York P2DHX16F12001, P3DHX12F08001, P4LBX20F19001, P2LBX16F14501 User Manual
INSTALLATION
MANUAL
CONTENTS
OIL-FIRED WARM AIR
FURNACE
P3DHX12F08001 P2DHX16F12001
(Downflow or Horizontal Models)
P2LBX16F14501 P4LBX20F19001
INTRODUCTION............................................................. 2
HEAT LOSS....................................................................2
LOCATION OF UNIT ......................................................2
AIR CONDITIONING.......................................................4
COMBUSTION AIR......................................................... 4
CHIMNEY VENTING....................................................... 4
OIL TANK........................................................................6
PIPING INSTALLATION................................................. 6
ELECTRICAL CONNECTIONS ......................................6
CIRCULATING AIR BLOWER........................................ 7
OIL BURNER..................................................................8
FURNACE INSTALLATION SET-UP.............................9
MAINTENANCE AND SERVICE...................................10
OPERATING INSTRUCTIONS .....................................10
TABLE A-1: BECKETT OIL BURNER SET-UP ...........11
TABLE A-2: DIRECT DRIVE BLOWER SET-UP .........12
TABLE A-3: BELT DRIVE BLOWER SET-UP .............12
TABLE A-4: DIRECT DRIVE BLOWER
CHARACTERISTICS....................................................13
TABLE A-5: BELT DRIVE BLOWER
CHARACTERISTICS....................................................13
GENERAL DIMENSIONS - P2LBX16F14501...............14
GENERAL DIMENSIONS - P4LBX20F19001...............14
GENERAL DIMENSIONS - P4LBX20F19001...............15
GENERAL DIMENSIONS - P3DHX12F08001.............. 15
GENERAL DIMENSIONS - P3DHX12F08001.............. 16
GENERAL DIMENSIONS - P2DHX16F12001.............. 16
GENERAL DIMENSIONS - P2DHX16F12001.............. 17
WIRING DIAGRAM: MODEL P3DHX12F08001...........18
WIRING DIAGRAM: MODEL P2DHX16F12001...........18
WIRING DIAGRAM: MODEL P2LBX16F14501...........19
WIRING DIAGRAM: MODEL P4LBX20F19001...........19
R7184 DETAILED SEQUENCE OF OPERATION........ 20
R7184 LED DIAGNOSTIC LIGHT.................................22
Table C-1: Cad Cell Resistance................................. 22
R8184N NOTES............................................................22
TABLE C-2: R7184 TROUBLESHOOTING.................23
TABLE C-3: SYSTEM AND GENERAL
TROUBLESHOOTING.................................................. 25
P4LBX20F19001 ASSEMBLY NOTES.........................28
P3DHX SERIES DOWNFLOW CONFIGURATION
NOTES.......................................................................... 28
P3DHX12F08001 VESTIBULE KIT...............................29
REPAIR PART LIST – P3DHX12F08001A................... 30
REPAIR PART LIST – P2DHX16F12001A................... 31
REPAIR PART LIST – P2LBX16F14501A...................32
REPAIR PART LIST – P4LB SERIES..........................33
REPLACEMENT PART CONTACT INFORMATION.... 34
(Lowboy Models)
Read this manual completely before beginning
installation.
Important: These instructions must be kept with
the furnace for future reference.
1
IMPROPER INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD
CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.
IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR
MAINTENANCE CAN CAUSE INJURY
OR PROPERTY DAMAGE. REFER TO
THIS MANUAL FOR ASSISTANCE OR
ADDITIONAL INFORMATION, CONSULT A QUALIFIED INSTALLER, SERVICE AGENCY OR THE FUEL SUPPLIER.
THIS PRODUCT MUST BE INSTALLED
IN STRICT COMPLIANCE WITH THESE
INSTALLATION INSTRUCTIONS AND
ANY APPLICABLE LOCAL, STATE,
AND NATIONAL CODES INCLUDING
BUT NOT LIMITED TO: BUILDING,
ELECTRICAL AND MECHANICAL
CODES.
The furnace area must not be used as a
broom closet or for any other storage
purposes, as a fire hazard may be created. Never store items such as the following on, near or 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 fluids.
3. Paint thinners or other painting materials and compounds.
4. Paper bags, boxes, or other paper
or cardboard 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, CRANKCASE OIL, OR ANY OTHER OIL
CONTAINING GASOLINE AS A
FUEL FOR THIS FURNACE.
INTRODUCTION
Please read these instructions completely and carefully before installing and
operating the furnace.
The furnace must be installed and set up
by a qualified contractor.
Model P3DHX12F08001 is an oil fired
forced air multi-positional furnace, with
an output capacity range of 60,000
BTU/Hr. to 90,000 BTU/Hr. Model
P2DHX16F12001 is an oil fired forced air
multi-positional furnace, with an output
capacity range of 91,000 BTU/Hr. to
128,000 BTU/Hr. These models may be
installed in the down-flow position, as
well as both horizontal positions.
Model P2LBX16F14501 is a rear-breech
lowboy model with an output range of
130,000 to 143,000 BTUH. Model
P4LBX20F19001 is a rear-breech low-
boy model with an output range of
168,000 to 188,000 BTUH.
All models are listed with the Canadian
Standards Association, (CSA), and com-
ply with the standards of both the United
States and Canada for use with No. 1
(Stove) and No. 2 (Furnace) Oil.
In the United States, the installation of
the furnace and related equipment shall
be installed in accordance with the regu-
lations of NFPA No. 31, Installation of Oil
Burning Equipment, as well as in accor-
dance with local codes.
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.
When installation or application questions arise, regulations 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 P*DHX models are shipped assembled, pre-wired, ready for down-flow operation. P*DHX furnace models are air
conditioning ready. The furnace should
be carefully inspected for damage when
being unpacked.
The P2LBX16F14501 model is shipped
assembled, pre-wired, and ready for
lowboy furnace applications. The
P2LBX16F14501 model is air conditioning ready.
The P4LBX20F19001 is shipped in two
pieces, a furnace section and a blower
section, and must be assembled at the
installation site. Some field wiring is required. The P4LBX20F19001 is shipped
as a heating only furnace; however, air
conditioning may be added with the addition of field-installed controls.
HEAT LOSS
To determine the correct furnace and
firing rate for an application, it is necessary to calculate the maximum hourly
heat loss of the building based on local
design conditions. In new construction,
the heat loss should be calculated on a
room-by-room basis to enable proper
sizing of the trunk and branch ductwork.
In retrofit applications, a building shell
(overall) heat loss calculation may be
used.
In the United States, Manual J.
"Load Calculation
Conditioning Contractors of America,
(ACCA), describes a suitable procedure
for calculating the maximum hourly heat
loss.
In Canada, the maximum hourly heat
loss may be calculated in accordance
with the procedures described in the
manuals of the Heating, Refrigeration
and Air Conditioning Institute (HRAI), or
by other method prescribed by authorities having jurisdiction that are suitable
for local conditions.
" published by the Air
titled,
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 ductwork. A
central location minimizes the trunk duct
sizing.
Minimum installation clearances are
listed in Table 1.
NOTE: The recommended installation
clearances do not necessarily take into
consideration the clearances necessary
to replace the air filter or perform other
routine maintenance.
2
Table 1: Clearance to Combustibles
Furnace P2LBX P3DHX12F08001 P2DHX16F12001
Location Upflow Downflow Horizontal Downflow Horizontal
Top 3 in. 0 in. 6 in. 0 in. 3 in.
Bottom 0 in. 0 in. 1 in. 1 in. 1 in.
S/A
Plenum
0 in. 1 in. 1 in. 1 in. 3 in.
Rear 1 in.1 1 in. 1 in. 1 in. 1 in
Sides 6 in.2 1 in. 1 in. 1 in. 0 in.
Front 24 in. 6 in.1 24 in. 16 in.1 24 in.
Flue Pipe 9 in.3 9 in.3 9 in.3 9 in.3 9 in.3
Enclosure Standard Closet - - - Closet Alcove
1 24 inches is required for servicing.
2
18 inches is required on one side as service access to rear.
3
18 inches required in some U.S. jurisdictions
DOWN-FLOW INSTALLATION
All P*DHX furnace models have been
assembled for installation in the downflow position. Maintain all clearances to
combustibles as outlined in Table 1.
P*DHX models have available sub-bases
for installations on combustible floors.
The sub-bases provide a means of effectively mating the supply air plenum with
the furnace, and providing the necessary
one-inch clearance to combustibles
around the supply air plenum.
Fig. 1: Typical Suspended Application
HORIZONTAL INSTALLATION
P*DHX furnaces models 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 normal
upright position.
3. Re-align the oil burner assembly to
the combustion chamber (fire-pot),
and then secure into place with the
three nut and washer sets.
IMPORTANT: Model P3DHX12F08001
has an auxiliary limit control that must be
in the upper position. Be sure that the
auxiliary limit control is above the oil
burner assembly.
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 a noncombustible material 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.
3
SUSPENDED INSTALLATION
Refer to Figure 1. Maintain clearances to
combustibles as outlined in Table 1. The
furnace may be suspended by field fabricating a cradle of angle iron and
threaded rod. Secure the furnace with 2
inch minimum slotted angle or equivalent, as shown in Figure 1. The furnace
must be supported in such a way as to
not allow twisting or sagging of the cabinet. Position the supports so as to not
interfere with accessing the burner and
blower compartments. 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.
AIR CONDITIONING
If the furnace is used in conjunction with
air conditioning, the furnace shall be
installed in parallel with or upstream from
the evaporator coil to avoid condensation
in the heat exchanger. In a parallel
installation, the dampers or air controlling
means must prevent chilled air from entering the furnace. If the dampers are
manually operated, there must be a
means of control to prevent the operation
of either system unless the dampers are
in the full heat or full cool position. The
air heated by the furnace shall not pass
through a refrigeration unit unless the
unit is specifically approved for such
service.
Generally, a six-inch clearance between
the air conditioning evaporator coil and
the heat exchanger will provide adequate
airflow through the evaporator coil.
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.
COMBUSTION AIR
When a furnace is installed in the full
basement of a typical frame or brick
house, infiltration is normally adequate to
provide air for combustion and draft operation. If the furnace is installed in a
closet or utility room, two (2) 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. For furnaces located
in buildings of unusually tight construc-
4
tion, 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. Size all of the openings and associated ductwork by the
standards provided in the latest Oil Installation Code editions; NFPA 31 in the
United States, CAN/CSA B139 in Canada. Take all fuel burning appliances in
the area into consideration when calculating combustion and ventilation air requirements.
The Model CAS-2B-90E Furnace Boot
manufactured by Field Controls, Inc. may
be used with the furnace to 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
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
P3DHX12F08001 furnace only, the vent
should be sized at 4-inch minimum, 5inch maximum. If the chimney serves the
P2DHX16F12001 or P2LBX16F14501
furnace only, the vent should be sized at
4-inch minimum, 6-inch maximum. If the
chimney serves the P4LBX20F19001
furnace only, the vent should be sized at
5-inch minimum, 7-inch maximum. The
data provided in Table 3 is based on
dedicated venting. If the furnace is to be
co-vented with other appliances, refer to
NFPA 211, Standard for Chimneys, Fire-
places, Vents, and Solid Fuel-Burning
Appliances, NFPA 31, Standard for the
Installation of Oil Burning Equipment or
CAN/CSA B139, Installation Code For
Oil Burning Equipment for correct sizing
information.
NOTE: This furnace is approved for
use with L-Vent.
NOTE: Maximum temperature for LVent is 575°F (300°C).
IMPORTANT: The chimney must be
capable of providing sufficient draft at all
times for the safe removal of the products of combustion.
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 reevaluate the availability of combustion
and ventilation air, and take corrective
action.
The flue pipe should be as short as possible with horizontal pipes sloping upward toward the chimney at a rate of
one-quarter inch to the foot. The flue
pipe should not be smaller in cross sectional area than the flue collar on the
furnace. The flue pipe may be reduced in
size to fit a smaller diameter chimney
with the use of a tapered reducer fitting
at the chimney inlet. 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 2 for common
chimney problems and their remedies.
THE FURNACE MUST BE CONNECTED TO A FLUE HAVING SUFFICIENT DRAFT AT ALL TIMES TO ENSURE SAFE AND PROPER 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. In the United States, refer to the
latest edition of NFPA 31 for regulations
governing the installation of oil burning
equipment. In Canada, refer to the latest
edition of CAN/CSA B139 for rules governing the installation of oil burning
equipment.
Fig. 2: Common Chimney Problems
Table 2: Common Chimney Problems
Refer to Figure 2
Key Trouble Diagnostic Remedy
Top of chimney
lower than sur-
A
rounding objects
Chimney Cap
B
or ventilator.
Coping restricts
C
opening.
Observation
Observation Remove
Observation
Extend chimney
above all surrounding objects within 30
feet.
Make opening
as large as
inside of chimney.
Obstruction in
chimney
D
Joist protruding
E
into chimney.
Break in chim-
F
ney lining.
Collection of
soot at narrow
G
space in flue
opening.
H Offset
Two or more
I
openings to the
same chimney.
Loose-seated
J
pipe in flue
opening.
Smoke pipe
K
extends into
chimney.
Failure to extend the length
L
of flue partition
to the floor.
Loose-fitted
M
clean-out door.
DRAFT REGULATOR 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
from the furnace breeching and installed in accordance to the
instructions supplied with the regulator.
Can be found
by light and
mirror reflecting
conditions in
chimney.
Lowering a light
on an extension
cord.
Smoke test build smudge
fire blocking off
other opening,
watching for
smoke to escape.
Lower light on
extension cord.
Lower light on
extension cord.
Found by inspection from
basement.
Smoke test.
Measurement
of pipe from
within or observation of pipe
by means of a
lowered light.
By inspection or
smoke test.
Smoke test.
Use weight to
break 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.
Leaks should
be eliminated
by cementing
all pipe openings.
Length of pipe
must be reduced to allow
end of pipe to
be flush with
inside of tile.
Extend partition
to floor level.
Close all leaks
with cement.
5
Table 3: Minimum Chimney Base
Temperatures (°F)
Nozzle
Chimney Height (ft.)
11 20 28 36
Chimney Thermal Resistance < R6
0.50 300 400 535 725
0.65 275 340 430 535
0.75 260 320 380 475
0.85 250 300 355 430
1.00 245 300 355 430
1.10 245 290 345 400
1.20 240 275 320 365
1.50 240 275 320 365
1.65 235 270 300 345
Nozzle
Chimney Height (ft.)
11 20 28 36
Chimney Thermal Resistance > R6
0.50 185 200 220 250
0.65 175 185 205 220
0.75 175 185 195 210
0.85 165 185 195 205
1.00 165 185 195 205
1.10 165 185 195 205
1.20 165 180 190 200
1.50 165 175 185 195
1.65 165 175 180 190
< -
less than
, > -
greater than
OIL TANK
Oil storage tanks must be selected and
installed in compliance with applicable
codes; in the United States, NFPA 31,
Standard for the Installation of Oil Burning Equipment, Chapter 2. and in Can-
ada, CAN/CSA-B139, Installation Code
for Oil Burning Equipment, Section 6.
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 abovementioned 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.
PIPING INSTALLATION
In the United States, NFPA 31, Standard
for the Installation of Oil Burning Equipment, Chapter 2.
In Canada, the entire fuel system should
be installed in accordance with the requirements of CAN/CSA B139, and local
regulations. Use only approved fuel oil
tanks piping, fittings and oil filters.
Ensure that all fittings used in a copper
oil line system are high quality flare fittings. Do not use compression fittings.
Do not use Teflon tape on any fittings.
Pressurized or gravity feed installations
must not exceed 3 PSIG. Pressures
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 11½ feet, it may be necessary
to use a pressure-regulating device approved for this purpose.
The furnace may be installed with a onepipe system with gravity feed or lift. The
maximum allowable lift on a single line
system is 8 feet. 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. 2-stage
oil pumps are not available for either the
P*HMX or P*LBX furnaces. The following
chart shows the allowable line lengths
(horizontal + vertical) for single and twoline oil piping systems. All distances are
in feet.
Table 4: Oil Lines
Copper Tubing Oil Line Length (Feet)
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
Single-Pipe Two-Pipe
⅜”
OD
½” OD
⅜”
OD
½” OD
Continue
5 33 100 55 100
6 29 100 53 100
7 25 99 50 100
8 21 83 48 100
9 17 68 45 100
10 13 52 42 100
12 - - - - - - 37 100
14 - - - - - - 32 100
16 - - - - - - 27 100
18 - - - - - - 22 88
In retrofit applications, where an existing
oil line system is in place, a vacuum
check will help determine the efficacy of
the existing oil line system The vacuum
in a system should not exceed 6” Hg. for
a single pipe system, nor 12” Hg. for a
two-pipe system.
NOTE: The oil burner requires the use of
a bypass plug when converting from
single-pipe to two-pipe oil piping systems. See burner manufacturer’s instructions.
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.
ELECTRICAL CONNECTIONS
The furnace is listed by the Canadian
Standards Association (CSA). All models
except for the P4LBX20F19001 are factory wired and require minimal field wiring. The P4LBX20F19001 model is prewired except for the wiring connections
to the blower motor. The wires from the
furnace section are routed through the
grommet in the blower section blower
division panel, and then connected to the
blower motor. 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. In Canada, all field wiring should conform to
CAN/CSA C22.1 Canadian Electrical
Code, Part 1, and by local codes, where
they prevail.
The furnace should be wired to a separate and dedicated circuit in the main
electrical panel; however, accessory
equipment such as electronic air clean-
6
ers 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, installed in an easily accessible
area between the furnace and furnace
room entry, and be located in such a
manner to reduce the likelihood that it
would be mistaken as a light switch or
similar device.
The power requirements for all models:
120 VAC, 1 ∅, 60 Hz.
Maximum fuse size for the P*DHX models and P2LBX16F14501 model: 15
amps. Maximum fuse size for the
P4LBX20F19001 model: 20 amps.
Accessories requiring 120 VAC power
sources such as electronic air cleaners
and humidifier transformers may be
powered from the furnace circuit. 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 autogenerating windings of the direct drive
motor.
Thermostat wiring connections and air
conditioning contactor low voltage connections are shown in the wiring diagrams. 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.
Normal heat anticipator setting: for the
P*LBX models is 0.1 A. Normal heat
anticipator setting: for the P*DHX models
is 0.4 A .For more precise adjustment,
the heat anticipator may 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 circuit without
first removing one of the two wires first.
To determine the heating circuit amperage draw:
1. Disconnect one of the “R” or “W”
wires from the thermostat terminal.
2. Connect an ammeter between the
wire and the thermostat terminal to
which it was attached.
3. Note the amperage reading when
the heating contacts are closed.
HEAT
(System switch must be on “
” if
so equipped.
4. Re-connect the thermostat wire. 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.
CIRCULATING AIR BLOWER
Both P*DHX and the P2LBX16F14501
furnace models are equipped with a direct drive blower system. 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 Appendix B or the wiring diagram label affixed to the furnace.
THE NEUTRAL WIRE (normally the
white wire) IS NEVER MOVED TO ADJUST THE BLOWER SPEED.
DO NOT CONNECT POWER LEADS
BETWEEN MOTOR SPEEDS. THE
NEUTRAL WIRE MUST ALWAYS BE
CONNECTED TO THE MOTOR'S DESIGNATED NEUTRAL TERMINAL.
It is possible and acceptable to use a
single blower speed for both heating and
cooling modes. The simplest method to
connect the wiring from both modes is to
use a "piggy-back connector" accommodating both wires on a single motor tap.
It is also acceptable to connect the selected motor speed with a pigtail joined
to both heating and cooling speed wires
with a wire nut. As a safety precaution
against accidental disconnection of the
wires by vibration, it is advisable to secure the wire nut and wires with a few
wraps of electricians tape.
If the joining of the blower speed wiring
is done in the furnace junction box, tape
off both ends of the unused wire.
The P4LBX20F19001 furnace model is
equipped with a belt drive blower system. The blower speed (RPM) and resultant airflow can be varied by adjusting
the variable speed motor pulley.
DISCONNECT THE POWER SUPPLY
TO THE FURNACE BEFORE OPENING THE BLOWER ACCESS DOOR
TO SERVICE THE AIR FILTER, FAN
AND MOTOR. FAILURE TO SHUT OFF
POWER COULD ALLOW THE
BLOWER TO START UNEXPECTEDLY, CREATING A RISK OF DEATH
OR PERSONAL INJURY.
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
auto-generate sufficiently high voltages to damage accessory equipment.
Do not start the burner or blower fan
unless the blower access door is securely in place.
7
OIL BURNER
P*LBX furnaces are equipped with
Beckett AF Series oil burners with the
Beckett CleanCut pump and R7184B oil
primary control. P*DHX furnaces are
equipped with Beckett AF Series oil
burners with the R8184N oil primary control. The oil burner must align properly
with the cerafelt fiber chamber (firepot).
The cerafelt fiber chamber is initially
quite soft, but hardens and becomes
quite brittle after the first firing. The firepot is held in place by a retaining
bracket; however, it is possible for the
firepot to shift if subjected to rough handling during transit.
BEFORE OPERATING THE FURNACE CHECK BURNER ALIGNMENT
WITH COMBUSTION CHAMBER.
THE END CONE OF THE AIR TUBE
MUST BE CENTRED TO THE ACCOMODATING RING PROVIDED IN
THE DESIGN OF THE COMBUSTION
CHAMBER. ADJUST ALIGNMENT AS
NECESSARY BEFORE THE FIRST
FIRING.
OIL BURNER NOZZLES
All furnace models are certified for multiple firing rates. Choose the firing rate
that most closely matches the calculated
heat loss of the building. Models, firing
rates and nozzles are listed in Appendix
A: AF Burner Set-Up.
Fig. 4: Horizontal Smoke Test Port Location Fig. 5: Vertical Smoke Test Port Location
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, 5/16” 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.
Electrode positioning should be checked
before the first firing of the furnace.
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 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 flue pipe diameters away from
the furnace breeching, if venting horizontally from the furnace, (typically P*LBX)
or from the flue pipe elbow if venting
vertically (typically P*DHX) before reaching the furnace. (see Figures 4 and 5).
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.
The Beckett burner bulk air band should
be closed, and the air shutter initial setting should be approximately 7.00.
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.
PROCEDURE:
Start the burner and allow it to run at
least ten minutes. Set the air shutter to
give a good flame visually. The combustion air supply to the burner is controlled
by adjusting the air shutter on the left
side of the burner, and, if necessary, 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. The draft may be measured at the test port. The final breech
draft should be - 0.02 inches w.c. to
provide adequate over-fire draft.
8
Check the oil pump pressure. Standard
operating pressure is 100 PSIG.
After reaching steady state, take a
smoke test. If not indicating a trace, set
the combustion air controls to provide a
trace.
Typically, the CO
reading will range
2
from 11.5% to 13.5%.
After the air adjustments have been
completed, and the air shutter or air adjustment plate has been secured, recheck the breech draft and take another
smoke test to ensure that the values
have not changed.
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.
STACK TEMPERATURE:
Stack temperature will vary depending
on fuel input, circulating air blower
speed, and burner set up, etc. In general, stack temperature should typically
range between 380°F to 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 70°F and 85°F.
If the venting from the furnace to the
chimney is long, or exposed to cold ambient temperatures, it may be necessary
to use L-Vent as the vent connector to
reduce stack temperature loss to prevent
condensation. The venting should be
inspected annually to ensure that it is
intact.
9
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 following the procedures outlined above.
B) The furnace should operate within a
temperature rise of 85°F ±15°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.
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 on
direct drive equipped units by selecting
alternate circulation fan motor speeds,
on belt drive equipped units by adjusting
the variable speed motor pulley. 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 operating correctly. For direct
drive equipped units, this may be done
by temporarily removing the circulator
fan heating wire or neutral wire. For belt
drive equipped units, temporarily remove
the fan belt. Turn of electrical power to
the furnace before working with the motor wires or fan belt. 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. Finally, restore power to
the furnace.
E) Adjust the “Fan Off” setting on the
L6064A or L4064W fan limit controller. In
most cases, the “Fan Off” temperature
should be 90° to 100°F as indicated on
the thermometer used to measure the
supply air temperature. Once the “Fan
Off” setting has been established, set the
“Fan On” setting. In most cases, the “Fan
On” setting should be approximately
30°F higher than the Fan Off” setting.
NOTE: The L4064W fan/limit controller
has an auxiliary “fan on” function that
activates when the thermostat is calling
for heat. The controller is designed to
start the circulating fan in 20 to 30 seconds. Adjust the “fan on” setting on the
controller dial 30°F higher than the “fan
off” setting even though the circulating
fan will normally be started by the auxiliary “fan on” function.
F) 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.
G) Be sure that the homeowner is
familiar with the furnace. The
homeowner should be aware of 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 homeowner should be informed 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 thorough 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.
MAINTENANCE AND SERVICE
A: Routine Maintenance By Home
Owner
Other than remembering to arrange for
the annual professional servicing of the
furnace by the service or installation contractor, the most important routine service performed by the homeowner is to
maintain the air filter or filters. A dirty
filter can cause the furnace to over-heat,
fail to maintain indoor temperature during
cold weather, increase fuel consumption
and cause component failure.
The furnace filter(s) should be inspected,
cleaned or replaced monthly. The furnace is factory equipped with a semipermanent 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.
B: Annual Service By Contractor
A wire brush can be used to loosen dirt
and debris on the inside surfaces of the
radiator. Clean out all accumulated dirt,
soot and debris with a wire handled
brush and an industrial vacuum cleaner.
Replace the clean-out yoke assemblies
and clean-out covers.
Most circulating fan 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" oiler. This oiler has a long
flexible plastic spout. DO NOT OVERLUBRICATE. Excess oil may result in
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 draft regulator 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.
After the furnace warms sufficiently, the
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 until the furnace has cooled sufficiently.
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: If the furnace is to be shut down
for an extended period of time, close the
oil supply valve to the oil burner.
DO NOT ATTEMPT TO START THE
BURNER WHEN EXCESS OIL HAS
ACCUMULATED, WHEN THE FURNACE IS FULL OF VAPOUR, OR
WHEN THE COMBUSTION CHAMBER
IS VERY HOT. NEVER BURN GARBAGE OR PAPER IN THE FURNACE,
AND NEVER LEAVE PAPER OR RAGS
AROUND THE UNIT.
THE Combustion chamber (firepot) IS
FRAGILE. use care when inspecting
and cleaning this area.
The heat exchanger should be inspected
periodically and cleaned if necessary. if
cleaning is necessary, SHUT OFF
POWER TO THE FURNACE and re-
move 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 heat exchanger radiator, remove the covers on the front or inner
front panel, and then loosen the brass
nuts on the radiator clean-out yoke assembly. Do not remove the brass nuts.
The yoke assembly, once loosened, may
be removed to gain access to the heat
exchanger outer radiator.
10
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 thermostat above 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). If pressing the reset button does
not start the furnace, refer to Appendix
C, Troubleshooting.
TABLE A-1: BECKETT OIL BURNER SET-UP
FURNACE
MODEL
P3DHX12F08001
P2DHX16F12001
OUTPUT
BTU/Hr.
60,000 3 AF76BNHS 0.50 / 80°A 100 PSIG 0.50 GPH F3 1 3-3/8 in.
78,000 2 AF76BNHS 0.65 / 80°A 100 PSIG 0.65 GPH F3 1 3-3/8 in.
90,000 AF76BNHS 0.75 / 80°A 100 PSIG 0.75 GPH F3
91,000 AF76XN 0.75 / 80°A 100 PSIG 0.75 GPH F3 2-3/4 in.
101,000 AF76XN 0.85 / 80°A 100 PSIG 0.85 GPH F3 2-3/4 in.
117,000 2 AF76XN 1.00 / 60°A 100 PSIG 1.00 GPH F3 2-3/4 in.
128,000 AF76YB 1.10 / 70°A 100 PSIG 1.10 GPH F6 2-3/4 in.
BURNER
MODEL
BECKETT AF SERIES OIL BURNERS
NOZZLE
(Delavan)
PUMP
PRESSURE
FLOW
RATE
HEAD
1
3-3/8 in.
STATIC
PLATE
P2LBX16F14501
143,000
2
AF65YB 1.20 / 60°A 100 PSIG 1.20 GPH F6 2-3/4 in.
168,000 AF81WF 1.50 / 70°B 100 PSIG 1.50 GPH F16 2-3/4 in.
130,000 AF65YB 1.10 / 70°A 100 PSIG 1.10 GPH F6 2-3/4 in.
P4LBX20F19001
1
Used with ceramic insulator.
2
Factory supplied nozzle.
3
Requires a low firing rate baffle.
188,000
2
AF81WF 1.65 / 70°B 100 PSIG 1.65 GPH F16 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, breeching, etc. up the chimney between burner cycles.
NOTE: THE USE OF THIS CONTROL CAN OCCASIONALLY CAUSE POST COMBUSTION NOZZLE DRIP.
11
Loading...