Ultra 80 Furnace Manual

The Ultra 80 Furnace is a high-efficiency gas furnace with 80% AFUE rating, electronic ignition, multi-speed blower motor, built-in safety controls, and compatibility with standard thermostat systems. Designed for residential heating applications with input capacities ranging from 40,000 to 120,000 BTU/h. Below are key sections for safety, features, installation, 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 Procedures 8. Safety Features 9. Maintenance & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

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

Feature	Description
Heat Exchanger	Stainless steel primary and secondary heat exchangers
Burners	Inshot burners with precise air/fuel mixture
Inducer Motor	Draft inducer for proper venting and safety
Blower Assembly	Multi-speed ECM motor for efficient airflow
Gas Valve	Modulating gas valve with pressure regulation
Control Board	Integrated furnace controller with diagnostic LEDs
Pressure Switches	Safety switches for draft verification
Flame Sensor	Proves flame presence during operation
Limit Switches	High temperature safety cut-off
Filter Rack	Standard 1-inch or 4-inch media filter compatible

Installation

Unpack and inspect all components. Ensure proper clearances and venting requirements.

Position furnace: Place on stable, level surface with proper clearances (1-inch minimum from combustible materials).
Connect gas supply: Use approved gas piping with sediment trap; pressure test for leaks.
Install venting: Use Category I venting materials; maintain proper slope and termination clearances.
Electrical connections: Connect 120V AC power supply and thermostat wiring.
Ductwork: Connect supply and return ducts with proper sealing.

WARNING! Gas furnaces must be installed by qualified technicians only. Improper installation can cause fire, explosion, or carbon monoxide poisoning.

First-Time Setup

Complete installation verification and initial startup procedure.

Gas pressure adjustment: Set manifold pressure to 3.5" WC for natural gas.
Blower speed settings: Adjust dip switches for proper airflow (CFM).
Thermostat configuration: Connect R, W, G, C terminals; set to heat mode.
Initial ignition: Power on furnace; observe startup sequence and flame characteristics.
Combustion analysis: Verify CO levels and temperature rise within specifications.

CAUTION! Always verify proper venting and combustion air supply before operation.

Specifications

AFUE Rating: 80% Annual Fuel Utilization Efficiency
Input Capacity: 40,000 - 120,000 BTU/h (model dependent)
Gas Type: Natural gas (convertible to LP with kit)
Electrical: 120V AC, 60Hz, 5-10 Amps
Blower Motor: Multi-speed ECM or PSC
Airflow: 800-2000 CFM depending on model
Venting: Category I, 3-5 inch diameter
Operating Temp Rise: 35-65°F
Dimensions: Varies by model (typical 21"W x 21"D x 48"H)

Controls and Settings

Integrated control board with status LEDs and diagnostic codes. Access door switch for service mode.

Control Board: POWER, STATUS LED (green/red), RESET button, DIP switches for blower speeds.

Thermostat Connections: R (24V), W (Heat), G (Fan), Y (Cool), C (Common). Blower Settings: DIP switches for heating and cooling CFM. Gas Valve: Pressure adjustment screw, manual shutoff. Limit Controls: Auto-reset high limit switches. Pressure Switches: Verify inducer operation.

Connecting Thermostat

Standard 24V thermostat wiring with heat/cool/fan control.

Turn off power to furnace at disconnect or circuit breaker.
Remove furnace access panel to access control board.
Connect thermostat wires: R to R, W to W, G to G, C to C.
For AC compatibility: Connect Y to Y terminal.
Restore power and test thermostat operation.

Tip: Use 18-gauge thermostat wire and ensure proper polarity for C wire.

Operating Procedures

Normal heating cycle operation and seasonal startup.

Set thermostat to desired temperature above room temperature.
Furnace initiates: Inducer motor starts, pressure switch closes.
Ignition sequence: Hot surface igniter glows, gas valve opens.
Flame establishment: Flame sensor confirms ignition, main burners operate.
Blower activation: After heat exchanger warm-up delay, blower circulates warm air.
Cycle completion: Thermostat satisfied, gas valve closes, blower continues for post-purge.

WARNING! Never operate furnace without access panels properly installed.

Safety Features

Multiple safety systems: Flame rollout switches, high limit switches, pressure switches, flame sensor, door switch.

Maintenance & Cleaning

Annual maintenance required for safe and efficient operation.

Filter replacement: Change every 1-3 months depending on usage.
Burner inspection: Clean burners and check for proper flame pattern.
Heat exchanger: Visual inspection for cracks or corrosion.
Blower cleaning: Remove debris from blower wheel and housing.
Vent system: Inspect for obstructions and proper draft.

CAUTION! Always disconnect power and gas supply before performing maintenance.

Regulatory Information

ANSI Z21.47/CSA 2.3: Certified for natural and manufactured gas. UL listed. Complies with U.S. Department of Energy efficiency standards. Installation must comply with National Fuel Gas Code NFPA 54 and local building codes. For technical support, contact manufacturer at 1-800-555-HEAT or visit www.ultrafurnace.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, door switch	Check circuit breaker, thermostat setting, ensure door closed properly.
No heat	Gas supply, igniter, flame sensor	Verify gas valve on, check igniter glow, clean flame sensor.
Short cycling	Filter, limit switch, airflow	Replace dirty filter, check for blocked vents, verify proper airflow.
Blower doesn't run	Motor, capacitor, control board	Check for power at motor, test capacitor, verify control signal.
Lockout condition	Safety device tripped	Reset power, check error codes, inspect safety switches.

Error Codes: LED flash patterns indicate specific faults (1 flash = pressure switch, 2 flashes = ignition failure, etc.)

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