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OIL-FIRED CENTRAL FURNACE
Installation, Operation, and Service Manual
With Users Information Section
Models:
VC-CBP VLF-DBP VLR-DBP VLF-DCP VLR-DCP
WARNING: IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR
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EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF
THIS OR ANY OTHER APPLIANCE.
WARNING: IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE, OR MAINTENANCE CAN
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CAUSE INJURY OR PROPERTY DAMAGE. REFER TO THIS MANUAL. FOR ASSISTANCE OR ADDITIONAL
INFORMATION CONSULT A QUALIFIED INSTALLER, OR SERVICE AGENCY.
AVERTISSEMENT: SI L'INFORMATION DANS CES INSTRUCTIONS N'EST PAS SUIVI À LA LETTRE, UN
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INCENDIE OU UNE EXPLOSION ENTRAÎNANT DES DOMMAGES MATÉRIELS, DES BLESSURES
CORPORELLES OU DES PERTES DE VIE.
NE PAS ENTREPOSER NI UTILISER D'ESSENCE OU AUTRES VAPEURS ET LIQUIDES INFLAMMABLES À
PROXIMITÉ DE CET APPAREIL OU DE TOUT AUTRE APPAREIL.
AVERTISSEMENT: UNE MAUVAISE INSTALLATION, D'AJUSTEMENT, DE LA MODIFICATION,
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D'ENTRETIEN OU DE MAINTENANCE PEUVENT CAUSER DES BLESSURES OU DOMMAGES MATÉRIELS,
REPORTEZ-VOUS À CE MANUEL POUR OBTENIR DE L'AIDE OU DES RENSEIGNEMENTS
SUPPLÉMENTAIRES, CONSULTER UN INSTALLATEUR QUALIFIÉ, OU ORGANISME DE SERVICE.
PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE
PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE USER
AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.
VEUILLEZ LIRE CES INSTRUCTIONS AVANT L'INSTALLATION, LES PREMIERS TIRS, ET AVANT
D'EFFECTUER TOUT ENTRETIEN OU MAINTENANCE. CES INSTRUCTIONS DOIVENT ÊTRE LAISSÉS AVEC
L'UTILISATEUR ET DEVRAIT ÊTRE CONSERVÉ POUR RÉFÉRENCE FUTURE PAR UN TECHNICIEN
QUALIFIÉ.
THERMO PRODUCTS, LLC.
PO BOX 237
DENTON, NC 27239
PHONE: 800-476-4328
MO-554 Made in USA
ECN 5665-MA 210201
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Contents
SECTION PAGE
Notice to the Installer .................................................................................................. 3
INSTALLATION GUIDELINES ...................................................................................... 4
Codes ................................................................................................................. 4
Installation Location ............................................................................................ 4
Closet and Alcove Installation ............................................................................. 5
Standard Clearances .......................................................................................... 5
Air for Combustion and Ventilation ..................................................................... 6
Chimney Inspection ............................................................................................ 8
Flue / Chimney / Vent Connector ........................................................................ 8
Power (Side-Wall) Venting – Important Note Regarding ..................................... 9
Draft Regulator .................................................................................................... 8
Duct Work and Air Conditioning .......................................................................... 10
Air Filter Mounting ............................................................................................... 10
Electrical Connections ........................................................................................ 11
Room Thermostat ............................................................................................... 11
Combustion Chamber ......................................................................................... 11
Oil Burner and Oil Nozzle Installation .................................................................. 12
Fuel System Installation ....................................................................................... 13
Horizontal / Counterflow Furnace Setup ............................................................. 14
INITIAL OPERATION OF THE FURNACE .................................................................... 15
Initial Burner Operation ....................................................................................... 15
Supply/Return Airflow and Air Temperature ........................................................ 15
Furnace Limit and Blower Controls ..................................................................... 16
Room Thermostat ............................................................................................... 16
Instructions to Our Customer / End User ............................................................. 16
SERVICE ....................................................................................................................... 17
Troubleshooting .................................................................................................. 17
Flame Sensor (“Cad Cell”) Checkout Procedure ................................................ 19
Replacement Parts ............................................................................................. 19
MAINTENANCE ............................................................................................................. 19
Air Filter(s) ........................................................................................................... 19
Oil Burner ............................................................................................................ 20
Blower and Motor ................................................................................................ 20
Heat Exchanger .................................................................................................. 20
Flue and Chimney ............................................................................................... 21
USERS INFORMATION ................................................................................................. 22
Operating Instructions ........................................................................................ 22
Oil Supply ........................................................................................................... 23
Extended Shutdown ........................................................................................... 23
Combustion Air and Ventilation Supply ................................................................ 23
Inspection Areas ................................................................................................. 24
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APPENDIX A: START-UP DATA SHEET ..................................................................... 25
APPENDIX B: ELECTRICAL DIAGRAMS ..................................................................... 26
APPENDIX C: SPECIFICATION SHEETS .................................................................... 28
APPENDIX D: REPLACEMENT PARTS ....................................................................... 30
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Notice to the Installer
Installation of this oil-fired furnace must be performed by a qualified installer in accordance with
all local codes and authorities having jurisdiction. In the absence of local governing codes,
installation shall conform to these instructions and to the regulations of the National Fire
Protection Association’s Standard for the Installation of Oil-Burning Equipment, NFPA 31-2020,
and the National Electrical Code, ANSI/NFPA 70-2017, or the latest editions thereof.
A qualified installer, also referred to in this instruction manual as a “qualified heating
contractor”, is an individual, or agency, properly licensed and experienced to install and
service oil-burning equipment in accordance with all local codes and ordinances.
Material and Workmanship
This furnace was built with the highest quality materials and attention to workmanship.
However, omissions and defects occasionally occur. Before installing the furnace, inspect
the furnace thoroughly. If missing parts, defective material, or poor workmanship is
evident, report the model and serial numbers imprinted on the furnace rating label to
the seller for adjustment.
Packaging
A complete furnace is contained within a single package. The factory completed all
feasible assembly. However certain components including draft regulator and, if supplied,
door handle, air filter(s), and air filter rack(s), must be assembled to the furnace, or the
venting system, in the field. Refer to the assembly instructions.
Shipping Damage
If this furnace was damaged during transit, please immediately request the transportation
company inspect the furnace and issue a concealed damage report. The party
receiving the furnace should file the claim for shipping damage. Report any shipping
damage immediately.
It is absolutely essential that a damage report be obtained. If a concealed damage report
is not obtained, we cannot provide assistance in recovering your claim against the
transportation company.
Warranties
WARNING: The manufacturer of this equipment assumes no liability for any
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damages resulting from unauthorized modifications made to the furnace, or any
components thereof, or improper installation of the furnace in the field.
Furthermore, any such field modifications VOID THE WARRANTY and place
responsibility for safe and reliable operation of the furnace on those who
performed the modification(s).
Complete and return any enclosed warranty cards. These must be on file to verify
installation dates for replacement of any warrantied part(s).
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Codes
All local codes and regulations take precedence over the instructions in this manual and
shall be followed accordingly. In the absence of local codes, this installation must
conform to these instructions and to the regulations of the National Fire Protection
Association (NFPA) publications, the Standard for the Installation of Oil-Burning
Equipment, NFPA 31-2020, and the National Electrical Code, ANSI/NFPA 70-2017 or the
latest editions thereof,
Installation Location
WARNING:
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These furnaces are designed for indoor installation ONLY.
These furnaces are NOT to be used as construction heaters.
DO NOT hang the horizontal / counterflow furnace from a structure, or
surface, by any integral part or fastener of the furnace. The furnace was
not designed to support itself in this manner.
In as much as practical, the furnace should be positioned near a chimney or vent and
should be centralized with respect to the air distribution system.
For a utility room installation, the entrance door must be wide enough to permit the
largest part of the furnace to pass through the doorway or allow sufficient clearance to
permit the replacement of another appliance, e.g. a water heater, in the room.
If the furnace is installed in a residential garage, it must be installed so the burner is
located higher than 18 inches above the floor, unless the required combustion air is taken
from the exterior of the garage. Also, the furnace must be located or protected to avoid
physical damage from impacts by vehicles.
It is recommended that a commercially available CO alarm be installed in conjunction
with any fossil fuel burning appliance. The CO alarm shall be installed according to the
alarm manufacturer’s installation instructions and be listed in accordance with the latest
edition of the UL Standard for Single and Multiple Station Carbon Monoxide Alarms, UL
2034, or the CSA International Standard, Residential Carbon Monoxide Alarming
Devises, CSA 6.19.
The furnace shall not be operated in a condition where the return air is consistently below
55°F.
Lowboy furnace models must rest on sturdy, stable, and level surfaces.
The horizontal / counterflow model may be mounted on a level surface, as described
above, or it may be suspended from an overhead structure or surface. If this model is
suspended from hanger rods, support the furnace from the bottom casing surface at
three (3) places, across both ends of the casing and across the casing, near the middle
of the furnace. Generally, a simple support frame for the furnace can be fabricated from
INSTALLATION GUIDELINES
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structural steel angle, threaded steel rod, and fastener hardware, refer to Figure 1. Adjust
the height of the support angles to level the unit in position.
Figure 1: Recommended Support Frame for Horizontal / Counterflow Furnaces
Closet and Alcove Installation
All furnace models may be installed in a closet or alcove on combustible flooring with
specified (standard) clearances to combustible construction. The horizontal /
counterflow furnace model requires an optional combustible surface-mounting
base (model # VC-BASE) for vertical installation (i.e., counterflow configuration)
directly on combustible materials, refer to Figure 2.
Figure 2: Counterflow Furnace Combustible Surface-Mounting Base
Standard Clearances
Standard clearances are mandatory minimum clearances from heated surfaces of the
furnace to combustible materials to assure protection from fire hazard during furnace
operation. (Refer to the Standard for the Installation of Oil-Burning Equipment, NFPA 312020, or latest edition, for definitions of combustible and non-combustible materials.
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Accessibility clearances, which are typically greater, may exceed fire protection
clearances. Therefore, consider providing at least 24 inches of clearance from the front
and the rear, for lowboy furnaces) of the furnace to obstructions and surfaces for
adequate service and maintenance access.
The minimum clearances from furnace casing surfaces to combustible materials are:
3 inches from casing sides and rear
8 inches from front casing of furnace
o the lowboy rear flue model only requires 3 inches
o the horizontal / counterflow furnace requires 22 inches
9 inches from flue pipe/vent connector
3 inches from casing top
3 inches from any side of supply air plenum
3 inches above supply air ducts, within 6 feet of furnace
For the horizontal / counterflow furnace only, when the optional combustible
floor base is used with the furnace in the counterflow configuration, adequate
clearances from the supply end surface of the furnace casing to combustible
surfaces are provided by the design of the mounting base.
Air for Combustion and Ventilation
CAUTION: Relief openings in the front or top of the furnace casing should not
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be obstructed or blocked. These openings supply combustion and ventilation air
to the furnace.
Chloride, fluoride, iodide, and bromide bearing compounds when present, even in low
concentrations, are in air supplied for combustion to the furnace, can result in accelerated
and severe corrosion of the heat exchanger and/or the venting system.
Often, household chemicals contain chloride-bearing compounds. There are many
compounds representative of this classification of chemicals. A few common examples
are listed below.
Cleaning solvents
Varnish and paint removers
Bleaches
Fabric softeners
Water softener salt
Tile adhesives
Avoid storing or using these chemicals within close proximity to the furnace. In addition,
avoid storing or using any chemicals, of an unknown and possibly flammable nature, in
close proximity to the furnace.
The furnace shall be installed in a location within the building that permits a satisfactory
supply of air for combustion, ventilation, and proper operation of the venting system.
While all forms of building construction cannot be covered in detail in this manual, this
requirement may usually be met by application of one of the following methods in
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ordinary building construction. However, applicable local installation codes always take
precedence and shall be followed.
The content of certain pertinent passages of NFPA 31-2001 on methods to obtain and
ensure adequate airflow to the furnace has been excerpted and, in some cases,
paraphrased below for reference purposes. Consult the Standard for the Installation of
Oil-Burning Equipment, NFPA 31-2020, or latest addition for special cases and further
details.
1. Utility Room (example of a confined space)
a. In buildings of conventional construction with normal air infiltration, two (2)
permanent openings connecting to a well-ventilated crawl space, attic, or another
large, well-ventilated internal area shall be provided. Each opening shall have a
minimum free area of one (1) square inch per 1000 BTUH of total input rate (sum
of the individual appliance input rates) of all appliances to be installed in the utility
room. One opening should be located near, or in, the ceiling of the room and the
other should be located near, or in, the floor.
b. In buildings of unusually tight construction (those having 0.35 air changes per
hour, or less); provision must be made to provide sufficient air for combustion. The
following method will usually be adequate to ensure sufficient airflow into the
space.
Provide two (2) permanent openings, one (1) located within 12 inches of the floor and
one (1) within 12 inches of the ceiling, or roof, of the room. These openings shall allow for
direct exchange of air between the room and outdoors. If required, ducting between the
room and the outdoors shall be provided.
For horizontally -oriented ducts, each opening shall have a minimum free
area of one (1) square inch per 2000 BTUH of the total input rate (sum of
the individual appliance input rates) of all appliances to be installed in the
room.
For vertically -oriented ducts, the minimum free area may be reduced to
one (1) square inch per 4000 BTUH of the total input rate (sum of the
individual appliance input rates) of all appliances to be installed in the room.
The minimum dimension of any air opening shall not be less than 3-inches.
When an opening in the outside wall must be provided, it should be
furnished with properly screened metal sleeves.
2. Full Basement (example of an unconfined space)
a. Where a furnace is installed in a full basement, in a building of conventional
construction with normal air infiltration, infiltration is normally adequate to
provide air for combustion and ventilation.
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b. In buildings of unusually tight construction (such as those where weather
stripping and storm sash windows are used, and where basement windows are
also weather-stripped), one (1) permanent opening connecting to a wellventilated attic, or with the outdoors shall be provided, using a duct, if
necessary. This opening shall have a minimum free area of one (1) square inch
per 5000 BTUH of total input rate (sum of the individual appliance input rates)
of all appliances to be installed in the basement.
When an opening in the outside wall must be provided, it should be furnished with
properly screened metal sleeves.
If an exhaust fan or additional air consuming machines (e.g. a cloth dryer), is present in
the furnace room, there should be increased concern about providing adequate airflow to
the furnace. Additional efforts may be required to assure an adequate supply of
combustion and ventilation air is available to the furnace under all conditions.
Chimney Inspection
The chimney, vent, or any passageway for the stack gases to flow to the outdoor
atmosphere is a very important part of the heating system. No furnace, regardless of the
efficiency of the design, can perform satisfactorily when the chimney to which it is
connected is inadequate or in poor condition. Any of the following symptoms may indicate
a chimney has severe structural damage and is unsuitable for use.
Chimney appears to be leaning to the side.
Chimney appears to have structural damage, i.e. loose or missing blocks or bricks,
or excessive deterioration at mortar joints.
Tile liner damaged or missing.
Flue gas leakage along the length of the chimney between the chimney connector
and discharge termination.
Excessive corrosion at the cleanout port or at the chimney connector entrance into
the chimney.
Structural debris, i.e. mortar or tile liner flakes, in base of the flue way.
A qualified person shall inspect the chimney to confirm it is correctly sized for the
application, properly constructed, and in sound condition. Refer to the Standard for the
Installation of Oil-Burning Equipment, NFPA 31-2001, for details on proper chimney
sizing and construction. If needed, the chimney should be cleaned before installing the
furnace. Any accumulation of dirt or debris at the bottom of the flue should be removed.
Flue / Chimney / Vent Connector
CAUTION:
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DO NOT install a manual damper in the chimney or vent connector.
Thermally- activated type vent dampers are NOT recommended for use on
these furnaces.
It is desirable to install the shortest vent connector (also referred to as a flue or chimney
connector) possible with the fewest number of fittings, i.e. transitions and elbows.
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Generally, 6-inch diameter, 24 Ga. or heavier, single wall, lock seam-type, galvanized
steel vent pipe and fittings are satisfactory materials for the fabrication of a vent
connector. However, always consult local codes and authorities for specific minimum
requirements.
For some installations, it may be prudent to turn the furnace flue elbow 90 degrees
clockwise, with respect to the front of the furnace, such that the elbow is open to the
right-hand side of the unit, rather than upward. Due to the presence of the limit control
and the wiring harness, the elbow may not be rotated 90 degrees counterclockwise.
The installer must carefully mark and cut a hole in the furnace housing to allow the vent
connector to pass through the housing.
If desired, with the furnace flue elbow turned to the right, the standard furnace top front
panel (p/n 617346-2) may be replaced with the top front panel from the rear flue lowboy
model (p/n 617383-2). Refer to Appendix D: Replacement Parts for sketches of these
parts. Contact your distributor to purchase this part.
All horizontal sections of the vent connector must slope upward not less than ¼ inch per
foot from the furnace to the vent termination. Long horizontal sections of the venting
system must be supported at least every five (5) feet with metal straps to prevent sagging
of the vent piping. Secure all joints in the vent connector with sheet metal screws or
equivalent fasteners. Vent piping must not be inserted beyond the inside wall of the
chimney flue.
Power (Side-Wall) Venting – Important Note Regarding
CAUTION: Thermo Products, LLC will NOT assume responsibility for damage to,
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and deterioration of, exterior building materials, e.g. brick, siding, clapboards, and
etc., in close proximity to the vent terminal due to operation of a power vented, oil
furnace. This policy is applicable regardless of the cause of sooting.
NOTICE: Thermo Products recommends the use of a chimney to vent residential
oil furnaces. If a power venter must be used, it is the responsibility of the installer
and power venter manufacturer to design, assemble, and demonstrate proper
operation of the power venting system with the furnace.
Draft Regulator
A barometric-type, draft regulator is supplied with the furnace. Installation or operating
conditions that produce excess amounts of draft can reduce the heating efficiency of the
furnace. The purpose of the regulator is to adjust and control the flow of flue gases from
the furnace by stabilizing the amount of chimney draft to which the furnace is subjected.
Always refer to the draft regulator manufacturer’s installation instructions for application
specific recommendations.
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Duct Work and Air Conditioning
Design and installation of the duct system should follow the current guidelines of the Air
Conditioning Contractors of America (ACCA) or the American Society of Heating,
Refrigeration and Air Conditioning Engineers, Inc. (ASHRAE). Refer to the Residential
Duct Systems, Manual D, from the ACCA, and the ASHRAE Handbook Fundamentals
volume, from ASHRAE, for recommended practices in duct system design and
installation.
All furnaces are tested over a range of external static pressure that simulates the airflow
resistance of the ductwork, fittings, and diffusers connected to the furnace for a typical
(average) duct system. The furnace blower and blower motor have been selected to work
successfully against the following range of duct system resistance.
Recommended range of the duct system external static pressure for all models: 0.2
to 0.5 in. W.G...
Due to the need to maintain an adequate supply of combustion and ventilation air, the
furnace shall not be installed in small room without return air duct system. A return air
duct shall be connected to the furnace return air opening and extend to a location outside
the furnace room.
If the furnace is used in connection with a cooling coil, the coil must be installed in
parallel with, or on the supply side of the furnace to avoid water vapor condensation in
the furnace heat exchanger. If the cooling unit is installed in a parallel flow arrangement,
dampers (or other means used to control airflow) should be provided to prevent chilled air
from entering the furnace. If such a damper is manually operated, it must be equipped
with a means to prevent operation of either unit, unless the damper is placed in either the
full heat or full cool position.
NOTICE: Return air grilles and supply registers in the air distribution system
should never be obstructed.
Air Filter Mounting
Lowboy furnaces are factory-equipped with permanent-type, air filters located above the
blower compartment, in the rear of the furnaces.
NOTICE: Horizontal / counterflow furnaces are not factory-equipped with an air
filter or filter rack. Furthermore, the furnace blower compartment does not contain
enough free space to permit an air filter to be mounted within the furnace casing.
However, the installer should supply, or fabricate a filter rack and mount an air filter in the
return air plenum above, or upstream of, the furnace blower compartment.
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Electrical Connections
NOTICE: All field wiring must conform to local, state, and national installation
codes.
A disconnecting switch equipped with overcurrent protection rated at 15 A. (e.g. a time
delay-type fuse or inverse time, circuit breaker) should be installed in the service line.
Since the furnace is entirely pre-wired at the factory, it is only necessary to connect the
building electrical service lines to the two (2) pigtail wires extending from the junction box.
The junction box is mounted inside the furnace burner compartment or mounted on the
front exterior of the furnace, in the case of the horizontal / counterflow model. A ground
connection must also be made in the junction box. The service lines to the furnace
should be no smaller than 14 Ga., insulated copper wire with a temperature rating of
60ºC, or greater.
Refer to the electrical diagrams contained in Appendix B of this manual for an electrical
schematic, a connection diagram, and operating instructions.
Room Thermostat
A room thermostat must be connected to the Oil Furnace control. This is typically a low
voltage (24 VAC) circuit. Consult the National Electrical Code, ANSI/NFPA 70-2017, or
latest edition for guidelines for proper wiring methods and materials for this circuit. The
room thermostat should be located on an interior wall in the natural circulating path of the
room air.
The thermostat should not be installed in a location where it is directly exposed to,
cold air infiltration, i.e. drafts from outside openings such as windows and doors,
air currents produced by supply air registers, and
heat from a nearby source, such as a fireplace, electrical appliances, lamps, solar
radiation, a wall enclosing warm air ducts, a chimney, or a flue gas vent.
Most room thermostats are equipped with an adjustable heat anticipator, set the
thermostat heat anticipator to match the control current of the furnace as indicted on the
furnace wiring diagram.
Combustion Chamber
The furnace combustion chamber is a hollow, circular cylinder sealed at the bottom end
and open at the top end. The chamber is made of a lightweight, insulating, “soft”,
refractory material. The refractory material is composed of organically bound, aluminasilica fibers that protect the heat exchanger from the intense heat of the oil burner.
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Oil Burner and Oil Nozzle Installation
CAUTION: This oil furnace is designed to use No. 2 or lighter distillate fuel
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(home heating) oil. A Bio-fuel mixture may be used but the mixture is not to exceed
a B5.
This furnace is designed to utilize the following specially modified, oil burner:
R.W. Beckett Corp. model AFG burner, specification # EFL-401
Carlin Combustion Technology, Inc. model EZ-1HP, specification 99032D
NOTICE: NO other burners may be used in this application.
The heat output from the furnace is fixed, based on the size of nozzle installed in the oil
burner. Four (4) heat input rates are permissible: 85,000, 105,000, 120,000, and 140,000
BTUH, except for the counterflow/horizontal models which can only be fired at 85,000,
105,000 and 120,000 BTUH...
Nozzle selection (i.e. heating capacity of the furnace) shall be based on a rate of heat
loss (heating load) calculation for the building. These calculations should be made
according to the manuals provided by the Air Conditioning Contractors of America
(ACCA) or the American Society of Heating, Refrigeration and Air Conditioning
Engineers, Inc. (ASHRAE).
Refer to the Residential Load Calculation, Manual J, from the ACCA, and the ASHRAE
Handbook Fundamentals volume, from ASHRAE, for the recommended procedure to
compute the design heating load of a residence.
The oil burner was installed in the furnace at the factory. In the field, if it is necessary to
adjust the heating capacity of the furnace by changing the oil burner nozzle, refer to the
oil burner manufacturer’s operating instructions (included with the furnace) for detailed
instructions on this procedure.
The furnace may have been handled roughly while in transit. Under some conditions, the
combustion chamber can shift out of position. Check for proper alignment of the burner
air tube with the circular opening in the combustion chamber and trial fit the burner to
check the insertion depth of the oil burner into the combustion chamber.
The end of the burner air tube should be inserted no farther than 1/4 inch back from the
inside surface of the combustion chamber, refer to Figure 4. Do not allow the burner
tube/end cone to physically touch or protrude into the chamber. High temperatures in the
combustion chamber can result in damage to the tube, the end cone, or both. A distance
greater than 1/4 inch back from the inside chamber wall may cause flame impingement
on the combustion chamber wall and subsequent sooting or carbon char buildup.
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Figure 3: Side view of correct burner insertion into combustion chamber
The oil burner provided with this furnace requires initial inspection, set-up, and proper
adjustment. Refer to this manual and the oil burner manufacturer’s operating instructions
for detailed information on the following items.
Initial firing of burner
Adjusting the burner combustion air
Adjusting the fuel pump pressure
Setting the draft control
NOTICE: This oil furnace must be installed and adjusted by only qualified oil
heating contractor using calibrated combustion test instruments to ensure safe
and reliable operation of the furnace.
Fuel System Installation
In situations where the oil storage tank is installed at the same level with, or above, the
burner, a single oil supply line run from the oil tank to the burner will be usually be
adequate. No return line will be required. If the oil tank is installed below the burner and
the lift exceeds approximately 6-ft., an oil supply line and an oil return line are
recommended.
Refer to the Standard for the Installation of Oil-Burning Equipment, NFPA 31-2020, or
latest edition and the oil burner operating instructions for detailed information on oil
storage tank & oil supply/return line installation.
NOTICE: We recommend installing a high efficiency oil filter, in the oil supply line,
capable of filtering 10 to 20 micron diameter (or preferably smaller) particles from
the fuel.
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Horizontal / Counterflow Furnace Setup
The horizontal / counterflow furnace is shipped from the factory upright for vertical
installation (counterflow configuration). If the furnace is to be installed lying down on the
right-hand or left-hand side (horizontal configuration), the position may have to be
changed. The horizontal furnace may be turned end for end, or rotated, making the top
into the bottom, as shown in Figure 5. Refer to the following instructions for installing the
oil burner.
Figure 4: A horizontal furnace rotated 180° (or flipped end for end) to reverse
airflow direction
1) When the furnace is installed in the horizontal configuration, the oil burner
must be mounted in an upright position. It will be necessary to cutoff one (1) of the
threaded burner-mounting studs before attempting to install the burner. Trial fit the
burner to the burner mounting plate to determine which stud to remove. (A rotary
tool with a cutting (abrasive) disk or a hacksaw should work well to remove the
stud.) A machine screw (furnished with the parts package) will substitute for the
removed stud and provide a third point to secure the burner flange to the burner
mounting plate. Thread the screw through the burner-mounting flange and into the
open hole within the burner mounting plate.
2) Install the flange gasket and the burner on the mounting plate threaded studs.
Using fasteners supplied in the parts bag with each furnace [use two (2) or three
(3) 5/16 in. brass hex nuts and flat washers, as required], secure the burner to the
mounting studs on the burner mounting plate.
3) Secure the electrical conduit of the wiring harness to the oil burner junction box
with the hardware provided.
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Initial Operation of Furnace
Initial Burener Operation:
IMPORTANT: The start-up sheet found in Appendix A of this manual should be completed.
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1. Turn the electrical disconnecting switch to the “OFF” position.
2. Set the room thermostat above room temperature.
3. Be sure the oil tank is full of clean # 2 fuel oil.
4. Open all shutoff valves in the oil line.
5. Refer to the oil burner manufacturer’s operating instructions (included with the
furnace) for detailed startup instructions
6. Measure the oil pump pressure. If required, adjust it to deliver the appropriate
pressure for the burner. The oil pump should be set to produce,
130 PSIG, for the R.W. Beckett model AFG burner
140 PSIG, for the Carlin Combustion Technology model EZ-1HP
7. Carbon Dioxide (CO2) and Carbon Monoxide (CO) – In order to assure that
proper and safe combustion are taking place, carbon dioxide and carbon
monoxide measurements must be taken. A CO2 reading within the limits of
appendix C with no measurable CO is desirable. The maximum acceptable CO
reading is about 50 PPM. If the CO reading is too high, open the burner air
shutter, or air band, slightly to permit more combustion air to the flame.
Recheck the CO level and adjust as required.
8. Draft – Draft measurements should be taken through the overfire port and in
the vent connector, not more than 12 inches away from the furnace outlet. A
5/16 in. hex washer head bolt plugs the overfire port in the burner mounting
plate. Remove the bolt and insert a suitable draft measurement gage.
9. Flue Gas Temperature – The flue gas temperature will vary depending on heat
input rate, air temperature rise across the heat exchanger, and air flowrate
through the furnace. To prevent excessive water vapor condensation from the
flue gases, the gross flue gas temperature should not fall below 330ºF. In
addition, if the gross flue gas temperature exceeds 650ºF, the heating
efficiency of the furnace will be reduced.
10. Cycle the furnace several times to verify the burner lights off and shuts down
smoothly without excessive noise or smoke production.
Supply/Return Airflow and Air Temperature
The supply/return airflow shall be set to obtain an air temperature rise, across the
furnace, in the range of 55º to 85ºF for the lowboy models. The range for the
counterflow/horizontal furnace for inputs of 85,000 and 120,000 BTUH shall also be 55º
to 85ºF. The range for the 105,000 BTUH (as shipped) counterflow/horizontal shall be
47º to 77ºF. Since the flow resistance of each duct system is slightly different, the airflow
(fan speed) may have to be changed in the field to achieve a satisfactory temperature
rise.
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Page 18
The blower (fan) speed is adjusted by changing the fan motor winding energized by the
control system. The furnace is set on the med-low fan speed, “ML”, at the factory; refer to
furnace wiring diagram, Appendix B. To adjust the fan speed, follow this procedure.
a. Turn off all electrical power to the furnace at the disconnecting switch.
b. Remove the blower compartment access door on the counterflow/horizontal
furnace.
c. The “Heat” tab is the connection for the heating speed activation thru the fan
board. If a change in heating speed is desired simply pull the blue (ML) wire from
the heat tab and replace it with the yellow (MH) wire. This changes the speed
from medium-low to medium-high. Black (High) is connected to the “cool” tab for
A/C speed operation. If a lower speed is desired for A/C, the speed is charged the
same way. A tab marked “Low” is populated with a lower fan speed for continuous
fan operation thru the “G” circuit of your T-stat. Unused blower speeds are
connected to the “unused motor leads” tabs at bottom right of fan board.
d. Replace the blower compartment access door on the counterflow/horizontal unit.
e. Restore electrical power to the furnace at the disconnecting switch.
f. Recheck Temperature rise and adjust if needed.
Furnace Limit and Blower Controls
The control also has diagnostic features. A green light will illuminate under the
thermostat terminal that is being activated. Also any time the board receives a call from
the thermostat a red light near the center of control will illuminate.
If a limit switch opens the red light will flash, power will be interrupted to the Buner and
the circulating air blower will be energized. The blower will continue to run and the burner
will remain de-energized until the limit closes and the blower off delay expires.
! WARNING: The predetermined fan and limit locations on all of the Thermo Pride oil
fired furnaces have been tested and approved by Thermo Products, LLC. Any
attempt to relocate these safety controls or replace these safety controls with a
control that is not approved, or is incompatible, may result in personal injury,
substantial property damage or death.
Instructions to Our Customer / End User
! WARNING: If the burner does not operate properly after depressing the oil
primary reset button, turn off the electrical power to the furnace and close the
manual oil shutoff valve. Immediately contact a qualified heating contractor for
service.
Before leaving a new installation, the installer should show the customer or end user
where the furnace instruction manual is kept. He should also discuss the following points:
1) Describe the general operation of the furnace and, if properly equipped, the
cooling system.
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Page 19
2) Show the location of the furnace air filter(s) and those in the duct system, if
equipped. Demonstrate how to remove, clean, and replace the air filter(s).
3) Demonstrate how to set and adjust the room air temperature using the room
thermostat.
4) Demonstrate how to operate (turn on and off), the heating system and, if properly
equipped, the cooling system and the circulating air blower.
5) Show the location of the oil primary safety control in the furnace. Describe when
and demonstrate how to depress the oil primary reset button.
SERVICE
Troubleshooting
WARNING: When testing electrical equipment, always follow standard electrical
c
safety procedures.
Before beginning these troubleshooting procedures, always review these basic points.
1) Check for 120 VAC power to the furnace. If there is no voltage, check the
disconnecting switch for circuit breaker trip or blown fuses.
2) Make sure the room thermostat is set on the heating mode and is “calling for heat”.
3) Check for sufficient oil supply and that all oil shutoff valves are open.
4) To successfully service this oil furnace, the following recently (within the last year)
calibrated instruments must be available.
5) Be familiar with the correct operation of these instruments as well as how to adjust
the oil burner settings (refer to burner manufacturer’s literature).
A. Symptom: Furnace does not operate.
Items to check:
WARNING: Repeated operation of the oil primary safety control reset
c
button can cause a build-up of unburned oil in the combustion chamber. An
accumulation of oil in the combustion chamber is a hazardous situation and
may cause a fire or explosion.
Smoke spot test kit with Bacharach-type oil burner smoke scale
Carbon dioxide (CO2) and carbon monoxide (CO) test kit or analyzer
Flue gas temperature measuring instrument
Draft gauge, capable of measuring 0.01 to 0.25 in. W.G. draft
Multimeter (analog or digital type)
Oil pressure gauge, capable of measuring at least 0 to 200 PSIG
1) Make sure the disconnecting switch is “ON” and the circuit breaker has
not tripped, or fuses have not blown.
2) Confirm there is 120 VAC at the junction box and the oil furnace control
terminal S1.
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Page 20
3) Confirm the room thermostat is wired correctly, set on the “HEAT” mode,
and “calling for heat”.
4) Refer to the oil burner manufacturer’s operating instructions (included
with the furnace) for primary control troubleshooting
B. Symptom: Burner short cycles on high limit thermostat, but does not “lock out”
on oil primary safety control.
Items to check:
1) Open dampers or registers in the air distribution system. Clear any duct
system restrictions.
2) Inspect and clean all air filters in the air distribution system.
3) Inspect blower for interference with rotation or locked rotor condition.
Also, confirm the blower wheel is secured to the fan motor shaft.
4) The fan motor or run capacitor may be damaged. Test and replace the
motor or capacitor, as required.
5) Increase fan speed.
C. Symptom: Burner short cycles on high limit thermostat, but does not
“lock out” on oil primary safety control.
Items to check:
1) Open dampers or registers in the air distribution system. Clear any duct
system restrictions.
2) Inspect and clean all air filters in the air distribution system.
3) Inspect blower for interference with rotation or locked rotor condition.
Also, confirm the blower wheel is secured to the fan motor shaft.
4) The fan motor or run capacitor may be damaged. Test and replace the
motor or capacitor, as required.
5) Increase fan speed.
6) Measure the draft at the point where the vent connector attaches to the
heat exchanger flue pipe. With the burner operating, the stack draft
should not exceed 0.05 in. W.G. If the stack draft has been adjusted
above this value to give the proper overfire draft, the heat exchanger will
require cleaning. If there is little or no stack draft, the chimney flue way
may require cleaning, the chimney is too restrictive, or a downdraft
condition exists.
D. Symptom: Furnace blower will not start.
Items to check:
1) Confirm there is 120 VAC at the blower terminal labeled “HEAT” on the
oil furnace control.
2) If there is not 120 VAC at the blower motor terminal, measure the
voltage at the S1 terminal on the oil furnace control. If the fan can be
activated by itself from the room thermostat subbase, confirm it will
operate. If so, the oil furnace control may have a burnt or damaged
relay. Confirm and replace the control if necessary.
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Page 21
3) If there is 120 VAC at the blower motor terminal “HEAT”, either the run
capacitor or blower motor may be damaged. Test and replace the
capacitor or motor, as required.
E. Symptom: Blower cycles on and off after the burner has shutdown.
Item to check:
1) Increase the fan off time by changing the DIP switch selections on SW2.
Refer to Table 2 for blower delay off settings.
NOTICE: If the high limit control is faulty, it should be replaced. However, it must
only be replaced by the same make and model as the original. Refer to the
electrical diagrams for proper electrical connections.
Flame Sensor (“Cad Cell”) Checkout Procedure
Refer to the oil burner manufacturer’s operating instructions (included with the furnace)
for detailed cad cell troubleshooting.
Replacement Parts
Appendix D of this manual contains a list of replacement parts available for these
furnaces.
MAINTENANCE
Air Filter(s)
CAUTION: To avoid injury from moving parts, hot surfaces, or electrical shock,
c
shut off the power to the furnace and allow the furnace to cool BEFORE removing
any furnace access doors to service air filters.
Lowboy furnace models are factory-supplied with a permanent-type, air filter. At least
twice a year, remove the air filter(s) for cleaning. Clean a filter by soaking it in water with
a mild detergent and then rinsing it with clean water. Allow the filter to air dry before
reinstalling it in the furnace filter rack.
If the furnace, or duct system, is equipped with disposable-type (paper element), air
filters, inspect them every month for an excessive accumulation of dust and dirt. Replace
disposable air filters at least twice a year. Make certain the replacement filter is the same
size as the one being replaced. The filter size is marked on the outer edge of the air filter.
Install the filter with the arrow marked on the filter pointing toward the furnace.
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Page 22
Oil Burner
NOTICE: A qualified heating contractor MUST service the oil burner in this furnace
at least once a year.
Generally, service to the burner will involve a thorough inspection and cleaning of the
burner, replacement of the oil nozzle and oil filter, and readjustment of the burner to
achieve proper ignition and clean combustion.
Blower and Motor
NOTICE: The fan motor has sealed bearings that do NOT require lubrication.
The blower and fan motor will not normally require any service. This furnace is equipped
with a directly-driven blower. Therefore, it will not require any retensioning or
replacement of a drive belt.
Heat Exchanger
CAUTION: DO NOT attempt to clean the heat exchanger unless electrical power
c
and fuel flow to the furnace are turned off and the furnace is at room temperature.
CAUTION: The combustion chamber refractory material is fragile and can be
c
easily damaged. If the inner radiator of the heat exchanger is cleaned, avoid
scraping or hitting the walls of the combustion chamber.
CAUTION: Do not brush or scrape the surface of the combustion chamber. It can be
easily damaged.
NOTICE: A qualified heating contractor MUST inspect the heat exchanger in this
furnace at least once a year. If heavy deposits are found, immediate cleaning is
required.
All heat exchanger surfaces should be as clean as possible for the most efficient
operation of the furnace. The heat exchanger may require cleaning after every heating
season, as combustion of fuel oil tends to produce soot, particulate matter, and scale,
due to corrosion.
NOTICE: Accumulation of heavy soot deposits over one heating season may
indicate the oil burner is out of adjustment.
The heat exchanger may be inspected and cleaned through an access, or cleanout, port
located in the burner compartment, on lowboy models, or immediately behind the front
casing panel, on the horizontal/counterflow model. The cleanout port consists of a 4-inch
diameter stamped steel cap. The cap is retained by a single T-bolt through a circular
opening located in the outside wall of the heat exchanger, refer to Figure 8.
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Page 23
Figure 5: Location and Design of the Lowboy Heat Exchanger Cleanout Port
Using a screwdriver, remove the screws retaining the trim panel covering the cleanout
port. With a wrench, or a ratchet with a deep-well socket, loosen the nut retaining the Tbolt and the cap to the heat exchanger. Carefully, remove the T-bolt, nut, gasket, and the
cap from heat exchanger. Loosen and remove as much debris as possible.
The heat exchanger should also be cleaned through the flue pipe connection. Carefully
remove the vent connector and the heat exchanger flue pipe to inspect and clean the
heat exchanger.
Flue and Chimney
At least once a year, thoroughly inspect the heat exchanger flue pipe, the vent connector,
the chimney, or vent, and the barometric damper for signs of sagging, loose connections,
excessive corrosion, and deterioration. Clean, repair, or replace any components for
continued safe and proper operation of the furnace.
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Page 24
USERS INFORMATION
c
IMPORTANT: This furnace must be serviced annually by a licensed professional
technician, or equivalent.
WARNING:
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The area around the furnace should be kept free and clear of flammable vapors,
liquids, and material, especially papers and rags.
NEVER burn garbage or refuse in the furnace. NEVER try to ignite oil by tossing
burning papers or other material into the furnace.
This oil furnace is designed to burn No. 2 distillate fuel (home heating) oil ONLY.
NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE.
DO NOT attempt to make repairs to the furnace yourself!
Operating Instructions
For your safety, read this information before operating this furnace.
WARNING: Failure to follow these instructions may result in fire or explosion
c
causing property damage, personal injury, or loss of life.
WHAT TO DO IN THE EVENT OF AN OIL LEAK:
Do not try to operate this or any other nearby appliance.
If present, close the manual oil shutoff valve on the fuel oil supply line.
Immediately call a qualified heating contractor for service.
If you cannot reach a qualified heating contractor, call the fuel oil supplier or the
fire department.
DO NOT use this furnace if any component was underwater. Immediately call a qualified
heating contractor to inspect the furnace and replace any part of the furnace control
system that was underwater.
This furnace does not have a pilot light. It is equipped with an electronic ignition system
that automatically lights the burner. DO NOT attempt to light the burner by hand.
TO OPERATE THIS FURNACE:
1) Adjust the room thermostat to the lowest set point and set the operating mode, if
equipped, to “OFF”.
2) Turn the manual oil shutoff valve to the open or “ON” position.
22
Page 25
3) This furnace is equipped with an electronic ignition system that automatically lights
the burner. DO NOT try to light the burner by hand.
4) Turn on the electric power to the furnace at the disconnecting switch.
5) Adjust the room thermostat to the desired set point and set the operating mode, if
equipped, to “HEAT”.
6) If the furnace will not operate, call a qualified heating contractor for service.
TO INTERRUPT (STOP) OPERATION OF THIS FURNACE:
1) Adjust the room thermostat to the lowest set point and set the operating mode, if
equipped, to “OFF”.
2) If service will be performed, turn off all electric power to the furnace at the
disconnecting switch.
3) Turn the manual oil shutoff valve to the closed or “OFF” position.
Oil Supply
This oil furnace is designed to use No. 2 or lighter distillate fuel (home heating) oil. A Biofuel mixture may be used but the mixture is not to exceed a B5.
DO NOT allow the fuel tank to run completely dry during the heating season. If the
fuel tank runs completely dry, it may be necessary to purge the oil lines of trapped air.
I
During the warmer weather, keep the tank full to prevent condensation of moisture
on the inside surface of the tank.
Keep the cap on the fuel tank fill pipe tightly closed at all times to prevent the
entrance of moisture, foreign matter, insects, etc. Also, check the tank, vent, and fill
pipe for cracks and leaks.
Extended Shutdown
If the furnace will be shut down for an extended period of time:
1) Adjust the room thermostat to the lowest set point and set the operating mode, if
equipped, to “OFF”.
2) Open the disconnecting switch serving the furnace.
3) Close the manual oil shutoff valve.
Combustion and Ventilation Air Supply
The furnace and venting system require a generous amount of clean air to operate
safely. Lack of adequate combustion and ventilation air can result in erratic operation of
the burner, noisy and poor combustion, sooting of the combustion chamber, and fuel
odors in the air. Never block off or restrict the supply of air to the furnace.
23
Page 26
Inspection Areas
Burner Compartment: On the lowboy furnace models, the burner compartment can be
inspected by removing the front door of the furnace. Look for signs of excessive heat,
such as discoloration of components, damage to material from rust or corrosion, soot or
carbon build-up, and evidence of fuel oil leakage.
Exterior of Furnace: The exterior of the furnace should be inspected for signs of
excessive heat such as discoloration of materials and damage from rust or corrosion.
Confirm the base or frame supporting the furnace in level and in sound condition.
Venting System: The furnace flue pipe, vent connector, barometric damper, and
chimney should be inspected for:
Signs of excessive rust, corrosion pitting, and holes.
Signs of condensation or moisture leakage.
Evidence of structural damage, and loose or disconnected piping joints.
Presence animal nests.
Free movement of the vane of the barometric damper without binding or
interference.
If any problems are evident, call a qualified heating contractor for assistance.
NOTICE: A qualified heating contractor MUST service the oil burner and inspect
the heat exchanger in this furnace at least once a year.
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Page 27
INITIAL
SERVICE
SERVICE
SERVICE
DATE
TEST
Operate burner
NOZZLE (GPH/ANGLE/CONE)
PUMP PRESS (PSI)
CHECK FOR LEAKS
TECHNICIAN
ROOM TEMP (°F)
EFFICIENCY (%)
SUPPLY TEMP (°F)
RETURN TEMP (°F)
TEMP RISE (°F)
CO2 (%)
O2 (%)
GROSS FLUE TEMP (°F)
FURNACE SERIAL
TYPE OF VENTING & OIL SYSTEM (CHECK ALL THAT APPLY)
VENTER
□
DIRECT VENT
□
COMBUSTION AIR KIT
□
CLAY LINER
□
METAL LINER
MECANICAL ROOM
CO (PPM)
SMOKE NO.
APPENDIX A: STARTUP SHEET
Combustion and Efficiency Testing for Spirit Oil Fired Furnaces:
Complete this form for each Spirit furnace installed. Read instruction manual carefully before
taking test. Retain this form with furnace.
NAME
CUSTOMER
ADDRESS
CITY, STATE
FURNACE MODEL
BURNER MODEL NO.
HEATING
SYSTEM
□
MASONRY CHIMNEY
□ METAL CHIMNEY
□
SIDEWALL POWER
□
MAKE UP AIR TO
□
DRAFT CONTROL
□
FUEL FILTER
□
2 PIPE SYTEM
COMBUSTION
DRAFT -BREECH (IN W.C.)
DRAFT - OVERFIRE (IN W.C.)
for at least 10
min. before
taking
readings.
SAFTEY CONTROL OPERATION
INSTALLER
NAME ADDRESS
PHONE
25
Page 28
For your safety, read this info rmation before operating this
furnace.
WARNING: Failure to follow these instructions may
result in a fire or explosion causing property damage,
personal injury, or loss of life.
WHAT TO DO IN THE EVENT OF AN OIL LEAK:
Do not try to operate this or any other nearby appliance.
Immediately call a qualified heating contractor for service.
If you cannot reach a qualified heating contractor, call the
fuel oil supplier or the fire department.
DO NOT use this furnace if any component was underwater.
Immediately call a qualified heating contractor to inspect the
furnace and replace any part of the furnace control system
that was underwater.
This furnace does not have a pilot light. It is equipped with
an ignition system that automatically lights the burner. DO
NOT attempt to light the b urner by hand.
TO OPERATE THIS FURNACE:
26
1. Adjust the room thermostat to the lowest setpoint and set
the operating mode, if equipped, to "OFF",.
2. Turn off all electric powe r to the furnace at the
disconnecting switch.
3. Rotate the manual oil shutoff valve to the open or on
position.
4.This furnace is equipped with an electronic ignition system
that automatically lights the burner. DO NOT try to light the
burner by hand.
5. Turn on the electric power to the furnace at the
disconnecting switch.
6. Adjust the room thermostat to the desired setpoint and set
the operating mode, if equipped, to "HEAT".
7. If the furnace will not operate, call a qualified heating
contractor for service.
TO INTERRUPT (STOP ) OPERATION OF THIS FURNACE:
1. Adjust the room thermostat to the lowest setpoint and set
the operating mode, if equipped, to "OFF".
2. If service will be performed, turn off all electrical power to
the furnace at the disconnecting switch.
3. Turn the manual oil shutoff valve to the closed or off
position.
VLF-DBP, VLR-DBP, VLF-DCP, VLR-DCP Models
APPENDIX B: ELECTRICAL DIAGRAMS
NOTES:
1. USING WIRENUTS, CONNECT POWER SUPPLY WIRE L1 TO PIGTAIL MARKED "1" AND WIRE L2 TO
PIGTAIL MARKED "2" IN J-BOX. CONNECT AN EARTH GROUNDING WIRE TO GROUND WIRE
TERMINAL IN J-BOX.
2. IF ANY ELECTRICAL WIRING MUST BE REPLACED, NEW WIRING MUST HAVE AN INSULATION TYPE
RATED FOR 105°C OR GREATER.
3. USE ONLY COPPER CONDUCTORS FOR ALL FIELD AND REPLACEMENT WIRING.
4. FOR ADEQUATE OVERCURRENT PROTECTION, MAXIMUM ACCEPTABLE SIZE TIME DELAY TYPE
FUSE OR INVERSE TIME CIRCUIT BREAKER REFER TO NAME PLATE.
5. TYPICAL ROOM THERMOSTAT ANTICIPATOR SETTING IS 0.2 A.
WARNING: DUE TO SHOCK AND FIRE HAZARD, CLASS 2 HEATING AND COOLING CIRCUITS MUST
REMAIN SEPARATED.
Page 29
For your safety, read this information before operating this
furnace.
WARNING: Failure to follow these instructions may
result in a fire or explosion causing property damage,
personal injury, or loss of life.
WHAT TO DO IN THE EVENT OF AN OIL LEAK:
Do not try to operate this or any other nearby appliance.
Immediately call a qualified heating contractor for service.
If you cannot reach a qualified heating contractor, call the
fuel oil supplier or the fire department.
DO NOT use this furnace if any component was underwater.
Immediately call a qualified heating contractor to inspect the
furnace and replace any part of the furnace control system
that was underwater.
This furnace does not have a pilot light. It is equipped with
an ignition system that automatically lights the burner. DO
NOT attempt to light the burner by hand.
TO OPERATE THIS FURNACE:
1. Adjust the room thermostat to the lowest setpoint and set
the operating mode, if equipped, to "OFF",.
2. Turn off all electric power to the furnace at the
27
disconnecting switch.
3. Rotate the manual oil shutoff valve to the open or on
position.
4.This furnace is equipped with an electronic ignition system
that automatically lights the burner. DO NOT try to light the
burner by hand.
5. Turn on the electric power to the furnace at the
disconnecting switch.
6. Adjust the room thermostat to the desired setpoint and set
the operating mode, if equipped, to "HEAT".
7. If the furnace will not operate, call a qualified heating
contractor for service.
TO INTERRUPT (STOP) OPERATION OF THIS FURNACE:
1. Adjust the room thermostat to the lowest setpoint and set
the operating mode, if equipped, to "OFF".
2. If service will be performed, turn off all electrical power to
the furnace at the disconnecting switch.
3. Turn the manual oil shutoff valve to the closed or off
position.
VC-CBP Model
NOTES:
1. USING WIRENU TS, CONNECT POWER SUPPLY WIRE L1 T O PIGTAIL MARKED "1" AND WIRE L2 TO
PIGTAIL MAR KED "2" IN J-BOX. CONNECT AN EART H GROUNDING WIRE TO GROUND WIRE
TERMINAL IN J-BOX.
2. IF ANY ELECT RICAL WIRING MUST BE REPLACED, NE W WIRING MUST HAVE AN INSULATION TYPE
RATED FOR 105°C OR GREATER.
3. USE ONLY CO PPER CONDUCTORS FOR ALL FIELD AND REPLACEMENT WIRING.
4. FOR ADEQUATE OV ERCURRENT PROTECTION, MAXIMUM ACCEPTABLE SIZE TIME DELAY TYPE
FUSE OR INVERSE TIME CIRCUI T BREAKER REFER TO NAME PLATE.
5. TYPICAL ROOM THERMOSTAT ANTICIPATOR SETTING IS 0.2 A.
WARNING: DUE TO SHOC K AND FIRE HAZARD, CLASS 2 HEATING AND COOLING CIRCUITS MUST
REMAIN SEPARATED.
Page 30
VLF-DCP (Front Flue) or
VLF-DBP (Front Flue) or
APPENDIX C: SPECIFICATION SHEETS
MODEL NO.
HEAT INPUT RATE (BTUH)
OUTPUT BTUH [1]
SEASONAL EFFICIENCY (% AFUE)[2]
LARGEST REC A/C (Tons)
NOMINAL TEMP RISE (° F)
HEAT EXCHANGER AREA (SQ. FT.)
CASING HEIGHT (IN.)
CASING WIDTH (IN.)
CASING DEPTH (IN.)
NOMINAL FLUE OUTLET DIA. (IN.)
APPROX SHIPPING WEIGHT (LBS)
APPROVAL AGENCY
QTY AND SIZE OF PERMANENT
FILTERS (IN.)
ELECTRICAL REQUIREMENTS
TOTAL CURRENT (AMPS)
MAX FUSE SIZE (AMPS)
HEIGHT, FLOOR - CENTER OF FLUE
SUPPLY AIR OUTLET SIZE (IN.)
RETURN AIR INLET SIZE (IN.)
BURNER MODEL
AIR TUBE LENGTH (IN.)
BURNER HEAD TYPE
HEAD POSITIONING BAR
NOZZLE (GPH)
SPRAY ANGLE (Deg.)
SPRAY PATTERN:
OIL PUMP PRESSURE (PSIG)
IGNITION CONTROL TYPE
CONTROL TIMING PRE / POST (Sec.)
COMBUSTION CHAMBER TYPE
MINIMUM CLEARACNES TO COMBUSTILBE MA TERIALS
SIDES (IN.)
TOP (IN.)
FRONT (IN.)
REAR (IN.)
FLUE/VENT PIPE (IN.)
SUPPLY PLENUM (IN.)
1 OUTPUT BTUH BASED ON ANNU AL FUEL UTILIZATION EFFICIENCY RAT ED BY MAN UFACTURER.
2 SEASONAL EFFICIENCY (ALSO CALLED AFUE - ANNU AL FUEL UTILIZATION EFFICIENCY) RA TINGS ARE BASED ON
TESTS FOLLOWING U.S. DEPARTM ENT OF ENERGY TEST PROCEDURES.
3 AF UE RATINGS AS SHIPPED AT 105,000 BTU INPUT.
VLR-DBP (Rear Flue)
140,000 119,000 105,000 84,000 140,000 119,000 105,000 84,000
114,000 98,000 88,000 70,000 114,000 98,000 88,000 70,000
85 [3] 86 [3]
4
70
27.8 (front flue) / 30.0 (rear flue)
41.5
22.25
47
6
300
ETL
(2) 10 X 20
120v / 60hz / 1ph
11.2
15
30.375"
20 W X 20 D
20 W x 12.5 D
(BECKETT AFG) (CARLIN EZ-1HP)
5.875, effective
Fixed, flam e retention
NA NA NA NA .85-1.0 0.75 .60-.65
1.00 0.85 0.75 0.60 0.85 0.75 0.65 0.55
80
Hollow (A)
130
Interrupted, Direct Spark
15 / 0 15 / 15
Preformed, refractory (ceramic fiber matrix material)
3
3
8 (front flue) / 3 (rear flue)
3
9
3
VLR-DCP (Rear Flue)
5.875, effective
60 60 60 70
Hollow (A)
140
Interrupted, Direct Spark
28
Page 31
30.00 Counterflow (does not include any base)
MODEL NO.
VC-CBP
HEAT INPUT RATE (BTUH)
OUTPUT BTUH [1]
SEASONAL EFFICIENCY (% AFUE)[2]
LARGEST REC A/C (Tons) [4]
NOMINAL TEMP RISE (° F)
HEAT EXCHANGER AREA (SQ. FT.)
CASING HEIGHT (IN.)
CASING WIDTH (IN.)
CASING DEPTH (IN.)
NOMINAL FLUE OUTLET DIA. (IN.)
APPROX SHIPPING WEIGHT (LBS)
APPROVAL AGENCY
QTY AND SIZE OF PERMANENT
FILTERS (IN.)
ELECTRICAL REQUIREMENTS
TOTAL CURRENT (AMPS)
MAX FUSE SIZE (AMPS)
HEIGHT, BOTTOM OF FURNACE CENTER OF FLUE (IN.)
SUPPLY AIR OUTLET SIZE (IN.)
RETURN AIR INLET SIZE (IN.)
BURNER MODEL
AIR TUBE LENGTH (IN.)
BURNER HEAD TYPE
NOZZLE (GPH)
SPRAY ANGLE (Deg.)
SPRAY PATTERN:
OIL PUMP PRESSURE (PSIG)
IGNITION CONTROL TYPE
CONTROL TIMING PRE / POST (Sec.)
COMBUSTION CHAMBER TYPE
MINIMUM CLEARACNES TO COMBUSTILBE MATERIALS
SIDES (IN.)
TOP (IN.)
FRONT (IN.)
REAR (IN.)
FLUE/VENT PIPE (IN.)
SUPPLY PLENUM (IN.)
1 OUTPUT BTUH BASED ON ANNUAL FUEL UTILIZATION EFFICIENCY RA TED BY M ANUFA CTURER.
2 SEASONAL EFFICIENCY (ALSO CALLED AFUE - AN NUAL FUEL UTILIZATION EFFICIENCY) RA TINGS ARE BA SED ON
TESTS FOLLOWING U.S. DEPARTM ENT OF ENERGY TEST PROCEDURES.
3 A FUE RATINGS AS SHIPPED AT 105,000 B TU INPUT.
119,000
97,000 88,000 69,000
85 [3]
4
70 62 70
27.8 (front flue)
61.25 Counterflow / 22.25 Horizontal
22.25 Counterflow / 61.25 Horizontal
22.25
6
280
ETL
NA
120v / 60hz / 1ph
10.2
15
11.00 Horizontal
16 W X 16 D
16 W x 16 D
(BECKETT AFG)
5.875, effective
Fixed, flame retention
0.85 0.75 0.50
80
Hollow (A)
130
Interrupted, Direct Spark
15 / 0
Preformed, refractory (ceramic fiber matrix material)
3
3
22
3
9
3
84,000105,000
29
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APPENDIX D: REPLACEMENT PARTS
Lowboy Front Flue Model
30
Page 33
Lowboy Rear Flue Model
31
Page 34
Horizontal/Counterflow Model
32
Page 35
EFL 401 AFG BURNER PART# 380832
1
MODEL NOZZLE SIZE PART #
.60 80° A 380398
.75 80° A
.85 80° A 380381
1.0 80° A 380368
ITEM DESCRIPTION BECKETT PART # TP PART #
1 BURNER HOUSING ASSY. 5874GY
2 AIR BAND ASSY. 8 slot set @ 0 5151501
3 AIR SHUTTER 4 SLOT set @ 7 3709U 380289
4 ESCUTCHEON PLATE 3493
SCREW
5 HOLE PLUG
6 AIR GUIDE 31231U
7 LOW FIRING RATE BAFFLE 5880
8 *PUMP 130 PSI 21844 380674
*SOLENOID 21755 380654
9 VALVE CORD SET 21807 380653
11 PUMP ELBOW 2256 320815
12 CONNECTION TUBE 5394 380107
13 *MOTOR 1/7 HP 3450 RPM 21805E 380644
14 BLOWER WHEEL 4 ¼ X 2 7/16 TAB 2999 380271
15 *COUPLING 2454 380241
16 *PRIMARY CONTROL 7505B1500 350431
17 ELECTRICAL BOX 3741
18 *IGNITER W/ GASKETS 51771U 380645
19 IGNITER GASKET KIT
20 *CAD CELL w/ Socket C554A1919 7006Q 350104
21 FLANGE 3634BK 380265
GASKET 3616 380270
22 AIR TUBE COMBINATION AF57XNSS 380690
BLAST TUBE ONLY
23 HEAD F3 360003 380260
24 ELECTRODE NOZZLE ASSY
*ELECTRODES PAIR 5780 380269
STATIC PLATE, 2 ¾ U 3383 380330
25 SPLINED NUT(BULKHEAD NUT) 3666 320121
BULK HEAD FITTING 3488 320120
1
NOZZLE SHIPPED INSTALLED IN BURNER
33
380366
Page 36
99032 EZ1 CARLIN OIL BURNER, 380665
2 1/6HP PSC
MOTOR
98022S
380846
5 IGNITOR
41000S
380849
8 PUMP W/SOLENOID 140 PSI
98750S
380850
9 CONNECTION TUBE
34470
380852
.85 X 60° A
380400
ITEM DESCRIPTION CARLIN PART # TP PART #
1 PRIMARY W/ DISPLAY 70200
POST
15 S PRE / 0 S
ITEM MODEL NOZZLE SIZE PART #
.55 X 70° A 380861
32
VLF-DCP
VLR-DCP
70200S 380845
.65 X 60° A 380862
.75 X 60° A 380395
3 BLOWER WHEEL / FAN 77933S 380847
4 PUMP COUPLING 75564S 380848
6 IGNITOR BASEPLATE GASKET 40167S
7 IGNITOR TERMINAL KIT (2 TERM. & NUTS) 24463
SOLENOID 380851
PUMP ELBOW 3/16 FLARE X 1/8 NPT 29926
10 CAD CELL KIT 14407SES 380853
11 & 12 AIR BAND/AIR SHUTTER KIT @ .6 98055S
HEADER BAR KIT (7 BARS & SCREW) 98055S
13 & 30
14 COMBUSTION HEAD ASSY 7” 77966NOHTR 380863
15 ELECTRODE BRACKET 23135
18 & 19 C RING & THUMB NUT KIT 50624S
20 ELECTRODE WIRE SET 82776 380864
21 RETENTION RING ASSY 77438S 380856
22 NOZZLE LINE ADAPTER ASSEMBLY 56861
23 IGNITOR HOLD-DOWN TABS (2 Req.) 44842
24 ELECTRICAL BOX 44586
25 HOUSING 50685A
26 AIR TUBE W/FLANGE 98625 380865
27 FLANGE N/A
28 FLANGE GASKET 40204 380866
0.60/0.65 INSTALLED, W/ BURNER 0.50,
0.75, 0.85, 1.00
081820
34
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