Lennox O23V-154, O23V-140, O23V2-70, O23V5-154, O23V-90 User Manual
...
INSTALLATION
,t_2005 Lennox industries Inc,
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
A IMPORTANT
INSTRUCTIONS
O23V Series Units
OIL UNITS _ Technical
505,082M LL.L[ Publications
10/05 Litho U.S.A.
General ...................................... 1
Shipping & Packing List ........................ 1
O23V Unit Dimensions ......................... 2
O23V Unit Parts Arrangement ................... 3
O23V Oil BurnerPartsArrangement ................ 3
Requirements ................................. 4
Locate & Level the Unit ........................ 4
Unit Adjustments .............................. 5
Venting ...................................... 5
Flue Connections .............................. 10
Supply & Return Air Plenums ................... 10
Oil Supply Lines Sizing ......................... 10
Oil Supply Line & Filter Connections ............. 12
Leak Check ................................... 12
Electrical ..................................... 12
Blower Control ................................ 13
Unit Start-Up & Adjustments .................... 17
Service ...................................... 18
Heating Events Actions & Responses ............ 18
Troubleshooting ............................... 19
Oil Furnace Start-Up & Check List ............... 24
O23V SERIES UNITS ARE NOT FOR USE IN
ZONING APPLICATIONS!
These instructions are intended as a general guide and do
not supersede local codes in any way. Only qualified tech-
nicians can install and service the Dave Lennox Signa-
ture'" Collection O23V oil furnaces. In Canada, refer to
CSA B139 for recommended installation procedures. Con-
sult authorities who have jurisdiction before installation.
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.
a WARNING
a WARNING
10/05
NIIIIIIIIIIIIIIIIIIIIIIllllIlllIlll
Page 1
505,082M
NIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
3/4_19)
SIDE FLUE OUTLET
CENTERING HOLE_
(Field Fabricate Either Side)
ELECTRICAL INLET
(Right Side Only)
OIL PIPING INLET
(Left Side Only)_
OPT. OUTDOOR COMBUSTION
AIR INLET CENTERING HOLE
(Field Fabricate Right Side only)
RETURN AIR OPENING
(Either Side)
3/4 (19)
1-1/2 (38)--IP,
4
_" B
D-------_ c==_
C SUPPLY O
OPENING _
AIR czz_
TOP VIEW
' I
22-.4
I 14 (559) I
I (356) I
I I
I___t ..... /
CZ222ZD
,J
TOP FLUE OUTLET
J
CONNECTION
Exchanger)
J
,91_1-1/2
(38)
t
23-1/2
(597)
FLUE
(On Heat
T
54
(1372)
_ r
,_----- A -----_
\
It
AIR FLOW
1-1/4 (32)--Ip
_ 2151t___22
(559)
RETURN AIR SIDE VIEW
Figure 1
,_I_E
RETURN AIR FRONT VIEW
_, WARNING
iii_i_i_i_i_:_i_i_i_i_bi_i_i:_i_!_i!_i_i_i_i_ji_i!_i_i_iii_I_ii_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_i_!_!_!:
O23V Model A B C D E
-Q2/3-70/90
&-
Q3/4-105/120 (495) (778) (457) (498) (406)
-Q5-140/154
19-1/2 30-5/8 18 19-5/8 16
22-1/2 33-1/8 21 22-1/8 18
(572) (841) (533) (562) (457)
CAUTION
505082M 10/05
Page 2
CLEAN-OUT PORT
HEATEXCHANGER
FLUE OPENING
LIMIT SWITCH
CONTROL BOX WITH
FAN CONTROL BOARD
BECKETT@
AFIIBURNER
CLEAN-OUT PORT
OBSERVATION PORT
COMBUSTION AIR INTAKE
VARIABLE SPEED
BLOWER MOTOR
CAPACITOR
Figure 2
FLANGE GASKET IGNITION REAR ACCESS CONTROL BOX ADJUST
AIR TUBE REAR ACCESS \
ASSY FOR FLANGE DOOR ASSY
RETAIN- FB-HEADS X
ING CLIP ESCUTCHEON
SCREW
CONNECTOR TUBE ELECTRONIC PRIMARY 4X4 AIR
AIR TUBE TRANSFORMER DOOR GASKET IGNITOR DIAL
SCREWS
PLATE
SPLINED
NUT
MAIN
NOZZLE ADAPTER
NOZZLE LINE ELECTRODE
HEAD ASSY,
ELECTRODE ASSY FUEL
PRE-MOUNTED OIL-DELAY VALVE T- PEDESTAL COUPLING
Figure 3
Page 3
ASSY
PUMP
MOTOR BLOWER INLETAIR
WHEEL SCOOP
O23V SERIES
A CAUTION
A CAUTION
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 Equip-
ment, the Canadian Electrical Code Part1, CSA 22.1
(Canada), the recommendations of the National Envi-
ronmental Systems Contractors Association and any
state or provincial laws or local ordinances. Authorities
having jurisdiction should be consulted before installa-
tion. 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
O23V units in confined spaces such as utility rooms,
two combustion air openings are required. Dimen-
sions 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.
Table 1
Combustion Air Opening Dimensions
Model No.
O23V-70/90/105/120
O23V-140/154
(2 openings required)
10" X 20" (254 mm X 508 mm)
11" X 22" (279 mm X 559 mm)
The combustion air opening should provide a mini-
mum 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 2
O23V Installation Clearances
Clearances inches (mm)
top of plenum & duct 2 (51)
plenum sides 3 (76)
sides 0 (0)
rear 0 (0)
front 4 (120)
flue pipe 6 (152)
With the HEAT selector pin in the position shown in the
wiring diagram (on page 16), the unit must operate at
a temperature rise in the range listed in table 7 (on
page 17).
• When installed, furnace must be electrically grounded
in accordance with local codes or, in the absence of lo-
cal 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 connections with the unit must meet or ex-
ceed specifications of type T wire and must withstand
a 63'_F (17'_C) temperature rise.
• If installing a programmable thermostat, use a type
which retains its memory in event of a power loss.
• When the furnace is used in conjunction with cooling
units, it shall be installed in parallel with, or on the up-
stream 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 d air) shall
be adequate to prevent chilled air from entering the fur-
nace 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.
Xk WARNING
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 acces-
sibility clearances take precedence over fire protec-
tion clearances.
A IMPORTANT
505082M 10_5
Set the unit in desired location keeping in mind the clear-
ances listed in table 2. Also keep in mind oil supply connec-
tions, electrical supply, flue connections and sufficient clear-
ance for installing and servicing unit.
Level the unit from side to side and from front to rear. If the
furnace is not level, place fireproof wedges or shims be-
tween 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 ifweight of furnace is not evenly
distributed.
Page 4
Neitherthenozzlesettingnortheairadjustmentsarefac-
toryset.Thefurnaceisfiretestedandthelimitcontrolis
checkedtomakesureitfunctionsproperly;nofactoryset-
tingsaremade.Duringinstallation,thefurnacemustbe
"setup."Theinstallingdealer/contractormusthaveand
usepropertestequipmentinordertocorrectlysetupthe
oilfurnace.Propertestingequipmentisrequiredtoensure
correctoperationoftheunit.Theuseoftestequipmentis
nowmorecriticalthaneverduetotightertolerancesneed-
edtokeepthefurnaceoperatingefficiently.
Amongthetestequipmentforanoilfurnace,theproper
combustiontestkitshouldcontainthefollowing:
• Draftgauge
• CO 2 or 0 2 analyzer
• Smoke tester
• Pressure gauge
• High temperature thermometer
• Beckett T-500 gauge
• Oil vacuum gauge
• Knowledge of proper test equipment operation
O23V 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 illustra-
tion 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 5). At the same time, check the
nozzle alignment.
Beckett Oil Burner Nozzle Adjustment
Burner must be removed from furnace for this procedure.
GAUGE 2 1
Rotate burner counterclockwise on
slots then pull toward you,
Figure 4
CAUTION
Adjusting the Nozzle
Proper adjustment d the nozzle assembly is critical be-
cause alignment may have changed during shipping. Be-
fore the furnace and oil lines are installed, the nozzle as-
sembly 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 at-
tached 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. By loosen-
ing the nuts and by turning the whole burner assembly
counterclockwise (figure 4), the entire burner assembly
will come out of the furnace. There is adequate wire to re-
move the burner without disconnecting wires. Once re-
moved, turn the burner around in the vest panel area.
TO ADJUST NOZZLE:
1-Loosen screw.
2-Slide entire nozzle/electrode assembly back and forth until nozzle
just touches the gauge.
Figure 5
To check nozzle alignment, again insert the small end into
the end cone and measure the nozzle and electrode align-
ment against the center lines marked on the gauge (again
refer to enclosed illustration sheet). If the nozzle is not cen-
tered, but found to be too far left or right, a new nozzle as-
sembly will need to be ordered. Do not attempt to adjust by
bending the 90 degree elbow in the oil line.
A WARNING
Page 5
O23V SERIES
A, WARNING I
Wall Thimble
A WARNING
CAUTION
NOTE - Oil burning equipment may be vented into an ap-
proved masonry chimney or type L vent. (Type L vent is
similar in construction to type B gas vent. Type L vent car-
ties a 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 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 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 Stan-
dards of the National Board of Fire Underwriters. See
figure 6.
COMBUSTIBLE VENT PIPE
WALL
Figure 6
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 7.
Masonry Chimney
BAROMETRIC
CONTROL*
LINER
(
LOCATION)
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 7
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 area of the additional vent or vent con-
nection. 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 sec-
tions. See figure 8.
505082M 10/05
Page 6
16.Wherecondensationofventgasisapparent,thevent
shouldberepairedorreplaced,Accumulationof 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,
Combustion Air Requirements
WARNING
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
BAROMETRIC
CONTROL*
(IN EITHER_
LOCATION)
FACTORY
BUILT
CHIMNEY
/
\
E
DRAIN FOR
CONDENSATE
D
F _
U U LJ
*Barometric control ma_ be installed in either vertical or horizontal
section of flue pipe within 18" of flue outlet of furnace.
Figure 8
Combustion and Ventilation Air (Confined and
Unconfined Spaces)
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,
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 combus-
tion air needs as well as requirements for exhaust vents
and oil piping,
CAUTION
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
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 (e.g., 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 con-
fined space either from inside the building or from outside,
Page 7
O23V SERIES
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 9),
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
12).
Equipment In Confined Space - All Air
From Outside (Inlet Air From Crawl Space
& Outlet Air To Ventilated Attic)
CHIMNEY VENTILATION
OR OIL _ LOUVERS (Each
VENT end of attic)
Equipment In Confined Space -
All Air From Inside
CHIMNEY OR
OIL VENT
WATER
HEATER
OIL
FURNACE
OPENINGS
(To Adjacent
Room)
! ii ii ii ii ii ii ii ii i
| i
_1 I" =1 I"
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).
Figure 9
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 figures 10 and 12). When communi-
cating with the outdoors through horizontal ducts, each
OIL
FURNACE
VENTILATION
LOUVERS
(For unheated
crawl space)
r 1 f "I
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 en-
closure.
OUTLET
AIR
WATER
HEATER
INLET AIR
rrcrn
Figure
10
Equipment In Confined Space -All
Air From Outside (All Air Through
Ventilated Attic)
CHIMNEY
OR OIL
VENT
OIL (Ends 12" above
FURNACE
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.
VENTILATION LOUVERS
(Each end of a{tic)
INLET AIR
bottom)
HEATER
Figure 11
505082M 10/05
Page 8
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