Comfortaire OLF Series User manual

Installation and Operation Manual
ODF, ODR, OUF, OLF & OLR Series
Oil-Fired Furnaces
517.787.2100 • www.marsdelivers.com • www.heatcontroller.com

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
INSTALLATION INSTRUCTIONS
ODF, ODR, OUF, OLF, & OLR
Oil-Fired Furnaces
Save these instructions for future reference
TABLE OF CONTENTS
START-UP CHECKLIST ................................................ 2
INSTALLATION ............................................................. 3
Location .................................................................. 3
Clearances .............................................................. 3
Venting .................................................................... 6
Filters ................................................................... 10
START-UP ................................................................... 10
SEQUENCE OF OPERATION .................................... 12
MAINTENANCE .......................................................... 12
WIRING DIAGRAMS .................................................. 14
Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage.
Refer to this manual. For assistance or additional information, consult a qualified installer or service
agency.
WARNING
Do not store combustible materials, including gasoline
and other flammable vapors and liquids, near the
furnace, vent pipe, or warm air ducts. The homeowner
should be cautioned that the furnace area must not be
used as a broom closet or for any other storage
purposes. Such uses may result in actions that could
cause property damage, personal injury, or death.
WARNING
Never burn garbage or paper in the heating system and
never leave rags, paper, or any flammable items around
the unit.
CAUTION
The installation of the furnace, wiring, warm air ducts, venting, etc. must conform to the requirements of the National Fire
Protection Association Standard for the Installation of Oil Burning Equipment, NFPA No. 31; the National Electrical Code,
ANSI/NFPA No. 70 (in the USA); the Installation Code for Oil Burning Equipment, CSA Standard CAN/CSA B139 (in
Canada); the Canadian Electrical Code Part 1, CSA 22.1; the Recommendations of the National Environmental Systems
Contractors Association; and any state or provincial laws or local ordinances. Local authorities having jurisdiction should
be consulted before installation is made. Such applicable regulations or requirements take precedence over the general
instructions in this manual.
CAUTION
This furnace is not approved for installation in a mobile
home. Do not install this furnace in a mobile home.
Installation in a mobile home could result in actions that
could cause property damage, personal injury, or death.
WARNING 1900 Wellworth Ave.
Jackson, MI 49203
www.marsdelivers.com
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Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
OIL FURNACE START-UP CHECKLIST
(Complete this page and keep for future reference)
Furnace Location:
A. Basement – Open _________ Enclosed* ________
B. Utility room – Open ________ Enclosed* ________
C. Closet – Open ____________ Enclosed* ________
D. Crawl space – Open _______ Enclosed* ________
* Provisions must be made for adequate air for combustion.
See Combustion and Ventilation Air on page 7.
Chimney Data:
A. Inside _________ Outside _________
B. Brick or Masonry _________
C. Lined _________ Size: ___________
D. Type: Class A all-purpose ___________ Type L ________
E. Condition ________________________
Flue Pipe:
A. Distance to chimney ____________ Pitch __________
B. Diameter _____________________
C. Barometric damper installed __________
D. Drill 5/16" hole in flue pipe 12" upstream of barometric
damper _________
E. Obtain drafting reading; adjust barometric ____________
Oil Tank Data:
A. Installed in basement _____________
B. Outside ___________
C. Buried/Depth:_________________
D. Size: __________ gallons
E. Age: ________________________
F. Date of last cleaning: ___________________
Oil Lines:
A. Size: 3/8" ________ 1/2" _______ Other _______
B. Single pipe _________ Two pipe ________
C. Distance from tank __________ Lift_________
D. Filter type _____________ Inspect ______ Change _____
E. Pressure test ___________
F. Recheck all fittings for tightness ___________
Thermostat
A. Type: Heating ________ Cooling _______
B. Anticipator set ________
C. Wires: New __________ Old ___________
Air Filter
A. Type: Permanent ______ Disposable ______
B. Installed _____________
C. Size: ________________
A. Close disconnect switch ___________
B. Set thermostat to call for heat ___________
C. Bleed air from lines and pump; run for 20 seconds
after bubble disappears _________
D. Install vacuum gauge; check pump vacuum __________
E. Install pressure gauge; adjust pressure to 140 psig
(except on 57 models – adjust to 100 psig) _________
Always verify proper pump pressure to corresponding
tables with instructions supplied with unit.
F. After 10 minutes of operation, obtain flue temperature
reading: 1st ______________ 2nd ________________ 3rd ______________
G. Obtain smoke reading:
1st _______________ 2nd _________________ 3rd ______________
H. Measure CO2: 1st ______________ 2nd ______________ 3rd ____________
I. Check draft overfire _________ Breech _________
J. Air shutter setting ____________ Locked _________
K. Measure static pressure in duct system
Static pressure on supply side ___________
Static pressure on return side ___________
Static pressure drop __________
L. Temperature rise after steady state conditions have
been achieved: Supply side _______ Return side ______
M. Block off return air (limit control checkout); burner
should shut down in 2 or 3 minutes ___________
Installation DataStart-Up Procedure
Owner Record
Installed By: _____________________________________
Dealer _______________________________________
Address _______________________________________
_______________________________________
_______________________________________
Telephone # _____________________________________
License # ________________________________________
Customer Name________________________________________________________________________________
Address ______________________________________________________________________________________
City __________________________________________State ________________ Zip Code__________________
Furnace Model # ____________________________________________________ Serial # ___________________
Input Rate__________________________________________________________ Nozzle Used_______________
New Construction ___________________________________________________ Replacement ______________
Date of Installation _____________________________
These checks or tests are required for all oil units.
1900 Wellworth Ave.
Jackson, MI 49203
www.marsdelivers.com
www.heatcontroller.com
2

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
3
Clearances
A minimum of 24" is recommended in front of the furnace
for servicing the burner on all models.
See Table 2 on page 4 for a complete listing of the minimum
clearances required for basement type and upflow
installations. See Figure 2 on page 5 for the minimum
clearances required for horizontal installations and Figure 3
on page 5 for the minimum clearances required for
counterflow installations. When accessibility clearances
are greater than fire protection clearances, the
accessibility clearances take precedence.
In utility rooms or similar installations, the door or access
opening should be large enough to permit replacement of
the furnace, or another appliance such as a water heater,
without disturbing any other equipment.
Read all instructions before starting work so installation will
conform to Underwriter’s Laboratories or Canadian
Standards Association requirements. The furnace must be
level when placed on its foundation (upflow, counterflow, and
basement models) or in its suspended position (horizontal
models). Using a carpenter’s level, check the furnace in at
least two directions. The weight must be distributed evenly
before the duct work is attached.
These instructions must be placed on or near the
furnace in a conspicuous place.
Inspection of Shipment
This furnace is shipped in one package, completely
assembled and wired. The thermostat is shipped in a
separate carton when ordered.
Upon receipt of equipment, carefully inspect it for possible
shipping damage. If damage is found, it should be noted on
the carrier’s freight bill. Damage claims should be filed with
the carrier immediately. Claims of shortages should be filed
with the seller within 5 days.
Location
Locate the furnace as centrally as possible so that all warm
pipes to the various rooms are nearly the same length. This
allows each room to receive an equal and proper amount of
heat. This may vary with each particular installation. Position
the furnace so the pipe connection to the chimney will be of
minimum distance and have a minimum of fittings.
INSTALLATION
In any installation where damage from oil may occur, a
drain pan must be installed. The drain pan must be
large enough size to completely prevent any potential
oil damage. The drain pan piping must be sized to drain
the oil pump capacity and the piping must be routed to
drain the oil back to the oil tank.
WARNING
OUF, OLF ODF
* A passage, suitable for a large
person, shall be provided
between the furnace and
chimney for inspection or
replacement of the ue
connector when necessary.
A clearance of 24” shall be
allowed at the rear and on one
side of the furnace for service
and cleaning of the blower.
** The minimum clearance
shown to the ue pipe may
be reducted by using spectial
protection permitted by local
building codes and National
Fire Association Standards and
CSA 139.

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
4
Figure 1
Horizontal Installation
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B
GF
A
CC
Supply Return
Supply Return
Front View
Top View
Non-Suspended Horizontal Installation
To support the furnace from below, set the furnace on non-
combustible material suitable to support the weight of the unit.
Using a carpenter’s level, check furnace in at least two
directions. To make adjustments, use shims of non-
combustible material. Seven inches minimum clearance
between the bottom of the flue pipe and combustible material
is required. Installation on a combustible floor requires a 1"
clearance from the floor for units with a front flue and a 4"
clearance from the floor for units with a rear flue.
Horizontal Installation Reversing the Air Flow
This furnace is assembled to discharge warm air out the left
side (when viewed facing the burner side of the furnace). If
installation requires that the flow be reversed, follow these
steps:
1. Rotate the furnace 180° so that the warm air is
discharged out the right side.
2. Remove the oil burner and the screws securing the
burner mounting plate. Rotate the burner mounting plate
180° and reattach with screws. Remount the burner in
the upright position.
3. Remove the screws holding the limit control in place.
Relocate the limit control to the top side of the front panel
using the knockout hole provided.
Counterflow Installation
This furnace is assembled to discharge warm air out the left
side (when viewed facing the burner side of the furnace). To
convert to counterflow:
1. Rotate the furnace so the return is on top and the supply
is on bottom.
2. Remove the oil burner and the screws securing the
burner mounting plate. Rotate the burner mounting plate
90° clockwise and reattach the screws into the
heat exchanger. Remount the burner.
3. Refer to Figure 2 for minimum clearances required.
When installing a counterflow unit on combustible
flooring, a combustible floor base must be used. See
Figure 3 on page 6 for more information on using a
combustible floor base kit.

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
5
It is very important that the furnace be exactly level since a
level unit is necessary for proper fitting of parts. Using a
carpenter’s level, check the furnace in at least two directions.
If the furnace is not level, place fireproof wedges or shims
between the low side of the furnace and the floor and check
again with the level. The weight of the unit must be distributed
evenly on all four corners.
Air Conditioning
Figure 2
*The minimum clearance shown to the flue pipe may be
reduced by using special protection permitted by local building
codes and National Fire Protection Association Standards
and CSA 139.
A minimum of 24" must be provided in the front of the furnace
for servicing the burner and filter. A passage suitable for a large
person shall be provided between the furnace and chimney for
inspection or replacement of the flue connector when necessary.
Counterflow
(Closet Installation)
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Ced i Smune l Py l ppuS "1
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E
mo t t oBmune l Py l ppuS
"1
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JpoT 0
Figure 3
Combustible Floor Installation –
Counterflow Units
Burner
Warm Air Plenum Joist
Slab Flooring
(12" minimum)
Cold Air
Duct
Blower
Comparment
Combustible
Floor Base
Sub-base
Insulation
Kits are also available for counterflow applications where a
vestibule cover is needed for safety reasons.
Vestibule cover kits:
Kit for 57/72 & 84/95 counterflow models – AVEST547-1
Kit for 112/125 counterflow models – AVEST548-1
When an air conditioning unit is used in conjunction with
the furnace, the evaporator coil must be installed in the
discharge (supply) air. Do not install an evaporator coil
in the return air; excessive condensation will occur within
the furnace.
WARNING

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
6
Combustion and Ventilation Air
Adequate provisions for combustion air, ventilation of
furnace, and dilution of the gases must be made. When a
furnace is installed in an unconfined space in a building, it
can be assumed that infiltration will be sufficient to supply
the required air.
If the furnace is installed in a confined space and combustion
air is taken from the heated space, the supply air and
ventilating air must be through two permanent openings of
equal area. A confined space is “a space whose volume is
less than 50 cubic feet per 1000 btu per hour of the combined
input rating of all appliances installed in that space.” One
opening must be within 12” of the ceiling and the other within
12” of the floor. Each opening must have a minimum free
area of at least 1 square inch per 1000 btu per hour of total
input rating of all appliances with the space but not less than
100 square inches.
If the furnace is installed in a space within a building of tight
construction, air must be supplied from outdoors. In this
case, one opening shall be within 12” of the ceiling and the
other within 12” of the floor. If vertical combustion ducts are
run, each opening must have a free area of at least 1 square
inch per 4000 btu per hour. If horizontal combustion ducts
are run, 1 square inch per 2000 btu per hour of the total
input of all appliances is required.
The furnace is designed to use air inside the dwelling for
combustion. If additional combustion air is required, installing
fresh air kit ABOOT571 allows air from outside the dwelling
to be brought in to the oil burner. This kit brings air into the
burner through air inlet ductwork run through the furnace
cabinet side panel and terminated outside the dwelling (see
Figure 4). The kit includes a vacuum relief valve to guard
against combustion problems associated with directly
connecting oil burners to the outside.
A return air duct system is recommended. Where there is
no complete return air duct system, a return connection
should be run full size to a location outside the confined
space and completely sealed so that no air from the confined
space can be circulated through the heating duct system.
Outdoor Make Up Air
A minimum mixed return air temperature of 60 - 65°F must
be maintained for outdoor make up air to prevent
condensation and corrosion.
Venting
Chimney
Before installing the furnace, a thorough inspection of the
chimney should be made to determine whether repairs are
necessary and that the chimney is of the proper size and
constructed in accordance with the requirements of the
National Board of Fire Underwriters or Canadian Standards
Association. The smallest dimension of the chimney should
be at least equal to the diameter of the flue pipe of the
furnace. Be sure the chimney will produce a steady draft
sufficient to remove all the products of combustion from the
furnace. A fabricated vent system the same size as the flue
outlet of the furnace may also be used. If a manufactured
vent is used, it must be listed for use with oil-fired equipment.
1. Local building codes may have more stringent installation
requirements a nd should be consulted before installation
of the unit.
Figure 4
Fresh Air Kit ABOOT571 Installation
IMPORTANT: No more than 10’ of vertical piping allowed without
weight support.
This furnace is certified for use with Type “L” vent, Type
“A”, and “factory-built” chimneys. “B” vent must not be
used with oil furnaces.
WARNING
The barometric control shall be in the same atmospheric
pressure zone as the combustion air inlet to the furnace.
Deviation from this practice will cause improper burner
operation and may result in a fire hazard or injury.
WARNING
Combustion air openings in the front of the furnace must
be kept free of obstructions. Any obstruction will cause
improper burner operation and may result in a fire hazard
or injury.
WARNING

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
7
2. The flue pipe should be as short as possible to do the
job.
3. The internal diameter of the flue pipe or vent connector
shall equal the outlet diameter of the flue opening of the
appliance. If the flue vent collar is larger or smaller than
the flue pipe, a gradual transition piece shall be used
and the system shall be tested to ensure that adequate
draft is provided.
4. Single wall flue pipe should not run outside or through
any unconditioned space.
5. Chimney flue shall extend at least 3’ above the highest
point at which the chimney comes in contact with the
roof and not less than 2’ above the highest roof surface
or structure within 10’ of the chimney on a horizontal
plane perpendicular to the chimney. Not more than 4”
of chimney flue above the chimney cap shall be
considered in computing this height.
6. The flue pipe must not pass through a floor or ceiling.
Clearances to single wall flue pipe should be no less
than specified in the Clearances section beginning on
page 3.
7. The flue pipe may pass through a wall where provisions
have been made for a thimble as specified in the
Standards of the National Board of Fire Underwriters
(see Figure 5).
8. The flue pipe should slope upward toward the chimney
on a horizontal run of at least 1/4” per foot and should
be supported by something other than the furnace (see
Figure 6 on this page and Figure 7 on page 8).
9. Extend the flue pipe into the chimney so that it is flush
with the inside of the flue liner. Seal the joint between
the pipe and the liner.
10. The furnace shall be connected to a factory-built chimney
or vent complying with a recognized standard, or a
masonry or concrete chimney lined with a lining material
acceptable to the authority having jurisdiction.
11. When two or more appliances vent into a common flue,
the area of the common flue should not be less than the
area of the largest flue or vent connection plus 50% of
the areas of the additional vents or flue connections.
The chimney must be able to sufficiently vent all
appliances operating at the same time.
12. The flue pipe shall not be connected to a chimney
flue serving a solid fuel appliance or any mechanical
draft system.
13. All unused chimney openings should be closed.
14. All vent pipe run through unconditioned areas or outside
shall be constructed of factory-built chimney sections
(see Figure 6).
15. Where condensation of flue gases is apparent, the vent
shall be constructed to prevent the condensation from
entering the flue transition box opening. Provisions shall
be made to drain off the condensate (see Figure 6).
Figure 5
Wall Thimble
Factory-Built Chimney
Figure 6
Front Fllue
Rear Flue
* Barometric control may be installed in either the vertical or
horizontal section of the flue pipe within 18” of the flue outlet of
the furnace.

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
8
16. Vent connectors serving this appliance shall not be
connected into any portion of a mechanical draft system
operating under positive pressure.
17. Keep the area around the vent terminal free of snow,
ice, and debris.
Horizontal Venting
The design of this furnace has been approved for horizontal
venting with the following mechanical vent systems:
Tjernlund (sideshot) - Models SS1, SSC, SS2*
Field Control - Model SWG-5S with CK63 Control Kit
Vent systems are available through the local distributor.
Refer to the manufacturer’s installation instructions for proper
installation procedures and service parts information.
* SS2 Vent System is not approved for 196 oil furnaces
Barometric draft control must be used in the horizontal
venting (sidewall) system. It must be located within 18” of
the furnace flue outlet (see Figure 8).
Do not common vent with any other appliance when using
the sidewall system.
Maximum permissible vent length is 100 equivalent feet,
and minimum permissible length is 15 equivalent feet.
Calculate the equivalent vent pipe footage from the furnace
to the mechanical vent system by adding the straight vent
pipe length and equivalent elbow lengths together. Each
90° elbow is equivalent to 10’ of straight pipe; each 45° elbow
is equal to 5’ of straight pipe.
Removal of Unit from Common Venting System
When an existing furnace is removed from a common
venting system service other appliances, the venting system
is likely to be too large to properly vent the remaining attached
appliances. The following test should be conducted with
each appliance while the other appliances connected to the
common venting system are not in operation.
Figure 7
* Barometric control may be installed in either the vertical
or horizontal section of the flue pipe within 18” of the flue
outlet of the furnace.
Rear Flue
Front Flue
Masonry Chimney
Figure 8
Masonry Chimney
Front Flue
Rear Flue
* Barometric control may be installed in the horizontal
venting system and located within 18” of the flue outlet of
the furnace.

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
9
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion, or other deficiencies
which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows
between the space in which the appliances remaining
connected to the common venting system are located and
other spaces in the building. Turn on clothes dryers and any
appliance not connected to the common venting system. Turn
on exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.
4. Following the lighting instructions, place the unit being
inspected in operation. Adjust the thermostat so the
appliance will operate continuously.
5. Test for spillage at the draft control relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle.
6. After it has been determined that each appliance remaining
connected to the common venting system properly vents
when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers, and any other fuel
burning appliance to their previous condition of use.
7. If improper venting is observed during any of the above
tests, the common venting system must be corrected. See
National Fuel Gas Code, ANSI Z223.1 (latest edition)
or CAN/CGA B149.1 & .2 Installation Codes to correct
improper operation of common venting system.
Smoke Pipe and Draft Control
Connect the furnace vent to the chimney with galvanized
smoke pipe and fittings, maintaining full diameter of furnace
vent throughout. No reduction in diameter of pipe is allowed.
It is best to have smoke pipe as short and direct as possible.
The smoke pipe shall maintain a rise of at least 1/4” per foot.
Install draft control at least 12” beyond the furnace. If there is
no space to install the draft control in the smoke pipe, it may
be installed in the chimney above the smoke pipe (see Figure
9).
Supply and Return Air Plenum
Secure return air plenum to unit using sheet metal screws.
Follow these procedures when installing supply air plenum:
1. Use sealing strips of fiberglass.
2. Attach the plenum to the furnace or evaporator cabinet
with sheet metal screws.
3. Both supply and return air plenums shall be square and at
least 18” long. They should be the same dimension as the
furnace opening.
4. Install supply and return air ducts as desired.
Oil Supply and Oil Filter Connection
Continuous lengths of heavy wall copper tubing or steel pipe
are recommended and should be installed under the floor or
near walls to protect from damage. Do not run lines on floor
joists or other reverberating surfaces. Always use flare fittings
located in accessible places.
Install a generous capacity oil filter inside building between
the fuel shutoff valve and burner. Locate filter and valve close
to burner for easy servicing. An oil filter is required for all
models. A 100-micron filter is recommended.
Combustion Chamber
The combustion chamber is installed in the furnace at the
factory. Read the instruction plate on the front of the unit
concerning proper care of the chamber.
This combustion chamber is made of preformed ceramic
fiber material. Use extreme care when installing the oil
burner so that the chamber is not damaged around the burner
tube.
Figure 9
Draft Control Installation

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
10
Fan and Limit Control
The limit control and the separate time delay relay that
controls blower operation are installed and wired at the
factory. Should replacement of these controls be necessary,
the replacement control(s) must be the same model as
originally installed in this furnace. The use of any other
control(s) will void the warranty
Electrical Wiring
All wiring must conform to the National Electrical Code, the
Canadian Electrical Code, and any local codes. Connect
the 115-volt, single phase service to the unit at the junction
box. Use a separate fused branch electrical circuit containing
a properly sized fuse or circuit breaker. Run this circuit
directly from the main switch box to an electrical disconnect
that is readily accessible and located near the furnace.
Follow carefully the wiring diagrams adhered to the inside
of the blower compartment door.
The electrical supply to the mechanical vent system must
be supplied from the appliance. All wiring must be
appropriate Class I wiring. Wiring must be installed in rigid
metal conduit, intermediate metal, or be otherwise suitably
protected from physical damage. Refer to the wiring
diagrams supplied with the venter kit for proper electrical
connections.
Thermostat
Locate the thermostat on an inside wall in a room usually
occupied during the day, such as a living room or dining
room, at a height of 4-1/2” from the floor. Avoid direct sunlight
or supply air from a register. Make sure the location is not
adjacent to appliances such as ovens or lights. Wire the
thermostat with minimum of #18 AWG thermostat wire.
Humidifier
A humidifier can be installed with this furnace. Refer to the
humidifier manufacturer’s instructions for specific connection
information (see also Figure 11 on page 13).
Electronic Air Cleaner
An electronic air cleaner can be installed with this furnace.
Refer to the electronic air cleaner manufacturer’s instructions
for specific connection information (see also Figure 12 on
page 13).
Filters
Upflow and Horizontal/Counterflow Models
Air filters are not factory supplied with these models. Optional
filter kits are available.
Basement Models
Permanent filters are supplied with these units. To clean
the filters, shake to remove any excess dirt and/or use a
vacuum cleaner. Wash with soapy detergent water and dry.
Metal permanent filters need to be oiled after washing to
increase their effectiveness. The filters should be cleaned
at least once a month, or more frequently in unusually dusty
environments.
Never leave the access panels to the blower
compartment off or partially open.
START-UP
Oil Burner
Burner Specification: Factory Settings
1. Burner type: AFG (57 - 125)
2. Air Tube Combination:
AF46XZTHS (57/72)
AF46XNHS (84/95)
AF46WPHS (112/125)
3. AFG Static Plate 2-3/4” (57/72) (84/95)
3-3/8” (112/125)
Do Not attempt to start the burner when excess oil has
accumulated in the chamber, when the furnace is full
of vapor, or when the combustion chamber is very hot.
Such actions could result in property damage, personal
injury, or death.
WARNING
Do Not start burner unless blower access door is
secured in place.
CAUTION

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
11
Burner Start-Up
1. Open all shutoff valves in the oil supply line to the
furnace.
2. Turn on electrical power to the furnace.
3. Set the room thermostat to call for heat. If the burner
does not start immediately, check the manual overload
switch on the motor (if applicable), and the safety switch
of the furnace primary control.
4. While the ignition is on, press and release the reset
button (hold 1/2 second or less). If the control has not
locked out since its most recent complete heat cycle,
the lockout time will be extended to 4 minutes, and the
ignition will remain on for the entire heat cycle.
5. Bleed the pump until all froth and bubbles are purged.
The bleed port is located on the bottom of the fuel pump.
To bleed, attach a clear plastic hose over the vent plug.
Loosen the plug and catch the oil in an empty container.
Tighten the plug when all the air if purged. NOTE:
Bleeding might not be necessary with a two-pipe system.
6. If prime is not established within the extended lockout
time, the control will lock out. Press the reset button to
reset the control (see Step 4). NOTE: the reset button
can be held for 15 seconds for the Beckett 7505B
primary control, at any time to reset the control’s lockout
counter to zero and send the control to standby.
7. Repeat Steps 4 and 5, if needed, until pump is fully
primed and oil is free of bubbles. Then terminate the
call for heat, and the control will resume normal
operation.
Burner Adjustment
All adjustment to this furnace and its components must
be done by a qualified service technician.
Refer to Table 2 for nozzle and pump pressure information.
The proper way to adjust an oil burner is with a CO2 analyzer
and a smoke gun. A properly adjusted burner will result in a
quiet, clean fire which will prevent sooting and frequent
cleaning. To establish tolerance or a “window of operation”
into the unit, do not exceed #1 smoke. This will give the
burner more flexibility when there are changes in the
surrounding environment.
To adjust the burner:
1. Punch a 5/16” diameter service hole in the flue outlet.
This sampling hole should be at least two flue diameters
above the breeching, or elbow at the breeching, but
ahead of the barometric damper.
2. Operate burner, adjust air setting for good flame by visual
observation, and run for at least 10 minutes or until
operation has stabilized. A good flame will be entirely
contained in the combustion chamber and will be
predominantly yellow-white in color. As flame quality
lessens, the flame will turn more orange in color and
will start to rise above the combustion chamger.
3. Take a draft reading at the service hole. Adjust
barometric draft control in the stack to achieve and
overfire draft of –.01” to –.02” and a breach of –.02” to
–.04”.
4. Pull and record a smoke reading at the service hole
using an industry standard smoke tester. If smoke is
evident, it could be caused by a poor nozzle or
combustion setting. In some cases, it may be caused
by difference in oil or an unusual condition of installation.
5. If the burner is producing more than #1 smoke, loosen
the air control adjustment screw and rotate the band
until the flame appears clean.
6. Reset the draft if the combustion head or air settings
were adjusted (see Step 3).
7. Using a suitable test instrument for CO2 , take and record
a CO2 reading at the service hole. The CO2 measured
in the stack should be a minimum of 11% CO2 .
8. Using a suitable thermometer, obtain and record the flue
gas temperature at the service hole.
9. Use the CO2 reading and the flue gas temperature
reading to determine unit efficiency.
10. When the proper combustion and smoke readings have
been achieved, tighten the air adjustment screw.
11. Recheck the draft, smoke, combustion, and flue gas
temperature.

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
12
Nozzle and Electrode Alignment
Proper nozzle and electrode depth and alignment are
essential for proper burner operation. Figure 10 shows the
proper adjustment procedure using the Beckett “T” gauge.
To check and adjust the nozzle depth:
1. Insert the small end of the “T” gauge into the end of the
cone and measure from the flat of the end cone to the
tip of the nozzle. The proper measurement should be
1.13”. When the depth is correct, the tip of the nozzle
should just touch the base of the “T” gauge.
2. Nozzle adjustments are made by sliding the entire nozzle
assembly forward or backward within the blast tube (see
Figure 10).
To check nozzle alignment:
1. Insert the small end of the “T” gauge into the end of the
cone and measure the nozzle and electrode alignment
against the center lines marked on the gauge.
2. If the nozzle is not centered, but found to be too far left
or right, a new nozzle will need to be ordered. Do not
attempt to adjust by bending the 90° elbow in the
oil line.
SEQUENCE OF OPERATION
1. The thermostat calls for heat, activating the burner motor
and ignitor.
2. After a 15-second pre-purge period, the oil solenoid valve
is energized and ignition is established.
3. After thermostat is satisfied, thermostat circuit will open.
4. Power to the burner is interrupted, thus shutting down
the burner.
MAINTENANCE AND SERVICE
Oil Burner
It is recommended that the nozzle and oil filter be checked
before each heating season. Also recheck the conditions
shown on the OIL FURNACE START-UP CHECKLEST
found on page 2.
Always keep the valve shut off if the burner is shut down
for an extended period of time.
Flue Pipe
Have the flue pipe inspected annually by a qualified service
technician. If any soot or ash has formed inside the flue
pipe, remove and clean. If the flue pipe has any holes or is
rusted out, replace with a new flue pipe of the same size.
Inspect the flue draft control device and replace if defective.
Blower
Blower motor is pre-lubricated and sealed for extended
operation. No further lubrication is required.
The blower assembly may be removed from the cabinet for
cleaning and servicing of the blower. Disconnect power to
the unit before servicing.
Heat Exchanger
To clean the heat exchanger:
1. Remove the vent pipe from the furnace.
2. Remove the locking screws and the caps from the two
cleanout tubes; remove the flue access elbow.
3. Using a long spiral wire bursh, sweep down the outer
drum of the heat exchanger. Using a shop vacuum hose
attachment, vacuum out all loose debris.
4. Remove the locking screw and cap from the inspection
tube and with the spiral wire brush reach upward toward
the rear of the heat exchanger to clean out the crossover
tube; replace the locking screw and cap on the inspection
tube.
5. Do not attempt to clean the combustion chamber, as it
can be easily damaged.
6. Replace the three previously removed cleanout caps
and flue access elbow, making sure to reinstall the
locking screws.
7. Brush out and vacuum the vent outlet area of the outer
drum and reattach the vent pipe.
8. Clean up around burner, blower deck, and vestibule area.
Beckett Oil Burner Nozzle Adjustment
Burner must be removed from
furnace for this procedure.
To adjust nozzle:
1. Loosen screw.
2. Slide entire nozzle/electrode assembly back and forth
until nozzle just touches gauge
Figure 10

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
13
Heat exchanger cleanout kit #ABRSH380-3 is available from
the manufacturer.
Emergency Fuel Pump Replacement
If replacement of the A2EA6520 fuel pump becomes
necessary, replace it with another Beckett CleanCut fuel
pump. In an emergency situation where the correct
replacement parts are not available, an A2VA7116 fuel pump
could be used. This option can produce a smoky start-up
and shutdown that could result in fouling of a heat exchanger.
This is only a short-term option and should be used
only until the correct parts can be obtained and installed.
Complete National Fuel Gas Codes are available from:
1. American Gas Association
1515 Wilson Boulevard
Arlington, VA 22209
2. National Fire Protection Association, Inc.
1 Battery March Park
Quincy, MA 02269
3. American National Standards Institute, Inc.
Publications Sales Department
11 West 42nd Street
New York, NY 10036
Figure 11
Humidifier Wiring
This diagram is intended as a general guide only. See the humidifier manufacturer’s
installation instructions for detailed connection information.
Figure 12
Electronic Air Cleaner Wiring
This diagram is intended as a general guide only. See the humidifier manufacturer’s
installation instructions for detailed connection information.

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
14
Figure 13
Wiring Diagram
Direct Drive

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
15
Figure 14
Wiring Diagram
Belt Drive - Heating Only

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
16
Figure 15
Wiring Diagram for
Horizontal Venting with
the Tjernlund System
Wiring Diagram for
Horizontal Venting with
the Field Control System

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
17

Installation and Operation Manual - ODF, ODR, OUF, OLF & OLR Series
18

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