York GY8S160E30UH21 User Manual
USER’S INFORMATION,
MAINTENANCE AND
SERVICE MANUAL
HIGH EFFICIENCY
COMMERCIAL BELT DRIVE SERIES
MODELS: GY8S160E30UH21
(Single Stage Upflow /Horizontal)
TABLE OF CONTENTS
CONTACT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTRUCTIONS FOR EXAMINING THE
FURNACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . .3
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . .3
Read the Instructions Below Before Trying to Start the Furnace . . 3
Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . .4
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing the Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . 5
SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . .5
FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Intermittent Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . .7
DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL . . . . . .8
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL . . . . . .10
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . .10
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
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 immedia te l y.
• 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 quali-
fied 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 3 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.
272442-UUM-B-1211
272442-UUM-B-1211
NEUTRALS
EAC
COOL
HEAT
HUM
PARK
PARK
L1
XFMR
Y WR GC
VENT PIPE
PRESUURE
SWITCH
SILICONE
TUBE
MOTOR
PULLEY
GAS VALVE
FLAME
SENSOR
INDUCED DRAFT
ASSEMBLY
INDUCED DRAFT
MOTOR
LIMIT
SWITCH
IGNITOR
MANIFOLD
PIPE
SAFETY SHUTOFF
SWITCH
CONTROL
BOARD
FLUE
COLLAR
ELECTRICAL
JUNCTION BOX
LIMIT
CONTROL
BLOWER
SHAFT
BLOWER
HOUSING
FAN BELT
FAN
PULLEY
BLUE CONE PORTION OF FLAME SHOULD
ENTER HEAT EXCHANGER TUBE
4
EXAMINE
FURNACE
CASING
6
5
3
4
3
1
6
EXAMINE
RETURN AIR
DUCT
CONNECTION
REMOVE
PANEL
TO EXAMINE
BURNER
FLAMES
EXTERNAL HEAT EXCHANGER INTERNAL
VENT COMBUSTION AIR PIPE. MUST
REMOVE PANEL TO EXAMINE.
EXAMINE ENTIRE
FURNACE CASING
SHOWN IN ALL
DRAWINGS
EXAMINE
RETURN AIR
DUCT
CONNECTION
(side or bottom)
REMOVE
PANEL
TO EXAMINE
BURNER
FLAMES
EXAMINE EXTERNAL
VENT PIPE
EXAMINE
FURNACE
CASING
FIGURE 1: Component Locations
7. NEVER . . .Store flammable materials of any kind near your furnace. 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.
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 Figure 3 for visual reference.
1. Examine the heat exchanger, vent pipe, combustion air passages,
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 2 as a comparison to the actual flame.
FIRE OR EXPLOSION HAZARD
This furnace is designed and approved for use with Nat-
ural 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, Per-
FIGURE 2: Burner Flame Drawing
sonal Injury, and/or Property Damage.
FIGURE 3: Furnace Examination Checkpoints
2 Unitary Products Group
272442-UUM-B-1211
INLET
WRENCH
BOSS
INLET
PRESSURE
PORT
ON
OFF
ON/OFF SWITCH
(Shown in ON position)
MAIN REGULATOR
ADJUSTMENT
OUTLET
OUTLET
PRESSURE
PORT
VENT PORT
EXTERNAL MANUAL
SHUTOFF VALVE
TO GAS
SUPPLY
TO GAS
SUPPLY
GROUNDED JOINT UNION
MAY BE INSTALLED
INSIDE OR OUTSIDE UNIT.
DRIP
LEG
MANUAL
SHUT-OFF
VALV E
GAS
PIPE
GAS
PIPE
DRIP
LEG
MANUAL
SHUT-OFF VALVE
GAS VALVE
GAS BURNERS
DRIP
LEG
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
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 per-
formed.
3. Remove burner access panel.
4. Move gas control switch to the “OFF” position. See Figure 4.
5. Replace burner access panel.
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
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 5.
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
FIGURE 4: Gas Valve - White Rodgers
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” posi-
tion. 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. Imme-
diately 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 furnace door.
5. Move gas control switch to the “OFF” position. Do not force. See
Figure 4.
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. See
Figure 4.
8. Replace burner access panel.
9. Turn on all electric power to the appliance.
10. Set thermostat to the desired setting. Burner will light, which may
11. After three (3) trials for ignition, if the appliance will not operate fol-
Unitary Products Group 3
take 30-60 seconds.
low the instructions, “TO TURN OFF THE APPLIANCE” and call
your service technician or gas supplier.
FIGURE 5: Upflow Gas Piping
FIGURE 6: Horizontal 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.
272442-UUM-B-1211
A
B
FILTER
RACK
FURNACE
RETURN AIR
PLATFORM
RETURN
DUCT
SYSTEM
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.
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. Determine whether you have a bottom or side return air duct using
the following method.
a. If the return air filter is on the left or right side of the furnace it
is a side return
b. If the air filter is on the bottom of the furnace then you have a
bottom return.
c. If the air filters ar e on the bottom and the side of the f urnace
then you have a bottom and side return. You must replace
both air filters. Table 1 will indicate 2 filters by using brackets
with the number two (2).
d. If the air filters are on both sides of the furnace then you have
a two sided return. You must replace both air filters. Table 1
will indicate 2 filters by using brackets with the number two
(2).
2. After you determine the cabinet size and what return configuration
you have, look up the recommended filter size from Table 1.
Removing the Air Filters
Turn off ALL electrical power to the furnace when conducting any service or inspection procedure. Furnace may
have isolated electrical supplies - one providing power to
the Circulating Blower (230V or 115V) and another supplying the control circuit (115V), which controls the Circulating Blower. The spring loaded safety cutoff switch,
mounted to the blower deck DOES NOT interrupt all electrical potential in the blower compartment when the blower
access panel is removed.
Externally Bottom Mounted Air Filters
This furnace has the filter(s) mounted externally to the cabinet on either
both sides of the cabinet, one side and the bottom of the cabinet, or the
bottom of the cabinet only. DO NOT place the air filter(s) on the inside
of the blower compartment on this furnace. The air filter(s) must be
place in the externally mounted air filter hardware. Follow the instructions below to remove and replace the air filter(s).
1. Before removing the air filters follow the instructions “To turn off
the Appliance” on page 3.
2. Remove the cover on the front of the filter box by removing the
retaining screw or knob that secures the cover to the box. The
external filter box will be located on the bottom of the furnace cabinet. Refer to Figure 7 for upflow filter box locations or Figure 8 for
horizontal filter box locations.
3. Use your fingers to grab the outside edge of the filter and remove
the filter(s) from the filter box.
4. If the filter(s) are permanent cleanable filter(s) follow the instructions on how to clean your filter or you may replace the throwaway
filter with permanent cleanable filter(s) at this time. Refer to Table
1 for the recommended air filter size.
5. Install the filter(s). The filter(s) should fit in the entire filter track. If
the filter does not fit inside the entire filter track then the filter you
have is the wrong size. Refer to T able 1 for the recommended filter
size.
6. Reinstall the filter box access cover.
7. Follow the Operating Instructions on page 3 to place the furnace
back in service.
FIGURE 7: Bottom Return Filter Rack
4 Unitary Products Group
FIGURE 8: Bottom Return Filter Rack in the Horizontal Position
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