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.
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A10311
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Copyright 2011 CAC / BDP • 7310 W. Morris St. • Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 07/11
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations,
velificatio*l ol cei_ification fbi i*ldivid*lal plod*lctS,
Catalog No: IM-OBM154-01 / X40182 Rev. A
Replaces: New
TABLE OF CONTENTS
1 SAFETY REGULATIONS ...................................................................................................................................................... 4
1.1 SAFETY LABELING AND WARNING SIGNS ........................................................................................................... 4
1.2 IMPORTANT INFORMATION ..................................................................................................................................... 4
1.3 DETECTION SYSTEMS ................................................................................................................................................. 4
1.4 DANGER OF FREEZING ............................................................................................................................................... 4
2 INSTALLATION ..................................................................................................................................................................... 5
2.1 POSITIONING THE FURNACE .................................................................................................................................... 5
2.2 CONFIGURATIONS ....................................................................................................................................................... 5
2.3 ELECTRICAL SYSTEM ................................................................................................................................................. 6
2.4 INSTALLATION OF THE THERMOSTAT ................................................................................................................. 6
2.5 INSTALLATION OF THE BURNER ............................................................................................................................ 7
2.6 VENTING ......................................................................................................................................................................... 7
2.7 BLOCKED VENT SHUT-OFF DEVICE (BVSO) FOR CHIMNEY VENTING ........................................................ 8
2.8 COMBUSTION AIR SUPPLY AND VENTILATION ................................................................................................. 8
2.9 OIL TANK ........................................................................................................................................................................ 9
2.10 DUCTING ......................................................................................................................................................................... 9
2.11 SUPPLY AIR ADJUSTMENTS (4 SPEED MOTORS) ................................................................................................ 9
2.12 SUPPLY AIR ADJUSTMENTS (ECMVARIABLE SPEED MOTORS) ................................................................. l0
2.13 INSTALLATION OF ACCESSORIES ........................................................................................................................ l0
3 OPERATION .......................................................................................................................................................................... 11
3.1
START-UP ...................................................................................................................................................................... 11
3.2
OPERATING SEQUENCE OIL HEATING MODE .................................................................................................. 11
3.3
CHECKS AND ADJUSTMENTS ................................................................................................................................. 11
4 MAINTENANCE ................................................................................................................................................................... 13
4.1
CLEANING THE HEAT EXCHANGER ..................................................................................................................... 13
4.2
CLEANING THE BLOCKED VENT SHUT-OFF DEVICE (BVSO) ....................................................................... 13
4.3
CLEANING THE BURNER HEAD ............................................................................................................................. 13
4.4
CHANGING THE NOZZLE ......................................................................................................................................... 13
4.5
CHANGING THE OIL FILTER ................................................................................................................................... 13
4.6
CHANGING THE AIR FILTER ................................................................................................................................... 13
5 FURNACE INFORMATION ................................................................................................................................................ 14
FIGURES
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Table 1 -
Table 2 -
Table 3 -
Table 4 -
Table 5 -
Table 6 -
Table 7 -
Table 8 -
Table 9 -
Table 10
Table 11
1 - Location and dimensions of ventilation air openings in a closet door ................ 5
2 - Upflow Installation ..................................................................................................... 5
3 - Downflow Installation ................................................................................................ 6
4 - Horizontal Installation ................................................................................................ 6
5 - Thermostat wiring, heating and air conditioning with 4-speed motor ................. 6
6 - Thermostat wiring, heating and air conditioning with ECM
7 - Thermostat wiring,heating and air conditioning/heat pump with ECM
9-
10-
11 -
12-
13-
variable speed motor ................................................................................................ 7
variable speed motor ................................................................................................ 7
=
Blower Start/Stop Delays .......................................................................................... 9
Furnace Dimensions ................................................................................................ 18
Wiring diagram 4-speed motor (PSC) .................................................................. 19
Wiring diagram variable speed motor (ECM) ...................................................... 20
Parts list with 4-speed motor (PSC) ..................................................................... 21
Parts list with variable speed motor (ECM) ......................................................... 23
TABLES
Blower speed adjustments, 4-speed motor ............................................................... 9
Airflow adjustments heating mode ........................................................................... 10
Airflow adjustments air conditioning mode ............................................................. 10
Airflow adjustments all modes .................................................................................. 10
Delay adjustments heating mode .............................................................................. 10
Technical Specifications ............................................................................................ 15
Airflow data model with 1HP ECM motor ................................................................. 16
Airflow data model with 1HP 4-speed motor ........................................................... 17
Minimum clearances from combustible materials .................................................. 17
- Parts list with 4-speed motor (PSC) ........................................................................ 22
- Parts list with variable speed motor (ECM) ............................................................ 24
Printed on 100% recycled paper 2011-07-04 X40182 Rev. A
1 SAFETY REGULATIONS
1.1 SAFETY LABELING AND
WARNING SIGNS
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:
DANGER
Hazards or unsafe practices that CAN result in death
bodily injury and/or property damage.
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.
CAUTION
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 I
this manual will potentially lead to consequences I
resulting in death, serious bodily injury and/or I
property damage,
a) It is the homeowner's responsibility to engage a
qualified technician for the installation and
subsequent servicing of this furnace;
b) Do not use this furnace if any part of it was under
water, Call a qualified service technician
immediately to assess the damage and to replace
all critical parts that were in contact with water;
c) Do not store gasoline or any other flammable
substances, such as paper, carton, etc, near the
furnace;
d) This furnace is designed for use with #1 or #2
heating oil only, The use of gasoline, motor oil or
any other oil containing gasoline is prohibited;
e) Never block or otherwise obstruct the filter and/or
return air openings;
f) Ask the technician installing your furnace to show
and 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,)
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
I
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
I
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
CAUTION
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.
2 INSTALLATION
This furnace is a true multi-position unit, in that it will
function in an upflow, downflow or horizontal configuration
to the left or the right. Only a few modifications are required
during installation to change from one position to another.
The unit is shipped in the upflow configuration and
instructions as to how to change to the other positions are
included in this manual.
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:
ANSI/NFPA 31: Installation of oil burning equipment.
ANSI/NFPA 90B: Warm air heating and air conditioning
ANSI/NFPA 211: Chimneys, Fireplaces, Vents and solid
ANSI/NFPA 70: National Electrical Code.
CSA C22.1 : Canadian Electrical Code.
or CSA C22.10
Installation code for oil burning
equipment.
systems.
fuel burning appliances.
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
¢- >
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 4.
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.
2.2 CONFIGURATIONS
2.2.1 Upflow Installation
The return air opening may be located on either side of
the furnace. Care should be taken not to damage the
wires inside, while cutting the opening. Install the filter
rack supplied with the unit according to the instructions
provided with it. It is also recommended to install the
blower door before handling or moving the unit. Refer to
figure 2 for additional details.
Figure 2 - Upflow Installation
Burner position I
c::::::u
i\lR A TIRN
RETO JF D'AI, _
Filter 24X24 I
Combustible or non-
combustible floor
DNS-1227A
2.2.2 Upflow Installation
2.3 ELECTRICALSYSTEM
When the furnace is installed in the downflow position on a
combustible foor, the clearances from combustibles must
be adhered to. The downflow base DFB-104 or
KLASB1001DET can be used to ensure these clearances.
Refer to figure 3 and the installation instructions provided
with the base.
The burner must always be installed in the same manner,
regardless of the discharge position of the furnace. Refer
to figure 3 for additional details.
Figure 3 - Downflow Installation
AI_ F<E URN
RETOUR {YAR
Cv'ARM AIR
i'_l_ (I I,,_,UI)
,,_ Burner position I
Filter 24 x 24 i
Downflow base is
required for
combustible floor
DNS-1227A
l
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 10 and 11.
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.
2.4 INSTALLATION OFTHE
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 wiring diagrams provided with the heating/air
conditioning unit. The connections must be made as
indicated on the following diagrams and the wiring
diagrams, figures 10 and 11.
1.3.5 Horizontal
Installation
When the furnace is installed in the horizontal position,
either suspended or on a combustible floor with a choice of
right or left discharge, the clearances from combustible
material must be adhered to. If the unit is installed on a
combustible floor, the horizontal floor base HFB-101 or
KLASB0701DET can be used to ensure these clearances.
Refer to the instructions supplied with the base.
The burner must always be installed in the same manner,
regardless of the discharge position of the furnace. Refer
to figure 4 for additional details.
Figure 4 - Horizontal Installation
Figure 5 - Thermostat wiring, heating and air
conditioning with 4-speed motor
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Figure 6 - Thermostat wiring, heating and air
conditioning with ECM variable speed motor
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Figure 7 - Thermostat wiring, heating and air
conditioning/heat pump with ECM variable speed motor
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. Remove the burner drawer assembly or the air tube
assembly;
3. Install the nozzle (refer to Technical Specifications,
table 6);
4. Check the electrode settings;
5. Make the electrical connections;
6. Complete oil line connections.
2.5.1 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.
2.5.2 Air and Turbulator Settings
Before starting the burner for the first time, adjust the air
and turbulator settings to those listed in this manual. Once
the burner becomes operational, final adjustments will be
required. Refer to the section OPERATION of this manual.
2.6 VENTING
01 FURNACE
Ti IERbIOST/',T
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Note: On units with 2 stage cooling or heat pump, terminal Y1
must be used. When Y1 on the electronic control receives a 24
VAC signal, the air flow is reduced by 20%. Do not use
terminal Y1 with a single stage cooling or heat pump.
2.5 INSTALLATION OF THE BURNER
Poisonous carbon monoxide gas, fire and explosion
hazard.
Read and follow all instructions in this section.
Failure to properly vent this furnace 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.
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.
Refer to the burner manufacturer's instructions. Also, the
burner must be installed always in the same way
independently of the furnace orientation.
2.6.1 Masonry chimney
This furnace can be vented into an existing masonry
chimney. However, the unit must not be vented into a
chimneyintowhicha solidfuelburningfurnaceis already
beingvented.
Beforeventingthisfurnaceintoachimney,itsconditionmust
becheckedandrepairsmade,ifnecessary.Also,thechimney
lininganddimensionsmustconformto localandnational
codes.
2.6.2 Factory Built Chimneys
Oil fired furnaces are approved for use with "L" type vents. The
unit may also be used with an approved chimney of proper
dimensions and temperature ratings as specified in the
installation code. Refer to chimney manufacturer's instructions
for proper installation.
2.6.3 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.
2.6.4 Side-wall Venting
The heating unit is approved for side-wall venting. This system
includes model VTK-3 / KLAVT0201DET side-walt venter and
a 5" insulated vent pipe, model IFV5 / KLAFVxx01DET. Refer
to the installation instructions provided with the venting system.
2.7 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.
Refer to 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.
2.7.1 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.
2.8 COMBUSTION AIR SUPPLY
AND VENTILATION
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 2.2 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.
2.8.1 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;
c. 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.
2.8.2 Burner with Outdoor Combustion Air Kit
Certain burners are designed to function with combustion
air taken directly from the outside. Follow the instructions
providedwiththeburner,thefresh-airsupplykitortheside-
wallventingkit.
2.9 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.
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.
2.11 SUPPLY AIR ADJUSTMENTS
(4 SPEED MOTORS)
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, 4-speed motor
FURNACE
APPLICATION
HEATING
A/C
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. For upflow installation, the
recommended blower ON delay is 60 seconds and blower
OFF delay 2 minutes.
HEATING OR A/C
OUTPUT
0.90 USGPH
1.10 USGPH
3.0 TONS
3.5 TONS
4.0 TONS
5.0 TONS
RECOMMENDED
BLOWER SPEED
MED-LOW
MED-HIGH
LOW
MED-LOW
MED-HIGH
HIGH
2.10 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.
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 :
a. Commercial buildings;
b. Buildings with indoor pools;
c. Furnaces installed near chemical storage areas.
The installation must carefully be verified to ensure that the
combustion air comes from outside,
2.10.1 Air filter
A properly sized air filter must be installed on the return air
side of the unit, Refer to the Technical Specifications, table 6,
for the correct dimensions, Also refer to Section 2,2 and the
instructions supplied with the filter,
CAUTION
For horizontal and downflow installations only:
Adjust the ON delay to 30 sec.
Adjust the OFF delay to 4 min.
For other adjustments, proceed with tests in order to avoid
cycling.
Figure 8 - Blower Start/Stop Delays
Board # 1158
...................,o 2 ,_4 .......
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2.12 SUPPLY AIR ADJUSTMENTS
(ECM VARIABLE SPEED MOTORS)
On units equipped with ECM variable speed blower motors,
the air supply must be adjusted based on heating/air
conditioning output. The start/stop delays of the blower must
also be adjusted by positioning the DIP switches on the
electronic board.
Refer to the following tables, airflow tables and the wiring
diagram in this manual for the proper settings:
Table 2 - Airflow adjustments heating mode
SWl - HEAT
DIP Switch Positions
1
I 2 I POSITION
OFF 0.90
ON 1.10
OFF N / A
ON N/A
Table 3 - Airflow adjustments air conditioning mode
OFF A
OFF B
ON C
ON D
SW2 - COOL
DIP Switch Positions
1
OFF 5.0
OFF 3.5
SW3 - ADJ (Adjustment)
DIP Switch Positions
1 I 2 I POSITION
OFF OFF A
ON OFF B
OFF ON C
ON ON D
I 2 I POSITION
ON 4.0
ON 3.0
Table 4 - Airflow adjustments all modes
OFF A
OFF B
ON C
ON D
CFM HTG.
% increase
or decrease
O%
+10%
-10%
N/A
Input
USGPH
Output
Tons
CFM A/C
% increase
or decrease
0%
+10%
-10%
0%
2.13 INSTALLATION OF ACCESSORIES
Electrical shock hazard.
Turn OFF electrical power at the fuse box or service
panel before making any electrical connections and
ensure a proper ground connection is made before
connecting line voltage.
Failure to do so can result in death or bodily injury.
2.13.1 Humidifier (HUM)
The electronic board supply 120 VAC for a humidifier on
the HUM terminal. It supplies 120 VAC electric power
when the burner is in operation.
A 24 VAC signal can also be supplied from the W and C
terminals on the blower electronic board to activate a
switching relay.
Also refer to the instructions supplied with the accessory.
2.13.2 Electronic Air Cleaner (EAC)
The EAC terminal on the electronic board supplies 120
VAC when the blower is operating in the heating or air
conditioning mode. This signal can be used to activate an
electronic air cleaner that is not equipped with an air flow
switch. If the cleaner is equipped with an air flow switch,
the S terminal on the PSC electronic board or one of the
120 VAC terminals on the ECM electronic board can be
used to provide a constant supply of 120 VAC.
Also refer to the instructions supplied with the accessory.
2.13.3 Air Conditioner (or Heat Pump)
An air conditioning coil may be installed on the supply air
side ONLY.
Table 5 - Delay adjustments heating mode
SW4 - Delay
DIP Switch Positions
1
ON
ON
I 2 I POSITION
OFF A
OFF B
ON C
ON D
OFF
OFF
Input
USGPH
0.90
1.10
ALL
ALL
Poisonous carbon monoxide gas hazard.
Install the evaporator coil on the supply side of the
furnace ducting ONLY.
Never install on the return air side of the ducting an
evaporator coil. This can result in death, bodily injury
and/or property and/or unit damage.
A clearance of 15 cm (6") 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.
10
3 OPERATION
and pump. Slowly close and tighten the bleed screw.
Once closed, the flame will light up.
3.1 START-UP
Before starting up the unit, be sure to check that the following
items are in compliance:
1. The electrical installation, the oil supply system, the
venting system, combustion air supply and ventilation;
2. The blower access door is in place and the blower rail
locking screws are welt tightened;
3. The Blocked Vent Shut-Off (BVSO) is installed according
to instructions (for chimney venting);
4. The oil supply valve is open;
5. The burner "Reset" button is welt pushed in or re-armed;
6. The preliminary air adjustments on the burner comply
with the technical specifications in this manual;
7. The blower speed adjustments for heating and air
conditioning are appropriate and according to the
specifications in this manual;
8. The blower start/stop delays are satisfactory;
9. 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.
3.2
OPERATING SEQUENCE
OIL HEATING MODE
1. The W-R contact closes;
2. The burner motor starts up to pre-purge the combustion
chamber for a period of 10 to 15 seconds. During that time
a spark is established on the electrodes;
3. The solenoid valve opens and a flame is established.
Shortly after, the electrodes cease to spark;
4. Then the blower runs up to full speed. The delay depends
on the adjustments that were made on the electronic
board, which controls the blower motor. Refer to Sections
2.11 and 2.12 above as well as the airflow tables for more
details.
5. When the call for heat is satisfied, the solenoid valve
closes, the flame goes out and the burner motor stops
(after post purge delay, if applicable).
6. The blower stops shortly after the burner. The delay
depends on the adjustments that were made on the
electronic board that controls the blower. Refer to
Sections 2.11 and 2.12 above as well as the airflow table
for more details.
Note: A detailed operating sequence of the oil burner is
outlined in the instructions provided with the burner.
3.3.2 Pressure adjustment
The oil pressure must be adjusted according to the
Technical Specifications of this manual. An adjustment
screw and a connection for a pressure gauge are located
on the oil pump for that purpose. Also refer to the burner
instruction manual.
3.3.3 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.
1. Drill a test hole in the flue pipe, approximately 18
inches from the furnace breech. Insert the smoke test
probe into the hole. For installation using a sidewall
venting, use the orifice provided on the breech plate;
2. From a cold start, let the unit operate for about 5
minutes;
3. Set the burner air setting until you have between 0
and 1 on the Bacharach Scale (or a "trace");
4. Take a CO2 sample at the same test location where
the #1 smoke reading was taken and make note of it.
Example: 13.8% of CO2 or 2.5% of 02;
5. 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.
Example: 12.3% of CO2 or 4.5% of 02;
6. This method of adjusting the burner wilt result in clean
combustion (Bacharach smoke scale between 0 and
a trace) and ensure the proper functioning of the
system. The optimum CO2 level is around 12% to
13% (or 3.5% to 5.0% of 02).
3.3.4 Draft Regulator adjustment
3.3 CHECKS AND ADJUSTMENTS
3.3.1 Purging the oil line
Open the bleed port screw and start the burner. Allow the oil to
drain into a container for at least 10 seconds. The oil should
flow absolutely free of white streaks or air bubbles to indicate
that no air is being drawn into the suction side of the oil piping
On chimney installations only, 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 the
damper.) After the furnace has been firing for at least five
11
minutes,thedraftregulatorshouldbesettobetween-0.025"
and-0.060"W.C.
3.3.5 Overfire pressure test
The overfire draft that is taken through the observation port,
located above the burner, is a measurement necessary to
determine if there is a blockage in the heat exchanger or the
flue pipe. Refer to the Technical Specifications in this manual
for overfire 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.
3.3.6 Vent Temperature Test
1. After having adjusted the burner combustion, insert a
thermometer into the test hole in the breech pipe;
2. The total vent temperature should be between 204 and
302°C (400 and 575°F). If not, check for improper air
temperature rise, pump pressure, nozzle size or a badly
sooted heat exchanger.
CAUTION
Low flue gas temperature increases the risk of
condensation. Adjust the total temperature at or higher
then 204°C (400°F) in order for the heat exchanger
warranty to remain in force.
2. Press the reset button on the burner primary control
(relay);
3. Set the thermostat higher than room temperature;
4. If the burner motor does not start or ignition fails, turn
off the disconnect switch and CALL A QUALIFIED
SERVICE TECHNICIAN.
CAUTION
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 hot.
3.3.7 Supply Air Temperature Rise Test
1. Operate the burner for at least 10 minutes;
2. Measure the air temperature in the return air plenum;
3. Measure the air temperature in the supply duct just
outside the range of radiant heat from the heat exchanger.
0.3 m (12") from the plenum of the main take-off is usually
sufficient;
4. The temperature rise is calculated by subtracting the
return air temperature from the supply air temperature;
5. If the temperature rise is lower or exceeds the
temperature specified in Table 6, change to the next lower
or higher blower speed tap, until the temperature rise falls
to the target. If the excessive temperature rise cannot be
increased or reduced by changing fan speed, investigate
for ductwork obstructions, dirty or improper air filter,
improper firing caused by improper pump pressure or
nozzle sizing.
3.3.8 Limit Control Check
After operating the furnace for at least 15 minutes, restrict the
return air supply by blocking the filters or the return air register
and allow the furnace to shut off on High Limit. The burner will
shut off but the blower wilt continue to run.
Remove the obstruction and the burner should restart after a
few minutes. The time required for the restart also depends on
the adjustment of the blower "OFF" delay.
3.3.9 Restart after Burner Failure
1. Set the thermostat lower than room temperature;
12
4 MAINTENANCE
I Electrical shock hazard.
Turn OFF power and fuel to the furnace before any
disassembly or servicing.
Failure to do so can result in death, bodily injury and/or
property damage.
Preventive maintenance is the best way to avoid unnecessary
expense and inconvenience. Have your heating system and
burner inspected by a qualified service technician at regular
intervals.
To maintain the reliability and optimal performance of the
furnace, have a complete combustion check done after the
annual maintenance call. Do not attempt to repair the furnace
or its controls. Call a qualified service technician.
Before calling for repair service check the following
points:
1. Check the oil tank gauge and make sure that the valve is
open;
2. Check fuses and the circuit breaker;
3. Check if the main disconnect switch is ON ;
4. Set the thermostat above room temperature;
5. If ignition does not occur, turn off the disconnect switch
and call a qualified service technician.
4.2 CLEANING THE BLOCKED VENT
SHUT-OFF DEVICE (BVSO)
For continuous safe operation, the Blocked Vent Shut-off
device (BVSO) must be inspected and maintained annually
by a qualified service technician.
1. Disconnect power to the appliance;
2. Remove the two screws holding on the BVSO
assembly cover;
3. Remove the cover;
4. 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 from the heat
transfer tube assembly;
5.
Carefully remove any build-up from the thermal switch
surface;
Do not dent or scratch the surface of the thermal switch. If
I CAUTION I
the thermal switch is damaged it MUST be replaced.
6. Clean and remove any build-up or obstruction inside
the heat transfer tube;
7. Re-mount, lock and fasten the control box with the 2
screws removed in step 4;
8. Re-attach the assembly cover with the screws removed
in step 2;
9. Re-establish power to the unit.
4.3 CLEANING THE BURNER HEAD
When ordering replacement parts, please specify the
complete furnace model number and serial number.
4.1 CLEANING THE HEAT EXCHANGER
It is not generally necessary to clean the heat exchanger or
flue pipe every year, but it is advisable to have the oil burner
service technician check the unit before each heating season
to determine whether the cleaning or replacement of parts is
necessary.
If a cleaning is necessary, the following steps should be
performed:
1. Turn OFF all utilities upstream from the furnace;
2. Disconnect the flue pipe;
3. Remove the flue collar panel located at the front of the
furnace;
4. Remove the heat exchanger baffles;
5. Disconnect the oil line and remove the oil burner;
6. Clean the secondary tubes and the primary cylinder with a
stiff brush and a vacuum cleaner;
7. Before re-assembling the unit, the heat exchanger and
combustion chamber should be inspected to determine if
replacement is required;
8. After the cleaning, replace the heat exchanger baffles, flue
collar plate and oil burner;
9. Readjust the burner for proper operation.
Once annually, remove the retention head and electrodes
from the drawer assembly and remove all foreign matter, if
necessary. Also clean the extremity of the burner tube, if
necessary.
4.4 CHANGING THE NOZZLE
Change the nozzle once a year with the one specified in
table 6.
4.5 CHANGING THE OIL FILTER
Tank Filter
The tank filter should be changed as required. Follow the
manufacturer's instructions.
Secondary Filter
The 10 micron, or finer, filter cartridge should be changed
annually. Follow the manufacturer's instructions.
4.6 CHANGING THE AIR FILTER
Dirty filters have an impact on the efficiency of the furnace
and increase fuel consumption.
Air filters should be changed at least once a year. Very
dusty conditions, the presence of animal hair and the like
will require more frequent changing or cleaning.
13
5 FURNACE INFORMATION
Model:
Furnace installation date:
Service telephone #-Day:
Dealer name and address:
START-UP RESULTS
Nozzle:
Burner adjustments:
CO2 : %
Gross stack temperature:
Ambient temperature:
Primary air
Fine air
Drawer Assembly
Smoke scale:
Serial number:
Pressure:
oF
oF
Night:
Ib/po2
(Bacharach)
Chimney draft :
Overfire draft :
Test performed by:
" W.C.
" W.C.
14
Table 6 - Technical Specifications
154 Series, m ulti-position models I UNITS WITH 1,0 HP 4-SP, MOTOR _ UNITS WITH 1,0 HP ECM MOTOR
Firing rate (USGPH)* 0,90 1,10 0,90 1,10
Input (BTU/h)* 126 000 154 000 126 000 154 000
Maximum Heating capacity, (BTU/h)* 107 000 129 000 107 000 129 000
Heating temperature rise (Degr. F)* 55 - 75 Degr. F 60 - 72 Degr. F
Flue draft with chimney (inch of w .c.) -0.06 to -0.035 -0.06 to -0.035
Overfire pressure with chimney (inch of w .c.) -0.035 to +0.045 -0.035 to +0.045
Flue pressure w ith direct vent (inch of w .c. - no wind) +0.05 to +0.16 +0.05 to +0.16
Overfire pressure with direct vent (inch of w .c. - no wind) +0.06 to +0.22 +0.06 to +0.22
_ :_MO_(_|m _i, _
Burner tube insertion length (inches)
Head type
Nozzle (Delavan)
Minimum and Maximum pump pressure (PSlG)*
Head/Air setting
AFUE % (From CSA B212 standard and Canadian regulation)**
AFUE % (From ASHRAE 103 standard and US regulation)**
Burner tube insertion length (inches)
Nozzle (Delavan)
Minimum and Maximum pump pressure (PSlG)*
Combustion air adjustment (turbulator/damper)
AFUE % (From CSA B212 standard and Canadian regulation)**
AFUE % (From ASHRAE 103 standard and US regulation)**
Burner tube insertion length (inches) 2 3/4" 2 3/4"
Nozzle (Delavan) 0.75 - 70A 0.90 - 70A 0.75 - 70A 0.90 - 70A
Minimum and Maximum pump pressure (PSlG)* 145 150 145 150
Combustion air adjustment (turbulator/damper) 1.0 / 3.75 3.0 / 4.25 1.0 / 3.75 3.0 / 4.25
AFUE% (From CSA B212 standard and Canadian regulation)** _: 86.7% _: 85.3% $ 86.7% _: 85.3%
AFUE% (FromASHRAE 103 standard and US regulation)** _: 86.3% $ 85,0% $ 86.3% _: 85,0%
m m
1 3/4"
6 Slots - LC head
0.75 - 60B 0.90 - 60B
145 150
3,5 4
_: 87,0% _: 85.7%
_: 86.6% $ 85,2%
2 3/4"
0.75 - 70A 0.90 - 70A
145 150
1.5 / 2.25 2.5 / 2.75
_: 86.7% _: 85.3%
_: 86.3% $ 85,0%
1 3/4"
6 Slots - LC head
0.75 - 60B 0.90 - 60B
145 150
3,5 4
$ 87,0% _: 85.7%
$ 86.6% _: 85,2%
2 3/4"
0.75 - 70A 0.90 - 70A
145 150
1.5 / 2.25 2.5 / 2.75
$ 86.7% _: 85.3%
$ 86.3% _: 85,0%
Volts - Hertz - Phase 115 - 60 - 1 115 - 60 - 1
Rated current (Amps) 16,9 15,7
Minimum ampacity for w ire sizing (A raps) 19,5 18,1
Max. fuse size (Amps) 20 20
Control transformer (VA) 40 40
External control power available Heating (VA) 40 40
Cooling (VA) 30 30
Heating blow er speed at 0.25" W.C. SP MED-LOW MED-HIGH
Heating blow er speed at 0.50" W.C. SP MED-LOW MED-HIGH
Motor (HP) / nun_er of speeds 1.0 HP / 4 speeds 1.0 HP / ECM (with inductor)
Blow er size (diam. x w idth) 12" x 10" (tight housing) 12" x 10" (tight housing)
Overall dimensions (width x depth x height) 25" x 28 1/2" x 48" 25" x 28 1/2" x 48"
Supply air opening (width x depth) 20"x 22" 20" x 22"
Return air opening (width x depth) 23"x 23" 23" x 23"
Filter size 24" x 24" x 1" 24" x 24" x 1"
Shipping weight Lbs/Kg 200 / 90 200 / 90
Air conditioning, maximum output (tons) at 0.5" W.C. SP 5,0 5,0
* INPUT & OUTPUT ADJUSTMENT:
- Pump pressure can be adjusted to maintain proper firing rate.
- Increase pump pressure if flue gases temperature is under 400°F
- Adjust the tota._lflue gas temperature between 400 ° and 575°F (330 ° and 505 ° F net approx.)
- Adjust fan speed for air temperature rise of 55 ° to 85°F.
** AFUE value established after minimum 20 hours of operation.
See the ECM air flow table
15
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