Luxaire Furnace Installation Manual

The Luxaire Furnace is a high-efficiency heating system designed for residential and light commercial applications. This manual covers installation procedures, safety guidelines, technical specifications, and operational instructions for proper furnace setup and maintenance. Below are key sections covering safety precautions, installation steps, electrical connections, gas line connections, ventilation requirements, startup procedures, and troubleshooting guidelines.

1. Safety Precautions 2. Pre-Installation Requirements 3. Installation Steps 4. Technical Specifications 5. Electrical Connections 6. Gas Line Connections 7. Ventilation System 8. Startup and Commissioning 9. Maintenance Guidelines 10. Regulatory Compliance 11. Troubleshooting

Safety Precautions

Critical safety information for installers and homeowners. Always follow these guidelines to prevent injury and equipment damage.

Hazard	Precaution
Gas leaks	Check all connections with leak detection solution
Electrical shock	Disconnect power before servicing
Carbon monoxide	Ensure proper ventilation and exhaust
Fire hazard	Maintain clearance from combustible materials
Burn injuries	Allow unit to cool before handling
Explosion risk	Never use matches to check for gas leaks
Vent blockage	Inspect flue pipes regularly
Overheating	Ensure adequate airflow around unit
Gas pressure issues	Verify correct manifold pressure
Condensate drain	Ensure proper drainage to prevent water damage

Pre-Installation Requirements

Essential preparations before beginning furnace installation.

Verify local codes and obtain necessary permits
Check furnace model matches application requirements
Ensure adequate space for installation and service access
Confirm proper gas supply line size and pressure
Verify electrical service meets furnace requirements
Check combustion air and ventilation requirements

WARNING! Installation must comply with all local building codes and regulations. Professional installation recommended.

Installation Steps

Step-by-step furnace installation procedure.

Position furnace: Place on level surface with proper clearances
Install flue pipes: Connect venting system according to specifications
Connect gas line: Use approved pipe and fittings with proper sealant
Electrical wiring: Connect power and thermostat wiring
Ductwork connection: Attach supply and return air ducts
Condensate drain: Install drain line with proper slope
Final inspection: Verify all connections and clearances

CAUTION! Use two people for lifting; furnace is heavy. Ensure level installation for proper operation.

Technical Specifications

Model Series: Various models available (check unit label)
Input Capacity: 40,000-120,000 BTU/h
Efficiency Rating: 80%-98% AFUE
Gas Type: Natural gas or propane (field convertible)
Electrical: 120V AC, 60Hz, 1.5-5.0 amps
Vent Size: 2-6 inch diameter depending on model
Dimensions: Varies by model (check specifications)
Weight: 80-150 pounds
Sound Level: < 65 dB
Warranty: Limited lifetime heat exchanger

Electrical Connections

Proper electrical wiring procedures and requirements.

Main Power: Dedicated 15-amp circuit required. Ground fault circuit interrupter recommended.

Thermostat Wiring: Standard 5-wire connection (R, W, Y, G, C). Follow color coding and ensure proper polarity.

Safety: Install disconnect switch within sight of furnace. All wiring must meet NEC requirements.

Gas Line Connections

Gas supply line installation and testing procedures.

Shut off main gas supply before beginning work
Use approved black iron pipe or CSST flexible gas line
Apply pipe thread sealant rated for gas service
Install sediment trap before gas valve
Pressure test system at 14 inches water column
Check for leaks with bubble solution
Verify proper manifold pressure (3.5" WC natural gas)

Tip: Always use two wrenches when making gas connections to prevent stress on valves.

Ventilation System

Combustion air and flue gas venting requirements.

Install vent pipes according to manufacturer specifications
Maintain proper slope for condensate drainage
Ensure adequate combustion air supply
Use approved vent materials (PVC, CPVC, or metal)
Maintain required clearances from combustible materials
Install termination caps according to local codes
Verify draft inducer operation

WARNING! Improper venting can cause carbon monoxide poisoning. Test system operation before completion.

Startup and Commissioning

Final procedures to activate and test furnace operation.

Verify all connections are secure and proper
Open gas supply valve slowly
Restore electrical power to furnace
Set thermostat to call for heat
Observe ignition sequence and flame quality
Check temperature rise across heat exchanger
Verify proper vent operation and draft
Test safety controls and limit switches
Complete installation checklist

Maintenance Guidelines

Regular maintenance schedule for optimal performance.

Annual maintenance recommended. Replace air filter every 1-3 months. Clean flame sensor and burners annually. Inspect heat exchanger for cracks. Check condensate drain system. Verify safety controls operation.

CAUTION! Always disconnect power before performing maintenance. Only qualified technicians should service gas and electrical components.

Regulatory Compliance

ANSI Z21.47: Certified for safety standards. UL listed. Meets DOE efficiency requirements. Installation must comply with National Fuel Gas Code NFPA 54, National Electrical Code NFPA 70, and local building codes. For technical support, contact Luxaire at 1-800-XXX-XXXX or visit www.luxaire.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power loss/thermostat	Check circuit breaker; verify thermostat settings; ensure door switch engaged.
No heat	Gas supply/ignition	Verify gas valve open; check pilot/igniter; inspect flame sensor.
Short cycling	Airflow/overheating	Replace dirty filter; check blower operation; verify vent clearance.
Blower not working	Motor/capacitor	Check blower motor; test capacitor; verify control board signals.
Unusual noises	Mechanical issues	Inspect blower wheel; check motor bearings; verify duct connections.
Pilot outage	Draft/thermocouple	Check vent blockage; clean pilot assembly; replace thermocouple.
Error codes flashing	System faults	Refer to diagnostic chart; reset power; check sensor readings.

Reset: Power cycle unit to clear error codes. Consult manual for specific error code meanings.

Service: 1-800-XXX-XXXX; www.luxaire.com