Inter-City Products Furnace Manuals

The Inter-City Products furnace line includes high-efficiency gas and electric furnaces designed for residential and light commercial applications. These units feature advanced heat exchangers, variable-speed blowers, electronic ignition systems, and comprehensive safety controls. Below are key sections covering safety guidelines, model specifications, installation procedures, operation instructions, maintenance schedules, and troubleshooting guides.

1. Product Overview 2. Safety Precautions 3. Installation Guidelines 4. Technical Specifications 5. Operating Instructions 6. Maintenance Procedures 7. Control Settings 8. Error Codes 9. Parts Replacement 10. Warranty Information 11. Troubleshooting

Product Overview

Inter-City Products furnaces are available in various models including single-stage, two-stage, and modulating units with AFUE ratings from 80% to 98%.

Component	Description
Heat Exchanger	Stainless steel primary and secondary heat exchangers
Blower Motor	Variable-speed ECM motor for efficient airflow
Ignition System	Hot surface ignition with flame sensor
Gas Valve	Modulating gas valve for precise temperature control
Control Board	Microprocessor-based with diagnostic capabilities
Air Filter	High-efficiency pleated filter system
Vent System	PVC venting for high-efficiency models
Drain System	Condensate drain with safety switch
Thermostat Connection	Compatible with standard 24V thermostats
Safety Controls	Limit switches, pressure switches, rollout switches

Safety Precautions

Proper safety procedures must be followed during installation, operation, and maintenance.

Gas line connections: Use approved pipe compound and leak test all connections.
Electrical connections: Follow NEC codes and local regulations.
Vent installation: Ensure proper slope and termination clearances.
Combustion air: Provide adequate fresh air supply.

WARNING! Gas furnaces produce carbon monoxide; ensure proper venting and install CO detectors. Always shut off power and gas supply before servicing.

Installation Guidelines

Professional installation recommended for all Inter-City Products furnaces.

Location selection: Choose dry, level area with service clearance.
Venting: Install according to manufacturer specifications and local codes.
Gas connection: Use proper pipe size with sediment trap.
Electrical: Connect to dedicated circuit with proper grounding.
Ductwork: Ensure proper sizing and sealing.
Startup: Perform complete system checkout and combustion analysis.

CAUTION! Installation must comply with all local building codes and manufacturer specifications.

Technical Specifications

Models: ICP80, ICP90, ICP95 series
Input BTU/H: 40,000 to 120,000
AFUE Rating: 80% to 98%
Electrical: 115V/60Hz, 15 amp circuit
Gas Type: Natural gas or LP (with conversion kit)
Static Pressure: 0.1 to 0.8 inches WC
Blower Capacity: 800 to 2000 CFM
Sound Rating: Less than 75 dBA
Warranty: 20-year heat exchanger, 5-year parts
Dimensions: Varies by model (check specific model manual)

Operating Instructions

Proper operation ensures efficiency and extends equipment life.

Thermostat setting: Set to desired temperature and system mode (heat/cool/auto).
System startup: Unit will cycle automatically based on thermostat demand.
Normal operation: Listen for consistent airflow and burner operation.
Seasonal shutdown: Follow proper shutdown procedures for extended non-use.

Tip: Keep thermostat away from heat sources and direct sunlight for accurate temperature control.

Maintenance Procedures

Regular maintenance is essential for optimal performance and safety.

Monthly: Check and replace air filter if dirty.
Seasonal: Inspect vent system for obstructions.
Annual: Professional inspection including:
- Heat exchanger inspection
- Burner cleaning and adjustment
- Blower cleaning and lubrication
- Safety control testing
- Combustion analysis
Biannual: Drain line cleaning and trap priming.

WARNING! Only qualified technicians should perform internal component maintenance.

Control Settings

Integrated control board provides diagnostic lights and configuration dip switches.

Status Lights: Green (power), Yellow (heating call), Red (error/fault)

DIP Switch Settings: Blower speeds, heating delays, thermostat compatibility

Gas Valve Adjustment: Input rate adjustment for altitude and gas type

Blower Settings: Heating and cooling speeds, continuous fan option

Error Codes

Control board flashes error codes for diagnostic purposes.

Flash Pattern	Description	Action
1 Flash	Ignition failure	Check gas supply, igniter, flame sensor
2 Flashes	Pressure switch fault	Check venting, pressure switch tubing
3 Flashes	Limit switch open	Check airflow, filter, blower operation
4 Flashes	Rollout switch open	Check burner condition, heat exchanger
5 Flashes	Gas valve fault	Check wiring, valve operation
Continuous	Normal operation	No fault detected

Parts Replacement

Use only Inter-City Products approved replacement parts.

Igniter: Disconnect power, remove mounting screws, replace with same type.
Flame Sensor: Clean with emery cloth or replace if pitted.
Pressure Switch: Test with manometer, replace if out of calibration.
Blower Motor: Disconnect power, remove blower assembly, replace motor.
Control Board: Note wire locations, transfer all connections to new board.

CAUTION! Always disconnect power before replacing electrical components.

Warranty Information

Inter-City Products furnaces come with comprehensive warranty coverage.

Heat Exchanger: 20-year limited warranty
Parts: 5-year limited warranty
Labor: 1-year limited warranty (through installing dealer)
Registration: Warranty must be registered within 90 days of installation
Transferability: Limited warranty transfer to new homeowner

For warranty claims, contact authorized Inter-City Products dealers with proof of purchase and installation date.

Troubleshooting

Symptom	Possible Cause	Corrective Action
No heat	Thermostat, power, gas supply	Check thermostat setting, circuit breaker, gas valve
Short cycling	Dirty filter, airflow restriction	Replace filter, check vents and registers
Blower not running	Motor, capacitor, control board	Check power to motor, test capacitor, verify control signal
Burner won't ignite	Igniter, gas valve, pressure switch	Test igniter continuity, check gas pressure, verify switch closure
Unusual noises	Blower wheel, motor bearings	Inspect for debris, check motor mounting, lubricate if applicable
Error code flashing	Various system faults	Refer to error code chart for specific diagnosis

Reset Procedure: Turn power off for 30 seconds, then restore power to reset control board.

Technical Support: 1-800-ICP-HELP; www.intercityproducts.com