Nordyne O4HD-091A-14-FA-DV, O4HD-091A-12-FB, O4HD-091A-V-FA Maintenance Manual

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Installation, Operation and

Maintenance Manual

Oil Fired Warm Air Furnaces

O4HD-091A-12-FB (Up-Flow Model)

O4HD-091A-14-FA-DV (Up-Flow Model)

O4HD-091A-V-FA (Up-Flow Model with ECM)

FOR YOUR SAFETY:

Do not store or use gasoline or other flammable liquids or

vapors in the vicinity of this, or any other appliance.

ALL INSTALLATIONS MUST MEET ALL

LOCAL, PROVINCIAL/STATE, AND

FEDERAL CODES WHICH MAY

DIFFER FROM THIS MANUAL

NORDYN E INC.

Read this complete manual before beginning installation. These instructions

must be kept with the furnace for future reference.

151B-0810 (Replaces 151B-0909)

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TABLE OF CONTENTS

1. INTRODUCTION ................................................................................................................................. 3

2. HEAT LOSS ........................................................................................................................................ 3

3. LOCATION OF UNIT .......................................................................................................................... 3

4. AIR CONDITIONING APPLICATIONS ............................................................................................... 4

5. COMBUSTION AIR ............................................................................................................................. 4

6. CHIMNEY VENTING ........................................................................................................................... 4

7. BAROMETRIC DAMPER CONTROL ................................................................................................. 4

8. OPTIONAL SIDE WALL VENTING ..................................................................................................... 5

9a, 9b. FAN TIMER BOARD AND LIMIT CONTROL (FIGURE 4 AND 5) ............................................. 5

10. ELECTRICAL CONNECTIONS ......................................................................................................... 5

11. HUMIDIFIER ...................................................................................................................................... 6

12. PIPING INSTALLATION ................................................................................................................... 6

13. OIL FILTER ....................................................................................................................................... 6

14. OIL BURNER NOZZLES ................................................................................................................... 6

15. OIL BURNER ADJUSTMENT ........................................................................................................... 6

16. BURNER ELECTRODES .................................................................................................................. 7

17. BURNER PRIMARY (SAFETY) CONTROL ...................................................................................... 7

18. COMBUSTION CHAMBER ............................................................................................................... 7

19a, 19b. CIRCULATING AIR BLOWER ................................................................................................ 7

20. MAINTENANCE AND SERVICE ....................................................................................................... 8

21. OPERATING INSTRUCTIONS .......................................................................................................... 9

22. ECM BLOWER MOTOR OPERATION ...................................................................................... 9

APPENDIX A- O4HD-091A-12-FB, O4HD-091A-14-FA-DV AND O4HD-091A-V-FA ........................... 11

A.1 OIL BURNER AIR ADJUSTMENT .................................................................................................. 12

A.2 BURNER ELECTRODES ................................................................................................................ 12

A.3 START UP ....................................................................................................................................... 12

APPENDIX B: WIRING DIAGRAMS ...................................................................................................... 17

OPERATION OF OIL BURNER ............................................................................................................. 19

APPENDIX C OIL PRIMARY CONTROL DETAILED SEQUENCE OF OPERATION ......................... 20

OIL PRIMARY CONTROL LED DIAGNOSTIC LIGHT .......................................................................... 24

FINAL CHECK OUT ............................................................................................................................... 30

HOMEOWNER'S REFERENCE TABLE ................................................................................................ 31

PARTS LISTING: HIGHBOY MODEL: O4HD-091A-12-FB, O4HD-091A-14-FA-DV, AND

O4HD-091A-V-FA .................................................................................................................................. 32

NOTES: .................................................................................................................................................................. 35

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IMPORTANT:

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

1. INTRODUCTION 3. LOCATION OF UNIT

Please read these instructions completely and carefully before installing and operating the furnace.

MODELS O4HD-091A-12-FB, O4HD-091A-14-FA- DV, AND O4HD-091A-V-FA

Models O4HD-091A-12-FB, O4HD-091A-14-FA-DV and

O4HD-091A-V-FA are oil fired forced air up-flow furnaces with an output capacity range of 59,000 BTU/Hr. to 86,000 BTU/Hr.

I `cAUTION I

DO NOT USE GASOLINE, CRANK CASE OIL, OR

ANY OIL CONTAINING GASOLINE.

All models are CSA listed, (NRTL/C) for use with No. 1

(Stove) and No. 2 (Furnace) Oil. Please refer to the

tables in Appendix A for performance and dimensional data.

In Canada, the installation of the furnace and related

equipment shall be installed in accordance with the

regulations of CAN/CSA - B139, Installation Code for Oil-

Buming Equipment, as well as in accordance with local codes.

In the United States of America, the installation of the furnace and related equipment shall be installed in accordance with the regulations of NFPA No. 31,

Standard for the Installation of OiI-Buminq Equipment, as well as in accordance with local codes.

Regulations prescribed in the National Codes and Local

regulations take precedence over the general

instructions provided on this installation manual. When in doubt, please consult your local authorities.

All models are shipped assembled and pre-wired. The furnace should be carefully inspected for damage when

being unpacked.

The furnace should be located such that the flue connection to the chimney is short, direct and

consists of as few elbows as possible. When possible, the unit should be centralized with respect

to the supply and return air ductwork. A central location minimizes the trunk duct sizing. All models

may be installed on combustible floors. The minimum installation clearances are listed in

Table 1. Table 1: Clearances - (Inches)

Clearance to Combustibles

O4HD-091A-12-FB, O4HD-

Location

Top

Bottom

S/A Plenum

Rear

Sides

Front

Flue Pipe

Enclosure

"18 in. in USA ** 24 in. required for service clearance

091A-14-FA-DV and O4HD-

091A-V-FA

Up flow

1 1 1

1 **

Closet

2. HEAT LOSS

The maximum hourly heat loss for each heated space shall be calculated in accordance with the procedures

described in the manuals of the Heating, Refrigeration and Air Conditioning Institute of Canada (HRAI), or by

other means prescribed, or approved by the local authority having jurisdiction.

In the United States, Manual J. titled, "Load Calculation"

published by the Air Conditioning Contractors of America, describes a suitable procedure for calculating the maximum hourly heat loss.

HEAT EXCHANGER _PORT SCREWS

Before final placement of the furnace, the heat exchanger support screws shown in the picture may

be removed. This may be preferable if the furnace rear panel will be inaccessible after installation. The

screws must be removed if the heat exchanger must be removed from the cabinet.

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4. AIR CONDITIONING APPLICATIONS If the furnace is used in conjunction with air conditioning,

the furnace shall be installed in parallel with or upstream from the evaporator coil to avoid condensation in the

heat exchanger. In a parallel installation, the dampers or air controlling means must prevent chilled air from

entering the furnace. If the dampers are manually operated, there must be a means of control to prevent

the operation of either system unless the dampers are in the full heat or full cool position. The air heated by the

furnace shall not pass through a refrigeration unit unless the unit is specifically approved for such service.

The blower speed must be checked and adjusted to compensate for the pressure drop caused by the

evaporator coil. Refer to Appendix B for recommended wiring and electrical connections of the air conditioning

controls.

5. COMBUSTION AIR

If the furnace is installed in a closet or utility room, two

openings must be provided connecting to a well- ventilated space (full basement, living room or other

room opening thereto, but not a bedroom or bathroom). One opening shall be located above the level of the

upper vent opening and one opening below the combustion air inlet opening in the front of the furnace.

Each opening shall have a minimum free area of 1½

square inches per 1,000 Btu/h of total input rating of all appliances installed in the room.

regulations, to the requirements of the National Building Code.

NOTE: THE FURNACE IS APPROVED FOR USE WITH TYPE L VENT OR EQUIVALENT.

I I cAuTION I

CHIMNEY VENTED VERSIONS OF FURNACE MUST BE CONNECTED TO A FLUE HAVING SUFFICIENT DRAFT

TIMES TO ENSURE SAFE AND

OPERATION OF THE APPLIANCE.

NOTE: THE RECOMMENDED FLUE DRAFT PRESSURE IS -0.02 IN. W.C. (SEE FIG 2.)

The flue pipe must not pass through any floor or

ceiling, but may pass through a wall where suitable

fire protection provisions have been installed. Refer to the latest edition of CAN/CSA B-139 for rules

governing the installation of oil burning equipment.

In the United States, refer to the latest edition of NFPA 31 for regulations governing the installation of

oil burning equipment.

See appendix A for burner set-up.

Fig. 2: Checking Over-Fire Draft.

THE

AT ALL

PROPER

For furnaces located in buildings of unusually tight

construction, such as those with high quality weather stripping, caulking, windows and doors, or storm sashed

windows, or where basement windows are well sealed, a permanent opening communicating with a well ventilated

attic or with the outdoors shall be provided, using a duct if necessary. The duct opening shall have a free area of

1½ square inches per 1,000 Btu/h of total input rating of

all appliances to be installed. When a furnace is installed in a full basement, infiltration is normally adequate to

provide air for combustion and draft operation. Furnace rooms under 65m3 (700 ft3) should automatically be

treated as confined space.

6. CHIMNEY VENTING

The flue pipe should be as short as possible with horizontal pipes sloping upward toward the chimney at a

rate of one-quarter inch to the foot. The flue pipe should not be smaller in cross sectional area than the flue collar

on the furnace. The flue pipe should connect to the chimney such that the flue pipe extends into, and

terminates flush with the inside surface of the chimney liner. Seal the joint between the pipe and the lining. The

chimney outlet should be at least two feet above the highest point of a peaked roof. All unused chimney

openings should be closed. Chimneys must conform to local, provincial or state codes, or in the absence of local

Over-fire draft access port.

7. BAROMETRIC DAMPER CONTROL.

The barometric damper control, also known as a

draft regulator, is used on conventional chimney

venting only. This control automatically maintains a

constant negative pressure in the furnace to obtain maximum efficiency. It ensures that proper

pressures are not exceeded. If the chimney does not develop sufficient draft, the draft control cannot

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functionproperly.The draft regulator,wheninstalled shouldbeinthesameroomorenclosureasthefurnace

andshouldnotinterferewiththecombustionairsupplied to the burner.Thecontrolshouldalsobelocatednear

the furnaceflue outletand installedaccordingto the

instructionssuppliedwiththeregulator.Theflueoutlet pressure(measuredbetweenthe furnaceand draft

regulator,ortheoilburnermountingplateover-fireddraft

accessport.fig.2)shouldbesetto-0.02in.w.c.

8. OPTIONAL SIDE WALL VENTING O4HD-091A-14-FA-DV furnace models are

manufactured to be installed as sidewall vented units. Please refer to Direct Venting Instructions, P/N

240005236 included with the Vent Kit for details. Sidewall Venting (Direct Venting) requires the use of a specific oil

burner; the Beckett AFII. Please refer to Appendix A,

Table A2.

Note: Sidewall venting requires special attention to

combustion air supply. There is no natural draft in the venting system between furnace cycles; therefore, if the

indoor pressure is negative relative to the outdoors, the

vent terminal becomes a point of infiltration. This could

lead to oil odour control problems. This problem is rectified by the use of ducted outdoor air for combustion (semi-sealed combustion), using the Beckett AFII oil

burner. See Direct Vent Instructions supplied with the

Vent Kits.

9a. FAN TIMER BOARD AND LIMIT CONTROL

(FIG. 4) (page 22)

The Electronic Fan Timer integrates control of all burner and circulator fan operations. This control is the central

wiring point for most of the electrical components in the furnace. The United Technologies 1158-120 (O4HD-

091A-12-FB and O4HD-091A-14-FA-DV) has an adjustable fan on time that is set by selecting the

dipswitch combination displayed in Chart 1. This fan on delay can be set at 1, 2, 4 or 6 minutes. This provides a

delay between the burner ignition and blower start-up to eliminate excessive flow of cold air when the blower

comes on. The United Technologies 1158-120 (O4HD- 091A-12-FB and O4HD-091A-14-FA-DV) has an

adjustable fan off time of 30, 60, 90 or 120 seconds displayed in Chart 1. The fan off delay time starts when

the burner motor is de-energized at the end of a call for

heat. Blower shutdown is delayed to remove any residual heat from the heat exchanger and improve the annual

efficiency of the furnace. The electronic fan timer board works in conjunction with

snap disc limit controls, which perform a safety function, and breaks power to the oil burner primary control, which

shuts off the burner if the furnace over-heats. The limit control is thermally operated and automatically resets.

The limit control is factory installed, pre-set and is not adjustable.

If the limit control opens with the United

Technologies 1158-120 (O4HD-091A-12-FB and O4HD-091A-14-FA-DV) electronic fan control, the

circulating fan will be energized as well. When the limit closes, the fan off timer will begin. At the end of

the fan off time cycle the burner will be energized, initiating a normal burner cycle.

CHART 1

United Technologies 1158-120 (O4HD-091A-

12-FB and O4HD-091A-14-FA-DV)

Dip Switch Position Blower Delay Times

1 2 3 4 On Off

Seconds Minutes

Off Off 30 On Off 60 Off On 90 On On 120

Off Off 1 On Off 2

Off On 4 On On 6

9b. FAN TIMER BOARD AND LIMIT

CONTROL (FIG. 5) (page 22)

The United Technologies 1168-1 ECM (O4HD-

091A-V-FA) tap board has an adjustable fan on/off delay that must be adjusted in accordance with the

furnace input rating (nozzle size). Refer to Table A-

10 (pg 15) for ECM blower set-up.

10. ELECTRICAL CONNECTIONS The furnace is listed by the Canadian Standards

Association under the NRTL (North American) Standard. It is factory wired and requires minimal

field wiring. All field wiring should conform to CAN/CSA C22.1 Canadian Electrical Code, Part 1,

and by local codes, where they prevail. In the United States, the wiring must be in accordance with the National Fire Protection Association NFPA-70,

National Electrical Code, and with local codes and regulations.

The furnace should be wired to a separate and dedicated circuit in the main electrical panel;

however, accessory equipment such as electronic air cleaners and humidifiers may be included on the

furnace circuit. Although a suitably located circuit breaker can be used as a service switch, a separate

service switch is advisable. The service switch is necessary if reaching the circuit breaker involves

becoming close to the furnace, or if the furnace is located between the circuit breaker and the means

of entry to the furnace room. The furnace switch

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(serviceswitch)shouldbeclearlymarked,installedinan easilyaccessibleareabetweenthefurnaceandfurnace

roomentry,andbelocatedinsucha mannerto reduce thelikelihoodthatitwouldbemistakenasa lightswitch

orsimilardevice. The power requirementfor the O4HD-091A-12-FB,

O4HD-091A-14-FA-DVandO4HD-091A-V-FAmodelsis:

120VAC,10, 60Hz.,12A.

In the United States the installation must be in accordance with NFPA No. 31 and local codes and

authorities. Install the oil filter as close to the burner as possible.

For further details of the oil supply tank and piping requirements, please refer to the instructions and

illustrations in the oil burner and oil pump instructions shipped with the furnace.

Accessoriesrequiring120VACpowersourcessuchas electronicair cleanersandhumidifiertransformersmay

be poweredfromthe electronicfan timerboardwhere provisionshavebeenmadefor connections,butshould

havetheirowncontrols.Donotusethedirectdrivemotor connectionsasapowersource,sincethereisa highrisk

ofdamagingtheaccessoriesbyexposuretohighvoltage fromthe auto-generatingwindingsof the directdrive

motor. Thermostatwiring connectionsand air conditioning

contactorlow voltageconnectionsare shownin the wiringdiagramsin AppendixB. Somemicro-electronic

thermostatsrequireadditionalcontrolsandwiring.Refer tothethermostatmanufacturer'sinstructions.

Thethermostatshouldbe locatedapproximately5feet abovethefloor,on an insidewallwherethereis good

naturalair circulation,andwherethethermostatwillbe exposedto averageroomtemperatures.Avoidlocations

wherethethermostatwillbeexposedtocolddrafts,heat fromnearbylampsandappliances,exposuretosunlight,

heatfrominsidewallstacks,etc. Thethermostatheatanticipatorshouldbeadjustedtothe

amperagedraw of the heating control circuit as measuredatthe"R"and"W"terminalsofthethermostat.

Toreducetheriskof damagingthe heatanticipator,do notmeasurethiscurrentwiththethermostatconnected

to thecircuit.Measuretheamperagebyconnectingan ammeterbetweenthetwowiresthatwillconnecttothe

thermostat"R"and"W"terminals.

11. HUMIDIFIER

A humidifier is an optional accessory available through most heating supplies outlets. Installation should be

carried out in accordance with the humidifier manufacturer's installation instructions. Water or water

droplets from the humidifier should not be allowed to come into contact with the furnace heat exchanger. Do

not use direct drive motor connections as a source of power for 120 VAC humidifiers and humidifier

transformers.

12. PIPING INSTALLATION

The entire fuel system should be installed in accordance with the requirement of CAN/CSA B-139, and local

regulations. Use only an approved fuel oil tanks piping, fittings and oil filter.

13. OIL FILTER

All fuel systems should include an oil filter between the fuel oil storage tank and the oil burner. When

using an oil burner nozzle smaller than 0.65 U.S. Gallons Per Hour, install an additional 7 to 10 micron

filter as close as possible to the oil burner.

14. OIL BURNER NOZZLES

The O4HD-091A-12-FB, O4HD-091A-14-FA-DV and

O4HD-091A-V-FA are certified for multiple firing rates, ranging from 59,000 to 86,000 Btu/h. By

manipulating the oil burner nozzle, flame retention head, static plate and temperature rise; the furnace

may be fired at an ideal rate for a wide range of structures. Refer to Table A-l, and the furnace

rating plate to determine the proper combinations.

15. OIL BURNER ADJUSTMENT

The burner air supply is adjusted to maintain the fuel

to air ratio to obtain ideal combustion conditions. A

lack of air causes "soft" and "sooty" flames, resulting in soot build-up throughout the heat exchanger

passages. Excess combustion air causes a bright roaring fire and high stack temperatures resulting in

poor fuel efficiency. The O4HD-091A-12-FB, O4HD- 091A-14-FA-DV and O4HD-091A-V-FA furnaces

operate most efficiently with a No. 1 smoke spot on the Bacharach Scale. This is not necessarily the

optimum setting; however, because dust will

inevitably build up on the air moving components of

the oil burner assembly. This will result in decreased

air supply with the potential result of soot building up in the flue gas passageways of the heat exchanger.

Soot behaves as an insulator and impairs good heat

transfer. Stack temperature will increase, and the overall efficiency will decrease. As a means of

avoiding this problem, it is advisable to adjust the air supply to provide no more than a trace smoke spot

on the Bacharach Scale.

See the Venting Instructions included in the Vent Kits for set-up details for sidewall vented furnaces.

NOTE: SIDEWALL VENTED MODELS SHOULD BE SET UP TO DELIVER ZERO (0)

SMOKE.

Page 7

I'ACAUTION I

BEFORE OPERATING THE FURNACE CHECK BURNER ALIGNMENT WITH COMBUSTION

CHAMBER. THE END CONE OF THE AIR TUBE

MUST BE CENTRED TO THE ACCOMODATING RING PROVIDED IN THE DESIGN OF THE

COMBUSTION CHAMBER. ADJUST AS

NECESSARY.

16. BURNER ELECTRODES

Correct positioning of the electrode tips with respect to each other, to the fuel oil nozzle, and to the rest of the

burners is essential for smooth light ups and proper

operation. Refer to the oil burner instructions shipped with the furnace for electrode specifications.

NOTE: Beckett AF Series Burner electrode specifications have been revised. They should be adjusted to be 5/16"

above the nozzle centerline.

17. BURNER PRIMARY (SAFETY) CONTROL

The furnace is equipped with a primary combustion control, sometimes referred to as the burner relay or

burner protector relay, which uses a light sensing device (cad cell) located in the burner housing, to monitor and

control combustion. Over time, dust or combustion

residuals can build up on the lens of the cad cell impairing its response to the flame. The cad cell should

be checked for cleanliness and proper alignment if the primary control frequently shuts down combustion.

I'ACAUTION I

ALL FURNACE CONTROLS ARE SENSITIVE AND SHOULD NOT BE SUBJECTED TO

TAMPERING. IF PROBLEMS PERSIST, CALL YOUR SERVICE CONTRACTOR.

18. COMBUSTION CHAMBER

This furnace is equipped with a high quality cerafelt combustion chamber. It is held in place by a retaining

bracket.

CHECK THE ALIGNMENT OF THE COMBUSTION CHAMBER AND OIL BURNER BEFORE FIRING.

IT IS POSSIBLE FOR THE COMBUSTION

CHAMBER TO SHIFT IF SUBJECTED TO ROUGH

HANDLING DURING TRANSIT. The combustion

chamber should be inspected for damage or carbon build

up whenever the oil burner is removed for repairs or routine maintenance.

DO NOT START THE BURNER UNLESS THE BLOWER ACCESS DOOR IS SECURED IN PLACE.

19a. CIRCULATING AIR BLOWER (O4HD-

091A-12-FB)

The O4HD-091A-12-FB, O4HD-091A-14-FA-DV and O4HD-091A-V-FA furnace models are equipped with direct drive blower systems. O4HD-091A-12-

FB and O4HD-091A-14-FA-DV models are

equipped with PSC motors; O4HD-091A-V-FA models are equipped with electronically commutated

motors (ECM). Direct drive blower speed adjustments are not normally required in properly

sized extended plenum duct systems. The motor RPM and air CFM delivery will vary automatically to

accommodate conditions within the usual range of external static pressures typical of residential duct

systems. Under-sized duct systems may require a higher blower speed to obtain a reasonable system

temperature rise. Some older duct systems were not designed to provide static pressure. They typically

feature special reducing fittings at each branch run and lack block ends on the trunk ducts. These

systems may require modification to provide some resistance to the airflow to prevent over-amping of

the direct drive blower motor. Selecting a lower blower speed may correct this problem. Direct drive

blower speeds are adjusted by changing the "hot" wires to the motor winding connections. Please refer

to wiring diagrams in Appendix B or the wiring diagram label affixed to the furnace. THE NEUTRAL

WIRE (normally the w hite w ire) IS NEVER MOVED TO ADJUST THE BLOWER SPEED.

It is possible and acceptable to use a single blower

speed for both heating and cooling modes. The simplest method to connect the wiring from both

modes is to use a "piggy-back connector" accommodating both wires on a single motor tap. It

is also acceptable to connect the selected motor speed with a pigtail joined to both heating and

cooling speed wires with a wire nut. As a safety precaution against accidental disconnection of the wires by vibration, it is advisable to secure the wire

nut and wires with a few wraps of electricians tape.

Page 8

I'ACAUTION I

DO NOT CONNECT POWER LEADS BETWEEN MOTOR SPEEDS. THE NEUTRAL WIRE MUST ALWAYS BE CONNECTED TO THE MOTOR'S DESIGNATED NEUTRAL TERMINAL.

If the joining of the blower speed wiring is done in the

furnace junction box, tape off both ends of the unused wire.

Do not use the blow er speed w ires as a source of power to accessories as electronic air cleaners and humidifier transformers. The unused motor taps auto-

generate sufficiently high voltages to damage accessory equipment.

20. MAINTENANCE AND SERVICE Routine Maintenance By Home Owner

Other than remembering to arrange for the annual professional servicing of the furnace by the service

or installation contractor, the most important routine

service performed by the homeowner is to maintain

the air filter or filters. A dirty filter can cause the furnace to over-heat, fail to maintain indoor

temperature during cold weather, increase fuel

consumption and cause component failure.

The furnace filter(s) should be inspected, cleaned or

replaced monthly. The furnace is factory equipped

with a semi-permanent type filter. If the filter is

damaged, replace with filters of the same size and

type. (See Appendix A, Table A-8).

I_WARNINGI

DISCONNECT THE POWER SUPPLY TO THE FURNACE BEFORE OPENING THE BLOWER

ACCESS DOOR TO SERVICE THE AIR FILTER, FAN AND MOTOR. FAILURE TO SHUT OFF

POWER COULD ALLOW THE BLOWER TO START UNEXPECTEDLY, CREATING A RISK OF

DEATH OR PERSONAL INJURY.

19b. CIRCULATING AIR BLOWER (O4HD-091A-

V-FA) (See Section 22 Page 9)

During the routine service, inspect the general condition of the furnace watching for signs of oil

leaks in the vicinity of the oil burner, soot forming on any external part of the furnace, soot forming around

the joints in the vent pipe, etc. If any of these

conditions are present, please advise your service

or installation contractor.

Annual Service By Contractor

I'ACAUTION I

THE COMBUSTION CHAMBER (FIREPOT) IS

FRAGILE. USE CARE WHEN INSPECTING

AND CLEANING THIS AREA.

The heat exchanger should be inspected

periodically and cleaned if necessary. If cleaning is necessary, SHUT OFF POWER TO THE FURNACE

and remove the burner. Using a stiff brush with a

wire handle, brush off scale and soot from insidethe

drum and flue pipe. To clean the radiator, remove

the clean-out caps screws, and remove the caps

carefully to avoid tearing the gaskets. A wire brush can be used to loosen dirt and debris on the inside

surfaces of the radiator. Clean out all accumulated dirt, soot and debris with a wire handled brush and an industrial vacuum cleaner. Before replacing the clean-out caps, inspect the gaskets. If the gaskets are broken, remove the remnants and replace with

new gaskets.

The blower motor is factory oiled and permanently

sealed. DO NOT LUBRICATE. Excess oil causes premature electric motor failure.

Inspect the blower fan. Clean if necessary. Oil Burner Maintenance: Follow the instructions of

the oil burner manufacturer. (See oil burner

manufacturer's instructions supplied with furnace or burner). It is advisable to change the oil burner nozzle and oil filter on an annual basis.

Page 9

Theventingsystemshouldbecleanedandinspectedfor signsof deterioration.Replacepittedor perforatedvent

pipeandfittings.Thebarometricdampershouldopen

andclosefreely. All electricalconnectionsshouldbe checkedto ensure

tightconnections.Safetycontrolssuchasthehighlimit controlsshouldbetestedforfunctionality.Thefancontrol

shouldbe checkedto ensurethatthe fanon andoff delayfunctioncontinuestostartandstoptheblowerfan

attheoptimalsettings.

test is complete, shut off electrical power to the furnace, replace the neutral wire to the blower fan

motor, and then restore power. The blower fan will start up immediately. Once the temperature has

dropped and the limit control has reset, the fan will operate until the fan off time is achieved. The oil

burner will then resume operation and continue until the thermostat is satisfied. Restore the thermostat

setting to a comfortable temperature. To Shut Down Unit

21. OPERATING INSTRUCTIONS (O4HD-091A- 12-FB AN D O4HD-091A-14-FA-DV)

Before Lighting

Open all supply and return air registers and grilles. Open all valves in oil pipes.

Turn on electric power supply To Light Unit Set the thermostat above room temperature to call for

heat. The burner should start. NOTE: It may be necessary to press the RESET button on the primary

combustion control relay. There will be a fan on time delay before the circulating

fan is energized. The United Technologies 1158-120

has an adjustable fan on time that is set by selecting the

dipswitch combination displayed in Chart 1. This fan on delay can be set at 1,2, 4 or 6 minutes.

Set the thermostat below room temperature. The oil

burner should stop.

The air circulation blower will continue to run until the time off setting selected on the electronic fan timer

control times out. The United Technologies 1158-120

has an adjustable fan off time of 30, 60, 90 or 120

seconds. The fan timer control adjustments may be altered if the air at the room registers is uncomfortably

high upon blower start up or shutdown.

The necessary adjustments to the fan control settings should be determined by measuring the temperature of

the air in the supply air take-off, or within the first few

inches of the supply air trunk. The side mid point of the

transition is usually ideal, providing that the thermometer

probe is beyond the "line of sight" wherein false readings

from radiant heat could be observed. System temperature rise is the difference in temperature

between the supply air and return air.

To check the operation of the limit switch, shut off power to the furnace. Temporarily remove the neutral wire from

the direct drive blower motor. Restore the electrical

power to the furnace and set the thermostat above room

temperature. After three or four minutes of burner operation, the limit

control should turn the burner off. When the limit function

Set the thermostat to the lowest possible setting. Set the manual switch (if installed) in the Electrical

Power Supply Line to "OFF".

21. OPERATING INSTRUCTIONS (O4HD- 091A-V-FA)

Before Lighting

Open all supply and return air registers and grilles. Open all valves in oil pipes.

Turn on electric power supply To Light Unit

Set the thermostat above room temperature to call for heat. The burner should start. NOTE: It may be

necessary to press the RESET button on the primary combustion control relay.

There will be a fan on time delay before the circulating fan is energized. The United Technologies 1168-1 has an adjustable fan on/off

time delay that is programmed into the ECM motor, and is set by selecting the SW4 DIP switch combination displayed in Table A-10 page 15. Fan on/off delay must be adjusted according to input

(nozzle size).

1. Set the thermostat below room temperature. The

oil burner should stop. The air circulation blower will continue to run until

the blower off delay setting programmed into the

ECM motor times out.

To check the operation of the limit switch, shut off power to the furnace. Temporarily remove the 5 pin

power connector plug from the ECM blower motor. NOTE: Isolate the AC Line pins on the 5 pin power connector with electrical tape to prey ent

electric shock hazard. Restore the electrical power to the furnace and set the thermostat above

room temperature. After three or four minutes of burner operation, the

limit control should turn the burner off. When the limit function test is complete, shut off electrical

power to the furnace, replace the 5 pin power plug to the blower fan motor, and then restore power. The

blower fan will start up immediately. Once the

Page 10

temperaturehasdroppedandthelimitcontrolhasreset, thefanwilloperateuntilthefanofftimeisachieved.The

oilburnerwillthenresumeoperationandcontinueuntil thethermostatissatisfied.Restorethethermostatsetting

toacomfortabletemperature.

NOTE: IF THE FURNACE IS TO BE SHUT DOWN FOR AN EXTENDED PERIOD OF TIME, CLOSE

THE OIL SUPPLY VALVE TO THE BURNER.

I'ACAUTION I

DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED,

WHEN THE FURNACE IS FULL OF VAPOUR, OR WHEN THE COMBUSTION CHAMBER IS VERY

HOT. NEVER BURN GARBAGE OR PAPER IN THE FURNACE, AND NEVER LEAVE PAPER OR

RAGS AROUND THE UNIT.

22. ECM BLOWER MOTOR OPERATION (O4HD-091A-V-FA)

Setting Blower "ON" and "OFF" Timings

Blower on/off time delays are handled by ECM motor programming. Features of this ECM variable

speed motor are that it will deliver a constant airflow

within a wide range of external static pressures, and

also includes: Soft Start: This ECM variable speed motor will

slowly ramp up to the required operating speed.

This feature in the heating cycle allows the heat

exchanger to reach operating temperature before

the set heat speed, which minimizes noise and

increases comfort. Soft Stop: At the end of the heating cycle, the ECM

variable speed motor will slowly ramp down. This feature allows for increased energy efficiency and

reduced noise levels. Dehumidification: A dehumidification feature has

been programmed into the variable speed motor. At

the start of each cooling cycle, the variable speed

motor will run at 82% of the rated airflow for 7.5 minutes. After 7.5 minutes has elapsed, the motor

will increase to 100% of the rated airflow. This

profile is used to provide dehumidification and improve system efficiency.

Continuous Fan Operation : When the thermostat continuous fan (G) switch is on without a call for

heating or cooling, the indoor fan is immediately energized up to 50% of the cooling speed. This

feature allows continuous circulation of air between

calls for heating or cooling. If a call for heat (W) or cool (Y) occurs during

continuous fan, the blower will remain energized

Page 11

Appendix A- O4HD-091A-12-FB, O4HD-091A-14-FA-DV AN D O4HD-091A-V-FA

O4HD-091A-12-FB, O4HD-091A-14-FA-DV and O4HD-091A-V-FA furnaces may be used with the following oil burners.

Please note: The Beckett AF oil burner is for applications using indoor air for combustion only. For sidewall venting applications utilizing outdoor air for combustion, use the Beckett AFII (Balanced Flue) oil burner only.

Table A-1 Beckett AF Oil Burner Set-Up

Beckett AF Series Oil Burners

(For use with chimney vented units only)

Furnace Model Output Burner Nozzle Pump Flow Head 1 Static

BTU/Hr Model Pressure Rate Plate

O4HD-070A-12-FB 2

0.50 / 0.50

59,000 AF76BNHS 100 psig F3 3-¾in.

O4HD-070A-V-FA 2 80°A usgph

O4HD-091A-12-FB 0.65 / 0.65 O4HD-091A-12-FB

76,000 AF76BNHS 80OA 100 psig usgph F3 3-¾in.

O4HD-105A-12-FB 0.75 / 0.75 O4HD-105A-12-FB

86,000 AF76BNHS 80OA 100 psig usgph F3 3-¾in.

Head is shielded by ceramic insulator. _ Low Firing Rate Baffle required when using a 0.50-gallon

nozzle. Bold models indicate the factory equipped firing rate.

Table A-2 Beckett AFII Oil Burner Set-Up

Beckett AFII Series Oil Burners

(For use with sidewall vented units with outdoor combustion air, or chimney vented units with

indoor air for combustion)

Furnace Model Output BTU/Hr Burner Nozzle Pump Flow Head

O4HD-070A-14-FA-DV 65,000 AFII-85 60OA 120 psig usgph FB0

O4HD-091A-14-FA-DV 75,000 AFII-85 60OA 115 psig usgph FB3

O4HD-105A-14-FA-DV 86,000 AFII-85 60OA 115 psig usgph FB3

Model Pressure Rate

0.50 / 0.55

0.60 / 0.65

0.70 / 0.75

Page 12

NOTE: Air gate setting may vary for sidewall vented units where air gate must be adjusted to achieve zero smoke.

A.1 OIL BURNER AIR ADJUSTMENT

For complete details, consult the oil burner instruction

manual provided in the furnace documents envelope.

Beckett AF Burner

Adjust the air shutter by loosening the locking screws and moving the air shutter, and if necessary, the bulk

air band.

Beckett AFII Burner

Adjust the burner air supply by first loosening the locking screw located on the black dial to the right of

the burner. Turn the black dial clockwise to increase the combustion air and counter-clockwise to decrease

the combustion air. Re-tighten the locking screw after obtaining the proper setting.

A.2 BURNER ELECTRODES

Adjustment of the electrode tips with respect to each other, the nozzle, and to the rest of the burner is very

important to ensure smooth start-ups and to permit efficient combustion.

Beckett AF Burner

Electrode gap: 5/32 inch.

Distance above horizontal centerline: 5/16 inch. Older instruction sheets specify 7/16 inch. The current

specification is 5/16 inch. Distance ahead of nozzle: 1/16 inch.

"Z" dimension, the distance from the front of the end cone (head) to the face of the nozzle should be 1-1/8

inches, If a ceramic head is used, the distance from the end cone to the nozzle face is increased to 1-3/8 inches,

A.3 START UP The furnace should be operated for a minimum of 10

minutes to reach steady state conditions before fine

tuning combustion. The warm up time is ideal for testing the oil pump pressure.

Drill a 1/4-inch test port in the venting between the

furnace flue outlet and draft regulator (barometric damper). Insert a stack thermometer and note the flue

gas temperature. The flue gases should be within a

range of 350°F to 450°F. If the flue gases are below

the range, it may be necessary to slow down the

blower fan. If the flue gases are above the range, the blower fan may require speeding up. Stack

temperature varies directly with the system temperature rise. System temperature rise is the

difference between the furnace outlet temperature and furnace inlet temperature as measured in the vicinity of

the connection between the plenum take-offs and the trunk ducts. Temperature rise value is listed on the

system rating plate.

Perform a smoke spot test. The smoke spot should not

exceed No. 1 on the Bacharach Scale. After the air adjustments have been completed, re-

check the draft pressure at the test port on the burner

mounting plate as shown in Figure 2. The draft should be adjusted to -0.02 inches w.c.

In the United States, the Beckett AF Burner may be

equipped with Beckett's "Inlet Air Shut-Off" to increase efficiency. (Beckett Part No. AF/A 5861).

NOTE: USE OF THE INLET AIR SHUT-OFF

COULD CAUSE POST COMBUSTION NOZZLE

DRIP.

Page 13

Furnace Model

Table A-6 Direct Drive Blower Set-Up PSC Motor

Blower Set-Up Cooling Capacity

0.20 in. w.c. 0.50 in. w.c. CFM

Blower Speed Motor Speed Motor Tons Power Range

O4HD-070A-12-FB

O4HD-070A-14-FA-DV

O4HD-091A-12-FB

O4HD-091A-14-FA-DV

O4HD-105A-12-FB

O4H D-105A-14-FA-DV

100-10T

Low

Med-Low

Med-

High

1/2 HP

Med-Low

Med-High

High

1/2 HP

690 - 1500

Furnace Model

Table A-7 Direct Drive Blower Characteristics PSC Motor

Blower

Motor

FLA

Speed

CFM

External Static Pressure - Inches w.c.

0.2 0.3 0.4 0.5 0.6

O4HD-A-12-FB

O4HD-14-FA-DV

070-105

100-10T

1/2 HP 7 60°F

High 1741 1651 1556 1476 1369

Med-

1557 1497 1434 1369 1278

High

Med-

1063 1051 1037 1037 1011

Low Low 697 697 687 672 646

Page 14

Table A-8 Direct Drive Blower Characteristics ECM Motor

Furnace Model

O4HD-070A-V-FA O4HD-091A-V-FA O4HD-105A-V-FA

Blower

100-10

Motor

1/2 HP

ECM

Motor

FLA

7.7

60°F

Continuous

Fan

500 - 700

CFM RANGE

Heating

0.28 - 0.48

inches w.c.

825 - 1250

Cooling

0.5 inches

W.C.

600 - 1400

TIP: These Formulae will assist with the design of the ductwork and the determination of

airflow delivew:

CFM = Bonnet Output /(I.OgJx System Tetuloe_at.u_eRise(ATJ)

System Tempeiatu_eRise (AT)= B ozJnetOut.put/(i.0gJx CFM)

Page 15

Table A-9 General Dimensions (Inches)

Cabinet

Plenum Openings

Return

Supply Side Bottom

Flue

Diameter

Filter

Shipping

Weight

(LB.)

Furnace Model Width Depth Height Type Size

O4HD-A-12-FB

O4HD-A-14-FA-DV 16 x 25

070-105 22 30 -3/4 49-5/8 20½ x 20 14 x 22 14 x 22 5 Permanent x 1 210

Heiglit

-- '4_ictth-

DeMh

Supply --

Page 16

Table A-10 ECM Blower Set-Up (O4HD-091A-V-FA)

DIP SWITCH ADJUSTMENT CHART

FOR INPUT 0.50 USGPH TO 0.75 USGPH

SW1 - HEAT

DIP Switch

Position

1 2

OFF OFF

ON OFF

OFF ON

ON ON

POS.

A B C D

INPUT

USGPH

0.65 N/A

0.75

0.50

SW3 - ADJUST

DIP Switch

Position

1 2

OFF OFF

ON OFF

OFF ON

ON ON

POS.

A B C D

CFM

(+)15%

(415%

N/A

SW2 - COOL

DIP Switch Position

1 2

OFF OFF

ON OFF

OFF ON

ON ON

POS.

A B C D

AC Size

(TON)

2.5 2

1.5

SW4 - DELAY

DIP Switch Position

1 2

OFF OFF

ON OFF

OFF ON

ON ON

POS.

A B C D

INPUT

USGPH

0.65 N/A

0.75

0.50

NOTE:

SWl (HEAT) AND SW4 (DELAY) DIP SWITCHES MUST BOTH BE ADJUSTED ACCORDING TO INPUT (NOZZLE SIZE). SW2 (COOL): 1 TON is approximately equal to 400 CFM SW3 (ADJUST): (Heating Mode) Increase OR decrease temperature rise respectively

(Cooling Mode) Increase OR decrease CFM respectively

Page 17

APPENDIX B: WIRING DIAGRAMS

Chimney Vent Burner Wiring Diagram O4HD-091A- 12-FB O4HD-091A-V-

LEGEND/le ege_ede

120v ] FACTORY WIRING 24 V fllage a Fusine

120 V 7 FIELD WIRING 24 V ] filage au champs

(---:)_ GROUND/Terre

I TERMINAL PROVIDED/

point de raccord fourni

INDOOR / BR__

ventilateur _C oBR-_

-:2

N (COMMON)

O TRANSFORMER/

_nsformateur

530SE L

Vl WH L

.J J

TERMINAL NOT PROVIDED/point de raccord non-foumi

BK BLACK/noir Vl VIOLET/violet BL BLUE/bleu WH WHITE/blanc BR BROWN/brun YL YELLOW/jaune

GR GREEN/vert GND GROUND/Terre OR ORANGE/orange CAP CAPACITOR/capaciteur

RD RED/rouge

,,/A_, AUXILIARY LIMIT (IF EQUIPPED) \ .) limite auxiliaire- si 6quippee

/- \ {\ L)

,\F)

LIMIT/timite

LOW SPEED FAN SWITCH (IF EQUIPPED)

interupteur a basse vitesse (si equipp6e)

BLOCKED VENT SAFETY

f- \ (REQUIRED FOR CANADIAN INSTALLATIONS)

<BVS

\ /' commande d'epreuve de systeme d'evacuation bloque

(requis pourtes instalations au Canada)

_/-i\'_ IGNITER/

\--/ transformateur d'atumage

_- \ VALVE/

IxV) soupappe

POWER SUPPLY 120 VAC 60 HZ (FUSED DISCONNECT ON HOT LEG)

El aHmentation 120 VAC 60Hz

(disjoincteur avec fusible sur ]e fl d'alimentation)

_BK-- 120V 24V

WH | WHm COM 24V FL

f- \

BK i F '_ BL

\ .-/ \?;/

BL |

I ()

I I

L J

,A>

RD_

1158-1/1168-1

CONTROL

L t oRBK

l_j_-- GR_

. / ,w

/ ' ",_3T (T1)

BURNER MOLEX CONNECTOR/

........._'-T (T2) connecteur molex

du br01eur

30746 Rev A

R_ 1

_------[h:--=L-.

_,__LL CNI

\ /

RtELLO 40F BURNER/brCileur

(IF AVAILABLE)/(si disponible)

- - RD

- WI-

BK-

--WI-

AL 1808

,f_ / PRIMARY

) 2 CONTROL LI BK

O 3T r /

MOTOR,moteur OR--

INTERRUPTED

mtenomp6e BL -- -- /3\

.....CELL F--YL SEiS!R T

so_deaflame

BECKETT AF BURNER/br01eur

BELT DRIVE MOTOR ventilateur a courroie (IF AVAILABLE) (si disponible)

_WH_

/NLD?NOERR _ _'A°tOeTu/R ..... '

principale .....\

,BK 1158-I

CONTROL

ECM MOTOR ventilateur a ECM (IF AVAILABLE) (si disponible)

WH_

:%_.\/11-'1",,, .I,,o..o . NEbT

1112134P \ i iii _ iii

" YL C 8 z 6 5 4 3 2 .3

\ _ h" 1168-1

CONTROL

THERMOSTAT CONNECTIONS/ 1158-1 raccorde du thermostat CONTROL

< ) !, _) , ,

,:,w>-!)--[-"

',N C_/'

THERMOSTAT

THERMOSTAT CONNECTIONS/ 1168-1 raccorde du thermostat

CONTROL

0 0 O 0 0 0

': _} {_Y _ _ ':\W/" '::\ Ri }'c'

THERMOSTAT

Page 18

Direct Vent Burner Wiring Diagram

O4HD-091A-14-FA-DV

LEGEND/le#enae

/20V ] FACTORY WIRING 24V filage a Fusine

/20v ] FIELD WIRING 24V filage au champs

L__ GROUND/Terre

I TERMINAL PROVIDED/

point de raccord foumi

TERMINAL NOT PROVIDED/point de raccord non-foumi

BK BLACK/noIr VI VIOLET/violet BL BLUE/bleu WH WHITE/blanc BR BROWN/brun YL YELLOW/jaune GR GREEN/vert GND GROUND/Terre OR ORANGE/orange CAP CAPACITOR/capaciteur RD RED/rouge

@L_', AUXILIARY LIMIT (IF EQUIPPED)

. limite auxiliaire - si equipp6e

LIMIT/limite

(/-F \ LOW SPEED FAN SWITCH (IF EQUIPPED) \ --) interupteur a basse vitesse (si 6quippee)

¢-i ;', 'GN'TER/

transforrnateurd'allumage

/ m VALVE/

_NV) soupappe

POWER SUPPLY 120 VAC 60 HZ

(FUSED DISCONNECT ON HOT LEG)

h 1 aHmentation 120VAC 60Hz

(disjoincteur avec fusible sur le fll d'alimentation)

L1 N (COMMON)

INDOOR BLOWER _BR_,

ventlateur ,/ .=BF_ \\

_;N)_)C ..... L( CAF I

BK WH

TRANSFORMER/

nsformateur

/.I \

BK i: F )

BL _ I "/I

I ()

I I

_BK" 120V 24V --

(---_

_WH- COM 24V

=r_ / SWITCH ",,

123 _, i

" C NC

.oiT

VI RD

1-___ IGR_|

I l ....

_ GND

"----1 _--- _T2

CONNECTOR/ connecteur molex du brQleur

' L '

I' AL :If AL ',:

'\ ./ '\ _/

RD_

1158-1/1168-1

CONTROL

RD'

240005212 Rev A

TO T1

RIE LLO 40B F B U RN E:/OorT21euT YL _RTF 1

(IF AVAILABLE)/(sidisponiNe) _U WH

530SE L "1

_ RD

I r_ _ WH-II 3

'_I B. 7 _

-- _-- RD

_ MOTOR_._ 9 AL 1009

...." MOTOR _ 11 "

"_ .._'_WHI" 12

V] I_/H[ tVl WH

(_/T/ LIMIT RD_\

O T2 L/ BK(H__LV/)

L2 W

INTERRUPTED'

.....2::2

iyL ......... -

PRI',_TARRYL..... d f' _

BECKETT AFII SURNER/br01eur

BELT DRIVE MOTOR

(IF AVAILABLE)

I%°%

ventilateur _ \ principale _

ventilateur a courroie (si disponible)

_WH_

dOTOR

loteur

1158-1

CONTROL

ECM MOTOR ventitateur a ECM (IF AVAILABLE) (si disponible)

WH_

" YL C8 7 d s 4 3 2_

\ _ 2/ 1168-1

CONTROL

THERMOSTAT CONNECTIONS/ 1 1 58-1 raccorde du thermostat CONTROL

,::G )

N _J

THERMOSTAT

THERMOSTAT CONNECTIONS/ 1168-1

raccorde du thermostat

CONTROL

0 0 0 0 0 0

i 'Lw;,k R_j

THERMOSTAT

Page 19

OPERATION OF OIL BURNER Once the furnace flue pipe, electrical and oil line

connections have been made, use the following instructions to set the burner:

Shut off the electrical power to the furnace.

Install an oil pressure gauge to the pressure port on

the oil pump. (Refer to the oil pump specification sheet included with the burner instructions).

Restore electrical power to the furnace. Start the furnace and bleed all air from the fuel oil

lines.

Close the purge valve and fire the unit.

Allow the furnace to warm up to normal operating temperatures. During this time, set the pump pressure

in accordance with the data provided in Appendix A,

Table A-2, and A-5. When the furnace has reached "steady state" (after

approximately 10 minutes). Set combustion air damper

to get a TRACE of smoke.

Check the system temperature rise. The temperature

rise is the difference between the return air temperature measured at a point near the return air inlet, and the

supply air temperature measured near the furnace outlet. The system temperature rise is listed on the

furnace rating plate. If the temperature rise is too high, the airflow must be increased. If the temperature rise is

too low, the fan should be slowed down.

the heat anticipator. Set the heat anticipator to the amperage measured.

NOTE: THE FURNACE SHOULD BE RUN

THROUGH AT LEAST THREE FULL CYCLES

BEFORE LEAVING THE INSTALLATION, TO ENSURE THAT ALL CONTROLS ARE

OPERATING PROPERLY AND AS EXPECTED.

NOTE: ALL JOINTS IN ANY POSITIVE

PRESSURE VENTING SYSTEM MUST BE CHECKED FOR LEAKS BEFORE LEAVING THE INSTALLATION SITE.

Turn off the burner. Observing the duct thermometer in the supply air stream, note the temperature at which

the blower fan stops. The fan adjustments can be made by moving the dipswitch settings on the timer

control board for fan off delay. To check the operation of the limit switch, shut off

power to the furnace. Temporarily remove the neutral wire from the direct drive blower motor. Restore the

electrical power to the furnace and set the thermostat above room temperature. After three or four minutes of

burner operation, the limit control should turn the burner off. When the limit function test is complete,

shut off electrical power to the furnace, replace the neutral wire to the blower fan motor, and then restore

power. The blower fan will start up immediately. Once the temperature has dropped and the limit control has

reset, the fan will operate until the fan off time is achieved. The oil burner will then resume operation

and continue until the thermostat is satisfied. Restore the thermostat setting to a comfortable temperature.

Set the heat anticipator adjustment in the thermostat (if so equipped), by removing the "R" or "W" wire to the

thermostat, then reading the amperage draw between the two wires. Failure to remove one of the wires from

the thermostat while performing this test could burn out

3_9

Page 20

APPENDIX C OIL PRIMARY CONTROL DETAILED SEQUENCE OF OPERATION

Power is applied to unit. The oil primary control completes a self-diagnostic procedure. If no light or flame is present, and unit passes its self-diagnostic procedure, the control enters into the idle mode.

Thermostat calls for heat:

A) Safety check is made for flame (4 second delay).

1) If flame is not present, the oil primary control will apply power to the burner motor and igniter.

2) If flame is present, the control remains in the idle state.

B) Unit enters a pre-purge period of 15 seconds. C) After 10 seconds, control checks for flame presence.

1) If flame is not present, the oil primary control enters the trial for ignition state.

2) When flame is present, the control enters lock out mode.

D) The Oil Primary Control monitors the burner flame.

1) When flame is present, the control enters ignition carryover state. (Continues to spark for 10 sec.). a) Provides continuous spark after flame is sensed to assure that burner remains lit.

b) Turns on LED diagnostic light. c) Starts carryover timer.

(i) Flame and call for heat are monitored.

• If flame is lost and lockout timer has not expired, the control will return to trial for ignition state.

• If flame is lost and lockout timer has expired, the control will enter the recycle state.

• Recycle timer starts.

• Burner motor and igniter and solenoid valve are turned off.

• LED diagnostic light flashes slowly.

E) Carryover timer expires.

1) Enters run state. a) Igniter turns off.

Combustion continues until thermostat is satisfied, or the oil primary control detects a loss of flame and enters into Recycle Mode.

F) Thermostat is satisfied - call for heat is terminated:

a) Oil primary control shuts off burner motor and solenoid valve.

(i) If the control utilizes a blower motor off delay, after 30 seconds, flame presence is checked.

• If flame is not present, the control LED diagnostic light is off and returns to idle state.

• If flame is presence is detected, the control enters lock out mode.

Page 21

FIGURE 4: UNITED TECHNOLOGIES 1158-120 FAN TIMER BOARD

)4HD-091A-12-FB and C

FIGURE 5: UNITED TECHNOLOGIES 1168-1 ECM TAP BOARD (O4HD-091A-V-FA)

Page 22

IDLE STATE

THERMOSTAT CALLS FOR HEAT

SAFETYCHECKFORFLAME(5SEC.) I l

F OIL PRIMARY

REMAINS IN IDLE STATE

CONTROL

SEQUENCE of

OPERATION

NO FLAME

BURNER MOTOR & IGNITOR START I

10 SEC.

SAFETY CHECK FOR FLAME (5 SEC.) I

NO FLAME

SOLENOID VALVE OPENS

TRIAL FOR IGNITION

BURNER FLAME MONITORED

NO FLAME

FLAME

CARRYOVER STATE

• Provides continuous spark

• LED diagnostic light ON

• Start Carryover Timer

FLAME

CARRYOVER TIMER EXPIRES

FLAME LOST

FLAME

I OCKOUT STATE

OIL PRIMARY CONTROL: Shuts off burner motor

Shuts off igniter Shuts off Solenoid Valve

Fast Flashes LED Diagnostic Light

FLAME

RUN STATE

• Igniter turns off.

THERMOSTAT SATISFIED

FLAME LOST I

FLAME LOST

OIL PRIMARY CONTROL

SHUTS OFF:

• Burner Motor

• Solenoid Valve

30 SEC.

SAFETY CHECK FOR FLAME (5 SEC.) I

NO FLAME i

RETURNS TO IDLE STATE

RECYCLE TIMER STARTS

OIL PRIMARY CONTROL:

Shuts off Solenoid Valve Shuts off Igniter

Shuts off Burner Motor Slow Flashes LED

diagnostic light

FLAME

RECYCLE TIMER EXPIRES

(60 SECONDS

Page 23

Table C-1" 1158-120 ELECTRONIC FAN TIMER BOARD (EFT) DETAILED SEQUENCE OF OPERATION

Mode Action

EFT closes the oil primary control T - T connections).

Thermostat calls for heat. ("W" terminal is energized).

Thermostat ends call for heat.

HEAT

COOL energized),

FAN (G terminal is energized),

LIMIT EFT begins heat "fan off" delay sequence.

FAN connected. If fan operation is required by a call for heat, cool, or fan, the EFT switches off the

CW" terminal is de-energized).

Burner fails to light.

Established flame fails.

Thermostat begins call for cool, Cooling contactor is energized immediately, (G and Y terminals are Circulator fan is energized at cool speed,

Thermostat ends call for cool, (G Cooling contactor is de-energized immediately, and Y terminals are de-

energized), Thermostat begins call for fan.

Thermostat ends call for fan. (G terminal is de-energized). Circulator fan is de-energized immediately,

Limit switch string opens.

Limit switch string closes (with Circulating fan turns off after the selected heat "fan off" timing.

existing call for heat). EFT re-closes the oil primary control T - T connections.

Limit switch string closes

(without existing call for heat), command. Continuous circulating fan is Circulating fan is energized when there is no call for heat, cool, or fan.

Ignition system and the oil primary control start the furnace. Oil flows as long as the oil primary control senses flame.

Burner motor is energized and heat "fan on" delay timing begins. When timing is complete, the circulator fan is energized at heat speed.

The oil primary control is de-energized, terminating the burner cycle.

Heat "fan off" delay timing begins. Length of delay depends on EFT dipswitch settings.

When timing is complete, the circulator fan is de-energized.

EFT returns to standby mode, (Oil primary control and circulator fan are off, unless continuous fan operation is selected at the thermostat). Oil primary control locks out within lockout timing, (30 seconds).

Burner motor is de-energized. (Even though thermostat is still calling for heat). If circulator fan has started, it continues through the selected heat "fan off' delay

period. Burner motor is de-energized and oil primary control goes into recycle mode.

If the selected heat "fan off" delay timing is longer than the recycle delay timing, the circulator fan continues to run through the next trial for ignition.

Circulator fan turns off immediately,

Circulator fan is energized immediately at cooling speed,

Oil primary control shuts off burner. Circulator fan is energized immediately at heat speed.

EFT opens the 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 heating to cooling

speed.

Oil primary control is energized, initiating burner light off. Circulator fan turns off when heat "fan off" delay time is complete.

Normal operation resumes; EFT control is in standby mode awaiting next thermostat

continuous fan speed tap before energizing the other fan speed.

System Response

EAC connected, the circulator fan is energized. EAC connections are not energized when the optional

Electronic Air Cleaner is

HUM Humidity control is connected. Humidifier connections are energized when the oil burner motor is energized.

1168-1 ELECTRONIC FAN TIMER BOARD (EFT) DETAILED SEQUENCE OF OPERATION

Thermostat Input LEDs (LED1-5, LED8) Six green LEDs are placed behind their respective thermostat connections (Y1, Y/Y2, G, DH, O, and W) and operate whenever a

call is present. Thermostat calls for heat "W". The 24VAC input signal is passed to pin 2 of P1 and wilt drive the K1 relay that provides

dedicated contacts to the T-T input of the Oil Primary Control. Thermostat calls for cool "YI". The 24VAC input signal is passed to pin 6 of PI. Thermostat calls for fan "G". The 24VAC input signal is passed to pin 15 of PI. Thermostat calls for

dehumidification "DH". The 24VAC input signal is passed to pin 10 of PI. Thermostat calls for reversing valve "O". The 24VAC input signal is passed to pin 9 of PI.

Electronic air cleaner (EAC) connections are energized when the heat or cool speed of

continuous fan terminal is energized.

Page 24

OIL PRIMARY CONTROL LED DIAGNOSTIC

LIGHT

The LED diagnostic light has several functions. It indicates the state or mode in which the oil burner is

operating. It will also indicate fault conditions, and help determine cad cell resistance while the burner is

operating.

NORMAL CONDITIONS:

The LED diagnostic light will turn on when the burner enters the carryover state; the point at which ignition

spark is on, and will remain on through the run state, where the ignition spark is terminated but the burner

continues to fire. The LED diagnostic light will turn off at the end of the

burner cycle as the oil primary control enters the idle state, and will remain off until the next heating cycle.

FAULT CONDITIONS:

If the LED diagnostic light is flashing quickly; 1 Hz (½ second on / ½ second off), the oil primary control is in the lockout state or in restricted mode. To exit the

lockout state, press the reset button. If the LED diagnostic light is flashing slowly; 1¼Hz (2

seconds on / 2 seconds off), the oil primary control is in the recycle state. This indicates that flame sensing

was lost after the lockout timer expired during the ignition carryover state. The oil primary control will

return to the idle state within 60 seconds.

CAD CELL CONDITION:

If the LED diagnostic light is off, the cad cell is not sensing flame.

If the LED diagnostic light is on, the cad cell is sensing flame, or viewing ambient light.

The resistance of the cad cell may be checked while the oil primary control is in the run state by pressing

the reset button. The LED diagnostic light will flash the following code:

Table C-2: Cad Cell Resistance

TROUBLESHOOTING

IMPORTANT: Due to the potential hazard of line voltage, only a trained, experienced service technician should perform the troubleshooting procedure.

PRELIMINARY STEPS:

Check the diagnostic light for indications of burner condition. Refer to the oil primary control LED

DIAGNOSTICLIGHTsection for details.

IA° =,o.I

WHEN SIMULATING A CALL FOR HEAT AT

THE OIL PRIMARY CONTROL, DISCONNECT AT LEAST ONE THERMOSTAT LEAD WIRE FROM THE T1 - T2 TERMINALS TO PREVENT

DAMAGE TO THE THERMOSTAT. NEGLECTING THIS PROCEDURE MAY BURN OUT THE HEAT ANTICIPATOR OF A

STANDARD 24 VAC THERMOSTAT, OR CAUSE HARM TO COMPONENTS WITHIN A

MICRO-ELECTRONIC THERMOSTAT.

Before checking the oil primary control, perform these preliminary checks, (repair or replace controls as

necessary):

• Check the power supply; fuse box or breaker,

any service switches, all wiring connections, and burner motor reset button (if equipped).

• Check the limit switches to ensure that the

switch contacts are closed.

• Check the electrode gap and position.

• Check the contacts between the oil primary

control and the electrodes.

Check oil supply (tank gauge). Check the oil nozzle, oil filter, and oil valves.

• Check the piping or tubing to the oil tank.

Flashes Resistance in Ohms

1 Less than 400

2 Between 400 - 800

3 Between 800- 1600

4 Between 1600- 5000

• Check the oil pump pressure.

CHECK OIL PRIMARY CONTROL AND IGNITER

If the trouble does not appear to be in the burner or ignition hardware, check the oil primary control and the

igniter by using the following equipment: Screwdriver.

Voltmeter (0 - 150 VAC) Insulated jumper wires with both ends stripped.

Page 25

PRELIMINARY CHECKS:

IAWARNINGI

Make sure that limit switches are closed and those contacts are clean.

ELECTRICAL SHOCK HAZARD. TROUBLESHOOTING IS DONE WITH THE

Check for line voltage power on the oil primary control black and white lead wires.

SYSTEM POWERED. BE CAREFUL TO OBSERVE ALL NECESSARY PRECAUTIONS TO PREVENT ELECTRICAL SHOCK OR

Refer to Table C-4 or C-5 for further troubleshooting information.

EQUIPMENT DAMAGE.

Table C-3: Oil Primary Control TROUBLESHOOTING Condition: Burner motor does not start when there is a call for heat.

Procedure

1. Check that limit switches are

closed and contacts are clean.

2. Check for line voltage power at the oil primary control. Voltage

should be 120 Vac between the black and white lead wires on the

oil primary control.

3. Check indicator light with burner off, no call for heat (no

flame).

4. Shield cad cell from external light.

5 Jumper thermostat (T-T)

terminals on oil primary control

IMPORTANT

First remove one thermostat lead

wire.

N/A N/A

Indicator light is on. Indicator light is off.

Indicator light turns off.

Indicator light stays on.

Burner starts.

Burner does not start.

Status Corrective Action

for continuity.

Cad celt is defective, sees external light, or connections have shorted. Go to step 4.

Go to step 5. Eliminate external light source or permanently shield cad

cell.

Replace cad celt with new cad cell and recheck. If indicator light does not turn off, remove yellow lead

wires from oil primary control and recheck.

If indicator light is still on, replace the oil primary control. If the indicator light turns off, replace cad cell bracket

assembly.

Trouble is in thermostat circuit. Check thermostat-wiring connections.

If connections are clean and tight, check thermostat wires

Disconnect line voltage power and open line switch. Check all wiring connections. Tighten any loose connections and recheck.

If burner still doesn't start, replace the oil primary control If burner still doesn't start, check the oil burner motor. It

may be seized or burned out.

Condition: Burner starts then locks out on safety with indicator light flashing at 1 Hz rate (1/2second on, 1/2second off)

Procedure Status Corrective Action

1. Check that the limit switches are closed and contacts are clean.

2. Check for line voltage power at

the oil primary control. Voltage ......

should be 120 Vac (nominal)

3. Check indicator light with burner off, no call for heat (no

flame).

Indicator light is on.

Indicator light is off.

Cad celt or controller is defective, sees external light, or connections are shorted. Go to step 4.

Go to step 5.

Page 26

Table C-3: Oil Primary Control Troubleshooting continued from previous page

Procedure Status

Indicator light turns off.

4. Shield cad cell from external light.

5. Jumper thermostat (T -T) terminals on oil primary control

IMPORTANT First remove one thermostat

lead wire.

Condition: Burner starts then locks out on safety with indicator light flashing at 1 Hz rate (1/2second on, 1/2second

Indicator light stays on.

Burner starts.

Burner does not start.

Eliminate external light source or permanently shield cad cell. Replace cad celt with new cad cell and recheck.

If indicator light does not turn off, remove cad cell lead wires

from oil primary control and recheck.

If indicator light turns off, replace cad cell bracket assembly. If indicator light does not turn off, replace controller.

Trouble in thermostat or limit circuit. Check thermostat or limit wiring connections.

Disconnect the line voltage power and open line switch.

Check all wiring connections. Tighten any loose connections and recheck.

If burner does not start, replace oil primary control

Corrective Action

off)

6. Reset oil primary control by

pushing in and releasing red reset button.

7. Listen for spark after burner turns on (after 2 second delay).

8. Check indicator light after flame isestablished, but before

oil primary control locks out.

9. Check cad cell sighting for view of flame.

Disconnect line voltage power

and open line switch.

Unplug cad celt and clean cad

celt face with soft clothe. Check sighting for clear view of flame.

Replace cad celt in socket. Reconnect line voltage power

and close line switch. Start burner.

Indicator light stops flashing. Indicator light continues to

flash at 1 Hz rate.

Ignition is off

Ignition is on. Ignition is on but no oil is being sprayed into the combustion chamber.

Indicator light is on until the control locks out and starts

flashing during lockout.

Indicator light stays off. Burner locks out.

Burner keeps running.

Go to Step 7.

Verify that the control is not in restricted mode. (See notes at end of this table.). If not in restricted mode, replace oil

primary control Spark igniter could be defective. Check for line voltage at

igniter terminals. If line voltage is present, replace oil primary control.

Go to Step 8.

Wait for "Valve ON" delay to complete. Check oil supply, and oil line valve. Check for filter blockage or seized oil pump.

Replace oil primary control

Go to step 9. Go to step 10.

System is OK.

Page 27

Table C-3: Oil Primary Control Troubleshooting continued.

Procedure

10. Check cad cell. Disconnect line voltage power

and open line switch.

Remove existing cad cell and

replace with new cad celt.

Disconnect all wires from

thermostat terminals to ensure that there is no call for heat.

Reconnect line voltage power

and close line switch.

Expose new cad celt to bright

light such as a flashlight.

11. Check cad cell bracket

assembly.

Disconnect line voltage power

and open line switch.

Remove cad cell wires from

quick connect connectors on and leave control lead wires

open. Apply power to device.

Place jumper across cad cell

terminals after burner motor turns on.

NOTE: Restricted Mode - (Limited Reset): In order to limit the accumulation of unburned oil in the combustion chamber, the

control can be reset only 3 times, after which, the control locks out. The reset count returns to zero each time a call for heat is successfully completed.

To reset from RESTRICTEDMODE:press and hold the reset button for 30 seconds. When the LED flashes twice, the device has reset.

NOTE: Disable function: Pressing and holding the reset button will disable all functions until the button is released. The burner

will restart at the beginning of the normal heat cycle on SAFETYCHECK.

Status Corrective Action Indicator light is on. Remount control onto burner housing. Go to step 6.

Indicator light is off.

Indicator light is on.

Indicator light is off.

Go to step 11.

Replace cad cell bracket assembly.

Replace oil primary control.

Table C4: System and General Troubleshooting

Problem Possible Cause Remedy

Thermostat not calling for heat.

No power to furnace.

Furnace will not start. Remove thermostat wires from oil primary control terminals T-T.

Thermostat faulty. Place a jumper across T-T. If furnace starts, replace thermostat,

Oil primary control faulty, wires from oil primary control terminals T1 - T2. Check for 24V

Check thermostat and adjust. Also, check thermostat for accuracy; if it is a mercury switch type, it might be off level.

Check furnace switch, main electrical panel furnace fuse or circuit breaker. Also took for any other hand operated switch,

such as an old poorly located furnace switch, which was not removed during furnace replacement.

thermostat sub-base (if equipped), or both. Check reset button on oil primary control. Remove thermostat

across T -T. If no voltage is present, check for 115V to oil primary control. If 115V is present, go to Table C-3.

2"7

Page 28

Table C-4: System and General Troubleshooting continued

Problem

Furnace will not start.

Furnace will not start

without first pushing oil primary control reset button.

(Happens on frequent basis)

Furnace starts, but cuts out requiring manually resetting the oil protector

reset button.

Furnace starts, but cuts out requiring manually

resetting the oil protector reset button.

Oil burner sputtering at nozzle Replace fuel oil storage tank filter and / or fuel oil in-line filter.

Possible Cause

Photo Cell wiring shorted or room light leaking into photo

cell compartment Open safety switch.

No fuel oil.

Clogged nozzle. Clogged oil filter.

Low oil pump pressure.

Air getting into fuel oil lines, or fuel oil line dirty, clogged, or in

some manner defective. Defective burner motor.

Photo Cell (Cad Cell) defective.

No fuel oil.

Clogged nozzle. Clogged oil filter.

Low oil pump pressure.

Air getting into fuel oil lines, or fuel oil line dirty, clogged, or in

some manner defective. Defective burner motor.

Water or contaminants in oil.

Frozen oil line. Electrodes out of adjustment or

defective. Poor transformer high voltage

connections or defective transformer.

Fuel oil filter clogged. Defective oil pump. Fuel oil line partially clogged or

contains air.

Remedy

Check photo celt (cad celt) wiring for short circuits. Also, check for room light leaking into cad cell compartment. Repair light

leak if necessary. See Table C-3. Check for open limit or auxiliary limit. Also, check internal wiring

connections; loose connectors, etc. Check fuel oil supply. Check that all hand operated fuel oil

valves are in the open position. Fill oil storage tank if necessary. Replace nozzle with high quality replacement. Use rating plate

or Tables in Appendix A as a guide. Replace oil tank filter or in-line filter if used. Connect pressure gauge to oil pump. Adjust pump pressure, or

replace oil pump if necessary. Ensure that erratic pressure readings are not caused by defective fuel oil line. Check fuel oil lines. Replace any compression fittings found with

high quality flared fittings. Check for any signs of oil leaks. Any oil leak is a potential source of air or contaminants. Check burner motor. If burner motor is cutting out on over-load, determine why. Replace if necessary.

If cad cell is dirty, clean it. (Determine why cad celt is getting

dirty). If cad celt is poorly aimed, realign it. NOTE: The photocell should have a resistance of 100 KD in absence of light; a

maximum of 1500 D in the presence of light. Ensure that room light is not leaking into the cad cell compartment. (See diagnostic light section).

Check fuel oil supply. Check that all hand operated fuel oil valves are in the open position. Fill oil storage tank if necessary. Replace nozzle with high quality replacement. Use rating plate

or Tables in Appendix A as a guide. Replace oil tank filter or in-line filter if used.

Connect pressure gauge to oil pump. Adjust pump pressure, or replace oil pump if necessary. Ensure that erratic pressure

readings are not caused by defective fuel oil line. Check fuel oil lines. Replace any compression fittings found with

high quality flared fittings. Check for any signs of oil leaks. Any oil leak is a potential source of air or contaminants.

Check burner motor. If burner motor is cutting out on over-load, determine why. Replace if necessary.

Drain fuel oil storage tank; replace fuel oil. (Consult with fuel oil supplier).

Gently warm oil line. Insulate oil line. (Outdoor piping size may require increased diameter).

Check electrode settings. Check electrodes for dirt build-up or cracks in porcelain.

Check contacts between the igniter and electrodes. If OK, replace the igniter

Check burner motor and / or fuel oil pump coupling. Check oil pump pressure. Replace fuel oil pump if necessary.

Bleed air from oil line. If problem persists, replace oil line.

Page 29

Table C-4: System and General Troubleshooting continued

Problem Possible Cause

System temperature rise too high.

Poor "fan off" delay timing selection, (fan stops too soon).

Excessive fuel oil

consumption. Fuel oil leak.

Stack temperature too high.

Thermostat improperly amperage draw. Increase heat anticipator setting if necessary. adjusted or in poor location. If the thermostat is being influenced by drafts, sunlight, duct

Insufficient combustion air Adjust the oil burner combustion air band and draft regulator to adjustment at oil burner, or gain the highest practical CO2 or lowest practical 02 content in

Too much smoke, improper draft pressure, the flue gases. See Burner Set Up.

Heat exchanger partially Check for soot build-up in heat exchanger flue passages, clogged, especially in the outer radiator.

Poor alignment between oil

Soot building up on blast burner blast tube and fire pot. inside surface of the fire pot. tube (end coning). Flame impingement caused by Check nozzle size and angle. (See Appendix A). Check distance

Incorrect nozzle angle, from head to inside surface of the fire pot. Defective fire-pot Check fire-pot. Repair or replace.

Airflow blocked or dirty air filter.

Thermostat adjustments or amperage draw. Increase heat anticipator setting if necessary. location. If the thermostat is being influenced by drafts, sunlight, duct

Insufficient airflow, unused rooms. Check system temperature rise. If temperature

Furnace wilt not warm rise is too high, speed up blower fan.

home to desired Test high limit function of all limit switches. Use a duct temperature. Defective high limit control, obstructions to airflow around limit switch bi-metal elements.

Under-sized nozzle. Blower fan motor stopping Check blower fan motor amperage draw. Check motor

intermittently on overload, ventilation ports, clean if necessary. Replace motor if necessary. Burner motor stopping Check burner motor. Replace if necessary.

intermittently on overload.

Home does not heat

evenly Improper distribution of heat. This is not likely to be a furnace problem. Balance duct system.

System temperature rise ideally should not exceed 85°F. Check for clogged air filters. Check blower fan for excess dirt build-up

or debris. Speed up blower fan if necessary. Check "fan off" delay timing setting. Use a duct thermometer in

the supply air plenum take-off or first few inches of the supply air trunk duct. Ideally, the fan wilt shut off at a temperature of 90° -

100°F. Manipulate the dip switch settings to come as close as

possible to this "fan off" temperature. Check fuel oil line for leaks. Repair or replace if necessary. Check stack temperature. Stack temperatures will normally

range from 350 ° to 450°F. Check draft regulator. Draft should be set to -0.02 in. w.c.

Check thermostat heat anticipator setting against measured

work, etc., relocate to more suitable location.

Check alignment. Blast tube should be centered with fire pot burner opening. Oil burner head should be ¼ inch back from the

Clean or replace air filter. Check thermostat heat anticipator setting against measured

work, etc., relocate to more suitable location. Check all dampers. Open closed dampers including registers in

thermometer to assess accuracy of limit control. Check for

Replace control if necessary. Check nozzle. If problem is not caused by air flow problems, use

larger nozzle, if permitted by rating plate.

Remedy

Page 30

Table C-4: System and General Troubleshooting continued

Problem

Supply air temperature too hot.

Supply air temperature too cool.

Supply air temperature too cool during first

moments of furnace cycle.

Possible Cause

Airflow blocked or dirty air filter.

Insufficient airflow.

Excess airflow.

Excessive duct losses. Fan control "fan on" setting too

low. Excessive duct losses.

FINAL CHECK OUT

ENSURE THAT ALL SAFETY DEVICES AND ELECTRICAL COMPONENTS HAVE BEEN SET FOR NORMAL OPERATION. ENSURE THAT ALL ELECTRICAL CONNECTIONS ARE TIGHT AND THAT THE WIRING IS SECURE.

Remedy

Clean or replace air filter. Check all dampers. Open closed dampers including registers in

unused rooms. Check system temperature rise. If temperature rise is too high, speed up blower fan. Check system temperature rise. Slow down blower fan if necessary.

Check supply air ductwork. Seal leaky joints and seams.

Insulate ductwork if necessary. Increase "fan on" dipswitch settings on EFT if control has this

option.). Register air deflectors may help. Check supply air ductwork. Seal leaky joints and seams.

Insulate ductwork if necessary.

_IL IMPORTANT:

Please ensure that the homeowner is informed and

understands:

1. Where the circuit breaker or fuse is located in

the main electrical panel.

2. Where the furnace switch is located, and the switch "on" and "off" positions if not obvious.

3. Where the oil shut-off valve from the oil storage tank is located.

4. How to operate the thermostat, and other related accessories.

5. How to operate the manual reset button on the primary control, and especially when not to push the

reset button.

6. How and where to visually inspect the venting system for leaks or other problems.

7. How to inspect, clean and replace the air filter, and other homeowner maintenance procedures.

8. Who to call for emergency service and routine annual service.

9. The terms and conditions of the manufacturer's warranty and the contractor's warranty.

Page 31

HOMEOWNER'S REFERENCE TABLE

Model No.

Serial No.

Date Installed

Contractor

Contact

Address

Postal Code

Telephone No.

After Hours No.

FUEL SUPPLIER

Fuel Oil

Supplier

Contact

Telephone No.

After Hours No.

IF DIFFERENT FROM INSTALLATION CONTRACTOR:

Service Tech.

Telephone No.

After Hours No.

Page 32

5 6

LeftSidePanelAssembly RightSidePanelAssembly

RearPanel BlowerDivisionAssembly

BasePanel InnerFrontPanel

BlowerAccessPanel

29187L 29186L

29205L 29189 26216 30066

27721L

8 9 10 11

12 13

14 15

16 17 17

18 18

19 2O 21 24

26 27

28 29

TopPanel

HeatExchangerAssembly

CombustionChamberRetainerBracket

ReplacementCombustionChamber

OilBurnerMountingPlate

FlueConnector PouchGasket

FlueCollarGasket InsulationRetainer

RadiatorClean-outCover(2perunit) RadiatorClean-outCoverGasket(2perunit)

Clean-outGasketRetainer Clean-outTubeGasket

FilterFrame16"X25" FilterFrameEndSupport

Filter16"X25"X1"Permanent

ControlBox

UpperDoorPanel LogoBezel

LogoLabel LimitDisc60T11BOF155°F

FanTimerControl1158-120UTEC FanTimerControl1168-1ECMUTEC

WireHarness,ControlsFanTimer WireHarness,Blower

WireHarness,FanTimerBoard,Transformer WireHarness,ECMControl

WireHarness,ECMSupply Transformer

DraftRegulator

OilBurnerAssembly,BeckettAF76BNHS

BurnerMotor1/7HP3450RPMPSC BeckettClean-cutOilPumpA2EA6520

SolidStateIgnitor10SAY-01 OilPrimaryCombustionControl

FlameRetentionHead Nozzle,0.65/80°A

LowFireKit LowFiringRateBaffle

Nozzle,0.50/80°A

21437L 28675 27068 27000WP

29869 29005

2080175 21994

20602 29162 240006333

29161 29163

18020 5592B2 2180023 29362

30164L 28479 28563

30071 29388

240007048 29364

29365 29751

240006438 240005742 27738

27494(5") 30067

29689 29688

29522 29664

11961(F3) 210086

29880 25521101

29389

Page 33

BlowerAssemblyDirectDrive BlowerAssemblyDirectDriveECM

BlowerHousingandWheel,100-10TDD(O4HD-091A-12-FB

andO4HD-091A-V-FA)

30146

109007271

30626

102000131 109007272

17811

26251 27743

27760 27733

27731

BlowerMotor,1/2hp,4-Speed BlowerMotor,1/2hp,ECMProgrammed

MotorMountingBand- TR6884B MotorMountArms- 10-10DDBlower(3perunit)

MotorRunCapacitor,10mfd@370Vac

CapacitorStrap

BlowerSlideRail2 Per

RightSidePanel,AirBaffleO4HD-091A-12-FB

O4HD-091A-V-FA

All parts are the same as listed on the previous pages for Models O4HD-091A-12-FB and O4HD-091A-V-FA

except where noted below.

13 14

Oil Burner Mounting Plate Assembly Oil Burner Mounting Plate

Sight Glass Cover Plate Sight Glass Gasket (2 per unit) Sight Glass

Flue Connector Assembly 6" to 4" 90° Elbow Pouch Gasket (Second gasket required for Direct Vent)

Flue Collar Gasket (Second gasket required for Direct Vent) Upper Door Panel

Beckett Oil Burner AFII 85

Burner Motor 1/7 HP 3450 RPM PSC Beckett Clean-cut Oil Pump A2EA6520

Solid State Ignitor 10SAY-01 Oil Primary Combustion Control Air Tube Combination FBX80HGXS

Flame Retention Head (FB3) Nozzle, 0.60/60°A (O4HD-091A-14-FA-DV only)

29872 29867

29850 29870 29876

28952 2080175

21994 27722L

30069 28907 29688

28558 29649 28561 28533

28017

Page 34

Model O4HD-091A-12-FB, O4HD-091A-V-FA, and O4HD-091A-14-FA-DV

Page 35

NOTES:

NORDYNE, 8000 Phoenix Parkway, O'Fallon, Missouri, 63368

3 5 151B-0810 (Replaces 151B-0909)