Page 1
INSTALLATION
E2012 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
IMPORTANT
This unit must be serviced annually by a licensed
professional technician, or equivalent.
WARNING
Improper installation, adjustment, alteration, ser
vice, or maintenance can cause injury or property
damage. Refer to this manual. For assistance or
additional information, consult a licensed profes
sional installer, or equivalent, or service agency.
WARNING
Do not store or use gasoline or other flammable va
pors and liquids in the vicinity of this or any other
appliance.
CAUTION
When venting this appliance, keep vent terminal
free of snow, ice and debris.
INSTRUCTIONS
ELO183DH Series Units
OIL UNITS
506903-01
12/2012
Supersedes 04/2012
Table of Contents
Elite Series Oil Furnace 1........................
Shipping and Packing List 1......................
Unit Dimensions 2...............................
ELO183DH Unit Parts Arrangement 3.............
Oil Burner Parts Arrangement 3...................
Requirements 4.................................
Combustion & Ventilation Air 5....................
Installation 7....................................
Adjustments 8..................................
Venting 9......................................
Flue Connections 10..............................
Supply & Return Air Plenums 11...................
Optional Filter Kit 11..............................
Oil Supply Line Sizing 11.........................
Oil Supply Line & Filter Connections 13.............
Leak Check 13...................................
Electrical Wiring 13...............................
Unit Start-Up & Adjustments 15....................
Service 16......................................
Burner Control 17................................
Troubleshooting 19...............................
Start-Up & Performance Checklist 24...............
Elite® Series Oil Furnace
These instructions are intended as a general guide and do
not supersede local codes in any way. Only licensed pro
fessional technicians, or equivalent, can install and service
the Lennox Elite® Series ELO183DH oil furnaces. In Cana
da, refer to CSA B139 for recommended installation proce
dures. Consult authorities who have jurisdiction before
installation.
WARNING
Never push the ignition reset button more than one
time. Pushing the reset more than once can lead to
a build-up of oil within the heat exchanger resulting
in a fire or explosion.
Shipping & Packing List
Litho U.S.A.
CAUTION
As with any mechanical equipment, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
12/12
*2P1212*
1- Assembled oil furnace
1- Draft control
2- Nozzels
Check the components for shipping damage. If you find
any damage, immediately contact the last carrier.
Page 1
506903-01
*P506903-01*
Page 2
ELO183DH Unit Dimensions - Inches (mm)
Model No. A B C D E F G H
ELO183DH
101/114P36
ELO183DH
135/150P60
in. 20‐1/2 20‐1/2 18 18 18 18 3 10‐1/4
mm 521 521 457 457 457 457 76 260
in. 23‐1/2 23‐1/2 21 21 21 21 4‐3/4 11‐3/8
mm 597 597 533 533 533 533 121 289
53 (1346)
4 KNOCKOUTS
(For Suspending)
TOP VIEW
14‐1/2
3‐1/2
(89)
(368)
AIR
F A
FLOW
(4) SPACER LEGS
F
RETURN
E
AIR
OPENING
TOP VIEW
A
A
8
(203)
C
SUPPLY
D
AIR
OPENING
END VIEW FLUE OUTLET
3/4
(19)
HEAT EX
CHANGER
CLEAN OUT
PORTS (3)
1
(25)
BURNER
HORIZONTAL POSITION
OPTIONAL DOWNFLOW COMBUSTIBLE FLOOR BASE
B
3/4
(19)
FRONT OF
FURNACE
FLUE OUTLET
59 (1499)
G
32‐1/2 (826)
H
SIDE
VIEW
RETURN
AIR
3/4
(19)
E B
RETURN
AIR
SUPPLY
AIR DUCT
(Not
Furnished)
AIR
FLOW
32‐1/2
(826)
59
(1499)
HEAT
EXCHANGER
CLEAN OUT
PORTS (3)
BURNER
3/4
8
(203)
SUPPLY AIR OPENING
(19)
DC
SUPPLY AIR OPENING
SIDE VIEW FRONT VIEW
DOWNFLOW POSITION
101/114—
16‐1/4(413)
H
135/150—
20‐1/4(514)
FLUE
OUTLET
101/114—
16‐1/4(413)
135/150—
20‐1/4(514)
BURNER
Additive Base Raises Furnace
3/4 in. (19 mm) Inch above Floor Level
OPTIONAL
DOWNFLOW
ADDITIVE
BASE
COMBUSTIBLE
FLOOR
Page 2
Page 3
ELO183DH Unit Parts Arrangement
BECKETTR
AFG BURNER
CLEAN-OUT PORT
CLEAN-OUT PORT
FLUE OPENING
HEAT EXCHANGER
INDOOR
BLOWER
CONTROL BOX
Figure 1
ELO183DH Oil Burner Parts Arrangement
MAIN
HEAT
SHIELD
AIR TUBE WITH
ELECTRODE
ASSEMBLY AND
NOZZLE INSIDE
COPPER OIL
TUBE
HOUSING
ESCUTCHEON
PLATE
OIL DELAY
FUEL PUMP
VALVE
AIR BAND AND
AIR SHUTTER
Figure 2
IGNITER
BLOWER WHEEL
WITH AIR GUIDE
(Inside housing)
BURNER CONTROL
(with Reset Button)
BLOWER
MOTOR
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Page 4
Requirements
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose you
to fiberglass wool dust. Breathing this may cause
lung cancer. (Fiberglass wool is known to the State
of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact
your supervisor.
Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379-9900
air openings are required. Dimensions of combustion air
openings are shown in table 1. One opening shall be below
burner level and the other opening shall be no more than 6
inches from the room's ceiling.
Combustion air openings should provide a minimum free
area one‐half square inch per 1,000 Btu per hour input.
This combustion air should be brought into the area con
taining the furnace below the level of the furnace burner.
IMPORTANT
An opening to the outside for combustion air is
strongly recommended, especially in new homes.
Refer to table 1 or the unit rating plate for specific
combustion air opening dimensions.
Table 1
Combustion Air Opening Dimensions
Model No. (2 openings required)
WARNING
Improper installation, adjustment, alteration, ser
vice or maintenance can cause property damage,
personal injury or loss of life. Installation and ser
vice must be performed by a qualified installer or
service agency.
Installation of Lennox oil-fired furnaces must conform with
the National Fire Protection Association Standard for the
Installation of Oil Burning Equipment, NFPA No. 31, the
National Electrical Code, ANSI/NFPA No.70 (in the
U.S.A.), CSA Standard CAN/CSA-B139 (in Canada),
Installation Code for Oil Burning Equipment, the Canadian
Electrical Code Part1, CSA 22.1 (Canada), the recom
mendations of the National Environmental Systems Con
tractors Association and any state or provincial laws or lo
cal ordinances. Authorities having jurisdiction should be
consulted before installation. Such applicable regulations
or requirements take precedence over general instruc
tions in this manual.
Chimneys and chimney connectors must be of the type
and construction outlined in section 160 of NFPA No. 31.
Air for combustion and ventilation must conform to stan
dards outlined in section 140 of NFPA No. 31 or, in Cana
da, CSA Standard B139. When installing ELO183DH units
in confined spaces such as utility rooms, two combustion
ELO183DH
-101/114
ELO183DH
-135/150
This unit is approved for clearances to combustible materi
al as listed unit rating plate and in tables 2 or 3. Unit service
and accessibility clearances take precedence over fire
protection clearances.
10” X 20”
11” X 22”
Table 2
Horizontal Installation Clearances
Clearances Inches (mm)
Top of Cabinet 3 (76)
*Bottom and Rear of Cabinet 1 (25)
Front of Cabinet 24 (610)
Service Clearance (Front) 24 (610)
End of Supply Plenum 0 (0)
Supply Air Opening 0 (0)
Return Air Opening 0 (0)
Above Horizontal Warm Air Duct
within 3 ft. (914mm) of Furnace
Flue Pipe Horizontal 7 (178)
Flue Pipe Vertical 7 (178)
*NOTE-When furnace is installed on combustible floor,
1” (25 mm) spacer legs must be installed to elevate unit
off of mounting surface.
0 (0)
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Page 5
Table 3
Downflow Installation Clearances
Clearances Inches (mm)
Bottom of Plenum and Ductwork 1 (25)
Plenum Sides 1 (25)
Side of Cabinet 1 (25)
Rear of Cabinet 1 (25)
Front of Cabinet 16 (406)
Service Clearance (Front) 24 (610)
Flue Pipe Horizontal 1 (25)
Flue Pipe Vertical 7 (178)
Return Air Opening 0 (0)
*Floor *Combustible
*NOTE-Clearance for installation on combustible floor if
optional additive base is installed between the furnace
and combustible floor. Not required in add-on coiling ap
plications.
NOTE - Downflow Application Only - For installation on
combustible floors, appliance shall not be installed directly
on carpeting, tile or other combustible material other than
wood flooring. When installed on wood flooring, the addi
tive base must be used. See Unit Dimension illustration.
Combustion & Ventilation Air
Homes built with energy conservation in mind use tight
construction practices. These houses are sealed so well
that it becomes necessary to provide a means of bringing
in air from outside for combustion. Also, exhaust fans, ap
pliance vents, chimneys and fireplaces force additional air
that could be used for combustion out of the house. Unless
outside air is brought into the home for combustion, nega
tive pressure (pressure outside is greater than inside pres
sure) will build to the point that a down draft can occur in the
furnace vent pipe or chimney. Combustion gases enter the
living space creating a potentially dangerous situation. Ne
gative pressure may also interfere with proper combus
tion, causing sooting within the heat exchanger.
The importance of the previous paragraph cannot be over
stated. Users may inadvertently block fresh air intakes af
ter installation.
In the absence of local codes concerning air for combus
tion and ventilation, the following section outlines guide
lines and recommends procedures for operating oil fur
naces in a manner that ensures efficient and safe
operation. Special consideration must be given to com
bustion air needs as well as requirements for exhaust
vents and oil piping.
Combustion Air Requirements
NOTE - Unit must be adjusted to obtain a temperature rise
within the range listed in table 8.
When used in conjunction with a evaporator coil, the fur
nace shall be installed in parallel with, or on the upstream
side of the evaporator coil. In a parallel flow arrangement,
the dampers, or other measures used to control flow of air
flow, shall be adequate to prevent chilled air from entering
the furnace. If the furnace is manually operated, it must be
equipped with means to prevent operation of either unit un
less dampers are in the full‐heat or full‐cool position.
When installed, furnace must be electrically grounded in
accordance with local codes or, in the absence of local
codes, with the current National Electric Code, ANSI/
NFPA No. 70, if an external electrical source is utilized.
Field wiring connection with unit must meet or exceed
specifications of type T wire and withstand a 63_F (17_C)
temperature rise.
Notice to Home Owner
This furnace is equipped with safety devices that protect
you and your property. If one or more of these devices is
activated, furnace operation will stop. If your home is left
unattended for an extended period of time, equipment op
eration must be checked periodically. If this is not possible,
the water supply to the house should be shut off and the
pipes should be drained. This will prevent problems
associated with a NO HEAT condition (frozen pipes, etc.)
CAUTION
Insufficient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also cause
excess water in the heat exchanger resulting in rust
ing and premature heat exchanger failure. It can also
cause property damage.
All oil‐fired appliances require air to be used for the com
bustion process. If sufficient amounts of combustion air
are not available, the furnace or other appliance will oper
ate in an inefficient and unsafe manner. Enough air must
be provided to meet the needs of all fuel‐burning ap
pliances, as well as appliances such as exhaust fans which
force air out of the home. When fireplaces, exhaust fans,
or clothes dryers are used at the same time as the furnace,
much more air is required to ensure proper combustion
and to prevent a down‐draft situation. Insufficient amounts
of air also cause incomplete combustion which can result
in sooting. Requirements for providing air for combustion
and ventilation depend largely on whether the furnace is
installed in an unconfined or confined space.
Unconfined Space
An unconfined space is an area such as a basement or
large equipment room with a volume greater than 50 cubic
feet (1.4 cubic meters) per 1,000 Btu (293 W) per hour of
the combined input rating of all appliances installed in that
space. This space also includes adjacent rooms which are
not separated by a door. Though an area may appear to be
unconfined, it might be necessary to bring in outdoor air for
combustion if the structure does not provide enough air by
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Page 6
infiltration. If the furnace is located in a building of tight
construction with weather stripping and caulking around
the windows and doors, follow the procedures outlined for
using air from the outside for combustion and ventilation.
Confined Space
A confined space is an area with volume less than 50 cubic
feet (1.4 cubic meters) per 1,000 Btu (293 W) per hour of
the combined input rating of all appliances installed in that
space. This definition includes furnace closets or small
equipment rooms.
When the furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space con
taining the furnace, the return air must be handled by ducts
which are sealed to the furnace casing and which termi
nate outside the space containing the furnace. This is es
pecially important when the furnace is mounted on a plat
form in a confined space such as a closet or small
equipment room. Even a small leak around the base of the
unit at the platform or at the return air duct connection can
cause a potentially dangerous negative pressure condi
tion. Air for combustion and ventilation can be brought into
the confined space either from inside the building or from
outside.
Air from an Adjacent Space
If the confined space housing the furnace adjoins space
categorized as unconfined, air can be brought in by provid
ing two permanent openings between the two spaces.
Each opening must have a minimum free area of 1 square
inch (6.4 square centimeters) per 1,000 Btu (293 W) per
hour of the total input rating of all fuel‐fired equipment in the
confined space. Each opening must be at least 100 square
inches (614.5 square centimeters). One opening shall be
within 12” (305 mm) of the top of the enclosure and one
opening within 12” (305 mm) of the bottom (See figure 1).
Equipment In Confined Space
All Air From Inside
Chimney or
t
Oil Ven
Air from Outside
If air from outside is brought in for combustion and ventila
tion, the confined space shall be provided with two perma
nent openings. One opening shall be within 12” (305 mm)
of the top of the enclosure and one within 12” (305 mm) of
the bottom. These openings must communicate directly or
by ducts with the outdoors or spaces (crawl or attic) that
freely communicate with the outdoors or indirectly through
vertical ducts. Each opening shall have a minimum free
area of 1 square inch (6.4 square centimeters) per 4,000
Btu (1172 W) per hour of total input rating of all equipment
in the enclosure. (See figure 2.) When communicating with
the outdoors through horizontal ducts, each opening shall
have a minimum free area of 1 square inch (6.4 square
centimeters) per 2,000 Btu (586 W) per total input rating of
all equipment in the enclosure (See figure 3).
Equipment In Confined Space
(Inlet Air from Crawl Space and Outlet Air to
Chimney or
Oil Vent
Oil
Furnace
Ventilation
Louvers
(For unheated
crawl space)
NOTE-The inlet and outlet air openings shall each have a free area of
at least one square inch (6.4 square centimeters) per 4,000 Btu (1172
W) per hour of the total input rating of all equipment in the enclosure.
All Air From Outside
Ventilated Attic)
Ventilation Louvers
(Each End Of Attic)
Outlet
r
Ai
Water
Heater
Inlet
Air
Figure 2
Oil
Furnace
NOTE-Each opening shall have a free area of at least 1 square inch
(6.4 square centimeters) per 1,000 Btu (293 W) per hour of the total
input rating of all equipment in the enclosure, but not less than 100
square inches (614.5 square centimeters).
Water
Heater
Figure 1
Openings
(To Adjacent Room)
When ducts are used, they shall be of the same cross-sec
tional area as the free area of the openings to which they
connect. The minimum dimension of rectangular air ducts
shall be no less than 3” (76 mm). In calculating free area,
the blocking effect of louvers, grilles, or screens must be
considered. If the design and free area of protective cover
ing is not known for calculating the size opening required, it
may be assumed that wood louvers will have 20 to 25 per
cent free area and metal louvers and grilles will have 60 to
75 percent free area. Louvers and grilles must be fixed in
the open position or interlocked with the equipment so that
they are opened automatically during equipment opera
tion.
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Page 7
Equipment In Confined Space
All Air From Outside
Chimney
Or Oil
Vent
Oil
Furnace
NOTE-Each air duct opening shall have a free area of at least one
square inch (6.4 square centimeters) per 2,000 Btu (586 W) per hour
of the total input rating of all equipment in the enclosure. If the equip
ment room is located against an outside wall and the air openings
communicate directly with the outdoors, each opening shall have a
free area of at least one square inch (6.4 square centimeters) per
4,000 Btu (1172 W) per hour of the total input rating of all other equip
ment in the enclosure.
Water
Heate
r
Outlet Air
Inlet Air
Figure 3
CAUTION
Combustion air openings in the front of the furnace
must be kept free of obstructions. Any obstruction
will cause improper burner operation and may re
sult in a fire hazard or injury.
CAUTION
The barometric draft control shall be in the same at
mospheric pressure zone as the combustion air in
let to the furnace. Deviation from this practice will
cause improper burner operation and may result in
a fire hazard or injury.
Horizontal Application
The ELO183DH furnace is shipped from the factory in the
horizontal left hand air discharge application. Air flow may
be reversed to right side discharge or unit may be used as
downflow.
1. Reversing Airflow for Right Hand Discharge
D Rotate the furnace 180_ so that, when facing the
front, the warm discharge is to the right.
D Remove the nuts in the bracket that hold the burn
er to the furnace front. Rotate the burner and burn
er mounting plate 180_ and reinstall the nuts.
D Remove the screws that hold the limit control in
place. Use the provided knockout hole to relocate
the limit control to the top side of the front panel.
2. Installation on Non-Combustible Material
D Set the furnace on non‐combustible material
(such as concrete blocks, bricks or angle iron).
Install spacer legs, provided with unit, by using the
cabinet screws from each corner of the unit.
D Use a level to check the level of furnace in at least
two directions. Use shims or non‐combustible ma
terial. A minimum clearance of 1” must be main
tained between bottom of furnace and combus
tible material.
3. Suspended Installation
D To suspend the furnace, remove knockouts in top
of panel at warm air discharge and at blower panel
(Refer to unit dimensions). Use 3/8” rods cut to de
sired length.
D Use one flat washer and two nuts for each rod (a
nut and washer on the inside of unit and the other
“locking” nut on the outside of unit; see figure 4).
Level the unit by adjusting the nuts on the inside of
unit.
Hanger Rod Installation
ROD
LOCKING
NUT
TOP OF
FURNACE
Installation
When installed, ELO183DH furnaces must be level. If the
furnace is not level, place fireproof wedges or shims be
tween the low side of the furnace and floor. Make sure the
weight of the furnace is evenly distributed on all four cor
ners. Strain on sides of the cabinet causing cracking and
popping noises may occur if weight of furnace is not evenly
distributed.
Set the unit in desired location keeping in mind the clear
ances list in tables 2 and 3. Also keep in mind oil supply
connections, electrical supply, flue connections and suffi
cient clearance for installing and servicing unit.
ELO183DH series units may be installed in a crawl space
under a house, utility room or in a wide variety of sus
pended applications.
WASHER
NUT
BLOWER COMPARTMENT
DIVISION PANEL
Figure 4
Downflow Application
When installing the ELO183DH in a downflow position and
on combustible flooring, a combustible floor base must be
used. See Unit Dimension illustration.
1. Rotate the furnace so that return is on top and supply
is on bottom. Refer to table 3 for clearances to com
bustible flooring.
2. Remove the nuts in the bracket that hold the burner to
the furnace front. Rotate the burner and burner mount
ing plate 90_ and reinstall the nuts.
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Page 8
3. It is also recommended that the upper rear screw hold
ing the blower housing to the blower deck be removed
before installation in a closet. Removing this screw al
lows for easy service and removal of the blower as
sembly in a closet installation.
Adjustments
Neither the nozzle setting nor the air adjustments are fac
tory set. The furnace is fire-tested and the limit control is
checked to make sure it functions properly; no factory set
tings are made. During installation, the furnace must be
adjusted to ensure proper operation. The installing dealer/
contractor must have and use proper test equipment in or
der to correctly adjust the oil furnace. The use of test equip
ment is more critical than ever due to tighter tolerances
needed to keep the furnace operating efficiently.
Among the test equipment for an oil furnace, the proper
combustion test kit should contain the following:
D Draft gauge
D CO
or O2 analyzer
2
D Smoke tester
D Pressure gauge
D High temperature thermometer
D Oil vacuum gauge
D Beckett T-501 or Z-2000 nozzle gauge
D Knowledge of proper test equipment operation
CAUTION
Improper nozzle and/or air adjustment of this unit
may result in sooting problems. Refer to the follow
ing section for correct adjustment procedures.
Nozzle Adjustment
Proper adjustment of the nozzle assembly is critical. Be
fore the flue pipe and oil lines are installed, the nozzle as
sembly must be checked for proper depth and alignment.
You must remove the entire burner assembly (not just the
nozzle) from the furnace to check the nozzle depth and
alignment. The smaller sized firing nozzle has been facto
ry-installed. This should be verified by the installer. A larger
nozzle has been provided in the bag assembly for use with
ELO183DH114 and 150 units. Inspect the spark trans
former leads also to ensure they are still attached to the
electrodes.
The burner assembly is attached to the vestibule panel by
three nuts. Slots are provided in the mounting flange for re
moving the burner assembly from the vestibule. Loosen
the nuts and turn the whole burner assembly clockwise
(figure 5) to remove the entire burner assembly from the
furnace. There is adequate wire to remove the burner with
out disconnecting wires. Once removed, turn the burner
around in the vest panel area.
ELO183DH Series Burner Removal
First, loosen three nuts which
attach burner to vest panel.
Next, rotate burner clockwise
on slots then pull toward you.
Figure 5
To correctly check and adjust the nozzle depth and align
ment, use the Beckett T-501 or Z-2000 gauge.
To check the oil nozzle depth, insert the small end of the
gauge into the end of the cone and measure from the flat of
the end cone to the face of the nozzle. When nozzle depth
is correct, the tip of the nozzle should just touch the end of
the gauge. Refer to the illustration sheet provided with the
gauge. Note that the scale side of the gauge is not used for
this purpose. If necessary, loosen the escutcheon plate
securing screw and slide the entire nozzle assembly for
ward or backward within the air tube (figure 6). Re-secure
escutcheon plate screw when adjustment is completed.
To check nozzle alignment, again insert the small end of
gauge into the end cone and measure the nozzle and elec
trode alignment against the center lines marked on the
gauge (again refer to enclosed illustration sheet). If the
nozzle is not centered, but found to be too far left or right, a
new nozzle assembly will need to be ordered. Do not at
tempt to adjust by bending the 90 degree elbow in the oil
line.
Take care to properly re-install burner assembly when
nozzle adjustment has been completed.
Beckett Oil Burner Nozzle Adjustment
Burner must be removed from
furnace for this procedure.
T-501 Gauge
To Adjust Nozzle
1-Loosen escutcheon plate screw.
2-Slide entire nozzle/electrode assembly back and forth inside air
tube until nozzle just touches gauge.
2
1
Escutcheon Plate
Figure 6
Page 8
Page 9
Indoor Coil Placement
In cooling / heat pump applications, Lennox recommends
that the indoor coil be installed at least 4 inches above the
top of the furnace cabinet to allow proper airflow. If coil
cabinet does not provide proper clearance, use field-fabri
cated transition.
Venting
feet (0.6 m) higher than any portion of a building within
a horizontal distance of 10 feet (3 m).
7. The vent must not pass through a floor or ceiling.
Clearances to single wall vent pipe should be no less
than 6” (152 mm); more if local codes require it.
8. The vent may pass through a wall where provisions
have been made for a thimble as specified in the Stan
dards of the National Board of Fire Underwriters. See
figure 7.
WARNING
Combustion air openings in front of the furnace
must be kept free of obstructions. Any obstruction
will cause improper burner operation and may re
sult in a fire hazard.
WARNING
The barometric draft control shall be in the same at
mospheric pressure zone as the combustion air in
let to the furnace. Deviation from this practice will
cause improper burner operation and may result in
a fire hazard.
CAUTION
Do not store combustible materials near the furnace
or supply air ducts. The material (such as paint, mo
tor oil, gasoline, paint thinner, etc.) may ignite creat
ing a fire hazard.
WARNING
This furnace is certified for use with type “L” vent.
“B” vent must not be used with oil furnaces.
Prior to installation of unit, make a thorough inspection of
the chimney to determine whether repairs are necessary.
Make sure the chimney is properly constructed and sized
according to the requirements of the National Fire Protec
tion Association. The smallest dimensions of the chimney
should be at least equal to the diameter of the furnace vent
connector. Make sure the chimney will produce a steady
draft sufficient to remove all the products of combustion
from the furnace. A draft of at least .04” w.c. (9.9 Pa) is re
quired during burner operation.
1. Local building codes may have more stringent installa
tion requirements and should be consulted before
installation of unit.
2. The vent connector should be as short as possible.
3. The vent connector should not be smaller than the out
let diameter of the vent outlet of the furnace.
4. Pipe should be at least 24 gauge galvanized.
5. Single wall vent pipe should not run outside or through
any unconditioned space.
6. Chimney should extend 3 feet (0.9 m) above highest
point where the vent passes through the roof, and 2
Wall Thimble
THIMBLE
COMBUSTIBLE
WALL
VENT PIPE
Figure 7
Masonry Chimney
BAROMETRIC
CONTROL*
(IN EITHER
LOCATION)
horizontal
application
shown
clean out
*Barometric draft control may be installed in either vertical or
horizontal section of flue pipe no less than 12” and no more than
18” from furnace flue outlet.
LINER
clean out
MASONRY
CHIMNEY
Figure 8
9. The vent pipe should slope upward toward the chim
ney on horizontal run at least 1/4 inch (6 mm) to the
foot (0.3 m) and should be supported by something
other than the furnace, such as isolation hangers.
10. Extend the vent pipe into the chimney so that it is flush
with the inside of the vent liner. Seal the joint between
the pipe and the liner.
11. The furnace shall be connected to a factory-built chim
ney or vent complying with a recognized standard, or
masonry or concrete chimney lined with a lining mate
rial acceptable to the authority having jurisdiction.
12. When two or more appliances vent into a common
vent, the area of the common vent should not be less
than the area of the largest vent or vent connection
plus 50% of the areas of the additional vent or vent
connection. Chimney must be able to sufficiently vent
all appliances operating at the same time.
Page 9
Page 10
13. The vent pipe shall not be connected to a chimney vent
serving a solid fuel appliance or any mechanical draft
system.
14. All unused chimney openings should be closed.
15. All vent pipe run through unconditioned areas or out
side shall be constructed of factory-built chimney sec
tions. See figure 9.
16. Where condensation of vent gas is apparent, the vent
should be repaired or replaced. Accumulation of con
densation in the vent is unacceptable.
17. Vent connectors serving this appliance shall not be
connected into any portion of mechanical draft sys
tems operating under positive pressure.
18. Keep the area around the vent terminal free of snow,
ice and debris.
Factory‐Built Chimney
BAROMETRIC
CONTROL*
(IN EITHER
LOCATION)
horizontal ap
plication shown
FACTORY
BUILT
CHIMNEY
3 - Insofar as is practical, close all building doors and win
dows and all doors between the space in which the ap
pliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliances not con
nected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom ex
hausts, so they will operate at maximum speed. Do
not operate a summer exhaust fan. Close fireplace
dampers.
4 - Following the lighting instruction on the unit, place the
appliance being inspected in operation. Adjust ther
mostat so appliance will operate continuously.
5 - Test for spillage using a draft gauge.
6 - After it has been determined that each appliance re
maining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other fuel burning appliance to its previous condi
tion of use.
7 - If improper venting is observed during any of the
above tests, the common venting system must be
corrected.
DRAIN FOR
CONDENSATE
*Barometric draft control may be installed in either vertical or
horizontal section of flue pipe no less than 12” and no more than
18” from furnace flue outlet.
Figure 9
Removal of Unit from Common Venting System
In the event that an existing furnace is removed from a
venting system commonly run with separate appliances,
the venting system is likely to be too large to properly vent
the remaining attached appliances. The following test
should be conducted while each appliance is in operation
and the other appliances not in operation remain con
nected to the common venting system. If venting system
has been installed improperly, the system must be cor
rected as outlined in the previous section.
1 - Seal any unused openings in the common venting
system.
2 - Visually inspect venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion or other deficiencies
which could cause an unsafe condition.
Flue Connections
IMPORTANT
When flue pipe is installed at less than minimum
clearance listed in tables 2 and 3, radiation shields
must be installed. See figure 10.
Use 24 gauge or heavier galvanized smoke pipe and fit
tings to connect furnace to vent. Maintain rise of at least
one inch per foot. Connect flue pipe to chimney using the
least number of elbows and angles possible. Flue pipe or
vent connector must be inserted into but not beyond the
outside wall of the chimney flue. No reduction in diameter
of flue pipe is acceptable. It is best to have flue pipe as
short and direct as possible.
Where two or more appliances vent into a common flue,
the area of the common flue should be at least equal to the
area of the largest flue or vent connector, plus 50% of the
area of any additional flues or vent connectors. Install
barometric draft control (provided) and flue pipe according
to instructions packed with control.
Inspect flue pipe annually. Clean soot or ash from flue pipe,
if necessary. If pipe is rusted, replace.
Page 10
Page 11
Radiation Shield Installation
COMBUSTIBLE
MATERIAL
ELO183DH UNIT
(TOP)
RADIATION
UNIT
CABINET
NON-COMBUSTIBLE
SPACERS
NOTE 1-Radiation shields must be constructed of 24 gauge sheet
metal minimum.
NOTE 2-Radiation shields required when A is less than 9” (229mm).
NOTE 3-Radiation shields should extend from the top of the unit to
the top of the flue pipe.
(SEE NOTE 2)
SHIELDS
RADIATION SHIELDS
(SEE NOTE 1)
FLUE
PIPE
ELO183DH UNIT
(FRONT)
AA
(25 mm)
(305 mm)
7”
(178 mm)
B
(SEE
NOTE 3)
1”
min.
12”
Optional Filter Kit
An Optional filter kit is available for ELO183DH units. Kit
35K05 is used with ELO183DH-101/114 units, and kit
35K06 is used with ELO183DH-135/150 units. All kits in
clude the following:
S 2 filters
S 3 rods
S 7 screws
S 1 rack assembly
S 1 panel
ELO183DH Filter Rack Installation
1. Slide filter rack over return duct flanges.
2. Using a scriber through the filter rack mounting holes,
mark seven mounting hole locations in the return end
of the cabinet. See figure 11.
3. Remove filter rack and drill 1/8” diameter holes at the
marked positions.
4. Place filter rack in position again and secure it to the
cabinet using the sheet metal screws provided. Clear
ance for the screw driver is provided in outside holes
of rack and in filter support angles.
5. Bend the ends of filter rods and hook ends through
holes provided in top and bottom filter support angles.
6. Slide filter between the support angles and the plenum
side for the filter rack. The filter rods hold the filter in
place.
Figure 10
Barometric Draft Control Installation
Install the provided barometric draft control in the flue pipe
at least 12 inches beyond the furnace flue outlet to pro
vide space for flue gas sampling. The barometric draft con
trol may be installed in either vertical or horizontal sections
of the flue pipe; however, it should be positioned no more
than 18” beyond the furnace flue outlet. Follow the instruc
tions packed with the barometric draft control.
Supply & Return Air Plenums
NOTE - Following these suggestions when installing sup
ply and return air plenums.
1. Use sealing strips of fiberglass.
2. In all cases, the plenum should be secured to furnace
or evaporator cabinet with sheet metal screws.
3. Both supply and return air plenums shall be square
and least 18” long. They should be the same dimen
sion as the furnace opening.
4. If unit is installed in a confined space such as a utility
room where there is no complete return air duct sys
tem, a return air connection should be run (the same
size as the return air opening) to a location outside the
room containing the furnace.
5. Install supply and return air ducts as desired.
ELO183DH Optional Filter Kit
FILTER RACK
22 (559)
14 (356)
RETURN
AIR DUCT
(Not Furnished
by Lennox)
FILTER
OPENING
IN UNIT
(Either Side)
Figure 11
Oil Supply Line Sizing
Ensure that the restrictions of the piping system, plus any
lift involved, do not exceed the capability of the oil pump.
Use the following guidelines when determining whether to
use a single-or two-stage oil pump.
Page 11
Page 12
One-Pipe System
When using a one-pipe system even with the oil tank that is
above the burner and a vacuum of 6” (152 mm) Hg or less,
a single-stage fuel pump with a supply line should be ade
quate without a separate return line. See figure 12.
Manual bleeding of the fuel pump is required on initial start
up. Failure to bleed air from the oil pump could result in an
air lock/oil starvation condition.
NOTE - As an extra precaution, cycle heating on and off
ten times after bleeding air from the oil pump. This will elim
inate air in the gun assembly.
Oil Piping
Two‐Pipe System
Air Vent
Fill
Pipe
Return
pipe
Oil
Tank
3”-4”
(76 mm -102 mm)
Return
pipe
Outside tank fuel pump above bottom of tank.
R
Figure 13
Fuel
Pump
Miain
Filter
Inlet
H
Oil Piping
air vent
fill
pipe
To determine the correct tubing size for piping, refer to
table 4.
Line Length Pipe Diameter (OD Tubing)
0-50' (15 m) 3/8” (10 mm)
51-100' (15 m) 1/2” (12 mm)
When using a two-pipe system with the oil tank below the
level of the burner, use a single-stage fuel pump in lift con
ditions of up to 10 feet (3 m) and/or a vacuum of 10” (254
mm) Hg or less. See figure 13. Use a two-stage fuel pump
when lift exceeds 10 feet (3 m) and/or a vacuum of 12” Hg
to 17” Hg. Both conditions require that you use of a twopipe system, which consists of a return line that purges the
fuel pump of air by returning it to the tank. To determine the
run and lift for piping, refer to table 5.
One‐Pipe System
fuel
pump
Oil
Tank
Shut-off
Valve
Figure 12
Table 4
One-Pipe Oil Line Sizing
Two-Pipe System
Mian
Filter
8 ft (2.4 m)
Maximum
One Pipe Lift
Use continuous lengths of heavy wall copper tubing or
steel pipe for oil supply pipe. Install oil supply pipe under
floor or near walls to protect it from damage. Avoid running
pipes along joists or reverberating surfaces. Always use
flare fittings. All fittings must be accessible. Do not use
compression fittings.
IMPORTANT
Both oil supply and return pipes must be sub
merged in oil in the supply tank.
Table 5
Two-Pipe Maximum Pipe Length (H + R)
3450 RPM - 3 GPH (11.4 LPH)
Lift “H”
0'
(0.0 m)
2'
(0.6 m)
4'
(1.2 m)
6 '
(1.8m)
8'
(2.4 m)
10'
(3.0 m)
12'
(3.7 m)
14'
(4.3 m)
16'
(4.9 m)
18'
(5.5 m)
3/8” (10 mm) OD
Tubing
Single
Stage
84'
(25.6 m)
73'
(22.3 m)
63'
(19.2 m)
52'
(15.8 m)
42'
(12.8 m)
31'
(9.4 m)
21'
(6.4 m)
---
---
Two
Stage
93'
(28.3 m)
85'
(25.9 m)
77'
(23.5 m)
69'
(21.0 m)
60'
(18.3 m)
52'
(15.9 m)
44'
(13.4 m)
36'
(11.0 m)
27'
(8.2 m)
--- --- ---
1/2” (12 mm) OD
Tubing
Single
Stage
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
83'
(25.3 m)
41'
(12.5 m)
---
Two
Stage
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
100'
(30.5 m)
76'
(23.2 m)
Page 12
Page 13
Table 6
Fuel Pump Usage
Pump Piping Application Maximum Lift (vacuum)
Single-Stage Pump
Two-Stage Pump Two-Pipe System
One-Pipe System 8 ft. (6” Hg vacuum)
Two-Pipe System 10 ft. (12” Hg vacuum)
10 ft. or greater
(12” to 17” Hg vacuum)
Oil Supply Line & Filter Connections
One-Pipe Systems
CAUTION
Do not install the bypass plug into the pump on onepipe systems.
The burner is shipped with fuel pump set for one-pipe op
eration. For one-pipe systems, the oil supply pipe is con
nected to the inlet tap on the pump. A one-pipe system
should only be used where there is gravity oil flow to the
pump and the pipe is not run at any point above the oil level
in the tank.
1 - Connect the inlet pipe to the pump inlet. Start the
burner.
2 - Set the primary burner control for continuous opera
tion during purging.
3 - Turn the bleed valve one turn counterclockwise to
open.
4 - Bleed the unit until all air bubbles disappear.
NOTE - Hurried bleeding will prevent the unit from op
erating properly.
5 - Tighten the bleed valve securely.
Two-Pipe Systems
If the installation requires a two-pipe operation, install the
bypass plug included in the bag which is attached to the
pump. To convert the pump, install the bypass plug ac
cording to the provided pump instructions. Notice in the
two‐pipe system the return pipe must terminate in the tank
3” (76 mm) to 4” (102 mm) above the supply inlet. Ensure
the return pipe terminates at the correct measurement or
air may escape into the system. This could result in loss of
prime.
NOTE- If using an outside tank in cold climates a number
one fuel or an oil treatment is strongly recommended.
1 - Remove 1/4” plug from return port.
2 - Insert bypass plug and tighten it. See figure 13.
3 - Attach the return and inlet pipes. Start the burner. Air
bleeding is automatic.
NOTE - If a faster bleed is necessary, open the bleed
valve.
4 - The return pipe must terminate 3” to 4” above the sup
ply pipe inlet. See figure 13.
NOTE - If the return pipe does not terminate where it
should, air may enter the system, and prime may be
lost.
An oil filter is required for all models. Install a field sup
plied oil filter inside the building between the tank shut‐off
valve and the burner. Locate filter close to burner for easy
maintenance. Table 7 lists the filters for the ELO183DH
furnace.
Table 7
Oil Filters
10 micron filter (no mounting bracket) 81P89
10 micron filter (mounting bracket) 53P92
10 micron replacement cartridge for filter, 45 gph 53P93
Filter restriction indicator gauge 53P90
Consult burner manufacturer's instructions packaged with
unit for further details concerning oil supply pipe connec
tions.
Cat.
Number
Leak Check
After oil piping is completed, carefully check all piping con
nections (factory and field) for oil leaks.
Oil Line Heater (Optional)
A heater for the oil line is available for applications that are
located in cold climates. The heater warms the oil pipe to
assist the initial start-up. An oil line heater is available from
Beckett using part number 51621 (Beckett Start Helper).
Electrical Wiring
All wiring must conform to the National Electric Code
(NEC), or Canadian Electric Code (CEC) and any local
codes.
1 - Refer to the appliance rating plate for proper fuse size.
2 - Install the room thermostat and make wire connec
tions to the control. Avoid installing thermostat on an
outside wall or where it can be affected by radiant heat.
Set the adjustable heat anticipator on thermostat ac
cording to the wiring diagram sticker provided on unit.
3 - Install a separate fused disconnect switch near unit so
power can be shut off for servicing.
Page 13
Page 14
4 - Complete line voltage wiring from disconnect switch
near unit to make‐up box.
NOTE - An equipment ground screw is provided. Refer
to unit wiring diagram. Ground unit using a suitable
ground wire.
CAUTION
Use copper conductors only.
IMPORTANT
WARNING
Run 24V Class II wiring only through specified low
voltage opening. Run line voltage wiring only
through specified high voltage opening. Do not
combine voltage in one opening.
Typical ELO183DH Wiring Diagram
If using a programmable thermostat, be sure to use
a type of thermostat that retains its memory in event
of a power loss.
Figure 14
Page 14
Page 15
Unit Start-Up & Adjustments
CAUTION
Before starting unit, make sure the oil tank is adequately
filled with clean No. 1 or No. 2 furnace oil.
NOTE - Water, rust or other contaminants in oil supply sys
tem will cause malfunction and failure of the internal parts
of the fuel pump.
CAUTION
Never burn garbage or paper in the heating system.
Never leave papers near or around the unit.
CAUTION
Blower access door must be in place before startup.
Burner Start-Up
1 - Set thermostat for heating demand and turn on elec
trical supply to unit.
2 - Open all shut-off valves in the oil supply line to the
burner.
3 - While the ignition is on, press and release the reset
button on the burner control (hold 1/2 second or less).
4 - Bleed the pump until all froth and bubbles are purged.
The bleed port is located on the bottom of the fuel
pump. To bleed, attach a clear plastic hose over the
vent plug. Loosen the plug and catch the oil in an
empty container. Tighten the plug when all the air has
been purged.
NOTE - A two-line fuel system will normally bleed itself
by forcing air back to the tank through the return line.
This type of bleeding procedure is not necessary.
5 - If burner fails to start within the set time, the burner
control will lock out operation. Press the reset button
to reset the control as in step 3. See figure 2 for burner
parts arrangement.
Table 9
Burner Specifications
Unit
ELO183DH101/114 100591-05 ARM2008 AF46XNHS 105,000 0.65gph X 80° B 140 F3 5 2.75
ELO183DH101/114 100591-05 ARM2008 AF46XNHS 120,000 *0.75gph X 80° B 140 F3 5 2.75
ELO183DH135/150 100591-06 ARM2009 AF46WPHS 140,000 0.85gph X 80° B 140 F4 5 3.38
ELO183DH135/150 100591-06 ARM2009 AF46WPHS 150,000 *1.00gph X 80° B 140 F4 5 3.38
*Nozzle must be field-installed for conversion to higher heating input. NOTE - All nozzles are Delavan brand
Burner
Number
Beckett
Spec. No.
Beckett
Air Tube Part
No.
Do not push the reset button on the primary control
more than one time.
6 - If 2 pipe system fails to prime after pressing the reset
button one time, use the manual bleed port to prime
the pump.
Fuel Pump Pressure Adjustment
Measure fuel pump pressure with unit off. Attach pressure
gauge to pump outlet. Turn unit on and check pressure and
compare to table 9. Adjust if necessary.
Temperature Rise Adjustment
To measure temperature rise, place plenum thermome
ters in warm air and return air plenums. Locate thermome
ter in warm air plenum where thermometer will not “see”
the heat exchanger to prevent it from picking up radiant
heat. Set thermostat to its highest setting to start unit. After
plenum thermometers have reached their highest and
steadiest readings, subtract the readings. The difference
in temperatures in the supply and return air plenums
should approximate the temperatures listed in table 8 and
on the appliance rating plate.
If the temperature rise is not within the range listed, check
the following items:
D Make sure that properly sized nozzle has been
used (table 9).
D Make sure that fuel pump pressure is correct.
D If furnace is in cutback mode, check for:
Dirty filters,
Dirty indoor coil,
Restricted ducts, closed registers, etc.
Table 8
Temperature Rise
Unit Temperature Rise °F
ELO183DH101 65 - 75
ELO183DH114 70 - 80
ELO183DH135 65 - 75
ELO183DH150 70 - 80
Input
Rating
BTU/HR
Nozzle Size,
Spray, Angle, &
Pattern
Pump
Pressure
Head
Insertion
Length
Static
Plate
Diameter
Page 15
Page 16
Fan Delay
Fan on time is 1 to 30 seconds and non adjustable. Fan off
time is 60 to 120 seconds and non adjustabe.
Limit Control
Limit Control — Do not adjust from factory setting.
Burner Adjustment
The following instructions are essential to the proper op
eration of ELO183DH series oil furnaces. To prevent soot
ing and prevent premature failure of the heat exchanger,,
these instructions must be followed in sequence:
1. Draft—This test should be taken at the breach be
tween the outlet of the vent connector and the baro
metric draft control. Generally a 1/4” hole will need to
be drilled for the draft gauge to be inserted into the vent
connector.
A minimum of 0.03 draft must be established without
the burner in operation. With the burner in operation,
the draft should be 0.04 to 0.05. This is VERY critical to
the flame retention head burners.
Oil furnace installations also require careful inspection
to make sure the chimney is in good shape and can ac
commodate the products of combustion. The temper
ature in the unconditioned space will also affect the
draft if long vent connectors are allowed to get too
cold.
2. Overfire Draft—This test should be taken with the
burner in operation. Remove the plug from the center
of the inspection port. Insert your draft gauge into the
hole.
A reading of the overfire draft should be 0.02 less than
the reading found in the vent connector. If a positive
reading is seen at this point, the combustion fan is
pumping too much air into the heat exchanger. Make
the necessary adjustments with the air shutter or air
band.
3. Smoke Test—The smoke test should be taken at the
hole drilled in step 1.
Air Shutter / Band Adjustment
Loosen this screw
to adjust air band.
Using a smoke test gun, adjust the air so that you will
have just a trace (between 0 and #1) of smoke. If the
burner is producing more than #1 smoke, adjust the air
shutter (primary) and air band (secondary) to reduce
the smoke. See figure 15. To adjust the air shutter,
loosen the top screw on the air shutter (and lower
screw, if necessary). Then, rotate the shutter until the
desired smoke level is achieved. If smoke cannot be
reduced to the desired level by moving the air shutter,
adjust the air band to increase the air. To adjust the air
band, loosen the air band screw and rotate the
band.This is the starting point. Do not stop here.
4. CO2 Test—Again, take this sample at the vent pipe.
With the unit firing at a trace of smoke, take a sample
of the CO2. From the results of this test, a “window of
operation” will be determined. This window of opera
tion establishes some tolerance. The tolerance the in
staller builds in provides room within the set‐up for
those things which might affect combustion. Those
things which might affect combustion can then do so
without causing the unit to start sooting/smoking.
Things which might affect combustion include a nozzle
going bad, draft that changes during different climatic
conditions, dirty oil, dirt obstructing the air inlet, etc.
To build in a “window of operation,” set up the burner to
be 2% less in CO2. For example, if you find a reading of
12% CO2, adjust the air shutter (and air band, if neces
sary) to increase the air and drop the CO2 to 10%.
5. Retest the Smoke—With a drop in the CO2 and in
crease in the air you should see that the smoke has re
turned to 0.
6. Retest the Overfire Draft—This test serves to con
firm that you have not increased the air too much.
Again you do not want a positive pressure at the test
port. It should still be 0.02 less than the draft pressure
reading taken at the breach. You may need to increase
the stack draft by adjusting the barometric draft con
trol.
7. Stack Temperature—Take a stack temperature
reading in the vent pipe. Subtract the room air temper
ature from the stack temperature. This will give you the
net stack temperature. Use the efficiency charts pro
vided in most CO2 analyzers to determine furnace effi
ciency.
8. When the proper combustion and smoke readings
have been achieved, re-tighten the air shutter
screw(s) and air band screw.
Air Shutter
Air Band
(Secondary)
Air Band
Figure 15
Service
Servicing Filter
NOTE - Under no circumstances should the access panels
to the blower compartment be left off or left partially open.
1. Throw‐Away Type Filters — Filters should be checked
monthly and replaced when necessary to assure prop
er furnace operation. Replace filters with like kind and
size filters.
Page 16
Page 17
2. Reusable Type Filters — Filters should be checked
monthly and cleaned when necessary to assure prop
er furnace operation. Use warm water and a mild de
tergent. Replace filter when dry. Permanent filters
supplied with ELO183DH furnaces do not require oil
ing after cleaning. Examine filter label for any for spe
cial instructions that may apply.
Servicing Blower
Blower motor is pre-lubricated and sealed for extended op
eration. No further lubrication is required. Disconnect pow
er to unit before cleaning blower wheel for debris.
Servicing Nozzle
Replace nozzle every year to to ensure proper operation.
Clogged nozzles will result in improper firing or non‐firing of
unit.
Flue Pipe Inspection
The flue pipe should be inspected annually by a qualified
service technician. Remove and clean any soot or ash
found in the flue pipe. Inspect pipe for holes or rusted
areas. If replacement is necessary, replace with the same
size and type as required by code. Inspect the flue draft
control device and replace if found defective.
Cleaning Heat Exchanger
1. Remove the vent pipe from the furnace.
2. Remove the locking screws and the caps from the
clean-out tubes. Remove flue access elbow.
3. Using a long spiral wire brush, sweep down the outer
drum of the heat exchanger. Then using the hose at
tachment, vacuum out loose debris.
4. Remove the locking screw and cap from the observa
tion tube and with the spiral wire brush, reach upward
toward the rear of the heat exchanger to clean out the
crossover tube.
CAUTION
Do not attempt to clean the combustion chamber. It
can be easily damaged.
5. Replace the clean-out caps and flue access elbow.
Make sure locking screws are secure.
6. Brush out and vacuum the vent outlet area of the outer
drum and replace vent pipe.
7. Clean around burner, blower deck and vestibule area.
NOTE - A heat exchanger clean‐out kit ABRSH380
(35K09) is available from Lennox. The kit includes a
radiator brush, a tapered brush and a non-metallic 36”
spiral wire handle.
GeniSyst Primary Burner Control
ELO183DH units are equipped with the Beckett GeniSyst 7505B primary burner control. The control is positioned on the
upper right-hand side of the Beckett AFG burner assembly. The control includes a reset button and three status lights. See
figure 16 for location of reset buttons and status lights. Table 10 details reset button operation. Table 11 details status light
function.
Additional information on the GeniSyst 7505B primary burner control is provided with this furnace.
Beckett GeniSyst 7505B Primary Burner Control
Reset Button
with Red Status Light
FRONT VIEW
Yellow Pump
Prime Status Light
Green Flame
Status Light
Cad Cell
Connections
Wiring
Connections
REAR VIEW
Figure 16
Page 17
Page 18
Table 10
Reset Button Operation
If the burner is in the
below state:
Button Click
(press < 1 second)
Valve-on Delay, Trial for
Ignition, Ignition Carryover
Run (igniter is shut off) No action
Pump Prime No action Exit Pump Prime mode and return to Standby
Go to pump prime (see
“Priming the Pump” above)
No action
Status Light Function
R
Green
Flame Sensed during normal operation (Could be stray
light during standby)
Yellow
Control is in pump prime mode or
Reset button currently held for 15+ seconds.
Heating Sequence - Actions & Responses
1. Action: Thermostat calls for heat (W terminal is en
ergized)
Response:
D Primary control is energized.
D After 15-second prepurge, power is sent to the oil
delay valve, ignition occurs and flame is
established.
D Igition sequence continues for 10 seconds after
flame is sensed. Oil will continue to flow as long as
cad cell senses flame.
D Heat fan on timing (1 to 30 seconds) begins. When
timing is complete, the indoor blower is at heat
speed and warm air is delivered to the controlled
space.
2. Action: Thermostat ends call for heat (W terminal
is de-energized)
Response:
D After the thermostat is satisfied, the thermostat
circuit opens. The oil delay valve and burner are
de-energized.
D Burner is de-energized.
D Heat fan off timing (60 to 120 seconds) begins.
When timing is complete, indoor blower is de-en
ergized.
3. Action: Burner fails to light
Response:
D Oil primary control enters soft lockout after ignition
failure (15 seconds without flame being sensed).
Push reset button on primary control for one sec
ond to reset soft lockout.
Pushing the reset button will:
Button Hold
(press > 1 second)
tuokcoLtfoSmorfteseRtuokcoL
Disable the Burner:
Any time the burner is
running, press and hold
the reset button to disable
the burner. The burner will
remain off as long as the
button is held.
Table 11
D After soft lockout reset, oil primary control allows
second ignition attempt. Primary control enters
hard lockout after second ignition failure (15 sec
onds without flame being sensed). Push reset but
ton on primary control for 15 seconds until light on
control turns yellow to reset hard lockout.
D Burner motor is de-energized.
4. Action: Established flame fails
Response:
D Burner motor is de-energized and oil primary con
trol goes into recycle mode.
D If the fan off delay is longer than the recycle timing,
the indoor blower continues to run on heating
speed through the next trial for ignition.
5. Action: Limit Switch Opens
Response:
D Oil primary control de-energizes burner.
D Indoor blower is energized immediately at cool
speed.
D Oil primary control is de-energized.
D Indoor blower runs as long as limit stays open.
6. Action: Limit Switch Closes
Response: If there is a heating demand, oil primary
control and ignition sequence begins.
Button Hold
(press 15+ seconds)
Reset from Restricted
(Hard) Lockout
Enables pump priming
After the reset button has
been held for 15 seconds.
The button can then be
clicked during the next
ignition sequence to enter
pump prime mode.
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N/A
Page 18
Page 19
Troubleshooting
Burner failure or improper operation can result from a num
ber of different causes. Often the cause can be pinpointed
by observing the different types of failure or by the process
of elimination.
The following troubleshooting charts list some failures,
causes and a sequence of steps to isolate the point of fail
ure. Check the simplest and most obvious items before
progressing to other items.
Troubleshooting: Fan operating sequence
Action System Response
Thermostat calls for heat.
(W terminal is energized.)
Thermostat ends call for heat.
(W terminal is de-energized.)
Burner fails to light. Oil primary control locks out within lockout timing (timing depends on oil primary control).
Established flame fails. Burner motor is de-energized and oil primary control goes into recycle mode.
Thermostat begins call for cool.
(G and Y terminals are energized.)
Oil primary control is energized.
Ignition system and oil primary control start the furnace. Oil flows as long as cad cell
senses flame.
Burner motor is energized and heat fan on delay timing begins. When timing is complete,
the circulating fan is energized at heat speed and warm air is delivered to the controlled
space.
Oil primary control is de-energized, terminating the burner cycle.
Heat fan off delay (60 to 120 seconds) timing begins. When timing is complete, the circulat
ing fan is de-energized.
Oil primary control and circulating fan are off.
Burner motor is de-energized.
If heat fan has started, it continues through the delay off period.
If heat fan off delay is longer than the recycle delay timing, the heat fan continues to run
through the next trial for ignition.
Circulating fan is energized at the cool speed.
Cooling compressor turns on immediately.
Thermostat ends call for cool.
(G and Y terminals are de-energized.)
Thermostat begins call for fan.
(G terminal is energized.)
Thermostat ends call for fan.
(G terminal is de-energized.)
Limit switch string opens. Oil primary control shut off the burner.
Limit switch string closes. Heat fan off delay (60 to 120 seconds) begins.
Continuous circulating fan is connected.
(Optional connectors are available for separate circulat
ing fan speed tap.)
Humidity control is connected.
(Optional connectors are available for 120 Vac humidifi
er.)
Circulating fan and cooling compressor turn off immediately.
Circulating fan is energized immediately at cool speed.
Circulating fan is de-energized.
Circulating fan is energized immediately at heat speed.
Oil primary control is de-energized.
Circulating fan runs as long as limit string stays open.
If there is a call for cooling or fan, the circulating fan switches from heat speed to cool
speed.
Circulating fan turns off after the selected heat fan off delay timing.
Oil primary control is energized, initiating burner light off.
Circulating fan is energized at low speed when there is no call for heat, cool or fan.
Humidifier connections are energized when the burner motor is energized.
Page 19
Page 20
Troubleshooting: Burner fails to start.
Source Procedure Causes Correction
Thermostat in OFF or COOL Switch to HEAT.
Thermostat Check thermostat settings.
Check burner motor, primary
Safety Overloads
Power
Thermostat
Cad Cell
Primary Control
Burner
safety control, & auxiliary limit
switch.
Check furnace disconnect
switch & main disconnect.
Touch jumper wire across TRTW terminals on primary control.
If burner starts, then fault is in
the thermostat circuit.
Disconnect the flame detector
wires at the primary control. If
the burner starts, fault is in the
detector circuit.
Place trouble light between the
orange and white leads. No light
indicates that no power is going
to the control.
Place trouble light between the
orange and white leads. No light
indicates faulty control.
Place the trouble light between
the orange and white leads to
the burner motor. No light indi
cates that no power is getting to
the motor.
Place trouble light between the
black and white leads to the
blower motor. Light indicates
power to the motor and burner
fault.
Thermostat is set too low
Burner motor overload tripped Push reset button pump motor.
Primary control tripped on safe
ty
Auxiliary limit switch tripped on
safety
Open switch Close switch.
Blown fuse or tripped circuit
breaker
Broken or loose thermostat
wires
Loose thermostat screw con
nection
Dirty thermostat contacts Clean contacts.
Thermostat not level Level thermostat.
Faulty thermostat Replace thermostat.
Open circuit in wiring between
fan relay and oil primary control.
Flame detector leads are
shorted
Flame detector exposed to light Seal off false source of light.
short circuit in the flame detec
tor
Primary or auxiliary control
switch is open
Open circuit between discon
nect switch and limit control
Low line voltage or power fail
ure
Failed internal control circuit Replace the control.
Blown fuse Replace the fuse.
Binding burner blower wheel
Seized fuel pump
Failed burner motor Replace the motor.
Turn thermostat to higher tem
perature.
Reset primary control.
Reset auxiliary limit.
Replace fuse or reset circuit
breaker.
Repair or replace wires.
Tighten connection.
Check wiring between fan relay
and oil primary control.
Separate leads.
Replace detector.
Check adjustment. Set the
maximum setting.
Jumper terminals; if burner
starts, switch is faulty, replace
control.
Trace wiring and repair or re
place it.
Call the power company.
Turn off power and rotate the
blower wheel by hand. If
seized, free the wheel or re
place the fuel pump.
Page 20
Page 21
Troubleshooting: Burner starts, but no flame is established.
Source Procedure Causes Correction
Oil Supply
Oil Filters & Oil Line
Oil Pump
Nozzle
Ignition Electrodes
Ignition
Transformer
Burner Motor
Check tank gauge or use dip
stick.
Coat dip stick with litmus paste
and insert into bottom of tank.
Listen for pump whine. Tank shut-off valve closed Open valve.
Listen for pump whine.
Open bleed valve or gauge port.
Start the burner. No oil or milky
oil indicates loss or prime.
Install pressure gauge on pump
and read pressure. Should not
be less than 140 psi.
Observe the oil spray (gun as
sembly must be removed from
unit). Inspect the nozzle for
plugged orifice or carbon buildup around orifice.
Remove gun assembly and in
spect electrodes.
Start burner and observe spark.
Check line voltage to transform
er primary.
Motor does not come up to
speed and trips out on overload.
Turn off power and rotate blower
wheel by hand to check for bind
ing or excessive drag.
No oil in tank Fill tank.
Water in oil tank
Oil line filter is plugged Replace filter cartridges.
Kinks or restriction in oil line Repair or replace oil line.
Plugged fuel pump strainer Clean strainer or replace pump.
Air leak in oil supply line
Pump is partially or completely
frozen. No pressure and the
motor locks out on overload.
Coupling disengaged or broken
- no pressure
Fuel pressure too low Adjust to 140 psi.
Nozzle orifice plugged
Nozzle strainer plugged
Poor or off center spray
Fouled or shorted electrodes
Dirty electrodes
Eroded electrode tips
Improper electrode gap spacing
Improper position of electrode
tips
Bad buss bar connection Retension and realign.
Cracked or chipped insulators Replace electrode.
Low line voltage
Burned out transformer wind
ings.
No spark or weak spark
Low line voltage
Pump or blower overloading
motor
Faulty motor Replace motor.
If water depth exceeds 1 inch,
pump or drain water.
Locate and correct leak.
Tighten all connections.
Replace pump.
Re-engage or replace coupling.
Replace nozzle with the same
size, spray angle, and spray
pattern.
Clean or replace electrodes.
Clean electrode tips and use
T-501 gauge to reset the gap to
5/32 inches and correctly posi
tion tips.
Check voltage at power source.
Correct cause of voltage drop
or call the power company.
Replace the transformer.
Properly ground the transformer
case.
Check voltage at power source.
Correct cause of voltage drop
or the call power company.
Correct cause of overloading.
Page 21
Page 22
Troubleshooting: Burner starts and fires, but lock out on safety.
Source Procedure Causes Correction
Unbalanced fire Replace nozzle
Reduce combustion air - check
combustion.
Increase combustion air - check
combustion.
Adjust barometric draft control
for correct draft.
Correct draft or remove restric
tion.
Secure connections or replace
cad cell holder and wire leads.
Check cad cell for proper align
ment. Check cad cell face and
clean, if necessary.
Poor Fire
Flame Detector
Primary Control
After burner
fires, immedi
ately jumper
across flame
detector termi
nals at the pri
mary control.
If burner con
tinues to run,
this may be
due to poor
fire. Inspect
fire.
If fire is good,
fault is in the
flame detector.
Check detec
tor circuit.
If burner locks
out on safety,
fault is in the
primary con
trol.
Too much air - -lean short fire
Too little air - - long dirty fire
Excessive draft
Too little draft or restriction
Faulty cad cell (open circuit) Replace cad cell.
Loose connections or broken
cad cell wires
Cad cell cannot sense flame
Primary control circuit failed Replace primary control.
Troubleshooting: Burner Starts and Fires, but Loses Flame and Lock Out on Safety
Source Procedure Causes Correction
Unbalanced fire Replace nozzle
Poor Fire
Flame Detector
Oil Supply
After burner
fires, immedi
ately jumper
across flame
detector termi
nals at the pri
mary control.
Listen for pump whine
If burner con
tinues to run
(does not lock
out of safety),
fault may be
due to poor
fire. Inspect
fire.
If fire is good,
fault is in the
flame detector.
Check detec
tor circuit.
If burner loses
flame (does
not lock out on
safety), fault is
in the fuel sys
tem.
Too much air - - lean short fire
Too little air - - long dirty fire
Excessive draft
Too little draft or restriction
Faulty cad cell (open circuit) Replace cad cell.
Loose connections or broken
cad cell wires
Cad cell cannot sense flame
Pump loses prime - air slug Prime pump at bleed port
Pump loses prime - air leak in
supply line
Water slug in line Check oil tank for water (over 1
Partially plugged nozzle or
nozzle strainer
Restriction in oil line Clear restriction.
Plugged fuel pump strainer Clean strainer or replace pump.
Cold oil - outdoor tank Change to number 1 oil.
Reduce combustion air - check
combustion.
Increase combustion air - check
combustion.
Adjust barometric draft control
for correct draft.
Correct draft or remove restric
tion.
Secure connections or replace
cad cell holder and wire leads.
Check cad cell for proper align
ment. Check cad cell face and
clean, if necessary.
Check supply line for loose con
nections and tighten fittings.
inch) pump or drain out water.
Replace nozzle.
Page 22
Page 23
Troubleshooting: Burner starts and fires, but short cycles (too little heat)
Source Procedure Causes Correction
Heat anticipator set too low Correct heat anticipator setting.
Thermostat Check thermostat.
Connect voltmeter between line
voltage connections to primary
Limit Control
control (black & white leads). If
burner cycles due to power inter
ruption, it is cycling on limit.
Vibration at thermostat Correct source of vibration.
Thermostat in the path of a
warm air draft
Dirty furnace air filters Clean or replace filter.
Temperature rise too high
Blower motor seized or burned
out
Blower wheel dirty Clean blower wheel.
Wrong motor rotation Replace motor.
Restrictions in return or supply
air system
Shield thermostat from draft or
relocate.
Check fo proper nozzle size.
Replace nozzle, if necessary.
Check for restrictions and re
move, if necessary.
Check speed tap jumper and
make sure it is still in factory
position.
Replace motor.
Correct cause of restriction.
Power
If voltage fluctuates, fault is in the
power source. Recheck voltage
at the power source.
Loose wiring connection Locate and secure connection.
Low or fluctuating line voltage Call power company.
Troubleshooting: Burner runs continuously (too much heat).
Source Procedure Causes Correction
Thermostat
Primary control
Disconnect
thermostat
wires at the pri
mary control.
If burner turns
off, fault is in
the thermostat
circuit.
If burner does
not turn off,
fault is in the
primary control.
Shorted or welded thermostat
contacts
Stuck thermostat bimetal
Thermostat not level Level thermostat.
Shorted thermostat wires Repair short or replace wires.
Thermostat out of calibration Replace thermostat.
Thermostat in cold draft
Failed primary control Replace the primary control.
Repair or replace the thermo
stat.
Clear obstruction or replace
thermostat.
Correct draft or relocate the
thermostat.
Page 23
Page 24
Troubleshooting: Burner runs continuously (too little heat).
Source Procedure Causes Correction
Too much combustion air Reduce combustion air.
Combustion
Oil Pressure
Check burner
combustion for
CO2, stack tem
perature, and
smoke
Inspect fire and check
oil pressure.
Low CO
2
less
than 10%.
High smoke
reading more
than a trace.
High stack tem
perature is more
than 550
_F Net.
Air leaks into heat exchanger
around inspection door, etc.
Excessive overfire draft
Incorrect nozzle assembly
depth
Dirty or plugged heat exchanger
Insufficient overfire draft Increase draft.
Incorrect nozzle assembly
depth
Too little combustion air Increase combustion air.
Low volume indoor blower air
Dirty heat exchanger Clean heat exchanger.
Dirty burner blower wheel Clean burner blower wheel.
Dirty furnace air filters Clean or replace filter.
Restricted or closed registers or
dampers
Partially plugged or bad nozzle Replace nozzle.
Oil pressure is too low
(less than 140 psi.)
Correct cause of air leak.
Adjust barometric draft con
trol for correct draft.
Set to 1.13.
Clean heat exchanger.
Readjust burner.
Set to 1.13.
Check pump coupling for
wear / slippage.
Readjust registers or damp
ers.
Increase oil pressure to 140
psi.
ELO183DH Start-Up & Performance Check List
Job Name
Job Location
Installer
Unit Model No.
HEATING SECTION
Electrical Connections Tight?
Supply Voltage
Blower Motor H.P.
Piping Connections Tight?
Flue Connections Tight?
Burner Model No.
Oil Pump Pressure [recommended minimum 140 psi]
Blower Motor Amps
All Valves Open?
Vent Clear?
Serial Number
Filter Clean & Secure?
Job No.
Serial No.
Date
City
City
PROPER DRAFT
Draft Reading (recommended .03-.04 inches w.c.)
% CO
2
Smoke Test
Stack Draft Overfire Draft
Net Stack Temp
Calibrated? Heat Anticipator Properly Set? Level?
% O
2
THERMOSTAT
State
State
Serviceman
ppm CO
Ambient Temp
Temperature RiseExternal Static Pressure
Page 24
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