Furnace GC96VC Installation Manual

The Furnace GC96VC is a high-efficiency gas furnace with variable-capacity operation, AFUE rating up to 96%, multi-speed ECM blower motor, two-stage gas valve, durable heat exchanger, integrated control board, pressure switch, inducer motor, flame sensor, and diagnostic LED. Designed for residential forced-air heating systems with proper venting requirements. Below are key sections for safety, specifications, installation procedures, wiring, startup, and troubleshooting.

Features at a Glance

Key components: Two-stage gas valve, variable-speed ECM blower, aluminized steel heat exchanger, integrated control board, pressure switches, inducer assembly, flame sensor, diagnostic LED.

Safety Precautions

Read all instructions before installation. Follow local codes and manufacturer guidelines.

1. Disconnect power: Turn off electrical power at service panel before installation.
2. Gas line safety: Shut off gas supply and check for leaks with soap solution.
3. Venting requirements: Ensure proper vent sizing and clearances.
4. Combustion air: Provide adequate combustion and ventilation air.

WARNING! Failure to follow safety procedures may result in fire, explosion, carbon monoxide poisoning, or electrical shock. Installation must be performed by qualified technician.

Specifications

• Model: GC96VC
• Input BTU/H: 40,000 - 120,000 (varies by model)
• AFUE: Up to 96%
• Gas Type: Natural Gas
• Gas Pressure: 3.5" W.C. natural gas
• Electrical: 120V AC, 60Hz, 15 Amp circuit
• Blower Motor: ECM variable-speed
• Stages: Two-stage heating
• Venting: PVC, CPVC, or ABS (check local codes)
• Dimensions: Varies by model capacity

Pre-Installation Requirements

Verify site conditions and gather necessary tools before beginning installation.

1. Location: Install in approved location with proper clearances to combustibles.
2. Combustion air: Ensure adequate air supply per local codes.
3. Ductwork: Verify existing ductwork is properly sized and sealed.
4. Tools required: Manometer, multimeter, pipe wrenches, tubing cutter, level.

CAUTION! Ensure installation location meets all clearance requirements specified in manual.

Installation Procedures

Follow step-by-step installation sequence for proper furnace setup.

1. Position furnace: Place on level surface in approved location.
2. Remove old unit: Properly disconnect and remove existing furnace if replacing.
3. Install filter rack: Mount cleanable or disposable filter system.
4. Connect ductwork: Attach supply and return ducts with proper sealing.
5. Secure furnace: Anchor unit according to local seismic requirements.

Tip: Use two people for handling; furnace is heavy and requires careful lifting.

Electrical Wiring

Connect electrical power and thermostat wiring following wiring diagram.

1. Disconnect power: Turn off circuit breaker before wiring.
2. Line voltage: Connect 120V power leads to furnace junction box.
3. Thermostat wiring: Run 18-22 gauge wire from thermostat to furnace.
4. Grounding: Ensure proper equipment grounding per NEC.
5. Humidifier/AC: Connect accessory terminals if installing additional equipment.

WARNING! Electrical shock hazard. All wiring must comply with NEC and local codes.

Gas Line Connection

Connect gas supply line using proper materials and techniques.

1. Shut off gas: Turn off main gas supply before connecting.
2. Pipe sizing: Use properly sized black iron or CSST gas pipe.
3. Drip leg: Install sediment trap/drip leg before gas valve.
4. Connection: Use pipe joint compound or Teflon tape on threaded connections.
5. Leak test: Test all connections with soap solution before startup.

CAUTION! Gas leak hazard. All gas connections must be tested for leaks before operation.

Venting System

Install venting system according to manufacturer specifications and local codes.

1. Vent material: Use PVC, CPVC, or ABS pipe as approved.
2. Vent sizing: Follow manual for proper pipe diameter based on furnace size.
3. Clearances: Maintain required clearances from combustible materials.
4. Termination: Install vent termination with proper clearance from openings.
5. Slope: Ensure proper slope back to furnace for condensate drainage.

WARNING! Improper venting may cause carbon monoxide poisoning. Follow all venting requirements.

Startup & Commissioning

Complete startup procedure and verify proper operation.

1. Restore power: Turn on electrical power to furnace.
2. Set thermostat: Set to heating mode and raise temperature above room temp.
3. Sequence check: Verify proper ignition sequence and flame establishment.
4. Gas pressure: Check and adjust manifold pressure if necessary.
5. Temperature rise: Measure temperature rise across heat exchanger.
6. Airflow: Verify proper airflow and adjust blower speed if needed.

Tip: Keep installation manual and wiring diagram for future reference.

Maintenance

Regular maintenance ensures optimal performance and longevity.

• Monthly: Check and replace air filter as needed.
• Annual: Professional inspection and cleaning recommended.
• Burner inspection: Clean burners and check flame pattern.
• Heat exchanger: Inspect for cracks or damage.
• Drain system: Clean condensate trap and drain line.

CAUTION! Turn off power and gas before performing any maintenance.

Troubleshooting

Reset: Power cycle furnace to clear temporary faults.

Service: Contact qualified HVAC technician for complex issues.