Tempstar 5000 Furnace Manual

The Tempstar 5000 Furnace is a high-efficiency gas furnace with AFUE ratings up to 96%, variable-speed blower motor, two-stage heating operation, durable heat exchanger, diagnostic LED system, quiet operation technology, easy-access control panel, and compatibility with most thermostats. Designed for residential use with natural gas or propane capability. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Thermostat 7. Operating Modes 8. Maintenance Schedule 9. Care & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: Two-stage gas valve, variable-speed blower motor, aluminized steel heat exchanger, diagnostic LED, pressure switches, flame sensor, igniter, filter access door.

Feature	Description
Two-stage heating	Provides efficient low-stage and high-stage heating operation
Variable-speed blower	Automatically adjusts airflow for optimal comfort and efficiency
Diagnostic LED	Displays error codes for easy troubleshooting
Durable heat exchanger	Aluminized steel construction for long service life
Quiet operation	Insulated cabinet and vibration dampeners reduce noise
Easy filter access	Front-loading filter door for simple maintenance
Pressure switches	Safety devices that verify proper venting operation
Flame sensor	Detects burner flame for safe operation
Hot surface igniter	Reliable electronic ignition system
Gas valve	Precise gas flow control for natural gas or propane

Installation

Unpack and inspect contents. Ensure proper location with adequate clearance.

Position furnace: Place on stable, level surface with proper clearances (minimum 1" sides, 6" front).
Connect gas line: Use approved gas piping and fittings; pressure test for leaks.
Connect electrical: 120V AC power supply with proper grounding and disconnect switch.
Connect venting: Use approved PVC or metal vent pipe per local codes.
Connect thermostat: Low-voltage wiring to R, W, G, C terminals.
Install filter: Insert proper size filter in filter rack.

WARNING! Installation must be performed by qualified HVAC technician. Gas leaks can cause explosion or fire.

First-Time Setup

Power on furnace; follow startup sequence.

Verify gas supply: Ensure gas valve is open and gas pressure is correct.
Check electrical: Confirm proper voltage at unit and thermostat.
Set thermostat: Program heating schedule and temperature settings.
Test operation: Turn on heat and verify proper ignition sequence.
Check airflow: Verify adequate airflow from all registers.
Monitor operation: Observe for proper cycling and temperature rise.

CAUTION! Never bypass safety devices. Ensure proper combustion air supply.

Specifications

AFUE Rating: Up to 96% efficiency.
Heating Capacity: 40,000 to 120,000 BTU/h.
Stages: Two-stage heating operation.
Blower Type: Variable-speed ECM motor.
Fuel Type: Natural gas or propane.
Electrical: 120V AC, 60Hz.
Control Voltage: 24V AC.
Venting: PVC or approved metal vent pipe.
Sound Level: As low as 65 dB.
Warranty: Limited lifetime heat exchanger, 10-year parts.

Controls and Settings

Access control board via front panel. LED diagnostic light indicates system status.

Control Board: Power switch, diagnostic LED, dip switches, terminal strip.

Heating Settings: Temperature rise adjustment, blower speed settings, staging control. Safety: Pressure switch settings, flame sensor monitoring, limit switch control. Diagnostics: LED flash codes for troubleshooting (1 flash = normal, 2-7 flashes = specific errors).

Connecting Thermostat

Compatible with most 24V thermostats. Standard wiring: R (power), W (heat), G (fan), C (common), Y (cooling).

Turn off power to furnace before wiring.
Connect thermostat wires to control board terminals.
Match wire colors to terminal labels.
Secure connections and replace access panel.
Restore power and test operation.

Tip: Use thermostat compatible with two-stage heating for optimal performance.

Operating Modes

Supports heating and continuous fan operation.

Heating Mode: Thermostat calls for heat, furnace ignites and provides warm air.
Two-Stage Operation: Low stage for mild days, high stage for cold weather.
Fan Mode: Continuous circulation without heating.
Standby Mode: System ready but not actively heating.
Lockout Mode: Safety shutdown after multiple ignition failures.

WARNING! Never operate without proper filter installed. Monitor for unusual noises or odors.

Maintenance Schedule

Monthly: Check filter, listen for unusual noises. Annually: Professional inspection and cleaning.

Care & Cleaning

Turn off power before maintenance. Replace filter monthly during heating season. Keep area around furnace clean and unobstructed.

CAUTION! Do not attempt to clean heat exchanger or burners. Leave to qualified technician.

Regulatory Information

UL certified for safety. Meets ANSI Z21.47 standards. CSA design certified. For natural gas or propane use only. Installation must comply with National Fuel Gas Code NFPA 54 and local codes. For support, visit www.tempstar.com or contact 1-800-772-2179.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power/thermostat	Check circuit breaker; verify thermostat settings; ensure gas valve open.
No heat	Ignition failure	Check diagnostic LED; verify gas supply; inspect flame sensor.
Short cycling	Dirty filter/overheating	Replace air filter; check for blocked vents; verify proper airflow.
Blower not running	Motor/control issue	Check blower door switch; verify motor operation; inspect capacitor.
Unusual noises	Mechanical issues	Inspect blower wheel; check motor bearings; verify proper clearance.

Reset: Turn power off for 30 seconds, then restore.

Service: 1-800-772-2179; www.tempstar.com