Failure to follow this warning could lead to sooting, fire,
explosion, and/or severe bodily harm.
For use with grade 1 or 2 Fuel Oil. Do not use Gasoline,
Crankcase Oil, or any Oil containing gasoline!
CAUTION: FIRE HAZARD
Failure to follow this caution may result in fire and
property damage.
Never burn garbage or paper in the heating system and
never leave rags, paper, or any flammable items around
the unit.
SAFETY CONSIDERATIONS
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
DO NOT ATTEMPT TO START THE BURNER
WHEN EXCESS OIL HAS ACCUMULATED, WHEN
THE FURNACE IS FULL OF VAPOR, OR WHEN
THE COMBUSTION CHAMBER IS VERY HOT.
CAUTION: UNIT RELIABILITY HAZARD
These instructions are intended to be used by qualified
personnel who have been trained in installing this type of
furnace. Installation of this furnace by an unqualified
person may lead to equipment damage and/or a hazardous
condition which may lead to bodily harm.
All local and national code requirements governing installation of
oil burning equipment, wiring, and flue connections must be
followed. Some of the codes (issued by the Canadian Standards
Association, the National Fire Protection Agency, and/or the
American National Standards Institute) that may be applicable are:
could result in personal injury or death. CAUTION is used to
identify unsafe practices which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
ANSI/NFPA 31: INSTALLATION OF OIL BURNING EQUIPMENT
INTRODUCTION
ANSI/NFPA 211: CHIMNEYS, FIREPLACES, VENTS, AND
SOLID FUEL BURNING APPLIANCES
ANSI/NFPA 90B: WARM AIR HEATING AND AIR CONDITIONING SYSTEMS
ANSI/NFPA 70: NATIONAL ELECTRICAL CODE
CSA B139: INSTALLATION CODE FOR OIL BURNING
EQUIPMENT
CAS C22.1: CANADIAN ELECTRICAL CODE
Only the latest issues of these codes should be used, and are
available from either The National Fire Protection Agency, Batterymarch Park, Quincy, MA 02269 or The Canadian Standards
Association, 178 Rexdale Blvd., Rexdale, Ontario M9W 1R3.
Recognize safety information. This is the safety-alert symbol
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and CAU-
The model 368RAN Furnaces are available in 2 sizes. Each size
unit can be fired at 3 different rates by a simple nozzle change.
Unit 036105 covers input ranges from 91,000 to 105,000 Btuh,
unit 060120 covers input ranges from 119,000 to 154,000 Btuh.
This furnace is a Low-Boy unit. It may be operated only in the
upflow configuration.
The furnace is shipped as a packaged unit, complete with burner
and controls. It requires a line voltage (115 vac) connection to
control box, a thermostat hook-up as shown on wiring diagram, oil
line connection(s), adequate duct work, and connection to a
properly sized vent.
The air handling capacity of this furnace is designed for cooling
airflow. Refer to Table 13 of 14 for expected airflows at various
external duct static pressures.
TION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies a hazard which
A98009
VENT
CONN
—2—
LOCATION
I. GENERAL
WARNING: ELECTRICAL SHOCK, FIRE OR
UNIT DAMAGE HAZARD
Failure to follow this warning could result in property
damage or personal injury or death.
This furnace is not water tight and is not designed for
outdoor installation. This furnace shall be installed in
such a manner as to protect electrical components from
water. Outdoor installation would lead to a hazardous
electrical condition and to premature furnace failure.
CAUTION: UNIT DAMAGE HAZARD
This oil furnace may be used for construction heat provided that:
-The furnace operating conditions, including ignition, input rate, temperature rise and venting, are verified per instructions in this manual.
-The furnace is permanently installed with all electrical wiring, piping, venting and ducting installed according to these installation
instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace. This
prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion
products into the structure.
-The furnace is controlled by a thermostat. It may not be ″hot wired″ to provide heat continuously to the structure without thermostatic
control.
-Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction
materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace
components.
-The temperature of the return air to the furnace is no less than 55°F, with no evening setback or shutdown. The use of the furnace while
the structure is under construction is deemed to be intermittent operation per our installation instructions.
-The air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the nameplate value.
-The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to
occupancy.
-The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system
components after construction is completed.
This furnace is approved for reduced clearances to combustible
construction, therefore, it may be installed in a closet or similar
enclosure. It may be located in a basement or on the same level as
area to be heated. In any case, unit should always be installed level.
The required minimum clearances for this furnace are specified in
Table 1. The furnace should be located as close as possible to
chimney or vent in order to keep vent connections short and direct.
The furnace should also be located as near as possible to center of
air distribution system.
II. LOCATION RELATIVE TO COOLING EQUIPMENT
When installing furnace with cooling equipment for year-round
operation, the following recommendations must be followed for
series or parallel airflow:
1. In series airflow applications, coil is mounted after furnace
in an enclosure in supply-air stream. The furnace blower
used for both heating and cooling airflow.
WARNING: UNIT DAMAGE HAZARD
The coil MUST be installed on air discharge side of
furnace. Under no circumstances should airflow be such
that cooled, conditioned air can pass over furnace heat
exchanger. This will cause condensation in heat exchanger and possible failure of heat exchanger which
could lead to a fire hazard and/or a hazardous condition
which may lead to bodily harm. Heat exchanger failure
due to improper installation may not be covered by
warranty.
TABLE 1—MINIMUM CLEARANCES TO
COMBUSTIBLE MATERIALS (IN.)
UNIT APPLICATIONLOW-BOY
Furnace1
Sides
Supply Plenum and Warm-Air Duct Within 6 ft
of Furnace
Back Service Clearance19
Furnace Casing or Plenum2
Top
Horizontal Warm-Air Duct Within 6 ft of
Furnace
Bottom*0
Horizontally or Below Pipe4
Flue
Pipe
Vertically Above Pipe9
Front8
* Floor may be combustible.
NOTE: Adequate service clearances should be provided over and abovethese
dimensions as required.
1
2
2. In parallel airflow applications, dampers must be provided
to direct air over furnace heat exchanger when heat is
desired and over cooling coil when cooling is desired.
IMPORTANT: The dampers should be adequate to prevent
cooled air from entering furnace. If manually operated, dampers
must be equipped with a means to prevent operation of either
cooling unit or furnace unless damper is in full cool or heat
position.
—3—
INSTALLATION
I. AIR FOR COMBUSTION AND VENTILATION
WARNING: CARBON MONOXIDE POISONING
AND UNIT CORROSION HAZARD
Failure to follow this warning could lead to premature
rusting of heat exchanger and possible premature furnace
failure and/or vent failure which could result in fire
hazard and/or personal injury or death.
Installation of this furnace in an area where it will receive
contaminated combustion air must be avoided. Such
contamination would include the following: ammonia,
chlorine, hydrogen sulfide, halogenated hydrocarbons,
carbon tetrachloride, cleaning solvents, hydrochloric
acid, water softening chemicals, and similar chemicals.
WARNING: CARBON MONOXIDE POISONING
AND FIRE HAZARD
Failure to follow this warning could result in property
damage, personal injury or death.
Do not block combustion-air openings in the furnace.
Any blockage could result in improper combustion.
II. GENERAL
This furnace should be installed in a location in which facilities for
ventilation permit satisfactory combustion of oil, proper venting,
and maintenance of ambient temperature at safe limits under
normal conditions of use. The location should not interfere with
proper circulation of air within the confined space. (See NFPA-31,
Section 1.5.)
In addition to air needed for combustion, process air shall be
provided as required for: cooling of equipment or material,
controlling dew point, heating, drying, oxidation or dilution, safety
exhaust, and odor control.
In addition to air needed for combustion, air shall be supplied for
ventilation, including all air required for comfort and proper
working conditions for personnel.
The barometric draft regulator (included with furnace) shall be
installed in same room or enclosure as furnace in such a manner as
to prevent any difference in pressure between regulator and
combustion-air supply.
Air requirements for operation of exhaust fans, kitchen ventilation
systems, clothes dryers, and fireplaces shall be considered in
determining the adequacy of a space to provide combustion-air
requirements.
The lack of a proper amount of combustion air can lead to serious
furnace operational problems. Some of these problems are:
1. Excessive oil burner after drip and oil fumes.
2. Sooting.
3. Melted ignitor/relay control.
4. Air band or air turbulator settings more open than normal.
5. Lockouts on start-up.
The requirements for combustion and ventilation air depend upon
whether the furnace is located in a CONFINED or UNCONFINED
space.
III. UNCONFINED SPACE
An unconfined space must have at least 50 cu ft for each 1000
Btuh of total input for all the appliances (such as furnaces, clothes
dryers, water heaters, etc.) in the space. (Refer to Table 2.)
In unconfined spaces in buildings of conventional frame, brick, or
stone construction, infiltration MAY be adequate to provide air for
combustion, ventilation, and dilution of flue gases. This determi-
nation must be made on an individual installation basis and must
take into consideration the overall volume of unconfined space, the
number of windows and ventilation openings, the number of doors
to the outside, internal doors which can close off unconfined space,
and overall tightness of building construction. Consideration must
also be given to the amount of storage items (furniture, boxes, etc.)
within the unconfined space which take away from the air volume.
Many new buildings and homes (and older ones that have been
weatherized) MUST BE considered as being of tight construction,
therefore, infiltration will not be sufficient to supply necessary air
for combustion and ventilation.
A building can be considered as being of tight construction when:
1. Walls and ceilings exposed to outside atmosphere have a
continuous water vapor retarder with a rating of 1 perm or
less with openings gasketed or sealed, and/or
2. Weatherstripping has been added on operable windows and
doors, and/or
3. Caulking or sealants are applied to areas such as joints
around window and door frames; between sole plates and
floors; between wall-ceiling joints; between wall panels; at
penetrations for plumbing, electrical, and fuel lines; and at
other openings.
If combustion and ventilation air must be supplied to an unconfined space from outside, an opening with a FREE AREA of not
less than 1 sq in. per 1000 Btuh of total input of all appliances
within unconfined space (but not less than 100 sq in.) must be
provided. This opening must be located such that it can not be
blocked at any time.
IV. CONFINED SPACE
A confined space has a volume of less than 50 cu ft per 1000 Btuh
of the total input rating for all appliances installed in that space.
When furnace is installed in a closet or enclosure, 2 ventilation
openings, with OPEN AREA as dimensioned in example below
are required for combustion air. The openings should be located
about 6 in. from top and bottom of enclosure at front of furnace.
(Refer to Table 3.)
TABLE 3—COMBUSTION AIR FROM CONFINED SPACE
368RAN FURNACE
INPUT BTUH
70,000-105,000168
119,000-154,0002010
LENGTH
(IN.)
HEIGHT
(IN.)
NOTE: In calculating free area, consideration shall be given to
blocking effect of louvers, grilles, or screens protecting openings.
Screens used shall not be smaller than 1/4 in. mesh and shall be
readily accessible for cleaning. If free area through a design of
louver or grille is known, it shall be used in calculating size design
and free area specified. If design and free area are not known, it
may be assumed that wood louvers have 20 percent free area and
metal louvers and grilles have 60 percent free area. Louvers shall
be fixed in open position or interlocked with furnace so they open
automatically at furnace start-up and remain open during furnace
operation.
—4—
The size of the openings depends upon whether the air comes from
outside of the structure or an unconfined space inside the structure.
A. All Air from Inside the Structure
For a confined space, where air is taken from an interior space, 2
permanent openings of equal area are required. One opening must
be within 12 in. of ceiling and the other within 12 in. of floor. Each
opening must have a free area of at least 1 sq in. per 1000 Btuh of
total input rating but not less than 100 sq in. (Refer to Table 4.)
If outside air is supplied to a confined space, then the 2 openings
must be equal and located as above.
1. If combustion air is taken through a permanent opening
directly communicating with the outdoors, the opening shall
have a minimum free area of 1 sq in. per 4000 Btuh of total
input rating for all equipment in the enclosure.
2. If combustion air is taken from outdoors through vertical
ducts, the openings and ducts MUST have at least 1 sq in.
of free area per 4000 Btuh of the total input for all
equipment within the confined space. (Refer to Table 5.)
3. If combustion air is taken from outdoors through horizontal
ducts, the openings and ducts MUST have at least 1 sq in.
of free area per 2000 Btuh of the total input for all
equipment within the confined space. (Refer to Table 6.)
When ducts are used to supply air, they must be of the same cross
sectional area as free area of openings to which they connect.
The minimum dimension of rectangular air ducts must not be less
than 3 in.
C. Duct Work Recommendations
WARNING: CARBON MONOXIDE POISONING
HAZARD
Failure to follow this warning could result in personal
injury or death.
When supply ducts carry air circulated by furnace to areas
outside spaces containing furnace, return air MUST also
be handled by a duct sealed to furnace casing and
terminating outside space containing furnace.
CAUTION: FIRE HAZARD or UNIT MAY
NOT OPERATE
Failure to follow this caution may result in property
damage or intermittent unit operation.
Return-air grilles and warm air registers MUST NOT be
obstructed.
The proper sizing of warm air ducts is necessary to ensure
satisfactory furnace operation. Duct work should be in accordance
with the latest editions of NFPA-90A (Installation of Air Conditioning and Ventilating Systems) and NFPA-90B (Warm Air
Heating and Air Conditioning Systems) or Canadian equivalent.
The supply duct work should be attached to flanged front opening
provided at discharge end of furnace. The return-air duct work
should be attached to flanged rear opening of furnace. See Fig. 2
for dimensions of these openings.
NOTE: The back (blower access opening) should not be used for
return air.
The following recommendations should be followed when installing duct work:
1. Install locking-type dampers in all branches of individual
ducts to balance out system. Dampers should be adjusted to
impose proper static at outlet of furnace
2. A flexible duct connector of noncombustible material
should be installed at unit on both supply- and return-air
systems. In applications where extremely quiet operation is
necessary, the first 10 ft (if possible) of supply and return
ducts should be internally lined with acoustical material.
3. In cases where return-air grille is located close to fan inlet,
there should be at least one 90° air turn between fan inlet
and grille. Further reduction in sound level can be accomplished by installing acoustical air turning vanes or lining
duct as described in item 2 above.
4. When a single air grille is used, duct between grille and
furnace must be the same size as return opening in furnace.
D. Venting
Venting of furnace should be to the outside and in accordance with
local codes or requirements of local utility.
OIL-FIRED APPLIANCES SHALL BE CONNECTED TO
FLUES HAVING SUFFICIENT DRAFT AT ALL TIMES TO
ENSURE SAFE AND PROPER OPERATION OF APPLIANCE.
For additional venting information, refer to ANSI/NFPA 211
Chimney, Fireplaces, Vents, and Solid Fuel Burning Appliances
and/or CSA B139 Installation Code.
This furnace is certified for use with Type ″L″ vent (maximum flue
gas temperature 575°F).
VENT SYSTEM INSPECTION
Before furnace is installed, it is highly recommended that any
existing vent system be completely inspected.
* Permissible limits of voltage range at which unit will operate satisfactorily.
† Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.
‡ Time-delay fuse is recommended.
VOLTS—
HERTZ—
PHASE—
OPERATING
VOLTAGE RANGE
Max*Min*
MAX
UNIT
AMPS
MIN
WIRE
GAGE
MAX WIRE
LENGTH (FT)†
MAX FUSE OR
CKT BKR AMPS‡
For any chimney or vent, this should include the following:
1. Inspection for any deterioration in chimney or vent. If
deterioration is discovered, chimney must be repaired or
vent must be replaced.
2. Inspection to ascertain that vent system is clear and free of
obstructions. Any blockage must be cleared before installing furnace.
3. Cleaning chimney or vent if previously used for venting a
solid fuel burning appliance or fireplace.
4. Confirming that all unused chimney or vent connections are
properly sealed.
5. Verification that chimney is properly lined and sized per the
applicable codes. (Refer to list of codes in Safety Considerations section.)
MASONRY CHIMNEYS
This furnace can be vented into an existing masonry chimney. This
furnace must not be vented into a chimney servicing a solid fuel
burning appliance. Before venting furnace into a chimney, the
chimney MUST be checked for deterioration and repaired if
necessary. The chimney must be properly lined and sized per local
or national codes.
If furnace is vented into a common chimney, the chimney must be
of sufficient area to accommodate the total flue products of all
appliances vented into chimney.
The following requirements are provided for a safe venting
system:
1. Be sure that chimney flue is clear of any dirt or debris.
2. Be sure that chimney is not servicing an open fireplace.
3. Never reduce pipe size below the outlet size of furnace.
(See Fig. 2.)
4. All pipe should be supported using proper clamps and/or
straps. These supports should be at least every 4 ft.
5. All horizontal runs of pipe should have at least 1/4 in. per
ft of upward slope.
6. All runs of pipe should be as short as possible with as few
turns as possible.
7. Seams should be tightly joined and checked for leaks.
8. The flue pipe must not extend into chimney but be flush
with inside wall.
9. The chimney must extend 3 ft above highest point where it
passes through the roof of a building and at least 2 ft higher
than any portion of a building within a horizontal distance
of 10 ft. It shall also be extended at least 5 ft above highest
connected equipment flue collar.
10. Check local codes for any variance.
FACTORY-BUILT CHIMNEYS
Listed factory-built chimneys may be used. Refer to chimney
manufacturer’s instructions for proper installation.
E. Oil Burner
This furnace is supplied with a high-pressure atomizing retention
head-type burner (for use with grade 1 or 2 fuel oil). The Riello oil
burner operates with a prepurge period of 10 sec and a safety
timing of 5 sec. The burner flange is factory installed for an
inspection length of 3-3/4–in. The oil pump is set to operate on a
single line system. To operate on a two-line system the by-pass
plug must be installed.
F. Oil Connections
CAUTION: UNIT DAMAGE HAZARD
Failure to follow this caution may result in unit component damage.
This burner is shipped with the oil pump set to operate on
a single line system. To operate on a two-line system the
by-pass plug must be installed. Do not operate a single
line system with the by-pass plug installed. Operating a
single line system with the by-pass plug installed will
result in damage to the pump shaft seal.
Pump pressure must be set at time of burner start-up. A
pressure gauge is attached to the PRESSURE PORT for
pressure readings. Two PIPE CONNECTORS are supplied with the burner for connection to either a single or
two-line system. Also supplied are two ADAPTORS,
two female 1/4–in. NPT, to adapt oil lines to burner pipe
connectors. All pump ports are British Parallel Thread
design. Direct connection of NPT threads to the pump
will damage the pump body.
Riello manometers and vacuum gauges do not require
any adapters and can be safely connected to the pump
ports. An NPT (metric) adapter must be used when
connecting other gauge models.
Complete instructions for installing fuel oil piping can be found in
oil burner Installation Instructions included with furnace.
Oil line entry holes are provided in side panels. Two holes are
provided in each location so that a 2-pipe system may be used if
desired.
An oil filter should be used with all oil burners and should be
installed as close to burner as possible.
G. Barometric Draft Control
The barometric draft control shipped with furnace MUST be used
with furnace to ensure proper operation. Instructions for installing
control are packed with control.
H. Electrical Connections
WARNING: ELECTRICAL SHOCK AND FIRE
HAZARD
Failure to follow this warning could result in serious
injury, death, or property damage.
The unit cabinet must have an uninterrupted or unbroken
electrical ground to minimize personal injury if an
electrical fault should occur. A green ground screw is
provided in control box for this connection.
115-V WIRING
Before proceeding with electrical connections, make certain that
voltage, frequency, and phase correspond to that specified on unit
—6—
rating plate. Also, check to be sure that service provided by utility
is sufficient to handle load imposed by this equipment. Refer to
rating plate or Table 7 for equipment electrical specifications.
Make all electrical connections in accordance with National
Electrical Code (NEC) ANSI/NFPA 70-2001 and any local codes
or ordinances that might apply. For Canadian installations, all
electrical connections must be made in accordance with Canadian
Electrical Code CSA C22.1 or subauthorities having jurisdiction.
WARNING: FIRE HAZARD
Failure to follow this warning could result in serious
injury, death, or property damage.
Do not connect aluminum wire between disconnect
switch and furnace. Use only copper wire.
The control system depends on correct polarity of power supply.
Connect HOT wire (H) and NEUTRAL wire (N) as shown in Fig.
3.
A separate line voltage supply MUST be used with a fused
disconnect switch or circuit breaker between main power panel
and unit. (See Fig. 3.)
Metallic conduit (where required/used) may terminate at side panel
of unit. It is not necessary to extend conduit inside unit from side
panel to control box.
When replacing any original furnace wiring, use only 105°C No.
14 AWG copper wire.
24-V WIRING
Instructions for wiring thermostat (field supplied) are packed in
thermostat box. Make thermostat connections as shown in Fig. 3 at
24-v terminal board on fan timer board. See Fig. 4-7 for thermostat
wiring.
ACCESSORIES
When installing optional accessories to this appliance, follow
manufacturer’s Installation Instructions included with accessory.
Other than wiring for thermostat, wire with a minimum of type ″T″
insulation (63°F rise) must be used for accessories.
I. Filters
WARNING: FIRE, CARBON MONOXIDE AND
POISONING HAZARD
Failure to follow this warning could result in fire,
personal injury, or death.
Never operate unit without a filter or with filter access
door removed.
An internal filter rack is provided as standard equipment with
furnace and is located in blower compartment. A sufficient
clearance should be provided for air filter access. Refer to Table 8
for filter rack flange dimensions for return air duct.
Installation of furnace is now complete. Run through the following
checkout and ensure each item has been performed.
1. Correct nozzle size has been selected for desired input rate.
2. Blower wheel support is removed.
3. Electrical wiring is completed according to Fig. 3.
4. Blower access door is secured in place.
5. Valve on oil supply line is open.
6. RESET BUTTON on primary control is pushed down.
7. Flame observation door is closed.
8. Thermostat is set for heating mode and set above room
temperature.
If all of the above items have been performed, set main electrical
switch to ON position and burner should start. When burner starts,
proceed to Combustion Check section.
II. COMBUSTION CHECK
In order to obtain optimum performance from oil burner, the
following setup procedures must be followed:
1. A test kit to measure smoke, stack draft, over-fire draft, oil
pump pressure, CO
, and stack temperatures MUST be used
2
in order to obtain proper air band setting. Although all of
the above measurements are required for optimum setup
and efficiency data, the most important readings that must
be taken are smoke number, over-fire draft, stack draft, and
pump pressure.
2. The proper smoke number has been established by engineering tests to be between 0 and 1. This degree of smoke
emission is commonly referred to as a “trace” of smoke. It
is recommended to use a Bacharach true spot smoke test set
or equivalent.
3. In order to ensure proper draft through furnace, a barometric draft regulator (supplied with furnace) must be installed.
In order for this device to function properly, barometric
damper must be mounted with hinge pins horizontal and
face of damper vertical. (See instructions included with
damper.) The draft regulator should be adjusted after
furnace has been firing for at least 5 minutes, and set
between -0.025 and -0.035 in. wc. (See Table 9.)
TABLE 9—FURNACE DRAFT CONDITIONS (IN. WC)
FURNACE
INPUT
(BTUH)
70,000-0.0250.0100.020 to 0.035
91,000-0.0250.0200.030 to 0.045
105,000-0.0250.0250.035 to 0.050
119,000-0.0250.0250.035 to 0.050
140,000-0.0250.0250.035 to 0.050
154,000-0.0250.0250.035 to 0.050
FLUE
DRAFT
MINIMUM
OVER-FIRE
DRAFT
MAXIMUM
TOTAL RESTRICTION
THROUGH
HEAT EXCHANGER
4. The over-fire draft, which is taken through observation door
(located in center line above burner in front panel of
furnace), is a measurement necessary to determine if there
is a blockage between oil burner and flue outlet.
There should be a total pressure drop of between 0.020 and
0.05 in. wc through furnace as shown in Table 9. The
over-fire draft must be set within the range shown in Table
9.A reading outside the range shown in Table 9 (for
example +0.1 in. wc) would indicate that furnace is in an
extremely high-pressure condition in primary section. This
condition may be caused by any of the following problems:
a. Excessive combustion air due to air shutter being too
wide open.
—7—
A04182
Fig. 3—Wiring Diagram
—8—
Fig. 4—24 VAC Oil Furnace Wiring with 1-Speed
Air Conditioner
A04183
A04185
Fig. 6—24 VAC Oil Furnace Wiring with 1-Speed
Heat Pump
Fig. 5—24 VAC Oil Furnace Wiring with 2-Speed
Air Conditioner
A04184
—9—
A04186
Fig. 7—24 VAC Oil Furnace Wiring with 2-Speed
Heat Pump
b. A lack of flue draft (chimney effect) or some other
blockage, such as soot, in secondary section of heat
exchanger.
c. Use of an oversized nozzle input.
d. Pump pressure over the values listed in Table 10.
5. The CO
and stack temperature instruments enable you to
2
obtain data required to determine thermal efficiency of
furnace.
6. An oil filter should be installed as close to burner as
possible with ALL oil burners and is essential on lower
firing rate burners. We recommend the use of a low
pressure drop oil filter such as the General Filter, Inc. model
#1A-25A or equivalent.
7. The oil pressure regulator is factory set to give oil pressure
of 135 psig for the model having 105,000 BTUH input and
135 psig for the model having 119,000 BTUH input. The
firing rate noted on nameplate may be obtained using the
nozzles and pump pressures indicated in Table 10. The
proper oil burner turbulator setting for all the firing rates is
0 (zero).
8. On a new installation, air entrapped in oil line leading from
tank to nozzle must be thoroughly purged in order to
prevent excessive after drip. The oil pump is provided with
a special fitting which allows purging of any air between
tank and oil pump. The proper procedure for performing
this operation is as follows:
a. Place a piece of clear plastic 1/4-in. diameter tubing over
purge fitting on oil pump.
b. Start oil burner, then open purge fitting and allow burner
to run until purge tube is completely free of air bubbles.
c. Tighten purge fitting. Allow oil to run to nozzle and fire
d. If purging takes longer than 15 sec and no flame has
been established, burner stops. Push reset button on front
of primary control to restart burner.
e. For detailed information on operation of primary control,
refer to instructions included with furnace.
After all the setup procedures mentioned above have been completed, the burner should be allowed to operate and an inspection
mirror should be used to observe the flame pattern at tip of nozzle.
Any irregularities such as burning to 1 side or pulsating flame
patterns should be corrected by changing nozzle.
III. FAN ADJUSTMENT CHECK
This furnace is equipped with a variable speed motor to deliver a
constant airflow. Adjust DIP switches on the electronic board
ACCORDING TO OIL INPUT SELECTED AND A/C SIZE. (See
Tables 11A, 11B, and 11C or Tables 12A, 12B, and 12C.)
TABLE 11A— 368RAN 105 SIZE DIP SWITCH
ADJUSTMENT FOR OIL HEATING MODE
SW1-HEAT
DIP SWITCH
POSITION
1212
OFFOFF0.75OFFOFF0.75
ONOFF0.65ONOFF0.65
OFFON0.5OFFON0.5
ONONN/AONONN/A
INPUT
USGPH
SW4-DELAY
DIP SWITCH
POSITION
INPUT
USGPH
TABLE 11B— 368RAN 105 SIZE DIP SWITCH
ADJUSTMENT FOR HEAT PUMP AND COOLING MODE
SW2-COOL
DIP SWITCH POSITION
12
OFFOFF3.0
ONOFF2.5
OFFON2.0
ONON1.5
A/C SIZE
(TONS)
TABLE 11C— 368RAN 105 SIZE DIP SWITCH
CFM ADJUSTMENTS IN ALL MODES
SW2-ADJUST
DIP SWITCH POSITION
12
OFFOFF00
ONOFF+ 13+ 10
OFFON- 15- 10
ONONN/A0
HEATING CFM %
INCREASE OR
DECREASE
COOLING CFM %
INCREASE OR
DECREASE
WARNING: FIRE HAZARD AND UNIT
RELIABILITY
Failure to follow this warning could result in property
damage, personal injury or death.
When operating furnace in heating mode, static pressure
and temperature rise (supply-air temperature minus
return-air temperature) must be within those limits specified on rating label.
IV. LIMIT CONTROL CHECK
After furnace has been in operation for at least 15 minutes, restrict
return-air supply by blocking filters or closing return registers and
allow furnace to shut down on high limit. The burner should shut
off, and main blower should continue to run.
V. FOR YEAR-ROUND AIR CONDITIONING
This furnace is designed for use in conjunction with cooling
equipment to provide year-round air conditioning. The blower has
been sized for both heating and cooling, however, fan motor speed
may need to be changed to obtain necessary cooling airflow.
VI. HEATING
The blower speed is factory set to deliver required airflow at
normal duct static pressure for 0.75 GAL/HR (US) INPUT for the
368RAN 105 size (See Tables 11A, 11B, and 11C) and 0.85
GAL/HR (US) INPUT for the 368RAN 120 size. (See Tables 12A,
12B, and 12C.) The blower motor may be field adjusted to deliver
required airflow for other capacity.
VII. COOLING
The blower speed may be field adjusted to deliver required airflow
for cooling application. (See Table 13 or 14.)
—10—
120 VA C
NEUTRALS
HUM
P2
SW1
1
OFF OFF
OFF
OFFONON
ON
ON
ON
OFF
SW3
1
OFF OFF
OFF
OFFONON
ON
ON
ON
OFF
SW2
1
OFF OFF
OFF
OFFONON
ON
ON
ON
OFF
SW4
1
OFF OFF
OFF
OFFONON
ON
ON
ON
OFF
P1
R14
R12
D18
2
2
LED7
GRN
GRN
COOL
DELAY
D17
A
B
C
D
A
B
C
D
JW5
D6
D7
SW2
D8
D9
D10
D11
D12
D14
SW4
R2
JW7
D19
GRN
JW6
R1
JW3
GRN
HEAT
2
A
B
C
D
SW1
ADJ
2
A
B
C
D
SW3
LED4LED3LED5LED7LED8LED1
GRN
JW4
GRN
120 VAC
JW1
R3
D20
GRN
R23
R13
D16
R21
D21
LED
RED
24 VA C
C
F1
U1
01
R20
C2
U2
D13
D02
D04
D1
D3
JW2
D15
KJ
R22
MO V1
C1
HSC 1
1168-83-1
P3
Y
Y/Y2GDHOWRC
NOTES
1. The Red LED to the right of P-1 will illuminate whenever the limit switch is open.
2. The Green LED below the left end of P-1 will flash when the blower motor is operating.
The LED will flash one time for each 100 RPM.
3. The Green LEDs above Y1, Y/Y2, G, O, and W will illuminate whenever there is a 24V
input from the thermostat.
4. The Green LED above DH will illuminate whenever there is not a 24VAC input applied.
Fig. 8—Control Board
—11—
A04194
TABLE 12A— 368RAN 120 SIZE DIP SWITCH
ADJUSTMENT FOR OIL HEATING MODE
SW1-HEAT
DIP SWITCH
POSITION
1212
OFFOFF0.85OFFOFF0.85
ONOFF1.00ONOFF1.00
OFFON1.10OFFON1.10
ONONN/AONONN/A
INPUT
USGPH
SW4-DELAY
DIP SWITCH
POSITION
INPUT
USGPH
basis. This servicing includes a nozzle change, a burner inspection,
a visual check of tube passages through flue outlet and cleanout
ports, and a visual inspection of combustion chamber when burner
is removed.
Depending on above inspection, service could also include a
cleaning and vacuuming of heat exchanger tubes and possibly the
heat exchanger drum section.
Removal of any heat exchanger components which are sealed by
gaskets requires replacement of gasket.
TABLE 12B— 368RAN 120 SIZE DIP SWITCH
ADJUSTMENT FOR HEAT PUMP AND COOLING MODE
SW2-COOL
DIP SWITCH POSITION
12
OFFOFF5.0
ONOFF4.0
OFFON3.5
ONON3.0
A/C SIZE
(TONS)
TABLE 12C— 368RAN 120 SIZE DIP SWITCH
CFM ADJUSTMENTS IN ALL MODES
SW2-ADJUST
DIP SWITCH POSITION
12
OFFOFF00
ONOFF+ 13+ 10
OFFON- 15- 10
ONONN/A0
HEATING CFM %
INCREASE OR
DECREASE
COOLING CFM %
INCREASE OR
DECREASE
MAINTENANCE
WARNING: ELECTRICAL SHOCK, FIRE OR
EXPLOSION HAZARD
Failure to follow this warning could result in possible
damage to this equipment, serious personal injury, or
death.
The ability to properly perform maintenance on this
equipment requires certain expertise, mechanical skills,
tools, and equipment. If you do not possess these, do not
attempt to perform any maintenance on this equipment
other than those procedures recommended in the User’s
Manual.
WARNING: ELECTRICAL SHOCK HAZARD
Failure to comply with this warning could cause electrical
shock resulting in personal injury or death.
Before performing any service functions, unless operations specifically require power to be on, make sure all
utilities are turned off upstream of appliance.
WARNING: ELECTRICAL SHOCK HAZARD
Failure to follow this warning could lead to electrical
shock resulting in personal injury or death.
To avoid personal injury, make sure electrical supply
power is off before servicing.
I. GENERAL
In order to keep this furnace in good operating condition and to
maintain its warranty, the furnace MUST be serviced on an annual
WARNING: CARBON MONOXIDE POISONING
HAZARD
Failure to replace any heat exchanger gaskets with new
gaskets when any heat exchanger plates or covers are
removed could lead to heat exchanger leakage, sooting,
and/or a hazardous condition capable of causing personal
injury or death.
This furnace should never be operated without an air filter.
Disposable filters should be replaced at least once a year. If
equipped to provide cooling, filters should be replaced a minimum
of twice a year. Permanent filters should be cleaned at least twice
a year.
ALWAYS KEEP MAIN OIL VALVE TURNED OFF IF
BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF
TIME.
II. OIL BURNER
For optimum performance, oil burner nozzle should be replaced
once a year. Contact your service technician if you are unsure of
this procedure.
The procedure for nozzle installation and/or replacement is outlined in oil burner instruction manual which came with furnace.
After replacement of nozzle, burner should be adjusted in accordance with Combustion Check section of this instruction.
III. HEAT EXCHANGER AND FLUE PIPE
Ordinarily, it is not necessary to clean heat exchanger or flue pipe
every year, but it is necessary to have your service technician
check unit before each heating season to determine whether
cleaning or replacement of parts is required.
If cleaning is necessary, the following steps should be performed:
1. Turn off all oil and electrical supplies upstream of furnace.
CAUTION: BURN HAZARD
Failure to follow this catuion may result in minor
personal injury.
If furnace has been in operation, some surfaces may be
hot. Allow time for unit to cool down.
2. Disconnect flue pipe.
3. Remove flue collar panel located in rear part of furnace.
4. Remove flue silencer from secondary heat exchanger.
5. Disconnect oil line and remove oil burner from furnace.
6. Clean primary and secondary heat exchangers with a stiff
brush and vacuum cleaner.
7. Before reassembly, heat exchanger/combustion chamber
should be inspected to determine if replacement is required.
8. After cleaning, replace flue silencer, flue collar, and oil
burner.
9. Readjust burner for proper operation.
IV. BLOWER REMOVAL
To remove blower from furnace:
1. Turn off all oil and electrical supplies upstream of furnace.
2. Remove blower access door.
—12—
TABLE 13—368RAN 105 AIRFLOW DATA (CFM)
OIL HEATING MODE
24 VAC INPUT (R) ON W ONLY
SW1-HEAT
Dip Switch Position
A (1=OFF, 2=OFF)0.75126014251070
B (1=ON, 2=OFF)0.6510501190895
C (1=OFF, 2=ON)0.5850960725
D (1=ON, 2=ON)Same Value then A Dip Switch Position
SW2-COOL
Dip Switch Position
A (1=OFF, 2=OFF)3.0785905670
B (1=ON, 2=OFF)2.5655755560
C (1=OFF, 2=ON)2.0525605445
D (1=ON, 2=ON)1.5395455335
SW2-COOL
Dip Switch Position
A (1=OFF, 2=OFF)3.010501155945
B (1=ON, 2=OFF)2.5875965790
C (1=OFF, 2=ON)2.0700770630
D (1=ON, 2=ON)1.5525580475
NOTE: In cooling-Dehumidification mode, with no 24 VAC input to DH, the CFM-STD is reduced by 15%
SW2-COOL
Dip Switch Position
A (1=OFF, 2=OFF)3.0580635520
B (1=ON, 2=OFF)2.5480530435
C (1=OFF, 2=ON)2.0385425345
D (1=ON, 2=ON)1.5290320260
NOTE: In Cooling-Dehumidification mode, with no 24 VAC input to DH, the CFM-STD is reduced by 15%
SW4-DELAY
Dip Switch Position
A (1=OFF, 2=OFF)0.7545 sec19% - 30 sec38% - 3 min.
B (1=ON, 2=OFF)0.6545 sec19% - 30 sec38% - 3 min.
C (1=OFF, 2=ON)0.560 sec13% - 30 sec38% - 3 min.
D (1=ON, 2=ON)All30 sec100% - 0 sec100% - 2 min.
Short Run is the time before the blower start at normal speed, with very low CFM, to minimize cool draft in the air distribution system.
Off Delay is the time required to cool down the heat exchanger, with low CFM, to minimize cool draft in the air distribution system.
No Adjustment
Required
-All30 sec75% - 2.5 min.50% - 3 min.
Short Run is the time before the blower start at normal speed, with lower CFM, to minimize cool draft in the air distribution system.
Off Delay is the time required to cool down the coil (heating mode), with low CFM, to minimize cool draft in the air distribution system.
3. Remove air filters.
4. Remove blower retaining wing nuts.
5. Slide blower on rails toward rear of unit.
HEAT INPUT
(USGPH)
A/C Size
(TON)
COOLING OR HEAT PUMP HEATING MODE - SINGLE SPEED OR 2-SPEED HIGH
A/C Size
(TON)
24 VAC INPUT (R) TO G, Y/Y2 AND O (FOR COOLING)
A/C Size
(TON)
COOLING MODE OR HEAT PUMP HEATING MODE - 2-SPEED LOW
24 VAC INPUT (R) TO G, Y1 AND O (FOR COOLING)
CFM-STD with SW3-ADJ
DELAY PROFILE FOR OIL HEATING MODE
HEAT INPUT
(USGPH)
DELAY PROFILE FOR COOLING OR HEAT PUMP HEATING MODE
A/C Size
CFM with SW3-ADJ
Dip Switch A Position
CONTINUOUS FAN
24 VAC INPUT (R) ON G ONLY
CFM with ADJ
Dip Switch A Position
CFM with SW3-ADJ
Dip Switch A Position
Dip Switch A Position
On-Delay Time
On-Delay
Time
CFM with SW3-ADJ
Dip Switch B Position
CFM with ADJ
Dip Switch B Position
CFM with SW3-ADJ
Dip Switch B Position
CFM-HIGH with SW3-ADJ
Dip Switch B Position
Short Run On-Delay
CFM Level - Time
Short Run On-Delay
CFM Level - Time
6. Reverse items 1 through 5 to reinstall blower. Refer to
wiring diagram (See Fig. 3) of these instructions or diagram
located on inside of blower door to properly rewire unit.
CFM with SW3-ADJ
Dip Switch C Position
Dip Switch C Position
CFM with SW3-ADJ
Dip Switch C Position
CFM-LOW with SW3-ADJ
Dip Switch C Position
CFM Level - Time
CFM with ADJ
Off-Delay
CFM Level - Time
Off-Delay
—13—
TABLE 14—368RAN 120 AIRFLOW DATA (CFM)
OIL HEATING MODE
24 VAC INPUT (R) ON W ONLY
SW1-HEAT
Dip Switch Position
A (1=OFF, 2=OFF)0.85145016401235
B (1=ON, 2=OFF)1.00170019201445
C (1=OFF, 2=ON)1.10185020901575
D (1=ON, 2=ON)Same Value then A Dip Switch Position
SW2-COOL
Dip Switch Position
A (1=OFF, 2=OFF)5.0131515101115
B (1=ON, 2=OFF)4.010501210895
C (1=OFF, 2=ON)3.59201055780
D (1=ON, 2=ON)3.0790905670
SW2-COOL
Dip Switch Position
A (1=OFF, 2=OFF)5.0175019251575
B (1=ON, 2=OFF)4.0140015401260
C (1=OFF, 2=ON)3.5122513501105
D (1=ON, 2=ON)3.010501155945
NOTE: In cooling-Dehumidification mode, with no 24 VAC input to DH, the CFM-STD is reduced by 15%
SW2-COOL
Dip Switch Position
A (1=OFF, 2=OFF)5.09651060865
B (1=ON, 2=OFF)4.0770845695
C (1=OFF, 2=ON)3.5675740605
D (1=ON, 2=ON)3.0580635520
NOTE: In Cooling-Dehumidification mode, with no 24 VAC input to DH, the CFM-STD is reduced by 15%
SW4-DELAY
Dip Switch Position
A (1=OFF, 2=OFF)0.850% - 45 sec44% - 30 sec38% - 3 min.
B (1=ON, 2=OFF)1.000% - 30 sec44% - 30 sec38% - 3 min.
C (1=OFF, 2=ON)1.100% - 30 sec50% - 30 sec38% - 3 min.
D (1=ON, 2=ON)All0% - 30 sec100% - 0 sec100% - 2 min.
Short Run is the time before the blower start at normal speed, with very low CFM, to minimize cool draft in the air distribution system.
Off Delay is the time required to cool down the heat exchanger, with low CFM, to minimize cool draft in the air distribution system.
No Adjustment
Required
-All30 sec75% - 2.5 min.50% - 3 min.
Short Run is the time before the blower start at normal speed, with lower CFM, to minimize cool draft in the air distribution system.
Off Delay is the time required to cool down the coil (heating mode), with low CFM, to minimize cool draft in the air distribution system.
HEAT INPUT
(USGPH)
CFM with SW3-ADJ
Dip Switch A Position
CFM with SW3-ADJ
Dip Switch B Position
CONTINUOUS FAN
24 VAC INPUT (R) ON G ONLY
A/C Size
(TON)
CFM with ADJ
Dip Switch A Position
CFM with ADJ
Dip Switch B Position
COOLING OR HEAT PUMP HEATING MODE - SINGLE SPEED OR 2-SPEED HIGH
24 VAC INPUT (R) TO G, Y/Y2 AND O (FOR COOLING)
A/C Size
(TON)
CFM with SW3-ADJ
Dip Switch A Position
CFM with SW3-ADJ
Dip Switch B Position
COOLING MODE OR HEAT PUMP HEATING MODE - 2-SPEED LOW
24 VAC INPUT (R) TO G, Y1 AND O (FOR COOLING)
A/C Size
(TON)
CFM-STD with SW3-ADJ
Dip Switch A Position
CFM-HIGH with SW3-ADJ
Dip Switch B Position
DELAY PROFILE FOR OIL HEATING MODE
HEAT INPUT
(USGPH)
On-Delay
CFM Level - Time
Short Run On-Delay
CFM Level - Time
DELAY PROFILE FOR COOLING OR HEAT PUMP HEATING MODE
A/C Size
PreRun On-Delay
CFM Time
Short Run On-Delay
CFM Level - Time
CFM with SW3-ADJ
Dip Switch C Position
Dip Switch C Position
CFM with SW3-ADJ
Dip Switch C Position
CFM-LOW with SW3-ADJ
Dip Switch C Position
CFM Level - Time
CFM with ADJ
Off-Delay
CFM Level - Time
Off-Delay
—14—
SER VICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization • Maintenance
• Installation Overview • Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-644-5544
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