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

'_ 2002 Lennox industries inc.

Dallas, Texas, USA

INSTALLATION

INSTRUCTIONS

OF23 SERIES UNITS

OIL UNITS _-_--_ Technical

504,627M

38152A060 ,LLL_ Publications

01/04 Lithe U.S.A.

Supersedes 04/02

Front

Flue Model

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

WARNING

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

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

OF23 Unit Dimensions .......................... 2

OF23 Start-Up & Performance Check List ....... 2

OF23 Unit Parts Arrangement .................... 3

OF23 Oil AFII Burner Parts Arrangement .......... 4

Requirements ................................. 4

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

Unit Adjustments .............................. 5

Venting ...................................... 6

Flue Connect ions ............................ 11

Supply & Return Air Plenums .................... 11

Oil Supply Lines Sizing ...................... 11

Connect Oil Supply Line and Filter ............. 13

Leak Check ................................ 13

Electrical Wiring .............................. 12

Start-Up & Adjustment ......................... 15

Service ..................................... 16

Troubleshooting .............................. 17

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

OF23 oil furnaces. In Canada, refer to CSA B139 for rec-

ommended installation procedures, Consult authorities

who have jurisdiction before installation.

A WARNING

A, CAUTION

,A, CAUTION

1- Assembled oil furnace

1- Barometric draft control

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 Page 1

504,627M

IIIHIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII

1-1/2

(38)

3/4 3/4 /

(19) f (19) f

3-1/4 &I

G -IP.-(83_'_-_ F _1

3/4 3/4 A

(19) /(19) /

TOP VIEW

FLUE CONNECTION

OF23Q314-1051120R,

OF23Q5-140/154R

OF23Q5-175/210R

I_ C _

AIR_]TF LOW AIR t FLOW

i i i iI

FLUE CONNECTION ""_I C_

OF23Q3/4-105/140 &

OF23Q5-140/154 I

(On Heat Exchanger)

ELECTRICAL INLETS _O

(Right Side Only)

,4,

OIL PIPING INLET/ _ -

(Both Sides) |

1 (25)

SIDE VIEW

TOP FLUE

/OUTLET

SIDE

FLUE OUTLET

CENTERING HOLE

(Field Fabricate

/Either Side)

OPT. OUTDOOR

COMBUSTION

AIR INLET

CENTERING HOLE

(Field Fabricate

Right Side only)

6-1/2

(165)

.... (_)

,, 1

FRONT VIEW

Model No. in. mm in.

OF23Q3/4-105/120 19-1/2 4959 37

OF23Q3/4-105/120R 19-1/2 495 37

OF23Q5-140/154 22-1/2 572 37

OF23Q5-140/154R 22-1/2 572 37

OF23Q5-175/210R 24

B C D

mm in. mm in. mm

940 52-1/2 1334 27 686

610 39-1/4 997 55 1397 29 737

E x F (Supply)

in. mm

18 x 21 457 x 533

21 x 21 533 x 533

22-1/2 x 23-1/8 572 x 587

E x G (Return)

in. mm

18 x 16 457 x 406

21 x 16 533 x406

22-1/2 x 16-1/2 572 x 419

i!i!i!ialFiii iii3 ii ii ......

Job Name

Job Location

Installer

Unit Model No.

HEATING SECTION

Electrical Connections Tight? 13

Supply Voltage Blower Motor Amps

Blower Motor H.P.

Blower Motor Lubrication O.K.? []

Piping Connections Tight? [] All Valves Open? []

Burner Model No. Serial Number

Oil Pump Pressure [recommended minimum 140 psi]

Job No. Date

City State

Serial No. Serviceman

PROPER DRAFT

Draft Reading (recommended .03-.04 inches w.c.)

% CO 2 (recommended 12%)

Flue Connections Tight? []

• Fan Control Setting (maximum 130 ° F)

(55°C)

Fan Control Cutout Temperature Rise

Filter Clean & Secure? [] Vent Clear? []

THERMOSTAT

Calibrated?[] Heat Anticipator Properly Set? [] Level? []

Page 2

flue opening

filter

clean-out port

limit switch

indoor blower

control box

with fan control

board

observation port

heat exchanger

Beckett_ _,AFII Burner clean-out

(Shown) port

Figure 1

FLANGE AIR TUBE ELECTRONICIGNITION PRIMARY 4X4

GASKET SCREWS TRANSFORMER IGNITOR CONTROL BOX

FLANGE REARACCESS X

DOOR GASKETRETAINING AIR TUBE

ASSY FOR

CLIP FB HEADS

1/4"HEX X

HEAD SCREW

DOORASSY

NUT

INSULATOR

NOZZLE

ADAPTER

NOZZLE LINE

ELECTRODE HEAD /

ASSY. ELECTRODE

ASSY

FUELPUMP

MOTOR BLOWER

WHEEL

Figure 2

VALVE

INLET

AIR SCOOP

Page 3

IWARNING I

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.

Air for combustion and ventilation must conform to stan-

dards outlined in section 140 dNFPA No. 31 or, in Canada,

CSA Standard B139. When installing OF23 units in con-

fined 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.

AIMPORTANT

Table 1

Combustion Air Opening Dimensions

Combustion Air Opening

Model No. Dimensions (2 required)

O23-105/120 10" X 20" (254 mm X 508 mm)

O23-105R/120R

O23-140/154 11" X 22" (279 mm X 559 mm)

023-140R/154R

O23-175R/210R 20" X 40" (508 mm X 1016 mm)

O23-175R/210R

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

All Unit Sizes

Clearances 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** 9 (229)

(measured from above)

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 prece-

dence.

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

Thecompactdesignof thisfurnacemakesit idealfora

basementor utilityroominstallation.Choosea central

locationfor thefurnacesothatsupplyairductsapproxi-

matelythesamelength.Thiswillalloweachroomto re-

ceivetheproperamountof heat.Thefurnaceshouldbe

placedsothattheflueconnectiontothechimneywillbeof

minimumlengthandhaveaminimumnumberofelbows.

1- Setthe unitin desiredlocationkeepingin mindthe

clearanceslistedintable2.Alsokeepinmindoilsup-

ply connections,electricalsupply,flueconnections

andsufficientclearancefor installingandservicing

unit.

2- Leveltheunitfromsidetosideandfromfronttorear.If

thefurnaceis not level,placefireproofwedgesor

shimsbetweenthe lowsideof thefurnaceandthe

floor.Makesuretheweightofthefurnaceisdistributed

evenlyonallfourcorners.Strainonsidesof cabinet

causingcrackingand poppingnoisesmayoccurif

weightoffurnaceisnotevenlydistributed.

Neitherthenozzlesettingnortheairadjustmentsarefacto-

ry set.Thefurnaceisfiretestedandthelimitcontrolis

checkedtomakesureitfunctionsproperly;nofactoryset-

tingsaremade.Duringinstallation,thefurnacemustbe

"setup,"Theinstallingdealer/contractormusthaveand

usepropertestequipmentinordertocorrectlysetuptheoil

furnace,Propertestingequipmentis requiredto ensure

correctoperationoftheunit.Theuseoftestequipmentis

nowmorecriticalthaneverduetotightertolerancesneed-

edto keepthefurnaceoperatingefficiently.

Amongthetestequipmentfor anoilfurnace,theproper

combustiontestkitshouldcontainthefollowing:

• Draftgauge

• CO2or02Analyzer

• Smoketester

• Pressuregauge

• Hightemperaturethermometer

• Oilvacuumgauge

• BeckettT-500gauge

• Knowledgeofpropertestequipmentoperation

CAUTION

Nozzle Adjustment

Proper adjustment of the nozzle assembly is critical because

alignment may have changed during shipping. Before the fur-

nace 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 re-

moving the burner assembly from the vestibule. By loosen-

ing the nuts and by turning the whole burner assembly coun-

terclockwise (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.

Next, rotate burner counter-

clockwise 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 illustra-

tion 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 Oil Burner Nozzle Adjustment

Burner must be removed from

furnace for thisprocedure. 2 1

gauge

To Adjust Nozzle

1-Loosen screw.

2-Slide entire nozzle/electrode assembly back and forth until

nozzle just touches gauge.

Figure 4

WARNING

CAUTION

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

liner 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 accord-

ing to the requirements of the National Fire Protection Asso-

ciation. The smallest dimensions dthe chimney should be

at least equal to the diameter dthe furnace vent connector.

Make sure the chimney will produce a steady draft sufficient

to remove all the products of combustion from the furnace. A

draft of at least ,04" w,c, (9,9 Pa) is required during burner

operation,

1 - Local building codes may have more stringent 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 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,

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 fig-

ure 5,

Wall Thimble

combustible

wall vent pipe

Figure 5

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 6.

Page 6

Front Flue /Masonry Chimney

barometric

control* liner

in either location

clean out

masonry

chimney

clean out

Rear Flue /Masonry Chimney

barometric

control* _ _'

(in either location) - -_S .......... I -- '

lean o _m,m, asonry

ichimney

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

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

Figure 6

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 7,

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,

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.

Front Flue /Factory-Built Chimney

barometric

control*

in either location

\factory

_built

chimney

drain for

condensate

Rear Flue /Factory-Built Chimney

barometric

control*

(in either location

i o

factory

Jc built

himney

drain for

condensate

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

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

Figure 7

Page 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 pro-

vided 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 after

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

Ak 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.

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 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 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),

Equipment In Confined Space

rom Inside

Chimney or

Oil Vent

Oil

Furnace

Openings

(To Adjacent Room)

i ii ii ii ii ii ii ii ii i

'"1 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

Page 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 10). When communi-

cating 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 in-

put rating of all equipment in the enclosure (See figure 11).

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

(For unheate( Air

crawt

rrrm

r1r

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.

Chimney

or Oil

Vent

Figure 9

Equipment In Confined Space

All Air From Outside

(All Air Through Ventilated Attic)

Ventilation Louvers

• (Each End Of Attic)

Oil Inlet Air

(Ends 12"

Furnace Above BoSom)

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

Equipment In Confined Space

AII Air From Outside

Or Oil

Vent Heater

1 1 I I I I I 1 1 I I I

I 1 1 I I I I 1 1 1 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 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 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 equip-

ment in the enclosure.

Figure 11

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.

CAUTION

A CAUTION

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 facili-

tate 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

combustionair,removethethreescrewswhichattachthe

inletairscooptotheburnerandinsert4"(102mm)directair

intakepiping.

Theuseofa barometricreliefplacedintheintakepipeis

recommendedwhenoutdoorcombustionair is directly

connectedtotheburner.Thiswillallowconfinedspaceair

tobeusedascombustionairintheeventthattheopening

totheoutdoorairbecomesblocked.Useabarometricrelief

intheintaketoreducethechanceofsooting.

CAUTION

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

system.

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 its previous condi-

tion of use.

7- If improper venting is observed during any of the

above tests, the common venting system must be cor-

rected.

Horizontal Venting

The OF23 is approved for horizontal venting with the fol-

lowing mechanical vent systems:

Tjernlund (sideshot) #SSlC (Cat. #35E08) or Field Con-

trols #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.

The barometric draft control must be installed within 18

inches of the furnace flue outlet. See figure 12 for baromet-

ric draft control location.

Do not common vent with any other appliance when using

sidewall vent system.

The maximum equivalent length of pipe is 70 equivalent

feet. A 90_ elbow equals 6 ft. Minimum length is 15 equiva-

lent 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 Venting

bar°_;tlr) c "__::-- control for

[ZZ horizontal

venting

Rear Flue /Horizontal Venting

barometric

control*

*Barometric control must be installed in the horizontal venting

system and located within 18" of flue outlet of furnace.

Figure 12

Page 10

IMPORTANT

Radiation Shield Installation

combustible

material

unit

cabinet

(25 mm)

min

12" (305 mm)

min

7" (178 mm)

noncombustible

spacers radiation shields

(see note 1)

see note 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 ram),

NOTE 3-Radiation shields should extend from the top of the unit to

the top of the flue pipe.

Figure 13

For front flue models, the enclosed exhaust pipe ring may

be used for pipe to exit the left or right side of cabinet. Cen-

ter line marks are provided in cabinet.

Use 24 gauge or heavier galvanized smoke pipe and fit-

tings to connect furnace to vent. Connect flue pipe to chim-

ney 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 ap-

pliances 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 connectors. Install the barometric draft control (pro-

vided) 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.

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

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-

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

inches dthe furnace flue outlet. Attach the provided finish-

ing plate to cover rough edges.

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.

Ensure that the restrictions of the piping system, plus any

lift involved, do not exceed the capability of the oil pump.

Use the following guidelines when determining whether to

use a single-or two-stage oil pump.

One-Pipe System

When using a one-pipe system with the oil tank above the

burner and a vacuum of 6" (152 mm) Hg or less, a single-

stage 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 condi-

tion.

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.

To determine the length of the run for piping, refer to table 2

Page 11

r_ Oil Piping

IIOne-Pipe System

alrv LII

fill / dl I_ fuel

,oum Aux

pipe o_L P: P Filter

t-)_r

O O _'-'

IIT;,kI ..... 18ft<24m)

o ° ol II / _nut-o_ _ ,'

o_-I I1 _ Valve ] Maximum

o;;I It_ ,_ I One Pipe Lift

o_ .........

ITlllT--- t

xql !') Uu

x_,o ;,o;,o;,o;,o;,o;,o;,o;,

Figure 14

Table 2

One-Pipe Oil Sizing

Line Length Pipe Diameter (OD Tubing)

0-50' (15 m) 3/8" (10 mm)

51-100' (15 m) 1/2" (12 mm)

Two-Pipe System

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.

Oil Piping

Two-pipe System fuel

Fill Air Vent

Pipe _, r] pump Aux

\ "_11 _ Filter

I eturn

/_IF_J I p,pe_,,__ _

•:,)-_ /

__ J_-v_7_L_._- - _

_ _-1o2 mintJ

outside tank fuel pump above bottom of tank

Figure 15

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.

_k IMPORTANT

Two-Pi

Table 3

)e Maximum Pipe Length (H + R)

3450 RPM- 3 GPH (11.4 LPH)

3/8" (10 mm) OD 1/2" (12 mm) OD

Lift "H" Tubing Tubing

Single Two Single Two

Stage Stage Stage Stage

84' 93' 100' 100'

(25.6 m) (28.3 m) (30.5 m) (30.5 m)

73' 85' 100' 100'

(22.3 m) (25.9 m) (30.5 m) (30.5 m)

63' 77' 100' 100'

(19.2 m) (23.5 m) (30.5 m) (30.5 m)

52' 69' 100' 100'

(15.8 m) (21.0 m) (30.5 m) (30.5 m)

42' 60' 100' 100'

(12.8 m) (18.3 m) (30.5 m) (30.5 m)

31' 52' 100' 100'

(9.4 m) (15.9 m) (30.5 m) (30.5 m)

21' 44' 83' 100'

(6.4 m) (13.4 m) (25.3 m) (30.5 m)

36' 41' 100'

(11.0 m) (12.5 m) (30.5 m)

27' 100'

(8.2 m) (30.5 m)

76'

(0.0 m)

(0.6 m)

(1.2m)

(1.8m)

(2.4m)

10'

(3.0m)

12'

(3.7m)

14'

(4.3m)

16'

(4.9m)

18'

(5.5m) (23.2 m)

One-Pipe Systems

A CAUTION

The burner is shipped with fuel pump set for one-pipe op-

eration. For one-pipe systems, the oil supply pipe is con-

nected 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- Connecttheinletpipetothepumpinlet,Starttheburner.

2 - Arrangetheprimaryburnercontrolforcontinuousop-

erationduringpurging,Seefigure14,

3- Turnthebleedvalveoneturncounterclockwise,

4 - Bleedtheunituntilallairbubblesdisappear.

NOTE -Hurried bleeding will prevent the unit from op-

erating properly.

5 - Tighten the bleed valve securely,

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 accord-

ing 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,

NOTE- If using an outside tank in cold climates a number

one fuel or an oil treatment is strongly recommended.

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,

4 - The return pipe must terminate 3" to 4" above the sup-

ply 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.

Table 4

Oil Filters (All Models)

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

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

nections (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.

All wiring must conform to the National Electric Code

(NEC), or Canadian Electric Code (CEC) and any local

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 ac-

cording to the wiring diagram sticker provided on unit,

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 en-

ergized when the blower is in operation.

Page 13

Fan Control Board

thermostat _[]

terminal strip DEL^¥_F

SELECT

° o

Figure 16

Typical OF23 Wiring Diagram

120 VOLT

POtL_ _Y

JLENCTION BOX -- FACTORY WIRING

LINE VOLTAGE-FIELD

_LOW VOLTAGE-FIELD TI

TRANSFORMER

CIRCULATING

S_A4RT FAN

CAPACITOR

AUX MAIN

LIMIT LIMIT

(IF USED) SlO

s2'rY I _?

RI G

TH_MOSTATI(_ (p _) (_

NG_s L LI'L J J

:H Ii°i°i l]- Ij

l l-t-- //

_; '_/

_-s_ NOTEZ _E NOTES,_s I I

RED-GEE NOTE 2

ow,_,, Y cF{'_-_....._

_ _ ._, FOR HEAT ONLY(TWO WIRE)

_. _._ z_v.z THERMOSTAT.CONNECT R & W.

I I.'F: c_NGING

jJu -L_____ ONIT

YLW |

r...._! YLW [-'" IF,

5AMP

RED

R7184S

PRIMARY

CONTROL

0TZ

Wfl,tITE

ORANGE

I.T _TO_ BLUE

_" IONITOR_

I I_T *HT

PUMP VALVE

DELAY OFF DIP SWITCH SETTINGS

I BO SEC 90 REC 120 GEC I50 GEC

I. IF ANY WIRE IN THIS APPLIANCE IS REPLACED,

IT MUST B_ REPLACED WITH LIKE SIZE,HATING

IKSULATION THICKNESS AND TERMINATIOn4

2. IF HONIZONTAL APPLICATION IS USED,

PURPLE IS WIRE COLON DESIGNATION.

5. THERMOSTAT HEAT ANTICIPATO_ SETTING--O. lAMP

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.

OTI

INTERRUPT

0R26

0 CELL, CAD

0LZ

0 u

______R_o

L_N_OX® HEATING UNITS-OIL

02302-70 0F2305-140115_ 0HR2305- I(R/120

02503-1051120 OF2303-105/I2OR 0HR2305-1401154

02305- 140/154 0F2305-140/154R

0F2303- 105/120 01=2305-175/210

OIL HEAT-SECT tON

,q;;::;;.

N=I Form No.

534,563W

_O_S I.•*_*= I_•trl*• la,_. Lithe U.S*A.

Figure 17

Page 14

Typical OF23 Wiring Diagram

A ON 140,154 CSA UNTTS ONLY

_TO CHANGE MOTOR SPEED TAP AND

FOR BLOWER SPEED GELECIION

PROCEDURE,REFER TO INSTALLATION

INSTRUCTION, _

A SWITCH OPENS WHEN FLAME IS SIGHTED F22

A $21 USED ON OHR23 SERIES 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.

NOTEIF ANY WIRE IN THIS APPLIANCE IS REPLACED,

IT MUST BE REPLACED WITH WIRE OF LIKE SIZE,

RATING,INSULATION ¸THICKNESS AND TERMINATION

SET THERMOSTAT HEAl ¸¸ ANTICIPATION

FOR 023/OF23/OHR23 UNITS.. 0,1 AMP

ORANGE

SS H[R

KE25-1

WHILE

WHITE :s

i:iJ

24V POWER

UNIIS

ILIMIT

P94

_p ECON

BLOWER (G)

HEAT I (WI)

K56

DELAY ON I

DELAY OFF I

LzAv COMMON (C/

SLOWER SPEED CHART

FACTORY CONNECTED MOTOR

SPEED TAPS SPEEDS

AVAILABLE

ALL 2

BLOWER SPEED SELEC]ION

HI LO

SPEED IBK YLW BLUE RED

TAPS I

[

EOUIPMENT

GROUND

IMPORTANT-TO PREVENT MOTOR

BURNOUT,NEVER CONNECT MORE

THAN ONE MOTOR LEAD TO ANY

ONE CONNECTION.

L_ IF HEATING AND LOW SPEED

ARE TG BE GAME,CGNNECT

JUMPER BETWEEN $68-1 AND

AI5 H(AS SHOWN).REMOVE

UNUSED MOTOR SPEED WIRE.

ILINE VOLTAGE FIELD INSTALLED

.... CLASS II VOLTAGE FIELD WIRING

I._IIRUA® HEARING UNIIS OIL

02302=70 0F2305 105/120R

02303 105/E 20 DF2505- ] _-0/I!:i4R

02505 140/E 54 OF 2505 = 175/210

0F2505- 105/120 OHR25Q5 105/120

0F2505-140/154 O_ R2505 = 140/154

N_w Form No,

554,564W

41969005

(_)zoo_Le_ _d_ fr_s la_ Lfho U.S. A

Figure 18

Page 15

Beforestartingunit,makesuretheoiltankisadequately

filledwithcleanNo,1or 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 unit.

CAUTION

Ai, CAUTION

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

cal 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,

CAUTION

5- If burner fails to light again, refer to the troubleshooting

section in this manual,

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

readings, subtract the readings. The difference in tempera-

tures in the supply and return air plenums should approxi-

mate 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 nozzle size, input output head temp

Unit spray, angle, & rating rating rise F°

pattern BTU/HR BTU/HR

-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

*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 sec-

onds.

Delay Off Switch Settings

60 sec 90 sec 120 sec 150 sec

Figure 19

E- Burner Adjustment

The following instructions are essential to the proper op-

eration 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. Gen-

erally a 1/4" hole will need to be drilled for the draft gauge to

be inserted into the vent connector.

Page 16

A minimumof 0,03draftmustbeestablishedwithoutthe

burnerinoperation,Withtheburnerinoperation,thedraft

shouldbe0.04to 0.05.ThisisVERYcriticalto theflame

retentionheadburners.

Oilfurnaceinstallationsalsorequirecarefulinspectionto

makesurethechimneyisingoodshapeandcanaccom-

modatethe productsof combustion.Thetemperaturein

theunconditionedspacewillalsoaffectthedraftif longvent

connectorsareallowedtogettoocold,

2- OverfireDraft

Thistestshouldbetakenwiththeburnerinoperation.Re-

movethescrewfromthecenteroftheinspectiondoor.In-

sertyourdraftgaugeintothehole,

A readingoftheoverfiredraftshouldbe0,02lessthanthe

readingfoundintheventconnector.Ifapositivereadingis

seenatthispoint,thecombustionfanispumpingtoomuch

airintotheheatexchanger,Makethenecessaryadjust-

mentsattheairadjustmentdial,

3- SmokeTest

Thesmoketestshouldbetakenattheholedrilledinstep1,

Usingasmoketestgunadjusttheairinletshuttersothat

youwillhavejustatraceofsmoke.Somewherebetween0

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 clima-

tic 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%.

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,

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 pres-

sure reading taken at the breach. You may need to

increase the stack draft by adjusting the barometric draft

control,

7 - Stack Temperature

Take a stack temperature reading in the vent pipe, Subtract

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 fur-

nace 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 prop-

er 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 prop-

er furnace operation. Use warm water and a mild de-

tergent. Replace filter when dry. Permanent filters

supplied with OF23 furnaces do not require oiling after

cleaning. Examine filter label for any for special in-

structions that may apply,

B - Blower

Blower motor is pre-lubricated and sealed for extended op-

eration. No further lubrication is required. Disconnect pow-

er 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 at-

tachment, vacuum out loose debris,

4- Remove the locking screw and cap from the observa-

tion tube and with the spiral wire brush, reach upward

toward the rear of the heat exchanger to clean out the

crossover tube,

CAUTION

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.

NOTE -A heat exchanger clean-out kit ABRSH380

(35K09) is available from Lennox.

Page 17

Burnerfailureorimproperoperationcanresultfromanum-

berofdifferentcauses,

Oftenthecausecanbepinpointedbyobservingthediffer-

enttypesoffailureorbytheprocessofelimination.Thefol-

lowingtroubleshootingchartslist somefailures,causes

anda sequenceof stepsto isolatethe pointof failure.

Checkthesimplestandmostobviousitemsbeforeprog-

ressingtootheritems.

Action

Thermostat calls for heat.

(W terminal is energized.)

Thermostat ends call for heat.

(W terminal is de-energized.)

Burner fails to light.

Established flame fails.

Thermostat begins call for cool.

(G and Y terminals are energized.)

Thermostat ends call for cool.

(G and Y terminals are de-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.

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-ener-

gized,

ST9103A returns to standby mode (oil primary control and circulating fan are off).

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 through the selected delay off period.

Burner motor is de-energized and oil primary control goes into recycle mode.

If selected heat fan off delay is longer than the recycle delay timing, the heat fan contin-

ues to run through the next trial for ignition.

Circulating fan is energized at the cool speed.

Cooling compressor turns on immediately.

Circulating fan and cooling compressor turn off immediately.

Thermostat begins call for fan. Circulating fan is energized immediately at cool speed.

(G terminal is energized.) ST9103A may be factory-configured to operate heat speed in this mode.

Thermostat ends call for fan. Circulating fan is de-energized.

(G terminal is de-energized.)

Limit switch string opens.

Limit switch string closes.

Oil primary control shut off the burner.

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.

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 circu- If fan operation is required by a call for heat, cool, or fan, the ST9103A switches off the

lating fan speed tap.) continuous fan speed tap before energizing the other fan speed.

Electronic air cleaner is connected. Electronic air cleaner (EAC) connections are energized when the heat or cool speed of

(Optional connectors are available for 120 Vac elec- the circulating fan is energized. EAC connections are not energized when the optional

tronic air cleaner.) continuous fan terminal is energized.

Humidity control is connected. Humidifier connections are energized when the burner motor is energized.

(Optional connectors are available for 120 Vac humidi-

fier.)

Page 18

Source

Thermostat

Safety Overloads

Power

Thermostat

CAD Cell

Primary Control

Burner

Procedure Causes

Thermostat in OFF or COOL

Check thermostat settings.

Check burner motor, primary

safety control, & auxiliary limit

switch.

Check furnace disconnect

switch & main disconnect.

Touch jumper wire across ther-

mostat terminals on primary

control. If burner starts, then

fault is in the thermostat circuit.

Disconnect the flame detector

wires at the primary control. If

the burner starts, fault is in the

detector circuit.

Place trouble light between the

black and white leads. No light

indicates that no power is going

to the control.

Place trouble light between the

orange and white leads. No light

indicates faulty 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.

Place trouble light between the

black and white leads to the

blower motor. Light indicates

power to the motor and burner

fault.

Thermostat is set too low

Burner motor overload tripped

Primary control tripped on safe-

Auxiliary limit switch tripped on

safety

Open switch

Blown fuse or tripped circuit

breaker

Broken or loose thermostat

wires

Loose thermostat screw con-

nection

Dirty thermostat contacts

Thermostat not level

Faulty thermostat

Flame detector leads are

shorted

Flame detector exposed to light

short circuit in the flame detec-

tor

Primary or auxiliary control

switch is open

Open circuit between discon-

nect switch and limit control

Low line voltage or power fail-

ure

Defective internal control circuit

Blown fuse

Correction

Switch to HEAT.

Turn thermostat to higher tem-

perature.

Push reset button pump motor.

Reset primary control.

Reset auxiliary limit.

Close switch.

Replace fuse or reset circuit

breaker.

Repair or replace wires.

Tighten connection.

Clean contacts.

Level thermostat.

Replace thermostat.

Separate leads.

Seal off false source of light.

Replace detector.

Check adjustment. Set the

maximum setting.

Jumper terminals; if burner

starts, switch is faulty, replace

control.

Trace wiring and repair or re-

place it.

Call the power company.

Replace the control.

Replace the fuse.

Binding burner blower wheel

Sized fuel pump

Defective burner motor

Turn off power and rotate the

blower wheel by hand. If seized,

free the wheel or replace the

fuel pump.

Replace the motor.

Page 19

Source

Oil Supply

Oil Filters & Oil Line

Oil Pump

Nozzle

Ignition Electrodes

Ignition

Transformer

Burner Motor

Procedure

Check tank gauge or use dip

stick.

Coat dip stick with litmus paste

and insert into bottom of tank.

Listen for pump whine.

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. Ob-

serve the oil spray (gun assem-

bly must be removed from unit).

Inspect the nozzle for plugged

orifice or carbon build-up around

orifice.

Remove gun assembly and in-

spect electrodes and leads.

Connect ignition leads to the

transformer. Start burner and ob-

serve 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 bind-

ing or excessive drag.

Causes

No oil in tank

Water in oil tank

Tank shut-off valve closed

Oil line filter is plugged

Kinks or restriction in oil line

Plugged fuel pump strainer

Air leak in oil supply line

Pump is partially or completely

frozen. No pressure and the

motor locks out on overload.

Correction

Fill tank.

If water depth exceeds 1 inch,

pump or drain water.

Open valve.

Replace filter cartridges.

Repair or replace oil line.

Clean strainer or replace pump.

Locate and correct leak.

Tighten all connections.

Replace pump.

Coupling disengaged or broken Re-engage or replace coupling.

- no pressure

Fuel pressure too low Adjust to 100 psi.

Nozzle orifice plugged

Nozzle strainer plugged

Poor or off center spray

Fouled or shorted electrodes

Dirty electrodes and leads

Eroded electrode tips

Improper electrode gap spacing

Improper position of electrode

tips

Bad buss bar connection

Cracked or chipped insulators

Cracked or burned lead insula-

tors

Low line voltage

Burned out transformer wind-

ings.

No spark or weak spark

Low line voltage

Pump or blower overloading

motor

Faulty motor

Replace nozzle with the same

size, spray angle, and spray

type.

Clean electrode leads.

Clean electrode tips and reset

the gap to 5/32 inches and cor-

rectly position tips.

Retension and realign.

Replace electrode.

Replace electrode leads.

Check voltage at power source.

Correct cause of voltage drop

or call the power company.

Replace the transformer.

Properly ground the transformer

case.

Check voltage at power source.

Correct cause of voltage drop

or the call power company.

Correct cause of overloading.

Replace motor.

Page 20

Source Procedure

Poor Fire

Flame Detector

Primary Control

After burner

fires, immedi-

ately jumper

across flame

detector termi-

nals at the pri-

mary control.

If burner con-

tinues to run,

this may be

due to poor

fire. Inspect

fire.

If fire is good,

fault is in the

flame detector.

Check detec-

tor circuit.

If burner locks

out on safety,

fault is in the

primary con-

trol.

Causes

Unbalanced fire

Too much air - -lean short fire

Too little air - - long dirty fire

Excessive draft

Too little draft or restriction

Dirty cad cell face

Faulty cad cell - exceeds 15000

hms

Loose or defective cad cell

wires

Primary control circuit defective

Correction

Replace nozzle

Reduce combustion air - check

combustion.

Increase combustion air - check

combustion.

Adjust barometric damper for

correct draft.

Correct draft or remove restric-

tion.

Clean cad cell face.

Replace cad cell.

Secure connections or replace

cad cell holder and wire leads.

Replace primary control.

Source Procedure

Poor Fire

Flame Detector

Oil Supply

After burner

fires, immedi-

ately jumper

across flame

detector termi-

nals at the pri-

mary control,

If burner con-

tinues to run

(does not lock

out of safety),

fault may be

due to poor

fire. Inspect

fire.

If fire is good,

fault is in the

flame detector.

Check detec-

tor circuit.

If burner loses

flame (does

not lock out on

safety), fault is

in the fuel sys-

tem.

Listen for pump whine

Causes

Unbalanced fire

Too much air - - lean short fire

Too little air - - long dirty fire

Excessive draft

Too little draft or restriction

Dirty CAD cell face

Faulty CAD cell - - exceeds

15000 h p

Loose or defective cad cell

wires

Pump loses prime - air slug

Pump loses prime - air leak in

supply line

Water slug in line

Partially plugged nozzle or

nozzle strainer

Restriction in oil line

Plugged fuel pump strainer

Cold oil - outdoor tank

Correction

Replace nozzle

Reduce combustion air - check

combustion.

Increase combustion air - check

combustion.

Adjust barometric damper for

correct d raft.

Correct draft or remove restric-

tion.

Clean CAD cell face.

Replace CAD cell.

Secure connections or replace

cad cell holder and wire leads.

Prime pump at bleed port

Check supply line for loose con-

nections and tighten fittings.

Check oil tank for water (over 1

inch) pump or drain out water.

Replace nozzle.

Clear restriction.

Clean strainer or replace pump.

Change to number 1 oil.

Page 21

Source Procedure

Thermostat

Limit Control

Power

Check thermostat.

Connect voltmeter between line

voltage connections to primary

control (black & white leads). If

burner cycles due to power inter-

ruption, it is cycling on limit.

If voltage fluctuates, fault is in the

power source. Recheck voltage

at the power source.

Causes

Heat anticipator set too low

Vibration at thermostat

Thermostat in the path of a

warm air draft

Dirty furnace air filters

Burner running too slow

Blower motor seized or burned

out

Blower bearings seized

Blower wheel dirty

Blower wheel in backward

Wrong motor rotation

Restrictions in return or supply

air system

Adjustable limit control set too

low

Loose wiring connection

Low or fluctuating line voltage

Correction

Correct heat anticipator setting.

Correct source of vibration.

Shield thermostat from draft or

relocate.

Clean or replace filter.

Increase blower speed to main-

tain proper temp. rise.

Replace motor.

Replace bearings and shaft.

Clean blower wheel.

Reverse blower wheel.

Replace with properly rotating

wheel.

Correct cause of restriction.

Reset limit to maximum stop

setting.

Locate and secure connection.

Call power company.

Source Procedure

Thermostat

Primary control

Disconnect

thermostat

wires at the pri-

mary control.

If burner turns

off, fault is in

the thermostat

circuit.

If burner does

not turn off,

fault is in the

primary control.

Causes

Shorted or welded thermostat

contacts

Stuck thermostat bimetal

Thermostat not level

Shorted thermostat wires

Thermostat out of calibration

Thermostat in cold draft

Defective primary control

Correction

Repair or replace the thermo-

stat.

Clear obstruction or replace

thermostat.

Level thermostat.

Repair short or replace wires.

Replace thermostat.

Correct draft or relocate the

thermostat.

Replace the defective primary

control.

Page 22

Source Procedure

Combustion

Oil Pressure

Check burner

combustion for

CO2, stack tem-

perature, and

smoke

Low CO 2 less

than 10%.

Causes

Too much combustion air

Air leaks into heat exchanger

around inspection door, etc.

Excessive draft

Incorrect burner head adjust-

ment

Dirty or plugged heat exchanger

High smoke Insufficient draft

reading more

than a trace. Incorrect burner head adjust-

ment

Too little combustion air

Too little blower air

High stack tem-

perature is

more than

550"F Net.

Inspect fire and check

oil pressure.

Blower belt too loose (if

equipped)

Dirty or plugged heat exchanger

Dirty blower wheel

Dirty furnace air filters

Restricted or closed registers or

dampers

Partially plugged or defective

nozzle

Oil pressure is too low: less

than 100 psi.

Correction

Reduce combustion air.

Correct cause of air leak.

Adjust barometric draft con-

trol for correct draft.

Correct burner head setting.

Clean heat exchanger.

Readjust burner.

Increase d raft.

Correct burner setting.

Increase combustion air.

Increase blower speed to

maintain proper temp. rise.

Tighten blower belt.

Clean heat exchanger.

Clean blower wheel.

Clean or replace filter.

Readjust registers or damp-

ers.

Replace nozzle.

Increase oil pressure top

100psi.

Page 23

LENNOX Furnace/Heater, Oil Manual L0806376

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