Olsen HTL-140D, HTL-100D, HTL-120D, HTL-130D, HTLV-90DNX Installation, Operation & Maintenance Manual
...
HTL-D (Up-Flow Model)
R
HTLV-D (Up-Flow Model with ECM)
Oil Fired Warm Air Furnaces
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2000 Certified Company
ECR International
2201 Dwyer Avenue
Utica •New York • 13504 • USA
www.ecrinternational.com
P/N# 240007799, Rev. C [12/2009]
HTLD & HTLDV OIL FIRED WARM AIR FURNACE
IMPORTANT: THIS MANUAL MUST BE KEPT NEAR THE FURNACE FOR FUTURE REFERENCE!!
ALL INSTALLATIONS MUST MEET ALL LOCAL, PROVINCIAL/STATE, AND FEDERAL
CODES WHICH MAY DIFFER FROM THIS MANUAL
Read this complete manual before beginning installation.
These instructions must be kept with the furnace for future
reference.
2
TITLE OF DOCUMENT
Installation Requirements .....................................................................................................................................4
Location Of The Unit ...............................................................................................................................................5
Controls & Connections ........................................................................................................................................6
Oil Burners ...............................................................................................................................................................7
Combustion Chamber ............................................................................................................................................8
Circulating Air Blower ............................................................................................................................................8
Maintenance And Service ......................................................................................................................................9
Operating Instructions (HTL-D) .............................................................................................................................9
Operating Instructions (HTLV-D) ........................................................................................................................ 10
ECM Blower Motor Operation (HTLV-D) ............................................................................................................. 10
Oil Burner Set-Ups ............................................................................................................................................... 11
Oil Burner Air Adjustment ................................................................................................................................... 12
Burner Electrodes ................................................................................................................................................ 12
Start Up ................................................................................................................................................................. 13
Special Instructions For Units Equipped With Riello Burners ........................................................................... 13
Direct Drive Blower PSC Motor ........................................................................................................................... 14
HTL-D & HTLV-D Dimensions .............................................................................................................................. 15
ECM Blower (HTLV-D) .......................................................................................................................................... 16
Wiring Diagrams .................................................................................................................................................. 18
Oil Burner Operation ........................................................................................................................................... 19
Oil Primary Control - Sequence Of Operation .................................................................................................... 20
Oil Primary Control -Troubleshooting ................................................................................................................ 25
Homeowner's Reference Table ........................................................................................................................... 31
Parts Listing: Highboy Model: HTL-D And HTLV-D ............................................................................................ 32
WARNINGS AND SAFETY SYMBOLS
DANGER
Indicates an imminently hazardous situation which, if not
!
avoided, WILL result in death, serious injury or substantial
property damage.
!
Indicates an imminently hazardous situation which, if not
avoided, may result in injury or property damage.
CAUTION
WARNING
Indicates an imminently hazardous situation which, if not
!
avoided, may result in death, serious injury or substantial
property damage.
NOTICE
Indicates information which should be followed to ensure
proper installation and operation.
3
INSTALLATION REQUIREMENTS
Introduction
Please read these instructions completely and carefully before installing and operating the furnace.
MODELS HTL-D AND HTLV-D
Models HTL-D and HTLV-D are oil red forced air up-ow furnaces
with an output capacity range of 89,000 BTU/Hr. to 140,000 BTU/
Hr.
CAUTION
DO NOT USE GASOLINE, CRANK CASE OIL, OR ANY
OIL CONTAINING GASOLINE.
!
FOR YOUR SAFETY:
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.
All models are CSA listed, (NRTL/C) for use with No. 1 (Stove) and
No. 2 (Furnace) Oil. Please refer to the tables on page 11 (Oil Burner
Setups) of this manual 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-Burning 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 Oil-Burning
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 in this installation manual. When in doubt, please consult your local authorities.
All models are shipped assembled and pre-wired. e furnace should
be carefully inspected for damage when being unpacked.
Location of Unit
e furnace should be located such that the ue 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 oors.
e minimum installation clearances are listed in
Table 1
.
Table 1 - Clearances
Clearance to Combustibles
Location
HTL-D and HTLV-D
Up ow
To p 1"
Bottom 0* Combustible Floor
S /A Plenum 1"
Rear 1"
Sides 1"
Front 1" **
Flue Pipe 9"
Enclosure Closet
* No carpet or vinyl
** 24 in. Required for service clearance
Figure 1 - Heat Exchanger Support Screws
Heat Loss
e 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 SUPPORT SCREWS
Before nal placement of the furnace, the heat exchanger support
screws should be removed (See
Figure 1
). is may be preferable
if the furnace rear panel will be inaccessible aer installation. e
screws must be removed if the heat exchanger needs to be removed
from the cabinet.
4
LOCATION OF THE UNIT
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.
e air heated by the furnace shall not pass through a refrigeration
unit unless the unit is specically approved for such service.
e blower speed must be checked and adjusted to compensate for
the pressure drop caused by the evaporator coil. Refer to page 18 of
this manual, for recommended wiring and electrical connections of
the air conditioning controls.
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.
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. e 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, inltration
is normally adequate to provide air for combustion and dra operation. Furnace rooms under 65m³ (2295
treated as conned space.
3
) should automatically be
NOTICE
THE FURNACE IS APPROVED FOR USE WITH TYPE L
VENT OR EQUIVALENT.
CAUTION
CHIMNEY VENTED VERSIONS OF THE FURNACE
!
MUST BE CONNECTED TO A FLUE HAVING SUFFICIENT DRAFT AT ALL TIMES TO ENSURE SAFE AND
PROPER OPERATION OF THE APPLIANCE.
NOTICE
THE RECOMMENDED FLUE DRAFT PRESSURE IS
-0.02 IN. W.C. (See
e ue pipe must not pass through any oor or ceiling, but may
pass through a wall where suitable re 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 Page 11, (Oil Burner Setups) of this manual for burner set-up.
Figure 2
)
Figure 2 - Checking Over-Fire Draft
Chimney Venting
e ue 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. e ue pipe should not be smaller in cross sectional area
than the ue collar on the furnace. e ue pipe should connect to
the chimney such that the ue pipe extends into, and terminates
ush with the inside surface of the chimney liner. Seal the joint
between the pipe and the lining. e 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 regulations,
to the requirements of the National Building Code.
Over-re dra access port
5
CONTROLS & CONNECTIONS
Barometric Damper Control
e barometric damper control, also known as a dra regulator,
is used on conventional chimney venting only. is control automatically maintains a constant negative pressure in the furnace to
obtain maximum eciency. It ensures that proper pressures are
not exceeded. If the chimney does not develop sucient dra, the
dra control cannot function properly. e dra regulator, when
installed should be in the same room or enclosure as the furnace and
should not interfere with the combustion air supplied to the burner.
e control should also be located near the furnace ue outlet and
installed according to the instructions supplied with the regulator.
e ue outlet pressure (measured between the furnace and dra
regulator, or the oil burner mounting plate over-red dra access
port ,
Figure 2
) should be set to -0.02 in. w.c.
Fan Timer Board and Limit Control (FIG. 4) (page 21)
e Electronic Fan Timer integrates control of all burner and circulator fan operations. is control is the central wiring point for most
of the electrical components in the furnace. e United Technologies 1158-120 (HTL-D) has an adjustable fan on time that is set by
selecting the dipswitch combination displayed in
Table 2
. is
fan on delay can be set at 30, 60 90 or 120 seconds. is provides a
delay between the burner ignition and blower start-up to eliminate
excessive ow of cold air when the blower comes on. e United
Technologies 1158-120 (HTL-D) has an adjustable fan o time of 1,
2, 4 or 6 minutes displayed in
Table 2
. e fan o 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 eciency of the furnace.
e 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 o the burner if the
furnace over-heats. e limit control is thermally operated and
automatically resets. e limit control is factory installed, pre-set and
is not adjustable.
If the limit control opens with the United Technologies 1158-120
(HTL-D) electronic fan control, the circulating fan will be energized
as well. When the limit closes, the fan o timer will begin. At the
end of the fan o time cycle the burner will be energized, initiating a
normal burner cycle.
Fan Timer Board and Limit Control (Fig. 5) (Page 21)
e United Technologies 1168-1 ECM (HTLV-D) tap board has an
adjustable fan on/o delay that must be adjusted in accordance with
the furnace input rating (nozzle size).
(pg 16 and 17)
for ECM blower set-up.
Refer to Tables 8A and 8B
Table 2 - United Technologies 1158-120 (HTL-D)
Dip Switch Position Blower Delay Times
1 2 3 4
O O 30
On O 60
O On 90
On On 120
O O 1
On O 2
O On 4
On On 6
ON
Seconds
OFF
Minutes
Electrical Connections
e furnace is listed by the Canadian Standards Association under the NRTL (North American) Standard. It is factory wired and
requires minimal eld wiring. All eld 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.
e furnace should be wired to a separate and dedicated circuit in
the main electrical panel; however, accessory equipment such as
electronic air cleaners and humidiers 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. e 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. e furnace
switch (service switch) should be clearly marked, installed in an easily accessible area between the furnace and furnace room entry, and
be located in such a manner to reduce the likelihood that it would be
mistaken as a light switch or similar device.
e power requirement for the HTL-D and HTLV-D models is: 120
VAC, 1 Ø, 60 Hz., 12A.
Accessories requiring 120 VAC power sources such as electronic
air cleaners and humidier transformers may be powered from the
electronic fan timer board where provisions have been made for connections, but should have their own controls. Do not use the direct
drive motor connections as a power source, since there is a high risk
of damaging the accessories by exposure to high voltage from the
auto-generating windings of the direct drive motor.
ermostat wiring connections and air conditioning contactor low
voltage connections are shown in the wiring diagrams on page 18 of
this manual. Some micro-electronic thermostats require additional
controls and wiring. Refer to the thermostat manufacturer's instructions.
6
OIL BURNERS
e thermostat should be located approximately 5 feet above the
oor, on an inside wall where there is good natural air circulation,
and where the thermostat will be exposed to average room temperatures. Avoid locations where the thermostat will be exposed to cold
dras, heat from nearby lamps and appliances, exposure to sunlight,
heat from inside wall stacks, etc.
e thermostat heat anticipator should be adjusted to the amperage draw of the heating control circuit as measured at the "R" and
"W" terminals of the thermostat. To reduce the risk of damaging the
heat anticipator, do not measure this current with the thermostat
connected to the circuit. Measure the amperage by connecting an
ammeter between the two wires that will connect to the thermostat
"R" and "W" terminals.
Humidier
A humidier is an optional accessory available through most heating
supply outlets. Installation should be carried out in accordance with
the humidier manufacturer's installation instructions. Water or
water droplets from the humidier 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 humidiers
and humidier transformers.
Piping Installation
e entire fuel system should be installed in accordance with the
requirement of CAN/CSA B-139, and local regulations. Use only approved fuel oil tanks, piping, ttings and oil lter.
In the United States the installation must be in accordance with
NFPA No. 31 and local codes and authorities.
Install the oil lter 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.
Oil Burner Adjustment
e burner air supply is adjusted to maintain the fuel to air ratio
to obtain ideal combustion conditions. A lack of air causes "so"
and "sooty" ames, resulting in soot build-up throughout the heat
exchanger passages. Excess combustion air causes a bright roaring
re and high stack temperatures resulting in poor fuel eciency. e
HTL-D and HTLV-D furnaces operate most eciently with a No. 1
smoke spot on the Bacharach Scale. is is not necessarily the optimum setting; however, because dust will inevitably build up on the
air moving components of the oil burner assembly. is will result
in decreased air supply with the potential result of soot building up
in the ue gas passageways of the heat exchanger. Soot behaves as an
insulator and impairs good heat transfer. Stack temperature will increase, and the overall eciency 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.
CAUTION
BEFORE OPERATING THE FURNACE CHECK BURNER ALIGNMENT WITH COMBUSTION CHAMBER.
!
THE END CONE OF THE AIR TUBE MUST BE CENTRED TO THE ACCOMMODATING RING PROVIDED
IN THE DESIGN OF THE COMBUSTION CHAMBER.
ADJUST AS NECESSARY.
Burner Electrodes
Correct positioning of the electrode tips with respect to each other,
to the fuel oil nozzle, and to the rest of the burner is essential for
smooth light ups and proper operation. Refer to the oil burner instructions shipped with the furnace for electrode specications.
NOTICE
Oil Filter
All fuel systems should include an oil lter 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
lter as close as possible to the oil burner.
Oil Burner Nozzles
e HTL-D and HTLV-D are certied for multiple ring rates, ranging from 89,000 to 140,000 Btu/h. By manipulating the oil burner
nozzle, ame retention head, static plate and temperature rise; the
furnace may be red at an ideal rate for a wide range of structures.
Refer to Tables 3A, B and C,
to determine the proper combinations.
page 11 and the furnace rating plate
Beckett AF Series Burner electrode specications have
been revised. ey should be adjusted to be 5/16” above
the nozzle centerline.
Burner Primary (Safety) Control
e 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 ame. e cad cell should be checked for cleanliness
and proper alignment if the primary control frequently shuts down
combustion.
7
COMBUSTION CHAMBER
CAUTION
ALL FURNACE CONTROLS ARE SENSITIVE AND
!
SHOULD NOT BE SUBJECTED TO TAMPERING. IF
PROBLEMS PERSIST, CALL YOUR SERVICE CONTRACTOR.
Combustion Chamber
is furnace is equipped with a high quality cerafelt combustion
chamber. It is held in place by a retaining bracket.
NOTICE
Check the alignment of the combustion chamber and
oil burner before ring. It is possible for the combustion
chamber to shi if subjected to rough handling during
transit.
CIRCULATING AIR BLOWER
Circulating Air Blower (HTL-D)
e HTL-D and HTLV-D furnace models are equipped with direct
drive blower systems. HTL-D models are equipped with PSC motors; HTLV-D models are equipped with electronically commutated
motors (ECM). Direct drive blower speed adjustments are not
normally required in properly sized extended plenum duct systems.
e motor RPM and air CFM delivery will vary automatically (on
ECM motor equipped models) 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. ey
typically feature special reducing ttings at each branch run and lack
block ends on the trunk ducts. ese systems may require modication to provide some resistance to the airow 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 on page 18 of this manual or the wiring diagram label axed to the furnace. THE NEUTRAL WIRE (normally
the white wire) 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. e 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.
e combustion chamber should be inspected for damage or carbon
build up whenever the oil burner is removed for repairs or routine
maintenance.
CAUTION
!
DO NOT START THE BURNER UNLESS THE BLOWER
ACCESS DOOR IS SECURED IN PLACE.
CAUTION
DO NOT CONNECT POWER LEADS BETWEEN MO-
!
TOR 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 o both ends of the unused wire.
Do not use the blower speed wires as a source of power to accessories as electronic air cleaners and humidier transformers. e
unused motor taps auto-generate suciently high voltages to damage accessory equipment.
WARNING
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.
Circulating Air Blower (HTLV-D) - (See Page 10, ECM
BLOWER MOTOR OPERATION HTLVD)
8
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 lter or lters. A dirty lter can cause the furnace to
over-heat, fail to maintain indoor temperature during cold weather,
increase fuel consumption and cause component failure.
e furnace lter(s) should be inspected, cleaned or replaced monthly. e furnace is factory equipped with a semi-permanent type lter.
If the lter is damaged, replace with lters of the same size and type.
(See Parts Listing Ref. No. 21).
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
CAUTION
THE COMBUSTION CHAMBER (FIREPOT) IS FRAG-
!
ILE. USE CARE WHEN INSPECTING AND CLEANING
THIS AREA.
e 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 sti brush with a wire
handle, brush o scale and soot from inside the drum and ue 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 cleanout caps, inspect the gaskets. If the gaskets are broken, remove the
remnants and replace with new gaskets.
e 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 lter on an annual basis.
e venting system should be cleaned and inspected for signs of
deterioration. Replace pitted or perforated vent pipe and ttings. e
barometric damper should open and close freely.
All electrical connections should be checked to ensure tight connections. Safety controls such as the high limit controls should be
tested for functionality. e fan control should be checked to ensure
that the fan on and o delay function continues to start and stop the
blower fan at the optimal settings.
OPERATING INSTRUCTIONS HTLD
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. e
burner should start. NOTE: It may be necessary to press the RESET
button on the primary combustion control relay.
ere will be a fan on time delay before the circulating fan is energized. e United Technologies 1158-120 has an adjustable fan on
time that is set by selecting the dipswitch combination displayed in
Table 2 on page 6.
seconds. Set the thermostat below room temperature. e oil burner
should stop.
e air circulation blower will continue to run until the time o
setting selected on the electronic fan timer control times out. e
United Technologies 1158-120 has an adjustable fan o time of 1, 2,
4,or 6 minutes.
e necessary adjustments to the fan control settings should be
determined by measuring the temperature of the air in the supply
air take-o, or within the rst few inches of the supply air trunk. e
is fan on delay can be set at 30, 60, 90 or 120
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 dierence in temperature between the supply air and return air.
To check the operation of the limit switch, shut o 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.
Aer three or four minutes of burner operation, the limit control
should turn the burner o. When the limit function test is complete,
shut o electrical power to the furnace, replace the neutral wire to
the blower fan motor, and then restore power. e blower fan will
start up immediately. Once the temperature has dropped and the
limit control has reset, the fan will operate until the fan o time is
achieved. e oil burner will then resume operation and continue
until the thermostat is satised. Restore the thermostat setting to a
comfortable temperature.
To Shut Down Unit
Set the thermostat to the lowest possible setting.
Set the manual switch (if installed) in the Electrical Power Supply
Line to "OFF".
9
OPERATING INSTRUCTIONS HTLVD
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. e
burner should start. NOTE: It may be necessary to press the RESET
button on the primary combustion control relay.
ere will be a fan on time delay before the circulating fan is energized. e United Technologies 1168-1 has an adjustable fan on/
o time delay that is programmed into the ECM motor, and is set by
selecting the SW4 DIP switch combination displayed in
and B
pages 16 and 17. Fan on/o delay must be adjusted according
to input (nozzle size).
1.
Set the thermostat below room temperature. e oil burner
should stop.
2.
e air circulation blower will continue to run until the blower
o delay setting programmed into the ECM motor times out.
3.
To check the operation of the limit switch, shut o power to the
furnace. Temporarily remove the 5 pin power connector plug
from the ECM blower motor.
NOTICE
Tables 8 A
4.
Aer three or four minutes of burner operation, the limit
control should turn the burner o. When the limit function
test is complete, shut o electrical power to the furnace, replace
the 5 pin power plug to the blower fan motor, and then restore
power. e blower fan will start up immediately. Once the
temperature has dropped and the limit control has reset, the
fan will operate until the fan o time is achieved. e oil burner
will then resume operation and continue until the thermostat
is satised. Restore the thermostat setting to a comfortable
temperature.
NOTICE
IF THE FURNACE IS TO BE SHUT DOWN FOR AN
EXTENDED PERIOD OF TIME, CLOSE THE OIL SUPPLY VALVE TO THE BURNER.
CAUTION
DO NOT ATTEMPT TO START THE BURNER WHEN
EXCESS OIL HAS ACCUMULATED, WHEN THE
!
FURNACE IS FULL OF VAPOR, 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.
Isolate the AC Line pins on the 5 pin power connector with electrical tape to prevent electric shock hazard.
Restore the electrical power to the furnace and set the
thermostat above room temperature.
ECM BLOWER MOTOR OPERATION HTLVD
Setting Blower “ON” and “OFF” Timings
Blower on/o time delays are handled by ECM motor programming.
Features of this ECM variable speed motor are that it will deliver a
constant airow within a wide range of external static pressures, and
also includes:
Soft Start
the required operating speed. is feature in the heating cycle allows
the heat exchanger to reach operating temperature before the blower
motor starts, which minimizes noise and increases comfort.
Soft Stop
motor will slowly ramp down. is feature allows for increased
energy eciency and reduced noise levels.
: is ECM variable speed motor will slowly ramp up to
: At the end of the heating cycle, the ECM variable speed
Dehumidication
grammed into the variable speed motor. At the start of each cooling
cycle, the variable speed motor will run at 82% of the rated airow
for 7.5 minutes. Aer 7.5 minutes has elapsed, the motor will
increase to 100% of the rated airow. is prole is used to provide
dehumidication and improve system eciency.
Continuous Fan Operation:
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. is
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.
: A dehumidication feature has been pro-
When the thermostat continuous
10
OIL BURNER SETUPS
HTL-D and HTLV-D furnaces may be used with the following oil
burners.
Please note: e Beckett AF, NX and Riello 40F oil burners are for
applications using indoor air for combustion only.
Table 3A - Beckett AF Oil Burner Set-Up
Beckett AF Series Oil Burners
(For use with chimney vented units only)
Furnace
Model
Output
BTU/Hr
Burner
Model
Nozzle
Pump
Pressure
Flow Rate Head 1
HTL-90D 89,200 AF76XN 0.75 / 60°W 100 PSIG 0.75 USGPH F3 2- ¾ in.
HTL-100D 101,100 AF76XN 0.85 / 60°W 100 PSIG 0.85 USGPH F3 2- ¾ in.
HTL-120D 117,600 AF76XN 1.00 / 60°W 100 PSIG 1.00 USGPH F3 2- ¾ in.
HTL-130D 129,300 AF76YB 1.10 / 60°W 100 PSIG 1.10 USGPH F6 2- ¾ in.
HTL-140D 139,400 AF76YB 1.20 / 60°W 100 PSIG 1.20 USGPH F6 2- ¾ in.
Table 3B - Beckett NX Oil Burner Set-Up
Beckett NX Series Oil Burners
(For use with chimney vented units only)
Furnace
Model
Output
BTU/Hr
Burner
Model
Nozzle Pump
Pressure
Flow Rate
HTLV-90DNX 93,000 NX70LHHS 0.65 x 60°W 120 PSIG 0.75 USGPH
HTLV-100DNX 101,100 NX70LHHS 0.75 x 60°W 125 PSIG 0.85 USGPH
HTLV-120DNX 117,600 NX70LHHS 0.90 x 60°W 125 PSIG 1.00 USGPH
HTLV-130DNX 129,300 NX70LB 1.00 x 60°W 120 PSIG 1.10 USGPH
HTLV-140DNX 139,400 NX70LB 1.10 x 60°W 120 PSIG 1.20 USGPH
Static
Plate
Furnace
Model
Output
BTU/Hr
HTL-90DRF
90,300 40F3 0.65 / 60°W 120 PSIG 0.75 USGPH
HTLV-90DRF
HTL-100DRF
101,100 40F3 0.75 / 60°W 125 PSIG 0.85 USGPH
HTLV-100DRF
HTL-115DRF
114,600 40F3 0.85 / 60°W 115 PSIG 0.95 USGPH
HTLV-115DRF
Table 3C - Riello 40F Series Oil Burner Set-Up
Riello 40F Series Oil Burners
(For use with chimney vented units only)
Burner
Nozzle Pump
Model
11
Flow Rate
Pressure
OIL BURNER AIR ADJUSTMENT
e burner air supply is adjusted to maintain the fuel to air ratio
to obtain ideal combustion conditions. A lack of air causes "so"
and "sooty" ames, resulting in soot build-up throughout the heat
exchanger passages. Excess combustion air causes a bright roaring
re and high stack temperatures resulting in poor fuel eciency. e
HTL-D and HTLV-D furnaces operate most eciently with a No. 1
smoke spot on the Bacharach Scale. is is not necessarily the optimum setting; however, because dust will inevitably build up on the
air moving components of the oil burner assembly. is will result
in decreased air supply with the potential result of soot building up
in the ue gas passageways of the heat exchanger. Soot behaves as an
insulator and impairs good heat transfer. Stack temperature will increase, and the overall eciency 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.
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 NX Burner
Adjust the burner Head/Air supply by rst loosening the spline
screw. Turn the adjustment screw clockwise to decrease the combustion air and counter-clockwise to increase the combustion air.
Re-tighten the spline screw aer obtaining the proper setting. (Refer
to Beckett NX Oil Burner manual).
Riello 40 Series (Chimney Vented)
Riello burners are factory set with respect to nozzle size; pump pressure, air gate and turbulator adjustments for each model and ring
rate. By removing the burner cover and loosening the screws that
secure the air adjustment plate, the combustion air can be adjusted.
Move the adjusting plate to either increase or decrease combustion
air. When the proper air setting is achieved, retighten the xing
screws.
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 ecient combustion.
Beckett AF Burner
Electrode gap: 5/32 inch.
Distance above horizontal centerline: 5/16 inch. Older instruction
sheets specify 7/16 inch. e current specication 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.
BURNER ELECTRODES
Beckett NX Burner
Electrode gap: 5/32 inch.
Distance above nozzle centre line: 1/4 inch.
Nozzle-to-electrode tip Spacing: 3/32 inch.
Riello 40F
Electrode gap: 5/32 inch.
Distance above horizontal centerline: 13/64 inch.
Distance ahead of nozzle: 5/64 to 7/64 inch.
12
START UP
e furnace should be operated for a minimum of 10 minutes to
reach steady state conditions before ne tuning combustion. e
warm up time is ideal for testing the oil pump pressure.
Drill a 1/4-inch test port in the venting between the furnace ue
outlet and dra regulator (barometric damper). Insert a stack thermometer and note the ue gas temperature. e ue gases should
be within a range of 350°F to 450°F. If the ue gases are below the
range, it may be necessary to slow down the blower fan. If the ue
gases are above the range, the blower fan may require speeding up
or the barometric damper needs adjusting. Stack temperature varies
directly with the system temperature rise. System temperature rise is
the dierence between the furnace outlet temperature and furnace
inlet temperature as measured in the vicinity of the connection
between the plenum take-os and the trunk ducts. Temperature rise
value is listed on the system rating plate.
Perform a smoke spot test. e smoke spot should not exceed No. 1
on the Bacharach Scale.
Aer the air adjustments have been completed, re-check the dra
pressure at the test port on the burner mounting plate as shown in
Figure 2.
In the United States, the Beckett AF Burner may be equipped with
Beckett's "Inlet Air Shut-O" to increase eciency. (Beckett Part No.
AF/A 5861).
e dra should be adjusted to -0.02 inches w.c.
NOTICE
USE OF THE INLET AIR SHUT-OFF COULD CAUSE
POST COMBUSTION NOZZLE DRIP.
SPECIAL INSTRUCTIONS FOR UNITS EQUIPPED WITH RIELLO BURNERS
Riello burners are factory set with respect to nozzle size, pump pressure, air gate and turbulator adjustments for each model and ring
rate; therefore, do not use the above listed set up procedures.
Riello specications are listed in
Consult the Riello Installation Instructions supplied with the Burner
for specic information concerning burner adjustments, operation,
and trouble-shooting.
Table 3C,
page 11 of this manual.
13
DIRECT DRIVE BLOWER PSC MOTOR
Table 4 - Direct Drive Blower Set-Up PSC Motor
Blower Set-Up Cooling Capacity
Furnace Model Blower
0.20 in. w.c. 0.50 in. w.c.
To ns Power CFM Range
Speed Motor Speed Motor
HTL-90D 100-10 DD Med-Low 1/2 HP Med-High 1/2 HP 3 1/2 HP 650 – 1400
HTL-100D 100-10 DD Med-Low 1/2 HP Med-High 1/2 HP 3 1/2 HP 650 – 1400
HTL-120D 100-10 DD Med-High 1/2 HP Med-High 1/2 HP 3 1/2 HP 650 – 1400
HTL-120D 120-10 DD Low 3/4 HP High 3/4 HP 5 3/4 HP 1500 - 2000
HTL-130D 120-10 DD Low 3/4 HP High 3/4 HP 5 3/4 HP 1500 - 2000
HTL-140D 120-10 DD Med-Low 3/4 HP High 3/4 HP 5 3/4 HP 1500 - 2000
Table 5 - Direct Drive Blower Characteristics PSC Motor
CFM
Furnace
Model
Blower
Motor HPMotor
FLA
∆T Speed
External Static Pressure – Inches w.c.
0.2 0.3 0.4 0.5 0.6
High 1639 1581 1507 1440 1374
HTL-D 90-120 100-10 DD 1/2 HP 7 70°F
HTL-D 120-
140
120-10 DD 3/4 HP 9 70°F
Med-High 1544 1493 1429 1366 1300
Med-Low 1158 1144 1121 1084 1040
Low 766 743 703 696 661
High 2111 2030 1974 1924 1857
Med-High 1974 1923 1885 1832 1792
Med-Low 1785 1753 1729 1679 1636
Low 1623 1594 1564 1513 1468
Furnace
Model
HTLV-D
90 – 120
HTLV-D
90 – 140
Table 6- Direct Drive Blower Characteristics ECM Motor
CFM RANGE
Blower
Motor HPMotor
FLA
∆T
Continuous
Fan
Heating Cooling
0.38 - 0.48 inches w.c. 0.5 inches w.c.
100-10 DD
120-10 DD 1 HP ECM 12.8 70°F 750 - 1000 1100 - 2100 800 - 2000
TIP: ese formulae will assist with the design of the ductwork and the determination of
airow delivery:
CFM = BONNET OUTPUT / (1.085 X System Temperature Rise (∆T))
System Temperature Rise (∆T) = Bonnet Output/(1.085 x CFM)
1/2 HP
ECM
7.7 70°F 500 - 700 1100 - 1500 600 - 1200
14
Furnace
Model
HTLD & HTLVD DIMENSIONS
Table 7 - General Dimensions (Inches)
Cabinet Plenum Openings
Width Depth Height Supply
Return
Side Bottom
Flue
Diameter
Filter Shipping
Type Size
Weight
(LB.)
HTL-D
HTLV-D
22 30-3/4 58
Figure 3 - HTL-D & HTLV-D Dimensions
20½ x
20
14 x 22 14 x 22 6 Permanent 16 x 25 x 1 270
15
ECM BLOWER HTLVD
Table 8A - ECM Blower Set-Up (HTLV-D)
100-10DD Blower with ½ HP ECM
DIP SWITCH ADJUSTMENT CHART
FOR INPUT 0.75 USGPH TO 1.00 USGPH
SW1 - HEAT
INPUT
DIP Switch Position DIP Switch Position
1 2 1 2
OFF OFF A 1.00 OFF OFF A 3
ON OFF B 1.10 ON OFF B 4
OFF ON C 1.20 OFF ON C 5
ON ON D 0.85 ON ON D 2
POS.
USGPH
SW3- ADJUST
DIP Switch Position DIP Switch Position
1 2 1 2
OFF OFF A 0% OFF OFF A 1.00
ON OFF B (+) 15% ON OFF B 1.10
OFF ON C (-) 15% OFF ON C 1.20
ON ON D N/A ON ON D 0.85
POS. CFM
SW2 - COOL
POS.
SW4- DELAY
POS.
Figure 4 - ECM Blower Set-Up (HTLV-D)
AC
SIZE
(TON)
INPUT
USGPH
NOTICE
SW1 (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
16
ECM BLOWER HTLVD
Table 8B - ECM Blower Set-Up (HTLV-D)
120-10DD Blower with 1 HP ECM
DIP SWITCH ADJUSTMENT CHART
FOR INPUT 0.85 USGPH TO 1.20 USGPH
SW1 - HEAT
INPUT
DIP Switch Position DIP Switch Position
1 2 1 2
OFF OFF A 1.00 OFF OFF A 3
ON OFF B 1.10 ON OFF B 4
OFF ON C 1.20 OFF ON C 5
ON ON D 0.85 ON ON D 2
POS.
USGPH
SW3- ADJUST
DIP Switch Position DIP Switch Position
1 2 1 2
OFF OFF A 0% OFF OFF A 1.00
ON OFF B (+) 15% ON OFF B 1.10
OFF ON C (-) 15% OFF ON C 1.20
ON ON D N/A ON ON D 0.85
POS. CFM
SW2 - COOL
POS.
SW4- DELAY
POS.
Figure 5 - ECM Blower Set-Up (HTLV-D)
AC
SIZE
(TON)
INPUT
USGPH
NOTICE
SW1 (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
HTLV-90DRF Riello 40F3 Input 0.75 USGPH. SET: SW1-HEAT “D”, SW3-ADJUST “C”, SW4-DELAY “D”
17
WIRING DIAGRAMS
Figure 6 - Chimney Vent Burner Wiring Diagram HTL-D & HTLV-D
18
OIL BURNER OPERATION
Once the furnace ue pipe, electrical and oil line connections have
been made, use the following instructions to set the burner:
Shut o the electrical power to the furnace.
Install an oil pressure gauge to the pressure port on the oil pump.
(Refer to the oil pump specication 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 re 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
Tables 3A, B & C ,
page 11
.
When the furnace has reached "steady state" (aer approximately 10
minutes). Set combustion air damper to get a TRACE of smoke.
Check the system temperature rise. e temperature rise is the
dierence between the return air temperature measured at a point
near the return air inlet, and the supply air temperature measured
near the furnace outlet. e system temperature rise is listed on the
furnace rating plate. If the temperature rise is too high, the airow
must be increased. If the temperature rise is too low, the fan should
be slowed down.
Turn o the burner. Observing the duct thermometer in the supply
air stream, note the temperature at which the blower fan stops. e
fan adjustments can be made by moving the dipswitch settings on
the timer control board for fan o delay.
To check the operation of the limit switch, shut o 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. Aer three or four minutes
of burner operation, the limit control should turn the burner o.
When the limit function test is complete, shut o electrical power
to the furnace, replace the neutral wire to the blower fan motor, and
then restore power. e blower fan will start up immediately. Once
the temperature has dropped and the limit control has reset, the fan
will operate until the fan o time is achieved. e oil burner will
then resume operation and continue until the thermostat is satised.
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 the heat anticipator. Set the heat anticipator to the
amperage measured.
NOTICE
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.
NOTICE
ALL JOINTS IN ANY POSITIVE PRESSURE VENTING
SYSTEM MUST BE CHECKED FOR LEAKS BEFORE
LEAVING THE INSTALLATION SITE.
19
OIL PRIMARY CONTROL SEQUENCE OF OPERATION
Oil Primary Control Detailed Sequence of Operation
Power is applied to unit. e oil primary control completes a selfdiagnostic procedure. If no light or ame is present, and unit passes
its self-diagnostic procedure, the control enters into the idle mode.
5.
Carryover timer expires.
Enters run state.A.
Igniter turns o.•
ermostat calls for heat:
1.
Safety check is made for ame (4 second delay).
If ame is not present, the oil primary control will apply A.
power to the burner motor and igniter.
If ame is present, the control remains in the idle state.B.
2.
Unit enters a pre-purge period of 15 seconds.
Aer 10 seconds, control checks for ame presence.
3.
If ame is not present, the oil primary control enters the A.
trial for ignition state.
When ame is present, the control enters lock out mode. B.
4.
e Oil Primary Control monitors the burner ame.
When ame is present, the control enters ignition carry-A.
over state. (Continues to spark for 10 sec.).
Provides continuous spark aer ame is sensed to assure •
that burner remains lit.
Turns on LED diagnostic light.•
Starts carryover timer.•
a) Flame and call for heat are monitored.
■ If ame is lost and lockout timer has not expired,
the control will return to trial for ignition state.
■ If ame 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 o.
LED diagnostic light ashes slowly.•
Combustion continues until thermostat is satised, or the oil primary control detects a loss of ame and enters into Recycle Mode.
6.
ermostat is satised - call for heat is terminated:
Oil primary control shuts o burner motor and solenoid A.
valve.
If the control utilizes a blower motor o delay, aer 30 •
seconds, ame presence is checked.
■ If ame is not present, the control LED diagnostic
light is o and returns to idle state.
■ If ame is presence is detected, the control enters
lock out mode.
20
OIL PRIMARY CONTROL SEQUENCE OF OPERATION
Figure 7 - United Technologies 1158-120 Fan Timer Board (HTL-D)
Figure 8 - United Technologies 1168-1 ECM Tap Board (HTLV-D)
21
OIL PRIMARY CONTROL SEQUENCE OF OPERATION
22
OIL PRIMARY CONTROL SEQUENCE OF OPERATION
Table 9: 1158-120 Electronic Fan Timer Board (Eft) Detailed Sequence Of Operation
23
OIL PRIMARY CONTROL SEQUENCE OF OPERATION
Oil Primary Control Led Diagnostic Light
e 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. Please refer to included burner manual for more
details.
Normal Conditions:
e 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 re.
e LED diagnostic light will turn o at the end of the burner cycle
as the oil primary control enters the idle state, and will remain o
until the next heating cycle.
Fault Conditions:
If the LED diagnostic light is ashing quickly; 1 Hz (½ second on
/ ½ second o), 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 ashing slowly; ¼ Hz (2 seconds on
/ 2 seconds o), the oil primary control is in the recycle state. is
indicates that ame sensing was lost aer the lockout timer expired
during the ignition carryover state. e oil primary control will
return to the idle state within 60 seconds.
NOTICE
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 DIAGNOSTIC LIGHT section for
details.
CAUTION
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 THERMO-
!
STAT. NEGLECTING THIS PROCEDURE MAY BURN
OUT THE HEAT ANTICIPATOR OF A STANDARD 24
VAC THERMOSTAT, OR CAUSE HARM TO COMPONENTS WITHIN A MICRO-ELECTRONIC THERMOS TAT.
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).
Cad Cell Condition:
If the LED diagnostic light is o, the cad cell is not sensing ame.
If the LED diagnostic light is on, the cad cell is sensing ame, or
viewing ambient light.
e resistance of the cad cell may be checked while the oil primary
control is in the run state by pressing the reset button. e LED
diagnostic light will ash the following code:
Table 10: Cad Cell Resistance
Flashes Resistance in Ohms
1 Less than 400
2 Between 400 - 800
3 Between 800 – 1600
4 Between 1600- 5000
Troubleshooting
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 lter, and oil valves.•
Check the piping or tubing to the oil tank.•
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.
24
OIL PRIMARY CONTROL TROUBLESHOOTING
WARNING
ELECTRICAL SHOCK HAZARD.
!
TROUBLESHOOTING IS DONE WITH THE SYSTEM
POWERED. BE CAREFUL TO OBSERVE ALL NECESSARY PRECAUTIONS TO PREVENT ELECTRICAL
SHOCK OR EQUIPMENT DAMAGE.
Table 11: Oil Primary Control TROUBLESHOOTING
Preliminary Checks:
Make sure that limit switches are closed and those contacts are clean.
Check for line voltage power on the oil primary control black and
white lead wires.
Refer to
Table 11 or 12
for further troubleshooting information
25
OIL PRIMARY CONTROL TROUBLESHOOTING
Table 11: Oil Primary Control TROUBLESHOOTING continued from previous page
26
OIL PRIMARY CONTROL TROUBLESHOOTING
Table 11: Oil Primary Control TROUBLESHOOTING continued from previous page
Table 12: System and General Trouble Shooting
27
OIL PRIMARY CONTROL TROUBLESHOOTING
Table 12: System and General Trouble Shooting continued from previous page
Problem Possible Cause Remedy
Furnace will not start
Furnace will not start without
rst 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
Photo Cell wiring shorted or room
light leaking into photo cell compartment.
Open safety switch
No fuel oil.
Clogged nozzle.
Clogged oil lter. Replace oil tank lter or in-line lter if used.
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 lter. Replace oil tank lter or in-line lter if used.
Low oil pump pressure.
Air getting into fuel oil lines, or fuel
oil line dirty, clogged, or in some
manner defective.
Defective burner.
Water or contaminants in oil. Drain fuel oil storage tank; replace fuel oil. (Consult with fuel oil supplier).
Frozen oil line.
Electrodes out of adjustment or
defective.
Poor transformer high voltage connections or defective transformer.
Fuel oil lter clogged. Replace fuel oil storage tank lter and/or fuel oil in-line lter.
Defective oil pump.
Fuel oil line partially clogged or
contains air.
Clogged nozzle. Replace nozzle or clean it out.
Check photo cell (cad cell) 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.
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 ttings found with high
quality ared ttings. 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 cell is getting dirty). If cad
cell is poorly aimed, realign it. NOTE: e photocell should have a resistance of 100Ω in absence of light; a maximum of 1500 Ω 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.
Replaces nozzle with high quality replacement. Use rating plate or Tables
in Appendix A as a guide.
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 ttings found with high
quality ared ttings. 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.
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.
28
OIL PRIMARY CONTROL TROUBLESHOOTING
Table 12: System and General Trouble Shooting continued from previous page
Check Blower fan speed.
29
OIL PRIMARY CONTROL TROUBLESHOOTING
Table 12: System and General Trouble Shooting continued from previous page
NOTICE
FINAL CHECK OUT
ENSURE THAT ALL SAFETY DEVICES AND ELECTRI-
CAL COMPONENTS HAVE BEEN SET FOR NORMAL
OPERATION. ENSURE THAT ALL ELECTRICAL CONNECTIONS ARE TIGHT AND THAT THE WIRING IS
SECURE.
NOTICE
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 "o" positions if not obvious.
3.
Where the oil shut-o 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 lter, and
other homeowner maintenance procedures.
8.
Who to call for emergency service and routine annual
service.
9.
e terms and conditions of the manufacturer's warranty and the contractor's warranty.
30
HOMEOWNER'S REFERENCE TABLE
31
PARTS LISTING HIGHBOY MODELS: HTLD AND HTLVD
Ref.
No.
1 109007731L Le Side Panel Assembly
2 109007729L Right Side Panel Assembly
3 109007727L Rear Panel
4 29189 Blower Division Assembly
5 26216 Base Panel
6 109007728 Inner Front Panel
7 29122L Blower Access Panel
8 21437L Top Panel
9 26097 Heat Exchanger Assembly
10 27068 Combustion Chamber Retainer Bracket
11 27000WP Replacement Combustion Chamber
12 109007674 Oil Burner Mounting Plate
13 28306 Flue Connector
14 2080175 Pouch Gasket
15 109007733 Air Bae
16 20602 Insulation Retainer
17
18
19 18020 Filter Frame 16” X 25”
20 5592B2 Filter Frame End Support
21 2180023 Filter 16” X 25” X 1” Permanent
24 29362 Control Box
25
26 28841 Limit Disc 60T11 BOF 220°F
27
28 29364 Wire Harness, Controls Fan Timer
29 29365 Wire Harness, Blower
30 29751 Wire Harness, Fan Timer Board, Transformer
31
32 240005330 Transformer
33 12240 (6”) Dra Regulator
Part No. DESCRIPTION
240007841 Radiator Clean-out Cover (2 per unit)
240006333 Radiator Clean-out Cover Gasket (2 per unit)
29161 Clean-out Gasket Retainer
29163 Clean-out Tube Gasket
21338L Upper Door Panel
28479 Logo Bezel
28563 Logo Label
29388 Fan Timer Control 1158-120 UTEC HTL
240007048 Fan Timer Control 1168-1 ECM UTEC HTLV
240006438 Wire Harness, ECM Control HTLV
240005742 Wire Harness, ECM Supply HTLV
Ref.
No.
34a
34b
34c
35b
Part No. DESCRIPTION
240007760 Oil Burner Assembly, Beckett AF76XN
29689 Burner Motor 1/7 HP 3450 RPM PSC
29688 Beckett Clean-cut Oil Pump A2EA6520
29522 Solid State Ignitor 10SAY-01
240007858 Oil Primary Combustion Control Genisys
11961 Flame Retention Head F6
14619329 Nozzle, 1.00/60ºW
240007786 Oil Burner Assembly, Beckett AF76YB
29689 Burner Motor 1/7 HP 3450 RPM PSC
29688 Beckett Clean-cut Oil Pump A2EA6520
29522 Solid State Ignitor 10SAY-01
240007858 Oil Primary Combustion Control Genisys
12646 Flame Retention Head F6
14619333 Nozzle, 1.20/60ºW
240007794 Oil Burner Assembly, Beckett NX70LHHS
21839 Burner Motor 1/7 HP 3450 RPM PSC
27593
29522 Solid State Ignitor 10SAY-01
240007858 Oil Primary Combustion Control Genisys
240007859 Retention Head Assembly
240006431 Nozzle, 0.65/60ºW
109007722
109007724
30095 Blower Housing and Wheel, 120-10T DD
102000132 Blower Motor, 3/4 hp, 4-Speed HTL
109007745 Blower Motor, 1hp, ECM Programmed HTLV
17811 Motor Mounting Band – TR6884B
30259
27745 Motor Run Capacitor, 20 mfd @ 370 Vac HTL
27761 Capacitor Strap
27733 Blower Slide Rail 2 Per
Beckett Clean-cut Oil Pump A2EA6520
Blower Assembly Direct Drive 5-Ton PSC Motor
HTL
Blower Assembly Direct Drive ECM 5-Ton ECM
Motor HTLV
Motor Mount Arms – 12-10 DD Blower (3 per
unit)
32
PARTS LISTING: HIGHBOY MODEL: HTLD AND HTLVD
Figure 9 - Model HTL-D and HTLV-D
33
NOTES:
HTLD & HTLVD OIL FIRED WARM AIR FURNACE
34
HTLD & HTLVD OIL FIRED WARM AIR FURNACE
35
HTLD & HTLVD OIL FIRED WARM AIR FURNACE
ECR International
2201 Dwyer Avenue
Utica •New York • 13504 • USA
www.ecrinternational.com
36
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