Maytag POF1HD140AVFA Operating instructions

Installation, Operation and
Maintenance Manual
Oil Fired Warm Air Furnaces
POF1HD140AVFA (Up-Flow Model with ECM)
POF1HD091AVFA (Up-Flow Model with ECM)
FOR YOUR SAFETY:
Do not store or use gasoline or other flammable liquids or
vapors in the vicinity of this, or any other appliance.
ALL INSTALLATIONS MUST MEET ALL
LOCAL, PROVINCIAL/STATE, AND
FEDERAL CODES WHICH MAY
DIFFER FROM THIS MANUAL
MAYTAG
Read this complete manual before
beginning installation. These instructions
must be kept with the furnace for future
reference.
766B-0909
TABLE OF CONTENTS
1. INTRODUCTION................................................................................................................................................... 3
2. HEAT LOSS.......................................................................................................................................................... 3
3. LOCATION OF UNIT ............................................................................................................................................ 3
4. AIR CONDITIONING APPLICATIONS ................................................................................................................ 4
5. COMBUSTION AIR .............................................................................................................................................. 4
6. CHIMNEY VENTING............................................................................................................................................. 4
7. BAROMETRIC DAMPER CONTROL. ................................................................................................................. 5
9. FAN TIMER BOARD AND LIMIT CONTROL ...................................................................................................... 5
10. ELECTRICAL CONNECTIONS.......................................................................................................................... 5
11. HUMIDIFIER ....................................................................................................................................................... 5
12. PIPING INSTALLATION..................................................................................................................................... 5
13. OIL FILTER......................................................................................................................................................... 6
14. OIL BURNER NOZZLES.................................................................................................................................... 6
15. OIL BURNER ADJUSTMENT ............................................................................................................................ 6
16. BURNER ELECTRODES ................................................................................................................................... 6
17. BURNER PRIMARY (SAFETY) CONTROL ...................................................................................................... 6
18. COMBUSTION CHAMBER ................................................................................................................................ 6
19. CIRCULATING AIR BLOWER ........................................................................................................................... 7
19B. CIRCULATING AIR BLOWER ........................................................................................................................ 7
20. MAINTENANCE AND SERVICE........................................................................................................................ 8
21. OPERATING INSTRUCTIONS........................................................................................................................... 8
22. ECM BLOWER MOTOR OPERATION .............................................................................................................. 9
A.1 OIL BURNER AIR ADJUSTMENT ................................................................................................................... 11
A.2 BURNER ELECTRODES ................................................................................................................................. 11
A.3 START UP......................................................................................................................................................... 11
APPENDIX B: WIRING DIAGRAMS....................................................................................................................... 17
OPERATION OF OIL BURNER .............................................................................................................................. 18
APPENDIX C OIL PRIMARY CONTROL DETAILED SEQUENCE OF OPERATION .......................................... 19
OIL PRIMARY CONTROL LED DIAGNOSTIC LIGHT........................................................................................... 22
FINAL CHECK OUT ................................................................................................................................................ 28
HOMEOWNER’S REFERENCE TABLE................................................................................................................. 29
PARTS LISTING: HIGHBOY MODEL: POF1HD140AVFA.................................................................................... 31
PARTS LISTING: HIGHBOY MODEL: POF1HD091AVFA.................................................................................... 34
2
IMPORTANT:
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
other means prescribed, or approved by the local
authority having jurisdiction.
1. INTRODUCTION
Please read these instructions completely and
carefully before installing and operating the furnace.
In the United States, Manual J. titled, "Load
Calculation" published by the Air Conditioning
Contractors of America, describes a suitable
procedure for calculating the maximum hourly heat
loss.
Model POF1HD140AVFA is an oil fired forced air up-flow
furnace with an output capacity range of 87,000 BTU/Hr.
to 116,000 BTU/Hr. Model POF1HD091AVFA is an oil
fired forced air up-flow furnace with an output capacity
range of 58,000 BTU/Hr. to 87,000 BTU/Hr.
3. 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. All models
may be installed on combustible floors. The
minimum installation clearances are listed in Table
1.
POF1HD140AVFA and POF1HD091AVFA are equipped
with direct drive ECM motors.
DO NOT USE GASOLINE, CRANK CASE OIL, OR
ANY OIL CONTAINING GASOLINE.
FOR YOUR SAFETY
Table 1: Clearances – (Inches)
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE.
Clearance to Combustibles
Location
POF1HD140AVFA
POF1HD091AVFA
Models
All models are CSA listed, (NRTL/C) for use with No. 1
(Stove) and No. 2 (Furnace) Oil. Please refer to the
tables in Appendix A for performance and dimensional
data.
In Canada, the installation of the furnace and related
equipment shall be installed in accordance with the
regulations of CAN/CSA - B139, Installation Code for OilBurning Equipment, as well as in accordance with local
codes.
In the United States of America, the installation of the
furnace and related equipment shall be installed in
accordance with the regulations of NFPA No. 31,
Standard for the Installation of Oil-Burning Equipment, as
well as in accordance with local codes.
Top
1
Bottom
0
S/A Plenum
1
Rear
1
Sides
1
Front
1**
Flue Pipe
9*
Enclosure
Closet
*18 in. in USA
** 24 in. required for service clearance
Regulations prescribed in the National Codes and Local
regulations take precedence over the general
instructions provided on 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.
2. 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, Refrigeration
and Air Conditioning Institute of Canada (HRAI), or by
HEAT EXCHANGER SUPPORT SCREWS
3
Before final placement of the furnace, the heat
exchanger support screws shown in the picture may be
removed. This may be preferable if the furnace rear
panel will be inaccessible after installation. The screws
must be removed if the heat exchanger must be removed
from the cabinet.
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.
4. AIR CONDITIONING APPLICATIONS
If the furnace is used in conjunction with air conditioning,
the furnace shall be installed in parallel with or upstream
from the evaporator coil to avoid condensation in the
heat exchanger. In a parallel installation, the dampers or
air controlling means must prevent chilled air from
entering the furnace. If the dampers are manually
operated, there must be a means of control to prevent
the operation of either system unless the dampers are in
the full heat or full cool position. The air heated by the
furnace shall not pass through a refrigeration unit unless
the unit is specifically approved for such service.
NOTE: THE FURNACE IS APPROVED FOR
USE WITH TYPE L VENT OR EQUIVALENT.
CHIMNEY VENTED VERSIONS OF THE
FURNACE MUST BE CONNECTED TO A
FLUE HAVING SUFFICIENT DRAFT AT ALL
TIMES TO ENSURE SAFE AND PROPER
OPERATION OF THE APPLIANCE.
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.
NOTE: THE RECOMMENDED FLUE DRAFT
PRESSURE IS -0.02 IN. W.C. (SEE FIG 2.)
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.
5. COMBUSTION AIR
If the furnace is installed in a closet or utility room, two
openings must be provided connecting to a wellventilated space (full basement, living room or other
room opening thereto, but not a bedroom or bathroom).
One opening shall be located above the level of the
upper vent opening and one opening below the
combustion air inlet opening in the front of the furnace.
Each opening shall have a minimum free area of 1½
square inches per 1,000 Btu/h of total input rating of all
appliances installed in the room.
See appendix A for burner set-up.
Fig. 2: Checking Over-Fire Draft.
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.
6. CHIMNEY VENTING
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 should connect to the
chimney such that the flue pipe extends into, and
Over-fire draft access port.
4
be powered from the electronic fan timer board
where provisions have been made for connections,
but should have their own controls. Do not use the
direct drive motor connections as a power source,
since there is a high risk of damaging the
accessories by exposure to high voltage from the
auto-generating windings of the direct drive motor.
7. BAROMETRIC DAMPER CONTROL.
The barometric damper control, also known as a draft
regulator, is used on conventional chimney venting only.
This control 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,
when installed should be in the same room or enclosure
as the furnace and should not interfere with the
combustion air supplied to the burner. The control should
also be located near the furnace flue outlet and installed
according to the instructions supplied with the regulator.
The flue outlet pressure (measured between the furnace
and draft regulator, or the oil burner mounting plate overfired draft access port. fig. 2) should be set to -0.02 in.
w.c.
Thermostat wiring connections and air conditioning
contactor low voltage connections are shown in the
wiring diagrams in Appendix B. Some microelectronic 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.
9. FAN TIMER BOARD AND LIMIT CONTROL
(FIG. 4) (page 19)
The United Technologies 1168-1 ECM
(POF1HD140AVFA and POF1HD091AVFA) tap board
has an adjustable fan on/off delay that must be adjusted
in accordance with the furnace input rating (nozzle size).
Refer to Table A-10 (pg 15) for ECM blower set-up.
The thermostat heat anticipator should be adjusted
to the amperage draw of the heating control circuit
as measured at the "R" and "W" terminals of the
thermostat. To reduce the risk of damaging the heat
anticipator, do not measure this current with the
thermostat connected to the circuit. Measure the
amperage by connecting an ammeter between the
two wires that will connect to the thermostat "R" and
"W" terminals.
10. ELECTRICAL CONNECTIONS
The furnace is listed by the Canadian Standards
Association under the NRTL (North American) Standard.
It is factory wired and requires minimal field wiring. 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.
11. 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. Do not use direct drive motor
connections as a source of power for 120 VAC
humidifiers and humidifier transformers.
The furnace should be wired to a separate and dedicated
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,
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.
12. PIPING INSTALLATION
The entire fuel system should be installed in
accordance with the requirement of CAN/CSA B139, and local regulations. Use only an approved
fuel oil tanks piping, fittings and oil filter.
In the United States the installation must be in
accordance with NFPA No. 31 and local codes and
authorities.
Install the oil filter as close to the burner as possible.
For further details of the oil supply tank and piping
requirements, please refer to the instructions and
illustrations in the oil burner and oil pump
instructions shipped with the furnace.
The power requirement for the POF1HD140AVFA and
POF1HD091AVFA models is: 120 VAC, 1 Ø, 60 Hz.,
12A.
Accessories requiring 120 VAC power sources such as
electronic air cleaners and humidifier transformers may
5
16. 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. Refer to the oil burner instructions
shipped with the furnace for electrode specifications.
13. OIL FILTER
All fuel systems should include an oil filter between the
fuel oil storage tank and the oil burner. When using an oil
burner nozzle smaller than 0.65 U.S. Gallons Per Hour,
install an additional 7 to 10 micron filter as close as
possible to the oil burner.
NOTE: Beckett AF Series Burner electrode
specifications have been revised. They should be
adjusted to be 5/16” above the nozzle centerline.
14. OIL BURNER NOZZLES
17. BURNER PRIMARY (SAFETY) CONTROL
The POF1HD140AVFA and POF1HD091AVFA are
certified for multiple firing rates, ranging from 58,000 to
116,000 Btu/h. By manipulating the oil burner nozzle,
flame retention head, static plate and temperature rise;
the furnace may be fired at an ideal rate for a wide range
of structures. Refer to Table A-1 and the furnace rating
plate to determine the proper combinations.
The furnace is equipped with a primary combustion
control, sometimes referred to as the burner relay or
burner protector relay, which uses a light sensing
device (cad cell) located in the burner housing, to
monitor and control combustion. Over time, dust or
combustion residuals can build up on the lens of the
cad cell impairing its response to the flame. The cad
cell should be checked for cleanliness and proper
alignment if the primary control frequently shuts
down combustion.
15. OIL BURNER ADJUSTMENT
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.
The POF1HD140AVFA and POF1HD091AVFA furnaces
operate most efficiently with a No. 1 smoke spot on the
Bacharach Scale. This is not necessarily the optimum
setting; however, because dust will inevitably build up on
the air moving components of the oil burner assembly.
This will result in decreased air supply with the potential
result of soot building up in the flue gas passageways of
the heat exchanger. Soot behaves as an insulator and
impairs good heat transfer. Stack temperature will
increase, and the overall efficiency will decrease. As a
means of avoiding this problem, it is advisable to adjust
the air supply to provide no more than a trace smoke
spot on the Bacharach Scale.
ALL FURNACE CONTROLS ARE SENSITIVE
AND SHOULD NOT BE SUBJECTED TO
TAMPERING. IF PROBLEMS PERSIST, CALL
YOUR SERVICE CONTRACTOR.
18. COMBUSTION CHAMBER
This furnace is equipped with a high quality cerafelt
combustion chamber. It is held in place by a
retaining bracket.
CHECK
THE
ALIGNMENT
OF
THE
COMBUSTION CHAMBER AND OIL BURNER
BEFORE FIRING. IT IS POSSIBLE FOR THE
COMBUSTION CHAMBER TO SHIFT IF
SUBJECTED
TO
ROUGH
HANDLING
DURING TRANSIT. The combustion chamber
should be inspected for damage or carbon build up
whenever the oil burner is removed for repairs or
routine maintenance.
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
AS
NECESSARY.
DO NOT START THE BURNER UNLESS THE
BLOWER ACCESS DOOR IS SECURED IN
PLACE.
6
19. CIRCULATING AIR BLOWER
(POF1HD140AVFAand POF1HD091AVFA)
19b. CIRCULATING AIR BLOWER
(POF1HD140AVFA and POF1HD091AVFA)
(See Section 22 Page 9)
The POF1HD140AVFA and POF1HD091AVFA furnace
models are equipped with direct drive blower systems.
POF1HD140AVFA and POF1HD091AVFA models are
equipped with electronically commutated motors (ECM).
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.
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.
7
pipe and fittings. The barometric damper should
open and close freely.
20. MAINTENANCE AND SERVICE
Routine Maintenance By Home Owner
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 should be checked to
ensure that the fan on and off delay function
continues to start and stop the blower fan at the
optimal settings.
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.
21. OPERATING INSTRUCTIONS
(POF1HD140AVFA and POF1HD091AVFA)
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. (See Parts
Listing Ref. No. 21).
Before Lighting
Open all supply and return air registers and grilles.
Open all valves in oil pipes. Turn on electric power
supply
During the routine service, inspect the general condition
of the furnace watching for signs of oil leaks in the vicinity
of the oil burner, soot forming on any external part of the
furnace, soot forming around the joints in the vent pipe,
etc. If any of these conditions are present, please advise
your service or installation contractor.
To Light Unit
Set the thermostat above room temperature to call
for heat. The burner should start. NOTE: It may be
necessary to press the RESET button on the
primary combustion control relay.
Annual Service By Contractor
There will be a fan on time delay before the
circulating fan is energized.
The United
Technologies 1168-1 has an adjustable fan on/off
time delay that is programmed into the ECM motor,
and is set by selecting the SW4 DIP switch
combination displayed in Table A-10 page 15. Fan
on/off delay must be adjusted according to input
(nozzle size).
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 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 clean-out caps screws,
and remove the caps carefully to avoid tearing the
gaskets. A wire brush can be used to loosen dirt and
debris on the inside surfaces of the radiator. Clean out all
accumulated dirt, soot and debris with a wire handled
brush and an industrial vacuum cleaner. Before replacing
the clean-out caps, inspect the gaskets. If the gaskets
are broken, remove the remnants and replace with new
gaskets.
Set the thermostat below room temperature. The oil
burner should stop.
The air circulation blower will continue to run until
the blower off delay setting programmed into the
ECM motor times out.
To check the operation of the limit switch, shut off
power to the furnace. Temporarily remove the 5 pin
power connector plug from the ECM blower motor.
NOTE: Isolate the AC Line pins on the 5 pin
power connector with electrical tape to prevent
electric shock hazard.
Restore the electrical
power to the furnace and set the thermostat above
room temperature.
The blower motor is factory oiled and permanently
sealed. DO NOT LUBRICATE. Excess oil causes
premature electric motor failure.
After three or four minutes of burner operation, the
limit control should turn the burner off. When the
limit function test is complete, shut off electrical
power to the furnace, replace the 5 pin power plug to
the blower fan motor, and then restore power. The
blower fan will start up immediately. Once the
temperature has dropped and the limit control has
reset, the fan will operate until the fan off time is
achieved. The oil burner will then resume operation
and continue until the thermostat is satisfied.
Inspect the blower fan. Clean if necessary.
Oil Burner Maintenance: Follow the instructions of the oil
burner manufacturer. (See oil burner manufacturer's
instructions supplied with furnace or burner). It is
advisable to change the oil burner nozzle and oil filter on
an annual basis.
The venting system should be cleaned and inspected for
signs of deterioration. Replace pitted or perforated vent
8
Restore the
temperature.
thermostat
setting
to
a
comfortable
22. ECM BLOWER MOTOR OPERATION
(POF1HD140AVFA and POF1HD091AVFA)
Setting Blower “ON” and “OFF” Timings
Blower on/off time delays are handled by ECM
motor programming. Features of this ECM variable
speed motor are that it will deliver a constant airflow
within a wide range of external static pressures, and
also includes:
NOTE: IF THE FURNACE IS TO BE SHUT DOWN
FOR AN EXTENDED PERIOD OF TIME, CLOSE
THE OIL SUPPLY VALVE TO THE BURNER.
Soft Start: This ECM variable speed motor will
slowly ramp up to the required operating speed.
This feature in the heating cycle allows the heat
exchanger to reach operating temperature before
the set heat speed, which minimizes noise and
increases comfort.
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.
Soft Stop: At the end of the heating cycle, the ECM
variable speed motor will slowly ramp down. This
feature allows for increased energy efficiency and
reduced noise levels.
Dehumidification: A dehumidification feature has
been programmed into the variable speed motor. At
the start of each cooling cycle, the variable speed
motor will run at 82% of the rated airflow for 7.5
minutes. After 7.5 minutes has elapsed, the motor
will increase to 100% of the rated airflow. This
profile is used to provide dehumidification and
improve system efficiency.
Continuous Fan Operation: When the thermostat
continuous fan (G) switch is on without a call for
heating or cooling, the indoor fan is immediately
energized up to 50% of the cooling speed. This
feature allows continuous circulation of air between
calls for heating or cooling.
If a call for heat (W) or cool (Y) occurs during
continuous fan, the blower will remain energized
9
Appendix APOF1HD140AVFA AND POF1HD091AVFA
Please note: The Beckett AF oil burner is for applications using indoor air for combustion only.
Table A-1 Beckett AF Oil Burner Set-Up
Beckett AF Series Oil Burners
(For use with chimney vented units only)
Furnace Model
Output
BTU/Hr
Burner
Model
Nozzle
Pump
Pressure
Flow
Rate
Head 1
Static
Plate
POF1HD070AVFA ²
59,000
AF76BNHS
0.50 /
80°A
100 psig
0.50
usgph
F3
3- ⅜ in.
POF1HD091AVFA
76,000
AF76BNHS
0.65 /
80°A
100 psig
0.65
usgph
F3
3- ⅜ in.
POF1HD105AVFA
87,000
AF76BNHS
0.75 /
80°A
100 psig
0.75
usgph
F3
3- ⅜ in.
1
Head is shielded by ceramic insulator. 2 Low Firing Rate Baffle required when using a 0.50-gallon
nozzle. Bold models indicate the factory equipped firing rate.
Beckett AF Series Oil Burners
(For use with chimney vented units only)
Furnace Model
Output
BTU/Hr
Burner
Model
Nozzle
Pump
Pressure
Flow
Rate
Head 1
Static
Plate
POF1HD105AVFA
87,150
AF76XN
0.75 /
60°W
100 psig
0.75
usgph
F3
2- ¾ in.
POF1HD119AVFA
98,770
AF76XN
0.85 /
60°W
100 psig
0.85
usgph
F3
2- ¾ in.
POF1HD140AVFA
116,200
AF76XN
1.00 /
60°W
100 psig
1.00
usgph
F3
2- ¾ in.
Bold models indicate the factory equipped firing rate.
10
A.1 OIL BURNER AIR ADJUSTMENT
A.3 START 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.
The
POF1HD140AVFA
and
POF1HD091AVFA furnaces operate most efficiently
with a No. 1 smoke spot on the Bacharach Scale. This
is not necessarily the optimum setting; however,
because dust will inevitably build up on the air moving
components of the oil burner assembly. This will result
in decreased air supply with the potential result of soot
building up in the flue gas passageways of the heat
exchanger. Soot behaves as an insulator and impairs
good heat transfer. Stack temperature will increase,
and the overall efficiency will decrease. As a means of
avoiding this problem, it is advisable to adjust the air
supply to provide no more than a trace smoke spot on
the Bacharach Scale.
The furnace should be operated for a minimum of 10
minutes to reach steady state conditions before fine
tuning combustion. The warm up time is ideal for
testing the oil pump pressure.
Drill a 1/4-inch test port in the venting between the
furnace flue outlet and draft regulator (barometric
damper). Insert a stack thermometer and note the flue
gas temperature. The flue gases should be within a
range of 350°F to 450°F. 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. Temperature rise value is listed on the
system rating plate.
Perform a smoke spot test. The smoke spot should not
exceed No. 1 on the Bacharach Scale.
For complete details, consult the oil burner instruction
manual provided in the furnace documents envelope.
After the air adjustments have been completed, recheck the draft pressure at the test port on the burner
mounting plate as shown in Figure 2. The draft should
be adjusted to -0.02 inches w.c.
Beckett AF Burner
Adjust the air shutter by loosening the locking screws
and moving the air shutter, and if necessary, the bulk
air band.
In the United States, the Beckett AF Burner may be
equipped with Beckett's "Inlet Air Shut-Off" to increase
efficiency. (Beckett Part No. AF/A 5861).
A.2 BURNER ELECTRODES
NOTE: USE OF THE INLET AIR SHUT-OFF
COULD CAUSE POST COMBUSTION NOZZLE
DRIP.
Adjustment of the electrode tips with respect to each
other, the nozzle, and to the rest of the burner is very
important to ensure smooth start-ups and to permit
efficient combustion.
Beckett AF Burner
Electrode gap: 5/32 inch.
Distance above horizontal centerline: 5/16 inch. Older
instruction sheets specify 7/16 inch. The current
specification is 5/16 inch.
Distance ahead of nozzle: 1/16 inch.
“Z” dimension, the distance from the front of the end
cone (head) to the face of the nozzle should be 1-1/8
inches. If a ceramic head is used, the distance from
the end cone to the nozzle face is increased to 1-3/8
inches.
11
Table A-8 Direct Drive Blower Characteristics ECM Motor
CFM RANGE
Furnace Model
POF1HD105AVFA
POF1HD119AVFA
POF1HD140AVFA
Blower
100-10
DD
Motor
HP
1/2 HP
ECM
Motor
FLA
7.7
∆T
70°F
Continuous
Heating
Cooling
Fan
0.28 - 0.48
inches w.c.
0.5 inches
w.c.
500 - 700
1100 - 1525
600 - 1400
CFM RANGE
Furnace Model
POF1HD070AVFA
POF1HD091AVFA
POF1HD105AVFA
Blower
100-10
DD
Motor
HP
1/2 HP
ECM
Motor
FLA
7.7
∆T
70°F
12
Continuous
Heating
Cooling
Fan
0.28 - 0.48
inches w.c.
0.5 inches
w.c.
500 - 700
825 - 1525
600 - 1400
Table A-9 General Dimensions (Inches)
Cabinet
Plenum Openings
Return
Furnace Model
POF1HD140AVFA
Width
Depth
Height
Supply
Side
Bottom
22
30 3/4
58
20½ x
20
14 x 22
14 x 22
13
Flue
Diameter
6
Filter
Shipping
Weight
Type
Size
Permanent
16 x 25
x1
270
Table A-9 General Dimensions (Inches)
Cabinet
Plenum Openings
Return
Furnace Model
POF1HD091AVFA
Width
Depth
Height
Supply
Side
Bottom
22
30 3/4
49-5/8
20½ x
20
14 x 22
14 x 22
14
Flue
Diameter
5
Filter
Shipping
Weight
Type
Size
Permanent
16 x 25
x1
210
Table A-10 ECM Blower Set-Up (POF1HD091AVFA)
100-10DD blower with ½ HP ECM
DIP SWITCH ADJUSTMENT CHART
FOR INPUT 0.50 USGPH TO 0.75 USGPH
SW1 - HEAT
DIP Switch
Position
1
2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
SW3 - ADJUST
DIP Switch
Position
1
2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
SW2 - COOL
POS.
A
B
C
D
INPUT
USGPH
0.65
N/A
0.75
0.50
DIP Switch Position
1
2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
POS.
A
B
C
D
AC Size
(TON)
3
2.5
2
1.5
SW4 - DELAY
POS.
A
B
C
D
CFM
0%
(+)15%
(-)15%
N/A
DIP Switch Position
1
2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
POS.
A
B
C
D
INPUT
USGPH
0.65
N/A
0.75
0.50
NOTE:
SW1 (HEAT) AND SW4 (DELAY) DIP SWITCHES MUST BOTH BE ADJUSTED ACCORDING TO INPUT (NOZZLE SIZE).
SW2 (COOL): 1 TON is approximately equal to 400 CFM
SW3 (ADJUST): (Heating Mode) Increase OR decrease temperature rise respectively
(Cooling Mode) Increase OR decrease CFM respectively
15
Table A-10 ECM Blower Set-Up (POF1HD140AVFA)
100-10DD blower with ½ HP ECM
DIP SWITCH ADJUSTMENT CHART
FOR INPUT 0.75 USGPH TO 1.00 USGPH
SW1 - HEAT
DIP Switch
Position
1
2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
SW3 - ADJUST
DIP Switch
Position
1
2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
SW2 - COOL
POS.
A
B
C
D
INPUT
USGPH
1.00
0.85
N/A
0.75
DIP Switch Position
1
2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
POS.
A
B
C
D
AC Size
(TON)
3
2.5
2
1.5
SW4 - DELAY
POS.
A
B
C
D
CFM
0%
(+)15%
(-)15%
N/A
DIP Switch Position
1
2
OFF
OFF
ON
OFF
OFF
ON
ON
ON
POS.
A
B
C
D
INPUT
USGPH
1.00
0.85
N/A
0.75
NOTE:
SW1 (HEAT) AND SW4 (DELAY) DIP SWITCHES MUST BOTH BE ADJUSTED ACCORDING TO INPUT (NOZZLE SIZE).
SW2 (COOL): 1 TON is approximately equal to 400 CFM
SW3 (ADJUST): (Heating Mode) Increase OR decrease temperature rise respectively
(Cooling Mode) Increase OR decrease CFM respectively
16
Chimney Vent Burner Wiring Diagram
HTL-C HTLV-C
POF1HD140AVFA
APPENDIX B: WIRING DIAGRAMS
LEGEND/legende
120 V
24 V
FACTORY WIRING
filage a l'usine
120 V
24 V
FIELD WIRING
filage au champs
INDOOR
BLOWER
ventilateur
principale
MOTOR
moteur
L
C
ML
H
MHI
L1
530SE
BL
COM 24V
BK
YL
WH
CAP
BL
V
VALVE/
soupappe
3
4
5
N
EAC
2
6
HUM
2
COOL
1
1
HEAT
3
7
VI
C
YL
GR
3
3
WH
4
WH
AL 1008
11
BR
BL
3
1
2
4
1
3T (T1)
2
BURNER MOLEX
CONNECTOR/
connecteur molex
du brûleur
1
2
BECKETT OIL
PRIMARY
CONTROL
L1
BK
L2
WH
3T
T
RD
INTERRUPTED/
interrompée
AL
BK
BL
RD
CAD
CELL
WH
V
I
VI
VALVE/soupappe
AL
1
2
OR
MOTOR/moteur
L
BVS
4
VI
VI
GND
F
YL
F
YL
MOTOR
moteur
BECKETT AF BURNER/brûleur
30746 Rev A
ventilateur a courroie
(si disponible)
ECM MOTOR
(IF AVAILABLE)
WH
EAC
2
BK
2
1158-1
CONTROL
3
COOL
1
1
4
HEAT
L1 N
CONT
3
UNUSED
MOTOR
MOTOR
moteur
BURNER
INDOOR
BLOWER
ventilateur
principale
BK
7
RIELLO 40F BURNER/brûleur
(IF AVAILABLE)/(si disponible)
BK
OR
X
T (T2)
POWER SUPPLY 120 VAC 60 HZ
(FUSED DISCONNECT ON HOT LEG)
alimentation 120 VAC 60Hz
(disjoincteur avec fusible sur le fil d'alimentation)
BELT DRIVE MOTOR
(IF AVAILABLE)
6
BK
9
BLOCKED VENT SAFETY
(REQUIRED FOR CANADIAN INSTALLATIONS)
commande d'épreuve de système d'évacuation bloqué
(requis pourles installations au Canada)
I
RD
WH
8
YL
IGNITER/
transformateur d'allumage
T2
3
BL
CONT
LOW SPEED FAN SWITCH (IF EQUIPPED)
interupteur a basse vitesse (si équippée)
T1
2
WH
F
UNUSED
MOTOR
F
L
1
V
24V
MOTOR
moteur
LIMIT/limite
L1
BK
WH
120V
RD
AUXILIARY LIMIT (IF EQUIPPED)
limite auxiliaire - si équippée
L
BVS
RD
BURNER
AL
TRANSFORMER/
transformateur
BK
VI VIOLET/violet
WH WHITE/blanc
YL YELLOW/jaune
GND GROUND/Terre
CAP CAPACITOR/capaciteur
WH
N
WH
1 2 3 4 5
WH
BK
OR
VI
BK
TERMINAL NOT PROVIDED/point
de raccord non-fourni
BK BLACK/noir
BL BLUE/bleu
BR BROWN/brun
GR GREEN/vert
OR ORANGE/orange
RD RED/rouge
N (COMMON)
CAP
GROUND/Terre
TERMINAL PROVIDED/
point de raccord fourni
1
2
4
3
BR
BR
THERMOSTAT CONNECTIONS/
raccorde du thermostat
ventilateur a ECM
(si disponible)
WH
BK
INDOOR
BLOWER
ventilateur
principale
YL
1168-1
CONTROL
17
1158-1
CONTROL
THERMOSTAT CONNECTIONS/
raccorde du thermostat
1168-1
CONTROL
OPERATION OF OIL BURNER
Once the furnace flue pipe, electrical and oil line
connections have been made, use the following
instructions to set the burner:
Shut off the electrical power to the furnace.
Install an oil pressure gauge to the pressure port on
the oil pump. (Refer to the oil pump specification sheet
included with the burner instructions).
Restore electrical power to the furnace.
Start the furnace and bleed all air from the fuel oil
lines.
Close the purge valve and fire the unit.
Allow the furnace to warm up to normal operating
temperatures. During this time, set the pump pressure
in accordance with the data provided in Appendix A,
Table A-1.
When the furnace has reached "steady state" (after
approximately 10 minutes). Set combustion air damper
to get a TRACE of smoke.
Check the system temperature rise. The temperature
rise is the difference between the return air temperature
measured at a point near the return air inlet, and the
supply air temperature measured near the furnace
outlet. The system temperature rise is listed on the
furnace rating plate. If the temperature rise is too high,
the airflow must be increased. If the temperature rise is
too low, the fan should be slowed down.
Turn off the burner. Observing the duct thermometer in
the supply air stream, note the temperature at which
the blower fan stops. The fan adjustments can be
made by moving the dipswitch settings on the timer
control board for fan off delay.
To check the operation of the limit switch, shut off
power to the furnace. Temporarily remove the neutral
wire from the direct drive blower motor. Restore the
electrical power to the furnace and set the thermostat
above room temperature. After three or four minutes of
burner operation, the limit control should turn the
burner off. When the limit function test is complete,
shut off electrical power to the furnace, replace the
neutral wire to the blower fan motor, and then restore
power. The blower fan will start up immediately. Once
the temperature has dropped and the limit control has
reset, the fan will operate until the fan off time is
achieved. The oil burner will then resume operation
and continue until the thermostat is satisfied. Restore
the thermostat setting to a comfortable temperature.
Set the heat anticipator adjustment in the thermostat (if
so equipped), by removing the "R" or "W" wire to the
thermostat, then reading the amperage draw between
the two wires. Failure to remove one of the wires from
the thermostat while performing this test could burn out
the heat anticipator. Set the heat anticipator to the
amperage measured.
NOTE:
THE FURNACE SHOULD BE RUN
THROUGH AT LEAST THREE FULL CYCLES
BEFORE LEAVING THE INSTALLATION, TO
ENSURE THAT ALL CONTROLS ARE
OPERATING PROPERLY AND AS EXPECTED.
NOTE:
ALL JOINTS IN ANY POSITIVE
PRESSURE VENTING SYSTEM MUST BE
CHECKED FOR LEAKS BEFORE LEAVING
THE INSTALLATION SITE.
18
APPENDIX C OIL PRIMARY CONTROL DETAILED SEQUENCE OF OPERATION
Power is applied to unit. The oil primary control completes a self-diagnostic procedure. If no light or flame is present,
and unit passes its self-diagnostic procedure, the control enters into the idle mode.
Thermostat calls for heat:
A) Safety check is made for flame (4 second delay).
1) If flame is not present, the oil primary control will apply power to the burner motor and igniter.
2) If flame is present, the control remains in the idle state.
B) Unit enters a pre-purge period of 15 seconds.
C) After 10 seconds, control checks for flame presence.
1) If flame is not present, the oil primary control enters the trial for ignition state.
2) When flame is present, the control enters lock out mode.
D) The Oil Primary Control monitors the burner flame.
1) When flame is present, the control enters ignition carryover state. (Continues to spark for 10 sec.).
a) Provides continuous spark after flame is sensed to assure that burner remains lit.
b) Turns on LED diagnostic light.
c) Starts carryover timer.
(i)
Flame and call for heat are monitored.
•
If flame is lost and lockout timer has not expired, the control will return to trial for ignition state.
•
If flame is lost and lockout timer has expired, the control will enter the recycle state.
♦
Recycle timer starts.
♦
Burner motor and igniter and solenoid valve are turned off.
♦
LED diagnostic light flashes slowly.
E) Carryover timer expires.
1) Enters run state.
a) Igniter turns off.
Combustion continues until thermostat is satisfied, or the oil primary control detects a loss of flame and enters into
Recycle Mode.
F) Thermostat is satisfied - call for heat is terminated:
a) Oil primary control shuts off burner motor and solenoid valve.
(i)
If the control utilizes a blower motor off delay, after 30 seconds, flame presence is checked.
•
If flame is not present, the control LED diagnostic light is off and returns to idle state.
•
If flame is presence is detected, the control enters lock out mode.
19
FIGURE 5: UNITED TECHNOLOGIES 1168-1 ECM TAP BOARD
(POF1HD140AVFA and POF1HD091AVFA)
1168-1 ELECTRONIC FAN TIMER BOARD (EFT) DETAILED SEQUENCE OF OPERATION
Thermostat Input LEDs (LED1-5, LED8)
Six green LEDs are placed behind their respective thermostat connections (Y1, Y/Y2, G, DH, O, and W) and operate
whenever a call is present.
Thermostat calls for “W”. The 24VAC input signal is passed to pin 2 of P1 and will drive the K1 relay that provides
dedicated contacts to the T-T input of the Oil Primary Control. Thermostat calls for cool “Y1”. The 24VAC input
signal is passed to pin 6 of P1. Thermostat calls for fan “G”. The 24VAC signal is passed to pin 15 of P1.
Thermostat calls for dehumidification “DH”. The 24VAC input signal is passed to pin 10 of P1. Thermostat calls
for reversing valve “O”. The 24VAC input signal is passed to pin 9 of P1.
20
IDLE STATE
THERMOSTAT CALLS FOR HEAT
SAFETY CHECK FOR FLAME (5 SEC.)
OIL PRIMARY
CONTROL
SEQUENCE of
OPERATION
REMAINS IN IDLE STATE
NO FLAME
FLAME
BURNER MOTOR & IGNITOR START
10 SEC.
SAFETY CHECK FOR FLAME (5 SEC.)
NO FLAME
FLAME
SOLENOID VALVE OPENS
LOCKOUT STATE
TRIAL FOR IGNITION
•
•
•
•
BURNER FLAME MONITORED
NO FLAME
FLAME
•
•
•
CARRYOVER STATE
Provides continuous spark
LED diagnostic light ON
Start Carryover Timer
OIL PRIMARY CONTROL:
Shuts off burner motor
Shuts off igniter
Shuts off Solenoid Valve
Fast Flashes LED Diagnostic
Light
FLAME LOST
TO EXIT LOCKOUT
PRESS RESET
FLAME
CARRYOVER TIMER EXPIRES
FLAME LOST
FLAME
•
RUN STATE
Igniter turns off.
FLAME LOST
RECYCLE TIMER STARTS
THERMOSTAT SATISFIED
•
•
OIL PRIMARY CONTROL
SHUTS OFF:
Burner Motor
Solenoid Valve
•
•
•
•
30 SEC.
OIL PRIMARY CONTROL:
Shuts off Solenoid Valve
Shuts off Igniter
Shuts off Burner Motor
Slow Flashes LED
diagnostic light
SAFETY CHECK FOR FLAME (5 SEC.)
RECYCLE TIMER EXPIRES
(60 SECONDS
NO FLAME
FLAME
RETURNS TO IDLE STATE
21
TROUBLESHOOTING
OIL PRIMARY CONTROL LED DIAGNOSTIC
LIGHT
IMPORTANT: Due to the potential hazard of line
voltage, only a trained, experienced service technician
should perform the troubleshooting procedure.
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.
PRELIMINARY STEPS:
Check the diagnostic light for indications of burner
condition. Refer to the oil primary control LED
DIAGNOSTIC LIGHT section for details.
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 oil primary control enters the idle
state, and will remain off until the next heating cycle.
WHEN SIMULATING A CALL FOR HEAT AT
THE OIL PRIMARY CONTROL, DISCONNECT
AT LEAST ONE THERMOSTAT LEAD WIRE
FROM THE T1 - T2 TERMINALS TO PREVENT
DAMAGE TO THE THERMOSTAT.
NEGLECTING THIS PROCEDURE MAY BURN
OUT THE HEAT ANTICIPATOR OF A
STANDARD 24 VAC THERMOSTAT, OR
CAUSE HARM TO COMPONENTS WITHIN A
MICRO-ELECTRONIC THERMOSTAT.
FAULT CONDITIONS:
If the LED diagnostic light is flashing quickly; 1 Hz (½
second on / ½ second off), the oil primary control is in
the lockout state or in restricted mode. To exit the
lockout state, press the reset button.
If the LED diagnostic light is flashing slowly; ¼ Hz (2
seconds on / 2 seconds off), the oil primary control is
in the recycle state. This indicates that flame sensing
was lost after the lockout timer expired during the
ignition carryover state. The oil primary control will
return to the idle state within 60 seconds.
Before checking the oil primary control, perform these
preliminary checks, (repair or replace controls as
necessary):
•
Check the power supply; fuse box or breaker,
any service switches, all wiring connections, and
burner motor reset button (if equipped).
If the LED diagnostic light is off, the cad cell is not
sensing flame.
•
Check the limit switches to ensure that the
switch contacts are closed.
If the LED diagnostic light is on, the cad cell is sensing
flame, or viewing ambient light.
•
Check the electrode gap and position.
•
Check the contacts between the oil primary
control and the electrodes.
CAD CELL CONDITION:
The resistance of the cad cell may be checked while
the oil primary control is in the run state by pressing
the reset button. The LED diagnostic light will flash the
following code:
•
Check oil supply (tank gauge).
•
Check the oil nozzle, oil filter, and oil valves.
Table C-2: Cad Cell Resistance
•
Check the piping or tubing to the oil tank.
•
Check the oil pump pressure.
Flashes
Resistance in Ohms
1
Less than 400
2
Between 400 - 800
3
Between 800 – 1600
4
Between 1600- 5000
CHECK OIL PRIMARY CONTROL AND
IGNITER
If the trouble does not appear to be in the burner or
ignition hardware, check the oil primary control and the
igniter by using the following equipment:
Screwdriver.
Voltmeter (0 - 150 VAC)
Insulated jumper wires with both ends stripped.
22
PRELIMINARY CHECKS:
Make sure that limit switches are closed and those
contacts are clean.
ELECTRICAL SHOCK HAZARD.
Check for line voltage power on the oil primary
control black and white lead wires.
TROUBLESHOOTING IS DONE WITH THE
SYSTEM POWERED. BE CAREFUL TO
OBSERVE ALL NECESSARY PRECAUTIONS
TO PREVENT ELECTRICAL SHOCK OR
EQUIPMENT DAMAGE.
Refer to Table C-3 or C-4 for further troubleshooting
information.
Table C-3: Oil Primary Control TROUBLESHOOTING
Condition: Burner motor does not start when there is a call for heat.
Procedure
Status
Corrective Action
1. Check that limit switches are
N/A
N/A
closed and contacts are clean.
2. Check for line voltage power at
the oil primary control. Voltage
N/A
N/A
should be 120 Vac between the
black and white lead wires on the
oil primary control.
Cad cell is defective, sees external light, or connections
3. Check indicator light with
Indicator light is on.
have shorted. Go to step 4.
burner off, no call for heat (no
flame).
Indicator light is off.
Go to step 5.
Eliminate external light source or permanently shield cad
Indicator light turns off.
cell.
Replace cad cell with new cad cell and recheck.
4. Shield cad cell from external
If indicator light does not turn off, remove yellow lead
light.
wires from oil primary control and recheck.
Indicator light stays on.
If indicator light is still on, replace the oil primary control.
If the indicator light turns off, replace cad cell bracket
assembly.
Trouble is in thermostat circuit. Check thermostat-wiring
connections.
Burner starts.
5. Jumper thermostat (T -T)
If connections are clean and tight, check thermostat wires
terminals on oil primary control
for continuity.
Disconnect line voltage power and open line switch.
Check all wiring connections.
IMPORTANT
Tighten any loose connections and recheck.
First remove one thermostat lead
Burner does not start.
If burner still doesn't start, replace the oil primary control
wire.
If burner still doesn't start, check the oil burner motor. It
may be seized or burned out.
Condition: Burner starts then locks out on safety with indicator light flashing at 1 Hz rate (½ second on, ½ second off)
Procedure
Status
Corrective Action
1. Check that the 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
connections are shorted. Go to step 4.
Indicator light is off.
Go to step 5.
23
Table C-3: Oil Primary Control Troubleshooting continued from previous page
Procedure
4. Shield cad cell from external
light.
5. Jumper thermostat (T -T)
terminals on oil primary control
IMPORTANT
First remove one thermostat
lead wire.
Status
Indicator light turns off.
Indicator light stays on.
Burner starts.
Burner does not start.
Corrective Action
Eliminate external light source or permanently shield cad cell.
Replace cad cell with new cad cell and recheck.
If indicator light does not turn off, remove cad cell lead wires
from oil primary control and recheck.
If indicator light turns off, replace cad cell bracket assembly.
If indicator light does not turn off, replace controller.
Trouble in thermostat or limit circuit. Check thermostat or limit
wiring connections.
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 oil primary control
Condition: Burner starts then locks out on safety with indicator light flashing at 1 Hz rate (½ second on, ½ second
off)
6. Reset oil primary control by
pushing in and releasing red
reset button.
Indicator light stops flashing.
Indicator light continues to
flash at 1 Hz rate.
Ignition is off
7. Listen for spark after burner
turns on (after 2 second delay).
8. Check indicator light after
flame is established, but before
oil primary control locks out.
9. Check 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 clothe. Check
sighting for clear view of flame.
Replace cad cell in socket.
Reconnect line voltage power
and close line switch.
Start burner.
Ignition is on.
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.
Burner locks out.
Burner keeps running.
Go to Step 7.
Verify that the control is not in restricted mode. (See notes at
end of this table.). If not in restricted mode, replace oil
primary control
Spark igniter could be defective. Check for line voltage at
igniter terminals. If line voltage is present, replace oil primary
control.
Go to Step 8.
Wait for “Valve ON” delay to complete. Check oil supply, and
oil line valve. Check for filter blockage or seized oil pump.
Replace oil primary control
Go to step 9.
Go to step 10.
System is OK.
24
Table C-3: Oil Primary Control Troubleshooting continued.
Procedure
Status
Corrective Action
Indicator light is on.
Remount control onto burner housing. Go to step 6.
10. Check cad cell.
Disconnect line voltage power
and open line switch.
Remove existing cad cell and
replace with new cad cell.
Disconnect all wires from
thermostat terminals to ensure
Indicator light is off.
Go to step 11.
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.
Indicator light is on.
Replace cad cell bracket assembly.
11. Check cad cell bracket
assembly.
Disconnect line voltage power
and open line switch.
Remove cad cell wires from
quick connect connectors on
and leave control lead wires
Indicator light is off.
Replace oil primary control.
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 RESTRICTED MODE: press and hold the reset button for 30 seconds. When the LED flashes twice, the device has
reset.
NOTE: Disable function: Pressing and holding the reset button will disable all functions until the button is released. The burner
will restart at the beginning of the normal heat cycle on SAFETY CHECK.
Table C4: System and General Troubleshooting
Problem
Possible Cause
Thermostat not calling for heat.
No power to furnace.
Furnace will not start.
Thermostat faulty.
Oil primary control faulty.
25
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 as an old poorly located furnace switch, which was not
removed during furnace replacement.
Remove thermostat wires from oil primary control terminals T-T.
Place a jumper across T-T. 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 T1 - T2. Check for 24V
across T -T. If no voltage is present, check for 115V to oil
primary control. If 115V is present, go to Table C-3.
Table C-4: System and General Troubleshooting continued
Problem
Furnace will not start.
Possible Cause
Photo Cell wiring shorted or
room light leaking into photo
cell compartment
Open safety switch.
No fuel oil.
Clogged nozzle.
Furnace will not start
without first pushing oil
primary control reset
button.
(Happens on frequent
basis)
Clogged oil 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.
Furnace starts, but cuts
out requiring manually
resetting the oil protector
reset button.
Photo Cell (Cad Cell)
defective.
No fuel oil.
Clogged nozzle.
Clogged oil filter.
Furnace starts, but cuts
out requiring manually
resetting the oil protector
reset button.
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.
Oil burner sputtering at
nozzle
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.
Remedy
Check photo cell (cad cell) wiring for short circuits. Also, check
for room light leaking into cad cell compartment. Repair light
leak if necessary. See Table C-3.
Check for open limit or auxiliary limit. Also, check internal wiring
connections; loose connectors, etc.
Check fuel oil supply. Check that all hand operated fuel oil
valves are in the open position. Fill oil storage tank if necessary.
Replace nozzle with high quality replacement. Use rating plate
or Tables in Appendix A as a guide.
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 photocell
should have a resistance of 100 KΩ in absence of light; a
maximum of 1500 Ω in the presence of light. Ensure that room
light is not leaking into the cad cell compartment. (See
diagnostic light section).
Check fuel oil supply. Check that all hand operated fuel oil
valves are in the open position. Fill oil storage tank if necessary.
Replace nozzle with high quality replacement. Use rating plate
or Tables in Appendix A 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.
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 increased diameter).
Check electrode settings. Check electrodes for dirt build-up or
cracks in porcelain.
Check contacts between the igniter and electrodes. If OK,
replace the igniter
Replace fuel oil storage tank filter and / or fuel oil in-line filter.
Check burner motor and / or fuel oil pump coupling. Check oil
pump pressure. Replace fuel oil pump if necessary.
Bleed air from oil line. If problem persists, replace oil line.
26
Table C-4: System and General Troubleshooting continued
Problem
Possible Cause
System temperature rise too
high.
Poor “fan off” delay timing
selection, (fan stops too soon).
Excessive fuel oil
consumption.
Fuel oil leak.
Check fuel oil line for leaks. Repair or replace if necessary.
Stack temperature too high.
Check stack temperature. Stack temperatures will normally
range from 350° to 450°F. Check draft regulator. Draft should be
set to -0.02 in. w.c.
Thermostat improperly
adjusted or in poor location.
Too much smoke.
Soot building up on blast
tube (end coning).
Insufficient combustion air
adjustment at oil burner, or
improper draft pressure.
Heat exchanger partially
clogged.
Poor alignment between oil
burner blast tube and fire pot.
Flame impingement caused by
Incorrect nozzle angle.
Defective fire-pot
Airflow blocked or dirty air
filter.
Thermostat adjustments or
location.
Insufficient airflow.
Furnace will not warm
home to desired
temperature.
Defective high limit control.
Under-sized nozzle.
Blower fan motor stopping
intermittently on overload.
Burner motor stopping
intermittently on overload.
Home does not heat
evenly
Remedy
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 thermometer in
the supply air plenum take-off or first few inches of the supply air
trunk duct. Ideally, the fan will shut off at a temperature of 90° 100°F. Manipulate the dip switch settings to come as close as
possible to this “fan off” temperature.
Improper distribution of heat.
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 CO2 or lowest practical O2 content in
the flue gases. See Burner Set Up.
Check for soot build-up in heat exchanger flue passages,
especially in the outer radiator.
Check alignment. Blast tube should be centered with fire pot
burner opening. Oil burner head should be ¼ inch back from the
inside surface of the fire pot.
Check nozzle size and angle. (See Appendix A). Check distance
from head to inside surface of the fire pot.
Check fire-pot. Repair or replace.
Clean or replace air filter.
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.
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 airflow 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.
This is not likely to be a furnace problem. Balance duct system.
27
Table C-4: System and General Troubleshooting continued
Problem
Supply air temperature
too hot.
Supply air temperature
too cool.
Supply air temperature
too cool during first
moments of furnace
cycle.
Possible Cause
Airflow blocked or dirty air
filter.
Insufficient airflow.
Excess airflow.
Excessive duct losses.
Fan control "fan on" setting too
low.
Excessive duct losses.
Remedy
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.
Check system temperature rise. Slow down blower fan if
necessary.
Check supply air ductwork. Seal leaky joints and seams.
Insulate ductwork if necessary.
Increase "fan on” dipswitch settings on EFT if control has this
option.). Register air deflectors may help.
Check supply air ductwork. Seal leaky joints and seams.
Insulate ductwork if necessary.
3. Where the oil shut-off valve from the oil storage
FINAL CHECK OUT
tank is located.
ENSURE THAT ALL SAFETY DEVICES AND
ELECTRICAL COMPONENTS HAVE BEEN
SET FOR NORMAL OPERATION. ENSURE
THAT ALL ELECTRICAL CONNECTIONS
ARE TIGHT AND THAT THE WIRING IS
SECURE.
4. How to operate the thermostat, and other
related accessories.
5. How to operate the manual reset button on the
primary control, and especially when not to push the
reset button.
6. How and where to visually inspect the venting
system for leaks or other problems.
IMPORTANT:
7. How to inspect, clean and replace the air filter,
and other homeowner maintenance procedures.
Please ensure that the homeowner is informed and
understands:
8. Who to call for emergency service and routine
annual service.
1. Where the circuit breaker or fuse is located in
the main electrical panel.
9. The terms and conditions of the manufacturer's
warranty and the contractor's warranty.
2. Where the furnace switch is located, and the
switch "on" and "off" positions if not obvious.
28
HOMEOWNER’S REFERENCE TABLE
Model No.
Serial No.
Date Installed
Contractor
Contact
Address
Postal Code
Telephone No.
After Hours No.
FUEL SUPPLIER
Fuel Oil
Supplier
Contact
Telephone No.
After Hours No.
IF DIFFERENT FROM INSTALLATION CONTRACTOR:
Service Tech.
Telephone No.
After Hours No.
29
30
PARTS LISTING: HIGHBOY MODEL: POF1HD140AVFA
Ref.
No.
Description
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
18
18
19
20
21
24
25
Left Side Panel Assembly
Right Side Panel Assembly
Rear Panel
Blower Division Assembly
Base Panel
Inner Front Panel
Blower Access Panel
Top Panel
Heat Exchanger Assembly
Combustion Chamber Retainer Bracket
Replacement Combustion Chamber
Oil Burner Mounting Plate
Flue Connector
Pouch Gasket
Air Baffle
Insulation Retainer
Radiator Clean-out Cover (2 per unit)
Radiator Clean-out Cover Gasket (2 per unit)
Clean-out Gasket Retainer
Clean-out Tube Gasket
Filter Frame 16” X 25”
Filter Frame End Support
Filter 16” X 25” X 1” Permanent
Control Box
Upper Door Panel
Logo Bezel
Logo Label
Limit Disc 60T11 BOF 220°F
Fan Timer Control 1168-1 ECM UTEC
Wire Harness, Controls Fan Timer
Wire Harness, Fan Timer Board, Transformer
Wire Harness, ECM Control
Wire Harness, ECM Supply
Transformer
109007731L
109007729L
109007727L
29189
26216
109007728
29122L
21437L
26097
27068
27000WP
109007674
28306
2080175
109007733
20602
29162
240006333
29161
29163
18020
5592B2
2180023
29362
21338L
28479
28563
28841
240007048
29364
29751
240006438
240005742
27738
26
27
28
30
31
31
32
31
33
34a
Draft Regulator
Oil Burner Assembly, Beckett AF76XN
Burner Motor 1/7 HP 3450 RPM PSC
Beckett Clean-cut Oil Pump A2EA6520
Solid State Ignitor 10SAY-01
Oil Primary Combustion Control Genisys
Flame Retention Head F6
Nozzle, 1.00/60ºW
Ref.No.
Description
35a
12240 (6”)
240007760
29689
29688
29522
240007858
11961
14619329
Part No.
Blower Assembly Direct Drive 3-Ton ECM Motor
Blower Housing and Wheel, 100-10R DD
Blower Motor, 1/2 hp, ECM Programmed
Motor Mounting Band – TR6884B
Motor Mount Arms – 10-10 DD Blower (3 per unit)
Blower Slide Rail 2 Per
32
109007723
30624
109007744
17811
26251
27733
33
PARTS LISTING: HIGHBOY MODEL: POF1HD091AVFA
Ref.
No.
Description
Part No.
1
2
3
4
5
6
7
Left Side Panel Assembly
Right Side Panel Assembly
Rear Panel
Blower Division Assembly
Base Panel
Inner Front Panel
Blower Access Panel
29187L
29186L
29205L
29189
26216
30066
27721L
8
9
10
11
12
13
14
15
16
17
17
18
18
19
20
21
24
25
Top Panel
Heat Exchanger Assembly
Combustion Chamber Retainer Bracket
Replacement Combustion Chamber
Oil Burner Mounting Plate
Flue Connector
Pouch Gasket
Flue Collar Gasket
Insulation Retainer
Radiator Clean-out Cover (2 per unit)
Radiator Clean-out Cover Gasket (2 per unit)
Clean-out Gasket Retainer
Clean-out Tube Gasket
Filter Frame 16” X 25”
Filter Frame End Support
Filter 16” X 25” X 1” Permanent
Control Box
Upper Door Panel
Logo Bezel
Logo Label
Limit Disc 60T11 BOF 155°F
Fan Timer Control 1168-1 ECM UTEC
21437L
28675
27068
27000WP
29869
29005
2080175
21994
20602
29162
240006333
29161
29163
18020
5592B2
2180023
29362
30164L
28479
28563
30071
240007048
Wire Harness, Controls Fan Timer
Wire Harness, Blower
Wire Harness, Fan Timer Board, Transformer
Wire Harness, ECM Control
Wire Harness, ECM Supply
Transformer
Draft Regulator
Oil Burner Assembly, Beckett AF76BNHS
Burner Motor 1/7 HP 3450 RPM PSC
Beckett Clean-cut Oil Pump A2EA6520
Solid State Ignitor 10SAY-01
Oil Primary Combustion Control
Flame Retention Head
Nozzle, 0.65/80ºA
Low Fire Kit
Low Firing Rate Baffle
Nozzle, 0.50/80° A
29364
29365
29751
240006438
240005742
27738
27494 (5”)
30067
29689
29688
29522
29664
11961 (F3)
210086
29880
25521101
29389
26
27
28
29
30
31
31
32
33
34
34
Ref. No.
Description
Part No.
35
Blower Assembly Direct Drive
Blower Assembly Direct Drive ECM
Blower Housing and Wheel, 100-10T DD (POF1HD091AVFA)
30146
109007271
30626
Blower Motor, 1/2 hp, ECM Programmed
Motor Mounting Band – TR6884B
Motor Mount Arms – 10-10 DD Blower (3 per unit)
Blower Slide Rail 2 Per
Right Side Panel, Air Baffle POF1HD091AVFA
109007272
17811
26251
27733
27731
36
35
NOTES:
Nordyne, Inc., 8000 Phoenix Parkway, O’Fallon, Missouri, 63368
766B-0909