Tappan Gas Furnace Manual

The Tappan Gas Furnace is a high-efficiency heating system designed for residential use, featuring natural gas operation, electronic ignition, multi-speed blower motor, safety shut-off valves, thermal efficiency ratings up to 95% AFUE, programmable thermostat compatibility, and built-in diagnostic systems. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation Requirements 3. Initial Setup & Startup 4. Technical Specifications 5. Controls and Operation 6. Venting and Airflow 7. Maintenance Procedures 8. Safety Features 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Gas valve assembly, heat exchanger, blower motor, electronic control board, igniter, flame sensor, pressure switches, and venting system.

Feature	Description
Gas Valve	Regulates natural gas flow to burner assembly
Heat Exchanger	Stainless steel primary and secondary heat exchangers
Blower Motor	Multi-speed ECM motor for efficient airflow
Electronic Ignition	Hot surface igniter for reliable startup
Flame Sensor	Monitors burner flame for safety shutdown
Pressure Switches	Ensures proper venting operation
Control Board	Microprocessor for system operation and diagnostics
Thermostat Connection	Compatible with programmable thermostats
Safety Shut-off	Automatic gas shut-off in case of malfunction
Diagnostic LED	Flashing codes for troubleshooting

Installation Requirements

Professional installation required. Verify local codes and obtain permits.

Location: Install in well-ventilated area with proper clearances to combustibles.
Gas Connection: Use approved gas piping; pressure test for leaks.
Electrical: Connect to dedicated 120V circuit with proper grounding.
Venting: Install approved PVC venting system per manufacturer specifications.
Drainage: Connect condensate drain line to proper disposal.

WARNING! Gas appliances can be hazardous; installation must be performed by qualified technician. Ensure proper ventilation and combustion air supply.

Initial Setup & Startup

After installation, perform initial startup procedure.

Gas pressure check: Verify inlet and manifold pressures within specifications.
Venting verification: Confirm proper draft and venting operation.
Electrical check: Verify proper voltage and grounding.
Initial ignition: Follow lighting instructions; observe flame pattern.
Temperature rise: Measure and adjust airflow as needed.
Thermostat programming: Set desired temperature schedules.

CAUTION! Never bypass safety controls. If furnace fails to start, wait 5 minutes before retry.

Technical Specifications

Fuel Type: Natural Gas
Input Capacity: 40,000 - 120,000 BTU/H (model dependent)
AFUE Rating: Up to 95%
Electrical: 120V, 60Hz, 5-8 Amps
Blower Motor: ECM multi-speed
Venting: PVC Category IV
Gas Pressure: 3.5" WC natural gas
Temperature Rise: 35-65°F
Warranty: Limited lifetime heat exchanger, 10 years parts

Controls and Operation

Main control board manages all furnace operations. Access door switch must be engaged for operation.

Thermostat Operation: Set temperature; furnace cycles automatically. Green LED indicates normal operation.

Blower Speeds: Adjustable for heating and continuous fan operation. Gas Valve: Modulating or two-stage depending on model. Ignition Sequence: Purge, ignition trial, flame establishment, main burner operation. Safety Controls: Limit switches, pressure switches, flame rollout protection.

Venting and Airflow

Category IV sealed combustion system with PVC venting.

Vent pipes must slope slightly toward furnace for condensate drainage.
Maintain proper clearances from windows, doors, and air intakes.
Ensure combustion air pipes are unobstructed and properly terminated.
Verify adequate return air and supply air duct sizing.
Check filters monthly; replace when dirty.

Tip: Never block return air grilles or supply registers for proper airflow.

Maintenance Procedures

Annual professional maintenance recommended. Basic user maintenance:

Filter replacement: Change every 1-3 months depending on usage.
Visual inspection: Check for soot, corrosion, or water leakage.
Vent inspection: Ensure vent terminals are clear of debris.
Burner inspection: Professional cleaning of burners and heat exchanger.
Blower cleaning: Vacuum blower compartment annually.
Drain system: Flush condensate trap and drain line.

WARNING! Turn off gas and electrical power before any maintenance. Only qualified technicians should service gas components.

Safety Features

Multiple safety systems protect against hazardous conditions: Flame rollout switch, high limit switch, pressure switches, flame sensor, igniter safety timeout, gas valve safety shut-off.

Care & Cleaning

Keep furnace area clean and free of combustible materials. Use vacuum with soft brush attachment for exterior cleaning.

CAUTION! Never use water or liquid cleaners on electrical components. Keep filter clean for efficient operation.

Regulatory Information

ANSI Z21.47/CSA 2.3: Certified for natural gas operation. UL listed. FCC Part 15: Class B digital device. Manufactured to meet national safety standards. For technical support, contact Tappan Customer Service at 1-800-XXX-XXXX or visit www.tappan.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, door switch	Check circuit breaker; verify thermostat setting; ensure door closed properly.
No heat	Gas supply, igniter, flame sensor	Verify gas valve on; check for flashing LED codes; clean flame sensor.
Short cycling	Filter, limit switch, airflow	Replace dirty filter; check for blocked vents; verify proper airflow.
Blower won't stop	Thermostat fan setting	Check thermostat fan setting (Auto/On); verify control board operation.
Unusual noises	Blower, inducer motor, ducts	Inspect blower wheel; check inducer motor; examine ductwork for restrictions.

Reset: Turn power off for 30 seconds, then restart. Check diagnostic LED for error codes.

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