Heat Controller Furnace Manual

The Heat Controller Furnace is a high-efficiency heating system designed for residential use, featuring advanced temperature control, multiple heating stages, energy-saving modes, built-in safety features, digital thermostat interface, filter monitoring system, and compatibility with various venting options. Powered by standard household electrical supply with natural gas or propane fuel sources. Below are key sections for safety, features, installation, setup, operation, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Thermostat 7. Operating Modes 8. Safety Features 9. Maintenance & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: High-efficiency heat exchanger, Digital control board, Blower motor, Gas valve, Ignition system, Filter compartment, Thermostat connections, Safety switches.

Feature	Description
Digital control board	Manages all furnace operations and diagnostics
Multi-speed blower motor	Variable speed for optimal airflow and efficiency
Electronic ignition	Reliable spark ignition system
Filter monitoring system	Alerts when filter needs replacement
Safety shut-off switches	High-limit and rollout protection
Thermostat connections	Compatible with most digital thermostats
POWER switch	Main power control
Diagnostic LED	Displays error codes for troubleshooting
Gas valve	Precise fuel control
Vent connections	PVC venting compatible

Installation

Unpack and inspect all components. Ensure proper location with adequate clearance.

Position furnace: Place on stable, level surface with proper clearances.
Connect gas line: Use approved gas piping and fittings; pressure test required.
Connect electrical: Follow local electrical codes; proper grounding essential.
Install venting: Use approved PVC vent pipes with proper slope.
Connect thermostat: Use low-voltage wiring per diagram.
Install air filter: Insert proper size filter in filter compartment.

WARNING! Installation must be performed by qualified technician. Gas leaks can cause explosion. Follow all local codes.

First-Time Setup

Power on furnace; follow startup sequence.

Verify gas connection: Check for leaks with soap solution.
Set thermostat: Program desired temperature settings.
Test operation: Run through complete heating cycle.
Adjust blower speed: Set for optimal airflow if adjustable.
Configure filter reminder: Set replacement interval.

CAUTION! Ensure proper ventilation. Test carbon monoxide detectors.

Specifications

Heating Capacity: 40,000-120,000 BTU/h (model dependent)
Efficiency: Up to 96% AFUE
Fuel Type: Natural gas or propane
Electrical: 120V AC, 60Hz
Blower Motor: ECM or PSC multi-speed
Venting: PVC pipe (2-3 inch)
Filter Size: Standard 16x25x1 inch or model specific
Operating Temp Range: -30°F to 120°F ambient
Warranty: 10-year heat exchanger, 5-year parts

Controls and Settings

Access control board via front panel. Diagnostic LED displays status codes.

Thermostat Controls: Temperature setting, Fan mode (Auto/On), System mode (Heat/Off), Program schedules.

Furnace Settings: Blower speed adjustments, Filter timer reset, Diagnostic mode access, Gas pressure adjustment (qualified technician only). Safety: High-limit settings, Ignition retry attempts, Pressure switch monitoring, Flame sensor monitoring.

Connecting Thermostat

Compatible with most 24VAC thermostats. Standard connections: R, W, G, Y, C.

Turn off power to furnace before wiring.
Match thermostat wires to control board terminals.
Use proper low-voltage thermostat wire.
Secure connections and replace access panel.
Restore power and test operation.

Tip: Use programmable thermostat for maximum energy savings.

Operating Modes

Multiple operating modes for efficiency and comfort.

Heating Mode: Primary heating operation with variable output.
Fan Only: Circulates air without heat.
Standby: Ready state waiting for heat demand.
Diagnostic: Service mode for troubleshooting.
Lockout: Safety shutdown with error code display.

WARNING! Do not attempt to override safety lockouts. Contact qualified service technician.

Safety Features

Multiple safety systems protect against hazardous conditions.

Safety Feature	Function
Flame rollout switch	Detects improper burner operation
High limit switch	Prevents overheating
Pressure switches	Ensures proper venting
Flame sensor	Confirms burner ignition
Gas valve	Automatic shut-off if no ignition
Ignition control	Limited retry attempts

Maintenance & Cleaning

Regular maintenance ensures optimal performance and safety.

Monthly: Check and replace air filter as needed.
Annual: Professional inspection and cleaning.
Seasonal: Check vent pipes for obstructions.
As needed: Clean flame sensor and burners.

CAUTION! Turn off power and gas supply before servicing. Only qualified technicians should perform internal maintenance.

Regulatory Information

UL certified: Meets UL 1995 standards for heating and cooling equipment. ANSI compliance: Meets ANSI Z21.47 standards for gas-fired central furnaces. EPA compliant: Meets emissions standards for residential heating equipment. For support, visit www.heatcontroller.com or contact 1-800-HEAT-CTL. Manufactured under license and patents.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, switch	Check power supply; verify thermostat settings; ensure door switch engaged.
No heat	Gas supply, ignition	Verify gas valve on; check pilot/ignition; review error codes.
Short cycling	Filter, limit switch	Replace dirty filter; check for blocked vents; verify proper airflow.
Blower doesn't run	Motor, capacitor, board	Check blower motor; test capacitor; verify control board signals.
Error code flashing	Various faults	Refer to diagnostic chart in service manual; reset if safe.
Gas odor	Leak, improper combustion	Immediately shut off gas; evacuate area; contact professional.

Reset: Power cycle furnace if safe. Some errors require professional reset.

Service: 1-800-HEAT-CTL; www.heatcontroller.com