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

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,

_" 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

TOP FLUE OUTLET

CONNECTION

Exchanger)

,91_1-1/2

(38)

23-1/2

(597)

FLUE

(On Heat

(1372)

_ r

,_----- A -----_

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

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

DRAIN FOR CONDENSATE

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

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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