Duo-Therm RV Furnace Service Manual

The Duo-Therm RV Furnace is a high-efficiency heating system designed for recreational vehicles, featuring electronic ignition, multiple heat settings, safety shut-off systems, and compatibility with various RV models. This manual covers installation, operation, maintenance, troubleshooting, and safety procedures for proper furnace service and repair.

1. Safety Precautions 2. System Overview 3. Installation Procedures 4. Technical Specifications 5. Control Panel Operation 6. Maintenance Schedule 7. Troubleshooting Guide 8. Parts Replacement 9. Electrical Wiring Diagrams 10. Regulatory Compliance 11. Service Contacts

Safety Precautions

Critical safety information for furnace installation, operation, and maintenance.

Hazard	Precaution
Gas Leaks	Always check for gas leaks before operation; use leak detection solution
Carbon Monoxide	Ensure proper ventilation; install CO detectors in living area
Electrical Shock	Disconnect power before servicing electrical components
High Temperatures	Allow furnace to cool before handling internal components
Combustible Materials	Maintain clearance from flammable materials as specified

System Overview

Key components: Burner assembly, heat exchanger, blower motor, thermostat, gas valve, control board, limit switches.

Burner Assembly: Stainless steel construction for durability
Heat Exchanger: Aluminum construction with multiple passes
Blower Motor: Variable speed for optimal airflow
Control Board: Microprocessor-based for precise operation
Gas Valve: Regulates propane/natural gas flow

WARNING! Only qualified technicians should service gas components.

Installation Procedures

Proper installation ensures safe and efficient furnace operation.

Select mounting location with adequate clearance and ventilation
Secure furnace to RV frame using provided brackets
Connect gas line using approved fittings and leak test
Wire according to electrical diagram (12V DC system)
Install venting system according to manufacturer specifications
Test operation and verify all safety systems function properly

CAUTION! Improper installation may cause fire or carbon monoxide hazards.

Technical Specifications

Input Rating: 16,000 - 30,000 BTU/hr (model dependent)
Fuel Type: Propane/LP Gas
Electrical: 12V DC, 3-8 Amps
Airflow: 100-180 CFM
Dimensions: Varies by model (typically 14"W x 20"H x 9"D)
Weight: 15-25 lbs
Efficiency: 85-92% AFUE
Noise Level: < 65 dB

Control Panel Operation

Thermostat and control system operation for optimal heating performance.

Basic Controls: Power On/Off, Temperature Setting, Fan Speed (Auto/Manual), Mode Selection

Advanced Features: Programmable thermostat, fault code display, diagnostic mode, remote control compatibility. LED indicators show system status: Green (normal operation), Yellow (warning), Red (fault condition).

Maintenance Schedule

Regular maintenance ensures long-term reliability and safety.

Monthly: Check air intake/exhaust for obstructions
Seasonal: Clean burner assembly and heat exchanger
Annual: Inspect and clean blower assembly
Every 2 Years: Replace sail switch and limit switches
As Needed: Check and clean electrical connections

Tip: Keep maintenance records for warranty validation.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
No ignition	Gas supply, igniter, control board	Check gas valve; test igniter; verify control board power
Short cycling	Dirty filter, limit switch	Clean/replace filter; test limit switch operation
No heat output	Blower motor, thermostat	Check blower operation; verify thermostat settings
Unusual odors	Dust buildup, combustion issues	Clean heat exchanger; check combustion air supply
Error codes displayed	Sensor faults, system errors	Refer to diagnostic chart; reset system if applicable

Parts Replacement

Authorized replacement parts and installation procedures.

Always use genuine Duo-Therm replacement parts
Disconnect power and gas supply before parts replacement
Follow torque specifications for all fasteners
Test system operation after any parts replacement
Document all replaced parts for service records

WARNING! Unauthorized parts may void warranty and create safety hazards.

Electrical Wiring Diagrams

Complete electrical schematics for all furnace models.

Standard wiring includes: 12V DC power input, thermostat connections, blower motor wiring, control board connections, safety switch circuits. Color-coded wiring: Red (12V+), Black (Ground), White (Thermostat), Green (Fan), Yellow (Gas Valve).

Regulatory Compliance

Meets ANSI Z21.44 standards for RV heaters. CSA certified for North American use. EPA compliant for emissions. All installations must comply with local building codes and RV industry standards.

Service Contacts

For technical support and service inquiries:

Customer Service: 1-800-DUOTHERM (1-800-386-8437)
Technical Support: Available Monday-Friday 8AM-5PM EST
Website: www.duotherm-rv.com
Email Support: [email protected]
Warranty Claims: Contact through authorized dealer network

Emergency Service: For gas leaks or carbon monoxide concerns, evacuate immediately and contact emergency services.