Lennox OHR23-105, OHR23-120, OHR23-140, OHR23-154 Installation Instructions Manual
®
INSTALLATION
2004 Lennox Industries Inc.
Dallas, Texas, USA
WARNING
This product contain fiberglass wool.
Disturbing the insulation 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
INSTRUCTIONS
OHR23 Series Units
OIL UNITS
504,628M
38152A061
06/04
Supersedes 4/02
Table of Contents
Elite Series Oil Furnace 1. . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List 1. . . . . . . . . . . . . . . . . . . . . . . .
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OHR23 Unit Parts Arrangement 3. . . . . . . . . . . . . . . . . . .
Oil Burner Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . .
Requirements 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply & Return Air Plenums 5. . . . . . . . . . . . . . . . . . . . .
Optional Filter Kit 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Unit Adjustments 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Venting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion and Ventilation Air 8. . . . . . . . . . . . . . . . . . . .
Flue Connections 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Supply Lines Sizing 12. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Supply Line & Filter Connections 13. . . . . . . . . . . . . .
Leak Check 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start−Up & Adjustments 15. . . . . . . . . . . . . . . . . . . . .
Service 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up & Performance Checklist 17. . . . . . . . . . . . . . . .
Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Litho U.S.A.
Elite® Series Oil Furnace
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
OHR23 oil furnaces. In Canada, refer to CSA B139 for recommended installation procedures. Consult authorities
who have jurisdiction before installation.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause personal injury, loss
of life, or damage to property.
Installation and service must be performed by a
qualified installer or service agency.
06/04 504,628M
Page 1
Shipping & Packing List
1− Assembled oil furnace
1− Draft control
Check the components for shipping damage. If you find
any damage, immediately contact the last carrier.
CAUTION
Never burn garbage or paper in the heating system.
Never leave papers near or around the unit.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other
appliance.
When venting this appliance, keep vent terminal
free of snow, ice and debris.
*2P0604* *P504628M*
OHR23 Unit Dimensions − Inches (mm)
OHR23Q3-
OHR23Q5-
Model No. A B C D E F G H
OHR23Q3-
105/120
OHR23Q5-
140/154
in. 20-1/2 20-1/2 18 18 18 18 3 10-1/4
mm 521 521 457 457 457 457 76 260
in. 23-1/2 23-1/2 21 21 21 21 4-3/4 11- 3/ 8
mm 597 597 533 533 533 533 121 289
53 (1346)
4 KNOCKOUTS
(For Suspending)
TOP VIEW
14-1/2
3-1/2
(89)
(368)
AIR
F A
FLOW
F
RETURN
E
AIR
OPENING
TOP VIEW
A
A
8
(203)
C
SUPPLY
D
AIR
OPENING
END VIEW FLUE OUTLET
(4) SPACER
LEGS
3/4
(19)
HEAT EXCHANGER
CLEAN OUT
PORTS (3)
1
(25)
BURNER
HORIZONTAL POSITION
OPTIONAL DOWNFLOW COMBUSTIBLE FLOOR BASE
B
3/4
(19)
FRONT OF
FURNACE
FLUE OUTLET
59 (1499)
G
32-1/2 (826)
H
SIDE
VIEW
RETURN
AIR
3/4
(19)
E B
RETURN
AIR
SUPPLY
AIR DUCT
(Not
Furnished)
AIR
FLOW
32-1/2
(826)
59
(1499)
HEAT
EXCHANGER
CLEAN OUT
PORTS (3)
BURNER
3/4
8
(203)
SUPPLY AIR OPENING
(19)
DC
SUPPLY AIR OPENING
SIDE VIEW FRONT VIEW
DOWNFLOW POSITION
105/120
16-1/4(413)
H
140/154
20-1/4(514)
FLUE
OUTLET
105/120
16-1/4(413)
140/154
20-1/4(514)
BURNER
Additive Base Raises Furnace
3/4 in. (19 mm) Inch above Floor Level
OPTIONAL
DOWNFLOW
ADDITIVE
BASE
COMBUSTIBLE
FLOOR
Page 2
OHR23 Unit Parts Arrangement
BECKETT
AFII BURNER
CLEAN−OUT PORT
CLEAN−OUT PORT
WITH FAN CONTROL BOARD
FLUE OPENING
HEAT EXCHANGER
INDOOR
BLOWER
CONTROL BOX
OHR23 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
PEDESTAL
PRE−MOUNTED OIL−DELAY
Figure 1
ELECTRONIC IGNITION
TRANSFORMER
REAR ACCESS
DOOR ASSY
MAIN
HOUSING
ASSY
ESCUTCHEON
PLATE
CONNECTOR
TUBE
FUEL PUMP
COUPLING
VALV E
Figure 2
REAR ACCESS
DOOR GASKET
SPLINED
NUT
IGNITOR
MOTOR
PRIMARY
CONTROL
BLOWER
WHEEL
4X4
BOX
0
3
4
5
6
7
8
AIR
ADJ.
DIAL
INLET
AIR SCOOP
Page 3
Requirements
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 OHR23 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
inches from the room’s ceiling.
Combustion air openings should provide a minimum free
area one-half square inch per 1,000 Btu per hour input.
This combustion air should be brought into the area 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 rating plate for specific
combustion air opening dimensions.
Table 1
Combustion Air Opening Dimensions
Model No. (2 openings required)
OHR23−105/120 10" X 20"
OHR23−140/154 11" X 22"
This unit is approved for clearances to combustible material as listed unit rating plate and in tables 2 or 3. Unit service
and accessibility clearances take precedence over fire
protection clearances.
Table 2
Horizontal Installation Clearances
Clearances Inches (mm)
Top of Cabinet 3 (76)
*Bottom and Rear of Cabinet 1 (25)
Front of Cabinet 24 (610)
Service Clearance (Front) 24 (610)
End of Supply Plenum 0 (0)
Supply Air Opening 0 (0)
Return Air Opening 0 (0)
Above Horizontal Warm Air Duct
within 3 ft. (914mm) of Furnace
Flue Pipe Horizontal 7 (178)
Flue Pipe Vertical 7 (178)
*NOTE−When furnace is installed on combustible floor, 1 "
(25 mm) spacer legs must be installed to elevate unit off of
mounting surface.
0 (0)
Table 3
Downflow Installation Clearances
Clearances Inches (mm)
Bottom of Plenum and Ductwork 1 (25)
Plenum Sides 1 (25)
Side of Cabinet 1 (25)
Rear of Cabinet 1 (25)
Front of Cabinet 16 (406)
Service Clearance (Front) 24 (610)
Flue Pipe Horizontal 1 (25)
Flue Pipe Vertical 7 (178)
Return Air Opening 0 (0)
*Floor *Combustible
*NOTE−Clearance for installation on combustible floor if optional additive base is installed between the furnace and
combustible floor. Not required in add−on coiling applications.
NOTE − Downflow Application Only For installation on
combustible floors, appliance shall not be installed directly
on carpeting, tile or other combustible material other than
wood flooring. When installed on wood flooring, the additive base must be used. See Unit Dimension illustration.
NOTE − Unit must be adjusted to obtain a temperature rise
within the range listed in table 7 (see Page 15).
When used in conjunction with a evaporator coil, the furnace shall be installed in parallel with, or on the upstream
side of the evaporator coil. In a parallel flow arrangement,
the dampers, or other measures used to control flow of air
flow, shall be adequate to prevent chilled air from entering
the furnace. If the furnace is manually operated, it must be
equipped with means to prevent operation of either unit unless dampers are in the full-heat or full-cool position.
Page 4
When installed, furnace must be electrically grounded in
accordance with local codes or, in the absence of local
codes, with the current National Electric Code, ANSI/
NFPA No. 70, if an external electrical source is utilized.
Field wiring connection with unit must meet or exceed
specifications of type T wire and withstand a 63F (17C)
temperature rise.
Installation
When installed, OHR23 furnaces must be level. If the furnace is not level, place fireproof wedges or shims between
the low side of the furnace and floor. Make sure the weight
of the furnace is evenly distributed on all four corners.
Strain on sides of the cabinet causing cracking and popping noises may occur if weight of furnace is not evenly distributed.
Set the unit in desired location keeping in mind the clearances list in tables 2 and 3. Also keep in mind oil supply
connections, electrical supply, flue connections and sufficient clearance for installing and servicing unit.
OHR23 series units may be installed in a crawl space under a house, utility room or in a wide variety of suspended
applications.
Horizontal Application
The OHR23 furnace is shipped from the factory in the horizontal left hand air discharge application. Air flow may be
reversed to right side discharge or unit may be used as
downflow.
Reversing Airflow for Right Hand Discharge
1. Rotate the furnace 180 so that when facing the front,
the warm discharge is to the right.
2. Remove the nuts in the bracket that hold the burner to
the furnace front. Rotate the burner and burner mounting plate 180 and reinstall the nuts.
3. Remove the screws that hold the limit control in place.
Use the provided knockout hole to relocate the limit
control to the top side of the front panel.
Installation on Non−Combustible Material
Set the furnace on non-combustible material (such as concrete blocks, bricks or angle iron). Install spacer legs, provided with unit, by using the cabinet screws from each corner of the unit. Use a level to check level of furnace in at
least two directions. Use shims or non-combustible material. A minimum clearance of 1" must be maintained between bottom of furnace and combustible material.
Suspended Installation
To suspend furnace, remove knockouts in top of panel at
warm air discharge and at blower panel (Refer to unit dimensions). Use 3/8" rods cut to desired length. Use one
flat washer and two nuts for each rod. One nut and the
washer on the inside of unit and the other nut on the outside
of unit (the locking nut). Level the unit by adjusting the nuts
on the inside of unit. See figure 3 to suspend unit.
Hanger Rod Installation
rod
nut
blower compartment
top of
furnace
washer
nut
division panel
Figure 3
Downflow Application
When installing the OHR23 in a downflow position and on
combustible flooring, a combustible floor base must be
used. See Unit Dimension illustration.
1. Rotate the furnace so that return is on top and supply
is on bottom. Refer to table 3 for clearances to combustible flooring.
2. Remove the nuts in the bracket that hold the burner to
the furnace front. Rotate the burner and burner mounting plate 90 and reinstall the nuts.
3. It is also recommended that the upper rear screw holding the blower housing to the blower deck be removed
before installation in a closet. Removing this screw allows for easy service and removal of the blower assembly in a closet installation.
Supply & Return Air Plenums
NOTE − Following these suggestions when installing supply and return air plenums.
1. Use sealing strips of fiberglass.
2. In all cases, the plenum should be secured to furnace
or evaporator cabinet with sheet metal screws.
3. Both supply and return air plenums shall be square
and least 18" long. They should be the same dimension as the furnace opening.
4. If unit is installed in a confined space such as a utility
room where there is no complete return air duct system, a return air connection should be run (the same
size as the return air opening) to a location outside the
room containing the furnace.
5. Install supply and return air ducts as desired.
Optional Filter Kit
An Optional filter kit is available for OHR23 units. Kit 35K05
is used with OHR23−105/120 units, and kit 35K06 is used
with OHR23−140/154 units. All kits include the following:
2 filters
3 rods
7 screws
1 rack assembly
1 panel
Page 5
OHR23−140/154 Filter Rack Installation
1. Slide filter rack over return duct flanges.
2. Using a scriber through the filter rack mounting holes,
mark seven mounting hole locations in the return end
of the cabinet. See figure 4.
3. Remove filter rack and drill 1/8" diameter holes at the
marked positions.
4. Place filter rack in position again and secure it to the
cabinet using the sheet metal screws provided. Clearance for the screw driver is provided in outside holes
of rack and in filter support angles.
5. Bend the ends of filter rods and hook ends through
holes provided in top and bottom filter support angles.
6. Slide filter between the support angles and the plenum
side for the filter rack. The filter rods hold the filter in
place.
OHR23 105/120 Optional Filter Kit
FILTER RACK
(FURNISHED)
22 (559)
14 (356)
RETURN
AIR DUCT
(NOT FURNISHED
BY LENNOX)
Oil vacuum gauge
Beckett T−500 gauge
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 set-up 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. 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.
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 5), 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.
FILTER
(FUR-
NISHED)
OPENING
IN UNIT
(EITHER SIDE)
Figure 4
Initial 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:
Draft gauge
CO
or O2 analyzer
2
Smoke tester
Pressure gauge
High temperature thermometer
OHR23 Series Burner Removal
LOOSEN THREE NUTS WHICH ATTACH BURNER TO VEST PANEL.
ROTATE BURNER COUNTERCLOCKWISE
ON SLOTS THEN PULL TOWARD YOU.
Figure 5
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 6). At the same time, check the
nozzle alignment.
Page 6
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.
GAUGE
2
TO ADJUST NOZZLE:
1−LOOSEN SCREW.
2−SLIDE ENTIRE NOZZLE/ELECTRODE ASSEMBLY BACK AND FORTH UNTIL
NOZZLE JUST TOUCHES GAUGE.
1
Figure 6
Venting
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.
This furnace is certified for use with type L" vent.
B" vent must not be used with oil furnaces.
Prior to installation of unit, make a thorough inspection of
the chimney to determine whether repairs are necessary.
Make sure the chimney is properly constructed and sized
according to the requirements of the National Fire 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 installation 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 outlet 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 7.
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.
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).
Page 7
COMBUSTIBLE
WALL
VENT PIPE
Figure 7
9. The vent pipe should slope upward toward the chimney 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 8.
BAROMETRIC
CONTROL*
(IN EITHER
LOCATION)
HORIZONTAL
APPLICATION
SHOWN
Masonry Chimney
LINER
CLEAN
OUT
MASONRY
CHIMNEY
BAROMETRIC
CONTROL*
(IN EITHER
LOCATION)
HORIZONTAL
APPLICATION
SHOWN
Factory-Built Chimney
FACTORY
BUILT
CHIMNEY
DRAIN FOR
CONDENSATE
CLEAN OUT
*BAROMETRIC CONTROL MAY BE INSTALLED IN EITHER VERTICAL OR HORIZONTAL SECTION OF FLUE PIPE WITHIN 18" OF FLUE OUTLET OF FURNACE.
Figure 8
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 chimney or vent complying with a recognized standard, or
masonry or concrete chimney lined with a lining material acceptable to the author ity having jurisdiction.
12. When two or more appliances vent into a common
vent, the area of the common vent should not be less
than the area of the largest vent or vent connection
plus 50% of the areas of the additional vent or vent
connection. Chimney must be able to sufficiently vent
all appliances operating at the same time.
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 outside shall be constructed of factory built chimney sections. See figure 9.
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 MAY BE INSTALLED IN EITHER VERTICAL OR HORIZONTAL SECTION OF FLUE PIPE WITHIN 18" OF FLUE OUTLET OF FURNACE.
Figure 9
Combustion and Ventilation Air (Confined and
Unconfined Spaces)
Homes designed with energy conservation in mind use
air-tight construction practices. Therefore, it is necessary
to bring in outside air for combustion. Consideration must
also be given to the use of exhaust fans, appliance vents,
chimneys and fireplaces that force out air which might
have otherwise been used for combustion. 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 downdraft can occur in the furnace
vent pipe or chimney. Combustion gases entering the living space create a potentially dangerous situation.
NOTE − 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.
Combustion Air Requirements
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.
Page 8
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