Gaffers and Sattler U100 Furnace Manual

The Gaffers and Sattler U100 Furnace is a high-efficiency residential heating unit with 80,000 BTU output, electronic ignition, variable-speed blower motor, multi-position installation capability, digital thermostat compatibility, safety shutoff features, and energy-saving operation modes. Designed for natural gas operation with optional LP conversion kit. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation Requirements 3. Initial Setup and Startup 4. Technical Specifications 5. Controls and Operation 6. Maintenance Procedures 7. Safety Features 8. Thermostat Configuration 9. Seasonal Maintenance 10. Regulatory Compliance 11. Troubleshooting Guide

Features at a Glance

Key components: Stainless steel heat exchanger, electronic ignition system, variable-speed blower motor, multi-position flue, integrated control board, pressure switches, flame sensor, and diagnostic LED.

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
Installation Positions	Upflow, downflow, horizontal left, horizontal right
Control Board	Integrated microprocessor with diagnostic capabilities
Flue Options	PVC or ABS venting for sidewall or roof termination
Gas Valve	Modulating for precise temperature control
Filter Size	Standard 16x25x1 inch filter
Safety Features	Flame rollout switch, pressure switches, high limit control
Diagnostic LED	Flashing codes for troubleshooting

Installation Requirements

Proper installation is critical for safe and efficient operation. Follow all local codes and manufacturer specifications.

Location: Install in well-ventilated area with adequate clearance (minimum 24 inches front, 6 inches sides)
Gas Connection: Use approved gas pipe and fittings; pressure test for leaks
Electrical: 120V AC, 15 amp dedicated circuit required
Venting: Properly size and install vent pipes according to installation manual
Drain Lines: Install condensate drain with proper trap and routing

WARNING! Installation must be performed by qualified HVAC technician. Improper installation can cause fire, explosion, or carbon monoxide poisoning.

Initial Setup and Startup

After installation, perform initial setup and verification before regular operation.

Gas Pressure Check: Verify inlet and manifold pressures are within specifications
Vent Verification: Confirm proper draft and venting operation
Electrical Check: Verify proper voltage and grounding
Control Setup: Configure thermostat and furnace settings
Test Sequence: Run complete heating cycle and monitor operation

CAUTION! Never bypass safety controls or operate furnace with access panels removed.

Technical Specifications

Heating Capacity: 80,000 BTU/H input
Efficiency: 80% AFUE
Gas Type: Natural gas (LP conversion kit available)
Electrical: 120V AC, 60Hz, 5.2 amps
Blower Motor: ECM variable speed, 1/3 HP
Static Pressure: 0.1 to 0.8 inches water column
Temperature Rise: 35-65°F
Vent Size: 2-inch or 3-inch PVC/ABS
Dimensions: 21"W x 48"H x 26"D
Weight: 128 pounds

Controls and Operation

Integrated control board manages all furnace functions with LED status indicators.

Control Board Features: POWER ON/OFF switch, diagnostic LED, mode selection, fan control, temperature limits.

Operation Modes: HEAT, COOL (with AC), FAN ONLY. Temperature Settings: Adjust via compatible thermostat. Fan Control: AUTO or CONTINUOUS operation. Safety Monitoring: Continuous monitoring of flame, pressure, and temperature conditions.

Maintenance Procedures

Regular maintenance ensures optimal performance and extends furnace life.

Monthly: Check and replace air filter if dirty
Seasonal: Inspect burners, heat exchanger, and vent system
Annual: Professional inspection and cleaning recommended
Blower Maintenance: Clean blower wheel and motor annually
Drain System: Clear condensate drain and trap monthly

Tip: Keep area around furnace clean and free of combustible materials.

Safety Features

Multiple safety systems protect against hazardous conditions.

Safety Feature	Function
Flame Rollout Switch	Detects flame outside combustion chamber
High Limit Switch	Prevents overheating by shutting off burners
Pressure Switches	Verify proper venting operation
Flame Sensor	Confirms burner ignition within safety time
Gas Valve	Automatic shutoff if ignition fails
Ignition Control	Limited trial-for-ignition period

Thermostat Configuration

Compatible with most 24V digital thermostats for precise temperature control.

Wiring: Connect R, W, G, Y, C terminals as needed
Programming: Set heating schedule and temperature preferences
Fan Control: Configure AUTO or ON operation
Temperature Differential: Adjust for comfort and efficiency
System Mode: Select HEAT, COOL, or OFF

WARNING! Always turn off power before working on thermostat wiring.

Seasonal Maintenance

Prepare furnace for heating season and perform off-season maintenance.

Pre-Season Checklist: Replace filter, inspect vent system, test safety controls, verify thermostat operation. Off-Season: Clean furnace interior, cover if not in use, schedule professional service.

CAUTION! Never operate furnace without proper air filter installed.

Regulatory Compliance

UL certified for safety standards. ANSI Z21.47 compliant for gas-fired central furnaces. Meets DOE energy efficiency requirements. EPA compliant for emissions. For technical support, contact Gaffers and Sattler at 1-800-555-HEAT or visit www.gaffers-sattler.com.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, safety lockout	Check power switch, thermostat settings, reset safety controls
No heat	Gas supply, ignition, filter	Verify gas valve on, check for ignition, replace dirty filter
Short cycling	Dirty filter, high limit	Replace filter, check for restricted airflow
Blower not running	Motor, capacitor, control	Check blower motor, capacitor, control board signals
Unusual noises	Loose parts, motor, ductwork	Tighten components, inspect blower, check duct connections

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

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