTION I of these instructions. 3. A gas-fired furnace for installation in a residential garage must be installed as specified in SECTION I of these instructions. 4.
PAGE 3
035-17736-003 Rev. A (0504) Installation in freezing temperatures: 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 furnace. 1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners or other cleaning tools. 2.
PAGE 4
035-17736-003 Rev. A (0504) TABLE 2: Minimum Duct Sizing For Proper Airflow Input Airflow Return1 Rectangular2 Round2 Supply3 Rectangular2 Round2 The duct system must be properly sized to obtain the correct airflow for the furnace size that is being installed.
PAGE 5
035-17736-003 Rev. A (0504) If a matching cooling coil is used, it may be placed directly on the furnace outlet and sealed to prevent leakage. Follow the coil instructions for installing the supply plenum. On all installations without a coil, a removable access panel is recommended in the outlet duct such that smoke or reflected light would be observable inside the casing to indicate the presence of leaks in the heat exchanger. This access cover shall be attached in such a manner as to prevent leaks.
PAGE 6
035-17736-003 Rev. A (0504) SECTION III: FILTERS IMPORTANT: Plan your gas supply before determining the correct gas pipe entry. Use 90-degree service elbow(s), or short nipples and conventional 90-degree elbow(s) to enter through the cabinet access holes. FILTER INSTALLATION All applications require the use of a filter. A high velocity filter and a side return filter rack are provided for field installation on GM9 and GY9 models. GF9 models must have a field-supplied filter and mounting hardware.
PAGE 7
035-17736-003 Rev. A (0504) TABLE 6: High Altitude Conversion Type Of Gas 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 8
035-17736-003 Rev. A (0504) ELECTRICAL POWER CONNECTIONS LOW VOLTAGE CONTROL WIRING CONNECTIONS Field wiring to the unit must be grounded. Electric wires that are field installed shall conform to the temperature limitation for 63°F (35°C) rise wire when installed in accordance with instructions. Refer to Table 7 in these instructions for specific furnace electrical data. Install the field-supplied thermostat by following the instructions that come with the thermostat.
PAGE 9
035-17736-003 Rev. A (0504) SECTION VI: TWINNING AND STAGING NOTE: You can twin two furnaces that have the same integrated control module. Check the part number on the integrated control module. You cannot twin two furnaces that have different integrated control module part numbers. If the part numbers of the two integrated control modules are different they may not communicate with each other so they will not work in a twinning application.
PAGE 10
035-17736-003 Rev. A (0504) Continuous Fan - On a thermostat call for continuous fan (G signal), both furnace blowers will come on at the same time in cooling speed and will stay on until the G signal is removed. FURNACE 2 CONTROL BOARD FURNACE 1 CONTROL BOARD W W G G Continuous Fan - On a thermostat call for continuous fan (G signal), both furnace blowers will come on at the same time in cooling speed and will stay on until the G signal is removed.
PAGE 11
035-17736-003 Rev. A (0504) COMBUSTION AIR/VENT PIPE SIZING 7. The use of flexible connectors or no hub connectors in the vent system is not allowed. This type connection is allowed in the combustion air pipe near the furnace for air conditioning coil accessibility. 8. Sidewall horizontal vent terminals and roof mounted vertical terminals may be field fabricated. Standard PVC/SRD fittings may be used. Terminal configuration must comply as detailed in this section. 9. The minimum vent length is 5 ft.
PAGE 12
035-17736-003 Rev. A (0504) VENT CLEARANCES G V A D V E B L V B X AIR SUPPLY B B I V C F VENT TERMINAL H FIXED CLOSED V V V V V B B M X V AREA WHERE TERMINAL IS NOT PERMITTED K X J FIXED CLOSED OPERABLE FIGURE 12: Home Layout Canadian Installation1 A.Clearance above grade, veranda, porch, deck, or balcony 12 inches (30 cm) 6 inches (15 cm) for applications ≤ 10,000 Btuh (3kW), 12 inches (30 cm) for appliances > 10,000 B.
PAGE 13
035-17736-003 Rev. A (0504) VENT SYSTEM This furnace is certified to be installed with one of two possible vent configurations. 1. Horizontal vent system. This vent system can be installed completely horizontal or combinations of horizontal, vertical, or offset using elbows. 2. Vertical vent system. This vent system can be installed completely vertical or a combination of horizontal, vertical, or offset using elbows. 12” MIN. 12” MIN.
PAGE 14
035-17736-003 Rev. A (0504) COMBUSTION AIR SUPPLY All installations must comply with Section 5.3, Air for Combustion and Ventilation of the National Fuel Gas Code, ANSI Z223.1 or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149.1 or .2 Installation Code - latest editions. VENT This furnace is certified to be installed with one of three possible combustion air intake configurations. 1. COMBUSTION AIR 2” FIGURE 16: Double Horizontal Sealed Combustion Air and Vent Termination 2. 6” 3.
PAGE 15
035-17736-003 Rev. A (0504) Ambient Combustion Air Supply Combustion Air Source From Outdoors This type installation will draw the air required for combustion from within the space surrounding the appliance and from areas or rooms adjacent to the space surrounding the appliance. This may be from within the space in a non-confined location or it may be brought into the furnace area from outdoors through permanent openings or ducts. It is not piped directly into the burner box.
PAGE 16
035-17736-003 Rev. A (0504) SOFFIT VENT VENTILATED ATTIC TOP ABOVE INSULATION OUTLET AIR (a) GAS WATER HEATER FURNACE OPTIONAL INLET (a) AIR SUPPLY OPENINGS AND DUCTS 4. The duct shall terminate within 12 in (30.5 cm) above, and within 24 in (61 cm) horizontally from, the burner level of the appliance having the largest input. GAS VENT GABLE VENT 5. A square or rectangular shaped duct shall only be used when the required free area of the supply opening is 2 2 9 in (58.06 cm ) or larger.
PAGE 17
035-17736-003 Rev. A (0504) 1. 12” MINIMUM BETWEEN BOTTOM OF BELOW AND ANY MATERIAL 2. 3. 12” MIN. Disconnect the condensate drain hose from the induced draft blower discharge. Elevate this hose and fill with water using a funnel. Replace the condensate drain hose and clamps. IMPORTANT: If this procedure is not followed, the unit may not properly drain on initial start up. CONDENSATE DRAIN TERMINATION DO NOT terminate condensate drain in a chimney, or where the drain line may freeze.
PAGE 18
035-17736-003 Rev. A (0504) 4. Blockage of condensate drain piping. LIMIT CONTROLS There is high temperature limit control located on the furnace vestibule panel near the gas valve. This is an automatic reset control that provides over temperature protection due to reduced airflow, that may be caused by a dirty filter, or if the indoor fan motor should fail. The control module will lockout if the limit trips 5 consecutive times within a single call for heat.
PAGE 19
035-17736-003 Rev. A (0504) 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/m3), times 2 cubic ft. (0.056 m) of gas measured at 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. (0.056 m) of gas from the gas meter.
PAGE 20
035-17736-003 Rev. A (0504) IMPORTANT: The cap for the pressure regulator must be removed entirely to gain access to the adjustment screw. Loosening or tightening the cap does not adjust the flow of gas. Be sure to relight any gas appliances that were turned off at the start of this input check. 1. Refer to Figure 25 for location of pressure regulator adjustment cap and adjustment screw on main gas valve. 2.
PAGE 21
035-17736-003 Rev. A (0504) WITH BURNER BOX COVER IN PLACE WITH BURNER BOX COVER REMOVED BURNER BOX PRESSURE REFERENCE HOSE BURNER BOX PRESSURE REFERENCE HOSE (not used) TEE FITTING BURNER BOX WITH COVER REMOVED BURNER BOX WITH COVER OUTLET PRESSURE TAP 6 5 4 3 2 1 0 1 2 3 4 5 6 GAS VALVE U-TUBE MANOMETER 6 5 4 3 2 1 0 1 2 3 4 5 6 3.5 IN WATER COLUMN GAS PRESSURE SHOWN OUTLET PRESSURE TAP U-TUBE MANOMETER GAS VALVE 3.
PAGE 22
035-17736-003 Rev. A (0504) TABLE 15: Blower Performance CFM AIRFLOW WITH BOTTOM OR ONE SIDE RETURN MODELS Input/ Airflow/cabinet 80/1200/B 60/1200/B 100/1600/C 80/1600/C 120/2000/D EXTERNAL STATIC PRESSURE, INCHES W.C. (kPa) Speed Tap 0.1 (0.025) 0.2 (0.050) 0.3 (0.075) 0.4 (0.099) 0.5 (0.124) 0.6 (0.149) 0.7 (0.174) 0.8 (0.199) 0.9 (0.224) 1.0 (0.
PAGE 23
035-17736-003 Rev. A (0504) APPLYING FILTER PRESSURE DROP TO DETERMINE SYSTEM AIRFLOW To determine the approximate airflow of the unit with a filter in place, follow the steps below: Subtract the total system static from 0.50 w.c. (125 Pa) and divide this difference by the difference in ESP values in the table, 0.60 w.c. (150 Pa) - 0.50 w.c. (125 Pa), to obtain a percentage. (0.58 - 0.50) / (0.60 - 0.50) = 0.8 1. Select the filter type.
PAGE 24
SECTION XI: WIRING DIAGRAM FIGURE 28: Wiring Diagram Subject to change without notice. Printed in U.S.A. Copyright © by York International Corp. 2004. All rights reserved. Unitary Product Group 035-17736-003 Rev. A (0504) Supersedes: 035-17736-002 Rev.