Coleman Forced Air Furnace Manual

The Coleman Forced Air Furnace is a high-efficiency heating system designed for residential use, featuring variable-speed blower technology, electronic ignition, multiple heat exchanger stages, programmable thermostat compatibility, safety shut-off switches, air filtration system, and energy-efficient operation. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Heat exchanger assembly, blower motor, gas valve, electronic ignition system, air filter compartment, pressure switches, limit controls, venting system.

Installation

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

1. Position furnace: Place on stable, level surface with proper clearances (refer to specifications).
2. Connect gas supply: Use approved gas piping; pressure test for leaks.
3. Install venting: Follow manufacturer guidelines for proper vent sizing and routing.
4. Electrical connections: Connect 120V AC power and thermostat wiring.
5. Ductwork: Connect supply and return air ducts securely.

WARNING! Installation must be performed by qualified HVAC technician. Gas leaks can cause explosion or fire.

First-Time Setup

After installation, perform initial startup procedure.

1. Verify all connections: Gas, electrical, venting, and ductwork.
2. Install air filter: Ensure proper size and orientation.
3. Power on: Turn on electrical power and gas supply.
4. Test operation: Set thermostat to heat mode and verify proper ignition sequence.
5. Check airflow: Verify adequate airflow from all supply registers.
6. Monitor operation: Observe first heating cycle for proper function.

CAUTION! Never bypass safety controls. Ensure proper combustion air supply.

Specifications

• Heating Capacity: 40,000-120,000 BTU/hr (model dependent)
• Efficiency: 80-98% AFUE (model dependent)
• Blower Motor: Variable-speed ECM
• Stages: Single or two-stage operation
• Voltage: 120V AC, 60Hz
• Gas Type: Natural gas or LP (conversion kit required)
• Venting: Category I (natural draft) or Category IV (direct vent)
• Filter Size: Standard 16x25x1 inch or custom sizes
• Sound Level: < 65 dB during operation
• Warranty: Limited lifetime heat exchanger, 10 years parts

Controls and Settings

Integrated control board with diagnostic capabilities. Thermostat controls heating cycles and fan operation.

Control Board: POWER switch, Diagnostic LED, DIP switches for configuration, Reset button.

Thermostat Settings: Heat/Cool/Auto mode, Temperature setpoint, Fan Auto/On, Program schedules. Control Board: Blower speed settings, Heating stages configuration, Timing adjustments, Lockout reset. Safety: High limit control, Pressure switches, Rollout switches, Flame sensor.

Connecting Thermostat

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

1. Turn off power to furnace at electrical panel.
2. Remove thermostat cover and connect wires: R (power), W (heat), G (fan), C (common).
3. For multi-stage units: Additional W2 terminal for second stage heat.
4. Secure wiring and replace cover.
5. Restore power and test operation.

Tip: Use color-coded thermostat wire for easy identification.

Operation

Normal heating cycle sequence and user controls.

1. Thermostat call: Set thermostat above room temperature.
2. Ignition sequence: Inducer motor starts, pressure switch proves, igniter glows, gas valve opens.
3. Flame establishment: Flame sensor confirms ignition, main burners operate.
4. Blower activation: After heat exchanger warm-up delay, blower circulates warm air.
5. Cycle completion: When thermostat satisfied, gas valve closes, blower continues for cool-down.
6. Fan operation: Auto mode runs with heat cycle; On mode provides continuous circulation.

WARNING! Never adjust gas pressure without proper training and equipment.

Maintenance

Regular maintenance ensures efficient operation and longevity.

1. Monthly: Check and replace air filter as needed.
2. Seasonal: Inspect vent system for obstructions.
3. Annual: Professional inspection and cleaning of burners, heat exchanger, and flue.
4. Blower maintenance: Clean blower wheel and motor annually.
5. Drain lines: Clear condensate drain on high-efficiency models.

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

Safety Features

Multiple safety systems protect against hazardous conditions.

• Flame rollout switches: Shut off gas if flame escapes burners
• High limit switches: Turn off burners if overheating detected
• Pressure switches: Verify proper venting before ignition
• Flame sensor: Confirms burner ignition within trial period
• Gas valve: Automatic shut-off if ignition fails
• Blower door switch: Disables operation when access panel removed

Regulatory Information

UL listed and ANSI certified for safety standards. Complies with Department of Energy efficiency requirements. Natural gas models certified to ANSI Z21.47 standards. LP gas models certified to ANSI Z21.66 standards. Manufactured to meet or exceed all applicable safety and performance standards. For technical support, contact Coleman HVAC at 1-800-426-5362 or visit www.colemanac.com.

Troubleshooting

Reset: Turn power off for 30 seconds, then restore. For lockout conditions, wait 1 hour for automatic reset.

Service: 1-800-426-5362; www.colemanac.com