Royal Appliance Furnace Air Furnace User Guide

Installation, Operation and

Maintenance Manual

Oil Fired Warm Air Furnace

HO-B Series Up-flow or Horizontal Model

THE INSTALLATION OF THIS FURNACE SHALL BE IN

ACCORDANCE WITH THE REGULATION OF

AUTHORITIES HAVING JURISDICTION AND NFPA

STANDARD 31 (U.S.A.) OR CSA STANDARD B139 (CAN.).

FOR YOUR SAFETY

Do not store or use gasoline or

other flammable vapors or liquids

in the vicinity of this or any other

appliance.

Oneida Royal Division

Utica, New York

Please read this manual completely

before beginning installation. These

instructions must be kept with the

furnace for future reference.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Table of Contents

1. Introduction..........................................................................................................................................................4

2. Heat Loss..............................................................................................................................................................4

3. Location of Unit ...................................................................................................................................................4

4. Air Conditioning Applications ............................................................................................................................6

5. Combustion Air....................................................................................................................................................6

6. Chimney Venting .................................................................................................................................................7

7. Barometric Damper Control................................................................................................................................8

8. Furnace Controls.................................................................................................................................................9

9. Electrical Connections........................................................................................................................................9

10. Humidifier.........................................................................................................................................................10

11. Oil Tank.............................................................................................................................................................10

12. Piping Installation............................................................................................................................................10

13. Oil Filter ............................................................................................................................................................11

14. Oil Burner Nozzles...........................................................................................................................................11

15. Combustion Chamber ......................................................................................................................................11

16. Burner Electrodes............................................................................................................................................12

17. Oil Burner Set Up.............................................................................................................................................12

18. Circulating Air Blower.....................................................................................................................................14

19. Maintenance and Service................................................................................................................................15

20. Furnace Installation Set Up ............................................................................................................................16

21. Operating Instructions ....................................................................................................................................17

Table A-1 Beckett AF Oil Burner Set-Up..............................................................................................................18

Table A-2 Riello 40F Oil Burner Set-Up ...............................................................................................................18

Table A-3 Direct Drive Blower Set-Up..................................................................................................................19

Table A-4 Direct Drive Blower Characteristics ...................................................................................................19

Table A-5 Belt Drive Blower Set-Up .....................................................................................................................20

Table A-6 Belt Drive Blower Characteristics.......................................................................................................20

General Dimensions...............................................................................................................................................21

Wiring Diagram: Oil Furnace With ST9103 EFT & R7184 Control.....................................................................22

Wiring Diagram: Oil Furnace With ST9103 EFT & Riello Oil Burner.................................................................23

Wiring Notes: ..........................................................................................................................................................24

R7184 Detailed Sequence of Operation................................................................................................................25

Table C-1: ST9103 Detailed Sequence of Operation ..........................................................................................29

R7184 LED Diagnostic Light..................................................................................................................................31

Table C-2: Cad Cell Resistance............................................................................................................................31

Table C-3: R7184 Troubleshooting ......................................................................................................................32

Table C-4: System and General Troubleshooting ..............................................................................................36

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

IMPORTANT:

SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE

1. INTRODUCTION

All models are shipped assembled and pre-wired. The

furnace should be carefully inspected for damage when

being unpacked.

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

2. HEAT LOSS

MODEL 80F

To determine the correct furnace and firing rate for an

application, it is necessary to calculate the maximum

hourly heat loss of the building based on local design

conditions. In new construction, the heat loss should be

calculated on a room-by-room basis to enable proper

sizing of the trunk and branch ducts. In retrofit

Model 80F is an oil-fired upflow forced air furnace, with

an output capacity range of 58,100 BTU/Hr. to 78,900

BTU/Hr. The 80F furnace equipped with a direct drive

blower may be installed in both horizontal positions.

applications,

calculation may be used.

building shell (overall) heat loss

MODEL 120F

Model 120F is an oil-fired upflow forced air furnace, with

an output capacity range of 87,700 BTU/Hr. to 113,400

BTU/Hr. The 120F furnace equipped with a direct drive

blower may be installed in both horizontal positions.

In the United States, Manual J. titled, "Load

Calculation" published by the Air Conditioning

Contractors of America, describes a suitable procedure

for calculating the maximum hourly heat loss.

NOTE: Furnace models equipped with belt drive blowers

are not suitable for horizontal applications.

In Canada, the maximum hourly heat loss may be

calculated in accordance with the procedures described

in the manuals of the Heating, Refrigeration and Air

Conditioning Institute of Canada (HRAI), or by other

method prescribed by authorities having jurisdiction that

are suitable for local conditions.

Both 80F & 120F Model furnaces are listed with the

Canadian Standards Association, (CSA), complies with

both Canadian and American (U.S.) standards for use

with No. 1 (Stove) and No. 2 (Furnace) Oil. Please refer

to the tables in the appendix for performance and

dimensional data.

3. LOCATION OF UNIT

The furnace should be located such that the flue

connection to the chimney is short, direct and consists of

as few elbows as possible. When possible, the unit

should be centralized with respect to the supply and

return air duct work. A central location minimizes the

trunk duct sizing. All models may be installed on

combustible floors.

DO NOT USE GASOLINE, CRANK CASE OIL,

OR ANY OIL CONTAINING GASOLINE.

In the United States of America, the installation of the

furnace and related equipment shall be installed in

accordance with the regulations of NFPA No. 31,

Installation of Oil Burning Equipment, as well as in

accordance with local codes.

Minimum installation clearances are listed in Table 1.

Table 1: Clearance to Combustibles

HO-B – All Models

In Canada, the installation of the furnace and related

equipment shall be installed in accordance with the

regulations of CAN/CSA - B139, Installation Code For

Oil Burning Equipment, as well as in accordance with

local codes.

Location

Top

Bottom

S/A Plenum

Rear

Sides

Front

Flue Pipe

Up-flow

2 in.

0 in.

1 in.

Horizontal

2 in.

1 in.

When installation or application questions arise,

regulations prescribed in the National Codes and Local

1 in.

9 in. ¹

9 in.

9 in. ¹

9 in.

Regulations take precedence over the general

instructions provided with this installation manual. When

in doubt, please consult your local authorities.

Enclosure

Closet

Alcove

24” clearance is required for servicing.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE 2.: GENERAL SPECIFICATIONS

BECKETT AFG BURNER

INPUT

U.S. GPH

OUTPUT

BTU/Hr.

BURNER

MODEL

BURNER

HEAD

PUMP

PRESSURE

NOZZLE

(Delavan)

MODEL

0.50

0.65

0.70

0.75

0.85

1.00

58,100

68,000

78,900

87,700

98,800

113,400

0.50 / 70° W

0.65 / 70° W

0.70 / 70° W

0.75 / 70° W

0.85 / 70° W

1.00 / 70° W

AF76BO

AF76BN

80F

100 PSIG

120F

AF76BZHS

NOTES:

OVER-FIRE DRAFT FOR ALL MODELS IS -0.02 IN. W.C.

STATIC PLATE DIAMETER: 3-3/8 inch for AF76BO and 2-3/4 inch for AF76XN.

RIELLO 40F3 BURNER

INPUT

U.S. GPH

OUTPUT

BTU/Hr.

PUMP

PRESSURE

TURBULATOR

SETTING

AIR BAND

SETTING

NOZZLE

(Delavan)

MODEL

0.50

0.60

0.70

0.75

0.85

0.95

58,000

73,000

79,000

87,000

100,000

112,000

0.40 / 60°W

0.50 / 60°W

0.60 / 60°W

0.70 / 60°W

0.75 / 60°W

160 PSIG

150 PSIG

145 PSIG

150 PSIG

160 PSIG

1.5

2.0

2.5

3.0

2.25

2.5

3.0

3.5

4.0

6.0

80F

120F

NOTE:

OVER-FIRE DRAFT FOR ALL MODELS IS -0.02 IN. W.C.

In the upflow position, the heat exchanger support screw

shown in picture may be removed. This may be

preferable if the furnace rear panel will be inaccessible

after installation. The screw must be removed if the heat

exchanger must be removed from the cabinet. Do not

remove this screw if installing furnace in a horizontal

position.

NOTE: The recommended installation clearances do not

take into consideration the clearances necessary to

replace the air filter or perform other routine

maintenance.

UP-FLOW INSTALLATION

Both furnaces models have been assembled for

installation in the up-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.

HORIZONTAL INSTALLATION

The furnaces are assembled and shipped ready for

installation in the up-flow position. The direct drive

equipped furnace may be installed in either of the

horizontal positions; warm air discharging left or warm

air-discharging right by following these steps:

1. Rotate the furnace 90° to the desired position.

2. Remove the three nut and washer sets fastening the

oil burner assembly to the furnace (Beckett Burner)

or loosen the burner mount Allen screw (Riello

burner). Rotate the oil burner assembly to be in the

normal upright position.

Heat

Exchanger

Support

Screw

3. Re-align the oil burner assembly to the combustion

chamber (fire-pot), then secure into place with the

three nut and washer sets (Beckett burner) or by re-

tightening the mounting Allen screw (Riello burner).

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

specifically approved for such service.

NON-SUSPENDED INSTALLATION

The blower speed must be checked and adjusted to

compensate for the pressure drop caused by the

evaporator coil. Refer to Appendix B for recommended

wiring and electrical connections of the air conditioning

controls.

Maintain clearances to combustibles as outlined in Table

1. Installation on a combustible floor requires a clearance

of 1 inch. This can be done by using a noncombustible

material such as one-inch thick channel iron or similar

material. The furnace must be supported in such a way

as to not allow twisting or sagging of the cabinet.

Suggestion; as a measure to prevent fuel oil from

accumulating in locations other than the fire pot, as could

be the case in the event of nozzle drip, install the furnace

with an approximate 2 degree slope from the oil burner

casing towards the fire pot. Use shims made of

noncombustible material.

5. COMBUSTION AIR

When a furnace is installed in the full basement of a

typical frame or brick house, infiltration is normally

adequate to provide air for combustion and draft

operation. If the furnace is installed in a closet or utility

room, two (2) ventilation openings must be provided

connecting to a well ventilated space (full basement,

living room or other room opening thereto, but not a

bedroom or bathroom). One opening shall be located 6"

from the top and bottom of the enclosure at the front of

the furnace. For furnaces located in buildings of

unusually tight construction, such as those with high

quality weather stripping, caulking, windows and doors, or

storm sashed windows, or where basement windows are

well sealed, a permanent opening communicating with a

well ventilated attic or with the outdoors shall be provided,

using a duct if necessary. 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.

SUSPENDED INSTALLATION

Refer to Figure 1. Maintain clearances to combustibles

as outlined in Table 1. The furnace may be suspended by

field fabricating a cradle of angle iron and threaded rod.

Secure the furnace with 2 inch minimum slotted angle or

equivalent, as shown in Figure 1. The furnace must be

supported in such a way as to not allow twisting or

sagging of the cabinet. Position the supports so as to not

interfere with accessing the burner and blower

compartments. Suggestion; as a measure to prevent fuel

oil from accumulating in locations other than the fire pot,

as could be the case in the event of nozzle drip, install

the furnace with an approximate 2 degree slope from the

oil burner casing towards the fire pot.

4. AIR CONDITIONING APPLICATIONS

The Model CAS-2B-90E Furnace Boot manufactured by

Field Controls, Inc. may be used with the furnace to

obtain combustion air directly from outdoors. Use of this

device does not alter the need for ventilation air;

however, it does provide a good direct source of

combustion air and is connected directly to the oil burner.

If the furnace is used in conjunction with air conditioning,

the furnace shall be installed in parallel with or upstream

from the evaporator coil to avoid condensation in the heat

exchanger. In a parallel installation, the dampers or air

controlling means must prevent chilled air from entering

the furnace. If the dampers are manually operated, there

must be a means of control to prevent the operation of

either system unless the dampers are in the full heat or

full cool position. The air heated by the furnace shall not

pass through a refrigeration unit unless the unit is

Figure 1: Typical Suspended Application

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Installation Code For Oil Burning Equipment for correct

Figure 2: Common Chimney Problems

sizing information

Table 3: Common Chimney Problems

Refer to Figure 2

Key

Trouble

Diagnostic

Remedy

Extend

chimney above

all surrounding

objects within

30 feet.

Top of chimney

lower than

surrounding

objects

Observation

Chimney Cap

or ventilator.

Observation

Remove

Make opening

as large as

inside of

Coping restricts

opening.

chimney.

Can be found

by light and

mirror reflecting break and

Obstruction in

chimney

Use weight to

conditions in

chimney.

dislodge.

Must be

Lowering a light handled by

on an extension competent

cord.

Joist protruding

into chimney.

masonry

contractor.

Smoke test -

build smudge

fire blocking off

other opening,

watching for

smoke to

Must be

handled by

competent

masonry

Break in

chimney lining.

contractor.

escape.

Clean out with

weighted brush

or bag of loose

gravel on end

of line.

Collection of

soot at narrow

space in flue

opening.

Lower light on

extension cord.

Change to

straight or to

long offset.

Lower light on

extension cord.

Offset

The least

important

6. CHIMNEY VENTING

Two or more

openings to the inspection from be closed,

same chimney.

Found by

opening must

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.

basement.

using some

other chimney

flue.

Leaks should

be eliminated

by cementing

all pipe

Loose-seated

pipe in flue

opening.

Smoke test.

If the chimney serves the furnace only, the vent should

be sized at 4 inch minimum, 5 inch maximum. The table

below is based on dedicated venting. If the furnace is to

be co-vented with other appliances, refer to NFPA 31,

Standard for the Installation of Oil Burning Equipment and

NFPA 211, Standard for Chimneys, Fireplaces, Vents,

and Solid Fuel-Burning Appliances or CAN/CSA B139,

openings.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Table 2: Common Chimney Problems - continued

Key

Trouble

Diagnostic

Remedy

Measurement

of pipe from

within or

observation of

pipe by means

of a lowered

light.

Length of pipe

must be

Smoke pipe

extends into

chimney.

reduced to

allow end of

pipe to be flush

with inside of

tile.

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 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.

Failure to

extend the

length of flue

partition to the

floor.

By inspection

or smoke test.

Extend partition

to floor level.

Loose-fitted

clean-out door.

Close all leaks

with cement.

Smoke test.

NOTE: This furnace is approved for use with L-Vent.

NOTE: Maximum temperature for L-Vent is 575°F

(300°C).

See Figure 2 and Table 3 for common chimney problems

and their remedies.

Table 4: Min. Chimney Base Temperatures (°F)

Chimney Height (ft.)

Model

Chimneys with Thermal Resistance less than R6

THE FURNACE MUST BE CONNECTED TO A FLUE

HAVING SUFFICIENT DRAFT AT ALL TIMES TO

ENSURE SAFE AND PROPER OPERATION OF THE

APPLIANCE.

80F (060)

80F (070)

80F (080)

120F (090)

120F (100)

120F (120)

300

275

270

260

250

225

400

340

330

320

300

535

430

405

380

355

365

725

535

505

475

430

The flue pipe must not be routed through concealed

space, because it must be visually checked for signs of

deterioration during the annual inspection and servicing.

The flue pipe must not pass through any floor or ceiling,

but may pass through a wall where suitable fire protection

provisions have been installed. Refer to the latest edition

of CAN/CSA B139 for rules governing the installation of

oil burning equipment. In the United States, refer to the

latest edition of NFPA 31 for regulations governing the

installation of oil burning equipment.

Chimney Height (ft.)

20 28

Model

Chimneys with Thermal Resistance greater than R6

80F (060)

80F (070)

80F (080)

120F (090)

120F (100)

120F (120)

185

175

165

200

185

220

205

195

250

220

215

210

205

7. BAROMETRIC DAMPER CONTROL

This device is used in conjunction with conventional

chimney venting. This control (or draft regulator)

automatically maintains a constant negative pressure in

the furnace to obtain maximum efficiency. It ensures that

proper pressures are not exceeded. If the chimney does

not develop sufficient draft, the draft control cannot

function properly. The draft regulator, must be installed

within the same room or enclosure as the furnace, and

should not interfere with the combustion air supplied to

the burner. The control should be located a minimum of 3

flue pipe diameters from the furnace breeching and

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

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

installed in accordance to the instructions supplied with

the regulator.

8. FURNACE CONTROLS

The furnace is controlled by either of two systems,

depending on the oil primary control and electronic fan

timer combination. System 1, used with Beckett burners,

includes the blower mounted Honeywell ST9103

ELECTRONIC FAN TIMER (EFT) combined with the R7184

OIL PRIMARY CONTROL. System 2, used with Riello

burners, includes the blower mounted Honeywell ST9103

ELECTRONIC FAN TIMER (EFT) combined with

transformer / burner relay mounted internally on the 40F3

burner housing to operate the oil burner.

Figure 4: ST9103 EFT

condition is detected, one or both limit switches will

interrupt power to the oil primary control, which will shut

of the oil burner. The circulating fan will continue to

operate. The high limit switches will automatically reset

when the furnace returns to a safe temperature.

9. ELECTRICAL CONNECTIONS

Figure 3: R7184 Oil Primary

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 functions are controlled by either System 1

or System 2, and bi-metallic snap disc limit switches.

These groupings also provide control for add-on air

conditioning. The ST9103 EFT is located in a control box

mounted to the blower support rails.

The circulating fan is controlled by the ST9103 EFT. The

heat delay-on time is fixed, at 30 seconds. This provides

a delay between the start of the burner and the start of

the circulating fan to reduce the amount of ambient

unheated air flowing through the ductwork. The end of

the circulating fan cycle is also delayed to remove

residual heat from the furnace. There are four delay-off

choices, 60, 90, 120 and 150 seconds, which are field

adjustable by manipulating the DIP switches on the

ST9103 EFT board.

The furnace should be wired to a separate and dedicated

circuit in the main electrical panel; however, accessory

equipment such as electronic air cleaners and humidifiers

may be included on the furnace circuit. Although a

suitably located circuit breaker can be used as a service

switch, a separate service switch is advisable. The

service switch is necessary if reaching the circuit breaker

involves becoming close to the furnace, or if the furnace

is located between the circuit breaker and the means of

entry to the furnace room. The furnace switch (service

switch) should be clearly marked, installed in an easily

accessible area between the furnace and furnace room

entry, and be located in such a manner to reduce the

likelihood that it would be mistaken as a light switch or

similar device.

The cooling delay-on and delay-off times are fixed at 30

seconds.

The furnace is protected against over-heating by fixed

high temperature limits. These controls are factory set

and are not field adjustable. If an over temperature

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

The power requirements for the HO-B Series models are: control. Do not use direct drive motor connections as a

source of power for 120 VAC humidifiers and humidifier

transformers.

120 VAC, 1 b, 60 Hz., 12A. 5-ton models: 120 VAC, 1 b,

60 Hz., 16A.

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.

11. 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. Observe all local codes and by-

laws. And in Canada, CAN/CSA-B139, Installation Code

for Oil Burning Equipment, Section 6

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.

In general, the oil tank must be properly supported and

remain stable in both empty and full condition. The oil

tank must be fitted with vent and supply pipes to the

outdoors. Refer to the above-mentioned codes for sizing.

The vent pipe must be no less than 1¼ inches I.P.S., and

terminate with an appropriate vent cap in a location

where it will not be blocked. The fill pipe must be no less

than 2 inches I.P.S., and terminate with an appropriate

cap in a location where debris will not enter the fill pipe

during oil delivery.

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.

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.

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. To reduce the risk of damaging the heat

anticipator, do not measure circuit without first removing

one of the two wires first. To determine the heating circuit

amperage draw:

12. PIPING INSTALLATION

In the United States the installation must be in

accordance with the requirements of NFPA No. 31 and

local codes and regulations.

1. Disconnect one of the “R” or “W” wires from the

thermostat terminal.

In Canada, the entire fuel system should be installed in

accordance with the requirements of CAN/CSA B139,

and local regulations. Use only approved fuel oil tanks

piping, fittings and oil filters.

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.

Ensure that all fittings used in a copper oil line system are

high quality flare fittings. Do not use compression fittings.

4. Re-connect the thermostat wire. If the thermostat is

serving a combination heating and air conditioning

system, pay particular attention to polarity.

Do not use Teflon tape on any fittings.

5. When the thermostat is reconnected and re-

plumbed, adjust the heat anticipator setting to match

the observed amperage reading.

Pressurized or gravity feed installations must not exceed

3 PSIG. Pressures greater than 10 PSIG may cause

damage to the shaft seal. If the height of the oil stored in

a tank above the oil burner exceeds 11½ feet, it may be

necessary to use a pressure-regulating device approved

for this purpose.

10. HUMIDIFIER

A humidifier is an optional accessory available through

most heating supplies outlets. Installation should be

carried out in accordance with the humidifier

manufacturer's installation instructions. Water or water

droplets from the humidifier should not be allowed to

come into contact with the furnace heat exchanger.

Terminals (115 v) are provided on the ST9103 EFT

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

The furnaces may be installed with a one-pipe system For additional information, see the installation information

with gravity feed or lift. The maximum allowable lift on a sheet included in the documents envelope or affixed to

single line system is 8 feet. Lift should be measured from the oil burner.

the bottom (outlet) of the tank, to the inlet of the burner.

Sizing a single line system is complex because of the

difficulty estimating the pressure drop through each

fitting, bend and component in the line. In general, keep

single line systems short as possible. If the furnace is to

be installed in a suspended position, a two-pipe system

may be the better alternative. 2-stage oil pumps are not

available for either the Beckett or Riello burner. The

following chart shows the allowable line lengths

(horizontal + vertical) for single and two stage oil pumps.

All distances are in feet.

NOTE: Both the Beckett and Riello oil burners require the

use of a bypass plug when converting from single-pipe to

two-pipe oil piping systems. See burner manufacturer’s

instructions.

NOTE: The Riello oil burner is manufactured with British

Parallel Thread pump ports. Adapters are supplied with

the oil burner to convert from British Parallel Thread to

NPT (National Pipe Thread). Direct connection of NPT

fittings to the Riello oil burner ports will result in damage

to the pump body. This also applies to pressure and

vacuum gauges. (See Riello manual)

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

featuring a Beckett burner should not exceed 6” Hg. for a

single pipe system, nor 12” Hg. for a two-pipe system.

The vacuum in a system featuring a Riello burner should

not exceed 6” Hg. for a single pipe system, nor 11.44”

Hg. for a two-pipe system.

13. OIL FILTER

All fuel systems should include an oil filter between the

fuel oil storage tank and the oil burner. For best results,

install the oil filter as close to the burner as possible.

When using an indoor oil tank, the oil filter may be

installed at the tank downstream from the shut-off valve.

If firing the furnace under the 0.65 gph rate, a 7 to 10

micron line filter should be installed as close to the oil

burner as possible.

Table 5: Oil Lines

Copper Tubing Oil Line Lengths (Feet)

Beckett Oil Burner

Single-Pipe

⅜” O.D. ½” O.D. ⅜” O.D.

Two-Pipe

Lift

(feet)

½” O.D.

Tubing

100

14. OIL BURNER NOZZLES

Tubing

100

Tubing

The 80F Series furnace is certified for multiple firing

rates, ranging from 58,100 to 78,900 BTU/hr, while the

120F Series Furnace is certified for multiple firing rates of

87,000 113,400 BTU/hr. By changing the oil burner

nozzle within the specific Model Range, and temperature

rise, the furnace may be fired at an ideal rate for a wide

range of structures.

Table 6: Nozzles (Beckett Oil Burner)

NOZZLE (Delavan)

HEAD

MODEL

STD.

ALT.

80F (060)

80F (070)

80F (080)

120F (090)

120F (100)

120F (120)

0.50/70°W

0.65/70°W

0.70/70°W

0.75/70°W

0.80/70°W

1.00/70°W

0.50/80°A

0.65/80°A

0.70/80°A

0.75/80°A

0.80/80°A

1.00/80°A

- - -

Riello Oil Burners

Single-Pipe

⅜” O.D. ½” O.D. ⅜” O.D.

Two-Pipe

Lift

(feet)

½” O.D.

Tubing

330

295

230

100

Tubing

130

195

- - -

Tubing

130

260

325

- - -

Tubing

100

15. COMBUSTION CHAMBER

1.5

3.0

5.0

6.5

9.5

This furnace is equipped with an efficient cerafelt

combustion chamber. It is held in place by a retaining

bracket.

- - -

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

build-up throughout the heat exchanger passages.

Excess combustion air causes a bright roaring fire and

high stack temperatures resulting in poor fuel efficiency.

CHECK THE ALIGNMENT OF THE COMBUSTION

CHAMBER AND OIL BURNER BEFORE FIRING. IT

IS POSSIBLE FOR THE COMBUSTION CHAMBER

TO SHIFT IF SUBJECTED TO ROUGH HANDLING

DURING TRANSIT.

PREPARATIONS:

Drill a ¼” test port in the venting, ideally at least 2 flue

pipe diameters away from the furnace breeching, if

venting horizontally from the furnace, or from the flue

pipe elbow if venting vertically before reaching the

furnace. (see Figures 5 and 6).

The cerafelt combustion chamber is quite soft initially.

After firing, it becomes very brittle. Be sure to do all

alignment and positioning adjustments before the first

firing.

The test port will allow flue gas samples to be taken and

stack temperatures to be measured.

The combustion chamber should be inspected for

damage or carbon build up whenever the oil burner is

removed for repairs or routine maintenance.

Before starting the burner, check the burner alignment

with the combustion chamber (fire pot), check that the

correct nozzle is tightened into place, and that the burner

electrodes are properly positioned. The Beckett burner

bulk air band is should be closed, and the air shutter

initial setting should be approximately 7.00.

BEFORE OPERATING THE FURNACE CHECK

BURNER

ALIGNMENT

WITH

COMBUSTION

Refer to Table A-2, page 18, for Riello oil burner air

damper and turbulator settings.

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

AND AMULET POSITION (RIELLO BURNER) AS

NECESSARY BEFORE FIRST FIRING.

Figure 5:

Test port location for smoke test

horizontal.

16. BURNER ELECTRODES

Correct positioning of the electrode tips with respect to

each other, to the fuel oil nozzle, and to the rest of the

burners is essential for smooth light ups and proper

operation.

Beckett Oil Burner:

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.

Riello Oil Burner:

The electrode tips should be adjusted to a gap of 5/32”,

3/32” ahead of the nozzle, 13/64” above the centerline of

the nozzle.

The electrode porcelains should be free of cracks, the

electrode tips should be tapered and free of burrs, and

the contact rods must be clean and be in firm contact

with the ignition transformer contact springs. The

electrodes must not come into contact with the burner

head.

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.

17. OIL BURNER SET UP

The burner air supply is adjusted to maintain the fuel to

air ratio to obtain ideal combustion conditions. A lack of

air causes "soft" and "sooty" flames, resulting in soot

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Check the oil pump pressure. Refer to Table A1, page

18, for pump pressure settings.

Figure 6: Test port location for smoke test vertical.

After reaching steady state, take a smoke test. If not

indicating a trace, set the combustion air controls to

provide a trace.

Typically, the CO2 reading will range between 11.5% to

13.5%.

After the air adjustments have been completed, and the

air shutter or air adjustment plate has been secured, take

another smoke test to ensure that the values have not

changed.

NOTE: Riello Oil Burners - When taking final test

readings be sure that the burner cover is in place.

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.

PROCEDURE:

Start the burner and allow it to run at least ten minutes.

Set the air shutter to give a good flame visually. On

Beckett burners, the combustion air supply to the burner

is controlled by manipulating the air shutter on the left

side of the burner, and, if necessary, the bulk air band.

To adjust, loosen the bolt on the movable shutter. Move

the shutter gradually until a good flame (visually) has

been achieved. Re-snug the bolt.

STACK TEMPERATURE:

Stack temperature will vary depending on fuel input,

circulating air blower speed, and burner set up, etc. In

general, stack temperature should typically range

between 380°F to 550°F, assuming that the combustion

air is approximately room temperature (65°F - 70°F). In

general, lower stack temperature indicates greater

efficiency; however, excessively low stack temperature

can lead to condensation forming in the chimney and / or

venting. Sulphur and similar contaminants in the fuel oil

will mix with condensation to form acids. Acids and

resultant chemical salts will cause rapid deterioration of

the chimney and venting components, and may attack

the furnace.

Refer to the Riello Oil Burner Manual for setting the air

adjustment plate.

Figure 7: Checking Over-Fire Draft.

If the flue gases are below the range, it may be

necessary to slow down the blower fan. If the flue gases

are above the range, the blower fan may require

speeding up. Stack temperature varies directly with the

system temperature rise. System temperature rise is the

difference between the furnace outlet temperature and

furnace inlet temperature as measured in the vicinity of

the connection between the plenum take-offs and the

trunk ducts. Typical temperature rise values range

between 60° and 90°F for the Model 80F, 55°F and 85°F

for the Model 120F.

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.

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.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

DO NOT CONNECT POWER LEADS BETWEEN

MOTOR SPEEDS. THE NEUTRAL WIRE MUST

ALWAYS BE CONNECTED TO THE MOTOR'S

DESIGNATED NEUTRAL TERMINAL.

IF THE FURNACE FAILS TO IGNITE, CHECK THE

OIL TANK FUEL GAUGE. IF THE FUEL GAUGE

SHOWS THAT OIL IS PRESENT, PRESS THE

RESET BUTTON ONCE ONLY. IF THE BURNER

FAILS TO IGNITE, CONTACT YOUR SERVICE

CONTRACTOR.

It is possible and acceptable to use a single blower speed

for both heating and cooling modes. The simplest

method to connect the wiring from both modes is to use a

"piggy-back connector" accommodating both wires on a

single motor tap. It is also acceptable to connect the

selected motor speed with a pigtail joined to both heating

and cooling speed wires with a wire nut. As a safety

precaution against accidental disconnection of the wires

by vibration, it is advisable to secure the wire nut and

wires with a few wraps of electricians tape.

ALL FURNACE CONTROLS ARE SENSITIVE AND

SHOULD NOT BE SUBJECTED TO TAMPERING. IF

PROBLEMS PERSIST, CALL YOUR SERVICE

CONTRACTOR.

If the joining of the blower speed wiring is done in the

furnace junction box, tape off both ends of the unused

wire.

BELT DRIVE

18. CIRCULATING AIR BLOWER

The HO-B Models are available with an optional belt drive

blower assembly. Belt drive blower systems can be

modified for a variety of speeds and air delivery by

adjusting the variable speed motor pulley, and / or by

changing the blower pulley.

DIRECT DRIVE

The HO-B furnaces may be equipped with a direct drive

blower system. Direct drive blower speed adjustments

are not normally required in properly sized extended

plenum duct systems. The motor RPM and air CFM

delivery will vary automatically to accommodate

conditions within the usual range of external static

pressures typical of residential duct systems. Under-sized

duct systems may require a higher blower speed to

obtain a reasonable system temperature rise. Some older

duct systems were not designed to provide static

pressure. They typically feature special reducing fittings

at each branch run and lack block ends on the trunk

ducts. These systems may require modification to

provide some resistance to the airflow to prevent over-

amping of the direct drive blower motor. Selecting a lower

blower speed may correct this problem.

The variable speed motor pulley may be adjusted by

loosening the 5/32 Allen set screw in the outer sheave,

and turning the outer sheave clockwise to increase

blower speed; counter clockwise to reduce blower speed.

Ensure that the setscrew is tightened at one of the "flat

spots", failure to do so will convert the variable speed

pulley to a fixed speed pulley by ruining the threads.

Changing the blower pulley can also modify the blower

speed. A smaller blower pulley will cause the blower to

turn faster; a larger pulley will reduce blower speed.

Large increases in blower speed will increase power

requirements. Check the amperage draw of the blower

motor after changes have been made. If the amperage

draw is greater than the value listed on the motor rating

plate, replace with a motor with a higher horsepower

rating.

Direct drive blower speeds are adjusted by changing the

"hot" wires to the motor winding connections. Please

refer to wiring diagram in Appendix B or the wiring The fan belt tension is very important. There should be a

deflection of between ¾ of an inch to 1 inch. Less

deflection places a strain on the blower bearings, and

increases start up amperage draw. More deflection

allows excess slippage and causes premature motor

pulley wear. Automotive belt dressings are not

recommended. A hard soap such as Sunlight^®soap will

work well as a belt dressing, for the purpose of reducing

belt squeaks, etc. If used, the soap should be applied to

the sides of the belt only.

diagram label affixed to the furnace. THE NEUTRAL

WIRE (normally the white wire) IS NEVER MOVED TO

ADJUST THE BLOWER SPEED.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

THE BELT DRIVE COMPONENTS OPERATE AT

HIGH SPEEDS AND CAN EASILY SNAG LOOSE

CLOTHING, CAUSING SERIOUS PERSONAL

INJURY. THIS PROCEDURE SHOULD BE LEFT TO

TRAINED SERVICE PERSONNEL.

If the blower RPM operates above 1000 RPM, it is

advisable to replace the sintered bronze blower bearings

with roller Bearings.

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 ST9103 EFT

The circulating fan start-up is delayed 30 or 45 seconds

(depending on EFT) in the heating mode.

The circulating fan start-up is delayed 30 seconds in the

cooling mode. The “fan off” is delayed 30 seconds in the

cooling mode.

The “fan off” delay may be field adjusted by manipulating

the dipswitches. See Figures 8.

DO NOT START THE BURNER OR BLOWER FAN

UNLESS THE BLOWER ACCESS DOOR IS

SECURELY IN PLACE.

Figure 8: Heating Mode “Blower Off” Timings, ST9103

Additional ST9103 Fan Timer Control information is in

Appendix A, Tables, and in Appendix B, Wiring

Diagrams.

19. MAINTENANCE AND SERVICE

A: Routine Maintenance By Home Owner

Other than remembering to arrange for the annual

professional servicing of the furnace by the service or

installation contractor, the most important routine service

performed by the homeowner is to maintain the air filter

or filters. A dirty filter can cause the furnace to over-heat,

fail to maintain indoor temperature during cold weather,

increase fuel consumption and cause component failure.

The furnace filter(s) should be inspected, cleaned or

replaced monthly. The furnace is factory equipped with a

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.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

A) The oil burner must be set up following the

procedures outlined in section 17: Oil Burner Set Up.

B: Annual Service By Contractor

B) The 80F should operate within a temperature rise of

60°F to 90°F, the 120F; 55°F to 85°F. To determine the

temperature rise, measure the supply air and return air

temperatures when the furnace has reached steady state

conditions. This is the point at which the supply air

temperature stops increasing relative to the return air

temperature. The furnace may have to run 10 to 15

minutes to reach steady state conditions. The

measurements may be made with duct thermometers or

thermocouples used in conjunction with multi-meters with

temperature measurement capabilities.

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 covers on the inner

radiator access pipes located on the front panel between

the oil burner and the flue pipe.

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.

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.

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.

Most circulating fan motors are permanently lubricated by

the motor manufacturer. These motors will have no oil

ports. If the blower motor does contain oil ports, under

normal operating conditions it will not require oiling for the

first two years. Oil sparingly; a few drops in each oil port

with SAE 20 non-detergent oil. Oiling is most easily done

with a "tele-spout" oiler. This oilier has a long flexible

plastic spout. DO NOT OVER-LUBRICATE. Excess oil

may result in premature electric motor failure.

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, or on

belt drive equipped units, by adjusting the variable speed

motor pulley or by blower pulley changes. If the

temperature rise is too high, speed the fan up. If the

temperature rise is too low, slow the fan down.

Inspect the blower fan. Clean it if necessary.

Oil Burner Maintenance: Follow the instructions of the oil

burner manufacturer. (See oil burner manufacturer's

instructions supplied with furnace). The oil burner nozzle

should be replaced annually. We recommend that the oil

filter be changed on an annual basis.

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.

The venting system should be cleaned and inspected for

signs of deterioration. Replace pitted or perforated vent

pipe and fittings. The barometric damper should open

and close freely.

All electrical connections should be checked to ensure

tight connections. Safety controls such as the high limit

controls should be tested for functionality. The fan control

functions should be checked to ensure that all fan speeds

are operating properly.

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.

On furnaces equipped with belt drive blowers, the fan belt

may be temporarily removed. 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

20. FURNACE INSTALLATION SET UP

The furnace must be set up as the final step in the

installation.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

motor wiring, or replace the fan belt. Finally, restore The air circulation blower will continue to run for 60, 90,

power to the furnace.

120 or 150 seconds after the oil burner has stopped,

depending on the dip switch settings.

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.

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.

F) Be sure that the homeowner is familiar with the

furnace. The homeowner should be aware of the location

of electrical circuit breaker or fuse, the location of any

electrical switches controlling the furnace, the location of

the oil tank shut-off valve and how to operate the valve.

The homeowner should know where the oil tank gauge is

located and how to read it.

DO NOT ATTEMPT TO START THE BURNER WHEN

EXCESS OIL HAS ACCUMULATED, WHEN THE

FURNACE IS FULL OF VAPOUR, OR WHEN THE

COMBUSTION CHAMBER IS VERY HOT. NEVER

BURN GARBAGE OR PAPER IN THE FURNACE, AND

NEVER LEAVE PAPER OR RAGS AROUND THE UNIT.

It would be beneficial to review safety issues with the

home owner, such as the danger of storing combustibles

too close to the furnace, hanging anything on the furnace

vent pipe, and especially the dangers of indiscriminately

pressing the burner reset button.

IMPORTANT: Be sure that the home owner knows where

the burner reset switch is located, and is aware that the

reset switch is not to be activated more than once without

a look for the cause of the problem, (lack of fuel, etc.). Be

sure that the homeowner knows when to quit trying to

start the furnace during these conditions and who to call

for emergency service.

21. OPERATING INSTRUCTIONS

Before Lighting

Open all supply and return air registers and grilles.

Open all valves in oil pipes.

Turn on electric power supply.

To Light Unit

Set the thermostat above room temperature to call for

heat. The burner will start. NOTE: If the furnace has been

off for an extended period of time, it may be necessary to

press the RESET button on the primary combustion

control relay, (once only). If pressing the reset button

does not start the furnace, refer to Appendix C,

Troubleshooting.

After 30 or 45 seconds (depending on EFT), as the

furnace becomes warm, circulation fan will start.

The furnace will continue to run until the thermostat call

for heat is satisfied.

Set the thermostat below room temperature. The oil

burner will stop.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Appendix A

HO-B DATA

TABLE A-1 BECKETT AFG OIL BURNER SET-UP

BECKETT AFG SERIES OIL BURNERS

FURNACE

MODEL

OUTPUT

BTU/Hr

58,100 ^{1, 2}

68,000 ²

78,900 ²

BURNER

MODEL

PUMP

PRESSURE

FLOW

RATE

STATIC

NOZZLE

HEAD

PLATE

3-3/8 in.

80F (060)

80F (070)

80F (080)

AF76BO

AF76BN

0.50 / 70° W

0.65 / 70° W

0.70 / 70° W

100 PSIG

0.50 GPH

0.65 GPH

0.70 GPH

120F (090)

120F (100)

120F (120)

87,700 ²

98,800

AF76BZHS

0.75 / 70° W

0.85 / 70° W

1.00 / 70° W

100 PSIG

0.75 GPH

0.85 GPH

1.00 GPH

3-3/8 in.

113,400

¹F0 Head required for proper combustion. ²Low Firing Rate Baffle required, Beckett Part No. 3708

In the United States, the R. W. Beckett “AFG” Burner may be equipped with Beckett’s “Inlet Air Shut-Off”, Beckett Part No. AF/A 5861, to increase efficiency. It

reduces the amount of air passing through the oil burner, combustion chamber, breeching, etc. up the chimney between burner cycles.

NOTE: THE USE OF THIS CONTROL CAN OCCASIONALLY CAUSE POST COMBUSTION NOZZLE DRIP.

TABLE A-2 RIELLO 40F OIL BURNER SET-UP

RIELLO 40 F SERIES OIL BURNERS

FURNACE

MODEL

OUTPUT

BTU/Hr

58,000

73,000

79,000

BURNER

MODEL

40 F3

PUMP

PRESSURE

160 PSIG

150 PSIG

145 PSIG

FLOW

RATE

STATIC

PLATE

2.25

NOZZLE

HEAD

80F (060)

80F (070)

80F (080)

0.40 / 60° W

0.50 / 60° W

0.60 / 60° W

0.50 GPH

0.60 GPH

0.70 GPH

1.5

2.0

40 F3

2.5

40 F3

3.0

120F (090)

120F (100)

120F (120)

87,000

100,000

118,000

40 F3

0.75 / 70° W

0.85 / 70° W

1.00 / 70° W

150 PSIG

160 PSIG

0.75 GPH

0.85 GPH

0.95 GPH

2.0

2.5

3.0

3.52

4.0

6.0

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE A-3 DIRECT DRIVE BLOWER SET-UP

BLOWER SET-UP

COOLING CAPACITY

FURNACE

MODEL

MOTOR

BLOWER

G10 DD

0.20 in. w.c.

Speed

0.50 in w.c.

Speed

Htg. CFM

Range ¹

MOTOR

Clg. CFM

Tons ²

Range

80F (060)

80F (070)

80F (080)

120F (090)

120F (100)

120F (120)

120F (090)

120F (100)

120F (120)

Low

Med - Low

Med - High

High

629 - 972

900 - 1150

Med - Low

Med - High

Med - Low

Med - High

High

792 - 1223

857 - 1324

976 - 1508

1084 - 1676

1279 - 1977

1106 - 1843

1229 - 2048

1450 - 2417

Med - High

High

G10 DD

800 - 1300

High

Low

G12-10 DD

1400 - 1870

Med - Low

Med - High

High

⁽¹⁾Heating Range values based on temperature rise. Upper values may exceed measured airflow values in Table A-3.

⁽²⁾Nominal Values Only

TABLE A-4 DIRECT DRIVE BLOWER CHARACTERISTICS

Temp.

Rise

(ꢀT)

CFM

External Static Pressure - inches w.c.

Furnace

Model

Motor

FLA

Blower

Speed

0.20

0.30

0.40

0.50

0.60

0.70

High

Med-High

Med-Low

Low

1368

1318

1173

856

1298

1256

1132

833

1223

1178

1071

791

1144

1108

993

1046

1007

909

938

909

816

610

80F

120F

G10 DD

60° - 90°F

55° - 85°F

45° - 75°F

7.7

748

692

High

Med-High

Med-Low

Low

1604

1507

1172

810

1527

1425

1146

771

1446

1338

1119

731

1360

1270

1064

690

1245

1171

977

1092

1035

879

G10 DD

7.7

645

597

High

Med-High

Med-Low

Low

1957

1764

1677

1446

1911

1730

1658

1446

1846

1695

1603

1446

1797

1640

1565

1404

1729

1584

1506

1315

1658

1526

1424

1245

GT12-10 DD

12.5

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE A-5 BELT DRIVE BLOWER SET-UP

Model

HO-B

Blower Set-Up

Cooling Capacity

Tons CFM Range

Motor

0.20 in. w.c.

Pulley

0.50 in. w.c.

Blower

Fan Belt

Pulley

Motor

Bonnet Output

(BTUH)

Blower

Motor

Turns Out

Blower

Turns Out

80 (60,000)

80 (70,000)

80 (80,000)

G10

4L360

5 x ¾

3¼ x ½

5 x ¾

3¼ x ½

1000 - 1300

1000 - 1500

120 (90,000)

120 (100,000)

120 (120,000)

5 x ¾

TABLE A-6 BELT DRIVE BLOWER CHARACTERISTICS

Temp.

Rise

(ꢀT)

CFM

Motor

Pulley

Turns Out

Furnace

Model

Motor

FLA

Blower

External Static Pressure - inches w.c.

0.20

0.30

0.40

0.50

0.60

0.70

1596

1505

1567

1429

1518

1434

1453

1332

1435

1347

1291

1180

1330

1220

1125

1064

1247

1081

996

1184

993

817

558

80F

G10

60° - 90°F

55° - 85°F

5.8

818

1832

1694

1566

1383

1747

1603

1467

1270

1658

1507

1339

1120

1546

1382

1196

1006

1446

1245

1064

771

1338

1119

880

120F

G10

545

TIP:

These formulae will assist with the design of the ductwork and the determination of airflow delivery:

Bonnet Output

1.085x SystemTemperature Rise

Bonnet Output

CFM ꢀ

SystemTemperature Riseꢀ

1.085xCFM

ꢀ

ꢁ

ꢀ

ꢁ

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

GENERAL DIMENSIONS

Table A-6: General Dimensions (inches)

Plenum Openings

Flue

Ship

Weight

(lb)

Cabinet

Filter

Supply Air

Return Air

(Perm.)

Width

Depth

Height

Side

Height

Bottom

Dia.

D x E

F x G

80F

14 x 22

120F

14 x 22

49-½

20½ x 20

14 x 22

16 x 25 x 1

190

270

58-⅛

46-½

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Appendix B

WIRING

WIRING DIAGRAM: OIL FURNACE WITH ST9103 EFT & R7184 CONTROL

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Appendix B

WIRING

WIRING DIAGRAM: OIL FURNACE WITH ST9103 EFT & RIELLO OIL BURNER

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

WIRING NOTES:

NOTE: It is seldom advisable to operate an electronic air

cleaner at the continuous low speed because of the

potential for excess ozone generation.

HO-B SERIES OIL FURNACE

CONTINUOUS FAN OPERATION:

The HUM terminals provide power to a line voltage

humidifier or humidifier step down transformer when the

oil burner motor is operating.

The ST9103 EFT has provisions to run the blower motor

continuously on a speed lower than the cooling or heating

speeds. On a call for cooling, the fan motor will switch to

cooling speed, and on a call for heating, the fan will

switch to heating speed, each over-riding the continuous

low speed fan.

THERMOSTAT HEATING CONNECTIONS:

The thermostat connections “R” and “W”, or “RH” and

“W” connect to the “R” and “W” screw terminals shown

on the left hand side of Figure 10, on the ST9103 EFT

located in the control box mounted to the blower

mounting rails.

To obtain continuous low speed fan, route a 16 gauge

stranded, type TEW, 105°C wire from the CONT Terminal

on the ST9103 EFT to the low speed or medium low

speed motor terminal. Both wire ends will require ¼ inch

quick connects, (also known as “Faston” connectors or

¼” spade connectors). For additional control over the

continuous low speed fan circuit, a SPST toggle switch

may be wired in series between the motor terminal and

the ST9103 terminal. The continuous low speed fan

operation operates at 115 vac. Use appropriate wiring

methods to prevent electrical shock.

Figure 9: Thermostat Connections ST9103

TURN OFF ELECTRICAL POWER TO THE

FURNACE WHEN SERVICING OR ALTERING

FURNACE WIRING.

FAILURE TO DO SO MAY RESULT IN SEVERE

PERSONAL INJURY, PROPERTY DAMAGE OR

DEATH.

NOTE: All thermostat wires for both heating and cooling

connect to the furnace at this point. A factory installed

wiring harness connects the heating control functions to

the R7184 oil primary control.

ACCESSORIES:

The ST9103 EFT has provisions for supplying 115 volt

power to an electronic air cleaner (EAC) as well as 115

volts to a line voltage humidifier or humidifier step down

transformer. Both sets of terminals are ¼ inch quick

connect type, rated at 1 A each.

Figure 8, page 14, shows the detail of the timed “Blower

Off” dipswitch settings. Figure 10 shows the dipswitch

location along the bottom edge of the control board, just

above the “Honeywell” label.

The EAC terminals provide power to an electronic air

cleaner whenever the heating or cooling speeds are

activated. Power is not provided when the continuous

speed is activated. If the electronic air cleaner must run

during continuous low speed fan operation, wire the EAC

into the furnace L1 terminal.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Appendix C

TROUBLESHOOTING

R7184 DETAILED SEQUENCE OF OPERATION

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 heat:

A. Safety check is made for flame (4 second delay).

1. When flame is not present, the R7184 will apply power to the burner motor and igniter.

2. When flame is present, the control remains in the idle state.

B. Unit enters and completes a pre-purge period of 15 seconds, then applies power to the solenoid valve.

C. Control enters the trial for ignition state.

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.

c. Starts carryover timer.

Flame and call for heat are monitored.

Sꢀ If flame is lost and lockout timer has not expired, R7184 will return to trial for ignition state.

Sꢀ If flame is lost and lockout timer has expired, R7184 will enter the recycle state.

Dꢀ Recycle timer starts.

Dꢀ Burner motor and igniter and solenoid valve are turned off.

Dꢀ LED diagnostic light flashes slow.

Dꢀ Returns to idle state when recycle timer expires (60 seconds).

E. Carryover timer expires.

Enters run state.

Sꢀ Igniter turns off.

Combustion continues until thermostat is satisfied, or R7184 detects a loss of flame and enters into Recycle Mode.

Thermostat is satisfied - call for heat is terminated:

Sꢀ

R7184 shuts off burner motor and solenoid valve.

LED diagnostic light is off.

Sꢀ

R7184 returns to idle state.

Please see flow chart on page 26.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

IDLE STATE

R7184

SEQUENCE of

OPERATION

THERMOSTAT CALLS FOR HEAT

SAFETY CHECK FOR FLAME (5 SEC.)

NO FLAME

FLAME

REMAINS IN IDLE STATE

BURNER MOTOR & IGNITOR START

15 SEC.

SOLENOID VALVE OPENS

LOCKOUT STATE

TRIAL FOR IGNITION

R7184:

Sꢀ Shuts off burner motor

Sꢀ Shuts off igniter

Sꢀ Shuts off Solenoid Valve

Sꢀ Fast Flashes LED Diagnostic

Light

BURNER FLAME MONITORED

FLAME

NO FLAME

CARRYOVER STATE

Sꢀ Provides continuous spark

Sꢀ LED diagnostic light ON

TO EXIT LOCKOUT

PRESS RESET

Sꢀ Start Carryover Timer

FLAME LOST

FLAME

CARRYOVER TIMER EXPIRES

FLAME

RECYCLE TIMER STARTS

RUN STATE

Sꢀ Ignitor turns off.

FLAME LOST

R7184:

Sꢀ Shuts off Solenoid Valve

Sꢀ Shuts off Ignitor

Sꢀ Shuts off Burner Motor

Sꢀ Slow Flashes LED

diagnostic light

THERMOSTAT SATISFIED

R7184 SHUTS OFF:

Sꢀ Burner Motor

Sꢀ Solenoid Valve

Sꢀ LED Diagnostic Light

RECYCLE TIMER EXPIRES

(60 SECONDS

RETURNS TO IDLE STATE

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

RIELLO 40F3 TROUBLESHOOTING CHART

Thermostat is calling for heat, burner is not running.

Reset control box.

Burner Starts

Burner Does Not Start

Test for 120 Vac Supply at sub-base between L and N or terminals #3 and #5.

120 Vac

No Voltage

Turn off power supply. Remove control

box and jumper terminals #5 and #6.

Restore power.

Sꢀ Check system fuse, ensure service switch is ON.

Sꢀ Verify that all control limits are closed.

Sꢀ Verify 24 Vac at T-T on switching relay.

Motor Runs

Motor Does Not Run.

Sꢀ Verify reduced voltage (42 – 52 Vac

between terminals #3 and #7.

Sꢀ Ensure good contact between control box

spades and sub-base terminals.

Sꢀ Verify electrical connections.

Sꢀ Check for seized pump, motor, or fan

against housing.

Sꢀ Defective motor capacitor.

Sꢀ Thermal Overload (Hot motor).

Sꢀ Defective control box / Replace.

Burner stays in Pre-purge

Sꢀ Faulty CAD cell or seeing light before trial for ignition.

Sꢀ Coil wires on terminals #1 and #2 or #1 and #8 reversed.

Sꢀ Open coil circuit; terminals #2 and #8.

Sꢀ Open coil circuit; terminal #1

Sꢀ Defective 42 – 52 Vac supply, terminals #3 and #7.

Sꢀ Defective control box / Replace.

Burner Continues to Purge and Light-off with Immediate Flame Drop-out

Sꢀ Metal yoke for coil missing.

Sꢀ Coil wire #2 and #8 reversed.

Sꢀ Low resistance of coil holding circuit, terminals #1 and #2,

(1350 ohms ± 10%).

Burner Locks Out After Trial For Ignition

Continued on next page.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Burner Locks Out After Trial For Ignition

Sꢀ Low resistance or no contact on starting circuit of coil,

terminals #2 and #8. (1.3 ohm ± %).

Sꢀ No oil supply – tank empty, valve closed, dirty filter,

damaged supply lines.

Sꢀ Defective or dirty oil valve stem, nozzle, or pump strainer.

Sꢀ Broken pump drive key, defective pump, no oil pressure.

Sꢀ Ignition electrodes shorted, cracked porcelain.

Sꢀ Burner motor not up to speed.

Sꢀ Excessive draft over fire.

Sꢀ Defective control box / Replace.

Riello Oil Burner Automatic Air Shutter.

Riello Oil Burner Electronic Ignition Control.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE C-1: ST9103 DETAILED SEQUENCE OF OPERATION

Mode

Action

System Response

a. ST9103 closes oil primary control T - T connections).

b. Ignition system and R7184 oil primary control start the furnace.

Oil flows as long as the oil primary control senses flame.

Thermostat calls for heat.

("W" terminal is energized).

HEAT

c. Burner motor is energized and heat "fan on" delay timing

begins. When timing is complete (30 seconds), the circulator

fan is energized at heat speed.

a. R7184 oil primary control is de-energized, terminating the

burner cycle.

b. Heat "fan off" delay timing begins. Length of delay depends on

ST9103 dip switch settings. When timing is complete, the

circulator fan is de-energized.

Thermostat ends call for heat.

("W" terminal is de-

energized).

c. ST9103 returns to standby mode, (Oil primary 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).

b. Burner motor is de-energized. (even though thermostat is still

calling for heat).

Burner fails to light.

c. If 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 trial for ignition.

Thermostat begins call for

cool. (G and Y terminals are

energized).

a. Cooling contactor is energized immediately.

b. Circulator fan is energized at cool speed.

COOL

Thermostat ends call for cool.

(G and Y terminals are de-

energized).

a. Cooling contactor is de-energized immediately.

b. Circulator fan turns off immediately.

Thermostat begins call for

fan. (G terminal is energized).

a. Circulator fan is energized immediately at cooling speed.

a. Circulator fan is de-energized immediately.

FAN

Thermostat ends call for fan.

(G terminal is de-energized).

a. Oil primary control shuts off burner.

b. Circulator fan is energized immediately at heat speed.

c. ST9103 opens oil primary control T - T connections.

LIMIT

Limit switch string opens.

Continued on following page.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Continued from last page

Mode

Action

System Response

d. Circulating fan runs as long as limit string stays open.

Limit switch string opens.

(continued)

If there is a call for cooling or fan, the circulating fan switches from

heating to cooling speed.

a. ST9103 begins heat “fan off” delay sequence.

LIMIT

b. Circulating fan turns off after the selected heat “fan off” timing.

c. ST9103 re-closes oil primary control T - T connections.

d. Oil primary control is energized, initiating burner light-off.

Limit switch string closes

(with existing call for heat).

a. Circulator fan turns off when heat “fan off” delay time is

complete.

Limit switch string closes

(without existing call for heat).

b. Normal operation resumes; ST9103 control is in standby mode

awaiting next thermostat command.

a. Circulating fan is energized when there is no call for heat, cool,

or fan.

Continuous circulating fan is

connected.

FAN

b. If fan operation is required by a call for heat, cool, or fan, the

ST9103 switches off the continuous fan speed tap before

energizing the other fan speed.

Sꢀ Electronic air cleaner (EAC) connections are energized when

the heat or cool speed of the circulator fan is energized. EAC

connections are not energized when the optional continuous

fan terminal is energized.

Electronic Air Cleaner is

connected.

EAC

Sꢀ Humidifier connections are energized when the oil burner

HUM

Humidity control is connected.

motor is energized.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

R7184 LED DIAGNOSTIC LIGHT

Troubleshooting

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.

IMPORTANT:

Due to the potential hazard of line voltage,

only a trained, experienced service

technician should perform the

troubleshooting procedure.

NORMAL CONDITIONS:

PRELIMINARY STEPS:

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.

Check the diagnostic light for indications of burner

condition. Refer to R7184 LED DIAGNOSTIC LIGHT

section for details.

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:

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

anticipator of a standard 24 VAC thermostat, or cause

If the LED diagnostic light is flashing quickly; 1 Hz (½

second on / ½ second off), the R7184 is in the lockout

state or in restricted mode. To exit the lockout state,

press the reset button.

harm to components within

thermostat.

micro-electronic

If the LED diagnostic light is flashing slowly; ¼ Hz (2

seconds on / 2 seconds off), the R7184 is in the

recycle state. This indicates that flame sensing was

lost after the lockout timer expired during the ignition

carryover state. The R7184 will return to the idle state

within 60 seconds.

Before checking the oil primary control, perform these

preliminary checks, (repair or replace controls as

necessary):

CAD CELL CONDITION:

If the LED diagnostic light is off, the cad cell is not

sensing flame.

Sꢀ check the power supply; fuse box or breaker, any

service switches, all wiring connections, and

burner motor reset button (if equipped).

Sꢀ check the limit switches to ensure that the switch

If the LED diagnostic light is on, the cad cell is sensing

flame, or viewing ambient light.

contacts are closed.

Sꢀ check the electrode gap and position.

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 light will flash the following

code:

Sꢀ check the contacts between the oil primary control

and the electrodes.

Sꢀ check oil supply (tank gauge).

TABLE C-2: CAD CELL RESISTANCE

Sꢀ check the oil nozzle, oil filter, and oil valves.

Sꢀ check the piping or tubing to the oil tank.

Sꢀ check the oil pump pressure.

Flashes

Resistance in Ohms

Less than 400

Between 400 - 800

Between 800 – 1600

Between 1600 - 5000

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

CHECK OIL PRIMARY CONTROL AND IGNITOR

If the trouble does not appear to be in the burner or

ignition hardware, check the oil primary control and the

ignitor by using the following equipment:

Electrical Shock Hazard.

ꢁꢀ screwdriver.

Troubleshooting is done with the system powered. Be

careful to observe all necessary precautions to prevent

electrical shock or equipment damage.

ꢁꢀ voltmeter (0 - 150 VAC)

ꢁꢀ insulated jumper wires with both ends stripped.

Preliminary Checks:

1. Make sure that limit switches are closed and that

contacts are clean.

2. Check for line voltage power on the oil primary

control black and white lead wires.

3. Refer to Table C-4 or C-5 for further

troubleshooting information.

TABLE C-3: R7184 TROUBLESHOOTING

Condition: Burner motor does not start when there is a call for heat.

Procedure

Status

Corrective Action

1. Check that limit switches

are closed and contacts

are clean. This includes

the burner motor reset

button.

N/A

2. Check for line voltage

power at the oil primary

control. Voltage should

be 120 Vac between the

black and white lead

wires on the oil primary

control.

N/A

Cad cell is defective, sees external light, or

connections have shorted. Go to step 4.

3. Check indicator light with

burner off, no call for heat

(no flame).

Indicator light is on.

Indicator light is off.

Indicator light turns off.

Go to step 5.

Eliminate external light source or permanently

shield cad cell.

Sꢀ Replace cad cell with new cad cell and

recheck.

4. Shield cad cell from

external light.

Sꢀ If indicator light does not turn off, remove

yellow leadwires from R7184 and recheck.

Indicator light stays on.

Sꢀ If indicator light is still on, replace the R7184

control.

Sꢀ If the indicator light turns off, replace cad cell

bracket assembly.

Sꢀ continued on following page

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Sꢀ Table C-3: R7184 Troubleshooting continued from previous page

Procedure

Status

Corrective Action

Trouble is in thermostat circuit. Check thermostat

wiring connections.

Burner starts.

If connections are clean and tight, check

thermostat wires for continuity.

5. Jumper thermostat (T -T)

terminals on R7184

Sꢀ Disconnect line voltage power and open line

switch.

Sꢀ Check all wiring connections.

IMPORTANT

Burner does not start.

Sꢀ Tighten any loose connections and recheck.

Sꢀ If burner still doesn't start, replace R7184

First remove one thermostat

lead wire.

If burner still doesn't start, check the oil burner

motor. It may be seized or burned out.

Condition: Burner starts then locks out on safety with indicator light flashing at 1 Hz rate (½ second

on, ½ second off)

Procedure

Status

Corrective Action

1. Check that the limit

switches are closed and

contacts are clean.

- - -

2. Check for line voltage

power at the oil primary

control. Voltage should be

120 vac (nominal)

- - -

Cad cell or controller is defective, sees external

light, or connections are shorted. Go to step 4.

3. Check indicator light with

burner off, no call for heat

(no flame).

Indicator light is on.

Indicator light is off.

Indicator light turns off.

Go to step 5.

Eliminate external light source or permanently

shield cad cell.

Sꢀ Replace cad cell with new cad cell and

recheck.

4. Shield cad cell from

external light.

Sꢀ If indicator light does not turn off, remove cad

cell leadwires from R7184 and recheck.

Indicator light stays on.

Sꢀ If indicator light turns off, replace cad cell

bracket assembly.

Sꢀ If indicator light does not turn off, replace

controller.

Continued on next page

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Table C-3: R7184 Troubleshooting continued from previous page

Procedure

Status

Burner starts.

Corrective Action

Trouble in thermostat or limit circuit. Check

thermostat or limit wiring connections.

5. Jumper thermostat (T -T)

terminals on R7184

Sꢀ Disconnect the line voltage power and open

line switch.

IMPORTANT

First remove one thermostat

lead wire.

Sꢀ Check all wiring connections.

Burner does not start.

Sꢀ Tighten any loose connections and recheck.

Sꢀ If burner does not start, replace R7184

Condition: Burner starts then locks out on safety with indicator light flashing at 1 hz rate (½ second on,

½ second off)

Indicator light stops

Go to Step 7.

6. Reset oil primary control

by pushing in and

releasing red reset

button.

flashing.

Verify that the control is not in restricted mode.

(See notes at end of this table.). If not in restricted

mode, replace R7184

Indicator light continues

to flash at 1 Hz rate.

Spark ignitor could be defective. Check for line

voltage at ignitor terminals. If line voltage is

present, replace R7484.

Ignition is off

Ignition is on.

7. Listen for spark after

burner turns on (after 2

second delay).

Go to Step 8.

Ignition is on but no oil is

being sprayed into the

combustion chamber.

Wait for “Valve ON” delay to complete. Check oil

supply, and oil line valve. Check for filter blockage

or seized oil pump.

Indicator light is on until

the control locks out and

starts flashing during

lockout.

8. Check indicator light after

flame is established, but

before oil primary control

locks out.

Replace R7184

Go to step 9.

Indicator light stays off.

Continued on next page

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Table C-3: R7184 Troubleshooting continued from previous page

Procedure

Status

Corrective Action

9. Check cad cell sighting

for view of flame.

Burner locks out.

Go to step 10.

Sꢀ Disconnect line

voltage power and

open line switch.

Sꢀ Unplug cad cell and

clean cad cell face

with soft cloth. Check

sighting for clear view

of flame. Replace cad

cell in socket.

Burner keeps running. System is OK.

Sꢀ Reconnect line

voltage power and

close line switch.

Sꢀ Start burner.

10. Check cad cell.

Indicator light is on.

Remount control onto burner housing. Go to step 6.

Sꢀ Disconnect line

voltage power and

open line switch.

Sꢀ Remove existing cad

cell and replace with

new cad cell.

Sꢀ Disconnect all wires

from thermostat

terminals to ensure

that there is no call

for heat.

Indicator light is off.

Go to step 11.

Sꢀ Reconnect line

voltage power and

close line switch.

Sꢀ Expose new cad cell

to bright light such as

a flashlight.

Continued on next page.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Table C-3: A Troubleshooting continued from previous page.

Procedure

Status

Corrective Action

11. Check cad cell bracket

assembly.

Indicator light is on.

Replace cad cell bracket assembly.

Sꢀ Disconnect line voltage

power and open line

switch.

Sꢀ Remove cad cell wires

from quick connect

connectors on the and

leave control leadwires

open.

Indicator light is off.

Replace R7184.

Sꢀ Apply power to device.

Sꢀ Place jumper across cad

cell terminals after burner

motor turns on.

NOTE: Restricted Mode - (Limited Reset): In order to limit the accumulation of unburned oil in the combustion chamber,

the control can be reset only 3 times, after which, the control locks out. The reset count returns to zero each time

a call for heat is successfully completed.

To reset from RESTRICTED MODE: press and hold the reset button for 30 seconds. When the LED flashes twice, the

device has reset.

NOTE: Disable function: Pressing and holding the reset button will disable all functions until the button is released. The

will restart at the beginning of the normal heat cycle on SAFETY CHECK.

TABLE C-4: SYSTEM AND GENERAL TROUBLESHOOTING

Problem

Possible Cause

Remedy

Check thermostat and adjust. Also, check thermostat for

accuracy; if it is a mercury switch type, it might be off

level.

Thermostat not calling for

heat.

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.

Thermostat faulty.

Remove thermostat wires from oil primary control

terminals T-T. Place a jumper across T-T. If furnace

starts, replace thermostat, thermostat sub-base (if

equipped), or both.

Furnace will not start.

Check reset button on oil primary control. Remove

thermostat wires from oil primary control terminals T1 -

T2. Check for 24v across T -T. If no voltage is present,

check for 115v to oil primary control. If 115v is present,

go to Table C-3.

Oil primary control faulty.

Photo Cell wiring shorted

or room light leaking into

photo cell compartment

Check photo cell (cad cell) wiring for short circuits. Also,

check for room light leaking into cad cell compartment.

Repair light leak if necessary. See Table C-3.

Check for open limit or auxiliary limit. Also, check internal

wiring connections; loose connectors, etc.

Open safety switch.

Continued on next page

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE C-4: SYSTEM & GENERAL TROUBLESHOOTING, continued from previous page

Problem

Possible Cause

Remedy

Check fuel oil supply. Check that all hand operated fuel

oil valves are in the open position. Fill oil storage tank if

necessary.

No fuel oil.

Replace nozzle with high quality replacement. Use rating

plate or Tables in Appendix A as a guide.

Clogged nozzle.

Clogged oil filter.

Furnace will not start

without first pushing

oil primary control

reset button.

Replace oil tank filter or in-line filter if used.

Connect pressure gauge to oil pump. Adjust pump

pressure, or replace oil pump if necessary. Ensure that

erratic pressure readings are not caused by defective

fuel oil line.

Low oil pump pressure.

(Happens on frequent

basis)

Air getting into fuel oil

lines, or fuel oil line dirty,

clogged, or in some

manner defective.

Check fuel oil lines. Replace any compression fittings

found with high quality flared fittings. Check for any signs

of oil leaks. Any oil leak is a potential source of air or

contaminants.

Check burner motor. If burner motor is cutting out on

over-load, determine why. Replace if necessary.

Defective burner motor.

If cad cell is dirty, clean it. (Determine why cad cell is

getting dirty). If cad cell is poorly aimed, realign it. NOTE:

The photocell should have a resistance of 100K ꢂ in

absence of light; a maximum of 1500 ꢂ in the presence

of light. Ensure that room light is not leaking into the cad

cell compartment. (see diagnostic light section).

Furnace starts, but

cuts out requiring

manually resetting

the oil protector reset

button.

Photo Cell (Cad Cell)

defective.

Check fuel oil supply. Check that all hand operated fuel

oil valves are in the open position. Fill oil storage tank if

necessary.

No fuel oil.

Replace nozzle with high quality replacement. Use rating

plate or Tables in Appendix A as a guide.

Clogged nozzle.

Clogged oil filter.

Replace oil tank filter or in-line filter if used.

Connect pressure gauge to oil pump. Adjust pump

pressure, or replace oil pump if necessary. Ensure that

erratic pressure readings are not caused by defective

fuel oil line.

Furnace starts, but

cuts out requiring

manually resetting

Low oil pump pressure.

Air getting into fuel oil

lines, or fuel oil line dirty,

clogged, or in some

manner defective.

Check fuel oil lines. Replace any compression fittings

found with high quality flared fittings. Check for any signs

of oil leaks. Any oil leak is a potential source of air or

contaminants.

the oil protector reset

button.

Check burner motor. If burner motor is cutting out on

over-load, determine why. Replace if necessary.

Defective burner motor.

Water or contaminants in

oil.

Drain fuel oil storage tank, replace fuel oil. (Consult with

fuel oil supplier).

Gently warm oil line. Insulate oil line. (Outdoor piping

size may require increased diameter).

Frozen oil line.

Continued on next page

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE C-4: SYSTEM & GENERAL TROUBLESHOOTING, continued from previous page

Problem

Possible Cause

Electrodes out of

Remedy

Check electrode settings. check electrodes for dirt build-

up or cracks in porcelain.

adjustment or defective.

Poor transformer high

voltage connections or

defective transformer.

Check contacts between the igniter and electrodes. If

OK, replace the igniter

Oil burner sputtering

at nozzle

Replace fuel oil storage tank filter and / or fuel oil in-line

filter.

Fuel oil filter clogged.

Defective oil pump.

Check burner motor / fuel oil pump coupling. Check oil

pump pressure. Replace fuel oil pump if necessary.

Fuel oil line partially

clogged or contains air.

Bleed air from oil line. If problem persists, replace oil

line.

System temperature rise ideally should not exceed 85°F.

Check for clogged air filters. Check blower fan for

excess dirt build-up or debris. Speed up blower fan if

necessary.

System temperature rise

too high.

Check “fan off” delay timing setting. Use a duct

thermometer in the supply air plenum take-off or first few

inches of the supply air trunk duct. Ideally, the fan will

shut off at a temperature of 90° - 100°F. Manipulate the

dip switch settings to come as close as possible to this

“fan off” temperature.

Poor “fan off” delay timing

selection, (fan stops too

soon).

Excessive fuel oil

consumption.

Check fuel oil line for leaks. Repair or replace if

necessary.

Fuel oil leak.

Check stack temperature. Stack temperatures will

normally range from 350° to 450°F. Check draft

regulator. Draft should be set to 0.02 in. w.c.

Stack temperature too

high.

Check thermostat heat anticipator setting against

measured amperage draw. Increase heat anticipator

setting if necessary. If the thermostat is being influenced

by drafts, sunlight, duct work, etc., relocate to more

suitable location.

Thermostat improperly

adjusted or in poor

location.

Insufficient combustion

air adjustment at oil

burner, or improper draft

pressure.

Adjust the oil burner combustion air band and draft

regulator to gain the highest practical CO₂or lowest

practical O₂content in the flue gases. See Burner Set

Up.

Too much smoke.

Heat exchanger partially

clogged.

Check for soot build-up in heat exchanger flue

passages, especially in the outer radiator.

Poor alignment between

oil burner blast tube and

fire pot.

Check alignment. blast tube should be centered with fire

pot burner opening. Oil burner head should be ¼ inch

back from the inside surface of the fire pot.

Soot building up on

blast tube (end

coning).

Flame impingement

caused by Incorrect

nozzle angle.

Check nozzle size and angle. (See Appendix A). Check

distance from head to inside surface of the fire pot.

Defective fire-pot

Check fire-pot. Repair or replace.

Continued on next page

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE C-4: SYSTEM & GENERAL TROUBLESHOOTING, continued from previous page

Problem

Possible Cause

Remedy

Clean or replace air filter.

Airflow blocked or dirty air

filter.

Check thermostat heat anticipator setting against

measured amperage draw. Increase heat anticipator

setting if necessary. If the thermostat is being influenced

by drafts, sunlight, duct work, etc., relocate to more

suitable location.

Thermostat adjustments

or location.

Check all dampers. Open closed dampers including

registers in unused rooms. Check system temperature

rise. If temperature rise is too high, speed up blower fan.

Insufficient airflow.

Furnace will not warm

home to desired

temperature.

Test high limit function of all limit switches. Use a duct

thermometer to assess accuracy of limit control. Check

for obstructions to airflow around limit switch bi-metal

elements. Replace control if necessary.

Defective high limit

control.

Check nozzle. If problem is not caused by air flow

problems, use larger nozzle, if permitted by rating plate.

Under-sized nozzle.

Blower fan motor

stopping intermittently on

overload.

Check blower fan motor amperage draw. Check motor

ventilation ports, clean if necessary. Replace motor if

necessary.

Burner motor stopping

intermittently on overload.

Check burner motor. Replace if necessary.

Home does not heat

evenly

Improper distribution of

heat.

This is not likely to be a furnace problem. Balance duct

system.

Airflow blocked or dirty air

filter.

Clean or replace air filter.

Supply air

Check all dampers. Open closed dampers including

registers in unused rooms. Check system temperature

rise. If temperature rise is too high, speed up blower fan.

temperature too hot.

Insufficient airflow.

Check system temperature rise. Slow down blower fan if

necessary.

Excess airflow.

Supply air

temperature too cool.

Check supply air ductwork. Seal leaky joints and seams.

Insulate ductwork if necessary.

Excessive duct losses.

Increase differential between fan control "fan off" and

"fan on" settings. (L4064B, L6064A fan / limit controls

only, no adjustments available for L4064W fan / limit

control). Register air deflectors may help.

Fan control "fan on"

setting too low.

Supply air

temperature too cool

during first moments

of furnace cycle.

Check supply air ductwork. Seal leaky joints and seams.

Insulate ductwork if necessary.

Excessive duct losses.

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

HOME OWNER’S REFERENCE TABLE:

Installation Contractor:

Model No.

Serial No.

Date Installed

Contractor

Contact

Address

Postal Code

Telephone No.

After Hours No.

Service Contractor if different from Installation Contractor:

Service Tech.

Telephone No.

After Hours No.

Fuel Supplier:

Oil Supplier

Contact

Telephone No.

After Hours No.

Oneida Royal Division

2201 Dwyer Avenue, Utica, NY 13504-4729

315-797-1310

www.uticaboilers.com

29733 R2 06/01/2003

Download from Www.Somanuals.com. All Manuals Search And Download.

Quadra Fire Indoor Fireplace QV36DC A User Guide
RCA Clock Radio RP4801 User Guide
RCA Projection Television HD44LPW164 User Guide
Roland Musical Instrument Amplifier DB 700 User Guide
Rotel Stereo Amplifier RC 960BX User Guide
Ryobi Cordless Saw RJ161V User Guide
Samsung Flat Panel Television LA40A330J1 User Guide
Samsung TV Receiver MR 16SA1 User Guide
Sears Garage Door Opener 13953930D User Guide
Sennheiser Headphones 830 TV User Guide