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.
A09489
EFFICIENCY
Copyright 2009 CAC / BDP • 7310 W, Morris St. • Indianapolis, IN 46231 Printed in U,S,A, Edition Date: 03/13
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations,
B140.4- UL727
Catalog No: IM-OBL098-04 / X40167 Rev.D
Replaces:lM---O BL098---03
TABLE OF CONTENTS
1 SAFETY REGULATIONS ...................................................................................................................................................... 3
1.1 SAFETY LABELING AND WARNING SIGNS .............................................................................................................. 3
1.2 IMPORTANT INFORMATION ........................................................................................................................................ 3
1.3 DETECTION SYSTEMS ................................................................................................................................................... 3
1.4 DANGER OF FREEZING ................................................................................................................................................. 3
2 INSTALLATION ..................................................................................................................................................................... 4
2.1 POSITIONING THE FURNACE ....................................................................................................................................... 4
2.2 ELECTRICAL SYSTEM ................................................................................................................................................... 4
2.3 INSTALLATION OF THE THERMOSTAT ................................................................................................................................... 4
2.4 INSTALLATION OF THE BURNER ................................................................................................................................ 5
2.5 VENTING .......................................................................................................................................................................... 5
2.6 BLOCKED VENT SHUT-OFF DEVICE (BVSO) FOR CHIMNEY VENTING .............................................................. 6
2.7 COMBUSTION AIR SUPPLY AND VENTILATION ..................................................................................................... 6
2.8 OIL TANK ......................................................................................................................................................................... 7
2.9 DUCTING .......................................................................................................................................................................... 7
2.10 SUPPLY AIR ADJUSTMENT (ECM VARIABLE SPEED MOTORS) ................................................................................................. 7
2.1 1 INSTALLATION OF ACCESSORIES .............................................................................................................................. 8
3 OPERATION ............................................................................................................................................................................ 9
3.1 START-UP ......................................................................................................................................................................... 9
3.2 OPERATING SEQUENCE OIL HEATING MODE .......................................................................................................................... 9
3.3 CHECKS AND ADJUSTMENTS ................................................................................................................................................. 9
4 MAINTENANCE ................................................................................................................................................................... 10
4.1 CLEANING THE HEAT EXCHANGER ........................................................................................................................ 11
4.2 CLEANING THE BLOCKED VENT SHUT-OFF DEVICE (BVSO) ............................................................................. 11
4.3 CLEANING OF THE BURNER HEAD .......................................................................................................................... 11
4.4 REPLACING THE NOZZLE ........................................................................................................................................... 11
4.5 REPLACING THE OIL FILTER ..................................................................................................................................... 11
4.6 REPLACING THE AIR FILTER ..................................................................................................................................... 11
5 FURNACE INFORMATION ................................................................................................................................................ 12
TABLES & FIGURES
TABLE 1: BLOWER SPEED ADJUSTMENTS (HEATING MODE, 4 SPEED MOTOR) ................................................................................... 7
TABLE
2: BLOWER SPEED ADJUSTMENTS (A/C MODE, 4 SPEED MOTOR) .......................................................................................... 7
TABLE
3: HEATING MODE ............................................................................................................................................................... 8
TABLE
4: AIR CONDITIONING MODE ............................................................................................................................................... 8
TABLE
5: CFM ADJUSTMENT - ALL MODES .................................................................................................................................... 8
TABLE
6: DELAY ADJUSTMENTS - HEATING MODE .......................................................................................................................... 8
TABLE
7:TECHNICAL SPECIFICATIONS .......................................................................................................................................... 13
TABLE
8: AIRFLOW DATA, MODELS WITH 1/2 HP ECM MOTORS.................................................................................................. 14
TABLE
9: AIRFLOW DATA, MODELS WITH 1/3 HP PSC MOTORS ................................................................................................... 15
TABLE
10:MINIMUM CLEARANCES FROM COMBUSTIBLEMATERIAL .............................................................................................. 15
TABLE
11: PARTS LIST - WITH 4 SPEED MOTOR PSC ..................................................................................................................... 20
TABLE
12: PARTS LIST - WITH VARIABLE SPEED MOTOR ECM ..................................................................................................... 22
FIGURE 1 : LOCATION AND DIMENSIONS OF VENTILATION AIR OPENINGS IN A CLOSET DOOR ............................................................ 4
FIGURE 2: HEATING & AIR CONDITIONING - WITH 4 SPEED MOTOR ............................................................................................... 5
FIGURE 3 : THERMOSTAT WIRING- HALTING & AIR CONDITIONING - WITH ECM VARIABLE SPEED MOTOR .................................. 5
FIGURE 4: THERMOSTAT WIRING-HEATING &AAIR CONDITIONING/HEATPUMP - WITH ECM VARIABLE SPEED MOTOR .............. 5
FIGURE 5: BLOWER START / STOP DELAYS - BOARD #1158 .............................................................................................................. 7
FIGURE 6: FURNACE DIMENSIONS ................................................................................................................................................. 16
FIGURE 7: WIRING DIAGRAM - 4 SPEED MOTOR (PSC) ................................................................................................................. 17
FIGURE g: WIRING DIAGRAM- VARIABLE SPEED MOTOR (ECM) ................................................................................................. 18
FIGURE 9: PARTS LIST - WITH 4 SPEED MOTOR PSC ..................................................................................................................... 19
FIGURE 10: PARTS LIST - WITH VARIABLE SPEED MOTOR ECM .................................................................................................... 21
1 SAFETY REGULATIONS
1.1
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:
Hazards or unsafe practices that CAN result in death,
bodily injury and/or property damage.
Hazards or unsafe practices that CAN result in bodily injury
and/or property damage.
1.2 IMPORTANT INFORMATION
Non-observance of the safety regulations outlined in this
manual will potentially lead to consequences resulting in
death, serious bodily injury and/or property damage.
a) It is the homeowner's responsibility to engage a
b) Do not use this furnace if any part of it was under
c) Do not store gasoline or any other flammable
d) This furnace is designed for use with #1 or #2 heating
e) Never block or otherwise obstruct the filter and/or
f) Ask the technician installing your furnace to show and
SAFETY LABELING AND WARNING
SIGNS
DANGER
CAUTION
qualified technician for the installation and subsequent
servicing of this furnace;
water. Call a qualified service technician immediately
to assess the damage and to replace all critical parts
that were in contact with water;
substances, such as paper, carton, etc. near the
furnace;
oil only. The use of gasoline, motor oil or any other oil
containing gasoline is prohibited;
return air openings;
explain to you the following items:
i) The main disconnect switch;
ii) The shut-off valve on the oil tank;
iii) The oil filter and how to change it (once a year);
iv) The air filter and how to change it (check monthly
and clean or replace if necessary.)
g) Before calling for service, be sure to have the
information page of your manual close by in order
to be able to provide the contractor with the
required information, such as the model and serial
numbers of the furnace.
Installations and repairs performed by unqualified
persons can result in hazards to them and to others.
Installations 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 technician, familiar with safety
procedures and who is equipped with the proper tools
and test instruments.
Failure to carefully read and follow all instructions in
this manual can result in death, bodily injury and/or
property damage.
1.3 DETECTION SYSTEMS
It is recommended that carbon monoxide detectors be
installed wherever oil or gas fired heaters are used.
Carbon monoxide can cause bodily harm or death. For
this reason, agency approved carbon monoxide detectors
should be installed in your residence and properly
maintained to warn of dangerously high carbon monoxide
levels.
There are several sources of possible smoke and flames
in a residence. Smoke and flames can cause bodily harm
or death. For this reason, agency approved smoke
detectors should be installed in your residence and
properly maintained, to warn early on, of a potentially
dangerous fire. Also, the house should be equipped with
approved and properly maintained fire extinguishers.
Your unit is equipped with safety devices that can prevent it
from functioning when anomalies are detected such as a
blocked venting system.
1.4 DANGER OF FREEZING
If your furnace is shut down during the cold weather
season, water pipes may freeze, burst and cause serious_
water damage. Turn off the water supply and bleed the_
pipes.
If the heater is left unattended during the cold weather
season, take the following precautions:
a. Close the main water valve in the house and purge the
pipes if possible. Open all the faucets in the house;
b. Ask someone to frequently check the house during the
cold weather season to make sure that there is
sufficient heat to prevent the pipes from freezing. Tell
this person to call an emergency number if required.
CAUTION ]
J
2 INSTALLATION
The unit is shipped with a burner and its controls. It requires a
115VAC power supply to the control panel and thermostat
hook-up as shown on the wiring diagram, one or more oil line
connections, suitable ductwork and connection to a properly
sized vent.
All local and national code requirements governing the
installation of oil burning equipment, wiring and the flue
connection MUST be followed. Some of the codes that may
apply are:
CSA B139: Installation code for oil burning equipment.
ANSI/NFPA 31 : Installation of oil burning equipment.
ANSI/NFPA 90B: Warm air heating and air conditioning
systems.
ANSI/NFPA 211 : Chimneys, Fireplaces, Vents and solid fuel
burning appliances.
ANSI/NFPA 70: National Electrical Code.
CSA C22.1 or CSA C22.10: Canadian Electrical Code.
Only the latest issues of these codes may be used.
2.1 POSITIONING THE FURNACE
Fire and explosion hazard.
The furnace must be installed in a level position, never
where it will slope toward the front.
Do not store or use gasoline or any other flammable
substances near the furnace.
Non-observance of these instructions will potentially result
in death, bodily injury and/or property damage.
CAUTION
This furnace is not watertight and is not designed for outdoor
installation. It must be installed in such a manner as to protect
its electrical components from water. Outdoor installation will
lead to a hazardous electrical condition and to premature
failure of the equipment.
The minimum clearances from combustible material for
each of the positions are specified in Table 10.
If the furnace is installed in a basement or on a dirt floor, in a
crawl space for example, it is recommended to install the unit
on a cement base 2.5 cm to 5.0 cm (1" to 2") thick.
The unit must be installed in an area where the ambient and
return air temperatures are above 15°C (60°F). In addition, the
furnace should be installed as closely as possible to the vent,
so that the connections are direct and kept to a minimum. The
heater should also be located close to the centre of the air
distribution system.
2.1.1 INSTALLATION IN AN ENCLOSURE
The unit can be installed in an enclosure such as a closet.
However, 2 ventilation openings are required for combustion
air. The openings should be located in front of the furnace
approximately 15 cm (6") above the floor and 15 cm (6") below
the ceiling. Figure 1 indicates the minimum dimensions
required and the location of the openings.
Figure 1: Location and dimensions of ventilation air
openings in a closet door
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i
2.2 ELECTRICAL SYSTEM
CAUTION
The exterior of the unit must have an uninterrupted ground
to minimize the risk of bodily harm, if ever an electrical
problem develops. A green ground screw is supplied with
the control box for that purpose.
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 7 and 8.
A separate line voltage supply should be used, with fused
disconnect switch or circuit breaker, between the main
power panel and the unit.
Only copper wire may be used for the 115V circuit on this
unit. If wires need to be changed, the replacements must
have the same temperature resistance as the originals.
2.3 INSTALLATION OF THE
THERMOSTAT
A thermostat must be installed to control the temperature
of the area to be heated. Follow the instructions supplied
with the thermostat. Also refer to the winng diagrams
provided with the heating/air conditioning unit. The
connections must be made as indicated on the following
diagrams and the wiring diagrams.
Figure 2: Heating & Air Conditioning - With 4 Speed Motor
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WAZOU i '{}t Ib ATSELR
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Figure 3: Thermostat Wiring- Haeting & Air Conditioning -
With ECM Variable Speed Motor
0090@< H_<MCS'_T f
co_ o,,o_'#2; ...................................................
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2. Remove the burner drawer assembly or the air tube
assembly;
3. Install the nozzle (refer to Technical Specifications,
p.13);
4. Check the electrode settings;
5. Make the electrical connections;
6. Complete oil line connections.
2.4.1 NOZZLES
The burner comes equipped with an appropriate nozzle.
However, if another size or a replacement nozzle is
required, use the manufacturer's recommended spray
angle and type a shown in Table 1 and based on a pump
pressure of 100 psi.
Always select nozzle sizes by working back from the
desired flow rate at operating pressure and not the nozzle
marking.
2.4.2 AIR AND TURBULATOR SETTINGS
Before starting the burner for the first time, adjust the air
and turbulator settings to those listed in this manual, Table
6. Once the burner becomes operational, final
adjustments will be required. Refer to section 3 of this
manual.
2.4.3 POST PURGE DELAY ADJUSTMENT
The post purge delay on the oil-fired burners is factory set
to zero second. This delay is applicable for all installations
with chimney venting. For heating units installed with side
walt venting and a burner equipped with this feature, the
post purge delay must be set to 15 seconds. No delay is
required for Rietto burners. Refer to the burner control
instruction manual and markings for proper adjustment of
the post purge delay.
Figure 4: Thermostat Wiring-Heating &Aair
Conditioning/HeatPump - With ECM Variable Speed Motor
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2.4 INSTALLATION OF THE BURNER
Also refer to the burner manufacturer's instructions.
1,
Position the mounting gasket between the mounting
flange and the burner mounting plate. Align the holes in
the burner mounting plate with the studs on the mounting
flange and bolt securely in place.
2.5 VENTING
Poisonous carbon monoxide gas hazard.
Never install a hand operated damper in the vent pipe.
However, any Underwriters Laboratories listed,
electrically operated automatic type vent damper may
be installed if desired. Be sure to follow the
instructions provided with vent damper. Also, read
and follow all instructions in this section of the
manual.
Failure to properly vent this furnace or other
appliances can result in death, bodily injury and/or
property damage.
To ensure the safe and proper functioning of an oil
furnace, it must always be connected to a flue with
sufficient draft or to an approved side-walt venting system.
In addition, it is strongly recommended to perform a
complete inspection of all the existing venting systems.
2.5.1 MASONRY CHIMNEY
This furnace can be vented into an existing masonry
chimney. However, the unit must not be vented into a
chimney into which a solid fuel burning furnace is already
being vented.
Beforeventingthisfurnaceintoachimney,itsconditionmust
becheckedandrepairsmade,ifnecessary.Also,thechimney
lininganddimensionsmustconformto localandnational
codes.
2.7 COMBUSTION AIR SUPPLY
AND VENTILATION
2.5.2 FACTORYBUILTCHIMNEYS
Oilfiredfurnacesareapprovedforusewith"L"typevents.The
unitmayalsobeusedwithanapprovedchimneyof proper
dimensionsandtemperatureratingsas specifiedin the
installationcode.Refertochimneymanufacturer'sinstructions
forproperinstallation.
2.5.3 DRAFT REGULATOR
It is recommended that a draft regulator be installed in cases
where the draft is either high or variable due to external
conditions. Follow the instructions provided with the regulator.
2.5.4 SIDE-WALL VENTING
The heating unit is approved for side-walt venting. This system
is comprised of a model VTK-54 / VTK-098 / KLAVT0101DET
side-wall venter and a 4" insulated vent pipe, model IFV-410 /
IFV098-10 / KLAFV0101DET, IFV-420 / IFV098-20 /
KLAFV0201DET. Refer to the installation instructions provided
with the venting system.
2.6 BLOCKED VENT SHUT-OFF DEVICE
(BVSO) FOR CHIMNEY VENTING
CAUTION
It is imperative that this device be installed by a qualified service
technician.
A positive pressure venting system (Sealed Combustion System
or Direct Vent) MUST NOT use the BVSO. Follow the
instructions supplied with the venting system.
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.
--Referto the detailed instructions and wiring diagrams supplied
with the BVSO for the installation and wiring procedures. The
length of wires supplied with the unit is such that the safety
device must be installed between the flue outlet of the
appliance and the draft regulator, as indicated in the
instructions.
It is also essential that the BVSO be maintained annually. For
more details refer to the instructions supplied with the device
itself, as well as Section 3 of this Manual.
2.6.1 BVSO PERFORMANCE TEST
The purpose of the following test is to check that the electrical
outlet on the furnace, designated to the BVSO, is functional.
1. Start up the burner;
2. Remove the three-pole plug from the BVSO outlet on the
furnace;
3. The burner must shut-off immediately, while the blower
continues to run to the end of the cool-down cycle.
If the test is not in line with the above, call a QUALIFIED
SERVICE TECHNICIAN.
Poisonous carbon monoxide gas hazard.
Comply with NFPA 31 (U.S.) and CSA B139 (Canada)
standards for the installation of Oil Burning
Equipment and applicable provisions of local building
codes to provide combustion and ventilation air.
Failure to provide adequate combustion and
ventilation air can result in death, bodily injury and/or
property damage.
Oil furnaces must have an adequate supply of combustion
air. It is common practice to assume that older homes
have sufficient infiltration to accommodate the combustion
air requirement for the furnace. However, home
improvements such as new windows, doors, and weather
stripping have drastically reduced the volume of air
infiltration into the home.
Refer to oil furnace installation codes relative to
combustion and ventilation air requirements. Consult
Section 2.1 in this manual, specifically for units installed in
an enclosed space.
Home air exhausters are common. Bathroom and kitchen
fans, power vented clothes dryers and water heaters all
tend to create a negative pressure condition in the home.
Should this occur the chimney becomes less and tess
effective and can easily downdraft. In certain cases,
mechanically supplied air, by way of a blower, interlocked
with the unit, is necessary. It is the installer's responsibility
to check that.
2.7.1 CONTAMINATED COMBUSTION AIR
Installations in certain areas or types of structures wilt
increase the exposure to chemicals or halogens that may
harm the furnace. These conditions will require that only
outside air be used for combustion.
The following areas or types of structures may contain or
be exposed to certain substances, potentially requiring
outside air for combustion:
a. Commercial buildings;
b. Buildings with indoor pools;
o Furnaces installed near chemical storage areas.
Exposure to the followinq substances:
a. Permanent wave chemicals for hair;
b. Chlorinated waxes and cleaners;
c. Chlorine based swimming pool chemicals;
d. Water softening chemicals;
e. De-icing salts or chemicals;
f. Carbon tetrachloride;
g. Halogen type refrigerants;
h. Cleaning solvents (such as perchloroethylene);
i. Printing inks, paint removers, varnishes, etc. ;
j. Hydrochloric acid;
k. Solvent based glue;
I. Antistatic fabric softeners for clothes dryers;
m. Acid based masonry cleaning materials.
2.7.2 BURNER WITH OUTDOOR COMBUSTION AIR
KIT
Certain burners are designed to function with combustion air
taken directly from the outside. Follow the instructions provided
with the burner, the fresh-air supply kit or the side-wall venting
kit.
2.8 OIL TANK
Fire and explosion hazard.
Use only approved heating type oil in this furnace.
DO NOT USE waste oil, used motor oil, gasoline or
kerosene.
Use of these will result in death, bodily injury and/or
property damage.
CAUTION
When a 0.75 USGPH or smaller nozzleis used, a 10micron or
finer filter, must be installed on the oil supply line to the
furnace insidethe building where the unit islocated.
This is arequirement inorder for the heat exchanger warranty
to remain in force.
Check your local codes for the installation of the oil tank and
accessories.
At the beginning of each heating season or once a year, check
the complete oil distribution system for leaks.
Ensure that the tank is full of clean oil. Use No.1 or No.2
Heating Oil (ASTM D396 U.S.) or in Canada, use No.1 or No.2
Furnace Oil.
A manual shut-off valve and an oil filter shall be installed in
sequence from tank to burner. Be sure that the oil line is clean
before connecting to the burner. The oil line should be
protected to eliminate any possible damage. Installations
where the oil tank is below the burner level must employ a two-
pipe fuel supply system with an appropriate fuel pump. A rise
of 2.4 m (8') and more requires a two stage pump and a rise
greater than 4.9 m (16') an auxiliary pump. Follow the pump
instructions to determine the size of pipe needed in relation to
the rise or to the horizontal distance.
2.9 DUCTING
Poisonous carbon monoxide gas hazard.
DO NOT draw return air from inside a closet or utility
room. Return air MUST be sealed to the furnace casing.
Failure to properly seal ducts can result in death, bodily
injury and/or property damage.
A properly sized air filter must be installed on the return air
side of the unit. Refer to the Technical Specifications,
table 7, for the correct dimensions. Also refer to the
instructions supplied with the filter.
2.9.2 SUPPLY AIR ADJUSTMENT (4 SPEED
MOTOR)
On units equipped with 4-speed blower motors, the supply
air must be adjusted based on heating/air conditioning
output and the static pressure of the duct system. For the
desired air flow refer to the following table as welt as the
air flow tables based on static pressure in the Technical
Specifications section of this manual.
Table 1: Blower speed adjustments (heating mode, 4
speed motor)
HEATING STATIC
CAPACITY PRESSURE
(USGPH) (W.C.)
0.55 0.25"
0.55 0.50"
0.70 0.25"
0.70 0.50"
Table 2: Blower speed adjustments (A/C mode, 4
speed motor)
A/C CAPACITY RECOMMENDED
(TONS) BLOWER SPEED
2.0 MED-LOW
2.5 MED-HIGH
3.0 HIGH
To effect the adjustment, the RED (for heating) and BLUE
(for cooling and heat pump) wires can be changed on the
motor. Also, refer to the position of the wires on the
electronic board of the unit and consult the wiring
diagrams. If the heating and air conditioning speeds are
the same, the RED wire must be moved to "UNUSED
LEADS" on the electronic board and the jumper provided
with the BLUE wire must be used between the "HEAT"
and "COOL" terminals.
The blower start/stop delays can be adjusted by
positioning the DIP switches on the electronic board as
shown in the following figures. However, the
recommended adjustments are 60 seconds blower ON
delay and 2 minutes blower OFF delay.
Figure 5: Blower start/stop delays -Board #1158
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issss
.................................................t
120 Sec 6 v;-, 9(} Sec 4 M;n
} I AY ON J} I AY OFF D I i\Y ON } I AY OF
RECOMMENDED
BLOWER SPEED
MED-LOW
MED-LOW
MED-HIGH
HIGH
The ducting must be designed and installed according to
approved methods, local and national codes as well as good
trade practices.
When ducting supplies air to a space other than where the
furnace is located, the return air must be sealed and also be
directed to the space other than where the furnace is located.
2.9.1 AIR FILTER
J}{! AY ON J}{! AY (}I J} I i\Y (}N J} JAY (}1
2.10 SUPPLY AIR ADJUSTMENT (ECM
VARIABLE SPEED MOTORS)
On units equipped with ECM variable speed blower
motors, the air supply must be adjusted based on
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