LENNOX Furnace/Heater, Oil Manual L0806374

User Manual: LENNOX LENNOX Furnace/Heater, Oil Manual LENNOX Furnace/Heater, Oil Owner's Manual, LENNOX Furnace/Heater, Oil installation guides

Open the PDF directly: View PDF .
Page Count: 18

Download
Open PDF In Browser	View PDF

INSTALLATION
INSTRUCTIONS

zEA, vO. .
,t_2005 Lennox Industries Inc,
Dallas, Texas, USA

025 SERIES UNITS
OIL UNITS
505,149M
38152A075
12/2005

_
Technical
.LLJJ. Publications
Litho U.S.A.

General .....................................
Shipping & Packing ..........................
025 Unit Dimensions .........................
025 Unit Parts Arrangement ...................
025 Riello Oil Burner Parts Arrangement ........
Locate & Level the Unit .......................
Unit Set-Up ..................................
Requirements ................................
Venting .....................................
Flue Connections ...........................
Supply & Return Air Plenums .................
Oil Supply Piping ............................
Leak Check ................................
Electrical Wiring .............................
Pump Purging ..............................
Unit Start-Up & Adjustments ..................
Service ....................................
025 Start-Up & Performance Check List .......

1
1
2
3
3
4
4
6
9
10
12
12
14
15
16
16
17
18

,A, CAUTION

These instructions are intended as a general guide and do
not supersede local codes in any way, Only qualified technicians can install and service the Lennox Elite® Series
025 oil furnaces. In Canada, refer to CSA B139 for recommended installation procedures, Consult authorities who
have jurisdiction before installation.

RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE

,_, WARNING

Ak CAUTION

1 - Assembled oil furnace

,_, WARNING

1 - Barometric draft control
1 - Bypass plug (used on two oil line lift systems)
1 - Side filter adapter kit (includes filter)
1 - Return line adapter
Check the components for shipping damage. If you find
any damage, immediately contact the last carrier.

12/05

IIIH]IIIIIIIIIIIIIIIIIHIIIIIIIIIIIII

505,149 M
Page

IIIllllllllllllllll]llllllHII

SIDE FILTER ADAPTER KIT
(Furnished With Unit)
/

FILTER
RACK
(Furnished)

f3/4

3/4 --IP

TOP FLUE
OUTLET

J
C

SUPPLY

OPENING
AIR

OPENING
IN UNIT
(Either

TOP VIEW

Side)

FILTER
(Furnished)

FLUE
CONNECTION

B
Exchanger)
(On Heat

FLUE OUTLET
CENTERING HOLE
(Field Fabricate
Either
Side)
SIDE

ELECTR,CAL
i"
INLET _ _J
(Right Side "_
Only)
_

FLUE
CONNECTION
(On Heat
Exchanger)

OIL PIPING INLET
(Left Side Only)

AIR FLOW
91_1-1/2

OPT. OUTDOOR
COMBUSTION
AIR INLET
CENTERING HOLE
(Field Fabricate
Right Side only)

1-1/_1 P

22----_

RETURN AIR
OPENING
(Either

L--L

23-1/2

Side)

.....

1-1/4

RETURN AIR

SIDE VIEW

Model No.

FRONT VIEW

025Q2-80
025Q2/3-105/120

19-1/2

30-5/8

19-5/8

025Q3/4-140/154

22-1/2

33-1/8

22-1/8

Page 2

heatexchanger

flue opening

clean-out port

limit switch

clean-out port

observation/sampling
port
Riello
burner

combustion air intake

blower motor
indoor blower

Figure 1

Turbulator
Lockout
Indicator

Adjustment
Screw

Lamp &
Reset

Air Tube
Cover

Flange

Button

Combustion

Head

Coil

Primary
Control
Primary,
Control
Sub-Base

Capacitor

Pump
Pressure

Vacuum
Gauge
Port

Regulator
Air Adjustment
Fixing Screw
Capillary
Tube

Motor

Supply
Fuel Line
Port

Figure 2

Page 3

Return
Fuel Line
Port

Pressure
Tube &
Gauge Port

1 - Setthe unitin desiredlocationkeepingin mindthe
clearances
listedintable2,Alsokeepinmindoilsupply connections,
electricalsupply,flue connections
andsufficientclearancefor installingandservicing
unit,
2 - Leveltheunitfromsidetosideandfromfronttorear.If
the furnaceis not level,placefireproofwedgesor
shimsbetweenthe lowsideof the furnaceandthe
floor.Makesuretheweightofthefurnaceis distributed
evenlyonallfourcorners,Strainon sidesof cabinet
causingcrackingand poppingnoisesmayoccurif
weightoffurnaceis notevenlydistributed.

7 - Insert the proper nozzle into the adapter. Tighten the
nozzle securely; however, do not overtighten.
8 - Reverse steps to re-assemble burner.

WARNING

Drawer Assembly Removal
Combustion Head

/
Control Box

Air Tube
Cover
Plate

Screw
Screw

Screw
FIGURE 3
Input Selection
1 - Determine the desired furnace firing rate, Use table 1
to select the proper nozzle and pump pressure required
to obtain the desired input from the burner, tf necessary,
replace the nozzle to achieve the higher input rate.

Nozzle Replacement

2- Remove the oil burner cover.
3 - Locate drawer assembly. Loosen screw which holds
control box in place, Remove control box by carefully
pulling it back and then up, See figure 3,
4 - Loosen the screw(s) which secure the air tube cover
plate, Remove the air tube cover plate,

Nozzle _
Adapter

__-__
/

Nozzle/Sc

_...

':'_

___

5 - Loosen the screw which secures the drawer assembly
Drawer
Assembly

in place. Slide the drawer assembly out of the combustion head as shown in figure 3.
6 - Remove the screw as shown in figure 4 and slide the
nozzle adapter from the drawer assembly.

Page 4

FIGURE 4

Table 1
Burner Set-Up

Furnace
Model
801
105/1201
105/1202
140/1541
140/1542
1.
2.
3.
4.
5.

Riello
Burner
Model
F3
F3
F3
F5
F5

Fuel Input
Rating

Nozzle

Gph

Btu/Hr.

0.60
0.75
0.85
1.00
1.10

80,000
105,000
119,000
140,000
154,000

Angle

Pump
Pressure
(Psig)

0.50 x 80 ° B 3
0.65 x 80 ° B

135
140

0.75 x 80 ° B
0.85 x 80 ° B
1.00 x 80 ° B

140
140
140

Air Adj Turbulato
Plate
Setting
Setting
(Index)
(Index)
2.0
2.0
3.0
2.0
3.5
2.5
3.0

Denotes factory default burner configuration
as shipped
Denotes optional firing rate and burner configuration
Delavan nozzle type Del-o-FIo 0.50 X 80°B (Only for O25Q2-80)
All other nozzles type B -- Delavan
All burner preset and configured
for single line gravity-fed
oil supply
Electrode Gap Verification
Electrode
IMPORTANT:

These dimensions

Gap

must be observed and verified.

4am

13/64"
5mm

5/64" to 7/64" or 2 to2.5mm

Figure 5

Page 5

2.0
2.0
2.0

system

TurbulatorSetting
1 - Loosennutandturnscrewuntilindexmarkerisaligned
withnumber2,whichcorresponds
withdesiredinput
settingpertable1.Seefigure6,
2- Retightenretainingnut,

A WARNING

NOTE - Scale on F3 burner is 3 to O,Scale on F5 bumer is 4 to O,
Turbulator

Setting

Index
Marker

_
4--L_

\4111110J

Screw

Retaining Nut

Ak WARNING
FIGURE 6
Air Adjustment Plate Positioning
The initial adjustment of the air adjustment plate should
match the value given in table 1 which corresponds with the
desired input,
1 - Loosen the two screws which secure the plate in position. See figure 6.
2- Turn the air adjustment plate until the desired value
given in table is aligned with the setting indicator on the
fan housing cover, Retighten two securing screws,
NO TE - Air adjustment plate may need additional positioning at unit start-up to ensure proper unit operation,
Air Adjustment Plate Position

Installation of Lennox oil-fired furnaces must conform with
the National Fire Protection Association Standard for the
Installation of Oil Burning Equipment, NFPA No. 31, the
National Electrical Code, ANSI/NFPA No.70 (in the
U.S.A.), CSA Standard CAN/CSA-B139
(in Canada),
Installation Code for Oil Burning Equipment, the Canadian
Electrical Code Part1, CSA 22.1 (Canada), the recommendations of the National Environmental Systems Contractors Association and any state or provincial laws or local ordinances. Authorities
having jurisdiction
should be
consulted before installation. Such applicable regulations
or requirements take precedence over general instructions
in this manual.
Chimneys and chimney connectors must be of the type and
construction outlined in section 160 of NFPA No. 31.

Setting
Indicator

Clearances
This unit is approved for use on combustible flooring and
for clearances to combustible material as listed on unit rating plate and in table 2. Unit service and accessibility
clearances take precedence over fire protection clearances,
Screw

Adjustment
Plate

Screw

FIGURE 7

Page 6

Table 2

pressure (pressure outside is greater than inside pressure)
will build to the point that a down draft can occur in the furnace vent pipe or chimney. Combustion gases enter the living space creating a potentially dangerous situation,

Installation Clearances inches (mm)
Clearances

80/
105/120

Top of plenum and duct

2 (51)

Plenum sides

3 (76)

Furnace sides

0 (0)

Furnace rear

0 (0)

Front of access panel

4 (120)

Flue pipe**

6 (152)

The importance of the previous paragraph cannot be overstated, Users may inadvertently block fresh air intakes after installation,

NOTE - Service access clearance of 24" in the front of the unit must be
maintained to accommodate burner service.
*A passage, suitable for a large person, shaft be provided between the furnace and chimney for inspection or replacement of the flue collector when

In the absence of local codes concerning air for combustion and ventilation, the following section outlines guidelines and recommends procedures for operating oil furnaces in a manner that ensures efficient and safe
operation. Special consideration must be given to combustion air needs as well as requirements for exhaust vents
and oil piping,
Combustion Air Requirements

CAUTION

necessar_ A clearance of 24" shaft be allowed at the rear and on one side
of the furnace for service and flor cleaning of the blower.
**Minimum clearance shown forflue pipe may be reduced by using special
protection as provided by local building codes and the National Fire
Protection Association Standards.

Temperature

Rise

Unit must be adjusted to obtain a temperature rise in the
range listed on the unit rating plate,
When installed, furnace must be electrically grounded in
accordance with local codes or, in the absence of local
codes, with the current National Electric Code, ANSI/NFPA
No. 70, or Canadian Electric Code (CEC) if an external
electrical source is utilized,
Field Wiring
Field wiring connections must meet or exceed specifications of type T wire and withstand a 63 <_
F (17 <_
C) temperature rise,
Cooling

Applications

When furnace is used in conjunction with cooling units, it
shall be installed in parallel with, or on the upstream side
of, cooling units to avoid condensation in the heating element. With a parallel flow arrangement, a damper (or other means to control the flow of air) shall be adequate to
prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent
operation of either unit, unless damper is in the full "heat"
or "cool" position,
Combustion and Ventilation Air
(Confined and Unconfined Spaces)
In the past, there was no problem in bringing in sufficient
amounts of outdoor air for combustion - infiltration provided
all the air that was needed and then some, In today's
homes built with energy conservation in mind, tight
construction practices make it necessary to bring in air
from outside for combustion, Consideration must also be
given to the use of exhaust fans, appliance vents, chimneys and fireplaces because they force additional air that
could be used for combustion out of the house, Unless outside air is brought into the home for combustion, negative

All oil-fired appliances require air to be used for the combustion process. If sufficient amounts of combustion air are
not available, the furnace or other appliance will operate in
an inefficient and unsafe manner. Enough air must be provided to meet the needs of all fuel-burning appliances, as
well as appliances such as exhaust fans which force air out
of the home. When fireplaces, exhaust fans, or clothes dryers are used at the same time as the furnace, much more
air is required to ensure proper combustion and to prevent
a down-draft situation. Insufficient amounts of air also
cause incomplete combustion which can result in sooting.
Requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in an
unconfined or confined space.
Air for combustion and ventilation must conform to standards outlined in section 140 of NFPA No. 31 or, in Canada,
CSA Standard B139, When installing 025 units in confined
spaces such as utility rooms, two combustion air openings
are required. Dimensions of combustion air openings are
shown in table 3. One opening shall be within 12" of the ceiling and the other opening shall be within 12" of the floor,

IMPORTANT

The combustion air opening should provide a minimum
free area one-half square inch per 1,000 Btu per hour input.
This combustion air should be brought into the area containing the furnace below the level of the furnace burner.

Page 7

Table 3
Combustion
Model No.

EQUIPMENT

Air Opening Dimensions
CHIMNEY OR
OIL VENT

Combustion Air Opening
Dimensions (2 required)

O25-80/105/120

10" X 20"

O25-140/154

11"X 22"

IN CONFINED SPACE
FROM INSIDE

_.\

OIL
FURNACE

Unconfined Space
An unconfined space is an area such as a basement or
large equipment room with a volume greater than 50 cubic
feet (1.4 cubic meters) per 1,000 Btu (293 W) per hour of
the combined input rating of all appliances installed in that
space. This space also includes adjacent rooms which are
not separated by a door. Though an area may appear to be
unconfined, it might be necessary to bring in outdoor air for
combustion if the structure does not provide enough air by
infiltration. If the furnace is located in a building of tight
construction with weather stripping and caulking around
the windows and doors, follow the procedures outlined for
using air from the outside for combustion and ventilation.
Confined Space
A confined space is an area with volume less than 50 cubic
feet (1.4 cubic meters) per 1,000 Btu (293 W) per hour of
the combined input rating of all appliances installed in that
space. This definition includes furnace closets or small
equipment rooms.
When the furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the furnace, the return air must be handled by ducts
which are sealed to the furnace casing and which terminate
outside the space containing the furnace. This is especially
important when the furnace is mounted on a platform in a
confined space such as a closet or small equipment room.
Even a small leak around the base d the unit at the platform
or at the return air duct connection can cause a potentially
dangerous negative pressure condition. Air for combustion
and ventilation can be brought into the confined space either from inside the building or from outside.

OPENINGS
(To Adjacent

Room)

i,/
!
|

i I

!
|

NOTE-Each opening shall have a free area of at least ! square inch
(6.4 square centimeters) per !, 000 Btu (293 W) per hour of the total
input rating of all equipment in the enclosure, but not less than 100
square inches (6!4.5 square centimeters).

FIGURE 8
Air from Outside
If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent openings. One opening shall be within 12" (305 mm)
of the top of the enclosure and one within 12" (305 mm) of
the bottom. These openings must communicate directly or
by ducts with the outdoors or spaces (crawl or attic) that
freely communicate with the outdoors or indirectly through
vertical ducts. Each opening shall have a minimum free
area of 1 square inch (6.4 square centimeters) per 4,000
Btu (1172 W) per hour of total input rating of all equipment
in the enclosure (See figures 9 and 11). When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch (6.4
square centimeters) per 2,000 Btu (586 W) per total input
rating of all equipment in the enclosure (See figure 11).

Air from an Adjacent Space
If the confined space housing the furnace adjoins space
categorized as unconfined, air can be brought in by providing two permanent openings between the two spaces.
Each opening must have a minimum free area of 1 square
inch (6.4 square centimeters) per 1,000 Btu (293 W) per
hour of the total input rating of all fuel-fired equipment in the
confined space. Each opening must be at least 100 square
inches (614.5 square centimeters). One opening shall be
within 12" (305 mm) of the top of the enclosure and one
opening within 12" (305 mm) of the bottom (See figure 8).

Page 8

A return air duct system is recommended. If a complete return air duct system is not installaed, a full-sized return duct
should be run to a location outside of the confined space. In
either case, the return air duct must be completely sealed
so that no air from the confined space can be circulated
through the duct system.

EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
(Inlet Air from Crawl Space and
Outlet Air to Ventilated Attic)
CHIMNEY
OR OIL "_
VENT

A minimum mixed return air temperature of 60°F to 65 ° F
must be maintained for outdoor make-up air in order to prevent condensation and corrosion.
OIL
FURNACE

WATER
HEATER

VENTILATION
LOUVERS
(Forunheated
crawl 5

EQUIPMENT

IN CONFINED

SPACE

INLET
AIR

WATER

rrrm
r

NOTE - The inlet and outlet air openings shaft each have a free area of
at least one square inch (6.4 square centimeters) per 4,000 Btu (1172
W) per hour of the total input rating of all equipment in the enclosure.

FIGURE 9
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
CHIMNEY
OR OIL
VENT

I
I

NOTE - Each air duct opening shaft have a free area of at least one
square inch (6.4 square centimeters) per 2,000 Btu (586 W) per hour
of the total input rating of all equipment in the enclosure, ff the equipment room is located against an outside wall and the air openings
communicate directly with the outdoors, each opening shall have a
free area of at least one square inch (6.4 square centimeters) per
4,000 Btu (1172 W) per hour of the total input rating of all other equipment in the enclosure.

VENTILATION
LOUVERS
(Each end of attic)

FIGURE 11

INLET AIR
(Ends 12" above
bo{tom)

OIL
FURNACE

I
I

WARNING

HEATER

NO TE-The inlet and outlet air openings shall each have a free area of at
least one square inch (6.4 square centimeters) per 4,000 Btu (1172 W)
per hour of the total input rating of all equipment in the enclosure.

FIGURE 10

Ak WARNING

When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they
connect. The minimum dimension of rectangular air ducts
shall be no less than 3" (76 mm). In calculating free area,
the blocking effect of louvers, grilles, or screens must be
considered. If the design and free area of protective covering is not known for calculating the size opening required, it
may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to
75 percent free area. Louvers and grilles must be fixed in
the open position or interlocked with the equipment so that
they are opened automatically during equipment operation.

Page 9

Ak CAUTION

WALL THIMBLE

A, WARNING

THIMBLE

NOTE - Oil burning equipment may be vented into an approved masonry chimney or type L vent. (Type L vent is
similar in construction to type B gas vent except it carries a
higher temperature rating and is constructed with an inner
finer of stainless steel rather than aluminum).

Prior to installation of unit, make a thorough inspection of
the chimney to determine whether repairs are necessary.
Make sure the chimney is properly constructed and sized
according to the requirements of the National Fire Protection Association. The smallest dimensions of the chimney
should be at least equal to the diameter of the furnace vent
connector. Make sure the chimney will produce a steady
draft sufficient to remove all the products of combustion
from the furnace. A draft of at least ,04" w,c, (9,9 Pa) is required during burner operation,
1 - Local building codes may have more stringent installation requirements and should be consulted
installation of unit.

COMBUSTIBLE
WALL

VENT PIPE

FIGURE 12
9 - The vent pipe should slope upward toward the chimney on horizontal run at least 1/4 inch (6 mm) to the
foot (0.3 m) and should be supported by something
other than the furnace, such as isolation hangers. See
figure 14.
10- Extend the vent pipe into the chimney so that it is flush
with the inside of the vent liner. Seal the joint between
the pipe and the liner.
11- The furnace shall be connected to a factory built chimney or vent complying with a recognized standard, or

before

masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction.

2 - The vent connector should be as short as possible to
do the job.

12- When two or more appliances vent into a common
vent, the area of the common vent should not be less
than the area of the largest vent or vent connection
plus 50% of the area of the additional vent or vent connection. Chimney must be able to sufficiently vent all

3 - The vent connector should not be smaller than the outlet diameter of the vent outlet of the furnace,
4 - Pipe should be at least 24 gauge galvanized,

appliances operating at the same time.

5 - Single wall vent pipe should not run outside or through
any unconditioned space.

13- The vent pipe shall not be connected to a chimney
vent serving a solid fuel appliance or any mechanical
draft system.

6 - Chimney should extend 3 feet (0.9 m) above any flat
section of roof within a horizontal distance d 10 feet (3
m). The chimney must also extend 2 feet (0.6 m)
above the highest roof peak within a horizontal distance of 10 feet (3 m).

14- All unused chimney openings should be closed.

7- The vent must not pass through a floor or ceiling.
Clearances to single wall vent pipe should be no less
than 6" (152 mm); more if local codes require it.
8 - The vent may pass through a wall where provisions
have been made for a thimble as specified in the Standards of the National Board of Fire Underwriters. See
figure 12.

15- All vent pipe run through unconditioned areas or outside shall be constructed of factory built chimney sections. See figure 13.
16- Where condensation of vent gas is apparent, the vent
should be repaired or replaced. Accumulation of condensation in the vent is unacceptable.
17- Vent connectors serving this appliance shall not be
connected into any portion of mechanical draft systems operating under positive pressure.
18- Keep the area around the vent terminal free of snow,
ice and debris.

Page 10

NOTE - If vent pipe needs to exit from side of cabinet,
use the pilot hole (located on either side of the unit) to
cut a 6" (152 mm) round hole. Attach finishing plate
(provided) with four sheet metal screws to cover rough
edges.
FACTORY-BUILT

CHIMNEY

BAROMETRIC
CONTROL*
(IN EITHER
LOCATION)

Do not use the same vent with any other appliance
when using a sidewall vent system.
Maximum permissible vent length is 100 equivalent feet,
Minimum length is 15 equivalent feet. Calculate the equivalent vent pipe footage from the furnace to the mechanical
vent system (Tjernlund or Field Controls) by adding the
straight vent pipe length and the equivalent elbow lengths
together, Each 90 ° elbow is equivalent to 10 feet of straight
pipe. Each 45 ° elbow is equal to 5 feet of straight pipe,
Locate the barometric draft control within 18 inches of the

furnace flue outlet, See figure 15 for barometric draft control location,
E

HORIZONTAL VENTING
DRAIN FOR
CONDENSATE

barometric
control*

horizontal venting
control

F }

*Barometric
control may be installed in either vertical or horizontal section of flue pipe within 18" of flue outlet of furnace.

Figure

*Barometric
control must
be installed in the horizontal venting system and
located within 18" of flue

MASONRY CHIMNEY

outlet of furnace.

BAROMETRIC
CONTROL*
(IN EITHER
LOCATION)

LINER

Figure 15
Vent Connector (Smoke

IMPORTANT

CLEAN OUT

Use 24 gauge or heavier galvanized smoke pipe and fittings to connect the furnace to the vent. Connect the vent
connector (smoke pipe) to the chimney using the least
number of elbows and angles possible, Flue pipe or vent
connector must be inserted into but not beyond the outside
wall of the chimney flue, No reduction in diameter of pipe is

MASONRY
CHIMNEY
CLEAN OUT
*Barometric
control may be installed in either vertical or horizontal section of flue pipe within 18" of flue outlet of furnace.

Figure 14
Horizontal

Pipe) and Draft Control

Venting

The 025 is approved for horizontal venting with the following mechanical vent systems:
Tjernlund (sideshot) #SS1C (Cat, #35E08) or Field Controis #SWG-5 (Cat, #35P08) with the CK-61 (Cat. #18N28)
control kit, Refer to the manufacturers' installation instructions for proper installation procedures and service parts
information,

acceptable, It is best to have the smoke pipe as short and
direct as possible, Where two or more appliances vent into
a common flue, the area of the common flue should be at
least
plus
tors.
pipe

equal to the area of the largest flue or vent connector,
50% of the area of any additional flues or vent connecInstall a barometric draft control (provided) and flue
according to instructions packed with control,

Inspect flue pipe annually. Clean soot or ash from flue pipe,
if necessary. If pipe is rusted, replace.

Page 11

Installdraftcontrolatleast12inchesbeyondthefurnace.If
thereis nospacetoinstallthedraftcontrolinthefluepipeit
maybeinstalled
intheventabovethefluepipe.Followthe
instructions
packedwiththedraftcontrol.
RadiationShieldInstallation
combustibl_
material
(25 mm)
min

6 - After it has been determined that each appliance remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other fuel burning appliance to their previous condition of use.

12"

(305 mm)
min

spacers

A._ _
_See note:

4 - Following the lighting instruction on the unit, place the
appliance being inspected in operation. Adjust thermostat so appliance will operate continuously.
5 - Test for spillage using a draft gauge.

unit
cabinet

noncombustible

nected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.

711'- A-P'I

radiation shields
(see note 1)

(178 mm)
min

If improper venting is observed during any of the
above tests, the common venting system must be corrected.

Secure retum air plenum to unit using sheet metal screws.
NOTE - The following are suggested procedures that should
be followed when installing the supply air plenum.

B
See no{e 3

1 - Use fiberglass sealing strips to seal the plenum.
2 - In all cases, the plenum should be secured to furnace or
evaporator cabinet using sheet metal screws.
3 - Supply and return air ducts must be the same dimension as the furnace opening. They must each be a
minimum of 18" long.
4 - Install supply and return air ducts as desired.

NOTE 1-Radiation shields must be constructed of 24 gauge sheet
metal minimum.
NOTE 2-Radiation shields required when A is less than 9" (229 mm).
NOTE 3-Radiation shields should extend from the top of the unit to
the top of the flue pipe.

Figure 16
Removal of Unit from Common Venting System
In the event that an existing furnace is removed from a
venting system commonly run with separate appliances,
the venting system is likely to be too large to properly vent
the remaining attached appliances. The following test
should be conducted while each appliance is in operation
and the other appliances not in operation remain connected to the common venting system. If venting system
has been installed improperly, the system must be corrected as outlined in the previous section.
1 - Seal any unused openings in the common venting system.

Use continuous lengths of heavy wall copper tubing or
steel pipe for oil supply pipe. Install oil supply pipe under
floor or near walls to protect it from damage. Avoid running
pipes along joists or reverberating surfaces. Always use
flare fittings. All fittings must be accessible.
compression fittings.

Do not use

Manual bleeding of the fuel pump is required on initial start
up. Failure to bleed air from the oil pump could result in an
air lock/oil starvation condition.
NOTE - As an extra precaution, cycle heating on and off ten
times after bleeding air from the oil pump. This will eliminate air in the gun assembly.

2 - Visually inspect venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion or other deficiencies
which could cause an unsafe condition.
3 - Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliances not con-

Page 12

Ak WARNING

Oil

Pump

Pump Nozzle
Port
Pump

Vacuum Port

Cover

<_
Supply

Line

[::>

Pressure Port

_,_/
"-'_
//]_-_.JJ
__.7/
.__._

Port.

O-Ring

\
Bypass

BleederValve
Bypass Plug
..... (Install in return

_ /
_ /
-'

Plug

two-line system
is used.)

Return Line Port
/
line port if
Return Line Adapter
(Install if two-line
system is used)

Supply Line Adapter
(Factory-Installed)

Adapter with Two
Female 1/4" NPT

Figure 17
Oil Filter
An oil filter is required. Install the filter inside the building
between the tank shut-off valve and the burner. Locate the
filter close to the burner for easy maintenance; however, filter should be at least 3 feet away from the burner to avoid
pressure drop problems. Table 4 lists the filters for the 025
furnace.

the pump body. Riello manometers and vacuum gauges
do not require adapters to be safely connected to the pump
ports. A metric NPT adapter must be used when other
gauges are used.
Single-Pipe

Systems

CAUTION

Table 4
Oil Filters

Cat.
Number

10 micron filter (no mounting bracket)

81P89

10 micron filter (mounting bracket)

53P92

10 micron replacement cartridge for filter, 45 gph

53P93

Filter restriction indicator gauge

53P90

1 - Size the oil piping in a single-pipe system per table 5
and figure 18,
2 - Connect the properly sized pipe to the factory-installed
adapter on the pump supply port,
3 - Check the plug in the return port to make sure that it is
tightened securely.

Piping System
The 025 unit is shipped with the oil pump set to operate in a
single-line system. Ensure that the restrictions of the piping
system, plus any lift involved, do not exceed the capability
of the oil pump. Use the following guidelines when determining whether to use a single-or two-stage oil pump,
NOTE - Two pipe connectors are supplied with the unit. In
addition, two adapters, each with two 1/4" NPT are provided to adapt oil lines to burner pipe connectors. All pump
port threads are British parallel thread design. Direct
connection of NPT threads to the pump will damage

Page 13

Table 5
Single-Pipe Sizing
Height (H)

Maximum
Length 3/8" OD
Tubing

Maximum
Length 1/2" OD
Tubing

1,5'

130

26O

6,5'

195

325

Oil Piping
Two-Pipe System

Oil Piping
Single-Pipe System

Maximum
13 feet

Maximum
13

NOTE

- Do not exceed

lengths

given

in table 5.

Figure 18

Two-Pipe Systems
1 - Use the provided 2.5mm hexagonal key to install the
provided bypass plug in the pump return port.
NOTE- Use of an improperly sized, non-metric key
may result in damage to the bypass plug.

NOTE - Do not exceed
lengths given in table 6.

2 - Install the provided NPT adapter on the pump return
Figure 19

port
3 - Use table 6 and figure 19 to properly size the supply

A, IMPORTANT

and return line piping,
4 - Connect the properly sized pipe to the adapters on the
pump supply and return ports,
NOTE - Supply and return piping must be the same
diameter and should extend to the same depth inside t he fuel tank.
Table 6
Two-Pipe Sizing
Height (H)

Maximum
Length 3/8" OD
Tubing

Maximum
Length 1/2" OD
Tubing

115

330

1.5'

100

330

295

6.5'

230

9.5'

100

11'

After oil piping is completed, carefully check all piping connections (factory and field) for oil leaks.

Page 14

All wiringmustconformto the NationalElectricCode
(NEC),or CanadianElectricCode(CEC)andany local
codes,Refertofigure20forlowvoltageandhighvoltage
wiringconnections,
1- Refertotheappliance
ratingplateforproperfusesize.
2- Installtheroomthermostat
andmakewireconnections
tothe unit.Avoidinstallingthermostatonan outside
wallorwhereitcanbeaffectedbyradiantheat,Setthe

adjustable heat anticipator on thermostat according to
the wiring diagram sticker provided on unit,
_

Install a separate fused disconnect switch near unit so
power can be shut off for servicing,

4- Complete line voltage wiring from disconnect switch

Typical 025 Wiring

near unit to make-up box,
NOTE - An equipment ground screw is provided. Refer
to un# wiring diagram in figure 20. Ground unit using a
suitable ground wire.

Diagram

FAN&
UM_T
8W_TON

....................................
YELLOW {IF USE#}

YE&OW(IFUSE#}

...........................

Figure 20

Page 15

UNE VOLTAGE=F_Y
L_NE VOLTAGE4 NSTA_LER
LOW VOLTAG_FACTORY
LOW VOLTAGE4N_ALL_R

Before starting unit, make sure the oil tank is adequately filled with clean No. 2 furnace oil.

CAUTION

NOTE - Water, rust or other contaminants in oil supply system will cause malfunction and failure of the internal parts
of the fuel pump.
Single-Pipe

Systems

1 - Loosen the pump bleeder valve until oil flows out.
NOTE - If no oil comes out of the loosened bleeder
port, re-tighten the bleeder valve securely and add oil
through the vacuum port. Use 4mm hex key to remove
vacuum port plug.

A WARNING

2 - Disconnect nozzle oil supply line at the pump nozzle
port,
3 - Attach one end of a flexible plastic tube to the pump
nozzle port, Direct the other end of the flexible tube
into a bucket and allow the oil to flow into the bucket.
4 - Loosen the screw(s) which secure the air tube cover,
5 - Hold the air tube cover in its proper position and start
the burner,
6 - Allow the solenoid valve to engage (approximately 10
seconds after burner fires), Remove the air tube cover
and shine a light source on the photo-cell, The cell
must sense light.
7 - Run the burner until the fuel pump has been purged of
air, then tighten the bleeder valve and immediately
shut down the burner.
8 - Reinstall the air tube cover and nozzle line.
9 - Start the burner normally.

1 - Set thermostat for heating demand and turn on electrical supply to unit.
2 - If burner fails to start, push reset button on primary
safety control and the burner motor reset button on the
front of the burner,

CAUTION

3 - If the burner fails to light again, refer to the troubleshooting section in this manual.
Fuel Pump Pressure
Use 11mm wrench to remove bleeder port cover, Attach
Riello gauge (or use adapter to attach NPT gauge) to
bleeder port, Turn unit on and measure fuel pump pressure. Check pressure and compare to table 1. Adjust if necessary.
Vacuum Pressure

WARNING

Two-Pipe Systems
1 - Turn off main power source to the burner and remove
the air tube cover.
2 - Shine a light source on the photo-cell. As long as the
light source remains on the photo-cell, the solenoid
valve will not open and the burner will continue to operate in pre-purge mode only,
3 - Return power to the burner and fire the burner,
NOTE - Burner will operate in pre-purge only as long
as the light source shines on the photo-cell,
4 - Run the burner until the fuel pump has been purged of
air,
5 - Replace air tube cover.
6 - Restore power to the burner and start the burner normally.

Use 4mm hex key to remove vacuum port cover, Attach
Riello gauge (or use adapter to attach NPT gauge) to
bleeder port, Start burner and measure operating vacuum,
Operating vacuum should not exceed 11.44 inches w.c.
Correct, if necessary,
Temperature Rise
To measure temperature rise, place plenum thermometers
in warm air and return air plenums, Locate thermometer in
warm air plenum where thermometer will not "see" the heat
exchanger to prevent it from picking up radiant heat. Set
thermostat to its highest setting to start unit, After plenum
thermometers have reached their highest and steadiest
readings, subtract the readings, The difference in temperatures in the supply and return air plenums should approximate the temperature rise range listed on the unit rating
plate. If not, adjust the blower motor pulley to adjust the
blower speed.
Fan and Limit Control
The fan and limit control is factory installed and wired.

Page 16

Burner Adjustment

WARNING

The following instructions are essential to the proper operation of 025 series oil furnaces,
Refer to table 1 for
nozzle and pump pressure information. The proper way to
adjust an oil burner is with a CO2 analyzer and a smoke
gun. A properly adjusted burner will result in a quiet, clean
fire which will prevent sooting and frequent cleaning. To establish tolerance or a "window of operation" into the unit, do
not exceed #0 smoke, This will give the burner more flexibility when there are changes in the surrounding environment,
1 - Punch a 5/16" diameter service hole in the flue outlet.
This sampling hole should be at least two flue diameters above the breeching, or elbow at the breeching
but ahead of the barometric damper,
2 - Place burner into operation. Adjust air setting for good
flame by visual observation, and run for at least 10 minutes or until operation has stabilized. A good flame will be
entirely contained in the combustion chamber and will be
predominantly yellow-white in color. As flame quality lessens, the flame will turn more orange in color and will start
to rise above the combustion chamber.
3 - Take a draft reading at the service hole. Adjust baremetric draft control in the stack to achieve an overfire
draft of 0" to -,01" and a breach of -,02" to -.04",
4 - Use an industry standard smoke tester to take and record a smoke reading at the service hole. If smoke is
evident, it could be caused by a poor nozzle or combustion setting. In some cases, it may be caused by a difference in oil or an unusual condition of installation,
5 - If the burner is producing more than #0 smoke, loosen
the air adjustment plate screw and rotate the air adjustment plate until the flame appears clean. Take
care to re-tighted air adjustment plate screw when adjustments are complete, It may also be necessary to
adjust the turbulator settings slightly (toward a higher
number) in order to reduce smoke,
6 - Reset the draft if combustion head or air settings were
adjusted.
7 - Use a suitable emissions test instrument to take and
record a reading at the service hole, The CO2 measured in the stack should be in the 11 to 12 percent
range,
8 - Use a suitable thermometer to obtain and record the
flue gas temperature at the service hole,
g - If necessary, adjust the air plate to achieve the desired
operating range.
10-When
the proper combustion and smoke readings
have been achieved, tighten the air adjustment plate
screw.

CAUTION
Filter

NOTE - Under no circumstances should the access panels
to the blower compartment be left off or left partially open.
Check filters monthly and replace when necessary to assure proper furnace operation, Replace filters with like kind
and size filters,
Blower
Blower motor is prelubricated and sealed for extended operation. No further lubrication is required, Blower assembly
may be removed from cabinet to clean, Disconnect power
to unit before checking blower wheel for debris,
Flue Pipe
The flue pipe should be inspected annually by a qualified
service technician, Remove and clean any soot or ash
found in the flue pipe. Inspect pipe for holes or rusted
areas. If replacement is necessary, replace with the same
size and type as required by code, Inspect the flue draft
control device and replace if found defective,
Burner
Check the nozzle and oil filter before each heating season.
Also check the items listed in the oil furnace start-up checklist on page 18. The oil supply line shut-off valve should
be closed when the unit is shut down over an extended
period of time.
Cleaning the Heat Exchanger
1 - Remove the vent pipe from the furnace,
2 - Loosen the clean-out cap screw, rotate the clean-out
cap to the notch and remove the cap, Remove flue access elbow.
3 - Use a long spiral wire brush to sweep down the outer
drum of the heat exchanger. Use the hose attachment
to vacuum loose debris.
4 - Loosen the observation port cap screw, rotate the cap
to the notch and remove the cap, Use a spiral wire
brush to reach up toward the rear of the heat exchanger to clean the crossover tube, Replace the cap and
screw on the observation port,

Ak CAUTION
5 - Replace the three clean out caps and flue access elbow. Make sure locking screws are secure,
6 - Brush out and vacuum the vent outlet area of the outer
drum and replace vent pipe,
7 - Clean the burner, blower deck and vestibule area,

11 - Re-secure the burner cover and re-check the draft,
smoke, combustion and flue gas temperature,

Page 17

NOTE - A heat exchanger brush ABRSH380 (35K09)
is available from Lennox.

OIL FURNACE

START-UP

CHECKLIST

(Complete this page and keep for future reference)
Customer Name
Address

Furnace Model #

Serial #

Input Rate

Nozzle Used

New Construction

Replacement

Date of Installation

Start-Up

Procedure

A. Close disconnect switch
B. Set thermostat to call for heat
C, Bleed air from lines and pump; run for 20 seconds
after bubbles disappear
D. Install vacuum gauge; check pump vacuum
E, Install pressure gauge; adjust pressure to 140 psig
(except on Q2-80 models - adjust to 100 psig) __
Always verify proper pump pressure to corresponding
tables with instructions supplied with unit.
F, After 10 minutes of operation, obtain flue temperature
3 _
reading: 1_
2nd
G, Obtain smoke reading:
1st
2nd
3 rd
2 nd
3 rd
Measure CO2:1 st
Check draft overfire
Breech
Locked
Air shutter setting
Measure static pressure in duct system
Static pressure on supply side
Static pressure on return side
Static pressure drop
L,
Temperature rise after steady state conditions have
been achieved: Supply side __
Return side __
M Block off return air (limit control checkout); burner
should shut down in 2 or 3 minutes

H,
I,
J.
K,

Owner Recoil
Installed By:
Dealer
Address

Telephone #
License #

Page 18

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.2
Linearized                      : No
Page Count                      : 18
Page Layout                     : SinglePage
Page Mode                       : UseNone
Producer                        : Goby Monitor Application version 4, 0, 0, 13
Create Date                     : Mon Jun 30 04:51:40 2008
Author                          : 
Title                           : 
Subject                         :

EXIF Metadata provided by EXIF.tools

LENNOX Furnace/Heater, Oil Manual L0806374

Navigation menu

Versions of this User Manual:

Views

Navigation