92-22876-07-03
SUPERSEDES 92-22876-07-02
!
If the information in these instructions is not followed exactly, a
fire or explosion may result, causing property damage, personal
injury or death.
THESE INSTRUCTIONS ARE
INTENDED AS AN AID TO
QUALIFIED SERVICE
PERSONNEL FOR PROPER
INSTALLATION, ADJUSTMENT
AND OPERATION OF THIS
UNIT. READ THESE
INSTRUCTIONS THOROUGHLY
BEFORE ATTEMPTING
INSTALLATION OR
OPERATION. FAILURE TO
FOLLOW THESE
INSTRUCTIONS MAY RESULT
IN IMPROPER INSTALLATION,
ADJUSTMENT, SERVICE OR
MAINTENANCE, POSSIBLY
RESULTING IN FIRE,
ELECTRICAL SHOCK, CARBON
MONOXIDE POISONING,
EXPLOSION, PROPERTY
DAMAGE, PERSONAL INJURY
OR DEATH.
Do Not Destroy this Manual.
Please read carefully and keep
in a safe place for future
reference by a serviceman.
WARNING
Recognize this symbol as an indication of Important Safety Information!
!
— Do not store or use gasoline or other
flammable vapors and liquids, or other
combustible materials in the vicinity of this
or any other appliance.
—
WHAT TO DO IF YOU SMELL FUEL OIL VAPORS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your fuel oil supplier
from a neighbor’s phone. Follow the fuel
oil supplier’s instructions.
• If you cannot reach your fuel oil supplier,
call the fire department.
• Do not return to your home until
authorized by the fuel oil supplier or fire
department.
— DO NOT RELY ON SMELL ALONE TO
DETECT LEAKS. DUE TO VARIOUS
FACTORS, YOU MAY NOT BE ABLE TO
SMELL FUEL GASES.
• U.L. recognized fuel gas and CO
detectors are recommended in all
applications, and their installation should
be in accordance with the manufacturer’s
recommendations and/or local laws,
rules, regulations, or customs
— Improper installation, adjustment, alteration,
service or maintenance can cause injury,
property damage or death. Refer to this
manual. Installation and service must be
performed by a qualified installer, service
agency or the fuel oil supplier.
WARNING
!
PROPOSITION 65: THIS FURNACE CONTAINS FIBERGLASS
INSULATION. RESPIRABLE PARTICLES OF FIBERGLASS ARE
KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER.
EXHAUST GAS FROM THIS FURNACE CONTAINS CHEMICALS,
INCLUDING CARBON MONOXIDE, KNOWN TO THE STATE OF
CALIFORNIA TO CAUSE BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM.
WARNING
!
FOR YOUR SAFETY
!
INSTALLATION INSTRUCTIONS
FOR UPFLOW OIL FIRED FURNACES
2
Before beginning any troubleshooting procedure, complete the following installation checklist. A furnace malfunction is
sometimes caused by an improper installation. By completing this checklist, the problem may be found and corrected. Make
copies of the checklist and complete one for every Low Profile Furnace service call for your records.
INSTALLATION CHECKLIST
(Refer to this manual for specifics.)
GAS SUPPLY
Adequate pipe size
No gas leaks
Proper supply and manifold gas pressure (check with an accurate U-tube manometer with the furnace and all other gas
appliances operating.)
ELECTRICAL
Correct thermostat and subbase Thermostat model Subbase model
Correct thermostat mode and setting
Correct line supply voltage
Correct polarity (important with hot surface ignition)
Correct furnace ground to electrical panel
DC microamp (
µA) flame signal (hot surface ignition units)
Correct control voltage
Measure and set heat anticipator amperage
Air conditioning low voltage wires connected to terminals “Y” “C” - not with wire nuts
VENTING
Correct vent pipe diameter and length (according to AGA/GAMA tables) Vent connection size
Correct venting material (according to AGA/GAMA tables)
Correct lining for masonry chimneys
Adequate clearance from combustibles
Proper negative pressure reading in the vent
Vent pipe secured to induced draft blower housing
COMBUSTION AIR
Proper source of combustion air
Correct combustion air opening size
FURNACE INSTALLATION
Adequate clearance from combustibles
Adequate clearance for service
Proper air temperature rise (See furnace rating plate)
External static pressure inches w.c.
Correct filter(s)
Correct cooling coil or accessories (if equipped)
Adequate supply and return air ducting Return Air Duct Size Supply Air Duct Size
Air ducts sealed to prevent leakage
3
IMPORTANT: TO ENSURE PROPER INSTALLATION AND OPERATION OF
THIS PRODUCT, COMPLETELY READ ALL INSTRUCTIONS PRIOR TO
ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE, MAINTAIN OR REPAIR
THIS PRODUCT. ADDITIONALLY, UPON UNPACKING OF FURNACE,
INSPECT ALL PARTS FOR DAMAGE PRIOR TO INSTALLATION AND START
UP.
CONTENTS
Safety Rules..........................................................................................................4
Helpful Information................................................................................................4
Installation Instructions......................................................................................4
Requirements........................................................................................................4
Location/Clearances .............................................................................................4
Combustion Air Supply..........................................................................................5
Circulating Air Supply............................................................................................7
Venting..................................................................................................................7
Barometric Draft Control........................................................................................8
Oil Burner/Primary Control....................................................................................8
Tank & Oil LInes....................................................................................................9
Electrical Wiring ....................................................................................................9
Thermostat............................................................................................................9
Heat Anticipator Settings.......................................................................................9
Typical Installation Diagrams ..............................................................................10
Operating Instructions......................................................................................11
Lighting Instructions ............................................................................................11
Burner Adjustment ..............................................................................................12
Furnace Adjustment..........................................................................................12
Air Volume Adjustment........................................................................................15
Fan/Limit Control.................................................................................................17
Maintenance ......................................................................................................19
Burner Maintenance............................................................................................19
Lubrication...........................................................................................................19
Air Filters.............................................................................................................19
Draft Problems/Troubleshooting .........................................................................20
Oil Furnace Burner Data .....................................................................................21
Troubleshooting ..................................................................................................22
Wiring Diagrams..................................................................................................26
➤ Installation Instructions are updated on a regular basis. This is done as
product changes occur or if new information becomes available. In this
publication, an arrow (➤) denotes changes from the previous edition or additional
new material.
INSTALLER: HANG THESE INSTRUCTIONS
ADJACENT TO FURNACE
HOMEOWNER: KEEP THESE INSTRUCTIONS
FOR FUTURE REFERENCE
REQUIREMENTS
IMPROPER INSTALLATION,
ADJUSTMENT, ALTERATION,
SERVICE OR MAINTENANCE CAN
CAUSE PROPERTY DAMAGE,
INJURY OR DEATH. CONSULT A
QUALIFIED INSTALLER OR
SERVICE AGENCY FOR SERVICE
AND ASSISTANCE.
The furnace should be installed in
accordance with the latest editions of
the NFPA 31 booklet, “Installation of
Oil Burning Equipment,” the NFPA 90B
booklet, “Warm Air Heating and Air
Conditioning Systems” the NFPA 90A
booklet, “Installation of Venting and Air
Conditioning Systems” and the NFPA
211 booklet “Standard for Chimneys,
Fireplaces, Vents, and Solid FuelBurning Appliances” published by the
National Fire Protection Associaiton,
Batterymarch Park, Quincy, MA 02269.
THIS FURNACE IS DESIGN
CERTIFIED TO OPERATE ON #2
FUEL OIL. DO NOT ATTEMPT TO
CONVERT THIS FURNACE TO
BURN NATURAL GAS OR LP GAS.
FAILURE TO FOLLOW THIS
WARNING CAN CAUSE A FIRE OR
EXPLOSION RESULTING IN
PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
LOCATION
THIS FURNACE IS NOT APPROVED
FOR INSTALLATION IN A MOBILE
HOME. DO NOT INSTALL THIS
FURNACE IN A MOBILE HOME.
INSTALLATION IN A MOBILE HOME
COULD CAUSE FIRE, PROPERTY
DAMAGE AND PERSONAL INJURY
OR DEATH.
Locate furnace as close to chimney as
practical, giving considerations to duct
trunk lines and accessibility of oil
burner, controls, blower and filter. For
basement installation, if there is no
level concrete floor or if water may be
encountered, a level concrete base
should be provided. Furnaces may be
installed on combustible floors. Allow a
minimum of twenty-four inches at front
of furnace for servicing oil burner and
controls. Fire protection clearances are
printed in Figure 1 and on the rating
plate of the furnace.
An oil-fired furnace installed in a
residential garage must be located or
protected to avoid physical damage by
vehicles.
This furnace is approved for installation
indoors only. Do not install unit
outdoors.
COMBUSTIBLE MATERIAL MUST
NOT BE PLACED ON OR AGAINST
THE FURNACE JACKET. THE AREA
AROUND THE FURNACE MUST BE
KEPT CLEAR AND FREE OF ALL
COMBUSTIBLE MATERIAL
INCLUDING GASOLINE AND OTHER
FLAMMABLE VAPOR OR LIQUIDS.
THE HOMEOWNER SHOULD BE
CAUTIONED THAT THE FURNACE
AREA MUST NOT BE USED AS A
BROOM CLOSET OR FOR ANY
OTHER STORAGE PURPOSES.
COMBUSTIBLE MATERIAL PLACED
AGAINST FURNACE JACKET COULD
CAUSE FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
HELPFUL INFORMATION
The following national standards will
help you in making this installation.
Current editions of these standards
should be obtained from:
American National Standards Institute
1430 Broadway
New York, NY 10018
National Electric Code
ANSI/NFPA No. 70
National Fire Protection Association,
Inc.
Batterymarch Park
Quincy, MA 02269
Installation of Oil Burning
Equipment
NFPA No. 31
Installation of Air Conditioning and
Ventilating Systems
NFPA No. 90A
Warm Air Heating and Air
Conditioning Systems
NFPA No. 90B
Standard for Chimneys, Fireplaces,
Vents, and Solid Fuel-Burning
Appliances NFPA No. 211
4
1. Do not install this furnace in a
mobile home, trailer or recreational
vehicle.
2. Keep area around furnace free and
clear of combustible materials
including gasoline and other
flammable vapors and liquids.
3. Do not use furnace area for storage
purposes or as a broom closet.
THIS FURNACE IS DESIGN
CERTIFIED TO OPERATE ON #2
FUEL OIL. DO NOT ATTEMPT TO
CONVERT THIS FURNACE TO
BURN NATURAL GAS OR LP GAS.
FAILURE TO FOLLOW THIS
WARNING CAN CAUSE A FIRE OR
EXPLOSION RESULTING IN
PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
4. This furnace must be vented
through a good chimney to carry
combustion products outdoors as
described under the VENTING
INSTALLATION section of this
manual.
5. Provide adequate ventilation to the
furnace area.
6. Make sure supply and return air
ducts are sealed to the furnace
casing. These ducts must be
entirely separated from area
supplying combustion and
ventilation air.
7. Disconnect electrical power before
servicing appliance.
SAFETY RULES
LOCATION REQUIREMENTS AND CONSIDERATIONS
INSTALLATION INSTRUCTIONS
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
5
FIGURE 1
DIMENSIONS AND CLEARANCES TO COMBUSTIBLES
COMBUSTION AIR SUPPLY
THIS FURNACE MUST BE PROVIDED WITH ENOUGH FRESH AIR
FOR PROPER COMBUSTION AND
VENTILATION OF FLUE GASES.
SOME HOMES MAY REQUIRE THAT
OUTSIDE AIR BE SUPPLIED TO THE
FURNACE AREA. FAILURE TO
PROVIDE ENOUGH FRESH AIR CAN
CAUSE DEATH FROM CARBON
MONOXIDE POISONING.
Adequate facilities for combustion and
ventilation must be provided in
accordance with section number 1-5,
“Air for Combustion and Ventilation,” of
the
Standard for Installation of Oil
Burning Equipment, NFPA No. 31
,
latest edition or other applicable
provisions of local building codes. The
flow of combustion air to the furnace
area must not be obstructed.
Important: Air for combustion and
ventilation must not come from a
corrosive atmosphere. Any failure due
to corrosive elements in the atmosphere
is excluded from warranty coverage.
Combustion air must be free of acidforming chemicals such as sulphur,
fluorine and chlorine. These elements
are found in aerosol sprays, detergents,
bleaches, cleaning solvents, air
fresheners, paint and varnish removers,
refrigerants and many other commercial
and household products. Vapors from
these products when burned in a flame
form acidic compounds and are highly
corrosive when they condense.
When appliances are installed within a
confined space and combustion air is
taken from within the heated space, the
air supply must be through two
permanent openings of equal area, one
located within 12 inches of the ceiling
and one within 12 inches of the floor
(see figure 2). Refer to the rating plate
label on the furnace for information on
the minimum free area of these two
openings.
When appliances are installed in an
unconfined space in a building of conventional frame, brick or stone
construction, infiltration normally is
adequate to provide for combustion
ventilation and draft control dilution. If
the unconfined space is within a
building of unusually tight construction,
a supply of combustion, ventilation and
draft control dilution air must be
obtained from outdoors or spaces freely
connected to the outdoors. Under these
conditions a permanent opening or
openings having a total free area of not
less than 1 sq. in. per 5,000 BTU/HR of
total input rating of all appliances shall
be provided. This code is found in
NFPA 31, Standard for Installation of Oil
Burning Equipment
. Other State,
Provincial, and Local codes may apply,
check with local inspectors.
When appliances are installed in a
confined space within a building of
unusually tight construction, air for
combustion must be obtained from
outdoors or from spaces or ducts freely
drawing from the outdoors. Under these
WARNING
!
Figure 2
Openings for confined spaces
6
conditions, two openings of
approximately equal area (one located
near the top and one located near the
bottom of the enclosure) must be
provided each with a total free area of not
less than 1 square inch per 4,000 BTU’s /
Hr. of total input rating of all appliances in
the enclosure (see figure 3).
If horizontal ducts are used, each
opening shall have a free area of not
less than 1 sq. in. per 2,000 BTU/HR of
total input of all appliances in the
enclosure (see figure 4).
Appliances installed in confined
spaces may be installed with ventilation
air from inside the building and
combustion air from outdoors. Consult
state and local codes and the
NFPA
No. 31, Standard for Installation of Oil
Burning Equipment
for specific details
(see figure 5 for an example).
Appliances installed in confined
spaces with all required air coming
from the outdoors may also get inlet
air from continuously ventilated crawl
spaces and outlet air to a ventilated
attic (see figure 6).
"NFPA 31, Standard for Installation of
Oil Burning Equipment"
defines
"confined space" and "unconfined
space" as follows.
Confined Space - Any space whose
volume is less than 50 cu. ft. per 1,000
BTU/HR (4.8 M3 per KW) of the
aggregate input rating of all fuel-burning
appliances installed therein.
Unconfined Space - Any space whose
volume is equal to or greater than 50
cu. ft. per 1,000 BTU/HR (4.8 M3 per
KW) of the aggregate input rating of all
fuel-burning appliances installed
therein. Rooms connecting directly with
the space in which the appliances are
located by means of openings that have
no doors or closures, unless fully
louvered, shall be considered part of the
unconfined space.
When determining if the furnace is
located in a confined or unconfined
space it is important to realize that
some buildings are so tight that normal
infiltration does not meet air
requirements for proper combustion or
venting and outside air must be
introduced.
Important: All applicable codes must
be followed when providing air to the
confined space.
Figure 3
All air from ventilated attic
Figure 4
Directly connecting horizontal
ducts to outdoors
Figure 5
Inside Ventilation Air, Outside
Combustion Air
Figure 6
Outside Air From Attic and Crawl Space
7
CIRCULATING AIR SUPPLY
Plenum chambers and air ducts must
be installed in accordance with the
Standard for the Installation of Air
Conditioning and Ventilating Systems,
NFPA No. 90A, or the Standard for the
Installation of Warm Air Heating and
Air Conditioning Systems, NFPA No.
90B.
The circulating air supply may be
taken: (1) exclusively from return air
ducts from several rooms, or (2)
combined with outside air. When
outside air is utilized, the system
should be designed and adjusted such
that the temperature of the combined
return air to the furnace will not be
below 50°F during the heating season.
When using a combination of outside
air and return air, be sure the ducts are
so designed and a diverting damper so
installed that the volume of circulating
air entering the furnace cannot be
reduced or restricted below that which
would normally enter through the
circulating air intake of the furnace.
When the furnace is installed so that
the supply ducts carry air circulated by
the furnace to areas outside the space
containing the furnace, the return air
shall be handled by a duct or ducts
sealed to the furnace casing and
terminated outside the space
containing the furnace.
IF THERE IS NO COMPLETE
RETURN AIR DUCT SYSTEM, THE
RETURN AIR CONNECTION MUST
RUN FULL SIZE TO A LOCATION
OUTSIDE THE UTILITY ROOM OR
SPACE HOUSING THE FURNACE
TO PREVENT A NEGATIVE
PRESSURE ON THE VENTING
SYSTEMS. A NEGATIVE PRESSURE
CAN DRAW PRODUCTS OF
COMBUSTION INTO CIRCULATING
AIR.
NEVER ALLOW THE PRODUCTS OF
COMBUSTION OR THE FLUE
PRODUCTS TO ENTER THE RETURN
AIR DUCTWORK OR THE
CIRCULATING AIR SUPPLY. ALL
RETURN DUCTWORK MUST BE
ADEQUATELY SEALED AND
SECURED TO THE FURNACE WITH
SHEET METAL SCREWS, AND
JOINTS TAPED. ALL OTHER DUCT
JOINTS MUST BE SECURED WITH
APPROVED CONNECTIONS AND
SEALED AIRTIGHT.
FAILURE TO PREVENT PRODUCTS
OF COMBUSTION FROM BEING
CIRCULATED INTO THE LIVING
SPACE CAN CREATE SOOT
DAMAGE, SMOKE, ODORS OR
CARBON MONOXIDE POISONING.
IMPORTANT: One of the most
common causes of trouble in forced
air heating systems is insufficient
return air to the furnace. The return air
system should be approximately equal
to or greater than the area of the warm
air discharge. CONSULT LOCAL
CODES FOR SPECIAL
REQUIREMENT.
DO NOT, UNDER ANY
CIRCUMSTANCES, CONNECT
RETURN OR SUPPLY DUCTWORK
TO OR FROM ANY OTHER HEAT
PRODUCING DEVICE SUCH AS A
FIREPLACE INSERT, STOVE, ETC.
DOING SO MAY RESULT IN FIRE,
CARBON MONOXIDE POISONING,
EXPLOSION, PERSONAL INJURY,
PROPERTY DAMAGE OR DEATH.
Install the cold air return to terminate
through the floor under the furnace. A
direct connection should be made to
the bottom of the furnace. For
installations where return air ducts
cannot be run under the floor, return air
may be taken from the sides and/or
back by cutting the furnace casing and
installing the appropriate accessory.
NOTE: Where the maximum air flow is
1800 CFM or more, both sides or the
bottom must be used for return air.
When a cooling coil is used in
conjunction with the furnace, it must be
installed downstream of the outlet end
of the furnace or in parallel with the
furnace to avoid condensation in the
heating element.
If the furnace is installed in parallel with
a cooling unit, the damper or other
means used to control the flow of air
must be adequate to prevent chilled air
from entering the furnace, and if
manually operated must be equipped
with means to prevent operation of the
other unit unless the damper is in the
full heat or cool position.
IMPORTANT: Air openings in the
casing front, return air grilles and warm
air registers must not be obstructed.
BLOWER AND BURNERS MUST
NEVER BE OPERATED WITHOUT
BLOWER DOOR IN PLACE. THIS IS
TO PREVENT DRAWING FUMES
(WHICH COULD CONTAIN
ANNOYING AND HAZARDOUS
GASES) INTO THE HOME THAT
COULD RESULT IN PERSONAL
INJURY OR DEATH.
FLUE AND CHIMNEY
EXHAUST
The vent connector should be as short
as possible and installed so that it has
a continuous rise from the furnace to
the chimney or flue.
The number of elbows should be
minimized and the flue pipe shnould be
joined with sheet metal screw and
properly supported with suitable pipe
hangers.
A barometric draft regulator is required
in each furnace vent connector and
must be installed before the vent
connector enters the chimney or flue.
NOTE: The size of the draft regulator
diameter must be no smaller than the
vent connector diameter.
The vent connector should be the
same size as the furnace flue pipe
connection. The sizes are:
FURNACE FLUE SIZE
BTU OUTPUT INCHES
056 5
067 5
084 5
095 5
112 5
130 7
150 7
CHIMNEY SIZE
RECOMMENDATIONS
The following table shows
recommended size and height for
chimneys based on total BTU input of
all the oil appliances being vented.
GROSS BTU RECTANGULAR ROUND MINIMUM
INPUT TILE TILE HEIGHT
(INCHES) (INCHES) (FEET)
144,000 81⁄2 x 81⁄2 8 20
235,000 81⁄2 x 13 10 30
372,000 13 x 13 12 35
516,000 13 x 18 14 40
612,000 — 15 45
768,000 18 x 18 — 50
960,000 20 x 20 18 55
VENTING
Unit must be vented through a chimney
or flue. Check chimney for soot, leaks,
obstruction and proper height to
prevent down draft. Clean chimney and
base if necessary.
The height of the chimney or flue shall
be at least 3 feet above the highest
point where it passes through the roof
of a building and at least 2 feet higher
than any portion of a building within 10
feet of such chimney.
WARNING
!
WARNING
!
WARNING
!
Install a single wall, vent connector
from flue outlet to chimney, sloping flue
pipe continuously upward (at least 1/4
inch per foot) toward chimney. The
vent connector should be the same
diameter as the flue collar of the
furnace for the entire length of run and
should not exceed 10 feet in length.
Avoid sharp turns that would create
resistance to the flow of flue gasses.
Vent connector should not extend
beyond the inside wall of the chimney
and must be firmly cemented to
masonry.
IMPORTANT: This furnace is agency
approved by UL, ULC and CSA for use
with the Tjernlund SS1-R sidewall vent
system when installed in accordance
with the installation instructions for the
SS1-R provided by Tjernlund. The
maximum vent length is 10 feet with 3
elbows when venting with the SS1-R.
This is the only option given for side
wall venting. It should be noted that
common venting with another
appliance is not an option when using
the Tjernlund SS1-R. The use of any
other type of power vent system is not
approved or recommended by the
manufacturer.
No other appliances or heating
equipment should be connected to the
vent connector servicing the furnace.
Bolt, screw and/or support joints to
avoid sag. Fasten the single-wall vent
connector to the outlet collar of the
furnace with at least two sheet metal
plumb. Tilting causes erratic damper
operation. Installation of a barometric
damper must be in accordance with the
Installation and Operation Instructions
provided with the damper.
The following standards and codes will
help to make the installation. Current
editions of these standards can be
obtained from:
American National Standards Institute,
1430 Broadway, New York, NY 10018
OIL BURNER / PRIMARY
CONTROL
Oil burner and primary control are
mounted to the furnace as a complete
assembly. Standard equipment
consists of the oil burner, primary
control and flame sensor mounted as a
single assembly to the furnace. The
heat/cool relay is mounted to the unit’s
main junction box and the flame sensor
(cadmium sulfide cell) is enclosed in
the burner housing above the blower
wheel.
The standard oil burner is equipped
with a single stage fuel pump. This
single stage fuel pump may be used in
either a one or two pipe system. If a
two pipe system is required (burner is
screws. Refer to Figure 1 for distances
to combustible materials.
DEVICES ATTACHED TO THE FLUE
OR VENT FOR THE PURPOSE OF
REDUCING HEAT LOSS UP THE
CHIMNEY HAVE NOT BEEN TESTED
AND HAVE NOT BEEN INCLUDED IN
THE DESIGN CERTIFICATION OF
THIS FURNACE. WE, THE
MANUFACTURER, CANNOT AND
WILL NOT BE RESPONSIBLE FOR
INJURY OR DAMAGE CAUSED BY
THE USE OF SUCH UNTESTED
AND/OR UNCERTIFIED DEVICES,
ACCESSORIES OR COMPONENTS.
BAROMETRIC DRAFT
CONTROL
The barometric damper (see figure 7) is
a control installed in the flue pipe to
regulate the draft in the furnace. If the
draft increases in the chimney, the
damper opens to maintain the preset
draft in the furnace. Should the draft
decrease in the chimney, the damper
will close to maintain the preset draft of
the oil furnace. A barometric damper is
supplied with each furnace and must be
installed by the following the
instructions supplied by the
manufacturer. The barometric damper
control should be installed between the
flue outlet of the furnace and the
chimney (see figure 8). The barometric
damper control should be set for proper
draft on start up after the furnace has
been operating for 10 to 15 minutes.
See Oil Burner Adjustment Procedure
Section for proper draft settings.
On start up, the furnace must be set
for field conditions with a
combustion kit for proper operation.
Note: Always use a seperate
barometric damper for each oil-fired
appliance. Install the barometric
damper with its hinge level and the face
8
TABLE 1. Metal Thickness for Galvanized Steel Pipe
Connectors
Diameter of Galvanized Minimum
Connector Sheet Thickness
(in.) (mm) Gauge No. (in.) (mm)
< 6 < 152 26 0.019 0.48
≥ 6 to ≤ 10 ≥ 152 to ≤ 254 24 0.024 0.61
> 10 to ≤ 16 > 254 to ≤ 406 22 0.029 0.74
>16 > 406 16 0.056 1.42
Figure 8
Recommended Barometric Damper Locations
Figure 7
Barometric Damper
ELECTRIC WIRING
TURN OFF ELECTRIC POWER AT
FUSE BOX OR SERVICE PANEL
BEFORE MAKING ANY ELECTRICAL
CONNECTIONS. FAILURE TO DO SO
CAN CAUSE ELECTRICAL SHOCK
RESULTING IN PERSONAL INJURY
OR DEATH.
CABINET MUST BE PERMANENTLY
GROUNDED. A GROUND SCREW IS
PROVIDED IN THE JUNCTION BOX
FOR THIS PURPOSE.
GROUND CONNECTION MUST BE
COMPLETED BEFORE MAKING ANY
LINE VOLTAGE CONNECTIONS.
FAILURE TO GROUND APPLIANCE
COULD RESULT IN ELECTRICAL
SHOCK, FIRE, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
Installation of the electric supply line
should be in accordance with the
National Electric Code ANSI/NFPA No.
70, latest edition, and local building
codes.
Use a separate fused branch electrical
circuit containing a properly sized fuse
or circuit breaker. Run this circuit
directly from the main switch box to an
electrical disconnect (switch) which
must be readily accessible and located
within sight of the furnace.
above tank) the lift and length of run
must be considered so as not to
overload the fuel unit. NOTE: If the
length of run and the lift is beyond the
recommended limits of the charts
below, a booster prep unit should be
used.
TANK AND OIL LINES
Oil storage tank should be of an
approved type installed in accordance
with the National Board of Fire
Underwriters and local regulations.
In accordance with standards of the
National Board of Fire Underwriters,
inside tanks should be at least seven
feet from burner, convenient for
installing the fill, vent and feed lines.
The fill and vent lines should be run to
a convenient outdoor location and
should slope downward to tank. They
should terminate in approved fittings.
An approved type of oil gauge should
be installed in accordance with
manufacturer’s instructions. Copper
tubing no smaller than 3/8” O.D. is
recommended for suction or feed line
on basement tank installations. A hand
shut-off valve should be installed at the
tank outlet. An oil filter should be
installed in the suction or feed line.
Underground tanks or tanks below the
burner may require a two-pipe hookup. A check valve should be installed
in the suction line to keep the line
primed and the internal by-pass in the
fuel unit must be plugged as per
instructions furnished with the burner.
All oil lines must be tight and free of
traps. Lines should be buried or
otherwise protected from mechanical
injury. (See Typical Installation
Diagrams.)
9
WARNING
!
WARNING
!
Lift (in feet) 0 2 4 6 8 10 12 14 16 18
3/8" O.D.
68 63 58 53 48 42 37 32 27 22
Tubing
1/2" O.D.
100 100 100 100 100 100 100 100 100 88
Tubing
Recommended Maximum Length of Tubing
Used on a Two Stage (3450 RPM) Pump Two
Pipe System
Lift (in feet) 0 1 2 3 4 5 6 7 8 9 10
3/8" O.D.
53 40 45 41 38 33 20 25 21 18 13
Tubing
1/2" O.D.
100 100 100 100 100 100 100 99 83 68 52
Tubing
Recommended Maximum Length of Tubing
Used on a Single Stage (3450 RPM) Pump Two
Pipe System
Connect from the disconnect to the
junction box on the furnace inside the
control compartment. Discard test
leads and connect the line voltage
wires in their place. (See appropriate
wiring diagrams.)
NOTE: H (hot) and N (neutral) polarity
must be observed when making field
connections to the furnace. The limit
control will not interrupt H (hot) circuit
if leads are reversed.
THERMOSTAT
Install the room thermostat in
accordance with the instruction sheet
packed in the box with the thermostat.
Run the thermostat lead wires inside
the blower compartment and connect
to low voltage terminals as shown on
the wiring diagram. Never install the
thermostat on an outside wall or where
it will be influenced by drafts,
concealed hot or cold water pipes or
ducts, lighting fixtures, radiation from
fireplace, sun rays, lamps, televsions,
radios or air streams from registers.
Refer to instructions packed with the
thermostat for “heater” selection or
adjustment.
NOTE: Do not use 24 volt control
wiring smaller than No. 18 AWG.
HEAT ANTICIPATOR
SETTING
The heating thermostat anticipator
should be set for a 0.10 amp draw.
TABLE 1
LOW VOLTAGE WIRING
SOLID COPPER WIRE - AWG
3.0 16 14 12 10 10 10
2.5 16 14 12 12 10 10
2.0 18 16 14 12 12 10
50 100 150 200 250 300
LENGTH OF RUN - FEET ➀
➀ The total wire length is the distance from the furnace to the thermostat and back
to the furnace.
NOTE: Do not use 24 volt control wiring smaller than No. 18.
THERMOSTAT
LOAD - AMPS
10
TYPICAL INSTALLATION DIAGRAMS
FIGURE 9. TWO PIPE INSTALLATION
FIGURE 10. ONE PIPE INSTALLATION
LIGHTING INSTRUCTIONS
This appliance is equipped with an
automatic electronic ignition device.
This device lights the oil burner each
time the room thermostat (closes) calls
for heat. See oil burner instructions
enclosed with furnace for further detail.
MAKE SURE THAT COMBUSTION
CHAMBER IS FREE OF OIL BEFORE
USING RESET BUTTON ON
PRIMARY CONTROL. FAILURE TO
DO SO CAN CAUSE FLASH FIRE OR
EXPLOSION RESULTING IN
PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
TO START FURNACE
1. Set room thermostat to highest
setting.
2. Open shut-off valve in oil supply line.
3. Close line switch. Burner should
start automatically.
4. Bleed the fuel pump as soon as the
burner motor starts rotating. To
bleed the fuel unit, attach a clear
plastic hose over the bleed plug.
Loosen the plug and catch the oil in
an empty container. Tighten the plug
when all air is purged.
5. Reset room thermostat to desired
temperature setting.
11
WARNING
!
TO STOP FURNACE
1. Set the room thermostat to lowest
temperature setting.
2. Turn “Off” line switch to the furnace.
IF BURNER DOES NOT START
1. Check fuse or breaker in the furnace
circuit.
2. Assure room thermostat is set above
room temperature.
3. Check oil level in the tank.
4. Make sure that oil line shut-off
valves are open.
5. Wait five minutes to allow the control
to cool, so that it will recycle. Reset
the button on the primary control.
6. Depress manual reset button on the
motor.
NOTE: Do not expose cad cell to
direct electric bulb light or sunlight.
Light may enter through the air control
band slot and upset the electric circuit
of this device.
OPERATING INSTRUCTIONS
FIGURE 11. COMPONENT LOCATION
I421
OIL PROP
12
FIGURE 12
FLUE SAMPLING LOCATIONS
OIL BURNER ADJUSTMENT
AFTER FURNACE INSTALLATION,
EACH OIL FURNACE MUST
BE
OPERATED IN THE HEATING
CYCLE AND PROPER BURNER
ADJUSTMENTS COMPLETED FOR
EACH FURNACE INSTALLATION
FIELD CONDITION. THIS IS
REQUIRED FOR EACH OIL
FURNACE INSTALLED. SEE
“BURNER ADJUSTMENT” PORTION
OF THE FURNACE INSTALLATION
AND OPERATINIG INSTRUCTION.
THE ADJUSTMENTS ARE
NECESSARY TO PREVENT SMOKE,
SOOT, ODOR FROM ENTERING THE
STRUCTURE AND SUBSEQUENT
FURNACE DAMAGE.
THE FOLLOWING ADJUSTMENTS
ARE NECESSARY TO PREVENT
SMOKE, SOOT, ODOR AND
POSSIBLE EQUIPMENT DAMAGE.
AN EXPERIENCED SERVICE
MECHANIC AND RELIABLE
INSTRUMENTS ARE REQUIRED.
The following procedure is based on
guidelines taken from
"The Professional Serviceman's Guide To Oil Heat
Savings"
by R.W.Beckett Corporation,
who based theirs on the U.S.
Environmental Protection Agency's
"Guidelines for Residential Oil Burner
Adjustments"
printed in 1975. Some
procedures have been changed to
meet the specific units being
addressed.
CAUTION
!
FURNACE ADJUSTMENT
PREPARATION STEPS
1. Calibrate and check the operation
of all measuring equipment. Follow
the manufacturer's recommended
procedures for calibration and
equipment check out. Calibration
instructions are included in the
operation instructions for the Fyrite
CO2Gas Analyzer. See Fyrite
CO2section in this manual.
2. Prepare the heating unit for
testing. Drill ONE 1/4 inch hole in
the flue between the heating plant
and the barometric damper, if not
already there as shown in Figure
12. If space permits, the hole
should be located in a straight
section of the flue, at least two flue
diameters from the elbow in the
flue pipe and at least one diameter
from the barometric damper.
Another 1/4 inch hole is provided
by the manufacturer for testing
over the fire.
Drill another 1/4
( hole between the
barometric damper and the
chimney as shown in Figure 12.
The draft at this location must
measure at least -.05 to -.06
inches W.C. within three minutes
after the burner starts. Failure to
achieve this measurement
indicates chimney draft problems
which must be corrected for proper
operation. See Figure 22 for
chimney problem correction.
3. Make sure the burner air tube, fan
housing, and blower wheel are
clear of dirt and lint.
4. Nozzle inspection. Annual replacement of the nozzle is recommend-
ed. The nozzle size should match
the capacity of the unit installed.
Nozzle si/ze is listed on the unit
nameplate. An in-line oil filter will
reduce service problems due to
nozzle clogging. It should be
located as close as possible to the
oil burner. Care should be taken to
prevent air leakage into the oil
suction line. Use continuous runs
of copper tubing and use a
minimum number of joints and
fittings. Always use flare fittings.
Refer to the nozzle specifications
for the correct nozzle and spray
pattern, whenever replacing the
nozzle.
5. Adjustment of electrodes. Adjust
the ignition electrodes according
to the burner manufacturer’s
instructions to assure prompt
ignition. See the electrode
adjustment section in this manual
for more information.
6. Operate the burner; adjust the air
setting for a proper flame by visual
observation (until no smoke is
present), and run for at least 10
minutes or until operation has
stabilized. If a proper flame is not
obtainable reset the air band and
air shutter settings to the original
factory settings (see table 11).
7. Check pump pressure. Bleed air
from the pump and nozzle piping.
Check the pump pressure and
adjust to 100 psi, if necessary.
See the pump section in this
manual for more information.
COMBUSTION ADJUSTMENT
THE FOLLOWING BURNER
ADJUSTMENTS MUST BE MADE
AFTER 10 TO 15 MINUTES OF
OPERATION.
8. Set the draft. Remove the heat
shield and then remove the metal
plug in the burner mounting plate.
Check the draft reading over the
fire with a draft gage through the
5/16" hole located in the burner
plate. See the draft gauge section
in this manual for more
information. Adjust the barometric
damper to give the overfire draft
recommended by the manufacturer.
If no such recommendations are
available, set the overfire draft to
assure a negative pressure within
the combustion chamber (usually a
negative 0.01 to 0.02 inches water
column).
Replace the hole plug in the
burner mounting plate after these
tests have been made.
9. Check the smoke readings. After
the burner has been operating 10
minutes, make a smoke measurement in the flue following the
smoke tester instructions. See the
smoke pump section in this
manual for more information. Oily
or yellow smoke spots on the filter
paper are usually a sign of unburned fuel, indicating very poor
combustion (and likely high emissions of carbon monoxide and
unburned hydrocarbons). This
condition can sometimes be
caused by too much air, or other
factors. If this condition cannot be
corrected, major correction or
even burner replacement may be
necessary. Adjust the air shutter
and air band for a 0 to a 1 smoke
number (a trace).
10. Check the CO
2
with the Fyrite
analyzer. See Fyrite Gas Analyzer
section for methods and
procedures. Adjust the air setting
to reduce the CO
2
reading by
between 1% and 2%. Lock the air
adjustment and repeat all draft,
CO
2
, and smoke measurements to
make sure the setting has not
shifted.
COMBUSTION DIAGNOSIS
11. Check performance. A wellmatched and well-tuned burner
should be capable of operation at
a CO
2
level between 10% and
12%.
FINAL CHECKS
12. Measure the flue temperature.
See the stack thermometer
section in this manual for more
information. Operating the unit at
an excessive firing rate generates
pollutant emissions. Check for
prompt pump cutoff by observing
the flame or by checking for
smoke at shutdown. If poor cutoff
is observed, make sure all air is
purged from the pump and nozzle
line. If poor cutoff continues check
for proper cutoff pressure.
15. Check Controls. Check the
settings of all operating controls
before leaving the installation and
verify that they are in working
order.
16. Check for proper temperature rise
of the supply air. See the air
supply temperature section in this
manual for details.
17. Annual Cleanup. An overall burner
checkup and cleanup is
recommended annually. See the
annual cleanup section in this
manual for more information.
13
more heat than the heat
exchanger can utilize and results
in unnecessary heat loss up the
chimney. Other causes of
excessive heat loss are badly
sooted heat-exchanger surfaces
and excessive draft. The temperature of the flue gas provides an
indication of these heat losses.
Measure the net flue temperature
by subtracting the room air temperature from the thermometer
reading. Excessive flue loss is
indicated if the net flue
temperature during steady
operation exceeds 600° F.
13. Check Ignition. Check the
operation over repeated cycles to
insure prompt ignition on starting.
14. Check pump cutoff. See pump
section for the procedure for
checking cut off pressure. Slow
pump cutoff at the end of a firing
cycle can cause smoke and other
FIGURE 13
FIGURE 14
Table 11
FACTORY AIR ADJUSTMENT SETTINGS
BURNER
AIR SHUTTER
SETTING
AIR BAND
SETTING
OIL FURNACE
MODEL
BECKETT
MODEL
AFG AF42JYPWHS 10 BLANK -056
AFG AF42JYPWHS 10 BLANK -067
AFG AF42XNPWHS 10 2 -084
AFG AF42XNPWHS 10 2 -095
AFG
AFG
AFG
AF42XNPWHS
AF42JZPWHS
AF42JZPWHS
10
7
7
2
4
4
-112
-130
-150
BECKETT
DESIGNATION
For Use as Gage
Port. Remove vent
plug to install 1/49
pipe threaded gage.
To Adjust Pressure:
Insert standard
screwdriver. Turn
counterclockwise to
below pressure
desired. Turn
clockwise to set to
desired pressure.
GAGE PORT
PRESSURE
PRESSURE ADJUSTMENT
14
FIGURE 15
BURNER SEQUENCE OF OPERATION
CHECK MAIN POWER, PRESS PRIMARY CONTROL RESET.
CHECK LOW VOLTAGE WIRING/CONTROLS
CHECK FOR FALSE LIGHT ON CAD CELL
CHECK FUEL SUPPLY, OIL LINES, OIL LINE VALVES, TRIAL
CHECK OIL NOZZLE,
CHECK PRIMARY CONTROL / CAD CELL,
CHECK IGNITION TRANSFORMER / ELECTRODES
CHECK ELECTRODES, IGNITION TRANSFORMER,
CHECK FUEL SUPPLY, NOZZLE
CHECK CAD CELL / PRIMARY CONTROL
CHECK FAN CENTER
CHECK BLOWER MOTOR WIRING
CHECK BLOWER MOTOR CAPACITOR
CHECK THERMOSTAT AND CONTROL WIRING.
CHECK ISOLATION RELAY
CHECK PRIMARY CONTROL
CHECK PRIMARY CONTROL
CHECK FAN CENTER AND WIRING
T’STAT CALLS FOR HEAT
IGNITOR / MOTOR START
BURNER STARTS 15 SEC
FOR IGNITION
FLAME ESTABLISHED,
MOTOR & IGNITOR
CONTINUE
MAIN BLOWER STARTS
THERMOSTAT OPENS,
HEAT CALL ENDS
IGNITOR AND MOTOR
STOP / BURNER OFF
MAIN BLOWER OFF
YES
NO
YES
YES
YES
YES
YES
YES
NO
NO
NO
NO
NO
NO
3. If the electrode position is correct,
the tips should be positioned where
the identifying marks on the gauge
intersect. These two lines
determine:
a. Correct tip spacing above the
nozzle.
b. Correct tip spacing ahead of
the nozzle.
The actual distance between
electrodes must be correct within +/1/32".
4. If the electrode position is not
correct, the electrodes must be
readjusted and rechecked.
NOZZLE POSITION
1. Insert the nozzle line/electrode
assembly into the air tube (see
figure 18).
2. Place the wide section of the
gauge against the burner head
face with 1-1/8" wide end of the
gauge inserted into head.
3. Slide the nozzle line/electrode assembly forward until the nozzle
touches the gauge.
4. Secure the adjustable plate on the
burner housing side by tightening
the screw. Then tighten the nut,
securing the nozzle line where it
passes through the side of the
The T231H nozzle, electrode and head
position gauge (see figure 16) is used
to correctly position the electrodes,
nozzle, and head. The gauge is the
best way to ensure that these adjustments are correct.
This gauge is used on the Beckett
model "AFG" burners.
ELECTRODE POSITION
1. With nozzle line/electrode assembly out of the burner, place the 11/8" wide gauge edge against the
face of the nozzle and between the
electrode tips (see figure 17).
2. Position the gauge so the center
scribe mark is in line with the
nozzle orifice. (Do not scratch the
nozzle face)
15
housing. This locks the assembly
into position.
The nozzle should now be located
properly with 1-1/8" set back from
the face of the burner head.
NOZZLE CONCENTRICITY
For proper burner operation the nozzle
must be concentric with the burner
head opening.
1. With the gauge inserted into the
head (see figure 14), the nozzle
orifice should be approximately in
line with the center scribe mark on
the 1-1/8" wide edge of the gauge.
The maximum eccentricity
allowable is identified by the two
outer scribe marks (+/- 1/16").
2. Rotate the gauge to assure
concentricity in a side-to-side as
well as up-down position.
If the nozzle is not concentric
within allowable limits, it generally
indicates either improper
construction or damaged parts. Do
not use. Replace with a correct assembly.
AIR VOLUME
ADJUSTMENTS
The amount of air delivered by the
blower is affected by the resistance of
the ductwork and registers. The factory
adjustment of the blower speed has
been made to suit the average
installation, designed and installed
according to the manuals published by
the National Warm Air Heating and Air
Conditioning Association. The speed of
the direct drive blower can be changed
by rewiring motor leads as described in
the wiring diagrams.
ELECTRODE ADJUSTMENT
Figure 16
T231H
Figure 17
Electrode Adjustment
Figure 18
Nozzle Depth and Concentricity
16
SUPPLY AIR
TEMPERATURE
The temperature rise of the air through
a furnace will vary with each furnace.
For proper temperature rise of the
furnace in question, check the rating
plate on the furnace or Table 7 in this
manual.
A. Temperature rise is the
temperature difference between
the air entering and leaving the
furnace.
B. The proper way to measure the
temperature rise follows: First
open all registers and dampers to
allow proper air flow. Then allow
the furnace to operate 10 to 15
minutes before taking the
readings.
C. Use two thermometers; insert one
in the supply air duct and one in
the return air duct. Do not place a
thermometer in the supply duct
directly above the heat exchanger
as the thermometer will pick up
radiant heat from the heat exchanger. (See Figure 19.)
D. Calculate by subtracting the return
air temperature from the supply air
temperature.
Example
Supply air
temperature 155 degrees
Return air
temperature
75 degrees
Temperature
rise = 80 degrees
E. Compare the calculated tempera-
ture rise with the specified
temperature rise on the rating
plate.
TEMPERATURE RISE TOO
HIGH
• Check for proper fan speed
• Check static pressure on duct
system for proper air flow.
• Check proper cooling coil size.
• Check duct static pressures for
proper air flow.
• Check for proper oil pressure.
• Check nozzle size for overfiring.
• Check for a clean air filter.
• Check duct sizes to assure
adequate size for desired air flow.
The blower speed can be increased to
deliver more air over the heat
exchanger if the duct system is large
enough to allow the increase. If the
duct system is not of adequate size increasing fan speed may result in less
air flow than originally found.
TEMPERATURE RISE TOO
LOW
• Check for proper fan speed.
• Check nozzle size to make sure it
is of proper size.
• Check for excessive soot in the
heat exchanger. Low system
efficiency may indicate a sooted
heat exchanger.
The motor speed can be changed to a
lower speed to decrease the air flow
over the heat exchanger.
TRUE-SPOT
True-Spot smoke tester (see figure 19)
by Bacharach is used to check smoke
levels in flue products.
Figure 19
Determining Temperature Rise
17
INSTRUCTIONS FOR USE:
1. Tear a sample strip of filter paper
along the perforation line; loosen
the clamp screw, insert the filter
paper strip in the slot and tighten
the clamp screw.
2. Insert the sampling tube into the
flue through a 1/4" diameter hole
between the draft regulator and
the furnace flue outlet (see figure
21).
UPFLOW OIL FURNACE
TEMPERATURE RISE CHART
MODEL
TEMPERATURE
RANGE
DEGREES F.
056
&
067
40 - 70
084
095
& 112
50 - 80
130
&
15-
60 - 90
Table 7
6. To take additional samples clamp
the filter paper strip in the slot so
that the previous spot is visible.
SMOKE SCALE READINGS:
1. Excellent - Little, if any, sooting.
2. Good - May be slight sooting, with
little, if any, increase in flue gas
temperature.
3. Fair - Substantial sooting, but
rarely will require cleaning more
than once a year.
4. Poor - This is a borderline smoke
- some units may soot only moderately, others may soot rapidly.
5 Very Poor - Heavy sooting in all
cases - may require cleaning
several times during a heating
season.
6 Extremely Poor - Severe and
rapid sooting - may result in damage to the stack control and
reduce the overfire draft
dangerously.
TIPS FOR BETTER SMOKE
READINGS
1. Before using, tap the sampling
tube to loosen any soot or rust,
tighten the clamp screw without
any filter paper in the slot and
purge with several rapid pump
strokes of room air.
2. Warm the True-Spot to room
temperature before using.
3. In sampling, be sure to pull the
pump handle through 10 full
strokes and hold for several
seconds at the end of each pull
stroke. Use a steady pull motion
such that a full stroke is obtained
in 3 or 4 seconds.
4. Hold the smoke scale with the
filter paper at arm’s length when
comparing the spot with the chart.
5. Take several readings.
6. Keep the Smoke Scale clean and
store in an envelope provided
when not in use.
FAN/LIMIT CONTROL
The high limit cut-off switch is factory
set to meet safety requirements. This
setting is not adjustable.
The fan is cycled by a solid state fan
timer control located in the blower
cavity. (See Figure 11.)
3. Pull the True Spot handle through
10 full pump strokes.
4. Remove the filter paper strip from
slot (see figure 22).
5. Match the smoke spot on the filter
paper to the closest color shade on
the Bacharach oil burner smoke
scale RR 776 (see figure 22).
Figure 20
True-Spot
Figure 21
Smoke Sample
Figure 22
Smoke Spot
Figure 23
Smoke Scale
BURNER
For proper operation, replace the
burner oil nozzle each year. It is
located in the burner drawer. (See
instructions furnished with burner for
details.)
Periodically clean ignition electrodes,
blower wheel and all filters in the oil
line. Service should be performed by a
qualified service technician at least
once yearly at the beginning of the
heating season.
18
LUBRICATION
IMPORTANT: DO NOT attempt to
lubricate the bearings on the blower
motor. Addition of lubricants can
reduce the motor life and void the
warranty.
The blower motor is permanently
lubricated by the manufacturer and
does not require further attention.
The blower motor must be cleaned
periodically by a qualified installer,
service agency, or the oil supplier to
prevent the possibility of overheating
due to an accumulation of dust and dirt
on the windings or on the motor
exterior.
AIR FILTER
The air filters must be kept clean. Dirty
filters can restrict airflow. The motor
depends upon sufficient air flowing
across and through it to keep from
overheating.
In a new house, the air filter may
become clogged within a short time
due to the presence of dust in the air
and air ducts. A dirty filter retards the
flow of air and prevents proper airflow.
Permanent filters should be cleaned
and disposable filters should be
replaced at least once a year and more
often if necessary (see User’s Info.
Manual).
NOTE: Do not use high static return
air filters to replace standard furnace
filters.
MAINTENANCE
19
BLOWER PERFORMANCE DATA—UPFLOW MODELS
MODEL
NUMBER
(-)OBC-056LBA
(-)OBC-056LBE
10 x 7
[254 x 178]
(-)OBC-067LBA
10 x 7
[254 x 178]
(-)OBC-067LBE
10 x 7
[254 x 178]
(-)OBC-084QBA
10 x 10
[254 x 254]
(-)OBC-084QBE
10 x 10
[254 x 254]
(-)OBC-095QBA
10 x 10
[254 x 254]
(-)OBC-095QBE
10 x 10
[254 x 254]
(-)OBC-112QBA
10 x 10
[254 x 254]
(-)OBC-112QBG
10 x 10
[254 x 254]
(-)OBC-130RBA
11 x 10
[279 x 254]
(-)OBC-130RBJ
11 x 10
[279 x 254]
(-)OBC-150RBA
11 x 10
[279 x 254]
(-)OBC-150RBJ
NOTES: *HEATING SPEED
+COOLING SPEED
[ ] Designates Metric Conversions
11 x 10
[279 x 254]
10 x 7
[254 x 178]
1/4
[186]
1/4
[186]
1/4
[186]
1/4
[186]
1/4
[186]
1/2
[373]
1/4
[186]
1/2
[373]
1/2
[373]
1/2
[373]
1/2
[373]
3/4
[559]
1/2
[373]
3/4
[559]
LOW
MED-LO*
MED-HI
HIGH
LOW
MED-LO*
MED-HI
HIGH+
LOW
MED-LO
MED-HI*
HIGH
LOW
MED-LO
MED-HI*
HIGH+
LOW
MED-LO
MED-HI*
HIGH
LOW*
MED-LO
MED-HI+
HIGH
LOW
MED-LO
MED-HI
HIGH*
LOW
MED-LO*
MED-HI+
HIGH
LOW
MED-LO
MED-HI*
HIGH
LOW
MED-LO
MED-HI*
HIGH+
LOW
MED-LO
MED-HI
HIGH*
LOW
MED-LO
MED-HI*
HIGH+
LOW
MED-LO
MED-HI
HIGH*
LOW
MED-LO
MED-HI*
HIGH+
600 [283]
795 [374]
915 [432]
1140 [538]
600 [ 283]
795 [375]
915 [432]
1140 [538]
600 [283]
795 [375]
915 [432]
1140 [538]
600 [283]
795 [375]
915 [432]
1140 [538]
580 [274]
840 [396]
995 [470]
1260 [595]
1040 [491]
1230 [580]
1375 [649]
1500 [708]
580 [274]
840 [396]
995 [470]
1260 [595]
1040 [491]
1230 [580]
1375 [649]
1500 [708]
1040 [491]
1230 [580]
1375 [649]
1500 [708]
1040 [491]
1230 [580]
1375 [649]
1500 [708]
890 [420]
1135 [536]
1415 [668]
1670 [788]
1045 [493]
1375 [649]
1715 [809]
2070 [977]
890 [420]
1135 [536]
1415 [668]
1670 [788]
1045 [493]
1375 [649]
1715 [809]
2070 [977]
620 [293]
835 [394]
940 [444]
1190 [562]
620 [293]
835 [394]
940 [444]
1190 [562]
620 [293]
835 [394]
940 [444]
1190 [562]
620 [293]
835 [394]
940 [444]
1190 [562]
620 [293]
865 [408]
1030 [486]
1290 [609]
1065 [503]
1260 [595]
1430 [675]
1575 [743]
620 [293]
865 [408]
1030 [486]
1290 [609]
1065 [503]
1260 [595]
1430 [675]
1575 [743]
1065 [503]
1260 [595]
1430 [675]
1575 [743]
1065 [503]
1260 [595]
1430 [675]
1575 [743]
900 [425]
1145 [540]
1435 [677]
1690 [798]
1055 [498]
1400 [661]
1745 [824]
2110 [996]
900 [425]
1145 [540]
1435 [677]
1690 [798]
1055 [498]
1400 [661]
1745 [824]
2110 [996]
635 [300]
870 [411]
955 [451]
1230 [580]
635 [300]
870 [411]
955 [451]
1230 [580]
635 [300]
870 [411]
955 [451]
1230 [580]
635 [300]
870 [411]
955 [451]
1230 [580]
645 [304]
890 [420]
1070 [505]
1320 [623]
1080 [510]
1285 [606]
1480 [698]
1645 [776]
645 [304]
890 [420]
1070 [505]
1320 [623]
1080 [510]
1285 [606]
1480 [698]
1645 [776]
1080 [510]
1285 [606]
1480 [698]
1645 [776]
1080 [510]
1285 [606]
1480 [698]
1645 [776]
910 [429]
1160 [547]
1445 [682]
1710 [807]
1070 [505]
1435 [677]
1760 [831]
2145 [1012]
910 [429]
1160 [547]
1445 [682]
1710 [807]
1070 [505]
1435 [677]
1760 [831]
2145 [1012]
645 [304]
885 [418]
970 [458]
1260 [595]
645 [304]
885 [418]
970 [458]
1260 [595]
645 [304]
885 [418]
970 [458]
1260 [595]
645 [304]
885 [418]
970 [458]
1260 [595]
670 [316]
910 [429]
1090 [514]
1340 [632]
1090 [514]
1300 [614]
1530 [722]
1705 [805]
670 [316]
910 [429]
1090 [514]
1340 [632]
1090 [514]
1300 [614]
1530 [722]
1705 [805]
1090 [514]
1300 [614]
1530 [722]
1705 [805]
1090 [514]
1300 [614]
1530 [722]
1705 [805]
915 [432]
1170 [552]
1460 [689]
1720 [812]
1090 [514]
1450 [684]
1770 [835]
2175 [1026]
915 [432]
1170 [552]
1460 [689]
1720 [812]
1090 [514]
1450 [684]
1770 [835]
2175 [1026]
BLOWER
SIZE (IN.)
[mm]
MOTOR
H.P.
[W]
BLOWER SPEED
0.5 [.12]
CFM [L/s] AIR DELIVERY
E.S.P. INCHES [kPa] WATER COLUMN
0.4 [.10] 0.3 [.07] 0.2 [.05]
20
CAUSE
1. Roof peak or other surrounding
objects higher than chimney top.
2. Flue cap on chimney.
3. Coping smaller than chimney
interior.
4. Air leak from loose bricks or
mortar.
5. Inside dimensions of chimney are
too small.
6. Double chimney separation wall
leaks due to loose bricks or
mortar.
7. Joist protruding into chimney.
8. Brick, mortar or other obstruction
lodged in chimney.
9. Soot accumulation in offset.
10. Offset is too short.
11. More than one heating appliance
connected to same chimney flue.
12. Smoke pipe protrudes into chimney
or elbow too far.
13. Smoke pipe is loose fitting, too
long or has too many elbows.
14. Opening between chimney flues.
15. Loose fitting cleanout door.
16. New chimney.
17. Excessive draft..
CORRECTION
Extend chimney 24 inches above roof
and surrounding objects within 30 feet.
Remove.
Enlarge to match chimney interior.
Replace loose bricks and mortar.
If all other causes have been
eliminated a new chimney may have
to be built.
Replace loose bricks or mortar.
Remove.
Have chimney cleaned.
Clean out.
Straighten or lengthen offset.
Furnace ideally should have its own
flue. If this is not possible, smoke pipe
should be connected as shown in
Figure 23.
Make flush with inside of chimney.
Cement joints, shorten and eliminate
elbows.
Seal openings permanently.
Seal openings, close door tightly.
Allow 2 to 4 weeks to dry.
Open barometric damper.
CORRECTION OF POOR CHIMNEY DRAFT CONDITIONS
FIGURE 24. CHIMNEY PROBLEMS
FIGURE 25. Pipe pushed too far
inside elbow, as shown, interferes
with draft.
FIGURE 26. If chimney ends only a
short distance below point where
flue enters, make a “toothpick joint”
as shown. Remove soot from below
regularly.
FIGURE 27. If it is necessary to
connect more than one heating
appliance to the same chimney,
connect furnace flue pipe as “B.”
Connect lower BTU appliance pipe
as “A.”
UNIT SIZE
NOZZLE*
G.P.H./ANGLE/PATTERN
END
CONE
STATIC DISC RATING
21
FIGURE 28. BECKETT MODEL “AFG” BURNER
OIL BURNER DATA
DRAWER ASSEMBLY DATA
056/067
084/095/112
130/150
*NOTE: This appliance should only be used with specified Delavan or Monarch nozzles. Use of other nozzles may result
in unsatisfactory performance.
DELAVAN (.50, .60)-70°B
DELAVAN (.75, .85, 1.0)-70°B
DELAVAN (1.2, 1.35)-70°B
F0
F3
F6
3-3/8( SOLID
3-3/8( SOLID
3-3/8( SOLID
AF**JY
AF**XN
AF**JZ
BECKETT MODEL “AFG” BURNER
22
➤Troubleshooting
Important: 90% of start-up
problems are due to air leaks in
the suction line.
Complaint
Odor, soot and smoky fire
Delayed ignition
Burner will not operate
Burner motor runs but does not fire
Pulsations
Check for:
1. Insufficient combustion air
2. Lack of proper draft
3. Cracked/plugged heat exchanger
4. Burner not adjusted properly with combustion kit
5. Improper setting of barometric draft control
6. Oil leaks
7. Wrong nozzle size, or nozzle worn or partially clogged
8. Improper setting of electrodes
9. Plugged oil filter
10. Fuel pump cutoff valve not cutting off
11. Nozzle or electrodes improperly positioned
12. Leakage on return side of air distribution system
13. After drip, reflected heat, or impingement of flame
14. Improper or distorted end cone
15. Air leakage into oil pump supply line
16. Burner blower air inlet restricted or burner blower wheel dirty
17. Restricted flue
1. Cracked, dirty or loose electrodes
2. Electrodes not properly adjusted
3. Incorrect nozzle
4. Improper primary air adjustment
5. Faulty ignition transformer
6. Water in fuel oil
7. Incorrect pump pressure
8. Furnace not properly set-up
9. Air leakage into oil supply line
1. Open switch
2. Open fuse or circuit breaker
3. Burner motor overload open
4. Thermostat improperly set
5. Burner primary control safety open
1. Oil supply insufficient
2. Faulty oil pump
3. Broken oil pump drive coupling
4. Coke deposits on electrodes
5. Air in oil supply line
6. Restricted oil supply line
7. Clogged nozzle
8. Restricted oil line filter
9. Leak in oil line
10. Failed ignition transformer
11. Electrodes not properly set
12. Dirty fire detector
1. Improper nozzle
2. Inadequate draft
3. Air in oil line
4. Clogged flue
5. Furnace not properly set-up
6. Partially clogged pump strainer or oil line filter
23
Complaint
Cad cell not functioning
Low CO
2
High stack temperatures
High smoke reading
Burner motor runs but does not fire
Poor draft - overfire and stack
Noisy Operation
Check for:
7. Nozzle plugged
8. Nozzle too far forward in air tube
9. Barometric damper set wide open
1. Requires direct view of flame
2. External light effecting cell operation
3. Remove cad cell and check with an ohmmeter:
a. With cad cell covered, the resistance should be over 100K ohms
b. With cad cell exposed to room light, the resistance should be
under 1.5 K ohms
1. High draft through furnace
2. Improper primary air adjustment
3. Damaged combustion chamber
4. Faulty nozzle
5. Incorrect oil pressure
6. Draft regulator iimproperly set
7. Incorrect fuel/air mixture
1. Damaged combustion chamber
2. Furnace not set-up with combustion kit
3. Undersized return air
4. Overfired furnace
5. Dirty heat exchanger
6. High draft, barometric damper not properly set
7. Excessive temperature rise
8. Air shutter adjustment open too much.
1. Lack of combustion air
2. Inadequate overfire draft
3. Incorrect oil pressure
4. Dirty burner blower wheel
5. Incorrect nozzle
6. Faulty oil pump
7. Dirty oil
8. Burner motor not obtaining full speed
9. Damaged combustion chamber
10. Flame impingement
11. Incorrect fuel/air mixture
1. Improperly sized chimney or not enough chimney height
2. Holes or cracks in chimney
3. Restricted chimney
4. Too many 90 degree elbows in vent pipe
5. Outside chimney too cool
6. Cool flue gases
7. Barometric damper not properly set, sticking or in wrong location
8. Oil furnace and fireplace chimney interconnected
9. Heat exchanger passages plugged
10. Overfired furnace
11. Improper air shutter adjustment
1. Bad coupling alignment
2. Air in oil supply line (use only good flare fittings)
3. Tank hum on two-pipe system and inside tank
24
Oil Pump Pressure Problems And
Their Possible Causes
Complaint
Excessive Pressure
Insufficient Pressure
Fluctuating Pressure
No Pressure
Check for:
1. Bypass plug in place with a single oil line system
2. Return oil line on two-pipe system clogged, kinked or restricted
3. Pressure regulating valve stuck
4. Oil too heavy
5. Improper pump setting
1. Nozzle size beyond rated pump pressure
2. Pump vapor bound due to high oil line vacuum
3. Nozzle badly worn
4. Pump gears worn
5. Suction line kinked, clogged or restricted
6. Pressure regulating valve worn or stuck in operating position
7. Dirty strainers
8. Dirty line filter
9. Motor does not come up to speed
10. Bad air leak at seal
11. Improper pump setting
1. Pump gears worn
2. Vertical oil lift too great (over 10 feet)
3. Pump strainer or oil line filter partially clogged
4. Bypass plug not in place with two line system
5. Pump vapor bound due to high vacuum
6. Faulty foot or check valve
7. Suction line too small
8. Sticky pressure regulating valve
9. Motor coupling grabbing
1. Pump air bound
2. Loose coupling
3. Oil tank empty
4. Strainer or filter completely clogged
5. Suction line completely restricted
6. Air leaks in suction line
7. Gears badly worn and pump cannot create vacuum to lift oil
8. Badly leaking pump or filter seal
9. Wrong pump rotation
10. Tank vent clogged
25
FURNACE ADJUSTMENT CHECK SHEET
Customer’s Name Date:
Address
Furnace Model #
Serial #
Nozzle Size/Angle/spray pattern gal./hr.
/
°
/ pattern
Electrodes Adjusted
Nozzle Oil Pressure p.s.i.g.
Overfire Draft inches negative H2O
Breech Draft inches negative H2O
Chimney Draft inches negative H2O
Smoke Reading
%CO
2
%CO
2
Stack Temperature degrees F.
Room Temperature degrees F.
Net Stack Temperature degrees F.
Burner Efficiency
Supply Air Temperature degrees F.
Return Air Temperature degrees F.
Supply Air Temperature Rise degrees F.
Air Band / Air Shutter settings
Installer’s signature
HEATING AND COOLING CONTINUOUS LOW SPEED BLOWER SCHEMATICFIGURE 38
FOR MODELS WITH UTEC 1012-925 INTEGRATED FURNACE CONTROL
26
27
PARALLEL WIRING UPFLOW OIL FURNACES SCHEMATIC
28
HEATING AND COOLING CONTINUOUS LOW SPEED BLOWER SCHEMATICFIGURE 38
29
FIGURE 38
FOR MODELS WITH UTEC 1012-925 INTEGRATED FURNACE CONTROL
303132 CM 898
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