NATE M5S Series Downflow Direct Vent Forced Air Oil Furnaces Installation Guide
- July 29, 2024
- NATE
Table of Contents
M5S Series Downflow Direct Vent Forced Air Oil Furnaces
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Product Specifications
-
Product Name: M5S Series Downflow, Direct Vent Forced Air Oil
Furnace -
Installation Type: Sealed Combustion
-
Application: Suitable for use in manufactured homes
-
Compatibility: Requires certified air conditioning or heat pump
equipment for use in manufactured homes -
Clearances: Refer to minimum clearance requirements
Product Usage Instructions
Installation
Before proceeding with the installation, ensure compliance with
all safety standards and guidelines.
General Information
Review the installation manual thoroughly before beginning the
installation process.
Locating & Cutting Duct Openings
Follow the provided guidelines for locating and cutting duct
openings to ensure proper airflow.
Furnace Installation
Properly install the furnace according to the instructions
provided, ensuring secure attachment.
Fuel Line Hook-Up
Connect the fuel line following the specified instructions.
Bleed the fuel line and prime the furnace before operation.
Operating Sequence
Familiarize yourself with the operating sequence of the furnace
for efficient use.
Maintenance & Troubleshooting
Refer to the troubleshooting section for guidance in case of
operational issues.
Electrical Information
Follow the wiring instructions carefully for both line voltage
and low voltage connections. Ensure proper grounding.
Roof Jack Installation
If installing a roof jack, select the appropriate type, cut
openings as directed, and install securely.
FAQ (Frequently Asked Questions)
Q: Can this furnace be used in a manufactured home?
A: Yes, this furnace is suitable for installation in
manufactured homes, but specific guidelines must be followed.
Q: What should I do if I detect a gas smell?
A: If you smell gas, follow the safety instructions provided in
the manual immediately and contact your local distributor for
assistance.
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M5S Series
INSTALLATION INSTRUCTIONS
Downflow, Direct Vent (Sealed Combustion) Forced Air Oil Furnaces
For installation in:
· Manufactured Homes · Recreational Vehicles, Park Models, & Manufactured
Buildings · Modular Homes / Buildings
WARNING
CAUTION
FIRE OR EXPLOSION HAZARD
· Failure to follow safety warnings exactly could result in serious injury or
property damage.
· Installation and service must be performed by a qualified installer, service
agency or the gas supplier.
· Do not store or use gasoline or other flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
· Do not try to light any appliance. · Do not touch any electrical switch; do
not
use any phone in your building. · Leave the building immediately. ·
Immediately call your gas supplier from a
neighbors phone. Follow the gas suppliers instructions. · If you cannot reach
your gas supplier, call the fire department.
HUD Manufactured Home Construction and Safety Standards (3280.714) prohibit
the use of noncertified air conditioning or heat pump equipment with this
furnace. It is strongly recommended that manufactured housing air conditioning
components from the manufacturer be selected to provide a matched system
specifically designed to meet these requirements.
The cutting, splicing or modifying of any internal electrical wiring may void
product warranties and create a hazardous condition. Failure to comply with
these standards could also provide inadequate heating or cooling performance
and cause structural damage to a manufactured home.
Please contact your local distributor for help. A directory of factory
authorized servicers is located in the furnace homeowner packet.
Reference: HUD Manufactured Home Construction and Safety Standards 3280.714.
DO NOT DESTROY. PLEASE READ CAREFULLY & KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
TABLE OF CONTENTS
IMPORTANT SAFETY INFORMATION………………… 3
REQUIREMENTS & CODES ………………………………. 3
GENERAL INFORMATION…………………………………. 4 Minimum Clearances ……………………………………….. 4
Applications ……………………………………………………. 4 Unit Location…………………………………………………… 6
CIRCULATING AIR REQUIREMENTS…………………. 6 Return Air……………………………………………………….. 6
Supply Air ………………………………………………………. 6
FURNACE INSTALLATION………………………………… 7 General Information …………………………………………. 7
Locating & Cutting Duct Openings……………………… 7 Standard Duct Connector
Installation …………………. 8 Alternate Attachment Method………………………….. 8 Round Duct
Connector Installation …………………….. 8 Installing the Furnace ………………………………………. 8
Fuel line Hook-Up ……………………………………………. 15 Fuel Line Bleeding ……………………………………………
16 Priming the furnace………………………………………….. 16 Fuel Oil Type
………………………………………………….. 16
STARTUP & ADJUSTMENTS …………………………….. 16 Operating Instructions……………………………………….
16 How to Shut Off Oil Gun Models ……………………… 16 Verifying & Adjusting
Temperature Rise ……………… 16 Burner Adjustments …………………………………………. 17 Combustion
Air ……………………………………………….. 17 Electrode Setting …………………………………………….. 17 Switching
Ignition Control between Interrupted and Intermittent Duty ………………………………………..
17
OPERATING SEQUENCE ………………………………….. 18
TROUBLESHOOTING ……………………………………….. 18
FURNACE CONTROLS & FUNCTIONS ………………. 19
ROOF JACK INSTALLATION …………………………….. 10 Roof Jack Selection ………………………………………….
10 Locating & Cutting Roof / Ceiling Openings ………… 10 Installing The Roof Jack
…………………………………… 10
ELECTRICAL INFORMATION ……………………………. 13 Line Voltage Wiring…………………………………………..
13 Connecting Power Supply Wires……………………… 13 Low Voltage
Wiring………………………………………….. 13 Connecting Thermostat Wires…………………………. 13
Verifying Anticipator Setting ……………………………. 14 Grounding ……………………………………………………….
14
FUEL SUPPLY & PIPING …………………………………… 15 Flue Gas Sampling ………………………………………….. 15
Oil Tank & Piping Installation…………………………….. 15 One-Line System
………………………………………….. 15 Two-Line System…………………………………………… 15
MAINTENANCE ………………………………………………… 19 Installer Information …………………………………………. 19
Additional Oil Furnace Maintenance…………………… 19
OPTIONAL ACCESSORIES……………………………….. 20 Optional Add-On Air
Conditioning………………………. 20
FIGURES & TABLES…………………………………………. 21 Table 10. M5 Furnace Specifications and
Factory Settings ……………………………… 21 Table 11. A/C Blower Speed Selection Chart
……. 21 Figure 31. M5S Wiring Diagram (A/C Ready) ……. 22
INSTALLATION CHECKLIST……………………………… 24
2
IMPORTANT SAFETY INFORMATION
Safety markings are used frequently throughout this manual to designate a
degree or level of seriousness and should not be ignored. WARNING indicates a
potentially hazardous situation that if not avoided, could result in personal
injury or death. CAUTION indicates a potentially hazardous situation that if
not avoided, may result in minor or moderate injury or property damage.
WARNING:
The safety information listed below must be followed during the installation,
service, and operation of this furnace. Failure to follow safety
recommendations could result in possible damage to the equipment, serious
personal injury or death.
WARNING:
Do not install this furnace if any part has been submerged under water. A
flood damaged furnace is extremely dangerous. Attempts to use the furnace may
result in fire or explosion. A qualified service agency should be contacted to
inspect the furnace and to replace any electrical or control system parts that
have been wet or under water.
CAUTION:
Operating gas furnaces in construction environments can cause a variety of
problems within the furnace and may significantly reduce the life or the
performance of the furnace. Therefore operating the furnace during
construction is not permitted and will void the warranty.
REQUIREMENTS & CODES
· This furnace must be installed in accordance with these instructions, all
applicable local building codes and the current revision of the National Fuel
Gas Code (NFPA54/ANSI Z223.1) or the Natural Gas and Propane Installation
Code, CAN/CSA B149.1.
· Use only with type of gas approved for this furnace. Refer to the furnace
rating plate.
· Install this furnace in accordance to the minimum clearances to combustible
materials listed in Table 1, (page 5).
· Provide adequate combustion and ventilation air to the furnace space as
specified on page 6 and page 17. Do not block or obstruct air openings on the
furnace, air openings to the area where the furnace is installed, or the space
around the furnace.
· Combustion products must be discharged outdoors. Connect this furnace to an
approved vent system, as specified on page 10.
· This furnace is designed to operate with a maximum external pressure rise of
0.5 inches of water column. NOTE 1: The static pressure measurement should not
include the coil (if applicable). Consult Table 10, (page 21) and the rating
plate for the proper circulating air flow and temperature rise. NOTE 2: It is
important that the duct system be designed to handle the desired flow rate and
external pressure rise. An improperly designed duct system can result in
nuisance shutdowns, and comfort or noise issues.
· When supply ducts carry air circulated by the furnace to areas outside the
space containing the furnace, the return air shall also be handled through the
front door of the furnace. Make sure there is sufficient return air through
the door. See return air connections page 6.
· Additional information listed below is for reference purposes only and does
not necessarily have jurisdiction over local or state codes. Always consult
with local authorities before installing any gas appliance.
Combustion & Ventilation Air · US: National Fuel Gas Code (NFGC), Air for
Combustion and
Ventilation · CANADA: Natural Gas and Propane Installation Codes
(NSCNGPIC), Venting Systems and Air Supply for Appliances
Duct Systems · US and CANADA: Air Conditioning Contractors Association
(ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National
Association (SMACNA), or American Society of Heating, Refrigeration, and Air
Conditioning Engineers (ASHRAE) Fundamentals Handbook
Electrical Connections · US: National Electrical Code (NEC) ANSI/NFPA 70 ·
CANADA: Canadian Electrical Code CSA C22.1
Gas Piping & Gas Pipe Pressure Testing · US: NFGC and National Plumbing Codes
· CANADA: NSCNGPIC
General Installation · US: Current edition of the NFGC and the NFPA 90B. For
copies, contact the National Fire Protection Association Inc., Batterymarch
Park, Quincy, MA 02269; or American Gas Association, 400 N. Capitol, N.W.,
Washington DC 20001 or www.NFPA.org · CANADA: NSCNGPIC. For a copy, contact
Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto),
Ontario, M9W 1R3 Canada
Safety · US: (NFGC) NFPA 541999/ANSI Z223.1 and the Installation
Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B. ·
Federal Manufactured Home Constructions & Safety Standard (H.U.D. Title 24,
Part 3280.707[a][2]) · The Standard for Manufactured Home Installations
(Manufactured Home Sites, Communities, and Set-Ups) ANSI A225.1 and/or
CAN/CSA-2240 MH Series). · American National Standard (ANSI-119.2/NFPA-501C)
for all recreational vehicle installations. · CANADA: CAN/CSA-B149.1 and
.2M00 National Standard of Canada. (NSCNGPIC)
3
· The Commonwealth of Massachusetts requires compliance with regulation 248
CMR 4.00 and 5.00 for installation of through the wall vented gas
appliances as follows:
1. For direct-vent appliances, mechanical-vent heating appliances or domestic
hot water equipment, where the bottom of the vent terminal and the air intake
is installed below four feet above grade the following requirements must be
satisfied: a.) A carbon monoxide (CO) detector and alarm shall be placed on
each floor level where there are bedrooms. The detector shall comply with NFPA
720 (2005 Edition) and be mounted in the living area outside the bedroom(s).
b.) A (CO) detector shall be located in the room that houses the appliance or
equipment and shall: · Be powered by the same electrical circuit as the
appliance or equipment. Only one service switch shall power the appliance and
the (CO) detector; · Have battery back-up power; · Meet ANSI/UL 2034 Standards
and comply with NFPA 720 (2005 Edition); and Approved and listed by a
Nationally Recognized Testing Laboratory as recognized under 527 CMR. c.) A
Product-approved vent terminal must be used, and if applicable, a product-
approved air intake must be used. Installation shall be in strict compliance
with the manufacturer’s instructions. A copy of the installation instructions
shall remain with the appliance or equipment at the completion of the
installation. d.) A metal or plastic identification plate shall be mounted at
the exterior of the building, 4 feet directly above the location of vent
terminal. The plate shall be of sufficient size, easily read from a distance
of eight feet away, and read “Gas Vent Directly Below”.
2. For direct-vent appliances, mechanical vent heating appliances or domestic
hot water equipment where the bottom of the vent terminal and the air intake
is installed above four feet above grade the following requirements must be
satisfied: a.) A (CO) detector and alarm shall be placed on each floor level
where there are bedrooms. The detector shall comply with NFPA 720 (2005
Edition) and be mounted in the living area outside the bedroom(s). b.) The
(CO) detector shall: · Be located in the room that houses the appliance or
equipment; · Be hard-wired, battery powered or both. · Shall comply with NFPA
720 (2005 Edition). c.) A product-approved vent terminal must be used, and if
applicable, a product-approved air intake must be used. Installation shall be
in strict compliance with the manufacturer’s instructions. A copy of the
installation instructions shall remain with the appliance or equipment at the
completion of the installation.
GENERAL INFORMATION
CAUTION:
· Do Not alter or modify this furnace or any of its components.
· Never attempt to repair damaged or inoperable components. This may cause
unsafe operation, explosion, fire and/or asphyxiation.
· If furnace malfunctions or does not operate properly, contact a qualified
service agency or gas utility for assistance.
Minimum Clearances
This heating appliance must be installed with clearances not less than the
minimums listed in Table 1, (page 5). This furnace must be installed with
ample clearance for easy access to the air filter, blower assembly, burner
assembly, controls, and vent connections. See Figure 1, Figure 2, and Figure 3
(page 5). · The dimensions of the room or alcove must be able to
accommodate the overall size of the furnace and the installation clearances
listed in Table 1 and in Figure 4 (page 5). · Alcove installations: minimum
18″ clearance at front of furnace shall be provided for future servicing. A
removable access panel should be installed between top of the furnace door
frame and the ceiling. · Closet installations must use a louvered door having
a minimum free area of 235 in2 when located 6″ from furnace or 390 in2 for 5
ton ready M5 furnaces. For special clearance between 1″ – 6″, requirements are
a louvered door with a minimum of 250 in2 free area, with the openings in the
closet door in line with the louvered openings in the furnace door. A fully
louvered closet door may be used. See Circulating Air Requirements section
(page 6). · The furnace must be kept free and clear of insulating material.
Examine the furnace area when the furnace is installed or when insulation is
added. Insulating material may be combustible.
Applications
M5 Series oil furnaces are listed as direct vent (sealed combustion), downflow
heating appliances for manufactured (mobile) homes and recreational vehicles.
The furnace must be located so that venting can be properly achieved.
Air conditioning may be added to structures with M5 series furnaces using air
conditioning or conventional units. This instruction manual includes special
requirements for incorporation of air conditioning equipment to the M5 series
furnaces. See Table 11, (page 21).
Multi-speed blower assemblies shown in Table 2, (page 5), have been certified
for field installation in M5 series furnaces.
4
6″ (152 mm) Top Clearance
0″ Side Clearance to Furnace Cabinet
Removable access panel should be installed above furnace door frame to access roof jack
(45718m”m)
Nearest Wall or Partition
Figure 1. Alcove Installation
6″ (152 mm) Top Clearance
0″ Side Clearance to Furnace Cabinet
Provide min. 235 sq. in. (1516 cm 2 ) open free area in front or side wall
or In closet door located at top, center or bottom
(1526m” m)
CLOSET DOOR
Figure 2. Closet Installation
6″ (152 mm) Top Clearance
0″ Side Clearance to Furnace Cabinet
Provide min. 250 sq. in. (1613 cm 2) open free area in front or side wall
or in closet door
a fully louvered door may be used
(25
1″ mm)
CLOSET DOOR
Figure 3. Special 1″ Clearance
“A”- 56″
“A” Model w/o Coil Cabinet
“B” Model w/Coil Cabinet
“B”- 76″
19 3/4″
23 3/4″
Figure 4. Overall Dimensions
ALL MODELS
Front Back Sides Roof Jack Top Top and Sides of Duct Bottom of Duct
A Cabinet (w/ coil box) A Cabinet (w/o coil box) B Cabinet
CLOSET
6″ 0″ 0″ 0″ 6″ 0″ — 0″ 1/4″ 0″
ALCOVE
18″ 0″ 0″ 0″ 6″ 0″ — 0″ 1/4″ 0″
Table 1. Minimum Clearances
PART NO.
903413 903890
BLOWER / MOTOR ASSEMBLY
BLOWER WHEEL
MOTOR (HP)
11 x 8
1/2
11 x 8
3/4
A/C CAPACITY (TONS)
2, 2½, 3 & 4 2, 2½, 3, 4 & 5
Table 2. Blower Assemblies
5
Unit Location
· The furnace shall be appropriately located to the supply and return air
distribution system (page 6). Sides and back of the furnace may be enclosed by
wall framing. See Minimum Clearances section on page 4.
· The furnace installation is only intended for free air return through the
furnace door louvers. DO NOT connect a ducted return air system directly to
the furnace. Improper installation may create a hazard and damage equipment,
as well as void all warranties.
· Furnace may be installed on combustible flooring when using manufacturer
approved duct connectors. See page 6.
· When installed in a residential garage, the furnace must be positioned so
the burners and the source of the ignition are located no less than 18 inches
above the floor and protected from physical damage by vehicles.
CIRCULATING AIR REQUIREMENTS
WARNING:
Do not allow combustion products to enter the circulating air supply. Failure
to prevent the circulation of combustion products into the living space can
create potentially hazardous conditions including carbon monoxide poisoning
that could result in personal injury or death.
The surface that the furnace is mounted on must provide sound physical support
of the furnace with no gaps, cracks or sagging between the furnace and the
floor or platform.
Circulating air ductwork must not be connected to any other heat producing
device such as a fireplace insert, stove, etc. This may result in fire,
explosion, carbon monoxide poisoning, personal injury, or property damage.
Return Air
U.S.A. home manufacturers shall comply with all of the following conditions to
have acceptable return air systems for closet installed forced air heating
appliances:
· Means shall be provided that prevent inadvertent closure of flat objects
placed over the return air opening located in the floor of the closet (versus
the vertical front or side wall).
· The total free area of openings in the floor or ceiling registers serving
the return air duct system must be at least 235 in2. At least one register
should be located where it is not likely to be covered by carpeting, boxes and
other objects.
· Materials located in the return duct system must have a flame spread
classification of 200 or less. This includes a closet door if the furnace is
in a closet.
· Noncombustible pans having 1″ upturned flanges are located beneath openings
in a floor duct system.
· Wiring materials located in the return duct system shall conform to Articles
300-22 of the National Electrical Code (ANSI C1/NFPA-70).
· Oil piping is not run in or through the return duct system.
CAUTION:
HAZARD OF ASPHYXIATION: Negative pressure inside the closet, with closet door
closed and the furnace blower operating on high speed, shall be no more
negative than minus 0.05 inch water column.
· Test the negative pressure in the closet with the aircirculating fan
operating at high speed and the closet closed. The negative pressure is to be
no more negative than minus 0.05 inch water column.
· Air conditioning systems may require more duct register and open louver area
to obtain necessary airflow.
Supply Air
For proper air distribution, the supply duct system must be designed so that
the static pressure measured external to the furnace does not exceed the
listed static pressure rating shown on the furnace rating plate.
Location, size, and number of registers should be selected on the basis of
best air distribution and floor plan of the home. The supply air must be
delivered to the conditioned space by duct(s) secured to the furnace casing,
running full size and without interruption. Three typical distribution systems
are shown in Figure 5.
CAUTION:
HAZARD OF ASPHYXIATION: Do not cover or restrict return air opening.
· The return air opening into the closet shall not be less than specified in
the appliance’s listing.
· The cross-sectional area of the return duct system leading into the closet,
when located in the floor or ceiling shall not be less than 235 in2 (or 390
in2 for M5 furnaces with 5 ton blower kits).
A Single trunk duct
B
Dual trunk duct w/crossover connector
Transition duct
C
w/branches
Figure 5. Typical Supply Duct System
6
FURNACE INSTALLATION
NOTE: These Installation procedures are suggested for typical furnace
installations. Since each installation is different, the sequence of
instructions may differ from the actual installation. Only qualified HVAC
technicians should install this furnace.
The installer must be familiar with and comply with all codes and regulations
applicable to the installation of these heating appliances and related
equipment. In the absence of local codes, the installation must be in
accordance with the current provisions of one or more of the following
standards.
· Federal Manufactured Home Constructions & Safety Standard (H.U.D. Title 24,
Part 3280.707[a][2])
· American National Standard (ANSI-119.2/NFPA-501C) for all recreational
vehicle installations.
· American National Standard (ANSI-Z223.1/NFPA-54) and/or CAN/CSA B149 for all
gas-fired furnace models.
· American National Standard (ANSI-Z95.1/NFPA-31) and/or CSA B139 for all oil-
fired furnace models.
· American National Standard (ANSI-C1/NFPA-70) and/or CSA 22.1 Canadian
Electric Code Part 1 for all electrical field wiring.
· Units have been certified under standards UL 307A & B, UL727-1999, ANSI
Z21.47/CSA 2.3, and CSA B140.10.
General Information
· The furnace must be leveled at installation and attached to a properly
installed duct system. Do not use the back of the furnace for return air. See
page 6 for circulating requirements.
· The furnace must be installed so that all electrical components are
protected from water
· The dimensions of the room or alcove must be able to accommodate the overall
size of the furnace and the installation clearances listed in Table 1, (page
5) and Figure 1 (page 5)
· The furnace must be installed upstream from a refrigeration system.
· M5 series oil furnaces are certified for use on wood flooring or supports,
but must be installed on top of a duct connector. This factory supplied
accessory must be installed in the floor cavity and attached to the supply air
duct before the furnace is installed.
Locating & Cutting Duct Openings
Floor cut-outs and fuel line holes must be carefully located to avoid
misalignment of the furnace, and vent piping. To locate standard ducts see
Figure 6. For round ducts, see Figure 7. 1. Measure 10″ from the rear wall or
alcove and mark the
centerline of the cut-out on the floor. 2. Using the centerline as a starting
point, draw the rest
of the duct cut-out to the dimensions shown in Figure 6 or Figure 7. 3. Cut
out the floor opening 1/16″ larger than the actual cutout drawn. This will
allow some clearance when installing the duct connector. 4. Measure from the
top of the floor down to the top of the supply air duct to obtain the depth of
the floor cavity. NOTE: The depth of the floor cavity shown as “X” in
20″ 14 1/2″
CL
REAR WALL OF CLOSET OR ALCOVE
2 1/4″
2 3/4″
24″ 23 1/4″
21 3/4″ 14 1/2″
FURNACE OUTLINE
10″
FLOOR CUT-OUT
FOR STANDARD
CL
DUCT CONNECTORS
CL CL
CUT-OUT FOR OPTIONAL
CL 1 3/4″
COOLING COIL
3/4″
CL
CL
1 3/4″ 3/4″ 1 7/8″
2 7/8″
ALT FUEL-LINE ENTRY 1 1/4″ Dia.
FUEL 2″
LINE
FURNACE OUTER DOOR
Figure 6. Cut-Out Dimensions for Standard Duct Connectors
20″
CL
10″
REAR WALL OF CLOSET OR ALCOVE
24″ 23 1/4″ 21 3/4″
FURNACE OUTLINE
10″
FLOOR
CUT-OUT FOR ROUND DUCT
CL
(14 1/4″ DIAMETER)
CL CL
CL
1 3/4″ 3/4″ 1 7/8″ 2 7/8″
1 3/4″
CUT-OUT FOR CL
OPTIONAL
3/4″
COOLING COIL
CL
ALT FUEL-LINE ENTRY 1 1/4″ Dia.
FUEL 2″
LINE
FURNACE OUTER DOOR
Figure 7. Cut-Out Dimensions for Round Duct Connectors
Hole for Gas Line
Wood Floor
ConTnaebcstor
Duct Connector
SAuiprpDlyuct
Bend tabs up 90°
Mounting Plate
Figure 8. Standard Duct Connector Installed
7
Figure 9 (page 9) will determine the correct duct connector. 5. Determine
which duct connector to use from Table 3, (page 9). 6. Measure and drill gas
hole and cut out for cooling coil (if applicable). See Figure 6 or Figure 7.
Standard Duct Connector Installation
The standard duct connector is designed for use on ducts 12″ in width. Ducts
narrower than 12″ may not allow sufficient clearances for this type of
installation. See Alternate Attachment Method section below.
1. Center the duct connector in the floor opening with bottom tabs resting on
top of the supply air duct.
2. Mark the cut-out area on the supply air duct by tracing around the
connector tabs of the duct connector. See Figure 8 (page 7).
3. Remove the duct connector and cut out the marked area of the supply air
duct 1/4″ larger the actual cutout drawn.
4. Install the duct connector back in the floor opening with the bottom tabs
extending into the supply air duct.
5. Install the mounting plate under the back side of the duct connector as
shown in Figure 8. Align the screw holes in both components.
6. Secure the duct connector and the mounting plate to the wood floor with
appropriate size screws.
7. Bend the connector tabs on the bottom of the duct connector upwards and as
tight as possible against the supply air duct.
8. Bend both tabs up 90° on the mounting plate. See Figure 10 (page 9).
9. Seal all connections with industrial grade sealing tape or liquid sealant.
NOTE: Requirements for sealing ductwork vary from region to region. Consult
with local codes for requirements specific to your area.
Alternate Attachment Method
The standard duct connector is designed for use on ducts 12″ in width. However
if there is insufficient clearance to bend the duct connector tabs, this
alternate attachment method may be used. 1. Score and cut the top of the
supply air duct as indicated
in Option 1 or Option 2. See Figure 11 (page 9). NOTE: If Option 1 is
selected, cut out the metal from the shaded area. 2. Fold the two flaps
(Options 1 or 2) up to form the opening for the duct connector. 3. Install the
duct connector with the bottom tabs extending into the supply air duct. 4.
Bend the tabs on the bottom of the duct connector upwards and as tight as
possible against the supply air duct. See Figure 12 (page 9).
5. Form the flaps (Options 1 or 2) up against the duct connector as tight as
possible.
6. Secure the duct connector flaps to the supply air duct with staples (3
minimum) or if a 2x block/joist is not provided, use sheet metal screws (2
minimum).
NOTE: The duct connector tabs may be attached to the air duct with sheet metal
screws or other suitable fasteners as long as the duct connector and the air
duct are securely attached.
7. Seal all connections with industrial grade sealing tape or liquid sealant.
NOTE: Requirements for sealing ductwork vary from region to region. Consult
with local codes for requirements specific to your area.
Round Duct Connector Installation
1. Apply a bead of caulking, mastic, or other approved sealant around bottom
side of connector.
2. Install and center the duct connector in the floor opening. 3. Install the
mounting plate under the back side of the
duct connector. See Figure 13 (page 9). NOTE: Align the screw holes in both
components. 4. Secure the duct connector and the mounting plate to the wood
floor with appropriate size screws. 5. Connect the round supply duct to the
underside of the duct connector and secure them with field supplied sheet
metal screws. 6. Seal all connections with industrial grade sealing tape or
liquid sealant.
NOTE: Requirements for sealing ductwork vary from region to region. Consult
with local codes for requirements specific to your area.
Installing the Furnace
Sides and back of the furnace may be enclosed by wall framing such as in a
closet or alcove. The dimensions of the room or alcove must be able to
accommodate the overall size of the furnace shown in Figure 4 (page 5) and the
installation clearances outlined on page 4. The furnace shall be appropriately
connected to the supply distribution system as shown in Figure 14 (page 9) &
Figure 15 (page 9).
1. Remove furnace outer door(s) and bottom fuel line knockout.
2. Place furnace onto duct connector and center with floor opening.
3. Slide onto mounting plate. (Bottom rear slots on furnace should engage
with mounting plate tabs.)
4. Secure front with one (1) fastener at each corner. See Figure 14 & Figure
15.
NOTE: Additional fasteners may be used at rear, sides or through door frame,
as desired, to secure furnace to closet or alcove framing.
8
IF FLOOR CAVITY “X” IS:
7/8″ / (22) 2″ / (51) 4-1/4″ / (108) 6-1/4″ / (159) 8-1/4″ / (210) 10-1/4″ /
(260) 12-1/4″ / (311)
DUCT CONNECTOR TYPE & PART NUMBER
STANDARD DUCT
901987A 901988A 901989A 901990A 901991A 901992A 901993A
ROUND DUCT
904008 N/A
904010 904011 904012 904013 904014
NOTE: Dimensions shown as Inches / (Millimeter)
Table 3. Duct Connector Sizes
“X”
FLOOR CAVITY
FLOOR OPENING
SUPPLY AIR DUCT
Figure 9. Floor Cavity
Duct connector tabs Staples or sheet metal screws
Narrow Duct Duct Flap
Sheet metal screws
Duct Connector
Narrow Duct
Narrow Duct
Figure 12. Narrow Ducts
DUCT CONNECTOR
SCREWS
MOUNTING PLATE
FUEL LINE HOLE
FUEL LINE HOLE
14″ SUPPLY CONNECTION
Figure 13. Round Duct Connector Installed
DUCT CONNECTOR
SUPPLY AIR DUCT
BEND TABS TIGHTLY AGAINST SUPPLY AIR DUCT
Figure 10. Duct Connector Tabs
OPTION 1
Remove this Flap
Cut Here
Supply Air Duct
OPTION 2
Cut Here
Cut Here Cut Here
Cut Here
Remove this Flap
Cut Here
Figure 11. Narrow Air Duct Openings
MTG. PLATE TABS
SECURE FURNACE WITH 2 FASTENERS AT FRONT
CORNER HOLES
SLIDE FURNACE ALL THE WAY BACK ONTO MTG. PLATE
Knockout Over Holes SUPPLY AIR DUCT
Figure 14. “A” & “B” Cabinet Furnaces
MTG. PLATE TABS
SECURE FURNACE WITH 2 FASTENERS AT FRONT CORNER HOLES
SLIDE FURNACE BACK AGAINST
MTG. PLATE
SUPPLY AIR DUCT
FUEL LINE HOLES
Figure 15. “A” Cabinet Furnace on Coil Cabinet
9
Fold Flap Here Cut Here Cut Here
Fold Flap Here Fold Flap Here
Cut Here Fold Flap Here
ROOF JACK INSTALLATION
Required ceiling and roof cut-out openings must be carefully located to avoid
misalignment of the furnace and Roof Jack. NOTE: Install only roof jack
assemblies listed in Table 4, (page 11) on this heating appliance.
Roof Jack Selection
1. Determine depth of ceiling cavity from center of roof opening to center of
ceiling opening noted as “Dimension A” in Figure 16 (page 11).
2. Determine ceiling height and subtract height of furnace noted as
“Dimension B” in Figure 16 (page 11).
3. Add dimensions “A” & “B” (and X from Table 5, (page 11) if slant deck
flashing is used). The total length of [A] + [B] + [X] must be within the
minimum and maximum range of the roof jack listed in Table 4.
Application Notes
· FAW, FAWT, SAW and SAWT series roof jacks with a 5″ diameter inner vent pipe
may be used with all M5 Series oil furnaces.
F = Flat Flashing: flexes from 0/12 to 1/12 roof slope. See Figure 17 (page
11). S = Slant Flashing: 2.5/12 Slope flexes from 1/12 to 4/12 roof slope,
4/12 flexes from 3/12 to 5/12. See Figure 18 (page 11).
· M5 furnaces may be used with roof jack systems and extension accessories as
tall as 170″. An internal roof jack extension (p/n 901935 – 10″, p/n 903107 –
18″) can be used to increase roof jack height. All connections inside the home
must be made below the ceiling.
· This furnace must never be connected to a chimney flue servicing a fireplace
or other appliance designed to burn solid fuel.
· If the roof jack crown is covered or blocked with snow, the furnace will not
operate properly. If the home is located in regions where snow accumulation
exceeds 7″ (HUD snowload zones) use an external roof jack extension (p/n
901937). A maximum of 2 extensions per roof jacks can be used. Extensions are
optional accessories and may be purchased through your distributor.
Locating & Cutting Roof / Ceiling Openings
IMPORTANT NOTE: Do not allow debris to fall into the furnace. This could cause
unsafe operation and void the furnace warranty. Use the top cap that comes
with the furnace packaging (or alternate protector) to prevent debris from
falling into the furnace before the final roof jack connection is made.
NOTE: Refer to the installation instructions provided with optional air
conditioning packages when installing furnaces with optional cooling coil
cabinet or with optional C* series indoor coils.
1. Locate center of Roof Jack opening, measure 13 1/2″ from the rear wall of
closet or alcove along the center line of furnace and floor opening. See
Figure 19.
2. Cut ceiling and roof holes: · Ceiling = 8 3/4″ (222 mm) diameter · Roof =
9 3/8″ (238 mm) diameter
Installing The Roof Jack
1. Apply caulking compound on underside of roof flashing to form a continuous
strip at least 3/8″ wide around the underside of the perimeter of the
flashing. For flat roof, see Figure 20 or see Figure 21 (page 12) if roof is
pitched.
2. Connect roof jack assembly to the furnace. Insert telescoping roof jack
assembly through the opening cut on the roof.
3. Connect inner flue pipe to vent collar of the furnace. See Figure 22 (page
12).
4. Connect combustion air pipe to furnace collar with sheet metal screw. See
Figure 22.
NOTES: · It is recommended that the connection of the combustion
air pipe to the furnace be made before the flashing is secured to the roof to
maintain alignment of roof jack and furnace connections. · For replacement
furnaces, be sure the inner flue pipe connects over the furnace vent collar.
DO NOT use a smaller diameter inner flue pipe which could slide inside the
furnace vent collar and restrict the flow of furnace flue products.
5. Attach roof flashing. If necessary, shift roof flashing slightly in the
roof opening so that assembly is in alignment with furnace.
NOTE: If flashing is mounted on 12 degree angle, it may be necessary to adjust
the angle to match the roof pitch; (1/12 – 4/12 maximum).
6. Press down firmly on roof flashing (over caulking) to make the seal with
roof water tight.
7. Secure flashing with appropriate fasteners. NOTE: For added protection
against leaks, coat the flashing plate and fasteners with approved roofing
compound.
NOTE: Upper roof jack crown to be stored in a prominent location inside
manufactured home until on-site installation.
Installing Transit-Mode Venting System (Before Home is Moved to Site)
NOTE: For transit purposes, the transit kit (P/N 903838) should be installed
before home is moved to site.
1. Furnace must be installed in accordance to furnace installation manual.
2. Select appropriate roof jack from Table 4, (page 11)
3. Roof jack (less upper roof jack crown), with weather cap to be installed
as described in Installing The Roof Jack section.
4. Install the four warning tags (factory supplied) on these items: · Weather
cap · Fuel line connection point · Furnace flame observation door · Furnace
wall thermostat
10
ROOF JACK CROWN
CEILING CAVITY
“A” CEILING “B”
SLANT DECK FLASHING
“X” (SEE TABLE 5)
Roof Opening
PITCHED ROOF
Flue Pipe
Combustion Air Pipe
56″
Furnace or
76″
Figure 16. Ceiling Cavity Depth
ROOF JACK CROWN
SLANT DECK FLASHING
CEILING CAVITY
CEILING
CEILING OPENING
ROOF OPENING
“X” (SEE TABLE 5)
PITCHED ROOF
Figure 17. Example of Flat Jack with Flashing
MODEL NUMBER
APPROX. LENGTH BELOW FLASHING
(F,S)AW1523-(0,2,4)(A,S) (F,S)AW2135-(0,2,4)(A,S) (F,S)AW2747-(0,2,4)(A,S) (F,S)AW3563-(0,2,4)(A,S) (F,S)AW5195-(0,2,4)(A,S)
15″ – 23″ 21″ – 35″ 27″ – 47″ 35″ – 63″ 51″ – 95″
NOTE: Not all models are available. Check with your local distributor for
available models.
S AW 27 47 – 2 S
F = FLAT FLASHING S = SLANT FLASHING
AW= ALL WEATHER
MIN. ADJ. LENGTH
FLUE STEEL TYPE A= ALUMINIZED S=STAINLESS
FLASHING PITCH/12″ RISE 0=FLAT 2=2.5/12 4=4/12
MAX. ADJ. LENGTH
Table 4. Roof Jack Assemblies
ROOF JACK SERIES
IF ROOF PITCH IS:
SLANT DECK FLASHING NUMBER
“X”
2″ in 12″ 903893 (2.5/12) 2-1/8″
2-1/2″ in 12″ 903893 (2.5/12) 2-1/2″
“F Series
3″ in 12″
903894 (3/12)
2-7/8″
3-1/2″ in 12″ 903894 (3/12)
3-1/4″
4″ in 12″
903895 (4/12)
3-5/8″
4-1/2″ in 12″ 903895 (2.5/12) 2-1/8″
5″ in 12”
“S” Series (2.5 / 12 Pitch only)
5-1/2″ in 12″
6″ in 12″
903895 (2.5/12) 903894 (3/12) 903894 (3/12)
2-1/2″ 2-7/8″ 3-1/4″
6-1/2″ in 12″ 903895 (4/12)
3-5/8″
Optional deck flashings for flat and 2.5/12 pitch roof jacks. 4/12 pitch roof jacks not applicable.
Table 5. Slant Deck Flashings
20″
CL
10″
REAR WALL OF CLOSET OR ALCOVE
ROOF JACK WITH 2 1 2 /12 SLANT
FLASHING
5/12 ROOF SLOPE
2 1 2 /12 SLANT DECK
Figure 18. Example of 2½ / 12 Slant Jack with Flashing
FURNACE OUTLINE
13 1/2″
24″
CEILING CUT-OUT FOR
FLUE AND ROOF JACK
CL
FURNACE OUTER DOOR
Figure 19. Cut-Out Dimensions for Flue & Roof Jack
11
Secure roof jack with appropriate fasteners
after connecting to furnace
Caulk under roof flashing to prevent
water leakage
Optional 2-piece ceiling ring #902521
Figure 20. Flat Roof
Roof Ceiling
Removing the Transit-Mode Venting System (After home is moved to site)
WARNING:
Failure to properly secure the flue pipe to the furnace may result in fire,
explosion or asphyxiation when operating the furnace.
1. Transit-mode weather cap to be removed and upper roof jack crown
installed. Do not discard the screws. See Figure 23.
2. Place upper roof jack (crown) on the flue pipe assembly.
NOTE: Make sure inside flue pipe attaches over inner flue pipe and outer Roof
Jack pipe fits over outer pipe.
3. Secure in place using three sheet metal screws (#10 x 1/2″) removed in
step 1. Do not use the same holes which secured the rain cap in place.
4. Remove and discard all 4 venting system warning tags.
Secure lower roof jack section with no. 10 S.M. screws
Caulk under roof flashing to prevent
water leakage
Upper Roof Jack Section
Optional Slant Deck Flashing
Secure flashing with appropriate
fasteners
Ceiling
COMPLETED ASSEMBLY
UPPER ROOF JACK (CROWN)
WEATHER CAP
SCREWS
FLASHING OUTER PIPE
Figure 21. Pitched Roof
CONNECT OUTER FLUE SHIELD INNER FLUE PIPE
VENT COLLAR MOUNTING FLANGE
Figure 22. Combustion Air Pipe Connection
INNER FLUE PIPE FLUE ASSEMBLY
TO FURNACE
Figure 23. Roof Jack Crown
On-Off Switch
Blower Plug Power Entry
Thermostat Wires
Furnace Control Box
To combustion Blower or Flame Roll-out Switch
To Gas Valve On-Auto Switch or Burner (Heating Models Only)
Figure 24. Control Panel (All Models)
12
ELECTRICAL INFORMATION
WARNING:
ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in serious injury or
property damage.
Improper servicing could result in dangerous operation, serious injury, death
or property damage.
· Before servicing, disconnect all electrical power to furnace.
· When servicing controls, label all wires prior to disconnecting. Reconnect
wires correctly.
· Verify proper operation after servicing.
Line Voltage Wiring
WARNING:
To avoid electric shock, personal injury, or death, turn off the electric
power at the disconnect or the main service panel before making any electrical
connections.
· Electrical connections must be in compliance with all applicable local codes
with the current revision of the National Electric Code (ANSI/NFPA 70).
· For Canadian installations the electrical connections and grounding shall
comply with the current Canadian Electrical Code (CSA C22.1 and/or local
codes).
It is recommended that 115VAC line voltage be supplied to the furnace from a
dedicated branch circuit containing the correct fuse or circuit breaker for
the furnace as listed in Table 6, (page 14).
CAUTION:
Label all wires prior to disconnection when servicing controls. Wiring errors
can cause improper and dangerous operation. Verify proper operation after
servicing.
IMPORTANT NOTES: · Refer to the wiring diagram inside the control box
cover or Figure 31 (page 22) for the wiring of your particular unit. Any other
wiring methods must be acceptable to authority having jurisdiction. · Proper
line voltage polarity must be maintained in order for the control system to
operate correctly. Verify the incoming neutral line is connected to the white
wire and the incoming “hot” line is connected to the black wire. The furnace
will not operate unless the polarity and ground are properly connected as
shown in Figure 25 (page 14).
For installation of A-size Cabinet furnaces, allow sufficient slack in the
wiring if an optional cooling coil cabinet is added at a later time. Use of
copper conductors is recommended.
Connecting Power Supply Wires
1. Remove the furnace control panel cover. 2. Route wires (115 VAC) through
the strain relief on the
left side of the furnace control box. See Figure 24 (page 12). 3. Connect the
hot wire to the black pigtail lead, and the neutral wire to the white pigtail
lead. Secure all connections with suitable wire nuts. 4. Connect the ground
wire to the grounding screw. 5. Reinstall the control panel cover and secure
with the original mounting screws.
Low Voltage Wiring
· The furnace is designed to be controlled by a 24 VAC thermostat. The
thermostat’s wiring must comply with the current provisions of the NEC
(ANSI/NFPA 70) and with applicable local codes having jurisdiction.
· The thermostat must be installed according to the instructions supplied by
the thermostat manufacturer. Low voltage connections (24 VAC) from the
thermostat are wired to the terminal strip on the integrated control in the
furnace.
· The thermostat should be mounted about 5 feet above the floor on an inside
wall. DO NOT install the thermostat on an outside wall or any other location
where its operation may be adversely affected by radiant heat from fireplaces,
sunlight, or lighting fixtures, and convective heat from warm air registers or
electrical appliances. Refer to the thermostat manufacturer’s instruction
sheet for detailed mounting information.
· The nominal anticipator setting is 0.4. Refer to the thermostat literature
for additional information.
· Five-conductor thermostat wire is recommended for 24 volt low-voltage
circuit (2-wire is required for furnace only; 5-wire for heating and optional
cooling systems). Refer to Table 6, (page 14) for thermostat wire information.
Connecting Thermostat Wires
1. Insert 24 volt wires through the plastic grommet just above the control
panel.
2. Connect the thermostat wires to the furnace low voltage pigtails
(dependent on the installation application). See Figure 25 (page 14). NOTE: To
connect an M5 to a thermostat without an RH & RC connection, please refer to
the wiring diagram and the installation instructions supplied in the kit [P/N
1018453]. Units installed with kit [P/N 1018453] will not use the RH
connection from the furnace, RC on the furnace connects to the thermostat.
3. Connect low-voltage circuit to the wall thermostat. 4. A hole may be made
in the furnace cabinet to ease
thermostat wiring. Make sure that the wiring is protected from the sharp edge
of the added hole.
13
Verifying Anticipator Setting
After the furnace is installed, check the thermostat anticipator against the
nominal setting of 0.4. 1. Connect the milliamp meter in series with one of
the
gas valve’s low voltage terminals. 2. Energize the gas valve. 3. Read the
value of the milliamps. 4. Adjust the heat anticipator of the thermostat to
the
value on the milliamp meter. If the heat anticipator is set too high, the
furnace may delay turning on. If set too low, the furnace may cycle frequently
and not provide comfort to the homeowner.
Grounding
WARNING:
To minimize personal injury, the furnace cabinet must have an uninterrupted or
unbroken electrical ground. The controls used in this furnace require an earth
ground to operate properly. Acceptable methods include electrical wire or
conduit approved for ground service. Do not use gas piping as an electrical
ground!
Thermostat
Rc
Red
RH
Red
White
W
G
Green
Y Yellow
M5 Furnace Red
Red
TR
White Green
TW Oil Burner
Grey
To AC Contactor Figure 25. Thermostat Wiring
FURNACE MODEL NUMBER
FURNACE INPUT (BTUH)
CABINET WIDTH (IN.)
NOMINAL ELECTRICAL
SUPPLY
MINIMUM OPERATING
VOLTAGE
MAXIMUM OPERATING
VOLTAGE
MAXIMUM FURNACE AMPERES
MAXIMUM FUSE OR CIRCUIT BREAKER AMPS*
MINIMUM
MAXIMUM
CIRCUIT OVERCURRENT
AMPACITY1 PROTECTION2
M5SB 66
66,000
19 3/4
115-1-60
103
127
10.0
15
11.1
16.1
M5SB 86
86,000
19 3/4
115-1-60
103
127
10.0
15
11.1
16.1
M5SC 66
66,000
19 3/4
115-1-60
103
127
14.0
15
15.3
24.3
M5SC 86
86,000
19 3/4
115-1-60
103
127
14.0
15
15.3
24.3
NOTE: Minimum wire gauge and maximum fuse/circuit breaker amperage are based on MCA1 and MOP2 calculations. This furnace is approved for installation with a 15 or 20 amp fuse/circuit breaker however wiring sizing must adhere to current version of the NEC and/or applicable local codes depending upon the overcurrent protection.
- Time-delay fuses or circuit breakers are required.
THERMOSTAT WIRE GAUGE
24 22 20 18
RECOMMENDED THERMOSTAT WIRE LENGTH (TOTAL LENGTH)
2 – WIRE – HEATING
4 OR 5 WIRE – COOLING
55 ft. 90 ft. 140 ft. 225 ft.
25 ft. 45 ft. 70 ft. 110 ft.
Total wire length includes wire from furnace to the thermostat, from
thermostat to outdoor unit, & from outdoor unit back to the furnace.
Table 6. Voltage Specifications & Thermostat Wire Gauge
14
FUEL SUPPLY & PIPING
Flue Gas Sampling
It may be necessary to take flue gas sampling from the oil furnace in order to
check the performance after furnace installation. A flue gas sample may be
taken from the heat exchanger, which is located behind the hole of the top-
front of blower compartment.
1. Turn off all electric power to the appliance. 2. Remove the black plastic
cap located above the blower.
Do not discard cap. 3. Drill a hole through the top of the blower compartment.
NOTE: Hole diameter should be same size as sampling tube. 4. Insert sampling
tube through the drilled hole and into the heat exchanger. 5. After a complete
check and adjustment of furnace performance, seal the drilled hole with a
screw larger than the hole. NOTE: Seal the screw threads with silicon sealant
– rated at least 500° F. 6. Plug the outside hole with the plastic cap removed
in step 3.
Oil Tank & Piping Installation
The following procedures are recommended as good practice. However,
requirements of local codes and ordinances, H.U.D. Manufactured Home and
Safety Standards or National Fire Protection Association must be satisfied,
where they apply, for an approved installation. · Use a tank capacity suitable
for the application with a
weatherproof, capped fill opening and a shielded vent to let in air as fuel is
used. · The inside of the tank must be clean before filling. All water, rust,
sediment, and debris must be flushed out. · A fuel or tank gauge is
recommended for easy checking of the fuel level. Check the gauge reading with
a dipstick. See Figure 26. · Locate the storage tank conveniently near the
home. If the fuel tank is installed above ground, the tank may
rest 3 to 4 inches off the ground. Fuel tanks may also be buried if properly
coated to resist corrosion. The vertical dimension from the bottom of the fuel
tank to the fuel pump must not exceed 10 feet. · Keep the tank filled,
especially in the summer to reduce the accumulation of condensation.
One-Line System
The One-Line System is highly recommended where vertical lift, from bottom of
tank to pump, is less than 8 feet. See Figure 26. A single line hookup has the
advantage of lower cost and quieter operation.
Two-Line System
If a Two-Line system is used or if oil is taken from the bottom of the tank, a
filter is recommended. A Two-Line system should only be used if vertical lift
exceeds 8 feet. 1. Install the oil feed line as outlined in steps 1 – 6 below.
2. Install the oil pump bypass plug in the bottom return
port. 3. Route the return line up through the furnace base to
the return port of the pump. Route the other end of the line to the tank,
using 3/8″ O.D. copper tubing or 1/4″ pipe with the ends capped. 4. Insert the
return line through the second opening in the duplex bushing. If the bottom of
the tank is lower than the pump intake, the tube should be inserted three or
four inches from the tank bottom. If the bottom of the tank is higher than the
pump intake, the return line should extend not more than 8″ inside the tank.
Fuel line Hook-Up
1. Use a 3/8″ O.D. copper tubing for the fuel line. NOTE: Cap the end with
tape to keep out dirt while the line is being routed.
2. Install duplex bushing for two 3/8″ lines in the top fitting of the tank.
See Figure 26.
3. Insert one end of the tubing through the duplex bushing until it is three
to five inches from the bottom drain. Tighten the bushing.
3/8″ Oil Supply Line
Vent with cap Gauge
2″ Duplex Bushing
2″ Fill
Top of Tank
Oil Furnace
Flue Gas Sampling
Hole
On-Off-Fan Switch
Guide Pipe
Shut-off
8 ft.
Valve
Drain
End of Oil Supply Line 3″ to 5″ Above Bottom Drain
Optional Fuel Filter
NOTE: Additional venting may be required if tank is filled rapidly.
Alternate Fuel Line
Entry
Control Panel
Oil-Gun Burner Floor Floor Cavity
Some codes may require installation of a manual main shut-off valve and ground joint union external to the furnace. The shut-off valve should be readily accessible for service and/or emergency use. Consult the local utility or gas supplier for additional requirements regarding placement of the manual main gas shut-off.
If fuel pump fails to lift oil, check for air leaks and tighten all fuel fittings. Reprime fuel pump by injecting fuel oil into optional (top) return port. Replace return port plug and repeat priming procedure.
Bypass Solenoid Valve
Nozzle Port 3/16 Flare Fitting
Cordset
Beckett
USE ONLY WITH VALVE ON DELAY
INLET
A2EA-6520
4 GPH 100-150 PSI 3450 RPM NO. 2 & LIGHTER FUEL
3 GPH 150-200 PSI 3450 RPM
NO. 2 FUEL
INLET
BY-PASS
Made by Suntec Exclusively for Beckett
Pressure Adjustment
Screw
Inlet Port 1/4 NPTF
Inlet Port 1/4 NPTF
Bleed & Gauge Port
Return Port – Install 1/6″ Bypass Pipe Plug for 2-pipe System Only. (Use 5/32″
Allen Wrench)
Figure 26. Typical Oil Piping for Above Ground (Single-Line) Supply
15
4. Route the line where it will not incur any damage. Make bends gradual and
avoid kinks which might restrict oil flow.
5. Open the furnace door and connect the oil line to the intake port on the
pump. Tighten other port plugs on the pump. NOTE: Verify the oil line is
airtight! Air leaks can cause the pump to lose prime and will create other
problems such as nozzle failure, odors, rumbling noise, and false safety
shutdown.
6. Insert the short length of the copper tube level with the bottom of the
duplex bushing. Form the tube into an inverted “U” to serve as a vent.
Fuel Line Bleeding
To eliminate problems caused by air in the oil line, all connections in the
oil supply line and all plugs, nuts, and fittings on the pump must be
airtight. NOTE: This includes the nut that covers the pressure adjustment. It
is important that the hook-up be done carefully and with a good flaring tool.
Prepare the burner for priming by attaching a clear plastic hose over the
bleed port fitting and fully opening the pump bleed port. Use a suitable
container to collect purged oil.
To ensure continuous operation, use a wire to jump terminals T-T on the
primary control while burner is running.
Priming the furnace
1. After the burner starts, press and hold the reset button until the yellow
LED turns on (15 seconds). This indicates that the button has been held long
enough.
2. Release the reset button. The yellow LED will turn off and the burner will
start up again.
3. At burner start up, click the reset button while the igniter is still on.
This transitions the control to a dedicated pump prime mode, during which the
motor, igniter and valve are powered for 4 minutes. The yellow LED will be on.
NOTE: If prime is not established during the four minute pump prime mode,
repeat step 3 until the oil pump is fully primed.
4. When oil flow is clear and free of air bubbles, close air-bleed valve and
tighten. NOTE: Air bleed out time will varies depending on length of oil line,
number of bends, etc.
Fuel Oil Type
WARNING:
Do not use gasoline, crankcase oil, or any oil containing gasline. Failure to
keep supply of oil clean by various procedures described above may cause
failure of certain components such as the fuel pump gears, check valve, shaft
seal, or burner nozzle which may result in a burner fire.
Do not use fuel oil heavier than Grade No. 2. In areas where the oil supply is
subject to low temperatures, Grade No. 1 may be used.
STARTUP & ADJUSTMENTS
PLEASE READ ALL SAFETY INFORMATION BEFORE OPERATING THE FURNACE
· The first operation of the furnace after any home setup must be performed by
a qualified service technician.
· Do not use this furnace if any part has been under water. Immediately call a
service technician to inspect the furnace and to replace any part of the oil
gun or control system which has been under water.
WARNING:
Close the hinged fire door. If door is left open or spring is broken it may
allow products of combustion into the living space by the furnace blower,
resulting in possible asphyxiation.
Operating Instructions
If your furnace model number begins with M5S*, the furnace is equipped with an
ignition device which automatically lights the burner. Do not try to light
this furnace manually.
1. Open all valves in the oil line. 2. Verify the fire door is closed. 3. Set
the furnace On-Off switch to ON. 4. Set the thermostat to the desired setting.
NOTE: M5 oil gun furnaces may be converted to gas gun in the field by using
the proper conversion kit listed in the Replacement Parts List or Technical
Sales Literature.
How to Shut Off Oil Gun Models
1. Set the thermostat to the lowest setting. 2. Turn off all electric power
to the appliance at the breaker
or fuse box. 3. Set the thermostat MODE switch to OFF.
Verifying & Adjusting Temperature Rise
Confirm the temperature rise through the furnace is within the limits
specified on the furnace rating plate. Any temperature rise outside the
specified limits could result in premature failure of the heat exchanger. 1.
Place thermometers in the return and supply air stream
as close to the furnace as possible. To avoid false readings, the thermometer
on the supply air side must be shielded from direct radiation from the heat
exchanger. 2. Adjust all registers and duct dampers to the desired position
and run the furnace for 10 to 15 minutes in high fire before taking any
temperature readings. The temperature rise is the difference between the
supply and return air temperatures.
For typical duct systems, the temperature rise will fall within the limits
specified on the rating plate with the blower speed at the factory recommended
setting. If the measured temperature rise is outside the specified limits, it
may be necessary to change the speed of the blower. NOTE: Lowering the blower
speed increases the temperature rise and a higher blower speed will decrease
the temperature rise.
16
The furnace is equipped with a multi-speed motor. Refer to the furnace wiring
diagram, Figure 31 (page 22) for blower speed selection.
Burner Adjustments
Burner settings are made at the factory. However, these settings may change
during shipping, handling, and installation. The following items should be
checked and readjusted if necessary.
Combustion Air
CAUTION:
· Combustion air adjustment must be made only by a qualified technician.
Improper air adjustment may cause unsafe operation, explosion and/or fire
asphyxiation.
· If the input to the furnace is too great because of excessive oil pressure,
wrong size nozzle or orifice, etc., the burner flame will be sooty and can
produce carbon monoxide, which could result in unsafe operation, explosion
and/or fire or asphyxiation.
5/32″ GAP
ELECTRODE
5/16″ ABOVE CL 0-1/16″ 1 1/8″
NOZZLE
In order for the flame to burn efficiently, it must receive adequate
combustion air. The amount of combustion air required varies according to
altitude, actual BTU content of the fuel, gas pressure, conversion to another
gas and other factors. The burner flame should be observed and any necessary
adjustments made before the furnace is placed into service. See Table 7 for
factory air settings.
It is recommended that the CO2 and Smoke levels be measured for maximum
performance. CO2 readings should be 10 – 11% for 66,000 Btuh furnaces and 12 –
13% for 86,000 Btuh furnaces. The Smoke should be N0. 0 on the Bacharach
Scale, and 0 to 0.02 negative draft over fire.
MODEL
BTUH
OIL
M5
66,000
3.5
M5S
86,000
5
Table 7. Factory Combustion Air Settings
Figure 27. Oil Gun electrode Position
Electrode Setting
Poor ignition of the oil spray may result if the electrodes are not adjusted
as shown in Figure 27. Do not permit any electrodes to be grounded to any
surface.
Switching Ignition Control between Interrupted and Intermittent Duty
Beckett oil primary controls can be switched between interrupted and
intermittent ignition control. To switch from interrupted duty (Factory set)
to intermittent duty, remove the blue wire from the quick-connect terminal.
Attach the burner motor and igniter wire to the burner motor (orange) control
terminal by splicing or adding tab adapters. Seal and isolate any bare wires.
17
OPERATING SEQUENCE
1. When a call for heat is initiated, there is a 2 to 6 second delay while
the control performs a safe start check.
2. The ignition and motor are turned on and a flame should establish within a
15-second lockout time. NOTE: Burner will prepurge for 15 seconds if equipped
with Beckett 7505B control.
3. If flame is not sensed within the 15-second lockout time, the control
shuts down on safety lockout and must be manually reset by pushing the reset
button on the control. If control locks over three times in a row, the control
enters restricted lockout. To reset, hold down the reset button for 15 seconds
until the red LED turns off and the yellow LED turns on.
WARNING:
If furnace still doesn’t light, turn the furnace off as described above and
call your technician. In the event of flashback or explosion, immediately shut
off furnace and call your service technician.
4. After flame is established, the ignition remains on for 10 seconds to
ensure flame stability. It then turns off.
5. The circulating air blower will energize after the temperature fan switch
closes.
6. The furnace runs until the call for heat is satisfied. 7. The circulating
air blower will de-energize when the
temperature fan switch opens.
TROUBLESHOOTING
Burner does not start with a call for heat
· Check the electrical supply to furnace. · Verify the furnace door switch is
in the ON position.
See Figure 28 (page 19). · Check for line voltage (115 VAC) at the oil primary
control. · Check indicator LED with burner off, no call for heat
(no flame). See Table 9. – If green LED indicator is on, the cad cell is
seeing
stray light or the cad cell of controller is defective. – If green LED
indicator is off, go immediately to step
5. – If LED indicator is flashing (red or green on Beckett
7505 control), refer to the next step 1 below – Reset primary control. ·
Jumper T to T terminals on primary control. – If burner starts, check
thermostat or limit wiring connections. – If burner does not start, turn off
power. Check all wiring connections. – If burner does not start, replace
primary control.
Burner starts & then locks out on safety and
the red LED flashes
1. Reset primary control: To reset the control from (soft) lockout, the RED
button needs only to be pressed and released. If the control is in restricted
mode, press and hold the RED button in for 15 seconds until the red LED turns
off and the yellow LED turns on.
LED FLASHES (OHMS)
1 2 3 4
CAD CELL RESISTANCE
0-400 400-800 800-1600 >1600
Table 8. Cad Cell Resistance when sensing flame
LED INDICATOR
Red Green
Yellow
BECKETT 7505 CONTROL
CONTINUOUSLY ON
FLASHING
Restricted (hard) lockout
Cad cell is sensing flame (could be flame or stray light)
Pump prime mode or reset button currently held for 15+ sec.
Soft lockout Recycle N/A
Table 9. Control Module Status Indicators
NOTE: Restricted Lockout: If the control locks out three times in a row
without a complete heat cycle between attempts, the lockout becomes a
restricted (hard) lockout.
2. If the LED indicator stops flashing and the ignition remains off, the
primary control could be defective. If line voltage is present at the igniter
terminals, and there is no ignition, the igniter is likely defective and needs
to be replaced.
3. If the stops flashing, burner turns on, but the control locks out again,
check the cad cell. See Table 8. If the cad cell is operational, replace the
primary control.
4. If the LED continues to flash at the interval listed above, verify that
the control is not in restricted mode. If in restricted mode, reset it. If not
in restricted mode, replace the control.
5. If the green LED stays off while the flame is on, check the cad cell
sighting for view of the flame.
6. If the burner locks out, check the cad cell resistance. See Table 8.
7. If the burner stays running, the system is operational. 8. If the green
LED is off, check the cad cell assembly
after disconnecting the line voltage.
Burner will not start and the green LED
flashes
· Hold the reset button down for 1 – 2 seconds. If LED indicator continues to
flash, wait for 60 – 70 seconds. If it still continues to flash, replace the
primary control.
· To check cad cell resistance, unplug the cad cell leads (yellow wires) from
the control. Measure the resistance with a meter in the conventional way (when
a flame is present). For proper burner operation, it is important that the cad
cell resistance is under 1,600 Ohms.
18
FURNACE CONTROLS & FUNCTIONS
Furnace On / Off Switch: This switch turns electrical power to the furnace on
and off. The switch must be set in the ON position for the furnace to operate.
If blower operation is not desired, the furnace On-Off switch may be set in
the Off position to cut the electrical power to the furnace. See Figure 28.
Limit Control: This furnace is protected by two high temperature safety limit
switches. The auxiliary (upper) limit switch and the high temperature (lower)
limit switch are automatic reset types. If either limit trips, the burner will
shut off. If either limit switch trips off again soon after resetting, set the
furnace furnace On-Off switch to the Off position and call your authorized
serviceman. See Figure 28.
Blower Off Delay: When the blower fan operates under cooling mode, there is a
40 second delay after the call for cooling (from the thermostat) is satisfied
before the blower turns off.
Oil Burner Primary Control: The primary control for oil gun furnaces starts
the burner, monitors a safe operating cycle, and shuts the burner off at the
end of a heating cycle. The control uses a light sensing transducer to
determine if fuel ignition has been successfully attained. If ignition is not
attained by the end of the safety ignition timing period, the control shuts
the burner off and enters “lock-out.” See Figure 28.
Summer Cooling – (B & C Series): The unit is equipped to use a 4-wire
thermostat. When using a 5-wire thermostat, RC and RH should be jumped. See
instructions included with thermostat. A burner isolation kit is available for
purchase.
MAINTENANCE
Installer Information
All furnaces need periodic service at the beginning of each heating season.
Call your qualified service contractor for these items: · Remove the air
circulator and clean all dust and lint
from the unit with a stiff bristle brush. · Inspect the combustion chamber
blower compartment,
flue collar and Roof Jack. · Check fuel line connections for leaks. · Make any
adjustments necessary for good operation.
WARNING:
Use of furnace or air conditioning components that are not included in the
certification of this appliance may create a hazard, invalidate the
certification, and in many states, make installations illegal. Listed air
conditioning components are specified on the furnace label.
Additional Oil Furnace Maintenance
In addition to the preceding, the following should be performed by a qualified
service contractor at least once each season for oil-fired furnaces: · Replace
the oil nozzle with the type nozzle specified
for this furnace. · Clean, adjust and replace if necessary the spark
electrodes. · Reset the nozzle/drawer assembly to factory
specifications. · Clean the inside of the furnace heat exchanger and
replace the combustion liner if necessary. · Clean or replace the oil filter
element at the oil tank. · Adjust the burner for top efficiency and check to
make
sure all fittings are leak-tight.
Upper Limit Switch
Furnace On-Off Switch
Oil Pump
Lower Limit Switch
Fan Control
Oil Burner Control
Figure 28. Furnace Controls – Oil Furnace
19
OPTIONAL ACCESSORIES
Necessary when the furnace is used with packaged air conditioners If an air
conditioner is installed that does not use the furnace blower for air
distribution and operates independently of the furnace, the thermostat system
must have an interlock to prevent the furnace and air conditioner from
operating at the same time. This interlock system usually contains either a
“Heat-Cool” switch which must be turned to one of the positions to activate
heat or cool operation, or a positive “OFF” switch on the cooling thermostat.
The furnace must also be equipped with an automatic damper to prevent cold air
from being discharged up around the heat exchanger (p/n 901996 for furnaces
without coil cavity, or p/n 901083 with coil cavity). See Figure 29 or Figure
30. Cold air may cause condensation inside the heat exchanger which can rust
and lead to early failure.
Optional Add-On Air Conditioning
Whether split system or single package, an energysaving air conditioner is
available that has been designed specifically for manufactured housing
applications and can best handle your home comfort needs. Ask your dealer or
contractor about add-on central air conditioning systems.
Single package unit includes cooling coils, compressor, and vertical discharge
fan. This type of unit connects with the existing home air duct system (an
optional close-off damper is required with the furnace).
Split system unit with vertical discharge for quiet operation connects with
cooling coil furnace (optional coil cavity required with “A” model furnaces).
Figure 29. Coil Cavity Damper Figure 30. Without Coil Cavity
20
FIGURES & TABLES
FURNACE MODEL #
M5SB 066 M5SC 066 M5SB 086 M5SC 086
INPUT MBTU/H
66 66 86 86
OUTPUT MBTU/H
56 56 73 73
E.S.P. IN WC
0.3 0.3 0.3 0.3
OIL NOZZLE
.50 Gph .50 Gph .65 Gph .65 Gph
IGNITOR DIRECT
Y Y Y Y
COMB. BLOWER
Burner Model: AF-10
Spray Angle: 80° A
MOTOR HP
1/4 1/2 1/4 1/2
A/C READY TONS
3 4 3 4
NOTES:
· Electrical Supply: 120 volts, 60HZ, 1 Ph. Fuse or Breaker – 15 amps
· Temperature Rise: 45° F to 75° F
· Thermostat Circuit: 24 volts, 60HZ, 30 vac · Normal Anticipator Setting: 0.4 · Oil Pressure: 100 psi
Table 10. M5 Furnace Specifications and Factory Settings
FURNACE INPUT 086 066
FURNACE INPUT 086 066
FURNACE INPUT 086 066
M5*B MODELS & FOR USE WITH BLOWER KIT NO. 903773 1/4 HP 3 SPEED
HEATING SPEED SETTING
2 TON
COOLING SPEED/ EVAP COIL 2-1/2 TON
H
L
M
M
L
M
M5*C MODELS & FOR USE WITH BLOWER KIT NO. 903413 1/2 HP 4 SPEED
HEATING SPEED SETTING
2 TON
COOLING SPEED/ EVAP COIL
2-1/2 TON & 3 TON
3-1/2 TON
ML
L
ML
MH
L
L
ML
MH
M5 MODELS WITH BLOWER KIT NO. 903890 3/4 HP 4 SPEED
HEATING SPEED SETTING
2 TON
COOLING SPEED/ EVAP COIL 2-1/2 TON & 3 TON 3-1/2 TON & 4 TON
ML
L
ML
MH
L
L
ML
MH
3 TON H H
4 TON H H
5 TON H H
Table 11. A/C Blower Speed Selection Chart
21
WIRING DIAGRAM
M5S Furnace Series
NOTES: 1. Incoming power must be polarized. Observe color coding.
(See furnace data label for electrical information.) 2. If any of the original
wires (as supplied with the appliance) must
be replaced, use 105°C Thermoplastic type wire or its equivalent. 3. On models
M5S 086 jumper wire is installed.
On all other models, cooling speed is connected to black wire. 4. A/C Heating
Speeds: Refer to Table 12, A/C Blower Selection 5. If any of the original wire
supplied with the appliance is replaced,
use 105°C wire or equivalent.
120 Volt
Single Phase / 60 Hz
6. Use copper conductors only. 7. Flash Codes: Refer to Table 9, Control Module Status Indicators. 8. For M5 installations paired with thermostats without RH and RC connections, please refer to the wiring diagram and the installation instructions supplied in the kit [P/N 1018453]. NOTE: For units with kit [P/N 1018453], the RH terminal on the furnace is not used; RC on the furnace connects to the thermostat.
3 SPEED BLOWER MOTOR
4 SPEED BLOWER MOTOR
Y W G Rc C
Rh
TO OUTDOOR UNIT
AUX. LIMIT BLUE
RED GREEN WHITE
BLACK (HI) BLUE (MEDHI)
RED (LO) WHITE
RED (LO) BLACK (HI) BLUE (MEDHI) ORANGE (MEDLO) WHITE
BLACK
ON/OFF SWITCH
RED (SEE NOTE 3)
1 2 34 5 6 1 2 34 5 6
CONNECTOR HOUSING CAP
TIE WIRE
RED BLUE
WHITE
BLACK ORANGE
4 6 3 A/C BLOWER
2 5 1 RELAY
GREEN
GRAY
HI-LIMIT
GRAY 3A FUSE
GRAY BLUE-WHITE STRIPE
SUPPLIED BY INSTALLER
BLACK GRAY
TRANSFORMER
BLACK
GREEN R 24 V C
L1 115 V N
WHITE
BLACK
L1 NEUTRAL
GROUND SCREW
BLACK ORANGE WHITE WHITE
FURNACE ELECTRICAL BOX
BLUE
FAN SWITCH
GAS GUN BURNER
TERMINAL HOUSING
BUSHING
RECEPTACLE
C RW TO BURNER CONTROL
L1 N
BLACK BLACK
BUSHING
IGNITER
BUSHING
IND
BLACK
L1
BLACK
HSI
CONTROL MODULE
HSIG L2
WHITE
W
RED
BUSHING
BLACK BLACK
PSI RED FSI
BLACK BLACK
GV
RED
PSO RED
RED
FSG GREEN
C GRAY
GROUND SCREW
BLUE
BLUE
CW
BURNER ELECTRICAL BOX BUSHING TERMINAL
FROM “W” WIRE (BLUE)
GAS VALVE
LINE CORD
FROM “C” WIRE (GRAY)
FROM ‘R’ WIRE (BLUE W/ WHITE STRIPE)
FROM ‘W’ WIRE (BLUE)
CAD CELL
YELLOW YELLOW
OIL GUN BURNER
T T
CAD
IGNITER
7505B
L2
OR R7184B PRIMARY
MOTOR L2
CONTROL
L1
L2
CELL
VALVE L2
BLUE W/WHITE STRIPE WHITE
ORANGE WHITE
IGNITION MODULE
BURNER MOTOR
BLACK
BLACK W/WHITE STRIPE
VIOLET WHITE
VALVE
LINE CORD
LEGEND: FIELD WIRING LOW VOLTAGE HIGH VOLTAGE
22
1018721A (Replaces 10187210)
05/18
Figure 31. M5S Wiring Diagram (A/C Ready)
23
INSTALLATION CHECKLIST
ATTENTION INSTALLERS:
It is your responsibility to know this product better than your customer. This
includes being able to install the product according to strict safety
guidelines and instructing the customer on how to operate and maintain the
equipment for the life of the product. Safety should always be the deciding
factor when installing this product and using common sense plays an important
role as well. Pay attention to all safety warnings and any other special notes
highlighted in the manual. Improper installation of the furnace or failure to
follow safety warnings could result in serious injury, death, or property
damage.
These instructions are primarily intended to assist qualified individuals
experienced in the proper installation of this appliance. Some local codes
require licensed installation/service personnel for this type of equipment.
Please read all instructions carefully before starting the installation.
Return these instructions to the customer’s package for future reference.
INSTALLATION ADDRESS: CITY:
STATE:
UNIT MODEL #
UNIT SERIAL #
Unit Installed Minimum clearances per Table 1, (page 5)?
YES
NO
INSTALLER NAME: CITY:
STATE:
Has the owner’s information been reviewed with the customer?
YES
NO
Has the Literature Package been left with the unit?
YES
NO
PROPOSITION 65 WARNING:
WARNING: This product contains chemicals known to the state of California to
cause cancer.
WARNING: This product contains chemicals known to the state of California to
cause birth defects or other reproductive harm.
ELECTRICAL SYSTEM
Electrical connections tight? Line voltage polarity correct? Supply Voltage Has the thermostat been calibrated? Is the thermostat level? Is the heat anticipator setting correct?
YES YES VOLTS: YES YES YES
GAS SYSTEM
Oil Type: (circle one) Oil line connection leak-tested? Number of pipes connected to pump Oil line pressure Furnace Input: Supply Air Temperature Return Air Temperature Temperature Rise
NO. 1 YES
1 (PSI) (BTUH) (° F) (° F) (° F)
NO NO
NO NO NO
NO. 2 NO 2
COMBUSTION AIR & VENTING SYSTEM
Is there adequate fresh air supply for combustion & ventilation?
YES
NO
Vent free from restrictions?
YES
NO
Filter(s) secured in place?
YES
NO
Filter(s) clean?
YES
NO
Flue connections tight?
YES
NO
Is there proper draft?
YES
NO
Specifications & illustrations subject to change without notice or incurring obligations (05/18). O’Fallon, MO, © Nortek Global HVAC LLC 2018. All Rights Reserved.
1018704A (Replaces 10187040)