ICP OLR, OLR160B20B, OLR105A12B, OUF, OLF Installation Instructions And Homeowner's Manual

Models:

OLR105A12B
OLR160B20B
OUF105A12B
OUF160B18B

OLR

OLF

OUF

DNS-0562 Rev A

OLF105A12B
NOLF105A12B
NOUF105A12B
NOUF160B18B

TABLE OF CONTENTS

Part 1, installation…………..…...
Part 2, operation…………………
Part 3, maintenance…………….
Part 4, information…………….…
Technical specifications………...
Wiring diagram……………….….
Parts list……………………….….

Manufactured by:

ICP Corporation (Canada)

3400 Blvd Industriel Sherbrooke PQ Canada

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3

OIL WARM AIR FURNACE

Save these instructions for future reference.

Printed in Canada

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

2000/11/23 X40030 Rev. i

445 01 4030 05

PART 1

INSTALLATION

SAFETY CONSIDERATIONS

INSTALLATION OF OIL FIRED HEATING UNITS
SHALL BE IN ACCORDANCE WITH THE
REGULATION OF AUTHORITIES HAVING
JURISDICTION AND THE CAN/CSA B139 OR
USA/NFPA NO.31-1992 INSTALLATION CODE FOR
OIL BURNING EQUIPMENT.

DO NOT OPERATE FURNACE IN A CORROSIVE
ATMOSPHERE CONTAINING CHLORINE, FLUORINE
OR ANY OTHER DAMAGING CHEMICALS.

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

1) SAFETY LABELLING AND SIGNAL
WORDS

1.1) Danger, Warning and Caution:

The signal words DANGER, WARNING and CAUTION
are used to identify levels of hazard seriousness. The
signal word DANGER is only used in product labels to
signify an immediate hazard. The signal words
WARNING and CAUTION will be used on product
labels and throughout this manual and other manuals
that may apply to the product.

CAUTION

2) SAFE INSTALLATION
REQUIREMENTS

WARNINGWARNING

Installation or repairs made by unqualified
persons can result in hazards to you and
others. Installation MUST conform with
codes or, in the absence of local codes,
with codes of the country having
jurisdiction.

The information contained in this manual
is intended for use by a qualified service
technician familiar with safety procedures
and equipped with the proper tools and
test instruments.

Failure to carefully read and follow all
instructions in this manual can result in
furnace malfunction, property damage,
personal injury and/or death.

1.2) Signal Words:

DANGER – Immediate hazards which WILL result in

death or serious injury.

WARNING – Hazards or unsafe practices which
COULD result in death or injury.

CAUTION – Hazards or unsafe practices which COULD

result in personal injury or product or property damage.

1.3) Signal Words in Manuals

The signal word WARNING is used throughout this
manual in the following manner:

WARNINGWARNING

The signal word CAUTION is used throughout this
manual in the following manner:

NOTE: It is the personal responsibility and obligation of
the customer to contact a qualified installer to ensure
that the installation is adequate and conforms to
governing codes and ordinances.

WARNINGWARNING

Fire hazard
The furnace must be installed in a level

position, never where it will slope to the
front.

If the furnace were installed in that
position, oil could drain into the furnace
vestibule and create a fire hazard, instead
of draining properly into the combustion
chamber.

3

a. This furnace is NOT approved for installation in

mobile homes, trailers or recreation vehicles.

b. You must have a sufficient supply of fresh air for

combustion and ventilation to the area in which the
furnace is located.

c. Do NOT use this furnace as a construction heater

or to heat a building that is under construction.

d. Use only the Type of fuel oil approved for this

furnace (see Rating Plate on unit). Overfiring will
result in failure of heat exchanger and cause
dangerous operation.

e. Visually check all oil line joints for signs of wetness,

which would indicate a leak.
f. Connect furnace to a side-wall terminal or chimney.
g. The points in Part 2 “Operation” are vital to the

proper and safe operation of the heating system.

Take the time to be sure they are all done.
h. Follow the rules of the NFPA Pamphlet No.31 (for

USA) and B-139 (for Canada) or local codes for

locating and installing the oil storage tank.
i. Follow a regular service and maintenance schedule

for efficient and safe operation.
j. Before servicing, allow furnace to cool. Always shut

off electricity and fuel to furnace when servicing.

This will prevent electrical shock or burns.
k. Seal supply and return air ducts.
l. The vent system MUST be checked to determine

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

are protected from direct contact with water.

2.1) Safety Rules:

potentially dangerous fire or smoke, you should
have fire and smoke detectors listed by
Underwriters Laboratories installed and maintained
in the building or dwelling (see Note below).

NOTE: The manufacturer of your furnace does not test
any detectors and makes no representations regarding
any brand or type of detector.

CAUTION

Insure that the area around the combustion air
intake terminal is free of snow, ice and debris.

CAUTION

The air pressure switch MUST be used when
the furnace is vented by the side-wall.

CAUTION

Do not use any commercially available soot
remover. This furnace has fiber type
refractory combustion chamber. Normal
servicing of this unit does not require
cleanings of the combustion chamber. Use
extreme care if for any reason you have to
work in the area of the combustion chamber.

Your unit is built to provide many years of safe and
dependable service providing it is properly installed and
maintained. However, abuse and/or improper use can
shorten the life of the unit and create hazards for you,
the owner.

a. The U.S. Consumer Product Safety Commission

recommends that users of oil-burning appliances

install carbon monoxide detectors. There can be

various sources of carbon monoxide in a building or

dwelling. The sources could be gas-fired clothes

dryers, gas cooking stoves, water heaters,

furnaces, gas-fired fireplaces, wood fireplaces, and

several other items. Carbon monoxide can cause

serious bodily injury and/or death. Therefore, to

help alert people of potentially dangerous carbon

monoxide levels, you should have carbon monoxide

detectors listed by a nationally recognised agency

(e.g. Underwriters Laboratories or International

Approval Services) installed and maintained in the

building or dwelling (see Note).
b. There can be numerous sources of fire or smoke in

a building or dwelling. Fire or smoke can cause

serious bodily injury, death, and/or property

damage. Therefore, in order to alert people of

2.2) Freezing Temperatures and Your
Structure:

WARNINGWARNING

Freeze warning.
Turn off water system.
If your unit remains shut off during cold

weather the water pipes could freeze and
burst, resulting in serious water damage.

Your unit is equipped with safety devices that may keep
it from operating if sensors detect abnormal conditions
such as clogged exhaust flues.

If the structure will be unattended during cold weather
you should take these precautions.

4

a. Turn off main water supply into the structure and

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

b. Have someone check the structure frequently

during cold weather to make sure it is warm enough
to prevent pipes from freezing. Suggest they call a
qualified service agency, if required.

3.1) Location:

Locate the furnace as closely as possible to the
chimney or vent terminal, providing ample clearance to
permit easy accessibility for cleaning the inside of the
furnace, the removal of filters, blower, motors, controls
and flue connections. The furnace may be installed on
a combustible floor.

2.3) Installation regulation:

Installation MUST conform with local building codes or
in the absence of local codes, with the National
Electrical Code, ANSI/NFPA No.70-1990 or current
edition and Installation of Oil Equipment, NFPA No.31.

Do not install furnace directly on carpeting, tile or other
combustible material.

The furnace must be installed level for safe quiet
operation.

CAUTION

3) LOCATING THE FURNACE

Do NOT operate furnace in a corrosive
atmosphere containing chlorine, fluorine or

CAUTION

Check carefully your furnace upon delivery for

any other damaging chemicals. Refer to Part
1, section 5.2.

any evidence of damage that may have
occurred during shipping and handling. Any
claims for damages or lost parts must be
made with the Transport Company.

TABLE #1

Minimum Installation clearances from combustible materials (Chimney installation*)

LOCATION APPLICATION OLR160 - OUF160 –

NOUF160

Furnace 1” 1”

Sides Supply plenum, warm air duct

within 6 ft of furnace
Back Furnace 18” 1”
Top Furnace casing or plenum 2” 1”
Bottom Furnace – combustible floor 0” 0”
Front Furnace 24” 24”
* See Part 1 section 4.3 for Direct Vent application clearance.

1” 1”

OLR105 –OLF105 – NOLF105 -

OUF105 – NOUF105

4) VENTING

4.1) General:

The furnaces can be vented in several ways:

Chimney Vented:

Using the Beckett AFG or Riello 40-F burner, the
furnaces can be chimney vented with or without a
barometric damper. The unit will be operated at a
negative over fire draft and stack draft.

WARNINGWARNING

Poison carbon monoxide gas, fire and
explosion hazard.

Read and follow all instructions in this
section.

5

Failure to properly vent this furnace can
result in property damage, personal injury
and/or death.

Additionally, the liner must be insulated according to the
insulating procedure recommended by the
manufacturer of the liner.

Side-wall Vented:

Using the Beckett AFII or Riello 40-BF burner with the
integral pre and post purge controls, the system can be
side-wall vented with the new DV-2000™ venting
system for maximum efficiency, and without the use of a
side-wall power ventor. The unit will be operated at a
positive overfire draft and stack draft.

WARNINGWARNING

Poison carbon monoxide gas hazard
Never co-vent the furnace with another

combustion appliance when side-wall
venting.

To do so may result in asphyxiation and
death to the occupants

4.2) Chimney installations:

The oil furnaces, when set up for chimney venting, are
certified for use with L-vent, A-vent, tile-lined and metal­liner-tile-lined chimneys, and can be vented both with
and without a barometric draft damper. However, the
furnace has not been certified without the barometric
damper when it is to be co-vented with another oil-fired
appliance, such as a water heater.

When a damper is used, the basement air entering the
damper reduces the possibility of vent condensation.
However, if the barometric damper is not used, a
chimney liner with insulation must be employed.

With a barometric damper:

WARNINGWARNING

Poison carbon monoxide gas hazard
Never install a hand operated damper in

the vent pipe. However, any Underwriters
Laboratories listed electrically operated
automatic type vent damper may be
installed if desired. Be sure to follow
instructions provided with vent damper.
Read and follow all instructions in this
section.

Failure to properly vent this furnace or
other appliances can result in property
damage, personal injury and/or death.

Vent connectors:

For installations without barometric damper, the vent
connector should be as short as possible and either be
of double wall construction, or be of single wall
construction insulated with 1” of insulation. It should
rise a minimum of 1/4” per foot from the furnace to the
chimney. Field fabricated connectors should be a
minimum of 28 gauge. The joints must be mechanically
secure and there must be no flue product leakage at the
joints.

CAUTION

When the furnace (chimney installation) is co­vented with other combustion appliances such
as a water heater, the allowable venting
materials (i.e. L-Vent etc.) for use with those
appliances should also be investigated.

The appliance may be installed in a chimney of the
proper size and adequate chimney base temperature as
specified in the Installation Code. The relevant excerpt
from the code is found in this section - Use it as a guide
when local or national codes do not exist.

Without a barometric damper:

Due to the lack of dilution air that would ordinarily be
drawn into the barometric damper, the dew point of the
flue gasses is raised. To offset the increased tendency
for vent condensation, the chimney must be lined.

6

Flue pipe sizing:

The following table is an except from the installation
code and indicates permitted flue sizes and minimum
base temperatures for circular flues in chimney with
thermal resistance less than R6 (6 ft2 •hr •°F / Btu).
Where a new appliance, burner, or chimney is installed,
chimney vent sizes and maximum flue-gas
temperatures (measured at the chimney connector with
the barometric damper shut, after 5 minutes of
operation) shall comply with the table #2.

Notes: Thermal resistance values for typical chimneys
are as follows:

R2 (2 ft2 •hr •°F / Btu): clay-lined masonry, A-vent
R3 (3 ft2 •hr •°F / Btu): metal liner in clay-lined

Masonry

R6 (6 ft2 •hr •°F / Btu): metal or clay-lined masonry

with R4.5 (4.5 ft2 •hr •°F / Btu)
insulation between liner and
masonry (e.g. 2 in. of
expanded mica or 1 3/8 in. of
high density glass fibreboard.)

Applying the Table:

If a furnace with 0.60 USGPH nozzle is to be connected
to a 20 ft. tall clay-lined masonry chimney, the thermal
resistance of this chimney type is R2, which is less than
R6. The actual firing rate at 156 psig is 1.25 x .60 = .75.
Therefore this table shall apply as:

The minimum size permitted shall be 4 in. inside
diameter.

The maximum size permitted shall be 5 in. inside
diameter.

The minimum base temperature shall be about 320ºF.

TABLE # 2

Total input rating of all

connected appliances

kW kBtu/h USGPH Min. Max. 11 20 28 36

21 70 0.50 3 5 300 400 535 725
27 91 0.65 3 5 275 340 430 535
31 105 0.75 4 5 260 320 380 475
36 119 0.85 4 5 250 300 355 430
41 140 1.00 4 6 225 300 365 430
51 175 1.25 4 6 240 275 320 365

4.3) Side-wall venting, DV-2000™ Direct

Vent System:

The furnace can be side-wall vented without the use of
a side-wall power ventor using the new DV-2000™
venting system with the high static pressure Beckett
AFII and Riello 40-BF oil burners. Outdoor

combustion air must be directly connected to the
burner of the DV-2000™ venting system will not
function.

The notable characteristics of the DV-2000™ system
are as follows:

Certified to use the following materials for ducting the
intake air from the terminal to the burner; Schedule 40
PVC DWV, Schedule 40 ABS DWV, And ASTM 2729
Sewer Pipe.

One hole of minimal size (6”) is required to be cut in the
side-wall, and the terminal is designed to fit through a
minimum 2 X 8-joist space.

Flue inside diameter

(in)

Minimum base temperature (ºF)

for chimney height (ft) of :

Incorporates a vent blockage safety shutdown system.
If the vent or intake opening ever becomes partially or
fully blocked, the burner will shut down before a #1
smoke occurs.

The intake and vent circuits within the terminal can be
accessed for cleaning.

There are 3 main components to the DV-2000™
system; the VTK vent terminal kit, the IFV insulated
flexible venting material and the field-supplied 3” PVC
or ABS intake piping.

Vent terminal kits – DV-2000™:

The certified standard vent terminal kit is Model No.
VTK-1 or VTK-2, and is suitable for installation in walls
up to 14” thick. An alternate kit, Model VTK-1-DW or
VTK-2-DW is available to accommodate walls up to 25”
thick. Both kits contain the following items to complete
the hook-up to the venting and furnace:

The standard terminal is designed for a wall thickness
up to 14”, and the deep wall terminal for wall thickness
up to 25”.

1 Terminal
2 Sealing Clamps
1 Side-wall Venting Breech Plate
2 Sealing Strips
1 Inner Wall Plate
1 Pressure Control with Tubing
2 Insulated Quick-connect Terminals

7

3 Stainless Steel Screws
6 Self tapping stainless steel screws

Insulated flexible venting - DV-2000™:

The certified venting materials come in 3 lengths, Model
No. IFV3-15, IFV3-23 and IFV3-30 (or IFV4-15, IFV4-23
and IFV4-30 for 160 models) are corresponding to 15’,
23’ and 30’ continuous lengths of vent. The vent
construction is coaxial and incorporates a stainless
steel corrugated flexible liner surrounded by a thick
insulation blanket and covered with an outer layer of
flexible corrugated aluminium sleeve to protect the
insulation. Splicing vent lengths together is prohibited.
The maximum and minimum continuous vent lengths
permitted for installation are:

5 feet minimum 30 feet maximum

WARNINGWARNING

Poison carbon monoxide gas hazard

c. within 6 feet of a window or door, or mechanical air

supply inlet to any building, including soffit
openings;

d. above a gas meter/regulator assembly within 3 feet

of a vertical centerline of the regulator;

e. within 6 feet of any gas service regulator vent

outlet, or within 3 feet of an oil tank vent, or an oil fill

inlet;
f. within less than 1 foot above ground level;
g. 6 feet of any other combustion air inlet;
h. within 6 feet of a property line;
i. underneath a veranda, porch or deck;
j. so that the flue gases are directed at combustible

material or any openings of surrounding buildings

that are within 6 feet;
k. less than 3 feet from an inside corner of an L-

shaped structure;
l. so that the bottom of the vent termination opening is

less than 1 foot above any surface that may support

ice, snow, or debris;
m. so that the flue gases are directed toward

brickwork, siding or other construction, in such a

manner that may cause damage from heat or

condensation from flue gases.

Even though the flexible venting is insulated, it
cannot be run through an unheated space.

To do so could cause residual condensation
inside the stainless steel liner, which may
eventually perforate the liner and allow vent
gasses to enter the dwelling.

TABLE # 3

Side-wall venting clearances to combustibles

PORTION OF VENT CLEARANCES

Vent pipe, up to vent terminal* 3”
Vent terminal ZERO

*Do not enclose venting

Installation considerations - DV-2000™:

Select a location for the vent terminal in accordance
with all local and national codes. The following
requirements shall be considered to be minimum
requirements that can be overridden by stricter local
and national codes.

The vent shall not terminate:

a. directly above a paved sidewalk or paved driveway

that is located between two buildings, and that
serves both buildings;

b. less than 7 feet above any paved driveway;

CAUTION

Most codes have a notwithstanding clause
that states that products of combustion shall
not enter the dwelling under any
circumstances, even if all other code
requirements as to construction and location
have been complied with. The installer is
ultimately responsible to do whatever is
necessary to ensure that flue gasses do not
enter the dwelling.

Installation of side-wall venting - DV-2000™:

WARNINGWARNING

Cuts and abrasion hazard.
Always wear protective gloves and eye

protection when handling the vent material
The process of cutting and fitting the flexible

venting material exposes the installer to sharp
edges that could cause severe cuts to the
skin.

8

FIGURE # 1.1 FIGURE # 1.2

CUT OUTER SLEEVE BACK 5”

THREAD SPIN SLEEVE
ONTO OUTER SLEEVE

FIGURE # 1.3 FIGURE # 1.4

THREAD SPIN SLEEVE BACK 10” CUT STAINLESS STEEL

CORE BACK BY 3”

FIGURE # 1.5 FIGURE # 1.6

INSERT STAINLESS STEEL
CORE ONTO BREECH TUBE

DRIVE THREE STAINLESS STEEL
SCREWS, STARTING NEAR TOP

9

Connection to the furnace breech - DV-2000™:

1. Remove the standard breech plate by removing the
brass nuts.

2. Determine which direction the venting will be routed
from the furnace and then install the special side­wall venting breech plate provided in the VTK
Series vent kit so that the breech plate test port will
be accessible after vent installation. However, do
not install the breech plate with the test port
pointing downward. Tighten the brass nuts.

3. The flexible venting has 4 pieces of corrugated spin
sleeving that has been temporarily screwed on over
top of it. Remove the spin sleeving completely by
unscrewing it in a counter-clockwise direction.

4. Using tin snips, cut the aluminium outer sleeve back
by 5” for the IFV Series vent (see figure #1.1).
Ensure the snips are well adjusted and sharp or the
cut end of the venting will be too jagged to start the
threads of the spin sleeve (see figure #1.1).

5. Prepare the furnace breech end of the insulated flex
vent by first screwing the spin sleeve onto the
corrugated aluminium jacket (see figure #1.2) until
the trailing edge of the spin sleeve is about 12” from
the end of the vent (see figure #1.3).

6. Pull the insulation back to expose the corrugated
stainless steel core.

the seal strip around once, allow 1/2” overlap and
tear off the residual length (see figure #1.7).

10. Break the residual length of seal strip in to 3 equal
parts and stuff them onto the screw heads of the
stainless steel self-drilling screws so that the screw
heads are completely covered.

11. Two stainless steel band clamps are provided in the
VTK Series kits. Position one stainless steel band
clamp over the gum seal joint so that the edge of
the clamp closest to the breech lines up with the
edge of the gum seal that is closest to the breech.
Ensure that the band will close with an action of one
strip sliding over the other - not under the gearhead
of the draw clamp (see figure #1.8). Tighten the
band clamp with considerable torque to cause the
gum seal be squeezed into all crevices and to ooze
out of the end of the clamp closest to the breech
(see figure #1.9). The gum will eventually become
rubbery.

12. The seal is permanent and should never need to be
disconnected as the breech plate can be removed
for cleaning and inspection using the 4-bolt joint.

13. Tuck the vent insulation into the breech collar.

14. Screw the spin sleeve tightly into the breech collar
for a finished appearance. Wrap the other end of
the spin sleeve with aluminium tape to cover any
metal burrs that may be present (see figure #1.10).

7. Cut the corrugated stainless steel core back by 3”
for the IFV Series vent. You should now have about
3” of insulation hanging out past the stainless steel
core (see figure #1.4).

8. Push the stainless steel core onto the breech pipe
as far as it will go (see figure #1.5) and
mechanically attach the vent to the breech using
three of the #8 X 1/2” self-drilling screws provided
with the VTK Series kit. The screws should be
equally spaced around the circumference of the
stainless steel core, starting with the first screw at
top dead center. Start the drill point of the screws in
the valleys of the corrugations at 3/8”-5/8” back
from the end of the stainless steel core, so the
screw heads can be properly sealed in the
forthcoming operations (see figure #1.6).

9. With the stainless steel core now firmly attached to
the breech, tear off one green gum-sealing strip
from the backing strip. Wrap the seal strip around
the joint, always keeping the centerline of the seal
strip over the line where the corrugated stainless
steel core makes the transition to the smooth outer
surface of the breech pipe. In other words, the seal
strip must be centered over the joint. After wrapping

15. Bend the venting into the desired radius coming off
the breech.

Connection to the vent terminal - DV-2000™:

1. Prepare the terminal end of the insulated flex vent
by first screwing the spin sleeve onto the
corrugated aluminium jacket until the trailing edge
of the spin sleeve is about 10” from the end of the
vent.

2. Using sharp tin snips, cut the aluminium outer
sleeve back by 5” for the IFV Series vent

3. Pull the insulation back to expose the corrugated
stainless steel core.

4. Cut the corrugated stainless steel core back by 3”
for the IFV Series vent. You should now have
about 3” of insulation hanging out past the stainless
steel core.

5. Push the stainless steel core onto the pipe on the
back of the terminal as far as it will go and
mechanically attach the vent to the terminal using
three of the #8 X 1/2” self-drilling screws provided
with the VTK Series kit. The screws should be

10

FIGURE # 1.7 FIGURE # 1.8

APPLY THE SEALANT
TO THE TUBE END

FIGURE # 1.9 FIGURE # 1.10

CORRECT BAND
OVERLAP

SEALANT FLOWING
OUT FROM UNDER

TWIST SPIN SLEEVE TIGHTLY INTO

BREECH COLLAR
BAND CLAMP AT
BREECH

SEALANT OUTFLOW

FIGURE # 1.11

SEALANT FLOWING OUT FROM UNDER BOND CLAMP AT
TERMINAL

SEALANT OUT FLOW

11

equally spaced around the circumference of the
stainless steel core, starting with the first screw at
top dead center. Start the drill point of the screws in
the valleys of the corrugations at 3/8”-5/8” back
from the end of the stainless steel core.

downward slope of the terminal, in the direction
from the inside to the outside.

3. Remove the 2 screws fastening the end cone in
place and remove the cone.

6. With the stainless steel core now firmly attached to
the terminal, tear off the other green gum-sealing
strip from the backing strip. Wrap the seal strip
around the joint, always keeping the centerline of
the seal strip over the line where the corrugated
stainless steel core makes the transition to the
smooth outer surface of the terminal pipe. After
wrapping the seal strip around once, allow 1/2”
overlap and tear off the residual length.

7. Break the residual length of seal strip in to 3 equal
parts and stuff them onto the screw heads of the
stainless steel self-drilling screws so that the screw
heads are completely covered.

8. Position the other stainless steel band clamp over
the gum seal joint so that the edge of the clamp
closest to the terminal lines up with the edge of the
gum seal that is closest to the terminal. Tighten the
band clamp with considerable torque to cause the
gum seal be squeezed into all crevices and to ooze
out of the end of the clamp closest to the terminal
(see figure #1.11).

9. The seal is permanent and should never need to be
disconnected as the end of the terminal can be
opened for cleaning and inspection by removing the
screened end-cone assembly. Tuck the vent
insulation into the recess in the terminal body.

10. Screw the spin sleeve tightly into the recess for a
finished appearance. Wrap the other end of the
spin sleeve with aluminium tape to cover any metal
burrs that may be present (see figure #1.12).

11. Bend the venting into the desired radius coming off
the terminal.

Installing terminal in the wall - DV-2000™:

1. Cut a 6” hole in the side-wall in accordance with the
location considerations outlined in the previous
section.

2. Fasten the wall plate to the inside-wall using 4 field­provided fasteners appropriate for the material
behind the wall plate. Depending on the angle of
access, the pressure control bracket may need to
be removed to access the top right wall plate screw
hole. For concrete and block, Tapcon™ screws or
equivalent are recommended. Install the wall plate
so that the top of the hole in the wall plate is
positioned 1/8” lower than the top of the 6” hole in
the wall. This will accommodate the proper

4. Remove the 2 screws fastening the stabiliser
shroud in place and remove the stabiliser shroud.

5. Insert the main body of the terminal through the wall
plate so that the end of the terminal extends about
2” past the outside wall.

6. Install the stabiliser shroud and replace the two
mounting screws. (see figure #1.13).

7. For concrete and block wall installations in
particular, If it appears that the flange on the back
of the stabiliser shroud is not large enough to cover
the irregularities in the hole, a field fabricated wall
plate can be constructed out of 304, 316, or 316L
stainless steel.

8. Silicone seal the circumference of the joint where
the stabiliser shroud connects to the main body of
the terminal.

9. Apply caulking to the back plate of the stabiliser
shroud and push the terminal back firmly against
the wall.

10. While pushing down gently on the top of the
stabiliser shroud, install the 3 stainless steel 2”
screws provided with the kit to secure the back of
the shroud to the wall. Do not overtighten the
screws or it will distort the stabiliser shroud. The
screws will not be necessary in a concrete or block
wall as the mortar can provide positive positioning.

11. Tighten the clamp on the wall plate to secure the
terminal in position.

12. Apply more caulking all around the seam where the
stabiliser shroud meets the wall. It is important to
have a good seal to prevent water from entering the
dwelling (see figure #1.14). A considerable amount
of caulking may be necessary for irregular wall
surfaces such as lapped siding.

13. Install the end cone and replace the two mounting
screws.

14. Support the vent and intake air piping so that a 1/4”
to 1/2” downward slope (toward the outside) results
for proper drainage out the terminal body.

12

FIGURE # 1.12

TWIST SPIN SLEEVE TIGHTLY INTO RECESS

VENT TERMINAL PRESSURE SWITCH.
REFER TO WIRING DIAGRAM FOR ELECTRICAL
CONNECTION.

FIGURE # 1.13 FIGURE # 1.14

INSTALL
STABILIZER

CAULK TO SEAL STABILIZER
SHROUD TO THE WALL

SHROUD

13

Connection of combustion air piping to the terminal

- DV-2000™:

Refer to Part 1, section 5.3, Outdoor Combustion Air –
Side-wall Venting, DV-2000™ for a complete
description.

5) AIR FOR COMBUSTION

WARNING WARNING

Poison carbon monoxide gas hazard.
Comply with NFPA standard for the

installation of Oil Burning Equipment and
applicable provision of local building
codes to provide combustion and
ventilation air.

Failure to provide adequate combustion
and ventilation air can result in personal
injury and/or death.

The following areas or types of structures may contain
or have exposure to the substances listed below. The
installation must be evaluated carefully as it may be
necessary to provide outside air for combustion.

a. Commercial building.
b. Building with indoor pools.
c. Furnaces installed near chemical storage areas.

Exposure to these substances:
a. Permanent wave solutions for hair.

b. Chlorinated waxes and cleaners.
c. Chlorine based swimming pool chemicals.
d. Water softening chemicals.
e. De-icing salts or chemicals.
f. Carbon tetrachloride.
g. Halogen type refrigerants.
h. Cleaning solvent (such as perchloroethylene).
i. Printing inks, paint removers, varnishes, etc..
j. Hydrochloric acid.
k. Solvent cements and glues.
l. Antistatic fabric softeners for clothes dryers.
m. Masonery acid washing materials.

5.3) Ducted outdoor combustion air:

5.1) General:

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 dramatically reduced
the volume of air leakage into the home.

Home air exhausters are common. Bath and kitchen
fans, power vented clothes dryers, and water heaters all
tend to create a negative pressure in the home. Should
this occur, the chimney becomes less and less effective
and can easily downdraft.

Heat recovery ventilation (HRV) systems are gaining in
popularity. The HRVs are not designed to supply
combustion air. If not properly balanced, a serious
negative pressure condition could develop in the
dwelling.

5.2) Contaminated Combustion Air :

Installation in certain areas or types of structures will
increase the exposure to chemicals or Halogens which
may harm the furnace. These instances will require that
only outside air for combustion.

Three burners are set up to duct outside combustion air
directly to the burner; the Beckett AFII and Riello 40-BF
for side-wall venting using the new DV-2000™ venting
system, and the Beckett AFG for use with conventional
chimney venting. The Riello 40-F is not suitable for
direct-connected outdoor air.

CAUTION

The use of ducted outside combustion air is
mandatory for the DV-2000™ venting system.
This system operates on a balanced flue
principle and will not function properly if the
combustion air piping is not attached and
sealed at all connections between the vent
terminal and burner inlet.

Outdoor combustion air kit – chimney venting:

The following kit has been certified for use on the
appliance. The component kits contain an important
safety feature, namely a vacuum relief valve, or VRV.
During normal operation the burner aspirates outdoor
air. If the intake terminal ever becomes partially blocked
or fully blocked from ice or snow etc., the VRV will open
to allow a proportion of air from the dwelling to enter the
burner thus maintaining proper combustion. Once the
blockage is removed, the VRV will close and the burner
will draw all air from the outdoors again:

14

CAS-2B Components (except air duct) for the
Beckett AFG burner. The kit includes the intake
terminal, vacuum relief valve (VRV) and special air boot
connection with integral air adjustment means for the
AFG burner. The CAS-2B can be used with 4”
galvanised air duct or with 4” flexible aluminium air duct.
It is recommended that the metallic air ducting material
should be insulated from the air intake up to 5 feet from
the burner to avoid condensation on the outside of the
intake pipe.

CAD-1 Air duct kit consists of 25 feet of insulated
UL/ULC Listed Class 1 air duct, and two 4” steel band
clamps. The duct incorporates a corrugated flexible
aluminium core, surrounded by fibreglass insulation

covered with a vinyl vapour barrier.

CAUTION

The CAS-2B does not turn the furnace
installation into a direct vent system.
Therefore the building structure must provide
for adequate combustion air to be delivered at
the vacuum relief valve. The burner will
need to draw combustion air from the VRV’s
surroundings if the intake ever becomes
blocked. Therefore non-direct vent installation
codes must be followed.

Comprehensive installation instructions are provided
with the kit.

Outdoor combustion air – side-wall venting, DV­2000™:

The new DV-2000™ venting system is a sealed system
and completely isolates the furnace from the interior of
the building. The burner is totally unaffected by any
pressure fluctuations within the building which makes it
ideal for tight home constructions.

The DV-2000 ™ venting system requires additional
parts, which are not included with the kit. These
additional parts must be constructed of 3” Schedule 40
PVC, PVC-SWV, SDR-26,SDR-21, Septic Sewer Pipe,
or ABS plastic pipe, fittings and sealant. Also,
installation procedures, piping and fittings must conform
to the following ANSI /ASTM standards:

Procedure for
Cementing Joints ASTM D-2855

Additional parts required (not included in VTK kit):

a. 3” elbow fitting as required
b. 3” plastic pipe
c. 3” 90°elbow, female-female(for terminal)
d. 3” female to 2” female reducer (Riello 40-BF burner

only)

e. 2” 90°elbow, street type, female-male (Riello 40-BF

burner only)

f. 3” female-female PVC or ABS coupling (not sewer

pipe) (Beckett AFII burner only)

g. transition bushings to go from PVC or ABS to

ASTM D2729 Septic Sewer Pipe (if applicable).

If PVC fittings are mixed with ABS fittings, use a solvent
cement that is approved for bonding the two plastics.

Intake pipe length - DV-2000™:

The DV-2000 ™ venting system has been certified for
120 equivalent feet of 3” intake pipe. Count a 90°elbow
as 10 equivalent feet and a 45°elbow as 5 equivalent

feet in the calculation.
For Example:
1 5’ Length = 5 equivalent feet

2 10’ Lengths = 20 equivalent feet
3 90°elbows = 30 equivalent feet
2 45°elbows = 10 equivalent feet
1 90°elbow (terminal) = 10 equivalent feet
1 90°elbow (Riello Burner)= 10 equivalent feet

Total = 85 equivalent feet,
which is less than 120 feet,
which is acceptable.

Intake pipe installation - DV-2000™:

Obtain the necessary additional parts, to complete the
installation, and start by piping at the burner. If the
optional vestibule has been installed, remove the
appropriate knockouts in the side panels of the
vestibule. The lower 5” knockout in the right hand panel
is used for the Beckett AFII burner. The higher 5”
knockouts on the right and left-hand panels are for right
or left connection to the Riello 40-BF burner.

Beckett AFII burner:

PVC ASTM D-1785
SDR26, SDR21 ASTM D-2241
Septic Sewer Pipe ASTM D-2729
PVC-DWV ASTM D-2665
PVC Primer and
Solvent Cement ASTM D-2564
ABS Pipe and Fittings ASTM D-2235

Remove the burner intake cover by removing the 3
screws securing it in place. Discard the cover and
screws. Apply silicone liberally around the end of a 3”
coupling and fully insert the silicone end onto the burner
opening. Fasten securely with 3 self-tapping sheet
metal screws.

15

Riello 40-BF burner:

7) BURNER INSTALLATION

Fully insert the female end of the 2” 90° street elbow
into the combustion air fitting on top of the burner.
Fasten securely with 3 self-tapping sheet metal screws.
Cement the 2” end of the 3” female to 2” female reducer

onto the male end of the 2” 90° street elbow. If these
parts are not easily obtained, use a 3” 90° street elbow
with the male end fitted over the combustion air fitting.
The fitting will have to be silicone sealed as the fit is a
bit loose. Fasten securely with 3 self-tapping sheet
metal screws.

Terminal connection:

Insert the 3” 90° female-female elbow onto the stainless
steel air intake fitting located on the right side of the
vent terminal (viewing from the rear). Fasten securely
with 3 self-tapping sheet metal screws.

Intermediate piping:

Pipe as required between the terminal and the burner.
Ensure that the 3” piping is routed and supported in
accordance with local and national codes. Obey
minimum furnace clearances to combustibles when
routing any sections of 3” piping in the vicinity of the
furnace. If Septic Sewer Pipe is to be used, install
transition bushings at the 3” female ends of the fittings
at the burner and at the terminal. Transition bushings
are readily available and are required because 3” PVC
and ABS pipes have a typical outside diameter of 3.5”,
whereas Septic Sewer Pipe has a typical outside
diameter of 3.25”.

6) OIL TANKS AND LINES

Check your local codes for the installation of the tank
and accessories.

A manual shut-off valve and an oil filter shall follow
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 having the fuel oil tank below the burner
level must employ a two pipe fuel supply system with an
appropriate fuel pump (more than 8’ lift use 2 stage
pump and more than 16’ an auxiliary pump).

Mounting the burner:

a. The warm air furnace burner mounting plate has a

four bolts configuration.

b. Position the mounting gasket between the mounting

flange and the appliance burner mounting plate.
Line up the holes in the mounting flange with the
studs on the appliance mounting plate and securely

bolt in place.

After the burner is mounted:

a. Remove drawer assembly or air tube combination
b. Install nozzle (see specifications)
c. Confirm electrode settings
d. Make the electrical connections
e. Complete oil line connections

CAUTION

Do not turn on the burner until you have
checked the polarity

Checking the polarity:

The oil burners used on the furnaces have solid state
control systems which makes them sensitive to the
proper connections of the hot and neutral power lines.
The controls will be damaged if the two lines are
reversed.

a. Set your voltmeter to line voltage.
b. Place one prong on your grounded electric entry

box and one prong on the black wire.

c. Read the voltage.
d. If the voltage is zero, check the white wire. If line

voltage shows. Reverse the 115-volt leads entering
the furnace junction box.

FIGURE # 2

Follow the pump instructions to determine the size of
tubing you need in relation of the lift, or the horizontal
distance.

16

Nozzles:

The burners are provided with the highest capacity
USGPH nozzle installed. If another size nozzle, or
replacement nozzle is required, use the nozzle spray
angle, type and manufacturer recommended in Table
#4.1 to 4.3. Note that all nozzle-marked sizes are
based on a pump pressure of 100 psi.

NOTE: You may notice a slight odor the first time your
furnace is operated. This will soon disappear. It is only
the oil used on the parts during manufacturing.

8) INSTALLING ACCESSORIES

Always select nozzle sizes by working back from the
actual desired flow rate at operating pressure, and not
by the nozzle marking.

Air and turbulator settings:

Before starting the burner for the first time, adjust the air
and turbulator settings to those listed in the Table #4.1
to #4.3. Once the burner becomes operational, final
adjustment will be necessary.

Fuel supply system:

Fuel Specifications

NOTE: Use No.1 or No.2 Heating Oil (ASTM D396) or
in Canada, use No.1 or No.2 Furnace Oil.

Before starting the burner be sure the fuel tank is
adequately filled with clean oil.

WARNING WARNING

WARNING WARNING

Electrical shock hazard.
Turn OFF electric power at 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 could result in property
damage, bodily injury or death.

8.1) Electronic air cleaner:

Wire leads are provided to direct 115 volts @ 0.5 Amp
maximum to an electronic air cleaner (EAC). Power will
be available to the EAC at all times, so it must
incorporate a flow proving switch if it is to be wired into
the furnace control box. Most modern EACs have the
required integral airflow-proving switch. Wire the
electronic air cleaner as indicated in figure #6.

Fire and explosion hazard.
Use only approved heating type oil in this

furnace. DO NOT USE waste oil, used
motor oil, gasoline or kerosene.

Use of these will result in death, personal
injury and/or property damage.

IMPORTANT

When using nozzle sizes of less than .75
USGPH, the Installation Code for oil burning
equipment requires the installation of a 10
micron (or less) filter in the fuel oil line. ICP
requires that this practice be followed in order
to keep the lifetime heat exchanger warranty
intact.

8.2) Humidifier:

Terminals are provided to direct 115 volts @ 1.0 Amp
maximum to the transformer powering the humidifier.
The humidifier will be energised anytime the blower is
operating on the “Heating Speed”. Wire the 115-volt
power as indicated in figure #6.

8.3) Air conditioning:

An air conditioning coil may be installed on the supply
airside only. Also, notwithstanding the evaporator coil
manufacturer’s instructions, a minimum of 6 inches
clearance must be allowed between the bottom of the
coil drain pan, and the top of the heat exchanger. Wire
the thermostat and condensing unit contactor as
indicated in figure #6.

17

8.4) Ductwork and Filter:

Installation:

Design and install air distribution system to comply with
Air Conditioning Contractors of America manuals or
other approved methods that conform to local codes
and good trade practices.

When furnace supply ducts carry air outside furnace
area, seal return air duct to furnace casing and
terminate duct outside furnace space.

Install air conditioning cooling coil (evaporator) on
downstream side (in the supply air plenum) or furnace.

If separate evaporator and blower unit is used, install
good sealing dampers for air flow control. Cold air from
the evaporator coil going through the furnace could
cause condensation and shorten furnace life.

WARNINGWARNING

Poison carbon monoxide gas hazard.
Do NOT draw return air from inside a

closet or utility room. Return air duct
MUST be sealed to furnace casing.

Failure to properly seal duct can result in
death, personal injury and/or property
damage.

WARNINGWARNING

Poison carbon monoxide gas hazard.

CAUTION

Dampers (purchased locally) MUST be
automatic.

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

Evaporator coil installed in return side
ducting can cause condensation to form
inside heat exchanger resulting in heat
exchanger failure. This could result in
death, personal injury and/or property
damage.

18

PART 2

OPERATION

1) MANUAL OPERATION SWITCHES

FIGURE # 3

Constant blower
operation switch
(low speed)

Main power ON­OFF switch

7. After fan-limit control heats up to the factory set
point, the circulating air blower starts.

8. The circulating air blower, burner motor and ignition
transformer remains on until the thermostat is
satisfied. Also, the solenoid valve remains open.

9. Thermostat is satisfied.

10. SPDT relay contacts open, solenoid valve closes,
burner fan motor post-purges the combustion
chamber and vent for a pre-set time (30 sec. to 4
min.). The ignition transformer also continues to
spark for this time period.

11. During the post-purge cycle, the fan-limit control
cools down to the factory set point of 90 degrees
Fahrenheit, and the circulating air blower turns off.

2.2) Sequence of operation - Riello 40-

BF, Side-wall Venting:

1. Normally open contact (W-R) on SPDT relay closed
when thermostat calls for heat.

DNS-0574 Rev. B

2) SEQUENCE OF OPERATION

2.1) Sequence of operation - Beckett
AFII, Side-wall venting:

1. For the Beckett AFII burner, the T-T terminal have

to be jumped on the primary control of the burner.

2. Normally open contact (W-R) on SPDT relay closed

when thermostat calls for heat.

3. Burner motor starts and spark is established. The

burner motor fan pre-purges the combustion
chamber and vent for 15 or 20 seconds,
establishing the combustion air pattern.

4. After prepurge period, solenoid valve opens

allowing oil to flow through nozzle.

5. The ignition transformer spark ignites oil spray.

6. Cad cell senses flame and burner continues to fire.

2. Burner motor starts. The burner motor fan pre­purges the combustion chamber and vents for 10
seconds, establishing the combustion air pattern.
During this time the solenoid valve holding coil
pressure will be approximately 100 psig.

3. After prepurge period, solenoid valve opens,
allowing oil to flow through nozzle. At the same
time, the burner motor’s ignition coil produces
spark.

4. The ignition transformer spark ignites oil spray.

5. Cad cell senses flame and burner continues to fire.
Ignition transformer ceases sparking.

6. After fan-limit control heats up to the factory set
point, the circulating air blower starts.

7. The circulating air blower and burner motor remain
on until the thermostat is satisfied. Also, the
solenoid valve remains open.

8. Thermostat is satisfied.

9. Relay contacts open, solenoid valve closes, and
then the burner fan motor post-purges the
combustion chamber and vent for a pre-set time (5”
breech model only) (0 min. to 6 min.).

19

10. During the post-purge cycle, the fan-limit control BI­metal cools down to the factory set point of 90
degrees Fahrenheit, and the circulating air blower
turns off.

2.4) Sequence of operation – internal
furnace controls (All models) :

No call for heating or cooling:

NOTE: With burner relay contact open, the Riello 40-

BF will post-purge when 115 volt power is applied to the
burner.

2.3) Sequence of operation - Beckett
AFG and Riello 40-F, chimney:

1. For the AFG burner, the T-T terminal have to be

jumped on the primary control of the burner.

2. Normally open contact (W-R) on SPDT relay closed

when thermostat calls for heat.

3. AFG Burner: The motor starts and spark is

established. The pump pressure builds and the
poppet valve opens admitting fuel to the nozzle.
Pressure builds and poppet valve opens, allowing
oil to flow through nozzle.

40F: Burner motor starts. The burner motor fan
pre-purges the combustion chamber and vent for
10 seconds, establishing the combustion air
pattern. During this time the solenoid valve holding
coil pressure will be approximately 100 psig.
Solenoid valve opens, allowing oil to flow through
nozzle. At the same time, the burner motor’s
ignition coil produces spark.

Power is available to the Electronic Air Cleaner (EAC)
at all times. Power at L1 enters the common terminal of
the single pole double throw (SPDT) relay, and then
passes through the normally closed (NC) switch of the
relay and continues to the normally closed (NC) switch
of the fan control. This provides power to the constant
blower operation speed tap on the blower motor if the
constant (low speed) blower operation switch is
selected to be close. The low speed motor tap would
normally be chosen for constant blower operation.

Call for heat:

Power comes from L1 to the limit control and then
leaves the limit control via the red wire to provide power
to the burner. RH - W close in the thermostat
completing a 24 volt circuit the SPDT relay coil. This
relay energises and switches 115 volts power to
operate the oil burner.

When the plenum temperature reaches the fan “On”
setting, the normally open (NO) fan control contacts
close and the normally closed (NC) contacts open.
Power then flows to the heating speed tap selected on
the blower motor, and to the HUM power lead to supply
115 volts to the humidifier transformer.

Call for cooling:

4. Spark ignites oil droplets.

5. Cad cell senses flame and burner continues to fire.

Ignition transformer ceases sparking (Riello R40-F).

6. After fan-limit control heats up to the factory set

point, the circulating air blower starts.

7. The circulating air blower and burner motor remain

on until the thermostat is satisfied (AFG). The
ignition transformer continues to spark (AFG). The
solenoid valve remains open (R40-F).

8. Thermostat is satisfied.

9. SPDT relay contacts open, solenoid valve closes

(R40-F), burner fan motor shuts down. The ignition
transformer ceases sparking (AFG).

10. The fan-limit control BI-metal cools down to the

factory set point of 90 degrees Fahrenheit, and the
circulating air blower turns off.

20

Rc - G close in the thermostat completing a 24-volt
circuit to the SPDT relay coil. The NC contacts open
interrupting power to the fan control. The NO contacts
close and power flows to the cooling speed tap
selected.

Rc - Y also close in the thermostat completing a 24-volt
circuit to the outdoor condensing unit contactor coil. The
contactor closes and switches power to the compressor
and condenser fan in the condensing unit.

2.5) Sequence of operation - DV-2000™
Venting system:

Normal operation:

1. Before a call for heat the contacts of the pressure

switch are closed.

2. When the room thermostat calls for heat the

normally open contact W-R close and the burner
blower starts and creates suction in the intake
piping circuit and a pressure in the vent piping
circuit.

3. The differential pressure setpoint of the pressure
switch is not exceeded and the thermostat circuit
remains closed until the call for heat has ended.

Abnormal operation:

should flow absolutely free of white streaks or bubbles
to indicate that no air is being drawn into the suction
side of the oil piping and pump. Tighten the bleed screw
and the burner will fire. Adjust the oil pressure as
indicated in Table #4.1 to #4.3.

Start-up:

1. When the room thermostat calls for heat the
normally open contact W-R close and the burner
blower starts and creates suction in the intake
piping circuit and a pressure in the vent piping
circuit.

2. If there is a blockage in the intake or vent openings
to cause a pressure differential beyond the set point
of the pressure switch, then the thermostat circuit is
opened and the burner will go into a 2 minute post­purge and then shut down.

3. After the post-purge, once the burner blower shuts
down, the pressure switch contacts will re-close. If
the call for heat remains, the burner will re-start. If
the blockage still exists, the thermostat is again
opened, and the burner post- purges again. The
post-purge function thus becomes an inherent anti­short cycling device.

4. The unit will essentially go into a continuous re­cycling post-purge mode with no heat being
supplied to the dwelling, which will prompt a call for
service to the equipment.

IMPORTANT

The burner must be put in operation for at
least 10 minutes before any test readings are
taken. For new installations, set up the burner
to the settings (see table #4.1 to 4.3), before
firing. These are rough adjustments but they
will ensure that the burner will start and run
smoke-free in advance of the fine adjustments
being made.

3.2) Restart if Burner Should Stop:

1. Set thermostat lower than the room temperature.

2. Press the reset button on the burner primary control
(relay).

3. Set thermostat higher than the room temperature
for 10 seconds and set lower than room
temperature. This will start pre purge cycle.
Repeat twice.

4. Set thermostat higher than the room temperature.

5. During the re-cycling post-purges, if the blockage of
the terminal is removed, the burner will immediately
fire up at the end of the current post purge cycle.

During operation:

If the terminal vent or intake openings become blocked
to the point where the set point of the pressure switch is
exceeded, during a firing cycle, the burner flame will
shut down and the burner will go into the indefinite
recycling post-purge mode as described above, until the
blockage is removed.

3) CHECKS AND ADJUSTMENTS

3.1) General:

During initial start-up and subsequent yearly
maintenance calls, the furnace must be thoroughly
tested.

Open the oil bleed port screw and start the burner.
Allow the oil to flush into a portable container for at least
10 seconds. Slowly close the bleed screw - the oil

5. If the burner motor does not start or ignition fails,
turn off the disconnect switch and CALL YOUR
SERVICEMAN

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 very hot.
Always keep the supply valve shut off if the
burner is shut down for an extended period of
time.

3.3) Combustion chamber curing:

Some moisture and binders remain in the ceramic
combustion chambers after fabrication. It is important to
clear the chamber of these residues before testing. If
you smoke test before curing, the instrument may
become damaged. To cure the chamber, run the unit for
3 consecutive cycles, with 3 minutes of elapsed time in
between each cycle. Each burn cycle should be 3

21

minutes duration. The exhaust will have a pungent odor
and produce a white cloud of steam.

3.4) Perform the smoke / CO2 test:

fan speed, investigate for ductwork restriction(s),
dirty or improper air filter, or overfiring caused by
excessive pump pressure, or inproper nozzle
sizing.

1. For chimney installations, pierce a test hole in the
smoke pipe near the furnace breech. For side-wall
vented installations, remove the threaded cap from
the extended test pipe that is welded into 4-bolt
breech plate. Insert the smoke test instrument
probe into the open hole.

2. Starting with a zero smoke reading, gradually
reduce the burner air setting until just a trace (#1 on
Bacharach Scale) of smoke results.

3. Take a CO2 sample at the same test location
where the smoke sample was taken. Note the CO2
reading associated with the #1 smoke condition.

4. For chimney vented installations, adjust the burner
air setting to obtain a CO2 reading 1% lower than
the reading associated with the #1 smoke.

5. For side-wall vented installations, adjust the burner
air setting to obtain a CO2 reading 1.5% lower than
the reading associated with the #1 smoke.

1. This method of adjusting the CO2 will allow
adequate excess air to ensure that the burner will
burn clean for the entire heating season, and will
ensure proper calibration of the DV-2000™ blocked
intake/ vent safety shutdown system used in side­wall venting applications.

3.5) Perform the supply air temperature

rise test:

1. Operate the burner for at least 10 minutes.

2. Measure the temperature of the air in the return air
plenum.

3.6) Fan limit adjustment:

FIGURE # 4

DNS-0355 Rev.B

1

Limit “FAN OFF”

2

Limit “FAN ON”
Model : OLR160
Model : OUF105, OLF105, OLR105,

OUF160, NOUF105, NOLF105 &
NOUF160

3

Limit “HI”
Model: OLR160
Model: OUF105, OLF105, OLR105,
NOUF105 & NOLF105
Model: OUF160 & NOUF160

900F

1100F
1300F

1700F
1800F

2200F

3. Measure the temperature of the air in the largest
trunk coming off the supply air plenum, just “out of
the line of sight” of the radiation coming off the heat
exchanger; 12” away from the plenum on the main
take-off usually satisfies this objective.

4. The temperature rise is calculated by subtracting
the return air temperature from the supply air
temperature.

5. If the temperature rise exceeds the temperature
specified in table #4.1 to #4.3, change to the next
higher blower speed tap until the temperature rise
falls to at this temperature or below. If the excessive
temperature rise cannot be reduced by increasing

22

3.7) Vent temperature test:

1. Place a thermometer in the test hole located in the
breech pipe.

2. The vent temperature should be between 400 and
575°F. If not, check for improper air temperature

rise, pump pressure, nozzle size, or for a badly
sooted heat exchanger.

3.8) DV-2000™ Blocked intake / blocked
vent test:

Test, and allow the 1.5% CO2 operating headroom
required by the instructions.

For side-wall venting the furnace the DV-2000™
venting system incorporates a safety shutdown system
that will shut the burner down before a #1 smoke occurs
due to the presence of a blocked intake or blocked vent
outlet. Test the system as follows:

1. Ensure that the furnace has been running for at

least 10 minutes.

2. Gradually block the intake. The burner flame should

shut down before a #1 smoke reading occurs.

3. Gradually block the vent outlet. The burner flame

should shut down before a #1 smoke reading
occurs.

4. If the burner does not shut down before a #1 smoke

occurs, ensure that the burner is set up according
to Part 2, section 3.4. Perform the CO2/ Smoke

5. If the burner still does not shut down before a #1
smoke occurs, check for blockage of the pressure
hose, or at the hose connection points.

IMPORTANT

The DV-2000™ safety shutdown system will
act to shut down the burner flame during a
blocked intake or blocked vent condition if and
only if the burner has been set up and
calibrated in accordance with Part 2, section

3.4. Perform the CO2/ Smoke Test. For

instance, if the burner is adjusted and final-set
to a #1 smoke condition during normal
operation, the burner flame can’t possibly shut
down before a #1 smoke occurs during a
blockage condition.

MAINTENANCE

1) GENERAL

Preventive Maintenance:
“Preventive maintenance” is the best way to avoid

unnecessary expense and inconvenience. Have
your heating system and burner inspected at
regular intervals by a qualified service man.

After inspection, a complete combustion test must be
performed after each annual service of the unit to
maintain optimum performance and reliability.

WARNINGWARNING

Electrical shock hazard.
Turn OFF power to furnace before any

disassembly or servicing.
Failure to do so can result in property

damage, bodily injury and/or death.

PART 3

Do not tamper with the unit or controls. Call your
service technician.

Before calling for service, check the following.

a. Check oil tank gauge and check if the oil tank valve

in oil is open.

b. Check fuse or circuit breaker.
c. Check if shut-off switch is “ON”.
d. Reset thermostat above room temperature.
e. If ignition does not occur turn off the disconnect

switch and call your qualified service technician.

When ordering replacement parts, specify the
complete furnace model number.

1.1) Heat exchanger:

The entire heat exchanger should be inspected
annually for soot accumulation. If the burner is
operating normally there should very little soot
accumulation. If the heat exchanger requires scale
removal, use a wire brush first to loosen the scale and
then vacuum the soot and scale that has fallen into the
secondary heat exchanger (radiator) section. You will

23

find that a 36” long flexible hose attachment will be
helpful to reach into the back of the radiator; a piece of
1/2” flexible gas connector, or a piece of 1/2” liquid-tight
vinyl jacket metallic electrical conduit works well as a
makeshift device.

Cleaning the heat exchanger:

Remove the 4-bolt flange from the front of the furnace
to reveal the clean-out port and check for soot deposits.
If there is very little soot in the radiator section visible
from the clean-out port, you will not need to clean it.
However, if you notice scaling in the radiator, you
should remove the scale.

The wrap-around radiator can now be cleaned entirely
from the front inspection port. Also the new furnace has
external clean-out ports so the soot does not fall into the
fan compartment during the cleaning operation.

Flooding of the fire pot:

Flooding can occur when the oil primary control has
been reset a number of times in a no-heat situation.
Each time oil is fired into the pot and does not ignite, it
is absorbed in the pot. Even if the burner is removed
and the pot is felt for wetness, it is difficult to assess the
degree of oil absorption by the pot.

There is only one way to properly service a flooded fire
pot, and that is to change it.

CAUTION

If you observe the red warning light on the
burner, push once ONLY to try and restart. If
the burner will not start, phone your authorised
service agent. Do not press the button again.

IMPORTANT

Do not vacuum the ceramic chambers—they
are easily damaged.

Soot will have collected in the first sections of the heat
exchangers only if the burner was started after the
combustion chamber was flooded with fuel oil, or if the
burner has been operating in a severely fouled
condition.

1.2) Refractory fire pot:

Remove the burner and check the fire pot.

IMPORTANT

Use extreme care if cleaning of the pot is
required. After firing, the pot becomes very
fragile. Do not use any commercially available
soot remover. This furnace has a fiber type
refractory combustion chamber. Normal
servicing of this unit does not require cleaning
of the combustion chamber.

Self-aligning firepot:

a. The appliance primary heat exchanger is comprised

of an upper and lower half. The lower half is
essentially a “can” that houses a self-aligning
firepot. the firepot will fit into the bottom half in one
orientation only.

b. A slot in the front of the firepot acts as a track that

captures a burner tube sleeve that extends into the
bottom heat exchanger half. This provides
automatic rotational alignment, vertical alignment.

c. Five tabs around the bottom and four tabs around

the top provide automatic centering of the firepot.

Removing the firepot:

The firepot is seldom replaced, but when it must be
replaced one must simply :

1. Remove the burner.

2. Remove the burner limit control.

3. Remove the breech plate.

4. Remove the front panel.

5. Remove the brass nuts on the stainless steel heat
exchanger studs.

If the pot is damaged, it must be replaced. A damaged
pot could lead to premature heat exchanger failure.
Cracking of the fire pot is normal, however, replace the
pot if the cracks have propagated more than 2/3 the
way through the wall thickness. The average wall
thickness of the firepot is 3/4”.

24

6. Pry the bottom heat exchanger halves apart using
the designated prying tabs.

7. Remove the bottom heat exchanger half from the
furnace cavity through the front of the furnace.

8. Pull the firepot up and out of the bottom heat
exchanger half.

9. Pull the old sealing gasket down off the flange of
the upper heat exchanger half.

10. Scrape off any residual gasket material off the heat
exchanger mating flanges.

Replacing the firepot:

1. Align the slot in the front face of the firepot with the
burner tube sleeve and gently lower the firepot into
the bottom heat exchanger half.

2. Holding the firepot near the perimeter, gently push
the firepot all the way into the bottom heat
exchanger half until it seats.

3. Completely wet the gasket with water using a spray
pump bottle, position the tabs over the studs, and
push the gasket upward against the sealing flange
of the upper heat exchanger half.

4. Install the brass nuts on the studs by engaging only
2 or 3 threads.

be removed to check the retention head and to check
for proper “Z” dimension with the Beckett “T” gauge
supplied with every burner. Check for any sign of oil
boiling out of the nozzle and caulking - the solenoid
valve could be leaking (if applicable).

1.4) Nozzle:

Replace the nozzle with the one specified in table #4.1
to #4.3.

1.5) Oil filter:

Tank filter:

The tank filter should be replaced as required.

Secondary filter:

The 10 micron (or less) filter cartridges should be
replaced annually.

5. Position the bottom heat exchanger half underneath
the upper heat exchanger half and rotate the
bottom half so that the slots in the bolting tabs
engage the stainless steel studs. There is no further
need to hold onto the bottom half as it will now be
suspended on the stud nuts.

6. Push upward on the can and thread the nuts finger­tight as far as possible.

7. Intermittently tighten the stud nuts with a wrench in
a sequence that will pull the heat exchanger halves
together evenly. Tighten all nuts to 90 inch-lbs
Torque once and then alternately re-tighten all nuts
again to 100 inch-lbs THE RE-TIGHTENING

SEQUENCE IS ABSOLUTELY NECESSARY TO
ENSURE A TIGHT JOINT.

8. Tighten the nuts until further torquing meets with
much resistance. The heavy spring action of the
bolting tabs keeps a constant tension on the joint.

9. Re-assemble the front panel, breech plate, limit
control and burner in opposite sequence to their
removal.

1.6) Air filters:

Air filters are the disposable types. The disposable
filters should be replaced on at least an annual basis.
Dusty conditions, presence of animal hair etc. may
demand much more frequent filter changes. Dirty filters
will impact furnace efficiency and increase oil
consumption.

1.7) Motor lubrication:

Do not lubricate the oil burner motor or the direct drive
blower motor as they are permanently lubricated.

1.8) CAS-2B combustion air kit (chimney
venting):

If used, check the CAS-2B combustion air kit for proper
operation. Check to see that the inlet screen is not
plugged. Block the air inlet completely and ensure that a
zero smoke reading results. If a zero smoke reading is
not obtained, set up the burner as indicated in Part 2,
section 3.

10. Follow the instructions for starting the burner for the
first time to cure the firepot and perform combustion
checks.

1.3) Drawer assembly:

Remove the drawer assembly. Clean all foreign matter
from the retention head and electrodes. If a Beckett
AFG burner has been installed, the burner will have to

Gradually block off the intake. The CO2 should increase
by a maximum of 0.5 percentage points at the fully
blocked condition. If not, check that the VRV gate is
pivoting freely and that the pivot rod is in a horizontal
position. Also, check that the counterweight has been
properly adjusted in accordance with the CAS-2B
installation instructions.

25

PART 4

INFORMATION

Model : Serial number:
Date of installation of the furnace :
Service telephones - day : Night :
Dealer’s name and address :

RESULT OF START-UP TEST

Nozzle: Pressure : lbpsi
Burner adjustments : Primary air

Fine air

Draw Assembly
CO2 : % Smoke scale : (Bacharach)
Gross stack temperature:
Ambiant temperature:
Chimney draft: " C.E.
Overfire draft : " C.E.

Test made by :

0

F

0

F

26

TABLE # 4.1

Technical specifications

Model : OLR

RATING AND PERFORMANCE

Firing rate .50 .63 .75 .72 0.85 0.97 1.14
Pump pressure (PSIG) 100 156 156 145 130 130 130
Input (BTU/h) 70 000 88 200 105 000 100 800 119 000 135 800 159 600
Heating capacity, chimney installation (BTU/h) 59 200 73 000 87 800 98 000 110 000 127 000
Heating capacity, side-wall installation (BTU/h) 59 400 73 200 88 200 84 200 98 000 110 000 127 000
Minimum - maximum temperature rise
Stack draft, (Chimney), (Side-wall)
Overfire pressure (chimney), (Side-wall)

BECKETT BURNER, CHIMNEY INSTALLATION

Low firing rate baffle Yes Yes Yes Yes Yes Yes
Static disc, model 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383
Nozzle (Delavan) 0.50 - 70A 0.50 - 70A 0.60 - 70B 0.75 - 70B 0.85 - 70B 1.00 - 70B
Combustion air adjustment (shutter / band) 4.5 / 0 8 / 0 7.5 / 0 5 / 0 6.5 / 0 10 / 0

RIELLO BURNER, CHIMNEY INSTALLATION

Nozzle (Delavan) 0.50 - 60A 0.60 - 60A 0.75 - 70B 0.85 - 70B 1.00 - 70B
Combustion air adjustment (turbulator / damper) 0 / 3 0 / 4 1 / 2 1 / 2.5 1 / 3

RIELLO BURNER, CHIMNEY INSTALLATION

Nozzle (Delavan) 0.50 - 60A 0.60 - 60A N /A N /A N /A
Combustion air adjustment (turbulator / damper) 0 / 3 0 / 4 N /A N /A N /A

BECKETT BURNER, SIDE-WALL INSTALLATION

Nozzle (Delavan) 0.50 - 60W 0.50 - 60W 0.60 - 60W 0.75 - 70B 0.85 - 70B 1.00 - 70B
Combustion air adjustment (screw / dial) or (dial only) 3 / 1.5 3 / 3 3 / 4.5 2.75 4.25 6.75

RIELLO BURNER, SIDE-WALL INSTALLATION

Nozzle (Delavan) 0.50 - 60W 0.60 - 60W 0.75 - 70B 0.85 - 70B 1.00 - 70B
Combustion air adjustment (turbulator / damper) 0 / 6 0 / 7.5 1 / 3 1 / 4 2 / 4.5

ELECTRICAL SYSTEM

Volts - Hertz - Phase
Operating voltage range
Rated voltage Amp
Minimum ampacity for wiring sizing
Max. fuse size (Amps)
Control transformer
Ext. control power available, cooling and accessories

BLOWER DATA

Blower speed at 0.5" W.C. static pressure MED-LO MED-HI HIGH HIGH MED-LO MED-HI HIGH
Blower speed at 0.25" W.C. static pressure LOW MED-HI MED-HI MED-HI MED-LO MED-HI MED-HI
Maximum cooling, speed LOW MED-LO MED-HI HIGH MED-LO MED-HI HIGH
Maximum cooling, tons @ 0.5" W.C. 1.5 2 2.5 3 3.5 4 5
Motor (HP) / number of speeds
Blower wheel size (in.)
Filter quantity and size (1) 20 X 20

(-0,035 to -0,06) (+0,04 to +0,16)

(0,00 to +0,035) (+0,10 to +0,25) (-0.00 to +0.04) (+0.10 to +0.25)

AFG-F0 (tube insersion 5 1/8")

40-F3 (tube insersion 5 3/16")

R35.3 (tube insersion 5 3/16")

AFII-85 (tube insersion 4 15/16")

40-BF3 (tube insersion 5 3/16")

OLR105A12B OLR160B20B

52 - 75 Degr. F

(-0.035 to -0.06) (+0.04 to +0.22)

AFG-F3 (tube insersion 6 5/8")

40-F5 (tube insersion 6 5/8")

AFII-150 (tube insersion 6 5/8")

40-BF5 (tube insersion 6 5/8")

115-60-1
104 - 132

12,2

13.7
15

40 Va
30 Va

1/3 HP / 4 speeds

10 X 10

50 - 80 Degr.F

115-60-1

104 - 132

15.7

18.1

40 Va

30Va

3/4 HP / 4 speeds

12 X 10

(2) 16 X 24

20

TABLE # 5.1

Air delevery - CFM with air filter

OLR105A12B OLR160B20B

EXTERNAL STATIC PRESSURE WITH AIR FILTER EXTERNAL STATIC PRESSURE WITH AIR FILTER

SPEED 0.25 0.5 0.25 0.5

LOW 850 700 1100 1020

MED-LO 940 750 1360 1350

MED-HI 1090 1000 1625 1540

HIGH 1390 1300 2100 1850

27

TABLE # 4.2

Technical specifications

Model : OUF / NOUF

RATING AND PERFORMANCE

Firing rate .50 .63 .75 .72 .85 .97 1.14
Pump pressure (PSIG) 100 156 156 145 130 130 130
Input (BTU/h) 70 000 88 200 105 000 100 800 119 000 135 800 159 600
Heating capacity, chimney installation (BTU/h) 58 900 73 500 86 100 98 000 110 000 127 000
Heating capacity, side-wall installation (BTU/h) 59 800 74 600 87 800 83 900 97 000 110 000 127 000
Minimum - maximum temperature rise
Stack draft, (Chimney), (Side-wall)
Overfire pressure (chimney), (Side-wall)

BECKETT BURNER, CHIMNEY INSTALLATION

Low firing rate baffle Yes Yes Yes Yes Yes Yes
Static disc, model 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383
Nozzle (Delavan) 0.50 - 70A 0.50 - 70A 0.60 - 70B 0.75 - 70B 0.85 - 70B 1.00 - 70B
Combustion air adjustment (shutter / band) 4.5 / 0 8 / 0 7.5 / 0 5 / 0 6,5 / 0 10 / 0

RIELLO BURNER, CHIMNEY INSTALLATION

Nozzle (Delavan) 0.50 - 60A 0.60 - 60A 0.75 - 70B 0.85 - 70B 1.00 - 70B
Combustion air adjustment (turbulator / damper) 0 / 3 0 / 4 0 / 2.5 0 / 2.8 0 / 3.9

BECKETT BURNER, SIDE-WALL INSTALLATION

Nozzle (Delavan) 0.50 - 60W 0.50 - 60W 0.60 - 60W 0,75 - 70B 0,85 - 70B 1,00 - 70B
Combustion air adjustment (screw / dial) or (dial only) 3 / 1.5 3 / 3 3 / 4.5 2,75 4,25 6,0

RIELLO BURNER, SIDE-WALL INSTALLATION

Nozzle (Delavan) 0.50 - 60W 0.60 - 60W 0,75 - 70B 0,85 - 70B 1,00 - 70B
Combustion air adjustment (turbulator / damper) 0 / 6 0 / 7.5 0 / 3,75 0 / 4 0 / 4,875

ELECTRICAL SYSTEM

Volts - Hertz - Phase
Operating voltage range 104 - 132
Rated voltage Amp
Minimum ampacity for wiring sizing
Max. fuse size (Amps)
Control transformer
Ext. control power available, cooling and accessories

BLOWER DATA

Blower speed at 0.5" W.C. static pressure LOW LOW MED-HI MED-HI MED-LO MED-HI HIGH
Blower speed at 0.25" W.C. static pressure LOW LOW MED-LO MED-LO MED-LO MED-LO MED-HI
Maximum cooling, speed LOW MED-LO MED-HI HIGH MED-LO MED-HI HIGH
Maximum cooling, tons @ 5" W.C. 2 2.5 2.5 3 3.5 4 5
Motor (HP) / number of speeds
Blower wheel size (in.)
Filter quantity and size

OUF105A12B / NOUF105A12B OUF160B18B / NOUF160B18B

52 - 75 Degr. F

(-0,035 to -0,06) (+0,04 to +0,16) (-0,035 to -0,6) (+0,04 to +0,18)

(0,00 to +0,035) (+0,10 to +0,25) (0,00 to +0,04) (+0,10 to +0,25)

AFG-F0 (tube insersion 5 1/8")

40-F3 (tube insersion 5 3/16")

AFII-85 (tube insersion 4 15/16")

40-BF3 (tube insersion 5 3/16")

115-60-1

104 - 132

15.4

17.7
20

40 Va
30 Va

1/2 HP / 4 speeds

10 X 10

(1) 20 X 20

AFG-F3 (tube insersion 6 5/8")

40-F5 (tube insersion 6 5/8")

AFII-150 (tube insersion 6 5/8")

40 - BF5 (tube insersion 6 5/8")

50 - 80 Degr. F

115-60-1

16.9

19.5
20

40 Va
30 Va

0.85 HP / 4 speeds
12 X 10

(1) 24 X 24

TABLE #5.2

Air delevery - CFM with air filter

OUF105A12B / NOUF105A12B OUF160B18B / NOUF160B18B

EXTERNAL STATIC PRESSURE WITH AIR FILTER EXTERNAL STATIC PRESSURE WITH AIR FILTER

SPEED 0.25 0.5 0.25 0.5

LOW 960 920 1080 990

MED-LO 1100 1000 1350 1310

MED-HI 1300 1150 1605 1510

28

TABLE # 4.3

AFII-85 (tube insersion 4 15/16")

Technical specifications

Model : OLF / NOLF

RATING AND PERFORMANCE

Firing rate .50 .63 .75 .72
Pump pressure (PSIG) 100 156 156 145
Input (BTU/h) 70 000 88 200 105 000 100 800
Heating capacity, chimney installation (BTU/h) 59 200 73 000 87 800
Heating capacity, side-wall installation (BTU/h) 59 400 73 200 88 200 84 200
Minimum - maximum temperature rise
Stack draft, (Chimney), (Side-wall)
Overfire pressure (chimney), (Side-wall)

BECKETT BURNER, CHIMNEY INSTALLATION

Low firing rate baffle Yes Yes No
Static disc, model 2 3/4 #3383 2 3/4 #3383 2 3/4 #3383
Nozzle (Delavan) 0.50 - 70A 0.50 - 70A 0.60 - 70B
Combustion air adjustment (shutter / band) 4.5 / 0 8 / 0 7.5 / 0

RIELLO BURNER, CHIMNEY INSTALLATION

Nozzle (Delavan) 0.50 - 60A 0.60 - 60A
Combustion air adjustment (turbulator / damper) 0 / 3 0 / 4

BECKETT BURNER, SIDE-WALL INSTALLATION

Nozzle (Delavan) 0.50 - 60W 0.50 - 60W 0.60 - 60W
Combustion air adjustment (screw / dial) 3 / 1.5 3 / 3 3 / 4.5

RIELLO BURNER, SIDE-WALL INSTALLATION

Nozzle (Delavan) 0.50 - 60W 0.60 - 60W
Combustion air adjustment (turbulator / damper) 0 / 6 0 / 7.5

ELECTRICAL SYSTEM

Volts - Hertz - Phase
Operating voltage range
Rated voltage Amp
Minimum ampacity for wiring sizing
Max. fuse size (Amps)
Control transformer
Ext. control power available, cooling and accessories

BLOWER DATA

Blower speed at 0.5" W.C. static pressure LOW MED-HI HIGH HIGH
Blower speed at 0.25" W.C. static pressure LOW MED-HI HIGH HIGH
Maximum cooling, speed LOW MED-LO MED-HI HIGH
Maximum cooling, tons @ 5" W.C. 1.5 2 2.5 3
Motor (HP) / number of speeds
Blower wheel size (in.) 10 X 10

OLF105A12B / NOLF105A12B

52 - 75 Degr. F

(-0,035 to -0,06) (+0,04 to +0,16)

(0,00 to +0,035) (+0,10 to +0,25)

AFG-F0 (tube insersion 5 1/8")

40-F3 (tube insersion 5 3/16")

40-BF3 (tube insersion 5 3/16")

115-60-1

104 - 132

12,2

13.7
15

40 Va
30 Va

1/3 HP / 4 speeds

SPEED 0.25 0.5

LOW 840 770

MED-LO 960 800

MED-HI 1050 980

HIGH 1300 1200

TABLE # 5.3

Air delevery - CFM with air filter

OLF105A12B / NOLF105A12B

EXTERNAL STATIC PRESSURE WITH AIR FILTER

29

FIGURE # 5.1

Model: OLR105A12B

DNS-0571 Rev. B

FIGURE # 5.2

Model: OLR160B20B

DNS-0573 Rev. B

30

FIGURE # 5.3

Model: OUF105A12B

DNS-0568 Rev. C

FIGURE # 5.4

Model: OUF160B18

DNS-0572 Rev. C

31

FIGURE # 5.5

Model : OLF105A12B

DNS-0570 Rev. B

FIGURE # 5.6

Model: NOUF105A12B

DNS-0674 Rev. C

32

FIGURE # 5.7

Model: NOUF160B18B

DNS-0675 Rev. D

FIGURE # 5.8

Model: NOLF105A12B

DNS-0676 Rev. C

33

FIGURE # 6

Wiring diagram, OLR105A12B, OLR160B20B, OUF105A12B, NOUF105A12B, OUF160B18B,

NOUF160B18B, OLF105A12B & NOLF105A12B

DNS-0447 Rev. I

34

PARTS LIST

ITEM

DESCRIPTION

MANUFAC.

ITEM

DESCRIPTION

MANUFAC.

Model : OLR105A12B Serial # > 264 000

DNS-0564 Rev. D

1 Complet heat exchanger B30756-02
2 Top heat exchanger B30465-02
3 Combustion chamber B30414
4 Gasket, heat exchanger B30517
5 Bottom heat exchanger B30757
6 Hexagonal flange nut 3/8-16NC brass F07O001
7 Gasket panel, peep hole B30753
8 Division panel B30488

9 Plenum divider B30478
10 Floor B30472
11 Left side panel ass'y B30509-02
12 Left side panel insulation B30493-04
13 Top rear panel B30511
14 Blower door ass'y B30512
15 Air filter drawer B30507
16 Right side panel ass'y B30509-01
17 Right side panel insulation B30493-03
18 Right filter support B30479-01
19 Left filter support B30479-02
20 Gasket, extruded 1/2" X 1/8" x 25' J06L001
21 Front panel ass'y B30768-01
22 Front panel insulation B30762
23 Washer 3/8" AA zinc F06F005
24 Hexagonal nut 3/8-16NC brass F07F024
25 Washer, peep hole B30752
26 Hexagonal flange nut 3/8-16NC brass F07O001

27A 5" breech plate B30459
27B 3" breech plate B30515

28 Gasket, breech plate B30415-02
29 Electrical box cover (without cosmetic) B40085
30 Electrical box B30514
31 Rocker switch SPST L07F003

32 Fan limit control R02I005
33 Transformer 120/24 VAC / 40 VA K03040
34 Relay SPDT 24VAC L01H009
35 Terminal strip, 6 positions L05F011
36 Blower weel 10 X 10 Z01L002
37 Capacitor holder B01024
38 5 MF capacitor L01I001
39 Blower electrical kit B30057
40 Screw cable tie F11F007
41 Blower support bracket B30473
42 1/3 HP direct drive motor B01890-01

43 Motor mount ass'y B01888
44A Blower 10 X 10 Z01I004
44B Blower ass'y B01405-03

45 Rubber grommet #19 Z01F006

46 Sealing strip B01291-01

47 Strip B30188-02

48 Gasket, access cover B30415-01

49 Flange plate B30487

50 Hexagonal flange nut 3/8-16NC brass F07O001

51 Access cover B30486

52 Rocker switch SPST L07F016

53 Terminal strip, 6 positions A00336

54 Floor baffle B30480

55 Gasket, access cover B30415-02

56 Gasket, burner B30534

57 Gasket, access cover B30415-02

58 Gasket, sealing plate B30533
59A Peep hole kit K30011
59B Overfire pressure test kit K30012

60 Gasket, glass B30055

61 Glass, neoceram B30041-01

35

PARTS LIST

ITEM

DESCRIPTION

MANUFAC.

ITEM

DESCRIPTION

MANUFAC.

Model : OLR160B20B Serial # > 264 000

DNS-0567 Rev. D

1 Complet heat exchanger B30786-02
2 Top heat exchanger B30596
3 Combustion chamber B30584
4 Hexagonal flange nut 3/8-16NC brass F07O001
5 Gasket, panel, peep hole B30753
6 Bottom heat exchanger B30787
7 Gasket, heat exchanger B30532
8 Gasket, heat exchanger B30534

9 Gasket, heat exchanger B30415-02
10 Front baffle B30665
11 Rear baffle B30664
12 Division panel B30666
13 Plenum divider B30669
14 Floor baffle B30481
15 Floor B30663
16 Left side panel ass'y B30680-02
17 Left side panel insulation B30686-02
18 Left bottom filter support B30668-02
19 Left top filter support B30667
20 Strip B10256-99
21 Sealing strip B01291-02
22 Blower door ass'y B30683
23 Air filter drawer B30678
24 Top rear panel B30682
25 Gasket, breech plate B30589-01

26A 5" breech plate B30646
26B 4" breech plate B30647

27 Hexagonal flange nut 3/8-16NC brass F07O001
28 Gasket, extruded 1/2" X 1/8" x 25' J06L001
29 Right side panel ass'y B30680-01
30 Right side panel insulation B30686-01
31 Right bottom filter support B30668-01
32 Right top filter support B30667

33 Front panel ass'y B30782-01
34 Front panel insulation B30780
35 Washer, peep hole B30752
36 Washer 3/8" AA zinc F06F005
37 Hexagonal nut 3/8-16NC brass F07F024
38 Flange plate B30676
39 Hexagonal flange nut 3/8-16NC brass F07O001
40 Access cover B30486
41 Electrical box cover (without cosmetic) B40085
42 Terminal strip, 6 positions L05F011
43 Rocker switch SPST L07F016
44 Rocker switch SPST L07F003
45 Electrical box B30514
46 Fan limit control R02I005
47 Transformer 120/24 VAC / 40 VA K03040
48 Terminal strip, 6 positions A00336
49 Relay SPDT 24VAC L01H009
50 Rubber grommet #19 Z01F006
51 Blower support bracket B01756
52 Blower electrical kit B30530-01
53 Strain release bushing SR-9P-2 L04I010
54 Capacitor holder B01024
55 15 MF capacitor L01I005

56 Blower weel 12 X 10 Z01L003
57A Blower 12 X 10 Z01I008
57B Blower ass'y B01406-05

58 Motor mount ass'y B01889

59 3/4 HP direct drive motor L06I004
60A Peep hole kit K30011
60B Overfire pressure test kit K30012

61 Gasket, glass B30055

62 Gasket, neoceram B30041-01

36

PARTS LIST

Model : OUF105A12B Serial # > 264 000

DNS-0563 Rev. D

ITEM DESCRIPTION MANUFAC.

1 Complet heat exchanger B30756-01
2 Top heat exchanger B30465-01
3 Gasket, heat exchanger B30517
4 Combustion chamber B30414
5 Bottom heat exchanger B30757
6 Hexagonal flange nut 3/8-16NC brass F07O001
7 Gasket panel, peep hole B30753
8 Division panel B30431

9 Floor B30430
10 Baffle B30426
11 Rear panel ass'y B30457
12 Rear panel insulation B30419
13 Right side panel ass'y B30458-01
14 Right side panel insulation B30418
15 Front panel ass'y B30760-01
16 Front panel insulation B30761
17 Blower door ass'y B30455
18 Door handle Z99F050
19 Left side panel ass'y B30458-02
20 Left side panel insulation B30418

21A 5" breech plate B30459
21B 3" breech plate B30515

22 Gasket, breech plate B30415-02
23 Hexagonal flange nut 3/8-16NC brass F07O001
24 Hexagonal nut 3/8-16NC brass F07F024
25 Washer 3/8" AA zinc F06F005

ITEM DESCRIPTION MANUFAC.

26 Terminal strip, 6 positions L05F011
27 Electrical box cover (without cosmetic) B40085
28 Relay SPDT 24VAC L01H009
29 Transformer 120/24 VAC / 40 VA K03040
30 Fan limit control R02I005
31 Rocker switch SPST L07F003
32 Electrical box B30514
33 Blower side rails B30433
34 Blower weel 10 X 10 Z01L002
35 1/2 HP direct drive motor L06H004
36 Blower electrical kit B30096
37 Capacitor holder B01024
38 7.5 MF capacitor L01I002
39 Motor mount ass'y B01888

40 Sealing strip B01291-01
41A Blower 10 X 10 Z01I004
41B Blower ass'y B01405-02

42 Blower slide support B30513

43 Washer, peep hole B30752

44 Rocker switch SPST L07F016

45 Terminal strip, 6 positions A00336

46 Gasket, burner B30534
47A Peep hole kit K30011
47B Overfire pressure test kit K30012

48 Gasket, glass B30055

49 Glas, neoceram B30041-01

37

PARTS LIST

Model : OUF160B18B Serial # > 264 000

DNS-0566 Rev. D

ITEM DESCRIPTION MANUFAC.

1 Complet heat exchanger B30786-01
2 Top heat exchanger B30597
3 Combustion chamber B30584
4 Hexagonal flange nut 3/8-16NC brass F07O001
5 Gasket, heat exchanger B30532
6 Bottom heat exchanger B30787
7 Rear baffle B30619
8 Front baffle B30618

9 Top baffle B30639
10 Division panel B30627
11 Blower slide support B30625
12 Floor B30628
13 Left side panel ass'y B30653-02
14 Left side panel insulation B30658
15 Rear panel ass'y B30652
16 Rear panel insulation B30659
17 Hexagonal flange nut 3/8-16NC brass F07O001
18 Breech plate B30487
19 Gasket, access cover B30415-01
20 Gasket, access cover B30415-02
21 Right side panel ass'y B30653-01
22 Right side panel insulation B30658
23 Gasket panel, peep hole B30753
24 Gasket, burner B30534
25 Gasket, breech plate B30589-01
26 Front panel ass'y B30781-01
27 Front panel insulation B30779
28 Blower door ass'y B30651
29 Door handle Z99F050
30 Washer 3/8" AA zinc F06F005

ITEM DESCRIPTION MANUFAC.

31 Hexagonal nut 3/8-16NC brass F07F024
32A 5" breech plate B30646
32B 4" breech plate B30647

33 Hexagonal flange nut 3/8-16NC brass F07O001

34 Electrical box B30514

35 Relay SPDT 24VAC L01H009

36 Transformer 120/24 VAC / 40 VA K03040

37 Fan limit control R02I005

38 Rocker switch SPST L07F003

39 Electrical box cover (without cosmetic) B40085

40 Washer, peep hole B30752

41 .85 HP direct drive motor L06K001

42 Motor mount ass'y B01889

43 Terminal strip, 6 positions L05F011

44 Blower electrical kit B30530

45 Blower wheel 12 X 10 Z01L003

46 Sealing strip B01291-01

47 Blower side rails B30626
48A Blower 12 X 10 Z01I008
48B Blower ass'y B02167-01

49 Capacitor holder B01024

50 10 MF capacitor L01I003

51 Rocker switch SPST L07F016

52 Terminal strip, 6 positions A00336

53 Gasket, sealing plate B30533
54A Peep hole kit K30011
54B Overfire pressure test kit K30012

55 Gasket, glass B30055

56 Glass, neoceram B30041-01

38

PARTS LIST

ITEM

DESCRIPTION

MANUFAC.

Model : OLF105A12B Serial # > 264 000

DNS-0565 Rev. D

ITEM DESCRIPTION MANUFAC.

1 Complet heat exchanger B30756-01
2 Top heat exchanger B30465-01
3 Combustion chamber B30414
4 Gasket, heat exchanger B30517
5 Bottom heat exchanger B30757
6 Hexagonal flange nut 3/8-16NC brass F07O001
7 Gasket panel, peep hole B30753
8 Division panel B30477

9 Plenum divider B30478
10 Floor B30472
11 Left side panel ass'y B30504-02
12 Left side panel insulation B30493-02
13 Top rear panel B30506
14 Blower door ass'y B30512
15 Air filter drawer B30507
16 Right side panel ass'y B30504-01
17 Right side panel insulation B30493-01
18 Right filter support B30479-01
19 Left filter support B30479-02
20 Gasket, extruded 1/2" X 1/8" X 25' B30483
21 Front panel ass'y B30767-01
22 Front panel insulation B30761
23 Washer 3/8" AA zinc F06F005
24 Hexagonal nut 3/8-16NC brass F07F024
25 Washer, peep hole B30752
26 Hexagonal flange nut 3/8-16NC brass F07O001

27A 5" breech plate B30459

27B 3" breech plate B30515

28 Gasket, breech plate B30415-02
29 Electrical box cover (without cosmetic) B40085

30 Electrical box B30514
31 Rocker switch SPST L07F003
32 Fan limit control R02I005
33 Transformer 120/24 VAC / 40 VA K03040
34 Relay SPDT 24VAC L01H009
35 Terminal strip, 6 positions L05F011
36 Blower weel 10 X 10 Z01L002
37 Capacitor holder B01024
38 5 MF capacitor L01I001
39 Blower electrical kit B30057
40 Screw cable tie F11F007
41 Blower support bracket B30473
42 1/3 HP direct drive motor B01890-01

43 Motor mount ass'y B01888
44A Blower 10 X 10 Z01I004
44B Blower ass'y B01405-03

45 Rubber grommet #19 Z01F006

46 Sealing strip B01291-01

47 Strip B30188-02

48 Rocker switch SPST L07F016

49 Terminal strip, 6 positions A00336

50 Gasket, breech plate B30415-02

51 Gasket, burner B30534

52 Rear baffle B30490

53 Front baffle B30480
54A Peep hole kit K30011
54B Overfire pressure test kit K30012

55 Gasket, glass B30055

56 Glass, neoceram B30041-01

39

PARTS LIST

ITEM

DESCRIPTION

MANUFAC.

ITEM

DESCRIPTION

MANUFAC.

Model : NOUF105A12B Serial # > 264 000

DNS-0681 Rev. B

1 Complet heat exchanger B30756-01
2 Top heat exchanger B30465-01
3 Gasket, heat exchanger B30517
4 Combustion chamber B30414
5 Bottom heat exchanger B30757
6 Hexagonal flange nut 3/8-16NC brass F07O001
7 Gasket panel, peep hole B30753
8 Division panel B30431

9 Floor B30430
10 Baffle B30426
11 Rear panel ass'y B30457
12 Rear panel insulation B30419
13 Right side panel ass'y B30458-01
14 Right side panel insulation B30418
15 Front panel ass'y B30760-01
16 Front panel insulation B30761
17 Blower door ass'y B30455
18 Door handle Z99F050
19 Left side panel ass'y B30458-02
20 Left side panel insulation B30418

21A 5" breech plate B30459
21B 3" breech plate B30515

22 Gasket, breech plate B30415-02
23 Hexagonal flange nut 3/8-16NC brass F07O001
24 Hexagonal nut 3/8-16NC brass F07F024
25 Washer 3/8" AA zinc F06F005
26 Terminal strip, 6 positions L05F011
27 Electrical box cover (without cosmetic) B40085
28 Relay SPDT 24VAC L01H009

29 Transformer 120/24 VAC / 40 VA K03040
30 Fan limit control R02I005
31 Rocker switch SPST L07F003
32 Electrical box B30514
33 Blower side rails B30433
34 Blower weel 10 X 10 Z01L002
35 1/2 HP direct drive motor L06H004
36 Blower electrical kit B30096
37 Capacitor holder B01024
38 7.5 MF capacitor L01I002
39 Motor mount ass'y B01888

40 Sealing strip B01291-01
41A Blower 10 X 10 Z01I004
41B Blower ass'y B01405-02

42 Blower slide support B30513

43 Washer, peep hole B30752

44 Rocker switch SPST L07F016

45 Terminal strip, 6 positions A00336

46 Gasket, burner B30534

47 Front door, vestibule B40293

48 Right panel, vestibule B30725

49 Left panel, vestibule B30726

50 Top panel, vestibule B30723

51 Bottom panel, vestibule B30724

52 Draft regulator Z06F001
53A Peep hole kit K30011
53B Overfire pressure test kit K30012

54 Gasket, glass B30055

55 Glass, neoceram B30041-01

40

PARTS LIST

ITEM

DESCRIPTION

MANUFAC.

Model : NOUF160B18B Serial # > 264 000

DNS-0680 Rev. B

ITEM DESCRIPTION MANUFAC.

1 Complet heat exchanger B30786-01
2 Top heat exchanger B30597
3 Combustion chamber B30584
4 Hexagonal flange nut 3/8-16NC brass F07O001
5 Gasket, heat exchanger B30532
6 Bottom heat exchanger B30787
7 Gasket panel, peep hole B30619
8 Front baffle B30618

9 Top baffle B30639
10 Division panel B30627
11 Blower slide support B30625
12 Floor B30628
13 Left side panel ass'y B30653-02
14 Left side panel insulation B30658
15 Rear panel ass'y B30652
16 Rear panel insulation B30659
17 Hexagonal flange nut 3/8-16NC brass F07O001
18 Breech plate B30487
19 Gasket, access cover B30415-01
20 Gasket, access cover B30415-02
21 Right side panel ass'y B30653-01
22 Right side panel insulation B30658
23 Gasket panel, peep hole B30753
24 Gasket, burner B30534
25 Gasket, breech plate B30589-01
26 Front panel ass'y B30781-01
27 Front panel insulation B30779
28 Blower door ass'y B30651
29 Door handle Z99F050
30 Washer 3/8" AA zinc F06F005
31 Hexagonal nut 3/8-16NC brass F07F024

32A 5" breech plate B30646
32B 4" breech plate B30647

33 Hexagonal flange nut 3/8-16NC brass F07O001
34 Electrical box B30514
35 Relay SPDT 24VAC L01H009
36 Transformer 120/24 VAC / 40 VA K03040
37 Fan limit control R02I005
38 Rocker switch SPST L07F003
39 Electrical box cover (without cosmetic) B40085
40 Washer, peep hole B30752
41 .85 HP direct drive motor L06K001
42 Motor mount ass'y B01889
43 Terminal strip, 6 positions L05F011
44 Blower electrical kit B30530
45 Blower wheel 12 X 10 Z01L003
46 Sealing strip B01291-01

47 Blower side rails B30626
48A Blower 12 X 10 Z01I008
48B Blower ass'y B02167-01

49 Capacitor holder B01024

50 10 MF capacitor L01I003

51 Rocker switch SPST L07F016

52 Terminal strip, 6 positions A00336

53 Gasket, sealing plate B30533

54 Front door, vestibule B40295

55 Right panel, vestibule B30632

56 Left panel, vestibule B30633

57 Top panel, vestibule B30732

58 Bottom panel, vestibule B30728

59 Draft regulator Z06F001
60A Peep hole kit K30011
60B Overfire pressure test kit K30012

61 Gasket, glass B30055

62 Glass, neoceram B30041-01

41

PARTS LIST

ITEM

DESCRIPTION

MANUFAC.

ITEM

DESCRIPTION

MANUFAC.

Model : NOLF105A12B Serial # > 264 000

DNS-0679 Rev. B

1 Complet heat exchanger B30756-01
2 Top heat exchanger B30465-01
3 Combustion chamber B30414
4 Gasket, heat exchanger B30517
5 Bottom heat exchanger B30757
6 Hexagonal flange nut 3/8-16NC brass F07O001
7 Gasket panel, peep hole B30753
8 Division panel B30477

9 Plenum divider B30478
10 Floor B30472
11 Left side panel ass'y B30504-02
12 Left side panel insulation B30493-02
13 Top rear panel B30506
14 Blower door ass'y B30512
15 Air filter drawer B30507
16 Right side panel ass'y B30504-01
17 Right side panel insulation B30493-01
18 Right filter support B30479-01
19 Left filter support B30479-02
20 Gasket, extruded 1/2" X 1/8" X 25' B30483
21 Front panel ass'y B30767-01
22 Front panel insulation B30761
23 Washer 3/8" AA zinc F06F005
24 Hexagonal nut 3/8-16NC brass F07F024
25 Washer, peep hole B30752
26 Hexagonal flange nut 3/8-16NC brass F07O001

27A 5" breech plate B30459
27B 3" breech plate B30515

28 Gasket, breech plate B30415-02
29 Electrical box cover (without cosmetic) B40085
30 Electrical box B30514
31 Rocker switch SPST L07F003
32 Fan limit control R02I005

33 Transformer 120/24 VAC / 40 VA K03040
34 Relay SPDT 24VAC L01H009
35 Terminal strip, 6 positions L05F011
36 Blower weel 10 X 10 Z01L002
37 Capacitor holder B01024
38 5 MF capacitor L01I001
39 Blower electrical kit B30057
40 Screw cable tie F11F007
41 Blower support bracket B30473
42 1/3 HP direct drive motor B01890-01

43 Motor mount ass'y B01888
44A Blower 10 X 10 Z01I004
44B Blower ass'y B01405-03

45 Rubber grommet #19 Z01F006

46 Sealing strip B01291-01

47 Strip B30188-02

48 Rocker switch SPST L07F016

49 Terminal strip, 6 positions A00336

50 Gasket, breech plate B30415-02

51 Gasket, burner B30534

52 Rear baffle B30490

53 Front baffle B30480

54 Front door, vestibule B40292

55 Right panel, vestibule B30729

56 Left panel, vestibule B30730

57 Top panel, vestibule B30723

58 Bottom panel, vestibule B30724

59 Draft regulator Z06F001
60A Peep hole kit K30011
60B Overfire pressure test kit K30012

61 Gasket, glass B30055

62 Glass, neoceram B30041-01

42