Lennox OF23Q3/4-105, OF23Q3/4-120R, OF23Q3/4-120, OF23Q5-140, OF23Q5-154 Installation Instructions Manual
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INSTALLATION
E 2002 Lennox Industries Inc.
Dallas, Texas, USA
Front
Flue Model
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.
INSTRUCTIONS
OF23 SERIES UNITS
OIL UNITS
504,627M
38152A060
01/04
Supersedes 04/02
Table of Contents
General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping & Packing List 1. . . . . . . . . . . . . . . . . . . . . . .
OF23 Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . .
OF23 Start−Up & Performance Check List 2. . . . . . .
OF23 Unit Parts Arrangement 3. . . . . . . . . . . . . . . . . . . .
OF23 Oil AFII Burner Parts Arrangement 4. . . . . . . . . .
Requirements 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locate & Level Unit 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Adjustments 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flue Connect ions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply & Return Air Plenums 11. . . . . . . . . . . . . . . . . . . .
Oil Supply Lines Sizing 11. . . . . . . . . . . . . . . . . . . . . .
Connect Oil Supply Line and Filter 13. . . . . . . . . . . . .
Leak Check 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up & Adjustment 15. . . . . . . . . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
OF23 oil furnaces. In Canada, refer to CSA B139 for recommended installation procedures. Consult authorities
who have jurisdiction before installation.
Litho U.S.A.
®
Series
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.
01/04
*2P0104*
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 (front flue units only)
1− Direct intake collar (AFII burner units only)
Check the components for shipping damage. If you find any
damage, immediately contact the last carrier.
504,627M
Page 1
*P504627M*
OF23 Unit Dimensions − Inches (mm)
1-1/2
(38)
FLUE CONNECTION
OF23Q3/4-105/120R,
OF23Q5-140/154R
OF23Q5−175/210R
C
3/4
(19)
RETURN
E
OPENING
3/4
(19)
AIR FLOW
3/4
(19)
3-1/4
(83)
E
AIR
3/4
(19)
TOP VIEW
C
AIR FLOW
FLUE CONNECTION
OF23Q3/4-105/140 &
OF23Q5-140/154
(On Heat Exchanger)
ELECTRICAL INLETS
(Right Side Only)
FG
SUPPLY
AIR
OPENING
TOP FLUE
OUTLET
SIDE
FLUE OUTLET
CENTERING HOLE
(Field Fabricate
Either Side)
OPT. OUTDOOR
COMBUSTION
AIR INLET
CENTERING HOLE
(Field Fabricate
Right Side only)
A
B
1
(25)
Model No.
OIL PIPING INLET
(Both Sides)
SIDE VIEW FRONT VIEW
1 (25)
6-1/2
(165)
A B C D E x F (Supply) E x G (Return)
in. mm in. mm in. mm in. mm in. mm in. mm
OF23Q3/4-105/120 19-1/2 4959 37 940 52−1/2 1334 27 686 18 x 21 457 x 533 18 x 16 457 x 406
OF23Q3/4-105/120R 19-1/2 495 37 940 52−1/2 1334 27 686 18 x 21 457 x 533 18 x 16 457 x 406
OF23Q5-140/154 22-1/2 572 37 940 52−1/2 1334 27 686 21 x 21 533 x 533 21 x 16 533 x 406
OF23Q5-140/154R 22-1/2 572 37 940 52−1/2 1334 27 686 21 x 21 533 x 533 21 x 16 533 x 406
OF23Q5-175/210R 24 610 39−1/4 997 55 1397 29 737 22−1/2 x 23−1/8 572 x 587 22−1/2 x 16−1/2 572 x 419
OF23 Start−Up & Performance Check List
Job Name
Job Location
Installer
Unit Model No.
HEATING SECTION
Electrical Connections Tight?
Supply Voltage
Blower Motor Amps
Blower Motor H.P.
Blower Motor Lubrication O.K.?
Piping Connections Tight?
Burner Model No.
All Valves Open?
Serial Number
Oil Pump Pressure [recommended minimum 140 psi]
Job No.
City
City
Serial No.
Date
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?
Page 2
OF23 Unit Parts Arrangement
flue opening
clean-out port
limit switch
control box
with fan control
board
observation port
filter
indoor blower
heat exchanger
BeckettR AFII Burner
(Shown)
OF23 Oil AFII Burner Parts Arrangement
RETAINING
CLIP
HEAD SCREW
HEAD
INSULATOR
ADAPTER
FLANGE
GASKET
AIR TUBE
ASSY FOR
FB HEADS
1/4" HEX
FB−HEAD
NOZZLE
NOZZLE LINE
ELECTRODE HEAD
ASSY.
FLANGE
ELECTRODE
ASSY
AIR TUBE
SCREWS
PEDESTAL
PREMOUNTED OIL−DELAY VALVE
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
clean−out
port
IGNITOR
MOTOR
PRIMARY
CONTROL
BLOWER
WHEEL
4X4
BOX
0
3
4
5
6
7
8
AIR
ADJ.
DIAL
INLET
AIR SCOOP
Figure 2
Page 3
Requirements
Table 1
Combustion Air Opening Dimensions
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
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 OF23 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.
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.
IMPORTANT
An opening to the outside for combustion air is
strongly recommended, especially in new homes.
Refer to table 1 or the unit plate for specific combustion air opening dimensions.
Model No.
O23−105/120
O23−105R/120R
O23−140/154
O23−140R/154R
O23−175R/210R
O23−175R/210R
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.
Combustion Air Opening
Dimensions (2 required)
10" X 20" (254 mm X 508 mm)
11" X 22" (279 mm X 559 mm)
20" X 40" (508 mm X 1016 mm)
Table 2
Installation Clearances
Clearances
top of plenum and duct 2 (51)
plenum sides 3 (76)
sides* 6 (152)
rear 24 (610)
front 4 (102)
flue pipe measured vertical**
(measured from above)
NOTE−Service access clearance must be maintained.
*Clearance to allow inspection of furnace and flue connector
shall be provided. 24" (610 mm) at rear and on one side of furnace should
be allowed for cleaning and service of the blower.
**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 and CSA 189.
NOTE − When service clearances are greater than fire
protection clearances, service clearances take precedence.
Unit must be adjusted to obtain a temperature rise within
the range listed in table 3 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.
All Unit Sizes
inches (mm)
9 (229)
Page 4
Locate & Level the Unit
The compact design of this furnace makes it ideal for a
basement or utility room installation. Choose a central
location for the furnace so that supply air ducts approximately the same length. This will allow each room to receive the proper amount of heat. The furnace should be
placed so that the flue connection to the chimney will be of
minimum length and have a minimum number of elbows.
1− Set the unit in desired location keeping in mind the
clearances 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 Oil vacuum gauge
D Beckett T−500 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.
Nozzle Adjustment
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. This may easily be done by removing 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. Note that
OF23−105/120 and OF23−140/154 series units use the
Beckett AFII burner. OF23−175/210R series units use the
Beckett AFG burner.
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, just turn
the burner around in the vest panel area.
OF23 Series Burner Removal
First, loosen three nuts which
attach burner to vest panel.
Next, rotate burner counter-
clockwise on slots then pull
toward you.
Figure 3
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. Corrections are
made by sliding the entire nozzle assembly forward or
backward within the blast tube (figure 4). At the same time,
nozzle alignment must be checked.
To check nozzle alignment, again insert the small end of
gauge 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.
Page 5
Beckett Oil Burner Nozzle Adjustment
Burner must be removed from
furnace for this procedure.
gauge
To Adjust Nozzle
1−Loosen screw.
2−Slide entire nozzle/electrode assembly back and forth until
nozzle just touches gauge.
2
1
Figure 4
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.
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
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
higher temperature rating and is constructed with an inner
liner of stainless steel rather than aluminum).
thimble
combustible
wall
vent pipe
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
Front Flue / Masonry Chimney
barometric
control*
(in either location)
Rear Flue / Masonry Chimney
barometric
control*
(in either location)
clean out
liner
clean out
masonry
chimney
liner
clean out
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.
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.
Front Flue / Factory−Built Chimney
barometric
control*
(in either location)
factory
built
chimney
clean out
*Barometric control may be installed in either vertical or horizontal section of flue pipe within 18" of flue outlet of furnace.
masonry
chimney
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.
drain for
condensate
Rear Flue / Factory−Built Chimney
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
Page 7
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