Dornback Furnace Manual

The Dornback Furnace is a high-efficiency residential heating system designed for reliable performance and energy savings. This manual covers installation, operation, maintenance, and troubleshooting for various Dornback furnace models. Below are key sections for safety, features, installation, setup, operation, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Components 7. Operating Procedures 8. Safety Features 9. Maintenance & Cleaning 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: High-efficiency heat exchanger, electronic ignition system, variable-speed blower motor, digital thermostat interface, air filter compartment, gas valve assembly, and exhaust vent system.

Feature	Description
Heat Exchanger	Stainless steel construction for maximum efficiency and durability
Ignition System	Electronic hot surface ignition for reliable startup
Blower Motor	Variable-speed ECM motor for quiet operation and energy savings
Thermostat Interface	Compatible with most digital thermostats
Air Filter	Standard 1-inch or 4-inch media filter compatibility
Gas Valve	Precise gas flow control with safety shutoff
Exhaust System	PVC venting for high-efficiency operation
Control Board	Microprocessor-based for advanced diagnostics
Safety Switches	Multiple safety interlocks for protection
Access Doors	Removable panels for easy service access

Installation

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

Position furnace: Place on stable, level surface in approved location with proper clearances.
Install venting: Connect PVC exhaust and intake pipes according to local codes.
Connect gas supply: Use approved gas line with shutoff valve and sediment trap.
Electrical connections: Connect 120V power supply and thermostat wiring.
Ductwork: Connect supply and return ducts securely.

WARNING! Installation must be performed by qualified HVAC technician. Follow all local codes and manufacturer specifications.

First-Time Setup

Complete installation verification and initial startup procedure.

Gas pressure check: Verify correct manifold pressure per specifications.
Vent system test: Confirm proper draft and secure connections.
Electrical verification: Check all wiring connections and voltage.
Initial startup: Follow lighting instructions for first-time operation.
System check: Verify proper heating cycle and temperature rise.

CAUTION! Never bypass safety controls. Test carbon monoxide detectors after installation.

Specifications

Input Capacity: 40,000 - 120,000 BTU/H (varies by model)
Efficiency: 80% - 96% AFUE
Fuel Type: Natural Gas or Propane
Electrical: 120V, 60Hz, 15 Amp circuit
Blower Capacity: 800 - 2000 CFM
Venting: PVC or ABS (2" - 3" diameter)
Dimensions: Varies by model (typical: 21"W x 21"D x 56"H)
Weight: 80 - 150 lbs
Warranty: 20-year heat exchanger, 5-year parts

Controls and Settings

Access control board via front service panel. Thermostat controls heating cycles and fan operation.

Control Board: LED status lights, diagnostic codes, dip switch settings for blower speeds and timing.

Temperature Settings: Adjust via thermostat. Fan Control: AUTO or ON modes. Blower Speeds: Cooling, heating, and continuous fan speeds adjustable via dip switches. Diagnostic Codes: Flash patterns indicate specific operational status or fault conditions.

Connecting Components

Gas supply, electrical power, thermostat, ductwork, and venting systems.

Turn off gas and electrical power before making connections.
Match pipe sizes and use proper sealants for gas connections.
Follow wiring diagram for thermostat and power connections.
Ensure ductwork is properly sized and sealed.

Tip: Use only approved materials and follow all local building codes.

Operating Procedures

Normal heating operation and seasonal startup/shutdown.

Thermostat setting: Set desired temperature on thermostat.
System startup: Furnace will ignite automatically when heat is called.
Normal operation: Blower starts after warm-up period, circulates heated air.
System shutdown: Thermostat satisfied, gas valve closes, blower continues for cool-down.
Seasonal shutdown: Turn off gas supply and electrical power if not used for extended periods.

WARNING! Never operate furnace with access panels removed. Keep combustible materials away from furnace.

Safety Features

Flame rollout switch, high limit switch, pressure switch, ignitor safety lockout, and carbon monoxide detection compatibility.

Maintenance & Cleaning

Regular maintenance ensures optimal performance and safety.

Monthly: Check and replace air filter as needed.
Annual: Professional inspection and cleaning of burners, heat exchanger, and vent system.
Seasonal: Verify proper operation before heating season.

CAUTION! Turn off gas and electrical power before performing any maintenance. Only qualified technicians should service internal components.

Regulatory Information

UL listed and ANSI certified. Complies with ASHRAE standards. Installation must meet National Fuel Gas Code and local building codes. For technical support, contact Dornback customer service at 1-800-DORNBACK or visit www.dornback.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, or safety switch	Check circuit breaker, thermostat setting, and safety switch reset.
No heat	Gas supply, ignition, or filter	Verify gas valve on, check for ignition attempts, replace dirty filter.
Short cycling	Dirty filter, high limit, or airflow	Clean/replace filter, check for blocked vents, verify proper airflow.
Blower won't stop	Thermostat fan setting	Check thermostat fan setting (should be AUTO, not ON).
Unusual noises	Loose components or airflow	Check for loose panels, clean blower wheel, verify ductwork clear.

Reset: Turn power off for 30 seconds, then restore power to reset control board.

Service: 1-800-DORNBACK; www.dornback.com