ICP OLR105A12D, OLR160B20C, OUF105A12C, OUF160B18C, OLF105A12C Installation Instructions Manual

OIL FIRED FURNACE

UPFLOW

Models:

OLR105A12D
OLR160B20C
OUF105A12C
OUF160B18C

A
v

e
R
0
6
5
0

­S
N
D

OLR105
OLR160

A
v

e
R
8
5
5
0

­S
N
D

OUF105

A
v

e
R
1
6
5
0

­S
N
D

OUF160
NOUF105

OLF105
NOLF105

INSTALLER / SERVICE TECHNICIAN:
USE THE INFORMATION IN THIS MANUAL FOR THE INSTALLATION
AND SERVICING OF THE FURNACE AND KEEP THE DOCUMENT
NEAR THE UNIT FOR FUTURE REFERENCE.

HOMEOWNER:
PLEASE KEEP THIS MANUAL NEAR THE FURNACE FOR FUTURE
REFERENCE.

OLF105A12C
NOLF105A12D
NOUF105A12D

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

Manufactured by:

Dettson Industries inc.

3400 Industrial Boulevard
Sherbrooke, Quebec -Canada
J1L 1V8

Printed in Canada
Printed on 100% recycled paper

2010-11-15

X40083 Rev. Z

445 01 4083 22

PART 1

INSTALLATION

THE INSTALLATION OF OIL FIRED HEATING UNITS
SHALL BE IN STRICT ACCORDANCE WITH THE
REGULATIONS OF THE AUTHORITIES HAVING
JURISDICTION. IN CANADA CSA B139 AND IN THE
UNITED STATES NFPA NO.31-1992 INSTALLATION
CODES FOR OIL BURNING EQUIPMENT APPLY.

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.

1.1 SAFETY LABELLING AND WARNING SIGNS

DANGER, WARNING AND CAUTION

The words DANGER, WARNING and CAUTION are used to
identify the levels of seriousness of certain hazards. It is
important that you understand their meaning. You will notice
these words in the manual as follows:

Immediate hazards which WILL result in death or
serious injury.

SAFETY CONSIDERATIONS

DANGER

WARNING

Hazards or unsafe practices which CAN result
in death or injury.

CAUTION

Hazards or unsafe practices which CAN result in
personal injury, product or property damage.

1.2 SAFE INSTALLATION REQUIREMENTS

WARNING

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

The information contained in this manual is
intended for use by a qualified 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 death, bodily injury
and/or property damage.

WARNING

Fire hazard.
The furnace must be installed in a level position,

never where it will slope toward the front.
If the furnace is installed in that position, oil will

drain into the furnace vestibule and create a fire
hazard, instead of being directed into the
combustion chamber.

NOTE: It is the personal responsibility and obligation of the

customer to contact a qualified installer to ensure that the
installation conforms to governing local and/or national codes
and ordinances.

a. This furnace is NOT approved for installation in mobile

homes, trailers or recreational vehicles;

b. Do NOT use this furnace as a construction heater or to

heat a building under construction ;

c. There must be a sufficient supply of fresh air for

combustion as well as ventilation in the area where th e
furnace is located;

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 operating

conditions;
e. Visually check all oil line joints for leaks;
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 heat ing system. Take the time

to ensure that all steps were followed;
h. Follow the regulations of the NFPA Pamphlet No.31

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

placing and installing the oil storage tank;
i. Follow a regular service and maintenance schedule for

efficient and safe operation;

3

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 deter mine that it is

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

protected from direct contact with water.

1.2.1 Safety Rules

Your unit is built to provide many years of safe and
dependable service provided it is properly installed and
maintained. However, abuse and/or improper use can shorten
the life of the unit and create haza rds fo r you , the ow ner.

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 others. Carbon monoxide

can cause death and/or serious bodily injury. Therefore,

to help alert people of potentially dangerous carbon

monoxide levels, you should have carbon monoxide

detectors listed by a nationally recognised agency

(Underwriters Laboratories or International Approval

Services) installed and maintained in the building or

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

building or dwelling. Fire or smoke can cause death,

serious bodily injury, and/ or property damage. Ther efore,

in order to alert people to 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 bel ow ).

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

CAUTION

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

CAUTION

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

CAUTION

Do not use any commercially available soot remover.
This furnace has a ceramic fibre type of combustion
chamber. Normal servicing of this unit does not require
the cleaning of same. Use extreme caution if for any
reason you have to work in the area of the combustion
chamber.

1.2.2 Freezing Temperature and Your Structure

WARNING

Freezing temperature warning.
Turn off water supply.
If your heater 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 ke ep it from
operating if sensors detect abnormal conditions such as
exhaust flues obstructed by snow, ice o r de bris.

If the structure is unattended during cold weather you should
take the following precautions:

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. Contact a qualified service agency, if
required.

1.2.3 Installation regulations

All local and national code requirements governing the
installation of oil burning equipment, wiring and flue
connections MUST be followed. Some of the codes that may
be applicable are:

CSA B139 Installation Code for Oil Burning

Equipment

NFPA 31 Installation of Oil Burning Equipment
ANSI/NFPA 90B Warm Air Heating and Air Conditioning

Systems

ANSI/NFPA 70 National Electrical Code
CSA C22.1 Canadian Electrical Code

Only the latest issues of the above codes should be used.

1.3 POSITIONING THE FURNACE

CAUTION

Carefully check your furnace upon delivery for 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.

1.3.1 Location

The unit must be installed in a location where the
ambient and return air temperatures are over 15°C
(60°F).

Position 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.

4

TABLE 1

Minimum Installation clearances from combustible materials (Chimney installation*)

LOCATION APPLICA T ION OLR160 - OUF160

Sides

Back Furnace 45.72 cm (18") 2.54 cm (1")

Top Furnace casing or plenum 5.08 cm (2") 2.54 cm (1")

Bottom Furnace – combustible floor ** ø ø

Front Furnace 60.96 cm (24") 60.96 cm (24")

* See paragraph 1.4.3, p. 6 for Direct Vent application clearances.

** Combustible floor requires accessory bases CFB-1 or HFB-1.

Furnace 2.54 cm (1") 2.54 cm (1")
Supply plenum, warm air duct within 6‘ of furnace 2.54 cm (1") 2.54 cm (1")

However, do not install furnace directly on carpet or other

combustible material which can trap air under the furnace

floor.

The furnace must be installed level for safe and quiet

operation.

The required minimum clearances for this furnace are

specified in Table 1 above.

CAUTION

Do NOT operate furnace in a corrosive atmosphere

containing chlorine, fluorine or any other damaging

chemicals. Refer to Part 1, section 5.2.

1.4 VENTING

1.4.1 General

Furnaces can be vented in seve ra l way s:

Chimney Vented

Using the Beckett AFG or Riello 40-F burner, the furnaces can

be chimney vented with or without a b arometric damper. Th e

unit will operate at a negative overfire draft and flue draft.

WARNING

Poisonous carbon monoxide gas, fire and

explosion hazard.

Read and follow all instructions in this section.

Failure to properly vent this furnace can cause

death, bodily injury and/or property damage.

WARNING

Poisonous carbon monoxide gas hazard.

Never vent this furnace together with another

combustion appliance when side-wall venting.

To do so may result in asphyxiation and death to

the occupants.

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 for maximum efficiency and wit hout the use of a side-

OLR105 - OLF105 - NOLF105

OUF105 - NOUF105

1.4.2 Chimney installations

When set up for chimney venting, this furnace is certified for
use with an L-vent, A-vent, tile-lin ed and metal-liner-tile lined
chimney, and can be vented both with and without a
barometric draft damper. However, this furnace is not
approved for use without a barometric damper if it is to be
vented together with another oil-fired appliance such as a
water heater.

With a barometric damper

This furnace may be vented into a chimney of suitable size
and adequate chimney base temperature, as specified in the
Installation Code. When a bar ometric damper is used, the air
entering the damper reduces the possibility of vent
condensation. The relevant excerpt from the code is found in
this section and can be used as a guide where local or
national codes do not exist. One option to increase the
chimney base temperature is to use vent connection
insulation.

WARNING

Poisonous carbon monoxide gas hazard.
Never install a hand operated damper in the vent

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

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

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 gases is
raised. To offset the increased tendency for vent
condensation, the chimney must be lined. The liner must be
insulated according to t he insulati ng procedur e recommended
by the manufacturer of the liner. Also, the vent connector
should be as short as possible and be either of double wall
construction or of single wall constr uction with 2.54 cm (1”) of
insulation.

wall power vent. The unit will operate at a positive overfire

draft and flue draft.

5

CAUTION

When the furnace (chimney installation) is vented
together with other combustion appliances such as a
water heater, the allowable venting materials for use
with those appliances must be investigated (“L”-vent,
etc.).

Flue pipe sizing

The following table is an excerpt from the Installation Code
and indicates the permitted flue sizes and minimum base
temperatures for circular flues in chimneys with a thermal
resistance of less than R6 (6 ft
appliance, burner, or chimney is installed, chimney vent sizes
and maximum flue gas temperat ures shall comply with Table
2 (measured at the chimney connector with the barometric
damper shut, after 5 minutes o f operation).

Note: 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

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

Applying Ta ble 2

If a furnace with a 0.60 USGPH nozzle is to be connected to a

6.1 m (20') tall clay-lined masonry chimney, the thermal
resistance of this type of chimney is R2, (which is less than
R6). The actual firing rate at 156 psig is 1.25 x .60 = .75
USGPH. Therefore this table shall apply as follows:

The minimum size permitted shall be 10.16 cm (4") in. insid e
diameter;

The maximum size permitted shall be 12.70 cm (5") inside
diameter;

The minimum base temperature shall be about 160°C
(320°F).

1.4.3 Side-wall venting - DV-2000™

Direct Vent System

The furnace can be side-wall vented, without the use of a
side-wall power vent, with the high static pressure Beckett
AFII and Riello 40-BF oil burners. Outdoor combustion air

2

•hr •°F / Btu). Where a new

Masonry

2

with R4.5 ( 4.5 ft

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

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

a) 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;

b) One hole of minimal size 15.24 cm (6") is required to be

cut into the side-wall, and the terminal is designed to fit
through a minimum 2 x 8 joist space;

c)

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

d) The intake and vent circuits within the terminal can be

accessed for cleaning.

There are 3 main components to the DV-2000™ system; the
vent terminal kit VTK-1 (for models OLF/R105, OUF105,
NOUF105 and NOLF105) or VTK-2 (for models OLR160,
OUF160) and the insulated flexible venting material IFV3 (for
models OLF/R105, OUF105, NOUF105, NOLF105) or IFV4
(for models OLR160, OUF160) and the f ield-supplied 3” PVC
or ABS intake piping.

WARNING

Poisonous carbon monoxide gas hazard.
Even though the flexible venting is insulated, it

must not be run through an unheated space.
To do so can cause residual condensation inside

the stainless steel liner. This may eventually
perforate the liner and allow vent gasses to enter
the dwelling, which can result in death, personal
injury and/or property damage.

Insulated flexible venting - DV-2000™

The certified venting materia ls come in 3 lengths, Model No.
IFV3-15, IFV3-23 and IFV3-30 or IFV4-1 5, IFV4-23 and IFV4­30 for 160 models correspond to 15, 23 and 30' of 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:

1.5 m (5') minimum 9 m (30') maximum

must be directly connected to the burner or the DV­2000™ venting system will not function.

TABLE 2

Total input rating of all

connected appliances

kW BTU/h USGPH Min. Max. 11' 20' 28' 36'

21 70000 0.50 7.62 cm (3") 12.70 cm (5") 149°C (300°F) 204°C (400°F) 279°C (535°F) 385°C (725°F)
27 91000 0.65 7.62 cm (3") 12.70 cm (5") 135°C (275°F) 171°C (340°F) 221°C (430°F) 279°C (535°F)
31 105000 0.75 10.16 cm (4") 12.70 cm (5") 127°C (260°F) 160°C (320°F) 193°C (380°F) 246°C (475°F)
36 119000 0.85 10.16 cm (4") 12.70 cm (5") 121°C (250°F) 149°C (300°F) 179°C (355°F) 221°C (430°F)
41 140000 1.00 10.16 cm (4") 15.24 cm (6") 107°C (225°F) 149°C (300°F) 185°C (365°F) 221°C (430°F)
51 175000 1.25 10.16 cm (4") 15.24 cm (6") 116°C 240°F) 135°C (275°F) 160°C (320°F) 185°C (365°F)

Inside diameter of flue Minimum base temperature according to chimney height :

6

TABLE 3

Minimum clearances of side-wall vents

installation

PORTION OF VENT

CANADA AND

UNITED STATES

Vent pipe, up to vent terminal* 7.62 cm (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 shall be
considered as minimum requirements that can be
overridden by stricter local and national codes.

The vent shall not terminate

a. Dire ctly above a paved sidewalk or paved driv eway

that is located between two buildings, and that

serves both buildings;
b. Less than 2.1 m (7') above any paved driveway;
c. Within 1.8 m (6') (in Canada) of a window or door, or

mechanical air supply inlet to any building;*
d. Within 1.8 m (6') (in Canada) from the soffit of the

roof of the structure;*
e. Above a gas meter/regulator assembly or at least 0. 9

m (3') from the vertical centreline of the regulator;
f. Within 1.8 m (6') of any gas service regulator vent

outlet, or within 0.9 m (3') of an oil tank vent, or an oil

fill inlet;
g. Less than 0.3 m (1') above ground level;
h. Within 1.8 m (6') of any other combustion air inlet;
i. Within 1.8 m (6') of a property line;
j. Underneath a veranda, porch or deck;
k. So that the flue gases are directed at combustible

material or any openings of surrounding buildings

that are within 1.8 m (6');
l. Less than 0.9 m (3') from an inside corn er of an “L”-

shaped structure;
m. So that the bottom of the vent termination opening is

less than 0.3 m (1') above any surface that may

support ice, snow, or debris;
n. So that t he flue gas es are dir ected towar d brick work,

siding or other construction, in such a manner that

may cause damage from heat or condensation from

flue gases.

*For installations in the U.S.A. r efer to Section 6.7.3. 4
of the NFPA 31.

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.

WARNING

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.

DNS-0623 Rev. A

FIGURE 1

WARNING

Do not enclose the vent pipe in a ceiling or combustible
structure.

Connection to the furnace breech - DV-2000™

1. Remove the breech plate that is on the furnace by removing
the brass nuts;

2. Determine in which direction the venting will be routed and
then install the special side-wall venting breech plate provided
in the VTK Series kit so that the breech plate test port will be
accessible after installation. Do not install the breech plate
with the test port pointing downward. Tigh ten the brass nuts;

3. Remove the spin sleeve by unscrewing it in a counter­clockwise direction;

4. Using tin snips, cut the spin sleeve back by 30.48 cm (12”).
Ensure the snips are well a djus t ed a n d s har p or t h e c ut end of
the venting will be too jagged to start the threads of the spin
sleeve;

5. Using tin snips, cut the corrugated aluminium layer (outer skin)
back by 12.70 cm (5"). 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;

6. Prepare the furnace breech end of the insulated flex vent by
first screwing the spin sleeve onto th e corrugated aluminium
jacket (see Figure 1.2) until the trailing edge of the spin sleeve
is about 30 cm (12") from the end of the vent (see Figu re 1. 3);

7

THREAD SPIN SLEEVE
ONTO OUTER SLEEVE

CUT OUTER SLEEVE

BACK 5”

THREAD SPIN SLEEVE BACK 10” CUT STAINLESS STEEL

CORE BACK BY 3”

FIGURE 1.3 FIGURE 1.4

FIGURE 1.1 FIGURE 1.2

DRIVE THREE STAINLESS STEEL
SCREWS, STARTING NEAR TOP

FIGURE 1.5 FIGURE 1.6

8

INSERT STAINLESS STEEL
CORE ONTO BREECH TUBE

CORRECT BAND
OVERLAP

FIGURE 1.9 FIGURE 1.10

FIGURE 1.7 FIGURE 1.8

SEALANT FLOWING OUT FROM UNDER BAND CLAMP AT
TERMINAL

SEALANT OUTFLOW

FIGURE 1.11

APPLY THE SEALANT TO
THE TUBE END

9

SEALANT FLOWING
OUT FROM UNDER
BAND CLAMP AT
BREECH

SEALANT OUTFLOW

TWIST SPIN SLEEVE TIGHTLY INTO
BREECH COLLAR

TWIST SPIN SLEEVE TIGHTLY INTO RECESS

INSTALL
STABILIZER
SHROUD

CAULK TO SEAL STABILIZER
SHROUD TO THE WALL

FIGURE 1.13 FIGURE 1.14

FIGURE 1.12

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

10

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

8. Cut the c orrugated stainless steel core back by 7.6
cm (3") on the IFV Series vent. You should now have
about 7.6 cm (3") of insulation hanging out past the
stainless steel core (see Figure 1.4);

9. Push the stainless steel core onto the breech p ipe as
far as it will go (see Figure 1.5) and mechanically
attach the vent to th e 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 in the centre at the top. Start the
drill point of the screws in the valleys of the
corrugations 9-16 mm (3/8"-5/8") back from the end
of the stainless steel core, so the screw heads can
be properly sealed in the following operations (see
Figure 1.6);

10. With the stainless steel core now firmly attached to
the breech, tear off one green gum-sea ling strip f rom
the backing. Wrap the seal strip around the joint,
always keeping t he centreline of the seal strip over
the line where the corrugated stainless steel core
makes the transition to th e smooth outer surface of
the breech pipe. In other words, the seal strip must
be centred over the joint. After wrapping the seal
strip around once, allow a 12 mm (1/2") overlap and
tear off the residual length (see Figure 1.7);

11. Break the residual length of seal strip in to 3 equal
parts and stick them onto the heads of the stainless
steel self-drilling screws so t hat they are completely
covered;

12. 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 lin es up with the edg e 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 gear head of the
draw clamp (see Figure 1.8). Tighten the band clamp
with considerable torqu e t o c au se t h e gum s e a l t o 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;

13. 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;

14. Tuck the vent insulation into the breech collar;

15. 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);

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 0.25 m (10") from the end of the
vent;

2. Us ing s harp ti n snips, c ut the al umi nium oute r sleeve
back by 0.13 m (5") on 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 76 mm (3") on
the IFV Series vent. You should now have about 76 mm (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
equally spaced around the circumference of the stainless steel
core, starting with the first screw in the centre at the top. Start
the drill point of the scre ws in th e valleys of the corrugations 9­16 mm (3/8"-5/8") back from the end of the stainless steel
core;

6. With the stainless steel core now firmly attached to the
terminal, tear off the other green gum-sealing strip from the
backing. Wrap the seal strip around the joint, always keeping
the centreline 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 a 12 mm (1/2") overlap and tear
off the residual length;

7. Break the residual length of seal strip in to 3 equal parts and
stick them onto the heads of the stainless steel self-drilling
screws so that they are comp lete ly co ve red ;

8. Position the other stainless steel band clamp over the gum
seal joint so that the edge of the clamp cl osest to the terminal
lines up with the edge of the gum se al that is closest to the
terminal. Tighten the band clam p with considerable torque to
cause the gum seal be s queez ed int o all cr evic es and t o ooz e
out of the end of the clamp closest to the te rminal (see Fig ure

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 0.15 m (6") hole in the side-wall i n accordance with the

location considerations outlined in the previous section;

2. Fasten the wall plate to the inside-wall using 4 field-pr ovided

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 ac cess the top right wall
plate screw hole. For concrete and block, Tapcon™ screws or
equivalent are recommend ed. Install the wall plate so that th e
top of the hole in the wall plat e is posit i o ned 3 mm ( 1/8 ") l ower
than the top of the 0.15 m (6") hole in the wall. This will
accommodate the proper 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

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
50 mm (2") past the outside wall;

6. Install the stabiliser shroud and replace the two

mounting screws. (see Figure 1.13);

7. On concrete and block wall installati ons 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 circumfere nce of t he j oint 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, making sure the pressure switch is located at
the top, in a horizontal position;

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 over t ighten 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 posi tioning;

11. Tighten the clamp on the wall plate to secure the

terminal in place;

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 surfac es
such as lapped siding;

13. Install the end cone and replace the two mounting

screws;

14. Support the vent and intake air piping so tha t a 6 to

13 mm (1/4 to 1/2") s lope (toward the outside) r e s u lts
for proper drainage out the terminal body.

Connection of combustion air piping to the terminal
DV-2000™

Refer to Part 1, section 5.3 (1.5.3), Outdoor Combustion
Air – Side-wall Venting, DV-2000™ for a complete
description.

1.5 AIR FOR COMBUSTION

WARNING

Poisonous carbon monoxide gas hazard.
Comply with NFPA or CSA standards for the

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

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

1.5.1 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 requirements for the
furnace. However, home improvements such as new windows,
doors, and weather stripping hav e drastically reduced the volume
of air infiltratio n i n to the home .

Home air exhausters are common. Bathroom 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 Systems (HRVS) are gaining in
popularity. HRVS are not designed to supply combustion air. If not
properly balanced, a serious negative pressure condition could
develop in the dwelling.

1.5.2 Contaminated Combustion Air

Installations 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 be used for
combustion.

The following areas or types of structures may contain or be
exposed to certain substa nces, potentially requiri ng outside air for
combustion:

a. Commercial buildings;
b. Buildings with indoor pools;
c. Furnaces installed near chemical storage areas.

Exposure to the following substances:
a. Permanent wave chemicals for hair;
b. Chlorinated waxes and cleaners;
c. Chlorine based swimming pool chemicals;
d. Water softening chemicals;
e. De-icing salts or chemicals;
f. Carbon tetrachloride;
g. Halogen type refrigerants;
h. Cleaning solvent (such as perchloroe thy lene);
i. Printing inks, paint removers, varnishes, etc. ;
j. Hydrochloric acid;

k. Solvent based glue;
l. Antistatic fabric softeners for clothes dryers;
m. Acid based masonry cleaning materi als.

1.5.3 Ducted outdoor combustion air

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 and the
Beckett AFG for use with conventional chimne y 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.

12

Outdoor combustion air kit – chimney venting

The following kit has been certified for use on this
appliance. The kit contains 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 cl ose and the burner will dra w all
air from the outdoors again.

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 a 0.10 m (4") galvani zed steel
air duct or with a 0.10 m (4") flexible aluminium air duct. It
is recommended that the metallic air ducting material be
insulated from the air intake up to 1.5 m (5') from the
burner, to avoid condensation on the outside of the intake
pipe.

CAD-1 This air duct kit consists of 7.6 m (25') of
insulated UL/ULC Listed Class 1 air duct and two 0.10 m
(4") steel band clamps. The duct incorporates a
corrugated flexible aluminium core, surrounded by
fibreglass insulation and a viny l 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 to 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 DV-2000™ venting system is a sealed system and
completely isolates the furnace from the interior of the
building. The burner is total ly unaffected by any pr essure
fluctuations within the building which makes it ideal for
tight home construction.

The DV-2000 ™ venting system req uires ad ditio nal 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 Sewe r Pipe, or ABS plast ic pip e,
fittings and sealant. Also, installation procedures, piping
and fittings must conform to the following ANSI /ASTM
standards:

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
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” redu ce r (Riello 40-BF burner only);
e. 2".-.9 0° elbow, street type, female-male (Riello 40-BF burn er

only);

f. 3" female-female PVC or ABS coupling (not sewer pipe)

(Beckett AFII burner only);

g. Transition bushings to go fr om PVC or ABS to ASTM D2729

Septic Sewer Pipe (if applicable).

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

Intake pipe length - DV-2000™

The DV-2000 ™ venting system has been certified for 36
equivalent meters (120') of 3" intake pipe. Count a 90° elbow as

3.0 equivalent meters (10') and a 45° elbow as 1.5 equivalent

meters (5') in the calculation.
For Example:
2 lengths of 1.5 m (5') = 3.0 equivalent meters (10')

1 length of 3.0 m (10') = 3.0 equivalent meters (10')
3 elbows 90° = 9.0 equivalent me ters (30 ')
2 elbows 45° = 3.0 equivalent me ters (10 ')
1 elbow 90° = 3.0 equivalent me te rs (10')
1 elbow 45° (Riello Burner) = 1.5 equivalent meters ( 5')

Total =23.0 equivalent meters (75'),

Intake pipe installation - DV-2000™

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

Beckett AFII burner

Remove the burner intake cover by removing the 3 screws
securing it in place. Discard the cover and screws. Liberally apply
silicone around the end of a 3" coupling and fully insert the
siliconed end into the burner opening. Fasten securely with 3 self­tapping sheet metal screws.

Riello 40-BF burner

Fully insert the female end of the 2" - 90° street elbow into the
combustion air fitting on top of the burn er. Fasten securely with 3
self-tapping sheet metal screws. Cement the 2" end of the 3"
female to the 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 combust ion air fitting.
The fitting will have to be silicone sealed as the fit is a bit loose.
Fasten securely with 3 self- tapping she et me tal screws.

Terminal connection

Insert the 3" - 90° female-female elbow onto the st ainless steel air
intake fitting located o n the right side of the vent term inal (viewed
from the rear). Fasten securely with 3 self-tapping sheet metal
screws.

which is acceptable.

13

Intermediate piping

Piping 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 section 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", wher eas Septic Sewer Pi pe has
a typical outside diameter of 3.25".

1.6 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 be installed
in sequence from tank to burner. Be sure that the oil line
is clean before connecting to the burner. The oil line
should be protected to eliminate any possible damage.
Installations having the fuel oil tank below burner level
must employ a two pipe fuel supply system with an
appropriate fuel pump; for more th an a 2.4 m (8') r ise us e
a 2-stage pump; for more than 4.9 m (16') rise an
auxiliary pump.

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

Prior to each heating season, have the entire oil
distribution system checked for leaks.

1.7 BURNER INSTALLATION

Mounting the burner

1. Check the insertion depth of the burner tube. Refer

to the Technical Specifications p. 23 to 25.

2. The burner mounting plate on the furnace has a 4-

bolt configuration;

3. Position the mounting g asket between the mounting

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

Checking the polarity

The oil burner used on the furnace has a solid state
control system which is sensitive to the proper connection
of the hot and neutral power lines. The controls will be
damaged if the two lines are reversed.

1. Set your voltmeter to line voltage;

2. Place one prong on your grounded electric entry box and one

prong on the black wire;

3. Read the voltage;

4. If the voltage is zero, check the white wire. If line voltage
shows, reverse the 115-volt leads entering the furnace
junction box;

5. If you do not have a voltmeter, use a pilot light.

FIGURE 2

Checking the nozzle

DNS-0864 Rev. A

The burner is equipped with the appropriate nozzle. However, if
another size nozzle or replacement nozzle is required, use the
manufacturer’s nozzle data concerning spray angle, type as
shown in Tables 4.1 to 4.3. Note that all nozzle sizes are based
on a pump pressure of 100 psig.

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

Checking air and turbulator settings

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

Checking the 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 f illed with clean
oil.

IMPORTANT

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

14

WARNING

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 injur y
and/or property damage.

NOTE: You may notice a slight odour the first time

your furnace is operated. This will soon disappear.
It is only the oil used on certain parts during
manufacturing.

1.8 BLOCKED VENT SHUT-OFF DEVICE
(BVSO) For chimney venting

WARNING

It is imperative that this device be installed by
a qualified technician.

This device is designed to detect the insufficient
evacuation of combustion gases in the event of a vent
blockage. In such a case the thermal switch will shut
down the oil burner. The device will then need to be
restarted MANUALLY.

Refer to the wiring diagrams and the detailed
instructions supplied with the BVSO for the installation
and wiring procedures. The length of wires supplied with
the unit is such that the safety device must be installed
between the flue outlet of the appliance and the draft
regulator, as indicated in the instructions.

It is further imperative that the BVSO be maintained
annually. Refer to the instructions supplied with the
device itself, as well as Section 3. of this Manual.

CAUTION

Do NOT use the BVSO on a positive pressure
venting system (Sealed Combustion System or
Direct Vent). Follow the instructions supplied with
the venting system.

1.9 INSTALLING ACCESSORIES

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 death, bodily
injury and/or property damage.

1.9.1 Electronic air cleaner

Wire terminals 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 wire d into the furnac e control box. Most
modern EACs have the required integral airflow proving switch.
Wire the electronic air cleaner between terminals #5 and #2. Refer
to wiring diagram, Figure 6.

1.9.2 Humidifier

The red wire from burner can be used to direct 115 volts @ 1.0
Amp maximum to the transformer

powering the humidifier. The
humidifier will be energised anytime the burner is operating in the
“Heating Mode”. Refer to wiring diagram, Figure 6.

1.9.3 Air conditioning

An air conditioning coil may be installed on the supply air side only.
Also, notwithstanding the evaporator coil manufacturer’s
instructions, a minimum of 15 cm (6") c learance must be allowed
between the bottom of the coi l drain pan and the top of the heat
exchanger. Wire the thermostat and condensing unit contactor as
indicated in Figure 6 .

1.9.4 Ductwork and Filter

Installation

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

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

Install air conditioning cooling coil (evaporator) on downstream
side from the supply air plenum of the furnace. If a separate
evaporator and blower unit is used, install appropriate sealing
dampers for air flow control. Cold ai r fro m the ev apor at or c o il go i ng
through the furnace could cause condensation an d shor ten fu rna ce
life.

CAUTION

Dampers (purchased locally) MUST be automatic.

WARNING

Poisonous 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.

15