ICP OMF112K14A, OMV112K14A Installation Instructions And Homeowner's Manual

MULTIPOSITION
HIGH-BOY OIL-FIRED MODELS:
FURNACE
OMF112K14A OMV112K14A
INSTALLER / SERVICE TECHNICIAN:
USE THE INFORMATION IN THIS MANUAL FOR THE IN­STALLATION AND SERVICING OF THE FURNACE AND KEEP THE DOCUMENT NEAR THE UNIT FOR FUTURE REFERENCE.
HOMEOWNER: Manufactured by: Dettson Industries Inc.
PLEASE KEEP THIS MANUAL NEAR THE FURNACE FOR FUTURE REFERENCE.
Printed in Canada on 100% recycled paper 2017-08-31 X40165 Rev.M
Attention:
Sherbrooke, Qc, Canada www.dettson.com
Table of content
1 SAFETY 2
1.1 SAFETY LABELING AND WARNING SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 DETECTION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 DANGER OF FREEZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 INSTALLATION 3
2.1 POSITIONING THE FURNACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Installation in an enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.1 Upflow installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.2 Downflow Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2.3 Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 INSTALLATION OF THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 INSTALLATION OF THE BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.1 Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.2 Air and Turbulator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.3 Post purge delay adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6.1 Masonry chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6.2 Factory-built chimneys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6.3 Draft regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6.4 Side wall venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7 BLOCKED VENT SHUT-OFF DEVICE (BVSO) FOR CHIMNEY VENTING . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7.1 BVSO Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 COMBUSTION AIR SUPPLY AND VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8.1 Contaminated Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.8.2 Burner with Outdoor Combustion Air Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.9 DUCTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.9.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.10 SUPPLY AIR ADJUSTMENTS (4 SPEED MOTORS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.11 SUPPLY AIR ADJUSTMENTS (ECM VARIABLE SPEED MOTORS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.12 INSTALLATION OF ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.12.1 Humidifier (HUM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.12.2 Electronic Air Cleaner (EAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.12.3 Air Conditioner (or Heat Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.12.4 Emergency Heating Mode - variable speed Motor (ECM) . . . . . . . . . . . . . . . . . . . . . . . 11
3 OPERATION 11
1
3.1 START-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 OPERATING SEQUENCE OIL HEATING MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 CHECKS AND ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.1 Purging the oil line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.2 Pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.3 Combustion Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.4 Draft Regulator adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.5 Overfire pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.6 Vent Temperature Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.7 Supply Air Temperature Rise Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.8 Limit control check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.9 Restart after Burner Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 MAINTENANCE 13
4.1 CLEANING THE HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 CLEANING THE BLOCKED VENT SHUT-OFF DEVICE (BVSO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 CLEANING THE BURNER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.4 REPLACING THE NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 REPLACING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.6 CHANGING THE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 FURNACE INFORMATION 15
6 TECHNICAL SPECIFICATIONS 16
List of figures
Figure 1: Location and dimensions of ventilation air openings in a closet door . . . . . . . . . . . . . . . . . 4
Figure 2: Upflow Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3: Downflow Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 4: Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 5: Heating & Air Conditioning with 4-speed motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 6: Thermostat wiring, heating and air conditioning with ECM variable speed motor . . . . . . . . . . 5
Figure 7: Thermostat wiring, heating and air conditioning/heat pump with ECM variable speed motor . . . . 5
Figure 8: Blower “OFF” delay - Board #ST9103A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 9: Blower Start/Stop Delays - Board#1158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 10: Furnace Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 11: Wiring diagram 4-speed motor (PSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 12: Wiring diagram variable speed motor (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 13: Parts list with 4-speed motor (PSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 14: Parts list with variable speed motor (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2
List of tables
Table 1: Blower speed adjustments, 4-speed motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 2: Airflow adjustments heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 3: Airflow adjustments air conditioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 4: Airflow adjustments heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 5: Delay adjustments heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table 6: Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 7: Airflow data, models with 1/2HP ECM motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 8: Airflow data model with 1/2 HP 4-speed motor (PSC) . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 9: Minimum clearances from combustible materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 10: Parts list with 4-speed moto (PSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 11: Parts list with 4-speed moto (PSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 12: Accessoires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3

1 SAFETY

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:
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 sub-
stances, such as paper or carton, near the furnace;
d) Do not stack items or boxing within the required
clearances to combustible materials specified in Ta­ble 9;
DANGER
Immediate hazards which WILL result in death or serious bodily and/or material damage.
WARNING
Hazards or unsafe practices which CAN result in death or serious bodily and /or material damage.
CAUTION
Hazards or unsafe practices which CAN result in mi-
nor bodily and /or material damage.

1.2 IMPORTANT INFORMATION

WARNING
Non-observance of the safety regulations out­lined in this manual will potentially lead to conse­quences resulting in death, serious bodily injury and/or property damage.
WARNING
Installation 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 such codes, 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.
e) This furnace is designed for use with #1 or #2 heat-
ing oil only. The use of gasoline, motor oil or any other oil containing gasoline is prohibited;
f) Never block or otherwise obstruct the filter and/or
return air openings;
g) Ask the technician installing your furnace to show
and explain to you the following items:
i. The main disconnect switch or circuit breaker;
ii. The shutt off valve on the oil tank
iii. The oil filter and how to change it (it must be
changed once a year);
iv. The air filter and how to change it (check
monthly and clean or replace if necessary);
h) Before calling for service, be sure to have the in-
formation of section 5 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.

1.3 DETECTION SYSTEMS

It is recommended that carbon monoxide detectors be installed wherever oil or gas fired heaters are used. Car­bon monoxide can cause bodily harm or death. For this reason, agency approved carbon monoxide detectors should be installed in your residence and properly main­tained to warn of dangerously high carbon monoxide levels. There are several sources of possible smoke and flames in a residence. Smoke and flames can cause bodily harm or death. For this reason, agency approved smoke de­tectors should be installed in your residence and properly maintained, to warn early on, of a potentially dangerous fire. Also, the house should be equipped with approved and properly maintained fire extinguishers. Your unit is equipped with safety devices that can prevent it from functioning when anomalies are detected such as a blocked venting system.
4
1.4 DANGER OF FREEZING

2.1 POSITIONING THE FURNACE

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: Installation code for oil burning equip-
ment;
ANSI/NFPA 31: Installation of oil burning equipment; ANSI/NFPA 90B: Warm air heating and air conditioning
systems;
ANSI/NFPA 211: Chimneys, Fireplaces, Vents and
solid fuel burning appliances;
ANSI/NFPA 70: National Electrical Code; CSA C22.1 : Canadian Electrical Code; or CSA C22.10
Only the latest issues of these codes shall be used.
WARNING
FI RE AND EXPL OSI ON HA ZAR D 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 9.
If the furnace is installed in a basement or on a dirt floor, in a crawl space for example, it is recommended to install the unit on a cement base 2.5 cm to 5.0 cm (1" to 2") thick. The unit must be installed in an area where the ambient and return air temperatures are above 15°C (60°F). In addition, the furnace should be installed as closely as possible to the vent, so that the connections are direct and kept to a minimum. The heater should also be lo­cated close to the centre of the air distribution system.

2.1.1 Installation in an enclosure

The unit can be installed in an enclosure such as a closet. However, two 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.
5
Figure 1 – Location and dimensions of ventilation air openings in a closet door
2.2.2 Downflow Installation
When the furnace is installed in the downflow position on a combustible floor, the clearances from combustibles must be adhered to. The downflow base DFB-102 or KLASB0801DET can be used to ensure these clear­ances. Refer to Figure 3 and the installation instructions provided with the base. In cases where the return air enters through the floor, the floor return base FRB-101 or KLARB0101DET must be used. 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.
The protection plate (B03789) must be installed on the plastic cover of the Beckett NX burner to protect it from vent. ONLY the AMP098 in downflow position
requires the protection plate provided with the unit.
Figure 3 – Downflow Installation

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

2.2.3 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. In cases where the return air enters through the floor, the floor return base FRB-101 or KLARB0101DET can be installed as per the supplied instructions. 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.
6
Figure 4 – Horizontal Installation

2.3 ELECTRICAL SYSTEM

Figure 5 – Heating & Air Conditioning with 4-speed motor
Figure 6 – Thermostat wiring, heating and air condi­tioning with ECM variable speed motor
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 11 and 12. 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 OF THE
Figure 7 – Thermostat wiring, heating and air condi­tioning/heat pump with ECM variable speed motor
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, Figure 11 and Figure
12.
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 airflow is re­duced by 20%. Do not use termninal Y1 with a single stage cooling or heat pump.
7
2.5 INSTALLATION OF THE BURNER

2.6 VENTING

Refer to the burner manufacturer’s instructions. Also, the burner must be installed always in the same way independently of the furnace orientation.
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 in Table 6);
4. Check the electrode settings;
5. Make the electrical connections;
6. Complete oil line connections.

2.5.1 Nozzles

WARNING
PO ISONO US CARBO N M ONOX IDE GAS, FIR E A ND EX-
PL OSION HA ZARD.
Read and follow all instructions in this section. Never install a hand operated damper in the vent pipe. However, any Underwriters Laboratories listed, electrically operated automatic type vent damper may be installed if desired. Be sure to follow the instructions provided with vent damper. Also, read and follow all instructions in this sec­tion of the manual. Failure to properly vent this furnace or other ap­pliances can result in death, bodily injury and/or property damage.
To ensure the safe and proper functioning of an oil furnace, it must always be connected to a flue with suf­ficient draft or to an approved side-wall venting system. In addition, it is strongly recommended to perform a complete inspection of all the existing venting systems.

2.6.1 Masonry chimney

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 as shown in Table 6 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 (Table 6). Once the burner becomes operational, final adjustments will be required. Refer to the section 3 of this manual.

2.5.3 Post purge delay adjustment

The post purge delay on the oil-fired burners is factory set to zero second. This delay is applicable for all instal­lations with chimney venting. For heating units installed with side wall venting and a burner equipped with this fea­ture, the post purge delay must be set to 15 seconds. No delay is required for Riello burners. Refer to the burner control instruction manual and markings for proper ad­justment of the post purge delay.
This furnace can be vented into an existing masonry chimney. However, the unit must not be vented into a chimney into which a solid fuel burning furnace is already being vented. Before venting this furnace into a chimney, its condition must be checked and repairs made, if necessary. Also, the chimney lining and dimensions must conform to local and national 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-54 / VTK-098 /
8
KLAVT0101DET side-wall venter and a 4” insulated vent pipe, model IFV-410 / IFV098-10 / KLAFV0101DET, IFV­420 / IFV098-20 / KLAFV0201DET. 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 in section 4 of this Manual.

2.8 COMBUSTION AIR SUPPLY AND VENTILATION

WARNING
PO ISONO US CAR BO N MONOX IDE GA S HAZARD. Comply with NFPA 31 (U.S.) and CSA B139 (Canada) standards for the installation of Oil Burn­ing Equipment and applicable provisions of local building codes to provide combustion and ventila­tion air. Failure to provide adequate combustion and ven­tilation air can result in death, bodily injury and/or property damage.
Oil furnaces must have an adequate supply of combus­tion air. It is common practice to assume that older homes have sufficient infiltration to accommodate the combustion air requirement for the furnace. However, home improvements such as new windows, doors, and weather stripping have drastically reduced the volume of air infiltration into the home. Refer to oil furnace installation codes relative to com­bustion and ventilation air requirements. Consult Section
2.1.1 in this manual, specifically for units installed in an
enclosed space. Home air exhausters are common. Bathroom and kitchen fans, power vented clothes dryers and water heaters all tend to create a negative pressure condition in the home. Should this occur the chimney becomes less and less effective and can easily downdraft. In certain cases, mechanically supplied air, by way of a blower, in­terlocked with the unit, is necessary. It is the installer’s responsibility to check that.

2.7.1 BVSO Functional Test

The purpose of the following test is only to check that the electrical outlet on the furnace, designated to the BVSO, is functional only.
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.
9
2.8.1 Contaminated Combustion Air
Installations in certain areas or types of structures will 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:
1. Commercial buildings;
2. Buildings with indoor pools;
3. Furnaces installed near chemical storage areas.
Exposure to the following substances:
a) Permanent wave chemicals for hair;
b) Chlorinated waxes and cleaners;
requires a two stage pump and a rise greater than 4.9 m (16’) an auxiliary pump. Follow the pump instructions to determine the size of pipe needed in relation to the rise or to the horizontal distance.

2.9 DUCTING

WARNING
PO ISONO US CAR BO N MONOX IDE GA S 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.
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;
l) Antistatic fabric softeners for clothes dryers;
m) Acid based masonry cleaning materials.

2.8.2 Burner with Outdoor Combustion Air Kit

Some burners are designed to function with combustion air taken directly from the outside. Follow the instructions provided with the burner, the fresh-air supply kit or the side-wall venting kit. 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
The ducting must be designed and installed according to approved methods, local and national codes as well as good trade practices. When ducting supplies air to a space other than where the furnace is located, the return air must be sealed and also be directed to the space other than where the furnace is located.
2.9.1 Air filter
A properly sized air filter must be installed on the return air side of the unit. Refer to the Technical Specifications in Table 6, for the correct dimensions. Also refer to Sec­tion 2.2 and the instructions supplied with the filter.

2.10 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 Table 1 as well as the table 8 based on static pressure in the Technical Specifications section of this manual.
Figure 8 – Blower “OFF” delay - Board #ST9103A
10
To effect the adjustment, the RED (for heating) and
Carte#1158 Board
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”
Figure 9 – Blower Start/Stop Delays - Board#1158
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.
Table 1 – Blower speed adjustments, 4-speed motor
FURNACE
APPLICATION
HEATING
A/C
HEATING OR A/C
OUTPUT
0.68 USGPH MED-LOW
0.80 USGPH MED-HIGH
2.0 TONS LOW
2.5 TONS MED-LOW
3.0 TONS MED-HIGH
3.5 TONS HIGH
RECOMMENDED BLOWER SPEED
11

2.11 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
SW1-HEAT
DIP Switch Positions
1 2 POSITION
OFF OFF A
ON OFF B
OFF ON C*
ON ON D*
*Alternate adjustments for both input rate (refer to air flow tables)
Table 4 – Airflow adjustments heating mode
SW3-ADJ (Adjustment)
DIP Switch Positions
1 2 POSITION
OFF OFF A
ON OFF B
OFF ON C
ON ON D
CFM HT G. CFM A/G.
% Increase % Increase
or decrease or decrease
0% 0%
10% 10%
-10% -10%
N/A 0%
INPUT
USGPH
0.63
0.80
0.68
0.80
Table 3 – Airflow adjustments air conditioning mode
SW2-COOL
DIP Switch Positions
1 2 POSITION
OFF OFF A
ON OFF B
OFF ON C
ON ON D
Table 5 – Delay adjustments heating mode
SW4-Delay
DIP Switch Positions
1 2 POSITION
OFF OFF A
ON OFF B
OFF ON C
ON ON D
INPUT
USGPH
3.5
3.0
2.5
2.0
INPUT
USGPH
0.68
0.80
ALL
ALL

2.12 INSTALLATION OF ACCESSORIES

WARNING
EL ECTRI CAL SHOC K HAZA RD. 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.
2.12.1 Humidifier (HUM)
The electronic board supplies 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.

2.12.2 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.
12
2.12.3 Air Conditioner (or Heat Pump)
An air conditioning coil may be installed on the supply air side ONLY.
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;
WARNING
PO ISONO US CAR BO N MONOX IDE GA S HAZARD. Install the evaporator coil on the supply side of the furnace ducting ONLY. An evaporator coil installed on the return air side of the ducting can cause condensation to form inside the heat exchanger, resulting in heat ex­changer failure. This in turn, can result in death, bodily injury and/or property 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. If a coil blower compartment is used, install air tight, mo­torized and automatic air dampers. Cold air coming from the coil and passing across the furnace can cause con­densation and shorten the life of the heat exchanger.
2) The blower access door is in place and the blower rail locking screws are well 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 well pushed in or re­armed;
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

2.12.4 Emergency Heating Mode - variable speed Motor (ECM)

If the ECM blower motor is defect and that no spare are available right away, you can temporarily replace it with a conventional fractional PSC blower motor. Connect neu­tral wire to neutral terminal on the control panel of the machine and the hot line to the EAC terminal. This one is working as long as heating or cooling is requested, and the blower will work until a new ECM motor is installed.
CAUTION
We recommend to use this mode only for a short pe­riod of time since it affects the efficiency of the unit and the user comfort..

3 OPERATION

3.1 START-UP

CAUTION
DO NOT START THE BURNER UNLESS THE
BLOWER ACCESS DOOR IS SECURED IN PLACE.
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 2.10 and 2.11 above as well as to the airflow tables 7 and 8 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 2.10 and 2.11 above as well as to the airflow table 7 and 8 for more details.
Note: A detailed operating sequence of the oil burner is outlined in the instructions provided with the burner.
13
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 and pump. Slowly close and tighten the bleed screw. Once closed, the flame will light up.

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.
5. the burner air setting to obtain a CO2 reading 1.5% lower (or a O2 reading 2.0% higher) than the read­ing associated with the “trace” of smoke. Example:
12.3% of CO2 or 4.5% of O2;
6. This method of adjusting the burner will result in clean combustion (Bacharach smoke scale be­tween 0 and a trace) and ensure the proper func­tioning of the system. The optimum CO2 level is around 12% to 13% (or 3.5% to 5.0% of O2).

3.3.4 Draft Regulator adjustment

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 minutes, the draft regulator should be set to between
-0.025" and -0.060" W.C.

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;
3.3.5 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.
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 O2;

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;
14
3. Measure the air temperature in the largest trunk coming off the supply air plenum, 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 MAINTENANCE

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 will 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.
WARNING
EL ECTRI CAL SHOC K HAZA RD. 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 and after extended periods of shutdown. 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. ALWAYS KEEP THE OIL SUPPLY VALVE SHUT OFF IF THE BURNER IS SHUT DOWN FOR AN EXTENDED PERIOD OF TIME.
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;

3.3.9 Restart after Burner Failure

1. Set the thermostat lower than room temperature;
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. 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.
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;
15
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.
4.2 CLEANING THE BLOCKED
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

Once a year, 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.
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;
CAUTION
Do not dent or scratch the surface of the thermal switch. If the thermal switch is damaged it MUST be replaced.

4.4 REPLACING THE NOZZLE

Change the nozzle once a year with the one specified in Table 6.

4.5 REPLACING 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.
16

5 FURNACE INFORMATION

Model: . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . Serial number: . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .
Furnace installation date: . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .
Service telephone # - Day: . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . Night: . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .
Dealer name and address: . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .
. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .
START-UP RESULTS
Nozzle: . . . . . .. . Pressure: . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . lb/po2
Burner adjustments: Primary air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
Fine air . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .
Drawer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
% CO2: . . . . . . . . Smoke scale: . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . (Bacharach)
Gross stack temperature: . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . °F
Ambient temperature: . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . °F
Chimney draft: . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .” W.C.
Overfire draft: . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .” W.C.
Test performed by: . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .
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