LENNOX':?2004 Lennox Industries Inc.

Dallas, Texas, USA

INSTALLATIONINSTRUCTIONS

OHR23 Series Units

OIL UNITS _ Techmcal504,628M j_ Publications38152A06106/04 Litho U.S.A.Supersedes 4/02

WARNING

Elite Series Oil Furnace .......................... 1Shipping and Packing List ........................ 1Unit Dimensions ................................. 2OHR23 Unit Parts Arrangement ................... 3Oil Burner Parts Arrangement ..................... 3Requirements ................................... 4Installation ...................................... 5Supply & Return Air Plenums ..................... 5Optional Filter Kit ................................ 5Initial Unit Adjustments .......................... 6Venting ........................................ 7Combustion and Ventilation Air .................... 8Flue Connections ............................... 11Oil Supply Lines Sizing ......................... 12Oil Supply Line & Filter Connections .............. 13Leak Check .................................... 13Electrical Wiring ................................ 14Unit Start-Up & Adjustments ..................... 15Service ....................................... 16Start-Up & Performance Checklist ................ 17Troubleshooting ................................ 18

RETAIN THESE INSTRUCTIONSFOR FUTURE REFERENCE

These instructions are intended as a general guide and donot supersede local codes in any way. Only qualified tech-nicians can install and service the Lennox Elite® Series

OHR23 oil furnaces. In Canada, refer to CSA B139 for rec-ommended installation procedures. Consult authorities

who have jurisdiction before installation.

WARNING

1- Assembled oil furnace1- Draft control

Check the components for shipping damage, If you findany damage, immediately contact the last carrier,

CAUTION

06/04

IIIIIIIIIIIIIIIIIIIIIIIIIIII1[111111111[Page 1504,628M

IIIll[llll[lllllllllllllllllllllllllllllll

Model No. A

OHR23Q3- in. 20-1/2

105/120 mm 521

OHR23Q5- in. 23-1/2

140/154 mm 597

TOP VIEW

B C D E F G H 1 I'_1 4K 53(1346)

20-1/2 18 18 18 18 3 10-1/4

521 457 457 457 457 78 280NOCKOUTS

23-1/2 21 21 21 21 4-3/4 11-3/8 ' ' ' 'c_" Suspending)597 533 533 533 533 121 289

3/4(19)

AIR14-1/2

3-1/2(89) (3_8) FLOW

_ 1_" 1_" i i I I

/,FLUE OUTLET

t' 59 (1499)

D SUPPLY

,_, AIROPENING

END VIEW

TOP VIEW

HEAT EX-CHANGERCLEAN OUT

PORTS (3) _

SPACER 1

LEGS (25) _--

AIRIFLOW

3/4 _'

-qHEAT

_EXCHANGER _CLEAN OUT

] PORTS (3)

._ BURNER !

_._ 3/4' _ 8 (19) •

C _ (203)

SUPPLY AIR OPENING

(19)

32-1/2

(826)

(1499)

,9_-- B ---_

@ @@

I I

SIDE VIEW

BURNER

FLUE OUTLET

32-1/2 (826)

Fi

/SIDEVl EW

HORIZONTAL POSITION

7fFA

RETURNAIR

_'_ _ 3/4

(19}

7'.,,. EE

L RETURN

AIR

OPTIONAL DOWNFLOW COMBUSTIBLE FLOOR BASE

FURNACE "_ SUPPLYAIR DUCT

(NotFurnished)

105/120--

16-1/4(413)140/154--

20-1/4

FLUEOUTLET

SUPPLY AIR OPENING

FRONT VIEW

105/120--

16-1/4(413)140/154--

20-1/4(514)

BURNER

OPTIONALDOWNFLOWADDITIVEBASE

Additive Base Raises Furnace3/4 in. (19 mm) Inch above Floor Level

COMBUSTIBLEFLOOR

DOWNFLOW POSITION

Page 2

CLEAN-OUT PORT FLUE OPENING

HEATEXCHANGER

BECKETT®AFIIBURNER

CLEAN-OUT PORT

CONTROL BOXWITH FAN CONTROL BOARD

INDOORBLOWER

Figure 1

FLANGE AIR TUBEGASKET SCREWS

FLANGE

RETAINING AIR TUBECLIP ASSY FOR

1/4" HEX

ELECTRONIC IGNITIONTRANSFORMER IGNITOR

REAR ACCESSDOOR GASKET

REAR ACCESSDOORASSY

MAINHOUSING

ASSYSPLINED

NUTESCUTCHEON

PLATE

PRIMARYCONTROL 4X4

BOX

TUBE

HEADINSULATOR

NOZZLEADAPTER

NOZZLE LINEELECTRODE HEAD

ASS_ELECTRODE

ASSY

FUELPUMP

MOTOR BLOWERWHEEL

PRE-MOUNTED OIL-DELAY

',i,,_V Efigure 2

INLETAIR SCOOP

Page 3

InstallationofLennoxoil-firedfurnacesmustconformwiththeNationalFireProtectionAssociationStandardfortheInstallationof OilBurningEquipment,NFPANo.31,theNationalElectricalCode,ANSI/NFPANo.70 (in theU.S.A.),CSA StandardCAN/CSA-B139(in Canada),InstallationCodeforOilBurningEquipment,theCanadianElectricalCodePart1,CSA22.1(Canada),the recom-mendationsoftheNationalEnvironmentalSystemsCon-tractorsAssociationandanystateorprovinciallawsorlo-calordinances.Authoritieshavingjurisdictionshouldbeconsultedbeforeinstallation.Suchapplicableregulationsorrequirementstakeprecedenceovergeneralinstructionsinthismanual.

Chimneysandchimneyconnectorsmustbeof thetypeandconstructionoutlinedinsection160of NFPANo.31.Air forcombustionandventilationmustconformto stan-dardsoutlinedinsection140ofNFPANo.31or,inCana-da,CSAStandardB139.WheninstallingOHR23unitsinconfinedspacessuchasutilityrooms,twocombustionairopeningsare required.Dimensionsof combustionairopeningsareshownintable1.Oneopeningshallbebelowburnerlevelandtheotheropeningshallbenomorethan6inchesfromtheroom'sceiling.Combustionairopeningsshouldprovideaminimumfreeareaone-halfsquareinchper1,000Btuperhourinput.Thiscombustionairshouldbebroughtintotheareacon-tainingthefurnacebelowthelevelofthefurnaceburner.

A, IMPORTANT

Table 1

Combustion Air Opening Dimensions

Model No. (2 openings required)

OHR23-105/120 10"X 20"

OHR23-140/154 11" X 22"

This unit is approved for clearances to combustible materi-al as listed unit rating plate and in tables 2 or3. Unit serviceand accessibility clearances take precedence over fireprotection clearances.

Table 2

Horizontal Installation Clearances

Clearances Inches (mm)

Top of Cabinet 3 (76)

*Bottom and Rear of Cabinet 1 (25)Front of Cabinet 24 (610)

Service Clearance (Front) 24 (610)

End of Supply Plenum 0 (0)

Supply Air Opening 0 (0)

Return Air Opening 0 (0)Above Horizontal Warm Air Duct

0 (0)within 3 ft, (914mm) of Furnace

Flue Pipe Horizontal 7 (178)Flue Pipe Vertical 7 (178)

*NOTE-When furnace is installed on combustible floor, 1(25 mm) spacer legs must be installed to elevate unit off ofmounting surface.

Table 3

Downflow Installation Clearances

Clearances Inches (mm)

Bottom of Plenum and Ductwork 1 (25)

Plenum Sides 1 (25)

Side of Cabinet 1 (25)

Rear of Cabinet 1 (25)

Front of Cabinet 16 (406)

Service Clearance (Front) 24 (610)

Flue Pipe Horizontal 1 (25)

Flue Pipe Vertical 7 (178)

Return Air Opening 0 (0)*Floor *Combustible

*NOTE-Clearance for installation on combustible floor if op-tional additive base is installed between the furnace andcombustible floor. Not required in add-on coiling applications.

NOTE - Downflow Appfication Only -- For installation oncombustible floors, appliance shall not be installed directlyon carpeting, tile or other combustible material other thanwood flooring. When installed on wood flooring, the addi-tive base must be used. See Unit Dimension illustration.

NOTE - Unit must be adjusted to obtain a temperature risewithin the range fisted in table 7 (see Page 15).

When used in conjunction with a evaporator coil, the fur-nace shall be installed in parallel with, or on the upstreamside of the evaporator coil. In a parallel flow arrangement,the dampers, or other measures used to control flow of airflow, shall be adequate to prevent chilled air from enteringthe furnace. If the furnace is manually operated, it must beequipped with means to prevent operation of either unit un-less dampers are in the full-heat or full-cool position.

Page 4

Wheninstalled,furnacemustbeelectricallygroundedinaccordancewithlocalcodesor,in theabsenceof localcodes,with the currentNationalElectricCode,ANSI/NFPANo,70,if anexternalelectricalsourceis utilized,Fieldwiringconnectionwithunitmustmeetor exceedspecificationsoftypeTwireandwithstanda63'_F(17<_C)temperaturerise.

Wheninstalled,OHR23furnacesmustbelevel.Ifthefur-naceisnotlevel,placefireproofwedgesorshimsbetweenthelowsideofthefurnaceandfloor,Makesuretheweightof thefurnaceis evenlydistributedon all fourcorners.Strainonsidesof thecabinetcausingcrackingandpop-pingnoisesmayoccurifweightoffurnaceisnotevenlydis-tributed.Settheunitindesiredlocationkeepinginmindtheclear-anceslistin tables2 and3,Alsokeepinmindoil supplyconnections,electricalsupply,flueconnectionsandsuffi-cientclearanceforinstallingandservicingunit,OHR23seriesunitsmaybeinstalledinacrawlspaceun-derahouse,utilityroomor inawidevarietyofsuspendedapplications,Horizontal ApplicationThe OHR23 furnace is shipped from the factory in the hori-zontal left hand air discharge application, Air flow may bereversed to right side discharge or unit may be used asdownflow.

Reversing Airflow for Right Hand Discharge1. Rotate the furnace 180 _ so that when facing the front,

the warm discharge is to the right.2. Remove the nuts in the bracket that hold the burner to

the furnace front. Rotate the burner and burner mount-ing plate 180 '_and reinstall the nuts.

3. Remove the screws that hold the limit control in place,Use the provided knockout hole to relocate the limitcontrol to the top side of the front panel,

Installation on Non-Combustible MaterialSet the furnace on non-combustible material (such as con-

crete blocks, bricks or angle iron). Install spacer legs, pro-vided with unit, by using the cabinet screws from each cor-ner of the unit, Use a level to check level of furnace in atleast two directions. Use shims or non-combustible materi-

al, A minimum clearance of 1" must be maintained be-tween bottom of furnace and combustible material.

Suspended InstallationTo suspend furnace, remove knockouts in top of panel atwarm air discharge and at blower panel (Refer to unit di_

mensions). Use 3/8" rods cut to desired length. Use onefiat washer and two nuts for each rod. One nut and the

washer on the inside of unit and the other nut on the outside

of unit (the locking nut). Level the unit by adjusting the nutson the inside of unit, See figure 3 to suspend unit,

Hanger Rod Installation

,/rodtop of

[_nut _._ furnace

washer

iU_mpartment

II division panel

Figure 3

Downflow ApplicationWhen installing the OHR23 in a downflow position and oncombustible flooring, a combustible floor base must beused. See Unit Dimension illustration.

1. Rotate the furnace so that return is on top and supplyis on bottom. Refer to table 3 for clearances to com-bustible flooring.

2. Remove the nuts in the bracket that hold the burner tothe furnace front. Rotate the burner and burner mount-ing plate g0 _ and reinstall the nuts,

3. It is also recommended that the upper rear screw hold-ing the blower housing to the blower deck be removedbefore installation in a closet. Removing this screw al-lows for easy service and removal of the blower as-sembly in a closet installation.

NOTE - Following these suggestions when installing sup-ply and return air plenums,

1. Use sealing strips of fiberglass.

2. In all cases, the plenum should be secured to furnaceor evaporator cabinet with sheet metal screws,

3. Both supply and return air plenums shall be squareand least 18" long. They should be the same dimen-sion as the furnace opening.

4. If unit is installed in a confined space such as a utilityroom where there is no complete return air duct sys-tem, a return air connection should be run (the samesize as the return air opening) to a location outside theroom containing the furnace,

5. Install supply and return air ducts as desired.

An Optional filter kit is available for OHR23 units, Kit 35K05is used with OHR23-105/120 units, and kit 35K06 is usedwith OHR23-140/154 units. All kits include the following:

• 2 filters

• 3 rods

• 7 screws

• 1 rack assembly

• 1 panel

Page 5

OHR23-140/154 Filter Rack Installation

1, Slide filter rack over return duct flanges,

2, Using a scriber through the filter rack mounting holes,mark seven mounting hole locations in the return endof the cabinet. See figure 4.

3, Remove filter rack and drill 1/8" diameter holes at themarked positions,

4, Place filter rack in position again and secure it to thecabinet using the sheet metal screws provided. Clear-ance for the screw driver is provided in outside holesof rack and in filter support angles.

5, Bend the ends of filter rods and hook ends throughholes provided in top and bottom filter support angles.

6, Slide filter between the support angles and the plenumside for the filter rack, The filter rods hold the filter inplace,

14 (356)

FILTER(FUR- OPENING

NISHED) IN UNIT(EITHER SIDE)

Figure 4

Neither the nozzle setting nor the air adjustments are fac-tory set. The furnace is fire-tested and the limit control ischecked to make sure it functions properly; no factory set-tings are made. During installation, the furnace must be setup. The installing dealer/contractor must have and useproper test equipment in order to correctly set up the oil fur-nace. Proper testing equipment is required to ensure cor-

rect operation of the unit. The use of test equipment is nowmore critical than ever due to tighter tolerances needed tokeep the furnace operating efficiently.

Among the test equipment for an oil furnace, the propercombustion test kit should contain the following:

• Draft gauge• CO 2 or 0 2 analyzer• Smoke tester• Pressure gauge• High temperature thermometer

• Oil vacuum gauge• Beckett T-500 gauge• Knowledge of proper test equipment operation

At, CAUTION

Adjusting the NozzleProper adjustment of the nozzle assembly is critical be-

cause alignment may have changed during shipping. Be-fore the furnace and oil lines are installed, the nozzle as-

sembly must be checked. This may easily be done byremoving the entire burner assembly (not just the nozzle)from the furnace. The lower firing nozzle is factoryinstalled. This should be verified by the installer. Inspectthe spark transformer leads also to ensure they are still at-tached to the electrodes,

The burner assembly is attached to the vestibule panel bythree 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 assemblycounterclockwise (figure 5), the entire burner assemblywill come out of the furnace, There is adequate wire to re-move the burner without disconnecting wires, Once re-moved, just turn the burner around in the vest panel area,

OHR23 Series Burner RemovalLOOSEN THREE NUTS WHICH A% ROTATE BURNER COUNTERCLOCKWISETACH BURNER TO VEST PANEL. ON SLOTS THEN PULL TOWARD YOU.

Figure 5

To correctly adjust the nozzle, use a Beckett #T-500gauge.

Insert the small end of the gauge into the end of the coneand measure from the flat of the end cone to the tip of the

nozzle. When nozzle depth is correct, the tip of the nozzleshould just touch the end of the gauge. Refer to the illustra-

tion sheet provided with the gauge. Note that the scale sideof the gauge is not used for this purpose. Make correctionsby sliding the nozzle assembly forward or backward withinthe blast tube (figure 6). At the same time, check thenozzle alignment.

Page 6

Tochecknozzlealignment,againinsertthesmallendintotheendconeandmeasurethenozzleandelectrodealign-mentagainstthecenterlinesmarkedonthegauge(againrefertoenclosedillustrationsheet).Ifthenozzleisnotcen-tered,butfoundtobetoofarleftorright,a newnozzleas-semblywillneedtobeordered.Donotattempttoadjustbybendingthe90degreeelbowin theoil line.

Beckett Oil Burner Nozzle Adjustment

BURNER MUST BE REMOVED FROM FURNACE FOR THIS PROCEDURE.

2 1GAUGE

1-LOOSEN SCREW.

2-SLIDE ENTIRE NOZZLE/ELECTRODE ASSEMBLY BACK AND FORTH UNTILNOZZLE JUST TOUCHES GAUGE.

Figure 6

WARNING

CAUTION

NOTE - Oil burning equipment may be vented into an ap-proved masonry chimney or type L vent. (Type L vent issimilar in construction to type B gas vent except it carries ahigher temperature rating and is constructed with an innerliner of stainless steel rather than aluminum).

Prior to installation of unit, make a thorough inspection ofthe chimney to determine whether repairs are necessary.Make sure the chimney is properly constructed and sizedaccording to the requirements of the National Fire Protec-tion Association. The smallest dimensions of the chimneyshould be at least equal to the diameter of the furnace ventconnector. Make sure the chimney will produce a steadydraft sufficient to remove all the products of combustionfrom the furnace. A draft of at least .04" w.c. (9.9 Pa) is re-quired during burner operation.

1. Local building codes may have more stringent installa-tion requirements and should be consulted beforeinstallation of unit.

2. The vent connector should be as short as possible todo 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 throughany unconditioned space.

6. Chimney should extend 3 feet (0.9 m) above highestpoint where the vent passes through the roof, and 2feet (0.6 m) higher than any portion of a building withina horizontal distance of 10 feet (3 m).

7. The vent must not pass through a floor or ceiling. Clear-ances 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 havebeen made for a thimble as specified in the Standardsof the National Board of Fire Underwriters. See figure 7.

Wall Thimble

THIMBLE

COMBUSTIBLEWALL VENT PIPE

Figure 7

9. The vent pipe should slope upward toward the chim-ney on horizontal run at least 1/4 inch (6 mm) to thefoot (0.3 m) and should be supported by somethingother than the furnace, such as isolation hangers. Seefigure 8.

Page 7

BAROMETRIC

(IN EITHERLOCATION)

APPLICATIONSHOWN

Masonry Chimney

OUT

1MASONRYCHIMNEY

CLEAN OUT

*BAROMETRIC CONTROL MAY BE INSTALLED IN EITHER VERTICAL OR HORIZON-TAL SECTION OF FLUE PIPE WITHIN 18" OF FLUE OUTLET OF FURNACE,

Figure 8

Factory-Built Chimney

BAROMETRICCONTROL*

(IN EITHER

LOCATION) _

HORIZONTALAPPLICATION

SHOWN

Ei1111 L

_ ACTORY

BUILTCHIMNEY

DRAIN FORCONDENSATE

*BAROMETRIC CONTROL MAY BE INSTALLED IN EITHER VERTICAL OR HORI-ZONTAL SECTION OF FLUE PIPE WITHIN 18" OF FLUE OUTLET OF FURNACE.

Figure 9

10. Extend the vent pipe into the chimney so that it is flushwith the inside of the vent liner. Seal the joint betweenthe pipe and the liner,

11. The furnace shall be connected to a factory built chim-ney or vent complying with a recognized standard, ormasonry or concrete chimney lined with a lining mate-rial acceptable to the authority having jurisdiction,

12. When two or more appliances vent into a commonvent, the area of the common vent should not be lessthan the area of the largest vent or vent connectionplus 50% of the areas of the additional vent or ventconnection. Chimney must be able to sufficiently ventall appliances operating at the same time,

13. The vent pipe shall not be connected to a chimney ventserving a solid fuel appliance or any mechanical draftsystem.

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 9,

16. Where condensation of vent gas is apparent, the ventshould be repaired or replaced. Accumulation of con-densation in the vent is unacceptable,

17. Vent connectors serving this appliance shall not beconnected 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.

Homes designed with energy conservation in mind useair-tight construction practices. Therefore, it is necessaryto bring in outside air for combustion, Consideration mustalso be given to the use of exhaust fans, appliance vents,chimneys and fireplaces that force out air which mighthave otherwise been used for combustion. Unless outside

air is brought into the home for combustion, negative pres-sure (pressure outside is greater than inside pressure) willbuild to the point that a downdraft can occur in the furnacevent pipe or chimney, Combustion gases entering the liv-

ing space create a potentially dangerous situation,

NO TE- The importance oft he previous paragraph can-not be overstated, Users may inadvertently block freshair 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 RequirementsAll oil-fired appliances require air to be used for the com-bustion process. If sufficient amounts of combustion airare not available, the furnace or other appliance will oper-ate in an inefficient and unsafe manner. Enough air mustbe provided to meet the needs of all fuel-burning ap-

pliances, as well as appliances such as exhaust fans whichforce air out of the home.

Page 8

CAUTION

When fireplaces, exhaust fans, or clothes dryers are usedat the same time as the furnace, much more air is requiredto ensure proper combustion and to prevent a down-draftsituation. Insufficient amounts of air also cause incompletecombustion which can result in sooting. Requirements forproviding air for combustion and ventilation depend largelyon whether the furnace is installed in an unconfined or con-

fined space.

Unconfined SpaceAn unconfined space is an area such as a basement orlarge equipment room with a volume greater than 50 cubicfeet (1.4 cubic meters) per 1,000 Btu (293 W) per hour ofthe combined input rating of all appliances installed in thatspace. This space also includes adjacent rooms which arenot separated by a door. Though an area may appear to beunconfined, it might be necessary to bring in outdoor air for

combustion if the structure does not provide enough air byinfiltration. If the furnace is located in a building of tightconstruction with weather stripping and caulking aroundthe windows and doors, follow the procedures outlined forusing air from the outside for combustion and ventilation.

Confined SpaceA confined space is an area with volume less than 50 cubicfeet (1.4 cubic meters) per 1,000 Btu (293 W) per hour ofthe combined input rating of all appliances installed in that

space. This definition includes furnace closets or smallequipment rooms.

When the furnace is installed so that supply ducts carry aircirculated by the furnace to areas outside the space con-taining the furnace, the return air must be handled by ductswhich are sealed to the furnace casing and which termi-nate outside the space containing the furnace. This is es-pecially important when the furnace is mounted on a plat-form in a confined space such as a closet or smallequipment room.

Small leaks around the base d the unit at the platform or atthe return air duct connection can cause a potentially dan-gerous negative pressure condition. Air for combustionand ventilation can be brought into the confined space ei-ther from inside the building or from outside.

Air from an Adjacent SpaceIf the confined space housing the furnace adjoins spacecategorized 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 squareinch (6.4 square centimeters) per 1,000 Btu (293 W) perhour of the total input rating of all fuel-fired equipment in theconfined space. Each opening must be at least 100 squareinches (614.5 square centimeters). One opening shall bewithin 12" (305 mm) of the top of the enclosure and oneopening within 12" (305 mm) of the bottom (See figure 10).

Equipment In Confined Space -All Air From Inside

CHIMNEY OR

OIL VENT

OILFURNACE

OPENINGS(TO ADJACENT

, ROOM)

! ii ii ii ii ii ii ii ii i

NOTE-EACH OPENING SHALL HAVE A FREE AREA OF AT LEAST 1 SQUAREINCH (6.4 SQUARE CENTIMETERS) PER 1,009 BTU (293 W) PER HOUR OF THETOTAL INPUT RATING OF ALL EQUIPMENT IN THE ENCLOSURE, BUT NOT LESSTHAN 100 SQUARE INCHES (614.5 SQUARE CENTIMETERS).

Figure 10

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) ofthe bottom. These openings must communicate directly orby ducts with the outdoors or spaces (crawl or attic) thatfreely communicate with the outdoors or indirectly throughvertical ducts.

Each opening shall have a minimum free area of 1 squareinch (6.4 square centimeters) per 4,000 Btu (1172 W) perhour of total input rating of all equipment in the enclosure

(See figures 11 and 12). When communicating with theoutdoors through horizontal ducts, each opening shallhave a minimum free area of 1 square inch (6.4 squarecentimeters) per 2,000 Btu (586 W) per total input rating ofall equipment in the enclosure (See figure 13).

Page 9

Equipment In Confined Space - All Air FromOutside (Inlet Air from Crawl Space and

Outlet Air to Ventilated Attic)CHIMNEY

OR OIL ",VENT

OILOUTLET

FURNACE •AIR

WATERVENTILATION HEATEP

LOUVERS(FOR UNHEATED INLET

CRAWL SPACE)

rlTm ITITnr 1 r l

NOTE-THE lit!LET AND OUTLET AtR OPENINGS SHALL EACH HAVE A FREEAREA OF AT LEAST ONE SQUARE INCH (6.4 SQUARE CENTIMETERS) PER 4,000BTU (1172 IN) PER HOUR OF THE TOTAL INPUT RATING OF ALL EQUIPMENT INTHE ENCLOSURE.

Figure 11

Equipment In Confined Space - All Air FromOutside (via Ventilated Attic)

CHIMNEYOR OILVENT _ VENTILATION LOUVERS

(Each end of altic)

INLET AIROIL (Ends 12" above

FURNACE bottom)

WATERHEATER

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

Figure 12

When ducts are used, they shall be of the same cross-sec-tional area as the free area of the openings to which theyconnect. The minimum dimension of rectangular air ductsshall be no less than 3" (76 mm). In calculating free area,the blocking effect of louvers, grilles, or screens must beconsidered. If the design and free area of protective cover-ing is not known for calculating the size opening required, itmay be assumed that wood louvers will have 20 to 25 per-cent free area and metal louvers and grilles will have 60 to75 percent free area. Louvers and grilles must be fixed in

the open position or interlocked with the equipment so thatthey are opened automatically during equipment opera-tion.

WATER __

HEATER

i i i i i i i

Equipment In Confined Space - All Air From

CHIMNEY _ Outside

_OR OIL

WATER

HEATER

uNOTE-EACH AIR DUCT OPENING SHALL HAVE A FREE AREA OF AT LEAST ONE

SQUARE INCH (6.4 SQUARE CENTIMETERS) PER 2, 800 B TU (586 IN) PER HOUROF THE TOTAL INPUT RATING OF ALL EQUIPMENT IN THE ENCLOSURE. IF THEEQUIPMENT ROOM IS LOCATED AGAINST AN OUTSIDE WALL AND THE AIR

OPENINGS COMMUNICATE DIRECTLY WITH THE OUTDOORS, EACH OPENINGSHALL HAVE A FREE AREA OF AT LEAST ONE SQUARE INCH (6.4 SQUARECENTIMETERS) PER 4,800 BTU (1172 IN) PER HOUR OF THE TOTAL INPUT RAT-ING OF ALL OTHER EQUIPMENT IN THE ENCLOSURE.

Figure 13

CAUTION

Direct Connection of Outdoor Air for Combus-tionThe Beckett AFII burner was designed to allow for direct airintake piping (4" [102 mm]), The maximum equivalentlength of pipe is 70 feet (21.3 m). A 90<_elbow equals 6feet(1,8 m). The enclosed intake pipe ring may be used to facil-itate direct air intake to the burner through the right side of

the cabinet, The AFG burner requires a special kit for directair intake, Refer to kit instructions.

To convert the AFII burner from confined space to outsidecombustion air, simply remove the three screws attachingthe inlet air scoop to the burner and insert 4" (102 mm) di-rect air intake piping.

The use of a barometric relief placed in the intake pipe isrecommended when outdoor combustion air is directlyconnected to the burner. This will allow confined space airto be used as combustion air in the event that the openingto the outdoor air becomes blocked. Using a barometric re-lief in the intake will reduce the chance of sooting,

Xk CAUTION

Page 10

Removal of Unit from Common Venting SystemIn the event that an existing furnace is removed from aventing system commonly run with separate gas ap-pliances, the venting system is likely to be too large toproperly vent the remaining attached appliances. The fol-lowing test should be conducted while each appliance is inoperation and the other appliances not in operation remain

connected to the common venting system, If the ventingsystem has been installed improperly, the system must becorrected as outlined in the previous section,

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

2, Visually inspect the venting system for proper size andhorizontal pitch and determine there is no blockage orrestriction, leakage, corrosion or other deficiencieswhich could cause an unsafe condition.

3. If possible, close all building doors and windows andall doors between the space in which the appliancesremaining connected to the common venting systemare located and other spaces of the building. Turn onclothes dryers and any appliances not connected tothe common venting system. Turn on any exhaustfans, such as range hoods and bathroom exhausts, sothey will operate at maximum speed. Do not operatea summer exhaust fan. Close fireplace dampers,

4, Following the lighting instruction, place the appliancebeing inspected in operation, Adjust thermostat so ap-pliance 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 systemproperly vents when tested as outlined above, returndoors, windows, exhaust fans, fireplace dampers andany other gas burning appliance to their previous con-dition of use,

7, If improper venting is observed during any of theabove tests, the common venting system must be cor-rected,

Horizontal VentingThe OHR23 is approved for horizontal venting with the fol-lowing mechanical vent systems:Tjernlund (sideshot) #SS1C (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 partsinformation,

Do not use the same vent with any other appliance whenusing a sidewall vent system,

Maximum permissible vent length is 70 equivalent feet,

Minimum length is 15 equivalent feet. Calculate the equiv-alent vent pipe footage from the furnace to the mechanicalvent system (Tjernlund or Field Controls) by adding thestraight vent pipe length and the equivalent elbow lengthstogether,

Use the barometric draft control in the horizontal (sidewall)venting system. Locate the barometric draft control within18 inches of the furnace flue outlet, See figure 14 for baro-metric draft control location,

BAROMETRICCONTROL*

HORIZONTALVENTING CON-TROL

Horizontal Venting / Downflow Application

BAROMiTRI[_ _

CONTROL*

CONTROL FORHORIZONTAL

ING

Horizontal Venting / Horizontal Application*BAROMETRIC CONTROL MUST BE INSTALLED IN THE HORIZONTAL VENTINGSYSTEM AND LOCATED WITHIN 18" OF FLUE OUTLET OF FURNACE,

Figure 14

IMPORTANT

Use 24 gauge or heavier galvanized smoke pipe and fit-tings to connect furnace to vent. Maintain rise of at leastone inch per foot, Connect flue pipe to chimney using theleast number of elbows and angles possible, Flue pipe orvent connector must be inserted into but not beyond theoutside wall of the chimney flue, No reduction in diame-ter of fiue pipe is acceptable. It is best to have flue pipe asshort 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 tothe area of the largest flue or vent connector, plus 50% of

the area of any additional flues or vent connectors.Install barometric draft control (provided) and flue pipeaccording to instructions packed with control,

1, Install draft control, provided, and flue pipe accordingto instructions packed with control.

2, Connect flue outlet to chimney using at least 24 gaugevent pipe and fittings, the same size as the flue outlet.

3, Use the least number of elbows and angles possible.Slope flue pipe toward chimney approximately 1/4" for

Page 11

everyfootofhorizontalrun.Fluepipeorventconnec-tormustbe insertedintobutnotbeyondtheoutsidewallofthechimneyflue.

Wheretwoormoreappliancesventintoa commonflue,theareaofthecommonflueshouldbeatleastequaltotheareaofthelargestflueorventconnector,plus50%oftheareaofanyadditionalfluesorventconnectors.Inspectfluepipeannually.Cleansootorashfromfluepipe,if necessary.Ifpipeis rusted,replace.

COMBUSTIBLE

Radiation Shield Installation

1" (25ram)rain

UNITCABINET

12"(305ram)

NON- _'-A_ "- A-'_COMBUSTIBLE SEE NOTE 2SPACERS

RADIATION SHIELDS

(SEE NOTE 1)

_OTE 3

NOTE 1-Radiation shields must be constructed of 24 gauge sheet metal mininlunl.

NOTE 2-Radiation shields required when A is less than 9" (229mm).

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

Figure 15

Ensure that the restrictions of the piping system, plus anylift involved, do not exceed the capability of the oil pump.Use the following guidelines when determining whether touse a single-or two-stage oil pump.

One-Pipe SystemWhen using a one-pipe system with the oil tank even abovethe burner and a vacuum of 6" (152 mm) Hg or less, a single-

stage fuel pump with a supply line and no return line shouldbe adequate. See figure 16. Manual bleeding of the fuelpump is required on initial start up. Failure to bleed air fromthe oil pump could result in an air lock/oil starvation condition.

NO TE -As an extra precaution, cycle heating on and offten times after bleeding air from the oil pump. This willeliminate air in the gun assembly.

Oil Piping One-Pipe System

fuelpump Aux

liter

8 FT (2.4 M)MAXIMUM

ONE PIPE LIFT

Figure 16

Table 4

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 SystemWhen using atwo-pipe system with the oil tank below thelevel of the burner, a single-stage fuel pump should beused in lift conditions of up to 10 feet (3 m) and/or a vacu-

um of 10" (254 mm) Hg or less. See figure 17. Use a two-stage fuel pump when lift exceeds 10 feet (3 m) and/or avacuum of 10" (254 mm) Hg to 15" (381 mm) Hg. Both con-ditions require that you use a two-pipe system, which con-sists of a return line that purges the fuel pump of air by return-ing it to the tank. To determine the run and lif[ for piping, referto table 5.

To determine the length of the run for piping, refer to table 4

Oil Piping Two-Pipe System

fuelFill Air VentPipe \r--I pumpAux

\ I Return/ Filter

_ pipe __ Inlet

pipeoutside tank fuel pump above bottom of tank.

Figure 17

Page 12

Usecontinuouslengthsof heavywallcoppertubingorsteelpipeforoilsupplypipe,Installoilsupplypipeunderfloorornearwallstoprotectitfromdamage.Avoidrunningpipesalongjoistsorreverberatingsurfaces.Alwaysuseflarefittings,All fittingsmustbeaccessible,Donotusecompressionfittings,

A IMPORTANT

Table 5

Two-Pipe Maximum Pipe Length (H + R)3450 RPM - 3 GPH (11.4 LPH)

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

1-Stage 2-Stage 1-Stage 2-Stage0' (0.0m) 84' (25.6m) 93' (28.3 m) 100' (30.5m) 100' (30.5m)

2' (0.6m) 73' (22.3m) 85' (25.9 m) 100' (30.5m) 100' (30.5m)

4' (1.2m) 63' (19.2m) 77' (23.5 m) 100' (30.5m) 100' (30.5m)

6' (1.8m) 52' (15.8m) 69' (21.0 m) 100' (30.5m) 100' (30.5m)

8' (2.4m) 42' (12.8m) 60' (18.3 m) 100' (30.5m) 100' (30.5m)

10' (3.0m) 31' (9.4m) 52' (15.9 m) 100' (30.5m) 100' (30.5m)

12' (3.7m) 21' (6.4m) 44' (13.4 m) 83' (25.3m) 100' (30.5m)

14' (4.3m) --- 36' (11.0 m) 41' (12.5m) 100' (30.5m)

16' (4.9m) --- 27' (8.2 m) --- 100' (30.5m)

18' (5.5m) ......... 76' (23.2 m)

One-Pipe Systems

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 systemshould only be used where there is gravity oil flow to thepump and the pipe is not run at any point above the oil levelin the tank.

1. Connect the inlet pipe to the pump inlet, Start the burn-er,

2, Arrange the primary burner control for continuous op-eration during purging, See figure 16.

3, Turn the bleed valve one turn counterclockwise toopen.

4. Bleed the unit until all air bubbles disappear,

NOTE -Hurried bleeding will prevent the unit from op-erating properly,

5. Tighten the bleed valve securely,

Two-Pipe SystemsIf the installation requires a two-pipe operation, install thebypass plug included in the bag which is attached to thepump, 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 thereturn pipe terminates at the correct measurement or airmay escape into the system. This could result in loss ofprime,

NOTE- if using an outside tank in cold climates a number onefuel or an oil treatment is strongly recommended,1, Remove 1/4" plug from return port,

2, Insert bypass plug and tighten it, See figure 17.

3. Attach the return and inlet pipes, Start the burner, Airbleeding is automatic,

NOTE - If a faster bleed is necessary, open the bleedvalve,

4, The return pipe must terminate 3" to 4" above the sup-ply pipe inlet. See figure 17,

NOTE - If the return pipe does not terminate where itshould, air may enter the system, and prime may be IosLAn oil filter is required for all models. Install filter inside

the building between the tank shut-off valve and the burn-er. Locate filter close to burner for easy maintenance,Table 6 lists the filters for the OHR23 furnace,

Table 6

Installation Clearances inches (mm)

Cat.Oil Filters Number

10 micron filter (no mounting bracket) 81P89

10 micron filter (mounting bracket) 53P92

10 micron replacement cartridge for filter, 53P9345 gph

Filter restriction indicator gauge 53P90

Consult burner manufacturer's instructions packaged withunit for further details concerning oil supply pipe connec-tions.

After oil piping is completed, carefully check all piping con-nections (factory and field) for oil leaks,

Oil Line Heater (Optional)An oil line heater is available for the burner nozzle, When

applied to units installed in cold areas, the heater warms

the oil line for start-up.

Page 13

Allwiringmustconformto theNationalElectricCode(NEC),orCanadianElectricCode(CEC)andanylocalcodes,Refertofigure18forterminaldesignationsonblowercontrol,1, Refertoapplianceratingplateforproperfusesize.2. Installroomthermostatandmakewireconnectionsto

theblowercontrol.Avoidinstallingthermostatonanoutsidewallorwhereitcanbeaffectedbyradiantheat.Settheadjustableheatanticipatoronthermostatac-cordingto thewiringdiagramstickerprovidedonunit,

3. Installaseparatefuseddisconnectswitchnearunitsopowercanbeshutoffforservicing,

4. Completelinevoltagewiringfromdisconnectswitchnearunitto make-upbox.NOTE - An equipment ground screw is provided, Re-fer to unit wiring diagram (figure 19) and figure 18 forOHR23 series units, Ground unit using a suitableground wire,

5. Any accessory rated up to 1 amp can be connected tothe accessory terminal, The accessory terminal is en-ergized whenever the blower is in operation.

Fan Control Board

O,,_,;# O

THERMOSTAT :[]TERMINAL STRIP _._Y o_

S_l cl

o o

Figure 18

B_CIRCULATING

CAPACITO_R

Typical OHR23 Wiring Diagram

I It

120 VOLT

POWER SUPPLYJUNCTION BOX --FACTORY WIRING

LINE VOLTAGE-FIELDm m LOVt VOLTAGE-FIELD

l_lUNUSED 13_i 4_ _ "_ r_ iI I I I r

16 7 {_)

RED

BLK

WriT

RED-SEE NOTE 2 SEE NOTES 4 & 5 /

(_ RED-SEE NOTE 2 ,,,,,_ z

,ux M.NLIMIT LIMIT

(IF USED} SIO G WZ_ R Y C

S2l THERMOSTAT _ (_ ? (_ (_ A FOR HEAT ONLY(NO WIRE)_" y _ THERMOSTAT.CONNECT R & W.

"' ii' I I CONNSINSI L LL'-'J J jI,._ _J

NOTES CONNECT RED_IRED MOTOR LEADIF ANY WIRE IN THIS APPLIANCE 15 REPLACED. 4, TO PEAT TERMINAL ON TERMINAL

I. IT MUST BE REPLACED WITH LIKE SIZE,RATING BOARD.AND INSULATION THICKNESS.

WHEN THE SAME MOTOR SPEED IS TO BE

Z, IF HORIZONTAL APPLICATION 5. USED FOR HEAT AND COOL,DISCONNECTUSED,PURPLE IS WIRE COLOR AND ISOLATE THE UNUSED MOTOR SPEED LEAD,

DESIONATION. CONNECT THE REOUIRED MOTOR SPEED LEAD

5. THERMOSTAT HEAT TO THE HEAT TERMINAL AND ADD A JUMPERANTICIPATOR SETTINO--O. IAMP WIRE BETWEEN THE HEAT ARD COOL TERMINALS

TITRANSFORMER

YLW I

3AMP

RED

RTIB¢DA3

PRIMARYCONTROl.

O T2

WHITE

ORANGE

r_ BLK _RANOE

BURN["RMOTOR

I_IWH_I_WHTT I I BLU[SPARK

WHT WHT

_55 BL_VT

PUMP VALVE

m_.[DELAY OFF DIP SWITCH SETTINGS

1(_ O_ ONI_O_60 SEC 90 SEC 120 SEC 150 SEC

OTI

o

INTERRUPT

0<)R26

_0DELL. CAD

0 L2

OLI

o

Figure 19

Page 14

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

ly filled with clean No. 1 or No. 2 furnace oil,

NOTE - Water rust or other containments in oil supply sys-tem will cause malfunction and failure of the internal partsof the fuel uniL

CAUTION

1. Set thermostat for heating demand and turn on electri-cal supply to unit,

2. Check initial air adjustment, All units are equipped withan 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 bleedport located on the fuel pump. Loosen nut on bleedport to release air and oil mixture from fuel line. Allowmixture to escape until a steady stream of oil is emittedfrom the port. Drain at least 1/2 pint of oil from thepump, Retighten nut on bleed port, If lockout occurs,press reset button and continue with bleed procedure,

NOTE - A twoqine fuel system will normally bleed itselfby 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 primarysafety control and the burner motor reset button once.See part arrangement illustration.

CAUTION

5, If burner fails to light again, refer to the troubleshootingsection in this manual (beginning on Page 18).

Fuel Pump Pressure

Measure fuel pump pressure with unit off. Attach pressure

gauge to pump outlet, Turn unit on and check pressure andcompare to table 7. Adjust if necessary.

Temperature Rise

To measure temperature rise, place plenum thermometersin warm air and return air plenums, Locate thermometer inwarm air plenum where thermometer will not "see" the heatexchanger to prevent it from picking up radiant heat. Set

thermostat to its highest setting to start unit, After plenumthermometers have reached their highest and steadiestreadings, subtract the readings, The difference in temper-atures in the supply and return air plenums should approxi-mate the temperature rise range listed in table 7 and theappliance rating plate, If not, adjust the blower motor pulleyto adjust the blower speed.

Limit Control

Limit Control -- Do not adjust from factory setting,

Fan Control

The fan on time of 30 seconds is not adjustable, Fan offtime (time that the blower operates after the heat demandhas been satisfied) can be adjusted by moving the delayswitches on the fan control board, Fan off time will affect

comfort and is adjustable to satisfy individual applications.See figure 20,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 20

Table 7

OHR23 Operating Parameters

Fuel Nozzle Size, Input Output Temp. riseUnit Spray Angle, & Rating Rating Head +10 ° F hrz/

Type Pattern Btu/Hr Btu/Hr Type down

.65 GPH -.80 °, B

-105/ for-t05 input t05,000 85,000

-120 *.75 GPH -.80 °, B t19,000 97,000

for-120 input

.85 GPH - .80 °, B

-140/ for-140 input 140,000 113,000

-154 "t.0 GPH -.80 °, B 154,000 125,000

for-t54 input

FB3 70/70

FB6 60/70

*Nozzle must be field provided for field conversion to high-er heating inpuL Oil burner pump pressure is 140 psi foreach unit.

Burner AdjustmentThe following steps are essential to the proper operation ofOHR23 series oil furnaces. To prevent sooting, followthese instructions in the sequence given,

1. Perform Draft Test

Perform a draft test at the breach between the outlet ofthe vent connector and the barometric draft control.Drill a 1/4" access hole to allow the draft gauge to beinserted into the vent connector,

A minimum draft of 0.03 inches w.c. must be estab-

lished without the burner in operation. With the burnerin operation, the draft should be 0.04 to 0.05 inchesw.c. This is VERY critical to the flame retention headburners.

Oil furnace installations also require careful inspectionto make sure the chimney is in good shape and can ac-commodate the products of combustion. The temper-ature in the unconditioned space will also affect thedraft if long vent connectors are allowed to get toocold.

Page 15

2, PerformOverfireDraftPerformthistestwiththeburnerinoperation.Removethescrewfromthecenteroftheinspectionport,Insertthedraftgaugeintothehole.A readingof theoverfiredraftshouldbe0,02inchesw.c.lessthanthereadingfoundintheventconnectorduringtheDraftTest.Ifa positivereadingis seenatthispoint,thecombustionfanispumpingtoomuchairintotheheatexchanger.Makethenecessaryadjust-mentsattheairadjustmentdial,

3, PerformSmokeTestPerformthesmoketestatthesameholedrilledinstep1,Donotexceed#1smoke,

4, PerformCO2TestObtaintheCO2sampleat theventpipe.Withtheunitfiringata traceofsmoke,takea sampleoftheCO2.Fromtheresultsof thistest,a "windowof operation"(operationaltolerance)willbedetermined,Thebuilt-intoleranceprovidesroomwithintheset-upforelementsaffectingcombustion.Thosethingswhichmightaffectcombustioncanthendosowithoutcausingtheunittostartsooting/smoking,Thingswhichmightaffectcom-bustionincludea nozzlegoingbad,draftthatchangesduringdifferentclimaticconditions,dirtyoil,dirtobstruct-ingtheairinlet,etc,Tobuildawindowofoperation,settheburnerupsoitdoesnotexceed13%co2.

5. RetesttheSmokeWitha dropin theCO2andincreasein theair youshouldseethatthesmokehasreturnedto0,

6, RetesttheOverfireDraftThistestservestoconfirmthatyouhavenotincreasedtheair toomuch.Againyoudo notwanta positivepressureatthetestport.Itshouldstillbe0,02lessthanthedraftpressurereadingtakenat thebreach.Youmayneedto increasethestackdraftbyadjustingthebarometricdraftcontrol,

7. PerformStackTemperatureTestTakea stacktemperaturereadingin theventpipe.Subtracttheroomairtemperaturefromthestacktem-perature.Thiswillgiveyouthenetstacktemperature,UsetheefficiencychartsprovidedinmostCO2analyz-ersto determinefurnaceefficiency.

Servicing FilterNOTE - Under no circumstances should the access panels tothe blower compartment be left off or left partially open.

1, Throw-Away Type Filters -- Filters should be checkedmonthly and replaced when necessary to assure prop-

er furnace operation, Replace filters with like kind andsize filters,

2. Reusable Type Filters -- Filters should be checkedmonthly and cleaned when necessary to assure prop-er furnace operation. Use warm water and a mild de-tergent, Replace filter when dry. Permanent filters sup-plied with OHR23 furnaces do not require oiling aftercleaning. Examine filter label for any for special in-structions that may apply,

Servicing BlowerBlower 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,

Servicing NozzleReplace nozzle every year to to ensure proper operation,

Clogged nozzles will result in improperfi ring ornon-firing ofunit,

Flue Pipe InspectionThe flue pipe should be inspected annually by a qualifiedservice technician, Remove and clean any soot or ashfound in the flue pipe, Inspect pipe for holes or rustedareas, If replacement is necessary, replace with the samesize and type as required by code. Inspect the flue draftcontrol device and replace if found defective,

Cleaning Heat Exchanger1, Remove the vent pipe from the furnace,

2, Remove the locking screws and the caps from theclean-out tubes, Remove flue access elbow.

3, Using a long spiral wire brush, sweep down the outerdrum 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 upwardtoward the rear of the heat exchanger to clean out thecrossover 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 outerdrum 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 16

JobNameJobLocationInstallerUnitModelNo. SerialNo,HEATINGSECTIONElectricalConnectionsTight? [] SupplyVoltageBlowerMotor BurnerModelNo,Piping Connections Tight? [] All Valves Open? []

Oil Pump Pressure (recommended minimum 140 psi)

PROPER DRAFT

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

Percent CO2 (recommended 12%)

Flue Connections Tight? _)

Job no,

City

City

Date

State

State

Service Technician

Blower Motor Amps

Serial Number

Blower Motor Lubrication OK?

Fan Control Setting (maximum 130_F 55<_C).

[]

Percent CO 2 (recommended 12%)

Fan Control Cutout

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

Temperature Rise

THERMOSTAT

Heat AnticipatorCalibrated? [] Properly Set? [] Level? []

Page 17

Burnerfailureorimproperoperationcanresultfroma num-berofdifferentcauses.Oftenthecausecanbepinpointedbyobservingthedifferenttypesoffailureorbytheprocessofelimination.

Thefollowingtroubleshootingchartslist somefailures,causesandasequenceofstepstoisolatethepointoffail-ure.Checkthesimplestandmostobviousitemsbeforeprogressingtootheritems.

Action System Response

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.)

Thermostat begins call for fan.(G terminal is energized.)

Thermostat ends call for fan.(G terminal is de-energized.)

Limit switch string opens.

Limit switch string closes.

ST9103A closes oil primary control T-T connections.

Ignition system and oil primary control start the furnace. Oil flows as longas oil primary control senses flame.

Burner motor is energized and heat fan on delay timing begins. When tim-ing is complete, the circulating fan is energized at heat speed and warmair 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 circulatingfan is de-energized.

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

Oil primary control locks out within lockout timing (timing depends on oilprimary 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 recyclemode.

If selected heat fan off delay is longer than the recycle delay timing, theheat fan continues 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.

Circulating fan is energized immediately at cool speed.

ST9103A may be factory-configured to operate heat speed in this mode.

Circulating fan is de-energized.

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 heatspeed 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.

table continued on next page

Page 18

Action

Continuous circulating fan is connected.(Optional connectors are available forseparate circulating fan speed tap,)

System Response

Circulating fan is energized at low speed when there is no call for heat,cool or fan.

If fan operation is required by a call for heat, cool, or fan, the ST9103Aswitches off the continuous fan speed tap before energizing the other fanspeed.

Electronic air cleaner (EAC) connections are energized when the heat orcool speed of the circulating fan is energized. EAC connections are notenergized when the optional continuous fan terminal is energized.

Humidifier connections are energized when the burner motor is energized.

Electronic air cleaner is connected.(Optional connectors are available for120 Vac electronic air cleaner.)

Humidity control is connected.(Optional connectors are available for120 Vac humidifier.)

Source

Thermostat

SafetyOverloads

Power

Thermostat

CAD Cell

Procedure

Check thermostat settings.

PrimaryControl

Check burner motor, primarysafety control, & auxiliary limitswitch.

Check furnace disconnectswitch & main disconnect.

Touch jumper wire acrossthermostat terminals onprimary control. If burnerstarts, then fault is in thethermostat circuit.

Disconnect the flame detectorwires at the primary control. Ifthe burner starts, fault is in thedetector circuit.

Place trouble light probesbetween the black and whiteleads. No light indicates thatno power is going to thecontrol.

Place trouble light probesbetween the orange and whiteleads. No light indicates faultycontrol.

Causes

Thermostat in OFF or COOL

Thermostat is set too low

Burner motor overload tripped

Primary control tripped on safety

Auxiliary limit switch tripped onsafety

Open switch

Blown fuse or tripped circuitbreaker

Broken or loose thermostat wires

Loose thermostat screwconnection

Dirty thermostat contacts

Thermostat not level

Faulty thermostat

Flame detector leads are shorted

Flame detector exposed to light

short circuit in the flame detector

Primary or auxiliary controlswitch is open

Open circuit between disconnectswitch and limit control

Low line voltage or power failure

Defective internal control circuit

Correction

Switch to HEAT.

Turn thermostat to highertemperature,

Push reset button pump motor,

Reset primary control.

Reset auxiliary limit.

Close switch.

Replace fuse or reset circuitbreaker.

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 themaximum setting.

Jumper terminals; if burnerstarts, switch is faulty, replacecontrol.

Trace wiring and repair or replaceit.

Call the power company.

Replace the control.

table continued on next page

Page 19

Source Procedure Causes Correction

Burner Blown fuse Replace the fuse,Place the trouble lightbetween the black and whiteleads to the burner motor. Nolight indicates that no power isgetting to the motor,

Place trouble light betweenthe black and white leads tothe blower motor, Lightindicates power to the motorand burner fault,

Binding burner blower wheel

Sized fuel pump

Defective burner motor

Turn off power and rotate theblower wheel by hand. If seized,free the wheel or replace the fuelpump.

Replace the motor.

Source

Oil Supply

Oil Filters &Oil Line

Oil Pump

Nozzle

Procedure

Check tank gauge or use dip stick,

Coat dip stick with litmus paste andinsert into bottom of tank,

Listen for pump whine,

Listen for pump whine,

Open bleed valve or gauge port,Start the burner, No oil or milky oilindicates loss or prime.

Install pressure gauge on pump andread pressure, Should not be lessthan 140 psi.

Disconnect ignition leads. Observethe oil spray (gun assembly mustbe removed from unit). Inspect thenozzle for plugged orifice or carbonbuild-up around orifice.

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 completelyfrozen. No pressure and themotor locks out on overload.

Coupling disengaged orbroken - no pressure

Fuel pressure too low

Nozzle orifice plugged

Nozzle strainer plugged

Poor or off center spray

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 replacepump.

Locate and correct leak.

Tighten all connections.

Replace pump.

Re-engage or replacecoupling,

Adjust to 100 psi.

Replace nozzle with the samesize, spray angle, and spraytype.

table continued on next page

Page 20

Source

IgnitionElectrodes

IgnitionTransformer

Burner Motor

Pro ced u re

Remove gun assembly and inspectelectrodes and leads.

Connect ignition leads to thetransformer. Start burner andobserve spark. Check line voltageto transformer primary.

Motor does not come up to speedand trips out on overload. Turn offpower and rotate blower wheel byhand to check for binding orexcessive drag,

Causes

Fouled or shorted electrodes

Dirty electrodes and leads

Eroded electrode tips

Improper electrode gapspacing

Improper position of electrodetips

Bad buss bar connection

Cracked or chipped insulators

Cracked or burned leadinsulators

Low line voltage

Burned out transformerwindings.

No spark or weak spark

Low line voltage

Correction

Clean electrode leads.

Clean electrode tips and resetthe gap to 5/32 inches andcorrectly position tips.

Retension and realign.

Replace electrode.

Replace electrode leads.

Check voltage at powersoume. Correct cause ofvoltage drop or call the powercompany.

Replace the transformer.

Pump or blower overloadingmotor

Faulty motor Replace motor.

Properly ground thetransformer case.

Check voltage at powersource. Correct cause ofvoltage drop or the call powercompany.

Correct cause of overloading,

Page 21

Source Procedure Check

Poor Fire

FlameDetector

PrimaryControl

After burnerfires,

immediatelyjumper acrossflame detectorterminals at theprimary control.

If burnercontinues torun, this maybe due topoor fire.Inspect fire.

If fire is good,fault is in theflamedetector.Checkdetectorcircuit.

If burner locksout on safety,fault is in theprimarycontrol.

Causes

Unbalanced fire

Too much air- -lean shortfire

Too little air- - long dirtyfire

Excessive draft

Too little draft or restriction

Dirty cad cell face

Faulty cad cell - exceeds15000 hms

Loose or defective cad cellwires

Primary control circuitdefective

Correction

Replace nozzle

Reduce combustion air - checkcombustion,

Increase combustion air - checkcombustion,

Adjust barometric damper for correctdraft,

Correct draft or remove restriction,

Clean cad cell face,

Replace cad cell,

Secure connections or replace cad cellholder and wire leads.

Replace primary control.

Source

Poor Fire

FlameDetector

Oil Supply

Procedure

After burnerfires,

immediatelyjumper across

flamedetector

terminals atthe primary

control.

Check

tf burner continuesto run (does notlock out of safety),fault may be due topoor fire. Inspectfire.

If fire is good, faultis in the flamedetector. Checkdetector circuit.

Causes

Unbalanced fire

Too much air - - lean short fire

Too little air - - long dirty fire

Excessive draft

Too little draft or restriction

If burner losesflame (does notlock out on safety),fault is in the fuelsystem.

Water slug in line

Partially plugged nozzle ornozzle strainer

Dirty CAD cell face

Faulty CAD cell - - exceeds15000 hms

Loose or defective cad cellwires

Pump loses prime - air slug

Pump loses prime - air leak insupply line

Correction

Replace nozzle

Reduce combustion air-check combustion.

Increase combustion air -check combustion.

Adjust barometric damper forcorrect draft.

Correct draft or removerestriction.

Clean CAD cell face.

Replace CAD cell.

Secure connections or replacecad cell holder and wire leads.

Prime pump at bleed port

Check supply line for looseconnections and tightenfittings.

Check oil tank for water (over1 inch) pump or drain outwater.

Replace nozzle.

table continued on next page

Page 22

Source

Oil Supply

Procedure Check

Listen for pump whine

Causes

Restriction in oil line

Plugged fuel pump strainer

Cold oil - outdoor tank

Correction

Clear restriction.

Clean strainer or replacepump.

Change to number 1 oil.

Source Proced ure

Thermostat Check thermostat,

Limit Control

Power

Connect voltmeterbetween linevoltageconnections toprimary control(black & whiteleads). If burnercycles due topower interruption,it is cycling on limit.

If voltagefluctuates, fault isin the powersource. Recheckvoltage at thepower source.

Causes

Heat anticipator set too low

Vibration at thermostat

Thermostat in the path of a warm airdraft

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 airsystem

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 orrelocate.

Clean or replace filter.

Increase blower speed to maintainproper 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.

Page 23

Source

Thermostat

Primarycontrol

Procedure Check

Disconnectthermostatwires at the

primarycontrol,

Check Burner; if burnerturns off, fault is in thethermostat circuit,

Check Burner: if burnerdoes not turn off, fault isin the primary control.

Ca uses

Shorted or weldedthermostat contacts

Stuck thermostat bimetal

Thermostat not level

Shorted thermostat wires

Thermostat out ofcalibration

Thermostat in cold draft

Defective primary control

Correction

Repair or replace thethermostat,

Clear obstruction or replacethermostat,

Level thermostat,

Repair short or replace wires.

Replace thermostat,

Correct draft or relocate thethermostat,

Replace the defective primarycontrol.

Source

Combustion

Oil Pressure

Procedure

Check burnercombustionfor CO 2 . LowCO 2 if lessthan 10%.

Check burnercombustionfor smoke -High smokereading morethan a trace.

Ca uses

Too much combustion air

Air leaks into heat exchangeraround inspection door, etc.

Excessive draft

Incorrect burner head adjustment

Dirty or plugged heat exchanger

Insufficient draft

Incorrect burner head adjustment

Too little combustion air

Check burner Too little blower aircombustionstacktemperature -High stacktemperatureis more than550"F Net,

Inspect fireand check oilpressure.

Blower belt too loose (if equipped)

Dirty or plugged heat exchanger

Dirty blower wheel

Dirty furnace air filters

Restricted or closed registers ordampers

Partially plugged or defectivenozzle

Oil pressure is too low: less than100 psi.

Correction

Reduce combustion air.

Correct cause of air leak,

Adjust barometric draft control for correct draft,

Correct burner head setting,

Clean heat exchanger.

Readjust burner.

Increase draft,

Correct burner setting,

Increase combustion air.

Increase blower speed to maintain propertemp. rise.

Tighten blower belt,

Clean heat exchanger.

Clean blower wheel.

Clean or replace filter.

Readjust registers or dampers.

Replace nozzle.

Increase oil pressure top 100psi.

Page 24