Gaffers & Sattler U100 Furnace Manual

The Gaffers & Sattler U100 Furnace is a high-efficiency residential heating unit with 100,000 BTU capacity, electronic ignition system, variable-speed blower motor, stainless steel heat exchanger, and advanced diagnostic controls. Designed for natural gas operation with optional LP conversion kit. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation Requirements 3. First-Time Setup 4. Technical Specifications 5. Controls and Operation 6. Venting System 7. Maintenance Procedures 8. Safety Features 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Stainless steel heat exchanger, electronic ignition system, variable-speed blower, diagnostic LED, pressure switches, gas valve, flame sensor, and condensate drain system.

Feature	Description
Heat Exchanger	Stainless steel construction for durability and efficiency
Ignition System	Electronic hot surface ignition
Blower Motor	Variable-speed ECM for quiet operation
Diagnostic System	LED status light for error codes
Gas Valve	Precision modulating gas control
Pressure Switches	Dual pressure verification for safety
Flame Sensor	Continuous flame monitoring
Condensate Drain	PVC piping for condensate removal
Thermostat Connection	Standard 24V thermostat terminals
Filter Access	Front-loading filter compartment

Installation Requirements

Professional installation recommended. Verify local codes and obtain permits.

Location: Install in dry, well-ventilated area with adequate clearance.
Gas Connection: Use black iron pipe with proper thread sealant.
Electrical: 120V AC, 15 amp dedicated circuit required.
Venting: PVC vent pipes per manufacturer specifications.
Drainage: Proper condensate drain line installation.

WARNING! Gas appliances can be dangerous if improperly installed. Use licensed professional for installation.

First-Time Setup

Initial startup must be performed by qualified technician.

Gas pressure check: Verify inlet and manifold pressures.
Venting verification: Confirm proper draft and vent sizing.
Electrical connections: Check wiring and ground.
System startup: Follow lighting instructions precisely.
Combustion analysis: Verify proper CO levels and efficiency.

CAUTION! Never attempt first startup without proper training and equipment.

Technical Specifications

Heating Capacity: 100,000 BTU/hr
Efficiency: 95% AFUE
Fuel Type: Natural Gas (LP conversion available)
Electrical: 120V AC, 60Hz, 5.2 amps
Blower Motor: ECM variable speed
Static Pressure: 0.1-0.8 in. w.c.
Vent Size: 2" or 3" PVC
Gas Connection: 1/2" NPT
Dimensions: 34" H x 17.5" W x 28" D
Weight: 98 lbs

Controls and Operation

Integrated control board with diagnostic LED. Front access panel contains power switch and service light.

Control Board: Monitors system operation, displays error codes via LED flashes.

Operation Sequence: Thermostat call for heat → inducer motor starts → pressure switch verification → hot surface ignition → gas valve opens → flame sensor confirmation → blower motor starts.

Settings: DIP switches for blower delays, thermostat type, and accessory configuration.

Venting System

Direct vent system using PVC pipe. Follow specific requirements for pipe sizing and length.

Vent pipe must slope back to furnace for condensate drainage.
Maximum vent length: 60 feet equivalent for 2" pipe.
Minimum clearance from combustion air intake: 12 inches.
Termination must be above anticipated snow level.

Tip: Always use manufacturer-approved PVC cement for joints.

Maintenance Procedures

Annual maintenance required for optimal performance and safety.

Filter replacement: Monthly during heating season.
Heat exchanger inspection: Annual visual check.
Blower cleaning: Remove and clean annually.
Flame sensor cleaning: Light sanding to remove buildup.
Drain system: Flush with clean water annually.
Vent inspection: Check for obstructions annually.

WARNING! Disconnect power and gas before performing any maintenance.

Safety Features

Multiple safety systems: Rollout switches, high limit switches, pressure switches, flame rollout protection, and ignition lockout.

Care & Cleaning

Keep area around furnace clean and free of combustible materials. Use soft brush for heat exchanger cleaning.

CAUTION! Never use water or cleaning solvents on electrical components.

Regulatory Information

ANSI Z21.47/CSA 2.3 certified. UL listed. Meets all applicable US and Canadian safety standards. For technical support, contact Gaffers & Sattler at 1-800-555-HEAT or visit www.gaffers-sattler.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
No heat	Thermostat/power/gas	Check thermostat setting; verify power and gas supply; check error codes.
Furnace locks out	Ignition failure	Check gas pressure; clean flame sensor; verify igniter operation.
Blower won't run	Motor/control board	Check capacitor; verify control board signal; check for obstructions.
Error code flashes	System fault	Count flashes and refer to diagnostic chart in service manual.
Condensate backup	Drain blockage	Clear drain line; check trap; verify proper slope.

Reset: Power cycle furnace to clear temporary lockouts.

Service: 1-800-555-HEAT; www.gaffers-sattler.com