Boyertown Regal Oil Furnace Nrg Max User Manual

Regal Oil Fired Furnace

Installation and Operation Instructions

Manual

Keep these instructions with the furnace at all times

for future reference

Boyertown Furnace Co.

PO Box 100

Boyertown, PA 19512

610-369-1450

www.boyertownfurnace.com 7-1-14

Be Aware of Hazard Definitions

Danger

Warnin

Caution

Notice

Denotes presence of a hazard which, if ignored, will result in severe personal injury, death or property damage

Denotes presence of a hazard which, if ignored could result in severe personal injury, death or substantial property damage.

Denotes the presence of a hazard, which if ignored, could result in minor personal injury or property damage

Intended to bring attention to information, but not related to personal injury or property damage.

Danger

This equipment must be installed, adjusted and started only by a qualified service agency – an

individual or agency, licensed and experienced with all codes and ordinances, and who is responsible for the installation and adjustment of the equipment. THE INSTALLATION OF THE EQUIPMENT SHALL BE IN ACCORDANCE WITH THE REGULATION OF AUTHORITIES HAVING JURIDICTION AND OR NFPA

31.

Read all instructions before proceeding. Follow all instructions completely. Failure to follow these instructions could result in equipment malfunction causing severe personal injury, death or substantial property

Warnin

damage.

DO NOT TAMPER WITH THE UNIT OR CONTROLS – CALL YOUR SERVICEMAN. The manufacturer

will not be liable for any damage resulting from changes made in the field to the furnace or its components or from improper installation. Failure to comply could result in severe personal injury, death, or substantial property damage.

DO NOT USE WITH OILS HEAVIER THAN NO. 2. NEVER USE GASOLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE. Your oil fired furnace is designed to burn No. 1 and No. 2 heating oil only.

DO NOT START THE BURNER UNLESS THE BLOWER ACCESS DOOR IS SECURED IN PLACE.

Do not store gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

The area around the furnace should be kept free and clear of combustible materials.

NEVER BURN GARBAGE OR REFUSE IN THE HEATING SYSTEM, AND NEVER LEAVE PAPER OR RAGS AROUND THE UNIT.

Never try to ignite oil by tossing burning papers or other material into your furnace.

DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED OR THE FURNACE IS FULL OF VAPORS OR WHEN THE CHAMBER IS VERY HOT

Do not use the furnace as a construction heater.

Do not operate furnace if the heat exchanger is damaged. Toxic flue products could enter air stream.

Do not jumper, attempt to bypass or override any of the safety limit controls.

Do not use this furnace if any part has been under water. Immediately call a qualified service technician to inspect the furnace and replace any part of the furnace, control system or burner that has been under water.

Do not operate furnace if temperature rise through the heat exchanger exceeds that which is listed on the Ratings Label (Typically75

Do not operate furnace without return air properly sized or ducted.

NOTICE

Concealed Damage- If you discover damage to the burner, furnace or controls during

F).

unpacking, notify the carrier at once and file the appropriate claim. When calling or writing about the furnace please have the following information available: the furnace model number and serial number which is located on the upper portion of the front of the unit. Record the model and serial number for future reference in the space provided in this manual.

TABLE OF CONTENTS PAGE NO.

FURNACE SPECIFICATIONS 4 INSTALLATION CLEARANCES

Standard Clearances

Reduced Clearances

DUCT WORK

Sizing Blower Specifications Filter Racks Multiple Furnace Installation

ECM MOTORS

Operating Modes

Air Flow Selection Motor Connections

PSC MOTORS

Air Flow Selection

VENTING

Chimney Venting Chimney Relining Chimney Connector Power Venting Vent Dampers

VENTILATION AND COMBUSTION AIR 15 BURNER INSTALLATION 15 WIRING

Power Thermostat

OIL TANK AND PIPING 23 START UP

Start Up Equipment

Burner Adjustments

OPERATING AND MAINTENANCE

Cleaning the Furnace

Oil Burner Blowers – Direct Drive Vent System Fuel Oil System Filters

PARTS BREAKDOWN LISTS 28 TROUBLE SHOOTING GUIDE 31 WARRANTY 32 INSTALLATION AND SERVICE CHECKLIST 33 WARRANTY REGISTRATION 34

1000

175,000

140,000

1.25 80B

1.00 80B

1.25 60SS

82.3%

100-10T

2283

3/4 Hp 4 sp

16x25

2130

1901

N/R

2007

1832

N/R

347

56 1/2

25 1/2

52 5/8

12 3/4

23 3/8

23 3/4

23 5/8

REH

REH750

1000 REL

140,000

120,000

105,000

85,000

175,000

140,000

115,000

1.00 80B

95,000

.85 8 0 B

85,000

.75 80B

70,000

.60 80A

140,000

1.25 80B

115,000

1.00 80B

.85 80B

1.00 60SS

.65 6 0 A

.85 7 0 A

.60 60A

.75 70A

.50 60A

.60 70A

1.00 80B

1.25 60SS

.85 80B

1.00 60SS

85.0%

85.4%

85.9%

84.2%

85.0%

16x25

(2 )1 6x 2 0

(2)16x20

100-10T

2283

3/4 Hp 4 sp

1745

3/4 Hp 4 sp

1745

3/4 Hp 4 sp

1745

3/4 Hp 4 sp

2466

3/4 Hp 4 sp

2466

3/4 H p 4 sp

2130

1901

1550

1376

1550

1376

1550

1376

2150

1839

2150

1839

1717

2007

1250

1480

1250

1480

1250

1480

N/R

2072

1600

2072

1832

1644

N/R

1343

1175

1343

1175

N/R

1859

1610

1501

N/R

3 1/2

N/R

3 1/2

1043

3 1/2

N/R

347

298

362

56 1/2

53 5/8

25 1/2

52 5/8

12 3/4

22 1/4

33 1/8

49 1/8

11 1/8

22 1/4

33 1/8

49 1/8

11 1/8

22 1/4

33 1/8

49 1/8

11 1/8

25 1/8

53 5/8

38 1/2

21 1/2

25 1/8

53 5/8

38 1/2

12 1/2

23 3/8

23 3/4

23 5/8

19 3/4

20 1/2

23 5/8

19 3/4

20 1/2

23 5/8

19 3/4

20 1/2

23 5/8

21 1/2

22 7/8

13 5/8

21 1/2

22 7/8

13 5/8

Regal Specifications

RE L750

Model

120,000

105,00

85,000

BTU/Hr Input

95,000

.85 80B

85,000

.75 80B

70,000

.60 8 0 A

BTU/Hr Output

Nozzle Beckett AFG @ 100PSI

.65 60A

.85 70A

.60 60A

.75 70A

.50 6 0 A

.60 7 0 A

Nozzle R iello 40 Series @ 150P SI

N o z z le C a r lin E Z - 1 @ 1 0 0 P S I

Flue Size

85.0%

84.4%

85.9%

AFU E S easonal Efficiency

(2)1 6 x 20

(2)16x20

(2)1 6 x2 0

Filter Size (inches)

100-10T

Blower S ize

1903

3/4 H p 4 sp

1903

3/4 H p 4 sp

1903

3/4 H p 4 sp

Blower M otor

C F M @ 0.2 "W C Hig h

1711

Med High

1547

1399

1547

1399

1547

1399

Low

M ed Low

1661

C F M @ 0.5 "W C Hig h

1485

Med High

N/R

1355

1227

1355

1227

Low

M ed Low

Cooling C apacity (Tons)

323

Shipping W eight (lbs)

Dimensions (Inches)

20 1/4

47 1/2

31 1/4

10 1/8

17 1/2

20 1/4

47 1/2

31 1/4

10 1/8

17 1/2

20 1/4

47 1/2

31 1/4

10 1/8

17 1/2

C a b in et H eig h t A

C a b in et W id th B

C a b in et D ep th C

Center Line Flue to Floor D

Center Line Flue to Side E

W arm A ir Supply D epth G

18 1/4

W arm A ir Supply Width H o

R e tu rn A ir W idth Hr

R e tu rn A ir Dep th J

Installation Clearances

Furnaces in rooms shall be installed with the clearances from combustible materials not

WARNING

less than indicated in Table 1. Combustible materials are those made of or surfaced with wood, compressed paper, plant fibers, plastics, or other material that will ignite and burn, whether flame proofed or not, or whether plastered or not.

Place the furnace near the center of the supply and return ducts and as close to the chimney connector as possible. Provide a solid brick or 2” thick minimum concrete pad if the furnace mounting area is not level or if the floor can become flooded.

Table 1 Standard Installation Clearances

MODEL

Sides

“A”

Top “B”

Front

“C”

Rear

“D”

Flooring Chimney

Connector

“E”

Plenum

Top &

Sides REH600 2” 2” Alcove-24” 2” Combustible 18” 2” REL600 2” 2” Alcove-24” 2” Noncombustible 18” 2” REH750 2” 2” Alcove-24” 2” Combustible 18” 2” REL750 2” 2” Alcove-24” 2” Noncombustible 18” 2” REH850 2” 2” Alcove-24” 2” Combustible 18” 2” REL850 2” 2” Alcove-24” 2” Noncombustible 18” 2” REH1000 2” 2” Alcove-24” 2” Combustible 18” 2” REL1000 2” 2” Alcove-24” 2” Noncombustible 18” 2” REH1250 2” 2” Alcove-24” 2” Combustible 18” 2” REL1250 2” 2” Alcove-24” 2” Noncombustible 18” 2”

Lowboy furnaces not listed for combustible floor may be placed on combustible floors although not listed for such installation, provided the floor under the furnace is protected in accordance with the requirements of accepted building code practice and NFPA 31. The furnaces shall be permitted to be placed on combustible flooring protected by 4” hollow block placed with ends unsealed and joints matching in such a fashion as to permit free circulation of air from side to side through the masonry. The block must be covered with sheet metal not less than 24 gauge.

Furnaces are permitted to be installed in rooms, but not closets, with lesser clearances to combustible material, provided the combustible material is protected as described in Table 2 and NFPA 31. In no case shall the clearance be such as to interfere with the requirements for combustion air, draft regulators and accessibility.

All clearances shall be measured from the outer surface of the combustible material to the nearest point on the surface of the appliance or chimney connector, disregarding any intervening protection applied to the combustible material.

Spacers and ties are to be of noncombustible material. No spacer or tie shall be used directly opposite an appliance or chimney connector.

With all clearance reduction systems using ventilated air space there shall be at least 1” clearance between the reduction systems using ventilated air space.

Mineral wool batts, blanket or board shall have a minimum density of 8lb/ft3 and a minimum melting temperature of 15000F.

Insulation material used as part of a clearance reduction system shall have a thermal conductivity of

1.0(Btu/In)/ (Ft2/Hr/0F).

Table 2 Allowable Clearances with Specified Protection Type of protection applied to and covering all surfaces within the distance specified as the required clearance with no protection

Where the Specified Clearance with No Protection from the Appliance or

Chimney Connector

18” 12” 9” 6”

Above Rear &

Sides

Above Rear &

Sides

Above Rear &

Sides

Above Rear &

Sides

3½” thick masonry wall without ventilated air space

½” insulation board over 1” glass fiber or mineral wool batts

24 gauge sheet metal over 1” glass fiber or mineral wool batts reinforced with wire on rear face with ventilated air space

3½” thick masonry wall with ventilated air space

24 gauge sheet metal with ventilated air space

½” insulation board with ventilated air space

24 gauge sheet metal with ventilated air space over 24 gauge sheet metal with ventilated air space 1” glass fiber or mineral wool batts sandwiched between 2 sheets 24 gauge sheet metal with ventilated air space

N/A 12” N/A 9” N/A 6” N/A 5”

12” 9” 9” 6” 6” 5” 4” 3”

9” 6” 6” 4” 5’ 3” 3” 3”

N/A 6” N/A 6” N/A 6” N/A 6”

9” 6” 6” 4” 5” 3” 3” 2”

9” 6” 6” 4” 5” 3” 3” 3”

6” 6” 6” 4” 5” 3” 3” 3”

If the furnace is to be installed in a residential garage, the furnace must be a minimum of 18” above the garage floor and located so it cannot be damaged by a moving vehicle.

Duct Work

NOTICE

The duct system should follow the design standards of Air Conditioning Contractors of America (ACCA) or ASHRAE. The duct system should be sized for the maximum CFM capabilities of the furnace being installed.

All trunk lines, take-offs, registers and grill free areas must be figured when determining the air handling capacity of a duct system. By utilizing the Tables 3 through 5, one can obtain the necessary duct system size. Use a supplier's catalog for proper sizing of outlet and return air registers to insure that the register will meet the CFM requirements of the run to which it is connected. Do not exceed the recommended flow rate. The pressure drop for each should not exceed 0.05 inch water column.

The return air ducts should equal the warm air duct system in CFM capacities. Avoid locating a return air duct in rooms that may contain undue odors. Use only a return air filter mounted to or integral to the furnace. Do not add additonal filters unless the duct system is sized to allow for the additional

pressure drop. An open return in a basement does not meet the requirements of return air. Instruct the homeowner not to block any returns.

Always check the size of existing ducts, particularly if you are adding air conditioning. The pressure drop through the cooling evaporator coil reduces available air flow. If the ducts are too small the system may not work satisfactorily or be noisy on either heat or cooling.

If the furnace is used in connection with summer air conditioning, the furnace should be installed parallel with or on the upstream side of the evaporator coil to avoid condensation in the furnace heat exchanger. The evaporator coil must be installed at least 6” above the heat exchanger for proper air flow. Distances less than 6” will result in decreased air flow. In all cases refer to the manufacturers data for static pressure losses to ensure the total system static pressure does not exceed 0.5” WC. If the cooling unit is installed with a parallel flow arrangement, dampers or other means used to control flow of air should be provided to prevent chilled air from entering the furnace. If such a damper is manually operated, it must be equipped with a means to prevent operation of either unit, unless the damper is in the full heat or cool position.

NOTE: When a return register is located in the same room as the furnace, the register must be at least 20 feet away from the furnace.

To obtain proper CFM on a direct drive unit the blower motor speed may need to be changed depending upon the size of the air conditioning system installed and the static resistance of the duct system. See blower specifications for air conditioning CFM's at a .5 static.

Determining Air Flow CFM

The temperature rise through the furnace should not exceed the rated temperature rise as listed on the Rating Label (Typically750F) and should be at least 550F for comfort.

The sensible heat temperature change for cooling would be approximately 300F. Actual temperature change will be approximately 20

F due to the humidity in the air.

To calculate the sensible heat change or temperature rise the following formula applies ∆T = (Btuh – Output)/(1.1 x CFM) To calculate the air flow when you know the temperature rise the following formula applies CFM = (Btuh – Output)/ (1.1 x ∆T)

An estimate of air flow can be achieved by the following rules of thumb: Heating: 1300 CFM per 100,000 Btuh output

Cooling: 400 CFM per ton of air conditioning Determine the required air flow for the system based on both heating and cooling requirements. Use the larger of either for duct design.

Table 3 lists the maximum recommended air velocities for ducts. Velocities greater than those as listed may result in objectionable air noise in the ducts.

Table 3 Recommended Maximum Duct Velocities, Feet Per Minute (FPM)

Application

Supply Return Supply Return

Main Ducts* Branch Ducts

Apartments 900 700 600 600 Auditoriums 1200 1000 1000 800 Banks 2000 1500 1600 1200 Hotel Rooms 1500 1300 1200 1000 Libraries 2000 1500 1600 1200 Meeting Rooms 2000 1500 1600 1200 Offices 2000 1500 1600 1200 Residences 900 700 600 600 Restaurants 2000 1500 1600 1200 Retail Stores 2000 1500 1600 1200

*When sound control is critical use branch duct velocities

Table 4 Duct Area Required at Listed Flow Conditions

CFM Area

Sq. In.

600FPM

Area

Sq. In.

800FPM

Area

Sq. In.

1000FPM

Area

Sq. In.

1200FPM

Area

Sq. In.

1600FPM

Area

Sq. In.

2000FPM 50 12 100 24 18 14 12 150 36 27 22 18 14 200 48 36 29 24 18 14 250 60 45 36 30 23 18 300 72 54 43 36 27 22 400 96 72 58 48 36 29 500 120 90 72 60 45 36 750 180 135 108 90 68 54 1000 240 180 144 120 90 72 1250 300 225 180 150 113 90 1500 360 270 216 180 135 108 1750 420 315 252 210 158 126 2000 480 360 288 240 180 144 Note: For Systems not over 100 feet equivalent length. Do not apply this table to duct systems which exceed 100 equivalent feet in length. For longer systems refer to ACCA Manual D. Incorrectly sized ducts can result in unsafe or uncomfortable operation.

Table 5 Round Duct Equivalent Area Nominal Size 4 5 6 7 8 9 10 12 Area in.2 12.5 19.6 28.3 38.5 50.3 63.6 78.5 113.1

Table 7 Direct Drive Blower Specifications

Model HP Speeds RPM Volts Full

Load

Amp.

REL750 3/4 4 1075 115 9.2 15 CCW 100-10T Hi

REL1000 3/4 4 1075 115 9.2 15 CCW 100-10T Hi

REH 750 3/4 4 1075 115 9.2 15 CCW 100-10T Hi

REH1000 3/4 4 1075 115 9.2 15 CCW 100-10T Hi

Capacitor

370 volt

mfd

Rotation Blower

Model

Blower

Speed

Blower

Speed

Change

Med Low Med

Med

Table 8 Direct Drive Blower Performance

0.2 In. W.C. Static Pressure 0.5 In. W.C. Static Pressure

Blower

Speed

Heat Low

Med Low

Low

Med Low

High

REL-600 1903 1711 1547 1399 1661 1485 1355 1227

REL-750 1903 1711 1547 1399 1661 1485 1355 1227

REL-850 1903 1711 1547 1399 1661 1485 1355 N/R

REL-1000 2466 2150 1839 1600 2072 1859 1610 N/R

REL-1250 2466 2150 1839 N/R 2072 1859 N/R N/R

REH-600 1745 1550 1376 1250 1480 1343 1175 1043

REH-750 1745 1550 1376 1250 1480 1343 1175 N/R

REH-850 1745 1550 1376 1250 1480 1343 N/R N/R

REH-1000 2283 2130 1901 1717 2007 1832 1644 1501

REH-1250 2283 2130 1901 N/R 2007 1832 N/R N/R

Med. High

Med. Low Low High

Med. High

Med. Low Low

MULTIPLE FURNACES IN COMMON DUCT WORK

Multiple furnaces connected to common duct work, either supply, return, or both supply and return must be wired so that all furnace blower motors are energized at the same time.

Failure to turn all blowers on at the same time can cause a reversal of air flow in those

WARNING

units where the blower motor is not operating. This reversal of air flow can cause premature blower, blower motor, wiring and or heat exchanger failure.

Please consult the factory for specific wiring instructions for your application.

ECM MOTOR OPERATING MODES

Introduction

The ECM 5.0 motor is a variable speed, high effiency motor which has the ability to produce constant air flow within a system, independent of static pressure. It achieves constant air flow by adjusting speed and torque to account for changes in system static pressure. The GE ECM uses a proprietary mathmatical algorithim to model air moving systems driven by forward curved blower wheels.

Operating Modes

The ECM motor is controlled by 24VAC thermostat signals to determine which mode of operation the blower is to run. Air flow rates in the different modes are controled by the setting of the DIP switches.

Standby Mode:

The thermostat inputs are being continuously monitored . The motor will respond to the 24 volt AC input signal from the thermostat.

Fan Mode:

When a call for fan operation is received from the thermostat (“G” line is energized) the blower will operate at a reduced speed as determined by the position of the cooling DIP switches as set for the airconditioning speed. See air flow tables for DIP switch and air flows. If a call for cooling or for heating is energized along with the call for fan only the unit will run at the respective air flow for heating or cooling. Electronic air cleaner terminal “EAC” is energized

Cooling Mode:

When a call for cooliong is received from the thermostat (“Y” line is energized) the motor will operate at the cooling speed and profile as adjusted by the cooling DIP switches. Cooling air flow is profiled to ramp the air flow up to the full cooling air flow to allow for maximum dehumidification. Electronic air cleaner terminal “EAC” is energized

Heat Mode:

When a call for heat is received from the thermostat (“W” line is energized) the motor will operate through the heating cycle at the air flow as adjusted by the heating DIP switch. When a call for heat is initiated the blower will turn on after a 30 second delay to ensure warm plenum temperatures as the furnace heats up. The blower then runs at a reduced rate before increasing its speed to the full air flow requireements.

When the call for heat is satisfied the blower will continue to operate at a reduced rate for a period of 3 minutes to remove all of the usable heat from the furnace while still maintaining the plenum temperatures at a comfortable level. Electronic air cleaner terminal “EAC” and humidifer terminal “H” are energized

ECM Motor Air Flow Selection

Air flow settings for both heating and cooling are made by setting the heat and the cool airflow DIP switches to the proper location. Ensure the furnace power supply is off before adjusting blower speeds. Do not adjust the heating air flow below the firing rate of the furnace. The air flows for heating are designed to give a 70oF temperature rise.

ECM REH/REL 750 Heating Speed Selection Burner Firing Rate

0.60 GPH ON ON D 950 CFM

0.75 GPH OFF OFF A 1175 CFM

0.85 GPH ON OFF B 1325 CFM

Heat Switch

#1 Position

Heat Switch

#2 Position

Program Heating

Air Flow

ECM REH/REL 1000 Heating Speed Selection Burner Firing Rate

1.00 GPH ON ON D 1575 CFM

1.25 GPH OFF OFF A 1925 CFM

AC Tons 4 Tons OFF OFF A 1600 CFM 1200 800 3 Tons ON OFF B 1200 CFM 900 600 2-1/2 Tons OFF ON C 1000 CFM 750 550 2 Tons ON ON D 800 CFM 600 550

AC Tons 5 Tons OFF OFF A 2000 CFM 1500 1000 4 Tons ON OFF B 1600 CFM 1200 800 3 Tons OFF ON C 1200 CFM 900 600 2-1/2 Tons ON ON D 1000 CFM 750 550

Heat Switch

#1 Position

ECM REH/REL 750 Cooling Speed Selection

Cool Switch

#1 Position

ECM REH/REL 1000 Cooling Speed Selection

Cool Switch

#1 Position

Heat Switch

#2 Position

Cool Switch

#2 Position

Cool Switch

#2 Position

Program Heating

Air Flow

Program Cooling

Air FlowY2

Program Cooling

Air Flow Y2

Cooling

Air FlowY1

Cooling

Air FlowY1

Air Flow

“G”

Air Flow

“G”

ECM Motor Connections

The operation of the motor requires two main connections: the power input connector which is 120VAC, and the signal input connector from a 24VAC thermostat. Figure 1 shows the location of the connectors

on the motor. When wiring your ECM, the pin

locations are crucial in assuring that no damage is done to the motor or the control. The figures show the pin locations for both connectors, when viewing the motor as shown below

Power Connector

Pin Description

1 JUMPER PIN 1 TO PIN 2 2 120 VAC LINE INPUT 3 CHASSIS GROUND 4 AC LINE 5 AC LINE

Power connector

Signal connector

Signal Connector

PinDescription

1 C1 2 W/W1 3 C2 4 DELAY 5 COOL 6 Y1 7 ADJUST 8 OUT9 O 10 BK/PWM 11 HEAT 12 R 13 EM/W2 14 Y/Y2 15 G 16 OUT+

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Boyertown Regal Oil Furnace Nrg Max User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual