Coleman 38001 Assembly-Installation

The Coleman 38001 is a high-performance gas furnace designed for residential heating applications. This guide provides comprehensive instructions for the safe and proper assembly, installation, and initial setup of the unit. It is crucial to follow all steps in sequence and adhere to all safety warnings to ensure correct operation and prevent personal injury or property damage. Below are key sections covering safety, parts identification, step-by-step assembly, installation procedures, and initial startup.

Safety Precautions

Before beginning any work, read and understand all warnings. Failure to comply can result in fire, explosion, carbon monoxide poisoning, electric shock, or severe injury.

WARNING! Installation must comply with all local building codes and the National Fuel Gas Code (NFPA 54/ANSI Z223.1).

Parts Identification & Kit Contents

Unpack all components and verify against the packing list. Inspect for shipping damage.

1. Main Furnace Cabinet: Contains heat exchanger, blower assembly.
2. Burner Assembly: Includes manifold, orifices, igniter.
3. Vent Kits: PVC pipes and fittings for intake/ exhaust.
4. Installation Hardware Bag: Screws, anchors, mounting brackets.
5. Control Board & Thermostat Wires: Pre-wired harness.
6. Gas Valve & Flexible Connector: For gas supply line.
7. Drain Trap & Tubing: For condensate removal.
8. User Manual & Warranty Card.

CAUTION! Do not discard any packing material until all parts are accounted for. Report missing/damaged parts immediately.

Pre-Installation Requirements

Ensure the installation site meets all requirements before proceeding.

1. Location: Install in a clean, dry, ventilated area (closet, basement, utility room) with sufficient clearance for service (min 24" front, 6" sides, 6" top).
2. Combustion Air: Provide adequate fresh air per local codes. Two permanent openings may be required.
3. Floor/Platform: Must be level, solid, and non-combustible.
4. Utilities: Verify availability of correct gas type (Natural Gas), 120V AC electrical outlet, and condensate drain.
5. Permits: Obtain all necessary local permits before installation.

WARNING! Do not install in areas where flammable liquids or vapors are present.

Step-by-Step Assembly

Assemble the furnace components before securing it in its final location.

• Step 1 - Attach Feet/Bracket: Secure the four leveling feet to the bottom of the cabinet using provided screws.
• Step 2 - Install Burner Tray: Slide the burner assembly into the cabinet until it clicks into place. Secure with two screws.
• Step 3 - Mount Blower Assembly: Position the blower on its rails inside the cabinet. Tighten the four mounting bolts.
• Step 4 - Connect Drain Trap: Attach the condensate trap to the outlet on the heat exchanger. Connect the vinyl tubing.
• Step 5 - Install Front Panels: Place the lower access panel and secure the main front panel with its latches.

Tip: Do not fully tighten any screws until all components are aligned.

Installation Procedures

Position and secure the assembled furnace.

1. Move the furnace to its final location using a dolly. Use two people.
2. Place the unit on the level platform. Use a spirit level and adjust feet until perfectly level (front-to-back and side-to-side).
3. Mark and drill holes for the mounting brackets (if required by code). Secure the furnace to the floor or wall.
4. Ensure all clearances are maintained. The furnace must not touch any combustible materials.

WARNING! The unit is heavy. Lift with your legs, not your back, to avoid injury.

Electrical & Gas Connections

Make all utility connections. Power must be OFF. Gas must be OFF.

CAUTION! A gas leak test is mandatory before proceeding to startup.

Venting System Installation

The Coleman 38001 uses a direct-vent (sealed combustion) system with separate intake and exhaust PVC pipes.

1. Plan the vent route: Maximum equivalent length is 40 feet. Use no more than three 90° elbows.
2. Cut PVC pipe to required lengths. Deburr the ends.
3. Dry-fit all pipes and fittings from the furnace vent collars to the termination cap outside.
4. Apply PVC cement to all joints and assemble permanently. Ensure all joints are fully seated and sealed.
5. Support pipes every 3 feet. Maintain a 1/4" per foot slope back to the furnace for condensate drainage.
6. Install the exterior termination cap. Maintain clearances from doors, windows, and ground as per manual.

WARNING! Improper venting is the leading cause of carbon monoxide hazards. Follow instructions exactly.

Initial Startup & Testing

After all connections are made and verified, proceed with initial startup.

1. Gas Leak Test: Turn gas ON at shut-off valve. Apply a soapy water solution to all gas joints. Look for bubbles. If a leak is found, turn gas OFF, tighten, and retest.
2. Power Up: Restore electrical power at the main breaker and at the furnace switch.
3. Thermostat Call for Heat: Set the thermostat above room temperature to initiate a heating cycle.
4. Sequence Observation: Listen for the inducer fan to start, then the igniter to glow, followed by the main burners lighting. The blower should start after a short delay.
5. Performance Check: Verify flame is steady and blue (not yellow or lifting). Check that warm air is discharging from all supply registers.

Tip: The first cycle may have a slight odor as manufacturing oils burn off. This is normal.

Control Settings & Adjustment

Access the furnace control board for basic settings.

DIP Switches (on control board): Configure for blower speed (HIGH, MED, LOW), thermostat type (single-stage), and accessory control.

LED Diagnostic Light: Flashes a code indicating system status. Refer to the code chart on the inner door panel.

Gas Pressure Adjustment: Manifold pressure should be set to 3.5" W.C. for Natural Gas. Use a manometer on the test port. Qualified technician only.

Fan-On/Fan-Off Delays: Factory set. Adjust only if necessary for comfort.

Maintenance Schedule

Regular maintenance ensures efficiency, safety, and longevity.

CAUTION! Always turn off power and gas before performing any maintenance.

Troubleshooting & Support

Reset: To reset a lockout, turn the thermostat off, turn off furnace power for 60 seconds, then restore.

Service: For technical support or to locate a certified Coleman dealer, call 1-800-XXX-XXXX or visit www.coleman.com/furnace.