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OIL-FIRED CENTRAL FURNACE

1. Figure 8 Location and Design of the Highboy Heat Exchanger Cleanout Port Using a screwdriver remove the screws retaining the trim panel covering the cleanout port With a wrench or a ratchet with a deep well socket loosen the nut retaining the T bolt and the cap to the heat exchanger Carefully remove the T bolt nut gasket and the cap from heat exchanger With the aid of a portable light source peer into the heat exchanger As much as possible loosen all material and deposits clinging to the heat exchanger walls using wire brushes or any suitable tool Collect and remove this material by hand or with the assistance of a vacuum cleaner and a nozzle type attachment 32 The heat exchanger may also be cleaned through the flue pipe connection With the furnace turned off and at room temperature carefully remove the vent connector and the heat exchanger flue pipe if equipped to inspect and clean the heat exchanger The inner radiator of the heat exchanger may be cleaned from the inside of the combustion chamber This involves removal of the burner and the burner mounting plate from the heat exchanger Using a portable light source with a mirror inserted through and into the heat exchanger check for an accumulation of soot scale and particulate matter on the walls and in the base of the drum or on the floor of the combustion chamber If a significant accumulation is present it should be removed Use
2. SSV 19 LHOIS X3 31719 9NILNDON ALV 1d 9NILNDON YANN 149592 0878590 2716 3015 13759 110 3409 LHO ayaa 7 32314 NOLLOS MOVE 83 FICAN 201 39319 NAN 1340v48 55419 1H9 19 5548 1133038 YANN LS3A 55 393 q 3100 Ove YILT 1 CN Ov 831 13 TAN ovs 3L Il 9530 51974 49 Horizontal Counterflow Model 11084 TANVd l340v88 55413 LHOIS 8 1132038 YAN L gv 1109 i 1013 144549 LAO NVITO INY Jz ge o5 Y 1015 40014 318 ON 1974 50 EL 101 AF BURNER PART 380664 Replacement parts MODEL NOZZLE SIZE PART 1 60807 380398 1715807 3803
3. aouel dde Aqueau Jayjo Aue 10 514 oj jou e ele 235 1 7 AvTad 330 AVT3U NO NV JO 3HL NI OQ OL LVHM aoe 35 10 SSO Aunful aBewep uolsojdxa 10 suono nmnsul asay MOJO eoeuunj siu uoneuuojul stu peal Ajes 404 onuls UO WO VU CN JN xj JI VU 1 INGA 0 538 03 3 8 39 VC BNP Models 3531 435 NIVASH LSNW SLINDYID SNILV3H Z 55710 JYl4 ANY MOOHS OL 3NA NINYYM V 20 SI ONILLAS HOLVdIOLLNV LVLSOWYSHL WOON TVOIdAL S 3INVN OL 88484 LINDHIO SINLL SSH3ANI HO ISNA AV T3Q 3INLL 3215 3 1T8V Ld39OV WAWIXVW NOLLOS LOMd LNSYYNOYSAO 31VnO3GV LN3A3OV 1d33 07314 11 SHOLONGNOD Y3ddO9 AINO ASN HO 2 60 GALVY NOLLVINSNI NV 3AVH LSNW MAN 38 LSNW SNIHIM TvOIHIO313 Z XO NI
4. Blower Motor Size HP Motor Type amp Number of Speeds High Speed Airflow SCFM 9 0 4 W G External Static Pressure Burner Specifications Air Tube Length in Burner Head Type Fuel Type Nozzle Rating for Beckett AF GPH Spray Angle Deg Spray Pattern Oil Pump Pressure PSIG Ignition Control Type Pre Post Purge Feature s Automatic Oil Solenoid Valve Combustion Chamber Type Clearances to Combustible Materials Minimums Sides in Top in Front in Rear in Flue Vent Pipe in Supply Plenum Surfaces in 84 000 69 000 70 83 0 27 8 22 25 in horizontal configuration 61 25 in counterflow vertical configuration 61 25 in horizontal configuration 22 25 in counterflow vertical configuration 22 25 6 11 in horizontal configuration flue exits horizontally forward 30 5 in counterflow vertical configuration flue exits horizontally 16 x 16 16 x 16 None Supplied 280 120 60 1 10 2 w R W Beckett oil burner 15 Directly driven DWDI FC centrifugal w 10 in dia wheel 1 2 Permanent split capacitor 4 1350 R W Beckett pressure atomizing type Model AF 5 875 effective Fixed flame retention 2 distillate domestic heating oil 0 60 80 Hollow 130 Interrupted Direct Spark None Clean cut w solenoid Preformed refractory ceramic fiber matrix material O 45 Spirit Oil Fired Horizontal
5. Nozzle Rating for Beckett AF GPF 0 55 Spray Angle Deg 60 Spray Pattern w Oil Pump Pressure PSIG 175 Ignition Control Type Interrupted Direct Spark Pre Post Purge Feature s None Automatic Oil Solenoid Valve Clean cut solenoid Combustion Chamber Type Preformed refractory ceramic fiber matrix material Clearances to Combustible Materials Minimums Sides in 3 Top in 3 Front in 22 Rear in 3 Flue Vent Pipe in 9 Supply Plenum Surfaces in 3 46 REPLACEMENT PARTS ighboy Model APPENDIX D H SS3NHVH 834018 SS3N NH 34M 3109053 OHS LON 86 OHS 10N 8 ZEN 5 LHOIS L3ISv 55 19 1H9I5 XA 21719 31V ld 13759 1041 YILT 553997 4078 5006 LNOYS 8006 9NILV IS 90166 Ci 24 06 dus 1041802 22 404 10 4019 Layo 55919 1 9 jv ld 9 SSY L340v38 SOLON C89 SdOVY 0 8 z 197 9 LHOIN
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7. installation shall conform to these instructions and to the regulations of the National Fire Protection Association s Standard for the Installation of Oil Burning Equipment NFPA 31 2001 and the National Electrical Code ANSI NFPA 70 2002 or the latest editions thereof A qualified installer also referred to in this instruction manual as a qualified heating contractor is an individual or agency properly licensed and experienced to install and service oil burning equipment in accordance with all local codes and ordinances Material and Workmanship This furnace was built with the highest quality materials and attention to workmanship However omissions and defects occasionally occur Before installing the furnace inspect the furnace thoroughly If missing parts defective material or poor workmanship are evident report the model and serial numbers imprinted on the furnace rating label to the seller for adjustment Packaging A complete furnace is contained within a single package The factory completed all feasible assembly However certain components including draft regulator and if supplied door handle air filter s and air filter rack s must be assembled to the furnace or the venting system in the field Refer to the assembly instructions Shipping Damage If this furnace was damaged during transit please immediately request the transportation company inspect the furnace and issue a concealed damage report The
8. 6 Air for Combustion and Ventilation 03 abono 7 Chimney aerei 10 Flue Chimney Vent Connector 10 Power Side Wall Venting Important Note Regarding 11 auc Em 11 Duct Work and Air Conditioning 12 Air Fiter MOUNTO dos tede eh ete LLL LLL LA n i 12 Electrical Gonnections usuy Ce co out Eae edere a Nereus 14 Room Thermostat amem band rU rti n 14 Combustion Chamber 15 Oil Burner and Oil Nozzle Installation 15 SystetrkInstellatloli xe cvs tres teo 17 Horizontal Counterflow Furnace Setup 18 INITIAL OPERATION OF THE FURNACE _ 19 Initial Burner Operation ta 19 Supply Return Airflow and Air Temperature 21 Furnace Limit and Blower Controls 2 204 21 23 ROOM Thermostat duda 24 Instructions to Our Customer End User 24 T
9. ONISYO 305 0 2 19 wove 9 5 2 06 305 LHW 34398 9 3015 1431 371438 5 8 SS3NHVH JY H 38 ALEC 070 5 066 0 ASSY 302 Lm 41 2530 Sle aLI ALO 47 Lowboy Front Flue Model 559 19 LHOIS N N 0 UU e JOYLNOD JOVNYAA 10 TANVd 97 435 cc 110 1102 7 48 8 3014 13 mx ASSY 149 10 d 8 84113 9 22319 100 NV3D 9 YAMOTE SSSNYVH 38 43 09 170 40 SS3NEVH 310811 193 39319 NAGI N CN 20319 1015 IJNvg 201 83113 CM lt 218 393 AL 31 31 Lowboy Rear Flue Model IS LON SWALI v 1H
10. Open dampers or registers in the air distribution system Clear any duct system restrictions Inspect and clean all air filters in the air distribution system Inspect blower for interference with rotation or locked rotor condition Also confirm the blower wheel is secured to the fan motor shaft The fan motor or run capacitor may be damaged Test and replace the motor or capacitor as required Increase fan speed D Symptom Unable to achieve clean combustion by making burner air adjustments Items to check 1 Measure the burner air tube insertion depth and alignment The end of the tube should not protrude inside the combustion chamber The end of the tube should be approximately 1 4 inch away from the inner wall surface of the combustion chamber Inspect the oil nozzle for excessive wear blockage or deterioration Measure and if necessary reset the nozzle depth or turbulator location with respect to end of the burner head Replace the nozzle if necessary refer to the oil burner manufacturer s instructions Measure the oil pump pressure If required adjust the pressure to burner nameplate value This is the typical minimum pressure required to obtain the full input rate from the furnace Verify the burner is configured as specified in Table 1 and adjusted according to the Initial Burner Operation section of this manual and the burner manufacturer s instructions Measure the overfire draft If required ad
11. as how to adjust the oil burner settings refer to burner manufacturer s literature A Symptom Furnace does not operate Items to check A WARNING Repeated operation of the oil primary safety control reset button can cause a build up of unburned oil in the combustion chamber An accumulation of oil in the combustion chamber is a hazardous situation and may cause a fire or explosion 1 Make sure the disconnecting switch is ON and the circuit breaker has not tripped or fuses have not blown 26 2 3 Confirm there is 120 VAC at the junction box and the oil furnace control terminal 51 Confirm the room thermostat is wired correctly set on the HEAT mode and calling for heat For all primary controls lockout can be confirmed by measuring voltage from the oil primary safety control to the burner motor If none depress the oil primary reset button On the Honeywell oil primary control lockout has occurred if the indicator light an LED is rapidly flashing depress the oil primary reset button If the burner does not operate properly after depressing the reset button three 3 times turn off the electrical power to the furnace and close the manual oil shutoff valve Immediately contact a qualified heating contractor for service B Symptom Burner short cycles or locks out on oil primary safety control Items to check 1 2 Fuel oil tank nearly empty or oil flow restriction Refill
12. duct system A duct the full size of the furnace return air opening shall extend to a location outside the furnace room If the furnace is used in connection with summer air conditioning cooling the furnace should be installed in parallel with or on the upstream side of the evaporator coil to avoid water vapor condensation in the furnace heat exchanger If the cooling unit is installed in a parallel flow arrangement dampers or other means used to control airflow should be provided to prevent chilled air from entering the furnace If such a damper is manually operated it must be equipped with a means to prevent operation of either unit unless the damper is placed in either the full heat or full cool position NOTICE Return air grilles and supply registers in the air distribution system should never be obstructed Air Filter Mounting N CAUTION If cutting openings in the furnace casing is required DO NOT cut any supporting clips or angles Cut as close to the scribed line as possible but DO NOT cut the base clip or blower pan support angle Lowboy furnaces are factory equipped with permanent type air filters located above the blower compartment in the rear of the furnaces NOTICE Horizontal counterflow furnaces are not factory equipped with an air filter or filter rack Furthermore the furnace blower compartment does not contain enough free space to permit an air filter to be mounted within the furnace casing However the i
13. effective Fixed flame retention 2 distillate domestic heating oil 0 60 80 Hollow 130 Interrupted Direct Spark None None Preformed refractory ceramic fiber matrix material 3 3 8 front flue 3 rear flue 3 9 3 43 Spirit Oil Fired Lowboy Furnace Specifications Model Heat Input Rate BTUH Output BTUH Nominal Temp Rise deg F Minimum AFUE Rating Gross Heat Exchange Area sq ft Casing Height in Casing Width in Casing Depth in Nominal Flue Outlet Dia in Height from Floor to Center of Flue in Supply Air Outlet Size in x in Return Air Inlet Size in x in Air Filter Quantity amp Size in x in Approx Shipping Weight 15 Electrical Requirements VAC Hz Ph Total Current Amps Max Fuse Size Amps Blower Specifications Blower Motor Size HP Motor Type amp Number of Speeds High Speed Airflow SCFM 0 4 in W G External Static Pressure Burner Specifications Air Tube Length in Burner Head Type Fuel Type Nozzle Rating for Beckett AF GPH Spray Angle Deg Spray Pattern Oil Pump Pressure PSIG Ignition Control Type Pre Post Purge Feature s Automatic Oil Solenoid Valve Combustion Chamber Type Clearances to Combustible Materials Minimums Sides in Top in Front in Rear in Flue Vent Pipe in Supply Plenum Surfaces in for front flue model for r
14. furnace is subjected Generally install the barometric draft regulator in the vent connector as close as possible to the flue outlet collar of the furnace However always refer to the draft regulator manufacturers installation instructions for application specific recommendations 11 Duct Work and Air Conditioning Design and installation of the duct system should follow the current guidelines of the Air Conditioning Contractors of America ACCA or the American Society of Heating Refrigeration and Air Conditioning Engineers Inc ASHRAE Refer to the Residential Duct Systems Manual D from the ACCA and the ASHRAE Handbook Fundamentals volume from ASHRAE for recommended practices in duct system design and installation To obtain copies of these publications for a fee contact the ACCA and the ASHRAE at the addresses given in Appendix A of this manual All furnaces are tested over a range of external static pressure that simulates the airflow resistance of the ductwork fittings and diffusers connected to the furnace for a typical average duct system The furnace blower and blower motor have been selected to work successfully against the following range of duct system resistance Recommended range of duct system resistance for all models 0 2 to 0 5 in W G external static pressure Due to the need to maintain an adequate supply of combustion and ventilation air the furnace shall not be installed in small room without return air
15. motor may be damaged Test and replace the capacitor or motor as required F Symptom Blower cycles on and off after the burner has shutdown Item to check 1 Increase the fan off time by changing the DIP switch selections on SW2 Refer to Table 2 for blower delay off settings NOTICE If the high limit control is faulty it should be replaced However it must only be replaced by the same make and model as the original Refer to the electrical diagrams for proper electrical connections 29 Flame Sensor Cad Cell Checkout Procedure On the Honeywell oil primary control to check the electrical resistance of the flame sensor referred to as a cadmium sulfide photocell or cad cell depress the reset button on the oil primary safety control while the burner is firing The oil primary control will report the measured resistance range of the cad cell by flashing the LED light emitting diode one 1 to four 4 times Refer to the oil burner manufacturer s instructions for further details For all primary controls an alternate procedure to check the flame sensor operation is as follows 1 Remove the flame sensor lead wires from the terminals labeled CAD CELL on the underside of the Honeywell control of the oil primary safety control module Start the burner Shortly after combustion is established place a temporary jumper wire across the cad cell terminals or leads of the control Connect an ohmmeter ac
16. n I 26 Troubleshooting MM DEM DEDI D A PM eee 26 Flame Sensor Cad Cell Checkout Procedure 30 Replacement PANS uyay 30 MAINTENANGE 31 Ar Ei E Sua tI 31 potete vison cos pat 31 Blower and ER Du EL viet 31 Heat Exchanger gc EXTR 31 Flue and lt oe eee 33 USERS INFORMATION u d ORO vage ge adde 34 Operating Instructions 34 Eo Wee RR 35 Extended Shutdown ee 36 Combustion Air and Ventilation Supply 36 t u CD 36 APPENDIX A SOURCES FOR REFERENCED STANDARDS 38 APPENDIX B ELECTRICAL DIAGRAMS a 39 APPENDIX C SPECIFICATION SHEETS eene 41 APPENDIX D REPLACEMENT PARTS 47 Notice to the Installer Installation of this oil fired furnace must be performed by a qualified installer in accordance with all local codes and authorities having jurisdiction In the absence of local governing codes
17. oil tank replace oil filter open all shutoff valve s and purge oil line s of air If the oil primary control has not locked out e g on the Honeywell primary control the indicator light is not flashing measure the electrical current to the room thermostat Set the heat anticipator on the room thermostat to the current value measured Also check the wiring between the thermostat and primary control to be sure it is correct and no loose connections exist Inspect the burner flame sensor cad cell to be sure the lens is clean and the cell is correctly aimed at the flame Inspect the burner oil nozzle for blockages and signs of deterioration Replace the nozzle if required Also measure and reset the electrode gap and alignment If badly worn or deformed replace the electrodes Refer to the burner manufacturer s instructions Confirm there is a strong spark across electrodes Generally viewing a spark jump across the electrodes is sufficient indication the ignition transformer is operating correctly Testing an electronic ignition transformer with a transformer tester is generally not recommended Inspect the heat exchanger through the cleanout ports for signs of excessive soot scale buildup or blockage If a heavy deposits are present clean the heat exchanger 27 Symptom Burner short cycles on high limit thermostat but does not lock out on oil primary safety control Items to check 9
18. party receiving the furnace should file the claim for shipping damage Report any shipping damage immediately It is absolutely essential that a damage report be obtained If a concealed damage report is not obtained we cannot provide assistance in recovering your claim against the transportation company Warranties WARNING The manufacturer of this equipment assumes no liability for any damages resulting from unauthorized modifications made to the furnace or any components thereof or improper installation of the furnace in the field Furthermore any such field modifications VOID THE WARRANTY and place responsibility for safe and reliable operation of the furnace on those who performed the modification s Complete and return any enclosed warranty cards These must be on file to verify installation dates for replacement of any warrantied part s 4 INSTALLATION GUIDELINES Codes All local codes and regulations take precedence over the instructions in this manual and shall be followed accordingly In the absence of local codes this installation must conform to these instructions and to the regulations of the National Fire Protection Association NFPA publications the Standard for the Installation of Oil Burning Equipment NFPA 31 2001 and the National Electrical Code ANSI NFPA 70 2002 or the latest editions thereof To obtain copies of these publications for a fee contact the NFPA at the address given in Appendix A of this man
19. the air filter into position 13 Electrical Connections NOTICE All field wiring must conform to local state and national installation codes A disconnecting switch equipped with overcurrent protection rated at 15 A e g a time delay type fuse or inverse time circuit breaker should be installed in the service line for shutting down and protecting the furnace and electrical system Since the furnace is entirely pre wired at the factory it is only necessary to connect the building electrical service lines to the two 2 pigtail wires extending from the junction box The junction box is mounted inside the furnace burner compartment or mounted on the front exterior of the furnace in the case of the horizontal counterflow model The service lines to the furnace should be no smaller than 14 Ga insulated copper wire with a temperature rating of 60 C or greater Connect an equipment ground wire to the furnace at the junction box If wiring is run through metal electrical conduit it may not be necessary to run a separate equipment ground wire Consult local codes and authorities for specific minimum requirements A two 2 wire connection to the room thermostat from the oil furnace control is also necessary This is typically a low voltage 24 VAC circuit Consult the National Electrical Code ANSI NFPA 70 2002 for guidelines for proper wiring methods and materials for this circuit Refer to the electrical diagrams contained in Ap
20. the rear for lowboy furnaces of the furnace to obstructions and surfaces for adequate service and maintenance access The minimum clearances from furnace casing surfaces to combustible materials are inches from casing sides and rear 8 inches from front casing of furnace to the closet door with exception of o the lowboy rear flue model only requires 3 inches from front casing of the furnace to the closet door o the horizontal counterflow furnace requires 22 inches from front casing of the furnace to the closet door 9 inches from flue pipe vent connector 3 inches from casing top 3 inches from any side of supply air plenum 3 inches above supply air ducts within 6 feet of furnace For the horizontal counterflow furnace only when the optional combustible surface mounting base is used with the furnace in the counterflow configuration adequate clearances from the supply end surface of the furnace casing to combustible surfaces are provided by the design of the mounting base Though these are approved clearances for these furnaces space must be provided at the front 18 inches minimum 24 inches recommended and at the rear of the furnace for access service and replacement of the oil burner air filter s circulating air blower and fan motor Air for Combustion and Ventilation CAUTION Relief openings in the front or top of the furnace casing should not be obstructed or blocked These openings supply combustion and venti
21. to physically touch or protrude into the chamber High temperatures in the combustion chamber can result in damage to the tube the end cone or both A distance greater than 1 4 inch back from the inside chamber wall may cause flame impingement on the combustion chamber wall and subsequent sooting or carbon char buildup BURNER AIR TUBE Me HEAT EXCHANGER DRUM POUCH FRONT _ BI mu paara map sss BURNER AIR TUBE IS H 1 4 BACK FROM INSIDE fF N CHAMBER WALL dee INSIDE OF CHAMBER CHAMBER WALL Figure 4 Side view of correct burner insertion into combustion chamber 16 The oil burner provided with this furnace requires initial inspection set up and proper adjustment Refer to this manual and the oil burner manufacturer s operating instructions for detailed information on the following items Initial firing of burner e Adjusting the burner combustion air e Adjusting the fuel pump pressure Setting the draft control NOTICE This oil furnace must be installed and adjusted by only qualified oil heating contractor using calibrated combustion test instruments to ensure safe and reliable operation of the furnace Fuel System Installation In situations where the oil storage tank is installed at the same level with or above the burner a single oil supply l
22. to the pump manufacturer s instructions D When ignition is established make a temporary air adjustment for a clean smoke free flame At this point the final burner adjustment should be made using test instruments to measure oil pump pressure smoke number carbon dioxide CO2 carbon monoxide CO draft and flue gas temperature e Refer to item 4 under the Troubleshooting section of this manual for a list of required test instruments In order to achieve the best combustion efficiency the following procedure is recommended 19 7 8 Measure the oil pump pressure If required adjust it to deliver the appropriate pressure for the burner The oil pump should be set to produce e 130 PSIG for the R W Beckett model AF burner e 175 PSIG for the R W Beckett model NX burner Carbon Dioxide and Carbon Monoxide CO In order to assure that proper and safe combustion is taking place carbon dioxide and carbon monoxide measurements must be taken reading within the limits of Table 1 with no measurable CO is desirable The maximum acceptable CO reading is about 50 PPM If the CO reading is too high open the burner air shutter or air band slightly to permit more combustion air to the flame Recheck the CO level and adjust as required Draft Draft measurements should be taken through the overfire port and in the vent connector not more than 12 inches away from the furnace outlet A 5 16 in hex washe
23. 0121 4 ___ COUPLING 380241 CLEAN CUT FUEL PUMP 175 PSI 380674 SOLENOID COIL 380654 VALVE CORD SET 18 5 380751 VALVE STEM 380676 6 CONNECTOR TUBE 11 INLET AIR BOX 1010 8ST INLETAIRLOUVERS 1033U 9 ____ INLETAIRADAPTEROUTSIDEAIRKIT 1014U 38740 10811 RETENTION HEAD ASSEMBLY 9 SLOT 51815 3807433 AIR TUBE COMBINATION 7 0 INSERTION DEPTH GASKET AOPS0524 NOZZLE LINE ELECTRODE AND HEAD GUN ASSY NLH7OLB J ELECTRODE INSULATORKIT 58 380746 SPRING IGNITER PROP 3208U 1 380645 18 A D PSC MOTOR OH 2 2 2 27 6 11 _ 1 2 2 2 2 3 7 1 2 3 4 5 0 6 j N 52
24. 66 ________ 1 BURNER HOUSING ASSY 2 AIR BAND ASSY 8 slot set 0 5151501 TC Cid 3 __ AIR SHUTTER set 7 344 177 ESCUTCHEON PLATE 3493 SCREW 114 5 HOLEPLUG 114 6 AIRGUIDE 9844 2 7 LOWFIRINGRATEBAFFLE 5880 130 PSI SOLENOID 9 VALVECORDSET _ 210 i 380653 11 PUMPELBOW 2256 320815 12 5394 38008 13 _ 1 7 3450 ______ 218052 30644 7 14 BLOWERWHEEL 4 X 3 7 16 2455 7 30359 15 COUPLING 44 38021 16 PRIMARY CONTROLR7184B 7486 3541 17 ELECTRICALBOX 3741 18 IGNITERW GASKETS 57 304 19 IGNITERGASKETKT o 20 CELL w Socket 55441919 70060 35004 GASKET 166 00 AIR TUBE COMBINATION BLAST TUBE ONLY E ELECTRODE NOZZLE ASSY ___________ ee ELECTRODES PAIR STATIC PLATE 2 U 25 SPLINED NUT BULKHEADNUT 36 320127 S L BULKHEAD FITTING 13948 0900 NOZZLE SHIPPED INSTALLED IN BURNER 8 11 14 51 EL301 BECKETT NX BURNER PART 380783 Replacement Parts Model Nozzle Size 40X70 A 380748 50 70 380 A 60 X 70 380750 DESCRIPTION TP PART 101101 380747 HEAD AIR ADJ MECHANISM ASSEMBLY 35 380744 SPLINED NUT 32
25. Counterflow Furnace Specifications Model VC BNP Heat Input Rate BTUH 84 000 Output BTUH 69 000 Nominal Temp Rise deg 70 Minimum Efficiency Rating AFUE 86 0 Gross Heat Exchange Area sq ft 27 8 22 25 in horizontal configuration 61 25 in counterflow vertical configuration 61 25 horizontal configuration Casing Width in 22 25 in counterflow vertical configuration Casing Depth in 22 25 Nominal Flue Outlet Dia in 6 11 in horizontal configuration flue exits horizontally forward 30 5 in counterflow vertical configuration flue exits horizontally Casing Height in Height from Floor to Center of Flue in Supply Air Outlet Size in x in 16 x 16 Return Air Inlet Size in x in 16 16 Air Filter Quantity amp Size x in None Supplied Approx Shipping Weight 280 Electrical Requirements VAC Hz Ph 120 60 7 1 Total Current Amps 10 2 w R W Beckett oil burner Max Fuse Size Amps 15 Blower Specifications Directly driven DWDI FC centrifugal w 10 in dia wheel Blower Motor Size HP 1 2 Motor Type amp Number of Speeds Permanent split capacitor 4 High Speed Airflow SCFM 0 4 in 1350 W G External Static Pressure Burner Specifications R W Beckett pressure atomizing type Model NX Air Tube Length in 5 875 effective Burner Head Type Variable flame retention Fuel Type 2 distillate domestic heating oil
26. H 1 49 4 NI Aviad 33 300v 40 APPENDIX SPECIFICATION SHEETS Spirit Oil Fired Highboy Furnace Specifications Model VH BBP Heat Input Rate BTUH 84 000 Output BTUH 70 000 Nominal Temp Rise deg F 70 Minimum AFUE Rating 83 Gross Heat Exchange Area sq 27 8 Casing Height in 58 Casing Width in 22 25 Casing Depth in 31 Nominal Flue Outlet Dia in 6 Height from Floor to Center of Flue in 53 5 flue opens upward Supply Air Outlet Size in x in 20 x 20 Return Air Inlet Size in x in 23 5 x 13 installer must cut opening in lower side casing Air Filter Quantity amp Size in x in one 16 x 25 Approx Shipping Weight Ib 260 Electrical Requirements VAC Hz Ph 120 60 1 Total Current Amps 10 2 w R W Beckett oil burner Max Fuse Size Amps 15 Blower Specifications Directly driven DWDI FC centrifugal w 10 in dia wheel Blower Motor Si
27. IHIM MAN I39v1d38 38 LSNW TVOIH LO3T3 2 NI 1 38IM ONIGNNOYS NV LOANNOOD NI TIVLOld OL JAIM ANY G3M3VN 111919 OL 17 AlddNS H3MOd 1O3NNOO SLANSYIM ONISN L SALON uonisod JO JO pasoj jjojnus y yoyms Bunoeuuoosip e euunj y eod e2ujoele Ie peuuoped eq 9IAJ8S JI Z 3dO peddinbe pouu y 195 pue julodjes samo o WOO y 1sn py JOVNUYNG SIHL 30 NOLLVH3dO 4015 LdNYYSLNI OL 10 1 9 enb e ayesado jou Jl Z peddinbe y 195 pue jurodjes e sOWWaY 15 9 yoylms Buno uuoosip 1135 ave na 10 oma OHS Ld NI 03395 3014 AO8 3014 INOH4 AOBHOIH SAT MOLI Jao e z1 8 anno IVANIN OVA SWYOISNVYL u B
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29. U amod uo uin Aq eu o LON OG SIUSI Alleoneuuo ne uu s s uoniuBi 2 ue peddinbe s stu p uonisod y yoyms Bunoeuuoosip je o Z 940 9 p ddinb ji Bunejedo y 195 pue julodjes WOOL Uo Jo uedo jJjoinus SIHL 31vs3dO OL puey Aq Jeuunq ay 1461 dwene LON eui 91461 Ajjeoneuojne yey uoniuBi ue peddinbe 511 3461 jou seop eoeuunj 541 yey Weis s Ionuoo eoeuunj y Wed Aue pue oj peyijenb jeo 3ueuoduioo Aue J siy esn LON OG 10 4erddns 0 8 072 uoe u youueo J e 9 4 d 5 10 1oloe nuoo e e
30. a flexible wire brush to loosen the deposits on the heat exchanger walls Remove any loose foreign material using a vacuum cleaner Replace all gaskets if removed with new unused gaskets Reassemble the burner mounting plate burner flange and new gaskets in the reverse order they were removed Using a new cleanout cover gasket reinstall the cleanout cap and tighten the nut on the T bolt enough to establish a good seal at the joint with the heat exchanger Reassemble the cleanout cover trim panel to the furnace using the original hardware Flue and Chimney At least once a year thoroughly inspect the heat exchanger flue pipe the vent connector the chimney or vent and the barometric damper for signs of sagging loose connections excessive corrosion and deterioration Clean repair or replace any components for continued safe and proper operation of the furnace 33 USERS INFORMATION WARNING The area around the furnace should be kept free and clear of flammable vapors liquids and material especially papers and rags NEVER burn garbage or refuse in the furnace NEVER try to ignite oil by tossing burning papers or other material into the furnace This oil furnace is designed to burn No 2 distillate fuel home heating oil ONLY NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE DO NOT attempt to make repairs to the furnace yourself Operating Instructions For your safety read this information before operati
31. amage to and deterioration of exterior building materials e g brick siding clapboards and etc in close proximity to the vent terminal due to operation of a power vented oil furnace This policy is applicable regardless of the cause of sooting Two 2 problems typically arise when power venting any oil fired appliance 1 Soot buildup may occur at an accelerated rate on critical components of the furnace oil burner e g the primary control flame sensor cad cell the burner head and oil nozzle 2 Severe damage may occur to external surfaces of the structure in the event the furnace continually produces a high level of smoke in the flue gases Excess smoke and soot can be produced for many reasons some of which cannot be successfully controlled by the installer and the appliance manufacturer NOTICE Thermo Products recommends the use of a chimney to vent residential oil furnaces If a power venter must be used it is the responsibility of the installer and power venter manufacturer to design assemble and demonstrate proper operation of the power venting system with the furnace Draft Regulator A barometric type draft regulator is supplied with the furnace Installation or operating conditions that produce excess amounts of draft can reduce the heating efficiency of the furnace The purpose of the regulator is to adjust and control the flow of flue gases from the furnace by stabilizing the amount of chimney draft to which the
32. ations In addition for non low sulfur fuel oils an antioxidant additive may be beneficial in promoting fuel stability After adding any fuel oil treatment completely fill the oil tank to promote mixing of the additive with the fuel Combustion and Ventilation Air Supply The furnace and venting system require a generous amount of clean air to operate safely Lack of adequate combustion and ventilation air can result in erratic operation of the burner noisy and poor combustion sooting of the combustion chamber and fuel odors in the air Never block off or restrict the supply of air to the furnace Inspection Areas Burner Compartment On the highboy and lowboy furnace models the burner compartment can be inspected by removing the front door of the furnace Look for signs of excessive heat such as discoloration of components damage to material from rust or corrosion soot or carbon build up and evidence of fuel oil leakage Exterior Of Furnace The exterior of the furnace should be inspected for signs of excessive heat such as discoloration of materials and damage from rust or corrosion Confirm the base or frame supporting the furnace in level and in sound condition 36 Venting System The furnace flue pipe vent connector barometric damper and chimney should be inspected for e Signs of excessive rust corrosion pitting and holes e Signs of condensation or moisture leakage sometimes indicated by soot or condensate streak
33. be turned end for end or rotated making the top into the bottom as shown in Figure 5 Refer to the following instructions for installing the oil burner ROTATED OTTOM T ss F P TURNED END FOR END BOTTOM TOP F DIRECTION Lm W RAT OF 4 a AIRFLOW Figure 5 horizontal furnace rotated 180 or flipped end for end to reverse airflow direction 1 When the furnace is installed in the horizontal configuration the oil burner must be mounted in an upright position It will be necessary to cutoff one 1 of the threaded burner mounting studs before attempting to install the burner Trial fit the burner to the burner mounting plate to determine which stud to remove A rotary tool with a cutting abrasive disk or a hacksaw should work well to remove the stud A machine screw furnished with the parts package will substitute for the removed stud and provide a third point to secure the burner flange to the burner mounting plate Thread the screw through the burner mounting flange and into the open hole within the burner mounting plate 2 Install the flange gasket and the burner on the mounting plate threaded studs Using fasteners supplied
34. cle To adjust the heat anticipator measure the electrical current output of the oil burner primary safety control to the room thermostat If measurement is not possible the value of current output may be marked on the cover of the control Set the thermostat heat anticipator to match the electrical current output of the oil primary safety control Instructions to Our Customer End User WARNING If the burner does not operate properly after depressing the oil primary reset button three 3 times turn off the electrical power to the furnace and close the manual oil shutoff valve Immediately contact a qualified heating contractor for service Before leaving a new installation the installer should show the customer or end user where the furnace instruction manual is kept He should also discuss the following points 1 Describe the general operation of the furnace and if properly equipped the cooling system 2 Show the location of the furnace air filter s and those in the duct system if equipped Demonstrate how to remove clean and replace the air filter s 3 Demonstrate how to set and adjust the room air temperature using the room thermostat 24 4 Demonstrate how to operate turn on and off the heating system if properly equipped the cooling system and the circulating air blower 5 Show the location of the oil primary safety control in the furnace Describe when and demonstrate how to depress the oil pri
35. e furnace flue elbow 90 degrees clockwise with respect to the front of the furnace such that the elbow is open to the right hand side of the unit rather than upward Turning the flue elbow may better facilitate connection of the vent connector piping to the flue elbow on the highboy and front flue lowboy furnaces Due to the presence of the limit control and the wiring harness the elbow may not be rotated 90 degrees counterclockwise The installer must carefully mark and cut a hole in the furnace housing to allow the vent connector to pass through the housing 10 desired with the furnace flue elbow turned to the right the standard furnace top front panel p n 17346 2 may be replaced with the top front panel from the rear flue lowboy model p n 17383 2 Refer to Appendix D Replacement Parts for sketches of these parts Contact your distributor to purchase this part All horizontal sections of the vent connector must slope upward not less than inch per foot from the furnace to the vent termination Long horizontal sections of the venting system must be supported at least every five 5 feet with metal straps to prevent sagging of the vent piping Secure all joints in the vent connector with sheet metal screws or equivalent fasteners Vent piping must not be inserted beyond the inside wall of the chimney flue Power Side Wall Venting Important Note Regarding CAUTION Thermo Products LLC will NOT assume responsibility for d
36. ear flue model VLF BNP Front Flue or VLR BNP Rear Flue 140 000 119 000 105 000 84 000 89 000 front 7 114 000 98 000 Hopes sk 0 000 70 85 9 front flue 86 0 rear flue 27 8 front flue 30 0 rear flue 41 5 22 25 47 6 37 5 front flue opens upward 31 rear flue exits horizontally rearward 20 x 20 20 x 12 5 two 10 x 20 ea 300 120 60 1 10 2 R W Beckett oil burner 15 Directly driven DWDI FC centrifugal w 10 in dia wheel 1 2 Permanent split capacitor 4 1400 R W Beckett pressure atomizing type Model NX 5 875 effective Variable flame retention 2 distillate domestic heating oil 0 55 60 w 175 Interrupted Direct Spark None Clean cut vA solenoid Preformed refractory ceramic fiber matrix material 3 3 8 front flue 3 rear flue 3 9 3 44 Spirit Oil Fired Horizontal Counterflow Furnace Specifications Model Heat Input Rate BTUH Output BTUH Nominal Temp Rise deg F Minimum Efficiency Rating AFUE Gross Heat Exchange Area sq ft Casing Height in Casing Width in Casing Depth in Nominal Flue Outlet Dia in Height from Floor to Center of Flue in Supply Air Outlet Size in x in Return Air Inlet Size in x in Air Filter Quantity amp Size in x in Approx Shipping Weight Electrical Requirements VAC Hz Ph Total Current Amps Max Fuse Size Amps Blower Specifications
37. ed and where basement windows are also weather stripped one 1 permanent opening connecting to a well ventilated attic or with the outdoors shall be provided using a duct if necessary This opening shall have a minimum free area of one 1 square inch per 5000 BTUH of total input rate sum of the individual appliance input rates of all appliances to be installed in the basement When an opening in the outside wall must be provided it should be furnished with properly screened metal sleeves If an exhaust fan additional air consuming machines e g an air compressor or a return air grill is present in the furnace room there should be increased concern about providing adequate airflow to the furnace Additional efforts may be required to assure an adequate supply of combustion and ventilation air is available to the furnace under all conditions Chimney Inspection The chimney vent or any passageway for the stack gases to flow to the outdoor atmosphere is a very important part of the heating system No furnace regardless of the efficiency of the design can perform satisfactorily when the chimney to which it is connected is inadequate or in poor condition Any of the following symptoms may indicate a chimney has severe structural damage and is unsuitable for use Chimney appears to be leaning to the side e Chimney appears to have structural damage i e loose or missing blocks or bricks or excessive deterioration at mortar jo
38. fficient air for combustion The following method will usually be adequate to ensure sufficient airflow into the space Provide two 2 permanent openings 1 located within 12 inches of the floor and one 1 within 12 inches of the ceiling or roof of the room These openings shall allow for direct exchange of air between the room and outdoors required ducting between the room and the outdoors shall be provided For horizontally oriented ducts each opening shall have a minimum free area of one 1 square inch per 2000 BTUH of the total input rate sum of the individual appliance input rates of all appliances to be installed in the room e For vertically oriented ducts the minimum free area may be reduced to 1 square inch per 4000 BTUH of the total input rate sum of the individual appliance input rates of all appliances to be installed in the room e The minimum dimension of any air opening shall not be less than 3 inches e When an opening in the outside wall must be provided it should be furnished with properly screened metal sleeves 2 Full Basement example of an unconfined space a Where a furnace is installed in a full basement in a building of conventional construction with normal air infiltration infiltration is normally adequate to provide air for combustion and ventilation b In buildings of unusually tight construction such as those where weather stripping and storm sash windows are us
39. imit or if equipped the auxiliary high temperature limit may activate to prevent very high discharge air temperatures from occurring 23 Should airflow be restricted the furnace might cycle on and too frequently or become inoperative The fan timer board will indicate this limit activation sequence by the flashing of the red LED When this LED is flashing the call for heat is disrupted and the blower will run continuously until the limit has been satisfied Then the LED will stop flashing To correct this condition verify that all supply and return dampers and registers in the air distribution system are open If this fails to resolve the problem turn off the electrical power to the furnace Remove the blower compartment access door to examine the air filter s and blower for blockages or a loose blower wheel On the highboy and horizontal counterflow furnaces air filters should be mounted external to the furnace casing If possible correct the condition by cleaning or replacing the air filter s freeing the blower wheel of any foreign materials or securing the blower wheel to the fan motor shaft Always replace the blower compartment access door when service is finished Restore electrical power to the furnace Room Thermostat Most room thermostats are equipped with user adjustable or selectable levels of heat anticipation This feature helps to reduce the amount of room air temperature overshoot that occurs after a heating cy
40. in the parts bag with each furnace use two 2 or three 3 5 16 in brass hex nuts and flat washers as required secure the burner to the mounting studs on the burner mounting plate 3 Secure the electrical conduit of the wiring harness to the oil burner junction box with the hardware provided 18 INITIAL OPERATION OF THE FURNACE Initial Burner Operation A WARNING To avoid possible explosion DO NOT attempt to light the burner if Oil has accumulated in the base of the combustion chamber The furnace is full of fuel vapors The combustion chamber is very hot CAUTION The oil burner must be installed and adjusted using recently within the last year calibrated combustion instruments by a qualified heating contractor prior to placing the furnace in operation Refer to this manual and the oil burner instruction manual for details CAUTION To minimize initial fuel oil and combustion odors ventilate the building well while operating the furnace for the first time Do notrun the oil pump dry without oil for more than two 2 minutes Damage to the oil pump may result To initially operate the furnace 1 Turn the electrical disconnecting switch to the OFF position 2 Set the room thermostat above room temperature 3 Be sure the oil tank is full of clean 2 fuel oil 4 Open all shutoff valves in the oil line 5 Turn on the electrical disconnecting switch and prime the burner oil pump according
41. ine run from the oil tank to the burner will be usually be adequate No return line will be required If the oil tank is installed below the burner and the lift exceeds approximately 8 ft an oil supply line and an oil return line are recommended Refer to the Standard for the Installation of Oil Burning Equipment NFPA 31 2001 and the oil burner operating instructions for detailed information on oil storage tank amp oil supply return line installation NOTICE We recommend installing a high efficiency oil filter in the oil supply line capable of filtering 10 to 20 micron diameter or preferably smaller particles from the fuel If available the use of ultra low low sulfur less than 0 001596 S and 0 0015 0 05 S by weight respectively no 2 fuel oil is highly recommended Low sulfur fuel oil can help to significantly reduce instances of blockage and corrosion of the oil burner fuel delivery system especially the nozzle the furnace heat exchanger and the flue gas venting system Air pollutants emitted by the furnace and the typical malodorous smell of oil combustion will be reduced 17 Horizontal Counterflow Furnace Setup The horizontal counterflow furnace is shipped from the factory upright for vertical installation counterflow configuration If the furnace is to be installed lying down on the right hand or left hand side horizontal configuration the position may have to be changed The horizontal furnace may
42. ints e Tile liner damaged or missing e Flue gas leakage along the length of the chimney between the chimney connector and discharge termination e Excessive corrosion at the cleanout port or at the chimney connector entrance into the chimney e Structural debris i e mortar or tile liner flakes in base of the flue way A qualified person shall inspect the chimney to confirm it is correctly sized for the application properly constructed and in sound condition Refer to the Standard for the Installation of Oil Burning Equipment NFPA 31 2001 for details on proper chimney sizing and construction If needed the chimney should be cleaned before installing the furnace Any accumulation of dirt or debris at the bottom of the flue should be removed Flue Chimney Vent Connector CAUTION DO NOT install a manual damper in the chimney or vent connector Thermally activated type vent dampers are NOT recommended for use on these furnaces It is desirable to install the shortest vent connector also referred to as a flue or chimney connector possible with the fewest number of fittings i e transitions and elbows Generally 6 inch diameter 24 Ga or heavier single wall lock seam type galvanized steel vent pipe and fittings are satisfactory materials for the fabrication of a vent connector However always consult local codes and authorities for specific minimum requirements For some installations it may be prudent to turn th
43. just the barometric damper to increase the stack draft to obtain an overfire draft of 0 02 in W G with the burner operating This is the typical minimum draft required to obtain the specified flue gas combustion analysis values given in Table 1 If the specified overfire draft cannot be obtained with a stack draft of 0 02 in W G the heat exchanger may be partially blocked and could require cleaning 28 6 Measure the draft at the point where the vent connector attaches to the heat exchanger flue pipe With the burner operating the stack draft should not exceed 0 05 in W G If the stack draft has been adjusted above this value to give the proper overfire draft the heat exchanger will require cleaning If there is little or no stack draft the chimney flue way may require cleaning the chimney is too restrictive or a downdraft condition exists E Symptom Furnace blower will not start Items to check 1 2 Confirm there is 120 VAC at the blower terminal labeld HEAT on the oil furnace control If there is not 120 VAC at the blower motor terminal measure the voltage at the S1 terminal on the oil furnace control If the fan can be activated by itself from the room thermostat subbase confirm it will operate If so the oil furnace control may have a burnt or damaged relay Confirm and replace the control if necessary If there is 120 VAC at the blower motor terminal HEAT either the run capacitor or blower
44. lation air to the furnace Chloride fluoride iodide and bromide bearing compounds when present even in low concentrations in air supplied for combustion to the furnace can result in accelerated and severe corrosion of the heat exchanger and or the venting system This condition can occur with less efficient furnaces but is more likely to happen on furnaces with efficiencies of 80 or greater Often household chemicals contain chloride bearing compounds There are many compounds representative of this classification of chemicals A few common examples are listed below Cleaning solvents Varnish and paint removers Bleaches Fabric softeners Water softener salt Tile adhesives Avoid storing or using these chemicals within close proximity to the furnace In addition avoid storing or using any chemicals of an unknown and possibly flammable nature in close proximity to the furnace If it is necessary to store or use chemicals in the same space as the furnace the area should be well ventilated and all containers should be sealed when not in use If possible keep chemicals in a separate well ventilated room closed off from the furnace with a door The furnace shall be installed in a location within the building that permits a satisfactory supply of air for combustion ventilation and proper operation of the venting system While all forms of building construction cannot be covered in detail in this manual this requirement may usua
45. lly be met by application of one of the following methods in ordinary building construction However applicable local installation codes always take precedence and shall be followed The content of certain pertinent passages of NFPA 31 2001 on methods to obtain and ensure adequate airflow to the furnace has been excerpted and in some cases paraphrased below for reference purposes Consult the Standard for the Installation of Oil Burning Equipment NFPA 31 2001 for special cases and further details 1 Utility Room example of a confined space a In buildings of conventional construction with normal air infiltration two 2 permanent openings connecting to a well ventilated crawl space attic or another large well ventilated internal area shall be provided Each opening shall have a minimum free area of one 1 square inch per 1000 BTUH of total input rate sum of the individual appliance input rates of all appliances to be installed in the utility room One opening should be located near or in the ceiling of the room and the other should be located near or in the floor b In buildings of unusually tight construction e g those having continuous water vapor barriers tightly fitting or weather stripped doors and windows and gasketed caulked or sealed outer wall joints and penetrations wherein infiltration and air exchange with the outdoors is very limited 0 35 air changes per hour or less provision must be made to provide su
46. low the filter to air dry before reinstalling it in the furnace filter rack If the furnace or duct system is equipped with disposable type paper element air filters inspect them every month for an excessive accumulation of dust and dirt Replace disposable air filters at least twice a year Make certain the replacement filter is the same size as the one being replaced The filter size is marked on the outer edge of the air filter Install the filter with the arrow marked on the filter pointing toward the furnace Cil Burner NOTICE A qualified heating contractor MUST service the oil burner in this furnace at least once a year Generally service to the burner will involve a thorough inspection and cleaning of the burner replacement of the oil nozzle and oil filter and readjustment of the burner to achieve proper ignition and clean combustion Blower and Motor NOTICE The fan motor has sealed bearings that do NOT require lubrication The blower and fan motor will not normally require any service This furnace is equipped with a directly driven blower Therefore it will not require any retensioning or replacement of a drive belt Heat Exchanger CAUTION DO NOT attempt to clean the heat exchanger unless electrical power and fuel flow to the furnace are turned off and the furnace is at room temperature CAUTION The combustion chamber refractory material is fragile and can be easily damaged If the inner radiator of the heat e
47. m m Series Ihermo Products LLC OIL FIRED CENTRAL FURNACE Installation Operation And Service Manual With Users Information Section Models VH BBP VC BBP VLF BBP VLR BBP VH BNP VC BNP VLF BNP VLR BNP A WARNING Do NOT store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Improper installation adjustment alteration service or maintenance can cause a fire or explosion resulting in property damage personal injury or loss of life For assistance or additional information consult a qualified installer or service agency These instructions should be e read prior to installing the furnace e retained for reference by qualified service personnel reviewed before performing any service or maintenance Thermo Products LLC US CERTIFIED 5235 West State Road 10 www ahridirectory org North Judson indiana 46366 nterte Made in USA MO 499 ECN 5396 MA 141211 Contents SECTION PAGE Notice to the Installer ede ee ote 4 INSTALLATION GUIDELINES ne edant 5 2008876 uqu 5 Installation Location a aa oer SERERE UEE CLER AR ek up 5 Closet and Alcove Installation 6 Standard en au dr Dri ones DI muUa
48. mary reset button 25 Troubleshooting SERVICE A WARNING When testing electrical equipment always follow standard electrical safety procedures Before beginning these troubleshooting procedures always review these basic points 1 Check for 120 VAC power to the furnace If there is no voltage check the disconnecting switch for circuit breaker trip or blown fuses 2 Make sure the room thermostat is set on the heating mode and is calling for heat 3 Check for sufficient oil supply and that all oil shutoff valves are open 4 To successfully service this oil furnace the following recently within the last year calibrated instruments must be available Smoke spot test kit with Bacharach type oil burner smoke scale Carbon dioxide COz and carbon monoxide CO test kit or analyzer Flue gas temperature measuring instrument Draft gauge capable of measuring 0 01 to 0 25 in W G draft Draft is the pressure differential between the static pressure measured in the vent pipe or just above the combustion chamber and the indoor atmospheric pressure Under normal operating conditions it will have a negative value i e the pressure in the combustion chamber and the vent system are less than room air pressure Multimeter analog or digital type Oil pressure gauge capable of measuring at least 0 to 200 PSIG Burner electrode and nozzle setting gauge 5 Be familiar with the correct operation of these instruments as well
49. nace heat exchanger that would ordinarily be lost to the outdoor atmosphere a longer or shorter cooldown period is desired the fan control timing may be reset to lengthen or shorten the cycle as desired Refer to Table 2 for the standard fan and high limit control settings Table 2 Standard Furnace Fan Timings Limit Temp Settings amp Speed Settings High Limit Thermostat Setting deg 130 highboy lowboy models 150 lowboy rear flue models 190 horizontal counterflow model Fan Setting 60 second delay Fan Setting 4 minute delay Standard Fan Speed for 105 MBTUH Input Rate ML Blue wire to Heat Terminal DIP SWITCH 2 SECTION STATE BLOWER DELAY TIMES 1 2 3 4 ON SEC OFF MIN OFF OFF 30 ON OFF 60 OFF ON 120 ON ON 240 OFF OFF 2 ON OFF 4 OFF ON 6 ON ON 8 In addition to the high limit control the horizontal counterflow furnace is equipped with an auxiliary high limit temperature control located in the blower compartment refer to the electrical diagram in Appendix B The purpose of this control is to prevent overheating of the blower motor and air filter s if airflow is severely reduced If the duct system becomes partially or totally blocked or the furnace air filter s become excessively dirty causing the blower to fail to circulate enough air the thermostatic high temperature l
50. ng this furnace A WARNING Failure to follow these instructions may result in fire or explosion causing property damage personal injury or loss of life WHAT TO DO IN THE EVENT OF AN OIL LEAK Do not try to operate this or any other nearby appliance If present close the manual oil shutoff valve on the fuel oil supply line Immediately call a qualified heating contractor for service If you cannot reach a qualified heating contractor call the fuel oil supplier of the fire department DO NOT use this furnace if any component was underwater Immediately call a qualified heating contractor to inspect the furnace and replace any part of the furnace control system that was underwater This furnace does not have a pilot light It is equipped with an electronic ignition system that automatically lights the burner DO NOT attempt to light the burner by hand TO OPERATE THIS FURNACE 1 Adjust the room thermostat to the lowest setpoint and set the operating mode if equipped to OFF 2 Turn off all electric power to the furnace at the disconnecting switch 3 Turn the manual oil shutoff valve to the open or ON position 34 E This furnace is equipped with an electronic ignition system that automatically lights the burner DO NOT try to light the burner by hand 5 Turn on the electric power to the furnace at the disconnecting switch 6 Adjust the room thermostat to the desired setpoint and set the operating mode if eq
51. nstaller should supply or fabricate a filter rack and mount an air filter in the return air plenum above or upstream of the furnace blower compartment 12 the highboy furnace it is necessary to cut the return air opening in the lower side or rear of the casing depending upon the needs of the specific installation refer to Figure 3 BLOWER PAN BLOWER PAN SUPPORT ANGLE Y Figure 3 Cutaway view of fan section of a typical highboy furnace The side casings have each been pre punched with four 4 square knockout openings for use in locating the proper position for the return air filter rack On the side of the furnace where the return air duct will attach scribe a line connecting the outside edges of the knockout openings to form a rectangle Using a punch or a large screwdriver and a hammer remove the knockouts and cut the return air opening in the casing Sheet metal shears or a power metal cutting tool will be required to cut the casing Position the open end of the filter rack to the front of the furnace to permit access for filter replacement Align the filter rack with the rectangular hole and mark the locations on the casing of the pre punched mounting holes in the filter rack flange Drill pilot holes in the casing and permanently attach the filter rack to the furnace with screws or pop rivets these fasteners are not included Connect the return air plenum to the filter rack and slide
52. of supply return airflow 11 Cycle the furnace several times to verify the burner lights off and shutsdown smoothly without excessive noise or smoke production 20 Table 1 Oil Burner Application and Specifications Furnace Model A fk E MA Carbon Dioxide E S Carbon Dioxide CO2 Minimum Carbon Monoxide co PPM 0 k PrepurgeTime sec Noe Postpurge Time sec 1 Noe When operating these furnaces at the lowest input rate 84 000 BTUH the carbon dioxide CO value may not be able to be adjusted above 12 This is normal and does not necessarily indicate a problem Supply Return Airflow and Air Temperature The supply return airflow shall be set to obtain an air temperature rise across the furnace in the range of 55 to 85 F Since the flow resistance of each duct system is slightly different the airflow fan speed may have to be changed in the field to achieve a satisfactory temperature rise One way to measure the temperature rise across the furnace is to insert temperature measuring devices e g thermometers into the return air duct and into the supply air duct about 12 inches from the furnace After the furnace has been firing continually for over 20 minutes read the temperature difference between the two 2 thermometers The temperature difference should not exceed 85 F nor be less
53. oisture on the inside surface of the tank The presence of moisture in the tank is beneficial to the growth of biological fuel contaminants bacteria mold fungus yeast etc Keep the cap on the fuel tank fill pipe tightly closed at all times to prevent the entrance of moisture foreign matter insects etc Consider adding a guard or filter to the tank vent pipe to reduce the entrance of water and foreign matter into the tank Also check the tank vent and fill pipe for cracks and leaks Have any necessary tank repairs performed ASAP 35 e Annually have a bottom sample from the fuel oil tank taken for analysis If present in excessive quantities sludge and water should be removed Fuel oil additives may be of benefit in helping to resolve some problems that are indicated by the analysis In severe cases tank cleaning may be required Consult your fuel oil supplier for recommendations Extended Shutdown If the furnace will be shutdown for an extended period of time 1 Adjust the room thermostat to the lowest set point and set the operating mode if equipped to OFF 2 Open the disconnecting switch serving the furnace 3 Close the manual oil shutoff valve 4 To promote smooth startup and nuisance free operation fuel oil quality must be maintained at a high level In cases where biological contamination of the fuel oil tank is evident or suspected consider treating the fuel oil with a biocide approved for fuel oil applic
54. pendix B of this manual for an electrical schematic a connection diagram and operating instructions Room Thermostat A room thermostat is not furnished with this furnace However a thermostat is required to properly operate the furnace control system in a typical residential heating application The room thermostat should be located on an interior wall in the natural circulating path of the room air The thermostat should not be installed in a location where it is directly exposed to e cold air infiltration i e drafts from outside openings such as windows and doors air currents produced by supply air registers and heat from nearby source such as fireplace electrical appliances lamps solar radiation a wall enclosing warm air ducts a chimney or a flue gas vent These phenomena will adversely influence the operation of the thermostat preventing it from properly controlling the room temperature Conversely avoid installing the room thermostat in a location where the natural circulation of air is blocked such as behind doors in shelves or in corners 14 Generally a room thermostat should be set at the lowest temperature that is comfortable to the building occupants This will result in the lowest cost to heat the building Combustion Chamber The furnace combustion chamber is a hollow circular cylinder sealed at the bottom end and open at the top end The chamber is made of a lightweight insulating
55. pping Weight Ib 260 Electrical Requirements VAC Hz Ph 120 60 7 1 Total Current Amps 10 2 w R W Beckett oil burner Max Fuse Size Amps 15 Blower Specifications Directly driven DWDI FC centrifugal w 10 in dia wheel Blower Motor Size HP 1 2 Motor Type amp Number of Speeds Permanent split capacitor 4 High Speed Airflow SCFM 0 4 in 1350 W G External Static Pressure Burner Specifications R W Beckett pressure atomizing type Model NX Air Tube Length in 5 875 effective Burner Head Type Variable flame retention Fuel Type 2 distillate domestic heating oil Nozzle Rating for Beckett AF GPH 0 55 Spray Angle Deg 60 Spray Pattern w Oil Pump Pressure PSIG 175 Ignition Control Type Interrupted Direct Spark Pre Post Purge Feature s None Automatic Oil Solenoid Valve Clean cut w solenoid Combustion Chamber Type Preformed refractory ceramic fiber matrix material Clearances to Combustible Materials Minimums Sides in 3 Top in 3 Front in Rear in 3 Flue Vent Pipe in 9 Supply Plenum Surfaces in 3 42 Spirit Oil Fired Lowboy Furnace Specifications Model Heat Input Rate BTUH Output BTUH Nominal Temp Rise deg F Minimum AFUE Rating Gross Heat Exchange Area sq ft Casing Height in Casing Width in Casing Depth in Nominal Flue Outlet Dia in Height from Floor to Center of Flue in S
56. r head bolt plugs the overfire port in the burner mounting plate Remove the bolt and insert a suitable draft measurement gage After the chimney or stack gas passageway has warmed up to operating temperature approximately 15 to 20 minutes of burner operation adjust the barometric damper to obtain the correct overfire draft reading The overfire draft should read 0 02 in W G The draft measured at the flue stack draft should read no more than 0 05 in W G NOTICE The overfire draft is the more important measurement and should be used to adjust the setting of the barometric draft control 10 Flue Gas Temperature The flue gas temperature will vary depending on heat input rate air temperature rise across the heat exchanger and air flowrate through the furnace To prevent excessive water vapor condensation from the flue gases the gross flue gas temperature should not fall below 330 F In addition if the gross flue gas temperature exceeds 650 F the heating efficiency of the furnace will be reduced To reduce high flue temperatures after properly adjusting the burner check for blocked supply return airflow Remove any blockages increase fan speed or consider reducing the furnace heat input rate Also verify there is no air leakage into the combustion chamber from around the burner mounting flange or heat exchanger mounting plate If flue gas temperatures are too low consider increasing the heat input rate or reducing the amount
57. rocedure 2 Y G DEHUM A ZS CS GY ES 25 CT XuZ A gt ox gt T 2 MA MA AMA MA OIL FURNACE CONTROL FAN TIMER BOARD 2 SPEED BY INPUT ON OFF gt 119 000 140 000 i MAS MH H LOW MH H ML MH MH H MH H IN BLACK COOL D T 5 _ BLUE HEAT 1 RED ay __ YELLOW UNUSED 2 7 6 L lt J 120 vac N P2 SEE E WHITE NEUTRAL BLOWER MOTOR LEADS v Figure 7 Fan Timer Board Blower Motor Wiring 22 Furnace Limit Blower Controls All furnaces are equipped with a thermostatic high temperature limit The high temperature limit is set such that it does not permit a supply discharge air temperature above 200 F The thermostatic fan control should be set so the greatest fuel utilization efficiency of the furnace is obtained Generally a blower ON timing of 60 seconds should give the best result After the burner shuts down the circulating air blower will continue to operate until the fan delay has been satisfied Factory setting for this delay is 4 minutes This delay on blower shutdown extracts residual heat from the fur
58. ross the casing near the middle of the furnace Generally a simple support frame for the furnace can be fabricated from structural steel angle threaded steel rod and fastener hardware refer to Figure 1 Adjust the height of the support angles to level the unit in position 1 2 OR HEAVIER CASKET MATERIAL 25 8 OR HEAVIER THREADED ROD 21 8 OR HEAVIER ANGLE IRON Figure 1 Recommended Support Frame for Horizontal Counterflow Furnaces Closet and Alcove Installation All furnace models may be installed in a closet or alcove on combustible flooring with specified standard clearances to combustible construction The horizontal counterflow furnace model requires an optional combustible surface mounting base model VC BASE for vertical installation i e counterflow configuration directly on combustible materials refer to Figure 2 Figure 2 Counterflow Furnace Combustible Surface Mounting Base Standard Clearances Standard clearances are mandatory minimum clearances from heated surfaces of the furnace to combustible materials to assure protection from fire hazard during furnace operation Refer to the Standard for the Installation of Oil Burning Equipment NFPA 31 2001 for definitions of combustible and non combustible materials Accessibility clearances which are typically greater may exceed fire protection clearances Therefore consider providing at least 24 inches of clearance from the front and
59. ross the flame sensor lead wires The measured resistance should be less than 1600 Ohms for the Honeywell cad cell 2 Stop the burner and remove the jumper wire 3 With the burner off measure the resistance of the flame sensor with the ohmmeter The resistance of the sensor without seeing a light source so called dark cell resistance should be greater than 20 000 Ohms for the Honeywell cad cell 4 If the sensor resistances are outside the acceptable ranges given above confirm the lens of the cell is clean and the cell is located correctly in the burner housing If the cell is clean and correctly located replace the flame sensor NOTICE All resistances are approximate values only and will vary depending upon the intensity of the light source flame or sunlight and the condition or age of the cad cell Replacement Parts Appendix D of this manual contains a list of replacement parts available for these furnaces 30 Air Filter s CAUTION To avoid injury from moving parts hot surfaces or electrical shock shut off the power to the furnace and allow the furnace to cool BEFORE removing any furnace access doors to service air filters Highboy and lowboy furnace models are factory supplied with a permanent type air filter At least twice a year remove the air filter s for cleaning Clean a filter by soaking itin water with a mild detergent and then rinsing it with clean water Al
60. s e Evidence of structural damage and loose or disconnected piping joints e Presence animal nests e Free movement of the vane of the barometric damper without binding or interference If any problems are evident call a qualified heating contractor for assistance NOTICE A qualified heating contractor MUST service the oil burner and inspect the heat exchanger in this furnace at least once a year 37 APPENDIX A SOURCES FOR REFERENCED STANDARDS 1 Air Conditioning Contractors of America 1712 New Hampshire Avenue N W Washington D C 20009 http www acca org 2 American Society of Heating Refrigeration and Air Conditioning Engineers Inc 1791 Tullie Circle N E Atlanta Georgia 30329 http www ashrae org 3 National Fire Protection Association 1 Batterymarch Park Quincy Massachusetts 02269 http www nfpa org 38 ELECTRICAL DIAGRAMS APPENDIX B VH BBP VH BNP VLF BBP VLF BNP VLR BBP VLR BNP Models QN3931 aa1vuvdas NIVIW3H LSNW SLINDYIO ANY SNILV3H 2 55710 Sula ONY 390HS OL SNINSVM V Z O SI ONILLAS HOLVdIOLLNV LVLSOWYSHL WOO WOIdAL S ALW1d SWVN 33338 H3 V3 LIDOMIO SSH3ANI 3503 AVIAG 3ZIS 3 18v Ld399V NOLLO3LOSd LNdSSOH3AO 31Vno3dv LN3IN3OV 1d3H 07314 SHOLONGNOSD H3ddOO AINO ASN H3lV3u9 YO 2 901 Q31VH NOILVINSNI NV 3AVH LSNW SN
61. s manual The oil burner was installed in the furnace at the factory In the field if it is necessary to adjust the heating capacity of the furnace by changing the oil burner nozzle refer to the following instructions Also consult the oil burner manufacturer s operating instructions included with the burner for detailed instructions on this procedure 1 The oil nozzle is factory installed in the oil burner The gun electrode assembly with nozzle may be removed from the rear of the burner assembly without removing the oil burner from the furnace To access the gun electrode assembly loosen two 2 machine screws and clamps holding the burner ignition transformer in position Rotate the transformer forward and out of the way 15 2 Install an appropriate replacement nozzle of the correct size spray angle and 3 spray type Refer to the Specification Sheets in Appendix C of this manual for nozzle recommendations The furnace may have been handled roughly while in transit Under some conditions the combustion chamber can shift out of position Check for proper alignment of the burner air tube with the circular opening in the combustion chamber and trial fit the burner to check the insertion depth of the oil burner into the combustion chamber The end of the burner air tube should be inserted no farther than 1 4 inch back from the inside surface of the combustion chamber refer to Figure 4 Do not allow the burner tube end cone
62. soft refractory material The refractory material is composed of organically bound alumina silica fibers that provide a high temperature region for combustion of the oil to occur Oil Burner and Oil Nozzle Installation N CAUTION This oil furnace is designed to use No 2 distillate fuel home heating oil only This furnace is designed to utilize the following specially modified oil burner e R W Beckett Corp model AF burner specification EFL 101 e R W Beckett Corp model NX burner specification EFL 301 NOTICE NO other burners may be used in this application The heat output from the furnace is fixed based on the size of nozzle installed in the oil burner Four 4 heat input rates are permissible 85 000 105 000 120 000 and 140 000 BTUH Nozzle selection i e heating capacity of the furnace shall be based on a rate of heat loss heating load calculation for the building These calculations should be made according to the manuals provided by the Air Conditioning Contractors of America ACCA or the American Society of Heating Refrigeration and Air Conditioning Engineers Inc ASHRAE Refer to the Residential Load Calculation Manual J from the ACCA and the ASHRAE Handbook Fundamentals volume from ASHRAE for the recommended procedure to compute the design heating load of a residence To obtain copies of these publications for a fee contact the ACCA and the ASHRAE at the addresses given in Appendix A of thi
63. than 55 F For better energy efficiency a temperature rise closer to 70 F is recommended The blower fan speed is adjusted by changing the fan motor winding energized by the control system The furnace is set on the med low fan speed ML at the factory refer to Table 2 To adjust the fan speed follow this procedure a Turn off all electrical power to the furnace at the disconnecting switch b Remove the blower compartment access door on the counterflow horizontal furnace c The Heat tab is the connection for the heating speed activation thru the fanboard If a change in heating speed is desired simply pull the blue ML wire from the heat tab and replace it with the yellow MH wire This changes the speed from medium low to medium high Black High is connected to the cool 21 tab for A C speed operation If a lower speed is desired for A C the speed is charged the same way A tab marked Low is populated with a lower fan speed for continuous fan operation thru the G circuit of your T stat Unused blower speeds are connected to the unused motor leads tabs at bottom right of fanboard d Replace the blower compartment access door on the counterflow horizontal unit e Restore electrical power to the furnace at the disconnecting switch With the furnace operating measure the air temperature rise across the furnace again If the value does not fall in the range of 55 to 85 F repeat the above p
64. ual Installation Location A WARNING e These furnaces are designed for indoor installation ONLY e These furnaces are NOT to be used as construction heaters DO NOT hang the horizontal counterflow furnace from a structure or surface by any integral part or fastener of the furnace The furnace was not designed to support itself in this manner In as much as practical the furnace should be positioned near a chimney or vent and should be centralized with respect to the air distribution system For a utility room installation the entrance door must be wide enough to permit the largest part of the furnace to pass through the doorway or allow sufficient clearance to permit the replacement of another appliance e g a water heater in the room If the furnace is installed in a residential garage it must be installed so the burner is located higher than 18 inches above the floor unless the required combustion air is taken from the exterior of the garage Also the furnace must be located or protected to avoid physical damage from impacts by vehicles Highboy and lowboy furnace models must rest on sturdy stable and level surfaces The horizontal counterflow model may be mounted on a level surface as described above or it be suspended from an overhead structure or surface If this model is suspended from hanger rods support the furnace from the bottom casing surface at three 3 places across both ends of the casing and ac
65. uipped to HEAT 7 If the furnace will not operate call a qualified heating contractor for service TO INTERRUPT STOP OPERATION OF THIS FURNACE 1 Adjust the room thermostat to the lowest setpoint and set the operating mode if equipped to OFF 2 If service will be performed turn off all electric power to the furnace at the disconnecting switch 3 Turn the manual oil shutoff valve to the closed or OFF position Oil Supply If available the use of ultra low or low sulfur less than 0 001596 S and 0 0015 0 05 S by weight respectively no 2 fuel oil is highly recommended Low sulfur fuel oil can help to significantly reduce instances of blockage and corrosion of the oil burner fuel delivery system including the nozzle the furnace heat exchanger and the flue gas vent system These benefits can appreciably decrease or eliminate service calls due to poor fuel quality Air pollutants emitted by the furnace as well as the typical malodorous smell of oil combustion will also be reduced Consult your fuel oil supplier about the availability of low sulfur fuel oil DO NOT allow the fuel tank to run completely dry during the heating season If the fuel tank runs completely dry it may be necessary to purge the oil lines of trapped air If necessary contact a qualified heating contractor to bleed the oil lines and restart the burner During the warmer weather keep the tank full to prevent condensation of m
66. upply Air Outlet Size in x in Return Air Inlet Size in x in Air Filter Quantity amp Size in x in Approx Shipping Weight Ib Electrical Requirements VAC Hz Ph Total Current Amps Max Fuse Size Blower Specifications Blower Motor Size HP Motor Type amp Number of Speeds High Speed Airflow SCFM 0 4 in W G External Static Pressure Burner Specifications Air Tube Length in Burner Head Type Fuel Type Nozzle Rating for Beckett AF GPH Spray Angle Spray Pattern Oil Pump Pressure PSIG Ignition Control Type Pre Post Purge Feature s Automatic Oil Solenoid Valve Combustion Chamber Type Clearances to Combustible Materials Minimums Sides in Top in Front in Rear in Flue Vent Pipe in Supply Plenum Surfaces in for front flue model for rear flue model VLF BBP Front Flue or VLR BBP Rear Flue 140 000 119 000 105 000 84 000 86 000 front 114 000 98 000 88 000 rear 70 000 70 83 0 front flue 85 0 rear flue 27 8 front flue 30 0 rear flue 41 5 22 25 47 6 37 5 front flue opens upward 31 rear flue exits horizontally rearward 20 x 20 20 x 12 5 two 10 x 20 ea 300 120 60 1 10 2 w R W Beckett oil burner 15 Directly driven DWDI FC centrifugal w 10 in dia wheel 1 2 Permanent split capacitor 4 1400 R W Beckett pressure atomizing type Model AF 5 875
67. xchanger is cleaned avoid scraping or hitting the walls of the combustion chamber CAUTION Do not brush or scrape the surface of the combustion chamber It can be easily damaged 31 NOTICE A qualified heating contractor MUST inspect the heat exchanger in this furnace at least once a year If heavy deposits are found immediate cleaning is required All heat exchanger surfaces should be as clean as possible for the most efficient operation of the furnace The heat exchanger may require cleaning after every heating season as combustion of fuel oil tends to produce soot particulate matter and scale due to corrosion These materials coat the inner walls of the heat exchanger This coating reduces the heat transfer effectiveness of the heat exchanger and can hinder the flow of flue gases from the furnace NOTICE Accumulation of heavy soot deposits over one heating season may indicate the oil burner is out of adjustment The heat exchanger may be inspected and cleaned through an access or cleanout port located in the burner compartment on highboy and lowboy models or immediately behind the front casing panel on the horizontal counterflow model The cleanout port consists of a 4 inch diameter stamped steel cap The cap is retained by a single T bolt through a circular opening located in the outside wall of the heat exchanger refer to Figure 8 HEAT EXCHANGER OPENING HEAT EXCHANGER CLEAN OUT COVER BAR T BOLT
68. ze HP 1 2 Motor Type amp Number of Speeds Permanent split capacitor 4 High Speed Airflow SCFM 0 4 in 1350 W G External Static Pressure Burner Specifications R W Beckett pressure atomizing type Model AF Air Tube Length in 5 875 effective Burner Head Type Fixed flame retention Fuel Type 2 distillate domestic heating oil Nozzle Rating for Beckett AF GPH 0 60 Spray Angle Deg 80 Spray Pattern Hollow Oil Pump Pressure PSIG 130 Ignition Control Type Interrupted Direct Spark Pre Post Purge Feature s None Automatic Oil Solenoid Valve None Combustion Chamber Type Preformed refractory ceramic fiber matrix material Clearances to Combustible Materials Minimums Sides in 3 Top in 3 Front in 8 Rear 3 Flue Vent Pipe in 9 Supply Plenum Surfaces in 3 41 Spirit Oil Fired Highboy Furnace Specifications Model VH BNP Heat Input Rate BTUH 84 000 Output BTUH 70 000 Nominal Temp Rise deg F 70 Minimum AFUE Rating 96 86 Gross Heat Exchange Area sq ft 27 8 Casing Height in 58 Casing Width in 22 25 Casing Depth in 31 Nominal Flue Outlet Dia in 6 Height from Floor to Center of Flue in 53 5 flue opens upward Supply Air Outlet Size in x in 20 x 20 Return Air Inlet Size in x in 23 5 x 13 installer must cut opening in lower side casing Air Filter Quantity amp Size in x in one 16 x 25 Approx Shi

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