Nordyne 04MD-091A-12-FA User manual

Installation, Operation and
Maintenance Manual
Oil Fired Warm Air Furnaces
04MD-091A-12-FA AND 04MD-140A-16-FA
(Down-Flow or Horizontal Model)
ALL INSTALLATIONS MUST MEET ALL
LOCAL, PROVINCIAL/STATE, AND
FEDERAL CODES WHICH MAY DIF-
FER FROM THIS MANUAL
@.
955B0605
Read this complete manual before
beginning installation. These in-
structions must be kept with the fur-
nace for future reference.

TABLE OF CONTENTS
INTRODUCTION ooo nn i ee ne ne enne cent enneeeneeteeeseeee cesses see taesiaessesnneseeeseneesieesitesieetiesiesnaes 3
HEAT LOSS. nr nn ee ne eed eee ene seeeteee snes tee nee saeesnaesiesseseneeenresieesereseneesnenas 3
LOCATION OF UNIT ooo nn in in ie eer ennteenr niet tneesees sire niee tiie sde sie tineesieetiessiessneseneeentesntenes 3
AIR CONDITIONING oo... en nn nn i ne ne erred een serene sent eseeeseeecieesieetieesieesiaeenennaees 4
COMBUSTION AIR 0... een rr nn nn nn ee ne eee eee ener nneeseees nee seeeseessieesieenieesiaesnennated 5
CHIMNEY VENTING o.oo rn nn nn nn ee ee fnnd sent enne erie eseeeseeesaeesenessieesieesieesiaesieenated 5
DRAFT REGULATOR CONTROL... cece eee rer nr it ee ener enne een esneeseeeseneeciresieesieesieetietiiesnresereseneeseenas 5
OIL TANK oo ni nnn nn nn ee ne eed eee ene nneeteee snes see tieeseesiesiieenneeeneennnee 7
PIPING INSTALLATION 0.00... et ein eerie een ene ene eter niente ties tee teste sire ties siesiessieesieeeneesntesereseneesneesneenaes 7
ELECTRICAL CONNECTIONS 0... eee ern een een en ener renee siete siete tiie sinesnneseneeeneesieeseeeseneesntesieesieetieesseenaes 7
FAN TIMER BOARD AND LIMIT CONTROL... eee er err nt nt erie tiie sneer eenresneesneeseneseneesiresitetieesieesieenaes 8
CIRCULATING AIR BLOWER... cn i i i rn in it ie ie ene ennr sent enneesneeseeseieesieetietietiiesiieenieeenrenntee 8
HUMIDIFIER... eee nn nn nnn eee ete ene cece ene seneeeneeseeeseeesciesniesiesenesenessneesnresereseneeeeeeas 9
OIL BURNER... . enn nn ne eee eee eee eneeeee eee eeeee see snee tee siiesieenneseneennnee 9
FURNACE INSTALLATION SET-UP 0. rr nr in in ie eter eent enn eneneseneesneeseeeseneesieenieetieetiesiesiaees 11
MAINTENANCE AND SERVICE 1.000. en ir in ie ie enters iereenneeenreeneesnreseeeseneesieetieesieesieetiaesieeiaees 11
OPERATING INSTRUCTIONS 000... eee teen een een ereeereneetiee sire snee testis snesnesenteeneesieeeeesentesieesereseeeeneesneenags 12
APPENDIX A- 04MD-091A-12-FA AND 04MD-140A-16-FA BURNER SET UP uu... eee eereneeereeenteeas 13
A.1 OIL BURNER AIR ADJUSTMENT |... re int eee eine eenr een esneesereenieesieesieetiesiesiiessnrseneeenteentene 13
A.2 BURNER ELECTRODES |... rn i eerie en rn reesei eeneneesniee siete nie tietiiesiiesenresiiessnresieeeneenntene 13
A.3 START UP Loin i rn nn ne ee nd ene ene neared nee nee tee tee teenie tee siesiessneesneeeneeentenes 13
TABLE A-6 DIRECT DRIVE BLOWER SET-UP ooo. ee eter rr enteritis tie tietiiesiieetiesiessnresneseneeentenes 14
TABLE A-8 DIRECT DRIVE BLOWER CHARACTERISTICS ooo... eee eer teens rie eiieseneeenrenniesenresneeeneeenteees 15
TABLE A-9 GENERAL DIMENSIONS (INCHES) 0... eee eer ere inet rie nieetietiesinesiesiessnresneeeneeeneenes 16
APPENDIX B: WIRING DIAGRAMS 0.0... ecient ener enn eenr een eene eters eieesieesneetieetiesiesiieesneeeneeesnreeneseneesntenes 17
OPERATION OF OIL BURNER o.oo eee en en en re renee nire tiers tess sess senrseneesireseeeseeseeesereseeesneenneenags 18
APPENDIX C-R7184 TROUBLESHOOTING |... eee eeneen een entree eeesieciesieetietiessnessneeeieessntesneseneeentenes 19
R7184 DETAILED SEQUENCE OF OPERATION (FIGURE 7)... cece ee tern crne cent eene een etenteeneennteseneneeeneeee 19
TABLE C-1: ELECTRONIC FAN TIMER BOARD (EFT) DETAILED SEQUENCE OF OPERATION... 22
R7184 LED DIAGNOSTIC LIGHT 0... eee rr err nt it ieee ie tint eine eenne sie eeneseneesieeseteseneesieesieetieetiesiaeenaees 23
TABLE C-3: R7184 TROUBLESHOOTING... eee een een en entrees sie tie siesiiesinesentesiieseneeeneeeneeentenes 24
TABLE C4: SYSTEM AND GENERAL TROUBLESHOOTING occ eet entries rete teneeeneesneseeesneeeneeenrenes 26
FINAL CHECK OUT oo nn nn nn ne ne ne need eee denne nneeseee nee naeegeneenieenieenieetiesieenaees 28
PARTS LISTING: COUNTERFLOW HORIZONTAL MODEL: 04MD-091A-12-FA Loo. ee nett eerie tneenaees 29
PARTS LISTING: COUNTERFLOW HORIZONTAL MODEL: 04MD-140A-16-FA Loo... enetterneeniees 32
HOMEOWNER’S REFERENCE TABLE 1.00... eee er reir ieenne sensei een eseeeeieesietietietietietiiesnieensesieenates 35
NOTES: ooo nn nn nn ne ee ne ne ee eee ene ene seeeseeeesneeseeeseesnieesieesieesieesiesnesiates 36

AWARNING
IMPROPER INSTALLATION MAY CRE-
ATE A CONDITION WHERE THE OP-
ERATION OF THE PRODUCT COULD
CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.
IMPROPER INSTALLATION, ADJUST-
MENT, ALTERATION, SERVICE OR
MAINTENANCE CAN CAUSE INJURY
OR PROPERTY DAMAGE. REFER TO
THIS MANUAL FOR ASSISTANCE OR
ADDITIONAL INFORMATION, CON-
SULT A QUALIFIED INSTALLER, SER-
VICE AGENCY OR THE FUEL SUP-
PLIER.
AWARNING
DO NOT USE GASOLINE, CRANK-
CASE OIL, OR ANY OTHER OIL CON-
TAINING GASOLINE AS A FUEL FOR
THIS FURNACE.
ACAUTION
THIS PRODUCT MUST BE INSTALLED
IN STRICT COMPLIANCE WITH THESE
INSTALLATION INSTRUCTIONS AND
ANY APPLICABLE LOCAL, STATE,
AND NATIONAL CODES INCLUDING
BUT NOT LIMITED TO: BUILDING,
ELECTRICAL AND MECHANICAL
CODES.
AWARNING
The furnace area must not be used as a
broom closet or for any other storage
purposes, as a fire hazard may be cre-
ated. Never store items such as the fol-
lowing on, near or in contact with the
furnace:
1. Spray or aerosol cans, rags,
brooms, dust mops, vacuum clean-
ers or other cleaning tools.
2. Soap powders, bleaches, waxes or
other cleaning compounds; plastic
items or containers, gasoline, Kero-
sene, cigarette lighter fluid, dry
cleaning fluids, or other volatile flu-
ids.
3. Paint thinners or other painting ma-
terials and compounds.
4. Paper bags, boxes, or other paper
or cardboard products.
Never operate the furnace with the
blower door removed. To do so could
result in serious personal injury and/or
equipment damage.
INTRODUCTION
Please read these instructions com-
pletely and carefully before installing and
operating the furnace.
The furnace must be installed and set up
by a qualified contractor.
Model 04MD-091A-12-FA is an oil fired
forced air multi-positional furnace, with
an output capacity range of 58,000
BTU/Hr. to 85,600 BTU/Hr. The 04MD-
140A-16-FA is also an oil fired forced air
multi-positional furnace with an output
capacity range of 85,500 BTU/Hr. to
123,000 BTU/Hr. The 04MD-091A-12-
FA AND 04MD-140A-16-FA furnace may
be installed in the down-flow position, as
well as both left and right horizontal posi-
tions.
Ail models are listed with the Canadian
Standards Association, (CSA), and com-
ply with the standards of both the United
States and Canada for use with No. 1
(Stove) and No. 2 (Furnace) Oil.
In the United States, the installation of
the furnace and related equipment shall
be installed in accordance with the regu-
lations of NFPA No. 31, Installation of Oj!
Burning Equipment, as well as in accor-
dance with local codes.
In Canada, the installation of the furnace
and related equipment shall be installed
in accordance with the regulations of
CAN/CSA - B139, Installation Code For
Oi Burning Equipment, as well as in
accordance with local codes.
When installation or application ques-
tions arise, regulations prescribed in the
National Codes and Local Regulations
take precedence over the general in-
structions provided with this installation
manual. When in doubt, please consult
your local authorities.
Ail models are shipped assembled and
pre-wired. The furnace should be care-
fully inspected for damage when being
unpacked.
HEAT LOSS
To determine the correct furnace and
firing rate for an application, it is neces-
sary to calculate the maximum hourly
heat loss of the building based on local
design conditions. In new construction,
the heat loss should be calculated on a
room-by-room basis to enable proper
sizing of the trunk and branch ductwork.
In retrofit applications, a building shell
(overall) heat loss calculation may be
used.
In the United States, Manual J. titled,
"Load Calculation" published by the Air
Conditioning Contractors of America,
(ACCA), describes a suitable procedure
for calculating the maximum hourly heat
loss.
In Canada, the maximum hourly heat
loss may be calculated in accordance
with the procedures described in the
manuals of the Heating, Refrigeration
and Air Conditioning Institute (HRAI), or
by other method prescribed by authori-
ties having jurisdiction that are suitable
for local conditions.
LOCATION OF UNIT
The furnace should be located such that
the flue connection to the chimney is
short, direct and consists of as few el-
bows as possible. When possible, the
unit should be centralized with respect to
the supply and return air ductwork. A
central location minimizes the trunk duct
sizing. All models may be installed on
combustible floors. Do not install the
furnace on carpet or tiled floors.
Minimum installation clearances are
listed in Table 1.
NOTE: The recommended installation
clearances do not necessarily take into
consideration the clearances necessary
to replace the air filter or perform other
routine maintenance.
DOWN-FLOW INSTALLATION
All O4MD-091A-12-FA AND 04MD-140A-
16-FA furnace models have been as-
sembled for installation in the down-flow
position. Maintain all clearances to com-
bustibles as outlined in Table 1. Sugges-
tion, as a measure to prevent fuel oil
from accumulating in locations other than
the fire pot, as could be the case in the
event of nozzle drip, install the furnace
with an approximate 2 degree slope from
the oil burner casing towards the fire pot.
Use shims made of noncombustible ma-
terial.

HORIZONTAL INSTALLATION
04MD-091A-12-FA AND 04MD-140A-16-
FA furnaces models are assembled and
shipped ready for installation in the
down-flow position. The furnace may be
installed in either of the horizontal posi-
tions; warm air discharging left or warm
air-discharging right by following these
steps:
1. Rotate the furnace 90° to the de-
sired position.
2. Remove the three nut and washer
sets fastening the oil burner assem-
bly to the furnace. Rotate the oil
burner assembly to be in the normal
upright position.
3. Re-align the oil burner assembly to
the combustion chamber (fire-pot),
and then secure into place with the
three nut and washer seis.
NON-SUSPENDED INSTALLATION
Maintain clearances to combustibles as
outlined in Table 1. Installation on a
combustible floor requires a clearance of
1 inch. This can be done by using a non-
combustible material such as one-inch
thick channel iron or similar material. The
furnace must be supported in such a way
as to not allow twisting or sagging of the
cabinet. Suggestion; as a measure to
prevent fuel oil from accumulating in
locations other than the fire pot, as could
be the case in the event of nozzle drip,
install the furnace with an approximate 2-
degree slope from the oil burner casing
towards the fire pot. Use shims made of
Table 1: Clearance to Combustibles
Furnace O4MD-091A-12-FA O04MD-140A-16-FA
Location Down flow | Horizontal | Down flow | Horizontal
Top O in. 3 in. O in. 3 in.
Bottom Oin. 1 in. 1 in. 1 in.
S/A Plenum 1 in. 1 in. 1 in. 1 in.
Rear 1 in. 1 in. 1 in. 1 in.
Sides 1 in. 1 in. 1 in. 1 in.
Front 10 in." 10 in." 10 in." 10 in."
Flue Pipe 9 in.? 9 in.? 9 in.? 9 in.?
Enclosure Closet Closet Closet Closet
1 24 inches is required for servicing.
? 48 inches required in the United States.
noncombustible material.
SUSPENDED INSTALLATION
Refer to Figure 1. Maintain clearances to
combustibles as outlined in Table 1. The
furnace may be suspended by field fabri-
cating a cradie of angle iron and
threaded rod. Secure the furnace with 2
inch minimum slotted angle or equiva-
lent, as shown in Figure 1. The furnace
must be supported in such a way as to
not allow twisting or sagging of the cabi-
net. Position the supports so as to not
interfere with accessing the burner and
blower compartments. Suggestion; as a
measure to prevent fuel oil from accumu-
lating in locations other than the fire pot,
as could be the case in the event of noz-
zie drip, install the furnace with an ap-
proximate 2 degree slope from the oil
burner casing towards the fire pot.
AIR CONDITIONING
If the furnace is used in conjunction with
air conditioning, the furnace shall be
installed in parallel with or upstream from
the evaporator coil to avoid condensation
in the heat exchanger. In a parallel in-
stallation, the dampers or air controlling
means must prevent chilled air from en-
tering the furnace. If the dampers are
manually operated, there must be a
means of control to prevent the operation
of either system unless the dampers are
in the full heat or full cool position. The
air heated by the furnace shall not pass
SUGGESTED METHOD FOR
SUSPENDING HORIZONTAL FURNACE
Fig 1 Suspended Installation
RETURN AIR PLENUM
as
_— 318 INCH THREADED ROD
2 INCH ANGLE IRON
JAM NUTS
LOGK WASHER
ALLOW ENOUGH ANGLE IRON FLAT WASHER
OVERHANG TO PERMIT
OPENING THE BLOWER DOOR.
(le iy SUPPLY AIR PLENUM
NZ
Z™
NZ
4™

through a refrigeration unit unless the
unit is specifically approved for such
service.
Generally, a six-inch clearance between
the air conditioning evaporator coil and
the heat exchanger will provide adequate
airflow through the evaporator coil.
The blower speed musi be checked and
adjusted to compensate for the pressure
drop caused by the evaporator coil. Re-
fer to Appendix B for recommended wir-
ing and electrical connections of the air
conditioning controls.
COMBUSTION AIR
When a furnace is installed in the full
basement of a typical frame or brick
house, infiltration is normally adequate to
provide air for combustion and draft op-
eration. If the furnace is installed in a
closet or utility room, two (2) ventilation
openings must be provided connecting to
a well ventilated space (full basement,
living room or other room opening
thereto, but not a bedroom or bathroom).
One opening shall be located 6" from the
top and bottom of the enclosure at the
front of the furnace. For furnaces located
in buildings of unusually tight construc-
tion, such as those with high quality
weather stripping, caulking, windows and
doors, or storm sashed windows, or
where basement windows are well
sealed, a permanent opening communi-
cating with a well ventilated attic or with
the outdoors shall be provided, using a
duct if necessary. Size all of the open-
ings and associated ductwork by the
standards provided in the latest Oil In-
stallation Code editions; NFPA 31 in the
United States, CAN/CSA B139 in Can-
ada. Take all fuel burning appliances in
the area into consideration when calcu-
lating combustion and ventilation air re-
quirements.
The Model CAS-2B-90E Furnace Boot
manufactured by Field Controls, Inc. may
be used with the furnace to obtain com-
bustion air directly from outdoors. Use of
this device does not alter the need for
ventilation air; however, it does provide a
good direct source of combustion air and
is connected directly to the oil burner.
CHIMNEY VENTING
The chimney must be sized correctly and
be in good repair. If the chimney is over-
sized, there is a high risk of the flue
gases condensing resulting in damage to
the chimney and other venting parts.
This problem may be corrected by the
use of an appropriately sized chimney
liner.
If the chimney serves the 04MD-091A-
12-FA furnace only, the vent should be
sized at 5-inch minimum. The O4MD-
140A-16-FA should be 6-inch minimum.
The data provided in Table 3 is based on
dedicated venting. If the furnace is to be
co-vented with other appliances, refer to
NFPA 211, Standard for Chimneys, Fire-
places, Vents, and Solid Fuel-Burning
Appliances, NFPA 31, Standard for the
Installation of Oil Burning Equipment or
CAN/CSA B139, Installation Code For
Oi Burning Equipment for correct sizing
information.
NOTE: This furnace is approved for
use with L-Vent.
NOTE: Maximum temperature for L-
Vent is 575°F (300°C).
IMPORTANT: The chimney must be
capable of providing sufficient draft at all
times for the safe removal of the prod-
ucts of combustion.
The chimney should be tested under
“winter” conditions; doors and windows
closed, all other fossil fuel burning appli-
ances on, clothes dryer on, bathroom
fans on, etc. If the chimney cannot over-
come the competition for air, it will be
necessary to access the reason for it,
and take corrective action. If the chimney
is found to be sized correctly and in good
repair, it will probably be necessary to re-
evaluate the availability of combustion
and ventilation air, and take corrective
action.
The flue pipe should be as short as pos-
sible with horizontal pipes sloping up-
ward toward the chimney at a rate of
one-quarter inch to the foot. The flue
pipe should not be smaller in cross sec-
tional area than the flue collar on the
furnace. The flue pipe should connect to
the chimney such that the flue pipe ex-
tends into, and terminates flush with the
inside surface of the chimney liner. Seal
the joint between the pipe and the lining.
The chimney outlet should be at least
two feet above the highest point of a
peaked roof. All unused chimney open-
ings should be closed. Chimneys must
conform to local, provincial or state
codes, or in the absence of local regula-
tions, to the requirements of the National
Building Code.
See Figure 2 and Table 2 for common
chimney problems and their remedies.
ACAUTION
THE FURNACE MUST BE CON-
NECTED TO A FLUE HAVING SUFFI-
CIENT DRAFT AT ALL TIMES TO EN-
SURE SAFE AND PROPER OPERA-
TION OF THE APPLIANCE.
The flue pipe must not be routed through
concealed space, because it must be
visually checked for signs of deteriora-
tion during the annual inspection and
servicing. The flue pipe must not pass
through any floor or ceiling, but may
pass through a wall where suitable fire
protection provisions have been in-
stalled. In the United States, refer to the
latest edition of NFPA 31 for regulations
governing the installation of oil burning
equipment. In Canada, refer to the latest
edition of CAN/CSA B139 for rules gov-
erning the installation of oil burning
equipment.
NOTE: THE RECOMMENDED FLUE
DRAFT PRESSURE IS -0.02 IN. W.C.
(AS MEASURED UPSTREAM OF THE
BAROMETRIC DRAFT REGULATOR).
SHOWN IN FIGURE 1.
DRAFT REGULATOR CONTROL
This device is used in conjunction with
conventional chimney venting. This con-
trol (or draft regulator) automatically
maintains a constant negative pressure
in the furnace to obtain maximum effi-
ciency. It ensures that proper pressures
are not exceeded. If the chimney does
not develop sufficient draft, the draft con-
trol cannot function properly. The draft
regulator, must be installed within the
same room or enclosure as the furnace,
and should not interfere with the com-
bustion air supplied to the burner. The
control should be located a minimum of 3
flue pipe diameters from the furnace
breeching and installed in accordance to
the instructions supplied with the regula-
tor.

Fig. 2: Common Chimney Problems
Se
Ash Dump
for
Fireplace
Fireplace
SKS
B
Obstruction in
chimney
Can be found
by light and
mirror reflecting
conditions in
chimney.
Use weight to
break and dis-
lodge.
Joist protruding
into chimney.
Lowering a light
on an extension
cord.
Must be han-
died by compe-
tent masonry
contractor.
Break in chim-
Smoke test -
build smudge
fire blocking off
other opening,
Must be han-
dled by compe-
Table 2: Common Chimney Problems
Refer to Figure 2
ney lining. watching for tent masonry
smoke to es- contractor.
cape.
Collection of Clean out with
. weighted brush
soot at narrow Lower light on
. : or bag of loose
space in flue extension cord.
opening gravel on end
‘ of line.
. Change to
Offset Lower ight on straight or to
extension cord.
long offset.
The least im-
Two or more Found by in- portant opening
: : must be closed,
openings to the | spection from using some
same chimney. | basement. g SOI
other chimney
flue.
Leaks should
Loose-seated be eliminated
pipe in flue Smoke test. by cementing
opening. all pipe open-
ings.
Measurement Length of pipe
Smoke pipe of pipe from must be re-
Pip within or obser- | duced to allow
extends into . . .
chimney vation of pipe end of pipe to
‘ by means of a be flush with
lowered light. inside of tile.
Failure to ex-
tend the length By inspection or Extend partition
of flue partition smoke test. to floor level.
to the floor.
Loose-fitted Smoke test. Close all leaks
clean-out door. with cement.
Key Trouble Diagnostic Remedy
Top of chimney Extend chimney
above all sur-
lower than sur- . .
A . Observation rounding ob-
rounding ob- . a
: jects within 30
jects
feet.
B Chimney Cap Observation Remove
or ventilator.
Make opening
C Coping restricts Observation as large as
opening. inside of chim-
ney.

Table 3: Minimum Chimney Base
Temperatures (°F)
Chimney Height (ft.)
Nozzle
11 | 20 | 28 | 36
Chimney Thermal Resistance < R6
0.50 300 400 535 725
0.65 275 340 430 535
0.70 270 330 405 505
0.75 260 320 380 475
0.85 250 300 355 430
1.00 225 300 365 430
Chimney Height (ft.)
Nozzle
11 | 20 | 28 | 36
Chimney Thermal Resistance > R6
0.50 185 200 220 250
0.65 175 185 205 220
0.70 175 185 195 215
0.75 175 185 195 210
0.85 165 185 195 205
1.00 165 185 195 205
<-less than, > - greater than
OIL TANK
Oil storage tanks must be selected and
installed in compliance with applicable
codes; in the United States, NFPA 31,
Standard for the Installation of Oi! Burn-
ing Equipment, Chapter 2. and in Can-
ada, CAN/CSA-B139, Installation Code
for Of Burning Equipment, Section 6.
Observe all local codes and by-laws.
In general, the oil tank must be properly
supported and remain stable in both
empty and full condition. The oil tank
must be fitted with vent and supply pipes
to the outdoors. Refer to the above-
mentioned codes for sizing. The vent
pipe must be no less than 1% inches
|.P.S., and terminate with an appropriate
vent cap in a location where it will not be
blocked. The fill pipe must be no less
than 2 inches I|.P.S., and terminate with
an appropriate cap in a location where
debris will not enter the fill pipe during oil
delivery.
If located indoors, the tank should nor-
mally be in the lowest level, (cellar,
basement, eic.). It must be equipped
with a shut-off valve at the tank outlet
used for the oil supply. The oil tank must
be located as to not block the furnace /
room exit pathway. Observe all clear-
ances specified in the above-mentioned
codes.
PIPING INSTALLATION
In the United States, NFPA 31, Standard
for the Installation of Oil Burning Equip-
ment, Chapter 2.
In Canada, the entire fuel system should
be installed in accordance with the re-
quirements of CAN/CSA B139, and local
regulations. Use only approved fuel oil
tanks piping, fittings and oil filters.
Ensure that all fittings used in a copper
oil line system are high quality flare fit-
tings. Do not use compression fittings.
Do not use Teflon tape on any fittings.
Pressurized or gravity feed installations
must not exceed 3 PSIG. Pressures
greater than 10 PSIG may cause dam-
age to the shaft seal. If the height of the
oil stored in a tank above the oil burner
exceeds 11% feet, it may be necessary
to use a pressure-regulating device ap-
proved for this purpose.
The furnace may be installed with a one-
pipe system with gravity feed or lift. The
maximum allowable lift on a single line
system is 8 feet. Lift should be measured
from the bottom (outlet) of the tank, to
the inlet of the burner. Sizing a single
line system is complex because of the
difficulty estimating the pressure drop
through each fitting, bend and compo-
nent in the line. In general, keep single
line systems short as possible. The
following chart shows the allowable line
lengths (horizontal + vertical) for single
and two-line oil piping systems. All dis-
tances are in feet.
Table 4: Oil Lines
Copper Tubing Oil Line Length (Feet)
Lift Single-Pipe OD Two-Pipe OD
(Feet) | 3/8” 1/2” 3/8” 1/2"
0) 53 100 68 100
1 49 100 65 100
2 45 100 63 100
3 41 100 60 100
4 37 100 58 100
5 33 100 55 100
6 29 100 53 100
7 25 99 50 100
8 21 83 48 100
i) 17 68 45 100
10 13 52 42 100
12 --- --- 37 100
14 --- --- 32 100
16 --- --- 27 100
18 --- --- 22 88
In retrofit applications, where an existing
oil line system is in place, a vacuum
check will help determine the efficacy of
the existing oil line system The vacuum
in a system should not exceed 6” Hg. for
a single pipe system, nor 12” Hg. for a
two-pipe system.
NOTE: The oil burner requires the use of
a bypass plug when converting from
single-pipe to two-pipe oil piping sys-
tems. See burner manufacturer’s instruc-
tions.
Ail fuel systems should include an oil
filter between the fuel oil storage tank
and the oil burner. For best results, in-
stall the oil filter as close to the burner as
possible. When using an indoor oil tank,
the oil filter may be installed at the tank
downstream from the shut-off valve. If
firing the furnace under the 0.65 gph
rate, a 7 to 10 micron line filter should be
installed as close to the oil burner as
possible.
ELECTRICAL CONNECTIONS
The furnace is listed by the Canadian
Standards Association (CSA). It is fac-
tory wired and requires minimal field
wiring. In the United States, the wiring
must be in accordance with the National
Fire Protection Association NFPA-70,
National Electrical Code, and with local
codes and regulations. In Canada, all
field wiring should conform to CAN/CSA
C22.1 Canadian Electrical Code, Part 1,
and by local codes, where they prevail.
The furnace should be wired to a sepa-
rate and dedicated circuit in the main

electrical panel; however, accessory
equipment such as electronic air clean-
ers and humidifiers may be included on
the furnace circuit. Although a suitably
located circuit breaker can be used as a
service switch, a separate service switch
is advisable. The service switch is nec-
essary if reaching the circuit breaker
involves becoming close to the furnace,
or if the furnace is located between the
circuit breaker and the means of entry to
the furnace room. The furnace switch
(service switch) should be clearly
marked, installed in an easily accessible
area between the furnace and furnace
room entry, and be located in such a
manner to reduce the likelihood that it
would be mistaken as a light switch or
similar device.
The power requirements for all models:
120 VAC, 1 ©, 60 Hz., 12A.
Accessories requiring 120 VAC power
sources such as electronic air cleaners
and humidifier transformers may be
powered from the ST9103 EFT. Do not
use the direct drive motor connections as
a power source, since there is a high risk
of damaging the accessories by expo-
sure to high voltage from the auto-
generating windings of the direct drive
motor.
Thermostat wiring connections and air
conditioning contactor low voltage con-
nections are shown in the wiring dia-
grams. Some micro-electronic thermo-
stats require additional controls and wir-
ing. Refer to the thermostat manufac-
turer's instructions.
The thermostat should be located ap-
proximately 5 feet above the floor, on an
inside wall where there is good natural
air circulation, and where the thermostat
will be exposed to average room tem-
peratures. Avoid locations where the
thermostat will be exposed to cold drafts,
heat from nearby lamps and appliances,
exposure to sunlight, heat from inside
wall stacks, etc.
Normal heat anticipator setting: 0.1 A.
For more precise adjustment, the heat
anticipator may be adjusted to the am-
perage draw of the heating control circuit
as measured between the "R" and "W"
terminals of the thermostat. To reduce
the risk of damaging the heat anticipator,
do not measure circuit without first re-
moving one of the two wires first. To
determine the heating circuit amperage
draw:
1. Disconnect one of the “R” or “W"
wires from the thermostat terminal.
2. Connect an ammeter between the
wire and the thermostat terminal to
which it was attached.
3. Note the amperage reading when
the heating contacts are closed.
(System switch must be on “HEAT” if
so equipped.
4. Re-connect the thermostat wire. If
the thermostat is serving a combina-
tion heating and air conditioning sys-
tem, pay particular attention to po-
larity.
5. When the thermostat is reconnected
and re-plumbed, adjust the heat an-
ticipator setting to match the ob-
served amperage reading.
FAN TIMER BOARD AND LIMIT
CONTROL
The Electronic Fan Timer integrates con-
trol of all burner and circulator fan opera-
tions. This control is the central wiring
point for most of the electrical compo-
nents in the furnace. The Honeywell
$T9103 has a fixed fan delay on time of
30 seconds after the burner ignites. The
United Technologies 1158-120 has an
adjustable fan on time that is set by se-
lecting the dipswitch combination dis-
played in Table 6. This fan on delay can
be set at 30, 60, 90 or 120 seconds. This
provides a delay between the burner
ignition and blower start-up to eliminate
excessive flow of cold air when the
blower comes on. The Honeywell
$T9103 has an adjustable fan off time of
60, 90, 120 and 150 seconds that is set
by selecting a dipswitch combination on
the control board displayed in Table 5.
Similarly the United Technologies
1158-120 have an adjustable fan off time
of 2, 3, 4 or 6 minutes displayed in Table
6. The fan off delay time starts when the
burner motor is de-energized at the end
of a call for heat. Blower shutdown is
delayed to remove any residual heat
from the heat exchanger and improve
the annual efficiency of the furnace.
The electronic fan timer board works in
conjunction with snap disc limit controls,
which perform a safety function, and
breaks power to the oil burner primary
control, which shuts off the burner if the
furnace over-heats. The limit control is
thermally operated and automatically
resets. The limit control is factory in-
stalled, pre-set and is not adjustable.
If a limit control opens, the Honeywell
$T9103 will energize the circulating fan.
When the limit control closes the burner
is re-energized and the heating cycle
begins again.
If the limit control opens with the United
Technologies 1158-120 electronic fan
control, the circulating fan will be ener-
gized as well. When the limit closes, the
control initiates a two minute delay.
When this delay is finished, the fan off
timer will begin. At the end of the fan off
time cycle the burner will be energized,
initiating a normal burner cycle.
TABLE 5
Honeywell ST9103
Dip Switch Blower Off Delay
Position Time
1 2
On On 60 seconds
On Off 90 seconds
Off On 120 seconds
Off Off 150 seconds
TABLE 6
United Technologies 1158-120
Dip Switch Position Blower Delay
Times
1 2 3 4 On Off
Sec- | Minutes
onds
Off | Off 30
On | Off 60
Off | On 90
On | On 120
Off | Off 2
On | Off 3
Off | On 4
On | On 6
Note: It is advisable not to set the
fan on delay time for a time period
longer than 90 seconds on the
04MD-140A-16-FA with 128,000
BTUH output. Longer fan on delay
times may result in nuisance limit
trips.
CIRCULATING AIR BLOWER
All O4MD-091A-12-FA AND 04MD-140A-
16-FA furnace models are equipped with
a direct drive blower system. Direct drive
blower speed adjustments are not nor-
mally required in properly sized extended
plenum duct systems. The motor RPM
and air CFM delivery will vary automati-
cally to accommodate conditions within
the usual range of external static pres-
sures typical of residential duct systems.
Under-sized duct systems may require a
higher blower speed to obtain a reason-
able system temperature rise. Some

older duct systems were not designed to
provide static pressure. They typically
feature special reducing fittings at each
branch run and lack block ends on the
trunk ducts. These systems may require
modification to provide some resistance
to the airflow to prevent over-amping of
the direct drive blower motor. Selecting a
lower blower speed may correct this
problem.
Direct drive blower speeds are adjusted
by changing the "hot" wires to the motor
winding connections. Please refer to
wiring diagram in Appendix B or the wir-
ing diagram label affixed to the furnace.
THE NEUTRAL WIRE (normally the
white wire) IS NEVER MOVED TO AD-
JUST THE BLOWER SPEED.
wraps of electricians tape.
If the joining of the blower speed
wiring is done in the furnace junction
box, tape off both ends of the unused
wire.
ACAUTION
DISCONNECT THE POWER SUPPLY
TO THE FURNACE BEFORE OPEN-
ING THE BLOWER ACCESS DOOR
TO SERVICE THE AIR FILTER, FAN
AND MOTOR. FAILURE TO SHUT OFF
POWER COULD ALLOW THE
BLOWER TO START UNEXPECT-
EDLY, CREATING A RISK OF DEATH
OR PERSONAL INJURY.
ACAUTION
DO NOT CONNECT POWER LEADS
BETWEEN MOTOR SPEEDS. THE
NEUTRAL WIRE MUST ALWAYS BE
CONNECTED TO THE MOTOR'’'S DES-
IGNATED NEUTRAL TERMINAL.
It is possible and acceptable to use a
single blower speed for both heating and
cooling modes. The simplest method to
connect the wiring from both modes is to
use a "piggy-back connector" accommo-
dating both wires on a single motor tap.
It is also acceptable to connect the se-
lected motor speed with a pigtail joined
to both heating and cooling speed wires
with a wire nut. As a safety precaution
against accidental disconnection of the
wires by vibration, it is advisable to se-
cure the wire nut and wires with a few
Figure 4: Horizontal Smoke Test Port Location
Do not use the blower speed wires as
a source of power to accessories as
electronic air cleaners and humidifier
transformers. The unused motor taps
auto-generate sufficiently high volt-
ages to damage accessory equip-
ment. Use the terminals provided on
the electronic fan timer.
HUMIDIFIER
A humidifier is an optional accessory
available through most heating supplies
outlets. Installation should be carried out
in accordance with the humidifier manu-
facturer's installation instructions. Water
or water droplets from the humidifier
should not be allowed to come into con-
tact with the furnace heat exchanger. Do
not use direct drive motor connections as
a source of power for 120 VAC humidifi-
ers and humidifier transformers.
OIL BURNER
The oil burner must align properly with
the cerafelt fiber chamber (firepot). The
cerafeilt fiber chamber is initially quite
soft, but hardens and becomes quite
brittle after the first firing. The firepot is
held in place by a retaining bracket;
however, it is possible for the firepot to
shift if subjected to rough handling during
transit.
ACAUTION
Do not start the burner or blower fan
unless the blower access door is se-
curely in place.
Additional ST9103 Fan Timer Control
information is in Appendix A, Tables, and
in Appendix B, Wiring Diagrams.
ACAUTION
BEFORE OPERATING THE FUR-
NACE CHECK BURNER ALIGNMENT
WITH COMBUSTION CHAMBER.
THE END CONE OF THE AIR TUBE
MUST BE CENTRED TO THE AC-
COMODATING RING PROVIDED IN
THE DESIGN OF THE COMBUSTION
CHAMBER. ADJUST ALIGNMENT AS
NECESSARY BEFORE THE FIRST
FIRING.
Figure 5: Vertical Smoke Test Port Location
Horizontal Flue Connection
Chimney ~, | ara
flue pipe Ne
A
Draft regulator ~
Location for C)
sampling hole, 1/4" diam. P
aS
Wy
Furnace
&
wu
>
i-galgi=
3
“= Oil burner
breeching
Vertical Flue Connection
Location for
sampling hole
Note B Note A

OIL BURNER NOZZLES
04MD-091A-12-FA AND 04MD-140A-16-
FA furnaces are certified for multiple
firing rates, ranging from approximately
56,000 to 85,600 BTU/hr. on the 04MD-
O091A-12-FA and 85,500 to 123,000
BTU/Hr. on the 04MD-140A-16-FA By
changing the oil burner nozzle within the
specific model range, and temperature
rise, the furnace may be fired at an ideal
rate for a wide range of structures.
BURNER ELECTRODES
Correct positioning of the electrode tips
with respect to each other, to the fuel oil
nozzle, and to the rest of the burners is
essential for smooth light ups and proper
operation. The electrode tips should be
adjusted to a gap of 5/32”, 1/16” ahead
of the nozzie, 5/16” above the centerline
of the nozzle. The “Z” dimension (front
edge of the burner head to the front face
of the nozzle is 1-1/8 inches.
Electrode positioning should be checked
before the first firing of the furnace.
The electrode porcelains should be free
of cracks, the electrode tips should be
tapered and free of burrs, and the con-
tact rods must be clean and be in firm
contact with the ignition transformer con-
tact springs. The electrodes must not
come into contact with the burner head.
OIL BURNER SET-UP
The burner air supply is adjusted to
maintain the fuel to air ratio to obtain
ideal combustion conditions. A lack of air
causes "soft" and “sooty” flames, result-
ing in soot build-up throughout the heat
exchanger passages. Excess combus-
tion air causes a bright roaring fire and
high stack temperatures resulting in poor
fuel efficiency.
PREPARATIONS:
Drill a %” test port in the venting, ideally
at least 2 flue pipe diameters away from
the furnace breeching, if venting horizon-
tally from the furnace, or from the flue
pipe elbow if venting vertically before
reaching the furnace. (See Figures 4 and
5).
The test port will allow flue gas samples
to be taken and stack temperatures to be
measured.
Before starting the burner, check the
burner alignment with the combustion
chamber (fire pot), check that the correct
nozzle is tightened into place, and that
the burner electrodes are properly posi-
tioned.
The Beckett burner bulk air band is
should be closed, and the air shutter
initial setting should be approximately
7.00.
Note A: Locate hole at least 6 inches on
the furnace side of the draft control.
Note B: Ideally, hole should be at least
12 inches from breeching or elbow.
PROCEDURE:
Start the burner and allow it to run at
least ten minutes. Set the air shutter to
give a good flame visually. The combus-
tion air supply to the burner is controlled
by manipulating the air shutter on the left
side of the burner, and, if necessary, the
bulk air band. To adjust, loosen the bolt
on the movable shutter. Move the shutter
gradually until a good flame (visually)
has been achieved. Re-snug the bolt.
Check the initial draft setting as the fur-
nace warms up. The draft may be meas-
ured at the test port. The breech draft
should be approximately - 0.05” w.c. to
obtain an over fire draft reading of - 0.02
inches w.c.
Check the oil pump pressure. Standard
operating pressure is 100 PSIG.
After reaching steady state, take a
smoke test. If not indicating a trace, set
the combustion air controls to provide a
trace.
Typically, the COz2 reading will range
from 11.5% to 13.5%.
After the air adjustments have been
completed, and the air shutter or air ad-
justment plate has been secured, re-
check the over fire draft and take another
smoke test to ensure that the values
have not changed.
Figure 6: Checking Over-Fire Draft.
SMOKE TEST NOTE:
If oily or yellow smoke spots are found
on the smoke test filter paper, it is usu-
ally a sign of unburned fuel. This indi-
cates poor combustion. This type of
problem may be caused by excess draft,
excess air, or contaminated fuel. Do not
ignore this indicator.
STACK TEMPERATURE:
Stack temperature will vary depending
on fuel input, circulating air blower
speed, and burner set up, etc. In gen-
eral, stack temperature should typically
range between 380°F to 550°F, assum-
ing that the combustion air is approxi-
mately room temperature (65°F - 70°F).
In general, lower stack temperature indi-
cates greater efficiency; however, ex-
cessively low stack temperature can lead
to condensation forming in the chimney
and / or venting. Sulphur and similar
contaminants in the fuel oil will mix with
condensation to form acids. Acids and
resultant chemical salts will cause rapid
deterioration of the chimney and venting
components, and may attack the fur-
nace.
If the flue gases are below the range, it
may be necessary to slow down the
blower fan. If the flue gases are above
the range, the blower fan may require
speeding up. Stack temperature varies
directly with the system temperature rise.
System temperature rise is the difference
between the furnace outlet temperature
and furnace inlet temperature as meas-
ured in the vicinity of the connection be-
tween the plenum take-offs and the trunk
ducts.

lf the venting from the furnace to the
chimney is long, or exposed to cold am-
bient temperatures, it may be necessary
to use L-Venit as the vent connector to
reduce stack temperature loss to prevent
condensation. The venting should be
inspected annually to ensure that it is
intact.
FURNACE INSTALLATION SET-
UP
The furnace must be set up as the final
step in the installation.
A) The oil burner must be set up follow-
ing the procedures outlined above.
B) The O4MD-091A-12-FA models
should operate within a temperature rise
of 45°F to 75°F. The 04MD-140A-16-FA
temperature rise range should be 50 to
80°F. To determine the temperature rise,
measure the supply air and return air
temperatures when the furnace has
reached steady state conditions. This is
the point at which the supply air tem-
perature stops increasing relative to the
return air temperature. The furnace may
have to run 10 to 15 minutes to reach
steady state conditions. The measure-
ments may be made with duct ther-
mometers or thermocouples used in con-
junction with multi-meters with tempera-
ture measurement capabilities.
The return air should be measured at a
point where the thermometer will be well
within the air stream near the furnace
return air inlet. Actual location is not par-
ticularly critical; however, avoid locations
where the temperature readings could be
affected by humidifier bypass ducts, the
inside radius of elbows, etc.
The supply air temperature should be
measured at a point where the ther-
mometer will be well within the air stream
near the furnace supply air outlet. Usu-
ally, the side mid-point of the supply air
plenum take-off is ideal, providing it is
out of the line of sight to the heat ex-
changer. If the thermometer is within the
line of sight of the heat exchanger, the
supply air readings may be skewed by
radiant heat from the heat exchanger. If
the plenum take-off is unsuitable, the
supply air temperature may be measured
within the first 18 inches of the first seg-
ment of supply air trunk duct.
If the temperature rise is outside the rec-
ommended range, it may be adjusted on
direct drive equipped units by selecting
alternate circulation fan motor speeds. If
the temperature rise is too high, speed
the fan up. If the temperature rise is too
low, slow the fan down.
C) Keep in mind that the stack tem-
perature varies directly with the tempera-
ture rise. The higher the temperature
rise, the higher the stack temperature will
be, resulting in lower efficiency. The
lower the temperature rise, the lower the
stack temperature will be, which, in some
cases, may allow condensation to form
in the chimney and other vent parts.
D) Test the high limit control to ensure
that it is operating correctly. This may be
done by temporarily removing the circu-
lator fan heating wire or neutral wire.
Turn off electrical power to the furnace
before working with the motor wires. Be
sure to protect any removed wires from
shorting out on metal furnace parts. If the
high limit test is successful, shut off the
electrical power to the furnace, restore
the proper motor wiring. Finally, restore
power to the furnace.
E) Operate the furnace through a
minimum of three full heating cycles.
During this time, check for fuel oil leaks,
gross air leakage from the supply air
ductwork, unusual noises originating
anywhere within the heating system
which may cause some concern or an-
noyance to the home owner, etc.
F) Be sure that the homeowner is fa-
miliar with the furnace. The homeowner
should be aware of the location of elec-
trical circuit breaker or fuse, the location
of any electrical switches controlling the
furnace, the location of the oil tank shut-
off valve and how to operate the valve.
The homeowner should be informed
where the oil tank gauge is located and
how to read it.
It would be beneficial to review safety
issues with the home owner, such as the
danger of storing combustibles too close
to the furnace, hanging anything on the
furnace vent pipe, and especially the
dangers of indiscriminately pressing the
burner reset button.
IMPORTANT: Be sure that the home
owner knows where the burner reset
switch is located, and is aware that the
reset switch is not to be activated more
than once without a thorough look for the
cause of the problem, (lack of fuel, etc.).
Be sure that the homeowner knows
when to quit trying to start the furnace
during these conditions and who to call
for emergency service.
MAINTENANCE AND SERVICE
A: Routine Maintenance By Home
Owner
Other than remembering to arrange for
the annual professional servicing of the
furnace by the service or installation con-
tractor, the most important routine ser-
vice performed by the homeowner is to
maintain the air filter or filters. A dirty
filter can cause the furnace to over-heat,
fail to maintain indoor temperature during
cold weather, increase fuel consumption
and cause component failure.
The furnace filter(s) should be inspected,
cleaned or replaced monthly. The fur-
nace is factory equipped with a semi-
permanent type filter. If the filter is dam-
aged, replace with filters of the same
size and type.
During the routine service, inspect the
general condition of the furnace watching
for signs of oil leaks in the vicinity of the
oil burner, soot forming on any external
part of the furnace, soot forming around
the joints in the vent pipe, etc. If any of
these conditions are present, please
advise your service or installation con-
tractor.
B: Annual Service By Contractor
ACAUTION
THE COMBUSTION CHAMBER (FIRE-
POT) IS FRAGILE. USE CARE WHEN
INSPECTING AND CLEANING THIS
AREA.
The heat exchanger should be inspected
periodically and cleaned if necessary. If
cleaning is necessary, SHUT OFF
POWER TO THE FURNACE and te-
move the burner. Using a stiff brush with
a wire handle, brush off scale and soot
from inside the drum and flue pipe. To
clean the radiator, remove the round
cover or covers on the inner radiator
access pipes located on the front panel
between the oil burner and the flue pipe.
Rear breech models have a single front
cleanout and front breech models have
two front cleanouts.
A wire brush can be used to loosen dirt
and debris on the inside surfaces of the
radiator. Clean out all accumulated dirt,
soot and debris with a wire handled
brush and an industrial vacuum cleaner.
Replace the clean-out covers.
Most circulating fan motors are perma-
nently lubricated by the motor manufac-
turer. These motors will have no oil
ports. If the blower motor does contain
oil ports, under normal operating condi-
tions it will not require oiling for the first
two years. Oil sparingly; a few drops in
each oil port with SAE 20 non-detergent
oil. Oiling is most easily done with a
"tele-spout" oiler. This oiler has a long

flexible plastic spout. DO NOT OVER-
LUBRICATE. Excess oil may result in
premature electric motor failure.
Inspect the blower fan. Clean it if neces-
sary.
Oil Burner Maintenance: Follow the in-
structions of the oil burner manufacturer.
(See oil burner manufacturer's instruc-
tions supplied with furnace). The oil
burner nozzle should be replaced annu-
ally. We recommend that the oil filter be
changed on an annual basis.
The venting system should be cleaned
and inspected for signs of deterioration.
Replace pitted or perforated vent pipe
and fittings. The barometric draft regula-
tor should open and close freely.
All electrical connections should be
checked to ensure tight connections.
Safety controls such as the high limit
controls should be tested for functional-
ity. The fan control functions should be
checked to ensure that all fan speeds
are operating properly.
OPERATING INSTRUCTIONS
Before Lighting
Open all supply and return air registers
and grilles.
Open all valves in oil pipes.
Turn on electric power supply
To Light Unit
Set the thermostat above room tempera-
ture to call for heat. The burner should
start. NOTE: It may be necessary to
press the RESET button on the primary
combustion control relay.
There will be a fan on time delay before
the circulating fan is energized. The
Honeywell ST9103 has a fixed fan delay
on time of 30 seconds after the burner
ignites. The United Technologies 1158-
120 has an adjustable fan on time that is
set by selecting the dipswitch combina-
tion displayed in Chart 1. This fan on
delay can be set at 30, 60, 90 or 120
seconds.
Set the thermostat below room tempera-
ture. The oil burner should stop.
The air circulation blower will continue to
run until the time off setting selected on
the electronic fan timer control times out.
The Honeywell ST9103 has an adjust-
able fan off time of 60, 90, 120 and 150
seconds that is set by selecting a dip-
switch combination on the control board.
Similarly the United Technologies
1158-120 has an adjustable fan off time
of 2, 3, 4 or 6 minutes The fan timer con-
trol adjustments may be altered if the air
at the room registers is uncomfortably
high upon blower start up or shutdown.
The necessary adjustments to the fan
control settings should be determined by
measuring the temperature of the air in
the supply air take-off, or within the first
few inches of the supply air trunk. The
side mid point of the transition is usually
ideal, providing that the thermometer
probe is beyond the "line of sight"
wherein false readings from radiant heat
could be observed. The system tempera-
ture rise, the difference in temperature
between the supply air and return air, will
typically range between 65°F and 70°F.
To check the operation of the limit
switch, shut off power to the furnace.
Temporarily remove the neutral wire
from the direct drive blower motor. Re-
store the electrical power to the furnace
and set the thermostat above room tem-
perature. After three or four minutes of
burner operation, the limit control should
turn the burner off. When the limit func-
tion test is complete, shut off electrical
power to the furnace, replace the neutral
wire to the blower fan motor, and then
restore power. The blower fan will start
up immediately. Once the temperature
has dropped and the limit control has
reset, the fan will operate until the fan off
time is achieved. The oil burner will then
resume operation and continue until the
thermostat is satisfied. Restore the ther-
mostat setting to a comfortable tempera-
ture.
To Shut Down Unit
Set the thermostat to the lowest possible
setting.
Set the manual switch (if installed) in the
Electrical Power Supply Line to "OFF".
NOTE: If the furnace is to be shut down
for an extended period of time, close the
oil supply valve to the oil burner.
AWARNING
DO NOT ATTEMPT TO START THE
BURNER WHEN EXCESS OIL HAS
ACCUMULATED, WHEN THE FUR-
NACE IS FULL OF VAPOUR, OR
WHEN THE COMBUSTION CHAMBER
IS VERY HOT. NEVER BURN GAR-
BAGE OR PAPER IN THE FURNACE,
AND NEVER LEAVE PAPER OR RAGS
AROUND THE UNIT.

APPENDIX A- 04MD-091A-12-FA AND 04MD-140A-16-FA BURNER SET UP
04MD-091A-12-FA AND 04MD-140A-16-FA furnaces may be used with the following oil burners.
Please note: The Beckett AF oil burners are for applications using indoor air for combustion only.
Table A-1 Beckett AF Oil Burner Set-Up
Beckett AF Series Oil Burners
(For use with chimney vented units only)
Furnace Model ort praia Nozzle Pee Flow Rate Head ' Sate
04MD-091A-12-FA * 58,000 AF76BNHS 0.50 / 80°A 100 Psic 0.50 USGPH F3 3- % in.
04MD-091 A-12-FA 75,000 AF76BNHS 0.65 / 80°A 100 Psic 0.65 USGPH F3 3- % in.
04MD-091 A-12-FA 85,600 AF76BNHS 0.75 / 80°A 100 Psic 0.75 USGPH F3 3- % in.
04MD-140A-16-FA 85,500 AF76XN 0.75 / 80°A 100 Psic 0.75 USGPH F3 2- %in.
04MD-140A-16-FA 96,000 AF76XN 0.85 / 80°A 100 Psic 0.85 USGPH F3 2- %in.
04MD-140A-16-FA 112,000 AF76XN 1.00 / 60°A 100 Psic 1.00 USGPH F3 2- %in.
04MD-140A-16-FA 123,000 AF76YB 1.10/70°A 100 Psic 1.10 USGPH F6 2- %in.
T Head is shielded by ceramic insulator. ° Low Firing Rate Baffle required when using a 0.50-gallon nozzle.
A.1 OIL BURNER AIR ADJUST-
MENT
For complete details, consult the oil
burner instruction manual provided in
the furnace documents envelope.
Beckett AF Burner
Adjust the air shutter by loosening the
locking screws and moving the air shut-
ter, and if necessary, the bulk air band.
A.2 BURNER ELECTRODES
Adjustment of the electrode tips with
respect to each other, the nozzle, and
to the rest of the burner is very impor-
tant to ensure smooih start-ups and to
permit efficient combustion.
Beckett AF Burner
Electrode gap: 5/32 inch.
Distance above horizontal centerline:
5/16 inch. Older instruction sheets
specify 7/16 inch. The current specifi-
cation is 5/16 inch.
Distance ahead of nozzle: 1/16 inch.
“Z’ dimension, the distance from the
front of the end cone (head) to the face
of the nozzle should be 1-1/8 inches. If
a ceramic head is used, the distance
from the end cone to the nozzle face is
increased to 1-3/8 inches.
A.3 START UP
The furnace should be operated for a
minimum of 15 minutes to reach steady
state conditions before fine tuning
combustion. The warm up time is ideal
for testing the oil pump pressure.
Drill a 1/4-inch test port in the venting
between the furnace flue outlet and
draft regulator (barometric damper).
Insert a stack thermometer and noite
the flue gas temperature. The flue
gases should be within a range of
350°F to 450°F. If the flue gases are
below the range, it may be necessary
to slow down the blower fan. If the flue
gases are above the range, the blower
fan may require speeding up. Stack
temperature varies directly with the
system temperature rise. System tem-
perature rise is the difference between
the furnace outlet temperature and
furnace inlet temperature as measured
in the vicinity of the connection be-
tween the plenum take-offs and the
trunk ducts.
Perform a smoke spot test. The smoke
spot should not exceed No. 1 on the
Bacharach Scale.
After the air adjustments have been
completed, re-check the draft pressure
at the test port on the burner mounting
plate as shown in Figure #6. The draft
should be adjusted to 0.02 inches w.c.
In the United States, the Beckett AF
Burner may be equipped with Beckett's
"Inlet Air Shut-Off’ to increase effi-
ciency. (Beckett Part No. AF/A 5861).
NOTE: USE OF THE INLET AIR
SHUT-OFF COULD CAUSE POST
COMBUSTION NOZZLE DRIP.

Table A-6 Direct Drive Blower Set-Up
Blower Set-Up Cooling Capacity
Furnace Model - :
Blower 0.20 in. w.c. 0.50 in. w.c.
Output Tons Power CFM Range
Speed Motor Speed Motor
rene
GT10
DD
Low
Ye
HP
Med-Low
Ye
HP
3
“a
HP
763
—
1505
reianie
GT10
DD
Med-Low
Ye
HP
Med-High
Ye
HP
3
“a
HP
763
—
1505
ecco
GT10
DD
Med-High
Ye
HP
High
%
HP
3
“HP
763
—
1505
sesso
SFA
|
GT12-40DD
Low
%
HP
Med-High
%
HP
4
va
HP
1365
—
1823
se
sooo
SFA
|
GT12-40DD
Med-High
%
HP
High
%
HP
4
va
HP
1365
—
1823
sane
to
oto
SFA
|
GT12-40DD
High
%
HP
High
%
HP
4
%
HP
1365
~
1823
cae
osoao
|
GT12-100D
High
%
HP
High
%
HP
4
“HP
1365
—
1823

Table A-8 Direct Drive Blower Characteristics
CFM
Furnace Model Blower | Motor HP | Motor FLA AT Speed External Static Pressure — Inches w.c.
0.20 0.30 0.40 0.50 0.60
LOW 813 813 797 763 690
- -12- MED-LOW 1170 1144 1118 1063 1005
04MD-091A-12-FA GT10 % HP 7.0 45-75°F
58 - 85 MED-HIGH 1423 1381 1291 1220 1144
HIGH 1505 1444 1359 1291 1196
LOW 1535 1494 1456 1406 1346
- -6- _ MED-LOW
04MD-140A-16-FA G12 HP 425 50-80°F 1648 1604 1542 1486 1438
85-123 MED-HIGH 1747 1689 1630 1569 1495
HIGH 1833 1786 1722 1656 1568
TIP:
These Formulae will assist with the design of the ductwork and the determination of airflow delivery:
Bonnet Output / _ Bonnet Output
= ; ; System Temperature Rise=——————_
(1.085. System Temperature Rise) (1.085. CFM )

Table A-9 General Dimensions (Inches)
Cabinet Plenum Openings Flue Di- Filter
Furnace ; ; Shipping
ameter .
Model Width Depth Height Supply Return H Type Size Weight
A B c DxE Side | Bottom
areal 22 22-1/8 55-1/4 19x 19 14 x 22 18x18 5 Permanent 16x 25x 1 265
04MD-140A- 22-1/4 22-1/4 62 20-1/2 x 20- 18x18 18 x 18 6 Permanent 20x 20x 1 292
16-FA 1/2
04MD-091A-12-FA & 04MD-140A-16-FADown flow
A B
04MD-091A-12-FA & 04MD-140A-16-FA Horizontal
| [_]
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j
c i
| . .
Pe !
EB
|

APPENDIX B: WIRING DIAGRAMS
Beckett AF Burner Wiring Diagram
I TERMINAL PROVIDED
PERMINAL NUT PROIVIDEL
Aa? MIENALY
| [
BURNER MU

OPERATION OF OIL BURNER
Once the furnace flue pipe, electrical
and oil line connections have been
made, use the following instructions to
set the burner:
Shut off the electrical power to the fur-
nace.
Install an oil pressure gauge to the
pressure port on the oil pump. (Refer to
the oil pump specification sheet in-
cluded with the burner instructions).
Restore electrical power to the furnace.
Start the furnace and bleed all air from
the fuel oil lines.
Close the purge valve and fire the unit.
Allow the furnace to warm up to normal
operating temperatures. During this
time, set the pump pressure in accor-
dance with the data provided in Appen-
dix A, Table A-1, and A-2.
When the furnace has reached "steady
state" (after approximately 15 minutes).
Set combustion air damper to get a
TRACE of smoke.
Check the system temperature rise.
The temperature rise is the difference
between the return air temperature
measured at a point near the return air
inlet, and the supply air temperature
measured near the furnace outlet. If the
temperature rise is too high, the airflow
must be increased. If the temperature
rise is too low, the fan should be
slowed down.
Turn off the burner. Observing the duct
thermometer in the supply air stream,
note the temperature at which the
blower fan stops. The fan adjustments
can be made by moving the dipswitch
settings on the timer control board for
fan off delay.
To check the operation of the limit
switch, shut off power to the furnace.
Temporarily remove the neutral wire
from the direct drive blower motor. Re-
store the electrical power to the furnace
and set the thermostat above room
temperature. After three or four minutes
of burner operation, the limit control
should turn the burner off. When the
limit function test is complete, shut off
electrical power to the furnace, replace
the neutral wire to the blower fan mo-
tor, and then restore power. The blower
fan will start up immediately. Once the
temperature has dropped and the limit
control has reset, the fan will operate
until the fan off time is achieved. The oil
burner will then resume operation and
continue until the thermostat is satis-
fied. Restore the thermostat setting toa
comfortable temperature.
Set the heat anticipator adjustment in
the thermostat (if so equipped), by re-
moving the "R" or "W" wire to the ther-
mostat, then reading the amperage
draw between the two wires. Failure to
remove one of the wires from the ther-
mostat while performing this test could
burn out the heat anticipator. Set the
heat anticipator to the amperage
measured.
NOTE: THE FURNACE SHOULD BE
RUN THROUGH AT LEAST THREE
FULL CYCLES BEFORE LEAVING
THE INSTALLATION, TO ENSURE
THAT ALL CONTROLS ARE OPER-
ATING PROPERLY AND AS EX-
PECTED.
NOTE: ALL JOINTS IN ANY POSI-
TIVE PRESSURE VENTING SYSTEM
MUST BE CHECKED FOR LEAKS
BEFORE LEAVING THE INSTALLA-
TION SITE.

APPENDIX C-R7184 TROUBLESHOOTING
R7184 DETAILED SEQUENCE OF OPERATION (FIGURE 7)
Power is applied to unit. The R7184 completes a self-diagnostic procedure. If no light or flame is present, and unit
passes its self-diagnostic procedure, the control enters into the idle mode.
Thermostat calls for heat:
A) Safety check is made for flame (4 second delay).
1) If flame is not present, the R7184 will apply power to the burner motor and igniter.
2) If flame is present, the control remains in the idle state.
B) Unit enters a pre-purge period of 15 seconds.
C) After 10 seconds, control checks for flame presence.
1) If flame is not present, the R7184 enters the trial for ignition state.
2) When flame is present, the control enters lock out mode.
D) Control monitors the burner flame.
1) When flame is present, the control enters ignition carryover state. (Continues to spark for 10 sec.).
a) Provides continuous spark after flame is sensed to assure that burner remains lit.
b) Turns on LED diagnostic light.
c) Starts carryover timer.
(i) Flame and call for heat are monitored.
e If flame is lost and lockout timer has not expired, R7184 will return to trial for ignition state.
e = If flame is lost and lockout timer has expired, R7184 will enter the recycle state.
# Recycle timer starts.
¢ Burner motor and igniter and solenoid valve are turned off.
¢ LED diagnostic light flashes slowly.
E) Carryover timer expires.
1) Enters run state.
a) Igniter turns off.
Combustion continues until thermostat is satisfied, or R7184 detects a loss of flame and enters into Recycle Mode.
F) Thermostat is satisfied - call for heat is terminated:
a) R7184 shuts off burner motor and solenoid valve.
(i) lf control utilizes a blower motor off delay, after 30 seconds, flame presence is checked.
e = If flame is not present, the R7184 LED diagnostic light is off and returns to idle state.
e = If flame is presence is detected, the control enters lock out mode.

R7184 INTERRUPTED ELECTRONIC OIL PRIMARY CONTROL
FIGURE 7
annie
ee
ot ares
ee
ELECTRONIC FAN TIMER BOARD ON CONTROL PANEL
FIGURE 8
a i Lecce
i
TT