Thermo Products Spirit Series Setup guide

MO-525 Made in USA
ECN 5635-MA 200715
OIL-FIRED CENTRAL FURNACE
Installation, Operation, and Service Manual
ith Users Information Section
Models:
VHF-ABP VHF-ABT VHF-ACP VHF-ACT
c ARNING: IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTL , A FIRE OR
EXPLOSION MA RESULT CAUSING PROPERT DAMAGE, PERSONAL INJUR , OR LOSS OF LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINIT OF
THIS OR AN OTHER APPLIANCE.
c ARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN
CAUSE INJUR OR PROPERT DAMAGE. REFER TO THIS MANUAL. FOR ASSISTANCE OR ADDITIONAL
INFORMATION CONSULT A QUALIFIED INSTALLER, OR SERVICE AGENC .
c AVERTISSEMENT: SI L'INFORMATION DANS CES INSTRUCTIONS N'EST PAS SUIVI À LA LETTRE, UN
INCENDIE OU UNE EXPLOSION ENTRAÎNANT DES DOMMAGES MATÉRIELS, DES BLESSURES
CORPORELLES OU DES PERTES DE VIE.
NE PAS ENTREPOSER NI UTILISER D'ESSENCE OU AUTRES VAPEURS ET LIQUIDES INFLAMMABLES À
PROXIMITÉ DE CET APPAREIL OU DE TOUT AUTRE APPAREIL.
c AVERTISSEMENT: UNE MAUVAISE INSTALLATION, D'AJUSTEMENT, DE LA MODIFICATION,
D'ENTRETIEN OU DE MAINTENANCE PEUVENT CAUSER DES BLESSURES OU DOMMAGES MATÉRIELS,
REPORTEZ-VOUS À CE MANUEL POUR OBTENIR DE L'AIDE OU DES RENSEIGNEMENTS
SUPPLÉMENTAIRES, CONSULTER UN INSTALLATEUR QUALIFIÉ, OU ORGANISME DE SERVICE.
PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE
PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT ITH THE USER
AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.
VEUILLEZ LIRE CES INSTRUCTIONS AVANT L'INSTALLATION, LES PREMIERS TIRS, ET AVANT
D'EFFECTUER TOUT ENTRETIEN OU MAINTENANCE. CES INSTRUCTIONS DOIVENT ÊTRE LAISSÉS AVEC
L'UTILISATEUR ET DEVRAIT ÊTRE CONSERVÉ POUR RÉFÉRENCE FUTURE PAR UN TECHNICIEN
QUALIFIÉ.
THERMO PRODUCTS, LLC.
PO BOX 237
DENTON, NC 27239
PHONE: [phone]

1
Contents
SECTION PAGE
Notice to the Installer .................................................................................................. 3
INSTALLATION GUIDELINES ...................................................................................... 4
Codes ................................................................................................................. 4
Installation Location ............................................................................................ 4
Closet and Alcove Installation ............................................................................. 4
Standard Clearances .......................................................................................... 5
Air for Combustion and Ventilation ..................................................................... 5
Chimney Inspection ............................................................................................ 7
Flue / Chimney / Vent Connector ........................................................................ 8
Draft Regulator ……………………………………………………………………….. 8
Direct Venting ..................................................................................................... 8
Power (Side-Wall) Venting – Important Note Regarding ..................................... 9
Duct Work and Air Conditioning .......................................................................... 10
Air Filter Mounting ............................................................................................... 10
Electrical Connections ........................................................................................ 11
Room Thermostat ............................................................................................... 11
Combustion Chamber ......................................................................................... 11
Oil Burner and Oil Nozzle Installation .................................................................. 12
Fuel System Installation ....................................................................................... 13
INITIAL OPERATION OF THE FURNACE .................................................................... 14
Initial Burner Operation ....................................................................................... 14
Supply/Return Airflow and Air Temperature ........................................................ 14
Furnace Limit and Blower Controls ..................................................................... 15
Instructions to Our Customer / End User ............................................................. 15
SERVICE ....................................................................................................................... 16
Troubleshooting .................................................................................................. 16
Flame Sensor (“Cad Cell”) Checkout Procedure ................................................ 18
Replacement Parts ............................................................................................. 18
MAINTENANCE ............................................................................................................. 18
Air Filter(s) ........................................................................................................... 18
Oil Burner ............................................................................................................ 19
Blower and Motor ................................................................................................ 19
Heat Exchanger .................................................................................................. 19
Flue and Chimney ............................................................................................... 20
USERS INFORMATION ................................................................................................. 20
Operating Instructions ........................................................................................ 21
Oil Supply ........................................................................................................... 21
Extended Shutdown ........................................................................................... 22
Combustion Air and Ventilation Supply ................................................................ 22
Inspection Areas ................................................................................................. 22

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APPENDIX A: START-UP DATA SHEET ..................................................................... 24
APPENDIX B: ELECTRICAL DIAGRAMS ..................................................................... 25
APPENDIX C: SPECIFICATION SHEETS .................................................................... 27
APPENDIX D: REPLACEMENT PARTS ....................................................................... 28

3
Notice to the Installer
Installation of this oil-fired furnace must be performed by a qualified installer in accordance with
all local codes and authorities having jurisdiction. In the absence of local governing codes,
installation shall conform to these instructions and to the regulations of the National Fire
Protection Association’s Standard for the Installation of Oil-Burning Equipment, NFPA 31-2020,
and the National Electrical Code, ANSI/NFPA 70-2017, or the latest editions thereof.
A qualified installer, also referred to in this instruction manual as a “qualified heating
contractor”, is an individual, or agency, properly licensed and experienced to install and
service oil-burning equipment in accordance with all local codes and ordinances.
Material and orkmanship
This furnace was built with the highest quality materials and attention to workmanship.
However, omissions and defects occasionally occur. Before installing the furnace, inspect
the furnace thoroughly. If missing parts, defective material, or poor workmanship is
evident, report the model and serial numbers imprinted on the furnace rating label to
the seller for adjustment.
Packaging
A complete furnace is contained within a single package. The factory completed all
feasible assembly. However certain components including draft regulator and, if supplied,
door handle, air filter(s), and air filter rack(s), must be assembled to the furnace, or the
venting system, in the field. Refer to the assembly instructions.
Shipping Damage
If this furnace was damaged during transit, please immediately request the transportation
company inspect the furnace and issue a concealed damage report. The party
receiving the furnace should file the claim for shipping damage. Report any shipping
damage immediately.
It is absolutely essential that a damage report be obtained. If a concealed damage report
is not obtained, we cannot provide assistance in recovering your claim against the
transportation company.
arranties
c ARNING: The manufacturer of this equipment assumes no liability for any
damages resulting from unauthorized modifications made to the furnace, or any
components thereof, or improper installation of the furnace in the field.
Furthermore, any such field modifications VOID THE ARRANTY and place
responsibility for safe and reliable operation of the furnace on those who
performed the modification(s).
Complete and return any enclosed warranty cards. These must be on file to verify
installation dates for replacement of any warrantied part(s).

4
INSTALLATION GUIDELINES
Codes
All local codes and regulations take precedence over the instructions in this manual and
shall be followed accordingly. In the absence of local codes, this installation must
conform to these instructions and to the regulations of the National Fire Protection
Association (NFPA) publications, the Standard for the Installation of Oil-Burning
Equipment, NFPA 31-2020, and the National Electrical Code, ANSI/NFPA 70-2017 or the
latest editions thereof,
Installation Location
c ARNING:
 These furnaces are designed for indoor installation ONLY.
 These furnaces are NOT to be used as construction heaters.
 DO NOT hang the horizontal / counterflow furnace from a structure, or
surface, by any integral part or fastener of the furnace. The furnace was
not designed to support itself in this manner.
In as much as practical, the furnace should be positioned near a chimney or vent and
should be centralized with respect to the air distribution system.
For a utility room installation, the entrance door must be wide enough to permit the
largest part of the furnace to pass through the doorway or allow sufficient clearance to
permit the replacement of another appliance, e.g. a water heater, in the room.
If the furnace is installed in a residential garage, it must be installed so the burner is
located higher than 18 inches above the floor, unless the required combustion air is taken
from the exterior of the garage. Also, the furnace must be located or protected to avoid
physical damage from impacts by vehicles.
It is recommended that a commercially available CO alarm be installed in conjunction
with any fossil fuel burning appliance. The CO alarm shall be installed according to the
alarm manufacturer’s installation instructions and be listed in accordance with the latest
edition of the UL Standard for Single and Multiple Station Carbon Monoxide Alarms, UL
2034, or the CSA International Standard, Residential Carbon Monoxide Alarming
Devises, CSA 6.19.
The furnace shall not be operated in a condition where the return air is consistently below
55°F.
Closet and Alcove Installation
All furnace models are approved to be installed in a closet or alcove. Proper clearances
to combustible material and adequate supply of combustion air must be provided. See
the following sections for additional information.

5
Standard Clearances
Standard clearances are mandatory minimum clearances from heated surfaces of the
furnace to combustible materials to assure protection from fire hazard during furnace
operation. (Refer to the Standard for the Installation of Oil-Burning Equipment, NFPA 31-
2020, or latest edition, for definitions of combustible and non-combustible materials.
Accessibility clearances, which are typically greater, may exceed fire protection
clearances. Therefore, consider providing at least 24 inches of clearance from the front of
the furnace to obstructions and surfaces for adequate service and maintenance access.
The minimum clearances from furnace casing surfaces to combustible materials are:
 0 inches from casing sides and rear
 6 inches from front casing of furnace
 7 inches from flue pipe/vent connector
 1 inches from casing top
 1 inches from any side of supply air plenum
 3 inches above supply air ducts, within 6 feet of furnace
Air for Combustion and Ventilation
c CAUTION: Relief openings in the front or top of the furnace casing should not
be obstructed or blocked. These openings supply combustion and ventilation air
to the furnace.
Chloride, fluoride, iodide, and bromide bearing compounds when present, even in low
concentrations, are in air supplied for combustion to the furnace, can result in accelerated
and severe corrosion of the heat exchanger and/or the venting system.
Often, household chemicals contain chloride-bearing compounds. There are many
compounds representative of this classification of chemicals. A few common examples
are listed below.
 Cleaning solvents
 Varnish and paint removers
 Bleaches
 Fabric softeners
 Water softener salt
 Tile adhesives
Avoid storing or using these chemicals within close proximity to the furnace. In addition,
avoid storing or using any chemicals, of an unknown and possibly flammable nature, in
close proximity to the furnace.
The furnace shall be installed in a location within the building that permits a satisfactory
supply of air for combustion, ventilation, and proper operation of the venting system.
While all forms of building construction cannot be covered in detail in this manual, this
requirement may usually be met by application of one of the following methods in

6
ordinary building construction. However, applicable local installation codes always take
precedence and shall be followed.
The content of certain pertinent passages of NFPA 31-2001 on methods to obtain and
ensure adequate airflow to the furnace has been excerpted and, in some cases,
paraphrased below for reference purposes. Consult the Standard for the Installation of
Oil-Burning Equipment, NFPA 31-2020, or latest addition for special cases and further
details.
1. Utility Room (example of a confined space)
a. In buildings of conventional construction with normal air infiltration, two (2)
permanent openings connecting to a well-ventilated crawl space, attic, or another
large, well-ventilated internal area shall be provided. Each opening shall have a
minimum free area of one (1) square inch per 1000 BTUH of total input rate (sum
of the individual appliance input rates) of all appliances to be installed in the utility
room. One opening should be located near, or in, the ceiling of the room and the
other should be located near, or in, the floor.
b. In buildings of unusually tight construction (those having 0.35 air changes per
hour, or less); provision must be made to provide sufficient air for combustion. The
following method will usually be adequate to ensure sufficient airflow into the
space.
Provide two (2) permanent openings, one (1) located within 12 inches of the floor and
one (1) within 12 inches of the ceiling, or roof, of the room. These openings shall allow for
direct exchange of air between the room and outdoors. If required, ducting between the
room and the outdoors shall be provided.
 For horizontally -oriented ducts, each opening shall have a minimum free
area of one (1) square inch per 2000 BTUH of the total input rate (sum of
the individual appliance input rates) of all appliances to be installed in the
room.
 For vertically -oriented ducts, the minimum free area may be reduced to
one (1) square inch per 4000 BTUH of the total input rate (sum of the
individual appliance input rates) of all appliances to be installed in the room.
 The minimum dimension of any air opening shall not be less than 3-inches.
 When an opening in the outside wall must be provided, it should be
furnished with properly screened metal sleeves.
2. Full Basement (example of an unconfined space)
a. Where a furnace is installed in a full basement, in a building of conventional
construction with normal air infiltration, infiltration is normally adequate to
provide air for combustion and ventilation.

7
b. In buildings of unusually tight construction (such as those where weather
stripping and storm sash windows are used, and where basement windows are
also weather-stripped), one (1) permanent opening connecting to a well-
ventilated attic, or with the outdoors shall be provided, using a duct, if
necessary. This opening shall have a minimum free area of one (1) square inch
per 5000 BTUH of total input rate (sum of the individual appliance input rates)
of all appliances to be installed in the basement.
When an opening in the outside wall must be provided, it should be furnished with
properly screened metal sleeves.
If an exhaust fan or additional air consuming machines (e.g. a cloth dryer), is present in
the furnace room, there should be increased concern about providing adequate airflow to
the furnace. Additional efforts may be required to assure an adequate supply of
combustion and ventilation air is available to the furnace under all conditions.
When needed it is possible to have combustion air connected directly to the burner of this
furnaces from the outdoors when using the one of following the following kits.
Furnace Models Combustion Air Kit
(Part #)
VHF-ABP, VHF-ABT AOPS8393
VHF-ACP, VHF-ACT AOPS8393
Table1: Approved Combustion Air Kits
Chimney Inspection
The chimney, vent, or any passageway for the stack gases to flow to the outdoor
atmosphere is a very important part of the heating system. No furnace, regardless of the
efficiency of the design, can perform satisfactorily when the chimney to which it is
connected is inadequate or in poor condition. Any of the following symptoms may indicate
a chimney has severe structural damage and is unsuitable for use.
 Chimney appears to be leaning to the side.
 Chimney appears to have structural damage, i.e. loose or missing blocks or bricks,
or excessive deterioration at mortar joints.
 Tile liner damaged or missing.
 Flue gas leakage along the length of the chimney between the chimney connector
and discharge termination.
 Excessive corrosion at the cleanout port or at the chimney connector entrance into
the chimney.
 Structural debris, i.e. mortar or tile liner flakes, in base of the flue way.
A qualified person shall inspect the chimney to confirm it is correctly sized for the
application, properly constructed, and in sound condition. Refer to the Standard for the
Installation of Oil-Burning Equipment, NFPA 31-2001, for details on proper chimney
sizing and construction. If needed, the chimney should be cleaned before installing the
furnace. Any accumulation of dirt or debris at the bottom of the flue should be removed.

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Flue / Chimney / Vent Connector
c CAUTION:
 DO NOT install a manual damper in the chimney or vent connector.
 Thermally- activated type vent dampers are NOT recommended for use on
these furnaces.
It is desirable to install the shortest vent connector (also referred to as a flue or chimney
connector) possible with the fewest number of fittings, i.e. transitions and elbows.
Generally, 5-inch diameter, 24 Ga. or heavier, single wall, lock seam-type, galvanized
steel vent pipe and fittings are satisfactory materials for the fabrication of a vent
connector. However, always consult local codes and authorities for specific minimum
requirements.
For some installations, it may be prudent to turn the furnace flue elbow 90 degrees
counterclockwise, with respect to the front of the furnace, such that the elbow is open to
the left-hand side of the unit, rather than upward. Due to the presence of the limit control
and the wiring harness, the elbow may not be rotated 90 degrees clockwise. The
installer must carefully mark and cut a hole in the furnace housing to allow the vent
connector to pass through the housing.
A trim collar may be ordered from the manufacture of this furnace to hide the gap around
the flue pipe. This trim collar, however, is not required for operation. Trim collar/gasket
part numbers(s) 14121 / 330073
All horizontal sections of the vent connector must slope upward not less than ¼ inch per
foot from the furnace to the vent termination. Long horizontal sections of the venting
system must be supported at least every five (5) feet with metal straps to prevent sagging
of the vent piping. Secure all joints in the vent connector with sheet metal screws or
equivalent fasteners. Vent piping must not be inserted beyond the inside wall of the
chimney flue.
Draft Regulator
A barometric-type, draft regulator is supplied with the furnace. Installation or operating
conditions that produce excess amounts of draft can reduce the heating efficiency of the
furnace. The purpose of the regulator is to adjust and control the flow of flue gases from
the furnace by stabilizing the amount of chimney draft to which the furnace is subjected.
Always refer to the draft regulator manufacturer’s installation instructions for application
specific recommendations.

9
Direct Venting
The VHF-A** may also be horizontally vented through a side wall. Direct venting is only
allowed when using an approved Direct Vent Termination , See Table 2, and is limited to
a maximum length of 15’.
Furnace Models DIRECT VENT
TERMINATION KIT
(Part #)
DIRECT VENT
ACCESSOR KIT
(Part #)
VHF-ABP, VHF-ABT AOPS8393 AOPS8394
VHF-ACP, VHF-ACT AOPS8393 AOPS8432
Table2: Approved Direct Vent Kits
The Direct Vent Termination kit consists of a concentric through-the-wall vent
termination/inlet air vent hood and 15’ of Stainless Steel Insulated Flexible Pipe that
requires 2” clearance to combustibles.
The vent pipe may be installed either through the upper knock-out on the left side
casing of the unit or vertically out the top opening of the vestibule. The 4” flexible vent
pipe included with the vent kit is able to be installed at 2” clearance to combustibles.
A field supplied smooth wall 4” combustion air pipe will need to be provide to connect the
combustion air from the termination hood to the burner. The accessory kit will provide the
fitting s needed to connect the 4” pipe to the burner. The combustion air inlet can be
installed through the either the lower left or right side casing knock-out.
For proper installation follow the Instruction provide with the Direct Vent Termination Kit.
Power (Side- all) Venting – Important Note Regarding
c CAUTION: Thermo Products, LLC will NOT assume responsibility for damage to,
and deterioration of, exterior building materials, e.g. brick, siding, clapboards, and
etc., in close proximity to the vent terminal due to operation of a power vented, oil
furnace. This policy is applicable regardless of the cause of sooting.
NOTICE: Thermo Products recommends the use of a chimney to vent residential
oil furnaces. If a power venter must be used, it is the responsibility of the installer
and power venter manufacturer to design, assemble, and demonstrate proper
operation of the power venting system with the furnace.

10
Duct ork and Air Conditioning
Design and installation of the duct system should follow the current guidelines of the Air
Conditioning Contractors of America (ACCA) or the American Society of Heating,
Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE). Refer to the Residential
Duct Systems, Manual D, from the ACCA, and the ASHRAE Handbook Fundamentals
volume, from ASHRAE, for recommended practices in duct system design and
installation.
All furnaces are tested over a range of external static pressure that simulates the airflow
resistance of the ductwork, fittings, and diffusers connected to the furnace for a typical
(average) duct system. The furnace blower and blower motor have been selected to work
successfully against the following range of duct system resistance.
Recommended range of the duct system external static pressure for all models: 0.2
to 0.5 in. .G...
Due to the need to maintain an adequate supply of combustion and ventilation air, the
furnace shall not be installed in small room without return air duct system. A return air
duct shall be connected to the furnace return air opening and extend to a location outside
the furnace room.
If the furnace is used in connection with a cooling coil, the coil must be installed in
parallel with, or on the supply side of the furnace to avoid water vapor condensation in
the furnace heat exchanger. If the cooling unit is installed in a parallel flow arrangement,
dampers (or other means used to control airflow) should be provided to prevent chilled air
from entering the furnace. If such a damper is manually operated, it must be equipped
with a means to prevent operation of either unit, unless the damper is placed in either the
full heat or full cool position.
NOTICE: Return air grilles and supply registers in the air distribution system
should never be obstructed.
Air Filter Mounting
On highboy furnaces, it is necessary to cut the return air opening in the side or rear
casing, depending upon the needs of the specific installation. For your convenience, (4)
locator knock-outs have been placed at the proper locations on both the left and right
side casings for the supplied filter rack. The filter rack can be fastened to the furnace with
screws or pop-rivets through the securing flange of the filter rack.

11
Electrical Connections
NOTICE: All field wiring must conform to local, state, and national installation
codes.
A disconnecting switch equipped with overcurrent protection rated at 15 A. (e.g. a time
delay-type fuse or inverse time, circuit breaker) should be installed in the service line.
Since the furnace is entirely pre-wired at the factory, it is only necessary to connect the
building electrical service lines to the two (2) pigtail wires extending from the junction box.
The junction box is mounted inside the furnace burner compartment or mounted on the
front exterior of the furnace, in the case of the horizontal / counterflow model. A ground
connection must also be made in the junction box. The service lines to the furnace
should be no smaller than 14 Ga., insulated copper wire with a temperature rating of
60ºC, or greater.
Refer to the electrical diagrams contained in Appendix B of this manual for an electrical
schematic, a connection diagram, and operating instructions.
Room Thermostat
A room thermostat must be connected to the Oil Furnace control. This is typically a low
voltage (24 VAC) circuit. Consult the National Electrical Code, ANSI/NFPA 70-2017, or
latest edition for guidelines for proper wiring methods and materials for this circuit. The
room thermostat should be located on an interior wall in the natural circulating path of the
room air.
The thermostat should not be installed in a location where it is directly exposed to,
 cold air infiltration, i.e. drafts from outside openings such as windows and doors,
 air currents produced by supply air registers, and
 heat from a nearby source, such as a fireplace, electrical appliances, lamps, solar
radiation, a wall enclosing warm air ducts, a chimney, or a flue gas vent.
Most room thermostats are equipped with an adjustable heat anticipator, set the
thermostat heat anticipator to match the control current of the furnace as indicted on the
furnace wiring diagram.
Combustion Chamber
The furnace combustion chamber is a hollow, circular cylinder sealed at the bottom end
and open at the top end. The chamber is made of a lightweight, insulating, “soft”,
refractory material. The refractory material is composed of organically bound, alumina-
silica fibers that protect the heat exchanger from the intense heat of the oil burner. A
chamber retainer is used to hold the chamber in place, do not remove or put the furnace
into operation without it.

12
Oil Burner and Oil Nozzle Installation
c CAUTION: This oil furnace is designed to use No. 2 or lighter distillate fuel
(home heating) oil. A Bio-fuel mixture may be used but the mixture is not to exceed
a B5.
This furnace is designed to utilize the following specially modified, oil burner:
 R.W. Beckett Corp. model AFG burner, specification # EFL-201
 Carlin Combustion Technology, Inc. model EZ-1HP, specification 99032B-1
NOTICE: NO other burners may be used in this application.
The heat output from the furnace is fixed, based on the size of nozzle installed in the oil
burner. Three (3) heat input rates are permissible: 70,000, 85,000, and 106,250 BTUH.
Nozzle selection (i.e. heating capacity of the furnace) shall be based on a rate of heat
loss (heating load) calculation for the building. These calculations should be 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).
Refer to the Residential Load Calculation, Manual J, from the ACCA, and the ASHRAE
Handbook Fundamentals volume, from ASHRAE, for the recommended procedure to
compute the design heating load of a residence.
The oil burner was installed in the furnace at the factory. In the field, if it is necessary to
adjust the heating capacity of the furnace by changing the oil burner nozzle, refer to the
oil burner manufacturer’s operating instructions (included with the furnace) for detailed
instructions on this procedure.
The furnace may have been handled roughly while in transit. Under some conditions, the
combustion chamber can shift out of position. A chamber retainer is used to hold the
chamber in place, do not remove or put the furnace into operation without it (see
Appendix D). Check for proper alignment of the burner air tube with the circular opening
in the combustion chamber and trial fit the burner to check the insertion depth of the oil
burner into the combustion chamber.
The end of the burner air tube should be inserted no farther than 1/4 inch back from the
inside surface of the combustion chamber, refer to Figure 1. Do not allow the burner
tube/end cone to physically touch or protrude into the chamber. High temperatures in the
combustion chamber can result in damage to the tube, the end cone, or both. A distance
greater than 1/4 inch back from the inside chamber wall may cause flame impingement
on the combustion chamber wall and subsequent sooting or carbon char buildup.

13
Figure 1: Side view of correct burner insertion into combustion chamber
The oil burner provided with this furnace requires initial inspection, set-up, and proper
adjustment. Refer to this manual and the oil burner manufacturer’s operating instructions
for detailed information on the following items.
 Initial firing of burner
 Adjusting the burner combustion air
 Adjusting the fuel pump pressure
 Setting the draft control
NOTICE: This oil furnace must be installed and adjusted by only qualified oil
heating contractor using calibrated combustion test instruments to ensure safe
and reliable operation of the furnace.
Fuel System Installation
In situations where the oil storage tank is installed at the same level with, or above, the
burner, a single oil supply line run from the oil tank to the burner will be usually be
adequate. No return line will be required. If the oil tank is installed below the burner and
the lift exceeds approximately 6-ft., an oil supply line and an oil return line are
recommended.
Refer to the Standard for the Installation of Oil-Burning Equipment, NFPA 31-2020, or
latest edition and the oil burner operating instructions for detailed information on oil
storage tank & oil supply/return line installation.
NOTICE: e recommend installing a high efficiency oil filter, in the oil supply line,
capable of filtering 10 to 20 micron diameter (or preferably smaller) particles from
the fuel

14
Initial Operation of Furnace
Initial Burner Operation:
c IMPORTANT: The start-up sheet found in Appendix A of this manual should be completed.
1. Turn the electrical disconnecting switch to the “OFF” position.
2. Set the room thermostat above room temperature.
3. Be sure the oil tank is full of clean # 2 fuel oil.
4. Open all shutoff valves in the oil line.
5. Refer to the oil burner manufacturer’s operating instructions (included with the
furnace) for detailed startup instructions
6. Measure the oil pump pressure. If required, adjust it to deliver the appropriate
pressure for the burner. The oil pump should be set to produce,
 130 PSIG, for the R.W. Beckett model AFG burner
 140 PSIG, for the Carlin Combustion Technology model EZ-1HP
7. Carbon Dioxide (CO2) and Carbon Monoxide (CO) – In order to assure that
proper and safe combustion are taking place, carbon dioxide and carbon
monoxide measurements must be taken. A CO2 reading within the limits of
appendix C with no measurable CO is desirable. The maximum acceptable CO
reading is about 50 PPM. If the CO reading is too high, open the burner air
shutter, or air band, slightly to permit more combustion air to the flame.
Recheck the CO level and adjust as required.
8. Draft – Draft measurements should be taken through the overfire port and in
the vent connector, not more than 12 inches away from the furnace outlet. A
5/16 in. hex washer head bolt plugs the overfire port in the burner mounting
plate. Remove the bolt and insert a suitable draft measurement gage.
9. Flue Gas Temperature – The flue gas temperature will vary depending on heat
input rate, air temperature rise across the heat exchanger, and air flowrate
through the furnace. To prevent excessive water vapor condensation from the
flue gases, the gross flue gas temperature should not fall below 330ºF. In
addition, if the gross flue gas temperature exceeds 650ºF, the heating
efficiency of the furnace will be reduced.
10. Cycle the furnace several times to verify the burner lights off and shuts down
smoothly without excessive noise or smoke production.
Supply/Return Airflow and Air Temperature
The supply/return airflow shall be set to obtain an air temperature rise, across the
furnace, in the range of 55º to 85ºF for all models. Since the flow resistance of each duct
system is slightly different, the airflow (fan speed) may have to be changed in the field to
achieve a satisfactory temperature rise.
The blower (fan) speed is adjusted by changing the fan motor winding energized by the
control system. Refer to furnace wiring diagram, Appendix B. To adjust the fan speed,
follow this procedure.
a. Turn off all electrical power to the furnace at the disconnecting switch.

15
b. Remove the blower compartment access door on the counterflow/horizontal
furnace.
c. The “Heat” tab is the connection for the heating speed activation thru the fan
board. If a change in heating speed is desired simply pull the wire from the heat
tab and replace it with the desired motor speed wire. The Black (High) is
connected to the “cool” tab for A/C speed operation. If a lower speed is desired for
A/C, the speed is charged the same way. A tab marked “Low” is populated with a
lower fan speed for continuous fan operation thru the “G” circuit of your T-stat.
Unused blower speeds are connected to the “unused motor leads” tabs at bottom
right of fan board.
d. Replace the blower compartment access door.
e. Restore electrical power to the furnace at the disconnecting switch.
f. Recheck Temperature rise and adjust if needed.
Furnace Limit and Blower Controls
The control also has diagnostic features. A green light will illuminate under the
thermostat terminal that is being activated. Also any time the board receives a call from
the thermostat a red light near the center of control will illuminate.
If a limit switch opens the red light will flash, power will be interrupted to the Buner and
the circulating air blower will be energized. The blower will continue to run and the burner
will remain de-energized until the limit closes and the blower off delay expires.
! ARNING: The predetermined limit locations on all of the Spirit oil fired furnaces
have been tested and approved by Thermo Products, LLC. Any attempt to relocate
these safety controls or replace these safety controls with a control that is not
approved, or is incompatible, may result in personal injury, substantial property
damage or death.
Instructions to Our Customer / End User
! ARNING: If the burner does not operate properly after depressing the oil
primary reset button, turn off the electrical power to the furnace and close the
manual oil shutoff valve. Immediately contact a qualified heating contractor for
service.
Before leaving a new installation, the installer should show the customer or end user
where the furnace instruction manual is kept. He should also discuss the following points:
1) Describe the general operation of the furnace and, if properly equipped, the
cooling system.
2) Show the location of the furnace air filter(s) and those in the duct system, if
equipped. Demonstrate how to remove, clean, and replace the air filter(s).
3) Demonstrate how to set and adjust the room air temperature using the room
thermostat.
4) Demonstrate how to operate (turn on and off), the heating system and, if properly
equipped, the cooling system and the circulating air blower.
5) Show the location of the oil primary safety control in the furnace. Describe when
and demonstrate how to depress the oil primary reset button.

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SERVICE
Troubleshooting
c ARNING: hen testing electrical equipment, always follow standard electrical
safety procedures.
Before beginning these troubleshooting procedures, always review these basic points.
1) Check for 120 VAC power to the furnace. If there is no voltage, check the
disconnecting switch for circuit breaker trip or blown fuses.
2) Make sure the room thermostat is set on the heating mode and is “calling for heat”.
3) Check for sufficient oil supply and that all oil shutoff valves are open.
4) To successfully service this oil furnace, the following recently (within the last year)
calibrated instruments must be available.
 Smoke spot test kit with Bacharach-type oil burner smoke scale
 Carbon dioxide (CO2) and carbon monoxide (CO) test kit or analyzer
 Flue gas temperature measuring instrument
 Draft gauge, capable of measuring 0.01 to 0.25 in. W.G. draft
 Multimeter (analog or digital type)
 Oil pressure gauge, capable of measuring at least 0 to 200 PSIG
5) Be familiar with the correct operation of these instruments as well as how to adjust
the oil burner settings (refer to burner manufacturer’s literature).
A. Symptom: Furnace does not operate.
Items to check:
c ARNING: Repeated operation of the oil primary safety control reset
button can cause a build-up of unburned oil in the combustion chamber. An
accumulation of oil in the combustion chamber is a hazardous situation and
may cause a fire or explosion.
1) Make sure the disconnecting switch is “ON” and the circuit breaker has
not tripped, or fuses have not blown.
2) Confirm there is 120 VAC at the junction box and the oil furnace control
terminal S1.
3) Confirm the room thermostat is wired correctly, set on the “HEAT” mode,
and “calling for heat”.
4) Refer to the oil burner manufacturer’s operating instructions (included
with the furnace) for primary control troubleshooting
B. Symptom: Burner short cycles on high limit thermostat, but does not “lock out”
on oil primary safety control.

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Items to check:
1) Open dampers or registers in the air distribution system. Clear any duct
system restrictions.
2) Inspect and clean all air filters in the air distribution system.
3) Inspect blower for interference with rotation or locked rotor condition.
Also, confirm the blower wheel is secured to the fan motor shaft.
4) The fan motor or run capacitor may be damaged. Test and replace the
motor or capacitor, as required.
5) Increase fan speed.
C. Symptom: Burner short cycles on high limit thermostat, but does not
“lock out” on oil primary safety control.
Items to check:
1) Open dampers or registers in the air distribution system. Clear any duct
system restrictions.
2) Inspect and clean all air filters in the air distribution system.
3) Inspect blower for interference with rotation or locked rotor condition.
Also, confirm the blower wheel is secured to the fan motor shaft.
4) The fan motor or run capacitor may be damaged. Test and replace the
motor or capacitor, as required.
5) Increase fan speed.
6) Measure the draft at the point where the vent connector attaches to the
heat exchanger flue pipe. With the burner operating, the stack draft
should not exceed 0.05 in. W.G. If the stack draft has been adjusted
above this value to give the proper overfire draft, the heat exchanger will
require cleaning. If there is little or no stack draft, the chimney flue way
may require cleaning, the chimney is too restrictive, or a downdraft
condition exists.
D. Symptom: Furnace blower will not start.
Items to check:
1) Confirm there is 120 VAC at the blower terminal labeled “HEAT” on the
oil furnace control.
2) If there is not 120 VAC at the blower motor terminal, measure the
voltage at the S1 terminal on the oil furnace control. If the fan can be
activated by itself from the room thermostat subbase, confirm it will
operate. If so, the oil furnace control may have a burnt or damaged
relay. Confirm and replace the control if necessary.
3) If there is 120 VAC at the blower motor terminal “HEAT”, either the run
capacitor or blower motor may be damaged. Test and replace the
capacitor or motor, as required.
E. Symptom: Blower cycles on and off after the burner has shutdown.
Item to check:
1) Increase the fan off time by changing the DIP switch selections on SW2.
Refer to Table 2 for blower delay off settings.

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NOTICE: If the high limit control is faulty, it should be replaced. However, it must
only be replaced by the same make and model as the original. Refer to the
electrical diagrams for proper electrical connections.
Flame Sensor (“Cad Cell”) Checkout Procedure
Refer to the oil burner manufacturer’s operating instructions (included with the furnace)
for detailed cad cell troubleshooting.
Replacement Parts
Appendix D of this manual contains a list of replacement parts available for these
furnaces.
MAINTENANCE
Air Filter(s)
c CAUTION: To avoid injury from moving parts, hot surfaces, or electrical shock,
shut off the power to the furnace and allow the furnace to cool BEFORE removing
any furnace access doors to service air filters.
The filter rack will be located between the return air plenum and the return air opening on
the side of the furnace, refer to figure 2. Slide the dirty filter out; clean it with a mild soap
and water solution. Make sure filter is thoroughly dry before replacing.
If the furnace, or duct system, is equipped with disposable-type (paper element), air
filters, inspect them every month for an excessive accumulation of dust and dirt. Replace
disposable air filters at least twice a year. Make certain the replacement filter is the same
size as the one being replaced. The filter size is marked on the outer edge of the air filter.
Install the filter with the arrow marked on the filter pointing toward the furnace.
Fig. 2: Location of the air filter on the typical highboy furnace.