The First 10 Minutes After Install Tony’s Full Startup & Commissioning Checklist

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Why What You Do Right After Installation Determines Whether the Furnace Succeeds or Fails Over the Next 20 Years

Ask any rookie installer what matters most during a furnace install, and they’ll say:
“Hooking up the venting,” or “Connecting the thermostat,” or “Running the gas line.”

Ask Tony the same question, and he’ll tell you:

“The real install starts AFTER you turn it on.”

Because the first 10 minutes after firing up a brand-new furnace tell Tony everything about:

airflow
venting
gas supply
combustion
temperature rise
blower tuning
ECM profile
static pressure
staging
safety
reliability
real efficiency

A furnace can look perfect, be level, be vented properly, have clean electrical work, and STILL fail — if commissioning is ignored.

And here’s Tony’s warning:

“If you don’t commission it, you didn’t install it.”

This is Tony’s complete 10-minute startup and commissioning checklist — the one he teaches every apprentice and uses on every 90%-to-96%+ furnace, especially two-stage or ECM-driven units.

Let’s go step-by-step.

100,000 BTU 96% AFUE Upflow/Horizontal Two Stage Goodman Gas Furnace - GR9T961004CN

🔌 1. Pre-Start Safety Check — Before You Hit the Switch

Before you ever energize the furnace, Tony runs a rapid inspection.

This takes 30–60 seconds and prevents disasters.

🧯 1.1 Gas Leak Test

Tony checks every joint:

drip leg
shutoff valve
manifold connection
union
flex connector

Using electronic detector + bubble test.

NFPA 54 requires leak testing before startup

Tony says:

“I don’t trust pipe dope. I trust bubbles.”

⚡ 1.2 Electrical Polarity and Grounding

Incorrect polarity will cause:

failure to ignite
board error codes
flame-sensing issues
premature component wear

Tony’s rule:

“If your ground sucks, your furnace will act possessed.”

🔥 1.3 Combustion Air Check

He makes sure:

intake is clear
exhaust is clear
no snow cover
no glued-shut intake screen
no room depressurization

EPA warns that improper combustion air causes CO production:
👉 https://www.epa.gov/indoor-air-quality-iaq

📏 1.4 Venting Slope Check

Condensing furnaces REQUIRE:

¼” per foot slope back toward furnace
no sags
no flat spots
correct pipe support

ICC venting rules:
👉 https://codes.iccsafe.org

Tony never trusts the vent until he inspects it personally.

🔥 2. Startup Sequence — Tony Watches the Furnace Like a Hawk

Most installers hit the switch, walk away, and wait for warm air.

Tony stays glued to the furnace during the ENTIRE ignition sequence.

Because the first 10 seconds reveal:

gas pressure problems
flame stability
inducer performance
igniter condition
venting issues
air starvation

Here’s Tony’s exact sequence.

⚙️ 2.1 Inducer Motor Check

When the furnace calls for heat:

Inducer starts
Pressure switch closes
Ignition cycle initiates

Tony listens for:

rattling
grinding
delayed startup
pressure switch flutter
gurgling (condensate issue)

Inducer sound tells Tony 50% of the story.

🔥 2.2 Igniter Check

Hot surface igniter should:

glow bright orange
not pulse or flicker
fire quickly
stay stable

Tony says:

“A lazy igniter means lazy flame.”

🌊 2.3 Flame Appearance

When gas lights, Tony looks for:

strong blue flame
even flame cones
no lifting
no rolling
no yellow tips
no delayed ignition pop

ASHRAE combustion guidelines:
👉 https://www.ashrae.org/technical-resources

A bad flame = bad fuel feed or venting.

🕓 2.4 Time to Flame Establishment

Furnace should:

ignite fully within 4–6 seconds
stabilize within 10 seconds

Anything longer means:

weak gas pressure
dirty manifold
incorrect line sizing
poor combustion air

🌬️ 3. Airflow Verification — The ECM Truth Test

Once the furnace fires, Tony immediately evaluates airflow.

This is where most installs fail.

ECM motors respond to system pressure — so if the ductwork is restrictive, the ECM “screams” by increasing torque.

🔧 3.1 Static Pressure Test (Tony’s Mandatory Check)

Tony attaches his manometer:

one probe before coil
one probe at return
total external static = supply + return

Targets:

0.50” WC max for most high-efficiency furnaces
0.60” WC max for larger ECM blowers
Anything over 0.70 = airflow failure

Documented by ACCA Manual D airflow standards:

Tony’s take:

“If your static is high, your system will die.”

🍃 3.2 Return Drop Velocity Check

Tony listens at the return grille.

If he hears:

whistling
roaring
suction noise

…the return drop is undersized or restrictive.

🔁 3.3 Filter Pressure Drop Test

High-MERV filters murder airflow unless the return is oversized.

Tony checks:

filter bending inward
drop > 0.20” WC
noise near the rack

EPA filter guidance

Tony’s rule: “Big furnace = big return = big filter.”

🌡️ 4. Temperature Rise — The Heat Exchanger Lie Detector

Temperature rise is the fastest way to confirm:

airflow
heat exchanger health
proper gas input
proper staging
proper blower setup

Every furnace has a temperature rise range.
Common examples: 35–65°F.

Tony does this in the FIRST few minutes:

Measure return temperature
Measure supply temperature
Subtract

If rise is:

❌ Too high

= not enough airflow
= return drop wrong
= coil clogged
= high static
= filter too restrictive

❌ Too low

= overfeeding gas
= blower running too fast
= improper tuning

Tony’s rule:

“Temperature rise is the system’s confession.”

🔥 5. Gas Pressure & Fuel Input — No Guessing Allowed

Now Tony checks the fuel supply.

🔧 5.1 Manifold Pressure Test

Natural gas target: 3.5” WC
Propane target: 10–11” WC

If pressure drops when the furnace hits high stage → gas line is undersized.

This is confirmed by NFPA 54:
👉 https://www.nfpa.org

Tony says:

“If the flame shrinks in high stage, your gas line is trash.”

🧮 5.2 Meter Clocking (Tony’s Favorite Trick)

He clocks the gas meter to verify BTU input.

If a 100k furnace is only receiving 70–80 CFH, it’s starved.

Most installers don’t clock meters.
Tony does it on EVERY install.

🧊 6. Condensate System — The Most Overlooked Failure Point

During startup, condensate begins forming immediately.

Tony checks:

trap orientation
correct slope
no gurgling
pump activation
drain termination
freeze protection

IPC and IMC require slope of ¼” per foot:
👉 https://codes.iccsafe.org

Tony adds:

“If I hear bubbling, I know someone screwed up the trap.”

📡 7. Control Board & ECM Setup — Tuning the Furnace for Reality, Not Theory

Factory settings almost NEVER match the home’s ductwork.

Tony reprograms:

CFM per ton
heating blower speed (low & high stage)
cooling airflow
delay-on timer
delay-off fan timer
staging logic
anti-short-cycle timers

This is where the furnace goes from “installed” to mastered.

Tony says:

“Factory settings don’t know your ductwork.
I do.”

🎧 8. Sound Check — The Furnace Should Disappear

Quiet furnaces don’t happen by accident.

Tony listens for:

✔ return whistling

→ undersized drop or filter

✔ inducer resonance

→ poor vent slope or water pooling

✔ blower hum

→ high static

✔ plenum boom

→ wrong transition or no cross-breaking

✔ coil whistle

→ high face velocity

If a furnace is loud, Tony doesn’t leave until it’s silent.

🧪 9. Safety Systems — Tony’s Rapid Verification

Tony checks:

flame sensor signal
pressure switch trip point
rollout switches
high limit
drain float switch
condensate pump safety
board error logs

He tests each safety manually.

Tony’s rule:

“If a safety can trip, I want it to trip in front of ME, not the homeowner.”

📄 10. Documentation — Tony Never Leaves Without It

The LAST thing Tony does?

He hands the homeowner (or builder) complete documentation:

static pressure readings
temperature rise
manifold pressure
BTU input
blower setup profile
venting inspection notes
model/serial numbers
commissioning sheet

Why?
Because it proves the job was done right.

And if something goes wrong later, Tony can say:

“Not my install.
Here are the numbers.”

🏁 **Tony’s Complete 10-Minute Commissioning Checklist

(Printable Summary)**

Here is Tony’s exact rapid process:

1. Before Startup

🔧 Gas leak check
⚡ Verify polarity & ground
🧯 Check combustion air
📏 Verify venting slope
💧 Check condensate trap & drain

2. During Startup

🌀 Inducer operation
🔥 Igniter behavior
🌊 Flame quality
⏱️ Time to ignition
🔁 Pressure switch stability

3. Airflow & Static

📉 Total static pressure
🍃 Filter pressure drop
🌀 Blower torque
🔉 Return drop sound

4. Heating Performance

🌡️ Temperature rise
🔥 Gas manifold pressure
🧮 Meter clocking

5. Condensate System

💧 Trap prime
🚰 Drain flow
🧊 Freeze protection

6. Safety & Controls

🛑 Limits
🔥 Flame sensor
🔁 Rollouts
📡 ECM tuning
🧠 Staging logic

7. Final Sign-Off

📝 Documentation
📸 Photos
📚 Homeowner explanation
🧼 Clean-up

🔥 Final Word from Tony

“Anybody can install a furnace.
Only pros COMISSION one.

The first 10 minutes decide whether that furnace will:

run quiet
run clean
run safe
run efficient
last 20 years

Or whether it’ll spend its life tripping limits, wasting gas, overheating, and breaking down.”

Tony always ends with the same line:

“Don’t trust the install. Trust the numbers.”

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In the next topic you will know more about: The 3 Tools Tony Never Installs a High-Efficiency Furnace Without — And Why Every DIYer Gets This Wrong

Tags: Tony’s toolbox talk

WRITTEN BY

Tony Marino

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