INOV8 F450 User manual

INOV8 Model F450 – Edited July 2010
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INTERNATIONAL INCORPORATED
ASSEMBLY, INSTALLATION, MAINTENANCE
AND OPERATING INSTRUCTIONS
INOV8 F450 Multi-fueled Unit Heater & Furnace
Save These Instructions! This manual must be kept near the furnace!

INOV8 Model F450 – Edited July 2010
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SECTION 1 – GENERAL GUIDELINES...........................................................................................0
Codes & Regulations........................................................................................................................................................ 0
U.S. EPA Regulations & Used oil Burning........................................................................................................................ 0
Listing Agencies ............................................................................................................................................................... 1
Fuels- general information................................................................................................................................................ 1
Special Precautions!......................................................................................................................................................... 1
Warranty is void if … ........................................................................................................................................................ 2
Disposal............................................................................................................................................................................ 2
Unpacking & Inspecting.................................................................................................................................................... 2
Minimum Clearances........................................................................................................................................................ 2
Shipping & parts information ............................................................................................................................................ 3
Figure 1 - Model F450 Dimensions & Specifications................................................................................................ 4
SECTION 2 – FURNACE INSTALLATION ......................................................................................5
FURNACE LOCATION ................................................................................................................................................ 5
Ceiling Mount Installation Considerations......................................................................................................................... 5
ATTACHING THE BURNER TO THE FURNACE............................................................................................................... 6
Installing the Burner:......................................................................................................................................................... 6
Installing the Electrical Plug.............................................................................................................................................. 6
Electrical Hookup of the Furnace...................................................................................................................................... 6
Attaching the Air Connection ............................................................................................................................................ 6
Attaching the Oil Delivery Line.......................................................................................................................................... 7
Attaching the Return Line ................................................................................................................................................. 7
Fan/Limit control............................................................................................................................................................... 7
INSTALLATION DETAILS............................................................................................................................................. 7
Air Supply Installation ....................................................................................................................................................... 7
Chimney Installation ......................................................................................................................................................... 8
Installing the Barometric Draft Control.............................................................................................................................. 9
Blocked Vent Switch –supplied with Canadian Furnaces (or optional) ............................................................................. 9
Draft Measurements & Adjustments............................................................................................................................... 10
Installing an Optional Draft Inducer ................................................................................................................................ 10
Figure 2 - Typical Installation Diagram................................................................................................................... 11
Electrical Supply Installation........................................................................................................................................... 11
Mounting the Wall Thermostat........................................................................................................................................ 11
TANK &PIPING CONSIDERATIONS........................................................................................................................... 12
Oil Storage Considerations............................................................................................................................................. 12
Piping & Fitting Recommendations................................................................................................................................. 12
Vapor Eliminator Filter / Pressure Relief Assembly ........................................................................................................ 13
Vent Line Installation from Vapor Eliminator back to the Tank ....................................................................................... 13
Vapor Eliminator Filter .................................................................................................................................................... 13
Tank Filter ...................................................................................................................................................................... 13
Bench Tank Installation .................................................................................................................................................. 14
Figure 3 - Bench Tank Setup ................................................................................................................................. 14
Boost Pump (optional) .................................................................................................................................................... 15
Figure 4 - Diagram Showing Installation of Suntec Boost Pump, Filter, Check valve, Regulator & Gauges .......... 16
Figure 5 – Burner Diagram .................................................................................................................................... 17
Final Installation Checklist .............................................................................................................................................. 18
SECTION 3 – OPERATING THE FURNACE .................................................................................19
FIRST START-UP OF FURNACE................................................................................................................................19
Priming the Oil System ................................................................................................................................................... 19
Firing up the Furnace the First Time .............................................................................................................................. 19
Ducted Furnace Installation Check................................................................................................................................. 20
NORMAL OPERATION OF FURNACE .........................................................................................................................21
FACTORY SETTINGS...............................................................................................................................................22
Figure 6 - Electrode Adjustment Diagram .............................................................................................................. 22
FLAME ADJUSTMENTS ............................................................................................................................................23
Figure 7 – Proper & Improper Flame appearances............................................................................................... 23
MAINTENANCE .......................................................................................................................................................24
General Information........................................................................................................................................................ 24

INOV8 Model F450 – Edited July 2010 iii
Changing Filters.............................................................................................................................................................. 24
Vacuuming the Combustion Chamber & Heat Exchanger Tubes ................................................................................... 24
Annual Maintenance ....................................................................................................................................................... 25
Chimney Inspection ........................................................................................................................................................ 25
Summer Burner Refurbishing Program........................................................................................................................... 26
SECTION 4 - TROUBLESHOOTING ............................................................................................. 27
General Failure Categories & Potential Causes ............................................................................................................. 27
Using Lights on the Controller to Diagnose Symptoms................................................................................................... 28
SECTION 5 –DETAILED SERVICING PROCEDURES ................................................................. 30
Removing the Module from the Burner ........................................................................................................................... 30
Replacing the Module into the Burner............................................................................................................................. 30
Flushing the Final Delivery.............................................................................................................................................. 30
Checking the Oil Spray ................................................................................................................................................... 31
Checking the Oil System................................................................................................................................................. 31
Checking the Ignition Arc................................................................................................................................................ 32
Checking the Atomizing Air System................................................................................................................................ 33
Checking the Draft & things that can cause it to be wrong.............................................................................................. 33
By-passing the Bimba Cylinder....................................................................................................................................... 34
Replacing the Vapor Eliminator Filter ............................................................................................................................. 34
Cleaning the Nozzle........................................................................................................................................................ 35
Rebuilding the Pump ...................................................................................................................................................... 35
Cleaning the Pump Internal Pressure Regulator............................................................................................................. 36
Oil Temperature Controller: Operation & Settings .......................................................................................................... 37
Oil Temperature & Pressure Settings..................................................................................................................... 37
Adjusting the Temperature Controller..................................................................................................................... 38
Removing Excess Oil from Combustion Chamber.......................................................................................................... 38
PROCEDURE FOR PARTS REPLACEMENT................................................................................................................. 39
ADDENDUM................................................................................................................................... 40
THEORY OF OPERATION......................................................................................................................................... 40
MAIN COMPONENTS &THEIR FUNCTIONS ............................................................................................................... 41
The Fireye Controller ...................................................................................................................................................... 41
The Oil System ............................................................................................................................................................... 42
The Primary (atomizing) Air System ............................................................................................................................... 43
ELECTRICAL DIAGRAMS ......................................................................................................................................... 44
Figure 8 – Basic Wiring Diagram for Furnace ........................................................................................................ 44
Figure 9 – SubbaseWiring Diagram ....................................................................................................................... 45
PARTS LIST &TOOLS............................................................................................................................................. 46
SECTION 6 - GLOSSARY ............................................................................................................. 47
Notations Used in this Manual
RISK OF INJURY OR SYSTEM DAMAGE – Identifies a possible dangerous
situation that can lead to personal injury or physical damage.
NOTICE – This is a tip or notice for optimum use of equipment and
adjustment as well as useful information.

INOV8 Model F450 – Edited July 2010
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SECTION 1–GENERAL GUIDELINES
Congratulations on your purchase of this INOV8 Multi-fueled Furnace. You have
selected the highest quality, precision-engineered piece of equipment available,
designed specifically to allow you to fully benefit from the used oils generated in
your business. INOV8 has not compromised in engineering this product for high
efficiency, safety, longevity, operating economy, and to allow you a maximum of fuel
choices; all while providing the highest standards of environmental considerations.
This manual was written for the novice technician with detailed instructions for the
installation, start-up, routine operation and maintenance of this furnace. If these
instructions and pertinent local regulations are followed closely you will be assured
full satisfaction.
CODES &REGULATIONS
This manual covers installation, maintenance and service of the INOV8 model F450
furnace. This manual covers the installation of the chimney system, fuel storage
and piping connections and electrical work. All work shall be performed by a
qualified contractor in strict accordance with the requirements of state, provincial
and local regulating agencies and codes pertaining to oil-burning equipment
installations. After start-up the owner or its representative should be instructed
about the furnace operation and be given this manual. This equipment must be
installed according to these national standards.
For furnace equipment: ANSI/NFPA # 31 – Standard for the Installation of Oil-
Burning Equipment – 2006 Edition, and in Canada to
CSA Standard B139.
For chimney installation: ANSI/NFPA # 211 – Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliance,
2006 Edition
For oil storage installation: NFPA # 31 – Standard for the Installation of Oil-
Burning Equipment – 2006 Edition
For electrical installation: NFPA # 70 – National Electrical Code – 2005
Cleaning and routine maintenance must be carried out at least quarterly during
operation. This shall include an overall check of the heating system. There should
be periodic inspection of the combustion chamber for possible deterioration. Any
discrepancies must be corrected immediately.
NOTE: This manual is for reference only. The manual does NOT purport to address all
design, installation and safety considerations. It is the responsibility of the user of this manual
to determine the applicability and safety of each individual application and ensure its
compliance with local building codes.
U.S. EPA REGULATIONS &USED OIL BURNING
On August 12, 1992 the U.S. Environmental Protection Agency (EPA) announced that it
would not list nor classify as hazardous waste, used oil destined for recycling. They also
affirmed the long-standing regulatory exemption, which allows the operation of used oil-fired
furnaces. Under this exemption, used oil-fired furnaces may operate without a regulation so
long as the owner burns "on-specification used oil". Used oil exceeding EPA designated
levels of contaminants is classified as "off-specification used oil" which means the owner
must comply with three requirements: the heater does not exceed 500,000 BTU per hour, it is
vented to the outside, and burns oil generated on-site or collected from do-it-yourself oil
changers. After years of careful study the EPA concluded that used oils that are recycled in
this manner do not pose a substantial present or potential hazard to human health or the
environment so long as they are managed properly. To this end, EPA's regulations are
designed to provide safe and environmentally sound used oil management practices.

INOV8 Model F450 – Edited July 2010 1
LISTING AGENCIES
This equipment is tested and listed by Intertek ETL Semko (ETL) - an
internationally recognized third party test agency to UL 296A - Standard for Safety
for Waste Oil Burning Air-Heating Appliances, Edition 2, Revision 2006/03/08 (the
U.S. used oil standard), and to CSA B140.0 General Requirements for Oil Burning
Equipment General Instruction No 2-4 (R1991) Rev: 1991/01/01and is listed with
the European Economic Community with a CE registration number 3884/97. The
INOV8 tanks are also tested and listed by ETL to UL 80 Standard for Steel Tanks
for Oil-Burned Fuel.
FUELS-GENERAL INFORMATION
This product is approved to burn the following oils: crankcase oil, crankcase oil with
up to 20% gasoline, fuel oils up to #6 heating oil, jet fuel, mineral spirits and
transmission oil. The following additional oils have been tested and passed
combustion analysis requirements but are not approved as fuels due to a lack of
standards to define them: used and crude vegetable oil, and biodiesel. DO NOT
attempt to burn other liquids without written authorization from INOV8 International,
Inc. Only used oil generated on the premises of the owner may be used in this
equipment, unless written authorization is obtained from the regulatory authority.
Caution – used oils may contain gasoline, heavy metallic compounds and foreign
materials. When burned, these compounds are emitted from or deposited within
this furnace and therefore care should be taken when storing these oils or when
using, cleaning and maintaining this equipment.
SPECIAL PRECAUTIONS!
1. This furnace is listed for commercial or industrial use only. It may not be
used for residential or any other unauthorized purpose.
2. All furnaces must be wired strictly in accordance with wiring diagram and
instructions in this manual.
3. Disconnect the power supply before making wiring connections to prevent
electrical shock and equipment damage.
4. Disconnect the power supply before cleaning the furnace.
5. Do not install furnace or chimney connector closer than 18 inches to
combustible materials in any direction, except the louver side of the furnace,
which must be unobstructed.
6. DO NOT add fluids with the classification of a hazardous waste, or fuels
with flash points below 100oF (such as gasoline) to your used oils. (Check
your local codes for restrictions.)
7. For your protection - DO NOT store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other appliance.
8. Canadian standards allow only used oil generated on the premises of the
owner to be used as fuel, unless permitted by the regulatory authority.
9. Hazardous Atmosphere - The INOV8 products are not designed for use in
hazardous atmospheres containing flammable vapors or combustible dust,
or atmospheres containing chlorinated or halogenated hydrocarbons.
10. Venting - Failure to provide proper venting could result in death, serious
injury, and/or property damage. Units must be installed with a flue
connection, draft regulator and proper vent to the outside of the building.
Safe operation of any gravity vented heating equipment requires a properly

INOV8 Model F450 – Edited July 2010
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operating vent system, correct provision for combustion air, and regular
maintenance and inspection.
WARRANTY IS VOID IF …
1. The heater is not installed in accordance with these instructions and
applicable codes and ordinances.
2. The wiring is not in accordance with drawings in this manual.
3. The Furnace or burner is not maintained in accordance with maintenance
requirements – particularly failure to clean the combustion chamber and
heat exchanger on a regular basis.
4. Other than specified fuel is burned.
5. Fuel input capacity is over the rated condition of maximum flow rate of 3.5
US gallons or 13.25 liters per hour.
Note: Information on the Limited Warranty was sent along with the sales order.
DISPOSAL
Dispose of packaging in an environmentally responsible manner. Dispose of all
heating system components that have to be replaced at an authorized disposal site.
Dispose of ash in a responsible manner.
UNPACKING &INSPECTING
Immediately upon receipt, check the cabinet and burner for any damage that may
have occurred in shipment. If damage is found, INOV8 or the sales representative
must be notified within two days in order to process shipping damage claims. Prior
to shipping, all components were inspected and the burner test fired, so the burner
will still have oil in it.
MINIMUM CLEARANCES
Furnaces must be installed so that the following clearances are provided for proper
air movement, service and distance from combustible materials. In addition to walls
and ceilings, combustibles include rags, paper, or any moveable combustibles like
gasoline or other flammable fluid.
Inches Millimeters Purpose
Blower inlet: 6 152 air movement
Chimney connector (flue pipe): 18 457 combustible
material
Below Furnace: 4 101 combustible
material
Above Furnace: 48 1,219 serviceability
Outlet Louver: Unobstructed air movement

INOV8 Model F450 – Edited July 2010 3
SHIPPING &PARTS INFORMATION
The INOV8 Waste Oil Furnace is shipped on a pallet with strapping and plastic
wrap. This includes the heat exchanger, fan, and fan motor (mounted and wired).
The burner is packed in a separate box that also contains other parts, based on the
following list and what was purchased. Immediately upon receipt of INOV8 products
inspect all parts for possible shipping damage or missing parts and report any
problems within 48 hours.
Check for the items shown in the photos, that they are received:
1. Oil Pickup Assembly, includes these parts from the top down:
a. One ¾” check valve
b. 3/4 “ x 2” black nipple
c. One 90ostreet elbow
d. Filter mount
e. One 90ostreet elbow
f. One ¾” x 12” pipe nipple
g. Double tap bushing, 2” with ¾” x ½”
reducing bushing
h. One primary filter, model Gar-Ber
Spin-on Filter #11V-R2000K with Filter
Restriction Indicator
2. Barometric draft control – 8”
(see photo at right)
The following items are shown in the lower photo:
3. Wall Thermostat - 120 volt (line voltage).
4. Other items include:
a. Instruction Manual
b. Spare vapor eliminator filter
c. Spare 10 amp (brown) & 4 amp
(orange) fuses
d. Burner gasket
5. Air regulator Assembly, includes:
a. Air regulator
b. Air gauge, 0 – 160 psig
c. Plastic nut
d. Bracket and screws
e. ¼” air tube
The following items are not shown in the photos:
6. Bench Tank - (optional), which includes:
a. 300 gallon bench-type tank
b. Optional stands
c. Tank gauge, oil supply and lines with fittings
2
3
5
4
1

INOV8 Model F450 – Edited July 2010
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Figure 1 - Model F450 Dimensions & Specifications
Model F450 Specifications
BTU Input/Output 450,000 / 382,500 Burner – Model R200 450,000 BTU
Fuel Wastes as specified Nozzle Delavan 30609-5
Height without Burner 41” Compressed Air 3 CFM, 38 PSIG
Height with Burner 55” Electrical Amps 18.6
Width 45” Burner electrical requirements 120 volts, 10 amps
Length with Blower 84” Circuit Protection 20 amp, dedicated
Weight 850 lbs. Fan motor electrical 220 volts, 8.6 amps
Stack, required 8” Electrical supply 220 volts with neutral
Cabinet fan motor 1 ½ Hp Oil pressure setting 8 to 9 psig
Required stack height 12 ft from furnace GPH 3.5
Squirrel cage blower 1725 CFM (230 volts) Required draft 0.03 to 0.05” of WC
Support openings 41 ½” x 52” Burner configuration
Downward firing,
upright for servicing

INOV8 Model F450 – Edited July 2010 5
SECTION 2–FURNACE INSTALLATION
FURNACE LOCATION
Furnace location and other installation requirements were covered in the “Pre-
installation Considerations” document that was sent along with the confirmation of
order. It is absolutely essential that you have read that document before proceeding
with the installation. If you don’t have it, contact INOV8 and it will be faxed or e-
mailed.
The furnace location is important to the efficient operation of the system. These
abbreviated guidelines will insure the most beneficial location. Further details are
found on subsequent pages.
1. The location of the chimney must be considered before other aspects of the
installation. See the section entitled, “Chimney Installation” for further details
2. Select a location as close as possible to the oil storage tank. The burner pump
can suck laterally easier than it can vertically but there are limits. If the distance
from the tank exceeds 30 feet or when the height exceeds 8 feet, a boost pump
may be necessary.
3. Furnaces hung higher than the standard 8 feet are not recommended. The
location should provide easy access to the furnace for routine servicing
and maintenance and for proper heat distribution.
4. To prevent premature heat exchanger failure, DO NOT locate in areas where
chlorinated, halogenated or acid vapors or other corrosive contaminants may
exist.
5. DO NOT install the furnace outdoors or in excessively wet conditions.
6. DO NOT attach air filters to the furnace.
7. In multiple furnace installations, arrange furnaces so that each supports the air
stream of the next furnace, thus creating circulatory air movement in the area.
A large portion of the heated air should be directed toward the side of the
building exposed to prevailing winds. The INOV8 dealer can provide
recommendations for the most efficient installation of multiple furnaces. These
installations will vary depending upon the unique layout of the facilities.
8. Adequate combustion air is required to maintain combustion. The INOV8
furnace will not operate in a negative building pressure (see section on sealed
combustion if this exists).
9. Minimum clearances from combustible surfaces must be adhered to. See the
section “Minimum Clearances” for more information.
It is recommended that the F450 furnace be installed on stands on the floor rather
than suspended from the ceiling because of the weight. If the furnace must be hung
make certain to adequately transfer the furnace weight to the roof/ceiling trusses.
Use a proper ceiling mounting system, such as a 2" x 2" x 1/4" angle iron. Lock all
mounting components in place using lock washers and double nuts. It is important
that the furnace be hung level side-to-side and front-to-back. Never use ropes or
chains to hang the furnace.
CEILING MOUNT INSTALLATION CONSIDERATIONS
Be aware that the F450 furnace weighs 1,100 pounds (410 kg) when planning its
installation. Before suspending the unit, check the supporting structure to ensure it
has sufficient load-carrying capacity. Securely transfer the furnace weight to the
roof/ceiling trusses. Use a proper ceiling mounting system, such as a 2" x 2" x 1/4"
angle iron. Lock all mounting components in place using lock washers and double
nuts. It is important that the furnace be hung level side-to-side and front-to-back
and level with the floor. Never hang the furnace with ropes or chains.

INOV8 Model F450 – Edited July 2010
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ATTACHING THE BURNER TO THE FURNACE
Once the furnace cabinet has been installed, then you are ready for the burner to be
attached to the furnace cabinet. Carefully remove the burner and components from
the shipping box. Be careful when handling the burner, as the electrodes and the
flame retention head are factory set and if either are bumped or moved, the
operation of the burner could be affected. If the electrodes get out of adjustment,
refer to page 22 for a diagram of the proper electrode settings. The burner has been
pre-fired in the factory prior to shipping and will have oil in it. A plug has been
installed in the pump for shipping and should be removed carefully to avoid spilling
oil.
INSTALLING THE BURNER:
1. Place the burner gasket onto the air tube.
2. Remove the three 3/8”-16 nuts from the burner mounting plate studs.
3. Place burner on mounting plate studs.
4. Now tighten the 3/8” nuts that hold the burner to the mounting plate.
INSTALLING THE ELECTRICAL PLUG
Insert the round burner power plug into the socket provided on the bottom of the
electrical junction box that houses the GFCI outlet.
ELECTRICAL HOOKUP OF THE FURNACE
1. Remove a convenient knock-out from the electrical junction box to allow
connection of your electrical supply conduit.
2. Attach the hot wire (typically black) to the 6” black pigtail that comes off the
GFCI “Line Hot” terminal.
3. Attach the Neutral wire (typically white) to the 6” white pigtail that comes off
the GFCI “Line Neutral” terminal.
4. Attach the earth ground wire to the 6” green pigtail that comes off of the
junction box.
5. Hook the other hot wire (typically red) to the red pigtail that comes off the
fan contactor.
ATTACHING THE AIR CONNECTION
The air regulator assembly is in a plastic bag in the burner box.
1. Remove the screws and all necessary parts from the plastic bag.
2. Mount the ‘L’ shaped bracket to the right side of the burner just above
the end of the motor (as shown in the photo at right).
3. Secure with the two screws that are provided.
4. Then mount the air regulator into the bracket, securing it with the black
plastic ring nut.
5. Connect the ¼” air line into the right-most fitting in the bottom of the
module block. It just slides in and locks. It can be removed by pushing
up on the ring on the fitting and then pulling the line back out.
6. There is a ¼” NPT hole in the regulator into which you can install a
quick-disconnect type of fitting. To this connect the air supply line
coming from the compressor. The regulator will be set during the
section on “Operating the Furnace”.

INOV8 Model F450 – Edited July 2010 7
ATTACHING THE OIL DELIVERY LINE
Specifics on the oil storage and plumbing are covered in the section titled “Tank &
Piping Considerations” starting on page 12. The items in that section must have
been completed in order to have an oil supply line run to the burner at this time.
Assuming the line is in place: the oil supply line will connect to the inlet port of the
pump on the burner. There are two inlet ports: one on the bottom of the pump and
one on the side. Connect to the one on the side. Attach the line to the pump via a
½” x ¼” NPT flare fitting and use the corresponding female portion with a barb fitting
to attach to a flexible oil line. DO NOT do the following:
•plumb the line directly into the pump,
•use any compression fittings,
•use rigid line that will be difficult to remove for servicing the burner.
Be sure to seal the ¼” NPT threads of the flare fitting at the pump inlet. ONLY Use
pipe sealant suitable for waste oil, such as Loctite #565.
ATTACHING THE RETURN LINE
As noted in the section “Installation of Vent Line from Vapor Eliminator Back to the
Tank” on page 13, a ¼” O.D. (minimum) copper or plastic line must be installed from
the burner back to the tank. This line will connect to the brass elbow on top of the
oil pressure release mechanism via the compression nut and ferrule supplied on
that elbow. There will be no pressure in this line as long as the line is open all the
way back to the tank. It is ABSOLUTELY IMPERATIVE that no valves or other
constrictions be placed or allowed to exist (like crimps) in this line.
FAN/LIMIT CONTROL
The fan/limit controls the on/off function of the motor that drives the fan or blower
unit. It also shuts down the burner in the event of excessive heat in the furnace.
This safety control is located in the upper corner (on the louver side of the furnace).
Make certain that the switch has the proper settings: Fan ON = 140oF, Fan OFF =
80oF, Limit = 170oF. It should be on the “AUTO” setting.
INSTALLATION DETAILS
AIR SUPPLY INSTALLATION
There are two air supplies used in the combustion process. Combustion air
entering the chamber through openings in the burner housing, located next to the oil
pump, is referred to as "secondary or combustion air". Air is also supplied to the
nozzle under pressure in order to atomize the oil into small particles for burning. A
shop air compressor supplies this air. This compressor air is referred to as either
primary air or atomizing air. Installation of the primary air is described below:
1. A continuous supply of compressed air (2.0 CFM at 30 psig) is required to
operate the furnace. The furnace includes a factory provided pressure regulator
rated at 300 PSIG with a gauge rated to 160 PSIG inlet for shop air. The
connection requires 1/4 " NPTM. The pressure regulator is located on the right
side of the burner housing (see photo on page 6) and controls air for use in
atomization.
2. The shop air must be free of dirt and water. A filter should be installed in the line
before attaching to the INOV8 burner. Do not attach the shop air directly to the
burner module as damage will occur from the high pressure.

INOV8 Model F450 – Edited July 2010
8
3. Air may be piped directly from the air compressor supply tank by using 1/4-inch
(or larger) pipe, seamless copper tubing, or air hose. If piping or rigid tubing is
used it is recommended that a short piece of hose be used to connect to the air
regulator (on the burner) in order to swing the burner away for cleaning the
combustion chamber. If air hose is used, it should have a minimum burst
pressure rating of 300 psig.
4. Water routinely condenses in the air lines of a shop compressor and must be
removed periodically. Water must be kept to a minimum to prevent component
failure and operating problems.
Note – If there are concerns for leaving the air compressor on during nights and
weekends, INOV8 has a compressor protection device available.
CHIMNEY INSTALLATION
Included in this section are the critical factors involved in the chimney installation.
The complete guidelines can be found in NFPA 211 – Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning Appliance, 2006 Edition, and in NFPA
#31 – Standard for the Installation of Oil-Burning Equipment – 2006 Edition. There
may also be local codes that need to be adhered to. The most critical factor in the
installation of your INOV8 furnace is a properly designed and located chimney. A
good draft (air movement up the chimney) is essential to the safe and reliable
operation of the furnace. The furnace will not run with any degree of success when
attached to an improperly installed chimney. The chimney MUST meet these
requirements:
1. The chimney must be 8” diameter pipe with a minimum of 12 vertical feet.
2. It must be tall enough and sufficiently clear of wind obstacles at the top to
provide constant, adequate draft to the furnace.
3. It must be free of any horizontal runs in excess of 3 feet. If any section of it
must be run laterally, run that section laterally upward at the sharpest possible
angle.
4. Avoid using elbows as much as possible, particularly 90o elbows. An additional
2 feet of chimney height is required for each elbow.
Most installation standards recommend that an insulated stainless steel chimney be
used from a point 18 inches below the ceiling to the top at the rain cap. The
purpose of the insulated chimney is to protect combustible building materials from
high temperature, but it also supports the chimney draft and prevents harmful
condensation within the chimney. For each gallon of oil burned, there is a gallon of
water vapor generated as a product of the combustion process. This water vapor
can condense inside the chimney in extremely cold weather. Some waste oils
contain various ingredients that will form acids when combined with the
condensation. These acids will prematurely corrode non-insulated, non-stainless
steel piping and the furnace heat exchanger.
An ideal chimney consists of 8” chimney pipe going straight up through the roof to
sufficient height to provide at least 12 feet between the furnace flue attachment and
the top of the chimney. Other items of importance include:
1. Each furnace must have a dedicated chimney.
2. New chimney pipe is recommended. Tying into old stacks often causes
problems because of soot build-up inside the chimney, too small of interior pipe,
the connection section is often a horizontal piece, concrete chimneys are cold
and difficult to heat up to create the draft and additional length is difficult to add.
3. A barometric draft damper must be installed at the bottom of the vertical
chimney.

INOV8 Model F450 – Edited July 2010 9
4. Single-wall flue pipe may be used for INTERIOR CHIMNEY ONLY! Stack
temperatures in excess of 500oare common.
5. A metal ventilated, approved thimble must be used when passing through a
combustible wall. Once through the wall, DO NOT use a single-wall
component.
6. Sidewall flue installations are prohibited without written factory authorization.
7. The last stack section must extend at least 3 feet above the highest point at
which it comes in contact with the roof, and at least 2 feet higher than any ridge,
parapet wall or roof structure within 10 feet of the chimney.
8. Install a non-restrictive stack cap (rain cap). In extremely windy locations, a
Breidert type vent cap is recommended. A screen to restrict birds from access
to the chimney is recommended.
9. It may be necessary to install a draft inducer on chimneys that fall short of
providing sufficient draft for whatever reason. See the following section for
more information.
INSTALLING THE BAROMETRIC DRAFT CONTROL
The barometric draft control is intended to provide consistent draft, especially in tall
chimneys where there may be excessive draft that could impact the flame. The best
location for the barometric draft control is in the first vertical section within one to
three feet of the furnace. The flapper on the barometric draft control should be
installed so it is facing away from the fan on the furnace. The flapper must be
vertical when closed. Use a spirit level to make sure the barometric draft control is
plumb in all directions, regardless of whether the flue is horizontal, vertical or
sloping. Do not attach the barometric draft control in a horizontal section of flue
pipe or in a room separate from the furnace. Additional installation instructions are
included with each damper.
BLOCKED VENT SWITCH –SUPPLIED WITH CANADIAN FURNACES (OR
OPTIONAL)
The Blocked Vent Switch responds to hot flue gases backing up through its heat
transfer tube during a blockage and shuts off the burner. The Backflow Sensor
Switch is supplied with furnaces shipped to Canada (or as an optional purchase)
and must be installed in accordance with these instructions and those that
accompany the switch, that are abbreviated here.
1. Drill or pierce a clean hole (about ¾” diameter) in the vent pipe near the heater
outlet.
2. The heat transfer tube must have the fiber gasket installed against the mounting
plate before attaching the unit to the vent pipe.
3. Insert the heat transfer tube with gasket into the ¾” diameter hole placed in the
vent pipe during step 1.
4. Secure the assembly to the vent pipe with a minimum of 4 sheet metal screws.
The channel must be mounted horizontally.
5. Refer to the electrical diagram in the Addendum for wiring connections – DO
NOT refer to the diagrams that accompany the switch.
This switch requires annual inspection and maintenance to remove any ash buildup
on the thermal switch surface.

INOV8 Model F450 – Edited July 2010
10
DRAFT MEASUREMENTS &ADJUSTMENTS
Tools Required: Dwyer Pressure Gauge, Draft Rite or Bacharach Draft Gauge
The barometric draft control must be set to maintain proper draft. Draft
measurements must be re-done any time there is a change in the combustion air
adjustment located on the burner housing (secondary air). Follow these instructions
for measuring the draft over the fire:
1. Check the draft while the burner is up to temperature and the cabinet fan is
running. Insert the draft gauge into the ¼” hole in the 2” view port. The
measurement must indicate a draft of 0.03 to 0.05 inches WC (water column)
for newly installed or newly cleaned furnaces. The furnace will not operate
properly with a draft less than 0.01.
2. A draft greater than 0.05 will induce excessive heat up the chimney resulting in
low heat output and abnormally high stack temperature. Make necessary
adjustments to the barometric draft damper, according to the factory instruction
sheet found in the box the damper comes in.
INSTALLING AN OPTIONAL DRAFT INDUCER
A draft inducer is a motor driven fan that attaches to the chimney for the purpose of
augmenting the natural draw of that chimney. It may be necessary to install a draft
inducer on chimneys that fall short of providing sufficient draft for some reason or
other, but a draft inducer is not a cure-all: It provides no relief for resonation
problems that can occur in horizontal runs, for instance, and it cannot overcome the
effects of an exhaust system operating within the building. Should you find that your
installation requires the assistance of a draft inducer, install it according to the
following guidelines:
Install it just above the barometric draft control in a vertical section. Avoid mounting
in horizontal sections for these reasons: a) ash will accumulate on the blades, b) it
will be exposed to excessive heat, and c) it will need to be supported in some
manner. A red wire is provided in the furnace’s electrical junction box which
functions to control a relay that turns the draft inducer on at the proper time. Wire
the draft inducer and relay in accordance with the electrical wiring diagram. Draft
inducers are adjustable and may need to be adjusted to obtain proper draft.

INOV8 Model F450 – Edited July 2010 11
Figure 2 - Typical Installation Diagram
ELECTRICAL SUPPLY INSTALLATION
Installation must be done only by a licensed electrician in accordance with the
NFPA 70-2005, National Electric Code® International Electrical Code® Series. See
electrical diagrams in the Addendum. The burner and controls power requirement is
10 Amps at 120 volts. The power load specifications are also found on the furnace
label. The fan motor power requirement is 8.6 amps at 220 volts. Do not operate
the furnace on other than a 20 Amp circuit breaker. The furnace must have a
proper dedicated electrical circuit.
MOUNTING THE WALL THERMOSTAT
A 120 volt ‘line’ type thermostat will have been included with the furnace shipment.
It should be mounted at eye level above the floor on an inside wall and not in the
path of warm or cold air currents. Do not install on, or suspend from the furnace.
Do not install on a cold outside wall unless over insulation. Do not wire relays or
other accessories to the thermostat. Use two conductor 12 or 14 gauge wire to
connect the thermostat back to the electrical junction box on the furnace. Since the
furnace is usually mounted eight feet above the floor, a good location for the
thermostat would be at eye level immediately under the furnace.
Two wires are needed to connect the wall thermostat into the electrical junction box
on the furnace. There are two unconnected wires in the junction box – one from the
burner socket is brown and one from the fan/limit control is yellow. Attach the wall
thermostat wires to these wires. It doesn’t matter which thermostat wire goes to
which wire. They both carry 120 volts.

INOV8 Model F450 – Edited July 2010
12
TANK &PIPING CONSIDERATIONS
OIL STORAGE CONSIDERATIONS
The proper storage and handling of oil is monitored by the federal EPA and most
state environmental agencies, such as the Department of Natural Resources (DNR),
your local Fire Marshall and/or the Regional Environmental Protection Agency.
Some states have adopted more stringent regulations which must be identified and
adhered to. Your installer is responsible for knowing these regulations and of any
pertinent application and/or approval requirements for your oil storage system.
Federal and some state and local regulations restrict the burning of gasoline, paint
thinners and other volatile (low-flash point) solvents, PCBs, benzenes (carburetor
solvent), and fluorinated hydrocarbons (refrigerants). DO NOT add anti-freeze, oil
additives, or paint as these will not burn and cause operating problems.
The instructions found in this manual are general guidelines; exact local regulations
must prevail. Installation of the oil storage and piping must be done by a licensed or
qualified installer in accordance with the pertinent state and local codes and the
nationally accepted standard, NFPA 31 – Standard for the Installation of Oil-Burning
Equipment 2006 Edition.
Many operational problems can be eliminated if proper care is taken in setting up an
oil storage system. All waste oil contains substantial amounts of water and sludge,
both of which settle to the bottom of a tank over a period of time. A storage system
that allows sufficient settlement time will provide trouble free operation. A two-tank
system is recommended allowing one tank to settle while drawing from the other.
Use a fill pipe when adding oil. This fill pipe should extend to within two inches of
the bottom of the tank to minimize the disturbance of the upper oil that is supplied to
the burner. At least once a year the water and sludge should be drained off the
bottom of the tank. If not drained, the pump will draw the water and sludge into the
filters and may cause a shutdown in operation. The tank should be located in close
proximity to the furnace. Inside, outside or buried tanks must be used in accor-
dance with state and local installation codes.
PIPING &FITTING RECOMMENDATIONS
Air leaks in the oil line will cause sporadic operation. The pipe or tubing size is
important for the best operation of the pump. The following recommendations will
produce airtight connections and trouble-free operations.
1. If the storage tank is inside the building, use 1/2" i.d. (Up to 30 feet to the
furnace).
2. If the tank is more than 30 feet away then 1" i.d. or bigger is required
(depending on the distance).
3. Copper piping or iron piping can be used if care is taken with each joint and the
line has a continuous upward incline of at least 1-inch per 1 foot to vent air to
the burner. Flexible copper tubing may be suitable. When using soft copper
tubing or plastic tubing flare fittings are required. Proper sized copper tubing
with proper flare fittings has the least potential for leaks. DO NOT use
numerous short lengths of pipe as each fitting is a potential source of a leak.
4. At no time should pipe unions or compression fittings be used. Sealant
(such as Locktite #565 or Permatex #2 Non-hardening Gasket Sealer) must
be used on all pipe threads.

INOV8 Model F450 – Edited July 2010 13
VAPOR ELIMINATOR FILTER /PRESSURE RELIEF ASSEMBLY
The vapor eliminator/pressure relief assembly (see items #2 and 26 on page 17)
serves three functions:
1. It vents any vapors that accumulate in the burner’s oil circulating system back to
the oil supply tank.
2. It filters the oil as it is heated and re-circulated at the burner.
3. It shunts the full volume of the pump back to the tank in the event the vapor
eliminator filter should become totally plugged.
VENT LINE INSTALLATION FROM VAPOR ELIMINATOR BACK TO THE TANK
A minimum of ¼” copper line or plastic tubing must be run from the compression
fitting on the pressure relief assembly back to the oil supply tank. There must be no
valves or constrictions in this line. See “Burner Ignition Start-up” for adjustment of
the valve controlling flow through this line.
1. Insert one end of the return line into the nut and ferrule
(provided) on the pressure relief valve on the vapor
eliminator.
2. Run the line along the oil supply line back to the oil storage
tank through an available opening. Make sure the return
line nearly touches the bottom of the tank to prevent loss of
prime in the oil supply line. If no opening is available, use a
“T” fitting to share the opening with the supply or fill opening.
3. While the burner is running there should be a steady rapid
drip (not a stream) coming from the end of the return line.
Adjust the valve accordingly. Excessive flow will take all the
hot oil back to the tank, inadequate flow will cause vapor to
build in the pump.
VAPOR ELIMINATOR FILTER
The filter element in the vapor eliminator canister can plug up over time due to the
normal collection of debris. When the filter is plugged, an amber light on the burner
will come on while the burner is firing to indicate that the filter should be changed. If
the filter is not changed, the pressure relief assembly will vent the over pressured oil
back to the tank through the ¼” return line.
TANK FILTER
INOV8 provides an in-line filter assembly to be installed in the oil supply line. This
filter will need to be changed every six months or as indicated on the filter restriction
indicator; the frequency depends on the type of oil. This filter is a General Filter,
model 11V-R2000K Gar-Ber Fuel/Water Separator. It has a machined aluminum
head. The filter dimensions are: 9” H x 4-3/4” W. It comes with a 1/8” vacuum
bleed port, a 3/8” NPT inlet and outlet, has 10 micron removal, filtering area of 500
square inches, working pressure of 15 psig and a flow rate of 90 gph, and is UL
listed. Replacement elements require part number R2000 Epoxy-coated
Disposable Spin-On Filter.

INOV8 Model F450 – Edited July 2010
14
BENCH TANK INSTALLATION
Tanks are available in a variety of sizes and configurations. Our model T300 HB, a
300 gallon tank with steel supports, holds the INOV8 furnace eight feet above the
floor. Installations using this bench tank are easier than those without a bench tank
because of the ease in mounting the furnace versus hanging and the short distance
for running the oil supply line. The bench tank comes fully supplied with all
necessary fittings for a complete installation. Many states and cities have additional
regulations regarding the storage of waste or other fuels that may require stricter
measures. It is very important to check with your local fire inspector, or the proper
authority, or a qualified tank installer regarding the requirements in your area. Refer
to these steps for a basic installation.
Figure 3 - Bench Tank Setup
Installation Instructions
1. It’s generally a good idea to locate the bench tank on an outside wall for ease in
venting the tank and venting the flue gases of the furnace.
2. Attach the upright support brackets to the back of the tank by sliding them into
the square tube receptacles having the support brackets. Use two 3/8" bolts
per support bracket to secure.
3. Secure the furnace to the top of the support brackets. Secure to the support
brackets with the four bolts provided. This is critical and if left undone may
result in the furnace falling.

INOV8 Model F450 – Edited July 2010 15
4. There are four openings on top of the tank, to be used for:
a. The fill – left front, 2”
b. The gauge – back middle
c. Venting – left back, 3”
d. Supply line to burner, right back, 2”
5. DO NOT MOVE the tank once the furnace has been mounted.
BOOST PUMP (OPTIONAL)
INOV8 supplies two different boost pumps: 1) an electric gear pump manufactured
by Suntec Industries, and 2) a Husky diaphragm pump manufactured by Graco
Industries. Both do a fine job moving waste oil from a storage tank to the burner.
The installations are different in that the Suntec pump requires an electrical
connection to power the pump, while the Graco pump requires air pressure to drive
the pump.
•Suntec pump: The pump MUST be mounted so the motor / pump shaft line
are horizontal and the pressure relief valve in the boost pump must be set to
20 PSI. The pump will not work if mounted upside down. See the electrical
hookup for the boost pump on the electrical diagram on page 44.
•Graco Diaphragm pump: an air pressure regulator and gauge assembly
must be installed in the airline prior to the pump. The air regulator controls
the pumping pressure and is usually set at 30 - 40 PSIG. This may be varied
to accommodate your installation. Instructions accompany the pump and
must be followed for the installation.
Follow these guidelines for either pump:
1. Install the boost pump as close to the oil tank as local code allows, but
always inside the building. Keep the suction line and suction lift as short as
possible. The maximum horizontal suction run is 30 feet and the maximum
suction lift is 4 feet.
2. Make sure the boost pump can be easily primed and serviced and it is
protected from water and combustible fumes. A strainer (not supplied by
INOV8) should be installed at the end of the oil suction line within the tank
to protect the boost pump from debris.
3. Locate the filter/check valve assembly at a convenient location between the
boost pump and the oil pressure regulator assembly (supplied by INOV8
with boost pumps). Connect to the outlet side of the boost pump with 1/2
inch copper tubing.
4. After the proper piping/tubing has been installed the pump may be turned
on for priming. For the Suntec Pump, leave the bleeder port of the boost
pump fully open until all entrapped air is purged from the suction line (at
least one-gallon of oil). When a steady stream of oil is flowing, close the
bleeder port and snug it tight with a 3/8” wrench. If the oil stream fluctuates
and sputters, check for air leaks in the suction line.
5. The oil pressure regulator and gauge assembly must be installed near and
at the same height as the burner.
6. The oil line between the tank and the boost pump must be absolutely
airtight so the pump does not suck air. It is very important that pipe
compound be used on all fittings and that they are tight. Pressure test the
line prior to use. Follow the recommendations in the following section for
installing the piping.

INOV8 Model F450 – Edited July 2010
16
If multiple furnaces are installed, one boost pump will supply a maximum of
three burners; however, a separate filter and regulator assembly is
recommended for each furnace.
Figure 4 - Diagram Showing Installation of Suntec Boost Pump, Filter, Check
valve, Regulator & Gauges
NOTE: The boost pump can be mounted at or below the level of the oil tank BUT
MUST NOT be mounted more than four feet above.
ALSO: The (+) (-) gauge on the outlet of the regulator shows positive (+) pressure
in pounds per square inch (PSI) and negative pressure in inches of mercury (in.
Hg). One PSI is equal to two inches of mercury and, with earth’s air pressure being
around 15 PSIG at sea level, a reading of –30 inches of mercury is equal to a
complete vacuum. A setting of –4 on this gauge should be adequate. If the
pressure falls below –10 there is an increased chance that you will start sucking air
through the pump seal or fail to get adequate firing pressure due to normal pump
wear. Positive pressure on this gauge means you are shoving oil into the burner
pump. The internal regulator in this pump will regulate properly only when the pump
is sucking on the inlet line – so don’t run with a positive pressure on this gauge. A
good rule of thumb for setting the pressure is to first set the regulating screw in the
burner pump at mid range and then adjust the external regulator for a proper flame
length. This allows you to make future flame length adjustments using the burner
pump pressure regulator screw – which is the correct procedure.