Climatrol Furnace Manual

The Climatrol Furnace is a high-efficiency heating system designed for residential and light commercial applications. This manual covers installation, operation, maintenance, and troubleshooting for various Climatrol furnace models. The system features advanced combustion technology, multiple safety controls, energy-efficient operation, and compatibility with standard thermostat controls. Below are key sections covering safety, features, installation, operation, and maintenance procedures.

Features at a Glance

Key components: Heat exchanger, blower assembly, gas valve, ignition system, limit switches, pressure switches, and control board.

Installation

Unpack and inspect all components. Ensure proper clearances and ventilation.

1. Position furnace: Place on stable, level surface with proper clearances (minimum 1 inch from combustible materials).
2. Connect gas supply: Use approved gas piping with drip leg and shutoff valve.
3. Install venting: Use PVC pipe for direct vent systems; maintain proper slope.
4. Electrical connections: Connect 120V power supply and thermostat wiring.
5. Ductwork: Connect supply and return ducts securely.

WARNING! Gas appliances can be dangerous if improperly installed. Only qualified technicians should perform installation.

First-Time Setup

Complete installation verification before initial startup.

1. Gas pressure check: Verify inlet and manifold pressures per specifications.
2. Venting verification: Confirm proper draft and vent pipe installation.
3. Electrical check: Verify proper voltage and grounding.
4. Startup sequence: Turn on gas supply, then electrical power.
5. System test: Operate through complete heating cycle.

CAUTION! Check for gas leaks using soap solution before energizing system.

Specifications

• Input Capacity: 40,000 - 120,000 BTU/H depending on model
• Efficiency: 80% - 96% AFUE
• Gas Type: Natural gas or LP (field convertible)
• Electrical: 120V, 60Hz, 15A circuit
• Blower Capacity: 800 - 2000 CFM
• Static Pressure: 0.1 - 0.8 in. w.c.
• Venting: Category IV (PVC) or Category I (metal)
• Operating Temp Rise: 35°F - 65°F
• Dimensions: Varies by model (typically 21"W x 21"D x 48"H)

Controls and Settings

Access control board via front panel. LED status lights indicate system operation.

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

Temperature: Set via thermostat. Blower Speed: Adjustable taps on blower motor. Gas Pressure: Adjustable at gas valve. Limit Controls: Factory set; do not adjust. Diagnostic Codes: Flash patterns indicate specific faults.

Connecting Thermostat

Standard 24V thermostat connection with R, W, Y, G, C terminals.

1. Turn off power to furnace at disconnect switch.
2. Remove control board cover to access thermostat terminals.
3. Connect thermostat wires: R (24V), W (Heat), G (Fan), C (Common).
4. Secure wires and replace cover.
5. Restore power and test thermostat operation.

Tip: Use 18-gauge thermostat wire for runs over 50 feet.

Operating Procedures

Normal heating cycle operation and seasonal startup.

1. Set thermostat to desired temperature above room temperature.
2. System will initiate: Inducer motor starts, pressure switch proves draft.
3. Ignition sequence: Hot surface igniter glows, gas valve opens.
4. Burner operation: Flame sensor confirms ignition, main burner operates.
5. Blower activation: Blower starts after heat exchanger warms up.
6. Cycle completion: System shuts down when thermostat satisfied.

WARNING! Never operate furnace without filter installed.

Safety Features

Multiple safety systems protect against hazardous conditions. Limit Switch: Prevents overheating. Pressure Switch: Ensures proper venting. Flame Sensor: Confirms burner ignition. Rollout Switch: Detects flame rollout. Gas Valve: Automatic shutoff on system fault.

Maintenance & Cleaning

Regular maintenance ensures optimal performance and safety.

1. Monthly: Check and replace air filter as needed.
2. Annual: Professional inspection and cleaning.
3. Clean burners and heat exchanger.
4. Check vent system for obstructions.
5. Verify safety controls operation.

CAUTION! Disconnect power and gas supply before performing any maintenance.

Regulatory Information

UL listed and ANSI Z21.47 compliant. Meets national fuel gas code requirements. Certified for installation in accordance with local building codes. For technical support, contact Climatrol Customer Service at 1-800-555-HEAT or visit www.climatrol.com.

Troubleshooting

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

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