Thermo Products Furnace ome 72d36 User Manual

OIL-FIRED FURNACE  
DOWN FLOW & DIRECT VENT (SEALED COMBUSTION)  
MODEL: OME-72D36  
INSTALLATION AND SERVICE MANUAL  
For installation in:  
1. Manufactured Homes  
2. Modular Homes/Buildings  
3. Site Construction—Residential  
:
FOR YOUR SAFETY  
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or  
any other appliance.  
WHAT TO DO IF YOU SMELL GAS  
Do not try to light any appliance.  
Do not touch any electrical switch; do not use any phone in your building.  
Immediately call your gas supplier from a neighbor’s phone.  
Follow the gas supplier’s instructions.  
If you cannot reach your gas supplier, call the fire department.  
: If the information in these instructions is not followed exactly, a fire or explosion may result  
causing property damage, personal injury or loss of life.  
: Improper installation, adjustment, alteration, service, or maintenance can cause injury or property  
damage. Refer to this manual. For assistance or additional information consult a qualified installer, service  
agency, or fuel supplier.  
: Do not use this appliance if any part has been underwater. Immediately call a qualified service  
technician to inspect the appliance and to replace any part of the electrical or control system that has been  
underwater.  
PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE  
PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE USER  
AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.  
THERMO PRODUCTS, LLC.  
POST OFFICE BOX 217  
NORTH JUDSON, IN 46366  
PHONE: (574) 896-2133  
MO-487  
ECN 5320-MA 130307  
MADE IN USA  
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All installations and services must be performed by qualified service personnel.  
: If you do not follow these instructions exactly, a fire or explosion may result  
causing personal injury, loss of life or property damage.  
: NEVER use gasoline or a mixture of oil and gasoline to start the burner or  
furnace.  
: HAZARD OF ASPHYXIATION: Negative pressure inside the closet with closet  
door closed and the furnace blower operating shall be no more negative than minus 0.05 inch  
water column.  
: Do not obstruct any return air openings, including the return grille on the  
furnace. To do so may cause the furnace to activate the high limit and shut down or it may  
cause asphyxiation.  
: Because of the potential of odorant fade, a gas leak may not be detected by smell.  
If this furnace is installed below grade, contact your gas supplier for a gas detector.  
: All gas pipe connections must be leak tested using a strong soap and water  
solution (with the gas turned on). Any leaks must be repaired immediately after turning off the  
gas supply. A final test for gas leakage must be made after purging the gas line.  
: DO NOT wet electronic components during the leak test. Wetting electronic  
components may damage circuitry and cause a hazardous situation. Dry moisture from all  
leads and terminals if wetting occurs. Wait at least 24 hours for the circuit to fully dry before  
energizing the system.  
: The furnace and its gas valve must be disconnected from the gas supply during  
pressure testing of the gas supply system at pressures in excess of 1/2 PSIG or 13.9 inches  
W.G. The furnace can be isolated from the gas supply by closing its manual shut off valve at  
test pressures equal to or less than 1/2 PSIG or 13.9 inches W.G.  
: Copper and brass tubing and fittings (except tin lined) shall not be used if the gas  
contains more than a trace (0.3 grains per 100 cubic ft.) of hydrogen sulfide gas. Check with  
your gas supplier.  
: All local codes and ordinances take precedence with regard to tank and oil lines.  
All lines must have shutoff valves, a good pipe joint compound approved for use with oil on all  
pipe threads, no kinks, no sharp bends and be properly tested for leaks. Flare fittings are  
recommended for tubing.  
: Do not use motor oil or any fuel heavier than No. 2 fuel oil..  
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All installations and services must be performed by qualified service personnel.  
: If you suspect there is a problem with the furnace, the venting system or any other  
related problem, immediately contact a qualified service agency. If a service agency is not  
available contact your fuel supplier.  
: Personal injury, or property damage, could result from major repair or service of  
this furnace by anyone other than a qualified contractor. Only the routine maintenance  
described in the user section of this manual should be performed by the user.  
: The area around the furnace should be kept free and clear of combustible  
materials, especially papers and rags.  
: Never burn garbage or refuse in your furnace. Never try to ignite oil or gas by  
tossing burning papers or other material into your furnace.  
: Do not attempt to start the burner when:  
1. Excess oil or gas has accumulated.  
2. The furnace is full of vapors.  
4. The combustion chamber is very hot.  
If one or more of these conditions exist, contact a qualified service person.  
: Do not block or obstruct air openings on the furnace or air openings  
communicating with the area in which the furnace is installed.  
: Do not allow the outside air intake to be blocked or obstructed by vegetation, ice,  
snow or any other materials.  
: Do not use this furnace if any part has been underwater. Immediately call a  
qualified service agency to inspect the furnace and to replace any part of the electrical or  
control system which has been underwater.  
: Should overheating occur or the fuel supply fail to shut off, shut off the manual  
fuel supply valve to the furnace before shutting off the electrical supply.  
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This page and the following page contain reproductions of the various warning and  
instruction labels placed on the Thermo Pride Oil Furnace. Please read and comply with  
the contents of these labels.  
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4a  
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TABLE OF CONTENTS  
SECTION  
BEGINNING PAGE  
I.  
SAFETY SECTION  
1
II.  
III.  
IV.  
GENERAL INSTRUCTIONS AND CLEARANCES  
FURNACE SPECIFICATIONS  
INSTALLATION  
6
8
10  
10  
10  
10  
11  
11  
13  
15  
15  
16  
19  
19  
21  
22  
22  
22  
23  
28  
29  
29  
32  
33  
34  
39  
39  
41  
41  
42  
42  
43  
43  
44  
44  
45  
A. ROOF JACK  
B. STANDARD CHIMNEY  
C. FURNACE LOCATION  
D. BASE INSTALLATION  
1. Combustible Floor Base Model: 70-BASE  
2. Cottage Base Model: 01COT-BASE  
E. ALCOVE INSTALLATION  
F. CLOSET INSTALLATION  
G. COMBUSTION AIR  
H. FUEL PIPING  
1. Oil Tank and Piping  
J. ELECTRICAL WIRING  
1. Electrical Branch Supply Circuit  
2. Connection of Power Supply Wires  
3. Connection of Thermostat Wires  
4. Blower Controller Information for PSC Motor  
5. Wiring Diagram  
K. BURNER INSTALLATION  
L. BURNER OPERATION AND ADJUSTMENT  
M. FLUE GAS COMBUSTION ANALYSIS  
DEALER MAINTENANCE  
V.  
A. TROUBLESHOOTING  
B. CAD CELL CHECKOUT PROCEDURE  
C. HEAT EXCHANGER CLEANING INSTRUCTIONS  
D. CLEANING OR REPLACING FLUE PIPES  
E. EXTENDED SHUTDOWN AND RESTART  
USERS INFORMATION SECTION  
A. WARNINGS & CAUTIONS  
B. COMPONENT LOCATIONS  
C. INSPECTION AREAS  
VI.  
D. FILTER LOCATION AND CLEANING  
E. CONTACT INFORMATION  
APPENDIX A - REPLACEMENT PARTS LIST  
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II. GENERAL INSTRUCTIONS AND CLEARANCES  
NOTE: READ THIS SECTION BEFORE STARTING INSTALLATION  
1. The selection of a furnace heating capacity for a proposed installation should be based on a  
heat loss calculation made according to the manuals provided by the Air Conditioning  
Contractors of America (ACCA) or the American Society of Heating, Refrigeration and Air  
Conditioning Engineers, Inc. (ASHRAE).  
2. The installer shall be familiar with and comply with all codes and regulations applicable to the  
installation of this heating appliance. In addition to the governing standards items a) through e)  
this appliance shall also comply with “CSA B139 for recommended installation practices” where  
applicable.  
a. Federal Manufactured Home Constructions & Safety Standard (HUD Total 24, Part 280).  
b. American National Standard (ANSI-119.2/NFPA-501C), for all recreational vehicle  
installations.  
c. American National Standard (ANSI-Z223.1/NFPA-54), for all gas-fired furnaces.  
d. American National Standard (ANSI-Z95.1/NFPA-31), for all oil-fired furnaces.  
e. American National Standard Electric Code (ANSI-C1/NFPA-70), for all electrical field  
wiring.  
The oil-fired furnace has been investigated under the UL 307A test standard and CSA B140 and  
is listed by ETL and described as, “For installation as central furnace special type”.  
: The area around the furnace must be kept free and clear of combustible  
materials, especially papers and rags.  
: This furnace is not to be used as a construction heater.  
1. Definitions of "combustible" and "non-combustible" materials as presented in the 1996  
version of the National Fuel Gas Code, ANSI Z223.1-1996/NFPA 70-1996, are as follows:  
a. Combustible material:  
“...materials made of or surfaced with wood, compressed  
paper, plant fibers, or other materials that are capable of  
being ignited and burned. Such materials shall be  
considered combustible even though flameproofed, fire-  
retardant treated, or plastered.”  
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b. Non-combustible material:  
“...material that is not capable of being ignited and burned;  
such as material consisting entirely of, or a combination of,  
steel, iron, brick, concrete, slate, asbestos, glass, and plaster.”  
This heating appliance must be installed with clearances to combustible material surfaces of not  
less than the minimum distances given below. Also, allow ample clearances for servicing the  
furnace for easy access to the air filter, blower assembly, burner assembly, controls, and vent  
connections.  
CLOSET  
ALCOVE  
MODELS OME  
FRONT  
BACK  
SIDES  
ROOF JACK  
VENT CONNECTOR  
TOP  
PLENUM SIDES  
TOP AND SIDES OF DUCT  
BOTTOM OF DUCT  
6”  
0”  
0”  
0”  
6”  
1”  
1”  
1”  
1”  
18”  
0”  
0”  
0”  
6”  
1”  
1”  
1”  
1”  
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III. FURNACE SPECIFICATIONS  
MODEL  
OME-72  
Low Fire  
High Fire1  
85,000  
HEAT INPUT RATE (BTUH)  
HEATING CAPACITY (BTUH)  
BURNER NOZZLE (GPH X  
ANGLE, HOLLOW CONE)  
OIL PUMP PRESSURE (PSIG)  
VENT PIPE SIZE (INCHES)  
70,000  
60,000  
72,000  
0.50X80°A  
0.60X80°A  
120  
4
DESIGN TEMPERATURE RISE (°F)  
MINIMUM RETURN AIR TEMP. (°F)  
SEASONAL EFFICIENCY  
(AFUE2 *, %)  
65  
50  
86  
1 Burner shipped with 0.60x80°A nozzle  
2 *AFUE - INCLUDES STEADY STATE THERMAL EFFICIENCY AND OFF CYCLE  
LOSSES.  
ELECTRICAL RATINGS AND SETTINGS:  
ELECTRICAL SUPPLY: 120 VAC / 60HZ / 1 PHASE  
MAXIMUM TIME DELAY TYPE FUSE OR HACR BREAKER RATING: 15 AMPS  
TOTAL RATED CURRENT (AMPS): 10.3  
NOMINAL HEAT ANTICIPATOR SETTING -- 0.2 mA  
DIMENSIONS & WEIGHTS:  
CABINET: WIDTH - 18 IN., DEPTH – 24-3/4 IN., HEIGHT - 57 IN.  
NO.70 MOBILE HOME BASE: WIDTH - 18 5/16 IN., DEPTH - 24¼ IN., HEIGHT - 4 IN.  
WARM AIR DUCT: WIDTH – 12 IN., DEPTH – 12 IN., HEIGHT - 14 ¼ IN.  
COTTAGE BASE: WIDTH – 18 3/16 IN., DEPTH - 24¼ IN., HEIGHT – 14¾ IN.  
FILTER QUANTITY & SIZE: (1) @ 18 IN. x 24 IN. x 1 IN. EA.  
APPROXIMATE SHIPPING WEIGHT: 240 LBS.  
BURNER DATA  
OME-72  
MANUFACTURER:  
MODEL:  
R.W. BECKETT CORP.  
AFG  
AIR TUBE LENGTH (IN.):  
HEAD DESIGN:  
3
F-3  
REFRACTORY TYPE:  
OIL PUMP  
ISOFORM (SOFT FIBER)  
PRESSURE (P.S.I.G.)  
120  
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FOR BURNER COMBUSTION INFORMATION, REFER TO SECTION (M) – FLUE GAS  
COMBUSTION ANALYSIS.  
BLOWER DATA  
MANUFACTURER: MORRISON PRODUCTS, INC.  
BLOWER MODEL:12-9T, DIRECT DRIVE  
NOMINAL MOTOR POWER OUTPUT (HORSEPOWER): 1/2 HP 4 SPEED  
HIGH SPEED AIRFLOW (SCFM)  
@ 0.5 IN. W.G. EXTERNAL  
STATIC PRESSURES  
1195  
ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.  
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IV. INSTALLATION  
A. ROOF JACK  
The roof jack assembly and accessories must be listed by a nationally recognized testing agency  
for the appropriate fuel.  
The roof jack assembly must be installed according to the vent manufacturer’s instructions prior  
to the furnace installation. (Refer to Figure 2 for flue location on furnace.) Adapters for pitched  
roofs as well as extended barrel length roof jacks are available from Thermo Products.  
All vent seams and connections must be sealed with high temperature silicone caulk and/or high  
temperature aluminum tape.  
B. STANDARD CHIMNEY  
When installed as a central furnace special type for single story dwelling, venting into a metal  
vent system approved by a nationally recognized testing agency for the appropriate fuel type is  
permitted. Lined masonry chimneys are acceptable when sized appropriately. The minimum  
chimney size should equivalent to the inside free area of the 4-inch diameter vent collar exiting  
the furnace, or 12.5 square inches.  
Maximum chimney sizes and acceptable installation practices are referenced in the following  
publications. In lieu of local codes, when installing the OME-72 with fuel oil, refer to the latest  
edition of the installation standard NFPA 31, Installation of Oil Burning Equipment.  
Notice: Blocked Vent Switch Installation for cottage type homes or non-mobile home type  
dwellings. The blocked vent switch kit must be installed to comply with CAN STD B140.4  
where applicable. For installation instructions see AOPS2686 kit.  
C. FURNACE LOCATION  
1. For best performance, locate the furnace so that it is centralized with respect to the duct  
system.  
2. This furnace is only intended for installation with free air return through the furnace door  
louvers. DO NOT connect a ducted return air system directly to the furnace. Improper  
installation may create a fire hazard and damage internal equipment, as well as void all  
manufacturer’s warranties.  
3. This furnace may be installed on combustible flooring when utilizing either the No. 70  
counterflow floor base, for below the floor duct systems, or with the cottage base, for floor  
level air distribution. See Figures 1 for depictions of the No. 70 and the cottage bases.  
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4. This furnace is ETL listed for closet, alcove or freestanding applications. All applications  
must comply with the requirements of this manual.  
Combustible Floor Base  
Model: 70-BASE  
Figure 1A.  
Cottage Base  
Model: 01COT-BASE  
Figure 1B.  
D. BASE INSTALLATION  
1. Combustible Floor Base Model: 70-BASE  
11  
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Use the base bottom panel as a template to mark floor opening locations (see Figure 2). Cut a  
square opening in the floor for the supply air connector duct. Cut the opening 1-inch larger  
than the square template opening. (duct requires 1-inch clearance to combustible floor). Cut a  
combustion air duct opening in the floor 1/8-inch larger than the template opening.  
Figure 2.  
After cutting openings in the floor, place the bottom panel in position. Mark the square  
opening location on the distribution duct at the connection point of the connector duct.  
Remove the bottom panel. Cut an opening in the distribution duct slightly larger than the  
connector duct. (refer to Figure 2 for location of this cut.) Cut the connector duct to length.  
Install the connector duct. Bend over each tab. Insure an airtight seal by using high  
temperature sealant or tape on the joint. Reinstall the bottom panel over the connector duct.  
Insert and secure the combustion air duct. Put the base top assembly in place (see Figure-3).  
IMPORTANT: A combustion air duct must be used. If the underside of the mobile home is  
skirted or enclosed (e.g. enclosed in a crawlspace), the combustion air intake should exit  
through the skirting, or enclosure, if at all possible. All joints and seams of supply ducts and  
combustion air ducts must be closed with a sealing method suitable to the application  
conditions and temperatures ( e.g. high temperature silicone caulk and/or aluminum tape).  
Notice: If desired, combustion air can be brought in thru the roof of the dwelling and into to the  
furnace cabinet with Thermo Products Kit AOPS7512. See your local Thermo Pride  
representative for details or call customer service.  
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If the combustion air passageway cannot terminate outside of the skirting or enclosure, a  
permanent opening with a minimum of 50 square inches of unobstructed infiltration (free  
area) for ventilation air must be provided for adequate combustion. This permanent opening  
must be located no less than 12 inches from the bottom of the enclosure or skirting.  
Figure 3.  
Slit the corners of connector duct down to the top of the base assembly. If metal projects more  
than 1-inch above the top of the base assembly, trim the flanges down to 1-inch. While the top  
of distribution duct is being pulled up with one hand, bend down each side of the connector  
duct tightly to the base assembly with the other hand. This assures a tight connection between  
the base assembly and the connector duct and that the distribution duct will be full size. Use  
high temperature tape and/or high temperature silicone caulking on all joints and seams to  
minimize air leakage. Secure the base assembly to the floor with two screws in the front  
flange.  
2. Cottage Base Model: 01COT-BASE  
The 01COT-BASE cottage base (Figure 1B) is required for a freestanding cottage base  
installation. The cottage base is designed to permit the installation of an 8-inch x 12-inch register  
in each of the two side panels and the rear panel. This allows combustion air to be drawn from  
outside, or inside, the structure whichever is appropriate, or permissible. See section G.  
COMBUSTION AIR for further details regarding combustion air requirements.  
13  
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IMPORTANT: Adequate combustion air must be provided under all circumstances. If the  
underside of the home is skirted or enclosed (e.g. by an enclosed crawlspace), the combustion  
air intake should exit through the side of cottage base and terminate outside of the structure.  
All joints and seams of supply ducts and combustion air ducts must be closed with a sealing  
method suitable to the application conditions and temperatures (e.g. using high temperature  
silicone caulk and/or aluminum tape).  
If the combustion air passageway cannot terminate outside of the structure, a permanent  
opening with a minimum of 50 square inches of unobstructed infiltration (free area) for  
ventilation and combustion air must be provided to the interior of the structure. Additional  
make-up air may need to be supplied to the interior of the structure to compensate for exhaust  
fans, appliances, or vents which consume air from the interior of the structure.  
Refer to the assembly installation instructions included with 01COT-BASE cottage base for  
additional information.  
14  
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E. ALCOVE INSTALLATION  
In this application, a minimum of 18 inches  
of clearance must be provided to the front of  
the unit. Refer to Figure 4.  
Alcove installations must use the No. 70  
mobile home base.  
Note – access to diagnostic view port.  
Refer to section G. COMBUSTION AIR for  
additional combustion air requirements.  
Figure 4.  
F. CLOSET INSTALLATION  
: HAZARD OF  
ASPHYXIATION: A suction effect  
will occur when the furnace is  
operating inside the closet with the  
closet door closed. For proper  
operation, the furnace blower shall  
create no more than a 0.05-inch  
water column pressure differential  
between the closet and the  
adjoining space.  
Figure 5.  
1. The return air opening into the  
closet is to have a minimum free  
area of 250 square inches, (refer  
to Figure 5).  
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2. The return air opening may be located in the top, the center or (ideally) the bottom of the  
closet door, or side wall.  
: Do not obstruct any return air openings, including the return grille on the  
furnace. To do so may cause the furnace to activate the high temperature limit and shutdown,  
or it may cause asphyxiation.  
3. The cross-sectional area of the return air duct leading into the closet (when located in the  
floor or ceiling) shall not be less than 250 square inches.  
4. The total free area of openings in the floor or ceiling registers serving the return air duct  
system must be at least 350 square inches. At least one register must be located where it is  
not likely to be covered by carpeting, boxes, furniture, or any other objects.  
5. Materials located in the return duct system must have a flame spread classification of 200 or  
less.  
6. Pans made of a non-combustible material having 1 inch upturned flanges are to be located  
beneath openings in a floor, return air, duct system.  
7. Wiring materials located in the return air duct system must conform to Article 300-22 of the  
latest edition of the National Electrical Code, NFPA 70.  
8. Gas piping shall not be located in, or extend through, the return air duct system.  
9. Refer to section G. COMBUSTION AIR for additional combustion air requirements.  
G. COMBUSTION AIR  
The furnace requires the proper amount of combustion air be available to combust the fuel  
cleanly and efficiently. An inadequate combustion air supply can result in unsafe and erratic  
operation of the burner, sooting of the combustion chamber and the heat exchanger, and possibly,  
offensive fuel odors. The combustion air intake must provide an adequate source of combustion  
air to the appliance. Refer to part 5.3 of the National Fuel Gas Code, ANSI Z223.1 / NFPA 54-  
1999, or latest edition for application specific combustion air requirements.  
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The preferred location of the outside combustion air intake termination (e.g. an optional stainless  
steel intake hood, part no.370183) is through the side of the structure, skirting or enclosure. An  
alternate termination location is under the structure in the skirted or crawlspace area providing a  
minimum of 50 square inches of free area exists around the perimeter for outside combustion air  
to be drawn through. NOTE: Combustion air cannot be drawn from the occupied space of the  
home.  
The furnace is shipped with a 2” radiator hose, 2” pvc street ell, 3” dia flex hose and clamps. If  
combustion air needs to be pulled from the floor, attach the black plastic adapter to the base of  
the combustible floor base. Make sure the knock-out has been removed. Use hi-temperature  
silicone and screws to secure the adapter. If needed, the combustion air can be pulled from the  
rear of the floor base. For this method remove the knock out in the vertical wall and attach the  
adapter to this opening as indicated.  
The Beckett burner is equipped with a plastic air boot. The 2” radiator hose and 2” pvc street ell  
are to be attached to the boot inlet. Use the two smaller clamps to affix the hose to the boot and  
the boot to the male end of elbow. After cutting the flexible hose to the appropriate length,  
attach it to the street ell and the black adapter using the remaining two clamps.  
The material recommended for the combustion air duct under the structure is smooth, round,  
galvanized steel duct or schedule 20 PVC pipe. The maximum duct length allowed is equivalent  
to 40-feet of straight duct. Reduce this length by 6-feet for the intake hood and each 90-degree  
elbow used, and by 3-feet for each 45-degree elbow used the combustion air duct. Flexible,  
spiral, or corrugated duct is not recommended, due to the relatively high pressure drop associated  
with air movement through this type of passageway.  
If the combustion air is preferred thru the roof then kit AOPS7512 is required. The radiator hose  
is then placed over the Beckett boot opening and the hose is clamped over the radiator hose and  
boot adapter. Attach the other end to the 2-1/2” combustion air pipe that now protrudes out of  
the lower right separator panel with remaining clamp. An alternate installation method would be  
to secure the 2” pvc street ell to the metal combustion air pipe. Insert the male end with silicone  
sealant and then secure with a tek screw. Cut the 3” flex hose to length and attach it with clamp  
to female end of street ell. Attach the other end to burner air-boot as described earlier.  
17  
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Figure 6.  
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H. FUEL PIPING  
Sizing and installation of fuel lines must be in accordance with federal, state and local  
regulations.  
1. Oil Tank and Piping  
: All local codes and ordinances take precedence with regard to tank and oil lines.  
All lines must have oil shutoff valves, a good pipe joint compound approved for use with oil on  
all pipe threads, no kinks; no sharp bends and be properly tested for leaks. Flare fittings are  
recommended for tubing.  
: Do not run the oil pump dry for more than five minutes.  
Your furnace is factory equipped to operate on No. 2 distillate fuel (domestic heating) oil. In very  
cold weather, No. 1 distillate fuel oil may be used. Your oil supplier should be contacted for  
recommendations.  
: Do not use motor oil or any fuel heavier than No. 2 fuel oil..  
Burners are most commonly installed with a single stage fuel pump (refer to Figure 7). This type  
of fuel pump, when connected with a supply line only, is satisfactory where the fuel supply is  
level with, or above, the burner. This type of installation permits gravity flow of oil to the burner.  
When it is necessary to “lift” (raise) oil to the burner, a return line should be connected between  
the fuel pump and tank. This requires insertion of the “by-pass” plug into the fuel pump. If the  
lift exceeds approximately 10 feet, a two-stage pump should be installed with a return line. When  
a return line is used with either single or two-stage pumps, air is automatically returned to the  
tank, making the unit self-purging.  
Use of continuous runs of heavy wall copper tubing is recommended. Always use flare fittings.  
Avoid use of fittings in inaccessible locations. Avoid running tubing against any type of  
heating unit and across ceiling or floor joists.  
If possible, install the tubing under the floor. Specific information on piping, fuel pump  
connections, lift capabilities and tank installations is provided in the fuel pump manufacturer’s  
instructions.  
If the oil tank is located inside the building and the tank capacity is between 10 and 660  
gallons, it shall not be located within 5 feet horizontally from any source of heat, or oil-  
burning appliance. Furthermore, the oil tank shall not block access to utility service  
meters, switch panels, and shutoff valves.  
If an underground tank used, the top of the tank should be below all piping in order to prevent oil  
discharge through a broken connection. Underwriters Laboratories requirements now stipulate  
that all 275 gallon and larger tanks have a bottom outlet. This is to prevent the accumulation of  
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condensate, which causes the tank to rust. It is also recommended to use a water trap or additives  
to prevent condensate accumulation.  
If the tank is above the burner, and gravity oil feed to the burner is permitted, a single line system  
may be used. The line should have a gradual slope downward of approximately 1/2 inch per foot,  
or more, to a point directly below where it is connected to the pump. Installing the line with a  
downward slope will help prevent the formation of air pockets in the line.  
IMPORTANT: An oil safety valve or a delayed-action solenoid valve is required with all  
gravity feed oil supply systems.  
IMPORTANT: The oil storage tank must be free of water, sludge and scale to prevent  
excessive wear and possible damage to furnace oil pump and burner nozzle. A fuel oil filter  
installed in the oil supply line to the burner is required.  
OIL FILTER: For all installations, use a low micron, oil filter with the capacity to trap particles  
10 microns in diameter, or greater. Filtering the oil supply helps to prevent nozzle clogging.  
Install the oil filter inside the building between the tank shutoff valve and the burner. The filter  
cartridge should be replaced at least once a year. The filter body should be thoroughly cleaned  
before installing a new cartridge.  
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Figure 7.  
J. ELECTRICAL WIRING  
All electrical wiring must be installed in strict accordance with local ordinances and codes. In the  
absence of local ordinances and codes, all electrical wiring must conform to the requirements of  
the National Electric Code, ANSI/NFPA 70-1999, or latest edition.  
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: When testing electrical equipment, always follow standard electrical procedures  
and precautions.  
1. Electrical Branch Supply Circuit  
Route all electrical wiring to the left side of the furnace. The power supply circuit to the  
furnace must be installed and grounded in accordance with the provisions of the National  
Electrical Code, ANSI/NFPA-70-1999, or latest edition, and all local codes having  
jurisdiction. Electrical Branch Supply Circuit provisions of the Canadian Electrical Code  
Part 1 shall be observed and followed where applicable.  
2. Connection Of Power Supply Wires  
a. Remove the furnace control panel cover.  
b. Insert 120 VAC wires through the strain relief bushing (or conduit connection as  
applicable) on the left side of the furnace junction box.  
c. Connect the “Hot” wire to the black wire marked “L1.  
d. Connect the “Neutral” wire to the white wire marked L2”.  
e. Connect the “ground” wire to the ground lug.  
3. Connection Of Thermostat Wires  
NOTE: Class 1 thermostat wire must be used inside the furnace burner compartment.  
a. Insert 24 VAC wires through the plastic grommet on the left side of the furnace casing.  
b. Connect the thermostat wires to “R” and “W” for heating.  
c. Connect the thermostat wires to the room thermostat.  
IMPORTANT: The room thermostat should be installed 4 to 5 feet above the floor on  
interior wall which is relatively free from direct sources of heat (sunlight or supply airflow)  
or exposure to cold (drafts from open windows and doors). The nominal anticipator setting is  
0.2 amperes (refer to the thermostat literature for additional information).  
Four-conductor thermostat wire is recommended for 24 VAC, low-voltage, control circuit  
wiring. Only 2 wires are required for the furnace (a heating application only).  
Maximum Recommended  
Electrical Wire Diameter  
Thermostat Wire Length  
(AWG)  
(feet)  
24  
22  
20  
18  
55  
90  
140  
225  
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Once the furnace is installed, check the thermostat heat anticipator the proper nominal  
setting.  
a. Connect a multimeter, capable of reading milliamps (mA), in series with the low voltage  
wires to the thermostat.  
b. Increase the thermostat setting, or create a “call for heat”.  
c. Read the value of the thermostat current, in milliamps.  
d. Adjust the heat anticipator of the thermostat to the value read by the multimeter.  
If the heat anticipator is set too high, the furnace may delay activation of a heating cycle for  
too long. If the heat anticipator is set too low, the furnace may cycle too frequently. Either  
condition may not provide optimal comfort to the homeowner.  
4. BLOWER CONTROLLER INFORMATION FOR PSC MOTOR  
TERMINAL DEFINITIONS & FIELD WIRING  
Burner Harness Connector P1  
Pin 1- Limit switch connector.  
Pin 2- 120 VAC Line connection.  
Pin 3- Burner pilot contact.  
Pin 4&5-  
120 VAC Neutral connections.  
Pin 6- Burner pilot contact.  
Pin 7&8-  
From oil primary control.  
Pin 9- Limit Switch Input (LSI).  
Field Wiring to Burner  
Pilot (Tstat)  
Yellow Wires  
T-T terminals  
Neutral  
White  
White  
Line  
Red  
Black  
Harness Wires  
Beckett Connections  
Thermostat / Humidistat connections  
“C”  
Common / ground  
“W”  
“R”  
“G”  
“Y”  
Thermostat call for heat  
24 VAC to thermostat  
Thermostat call for fan  
Thermostat call for cool  
“DEHUM”  
Humidistat call for dehumidification (TXV systems ONLY)  
Male quick connect terminals.  
“S1-3”  
“N1-7”  
“EAC”  
“FAN”  
120 VAC Hot  
120 VAC Neutral  
Electronic Air Cleaner (120 VAC) connection  
Fan On Signal  
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“X”  
“C”  
“CC”  
24 VAC from transformer  
24 VAC common from transformer  
Compressor Contactor  
“CC_COM”  
“LOW”  
“HEAT”  
“COOL”  
Compressor Contactor Common  
Continuous Blower Speed  
Blower heat speed tap  
Blower cool speed tap  
A. Inputs  
Power supplies  
Line voltage is applied between the “S1” and “N1” quick connect terminals. 24 VAC Class II Transformer  
secondary voltage supplied to X and C  
Limit switch  
The 120 VAC optically isolated limit switch input is connected on pin P2-1 & 9. Refer to the Heat Mode  
section for the control operation.  
Thermostat call for heat “W”  
24 VAC thermostat input. A call for heat is recognized when the thermostat connects “W” to “R”. This input has  
an indicator LED that will light when the control receives a call for heat. Refer to the Heat Mode section for the  
control operation.  
Thermostat call for fan “G”  
24 VAC thermostat input. A call for fan is recognized when the thermostat connects “G” to “R”. This input  
has an indicator LED in that will light when the control receives a call for fan. Refer to the Fan Mode  
section for the control operation.  
B. Outputs  
PSC Control  
The control shall control a five speed indoor blower motor. Rating shall be 10 FLA, 30 LRA @ 120 VAC.  
Connections are made via 0.250 x 0.032” male quick connect terminals labeled “HEAT”, “COOL”, and  
“LOW”. “HEAT” is energized when the heat speed blower is to run. “COOL” is energized when the Cool  
speed blower is to run. “LOW” is energized during a call for fan is received or a call for dehumidification is  
received.  
Oil Burner  
Control  
The control provides dedicated contacts to operate the T-T input of an oil primary control.  
Rating shall be class 2 – 24 VAC pilot duty @ 24 VAC (<200mA).  
Power  
The switched 120 VAC power from the LIMIT switch passes through the board between Pins 1 & 2 of  
connector P1.  
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EAC (electronic air cleaner)  
The control provides a 120 VAC output for an electronic air cleaner. This output is energized whenever the  
fan motor is energized (either low, heat or cool speed). Connection is made via male quick connect terminal  
labeled “EAC”.  
Humidifier  
The control provides a 120 VAC output for a humidifier. Connections are made to a male quick connect  
terminal labeled “FAN”. The control does not switch this output, it provides a pass-through connection  
from P1-7 from the switched primary voltage of the Burner Module.  
Status LED  
A red LED is provided to indicate any thermostat input has been recognized by the microprocessor on the  
control. See Diagnostic Features for a function description of operation.  
Thermostat Input LEDs  
Four green LEDs are placed beneath their respective thermostat connections (W, Y, G and DEHUM) and  
operate whenever a call is present. See Diagnostic Features for a function description of operation.  
C. Operating Modes  
Standby Mode  
All outputs are off and the control is waiting for a thermostat demand. The thermostat inputs, and limit  
switch are continuously monitored. The control initiates action when a thermostat call is received or limit  
switch opens.  
Fan Mode  
A call for fan (“G”) is received from the thermostat. If no other mode is calling for blower operation, the  
control will operate the fan relay (K4) and power the “Low” blower speed terminal. The fan mode will be  
operated as long as the “G” input is calling and neither the Heat mode nor the Cool mode is calling for  
blower operation. When the Heat and Cool modes call for blower operation, their respective outputs will  
take precedence after their respective turn-on time delays have expired.  
Cooling Mode  
A call for cool (“Y”) is received from the thermostat. If the heat mode is not active or the anti-short cycle  
delay is not in effect, the control will energize the “CC” terminal and after a 10 second power demand  
conservation delay energizes the “COOL” speed blower terminal.  
When the call for cool is satisfied, the “CC” terminal is de-energized and the cooling off delay of 45  
seconds is started. Forty-five seconds later the “COOL” speed blower terminal is de-energized and the  
control reverts to Standby Mode.  
Dehumidification Operation  
If a call for dehumidification is received while the Cool Mode is active, blower speeds will be reduced. The  
PSC “COOL” blower speed terminal (1158-100 model only) will be de-energized and “Low” blower speed  
will be energized.  
Anti-Short Cycle Operation  
To prevent compressor short cycling, a call for cooling will be ignored for four minutes after the  
termination of any cooling call. The anti-short cycle delay is also in effect at power-up.  
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Heat Mode  
When a call for heat (“W”) is received from the thermostat, if the “Cool” mode is not already active, the “T-  
T” terminal is energized and the blower on delay is started. The on-off pattern of DIP switch SW2  
(positions 1 and 2) select one of four blower on delay values (see Table 11). When the delay time has  
elapsed, the “HEAT” blower speed is energized. The control remains in steady heat mode until the  
thermostat is satisfied. When the call for heat signal is removed, the “T-T” terminal is de-energized and the  
blower off delay is started. The on-off pattern of DIP switch SW2 (positions 3 and 4) select one of four  
blower off delay values (see Table 11). When the delay time has elapsed, the “HEAT” blower speed  
terminal is de-energized.  
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DIP SWITCH 2 SECTION STATE  
BLOWER DELAY TIMES  
1
2
3
4
ON - SEC  
30  
OFF - MIN  
OFF  
ON  
OFF  
ON  
OFF  
OFF  
ON  
ON  
FACTORY  
SETTING  
60  
120  
240  
OFF  
ON  
OFF  
OFF  
ON  
2
4
6
8
FACTORY  
SETTING  
OFF  
ON  
ON  
Table 11: ON and OFF Blower Delay Time Switch Settings  
Blower On and Off Delays  
Four Heat blower on and four blower off delays are selected by two dip switches for each function. Refer  
to Table 11 for specific delay values.  
PSC TROUBLE SHOOTING  
DIAGNOSTIC FEATURES  
The control board is equipped with 4 green Input Status LEDs and 1 red Board Status LED. These are  
intended to provide a quick view into furnace performance without requiring a voltmeter.  
The green Input Status LEDs are driven by the “Y”, “W”, “G”, and “DEHUM” inputs and are located  
directly below those inputs. They will light to indicate the presence of these signals.  
The red Board Status LED has two functions:  
It will light when the board recognizes a valid input signal and will stay lit until all valid signals are  
removed. This is intended to show that the board is functioning and able to respond to input signals.  
It will flash rapidly while 120VAC is missing from the LIMIT switch. This is intended to give a quick  
visual indication of the High Limit switch.  
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5. WIRING DIAGRAM  
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K. BURNER INSTALLATION  
The burner mounts to the furnace on three mounting bolt studs, located on the burner mounting  
plate, in the lower portion of the vestibule, directly in front of the heat exchanger.  
The burner insertion depth has been fixed by the factory for the design-specified, combination of  
the air tube length and the combustion chamber used with the furnace. The combustion chamber  
is pre-positioned during the assembly process and held in place by the drum and mounting plate.  
The burner insertion depth is not field-adjustable.  
Should access to the chamber be necessary, refer to the exploded diagram, in the back of this  
manual, to identify replacement parts.  
To install and ready the burner for firing, follow the steps below for both furnace models.  
1. With electrical power connected to the furnace, turn off all electrical power to unit.  
2. Remove the front lower access panel.  
3. Mount the burner to the furnace. Install the flange gasket over the mounting studs and  
secure the burner flange to the furnace using hex head machine screw nuts, provided in  
the Parts Kit.  
4. Connect the red and white wires from the burner harness to the black, red and white  
burner power leads found underneath the primary control. Then connect the two yellow  
wires to the “T & T” terminals on the front of the primary control.  
For the oil burner installation only:  
5. Determine whether an oil return line is required and connect the fuel oil piping to the  
burner oil pump through the base of the unit.  
6. Turn on electrical power to the furnace. Cause or simulate a “call for heat” to bleed  
air from the oil line at the oil pump. (Temporarily, connect the two thermostat leads to  
cause the oil pump to run.)  
7. With all oil shutoff valves open, open the air-bleed valve on the oil pump and capture  
the oil flow in a container until all traces of air in the line are gone.  
8. Close the air-bleed valve. Check for and correct any oil leaks. The furnace is now  
ready for burner adjustment. Refer to the following “BURNER OPERATION AND  
ADJUSTMENT” section.  
L. BURNER OPERATION AND ADJUSTMENT  
: NEVER burn garbage or refuse in the furnace. NEVER try to ignite oil or gas by  
tossing burning papers or other material into your furnace.  
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: If you do not follow these instructions exactly, a fire or explosion may result  
causing personal injury, loss of life or property damage.  
: NEVER use gasoline or a mixture of oil and gasoline to start the burner or  
furnace.  
1. Qualified service personnel must perform the first lighting of the burner.  
2. The burner instructions must be read and understood before any attempt is made to  
light this burner.  
NOTE: For the sequence of burner operations, see individual burner manual. To  
successfully service and initially set up this furnace you must use the following  
instruments:  
[Items (a)-(d) ... apply to both oil and gas furnaces), item (e) ... applies to gas units only,  
and items (f)-(h) ... applies to oil units only]  
a. Carbon dioxide (CO2) or oxygen (O2) analyzer.  
b. Flue gas thermometer (range 100°F to 1000°F) and temperature-measuring  
device (range -40°F to 240°F, for return and supply air temperatures).  
c. Carbon monoxide (CO) detector  
d. Electrical multimeter  
e. Liquid, U-tube type manometer or equivalent pressure measuring instrument  
(range: 0 – 28 in.W.G.)  
f. Smoke spot tester or equivalent smoke density measuring device  
g. Oil pressure gauge (range: 0-150 PSIG)  
h. Vacuum gauge (range: 0-30 in. W.G. vacuum)  
Turn the main service switch that provides power to the furnace to the “off” position. Set  
thermostat above room temperature. Open all fuel supply valves. Bleed air out of fuel  
supply line, if not already completed (for oil, power must be “on” to the burner and the  
pump must be operating to expel air in the supply line).  
When ignition is established, if necessary, make a preliminary burner air adjustment to  
attain a clean combustion flame (one which does not create smoke by eye). The flame  
may be viewed through the overfire inspection cover (see exploded diagram of  
replacement parts for location identification). After the furnace is warmed up to a steady-  
state condition (about 15 minutes), the final burner adjustment should be made using  
combustion instrumentation for measuring carbon dioxide (CO2) or oxygen (O2), carbon  
monoxide (CO), smoke, and stack temperature. In order to achieve the most efficient  
combustion possible, the following steps must be taken.  
IMPORTANT: To achieve proper combustion and efficiency instruments must be used  
to secure CO2, O2 and CO readings.  
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1. CARBON DIOXIDE (CO2) or OXYGEN (O2): Take a CO2 sample from the flue pipe  
or vent connector at a position close to the furnace. It is possible to achieve relatively  
high CO2 (or low O2) readings with low stack temperatures to produce maximum  
combustion efficiency. However, the CO2 and O2 values recommended are slightly  
less, though this means slightly lower efficiency, to allow the burner to better tolerate  
adverse operating conditions, such as a cold heat exchanger, downdraft conditions,  
heating content changes in the fuel. This working tolerance means less service and  
maintenance during heating seasons as well as a reduced chance of producing carbon  
monoxide under adverse conditions.  
2. CARBON MONOXIDE (CO): As described above, take a flue gas sample from the  
flue pipe or vent connector at a position close to the furnace. The amount of CO  
generated by combustion ideally should be zero or only a trace. In all cases, it must be  
less than 50 PPM. Carbon monoxide is a colorless and odorless gas, but it is toxic  
compound. The production of significant quantities of CO is a strong indicator of  
incomplete combustion. Check the fuel supply and the burner for fuel leakage. Check  
for an inadequate supply of clean air for combustion. Also, check for a restricted or  
blocked flue, vent, or chimney.  
3. SMOKE: (oil burners only) A smoke sample should be drawn from the flue pipe or  
vent connector at a position close to the furnace. For the greatest efficiency, if the first  
smoke reading is “0”, close the air shutter on the burner until a trace smoke reading is  
obtained.  
4. FLUE GAS TEMPERATURE: The flue gas temperature will vary to some degree  
depending on the heating content of the fuel, the amount of combustion air, and  
airflow across heat exchanger. In general, the lower the stack temperature, the higher  
the efficiency. However, stack temperatures under 350°F may cause flue gases to  
condense, which in turn may cause excessive metal corrosion.  
5. TEMPERATURE RISE: Supply air temperature (measured twelve inches into trunk,  
away from radiant heat from the furnace) minus (-) return air temperature, or  
Temperature rise = Supply air temperature - Return air temperature.  
The temperature rise across the furnace heat exchanger operating at steady-state  
conditions (about 15 to 20 minutes) should not exceed 100°F. The normal comfort  
range is between 70°F to 100°F. A lower temperature rise usually results in a higher  
system efficiency.  
: If the temperature rise exceeds 100°F, the heat exchanger may fail, voiding  
the heat exchanger warranty resulting in property damage, personal injury or loss of  
life.  
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M. FLUE GAS COMBUSTION ANALYSIS  
: Burner adjustments must be confirmed by instrumentation. Failure to  
use accurate or calibrated instrumentation to correctly setup the burner may result in  
reduced efficiency, sooting, and/or the production of hazardous carbon monoxide gas.  
For typical burner combustion analysis results, refer to the table below.  
BURNER COMBUSTION PARAMETERS  
FURNACE MODEL OME-72  
FUEL TYPE  
CO (CARBON MONOXIDE)  
CO2 (CARBON DIOXIDE)  
O2 (OXYGEN)  
LOW-FIRE  
#1 OR #2 FUEL OIL  
50PPM OR LESS  
10.5-11%  
HIGH-FIRE  
#1 OR #2 FUEL OIL  
50PPM OR LESS  
11-12%  
4.5-6%  
4.5-6%  
SMOKE SPOT RATING  
AIR SHUTTER ADJUSTMENT  
0
0
OPEN TO POSITION 3.5 OPEN TO POSITION 3.5  
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V. DEALER MAINTENANCE  
THIS SECTION IS ONLY TO BE PERFORMED BY TRAINED, QUALIFIED SERVICE  
PERSONNEL, AND NOT BY THE FURNACE OWNER.  
A. TROUBLESHOOTING  
Note: Check diagnostic code through view port prior to removing doors.  
: When testing electrical equipment, always follow standard electrical procedures  
and precautions.  
1. Check for line voltage (110-120VAC) to the furnace. If there is no line voltage applied to  
the furnace, check that disconnecting switch is “on”, fuses or circuit breakers have not  
blown or tripped.  
2. Make sure thermostat is “calling for heat”.  
3. Check for adequate fuel supply and pressure. Are all the fuel shutoff valves are open?  
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TROUBLESHOOTING FLOWCHART  
Note: Check diagnostic code through view port  
Set thermostat subbase to "HEAT"  
Does thermostat make contact?  
prior to removing doors.  
No  
Is room temperature  
above 90 deg. F?  
Yes  
Yes  
Wait for room air to cool.  
No  
Yes  
Is room temperature above  
thermostat setting?  
Turn thermostat setting  
above room temp.  
No  
Replace thermostat  
Does a "call for No  
heat" initiate an  
ignition cycle?  
Yes  
Turn power  
switch "on".  
Is the power switch "off"?  
No  
No  
Check input power. Reset circiut  
breaker, or replace blown fuse in  
disconnected switch.  
Is there 120 VAC  
across lines L1 & L2?  
Yes  
Yes  
Wait for furnace to cool.  
Look for cause(s) of high  
limit activation,eg. low  
airflow, over-firing,  
blocked flue,etc..  
No  
Have either of the  
high limit thermostats  
activated?  
Yes  
Is the oil primary control  
receiving 120 VAC?  
Correct any  
abnormal conditions.  
Yes  
No  
With power on,measure  
voltage across the aux.  
high limit thermostat N.C.  
contact to L2. If not 120 VAC,  
replace aux. high limit  
thermostat. Else,replace  
high limit thermostat.  
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No  
Are the thermostat wires  
Correct wire connections.  
connected properly?  
Yes  
Yes  
Is the oil primary control  
supplying 24 VAC to the  
thermostat?  
Yes  
Replace thermostat.  
No  
Try resetting the oil primary  
control. Replace the oil  
primary control, if necessary.  
Is the oil primary  
No  
No  
control receiving power?  
Reset primary control. If  
resetting the primary does  
not work, replace control.  
Is there combustion  
airflow to the furnace?  
Is there 120 VAC across  
the burner motor?  
Yes  
Is the blower impeller spinning?  
If so, check for blockages in or a  
collapsed air duct. Is the air boot  
shutter open adequately.  
Yes  
Yes  
Check wiring to burner motor.  
If okay, replace burner motor.  
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Try resetting the oil primary  
control by depressing the  
RESET button. Check cad cell  
function. If all else fails,  
After pre-purge, does the  
oil primary produce a  
spark at the  
No  
No  
Is there 120 VAC across  
the ignition transformer?  
ignition electrodes?  
replace the oil primary.  
Yes  
Yes  
Check wiring to the ignition transformer and the  
electrodes. Also, check ignition  
electrode gap. Reset if necessary.  
Replace electrodes or ignition transformer.  
Try resetting the oil primary control  
by depressing the RESET button.  
If this does not work, replace the  
oil primary.  
While ignition electrodes  
are sparking does fuel  
valve open?  
No  
Does the oil solenoid  
valve have 120 VAC across it  
during the ignition attempt?  
No  
Yes  
Yes  
Check wiring to fuel valve.  
If valve does not open,  
replace fuel valve.  
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No  
No  
Check the fuel supply.  
Open all manual shutoff  
valves serving the unit.  
Purge any air in the  
fuel line.  
After fuel valve opens,  
does the burner ignite?  
Is oil present in  
the fuel line at the valve?  
Yes  
No  
Are the ignition electrodes  
positioned correctly?  
Reposition to  
correct location.  
Yes  
Yes  
Check for blocked or severely  
worn burner nozzle. Clean  
or replace as required.  
Yes  
Add or replace fuel and fuel  
filter. Also, check cad cell  
for proper operation.  
Is the oil tank full of fuel? Is the  
fuel clean without contaminates?  
Is the fuel filter dirty?  
Does the burner stay  
lit past proof of flame  
check?  
No  
No  
Yes  
Check settings on fan  
timer against those  
on connection  
diagram. Is blower  
still inoperable  
after time delay  
with fan timer  
Check wiring to  
blower. If okay,  
set fan selector  
switch to manual.  
If fan operates,  
replace fan timer.  
Measure voltage  
on the circulating  
air blower terminals.  
Is it 120 VAC?  
Does the fan timer  
energize the circulating  
air blower after the 56  
second time delay?  
No  
Yes  
No  
set correctly?  
Yes  
Check for blower wheel  
Does blower wheel  
spin freely?  
No rubing against housing  
or motor shaft spinning  
freely. Adjust or replace  
as necessary.  
Yes  
Yes  
Is blower motor  
capacitor functioning  
properly?  
No  
Replace blower  
motor capacitor.  
Yes  
Replace motor  
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Yes  
No  
Has the high limit thermostat  
or auxiliary high limit  
No  
Does system run until  
thermostat is satisfied?  
Check all wiring for  
loose connections.  
thermostat activated?  
Yes  
Check for reduced airflow through  
the furnace. This may be caused  
by an excessively restrictive duct  
system, an inadequate amount of  
supply air,especially for furnaces  
installed in closets, or extremely  
dirty air filters. Also, check and  
confirm heat input rate to unit is  
within specifications.  
Yes  
Does burner shut off  
when thermostat is  
satisfied?  
No  
Check for short in wire  
to thermostat. Replace  
thermostat, if necessary.  
Yes  
Check fan timer settings  
against those on connection  
diagram. Is fan selector  
switch set on "manual".  
Reset if necessary. Does  
fan still fail to turn off?  
Does the circulating air  
blower turn off after  
thermostat is satisfied  
within 4 minutes?  
No  
Yes  
Replace fan timer.  
Yes  
Troubleshooting Complete.  
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B. CAD CELL CHECKOUT PROCEDURE:  
1. Remove cad cell lead wires, then start the burner. Shortly after burner starts, place a  
temporary jumper between terminals f & f of the oil primary control. Connect ohmmeter  
across cad cell lead wires - resistance should be less than 1600 ohms.  
2. Stop the burner and remove temporary jumper.  
3. With the burner off, check dark cell resistance across cad cell lead wires. Resistance  
should be greater than 20,000 ohms. If cell resistances are different from above, recheck  
wiring, location of cell, etc. If necessary, replace plug in portion of cell, (Part No.  
350104).  
4. Reconnect cad cell lead wires. Check out the oil primary control according to the  
instructions packed with the control.  
C. HEAT EXCHANGER CLEANING INSTRUCTIONS  
: The heat exchanger must be cleaned by a qualified service person.  
For oil-fired units, it is important to inspect and clean the heat exchanger once a year, or as  
necessary, to remove any build-up of soot. A layer of soot on the inside of the heat exchanger  
will act as an insulator, reducing heat transfer, resulting in reduced efficiency  
To clean the heat exchanger,  
1. First, turn off all power to the unit.  
2. Remove cleanout plugs, the vent connector pipe to the chimney, the burner and the burner  
mounting plate.  
3. With access to the inside of the heat exchanger through the burner cleanout openings and  
the vent pipe connection, it is now possible to use a long, flexible wire brush and an  
industrial-type vacuum cleaner to remove any soot build-up.  
NOTE: A one inch (outside diameter) vacuum cleaner hose will fit into the radiator.  
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To vacuum and brush the outer radiator of the heat exchanger, go through the cleanout  
openings in both directions, as shown in Figure 8.  
Figure 8.  
Reassemble the furnace to the original factory-built condition. Remount the burner,  
being certain that the air tube is properly inserted into the chamber opening. If heavy soot  
deposits were found in the heat exchanger, this indicates that the burner may be out of  
adjustment. Reset the burner, as indicated under the “BURNER OPERATION AND  
ADJUSTMENT”, SECTION L.  
secured in place.  
: Do not start burner unless blower door is  
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D. CLEANING OR REPLACING FLUE PIPES  
Flue pipes should be inspected during the annual maintenance check-up or during each  
subsequent service call.  
Check all flue pipes for restrictions due to soot, or carbon build-up, as well as foreign  
matter, or any materials, that cause the venting system to restrict the proper venting of  
combustion products. If a restriction is found, the flue pipe must be cleaned or replaced  
to ensure proper venting.  
Flue pipes should also be inspected for any signs of corrosion, deterioration or leakage  
that may cause combustion by-products to infiltrate the home or indoor environment.  
If signs of corrosion, deterioration or leakage are evident, the flue pipe must be replaced  
with a properly sized, agency-approved, flue pipe.  
E. EXTENDED SHUTDOWN  
If this furnace is shut down or off for an extended period of time, several steps can be taken  
to help insure a smooth and reliable start.  
ON SHUT DOWN:  
1. Close the fuel supply shutoff valve(s).  
2. Turn the furnace power switch “off” and disconnect electrical power to the unit.  
3. Fill the oil tank to prevent condensation (oil units only).  
4. If shutdown exceeds one season, an oil stabilizer should be added to the oil tank as  
recommended by your oil supplier (oil units only).  
ON START-UP:  
1. Have the heating system (and furnace) inspected and started by a qualified service person.  
2. Check for a clean, adequate supply of fuel.  
3. Set the room thermostat above room temperature.  
4. Open all shutoff valves in the fuel supply line.  
5. Turn “on” the main power at the disconnecting switch and at the furnace power switch to  
start the burner. If the burner does not start, immediately reset the burner primary  
(ignition) control module. On oil furnaces, if required, vent the fuel of air as soon as the  
burner motor starts. If the burner stops during venting, wait three to five minutes before  
attempting to restart.  
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: Do not attempt to start burner when excess fuel has accumulated inside the  
furnace.  
6. Follow the “BURNER OPERATION AND ADJUSTMENT” procedure in Section L.  
VI. USER INFORMATION SECTION  
A. WARNINGS AND CAUTIONS:  
: If you suspect there is a problem with the furnace, pertaining to the venting  
system or any other related problem, immediately contact a qualified service agency. If a  
service agency is not available, contact your fuel supplier.  
: Personal injury or property damage could result from major repair or service  
of this furnace by anyone other than a qualified contractor. The user should only perform  
the routine maintenance described in the user section of this manual.  
: The area around the furnace should be kept free and clear of combustible  
materials, especially papers and rags.  
: Never burn garbage or refuse in your furnace. Never try to ignite oil or gas by  
tossing burning papers or other material into the furnace.  
: Do not attempt to start the burner when:  
1. Excess oil or gas has accumulated,  
2. The furnace is full of vapors,  
3. The combustion chamber is very hot.  
If one or more of these conditions exist, contact a qualified service person.  
: Do not block or obstruct air openings on the furnace casing. Do not block or  
obstruct air openings communicating within the area in which the furnace is installed.  
: Do not allow the outside air intake to be blocked or obstructed by vegetation,  
ice, snow, or any other materials.  
: Do not use this furnace if any part has been underwater. Immediately call a  
qualified service agency to inspect the furnace and to replace any part of the electrical or  
control system which has been underwater.  
: Should overheating occur or the fuel supply fail to shut off, shut off the  
manual fuel supply valve to the furnace before shutting off the electrical supply.  
Should the furnace not operate – note diagnostic code through view port prior to removing  
doors.  
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B. COMPONENT LOCATIONS  
The following diagram shows a typical furnace installation and typical position of the  
components referenced in these instructions.  
Figure 9.  
C. INSPECTION AREAS  
IMPORTANT: For safe operation it is the responsibility of the owner and/or user that the  
burner, chimney/vent pipe, heat exchanger and controls should be inspected every year by  
a qualified heating contractor.  
1. VESTIBULE: The furnace vestibule areas or burner compartment should be  
inspected by opening the lower front door of the furnace and looking for signs of  
excessive heat such as discoloration of components, materials damaged from rust or  
corrosion, soot or carbon build-up.  
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2. EXTERIOR OF FURNACES: The furnace exterior should be inspected for signs of  
excessive heat such as discoloration of materials or damage from rust or corrosion.  
3. VENT CONNECTOR: The furnace vent pipe should be inspected for signs of rust,  
corrosion pitting, or holes in the pipe. Check for leakage around seams in pipe  
indicated by soot or condensate streaks.  
4. ROOF JACKS: The furnace roof jack should be inspected for signs of rust or  
corrosion, pitting or holes, signs of excessive condensation or moisture leaking from  
roof jack.  
D. FILTER LOCATION AND CLEANING  
The air filter should be inspected each month and cleaned when dirty. Cleaning the air  
filter frequently may prevent airborne contaminants from going through the furnace and  
depositing in the furnace, duct system and interior of the building.  
See Figure 9, in this section, for the location of the return air filter.  
E. CONTACT INFORMATION:  
INSTALLATION / SERVICE  
Installed by:  
________________________________________________  
________________________________________________  
Date Installed:  
Contact Information:  
________________________________________________  
________________________________________________  
________________________________________________  
________________________________________________  
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APPENDIX A. REPLACEMENT PARTS LIST  
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