INSTALLATION INSTRUCTIONS G2D93CT, G2D93CU, G2D95CT, & …€¦ · Allied Air Enterprises Inc. A...

506303-01 of 40Issue 0938

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INSTALLATION INSTRUCTIONSG2D93CT, G2D93CU, G2D95CT, & G2D95CU

High Efficiency Multiposition Gas Furnacewith System Sentry™ Control System

Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage.Refer to this manual. For assistance or additional information, consult a qualified installer, service agency,or the gas supplier.

WARNING

Do not store combustible materials, including gasoline andother flammable vapors and liquids, near the furnace, ventpipe, or warm air ducts. The homeowner should becautioned that the furnace area must not be used as abroom closet or for any other storage purposes. Such usesmay result in actions that could cause property damage,personal injury, or death.

WARNING

This furnace is not approved for installation in a mobilehome. Do not install this furnace in a mobile home.Installation in a mobile home could result in actions thatcould cause property damage, personal injury, or death.

WARNING

The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of the National FireProtection Association; the National Fuel Gas Code, ANSI Z223.1/NFPA No. 54 (latest edition) and the National ElectricalCode, ANSI/NFPA No. 70 (latest edition) in the United States; CSA B149.1 (latest edition) Natural Gas and Propane InstallationCodes and the Canadian Electrical Code Part 1, CSA 22.1 (latest edition) in Canada; and any state or provincial laws, localordinances (including plumbing or wastewater codes), or local gas utility requirements. Local authorities having jurisdictionshould be consulted before installation is made. Such applicable regulations or requirements take precedence over thegeneral instructions in this manual.

IMPORTANT

Manufactured ByAllied Air Enterprises Inc.

A Lennox International Inc. Company215 Metropolitan Drive

West Columbia, SC 29170

TABLE OF CONTENTS

SAFETY ........................................................ 2

INSTALLATION ............................................. 3

START-UP ................................................... 26

OPERATION ............................................... 27

MAINTENANCE .......................................... 32

CONTROL DIAGNOSTICS ......................... 33

REPAIR PARTS .......................................... 34

WIRING DIAGRAMS................................... 35

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The following is a list of safety rules and precautions thatmust be followed when installing this furnace.

1. Use only with the type of gas approved for this furnace.Refer to the furnace rating plate.

2. Install this furnace only in a location and position asspecified in the Location section on page 3 of theseinstructions.

3. Provide adequate combustion and ventilation air to thefurnace space as specified in the Combustion andVentilation Air section on page 4 of these instructions.

4. Adequate clearance must be provided around thevent-air intake terminals as specified in the Ventingsection beginning on page 5 of these instructions.

5. Combustion products must be discharged outdoors.Connect this furnace to an approved vent system only,as specified in the Venting section beginning on page5 of these instructions.

6. Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections, asspecified in Gas Supply and Piping beginning onpage 20 of these instructions.

IMPORTANT SAFETY INFORMATION7. Always install furnace to operate within the furnace’s

intended temperature-rise range with a duct systemwhich has an external static pressure within theallowable range, as specified in Temperature Riseon page 31 of these instructions. See furnace ratingplate.

8. When a furnace is installed so that the supply ductscarry air circulated by the furnace to areas outsidethe space containing the furnace, the return air shallalso be handled by duct(s) sealed to the furnacecasing and terminating outside the space containingthe furnace. See Circulating Air Supply on page 19of these instructions.

9. A gas-fired furnace for installation in a residentialgarage must be installed as specified in the Locationsection on page 3 of these instructions.

10. The furnace is permitted to be used for temporaryheating of buildings or structures under constructionas specified in the Location section beginning on page3 of these instructions.

In the State of Massachusetts:This product must be installed by a licensed Plumberor Gas Fitter. When flexible connectors are used, themaximum length shall not exceed 36". When lever-type gas shutoffs are used, they shall be T-handletype.

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INSTALLATION

These instructions must be placed on or near thefurnace in a conspicuous place.

The furnace design is certified by CSA International as aCategory IV furnace in compliance with the latest edition ofAmerican National Standard Z21.47/CSA Standard 2.3 forGas-Fired Central Furnaces, for operation with natural gasor propane. Consult the rating plate on the furnace for gastype before installing.

The maximum hourly heat loss of space shall be calculatedin accordance with the procedure described in the currentmanuals of Air Conditioning Contractors of America, or byany other recognized method which is suitable for localconditions, provided the results obtained are in substantialagreement with, and not less than, those obtained usingthe procedure described in the manuals.

G2D93CT and G2D95CT furnaces may be installed as upflowor horizontal right to left or left to right ariflow furnaces.When installed horizontally, the installer must install a sheetmetal screw to retain the upper door as shown in Figure 1.

G2D93CU and G2D95CU furnaces must be installed only asupflow furnaces.

Never install any furnace on its back.

Inspection of ShipmentThis furnace is shipped in one package, completelyassembled and wired. The thermostat is shipped in aseparate carton when ordered.

Upon receipt of equipment, carefully inspect it for possibleshipping damage. If damage is found, it should be notedon the carrier’s freight bill. Damage claims should be filedwith the carrier immediately. Claims of shortages shouldbe filed with the seller within 5 days.

LocationTo provide proper operation and satisfactory performance,care must be taken in choosing the location for this furnace.The atmosphere in which the furnace operates must be freeof contaminants such as chlorides and sulfates.

The furnace must be installed so that electrical componentsare protected from water. Unit must be level for propercondensate drainage.

To avoid property damage caused by condensate drainblockage, install a field-fabricated auxiliary drain pan with aseparate drain line to the outside under the entire furnaceand drain system. Install according to local codes.

All models are suitable for closet or utility room installation.

The furnace is suitable for installation in buildingsconstructed on-site. The furnace should be centralized inrespect to the heat distribution system as much aspracticable. When installed in a utility room, the doorshould be wide enough to allow the largest part of thefurnace to enter, or permit the replacement of anotherappliance, such as a water heater.

A gas-fired furnace for installation in a residential garage mustbe installed so the burner(s) and the ignition source are locatednot less than 18" above the floor. The furnace is to be locatedor protected to avoid physical damage by vehicles.

This furnace is not recommended to be used as a constructionheater during any phase of construction. Very low return airtemperatures, harmful vapors, and operation of the unit withclogged or misplaced filters will damage the unit.

The furnace may be used for heating of buildings orstructures under construction, if the following conditions aremet:

• The vent system must be permanently installed perthese installation instructions.

• A room thermostat must control the furnace. The useof fixed jumpers that will provide continuous heating isnot allowed.

The condensate system must not be exposed totemperatures under 32°F. The condensate system mustbe insulated if exposed to temperatures under 32°F. Useof heat tape is permissible provided the rate temperatureof the tape does not exceed 155°F.

CAUTION

Horizontal Installations

Figure 1

Horizontal right to left airflowshown

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Unconfined SpaceAn unconfined space is defined as “a space whose volumeis more than 50 cubic feet per 1000 BTU per hour of thecombined input rating of all appliances installed in thatspace.” When a furnace is installed in an unconfined spacein a building, it can be assumed that the infiltration will besufficient to supply the required air. If the furnace is installedin a ventilated attic or crawl space, it is assumed that theinfiltration is sufficient to supply the required air. However,in a building of unusually tight construction, additionaloutdoor air should be provided.

• The return air duct must be provided and sealed to thefurnace.

• Return air temperature range between 60°F and 80°Fmust be maintained.

• Air filters must be installed in the system and must bemaintained during construction.

• Air filters must be replaced upon constructioncompletion.

• The input rate and temperature rise must be set perthe furnace rating plate.

• One hundred percent (100%) outdoor air must beprovided for combustion air requirements duringconstruction. Temporary ducting may supply outdoorair to the furnace. Do not connect duct directly to thefurnace. Size the temporary duct following theinstructions given on this page in the Combustion andVentilation Air section regarding confined space withair from outside.

• The furnace heat exchanger, components, duct system,air filters, and evaporator coils must be thoroughlycleaned following final construction cleanup.

• All furnace operating conditions (including ignition, inputrate, temperature rise, and venting) must be verifiedaccording to these installation instructions.

G2D93CT and G2D95CT models installed in the horizontalposition are approved for attic installations. If the furnaceis to be installed in an attic or other insulated space, itmust be kept free and clear of insulating materials.

ClearancesAll servicing and cleaning of the furnace can be performedfrom the front. If installed in a closet or utility room, provide18" clearance in front for service if the door to the room isnot in line with the front of the furnace.

Refer to Table 1 for the minimum clearances to combustiblesrequired for construction and proper unit operation. Whereservicing clearances are greater than clearances tocombustibles, servicing clearances take precedence.

G2D93CT and G2D95CT models may be installed on woodflooring but shall not be installed directly on carpeting, tile, orany other combustible material.

Combustion and Ventilation AirAdequate provisions for combustion air and ventilation offurnace must be made. Refer to Section 5.3, “Air for

Combustion and Ventilation,” of the National Fuel Gas Code,ANSI Z223.1/NFPA54 (latest edition), Sections 7.2, 7.3, or7.4 of CSA B149.1 Natural Gas and Propane InstallationCodes (latest editions), or applicable provisions of the localbuilding codes.

Insufficient combustion air can cause headaches, nausea,dizziness, or asphyxiation. When considering combustionair requirements, enough air must also be provided tomeet the needs of all fuel-burning appliances and exhaustfans.

WARNING

Air openings in the front of the furnace must be kept freeof obstructions. Any obstruction may cause improperoperation that can result in a fire hazard or carbonmonoxide injury.

WARNING

Table 1

Minimum Clearances toCombustibles

Upflow Horizontal

Sides 0” 0”

Rear 0” 0”

2” 18”

0” 0”

1” 1”

Front

Flue Pipe

Plenum

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5. Exposure to the following substances in the combustionair supply may also require outdoor air for combustion:

• Permanent wave solutions• Chlorinated waxes and cleaners• Chlorine-based swimming pool chemicals• Water softening chemicals• Deicing salts or chemicals• Carbon tetrachloride• Halogen-type refrigerants• Cleaning solvents (such as perchloroethylene)• Printing inks, paint removers, varnishes, etc.• Cements and glues• Antistatic fabric softeners for clothes dryers• Masonry acid washing materials• Chlorinated laundry products• Hydrochloric acid

VentingThe high efficiency of this furnace is accomplished by theremoval of both sensible and latent heat from the flue gases.The removal of latent heat results in the condensation ofmoisture in the flue gases. This condensation occurs in thesecondary heat exchanger and in the vent system. Therefore,this furnace requires special venting considerations and theinstructions must be followed to insure proper operation. Allventing must be in accordance with the codes havingjurisdiction in the area and these instructions.

G2D93CT, G2D93CU, G2D95CT, and G2D95CU modelscan be installed as either direct vent or non-direct vent units.A direct vent (two pipe) installation requires that all the airnecessary for combustion be supplied from outside thedwelling through an air intake pipe. A non-direct vent (onepipe) installation uses air from inside the dwelling forcombustion.

The furnace is shipped with the air inlet pipe terminated to thetop panel for either inside or outside combustion air. An inlet airrestrictor plate (see Figure 2 on page 6) is supplied with thisfurnace and can be found in the plastic bag containing theseInstallation Instructions and the User’s Information Manual. Thisinlet restrictor plate must be used in all installations usinginside air for combustion (non-direct vent).

The inlet restrictor plate must be installed in the air inlet inone of three ways:

• Restrictor plate in inlet collar: Install the restrictorplate in the inlet pipe collar in the top panel of thefurnace. Insert a 3" to 36" section of PVC pipe (fieldsupplied) into the collar. Use high temperature RTVsealant to attach PVC pipe to collar. A 90° elbow (fieldsupplied) may be attached to the PVC pipe, but theelbow is not required. Use high temperature RTVsealant to attach elbow to PVC pipe (if applicable).

Confined SpaceA confined space is defined as “a space whose volume isless than 50 cubic feet per 1000 BTU per hour of the combinedinput rating of all appliances installed in that space.”

If the furnace is installed in a confined space within the buildingand combustion air is taken from a heated space, thecombustion air and ventilating air must enter and leave thespace through two permanent openings of equal area. Oneopening shall be located within 12" of the ceiling and the otherwithin 12" of the floor, each having a free area of1 square inch per 1000 BTU/HR of total input rating of allappliances within the space and not less than 100 squareinches each.

If the furnace is installed in a space within a building of tightconstruction, makeup air must be supplied from outdoors. Inthis case, one opening shall be within 12" of the ceiling andone opening within 12" of the floor. If combustion ducts arevertical, each opening shall have a free area of 1 square inchper 4000 BTU/HR of the total input rating of all applianceswithin the enclosure. If horizontal combustion ducts are run,1 square inch per 2000 BTU/HR is required.

Contaminated Combustion AirExcessive exposure to contaminated combustion air will resultin safety and performance related problems. Therecommended source of combustion air is outdoor air.However, the use of indoor air in most applications isacceptable if the following guidelines are followed:

1. If the furnace is installed in a confined space, it isrecommended that the necessary combustion air comefrom the outdoors by way of an attic, crawl space, airduct, or direct opening.

2. If indoor combustion air is used, there must be noexposure to the substances listed in Item 5.

3. All provisions for indoor combustion air must meet therequirements for combustion air indicated in the NationalFuel Gas Code, ANSI Z223.1/NFPA 54 (latest edition),and/or any applicable local codes. In Canada, see CSAB149.1, Natural Gas and Propane Installation Codes(latest edition).

4. The following types of installation may require outdoorair for combustion, due to chemical exposures:

• Commercial buildings• Buildings with indoor pools• Furnaces installed in laundry rooms• Furnaces installed in hobby or craft rooms• Furnaces installed near chemical storage areas

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The venting system must be supported with mounting strapsto prevent any weight load from being applied to the ventblower. Horizontal vent pipe must be supported every 5'and vertical pipe should be supported every 10' to preventsagging and provide rigid support.

When a furnace is installed as direct vent, provisions forventilation air should follow the same requirements as ifinstalled as non-direct vent. Proper ventilation air isnecessary to maintain furnace component temperatureswithin acceptable limits.

All vents passing through floors, ceilings, and walls mustbe installed in accordance with National Fuel Gas Code,ANSI Z223.1/NFPA 54 (latest edition).

The length of flue pipe exposed to outdoor conditions shouldbe kept to a minimum. When the installation requires morethan 3 feet of flue pipe be exposed to outdoor conditions,insulating the exposed flue pipe with 1/2” Armaflex orequivalent is recommended. In climates with designtemperatures below zero degrees (F), 3/4” Armaflex orequivalent is recommended.

MaterialsAll pipe, fittings, primer, and solvent cement must conformwith American National Standard Institute and the AmericanSociety for Testing and Materials (ANSI/ASTM) standards.The solvent shall be free flowing and contain no lumps,undissolved particles, or any foreign matter that adverselyaffects the joint strength or chemical resistance of the cement.The cement shall show no gelation, stratification, orseparation that cannot be removed by stirring.

Refer to Table 2 for approved piping and fitting materials.

Canadian Applications Only:PVC pipe, fittings, primer and solvent cement used to ventthis applicance must be certified to ULC S636 and suppliedby a single manufacturer as part of an approved ventingsystem. In addition, the first three feet of vent p ipe fromthe furnace flue collar must be accessible for inspection.Models that may be installed as a horizontal furnace includea horizontal drain kit. In Canada this dain kit must bereplaced by a locally available IPEX Drain Kit #196014. ForLocal IPEX Canadian Customer Service Center and Kitavailability call IPEX at 1-866-473-9462.

The primers and solvents used must also meet ASTMspecifications. PVC primer is specified in ASTM F656. UsePVC solvent as specified in ASTM D2564 and ABS solventcement as specified ASTM D2235. Low temperature solventcement is recommended. Metal or plastic strapping maybe used for vent pipe hangers.

• Restrictor plate in inlet pipe: Insert a 3" to 36" sectionof PVC pipe (field supplied) into the collar. Use hightemperature RTV sealant to attach PVC pipe to collar.Install the restrictor plate in the end of the inlet pipe justinstalled. Attach either a field-supplied coupler or 90°elbow to the end of the PVC pipe to keep the restrictorplate in place. Use high temperature RTV sealant toattach the coupler or elbow to PVC pipe.

• Restrictor plate in elbow: Insert a 3" to 36" section ofPVC pipe (field supplied) into the collar. Use hightemperature RTV sealant to attach PVC pipe to collar.Attach a 90° elbow (field supplied) to the PVC pipe. Usehigh temperature RTV sealant to attach elbow to PVCpipe. Install the restrictor plate into the elbow.

Two different sized inlet restrictor plates are supplied with thefurnace (2" and 3"). Use the proper restrictor plate for thefurnace model.Also included in the plastic bag containing the inlet airrestriction plate is a flue pipe screen (see Figure 2). In allinstallations, this screen should be installed at thetermination of the flue pipe and is designed to keep objectsout of the flue pipe.

For either type of installation (direct or non-direct vent),special venting considerations must be followed. Refer tothe proper section in pages 11 – 15 for the type of furnaceand venting being installed.

If at any time in the future the installation of this furnaceis changed to require outside fresh air for combustion,the inlet air restrictor plate must be removed. Failureto remove the inlet air restrictor could cause improperoperation that can result in a fire hazard or carbonmonoxide injury.

WARNING

Flue Pipe Screen

The flue pipe screen should beinstalled at the termination of the fluepipe in all installations.

Figure 2

Inlet Air Restrictor PlateThe inlet air restrictor plate must beinstalled in all installations using insideair for combustion (non-direct vent).

00709

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When making ABS joints, pieces can be prepared with a cleandry cloth to clean inside socket surface of fitting and maleend of pipe to depth of socket. Refer to procedure specifiedin ASTM D3138. When joining ABS to PVC materials, usetransition solvent.

Preferred fittings are DWV style or long sweep. Seal all jointsgas tight with appropriate cement. In areas where vent andair intake pipes are exposed to abnormal stress or are subjectto damage, schedule 80 pipe should be used.

Category IV Furnace LimitationsThis furnace shall not be connected to any Type B, BW, or Lvent or vent connector and shall not be connected to any portionof a factory-built or masonry chimney. This furnace is not tobe common vented with any other appliance. The ventpipe must not be connected to a chimney flue serving aseparate appliance designed to burn solid fuel.

Table 2

Piping and Fitting Specifications

D1785

Schedule 40 PVC

(Cellular Core Pipe)F891

Schedule 40 PVC

(Fittings)D2466

SDR-26

(Pipe)D2241

Schedule 40 ABS(Pipe)

D1527

Schedule 40 ABS(Fittings)

D2468

Schedule 40 & 80 CPVC(Pipe)

F441

ABS-DWVDrain Waste & Vent

(Pipe & Fittings)D2661

PVC-DWVDrain Waste & Vent

(Pipe & Fittings)D2665

Piping & Fitting

Material

ASTM

Specification

Schedule 40 PVC (Pipe)

SDR - 26 CPVC (Pipe) F442

Schedule 40 ABS

Cellular Core DWV

(Pipe)

F628

Schedule 40 & 80 CPVC

(Fittings)F438

Figure 4

Vent Tables *(numbers in inches unless specified otherwise)

Minimum Pipe Diameter40,000 – 60,000 BTU/HR Models

NR = Not Recommended

Minimum Pipe Diameter125,000 BTU/HR Models

Minimum Pipe Diameter80,000 – 100,000 BTU/HR Models

* 2” not recommended at altitude above 4,000 ft.3” required for altitude above 5,000 ft.

0 1 2 3 4 5 6 7 8 9

2 2 2 2 2 2 2 2 2

2 2 2 2 2 2 2

2

3 3 3 3

3 3 3 3 3

Vent Pipe

Length

(ft.)

Number of 90° Elbows

5

10

20

30

40

50

60

70

80

90

1.5 1.5

1.5

2 2 2 2 2 2 2 2

2.52 2 2 2 2 2 2 2 2

2.5 2.5 2.5

2.5 2.5 2.5 2.5 2.52 2 2 2 2

32.5 2.5 2.5 2.5 2.5 2.5 2.5

3332.5

2

2 2.5 2.5 2.5 2.5 2.5

2.52.52.52.52.5

2.52.52.5

2.52.5

3 3 3 3 3

NR

NR NR

NR NR NR

0 1 2 3 4 5 6 7 8 9

2 2 2 2 2 2

2 2 2 3 3 3

3 3 3 3 3 3

3 3 3 3

3 3

Vent Pipe

Length

(ft.)


5

10

20

30

40

50

60

70

80

90

3

3

3 3 3

3 3 3 3 3 3

3 3 3 3 3

2.5

2.5 2.5 2.5

2.5 2.5 2.5

2.5 2.5 2.5 2.5

2.5 2.5 2.5 2.5

2.5 2.5 2.5

2.5

2.5

2.5 2.5

NR

NR

NR

2

NR

2

2 2 2 2 2

2 2 2 2 2

2

2

NR NR NR

NR NR NR NR NR

NR NRNRNRNR

NR NR NR NR NR NR NRNR

0 1 2 3 4 5 6 7 8 9

.

3

3 3

Vent Pipe

Length

(ft.)


5

10

20

30

40

50

60

NR

2.5

33

33

3

33

NR

NR

NR

NR

NR NR NR NR NR NR NR NR

NRNRNRNRNRNR

NR NR NR

NR NR

2.5

2.5 2.5 2.5 2.5

2.5 2.5 2.5 2.5 2.5

2.52.52.52.52.52.52.5

2.52.52.52.52.5 2.5 2.5 2.5 2.5

2.52.52.52.52.52.52.52.52.5

Figure 3

Concentric Vent Kit Dimensions

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Concentric Vent KitA concentric vent kit (see Accessories section on page 34 forcorrect kit) is available for use when installing this furnace asa direct vent furnace and the air intake and vent pipe are tobe run through the same hole, whether horizontally throughthe wall or vertically through the roof (see Figure 3). Refer tothe instructions included with the concentric vent kit forinstallation specifics.

Vent Pipe Size and LengthThe vent pipe and air intake pipe (in direct vent installations)should be sized in accordance with the information foundin the appropriate table in Figure 4. One 90° elbow isequivalent to 5' of pipe. Two 45° elbows are equivalent toone 90° elbow. The minimum length certified for use withthis furnace is 5' and one elbow, not including the vent andair intake terminals.

In the event that the pipe length is in between the lengthslisted in the table, use the next larger length listed. Forexample, if a length of pipe needed to install the furnace is27', use the diameter values for the 30' row in the tables.For direct vent installations, if the vent and air intake pipeare not equal in length and number of elbows, thendetermine the minimum pipe diameter for both the vent andair intake. If the results indicate different diameters, usethe larger of the two for both the vent and air intake. Underno circumstances should the vent and air intake pipesize be different in diameter. For installation details, referto the appropriate section in pages 11 – 15 for the unit modeland type of installation.

High Altitude Installation: 2” pipe not recommended ataltitude above 4,000 feet. 3” pipe required for altitude above5,000 feet.

Horizontal VentingThe vent for this appliance shall not terminate over publicwalkways; or near soffit vents or crawl space vents or otherareas where condensate or vapor could create a nuisanceor hazard or cause property damage; or where condensatevapor could cause damage or could be detrimental to theoperation of regulators, relief valves, or other equipment.See Figures 5 and 6 on pages 9 and 10 for additionalinformation on where the horizontal vent terminal can andcannot terminate.

For Masschusetts Installations: The installation mustcomply with Massachusetts 248 CMR 5.08 Modificationsto sections of NFPA-54, Chapter 10. (See pages 39 and40)

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Figure 5

Sidewall Vent Terminal Clearances (Direct Vented Furnaces)

1 In accordance with the current CSA B149.1, Natural Gas andPropane Installation Code

2 In accordance with the current ANSI Z223.1/NFPA 54, National FuelGas Code

† A vent shall not terminate directly above a sidewalk or paveddriveway that is located between two single family dwellings andserves both dwellings.

‡ Permitted only if veranda, porch, deck, or balcony is fully open on aminimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1,the following statement shall be included:“Clearance in accordance with local installation codes and therequirements of the gas supplier and the manufacturer’s installationinstructions.”

V

X

Vent Terminal

Air Supply Inlet

Area Where Terminal IsNot Permitted

A ** Minimum 12” (30 cm) above grade or12” (30 cm) above average snow accumulation.

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Figure 6

Sidewall Vent Terminal Clearances (Non-Direct Vented Furnaces)

1 In accordance with the current CSA B149.1, Natural Gas andPropane Installation Code

2 In accordance with the current ANSI Z223.1/NFPA 54, National FuelGas Code

† A vent shall not terminate directly above a sidewalk or paveddriveway that is located between two single family dwellings andserves both dwellings.

‡ Permitted only if veranda, porch, deck, or balcony is fully open on aminimum of two sides beneath the floor.

* For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1,the following statement shall be included:“Clearance in accordance with local installation codes and therequirements of the gas supplier and the manufacturer’s installationinstructions.”

V

X

Vent Terminal

Air Supply Inlet

Area Where Terminal IsNot Permitted

A ** Minimum 12” (30 cm) above grade or12” (30 cm) above average snow accumulation.

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For horizontal venting in situations where clearance to floorjoists is limited, see Horizontal Venting – Low ClearanceInstallations on page 15.

Upflow Direct Vent InstallationAn inlet air restrictor plate (see Figure 2 on page 6) issupplied with this furnace and can be found in the plasticbag containing these Installation Instructions and the User’sInformation Manual. This restrictor plate is to be usedonly in non-direct vent applications. See page 5 for moreinformation on installing the restrictor plate in non-direct ventapplications.

The flue pipe screen (see Figure 2 on page 6) should beinstalled at the termination of the flue pipe and is designedto keep objects out of the flue pipe. An additional screenshould not be placed in the intake termination. If a screenis installed, the air intake may freeze shut.

For horizontal venting, refer to Figure 7. For vertical venting,refer to Figure 8. It is permissible to run the vent vertically

through the roof and terminate it as shown in Figure 8, andto run the combustion air intake pipe horizontally through aside wall and terminate as shown in Figure 7. The vent pipeon horizontal runs must slope upward, away from the furnace,at a minimum pitch of 1/4" per foot of run, to preventaccumulation of condensate.

Do not cement air intake into the connector on burnerbox. Use high temperature RTV silicone sealant sointake pipe can be removed if service is required.

In horizontal venting applications, the vent and air intakepipe must be installed on the same side of the housewithin the parameters shown in Figure 7.

Figure 7

Upflow Direct Vent – Horizontal Venting

* Maintaining a vertical separationbetween the flue outlet and the airintake of at least 18” is highlyrecommended to minimize thechance of flue gasses recirculatingand freezing in the air intake pipe.This distance may be reduced inmilder climates or where wind isunlikely to blow flue products to theintake pipe, but should not be lessthan 6”.

THIS PIECEIS OPTIONAL.

INTAKE PIPE

FLUE PIPE

3” MIN. - 48” MAX.

Overhead View

Upflow Direct Vent – Vertical Venting

Figure 8

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Horizontal Direct Vent InstallationAn inlet air restrictor plate (see Figure 2 on page 6) is supplied withthis furnace and can be found in the plastic bag containing theseInstallation Instructions and the User’s Information Manual. Thisrestrictor plate is to be used only in non-direct ventapplications. See page 5 for more information on installingthe restrictor plate in non-direct vent applications.

The flue pipe screen (see Figure 2 on page 6) should beinstalled at the termination of the flue pipe and is designedto keep objects out of the flue pipe. An additional screenshould not be placed in the intake termination. If a screenis installed, the air intake may freeze shut.

Maintaining a vertical separation between the flue outlet andthe air intake of at least 18” is highly recommended to minimizethe chance of flue gasses re-circulating and freezing in theair intake pipe. The 18” separation is shown for horizontal

Prime the trap system by slowly pouring 1 cup of water downthe vent pipe. On initial start-up of the unit, some of thewater used to prime the trap system may run down into thecombustion blower and cause noise.

Upflow Non-Direct Vent InstallationAn inlet air restrictor plate (see Figure 2 on page 6) issupplied with this furnace and can be found in the plasticbag containing these Installation Instructions and the User’sInformation Manual. This restrictor plate is to be used onlyin non-direct vent applications. See page 5 for moreinformation on installing the restrictor plate in non-direct ventapplications.

Two inlet air restrictor plates are supplied with each furnace– a 2" plate and a 3" plate. Use the proper restrictor platefor the furnace model.

The flue pipe screen (see Figure 2 on page 6) should beinstalled at the termination of the flue pipe and is designedto keep objects out of the flue pipe.

For horizontal venting, refer to Figure 9. For vertical venting,refer to Figure 10. The vent pipe on horizontal runs mustslope upward, away from the furnace, at a minimum pitchof 1/4" per foot of run, to prevent accumulation ofcondensate.

Prime the trap system by slowly pouring 1 cup of waterdown the vent pipe. On initial start-up of the unit, some ofthe water used to prime the trap system may run down intothe combustion blower and cause noise.

Figure 9

Upflow Non-Direct VentHorizontal Venting

(CL

OS

ED

)

DR

AIN

HO

LE

TH

RU

.

59

.69

/56

.64

"

"

THE VENT SYSTEM OFTHE FURNACE MUST BESELF-SUPPORTING ANDMUST NOT APPLY ANYWEIGHT LOAD TO THE

COMBUSTION BLOWER.

Upflow Non-Direct VentVertical Venting

Figure 10

(CL

OS

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)

DR

AIN

HO

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RU

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59

.69

/56

.64

"

506303-01 of 40Issue 0938

installations in Figure 11. This distance may be reduced inmilder climates or where wind is unlikely to blow flue productsto the intake pipe, but should not be less than 6”.

For horizontal venting, refer to Figure 11. For verticalventing, refer to Figure 12. It is permissible to run the ventvertically through the roof and terminate it as shown in Figure12, and to run the combustion air intake pipe horizontallythrough a side wall and terminate as shown in Figure 11.The vent pipe on horizontal runs must slope upward, awayfrom the furnace, at a minimum pitch of 1/4" per foot of run, toprevent accumulation of condensate.

Do not cement air intake into the connector on burnerbox. Use high temperature RTV silicone sealant sointake pipe can be removed if service is required.

In horizontal venting applications, the vent and air intakepipe must be installed on the same side of the housewithin the parameters shown in Figure 11.

Horizontal Direct Vent –Horizontal Venting

Figure 11

Airflow Left to Right

THIS PIECEIS OPTIONAL.

INTAKE PIPE

FLUE PIPE

3” MIN. - 48” MAX.

Overhead View

* Canadian installations: See “Canadian Applications Only” on page 6.

Long Piece ofDrain Tee(supplied)

Height toprovide

clearanceto averagesnow level

VentPipe

Air IntakePipe

Intake may be raised asshown to obtain minimum snow

clearance requirements.

3”2” Diameter Pipe

(supplied)

6”

18”

12”

**

**

18”

6”

12”

3”2”

Airflow Right to Left

Figure 12

Horizontal Direct Vent –Vertical Venting


12”

6.5” Min24” Max

3”

2”

*

*

Height toprovide


Drain Tee(supplied)

Vent Pipe Air Intake Pipe

See table for air intakelength and number ofelbows allowed.

See table for ventlength and numberof elbows allowed.

6.5” Min24” Max

12”

3” Long Piece of 2” Diameter Pipe

(supplied) *

*



506303-01 of 40 Issue 0938

Prime the trap system by slowly pouring 1 cup of water downthe vent pipe. On initial start-up of the unit, some of thewater used to prime the trap system may run down into thecombustion blower and cause noise.

Horizontal Non-Direct Vent InstallationAn inlet air restrictor plate (see Figure 2 on page 6) issupplied with this furnace and can be found in the plasticbag containing these Installation Instructions. This restrictorplate is to be used only in non-direct vent applications. Seepage 5 for more information on installing the restrictor platein non-direct vent applications.

Two inlet air restrictor plates are supplied with each furnace– a 2" plate and a 3" plate. Use the proper restrictor platefor the furnace model.

The flue pipe screen (see Figure 2 on page 6) should beinstalled at the termination of the flue pipe and is designedto keep objects out of the flue pipe.

For horizontal venting, refer to Figure 13. For vertical venting,refer to Figure 14. The vent pipe on horizontal runs must slope

upward, away from the furnace, at a minimum pitch of 1/4" perfoot of run, to prevent accumulation of condensate.

Prime the trap system by slowly pouring 1 cup of waterdown the vent pipe. On initial start-up of the unit, some ofthe water used to prime the trap system may run down intothe combustion blower and cause noise.


Figure 13

Horizontal Non-Direct Vent –Horizontal Venting


Drain Tee(supplied)

Inlet Air Restrictor Plate(see page

VentPipe

Height toprovide


6”

12”

6)

3” Long Piece of

2” Diameter Pipe

(supplied) *

*


6”

Drain Tee(supplied with unit)

Inlet Air Restrictor Plate( )see page 6

VentPipe

Height toprovide


*

3” Long Piece of

2” Diameter Pipe

(supplied) *

12”

Figure 14

Horizontal Non-Direct Vent –Vertical Venting


Height to

clearance to

snow levelaverage

Drain Tee(supplied)

Inlet Air Restrictor Plate( )see page 6

For venting material,see venting section

in these instructions.Vent Pipe

*

provide 12”

3” Long Piece of

2” Diameter Pipe

(supplied) *


Inlet Air Restrictor Plate( )see page

VentPipe

Height toprovide


Drain Tee(supplied)

See table forvent length

and numberof elbows

allowed

12”

6

3” Long Piece of 2” Diameter Pipe

(supplied) *

*


506303-01 of 40Issue 0938

Horizontal Venting – Low Clearance InstallationsVent pipe on horizontal runs must slope upward, away fromthe furnace, at a minimum pitch of 1/4" per foot of run, toprevent accumulation of condensate. In certain horizontal,left-to-right airflow applications, the furnace’s close proximityto the floor joists above the unit may make it difficult to obtainthe required pitch/slope. Figures 15 and 16 show the acceptedvent practice to obtain proper pitch/slope back to furnace forproper drainage. For direct vent applications, see Figure 15.For non-direct applications, see Figure 16.

In all applications, minimum clearances to combustiblesmust be observed (as shown in Table 1 on page 4) as wellas all other required clearances shown in Figures 11 and13 on pages 13 and 14.

Existing Venting SystemsWhen an existing furnace is removed or replaced, the originalventing system may no longer be sized to properly vent theattached appliances. An improperly sized venting system canresult in spillage of flue products into the living space, the

formation of condensate, leakage, etc. See the WARNINGbox below for proper test procedure.

Failure to follow the steps outlined below for eachappliance connected to the venting system beingplaced into operation could result in carbon monoxidepoisoning or death.The following steps shall be followed for each applianceconnected to the venting system being placed intooperation, while all other appliances connected to thecommon venting system are not in operation:1. Seal any unused openings in the common venting

system.2. Visually inspect the venting system for proper size

and horizontal pitch, as required in the National FuelGas Code, ANSI Z223.1/NFPA 54 (latest edition)or the CSA B149.1, Natural Gas and PropaneInstallation Codes and these instructions. Determinethat there is no blockage or restriction, leakage,corrosion, or other deficiencies which could causean unsafe condition.

3. As far as practical, close all building doors andwindows between the space in which theappliance(s) connected to the venting system arelocated and other spaces in the building.

4. Close fireplace dampers.5. Turn on clothes dryers and any appliance not

connected to the venting system. Turn on anyexhaust fans, such as range hoods and bathroomexhausts, so they are operating at maximum speed.Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the unit beinginspected in operation. Adjust the thermostat soappliance is operating continuously.

7. Test for spillage from draft hood equippedappliances at the draft hood relief opening after 5minutes of main burner operation. Use the flame ofa match or candle.

8. If improper venting is observed during any of theabove tests, the venting system must be correctedin accordance with the National Fuel Gas Code,ANSI Z223.1/NFPA 54 (latest edition) and/or theCSA B149.1, Natural Gas and Propane InstallationCodes.

9. After it has been determined that each applianceremaining connected to the venting system properlyvents when tested as outlined above, return doors,windows, exhaust fans, fireplace dampers, and anyother gas-fired burning appliance to their previousconditions of use.

CARBON MONOXIDE POISONING HAZARD

WARNING

Figure 15

Horizontal Direct Vent – Horizontal VentingLow Clearance Installation

3” Long Piece of

2” Diameter Pipe

(supplied) *

2 - 2” 90° Elbows

*


Floor Joist

Vent Pipe

Drain Tee(supplied) *

Inlet Air Restrictor Plate(see page 6)

3” Long Piece of

2” Diameter Pipe

(supplied) *

2 - 2” 90° Elbows

Figure 16

Horizontal Non-Direct Vent – Horizontal VentingLow Clearance Installation


506303-01 of 40 Issue 0938

Condensate Disposal InstallationThe condensate drain should be routed directly to a locallyacceptable disposal area. The condensate drain line shouldnot be run directly to the outdoors especially in colderclimates where temperatures may cause the condensateto freeze in the drain line.

In horizontal installations where clearance beneath the unitis limited, an alternate method for condensate disposal trapinstallation may be used (see Horizontal Installation –Tight Clearance Below Unit on page 18).

Upflow InstallationInstall the condensate drain line to the unit as follows. Thecondensate can be drained from either the right or left sideof the furnace. Install the 1/2" NPT x 3/4" PVC adapter(supplied) in the drain on the side that the draining will occur.Install the plastic pipe plug opposite of the drain. Using 3/4"PVC pipe, make a connection from the adapter just installedto extend just outside the unit. Install a 3/4" PVC tee asshown in Figure 17. From the tee, install the drain to thedisposal area. The top of the tee must be left open for propercondensate drainage.

Horizontal Installation – Right to Left AirflowFurnace must be mounted such that the side through whichthe condensate will drain is elevated a minimum of 9" abovea surface such as a floor.

Install unit at a slight pitch forward (see Figure 18).

1. Relocate the 1/2" NPT plug installed on the flue pan toone side of the internal trap assembly (as shown inFigure 19).

2. Connect the 1/2" NPT plug (supplied) to the oppositeside of the internal trap assembly from the plug installedin Step 1.

3. Insert trap assembly (supplied) into flue pan (see Figure20).

Figure 17

Condensate Disposal – Upflow

TH

RU

.

59.6

9/5

6.6

4

1/2” NPT PLUG(SUPPLIED)

1/2” NPT x 3/4”PVC ADAPTER(SUPPLIED)

3/4” PVC

TEE MUST REMAINOPEN

3/4” PVC

Figure 18

Tilt Unit Forward

1/4" Max

Figure 19

Insert Plugs

Figure 20

Install Trap Assembly

506303-01 of 40Issue 0938

6. From the tee, connect the drain to disposal area. The topof the tee must be left open for proper condensatedrainage. The open end of the tee must be oriented sothat condensate does not run out of the opening.

7. Remove 72" vinyl hose supplied with unit and cut in half.Connect one end of the vinyl hose to the 3/8" barbedfitting of the 2" x 2" x 1/2" tee in vent and the other end tothe 3/8" barbed fitting on the drain trap assembly.

Horizontal Installation – Left to Right AirflowFurnace must be mounted such that the side through whichthe condensate will drain is elevated a minimum of 9" abovea surface such as a floor.

Install unit at a slight pitch forward (see Figure 22).1. Relocate 1/2" NPT plug installed on flue pan to one side

of the internal trap assembly (as shown in Figure 23).

2. Connect the 1/2" NPT plug (supplied) to the oppositeside of the internal trap assembly from the plug installedin Step 1.

3. Insert trap assembly (supplied) into flue pan (see Figure24).

4. Connect a length of 3/4" PVC pipe (3' minimum) to thetrap assembly (see Figure 21).

5. Install 3/4" tee (supplied) as shown in Figure 21.

4. Connect a length of 3/4" PVC pipe (3' minimum) to thetrap assembly (see Figure 25 on page 18).

Completing CondensateDrain Installation

3/4" Tee

3/8" Vinyl Hose(supplied)

Be sure to avoid double-trapping the vinyl hose. Hose mustbe installed as shown.

Figure 21

Figure 22

Tilt Unit Forward

1/4” Max

Figure 23

Insert Plugs

Figure 24

Install Trap Assembly

1/2” NPT x 1/2” PVC

Adapter and Trap Assembly

(supplied)

Flue Pan

506303-01 of 40 Issue 0938

5. Install 3/4" tee (supplied) as shown in Figure 25.

6. From the tee, connect the drain to disposal area. Thetop of the tee must be left open for proper condensatedrainage. The open end of the tee must be oriented sothat condensate does not run out of the opening.

7. Connect one end of 72" vinyl hose (supplied) to 3/8"barbed fitting of the 2" x 2" x 1/2" tee in vent and the otherend to 3/8" barbed fitting on drain trap assembly.

Horizontal Installation – Tight Clearance Below UnitIn certain horizontal installations, clearance between unit anddrain pan beneath unit may be limited. In these applications,an alternate method may be used to install the condensate

drain trap assembly. Using two 90° elbows (field supplied),bring condensate trap out to side of unit beyond drain pan(see Figure 26). After trap assembly has been attached usingthis method, follow proper instructions on the previous pagesfor completing condensate drain installation.

Drain Pressure Switch Connection(for G2D93CT and G2D95CT multi-position units only. TheG2D93CU and G2D95CU dedicated upflow units do notrequire a drain switch).

Upflow InstallationThe G2D93CT and G2D95CT units are shipped from themanufacturer with a black hose having one end connected tothe 0.10” drain pressure switch and the other end shippedloose. FOR UPFLOW INSTALLATIONS the loose end is tobe connected to the capped tee in the hose assemblyleading from the primary pressure switch to the inducer.Remove and discard the plastic cap from the tee andconnect the hose from the 0.10” drain pressure switch tothe tee. (See Figure 31.)

Figure 26

Condensate Drain Trap Installation – Tight Clearance Below Unit

Drain Pan

Two 3/4" 90° Elbows

1/2" NPT x 1/2" PVCAdapter and Trap Assembly

(supplied)

End View

Field-Supplied Fittings

IMPORTANT: If vent tee is not located over theauxiliary drain pan, it must be extended over thepan with an elbow facing down to preventoverflow in the event of a blocked drain. Theelbow must be installed downward over theauxiliary pan to prevent wicking back down thecondensate line.

Do not install trap assembly any farther than 10" from unit. The pressure switch and venthoses must be able to reach the barbed fittings on the trap assembly.

NOTE: Vent tee to avoidvapor lock. If connectingto waste drain pipe, asecond trap must beinstalled downstream.

Figure 25

Completing CondensateDrain Installation

Be sure to avoid double-trapping the vinyl hose. Hose mustbe installed as shown.

To avoid property damage caused by condensate drainblockage, install a field-fabricated auxiliary drain pan witha separate drain line to the outside under the entire furnaceand drain system, including open vent tees.

CAUTION

506303-01 of 40Issue 0938

Be sure that the pressure switch hose does not form atrap to hold condensation that could form from the fluegas. Hose may be cut shorter to avoid forming a trap, ifrequired.

Horizontal InstallationThe G2D93CT and G2D95CT units are shipped from themanufacturer with a black hose having one end connectedto the 0.10” drain pressure switch and the other end shippedloose. FOR HORIZONTAL INSTALLATIONS the loose endMUST be connected to the external drain trap.

Route hose through gas line access hole in cabinet. Thenconnect to 1/4" barbed fitting on drain trap assembly.

For right to left airflow installations, see Figure 28. For leftto right airflow installations, see Figure 29.

Be sure that the pressure switch hose does not form atrap to hold condensation that could form from the fluegas. Hose may be cut shorter to avoid forming a trap, ifrequired.

Circulating Air SupplyWhen the furnace is installed so that the supply ducts carryair circulated by the furnace to areas outside the spacecontaining the furnace, the return air shall be handled by aduct or ducts sealed to the furnace casing and terminatedoutside the space containing the furnace. When an air conditioning unit is used in conjunction

with the furnace, the evaporator coil must be installedin the discharge (supply) air. Do not install an evaporatorcoil in the return air; excessive condensation will occurwithin the furnace.

CAUTION

Pressure Switch ConnectionHorizontal Installation – R to L Airflow

Figure 28

Pressure Switch ConnectionUpflow Installation

Figure 27

BlackHoses

Tee(supplied)

Low Fire-High FirePressure Switch

Assembly

Yellow Cap

BlowerHousing

Tap

Trap

0.10” w.c.

Pressure Switch

Pressure Switch ConnectionHorizontal Installation – L to R Airflow

Figure 29

A return air duct system is recommended. If the unit isinstalled in a confined space or closet, a return connectionmust be run, full size, to a location outside the closet. Theair duct in the closet must be tight to prevent any entranceof air from the closet into the circulating air.

If there is no complete return air duct system, the return airconnection must be sealed to the furnace casing and run, fullsize, to a location outside the utility room or space housing thefurnace to prevent a negative pressure on the venting system.

506303-01 of 40 Issue 0938

3. With the filter access opening toward the front of thefurnace, use sheet metal screws to fasten the rack(s)to the side panel(s).

The filter slides in the rack from the front of the unit. Installthe filter(s) with the mesh side towards furnace.

Model #AFILTHA7 single side filter frame kit is available forsingle side return air connection in installations requiring morethan 1600 CFM nominal air delivery. A bottom return filter kit(model #AFILT529) is also available from the manufacturer.

Outlet DuctFor installations not equipped with a cooling coil, aremovable access panel must be provided in the outlet duct.The opening should be accessible when the furnace isplaced in service. Smoke or reflected light may be observedinside the casing to indicate the presence of leaks in theheat exchanger. The cover for the opening shall be attachedin such a manner as to prevent leaks. The recommendedopening size is 6" x 14" for all sizes.

FiltersIf a filter other than one supplied by the furnace manufactureris used, it must be sized according to information providedin Table 3.

A filter rack and cleanable 16" x 25" x 1/2" filter are suppliedwith the furnace. (Models designed for more than 1600 CFMnominal air delivery include two of each.) The filter rack isto be installed between the return air duct and the side ofthe furnace.

Refer to Figure 30 and the following instructions to installthe filter rack:

1. Using the corner embossments as a guide, mark andcut a full-size opening in the side panel(s).

2. Using the filter rack as a template, mark and drill four7/64” diameter screw holes in the side panel(s).

Other filter accessories are also available from themanufacturer including a full line of indoor air quality products.For information on these products, contact the local distributor.

Gas Supply and PipingRefer to the furnace rating plate to make sure the furnaceis equipped to burn the gas supplied (natural or propane).

Gas supply piping should be installed in accordance with localcodes and the regulations of the utility. Piping must be ofadequate size to prevent undue pressure drop. Consult thelocal utility or gas supplier for complete details on specialrequirements for sizing gas piping.

Table 3

Minimum Filter Requirements

1. The Airflow Descriptor is the two digits following the “D”(example: G2D93CT080D16C) or “V” (example:G2D95CT080V16C) in the model number.

2. Areas and dimensions shown for cleanable filters are based onfilters rated at 600 feet per minute face velocity.

3. Typical filter sizes are shown; however, any combination offilters whose area equals or exceeds the minimum area shownis satisfactory.

Filter Rack Mounting Hole

Screw

Filter RackCorner EmbossmentsFront of Cabinet

Filter Rack Installation

Figure 30

Figure 31

Bottom Filter Location

FilterBase

Side

506303-01 of 40Issue 0938

If local codes allow the use of a flexible gas applianceconnector, always use a new listed connector. Do not use aconnector which has previously serviced another gasappliance.

Pipe connections must be tight, and a non-hardening pipecompound resistant to liquefied petroleum gases shouldbe used.

Connect the gas pipe to the furnace controls providing aground joint union as close to the controls as is possible tofacilitate removal of controls and manifold. Provide a dripleg on the outside of the furnace. A manual shutoff valveshall be installed in the gas line, outside the unit, 5' abovethe floor, or in accordance with any local codes. A test gaugeconnection must be installed with a 1/8" NPT pluggedtapping immediately upstream of the shutoff valve (seeFigure 32).

The furnace must be isolated from the gas supply pipingsystem by closing the individual manual shutoff valve duringany pressure testing of the gas supply piping system at testpressure equal to or less than 1/2 psig (3.5 kPa) or 14"W.C. If the piping system is to be tested at pressures inexcess of 1/2 psig (3.5 kPa), the furnace and its appliance

main gas valve must be disconnected from the gas supplypiping system.

After gas piping is complete, carefully check all pipingconnections (factory and field) for gas leaks. Use a leakdetecting solution or other preferred means. Some soapsused for leak detection are corrosive to certain metals.Carefully rinse piping thoroughly after leak detection hasbeen completed.

Any conversion of a natural gas unit to propane gas mustbe done by qualified personnel using a conversion kitavailable from the manufacturer, following the instructionsin the conversion kit. If done improperly, overfiring of theburners and improper burner operation can result. Thiscan create carbon monoxide which could causeasphyxiation.

WARNING

The gas valve supplied with this furnace is rated at 1/2psig maximum. Any higher pressure may rupture thepressure regulator diaphragm and may cause overfiringof the burners and improper burner operation. Theoverfiring may result in the creation of carbon monoxidewhich could cause asphyxiation.

WARNINGFailure to follow the safety warnings exactly could resultin serious injury, death, or property damage.

Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections. Afire or explosion may result causing property damage,personal injury, or loss of life.

WARNINGFIRE OR EXPLOSION HAZARD

Gas Piping Connection

Figure 32

ManualGas Valve

Union

Tee

Drip Leg

Cap

1/8" NPTPluggedTapping

UpflowInstallation

HorizontalInstallation

506303-01 of 40 Issue 0938

The furnace must be grounded and wired in accordancewith local codes or, in the absence of local codes, with theNational Electrical Code ANSI/NFPA No. 70 (latest edition)and/or CSA C22.1 Electrical Code (latest edition) if anexternal electrical source is utilized.

In all instances, other than wiring for thermostat, the wiring tobe done and any replacement of wire shall conform with thetemperature limitation for Type T wire – 63°F (35°C) rise.

Connect a sufficiently sized wire with ground to the furnace’sline voltage connections and ground lug. Refer to the furnacerating plate for electrical characteristics to be used in sizingfield supply wiring and over-current protection.

The line voltage supply should be routed through a readilyaccessible disconnect located within sight of the furnace.A junction box on the furnace side panel is provided forline voltage connections. Refer to the furnace wiringdiagram for specific connection information.

Proper polarity of the supply connections (“HOT” and“NEUTRAL”) must be observed to ensure that safetycontrols provide the protection intended.

A connection to the ground lug and actual earth ground(typically a ground stake or buried steel pipe) must bemaintained for proper operation.

ThermostatInstall a room thermostat according to the instructionsfurnished with it. Select a location on an inside wall that isnot subject to drafts, direct sunshine, or other heat sources.The initial heat anticipator setting should be equal to thetotal current draw of the control circuit.

Low voltage thermostat connections are to be made to theintegrated ignition/blower control board as indicated on thewiring diagram.

Single Stage Thermostat OperationThe automatic heat staging option allows a single stagethermostat to be used with a two stage furnace. To activatethis option, move the jumper pin (see Figure 33) to desiredsetting (5 minutes or 10 minutes). The furnace will start on 1st

Electrical Wiring

stage heat and stay at 1st stage heat for the duration of theselected time before switching to 2nd stage heat.

W1 on the control board must be connected to W1 on thethermostat.

HumidifierTerminals are provided on the integrated ignition/blower controlboard for connection to a 120-volt humidifier. The “HUM”terminal is energized whenever the thermostat calls for heat.Refer to furnace wiring diagram for specific connectioninformation.

Electronic Air CleanerTerminals are provided on the integrated ignition/blower controlboard for connection of a 120-volt electronic air cleaner. The“EAC” terminal is energized whenever the thermostat callsfor heat, cooling, or continuous blower. Refer to the furnacewiring diagram for specific connection information.

Continuous Blower Operation (G2D93CT/U Models)The comfort level of the living space can be enhanced whenusing this feature by allowing continuous circulation of airbetween calls for cooling or heating.

If continuous blower operation on low speed is desired,connect the lowest speed motor tap to the “CONT” terminalon the integrated ignition/blower control board (refer to thefurnace wiring diagram). The blower will operate on lowspeed whenever main power is connected to the furnace,except when it operates on heating or cooling speed duringthermostat call for heat or cooling. This constant airterminal is intended for low speed only. If a motor iswired for a higher speed, the increased amp draw couldcause the board control to fail and void the warranty.

Risk of electrical shock. Disconnect electrical power atthe circuit breaker or service panel before makingelectrical connections. Failure to disconnect powersupplies can result in property damage, personal injury,or death.

WARNING

Automatic Heat Staging Jumper

Figure 33

506303-01 of 40Issue 0938

NOTE: If a single stage thermostat is used, move theautomatic heat staging jumper pin (see Figure 33) from theNONE position to either the 5 or 10 minute setting. Connectrest of wiring as shown in Figure 34 or Figure 35 except inthis single stage thermostat configuration, the W2 mustremain open (only W1 should be connected).

If the red LED on the control board flashes a “9 flash” faultcode after the units are energized (see Table 5 on page 33),switch 24V leads on the transformer in one of the units tobring both transformers into phase.

Variable Speed Features (G2D95CT/U Models Only)The G2D95CT/U furnace is equipped with a variable speedcirculation air blower motor that will deliver a constant airflowwithin a wide range of external static pressures.

Other features of this variable speed motor include:

Soft StartThe variable speed motor will slowly ramp up to normaloperating speed. This minimizes noise and increasescomfort by eliminating the initial blasts of air encounteredwith standard motors.

Continuous Blower Operation (G2D95CT/U Models)The comfort level of the living space can be enhanced whenusing this feature by allowing continuous circulation of airbetween calls for cooling or heating. The circulation of airoccurs at half the full cooling airflow rate.

To engage the continuous blower operation, place the fanswitch on the thermostat into the ON position. A call for fanfrom the thermostat closes R to G on the control board.The control waits for a 1-second thermostat debounce delaybefore responding to the call for fan by ramping thecirculating blower up to 50% of the cooling speed. Whenthe call for continuous fan is satisfied, the controlimmediately ramps down the circulating blower.

Twinning (G2D93CT/U Models Only)The integrated ignition/blower control board is designed topermit “twinning” of furnaces (two furnaces connected to acommon supply and return air system, and controlled byone thermostat).

When “twinning” two furnaces, each furnace must haveits own dedicated vent system.

To twin two G2D93CT/U furnaces, connect wires as shownin either Figure 34 below or Figure 35 on page 24.G2D95CT/U furnaces cannot be twinned.

Figure 34

Wiring Connections for Twinning Two G2D93CT/U FurnacesTwo Stage Heating/Two Stage Cooling

506303-01 of 40 Issue 0938

Soft StopAt the end of a cooling or heating cycle, the variable speedmotor will slowly ramp down after a short blower “off” delay.If continuous blower operation has been selected, thevariable speed motor will slowly ramp down until it reachesthe airflow for that mode.

Passive and Active DehumidificationPassive DehumidificationFor situations where humidity control is a problem, adehumidification feature has been built into the variablespeed motor. At the start of each cooling cycle, the variablespeed motor will run at 82% of the rated airflow for 7.5minutes. After 7.5 minutes has elapsed, the motor willincrease to 100% of the rated airflow.

Active DehumidificationTo achieve additional dehumidification, clip the jumper wirelocated below the DEHUM terminal on the integrated ignition/blower control board and connect a humidity control thatopens on humidity rise to the DEHUM and R terminals. TheDEHUM terminal on the control board must be connected tothe normally closed contact of the humidity control so that theboard senses an open circuit on high humidity. In this setup,the variable speed motor will operate at a 18% reduction inthe normal cooling airflow rate when there is a call fordehumidification.

Both the passive and active dehumidification methodsdescribed above can be utilized on the same furnace.

Circulating Airflow AdjustmentsCooling ModeThe units are factory set for the highest airflow for each model.Adjustments can be made to the cooling airflow byrepositioning the jumper plug marked COOL – A, B, C, D(see Figure 36) based on the information found in the table.To determine what CFM the motor is delivering at any time,count the number of times the amber LED on the controlboard flashes. Each flash signifies 100 CFM; count the flashesand multiply by 100 to determine the actual CFM delivered(for example: 10 flashes x 100 = 1000 CFM).

Figure 35

Wiring Connections for Twinning Two G2D93CT/U FurnacesTwo Stage Heating/Single Stage Cooling

506303-01 of 40Issue 0938

Heating ModeThe unit as shipped is factory set to run at the middle of theheating rise range as shown on the unit rating plate. If higheror lower rise is desired, change the airflow 15% up or downby moving the ADJUST jumper plug (see Figure 36) fromthe NORM position to the (+) or (–) position. This adjustmentwill also cause the cooling airflow to be raised or loweredby 15%.

The TEST position on the ADJUST tap is not used.

The jumper plug on the HEAT tap should remain in theposition (A, B, C, or D) listed in the HEAT Setting column inthe table found in Figure 36. Changing the setpoints maynot increase or decrease heating blower speeds. In somecases, running the blower with the heat settings in the wrongposition may cause the furnace to operate outside thefurnace’s intended temperature rise range.

Figure 36

Adjusting Airflow – G2D95CT/U Models Only

ADJUST, HEAT, and COOL Tapson Integrated Ignition/Blower Control Board

A

1

Model Motor

HP

ADJUST

Setting HEAT

SettingHigh Fire Low Fire

COOL

Setting

A

COOL

Setting

B

COOL

Setting

C

COOL

Setting

D

Heating CFM @ .50 Static Cooling CFM @ .50 Static

G2D95CT/U040V12

G2D95CT/U060V14

G2D95CT/U080V16

G2D95CT/U080V20

G2D95CT/U100V20

G2D95CT/U125V20

1/2

1/2

3/4

1

1

NORM

NORM

NORM

NORM

NORM

NORM A

A

A

C, D

B

750

1000

1500

1500

1700

2100

500

650

950

950

1150

1450

1200

1400

1600

2000

2000

2000

1000

1200

1400

1800

1800

1800

800

1000

1200

1600

1600

1600

600

800

1000

1400

1400

1400

506303-01 of 40 Issue 0938

1. Set the room thermostat to lowest setting.

2. Remove burner access door.

START-UP

These furnaces are equipped with an ignition device whichautomatically lights the burners. Do not try to light theburners by hand.

Before operating, smell all around the appliance area forgas. Be sure to smell next to the floor because some gas isheavier than air and will settle on the floor.

What to do if you smell gas:

• Do not try to light any appliances.

• Extinguish any open flame.

• Do not touch any electric switch; do not use any phonein your building.

• Immediately call your gas supplier from a neighbor’sphone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the firedepartment.

Do not use this furnace if any part has been under water.Immediately call a qualified service technician to inspectthe furnace and to replace any part of the control systemand gas control which has been under water.

IMPORTANT: Refer to the Lighting Instruction label onthe furnace for instructions on operating the specificcontrols used on your unit.

To Start Furnace:

Lighting Instructions

For Your Safety, Read Before Operating

3. Move the gas control knob to the “ON” position. Useonly your hand to turn the gas control knob; never usetools. If the knob will not turn by hand, don’t try to repairit; call a qualified service technician. Force orattempted repair may result in a fire or explosion.

4. Replace the burner access door.

5. Turn on the electrical power to the furnace.

6. Set the room thermostat to a point above roomtemperature to light the burners. After the burners haveignited, set the room thermostat to desired temperature.

To Shut Down Furnace:

1. Set the room thermostat to the lowest setting.

2. Turn off all electric power to the furnace.

3. Remove burner access door.

4. Shut off the gas by moving the gas control knob to the“OFF” position.

5. Replace the burner access door.

If you do not follow these instructions exactly, a fire orexplosion may result causing property damage,personal injury, or loss of life.

WARNING

Be sure the manual gas control has been in the “OFF”position for at least 5 minutes before starting the unit.Do not attempt to manually light the burners.

CAUTION

Should overheating occur or the gas supply fail to shutoff, shut off the manual gas valve to the appliance beforeshutting off the electrical supply.

WARNING

506303-01 of 40Issue 0938

Fan OnA call for fan from the thermostat closes R to G on the controlboard. The control waits for a 1-second thermostatdebounce delay before responding by energizing the lowheat speed blower. When the call for fan is turned off, thecontrol de-energizes the blower.

CoolingDuring a call for cooling, the thermostat energizes the R-Ycircuit of the control board. After a 1-second cooling “on” delay,the control energizes the cooling fan speed. If the fan is alreadyenergized, it remains running and does not de-energize forthe 1-second cooling fan “on” delay.

The call for cooling has priority over continuous fan operationwhile a call for heating has priority over both a call for coolingor continuous fan. Ignition lockouts for any reason do notaffect cooling operation.

As cooling demand is met, the thermostat de-energizesthe R-Y circuit of the control board. After a 60-second cooling“off” delay, the control de-energizes the cooling speed fan.At the end of the cooling “off” delay period, the control returnsto the standby mode.

Sequence of Operation (G2D95CT/U Models)

Heating (see Figures 37 and 38 on page 28)On a call for heat from the room thermostat, the ignitioncontrol performs a 1-second self-check. Upon confirmationthat the pressure switch contacts are in an open position,the ignition control energizes the combustion blower on highspeed. The control then checks for adequate combustionair by making sure the low-fire pressure switch contactsare closed.

The igniter energizes and is allowed to warm up for7 seconds before the gas valve energizes on 1st stage andburners ignite. 45 seconds after the control confirms ignitionhas occurred, the control drops the combustion blower tolow speed.

The circulating blower ramps up to 50% of 1st stage heatspeed and operates at that speed for one minute (includingramp up time), then at 75% of 1st stage heat speed for anadditional minute. After that, the circulating blower operatesat full 1st stage heat speed until either the heat call is satisfiedor the thermostat initiates a call for 2nd stage heat. On a callfor 2nd stage heat, the control energizes the circulating airblower on full CFM 2nd stage heat.

If the automatic heat staging option is being used (seeSingle Stage Thermostat Operation on page 22), thefurnace does not switch to 2nd stage heat in response to acall from the thermostat but instead operates at 1st stageheat for the duration of the selected time beforeautomatically switching to 2nd stage heat.

OPERATION

Sequence of Operation (G2D93CT/U Models)

HeatingWhen the control is in standby mode, it continually monitorsthermostat input, rollout switch, and flame sense.

On a call for 1st stage heat, W1 and R are connected. Thecontrol verifies the limit switch is closed and both low andhigh pressure switches are open. The control always startson low-fire and ignores 2nd stage call for 30 seconds.

The induced draft blower is energized on high speed andwaits for the low pressure switch to close. The inducerremains on high speed and begins a pre-purge period whenthe low pressure switch closes. After a 15-second pre-purge,the control energizes the hot surface igniter for a period of7 seconds (15 seconds on retries) before the gas valve isenergized on 1st stage and burners ignite. After a 30-secondblower “on” delay, the control energizes the low heatcirculating air blower. Fifteen seconds after the circulatingair blower energizes, the combustion air blower switchesto low speed and runs at that speed until the thermostat issatisfied.

If the 1st stage is not sufficient to satisfy the heating demand,the room thermostat initiates call for the 2nd stage heat (W1and W2). The control energizes the combustion blower onhigh speed and confirms the high-fire pressure switchcontacts are closed. If the contacts are closed, the gas valveenergizes on the 2nd stage and the high-heat circulating airblower is energized.

If the automatic heat staging option is being used (seeSingle Stage Thermostat Operation on page 22), thefurnace does not switch to 2nd stage heat in response to acall from the thermostat but instead operates at 1st stageheat for the duration of the selected time beforeautomatically switching to 2nd stage heat.

When the 2nd stage heat is satisfied, the control shuts offthe gas valve and runs the combustion blower for a post-purge period of 15 seconds. The circulating air blowercontinues to run according until the selected blower “off”delay time (factory shipped at 120 seconds) ends.

In the event the unit loses ignition, the control will attemptto recycle up to five times before it goes into a 1-hour lockout.Lockout may be manually reset by removing power fromthe control for more than 1 second or removing thethermostat call for heat for more than 3 seconds.

If during a heating cycle the limit control senses anabnormally high temperature and opens, the circulating airblower is energized on high speed and continues to runwhile the limit is still open.

506303-01 of 40 Issue 0938

If during a heating cycle the limit control senses an abnormallyhigh temperature and opens, the ignition control de-energizesthe gas valve and the combustion blower while the circulatingblower ramps up to 2nd stage heat speed. The circulating blowerremains energized until the limits are closed.

Fan On (see Figure 39)When the thermostat is set for continuous fan operationand there is no demand for heating or cooling, a call for fancloses the R to G circuit and the circulating blower motor

runs at 50% of the selected cooling CFM until switched off.When the call for fan is turned off, the control de-energizesthe circulating blower.

CoolingThe unit is set up at the factory for single stage cooling. For twostage cooling operation, clip the jumper wire located betweenthe Y to Y2 terminals on the integrated ignition/blower controlboard.

When the call for heat is satisfied, the gas valve andcombustion air blower shut down. The ignition control shutsoff the gas valve and runs the combustion blower for anadditional 15 seconds. The circulating air blower continuesto run for 2 minutes at 82% of the selected heating speed(low fire or high fire) before ramping down.

In the event the unit loses ignition, the control will attemptto recycle up to five times before it goes into a 1-hour lockout.Lockout may be manually reset by removing power fromthe control for more than 1 second or removing thethermostat call for heat for more than 3 seconds.

High Heat (W2) Call(G2D95CT/U Models)

Figure 38

W2

100*82%*

2 min

CALL OFFW2 - High Heat Demand Present- High Heat Demand Satisfiedw2

* Percentage of High Fire CFM(see table in Figure on page )36 25

w2

Figure 37

1st Stage – 2nd Stage (W1/W2) Heat Call(G2D95CT/U Models)

W1

100%*

CALL

W2 - High Heat Demand Present- High Heat Demand Satisfiedw2

50%*

75%*

** Percentage of High Fire CFM(see table in Figure on page )36 25

1min

W1 - Heat Demand Present- Heat Demand Satisfiedw1

* Percentage of Low Fire CFM(see table in Figure 36 on page 25)

100%**82%**

2 min

OFF

W1/W2 w1 w2

82%*

2 min

w1

1min

Call for Fan(G2D95CT/U Models)

Figure 39

G g

50%

CALL OFF

G - Fan Switch ON

- Fan Switch OFFg

506303-01 of 40Issue 0938

Heat PumpFor heat pump operation, clip the jumper wire located belowthe O terminal on the integrated ignition/blower control board.In heat pump mode, a call for heat pump operation follows thesame sequence as a call for cooling with the exception thatthere is a 30-second blower ramp up to blower CFM.

ControlsFollowing is a description of the operation of some of thecontrols used in this furnace. All models use one of eachcontrol, except as noted.

Pressure SwitchThe pressure switch is a normally open switch that monitorscombustion air flow. Inadequate air flow resulting fromexcessive venting system restriction, a failed combustionblower, or a blocked drain will cause the switch to remainopen.

Rollout SwitchThe rollout switch is a normally closed switch that openswhen abnormal temperatures exist in the burner area. Thiscan be caused by a restricted heat exchanger causing theburner flame to “roll out” into the vestibule area or burnerbox. These units have two rollout switches. This switchmust be manually reset by pushing the button on top torestore furnace operation.

Primary Limit ControlThis is a normally closed control that opens if abnormallyhigh circulating air temperatures occur. It is an automaticreset control.

If the active dehumidification feature is enabled, thecirculating blower runs at 82% of the selected cooling speedas long as there is a call for dehumidification.

Two Stage Cooling (see Figure 41)A call for 1st stage cooling from the thermostat closes the Rto Y circuit on the control board. The control waits for a 1-second delay before energizing the circulating blower. Theblower motor runs at 57% of the selected air flow for thefirst 7.5 minutes of the 1st stage cooling demand (passivedehumidification mode). After 7.5 minutes, the blower motorruns at 70% of the selected cooling air flow until 1st stagecooling demand is satisfied.

A call for 2nd stage cooling from the thermostat closes the R toY2 circuit on the control board. The blower motor ramps up to100% of the selected cooling air flow. When the demand forcooling is met, the blower ramps down to Y1 until satisfied, thenramps down to 57% for 1 minute, then turns off.

Single Stage Cooling (see Figure 40)A call for cooling from the thermostat closes the R to Y circuiton the integrated ignition/blower control board. The controlwaits for a 1-second delay before energizing the circulatingblower to 82% of the selected cooling CFM (passivedehumidification mode). After 7.5 minutes, the circulatingblower automatically ramps up to 100% of the selectedcooling airflow. When the call for cooling is satisfied, thecirculating blower ramps back down to 82% of the selectedcooling airflow for 1 minute, then shuts off.

The system must not be in either the passive or activedehumidification mode when charging a cooling system.

IMPORTANT

7.5 minutes

Y y

82%

100%

82%

1min

CALL OFF

Y - Cool Demand Present

- Cool Demand Satisfiedy

Single Stage Cooling(G2D95CT/U Models)

Figure 40

Two Stage Cooling(G2D95CT/U Models)

Figure 41

Y1

y1

57%

100%

CALL OFF

7.5minutes 70%

Y1 - 1 Stage Cool Demand Presentst

- Demand Satisfied1 Stage Coolsty1

Y2 - 2 Stage Cool Demand Presentnd

- 2 Demand Satisfiednd Stage Cooly2

1min

70%

Y1 y2/Y1/ Y2 y1

57%

1min57%

506303-01 of 40 Issue 0938

Auxiliary Limit ControlThis is a normally closed control that opens under abnormal“reverse air flow” conditions that could occur in a counterflowor horizontal installation if the circulating blower fails. It isan automatic reset control.

G2D93CU and G2D95CU models do not include an auxiliarylimit control.

Interlock (Blower Door) SwitchWhen the blower door is removed, the interlock switchbreaks the power supply to the burner controls and blowermotor. The switch operation must be checked to confirm itis operating correctly.

System Sentry™ Integrated Ignition/Blower Control BoardThe System Sentry™ integrated ignition/blower control boardoperates all functions of the furnace and the accessoriesconnected to it.

G2D93CT/U models feature user-selectable blower “off”delay times (60, 90, 120, and 180 seconds) that are factoryset to provide a 120-second blower “off” delay on heating(see wiring diagram on page 35).

Refer to the furnace wiring diagram while using the followingprocedure to the change motor speed on a G2D93CT/Ufurnace:

1. Turn off electrical power to the unit.

2. Connect the desired speed tap for cooling on theintegrated ignition/blower control board.

3. For heating speed, check the temperature rise and, ifnecessary, adjust the blower speed tap to maintaintemperature rise within the range shown on the furnacerating plate.

To use the same speed tap for both heating and cooling,install a piggyback terminal on the speed tap using ashort jumper. Wire 1/4" quick connect terminals on bothends to jumper the “HEAT” and “COOL” speed on theintegrated ignition/blower control board.

4. The remaining speed taps must be connected to dummyterminals marked “PARK” on the integrated ignition/blower control board.

Checking and Adjusting Gas InputThe minimum permissible gas supply pressure for thepurpose of input adjustment is 5" W.C. for natural gas or11" W.C. for propane gas. This furnace requires conversion

for use with propane (see Accessories section on page 35for correct kit). The maximum inlet gas supply pressure is10.5" W.C. for natural gas and 13" W.C. for propane. Gasinput must never exceed the value shown on the furnacerating plate.

These units are rated for outlet (manifold) pressures of 1.7 "W.C. (1st stage) and 3.5" W.C. (2nd stage) for natural gas. Whenthese furnaces have been converted for use with propanegas, the outlet pressures are 4.9" W.C. (1st stage) and 10.0"W.C. (2nd stage).

To measure inlet or outlet pressure, remove plug fromdesired pressure tap (inlet or outlet) as shown in Figure 42and connect a water manometer or gauge to the properpressure tap.

These models have separate adjusting screws (3/32" hex)for 1st stage (marked “LO”) and 2nd stage (marked “HI”). Theadjusting screws are positioned on either side of the barbedfitting (see Figure 42). Turn the adjusting screws clockwise toincrease pressure and input; counterclockwise to decreasepressure and input. The pressure regulator adjustment issensitive; one turn of the adjusting screw will result in arelatively large change in manifold pressure.

To adjust the regulator:

1. Set high-fire (2nd stage) setting by turning hexadjustment screw to desired rate.

2. Set low-fire (1st stage) setting by turning hex adjustmentscrew to desired rate.

Make sure the final high- and low-fire manifoldpressures are within the allowable ranges specifiedabove for the gas being used.

Checking and Adjusting Gas Input

Figure 42

OFF

ON

Inlet Pressure Tap1/8" NPT

Outlet Pressure Tap1/8" NPT

High-Fire (2 Stage) AdjustmentUnder Vent Cap

nd

Low-Fire (1 Stage) AdjustmentUnder Vent Cap

st

506303-01 of 40Issue 0938

For Natural Gas: Check the furnace rate by observing thegas meter, when available, making sure all other gasappliances are turned off. The test hand on the meter shouldbe timed for at least one revolution. Note the number ofseconds for one revolution.

x 3600 x= Cubic Feet Per RevolutionBTU/HR INPUT # Seconds Per Revolution

HeatingValue

The heating value of the gas can be obtained from the localutility company.

For Propane Gas: The only check for the furnace rate is toproperly adjust the manifold pressure using a manometer andTable 4. Typical manifold set point for installations at altitudesfrom 0 to 4500 feet above sea level is 10.0" W.C.

Temperature RiseCheck the temperature rise and, if necessary, adjust blowerspeed to maintain temperature rise within the range shownon the unit rating plate.

The furnace rate must be within +/- 2% of the appliancerating input.

CAUTIONHigh AltitudeIn both the United States and Canada, this furnace is approvedfor operation at altitudes from 0 to 4500' above sea levelwithout any required modifications. From 4500' to 7500', thegas manifold pressure needs to be adjusted according to theinformation shown in Table 4. To adjust the manifold pressure,refer to section Checking and Adjusting Gas Input. Forinstallations above 7500', call Technical Service at 1-800-448-5872 for assistance.

For installations above 4500 feet fill in the appropiateinformation on the furnace label that has the words “Thisfurnace was converted on . . . . . . . . “.

For installation above 4,000 ft. refer to seciton Vent Pipe Sizeand Length on page 7 and Figure 4 on page 7 Vent PipeSizing.

Emergency Replacement Motor Operation (G2D95CT/U Models Only)If the variable speed motor in a G2D95CT/U furnace needs tobe replaced in an emergency situation (such as “no heat”)and an exact replacement motor is not immediately available,a standard PSC motor of equivalent frame size, voltage,rotation, and horsepower can be temporarily installed untilthe correct replacement motor can be obtained.

Manifold Pressure vs. Altitude

Table 4

* Consult local utility for actual heating value.

Furnace Input = Input Factor x Nameplate Input

Above 7500 feet, call Technical Services at 1-800-448-5872.

Altitude

(ft.)

Natural Gas Propane

Heating

Value*

(Btu/ft³)

Manifold

Pressure

Low Fire

(in. w.c.)

Manifold

Pressure

High Fire

(in. w.c.)

Heating

Value*

(Btu/ft³)

Manifold

Pressure

Low Fire

(in. w.c.)

Manifold

Pressure

High Fire

(in. w.c.)

Input

Factor

2000

3000

4000

4500

5000

5500

6000

6500

7000

7500

948

914

881

865

849

833

818

802

787

771

1.70

1.70

1.70

1.70

1.61

1.60

1.59

1.58

1.57

1.56

3.50

3.29

3.27

3.25

3.23

3.21

3.19

3.50

3.50

3.50

2278

2196

2116

2077

2039

2000

1964

1927

1891

1853

4.90

4.90

4.90

4.90

4.61

4.58

4.55

4.53

4.50

4.47

10.00

10.00

10.00

10.00

9.41

9.35

9.29

9.24

9.18

9.12

0.9666

0.9499

0.9332

0.9249

0.8900

0.8790

0.8680

0.8570

0.8460

0.8350

506303-01 of 40 Issue 0938

It is recommended that this furnace be inspected by aqualified service technician at the beginning of each heatingseason.

FiltersFilters should be checked at least every 6 weeks. Disposablefilters should be replaced when dirty, and cleanable filtersshould be cleaned regularly. It is important to keep the airfilters clean, as dirty filters can restrict airflow and the blowerand induced draft motors depend upon sufficient air flowingacross and through them to keep from overheating.

LubricationThe blower motor and induced draft motor are pre-lubricatedby the manufacturer and do not require further lubricatingattention. However, the motors should be cleaned periodicallyto prevent the possibility of overheating due to an accumulationof dust and dirt on the windings or on the motor exterior.

MAINTENANCE

Condensate Collection and Disposal SystemCheck the condensate drain line periodically for blockage.Visual inspection of condensate flow can be done easilywhile the furnace is in operation. Use a flashlight to illuminatethe discharge end of the condensate drain that is placed inthe sewer opening. If the condensate drain line becomesblocked or plugged, the furnace will not operate properly.

BurnersLight the burners and allow to operate for a few minutes toestablish normal burning conditions. Observe the burnerflames. Compare this observation to Figure 43 to determine ifproper flame adjustment is present. Flame should bepredominantly blue in color and strong in appearance. Checkthat all burners are lit, and that the flame does not impinge onthe sides of the heat exchanger.

Distorted flame or yellow tipping of the natural gas burnerflame, or long yellow tips on propane, may be caused bylint accumulation or dirt inside the burner or burner ports, atthe air inlet between the burner and manifold pipe, orobstructions over the burner orifice.

Use a soft brush or vacuum to clean the affected areas.

Connect the desired speed tap to the “EAC” terminal andthe neutral tap to the neutral terminal on the ignition control(refer to the furnace wiring diagram). The ignition controlwill control the motor’s operation, including a nominal 20-second “on” delay with a call for heat and a nominal 180-second “off” delay when the thermostat is satisfied. It willalso operate the motor on a call for cooling, with no “on” or“off” delays.

Verify that the unit is operating at the desired speed andwithin the rise range as shown on the unit rating plate.

The correct replacement motor must be installed assoon as possible to ensure continued satisfactoryoperation of the furnace.

Failure to follow the safety warnings exactly could resultin dangerous operation, serious injury, death, or propertydamage.

Improper servicing could result in dangerous operation,serious injury, death, or property damage.

• Before servicing, disconnect all electrical power tofurnace.

• When servicing controls, label all wires prior todisconnecting. Reconnect wires correctly.

• Verify proper operation after servicing.

WARNING

ELECTRICAL SHOCK, FIRE,OR EXPLOSION HAZARD

Typical Flame Appearance

Figure 43

HeatExchanger

BurnerFlame

(Blue Only)

Burner

GasManifold

506303-01 of 40Issue 0938

System Sentry™ CONTROL DIAGNOSTICS

TroubleshootingMake the following visual checks before troubleshooting:

1. Check to see that the power to the furnace and theintegrated ignition/blower control board is ON.

2. The manual shutoff valves in the gas line to the furnacemust be open.

3. Make sure all wiring connections are secure.

4. Review the Sequence of Operation (see page 27).

Start the system by setting thermostat above roomtemperature. Observe system response. Then use theinformation provided in this section to check the systemoperation.

The furnace has a built-in, self-diagnostic capability. If asystem problem occurs, a fault code is shown by a red LEDon the control board. The control continuously monitors itsown operation and the operation of the system. If a failureoccurs, the LED will indicate the failure code. The flashcodes are presented in Table 5.

Fault Code History ButtonThe control stores the last five fault codes in memory. Apushbutton switch is located on the control (see Figure 44 onpage 35 or Figure 46 on page 37). When the pushbuttonswitch is pressed and released, the control flashes the storedfault codes. The most recent fault code is flashed first; theoldest fault code is flashed last. To clear the fault code history,press and hold the pushbutton switch in for more than 5seconds before releasing.

High Heat State LEDOn these models, a green LED is provided on the controlboard to indicate high heat state (see Table 6).

CFM LED (G2D95CT/U Models Only)On G2D95CT/U models, an amber LED is provided on thecontrol board to display CFM. To determine what CFM themotor is delivering at any time, count the number of timesthe amber LED flashes. Each flash signifies 100 CFM; countthe flashes and multiply by 100 to determine the actual CFMdelivered (for example: 10 flashes x 100 = 1000 CFM).

High Heat State – Green LED

Table 6

LED

StatusDescription

LED Off

LED On

High heat demand, high pressure

switch not closedLED Flashing

High heat demand, operating

normally

No demand for high heat

Failure Codes – Red LED

Table 5

LED

StatusFault Description

LED Off

LED On

1 Flash

2 Flashes

3 Flashes

4 Flashes

5 Flashes

6 Flashes

7 Flashes

8 Flashes

9 Flashes

No power to control or control

hardware fault detedted

Normal operation

Flame present with gas valve off

Pressure switch closed with inducer off

Low-fire pressure, rollout, drain

pressure, or aux limit open

High limit switch open

Not used

Pressure switch cycle lockout

Lockout due to no ignition

Lockout due to too many flame dropouts

Incorrect polarity and phasing

506303-01 of 40 Issue 0938

REPAIR PARTS

The following repair parts are available from the localdistributor. When ordering parts, include the completefurnace model number and serial number which are printedon the rating plate located on the furnace.

Control GroupTransformerHigh limit controlAuxiliary limitGas valveIntegrated ignition/blower control boardFlame sensorPressure switches – 1st stage and 2nd stageBlower door interlock switchCombustion blower assemblyFlame rollout protector switchHot surface igniterInput choke

Heat Exchanger GroupHeat exchanger – primaryHeat exchanger – secondaryCondensate drain pan (header box)

Blower GroupBlower housing assemblyBlower wheelBlower mountBlower motorBlower motor mount

Burner GroupGas manifoldBurner orificesBurners

AccessoriesALPKT583 Natural Gas to Propane Conversion KitANGKT556 Propane to Natural Gas Conversion KitAFITLHA7 Single Side Filter Frame KitAFILT524 Side Return Filter KitAFILT529 Bottom Return Filter KitAFOSL500 Fossil Fuel Kit

Concentric Vent KitsACVK2 For US Applications only

For Canadian Application useIPEX Kit 196005 locally available *

* For a local IPEX Canadian Customer Service Center and Kitavailability call IPEX at 1-866-473-9462.

506303-01 of 40Issue 0938

Figure 44

G2D93CT/U Connection DiagramP/N 45604-005

5 A

MP

YC GRW1W2

LIN

EE

AC

XF

MR

CIR

C

HU

M

HU

M

XF

MR

LIN

E

PAR

K 1

CO

OL

EA

C

HI H

EAT

LO H

EAT

NE

UT

RA

L

HOT

IGNITION CONTROL

TRANSFORMER

INDUCEDDRAFT

BLOWER

INTERLOCKSWITCH

122 1

C HI

GAS VALVE

M

PRESSURESWITCH(LOW)

ROLLOUTSWITCH

(IF USED)

MAINLIMIT

PRESSURESWITCH(DRAIN)

(IF USED)

12 9 6 3

11 8 5 2

10 7 4 1

33

120V

24V

HOTNEUTRALGROUND

120/1/60SEE

NOTE 3

12345

BLK

RE

DW

HT

WH

TR

ED

BLK

5-PINCONNECTOR

W2 GR YW1

THERMOSTAT CONDENSER WHT

YELYEL

WHT

BLU

OR

NR

ED

/BLK

RE

DW

HT

YEL

VLT

BR

NG

RY

BLKBLK/WHT

WHT

RED/BLK

YE

LY

EL

BLK

WH

T

ORNBLUGRY

GR

N

WHT/BLKRED

BRN

BLK

221

12-PINCONNECTOR

CIRCULATIONBLOWER

FLAMESENSOR

HOT SURFACEIGNITER

WH

T (

NE

UT

)R

ED

(LO

)

BLU

(M

ED

)O

RN

(M

ED

/LO

)

YE

L M

ED

/HI

BLK

(H

IGH

)

SEE BLOWER SPEED CHART

S1P1

ROLLOUTSWITCH

AUX LIMITSWITCH(IF USED)

AUX LIMITSWITCH

VLT

VLT

PRESSURESWITCH(HIGH)

RED

VLT VLTVLT

BR

N

BRN

WHT

CO

NT

PAR

K 2

TW

IN

NONE510

P5

1801209060 P

4

LOW VOLTAGE - FIELDLOW VOLTAGE - FACTORYLINE VOLTAGE - FIELDLINE VOLTAGE - FACTORY

SW1

FAULT CODEHISTORYBUTTON

(SEE NOTE 1)

AUTOMATICHEAT STAGING

JUMPER

BLOWER OFFDELAY TIMING

180120

9060

C

NOTES:

3. PROPER POLARITY MUST BE OBSERVED FOR FIELD LINEVOLTAGE SUPPLY; IGNITION CONTROL WILL LOCK OUT IFPOLARITY IS REVERSED.

1. PRESS AND RELEASE FAULT CODE HISTORY BUTTON TODISPLAY FAULT CODES. TO ERASE CODES, PRESS AND HOLDBUTTON IN FOR MORE THAN 5 SECONDS.

2. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THEFURNACE MUST BE REPLACED, IT MUST BE REPLACED WITHWIRING MATERIAL HAVING A TEMP. RATING OF AT LEAST 90°C.

WH

T/B

LK

* 5 SPEED MOTOR USED ON THESE MODELS

BLOWER SPEED CHARTS

1ST STAGEHEATMODEL COOLING

2ND STAGEHEAT

BLUBLUYELBLUBLUYEL

BLKBLKBLKBLKBLKBLK

50D1275D14100D14

100D20 *125D20 *150D20 *

REDREDREDORNORNORN

1ST STAGEHEATMODEL COOLING

2ND STAGEHEAT

BLUBLUORNORNBLUYEL

BLKBLKBLKBLKBLKBLK

40D1260D12

80D16 *80D20 *100D20 *125D20 *

REDREDREDREDORNBLU

80% AFUE

93% AFUE

4. DO NOT CONNECT C (COMMON) CONNECTION BETWEENINDOOR UNIT AND THERMOSTAT EXCEPT WHEN REQUIREDBY THE INDOOR THERMOSTAT. REFER TO THE THERMOSTATINSTALLATION INSTRUCTIONS.

5. CHECK CODES FOR PROPER WIRING AND CIRCUITPROTECTION BEFORE INSTALLATION.

506303-01 of 40 Issue 0938

Figure 45

G2D93CT/U Wiring SchematicP/N 45604-005

506303-01 of 40Issue 0938

Figure 46

G2D95CT/U Connection DiagramP/N 46131-004

5 A

MP

IGNITION CONTROL

TRANSFORMER

INDUCEDDRAFT

BLOWER

INTERLOCKSWITCH

122 1

C HI

GAS VALVE

M

MAINLIMIT

12 9 6 3

11 8 5 2

10 7 4 1

33

120V

24V

HOTNEUTRALGROUND

120/1/60

12345

BLK

RE

DW

HT

WH

TR

ED

BLK

5-PINCONNECTOR

WHT

YELYEL

WHT

BLU

OR

NR

ED

/BLK

RE

DW

HT

YEL

VLT

BR

NG

RY

BLK

BLK/WHT

WHT

RED/BLK

YE

LY

EL

BLK

WH

T

ORNBLUGRY

GR

N

WHT/BLKRED

BRN

221

12-PINCONNECTOR

FLAMESENSOR

HOT SURFACEIGNITER

S1P1

AUX LIMITSWITCH

VLT

VLT

PRESSURESWITCH(HIGH)

RED

VLT VLTVLT

BR

N

BRN

WHT

CIRCULATIONBLOWER 5-PIN

CONNECTOR

1 2 4 53

INPUT CHOKE(IF USED)

BLK

GRN

WHT

BLK

YC GRW1W2

W2 GRYW1THERMOSTAT CONDENSER

LIN

EE

AC

XF

MR

CIR

C

HU

M

HU

M

XF

MR

LIN

E

PAR

K 1

CO

OL

EA

C

HI H

EAT

LO H

EAT

NE

UT

RA

L

HOT

CO

NT

PAR

K 2

DE

HU

M

OY2

C

BRNTYP

LINE VOLTAGE - FACTORY

LINE VOLTAGE - FIELD

LOW VOLTAGE - FACTORY

LOW VOLTAGE - FIELD

PRESSURESWITCH(LOW)

PRESSURESWITCH -

DRAIN(IF USED)

ROLLOUTSWITCH

(IF USED)ROLLOUTSWITCH

NONE

105

P5

AUX LIMITSWITCH

(IF USED)

WH

T/B

LK

SW1

GREEN LEDRED LED

AMBER LED

FAULT CODEHISTORYBUTTON

(SEE NOTE 1)

AUTOMATICHEAT STAGING

JUMPER

NOTES:

1. PRESS AND RELEASE FAULT CODE HISTORY BUTTON TODISPLAY FAULT CODES. TO ERASE CODES, PRESS AND HOLDBUTTON IN FOR MORE THAN 5 SECONDS

2. IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE FURNACE MUST BE REPLACED, IT MUST BE REPLACEDWITH WIRING MATERIAL HAVING A TEMP. RATING OF AT LEAST 90°C.

3. PROPER POLARITY MUST BE OBSERVED FOR FIELD LINE VOLTAGE SUPPLY; IGNITION CONTROL WILL LOCKOUT IF POLARITY IS REVERSED.

4. FOR TEMPORARY SERVICE REPLACEMENT OF CIRCULATING BLOWER MOTOR WITH PSC MOTOR, CONNECTDESIRED SPEED TAP TO “EAC” TERMINAL AND NEUTRAL TAP TO NEUTRAL TERMINAL ON IGNITION CONTROL.

5. DO NOT CONNECT C (COMMON) CONNECTION BETWEEN INDOOR UNIT AND THERMOSTAT EXCEPT WHENREQUIRED BY THE INDOOR THERMOSTAT. REFER TO THE THERMOSTAT INSTALLATION INSTRUCTIONS.

6. CHECK CODES FOR PROPER WIRING AND CIRCUIT PROTECTION BEFORE INSTALLATION.

506303-01 of 40 Issue 0938

Figure 47

G2D95CT/U Wiring SchematicP/N 46131-004

506303-01 of 40Issue 0938

FOR MASSACHUSETTS ONLY

* “a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structureused in whole or in part for residential purposes, including those owned or operated by the Commonwealthand where the side wall exhaust vent termination is less than seven (7) feet above finished grade in thearea of the venting, including but not limited to decks and porches, the following requirements shall besatisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wallhorizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hardwired carbon monoxide detector with an alarm and battery back-up is installed on the floor level wherethe gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that abattery operated or hard wired carbon monoxide detector with an alarm is installed on each additionallevel of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment.It shall be the responsibility of the property owner to secure the services of qualified licensed professionalsfor the installation of hard wired carbon monoxide detectorsa. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl spaceor an attic, the hard wired carbon monoxide detector with alarm and battery back-up may beinstalled on the next adjacent floor level.b. In the event that the requirements of this subdivision can not be met at the time of completion of

installaiton, the owner shall have a period of thirty (30) days to comply with the above requirements;provided, however, that during said thirty (30) day period, a battery operated carbon monoxide

detector with an alarm shall be installed.2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in

accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAScertified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of thebuilding at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminalfor the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print sizeno less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALLOBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipmentshall not approve the installation unless, upon inspection, the inspector observes carbon monoxidedetectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most currentedition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structureseparate from the dwelling, building or structure used in whole or in part for residential purposes.”

For Side Wall Horizonal Venting

The installation must comply with 248 CMR 5.08 Modifications to sections of NFPA-54,Chapter 10 as listed below.

IMPORTANT

506303-01 of 40 Issue 0938

** “c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. Whenthe manufacturer of Product Approved side wall horizontally vented gas equipment provides a ventingsystem design or venting system components with the equipment, the instructions provided by themanufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components;and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. Whenthe manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does notprovide the parts for venting the flue gases, but identifies “special venting systems”, the followingrequirements shall be satisfied by the manufacturer:

1. The identification of each “special venting system” shall include the listing of either the website, phonenumber or manufacturer’s address where the venting system installation instructions can be obtained;and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for providedwith that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueledequipment and all the venting instructions, parts lists, and/or design instructions for the venting systemshall remain with the appliance or equipment at the completion of the installation.”

* Text from Commonwealth of Massachusetts Official Website of the Office of Consumer Affairs & Business Regulation(OCABR).

** Text from Joseph A Peluso, Jr. (Executive Director Board of State Examiners of Plumbers and Gas Fitters,Commonwealth of Massachusetts) letter of April 24, 2007 to GAMA.

INSTALLATION INSTRUCTIONS G2D93CT, G2D93CU, G2D95CT, & …€¦ · Allied Air Enterprises Inc. A...

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