USER’S INFORMATION, MAINTENANCE AND SERVICE MANUAL
MODELS: G8C/ GF8
(Single Stage Multi-Position)
EFFICIENCY
RATING
CERTIFIED
This product was manufactured in a plant whose quality system is certified/registered as being in conformity with ISO 9001.
TABLE OF CONTENTS
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DESCRIPTION (50-125 MBH INPUT MODELS) . . . . . . . . . . . . . . . 2 DESCRIPTION (150 MBH INPUT MODELS) . . . . . . . . . . . . . . . . . . 2 INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . . 4 START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . 4
Read the Instructions Below Before Trying to Start the Furnace . . 4 Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blower Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . 6
SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . .6 FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Intermittent Blower - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .8
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL . . . . . .11
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . .11 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
CONTACT INFORMATION
•Go to website at www.york.com click on “contact”, then click on “contact form” and follow the instructions.
•Contact us by mail:
York International
Consumer Relations
5005 York Drive
Norman, OK 73069
The manufacturer recommends that the user read all sections of this manual and keep the manual for future reference.
FIRE OR EXPLOSION HAZARD - Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
—Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
—WHAT TO DO IF YOU SMELL GAS:
•Do not try to light any appliance.
•Do not touch any electrical switch; do not use any phone (including cell phone) in your building.
•Leave the building immediately.
•Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
•If you cannot reach your gas supplier, call the fire department.
—Installation and service must be performed by a qualified installer, service agency or the gas supplier.
SECTION I: USER’S INFORMATION
SAFETY
1.The furnace area must be kept clear and free of combustible materials, gasoline and other flammable vapors and liquids.
2.Insulating materials may be combustible. The furnace must be kept free and clear of insulating materials. The furnace area must be examined when installed in an attic or other insulated space or when insulation is added to be sure that the insulation material has been kept away from the furnace.
3.The furnace needs air for combustion in order to operate properly and safely. Do not block or obstruct air openings on the furnace, air openings to the area where the furnace is installed, or spaces around the furnace.
4.Follow the instructions exactly as shown on the OPERATING INSTRUCTION LABEL or the Start-up and Shutdown Instructions on Page 4 of this manual when lighting the furnace or turning the furnace off.
5.Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply.
6.Do not use this furnace if any part has been under water. A flooddamaged furnace is extremely dangerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to inspect the furnace and replace all gas controls, control system parts, electrical parts that have been wet or the furnace if deemed necessary.
035-19992-001 Rev. A (0404)
035-19992-001 Rev. A (0404)
7.NEVER…Store flammable materials of any kind near your fur-
nace. Gasoline, solvents, and other volatile liquids should be stored only in approved containers outside your home. These materials vaporize easily and are extremely dangerous.
8.NEVER…Store cleaning materials near your furnace. Materials such as bleaches, detergents, powdered cleansers, etc., can cause corrosion of the heat exchangers.
9.NEVER…Use the area around your furnace as a storage area for items which could block the normal flow of air. This flow of air is required for ventilation of the various furnace components.
FIRE OR EXPLOSION HAZARD
This furnace is designed and approved for use with Natural Gas and (LP) Propane Gas ONLY. DO NOT BURN ANY LIQUID FUEL OR SOLID FUEL IN THIS FURNACE.
Burning any unapproved fuel will result in damage to the furnace heat exchanger, which could result in Fire, Personal Injury, and/or Property Damage.
DESCRIPTION (50-125 MBH INPUT MODELS)
This furnace can be installed in the upflow, downflow, or horizontal left or right position. Figure 2 shows a typical model in the downflow position and Figure 1 shows a typical model in the upflow position. The furnace may also lie on either side in a horizontal position. The furnace is equipped with an induced-draft vent blower and atmospheric burners. Combustion air is taken from the space or area in which the furnace is installed and drawn into the burners through the louvers in the front panel. Flue gas is drawn from the heat exchanger by the vent blower and discharged through the flue pipe to the outside atmosphere.
This is a forced air furnace. The furnace circulating air blower draws cool air from the house, passes it over the hot furnace heat exchanger and circulates the warmed air through the ductwork to the house.
The furnace is equipped with the controls necessary for proper operation. The various components referred to in this manual and on the furnace nameplate are identified in Figures 1, 2 & 3.
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PRESSURE |
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SWITCH |
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VENT |
GAS |
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VALVE |
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BLOWER |
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HOT |
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DIRT |
SURFACE |
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LEG |
IGNITOR |
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ROLL-OUT |
BURNERS |
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SWITCH |
ROLL-OUT |
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SWITCHES |
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BLOWER |
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DOOR |
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SWITCH |
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FURNACE |
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CONTROL |
FIGURE 1: Component Locations - Upflow (50 - 125 MBH Models)
VENT
FURNACE
CONTROL VENT PIPE TRANSITION
BLOWER |
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DOOR |
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SWITCH |
3” DIAMETER |
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VENT PIPE |
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ROLL-OUT |
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SWITCHES |
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BURNERS |
ROLL-OUT |
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HOT |
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SWITCH |
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SURFACE |
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IGNITOR |
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GAS |
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VALVE |
VENT |
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PRESSURE |
BLOWER |
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SWITCH |
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FIGURE 2: Component Locations - Downflow (50 - 125 MBH Models)
DESCRIPTION (150 MBH INPUT MODELS)
This furnace can be installed in the upflow or horizontal left or right position. Figure 3 shows the 150 MBH input model. The furnace may also lie on either side in a horizontal position. This furnace is not approved to be installed in a downflow application. The furnace is equipped with an induced-draft vent blower and atmospheric burners. Combustion air is taken from the space or area in which the furnace is installed and drawn into the burners through the louvers in the front panel. Flue gas is drawn from the heat exchanger by the vent blower and discharged through the flue pipe to the outside atmosphere.
This is a forced air furnace. The furnace circulating air blower draws cool air from the house, passes it over the hot furnace heat exchanger and circulates the warmed air through the ductwork to the house.
The furnace is equipped with the controls necessary for proper operation. The various components referred to in this manual and on the furnace nameplate are identified in Figure 3.
VENT |
PRESSURE |
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SWITCH |
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BLOWER |
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GAS |
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VALVE |
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ROLL-OUT |
HOT |
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SWITCH |
SURFACE |
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IGNITOR |
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BURNERS |
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ROLL-OUT |
BLOWER |
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SWITCHES |
DOOR |
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SWITCH |
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FURNACE |
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CONTROL |
FIGURE 3: Component Locations - Upflow (150 MBH Models)
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Unitary Products Group |
035-19992-001 Rev. A (0404)
INSTRUCTIONS FOR EXAMINING THE FURNACE INSTALLATION
It is the owner’s responsibility to ensure that an annual inspection of the entire heating portion of the unit is made by a qualified service agency. Examine the furnace as outlined below in steps “1 - 6” before each heating season. Use Figures 5 & 6 for visual reference.
1.Examine the heat exchanger, vent/combustion air piping, vent connectors and chimney to be sure they are clear and free of obstructions.
2.Examine the vent pipe making sure it is firmly in place, that it slopes slightly upward and is physically sound without holes and all of the connections are secure.
3.Examine the return-air duct connections to make sure they are physically sound, sealed to the furnace casing, and the ducts terminate outside the space containing the furnace.
4.Examine the furnace casing making sure the physical support is sound without sagging, cracks or gaps. Examine the furnace base making sure it is physically sound without cracks, gaps or sagging and has a good seal.
5.Examine the furnace casing for obvious signs of deterioration.
6.Examine the burner flames to make sure they are in good adjustment. Refer to the pictorial sketch shown in Figure 4 as a comparison to the actual flame.
BLUE CONE PORTION OF FLAME SHOULD
ENTER HEAT EXCHANGER TUBE
FIGURE 4: Burner Flame Drawing
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5 EXAMINE ENTIRE |
EXAMINE EXTERNAL |
FURNACE CASING |
VENT PIPE |
SHOWN IN ALL |
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DRAWINGS |
4 EXAMINE |
6 REMOVE |
PANEL |
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FURNACE |
TO EXAMINE |
CASING |
BURNER |
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FLAMES |
3 EXAMINE RETURN AIR DUCT CONNECTION
1 EXTERNAL HEAT EXCHANGER INTERNAL VENT COMBUSTION AIR PIPE. MUST REMOVE PANEL TO EXAMINE.
6 REMOVE |
4 EXAMINE |
PANEL |
FURNACE |
TO EXAMINE |
CASING |
BURNER |
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FLAMES |
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3EXAMINE RETURN AIR DUCT CONNECTION
FIGURE 5: Furnace Examination Checkpoints - Upflow
3 EXAMINE RETURN |
EXAMINE |
5 EXAMINE ENTIRE |
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AIR DUCT |
EXTERNAL |
FURNACE CASING |
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VENT PIPE |
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CONNECTION |
SHOWN IN ALL |
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DRAWINGS |
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1 EXTERNAL HEAT EXCHANGER INTERNAL VENT COMBUSTION AIR PIPE. MUST REMOVE PANEL TO EXAMINE.
3EXAMINE RETURN AIR DUCT CONNECTION
4 EXAMINE |
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4 EXAMINE |
FURNACE |
6 REMOVE |
6 REMOVE |
FURNACE |
CASING |
CASING |
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PANEL |
PANEL |
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TO EXAMINE |
TO EXAMINE |
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BURNER |
BURNER |
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FLAMES |
FLAMES |
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FIGURE 6: Furnace Examination Checkpoints - Downflow
Unitary Products Group |
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035-19992-001 Rev. A (0404)
HOW YOUR GAS FURNACE WORKS
Your furnace is a very easy appliance to take for granted. Season after season, it sits there in your home, keeping you warm and comfortable. For this reason, you may never have given much thought to the way your furnace operates. In order to get the safest and most efficient operation from your furnace, you should understand how your furnace does its job.
When you set your thermostat to provide more heat in your home, you are starting the heating cycle of the furnace. First, the inducer motor starts to purge the heat exchanger of any remaining gases. Next, the hot surface ignitor glows and after a warm-up period the gas valve opens and ignition occurs. A short time later, the blower starts and distributes the warm air throughout the home. When the temperature setting on your thermostat is reached, the gas valve closes, the main burners are turned off, and the blower continues to run until the remaining warm air in the system is distributed. When the blower stops, the heating cycle has ended.
START-UP AND SHUTDOWN INSTRUCTIONS
Read the Instructions Below Before Trying to Start the Furnace
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, and/or loss of life.
A.This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
B.BEFORE OPERATING; smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.
C.Use only your hand to push the gas control switch to the “on” position. Never use tools. If the switch will not operate by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D.Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.
Operating Instructions:
1.STOP! Read the safety information above.
2.Set the thermostat to the lowest setting.
3.Turn off all electric power to the appliance.
4.Remove burner door.
5.Move gas control switch to the “OFF” position. Do not force.
6.Wait five (5) minutes to clear out any gas. If you then smell gas, STOP! Follow “B” in the safety information above. If you don’t smell gas, go to next step.
7.Move gas control switch to the “ON” position. Do not force.
8.Replace burner door.
9.Turn on all electric power to the appliance.
10.Set thermostat to the desired setting. Burner will light, which may take 30-60 seconds.
11.After three (3) trials for ignition, if the appliance will not operate follow the instructions, “TO TURN OFF THE APPLIANCE” and call your service technician or gas supplier.
To Turn Off the Appliance:
1.Set the thermostat to lowest setting.
2.Turn off all electric power to the appliance if service is to be performed.
3.Remove burner access panel.
4.Move gas control switch to the “OFF” position.
5.Replace burner access panel.
Should overheating occur, or the gas valve fail to shut off, turn the external manual gas valve in the gas supply line to the furnace to the “off” position and let the furnace cool off before shutting off the electrical power supply. Refer to Figure 8.
OUTLET
PRESSURE
PORT
INLET
WRENCH BOSS
INLET PRESSURE PORT
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VENT PORT |
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OUTLET |
OFF |
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ON |
MAIN REGULATOR |
ON/OFF SWITCH |
ADJUSTMENT |
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(Shown in ON position) |
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FIGURE 7: Gas Valve - White Rodgers
EXTERNAL MANUAL
SHUTOFF VALVE
TO GAS |
TO GAS |
SUPPLY |
SUPPLY |
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DRIP |
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GROUNDED JOINT UNION |
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MAY BE INSTALLED |
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LEG |
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INSIDE OR OUTSIDE UNIT. |
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FIGURE 8: Gas Piping
NOTE: The spring-loaded safety cut-off switch, mounted under the blower deck will automatically cut off the electrical power supply to the furnace when the blower panel is removed. As a safety precaution, all electrical power and the gas supply to the furnace should be turned off before servicing.
FURNACE USER MAINTENANCE
Before proceeding, be sure the area is well ventilated. Turn the thermostat OFF. If the blower is running, wait until it stops automatically. Turn OFF the gas and electrical power supplies to the furnace. Check all metal parts and surfaces to be sure they have cooled to room temperature before you begin.
Every time the filters are changed the following items should be visually inspected:
•Check combustion air and vent pipe for blockage or leakage.
•Check all components to be sure they are in good condition and that there are no obvious signs of deterioration.
•Check the drain lines to make sure there are no cracks or leaks.
•Check for dirt or lint on any surfaces or on components. Do not try to clean any of the surfaces or components. Cleaning of the furnace and its components must be done by a qualified service professional.
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Unitary Products Group |
035-19992-001 Rev. A (0404)
If, during the inspection of your furnace, you find any of the following conditions:
•Excessive amounts of dust and lint on components.
•Damaged or deteriorated components or surfaces.
•Leaks or blockage in the vent pipe passages.
•Water on any surface inside or outside of the furnace.
Do not operate the furnace, call a certified dealer / servicing contractor to check and / or clean your furnace, or for more information if you have questions about the operation of your furnace.
If all components appear to be in good operating condition, replace the front panels. Turn ON the gas and electrical power supplies to the furnace, and set thermostat to the desired temperature.
Air Filters
Dirty filters greatly restrict the flow of air and may cause damage to the moving parts of the furnace. If the filters become clogged the heat exchangers and blower motor could overheat resulting in a potentially dangerous situation.
The filters should be checked every 3 months. On new construction, check the filters every week for the first four weeks and every three weeks after that, especially if the indoor fan is running continuously. When replacing the filter(s) you must use filters that are the same size as those recommended in Table 1. Use the following procedure to determine the filter size. Never operate your furnace without a suitable air filter.
1.Measure the furnace width. Use the following measurements to determine the cabinet size.
•A 17-1/2” wide cabinet is a “B” cabinet.
•A 21” wide cabinet is a “C” cabinet.
•A 24-1/2” wide cabinet is a “D” cabinet.
2.Locate the cabinet size on Table 1, then determine whether you have a bottom, side or top return using the following method.
a.If the return air filters are on the left or right side of the furnace it is a side return. Refer to Figure 11.
b.If the air filter is on the bottom of the furnace then you have a bottom return. Refer to Figure 12 or for horizontal applications refer to Figure 9.
c.If the air filters are on the bottom and the side of the furnace then you have a bottom and side return. You must replace both air filters. Brackets with the number two (2) before the filter size requires 2 filters. Refer to Figures 11 & 12.
d.If the air filters are on both sides of the furnace then you have a (2) sided return. You must replace both air filters.
e.If the air filters are in the return air plenum, above the furnace then you have a top return (Downflow Furnace). Refer to Figure 10.
3.After you determine the cabinet size and what return configuration you have, look up the recommended filter size from Table 1. You must replace the air filters with the same size as recommended.
Removing Filters
Externally Mounted Air Filters
The air filter is in a rack that is attached to the casing of the furnace or placed in the return air duct. Figures 9, 10, 11 & 12 indicate possible external air filter box locations.
AIR FILTER RACK
ACCESS DOOR
FILTER
RACK
FURNACE |
AIR FLOW |
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18”
MIN
FIGURE 9: External Air Filter Rack - Horizontal Left Position
AIR FLOW |
FILTER RACK |
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(factory supplied with some furnaces) |
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RACK AND FILTERS SECURED |
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INSIDE BLOWER SECTION |
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FOR SHIPMENT |
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CASING SIZE DIMENSION FH |
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16-1/4” |
12-3/4” |
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22-1/4” |
11” |
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26-1/4” |
8-1/4” |
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NOTE: FILTER ACCESS THROUGH |
BRANCH |
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DUCTWORK MUST BE PROVIDED |
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DUCTS |
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FOR REMOVAL AND CLEANING |
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FILTERS |
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DUCTWORK |
FILTER |
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RACK |
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FH |
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CROSS SECTION A-A (with Plenum and filters)
FIGURE 10: Downflow Filter
AIR FILTER |
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AIR FILTER |
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RACK |
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RACK |
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ACCESS |
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ACCESS |
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DOOR |
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DOOR |
FURNACE |
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DUCT |
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DUCT |
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AIR FLOW |
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AIR FLOW |
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LEFT SIDE |
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RIGHT SIDE |
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FILTER RACK |
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FILTER RACK |
FIGURE 11: External Air Filter Rack - Left & Right Side Position
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FURNACE |
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AIR FILTER RACK |
BOTTOM FILTER RACK |
ACCESS DOOR |
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AIR FLOW |
DUCT |
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FIGURE 12: External Air Filter Rack - Bottom Position
Unitary Products Group |
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