A control module for preventing acoustic resonance noise generation from a heat exchanger of a heating furnace, comprising a control signal generated by the control module. The control signal is configured to operate an induction fan of the heating furnace at more than one speed for a given heat demand mode of the heating furnace.

A burner system for a furnace. The system may have a wedged or other shaped burner box. An air-fuel mixer may be attached to a smaller end of the burner box at virtually any angle relative to a direction of a gas and air mixture leaving the larger box end. A burner head may be attached to the larger end of the box. The burner head may be sufficient for numerous heater sections of a heat exchanger. A spacer and a radiation shield may be situated between the burner head and heat exchanger. An addition of the radiation shield may reduce the operating temperature of the burner box, burner head and/or spacer. A fan may move the gas and air mixture from the mixer, through the box and the burner head. The mixture may be ignited into a flame which is moved into the heat exchanger.

Methods and related systems for operating a furnace are disclosed. In an embodiment, the method includes activating a burner assembly and a first fan of the furnace to combust fuel and air and circulate combustion gases along a flow path extending through a heat exchanger of the furnace. In addition, the method includes operating a second fan of the furnace to circulate air across an external surface of the heat exchanger of the furnace and produce a conditioned airflow. Further, the method includes monitoring one or more parameters of a motor of the second fan indicative of an airflow rate of the conditioned airflow, and deactivating the burner assembly, whereby combustion of the fuel and air in the furnace ceases, in response to the one or more parameters indicating that the airflow rate is less than a minimum airflow rate.