Carrier CBLAAA060120, CBLAAA036105, CBLAAR036105, CBLAAR060120 Installation Instructions Manual

Installation Instructions

THIS BOOKLET CONTAINS

IMPORTANT INFORMATION

INSTALLER: Use the information in this

booklet to install the appliance and affix this
booklet adjacent to the appliance after

installation.

USER: Keep this booklet of information for
future reference.

SERVICER: Use the information in this booklet

to service the appliance and affix the booklet

adjacent to the appliance after servicing.

J

Al1539

®

Use of the AttRI Certified TM Mark indicates a

C US

Copyright 2012 CAC / BDP • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 01/12

Manufacturer reserve8 the right to change, at any time, specification8 and design8 without notice and without obligations.

manufacturer's participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.

Catalog No: IM-CBL-01 / X40192 Rev. B

Replaces: New

TABLE OF CONTENTS FIGURES

1.0 SAFETY REGULATIONS ......................................... 4

1.1

DANGER, WARNING AND CAUTION ................. 4

1.2

SAFETY INSTALLATION REQUIREMENTS ........ 4

2.0 INSTALLATION ........................................................ 4

2.1 GENERAL ............................................................ 4

2.2 SAFE INSTALLATION REQUIREMENTS ............ 5

2.3 SAFETY RULES ................................................... 5

2.3.1 Detector ........................................................ 5

2.3.2 Freezing temperatures and your building ..... 5

2.4 LOCATION ........................................................... 6

2.4.1

2.4.2

2.4.3

2.4.4

2.4.5

2.4.6

2.4.7

2.4.8

2.4.9

3.0 OPERATION ........................................................... 10

3.1

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

Air for combustion and ventilation ................ 6

Duct recommendations ................................. 5

Venting instructions (chimney installation) .... ?

Draft Regulator ............................................. 8

Blocked vent shut-off (BVSO) ....................... 8

Off burner. ..................................................... 9

Electrical ..................................................... 10

Air filter ....................................................... 10

Air Conditioner (or Heat Pump) .................. 10

FAN ADJUSTMENT CHECK .............................. 10

OPERATIONAL CHECKLIST ............................. 11

PURGING THE OIL LINE ................................... 11

COMBUSTION CHECK ...................................... 11

LIMIT CONTROL CHECK ................................... 12

YEAR ROUND AIR CONDITIONING ................. 12

HEATING ........................................................... 12

COOLING ........................................................... 12

CONSTANT BLOWER SWITCH ........................ 12

1

Figure
Figure

Figure
Figure

Figure
Figure

Figure
Figure

Figure
Figure

Figure
Figure

Figure

: Wiring diagram, BVSO ......................................... 9

2

: Wiring for blocked vent shut-off (size 105) ........... 9

3

: Wiring for blocked vent shut-off (size 120) ........... 9

4

: BVSO switch installation ....................................... 9

5

: Fan OFF time dip switch settings ....................... 11

6

: Model CBL, SIZE 105......................................... 17

7

: Model CBL, SIZE 120......................................... 17

8

: Wiring diagram CBL Beckett burner ................... 18

9

: Wiring diagram CBL, RielIo burner ..................... 19

10 : Parts list - CBLAAA036105 .............................. 20

11 : Parts list- CBLAAA060120 .............................. 22

12 : Parts list - CBLAAR036105 .............................. 24

13 : Parts list - CBLAAR060120 .............................. 26

TABLES

Table

1 : Minimum ventilation openings dimensions required

in a closet or enclosure .......................................... 6

Table

2 :Air filter dimensions for return air duct ................. 10

Table

3 :Adjustments for fan speed selection .................... 11

Table

4 : Technical specifications ....................................... 15

Table

5 :Air delivery - CFM with air filter ............................ 16

Table

6 : Minimum clearances - combustible materials ...... 16

Table

7 : Parts list- CBLAAA036105 .................................. 21

Table

8 : Parts list- CBLAAA060120 ................................... 23

Table

9 : Parts list- CBLAAR036105 ................................. 25

Table

10: Parts list - CBLAAR060120 ................................ 27

4.0 MAINTENANCE ...................................................... 12

4.1

HEAT EXCHANGER CLEANING ....................... 12

4.2

BLOWER REMOVAL .......................................... 13

4.3

BLOCKED VENT SHUT OFF (BVSO)

CLEANING ......................................................... 13

5.0 FURNACE INFORMATION ..................................... 14

1.0 SAFETY REGULATIONS

FOR YOUR SAFETY

DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY
OF THIS OR ANY OTHER APPLIANCE.

DO NOT ATTEMPT TO START THE BURNER WHEN
EXCESS OIL HAS ACCUMULATED, WHEN THE

FURNACE IS FULL OF VAPOUR OR WHEN THE
COMBUSTION CHAMBER IS VERY HOT.

IMPORTANT: All local and national code requirements

governing the installation of oil burning equipment, wiring
and flue connections MUST be followed. Some of the codes

that may be applicable are:
CSA B139 Installation code for oil burning

equipment

NFPA 31 Installation of oil burning equipment

ANSI/NFPA 90B

ANSI/NFPA 211

ANSI/NFPA 70
CSA C22.1

Warm air heating and air conditioning
systems

Chimneys, fireplaces, vents and solid
fuel burning appliances

National electrical code
Canadian electrical code

1.1 DANGER, WARNING AND CAUTION

The words DANGER, WARNING and CAUTION are used to
identify the levels of seriousness of certain hazards. It is

important that you understand their meaning. You will notice
these words in the manual as follows:

_1_ DANGER

Hazards or unsafe practices which CAN result in death

or serious bodily and/or material damage.

Hazards or unsafe practices which CAN result in minor

bodily and/or material damage.

1.2 SAFETY INSTALLATION REQUIREMENTS

Only the latest issues of the above codes should be used,
and are available from either:

The National Fire Protection Agency
Batterymarch Park

Quincy, MA 02269

or

The Canadian Standards Association

178 Rexdale Blvd.

Rexdale, Ontario
M9W 1R3

ENVIRONMENTAL HAZARD
Failure to follow this caution may result in

environmental pollution.

Remove and recycle all components or materials (i.e.

oil, electrical and electronic components, insulation.
etc.) before unit final disposal.

2.0 INSTALLATION

2.1 GENERAL

For use with grade 2 fuel oil maximum. Do NOT use

gasoline, crankcase oil or any oil containing gasoline.

Never burn garbage or paper in the heating system and

never leave rags or paper around the unit.

These instructions are intended for the sole use of i
qualified personnel trained in installing this type of i
furnace. Installation of this furnace by an unqualified i

person can lead to hazardous conditions, resulting in i
bodily harm and/or equipment damage, i

This furnace is a Low-Boy unit and may be operated in an
upflow configuration only.

It is shipped as a packaged unit, complete with burner and

controls. It requires a line voltage (115 VAC) connection to
the control box, a thermostat hook-up as shown on the

wiring diagram, oil line connection(s), suitable ductwork, and
connection to a properly sized vent.

The air handling capacity of this furnace is also designed for
cooling. Refer to Table 5 for the expected airflow at various

I

=

external duct static pressures, based on the model selected.

2.2 SAFE INSTALLATION REQUIREMENTS 2.3 SAFETY RULES

Your unit is built to provide many years of safe and
dependable service, provided it is properly installed and

Installation or repairs performed by unqualified persons
can result in hazards to them and others. Installation

MUST conform to local codes or, in the absence of
same, to codes of the country having jurisdiction.

The information contained in this manual is intended for
use by a qualified service technician familiar with safety

procedures and quipped with the proper tools and test
instruments.

Failure to carefully read and follow all instructions in
this manual can result in death, furnace malfunction

and/or property damage.

FIRE HAZARD I

The furnace must be installed in a level position, never
where it will slope toward the front. If the furnace is not

installed level, oil will drain into the furnace vestibule l
and create a fire hazard.

NOTE: It is the personal responsibility and obligation of the I
customer to contact a qualified installer to ensure that the I

installation conforms to governing local and/or national I
codes and ordinances I

I

I

I

I

maintained. However, abuse and/or improper use can
shorten the life of the unit and create hazards for you, the

owner.

2.3.1 Detector

a. The U.S. Consumer Product Safety Commission

recommends that users of oil-burning appliances install
carbon monoxide detectors. There can be various

sources of carbon monoxide in a building or dwelling.
The sources could be gas-fired clothes dryers, gas
cooking stoves, water heaters, furnaces, gas-fired

fireplaces, wood fireplaces, and several other items.
Carbon monoxide can cause serious bodily injury and/or

death. Therefore, to help alert people to potentially
dangerous carbon monoxide levels, you should have
carbon monoxide detectors listed by a nationally

recognised agency (ex. Underwriters Laboratories or

International Approval Services) installed and

maintained in the building or dwelling (see Note below).

b. There can be numerous sources of fire or smoke in a

building or dwelling. Fire or smoke can cause serious
bodily injury, death, and/or property damage. Therefore,

in order to alert people to potentially dangerous fire or
smoke, you should have fire and smoke detectors listed
by Underwriters Laboratories installed and maintained in

the building or dwelling (see Note below).

a. This furnace is NOT approved for installation in mobile

homes, trailers or recreational vehicles;

b. Do NOT use this furnace as a construction heater or to

heat a building under construction;

c. There must be a sufficient supply of fresh air for

combustion as well as ventilation in the area where the

furnace is located;

d. Use only the type of fuel oil approved for this furnace

(see section 1.2 of this manual). Overfiring will result in
heat exchanger failure and cause dangerous operating

conditions;

e. Visually check all oil line joints for signs of leakage;
f. Connect furnace to the chimney;

g. The points in Part 3 "Operation" are vital to the proper

and safe operation of the heating system. Take the time
to ensure that all steps were followed;

h. Follow the regulations of the NFPA No.31 (in the USA)

and CSA B-139 (in Canada) or local codes for placing
and installing the oil storage tank;

i. Follow a regular service and maintenance schedule for

efficient and safe operation;

j. Before servicing, allow furnace to cool down. Always

shut off electricity and fuel to furnace when servicing.
This will prevent electrical shock or burns;

k. Seal supply and return air ducts;
I. The vent system MUST be checked to determine that it

is the correct type and size;

m. Install correct filter type and size;
n. Unit MUST be installed so that electrical components

are protected from direct contact with water.

detectors and makes no representations regarding any

I NOTE: The manufacturer of your furnace does not test any I

brand or type of detector.

Ensure that the area around the combustion air

intake is free of snow, ice and debris.

2.3.2 Freezing temperatures and your building

I FREEZING TEMPERATURE WARNING

Turn off water supply.
If your heater remains shut off during cold weather, the
water pipes could freeze and burst, resulting in serious

water damage.

Ifthe structure is unattended during cold weather you should

take the following precautions:
a. Turn off main water supply into the structure and drain

the water lines if possible. Open faucets in appropriate
areas;

b. Have someone check the structure frequently during

cold weather to make sure it is warm enough to prevent
pipes from freezing. Contact a qualified service agency,

if required.

I

2.4 LOCATION Chimney installation only

The barometric draft regulator shall be installed in the same
room or enclosure as the furnace, in such a manner as to

prevent any difference in pressure between the regulator
and the combustion air supply.

Air requirements for the operation of exhaust fans, kitchen

ventilation systems, clothes dryers, and fireplaces shall be
considered in determining the adequacy of the space to

provide the required combustion air.

In unconfined spaces, in buildings of conventional frame,
brick or stone construction, infiltration may be adequate to
provide air for combustion, ventilation and dilution of flue

gases. This determination must be made on an individual
installation basis and must take into consideration the overall

volume of the unconfined space, the number of windows and
ventilation openings, the number of doors to the outside,
internal doors which can close off the unconfined space and

the overall tightness of the building construction.

Many new buildings and homes (even older ones that have
been weatherized) must be considered as being of tight

construction and, therefore, infiltration will not be sufficient to
supply the necessary air for combustion and ventilation.

outdoor installation. This furnace shall be installed in I
such a manner as to protect the electrical components l

from water. Outdoor installation will lead to hazardous I

IThis furnace is not watertight and is not designed for I

electrical conditions and to premature furnace failure. I
The unit must be installed in a location where the ambient

and return air temperatures are above 15_C(601:).

This furnace is approved for reduced clearances to
combustible construction; therefore, it may be installed in a

closet or similar enclosure. This unit may be located in a
basement or on the same level as the area to be heated.

Whichever the case, the unit must always be installed level.

In a basement, or when installed on the floor, as in a
crawlspace, it is recommended that the unit be installed on a

concrete pad that is 2.54 to 5.08 cm (1 to 2") thick.

The required minimum clearances for this furnace are

specified in Table 6

I

The furnace should be positioned as closely as possible to
the chimney or vent in order to keep vent connections short

and direct. It should also be as close as possible to the
centre of the air distribution system.

2.4.1 Air for combustion and ventilation

This furnace should be installed in a location in which the
facilities for ventilation permit satisfactory combustion of oil,

proper venting and the maintenance of ambient
temperatures at safe limits under normal conditions of use.

The location should not interfere with the proper circulation
of air within the confined space.

Refer to the CAN/CSA-B139 installation code for complete
regulations, and for guidance on retrofit applications.

When this furnace is installed in a closet or enclosure, 2
ventilation openings are required for combustion air. The

openings should be located about 15.24 cm (6")from the top
and the bottom of the enclosure at the front of the furnace.

Table 1 indicates the minimum dimensions required for each
of these two ventilation openings.

Table 1 : Minimum ventilation openings dimensions

required in a closet or enclosure

Input Width Height

(BTU/h)

75,000 - 105,000 0.4 mm (16") 0.20 mm (8")

120,000 - 155,000 0.5 mm (20") 0.25 mm (10")

A building can be considered as being of tight construction
when:

a. Walls and ceilings exposed to the outside have a

continuous water vapour retarder with a rating of one
perm or less, with openings hermetically sealed and/or;

b. Weather-stripping has been added on operable

windows and doors, and/or;

c. Caulking or sealant have been applied to areas such as

joints around window and door frames, between sole

plates and floors, between wail-ceiling joints, between
wall panels, at penetrations for plumbing, electrical and

fuel lines and at other openings.

If combustion and ventilation air must be supplied to an
unconfined space from the outside, an opening with a free

area of not less than 6.45 cm2 (one inch2) per 1,000 BTU
per hour of total input of all appliances within the unconfined

space, but not less than 645.16 cm2 (100 inches 2) must be
provided. This opening must be located such a way that it

cannot be blocked in any way, at any time.

2.4.2 Duct recommendations

When ducting supplies air to a space other than where
the furnace is located, the return air ducts must be
sealed and also be directed to the space other than
where the furnace is located. Incorrect ductwork

termination and sealing will create a hazardous
condition that can lead to bodily harm.

Do not block the combustion air openings in the I
furnace. Any blockage will result in improper

combustion and may result in a fire hazard and/or cause I
bodily harm. I

I

Return air grilles and warm air registers must not be

obstructed.

IMPORTANT: The dampers should be adequate to prevent I
cooled air from entering the furnace, and if manualIy I

operated, must be equipped with the means to prevent I
operation of either the cooling unit or the furnace, unless the I

damper is in the full cool or heat position. I
The proper sizing of warm air ducts is necessary to ensure

satisfactory furnace operation. Ductwork should be in
accordance with the latest editions of ANSI / NFPA-90A

(Installation of Air Conditioning and Ventilating Systems) and
NFPA-90B (Warm Air Heating and Air Conditioning
Systems) or Canadian equivalent.

The supply air ductwork should be attached to the flanged
front opening provided at the discharge end of the furnace

and the return air ductwork should be attached to the flanged
rear opening of the furnace. See Figures 6 and 7, for the

dimensions of these openings, based on the model selected.

The following recommendations should be followed when
installing ductwork:

a. Install locking type dampers in all branches of the

individual ducts to balance out the system. Dampers
should be adjusted to achieve the desired static

pressure at the outlet of the furnace;

b. A flexible duct connector of non-combustible material

should be installed on both the supply and return air
sections of the unit. On applications where an extremely
quiet operation is necessary, the first 3 m (10') of supply

and return ducts should be internally lined with
acoustical material, if possible;

c. In cases where the return air grille is located close to the

fan inlet, there should be at least one 90° air turn
between the fan inlet and grille. Further reduction in
noise levels can be achieved by installing acoustical air

turning vanes or by lining the duct as described in b.
above;

d. When a single air grille is used, the duct between the

grille and the furnace must be the same size as the
return opening in the furnace.

When installing the furnace with cooling equipment for year
round operation, the following recommendations must be

followed for tandem or parallel air flow:

2.4.3 Venting instructions (chimney installation)

The furnace must be vented to the outside, in accordance
with local codes and other authorities having jurisdiction.

Oil fired appliances must be connected to flues having
sufficient draft at all times to ensure safe and proper

combustion.

For additional venting information refer to ANSI / NFPA 211
Chimneys, Fireplaces, Vents and Solid Fuel Burning

Appliances and/or CSA B139 Installation Code.

This furnace is certified for use with a Type "L" vent.

Pre-installation inspection of vent system

Before installing this furnace, it is highly recommended that
any existing vent system be completely inspected.

This inspection should include the following:
a. Inspection for any deterioration in the chimney or vent. If

deterioration is discovered, the chimney must be
repaired or the vent must be replaced;

b. Inspection to ascertain that the vent system is clear and

free of obstructions. Any blockages must be removed

before installing this furnace;

c. Cleaning the chimney or vent if previously used for

venting a solid fuel burning appliance or fireplace;

d. Confirming that all unused chimney or vent connections

are properly sealed;

e. Verification that the chimney is properly lined and sized

per the applicable codes (refer to list of codes in section

1.2).

Masonry Chimney

This furnace can be vented into an existing masonry
chimney. However, it must not be vented into a chimney

servicing a solid fuel burning appliance. Before venting this

furnace into a chimney, the chimney must be checked for

deterioration and repaired if necessary. The chimney must
be properly lined and sized per local or national codes.

POISONOUS CARBON MONOXIDE GAS HAZARD

Install the evaporator coil on the supply side of the
furnace ducting ONLY.

An evaporator coil installed on the return air side of the
ducting can cause condensation to form inside the heat
exchanger, resulting in heat exchanger failure. This in

turn can result in death, bodily injury.

a. On tandem airflow applications, the coil is mounted after

the furnace in an enclosure in the supply air stream. The
furnace blower is used for both heating and cooling
airflow;

b. On parallel airflow installation, dampers must be

provided to direct air over the furnace heat exchanger
when heat is desired and over the cooling coil when

cooling is desired.

If the furnace is vented into a common chimney, the chimney
must be of sufficient area to accommodate the total flue

products of alI appliances vented into the chimney.

Following are the preconditions for a safe venting system:
a. Ensure that the chimney flue is clear of any dirt or

debris;

b. Ensure that the chimney is not servicing an open

fireplace;

c. Never reduce the pipe size below the outlet size of the

furnace;

d. All pipes should be supported using the proper clamps

and/or straps. These supports should be at least every

1.2 m (4');

e. All horizontal runs of pipe should have an upward slope

of at least 2 cm per 1 m (1/4" per 1');

f. Allrunsofpipeshouldbeasshortaspossiblewithas

fewturnsaspossible;

g. Seamsshouldbetightlyjoinedandcheckedforleaks;
h. Thefluepipemustnotextendintothechimneybutbe

flushwiththeinsidewail;

i. Thechimneymustextend0.9m(3')abovethehighest

pointwhereitpassesthrougharoofofabuildingandat
least0.6m(2')higherthananyportionofa building
withinahorizontaldistanceof3m(10').Itshallalsobe

extendedat least 1.5 m (5') abovethe highest
connectedequipmentfluecollar;

j. Checklocalcodesforanyvariances.

FIRE, CARBON MONOXIDE POISONINC HAZARD
Failure to follow this warning could result in personal

injury, death, and/or property damage.
DO NOT reset the device or restart the furnace unless

the cause of the interruption has been identified and
corrected by a qualified agency. Ensure that the blocked
vent shut-off has been cleaned by a qualified agency
before placing into service.

Factory Built Chimneys

The furnace may be used with an approved factory built
chimney. Refer to chimney manufacturer's instructions for

proper installation.

2.4.4 Draft Regulator

The draft regulator supplied with the furnace must be used
for proper functioning. Installation instructions are included
with the control.

2.4.5

All oil furnaces installed in Canada must have a blocked vent
shut-off.

It is imperative that this device be installed by a
qualified agency.

This device is designed to detect the insufficient evacuation
of combustion gases in the event of a vent blockage. In such

a case the thermal switch will shut down the oil burner. The
device will then need to be re-armed MANUALLY.

Refer to figure 1, 2 and 3, and the installation instructions
supplied with the blocked vent shut-off for installation and
wiring procedures. Disconnect the red wire from the limit

switch that comes from terminal #9 of the fan control board.
Connect this red wire to one of the red wires of the BVSO.

Connect the other red wire of the BVSO to the limit switch.
Connect the green wire of the BVSO to cabinet ground.

The blocked vent shut-off must be installed in the flue
between 2 inches and 12 inches from the furnace outlet and
between the furnace outlet and draft regulator (See figure 4).

Blocked vent shut-off (BVSO)
For chimney venting

For more details, refer to the instructions supplied with the
device itself, as well as section 4 of this manual.

FIRE, CARBON MONOXIDE POISONINC HAZARD
Failure to follow this warning could result in personal

injury, death, and/or property damage.
The blocked vent shut-off MUST be inspected and

maintained annually by a qualified agency.

It is also essential that the BVSO be maintained annually.
For more details please refer to the instructions supplied with
the device itself, as well as Section 4 of this Manual.

ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal

injury or death.
Disconnect electrical power supply to the furnace before

wiring the blocked vent shut-off.

CUT HAZARD
Failure to follow this caution may result in personal

injury.
Sheet metal parts may have sharp edges or burrs. Use

care and wear appropriate protective clothing, safety
glasses, and gloves when handling parts and servicing

furnaces.

Figure1:Wiringdiagram,BVSO

120"/£C FRO!, ,SPPLI£NCE

LIMIT CIRCJIT OR _OUASTAT

N k

( E TRAL)

EOUIPEMENT

,',;R,J JN,

/20 isC BURNER START P_IbI'_RY
'filRE FROM 'M@'LIANCE

{FRO,'1 LIMIT CI_('UIT} B'/SO

120 ,iAC _ L1 (HOT)
FRO, ! L2 (_EUT{AL)

APPLIANCE

S ¸ -_

B'/SO

OROUbD

RED

LI41T

BLACK

L1

WHITE

,ilOLET

,,ALVEPRIMARY

BLUE

IONITION

ORANGE

J,3T0 _

YELLOW

C_D CELL TC_

YELLOW

C,SDCELL

CONTROL

Beckett Burner

Figure 2 : Wiring for blocked vent shut-off (size 105)

TO REbOTE LOW 'v'()LT/_,SE

A(_

/_C '_LS_lvl CIRC(IT (IF USEB]
IONSELE('TED dODELS

T(_

24 vAC

THERMOSTAT

DNS-01340 Rev/_

Figure 4 : BVSO switch installation

The BVSO must be installed
between the furnace outlet and
the draft control

SAFETYLMT SWITCH

8L'_CK _p,

BURKER CONTROL BOX

FACTORY Wl:_E(}

Riello Burner

ill

Figure 3 : Wiring for blocked vent shut-off (size 120)

The BVSO must
be installed

between 2" and

12" from the

furnace outlet

2.4.6 Oil burner

This furnace is supplied with a high pressure atomizing
retention head type burner (for use with not heavier than

grade 2 fuel oil). If the burner model is a Beckett AFG, the
mounting flange is fixed to the burner air tube and no

adjustment is required for insertion length. If a RielIo burner
is used, refer to the Technical Specifications, Table 4 for the
insertion length.

NEVER use the "interrupted ignition" function if a
Beckett AFG burner is installed on the furnace.

Oil Connections

Complete instructions for the installation of the fuel oil piping
can be found in the oil burner installation instructions

included with the furnace.

Oil line entry holes are provided in the side panels, so that a
two-pipe system may be used, if desired.

A 10 (or finer) micron oil filter should be used with all oil
burners and installed as closely as possible to the burner.

2.4.7 Electrical

unbroken electrical ground to minimize personal injury I
if an electrical fault should occur. A green ground screw I

IThe furnace cabinet must have an uninterrupted or I

is provided in the control box for this connection. I

The appliance must be installed in accordance with the
current ANSI / NFPA 70 National Electrical Code / CSA

C22.1 Canadian Electrical Code Part 1 and/or local codes.

The control system depends on the correct polarity of the
power supply. Connect "HOT" wire (H) and "NEUTRAL" wire
(N) as shown in Figures 8 and 9, based on the model

selected.

Metallic conduit (where required/used) may terminate at the
side panel of the unit. It is not necessary to extend the
conduit inside the unit from the side panel to the control box.

When replacing any original furnace wiring, use only 105°C,

16 AWG copper wire.

Instructions for wiring the thermostat are enclosed in the
thermostat carton (field supplied). Make the thermostat

connections as shown in Figures 8 and 9, based on the
selected model at the 24 Volt terminal board on the primary
relay.

When installing optional accessories on this appliance,
follow the manufacturer's installation instructions included

I

with the accessory. Other than wiring for the thermostat, wire
with a minimum of type "T" insulation (17°C rise (63°F)) must

be used for accessories.

2.4.9 Air filter

An internal filter rack, located in the blower compartment, is

provided as standard equipment with this furnace. A
sufficient clearance should be provided for air filter access.

Refer to Table 2 for filter rack flange dimensions for the
return air duct.

_k DANGER

A separate line voltage supply should be used with fused
disconnect switch or circuit breaker between the main power

panel and the unit.

Use only copper wire for 115V power supply to the unit.

Table 2 : Air filter dimensions for return air duct

Furnace

Model

CBLAAA036105 & CBLAAR036105
CBLAAA060120 & CBLAAR060120

2.4.8 Air Conditioner (or Heat Pump)

An air conditioning coil may be installed on the supply air
side ONLY.

POISONOUS CARBON MONOXIDE GAS HAZARD
Install the evaporator coil on the supply side of the

furnace ducting ONLY.
An evaporator coil installed on the return air side of the

ducting can cause condensation to form inside the heat
exchanger, resulting in heat exchanger failure. This in
turn can result in death, bodily injury.

No minimum clearance is required between the bottom of
the coil drain pan and the top of the heat exchanger. If a
heat pump is installed, a "dual-energy" thermostat, or other

control is required, in order to prevent the simultaneous
operation of the furnace and the heat pump. It also prevents
a direct transition from heating by way of the heat pump to

heating with oil. Refer to the thermostat instructions or those
of another control used for the proper wiring.

Air Filter

Quantity and Size Supply Opening Size

(2) 12" x 20" 0.5 m x 0.5 m (20" x 20")
(2) 16" x 20" 0.6 m x 0.5 m (24" x 20")

Return Opening Size

0.5 m x 0.5 m (20" x 20")

0.55 m x 0.5 m (22" x 20")

If a coil blower compartment is used, install air tight,
motorized and automatic air dampers. Cold air coming from

the coil and passing across the furnace can cause
condensation and shorten the life of the heat exchanger.

3.0 OPERATION

3.1 FAN ADJUSTMENT CHECK

This furnace is equipped with a 4 speed direct drive motor to
deliver a temperature rise within the range specified on the
rating plate.

Adjust the fan speed ACCORDING TO THE OIL INPUT
SELECTED, so that the temperature rise is within the range

specified on the rating plate (see Table 3). Consult the wiring
diagram for speed changes on the direct drive motor.

10

Table 3 : Adjustments for fan s )eed selection

FURNACE INPUT RECOMMENDED

UNIT SIZE

(BTUH) BLOWER SPEED

105
120

70,000 / 119,000 Med - Low
91,000 / 140,000 Med- High

105,000 / 154,000 High

To adjust fan off time, set DIP switches on control board to
obtain desired timing. (See Figure 5).

Figure 5 : Fan OFF time dip switch settings

DELAY OFF DIP SWITCH SETTINGS

{;0 _-,_,c 90 Sec 120 Sec 5"_ _ec

_' {/...... ;t I B]n _,_0 Sec 2 !'/in 90 ec I 4 bl]r DI?_'_ecEL_.X 6 Min

DELA_ _N DELAY OFF DELAh' ON DELAY OFF DELAY ON i DELAY OFF _ DELAY OFF

O '::_ I _,in 60 Sec 2 @in 90 Sec 4 Mfr 120 Sec 6 rdin

DELl/ON DELAI OFF 0ELAI ON DELAI OFF 0ELAI ON 0ELAI OFF DELAI ON DELAI OFF

BOL;TONS DIP AJ( STEMENT DE

DELAI .)E FERMET RE

b(', _-cc _40 _-,ec 20 _-,ec 1'50 Sec

I

SNS o6o Re A

3.2 OPERATIONAL CHECKLIST

Before starting up the unit, be sure to check that the
following items are in compliance:

1. The electrical installation, the oiI supply system, the
venting system, combustion air supply and ventilation;

2. The blower access door is in place and the blower raiI
locking screws are welI tightened;

3. The Blocked Vent Shut-Off (BVSO), if used, is installed
according to instructions (for chimney venting);

4. The oiI supply valve is open;

5. The flame observation door (located in front of the unit)
is welI closed;

6. The burner "Reset" button is welI pushed in or re-
armed;

7. The preliminary air adjustments on the burner comply
with the technical specifications in this manual;

8. The blower speed adjustments for heating and air
conditioning are appropriate and according to the

specifications in this manual;

9. The blower start/stop delays are satisfactory;

10. The thermostat of the room is in the heating mode and
is set higher than the ambient temperature.

To start the unit, turn the main electrical switch on.

Do not tamper with the unit or its controls. Call a
qualified service technician.

3.3

1.

PURGING THE OIL LINE

A 10-micron (or less) oil filter should be installed as
closely to the burner as possible with all oil burners, but

it is essential for burners with a low firing rate. We
recommend the use of a low pressure drop oil filter with
a capacity greater than that of the fuel pump;

2.

On a new installation, the air trapped in the oil line
leading from the tank to the nozzle must be thoroughly
purged in order to prevent excessive after drip. The oil
pump is equipped with a special fitting that facilitates the

purging of any air between it and the tank. The proper
procedure for performing this operation is as follows:

a. Place a piece of 1/4" diameter clear plastic tubing

over the purge fitting on the oil pump;

b. Start the oil burner, then open the purge fitting and

allow the burner to run until the purge tube is
completely free of air bubbles;

c. At this point tighten the purge fitting, which will

allow the oil to run to the nozzle and fire the burner.

If the purging takes longer than 15 seconds and no

flame has been established the burner will stop.

Push the reset button on top of the Primary Control

to restart the burner.

For detailed information on the operation of the Primary
Control please refer to the instructions included with the

furnace or the burner.

3.4 COMBUSTION CHECK

IMPORTANT: The heat exchanger metal surfaces may
have oil and the baffle insulation also contains binders.

These products will burn or evaporate when the unit
operates for the first time. Because of this, the smoke

reading may be inexact during the first minutes of operation.
Therefore, the unit must operate during at least 60 minutes

before taking any readings to adjust the combustion quality.
Let the unit cool down before making any adjustments.

IMPORTANT: The combustion check verification MUST be
performed after the nozzle replacement or the burner

cleaning. After these manipulations, the combustion
parameters are necessarily modified. Refer also to the

burner instruction manual.

In order to obtain optimum performance from the oil burner,
the following set-up procedures must be followed by
referring to the Technical Specifications, Table 5 in this

manual:

1. A test kit to measure the smoke, flue draft and over-fire
pressure should be used in order to obtain the proper air

band setting. Although all of the above measurements
are required for optimum set up and efficiency, the most
important reading that must be taken is the smoke

number in the flue pipe, downstream from the regulator;

2. The proper smoke number, as established by way of
engineering tests, is between 0 and 1. This degree of

smoke emission is commonly referred to as a "trace". It

11

isrecommendedthata BacharachTrueSpotSmoke
Testkitorequivalentbeused;

3. Followthenextstepsto do thecombustioncheck
verification:

a. Drillaminimumproperdiameter(about9/32")test

holeinthefluepipe,approximately18inchesfrom
thefurnacebreech;

b. From a cold start, let the unit operate for about 5

minutes;

c. Set the burner air setting until you have between 0

and 1 on the Bacharach Scale (or a "trace");

d. Take a CO2 sample at the same test location where

the smoke reading was taken and make note of it;

e. Adjust the burner air setting to obtain a CO2 reading

1.5% lower (or a 02 reading 2.0% higher) than the
reading associated with the "trace" of smoke;

f. This method of adjusting the burner will result in

clean combustion (Bacharach smoke scale
between 0 and a trace) and ensure the proper

functioning of the system.

4. A barometric draft regulator, supplied with the furnace,
must be installed, in order to ensure proper draft
through the furnace. The barometric damper must be

mounted with the hinge pins in a horizontal position and
the face of the damper vertical for proper functioning,
(see instructions included with damper). After the

furnace has been firing for at least five minutes, the draft
regulator should be set to between -0.025" W.C. and -

0.035" W.C.;

5. The over fire pressure that is taken through the
observation door located in the centre of the front panel
above the burner is a measurement that is necessary to

determine if there is a blockage in the heat exchanger or
the flue pipe. Please refer to the Technical

Specifications in this manual for over fire pressure
values. A high pressure condition may be caused by
excessive combustion air due to the air band being too

wide open or a lack of flue draft (chimney effect) or
some other blockage, such as soot in the secondary
section of the heat exchanger or the use of an oversize

nozzle input or high pressure pump;

6. After all the set up procedures mentioned above have
been completed, the burner should be fired and an

inspection mirror should be used to observe the flame
pattern at the tip of the nozzle. Any irregularities such as
burning to one side or pulsating flame patterns should

be corrected by changing the nozzle.

however, the fan motor speed may need to be changed to
obtain the necessary cooling airflow.

3.7 HEATING

The blower speed is factory set to deliver the required airflow
at normal duct static pressure.

3.8 COOLING

The blower speed may be adjusted in the field to deliver the
required airflow for cooling applications, as outlined in
Table 5.

3.9 CONSTANT BLOWER SWITCH

This furnace is equipped with a constant low speed blower
option. Whenever the room thermostat is not calling for

heating or cooling, the blower will run on low speed in order
to provide air circulation. If this constant blower option is not
desired, the rocker switch on the side of the control box can
be used to turn it off.

4.0 MAINTENANCE

I

Be sure to turn all power "OFF" upstream from the unit I

when servicing the furnace, unless power is required for I
specific operations. Failure to comply with thisl

CAUTION can result in bodily harm and/or cause a fire I
hazard. I

This furnace should never be operated without an air filter.
Disposable filters should be replaced at least once a year. If

equipped to provide cooling, filters should be replaced at a
minimum of twice a year.

To avoid personal injury, make sure the power is "OFF"
before servicing.

ALWAYS KEEP THE OIL VALVE CLOSED IF THE
BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD
OF TIME.

For optimum performance, the oil burner nozzle should be
replaced at least once a year.

3.5 LIMIT CONTROL CHECK

After the furnace has been in operation for at least 15
minutes, restrict the return air supply by blocking the filters or

closing the return registers and allow the furnace to shut
down on high limit. The burner will shut OFF and the main

blower should continue to run.

Remove the restriction and the burner should come back on
in a few minutes.

3.6 YEAR ROUND AIR CONDITIONING

The furnace is designed for use in conjunction with cooling
equipment, to provide year round air conditioning. The

blower has been sized for both heating and cooling;

The procedure for the installation and/or replacement of a
nozzle is outlined in the oil burner instruction manual which

is supplied with the furnace.

After replacing the nozzle, the burner should be adjusted in
accordance with the "COMBUSTION CHECK" section of this

manual.

4.1 HEAT EXCHANGER CLEANING

Normally, it is not necessary to clean the heat exchanger or
flue pipe every year, but it is advisable to have a qualified
service technician check the unit before each heating

season to determine whether cleaning or replacement of
parts is required.

12

If cleaning

is necessary,thefollowingstepsshouldbe

followed:

1.

Turn "OFF" all power upstream from the furnace;

2.

Disconnect the flue pipe and breach plate;

3.

Remove the radiator baffle;

4.

Disconnect the oil line and remove the oil burner from
the furnace;

5. Clean the secondary tubes and the primary cylinder with

a stiff brush and remove debris with a vacuum cleaner;

6. Before reassembling the furnace, the heat exchanger

and combustion chamber should be inspected to
determine if replacement is required;

7. After cleaning, replace the radiator baffle, flue collar

plate and oil burner;

8. Readjust burner for proper operation.

4.2 BLOWER REMOVAL

To remove the blower from the furnace:

1. Turn "OFF" all power upstream from the furnace;

2. Remove blower access door;

3. Remove the 4 blower retaining wing-nuts;

4. Slide the blower on the rails toward the rear of the unit;

5. Reverse the above steps to reinstall the blower. (Refer

to wiring diagram Figures 6, 7 and 8 of this instruction
manual or the diagram located on the inside of the

blower door to properly rewire the unit.

4.3 BLOCKED VENT SHUT OFF (BVSO) CLEANING

For continued safe operation, the Blocked Vent Shut-Off
System (BVSO) needs to be inspected and maintained
annually by a qualified service technician.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.
Disconnect electrical power supply to the furnace before

servicing the blocked vent shut-off.

1. Remove the two screws holding down the BVSO
assembly cover;

2. Remove the cover;

3. Remove the two screws holding the control box to the
heat transfer tube assembly. Sliding the control box in the

appropriate direction will unlock it form the heat transfer
tube assembly;

4. Carefully remove any build-up from the thermal switch
surface;

Do not dent or scratch the surface of the thermal switch.

If the thermal switch is damaged, it must be replaced.

5. Clear and remove any build-up or obstruction inside the
heat transfer tube;

6. Re-mount, lock and fasten the control box with the 2
screws removed in step 3;

7. Re-attach the assembly cover with the screws removed in
step 1;

8. Re-establish power to the appliance.

13

5.0 FURNACE INFORMATION

Model:

Furnace installation date:

Service telephone #-Day:

Dealer name and address:

START-UP RESULTS

Nozzle:

Burner adjustments:

002 : %

scale:

Primary air

Fine air

Drawer Assembly

Smoke

Serial number:

Night:

Pressure:

Ib/po 2

(Bacharach)

Gross stack temperature:

Ambient temperature:

Chimney draft :

Overfire draft :

Test performed by:

I=

1=

" W.C.

" W.C.

14

Table 4 : Technical specifications

Model:CBL 75 90 105 120 140 155

RATINGANDPERFORMANCE

Firingrate(USGR-I)
Input(BTU/h)

Heatingcapacity(BTU/h)
Heatingtemperaturerise
Fluedraftminimum(W.C.)(chimney)

Overfirepressure(W.C.)(chi_ey)

0.50 0.65 0.75 0.85 1.00 1.10
70000 91000 105000 119000 140000 154000
57000 74000 85000 97000 114000 123000

13- 2913(55- 85_F) 13- 2913(55- 85_F)

(-0.06"to-0.025") (-0.06"to-0.025")

(+0.010"to0.025") (max+0.025")

Fluedraftminimum(W.C.)(directvent)

.i :i:::__ i_ _:ii/:I /i_ _i_i:_i: (+0.10"to +0.25")

Overfirepressure(W.C.)(directvent)

i ii iii i (+0.12"to +0.27")

BECKETrBURNER;MODELAFG(3450rpm) AFG'F3(tubeinsertion 27/8") AFG-F3(ins, 27/8") AFG-F6(27/8")

Lowfiringratebaffle
Staticdisc,model
Nozzle(Delavan)

Pumppressure(PSIG)
Combustionairadjustment(band/shutter)
AFUE% (FromCSAB212standardandCanadianregulation)

AFUE% (FromASHRAE103standardandUSregulation)

RIELLOBURNER40-F(Chimneyvent)F3 (tube

0.50-70W 0.55-70B
100 140

0/5 0/7

82.4% 80.9%

82.6% 81.1%

APPLICABLE

3 3/8"#31646

insertion39/16")F5 (tube insertion39/16")

Nozzle(Delavan) 0.40-70A 0.50 - 70W
Pumppressure(PSIG) 155 170
Combustionairadjustment(turbulator/damper) 0/ 3 0/ 3.5

AFUE%(FromCSAB212standardandCanadianregulation) 84.4% 82.9%
AFUE% (FromASHRAE103standardandUSregulation) 80.5% 80.5%

0.65-70B
130

0/8

81.1%

81.4%

0.65- 70W
135

0/4

83.1%

80.5%

APPLICABLE
23/4"#3383

0.75-70B 0.85-70B
130 140

1/8 4/4

81.4% 80.3%

81.5% 80.6%

0.75- 70B
130

0/3

84.7%

80.0%

0.85- 70W
140

0/3.5

83.9%

80.0%

ELECTRICALSYSTBvl

APPLICABLE
23/4"# 3383

0.85-70B
170

2/8

80.1%

80.3%

1.00-70W
125

0/4

83.1%

80.0%

Volts- Hertz-Phase 115-60- 1
Operatingvoltagerange 104- 132
Ratedcurrent(Amps)
Minimumampacityforwiringsizing
Max.wirelenght

Max.fusesize(Amps)
Controltransformer

Externalcontrolpoweravailable

Heating
Cooling

12.2

13.7
26'

15

40VA
40VA

30VA

115-60- 1

104- 132

15.7

18.1
26'

20

40VA
40VA

30VA

BLOWI_DATA

Blowerspeedat0.50"W.C.staticpressure MED-LOW MED-HIGH HIGH MED-LOW MED-HIGH HIGH
Blowerspeedat0.25"W.C.staticpressure MED-LOW MED-HIGH HIGH LOW MED-LOW MED-HIGH

MotorHP/Speeds 1!3-4 3/4-4
Blowerwheelsize 10"x 8" 12"x 10"

GENERALINFORMATION

Overalldimensions(widthx depthx height)
Supplyairopening
Returnairopening

Filterquantityandsize
Shippingweight
Airconditioning,maximumoutput

21%"x 55"x 32"

20"x 20"
20"x 20"

(2) 12"x20"

86kg(190Ibs)

3 tons

21%"x 61½"x 351/4''

24"x 20"
20"x 22"

(2) 16"x20"

97kg(215Ibs)

5 tons

15

Table 5 : Air delivery - CFM with air filter

SPEED I EXTERNAL STATIC PRESSURE WITH AIR FILTER

-0.2" (W.C,) = 0.3" (W.C,) 0.4" (W.C,) i 0.5" (W.C,)

HIGH 1425 1350 1305 1250

M ED-HIGH 1130 1045 1000 950
M ED-LOW 840 810 770 740

LOW 725 730 740 745

SPEED i EXT B_.L STATIC PRESSURE WIT H AIR FILTER

- 0.2" (W.C.) = 0.3" (W.C.) i 0.4" (W.C.) i 0.5" (W.C.)

HIGH 2080 2041 1965 1864
M ED-HIGH 1892 1859 1770 1675
M ED-LOW 1556 1475 1394 1318

LOW 1221 1164 1081 998

Table 6 : Minimum clearances - combustible materials

SIDES

TOP

BOTTOM

FLUEPIPE

FRONT

FURNACE
SUPPLY PLENUMWITHIN 1.8 M(6') OF FURNACE

ACCESS PANEL TO BLOWER
FURNACEOR PLENUM

HORIZONTAL WARM AIR DUCTWITHIN 1.8 m(6') OF FURNACE
FURNACE(COMBUSTIBLEFLOOR)

HORIZONTALLY OR BELOW FLUE PIPE
VERTICALLY ABOVE FLUE PIPE

FURNACE I

2.54 cm (1")

2.54 cm (1")

10.16 cm (4")

50.8 mm(2")

50.8 mm(2")

0"

10.16 cm (4")

22.86 cm (9")

20.32 cm (8") 0.6 m (24")

0.6m(24")

0.6m (24")

16

Figure 6 : Model CBL, Size 105

5" DIA FLLE

',,[127 mrr]

%

20"

[so8 mr_,]

5"

[76 r_rr]

20"

[508 r_rr] _

27"

[686 mm]

Figure 7 : Model CBL, Size 120

20"

[5o8 mr-r]

I÷

55"

[i597 rrr_]

20"

[508 rr'm]

10" h

[294 rrr_]

20"

[508 r_rq]

32"

813 rrr _ ]

DNS-0173 Rev D

6" DIA FLLE

t [152 mini

21 25"

[540 ..... ] /

[15_

29"

[757 rrrr]

20"

[508 mm]

3"

22" 4"

[76 rrr_r ]_

[ss9 mm] [60 mrr']

1- !r _ ...............

_*

61 5"

[1562 mm]

20"

[508 rnm]

20"

[508 mm]

..... 7

F 5,

_ _--__fl [895 ...... ]

DNS-0172 Rev D

17