Olsen Furnace Manual

The Olsen Furnace is a high-efficiency residential heating system designed for reliable performance and energy savings. This manual covers the Olsen Series 2000 gas furnace with AFUE rating up to 96%, variable-speed blower motor, electronic ignition, multi-speed operation, built-in diagnostics, and compatibility with standard thermostat systems. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Gas valve assembly, heat exchanger, blower motor, electronic control board, igniter, flame sensor, pressure switches, and filter compartment.

Feature	Description
Gas valve	Precision gas flow control with safety shutoff
Heat exchanger	Stainless steel primary and secondary heat exchangers
Blower motor	Variable-speed ECM motor for quiet operation
Control board	Microprocessor-based with diagnostic LED
Ignition system	Hot surface igniter with flame sensor
Pressure switches	Safety verification of draft inducer operation
Filter access	Front-loading filter compartment
Thermostat terminals	Standard 5-wire connection (R, W, Y, G, C)
Service switch	External power disconnect
Vent connections	PVC venting for high-efficiency operation

Installation

Unpack and inspect all components. Ensure proper clearances and venting requirements.

1. Position furnace: Place on level surface with minimum clearances as specified.
2. Connect gas supply: Use approved gas pipe and fittings; pressure test for leaks.
3. Install venting: Use PVC pipe for intake and exhaust; maintain proper slope.
4. Electrical connections: Connect line voltage and thermostat wiring.
5. Install filter: Insert appropriate size filter in filter compartment.

WARNING! Gas appliances can be dangerous; installation must be performed by qualified technician. Ensure proper ventilation and combustion air supply.

First-Time Setup

Power on furnace; verify proper operation through startup sequence.

1. Set thermostat: Install compatible thermostat and configure heating mode.
2. Check gas pressure: Verify inlet and manifold pressures within specifications.
3. Test ignition: Observe startup sequence for proper ignition and flame.
4. Adjust blower speeds: Set appropriate heating and cooling airflow.
5. Configure dip switches: Set for proper operation with your system.

CAUTION! Never bypass safety devices. Ensure all covers are properly installed before operation.

Specifications

• Model Series: Olsen Series 2000
• AFUE Rating: Up to 96%
• Input Capacity: 40,000 - 120,000 BTU/h
• Gas Type: Natural gas or LP (with conversion kit)
• Electrical: 120V AC, 60Hz, 15A circuit
• Blower Motor: Variable-speed ECM
• Venting: PVC Category IV
• Filter Size: 16x25x1 inch standard
• Warranty: 20-year heat exchanger, 5-year parts
• Operating Temp Range: -30°F to 120°F ambient

Controls and Settings

Access control board via front service panel. LED diagnostic light indicates system status.

Control Board: Microprocessor with fault code display, dip switch settings for blower speeds, gas valve control, and safety monitoring.

Operating Modes: HEAT, COOL (with AC), FAN ONLY. Blower Settings: Heating speed, cooling speed, continuous fan speed. Safety Features: Limit switches, pressure switches, flame rollout protection, igniter control. Diagnostic Codes: LED flash patterns indicate specific fault conditions for troubleshooting.

Connecting Thermostat

Standard 5-wire thermostat connection: R (24V), W (Heat), Y (Cool), G (Fan), C (Common).

1. Turn off power to furnace before wiring.
2. Strip wires 1/4 inch and connect to appropriate terminals.
3. Match colors: Red to R, White to W, Yellow to Y, Green to G, Blue to C.
4. Secure thermostat to wall and restore power.

Tip: Use programmable thermostat for maximum energy efficiency and comfort control.

Operating Modes

Three main operating modes controlled by thermostat.

1. Heat Mode: Thermostat calls for heat, inducer starts, igniter heats, gas valve opens, flame sensor confirms ignition.
2. Cool Mode: With AC unit, blower operates at cooling speed when Y terminal energized.
3. Fan Mode: Continuous fan operation when G terminal energized independently.
4. Multi-stage Operation: Supports multi-stage heating for improved comfort and efficiency.
5. Smart Recovery: Anticipates temperature needs for precise temperature maintenance.

WARNING! Never operate furnace with access panels removed. Keep combustible materials away from furnace.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

1. Monthly: Check and replace air filter as needed.
2. Seasonal: Inspect vent system for obstructions.
3. Annual: Professional inspection of heat exchanger, burners, and safety devices.
4. As needed: Clean flame sensor and check electrical connections.

CAUTION! Always turn off power and gas supply before performing any maintenance.

Care & Cleaning

Keep furnace area clean and free of debris. Use soft brush and vacuum for cleaning.

CAUTION! Do not use water or liquid cleaners. Keep electrical components dry. Never block air intake or exhaust vents.

Regulatory Information

UL listed and ANSI certified for safety. Complies with ASHRAE standards for residential heating equipment. Manufactured to meet or exceed DOE efficiency requirements. Copyright © 2024 Olsen Heating Systems; all rights reserved. For technical support, visit www.olsenfurnace.com or contact 1-800-555-HEAT.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Furnace won't start	Power, thermostat, safety switch	Check circuit breaker, thermostat setting, door switch engagement.
No heat	Gas supply, igniter, flame sensor	Verify gas valve on, check igniter operation, clean flame sensor.
Short cycling	Filter, limit switch, airflow	Replace dirty filter, check for blocked vents, verify proper airflow.
Blower won't stop	Thermostat, control board	Check thermostat fan setting, test control board operation.
Unusual noises	Blower, inducer, ductwork	Inspect blower wheel, inducer motor, check for loose panels.

Reset: Turn power off for 30 seconds, then restore. Check diagnostic LED for error codes.

Service: 1-800-555-HEAT; www.olsenfurnace.com