Ducane Gas Furnace Manual

The Ducane Gas Furnace is a high-efficiency heating system designed for residential use, featuring advanced combustion technology, multiple safety controls, variable-speed blower motor, electronic ignition system, and compatibility with various thermostat types. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

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

Features at a Glance

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

Feature	Description
Heat Exchanger	Stainless steel construction for durability and efficiency
Burner Assembly	Multi-port inshot burners for clean combustion
Blower Motor	Variable-speed ECM motor for quiet operation
Gas Valve	Precise gas flow regulation with safety shutoff
Control Board	Microprocessor-based for system monitoring
Flame Sensor	Safety device to detect burner ignition
Pressure Switches	Verify proper venting operation
Venting System	PVC pipe compatible for sidewall or roof venting
Thermostat Connection	Compatible with standard 24V thermostats
Filter System	Standard 1-inch or 4-inch media filter compatible

Installation Requirements

Professional installation recommended. Ensure proper clearances and venting.

Location: Install in well-ventilated area with proper clearances to combustibles.
Gas Connection: Use approved gas pipe and fittings; pressure test required.
Electrical: 120V AC power supply with proper grounding.
Venting: Follow local codes for PVC vent pipe installation.
Ductwork: Ensure proper sizing and sealing of supply/return ducts.

WARNING! Gas furnaces produce carbon monoxide; proper venting is critical. Only qualified technicians should perform installation.

First-Time Setup

Initial startup must be performed by qualified technician.

Gas pressure adjustment: Set manifold pressure per specifications.
Blower speed settings: Adjust for proper airflow and temperature rise.
Thermostat configuration: Connect and program heating cycles.
Safety check: Verify all safety controls and limit switches function properly.
Combustion analysis: Check CO levels and combustion efficiency.

CAUTION! Never attempt to adjust gas pressure or combustion settings without proper training and equipment.

Technical Specifications

Input Capacity: 40,000 - 120,000 BTU/hr (model dependent)
Efficiency: 80% - 96% AFUE (model dependent)
Gas Type: Natural Gas or LP (conversion kit required)
Electrical: 120V AC, 60Hz, 15 Amp circuit
Blower Motor: ECM variable speed
Heat Exchanger: Stainless steel or aluminized steel
Venting: 2" - 3" PVC pipe
Operating Temp Range: -30°F to 120°F ambient
Warranty: Limited lifetime heat exchanger, 10 years parts

Controls and Settings

Integrated control board with LED status indicator. Access panel safety switch.

Control Board: Monitors system operation, displays error codes, manages safety controls.

Thermostat Settings: Heat/Off mode, temperature setpoint, fan auto/on. Blower Settings: Adjustable speed taps for heating and continuous fan. Gas Valve: Pressure regulation, safety shutoff. Limit Switches: High temperature cutoff. Pressure Switches: Verify inducer operation and venting.

System Operation

Standard heating cycle sequence:

Thermostat calls for heat
Inducer motor starts and pressure switch verifies operation
Hot surface igniter or intermittent pilot activates
Gas valve opens and burners ignite
Flame sensor confirms ignition
Blower motor starts after heat exchanger warm-up delay
System runs until thermostat satisfied
Gas valve closes, inducer continues for post-purge
Blower continues until heat exchanger cools

Tip: Allow system to complete full cycle; frequent short cycling reduces efficiency.

Maintenance Procedures

Regular maintenance ensures efficiency and safety.

Monthly: Check and replace air filter as needed
Annual: Professional inspection and cleaning
Burner inspection: Clean and verify proper flame pattern
Heat exchanger: Visual inspection for cracks or damage
Blower assembly: Clean wheel and housing
Drain system: Clear condensate lines and trap
Electrical: Check connections and component operation
Venting: Inspect for obstructions or damage

WARNING! Turn off power and gas supply before performing any maintenance. Only qualified technicians should service gas components.

Safety Features

Multiple safety systems protect against hazardous conditions: Flame rollout switches, high limit switches, pressure switches, flame sensor, gas valve safety shutoff, condensate overflow switch.

Care & Cleaning

Keep area around furnace clear of combustible materials. Clean exterior with damp cloth only.

CAUTION! Never use water or cleaning solutions on electrical components. Keep combustion air intake clear of debris.

Regulatory Information

UL listed and ANSI certified. Complies with ASHRAE standards. Installation must meet local building codes and NFPA 54. For support, visit www.ducanehvac.com or contact 1-800-338-9467.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, safety lockout	Check circuit breaker, thermostat setting, reset power
No heat	Gas supply, igniter, flame sensor	Verify gas valve on, check for ignition attempts
Short cycling	Dirty filter, blocked vent, limit switch	Replace filter, check venting, verify airflow
Blower won't stop	Thermostat fan setting, control board	Check thermostat fan setting, inspect control board
Unusual noises	Blower, inducer, ductwork	Inspect blower wheel, inducer motor, check ducts
Error codes flashing	Various system faults	Refer to control board LED flash pattern in service manual

Reset: Turn power off for 30 seconds then restore.

Service: 1-800-338-9467; www.ducanehvac.com