Oil Furnace Highboy with PSC or ECM Operation Manual

OIL FIRED FURNACE
INSTALLATION AND OPERATION MANUAL
WITH USERS INFORMATION SECTION
HIGHBOY MODELS:
VH8FA119P60B, VH8FA119T60B
c WARNING: IF THE INFORMATION IN THESE INSTRUCTIONS IS NOT FOLLOWED EXACTLY, A FIRE OR
EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE.
DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF
THIS OR ANY OTHER APPLIANCE.
c WARNING: 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, OR SERVICE AGENCY.
PLEASE READ THESE INSTRUCTIONS PRIOR TO INSTALLATION, INITIAL FIRING, AND BEFORE
PERFORMING ANY SERVICE OR MAINTENANCE. THESE INSTRUCTIONS MUST BE LEFT WITH THE USER
AND SHOULD BE RETAINED FOR FUTURE REFERENCE BY QUALIFIED SERVICE PERSONNEL.
Manufactured by:
Thermo Products, LLC
5235 West State Road 10
North Judson, Indiana 46366
MO-514
ECN 5321-MA 150301
Made in USA
CONTENTS
SECTION
PAGE
I. SAFETY SECTION
A. CODES AND CLEARANCES
B. MAKE-UP AIR
1
3
4
II. GENERAL INSTRUCTIONS
A. CHIMNEY
B. VENTING
C. DRAFT REGULATORS
D. DUCT WORK/AIR CONDITIONING
E. AIR FILTER(S)
F. LIMIT POSITION AND LOCATION
G. BURNER INSTALLATION
H. BURNER SPECIFICATIONS AND APPLICATIONS
I. OILTANK AND PIPING
FILTER
J. ELECTRICAL WIRIING
K. BLOWER SETUP
L. BLOWER CONTROLLER INFORMATION FOR PSC AND CTM MOTOR
M. STARTUP PROCEDURES
5
6
10
11
11
12
14
14
15
16
16
16
18
21
26
III.
USERS INFORMATION SECTION
A. OIL SUPPLY
B. COMBUSTION AIR SUPPLY
C. INSPECTION AREAS
D. STARTING THE BURNER
E. FILTER CLEANING AND LOCATION
28
28
28
28
29
29
IV.
DEALER MAINTENANCE
A. HEAT EXCHANGER CLEANING INSTRUCTIONS
30
30
V.
SEQUENCE OF OPERATIONS FLOW CHART
32
IX.
TROUBLE SHOOTING FLOW CHART
34
APPENDIX – A
REPLACEMENT PARTS LIST
40
APPENDIX – B
WIRING DIAGRAMS
42
i
I. SAFETY SECTION
This page and the following contain various warnings and cautions found
throughout the Oil Furnace Manual. Please read and comply with the statements
below.
WARNING AND CAUTIONS:
WARNING: This furnace is not to be used as a construction heater. See Page 3
WARNING: The predetermined limit locations on all of the Spirit oil-fired furnaces have
been tested and approved. Any attempt to relocate these safety controls or replace
these safety controls with a control that is not approved, or is incompatible, may result in
personal injury, substantial property damage or death. See Page 14
WARNING: THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED
SERVICE PERSON. See Page 30
CAUTION: DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF! See Page 28
WARNING: The area around the furnace should be kept free and clear of
combustible liquids and material, especially papers and rags. See Page 3
WARNING: NEVER burn garbage or refuse in your furnace. Never try to ignite oil
by tossing burning papers or other material into your furnace. See Page 28
WARNING: Spirit oil furnaces are designed to burn No. 1 or No. 2 distillate fuel
oil. NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE. See Page 28
CAUTION: DO NOT ATTEMPT TO START THE BURNER WHEN:
1. Excess oil has accumulated,
2. The furnace is full of vapors
3. The combustion chamber is very hot.
IF ONE OR MORE OF THESE CONDITIONS EXIST, CONTACT A QUALIFIED
SERVICE PERSON. See Page 28
WARNING: DO NOT START BURNER UNLESS BLOWER DOOR IS SECURED IN
PLACE.
1
2
The entire text of these instructions must be read and understood, before
installing the appliance. It is the installer's responsibility to do the following:
1. Inform and demonstrate to the user, the correct operation and maintenance of the appliance, as
explained in the Homeowner/User Information and Routine Maintenance section of this manual.
2. Inform the user of the hazards of flammable liquids and vapors and to remove such liquids and
vapors from the vicinity of the appliance.
3. Inform the user of all pertinent warnings and precautions concerning this appliance.
WARNING: This unit is not to be used for temporary heating of buildings, or structures, under
construction. Construction dust may enter the appliance or the duct system and cause a fire hazard.
Certain chemicals used during construction when burned, form corrosive condensate that can
substantially reduce the life of the heating system heat exchanger.
This appliance is shipped completely assembled and internally wired. All electrical wiring has been factory
installed and inspected. At the time of installation, the unit will require connection to electric power, fuel oil
supply, and supply and return air ductwork.
This unit uses a fan-assisted combustion system, consisting of a pressure atomizing, oil burner and
combustion air blower, used to push the products of combustion through the heat exchanger system.
After installation, the furnace and duct system must be adjusted to obtain a temperature rise of 56°- 81°F
through the unit. (Refer to the rating label located on side panel inside the burner compartment). The
installation must conform with local codes or, in the absence of local codes, with the Standard for the
Installation of Oil-Burning Equipment, NFPA 31-1997, or the latest edition, and to these instructions. The
installation must also comply with CSA B139 for recommended installation practices where applicable.
A. CODES AND CLEARANCES:
The following items must be considered when choosing the size and location of the unit.
1. All local codes and/or regulations take precedence over the instructions in this manual and
should be followed accordingly. In the absence of local codes, installation must conform to these
instructions and the guidelines of the National Fire Protection Association (NFPA). Two applicable
NFPA installation codes are the National Electrical Code, ANSI/NFPA 70-1999, and Standard for the
Installation of Oil-Burning Equipment, NFPA 31-1997. The latest editions of these codes should be
consulted.
2. The selection of a heating unit should be based on a rate of heat loss calculation for the residence
according to the manuals provided by the Air Conditioning Contractors of America (ACCA) or the
American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE). The heating
capacity of the unit proposed for installation should meet or slightly exceed the rate of heat loss for the
residence. Over sizing should not exceed 25% of the heat loss calculation.
3. When installed, this unit should be level. If possible, it should be installed in a central location, with
respect to outlet registers of the supply air ductwork.
4. Definitions of "combustible" and "non-combustible" materials as presented in the 1996 version of the
National Fuel Gas Code, ANSI Z223.1-1996/NFPA 70-1996, are as follows:
a. Combustible material:
“...materials made of or surfaced with wood, compressed paper, plant fibers, or
other materials that are capable of being ignited and burned. Such materials
shall be considered combustible even though flame proofed, fire-retardant
treated, or plastered.”
3
b. Non-combustible material:
“...material that is not capable of being ignited and burned; such as material
consisting entirely of, or a combination of, steel, iron, brick, concrete, slate,
asbestos, glass, and plaster.”
: Carefully read and thoroughly understand the following guidelines and warnings
before continuing with the installation of this appliance. Failure to follow these guidelines can
cause improper and unsafe operation of this appliance. Unsafe operation can result in substantial
property damage, severe personal injury, or death.
1. This appliance shall be used with only the type of fuel oil for which it is approved. Refer to the
appliance-rating label for the required type of fuel.
2. This appliance is an oil-fired furnace designed for installation on non-combustible materials. This
appliance is also approved for attic installation on non-combustible materials.
3. Ensure that adequate combustion and ventilation air is available to the unit.
4. The airflow resistance of the duct system attached to this appliance must fall within the allowable
external static pressure range for this unit. Refer to the Airflow Requirements and Sizing of
Ductwork section of this manual.
5. Make sure supply and return air ducts are completely sealed to the appliance casing. Refer to the
Airflow Requirements and Sizing of Ductwork section of this manual.
NOTE: The VH8FA119* furnace is approved for closet installation. The VH8FA119* requires two
openings in the closet door, each having a minimum area of 181 sq. inches. This free area intentionally
exceeds the recommended minimum free area of 1 square inch per 1000 BTUH of input rate.
Fig 1: Properly Positioned Combustion Air Openings In Walls (Fig. 1A) and Doors (Fig. 1B).
B. MAKE-UP AIR: Today's emphasis on home insulation increases the probability of inadequate air
supply to the furnace. Heavy insulation cuts off infiltration of outside air, which previously replaced inside
air removed by bathroom, kitchen and laundry vent fans, and air escaping up chimneys. This causes a
negative pressure differential within the home that reduces the supply of air available to the furnace for
combustion and ventilation.
The Spirit Make-Up-Air Control, installs quickly and easily on any warm air heating system, delivers
controlled, fresh air automatically during the winter and a constant supply of clean, fresh air for
comfortable summer living. It resolves the negative pressure differential problem.
4
II. GENERAL INSTRUCTIONS - READ BEFORE START OF INSTALLATION
1. The heating output capacity of the furnace proposed for installation should be based on a heat loss
calculation made according to the manuals provided by the Air Conditioning Contractors of America
(ACCA) or the American Society of Heating, Refrigeration and Air Conditioning Engineers, Inc.
(ASHRAE).
2. All local codes and/or regulations take precedence over the instructions in this manual and should be
followed accordingly. In the absence of local codes, installation must conform with these instructions and
regulations of the National Fire Protection Association, and to the provisions of the National Electrical
Code (ANSI/NFPA 70-1999 or latest edition).
3. The installed furnace must be level and positioned in a central location with respect to outlet registers.
It should be located near the chimney to minimize any horizontal run of flue pipe, which may be required.
4. A furnace installed in a residential garage must be installed so the burner and ignition source are
located higher than 18 inches above the floor. The furnace must also be located or protected to avoid
physical damage by vehicles.
WARNING: This furnace is not to be used as a construction heater.
5. Listed below are definitions of "COMBUSTIBLE MATERIAL" and "NON-COMBUSTIBLE MATERIAL."
Combustible Material: is made of or surfaced with wood, compressed paper, plant fibers, plastics, or
other material that will ignite and burn, whether flame resistant or not.
Non-Combustible Material: is material that is not capable of being ignited and burned. Such materials
consist entirely of, or a combination of, steel, iron, brick, tile, concrete, slate, or glass.
Table 1: MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS
TYPE OF
UNIT
MODEL NO.
Highboy
VH8FA119*
Note:
1
FROM
SIDES OF
FURNACE
FRONT
0”
Note
1
TOP &
SIDES OF
PLENUM
1”
FROM THE
FLUE/VENT
8”
REAR
0”
VH8FA119* front clearance: 8” for Closet, 24” for Alcove.
The minimum clearances listed in the preceding table are for fire protection. Clearance for servicing the
front of the furnace should be at least 24 inches.
5
A. CHIMNEY:
The furnace must be connected to an adequate chimney or an approved vent in accordance with these
instructions. An adequate chimney is one that is sealed and lined with the capability of producing a (-).04"
WC flue draft and having the capacity to handle the amount of stack gases that are introduced into it. A
chimney with an internal construction of corrosion resistant tile, stainless steel, or some other material
that will withstand flue gas temperatures up to 900°F is required.
Qualified service personnel must perform all installations and services.
The following are common chimney requirements necessary for the furnace to operate correctly:
A masonry chimney serving a Spirit oil fired furnace must comply with local codes and NFPA Standard for
Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances (NFPA211-1996 or latest edition).
1. PREVENTION OF CHIMNEY CONDENSING:
Stack gas may do one of two things as it escapes up the chimney:
A. Remain entirely in a gaseous state if the internal chimney wall temperature is above the dew
point
B. Condense water vapor on the chimney walls if they are chilled below the dew point.
Condensing will always occur on chimney walls whose temperatures are below the dew point, but the
condensate may evaporate when the walls warm above the dew point. If the chimney wall temperature
does not exceed the dew point during the heating cycle of the furnace, the moisture may accumulate in
large enough quantities to cause problems such as corrosion of a metal chimney (especially plain steel or
galvanized steel), erosion and break up of a tile liner in a masonry chimney and, in severe cases,
corrosion of the heat exchanger. Condensate also could enter the home through cracks or joints in the
chimney in a worse case situation.
Condensation most likely will not occur at the bottom of the chimney because the stack gas heats the
chimney walls as it rises and the bottom will be heated first. This heating of the walls will cause the stack
gas temperature to drop, which in turn may reduce the stack gas temperature below dew point, causing
condensation to appear on the upper part of the chimney first. This condensation may then run down
inside the chimney and drip back as far as the flue pipe and heat exchanger, where corrosion may occur,
if not treated.
To prevent condensation, it is necessary that the internal chimney wall temperature always be kept above
the dew point. If the chimney is a masonry type, it may have to be fitted with a flue liner, when the
temperature loss is too great for the furnace. If the chimney is a metal type, then an "all fuel" chimney
must be used, such as a Class "A" triple wall or insulated metal chimney. A liner will act as an insulator
and reduce the stack gas temperature loss. Insulation may be added around the liner for further
temperature stability. If the chimney is on the home's exterior or passes through a sizable, unheated area
of the building, such as a porch, high ceiling attic, etc., and condensing occurs, the chimney must be
insulated around its exterior to help the flue hold its temperature. Also, check to see if the chimney is too
large for the furnace and other appliances connected to it. If so, reduce to proper size (see Appendix E of
NFPA31) by lining. Be sure to use stainless steel liners, such as stainless types 430, 304, or for the
toughest corrosion problems, type 316. If the chimney is the correct size for the unit and condensing still
occurs, then insulating the vent connector and/or reducing the efficiency of the furnace may have to be
done to raise the chimney temperature.
More detailed information may be obtained from the latest edition of the ASHRAE HVAC Systems and
Equipment Handbook.
6
2. PROPER CHIMNEY HEIGHT:
The chimney shall terminate at least 3 feet above the highest point where it passes through the roof of a
building and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet.
(See Fig. 2a).
Fig. 2: Proper chimney termination height for pitched roofs
If the chimney penetrates a roof more than 10 feet from a ridge, wall or parapet, a minimum of 3 feet
above roof or exit point must be maintained. See Figure 2b.
If the roof is flat rather than the normal residential pitched roof, refer to Figure 3 for proper clearances.
Fig. 3: Proper chimney termination height for flat roofs
3. PROPER VENT CONNECTOR PIPE/CHIMNEY CONNECTION:
The vent connector pipe should extend only to (and not beyond) the inside wall of the chimney (See Fig.
4). A thimble should be used to connect the vent connector pipe to the chimney so that the vent
connector pipe may be readily removed in case of inspection or replacement.
Fig. 4: Proper insertion of the vent connector in the chimney.
7
4. PROPER CHIMNEY BOTTOM LEVEL:
In cases where the chimney extends to the basement floor, the draft can usually be improved by filling the
base of the chimney with sand to within 12 inches of the vent connector pipe after relocating the clean-out
door. (See Fig. 5).
Fig. 5: Suggested method to improve chimney draft.
5. TIGHT JOINTS:
All joints of the chimney must be tightly sealed. The inside of the chimney should be free of any
obstructions, such as loose brick, broken pieces of tile, or corroded metal.
6. TIGHT CLEAN-OUT DOORS AND CONNECTIONS:
All chimney clean-out doors and flue connections must fit tightly so they will seal to avoid air leaks.
7. NO INTERCONNECTED CHIMNEY FLUES:
If chimney flues are divided or there are multiple flues within one chimney, make sure there are no
openings in the partition separating the divided or individual flues.
8. FLUE PIPE CLEARANCES, SIZING AND TYPE:
The vent connector pipe must not pass through a combustible wall or partition unless adequate protection
is provided at the passageway. An acceptable passageway could be either an approved, ventilated metal
thimble which is at least 12 inches larger in diameter than the vent connector pipe, or brick work which is
at least 8 inches thick constructed into the wall and surrounding the vent connector pipe (See Fig. 6).
Fig. 6: Suggested method to accommodate vent connector passage through a wall composed of a combustible material.
8
Fig. 7: Alternate constructions that allow reduced clearances to combustible materials.
REDUCTION OF CLEARANCES WITH SPECIFIED FORMS OF PROTECTION:
Type of protection applied to and covering all surfaces of combustible material within the distance
specified as the required clearance with no protection unless otherwise noted, all dimensions in inches,
refer to Fig. 7.
18 inches
Sides &
Above Rear
Required clearance with no protection from the appliance or
chimney connector is:
9 inches
Sides &
Above Rear
6 inches
Sides &
Rear
a. 3-1/2" thick masonry wall without ventilation air space….
--
12
--
6
--
5
b. 1/2" insulation board over 1" glass fiber or mineral wool batts…
12
9
6
5
4
3
c. 0.024(24 gauge) sheet metal over 1" glass fiber or mineral
wool batts reinforced with wire on rear face with ventilated air
space…
9
6
5
3
3
3
d. 3- 1/2" thick masonry wall with ventilation air space..
--
6
--
6
--
6
e. 0.024 (24 gauge) sheet metal with ventilated air space.
9
6
5
3
3
2
f. 1/2" thick insulation board with ventilation air space..
9
6
5
3
3
3
g. 0.024 ( 24 gauge) sheet metal with ventilated air space over
0.024 (24 gauge) sheet metal with ventilated air space….
9
6
5
3
3
3
h. 1" glass fiber or mineral wool batts sandwiched between two
sheets 0.024 (24 gauge) sheet metal with ventilated air space
9
6
5
3
3
3
A. Equal the required clearance with no protection.
B. Equals the reduced clearance permitted in accordance with the preceding clearance chart.
C. The protection applied to the construction that covers the combustible material should extend far enough
in each direction to make C equal to A.
The vent connector pipe between the furnace and chimney shall be of equal diameter as the flue outlet of the
furnace. The vent connector pipe must be made of 24 gauge (or thicker) corrosion-resistant steel. The
vent connector pipe should be as short as possible and installed so that it has a continuous rise from the
furnace to the chimney. The horizontal length of a connector to a natural draft chimney or vent serving a single
appliance shall not be more than 75 percent of the height of the vertical portion of the chimney or vent above
the connector. Elbows should be minimized and the pipe should be joined with metal screws and supported by
straps. All horizontal runs of vent connector pipe should be pitched upward a minimum of ¼ inch per foot of run.
A thimble should be used to connect the vent connector pipe to the chimney so the pipe may be readily
removed in case of inspection or replacement. See Fig. 6 on preceding page.
9
B. VENTING:
NOTE: On the VH8FA119* it is possible to rotate the flue elbow (which is factory installed for vertical
discharge) 90° counter clockwise or clockwise from the vertical position to adapt to various venting
systems.
Notice: Blocked Vent Switch Installation
The blocked vent switch kit must be installed to comply with CAN STD B140.4 where applicable. For
installation instructions see AOPS2687 kit.
CAUTION MUST BE TAKEN NOT TO EXCEED 90° ROTATION (OF THE FLUE
ELBOW) .
ROTATION OF FRONT FLUE ELBOW:
When an installation requires that the flue exit out the left or right side casing, remove the screw securing
the 90 deg. elbow and rotate it 90°. Then, remove knock-out in side casing and extend vent through the
opening.
A trim collar may be ordered to hide the gap around the flue pipe. This trim collar, however, is not
required for operation. Trim collar/gasket part numbers(s) 14132 / 330006 for VH8FA119*.
The VH8FA119* may be vented through a standard correctly sized chimney.
The VH8FA119* may also be horizontally vented through a sidewall. A field model FDVS-67/FOVP-615
side wall vent kits for such applications is available. When installing the sidewall vent kits, outside
combustion air must also be applied to the burner. The following table identifies application order
information.
SIDE WALL VENTING APPLICATION ORDER INFORMATION
FIELD VENT TERMINATION
SIDE WALL VENT
KIT
ACCESSORIES KIT
BURNER
COMBUSTION AIR INTAKE
HOOD KIT
(FOR COMBUSTION AIR
APPLICATIONS ONLY)
(15’ application MAX)
(BURNER SPECIFIC)
PART NUMBER
PART NUMBER
PART NUMBER
AOPS8394
AOPS8397
VH8FA119*
Beckett AFG
AOPS8414
Table 2: Sidewall vent kits
The Field vent kit is set up with a 6 inch diameter vent pipe for the VH8FA119* with concentric throughthe-wall vent termination/inlet air vent hood. For Beckett, the combustion air inlet pipe will be reduced to
3” diameter with the Beckett sidewall vent kit.
The side wall vent may be installed either through the knock-out on the right or left side casing of the unit
or vertically out the top opening of the vestibule.
The combustion air inlet can be installed through the either the lower left side casing knockout or the
lower right side casing knockout.
10
C. DRAFT REGULATORS:
Note: Do not use with Direct Vent application.
A draft regulator is supplied with the furnace and should be installed according to the regulator
manufacturers recommendations. With the burner operating, use a draft gauge to adjust the regulator to
the proper setting. (refer to the instructions enclosed with draft regulator to adjust to the proper setting).
When the burner air supply and draft are properly adjusted, the over fire draft should be a negative (-).01"
to (-).02" WC, as measured at the 5/16" over fire air tap (See Fig. 12). This tap is provided in the upper
burner mounting plate. To measure the flue draft, punch a small hole in the vent connector pipe as close
to the furnace as possible and always before the draft regulator.
Note: Draft over fire may be positive for high fire applications but not to exceed (+).01" WC.
D. DUCT WORK/AIR CONDITIONING:
If the furnace is used in connection with summer air conditioning (cooling), the furnace should be installed
parallel with or on the upstream side of the evaporator coil to avoid condensation in the furnace heat
exchanger. If the cooling unit is installed with a parallel flow arrangement, dampers or other means used
to control flow of air should be provided to prevent chilled air from entering the furnace. If such a damper
is manually operated, it must be equipped with a means to prevent operation of either unit, unless the
damper is in the full heat or cool position.
The duct system should again follow the current design standard of Air Conditioning Contractors of
America (ACCA) or ASHRAE Fundamentals volume. The most common location for the A-shaped coil (A
style) is shown in Fig. 8.
Fig 8: Acceptable locations for the air conditioner evaporator coil.
NOTICE: The minimum coil pan clearance for a sectional or drum type heat exchanger is three inches
unless specified otherwise by the individual coil manufacturer.
NOTICE: The minimum return air temperature is 55° F.
The RETURN AIR DUCT SYSTEM should equal the warm air duct system in airflow capabilities.
Note: When a return register is located in the same room as the furnace, the register must be at least 20
feet away from the furnace.
11
E. Air Filter Mounted External to Furnace:
On highboy furnaces, it is necessary to cut the return air opening in the side, rear casing or base,
depending upon the needs of the specific installation. The filter rack provided with the furnace, refer to
Fig. 9, will serve as a template to scribe a mark for the return air opening on the casing. Place the filter
rack on a side casing approximately one inch up from the bottom of the furnace and centered from side to
side. Place the securing flange against the casing when locating the return air opening. For your
convenience, (4) locator knockouts have been placed at the proper locations on both the left and right
side casings.
PLEASE NOTE: While scribing the return air opening, the filter rack can be held in position by tape or
similar temporary means. Position the open end of the filter rack so as to provide access for filter
replacement. Once the filter rack is positioned correctly, scribe a line along the inside of the securing
flange on three of the sides. To scribe a line on the fourth side (the open end), use the open-end support
as a guide.
Remove the filter rack and cut the return air opening in the casing. Now the filter rack can be anchored to
the furnace with screws or pop-rivets through the securing flange of the filter rack.
Connect the return air plenum to the filter rack and slide the filter into place. Dimensions for adapting the
return air plenum to the filter rack are provided (See Fig. 9).
Fig. 9: A typical filter rack and dimensions for the VH8 furnace.
: Failure to comply with minimum filter installation requirements may affect the
performance and/or void the warranty on this unit.
12
If a method other than supplied filter rack is selected for retention of the filter and/or use of a different filter
type is desired, refer to Table 3 below for minimum sizing guidelines for selecting filters for the unit.
Filter Type
* Supplied Permanent
Standard
Permanent
Disposable
Maximum
Air Velocity
(ft/min)
600
Model Number
VH8FA119*
480 in²
500
576 in²
300
960 in²
Table 3: Minimum Required Filter Area (in square inches)
* The supplied filter can be cut to size to fit other filter retention systems as long as maximum
air velocity of the filter is not exceeded.
NOTICE: Any internal stiffeners used in the filter must not be removed, although
they can be cut to size as needed.
13
F. LIMIT POSITION AND LOCATION
WARNING: The predetermined limit locations on all of the Spirit oil-fired furnaces have been tested and
approved. Any attempt to relocate these safety controls or replace these safety controls with a control
that is not approved, or is incompatible, may result in personal injury, substantial property damage or
death.
The unit listed in the table below must have the limit control installed at the time of unit installation.
TABLE 4: Installation location of
the fan and limit control for each
furnace
Fig. 10: Limit location for VH8FA119*
G. BURNER INSTALLATION:
NOTICE: Remove all cardboard packing from around chamber before installing burner.
The oil burner will mount on three stud mounting bolts on the lower mounting plate covering the opening
in the front of the heat exchanger. The end of the burner tube should be inserted no further than 1/4 inch
back from the inside surface of the combustion chamber. A distance further than 1/4 inch back from the
inside chamber wall may cause impingement and sooting. This unit is equipped with a chamber retainer
(refer to Fig.11). The retainer secures the chamber during shipping and helps to maintain insertion depth.
DO NOT remove this retainer when installing burner.
Fig. 11: Typical location of the over fire air tap and components in burner mounting plate area
14
Fig. 12: Burner insertion illustration (Top view)
When mounting the burner, the mounting plate (Fig. 11) must be removed to provide access to the area
in front of the combustion chamber. A fiber insulating sleeve or amulet is provided on the burner tube of
specific burners.(see Fig. 12). See burner application chart for type of insulator. Do not allow the burner
tube or end cone to physically touch or protrude into the chamber, as excess heat transfer could result in
destruction of the tube, end cone or both. The burner tube/end cone is properly positioned, when the end
is ¼ inch back from the inside surface of the combustion chamber wall.
DO NOT CHANGE POSITION OF THE CHAMBER!
H. BURNER SPECIFICATIONS AND APPLICATIONS:
FURNACE MODEL
VH8FA119*
BURNER
SPEC
NO.
*
INS
TP2701
N
BURNER MODEL
& TUBE LENGTH
HEAD
STATIC
PLATE
MAXIMUM
NOZZLE
SIZE**
SHIPPED
NOZZLE
SIZE
BURNER
BECKETT (AFG)
AFG-4.5”
F6
2-3/4U
1.10X80° A
1.00X80° A
OIL
PUMP
PRESSURE
(PSIG)
120
Table 5: Burner specifications
* INSULATOR S = SLEEVE OR N = NONE
THE NOZZLE SIZE GIVES THE NOMINAL FLOWRATE, IN GPH, FOLLOWED BY THE SPRAY ANGLE, IN DEGREE’S, AND
THE SPRAY PATTERN, EITHER “A” FOR HOLLOW CONE OR “B” FOR SOLID CONE. FOR EXAMPLE, A NOZZLE RATED
AT 0.65 GPH @ 100 PSIG THAT PROVIDES AN 80° SPRAY ANGLE AND A HOLLOW SPRAY PATTERN WOULD BE
ABBREVIATED IN THE TABLE AS “0.65 X 80°A”.
UNITS
INPUT CAPACITY SELECTION CHART
EQUIVALENT
EFFECTIVE
HEAT INPUT
HEATING
RATE* (BTU/HR)
CAPACITY**
(BTU/HR)
NOZZLE SIZE (GPH x TYPE)
Beckett AFG
VH8FA119*
119,000
101,000
0.85 x 80° A
VH8FA119*
140,000
119,000
1.00 x 80° A
VH8FA119*
156,250
132,000
1.10 x 80° A
Table 6: Oil nozzle capacity
All rates shown achieved with 120 PSIG pump pressure for Beckett AFG.
* Based on #2 domestic heating fuel oil having heating value of 140,000 BTU per gallon.
** Based on thermal efficiency of 85.8%.
15
I. OIL TANK AND PIPING:
: All local codes and ordinances take precedence with regard to selection and
installation of oil storage tank and oil supply (and return) lines. In the absence of local codes, all
tanks and lines must be selected and installed according to the instructions in this manual and
the Standard for the Installation of Oil-Burning Equipment, NFPA 31-1997, or the latest edition.
Burners are equipped with a single-stage, fuel pump. This type of fuel pump, when connected with a
supply line only, is satisfactory where the fuel supply is level with, or above the burner thus permitting
gravity flow of oil to the burner. If the tank is above the burner, and gravity oil feed to the burner is
permitted, a single line system may be used. The line should have a gradual slope downward of
approximately 1/2 inch per foot, or more, from the tank to a point directly below where it is connected to
the pump. Pitching the line upward toward the tank will help prevent the formation of air pockets in the
line.
NOTICE: An oil safety valve or a delayed-action, solenoid valve should be
installed in the oil supply line of all gravity-fed systems.
J. OIL FILTER:
It is strongly recommended that an oil filter assembly be installed in the oil supply line to the unit. This
filter should have the capacity to trap a 40-50 micron particle.
The filter cartridge should be replaced at least once a year. The filter body should be thoroughly cleaned
before installing a new cartridge.
K. ELECTRICAL WIRIING:
: This appliance must be grounded in accordance with local codes, or in the absence
of local codes, with the National Electrical Code, ANSI/NFPA 70-1999, or the latest edition.
All wiring must conform to the provisions of local codes or, in the absence of local codes, with the
provisions of the National Electrical Code, ANSI/NFPA 70-1999, or the latest edition, and this instruction
manual.
This appliance requires 120 VAC, 60 Hz, single-phase power. Refer to Table 7 for typical electrical
current draws of the individual appliance motors, recommended sizes for over-current and short circuit
devices, and minimum recommended field wiring sizes. Electrical service must be brought to the unit from
a circuit breaker, or fused disconnect switch, in accordance with local codes. The disconnecting switch
must be located reasonably close to and within sight of the unit. Care must be taken to ensure correct
polarity when wiring the furnace.
Field wiring of power circuits to the appliance should consist of copper conductors rated for at least
15 amp service with an insulation temperature rating of at least 75°C temperature rise.
Oil
Burner
Assembly
Full Load
Current
(Amps) @
115 VAC
Maximum
Time Delay
Type Fuse
or Inverse
Time Circuit
Breaker Size
(Amps)
Minimum
Recommended
75 deg. C.
Copper Power
Wiring Size
(AWG)
Model
Potential/Frequency/
No. of Phases
(V/Hz/Ph)
Supply/Return
Air Blower
Full Load
Current
(Amps) @ 115
VAC
VH8FA119P*
120/60/1
19.2
2.6
20
12
VH8FA119T*
120/60/1
11
2.6
20
12
Table 7: Typical Electrical Requirements
16
Wire size selections in Table 7 are based upon Table 310-16 of the National Electrical Code for three
copper conductors, with insulation rated for 75 degrees Celsius, contained in raceway at 30 degrees
Celsius. For other wire insulation temperature ratings and ambient conditions, refer to the National
Electrical Code for the minimum wire sizing requirements.
NOTICE: Before the unit is started, the installer and/or electrician must check the following items:
1. Review wiring diagram for proper routing and connection of all field wiring. Ensure
that all wires and connectors are firmly secured.
Electronic Air Cleaner (EAC) and Humidifier Installation:
The fan timer on this unit has designated terminals to control the operation of an electronic air cleaner
and/or humidifier. These terminals provide line voltage for the control of these accessories, refer to
Figure 13. Connection between EAC and N6 provides a switched 115 vac to power an electronic fan
cleaner. The same-switched 115 vac is available between FAN and N7 and may be used in conjunction
with a humidistat to control a humidifier. These terminals are energized whenever the blower is active.
Figure 13: The Fan Control Module
NOTICE: It is important to confirm that the operating voltage of the humidifier or EAC being
installed matches the output of this control. If not, a field supplied relay or transformer may be
necessary to provide the proper control and supply voltage for the accessory being installed.
Refer to the manufacturer’s instructions for the humidifier or EAC for additional information.
Thermostat Anticipator Setting:
Proper control of the indoor air temperature can only be achieved if the thermostat is calibrated to the
heating and/or cooling cycle. Calibration will help to produce a more constant indoor temperature by
adjusting the length of the heating/cooling cycle to fit the application. A vital consideration of this
calibration is related to the thermostat heat anticipator.
17
The proper thermostat heat anticipator setting is 0.1 ampere. To increase the length of the cycle, increase
the setting of the heat scale; to decrease the length of the cycle, decrease the setting of the heat scale.
Thermostat models having a scale as shown in Figure 14 on the next page, must be adjusted to each
application.
Figure 14: Heat Anticipator Adjustment Scale
In many cases, this setting can be found in the thermostat installation instructions. If this information is not
available, or if the correct setting is questioned, the following procedures should be followed:
L. Blower Motor Speed Selection:
: Turn off the electrical power to the unit, before attempting to change supply air
blower speed wiring.
The furnace comes from the factory with the proper cooling speed selected and the heat rise set to
approximately 66°F on mid-fire.
The heat rise is determined by the nozzle size and the switch selection on the control board located in the
vestibule compartment.
18
VH8FA119P60B
ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE
COOLING UNIT
HTG Speed by Input
Low
Mid
High
Fire
Fire
Fire
Low
ML
MH
36,000
AS SHIPPED CLG. Recommended CLG Speed
Low
42,000
Low
ML
MH
Med Low
48,000
Low
ML
MH
Med High
60,000
Low
ML
MH
High
Furnace Airflow (CFM) vs. External Static pressure (in. WC.)
Speed Tap\ Static Pressure
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
1308
1300
1274
1265
1237
1169
1127
ML
1583
1526
1515
1491
1458
1420
1371
MH
1894
1874
1839
1804
1746
1683
1632
High
2254
2228
2195
2181
2069
1995
1897
Furnace Motor Current Draw (Amps/Watts) vs. External Static pressure (in. WC.)
7.56
Low
6.99
6.66
698
8.44
9.21
ML
MH
1040
13.5
High
999
13.2
1320
Speed Tap\ Static Pressure
1290
1270
864
10.7
1130
687
8.23
895
11.3
1240
715
8.68
923
12.4
568
6.93
745
9.01
971
12.8
578
7.28
772
9.38
5.83
602
7.61
786
9.87
5.91
623
8.01
801
10.2
6.21
637
8.19
867
10.6
6.50
660
829
10.2
1090
1020
High Fire Temperature Rise vs. External Static pressure (in. WC.)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
94
94
96
97
99
105
108
ML
78
80
81
82
84
86
90
MH
65
66
67
68
70
73
75
High
54
55
56
56
59
62
65
Mid Fire Temperature Rise vs. External Static pressure (in. WC.)
Speed Tap\ Static Pressure
AS SHIPPED HTG. 0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
84
84
86
87
89
94
98
ML
70
72
73
74
76
78
80
MH
58
59
60
61
63
65
68
High
49
49
50
51
53
55
58
Speed Tap\ Static Pressure
Low
Low Fire Temperature Rise vs. External Static pressure (in. WC.)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
72
72
73
74
76
80
83
ML
59
61
62
63
64
66
68
MH
49
50
51
52
54
56
57
High
42
42
43
43
45
47
49
Figure 15a: Heating speed by input VH8FA119P*
Speed vs. color code for *PSC Motor:
Low = Red
Med-Low = Blue
Med-High = Yellow
High = Black
*PSC is an abbreviation for Permanent Split Capacitor
19
VH8FA119T60B
ALTERATIONS REQ’D FOR A/C @ DESIGN EXTERNAL STATIC PRESSURE
COOLING UNIT
Recommended CLG Speed
HTG Speed by Input
Low
Fire
AS SHIPPED CLG. Mid
Fire
High
Fire
36,000
ML
Med
MH
Low
42,000
ML
Med
MH
Med Low
48,000
ML
Med
MH
Med High
60,000
ML
Med
MH
High
Furnace Airflow (CFM) vs. External Static pressure (in. WC.)
Speed Tap\ Static Pressure
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
1520
1429
1385
1311
1222
1139
1085
ML
1660
1593
1536
1491
1422
1369
1295
Med
1749
1693
1652
1572
1520
1465
1391
MH
1827
1766
1692
1674
1596
1540
1487
High
2253
2185
2142
2114
2045
1991
1955
Furnace Motor Current Draw (Amps/Watts) vs. External Static pressure (in. WC.)
2.62
2.81
2.92
3.07
3.22
3.35
3.46
211
228
237
253
268
279
289
3.34
3.55
3.72
3.84
4.02
4.13
4.31
279
294
310
325
339
350
364
3.74
3.91
4.11
4.25
4.39
4.60
4.74
314
327
345
360
374
390
406
4.21
4.40
4.57
4.73
4.90
501
5.12
356
373
390
407
422
432
450
7.2
7.43
7.68
7.92
8.16
8.29
7.2
650
665
688
712
714
751
638
Low
ML
Med
MH
High
High Fire Temperature Rise vs. External Static pressure (in. WC.)
Speed Tap\ Static Pressure
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
80
85
88
93
99
105
112
ML
73
76
79
81
85
89
94
Med
69
72
73
77
80
83
87
MH
66
69
72
72
76
79
82
High
54
56
57
57
59
61
62
Mid Fire Temperature Rise vs. External Static pressure (in. WC.)
AS SHIPPED HTG. Speed Tap\ Static Pressure
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
72
77
80
84
90
97
102
ML
66
69
72
74
77
80
85
Med
63
65
67
70
73
75
79
MH
60
62
65
66
69
72
74
High
49
50
51
52
54
55
56
Low Fire Temperature Rise vs. External Static pressure (in. WC.)
Speed Tap\ Static Pressure
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
62
66
68
71
77
82
86
ML
56
59
61
63
66
68
72
Med
54
55
57
60
62
64
67
MH
51
53
55
56
59
61
63
High
42
43
44
44
46
47
48
Figure 15b: Heating speed by input VH8FA119T*
20
Speed vs. color code for *CTM Motor:
Low = Red
Med-Low = Purple
Medium = Blue
Med-High = Yellow
High = Black
*CTM is an abbreviation for Constant Torque Motor
M. BLOWER CONTROLLER INFORMATION FOR PSC AND CTM MOTOR
TERMINAL DEFINITIONS & FIELD WIRING
Burner Harness Connector P1
Pin 1- Limit switch connector.
Pin 2- 120 VAC Line connection.
Pin 3- Burner pilot contact.
Pin 4&5120 VAC Neutral connections.
Pin 6- Burner pilot contact.
Pin 7&8From oil primary control.
Pin 9- Limit Switch Input (LSI).
Field Wiring to Burner
Harness Wires
Beckett Connections
Riello Connections
Pilot (Tstat)
Yellow Wires
T-T terminals
T-stat terminals
Neutral
White
White
White
Line
Red
Black
Black
Thermostat / Humidistat connections
“C”
Common / ground
“W”
Thermostat call for heat
“R”
24 VAC to thermostat
“G”
Thermostat call for fan
“Y”
Thermostat call for cool
“DEHUM”
Humidistat call for dehumidification (TXV systems ONLY)
Male quick connect terminals.
“S1-3”
120 VAC Hot
“N1-7”
120 VAC Neutral
“EAC”
Electronic Air Cleaner (120 VAC) connection
“FAN”
Fan On Signal
“X”
24 VAC from transformer
“C”
24 VAC common from transformer
“CC”
Compressor Contactor
“CC_COM”
Compressor Contactor Common
“LOW”
Continuous Blower Speed
“HEAT”
Blower heat speed tap
“COOL”
Blower cool speed tap
21
A. Inputs
Power supplies
Line voltage is applied between the “S1” and “N1” quick connect terminals. 24 VAC Class II
Transformer secondary voltage supplied to X and C
Limit switch
The 120 VAC optically isolated limit switch input is connected on pin P2-1 & 9. Refer to the Heat
Mode section for the control operation.
Thermostat call for heat “W”
24 VAC thermostat input. A call for heat is recognized when the thermostat connects “W” to “R”. This
input has an indicator LED that will light when the control receives a call for heat. Refer to the Heat
Mode section for the control operation.
Thermostat call for cool, “Y”
24 VAC thermostat input. A call for cooling is recognized when the thermostat connects “Y” to “R”. This
input has an indicator LED that will light when the control receives a call for cooling. Refer to the Cool
Mode section for the control operation.
Thermostat call for dehumidification “DEHUM”
24 VAC thermostat input. A call for dehumidification is recognized when the humidistat connects
“DEHUM” to “R”. This input has an indicator that will light when the control receives a call for
dehumidification. Refer to the Cool Mode section for the control operation.
Thermostat call for fan “G”
24 VAC thermostat input. A call for fan is recognized when the thermostat connects “G” to “R”. This
input has an indicator LED in that will light when the control receives a call for fan. Refer to the Fan
Mode section for the control operation.
B. Outputs
PSC Control
The control shall control a five-speed indoor blower motor. Rating shall be 10 FLA, 30 LRA @ 120
VAC. Connections are made via 0.250 x 0.032” male quick connect terminals labeled “HEAT”,
“COOL”, and “LOW”. “HEAT” is energized when the heat speed blower is to run. “COOL” is energized
when the Cool speed blower is to run. “LOW” is energized during a call for fan is received or a call for
dehumidification is received.
Oil Burner
Control
The control provides dedicated contacts to operate the T-T input of an oil primary control.
Rating shall be class 2 – 24 VAC pilot duty @ 24 VAC (<200mA).
Power
The switched 120 VAC power from the LIMIT switch passes through the board between Pins 1 & 2
of connector P1.
Compressor contactor
The control provides switched 24VAC to operate a compressor contactor. Rating shall be class 2 – 24
VAC pilot duty @ 24 VAC (<200mA).
22
EAC (electronic air cleaner)
The control provides a 120 VAC output for an electronic air cleaner. This output is energized whenever
the fan motor is energized (either low, heat or cool speed). Connection is made via male quick connect
terminal labeled “EAC”.
Humidifier
The control provides a 120 VAC output for a humidifier. Connections are made to a male quick
connect terminal labeled “FAN”. The control does not switch this output, it provides a pass-through
connection from P1-7 from the switched primary voltage of the Burner Module.
Status LED
A red LED is provided to indicate any thermostat input has been recognized by the microprocessor on
the control. See Diagnostic Features for a function description of operation.
Thermostat Input LEDs
Four green LEDs are placed beneath their respective thermostat connections (W, Y, G and DEHUM)
and operate whenever a call is present. See Diagnostic Features for a function description of
operation.
C. Operating Modes
Standby Mode
All outputs are off and the control is waiting for a thermostat demand. The thermostat inputs, and limit
switch are continuously monitored. The control initiates action when a thermostat call is received or
limit switch opens.
Fan Mode
A call for fan (“G”) is received from the thermostat. If no other mode is calling for blower operation, the
control will operate the fan relay (K4) and power the “Low” blower speed terminal. The fan mode will
be operated as long as the “G” input is calling and neither the Heat mode nor the Cool mode is calling
for blower operation. When the Heat and Cool modes call for blower operation, their respective
outputs will take precedence after their respective turn-on time delays have expired.
Cooling Mode
A call for cool (“Y”) is received from the thermostat. If the heat mode is not active or the anti-short
cycle delay is not in effect, the control will energize the “CC” terminal and after a 10 second power
demand conservation delay energizes the “COOL” speed blower terminal.
When the call for cool is satisfied, the “CC” terminal is de-energized and the cooling off delay of 45
seconds is started. Forty-five seconds later the “COOL” speed blower terminal is de-energized and the
control reverts to Standby Mode.
Dehumidification Operation
If a call for dehumidification is received while the Cool Mode is active, blower speeds will be reduced.
The PSC “COOL” blower speed terminal (1158-100 model only) will be de-energized and “Low” blower
speed will be energized.
Anti-Short Cycle Operation
To prevent compressor short cycling, a call for cooling will be ignored for four minutes after the
termination of any cooling call. The anti-short cycle delay is also in effect at power-up.
23
Heat Mode
When a call for heat (“W”) is received from the thermostat, if the “Cool” mode is not already active, the
“T-T” terminal is energized and the blower on delay is started. The on-off pattern of DIP switch SW2
(positions 1 and 2) select one of four blower on delay values (see Table 11). When the delay time has
elapsed, the “HEAT” blower speed is energized. The control remains in steady heat mode until the
thermostat is satisfied. When the call for heat signal is removed, the “T-T” terminal is de-energized and
the blower off delay is started. The on-off pattern of DIP switch SW2 (positions 3 and 4) select one of
four blower off delay values (see Table 8). When the delay time has elapsed, the “HEAT” blower
speed terminal is de-energized.
DIP SWITCH 2 SECTION STATE
3
4
BLOWER DELAY TIMES
Counter Flow
ON - SEC
OFF - MIN
ON - SEC
1
2
OFF
OFF
15
30
ON
OFF
24
60
OFF
ON
36
120
ON
ON
48
240
OFF
OFF
2
ON
OFF
4
OFF
ON
6
ON
ON
8
Table 8: ON and OFF Blower Delay Time Switch Settings
Motor Blower Speed
Three interconnected blower speed outputs are provided. A “G” call for fan will provide power to the
LOW speed tap only. A “W” heat call will provide power to the Heat speed tap only. A “Y” cooling call
will provide power to the Cool speed tap only.
In the case of thermostat calls for “Y” and “W” together, blower speed selection will be determined by
the input that was first initiated. In the case where the control is in a cooling mode with both “Y” and
“W” inputs energized and then the “Y” input is removed, the cooling blower off time will be executed
prior to the control switching into a heating mode. In the case where the control is in a heating mode
with both “Y” and “W” inputs energized and then the “W” input is removed, the heating blower off time
will be executed prior to the control switching into a cooling mode. In the case where a call for fan “G”
already exists and either a “W” or a “Y” call is initiated, the blower speed will switch to the respective
“W” or a “Y” speed following the blower on delay for that call.
The speed taps are interconnected and interlocked, only one speed may be powered at any one time.
When a speed is to be operated, the speed select relays are operated to select the path to the motor
tap and then the enable relay is operated to switch the operating power to the selected motor speed
tap. If the speed of the running motor is to be changed, first the enable relay removes power from the
motor, the new speed is selected and then power is restored to the motor.
Blower On and Off Delays
Four Heat blower on and four blower off delays are selected by two dip switches for each function.
Refer to Table 11 for specific delay values.
24
PSC AND CTM TROUBLE SHOOTING
DIAGNOSTIC FEATURES
The control board is equipped with 4 green Input Status LEDs and 1 red Board Status LED. These are
intended to provide a quick view into furnace performance without requiring a voltmeter.
The green Input Status LEDs are driven by the “Y”, “W”, “G”, and “DEHUM” inputs and are located
directly below those inputs. They will light to indicate the presence of these signals.
The red Board Status LED has two functions:
It will light when the board recognizes a valid input signal and will stay lit until all valid signals are
removed. This is intended to show that the board is functioning and able to respond to input signals.
It will flash rapidly while 120VAC is missing from the LIMIT switch. This is intended to give a quick
visual indication of the High Limit switch.
25
N. STARTUP PROCEDURES:
A. Heating System
1. Initial Startup:
: Turn off power to furnace. Before the oil piping system is placed into service, it must
have been leak tested by a qualified heating contractor.
: For initial start-up of the appliance after installation, it may be necessary to purge the
air out of the oil line. A qualified heating contractor should do this.
For Your Safety Read Before Operating:
: If you do not follow these instructions exactly, a fire or
explosion may result causing property damage, personal injury or loss of life.
•
•
This appliance does not have a pilot light. It is equipped with an ignition system that
automatically lights the burner. Do not attempt to light the burner by hand.
Do not use this appliance if any part has been under water. Immediately call a qualified
service technician to inspect the appliance and to replace any part of the control system
and any oil control that has been under water.
Operating Instructions:
i.
STOP! Read the safety information above.
ii. Set the thermostat to the lowest setting.
iii. Turn off all electric power to the appliance.
iv.
This appliance is equipped with an ignition system that automatically lights the
burner. Do not try to light the burner by hand.
v. Rotate the manual oil shutoff valve to the “ON” position.
vi. Turn on the electric power to the appliance.
vii. Set the thermostat to the desired setting.
viii.
If the appliance will not operate, call your qualified service technician or oil supplier.
To Turn Off Oil to Appliance:
i.
Set the thermostat to the lowest setting and set the operating mode switch to “OFF”.
ii. If service is to be performed, turn off the electrical power to the appliance.
iii. Turn the manual oil shutoff valve to the “OFF” position.
2. Adjustment of Burner Combustion:
: Maximum gross stack temperature must not exceed 550°F (288°C) under any
circumstances.
: Do not run the oil pump dry for more than five minutes, as irreparable damage may
result.
26
NOTICE: Read the burner operation and service instructions, Model AFG Oil
Burner Instruction Manual, before continuing.
To initially adjust and successfully service the oil burner in the appliance heating section, the following
test instruments are required:
•
A smoke density measuring and rating device,
•
A carbon-dioxide (CO2) or oxygen (O2) analyzer,
•
A flue gas temperature measuring device (e.g., thermocouple or thermister probe with readout
device),
•
An analog or digital multimeter, and
•
An oil pressure gauge capable of reading 0-150 PSIG.
Adjust burner per burner instruction manual.
27
III. USERS INFORMATION SECTION
A. OIL SUPPLY: Do not allow the fuel tank to run completely empty. During the summer, keep the
tank full to prevent condensation of moisture on the inside surface of the tank. If the fuel tank runs
completely dry, it may be necessary to purge the lines of trapped air. Contact a qualified technician to
bleed the lines and restart the burner.
OIL SUPPLY VALVE: Turn the oil supply valve off if the burner is shut down for an extended period of
time.
B. COMBUSTION AIR SUPPLY: The burner requires a generous amount of clean combustion air
to operate safely. Lack of adequate combustion air can result in erratic operation of the burner, noisy
combustion, or fuel odors in the air. NEVER BLOCK THE FURNACE FROM THE SUPPLY OF
COMBUSTION AIR. If there is an exhaust fan, dryer or return air grill in the furnace room, there should be
increased concern and additional efforts may be required to provide adequate combustion oil to the
furnace at all times.
C. INSPECTION AREAS
VESTIBULE: The furnace vestibule area or burner compartment should be inspected by removing the
front door of the furnace and looking for signs of excessive heat such as discoloration of components
materials damage, from rust or corrosion, soot or carbon build-up.
EXTERIOR OF FURNACE: The furnace exterior should be inspected for signs of excessive heat such as
discoloration of materials and damage from rust or corrosion.
FLUE PIPE, VENT PIPE OR CONNECTOR: The furnace vent pipe should be inspected for signs of rust,
corrosion pitting or holes in pipe, and leakage around seams in pipe, indicated by soot or condensate
streaks.
CHIMNEY OR VENTING SYSTEM: The furnace venting system should be inspected for signs of rust,
corrosion pitting or holes, and signs of condensation or moisture leakage from the venting system.
If any of the above symptoms are evident, call a qualified heating contractor for assistance.
CAUTION: DO NOT ATTEMPT TO MAKE REPAIRS YOURSELF!
WARNING: The area around the furnace should be kept free and clear of
combustible liquids and material, especially papers and rags.
WARNING: NEVER burn garbage or refuse in your furnace. Never try to ignite oil
by tossing burning papers or other material into your furnace.
WARNING: Spirit oil furnaces are designed to burn No. 1 or No. 2 distillate fuel oil.
NEVER USE GASOLINE OR A MIXTURE OF OIL AND GASOLINE.
CAUTION: DO NOT ATTEMPT TO START THE BURNER WHEN:
1. Excess oil has accumulated,
2. The furnace is full of vapors
3. The combustion chamber is very hot.
IF ONE OR MORE OF THESE CONDITIONS EXIST, CONTACT A QUALIFIED
SERVICE PERSON.
28
D. STARTING THE BURNER:
1. Turn the main service switch to "OFF" position.
2. Set thermostat substantially above room temperature.
3. Open shut-off valves in oil supply line to burner.
4. Turn service switch to furnace "ON". If burner starts and runs, but stops again on lockout, it may be
necessary to bleed the lines or make burner combustion air adjustments. Contact a qualified service
person to adjust and start burner.
E. FILTER CLEANING AND LOCATION:
WARNING: To avoid injury from moving parts, hot surfaces, or electrical shock,
shut off the power to the furnace before removing any furnace access doors to
service the air filters.
The air filters should be inspected each month and cleaned when dirty. Cleaning the air filters frequently
may reduce airborne contaminants from entering the furnace and depositing in the furnace, duct system
and home.
Filter maintenance procedure:
Shut off the electrical power to the unit. Open the access door. Slide the air filter out of the filter rack.
Clean the filter by either vacuuming, rinsing with tap water, hosing, or dipping in an ordinary detergent
solution. After cleaning and drying the filter, replace the completely dry filter in the rack. If the filter has a
supporting mesh, the mesh side of the filter must be placed towards the furnace.
Fig 16: Filter Location for Typical Highboy Furnace
29
IV. DEALER MAINTENANCE:
SAFETY DURING SERVICING AND INSPECTION
: Personal injury or property damage could result from repair or service of this
appliance by anyone other than a qualified heating contractor. The user may only perform the
activities described in the Homeowner/User Routine Maintenance section of this manual.
: To avoid injury from moving parts, or electrical shock, shut off the power to the
appliance before removing blower compartment door and servicing this appliance.
: When servicing controls, label all wires prior to disconnecting. Reconnect any
removed wires correctly. Wiring errors can cause improper and dangerous operation.
Dangerous operation can result in injury or damage.
IMPORTANT: Verify the proper operation of this appliance after any servicing is performed.
A qualified heating contractor should perform the following maintenance procedures at the
beginning of each heating season. Correct any deficiencies at once.
A. HEAT EXCHANGER CLEANING INSTRUCTIONS:
WARNING: THE HEAT EXCHANGER MUST BE CLEANED BY A QUALIFIED
SERVICE PERSON.
It is important to inspect and clean the heat exchanger once a year, or as necessary, to remove any buildup of soot. A layer of soot on the inside of the heat exchanger will act as an insulator and reduce heat
transfer, resulting in less efficiency.
1. To clean the heat exchanger, first turn off all power to the unit. Remove clean-out plugs, the vent
connector pipe to the chimney, the burner, and the burner mounting plates. When removing the clean-out
plugs, remove the screw at the 12 o’clock position. Then, pull clean-out plug straight back.
2. With access to the inside of the heat exchanger through the burner area, clean-out openings, and vent
pipe connection, it is possible to use a long, flexible wire brush and an industrial type vacuum cleaner to
remove any soot build-up. NOTE: A one inch (outside diameter) vacuum cleaner hose will fit into the
radiator.
To vacuum and brush the outer radiator of the heat exchanger, go through the clean-out openings in both
directions, as shown in figure 18 on the next page.
3. Reassemble the furnace to its original construction*. Remount the burner being certain that the air
tube is properly inserted into the chamber opening. If heavy soot deposits were found in the heat
exchanger, this may indicate the burner is out of adjustment.
*When returning clean-out plugs to their original position, insert plug and replace screw at the 12 o’clock
position. This is sufficient for sealing the access tube.
Replace any damaged or corroded components. All gaskets and insulation must
be inspected, and replaced, if they show any signs of damage.
30
Figure 17: Heat Exchanger Clean-Outs
Vacuum Hose Length
VH8FA119*
8FT
Fig. 18: Recommended method and device for cleaning inside of heat exchanger.
31
V. Sequence of Operations Flow Chart:
32
33
VI. Trouble Shooting Flow Chart:
34
35
36
37
38
COMBUSTION AND EFFICIENCY TESTING FOR
OIL FIRED CENTRAL FURNACES.
Complete this form for each furnace installed. Read instruction
manual carefully before making tests. Retain this form with furnace.
furnace.
CUSTOMER
NAME
ADDRESS
CITY, STATE
AIR SHUTTER OPENING
BURNER MODEL NO. BLAST TUBE LGTH.
HEATING
INS.
SYSTEM
CONDITION
COMBUSTION CHAMBER
% OF MAX. (EST)
MATERIAL
FURNACE MODEL
TYPE OF VENTING SYSTEM
MASONRY
CHIMNEY
METAL
CHIMNEY
W/INDUCER
FUEL LINE FILTER
METAL
SIDEWALL
CHIMNEY
POWER VENTER
MASONRY CHIMNEY
W/METAL LINER
DRAFT CONTROL
INITIAL
INSTALLATION
COMBUSTION
TESTS
(Operate burner
CO2 in stack pipe
Draft Over-fire
at least 10
minutes before
Draft in stack pipe
Smoke number
starting tests.)
Gross stack temp.
Furnace room temp.
Net stack temp.
(Gross stack minus
furnace room temp.)
Efficiency
Nozzle size and spray
Oil pump pressure
Operation of Controls
Burner Safety Controls
Check for oil leaks
Tests taken by
Date
NOTES:
INSTALLER NAME & ADDRESS
39
MASONRY
CHIMNEY
W/INDUCER
FURNACE SERIAL NUMBER
SERVICE
SERVICE
SERVICE
Appendix – A
Replacement Parts for VH8FA119*
40
41
Appendix – B
VH8FA119P60* PSC Wiring Diagram
42
VH8FA119T60* CTM Wiring Diagram
43