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

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zEA, vO. .

,t_2005 Lennox Industries Inc,

Dallas, Texas, USA

INSTALLATION

INSTRUCTIONS

025 SERIES UNITS

OIL UNITS _ Technical

505,149M .LLJJ. Publications

38152A075

12/2005 Litho U.S.A.

General ..................................... 1

Shipping & Packing .......................... 1

025 Unit Dimensions ......................... 2

025 Unit Parts Arrangement ................... 3

025 Riello Oil Burner Parts Arrangement ........ 3

Locate & Level the Unit ....................... 4

Unit Set-Up .................................. 4

Requirements ................................ 6

Venting ..................................... 9

Flue Connections ........................... 10

Supply & Return Air Plenums ................. 12

Oil Supply Piping ............................ 12

Leak Check ................................ 14

Electrical Wiring ............................. 15

Pump Purging .............................. 16

Unit Start-Up & Adjustments .................. 16

Service .................................... 17

025 Start-Up & Performance Check List ....... 18

,A, CAUTION

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

,_, WARNING

These instructions are intended as a general guide and do

not supersede local codes in any way, Only qualified tech-

nicians can install and service the Lennox Elite® Series

025 oil furnaces. In Canada, refer to CSA B139 for recom-

mended installation procedures, Consult authorities who

have jurisdiction before installation.

Ak CAUTION

,_, WARNING

12/05

IIIH]IIIIIIIIIIIIIIIIIHIIIIIIIIIIIII Page

1 - Assembled oil furnace

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.

505,149 M

1 IIIllllllllllllllll]llllllHIIIII]llllllll

SIDE FILTER ADAPTER KIT

(Furnished With Unit) / FILTER

RACK

(Furnished)

3/4 --IP

f3/4

C SUPPLY (_

AIR

OPENING

TOP VIEW

TOP FLUE

J OUTLET

OPENING

IN UNIT

(Either Side)

FILTER

(Furnished)

1-1/_1 P

1-1/4

ELECTR,CALi"

INLET _ _J

(Right Side "_

Only) _

OIL PIPING INLET

(Left Side Only)

_22----_

RETURN AIR

I 14 OPENING

I _ (Either Side)

L--L ..... J

RETURN AIR

SIDE VIEW

FLUE

CONNECTION

J(On Heat

Exchanger)

SIDE

FLUE OUTLET

CENTERING HOLE

(Field Fabricate

Either Side)

91_1-1/2

23-1/2

OPT. OUTDOOR

COMBUSTION

AIR INLET

CENTERING HOLE

(Field Fabricate

Right Side only)

FLUE

CONNECTION

(On Heat

Exchanger)

I I

AIR FLOW

RETURN AIR

FRONT VIEW

Model No. A B C D E

025Q2-80 19-1/2 30-5/8 18 19-5/8 16

025Q2/3-105/120

025Q3/4-140/154 22-1/2 33-1/8 21 22-1/8 18

Page 2

heatexchanger

flue opening

clean-out port

limit switch clean-out port

Riello

burner

observation/sampling

port

combustion air intake

blower motor

indoor blower

Figure 1

Turbulator

Lockout Adjustment

Indicator Screw

Lamp & Flange

Reset Button Combustion Head

Primary

Control

Air Tube

Cover

Coil

Primary,

Control Capacitor - -

Sub-Base

Pump

Pressure

Regulator

Air Adjustment

Fixing Screw Capillary

Tube

Vacuum

Gauge

Port

Motor Supply

Fuel Line Return Pressure

Port Fuel Line Tube &

Port Gauge Port

Figure 2

Page 3

1- Settheunitin desiredlocationkeepingin mindthe

clearanceslistedintable2,Alsokeepinmindoilsup-

ply connections,electricalsupply,flue connections

andsufficientclearancefor installingandservicing

unit,

2 - Leveltheunitfromsidetosideandfromfronttorear.If

thefurnaceis not level,placefireproofwedgesor

shimsbetweenthelowsideof the furnaceandthe

floor.Makesuretheweightofthefurnaceisdistributed

evenlyonallfourcorners,Strainon sidesof cabinet

causingcrackingand poppingnoisesmayoccurif

weightoffurnaceisnotevenlydistributed.

WARNING

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.

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,

5 - Loosen the screw which secures the drawer assembly

in place. Slide the drawer assembly out of the combus-

tion head as shown in figure 3.

6 - Remove the screw as shown in figure 4 and slide the

nozzle adapter from the drawer assembly.

7 - Insert the proper nozzle into the adapter. Tighten the

nozzle securely; however, do not overtighten.

8 - Reverse steps to re-assemble burner.

Drawer Assembly Removal

Combustion Head

Air Tube

Cover

Plate

Control Box

Screw

FIGURE 3

Nozzle Replacement

Nozzle _ __-__

Adapter /_... ':'_

Nozzle/Sc ___

Drawer

Assembly

FIGURE 4

Page 4

Furnace

Model

801

105/1201

105/1202

140/1541

140/1542

Riello

Burner

Model

Table 1

Burner Set-Up

Fuel Input

Rating

Gph Btu/Hr.

0.60 80,000

0.75 105,000

0.85 119,000

1.00 140,000

1.10 154,000

Nozzle

Angle

0.50 x 80 ° B 3

0.65 x 80 ° B

0.75 x 80 ° B

0.85 x 80 ° B

1.00 x 80 ° B

Pump

Pressure

(Psig)

135

140

Air Adj

Plate

Setting

(Index)

2.0

3.0

3.5

2.5

3.0

Turbulato

Setting

(Index)

2.0

1. Denotes factory default burner configuration as shipped

2. Denotes optional firing rate and burner configuration

3. Delavan nozzle type Del-o-FIo 0.50 X 80°B (Only for O25Q2-80)

4. All other nozzles type B -- Delavan

5. All burner preset and configured for single line gravity-fed oil supply system

Electrode Gap Verification

Electrode Gap

IMPORTANT: These dimensions must be observed and verified.

4am

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

13/64"

5mm

Figure 5

Page 5

TurbulatorSetting

1- Loosennutandturnscrewuntilindexmarkerisaligned

withnumber2,whichcorrespondswithdesiredinput

settingpertable1.Seefigure6,

2- Retightenretainingnut,

NOTE -Scale on F3 burner is 3 to O,Scale on F5 bum-

er is 4 to O,

\4111110J

Turbulator Setting

4--L_ j

Index

Marker

_ Screw

Retaining Nut

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 posi-

tion. 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 posi-

tioning at unit start-up to ensure proper unit operation,

Air Adjustment Plate Position

Setting

Indicator

Screw

Screw Adjustment

Plate

A WARNING

Ak WARNING

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 recommen-

dations of the National Environmental Systems Contrac-

tors Association and any state or provincial laws or local or-

dinances. 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.

Clearances

This unit is approved for use on combustible flooring and

for clearances to combustible material as listed on unit rat-

ing plate and in table 2. Unit service and accessibility

clearances take precedence over fire protection clear-

ances,

FIGURE 7

Page 6

Table 2

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)

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 fur-

nace and chimney for inspection or replacement of the flue collector when

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 specifica-

tions of type T wire and withstand a 63 <_F (17 <_C) tempera-

ture 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 ele-

ment. With a parallel flow arrangement, a damper (or oth-

er means to control the flow of air) shall be adequate to

prevent chilled air from entering the furnace and, if manu-

ally 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, chim-

neys and fireplaces because they force additional air that

could be used for combustion out of the house, Unless out-

side air is brought into the home for combustion, negative

pressure (pressure outside is greater than inside pressure)

will build to the point that a down draft can occur in the fur-

nace vent pipe or chimney. Combustion gases enter the liv-

ing space creating a potentially dangerous situation,

The importance of the previous paragraph cannot be over-

stated, Users may inadvertently block fresh air intakes af-

ter installation,

In the absence of local codes concerning air for combus-

tion and ventilation, the following section outlines guide-

lines and recommends procedures for operating oil fur-

naces in a manner that ensures efficient and safe

operation. Special consideration must be given to combus-

tion air needs as well as requirements for exhaust vents

and oil piping,

Combustion Air Requirements

CAUTION

All oil-fired appliances require air to be used for the com-

bustion 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 pro-

vided 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 dry-

ers 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 ventila-

tion depend largely on whether the furnace is installed in an

unconfined or confined space.

Air for combustion and ventilation must conform to stan-

dards 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 ceil-

ing 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 con-

taining the furnace below the level of the furnace burner.

Page 7

Table 3

Combustion Air Opening Dimensions

Model No. Combustion Air Opening

Dimensions (2 required)

O25-80/105/120 10" X 20"

O25-140/154 11"X 22"

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 con-

taining 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 dthe 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 ei-

ther from inside the building or from outside.

Air from an Adjacent Space

If the confined space housing the furnace adjoins space

categorized as unconfined, air can be brought in by provid-

ing 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).

CHIMNEY OR

OIL VENT

EQUIPMENT IN CONFINED SPACE

FROM INSIDE

OIL

FURNACE _.\

OPENINGS

(To Adjacent Room)

i,/

! ii ii ii ii ii ii ii ii !

| |

i I JL

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 ventila-

tion, the confined space shall be provided with two perma-

nent 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 communicat-

ing with the outdoors through horizontal ducts, each open-

ing 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).

Page 8

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(Inlet Air from Crawl Space and

Outlet Air to Ventilated Attic)

CHIMNEY

OR OIL "_

VENT

OIL WATER

FURNACE HEATER

VENTILATION

LOUVERS INLET

(Forunheated AIR

crawl 5

rrrm

r1r 1

NOTE -Theinlet 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

CHIMNEY

OR OIL

VENT

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

VENTILATION LOUVERS

(Each end of attic)

INLET AIR

OIL (Ends 12" above

FURNACE bo{tom)

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

When ducts are used, they shall be of the same cross-sec-

tional 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 cover-

ing is not known for calculating the size opening required, it

may be assumed that wood louvers will have 20 to 25 per-

cent 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.

A return air duct system is recommended. If a complete re-

turn 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.

A minimum mixed return air temperature of 60°F to 65 ° F

must be maintained for outdoor make-up air in order to pre-

vent condensation and corrosion.

EQUIPMENT IN CONFINED SPACE

WATER

III IIII III II

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 equip-

ment 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 equip-

ment in the enclosure.

FIGURE 11

WARNING

Ak WARNING

Ak CAUTION

Page 9

A, WARNING

NOTE -Oil burning equipment may be vented into an ap-

proved 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 Protec-

tion 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 re-

quired during burner operation,

1 - Local building codes may have more stringent installa-

tion requirements and should be consulted before

installation of unit.

2 - The vent connector should be as short as possible to

do the job.

3 - The vent connector should not be smaller than the out-

let diameter of the vent outlet of the furnace,

4 - Pipe should be at least 24 gauge galvanized,

5 - Single wall vent pipe should not run outside or through

any unconditioned space.

6 - Chimney should extend 3 feet (0.9 m) above any flat

section of roof within a horizontal distance d10 feet (3

m). The chimney must also extend 2 feet (0.6 m)

above the highest roof peak within a horizontal dis-

tance of 10 feet (3 m).

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 Stan-

dards of the National Board of Fire Underwriters. See

figure 12.

WALL THIMBLE

THIMBLE

COMBUSTIBLE

WALL VENT PIPE

FIGURE 12

9 - The vent pipe should slope upward toward the chim-

ney 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 chim-

ney or vent complying with a recognized standard, or

masonry or concrete chimney lined with a lining mate-

rial acceptable to the authority having jurisdiction.

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 con-

nection. Chimney must be able to sufficiently vent all

appliances operating at the same time.

13- The vent pipe shall not be connected to a chimney

vent serving a solid fuel appliance or any mechanical

draft system.

14- All unused chimney openings should be closed.

15- All vent pipe run through unconditioned areas or out-

side shall be constructed of factory built chimney sec-

tions. See figure 13.

16- Where condensation of vent gas is apparent, the vent

should be repaired or replaced. Accumulation of con-

densation in the vent is unacceptable.

17- Vent connectors serving this appliance shall not be

connected into any portion of mechanical draft sys-

tems 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)

DRAIN FOR

CONDENSATE

FHH L

*Barometric control may be installed in either vertical or hori-

zontal section of flue pipe within 18" of flue outlet of furnace.

Figure 13

MASONRY CHIMNEY

BAROMETRIC

CONTROL*

(IN EITHER

LOCATION)

LINER

CLEAN OUT

MASONRY

CHIMNEY

CLEAN OUT

*Barometric control may be installed in either vertical or hori-

zontal section of flue pipe within 18" of flue outlet of furnace.

Figure 14

Horizontal Venting

The 025 is approved for horizontal venting with the follow-

ing mechanical vent systems:

Tjernlund (sideshot) #SS1C (Cat, #35E08) or Field Con-

trois #SWG-5 (Cat, #35P08) with the CK-61 (Cat. #18N28)

control kit, Refer to the manufacturers' installation instruc-

tions for proper installation procedures and service parts

information,

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 equiva-

lent 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 con-

trol location,

HORIZONTAL VENTING

barometric

control*

horizontal venting

-- control

F }

*Barometric control must

be installed in the hori-

zontal venting system and

located within 18" of flue

outlet of furnace.

Figure 15

Vent Connector (Smoke Pipe) and Draft Control

IMPORTANT

Use 24 gauge or heavier galvanized smoke pipe and fit-

tings 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

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 equal to the area of the largest flue or vent connector,

plus 50% of the area of any additional flues or vent connec-

tors. Install a barometric draft control (provided) and flue

pipe 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

thereisnospacetoinstallthedraftcontrolinthefluepipeit

maybeinstalledintheventabovethefluepipe.Followthe

instructionspackedwiththedraftcontrol.

RadiationShieldInstallation

combustibl_

material

unit

cabinet

(25 mm)

min

12"

(305 mm)

min

noncombustible A._ _

spacers _See note: 11'- A-P'I 7"

radiation shields (178 mm)

(see note 1) min

See no{e 3

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 con-

nected to the common venting system. If venting system

has been installed improperly, the system must be cor-

rected as outlined in the previous section.

1 - Seal any unused openings in the common venting sys-

tem.

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 win-

dows and all doors between the space in which the ap-

pliances remaining connected to the common venting

system are located and other spaces of the building.

Turn on clothes dryers and any appliances not con-

nected to the common venting system. Turn on any

exhaust fans, such as range hoods and bathroom ex-

hausts, so they will operate at maximum speed. Do not

operate a summer exhaust fan. Close fireplace damp-

ers.

4 - Following the lighting instruction on the unit, place the

appliance being inspected in operation. Adjust ther-

mostat so appliance will operate continuously.

5 - Test for spillage using a draft gauge.

6 - After it has been determined that each appliance re-

maining 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 con-

dition of use.

7- If improper venting is observed during any of the

above tests, the common venting system must be cor-

rected.

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.

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 dimen-

sion as the furnace opening. They must each be a

minimum of 18" long.

4 - Install supply and return air ducts as desired.

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. Do not use

compression fittings.

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 elimi-

nate air in the gun assembly.

Ak WARNING

Page 12

Oil Pump

Pump Cover

O-Ring

Adapter with Two

Female 1/4" NPT

Pump Nozzle

Port

Supply Line Port.

Bypass Plug

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, fil-

ter should be at least 3 feet away from the burner to avoid

pressure drop problems. Table 4 lists the filters for the 025

furnace.

Table 4

Cat.

Oil Filters 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

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 deter-

mining 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 pro-

vided 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

I Vacuum Port

dPressure Port

_,_/ BleederValve

"-'_ Bypass Plug

<_ [::> //]_-_.JJ ..... (Install in return

_ -' /line port if

__.7/ _ /two-line system

.__._ _ /is used.)

Return Line Port

Return Line Adapter

(Install if two-line

system is used)

Supply Line Adapter

(Factory-Installed)

Figure 17

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

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.

Table 5

Single-Pipe Sizing

Maximum

Height (H) Length 3/8" OD

Tubing

1,5' 33

3' 65

5' 130

6,5' 195

Maximum

Length 1/2" OD

Tubing

130

26O

325

Page 13

Oil Piping

Single-Pipe System

I Maximum

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.

2 - Install the provided NPT adapter on the pump return

port

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

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 in-

side t he fuel tank.

Table 6

Two-Pipe Sizing

Maximum

Height (H) Length 3/8" OD

Tubing

0' 115

1.5' 100

3' 80

5' 65

6.5' 5O

9.5' 25

11' 20

Maximum

Length 1/2" OD

Tubing

330

295

230

100

Oil Piping

Two-Pipe System

Maximum

13 feet

NOTE -Do not exceed

lengths given in table 6.

Figure 19

A, IMPORTANT

After oil piping is completed, carefully check all piping con-

nections (factory and field) for oil leaks.

Page 14

All wiringmustconformto the NationalElectricCode

(NEC),or CanadianElectricCode(CEC)andany local

codes,Refertofigure20forlowvoltageandhighvoltage

wiringconnections,

1- Refertotheapplianceratingplateforproperfusesize.

2- Installtheroomthermostatandmakewireconnections

totheunit.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,

Complete line voltage wiring from disconnect switch

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.

Typical 025 Wiring Diagram

FAN&

UM_T

8W_TON

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

YE&OW(IFUSE#} o

UNE VOLTAGE=F_Y

........................... L_NE VOLTAGE4 NSTA_LER

LOW VOLTAG_FACTORY

LOW VOLTAGE4N_ALL_R

Figure 20

Page 15

Before starting unit, make sure the oil tank is ade-

quately filled with clean No. 2 furnace oil.

NOTE -Water, rust or other contaminants in oil supply sys-

tem 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.

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.

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 oper-

ate 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 nor-

mally.

A CAUTION

A WARNING

1 - Set thermostat for heating demand and turn on electri-

cal 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,

A CAUTION

3 - If the burner fails to light again, refer to the trouble-

shooting 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 pres-

sure. Check pressure and compare to table 1. Adjust if nec-

essary. Vacuum Pressure

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 tempera-

tures in the supply and return air plenums should approxi-

mate 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 A CAUTION

The following instructions are essential to the proper op-

eration 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 es-

tablish tolerance or a "window of operation" into the unit, do

not exceed #0 smoke, This will give the burner more flexi-

bility when there are changes in the surrounding environ-

ment,

1 - Punch a 5/16" diameter service hole in the flue outlet.

This sampling hole should be at least two flue diame-

ters 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 min-

utes 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 less-

ens, 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 bare-

metric 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 re-

cord a smoke reading at the service hole. If smoke is

evident, it could be caused by a poor nozzle or combus-

tion setting. Insome cases, it may be caused by a differ-

ence 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 ad-

justment plate until the flame appears clean. Take

care to re-tighted air adjustment plate screw when ad-

justments 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 mea-

sured 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.

11 - Re-secure the burner cover and re-check the draft,

smoke, combustion and flue gas temperature,

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 as-

sure proper furnace operation, Replace filters with like kind

and size filters,

Blower

Blower motor is prelubricated and sealed for extended op-

eration. 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 check-

list 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 ac-

cess 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 exchang-

er 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 el-

bow. 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,

NOTE -A heat exchanger brush ABRSH380 (35K09)

is available from Lennox.

Page 17

Customer Name

Address

OIL FURNACE START-UP CHECKLIST

(Complete this page and keep for future reference)

Furnace Model #

Input Rate

New Construction

Date of Installation

Serial #

Nozzle Used

Replacement

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

reading: 1_ 2nd

G, Obtain smoke reading:

1st 2nd

H, Measure CO2:1 st

I, Check draft overfire

J. Air shutter setting

3 _

3 rd

2 nd 3 rd

Breech

Locked

Measure static pressure in duct system

Static pressure on supply side

Static pressure on return side

Static pressure drop

Temperature rise after steady state conditions have

been achieved: Supply side __ Return side __

Block off return air (limit control checkout); burner

should shut down in 2 or 3 minutes

Installed By:

Dealer

Address

Owner Recoil

Telephone #

License #

Page 18

LENNOX Furnace/Heater, Oil Manual L0806374

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