Unitary products group P-HMX12F05701, P-HMX12F08001, P-HMX14F10001, P-HMX20F12001 Installation Instruction
INSTALLATION
INSTRUCTION
CONTENTS
INTRODUCTION....................................... 3
HEATLOSS .......................................... 3
LOCATIONOFUNIT.................................... 3
UPFLOWINSTALLATION................................ 4
HORIZONTALINSTALLATION............................ 4
NON-SUSPENDEDINSTALLATION ....................... 5
SUSPENDEDINSTALLATION............................ 5
AIRCONDITIONINGAPPLICATIONS...................... 5
COMBUSTIONAIR..................................... 5
CHIMNEYVENTING.................................... 5
BAROMETRICDAMPERCONTROL....................... 7
FURNACE CONTROLS ................................. 7
ELECTRICALCONNECTIONS............................8
HUMIDIFIER.......................................... 8
OILTANK ............................................ 8
PIPINGINSTALLATION................................. 9
OILFILTER........................................... 9
OILBURNERNOZZLES................................. 9
COMBUSTIONCHAMBER.............................. 10
BURNER ELECTRODES ............................... 10
OILBURNERSETUP.................................. 10
PREPARATIONS:..................................... 10
PROCEDURE:........................................ 11
STACKTEMPERATURE:............................... 11
CIRCULATING AIR BLOWE R ............................ 12
MAINTENANCEANDSERVICE.......................... 13
FURNACE INSTALLATION SET UP. ...................... 13
OPERATING INSTRUCTIONS ........................... 14
WIRINGNOTES...................................... 18
CONTINUOUSFANOPERATION: ........................18
ACCESSORIES:...................................... 18
THERMOSTAT HEATING
CONNECTIONS:...................................... 18
R7184 DETAILED SEQUENCE OF OPERATION .............20
R7184 LED DIAGNOSTIC LIGHT. . . ...................... 22
TROUBLESHOOTING ................................. 22
OIL FIRED WARM AIR FURNACE
P-HMX12F05701 - P-HMX12F08001
(Horizontal or Upflow Model)
P-HMX14F10001 - P-HMX20F12001
(Upflow Only)
Read this complete manual before beginning installation. These
instructions must be kept with the furnace for future reference.
CAUTION: READ ALL SAFETY GUIDES BEFORE
YOU BEGIN TO INSTALL YOUR UNIT.
035-17473-000-B-1101
WARNING
035-17473-000-B-1101)
INTRODUCTION
Please read these instructions completely and carefully
before installing and operating the furnace.
IMPROPER INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURYOR
PROPERTY DAMAGE.
IMPROPER INSTALLATION, ADJUSTMENT,
ALTERA TION,SERVICE OR MAINTENANCE CAN
CAUSEINJURYORPROPERTYDAMAGE. REFER
TO THIS MANUAL FOR ASSISTANCE OR ADDITIONAL INFORMATION, CONSULTA QUALIFIED
INSTALLER, SERVICE AGENCY OR THE GAS
SUPPLIER.
CAUTION
THIS PRODUCT MUST BE INSTALLED IN STRICT
COMPLIANCE WITH THE ENCLOSED INSTALLATION INSTRUCTIONS AND ANY APPLICABLE
LOCAL, STATE, AND NATIONAL CODES INCLUDING BUT NOT LIMITED TO,BUILDING, ELECTRICAL AND MECHANICAL CODES.
The furnace must be installed and set up by a qualified
contractor.
P*HMX12F05701 and P*HMX12F08001 are oil fired
forced air multi-positional furnaces, with an output
capacity range of 58,000 BTU/Hr to 79,000 BTU/HR.
These furnaces may be installed in the up-flow position, as well as both horizontal left and right positions.
P*HMX14F10001 and P*HMX20F12001 are oil fired
Upflow ONLY furnaces, with an output capacity range
of 100,000 BTU/Hr. to 118,000 BTU/Hr.These furnaces
shall be installed in the up-flow position only.
All model furnaces are listed with the Canadian Stan-
dards Association,(CSA) and comply with both
Canadian and American (U.S.) standards for use with
No. 1 (Stove) and No. 2 (Furnace) Oil. Please refer to
the tables in the appendix for performance and dimensional data.
WARNING
WARNING
Thefurnace area mustnot beused asa broomcloset
orforanyotherstoragepurposes,as afirehazardbay
be created. Never s tore items such as the following
on, nearor in contact with the furnace.
1. Spray or aerosol cans, rags, brooms, dust mops,
vacuum cleaners or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning
compounds; plastic items or containers; gasoline,
kerosene, cigarette lighter fluid, dry cleaning fluids
or other volatile fluid.
3. Paint thinners and other painting compounds.
4. Paper bags, boxes or other paper products
Never operate the furnace with the blower door
removed. To do so could result in serious personal
injury and/or equipment damage.
DO NOT USE GASOLINE, CRANK CASE OIL, OR
ANY OIL CONTAINING GASOLINE.
In Canada, the installation of the furnace and related
equipment shall be installed in accordance with the
regulations of CAN/CSA - B139, Installation Code
For Oil Burning Equipment, as well as in accordance
with local codes.
In the United States of America, the installation of the
furnace and related equipment shall be installed in
accordance with the regulations of NFPA No. 31,
Installation of Oil Burning Equipment
,aswellasin
accordance with local codes.
When installation or application questions arise, regu-
lations prescribed in the National Codes and Local
Regulations take precedence over the general instructions provided with this installation manual. When in
doubt, please consult your local authorities.
All models are shipped assembled and pre-wired. The
furnace should be carefully inspected for damage
when being unpacked.
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HEAT LOSS
The maximum hourly heat loss for each heated space
shall be calculated in accordance with the procedures
described in the manuals of the Heating, Refrigera-
tion and Air Conditioning Institute of Canada
(HRAI), or by any other method which is suitable for
local conditions, provided the results obtained are in
substantial agreement with, and not less than those
obtained using the procedure described in their manuals.
In the United States, Manual J.
titled, "Load Calcula-
tion" published by the Air Conditioning Contractors
of Amer ica, describes a suitable procedure for calcu-
lating the maximum hourly heat loss.
LOCATION OF UNIT
The furnace should be located such that the flue connection to the chimney is short, direct and consists of
as few elbows as possible. When possible, the unit
should be centralized with respect to the supply and
return air duct work. A central location minimizes the
trunk duct sizing. All models may be installed on combustible floors.
Minimum installation clearances are listed in Table 1.
035-17473-000-B-1101
Table 1: Clearance to Combustibles
Models: P*HMX12F05701 and P*HMX12F08001
Location Up-flow Horizontal
Top 2 in. 2 in.
Bottom 0 in. 1 in.
S/A Plenum 1 in. 1 in.
Rear 1 in. 1 in.
Sides 1 in. 1 in.
Front
Flue Pipe 9 in. 9 in.
Enclosure Closet Alcove
1
24” clearance is required for servicing.
Models: P*HMX14F10001 and P*HMX20F12001
Location Up-flow
Top 1 in.
Bottom 0 in.
S/A Plenum 1 in.
Rear 1 in.
Sides 1 in.
Front
Flue Pipe 4in. measured horizontally or below flue pipe.
Flue Pipe 9 in. measured vertically or above flue pipe.
Enclosure Closet
1
24” clearance is required for servicing.
9in.
9in.
1
1
NOTE: The recommended installation clearances do not take
intoconsiderationtheclearances necessary to replace
the air filter or perform otherroutine maintenance.
9in.
1
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035-17473-000-B-1101
Table 2: General Specifications
MODEL INPUT OUTPUT NOZZLE BECKETT AF BURNER AIR
P*HMX U.S. GPH BTU/Hr. Delavan BURNER MODEL BURNER HEAD FILTER
P*HMX12F05701 0.50 58,000 0.50 / 70°A AF76BO F0 16 x 25 x 1
P*HMX12F08001 0.70 79,000 0.70 / 70°A AF76BO F0 16 x 25 x 1
P*HMX14F10001 0.85 100,000 0.85 / 70°A AF76XN F3 16 x 25 x 1
P*HMX20F12001 1.00 118,000 1.00 / 70° A AF76XN F3 16 x 25 x 1
NOTE: Over-fire draft for all models is -0.02 in Water column. Static Plate Diameter: 3-3/8 inch for AF76BO and 2-
3/4 inc. for AF76XN.
UPFLOW INSTALLATION
These furnace models have been assembled for installation in the up-flow position. Maintain all clearances to
combustibles as outlined in Table 1 on page 3.
Suggestion; as a measure to prevent fuel oil from accumulating in locations other than the combustion chamber, as could be the case in the event of nozzle drip,
install the furnace with an approximate 2 degree slope
from the oil burner casing towards the combustion
chamber. Use shims made of noncombustible material.
HORIZONTAL INSTALLATION
The 057 & 080 BTU output model furnaces are assembled and shipped ready for installation in the upflow
position. The furnace may be installed in either of the
horizontal positions; warm air discharging left or warm
air discharging right by following these steps:
1. Rotate the furnace 90° to the desired position.
2. Remove the three nut and washer sets fastening the oil
burner assembly to the furnace. Rotate the oil burner
assembly to be in the upright position. (Ignition transformer and / or oil primary control control should be on
top).
3. Re-align the oil burner assembly to the combustion
chamber (fire-pot), then secure into place with the three
nut and washer sets.
FIGURE 1 : TYPICAL SUSPENDED OPERATION
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035-17473-000-B-1101
NON-SUSPENDED INSTALLATION
Maintain clearances to combustibles as outlined in
Table 1. Installation on a combustible floor requires a
clearance of 1 inch. This can be done by using noncombustible materials such as one inch thick channel
iron or similar material. The furnace must be supported
in such a way as to not allow twisting or sagging of the
cabinet. Suggestion; as a measure to prevent fuel oil
from accumulating in locations other than the fire pot,
as could be the case in the event of nozzle drip, install
the furnace with an approximate 2 degree slope from
the oil burner casing towards the fire pot. Use shims
made of noncombustible material.
SUSPENDED INSTALLATION
Refer to Figure 1. Maintain clearances to combustibles
as outlined in Table 1. Remove the four circular knockouts on the top panel, and similarly, the four circular
knock-outs on the bottom panel. The removed knockouts allow 3/8 inch treaded road to be inserted through
the interior of the furnace. Use care when inserting
rods, since the foil backed insulation can be easily
ripped and torn away from the panel surfaces. Secure
the furnace with 2 inch minimum slotted angle or equivalent, as shown in Figure 4. The furnace must be supported in such a way as to not allow twisting or sagging
of the cabinet. Suggestion; as a measure to prevent
fuel oil from accumulating in locations other than the
fire pot, as could be the case in the event of nozzle
drip, install the furnace with an approximate 2 degree
slope from the oil burner casing towards the fire pot.
COMBUSTION AIR
If the furnace is installed in a closet or utility room, two
ventilation openings must be provided connecting to a
well ventilated space (full basement, living room or
other room opening thereto, but not a bedroom or bathroom). One opening shall be located 6” from the top
and bottom of the enclosure at the front of the furnace.
Each opening shall have a minimum free area of 1½
square inches per 1,000 Btu/h of total input rating of all
appliances installed in the room.
For furnaces located in buildings of unusually tight construction, such as those with high quality weather stripping, caulking, windows and doors, or storm sashed
windows, or where basement windows are well sealed,
a permanent opening communicating with a well ventilated attic or with the outdoors shall be provided, using
a duct if necessary. The duct opening shall have a free
area of 1½ square inches per 1,000 Btu/h of total input
rating of all appliances to be installed. When a furnace
is installed in a full basement, infiltration is normally
adequate to provide air for combustion and draft operation. Furnace rooms under 65m³ (700 ft³) should automatically be treated as confined space.
The Model CAS-2B-90E Furnace Boot manufactured
byFieldControls,Inc.maybeusedwiththefurnaceto
obtain combustion air directly from outdoors. Use of
this device does not alter the need for ventilation air;
however, it does provide a good direct source of combustion air and is connected directly to the oil burner.
CHIMNEY VENTING
AIR CONDITIONING APPLICATIONS
If the furnace is used in conjunction with air conditioning, the furnace shall be installed in parallel with or with
the evaporator coil upstream from the furnace to avoid
condensation in the heat exchanger. In a parallel installation, the dampers or air controlling means must prevent chilled air from entering the furnace. If the
dampers are manually operated, there must be a
means of control to prevent the operation of either system unless the dampers are in the full heat or full cool
position. The air heated by the furnace shall not pass
through a refrigeration unit unless the unit is specifically approved for such service.
The blower speed must be checked and adjusted to
compensate for the pressure drop caused by the evaporator coil. Refer to Appendix B for recommended wiring and electrical connections of the air conditioning
controls.
Unitary Products Group 5
The chimney must be sized correctly and be in good
repair.If the chimney is oversized, there is a high risk of
the flue gases condensing resulting in damage to the
chimney and other venting parts. This problem may be
corrected by the use of an appropriately sized chimney
liner.
If the chimney serves the furnace only, the vent should
be sized at 4 inch minimum, 5 inch maximum. If the furnace is to be co-vented with other appliances, refer to
CAN/CSA B139, Installation Code For Oil Burning
Equipment or NFPA 2 11, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances for
correct sizing information.
035-17473-000-B-1101
Table 3: Min. Chimney Base Temperatures (°F)
Model Chimney Height (ft.)
P-HMX12F05701 300 400 535 725
P-HMX12F08001 270 330 405 505
P-HMX14F10001 250 300 355 430
P-HMX12F12001 225 300 365 430
P-HMX12F5701 185 200 220 250
P-HMX12F08001 175 185 195 215
P-HMX14F10001 165 185 195 205
P-HMX12F12001 165 185 195 205
Chimneys with Thermal Resistance less than R6
Chimneys with Thermal Resistance greater than R6
IMPORTANT: The chimney must be capable of providing sufficient draft at all times for the safe removal of
the products of combustion.
Table 4: Common Chimney Problems
Key Trouble Diagnostic Remedy
A Top of chimney lower
than surrounding
objects
B Chimney Cap or ven-
C Coping restricts
Key Trouble Diagnostic Remedy
D Obstruction in chim-
E Joist protruding into
F Break in chimney lin-
G Collection of soot at
H Offset Lower light on exten-
I Two or more open-
J Loose-seatedpipein
K Smoke pipe extends
L Failure to extend the
M Loose-fitted clean-
tilator.
opening.
ney
chimney.
ing.
narrow space in flue
opening.
ings to the same
chimney.
flue opening.
into chimney.
length of flue parti-
tion to the floor.
out door.
11 20 28 36
Observation Extend chimney
Observation Remove
Observation Make opening as
Can be found bylight
and mirror reflecting
conditions in chim-
ney.
Lowering a light on
an extension cord.
Smoke test - build
smudge fire blocking
off other opening,
watching for smoke
to escape.
Lower light on exten-
sion cord.
sion cord.
Found by inspection
from basement.
Smoke test. Leaks should be
Measurement of pipe
from within or obser-
vation of pipe by
means of a lowered
light.
By inspection or
smoke test.
Smoke test. Close all leaks with
above all surround-
ing objects within 30
feet.
large as inside of
chimney.
Useweighttobreak
and dislodge.
Must be handled by
competent masonry
contractor.
Must be handled by
competent masonry
contractor.
Clean out with
weighted brush or
bag of loose gravel
on end of line.
Change to straight or
to long offset.
The least important
opening must be
closed, using some
other chimney flue.
eliminated by
cementing all pipe
openings.
Length of pipe must
be reduced to allow
endofpipetobe
flush with inside of
tile.
Extend partition to
floor level.
cement.
FIGURE 2 : COMMON CHIMNEY PROBLEMS
The chimney should be tested under “winter” conditions; doors and windows closed, all other fossil fuel
burning appliances on, clothes dryer on, bathroom fans
on, etc. If the chimney cannot overcome the competition for air, it will be necessary to access the reason for
it, and take corrective action. If the chimney is found to
be sized correctly and in good repair, it will probably be
necessary to re-evaluate the availability of combustion
and ventilation air, and take corrective action.
NOTE: These furnaces are approved for use with LVent.
NOTE: Maximum Temperature for L-Vent is
575° F(300
°C).
The flue pipe should be as short as possible with horizontal pipes sloping upward toward the chimney at a
rate of one quarter inch per foot. The flue pipe should
not be smaller in cross section area than the flue collar
on the furnace. The flue pipe should connect to the
chimney such that the flue pipe extends into, and terminates flush with the inside surface of the chimney liner.
Seal the joint between the pipe and the lining. The
chimney outlet should be at least two feet above the
highest point of a peaked roof. All unused chimney
openings should be closed. Chimneys must conform to
local, provincial or state codes, or in the absence of
local regulations, to the requirements of the National
Building Code.
See Figure 2 and Table 4 for common chimney problems and their remedies.
6 UnitaryProductsGroup
CAUTION
Thefurnacemustbeconnectedtoafluehavingsufficientdraftat alltimes to ensuresafe andproper operation of the appliance.
The flue pipe must not be routed through concealed
space, because it must be visually checked for signs of
deterioration during the annual inspection and servicing. The flue pipe must not pass through any floor or
ceiling, but may pass through a wall where suitable fire
protection provisions have been installed. Refer to the
latest edition of CAN/CSA B-139 for rules governing
the installation of oil burning equipment. In the United
States, refer to the latest edition of NFPA 31 for regulations governing the installation of oil burning equipment.
035-17473-000-B-1101
FIGURE 3 : R7184 OIL PRIMARY CONTROL
BAROMETRIC DAMPER CONTROL
This device is used in conjunction with conventional
chimney venting. This control (or draft regulator) automatically maintains a constant negative pressure in the
furnace to obtain maximum efficiency. It ensures that
proper pressures are not exceeded. If the chimney
does not develop sufficient draft, the draft control cannot function properly. The draft regulator, must be
installed within the same room or enclosure as the furnace, and should not interfere with the combustion air
supplied to the burner. The control should be located a
minimum of 3 flue pipe diameters (18”) from the furnace breaching and installed in accordance to the
instructions supplied with the regulator. The flue outlet
pressure (measured between the furnace and draft
regulator) should be set to - 0.02 in. w.c.
FURNACE CONTROLS
The furnace is controlled by the ST9103 ELECTRONIC
FAN TIMER (EFT) combined with an R7184 Oil Primary Control.
These controls provide for add-on air conditioning. The
ST9103 EFT is located in a control box mounted to the
blower support rails. The R7184 primary control
mounts to a 4x4 junction box connected to the oil
burner, contains the safety circuits and provides input
voltage for the separately mounted ignition transformer
on top of the oil burner.
FIGURE 4 : ST9103 EFT
The circulating fan is controlled by the ST9103 EFT.
The heat delay-on time is fixed at 30 seconds. This
provides a delay between the start of the burner and
the start of the circulating fan to reduce the amount of
ambient unheated air flowing through the ductwork.
The end of the circulating fan cycle is also delayed to
remove residual heat from the furnace. There are four
delay-off choices, 60, 90, 120 and 150 seconds, which
are field adjustable by manipulating the DIP switches
on the ST9103 EFT Board.
The cooling delay-on and delay-off times are fixed at
30 seconds each.
The furnace is protected against over-heating by fixed
high temperature limits. These controls are factory set
and are not field adjustable. If an over temperature
condition is detected, one or both limit switches will
interrupt power to the oil primary control, which will shut
off the oil burner. The circulating fan will continue to
operate. The high limit switches will automatically reset
when the furnace returns to a safe temperature.
Unitary Products Group 7
035-17473-000-B-1101
ELECTRICAL CONNECTIONS
The furnace is listed by the Canadian Standards
Association (CSA). It is factory wired and requires
minimal field wiring. In Canada, all field wiring should
conform to CAN/CSA C22.1 Canadian Electrical
Code, Part 1, and by local codes, where they prevail.
In the United States, the wiring must be in accordance
with the National Fire Protection Association NFPA-
70, National Electrical Code, and with local codes
and regulations.
Thefurnaceshouldbewiredtoaseparateanddedicated circuit in the main electrical panel; however,
accessory equipment such as electronic air cleaners
and humidifiers may be included on the furnace circuit.
Although a suitably located circuit breaker can be used
as a service switch, a separate service switch is advisable. The service switch is necessary if reaching the
circuit breaker involves becoming close to the furnace,
or if the furnace is located between the circuit breaker
and the means of entry to the furnace room. The furnace switch (service switch) should be clearly marked,
installedinaneasilyaccessibleareabetweenthefurnace and furnace room entry , and be located in such a
manner to reduce the likelihood that it would be mistaken as a light switch or similar device.
The power requirement for the P-HMX Series model is:
120 VAC, 1 ∅,60Hz.,12A.
Accessories requiring 120 VAC power sources such as
electronic air cleaners and humidifier transformers may
be powered from the ST9103 EFT. Do not use the
direct drive motor connections as a power source,
since there is a high risk of damaging the accessories
by exposure to high voltage from the auto-generating
windings of the direct drive motor.
Thermostat wiring connections and air conditioning
contactor low voltage connections are shown in the wiring diagram. Some micro-electronic thermostats
require additional controls and wiring. Refer to the thermostat manufacturer's instructions.
The thermostat should be located approximately 5 feet
above the floor, on an inside wall where there is good
natural air circulation, and where the thermostat will be
exposed to average room temperatures. Avoid locations where the thermostat will be exposed to cold
drafts, heat from nearby lamps and appliances, exposure to sunlight, heat from inside wall stacks, etc.
For thermostats with heat anticipators, the heat anticipator should be adjusted to the amperage draw of the
heating control circuit as measured between the "R"
and "W" terminals of the thermostat. To reduce the risk
of damaging the heat anticipator, do not measure cir-
cuit without first removing one of the two wires. To
determine the heating circuit amperage draw:
1. Note and disconnectthe wires from the “R” and “W” thermostat terminals.
2. Connect an ammeter between the two disconnected
wires from the thermostat.
3. Note the amperage reading.
4. Re-connect the thermostat wires. If the thermostat is
serving a combination heating and air conditioning system, pay particular attention to polarity.
5. When the thermostat is reconnected and re-plumbed,
adjust the heat anticipator setting to match the observed
amperage reading.
HUMIDIFIER
A humidifier is an optional accessory available through
most heating supplies outlets. Installation should be
carried out in accordance with the humidifier manufacturer's installation instructions. Water or water droplets
from the humidifier should not be allowed to come into
contact with the furnace heat exchanger. Terminals
(115 v) are provided on the ST9103 EFT control. Do
not use direct drive motor connections as a source of
power for 120 VAC humidifiers and humidifier transformers.
OIL TANK
Oil storage tanks must be selected and installed in
compliance with applicable codes; in Canada, CAN/
CSA-B139, Installation Code for Oil Burning Equip-
ment, Section 6 and in the United States, NFPA 31,
Standard for the Installation of Oil Burning Equipment
Chapter 2. Observe all local codes and by-laws.
In general, the oil tank must be properly supported and
remain stable in both empty and full condition. The oil
tank must be fitted with vent and supply pipes to the
outdoors. Refer to the above mentioned codes for sizing. The vent pipe must be no less than 1¼ inches
I.P.S., and terminate with an appropriate vent cap in a
location where it will not be blocked. The fill pipe must
be no less than 2 inches I.P.S., and terminate with an
appropriate cap in a location where debris will not enter
the fill pipe during oil delivery.
If located indoors, the tank should normally be in the
lowest level, (cellar, basement, etc.). It must be
equipped with a shut-off valve at the tank outlet used
for the oil supply. The oil tank must be located as to not
block the furnace / room exit pathway. Observe all
clearances specified in the above mentioned codes.
,
8 UnitaryProductsGroup
035-17473-000-B-1101
PIPING INSTALLATION
In Canada, the entire fuel system should be installed in
accordance with the requirements of CAN/CSA B-139,
and local regulations. Use only approved fuel oil tanks
piping, fittings and oil filters.
In the United States the installation must be in accordance with the requirements of NFPA No. 31 and local
codes and regulations.
Ensure that all fittings used in a copper oil line system
are high quality flare fittings. Do not use compression
fittings.
Pressurized or gravity feed installations must not
exceed 3 PSIG. A pressure greater than 10 PSIG may
cause damage to the shaft seal. If the height of the oil
stored in a tank above the oil burner exceeds 11-1/2
feet, it may be necessary to use a pressure-regulating
device approved for this purpose.
The P*HMX series furnace may be installed with a one
pipe system with gravity feed or lift. The maximum
allowableliftonasinglelinesystemis8feet.Lift
should be measured from the bottom (outlet) of the
tank, to the inlet of the burner. Sizing a single line system is complex because of the difficulty estimating the
pressure drop through each fitting, bend and component in the line. In general, keep single line systems
short as possible. If the furnace is to be installed in a
suspended position, a two pipe system may be the better alternative. Two-stage oil pumps are not available
for oil burners featuring the Beckett Clean Cut Fuel
Unit. Table 5
tal + vertical) for single and two stage oil pumps. All distances are in feet.
In retrofit applications,where an existing oil line system
is in place, a vacuum check will help determine
whether a 2-stage oil pump is necessary. The vacuum
in a system featuring a single stage oil pump should
not exceed 6” Hg. The vacuum in a system featuring a
2-stage oil pump should not exceed 15” Hg. (inches of
mercury.
shows the allowable line lengths (horizon-
Table 5: Oil Lines
Copper Tubing Oil Line Lengths
Single Stage 2-Stage
Lift
(feet)
0 53 100 68 100
1 49 100 65 100
2 45 100 63 100
3 41 100 60 100
4 37 100 58 100
5 33 100 55 100
6 29 100 53 100
7 25 99 5 0 100
8 21 83 4 8 100
9 17 68 4 5 100
10 13 52 42 100
12 - - - - - - 37 100
14 - - - - - - 32 100
16 - - - - - - 27 100
18 - - - - - - 22 88
3/8”O.D.
Tubing
1/2”O.D.
Tubing
3/8”O.D.
Tubing
1/2”O.D.
Tubing
For additional information, see the installation information sheet affixed to the oil burner).
OIL FILTER
All fuel systems should include an oil filter between the
fuel oil storage tank and the oil burner. For best results,
install the oil filter as close to the burner as possible.
When using an indoor oil tank, the oil filter may be
installed at the tank downstream from the shut-off
valve. If firing the furnace under the 0.65 gph rate, a 7
to 10 micron line filter should be installed as close to
the oil burner as possible.
OIL BURNER NOZZLES
The P-HMX Series furnace is certified for multiple firing
rates, ranging from 58,000 to 120,000 BTU/Hr. By
manipulating the oil burner nozzle, flame retention
head, and temperature rise, the furnace may be fired at
an ideal rate for a wide range of structures.
Table 6: Nozzles
MODEL
P*HMX12F05701 0.50 / 70° A 0.50 / 80° A F0
P*HMX12F08001 0.70 / 70° A ) 0.70 / 80° A ) F0
P*HMX14F10001 0.80 / 70° A 0.80 / 80° A F3
P*HMX20F12001 1.00 / 70° A) 1.00 / 80° A) F3
NOZZLE (Delavan)
STD ALT HEAD
Unitary Products Group 9
035-17473-000-B-1101
COMBUSTION CHAMBER
This furnace is equipped with an efficient cerafelt combustion chamber. It is held in place by a retaining
bracket.
WARNING
CHECK THE ALIGNMENT OF THE COMBUSTION
CHAMBERAND OILBURNER BEFORE FIRING. ITIS
POSSIBLE FOR THE COMBUSTION CHAMBER TO
SHIFTIS SUBJECTED TOROUGH HANDLINGDURING TRANSIT.
The cerafelt combustion chamber is quite soft initially.
After firing, it becomes very brittle. Be sure to do all
alignment and positioning adjustments before the first
firing.
The combustion chamber should be inspected for damage or carbon build-up whenever the oil burner is
removed for repairs or routine maintenance.
of air causes "soft" and "sooty" flames, resulting in soot
build-up throughout the heat exchanger passages.
Excess combustion air causes a bright roaring fire and
high stack temperatures resulting in poor fuel efficiency.
PREPARATIONS:
Drill a ¼” test port in the venting, ideally at least 2 diameters (12”) away from the furnace breaching, if venting
horizontally from the furnace, or from the flue pipe
elbow if venting vertically before reaching the furnace.
(see Figures 6 and 7).
CAUTION
Before operating the furnacecheck burneralignment
with combustion chamber. The end cone of the air
tubemustbecenteredtotheaccommodatingringprovidedin thedesign of thecombustionchamber.Adjust
as necesssary before
BURNER ELECTRODES
Correct positioning of the electrode tips with respect to
each other, to the fuel oil nozzle, and to the rest of the
burners is essential for smooth light ups and proper
operation.
The electrode tips should be adjusted to a gap of 5/32”,
1/16” ahead of the nozzle, 7/16” above the centerline of
the nozzle. The “Z” dimension (front edge of the burner
head to the front face) of the nozzle is 1-1/8 inches.
The electrode porcelains should be free of cracks, the
electrode tips should be tapered and free of burrs, and
the contact rods must be clean and be in firm contact
with the ignition transformer contact springs. The electrodes must not come into contact with the burner
head.
OIL BURNER SET UP
The burner air supply is adjusted to maintain the fuel to
air ratio to obtain ideal combustion conditions. A lack
first firing.
FIGURE 5 : TEST PORT LOCATION FOR SMOKE
TEST VERTICAL
FIGURE 6 : TEST PORT LOCATION FOR SMOKE
TEST HORIZONTAL.
Note A: Locate hole at least 6 inches on the furnace
side of the draft control.
Note B: Ideally, hole should be at least 12 inches from
breeching or elbow.
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035-17473-000-B-1101
The test port will allow flue gas samples to be taken
and stack temperatures to be measured.
Before starting the burner, check the burner alignment
with the combustion chamber (fire pot), check that the
correct nozzle is tightened into place, and that the
burner electrodes are properly positioned.
PROCEDURE:
Start the burner and allow it to run at least ten minutes.
Set the air shutter to give a good flame visually. The air
supply to the burner is controlled by the air shutter on
the left side of the burner, and the bulk air band. To
adjust, loosen the bolt on the movable shutter. Move
the shutter gradually until a good flame (visually) has
been achieved. Re-snug the bolt.
Check the initial draft setting as the furnace warms up.
Thedraftmaybemeasuredatthetestport.Inmost
cases, the pressure drop between the test port and the
oil burner is negligible. The test port draft reading may
be interpreted as the “over fire draft” reading. The draft
should be set to - 0.02 inches w.c.
Check the oil pump pressure. All P-HMX furnaces are
designed to be operated at 100 PSIG.
After reaching steady state, take a smoke test. If not
indicating a trace, set the combustion air controls to
provide a trace.
When the trace smoke has been established, measure
the CO
ing will range between 11.5% to 13.5% or the O
ing approximately 3.3%.
Open the end air shutter (or open the bulk air band if
necessary) until the CO
age points, or, if measuring O
reading increases 2 or 3 percentage points.
Take another smoke test; it should now be zero smoke.
If the smoke test reads zero, tighten up the end air
shutter, and bulk air band.
Re-test the draft, and the CO
the settings have not shifted.
SMOKE TEST NOTE:
If oily or yellow smoke spots are found on the smoke
test filter paper, it is usually a sign of unburned fuel.
This indicates poor combustion. This type of problem
may be caused by excess draft, excess air, or contaminated fuel. Do not ignore this indicator.
2 or O2 in the flue gas. Typically, the CO2 read-
2 read-
2 readingdrops1or2percent-
2 content, until the O2
2 or O2 to be certain that
STACK TEMPERATURE:
Stack temperature will vary depending on fuel input,
circulating air blower speed, and burner set up, etc. In
general, stack temperature should range between
350°F to 450°F, but could be as high as 550°F, assuming that the combustion air is approximately room temperature (65°F - 70°F). In general, lower stack
temperature indicates greater efficiency; however,
excessively low stack temperature can lead to condensation forming in the chimney and / or venting. Sulphur
and similar contaminants in the fuel oil will mix with
condensation to form acids. Acids and resultant chemical salts will cause rapid deterioration of the chimney
and venting components, and may attack the furnace.
If the flue gases are below the range, it may be necessary to slow down the blower fan. If the flue gases are
above the range, the blower fan may require speeding
up. Stack temperature varies directly with the system
temperature rise. System temperature rise is the difference between the furnace outlet temperature and furnace inlet temperature as measured in the vicinity of
the connection between the plenum take-offs and the
trunk ducts. Typical temperature rise values range
between 65°F and 85°F.
If the venting from the furnace to the chimney is long,
or exposed to cold ambient temperatures, it is advisable to insulate the venting with a removable, non-combustible, wrap-around type insulation to reduce stack
temperature loss. The venting should be inspected
annually to ensure that it is intact.
WARNING
IF THE FURNACE FAILS TO IGNITE, CHECK THE
OIL TANK FUEL GAUGE. IF THE FUEL GAUGE
SHOWS THAT OIL IS PRESENT, PRESS THE
RESET BUTTON ONCE ONLY
FAILS TO IGNITE, CONTACT YOUR SERVICE
CONTRACTOR.
. IF THE BURNER
CAUTION
Unitary Products Group 11
ALL FURNACE CONTROLS ARE SENSITIVE AND
SHOULDNOT BE SUBJECTED TO TAMPERING. IF
PROBLEMSPERSIST, CALL YOUR SERVICECONTRACTOR.
035-17473-000-B-1101
CIRCULATING AIR BLOWER
These furnaces are equipped with direct drive blower
systems. Direct drive blower speed adjustments are
not normally required in properly sized extended plenum duct systems. The motor RPM and air CFM delivery will vary automatically to accommodate conditions
within the usual range of external static pressures typical of residential duct systems. Under-sized duct systems may require a higher blower speed to obtain a
reasonable system temperature rise. Some older duct
systems were not designed to provide static pressure.
They typically feature special reducing fittings at each
branch run and lack block ends on the trunk ducts.
These systems may require modification to provide
some resistance to the airflow to prevent over- amping
of the direct drive blower motor. Selecting a lower
blower speed may correct this problem.
Direct drive blower speeds are adjusted by changing
the "hot" wires to the motor winding connections.
Please refer to wiring diagram in Figure 9 or the wiring
diagram label affixed to the furnace. THE NEUTRAL
WIRE (normally the white wire) IS NEVER MOVED
TO ADJUST THE BLOWER SPEED.
FIGURE 7 : HEATING MODE “BLOWER OFF”
TIMINGS, ST9103
It is possible and acceptable to use a single blower
speed for both heating and cooling modes. The simplest method to connect the wiring from both modes is
to use a "piggy-back connector" accommodating both
wires on a single motor tap. It is also acceptable to connect the selected motor speed with a pig tail joined to
both heating and cooling speed wires with a wire nut.
As a safety precaution against accidental disconnection of the wires by vibration, it is advisable to secure
the wire nut and wires with a few wraps of electricians
tape.
If the joining of the blower speed wiring is done in the
furnace junction box, tape off both ends of the unused
wire.
The circulating fan start-up is delayed 30 seconds in
the heating mode.
The circulating fan start-up is delayed 30 seconds in
the cooling mode. The “fan off” is delayed 30 seconds
in the cooling mode.
The “fan off” heating delay may be field adjusted by
manipulating the dip switches. See Figure 7.
WARNING
DO NOT CONNECT POWER LEADS BETWEEN
MOTOR SPEEDS. THE NEUTRAL WIRE MUST
ALWAYSBE CONNECTEDTOTHEMOTOR'S DESIGNATED NEUTRAL TERMINAL.
CAUTION
DISCONNECTTHE POWER SUPPLY TOTHE FURNACE BEFORE OPENING THE BLOWER ACCESS
DOOR TO SERVICE THE AIR FILTER, FAN AND
MOTOR. FAILURETO SHUT OFF POWER COULD
ALLOW THE BLOWER TO START UNEXPECTEDLY, CREATING A RISK OF DEATH OR PERSONAL INJURY.
Do not use the blower speed wires as a source of
power to accessories as electronic air cleaners and
humidifier transformers. The unused motor taps autogenerate sufficiently high voltages and may damage
accessory equipment. Use the terminals provided on
the ST9103 EFT.
12 UnitaryProductsGroup
CAUTION
Do not start the burner or blower fan unless the
blower access door is securely in place.
MAINTENANCE AND SERVICE
Routine Maintenance By Home Owner
Other than remembering to arrange for the annual professional servicing of the furnace by the service or
installation contractor, the most important routine service performed by the home owner is to maintain the
air filter or filters. A dirty filter can cause the furnace to
over-heat, fail to maintain indoor temperature during
cold weather, increase fuel consumption and cause
component failure.
The furnace filter(s) should be inspected, cleaned or
replaced monthly. The furnace is factory equipped with
a semi-permanent type filter. If the filter is damaged,
replace with filters of the same size and type.
During the routine service, inspect the general condition of the furnace watching for signs of oil leaks in the
vicinity of the oil burner, soot forming on any external
part of the furnace, soot forming around the joints in the
vent pipe, etc. If any of these conditions are present,
please advice your service or installation contractor.
Annual Service By Contractor
CAUTION
The combustion chamber is fragile. use care when
inspecting and cleaning this area.
The heat exchanger should be inspected periodically
and cleaned if necessary. if cleaning is necessary,
SHUT OFF POWER TO THE FURNACE and remove
the burner. Using a stiff brush with a wire handle, brush
off scale and soot from inside the drum and flue pipe.
To clean the radiator, remove the round covers on the
inner radiator access pipes located on the front panel
between the oil burner and the flue pipe.
Awirebrushcanbeusedtoloosendirtanddebrison
the inside surfaces of the radiator. Clean out all accumulated dirt, soot and debris with a wire handled brush
and an industrial vacuum cleaner. Replace the cleanout covers.
035-17473-000-B-1101
Most direct drive blower motors are permanently lubricated by the motor manufacturer. These motors will
have no oil ports. If the blower motor does contain oil
ports, under normal operating conditions it will not
require oiling for the first two years. Oil sparingly (a few
drops) in each oil port with SAE 20 non-detergent oil.
Oiling is most easily done with a "tele-spout" oilier. This
oilier has a long flexible plastic spout. DO NOT OVERLUBRICATE. Excess oil causes premature electric
motor failure.
Inspect the blower fan. Clean it if necessary.
Oil Burner Maintenance: Follow the instructions of the
oil burner manufacturer. (See oil burner manufacturer's
instructions supplied with furnace). The oil burner nozzle should be replaced annually. We recommend that
the oil filter be changed on an annual basis.
The venting system should be cleaned and inspected
for signs of deterioration. Replace pitted or perforated
vent pipe and fittings. The barometric damper should
open and close freely.
All electrical connections should be checked to ensure
tight connections. Safety controls such as the high limit
controls should be tested for functionality. The fan control functions should be checked to ensure that all fan
speeds are operating properly.
FURNACE INSTALLATION SET UP
The furnace must be set up as the final step in the
installation.
A. THE OIL BURNER MUST BE SET UP FOL-
LOWING THE PROCEDURES OUTLINED IN
OIL BURNER SET UP ON PAGE 11.
B. THE P-HMX12F057011 AND P-HMX12F08001
SHOULD OPERATE WITHIN A TEMPERATURE RISE OF 50°F TO 85°F; THE
P-HMX14F10001 AND P-HMX20F1201
SHOULD OPERATE WITHIN A TEMPERATURE RISE OF 65°F TO 80°F. TO DETERMINE
THE TEMPERATURE RISE, MEASURE THE
SUPPLY AIR AND RETURN AIR TEMPERATURES WHEN THE FURNACE HAS REACHED
STEADY STATE CONDITIONS. THIS IS THE
POINT AT WHICH THE SUPPLY AIR TEMPERATURE STOPS INCREASING RELATIVE TO
THE RETURN AIR TEMPERATURE. THE FURNACE MAY HAVE TO RUN 10 TO 15 MINUTES
TO REACH STEADY STATE CONDITIONS.
THE MEASUREMENTS MAY BE MADE WITH
DUCT THERMOMETERS OR THERMOCOUPLES USED IN CONJUNCTION WITH MULTIMETERS WITH TEMPERATURE MEASUREMENT CAPABILITIES.
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035-17473-000-B-1101
The return air should be measured at a point where the
thermometer will be well within the air stream near the
furnace return air inlet.. Actual location is not particularly critical; however, avoid locations where the temperature readings could be affected by humidifier
bypass ducts, the inside radius of elbows, etc.
The supply air temperature should be measured at a
point where the thermometer will be well within the air
stream near the furnace supply air outlet. Usually, the
side mid-point of the supply air plenum take-off is ideal,
providing it is out of the line of sight to the heat
exchanger. If the thermometer is within the line of sight
of the heat exchanger, the supply air readings may be
skewed by radiant heat from the heat exchanger. If the
plenum take-off is unsuitable, the supply air temperature may be measured within the first 18 inches of the
first segment of supply air trunk duct.
If the temperature rise is outside the recommended
range, it may be adjusted by selecting alternate circulation fan motor speeds. If the temperature rise is too
high, speed the fan up. If the temperature rise is too
low, slow the fan down.
C. Keep in mind that the stack temperature varies
directly with the temperature rise. The higher the
temperature rise, the higher the stack temperature will be, resulting in lower efficiency. The
lower the temperature rise, the lower the stack
temperature will be, which, in some cases, may
allow condensation to form in the chimney and
other vent parts.
D. Test the high limit control to ensure that it is oper-
ating correctly. This may be done by temporarily
removing the circulator fan heating wire or neutral wire. Turn of electrical power to the furnace
before working with the motor wires. Be sure to
protect any removed wires from shorting out on
metal furnace parts. If the high limit test is successful, shut off the electrical power to the furnace, restore the proper motor wiring. Then
restore power to the furnace.
E. Operate the furnace through a minimum of three
full heating cycles. During this time, check for
fuel oil leaks, gross air leakage from the supply
air ductwork, unusual noises originating anywhere within the heating system which may
cause some concern or annoyance to the home
owner, etc.
F. Be sure that the home owner is familiar with the
furnace.The home owner shouldbe awareof the
location of electrical circuit breaker or fuse, the
location of any electrical switches controlling the
furnace, the location of the oil tank shut-off valve
and how to operate the valve. The home owner
should know where the oil tank gauge is located
and how to read it.
It would be beneficial to review safety issues with the
home owner, such as the danger of storing combustibles too close to the furnace, hanging anything on the
furnace vent pipe, and especially the dangers of indiscriminately pressing the burner reset button.
IMPORTANT: Be sure that the home owner knows
where the burner reset switch is located, and is aware
that the reset switch is not to be activated more than
once without a look for the cause of the problem, (lack
of fuel, etc.). Be sure that the homeowner knows when
to quit trying to start the furnace during these conditions and who to call for emergency service.
OPERATING INSTRUCTIONS
Before Lighting
• Open all supply and return air registers and grilles.
• Open all valves in oil pipes.
• Turn on electric power supply.
To Light Unit
• Set the thermostatabove room temperature to call
for heat. The burner will start. NOTE: If the furnace
has been off for an extended period of time, it may
be necessary to press the RESET button on the
primary combustion control relay, (once only
pressing the reset button does not start the furnace, refer to Appendix C, Troubleshooting.
• After 30 seconds , as the furnace becomes warm,
circulation fan will start.
• The furnace will continue to run until the thermostat
call for heat is satisfied.
• Set the thermostat below room temperature. The
oil burner will stop.
• The air circulation blower will continue to run for
60, 90, 120 or 150 seconds after the oil burner has
stopped, depending on the dip switch settings.
To Shut Down Unit
• Set the thermostat to the lowest possible setting.
• Set the manual switch (if installed) in the Electrical
Power Supply Line to "OFF".
NOTE:
Ifthefurnaceistobeshutdownforan
extended period of time, close the oil supply
valve to the oil burner.
). If
14 UnitaryProductsGroup
035-17473-000-B-1101
WARNING
donot attempt tostartthe burnerwhenexcess oil
has accumulated, when the furnace is full of
vapour, or when the combustion chamberis very
hot. never burn garbage or paper in the furnace,
and neverleave paper or rags around the unit.
Table 7: Becket AF Oil Burner Set-Up
BECKETT AF SERIES OIL BURNERS
FURNACE
MODEL
P-HMX12F05701 58,000 AF76BO 0.50 / 70° A 100 PSIG 0.50 GPH F0 3-3/8 in.
P-HMX12F08001 79,000 AF76BO 0.70 / 70° A 100 PSIG 0.70 GPH F0 3-3/8 in.
P-HMX14F10001 100,000 AF76XN 0.85 / 70° A 100 PSIG 0.85 GPH F3 2-3/4 in.
P-HMX20F12001 118,000 AF76XN 1.00 / 70° A 100 PSIG 1.00 GPH F3 2-3/4 in.
In the United States, the R. W. Beckett “AF” Burner may be equipped with Beckett’s “Inlet Air Shut-Off”,
Beckett Part No. AF/A 5861, to increase efficiency. It reduces the amount of air passing through the oil
burner, combustion chamber, breaching, etc. up the chimney between burner cycles.
NOTE: THE USE OF THIS CONTROL CAN OCCASIONALLY CAUSE POST COMBUSTION
NOZZLE DRIP.
OUTPUT
BTUH
BURNER
MODEL NOZZLE
PUMP
PRESSURE
FLOW
RATE HEAD
STATIC
PLATE
T able 8: Blower Performance Table
Furnace
Model
P-HMX12F05701
P-HMX12F08001
P-HMX14F10001 1/2 G10 - DD 55°-85°F 7.7
P-HMX20F12001 3/4 G12 - 10 DD 45°-75°F 12.5
Motor
HP
1/2 G10- DD 55°-85°F 77
Blower
Temp.
Rise
( ∆T)
Motor
Tip: These formulae will assist with the design of the duct work
CFM
OutputBonnet
()()
FLA
CFM
Speed
High 1368 1298 1223 1144 1046 938
Medium - High 1318 1256 1178 1108 1007 909
Medium - Low 1173 1132 1071 993 909 816
Low 856 833 791 748 692 610
High 1593 1493 1410 1321 1226 1110
Medium - High 1485 1410 1341 1258 1146 1035
Medium- Low 1182 1158 1135 1074 996 896
Low 810 802 785 750 703 633
High 2008 1977 1915 1867 1801 1715
Medium - High 1819 1802 1759 1724 1662 1588
Medium - Low 1734 1698 1680 1644 1588 1510
Low 1501 1491 1470 1428 1385 1319
RiseeTemperaturSystemx
External Static Pressure - Inches w.c.
0.20 0.30 0.40 0.50 0.60 0.70
RiseeTemperaturSystem
==
OutputBonnet
CFMx
085.1085.1
Unitary Products Group 15
035-17473-000-B-1101
FIGURE 8 : GENERAL DIMENSIONS (P-HMX SERIES)
20,500
20,000
Flue
Pipe
C
H
14,000
22.125
31,000
22,000
Table 9: general dimens ions (inches)
Cabinet Plenum Openings Flue Filter Ship
Return Air (perm) Weight
Side
FxG
Bottom Diam.
Height
H
WidthADepthBHeight
C
Supply Air
DxE
P*HMX12F05701 & P*HMX12F08001
22 31 49½ 20½ x 20 14 x 22 14 x 22 5 42 16 x 25 x 1 190
P*HMX14F10001 & P*HMX20F12001
22 31 58-1/8 20½ x 20 14 x 22 n / a 6 46½ 16 x 25 x 1 250
.
(lb.)
16 UnitaryProductsGroup
035-17473-000-B-1101
FIGURE 9 : WIRING DIAGRAM - OIL FURNACE WITH ST9103A EFT & R7184A CONTROL
Unitary Products Group 17
035-17473-000-B-1101
WIRING NOTES:P-HMX SERIES OIL FURNACE
CONTINUOUS FAN OPERATION:
The ST9103 EFT has provisions to run the blower
motor continuously on a speed lower than the cooling
or heating speeds. On a call for cooling, the fan motor
will switch to cooling speed, and on a call for cooling,
the fan will switch to heating speed, each over-riding
the continuous low speed fan.
To obtain continuous low speed fan, route a 16 gauge
stranded, type TEW, 105°C wire from the C
nal on the ST9103 EFT to the low speed or medium
low speed motor terminal. Both wire ends will require ¼
inch quick connects, (also known as “Faston” connectors or ¼” spade connectors). For additional control
over the continuous low speed fan circuit, an SPST
toggle switch may be wired in series between the
motor terminal and the ST9103 EFT terminal. The continuous low speed fan operation operates at 115 vac.
Use appropriate wiring methods to prevent electrical
shock.
ONT Termi-
WARNING
The HUM terminals provide power to a line voltage
humidifier or humidifier step down transformer when
the oil burner motor is operating.
THERMOSTAT HEATING CONNECTIONS:
The thermostat connections “R” and “W”, or “Rh” and
“W” connect to the “R” and “W” screw terminals shown
on the left hand side of Figure 10, on the ST9103 EFT
located in the control box mounted to the blower
mounting rails
TURN OFF ELECTRICAL POWER TO THE FURNACE WHEN SERVICING OR ALTERING FURNACE WIRING.
FAILURETODOSOMAYRESULTINSEVEREPERSONALINJURY,PROPERTY DAMAGE OR DEATH.
ACCESSORIES:
The ST9103 EFT has provisions for supplying 115 volt
power to an electronic air cleaner (EAC) as well as 115
volts to a line voltage humidifier or humidifier step down
transformer. Both sets of terminals are ¼ inch quick
connect type, rated at 1 A each.
TheEACterminalsprovidepowertoanelectronicair
cleaner whenever the heating or cooling speeds are
activated. Power is not
speed is activated. If the electronic air cleaner must run
during continuous low speed fan operation, wire the
EAC into the furnace L1 terminal.
provided when the continuous
FIGURE 10 : THERMOSTAT CONNECTIONS
ST9103A
NOTE: All thermostat wires for both heating and cooling connect to the furnace at this point. A factory
installed wiring harness connects the heating control
functions to the R7184A oil primary control.
Figure 7,on page 12, shows the detail of the timed
“Blower Off” dip switch settings. Figure 10 shows the
dip switch location along the bottom edge of the control
board, just above the “Honeywell” label.
NOTE: The Honeywell R8184G may be used in place
of the R7184A. The R8184G is an intermittent ignition
control whereas the R7184A is an interrupted ignition
control. the R8184G continues to provide a spark during the entire burner cycle whereas the R7184A discontinues the spark after the flame has been proved.
The R8184G does not have the diagnostic led features
found on the R7184A oil primary controls.
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035-17473-000-B-1101
R7184 DETAILED SEQUENCE OF OPERATION
A. SAFETY CHECK IS MADE FOR FLAME (4 SECOND
DELAY).
1. When flame is not present, the R7184 will apply
power to the burner motor and ignition transformer.
2. When flame is present, the control remains in the
idle state.
B. CONTROL ENTERS THE TRIAL FOR
IGNITION STATE.
C. CONTROL MONITORS THE BURNER FLAME.
1. When flame is present, the control enters ignition
carryover state. (Continues to spark for 10-30
seconds).
a Provides continuous spark after flame is
sensed to assure that burner remains lit.
b Turns on LED diagnostic light.
c Startscarryover timer.
•Flame and call for heat are monitored.
Ιf flame is lost and lockout timer has not expired,
R7184 will return to trial for i gnition state.
•If flame is lost and lockout timer has expired,
R7997 will enter the recycle state.
•Recycle timer starts.
•Burner motor and igniter are turned off.
•LED diagnostic light flashes slow.
•Returns to idle state when recycle timer
expires (60 seconds).
•Carryover timer expires.
•Enters run state.
•Igniter turns off.
Combustion continues until thermostat is satisfied or
R7184 detects a loss of flame and enters into Recycle
Mode.
Thermostat is satisfied - call for heat is terminated:
•R7184 shuts off burner motor.
•LED diagnostic light is off.
•R7184 returns to idle state.
Unitary Products Group 19
035-17473-000-B-1101
IDLE STATE
THERMOSTAT CALLS FOR HEAT
SAFETY CHECKFOR FLAME
NO FLAME
BURNER MOTOR STARTS
FLAME
SEQUENCE
OPERATION
REMAINS IN IDLE STATE
R7184
R7997
of
TRIAL F OR IGNITION
BURNER FLAME MONITORED
FLAME
CARRYOVER STATE
•
Provides Continuous Spark
•
LED Diagnostic Light On
• Start Carryover Timer
FLAME
CARRYOVER TIMER EXPIRES
FLAME
RUN STATE
•
IgnitorTurns Off
THERMOSTAT SATISFIED
R7184 SHUTS OFF
R7997 SHUTS OFF:
•
Burner Motor
• LED Diagnostic Light
NO FLAME
FLAME LOST
FLAME LOST
LOCKOUT STATE
R7997:
R7184
•
Shuts off burner motor
•
Shuts off ignitor
• Fast Flashes LED
diagnostic light.
TO EXIT LOCKOUT
PRESS RESET
RECYCLE TIMER START S
R7184
R7997:
•
Shuts off burner motor
• Shuts off ignitor
• Slow Flashes LED
diagnostic light.
RECYCLE TIMER EXPIRES
(60 SECONDS)
RETURNS TO IDLE STATE
FIGURE 11 : SEQUENCE OF OPERATION
20 UnitaryProductsGroup
Table 10: ST9301A Detailed Sequence of Operation
Mode Action System Response
HEAT Thermostat calls for heat. ("W" termi-
nal is energized).
Thermostat ends c all for heat. ("W"
terminal is de-energized).
Burner fails to light. Oil primarly control locks out wit hin lockout timing (30 seconds).
Established flame fails. Burner motor is de-energized and oil primary control goes into recycle mode.
COOL Thermostat beginscall for cool.(G and
Y terminals are energized).
Thermostat ends call for cool. (G and
Y terminals are de-energized).
FAN Thermostat begins call for fan. (G ter-
minal is energized).
Thermostat ends call for fan. (Y termi-
nal is de-energized).
Limit switch string opens. a Oil primary control shuts off burner.
ST9103A closes oil primary control T-T connections.
Ignition system and R7184A and R8184G oill primary control start the furnace. Oil
flows as long as the oil primary control senses flame.
Burner motor is energized and heat “fan on” delay timing begins. When timing is
complete (30 seconds), the circulator fan is energized a t heat speed.
R7184A or R8184G oil primary control is de-energized, terminating the burner cycle.
Heat “fan off” delay timing begins. Length of delay depends on ST9103A dip switch
settings. When timing is complete, the circulator fan is de-e nergized.
ST9103A returns to standby mode. (Oil primary control and circulator fan are off,
unless continuous fan operation is selected at the thermostat).
Burner motor is de-energized. (Even though thermostat is still calling for heat).
If circulator fan has started it continues through the selected heat (fan off” delay
period.
If the selected heat “fan off” delay timing is longer than the recycle delay timing, the
circulator fan continues to run through the next trial for ignition.
Cooling contactor is energized immediately.
Circulator fan is energized at cool speed.
Cooling contactor is de-energized immediately.
Circulator fan turns off immediately.
Circulator fan is energized immediately at cooling spe ed.
Circulator fan is de-energized immediately.
b Circulator fan is energized immediately at heat speed.
c ST9103A opens oil primary control T-T connections.
d Circulating fan runs as long as limit string stays open.
If there is a call for cooling or a fan, the circulating fan switches from heating to cool-
ing speed.
035-17473-000-B-1101
LIMIT
FAN Continuous circulating fan is con-
EAC Electronic Air Cleaner is connected Electronic air cleaner (EAC) connections are energized when the heat or cool speed
HUM Humidity control is connected. Humidifier connections are energized when the oil burner motor is energized.
Limit switch string closes (with existing
call for heat).
Limit switch string closes (without
existing call for heat).
nected.
a ST9103A begins heat “fan off” delay sequence.
b Circulating fan turns off after the selected heat “fan off” timing.
c ST9103A re-closes oil primary control T - T connections.
d Oil primary control is energized, initiating burner light-off.
a Circular fan turns off when heat “fan off” delay time is complete.
bNormal operation resumes; ST9103A control is in standby mode awaiting next ther-
mostat command.
Circulating fan is energized when there is no call for heat, cool, or fan.
If fan operation is required by a call for heat, cool, or fan, the S T9103A switches off
the continuous fan speed tap before energizing the other fan speed.
of the circulator fan is energized. E AC connections are not energized when the
optionional continuous fan termnal is energize d.
Unitary Products Group 21
035-17473-000-B-1101
R7184 LED DIAGNOSTIC LIGHT
The LED diagnostic light has several functions. It indicates the state or mode in which the oil burner is operating. It will also indicate fault conditions, and help
determine cad cell resistance while the burner is operating.
NORMAL CONDITIONS:
The LED diagnostic light will turn on when the burner
enters the carryover state; the point at which ignition
spark is on, and will remain on through the run state,
where the ignition spark is terminated but the burner
continues to fire.
The LED diagnostic light will turn off at the end of the
burner cycle as the R7184 enters the idle state, and will
remain off until the next heating cycle.
FAULT CONDITIONS:
If the LED diagnostic light is flashing quickly; 1 Hz (1/2
second on / 1/2 second off), the R7184 is in the lockout
state. To exit the lockout state, press the reset button.
If the LED diagnostic light is flashing slowly; ¼ Hz (2
seconds on / 2 seconds off), the R7184 is in the recycle
state. This indicates that flame sensing was lost after
the lockout timer expired during the ignition carryover
state. The R7184 will return to the idle state within 60
seconds.
CAD CELL CONDITION:
If the LED diagnostic light is off, the cad cell is not
sensing flame.
TROUBLESHOOTING
IMPORTANT:
Due to the potential hazard of line voltage, only a
trained, experienced service technician should perform
the troubleshooting procedure.
PRELIMINARY STEPS:
Check the diagnostic light for indications of burner con-
dition. Refer to R7184 LED
DIAGNOSTIC LIGHT section
for details.
CAUTION
To prevent damage to the R7184, do not use an iron
coretransformerignitiontestertocheckouttheR7997
ignitor.Iron core transformerignitiontesters can damage solid state ignitors.
CAUTION
When simulating a callfor heat atthe R7184, disconnectat leastonethermostatleadwire from theT1 -T2
terminalsofthe R7184topreventdamage tothethermostat. Neglecting this procedure may burn out the
heat anticipator of a standard 24
cause harm to components within a micro-electronic
thermostat.
VAC thermostat, or
If the LED diagnostic light is on, the cad cell is sensing
flame, or viewing ambient light.
The resistance of the cad cell may be checked while
theR7184isintherunstate
by pressing the reset button. The LED diagnostic light will flash the following
code:
Before checking the R7184, perform these preliminary
checks, (repair or replace controls as necessary):
• check the power supply; fuse box or breaker, any
service switches, all wiring connections, and
burner motor reset button (if equipped).
• check the limit switches to ensure that the switch
contacts are closed.
Table 11: Cad Cell Resistance
Flashes Resistance in Ohms
1 Lessthan 400
2 Between 400 - 800
3 Between 800 - 1600
4 Between 1600 - 5000
22 Unitary Products Group
• check the electrode gap and position.
• check the contacts between the R7184 and the
electrodes.
• check oil supply (tank gauge).
• check the oil nozzle, oil filter, and oil valves.
• check the piping or tubing to the oil tank.
• check the oil pump pressure.
035-17473-000-B-1101
Check Oil Primary Control and Ignitor
If the trouble does not appear to be in the burner or
ignition hardware, check the oil primary control and the
ignitor by using the following equipment:
• screwdriver.
• voltmeter (0 - 150
VAC)
• insulated jumper wires with both ends stripped.
Preliminary Checks:
Make sure that limit switches are closed and that
contacts are clean.
Check for line voltage power on the oil primary
control black and white leadwires.
Refer to R7184 Troubleshooting for further information.
CAUTION
Electrical Shock Hazard.
Troubleshootingis donewiththesystem powered. Be
careful to observe all necessary precautions.to prevent electrical shock or equipment damage.
R7184A Troubleshooting
CONDITION: Burner motor does not start when there is a call for heat.
Procedure Status Corrective Action
1. Check that the l imit switches are closed and contacts are clean. This includes the burner motor reset
button.
2. Check for line voltage power at the oil primary control. Voltage should be 120 vac between the black
and white lead wire on the oil primary control.
3. Check indicator light with burner off, no call for heat
(no flame).
4. Shield cad cell from external light. Indicator light turns
5. Jumper thermostat (T-T) terminals on R7184A
Important:
First remove one thermostat leadwire.
-- --
-- --
Indicator light is on. Cad cell or controller is defective, sees external light, or
connections are shorted. Go to s tep 4.
Indicator light is off. Go to step 5.
Eliminate external light source or permanently shield cad
off.
Indicatorlight stays
on.
Burner starts Trouble in thermostat or limit circuit. Check thermostat or
Burner does not
start
cell.
• Replace cad cell with new cad cell and recheck.
• If indicator light does not turn off, remove yellow leadwires from R7184A and r e check.
• If indicator light is still on, replace the R7184A
control.
• If the indicator light turns off, replace cad cell bracket
assembly.
limit wiring connections. If connections are clean and tight,
check thermostat for continuity.
Disconnect the line voltage power and open line switch.
Check all wiring connections.
Tighten any loose connections and recheck.
If burner does not start, replace R7184A. .
Unitary Products Group 23
035-17473-000-B-1101
R7184A Troubleshooting (continued from previous page)
CONDITION: Burner starts t hen locks out on safety with indictor light flashing at 1 hz rate (1/2 second on, 1/2 second off)
Procedure Status Corrective Action
1) Check th limit switches are closed and contacts are clean. -- --
2) Check for line voltage power at the oil primary control. Voltage
should be 120 vac. (nominal)
3) Check indicator light with burner off, no call for heat (no flame). Indicator light is on. Cad cell or controller is defective, sees external light, or connec-
4) Shield cad cell from external light. Indicator light turns off. Eliminate external light source or permanently recheck.
5) Jumper thermostat (T - T) terminals on R7184A
Important
First remove one thermostat leadwire.
6) Reset oil primary contro l by pushing in and releasing red reset
button.
7) Listen for spark after burner turns on (after 2 second delay). Ignition is off Spark ignitor could be defective. Check for line voltage at ignitor ter-
8) Check indicator light after flame is established, but before oil primary control locks out.
9) Check for cad cell sighting for view of flame:
Disconnect line voltage power and open line switch.
Unplug cad cell and clean cad cell face with soft cloth. Check sighting for clear view of flame. Replace cad cell in socket.
Reconnect line voltage power and close line switch.
Start burner.
10) Check cad cell.
Disconnect line voltage power and open line switch.
Remove existing cad cell and replace within new cad cell.
Disconnectall wires from thermostat terminals to ensure that there
is no call for heat.
Reconnect line voltage power and close line switch.
Expose new cad cell to bright light such as a flashlight.
11)Check cad cell bracket assembly.
• Disconnect line voltage power and open line switch.
• Remove cad cell wires from quick connect connectors on the
R7184 and leave control leadwires open.
• Apply power to device.
• Place jumper across cad cell terminals after burner motor
turns on.
NOTE: Restricted Mode - (Limited Reset): In order to limit the accumulation of unburned oil in the combustion chamber, the control can be reset only 3
times, after which, the control locks out. The reset count returns to zero each time a call for heat is successfully completed.
To reset from
NOTE: Disable function: Pressing and holding the reset button will disable all functions until the button is released. The R7184 will restart at the beginningof the
normal heat cycle on Safety Check
Restricted Mode: Press and hold the reset button for 30 seconds. When the LED flashes twice, the device has reset.
-- --
tions are shorted. Go to step 4.
Indicator light is off. Go to Step 5.
Indicator light stays on. Replace cad cell with new cad cell and recheck.
Burner starts. Trouble in thermostat or limit circuit. Check thermostat or limit wir-
Burner does not start. Disconnect the line voltage power and open line switch.
Indicator light stops
flashing.
Indicator light continues to flashat 1 Hz
rate.
Ignition is on. Go to step 8.
Ignition is on but no oil
is being sprayed into
the combustion chamber.
Indicator light is on
until the control locks
out and starts flashing
during lockout.
Indicator light stays off. Go to step 9.
Burner locks out. Go to step10.
Burner keeps running System is OK
Indicator light is on. Remount control onto burner housing. Go to step 6.
Indicator light is off. Go to step 11.
If indicator light does not turn off, remove cad cellleadwiresfrom
R7184 and recheck.
If indicator light turns off, replace cad cell bracketassembly.
If indicator light does not turn off, replace controller.
ing connections.
Check all wiring connections.
Tighten any loose connections and recheck.
If burner does not start, replace R7184A.
Go to step7.
Verify that the control is not in restrictedmode.(See notesat end of
this table.) If not in restricted mode, replace R7184A.
minals. If line voltage is not present, replace R7184.
Check oil supply, and oil ine valve. Check for filter blockage or
seized oil pump.
Replace R7184A.
Indicator light is on. Replace cad cell bracket assembly.
24 Unitary Products Group
Table 12: System & General Troubleshooting
035-17473-000-B-1101
Problem Possible Cause
Furnace will not start
Furnace will not start without first pushing oil primary control reset
button.
(Happens on frequent basis)
Furnace starts, but cuts out requiring manually resetting the oil
protector reset button.
Thermostat not calling for heat.
No power to furnace.
Thermostat faulty.
Oil primary control faulty.
Photo Cell wiring shorted or
room light leaking into photo
cell compartment.
Open safety switch.
No fuel oil.
Cloggednozzle.
Cloggedoil filter.
Low oil pump pressure.
Air getting into fuel oil lines, or
fuel oil line dirty, clogged, or in
some manner defective.
Defective burner motor.
Photo Cell (Cad Cell) defective.
Remedy
Check thermostat and adjust. Also, check thermostat
for accuracy; if it is a mercury switch type, it might be
off level.
Check furnace switch, main electrical panel furnace
fuse or circuit breaker. also look for any other hand
operated switch, such an old, poorly located furnace
switchwhich was not removed during furnacereplacement.
Remove thermostat wires from R7184 control terminals T1-T2. Place a jumper across T1-T2. If furnace
starts, replace thermostat, thermostat sub-base (if
equipped), or both.
Check reset button on oil primary control. Remove
thermostat wires from oil primary control terminals T1T2. Check for 24v across T-T. If no voltage is present,
check for 115vto oil primary control. If 115v is present,
go to Table 10.
Check photo cell (cad cell) wiring for short circuits.
Also, check for room light leaking into cad cell compartment. Repair light leak if necessary. See Table10.
Check for open limit or auxiliary limit. also, check internal wiring connections; loose connectors, etc.
Check fuel oil supply. Check that all hand operated
fuel oil valves are in the open position. Fill oil storage
tank if necessary.
Replace nozzle with high quality replacement. Use
rating plate or Table 2 as a guide.
Replace oil tank filter or in-line filter if used.
Connect pressure gauge to oil pump. Adjust pump
pressure, or replace oil pump if necessary. Ensure that
erratic pressure readings are not caused by defective
fuel oil line.
Check fuel oil lines. Replace any compression fittings
found with high quality flared fittings. Check for any
signs of oil leaks. Any oil leak is a potential source of
air or contaminants.
Check burner motor.If burner motor is cutting out on
over-load, determine why. Replace if necessary.
If cad cell is dirty, clean it. (Determine why cad cell is
getting dirty). If cad cell is poorly aimed, realign it.
NOTE: the photo cell shuld have a resistance of
100KΩ in absence of light; a maximum of 1500Ω in
the presence of light. Ensure that room light is not
leaking the cad cell compartment. (See diagnostic light
section).
Unitary Products Group 25
035-17473-000-B-1101
Table 12: System & General Troubleshooting (Continued)
Furnace starts but cuts out requiring manual resetting the oil protector
reset button.
Oil burner sputtering at nozzle.
No fuel oil
Cloggednozzle.
Cloggedoil filter.
Low oil pump pressure.
Air getting into fuel oil lines, or
fuel oil line dirty, clogged, or in
some manner defective.
Defective burner motor.
Water or contaminants in oil.
Frozen oil line.
Electrodes out of adjustment or
defective.
Poor transformer high voltage
connections or defective
transformer.
Fuel oil filter clogged.
Defective oil pump.
Fuel oil line partially clogged or
contains air.
Check fuel oil supply. Check that all hand operated
fuel oil valves are in the open position. Fill oil storage
tank if necessary.
Replace nozzle with high quality replacement. Use rating plate or Table 2 as a guide.
Replace oil tank filter or in-line filter if used.
Connect pressure gauge to oil pump. Adjust pump
pressure, or replace oil pump if necessary. Ensure that
erratic pressure readings are not caused by defective
fuel oil line.
Check oil fuel lines. Replace any compression fittings
found with high quality flared fittings. Check for any
signs of oil leaks. Any oil leak is a potential source of
air or contaminants.
Check burner motor. If burner motor is cutting out on
over-load, determine why. Replace if necessary.
Drain fuel oil storage tank, replace fuel oil. (Consult
with fuel oil supplier).
Gently warm oil line. Insulate oil line. (Outdoor piping
size may require increase diameter).
Check electrode settings. Check electrodes for dirt
buildup or cracks in porcelain.
Check contacts between ignition transformer and electrodes. If OK, replace ignition transformer.
Replace fuel oil storage tank filter and / or fuel oil inline filter.
Check burner motor / fuel oil pump coupling. Check oil
pump pressure. Replace fuel oil pump if necessary.
Bleed air from oil line. If problem persists replace oil
line.
Excessive fuel oil consumption
Too much smoke.
System temperature rise too
high.
Poor “fan off” delay timing
selection (fan stops too soon).
Fuel oil leak.
Stack temperature too high.
Thermostat improperly adjusted
or in poor location.
Insufficient combustion air
adjustment at oil burner, or
improper draft pressure.
Heat exchanger partially
clogged.
System temperature rise ideally should not exceed
85°F.Check for clogged air filters. Check blower fan
for excess dirt build-up or debris. Speed up blower fan
if necessary.
Check “fan off” delay timing setting. Use a duct thermmeter in the supply air plenum take-off or first few
inches of the suply air trunk duct. Ideally, the fan will
shut at a temperature90° - 100°F. Manipulate the dip
switch settings to come as close as possible to this
“fan off” temperature.
Check fuel oil line for leaks. Repair or replace if necessary.
Check stack temperature. Stacktemperatures will normally range from 350° to 450°F. Check draft regulator.
Draft should be set to 0.02 in w.c.
Check thermostat heat anticipator setting against
measured amperage draw. Increase heat anticipator
setting if necessary. If the thermostat is being influenced by drafts, sunlight, duct work, etc., relocate to
more suitable location.
Adjust the oil burner combustion air band and draft
regulator to gain the highest practical CO
practical O
Up.
Check for soot build-up in heat exchanger flue passages, especially in the outer radiator.
contentin the flue gases.See Burner Set
2
or lowest
2
26 Unitary Products Group
Table 12: System & General Troubleshooting (Continued)
035-17473-000-B-1101
Soot building up on blast tube (end coning).
Furnace will not warm home to desired temperature
Poor alignment betweenoil
burner blast tube and
combustion chamber.
Flame impingement caused by
Incorrect nozzle angle.
Defective combustion chamber.
Air flow blocked or dirty air filter.
Thermostat adjustments or
location.
Insufficient air flow.
Defective high limit control.
Under-sized nozzle.
Blower fan motor stopping
intermittently on overload.
Burner motor stopping
intermittently on overload.
check alignment. Blast tube should be centered with
fire pot burner opening. Oil burner head should be 1/4
inch back from the inside surface of the combustion
chamber.
Check nozzle size and angle. (See Table 2). Check
distance from head to inside surface of the combustion chamber.
Check combustion chamber. Repair or replace.
Clean or replace air filter.
Check thermostat heat anticipator setting against
measured amperage draw. Increase heat anticipator
etting if necessary. If the thermostat is being influenced by drafts, sunlight, duct work, etc. relocate to
more suitable location.
Check all dampers. Open closed dampers, including
registers in unused rooms. check system temperature
rise. If temperature rise is too high, speed up blower
fan.
Test high limit function of all limit switches. Use a duct
thermometer to assess accuracy of limit control.
Check for obstructions to air flow around limit switch
bi-metal elements. Replace control if necessary.
Check nozzle. If problem is not caused by air flow
problems, use larger nozzle, if permitted by rating
plate.
Check blower fan motor amperage draw. Check motor
ventilation ports, clean if necessary.Replace motor if
necessary.
Check burner motor. Replace if necessary.
Home does not heat evenly Improper distribution of heat.
Air flow blocked or dirty air filter.
Supplyair temperaturetoo hot.
Insufficient air flow.
This is not likely to be a furnace problem. Balance duct
system.
Clean or replace air filter.
Check all dampers. Open closed dampers including
registers in unused rooms. Check system temperature
rise. If temperature rise is too high, speed up blower
fan.
Unitary Products Group 27
035-17473-000-B-1101
HOME OWNER’S REFERENCE TABLE
Installation Contractor:
Model No.
Serial No.
Date Installed
Contractor
Address
Postal Code:
Telephone No.
Service Contractor if different from installation contractor
Service Tech
Telephone No.
After Hours No.
Fuel Supplier
Oil Supplier
Telephone No.
After Hours No.
28 Unitary Products Group
NOTES
035-17473-000-B-1101
Unitary Products Group 29
035-17473-000-B-1101
NOTES
30 Unitary Products Group
NOTES
035-17473-000-B-1101
Unitary Products Group 31
035-17473-000-B-1101
Heating and Air Conditioning
Unitary Products Group
5005 York Drive, Norman, Oklahoma 73069
Subject to change without notice. Printed in U.S.A.
Copyright© by Unitary Products Group 2001. All rights reserved. Supersedes: 035-17473-000-A-900 035-17473-000-B-1101)
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