INSTALLATION
E 2002 Lennox Industries Inc.
Dallas, Texas, USA
INSTRUCTIONS
O23 SERIES UNITS
OIL UNITS
504,626M
38152A059
01/04
Supersedes 04/02
Table of Contents
General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping & Packing 1. . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O23 Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
O23 Start−Up & Performance Check List 2. . . . . . . . .
O23 Unit Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . .
O23 Oil Burner Parts Arrangement 3. . . . . . . . . . . . . . . .
Locate & Level the Unit 5. . . . . . . . . . . . . . . . . . . . . . . .
Setting the Unit 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Adjustments 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flue Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply & Return Air Plenums 11. . . . . . . . . . . . . . . . .
Oil Supply Line & Filter Connections 12. . . . . . . . . . .
Leak Check 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start-Up & Adjustments 15. . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Litho U.S.A.
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
WARNING
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
WARNING
Improper installation, adjustment, alteration, service, or maintenance can cause injury or property
damage. Refer to this manual. For assistance or
additional information, consult a qualified installer
or service agency.
CAUTION
When venting this appliance, keep vent terminal free
of snow, ice and debris.
General
These instructions are intended as a general guide and do
not supersede local codes in any way. Only qualified technicians can install and service the Lennox Elite® Series
O23 oil furnaces. In Canada, refer to CSA B139 for recommended installation procedures. Consult authorities who
have jurisdiction before installation.
CAUTION
Never burn garbage or paper in the heating system.
Never leave papers near or around the unit.
Shipping & Packing List
1− Assembled oil furnace
1− Barometric draft control
1− Side exhaust pipe collar
1− Direct intake collar (AFII burner units only)
Check the components for shipping damage. If you find any
damage, immediately contact the last carrier.
01/04
*2P0104*
Page 1
504,626M
*P504626M*
O23 Unit Dimensions − Inches (mm)
O23Q2/3-70/90
3/4
(19)
3/4
(19)
C
D
SUPPLY
AIR
OPENING
TOP FLUE
OUTLET
FLUE OUTLET
CENTERING HOLE
(Field Fabricate
ELECTRICAL INLET
(Right Side Only)
OIL PIPING INLET
(Left Side Only)
OPT. OUTDOOR
COMBUSTION
CENTERING HOLE
(Field Fabricate
1-1/2
Right Side only)
(38)
1-1/4
(32)
Model No. A B C D E
O23Q2/3-70/90
O23Q3/4-105/120
O23Q5-140/154
TOP VIEW
SIDE
Either Side)
FLUE
CONNECTION
(On Heat
Exchanger)
AB
54
(1372)
AIR FLOW
AIR INLET
1-1/2
(38)
22
14
(356)
(559)
RETURN AIR
OPENING
(Either Side)
23-1/2
(597)
2 (51)
22
(559)
RETURN AIR
E
RETURN AIR
SIDE VIEW FRONT VIEW
in. 19-1/2 30-5/8 18 19-5/8 16
mm 495 778 457 498 406
in. 22-1/2 33-1/8 21 22-1/8 18
mm 572 841 533 562 457
O23 Start−Up & Performance Check List
Job Name
Job Location
Installer
Unit Model No.
HEATING SECTION
Electrical Connections Tight?
Supply Voltage
Blower Motor H.P.
Blower Motor Lubrication O.K.?
Piping Connections Tight?
Burner Model No.
Oil Pump Pressure [recommended min. 100 psig for −70;
min. 140 psig for all other units )]
Blower Motor Amps
All Valves Open?
Serial Number
Job No.
Serial No.
Page 2
Date
City
City
State
State
Serviceman
PROPER DRAFT
Draft Reading (recommended .03−.04 inches w.c.)
% CO2 (recommended 12%)
Flue Connections Tight?
Fan Control Setting (maximum 130_ F)
(55_C)
Temperature RiseFan Control Cutout
Filter Clean & Secure?
Vent Clear?
THERMOSTAT
Calibrated? Heat Anticipator Properly Set? Level?
O23 Unit Parts Arrangement
clean-out port
limit switch
control box
with fan control board
Beckettr
AFII burner
heat exchanger
flue opening
clean−out port
observation
port
combustion air intake
blower motor
indoor blower
O23 Oil Burner Parts Arrangement
RETAINING
CLIP
HEAD SCREW
HEAD
INSULATOR
FLANGE
GASKET
AIR TUBE
ASSY FOR
FB HEADS
1/4" HEX
FB−HEAD
NOZZLE
ADAPTER
NOZZLE LINE
ELECTRODE HEAD
ASSY.
FLANGE
ELECTRODE
ASSY
AIR TUBE
SCREWS
PREMOUNTED OIL−DELAY VALVE
PEDESTAL
Figure 1
ELECTRONIC IGNITION
TRANSFORMER
REAR ACCESS
DOOR GASKET
REAR ACCESS
DOOR ASSY
MAIN
HOUSING
ASSY
SPLINED
NUT
ESCUTCHEON
PLATE
CONNECTOR
TUBE
FUEL PUMP
COUPLING
Figure 2
capacitor
IGNITOR
MOTOR
PRIMARY
CONTROL
BLOWER
WHEEL
4X4
BOX
0
3
4
5
6
7
8
AIR
ADJ.
DIAL
INLET
AIR SCOOP
Page 3
Requirements
IMPORTANT
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
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal injury or loss of life. Installation and service 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 recommendations of the National Environmental Systems Contractors Association and any state or provincial laws or local ordinances. Authorities having jurisdiction should be
consulted before installation. Such applicable regulations
or requirements take precedence over general instructions
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 standards outlined in section 140 of NFPA No. 31 or, in Canada,
CSA Standard B139. When installing O23 units in confined
spaces such as utility rooms, two combustion 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"(152 mm)
from the room’s ceiling.
An opening to the outside for combustion air is
strongly recommended, especially in new homes.
Refer to table 2 or the unit rating plate for specific
combustion air opening dimensions.
The combustion air opening 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 containing the furnace below the level of the furnace burner.
Table 1
Combustion Air Opening Dimensions
Model No.
O23−70/105/120 10" X 20" (254 mm X 508 mm)
O23−140/154 11" X 22" (279 mm X 559 mm)
This unit is approved for use on combustible flooring and
for clearances to combustible material as listed on unit rating plate and in table 2. Unit service and accessibility clearances take precedence over fire protection clearances.
Installation Clearances inches (mm)
Clearances 70/105/120 140/154
top of plenum and duct 2 (51) 2 (51)
plenum sides 3 (76) 3 (76)
sides 0 (0) 0 (0)
rear 0 (0) 0 (0)
front 4 (120) 4 (120)
flue pipe measured from
above
flue pipe measured vertical 6 (152) 6 (152)
NOTE − Service access clearance must be maintained.
*Minimum clearance shown for flue pipe may be reduced by using special
protection as provided by local building codes and the National Fire
Protection Association Standards.
Unit must be adjusted to obtain a temperature rise in the
range listed in table 6 in the Start-Up section of this manual.
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, or Canadian Electric Code (CEC) 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.
Combustion Air Opening
Dimensions (2 required)
Table 2
6 (152) 6 (152)
Page 4
When furnace is used in conjunction with cooling units, it shall
be installed in parallel with, or on the upstream side of, cooling
units to avoid condensation in the heating element. With a
parallel flow arrangement, a damper (or other means to control the flow of air) shall be adequate to prevent chilled air from
entering the furnace and, if manually operated, must be
equipped with means to prevent operation of either unit, unless damper is in the full heat" or cool" position.
Locate & Level the Unit
1− Set the unit in desired location keeping in mind the clear-
ances listed in table 2. Also keep in mind oil supply connections, electrical supply, flue connections and sufficient clearance for installing and servicing unit.
2− Level the unit from side to side and from front to rear. If
the furnace is not level, place fireproof wedges or
shims between the low side of the furnace and the
floor. Make sure the weight of the furnace is distributed
evenly on all four corners. Strain on sides of cabinet
causing cracking and popping noises may occur if
weight of furnace is not evenly distributed.
Unit Adjustments
Neither the nozzle setting nor the air adjustments are factory set. The furnace is fire tested and the limit control is
checked to make sure it functions properly; no factory settings are made. During installation, the furnace must be
set up." The installing dealer/contractor must have and
use proper test equipment in order to correctly set up the oil
furnace. Proper testing equipment is required to ensure
correct operation of the unit. The use of test equipment is
now 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 Beckett T−500 gauge
D Oil vacuum 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 following section for correct adjustment procedures.
Adjusting the Nozzle
Proper adjustment of the nozzle assembly is critical because alignment may have changed during shipping. Before the furnace and oil lines are installed, the nozzle assembly must be checked. To check the nozzle assembly, remove
the entire burner assembly (not just the nozzle) from the furnace. The lower firing nozzle is factory installed. This should
be verified by the installer. Inspect the spark transformer
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 removing the burner assembly from the vestibule. By loosening the nuts and by turning the whole burner assembly
counterclockwise (figure 3), the entire burner assembly will
come out of the furnace. There is adequate wire to remove
the burner without disconnecting wires. Once removed,
turn the burner around in the vest panel area.
O23 Series Burner Removal
Loosen three nuts which at-
tach burner to vest panel.
To correctly adjust the nozzle, use a Beckett #T−500 gauge
Insert the small end of the gauge into the end of the cone
and measure from the flat of the end cone to the tip 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. Make corrections
by sliding the nozzle assembly forward or backward within
the blast tube (figure 4). At the same time, check the nozzle
alignment.
Rotate burner counterclockwise on
slots then pull toward you.
Figure 3
Page 5
To check nozzle alignment, again insert the small end into
the end cone and measure the nozzle and electrode 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 attempt to adjust by
bending the 90 degree elbow in the oil line.
Beckett Oil Burner Nozzle Adjustment
Burner must be removed from
furnace for this procedure.
2
GAUGE
TO ADJUST NOZZLE:
1−Loosen screw.
2−Slide entire nozzle/electrode assembly back and forth until
nozzle just touches gauge.
Figure 4
1
Venting
WARNING
Combustion air openings in front of the furnace must
be kept free of obstructions. Any obstruction will
cause improper burner operation and may result in
a fire hazard.
WARNING
The barometric damper shall be in the same atmospheric pressure zone as the combustion air inlet to
the furnace. Deviation from this practice will cause
improper burner operation and may result in a fire
hazard.
higher temperature rating and is constructed with an inner
liner of stainless steel rather than aluminum).
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 Protection 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 required 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 to
do the job.
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
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 Standards of the National Board of Fire Underwriters. See
figure 5.
WALL THIMBLE
THIMBLE
CAUTION
Do not store combustible materials near the furnace
or supply air ducts. The material (such as paint, motor oil, gasoline, paint thinner, etc.) may ignite by
spontaneous combustion creating a fire hazard.
WARNING
This furnace is certified for use with type L" vent.
B" vent must not be used with oil furnaces.
NOTE − Oil burning equipment may be vented into an approved masonry chimney or type L vent. (Type L vent is
similar in construction to type B gas vent except it carries a
COMBUSTIBLE
WALL
FIGURE 5
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. See
figure 6.
Page 6
VENT PIPE
BAROMETRIC
CONTROL*
(IN EITHER
LOCATION)
MASONRY CHIMNEY
LINER
NOTE − If vent pipe needs to exit from side of cabinet,
use the pilot hole (located on either side of the unit) to
cut a 6" (152 mm) round hole. Attach finishing plate
(provided) with four sheet metal screws to cover rough
edges.
FACTORY−BUILT CHIMNEY
CLEAN OUT
MASONRY
CHIMNEY
CLEAN OUT
*Barometric control may be installed in either vertical or horizontal section of flue pipe within 18" of flue outlet of furnace.
Figure 6
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 material 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 area of the additional vent or vent connection. Chimney must be able to sufficiently vent all
appliances operating at the same time.
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 sections. See figure 7.
16− Where condensation of vent gas is apparent, the vent
should be repaired or replaced. Accumulation of condensation in the vent is unacceptable.
17− Vent connectors serving this appliance shall not be
connected into any portion of mechanical draft systems operating under positive pressure.
18− Keep the area around the vent terminal free of snow,
ice and debris.
BAROMETRIC
CONTROL*
(IN EITHER
LOCATION)
*Barometric control may be installed in either vertical or horizontal section of flue pipe within 18" of flue outlet of furnace.
FACTORY
BUILT
CHIMNEY
DRAIN FOR
CONDENSATE
Figure 7
Combustion and Ventilation Air
(Confined and Unconfined Spaces)
In the past, there was no problem in bringing in sufficient
amounts of outdoor air for combustion − infiltration provided
all the air that was needed and then some. In today’s
homes built with energy conservation in mind, tight
construction practices make it necessary to bring in air
from outside for combustion. Consideration must also be
given to the use of exhaust fans, appliance vents, chimneys and fireplaces because they force additional air that
could be used for combustion out of the house. Unless outside air is brought into the home for combustion, negative
pressure (pressure outside is greater than inside pressure)
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.
The importance of the previous paragraph cannot be overstated. Users may inadvertently block fresh air intakes after
installation.
In the absence of local codes concerning air for combustion and ventilation, the following section outlines guidelines and recommends procedures for operating oil furnaces in a manner that ensures efficient and safe
operation. Special consideration must be given to combustion air needs as well as requirements for exhaust vents
and oil piping.
Page 7
Combustion Air Requirements
CAUTION
Insufficient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also cause
excess water in the heat exchanger resulting in rusting and premature heat exchanger failure. It can also
cause property damage.
All oil-fired appliances require air to be used for the combustion process. If sufficient amounts of combustion air are
not available, the furnace or other appliance will operate in
an inefficient and unsafe manner. Enough air must be provided to meet the needs of all fuel-burning appliances, 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
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 containing the furnace, the return air must be handled by ducts
which are sealed to the furnace casing and which terminate
outside the space containing the furnace. This is especially
important when the furnace is mounted on a platform 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 condition. 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 providing 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 8).
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM INSIDE
CHIMNEY OR
OIL VENT
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
OPENINGS
(To Adjacent Room)
FIGURE 8
Air from Outside
If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent 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 figures 9 and 11). When communicat-
Page 8
ing 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 11).
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
(Inlet Air from Crawl Space and
Outlet Air to Ventilated Attic)
CHIMNEY
OR OIL
VENT
VENTILATION LOUVERS
(Each end of attic)
OIL
FURNACE
VENTILATION
LOUVERS
(For unheated
crawl space)
OUTLET
AIR
WATER
HEATER
INLET
AIR
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.
FIGURE 9
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
CHIMNEY
OR OIL
VENT
OIL
FURNACE
OUTLET
AIR
VENTILATION LOUVERS
(Each end of attic)
INLET AIR
(Ends 12" above
bottom)
WATER
HEATER
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.
FIGURE 10
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 equipment 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-
WATER
HEATER
OUTLET AIR
INLET AIR
ment in the enclosure.
FIGURE 11
When ducts are used, they shall be of the same cross−sectional 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 covering is not known for calculating the size opening required, it
may be assumed that wood louvers will have 20 to 25 percent 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 operation.
Direct Connection of Outdoor Air for Combustion
The Beckett AFII burner was designed to allow for direct air
intake piping (4" [102 mm]). The maximum equivalent
length of pipe is 70 feet (21.3 m). A 90_ elbow equals
6feet (1.8 m). The enclosed intake pipe ring may be used
to facilitate direct air intake to the burner through the right
side of the cabinet. The AFG burner requires a special kit
for direct air intake. Refer to kit instructions.
To convert the AFII burner from confined space to outside
combustion air, simply remove the three screws attaching
the inlet air scoop to the burner and insert 4" (102 mm) direct air intake piping.
The use of a barometric relief placed in the intake pipe is
recommended when outdoor combustion air is directly
connected to the burner. This will allow confined space air
to be used as combustion air in the event that the opening
to the outdoor air becomes blocked. Using a barometric relief in the intake will reduce the chance of sooting.
Page 9
CAUTION
DO NOT USE a barometric draft relief in exhaust vent
pipe if outdoor combustion air is connected directly
to the burner.
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 connected to the common venting system. If venting system
has been installed improperly, the system must be corrected as outlined in the previous section.
1 − Seal any unused openings in the common venting sys-
tem.
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.
3 − Insofar as is practical, close all building doors and win-
dows and all doors between the space in which the appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any
exhaust fans, such as range hoods and bathroom exhausts, 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 thermostat 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 their previous condition of use.
7− If improper venting is observed during any of the
above tests, the common venting system must be corrected.
Horizontal Venting
The O23 is approved for horizontal venting with the following mechanical vent systems:
Tjernlund (sideshot) #SS1C (Cat. #35E08) or Field Controls #SWG−5 (Cat. #35P08) with the CK−61 (Cat. #18N28)
control kit. Refer to the manufacturers’ installation instructions for proper installation procedures and service parts
information.
Do not use the same vent with any other appliance
when using a sidewall vent system.
Maximum permissible vent length is 70 equivalent feet.
Minimum length is 15 equivalent feet. Calculate the equivalent vent pipe footage from the furnace to the mechanical
vent system (Tjernlund or Field Controls) by adding the
straight vent pipe length and the equivalent elbow lengths
together.
Locate the barometric draft control within 18 inches of the
furnace flue outlet. See figure 12 for barometric draft control location.
HORIZONTAL VENTING
barometric
control*
horizontal venting
control
*Barometric control must
be installed in the hori-
zontal venting system and
located within 18" of flue
outlet of furnace.
Figure 12
Flue Connections
IMPORTANT
When flue pipe is installed at less than minimum
clearance listed in table 2, radiation shields must be
installed. See figure 13.
Page 10
combustible
material
unit
cabinet
noncombustible
spacers
Radiation Shield Installation
O23 unit
(top)
radiation
shields
A
See note 2
radiation shields
(see note 1)
flue
pipe
A
See note 3
1"
(25 mm)
min
(305 mm)
(178 mm)
B
12"
min
7"
min
est flue or vent connector, plus 50% of the area of any additional flues or vent connectors. Install a 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.
Install draft control at least 12 inches beyond the furnace. If
there is no space to install the draft control in the flue pipe it
may be installed in the vent above the flue pipe. Follow the
instructions packed with the draft control.
Alternate Side Flue Connections
The vent pipe may exit the top or sides of the cabinet. A
hole is provided in the top cap for top exit. For side exit, locate the center hole punched in the side of the cabinet. See
unit dimensions on page 2. Using it as the center point, cut
a 6 inch (152 mm) round hole in the cabinet’s side. Install
the barometric draft control within 18 inches of the furnace
flue outlet.
Attach the provided finishing plate to cover rough edges.
O23 UNIT
(front)
NOTE 1−Radiation shields must be constructed of 24 gauge sheet
metal minimum.
NOTE 2−Radiation shields required when A is less than 9" (229 mm).
NOTE 3−Radiation shields should extend from the top of the unit to
the top of the flue pipe.
Figure 13
Use 24 gauge or heavier galvanized smoke pipe and fittings to connect the furnace to the vent. 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 larg-
Supply & Return Air Plenums
Secure return air plenum to unit using sheet metal screws.
NOTE − The following are suggested procedures that should
be followed when installing the supply air plenum.
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− Install supply and return air ducts as desired.
Oil Supply Lines 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.
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 and no return
line should be adequate. See figure 14.
Page 11
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 eliminate air in the gun assembly.
Fill
Pipe
Air Vent
Oil Piping
Two-Pipe System
Return
pipe
fuel
pump
Aux
Filter
Inlet
Oil Piping
air vent
fill
pipe
To determine the correct tubing size for piping, refer to table 3 .
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 conditions of up to 10 feet (3 m) and/or a vacuum of 10" (254
mm) Hg or less. See figure 15. Use a two−stage fuel pump
when lift exceeds 10 feet (3 m) and/or a vacuum of 10" (254
mm) Hg to 15" (381 mm) Hg. Both conditions require that
you use of a two−pipe 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 4 .
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.
One-Pipe System
Oil
Tank
Shut−off
Valve
Figure 14
Table 3
One−Pipe Oil Sizing
Two−Pipe System
fuel
pump
Aux
Filter
8 ft (2.4 m)
Maximum
One Pipe Lift
IMPORTANT
Both oil supply and return pipes must be submerged
in oil in the supply tank.
Oil
Tank
Return
pipe
3"−4"
(76 mm −102 mm)
R
outside tank fuel pump above bottom of tank.
H
Figure 15
Table 4
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)
(23.2 m)
76’
Oil Supply Line & Filter Connections
One−Pipe Systems
CAUTION
Do not install the bypass plug into the pump on one−
pipe systems.
The burner is shipped with fuel pump set for one−pipe operation. For one−pipe systems, the oil supply pipe is connected 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.
Page 12
1 − Connect the inlet pipe to the pump inlet. Start the burner.
2 − Arrange the primary burner control for continuous op-
eration during purging. See figure 14.
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 operating 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 according to the provided pump instructions. Notice in the twopipe 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 NO TAG.
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 NO TAG.
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 filter inside
the building between the tank shut-off valve and the burner.
Locate filter close to burner for easy maintenance. Table 5
lists the filters for the O23 furnace.
Table 5
Installation Clearances inches (mm)
Oil Filters
Cat.
Number
Consult burner manufacturer’s instructions packaged with
unit for further details concerning oil supply pipe connections.
Leak Check
After oil piping is completed, carefully check all piping connections (factory and field) for oil leaks.
Oil Pipe Heater (Optional)
A heater for the oil pipe is available for applications that are
located in cold climates. The heater warms the oil pipe to
assist the initial start−up.
Electrical Wiring
All wiring must conform to the National Electric Code
(NEC), or Canadian Electric Code (CEC) and any local
codes. Refer to figure 16 for the terminal designations on
the fan control board.
1− Refer to the appliance rating plate for proper fuse size.
2− Install the room thermostat and make wire connections
to the fan control board. Avoid installing thermostat on
an outside wall or where it can be affected by radiant
heat. Set the adjustable heat anticipator on thermostat
according 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.
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 and figure 16 for O23 series
units. Ground unit using a suitable ground wire.
5− Any accessory rated up to 1 amp can be connected to
the accessory terminal. The accessory terminal is energized when the blower is operating.
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
IMPORTANT
When an accessory is being used in a continuous fan
application which does not include the S68 ON/OFF
switch, the accessory must be wired between L1 and
N on the fan control board to ensure proper voltage.
Page 13
Fan Control Board
thermostat
terminal strip
Figure 16
Typical O23 Wiring Diagram
fan off
delay switches
Figure 17
Page 14
Typical O23 Wiring Diagram
Figure 18
Page 15
Unit Start−Up & Adjustments
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 system 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 door must be in place before start−up.
readings, subtract the readings. The difference in temperatures in the supply and return air plenums should approximate the temperature rise range listed in table 6 and the appliance rating plate. If not, adjust the blower motor pulley to
adjust the blower speed.
Table 6
O23
nozzle size,
Unit
−70 .50GPH−80° A 100 70,000 57,000 FB0 60−70
−105 .65GPH−80° B 140 105,000 84,000 FB3 65−75
−120 .75GPH−80° B 140 119,000 105,000 FB3 70−80
−140 .85GPH−80° B 140 140,000 112,000 FB6 65−75
−154 1.0GPH−80° B 140 154,000 125,000 FB6 70−80
spray
angle,
& pattern
pump
PSIG
input
rating
BTU/HR
output
rating
BTU/HR
head temp
rise
F°
1− Set thermostat for heating demand and turn on electri-
cal supply to unit.
2− Check initial air adjustment. All units are equipped with
an air adjustment dial on the right side of the burner.
See burner parts arrangement illustration.
3− Turn unit on. Place a can or container under the bleed
port located on the fuel pump. Loosen nut on bleed port
to release air and oil mixture from fuel line. Allow mixture to escape until a steady stream of oil is emitted
from the port. Drain at least 1/2 pint of oil from the
pump. Retighten the nut on bleed port. If lockout occurs, press reset button and continue with bleed procedure.
NOTE − A two−pipe 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.
4− If burner fails to start, push reset button on primary
safety control and the burner motor reset button. See
part arrangement illustration.
CAUTION
Do not push the reset button on the primary control
more than one time.
5− If the burner fails to light again, refer to the trouble-
shooting section in this manual.
A − Fuel Pump Pressure
Measure fuel pump pressure with unit off. Attach pressure
gauge to pump outlet. Turn unit on and check pressure and
compare to table 6. Adjust if necessary.
B − Temperature Rise
To measure temperature rise, place plenum thermometers
in warm air and return air plenums. Locate thermometer 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
C − Limit Control
Limit Control − Do not adjust it from factory setting.
D − Fan Control
The fan on time of 30 seconds is not adjustable. Fan off
time (time that the blower operates after the heat demand
has been satisfied) can be adjusted by moving the delay
switches on the fan control board. Fan off time will affect
comfort and is adjustable to satisfy individual applications.
See figure 19. Set the heat fan off delay switches to either
60, 90, 120, or 150 seconds. The factory setting is 90 seconds.
Fan Off Delay Switch Settings
120 sec90 sec60 sec
Figure 19
150 sec
E − Burner Adjustment
The following instructions are essential to the proper operation of O23 series oil furnaces. To prevent sooting,
these instructions must be followed in sequence:
1 − Draft
This test should be taken at the breach between the outlet
of the vent connector and the barometric 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 accommodate the products of combustion. The temperature in
the unconditioned space will also affect the draft if long vent
connectors are allowed to get too cold.
Page 16
2 − Overfire Draft
This test should be taken with the burner in operation. Remove the screw 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 at the air adjustment dial.
3 − Smoke Test
The smoke test should be taken at the hole drilled in step 1.
Using a smoke test gun adjust the air inlet shutter so that
you will have just a trace of smoke. Somewhere between a
0 and #1 smoke. 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 operation establishes some
tolerance. The tolerance the installer 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 inlet shutter to increase the air and drop
the CO2 to 10%.
5 − Retest the Smoke
With a drop in the CO2 and increase in the air you should
see that the smoke has returned to 0.
6 − Retest the Overfire Draft
Service
CAUTION
Do not tamper with unit controls. Call your qualified
service technician.
A − Servicing Filter
NOTE − Under no circumstances should the access panels
to the blower compartment be left off or left partially open.
Throw-Away Type Filters Check filters monthly and re-
place when necessary to assure proper furnace operation.
Replace filters with like kind and size filters.
Reusable Type Filters Filters should be checked monthly and cleaned when necessary to assure proper furnace
operation.
B − Blower
Blower motor is prelubricated and sealed for extended operation. No further lubrication is required. Disconnect power to unit before cleaning blower wheel for debris.
C − 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.
D − Cleaning the 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 attachment, 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.
This test serves to confirm 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 control.
7 − Stack Temperature
Take a stack temperature reading in the vent pipe. Subtract
the room air temperature from the stack temperature. This
will give you the net stack temperature. Use the efficiency
charts provided in most CO2 analyzers to determine furnace efficiency.
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 the burner, blower deck and vestibule
area.
NOTE − A heat exchanger clean-out kit ABRSH380
(35K09) is available from Lennox.
Page 17
Troubleshooting
Burner failure or improper operation can result from a number of different causes.
Often the cause can be pinpointed by observing the different types of failure or by the process of elimination. The fol-
Troubleshooting: Fan board operating sequence
Action System Response
lowing troubleshooting charts list some failures, causes
and a sequence of steps to isolate the point of failure.
Check the simplest and most obvious items before progressing to other items.
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.)
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.
ST9103A closes oil primary control T−T connections.
Ignition system and oil primary control start the furnace. Oil flows as long as oil primary
control 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 timing begins. When timing is complete, the circulating fan is de−energized.
ST9103A returns to standby mode (oil primary control and circulating fan are off).
Burner motor is de−energized.
If heat fan has started, it continues through the selected delay off period.
If selected 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.
Circulating fan and cooling compressor turn off immediately.
Circulating fan is energized immediately at cool speed.
ST9103A may be factory−configured to operate heat speed in this mode.
Circulating fan is de−energized.
Circulating fan is energized immediately at heat speed.
ST9103A opens oil primary control T−T connections.
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.
Limit switch string closes. ST9103A begins heat fan off delay sequence.
Continuous circulating fan is connected.
(Optional connectors are available for separate circulating fan speed tap.)
Electronic air cleaner is connected.
(Optional connectors are available for 120 Vac electronic air cleaner.)
Humidity control is connected.
(Optional connectors are available for 120 Vac humidifier.)
Circulating fan turns off after the selected heat fan off delay timing.
ST9103A closes oil primary control T−T connections.
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.
If fan operation is required by a call for heat, cool, or fan, the ST9103A switches off the
continuous fan speed tap before energizing the other fan speed.
Electronic air cleaner (EAC) connections are energized when the heat or cool speed of
the circulating fan is energized. EAC connections are not energized when the optional
continuous fan terminal is energized.
Humidifier connections are energized when the burner motor is energized.
Page 18
Troubleshooting: Burner fails to start.
Check f
t
Thermostat
mostat terminals on primary
fault is in the thermostat circuit
,
the burner starts, fault is in the
Pri
ili
l
indicat
black
hite leads to th
p
blower wheel by hand. If seized
power to the motor and burner
Source Procedure Causes Correction
Thermostat in OFF or COOL Switch to HEAT.
Thermostat Check thermostat settings.
Thermostat is set too low
Burner motor overload tripped Push reset button pump motor.
Turn thermostat to higher temperature.
Safety Overloads
Power
CAD Cell
Primary Control
Burner
Check burner motor, primary
safety control, & auxiliary limit
switch.
urnace disconnec
switch & main disconnect.
Touch jumper wire across thermostat terminals on primary
control. If burner starts, then
Disconnect the flame detector
wires at the primary control. If
the burner starts
detector circuit. short circuit in the flame detec-
Place trouble light between the
black and white leads. No light
es 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 black and white leads to the
burner motor. No light indicates
that no power is getting to the
motor.
Place trouble light between the
and w
blower motor. Light indicates
ower to the motor and burner
fault.
fault is in the
e
Primary control tripped on safety
Auxiliary limit switch tripped on
safety
Open switch Close switch.
Blown fuse or tripped circuit
breaker
Broken or loose thermostat
wires
Loose thermostat screw connection
Dirty thermostat contacts Clean contacts.
.
Thermostat not level Level thermostat.
Faulty thermostat Replace thermostat.
Flame detector leads are
shorted
Flame detector exposed to light Seal off false source of light.
tor
mary or aux
switch is open
Open circuit between disconnect switch and limit control
Low line voltage or power failure
Defective internal control circuit Replace the control.
Blown fuse Replace the fuse.
Binding burner blower wheel
Sized fuel pump
Defective burner motor Replace the motor.
ary contro
Reset primary control.
Reset auxiliary limit.
Replace fuse or reset circuit
breaker.
Repair or replace wires.
Tighten connection.
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 replace it.
Call the power company.
Turn off power and rotate the
blower wheel by hand. If seized,
free the wheel or replace the
fuel pump.
,
Page 19
Troubleshooting: Burner starts, but no flame is established.
Start the b
ilk
Air leak i
pggpp
pray (g
serve the oil spray (gun assem
Repl
Inspect the nozzle for plugged
type
Cl
gap
the gap to 5/32 inches and cor
g
p
to transformer primary
pp
ing or excessive drag
Source Procedure Causes Correction
Oil Supply
Oil Filters & Oil Line
Oil Pump
Nozzle
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.
urner. No oil or m
oil indicates loss or prime.
Install pressure gauge on pump
and read pressure. Should not
be less than 140 psi.
Disconnect ignition leads. Observe the oil s
bly must be removed from unit).
Inspect the nozzle for plugged
orifice or carbon build−up around
orifice.
un assem-
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.
y
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 100 psi.
Nozzle orifice plugged
Nozzle strainer plugged
Poor or off center spray
Fouled or shorted electrodes
Dirty electrodes and leads
n oil supply line
If water depth exceeds 1 inch,
pump or drain water.
Locate and correct leak.
Tighten all connections.
Replace pump.
Re−engage or replace coupling.
ace nozzle with the same
size, spray angle, and spray
.
ean electrode leads.
Ignition Electrodes
Ignition
Transformer
Burner Motor
Remove gun assembly and inspect electrodes and leads.
Connect ignition leads to the
transformer. Start burner and observe spark. Check line voltage
rimary.
to transformer
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-
.
.
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.
Cracked or burned lead insulators
Low line voltage
Burned out transformer windings.
No spark or weak spark
Low line voltage
Pump or blower overloading
motor
Faulty motor Replace motor.
Clean electrode tips and reset
the
rectly position tips.
Replace electrode leads.
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.
to 5/32 inches and cor-
Page 20
Troubleshooting: Burner starts and fires, but lock out on safety.
p
due to poor
ately jumper
y
If fire is good
mary control
(d
k
If fire is good
Fl
across flame
in the fuel sys
Source Procedure Causes Correction
Unbalanced fire Replace nozzle
Reduce combustion air − check
combustion.
Increase combustion air − check
combustion.
Adjust barometric damper for
correct draft.
Correct draft or remove restriction.
Replace cad cell.
Secure connections or replace
cad cell holder and wire leads.
Poor Fire
Flame Detector
Primary Control
After burner
fires, immedi-
across flame
detector terminals at the primar
control.
.
If burner continues to run,
this may be
due to
fire. Inspect
fire.
fault is in the
flame detector.
Check detector circuit.
If burner locks
out on safety,
fault is in the
primary control.
oor
Too much air − −lean short fire
Too little air − − long dirty fire
Excessive draft
Too little draft or restriction
Dirty cad cell face Clean cad cell face.
,
Faulty cad cell − exceeds 15000
hms
Loose or defective cad cell
wires
Primary control circuit defective Replace primary control.
Troubleshooting: Burner Starts and Fires, but Loses Flame and Lock Out on Safety
Source Procedure Causes Correction
Unbalanced fire Replace nozzle
Too much air − − lean short fire Reduce combustion air − check
combustion.
combustion.
Adjust barometric damper for
correct draft.
Correct draft or remove restriction.
Replace CAD cell.
Secure connections or replace
cad cell holder and wire leads.
Check supply line for loose connections and tighten fittings.
inch) pump or drain out water.
Replace nozzle.
Poor Fire If burner con-
tinues to run
oes not loc
out of safety),
fault may be
After burner
ame Detector
Oil Supply
fires, immediately jumper
across flame
detector terminals at the primary control.
fault is in the
flame detector.
Check detector circuit.
If burner loses
flame (does
not lock out on
safety), fault is
in the fuel system.
Too little air − − long dirty fire Increase combustion air − check
Excessive draft
Too little draft or restriction
Dirty CAD cell face Clean CAD cell face.
,
Faulty CAD cell − − exceeds
15000 hms
Loose or defective cad cell
wires
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.
Listen for pump whine
Plugged fuel pump strainer Clean strainer or replace pump.
Cold oil − outdoor tank Change to number 1 oil.
Page 21
Troubleshooting: Burner starts and fires, but short cycles (too little heat)
Thermostat
Check thermostat
(
Limit Control
control (black & white leads). If
P
If burner turns
Thermostat
p
circuit.
wires at the pri
Source Procedure Causes Correction
Heat anticipator set too low Correct heat anticipator setting.
Thermostat Check thermostat.
Connect voltmeter between line
Limit Control
ower power source. Recheck voltage
voltage connections to primary
control
burner cycles due to power interruption, it is cycling on limit.
If voltage fluctuates, fault is in the
at the power source.
black & white leads). If
.
Vibration at thermostat Correct source of vibration.
Thermostat in the path of a
warm air draft
Dirty furnace air filters Clean or replace filter.
Burner running too slow
Blower motor seized or burned
out
Blower bearings seized Replace bearings and shaft.
Blower wheel dirty Clean blower wheel.
Blower wheel in backward Reverse blower wheel.
Wrong motor rotation
Restrictions in return or supply
air system
Adjustable limit control set too
low
Loose wiring connection Locate and secure connection.
Low or fluctuating line voltage Call power company.
Shield thermostat from draft or
relocate.
Increase blower speed to maintain proper temp. rise.
Replace motor.
Replace with properly rotating
wheel.
Correct cause of restriction.
Reset limit to maximum stop
setting.
Troubleshooting: Burner runs continuously (too much heat).
Source Procedure Causes Correction
Thermostat
Primary control
Disconnect
thermostat
wires at the
mary control.
If burner turns
off, fault is in
the thermostat
circuit.
ri-
-
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
Defective primary control
Repair or replace the thermostat.
Clear obstruction or replace
thermostat.
Correct draft or relocate the
thermostat.
Replace the defective primary
control.
Page 22
Troubleshooting: Burner runs continuously (too little heat).
L
CO
l
Dirt
g
Check b
reading more
CO2, stack tem
smoke
High stack tem
550 F Net.
Oil P
Inspect fire and check
Source Procedure Causes Correction
Too much combustion air Reduce combustion air.
Combustion
ressure
urner
combustion for
CO2, stack temperature, and
Inspect fire and check
oil pressure.
ow
ess
2
than 10%.
High smoke
readin
more
than a trace.
High stack temperature is
more than
_F Net.
550
Air leaks into heat exchanger
around inspection door, etc.
Excessive draft
Incorrect burner head adjustment
Correct cause of air leak.
Adjust barometric draft control for correct draft.
Correct burner head setting.
Clean heat exchanger.
y or plugged heat exchanger
Readjust burner.
Insufficient draft Increase draft.
Incorrect burner head adjustment
Correct burner setting.
Too little combustion air Increase combustion air.
Too little blower air
Blower belt too loose (if
equipped)
-
Increase blower speed to
maintain proper temp. rise.
Tighten blower belt.
Dirty or plugged heat exchanger Clean heat exchanger.
Dirty blower wheel Clean blower wheel.
Dirty furnace air filters Clean or replace filter.
Restricted or closed registers or
dampers
Partially plugged or defective
nozzle
Oil pressure is too low: less
than 100 psi.
Readjust registers or dampers.
Replace nozzle.
Increase oil pressure top
100psi.
Page 23
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