LENNOX Furnace/Heater, Oil Manual L0806376
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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LENNOX
INSTALLATION
INSTRUCTIONS
'_ 2002 Lennox industries inc.
Dallas, Texas, USA
OF23 SERIES UNITS
OIL UNITS
504,627M
38152A060
01/04
Supersedes
Front
Flue Model
_-_--_
Technical
,LLL_ Publications
Lithe U.S.A.
04/02
General .....................................
Shipping & Packing List .......................
OF23 Unit Dimensions ..........................
OF23 Start-Up & Performance
Check List .......
OF23 Unit Parts Arrangement
....................
OF23 Oil AFII Burner Parts Arrangement
..........
Requirements .................................
Locate & Level Unit ............................
Unit Adjustments
..............................
Venting ......................................
Flue Connect ions ............................
Supply & Return Air Plenums ....................
Oil Supply Lines Sizing
......................
Connect Oil Supply Line and Filter .............
Leak Check
................................
Electrical Wiring ..............................
Start-Up & Adjustment .........................
Service .....................................
Troubleshooting
..............................
1
1
2
2
3
4
4
4
5
6
11
11
11
13
13
12
15
16
17
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 technicians can install and service the Lennox Elite® Series
OF23 oil furnaces. In Canada, refer to CSA B139 for recommended installation procedures, Consult authorities
who have jurisdiction before installation.
,A, CAUTION
A WARNING
1- Assembled oil furnace
1- Barometric draft control
A, CAUTION
1- Side exhaust pipe collar (front flue units only)
1- Direct intake collar (AFII burner units only)
Check the components for shipping damage. If you find any
damage, immediately contact the last carrier.
01/04
IIIHIIIIIIIIIIIIIIIIIIIIIllllllllllll
504,627M
Page 1
IIIHIIIIIIIIIIIIIIIIIIIIIIIII
3/4
(19) f
3/4 /
(19) f
3-1/4 &
1-1/2
(38)
I
G -IP.-(83_'_-_
3/4
(19) /
_1
F
TOP FLUE
OUTLET
/
3/4 A
(19) /
TOP VIEW
FLUE CONNECTION
OF23Q314-1051120R,
OF23Q5-140/154R
OF23Q5-175/210R
I_
C
AIR_]TF
LOW
i
_
AIR t
i
FLOW
i
iI
FLUE CONNECTION
OF23Q3/4-105/140 &
OF23Q5-140/154
(On Heat Exchanger)
ELECTRICAL
INLETS
/
SIDE
FLUE OUTLET
CENTERING HOLE
(Field Fabricate
Either Side)
C_
""_I
I
OPT. OUTDOOR
COMBUSTION
_O
AIR INLET
CENTERING
HOLE
(Right Side Only)
c
(Field
Right
L
6-1/2
(165)
|
A
1 (25)
B
(_)
,,
I
SIDE VIEW
Model No.
....
,4,
_ -
OIL PIPING INLET/
(Both Sides)
Fabricate
Side only)
1
FRONT
C
D
VIEW
E x F (Supply)
E x G (Return)
in.
mm
in.
mm
in.
mm
in.
mm
in.
mm
in.
mm
19-1/2
4959
37
940
52-1/2
1334
27
686
18 x 21
457 x 533
18 x 16
457 x 406
OF23Q3/4-105/120R
19-1/2
495
37
940
52-1/2
1334
27
686
18 x 21
457 x 533
18 x 16
457 x 406
OF23Q5-140/154
22-1/2
572
37
940
52-1/2
1334
27
686
21 x 21
533 x 533
21 x 16
533 x406
52-1/2
1334
27
686
21 x 21
533 x 533
21 x 16
533 x406
55
1397
29
737
22-1/2 x 23-1/8
572 x 587
22-1/2 x 16-1/2
572 x 419
OF23Q3/4-105/120
OF23Q5-140/154R
22-1/2
572
37
940
OF23Q5-175/210R
24
610
39-1/4
997
i!i!i!ialFiii iii3 ii ii
......
Job Name
Job Location
Installer
Unit Model No.
Job No.
Date
City
State
City
Serial No.
State
Serviceman
HEATING SECTION
Electrical Connections
Tight?
PROPER DRAFT
13
Supply Voltage
Draft Reading (recommended
Blower Motor Amps
% CO 2 (recommended
Blower Motor H.P.
Flue Connections
Blower Motor Lubrication O.K.?
Piping Connections
Tight?
[]
Burner Model No.
Oil Pump Pressure [recommended
Tight? []
• Fan Control Setting (maximum
[]
.03-.04 inches w.c.)
12%)
All Valves Open? []
Fan Control Cutout
Serial Number
Filter Clean & Secure? []
130 ° F)
(55°C)
Temperature
Rise
Vent Clear? []
THERMOSTAT
minimum 140 psi]
Calibrated?[]
Page 2
Heat Anticipator
Properly Set? []
Level? []
flue opening
filter
clean-out port
indoor blower
limit switch
control box
with fan control
board
heat exchanger
observation
port
Beckett_ _,AFII Burner
(Shown)
clean-out
port
Figure
FLANGE
GASKET
RETAINING
CLIP
AIR TUBE
ASSY FOR
FB HEADS
AIR TUBE
SCREWS
1
ELECTRONICIGNITION
TRANSFORMER
FLANGE
IGNITOR
REARACCESS
DOOR
GASKET
PRIMARY
CONTROL
4X4
BOX
X
DOORASSY
1/4"HEX
X
HEAD SCREW
NUT
INSULATOR
NOZZLE
ADAPTER
FUELPUMP
NOZZLE LINE
ELECTRODE HEAD
/
ASSY.
ELECTRODE
ASSY
MOTOR
VALVE
Figure 2
Page 3
BLOWER
WHEEL
INLET
AIR SCOOP
Table 1
I
I
WARNING
Combustion
Air Opening
Dimensions
Combustion Air Opening
Dimensions (2 required)
Model No.
O23-105/120
O23-105R/120R
10" X 20" (254 mm X 508 mm)
O23-140/154
023-140R/154R
11" X 22" (279 mm X 559 mm)
O23-175R/210R
O23-175R/210R
20" X 40" (508 mm X 1016 mm)
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,
Table 2
Installation
Clearances
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.
Air for combustion and ventilation must conform to standards outlined in section 140 d NFPA No. 31 or, in Canada,
CSA Standard B139. When installing OF23 units in confined spaces such as utility rooms, two combustion air
openings are required. Dimensions of combustion air
openings are shown in table 1. One opening shall be below
burner level and the other opening shall be no more than 6"
(152 mm) from the room's ceiling.
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.
A IMPORTANT
Clearances
All Unit Sizes
inches (mm)
top of plenum and duct
2 (51)
plenum sides
3 (76)
sides*
6 (152)
rear
24 (610)
front
4 (102)
flue pipe measured vertical**
(measured from above)
9 (229)
NOTE-Service
access clearance must be maintained.
*Clearance to allow inspection of furnace and flue connector
shall be provided, 24" (610 mm) at rear and on one side of furnace should
be allowed for cleaning and service of the blower.
**Minimum clearance shown for flue pipe may be reduced by using special
protection as provided by local building codes and the National Fire
Protection Association Standards and CSA 189.
NOTE - When service clearances are greater than fire
protection clearances, service clearances take precedence.
Unit must be adjusted to obtain a temperature rise within
the range listed in table 3 in the Start-Up section of this
manual.
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 connection with unit must meet or exceed
specifications of type T wire and withstand a 63<_F(17<_C)
temperature rise.
Page 4
Nozzle Adjustment
Thecompactdesignof thisfurnacemakesit idealfora
basementor utilityroominstallation.
Choosea central
locationfor thefurnaceso thatsupplyair ductsapproximatelythe samelength.Thiswill alloweachroomto receivethe properamountof heat.Thefurnaceshouldbe
placedsothattheflueconnection
tothechimneywillbeof
minimumlengthandhavea minimumnumberofelbows.
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.Makesuretheweightofthefurnaceisdistributed
evenlyonallfourcorners.Strainon sidesof cabinet
causingcrackingand poppingnoisesmayoccurif
weightoffurnaceis notevenlydistributed.
Proper adjustment of the nozzle assembly is critical because
alignment may have changed during shipping. Before the furnace and oil lines are installed, the nozzle assembly must be
checked. This may easily be done by removing the entire
burner assembly (not just the nozzle) from the furnace. The
lower firing nozzle is factory installed. This should be verified
by the installer. Inspect the spark transformer leads also to
ensure they are still attached to the electrodes. Note that
OF23-105/120 and OF23-140/154 series units use the
Beckett AFII burner. OF23-175/210R series units use the
Beckett AFG burner.
The burner assembly is attached to the vestibule panel by
three nuts. Slots are provided in the mounting flange for removing the burner assembly from the vestibule. By loosening the nuts and by turning the whole burner assembly counterclockwise (figure 3), the entire burner assembly will come
out of the furnace. There is adequate wire to remove the
burner without disconnecting wires. Once removed, just turn
the burner around in the vest panel area.
OF23 Series Burner Removal
First, loosen three nuts which
attach burner to vest panel.
Neitherthenozzlesettingnortheairadjustments
arefactory set.Thefurnaceis fire testedandthe limitcontrolis
checkedtomakesureitfunctionsproperly;nofactorysettingsare made.Duringinstallation,
thefurnacemustbe
"setup,"The installingdealer/contractor
musthaveand
usepropertestequipment
inordertocorrectly
setuptheoil
furnace,Propertestingequipmentis requiredto ensure
correctoperation
oftheunit.Theuseoftestequipment
is
nowmorecriticalthaneverduetotightertolerances
neededto keepthefurnaceoperating
efficiently.
Amongthetestequipment
for anoilfurnace,the proper
combustion
testkitshouldcontainthefollowing:
• Draftgauge
• CO2or 02Analyzer
• Smoketester
• Pressure
gauge
• Hightemperature
thermometer
• Oilvacuumgauge
• BeckettT-500gauge
• Knowledge
ofpropertestequipment
operation
CAUTION
Next, rotate burner counterclockwise on slots then pull
toward rou.
Figure
3
To correctly adjust the nozzle, use a Beckett #T-500 gauge.
Insert the small end of the gauge into the end of the cone
and measure from the flat of the end cone to the tip of the
nozzle. When nozzle depth is correct, the tip of the nozzle
should just touch the end of the gauge. Refer to the illustration sheet provided with the gauge. Note that the scale side
of the gauge is not used for this purpose. Corrections are
made by sliding the entire nozzle assembly forward or
backward within the blast tube (figure 4). At the same time,
nozzle alignment must be checked.
To check nozzle alignment, again insert the small end of
gauge into the end cone and measure the nozzle and
electrode alignment against the center lines marked on
the gauge (again refer to enclosed illustration sheet). If
the nozzle is not centered, but found to be too far left or
right, a new nozzle assembly will need to be ordered. Do
not attempt to adjust by bending the 90 degree elbow in
the oil line.
Page 5
Beckett
Burner
Oil Burner
must be removed
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 d the chimney should be
at least equal to the diameter d 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,
Nozzle Adjustment
from
furnace for this procedure.
2
gauge
1
1 - Local building codes may have more stringent installation requirements and should be consulted before
installation of unit,
To Adjust Nozzle
1-Loosen screw.
2-Slide entire nozzle/electrode
nozzle just touches gauge.
2 - The vent connector should be as short as possible to
do the job,
assembly back and forth until
Figure
3 - The vent connector should not be smaller than the outlet diameter of the vent outlet of the furnace.
4
4 - Pipe should be at least 24 gauge galvanized,
WARNING
I
5 - Single wall vent pipe should not run outside or through
any unconditioned space,
6 - Chimney should extend 3 feet (0.9 m) above highest
point where the vent passes through the roof, and 2
feet (0,6 m) higher than any portion of a building within
a horizontal distance 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,
WARNING
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 5,
Wall Thimble
CAUTION
combustible
wall
WARNING
vent
Figure
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
liner of stainless steel rather than aluminum).
pipe
5
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 6.
Page 6
Front Flue / Masonry
barometric
control*
in either location
15- All vent pipe run through unconditioned areas or outside shall be constructed of factory built chimney sections. See figure 7,
Chimney
liner
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,
clean out
18- Keep the area around the vent terminal free of snow,
ice and debris,
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.
masonry
chimney
clean out
Rear Flue / Masonry
Front Flue / Factory-Built
barometric
control* _
(in either
location)
Chimney
_'
- -_S .......... I --
barometric
control*
in either location
'
factory
\
lean o
Chimney
_
drain for
condensate
_m,m, asonry
i
built
chimney
chimney
*Barometric control may be installed in either vertical or horizontal section of flue pipe within 18" of flue outlet of furnace.
Figure
6
Rear Flue / Factory-Built
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
masonry or concrete chimney lined with a lining material acceptable to the authority having jurisdiction,
barometric
control*
(in either
Jc
location
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
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,
factory
built
himney
drain for
condensate
i
o
i
o
I
*Barometric control may be installed in either vertical or horizontal section of flue pipe within 18" of flue outlet of furnace.
Figure
Page 7
Chimney
7
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
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,
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,
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,
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 of 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,
Combustion
Air from an Adjacent
The importance of the previous paragraph cannot be overstated. Users may inadvertently block fresh air intakes after
installation,
Air Requirements
Ak CAUTION
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.
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),
Equipment
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
Page 8
Space
Chimney or
Oil Vent
Oil
Furnace
Openings
(To Adjacent Room)
'
Space
In Confined
rom Inside
i
Unconfined
Space
ii
ii
"1
ii
ii
ii
ii
ii
I"
ii
"I
i
I°
'
NO TE-Each opening shall have a free area of at least I square inch
(6.4 square centimeters) per 1,000 Btu (293 W) per hour of the total
input rating of all equipment in the enclosure, but not less than 100
square inches (614.5 square centimeters).
Figure
8
Air from Outside
Equipment
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 10). 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).
In Confined
AII Air From Outside
Or Oil
Vent
1
1
I
I
1
I
1
I
I
Heater
I
I
I
I
1
I
Chimney or
Oil Vent '_
Figure
Water
Heater
Ventilation
Louvers
Inlet
(For unheate(
crawt
Air
rrrm
r
1
r
NOTE-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 (!! 72
W) per hour of the total input rating of all equipment in the enclosure.
1
1
I
1
I
1
I
I
I
NOTE-Each air duct opening shall have a free area d 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 d at least one square inch (6.4 square centimeters) per
4,000 Btu (!! 72 W) per hour of the total input rating of all other equipment in the enclosure.
Equipment In Confined Space
All Air From Outside
(Inlet Air from Crawl Space and Outlet Air to
Ventilated Attic)
Oil
Furnace
Space
11
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.
CAUTION
Figure 9
Equipment In Confined Space
All Air From Outside
(All Air Through Ventilated Attic)
Chimney
or Oil
Vent
Ventilation Louvers
• (Each End Of Attic)
A
Oil
CAUTION
Inlet Air
(Ends 12"
Above BoSom)
Furnace
Water
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
Direct Connection of Outdoor Air for Combustion
The Beckett AFII burner was designed to allow for direct air
intake piping (4" [102 mm]). The maximum equivalent
length of pipe is 70 feet (21.3 m). A 90 _ elbow equals 6 feet
(1.8 m). The enclosed intake pipe ring may be used to facilitate direct air intake to the burner through the right side of
the cabinet. The AFG burner requires a special kit for direct
air intake. Refer to kit instructions.
Page 9
ToconverttheAFItburnerfromconfinedspacetooutside
combustion
air,removethethreescrewswhichattachthe
inletairscooptotheburnerandinsert4"(102mm)directair
intakepiping.
Theuseofa barometric
reliefplacedin theintakepipeis
recommended
whenoutdoorcombustionair is directly
connected
totheburner.Thiswillallowconfinedspaceair
tobeusedascombustion
airintheeventthattheopening
totheoutdoorairbecomes
blocked.Usea barometric
relief
intheintaketoreducethechanceofsooting.
7-
If improper venting is observed during any of the
above tests, the common venting system must be corrected.
Horizontal Venting
The OF23 is approved for horizontal venting with the following mechanical vent systems:
Tjernlund (sideshot) #SSlC (Cat. #35E08) or Field Controls #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.
The barometric draft control must be installed within 18
inches of the furnace flue outlet. See figure 12 for barometric draft control location.
CAUTION
Do not common vent with any other appliance when using
sidewall vent system.
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.
The maximum equivalent length of pipe is 70 equivalent
feet. A 90 _ elbow equals 6 ft. 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.
Front Flue / Horizontal
1 - Seal any unused openings in the common venting
system.
bar°_;tlr) c
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 connected 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.
Venting
"__::--
control for
[ZZ
horizontal
venting
Rear Flue / Horizontal
barometric
Venting
control*
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.
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 its previous condition of use.
*Barometric control must be installed in the horizontal venting
system and located within 18" of flue outlet of furnace.
Page 10
Figure
12
vent connector, plus 50% of the area of any additional flues
or vent connectors. Install the barometric draft control (provided) and flue pipe according to instructions packed with
control.
IMPORTANT
Inspect flue pipe annually. Clean soot or ash from flue pipe,
if necessary. If pipe is rusted, replace.
Radiation
Install draft control at least 12 inches beyond the furnace. If
there is no space to install the draft control in the flue pipe it
may be installed in the vent above the flue pipe. Follow the
instructions packed with the draft control.
Alternate Side Flue Connections
Shield Installation
combustible
material
(25 mm)
min
The vent pipe may exit the top or sides of the cabinet. A
hole is provided in the top cap for top exit. For side exit, lo-
unit
cabinet
cate the center hole punched in the side of the cabinet. See
unit dimensions on page 2. Using it as the center point, cut
a 6 inch (152 mm) round hole in the cabinet's side. Using it
as the center point, cut a 6 inch (152 mm) round hole in the
cabinet's side. Install the barometric draft control within 18
12" (305 mm)
min
7" (178 mm)
inches d the furnace flue outlet. Attach the provided finishing plate to cover rough edges.
noncombustible
spacers
radiation shields
(see note 1)
Secure return 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 sealing strips of fiberglass.
2- In all cases, the plenum should be secured to furnace
or evaporator cabinet with sheet metal screws.
3- Install supply and return air ducts as desired.
B
see note 3
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
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 ram),
use a single-or two-stage oil pump.
NOTE 3-Radiation shields should extend from the top of the unit to
the top of the flue pipe.
Figure
One-Pipe System
13
For front flue models, the enclosed exhaust pipe ring may
be used for pipe to exit the left or right side of cabinet. Center line marks are provided in cabinet.
Use 24 gauge or heavier galvanized smoke pipe and fittings to connect furnace to vent. Connect flue pipe to 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 flue pipe is acceptable. It is best to have flue
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
When using a one-pipe system with the oil tank above the
burner and a vacuum of 6" (152 mm) Hg or less, a singlestage fuel pump with a supply line and no return line should
be adequate. See figure 14. 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.
To determine the length of the run for piping, refer to table 2
Page 11
r_
Oil Piping
I I
One-Pipe System
alrv LII
dl I_
o
o_L
fill /
,
pipe
fuel
um
P: P
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.
Aux
Filter
t-)_r
O
O
II
T;,k
I .....
II
/
_nut-o_
o ° ol
o_-I I1
o;;I
o_
o_
_
Valve
] Maximum
I One Pipe Lift
ITlllT--It_
_k IMPORTANT
18ft<24m)
_
,'
_'-'
t
,_
.........
xql !') Uu
Table
Two-Pi )e Maximum
x_,o ;,o;,o;,o;,o;,o;,o;,o;,
Lift "H"
Figure
14
Table 2
One-Pipe Oil Sizing
0)
Line Length
Pipe Diameter (OD Tubing)
(0.0 m)
2'
0-50' (15 m)
3/8" (10 mm)
(0.6 m)
51-100' (15 m)
1/2" (12 mm)
4'
(1.2m)
6'
Two-Pipe System
(1.8m)
When using a two-pipe system with the oil tank below the
level of the burner, a single-stage fuel pump should be used
in lift conditions of up to 10 feet (3 m) and/or a vacuum of
10" (254 mm) Hg or less. See figure 15. Use a two-stage
fuel pump when lift exceeds 10 feet (3 m) and/or a vacuum
of 10" (254 mm) Hg to 15" (381 mm) Hg,
Both conditions require that you use of a two-pipe system,
which consists of a return line that purges the fuel pump of
air by returning it to the tank. To determine the run and lift for
piping, refer to table 3.
8'
(2.4m)
10'
(3.0m)
12'
(3.7m)
14'
(4.3m)
16'
(4.9m)
18'
(5.5m)
Oil Piping
Two-pipe System
Fill
Pipe
\
Air Vent
_,
r]
"_11
I eturn
/_IF_J
__
_
_
I p,pe
_,,__
•
J_-v_7_L_._-
:
,)-_
-_
_-1o2 mint
J
outside
tank fuel pump above
Figure
15
bottom of tank
Pipe Length
(H + R)
3450 RPM- 3 GPH (11.4 LPH)
3/8" (10 mm) OD
1/2" (12 mm) OD
Tubing
Tubing
Single
Stage
Two
Stage
Single
Stage
Two
Stage
84'
(25.6 m)
73'
(22.3 m)
63'
(19.2 m)
52'
(15.8 m)
42'
(12.8 m)
31'
(9.4 m)
21'
(6.4 m)
93'
(28.3 m)
85'
(25.9 m)
77'
(23.5 m)
69'
(21.0 m)
60'
(18.3 m)
52'
(15.9 m)
44'
(13.4 m)
36'
(11.0 m)
27'
(8.2 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
83'
(25.3 m)
41'
(12.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
76'
(23.2 m)
fuel
pump
3
F
Aux
Filter
One-Pipe Systems
A
_
CAUTION
/
The burner is shipped with fuel pump set for one-pipe operation. For one-pipe systems, the oil supply pipe is connected to the inlet tap on the pump, A one-pipe system
should only be used where there is gravity oil flow to the
pump and the pipe is not run at any point above the oil level
in the tank.
Page 12
1 - Connect
theinletpipetothepumpinlet,Starttheburner.
2 - Arrangetheprimaryburnercontrolforcontinuous
operationduringpurging,Seefigure14,
3 - Turnthebleedvalveoneturncounterclockwise,
4 - Bleedtheunituntilallairbubblesdisappear.
NOTE - Hurried bleeding will prevent the unit from operating properly.
5 - Tighten the bleed valve securely,
Table 4
Oil Filters
(All Models)
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
Two-Pipe Systems
If the installation requires a two-pipe operation, install the
bypass plug included in the bag which is attached to the
pump, To convert the pump, install the bypass plug according to the provided pump instructions, Notice in the two-pipe
system the return pipe must terminate in the tank 3" (76 mm)
to 4" (102 mm) above the supply inlet. Ensure the return pipe
terminates at the correct measurement or air may escape
into the system, This could result in loss of prime,
After oil piping is completed, carefully check all piping connections (factory and field) for oil leaks,
Oil Line Heater (Optional)
A heater for the oil pipe is available for applications that are
located in cold climates, The heater warms the oil pipe to
assist the initial start-up.
NOTE- If using an outside tank in cold climates a number
one fuel or an oil treatment is strongly recommended.
All wiring must conform to the National Electric Code
(NEC), or Canadian Electric Code (CEC) and any local
1 - Remove 1/4" plug from return port,
2 - Insert bypass plug and tighten it, See figure 15.
3 - Attach the return and inlet pipes, Start the burner. Air
bleeding is automatic,
NOTE - If a faster bleed is necessarj4 open the bleed
valve,
codes, Refer to figure 16 for terminal designations on fan
control board,
1- Refer to appliance rating plate for proper fuse size,
2- Install room thermostat and make wire connections to
the fan control board, Avoid installing thermostat on an
outside wall or where it can be affected by radiant heat,
Set the adjustable heat anticipator on thermostat according to the wiring diagram sticker provided on unit,
4 - The return pipe must terminate 3" to 4" above the supply pipe inlet, See figure 15,
NOTE - If the return pipe does not terminate where it
should, air may enter the system, and prime may be
lost.
An oil filter is required for all models. Install filter inside
the building between the tank shut-off valve and the burner.
Locate filter close to burner for easy maintenance, Table 4
lists the filters for the OF23 furnace,
Consult the burner manufacturer's
instructions that are in-
cluded with the unit for further details concerning oil supply
pipe connections.
3- Install a separate fused disconnect switch near unit so
power can be shut off for servicing.
4- Complete line voltage wiring from disconnect switch
near unit to make-up box.
NOTE - An equipment ground screw is provided. Refer
to unit wiring diagram and figure 16 for 0F23 series
units. Ground unit using a suitable ground wire.
5- Any accessory rated up to 1 amp can be connected to
the accessory terminal. The accessory terminal is energized when the blower is in operation.
Page 13
Fan Control
Board
©
thermostat
terminal
_[]
strip
DEL^¥_F
SELECT
°
o
Figure 16
Typical
I
OF23 Wiring
Diagram
f
POtL_
_Y
JLENCTION
120 VOLT BOX
-_
FACTORY WIRING
LINE VOLTAGE-FIELD
LOW VOLTAGE-FIELD
TI
TRANSFORMER
YLW |
r...._!
F,
5AMP
YLW [
-'"
I
RED
B3
CIRCULATING
S_A4RT
:H
FAN
I.T
AUX
LIMIT
MAIN
LIMIT
(IF USED)
SlO
NG_s
I.
I
G
(p _) (_
I
L LI'L
_E NOTES,
_s
I
Y c
_
_.
_?
J
0
_" IONITOR_
I I_T
I
I
_
_._
I I.'F:
J
j
IF HONIZONTAL APPLICATION
IS USED,
PURPLE IS WIRE COLON DESIGNATION.
5.
THERMOSTAT HEAT ANTICIPATO_
4.
CONE_CT REOUIflED MOTOR LEAD TO HEAT
TERMINAL ON TERMINAL BOARD.
S.
WHEN THE SAME MOTOR SPEED IS TO BE
USED FOR HEAT AND COOL,DISCONNECT
AND ISOLATE THE UNUSED MOTOR SPEED LEAD.
CONNECT THE REC_JIRED MOTOR SPEED LEAD
TO THE NEAT TERMINAL AND ADD A JUMPER
WIRE BETWEEN THE HEAT AND COOL TERMINALS.
SETTING--O.
0 LZ
0 u
2 ______R_
o
F{'_-_....._
PUMP VALVE
._,
HEAT ONLY(TWO WIRE)
z_v.z FOR
THERMOSTAT.CONNECT
R & W.
I BO SEC
SWITCH
SETTINGS
90 REC 120 GEC I50
GEC
c_NGING
J u -L_____ ONIT
L_N_OX®
IF ANY WIRE IN THIS APPLIANCE IS REPLACED,
IT MUST B_ REPLACED WITH LIKE SIZE,HATING
IKSULATION THICKNESS AND TERMINATIOn4
2.
0 CELL, CAD
*HT
DELAY OFF DIP
s2'rY_
TH_MOSTATI(
R
BLUE INTERRUPT
_TO_
NOTE 2
o w,_,,
OTI
_H
0R26
_; '_/
_-s_ NOTE
Z
0 TZ
0
l l-t-- //
RED-GEE
CONTROL
Wfl,tITE
ORANGE
Ii°i°i]-l Ij
CAPACITOR
R7184S
A3
PRIMARY
02302-70
02503-1051120
02305- 140/154
0F2303- 105/120
OIL
lAMP
HEATING
UNITS-OIL
0F2305-140115_
0HR2305- I(R/120
OF2303-105/I2OR
0HR2305-1401154
0F2305-140/154R
01=2305-175/210
HEAT-SECT
tON
,q;;::;;.
N=I Form No.
534,563W
_O_S
Figure
17
Page 14
I.•*_*=
I_•trl*•
la,_.
Lithe
U.S*A.
Typical
OF23 Wiring
Diagram
24V
POWER
I
L
ILIMIT
T
_p
ECON
P94
SS
A
ON 140,154
_TO
CHANGE MOTOR SPEED TAP AND
FOR BLOWER SPEED GELECIION
PROCEDURE,REFER
TO INSTALLATION
A
INSTRUCTION,
SWITCH OPENS
A
$21
CSA UNTTS
WHEN FLAME
USED ON OHR23
SERIES
(G)
HEAT
(WI)
IS
SIGHTED
_
F22
ONLY
ORANGE
KE25-1
A
WHILE
K56
DELAY
DELAY
NOTEIF
ANY WIRE IN THIS APPLIANCE
IS REPLACED,
IT MUST BE REPLACED WITH WIRE OF LIKE SIZE,
RATING,INSULATION
¸THICKNESS
AND TERMINATION
THERMOSTAT HEAl ¸¸ ANTICIPATION
023/OF23/OHR23
UNITS..
0,1
AMP
ON
OFF
I
I
WHITE
:s
i:iJ
LzAv
SLOWER SPEED CHART
FACTORY CONNECTED
SPEED TAPS
UNIIS
COMMON (C/
MOTOR
SPEEDS
AVAILABLE
2
ALL
IB
[
SPEED
TAPS
EOUIPMENT
GROUND
BLOWER SPEED SELEC]ION
HI
LO
IBK
YLW
BLUE
RED
I
I._IIRUA®
IMPORTANT-TO
PREVENT MOTOR
BURNOUT,NEVER
CONNECT
MORE
THAN ONE MOTOR LEAD TO ANY
ONE CONNECTION.
L_
IF HEATING
AND
LOW
I
ONLY
_WHEN
AN ACCESSORY
IS BEING USED IN A
CONTINUOUS
PAN APPLICATION
WITHOUT S6B
(CONTINUOUS
FAN SWITCH].THE
ACCESSORY
MUST BE WIRED BETWEEN LI AND N ON
BCC BOARD.
SET
FOR
BLOWER
H[R
HEARING
02302=70
02303
105/E 20
02505
140/E 54
0F2505105/120
0F2505-140/154
SPEED
OIL
UNIIS
0F2305
105/120R
DF2505] _-0/I!:i4R
OF 2505 = 175/210
OHR25Q5
105/120
O_ R2505 = 140/154
ARE TG BE GAME,CGNNECT
JUMPER BETWEEN
$68-1 AND
AI5 H(AS SHOWN).REMOVE
UNUSED MOTOR SPEED WIRE.
N_w Form
I
....
No,
554,564W
LINE VOLTAGE
FIELD
INSTALLED
CLASS
II VOLTAGE
FIELD WIRING
41969005
(_)zoo_
Le_
Figure 18
Page 15
_d_ fr_s la_
L fho U.S. A
Beforestartingunit,makesuretheoiltankis adequately
filledwithcleanNo,1 or No, 2 furnace oil,
NOTE - Water, rust or other contaminants in oil supply system will cause malfunction and failure of the internal parts
of the fuel unit.
readings, subtract the readings. The difference in temperatures in the supply and return air plenums should approximate the temperatures listed in table 5 and the appliance
rating plate. If not, adjust the blower motor pulley to adjust
the blower speed.
Table 5
OF23
Unit
nozzle size,
spray, angle, &
pattern
input
rating
BTU/HR
output
rating
BTU/HR
head
temp
rise F °
-105
.65GPH-.80
° B
105,000
85,000
FB3
60
-105R
.65GPH-.80
° B
105,000
85,000
FB3
65
-120
*.75GPH-.80 ° B
119,000
97,000
FB3
70
-120R
*.75GPH-.80 ° B
119,000
97,000
FB3
70
-140
.85GPH-.80
° B
140,000
113,000
FB6
60
-140R
.85GPH-.80
° B
140,000
113,000
FB6
65
-154
*I.00GPH-.80
°B
154,000
125,000
FB6
60
-154R
*I.00GPH-.80
°B
154,000
125,000
FB6
70
-175
1.10GPH- .80 ° B
175,000
142,000
FB6
70
-210R
1.25GPH- .80 ° B
210,000
166,000
FB6
70
CAUTION
Ai, CAUTION
1- Set thermostat for heating demand and turn on electrical supply to unit,
2-
Check initial air adjustment, All units are equipped with
an air adjustment dial on the right side of the burner.
See burner parts arrangement illustration.
3- Turn unit on. Place a can or container under the bleed
port located on the fuel pump. Loosen nut on bleed
port to release air and oil mixture from fuel line, Allow
mixture to escape until a steady stream of oil is emitted
from the port, Drain at least 1/2 pint of oil from the
pump, Retighten nut on bleed port.
NOTE - A two-line fuel system will normally bleed itself
by forcing air back to the tank through the return line.
This type of bleeding procedure is not necessary.
4-
If burner fails to start, push reset button on primary
safety control and the burner motor reset button once.
See part arrangement illustration,
*Nozzle must be field provided for field conversion
to higher
heating input.
Oil burner pump pressure is !40 psi for each unit.
C - Limit Control
Limit Control -- Do not adjust from factory setting.
D - Fan Control
The fan on time of 30 seconds is not adjustable, Fan off
time (time that the blower operates after the heat demand
has been satisfied) can be adjusted by moving the delay
switches on the fan control board, Fan off time will affect
comfort and is adjustable to satisfy individual applications.
See figure 19, Set the heat fan off delay switches to either
60, 90, 120, or 150 seconds. The factory setting is 90 seconds.
CAUTION
Delay Off Switch
5-
If burner fails to light again, refer to the troubleshooting
section in this manual,
60 sec
90 sec
A - Fuel Pump Pressure Adjustment
Measure fuel pump pressure with unit off. Attach pressure
gauge to pump outlet, Turn unit on and check pressure and
compare to table 3, Adjust if necessary,
B - Temperature Rise Adjustment
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
Figure
Settings
120 sec
150 sec
19
E - Burner Adjustment
The following instructions are essential to the proper operation of OF23 series oil furnaces, To prevent sooting,
these instructions must be followed in sequence:
1 - Draft
This test should be taken at the breach between the outlet
of the vent connector and the barometric draft control. Generally a 1/4" hole will need to be drilled for the draft gauge to
be inserted into the vent connector.
Page 16
A minimumof 0,03draftmustbeestablished
withoutthe
burnerinoperation,
Withtheburnerinoperation,
thedraft
shouldbe 0.04to 0.05.Thisis VERYcriticalto theflame
retentionheadburners.
Oilfurnaceinstallations
alsorequirecarefulinspection
to
makesurethechimneyis ingoodshapeandcanaccommodatethe productsof combustion.
Thetemperature
in
theunconditioned
spacewillalsoaffectthedraftif longvent
connectors
areallowedtogettoocold,
2 - OverfireDraft
Thistestshouldbetakenwiththeburnerinoperation.
Removethescrewfromthecenteroftheinspection
door.Insertyourdraftgaugeintothehole,
A readingoftheoverfiredraftshouldbe0,02lessthanthe
readingfoundintheventconnector.
Ifa positivereadingis
seenatthispoint,thecombustion
fanis pumping
toomuch
air intothe heatexchanger,
Makethe necessaryadjustmentsattheairadjustment
dial,
3 - SmokeTest
Thesmoketestshouldbetakenattheholedrilledinstep1,
Usinga smoketestgunadjusttheairinletshuttersothat
youwillhavejusta traceofsmoke.Somewhere
between
0
and#1smoke,Thisisthestarting point, Do not stop here.
4 - CO2 Test
Again, take the sample at the vent pipe, With the unit firing
at a trace of smoke, take a sample of the CO2,
From the results of this test, a "window of operation" will be
determined, This window of operation establishes some
tolerance. The tolerance the installer builds in provides
room within the set-up for those things which might affect
combustion, Those things which might affect combustion
can then do so without causing the unit to start sooting/
smoking. Things which might affect combustion include a
nozzle going bad, draft that changes during different climatic conditions, dirty oil, dirt obstructing the air inlet, etc,
To build in a "window of operation," set up the burner to be
2% less in CO2. For example, if you find a reading of 12%
CO2, adjust the air inlet shutter to increase the air and drop
the CO2 to 10%.
the room air temperature from the stack temperature. This
will give you the net stack temperature. Use the efficiency
charts provided in most C02 analyzers to determine furnace efficiency.
A - Servicing Filter
NOTE - Under no circumstances should the access panels
to the blower compartment be left off or left partially open.
1- Throw-Away Type Filters -- Filters should be checked
monthly and replaced when necessary to assure proper furnace operation, Replace filters with like kind and
size filters,
2-
Reusable Type Filters -- Filters should be checked
monthly and cleaned when necessary to assure proper furnace operation. Use warm water and a mild detergent. Replace filter when dry. Permanent filters
supplied with OF23 furnaces do not require oiling after
cleaning. Examine filter label for any for special instructions that may apply,
B - Blower
Blower motor is pre-lubricated and sealed for extended operation. No further lubrication is required. Disconnect power to unit before cleaning blower wheel for debris,
C - Flue Pipe Inspection
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,
D - Cleaning Heat Exchanger
1- Remove the vent pipe from the furnace,
2- Remove the locking screws and the caps from the
clean out tubes, Remove flue access elbow.
3- Using a long spiral wire brush, sweep down the outer
drum of the heat exchanger. Then using the hose attachment, vacuum out loose debris,
4- Remove the locking screw and cap from the observation tube and with the spiral wire brush, reach upward
toward the rear of the heat exchanger to clean out the
crossover tube,
5 - Retest the Smoke
With a drop in the CO2 and increase in the air you should
see that the smoke has returned to 0,
CAUTION
6 - Retest the Overfire Draft
This test serves to confirm that you have not increased the
air too much, Again you do not want a positive pressure at
the test port. It should still be 0.02 less than the draft pressure reading taken at the breach. You may need to
increase the stack draft by adjusting the barometric draft
control,
5- Replace the 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 around burner, blower deck and vestibule area.
7 - Stack Temperature
Take a stack temperature reading in the vent pipe, Subtract
Page 17
NOTE - A heat exchanger clean-out kit ABRSH380
(35K09) is available from Lennox.
Burnerfailureor improper
operation
canresultfroma numberofdifferentcauses,
Oftenthecausecanbepinpointed
byobserving
thedifferenttypesoffailureor bytheprocessofelimination.
Thefol-
lowingtroubleshooting
chartslist somefailures,causes
anda sequenceof stepsto isolatethe pointof failure.
Checkthesimplestandmostobviousitemsbeforeprogressingtootheritems.
Action
Thermostat calls for heat.
(W terminal is energized.)
System
Response
ST9103A closes oil primary control T-T connections.
Ignition system and oil primary control start the furnace. Oil flows as long as oil primary
control senses flame.
Burner motor is energized and heat fan on delay timing begins. When timing is complete.
the circulating fan is energized at heat speed and warm air is delivered to the controlled
space.
Thermostat ends call for heat.
(W terminal is de-energized.)
Oil primary control is de-energized,
terminating the burner cycle.
Heat fan off delay timing begins. When timing is complete, the circulating fan is de-energized,
ST9103A returns to standby mode (oil primary control and circulating fan are off).
Burner fails to light.
Oil primary control locks out within lockout timing (timing depends on oil primary control).
Burner motor is de-energized,
If heat fan has started, it continues
Established flame fails.
Burner motor is de-energized
through the selected delay off period.
and oil primary control goes into recycle mode.
If selected heat fan off delay is longer than the recycle delay timing, the heat fan continues to run through the next trial for ignition.
Thermostat begins call for cool.
(G and Y terminals are energized.)
Circulating fan is energized at the cool speed.
Thermostat ends call for cool.
(G and Y terminals are de-energized.)
Circulating fan and cooling compressor
Thermostat
Circulating fan is energized immediately
begins call for fan.
Cooling compressor
turns on immediately.
(G terminal is energized.)
ST9103A may be factory-configured
Thermostat ends call for fan.
(G terminal is de-energized.)
Circulating fan is de-energized.
Limit switch string opens.
Oil primary control shut off the burner.
turn off immediately.
at cool speed.
to operate heat speed in this mode.
Circulating fan is energized immediately
at heat speed.
ST9103A opens oil primary control T-T connections.
Circulating fan runs as long as limit string stays open.
If there is a call for cooling or fan, the circulating fan switches from heat speed to cool
speed.
Limit switch string closes.
ST9103A begins heat fan off delay sequence.
Circulating fan turns off after the selected heat fan off delay timing.
ST9103A closes oil primary control T-T connections.
Oil primary control is energized, initiating burner light off.
Continuous circulating fan is connected.
Circulating fan is energized at low speed when there is no call for heat, cool or fan.
(Optional connectors are available for separate circulating fan speed tap.)
If fan operation is required by a call for heat, cool, or fan, the ST9103A switches off the
continuous fan speed tap before energizing the other fan speed.
Electronic air cleaner is connected.
(Optional connectors are available for 120 Vac electronic air cleaner.)
Electronic air cleaner (EAC) connections are energized when the heat or cool speed of
the circulating fan is energized. EAC connections are not energized when the optional
continuous fan terminal is energized.
Humidity control is connected.
(Optional connectors are available for 120 Vac humidifier.)
Humidifier connections
Page 18
are energized when the burner motor is energized.
Source
Thermostat
Procedure
Check thermostat
settings.
Causes
Correction
Thermostat
in OFF or COOL
Switch to HEAT.
Thermostat
is set too low
Turn thermostat
perature.
Burner motor overload
Safety Overloads
Power
Thermostat
Check burner motor, primary
safety control, & auxiliary limit
switch.
Check furnace disconnect
switch & main disconnect.
Touch jumper wire across thermostat terminals on primary
control. If burner starts, then
fault is in the thermostat circuit.
tripped
Reset primary control.
Auxiliary
safety
Reset auxiliary limit.
limit switch tripped on
Open switch
Close switch.
Blown fuse or tripped circuit
breaker
Replace fuse or reset circuit
breaker.
Broken or loose thermostat
wires
Repair or replace wires.
Loose thermostat
nection
Tighten connection.
Dirty thermostat
screw concontacts
not level
Clean contacts.
Level thermostat.
Faulty thermostat
CAD Cell
Push reset button pump motor.
Primary control tripped on safety
Thermostat
Disconnect the flame detector
wires at the primary control. If
the burner starts, fault is in the
detector circuit.
to higher tem-
Replace thermostat.
Flame detector
shorted
leads are
Flame detector
exposed to light
short circuit in the flame detector
Separate
leads.
Seal off false source of light.
Replace detector.
Check adjustment.
maximum setting.
Primary Control
Place trouble light between the
black and white leads. No light
indicates that no power is going
to the control.
Primary or auxiliary
switch is open
control
Set the
Jumper terminals; if burner
starts, switch is faulty, replace
control.
Open circuit between disconnect switch and limit control
Trace wiring and repair or replace it.
Low line voltage or power failure
Call the power company.
Place trouble light between the
orange and white leads. No light
indicates faulty control.
Defective
Replace the control.
Place the trouble light between
the black and white leads to the
burner motor. No light indicates
that no power is getting to the
motor.
Blown fuse
Replace the fuse.
Binding burner blower wheel
Sized fuel pump
Turn off power and rotate the
blower wheel by hand. If seized,
free the wheel or replace the
fuel pump.
Defective
Replace the motor.
internal control circuit
Burner
Place trouble light between the
black and white leads to the
blower motor. Light indicates
power to the motor and burner
fault.
Page 19
burner motor
Source
Oil Supply
Procedure
No oil in tank
Fill tank.
Coat dip stick with litmus paste
and insert into bottom of tank.
Water in oil tank
If water depth exceeds
pump or drain water.
Listen for pump whine.
Tank shut-off valve closed
Open valve.
Oil line filter is plugged
Replace filter cartridges.
Kinks or restriction
Repair or replace oil line.
in oil line
Plugged fuel pump strainer
Oil Filters & Oil Line
Open bleed valve or gauge port.
Start the burner. No oil or milky
oil indicates loss or prime.
Install pressure gauge on pump
and read pressure. Should not
be less than 140 psi.
Disconnect ignition leads. Observe the oil spray (gun assembly must be removed from unit).
Inspect the nozzle for plugged
orifice or carbon build-up around
orifice.
Clean strainer or replace pump.
Locate and correct leak.
Tighten all connections.
Pump is partially or completely
frozen. No pressure and the
motor locks out on overload.
Replace pump.
Coupling disengaged
- no pressure
Re-engage
or broken
too low
or replace coupling.
Adjust to 100 psi.
Nozzle orifice plugged
Nozzle strainer
Replace nozzle with the same
size, spray angle, and spray
type.
plugged
Poor or off center spray
Fouled or shorted
electrodes
Clean electrode
Dirty electrodes
Improper electrode
Remove gun assembly and inspect electrodes and leads.
Improper
tips
tips
gap spacing
position of electrode
Burner Motor
Connect ignition leads to the
transformer. Start burner and observe spark. Check line voltage
to transformer primary.
Motor does not come up to
speed and trips out on overload.
Turn off power and rotate blower
wheel by hand to check for binding or excessive drag.
Clean electrode tips and reset
the gap to 5/32 inches and correctly position tips.
Bad buss bar connection
Retension
Cracked
or chipped insulators
Replace electrode.
Cracked
tors
or burned lead insula-
Burned out transformer
and realign.
Replace electrode
leads.
Check voltage at power source.
Correct cause of voltage drop
or call the power company.
Low line voltage
Ignition
Transformer
leads.
and leads
Eroded electrode
Ignition Electrodes
1 inch,
Air leak in oil supply line
Fuel pressure
Nozzle
Correction
Check tank gauge or use dip
stick.
Listen for pump whine.
Oil Pump
Causes
wind-
ings.
Replace the transformer.
No spark or weak spark
Properly ground the transformer
case.
Low line voltage
Check voltage at power source.
Correct cause of voltage drop
or the call power company.
Pump or blower overloading
motor
Correct cause of overloading.
Faulty motor
Replace motor.
Page 20
Source
Procedure
Causes
Unbalanced
If burner continues to run,
this may be
due to poor
fire. Inspect
fire.
Poor Fire
Flame Detector
After burner
fires, immediately jumper
across flame
detector terminals at the primary control.
If burner locks
out on safety,
fault is in the
primary control.
Primary Control
Source
If fire is good,
fault is in the
flame detector.
Check detector circuit.
Flame Detector
Oil Supply
After burner
fires, immediately jumper
across flame
detector terminals at the primary control,
If fire is good,
fault is in the
flame detector.
Check detector circuit.
If burner loses
flame (does
not lock out on
safety), fault is
in the fuel system.
Listen for pump whine
Replace nozzle
Reduce combustion
combustion.
Too little air - - long dirty fire
Increase combustion
combustion.
Excessive draft
Adjust barometric
correct draft.
Too little draft or restriction
Correct draft or remove
tion.
Dirty cad cell face
Clean cad cell face.
Faulty cad cell - exceeds
hms
Loose or defective
wires
15000
cad cell
Primary control circuit defective
Causes
Unbalanced
Poor Fire
fire
Too much air - -lean short fire
Procedure
If burner continues to run
(does not lock
out of safety),
fault may be
due to poor
fire. Inspect
fire.
Correction
air - check
air - check
damper for
restric-
Replace cad cell.
Secure connections or replace
cad cell holder and wire leads.
Replace primary control.
Correction
fire
Replace nozzle
Too much air - - lean short fire
Reduce combustion
combustion.
Too little air - - long dirty fire
Increase combustion
combustion.
Excessive draft
Adjust barometric
correct d raft.
Too little draft or restriction
Correct draft or remove
tion.
Dirty CAD cell face
Clean CAD cell face.
Faulty CAD cell - - exceeds
15000 h p
Replace CAD cell.
Loose or defective
wires
Secure connections or replace
cad cell holder and wire leads.
cad cell
air - check
air - check
damper for
restric-
Pump loses prime - air slug
Prime pump at bleed port
Pump loses prime - air leak in
supply line
Check supply line for loose connections and tighten fittings.
Water slug in line
Check oil tank for water (over 1
inch) pump or drain out water.
Partially plugged nozzle or
nozzle strainer
Replace nozzle.
Restriction
Clear restriction.
in oil line
Plugged fuel pump strainer
Clean strainer or replace pump.
Cold oil - outdoor tank
Change to number
Page 21
1 oil.
Source
Procedure
Causes
Heat anticipator
Thermostat
Limit Control
Check thermostat.
Connect voltmeter between line
voltage connections
to primary
control (black & white leads). If
burner cycles due to power interruption, it is cycling on limit.
Vibration
Source
If voltage fluctuates, fault is in the
power source. Recheck voltage
at the power source.
Thermostat
Disconnect
thermostat
wires at the primary control.
Primary control
If burner does
not turn off,
fault is in the
primary control.
Correct heat anticipator
Shield thermostat
relocate.
Dirty furnace
Clean or replace filter.
air filters
setting.
Correct source of vibration.
Thermostat in the path of a
warm air draft
from draft or
Burner running too slow
Increase blower speed to maintain proper temp. rise.
Blower motor seized or burned
out
Replace motor.
Blower bearings
Replace bearings
seized
and shaft.
Blower wheel dirty
Clean blower wheel.
Blower wheel in backward
Reverse blower wheel.
Wrong motor rotation
Replace with properly
wheel.
Restrictions
air system
Correct cause of restriction.
in return or supply
limit control set too
Reset limit to maximum
setting.
rotating
stop
Loose wiring connection
Locate and secure connection.
Low or fluctuating
Call power company.
Procedure
If burner turns
off, fault is in
the thermostat
circuit.
set too low
at thermostat
Adjustable
low
Power
Correction
line voltage
Causes
Correction
Shorted or welded thermostat
contacts
Repair or replace the thermostat.
Stuck thermostat
Clear obstruction
thermostat.
Thermostat
bimetal
not level
Shorted thermostat
or replace
Level thermostat.
wires
Repair short or replace wires.
Thermostat
out of calibration
Replace thermostat.
Thermostat
in cold draft
Correct draft or relocate the
thermostat.
Defective
Page 22
primary control
Replace the defective
control.
primary
Source
Procedure
Causes
Too much combustion
Low CO 2 less
than 10%.
Correction
air
Reduce combustion
air.
Air leaks into heat exchanger
around inspection door, etc.
Correct cause of air leak.
Excessive
Adjust barometric draft control for correct draft.
Incorrect
ment
draft
burner head adjust-
Correct burner head setting.
Clean heat exchanger.
Dirty or plugged heat exchanger
Combustion
Check burner
combustion for
CO2, stack temperature, and
smoke
High smoke
reading more
than a trace.
High stack temperature is
more than
550"F Net.
Readjust
burner.
Insufficient draft
Increase
d raft.
Incorrect burner head adjustment
Correct burner setting.
Too little combustion air
Increase
combustion
Too little blower air
Increase
maintain
blower speed to
proper temp. rise.
Blower belt too loose (if
equipped)
Tighten blower belt.
Dirty or plugged heat exchanger
Clean heat exchanger.
Dirty blower wheel
Clean blower wheel.
Dirty furnace
Clean or replace filter.
Restricted
dampers
Oil Pressure
Inspect fire and check
oil pressure.
air filters
or closed registers
or
Readjust
ers.
registers or damp-
Partially plugged or defective
nozzle
Replace
nozzle.
Oil pressure is too low: less
than 100 psi.
Increase
100psi.
oil pressure
Page 23
air.
top
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