Bryant 362AAN Furnace User Manual
Contents
1. 13101 IA es 1002 HDIH 891 971819 an NOLLO3NNOO IN Ave H3MO18 9 1V3H d33dS IN SOL pde UD AHOLOV i is 531 LOH NO 193NNOOSIG Q33dS 5NILV3H AlddNS H3MOd ZHO9 L OWA 911 13S AHOLO VJ ovig ya USER S INFORMATION HERE S HOW YOUR HEATING SYSTEM WORKS 3 Set thermostat to lowest setting The furnace operates automatically It is controlled by a thermostat 4 Turn on electric power to furnace which you set at the temperature most comfortable to you When the inside temperature drops below this setting your thermostat will turn on heating system 6 Check all connections to ensure there are no leaks When thermostat calls for heat power from transformer energizes Ill LIGHTING YOUR FURNACE fan control board The fan control energizes ignition control The ignition control lights burner automatically 5 Open oil supply valve CAUTION This furnace is equipped with an interrupted The electronic fan control automatically turns on blower after 30 AN type electronic ignition system DO NOT ATTEMPT TO sec Fan on control is not adjustable The air which is moved over LIGHT WITH A MATCH heat exchanger by the blower is warmed and passes through ducts to room regist2. NU UP NE ELECTRICAL CONNECTIONS 4 4 AM 7 1 Nur lt ele tke eee DIMENSIONS x 96309 UNIT UNIT DIMENSIONS DUCT SUPPLY OPENING 512 DIAMETER RETURN DUCT D E G H 036105 20 17 1 4 20 18 048125 22 1 4 060155 22 1 4 Fig 5 Dimensional Drawing 9 BAROMETRIC DAMPER LOCATIONS GOOD LOCATIONS WRONG E Ter U boc FIG G e FIG H Ls WRONG 2 lt WRONG WRONG bw WRONG BAD LOCATIONS A95117 Fig 6 Barometric Damper Locations BuurM lt 2 08 96 AGEE SITYNINWYEL WH 2 aasn at 9 te
3. Confirming that all unused chimney or vent connections are properly sealed 5 Verification that chimney is properly lined and sized per the applicable codes Refer to list of codes in Safety Consid erations section Il MASONRY CHIMNEY This furnace can be vented into an existing masonry chimney This furnace must not be vented into a chimney servicing a solid fuel burning appliance Before venting furnace into a chimney the chimney MUST be checked for deterioration and repaired if necessary The chimney must be properly lined and sized per local or national codes If furnace is vented into a common chimney the chimney must be of sufficient area to accommodate the total flue products of all appliances vented into chimney The following requirements are provided for a safe venting system 1 Be sure that chimney flue is clear of any dirt or debris 2 Be sure that chimney is not servicing an open fireplace 3 Never reduce pipe size below minimum certified furnace pipe size as shown in Table 2 TABLE 2 CERTIFIED FURNACE PIPE SIZE IN UNIT SIZE MINIMUM PIPE DIAMETER 036105 048125 060155 4 pipe should be supported using proper clamps and or straps These supports should be at least every 4 ft 5 horizontal runs of pipe should have at least 1 4 in per ft of upward slope 6 All runs of pipe should be as short as possible with as few turns as possible 7 Seams should b
4. 1 4 quick connect terminals marked HUM and are provided for 115 v humidifier connection See Fig 7 These terminals are energized with 115v 0 5 amp maximum during any call for heat FILTERS WARNING Never operate unit without a filter or with filter access door removed Failure to adhere to this warning could lead to a hazardous condition which could lead to equipment damage and bodily harm An internal filter is provided as standard equipment with furnace Refer to Keeping Filters Clean section for filter cleaning informa tion OPERATIONAL CHECKOUT DO NOT START BURNER UNLESS BLOWER ACCESS DOOR IS SECURED IN PLACE Installation of furnace is now complete and operational checkout may be performed START UP 1 Check wiring against wiring diagram shown in Fig 7 2 Open valve on oil supply line 3 Reset primary control 4 Set thermostat above room temperature 5 Set main electrical switch to ON position Burner should start DO NOT TAMPER WITH UNIT OR CONTROLS CALL YOUR SERVICE TECHNICIAN RECOMMENDED INSTALLATION PRACTICES AND COMBUSTION CHECK In order to obtain optimum performance from oil burner the following setup procedures must be followed 1 A test kit Bacharach No 5022 kit or equivalent to measure smoke stack draft over fire draft and stack tempera tures MUST be used in order to obtain proper air band setting Although all of the above measurements are re
5. 1 5 for proper combustion air requirements CAUTION USE METALLIC VENT PIPE ONLY A PLASTIC VENTING MATERIALS ARE PROHIB ITED OIL BURNER This furnace is supplied with a high pressure atomizing retention head type burner for use with not heavier than grade 2 Fuel Oil The air tube length from face of mounting plate to extreme face of end cone should be as shown in Table 3 TABLE 3 OIL BURNER AIR TUBE LENGTH UNIT SIZE LENGTH IN 036105 048125 060155 OIL CONNECTIONS Complete instructions for installation of fuel oil piping will be found in oil burner Installation Instructions included with furnace Oil line entry holes are provided in side panels Two holes are provided in each location so that a 2 pipe system may be used if desired A properly sized oil filter should be used with all oil burners and should be installed as close to burner as possible For a 2 pipe system a minimum capacity of 25 gph is needed BAROMETRIC DRAFT CONTROL The barometric draft control shipped with furnace MUST be used with furnace to ensure proper operation Instructions for installing control are packed with control Refer to Fig 6 for suggested locations ELECTRICAL The appliance must be installed in accordance with current ANSI NFPA 70 National Electrical Code CSA C22 1 Canadian Electrical Code Part 1 and or local codes The control system depends on correct polarity of power supply Connec
6. BOX PARTITION PANEL CLEANOUT PORT COVER CLEANOUT COVER GASKET CLEANOUT COVER CLAMP BRACKET WING at INSULATION 96311 Fig 3 Reinstalling Cleanout Port Covers 10 Turn on power to unit and readjust burner for proper operation Inspect cleanout ports and flue connection to make sure there are no leaks B Cleaning Both Primary and Secondary Heat Exchangers If a more thorough cleaning is required both primary and secondary heat exchanger sections the following steps should be performed 1 Turn off all oil and electrical supplies upstream of furnace CAUTION If furnace has been operation some surfaces may be hot Allow time for unit to cool down 2 Remove blower door 3 Disconnect flue pipe 4 Remove outside flue collar 5 Remove top rear panel NOTE Blower removal as described in Blower Oiling and Removal section may be desired for easier access when cleaning with duct work attached 6 Remove inside collar on flue pipe 7 Remove top partition 8 Place field fabricated cardboard on metal tray beneath collector box to prevent debris from entering blower com partment 9 Remove flue collector box from secondary heat exchanger tube flange This exposes inside surfaces of secondary tubes of heat exchanger 10 Clean secondary tubes and flue pipe with a stiff brush and vacuum cleaner 11 Remove louvered door 12 Disconnect limit control wires 13 Disconnect oil line a
7. OL SNOLLOSNNOO ATddNS H3MOd 01315 SAW 1 SILON 18 HO HM 5 ce 2 mim 9 OINOHLOGTH TIO ei i rp o T AuviWIHd i 091309 Hee NOLLO3NNOO 9 9NO 9NO 1V3H d33dS 3SN3S UNNT FEET e yg Sha pis ponesem d CH CN6 01616 18 2 085300 WNOILdO YAISIGINNH HM qu t e e t WOH 1770 i 2 9 3ID1 6 z1 dvo HOLOW v 9NO 2 9NO 9 z Ua YOOGNI Qv31HOLON 5 Nz HM MO 631 LOH NO LOANNOOSIC a3sn3 NOLLO3NNOO 1V3H 1NVISNOO ZH 09 OWA SLL G33ds WnIGSW AlddnSu3MOd 11 Oa NOLLO3NNOO 1V3H COIvNOLLdO SONILLAS HOLIMS did 4450 AN9 AHO10VJ 29819519 77777 T 091 296 021 996 06 295 09 HINT INN 3 LWIT LON TWNINYAL zx zo zl 2 HOLIOVdVO SNILHVIS dVO AVTI HOLOW GaSNNN m i RI m i H3WHOJSNVHL L TVNIWHL HOLIMS ds HOLIMS 03395 E 3 9 INVLSNOO MOTHA 1nN3HIM3ONVHO Q JUHM Mw
8. Sooting 3 Melted oil burner couplings and or ignitor relay control 4 A condition where air band or air shutter settings must be more open than normal to achieve proper combustion Rc E 5 Lockouts on start up DUCT WORK RECOMMENDATIONS The proper sizing of warm air ducts is necessary to ensure satisfactory furnace operation Duct work should be in accordance with the latest editions of NFPA 90A Installation of Air Condi tioning and Ventilating Systems and NFPA 90B Warm Air Heating and Air Conditioning Systems or Canadian equivalent The supply duct work should be attached to flanged opening provided at discharge end of furnace See Fig 5 for dimensions of this opening The following recommendations should be followed when install ing duct work 1 Install locking type dampers in all branches of individual ducts to balance out system Dampers should be adjusted to impose proper static at outlet of furnace 2 A flexible duct connector of noncombustible material should be installed at unit on both supply and return air systems In applications where extremely quiet operation is necessary the first 10 ft 1f possible of supply and return ducts should be internally lined with acoustical material 3 In cases where return air grille is located close to fan inlet there should be at least one 90 air turn between fan inlet and grille Further reduction in sound level can be accom plished by installing acoustical a
9. any flammable items around the unit CAUTION These instructions are intended to be used by qualified personnel who have been trained in installing A this type of furnace Installation of this furnace by an unqualified person may lead to equipment damage and or a hazardous condition which may lead to bodily harm local and national code requirements governing installation of oil burning equipment wiring and flue connections must be followed Some of the codes issued by the Canadian Standards Association the National Fire Protection Agency and or the American National Standards Institute that may be applicable are ANSI NFPA 31 INSTALLATION OF OIL BURNING EQUIPMENT ANSI NFPA 211 CHIMNEYS FIREPLACES VENTS AND SOLID FUEL BURNING APPLIANCES ANSI NFPA 90B WARM AIR HEATING AND AIR CONDITIONING SYSTEMS ANSI NFPA 70 NATIONAL ELECTRICAL CODE CSA B139 INSTALLATION CODE FOR OIL BURNING EQUIPMENT CSA C22 1 CANADIAN ELECTRICAL CODE Only the latest issues of above codes should be used and available from either The National Fire Protection Agency Bat terymarch Park Quincy MA 02269 or The Canadian Standards Association 178 Rexdale Blvd Rexdale Ontario MOW 1R3 Recognize safety information This is the safety alert symbol N When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CA
10. dirty filter reduces efficiency of your system causes erratic performance of controls and could result in damage to motor or heating element l Inspect filters at regular intervals depending upon dirt conditions For new homes check filters every week for 4 consecutive weeks In all cases inspect filters at least every 3 to 4 weeks when system is in constant operation Replace or clean filter at least at beginning of each season heating and cooling and thereafter as needed 2 If a permanent filter is used it can be cleaned with cold water and soap Be sure that filter is thoroughly dry before installing back into furnace WASHABLE PERMANENT NEEDS NO OIL MORE EFFICIENT LASTS FOR YEARS WASH FILTERS REGULARLY RE INSERT SO HAIRY SIDE CATCHES DUST NEEDS NO OIL DURA LAST PRODUCTS CORP NEW ORLEANS 70130 A95103 TABLE 5 AIRFLOW DATA CFM UNIT BLOWER SIZE SPEED EXTERNAL STATIC PRESSURE IN WC High 036105 Medium Low High 048125 Medium Low High 060155 Medium Low NOTES 1 Airflow values in cubic ft per minute CFM rounded to nearest 5 CFM 2 Data taken without filters in place CLEAN OUT PORTS SUPPLY RETURN DUCT UN DUCT B 1 Tl CER FEB a Gi inna
11. e dein 7148 1 33S 3215 NI ISNA WNWIXYN LInogio 5 1 91 19313 9 0 YHOLOVLNOO gU i E l po Z LV 1 15 NO HOLVdIOLLNV 1V3H 13S 9 OOG x i p SNL VH NO 031410345 SONVY NIHLIM ASIH 1 v OAO Q YAAITAG OL QHVOS LINOHIO NO TWNIWHAL LV3H OL HOLOW LOANNOO v TT Poinv 1009 N 1Y3H 4 ONIMIM 1314 3HIM H3ddOO 440 lt ISN 5 H3ddOO VO 91 30 WNWINIW V 38 601 1SV311V Mali ao dava HOLIMS did 5 ONILWH 3H LVESdINSL V ONIAVH TWIHSLVIN HLIM 38 LSAW LI Ti39 avo NOILO3T3S 9 gt LSNW Sv TVNIOIHO IHL JO dl 440 8 81000 1 201 1HVd 3009 1vOIH103 13 19313 qiavisnrav 97 D NVIQVNVO L Zz VSO 1 OL WHOJNOO LSNW VOVNVO NI S3009 1907 193135 CNV O 3 N OL LSNW 9NIHIM LSNW LINN ONINYWM d 440 we 9 TIVda 1 SLNN 35NVHO 0 0 WD pd En gt 4 0 S3HIM 31IHM
12. quired for optimum setup and efficiency data the most important readings that must be taken are smoke number over fire draft and stack draft 2 The proper smoke number has been established by engi neering tests to be between 0 and 1 This degree of smoke emission is commonly referred to as a Trace of smoke It is recommended to use a Bacharach true spot smoke test set or equivalent 3 In order to ensure proper draft through furnace a baromet ric draft regulator supplied with furnace must be installed as close to outlet of furnace as possible In order for this device to function properly barometric damper must be mounted with hinge pins horizontal and face of damper vertical See instructions included with damper The draft regulator should be adjusted after furnace has been firing for at least 10 minutes and stack draft should be measured and set between 0 025 and 0 035 in wc The draft should be checked with a Bacharach MZF draft gage or equivalent 4 The over fire draft which is taken through hole provided in observation door is a measurement necessary to determine if there is a blockage between oil burner and flue outlet There should be a pressure drop of between 0 005 and 0 015 in wc through furnace This would set the range of the over fire draft between 0 01 and 0 03 in wc A reading above 0 01 in wc for example 40 1 in wc would indicate that furnace is in an extremely high pressure condition in prim
13. to put your furnace into operation for the IV TURNING OFF YOUR FURNACE heating season you should perform the following procedures S 8 Follow these simple procedures to put your furnace into retire WARNING If you do not follow these instructions ment For the summer A exactly a fire or explosion may result causing property damage personal injury or loss of life Set thermostat to lowest setting Turn off all electrical power to appliance Turn off oil supply 1 Open all warm air registers and make sure all return air grilles are unobstructed If applicable turn off water supply to humidifier d N If furnace blower will be necessary for cooling system 2 If a humidifier is installed with your system open water remember to turn electrical power back on when needed for supply valve air conditioning FOR SERVICE CALL NAME ADDRESS TELEPHONE 1997 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis IN 46231 12 Printed in U S A 362a1051 Catalog No BDP 3336 203
14. 0 Sec 150 Sec DELAY OFF DIP SWITCH SETTINGS 60 Sec A95115 Fig 1 Fan Off Time DIP Switch Settings Black Box Represents Switch Position IV LIMIT CONTROL CHECK After furnace has been in operation for at least 15 minutes restrict return air supply by blocking filters or closing return registers and allow furnace to shut down on high limit The burner should shut off and main blower should continue to run Remove restriction and burner should come back on in a few minutes V FOR YEAR ROUND AIR CONDITIONING This furnace is designed for use in conjunction with cooling equipment to provide year round air conditioning The blower has been sized for both heating and cooling however fan motor speed may need to be changed to obtain necessary cooling airflow HEATING The blower speed is factory set to deliver required airflow at normal duct static pressure VII COOLING The blower speed may be field adjusted to deliver required airflow for cooling application See Table 5 ESL 1 CONSTANT BLOWER SWITCH This furnace is equipped with a constant low speed blower option Whenever room thermostat is not calling for heating or cooling blower runs on low speed in order to provide air circulation If constant blower option is not desired the rocker switch on side of control box may be used to turn off constant speed MAINTENANCE WARNING The ability to properly perform mainte nance on this equi
15. Pee 6 11 Generali xta diee 6 Oil 6 7 Heat Exchanger and Flue Pipe 1 8 Blower Oiling and 8 Keeping Filters Clean eese 8 Ar flow Datars SIEBEN RERBA 8 Dimensional Drawing eene 9 Barometric Damper Locations 10 Wiring Diagram well USER S INFORMATION 25 12 Here s How Your Heating System Works 12 Preparing Your Furnace For Operation 12 Lighting Your Furnace eese 12 Turning Off Your Furnace 12 362AAN Series 362 75 1 362 105 1 8 96 Cancels SAFETY CONSIDERATIONS FOR YOUR SAFETY DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQ UIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED WHEN THE FURNACE 1 FULL OF VAPOR OR WHEN THE COMBUSTION CHAMBER IS VERY HOT WARNING For use with grade 2 Fuel Oil maximum Do not use Gasoline Crankcase Oil or any Oil contain ing Gasoline Failure to follow this warning could lead to sooting fire explosion and or severe bodily harm CAUTION Never burn garbage or paper in the heating A system and never leave rags paper or
16. TION AND VENTILATION WARNING Installation of this furnace in an area where it will receive contaminated combustion air must be avoided Such contamination would include the follow ing ammonia chlorine hydrogen sulfide halogenated hydrocarbons carbon tetrachloride cleaning solvents hydrochloric acid water softening chemicals and similar chemicals Failure to follow this warning will lead to premature rusting of heat exchanger and possible prema ture furnace failure and or vent failure which could result in fire hazard and or bodily harm gt This furnace should be installed in a location in which facilities for ventilation permit satisfactory combustion of oil proper venting and maintenance of ambient temperature at safe limits under normal conditions of use The location should not interfere with proper circulation of air within the confined space See NFPA 31 Section 1 5 In addition to air needed for combustion process air shall be provided as required for cooling of equipment or material controlling dew point heating drying oxidation or dilution safety exhaust and odor control In addition to air needed for combustion air shall be supplied for ventilation including all air required for comfort and proper working conditions for personnel The barometric draft regulator included with furnace shall be installed in same room or enclosure as furnace in such a manner as to prevent any difference in pressur
17. U TION These words are used with the safety alert symbol DAN GER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage TABLE 1 MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS IN UNIT APPLICATION LOW BOY Furnace Sides Supply Plenum and Warm Air Duct Within 6 ft of Furnace Back Furnace Casing or Plenum Top Horizontal Warm Air Duct Within 6 ft of Furnace Bottom Flue Horizontally or Below Pipe Pipe Vertically Above Pipe Front Floor may be combustible NOTE Adequate service clearance should be provided over and above these dimensions as required INTRODUCTION The model 362AAN Furnaces are available in sizes 105 000 through 155 000 Btuh input capacities The furnace is shipped as a packaged unit complete with burner and controls It requires a line voltage 115 vac connection to control box a thermostat hook up as shown on wiring diagram oil line connection s adequate duct work and connection to a properly sized vent The air handling capacity of this furnace is designed for cooling airflow Refer to Table 5 for expected airflows at various external duct static pressures LOCATION WARNING This furnace is not water tight and is not designed for
18. ace heat exchanger when heat is desired and over cooling coil when cooling is desired IMPORTANT The dampers should be adequate to prevent cooled air from entering furnace If manually operated dampers must be equipped with a means to prevent operation of either cooling unit or furnace unless damper is in full cool or heat position VENTING INSTRUCTIONS Venting of furnace should be to the outside and in accordance with local codes or requirements of local utility OIL FIRED APPLIANCES SHALL BE CONNECTED FLUES HAVING SUFFICIENT DRAFT AT ALL TIMES TO ENSURE SAFE AND PROPER OPERATION OF APPLIANCE For additional venting information refer to ANSI NFPA 211 Chimney Fireplaces Vents and Solid Fuel Burning Appliances and or CSA B139 Installation Code This furnace is certified for use with Type L vent maximum flue gas temperature 575 F PRE INSTALLATION VENT SYSTEM INSPECTION Before furnace is installed it is highly recommended that any existing vent system be completely inspected For any chimney or vent this should include the following l Inspection for any deterioration in chimney or vent If deterioration is discovered chimney must be repaired or vent must be replaced 2 Inspection to ascertain that vent system is clear and free of obstructions Any blockage must be cleared before install ing furnace 3 Cleaning chimney or vent if previously used for venting a solid fuel burning appliance or fireplace 4
19. ary section This condition may be caused by excessive combustion air due to air band being too wide open or a lack of flue draft chimney effect or some other blockage such as soot in secondary section of heat exchanger 5 The CO and stack temperature instruments enable you to obtain data required to determine thermal efficiency of furnace 6 An oil filter should be installed as close to burner as possible with ALL oil burners and is essential on lower firing rate burners We recommend the use of a low pressure drop oil filter such as the General Filter Inc model 1 25 or equivalent It is critical that oil capacity be equivalent or greater than fuel pump gear capacity For a 2 pipe system this is 25 gph 7 The oil pressure regulator is factory set to give nozzle oil pressures of 100 psig The firing rate noted on nameplate may be obtained with standard nozzles by adjusting pump pressure as noted in Table 4 or on label on furnace On a new installation air entrapped in oil line leading from tank to nozzle must be thoroughly purged in order to prevent excessive after drip The oil pump is provided with a special fitting which allows purging of any air between tank and oil pump The proper procedure for performing this operation is as follows a Place a piece of clear plastic 1 4 in diameter tubing over purge fitting on oil pump b Start oil burner then open purge fitting and allow burner to run until purge tube is c
20. aulking or sealants are applied to areas such as joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and fuel lines and at other openings If combustion and ventilation air must be supplied to an uncon fined space from outside an opening with a FREE AREA of not less than 1 sq in per 1000 Btuh of total input of all appliances within unconfined space but not less than 100 sq in must be provided This opening must be located such that it can not be blocked at any time When furnace is installed in a closet or enclosure 2 ventilation openings with OPEN AREA as dimensioned in example below are required for combustion air The openings should be located about 6 in from top and bottom of enclosure at front of furnace For Example LENGTH IN HEIGHT IN 036105 048125 060155 For a confined space where air is taken from an interior space 2 permanent openings of equal area are required One opening must be within 12 in of ceiling and the other within 12 in of floor Each opening must have a free area of at least 1 sq in per 1000 Btuh of total input rating but not less than 100 sq in If outside air is supplied to a confined space then the 2 openings must be equal and located as above The free area of each must be 1 One sq in per 4000 Btuh of total input rating when air is directly communicat
21. condary heat exchanger tubes and flue pipe is necessary the following steps should be performed 1 Turn off all oil and electrical supplies upstream of furnace A CAUTION If furnace has been in operation some surfaces may be hot Allow time for unit to cool down 2 Disconnect flue pipe 3 For access to cleanout ports remove blower door and filter The 2 cleanout ports are located in blower compartment They protrude through the partition and are located on the left and right of flue pipe See Fig 2 4 Unscrew wing clamp nuts and remove cleanout port covers This allows access to tubes See Fig 2 CLEANOUT PORTS CLEANOUT PORT COVER amp CLAMP ASSEMBLY BLOWER DOOR A96310 Fig 2 Removing Cleanout Port Covers 5 Clean secondary tubes and flue pipe with a stiff brush and vacuum cleaner 6 Before reinstalling cleanout port covers the gasket on each cover MUST be replaced Use cleanout port gasket kit Part No 20196201 7 Reinstall covers and tighten in place making sure that covers are properly seated over ports and gasket has sealed opening See Fig 3 WARNING Failure to replace cleanout port cover gas kets failure to properly seat covers over ports and or failure to securely tighten wing nuts could lead to flue gas leakage This could lead to furnace damage oil fumes sooting and severe bodily harm 8 Reconnect flue pipe 9 Reinstall filter and blower door uel FLUE
22. e between regulator and combustion air supply Air requirements for operation of exhaust fans kitchen ventilation systems clothes dryers and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements In unconfined spaces in buildings of conventional frame brick or stone construction infiltration MAY be adequate to provide air for combustion ventilation and dilution of flue gases This determi nation must be made on an individual installation basis and must take into consideration the overall volume of unconfined space the number of windows and ventilation openings the number of doors to the outside internal doors which can close off unconfined space and overall tightness of building construction Consideration must also be given to the amount of storage items furniture boxes etc within the unconfined space which take away from the air volume Many new buildings and homes and older ones that have been weatherized MUST BE considered as being of tight construction therefore infiltration will not be sufficient to supply necessary air for combustion and ventilation A building can be considered as being of tight construction when 1 Walls and ceilings exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed or sealed and or 2 Weatherstripping has been added on operable windows and doors and or 3 C
23. e tightly joined and checked for leaks 8 The flue pipe must not extend into chimney but be flush with inside wall 9 The chimney must extend 3 ft above highest point where it passes through the roof of a building and at least 2 ft higher than any portion of a building within a horizontal distance of 10 ft It shall also be extended at least 5 ft above highest connected equipment flue collar 10 Check local codes for any variance Ill FACTORY BUILT CHIMNEYS Listed factory built chimneys may be used Refer to chimney manufacturer s instructions for proper installation IV HORIZONTAL VENTING This furnace may be vented horizontally through an outside wall when installed with 1 of the following auxiliary inducer blowers Tjernlund Products Inc Model 551 551 required in Canada available from Tjernlund Products Inc 1601 Ninth Street White Bear Lake MN 55110 6795 612 426 2993 or Fields Controls Model SWGII 5 with a CK 60 or CK 61 control kit available from Fields Controls Company 2308 Airport Road Kinston NC 28051 919 522 3031 NOTE In both cases the 24 v wiring schematic included with inducer is the recommended wiring setup The use of either inducer can create a negative pressure in the area where furnace is located if the proper combustion air openings are not available This negative pressure can lead to excessive heat being retained in heat exchanger coking and fumes Refer to NFPA 31 Section
24. ed from outdoors 2 One sq in per 4000 Btuh of total input rating when air is brought in through vertical ducts 3 One sq in per 2000 Btuh of total input rating when air is transferred through horizontal ducts When ducts are used to supply air they must be of the same cross sectional area as free area of openings to which they connect The minimum dimension of rectangular air ducts must not be less than 3 in In calculating free area consideration shall be given to blocking effect of louvers grilles or screens protecting openings Screens used shall not be smaller than 1 4 mesh and shall be readily accessible for cleaning If free area through a design of louver or grille is known it shall be used in calculating size design and free area specified If design and free area are not known it may be assumed that wood louvers have 20 percent free area and metal louvers and grilles have 60 percent free area Louvers shall be fixed in open position or interlocked with furnace so they open automatically at furnace start up and remain open during furnace operation WARNING Do not block combustion air openings in the furnace blockage will result in improper com bustion which may result in a fire hazard and or cause bodily harm gt The lack of a proper amount of combustion air can lead to serious furnace operational problems Some of these problems are 1 Excessive oil burner after drip and oil fumes 2
25. ers When thermostat is satisfied the circuit is de energized and m DANGER HIGH VOLTAGE AT IGNITOR Severe primary control shuts off burner The blower continues to run until selectable fan off time period has expired electrical shock personal injury or death could result The heat sensing switch performs as furnace high temperature limit switch If furnace overheats for any reason the limit switch nd 1 This appliance is equipped with an ignition device which opens breaking circuit to burner The blower motor is energized automatically lights burner Do NOT try to light burner by and as unit cools the limit switch closes This relights burner but hand unless overheating condition is corrected furnace will cycle on limit 2 After preparing furnace for heating operation see previous This unit is equipped with an interrupted ignition electronic Section and checking for proceeds follows control If main burner does not ignite within 30 sec from call for 3 For heating cooling system set thermostat to HEAT and fan heat the control locks out The red button on top of control must to AUTO Set thermostat to desired room temperature and be depressed for 3 sec in order to reset control The control turn on electrical power to furnace CATING Te fest froni toom thermostat 4 The burner should light and system should be controlled by Il PREPARING YOUR FURNACE FOR OPERATION thermostat Before attempting
26. installation start up operating instructions LOW BOY OIL FIRED FURNACE NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue Index SAFETY CONSIDERATIONS Minimum Clearance to Combustibles INTRODUCTION nene S LOCATION er eee Air for Combustion and Ventilation Duct Work Recommendations 3 VENTING INSTRUCTIONS Pre Installation Vent System Inspection Masonry 4 Factory Built Chimneys eee 4 Horizontal Venting esee nennen enne 4 OIE BURNER 4 OIL 8 0 2 20 4 BAROMETRIC DRAFT CONTROL ELECTRICAL A FILTERS ahaa tete e ett 5 OPERATIONAL 5 6 5 Recommended Installation Practices Combustion Check 5 6 Fan Adjustment 6 Limit Control Check 2 6 For Year Round Air Conditioning 2 6 OPERE 6 Cooling Jte deemed ee ret eene tents 6 Constant Blower Switch sese 6 MAINTENANCE x ertt EHE
27. ir turning vanes or lining duct as described in item 2 above 4 When a single air grille is used duct between grille and furnace must be the same size as return opening in furnace CAUTION Return air grilles and warm air registers MUST not be obstructed WARNING When supply ducts carry air circulated by furnace to areas outside spaces containing furnace return A air MUST also be handled by a duct sealed to furnace casing and terminating outside space containing furnace Incorrect duct work termination and sealing will create a hazardous condition which could lead to bodily harm When installing furnace with cooling equipment for year round operation the following recommendations must be followed for series or parallel airflow 1 In series airflow applications coil is mounted after furnace in an enclosure in supply air stream The furnace blower is used for both heating and cooling airflow WARNING The coil MUST be installed on air dis charge side of furnace Under no circumstances should airflow be such that cooled conditioned air can pass over furnace heat exchanger This will cause condensation in heat exchanger and possible failure of heat exchanger which could lead to a fire hazard and or a hazardous condition which may lead to bodily harm Heat exchanger failure due to improper installation may not be covered by warranty 2 In parallel airflow applications dampers must be provided to direct air over furn
28. nd remove oil burner from furnace 14 Remove observation door and collar on observation tube 15 Remove intermediate panel Care must be taken not to bend or damage limit control 16 Loosen to hand tightness the 3 nuts labeled A in Fig 4 Remove screws labeled B in Fig 4 Slide combustion chamber forward out of heat exchanger Be careful not to bump combustion chamber as it becomes brittle after having been fired 96398 Fig 4 Removing Combustion Chamber 17 Use a stiff brush and vacuum cleaner to clean inside of primary drum A CAUTION Never use incendiary type cleaners smoke sticks for cleaning WARNING For all heat exchanger plates that have been removed the gaskets MUST be replaced Failure to replace gaskets could lead to heat exchanger leakage sooting and a hazardous condition which could lead to bodily harm 18 Before reassembly heat exchanger and combustion cham ber should be inspected to determine if replacement is required After cleaning place combustion chamber back into primary drum and secure with B screws Ensure that cover plate gasket is in place before tightening screws Care must be taken not to damage combustion chamber The B screws should be tightened to 35 45 Ib in 19 Tighten A nuts to 30 Ib in of torque firm but not overly tight 20 Replace intermediate panel observation tube collar obser vation door limit wiring and oil burner 21 Replace collector b
29. ompletely free of air bubbles TABLE 4 BURNER NOZZLE AND PUMP PRESSURE CHART PUMP BECKETT OIL BURNER RATE PRESSURE GAL HR 05 PSIG 0 76 103 FIRING UNIT SIZE Nozzle 0 75 gph 70 Hollow 0 90 gph 70 Hollow 1 10 gph 70 Hollow 036105 048125 100 060155 104 c Tighten purge fitting Allow oil to run to nozzle and fire burner d If purging takes longer than 30 sec and no flame has been established burner stops Push reset button on top of primary control to restart burner e For detailed information on operation of primary control refer to instructions included with furnace Ill FAN ADJUSTMENT CHECK This furnace is equipped with a 3 speed direct drive motor to deliver a temperature rise between return and supply plenums within range specified on rating plate at external duct static pressure noted on rating plate CAUTION When operating furnace in heating mode static pressure and temperature rise supply air tempera N ture minus return air temperature must be within those limits specified on rating label Failure to follow this warning could lead to severe furnace damage Adjust fan speed so that temperature rise is within rise range specified on rating plate Consult wiring diagram for speed changes on direct drive motor To adjust fan off time set DIP switches on control board to obtain desired timing See Fig 1 Pu fen fes 90 Sec 12
30. outdoor installation This furnace shall be installed in such a manner as to protect electrical com ponents from water Outdoor installation would lead to a hazardous electrical condition and to premature furnace failure WARNING Do not use this furnace as a construction heater Use of this furnace as a construction heater exposes furnace to abnormal conditions contaminated combustion air and lack of air filters Failure to follow this warning can lead to premature furnace failure and or vent failure which could result in a fire hazard and or bodily harm This furnace is approved for reduced clearances to combustible construction therefore it may be installed in a closet or similar enclosure It may be located in a basement or on the same level as area to be heated In any case unit should always be installed level In a basement or when installed on the floor it is recommended that unit be installed on a concrete pad that is 1 to 2 in thick On dirt floors furnace may be installed on concrete blocks Place blocks under all 4 corners and under center of furnace Center block 22 in from back of furnace forward The required minimum clearances for this furnace are specified in Table 1 The furnace should be located as close as possible to chimney or vent in order to keep vent connections short and direct The furnace should also be located as near as possible to center of air distribution system AIR FOR COMBUS
31. ox on secondary tube flange ensuring proper placement of gasket Tighten screws to 35 45 of torque 22 Replace top partition inside collar on flue pipe top rear panel outside flue collar and blower door 23 Reconnect flue pipe and oil line s 24 Readjust burner for proper operation Check limit operation as outlined in Limit Control Check section IV BLOWER OILING AND REMOVAL Periodic oiling of blower motor may be necessary Check for instructions on inside of blower access door If it is ever necessary to remove blower from furnace 1 Turn off all electrical power to furnace 2 Remove blower door 3 Remove screws securing blower legs to blower rails mounted on bottom panel of furnace 4 Slide blower forward on rails toward rear of unit until motor wire connections at terminal block on motor can easily be reached and disconnected 5 Disconnect motor wires at terminal block on motor 6 Remove blower from unit 7 Reverse items 1 through 6 to reinstall blower Refer to wiring diagram Fig 7 of these instructions or diagram located on inside of louvered door to properly rewire unit V KEEPING FILTERS CLEAN WARNING Never operate unit without a filter or with A filter access door removed Failure to adhere to this warning could lead to a hazardous condition which could lead to equipment damage and bodily harm As a homeowner keeping filters clean is your most important responsibility A
32. pment requires certain expertise me chanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance A on this equipment other than those procedures recom mended in the User s Manual FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT SERIOUS PER SONAL INJURY OR DEATH WARNING Before performing any service functions unless operations specifically require power to be on make sure all utilities are turned off upstream of appli ance Failure to comply with this warning will cause a fire hazard and or bodily harm WARNING To avoid personal injury make sure elec trical supply power is off before servicing GENERAL In order to keep this furnace in good operating condition and to maintain its warranty the furnace MUST be serviced on an annual basis This servicing includes a nozzle change a burner inspection a visual check of tube passages through flue outlet and cleanout ports and a visual inspection of combustion chamber when burner is removed Depending on above inspection service could also include a cleaning and vacuuming of heat exchanger tubes and possibly the heat exchanger drum section Removal of any heat exchanger components which are sealed by gaskets requires replacement of gasket WARNING Failure to replace any heat exchanger gas kets with new gaskets when any heat exchanger plates or A covers are removed could lead
33. t HOT wire and NEUTRAL wire as shown in Fig 7 separate line voltage supply MUST be used with a fused disconnect switch or HACR type circuit breaker between main power panel and unit See Fig 7 Disconnecting means must be within sight from furnace WARNING The unit cabinet must have an uninter rupted or unbroken electrical ground to minimize per sonal injury if an electrical fault should occur A green ground screw is provided in control box for this connec tion Use only copper wire for 115 v supply service to unit Metallic conduit where required used may terminate at side panel of unit It is not necessary to extend conduit inside unit from side panel to control box When replacing any original furnace wiring use only 105 C No 16 AWG copper wire Instructions for wiring thermostat field supplied are packed in thermostat box Make thermostat connections as shown in Fig 7 at 24 v terminal board on control box When installing optional accessories to this appliance follow manufacturer s Installation Instructions included with accessory Other than wiring for thermostat wire with a minimum of type T insulation 63 F rise must be used for accessories Two 1 4 quick connect terminals marked and 5 are provided for electronic air cleaner EAC connection See Fig 7 These terminals are energized with 115v 0 5 amp maximum during blower motor operation Two
34. to heat exchanger leakage sooting and or a hazardous condition capable of causing bodily harm This furnace should never be operated without an air filter Disposable filters should be replaced at least once a year If equipped to provide cooling filters should be replaced a minimum of twice a year Permanent filters should be cleaned at least twice a year ALWAYS KEEP MAIN OIL VALVE TURNED OFF IF BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME Il OIL BURNER Contact your service technician for service Lubricate burner motor with SAE 10 oil Once each year pour 2 teaspoons of oil slowly into each oil cup To maintain proper performance oil burner nozzle must be replaced once a year II The procedure for nozzle installation and or replacement is out lined in oil burner instruction manual which came with furnace For ease of maintenance the oiling procedure for burner motor as outlined in burner manual should be performed at this time After replacement of nozzle burner should be adjusted in accor dance with Combustion Check section of this instruction HEAT EXCHANGER AND FLUE PIPE Ordinarily it is not necessary to clean heat exchanger or flue pipe every year but it is necessary to have your service technician check unit before each heating season to determine whether cleaning or replacement of parts is required A Cleaning Secondary Heat Exchanger Tubes and Flue Pipe Only If cleaning of only the se
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