Nordyne O4LD-140A-16F User manual

Installation, Operation and

Maintenance Manual

O4LD Oil-Fired Lowboy

Warm Air Furnaces

ALL INSTALLATIONS MUST MEET

ALL LOCAL, PROVINCIAL/STATE,

AND FEDERAL CODES WHICH MAY

DIFFER FROM THIS MANUAL

Read this complete manual before

beginning installation. These instructions

must be kept with the furnace for future

reference.

FOR YOUR SAFETY:

Do not store or use gasoline or other flammable liquids or

vapors in the vicinity of this, or any other appliance.

Table of Contents

1. Introduction..........................................................................................................................................................3

2. Heat Loss..............................................................................................................................................................3

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

4. Air Conditioning Applications............................................................................................................................3

5. Combustion Air....................................................................................................................................................4

6. Chimney Venting .................................................................................................................................................4

7. Barometric Damper Control ...............................................................................................................................4

8. Fan and Limit Control..........................................................................................................................................5

9. Electrical Connections........................................................................................................................................5

10. Humidifier...........................................................................................................................................................5

11. Piping Installation..............................................................................................................................................5

12. Oil Filter ..............................................................................................................................................................6

13. Oil Burner Nozzles.............................................................................................................................................6

14. Oil Burner Adjustment ......................................................................................................................................6

15. Burner Electrodes..............................................................................................................................................6

16. Burner Primary Control.....................................................................................................................................6

17. Combustion Chamber.......................................................................................................................................7

18. Circulating Air Blower.......................................................................................................................................7

19. Maintenance and Service..................................................................................................................................8

20. Operating Instructions......................................................................................................................................9

A.1 Oil Burner Air Adjustment..............................................................................................................................11

A.2 Burner Electrodes...........................................................................................................................................11

A.3 Start-Up............................................................................................................................................................11

21. Final Check-Out...............................................................................................................................................17

PARTS LISTS...........................................................................................................................................................18

Homeowner’s Reference Table.............................................................................................................................24

152B0801

1. INTRODUCTION

Please read these instructions completely and

carefully before installing and operating the

furnace.

Models O4LD-140A-16-R and O4LD-168A-16-R

are rear breeched oil fired forced air low boy

furnace, with output capacities ranging from

79,000 Btu/h to 143,000 Btu/h.

Models O4LD-140A-16-F and O4LD-168A-16-F

are front breeched oil fired forced air lowboy

furnaces, with output capacities ranging from

79,000 Btu/h to 143,000 Btu/h.

DO NOT USE GASOLINE, CRANK CASE

OIL, OR ANY OIL CONTAINING

GASOLINE.

All models are CSA listed, for use with No. 1

(Stove) and No. 2 (Furnace) Oil. Please refer to

the tables in Appendix A for performance and

dimensional data.

In 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.

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.

Regulations prescribed in the National Codes

and Local regulations take precedence over the

general instructions provided on this installation

manual. When in doubt, please consult your

local authorities.

All models are shipped completely assembled

and pre-wired. The furnace should be carefully

inspected for damage when being unpacked.

2. HEAT LOSS

The maximum hourly heat loss for each heated

space shall be calculated in accordance with the

procedures described in Manual J. titled, "Load

Calculation" published by the Air Conditioning

Contractors of America, or method suitable for

local conditions or prescribed by local codes.

The calculation results obtained should be in

substantial agreement with, and not less than

those obtained using the procedure described in

Manual J.

In Canada, the maximum hourly heat loss for

each heated space shall be calculated in

accordance with the procedures described in the

manuals of the Heating, Refrigeration and Air

Conditioning Institute of Canada (HRAI), or by

method suitable for local conditions.

3. LOCATION OF UNIT

The furnace should be located such that the flue

connection to the chimney is short, direct and

consists of as few elbows as possible. When

possible, the unit should be centralized with

respect to the supply and return air ductwork. A

central location minimizes the trunk duct sizing.

All models may be installed on combustible

floors.

The minimum installation clearances are listed in

Table 1.

Table 1: Installation Clearance

Clearance to / for

Location Combustible

s Service

Top 3 in. 3 in.

Bottom 0 in. 0 in.

S/A Plenum 0 in. 0 in.

Rear 1 in. 24 in.

Side 1 6 in. 6 in

Side 2 6 in. 18 in.

Front 24 in. 24 in.

Flue Pipe 9 in. 9 in.

Enclosure Standard Standard

4. AIR CONDITIONING APPLICATIONS

If the furnace is used in conjunction with air

conditioning, the furnace shall be installed in

parallel with or upstream from the evaporator coil

152B0801

to avoid condensation in the heat exchanger. In

a parallel installation, the dampers or air

controlling means must prevent chilled air from

entering the furnace. If the dampers are

manually operated, there must be a means of

control to prevent the operation of either system

unless the dampers are in the full heat or full

cool position. The air heated by the furnace shall

not pass through a refrigeration unit unless the

unit is specifically approved for such service.

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.

5. COMBUSTION AIR

If the furnace is installed in a closet or utility

room, two 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 above the level of the upper vent

opening and one opening below the combustion

air inlet opening in the front of the furnace. Each

opening shall have a minimum free area of 1½

square inches per 1,000 Btu/h of total input

rating of all appliances installed in the room.

For furnaces located in buildings of unusually

tight construction, such as those with high quality

weather stripping, caulking, windows and doors,

or storm sashed windows, or where basement

windows are well sealed, a permanent opening

communicating with a well ventilated attic or with

the outdoors shall be provided, using a duct if

necessary. The duct opening shall have a free

area of 1½ square inches per 1,000 Btu/h of total

input rating of all appliances to be installed.

When a furnace is installed in a full basement,

infiltration is normally adequate to provide air for

combustion and draft operation. Furnace rooms

under 65m³ (700 ft³) should automatically be

treated as confined space.

6. CHIMNEY VENTING

The flue pipe should be as short as possible with

horizontal pipes sloping upward toward the

chimney at a rate of one-quarter inch to the foot.

The flue pipe should not be smaller in cross

sectional area than the flue collar on the furnace.

The flue pipe should connect to the chimney

such that the flue pipe extends into, and

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.

NOTE: THE FURNACE IS APPROVED FOR

USE WITH TYPE L VENT OR

EQUIVALENT.

THE FURNACE MUST BE CONNECTED

TO A FLUE HAVING SUFFICIENT

DRAFT AT ALL TIMES TO ENSURE

SAFE AND PROPER OPERATION OF

THE APPLIANCE.

NOTE: THE RECOMMENDED FLUE DRAFT

PRESSURE IS -0.02 IN. W.C. (AS

MEASURED UPSTREAM OF THE

BAROMETRIC DRAFT REGULATOR).

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 NFPA 31

for regulations governing the installation of oil

burning equipment. In Canada, refer to the latest

edition of CAN/CSA B-139 for rules governing

the installation of oil burning equipment.

See appendix A for burner set-up.

7. BAROMETRIC DAMPER CONTROL

This control, also known as a 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, when installed

should be in the same room or enclosure as the

furnace and should not interfere with the

combustion air supplied to the burner. The

control should also be located near the furnace

flue outlet and installed according to the

instructions supplied with the regulator. The flue

outlet pressure (measured between the furnace

152B0801

and draft regulator) should be set to -0.02 in.

w.c.

8. FAN AND LIMIT CONTROL

The L6064A temperature sensitive fan switch is

actuated by a helical bi-metal sensing element

enclosed in a metal guard, and controls the

circulating air blower. This provides a delay

between the burner ignition and blower start-up

to eliminate excessive flow of cold air when the

blower comes on. Blower shutdown is also

delayed to remove any residual heat from the

heat exchanger and improve the annual

efficiency of the furnace. Fan on settings of 110º

F to 130º F (43º C to 55º C) and fan off settings

of 90º F to 100º F (32º C to 37ºC) will usually be

satisfactory.

9. ELECTRICAL CONNECTIONS

The furnace is listed by CSA to the North

American standard. The furnace is factory wired

and requires minimal field wiring. In the United

States, the wiring must be in accordance with the

National Fire Protection Association NFPA-70,

National Electrical Code, and with local codes

and regulations. In Canada, all field wiring

should conform to CAN/CSA C22.1 Canadian

Electrical Code, Part 1, and by local codes,

where they prevail.

The furnace should be wired to a separate and

dedicated circuit in the 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.

Furnace Power Requirements

Furnace Model Volts

AC Amps ∅ Hz

All Models 120 15 1 60

Accessories requiring 120 VAC power sources

such as electronic air cleaners and humidifier

transformers may be powered from the furnace

circuit, but should have their own controls. Do

not use the direct drive motor connections as a

power source, since there is a high risk of

damaging the accessories by exposure to high

voltage from the auto-generating windings of the

direct drive motor.

Thermostat wiring connections and air

conditioning contactor low voltage connections

are shown in the wiring diagram in Appendix B.

Some micro-electronic thermostats require

additional controls and wiring. Refer to the

thermostat manufacturer's instructions.

The thermostat should be located approximately

5 feet above the floor, on an inside wall where

there is good natural air circulation, and where

the thermostat will be exposed to average room

temperatures. Avoid locations where the

thermostat will be exposed to cold drafts, heat

from nearby lamps and appliances, exposure to

sunlight, heat from inside wall stacks, etc.

The thermostat heat anticipator should be

adjusted to the amperage draw of the heating

control circuit as measured at the "R" and "W"

terminals of the thermostat. To reduce the risk of

damaging the heat anticipator, do not measure

this current with the thermostat connected to the

circuit. Measure the amperage by connecting an

ammeter between the two wires that will connect

to the thermostat "R" and "W" terminals.

10. HUMIDIFIER

A humidifier is an optional accessory available

through most heating supplies outlets.

Installation should be carried out in accordance

with the humidifier manufacturer's installation

instructions. Water or water droplets from the

humidifier should not be allowed to come into

contact with the furnace heat exchanger. Do not

use direct drive motor connections as a source

of power for 120 VAC humidifiers and humidifier

transformers.

11. PIPING INSTALLATION

152B0801

The entire fuel system should be installed in

accordance with the requirement of NFPA No. 31

and local codes and authorities. In Canada, the

entire fuel system should be installed in

accordance with the requirement of CAN/CSA B-

139, and local regulations. Use only an approved

fuel oil tanks piping, fittings and oil filter.

Install the oil filter as close to the burner as

possible. For further details of the oil supply tank

and piping requirements, please refer to the

instructions and illustrations in the oil burner

instructions shipped with the furnace.

12. OIL FILTER

All fuel systems should include a high quality oil

filter between the fuel oil storage tank and the oil

burner.

13. OIL BURNER NOZZLES

Both front breech and rear breech models are

certified for multiple firing rates, ranging from

output capacities of 79,000 to 143,000 Btu/h. By

manipulating the oil burner nozzle, and

temperature rise, these furnaces may be fired at

an ideal rate for a wide range of structures. Refer

to Table A-1, and the furnace rating plate to

determine the proper combinations.

14. OIL BURNER ADJUSTMENT

The burner air supply is adjusted to maintain the

fuel to air ratio to obtain ideal combustion

conditions. A lack of air causes "soft" and "sooty"

flames, resulting in soot build-up throughout the

heat exchanger passages. Excess combustion

air causes a bright roaring fire and high stack

temperatures resulting in poor fuel efficiency.

Maximum combustion efficiency is achieved with

a No. 1 smoke spot on the Bacharach Scale.

This is not necessarily the optimum setting;

however, because dust will inevitably build up on

the air moving components of the oil burner

assembly. This will result in decreased air supply

with the potential result of soot building up in the

flue gas passageways of the heat exchanger.

Soot behaves as an insulator and impairs good

heat transfer. Stack temperature will increase,

and the overall efficiency will decrease. As a

means of avoiding this problem, it is advisable to

adjust the air supply to provide no more than a

trace smoke spot on the Bacharach Scale.

BEFORE OPERATING THE FURNACE

CHECK BURNER ALIGNMENT WITH

COMBUSTION CHAMBER. THE END

CONE OF THE AIR TUBE MUST BE

CENTRED TO THE ACCOMODATING

RING PROVIDED IN THE DESIGN OF

THE COMBUSTION CHAMBER.

ADJUST AS NECESSARY.

15. BURNER ELECTRODES

Correct positioning of the electrode tips with

respect to each other, to the fuel oil nozzle, and

to the rest of the burner is essential for smooth

light ups and proper operation. Refer to the oil

burner instructions shipped with the furnace for

electrode specifications.

NOTE: Beckett AF Series Burner electrode

specifications have been revised. They should

be adjusted to be 5/16” above the nozzle

centerline.

16. BURNER PRIMARY CONTROL

The furnace is equipped with a primary

combustion control, sometimes refer to as the

burner relay or burner protector relay, which

uses a light sensing device (cad cell) located in

the burner housing, to monitor and control

combustion. Over time, dust or combustion

residuals can build up on the lens of the cad cell

impairing its response to the flame. The cad cell

should be checked for cleanliness and proper

alignment if the primary control frequently shuts

down combustion.

ALL FURNACE CONTROLS ARE

SENSITIVE AND SHOULD NOT BE

SUBJECTED TO TAMPERING. IF

PROBLEMS PERSIST, CALL YOUR

SERVICE CONTRACTOR.

152B0801

17. COMBUSTION CHAMBER

This furnace is equipped with a high quality

cerafelt combustion chamber. It is held in place

by a support bracket and stainless steel retaining

band and clamp. CHECK THE ALIGNMENT OF

THE COMBUSTION CHAMBER AND OIL

BURNER BEFORE FIRING. IT IS POSSIBLE

FOR THE COMBUSTION CHAMBER TO SHIFT

IF SUBJECTED TO ROUGH HANDLING

DURING TRANSIT. The combustion chamber

should be inspected for damage or carbon build

up whenever the oil burner is removed for repairs

or routine maintenance.

DO NOT START THE BURNER UNLESS

THE BLOWER ACCESS DOOR IS

SECURED IN PLACE.

18. CIRCULATING AIR BLOWER

Both front breech and rear breech models are

equipped with direct drive blower systems. Direct

drive blower speed adjustments are not normally

required in properly sized extended plenum duct

systems. The motor RPM and air CFM delivery

will vary automatically to accommodate

conditions within the usual range of external

static pressures typical of residential duct

systems. Under-sized duct systems may require

a higher blower speed to obtain a reasonable

system temperature rise. Some older duct

systems were not designed to provide static

pressure. They typically feature special reducing

fittings at each branch run and lack block ends

on the trunk ducts. These systems may require

modification to provide some resistance to the

airflow to prevent over-amping of the direct drive

blower motor. Selecting a lower blower speed

may correct this problem.

Direct drive blower speeds are adjusted by

changing the "hot" wires to the motor winding

connections. Please refer to wiring diagram in

Appendix B or the wiring diagram label affixed to

the furnace. THE NEUTRAL WIRE (normally

the white wire) IS NEVER MOVED TO ADJUST

THE BLOWER SPEED.

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 pig tail 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.

DO NOT CONNECT POWER LEADS

BETWEEN MOTOR SPEEDS. THE

NEUTRAL WIRE MUST ALWAYS BE

CONNECTED TO THE MOTOR'S

DESIGNATED NEUTRAL TERMINAL.

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.

If the joining of the blower speed wiring is done

in the furnace junction box, tape off both ends of

the unused wire.

Do not use the blower speed wires as a

source of power to accessories. The unused

motor taps auto-generate sufficiently high

voltages to damage accessory equipment.

152B0801

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. (See Appendix A,

Table A-3).

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.

Annual Service By Contractor

THE COMBUSTION CHAMBER (FIREPOT)

IS FRAGILE. USE CARE WHEN

INSPECTING AND CLEANING THIS AREA.

The heat exchanger, and flue pipe on rear

breach units, 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. The

Flue Connector shall be removed to inspect and

clean the flue pipe area. To clean the radiator,

remove the round covers on the two pipes

located on the front panel between the front

panel and the flue pipe. Remove the covers

carefully to avoid tearing the gaskets. A wire

brush can be used to loosen dirt and debris on

the inside surfaces of the radiator. Clean out all

accumulated dirt, soot and debris with a wire

handled brush and industrial a vacuum cleaner.

Before replacing the clean-out covers, inspect

the gaskets. If the gaskets are broken, remove

the remnants and replace with new gaskets.

Replace the cleanout covers and screws.

The blower motor is factory sealed and requires

no routine lubrication.

Inspect the blower fan. Clean if necessary.

Oil Burner Maintenance: Inspect and clean the

oil burner. Be sure to remove any dust

accumulation in the air band, air shutter, and

blower wheel. The oil burner nozzle and oil filter

should be replaced on an annual basis. The

burner motor is factory sealed and requires no

routine lubrication.

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 should be checked

to ensure that the "fan off" function continues to

stop the blower fan at a suitable temperature,

usually between 90°F to 100°F.

152B0801

20. OPERATING INSTRUCTIONS

Before Lighting

1. Open all supply and return air registers and

grilles.

2. Open all valves in oil pipes.

3. Turn on electric power supply

To Light Unit

1. Set the thermostat above room temperature

to call for heat. The burner should start.

NOTE: It may be necessary to press the

RESET button on the primary combustion

control relay.

2. After a short period of time, as the furnace

becomes warm enough to act upon the fan

control (L6064A), the blower starts.

3. Set the thermostat below room temperature.

The oil burner stops.

4. The air circulation blower will continue to run

as long as the temperature remaining in the

furnace is higher than the "FAN OFF" setting

on the fan control. Typical "fan on" values

range from 110°F to 130°F. Typical "fan off"

temperatures range between 90°F and

100°F. The fan control settings may be

altered if the air at the room registers is

uncomfortably high or low upon blower start

up or shutdown.

5. Adjustment to the fan control settings should

be based on the temperature of the air at the

supply air take-off or within the first 24 inches

of the supply air trunk duct trunk. The side

mid point of the trunk is usually ideal,

providing that the thermometer probe is

beyond the "line of sight" in relation to the

Heat Exchanger, wherein false readings from

radiant heat could be observed. The system

temperature rise, the difference in

temperature between the supply air and

return air, should typically range between

65°F and 90°F.

To check the operation of the limit switch, shut

off power to the furnace. Temporarily remove the

neutral wire from the direct drive blower motor.

Restore the electrical power to the furnace and

set the thermostat above room temperature.

After three or four minutes of burner operation,

the limit control should turn the burner off. The

progress towards a high limit shut down can be

monitored by watching the dial on the L6064A

fan / limit control. When the limit function test is

complete, shut off electrical power to the

furnace, replace the neutral wire to the blower

fan motor, and then restore power. The blower

fan will start up immediately. Once the

temperature has dropped, the oil burner will

resume and continue until the thermostat is

satisfied. Restore the thermostat setting to a

comfortable temperature.

To Shut Down Unit

1. Set the thermostat to the lowest possible

setting.

2. 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

BURNER.

DO NOT ATTEMPT TO START THE

BURNER WHEN EXCESS OIL HAS

ACCUMULATED, WHEN THE FURNACE IS

FULL OF VAPOUR, OR WHEN THE

COMBUSTION CHAMBER IS VERY HOT.

NEVER BURN GARBAGE OR PAPER IN

THE FURNACE, AND NEVER LEAVE

PAPER OR RAGS AROUND THE UNIT.

152B0801

Table A-1: Beckett AF Oil Burner Set-up

Beckett AF Series Oil Burners

Furnace Model Burner

Model Nozzle Pump

Pressure Flow Rate Burner

Head Static

Plate

O4LD-140A-16-F AF65XN 0.65 / 80°A 100 PSIG 0.65 USGPH F3 2-¾ in.

O4LD-140A-16-F AF65XN 0.75 / 80°A 100 PSIG 0.75 USGPH F3 2-¾ in.

O4LD-140A-16-F AF65XN 0.85 / 80°A 100 PSIG 0.85 USGPH F3 2-¾ in.

O4LD-140A-16-F AF65XN 1.00 / 80°A 100 PSIG 1.00 USGPH F3 2-¾ in.

O4LD-140A-16-R AF65XN 0.65 / 80°A 100 PSIG 0.65 USGPH F3 2-¾ in.

O4LD-140A-16-R AF65XN 0.75 / 80°A 100 PSIG 0.75 USGPH F3 2-¾ in.

O4LD-140A-16-R AF65XN 0.85 / 80°A 100 PSIG 0.85 USGPH F3 2-¾ in.

O4LD-140A-16-R AF65XN 1.00 / 80°A 100 PSIG 1.00 USGPH F3 2-¾ in.

O4LD-168A-16-F AF65YB 1.10 / 70°A 100 PSIG 1.10 USGPH F6 2-¾ in.

O4LD-168A-16-F AF65YB 1.20 / 60°A 100 PSIG 1.20 USGPH F6 2-¾ in.

O4LD-168A-16-R AF65YB 1.10 / 70°A 100 PSIG 1.10 USGPH F6 2-¾ in.

O4LD-168A-16-R AF65YB 1.20 / 60°A 100 PSIG 1.20 USGPH F6 2-¾ in.

Appendix A

OIL-FIRED LOWBOY

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