Gaffers & Sattler Furnace Manual

The Gaffers & Sattler Furnace is a high-efficiency residential heating system designed for reliable performance and energy savings. This furnace features variable-speed blower technology, electronic ignition, multiple heat stages, smart thermostat compatibility, safety shut-off controls, air filtration system, and quiet operation. Rated for natural gas or propane operation with AFUE ratings up to 98%. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Heat exchanger, blower assembly, gas valve, ignition system, control board, air filter compartment, flue pipe connection, thermostat terminals.

Installation

Unpack and inspect contents. Position in approved location with proper clearances.

1. Gas line connection: Use black iron pipe with proper thread sealant. Pressure test for leaks.
2. Electrical connection: Connect 120V AC power with proper grounding. Install disconnect switch.
3. Venting system: Install PVC intake and exhaust pipes per local codes and manufacturer specifications.
4. Thermostat wiring: Connect low-voltage wires to control board terminals (R, W, Y, G, C).
5. Ductwork connection: Secure supply and return ducts with proper sealing.

WARNING! Gas appliances can be dangerous; installation must be performed by qualified HVAC technician. Ensure proper ventilation and combustion air supply.

First-Time Setup

Power on furnace; follow startup procedure.

1. Gas pressure adjustment: Set manifold pressure per specifications (3.5" WC natural gas, 10" WC propane).
2. Blower speed settings: Adjust dip switches for proper airflow (COOL, HEAT LOW, HEAT HIGH).
3. Thermostat configuration: Program heating schedules and temperature settings.
4. System check: Verify proper ignition sequence, flame sensing, and safety controls.
5. Combustion analysis: Check CO levels and efficiency readings.

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

Specifications

• Heating Capacity: 40,000 to 120,000 BTU/hr models available.
• AFUE Rating: Up to 98% annual fuel utilization efficiency.
• Fuel Type: Natural gas or propane (field convertible).
• Electrical: 120V AC, 60Hz, 5-15 amp circuit.
• Blower Motor: ECM variable-speed, multi-tap settings.
• Stages: Single-stage or two-stage heating operation.
• Sound Rating: Ultra-quiet operation below 65 dB.
• Warranty: 20-year heat exchanger, 10-year parts limited warranty.
• Operating Temp Range: -30°F to 120°F ambient.

Controls and Settings

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

Control Board: LED status lights, dip switches, terminal strip, fuse, reset button.

Dip Switch Settings: Blower speeds (COOL, HEAT LOW, HEAT HIGH), thermostat type (single-stage, multi-stage), fan control (continuous, auto). Diagnostic Codes: Flash patterns indicate specific faults (1 flash = pressure switch, 2 flashes = ignition failure, etc.). Temperature Limits: Adjustable high limit settings for different applications.

Connecting Thermostat

Compatible with most 24V thermostats. Wiring: R (power), W (heat), Y (cool), G (fan), C (common).

1. Turn off power to furnace before wiring.
2. Strip wires 1/4 inch and connect to terminal strip.
3. For smart thermostats: C wire required for continuous power.
4. Configure thermostat for proper system type (gas furnace, single or multi-stage).

Tip: Use thermostat with outdoor temperature sensor for optimal efficiency.

Operating Modes

Heating modes: Single-stage, two-stage, emergency heat.

1. Normal heating: Thermostat calls for heat, ignition sequence begins.
2. Two-stage operation: First stage for mild days, second stage for extreme cold.
3. Fan operation: AUTO (cycles with heat call) or ON (continuous circulation).
4. Smart recovery: Learns home characteristics for optimal temperature recovery.
5. Vacation mode: Maintains lower temperature setting while away.

WARNING! Do not operate without proper ventilation. Ensure flue pipes are clear and unobstructed.

Safety Features

Flame rollout switches: Shut off gas if flame detected outside burner area. Limit switches: Prevent overheating. Pressure switches: Verify proper venting. Ignition safety: Shuts off gas if no flame detected. Carbon monoxide detection: Compatible with home CO detectors.

Maintenance & Cleaning

Annual professional maintenance recommended. Monthly filter changes during heating season.

1. Filter replacement: Slide out old filter, insert new one with arrow pointing toward blower.
2. Burner inspection: Check for proper flame pattern and cleanliness.
3. Blower cleaning: Vacuum blower wheel and motor compartment.
4. Drain line: Clear condensate drain trap and tubing.
5. Venting: Inspect PVC pipes for obstructions or damage.

CAUTION! Turn off power and gas supply before performing any maintenance. Only qualified technicians should service gas components.

Regulatory Information

ANSI Z21.47: Certified for gas-fired central furnaces. UL 1995: Standard for heating and cooling equipment. Meets DOE energy efficiency standards. For natural gas models: ANSI Z21.47/CSA 2.3. For propane models: ANSI Z21.47/CSA 2.3. For support, visit www.gaffers-sattler.com or contact 1-800-555-HEAT.

Troubleshooting

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

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