Tempstar Gas Furnace Manual

The Tempstar Gas Furnace is a high-efficiency heating system designed for residential use, featuring advanced combustion technology, multiple safety systems, variable-speed blower motor, electronic ignition, and compatibility with standard thermostat controls. Available in various BTU capacities with AFUE ratings up to 98%. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Heat exchanger, burners, inducer motor, blower assembly, gas valve, pressure switches, flame sensor, control board.

Installation Requirements

Professional installation required. Verify local codes and obtain permits.

1. Location: Install in well-ventilated area with proper clearances (minimum 1 inch from combustible materials).
2. Gas Connection: Use approved gas pipe; pressure test for leaks before operation.
3. Electrical: 120V AC power supply with proper grounding.
4. Venting: Install PVC vent pipes according to manufacturer specifications.
5. Drainage: Connect condensate drain line to proper disposal.

WARNING! Gas appliances can be hazardous; installation must be performed by qualified technician. Carbon monoxide poisoning risk if improperly installed.

First-Time Setup

Initial startup must be performed by qualified technician.

1. Verify all connections: Gas, electrical, venting, and drainage.
2. Check gas pressure: Adjust manifold pressure to specifications.
3. Test safety controls: Verify pressure switches, limit switches, and flame sensor operation.
4. Program thermostat: Set heating parameters and fan control.
5. Commission system: Run through complete heating cycle and verify operation.

CAUTION! Never attempt first-time startup without proper training and equipment.

Technical Specifications

• BTU Capacity: 40,000 to 120,000 BTU/hr models available
• AFUE Rating: Up to 98% efficiency
• Gas Type: Natural gas or propane (conversion kit required)
• Electrical: 120V AC, 60Hz, 5-10 amps
• Static Pressure: 0.1 to 0.9 inches water column
• Temperature Rise: 35°F to 65°F
• Venting: 2-inch or 3-inch PVC
• Sound Level: Less than 70 dBA
• Warranty: Limited lifetime heat exchanger, 10 years parts

Controls and Settings

Access control board via front panel. LED status lights indicate system operation.

Control Board: POWER, STATUS LED, DIAGNOSTIC codes, DIP switches for configuration.

Heating Modes: Single-stage, two-stage, or modulating operation. Fan Control: Continuous, intermittent, or circulating modes. Temperature Limits: High limit switch protects against overheating. Diagnostic Codes: Flash patterns indicate specific error conditions. Configuration: DIP switches for blower delays, staging, and accessory control.

Thermostat Connection

Compatible with standard 24V thermostats. Wiring: R, W, G, C terminals.

1. Turn off power to furnace before connecting thermostat.
2. Match thermostat wires to control board terminals (R-red, W-white, G-green, C-common).
3. Configure thermostat for gas furnace operation.
4. Test heating and fan functions.

Tip: Use programmable thermostat for maximum energy efficiency.

Operating Procedures

Normal operation controlled by thermostat.

1. Call for heat: Thermostat sends signal to control board.
2. Inducer motor: Starts to create draft through heat exchanger.
3. Pressure switch: Verifies proper draft before ignition.
4. Ignition: Hot surface igniter glows, gas valve opens.
5. Flame detection: Flame sensor confirms ignition.
6. Blower operation: Blower starts after heat exchanger warms.
7. Shutdown: Gas valve closes when thermostat satisfied, blower continues for cool-down.

WARNING! Never override safety controls. If furnace fails to start, wait for reset before attempting again.

Safety Features

Multiple safety systems: Flame rollout switch, high limit switch, pressure switches, flame sensor, condensate overflow switch. Carbon monoxide detector recommended in living spaces.

Maintenance & Cleaning

Annual professional maintenance recommended. Monthly filter changes during heating season.

1. Filter replacement: Turn off power, remove old filter, install new filter with arrow pointing toward blower.
2. Visual inspection: Check for debris, corrosion, or damage.
3. Burner cleaning: Professional service only.
4. Drain line cleaning: Flush condensate trap and drain line.

CAUTION! Always turn off power and gas supply before maintenance. Never operate with access panels removed.

Regulatory Information

ANSI Z21.47: Certified for safe operation. UL listed. Meets DOE efficiency standards. For support, visit www.tempstar.com or contact 1-800-772-2179. Installation must comply with National Fuel Gas Code NFPA 54 and local building codes.

Troubleshooting

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

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