Gibson Gas Furnace Installation Manual

The Gibson Gas Furnace is a high-efficiency heating system designed for residential use, featuring advanced combustion technology, multiple heating stages, variable-speed blower motor, electronic ignition system, durable heat exchanger, integrated safety controls, and energy-efficient operation. Below are key sections for safety, features, installation, setup, operation, and troubleshooting.

Features at a Glance

Key components: Heat exchanger, burners, blower assembly, gas valve, control board, ignition system, safety switches.

Safety Precautions

Critical safety information for proper installation and operation.

1. Gas leak detection: Use approved leak detection solution on all connections.
2. Carbon monoxide: Install CO detectors in living areas near sleeping rooms.
3. Clearance requirements: Maintain minimum clearances to combustibles.
4. Venting: Ensure proper venting to prevent dangerous gas accumulation.

WARNING! Failure to follow safety precautions may result in fire, explosion, property damage, personal injury, or death. Installation must comply with local codes.

Installation Requirements

Tools and materials needed for proper installation.

1. Required tools: Pipe wrenches, tubing cutter, leak detection solution, multimeter, manometer.
2. Materials: Approved gas pipe, pipe thread sealant, vent pipe, electrical cable, condensate tubing.
3. Clearances: 1" sides, 6" front, 1" rear, 24" top minimum clearances.
4. Location: Indoor installation only in well-ventilated area.

CAUTION! Only qualified HVAC technicians should perform installation. Verify local code requirements.

Specifications

• Input Capacity: 40,000 - 120,000 BTU/h (model dependent)
• Efficiency: 80% - 96% AFUE (model dependent)
• Gas Type: Natural gas or LP/propane (conversion kit required)
• Gas Pressure: Natural gas: 7" WC, LP: 11" WC
• Electrical: 120V AC, 60Hz, 15 amp circuit
• Venting: Category I or IV venting (model dependent)
• Airflow: 800 - 2000 CFM (model dependent)
• Dimensions: Varies by model (check specific model data)
• Weight: 80 - 150 lbs (model dependent)

Installation Steps

Step-by-step installation procedure.

1. Position furnace: Place on level surface in approved location.
2. Install venting: Connect vent pipes according to manufacturer instructions.
3. Connect gas line: Use approved black iron pipe with proper sizing.
4. Electrical wiring: Connect line voltage and thermostat wiring.
5. Ductwork: Connect supply and return ducts with proper sealing.
6. Condensate drain: Install drain line with proper slope and trap.
7. Combustion air: Ensure adequate combustion and ventilation air supply.

Tip: Verify all connections before startup. Check for gas leaks with approved solution.

Venting System

Proper venting is critical for safe operation.

1. Determine vent category: Category I (natural draft) or Category IV (direct vent).
2. Vent pipe material: Use approved vent pipe (B-vent, PVC, or ABS).
3. Vent termination: Maintain proper clearances from windows, doors, and air intakes.
4. Vent slope: Ensure proper slope for condensate drainage in high-efficiency models.

WARNING! Improper venting can cause carbon monoxide poisoning. Follow manufacturer venting tables exactly.

Gas Line Connection

Gas piping requirements and connection procedures.

1. Pipe sizing: Use gas pipe sizing charts for proper diameter.
2. Pipe material: Black iron pipe with approved thread sealant.
3. Sediment trap: Install drip leg before gas valve connection.
4. Pressure test: Test gas line at 14" WC for 10 minutes with no pressure drop.
5. Gas valve connection: Use approved flexible connector if required by code.

CAUTION! Always use leak detection solution on all gas connections. Never use matches or open flame to check for leaks.

Electrical Wiring

Electrical connection requirements.

1. Power supply: Dedicated 15 amp, 120V circuit with proper grounding.
2. Thermostat wiring: 18-22 gauge thermostat cable with minimum 3 conductors.
3. Grounding: Proper equipment grounding required.
4. Low voltage: Connect R, W, G, C terminals as required.
5. Safety switches: Connect door safety switch and high limit controls.

WARNING! Disconnect power before servicing. Follow NEC and local electrical codes.

Startup and Testing

Initial startup procedure and system testing.

1. Gas pressure: Verify inlet and manifold pressures with manometer.
2. Combustion analysis: Check CO and CO2 levels in flue gases.
3. Temperature rise: Measure temperature rise across heat exchanger.
4. Airflow: Verify proper airflow through duct system.
5. Safety controls: Test all limit switches and safety devices.
6. Sequence of operation: Verify proper startup and shutdown sequence.

Tip: Complete startup checklist and leave copy with homeowner.

Maintenance

Routine maintenance requirements for optimal performance.

1. Annual inspection: Complete system check before heating season.
2. Filter replacement: Replace air filters every 1-3 months.
3. Burner cleaning: Clean burners and heat exchanger annually.
4. Blower maintenance: Clean blower wheel and housing.
5. Drain system: Clean condensate trap and drain lines.
6. Venting inspection: Check vent system for obstructions or damage.

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

Troubleshooting

Reset: Power cycle unit to reset control board if lockout occurs.

Service: Contact qualified HVAC technician for complex issues. Gibson Customer Service: 1-800-XXX-XXXX