MARS M5S Series Installation Instruction

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
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.
CAUTION
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
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
2
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
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
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 54–1999/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 .2–M00 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.
4
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.
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
1
(457 8"
mm)
Nearest
Wall or
Partition
Figure 1. Alcove Installation
6" (152 mm)
Top Clearance
0" Side
Clearance
to Furnace
Cabinet
“A”- 56"
“A” Model
w/o Coil
Cabinet
“B”- 76"
“B” Model
w/Coil
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
23 3/4"
19 3/4”
(1526"
mm)
Figure 4. Overall Dimensions
ALL MODELS
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
CLOSET
ALCOVE
Front
6”
18”
Back
0”
0”
Sides
0”
0”
Roof Jack
0”
0”
Top
6”
6”
Top and Sides of Duct
0”
0”
Bottom of Duct
—
—
A Cabinet (w/ coil box)
0”
0”
A Cabinet (w/o coil box)
1/4”
1/4”
0”
0”
B Cabinet
Table 1. Minimum Clearances
1
(25 "
mm)
PART
NO.
A/C CAPACITY
(TONS)
BLOWER
WHEEL
MOTOR
(HP)
903413
11 x 8
1/2
2, 2½, 3 & 4
903890
11 x 8
3/4
2, 2½, 3, 4 & 5
CLOSET DOOR
Figure 3. Special 1” Clearance
BLOWER / MOTOR ASSEMBLY
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.
• 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.
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:
CAUTION:
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.
A Single trunk duct
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).
Dual trunk duct
B w/crossover connector
C
Transition duct
w/branches
Figure 5. Typical Supply Duct System
6
FURNACE INSTALLATION
20"
14 1/2"
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.
• 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.
REAR WALL OF CLOSET OR ALCOVE
10"
FURNACE OUTLINE
2 1/4"
24"
23 1/4"
21 3/4"
14 1/2"
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.
2 3/4"
CL
FLOOR CUT-OUT
FOR STANDARD
DUCT CONNECTORS
CL
CL
CL
CUT-OUT FOR
OPTIONAL
COOLING COIL
1 3/4"
3/4"
CL
CL
CL
1 3/4"
3/4"
1 7/8"
2 7/8"
ALT FUEL-LINE
ENTRY 1 1/4" Dia.
Figure 6. Cut-Out Dimensions for
Standard Duct Connectors
20"
CL
10"
REAR WALL OF CLOSET OR ALCOVE
10"
FURNACE OUTLINE
24"
23 1/4"
21 3/4"
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.
FLOOR
CUT-OUT FOR
ROUND DUCT
(14 1/4” DIAMETER)
CL
CL
CL
CL
CUT-OUT FOR
OPTIONAL
COOLING COIL
1 3/4"
3/4"
CL
CL
1 3/4"
3/4"
1 7/8"
2 7/8"
ALT FUEL-LINE
ENTRY 1 1/4" Dia.
FUEL
LINE
FURNACE
OUTER
DOOR
2"
Figure 7. Cut-Out Dimensions for
Round Duct Connectors
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
2"
FUEL
LINE
FURNACE
OUTER
DOOR
Hole for
Gas Line
od
Wo
Bend tabs
up 90°
or
Flo
tor
nec
Con abs
T
Duct
Connector
Mounting Plate
ply
Sup Duct
r
i
A
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).
8
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.
Staples or sheet metal screws
Duct connector tabs
DUCT CONNECTOR
TYPE & PART NUMBER
IF FLOOR
CAVITY
“X” IS:
STANDARD DUCT
ROUND DUCT
7/8” / (22)
901987A
904008
2” / (51)
901988A
N/A
4-1/4” / (108)
901989A
904010
6-1/4” / (159)
901990A
904011
8-1/4” / (210)
901991A
904012
10-1/4” / (260)
901992A
904013
12-1/4” / (311)
901993A
904014
Narrow
Duct
Narrow
Duct
Duct
Flap
Duct
Connector
Sheet metal
screws
Narrow
Duct
NOTE: Dimensions shown as Inches / (Millimeter)
Figure 12. Narrow Ducts
Table 3. Duct Connector Sizes
SCREWS
MOUNTING
PLATE
DUCT
CONNECTOR
FLOOR OPENING
“X”
SUPPLY AIR DUCT
FUEL LINE
HOLE
FLOOR
CAVITY
FUEL LINE
HOLE
14” SUPPLY
CONNECTION
Figure 9. Floor Cavity
Figure 13. Round Duct Connector Installed
DUCT CONNECTOR
MTG. PLATE TABS
SUPPLY
AIR DUCT
SLIDE FURNACE
ALL THE WAY BACK
ONTO MTG. PLATE
SECURE FURNACE
WITH 2 FASTENERS AT FRONT
CORNER HOLES
BEND TABS TIGHTLY
AGAINST SUPPLY AIR DUCT
Knockout Over Holes
Figure 10. Duct Connector Tabs
OPTION 1
Figure 14. “A” & “B” Cabinet Furnaces
OPTION 2
Remove
this
Flap
Cut Here
Supply
Air Duct
SLIDE FURNACE
BACK AGAINST
MTG. PLATE
Cut Here
ere
Cut Here
SUPPLY
AIR DUCT
Fold Flap Here
Fold Flap Here
Cut Here
tH
Cu
Cut Here
Remove
this
Flap
MTG. PLATE TABS
Fold Flap Here
tH
Cu
ere
tH
Cu
ere
ere
tH
Cu
Fold Flap Here
SUPPLY AIR DUCT
Figure 11. Narrow Air Duct Openings
SECURE FURNACE
WITH 2 FASTENERS
AT FRONT CORNER HOLES
FUEL LINE HOLES
Figure 15. “A” Cabinet Furnace on Coil Cabinet
9
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.
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)
Locating & Cutting Roof / Ceiling Openings NOTE: For transit purposes, the transit kit (P/N 903838)
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
10
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
ROOF JACK
CROWN
SLANT DECK
FLASHING
"X" (SEE TABLE 5)
CEILING
“A”
Roof
PITCHED
Opening
ROOF
Flue Pipe
Combustion Air Pipe
“B”
APPROX. LENGTH
BELOW FLASHING
(F,S)AW1523-(0,2,4)(A,S)
15” - 23”
(F,S)AW2135-(0,2,4)(A,S)
21” - 35”
(F,S)AW2747-(0,2,4)(A,S)
27” - 47”
(F,S)AW3563-(0,2,4)(A,S)
35” - 63”
(F,S)AW5195-(0,2,4)(A,S)
51” - 95”
NOTE: Not all models are available. Check with your local distributor
for available models.
S AW
F = FLAT FLASHING
S = SLANT FLASHING
AW= ALL WEATHER
Furnace
56"
or
76"
S
FLUE STEEL TYPE
A= ALUMINIZED
S=STAINLESS
MIN. ADJ.
LENGTH
FLASHING
PITCH/12" RISE
0=FLAT
2=2.5/12
4=4/12
MAX. ADJ.
LENGTH
Table 4. Roof Jack Assemblies
ROOF JACK
SERIES
Figure 16. Ceiling Cavity Depth
ROOF JACK
CROWN
27 47 - 2
IF ROOF
PITCH IS:
2” in 12”
2-1/2” in 12”
3” in 12”
“F Series
3-1/2” in 12”
4” in 12”
4-1/2” in 12”
5” in 12”
“S” Series
5-1/2” in 12”
(2.5 / 12 Pitch only)
6” in 12”
6-1/2” in 12”
SLANT DECK
FLASHING
"X" (SEE TABLE 5)
CEILING
CAVITY
SLANT DECK
FLASHING
NUMBER
“X”
903893 (2.5/12)
903893 (2.5/12)
903894 (3/12)
903894 (3/12)
903895 (4/12)
903895 (2.5/12)
903895 (2.5/12)
903894 (3/12)
903894 (3/12)
903895 (4/12)
2-1/8”
2-1/2”
2-7/8”
3-1/4”
3-5/8”
2-1/8”
2-1/2”
2-7/8”
3-1/4”
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
PITCHED
ROOF
CEILING
20"
ROOF
OPENING
CL
10"
Figure 17. Example of Flat Jack with Flashing
REAR WALL OF CLOSET OR ALCOVE
ROOF JACK WITH
2 1 2 /12 SLANT
FLASHING
24"
2 1 2 /12
SLANT DECK
5/12 ROOF SLOPE
Figure 18. Example of 2½ / 12 Slant Jack
with Flashing
FURNACE OUTLINE
CEILING
OPENING
13 1/2"
CEILING
CAVITY
MODEL NUMBER
CEILING
CUT-OUT FOR
FLUE AND
ROOF JACK
CL
FURNACE
OUTER
DOOR
Figure 19. Cut-Out Dimensions for
Flue & Roof Jack
11
Removing the Transit-Mode Venting System
(After home is moved to site)
Secure roof jack with
appropriate fasteners
after connecting to
furnace
WARNING:
Failure to properly secure the flue pipe to
the furnace may result in fire, explosion or
asphyxiation when operating the furnace.
Caulk under roof
flashing to prevent
water leakage
Roof
Ceiling
NOTE: Make sure inside flue pipe attaches over inner
flue pipe and outer Roof Jack pipe fits over outer pipe.
Optional 2-piece ceiling
ring #902521
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.
Figure 20. Flat Roof
Secure lower roof
jack section with
no. 10 S.M. screws
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.
COMPLETED
ASSEMBLY
Upper Roof Jack Section
UPPER ROOF
JACK (CROWN)
Optional Slant
Deck Flashing
SCREWS
Secure flashing
with appropriate
fasteners
Caulk under roof
flashing to prevent
water leakage
WEATHER CAP
FLASHING
Ceiling
OUTER PIPE
INNER FLUE PIPE
Figure 21. Pitched Roof
TO FURNACE
FLUE ASSEMBLY
Figure 23. Roof Jack Crown
CONNECT OUTER
FLUE SHIELD
On-Off
Switch
Blower
Plug
INNER FLUE PIPE
VENT COLLAR
Power
Entry
Thermostat Wires
Furnace
Control Box
To combustion
Blower or Flame
Roll-out Switch
MOUNTING
FLANGE
To Gas Valve
or Burner
On-Auto Switch
(Heating Models Only)
Figure 24. Control Panel (All Models)
Figure 22. Combustion Air Pipe Connection
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.
M5 Furnace
Thermostat
Rc
RH
W
G
Grounding
Y
Red
Red
Red
Red
White
White
Green
Green
Yellow
TR
TW
Oil Burner
Grey
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!
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*
M5SB 66
M5SB 86
M5SC 66
M5SC 86
66,000
86,000
66,000
86,000
19 3/4
19 3/4
19 3/4
19 3/4
115-1-60
115-1-60
115-1-60
115-1-60
103
103
103
103
127
127
127
127
10.0
10.0
14.0
14.0
15
15
15
15
MAXIMUM
MINIMUM
OVERCURRENT
CIRCUIT
1
PROTECTION2
AMPACITY
11.1
11.1
15.3
15.3
16.1
16.1
24.3
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
RECOMMENDED THERMOSTAT WIRE LENGTH (TOTAL LENGTH)
2 - WIRE - HEATING
4 OR 5 WIRE - COOLING
24
22
55 ft.
90 ft.
25 ft.
45 ft.
20
18
140 ft.
225 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
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.
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
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
Oil
Furnace
2" Duplex
Bushing
Flue Gas
Sampling
Hole
Top of Tank
2" Fill
On-Off-Fan
Switch
Guide
Pipe
Shut-off
Valve
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.
8 ft.
Control
Panel
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
Oil-Gun
Burner
Floor
Floor Cavity
Pressure
Adjustment
Screw
Cordset
Bypass Solenoid Valve
Nozzle Port
3/16 Flare Fitting
Beckett
INLET
USE ONLY WITH
VALVE ON DELAY
Inlet Port
1/4 NPTF
A2EA-6520
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.
4 GPH 100-150 PSI 3450 RPM
NO. 2 & LIGHTER FUEL
3 GPH 150-200 PSI 3450 RPM
INLET
NO. 2 FUEL
BY-PASS
Made by Suntec
Exclusively for Beckett
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
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:
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.
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.
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.
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.
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.
16
Operating Instructions
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.
The furnace is equipped with a multi-speed motor. Refer
to the furnace wiring diagram, Figure 31 (page 22) for
blower speed selection.
5/32” GAP
ELECTRODE
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
5/16” ABOVE CL
NOZZLE
0-1/16”
CAUTION:
1 1/8”
• 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.
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
M5
M5S
BTUH
66,000
86,000
OIL
3.5
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.
18
LED FLASHES (OHMS)
CAD CELL RESISTANCE
1
0-400
2
400-800
3
800-1600
4
>1600
Table 8. Cad Cell Resistance when
sensing flame
BECKETT 7505 CONTROL
LED
INDICATOR
Red
CONTINUOUSLY ON
Restricted (hard) lockout
Green
Cad cell is sensing flame (could be flame or stray light)
Yellow
Pump prime mode or reset button
currently held for 15+ sec.
FLASHING
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.
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.
Upper
Limit
Switch
Furnace
On-Off
Switch
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.
Lower
Limit
Switch
Fan
Control
Oil
Burner
Control
Oil
Pump
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.
Figure 29. Coil Cavity Damper
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).
20
Figure 30. Without Coil Cavity
FIGURES & TABLES
FURNACE
MODEL #
INPUT
MBTU/H
OUTPUT
MBTU/H
E.S.P.
IN WC
OIL
NOZZLE
IGNITOR
DIRECT
COMB.
BLOWER
MOTOR
HP
A/C READY
TONS
M5SB 066
66
56
0.3
.50 Gph
Y
1/4
3
M5SC 066
66
56
0.3
.50 Gph
Y
Burner Model:
AF-10
1/2
4
M5SB 086
86
73
0.3
.65 Gph
Y
3
86
73
0.3
.65 Gph
Y
Spray Angle:
80° A
1/4
M5SC 086
1/2
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
M5*B MODELS & FOR USE WITH BLOWER KIT NO. 903773 1/4 HP 3 SPEED
FURNACE
INPUT
COOLING SPEED/ EVAP COIL
HEATING SPEED
SETTING
2 TON
2-1/2 TON
3 TON
086
H
L
M
H
066
M
L
M
H
M5*C MODELS & FOR USE WITH BLOWER KIT NO. 903413 1/2 HP 4 SPEED
FURNACE
INPUT
HEATING
SPEED
SETTING
2 TON
2-1/2 TON & 3 TON
3-1/2 TON
4 TON
086
ML
L
ML
MH
H
066
L
L
ML
MH
H
FURNACE
INPUT
HEATING
SPEED
SETTING
2 TON
2-1/2 TON & 3 TON
3-1/2 TON & 4 TON
5 TON
086
ML
L
ML
MH
H
066
L
L
ML
MH
H
COOLING SPEED/ EVAP COIL
M5 MODELS WITH BLOWER KIT NO. 903890 3/4 HP 4 SPEED
COOLING SPEED/ EVAP COIL
Table 11. A/C Blower Speed Selection Chart
21
WIRING DIAGRAM
120 Volt
M5S Furnace Series
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.
WHITE
Rc
C
RED (LO)
BLACK (HI)
BLUE (MEDHI)
ORANGE (MEDLO)
AUX. LIMIT
GREEN
Rh
CONNECTOR
HOUSING CAP
BLUE
RED
WHITE
BLACK (HI)
BLUE (MEDHI)
RED (LO)
TO OUTDOOR UNIT
W
G
1 2 3 4 5 6
1 2 3 4 5 6
ON/OFF
SWITCH
Y
4 SPEED
BLOWER
MOTOR
3 SPEED
BLOWER
MOTOR
WHITE
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.
TIE WIRE
GREEN
GRAY
2
3 A/C
BLOWER
5 1 RELAY
GRAY
FAN
SWITCH
3A FUSE
ORANGE
4 6
BLUE
WHITE
BLUE
BLACK
RED
(SEE NOTE 3)
BLACK
RED
HI-LIMIT
BLACK
SUPPLIED BY
INSTALLER
BLACK
BLACK
L1
NEUTRAL
GROUND
SCREW
BLACK
ORANGE
WHITE
WHITE
GRAY
BLUE-WHITE STRIPE
GRAY
TRANSFORMER
R
GREEN
24 V C
L1 115 V
N
WHITE
FURNACE
ELECTRICAL BOX
RECEPTACLE
TO BURNER CONTROL
C R W
GAS GUN BURNER
BUSHING
IGNITER
IND
L1
HSI
BLACK
BLACK
TERMINAL HOUSING
L1 N
BUSHING
BLACK
BLACK
OIL GUN BURNER
FROM 'R' WIRE
(BLUE W/ WHITE STRIPE)
FROM 'W' WIRE (BLUE)
W
PSI
FSI
WHITE
RED
RED
BUSHING
GV
PSO
RED
FSG GREEN
C
GRAY
BLACK
BLACK
BLACK
BLACK
RED
RED
GROUND SCREW
BLUE
BLUE
GAS VALVE
C W
BURNER ELECTRICAL BOX
LINE CORD
BUSHING
TERMINAL
T
T
BUSHING
HSIG
CONTROL
MODULE L 2
IGNITER
L2
7505B
OR
R7184B MOTOR
L2
PRIMARY
CONTROL
L1
CAD
YELLOW
CAD
CELL
YELLOW
CELL
VALVE
L2
ORANGE
WHITE
IGNITION
MODULE
BURNER
MOTOR
BLACK
BLACK W/WHITE STRIPE
VIOLET
WHITE
LINE CORD
VALVE
FROM "W"
WIRE (BLUE)
FROM "C"
WIRE (GRAY)
LEGEND:
1018721A
(Replaces 10187210)
FIELD WIRING
LOW VOLTAGE
HIGH VOLTAGE
05/18
Figure 31. M5S Wiring Diagram (A/C Ready)
22
L2
BLUE W/WHITE STRIPE
WHITE
23
INSTALLATION CHECKLIST
ELECTRICAL SYSTEM
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.
YES
NO
Line voltage polarity correct?
YES
NO
Supply Voltage
VOLTS:
Has the thermostat been calibrated?
YES
Is the thermostat level?
YES
NO
Is the heat anticipator setting correct?
YES
NO
STATE:
NO. 1
NO. 2
YES
NO
1
2
Oil Type: (circle one)
Oil line connection leak-tested?
Number of pipes connected to pump
Furnace Input:
(PSI)
(BTUH)
UNIT MODEL #
Supply Air Temperature
(° F)
UNIT SERIAL #
Return Air Temperature
(° F)
Temperature Rise
(° F)
Unit Installed Minimum clearances
per Table 1, (page 5)?
YES
NO
COMBUSTION AIR & VENTING SYSTEM
INSTALLER NAME:
CITY:
NO
GAS SYSTEM
Oil line pressure
INSTALLATION ADDRESS:
CITY:
Electrical connections tight?
STATE:
Has the owner’s information been
reviewed with the customer?
YES
Has the Literature Package been
left with the unit?
YES
NO
NO
PROPOSITION 65 WARNING:
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
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.
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)
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