Ameristar Furnace Manual

The Ameristar Furnace is a high-efficiency gas heating system designed for residential use, featuring advanced combustion technology, multiple safety controls, energy-saving modes, and user-friendly operation. Below are key sections covering safety precautions, installation guidelines, operation instructions, maintenance procedures, troubleshooting, and technical specifications.

Features at a Glance

Key components: High-efficiency heat exchanger, electronic ignition system, multi-speed blower motor, digital thermostat interface, safety pressure switches, and diagnostic LED indicators.

Feature	Description
Heat Exchanger	Stainless steel construction for maximum efficiency and durability
Ignition System	Electronic hot surface ignition for reliable startup
Blower Motor	Variable speed ECM motor for quiet operation
Thermostat Interface	Compatible with most digital thermostats
Safety Controls	Pressure switches, flame sensor, limit switches
Diagnostic LED	Flashing codes for troubleshooting
Gas Valve	Modulating gas valve for precise temperature control
Air Filter	Standard 1-inch or 4-inch media filter compatibility
Venting	PVC pipe compatible for sidewall or roof venting
Power Supply	120V AC, 60Hz standard household current

Safety Precautions

Important safety information for proper installation and operation.

1. Installation must be performed by qualified HVAC technician only.
2. Ensure proper clearance from combustible materials (minimum 1 inch).
3. Verify adequate combustion air and proper venting installation.
4. Install carbon monoxide detectors in living areas.
5. Keep area around furnace clear of flammable materials.

WARNING! Gas furnaces produce carbon monoxide. Ensure proper venting and never block air intakes or exhaust vents. Have unit inspected annually by qualified technician.

Installation Guidelines

Professional installation required. Follow all local codes and manufacturer specifications.

1. Location: Install in dry, level area with adequate service clearance.
2. Venting: Use approved PVC pipe; maintain proper slope for condensation drainage.
3. Gas Connection: Use approved pipe compound; pressure test all connections.
4. Electrical: Connect to dedicated 120V circuit; proper grounding required.
5. Ductwork: Ensure proper sizing and sealing for optimal performance.
6. Startup: Verify proper operation of all safety controls and ignition sequence.

CAUTION! Improper installation can create fire hazard or carbon monoxide risk. Always use qualified HVAC professional.

Specifications

• Input Capacity: 40,000 - 120,000 BTU/H (model dependent)
• Efficiency: 80% - 96% AFUE (model dependent)
• Gas Type: Natural gas or LP (conversion kit required)
• Electrical: 120V AC, 60Hz, 5-10 Amps
• Blower Motor: ECM variable speed
• Sound Level: < 65 dB
• Dimensions: Varies by model (typical: 21"W x 21"D x 45"H)
• Venting: 2" - 3" PVC pipe
• Warranty: 10-year heat exchanger, 5-year parts
• Operating Temp Range: -30°F to 120°F ambient

Controls and Settings

Access furnace controls through service panel. Thermostat controls heating operation.

Front Panel: Power switch, diagnostic LED, service access door.

Internal Controls: Gas valve, control board, pressure switches, limit switches, flame sensor, igniter, blower motor control.

Thermostat Settings: Heat/Off mode, temperature setpoint, fan auto/on. Advanced Settings: Blower delay, temperature differential, filter reminder (if equipped).

Operating Instructions

Normal operation controlled by thermostat.

1. Set thermostat to HEAT mode and desired temperature.
2. Furnace will initiate startup sequence when heat demanded.
3. Normal sequence: Inducer motor starts, pressure switch proves, igniter heats, gas valve opens, flame established, blower starts after heat exchanger warms.
4. When thermostat satisfied, gas valve closes, blower continues during cool-down period.
5. For continuous fan operation, set thermostat fan to ON position.

Tip: Maintain consistent temperature settings for optimal efficiency.

Maintenance Procedures

Regular maintenance ensures safe and efficient operation.

1. Monthly: Check and replace air filter as needed.
2. Seasonal: Inspect vent pipes for obstructions or damage.
3. Annual Professional Service: Clean heat exchanger, check burners, verify gas pressure, inspect safety controls, clean blower assembly, check electrical connections.
4. Biannual: Clean condensate drain line and trap.

WARNING! Always turn off power and gas supply before performing any maintenance. Only qualified technicians should service internal components.

Error Codes

Diagnostic LED flashes indicate specific error conditions.

Flash Pattern	Description	Action
1 Flash	Ignition failure	Check gas supply, igniter, flame sensor
2 Flashes	Pressure switch fault	Check inducer, venting, switch
3 Flashes	Limit switch open	Check airflow, filter, blower
4 Flashes	Flame sensed with gas off	Check gas valve, control board
5 Flashes	Rollout switch open	Check heat exchanger, venting
Continuous	Normal operation	No action required

Care & Cleaning

External cleaning only by homeowner. Internal cleaning by qualified technician.

Exterior: Wipe with damp cloth only. Keep area around furnace clean and free of debris. Air Filter: Replace every 1-3 months depending on usage and environment. Vent Pipes: Visually inspect for obstructions or damage.

CAUTION! Do not use water or cleaning solutions on electrical components. Never attempt to clean internal components without proper training.

Regulatory Information

UL certified for safety. ANSI Z21.47 standards compliant. Meets DOE energy efficiency requirements. Manufactured to ISO 9001 quality standards. For technical support, contact Ameristar Customer Service at 1-800-555-HEAT or visit www.ameristarhvac.com. All installations must comply with local building codes and utility requirements.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, switch	Check circuit breaker, thermostat settings, power switch
No heat	Gas supply, filter, pilot	Verify gas valve open, replace filter, check for ignition
Short cycling	Filter, thermostat, airflow	Clean/replace filter, check thermostat location, verify airflow
Blower won't stop	Thermostat, control board	Check thermostat fan setting, control board relay
Unusual noises	Motor, ductwork, components	Inspect blower wheel, check duct connections, tighten components
Error code flashing	System fault	Refer to error code chart; call for service if persistent

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

Service: 1-800-555-HEAT; www.ameristarhvac.com