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FIELD CONTROLS MPL-B User's Manual

1. Ba anh de date dera 9 FURNACE INSTALLATION SET UP aa tn nnn ca dua anda Cada dn Da Enna aa GE dan Arne DR se k r sasaqa EN se Coa an 10 MAINTENANCE t bpElduueccm 11 OPERATING INSTRUCTIONS 1 acu aa trina dahin rinite 12 APPENDIX A WML C AND MPL B BURNER SET UP I 13 A 1 OIL BURNER AIR ADJUSTMENT rr 14 A 2 BURNER ELECTRODES rss n iaia 14 A 3 START UP M 14 A 4 SPECIAL INSTRUCTIONS FOR UNITS EQUIPPED WITH RIELLO BURNERS u u 14 TABLE A 6 DIRECT DRIVE BLOWER SET UP ine 15 TABLE A 8 DIRECT DRIVE BLOWER CHARACTERISTICS rin 15 TABLE 9 GENERAL DIMENSIONS INCHES I l rire 16 APPENDIX WIRING DIAGRAMS i sinten ier i iii 17 OPERATION legii Rase 21 APPENDIX C R7184 TROUBLESHOOTING 21 04 4 4 22 R7184 DETAILED SEQUENCE OF OPERATION FIGURE 7 u nanna ninh nn Ann uuu u RR AR RR RR RA nn 22 TABLE C 1 ELECTRONIC FAN TIMER BOARD EFT DETAILED SEQUENCE OF 25 R7184 LED DIAGNOSTIC LIGHT eee 26 TABLE C 3 R7184 TROUBLESHOOTING rin
2. If the temperature rise is outside the recommended range it may be adjusted on direct drive equipped units by selecting alternate circulation fan motor speeds If the temperature rise is too high speed the fan up If the temperature rise is too low slow the fan down C Keep in mind that the stack temperature varies directly with the temperature rise The higher the temperature rise the higher the stack temperature will be resulting in lower efficiency The lower the temperature rise the lower the stack temperature will be which in some cases may allow condensation to form in the chimney and other vent parts D Test the high limit control to ensure that it is operating correctly This may be done by temporarily removing the circulator fan heating wire or neutral wire Turn of electrical power to the furnace before working with the motor wires Be sure to protect any removed wires from shorting out on metal furnace parts If the high limit test is successful shut off the electrical power to the furnace restore the proper motor wiring Finally restore power to the furnace E Operate the furnace through a minimum of three full heating cycles During this time check for fuel oil leaks gross air leakage from the supply air ductwork unusual noises originating anywhere within the heating system which may cause some concern or annoyance to the home owner etc F Be sure that the homeowner is familiar with the f
3. Installation Operation and Maintenance Manual Oil Fired Warm Air Furnaces WML C AND MPL B Down Flow or Horizontal Model ALL INSTALLATIONS MUST MEET ALL LOCAL PROVINCIAL STATE AND FEDERAL CODES WHICH MAY DIFFER FROM THIS MANUAL ECR International Limited OLSEN Division Heating amp Cooling Products Aree Heating amp Cooling Products Read this complete manual before beginning installation These instructions must be kept with the furnace for future reference TABLE CONTENTS INTRODUCTION da a a a aa a a Ba ni tak Sad u 3 HEATLOSS iid ta Ga a a ka aa a G SA A A at Sans a dot san 3 LOCATION OF UNIT A a a a a G B a a a aa 3 AIR GONDITIONIN cope 4 COMBUSTION AIRE iecit da b anp o ica sta a a Fa ee aw ir 5 CHIMNEY i i icm 5 DRAFT REGULATOR CONTROL rit agar na ida ida ada da AULAS A YA saa 5 leue PBIDAUARMUIalcm 7 PEE 7 PIPING INSTALLATION ci ETE 7 ELECTRICAL CONNECTIONS T S S iii 7 FAN TIMER BOARD AND LIMIT CONTROL I 8 CIRCULATING ubgdgEejiq Er Sken 8 HUMIDIFIER i Au a nn a iaia ci aaa a aaa aaa arida ani anandia iano Tat SR G ana SG 9 OIL BURNER 2 iti ien atta Ia
4. 9 in 2 9 in 2 9 in 2 9 2 Enclosure Closet Closet Closet Closet 24 inches is required for servicing 18 inches required in the United States shims made of noncombustible material SUSPENDED INSTALLATION Refer to Figure 1 Maintain clearances to combustibles as outlined in Table 1 The furnace may be suspended by field fabricating a cradle of angle iron and threaded rod Secure the furnace with 2 inch minimum slotted angle or equivalent as shown in Figure 1 The furnace must be supported in such a way as to not allow twisting or sagging of the cabinet Position the supports so as to not interfere with accessing the burner and blower compartments Suggestion as a measure to prevent fuel oil from accumulating in locations other than the fire pot as could be the case in the event ALLOW ENOUGH ANGLE IRON OVERHANG TO PERMIT lu OPENING THE BLOWER DOOR of nozzle drip install the furnace with an approximate 2 degree slope from the oil burner casing towards the fire pot AIR CONDITIONING If the furnace is used in conjunction with air conditioning the furnace shall be installed in parallel with or upstream from the evaporator coil to avoid condensation in the heat exchanger In a parallel installation the dampers or air controlling means must prevent chilled air from entering the furnace If the dampers are manually operated there must be a means of control to prev
5. NEVER BURN GARBAGE OR PAPER IN THE FURNACE AND NEVER LEAVE PAPER OR RAGS AROUND THE UNIT 12 30318 R4 9 9 2005 APPENDIX A WML C AND MPL B BURNER SET UP WML C AND MPL B furnaces may be used with the following oil burners Please note The Beckett AF and Riello 40F oil burners are for applications using indoor air for combustion oniv For sidewall venting applications utilizing outdoor air for combustion use the Beckett AFII or the Riello 40BF Balanced Flue oil burners only Table A 1 Beckett AF Oil Burner Set Up Beckett AF Series Oil Burners For use with chimney vented units only Furnace Output Burner Pump 1 Static Model BTU Hr Model No zja Pressure plow nate Plate WML 60C 58 000 AF76BNHS 0 50 80 100 PSIG 0 50 USGPH F3 3 in WML 80C 75 000 AF76BNHS 0 65 80 100 PSIG 0 65 USGPH F3 3 in WML 90C 85 600 AF76BNHS 0 75 80 A 100 PSIG 0 75 USGPH F3 3 in MPL 90B 85 500 AF76XN 0 75 80 A 100 PSIG 0 75 USGPH F3 2 in MPL 100B 96 000 AF76XN 0 85 80 100 PSIG 0 85 USGPH F3 2 in MPL 120B 112 000 AF76XN 1 00 60 A 100 PSIG 1 00 USGPH F3 2 in MPL 130B 123 000 AF76YB 1 10 70 100 PSIG 1 10 USGPH F6 2 Ain T Head is shielded by ceramic insulator Low Firing Rate Baffle required when using a 0 50 gallon
6. potential source of air or contaminants Check burner motor If burner motor is cutting out on over load Defective burner motor determine why Replace if necessary ARAN Drain fuel oil storage tank replace fuel oil Consult with fuel oil Water or contaminants in oil supplier Gently warm oil line Insulate oil line Outdoor piping size may require increased diameter Frozen oil line 29 30318 R4 9 9 2005 TABLE 4 SYSTEM AND GENERAL TROUBLESHOOTING continued Electrodes out of adjustment or Check electrode settings Check electrodes for dirt build up or cracks in defective porcelain Poor transformer high voltage connections or defective Oil burner sputtering at transformer nozzle Fuel oil filter clogged Replace fuel oil storage tank filter and or fuel oil in line filter Defective oil pump Check burner motor fuel oil pump coupling Check oil pump pressure Replace fuel oil pump if necessary Fuel al line partially clogged Bleed air from oil line If problem persists replace oil line contains air System temperature rise ideally should not exceed 85 F Check for System temperature rise too high clogged air filters Check blower fan for excess dirt build up or debris Speed up blower fan if necessary Check contacts between the igniter and electrodes If OK replace the igniter Check fan off delay timing setting Use a duct thermometer in the supply air plenum take off or firs
7. seconds that is set by selecting a dipswitch combination on the control board displayed in Table 5 Similarly the United Technologies 1158 120 have an adjustable fan off time of 2 3 4 or 6 minutes displayed in Table 6 The fan off delay time starts when the burner motor is de energized at the end of a call for heat Blower shutdown is delayed to remove any residual heat from the heat exchanger and improve the annual efficiency of the furnace The electronic fan timer board works in conjunction with snap disc limit controls which perform a safety function and breaks power to the oil burner primary control which shuts off the burner if the furnace over heats The limit control is thermally operated and automatically resets The limit control is factory installed pre set and is not adjustable If a limit control opens the Honeywell ST9103 will energize the circulating fan When the limit control closes the burner is re energized and the heating cycle begins again If the limit control opens with the United Technologies 1158 120 electronic fan control the circulating fan will be energized as well When the limit closes the control initiates a two minute delay When this delay is finished the fan off timer will begin At the end of the fan off time cycle the burner will be energized initiating a normal burner cycle TABLE 5 Honeywell ST9103 Dip Switch Blowe
8. 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 Do not install the furnace on carpet or tiled floors Minimum installation clearances listed in Table 1 NOTE The recommended installation clearances do not necessarily take into consideration the clearances necessary to replace the air filter or perform other routine maintenance DOWN FLOW INSTALLATION All WML C AND MPL B furnace models have been assembled for installation in the down flow position Maintain all clearances to combustibles as outlined in Table 1 Suggestion as a measure to prevent fuel oil from accumulating in locations other than the fire pot as could be the case in the event of nozzle drip install the furnace with an approximate 2 degree slope from the oil burner casing towards the fire pot Use shims made of noncombustible material 3 30318 R4 9 9 2005 HORIZONTAL INSTALLATION WML C AND MPL B furnaces models are assembled and shipped readv for installation in the down flow position The furnace be installed in either of the horizontal positions warm air discharging left or warm air discharging right bv following these steps 1 Rotate th
9. approximately room temperature 65 70 F In general lower stack temperature indicates greater efficiency however excessively low stack temperature can lead to condensation forming in the chimney and or venting Sulphur and similar contaminants in the fuel oil will mix with condensation to form acids Acids and resultant chemical salts will cause rapid deterioration of the chimney and venting components and may attack the furnace If the flue gases are below the range it may be necessary to slow down the blower fan If the flue gases are above the range the blower fan may require speeding up Stack temperature varies directly with the system temperature rise System temperature rise is the difference between the furnace outlet temperature and furnace inlet temperature as measured in the vicinity of the connection between the plenum take offs and the trunk ducts If the venting from the furnace to the chimney is long or exposed to cold ambient temperatures it may be necessary to use L Vent as the vent connector to reduce stack temperature loss to prevent condensation The venting should be inspected annually to ensure that it is intact FURNACE INSTALLATION SET UP The furnace must be set up as the final step in the installation A The oil burner must be set up following the procedures outlined above B The WML C models should operate within a temperature rise of 45 F to 75 F The MPL B temperature rise
10. overload Home does not heat evenly Improper distribution of heat This is not likely to be a furnace problem Balance duct system 30 30318 R4 9 9 2005 TABLE 4 SYSTEM AND GENERAL TROUBLESHOOTING continued Airflow blocked or dirty air filter Clean or replace air filter Supply air temperature too hot Insufficient airflow Supply air temperature too cool Supply air temperature too jow FINAL CHECK OUT 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 IMPORTANT Please ensure that the homeowner is informed and understands speed up blower fan Check all dampers Open closed dampers including registers in unused rooms Check system temperature rise If temperature rise is too high Check system temperature rise Slow down blower fan if necessary Check supply air ductwork Seal leaky joints and seams Insulate Excessive duct losses ductwork if necessary Fan control fan on setting too 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 cool during first moments of furnace cycle Excessive duct losses ductwork if necessarv Where the circuit breaker or fuse is located in the main electrical panel Where the furnace switch is loc
11. rate therefore do not use the above listed set up procedures Riello specifications are listed in Tables A 3 and 4 Consult the Riello Installation Instructions supplied with the Burner for specific information concerning burner adjustments operation and trouble shooting 30318 R4 9 9 2005 Table 6 Direct Drive Blower Set Up Blower Set Up Cooling Capacitv furnace Blower 0 20 in w c 0 50 in w c Model Tons Power CFM Range Speed Motor Speed Motor WML 60C GT10 DD Low HP Med Low HP 3 HP 763 1505 WML 80C GT10 DD Med Low HP Med High HP 3 HP 763 1505 WML 90C GT10 DD Med High HP High HP 3 HP 763 1505 MPL 90B GT12 10DD Low 3 4 HP Med High 3 4 HP 3 3 4 HP 1185 1553 MPL 100B GT12 10DD Med High 3 4 HP High HP 3 34 HP 1185 1553 MPL 120B GT12 10DD High 3 4 HP High 3 4 HP 3 3 4 HP 1185 1553 MPL 130B GT12 10DD High 3 4 HP High 3 4 HP 3 3 4 HP 1185 1553 Table A 8 Direct Drive Blower Characteristics CFM Furnace s Model Blower Motor HP Motor FLA AT Speed External Static Pressure Inches w c 0 20 0 30 0 40 0 50 LOW 813 813 797 763 WML C enu nons T MED LOW 1170 1144 1118 1063 60 90 3 MED HIGH 1423 1381 1291 1220 HIGH 1505 1444 1359 1291 LOW 1334 1286 1239 1185 MED LOW MPIB GT12 10DD 3 4 HP 12 5 50 80 F 1209 1992 1
12. the highest point of a peaked roof All unused chimney openings should be closed Chimneys must conform to local provincial or state codes or in the absence of local regulations to the requirements of the National Building Code See Figure 2 and Table 2 for common chimney problems and their remedies THE FURNACE MUST BE CONNECTED TO A FLUE HAVING SUFFICIENT DRAFT AT ALL TIMES TO ENSURE SAFE AND PROPER OPERATION OF THE APPLIANCE The flue pipe must not be routed through concealed space because it must be visually checked for signs of deterioration during the annual inspection and servicing The flue pipe must not pass through any floor or ceiling but may pass through a wall where suitable fire protection provisions have been installed In the United States refer to the latest edition of NFPA 31 for regulations governing the installation of oil burning equipment In Canada refer to the latest edition of CAN CSA B139 for rules governing the installation of oil burning equipment NOTE THE RECOMMENDED FLUE DRAFT PRESSURE IS 0 02 IN W C AS MEASURED UPSTREAM OF THE BAROMETRIC DRAFT REGULATOR SHOWN IN FIGURE 1 DRAFT REGULATOR CONTROL This device is used in conjunction with conventional chimney venting This control or draft regulator automatically maintains a constant negative pressure in the furnace to obtain maximum efficiency It ensures that proper pressures are not exceeded If the chimney does not de
13. 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 2 and A 5 When the furnace has reached steady state after approximately 15 minutes Set combustion air damper to get a TRACE of smoke Check the system temperature rise The temperature rise is the difference between the retum air temperature measured at a point near the return air inlet and the supply air temperature measured near the furnace outlet 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 bu
14. 174 inches I P S and terminate with an appropriate vent cap in a location where it will not be blocked The fill pipe must be no less than 2 inches I P S and terminate with an appropriate cap in a location where debris will not enter the fill pipe during oil delivery If located indoors the tank should normally be in the lowest level cellar basement etc It must be equipped with a shut off valve at the tank outlet used for the oil supply The oil tank must be located as to not block the furnace room exit pathway Observe all clearances specified in the above mentioned codes PIPING INSTALLATION In the United States NFPA 31 Standard for the Installation of Oil Burning Equipment Chapter 2 In Canada the entire fuel svstem should be installed in accordance with the requirements of CAN CSA B139 and local regulations Use only approved fuel oil tanks piping fittings and oil filters Ensure that all fittings used in a copper oil line system are high quality flare fittings Do not use compression fittings Do not use Teflon tape on any fittings Pressurized or gravity feed installations must not exceed 3 PSIG Pressures greater than 10 PSIG may cause damage to the shaft seal If the height of the oil stored in a tank above the oil burner exceeds 1175 feet it may be necessary to use a pressure regulating device approved for this purpose The furnace may be installed with a one pipe system with gravity feed o
15. 19 Filter Frame 21260 20 Filter Frame End Support 21306 21 Air Filter 20 x 20 x 1 Permanent 2180032 22 Junction Box 28723 23 Channel Wire Retainer 30239 24 Limit Control 60T11BOF L1809 F 28654 25 Wire Harness Control 30268 26 Wire Harness Blower Direct drive 30265 27 Fan Timer Control Honeywell ST9103A or UTC 1158 150 29388 28 Draft Regulator 5 27494 29 Beckett oil Burner AF76BNHS 30288 Burner Motor 1 7 HP 3450 RPM PSC 29689 Beckett Clean cut Oil Pump 29688 Solid State Igniter 29522 Primary Combustion Control R7184A 29664 Flame Retention Head 11961 F3 Nozzle 0 65 80 A 210086 30 Blower Assembly Complete Direct Drive hp 4 Speed 30313 Blower Housing and Wheel GT10 DD 28142 Blower Wheel GT10 DD 26430 Blower Motor 2 hp 4 Speed 26088 Motor Mounting Band TR6884B 17811 Motor Mount Arms 10 10 DD Blower 3 per unit 26251 Motor Run Capacitor 10 mfd 370 vac 27743 Capacitor Strap 27760 Low Fire Kit 29880 Low Firing Rate Baffle 25521101 Nozzle 50 80 A 29389 32 30318 R4 9 9 2005 PARTS LISTING COUNTERFLOW HORIZONTAL MODEL WML 31 Auxiliary Limit GOT11BOF L140 F 29198 32 Transformer 27738 33 Control Panel 30190 34 Wire Harness Junction Box to Control 30264 35 Wire Harness Supplv 29366 36 Limit Cover Left 30240 37 Limit Cover Right 30195 PARTS LISTING COUNTERFLOW HORIZONTAL DIRECT VENT MODEL WML CB2U Ref No Description PART NO All parts are the same as listed on the previous pag
16. 27 TABLE C4 SYSTEM AND GENERAL TROUBLESHOOTING u u nanna a rna RR AR Rn 29 FINAL CHECK OUT mrt 31 PARTS LISTING COUNTERFLOW HORIZONTAL MODEL WML C iii 32 HOMEOWNER S REFERENCE TABLE T u uama MAMMA am ua asse aa sana sn NR ra 38 NOTES nil TE E 39 2 30318 R4 9 9 2005 IMPROPER INSTALLATION MAY CREATE A CONDITION WHERE THE OPERATION OF THE PRODUCT COULD CAUSE PERSONAL INJURY OR PROPERTY DAMAGE IMPROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE CAN CAUSE INJURY OR PROPERTY DAMAGE REFER TO THIS MANUAL FOR ASSISTANCE OR ADDITIONAL INFORMATION CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE FUEL SUPPLIER DO NOT USE GASOLINE CRANKCASE OIL OR ANY OTHER OIL CONTAINING GASOLINE AS A FUEL FOR THIS FURNACE THIS PRODUCT MUST BE INSTALLED IN STRICT COMPLIANCE WITH THESE INSTALLATION INSTRUCTIONS AND ANY APPLICABLE LOCAL STATE AND NATIONAL CODES INCLUDING BUT NOT LIMITED TO BUILDING ELECTRICAL AND MECHANICAL CODES The furnace area must not be used as a broom closet or for any other storage purposes as a fire hazard may be created Never store items such as the following on near or in contact with the furnace 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning compounds plastic items con
17. 297 1236 90 130 MED HIGH 1423 1373 1326 1289 HIGH 1553 1491 1449 1331 TIP These Formulae will assist with the design of the ductwork and the determination of airflow delivery Bonnet Output Bonnet Output CFM i 1 085 System T emperature Rise 15 System Temperature Rise 1085x CFM 085x 30318 R4 9 9 2005 Table 9 General Dimensions Inches Cabinet Plenum Openings Flue Filter M ue Width Depth Height Supply Return Diameter a si pa A B C DxE Side Bottom H WML C 22 22 1 8 55 1 4 19x19 18 18 18 x 18 5 Permanent 20x20x1 265 MPL B 2244 4 22 1 4 62 O 18 x 18 18 x 18 6 Permanent 20x20 x1 292 WML C amp MPL B Down flow 16 WML C 6 MPL B Horizontal gt bn ts 30318 R4 9 9 2005 APPENDIX B WIRING DIAGRAMS Beckett AF Burner Wiring Diagram 17 30318 R4 9 9 2005 Beckett AFII Burner Wiring Diagram 30318 R4 9 9 2005 18 Riello 40F3 5 Wiring Diagram 19 30318 R4 9 9 2005 Riello 40 Wiring Diagram 20 30318 R4 9 9 2005 OIL BURNER Once 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
18. 533 Nozzle 0 85 70 A MPL 120BB2U only PARTS LISTING SUB BASE FOR COMBUSTIBLE FLOOR INSTALLATION MPL B Ref No Description PART NO Sub Base 006000073 36 30318 R4 9 9 2005 MODEL MPL B DIAGRAM 30318 R4 9 9 2005 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 38 30318 R4 9 9 2005 NOTES 39 30318 R4 9 9 2005 AV ECR international 6800 Base Line Wallaceburg Ontario NBA 5E5 Can Tel 519 627 0791 Fax 519 627 4719 2201 Dwver Avenue Utica New Vork 13504 USA Tel 315 797 1310 Fax 315 724 9319 85 Middle Road Dunkirk New York 14048 USA Tel 716 366 5500 Fax 716 366 1209 www ecrinternational com 40 30318 R4 9 9 2005
19. Combustion Control R7184A 29664 Air Tube Combination AF76XN 27610 Flame Retention Head MPL 80 to 120 11961 F3 Flame Retention Head MPL 130 12646 F6 Nozzle 1 00 60 A MPL 120 27104 Nozzle 1 10 70 A MPL 130 2100101 38 Blower Assembly Complete Direct Drive gt hp 4 Speed 30387 Blower Housing and Wheel GT12 10 DD 17559 Blower Wheel GT12 10 DD 29692 Blower Motor 3 4 hp 4 Speed 27161 Motor Mounting Band TR6884B 17811 Motor Mount Arms 12 12 DD Blower 3 per unit 17812 Motor Run Capacitor 20 mfd 370 vac 27745 Blower Slide 29026 39 Auxillary Limit L130 F 60T11 BOF 30388 40 Junction Box Cover 28722 PARTS LISTING COUNTERFLOW HORIZONTAL DIRECT VENT MODEL MPL BB2U Ref No Description PART NO All parts are the same as listed on the previous pages for Model MPL B except where noted below 12 Oil Burner Mounting Plate Assembly 29872 Oil Burner Mounting Plate 29867 Sight Glass Cover Plate 29850 Sight Glass Gasket 2 per unit 29870 Sight Glass 29876 13 Flue Connector Assembly 6 to 4 90 Elbow 28952 14 Pouch Gasket Second gasket required for Direct Vent 2080175 15 Flue Collar Gasket Second gasket required for Direct Vent 21994 37 Beckett Oil Burner AFII 150 30430 Burner Motor 1 7 HP 3450 RPM PSC 28907 Beckett Clean cut Oil Pump A2EA6520 29688 Solid State Ignitor 10SAY 01 28558 Primary Combustion Control R7184P 29649 Air Tube Combination FBX80HGXS 28561 Flame Retention Head FB3 28
20. N TIMER BOARD EFT DETAILED SEQUENCE OF OPERATION Mode Action Svstem Response a EFT closes oil primary control T T connections Thermostat calls for heat W b Ignition system and R7184 oil primary control start the furnace Oil flows as long as terminal is energized i the oil primary control senses flame c Burner motor is energized and heat fan on delay timing begins When timing is complete the circulator fan is energized at heat speed a R7184 oil primary control is de energized terminating the burner cycle Th imiostat ende tali for Baat b Heat fan off delay timing begins Length of delay depends on EFT dipswitch W terminal is de energized settings When timing is complete the circulator fan is de energized HEAT le EFT returns to standbv mode Oil primarv control and circulator fan are off unless continuous fan operation is selected at the thermostat a Oil primary control locks out within lockout timing 30 seconds Burner fails to light b Burner motor is de energized Even though thermostat is still calling for heat c df circulator fan has started it continues through the selected heat fan off delay period a Burner motor is de energized and oil primary control goes into recycle mode Established flame fails b If the selected heat fan off delay timing is longer than the recycle delay timing the circulator fan continues to run through the next tri
21. PATOR OF A STANDARD 24 VAC THERMOSTAT OR CAUSE HARM TO COMPONENTS WITHIN A MICRO ELECTRONIC THERMOSTAT 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 Check the limit switches to ensure that the switch contacts are closed Check the electrode gap and position Check the contacts between the oil primary control and the electrodes Check oil supply tank gauge Check the oil nozzle oil filter and oil valves Check the piping or tubing to the oil tank Check the oil pump pressure 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 26 PRELIMINARY CHECKS Make sure that limit switches are closed and those contacts are clean Check for line voltage power on the oil primary control black and white lead wires Refer to Table C 4 or C 5 for further troubleshooting information 30318 R4 9 9 2005 Table C 3 R7184 TROUBLESHOOTING Condition Burner motor does not start when there is a call for heat Procedure Status Corrective Act
22. Riello burners are factory set with respect to nozzle size pump pressure and turbulator adjustments for each model and firing rate The combustion air can be adjusted with the burner cover on by first removing the plastic cover on the top right hand side of the burner cover With a Philips head Screw driver turn the adjustment screw clockwise to increase combustion air or counter clockwise to decrease combustion air When the combustion air is set re insert the plastic cover A 2 BURNER ELECTRODES 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 Riello 40F amp BF Burners Electrode gap 5 32 inch Distance above horizontal centerline 13 64 inch Distance ahead of nozzle 5 64 to 7 64 inch A 3 START UP The furnace should be operated for a minimum of 15 minutes to reach steady state conditions before fine tuning combustion The warm up time i
23. al for ignition 27 Na a Cooling contactor is energized immediately energized b Circulator fan is energized at cool speed COOL io desea D a Cooling contactor is de energized immediately energized b Circulator fan turns off immediately RIS ted d tant a Circulator fan is energized immediatelv at cooling speed FAN Thermostat ends call for fan 3 3 G terminal is de energized a Circulator fan is de energized immediatelv a Oil primary control shuts off burner b Circulator fan is energized immediately at heat speed Limit switch string opens c EFT opens oil primary control T T connections Circulating fan runs as long as i limit string stays open d If there is a call for cooling or fan the circulating fan switches from heating to cooling speed LIMIT a EFT begins heat fan off delav sequence Limit switch string closes b Circulating fan turns off after the selected heat fan off timing with existing call for heat c EFT re closes oil primary control T T connections d Oil primary control is energized initiating burner light off Limit switch string closes a Circulator fan turns off when heat fan off delay time is complete without existing call b Normal operation resumes EFT control is in standbv mode awaiting next thermostat command Gontinugus teda fan is a Circulating fan is energized when there is no call for heat cool or fan FAN connected 9 b If fan operation is
24. alse readings from radiant heat could be observed The system temperature rise the difference in temperature between the supply air and return air should be within the indicated range on the appliance rating plate 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 To Shut Down Unit Set the thermostat to the lowest possible setting Set the manual switch if installed in the Electrical Power Supply Line to OFF NOTE If the furnace is to be shut down for an extended period of time close the oil supply valve to the oil burner DO NOT ATTEMPT TO START THE BURNER WHEN EXCESS OIL HAS ACCUMULATED WHEN THE FURNACE IS FULL OF VAPOUR OR WHEN THE COMBUSTION CHAMBER IS VERY HOT
25. ank and the oil burner For best results install the oil filter as close to the burner as possible When using an indoor oil tank the oil filter may be installed at the tank downstream from the shut off valve If firing the furnace under the 0 65 gph rate a 7 to 10 micron line filter should be installed as close to the oil burner as possible ELECTRICAL CONNECTIONS The furnace is listed by the Canadian Standards Association CSA It is factory wired and requires minimal field wiring In the United States the wiring must be in accordance with the National Fire Protection Association NFPA 70 National Electrical Code and with local codes and regulations In Canada all field wiring should conform to CAN CSA C22 1 Canadian Electrical Code Part 1 and by local codes where they prevail The furnace should be wired to a separate and dedicated circuit in the 30318 R4 9 9 2005 main electrical panel however accessorv equipment such as electronic air cleaners and humidifiers be included on the furnace circuit Although a suitabiv located circuit breaker can be used as a service switch a separate service switch is advisable The service switch is necessarv 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 ac
26. ated and the switch on and off positions if not obvious Where the oil shut off valve from the oil storage tank is located How to operate the thermostat and other related accessories How to operate the manual reset button on the primarv control and especiallv when not to push the reset button 31 How and where to visuallv inspect the venting svstem for leaks or other problems How to inspect clean and replace the air filter and other homeowner maintenance procedures Who to call for emergency service and routine annual service The terms and conditions of the manufacturers warranty and the contractor s warranty 30318 R4 9 9 2005 PARTS LISTING COUNTERFLOW HORIZONTAL MODEL WML P Ref No Description 1 Right and Left Side Panel 30072L 2 Rear Panel Baffle 27918 3 Rear Panel 30272L 4 Blower Division Panel Assembly 30311 5 Base Panel Assembly 29007 6 Front Panel 30073L 7 Blower Access Door 30074L Door Handle P2 41 28673 Logo Bezel 28479 Logo Label 28563 8 End Panel 29013L 9 Heat Exchanger Assembly 27876 10 Firepot Retainer Bracket 27068 11 Replacement Combustion Chamber 2700WP 12 Oil Burner Mounting Plate Assembly 29873 13 Flue Pipe Connecting Flange 29005 14 Junction Box Cover 28722 15 Pouch Gasket 2080175 16 Flue Pipe Gasket 2 per Unit 21994 17 Radiator Cleanout Cover Assembly 1061A Cleanout Cover Gasket 2080176 18 Casing Clean out Cover 3011325A
27. cessible area between the furnace and furnace room entry and be located in such a manner to reduce the likelihood that it would be mistaken as a light Switch or similar device The power requirements for all models 120 VAC 1 2 60 Hz 12A Accessories requiring 120 VAC power Sources such as electronic air cleaners and humidifier transformers may be powered from the ST9103 EFT Do not use the direct drive motor connections as a power source since there is a high risk of damaging the accessories by exposure to high voltage from the auto generating windings of the direct drive motor Thermostat wiring connections and air conditioning contactor low voltage connections are shown in the wiring diagrams Some micro electronic thermostats require additional controls and wiring Refer to the thermostat manufacturer s instructions The thermostat should be located approximately 5 feet above the floor on an inside wall where there is good natural air circulation and where the thermostat will be exposed to average room temperatures Avoid locations where the thermostat will be exposed to cold drafts heat from nearby lamps and appliances exposure to sunlight heat from inside wall stacks etc Normal heat anticipator setting 0 1 A For more precise adjustment the heat anticipator may be adjusted to the amperage draw of the heating control circuit as measured between the R and W terminals of the thermostat reduce the r
28. chamber Indicator light is on until the 9 Check indicator light after flame control locks out and starts Replace R7184 is established but before oil flashing during lockout primary control locks out Indicator light stays off Go to step 10 10 Check cad cell sighting for view of flame a Disconnect line voltage power Burner locks out Go to step 11 and open line switch b Unplug cad cell and clean cad cell face with soft clothe Check sighting for clear view of flame Replace cad cell in Socket B k rm c Reconnect line voltage power HERE See VOISINS and close line switch d Start burner 11 Check cad cell a Disconnect line voltage power and open line switch Indicator light is on Remount control onto burner housing Go to step 6 b Remove existing cad cell and replace with new cad cell c Disconnect all wires from thermostat terminals to ensure that there is no call for heat d Reconnect line voltage power Indicator light is off Go to step 12 and close line switch e Expose new cad cell to bright light such as a flashlight 12 Check cad cell bracket assembly a Disconnect line voltage power Indicator light is on Replace cad cell bracket assembly and open line switch b Remove cad cell wires from quick connect connectors on the R7184 and leave control lead wires open c Apply power to device Indicator light is off Replace R7184 d Place jumper across cad cell terminals after bur
29. connect line voltage power and open line switch Check all wiring connections e Tighten any loose connections and recheck e Ifburner still doesn t start replace R7184 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 safetv with indicator light flashing at 1 2 second on 1 2 second off Procedure Status Corrective Action 7 Reset oil primary control by pushing in and releasing red reset button Indicator light stops flashing Go to Step 8 Indicator light continues to flash at 1 2 second on 1 2 second off rate Verify that the control is not in restricted mode See notes at end of this table If not in restricted mode replace R7184 27 30318 R4 9 9 2005 Condition Burner starts then locks out on safetv with indicator light flashing at 1 2 second on 1 2 second off Cont Procedure Status Corrective Action lanition is off Spark igniter could be defective Check for line voltage at igniter 9 terminals If line voltage is present replace R7484 8 Listen for spark after burner Ignition is on Go to Step 9 t rns Creer 2 Second delay Ignition is on but no oil is being E 2 REN Wait for Valve ON delay to complete Check oil supply and oil line sprayed into the combustion valve for filter blockage or seized pump
30. cordance with the regulations of CAN CSA B139 Installation Code For Oil Burning Equipment as well as in accordance with local codes When installation application questions arise regulations prescribed in the National Codes and Local Regulations take precedence over the general instructions provided with this installation manual When in doubt please consult your local authorities All models are shipped assembled and pre wired The furnace should be carefully inspected for damage when being unpacked HEAT LOSS To determine the correct furnace and firing rate for an application it is necessary to calculate the maximum hourly heat loss of the building based on local design conditions In construction the heat loss should be calculated on a room by room basis to enable proper sizing of the trunk and branch ductwork In retrofit applications a building shell overall heat loss calculation may be used In the United States Manual J titled Load Calculation published by the Air Conditioning Contractors of America ACCA describes a suitable procedure for calculating the maximum hourly heat loss Canada the maximum hourly heat loss may be calculated in accordance with the procedures described in the manuals of the Heating Refrigeration and Air Conditioning Institute HRAI or by other method prescribed by authorities having jurisdiction that are suitable for local conditions LOCATION OF
31. d OIL BURNER SET UP The burner air supply is adjusted to maintain the fuel to air ratio to obtain ideal combustion conditions A lack of air causes soft and sootv flames resulting in soot build up throughout the heat exchanger passages Excess combustion air causes a bright roaring fire high stack temperatures resulting in poor fuel efficiency PREPARATIONS Drill a 4 test port in the venting ideally at least 2 flue pipe diameters away from the furnace breeching if venting horizontally from the furnace or from the flue pipe elbow if venting vertically before reaching the furnace See Figures 4 and 5 The test port will allow flue gas samples to be taken and stack temperatures to be measured Before starting the burner check the burner alignment with the combustion chamber fire pot check that the correct nozzle is tightened into place and that the burner electrodes properly positioned The Beckett burner bulk air band is should be closed and the air shutter initial setting should be approximately 7 00 Note A Locate hole at least 6 inches on the furnace side of the draft control Note B Ideally hole should be at least 12 inches from breeching or elbow PROCEDURE Start the burner and allow it to run at least ten minutes Set the air shutter to give a good flame visually The combustion air supply to the burner is controlled by manipulating the air shutter on the left side of th
32. d not be allowed to come Horizontal Flue Connection Draft regulator Location for sampling hole 1 4 diam N Note A B z Oil burner 9 b OIL BURNER NOZZLES WML C AND MPL B furnaces are certified for multiple firing rates ranging from approximatelv 58 000 to 85 600 BTU hr on the WML C and 85 500 to 123 000 BTU Hr on the MPL B Bv changing the oil burner nozzle within the specific model range and temperature rise the furnace be fired at an ideal rate for a wide range of structures Figure 5 Vertical Smoke Test Port Location Vertical Flue Connection Location for sampling hole breeching 30318 R4 9 9 2005 BURNER ELECTRODES Correct positioning of the electrode tips with respect to each other to the fuel oil nozzle and to the rest of the burners is essential for smooth light ups and proper operation The electrode tips should be adjusted to a gap of 5 32 1 16 ahead of the nozzle 5 16 above the centerline of the nozzle The Z dimension front edge of the burner head to the front face of the nozzle is 1 1 8 inches Electrode positioning should be checked before the first firing of the furnace The electrode porcelains should be free of cracks the electrode tips should be tapered and free of burrs and the contact rods must be clean and be in firm contact with the ignition transformer contact springs The electrodes must not come into contact with the burner hea
33. e burner and if necessary the bulk air band To adjust loosen the bolt on the movable shutter Move the shutter gradually until a good flame visually has been achieved Re snug the bolt Check the initial draft setting as the furnace warms up The draft may be measured at the test port The breech draft should be approximately 0 05 w c to obtain an over fire draft reading of 0 02 inches w c Check the oil pump pressure Standard operating pressure is 100 PSIG After reaching steady state take a smoke test If not indicating a trace set the combustion air controls to provide a trace Typically the reading will range from 11 5 to 13 596 After the air adjustments have been completed and the air shutter or air adjustment plate has been secured re check the over fire draft and take another smoke test to ensure that the values have not changed Figure 6 Checking Over Fire Draft SMOKE TEST NOTE If oily or yellow smoke spots are found on the smoke test filter paper it is usually a sign of unburned fuel This indicates poor combustion This type of problem may be caused by excess draft excess air or contaminated fuel Do not ignore this indicator STACK TEMPERATURE Stack temperature will vary depending on fuel input circulating air blower speed and burner set up etc In general stack temperature should typically range between 380 F to 550 F assuming that the combustion air is
34. e furnace 90 to the desired position 2 Remove the three nut and washer sets fastening the oil burner assembly to the furnace Rotate the oil burner assembly to be in the normal upright position 3 Re align the oil burner assembly to the combustion chamber fire pot and then secure into place with the three nut and washer sets NON SUSPENDED INSTALLATION Maintain clearances to combustibles as outlined in Table 1 Installation on a combustible floor requires a clearance of 1 inch This can be done by using a noncombustible material such as one inch thick channel iron or similar material The furnace must be supported in such a way as to not allow twisting or sagging of the cabinet Suggestion as a measure to prevent fuel oil from accumulating in locations other than the fire pot as could be the case in the event of nozzle drip install the furnace with an approximate 2 degree slope from the oil burner casing towards the fire pot Use SUGGESTED METHOD FOR SUSPENDING HORIZONTAL FURNACE Table 1 Clearance to Combustibles Furnace WML C MPL B Location Down flow Horizontal Down flow Horizontal Top 0 in 3 in 0 in 3 in Bottom 1 in 1 in 1 in 1 in S A Plenum 1 in 1 in 1 in 1 in Rear 1 in 1 in 1 in 1 in Sides 1 in 1 in 1 in 1 in Front 10 in 10 in 10 in 10 in Flue Pipe
35. ent 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 Fig 1 Suspended Installation 3 8 INCH THREADED 2 INCH ANGLE IRON JAM NUTS LOCK WASHER A FLAT WASHER SUPPLY AIR PLENUM RETURN AIR PLENUM k ZN 30318 R4 9 9 2005 through refrigeration unit unless the unit is specifically approved for such service Generallv a six inch clearance between the air conditioning evaporator coil and the heat exchanger will provide adequate airflow through the evaporator coil The blower speed must be checked and adjusted to compensate for the pressure drop caused bv the evaporator coil Refer to Appendix B for recommended wiring and electrical connections of the air conditioning controls COMBUSTION AIR When a furnace is installed in the full basement of a tvpical frame or brick house infiltration is normally adequate to provide air for combustion and draft operation If the furnace is installed in a closet or utility room two 2 ventilation openings must be provided connecting to a well ventilated space full basement living room or other room opening thereto but not a bedroom or bathroom One opening shall be located 6 from the top and bottom of the enclosure at the front of the furnace For furnaces located in buildings of unusually tight constr
36. es for Model VML C except where noted below 12 Oil Burner Mounting Plate Assembly 29872 Oil Burner Mounting Plate 29867 Sight Glass Cover Plate 29850 Sight Glass Gasket 2 per unit 29870 Sight Glass 29876 13 Flue Connector Assembly 6 to 4 90 Elbow 28952 14 Pouch Gasket Second gasket required for Direct Vent 2080175 15 Flue Collar Gasket Second gasket required for Direct Vent 21994 34 Beckett Oil Burner AFII 85 30069 Burner Motor 1 7 HP 3450 RPM PSC 28907 Beckett Clean cut Oil Pump A2EA6520 29688 Solid State Ignitor 10SAY 01 28558 Primary Combustion Control R7184P 29649 Air Tube Combination FBX80HGXS 28561 Flame Retention Head FB3 28533 Nozzle 60 60 A WML 80CB2U only 28017 PARTS LISTING VESTIBULE KIT WML C Ref No Description PART NO Vestibule Kit 30554 Door Handle 28673 Base Panel 29019 Top Panel 21437L Door Panel 29022L Left Side Panel 30527L Right Side Panel 30528L PARTS LISTING SUB BASE FOR COMBUSTIBLE FLOOR INSTALLATION WML C Ref No Description PART NO Sub Base 06000075 33 30318 R4 9 9 2005 MODEL WML 80C DIAGRAM 30318 R4 9 9 2005 34 PARTS LISTING COUNTERFLOW HORIZONTAL MODEL MPL Ref No Description PART NO 1a Right Side Panel 30360L 1b Left Side Panel 30351L 2 Side Panel Heat Exchanger Support 2 per unit 27038 3 Rear Panel 30353L 4 Blower Division Panel Assembly 30397 5 Base Heat Exchanger Su
37. heat A Safety check is made for flame 4 second delay 1 If flame is not present the R7184 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 R7184 enters the trial for ignition state 2 When flame is present the control enters lock out mode D 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 Starts carryover timer i Flame and call for heat are monitored e Ifflame is lost and lockout timer has not expired R7184 will return to trial for ignition state e Ifflame is lost and lockout timer has expired R7184 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 R7184 detects a loss of flame and enters into Recycle Mode F Thermostat is satisfied call for heat is terminated a R7184 shuts off burner motor and solenoid valve i If control utilizes a blower motor off delay after 30 seconds flame presence i
38. ion 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 should be 120 Vac between the N A N A black and white lead wires on the oil primary control 3 Check indicator light with burner off no call for heat no flame Indicator light is on Cad cell is defective sees external light or connections have shorted Go to step 4 4 Shield cad cell from external light Indicator light turns off Eliminate external light source or permanently shield cad cell Indicator light stays on Replace cad cell with new cad cell and recheck If indicator light does not turn off remove yellow lead wires from R7184 and recheck If indicator light is still on replace the R7184 control If the indicator light turns off replace cad cell bracket assembly 5 Verify that the oil valve is closed during the valve on delay period by opening view port and verifying that no flame is present during the 15 second valve on delay Indicator light is on If flame is present replace the oil valve 6 Jumper thermostat T T terminals on R7184 IMPORTANT First remove one thermostat lead wire Burner starts Trouble is in thermostat circuit Check thermostat wiring connections If connections are clean and tight check thermostat wires for continuity Burner does not start Dis
39. isk of damaging the heat anticipator do not measure circuit without first removing one of the two wires first To determine the heating circuit amperage draw 1 Disconnect one of the R or W wires from the thermostat terminal 2 Connect an ammeter between the wire and the thermostat terminal to which it was attached 3 Note the amperage reading when the heating contacts are closed System switch must be on HEAT if so equipped 4 Re connect the thermostat wire If the thermostat is serving combination heating air conditioning system pay particular attention to polarity 5 When the thermostat is reconnected and re plumbed adjust the heat anticipator setting to match the observed amperage reading FAN TIMER BOARD AND LIMIT CONTROL The Electronic Fan Timer integrates control of all burner and circulator fan operations This control is the central wiring point for most of the electrical components in the furnace The Honeywell ST9103 has a fixed fan delay on time of 30 seconds after the burner ignites The United Technologies 1158 120 has an adjustable fan on time that is set by selecting the dipswitch combination displayed in Table 6 This fan on delay can be set at 30 60 90 or 120 seconds This provides a delay between the burner ignition and blower start up to eliminate excessive flow of cold air when the blower comes on The Honeywell ST9103 has an adjustable fan off time of 60 90 120 and 150
40. jected to rough handling during transit It is possible and acceptable to use a single blower speed for both heating and cooling modes The simplest method to connect the wiring from both modes is to use a piggv back connector accommodating both wires on a single motor tap It is also acceptable to connect the selected motor speed with a pigtail joined to both heating and cooling speed wires with a wire nut As a safety precaution against accidental disconnection of the wires by vibration it is advisable to secure the wire nut and wires with a few wraps of electricians tape If the joining of the blower speed wiring is done in the furnace junction Figure 4 Horizontal Smoke Test Port Location Do not start the burner or blower fan unless the blower access door is securely in place BEFORE OPERATING THE FURNACE CHECK BURNER ALIGNMENT WITH COMBUSTION CHAMBER THE END CONE OF THE AIR TUBE MUST BE CENTRED TO THE ACCOMODATING RING PROVIDED IN THE DESIGN OF THE COMBUSTION CHAMBER ADJUST ALIGNMENT AS NECESSARY BEFORE THE FIRST FIRING Additional ST9103 Fan Timer Control information is in Appendix A Tables and in Appendix B Wiring Diagrams HUMIDIFIER A humidifier is an optional accessory available through most heating supplies outlets Installation should be carried out in accordance with the humidifier manufacturers installation instructions Water or water droplets from the humidifier shoul
41. lator Model BTU Hr Model Pressure Setting WML 60CRB 59 500 40BF3 0 50 60 W 105 PSIG 0 51 USGPH 1 0 WML 80CRB 75 000 40BF3 0 60 60 W 115 PSIG 0 65 USGPH 1 5 WML 90CRB 85 600 40BF3 0 65 60 W 135 PSIG 0 75 USGPH 2 0 NOTE Air gate setting may vary for sidewall vented units where air gate must be adjusted to achieve zero smoke A 1 OIL BURNER AIR ADJUSTMENT For complete details consult the oil burner instruction manual provided in the furnace documents envelope Beckett AF Burner Adjust the air shutter by loosening the locking screws and moving the air shutter and if necessary the bulk air band Beckett AFII Burner Adjust the burner air supply by first loosening the locking screw located on the black dial to the right of the burner Turn the black dial clockwise to increase the combustion air and counter clockwise to decrease the combustion air Re tighten the locking screw after obtaining the proper setting Riello 40 Series Chimnev Vented Riello burners are factorv set with respect to nozzle size pump pressure air gate and turbulator adjustments for each model and firing rate By removing the burner cover loosening the screws that secure the air adjustment plate the combustion air can be adjusted Move the adjusting plate to either increase or decrease combustion air When the proper air setting is achieved retighten the fixing Screws Riello Balanced Flue BF Series
42. nal becomes a point of infiltration This could lead to oil odour control problems This problem is rectified by the use of ducted outdoor air for combustion semi sealed combustion using the Beckett AFII or Riello 40BF oil burner See Direct Vent Instructions supplied with the Vent Kits Table 3 Minimum Chimney Base Temperatures F Chimney Height ft Nozzle 11 20 28 36 Chimney Thermal Resistance R6 0 50 300 400 535 725 0 65 275 340 430 535 0 70 270 330 405 505 0 75 260 320 380 475 0 85 250 300 355 430 1 00 225 300 365 430 Chimney Height ft Nozzle 11 20 28 36 Chimney Thermal Resistance R6 0 50 185 200 220 250 0 65 175 185 205 220 0 70 175 185 195 215 0 75 175 185 195 210 0 85 165 185 195 205 1 00 165 185 195 205 lt less than gt greater than OIL TANK Oil storage tanks must be selected and installed in compliance with applicable codes in the United States NFPA 31 Standard for the Installation of Oil Burning Equipment Chapter 2 and in Canada CAN CSA B139 Installation Code for Oil Burning Equipment Section 6 Observe all local codes and by laws In general the oil tank must be properly supported and remain stable in both empty and full condition The oil tank must be fitted with vent and supplv pipes to the outdoors Refer to the above mentioned codes for sizing The vent pipe must be no less than
43. ner 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 28 30318 R4 9 9 2005 TABLE C4 SYSTEM AND GENERAL TROUBLESHOOTING Check thermostat and adjust Also check thermostat for accuracy if it is hermostatnor calling ab eats 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 No power to furnace Furnace will not start Remove thermostat wires from oil primary control terminals T T Place a Thermostat faulty 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 acros
44. nozzle Table A 2 Beckett AFII Oil Burner Set Up Beckett AFII Series Oil Burners For use with sidewall vented units using outdoor combustion air Furnace Output Burner Pump Model BTU Hr Model Nozgle Pressure Plow Rate Dead WML 60CB2 63 500 AFII 85 0 50 60 A 145 PsIG 0 55 USGPH FBO WML 80CB2 75 000 AFII 85 0 60 60 A 145 PsIG 0 65 USGPH FB3 WML 90CB2 85 600 AFII 85 0 70 60 A 145 PsIG 0 75 USGPH FB3 MPL 90BB2 85 500 AFII 150 0 70 60 A 145 PSIG 0 75 USGPH FBO MPL 100BB2 96 000 AFIl 150 0 80 60 A 145 PSIG 0 85 USGPH MPL 120BB2 112 000 AFIl 150 0 85 70 A 145 PsIG 1 00 USGPH Table 3 Riello 40F Series Oil Burner Set Up Riello 40F Series Burners For use with chimnev vented units Furnace Output Burner Pump Turbulator Model BTU Hr Model Pressure Flow Rate sale Setting WML 6OCRF 59 500 40F3 0 50 60 W 105 PSIG 0 51 USGPH 2 6 1 0 WML 80CRF 75 000 40F3 0 60 60 W 115 PSIG 0 65 USGPH 2 6 1 5 WML 90CRF 85 600 40F3 0 65 60 W 135 PSIG 0 75 USGPH 3 6 2 0 MPL 90BRF 85 500 40F5 0 60 60 W 145 PSIG 0 75 USGPH 2 25 0 0 MPL 100BRF 96 000 40F5 0 65 60 W 145 PSIG 0 85 USGPH 2 5 0 5 MPL 120BRF 112 000 40F5 0 85 60 W 145 PSIG 1 00 USGPH 2 75 1 0 13 30318 R4 9 9 2005 Table 4 Riello Balanced Flue Burner Set Up Riello Balanced Flue Series Oil Burners For use with sidewall vented units using outdoor combustion air Furnace Output Burner Nozzle Pump Flow Rate Turbu
45. oot building up on blast tube end coning Flame impingement caused by Check nozzle size and angle See Appendix A Check distance from Incorrect nozzle angle head to inside surface of the fire pot Defective fire pot Check fire pot Repair or replace Airflow blocked or dirty air filter Clean or replace air filter Check thermostat heat anticipator setting against measured amperage Thermostat adjustments or draw Increase heat anticipator setting if necessary If the thermostat is location being influenced by drafts sunlight duct work etc relocate to more suitable location Check all dampers Open closed dampers including registers in unused Insufficient airflow rooms Check system temperature rise If temperature rise is too high speed up blower fan Furnace will not warm home to desired temperature Test high limit function of all limit switches Use a duct thermometer to Defective high limit control 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 Under sized nozzle nozzle if permitted by rating plate Blower fan motor stopping Check blower fan motor amperage draw Check motor ventilation ports intermittently on overload clean if necessary Replace motor if necessary Burner motor stopping Check burner motor Replace if necessary intermittently on
46. or Chimneys Fireplaces Vents and Solid Fuel Burning Appliances NFPA 31 Standard for the Installation of Oil Burning Equipment or CAN CSA B139 Installation Code For Oil Burning Equipment for correct sizing information NOTE This furnace is approved for use with L Vent NOTE Maximum temperature for L Vent is 575 F 300 C IMPORTANT The chimney must be capable of providing sufficient draft at all times for the safe removal of the products of combustion The chimney should be tested under winter conditions doors and windows closed all other fossil fuel burning appliances on clothes dryer on bathroom fans on etc If the chimney cannot overcome the competition for air it will be necessary to access the reason for it and take corrective action If the chimney is found to be sized correctly and in good repair it will probably be necessary to re evaluate the availability of combustion and ventilation air and take corrective action The flue pipe should be as short as possible with horizontal pipes sloping upward toward the chimney at a rate of one quarter inch to the foot The flue pipe should not be smaller in cross sectional area than the flue collar on the furnace The flue pipe should connect to the chimney such that the flue pipe extends into and terminates flush with the inside surface of the chimney liner Seal the joint between the pipe and the lining The chimney outlet should be at least two feet above
47. pected cleaned or replaced monthly The furnace is factory equipped with a semi permanent type filter If the filter is damaged replace with filters of the same size and type During the routine service inspect the general condition of the furnace watching for signs of oil leaks in the vicinity of the oil burner soot forming on any external part of the furnace soot forming around the joints in the vent pipe etc If any of these conditions are present please advice your service or installation contractor B Annual Service Bv Contractor 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 round cover or covers on the inner radiator access pipes located on the front panel between the oil burner and the flue pipe Rear breech models have a single front cleanout and front breech models have two front cleanouts A wire brush can be used to loosen dirt and debris on the inside surfaces of the radiator Clean out all accumulated dirt soot and debris with a wire handled brush and an industrial vacuum cleaner Replace the clean out covers Most circulating fan motors permanently l
48. pport 26975 6 Front Panel 30350L 7 Blower Access Door 30363L Door Handle P2 41 28673 Logo Bezel 28479 Logo Label 28563 8 End Panel 30352 9 Heat Exchanger Assembly 30380 10 Firepot Retainer Bracket 27068 11 Replacement Combustion Chamber 27000WP 12 Oil Burner Mounting Plate Assembly 29873 Inspection Door Gasket 29871 13 Flue Connector 28306 14 Pouch Gasket 2080175 15 Flue Pipe Gasket 21994 16 Radiator Cleanout Cover Assembly 1061A Cleanout Cover Gasket 2080176 17 Casing Clean out Cover 3011325A 18 Filter Frame 21260 19 Filter Frame End Support 21306 20 Air Filter 20 x 20 x 1 Permanent 2180032 21 Junction Box 28723 22 Channel Wire Retainer 30239 23 Limit Control 60T11BOF L150 F 29197 24 Limit Control 60T11BOF L160 F 29662 25 Wire Harness Junction Box to Control 30392 26 Wire Harness Blower Direct drive 30391 27 Fan Timer Control Honeywell ST9103A or UTC 1158 150 29388 28 Air Baffle 30364 29 Wire Harness Supply 29366 30 Limit Cover Left 30240 31 Limit Cover Right 30195 32 Draft Regulator 6 12240 33 Transformer 27738 34 Control Panel 30355 35 Wire Harness Burner to Timer Board 30390 36 Wire Harness Transformer to Timer Board 30393 35 30318 R4 9 9 2005 PARTS LISTING COUNTERFLOW HORIZONTAL MODEL MPL Ref No Description PART NO 37 Beckett oil Burner AF76XN 30389 Burner Motor 1 7 HP 3450 RPM PSC 29689 Beckett Clean cut Oil Pump A2EA6520 29688 Solid State Ignitor FRANCE 10SAY 04 29522 Primary
49. r Off Delay Position Time 1 2 On On 60 seconds On Off 90 seconds Off On 120 seconds Off Off 150 seconds TABLE 6 United Technologies 1158 120 Dip Switch Blower Delay Position Times 1 2 3 4 On Off Seconds Minutes Off Off 30 On Off 60 Off On 90 On On 120 Off Off 2 On Off 3 Off On 4 On On 6 Note It is advisable not to set the fan on delay time for a time period longer than 90 seconds at highest input Longer fan on delay times may result in nuisance limit trips CIRCULATING AIR BLOWER All WML C AND MPL B furnace models are equipped with a direct drive blower system Direct drive blower speed adjustments are not normallv required in properlv sized extended plenum duct svstems 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 30318 R4 9 9 2005 trunk ducts These svstems require modification to provide some resistance to the airflow to prevent over amping of the direct drive blower motor Selecting a lower blower speed may correct this problem Direct drive blower speeds are adju
50. r lift The maximum allowable lift on a single line system is 8 feet Lift should be measured from the bottom outlet of the tank to the inlet of the burner Sizing a single line system is complex because of the difficulty estimating the pressure drop through each fitting bend and component in the line In general keep single line systems short as possible The following chart shows the allowable line lengths horizontal vertical for single and two line oil piping systems All distances are in feet Table 4 Oil Lines Copper Tubing Oil Line Length Feet Lift Single Pipe OD Two Pipe OD Feet 3 8 1 2 3 8 1 2 0 53 100 68 100 1 49 100 65 100 2 45 100 63 100 3 41 100 60 100 4 37 100 58 100 5 33 100 55 100 6 29 100 53 100 7 25 99 50 100 8 21 83 48 100 9 17 68 45 100 10 13 52 42 100 12 En 336 37 100 14 SE 32 100 16 E 27 100 18 m ES 22 88 In retrofit applications where an existing oil line system is in place a vacuum check will help determine the efficacy of the existing oil line system The vacuum in a system should not exceed 6 Hg for a single pipe system nor 12 Hg for a two pipe system NOTE The oil burner requires the use of a bypass plug when converting from single pipe to two pipe oil piping systems See burner manufacturer s instructions All fuel systems should include an oil filler between the fuel oil storage t
51. r light on extension cord Lower light on extension cord Found by inspection from basement Smoke test Measurement of pipe from within or observation of pipe by means of a lowered light By inspection or smoke test Use weight to break and dislodge Must be handled by competent masonry contractor Must be handled by competent masonry contractor Clean out with weighted brush or bag of loose gravel on end of line Change to straight or to long offset The least important opening must be closed using some other chimney flue Leaks should be eliminated by cementing all pipe openings Length of pipe must be reduced to allow end of pipe to be flush with inside of tile Extend partition to floor level Close all leaks with cement 30318 R4 9 9 2005 OPTIONAL SIDE WALL VENTING Certain WML C AND MPL B furnace models are manufactured to be installed as sidewall vented units Please refer to Direct Venting Instructions P N 28888 included with the Vent Kit for details Sidewall Venting Direct Venting requires the use of specific oil burners the Beckett AFII or the Riello 40BF Please refer to Appendix A Tables A2 and A4 Note Sidewall venting requires special attention to combustion air supply There is no natural draft in the venting system between furnace cycles therefore if the indoor pressure is negative relative to the outdoors the vent termi
52. range should be 50 F to 80 F To determine the temperature rise measure the supply air and return air temperatures when the furnace has reached steady state conditions This is the point at which the supply air temperature stops increasing relative to the return air temperature The furnace may have to run 10 to 15 minutes to reach steady state conditions The measurements may be made with duct thermometers or thermocouples 10 30318 R4 9 9 2005 used conjunction with multi meters with temperature measurement capabilities The return air should be measured at a point where the thermometer will be well within the air stream near the furnace return air inlet Actual location is not particularly critical however avoid locations where the temperature readings could be affected by humidifier bypass ducts the inside radius of elbows etc The supply air temperature should be measured at a point where the thermometer will be well within the air stream near the furnace supply air outlet Usually the side mid point of the supply air plenum take off is ideal providing it is out of the line of sight to the heat exchanger If the thermometer is within the line of sight of the heat exchanger the supply air readings may be skewed by radiant heat from the heat exchanger If the plenum take off is unsuitable the supply air temperature may be measured within the first 18 inches of the first segment of supply air trunk duct
53. required by a call for heat cool or fan the EFT switches off the i continuous fan speed tap before energizing the other fan speed e Electronic air cleaner EAC connections are energized when the heat or cool EAC 2 Air Cleaner is speed of the circulator fan is energized EAC connections are not energized when i the optional continuous fan terminal is energized HUM Humidity control is connected e Humidifier connections are energized when the oil burner motor is energized 25 30318 R4 9 9 2005 R7184 LED DIAGNOSTIC LIGHT The LED diagnostic light has several functions It indicates the state or mode in which the oil burner is operating It will also indicate fault conditions and help determine cad cell resistance while the burner is operating NORMAL CONDITIONS The LED diagnostic light will turn on when the burner enters the carryover state the point at which ignition spark is on and will remain on through the run state where the ignition spark is terminated but the burner continues to fire The LED diagnostic light will turn off at the end of the burner cycle as the R7184 enters the idle state and will remain off until the next heating cycle FAULT CONDITIONS If the LED diagnostic light is flashing quickly 1 Hz second on second off the R7184 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 slowl
54. rner 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 immediatelv 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 OPERATING PROPERLY AND AS EXPECTED NOTE ALL JOINTS IN ANY POSITIVE PRESSURE VENTING SYSTEM MUST BE CHECKED FOR LEAKS BEFORE LEAVING THE INSTALLATION SITE 21 30318 R4 9 9 2005 APPENDIX C R7184 TROUBLESHOOTING R7184 DETAILED SEQUENCE OF OPERATION FIGURE 7 Power is applied to unit The R7184 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
55. s T T If no voltage is present check for 115v to oil primary control If 115v is present go to Table C 3 Oil primary control faulty Photo Cell wiring shorted or room Check photo cell cad cell wiring for short circuits Also check for room light leaking into photo cell light leaking into cad cell compartment Repair light leak if necessary Furnace will not start compartment See Table C 3 Check for open limit or auxiliarv limit Also check internal wiring Open safetv switch connections loose connectors etc A Check fuel oil supply Check that all hand operated fuel oil valves are in No fuel oil D pe the open position Fill oil storage tank if necessary Clogged nozzle Replace nozzle with high quality replacement Use rating plate or Tables in Appendix A as a guide Furhade ili Clogged oil filter Replace oil tank filter or in line filter if used first pushing oil primary Connect pressure gauge to oil pump Adjust pump pressure or replace control reset button Low oil pump pressure oil pump if necessary Ensure that erratic pressure readings are not Happens on frequent basis caused by defective fuel oil line Air getting into fuel oil lines or fuel Check fuel oil lines Replace any compression fittings found with high oil line dirty clogged or in some quality flared fittings Check for any signs of oil leaks Any oil leak is a manner defective potential source of air or contaminants Check b
56. s checked e Ifflame is not present the R7184 LED diagnostic light is off and returns to idle state e Ifflame is presence is detected the control enters lock out mode 22 30318 R4 9 9 2005 R7184 INTERRUPTED ELECTRONIC OIL PRIMARV CONTROL FIGURE 7 ELECTRONIC FAN TIMER BOARD ON CONTROL PANEL FIGURE 8 23 30318 R4 9 9 2005 d IDLE STATE lt THERMOSTAT CALLS FOR R7184 SEQUENCE of SAFETY CHECK FOR FLAME 5 SEC REMAINS IN IDLE STATE OPERATION NO FLAME BURNER MOTOR amp IGNITOR START 10 SEC SAFETY CHECK FOR FLAME 5 SEC NO FLAME FLAME SOLENOID VALVE OPENS LOCKOUT STATE TRIAL FOR IGNITION BURNER FLAME MONITORED CARRYOVER STATE e Provides continuous spark e LED diagnostic light ON e Start Carryover Timer FLAME LOST R7184 Shuts off burner motor Shuts off igniter Shuts off Solenoid Valve Fast Flashes LED Diagnostic Light TO EXIT LOCKOUT PRESS RESET FLAME CARRYOVER TIMER EXPIRES FLAME FLAME LOST RUN STATE e lgniter turns off THERMOSTAT SATISFIED R7184 SHUTS OFF Burner Motor FLAME LOST RECYCLE TIMER STARTS R7184 Shuts off Solenoid Valve Shuts off Igniter Solenoid Valve LED Diagnostic Light Shuts off Burner Motor Slow Flashes LED diagnostic light 30 SEC SAFETY CHECK FOR FLAME 5 SEC RECYCLE TIMER EXPIRES NO FLAME FLAME 60 SECONDS RETURNS TO IDLE STATE 24 30318 R4 9 9 2005 Table C 1 ELECTRONIC FA
57. s 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 14 system temperature rise System temperature rise is the difference between the furnace outlet temperature and furnace inlet temperature as measured the vicinity of the connection between the plenum take offs and the trunk ducts Perform a smoke spot test The smoke spot should not exceed No 1 on the Bacharach Scale After the air adjustments have been completed re check the draft pressure at the test port on the burner mounting plate as shown in Figure 6 The draft should be adjusted to 0 02 inches w c 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 NOTE USE OF THE INLET AIR SHUT OFF COULD CAUSE POST COMBUSTION NOZZLE DRIP A 4 SPECIAL INSTRUCTIONS FOR UNITS EQUIPPED WITH RIELLO BURNERS Riello burners are factory set with respect to nozzle size pump pressure air gate and turbulator adjustments for each model and firing
58. stat 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 There will be a fan on time delay before the circulating fan is energized The Honeywell ST9103 has a fixed fan delay on time of 30 seconds after the burner ignites The United Technologies 1158 120 has an adjustable fan on time that is set by selecting the dipswitch combination displayed in Chart 1 This fan on delay can be set at 30 60 90 or 120 seconds Set the thermostat below room temperature The oil burner should stop The air circulation blower will continue to run until the time off setting selected on the electronic fan timer control times out The Honeywell ST9103 has adjustable fan off time of 60 90 120 and 150 seconds that is set by selecting a dipswitch combination on the control board Similarly the United Technologies 1158 120 has adjustable fan off time of 2 3 4 or 6 minutes The fan timer control adjustments may be altered if the air at the room registers is uncomfortably high upon blower start up or shutdown The necessary adjustments to the fan control settings should be determined by measuring the temperature of the air in the supply air take off or within the first few inches of the supply air trunk The side mid point of the transition is usually ideal providing that the thermometer probe is beyond the line of sight wherein f
59. sted by changing the hot wires to the motor winding connections Please refer to wiring diagram in Appendix B or the wiring diagram label affixed to the furnace THE NEUTRAL WIRE normally the white wire IS NEVER MOVED TO ADJUST THE BLOWER SPEED box tape off both ends of the unused wire DISCONNECT THE POWER SUPPLY TO THE FURNACE BEFORE OPENING THE BLOWER ACCESS DOOR TO SERVICE THE AIR FILTER FAN AND MOTOR FAILURE TO SHUT OFF POWER COULD ALLOW THE BLOWER TO START UNEXPECTEDLY CREATING A RISK OF DEATH OR PERSONAL INJURY DO NOT CONNECT POWER LEADS BETWEEN MOTOR SPEEDS THE NEUTRAL WIRE MUST ALWAYS BE CONNECTED TO THE MOTOR S DESIGNATED NEUTRAL TERMINAL Do not use the blower speed wires as a source of power to accessories as electronic air cleaners and humidifier transformers The unused motor taps auto generate sufficiently high voltages to damage accessory equipment Use the terminals provided on the electronic fan timer 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 OIL BURNER The oil burner must align properly with the cerafelt fiber chamber firepot The cerafelt fiber chamber is initially quite soft but hardens and becomes quite brittle after the first firing The firepot is held in place by a retaining bracket however it is possible for the firepot to shift if sub
60. t 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 Excessive fuel i temperature 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 P gn 350 to 450 F Check draft regulator Draft should be set to 0 02 in w c Check thermostat heat anticipator setting against measured amperage Thermostat improperly adjusted or draw Increase heat anticipator setting if necessary If the thermostat is in poor location being influenced by drafts sunlight duct work etc relocate to more suitable location Poor fan off delay timing selection fan stops too soon Insufficient combustion air Adjust the oil burner combustion air band and draft regulator to gain the adjustment at burner highest practical CO or lowest practical O content the flue gases Too much smoke improper draft pressure See Burner Set Up Heat exchanger partially clogged 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 inch back from the inside surface of the fire pot Poor alignment between oil burner blast tube and fire pot S
61. tainers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluids 3 Paint thinners or other painting materials and compounds 4 Paper bags boxes or other paper or cardboard products Never operate the furnace with the blower door removed To do so could result in serious personal injury and or equipment damage INTRODUCTION Please read these instructions completely and carefully before installing and operating the furnace The furnace must be installed and set up by a qualified contractor Model WML C is an oil fired forced air multi positional furnace with an output capacity range of 58 000 BTU Hr to 85 600 BTU Hr The MPL B is also an oil fired forced air multi positional furnace with an output capacity range of 85 500 BTU Hr to 123 000 BTU Hr The WML C AND MPL B furnace may be installed in the down flow position as well as both left and right horizontal positions All models are listed with the Canadian Standards Association CSA and comply with the standards of both the United States and Canada for use with No 1 Stove and No 2 Furnace Oil In the United States the installation of the furnace and related equipment shall be installed in accordance with the regulations of NFPA No 31 nstallation of Oil Burning Equipment as well as in accordance with local codes In Canada the installation of the furnace and related equipment shall be installed in ac
62. ubricated by the motor manufacturer These motors will have no oil ports If the blower motor does contain oil ports under normal operating conditions it will not require oiling for the first two years Oil sparingly a few drops in each oil port with SAE 20 non detergent oil Oiling is most easily done with a tele spout oiler This oiler has a long flexible plastic spout DO NOT OVER LUBRICATE Excess oil may result in premature electric motor failure Inspect the blower fan Clean it if necessary Oil Burner Maintenance Follow the instructions of the burner manufacturer See oil burner manufacturer s instructions supplied with furnace The oil burner nozzle should be replaced annually We recommend that the oil filter be changed on an annual basis The venting system should be cleaned and inspected for signs of deterioration Replace pitted or perforated vent pipe and fittings The barometric draft regulator should open and close freely All electrical connections should be checked to ensure tight connections Safety controls such as the high limit controls should be tested for functionality The fan control functions 11 30318 R4 9 9 2005 should be checked to ensure that all fan speeds are operating properlv OPERATING INSTRUCTIONS Before Lighting Open all supplv and return air registers and grilles Open all valves in oil pipes Turn on electric power supply To Light Unit Set the thermo
63. uction such as those with high quality weather stripping caulking windows and doors or storm sashed windows or where basement windows are well sealed a permanent opening communicating with a well ventilated attic or with the outdoors shall be provided using a duct if necessary Size all of the openings and associated ductwork by the standards provided in the latest Oil Installation Code editions NFPA 31 in the United States CAN CSA B139 in Canada Take all fuel burning appliances in the area into consideration when calculating combustion and ventilation air requirements The Model CAS 2B 90E Furnace Boot manufactured by Field Controls Inc may be used with the furnace to obtain combustion air from outdoors Use of this device does not alter the need for ventilation air however it does provide a good source of combustion air and is connected to the oil burner CHIMNEY VENTING The chimney must be sized correctly and be in good repair If the chimney is oversized there is a high risk of the flue gases condensing resulting in damage to the chimney and other venting parts This problem may be corrected by the use of an appropriately sized chimney liner If the chimney serves the WML C furnace only the vent should be sized at 5 inch minimum The MPL B should be 6 inch minimum The data provided in Table 3 is based on dedicated venting If the furnace is to be co vented with other appliances refer to NFPA 211 Standard f
64. urnace The homeowner should be aware of the location of electrical circuit breaker or fuse the location of any electrical switches controlling the furnace the location of the oil tank shut off valve and how to operate the valve The homeowner should be informed where the oil tank gauge is located and how to read it It would be beneficial to review safety issues with the home owner such as the danger of storing combustibles too close to the furnace hanging anything on the furnace vent pipe and especially the dangers of indiscriminately pressing the burner reset button IMPORTANT Be sure that the home owner knows where the burner reset switch is located and is aware that the reset switch is not to be activated more than once without a thorough look for the cause of the problem lack of fuel etc Be sure that the homeowner knows when to quit trying to start the furnace during these conditions and who to call for emergency service MAINTENANCE AND SERVICE A Routine Maintenance By Home Owner Other than remembering to arrange for the annual professional servicing of the furnace by the service or installation contractor the most important routine service performed by the homeowner is to maintain the air filter or filters A dirty filler can cause the furnace to over heat fail to maintain indoor temperature during cold weather increase fuel consumption and cause component failure The furnace filter s should be ins
65. urner motor If burner motor is cutting out on over load Defective burner motor A determine whv Replace if necessarv If cad cell is dirty clean it Determine why cad cell is getting dirty If Furnace starts but cuts out cad cell is poorly aimed realign it NOTE The photocell should have a requiring manually resetting Photo Cell Cad Cell defective resistance of 100K in absence of light maximum of 1500 in the the oil protector reset button presence of light Ensure that room light is not leaking into the cad cell compartment See diagnostic light section Check fuel oil suppiv Check that all hand operated fuel oil valves in No fuel oil jiu the open position Fill oil storage tank if necessary Clogged nozzle Replace nozzle with high quality replacement Use rating plate or Tables in Appendix A as a guide Clogged oil filter Replace oil tank filter or in line filter if used Connect pressure gauge to oil pump Adjust pump pressure or replace Low oil pump pressure oil pump if necessary Ensure that erratic pressure readings are not Furnace starts but cuts out caused by defective fuel oil line requiring manually resetting Air getting into fuel oil lines or fuel Check fuel oil lines Replace any compression fittings found with high the oil protector reset button oil line dirty clogged or in some quality flared fittings Check for any signs of oil leaks Any oil leak is a manner defective
66. velop sufficient draft the draft control cannot function properly The draft regulator must be installed within the same room enclosure as the furnace and should not interfere with the combustion air supplied to the burner The control should be located a minimum of 3 flue pipe diameters from the furnace breeching and installed in accordance to the instructions supplied with the regulator 30318 R4 9 9 2005 Fig 2 Chimnev Problems DLL asa I T T TAL NOT ho Va ED ii Ash Dump for Fireplace Refer to Figure 2 Top of chimnev Extend chimnev lower than above all A Observation surrounding surrounding ng objects objects within 30 feet Chimney observation Remove or ventilator Make opening Coping restricts Observation as large as opening inside of chimney Obstruction in chimney Joist protruding into chimney Break in chimney lining Collection of soot at narrow space in flue opening Offset Two or more openings to the same chimney Loose seated pipe in flue opening Smoke pipe extends into chimney Failure to extend the length of flue partition to the Loose fitted clean out door Can be found by light and mirror reflecting conditions in chimney Lowering a light on an extension cord Smoke test build smudge fire blocking off other opening watching for smoke to escape Lowe
67. y Hz 2 seconds on 2 seconds off the R7184 is in the recycle state This indicates that flame sensing was lost after the lockout timer expired during the ignition carryover state The R7184 will return to the idle state within 60 seconds CAD CELL CONDITION If the LED diagnostic light is off the cad cell is not sensing flame If the LED diagnostic light is on the cad cell is sensing flame or viewing ambient light The resistance of the cad cell may be checked while the R7184 is in the run state by pressing the reset button The LED diagnostic following code TABLE C 2 CAD CELL RESISTANCE Resistance in Ohms 1 light will flash the Less than 400 Between 400 800 Between 800 1600 Between 1600 5000 TROUBLESHOOTING IMPORTANT Due to the potential hazard of line voltage only a trained experienced service technician should perform the troubleshooting procedure PRELIMINARY STEPS Check the diagnostic light for indications of burner condition Refer to R7184 LED DIAGNOSTIC LIGHT section for details Electrical Shock Hazard Troubleshooting is done with the system powered Be careful to observe all necessary precautions to prevent electrical shock or equipment damage WHEN SIMULATING A CALL FOR HEAT AT THE R7184 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 ANTICI

FIELD CONTROLS MPL-B User's Manual

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