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 |
FURNACE CLEANING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
USER’S INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1 |
Burner Removal/Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
1 |
Cleaning the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
INSTRUCTIONS FOR EXAMINING THE |
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SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
FURNACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
2 |
Continuous Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
HOW YOUR GAS FURNACE WORKS . . . . . . . . . . . . . . . . . . . . . . |
3 |
Intermittent Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
START-UP AND SHUTDOWN INSTRUCTIONS . . . . . . . . . . . . . . . |
3 |
Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.6 |
Read the Instructions Below Before Trying to Start the Furnace . . |
3 |
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.7 |
Operating Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3 |
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.7 |
To Turn Off the Appliance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
3 |
FURNACE CONTROL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . |
.7 |
FURNACE USER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . |
4 |
DIAGNOSTIC FAULT CODE STORAGE AND RETRIEVAL . . . . . |
.8 |
Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4 |
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
.9 |
Removing the Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
4 |
FIELD INSTALLED ACCESSORIES - NON-ELECTRICAL . . . . . . |
10 |
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5 |
REPLACEMENT PART CONTACT INFORMATION . . . . . . . . . . . . . |
10 |
SERVICE AND MAINTENANCE MANUAL . . . . . . . . . . . . . . . . . . . . |
5 |
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
11 |
SAFETY SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5 |
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
12 |
FURNACE MAINTENANCE SECTION . . . . . . . . . . . . . . . . . . . . . . |
5 |
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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 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 |
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VENT PIPE |
FLUE |
INSTRUCTIONS FOR EXAMINING THE FURNACE |
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INSTALLATION |
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COLLAR |
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PRESUURE |
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ELECTRICAL |
It is the owner’s responsibility to ensure that an annual inspection of the |
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SWITCH |
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JUNCTION BOX |
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INDUCED DRAFT |
entire heating portion of the unit is made by a qualified service agency. |
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SILICONE |
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ASSEMBLY |
Examine the furnace as outlined below in steps “1 - 6” before each |
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TUBE |
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MOTOR |
heating season. Use Figure 3 for visual reference. |
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INDUCED DRAFT |
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LIMIT |
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GAS VALVE |
1. Examine the heat exchanger, vent pipe, combustion air passages, |
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CONTROL |
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FLAME |
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LIMIT |
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vent connectors and chimney to be sure they are clear and free of |
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SENSOR |
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SWITCH |
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obstructions. |
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IGNITOR |
2. |
Examine the vent pipe making sure it is firmly in place, that it |
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MOTOR |
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MANIFOLD |
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PIPE |
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slopes slightly upward and is physically sound without holes and |
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PULLEY |
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SAFETY SHUTOFF |
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all of the connections are secure. |
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FAN BELT |
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SWITCH |
3. Examine the return-air duct connections to make sure they are |
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Y W R G C |
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CONTROL |
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FAN |
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BOARD |
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physically sound, sealed to the furnace casing, and the ducts ter- |
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PULLEY |
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minate outside the space containing the furnace. |
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BLOWER |
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BLOWER |
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SHAFT |
4. Examine the furnace casing making sure the physical support is |
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HOUSING |
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sound without sagging, cracks or gaps. Examine the furnace base |
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making sure it is physically sound without cracks, gaps or sagging |
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FIGURE 1: Component Locations |
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and has a good seal. |
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5. |
Examine the furnace casing for obvious signs of deterioration. |
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7. NEVER . . .Store flammable materials of any kind near your fur- |
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6. |
Examine the burner flames to make sure they are in good adjust- |
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nace. Gasoline, solvents, |
and other |
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liquids should be |
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ment. Refer to the pictorial sketch shown in Figure 2 as a compari- |
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stored only in approved |
containers |
outside |
your home. These |
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son to the actual flame. |
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materials vaporize easily and are extremely dangerous. |
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8.NEVER . . .Store cleaning materials near your furnace. Materials
such as bleaches, detergents, powdered cleansers, etc., can |
BLUE CONE PORTION OF FLAME SHOULD |
ENTER HEAT EXCHANGER TUBE |
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cause corrosion of the heat exchangers. |
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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 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.
EXAMINE EXTERNAL |
5 EXAMINE ENTIRE |
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FURNACE CASING |
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VENT PIPE |
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SHOWN IN ALL |
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DRAWINGS |
1EXTERNAL HEAT EXCHANGER INTERNAL VENT COMBUSTION AIR PIPE. MUST
REMOVE PANEL TO EXAMINE.
6 REMOVE |
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PANEL |
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TO EXAMINE |
4 EXAMINE |
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BURNER |
FURNACE |
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FLAMES |
CASING |
3 |
EXAMINE |
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RETURN AIR |
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DUCT |
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CONNECTION |
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6 REMOVE |
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4 |
EXAMINE |
PANEL |
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TO EXAMINE |
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FURNACE |
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BURNER |
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CASING |
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FLAMES |
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3 EXAMINE |
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RETURN AIR |
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DUCT |
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CONNECTION |
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(side or bottom) |
FIGURE 3: Furnace Examination Checkpoints
2 |
Unitary Products Group |
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 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 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.
272442-UUM-B-1211
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. See Figure 4.
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 5.
OUTLET
PRESSURE
PORT
INLET 
WRENCH BOSS INLET
PRESSURE PORT
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 4: Gas Valve - White Rodgers
EXTERNAL MANUAL
SHUTOFF VALVE
TO GAS |
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TO GAS |
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SUPPLY |
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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 |
INSIDE OR OUTSIDE UNIT. |
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FIGURE 5: Upflow Gas Piping
MANUAL
SHUT-OFF 
VALVE
GAS
PIPE
DRIP
LEG
GAS BURNERS
GAS 
GAS VALVE
PIPE
DRIP |
MANUAL |
LEG |
SHUT-OFF VALVE |
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.
Unitary Products Group |
3 |
272442-UUM-B-1211
FURNACE USER MAINTENANCE |
Removing the Air Filters |
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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 are on the bottom and the side of the furnace 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.
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 Table 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.
FURNACE
FILTER
RACK
A
B
RETURN AIR
PLATFORM
FIGURE 7: Bottom Return Filter Rack
RETURN
DUCT
SYSTEM
FIGURE 8: Bottom Return Filter Rack in the Horizontal Position
4 |
Unitary Products Group |
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