Coleman P-LBX16F14501, P-LBX20F19001 Installation Instructions Manual

INSTALLATION

INSTRUCTIONS

CONTENTS

INTRODUCTION.....................................................2

HEAT LOSS............................................................2

LOCATION OF UNIT..............................................2

AIR CONDITIONING...............................................3

COMBUSTION AIR.................................................3

CHIMNEY VENTING............................................... 3

OIL TANK ...............................................................6

PIPING INSTALLATION......................................... 6

ELECTRICAL CONNECTIONS.............................. 6

CIRCULATING AIR BLOWER...............................7

OIL BURNER.......................................................... 8

FURNACE INSTALLATION SET-UP..................... 9

MAINTENANCE AND SERVICE............................ 9

OPERATING INSTRUCTIONS...............................10

TABLE A-1: BECKETT OIL BURNER SET-UP .... 11

TABLE A-2: DIRECT DRIVE BLOWER SET-UP .. 11

TABLE A-3: BELT DRIVE BLOWER SET-UP ......11

TABLE A-4: DIRECT DRIVE BLOWER

CHARACTERISTICS..............................................12

TABLE A-5: BELT DRIVE BLOWER

CHARACTERISTICS..............................................12

WIRING DIAGRAM: MODEL P*LBX16F14501..... 13

WIRING DIAGRAM: MODEL P*LBX20F19001..... 13

R7184 TROUBLESHOOTING................................ 14

R7184 DETAILED SEQUENCE OF OPERATION

(FIGURE 7) .............................................................14

R7184 LED DIAGNOSTIC LIGHT.......................... 16

TABLE C-2: R7184 TROUBLESHOOTING..........17

TABLE C-3: SYSTEM AND GENERAL

TROUBLESHOOTING............................................ 19

P*LBX20F19001 ASSEMBLY NOTES...................23

OIL-FIRED WARM AIR

FURNACE

P-LBX16F14501 P-LBX20F19001

(Lowboy Models)

1

Read this manual completely before beginning
installation.
Important: These instructions must be kept with
the furnace for future reference.

IMPROPER INSTALLATION MAY
CREATE A CONDITION WHERE THE
OPERATION OF THE PRODUCT
COULD CAUSE PERSONAL INJURY
OR PROPERTY DAMAGE.

IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION,
SERVICE OR MAINTENANCE CAN
CAUSE INJURY OR PROPERTY
DAMAGE. REFER TO THIS MANUAL
FOR ASSISTANCE OR ADDITIONAL
INFORMATION, CONSULT A
QUALIFIED INSTALLER, SERVICE
AGENCY OR THE FUEL SUPPLIER.

THIS PRODUCT MUST BE INSTALLED
IN STRICT COMPLIANCE WITH THESE
INSTALLATION INSTRUCTIONS AND
ANY APPLICABLE LOCAL, STATE,
AND NATIONAL CODES INCLUDING
BUT NOT LIMITED TO: BUILDING,
ELECTRICAL AND MECHANICAL
CODES.

The furnace area must not be used as a
broom closet or for any other storage
purposes, as a fire hazard may be
created. Never store items such as the
following on, near or in contact with the
furnace:

1. Spray or aerosol cans, rags,
brooms, dust mops, vacuum
cleaners or other cleaning tools.

2. Soap powders, bleaches, waxes or
other cleaning compounds; plastic
items or containers, gasoline,
kerosene, cigarette lighter fluid, dry
cleaning fluids, or other volatile
fluids.

3. Paint thinners or other painting
materials and compounds.

4. Paper bags, boxes, or other paper
or cardboard products.

Never operate the furnace with the
blower door removed. To do so could
result in serious personal injury and/or
equipment damage.

DO NOT USE GASOLINE,
CRANKCASE OIL, OR ANY OTHER
OIL CONTAINING GASOLINE AS A
FUEL FOR THIS FURNACE.

Please read these instructions
completely and carefully before installing
and operating the furnace.

The furnace must be installed and set up
by a qualified contractor.

Model P*LBX16F14501 is a rear-breech
lowboy model with an output range of
130,000 to 143,000 BTUH. Model
P*LBX20F19001 is a rear-breech lowboy
model with an output range of 168,000 to
188,000 BTUH.

All models are listed with the Canadian
Standards Association, (CSA), and
comply with the standards of both the
United States and Canada for use with
No. 1 (Stove) and No. 2 (Furnace) Oil.

In the United States, the installation of
the furnace and related equipment shall
be installed in accordance with the
regulations of NFPA No. 31, Installation
of Oil Burning Equipment, as well as in
accordance with local codes.

In Canada, the installation of the furnace
and related equipment shall be installed
in accordance with the regulations of
CAN/CSA - B139, Installation Code For
Oil Burning Equipment, as well as in
accordance with local codes.

When installation or application
questions arise, regulations prescribed in
the National Codes and Local
Regulations take precedence over the
general instructions provided with this
installation manual. When in doubt,
please consult your local authorities.

The P*LBX16F14501 model is shipped
assembled, pre-wired, and ready for
lowboy furnace applications. The
P*LBX16F14501 model is air
conditioning ready. The furnace should
be carefully inspected for damage when
being unpacked.

INTRODUCTION

The P*LBX20F19001 is shipped in two
pieces, a furnace section and a blower
section, and must be assembled at the
installation site. Some field wiring is
required. The P*LBX20F19001 is
shipped as a heating only furnace;
however, air conditioning may be added
with the addition of field-installed
controls.

HEAT LOSS

To determine the correct furnace and
firing rate for an application, it is
necessary to calculate the maximum
hourly heat loss of the building based on
local design conditions. In new
construction, the heat loss should be
calculated on a room-by-room basis to
enable proper sizing of the trunk and
branch ductwork. In retrofit applications,
a building shell (overall) heat loss
calculation may be used.

In the United States, Manual J.
"Load Calculation
Conditioning Contractors of America,
(ACCA), describes a suitable procedure
for calculating the maximum hourly heat
loss.

In Canada, the maximum hourly heat
loss may be calculated in accordance
with the procedures described in the
manuals of the Heating, Refrigeration
and Air Conditioning Institute (HRAI), or
by other method prescribed by
authorities having jurisdiction that are
suitable for local conditions.

" published by the Air

titled,

LOCATION OF UNIT

The furnace should be located such that
the flue connection to the chimney is
short, direct and consists of as few
elbows as possible. When possible, the
unit should be centralized with respect to
the supply and return air ductwork. A
central location minimizes the trunk duct
sizing.

Minimum installation clearances are
listed in Table 1.

NOTE: The recommended installation
clearances do not necessarily take into
consideration the clearances necessary
to replace the air filter or perform other
routine maintenance.

2

Table 1: Clearance to
Combustibles

Furnace P*LBX
Location Upflow
Top 3 in.
Bottom 0 in.
S/A Plenum 0 in.
Rear 1 in.1
Sides 6 in.2
Front 24 in.
Flue Pipe 9 in.3
Enclosure Standard

1

24” Required for Service

2

18” Required on one Side for

access to rear

3

18” in USA

NON-SUSPENDED INSTALLATION

Maintain clearances to combustibles as
outlined in Table 1. Installation on a
combustible floor requires a clearance of
1 inch. This can be done by using a
noncombustible material such as one
inch thick channel iron or similar
material. The furnace must be supported
in such a way as to not allow twisting or
sagging of the cabinet. Suggestion; as a
measure to prevent fuel oil from
accumulating in locations other than the
fire pot, as could be the case in the event
of nozzle drip, install the furnace with an
approximate 2 degree slope from the oil
burner casing towards the fire pot. Use
shims made of noncombustible material.

SUSPENDED INSTALLATION

Maintain clearances to combustibles as
outlined in Table 1. The furnace may be
suspended by field fabricating a cradle of
angle iron and threaded rod. Secure the
furnace with 2 inch minimum slotted
angle or equivalent. The furnace must be
supported in such a way as to not allow
twisting or sagging of the cabinet.
Position the supports so as to not
interfere with accessing the burner and
blower compartments. Suggestion; as a
measure to prevent fuel oil from
accumulating in locations other than the
fire pot, as could be the case in the event
of nozzle drip, install the furnace with an
approximate 2 degree slope from the oil
burner casing towards the fire pot.

AIR CONDITIONING

If the furnace is used in conjunction with
air conditioning, the furnace shall be
installed in parallel with or upstream from
the evaporator coil to avoid condensation
in the heat exchanger. In a parallel
installation, the dampers or air controlling
means must prevent chilled air from
entering the furnace. If the dampers are
manually operated, there must be a
means of control to prevent the operation
of either system unless the dampers are
in the full heat or full cool position. The
air heated by the furnace shall not pass
through a refrigeration unit unless the
unit is specifically approved for such
service.

Generally, a six-inch clearance between
the air conditioning evaporator coil and
the heat exchanger will provide adequate
airflow through the evaporator coil.

The blower speed must be checked and
adjusted to compensate for the pressure
drop caused by the evaporator coil.
Refer to Appendix B for recommended
wiring and electrical connections of the
air conditioning controls.

COMBUSTION AIR

When a furnace is installed in the full
basement of a typical frame or brick
house, infiltration is normally adequate to
provide air for combustion and draft
operation. If the furnace is installed in a
closet or utility room, two (2) ventilation
openings must be provided connecting to
a well ventilated space (full basement,
living room or other room opening
thereto, but not a bedroom or bathroom).
One opening shall be located 6" from the
top and bottom of the enclosure at the
front of the furnace. For furnaces located
in buildings of unusually tight
construction, such as those with high
quality weather stripping, caulking,
windows and doors, or storm sashed
windows, or where basement windows
are well sealed, a permanent opening
communicating with a well ventilated
attic or with the outdoors shall be
provided, using a duct if necessary. Size
all of the openings and associated
ductwork by the standards provided in
the latest Oil Installation Code editions;
NFPA 31 in the United States, CAN/CSA
B139 in Canada. Take all fuel burning
appliances in the area into consideration
when calculating combustion and
ventilation air requirements.

CHIMNEY VENTING

The chimney must be sized correctly and
be in good repair. If the chimney is
oversized, there is a high risk of the flue
gases condensing resulting in damage to
the chimney and other venting parts.
This problem may be corrected by the
use of an appropriately sized chimney
liner.

If the chimney serves the
P*LBX16F14501 furnace only, the vent
should be sized at 4-inch minimum, 6­inch maximum. If the chimney serves the
P*LBX20F19001 furnace only, the vent
should be sized at 5-inch minimum, 7­inch maximum. The data provided in
Table 3 is based on dedicated venting. If
the furnace is to be co-vented with other
appliances, refer to NFPA 211, Standard

for Chimneys, Fireplaces, Vents, and
Solid Fuel-Burning Appliances, NFPA
31, Standard for the Installation of Oil
Burning Equipment or CAN/CSA B139,
Installation Code For Oil Burning
Equipment for correct sizing information.

NOTE: This furnace is approved for
use with L-Vent.

NOTE: Maximum temperature for L­Vent is 575°F (300°C).

IMPORTANT: The chimney must be

capable of providing sufficient draft at all
times for the safe removal of the
products of combustion.

The chimney should be tested under
“winter” conditions; doors and windows
closed, all other fossil fuel burning
appliances on, clothes dryer on,
bathroom fans on, etc. If the chimney
cannot overcome the competition for air,
it will be necessary to access the reason
for it, and take corrective action. If the
chimney is found to be sized correctly
and in good repair, it will probably be
necessary to re-evaluate the availability
of combustion and ventilation air, and
take corrective action.

3

The flue pipe should be as short as
possible with horizontal pipes sloping
upward toward the chimney at a rate of
one-quarter inch to the foot. The flue
pipe should not be smaller in cross
sectional area than the flue collar on the
furnace. The flue pipe may be reduced in
size to fit a smaller diameter chimney
with the use of a tapered reducer fitting
at the chimney inlet. The flue pipe should
connect to the chimney such that the flue
pipe extends into, and terminates flush
with the inside surface of the chimney
liner. Seal the joint between the pipe and
the lining. The chimney outlet should be
at least two feet above the highest point
of a peaked roof. All unused chimney
openings should be closed. Chimneys
must conform to local, provincial or state
codes, or in the absence of local
regulations, to the requirements of the
National Building Code.

See Figure 2 and Table 2 for common
chimney problems and their remedies.

THE FURNACE MUST BE
CONNECTED TO A FLUE HAVING
SUFFICIENT DRAFT AT ALL TIMES TO
ENSURE SAFE AND PROPER
OPERATION OF THE APPLIANCE.

The flue pipe must not be routed through
concealed space, because it must be
visually checked for signs of
deterioration during the annual
inspection and servicing. The flue pipe
must not pass through any floor or
ceiling, but may pass through a wall
where suitable fire protection provisions
have been installed. In the United States,
refer to the latest edition of NFPA 31 for
regulations governing the installation of
oil burning equipment. In Canada, refer
to the latest edition of CAN/CSA B139
for rules governing the installation of oil
burning equipment.

DRAFT REGULATOR CONTROL

This device is used in conjunction with
conventional chimney venting. This
control (or draft regulator) automatically
maintains a constant negative pressure
in the furnace to obtain maximum
efficiency. It ensures that proper
pressures are not exceeded. If the
chimney does not develop sufficient
draft, the draft control cannot function
properly. The draft regulator, must be
installed within the same room or
enclosure as the furnace, and should not
interfere with the combustion air supplied
to the burner. The control should be
located a minimum of 3 flue pipe
diameters from the furnace breeching
and installed in accordance to the
instructions supplied with the regulator.

4

Fig. 2: Common Chimney Problems

Table 2: Common Chimney Problems

Refer to Figure 2

Key Trouble Diagnostic Remedy

Top of chimney
lower than

A

surrounding
objects

Chimney Cap

B

or ventilator.

Coping restricts

C

opening.

Observation

Observation Remove

Observation

Extend chimney
above all
surrounding
objects within
30 feet.

Make opening
as large as
inside of
chimney.

D

E

F

G

H Offset

I

J

K

L

M

Obstruction in
chimney

Joist protruding
into chimney.

Break in
chimney lining.

Collection of
soot at narrow
space in flue
opening.

Two or more
openings to the
same chimney.

Loose-seated
pipe in flue
opening.

Smoke pipe
extends into
chimney.

Failure to
extend the
length of flue
partition to the
floor.

Loose-fitted
clean-out door.

Can be found
by light and
mirror reflecting
conditions in
chimney.

Lowering a light
on an extension
cord.

Smoke test ­build smudge
fire blocking off
other opening,
watching for
smoke to
escape.

Lower light on
extension cord.

Lower light on
extension cord.

Found by
inspection from
basement.

Smoke test.

Measurement
of pipe from
within or
observation of
pipe by means
of a lowered
light.

By inspection or
smoke test.

Smoke test.

Use weight to
break and
dislodge.

Must be
handled by
competent
masonry
contractor.

Must be
handled by
competent
masonry
contractor.

Clean out with
weighted brush
or bag of loose
gravel on end
of line.

Change to
straight or to
long offset.

The least
important
opening must
be closed,
using some
other chimney
flue.

Cementing all
pipe openings
should
eliminate leaks.

Length of pipe
must be
reduced to
allow end of
pipe to be flush
with inside of
tile.

Extend partition
to floor level.

Close all leaks
with cement.

5

Table 3: Minimum Chimney Base

Temperatures (°F)

Nozzle

Chimney Height (ft.)

11 20 28 36

Chimney Thermal Resistance < R6

0.50 300 400 535 725

0.65 275 340 430 535

0.75 260 320 380 475

0.85 250 300 355 430

1.00 245 300 355 430

1.10 245 290 345 400

1.20 240 275 320 365

1.50 240 275 320 365

1.65 235 270 300 345

Nozzle

Chimney Height (ft.)

11 20 28 36

Chimney Thermal Resistance > R6

0.50 185 200 220 250

0.65 175 185 205 220

0.75 175 185 195 210

0.85 165 185 195 205

1.00 165 185 195 205

1.10 165 185 195 205

1.20 165 180 190 200

1.50 165 175 185 195

1.65 165 175 180 190

< - less than, > - greater than

OIL TANK

Oil storage tanks must be selected and
installed in compliance with applicable
codes; in the United States, NFPA 31,

Standard for the Installation of Oil
Burning Equipment, Chapter 2. and in
Canada, CAN/CSA-B139, Installation
Code for Oil Burning Equipment, Section

6. Observe all local codes and by-laws.
In general, the oil tank must be properly

supported and remain stable in both
empty and full condition. The oil tank
must be fitted with vent and supply pipes
to the outdoors. Refer to the above­mentioned codes for sizing. The vent
pipe must be no less than 1¼ inches
I.P.S., and terminate with an appropriate
vent cap in a location where it will not be
blocked. The fill pipe must be no less
than 2 inches I.P.S., and terminate with
an appropriate cap in a location where
debris will not enter the fill pipe during oil
delivery.

If located indoors, the tank should
normally be in the lowest level, (cellar,
basement, etc.). It must be equipped
with a shut-off valve at the tank outlet
used for the oil supply. The oil tank must
be located as to not block the furnace /
room exit pathway. Observe all
clearances specified in the above­mentioned codes.

PIPING INSTALLATION

In the United States, NFPA 31, Standard
for the Installation of Oil Burning
Equipment, Chapter 2.

In Canada, the entire fuel system should
be installed in accordance with the
requirements of CAN/CSA B139, and
local regulations. Use only approved fuel
oil tanks piping, fittings and oil filters.

Ensure that all fittings used in a copper
oil line system are high quality flare
fittings. Do not use compression fittings.

Do not use Teflon tape on any fittings.
Pressurized or gravity feed installations

must not exceed 3 PSIG. Pressures
greater than 10 PSIG may cause
damage to the shaft seal. If the height of
the oil stored in a tank above the oil
burner exceeds 11½ feet, it may be
necessary to use a pressure-regulating
device approved for this purpose.

The furnace may be installed with a one­pipe system with gravity feed or lift. The
maximum allowable lift on a single line
system is 8 feet. Lift should be measured
from the bottom (outlet) of the tank, to
the inlet of the burner. Sizing a single
line system is complex because of the
difficulty estimating the pressure drop
through each fitting, bend and
component in the line. In general, keep
single line systems short as possible. 2­stage oil pumps are not available for
P*LBX furnaces. The following chart
shows the allowable line lengths
(horizontal + vertical) for single and two­line oil piping systems. All distances are
in feet.

Table 4: Oil Lines

Copper Tubing Oil Line Length (Feet)

Lift

(Feet)

0 53 100 68 100
1 49 100 65 100
2 45 100 63 100
3 41 100 60 100
4 37 100 58 100
5 33 100 55 100
6 29 100 53 100
7 25 99 50 100
8 21 83 48 100

9 17 68 45 100
10 13 52 42 100
12 - - - - - - 37 100
14 - - - - - - 32 100
16 - - - - - - 27 100
18 - - - - - - 22 88

Single-Pipe Two-Pipe

3/8”

OD

1/2”

OD

3/8”

OD

1/2”

OD

In retrofit applications, where an existing
oil line system is in place, a vacuum
check will help determine the efficacy of
the existing oil line system The vacuum
in a system should not exceed 6” Hg. for
a single pipe system, nor 12” Hg. for a
two-pipe system.

NOTE: The oil burner requires the use of
a bypass plug when converting from
single-pipe to two-pipe oil piping
systems. See burner manufacturer’s
instructions.

All fuel systems should include an oil
filter between the fuel oil storage tank
and the oil burner. For best results,
install the oil filter as close to the burner
as possible. When using an indoor oil
tank, the oil filter may be installed at the
tank downstream from the shut-off valve.
If firing the furnace under the 0.65 gph
rate, a 7 to 10 micron line filter should be
installed as close to the oil burner as
possible.

ELECTRICAL CONNECTIONS

The furnace is listed by the Canadian
Standards Association (CSA). All models
except for the P*LBX20F19001 are
factory wired and require minimal field
wiring. The P*LBX20F19001 model is
pre-wired except for the wiring
connections to the blower motor. The
wires from the furnace section are routed
through the grommet in the blower
section blower division panel, and then
connected to the blower motor. In the
United States, the wiring must be in

6

accordance with the National Fire
Protection Association NFPA-70,
National Electrical Code, and with local
codes and regulations. In Canada, all
field wiring should conform to CAN/CSA
C22.1 Canadian Electrical Code, Part 1,
and by local codes, where they prevail.

The furnace should be wired to a
separate and dedicated circuit in the
main electrical panel; however,
accessory equipment such as electronic
air cleaners and humidifiers may be
included on the furnace circuit. Although
a suitably located circuit breaker can be
used as a service switch, a separate
service switch is advisable. The service
switch is necessary if reaching the circuit
breaker involves becoming close to the
furnace, or if the furnace is located
between the circuit breaker and the
means of entry to the furnace room. The
furnace switch (service switch) should be
clearly marked, installed in an easily
accessible area between the furnace and
furnace room entry, and be located in
such a manner to reduce the likelihood
that it would be mistaken as a light
switch or similar device.

The power requirements for all models:
120 VAC, 1 ∅, 60 Hz.

Maximum fuse size for the
P*LBX16F14501 model: 15 amps.
Maximum fuse size for the
P*LBX20F19001 model: 20 amps.

Accessories requiring 120 VAC power
sources such as electronic air cleaners
and humidifier transformers may be
powered from the furnace circuit. Do not
use the direct drive motor connections as
a power source, since there is a high risk
of damaging the accessories by
exposure to high voltage from the auto­generating windings of the direct drive
motor.

Thermostat wiring connections and air
conditioning contactor low voltage
connections are shown in the wiring
diagrams. Some micro-electronic
thermostats require additional controls
and wiring. Refer to the thermostat
manufacturer's instructions.

The thermostat should be located
approximately 5 feet above the floor, on
an inside wall where there is good
natural air circulation, and where the
thermostat will be exposed to average
room temperatures. Avoid locations
where the thermostat will be exposed to
cold drafts, heat from nearby lamps and
appliances, exposure to sunlight, heat
from inside wall stacks, etc.

Normal heat anticipator setting for the
P*LBX models is 0.1 A. For more precise
adjustment, the heat anticipator may be
adjusted to the amperage draw of the
heating control circuit as measured
between the "R" and "W" terminals of the
thermostat. To reduce the risk of
damaging the heat anticipator, do not
measure circuit without first removing
one of the two wires first. To determine
the heating circuit amperage draw:

1. Disconnect one of the “R” or “W”
wires from the thermostat terminal.

2. Connect an ammeter between the
wire and the thermostat terminal to
which it was attached.

3. Note the amperage reading when
the heating contacts are closed.
(System switch must be on “

HEAT” if

so equipped.

4. Re-connect the thermostat wire. If
the thermostat is serving a
combination heating and air
conditioning system, pay particular
attention to polarity.

5. When the thermostat is reconnected
and re-plumbed, adjust the heat
anticipator setting to match the
observed amperage reading.

CIRCULATING AIR BLOWER

The P*LBX16F14501 furnace models
are equipped with a direct drive blower
system. Direct drive blower speed
adjustments are not normally required in
properly sized extended plenum duct
systems. The motor RPM and air CFM
delivery will vary automatically to
accommodate conditions within the usual
range of external static pressures typical
of residential duct systems. Under-sized
duct systems may require a higher
blower speed to obtain a reasonable
system temperature rise. Some older
duct systems were not designed to
provide static pressure. They typically
feature special reducing fittings at each
branch run and lack block ends on the
trunk ducts. These systems may require
modification to provide some resistance
to the airflow to prevent over- amping of
the direct drive blower motor. Selecting a
lower blower speed may correct this
problem.

Direct drive blower speeds are adjusted
by changing the "hot" wires to the motor
winding connections. Please refer to
wiring diagram in Appendix B or the
wiring diagram label affixed to the
furnace. THE NEUTRAL WIRE

(normally the white wire) IS NEVER

MOVED TO ADJUST THE BLOWER
SPEED.

DO NOT CONNECT POWER LEADS
BETWEEN MOTOR SPEEDS. THE
NEUTRAL WIRE MUST ALWAYS BE
CONNECTED TO THE MOTOR'S
DESIGNATED NEUTRAL TERMINAL.

It is possible and acceptable to use a
single blower speed for both heating and
cooling modes. The simplest method to
connect the wiring from both modes is to
use a "piggy-back connector"
accommodating both wires on a single
motor tap. It is also acceptable to
connect the selected motor speed with a
pigtail joined to both heating and cooling
speed wires with a wire nut. As a safety
precaution against accidental
disconnection of the wires by vibration, it
is advisable to secure the wire nut and
wires with a few wraps of electricians
tape.

If the joining of the blower speed wiring
is done in the furnace junction box, tape
off both ends of the unused wire.

The P*LBX20F19001 furnace model is
equipped with a belt drive blower
system. The blower speed (RPM) and
resultant airflow can be varied by
adjusting the variable speed motor
pulley.

DISCONNECT THE POWER SUPPLY
TO THE FURNACE BEFORE
OPENING THE BLOWER ACCESS
DOOR TO SERVICE THE AIR FILTER,
FAN AND MOTOR. FAILURE TO
SHUT OFF POWER COULD ALLOW
THE BLOWER TO START
UNEXPECTEDLY, CREATING A RISK
OF DEATH OR PERSONAL INJURY.

Do not use the blower speed wires as
a source of power to accessories as
electronic air cleaners and humidifier
transformers. The unused motor taps
auto-generate sufficiently high
voltages to damage accessory
equipment.

Do not start the burner or blower fan
unless the blower access door is
securely in place.

7

OIL BURNER

P*LBX furnaces are equipped with
Beckett AF Series oil burners with the
Beckett CleanCut pump and R7184B oil
primary control. The oil burner must align
properly with combustion chamber
(firepot). The combustion chamber is
initially quite soft, but hardens and
becomes quite brittle after the first firing.
The firepot is held in place by a retaining
bracket; however, it is possible for the
firepot to shift if subjected to rough
handling during transit.

BEFORE OPERATING THE
FURNACE CHECK BURNER
ALIGNMENT WITH COMBUSTION
CHAMBER. THE END CONE OF THE
AIR TUBE MUST BE CENTRED TO
THE ACCOMODATING RING
PROVIDED IN THE DESIGN OF THE
COMBUSTION CHAMBER. ADJUST
ALIGNMENT AS NECESSARY
BEFORE THE FIRST FIRING.

OIL BURNER NOZZLES

All furnace models are certified for
multiple firing rates. Choose the firing
rate that most closely matches the
calculated heat loss of the building.
Models, firing rates and nozzles are
listed in Table A-1.

BURNER ELECTRODES

Correct positioning of the electrode tips
with respect to each other, to the fuel oil
nozzle, and to the rest of the burners is
essential for smooth light ups and proper
operation. The electrode tips should be

adjusted to a gap of 5/32”, 1/16” ahead
of the nozzle, 5/16” above the centerline
of the nozzle. The “Z” dimension (front
edge of the burner head to the front face
of the nozzle is 1-1/8 inches.

Electrode positioning should be checked
before the first firing of the furnace.

The electrode porcelains should be free
of cracks, the electrode tips should be
tapered and free of burrs, and the
contact rods must be clean and be in
firm contact with the ignition transformer
contact springs. The electrodes must not
come into contact with the burner head.

OIL BURNER SET-UP

The burner air supply is adjusted to
maintain the fuel to air ratio to obtain
ideal combustion conditions. A lack of air
causes "soft" and "sooty" flames,
resulting in soot build-up throughout the
heat exchanger passages. Excess
combustion air causes a bright roaring
fire and high stack temperatures
resulting in poor fuel efficiency.

PREPARATIONS:
Drill a 1/4” test port in the venting, ideally

at least 2 flue pipe diameters away from
the furnace breeching, if venting
horizontally from the furnace, (typically
P*LBX) or from the flue pipe elbow if
venting vertically before reaching the
furnace. (see Figures 4 and 5).

The test port will allow flue gas samples
to be taken and stack temperatures to be
measured.

Before starting the burner, check the
burner alignment with the combustion
chamber (fire pot), check that the correct

nozzle is tightened into place, and that
the burner electrodes are properly
positioned.

The Beckett burner bulk air band should
be closed, and the air shutter initial
setting should be approximately 7.00.

Note A: Locate hole at least 6 inches on
the furnace side of the draft control.

Note B: Ideally, hole should be at least
12 inches from breeching or elbow.

PROCEDURE:

Start the burner and allow it to run at
least ten minutes. Set the air shutter to
give a good flame visually. The
combustion air supply to the burner is
controlled by adjusting the air shutter on
the left side of the burner, and, if
necessary, the bulk air band. To adjust,
loosen the bolt on the movable shutter.
Move the shutter gradually until a good
flame (visually) has been achieved. Re­snug the bolt.

Check the initial draft setting as the
furnace warms up. The draft may be
measured at the test port. The final
breech draft should be - 0.02 inches
W.C. to provide adequate over-fire draft.

Check the oil pump pressure. Standard
operating pressure is 100 PSIG.

After reaching steady state, take a
smoke test. If not indicating a trace, set
the combustion air controls to provide a
trace.

Typically, the CO

reading will range

2

from 11.5% to 13.5%.
After the air adjustments have been

completed, and the air shutter or air

Fig. 4: Horizontal Smoke Test Port Location

8

Fig. 5: Vertical Smoke Test Port Location

adjustment plate has been secured, re­check the breech draft and take another
smoke test to ensure that the values
have not changed.

SMOKE TEST NOTE:
If oily or yellow smoke spots are found

on the smoke test filter paper, it is
usually a sign of unburned fuel. This
indicates poor combustion. This type of
problem may be caused by excess draft,
excess air, or contaminated fuel. Do not
ignore this indicator.

STACK TEMPERATURE:
Stack temperature will vary depending

on fuel input, circulating air blower
speed, and burner set up, etc. In
general, stack temperature should
typically range between 380°F to 550°F ,
assuming that the combustion air is
approximately room temperature (65°F ­70°F). In general, lower stack
temperature indicates greater efficiency;
however, excessively low stack
temperature can lead to condensation
forming in the chimney and / or venting.
Sulphur and similar contaminants in the
fuel oil will mix with condensation to form
acids. Acids and resultant chemical salts
will cause rapid deterioration of the
chimney and venting components, and
may attack the furnace.

If the flue gases are below the range, it
may be necessary to slow down the
blower fan. If the flue gases are above
the range, the blower fan may require
speeding up. Stack temperature varies
directly with the system temperature rise.
System temperature rise is the difference
between the furnace outlet temperature
and furnace inlet temperature as
measured in the vicinity of the
connection between the plenum take-offs
and the trunk ducts. Temperature rise is
indicated on the furnace rating plate.

If the venting from the furnace to the
chimney is long, or exposed to cold
ambient temperatures, it may be
necessary to use L-Vent as the vent
connector to reduce stack temperature
loss to prevent condensation. The
venting should be inspected annually to
ensure that it is intact.

FURNACE INSTALLATION SET-UP

The furnace must be set up as the final
step in the installation.

A) The oil burner must be set up
following the procedures outlined above.

B) To determine the temperature rise,
measure the supply air and return air
temperatures when the furnace has

reached steady state conditions. This is
the point at which the supply air
temperature stops increasing relative to
the return air temperature. The furnace
may have to run 10 to 15 minutes to
reach steady state conditions. The
measurements may be made with duct
thermometers or thermocouples used in
conjunction with multi-meters with
temperature measurement capabilities.

The return air should be measured at a
point where the thermometer will be well
within the air stream near the furnace
return air inlet. Actual location is not
particularly critical; however, avoid
locations where the temperature
readings could be affected by humidifier
bypass ducts, the inside radius of
elbows, etc.

The supply air temperature should be
measured at a point where the
thermometer will be well within the air
stream near the furnace supply air outlet.
Usually, the side mid-point of the supply
air plenum take-off is ideal, providing it is
out of the line of sight to the heat
exchanger. If the thermometer is within
the line of sight of the heat exchanger,
the supply air readings may be skewed
by radiant heat from the heat exchanger.
If the plenum take-off is unsuitable, the
supply air temperature may be measured
within the first 18 inches of the first
segment of supply air trunk duct.

If the temperature rise is outside the
recommended range, it may be adjusted
on direct drive equipped units by
selecting alternate circulation fan motor
speeds, on belt drive equipped units by
adjusting the variable speed motor
pulley. If the temperature rise is too high,
speed the fan up. If the temperature rise
is too low, slow the fan down.

C) Keep in mind that the stack
temperature varies directly with the
temperature rise. The higher the
temperature rise, the higher the stack
temperature will be, resulting in lower
efficiency. The lower the temperature
rise, the lower the stack temperature will
be, which, in some cases, may allow
condensation to form in the chimney and
other vent parts.

D) Test the high l imit control to ensure
that it is operating correctly. For direct
drive equipped units, this may be done
by temporarily removing the circulator
fan heating wire or neutral wire. For belt
drive equipped units, temporarily remove
the fan belt. Turn of electrical power to
the furnace before working with the
motor wires or fan belt. Be sure to
protect any removed wires from shorting

out on metal furnace parts. If the high
limit test is successful, shut off the
electrical power to the furnace, restore
the proper motor wiring. Finally, restore
power to the furnace.

E) Adjust the “Fan Off” setting on the
L6064A or L4064W fan limit controller. In
most cases, the “Fan Off” temperature
should be 90° to 100°F as indicated on
the thermometer used to measure the
supply air temperature. Once the “Fan
Off” setting has been established, set the
“Fan On” setting. In most cases, the “Fan
On” setting should be approximately
30°F higher than the Fan Off” setting.

F) Operate the furnace through a
minimum of three full heating cycles.
During this time, check for fuel oil leaks,
gross air leakage from the supply air
ductwork, unusual noises originating
anywhere within the heating system
which may cause some concern or
annoyance to the home owner, etc.

G) Be sure that the homeowner is
familiar with the furnace. The
homeowner should be aware of the
location of electrical circuit breaker or
fuse, the location of any electrical
switches controlling the furnace, the
location of the oil tank shut-off valve and
how to operate the valve. The
homeowner should be informed where
the oil tank gauge is located and how to
read it.

It would be beneficial to review safety
issues with the home owner, such as the
danger of storing combustibles too close
to the furnace, hanging anything on the
furnace vent pipe, and especially the
dangers of indiscriminately pressing the
burner reset button.

IMPORTANT: Be sure that the home
owner knows where the burner reset
switch is located, and is aware that the
reset switch is not to be activated more
than once without a thorough look for the
cause of the problem, (lack of fuel, etc.).
Be sure that the homeowner knows
when to quit trying to start the furnace
during these conditions and who to call
for emergency service.

MAINTENANCE AND SERVICE

A: Routine Maintenance By Home
Owner

Other than remembering to arrange for
the annual professional servicing of the
furnace by the service or installation
contractor, the most important routine
service performed by the homeowner is
to maintain the air filter or filters. A dirty
filter can cause the furnace to over-heat,

9

fail to maintain indoor temperature during
cold weather, increase fuel consumption
and cause component failure.

The furnace filter(s) should be inspected,
cleaned or replaced monthly. The
furnace is factory equipped with a semi­permanent type filter. If the filter is
damaged, replace with filters of the same
size and type.

During the routine service, inspect the
general condition of the furnace watching
for signs of oil leaks in the vicinity of the
oil burner, soot forming on any external
part of the furnace, soot forming around
the joints in the vent pipe, etc. If any of
these conditions are present, please
advice your service or installation
contractor.

B: Annual Service By Contractor

THE Combustion chamber (firepot) IS
FRAGILE. Use care when inspecting
and cleaning this area.

The heat exchanger should be inspected
periodically and cleaned if necessary. if
cleaning is necessary, SHUT OFF
POWER TO THE FURNACE and
remove the burner. Using a stiff brush
with a wire handle, brush off scale and
soot from inside the drum and flue pipe.
To clean the heat exchanger radiator,
remove the covers on the front or inner
front panel, and then loosen the brass
nuts on the radiator clean-out yoke
assembly. Do not remove the brass nuts.
The yoke assembly, once loosened, may
be removed to gain access to the heat
exchanger outer radiator.

A wire brush can be used to loosen dirt
and debris on the inside surfaces of the
radiator. Clean out all accumulated dirt,
soot and debris with a wire handled
brush and an industrial vacuum cleaner.
Replace the clean-out yoke assemblies
and clean-out covers.

Most circulating fan motors are
permanently lubricated by the motor
manufacturer. These motors will have no
oil ports. If the blower motor does
contain oil ports, under normal operating
conditions it will not require oiling for the
first two years. Oil sparingly; a few drops
in each oil port with SAE 20 non­detergent oil. Oiling is most easily done
with a "tele-spout" oiler. This oiler has a
long flexible plastic spout. DO NOT
OVER-LUBRICATE. Excess oil may
result in premature electric motor failure.

Inspect the blower fan. Clean it if
necessary.

Oil Burner Maintenance: Follow the
instructions of the oil burner
manufacturer. (See oil burner
manufacturer's instructions supplied with
furnace). The oil burner nozzle should be
replaced annually. We recommend that
the oil filter be changed on an annual
basis.

The venting system should be cleaned
and inspected for signs of deterioration.
Replace pitted or perforated vent pipe
and fittings. The barometric draft
regulator should open and close freely.

All electrical connections should be
checked to ensure tight connections.
Safety controls such as the high limit
controls should be tested for
functionality. The fan control functions
should be checked to ensure that all fan
speeds are operating properly.

OPERATING INSTRUCTIONS

Before Lighting

Open all supply and return air registers
and grilles.

Open all valves in oil pipes.
Turn on electric power supply.

To Light Unit

Set the thermostat above room
temperature to call for heat. The burner
will start. NOTE: If the furnace has been
off for an extended period of time, it may
be necessary to press the RESET button
on the primary combustion control relay,
(once only
does not start the furnace, refer to
Appendix C, Troubleshooting.

After the furnace warms sufficiently, the
circulation fan will start.

The furnace will continue to run until the
thermostat call for heat is satisfied.

Set the thermostat below room
temperature. The oil burner will stop.

The air circulation blower will continue to
run until the furnace has cooled
sufficiently.

To Shut Down Unit

Set the thermostat to the lowest possible
setting. Set the manual switch (if
installed) in the Electrical Power Supply
Line to "OFF".

NOTE: If the furnace is to be shut down
for an extended period of time, close the
oil supply valve to the oil burner.

). If pressing the reset button

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. NEVER BURN
GARBAGE OR PAPER IN THE
FURNACE, AND NEVER LEAVE
PAPER OR RAGS AROUND THE UNIT.

10

11

TABLE A-1: BECKETT OIL BURNER SET-UP

BECKETT AF SERIES OIL BURNERS

FURNACE

MODEL

OUTPUT

BTU/Hr.

BURNER

MODEL

NOZZLE

(Delavan)

PUMP

PRESSURE

FLOW

RATE

HEAD

STATIC

PLATE

130,000 AF65YB 1.10 / 70°A 100 PSIG 1.10 GPH F6 2-3/4 in.

P*LBX16F14501

143,000 AF65YB 1.20 / 60°A 100 PSIG 1.20 GPH F6 2-3/4 in.
168,000 AF81WF 1.50 / 70°B 100 PSIG 1.50 GPH F16 2-3/4 in.

P*LBX20F19001

188,000 AF81WF 1.65 / 70°B 100 PSIG 1.65 GPH F16 2-3/4 in.

In the United States, the R. W. Beckett “AF” Burner may be equipped with Beckett’s “Inlet Air Shut-Off”, Beckett Part No. AF/A 5861, to increase efficiency. It reduces the
amount of air passing through the oil burner, combustion chamber, breeching, etc. up the chimney between burner cycles.

NOTE: THE USE OF THIS CONTROL CAN OCCASIONALLY CAUSE POST COMBUSTION NOZZLE DRIP.

TABLE A-2: DIRECT DRIVE BLOWER SET-UP

BLOWER SET-UP COOLING CAPACITY

0.20 in. w.c. 0.50 in. w.c.

FURNACE

OUTPUT

BTU/Hr.

BLOWER

MOTOR

HP

Speed Speed

Htg. CFM

Range 1

Tons

2

MOTOR

HP

Clg. CFM

Range

130,000 High High 1332 - 1712

P*LBX16F14501

143,000

G10 DD 1/2

High High 1465 - 1883

4 1/2 1065 - 1600

(1)

Heating Range values based on temperature rise. Upper values may exceed measured airflow values in Table A-3.

(2)

Nominal values only.

TABLE A-3: BELT DRIVE BLOWER SET-UP

Blower Set-Up Cooling Capacity

0.20 in. W.C. 0.50 in. W.C.

Pulley Belt Pulley Belt

Furnace

Model

Blower Motor

Motor Blower Motor Blower

Tons CFM Range

3 1/2 x 5/8 7 x 3/4 4L430 3 1/2 x 5/8 7 x 3/4 4L430

P*LBX20F19001 G12 3/4 HP

3 1/2 x 5/8 7 x 3/4 4L430 3 1/2 x 5/8 7 x 3/4 4L430

4 1300 - 1535

12

TABLE A-4: DIRECT DRIVE BLOWER CHARACTERISTICS

CFM

External Static Pressure – inches W.C.

FURNACE

MODEL

BLOWER

MOTOR

HP

MOTOR

FLA

TEMP.

RISE

(∆T)

SPEED

0.02 0.03 0.04 0.05 0.06

High 1810 1740 1675 1585 1510

Med-High 1570 1540 1495 1445 1375

Med-Low 1090 1080 1070 1065 1050

P*LBX16F14501 G10 1/2 7.7 70° - 90°F

Low 710 700 690 665 650

TABLE A-5: BELT DRIVE BLOWER CHARACTERISTICS

CFM

External Static Pressure – Inches water column

Furnace Model Motor HP

Motor

FLA

∆T

Blower

Blower

Pulley

Motor

Pulley

Turns

Out

0.20 0.30 0.40 0.50 0.60

0 2274 2080 1847 1532 1099
2 2107 1927 1712 1420 1019
4 1939 1775 1576 1308 939

P*LBX20F19001 3/4 HP 13.0 85°F G12 7 x 3/4

6 1772 1622 1441 1196 859

TIP: These formulae will assist with the design of the ductwork and the determination of airflow delivery:

() ()

CFM

Bonnet Output

x SystemTemp eratureRise

SystemTemperature Rise

Bonnet Output

xCFM

= =

1085 1085. .

WIRING DIAGRAM: MODEL P*LBX16F14501

WIRING DIAGRAM: MODEL P*LBX20F19001

13

R7184 TROUBLESHOOTING

R7184 Detailed Sequence of Operation (See Figure 7)
Power is applied to unit. The R7184 completes a self-diagnostic procedure. If no light or flame is present, and unit

passes its self-diagnostic procedure, the control enters into the idle mode.

Thermostat calls for heat:

A) Safety check is made for flame (4 second delay).

1) If flame is not present, the R7184 will apply power to the burner motor and igniter.

2) If flame is present, the control remains in the idle state.
B) Unit enters a pre-purge period of 15 seconds.
C) After 10 seconds, control checks for flame presence.

1) If flame is not present, the R7184 enters the trial for ignition state.

2) When flame is present, the control enters lock out mode.
D) Control monitors the burner flame.

1) When flame is present, the control enters ignition carryover state. (Continues to spark for 10 sec.).

a) Provides continuous spark after flame is sensed to assure that burner remains lit.
b) Turns on LED diagnostic light.
c) Starts carryover timer.

(i) Flame and call for heat are monitored.

• If flame is lost and lockout timer has not expired, R7184 will return to trial for ignition state.

• If flame is lost and lockout timer has expired, R7184 will enter the recycle state.
♦ Recycle timer starts.
♦ Burner motor and igniter and solenoid valve are turned off.
♦ LED diagnostic light flashes slowly.

E) Carryover timer expires.

1) Enters run state.
a) Igniter turns off.

Combustion continues until thermostat is satisfied, or R7184 detects a loss of flame and enters into Recycle Mode.

F) Thermostat is satisfied - call for heat is terminated:

a) R7184 shuts off burner motor and solenoid valve.

(i) If control utilizes a blower motor off delay, after 30 seconds, flame presence is checked.

• If flame is not present, the R7184 LED diagnostic light is off and returns to idle state.

6. If flame is presence is detected, the control enters lock out mode.

14

y

g

g

g

g

Fig. 7: R7184 Detailed Sequence of Operation

IDLE STATE

THERMOSTAT CALLS FOR HEAT

SAFETY CHECK FOR FLAME (5 SEC.)

BURNER MOTOR & IGNITOR START

SOLENOID VALVE OPENS

TRIAL FOR IGNITION

BURNER FLAME MONITORED

REMAINS IN IDLE STATE

LOCKOUT STATE

• Shuts off burner motor

• Shuts off igniter

• Shuts off Solenoid Valve

• Fast Flashes LED Diagnostic

Li

ht

R7184

SEQUENCE of

OPERATION

R7184:

CARRYOVER STATE

• Provides continuous spark

• LED diagnostic light ON

• Start Carr

CARRYOVER TIMER EXPIRES

• I

nitor turns off.

THERMOSTAT SATISFIED

R7184 SHUTS OFF:

• Burner Motor

• Solenoid Valve

• LED Dia

over Timer

RUN STATE

nostic Light

TO EXIT LOCKOUT

PRESS RESET

RECYCLE TIMER STARTS

R7184:

• Shuts off Solenoid Valve

• Shuts off Igniter

• Shuts off Burner Motor

• Slow Flashes LED

dia

nostic light

RECYCLE TIMER EXPIRES

(60 SECONDS

RETURNS TO IDLE STATE

15

R7184 LED Diagnostic Light

The LED diagnostic light has several
functions. It indicates the state or mode
in which the oil burner is operating. It will
also indicate fault conditions, and help
determine cad cell resistance while the
burner is operating.

NORMAL CONDITIONS:
The LED diagnostic light will turn on

when the burner enters the carryover
state; the point at which ignition spark is
on, and will remain on through the run
state, where the ignition spark is
terminated but the burner continues to
fire.

The LED diagnostic light will turn off at
the end of the burner cycle as the R7184
enters the idle state, and will remain off
until the next heating cycle.

FAULT CONDITIONS:

If the LED diagnostic light is flashing
quickly, 1 Hz (1/2 second on / 1/2
second off), the R7184 is in the lockout
state or in restricted mode. To exit the
lockout state, press the reset button.

If the LED diagnostic light is flashing
slowly, 1/4 Hz (2 seconds on / 2 seconds
off), the R7184 is in the recycle state.
This indicates that flame sensing was
lost after the lockout timer expired during
the ignition carryover state. The R7184
will return to the idle state within 60
seconds.

CAD CELL CONDITION:
If the LED diagnostic light is off, the cad

cell is not sensing flame.
If the LED diagnostic light is on, the cad

cell is sensing flame, or viewing ambient
light.

The resistance of the cad cell may be
checked while the R7184 is in the run
state by pressing the reset button. The
LED diagnostic light will flash the
following code:

TABLE C-1: CAD CELL RESISTANCE

Flashes Resistance in Ohms

1 Less than 400

TROUBLESHOOTING

IMPORTANT: Due to the potential
hazard of line voltage, only a trained,
experienced service technician should
perform the troubleshooting procedure.

PRELIMINARY STEPS:

Check the diagnostic light for indications
of burner condition. Refer to R7184 LED

DIAGNOSTIC LIGHT section for details.

WHEN SIMULATING A CALL FOR
HEAT AT THE R7184, DISCONNECT
AT LEAST ONE THERMOSTAT LEAD
WIRE FROM THE T1 - T2 TERMINALS
TO PREVENT DAMAGE TO THE
THERMOSTAT. NEGLECTING THIS
PROCEDURE MAY BURN OUT THE
HEAT ANTICIPATOR OF A
STANDARD 24 VAC THERMOSTAT,
OR CAUSE HARM TO COMPONENTS
WITHIN A MICRO-ELECTRONIC
THERMOSTAT.

Before checking the oil primary control,
perform these preliminary checks, (repair
or replace controls as necessary):

• Check the power supply, fuse
box or breaker, any service
switches, all wiring connections,
and burner motor reset button
(if equipped).

• Check the limit switches to
ensure that the switch contacts
are closed.

• Check the electrode gap and
position.

• Check the contacts between the
oil primary control and the
electrodes.

• Check oil supply (tank gauge).

• Check the oil nozzle, oil filter,

and oil valves.

• Check the piping or tubing to
the oil tank.

• Check the oil pump pressure.

CHECK OIL PRIMARY CONTROL
AND IGNITER

If the trouble does not appear to be in
the burner or ignition hardware, check
the oil primary control and the igniter by
using the following equipment:

Screwdriver.
Voltmeter (0 - 150
Insulated jumper wires with both ends

stripped.

Electrical Shock Hazard.
Troubleshooting is done with the system

powered. Be careful to observe all
necessary precautions to prevent
electrical shock or equipment damage.

PRELIMINARY CHECKS:
Make sure that limit switches are closed

and those contacts are clean.
Check for line voltage power on the oil

primary control black and white lead
wires.

Refer to Table C-4 or C-5 for further
troubleshooting information.

VAC)

2 Between 400 - 800

3 Between 800 – 1600

4 Between 1600- 5000

16

TABLE C-2: R7184 TROUBLESHOOTING

Condition: Burner motor does not start when there is a call for heat.

Procedure Status Corrective Action

1. Check that limit switches are
closed and contacts are
clean. This includes the
burner motor reset button.

2. Check for line voltage po wer
at the oil primary control.
Voltage should be 120 Vac
between the black and white
lead wires on the oil primary
control.

3. Check indicator light with
burner off, no call for heat (no
flame).

4. Shield cad cell from external
light.

5. Jumper thermostat (T -T)
terminals on R7184

IMPORTANT
First remove one thermostat lead

wire.

Condition: Burner starts then locks out on safety with indicator light flashing at 1 Hz rate (1/2 second on, 1/2 second
off)

Procedure Status Corrective Action

1. Check that the limit switches
are closed and contacts are
clean.

2. Check for line voltage po wer
at the oil primary control.
Voltage should be 120 vac
(nominal)

3. Check indicator light with
burner off, no call for heat (no
flame).

Continues on next page

Indicator light is on.
Indicator light is off. Go to step 5.
Indicator light turns off.

Indicator light stays on.

Burner starts.

Burner does not start.

Indicator light is on.
Indicator light is off. Go to step 5.

N/A N/A

N/A N/A

Cad cell is defective, sees external light, or connections
have shorted. Go to step 4.

Eliminate external light source or permanently shield cad
cell.

• Replace cad cell with new cad cell and recheck.

• If indicator light does not turn off, remove yellow

lead wires from R7184 and recheck.

• If indicator light is still on, replace the R7184
control.

• If the indicator light turns off, replace cad cell
bracket assembly.

Trouble is in thermostat circuit. Check thermostat-wiring
connections.

If connections are clean and tight, check thermostat wires
for continuity.

• Disconnect line voltage power and open line
switch.

• Check all wiring connections.

• Tighten any loose connections and recheck.

• If burner still doesn't start, replace R7184

If burner still doesn't start, check the oil burner motor. It
may be seized or burned out.

- - - - - -

- - - - - -

Cad cell or controller is defective, sees external light, or
connections are shorted. Go to step 4.

17

Table C-2: R7184 Troubleshooting continued from previous page

Procedure Status Corrective Action

Indicator light turns off. Eliminate external light source or permanently shield cad cell.

4. Replace cad cell with ne w cad cell and recheck.

4. Shield cad cell from
external light.

5. Jumper thermostat (T -T)
terminals on R7184

IMPORTANT

First remove one thermostat
lead wire.

Condition: Burner starts then locks out on safety with indicator light flashing at 1 hz rate (1/2 second on, 1/2
second off)

6. Reset oil primary control
by pushing in and
releasing red reset button.

7. Listen for spark after
burner turns on (after 2
second delay).

8. Check indicator light after
flame is established, but
before oil primary control
locks out.

view of flame.

• Disconnect line voltage
power and open line
switch.

• Unplug cad cell and clean
cad cell face with soft
cloth. Check sighting for
clear view of flame.
Replace cad cell in socket.

• Reconnect line voltage
power and close line
switch.

• Start burner.

Continues on next page

Indicator light stays on.

Burner starts.

Burner does not start.

Indicator light stops flashing. Go to Step 7.
Indicator light continues to

flash at 1 Hz rate.
Ignition is off
Ignition is on. Go to Step 8.

Ignition is on but no oil is
being sprayed into the
combustion chamber.

Indicator light is on until the
control locks out and starts
flashing during lockout.

Indicator light stays off. Go to step 9.
Burner locks out. Go to step 10. 9. Check cad cell sighting for

Burner keeps running. System is OK.

5. If indicator light does not turn off, remove cad cell lead
wires from R7184 and recheck.

6. If indicator light turns off, replace cad cell bracket
assembly.

7. If indicator light does not turn off, replace controller.

Trouble in thermostat or limit circuit. Check thermostat or li mit
wiring connections.

Disconnect the line voltage power and open line switch.
Check all wiring connections.
Tighten any loose connections and recheck.
If burner does not start, replace R7184

Verify that the control is not in restricted mode. (See notes at
end of this table.). If not in restricted mode, replace R7184

Spark igniter could be defective. Check for line voltage at
igniter terminals. If line voltage is present, replace R7484.

Wait for “Valve ON” delay to complete. Check oil supply, and
oil line valve. Check for filter blockage or seized oil pump.

Replace R7184

18

Table C-2: R7184 Troubleshooting continued from previous page
Procedure Status Corrective Action

Indicator light is on. Remount control onto burner housing. Go to step 6. 10. Check cad cell.

• Disconnect line voltage
power and open line switch.

• Remove existing cad cell
and replace with new cad
cell.

• Disconnect all wires from
thermostat terminals to
ensure that there is no call
for heat.

• Reconnect line voltage
power and close line switch.

• Expose new cad cell to
bright light such as a
flashlight.

11. Check cad cell bracket
assembly.

• Disconnect line voltage
power and open line switch.

• Remove cad cell wires from
quick connect connectors
on the control and leave
control lead wires open.

• Apply power to device.

• Place jumper across cad

cell terminals after burner
motor turns on.

NOTE: Restricted Mode - (Limited Reset): In order to limit the accumulation of unburned oil in the combustio n chamber, the

control can be reset only 3 times, after which, the control locks out. The reset count returns to zero each time a call for
heat is successfully completed.

To reset from R
device has reset.

NOTE: Disable function: Pressing and holding the reset button will disable all functions until the button is released. The burner

will restart at the beginning of the normal heat cycle on

Problem Possible Cause Remedy

Furnace will not start.

Continues on next page

ESTRICTED MODE: press and hold the reset button for 30 seconds. When the LED flashes twice, the

Thermostat not calling for heat.

No power to furnace.

Thermostat faulty.

Oil primary control faulty.

Indicator light is off. Go to step 11.

Indicator light is on. Replace cad cell bracket assembly.

Indicator light is off. Replace R7184.

SAFETY CHECK.

TABLE C-3: SYSTEM AND GENERAL TROUBLESHOOTING

Check thermostat and adjust. Also, check thermostat for accuracy;
if it is a mercury switch type, it might be off level.

Check furnace switch, main electrical panel furnace fuse or circuit
breaker. Also look for any other hand operated switch, suc h as an
old poorly located furnace switch, which was not removed during
furnace replacement.

Remove thermostat wires from oil primary control terminals T-T.
Place a jumper across T-T. If furnace starts, replace thermostat,
thermostat sub-base (if equipped), or both.

Check reset button on oil primary control. Remove thermostat
wires from oil primary control terminals T1 - T2. Check for 24v
across T -T. If no voltage is present, check for 115v to oil primar y
control. If 115v is present, go to Table C-2.

19

Table C-3: System and General Troubleshooting continued

Problem Possible Cause Remedy

Photo Cell wiring shorted or
room light leaking into photo

Furnace will not start.

Furnace will not start
without first pushing
oil primary control
reset button.

(Happens on frequent
basis)

Furnace starts, but
cuts out requiring
manually resetting the
oil protector reset
button.

Furnace starts, but
cuts out requiring
manually resetting the
oil protector reset
button.

Oil burner sputtering
at nozzle

Continues on next page

cell compartment
Open safety switch.

No fuel oil.

Clogged nozzle.
Clogged oil filter. Replace oil tank filter or in-line filter if used.

Low oil pump pressure.

Air getting into fuel oil lines, or
fuel oil line dirty, clogged, or in
some manner defective.

Defective burner motor.

Photo Cell (Cad Cell) defective.

No fuel oil.

Clogged nozzle.
Clogged oil filter. Replace oil tank filter or in-line filter if used.

Low oil pump pressure.

Air getting into fuel oil lines, or
fuel oil line dirty, clogged, or in
some manner defective.

Defective burner motor.

Water or contaminants in oil.

Frozen oil line.
Electrodes out of adjustment or

defective.
Poor transformer high voltage

connections or defective
transformer.

Fuel oil filter clogged. Replace fuel oil storage tank filter and / or fuel oil in-line filter.
Defective oil pump.
Fuel oil line partially clogged or

contains air.

Check photo cell (cad cell) wiring for short circuits. Also, check for
room light leaking into cad cell compartment. Repair light leak if
necessary. See Table C-2.

Check for open limit or auxiliary limit. Also, check internal wiring
connections; loose connectors, etc.

Check fuel oil supply. Check that all hand operated fuel o il valves
are in the open position. Fill oil storage tank if necessary.

Replace nozzle with high quality r eplacement. Use rating plate or
Tables in Appendix A as a guide.

Connect pressure gauge to oil pump. Adjust pump pressure, or
replace oil pump if necessary. Ensure that erratic pressure
readings are not caused by defective fuel oil line.

Check fuel oil lines. Replace any compression fittings found with
high quality flared fittings. Check for any signs of oil leaks. An y oil
leak is a potential source of air or contaminants.

Check burner motor. If burner motor is cutting out on over-load,
determine why. Replace if necessary.

If cad cell is dirty, clean it. (Determine why cad cell is getting dirty).
If cad cell is poorly aimed, realign it. NOTE: The photocell should
have a resistance of 100K Ω in absence of light; a maximum of
1500 Ω in the presence of light. Ensure that room light is not
leaking into the cad cell compartment. (see diagnostic light
section, or manually measure cad cell resistance).

Check fuel oil supply. Check that all hand operated fuel o il valves
are in the open position. Fill oil storage tank if necessary.

Replace nozzle with high quality r eplacement. Use rating plate or
Tables in Appendix A as a guide.

Connect pressure gauge to oil pump. Adjust pump pressure, or
replace oil pump if necessary. Ensure that erratic pressure
readings are not caused by defective fuel oil line.

Check fuel oil lines. Replace any compression fittings found with
high quality flared fittings. Check for any signs of oil leaks. An y oil
leak is a potential source of air or contaminants.

Check burner motor. If burner motor is cutting out on over-load,
determine why. Replace if necessary.

Drain fuel oil storage tank; replace fuel oil. (Consult with fuel oil
supplier).

Gently warm oil line. Insulate oil line. (Outdoor piping size may
require increased diameter).

Check electrode settings. Check electrodes for dirt build-up or
cracks in porcelain.

Check contacts between the igniter and electrodes. If OK, replace
the igniter

Check burner motor / fuel oil pump coupling. Check oil pump
pressure. Replace fuel oil pump if necessary.

Bleed air from oil line. If problem persists, replace oil line.

20

Table C-3: System and General Troubleshooting continued

Problem Possible Cause Remedy

System temperature rise too
high.

Poor “fan off” delay timing
selection, (fan stops too soon).

Excessive fuel oil
consumption.

Too much smoke.

Soot building up on
blast tube (end
coning).

Furnace will not warm
home to desired
temperature.

Home does not heat
evenly

Continues on next page

Fuel oil leak. Check fuel oil line for leaks. Repair or replace if necessary.

Stack temperature too high.

Thermostat improperly adjusted
or in poor location.

Insufficient combustion air
adjustment at oil burner, or
improper draft pressure.

Heat exchanger partially
clogged.

Poor alignment between oil
burner blast tube and fire pot.

Flame impingement caused by
Incorrect nozzle angle.

Defective fire-pot Check fire-pot. Repair or replace.
Airflow blocked or dirty air filter. Clean or replace air filter.

Thermostat adjustments or
location.

Insufficient airflow.

Defective high limit control.

Under-sized nozzle.
Blower fan motor stopping

intermittently on overload.
Burner motor stopping

intermittently on overload.
Improper distribution of heat. This is not likely to be a furnace prob lem. Balance duct system.

System temperature rise ideally should not exceed 85°F. Check
for clogged air filters. Check blower fan for excess dirt build-up or
debris. Speed up blower fan if necessary.

Check “fan off” delay timing setting. Use a duct thermometer in the
supply air plenum take-off or first few inches of the supply air trunk
duct. Ideally, the fan will shut off at a temperature of 90° - 100°F.
Manipulate the dip switch settings to come as close as possible to
this “fan off” temperature.

Check stack temperature. Stack temperatures will normally range
from 350° to 450°F. Check draft regulator. Draft should be set to

0.02 in. W.C.
Check thermostat heat anticipator setting against measured

amperage draw. Increase heat anticipator setting if necessar y. If
the thermostat is being influenced by drafts, sunlight, duct work,
etc., relocate to more suitable location.

Adjust the oil burner combustion air band and draft regulator to
gain the highest practical CO

or lowest practical O2 content in the

2

flue gases. See Burner Set Up.
Check for soot build-up in heat exchanger flue passages,

especially in the outer radiator.
Check alignment. air tube should be centered with fire pot burner

opening. Oil burner head should be ¼ inch back from the insid e
surface of the fire pot.

Check nozzle size and angle. (See Appendix A). Check distanc e
from head to inside surface of the fire pot.

Check thermostat heat anticipator setting against measured
amperage draw. Increase heat anticipator setting if necessar y. If
the thermostat is being influenced by drafts, sunlight, duct work,
etc., relocate to more suitable location.

Check all dampers. Open closed dampers including registers in
unused rooms. Check system temperature rise. If temperature rise
is too high, speed up blower fan.

Test high limit function of all limit switches. Use a duct
thermometer to assess accuracy of limit control. Check for
obstructions to airflow around limit switch bi-metal elements.
Replace control if necessary.

Check nozzle. If problem is not caused by air flow problems, use
larger nozzle, if permitted by rating plate.

Check blower fan motor amperage draw. Check motor ventilation
ports, clean if necessary. Replace motor if necessary.

Check burner motor. Replace if necessary.

21

Table C-3: System and General Troubleshooting continued

Problem Possible Cause Remedy

Airflow blocked or dirty air

Supply air temperature
too hot.

Supply air temperature
too cool.

Supply air temperature
too cool during first
moments of furnace
cycle.

filter.

Insufficient airflow.

Excess airflow.

Excessive duct losses.

Fan control "fan on" setting too
low.

Excessive duct losses.

Clean or replace air filter.
Check all dampers. Open closed dampers including regist ers in

unused rooms. Check system temperature rise. If temperature
rise is too high, speed up blower fan.

Check system temperature rise. Slow down blower fan if
necessary.

Check supply air ductwork. Seal leaky joints and seams.
Insulate ductwork if necessary.

Increase differential between fan control "fan off" and "fan on"
settings. (L4064B, L6064A fan / limit controls only, no
adjustments available for L4064W fan / limit control). Register
air deflectors may help.

Check supply air ductwork. Seal leaky joints and seams.
Insulate ductwork if necessary.

22

P*LBX20F19001 ASSEMBLY NOTES

The P*LBX20F19001 oil-fired furnace is shipped in two
pieces; the furnace section and the blower section. These
two sections must be assembled together at the installation
site.

1. Remove the crating and packaging materials from each
section. Remove the flue pipe flange gasket packed with
the furnace section. The flue pipe gasket will be lying
loose on the floor of the furnace section.

2. Remove the shipping brace from the furnace section
flue pipe flange and cabinet. Remove and save all of the
screws from the flue pipe flange, and the ten screws
from the rear edges of the furnace section cabinet, (5
per side). The screws will be re-used.

3. Place the furnace section and blower section in close
proximity. Route the wiring harness from the base of the
furnace section through the plastic grommet in the
blower section blower division panel.

4. Position and a lign the flue pipe flange gasket between
the furnace section and blower section flue pipe flanges,
and hold it in place with a pair of awls or similar tool.

5. Begin fastening the flue pipe flanges together from
inside the blower section to the furnace section with the
six 1/4-20 x 3/4 inch screws saved from the removal of
the shipping brace. Start each screw carefully so as not
to damage the flue pipe flange gasket. After all six
screws have been started, and proper gasket alignment
has been confirmed, tighten all six screws evenly.

6. Align the screw holes in the blower section blower
division panel with the screw holes in the furnace
section cabinet rear edge, from which the ten screws
were removed. The screws are started from the inside
of the blower section to the furnace section. Tighten all
ten screws evenly.

7. In a similar manner, start four of the extra screws
removed and saved from the furnace section flue pipe
flange into the screw holes along the top of the two
furnace sections.

8. Remove the blower motor electric wiring cover plate.
Connect the black lead from the wiring harness to motor
terminal L1, the white lead to motor terminal L2, and the
green lead to the motor casing ground terminal. Position
the wires in the motor casing indentations and re-install
the blower motor electric wiring cover plate.

23

REPAIR PART LIST – P2LBX16F14501A

ITEM DESCRIPTION

1 Panel, Side (Left)
2 Panel, Side (Right)
3 Panel, Rear (Upper)
4 Panel, Blower Division
5 Panel Assembly, Base

6 Panel, Inner Front
6A Bezel, Logo
6B Label, Logo

7 Door, Blower Access
7A Handle, Door

8 Panel, Front Door

9 Panel, Top Front
10 Heat Exchanger Assembly
11 Flue Pipe Assembly
12 Retaining Bracket, Firepot
13 Chamber, Replacement Combustion
14 Baffle, Top Front
15 Baffle, Inner Front
16 Baffle, Right Side Panel
17 Mounting Plate Assy., Oil Burner

17A Gasket, Inspection Door

18 Gasket, Pouch
19 Gasket, Flue Pipe (2 Req’d)
20 Cleanout Pipe Cover (2 per unit)

20A Cleanout Cap Gasket (2 per unit)

21 Clean-out Gasket Retainer (2 per unit)

21A Cleanout Gasket (2 per unit)

22 Filter, Air (20”x 20”x1”, Permanent)
23 Box, Junction
24 Wire Harness, Blower Direct Drive
25 Wire Harness, Fan and LImit

24

ITEM DESCRIPTION

26 Centre, Fan

26A Relay, Replacement (Centre Fan)

27 Control, Fan and LImit (5”, 200 Deg.)
27A Fuse ABC 15 Amp Slow Blow
27B Fuse Holder

28 Regulator, Draft (6”)

29 Support, Fan & LImit/Insulation Retainer

30 Insulation Retainer, Side Panel (2 Req’d)

31 Burner, Oil
31A Motor, Burner
31B Pump, Oil
31C Ignitor, Solid State
31D Combustion Control, Primary
31E Tube Combination, Air
31F Retention Head, Flame

Nozzle, (1.00/80 Deg.A)

31G

Nozzle, (1.20/60 Deg.A)

32 Blower Assembly, Complete
32A Housing, Blower and Wheel
32B Wheel, Blower
32C Motor, Blower
32D Mount Band, Motor
32E Mount Arms, Motor (3 Req’d)
32F Run Capacitor, Motor (10MFD/370VAC)
32G Strap, Capacitor
32H Insulator, Capacitor

32I Blower Feet, Blower (LH)

32J Blower Feet, Blower (RH)

REPAIR PART LIST – P4LB SERIES

ITEM DESCRIPTION

1 Panel, Left Side (Heating Compartment)
2 Panel, Right Side (Heating Compartment)
3 Panel, Left Side (Blower Compartment)
4 Panel, Right Side (Blower Compartment)
5 Panel, Upper Rear (Blower Compartment)
6 Panel, Blower Partition
7 Panel Assembly, Base (Heating Compartment)
8 Panel Assembly, Base (Blower Compartment)

9 Panel, Upper Rear (Heating Compartment)
10 Heat Exchanger Assembly
11 Firepot Bracket Assembly
12 Combustion Chamber, Replacement
13 Cleanout Pipe Cover (2 per unit)

13A Cleanout Cap Gasket (2 per unit)

14 Panel, Front

14A Logo Bezel
14B Logo Label

15 Control, Fan & Limit (8” Insertion, Set @ 200 Deg.F)
16 Box, Junction
17 Fuse Holder
18 Fuse (ABC-15)
19 Retainer Channel, Wire
20 Access Panel, Blower Door

20A Handle, Door

21 Baffle, Front Panel
22 Baffle, Top Front Panel
23 Burner Assembly, Oil

23A Motor, Burner

25

ITEM DESCRIPTION

23B Pump, Oil
23C Ignitor, Solid State
23D Control, Primary Combustion
23E Air Tube Combination
23F Retention Head, Flame (F16)
23G Nozzle, 1.65/70 Deg.B

24 Mounting Plate Assembly, Oil Burner
24A Door, Inspection
24B Gasket, Inspection Door

25 Gasket, Pouch

26 Flue Pipe Assembly

27 Gasket, Flue Pipe (2 Req’d)

28 Filter Rail Assembly (2 Req’d)

29 Filter Support, Top

30 Filter Support, Front and Rear (2 Req’d)

Filter (2 Req’d) (Disposable 20”x 25”x 1”)

31

Filter (2 Req’d) (Permanent 20”x 25”x 1”)

32 Regulator, Draft (7”)

33 Clean-out Gasket Retainer (2 per unit)
33A Cleanout Gasket (2 per unit)
34 Blower Assembly

34A Housing and Wheel, Blower
34B Motor, Blower
34C Pulley, Motor
34D Pulley, Blower
34E Belt, Fan
34F Base Feet, Blower (RH)
34G Base Feet, Blower (LH)

REPLACEMENT PART CONTACT INFORMATION

This is a generic parts list. To request a complete parts list, refer to the contact information below:

• Call Consumer Relations at 1-877-874-7378. Follow the instructions to contact the department and/or
representative that can assist you.

• Visit our website at www.source1parts.com for the following information:

1. Search for a part or browse the catalog.

2. Find a dealer or distributor.

3. Customer Service contact information.

a. Click on the “Brand Links” button
b. Click on the “Customer Service” button

• You can contact us by mail. Just send a written request to:

York International

Consumer Relations

5005 York Drive

Norman, OK 73069

26

NOTES

27

NOTES

Subject to change without notice. Printed in U.S.A. 280200-UIM-A-1206
Copyright © by Unitary Products Group. 2006. All rights reserved. Supersedes 035-14289-001 Rev. B (0605)

Unitary 5005 Norman

28

Products York OK
Group Drive 73069