Intertherm Furnace Manual Problems

The Intertherm furnace is a reliable heating system that may encounter various operational issues over time. Common problems include ignition failures, airflow restrictions, thermostat malfunctions, and component wear. This manual addresses troubleshooting procedures, maintenance requirements, and safety considerations for Intertherm furnace owners. Below are key sections covering common issues, diagnostic procedures, maintenance guidelines, and safety precautions.

1. Common Furnace Problems 2. Diagnostic Procedures 3. Maintenance Requirements 4. Safety Considerations 5. Component Specifications 6. Error Code Interpretation 7. Professional Service Guidelines 8. Warranty Information 9. Replacement Parts 10. Regulatory Compliance 11. Troubleshooting Guide

Common Furnace Problems

Typical issues encountered with Intertherm furnaces: ignition failure, poor airflow, thermostat issues, blower motor problems.

Problem	Description
Ignition Failure	Furnace fails to ignite or starts intermittently
Poor Airflow	Reduced heating efficiency and uneven temperature distribution
Thermostat Malfunction	Inaccurate temperature readings or failure to communicate with furnace
Blower Motor Issues	Unusual noises, failure to start, or inconsistent operation
Pilot Light Problems	Pilot won't stay lit or produces weak flame
Gas Valve Issues	Failure to open or close properly
Limit Switch Failure	Furnace overheats and shuts off prematurely
Draft Inducer Problems	Failure to create proper draft for combustion gases
Flame Sensor Issues	Furnace cycles on and off repeatedly
Electrical Connection Problems	Loose wiring or connection failures

Diagnostic Procedures

Systematic approach to identifying furnace problems.

Check power supply: Verify furnace is receiving power and circuit breaker hasn't tripped.
Inspect thermostat: Ensure proper settings and battery replacement if applicable.
Examine air filters: Replace clogged or dirty filters restricting airflow.
Test safety switches: Verify limit switch and rollout switch functionality.
Check flame sensor: Clean or replace if dirty or malfunctioning.

WARNING! Always turn off power and gas supply before performing diagnostics. Use proper safety equipment.

Maintenance Requirements

Regular maintenance prevents common furnace problems and ensures optimal performance.

Monthly: Check and replace air filters as needed.
Seasonal: Inspect burners, heat exchanger, and flue system.
Annual: Professional inspection and cleaning of all components.
Biannual: Lubricate motor bearings if required by model.
As needed: Clean flame sensor and check electrical connections.

CAUTION! Only qualified technicians should perform internal component maintenance.

Safety Considerations

Carbon Monoxide: Install CO detectors near furnace and sleeping areas.
Gas Leaks: If gas odor detected, evacuate immediately and contact utility company.
Electrical Safety: Always disconnect power before servicing.
Clearance Requirements: Maintain proper clearance around furnace unit.
Ventilation: Ensure adequate combustion air and proper venting.
Fire Safety: Keep flammable materials away from furnace.
Professional Service: Complex repairs require certified technicians.
Emergency Shutoff: Know location of gas shutoff valve and electrical disconnect.

Component Specifications

Key furnace components and their functions.

Burner Assembly: Creates combustion flame for heating. Heat Exchanger: Transfers heat to air while keeping combustion gases separate. Blower Motor: Circulates heated air through ductwork. Gas Valve: Controls gas flow to burners. Flame Sensor: Detects presence of flame for safety. Limit Switch: Prevents overheating by shutting off burners. Inducer Motor: Creates draft for combustion gases. Control Board: Manages furnace operation and safety features.

Error Code Interpretation

Modern Intertherm furnaces display error codes for specific problems.

Check control board LED: Count flashes or observe digital display.
Reference error code chart in technical manual.
Common codes: 1 flash (ignition failure), 2 flashes (pressure switch), 3 flashes (limit circuit).
Reset procedure: Turn power off for 30 seconds, then restore.

Tip: Document error codes before contacting service technician.

Professional Service Guidelines

When to contact certified HVAC technician.

Gas line issues or suspected leaks.
Electrical problems beyond basic troubleshooting.
Heat exchanger inspection or replacement.
Control board diagnostics or replacement.
Annual maintenance and performance testing.
Warranty-covered repairs requiring authorized service.
Installation of new components or system upgrades.
Complex diagnostic procedures requiring specialized equipment.

WARNING! Attempting complex repairs without proper training can be dangerous and void warranties.

Warranty Information

Standard Intertherm furnace warranty coverage and limitations.

Replacement Parts

Common replacement components and compatibility information.

CAUTION! Use only manufacturer-approved replacement parts to maintain safety and performance.

Regulatory Compliance

Intertherm furnaces comply with ANSI Z21.47 standards for gas-fired central furnaces. UL listed for safety. Meets DOE efficiency requirements. Manufactured in compliance with EPA regulations. For technical support, contact Intertherm customer service at 1-800-XXX-XXXX or visit www.intertherm.com.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power loss/thermostat	Check circuit breaker; verify thermostat settings; replace batteries.
No heat production	Gas supply/ignition	Ensure gas valve open; check pilot light; inspect ignition system.
Insufficient heat	Airflow/component failure	Replace air filter; check blower operation; verify gas pressure.
Frequent cycling	Dirty filter/limit switch	Clean or replace filter; test limit switch; check airflow.
Unusual noises	Mechanical wear/obstruction	Inspect blower wheel; check motor bearings; remove obstructions.
Burner won't stay lit	Flame sensor/thermocouple	Clean flame sensor; replace thermocouple; check gas pressure.
Yellow burner flame	Combustion air/contamination	Ensure adequate ventilation; clean burners; check gas quality.
Blower runs continuously	Fan switch/control board	Adjust fan limit switch; test control board; check wiring.

Reset Procedure: Turn thermostat to lowest setting, turn off power for 30 seconds, restore power, set thermostat to desired temperature.

Emergency Service: 1-800-XXX-XXXX; www.intertherm.com