Tempstar Furnace Installation Manual
The Tempstar Furnace is a high-efficiency gas heating system designed for residential applications. This manual covers installation procedures, safety guidelines, technical specifications, and operational instructions for proper setup and maintenance. Below are key sections for safety, installation procedures, technical specifications, operation, and troubleshooting.
Safety Precautions
Critical safety information for installers and homeowners.
| Hazard | Precaution |
|---|
| Gas Leaks | Check all connections with leak detection solution before startup |
| Electrical Shock | Disconnect power before servicing or installation |
| Carbon Monoxide | Ensure proper venting and install CO detectors in living areas |
| Fire Hazard | Maintain proper clearances from combustible materials |
| Burn Risk | Allow unit to cool before servicing internal components |
Installation Requirements
Essential requirements before beginning installation.
- Location: Install in dry, well-ventilated area with adequate clearance
- Clearances: Minimum 1-inch clearance from combustible materials
- Floor Protection: Required for installations on combustible flooring
- Access: Maintain service access to front and sides of unit
- Drainage: Proper condensate drain line installation required
WARNING! Installation must comply with local building codes and manufacturer specifications.
Technical Specifications
- Model Series: TEMPSTAR HG/TG Series
- Input Capacity: 40,000 - 120,000 BTU/H
- Efficiency: 80% - 96% AFUE
- Voltage: 120V AC, 60Hz
- Gas Type: Natural Gas or Propane
- Gas Pressure: Natural Gas: 3.5" WC, Propane: 10" WC
- Venting: Category I or IV depending on model
- Dimensions: Varies by model (typically 21"W x 26"D x 40"H)
Installation Procedures
Step-by-step installation process.
- Position furnace: Level unit on solid surface or approved pad
- Remove shipping materials: Remove all protective covers and shipping restraints
- Install filter: Install proper size air filter in filter rack
- Connect ductwork: Secure supply and return air ducts
- Install venting: Connect flue pipe according to venting requirements
- Connect gas line: Install gas supply line with shutoff valve
- Electrical connections: Connect line voltage and thermostat wiring
- Condensate drain: Install condensate drain line and trap
Electrical Connections
Proper electrical wiring procedures.
- Disconnect power: Turn off electrical power at main panel
- Line voltage: Connect 120V power supply with proper grounding
- Thermostat wiring: Connect low-voltage thermostat wires to control board
- Humidifier: Optional humidifier connection if equipped
- Safety check: Verify all connections are secure and properly insulated
CAUTION! Electrical work must be performed by qualified personnel only.
Gas Line Connections
Gas supply connection requirements.
- Pipe sizing: Use proper pipe size for BTU input and length
- Shutoff valve: Install manual gas shutoff valve within 6 feet
- Drip leg: Install sediment trap (drip leg) before gas valve
- Leak testing: Test all connections with bubble solution
- Pressure test: Verify gas pressure at manifold
WARNING! Gas connections must be made by licensed professional.
Venting System
Venting requirements and installation.
| Vent Type | Requirements |
|---|
| Category I | Conventional metal vent pipe, vertical termination |
| Category IV | PVC/CPVC pipe, sealed combustion, sidewall termination |
| Common Vent | Follow manufacturer specifications for multiple appliance venting |
| Clearances | Maintain required clearances to combustible materials |
Startup and Commissioning
Initial startup procedures.
- Verify installations: Confirm all connections are complete
- Gas pressure: Set and verify correct manifold pressure
- Ventilation: Check for proper draft and combustion air
- Ignition sequence: Observe proper ignition and flame operation
- Temperature rise: Measure and verify within specified range
- Safety devices: Test limit switches and safety controls
Operating Instructions
Normal operation and user controls.
Thermostat Settings: Set desired temperature using wall thermostat
Fan Operation: AUTO (cycles with heat call) or ON (continuous operation)
Filter Indicator: Replace filter when indicator light illuminates
Pilot Light: Electronic ignition - no standing pilot
Maintenance Guidelines
Routine maintenance schedule.
- Monthly: Check filter, clean if reusable type
- Seasonal: Replace air filter, inspect vent system
- Annual: Professional inspection and cleaning
- Components: Check burners, heat exchanger, blower motor
CAUTION! Annual professional maintenance required for warranty compliance.
Troubleshooting
| Symptom | Possible Cause | Corrective Action |
|---|
| No heat | Thermostat setting, power, gas supply | Check thermostat, circuit breaker, gas valve |
| Furnace not starting | Limit switch, pressure switch | Reset switches, check for obstructions |
| Blower not running | Motor, capacitor, control board | Check motor operation, replace capacitor if needed |
| Frequent cycling | Dirty filter, thermostat location | Replace filter, relocate thermostat |
| Unusual noises | Loose components, airflow restriction | Tighten components, check ductwork |
Service: Contact qualified HVAC technician for complex issues
Warranty: 1-800-XXX-XXXX; www.tempstar.com
Tempstar Furnace Installation Manual © - All Rights Reserved 2025