Heat Controller Inc Furnace Manual

The Heat Controller Inc Furnace is a high-efficiency residential heating system designed for reliable performance and energy savings. This manual covers installation, operation, maintenance, and troubleshooting for various models in the Heat Controller furnace lineup. 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. Operation 8. Maintenance 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: High-efficiency heat exchanger, Electronic ignition system, Multi-speed blower motor, Safety controls, Filter compartment, Gas valve, Venting system.

Feature	Description
AFUE Rating	Up to 96% Annual Fuel Utilization Efficiency
Heat Exchanger	Stainless steel tubular design
Ignition System	Hot surface electronic ignition
Blower Motor	Variable speed ECM motor
Safety Controls	Flame rollout switch, pressure switch, limit switch
Filter System	Standard 1-inch or 4-inch media filter compatible
Gas Valve	Modulating for precise temperature control
Venting	PVC pipe compatible
Thermostat Connection	Standard 24V connections
Diagnostic LED	Built-in status indicator

Installation

Unpack and inspect contents. Ensure proper location with adequate clearance.

Position furnace: Place on stable, level surface with proper clearances.
Connect gas supply: Use black iron pipe with proper thread sealant.
Install venting: Use approved PVC piping with proper slope.
Electrical connections: Connect 120V power and thermostat wiring.
Install filter: Insert appropriate size filter in filter rack.

WARNING! Installation must be performed by qualified HVAC technician. Gas leaks can cause explosion. Ensure all connections are leak-tested.

First-Time Setup

Power on furnace; follow startup procedure.

Gas pressure check: Verify incoming and manifold gas pressures.
Vent verification: Ensure proper draft and venting operation.
Blower speed setting: Adjust blower speeds for heating mode.
Thermostat configuration: Set up thermostat for proper operation.
System test: Run complete heating cycle to verify operation.

CAUTION! Only qualified technicians should perform startup procedures. Improper setup can create hazardous conditions.

Specifications

Input Capacity: 40,000 to 120,000 BTU/h
AFUE Rating: Up to 96%
Gas Type: Natural Gas or LP (conversion kit required)
Electrical: 120V AC, 60Hz, 15 Amp circuit
Blower Motor: ECM variable speed
Airflow: 600 to 2000 CFM
Venting: 2" to 3" PVC
Dimensions: Varies by model (typically 21"W x 21"D x 56"H)
Weight: 120 to 180 lbs
Warranty: 20-year heat exchanger, 5-year parts

Controls and Settings

Access control board via front panel. Integrated control module with diagnostic LED.

Control Board: POWER switch, Fuse, Status LED, Dip switches, Terminal connections.

Temperature Control: Via connected thermostat. Blower Settings: Adjustable heating speeds. Gas Pressure: Field adjustable manifold pressure. Safety Controls: Auto-reset limits, manual reset rollout switches. Diagnostic Codes: LED flash patterns indicate system status and faults.

Connecting Thermostat

Standard 24V thermostat connections: R (power), W (heat), G (fan), C (common), Y (cool).

Turn off power to furnace before wiring.
Connect thermostat wires to control board terminals.
Match wire colors to terminal labels.
Secure connections and replace access panel.
Restore power and test operation.

Tip: Use 18-gauge thermostat wire for best performance.

Operation

Heating cycle controlled by thermostat.

Call for heat: Thermostat sends signal to control board.
Inducer operation: Draft inducer motor starts first.
Pressure switch: Verifies proper draft before ignition.
Ignition sequence: Hot surface igniter glows, gas valve opens.
Flame verification: Flame sensor confirms ignition.
Blower operation: Blower starts after heat exchanger warms.
Cycle completion: System shuts down when thermostat satisfied.

WARNING! Never bypass safety controls. Regular professional maintenance required.

Maintenance

Regular maintenance ensures optimal performance and safety.

Monthly: Check and replace air filter as needed.
Seasonal: Professional inspection and cleaning.
Annual: Complete system check by qualified technician.
As needed: Clean flame sensor and burners.

Care & Cleaning

Turn off power before cleaning. Keep area around furnace clear.

Filter Replacement: Replace 1-inch filters monthly, 4-inch filters every 6 months.

CAUTION! Do not operate without filter. Keep combustion air intake clear. Never use compressed air to clean interior components.

Regulatory Information

UL listed and ANSI certified. Complies with ASHRAE standards. Manufactured to meet DOE efficiency requirements. For support, contact Heat Controller Inc technical service at 1-800-HEAT-CTL or visit www.heatcontroller.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, door switch	Check circuit breaker, thermostat setting, door switch engagement.
No heat	Gas supply, ignition, filter	Verify gas valve on, check for ignition attempts, replace dirty filter.
Short cycling	Dirty filter, airflow, overheating	Clean/replace filter, check vents, verify proper airflow.
Blower won't stop	Thermostat, control board	Check thermostat fan setting, inspect control board.
Unusual noises	Motor, blower wheel, ductwork	Inspect blower assembly, check for obstructions, tighten components.

Reset: Power cycle furnace by turning off/on at switch or breaker.

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