Milwaukee ThermFlo Gas Furnace Manual

The Milwaukee ThermFlo Gas Furnace is a high-efficiency residential heating system designed for reliable performance in cold climates. This natural gas furnace features variable-speed blower technology, electronic ignition, multi-stage heating, built-in diagnostics, and compatibility with smart thermostats. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation Requirements 3. First-Time Setup 4. Technical Specifications 5. Controls and Settings 6. Venting and Combustion Air 7. Operation Instructions 8. Maintenance Schedule 9. Safety Features 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Stainless steel heat exchanger, variable-speed ECM blower motor, electronic ignition system, pressure switches, flame sensor, and integrated control board.

Feature	Description
Heat Exchanger	Stainless steel construction for durability and efficiency
Blower Motor	Variable-speed ECM for quiet operation and energy savings
Ignition System	Electronic hot surface ignition for reliable starts
Stages	Multi-stage heating for better temperature control
AFUE Rating	95% or higher Annual Fuel Utilization Efficiency
Diagnostic Lights	LED status indicators for troubleshooting
Gas Valve	Modulating gas valve for precise fuel control
Filter System	Standard 1-inch or 4-inch media filter compatible
Thermostat Compatibility	Works with conventional and smart thermostats
Safety Controls	Multiple pressure switches and limit controls

Installation Requirements

Professional installation required. Unpack and inspect all components before beginning.

Location: Install in dry, level area with adequate clearance for service access.
Gas Connection: Use approved black iron pipe with proper thread sealant.
Electrical: 120V AC power supply with proper grounding required.
Venting: Use approved PVC or CPVC pipe for direct vent installation.
Drain Line: Install condensate drain line with proper trap and routing.

WARNING! Gas furnaces produce carbon monoxide. Proper venting is critical. Installation must comply with local codes and manufacturer specifications.

First-Time Setup

After installation, perform initial startup procedure.

Gas pressure check: Verify inlet and manifold gas pressures are within specifications.
Venting verification: Confirm proper draft and combustion air supply.
Electrical connections: Check all wiring connections for tightness.
System startup: Follow lighting instructions on unit label.
Temperature rise: Measure and adjust blower speed if necessary.

CAUTION! Only qualified HVAC technicians should perform startup and adjustment procedures.

Technical Specifications

Model Series: ThermFlo TF-95V
Input BTU/h: 40,000 - 120,000 (varies by model)
Output BTU/h: 38,000 - 114,000 (varies by model)
AFUE: 95% - 98%
Stages: 2-stage heating, variable-speed blower
Gas Type: Natural gas (LP conversion kit available)
Electrical: 120V/60Hz/1Ph, 5-8 Amps
Static Pressure: 0.2 - 0.8 in. w.c.
Temperature Rise: 35°F - 65°F
Venting: 2" - 3" PVC/CPVC
Warranty: 20-year heat exchanger, 10-year parts

Controls and Settings

Integrated control board with diagnostic capabilities. Access via control panel or thermostat.

Control Board Features: Status LED lights, dip switch settings, test mode, reset button.

DIP Switch Settings: Blower speeds, heating stages, thermostat compatibility. Diagnostic Lights: Flash codes for troubleshooting (see troubleshooting section). Temperature Settings: Adjust via compatible thermostat. Fan Control: Continuous fan or auto mode selection.

Venting and Combustion Air

Direct vent system using concentric or separate PVC pipes.

Vent pipe sizing: Follow manufacturer specifications for length and diameter.
Termination: Maintain proper clearances from windows, doors, and air intakes.
Combustion air: Ensure adequate fresh air supply for proper combustion.
Condensate disposal: Route condensate to approved drain location.

Tip: Check vent pipes annually for obstructions or damage.

Operation Instructions

Normal operation controlled through thermostat.

Heating cycle: Thermostat calls for heat, igniter glows, gas valve opens.
Blower operation: Blower starts after heat exchanger warms up.
Stage operation: First stage operates for moderate heating needs.
Second stage: Engages during extreme cold or rapid temperature recovery.
Shutdown: Gas valve closes, blower continues for cool-down period.

WARNING! Never operate furnace with access panels removed. Keep combustible materials away from furnace.

Maintenance Schedule

Annual professional maintenance recommended. Monthly homeowner maintenance required.

Frequency	Task
Monthly	Check and replace air filter if dirty
Annually	Professional inspection and cleaning
Annually	Check heat exchanger for cracks
Annually	Clean flame sensor and burners
Annually	Verify gas pressure and combustion
Annually	Check vent system and drains

Safety Features

Multiple safety systems protect against hazardous conditions.

Flame rollout switches: Detect improper burner flames
High limit switches: Prevent overheating
Pressure switches: Verify proper venting operation
Flame sensor: Confirms burner ignition
Ignition control: Safe start-up sequence

CAUTION! Install carbon monoxide detectors near sleeping areas when using gas appliances.

Regulatory Information

UL certified for safety. ANSI Z21.47 compliant. Meets DOE efficiency standards. Manufactured to comply with U.S. safety and performance requirements. For technical support, contact Milwaukee HVAC at 1-800-555-HEAT or visit www.milwaukeehvac.com. Serial number located on unit rating plate.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, switch	Check circuit breaker, thermostat settings, door switch
No heat	Gas supply, ignition	Verify gas valve on, check for ignition attempts
Short cycling	Filter, limit switch	Replace dirty filter, check for blocked vents
Blower won't stop	Thermostat, control board	Check thermostat fan setting, control board operation
Error codes flashing	Various faults	Count flashes and refer to diagnostic chart

Reset: Power cycle unit or press reset button on control board.

Service: 1-800-555-HEAT; www.milwaukeehvac.com