Nordyne O4HD-091A-12-FA, O4HD-091A-V-F, O4HD-140A-16-FA, O4HD-140A-V-F Installation Instructions Manual

NORDYNE

INSTALLATION

INSTRUCTIONS

TABLE OF CONTENTS

INTRODUCTION ....................................................... 3

HEAT LOSS .............................................................. 3

LOCATION OF UNIT................................................. 3

AIR CONDITIONING ................................................. 4

COMBUSTION AIR ................................................... 4

CHIMNEY VENTING .................................................5

OIL TANK.................................................................. 7

PIPING INSTALLATION ...........................................7

ELECTRICAL CONNECTIONS................................. 7

CIRCULATING AIR BLOWER (ECM)....................... 8

FURNACE CONTROLS ............................................ 9

OIL BURNER ............................................................ 9

FURNACE INSTALLATION SET-UP...................... 11

MAINTENANCE AND SERVICE............................. 12

OPERATING INSTRUCTIONS................................ 12

TABLE A-1: BECKETT OIL BURNER SET-UP...... 13

TABLE A-2: DIRECT DRIVE BLOWER SET-UP.... 13

TABLE A-3: DIRECT DRIVE BLOWER

CHARACTERISTICS .............................................. 14

GENERAL DIMENSIONS – O4HD MODELS ......... 15

APPENDIX A: WIRING DIAGRAM O4HD-091A-12-FA

AND O4HD-140A-16-FA ......................................... 16

APPENDIX B: WIRING DIAGRAM O4HD-091A-V-F

AND O4HD-140A-V-F ............................................. 17

WIRING NOTES ...................................................... 18

R7184 DETAILED SEQUENCE OF OPERATION .. 19

TABLE C-1: EFT DETAILED SEQUENCE OF

OPERATION ........................................................... 20

TABLE C-1: EFT DETAILED SEQUENCE OF

OPERATION ........................................................... 21

TABLE C-2: CAD CELL RESISTANCE................. 23

TABLE C-3: R7184 TROUBLESHOOTING ........... 24

TABLE C-4: SYSTEM AND GENERAL

TROUBLESHOOTING ............................................ 26

AIR FILTER LOCATION .........................................29

PARTS..................................................................... 30

OIL-FIRED WARM AIR

FURNACE

O4HD-091A-12-FA AND O4HD-091A-V-F
O4HD-140A-16-FA AND O4HD-140A-V-F

(UPFLOW OR HORIZONTAL MODELS)

Read this manual completely before beginning
installation.
Important: These instructions must be kept with
the furnace for future reference.

1

151B0801 R5 3/28/2006

IMPROPER INSTALLATION MAY
CREATE A CONDITION WHERE THE
OPERATION OF THE PRODUCT
COULD CAUSE PERSONAL INJURY
OR PROPERTY DAMAGE.

IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION,
SERVICE OR MAINTENANCE CAN
CAUSE INJURY OR PROPERTY
DAMAGE. REFER TO THIS MANUAL
FOR ASSISTANCE OR ADDITIONAL
INFORMATION, CONSULT A
QUALIFIED INSTALLER, SERVICE
AGENCY OR THE FUEL SUPPLIER.

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.

The furnace area must not be used as
a broom closet or for any other
storage purposes, as a fire hazard
may be created. Never store items
such as the following on, near or in
contact with the furnace:

1. Spray or aerosol cans, rags,
brooms, dust mops, vacuum
cleaners or other cleaning tools.

2. Soap powders, bleaches, waxes
or other cleaning compounds;
plastic items or containers,
gasoline, kerosene, cigarette
lighter fluid, dry cleaning fluids,
or other volatile fluids.

3. Paint thinners or other painting
materials 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.

DO NOT USE GASOLINE,
CRANKCASE OIL, OR ANY OTHER
OIL CONTAINING GASOLINE AS A
FUEL FOR THIS FURNACE.

INTRODUCTION

Please read these instructions
completely and carefully before installing
and operating the furnace.

The furnace must be installed and set up
by a qualified contractor.

Model O4HD-091A is an oil fired forced
air multi-positional furnace, with an
output capacity range of 58,000 BTU/Hr.
to 79,000 BTU/Hr. Model O4HD-140A is
an oil fired forced air multi-positional
furnaces, with output capacity ranges of
87,000 BTU/Hr. to 118,000 BTU/Hr.
These models may be installed in the up­flow position, as well as both horizontal
positions.

O4HD-091A-12-FA and O4HD-140A-16­FA are equipped with direct drive

permanent split capacitor motors.

O4HD-091A-V-F and O4HD-140A-V-F
are equipped with direct drive ECM
motors.

All models are listed with the Canadian
Standards Association, (CSA), and
comply 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
regulations of NFPA No. 31, Installation
of Oil Burning Equipment, as well as in
accordance 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 Oil Burning Equipment, as well as

in accordance with local codes.

When installation or application
questions arise, regulations prescribed in
the National Codes and Local
Regulations take precedence over the
general instructions provided with this
installation manual. When in doubt,
please consult your local authorities.

All models are shipped assembled and
pre-wired. The furnace should be
carefully inspected for damage when
being unpacked.

HEAT LOSS

To determine the correct furnace and
firing rate for an application, it is
necessary 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.

"Load Calculation
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
authorities having jurisdiction that are
suitable for local conditions.

" published by the Air

titled,

LOCATION OF UNIT

The furnace should be located such that
the flue connection to the chimney is
short, direct and consists of as few
elbows 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.

UP-FLOW INSTALLATION

All O4HD furnace models have been
assembled for installation in the up-flow
position. Maintain all clearances to
combustibles as outlined in Table 1.
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
noncombustible material.

2

151B0801 R5 3/28/2006

Table 1: Clearance to Combustibles

p

p

w

Furnace

Location Upflow Horizontal

Top 2 in. 2 in.

Bottom 0 in. 1 in.

S/A Plenum 1 in. 1 in.

Rear 1 in. 1 in.

Sides 1 in. 1 in.

Front 9 in.1 9 in.1

Flue Pipe 9 in. 9 in.

Enclosure Closet Alcove

1

24” clearance is required for servicing.

In the up flow position, the heat
exchanger support screw shown in the
picture may be removed. This may be
preferable if the furnace rear panel will
be inaccessible after installation. The
screw must be removed if the heat
exchanger must be removed from the
cabinet. Do not remove this screw if
installing furnace in a horizontal position.

HORIZONTAL INSTALLATION

O4HD furnaces models are

assembled and shipped ready for
installation in the up-flow position.
The furnace may be installed in
either of the horizontal

positions; warm

O4HD

air discharging left or warm air-

Heat Exchanger Su

discharging right by following these
steps:

ort Scre

1. Rotate the furnace 90° to the
desired position.

2. Remove the three nuts fastening the
oil burner assembly 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 nuts.

NON-SUSPENDED INSTALLATION

Maintain clearances to combustibles as
outlined in Table 1. Installation on a
combustible floor requires a clearance of
1 inch. Using a noncombustible material
such as one-inch thick channel iron or
similar material can do this. 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
noncombustible material.

SUSPENDED INSTALLATION

Refer to Figure 1. Maintain clearances to
combustibles as outlined in Table 1. The
furnace may be suspended by field
fabricating a cradle of angle iron and
threaded rod. Secure the furnace with 2
inch minimum slotted angle or
equivalent, as shown in Figure 1. The
furnace must be supported in such a way

Fig. 1: Typical Suspended Application

3

151B0801 R5 3/28/2006

as to not allow twisting or sagging of the
cabinet. Position the supports so as to
not interfere with accessing the burner
and blower compartments. 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.

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
installation, the dampers or air controlling
means must prevent chilled air from
entering 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
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 must be checked and
adjusted to compensate for the pressure
drop caused by the evaporator coil.
Refer to Appendix B for recommended
wiring 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
operation. 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
construction, 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
communicating with a well ventilated
attic or with the outdoors shall be
provided, using a duct if necessary. Size
all of the openings and associated
ductwork by the standards provided in

the latest Oil Installation Code editions;
NFPA 31 in the United States, CAN/CSA
B139 in Canada. Take all fuel burning
appliances in the area into consideration
when calculating combustion and
ventilation air requirements.

The Model CAS-2B-90E Furnace Boot
manufactured by Field Controls, Inc. may
be used with the furnace to obtain
combustion 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.

NOTE: THE VACUUM RELIEF VALVE
(VRV) INCLUDED IN THIS KIT MUST
BE USED IN CONJUNCTION WITH
THE FURNACE BOOT.

CHIMNEY VENTING

The chimney must be sized correctly and
be in good repair. If the chimney is
oversized, 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 O4HD-091A
furnace only, the vent should be sized at
4-inch minimum, 5-inch maximum. If the
chimney serves the O4HD-140A furnace
only, the vent should be sized at 4-inch
minimum, 6-inch maximum. 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,
Fireplaces, Vents, and Solid Fuel­Burning Appliances, NFPA 31,
Standard for the Installation of Oil
Burning Equipment or CAN/CSA

B139

,

Installation Code For Oil Burning
Equipment for correct sizing information.

NOTE: This furnace is approved for
use with L-Vent.

NOTE: Maximum temperature for L­Vent is 575°F (300°C).

IMPORTANT: The chimney must be

capable of providing sufficient draft at all
times for the safe removal of the
products of combustion.

The chimney should be tested under
“winter” conditions; doors and windows
closed, all other fossil fuel burning
appliances on, clothes dryer on,
bathroom fans on, etc. If the chimney
cannot overcome the competition for air,
it will be necessary to access the reason

for it, and take corrective action. If the
chimney is 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
possible with horizontal pipes sloping
upward toward the chimney at a rate of
one-quarter inch to the foot. The flue
pipe should not be smaller in cross
sectional area than the flue collar on the
furnace. The flue pipe should connect to
the chimney such that the flue pipe
extends 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
openings should be closed. Chimneys
must conform to local, provincial or state
codes, or in the absence of local
regulations, to the requirements of the
National Building Code.

See Figure 2 and Table 2 for common
chimney problems and their remedies.

THE FURNACE MUST BE
CONNECTED TO A FLUE HAVING
SUFFICIENT DRAFT AT ALL TIMES
TO ENSURE SAFE AND PROPER
OPERATION OF THE APPLIANCE.

The flue pipe must not be routed through
concealed space, because it must be
visually checked for signs of
deterioration 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 installed. 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 governing the installation of oil
burning equipment.

4

151B0801 R5 3/28/2006

Fig. 2: Common Chimney Problems

Table 2: Common Chimney Problems

Refer to Figure 2

Key Trouble Diagnostic Remedy

Top of chimney
lower than

A

surrounding
objects

Chimney Cap

B

or ventilator.

Coping restricts

C

opening.

Observation

Observation Remove

Observation

Extend chimney
above all
surrounding
objects within
30 feet.

Make opening
as large as
inside of
chimney.

Obstruction in
chimney

D

Joist protruding

E

into chimney.

Break in

F

chimney lining.

Collection of
soot at narrow

G

space in flue
opening.

H Offset

Two or more

I

openings to the
same chimney.

Loose-seated
pipe in flue

J

opening.

Smoke pipe
extends into

K

chimney.

Failure to
extend the
length of flue

L

partition to the
floor.

Loose-fitted

M

clean-out door.

DRAFT REGULATOR CONTROL

This device is used in conjunction with conventional chimney
venting. This control (or draft regulator) automatically maintains
a constant negative pressure in the furnace to obtain maximum
efficiency. It ensures that proper pressures are not exceeded. If
the chimney does not develop sufficient draft, the draft control
cannot function properly. The draft regulator, must be installed
within the same room or enclosure as the furnace, and should

Can be found
by light and
mirror reflecting
conditions in
chimney.

Lowering a light
on an extension
cord.

Smoke test ­build smudge
fire blocking off
other opening,
watching for
smoke to
escape.

Lower light on
extension cord.

Lower light on
extension cord.

Found by
inspection from
basement.

Smoke test.

Measurement
of pipe from
within or
observation of
pipe by means
of a lowered
light.

By inspection or
smoke test.

Smoke test.

Use weight to
break and
dislodge.

Must be
handled by
competent
masonry
contractor.

Must be
handled by
competent
masonry
contractor.

Clean out with
weighted brush
or bag of loose
gravel on end
of line.

Change to
straight or to
long offset.

The least
important
opening must
be closed,
using some
other chimney
flue.

Cementing all
pipe openings
should
eliminate leaks.

Length of pipe
must be
reduced to
allow end of
pipe to be flush
with inside of
tile.

Extend partition
to floor level.

Close all leaks
with cement.

5

151B0801 R5 3/28/2006

not interfere with the combustion 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
regulator.

Table 3: Minimum Chimney Base

Temperatures (°F)

Nozzle

Chimney Height (ft.)

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

1.00 255 300 365 430

Nozzle

Chimney Height (ft.)

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 Oil
Burning Equipment, Chapter 2 and in
Canada, CAN/CSA-B139, Installation
Code for Oil 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 above­mentioned codes for sizing. The vent
pipe must be no less than 1¼ inches
I.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
normally be in the lowest level, (cellar,

basement, etc.). 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
clearances specified in the above­mentioned codes.

PIPING INSTALLATION

In the United States, NFPA 31,
Standard for the Installation of Oil
Burning Equipment, Chapter 2.

In Canada, the entire fuel system should
be installed in accordance with the
requirements of CAN/CSA B139
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
fittings. 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
damage to the shaft seal. If the height of
the oil stored in a tank above the oil
burner exceeds 11½ feet, it may be
necessary to use a pressure-regulating
device approved for this purpose.

The furnace may be installed with a one­pipe 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
component in the line. In general, keep
single line systems short as possible. 2­stage oil pumps are not available for the
O4HD furnaces. The following chart
shows the allowable line lengths
(horizontal + vertical) for single and two­line oil piping systems. All distances are
in feet.

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
systems. See burner manufacturer’s
instructions.

, and

Table 4: Oil Lines

Copper Tubing Oil Line Length (Feet)

Lift

(Feet)

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

9 17 68 45 100

10 13 52 42 100

12 - - - - - - 37 100

14 - - - - - - 32 100

16 - - - - - - 27 100

18 - - - - - - 22 88

Single-Pipe Two-Pipe

⅜”

OD ½” OD ⅜” OD ½” OD

All fuel systems should include an oil
filter between the fuel oil storage tank
and the oil burner. For best results,
install 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

factory 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

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
separate and dedicated circuit in the
main electrical panel; however,
accessory equipment such as electronic
air cleaners 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 necessary 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

, and with local

6

151B0801 R5 3/28/2006

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 EFTB (Electronic Fan
Timer Board). Do not use the direct drive
motor connections as a power source,
since there is a high risk of damaging the
accessories by exposure to high voltage
from the auto-generating windings of the
direct drive motor.

Thermostat wiring connections and air
conditioning contactor low voltage
connections are shown in the wiring
diagrams. Some micro-electronic
thermostats require additional controls
and wiring. Refer to the thermostat
manufacturer's instructions.

The thermostat should be located
approximately 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 temperatures. 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
amperage 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 removing one of the two
wires first. To determine the heating
circuit amperage draw:

1. With the power off to the appliance,
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. Restore power to the appliance and
initiate a call for heat. Note the
amperage reading when the heating
contacts are closed. (System switch
must be on “

HEAT” if so equipped.

4. Terminate the call for heat, turn
power off and re-connect the
thermostat wire. If the thermostat is
serving a combination heating and

air conditioning system, pay
particular attention to polarity.

5. When the thermostat is reconnected
and re-plumbed, adjust the heat
anticipator setting to match the
observed amperage reading.

6. Restore power to the appliance.

CIRCULATING AIR BLOWER
(ECM)

All O4HD-***A-V-F furnace models are
equipped with a variable speed direct
drive blower system. The heart of the
variable speed blower is the “ECM”
motor. “ECM” stands for electronically
commutated motor. The ECM consists of
a brushless DC type motor with a
microcomputer based variable speed
drive located in the end bell. This drive
continually monitors RPM and torque
output of the motor. This information
along with a set of blower constants
developed in a laboratory is fed into pre­programmed algorithms in the
microprocessor to determine the correct
motor output required to maintain
constant airflow regardless of external
static pressure.

The microprocessor also stores delay
profiles developed in a laboratory to
optimize the efficiency and performance
of split system air conditioners and heat
pumps. More than just on and off delays,
the variable speed blower “steps”
through intermediate airflow levels during
the preprogrammed on and off profiles.
The result is smoother more efficient
operation. The microprocessor also
controls the rate of change of the motor’s
output to create quiet, gradual starts and
stops. This kind of control is not possible
with conventional motor technology.

CONFIGURING THE BLOWER

Blower configuration should be pre-set at
the factory for the selected heat output
only however proper speed selection
should be confirmed after installation.
For cooling configuration, blower
dipswitches must be adjusted to match
cooling system nominal capacity. With
the variable speed blower configured
properly, the furnace will respond directly
to thermostat inputs. During normal
operation the motor will gradually change
speed in response to changes in system
variables such as the thermostat
settings, duct static, filters etc. The
variable speed blower is configured by
setting the 7 dipswitches located on the
control panel inside the control box
mounted on the front of the blower.

THE VARIABLE SPEED BLOWER

HAS BEEN DESIGNED TO GIVE THE
INSTALLER MAXIMUM FLEXIBILITY
TO OPTIMIZE SYSTEM
PERFORMANCE, EFFICIENCY AND
COMFORT. BECAUSE THERE ARE
SO MANY WAYS TO CONFIGURE THE
BLOWER IT IS IMPORTANT THESE
INSTRUCTIONS CAREFULLY.

CHANGES TO BLOWER
CONFIGURATION MUST BE MADE
WITH THE POWER TO THE UNIT
TURNED OFF. THE BLOWER MAY
IGNORE CHANGES MADE WITH THE
POWER ON.

ECM BLOWER OPERATION

COOLING OR HEAT PUMP MODE

When the thermostat calls for cooling or
heat pump heating the circuit between R,
G and Y (O is ignored by the blower) is
completed and the blower begins a
preprogrammed on-cycle “profile”. First
the blower ramps up to approximately
1/3 of the selected airflow and stays
there for 30 seconds. The blower then
ramps up to the selected airflow until the
thermostat is satisfied. A one-minute off­cycle delay at approximately ½ of the
selected airflow is initiated when the call
from the thermostat ends.

HEATING MODE

When the thermostat calls for heating the
circuit between R and W is completed.
The furnace control board initiates the
ignition sequence. When the burner is
energized and the fan timer has
completed the selected on delay a relay
is energized sending a signal to the
blower. The blower will start and run at a
very low speed. After 30 seconds, the
blower ramps up to the selected heating
airflow. The blower will operate two
minutes after the off delay of the fan
timer is satisfied.

NOTE: It is highly recommended that the
minimum on and off delay timings on the
fan timer be utilized with this blower as
premature tripping of the limit may occur
at the higher settings.

7

151B0801 R5 3/28/2006

MANUAL FAN.

When the manual fan switch on the
thermostat is on, energizing G only, the
blower will ramp to 50% of the selected
cooling/heat pump airflow.

SEE TABLE A.2 & A.3 FOR PROPER
DIP SWITCH SETTINGS. (HEATING
ONLY)

SEE CHART ON COVER OF BLOWER
CONTROL BOX FOR PROPER DIP
SWITCH SETTINGS FOR AIR
CONDITIONING.

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 secure the wire nut and
wires with a few 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.

FURNACE CONTROLS

The Electronic Fan Timer integrates
control of all burner and circulator fan

DIRECT DRIVE

The O4HD-***A-**-FA furnaces are
equipped with a direct drive blower
system. Direct drive blower speed
adjustments are not normally required in
properly sized extended plenum duct
systems. The motor RPM and air CFM
delivery will vary automatically to
accommodate conditions within the usual
range of external static pressures typical
of residential duct systems. Under-sized
duct systems may require a higher
blower speed to obtain a reasonable
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
wiring diagram label affixed to the
furnace. THE NEUTRAL WIRE

(normally the white wire) IS NEVER
MOVED TO ADJUST THE BLOWER
SPEED.

operations. This control is the central
wiring point for most of the electrical
components in the furnace. The
Honeywell EFT 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
combination displayed in Table 5. 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 ST9103 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 chart 1. Similarly the
United Technologies 1158-120 have an
adjustable fan off time of 2, 3, 4,or 6
minutes displayed in Table 5. The fan off
delay time starts when the burner is de­energized 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

DO NOT CONNECT POWER LEADS
BETWEEN MOTOR SPEEDS. THE
NEUTRAL WIRE MUST ALWAYS BE
CONNECTED TO THE MOTOR'S
DESIGNATED 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"
accommodating both wires on a single
motor tap. It is also acceptable to
connect the selected motor speed with a

thermally operated and automatically
resets. The limit control is factory
installed, pre-set and is not adjustable.

If a limit control opens, the Honeywell
ST9103 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
energized as well. When the limit closes,
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.

The circulating fan start-up and
shutdown is immediate in the cooling
mode.

The heating mode “fan off” delay may be
field adjusted by manipulating the
dipswitches. See Table 5.

Table 5: Heating “Blower Off/On”
Timing

Honeywell ST9103

Dip Switch

Position

1 2
On On 60 seconds
On Off 90 seconds
Off On 120 seconds
Off Off 150 seconds

Blower Off Delay

Time

United Technologies 1158-120

Dip Switch Position

1 2 3 4 On Sec.

Off Off 30
On Off 60
Off On 90
On On 120
Off Off 2
On Off 3
Off On 4
On On 6

Blower Delay
Times

Off
Min.

DISCONNECT THE POWER SUPPLY
TO THE FURNACE BEFORE
OPENING THE BLOWER ACCESS
DOOR TO SERVICE THE AIR FILTER,
FAN AND MOTOR. FAILURE TO
SHUT OFF POWER COULD ALLOW
THE BLOWER TO START
UNEXPECTEDLY, CREATING A RISK
OF DEATH OR PERSONAL INJURY.

DO NOT START THE BURNER OR
BLOWER FAN UNLESS THE BLOWER
ACCESS DOOR IS SECURELY IN
PLACE.

OIL BURNER

O4HD furnaces are equipped with
Beckett AFG Series oil burners. The oil
burner must align properly with the
cerafelt fiber chamber (firepot). The
cerafelt 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.

8

151B0801 R5 3/28/2006

tapered and free of burrs, and the

BEFORE OPERATING THE FURNACE
CHECK BURNER ALIGNMENT WITH
COMBUSTION CHAMBER. THE END
CONE OF THE AIR TUBE MUST BE
CENTRED TO THE ACCOMODATING
RING PROVIDED IN THE DESIGN OF
THE COMBUSTION CHAMBER.
ADJUST ALIGNMENT AS
NECESSARY BEFORE THE FIRST
FIRING.

contact rods must be clean and be in
firm contact with the ignition transformer
contact 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,
resulting in soot build-up throughout the
heat exchanger passages. Excess
combustion air causes a bright roaring

OIL BURNER NOZZLES

O4HD-091A furnaces are certified for

multiple firing rates, ranging from
approximately 58,000 to 79,000 BTU/hr.
The O4HD-140A furnaces are certified
for multiple firing rates of approximately
87,000 115,000 BTU/hr. 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 nozzle, 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

fire and high stack temperatures
resulting in poor fuel efficiency.

PREPARATIONS:

Drill a ¼” test port in the venting, ideally
at least 2 flue pipe diameters away from
the furnace breeching, if venting
horizontally 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
positioned.

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. Manipulating
the air shutter on the left side of the
burner controls the combustion air
supply to 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
furnace warms up. The draft may be
measured 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 CO

reading will range

2

from 11.5% to 13.5%.

After the air adjustments have been
completed, and the air shutter or air
adjustment plate has been secured, re­check the over fire draft and take another
smoke test to ensure that the values
have not changed.

Fig.4 Vertical Smoke test Location Fig.3 Horizontal Smoke test Location

9

151B0801 R5 3/28/2006

Fig. 5: Checking Over-Fire Draft.

SMOKE TEST NOTE:

If oily or yellow smoke spots are found
on the smoke test filter paper, it is
usually a sign of unburned fuel. This
indicates 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
general, stack temperature should
typically range between 380°F to 550°F,
assuming that the combustion air is
approximately room temperature (65°F ­70°F). In general, lower stack
temperature indicates greater efficiency;
however, excessively 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 furnace.

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
measured in the vicinity of the
connection between the plenum take-offs
and the trunk ducts. Refer to the

appliance rating plate of model for
temperature rise range.

If the venting from the furnace to the
chimney is long, or exposed to cold
ambient temperatures, it may be
necessary to use L-Vent 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
following the procedures outlined above.

B) The appliance rating plate should be
consulted for model temperature rise
ranges. 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
temperature stops increasing relative to
the return air temperature. The furnace
may have to run 10 to 15 minutes to
reach steady state conditions. The
measurements may be made with duct
thermometers or thermocouples used in
conjunction with multi-meters with
temperature 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
particularly 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
thermometer will be well within the air
stream near the furnace supply air outlet.
Usually, 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
exchanger. 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
segment of supply air trunk duct.

If the temperature rise is outside the
recommended 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
temperature varies directly with the
temperature 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
circulator fan heating wire or neutral
wire. Turn of 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
annoyance to the home owner, etc.

F) Be sure that the homeowner is
familiar with the furnace. The
homeowner should be aware of the
location of electrical 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.

10

151B0801 R5 3/28/2006