Air Flow Furnace Manual

The Air Flow Furnace is a high-efficiency heating system designed for residential and light commercial use. This forced-air furnace features variable-speed blower technology, electronic ignition, multiple heat stages, smart thermostat compatibility, air filtration system, safety shut-off controls, and energy-saving modes. Operating on natural gas or propane with 120V AC power supply. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Heat exchanger, variable-speed blower motor, electronic ignition system, air filter compartment, gas valve, pressure switches, flame sensor, control board.

Feature	Description
Variable-speed blower	Automatically adjusts airflow for optimal efficiency
Electronic ignition	Eliminates standing pilot light for energy savings
Multi-stage heating	Two-stage operation for consistent comfort
Smart thermostat ready	Compatible with most modern thermostat systems
Air filter indicator	LED alerts when filter replacement is needed
Safety shut-off	Automatic shutdown if unsafe conditions detected
Diagnostic lights	LED codes for troubleshooting
AC power input	Standard 120V electrical connection
Gas connection	1/2" NPT for natural gas or propane
Airflow vents	Supply and return air connections

Installation Requirements

Professional installation recommended. Ensure proper clearances and ventilation.

1. Location: Install in well-ventilated area with minimum clearances as specified.
2. Gas connection: Use approved gas piping; pressure test before operation.
3. Electrical: Connect to dedicated 120V circuit with proper grounding.
4. Venting: Install according to local codes and manufacturer specifications.
5. Ductwork: Ensure proper sizing and sealing of supply and return ducts.

WARNING! Gas appliances can be hazardous; installation must comply with all local codes and regulations. Use qualified HVAC technician.

First-Time Setup

Complete installation verification before initial startup.

1. Gas pressure check: Verify inlet and manifold pressures are within specifications.
2. Electrical verification: Ensure proper voltage and polarity.
3. Thermostat wiring: Connect compatible thermostat following wiring diagram.
4. System startup: Turn on gas supply, then electrical power.
5. Initial operation: Run through complete heating cycle to verify proper operation.
6. Airflow adjustment: Set blower speeds for optimal performance.

CAUTION! Never bypass safety controls. Test carbon monoxide detectors after installation.

Technical Specifications

• Heating Capacity: 60,000 - 120,000 BTU/h (model dependent)
• AFUE Rating: 95%+ efficiency
• Fuel Type: Natural gas or propane (conversion kit required)
• Electrical: 120V AC, 60Hz, 5-8 amps
• Blower Motor: ECM variable speed
• Stages: Two-stage heating operation
• Sound Level: < 65 dB during operation
• Dimensions: Varies by model (check specific model data)
• Vent Size: 2" - 3" PVC depending on installation
• Warranty: 10-year heat exchanger, 5-year parts

Controls and Settings

Access control board via front panel. Diagnostic lights indicate system status.

Control Board: POWER switch, SYSTEM switch (HEAT/COOL/OFF), FAN switch (AUTO/ON), diagnostic LED, reset button.

Temperature Settings: Adjust via connected thermostat. Blower Settings: Adjust dip switches for airflow CFM. Gas Pressure: Factory set; verify during installation. Safety Controls: Automatic high-limit switch, pressure switches, flame rollout protection. Diagnostics: LED flash codes for troubleshooting (refer to code chart).

Connecting Thermostat

Compatible with most 24V thermostat systems. Standard 5-wire connection.

1. Turn off power to furnace at electrical disconnect.
2. Remove thermostat cover and identify wire terminals.
3. Connect wires: R (power), W (heat), G (fan), Y (cool), C (common).
4. Secure connections and replace cover.
5. Restore power and test thermostat operation.

Tip: Use programmable thermostat for maximum energy efficiency and comfort.

Operating Modes

Multiple operating modes for different comfort needs.

1. Heating Mode: Primary function; maintains set temperature.
2. Fan Only: Circulates air without heating.
3. Standby: System ready but not actively heating.
4. Diagnostic: Service mode for troubleshooting.
5. Energy Saver: Optimizes runtime for efficiency.
6. Vacation Mode: Maintains minimum temperature during absences.

WARNING! Do not operate without proper ventilation. Ensure combustion air supply is adequate.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Frequency	Maintenance Task
Monthly	Check air filter; replace if dirty
Seasonal	Inspect vent system for obstructions
Annually	Professional inspection and cleaning
Annually	Check heat exchanger for cracks
Annually	Verify gas pressure and connections
Annually	Clean blower assembly and motor
As needed	Check and clean flame sensor

CAUTION! Always turn off power and gas supply before performing maintenance.

Safety Features

Multiple safety systems protect against hazardous conditions.

• Flame Rollout Switch: Shuts off gas if flame escapes burners
• High Limit Switch: Prevents overheating
• Pressure Switches: Ensure proper venting operation
• Flame Sensor: Confirms burner ignition
• Gas Valve: Automatic shut-off if unsafe conditions detected
• Ignition Control: Safe lighting sequence

Regulatory Information

UL certified; meets ANSI Z21.47 standards for gas-fired central furnaces. CSA certified for Canadian installations. Complies with Department of Energy efficiency standards. This product incorporates safety standards established by American Gas Association. For technical support, contact 1-800-HEAT-HELP or visit www.airflowfurnace.com. Installation must comply with National Fuel Gas Code NFPA 54 and local building codes.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, safety lockout	Check power supply; verify thermostat settings; reset if locked out.
No heat	Gas supply, ignition, filter	Verify gas valve on; check for ignition; replace dirty air filter.
Short cycling	Dirty filter, airflow, thermostat	Clean/replace filter; check vents; verify thermostat location.
Blower not working	Power, motor, control board	Check electrical connections; test motor; inspect control board.
Unusual noises	Motor, blower, ductwork	Lubricate motor; clean blower wheel; inspect duct connections.
Pilot/ignition failure	Gas supply, sensor, pressure	Verify gas supply; clean flame sensor; check gas pressure.

Reset Procedure: Turn power off for 30 seconds, then restore.

Service: 1-800-HEAT-HELP; www.airflowfurnace.com